RADIATOR

EAS00454

RADIATOR
Removing the radiator

B
T.
R.

4 3

7
8

B 10
A
5
13
6
1 2

11

12

1 9

A
T.
R.

T.
R.

Order Job/Parts to remove Q’ty Remarks

Fuel tank Refer to “FUEL TANK” on page 7-1.
Coolant Drain. Refer to “CHANGING THE
COOLANT” on page 3-16.
1 Radiator cover 2
2 Radiator cap 1
3 Coolant reservoir cap 1
4 Coolant reservoir hose 1
5 Coolant reservoir breather hose 1
6 Coolant throttle body hose 1 Disconnect.
7 Coolant reservoir 1
8 Radiator inlet hose 1
9 Radiator outlet hose 1
10 Radiator fan motor coupler 1 Disconnect.
11 Protector 1
12 Radiator 1
13 Radiator fan 1
For installation, reverse the removal
procedure.

6-1
 RADIATOR

EAS00455

CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radi-
ator.
Damage → Repair or replace.
NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Straighten any flattened fins with a thin, flat-
head screwdriver. 4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-25.
EAS00456

INSTALLING THE RADIATOR

1. Install:
• Radiator inlet hose “1”
• Radiator outlet hose “2”
• Coolant throttle body hose “3”
• Coolant reservoir hose “4”
2. Check: • Hose clamps “5”
• Radiator hoses
Cracks/damage → Replace.
Hose clamp
3. Measure:
2 Nm (0.2 m·kg, 1.5 ft·lb)
• Radiator cap opening pressure
Below the specified pressure → Replace the
NOTE:
radiator cap.
• White painting mark “a” of hose shall be in-
stalled outside.
Radiator cap opening pressure • Clamp portion “b” shall be set downward.
110.0-140.0 kPa
(1.10-1.40 kg/cm2, • Yellow painting mark of hose and this projec-
16.0-20.3 psi) tion “c” shall be matched each other for in-
stalling.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Head of clip “d” shall be installed outside.
a. Install the radiator cap tester “1” and radiator • Head of clip “e” shall be installed lower side.
cap tester adaptor “2” and radiator cap tester
adaptor “3” to the radiator cap “4”.

Radiator cap tester

90890-01325
Radiator cap tester adaptor
90890-01352
Radiator cap tester adaptor
90890-01497

b. Apply the specified pressure for ten sec-

onds and make sure there is no drop in
pressure.

6-2
 RADIATOR

2
a 5
1

b e
4
5 1

c d
3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b
4. Measure:
• Radiator cap opening pressure
Bellow the specified pressure → Replace the
5 a radiator cap.
b
Refer to “CHECKING THE RADIATOR” on
c page 6-2.
2
5
b

2. Fill:
• Cooling system (with the specified amount
of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-16.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Attach the radiator cap tester “1” and radia-

tor tester adapter “2” to the radiator.

Radiator cap tester

90890-01325
Radiator tester adapter
90890-01496

b. Apply 100 kPa (1.0 kg/cm2, 14.2233 psi) of

pressure and make sure there is no drop in
pressure.

6-3
 THERMOSTAT

EAS00460

THERMOSTAT
Removing the thermostat

Order Job/Parts to remove Q’ty Remarks

Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-16.
1 Coolant temperature sensor coupler 1
2 Hose clamp 1
3 Radiator inlet hose 1 Disconnect.
4 Thermostat cover 1
5 O-ring 1
6 Thermostat 1
7 Coolant temperature sensor 1
8 Copper washer 1
For installation, reverse the removal
procedure.

6-4
 THERMOSTAT

EAS00462
2. Check:
CHECKING THE THERMOSTAT • Thermostat cover
1. Check: • Thermostat housing (cylinder head)
• Thermostat “1” Cracks/damage → Replace.
Does not open at 71-85 °C (159.8-185 °F) →
Replace. EAS00466

INSTALLING THE THERMOSTAT

1. Install:
• Thermostat “1”
• O-ring “2” New
• Thermostat cover “3”

Thermostat cover bolts

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 10 Nm (1.0 m·kg, 7.2 ft·lb)
a. Suspend the thermostat in a container filled
with water. NOTE:
b. Slowly heat the water. • Install the thermostat with its breather hole “a”
c. Place a thermometer in the water. facing up.
d. While stirring the water, observe the ther- • Lubricate the O-ring with a thin coat of
mostat and thermometer’s indicated tem- lithium-soap-based grease.
perature.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
1. Thermostat
2. Thermometer
3. Water
4. Container
å Fully closed 1
∫ Fully open
2 New
NOTE: 3
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause seri- 2. Install:
ous overheating or overcooling. • Radiator inlet hose “1”
• Hose clamp “2”

Hose clamp
2 Nm (0.2 m·kg, 1.5 ft·lb)

NOTE:
• Install the radiator inlet hose “1” so that the
yellow painting mark contacts the projection
“a” on the thermostat cover.
• Clamp portion shall be set downward.

6-5
 THERMOSTAT

3. Install:
• Copper washer New
• Coolant temperature sensor

Coolant temperature sensor

18 Nm (1.8 m·kg, 13 ft·lb)

CAUTION:
Use extreme care when handling the cool-
ant temperature sensor. Replace the sen-
sor if it is dropped or subjected to a strong
impact.

4. Fill:
• Cooling system (with the specified amount
of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-16.
5. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
6. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-2.

6-6
 WATER PUMP

EAS00468

WATER PUMP
Removing the water pump

Order Job/Parts to remove Q’ty Remarks

NOTE:
It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.

Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-16.
1 Hose clamp 3
2 Radiator outlet hose 1 Disconnect.
3 Water pump cover 1
4 Gasket 1
5 Water pump assembly 1
6 Water pump outlet pipe 1
7 O-ring 1
8 Water pump outlet hose 1
For installation, reverse the removal
procedure.

6-7
 WATER PUMP

Disassembling the water pump

9 New
LS
10

New 7
New 6
5

LS

1 New

4 2
8
E

Order Job/Parts to remove Q’ty Remarks

1 Circlip 1
2 Impeller shaft gear 1
3 Pin 1
4 Washer 1
5 Impeller shaft assembly 1
6 Water pump seal 1
7 Oil seal 1
8 Bearing 1
9 O-ring 1
10 Water pump housing 1
For assembly, reverse the disassembly
procedure.

6-8
 WATER PUMP

EAS00470

DISASSEMBLING THE WATER PUMP

1. Remove:
• Water pump seal “1”
NOTE:
Tap out the water pump seal from water pump
housing in the direction of the arrow shown.
2. Water pump housing

EAS00474

CHECKING THE WATER PUMP

1. Check:
• Water pump housing cover “1”
• Water pump housing “2”
• Impeller “3”
• Rubber damper “4”
• Rubber damper holder “5”
Cracks/damage/wear → Replace.
2. Remove:
• Bearing “1”
• Oil seal “2” 2

NOTE: 1
Tap out the bearing and oil seal from water 3
pump housing in the direction of the arrow
shown. 5
4
3. Water pump housing

2. Check:
• Water pump seal
• Oil seal
Cracks/damage/wear → Replace.
3. Check:
• Bearing
Rough movement → Replace.
4. Check:
• Impeller shaft gear
3. Remove: Pitting/wear → Replace.
• Rubber damper holder “1” 5. Check:
• Rubber damper “2” (from the impeller, with a • Water pump outlet pipe
thin, flat-head screwdriver) • Radiator outlet hose
• Water jacket inlet housing
NOTE:
Cracks/damage/wear → Replace.
Do not scratch the impeller shaft.

6-9
 WATER PUMP

EAS00475
å Push down.
ASSEMBLING THE WATER PUMP
1. Install:
• Oil seal “1” New
(into the water pump housing “2”)
• Bearing “3”
NOTE:
• Before installing the oil seal, apply tap water
or coolant onto its outer surface.
• Install the oil seal with a socket that matches
its outside diameter.
3. Install:
• Rubber damper “1” New
• Rubber damper holder “2” New

NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.

2. Install:
• Water pump seal “1” New

CAUTION:
Never lubricate the water pump seal sur-
face with oil or grease.
4. Measure:
NOTE:
• Impeller shaft tilt
• Install the water pump seal with the special
Out of specification → Repeat steps (3) and
tools.
(4).
• Before installing the water pump, apply
Yamaha bond No.1215 “2” to the water pump CAUTION:
housing “3”.
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Mechanical seal installer “4”
90890-04132 Impeller shaft tilt limit
Middle driven shaft bearing 0.15 mm (0.006 in)
driver “5”
90890-04058
Yamaha bond No.1215 1. Straightedge
90890-85505 2. Impeller

6-10
 WATER PUMP

5. Install: NOTE:
• Impeller shaft assembly “1” • Install the water pump outlet hose so that it
• Washer contacts the projection “a” on the water jacket
• Pin joint.
• Impeller shaft gear • Before installing the water pump outlet pipe,
• Circlip New lubricate the O-rings with a thin coat of lith-
ium-soap-based grease.
NOTE:
After installation, check that the impeller shaft 2. Install:
rotates smoothly. • Gasket New
• Water pump assembly

Water pump cover bolts

10 Nm (1.0 m·kg, 7.2 ft·lb)

• Water pump cover

1 Water pump assembly bolts

10 Nm (1.0 m·kg, 7.2 ft·lb)

3. Install:
EAS00478 • Radiator outlet hose “1”
INSTALLING THE WATER PUMP • Hose clamp “2”
1. Install:
Hose clamp
• Water pump outlet hose “1”
2 Nm (0.2 m·kg, 1.5 ft·lb)
• O-rings New
• Water pump outlet pipe NOTE:
(to the water pump assembly) • Install the radiator outlet hose “1” so that the
yellow painting mark contacts the projection
Water pump outlet pipe bolts “a” on the water pump cover.
10 Nm (1.0 m·kg, 7.2 ft·lb) • Clamp portion shall be set downward.

• Hose clamps “2”

Hose clamp a
2 Nm (0.2 m·kg, 1.5 ft·lb)
1
WARNING
Always use new O-rings.
2

4. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-16.
5. Check:
• Cooling system
Leaks → Repair or replace the faulty part.

6-11
 WATER PUMP

6. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-2.

6-12
 FUEL INJECTION SYSTEM

FUEL TANK .................................................................................................... 7-1

REMOVING THE FUEL TANK .................................................................. 7-2
REMOVING THE FUEL PUMP................................................................. 7-2
INSTALLING THE FUEL PUMP ............................................................... 7-3
INSTALLING THE FUEL HOSE................................................................ 7-3
CHECKING THE FUEL SENDER ............................................................ 7-3

THROTTLE BODY ASSEMBLY ..................................................................... 7-4

CHECKING THE FUEL INJECTOR.......................................................... 7-7
CHECKING THE THROTTLE BODY ........................................................ 7-7
INSTALLING THE THROTTLE BODY ASSEMBLY................................... 7-7
CHECKING THE FUEL PUMP ................................................................. 7-8
CHECKING THE THROTTLE POSITION SENSOR ................................ 7-9
ADJUSTING THE THROTTLE POSITION SENSOR ............................... 7-9

AIR INDUCTION SYSTEM ............................................................................7-11

AIR INJECTION........................................................................................7-11
AIR CUT-OFF VALVE................................................................................7-11
AIR INDUCTION SYSTEM DIAGRAMS...................................................7-12
AIR CUT-OFF VALVE ASSEMBLY............................................................7-13
CHECKING THE AIR INDUCTION SYSTEM...........................................7-15

FUEL INJECTION SYSTEM...........................................................................7-16

WIRING DIAGRAM...................................................................................7-17
ECU’S SELF-DIAGNOSTIC FUNCTION..................................................7-19
SELF-DIAGNOSTIC FUNCTION TABLE..................................................7-20
FAIL-SAFE ACTION TABLE .....................................................................7-20
TROUBLESHOOTING CHART.................................................................7-22
DIAGNOSTIC MODE................................................................................7-23
TROUBLESHOOTING DETAILS ..............................................................7-29

7
 FUEL TANK

FUEL TANK
Removing the fuel tank and fuel pump

1
1
8

T.
R.
2

New

5 4
6
T.
R.

Order Job/Parts to remove Q’ty Remarks

Seat Refer to “GENERAL CHASSIS” on page 4-1.
Fuel Drain.
1 Headlight panel (right and left) 2
2 Turn signal light coupler 2 Disconnect.
3 Fuel tank panel (right and left) 2
4 Fuel pump coupler 1 Disconnect.
5 Fuel sender coupler 1 Disconnect.
6 Fuel tank overflow hose 1 Disconnect.
7 Fuel hose 1 Disconnect.
8 Fuel tank 1
9 Fuel pump 1
For installation, reverse the removal
procedure.

7-1
 FUEL TANK

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Seat
Refer to “GENERAL CHASSIS” on page
4-1.
• Bolts “1”
• Panels “2” (right and left)

EC5YU1029

CAUTION:
Although the fuel has been removed from
the fuel tank be careful when removing the
fuel hoses, since there may be fuel remain-
ing in them.

NOTE:
• Remove the fuel hose manually without using
any tools.
• Before removing the hoses, place a few rags
in the area under where they will be removed.

6. Remove:
• Fuel tank
NOTE:
Do not set the fuel tank down on the installation
surface of the fuel pump. Be sure to lean the fu-
el tank against a wall or the like.

3. Remove:
• Fuel tank rear bolts “1” REMOVING THE FUEL PUMP
• Bracket “2” 1. Remove:
• Fuel pump
1 CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
2 • Do not touch the base section of the fuel
sender.

4. Remove:
• Fuel hose clamps “1”
5. Disconnect:
• Overflow pipe “2”
• Fuel hose “3”
• Fuel pump coupler “4”
• Fuel sender coupler “5”

7-2
 FUEL TANK

INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump
NOTE:
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Align the projection “A” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the bolts to the specified torque in the
proper tightening sequence as shown.
• Install the fuel pump in the direction shown in
the illustration.

2. Tighten:
• Fuel pump bolts

Fuel pump bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)

INSTALLING THE FUEL HOSE

1. Install:
• Fuel hose

CAUTION:
When installing the fuel hose, be sure to
securely connect it.

CHECKING THE FUEL SENDER

This fuel meter is equipped with a selfdiagnosis
system. When the key is turned to "ON", all of the
display segments of the fuel meter will appear
one after the other and then disappear in order to
test the electrical circuit.
If the electrical circuit is defective all the segments
will start flashing. If this occurs check the electri-
cal circuit.

7-3
 THROTTLE BODY ASSEMBLY

THROTTLE BODY ASSEMBLY

Removing the throttle body assembly

Order Job/Parts to remove Q’ty Remarks

Seat Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 4-5.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
on page 3-16.
1 Fuel injector coupler 1 Disconnect.
2 Throttle position sensor coupler 1 Disconnect.
3 Throttle cable 2 Disconnect.
Refer to “INSTALLING THE THROTTLE
BODY ASSEMBLY” on page 7-7.
4 Vacuum hose 1 Disconnect.
5 Fast idle plunger outlet hose 1 Disconnect.
6 Fast idle plunger inlet hose 1
7 Pilot air hose 1
8 Throttle body joint clamp screw 2 Loosen.
9 Throttle body assembly 1 Refer to “INSTALLING THE THROTTLE
BODY ASSEMBLY” on page 7-7.

7-4
 THROTTLE BODY ASSEMBLY

Removing the throttle body assembly

Order Job/Parts to remove Q’ty Remarks

10 Throttle body joint clamp 2
11 Throttle body joint 1
For installation, reverse the removal
procedure.

7-5
 THROTTLE BODY ASSEMBLY

Disassembling the throttle body assembly

New 3
New

Order Job/Parts to remove Q’ty Remarks

1 Throttle position sensor 1
2 Fuel injection pipe 1
3 Fuel injector 1 Refer to “AIR FILTER CASE” on page 4-5.
4 Throttle body 1 CAUTION:
Do not disassemble the throttle body.

For assembly, reverse the disassembly

procedure.

7-6
 THROTTLE BODY ASSEMBLY

EAS00912
b. Blow out all of the passages with com-
CHECKING THE FUEL INJECTOR pressed air.
1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

• Fuel injector
Damage → Replace. INSTALLING THE THROTTLE BODY
2. Check: ASSEMBLY
• Fuel injector resistance 1. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Throttle body joint clamps
a. Disconnect the injection wire harness cou-
NOTE:
pler from the fuel injector.
Align the projection “a” on the throttle body joint
b. Connect the pocket tester (Ω x 1) to the fuel
injector terminal as shown. with the slot “b” in the throttle body joint clamp.

• Positive tester probe → Red/Black “1” b

b
• Negative tester probe → Red/Blue “2”

1 2 a
a

R/L R/B

2. Install:
• Throttle body joint
NOTE:
c. Measure the fuel injector resistance. Align the projection “a” on the cylinder head
Out of specification → Replace the fuel in- with the slot “b” in the throttle body joint.
jector.
a
Fuel injector resistance
12 Ω at 20 °C (68 °F) b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

EAS00913

CHECKING THE THROTTLE BODY

1. Check:
• Throttle body
Cracks/damage → Replace the throttle body.
2. Check:
• Fuel passages
Obstructions → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petroleum-based
solvent.

CAUTION:
Do not use any caustic carburetor cleaning
solution.

7-7
 THROTTLE BODY ASSEMBLY

3. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Throttle body assembly a. Fill the fuel tank.
b. Put the end of the fuel hose into an open
NOTE:
container.
Align the projection “a” on the throttle body as- c. Connect a battery (DC 12 V) to the fuel
sembly with the slot “b” throttle body joint. pump coupler as shown.

b • Positive battery lead → Red/Blue “1”

a • Negative battery lead → Black “2”

4. Install:
• Throttle cable
5. Adjust:
• Throttle lever free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” on page 3-5.
6. Adjust:
• Engine idling speed
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” on page 3-5.
7. Check:
• Throttle position sensor
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” on
page 7-9. d. If fuel flows out of the fuel hose, the fuel
pump is OK. If fuel does not flow, replace the
EAS00819
fuel pump.
CHECKING THE FUEL PUMP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

WARNING
2. Check:
Gasoline is extremely flammable and under • Fuel pressure
certain circumstances there can be a dan- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ger of an explosion or fire. Be extremely
a. Remove the fuel tank.
careful and note the following points:
Refer to “FUEL TANK” on page 7-1.
• Stop the engine before refueling.
b. Connect the pressure gauge “1” to the
• Do not smoke, and keep away from open
adapter “2”.
flames, sparks, or any other source of fire.
c. Connect the fuel pressure adapter to the fu-
• If you do accidentally spill gasoline, wipe it
el pump and fuel hose “3”.
up immediately with dry rags.
• If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make sure Pressure gauge
the engine is completely cool before per- 90890-03153
forming the following test. Fuel pressure adapter
90890-03176
1. Check:
• Fuel pump operation

7-8
 THROTTLE BODY ASSEMBLY

d. Connect the fuel pump coupler “4” and fuel

• Tester positive lead → blue “1”
sender coupler “5” to the fuel pump.
• Tester negative lead → black/blue “2”
Refer to “FUEL TANK” on page 7-1.

2 1

B/L Y L

e. Set the main switch to “ON” and the engine

stop switch to “ I”. b. Measure the throttle position sensor maxi-
f. Start the engine. mum resistance.
g. Measure the fuel pressure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Fuel pressure 3. Install:

324 kPa (3.24 kg/cm2, 46.1 psi)
• Throttle position sensor
(to the throttle body)
Out of specification → Replace the fuel EAS27030
pump. ADJUSTING THE THROTTLE POSITION
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
SENSOR
EAS28300 NOTE:
CHECKING THE THROTTLE POSITION Before adjusting the throttle position sensor,
SENSOR the engine idling speed should be properly ad-
justed.
1. Remove:
• Throttle position sensor 1. Check:
(from the throttle body) • Throttle position sensor
2. Check: Refer to “CHECKING THE THROTTLE PO-
• Throttle position sensor maximum resist- SITION SENSOR” on page 7-9.
ance 2. Adjust:
Out of specification → Replace the throttle • Throttle position sensor angle
position sensor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Resistance a. Connect the throttle position sensor coupler

2.00-3.00 kΩ
Ω to the throttle position sensor.
b. Connect the digital circuit tester to the throt-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ tle position sensor.

a. Connect the pocket tester (Ω x 1k) to the

throttle position sensor terminals as shown. • Positive tester probe → yellow “1”
• Negative tester probe → black/blue “2”
Digital circuit tester
90890-03174
Digital circuit tester
90890-03174

7-9
 THROTTLE BODY ASSEMBLY

c. Turn the main switch to “ON”.

d. Measure the throttle position sensor voltage.
e. Adjust the throttle position sensor angle so
that the voltage is within the specified range.

Output voltage (at idle)

0.63-0.73 V

f. After adjusting the throttle position sensor

angle, tighten the throttle position sensor
screws “3” to specification.

Throttle position sensor screw

3.5 Nm (0.35 m·kg, 2.53 ft·lb)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

7-10
 AIR INDUCTION SYSTEM

AIR INDUCTION SYSTEM EAS00917

AIR CUT-OFF VALVE

EAS00507
The air cut-off valve is controlled by the signals
AIR INJECTION
from the ECU in accordance with the combus-
The air induction system burns unburned ex- tion conditions. Ordinarily, the air cut-off valve
haust gases by injecting fresh air (secondary opens to allow the air to flow during idle and
air) into the exhaust port, reducing the emission closes to cut-off the flow when the vehicle is be-
of hydrocarbons. ing driven. However, if the coolant temperature
When there is negative pressure at the exhaust is below the specified value, the air cut-off valve
port, the reed valve opens, allowing secondary remains open and allows the air to flow into the
air to flow into the exhaust port. The required exhaust pipe until the temperature becomes
temperature for burning the unburned exhaust higher than the specified value.
gases is approximately 600 to 700 °C (1,112 to
1,292 °F). A. From the air filter case
B. To the cylinder head
1. The air cut-off valve is closed.
2. The air cut-off valve is open.

A 1

B
2
A

7-11
 AIR INDUCTION SYSTEM

EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

1. Air filter case
2. Reed valve
3. Air cut-off valve
4. Exhaust port

7-12
 AIR INDUCTION SYSTEM

AIR CUT-OFF VALVE ASSEMBLY

Removing the air cut-off valve assembly

Order Job/Parts to remove Q’ty Remarks

Seat Refer to “GENERAL CHASSIS” on
page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Air induction system solenoid coupler 1 Disconnect.
2 Air cut-off valve outlet hose 1
3 Air-filter-to-air-cut-off-valve hose 1
4 Air cut-off valve assembly 1
For installation, reverse the removal
procedure.

7-13
 AIR INDUCTION SYSTEM

Disassembling the air cut-off valve assembly

LT

LT

3
2

Order Job/Parts to remove Q’ty Remarks

1 Air cut-off valve cover 1
2 Reed valve assembly 1
3 Air cut-off valve 1
For assembly, reverse the disassembly
procedure.

7-14
 AIR INDUCTION SYSTEM

EAS00918

CHECKING THE AIR INDUCTION SYSTEM

1. Check:
• Hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
• Pipe
Cracks/damage → Replace.
Refer to “CYLINDER HEAD” on page 5-8.
2. Check:
• Reed valve
• Reed valve stopper
• Reed valve seat
• Cracks/damage → Replace the reed valve
assembly.
3. Check:
• Air cut-off valve
Cracks/damage → Replace.
4. Check:
• Air induction system solenoid
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the air induction system solenoid
coupler from the air cut-off valve assembly.
b. Connect the pocket tester (Ω x 1) to the air
induction system solenoid terminal as
shown.

• Positive tester probe → Brown/Red “1”

• Negative tester probe → Red/White “2”

2 1

Br/R R/W

c. Measure the air induction system solenoid

resistance.
Out of specification → Replace the air cut-off
valve assembly.

Air induction system solenoid

resistance
18-22 Ω at 20 °C (68 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

7-15
 FUEL INJECTION SYSTEM

EAS00895

FUEL INJECTION SYSTEM

1. Fuel tank 12. Catalytic converter

2. Engine trouble warning light 13. Fuel injection system relay
3. Ignition coil 14. Battery
4. Spark plug 15. Intake air temperature sensor
5. Fuel pump 16. Coolant temperature sensor
6. Idling adjustment screw 17. Fuel injector
7. Throttle position sensor 18. Crankshaft position sensor
8. Intake air pressure sensor 19. O2 sensor
9. Air filter case 20. Air induction system solenoid
10. ECU 21. Air cut-off valve
11. Lean angle cut-off switch

7-16
 FUEL INJECTION SYSTEM

WIRING DIAGRAM

7-17
 FUEL INJECTION SYSTEM

1. Crankshaft position sensor

3. Neutral switch
4. Main switch
7. Battery
8. Main fuse
12. Relay unit
14. Fuel injection system relay
16. Ignition coil
17. Spark plug
18. Fuel injector
19. O2 sensor
20. Air induction system solenoid
21. Intake air temperature sensor
22. Coolant temperature sensor
23. ECU
24. Speed sensor
25. Throttle position sensor
26. Intake air pressure sensor
27. Lean angle cut-off switch
28. Multi-function meter unit
37. Engine trouble warning light
38. Fuel pump
39. Sidestand switch
42. Engine stop switch
67. Ignition fuse
70. Fuel injection system fuse

7-18
 FUEL INJECTION SYSTEM

ECU’S SELF-DIAGNOSTIC FUNCTION • To inform the rider that the fuel injection sys-
The ECU is equipped with a self-diagnostic tem is not functioning correctly, the engine
function in order to ensure that the engine con- trouble warning light flashes when the start
trol system is operating normally. If this function switch is being pushed to start the engine.
detects a malfunction in the system, it immedi- • If a malfunction is detected in the system by
ately operates the engine under substitute the self-diagnostic function, this mode pro-
characteristics and illuminates the engine trou- vides an appropriate substitute characteristic
ble warning light to alert the rider that a mal- operation, and alerts the rider of the detected
function has occurred in the system. Once a malfunction by illuminating the engine trouble
malfunction has been detected, a fault code is warning light.
stored in the memory of the ECU. • After the engine has been stopped, the low-
est fault code number displays on the FI diag-
nostic tool. This fault code remains stored in
the memory of the ECU until it is deleted.

1. Engine trouble warning light

Engine trouble warning light fault code indication

Digit of 10: Cycles of 1 sec. ON and 1.5 sec. OFF.
Digit of 1: Cycles of 0.5 sec. ON and 0.5 sec. OFF.
<Example> 42

Light ON

Light OFF

EAS00900

Engine trouble warning light indication and FI system operating condition

Engine condition Warning light FI operation Vehicle operation

indication
Flashing Operation stopped. Unable
Operates Remains ON Operated with substi- Able
(cranking with tute characteristics in
electric starter) accordance with the
description of the mal-
function.

Stopped Flashing (indicate — —

the fault code)

7-19
 FUEL INJECTION SYSTEM

EAS27380

SELF-DIAGNOSTIC FUNCTION TABLE

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu-
minates the engine trouble warning light and provides the engine with alternate operating instruc-
tions that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.

FAIL-SAFE ACTION TABLE

Self-diagnostic function

Fault
Item Symptom Fail-safe action Startability Driveability
code No.
Crankshaft position No normal signals are
12 — No No
sensor received from the sensor.
Intake air pressure Open or short circuit is • Fixes the intake air pres-
13 sensor (open or short detected. sure to 101 kPa Yes Yes
circuit) (760 mmHg, 29.9 inHg).
Intake air pressure Intake air pressure sensor • Fixes the intake air pres-
sensor hose is clogged or discon- sure to 101 kPa
14 nected, causing the constant (760 mmHg, 29.9 inHg). Yes Yes
application of atmospheric
pressure to the sensor.
Throttle position sensor Open or short circuit is • Fixes the throttle position
15 Yes Yes
(open or short circuit) detected. sensor to fully open.
Throttle position The throttle position sensor • Fixes the throttle position
16 Yes Yes
sensor (stuck) is detected stuck. sensor to fully open.
Broken or discon- Open circuit in the input line
19 nected blue/black (blue/black) of the ECU is — No No
lead of the ECU detected.
Coolant temperature Open or short circuit is • Fixes the coolant tempe-
21 Yes Yes
sensor detected. rature to 80 °C (176 °F).
Intake air temperature Open or short circuit is • Fixes the intake air tem-
22 Yes Yes
sensor detected. perature to 20 °C (68 °F).
No normal signal is received
24 O2 sensor — Yes Yes
from the O2 sensor.
Lean angle cut-off The motorcycle has
30 switch (latch up overturned. — No No
detected)
Open circuit is detected in
33 Faulty ignition the primary lead of the — No No
ignition coil.
Lean angle cut-off Open or short circuit is
41 switch (open or detected. — No No
short circuit)
Speed sensor, No normal signals are • Fixes the gear to the top
neutral switch received from the speed gear.
42 sensor or an open or short Yes Yes
circuit is detected in the
neutral switch.
Fuel system voltage The ECU is unable to • Fixes the battery voltage
(monitor voltage) monitor the battery voltage to 12 V. Yes Yes
43
(open circuit in the wire to
the ECU).
Error in writing the An error is detected while
amount of CO reading or writing on
44 — Yes Yes
adjustment on EEPROM (CO adjustment
EEPROM value).

7-20
 FUEL INJECTION SYSTEM

Fault
Item Symptom Fail-safe action Startability Driveability
code No.
Vehicle system Power supply to the fuel
46 power supply injection system relay is not — Yes Yes
(monitor voltage) normal.
ECU internal Faulty ECU memory. When
malfunction this malfunction is detected,
50 — No Yes
(memory check error) the code number might not
appear on the meter.
Start unable warning Relay is not turned ON even • Engine trouble warning
if the crank signal is input light flashes when the
while the start switch is start switch is turned ON.
turned ON. When the start
— No No
switch is turned ON while an
error is detected with the
fault code of No. 12, 19,
33, 41 or 50.

7-21
 FUEL INJECTION SYSTEM

EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.

The engine trouble warning light comes on. The engine trouble warning light does not come on.

Check the fault code number displayed on the FI Check the operation of following sensors and actua-
diagnostic tool. tors in the diagnostic mode. Refer to "Sensor opera-
tion table" and "Actuator operation table".
D01: Throttle position sensor (Throttle angle)
D30: Ignition coil
Identify the system with the malfunction. Refer to D36: Fuel injector
"Self-Diagnostic Function table".

Identify the probable cause of the malfunction. Refer

to "Diagnostic code table". OK NG

Engine malfunction Defective sensor or

Check and repair the probable cause of malfunction.
actuator
Fault code No. YES Fault code No. NO

Check and repair. Check and repair.

Refer to "TROUBLE- Refer to "Self-Diagnos- Check and repair the
SHOOTING DETAILS". tic Function table". Check and repair the
corresponding sen-
Monitor the operation of inner parts of engine.
sor or actuator.
the sensors and actua-
tors in the diagnostic
mode. Refer to "Sen-
sor operation table" and OK NG OK
"Actuator operation
table". Check the engine condition.

Perform ECU reinstatement action. Refer to "Rein-

statement method" in "TROUBLESHOOTING
DETAILS".
Fault code number
displayed OK
Turn the main switch to "OFF", turn the main switch
back to "ON", and then check if the fault code number
is still displayed.

Fault code number not displayed

Repairs completed

Erasing the malfunction history:*

The malfunction history is stored even if the main switch is turned OFF.
The malfunction history must be erased in the diagnostic mode. Refer to "Sensor operation table" and "Actuator oper-
ation table" (Diagnostic code No.D62).

* Operated when the engine trouble warning light is on.

7-22
 FUEL INJECTION SYSTEM

HAS00905

DIAGNOSTIC MODE
It is possible to monitor the sensor output data
FI Diagnostic Tool
or check the activation of actuators with the FI
diagnostic tool connected to the vehicle and set 1600rpm 35ßC
to the normal mode or the diagnostic monitor-
ing mode.

FI diagnostic tool
90890-03182
4. Stop the engine.
NOTE:
Setting the normal mode
If a malfunction is detected in the system, the
NOTE: fault code appears on the LCD of the FI
The engine speed,engine temperature, and diagnostic tool. And also, “WARNING” LED
fault code, if detected, can be displayed on the (Orange) comes on.
LCD of the FI diagnostic tool when the tool is
connected to the vehicle and is set to the nor-
mal mode.
FI Diagnostic Tool
1. Turn the main switch to “OFF” and set the 0rpm 35ßC
engine stop switch to “RUN”. S/D : 12
2. Remove the self-diagnosis signal coupler
cap, and then connect the FI diagnostic tool
“1” as shown.

1
5. Turn the main switch to “OFF” to cancel the
normal mode.
6. Disconnect the FI diagnostic tool and con-
nect the self-diagnosis signal connector.

Setting the diagnostic mode

1. Turn the main switch to “OFF” and set the
engine stop switch to “RUN”.
2. Remove the self-diagnosis signal coupler
3. Turn the main switch to “ON” and start the cap, and then connect the FI diagnostic tool
engine. “1” as shown.
NOTE:
• Coolant temperature and engine revolution 1
appear on the LCD of the FI diagnostic tool.
• “POWER” LED (Green) comes on.
• If a malfunction is detected in the system,
“WARNING” LED (Orange) comes on.

3. While press the “MODE” button, turn the

main switch to “ON”.

7-23
 FUEL INJECTION SYSTEM

NOTE:
• “DIAG” appears on the LCD of the FI diag-
nostic tool.
• “POWER” LED (Green) comes on.

4. Press the “UP” button to select the CO ad-

justment mode “CO” or the diagnostic mode
“DIAG”.
5. After selecting “DIAG”, press the “MODE”
button.
6. Select the diagnostic code number corre-
sponding to the fault code number by press-
ing the “UP” and “DOWN” buttons.
NOTE:
• The diagnostic code number appears on the
LCD (D01-D70).
• To decrease the selected diagnostic code
number, press the “DOWN” button. Press the
“DOWN” button for 1 second or longer to au-
tomatically decrease the diagnostic code
numbers.
• To increase the selected diagnostic code
number, press the “UP” button. Press the “UP”
button for 1 second or longer to automatically
increase the diagnostic code numbers.

FI Diagnostic Tool

D03 : 101

7. Verify the operation of the sensor or actua-

tor.
• Sensor operation
The data representing the operating condi-
tions of the sensor appear on the LCD.
• Actuator operation
Set the engine stop switch to “OFF” and then
to “RUN”.
8. Turn the main switch to “OFF” to cancel the
diagnostic mode.
9. Disconnect the FI diagnostic tool and con-
nect the self-diagnosis signal connector.

7-24
 FUEL INJECTION SYSTEM

EAS00906

Diagnostic monitoring code table

Fault Symptom Probable cause of malfunction Diagnostic code

code No.
No normal signals are received from • Open or short circuit in wire harness
the crankshaft position sensor. • Defective crankshaft position sensor
• Disconnected crankshaft position sensor coupler _
12
• Malfunction in A.C. magneto rotor
• Malfunction in ECU
• Improperly installed crankshaft position sensor
Open or short circuit is detected in • Open or short circuit in wire harness
the intake air pressure sensor. • Defective intake air pressure sensor D03
13
• Disconnected intake air pressure sensor coupler
• Malfunction in ECU
Faulty intake air pressure sensor • Disconnected, clogged, kinked, or pinched intake air
hose system: pressure sensor hose D03
14
• detected hose • Defective intake air pressure sensor
• clogged hose. • Malfunction in ECU
Open or short circuit is detected in • Open or short circuit in wire harness
the throttle position sensor. • Defective throttle position sensor
15 • Disconnected throttle position sensor coupler D01
• Malfunction in ECU
• Improperly installed throttle position sensor
Stuck throttle position sensor is • Stuck throttle position sensor
16 detected. • Improperly installed throttle position sensor D01
• Malfunction in ECU
Open circuit in the input line (blue/ • Open circuit in wire harness (ECU coupler)
19 black lead) of ECU is detected when • Malfunction in ECU D20
the start switch is pushed.
Open or short circuit is detected in • Open or short circuit in wire harness
the coolant temperature sensor. • Defective coolant temperature sensor
21 • Disconnected coolant temperature sensor coupler D06
• Malfunction in ECU
• Improperly installed coolant temperature sensor
Open or short circuit is detected in • Open or short circuit in wire harness
the intake air temperature sensor. • Defective intake air temperature sensor
22 • Disconnected intake air temperature sensor coupler D05
• Malfunction in ECU
• Improperly installed intake air temperature sensor
No normal signal is received from • Open or short circuit in wire harness
the O2 sensor. • Defective O2 sensor _
24
• Improperly installed sensor
• Malfunction in ECU
The motorcycle has overturned. • Overturned motorcycle
30 D08
• Malfunction in ECU
The amount of air-fuel ratio feedback • Open or short circuit in wiring harness
compensation is maintained • Fuel pressure too low
continuously in the vicinity of the • Clogged injectors
31 upper limit (lean air-fuel ratio). • Defective O2 sensor (unable to output a rich signal) _
• Malfunction in other areas of the fuel system
• Malfunction in ECU
The amount of air-fuel ratio feedback • Open or short circuit in wiring harness
compensation is maintained • Fuel pressure too high
continuously in the vicinity of the • Faulty injectors (excessive injection volume) _
32 lower limit (rich air-fuel ratio). • Defective O2 sensor (unable to output a lean signal)
• Malfunction in other areas of the fuel system
• Malfunction in ECU

7-25
 FUEL INJECTION SYSTEM

Fault Symptom Probable cause of malfunction Diagnostic code

code No.
Open circuit is detected in the • Open circuit in wire harness
primary lead of the ignition coil. • Malfunction in ignition coil
33 • Malfunction in ECU D30
• Malfunction in a component of the ignition cut-off
circuit system
Open or short circuit is detected in • Open or short circuit in wire harness
the lean angle cut-off switch. • Defective lean angle cut-off switch D08
41
• Disconnected lean angle cut-off switch coupler
• Malfunction in ECU
No normal signals are received from • Open or short circuit in wire harness
the speed sensor or an open or • Defective speed sensor
short circuit is detected in the • Disconnected speed sensor coupler
neutral switch. • Malfunction in vehicle speed sensor detected unit D07
42
• Defective neutral switch D21
• Disconnected neutral switch connector
• Malfunction in the engine side of the neutral switch
• Malfunction in ECU
Power supply to the injector and fuel • Open circuit in wire harness
43 pump is not normal. (The ECU is • Malfunction in ECU D09, D50
unable to monitor the battery voltage.) • Defective fuel injection system relay
An error is detected while reading • Malfunction in ECU (The CO adjustment value is
44 or writing on EEPROM. not properly written on or read from the internal D60
memory.)
Power supply to the fuel injection • Open circuit in wire harness
system relay is not normal. • Malfunction in rectifier/regulator
46 D09
• Malfunction in A.C. magneto rotor
Refer to “CHARGING SYSTEM” on page 8-11.
Faulty ECU memory. When this mal- • Malfunction in ECU (The program and data are not
50 function is detected, the code number properly written on or read from the internal _
might not appear on the meter. memory.)

7-26
 FUEL INJECTION SYSTEM

EAS00907

Diagnostic mode table

Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer
to “DIAGNOSTIC MODE”.
NOTE:
• Check the intake air temperature and coolant temperature as close as possible to the intake air tem-
perature sensor and the coolant temperature sensor respectively.
• If it is not possible to check the intake air temperature, use the ambient temperature as reference.

Diagnostic Data displayed on the

Item Action
code FI diagnostic tool (reference value)
Throttle angle Displays the throttle angle. 0 ~ 125 degrees
D01 • Check with throttle fully closed. • Fully closed (15 ~ 17 degrees)
• Check with throttle fully open. • Fully open (97 ~ 100 degrees)
Intake air pressure Displays the intake air pressure. When the engine is stopped:
Set the engine stop switch to “ ”. Atmospheric pressure 101.3 kPa
• Generate the pressure difference by cranking the (760 mmHg, 30 inHg)
D03 engine with the start switch, but do not start the When cranking the engine with start
engine. switch:
1.3 ~ 26.6 kPa
(10 ~ 200 mmHg, 0.4 ~ 7.9 inHg)
Intake air temperature Displays the intake air temperature. Compare the temperature in the air
D05 • Check the temperature in the air filter case. filter case to the value displayed on
the diagnostic tool.
Coolant temperature Displays the coolant temperature. Compare the coolant temperature to
D06
• Check the coolant temperature. the value displayed on the
diagnostic tool.
Vehicle speed pulse Displays the accumulation of the vehicle speed (0 ~ 199; resets to 0 after 199)
D07 pulses that are generated when the tire is spun. OK if the numbers appear on the
diagnostic tool.
Lean angle cut-off switch Displays the lean angle cut-off switch values. Upright: 0.4 ~ 1.4 V
D08
Overturned: 3.7 ~ 4.4 V
Fuel system voltage Displays the fuel system voltage (battery voltage). Approximately 12.0 V
D09
(battery voltage) Set the engine stop switch to “ ”.
Sidestand switch Displays that the switch is on or off. (When the gear Stand retracted: On
D20
is in a position other than neutral.) Stand extended: Off
Neutral switch Displays that the switch is on or off. Neutral: On
D21
In gear: Off
Ignition coil The engine stop switch is set to “ ”, the ignition Check that sparks are generated 5
coil operates 5 times every second and the engine times with the engine stop switch is
trouble warning light comes on. set to “ ”.
D30
• Connect an ignition checker to the spark plug cap.
• If the engine stop switch is set to “ ”, set it to
, and then set it to again.
Fuel injector The engine stop switch is set to “ “, the fuel injec- Check that the operating sound of the
tor operates 5 times every second and the engine fuel injector is generated 5 times
D36 trouble warning light comes on. when the engine stop switch is set to
• If the engine stop switch is set to “ ”, set it to “ ”.
“ ”, and then set it to “ ” again.
Air induction system The engine stop switch is set to “ ”, the air induc- Check that the operating sound of the
tion system solenoid operates 5 times every second air induction system solenoid is gen-
D48 and the engine trouble warning light comes on. erated 5 times when the engine stop
• If the engine stop switch is set to “ ”, set it to switch is set to “ ”.
“ ”, and then set it to “ ” again.
Fuel injection system The engine stop switch is set to “ ”, the fuel injec- Check that the operating sound of the
relay tion system relay operates 5 times every second and fuel injection system relay is gener-
the engine trouble warning light comes on (on when ated 5 times when the engine stop
D50 relay is operating, off when relay is not operat ing). switch is set to “ ”.
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.

7-27
 FUEL INJECTION SYSTEM

Diagnostic Data displayed on the

Item Action
code FI diagnostic tool (reference value)

Radiator fan motor relay The engine stop switch is set to “ “, the radiator Check that the operating sound of the
fan motor relay operates 5 times, 5 seconds each radiator fan motor relay is generated
time (2 seconds on, 3 seconds off), and the engine and that the radiator fan motor is
D51
trouble warning light comes on. operated 5 times when the engine
• If the engine stop switch is set to “ ”, set it to stop switch is set to “ ”.
“ ”, and then set it to “ ” again.
Headlight relay 1 The engine stop switch is set to “ ”, the headlight Check that the operating sound of the
relay operates 5 times, 5 seconds each time (2 sec- headlight relay is generated and that
onds on, 3 seconds off), and the engine trouble the headlight comes on 5 times when
D52
warning light comes on. the engine stop switch is set to “ ”.
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
E2PROM fault code • Tra nsmits the abnormal portion of the data in the 01
D60 display E2PROM that has been detected as fault code 44. “00” is displayed when there is no
malfunction.
Malfunction history code • Displays the codes of the history of the self-diag- 12 ~ 61
display nosis malfunctions (i.e., a code of a malfunction “00” is displayed when there is no
that occurred once and which has been corrected). malfunction.
D61
• If multiple malfunctions have been detected, differ-
ent codes are displayed at 2-second intervals, and
this process is repeated.
Malfunction history code • Displays the total number of codes that are being 00 ~ 17
erasure detected through self diagnosis and the fault codes “00” is displayed when there is no
in the past history. malfunction.
D62 • Erases only the history codes when the engine
stop switch is set to “ ”. If the engine stop switch
is set to “ ”, set it to “ ”, and then set it to “ ”
again.
Malfuction code reinstate • No malfuction code. “00” is displayed when there is no
(for fault code No. 24 only) malfunction.
D63 • Malfuction code exists. 24
To reinstate set the engine stop switch from “ ”
to “ ”.
D70 Control number • Displays the program control number. 00 ~ 255

7-28
 FUEL INJECTION SYSTEM

TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the FI diagnostic
tool. Check and service the items or components that are the probable cause of the malfunction fol-
lowing the order given.
After the check and service of the malfunctioning part has been completed, reset the FI diagnostic
tool display according to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the FI diagnostic tool when the engine failed to work normally.
Refer to “Diagnostic code table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOS-
TIC MODE”.

Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor.
Used diagnostic code No. – –
Order Item/components Check or maintenance job Restore method
1 Crankshaft position sensor installa- Check the sensor for looseness or pinching. Reinstated by crank-
tion ing the engine.
2 Coupler connections Check the couplers for any pins that may have
Crankshaft position sensor cou- pulled out.
pler Check that the couplers are securely locked.
ECU coupler
If necessary, repair the coupler or securely con-
nect it.
3 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Gray - Gray
Green/White - Black/Blue
4 Defective crankshaft position sen- Replace the sensor if it is defective.
sor Refer to “IGNITION SYSTEM” on page 8-1.

Communication error with the FI diagnostic tool

LCD Display Symptom Probable cause of malfunction

Waiting for connection.... No signals are received from the • Improper connection in connecting lead.
ECU. • The main switch is OFF position.
• Malfunction in FI diagnostic tool.
• Malfunction in ECU.
ERROR 4 Commands from the FI diagnostic • Turn the main switch to “OFF” once, and then set the FI diagnos-
tool are not accepted by the ECU. tic tool to CO adjustment mode or diagnostic mode.
• Vehicle battery is insufficiently charged.
• Malfunction in FI diagnostic tool.
• Malfunction in ECU.

7-29
 FUEL INJECTION SYSTEM

Fault code No. 13 Symptom Open or short circuit is detected from the intake air pressure sensor.
Used diagnostic code No. 03 (intake air pressure sensor)
Order Item/components Check or maintenance job Restore method
1 Coupler connections Check the couplers for any pins that may have Reinstated by crank-
Intake air pressure sensor coupler pulled out. ing the engine.
ECU coupler Check that the couplers are securely locked.
Sub-wire harness coupler
If necessary, repair the coupler or securely con-
nect it.
2 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Black/Blue - Black/Blue
Pink/White - Pink/White
Blue - Blue
3 Defective intake air pressure sen- Execute the diagnostic mode. (Code No. 03)
sor Replace the sensor if it is defective.
1. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler (wire har-
ness end) as shown.

• Positive tester probe → Pink/White “1”

• Negative tester probe → Black/Blue “2”

1 2

L P/W B/L

2. Set the main switch to “ON”.

3. Measure the intake air pressure sensor output
voltage.

Intake air pressure sensor out-

put voltage
3.4 ~ 3.8 V

4. Is the intake air pressure sensor OK?

7-30
 FUEL INJECTION SYSTEM

Fault code No. 14 Symptom Intake air pressure sensor hose is disconnected or clogged.
Used diagnostic code No. 03 (intake air pressure sensor)
Order Item/components Check or maintenance job Restore method
1 Disconnected, clogged, kinked, or Repair or replace the hose. Reinstated by start-
pinched intake air pressure sensor ing the engine and
hose operating it at idle.
Intake air pressure sensor malfunc- Check and repair the connection.
tion at intermediate electrical poten-
tial
Replace the sensor if there is a malfunction.
2 Coupler connections Check the couplers for any pins that may have
Intake air pressure sensor coupler pulled out.
ECU coupler Check that the couplers are securely locked.

If necessary, repair the coupler or securely con-

nect it.
3 Defective intake air pressure sen- Execute the diagnostic mode. (Code No. 03)
sor Replace the sensor if it is defective.
Refer to “Fault code No. 13”.

Fault code No. 15 Symptom Open or short circuit is detected from the throttle position senor.
Used diagnostic code No. 01 (throttle position sensor)
Order Item/components Check or maintenance job Restore method
1 Throttle position sensor installation Check the sensor for looseness or pinching. Reinstated by set-
Check that the sensor is installed in the specified ting the main switch
position. to “ON”.
2 Coupler connections Check the connections of the couplers.
Throttle position sensor coupler Check that the couplers are securely locked.
ECU coupler If necessary, repair the coupler or securely con-
nect it.
3 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Black/Blue - Black/Blue
Yellow - Yel low
Blue - Blue
4 Check the throttle position sensor Check for an open circuit and replace the throttle
lead open circuit output voltage. position sensor, if necessary.
Black/Blue - Yellow
Open circuit item Output voltage
Ground wire open cir- 5V
cuit
Output wire open circuit 0 V
Power supply wire 0V
open circuit
5 Defective throttle position sensor Execute the diagnostic mode. (Code No. 01)
Replace the sensor if it is defective.
Refer to “THROTTLE BODY ASSEMBLY”
in chapter 7.

7-31
 FUEL INJECTION SYSTEM

Fault code No. 16 Symptom The throttle position sensor is detected stuck.
Used diagnostic code No. 01 (throttle position sensor)
Order Item/components Check or maintenance job Restore method
1 Defective throttle position sensor Replace the sensor if it is defective. Reinstated by start-
Refer to “THROTTLE BODY ASSEMBLY”. ing the engine, oper-
ating it at idle, and
2 Throttle position sensor installation Execute the diagnostic mode. (Code No. 01) then racing it.
Check the sensor for looseness or pinching.
Check that the sensor is installed in the specified
position. Refer to “THROTTLE BODY ASSEM-
BLY” in chapter 7.

Fault code No. 19 Symptom Open circuit is detected in the input wire from the sidestand switch to the ECU.
Used diagnostic code No. 20 (sidestand switch)
Order Item/components Check or maintenance job Restore method
1 Coupler connections Check the couplers for any pins that may have If the transmission is
ECU coupler pulled out. in gear, it is rein-
Blue/Black connector Check that the couplers are securely locked. stated by retracting
the sidestand.
If necessary, repair the coupler or securely con- If the transmission is
nect it. in neutral, it is rein-
stated by reconnect-
2 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ing the wiring.
ness cuit between the ECU and sidestand switch.
Blue/Black
3 Defective sidestand switch Execute the diagnostic mode. (Code No. 20)
Replace the switch if it is defective.
Refer to “CHECKING THE SWITCHES”
on page 8-43.

Fault code No. 21 Symptom Open or short circuit is detected from the coolant temperature sensor.
Used diagnostic code No. 06 (coolant temperature sensor)
Order Item/components Check or maintenance job Restore method
1 Coolant temperature sensor instal- Check the sensor for looseness or pinching. Reinstated by set-
lation ting the main switch
to “ON’.
2 Coupler connections Check the coupler for any pins that may have
Coolant temperature sensor cou- pulled out.
pler Check that the couplers are securely locked.
ECU coupler
If necessary, repair the coupler or securely con-
nect it.
3 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Black/Blue - Black/Blue
Green/Red - Green/Red
4 Defective coolant temperature sen- Execute the diagnostic mode. (Code No. 06)
sor Replace the sensor if it is defective.
Refer to “COOLING SYSTEM” on page 8-25.

7-32
 FUEL INJECTION SYSTEM

Fault code No. 22 Symptom Open or short circuit is detected from the intake air temperature sensor.
Used diagnostic code No. 05 (intake air temperature sensor)
Order Item/components Check or maintenance job Restore method
1 Intake air temperature sensor Check the sensor looseness or pinching. Reinstated by set-
installation ting the main switch
to “ON”.
2 Coupler connections Check the couplers for any pins that may have
Intake air temperature sensor cou- pulled out.
pler Check that the couplers are securely locked.
ECU coupler
If necessary, repair the coupler or securely con-
nect it.
3 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Black/Blue - Black/Blue
Brown/White - Brown/White
4 Defective intake air temperature Execute the diagnostic mode. (Code No. 05)
sensor Replace the sensor if it is defective.
1. Remove the intake air temperature sensor
from the air filter case.
2. Connect the pocket tester (Ω x 100) to the
intake air temperature sensor terminal as
shown.

• Positive tester probe → Brown/White “1”

• Negative tester probe → Black/Blue “2”

Br/W B/L

2 1
3. Measure the intake air temperature sensor
resistance.

Intake air temperature sensor

resistance
2.21 ~ 2.69 Ω at 20 °C (68 °F)

WARNING
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.

4. Is the intake air temperature sensor OK?

7-33
 FUEL INJECTION SYSTEM

Fault code No. 24 Symptom No normal signal is received from the O2 sensor.
Used diagnostic code No. – –
Order Item/components Check or maintenance job Restore method
1 Installed condition of O2 sensor. Check the installed area for looseness or pinching. Starting the engine,
warming it up until
2 Connected state of connector Check the coupler for any pins that may have
the coolant
O2 sensor coupler pulled out.
ECU coupler Check the locking condition of the coupler. temperature is 60 °C
or more, and then
If there is a malfunction, repair it and connect it running it between
securely. 2000-3000 r/min until
3 Open or short circuit in wire Repair or replace if there is an open or short the engine trouble.
indicator turns off.
harness and/or sub lead. circuit.
Between O2 sensor coupler and ECU coupler.
Pink - Pink
Red/White - Red
Gray - Black/Blue
Gray/Green - Gray/Green

4 Check fuel pressure. Refer to “Checking the fuel pressure” in

“CHECKING THE FUEL PUMP” in
chapter 7.

5 Defective O2 sensor. Replace if defective.

Fault code No. 30 Symptom The motorcycle has overturned.

Used diagnostic code No. 08 (lean angle cut-off switch)
Order Item/components Check or maintenance job Restore method
1 The motorcycle has overturned. Raise the motorcycle upright. Reinstated by set-
ting the main switch
2 Lean angle cut-off switch installa- Check the switch for looseness or pinching.
to “ON” (the engine
tion
cannot be started
3 Coupler connections Check the coupler for any pins that may have unless the main
Lean angle cut-off switch coupler pulled out. switch is first set to
ECU coupler Check that the couplers are securely locked. “OFF”).

If necessary, repair the coupler or securely con-

nect it.
4 Defective lean angle cut-off switch Execute the diagnostic mode. (Code No. 08)
Replace the switch if it is defective.
Refer to “IGNITION SYSTEM” on page 8-1.

7-34
 FUEL INJECTION SYSTEM

Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil.
Used diagnostic code No. 30 (ignition coil)
Order Item/components Check or maintenance job Restore method
1 Coupler and connector connections Check the coupler and connector for any pins Reinstated by start-
Ignition coil primary connector that may have pulled out. ing the engine and
(Orange) Check the connector and coupler are securely operating it at idle.
ECU coupler locked.

If necessary, repair the coupler or securely con-

nect it.
2 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Orange - Orange
3 Defective ignition coil Execute the diagnostic mode. (Code No. 30)
Test the primary and secondary coils for continu-
ity.
Replace the coil if it is defective.
Refer to “IGNITION SYSTEM” on page 8-1.

Fault code No. 41 Symptom Open or short circuit is detected in the lean angle cut-off switch.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order Item/components Check or maintenance job Restore method
1 Coupler connections Check the couplers for any pins that may have Reinstated immedi-
Lean angle cut-off switch coupler pulled out. ately when it
ECU coupler Check that the couplers are securely locked. becomes normal.

If necessary, repair the coupler or securely con-

nect it.
2 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Black/Blue - Black/Blue
Yellow/Green - Yel low/Green
Blue - Blue
3 Defective lean angle cut-off switch Execute the diagnostic mode. (Code No. 08)
Replace the switch if it is defective.
Refer to "Fault code No. 30".

7-35
 FUEL INJECTION SYSTEM

Fault code No. 42 Symptom A. No normal signals are received from the speed sensor.
B. Open or short circuit is detected in the neutral switch.
Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4
Order Item/components Check or maintenance job Restore method
A-1 Coupler connections Check the couplers for any pins that may have Reinstated by starting
Speed sensor coupler pulled out. the engine, and input-
ECU coupler Check that the couplers are securely locked. ting the vehicle speed
signals by operating
If necessary, repair the coupler or securely con- the motorcycle at 20
nect it. to 30 km/h (12.4 to
18.6 mi/h).
A-2 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
Blue - Blue
White - White
Black/Blue - Black/Blue
A-3 Gear for detecting vehicle speed Replace the gear if it is defective.
has broken. Refer to “TRANSMISSION” on page 5-69.

A-4 Defective speed sensor Execute the diagnostic mode. (Code No. 07)
Replace the sensor if it is defective.
1. Measure the speed sensor output voltage.
2. Connect the pocket tester (DC 20 V) to the
speed sensor coupler as shown.

• Positive tester probe → Pink “1”

• Negative tester probe → Black/White “2”

P O/R L W
B/W B/L

3. Set the main switch to “ON”.

4. Elevate the rear wheel and slowly rotate it.
5. Measure the speed sensor output voltage.

Speed sensor output voltage

When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less

6. Is the speed sensor OK?

7-36
 FUEL INJECTION SYSTEM

Fault code No. 42 Symptom A. No normal signals are received from the speed sensor.
B. Open or short circuit is detected in the neutral switch.
Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4
Order Item/components Check or maintenance job Restore method
B-1 Coupler connections Check the couplers for any pins that may have Reinstated by starting
Neutral switch connector pulled out. the engine, and input-
Wiring harness ECU coupler Check that the couplers are securely locked. ting the vehicle speed
signals by operating
If necessary, repair the coupler or securely con- the motorcycle at 20
nect it. to 30 km/h (12.4 to
18.6 mi/h).
B-2 Open or short circuit in the wire har- Repair or replace if there is an open or short cir-
ness cuit between the wire harnesses.
between neutral switch and relay unit
Sky blue - Sky blue
between relay unit and ECU
Blue/Yellow - Blue/Black
B-3 Faulty shift drum (neutral detection Replace if defective.
area) Refer to “TRANSMISSION” on page 5-69.
B-4 Defective neutral switch Execute the diagnostic mode. (Code No. 21)
Replace the switch if it is defective.
Refer to “CHECKING THE SWITCHES ”
on page 8-43.

7-37
 FUEL INJECTION SYSTEM

Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage.
Used diagnostic code No. 09, 50 (fuel system voltage)
Order Item/components Check or maintenance job Restore method
1 Coupler connections Check the couplers for any pins that may have Reinstated by start-
Fuel injection system relay cou- pulled out. ing the engine and
pler Check that the couplers are securely locked. operating it at idle.
Wiring harness ECU coupler
If necessary, repair the coupler or securely con-
nect it.
2 Defective main relay Replace the relay if it is defective.
3 Open or short circuit in the wire har- Execute the diagnostic mode. (Code No. 09)
ness Repair or replace if there is an open or short cir-
cuit:
between battery and fuel injection system fuse
Red - Red
between fuel injection system fuse and fuel injec-
tion system relay
Brown - Brown
between fuel injection system relay and ECU
Red/Blue - Red/Blue
4 Malfunction or open circuit in the Execute the diagnostic mode. (Code No. 50)
fuel injection system relay Replace if defective.
1. Remove the relay unit.
2. Connect the pocket tester (Ω x 1) and battery
(12 V) to the relay terminals as shown.

• Positive battery terminal → Red/Black “1”

• Negative battery terminal → Blue/Red “2”
• Positive tester probe → Brown “3”
• Negative tester probe → Red/Blue “4”

3 2 1
4

3. Does the diode have continuity between

brown and red/blue?
If there is no malfunction with the fuel injection
system relay, replace the ECU.

7-38
 FUEL INJECTION SYSTEM

Fault code No. 44 Symptom Error is detected while reading or writing on EEPROM
(CO adjustment value).
Used diagnostic code No. 60 (EEPROM improper cylinder indication)
Order Item/components Check or maintenance job Restore method
1 Malfunction in ECU Execute the diagnostic mode. (Code No. 60) Reinstated by set-
• Check the faulty cylinder. ting the main switch
• Readjust the CO of the displayed cylinder. to “ON”.
Replace the ECU if it is defective.

Fault code No. 46 Symptom Power supply to the FI system relay is not normal.
Used diagnostic code No. 09
Order Item/components Check or maintenance job Restore method
1 Faulty battery Replace or change the battery. Reinstated by start-
Refer to “CHECKING AND CHARGING THE ing the engine and
BATTERY” on page 3-29. operating it at idle.

2 Open or short circuit in the wire har- Excute the diagnostic mode. (Code No. 09)
ness. Repair or replace if there is an open or short cir-
cuit:
between battery and main switch
Red - Red
between main switch and ignition fuse
Brown/Blue - Brown/Blue
between ignition fuse and engine stop switch
Red - Red
between engine stop switch and fuel injecton
system relay
Red/Black - Red/Black
between fuel injecton system relay and ECU
Blue/Red - Blue/Red
3 Coupler connections ECU coupler Check the coupler for any pins that may have
pulled out.
Check that the coupler is securely locked.
If necessary, repair the coupler or securely con-
nect it.

Fault code No. 50 Symptom Faulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Used diagnostic code No. – –
Order Item/components Check or maintenance job Restore method
1 Malfunction in ECU Replace the ECU. Reinstated by set-
ting the main switch
to “ON”.

7-39
 ELECTRICAL SYSTEM

IGNITION SYSTEM........................................................................................ 8-1

CIRCUIT DIAGRAM ................................................................................. 8-1
TROUBLESHOOTING ............................................................................. 8-3

ELECTRIC STARTING SYSTEM ................................................................... 8-5

CIRCUIT DIAGRAM ................................................................................. 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......................... 8-7
TROUBLESHOOTING ............................................................................. 8-9

CHARGING SYSTEM..................................................................................... 8-11

CIRCUIT DIAGRAM ................................................................................. 8-11
TROUBLESHOOTING .............................................................................8-13

LIGHTING SYSTEM.......................................................................................8-15
CIRCUIT DIAGRAM .................................................................................8-15
TROUBLESHOOTING .............................................................................8-17

SIGNALING SYSTEM ....................................................................................8-19

CIRCUIT DIAGRAM .................................................................................8-19
TROUBLESHOOTING .............................................................................8-21

COOLING SYSTEM .......................................................................................8-25

CIRCUIT DIAGRAM .................................................................................8-25
TROUBLESHOOTING .............................................................................8-27

IMMOBILIZER SYSTEM................................................................................8-29
CIRCUIT DIAGRAM .................................................................................8-29
GENERAL INFORMATION ......................................................................8-31
PART REPLACEMENT AND KEY CODE REGISTRATION
REQUIREMENTS.....................................................................................8-31
TROUBLESHOOTING .............................................................................8-35
SELF-DIAGNOSIS FAULT CODE INDICATION ......................................8-35

ELECTRICAL COMPONENTS ......................................................................8-39

CHECKING THE SWITCHES ..................................................................8-43
CHECKING THE BULBS AND BULB SOCKETS ....................................8-46
CHECKING THE LEDS............................................................................8-47
CHECKING THE FUSES .........................................................................8-48
CHECKING AND CHARGING THE BATTERY ........................................8-49
CHECKING THE RELAYS .......................................................................8-51
CHECKING THE TURN SIGNAL/HAZARD RELAY.................................8-53
8
CHECKING THE RELAY UNIT (DIODE) .................................................8-53
CHECKING THE SPARK PLUG CAP ......................................................8-54
CHECKING THE IGNITION COIL............................................................8-54
CHECKING THE IGNITION SPARK GAP................................................8-55
CHECKING THE CRANKSHAFT POSITION SENSOR ..........................8-55
CHECKING THE LEAN ANGLE CUT-OFF SWITCH...............................8-56
CHECKING THE STATOR COIL..............................................................8-56
CHECKING THE HORN...........................................................................8-57
CHECKING THE COOLANT TEMPERATURE SENSOR........................8-57
CHECKING THE FUEL SENDER ............................................................8-58
CHECKING THE SPEED SENSOR.........................................................8-58
CHECKING THE THROTTLE POSITION SENSOR................................8-59
CHECKING THE FUEL PUMP.................................................................8-59
CHECKING THE INTAKE AIR PRESSURE SENSOR ............................8-60
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....................8-60
CHECKING THE RADIATOR FAN MOTOR ............................................8-60
CHECKING THE STARTER MOTOR ......................................................8-61
 IGNITION SYSTEM
EAS27090

IGNITION SYSTEM
EAS27110

CIRCUIT DIAGRAM

8-1
 IGNITION SYSTEM

1. Crankshaft position sensor

3. Neutral switch
4. Main switch
7. Battery
8. Main fuse
13. Starting circuit cut-off relay
16. Ignition coil
17. Spark plug
23. ECU
27. Lean angle cut-off switch
39. Sidestand switch
42. Engine stop switch
46. Clutch switch
67. Ignition fuse

8-2
 IGNITION SYSTEM
EAS27150

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Seat
2. Side panels (left and right)
3. Fuel tank

1. Check the fuses.

(Main and ignition)
NG Replace the fuse(s).
Refer to “CHECKING THE FUSES”
on page 8-48.
OK
2. Check the battery.
Refer to “CHECKING AND • Clean the battery terminals.
NG
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-49.
OK
3. Check the spark plug.
Refer to “CHECKING THE NG Re-gap or replace the spark plug.
SPARK PLUG” on page 3-6.
OK
4. Check the ignition spark gap.
Refer to “CHECKING THE
OK Ignition system is OK.
IGNITION SPARK GAP” on page
8-55.
NG
5. Check the spark plug cap.
Refer to “CHECKING THE SPARK NG Replace the spark plug cap.
PLUG CAP” on page 8-54.
OK
6. Check the ignition coil.
Refer to “CHECKING THE NG Replace the ignition coil.
IGNITION COIL” on page 8-54.
OK
7. Check the crankshaft position
sensor.
Replace the crankshaft position
Refer to “CHECKING THE NG sensor.
CRANKSHAFT POSITION
SENSOR” on page 8-55.
OK

8-3
 IGNITION SYSTEM

8. Check the main switch.

Refer to “CHECKING THE NG Replace the main switch/immobilizer unit.
SWITCHES” on page 8-43.
OK
9. Check the engine stop switch.
Refer to “CHECKING THE NG Replace the right handlebar switch.
SWITCHES” on page 8-43.
OK
10.Check the neutral switch.
Refer to “CHECKING THE NG Replace the neutral switch.
SWITCHES” on page 8-43.
OK
11. Check the sidestand switch.
Refer to “CHECKING THE NG Replace the sidestand switch.
SWITCHES” on page 8-43.
OK
12. Check the clutch switch.
Refer to “CHECKING THE NG Replace the clutch switch.
SWITCHES” on page 8-43.
OK
13. Check the relay unit (starting
circuit cut-off relay).
NG Replace the relay unit.
Refer to “CHECKING THE
RELAYS” on page 8-51.
OK
14. Check the lean angle cut-off
switch. Refer to “CHECKING
NG Replace the lean angle cut-off switch.
THE LEAN ANGLE CUT-OFF
SWITCH” on page 8-56.
OK
15. Check the entire ignition system
wiring. Properly connect or repair the ignition
NG
Refer to “CIRCUIT DIAGRAM” system wiring.
on page 8-1.
OK
Replace the ECU.

8-4