Gl1800 servicemanual teil2 by Andreas Gäbler

FRONT WHEEL/SUSPENSION/STEERING

TROUBLESHOOTING Hard steering • Steering bearing adjustm ent nut too tight • Worn or dam aged steering head bearings • Worn or dam aged steering head bearing races • Bent steering stem • Insufficient tire pressure • Faulty front tire Steers to one side or does not track straight • Bent fork leg • Dam aged steering head bearings • Loose steering head bearings • Bent fram e • Worn w heel bearings • Bent front axle • Worn sw ingarm pivot com ponent (section 14) Front wheel wobbling • Bent rim • Worn w heel bearings • Faulty tire • Unbalanced tire and w heel Soft suspension • Weak fork spring • Low fluid level in fork • Insufficient fluid w eight (low viscosity) • Low tire pressure Hard suspension • High tire pressure • Bent fork tube • Fork slider binds • High fluid level in fork leg • Incorrect fluid w eight (high viscosity) • Clogged fork fluid passage • Clogged anti-dive orifice Front suspension noisy • Loose fork fasteners • Insufficient fluid w eight (low viscosity) Wheel turns hard • Faulty w heel bearings • Bent front axle • Brake drag

13-6

FRONT WHEEL/SUSPENSION/STEERING

HANDLEBAR LEFT HANDLEBAR REMOVAL Rem ove the m eter panel (page 2-7).

Rem ove the tw o screw s and handlebar center cover.

Hold the handlebar w eight and rem ove the m ounting screw and the w eight.

Rem ove the holder cap from the clutch m aster cylinder holder bolts.

Disconnect the clutch sw itch connectors. Disconnect the clutch cruise sw itch connectors. Keep the clutch reservoir upright to prevent air from entering the hydraulic system.

HOLDER

Rem ove the tw o bolts, holder and the clutch m aster cylinder assem bly.

BOLTS

13-7

FRONT WHEEL/SUSPENSION/STEERING Rem ove the left handlebar m ounting bolts.

SCREWS

Rem ove the tw o screw s and handlebar setting plate.

PLATE Rem ove the tw o screw s from the left handlebar sw itch.

5+4-95

SCREW

Rem ove the screw , setting plate and the left handlebar sw itch. Rem ove the left handlebar grip.

PLATE

13-8

FRONT WHEEL/SUSPENSION/STEERING LEFT HANDLEBAR INSTALLATION Clean the inside surface of the left handlebar grip and the outside surface of the handlebar. Apply Honda Bond A or equivalent to the inside surface of the left handlebar grip and to the outside surface of the left handlebar. Wait 3 â&#x20AC;&#x201C; 5 m inutes and install the grip. Allow the adhesive to dry for an hour before using.

Rotate the grip for even application of the adhesive.

Install the left handlebar sw itch, aligning its locating pin w ith the hole in the left handlebar.

HOLE

PIN Install the setting plate and tighten the screw .

Install the left handlebar sw itch screw s. Tighten the forw ard screw first, then the rear screw .

5+4-95

13-9

FRONT WHEEL/SUSPENSION/STEERING Route the wires and hose properly (page 1-23).

SCREWS

Install the handlebar setting plate and tighten the screw s.

PLATE Place the left handlebar onto the top bridge and align the bolt holes securely, then install the handlebar m ounting bolts and tighten them to the specified torque. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft)

Install the clutch m aster cylinder and holder. Align the end of the m aster cylinder w ith the punch m ark on the handlebar, and tighten the upper bolt first, then the low er bolt.

HOLDER

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Connect the clutch sw itch connectors. Connect the clutch cruise sw itch connectors.

BOLTS Install the holder cap onto the clutch m aster cylinder holder bolts.

13-10

FRONT WHEEL/SUSPENSION/STEERING Install the handlebar outer w eight onto the inner w eight, aligning the bosses and grooves. Install a new m ounting screw and tighten it w hile holding the w eight. TORQUE: 10 N路m (1.0 kgf路m, 7 lbf路ft) Install the handlebar center cover (page 13-7). Install the m eter panel (page 2-7).

RIGHT HANDLEBAR REMOVAL Rem ove the m eter panel (page 2-7). Rem ove the handlebar center cover (page 13-7). Hold the handlebar w eight and rem ove the m ounting screw and w eight.

Rem ove the holder cap from the brake m aster cylinder holder bolts.

+)2

Disconnect the brake light/cruise cancel sw itch connectors. Loosen the tw o brake m aster cylinder holder bolts, but do not rem ove them .

BOLTS

13-11

FRONT WHEEL/SUSPENSION/STEERING

Release the throttle cables from the handlebar clam p.

Rem ove the right handlebar m ounting bolts.

Rem ove the tw o screw s and handlebar setting plate.

BOLTS

PLATE

SCREWS Keep the brake reservoir upright to prevent air from entering the hydraulic system.

Rem ove the tw o bolts, holder and the brake m aster cylinder assem bly.

HOLDER

BOLTS

13-12

FRONT WHEEL/SUSPENSION/STEERING 5+4-95

Rem ove the tw o screw s from the right handlebar sw itch.

Rem ove the screw , and setting plate from the right handlebar sw itch.

SCREW

PLATE Rem ove the throttle grip from the right handlebar and disconnect the throttle cables from the throttle grip flange. Rem ove the throttle grip from the throttle pipe.

RIGHT HANDLEBAR INSTALLATION Clean the inside surface of the throttle grip and the outside surface of the throttle pipe. Apply Honda Bond A or equivalent to the inside surface of the throttle grip and to the outside surface of the throttle pipe. Wait 3 â&#x20AC;&#x201C; 5 m inutes and install the grip. Allow the adhesive to dry for 1 hour before using.

Rotate the grip for even application of the adhesive.

13-13

FRONT WHEEL/SUSPENSION/STEERING Apply grease to the throttle grip pipe flange and sliding surface. Route the cables properly (page 1-23).

Connect the throttle cables to the throttle grip pipe flange and install the throttle grip onto the handlebar. Install the right handlebar sw itch, aligning its locating pin w ith the hole in the right handlebar.

HOLE

Install the setting plate and tighten the screw .

SCREW

PLATE Install the right handlebar sw itch screw s. Tighten the forw ard screw first, then the rear screw .

Install the brake m aster cylinder and holder. Align the end of the m aster cylinder w ith the punch m ark on the handlebar and tem porarily tighten the holder bolts.

5+4-95

HOLDER

BOLTS

13-14

FRONT WHEEL/SUSPENSION/STEERING Route the wires and hose properly (page 1-23).

Install the handlebar setting plate and tighten the screw s.

PLATE

SCREWS BOLTS

Place the right handlebar onto the top bridge and align the bolt holes securely. Then install the handlebar m ounting bolts and tighten them to the specified torque. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft)

Securely clam p the throttle cables w ith the handlebar clam p.

M ake sure the end of the m aster cylinder aligns w ith the handlebar, and tighten the upper bolt first, then the low er bolt. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Connect the connectors.

brake

light/cruise

cancel

sw itch

BOLTS

13-15

FRONT WHEEL/SUSPENSION/STEERING Install the holder cap onto the brake m aster cylinder holder bolts.

+)2

Install the handlebar outer w eight onto the inner w eight, aligning the bosses and grooves. Install a new m ounting screw and tighten it w hile holding the w eight. TORQUE: 10 NÂˇm (1.0 kgfÂˇm, 7 lbfÂˇft)

Install and secure the handlebar center cover w ith the tw o screw s.

Install the m eter panel (page 2-7).

FRONT WHEEL REMOVAL Be careful not to damage the wheel speed sensor and pulse ring.

Rem ove the front fender covers and front fender A (page 2-6). Support the m otorcycle securely using a hoist or equivalent and raise the front w heel off the ground.

â&#x20AC;˘ Do not operate the brake lever and pedal after rem oving the brake caliper.

Cover both sides of the front w heel w ith protective tape or an equivalent to prevent dam aging it. Support the brake caliper so that it does not hang from the brake hoses. Do not twist the brake hoses.

13-16

Rem ove the tw o m ounting bolts (low er pivot and upper joint bolts) and left front brake caliper. Rem ove the pivot collars from the fork and caliper bracket.

FRONT WHEEL/SUSPENSION/STEERING

Rem ove the clam p bolt and speed sensor w ire clam p. Support the brake caliper so that it does not hang from the brake hoses. Do not twist the brake hoses.

Rem ove the tw o brake caliper m ounting bolts and right front brake caliper.

Loosen the right axle holder bolts. Rem ove the front axle bolt.

Loosen the left front axle holder bolts. Rem ove the front axle and the front w heel.

Rem ove the side collars.

13-17

FRONT WHEEL/SUSPENSION/STEERING INSPECTION AXLE Set the front axle in V-blocks. Turn the front axle and m easure the runout using a dial indicator. Actual runout is 1/2 the total indicator reading.

SERVICE LIMIT: 0.20 mm (0.008 in)

WHEEL RIM Check the rim runout by placing the w heel in a truing stand. Spin the w heel slow ly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)

Replace the wheel bearings in pairs.

WHEEL BEARING Turn the inner race of each bearing w ith your finger; the bearings should turn sm oothly and quietly. Also check that the bearing outer race fits tightly in the hub. Rem ove and discard the bearings if the races do not turn sm oothly and quietly, or if they fit loosely in the hub.

WHEEL BEARING DISASSEMBLY Rem ove the dust seals.

13-18

DUST SEALS

FRONT WHEEL/SUSPENSION/STEERING Rem ove the three bolts and front pulser ring from the right w heel hub.

Rem ove the six brake disc bolts and brake disc from the right w heel hub.

Rem ove the six brake disc bolts and brake disc from the left w heel hub.

Replace the wheel bearings in pairs. Do not reuse old bearings.

Install the bearing rem over head into the bearing. From the opposite side of the w heel, install the bearing rem over shaft and drive the bearing out of the w heel hub. Rem ove the distance collar and drive out the other bearing. TOOLS: Bearing remover shaft 07746-0050100 Bearing remover head, 20 mm 07746-0050600

13-19

FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY

Drive in a new right bearing squarely w ith the m arked side facing up until it is fully seated. Install the distance collar. Drive in a new left bearing squarely w ith the m arked side facing up until it is fully seated. TOOLS: Driver Attachment, 42 x 47 mm Pilot, 20 mm

07749-0010000 07746-0010300 07746-0040500

Install the brake discs w ith the arrow m ark facing out. Install new disc bolts and tighten them in a crisscross pattern in tw o or three steps.

TORQUE: 20 NÂˇm (2.0 kgfÂˇm, 14 lbfÂˇft)

13-20

FRONT WHEEL/SUSPENSION/STEERING Install the pulser ring onto the right w heel hub. Install new pulser ring bolts and tighten them in a crisscross pattern in tw o or three steps.

TORQUE: 8 N·m (0.8 kgf·m, 5.8 lbf·ft)

WHEEL BALANCE Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check balance before reinstalling the wheel.

ROTATING DIRECTION

• M ount the tire w ith the arrow m ark facing in the direction of rotation. • The w heel balance m ust be checked w hen the tire is rem ounted. • For optim um balance, the tire balance m ark (a paint dot on the side w all) m ust be located next to the valve stem . Rem ount the tire if necessary.

ARROW MARK M ount the w heel, tire and brake discs and pulser ring (ABS m odel only) assem bly on an inspection stand. Spin the w heel, allow it to stop, and m ark the low est (heaviest) part of the w heel w ith chalk. Do this tw o or three tim es to verify the heaviest area. If the w heel is balanced, it w ill not stop consistently in the sam e position.

To balance the w heel, install a balance w eight on the lightest side of the spoke, on the side opposite the chalk m arks. Add just enough w eight so the w heel w ill no longer stop in the sam e position w hen it is spun. Do not add m ore than 60 g (2.1 oz) to the front w heel.

TIRE BALANCE MARK (left side wall)

BALANCE WEIGHT

13-21

FRONT WHEEL/SUSPENSION/STEERING Do not get grease on the brake discs or stopping power will be reduced.

Apply grease to new dust seal lips and install the dust seals until they are flush w ith the w heel hub.

DUST SEALS

INSTALLATION Be careful not to damage the wheel speed sensor and pulser ring.

Install the side collars. â&#x20AC;˘ The right side collar is longer than the left side collar.

Place the front w heel betw een the fork legs. Insert the front axle from the left side until it is fully seated. M ake sure the index line on the axle is aligned w ith the fork leg.

Install the axle bolt and tighten it to the specified torque w hile holding the axle.

TORQUE: 59 NÂˇm (6.0 kgfÂˇm, 43 lbfÂˇft) Tighten the right axle holder bolts to the specified torque. TORQUE: 22 NÂˇm (2.2 kgfÂˇm, 16 lbfÂˇft)

13-22

FRONT WHEEL/SUSPENSION/STEERING

Install the right front brake caliper w ith new m ounting bolts so the disc is positioned betw een the pads, being careful not to dam age the pads. Tighten the m ounting bolts. TORQUE: 31 NÂˇm (3.2 kgfÂˇm, 23 lbfÂˇft) Install the speed sensor w ire clam p and tighten the bolt.

Apply grease to the low er pivot bearing and dust seal lips, and to the outer surface of the upper pivot collar. Install the pivot collars into the fork and caliper bracket.

Install the left front brake caliper w ith new m ounting bolts (low er pivot and upper joint bolts) and tighten them .

TORQUE: Pivot bolt: 31 NÂˇm (3.2 kgfÂˇm, 23 lbfÂˇft) Joint bolt: 25 NÂˇm (2.6 kgfÂˇm, 19 lbfÂˇft) Rem ove the protective tape.

With the front brake applied, pum p the forks up and dow n several tim es to seat the axle and check brake operation.

Tighten the left axle holder bolts to the specified torque.

LEFT AXLE HOLDER BOLTS

TORQUE: 22 NÂˇm (2.2 kgfÂˇm, 16 lbfÂˇft)

13-23

FRONT WHEEL/SUSPENSION/STEERING Check the clearance betw een the brake disc and caliper bracket on each side after installation. The clearance should be at least 0.7 m m (0.28 in).

FEELER GAUGE

If the feeler gauge cannot be inserted easily, loosen the axle holder bolts and pull the fork outw ard or push inw ard to adjust the clearance. Then tighten the axle holder bolts to the specified torque.

After installing the wheel, apply the front and rear brakes several times and recheck the caliper clearances between each surface of the brake disc and the brake caliper. Failure to provide clearance will damage the brake disc and affect braking efficiency. ABS model only.

Check the front w heel speed sensor air gap (page 16-29). Install front fender A (page 2-6). Install the front fender side covers (page 2-6).

FORK REMOVAL Rem ove the front w heel (page 13-16). Rem ove the follow ing: â&#x20AC;&#x201C; trim clip â&#x20AC;&#x201C; tw o bolts â&#x20AC;&#x201C; front fender top cover

â&#x20AC;&#x201C; tw o front fender B m ounting bolts from the left fork leg

13-24

BOLTS

FRONT WHEEL/SUSPENSION/STEERING â&#x20AC;&#x201C; tw o front fender B m ounting bolts from the right fork leg â&#x20AC;&#x201C; front fender B â&#x20AC;&#x201C; delay valve m ounting bolt

â&#x20AC;&#x201C; tw o bolts and anti-dive plunger case â&#x20AC;&#x201C; oil hose joint attaching bolt â&#x20AC;&#x201C; tw o secondary m aster cylinder m ounting bolts Do not hang the brake caliper and secondary m aster cylinder from the brake hoses.

The fork cap is under spring pressure; use care when loosening it.

Loosen the fork top bridge pinch bolts. When the fork is ready to be disassem bled, loosen the fork caps, but do not rem ove them .

FORK CAPS

TOP BRIDGE PINCH BOLTS Be careful not to drop the fork legs when loosening the bolts.

Loosen the bottom bridge pinch bolts and rem ove the fork tubes from the fork bridges.

BOTTOM BRIDGE PINCH BOLTS

13-25

FRONT WHEEL/SUSPENSION/STEERING LEFT FORK LEG DISASSEMBLY Rem ove the tw o bolts and front fender m ounting plate. Rem ove the axle holder bolts.

AXLE HOLDER BOLTS

PLATE NEEDLE BEARINGS

Rem ove the joint collar. Check the dust seals for w ear, dam age or fatigue. Check the needle bearings for dam age or loose fit. If the needle bearings are dam aged, replace them (page 13-32).

DUST SEALS JOINT COLLAR The fork cap is under spring pressure; use care when removing it.

Rem ove the fork cap from the fork tube. Rem ove the O-ring from the fork cap.

FORK CAP

Rem ove the follow ing: – spacer – spring seat – fork spring

FORK SPRING

Pour out the fork fluid by pum ping the fork tube up and dow n several tim es.

SPRING SEAT

13-26

SPACER

FRONT WHEEL/SUSPENSION/STEERING If the fork piston turns with the center bolt, temporarily install the fork spring, spring seat, spacer and fork cap.

Hold the fork slider in a vise w ith a soft jaw s or shop tow el and rem ove the center bolt and sealing w asher.

FORK CENTER BOLT

STOPPER RING

Rem ove the dust seal. Rem ove the stopper ring being careful not to scratch the fork tube sliding surface.

DUST SEAL Using quick successive m otions, pull the fork tube out of the fork slider.

Rem ove the follow ing: – stopper ring – oil lock valve – oil lock spring – spring seat – stopper ring Rem ove the fork piston and rebound spring from the fork tube.

13-27

FRONT WHEEL/SUSPENSION/STEERING Rem ove the oil seal, back-up ring and guide bushing from the fork tube. Do not remove the slider bushing unless it is necessary to replace it with a new one.

Carefully rem ove the slider bushing by prying the slot w ith a screw driver until the bushing can be pulled off by hand.

LEFT FORK LEG INSPECTION FORK SPRING M easure the fork spring free length. SERVICE LIMIT: 328.6 mm (12.94 in)

FORK TUBE/SLIDER/PISTON

FORK SLIDER

Check the fork tube, slider and fork piston for score m arks, and excessive or abnorm al w ear. Check the rebound spring for fatigue or dam age. Check the fork piston ring for w ear or dam age.

FORK TUBE

Replace any dam aged com ponent if necessary.

REBOUND SPRING Set the fork tube in V-blocks and m easure the fork tube runout w ith a dial indicator. Actual runout is 1/2 the total indicator reading.

FORK PISTON

DIAL INDICATOR

SERVICE LIMIT: 0.20 mm (0.008 in)

FORK TUBE

13-28

FRONT WHEEL/SUSPENSION/STEERING Visually inspect the slider and guide bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is w orn so that the copper surface appears on m ore than 3/4 of the entire surface.

Check the back-up ring; replace it if there is any distortion at the points show n.

LEFT FORK LEG ASSEMBLY Before assem bly, w ash all parts w ith a high flash point or non-flam m able solvent and w ipe them off com pletely.

13-29

FRONT WHEEL/SUSPENSION/STEERING Be careful not to damage the coating of the bushing. Do not spread open the bushing more than necessary.

Install a new slider bushing if the bushing has been rem oved. â&#x20AC;˘ Rem ove the burrs from the bushing m ating surface, being careful not to peel off the coating.

OIL SEAL GUIDE BUSHING

Install the guide bushing and install the back-up ring w ith its cham fered surface side facing dow n. Apply fork fluid to a new oil seal lip. Install the oil seal w ith the m arks side facing up.

BACK-UP RING SLIDER BUSHING Install the rebound spring onto the fork piston. Install the fork piston into the fork tube. Install the follow ing: â&#x20AC;&#x201C; stopper ring â&#x20AC;&#x201C; spring seat â&#x20AC;&#x201C; oil lock spring â&#x20AC;&#x201C; oil lock valve â&#x20AC;&#x201C; stopper ring

SPRING SEAT SPRING

STOPPER RINGS

Install the fork tube into the fork slider.

OIL LOCK VALVE If the fork piston turns with the center bolt, temporarily install the fork spring, spring seat, spacer and fork cap.

Hold the fork slider in a vise w ith soft jaw s or a shop tow el. Apply locking agent to the center bolt threads. Install the center bolt w ith a new sealing w asher and tighten it to the specified torque.

TORQUE: 20 NÂˇm (2.0 kgfÂˇm, 14 lbfÂˇft)

Drive the oil seal into the fork slider until the stopper ring groove is visible using the special tool. TOOL: Fork seal driver, 45 mm

13-30

07KMD-KZ30100 or 07KMD-KZ3010A (U.S.A. only)

FRONT WHEEL/SUSPENSION/STEERING Install the stopper ring into the groove into the fork slider being careful not to scratch the fork tube sliding surface. Apply fork fluid to the lip of a new dust seal and install the dust seal.

STOPPER RING DUST SEAL

Pour the specified am ount of the recom m ended fork fluid into the fork tube. RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-8 FORK FLUID CAPACITY: 529 ± 2.5 cm3 (17.9 ± 0.08 US oz, 18.6 ± 0.09 Imp oz)

FORK FLUID

Slow ly pum p the fork tube several tim es to rem ove any trapped air from the low er portion of the fork tube. Com press the fork tube fully. M easure the oil level from the top of the fork tube. FORK FLUID LEVEL: 128 mm (5.0 in)

OIL LEVEL

Pull the fork tube up and install the fork spring w ith the tightly w ound coil side facing dow n.

13-31

FRONT WHEEL/SUSPENSION/STEERING Install the spring seat and spacer.

Tighten the fork cap after installing the fork tube into the fork bridges.

Coat a new O-ring w ith fork fluid and install it into the fork cap groove. Install the fork cap into the fork tube.

O-RING

LEFT FORK LEG NEEDLE BEARING REPLACEMENT Rem ove the dust seals from the fork slider. Press the needle bearings out of the fork slider using the special tools and a hydraulic press. TOOL: Needle bearing remover Assembly collar

07946-KA50000 07965-166030A

Apply grease to the needle rollers of the new bearings. Carefully press the needle bearings in the fork slider until the depth from the fork slider outer surfaces is specified value, using the sam e tool and a hydraulic press. SPECIFIED DEPTH: 3.5 mm (1.4 in) Apply grease to the new dust seal lips and install the seal until it is fully seated.

13-32

FRONT WHEEL/SUSPENSION/STEERING RIGHT FORK DISASSEMBLY Rem ove the tw o bolts and front fender m ounting plate. Rem ove the axle holder bolts.

AXLE HOLDER BOLTS Rem ove the fork cap from the fork tube.

PLATE

FORK CAP

Hold the fork dam per lock nut and rem ove the fork cap from the fork dam per. Rem ove the O-ring from the fork cap.

LOCK NUT Rem ove the follow ing: – spacer – spring seat – fork spring

Pour out the fork fluid by pum ping the fork tube up and dow n several tim es.

13-33

FRONT WHEEL/SUSPENSION/STEERING If the fork damper turns with the center bolt, temporarily install the fork spring, spring seat, spacer and fork cap.

Hold the fork slider in a vise w ith soft jaw s or a shop tow el and rem ove the center bolt and sealing w asher.

FORK CENTER BOLT

STOPPER RING

Rem ove the dust seal. Rem ove the stopper ring being careful not to scratch the fork tube sliding surface.

DUST SEAL Using quick successive m otions, pull the fork tube out of the fork slider.

Rem ove the fork dam per and rebound spring from the fork tube. Rem ove the oil lock piece.

FORK DAMPER

OIL LOCK PIECE

13-34

FRONT WHEEL/SUSPENSION/STEERING

OIL SEAL

Rem ove the oil seal, back-up ring and guide bushing from the fork tube. Do not remove the slider bushing unless it is necessary to replace it with a new one.

Carefully rem ove the slider bushing by prying the slot w ith a screw driver until the bushing can be pulled off by hand.

SLIDER BUSHING

BACK-UP RING GUIDE BUSHING RIGHT FORK LEG INSPECTION FORK SPRING M easure the fork spring free length. SERVICE LIMIT: 328.6 mm (12.94 in)

FORK TUBE/SLIDER/DAMPER Check the fork tube, slider and fork dam per for score m arks, and excessive or abnorm al w ear. Check the rebound spring for fatigue or dam age. Replace the com ponent if necessary.

Set the fork tube in V-blocks and m easure the fork tube runout w ith a dial indicator. Actual runout is 1/2 the total indicator reading.

DIAL INDICATOR

SERVICE LIMIT: 0.20 mm (0.008 in)

FORK TUBE

13-35

Check the back-up ring; replace it if there is any distortion at the points show n.

RIGHT FORK LEG ASSEMBLY Before assem bly, w ash all parts w ith a high flash point or non-flam m able solvent and w ipe them off com pletely.

Be careful not to damage the coating of the bushing. Do not spread open the bushing more than necessary.

Install a new slider bushing if the bushing has been rem oved. â&#x20AC;˘ Rem ove the burrs from the bushing m ating surface, being careful not to peel off the coating. Install the guide bushing and install the back-up ring w ith its cham fered surface side facing dow n. Apply fork fluid to a new oil seal lip. Install the oil seal w ith the m arked side facing up. Install the rebound spring onto the fork dam per. Install the fork dam per into the fork tube. Install the oil lock piece onto the dam per end.

13-36

FRONT WHEEL/SUSPENSION/STEERING Install the fork tube into the fork slider.

FORK DAMPER

OIL LOCK PIECE

If the fork damper turns with the center bolt, temporarily install the fork spring, spring seat, spacer and fork cap.

Drive the oil seal into the fork slider until the stopper ring groove is visible using the special tool. TOOL: Fork seal driver, 45 mm

FORK SEAL DRIVER

07KMD-KZ30100 07KMD-KZ3010A (U.S.A. only)

Install the stopper ring into the groove in the fork slider being careful not to scratch the fork tube sliding surface. Apply fork fluid to the lip of a new dust seal and install the dust seal.

STOPPER RING

DUST SEAL

13-37

FRONT WHEEL/SUSPENSION/STEERING Pour the specified am ount of the recom m ended fork fluid into the fork tube. RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-8 FORK FLUID CAPACITY: 485 ± 2.5 cm3 (16.4 ± 0.08 US oz, 17.1 ± 0.09 Imp oz)

FORK FLUID

OIL LEVEL

Pull the fork tube up and install the fork spring w ith the tightly w ound coil side facing dow n.

Install the spring seat and spacer.

13-38

FRONT WHEEL/SUSPENSION/STEERING Coat a new O-ring w ith fork fluid and install it into the fork cap groove. Install the fork cap onto the fork dam per. Hold the fork dam per and screw the fork cap onto it.

O-RING

Hold the fork dam per lock nut and tighten the fork cap to the specified torque. TORQUE: Fork damper lock nut: 20 N路m (2.0 kgf路m, 14 lbf路ft)

LOCK NUT Tighten the fork cap after installing the fork tube into the fork bridges.

Screw the fork cap into the fork tube.

FORK CAP

INSTALLATION Route the wires, cables and hoses properly (page 1-23).

Install the fork tubes into the fork bridges. Align the top of the fork tubes w ith the upper surface of the top bridge as show n.

FORK CAP

TOP BRIDGE FORK TUBE

13-39

FRONT WHEEL/SUSPENSION/STEERING Tighten the bottom bridge pinch bolts to the specified torque. TORQUE: 29 NÂˇm (3.0 kgfÂˇm, 22 lbfÂˇft)

BOTTOM BRIDGE PINCH BOLTS FORK CAPS

Tighten the fork caps to the specified torque. TORQUE: 23 NÂˇm (2.3 kgfÂˇm, 17 lbfÂˇft) Tighten the top bridge pinch bolts to the specified torque. TORQUE: 26 NÂˇm (2.7 kgfÂˇm, 20 lbfÂˇft)

TOP BRIDGE PINCH BOLTS Install the secondary m aster cylinder onto the left fork w ith new m ounting bolts and tighten them . TORQUE: 31 NÂˇm (3.2 kgfÂˇm, 23 lbfÂˇft) Install the brake hose joint and tighten the bolt.

TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft)

Clean the m ating areas of the plunger case and front fork w ith com pressed air, and be sure that no foreign m aterials are allow ed.

BOLTS

Apply silicone grease to the anti-dive plunger tip. Install the anti-dive plunger case w ith new socket bolts and tighten them . TORQUE: 4 NÂˇm (0.4 kgfÂˇm, 2.9 lbfÂˇft)

PLUNGER CASE

13-40

FRONT WHEEL/SUSPENSION/STEERING Install the follow ing: â&#x20AC;&#x201C; delay valve and m ounting bolt â&#x20AC;&#x201C; front fender B â&#x20AC;&#x201C; four fender m ounting bolts w ith brake hose clam p

TORQUE: Delay valve mounting bolt: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft)

â&#x20AC;&#x201C; fender top cover and tw o bolts â&#x20AC;&#x201C; trim clip Install the front w heel (page 13-16).

FENDER TOP COVER

TRIM CLIP

BOLTS

STEERING STEM REMOVAL Rem ove the com bination m eter (page 20-17). Rem ove the handlebar center cover (page 13-7). Keep the brake and clutch reservoir upright to prevent air from entering the hydraulic system.

Rem ove the tw o bolts and hydraulic hose clam p. Rem ove the handlebar m ounting bolts.

13-41

FRONT WHEEL/SUSPENSION/STEERING Rem ove the steering stem nut cap and disconnect the turn signal cancel unit connector.

CAP

CONNECTOR

Loosen the steering stem nut. Rem ove the fork legs (page 13-24). Rem ove the steering stem nut and top bridge.

Rem ove the follow ing: – tw o bolts – tw o screw s

BOLTS

SCREWS – three screw s – turn signal cancel unit – w ind protector

13-42

FRONT WHEEL/SUSPENSION/STEERING Straighten the lock w asher tabs. Rem ove the steering bearing adjustm ent nut, lock nut and lock w asher.

Rem ove the steering bearing adjustm ent nut using the special tool. TOOL: Steering stem socket

07916-3710101 or 07916-3710100

Rem ove the follow ing: â&#x20AC;&#x201C; dust seal

â&#x20AC;&#x201C; upper bearing inner race â&#x20AC;&#x201C; steering stem â&#x20AC;&#x201C; upper bearing

DUST SEAL

INNER RACE

UPPER BEARING

13-43

FRONT WHEEL/SUSPENSION/STEERING â&#x20AC;&#x201C; low er bearing from the steering stem

STEERING BEARING REPLACEMENT Always replace the bearings and races as a set.

Replace the steering bearing outer races using the special tools listed below . TOOLS: Main bearing driver attachment Fork seal driver weight Oil seal driver Installer shaft Installer attachment A Remover attachment A Remover attachment B Installer attachment B

07946-ME90200 07947-KA50100 07965-MA60000 07VMF-KZ30200 07VMF-MAT0100 07VMF-MAT0300 07VMF-MAT0400 07ZMF-MCAA100

Install the special tools into the steering head pipe as show n. Align rem over attachm ent A w ith the groove in the steering head. While holding the installer shaft w ith the w rench, turn the upper nut gradually to rem ove the upper bearing outer race.

MAIN BEARING DRIVER ATTACHMENT FORK SEAL DRIVER WEIGHT UPPER BEARING OUTER RACE REMOVER ATTACHMENT A

INSTALLER SHAFT

INSTALLER ATTACHMENT B

13-44

UPPER NUT

LOWER NUT

FRONT WHEEL/SUSPENSION/STEERING Install the special tools into the steering head pipe as show n. Align rem over attachm ent B w ith the groove in the steering head. While holding the installer shaft w ith the w rench, turn the low er nut gradually to rem ove the low er bearing outer race.

Install a new upper bearing outer race and the special tools as show n. While holding the installer shaft w ith the w rench, turn the low er nut gradually until the outer race bottom s on the steering head pipe.

INSTALLER ATTACHMENT A

UPPER NUT

UPPER BEARING OUTER RACE INSTALLER SHAFT INSTALLER ATTACHMENT B

OIL SEAL DRIVER FORK SEAL DRIVER WEIGHT MAIN BEARING DRIVER ATTACHMENT

LOWER NUT

13-45

FRONT WHEEL/SUSPENSION/STEERING Install a new low er bearing outer race and the special tools as show n. While holding the installer shaft w ith the w rench, turn the upper nut gradually until the outer race bottom s on the steering head pipe.

MAIN BEARING DRIVER ATTACHMENT

UPPER NUT

FORK SEAL DRIVER WEIGHT

INSTALLER ATTACHMENT A INSTALLER SHAFT LOWER BEARING OUTER RACE

INSTALLER ATTACHMENT B Install the stem nut onto the stem to prevent the threads from being dam aged w hen rem oving the low er bearing inner race from the stem . Rem ove the low er bearing inner race w ith a chisel or equivalent tool, being careful not to dam age the stem . Rem ove the dust seal.

LOWER NUT

STEM NUT

Apply grease to a new dust seal lip and install it onto the steering stem . Press a new low er bearing inner race onto the steering stem using the special tools. TOOL: Attachment, 35 mm

07746-0030400

ATTACHMENT

13-46

FRONT WHEEL/SUSPENSION/STEERING INSTALLATION

CONNECTOR

STEM NUT CAP STEERING STEM NUT

HYDRAULIC HOSE CLAMP TOP BRIDGE

UPPER INNER RACE

LOWER OUTER RACE

LOCK NUT LOCK WASHER STEERING BEARING ADJUSTMENT NUT DUST SEAL

LOWER BEARING LOWER INNER RACE

UPPER OUTER RACE

UPPER BEARING

WIND PROTECTOR

STEERING STEM DUST SEAL

TURN SIGNAL CANCEL CONTROL UNIT

Apply grease to the steering bearings and bearing races. Install the low er bearing onto the steering stem . Install the steering stem into the steering head pipe.

Install the upper bearing and inner race.

INNER RACE

UPPER BEARING

13-47

FRONT WHEEL/SUSPENSION/STEERING Apply grease to a new dust seal lip and install it.

Apply engine oil to the steering bearing adjustm ent nut threads and install it.

DUST SEAL

1. Tighten the steering bearing adjustm ent nut to the specified torque. TOOL: Steering stem socket

07916-3710101 or 07916-3710100

TORQUE: 27 N路m (2.8 kgf路m, 20 lbf路ft) 2. Loosen the steering bearing adjustm ent nut and retighten it to the sam e torque.

3. Turn the steering stem left and right, lock-to-lock at least four tim es to seat the bearings. Retighten the adjustm ent nut to the sam e torque. 4. Repeat step 3.

13-48

FRONT WHEEL/SUSPENSION/STEERING Install a new lock w asher and bend the tw o opposite tabs dow n into the grooves in the steering bearing adjustm ent nut. Install and finger tighten the lock nut all the w ay. Hold the steering bearing adjustm ent nut and further tighten the lock nut, w ithin 90 degrees, to align its grooves w ith the tabs of the lock w asher. Bend up the lock w asher tabs into the grooves of the lock nut.

LOCK NUT

LOCK WASHER

Put the turn signal cancel unit w ire through the steering stem . Install the follow ing: – w ind protector – turn signal cancel unit – three screw s Tighten the screw s.

Install the tw o screw s and tw o bolts and tighten them .

BOLTS

TORQUE: Clamp bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft)

SCREWS Install the top bridge and steering stem nut. Tem porarily install the fork legs into the fork bridges.

13-49

FRONT WHEEL/SUSPENSION/STEERING Tighten the steering stem nut to the specified torque. TORQUE: 103 NÂˇm (10.5 kgfÂˇm, 76 lbfÂˇft) Rem ove the fork legs. M ake sure that the steering stem m oves sm oothly, w ithout play or binding. Install the forks legs (page 13-24).

Connect the turn signal cancel unit connector and install the steering stem nut cap.

CAP

CONNECTOR

Install the hydraulic hose clam p w ith the tw o bolts and tighten the bolts. Place the left and right handlebars onto the top bridge and align the bolt holes, then install the handlebar m ounting bolts and tighten them to the specified torque. TORQUE: 26 NÂˇm (2.7 kgfÂˇm, 20 lbfÂˇft) Install the handlebar center cover (page 13-7). Install the com bination m eter (page 20-17).

STEERING BEARING PRE-LOAD Rem ove the front fairing (page 2-10). Support the m otorcycle securely using safety stands or a hoist and raise the front w heel off the ground. Position the steering stem to the straight ahead position. Hook a spring scale to the fork tube betw een the fork top and bottom bridges. M ake sure there is no cable, w ire harness or hose interference. Pull the spring scale keeping it at a right angle to the steering stem . Read the scale at the point w here the steering stem just starts to m ove. STEERING BEARING PRE-LOAD: 8.8 â&#x20AC;&#x201C; 13.7 N (0.9 â&#x20AC;&#x201C; 1.4 kgf, 2.0 â&#x20AC;&#x201C; 3.1 lbf) If the readings do not fall w ithin the lim its, readjust the steering bearing adjustm ent. Install the front fairing (page 2-10).

13-50

90Â°

14. REAR WHEEL/SUSPENSION

COMPONENT LOCATION ··························· 14-2

SHOCK ABSORBER····································14-16

SERVICE INFORMATION ···························· 14-3

SUSPENSION LINKAGE ····························14-18

TROUBLESHOOTING ·································· 14-5

SWINGARM ················································14-22

REAR WHEEL ············································· 14-14

SUSPENSION LEVEL RELAY·····················14-29

14-1

REAR WHEEL/SUSPENSION

COMPONENT LOCATION REAR WHEEL/SUSPENSION

14-2

REAR WHEEL/SUSPENSION

SERVICE INFORMATION GENERAL • Riding on dam aged rim s im pairs safe operation of the vehicle. • When servicing the rear w heel, shock absorber, or sw ingarm , raise the rear w heel off the ground by supporting the fram e securely. • A contam inated brake disc or pad reduces stopping pow er. Discard contam inated pads and clean a contam inated disc w ith a high quality brake degreasing agent.

• The shock absorber contains nitrogen gas under high pressure. Do not allow fire or heat near the shock absorber. • Before discarding the shock absorber, release the nitrogen. • The damper unit is filled with nitrogen gas under high pressure, do not try to disassemble. • Use only genuine Honda replacem ent bolts and nuts for all suspension pivot and m ounting points. • When using the lock nut w rench, use a deflecting beam type torque w rench 20 inches long. The lock nut w rench increases the torque w rench’s leverage, so the torque w rench reading w ill be less than the torque actually applied to the lock nut. The specification given on page 14-3 is the actual torque applied to the lock nut, not the reading on the torque w rench w hen used w ith the lock nut w rench. The procedure later in the text gives both actual and indicated. • After installing the rear w heel, perform the air gap inspection if the rear brake disc w as rem oved (page 16-31). • Refer to section 15 for hydraulic brake system service. • The angle sensor digital pulse signal is sent to the suspension level control unit in the com bination m eter. For com bination m eter servicing, see section 19. • The follow ing color codes are indicated throughout this section. Bl: Black Br: Brow n

G: Green W: White

Lg: Light Green Bu: Blue

R: Red Y: Yellow

SPECIFICATIONS ITEM M inim um tire tread depth Cold tire pressure Driver only Driver and passenger Wheel rim runout Radial Axial Wheel balance w eight

STANDARD – 280 kPa (2.80 kgf/cm 2, 41 psi) 280 kPa (2.80 kgf/cm 2, 41 psi) – – –

Unit: m m (in) SERVICE LIMIT 2.0 (0.08) – – 2.0 (0.08) 2.0 (0.08) 70 g (2.5 oz) m ax.

TORQUE VALUES Rear w heel nut Rear pulser ring bolt (ABS m odel only) Rear brake disc screw Shock absorber m ounting nut Suspension level actuator m ounting bolt Shock arm -to-sw ingarm nut Shock arm -to-shock link nut Shock link-to-fram e nut Sw ingarm right pivot bolt Sw ingarm left pivot bolt Sw ingarm left pivot lock nut Rear brake light/cruise cancel sw itch holder screw Brake hose pipe clam p bolt (sw ing arm )

108 N·m (11.0 kgf·m , 80 lbf·ft) 8 N·m (0.8 kgf·m , 5.8 lbf·ft) 9 N·m (0.9 kgf·m , 6.5 lbf·ft) 42 N·m (4.3 kgf·m , 31 lbf·ft) 26 N·m (2.7 kgf·m , 20 lbf·ft) 64 N·m (6.5 kgf·m , 47 lbf·ft) 64 N·m (6.5 kgf·m , 47 lbf·ft) 64 N·m (6.5 kgf·m , 47 lbf·ft) 108 N·m (11.0 kgf·m , 80 lbf·ft) 34 N·m (3.5 kgf·m , 25 lbf·ft) 108 N·m (11.0 kgf·m , 80 lbf·ft) 2 N·m (0.2 kgf·m , 1.4 lbf·ft)

ALOC bolt: replace w ith a new one. ALOC screw : replace w ith a new one. U-nut.

U-nut. U-nut. U-nut.

Apply locking agent to the threads.

12 N·m (1.2 kgf·m , 9 lbf·ft)

14-3

REAR WHEEL/SUSPENSION TOOLS: Attachm ent, 32 x 35 m m 07746-0010100

Attachm ent, 42 x 47 m m 07746-0010300

Attachm ent, 24 x 26 m m 07746-0010700

Attachm ent, 22 x 24 m m 07746-0010800

Attachm ent, 28 x 30 m m 07946-1870100

Pilot, 17 m m 07746-0040400

Pilot, 20 m m 07746-0040500

Driver 07749-0010000

Driver 07949-3710001

Rem over w eight 07741-0010201

Rem over handle 07936-3710100

Bearing rem over, 20 m m 07936-3710600

used w ith 3/8" x 16 m m thread slide ham m er (com m ercially available in U.S.A.)

or 07936-371020A or 07936-3710200 (U.S.A. only)

14-4

REAR WHEEL/SUSPENSION Lock nut w rench, 9 x 45 m m 07ZM A-M CA0100

TROUBLESHOOTING Soft suspension • Weak shock absorber spring • Incorrect suspension adjustm ent • Oil leakage from dam per unit • Insufficient tire pressure Hard suspension • Incorrect suspension adjustm ent • Dam aged rear suspension pivot bearings • Im properly tightened sw ingarm pivot • Bent dam per rod • Tire pressure too high Rear suspension noise • Faulty rear shock absorber • Loose rear suspension fasteners • Worn rear suspension pivot bearings Rear wheel wobbling • Bent rim • Faulty rear tire • Unbalanced rear tire and w heel • Insufficient rear tire pressure • Faulty sw ingarm pivot bearings • Axle fastener not tightened properly • Low tire pressure Rear wheel turns hard • Rear brake drag (section 15)

14-5

REAR WHEEL/SUSPENSION SHOCK ABSORBER SPRING PRE-LOAD ADJUSTMENT SYSTEM • This electric shock absorber spring pre-load adjustm ent system functions w ith the follow ing conditions: – The ignition sw itch is turned to “ ON” or “ ACC.” – The m otorcycle is stopped. – The transm ission is in neutral. – The reverse system is off. • If the transm ission is shifted, the reverse system is on or the m otorcycle m oves above 1 km /h w hen the system is controlling the spring pre-load, the system w ill stop controlling and the pre-load position indicator bar w ill blink for 3 seconds. • The spring pre-load system has 26 positions (from 0 to 25) for different road or riding conditions. CIRCUIT DIAGRAM

MEMORY SWITCH 1

To reverse control unit From ACC relay From No. 20 fuse

To neutral switch To speed sensor

MANUAL HEIGHT SWITCH

MAIN RELAY MEMORY SWITCH 2

DOWN RELAY

COMBINATION METER

UP RELAY

MOTOR ANGLE SENSOR ACTUATOR ASSEMBLY BEFORE TROUBLESHOOTING • • • • •

Check that the battery is fully charged and in good condition. Check for a blow n No. 20 fuse. Check that the audio system functions properly. Check that the neutral indicator com es on w hen the ignition sw itch is turned to “ ON” w ith the transm ission in neutral. Check that the reverse shift sw itch is pushed to “ OFF” (the reverse indicator stays off).

14-6

REAR WHEEL/SUSPENSION Suspension level actuator operates and the preload position varies between 0 and 25 on the multidisplay with the manual height switch but the suspension level does not vary â&#x20AC;˘ Pre-load adjustm ent hydraulic system leakage; replace the shock absorber as an assem bly (page 14-16). â&#x20AC;˘ If the â&#x20AC;&#x153; SUS ADJ ERRORâ&#x20AC;? indication appears on the m ulti-display w hen the ignition sw itch is turned to â&#x20AC;&#x153; ON,â&#x20AC;? it w ill go off after 30 seconds. Suspension level actuator does not operate with the manual height switch 1. Suspension System Error Indicator Inspection Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? or â&#x20AC;&#x153; ACCâ&#x20AC;? and operate the m anual height sw itch. Check that the â&#x20AC;&#x153; SUS ADJ ERRORâ&#x20AC;? indication blinks on the m ulti-display. Does â&#x20AC;&#x153;SUS ADJ multi-display?

ERRORâ&#x20AC;?

YES

â&#x20AC;&#x201C; GO TO STEP 5.

â&#x20AC;&#x201C; GO TO STEP 2.

blink

the

2. Manual Height Switch Operation Inspection Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Rem ove the left fairing pocket (page 2-11). Disconnect the panel sw itch 14P gray connector. Check for continuity betw een the w ire term inals of the sw itch side connector in each m anual height sw itch position. Continuity should exist betw een the color coded w ires as follow s:

Color Position UP FREE DOWN

Lg/Bl

G/Y

Br/W

Is there continuity? NO

â&#x20AC;&#x201C; Faulty m anual height sw itch; replace the panel sw itch assem bly (page 20-32).

YES

â&#x20AC;&#x201C; GO TO STEP 3.

! "

14-7

REAR WHEEL/SUSPENSION 3. Manual Height Switch Harness Short Circuit Inspection Rem ove the com bination m eter (page 20-17). Check the follow ing w ires for continuity to ground at the panel sw itch 14P gray connector. – Light green/yellow – Brow n/w hite

WIRE HARNESS SIDE 14P CONNECTOR (viewed from the terminal side) Lg/Y

Is there continuity? YES

– Short circuit in the fairing sub-w ire harness.

– GO TO STEP 4.

4. Manual Height Inspection

Switch

G/Y

Br/W Harness

Continuity

Check the follow ing w ires for continuity betw een the panel sw itch 14P gray connector and com bination m eter 16P black connector. – Light green/yellow – Brow n/w hite – Green/yellow

G/Y

Lg/Y

Br/W

Is there continuity? NO

– Open circuit in the fairing sub-w ire harness.

YES

– • Loose or poor contact of the sw itch 14P gray connector and m eter 16P black connector. • Faulty com bination m eter; replace the m eter/ gauge assem bly (page 20-15).

METER 16P BLACK CONNECTOR (viewed from the terminal side)

5. Angle Sensor Power Input and Ground Line Inspection at Combination Meter Turn the ignition sw itch to “ OFF.” Rem ove the com bination m eter (page 20-17). M easure the angle sensor resistance betw een the Black/red and Blue/green w ire term inals of the com bination m eter 16P black connector. STANDARD: 4.0 – 6.0 kΩ (20° C/68° F)

Bl/R Bu/G

Is the resistance within the specified value?

14-8

– GO TO STEP 8.

YES

– GO TO STEP 6.

METER 16P BLACK CONNECTOR (viewed from the terminal side)

REAR WHEEL/SUSPENSION 6. Angle Sensor Signal Combination Meter

Line

Inspection

M easure the angle sensor resistance betw een the Yellow /red and Blue/green w ire term inals of the com bination m eter 16P black connector. STANDARD: 0.4 â&#x20AC;&#x201C; 5.4 kâ&#x201E;Ś (20Â° C/68Â° F)

Y/R

Bu/G

Is the resistance within the specified value? NO

â&#x20AC;&#x201C; GO TO STEP 9.

YES

â&#x20AC;&#x201C; GO TO STEP 7.

METER 16P BLACK CONNECTOR (viewed from the terminal side) 7. Actuator Motor Operation Inspection at Suspension Level Relays Rem ove the suspension level UP and DOWN relays (page 14-29). Check the actuator m otor operation by connecting a fully charged 12-V battery. â&#x20AC;˘ If the angle sensor resistance m easured on the previous step is 2.5 kâ&#x201E;Ś or m ore: Connect the battery positive (+) term inal to the UP relay connector Brow n/w hite w ire term inal and the battery negative (â&#x20AC;&#x201C;) term inal to the DOWN relay connector Green w ire term inal w ithin 3 seconds (m ax. 3 seconds). â&#x20AC;˘ If the angle sensor resistance m easured on the previous step is 2.5 kâ&#x201E;Ś or less: Connect the battery positive (+) term inal to the DOWN relay connector Green w ire term inal and the battery negative (â&#x20AC;&#x201C;) term inal to the UP relay connector Brow n/w hite w ire term inal w ithin 3 seconds (m ax. 3 seconds).

Do not connect the battery to the connector term inals for m ore than 3 seconds. Does the actuator motor operate when connected as described above? NO

â&#x20AC;&#x201C; GO TO STEP 12.

YES

â&#x20AC;&#x201C; GO TO STEP 10.

14-9

REAR WHEEL/SUSPENSION 8. Angle Sensor Power Input and Ground Line Inspection at Angle Rem ove the right saddlebag (page 2-15). Disconnect the angle sensor connector. M easure the angle sensor resistance betw een the Black/red and Blue/green w ire term inals of the sensor side connector. STANDARD: 4.0 – 6.0 kΩ (20° C/68° F) Is the resistance within the specified value? NO

– Faulty angle sensor; replace the shock absorber assem bly (page 14-16).

YES

– • Open or short circuit in the Black/red and Blue/green w ires betw een the com bination m eter 16P black connector and angle sensor connector. • Loose or poor contact of the angle sensor connector.

9. Angle Sensor Signal Line Inspection at Angle Sensor Rem ove the right saddlebag (page 2-15). Disconnect the angle sensor connector. M easure the angle sensor resistance betw een the Yellow /red and Blue/green w ire term inals of the sensor side connector. STANDARD: 0.4 – 5.4 kΩ (20° C/68° F) Is the resistance within the specified value? NO

– Faulty angle sensor; replace the shock absorber assem bly (page 14-16).

YES

– • Open or short circuit in the Yellow / red w ire betw een the com bination m eter 16P black connector and angle sensor connector. • Loose or poor contact of the angle sensor connector.

10. Suspension Level Relays Inspection Check the suspension level relays and their circuits (page 14-29). Does the suspension level relays and circuit check OK?

14-10

– • Faulty suspension level relay(s). • Open circuit in the w ire harness. • Loose or poor contact of the related connectors.

YES

– GO TO STEP 11.

ANGLE SENSOR CONNECTOR

REAR WHEEL/SUSPENSION 11. Suspension Level Relay Control Line Inspection Turn the ignition sw itch to “ ON” or “ ACC.” M easure the voltage betw een the follow ing w ire term inal (+) of the m eter 20P black connector and ground (–). – Red – Green/red – Green/yellow There should be battery voltage. Is battery voltage present? NO

– • Open or short circuit in the w ire harness betw een the com bination m eter and suspension level relays. • Loose or poor contact of the related connectors.

YES

– Faulty com bination m eter; replace the m eter/gauge assem bly (page 20-17).

G/R

METER 20P BLACK CONNECTOR (viewed from the terminal side)

G/Y

12. Actuator Motor Operation Inspection at Actuator Motor Rem ove the right saddlebag (page 2-15). Disconnect the actuator m otor connector. Check the actuator m otor operation by connecting the fully charged 12-V battery. • If the angle sensor resistance is 2.5 kΩ or m ore: Connect the battery positive (+) term inal to the Light green/red w ire term inal of the actuator m otor connector and the battery negative (–) term inal to the Green w ire term inal w ithin 3 seconds (m ax. 3 seconds). • If the angle sensor resistance is 2.5 kΩ or less: Connect the battery positive (+) term inal to the Green w ire term inal of the actuator m otor connector and the battery negative (–) term inal to the Light green/red w ire term inal w ithin 3 seconds (m ax. 3 seconds).

Does the actuator motor operate when connected as described above? NO

– Faulty actuator m otor; replace the shock absorber assem bly (page 14-16).

YES

– Open circuit in the Brow n/w hite and Green w ires betw een the suspension level relays and actuator m otor connector.

14-11

REAR WHEEL/SUSPENSION Suspension level cannot be memorized with the memory switch 1. Memory Switch 1 and 2 Operation Inspection Rem ove the left fairing pocket (page 2-11). Disconnect the panel sw itch 14P gray connector. Check for continuity betw een the w ire term inals of the sw itch side connector in either M EM O 1 or M EM O 2 sw itch positions. Continuity should exist betw een the color coded w ires as follow s:

Is there continuity between the wires as shown in the charts? NO

â&#x20AC;&#x201C; Faulty m em ory sw itch; replace the panel sw itch assem bly (page 20-32).

YES

â&#x20AC;&#x201C; GO TO STEP 2.

2. Memory Switch 1 and 2 Control Line Short Circuit inspection Rem ove the com bination m eter (page 20-17). Check the follow ing w ires for continuity to ground at the panel sw itch 14P gray connector. â&#x20AC;&#x201C; Brow n/yellow â&#x20AC;&#x201C; Brow n/blue Is there continuity?

14-12

YES

â&#x20AC;&#x201C; Short circuit in the fairing sub-w ire harness.

â&#x20AC;&#x201C; GO TO STEP 3.

WIRE HARNESS SIDE 14P CONNECTOR (viewed from the terminal side) Br/Bu Br/Y

REAR WHEEL/SUSPENSION 3. Memory Switch 1 and 2 Control Line Continuity inspection Check the follow ing w ires for continuity betw een the panel sw itch 14P gray connector and com bination m eter 16P black connector. – Brow n/yellow – Brow n/blue

Br/W

Lg/Y

Is there continuity? NO

– Open circuit in the fairing sub-w ire harness.

YES

– • Loose or poor contact of the sw itch 14P gray connector and m eter 16P black connector. • Faulty com bination m eter; replace the m eter/gauge assem bly (page 20-19).

METER 16P BLACK CONNECTOR (viewed from the terminal side)

14-13

REAR WHEEL/SUSPENSION

REAR WHEEL REAR WHEEL REMOVAL

NUTS

Rem ove rear fender A (page 2-13). Set the rear w heel on the ground and loosen the five rear axle nuts w hile applying the rear brake. Put the m otorcycle on its center stand and support the m otorcycle securely. Rem ove the five rear w heel nuts. M ove the rear w heel to the left to separate it from the final gear case and rem ove the rear w heel.

REAR BRAKE DISC REPLACEMENT Rem ove the rear w heel (page 14-14). Rem ove the follow ing: â&#x20AC;&#x201C; bolt and brake hose clam p â&#x20AC;&#x201C; tw o bolts and brake caliper â&#x20AC;&#x201C; tw o screw s (using an im pact driver) â&#x20AC;&#x201C; brake disc â&#x20AC;&#x201C; ABS m odel only: six bolts and pulser ring if necessary ABS model:

CALIPER

CLAMP

Install a new pulser ring w ith new bolts and tighten them . TORQUE: 8 NÂˇm (0.8 kgfÂˇm, 5.8 lbfÂˇft)

Clean the m ating surfaces of the final drive assem bly and brake disc, and m ake sure that no foreign m aterials are allow ed. Install a new brake disc onto the stud bolts. Install new screw s and tighten them . TORQUE: 9 NÂˇm (0.9 kgfÂˇm, 6.5 lbfÂˇft) Install the brake caliper w ith new bolts and tighten them . TORQUE: 45 NÂˇm (4.6 kgfÂˇm, 33 lbfÂˇft)

5+4-95 Install the brake hose clam p onto the gear case and tighten the bolt.

TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft) For rear w heel installation, see page 14-14. ABS model:

After installing the rear w heel, check the rear w heel speed sensor air gap (page 16-29).

14-14

REAR WHEEL/SUSPENSION WHEEL RIM INSPECTION Rem ove the axle cap from the rear w heel. Check the rim runout by placing the w heel in a truing stand. Spin the w heel slow ly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)

WHEEL BALANCE Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check balance before reinstalling the wheel.

• M ount the tire w ith the arrow facing in the norm al direction of rotation. • The w heel balance m ust be checked w hen the tire is rem ounted. • For optim um balance, the tire balance m ark (a paint dot on the side w all) m ust be located next to the valve stem . Rem ount the tire if necessary.

VALVE STEM TIRE BALANCE MARK (left side wall) M ount the w heel and tire assem bly on an inspection stand. Spin the w heel, allow it to stop, and m ark the low est (heaviest) part of the w heel w ith chalk. Do this tw o or three tim es to verify the heaviest area. If the w heel is balanced, it w ill not stop consistently in the sam e position.

To balance the w heel, install a balance w eight on the lightest side of the spoke, the side opposite the chalk m arks. Add just enough w eight so the w heel w ill no longer stop in the sam e position w hen it is spun. Do not add m ore than 70 g (2.5 oz) to the rear w heel. Install the axle cap.

14-15

REAR WHEEL/SUSPENSION REAR WHEEL INSTALLATION Check the w heel bolt holes for w ear, cracks or other dam age. Clean the m ating surfaces of the rear w heel and brake disc, and rem ove any foreign m aterial. Install the rear w heel by aligning the bolt holes in the rear w heel w ith the stud bolts of the final drive assem bly. Install five w heel nuts and tem porarily tighten them . Place the m otorcycle on its side stand so the rear w heel touches the ground. Tighten the five axle nuts to the specified torque w hile applying the rear brake. TORQUE: 108 N路m (11.0 kgf路m, 80 lbf路ft) Perform the air gap inspection if the rear brake disc w as rem oved (page 16-29). Install rear fender A (page 2-6).

SHOCK ABSORBER REMOVAL Rem ove the right saddlebag (page 2-17). Rem ove the fuel tank (page 5-56). Rem ove the rear w heel (page 14-14). Disconnect the angle sensor connectors from the suspension level actuator and disconnect the control m otor connector. Release the control m otor connector from the clam p. Rem ove the three m ounting bolts and suspension level actuator from the fram e.

Rem ove the shock absorber low er m ounting nut and bolt.

14-16

NUTS

REAR WHEEL/SUSPENSION Rem ove the shock absorber upper m ounting nut and bolt. Release the actuator hose from the clam p.

Rem ove the shock absorber assem bly.

INSPECTION

Check the dam per unit for leakage or other dam age. Check the upper joint bushing and dam per rubber for w ear or dam age. Inspect the actuator hose and fittings for loose connections, deterioration, cracks, dam age or signs of leakage. If necessary, replace the shock absorber as an assem bly.

DISPOSAL Center punch the dam per case to m ark the drilling point. DRILLING POINT: 40 mm (1.6 in) from the center of the upper eyelet as shown

40 mm (1.6 in)

Wrap the shock absorber inside a plastic bag. Support the shock absorber upright in a vise as show n. Through the open end of the bag, insert a drill m otor w ith a sharp 2 â&#x20AC;&#x201C; 3 m m (5/64 â&#x20AC;&#x201C; 1/8 in) drill bit.

â&#x20AC;˘ Do not use a dull drill bit which could cause a build-up of excessive heat and pressure inside the damper, leading to an explosion and severe injury. â&#x20AC;˘ The shock absorber contains nitrogen gas and oil under high pressure. Do not drill any further down the damper case than the measurement given above, or you may drill into the oil chamber. Then high pressure oil may cause serious injury. â&#x20AC;˘ Always wear eye protection to avoid getting metal shavings in your eyes when the gas pressure is released. The plastic bag is only intended to shield you from the escaping gas. Hold the bag around the drill m otor and briefly run the drill m otor inside the bag; this w ill inflate the bag w ith air from the m otor and help keep the bag from the getting caught in the drill bit w hen you start drilling into the shock.

14-17

REAR WHEEL/SUSPENSION INSTALLATION Route the wires and hose properly (page 1-23).

Install the shock absorber assem bly in the fram e by inserting the upper m ounting bolt from the left side. Install the upper m ounting nut.

Securely clam p the actuator hose w ith the clam p.

Install the low er m ounting bolt from the left side. Install the low er m ounting nut. Tighten the shock absorber upper and low er m ounting nuts to the specified torque. TORQUE: 42 NÂˇm (4.3 kgfÂˇm, 31 lbfÂˇft) Install the suspension level actuator w ith the three m ounting bolts. Tighten the m ounting bolt and the tw o 8-m m bolts to the specified torque. TORQUE: 26 NÂˇm (2.7 kgfÂˇm, 20 lbfÂˇft)

BOLT AND NUT Connect the angle sensor connector to the suspension level actuator and connect the control m otor connector. Clam p the control m otor connector onto the clam p. Install the rear w heel (page 14-14). Install the fuel tank (page 5-56). Install the right saddlebag (page 2-15).

SUSPENSION LINKAGE SHOCK ARM REMOVAL Rem ove the exhaust system (page 2-18). Rem ove the rear w heel (page 14-14). Rem ove the shock absorber low er m ounting nut and bolt. Rem ove the shock arm -to-sw ingarm nut and bolt. Rem ove the shock arm -to-shock link nut and bolt. Rem ove the shock arm .

14-18

REAR WHEEL/SUSPENSION Rem ove the pivot collars and dust seals from the shock arm .

SHOCK ARM INSPECTION Check the dust seals and collars for w ear, dam age or fatigue. Check the needle bearings for dam age or loose fit. If the needle bearings are dam aged, replace them (page 14-19).

SHOCK ARM NEEDLE BEARING REPLACEMENT SWINGARM AND SHOCK LINK SIDE: Rem ove the needle bearings from the shock arm pivot using the special tools. TOOLS: Bearing remover set – remover weight

– remover handle – remover, 20 mm

07936-3710001 (not available in U.S.A.) 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) 07936-3710100 07936-3710600

SHOCK ABSORBER SIDE: Rem ove the needle bearing from the shock arm pivot using the special tools and a hydraulic press. TOOLS: Driver Attachment, 22 x 24 mm Pilot, 17 mm

07949-3710001 07746-0010800 07746-0040400

DRIVER ATTACHMENT

Apply grease to the needle rollers of new bearings. Carefully press the needle bearing in the shock arm pivot until the depth from the shock arm outer surface is at specification, using the special tools and a hydraulic press. SPECIFIED DEPTH: Swingarm side: 5.5 – 6.0 mm (0.22 – 0.24 in) Shock link side: 5.5 – 6.0 mm (0.22 – 0.24 in) Shock absorber side: 5.3 – 5.7 mm (0.21 – 0.22 in) TOOLS: Swingarm side and shock link side: Driver 07749-0010000 Attachment, 24 x 26 mm 07746-0010700 Pilot, 20 mm 07746-0040500

14-19

REAR WHEEL/SUSPENSION Shock absorber side: Driver Attachment, 24 x 26 mm Pilot, 17 mm

07749-0010000 07746-0010700 07746-0040400

SHOCK ARM INSTALLATION Apply grease to new dust seal lips and install them into the shock arm pivots until they are fully seated.

Install the pivot collars into the shock arm pivots.

Install the shock arm onto the fram e by inserting the m ounting bolts from the left side. Install the m ounting nuts and tighten the nuts to the specified torque. TORQUE: Shock absorber lower mounting nut: 42 N·m (4.3 kgf·m, 31 lbf·ft) Shock arm-to-swingarm nut: 64 N·m (6.5 kgf·m, 47 lbf·ft) Shock arm-to-shock link nut: 64 N·m (6.5 kgf·m, 47 lbf·ft) Install the rear w heel (page 14-16). Install the exhaust system (page 2-20).

SHOCK LINK REMOVAL Rem ove the exhaust system (page 2-18). Rem ove the rear w heel (page 14-14). Rem ove the shock arm -to-shock link nut and bolt. Rem ove the shock link-to-fram e nut and bolt. Rem ove the shock link.

14-20

REAR WHEEL/SUSPENSION Rem ove the pivot collar and dust seals from the shock link.

SHOCK LINK INSPECTION Check the dust seals and collar for w ear, dam age or fatigue. Check the needle bearings for dam age or loose fit. If the needle bearings are dam aged, replace them (page 14-21).

SHOCK LINK NEEDLE BEARING REPLACEMENT

Rem ove the needle bearings from the shock arm pivot using the special tools. TOOLS: Bearing remover set – remover weight

– remover handle – remover, 20 mm

07936-3710001 (not available in U.S.A.) 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) 07936-3710100 07936-3710600

Apply grease to the needle rollers of new bearings. Carefully press the needle bearings into the shock link pivot until the depth from the shock link outer surface is at specification, using the special tools and a hydraulic press. SPECIFIED DEPTH: 5.5 – 6.0 mm (0.22 – 0.24 in) TOOLS: Driver Attachment, 24 x 26 mm Pilot, 20 mm

07749-0010000 07746-0010700 07746-0040500

SHOCK LINK INSTALLATION Apply grease to new dust seal lips and install them into the shock link pivot until they are fully seated.

Install the pivot collar into the shock link pivot.

14-21

REAR WHEEL/SUSPENSION

NUTS AND BOLTS

Install the shock link onto the fram e by inserting the m ounting bolts from the left side. Install the m ounting nuts and tighten the nuts to the specified torque. TORQUE: Shock arm-to-frame nut: 64 N·m (6.5 kgf·m, 47 lbf·ft) Shock arm-to-shock link nut: 64 N·m (6.5 kgf·m, 47 lbf·ft) Install the rear w heel (page 14-16). Install the exhaust system (page 2-20).

SWINGARM REMOVAL

Rem ove the final gear case (page 12-10). Rem ove the shock absorber (page 14-16). Rem ove the m ounting bolts and each sw ingarm pivot bolt cover.

PIPE CLAMP

Rem ove the bolt and brake pipe clam p.

BOLT

Rem ove the left pivot lock nut w ith the special tool. TOOL: Lock nut wrench, 10 x 44/6 x 46 mm 07ZMA-MCAA101

LOCK NUT

LOCK NUT WRENCH

14-22

REAR WHEEL/SUSPENSION Rem ove the left pivot bolt.

LEFT PIVOT BOLT

Rem ove the right pivot bolt.

Rem ove the shock arm -to-shock link nut and bolt.

Rem ove the tw o screw s and brake light/cruise cancel sw itch assem bly from the rear m aster cylinder. Rem ove the joint boot off the engine. Separate the drive shaft from the output shaft of the engine, then rem ove the sw ingarm .

14-23

REAR WHEEL/SUSPENSION Rem ove the joint boot. Check the joint boot for tears or other dam age and replace it if necessary.

Rem ove the drive shaft from the sw ingarm .

Rem ove the shock arm -to-sw ingarm nut and bolt and shock arm from the sw ingarm .

SHOCK ARM

NUT AND BOLT INSPECTION Both bearings, outer races and grease holders must be replaced as a set if any part is damaged or worn.

Rem ove the tapered roller bearings from the sw ingarm pivots. Check the bearings and dust seals for dam age or w ear. Check the outer races for dam age or w ear. Check the grease deform ation.

holders

for

dam age

14-24

REAR WHEEL/SUSPENSION Check that the universal joint m oves sm oothly w ithout binding or noise. Check the splines for w ear or dam age.

PIVOT BEARING OUTER RACE REPLACEMENT Punch or drill a 1/2 inch hole into the grease holder of the bearing race. Insert the threaded end of the slide ham m er into the hole and attach the special tools as show n. Rem ove the outer race and grease holder w ith the installed tools. TOOLS: Attachment, 32 x 35 mm Slide hammer, 3/8" x 16 mm thread

07746-0010100 Equivalent commercially available in U.S.A.

Insert a suitable driver through the sw ingarm and drive out the other side grease holder and bearing using a suitable hydraulic press.

Install the new grease holders into the sw ingarm pivot. Carefully press the new outer races into the sw ingarm pivots until they are fully seated, using the special tools and a hydraulic press. TOOLS: Driver Attachment, 42 x 47 mm

07749-0010000 07746-0010300

14-25

REAR WHEEL/SUSPENSION Apply grease to the tapered needle rollers and dust seals lips of new bearings and install them into the sw ingarm pivots.

SEAL LIPS

ROLLERS

INSTALLATION Install the shock arm onto the sw ingarm by inserting the m ounting bolt. Install the shock arm -to-sw ingarm nut and tighten the nut to the specified torque.

TORQUE: 64 NÂˇm (6.5 kgfÂˇm, 47 lbfÂˇft)

Apply 1 g (0.04 oz) of m olybdenum disulfide grease to the output shaft side splines of the drive shaft.

Place the drive shaft into the sw ingarm w ith the short shaft facing the front of the m otorcycle.

14-26

REAR WHEEL/SUSPENSION Install the joint boot onto the sw ingarm w ith one joint boot tab facing up vertically as show n.

Rem ove the joint shaft from the final gear case (page 12-10) and tem porarily install it into the drive shaft to ease installation of the drive shaft. Route the wires, hoses and pipes properly (page 1-23).

Set the sw ingarm into the fram e and engage the splines of the drive and output shafts securely.

Align the fram e pivot bolt hole w ith the sw ingarm securely. Install and tighten the right pivot bolt to the specified torque.

TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)

Align the fram e pivot bolt hole w ith the sw ingarm securely. Install and tighten the left pivot bolt to the specified torque.

LEFT PIVOT BOLT

TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) M ove the sw ingarm up and dow n several tim es to seat the pivot bearings.

14-27

REAR WHEEL/SUSPENSION Retighten the right pivot bolt to the sam e torque. TORQUE: 108 NÂˇm (11.0 kgfÂˇm, 80 lbfÂˇft) Install the left pivot lock nut. Refer to torque wrench reading information on page 14-3 â&#x20AC;&#x153;Service Information.â&#x20AC;?

Hold the left pivot bolt w hile tightening the left pivot lock nut to the specified torque. TOOL: Lock nut wrench, 10 x 44/6 x 46 mm 07ZMA-MCAA101 TORQUE: Actual: 108 NÂˇm (11.0 kgfÂˇm, 80 lbfÂˇft) Indicated: 98 NÂˇm (10.0 kgfÂˇm, 72 lbfÂˇft) Insert the shock arm -to-shock link bolt from the left side through the shock link, shock arm and shock link. Install the m ounting nut and tighten the nut to the specified torque.

NUT AND BOLT

TORQUE: 64 NÂˇm (6.5 kgfÂˇm, 47 lbfÂˇft)

SHOCK ARM Install the joint boot over the engine securely. Apply locking agent to the threads of the sw itch holder screw s. Install the brake light/cruise cancel sw itch assem bly w ith the screw s. Adjust the sw itch position so that the brake light com es on w hen pushing the brake pedal slightly and the push rod m oves 0.7 â&#x20AC;&#x201C; 1.7 m m . Tighten the holder screw s.

TORQUE: 2 NÂˇm (0.2 kgfÂˇm, 1.4 lbfÂˇft)

Install the brake pipe clam p w ith the bolt and tighten the bolt to the specified torque. TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft)

14-28

REAR WHEEL/SUSPENSION Install each sw ingarm pivot bolt cover. Install and tighten the m ounting bolts.

Install the final gear case (page 12-21). Install the shock absorber (page 14-18).

SUSPENSION LEVEL RELAY SYSTEM INSPECTION

Check that the audio system and m ulti-display functions properly. Shift the transm ission into neutral and m ake sure the reverse system is off. Rem ove the seat (page 2-5). Rem ove the tw o screw s and rem ove the relay box. Rem ove the relay blocks from the relay box.

1. Turn the ignition sw itch to “ OFF” and exchange the suspension level m ain relay w ith a know ngood one. Turn the ignition sw itch to “ ON” or “ ACC” and operate the m anual height sw itch. • If the suspension level actuator operates, replace the suspension level m ain relay w ith a new one. • If the suspension level actuator does not operate, go to step 2. 2. Turn the ignition sw itch to “ OFF” , and exchange the suspension level UP relay w ith a know n-good one. Turn the ignition sw itch to “ ON” or “ ACC” and operate the m anual height sw itch.

13 14

11. MAIN RELAY 13. UP RELAY 14. DOWN RELAY

• If the suspension level actuator operates, replace the suspension level UP relay w ith a new one and check again using the original suspension level m ain relay. • If the suspension level actuator does not operate, go to step 3. 3. Turn the ignition sw itch to “ OFF” , and exchange the suspension level DOWN relay a know n-good one. Turn the ignition sw itch to “ ON” or “ ACC” and operate the m anual height sw itch. • If the suspension level actuator operates, replace the suspension level DOWN relay w ith a new one and check again using the original suspension level m ain relay and UP relay. • If the suspension level actuator does not operate, go to step 4.

14-29

REAR WHEEL/SUSPENSION 4. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the suspension level m ain relay. M easure the voltage betw een the Brow n w ire term inal (+) of the suspension level m ain relay connector and ground (â&#x20AC;&#x201C;). â&#x20AC;˘ If there is battery voltage, go to step 5. â&#x20AC;˘ If there is no voltage, check for an open circuit in the Brow n w ire betw een the suspension level m ain relay and fuse box (No. 20 fuse).

5. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? or â&#x20AC;&#x153; ACC.â&#x20AC;? M easure the voltage betw een the Light green/ black w ire term inal (+) of each suspension level m ain relay connector and ground (â&#x20AC;&#x201C;). â&#x20AC;˘ If there is battery voltage, go to step 6. â&#x20AC;˘ If there is no voltage, check for an open circuit in the Light green/black w ire betw een the suspension level m ain relay and ACC relay.

6. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Rem ove the suspension level UP and DOWN relays. Check the Red/black w ires for continuity betw een the suspension level m ain relay and UP relay, and betw een the m ain relay and DOWN relay. â&#x20AC;˘ If there is continuity, go to step 7. â&#x20AC;˘ If there is no continuity, repair an open circuit in the Red/black w ire.

MAIN RELAY

UP DOWN RELAY RELAY

7. Check the actuator m otor ground circuit for continuity betw een each Green w ire term inal of the UP and DOWN relay connectors and ground. â&#x20AC;˘ If there is continuity, go to step 8. â&#x20AC;˘ If there is no continuity, repair an open circuit in the Green w ire (actuator m otor ground circuit).

14-30

REAR WHEEL/SUSPENSION 8. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? or â&#x20AC;&#x153; ACC.â&#x20AC;? M easure the voltage betw een each Light green/ black w ire term inal (+) of the suspension level UP and DOWN relay connectors and ground (â&#x20AC;&#x201C;). â&#x20AC;˘ If there is battery voltage, follow the troubleshooting flow chart on (page 14-10). â&#x20AC;˘ If there is no voltage, check for an open circuit in the Light green/black w ire betw een the suspension level UP and DOWN relay and ACC relay.

14-31

MEMO

15. BRAKE SYSTEM (Standard)

SYSTEM LOCATION···································· 15-2

REAR MASTER CYLINDER/BRAKE PEDAL ·························································15-19

SERVICE INFORMATION ···························· 15-3 SECONDARY MASTER CYLINDER ···········15-24 TROUBLESHOOTING ·································· 15-5 FRONT BRAKE CALIPER ····························15-27 BRAKE FLUID REPLACEMENT/AIR BLEEDING ···················································· 15-6

REAR BRAKE CALIPER·······························15-34

BRAKE PAD/DISC······································ 15-13

DELAY VALVE ············································15-38

FRONT MASTER CYLINDER ····················· 15-15

PROPORTIONAL CONTROL VALVE (PCV) ··············································15-39

15-1

BRAKE SYSTEM (Standard)

SYSTEM LOCATION BRAKE SYSTEM (Standard)

15-2

BRAKE SYSTEM (Standard)

SERVICE INFORMATION GENERAL Frequent inhalation of brake lining dust, regardless of m aterial com position, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assem blies. Use an OSHA-approved vacuum cleaner. • This m otorcycle is equipped w ith the follow ing system s: – LBS (Linked Brake System ) – that is designed to engage both front and rear brakes w hen either the brake lever or brake pedal is used. – ABS (Anti-lock Brake System ) – that is designed to help prevent w heel lock-up during hard braking on loose or slippery surfaces. • This section (15-A) covers service of the standard brake com ponents (including LBS) of the brake system . For ABS service, see section 15-B. • Note that there is no brake fluid in the ABS m odulator (except in the m odulator head), because the m odulator is the m otor-driven hydraulic pressure type. Therefore, brake fluid replacem ent and bleeding air from the m odulator body is not necessary. • A contam inated brake disc or pad reduces stopping pow er. Discard contam inated pads and clean a contam inated disc w ith a high quality brake degreasing agent. • Spilled brake fluid w ill severely dam age the plastic parts and painted surfaces. It is also harm ful to som e rubber parts. Be careful w henever you rem ove the reservoir cap; m ake sure the reservoir is horizontal first. • Never allow contam inants (e.g., dirt, w ater) to enter an open reservoir. • Once the hydraulic system has been opened, or if the brake feels spongy, the system m ust be bled. • Alw ays use fresh DOT 4 brake fluid from a sealed container w hen servicing the system . Do not m ix different types of fluid as they m ay not be com patible. • Alw ays check brake operation before riding the m otorcycle.

SPECIFICATIONS ITEM Specified brake fluid Front Brake disc thickness Brake disc runout M aster cylinder I.D. M aster piston O.D. Caliper cylinder I.D.

STANDARD DOT 4 4.5 (0.18)

Left

Right

Caliper piston O.D.

Left

Right

Rear

Brake disc thickness Brake disc runout Pedal m aster cylinder I.D. Pedal m aster piston O.D. Secondary m aster cylinder I.D. Secondary m aster piston O.D. Caliper cylinder I.D.

Caliper piston O.D.

Upper Center Low er Upper Center Low er Upper Center Low er Upper Center Low er

Upper Center Low er Upper Center Low er

– 14.000 – 14.043 (0.5512 – 0.5529) 13.957 – 13.984 (0.5495 – 0.5506) 22.650 – 22.700 (0.8917 – 0.8937) 27.000 – 27.050 (1.0630 – 1.0650) 22.650 – 22.700 (0.8917 – 0.8937) 25.400 – 25.450 (1.0000 – 1.0020) 25.400 – 25.450 (1.0000 – 1.0020) 22.650 – 22.700 (0.8917 – 0.8937) 22.585 – 22.618 (0.8892 – 0.8905) 26.935 – 26.968 (1.0604 – 1.0617) 22.585 – 22.618 (0.8892 – 0.8905) 25.335 – 25.368 (0.9974 – 0.9987) 25.335 – 25.368 (0.9974 – 0.9987) 22.585 – 22.618 (0.8892 – 0.8905) 11.0 (0.43) – 17.460 – 17.503 (0.6874 – 0.6891) 17.417 – 17.444 (0.6857 – 0.6868) 14.000 – 14.043 (0.5512 – 0.5529) 13.957 – 13.984 (0.5495 – 0.5506) 22.650 – 22.700 (0.8917 – 0.8937) 27.000 – 27.050 (1.0630 – 1.0650) 22.650 – 22.700 (0.8917 – 0.8937) 22.585 – 22.618 (0.8892 – 0.8905) 26.935 – 26.968 (1.0604 – 1.0617) 22.585 – 22.618 (0.8892 – 0.8905)

Unit: m m (in) SERVICE LIMIT – 3.5 (0.14) 0.30 (0.012) 14.055 (0.5533) 13.945 (0.5490) 22.71 (0.894) 27.06 (1.065) 22.71 (0.894) 25.46 (1.002) 25.46 (1.002) 22.71 (0.894) 22.56 (0.888) 26.91 (1.059) 22.56 (0.888) 25.31 (0.996) 25.31 (0.996) 22.56 (0.888) 10.0 (0.39) 0.30 (0.012) 17.515 (0.6896) 17.405 (0.6852) 14.055 (0.5533) 13.945 (0.5490) 22.71 (0.894) 27.06 (1.065) 22.71 (0.894) 22.56 (0.888) 26.91 (1.059) 22.56 (0.888)

15-3

BRAKE SYSTEM (Standard) TORQUE VALUES Brake caliper bleed valve Front fork anti-dive plunger bleed valve Front m aster cylinder reservoir cap screw Brake pad pin Brake hose oil bolt Brake lever pivot bolt Brake lever pivot nut Front brake light/cruise cancel sw itch screw Front m aster cylinder holder bolt Rear m aster cylinder reservoir m ounting bolt Rear m aster cylinder sw itch plate lock nut Rear m aster cylinder joint nut Rear m aster cylinder m ounting bolt Brake pedal pinch bolt Rider footpeg m ounting bolt Rear brake light/cruise cancel sw itch holder screw Secondary m aster cylinder m ounting bolt Front brake caliper bracket pin Front brake caliper pin Front brake caliper assem bly bolt Left front brake caliper low er m ounting bolt Left front brake caliper-to-secondary m aster cylinder joint bolt Right front brake caliper m ounting bolt Wheel speed sensor bolt Rear brake caliper bracket pin Rear brake caliper pin bolt Rear brake caliper assem bly bolt Rear brake disc screw

31 N·m (3.2 kgf·m , 23 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft) 23 N·m (2.3 kgf·m , 17 lbf·ft) 27 N·m (2.8 kgf·m , 20 lbf·ft) 32 N·m (3.3 kgf·m , 24 lbf·ft) 9 N·m (0.9 kgf·m , 6.5 lbf·ft)

Rear brake caliper m ounting bolt Proportional control valve m ounting bolt Delay valve m ounting bolt Brake pipe joint nut Brake hose clam p bolt Brake hose joint attaching bolt

45 N·m 12 N·m 12 N·m 17 N·m 12 N·m 12 N·m

TOOL Snap ring pliers 07914-SA50001

15-4

6 N·m (0.6 kgf·m , 4.3 lbf·ft) 6 N·m (0.6 kgf·m , 4.3 lbf·ft) 2 N·m (0.2 kgf·m , 1.4 lbf·ft) 18 N·m (1.8 kgf·m , 13 lbf·ft) 34 N·m (3.5 kgf·m , 25 lbf·ft) 1 N·m (0.1 kgf·m , 0.7 lbf·ft) 6 N·m (0.6 kgf·m , 4.3 lbf·ft) 1 N·m (0.1 kgf·m , 0.7 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft) 18 N·m (1.8 kgf·m , 13 lbf·ft) 18 N·m (1.8 kgf·m , 13 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft) 26 N·m (2.7 kgf·m , 20 lbf·ft) 26 N·m (2.7 kgf·m , 20 lbf·ft) 2 N·m (0.2 kgf·m , 1.4 lbf·ft) 31 N·m 13 N·m 23 N·m 32 N·m 31 N·m 25 N·m

(3.2 kgf·m , 23 lbf·ft) (1.3 kgf·m , 9 lbf·ft) (2.3 kgf·m , 17 lbf·ft) (3.3 kgf·m , 24 lbf·ft) (3.2 kgf·m , 23 lbf·ft) (2.6 kgf·m , 19 lbf·ft)

(4.6 kgf·m , 33 lbf·ft) (1.2 kgf·m , 9 lbf·ft) (1.2 kgf·m , 9 lbf·ft) (1.7 kgf·m , 12 lbf·ft) (1.2 kgf·m , 9 lbf·ft) (1.2 kgf·m , 9 lbf·ft)

Apply locking agent to the threads. ALOC bolt: replace w ith a new one. Apply locking agent to the threads. ALOC bolt: replace w ith a new one. ALOC bolt: replace w ith a new one. ALOC bolt: replace w ith a new one. ALOC bolt: replace w ith a new one. Apply locking agent to the threads. ALOC bolt: replace w ith a new one. ALOC screw : replace w ith a new one. ALOC bolt: replace w ith a new one.

Apply brake fluid to the threads.

BRAKE SYSTEM (Standard)

TROUBLESHOOTING Brake lever/pedal soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contam inated brake pad/disc • Worn caliper piston seals • Worn m aster cylinder piston cups • Worn brake pad/disc • Contam inated caliper • Contam inated m aster cylinder • Caliper not sliding properly • Low brake fluid level • Clogged fluid passage • Warped/deform ed brake disc • Sticking/w orn caliper piston • Sticking/w orn m aster piston • Bent brake lever/pedal Brake lever/pedal hard • Clogged/restricted hydraulic system • Sticking/w orn caliper piston • Sticking/w orn m aster piston • Caliper not sliding properly • Bent brake lever/pedal Brake drag • Contam inated brake pad/disc • M isaligned w heel • Badly w orn brake pad/disc • Warped/deform ed brake disc • Caliper not sliding properly • Clogged/restricted fluid passage • Sticking caliper piston • Im proper secondary m aster cylinder push rod length (rear brake) • Faulty proportional control valve (rear brake) Excessive nose dive and poor brake performance • Secondary m aster cylinder hydraulic line problem

15-5

BRAKE SYSTEM (Standard)

BRAKE FLUID REPLACEMENT/AIR BLEEDING â&#x20AC;˘ A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. â&#x20AC;˘ Do not allow foreign material to enter the system when filling the reservoir. â&#x20AC;˘ Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. â&#x20AC;˘ Use only DOT 4 brake fluid from a sealed container. â&#x20AC;˘ Do not mix different types of fluid. They are not compatible. â&#x20AC;˘ Once the hydraulic system has been opened, or if the brake feels spongy, the system m ust be bled. â&#x20AC;˘ When using a com m ercially available brake bleeder, follow the m anufacturerâ&#x20AC;&#x2122;s operating instructions.

BRAKE FLUID DRAINING LEVER BRAKE LINE

Rem ove front fender A and the fender covers (page 2-6). Support the m otorcycle on its center stand. Turn the handlebar to the left until the front m aster cylinder reservoir is level before rem oving the reservoir cap. Rem ove the screw s, reservoir cap, set plate and diaphragm .

15-6

BRAKE SYSTEM (Standard) Connect a com m ercially available brake bleeder to the bleed valve of the front caliper at the position as show n. Loosen the bleed valve and pum p the brake bleeder until no m ore fluid flow s out of the bleed valve. Tighten the bleed valve.

Perform the above procedure at the other front caliper.

Right front caliper:

Left front caliper:

UPPER BLEED VALVE LOWER BLEED VALVE PEDAL BRAKE LINE

Rem ove the follow ing: â&#x20AC;&#x201C; right engine side cover (page 2-5) â&#x20AC;&#x201C; front fender A and fender covers (page 2-6) Support the m otorcycle on its center stand.

Rem ove the rear m aster cylinder reservoir cap.

15-7

BRAKE SYSTEM (Standard) Connect a com m ercially available brake bleeder to the bleed valve of the brake pedal brake line as show n. Loosen the bleed valve and pum p the brake bleeder until no m ore fluid flow s out of the bleed valve.

Perform the above procedure at each rem aining valve of the brake pedal brake line.

Anti-dive plunger:

Rear caliper:

BLEED VALVE

BLEED VALVES

LEVER BRAKE LINE FLUID FILLING/ AIR BLEEDING FLUID FEEDING • It is not a problem if the fluid flow ing out from the bleed valve contains air bubbles because the lines w ill be bled in next steps (“ Air Bleeding” ). Fill the reservoir w ith DOT 4 brake fluid from a sealed container. Operate the brake lever several tim es to bleed air from the m aster cylinder.

15-8

BRAKE SYSTEM (Standard) BRAKE BLEEDER AVAILABLE Check the fluid level often while bleeding the brake to prevent air from being pumped into the system. If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape.

1. Connect a com m ercially available brake bleeder to the bleed valve of the front caliper at the position as show n. Pum p the brake bleeder and loosen the bleed valve. If an autom atic refill system is not used, add brake fluid w hen the fluid level in the reservoir is low .

Repeat above procedure until sufficient am ount of the fluid flow s out from the bleed valve. Close the bleed valve. • When using a brake bleeding tool, follow the m anufacturer’s operating instructions. 2. Perform step 1 at the other front caliper. Next, perform the air bleeding w ithout using a brake bleeder tool (page 15-10).

Right front caliper:

Left front caliper:

UPPER BLEED VALVE LOWER BLEED VALVE BRAKE BLEEDER NOT AVAILABLE 1. Connect a bleed hose to the bleed valve of the front caliper. Do not release the brake lever until the bleed valve has been closed.

Right front caliper:

Left front caliper:

Pum p the brake lever several (5 – 10) tim es quickly, then squeeze the brake lever all the w ay and loosen the bleed valve 1/4 turn. Wait several seconds and close the bleed valve. Release the brake lever slow ly and w ait several seconds after it reaches the end of its travel. Repeat above procedure until sufficient am ount of fluid flow s out of the bleed valve. 2. Perform step 1 at the other front caliper. Next, perform the air bleeding (page 15-10).

UPPER BLEED VALVE LOWER BLEED VALVE

15-9

BRAKE SYSTEM (Standard) AIR BLEEDING Air bleeding procedure is perform ed in the sam e w ay as in the fluid feeding procedure w ithout using a bleeder tool (page 15-9). Repeat this procedure until air bubbles do not appear in the plastic hose of each bleed valve. M ake sure that the bleed valves are closed and operate the brake lever. If it still feels spongy, bleed the system again. After bleeding air com pletely, tighten the bleed valves. TORQUE: 6 NÂˇm (0.6 kgfÂˇm, 4.3 lbfÂˇft)

Fill the reservoir to the casting ledge w ith DOT 4 brake fluid from a sealed container. Install the diaphragm , set plate and reservoir cap and tighten the screw s. TORQUE: 2 NÂˇm (0.2 kgfÂˇm, 1.4 lbfÂˇft) Install the fender covers and front fender A (page 2-6).

PEDAL BRAKE LINE FLUID FILLING/ AIR BLEEDING â&#x20AC;˘ Before perform ing this service, have at least 500 cc (16.9 US oz, 14.1 Im p oz) of brake fluid. â&#x20AC;˘ Feed fluid and bleed air from the pedal brake line in the follow ing sequence: 1. Left front caliper upper side bleed valve 2. Right front caliper low er side bleed valve 3. Rear caliper low er side bleed valve 4. Anti-dive plunger bleed valve 5. Rear caliper upper side bleed valve

(4)

(1)

(5)

(2) (3)

15-10

BRAKE SYSTEM (Standard) FLUID FEEDING • It is not a problem if the fluid flow ing out of the bleed valve contains air bubbles because the lines w ill be bled in next steps (“ Air Bleeding” ). Fill the reservoir w ith DOT 4 brake fluid from a sealed container. Operate the brake pedal several tim es until brake fluid level in the reservoir goes dow n.

BRAKE BLEEDER AVAILABLE 1. Connect a com m ercially available brake bleeder to the upper side bleed valve of the left front caliper. Check the fluid level often while bleeding the brake to prevent air from being pumped into the system. If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape.

Pum p the brake bleeder and loosen the bleed valve. If an autom atic refill system is not used, add brake fluid w hen the fluid level in the reservoir is low . Repeat above procedure until sufficient am ount of the fluid flow s out of the bleed valve. Close the bleed valve. • When using a brake bleeding tool, follow the m anufacturer’s operating instructions. Perform step 1 at each bleed valve in the sequence as follow s: 2. Right front caliper low er side bleed valve 3. Rear caliper low er side bleed valve 4. Anti-dive plunger bleed valve 5. Rear caliper upper side bleed valve Next, perform the air bleeding w ithout using a brake bleeder tool (page 15-12).

15-11

BRAKE SYSTEM (Standard) BRAKE BLEEDER NOT AVAILABLE 1. Connect a bleed hose to the upper side bleed valve of the left front caliper. Do not release the brake lever until the bleed valve has been closed.

Pum p the brake pedal several (5 – 10) tim es quickly, then depress the brake pedal all the w ay and loosen the bleed valve 1/4 turn. Wait several seconds and close the bleed valve. Release the brake pedal slow ly and w ait several seconds after it reaches the end of its travel. Repeat above procedure until sufficient am ount of the fluid flow s out of the bleed valve.

Perform step 1 at each bleed valve in the sequence as follow s: 2. Right front caliper low er side bleed valve 3. Rear caliper low er side bleed valve 4. Anti-dive plunger bleed valve 5. Rear caliper upper side bleed valve Next, perform the air bleeding.

AIR BLEEDING • Note that you m ay feel strong resistance on the brake pedal during pum ping to bleed air from the right front caliper. This sym ptom is caused by the delay valve function. Be sure to depress the brake pedal fully to the bottom . Air bleeding procedure m ust be perform ed in the sam e w ay as in the fluid feeding procedure w ithout using a brake bleeder tool (page 15-11). Repeat this procedure until air bubbles do not appear in the plastic hose of each bleed valve. After air bubbles cease to appear in the fluid, repeat air bleeding procedure about 2 – 3 tim es. M ake sure that the bleed valves are closed and operate the brake pedal. If it still feels spongy, bleed the system again.

15-12

BRAKE SYSTEM (Standard) After bleeding air com pletely, tighten the bleed valves. TORQUE: 6 N·m (0.6 kgf·m, 4.3 lbf·ft) Fill the reservoir to the upper level line w ith DOT 4 brake fluid from a sealed container. Install the reservoir cap.

Check the pedal brake operation (page 3-18). Install the follow ing: – fender covers and front fender A (page 2-6) – right engine side cover (page 2-5)

BRAKE PAD/DISC FRONT BRAKE PAD REPLACEMENT Always replace the brake pads in pairs to ensure even disc pressure. Check the brake fluid level in the brake reservoir as this operation causes the level to rise.

Push the caliper piston all the w ay in to allow installation of new brake pads by pushing the caliper body inw ard. Rem ove the pad pin plug and loosen the pad pin.

PAD PIN PLUG Pull the pad pins out of the caliper body w hile pushing in the pads against the pad spring. Rem ove the brake pads. Coat the stopper ring on the pad pin end w ith silicone grease.

STOPPER RING PAD PIN Make sure the pad spring is installed correctly.

Install new brake pads into the caliper body w ith the shim facing tow ard the w heel side so that their ends rest into the pad retainer on the bracket properly.

RETAINER

Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pads and caliper body. Tighten the pad pin.

PADS

TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) Install the pad pin plug securely. Operate the brake lever and pedal to seat the caliper piston against the pads.

15-13

BRAKE SYSTEM (Standard) REAR BRAKE PAD REPLACEMENT Always replace the brake pads in pairs to ensure even disc pressure. Check the brake fluid level in the brake reservoirs as this operation causes the level to rise.

Push the caliper piston all the w ay in to allow installation of new brake pads by pushing the caliper body inw ard. Rem ove the pad pin plug and loosen the pad pin.

PAD PIN PLUG Pull the pad pins out of the caliper body w hile pushing in the pads against the pad spring. Rem ove the brake pads. Coat the stopper ring on the pad pin end w ith silicone grease.

STOPPER RING

PAD PIN Make sure the pad spring is installed correctly.

Install new brake pads into the caliper body so that their ends rest into the pad retainer on the bracket properly. Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pads and caliper body. Tighten the pad pin. TORQUE: 18 N路m (1.8 kgf路m, 13 lbf路ft) Install the pad pin plug securely. Operate the brake pedal and right front caliper to seat the caliper piston against the pads.

BRAKE DISC INSPECTION Visually inspect the disc for dam age or cracks. M easure the brake disc thickness at several points. SERVICE LIMITS: Front: 3.5 mm (0.14 in) Rear: 10.0 mm (0.39 in)

15-14

RETAINER PADS

BRAKE SYSTEM (Standard) M easure the brake disc w arpage w ith a dial indicator. SERVICE LIMIT: 0.30 mm (0.012 in) Check the bearing for excessive play, if the w arpage exceeds the service lim it. Replace the brake disc if the bearings are norm al. For brake disc rem oval/installation, see section 13 or 14.

FRONT MASTER CYLINDER DISASSEMBLY Drain the brake fluid from the front lever brake hydraulic system (page 15-6).

OIL BOLT

Disconnect the brake light/cruise cancel sw itch connectors. When removing the oil bolt, cover the end of the hose to prevent contamination.

Disconnect the brake hose from the m aster cylinder by rem oving the oil bolt and sealing w ashers.

CONNECTORS

MASTER CYLINDER

Rem ove the holder cap. Rem ove the m aster cylinder holder bolts, holder and the m aster cylinder.

HOLDER CAP

Rem ove the follow ing from the m aster cylinder: – screw and brake light/cruise cancel sw itch – pivot nut – pivot bolt and brake lever

LEVER

SWITCH

15-15

BRAKE SYSTEM (Standard) – piston boot – snap ring TOOL: Snap ring pliers

07914-SA50001

– m aster piston – prim ary cup – spring Clean the m aster cylinder, reservoir and m aster piston in clean brake fluid.

INSPECTION Check the piston cups and boot for w ear, deterioration or dam age. Check the spring for dam age.

Check the m aster cylinder and piston for scoring, scratches or dam age. M easure the m aster cylinder I.D. SERVICE LIMIT: 14.055 mm (0.5533 in) M easure the m aster piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in)

15-16

BRAKE SYSTEM (Standard) ASSEMBLY

Do not allow the piston cup lips to turn inside out.

Coat the m aster piston and piston cups w ith clean brake fluid. Install the prim ary cup onto the spring. Install the spring and m aster piston into the m aster cylinder.

Make sure the snap ring is firmly seated in the groove.

Install the snap ring into the groove in the m aster cylinder using the special tool. TOOL: Snap ring pliers

07914-SA50001

SNAP RING

PLIERS

15-17

BRAKE SYSTEM (Standard) Apply silicone grease to the push rod contacting area of the m aster piston. Install the boot into the m aster cylinder and the piston groove. Apply silicone grease to the brake lever contacting surface of the piston.

Apply silicone grease to the brake lever pivot. Install the brake lever and pivot bolt, and tighten it. TORQUE: 1 NÂˇm (0.1 kgfÂˇm, 0.7 lbfÂˇft) Install the pivot nut and tighten it. TORQUE: 6 NÂˇm (0.6 kgfÂˇm, 4.3 lbfÂˇft) Install the brake light/cruise cancel sw itch w ith the screw . TORQUE: 1 NÂˇm (0.1 kgfÂˇm, 0.7 lbfÂˇft)

Install the m aster cylinder and holder by aligning the end of the m aster cylinder w ith the punch m ark on the handlebar. Tighten the upper bolt first, then tighten the low er bolt. TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft) Install the holder cap into the holder bolts.

Connect the brake hose to the m aster cylinder w ith the oil bolt and new sealing w ashers. Be sure to rest the hose joint pin against the stopper. Tighten the oil bolt.

TORQUE: 34 NÂˇm (3.5 kgfÂˇm, 25 lbfÂˇft) Connect the brake light/cruise cancel sw itch connectors. Fill and bleed the lever brake hydraulic system (page 15-6).

15-18

BRAKE SYSTEM (Standard)

REAR MASTER CYLINDER/BRAKE PEDAL REMOVAL Drain the brake fluid from the pedal brake hydraulic system (page 15-6). Rem ove the tw o screw s and brake light/cruise cancel sw itch assem bly from the m aster cylinder.

SWITCH ASSEMBLY When removing the hose joint and oil bolt, cover the ends of the hoses to prevent contamination.

Rem ove the snap ring and disconnect the reservoir hose joint from the m aster cylinder. Rem ove the O-ring.

OIL BOLT

Disconnect the brake hose by rem oving the oil bolt and sealing w ashers.

HOSE SNAP RING Rem ove the pinch bolt and the brake pedal. Rem ove the tw o bolts and right footpeg.

PEDAL FOOTPEG Unhook the spring end to rem ove the return spring from the fram e and pivot arm . Rem ove the m aster cylinder m ounting bolts. Rem ove the pedal pivot arm off the fram e w hile pushing the w ater hose aside, then the m aster cylinder/pivot arm assem bly out of the fram e.

MASTER CYLINDER

PIVOT ARM

SPRING

15-19

BRAKE SYSTEM (Standard) DISASSEMBLY Rem ove the follow ing from the m aster cylinder: – cotter pin – joint pin – pivot arm

– boot (from the m aster cylinder) – snap ring TOOL: Snap ring pliers

07914-SA50001

– piston/push rod assem bly – prim ary cup – spring

SPRING

Clean the m aster cylinder and m aster piston in clean brake fluid.

CUP

INSPECTION Check the piston cups and boot for w ear, deterioration or dam age. Check the spring for dam age.

PISTON Check the m aster cylinder and piston for scoring, scratches or dam age. M easure the m aster cylinder I.D. SERVICE LIMIT: 17.515 mm (0.6896 in) M easure the m aster piston O.D. SERVICE LIMIT: 17.405 mm (0.6852 in)

15-20

BRAKE SYSTEM (Standard) ASSEMBLY

Do not allow the piston cup lips to turn inside out.

Coat the m aster piston and piston cups w ith clean brake fluid. Install the prim ary cup onto the spring. Install the spring and piston/push rod assem bly into the m aster cylinder.

Make sure the snap ring is firmly seated in the groove.

Install the snap ring into the groove in the m aster cylinder using the special tool. TOOL: Snap ring pliers

07914-SA50001

Apply silicone grease to the boot groove in the push rod and install the boot into the m aster cylinder and boot groove.

BOOT

15-21

BRAKE SYSTEM (Standard) If the push rod joint is reinstalled, adjust the push rod length so the distance from the center of the low er m ounting bolt hole to the center of the joint pin hole is 106 m m (4.2 in) After adjustm ent, tighten the joint nut. TORQUE: 18 NÂˇm (1.8 kgfÂˇm, 13 lbfÂˇft)

106 mm

Install the pivot arm into the m aster cylinder push rod joint w ith the joint pin and a new cotter pin.

INSTALLATION

15-22

BRAKE SYSTEM (Standard) Apply grease to the pivot shaft groove of the pivot arm . Place the m aster cylinder/pivot arm assem bly into the fram e w hile pushing the w ater hose aside and insert the pivot arm into the pivot hole, being careful not to dam age its splines.

MASTER CYLINDER

Install the m aster cylinder onto the fram e and tighten the m ounting bolts. TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft) Install the return spring into the pivot arm and onto the fram e stopper pin.

SPRING

PIVOT ARM

Apply brake fluid to a new O-ring and install it onto the reservoir joint. Make sure the snap ring is firmly seated in the groove.

Install the reservoir hose joint into the m aster cylinder and secure it w ith the snap ring.

Connect the brake hose to the m aster cylinder w ith the oil bolt and new sealing w ashers, and tighten the oil bolt. TORQUE: 34 NÂˇm (3.5 kgfÂˇm, 25 lbfÂˇft)

Install the brake pedal by aligning the slit w ith the punch m ark on the pivot arm .

BOLT

Install the pinch bolt and tighten it. TORQUE: 26 NÂˇm (2.7 kgfÂˇm, 20 lbfÂˇft)

ALIGN

PEDAL

15-23

BRAKE SYSTEM (Standard) Install the footpeg and tighten the bolts. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft)

FOOTPEG Apply locking agent to the threads of the sw itch holder screw s. Install the brake light/cruise cancel sw itch assem bly w ith the screw s. Adjust the sw itch position so that the brake light com es on w hen pushing the brake pedal slightly and the push rod m oves 0.7 – 1.7 m m . Tighten the sw itch holder screw s. TORQUE: 2 N·m (0.2 kgf·m, 1.4 lbf·ft) Fill and bleed the pedal brake hydraulic system (page 15-7).

SECONDARY MASTER CYLINDER DISASSEMBLY Drain the brake fluid from the pedal brake hydraulic system (page 15-6). When removing the oil bolt, cover the ends of the hoses to prevent contamination.

Rem ove the follow ing: – front fender B (page 13-16) – oil bolt and sealing w ashers – upper side brake hose

– caliper-to-m aster cylinder joint bolt – m ounting bolts

15-24

OIL BOLT

BRAKE SYSTEM (Standard) – oil bolt and sealing w ashers (w hile holding the m aster cylinder firm ly) – front side brake hose – secondary m aster cylinder – pivot collar (from the caliper bracket)

– boot (from the m aster cylinder) – snap ring TOOL: Snap ring pliers

MASTER CYLINDER OIL BOLT

07914-SA50001

– m aster piston – prim ary cup – spring Clean the m aster cylinder and m aster piston in clean brake fluid.

SPRING CUP

INSPECTION Check the piston cups and boot for w ear, deterioration or dam age. Check the spring for dam age.

PISTON Check the m aster cylinder and piston for scoring, scratches or dam age. M easure the m aster cylinder I.D. SERVICE LIMIT: 14.055 mm (0.5533 in) M easure the m aster piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in)

15-25

BRAKE SYSTEM (Standard) ASSEMBLY

Do not allow the piston cup lips to turn inside out.

Coat the m aster piston and piston cups w ith clean brake fluid. Install the prim ary cup onto the spring. Install the spring and m aster piston into the m aster cylinder.

SPRING CUP

PISTON Install the push rod into the m aster cylinder. Make sure the snap ring is firmly seated in the groove.

Install the snap ring into the groove in the m aster cylinder using the special tool. TOOL: Snap ring pliers

SNAP RING

07914-SA50001

Apply silicone grease to the boot groove in the push rod and install the boot into the m aster cylinder and boot groove.

PLIERS

BOOT

If the push rod joint is reinstalled, adjust the push rod length so the distance from the center of the low er m ounting bolt hole to the center of the joint pin hole is 69 m m (2.7 in). After adjustm ent, tighten the joint nut. TORQUE: 18 NÂˇm (1.8 kgfÂˇm, 13 lbfÂˇft)

69 mm

15-26

BRAKE SYSTEM (Standard) Connect the brake hose to the m aster cylinder w ith the oil bolt and new sealing w ashers, and tighten the oil bolt w hile holding the m aster cylinder firm ly.

OIL BOLT

TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Install the m aster cylinder onto the fork leg w ith new m ounting bolts and tighten them .

SEALING WASHERS

TORQUE: 31 N·m (3.2 kgf·m, 23 lbf·ft) Install the pivot collar into the caliper bracket. Connect the m aster cylinder onto the caliper bracket w ith a new bolt and tighten it. TORQUE: 25 N·m (2.6 kgf·m, 19 lbf·ft) Connect the brake hose to the m aster cylinder w ith the oil bolt and new sealing w ashers, and tighten the oil bolt.

OIL BOLT

TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Install front fender B (page 13-39). Fill and bleed the pedal brake hydraulic system (page 15-10).

COLLAR

SEALING WASHERS

MOUNTING BOLTS

JOINT BOLT

FRONT BRAKE CALIPER REMOVAL Drain the brake fluid from the lever and pedal brake hydraulic system s (page 15-6). LEFT CALIPER Rem ove the brake pads (page 15-13). Disconnect the brake hoses from the brake caliper by rem oving the oil bolts and sealing w ashers.

OIL BOLTS

15-27

BRAKE SYSTEM (Standard) Rem ove the tw o m ounting bolts (low er pivot and upper joint bolts) and brake caliper. Rem ove the pivot collars from the fork and caliper bracket. Check the pivot bearings and dust seals in the fork leg for w ear or dam age. For pivot bearing replacem ent, see page 13-23.

RIGHT CALIPER Rem ove the brake pads (page 15-13). Disconnect the brake hoses from the brake caliper by rem oving the oil bolts and sealing w ashers.

OIL BOLTS

ABS model only: Being careful not to damage the speed sensor and sensor wire.

Rem ove the follow ing: – bolt and w ire clam p from fork leg – tw o bolts, clam p and w heel speed sensor from caliper bracket Rem ove the tw o m ounting bolts and brake caliper.

DISASSEMBLY Rem ove the follow ing: – caliper bracket – boots – pad spring

Left caliper shown: BRACKET

BOOT PAD SPRING

15-28

BOOT

BRAKE SYSTEM (Standard) â&#x20AC;&#x201C; assem bly bolts â&#x20AC;&#x201C; caliper body B

BODY A

BODY B Place a shop tow el over the pistons. Do not use high pressure air or bring the nozzle too close to the inlet.

Be careful not to damage the piston sliding surface.

Position the caliper body w ith the piston facing dow n and apply sm all squirts of air pressure to the fluid inlets to rem ove the pistons.

Push the dust and piston seals in and lift them out. Clean the seal grooves, caliper cylinders and pistons w ith clean brake fluid.

SEALS

INSPECTION Check the caliper cylinders and pistons for scoring, scratches or dam age. M easure the caliper cylinder I.D. SERVICE LIMITS: Left caliper: Upper/lower: 22.71 mm (0.894 in) Center: 27.06 mm (1.065 in) Right caliper:Upper/center: 25.46 mm (1.002 in) Lower: 22.71 mm (0.894 in)

15-29

BRAKE SYSTEM (Standard) M easure the caliper piston O.D. SERVICE LIMITS: Left caliper: Upper/lower: 22.56 mm (0.888 in) Center: 26.91 mm (1.059 in) Right caliper: Upper/center: 25.31 mm (0.996 in) Lower: 22.56 mm (0.888 in)

ASSEMBLY RIGHT CALIPER

15-30

BRAKE SYSTEM (Standard) LEFT CALIPER

Coat new piston and dust seals w ith clean brake fluid and install them into their correct seal grooves in the caliper. Coat the caliper pistons w ith clean brake fluid and install them into their correct caliper cylinders w ith the opening tow ard the pads.

Assem ble the caliper body halves w ith new assem bly bolts and tighten them . TORQUE: 32 NÂˇm (3.3 kgfÂˇm, 24 lbfÂˇft)

15-31

BRAKE SYSTEM (Standard) Install the pad spring onto the caliper body properly as show n (page 15-37).

Check the caliper and bracket pin boots and replace them if they are hard, deteriorated or dam aged. Install the boots into the caliper and bracket. Apply silicone grease to the inside of the boots and install the caliper bracket over the caliper body. Tighten the pad pin after installing the caliper onto the fork leg.

Install the brake pads (page 15-13).

INSTALLATION RIGHT CALIPER

Install the right brake caliper so the disc is positioned betw een the pads, being careful not to dam age the pads. Install new m ounting bolts and tighten them . TORQUE: 31 NÂˇm (3.2 kgfÂˇm, 23 lbfÂˇft)

CLAMP

Install the w heel speed sensor w ith the w ire clam p and tighten the bolts. TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft) Install the w ire clam p onto the fork leg and tighten the bolt.

CALIPER

15-32

MOUNTING BOLTS CLAMP SPEED SENSOR

BRAKE SYSTEM (Standard) Route the brake hoses properly (page 1-23).

Connect the brake hoses to the caliper w ith the oil bolts and new sealing w ashers, and tighten the oil bolts.

TORQUE: 34 NÂˇm (3.5 kgfÂˇm, 25 lbfÂˇft) Tighten the pad pin and install the pad pin plug. TORQUE: 18 NÂˇm (1.8 kgfÂˇm, 13 lbfÂˇft) ABS model only:

Perform the speed sensor air gap inspection (page 16-29).

LEFT CALIPER

Apply grease to the low er pivot bearing and dust seal lips, and to the outer surface of the upper pivot collar. Install the pivot collars into the fork and caliper bracket.

Install the left brake caliper so the disc is positioned betw een the pads, being careful not to dam age the pads. Install new m ounting bolts (low er pivot and upper joint bolts) and tighten them .

TORQUE: Pivot bolt: 31 NÂˇm (3.2 kgfÂˇm, 23 lbfÂˇft) Joint bolt: 25 NÂˇm (2.6 kgfÂˇm, 19 lbfÂˇft)

15-33

BRAKE SYSTEM (Standard) Route the brake hoses properly (page 1-23).

Connect the brake hoses to the caliper w ith the oil bolts and new sealing w ashers, and tighten the oil bolts.

SEALING WASHERS

TORQUE: 34 NÂˇm (3.5 kgfÂˇm, 25 lbfÂˇft) Tighten the pad pin and install the pad pin plug. TORQUE: 18 NÂˇm (1.8 kgfÂˇm, 13 lbfÂˇft) Fill and bleed the lever and pedal brake hydraulic system s (page 15-8 and 15-11).

OIL BOLTS

REAR BRAKE CALIPER DISASSEMBLY Rem ove the rear w heel (page 14-14). Drain the brake fluid from the pedal brake hydraulic system (page 15-6). Rem ove the brake pads (page 15-13). Disconnect the brake hoses from the brake caliper by rem oving the oil bolts and sealing w ashers.

OIL BOLTS

Rem ove the tw o m ounting bolts and brake caliper.

CALIPER

Rem ove the follow ing: â&#x20AC;&#x201C; caliper bracket â&#x20AC;&#x201C; boots â&#x20AC;&#x201C; pad spring

15-34

BRAKE SYSTEM (Standard) – assem bly bolts – caliper body B

BODY A

BODY B Place a shop tow el over the pistons. Position the caliper body w ith the pistons facing dow n and apply sm all squirts of air pressure to the fluid inlets to rem ove the pistons.

Push the dust and piston seals in and lift them out. Clean the seal grooves, caliper cylinders and pistons w ith clean brake fluid.

SEALS

INSPECTION Check the caliper cylinders and pistons for scoring, scratches or dam age. M easure the caliper cylinder I.D. SERVICE LIMITS: Upper/lower: 22.71 mm (0.894 in) Center: 27.06 mm (1.065 in)

15-35

BRAKE SYSTEM (Standard) M easure the caliper piston O.D. SERVICE LIMITS: Upper/lower: 22.56 mm (0.888 in) Center: 26.91 mm (1.059 in)

ASSEMBLY

Coat new piston and dust seals w ith clean brake fluid and install them in the seal grooves in the caliper. Coat the caliper pistons w ith clean brake fluid and install them into the caliper cylinders w ith the opening tow ard the pads.

PISTONS

SEALS

15-36

BRAKE SYSTEM (Standard) Assem ble the caliper body halves w ith new assem bly bolts and tighten them . TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

Install the pad spring onto the caliper body properly as show n.

PAD SPRING

Check the caliper and bracket pin boots and replace them if they are hard, deteriorated or dam aged.

BRACKET

Install the boots into the caliper and bracket.

BOOT

Apply silicone grease to the inside of the boots and install the caliper bracket over the caliper body. Install the brake pads (page 15-13).

BOOT

Install the brake caliper so the disc is positioned betw een the pads, being careful not to dam age the pads. Install new m ounting bolts and tighten them .

CALIPER

TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft)

15-37

BRAKE SYSTEM (Standard) Connect the brake hoses to the caliper w ith the oil bolts and new sealing w ashers as show n, and tighten the oil bolts. TORQUE: 34 NÂˇm (3.5 kgfÂˇm, 25 lbfÂˇft) Tighten the pad pin and install the pad pin plug. TORQUE: 18 NÂˇm (1.8 kgfÂˇm, 13 lbfÂˇft) Fill and bleed the pedal brake hydraulic system (page 15-11). Install the rear w heel (page 14-14).

DELAY VALVE REMOVAL Drain the brake fluid from the brake pedal hydraulic system (page 15-6). When removing the oil bolt and joint nut, cover the ends of the hoses and pipe to prevent contamination.

Rem ove the follow ing: â&#x20AC;&#x201C; clips â&#x20AC;&#x201C; oil bolts, sealing w ashers and brake hoses â&#x20AC;&#x201C; bolt and 3-w ay joint â&#x20AC;&#x201C; brake pipe (by loosening joint nut, being careful not to scratch the fender) â&#x20AC;&#x201C; m ounting bolts (8 m m head and 10 m m head; fender bolt) â&#x20AC;&#x201C; delay valve

INSTALLATION Route the speed sensor wire properly (page 1-23).

Install the delay valve onto the fork leg and tighten the m ounting bolts.

TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft) Apply brake fluid to the joint nut threads on the brake pipe. Connect the brake pipe by tightening the joint nut.

TORQUE: 17 NÂˇm (1.7 kgfÂˇm, 12 lbfÂˇft) Install the 3-w ay joint and tighten the bolt. TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft)

Connect the brake hoses w ith the oil bolts and new sealing w ashers, and tighten the oil bolts. TORQUE: 34 NÂˇm (3.5 kgfÂˇm, 25 lbfÂˇft) Secure the speed sensor w ire w ith the clips. Fill and bleed the pedal brake hydraulic system (page 15-10).

15-38

BRAKE SYSTEM (Standard)

PROPORTIONAL CONTROL VALVE (PCV) REMOVAL Rem ove the left radiator (page 6-10). Drain the brake fluid from the pedal brake hydraulic system (page 15-6). When removing the joint nut, cover the ends of the brake pipes to prevent brake fluid leakage.

Loosen the joint nuts to disconnect the brake pipes from the PCV. Rem ove the tw o m ounting bolts and the PCV.

INSTALLATION Install the PCV and tighten the bolts. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Apply brake fluid to the joint nut threads on the brake pipes. Connect the brake pipes by tightening the joint nuts. TORQUE: 17 N·m (1.7 kgf·m, 12 lbf·ft) Fill and bleed the pedal brake hydraulic system (page 15-11). Install the left radiator (page 6-15).

15-39

MEMO

16. BRAKE SYSTEM (ABS)

SYSTEM LOCATION···································· 16-2

BEFORE TROUBLESHOOTING····················16-8

SERVICE INFORMATION ···························· 16-3

TROUBLESHOOTING·································16-10

SYSTEM WIRING CONNECTIONS/ LOCATIONS ················································· 16-4

WHEEL SPEED SENSOR····························16-29 ABS MODULATOR ·····································16-31

BEFORE STARTING TROUBLESHOOTING ·································· 16-5

16-1

BRAKE SYSTEM (ABS)

SYSTEM LOCATION BRAKE SYSTEM (ABS)

ABS CONTROL UNIT

REAR ABS MODULATOR

REAR WHEEL SPEED SENSOR

FRONT ABS MODULATOR

FRONT WHEEL SPEED SENSOR

16-2

BRAKE SYSTEM (ABS)

SERVICE INFORMATION GENERAL • This section (15-B) covers service of the Anti-lock Brake System (ABS). For other service (conventional brake) of the brake system , see section 15-A. • When the ABS control unit detects a problem , it stops the ABS function and sw itches back to the conventional brake operation, and the ABS indicator blinks or it stays on. Take care during the test ride. • Troubles not resulting from a faulty ABS (e.g., brake disc squeak, unevenly w orn brake pad) cannot be recognized by the ABS diagnosis system . • Read “ Before Starting Troubleshooting” carefully, inspect and troubleshoot the ABS system according to the Diagnostic Troubleshooting Flow Chart. Observe each step of the procedures one by one. Write dow n the problem code and probable faulty part before starting diagnosis and troubleshooting. • After troubleshooting, erase the problem code and perform the pre-start self-diagnosis to be sure that the ABS indicator is operating norm ally. • Be careful not to dam age the w heel speed sensor and pulser ring w hen rem oving and installing the w heel or speed • sensor. • When the w heel speed sensor and/or pulser ring is replaced, check the clearance (air gap) betw een both com ponents. • The ABS control unit (ECU) m ay be dam aged if dropped. Also if a connector is disconnected w hen current is flow ing, the excessive voltage m ay dam age the ECU. Alw ays turn off the ignition sw itch before servicing. • Do not disassem ble the ABS m odulator. Replace the m odulator as an assem bly w hen it is faulty. • Refer to section 22 for circuit diagram of ABS. • The follow ing color codes are used throughout this section. Bu: Blue Bl: Black Br: Brow n

G: Green Gr: Gray Lb: Light Blue

Lg: Light Green O: Orange P: Pink

R: Red W: White Y: Yellow

TORQUE VALUES Brake pipe joint nut Wheel speed sensor bolt M odulator m ounting bolt Ignition coil/m odulator stay bolt M odulator brake pipe joint bolt

17 N·m 12 N·m 12 N·m 12 N·m 34 N·m

(1.7 kgf·m , 12 lbf·ft) (1.2 kgf·m , 9 lbf·ft) (1.2 kgf·m , 9 lbf·ft) (1.2 kgf·m , 9 lbf·ft) (3.5 kgf·m , 25 lbf·ft)

Apply brake fluid to the threads.

16-3

BRAKE SYSTEM (ABS)

SYSTEM WIRING CONNECTIONS/LOCATIONS Refer to page 16-5 for the parts that m ust be rem oved for service. For exam ple:

16-4

REAR M ODULATOR CONTROL M OTOR 2P â&#x20AC;&#x201C; Center inner fairing (page 2-6)

Electric com ponent The part that m ust be rem oved for service

BRAKE SYSTEM (ABS)

BEFORE STARTING TROUBLESHOOTING SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as w ell as the operating status of the m odulator. When there is any abnorm ality, the problem and the problem atic part can be detected by outputting the problem code. When the vehicle speed is approxim ately 10 km /h (6 m ph) or m ore, the w heel speed sensor signal is sent to the ABS control unit (ECU), then the ABS pre-start self-diagnosis system operates the control m otor on the m odulator, checks the crank angle condition w ith the ABS control unit and thus detects w hether the m odulator operation is norm al, and it com pletes the pre-start self-diagnosis. When the ABS is norm al, the ABS indicator goes off just after a road speed of 10 km /h (6 m ph) indicating that the diagnosis is com pleted. If a problem is detected, the ABS indicator blinks or com es on and stays on to notify the rider of the problem . The selfdiagnosis is also m ade w hile the m otorcycle is running, and the indicator blinks w hen a problem is detected. When the indicator blinks, the cause of the problem can be identified by retrieving the problem code, follow the specified retrieval procedure (page 16-6).

PRE-START SELF-DIAGNOSIS PROCEDURE (Daily check) 1. 2. 3. 4.

Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M ake sure the ABS indicator com es on. Start the engine. Ride the m otorcycle and increase the vehicle speed to approxim ately 10 km /h (6 m ph) (pre-start self-diagnosis com pleted). 5. The ABS is norm al if the ABS indicator goes off.

16-5

BRAKE SYSTEM (ABS) RETRIEVAL/ERASURE OF PROBLEM CODE • After retrieval, the ABS indicator indicates the problem code by blinking a specified num ber of tim es. • The problem code is not erased by turning the ignition sw itch to “ OFF” w hile the problem code is being output. Note that turning the ignition sw itch to “ ON” again does not indicate the problem code. To show the problem code again, repeat the problem code retrieval procedures from the beginning. • The ABS control unit stores up to tw o problem codes and indicates the latest problem code first, and then the earlier code alternately. When the tw o problem codes are indicated, begin diagnostic troubleshooting, beginning w ith the code that w as indicated first. • Be sure to m ake a note of the retrieval problem code(s). • After diagnostic troubleshooting, erase the problem code(s) and perform the pre-start self-diagnosis to be sure that there is no problem in the ABS indicator (indicator is operating norm ally). RETRIEVAL: 1. Rem ove the No. 3 and 4 control m otor fuses w ith the ignition sw itch turned to “ OFF” to be sure that each fuse is not burned out. • If either fuse is burned out, perform the troubleshooting of problem code “ 4” (No. 3 fuse) or “ 5” (No. 4 fuse) w ithout installing the fuse. 2. Turn the ignition sw itch to “ ON.” The ABS indicator should com e on. 3. Wait for 5 seconds and the ABS indicator goes off. 4. Install either the No. 3 or the No. 4 fuse im m ediately after the ABS indicator is off (w ithin 3 seconds). 5. The problem code is indicated by the num ber of tim es the ABS indicator blinks. TO ERASE THE PROBLEM CODE: 1. Install the rem aining fuse (No. 3 or No.4) w hile the problem code is being indicated (i.e., the ABS indicator is blinking). 2. When code erasure is com plete, the ABS indicator stays on.

16-6

BRAKE SYSTEM (ABS) PROBLEM CODE INDICATION PATTERN

When the problem code is not stored:

16-7

BRAKE SYSTEM (ABS)

BEFORE TROUBLESHOOTING SYMPTOM-TO-SYSTEM CHART • Before perform ing any ABS troubleshooting, check the pre-start self-diagnosis (page 16-5). Probable faulty part Fuse

Reference page

Riding conditions (NOTE)

Rear

Front

Wheel

Rear

Front

Tire

ABS control unit

ABS indicator

Wire harness

Rear

Front

Rear

Front

Rear

Front

Power circuit (charging)

Pulser ring

Wheel speed sensor

Crank angle sensor Rear

Front

Rear

Front

16-10 O

O 16-12

O O

O 16-14 16-16 16-18

16-21 O O

O O

ABS control unit

Front w heel 2 speed sensor system Rear w heel 3 speed sensor system Front control 4 m otor system Rear control 5 m otor system Front crank 6 angle sensor system Rear crank angle 7 sensor system Front control 8 circuit Rear control 9 circuit Front relay 10 circuit Rear relay 11 circuit Front m otor 12 driver circuit Rear m otor 13 driver circuit 14 Pow er circuit Problem s not — detected by ABS control unit

Control motor

Modulator control motor

ABS main

Problem code

Check part and system

Modulator

O O

16-10 16-12 16-23 16-24 16-25 16-25 16-26 16-27

• The ABS indicator m ight blink in the follow ing cases: – The m otorcycle has continuously run on bum py roads. – After riding (after the pre-start self-diagnosis), the engine w as kept running and the rear w heel turning (for m ore than 30 seconds) w ith the m otorcycle placed on the center stand. – The ABS control unit is disrupted by extrem ely pow erful radio w aves (electrom agnetic interference). This is a tem porary failure. erase the problem code and perform the pre-start self-diagnosis. The ABS is norm al if the ABS indicator goes off.

16-8

BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLESHOOTING FLOW CHART Be careful not to damage the wheel speed sensor and pulser ring when servicing. • The connector num ber (num ber in parenthesis) indicates the connector location as show n on page 16-4. All connector diagram s in the flow charts are view ed from the term inal side. • Perform inspection w ith the ignition sw itch turned to “ OFF,” unless otherw ise specified. • Use a fully charged battery. Do not diagnose w ith a charger connected to the battery. • When the ABS control unit or m odulator is detected to be faulty, recheck the w ire harness and connector connections closely before replacing it. • After troubleshooting, erase the problem code and perform the pre-start self-diagnosis to be sure that the ABS indicator is operating norm ally. • The ABS indicator m ight blink in the follow ing cases. Correct the faulty part. – Incorrect tire pressure. – Tires not recom m ended for the m otorcycle w ere installed (incorrect tire size). – Deform ation of the w heel or tire. • The ABS indicator m ight blink w hile riding under the follow ing conditions. Erase the problem code and perform the prestart self-diagnosis. The ABS is norm al if the indicator goes off. Ask the rider for the riding conditions in detail w hen the m otorcycle is brought in for inspection. – The m otorcycle has continuously run on bum py roads. – After riding (after the pre-start self-diagnosis), the engine w as kept running and the rear w heel turning (for m ore than 30 seconds) w ith the m otorcycle placed on the center stand. • If the pulser ring or speed sensor is replaced, perform the air gap inspection page 16-29.

16-9

BRAKE SYSTEM (ABS)

TROUBLESHOOTING Problem Code 2 and 8: Front wheel speed sensor system and ABS control unit 1. Wheel Pulser Air Gap Inspection Check the area around the front w heel speed sensor. M easure the air gap betw een the speed sensor and pulser ring (page 16-29). Is the gap correct?

– Check each part for deform ation and looseness and correct accordingly. Check air gap again.

YES

– GO TO STEP 2.

Wheel Pulser Magnetic Deposits Inspection Check to see if there are iron or other m agnetic deposits betw een the pulser ring and speed sensor. Are there magnetic deposits between the pulser ring and speed sensor? NO

– GO TO STEP 3.

YES

– Rem ove any deposits.

3. Speed Sensor/Pulser Ring Fit Inspection Check installation condition of the pulser ring and speed sensor for looseness. Does pulser ring and speed sensor fit properly? NO

– Install properly or replace the faulty part.

YES

– GO TO STEP 4.

4. Speed Sensor/Pulser Ring Damage Inspection Check the pulser ring for deform ation or dam age (e.g., chipped teeth) and the speed sensor tip for dam age. Is pulser ring or speed sensor deformed or damaged? NO

– GO TO STEP 5.

YES

– Replace the faulty part.

5. ABS Indicator Function Inspection Retrieve the problem code and erase it. Turn ignition sw itch to “ ON” (do not operate the ignition sw itch after erasing the problem code), turn the front w heel by hand (vehicle speed: approxim ately 4 km /h [2.5 m ph] or above) and check the ABS indicator. Is the indicator blinking?

16-10

YES

– Norm al (tem porary failure). The ABS control unit has been disrupted by an extrem ely pow erful radio w ave. Check the connector and w ire harness of the speed sensor system for loose connection.

– GO TO STEP 6.

BRAKE SYSTEM (ABS) 6. Speed Sensor Line Short Circuit Inspection at ABS Control Unit Disconnect the ABS control unit 12P connector (8). Check for continuity betw een the Black/w hite or Green/orange term inal of the connector (8) and ground.

(8)

Is there continuity? NO

– GO TO STEP 8.

YES

– GO TO STEP 7.

7. Speed Sensor Line Short Circuit Inspection at Sensor Connector Disconnect the front w heel speed sensor connector (1). Check for continuity betw een either term inal of the sensor side connector (1) and ground in the sam e m anner as the previous step.

(1)

Is there continuity? NO

– Short circuit betw een the ABS control unit and speed sensor.

YES

– Faulty front w heel speed sensor.

8. Wire Harness Continuity Inspection Disconnect the front w heel speed sensor connector (1). Short the term inals of the connector (1) w ith a jum per w ire. Check for continuity betw een the Black/w hite and Green/orange term inals of the connector (8). Is there continuity? YES

– GO TO STEP 9.

– Open circuit in the w ire betw een the ABS control unit and front w heel speed sensor.

(1)

(8)

9. Check Indicator Function Again Rem ove the front w heel speed sensor and replace it w ith a new one. Connect the control unit 12P connector (8). Perform the pre-start selfdiagnosis and check the ABS indicator. Is the indicator blinking? NO

– Faulty rem oved w heel speed sensor.

YES

– Faulty ABS control unit.

16-11

BRAKE SYSTEM (ABS) Problem Code 3 and 9: Rear wheel speed sensor system and ABS control unit 1. Wheel Pulser Air Gap Inspection Check the area around the rear w heel speed sensor. M easure the air gap betw een the speed sensor and pulser ring (page 16-29). Is the air gap correct? NO

– Check each part for deform ation and looseness and correct accordingly. Check for air gap again.

YES

– GO TO STEP 2.

2. Wheel Pulser Magnetic Deposits Inspection Check betw een pulser ring and speed sensor for any iron or other m agnetic deposits. Magnetic deposits found? NO

– GO TO STEP 3.

YES

– Rem ove any deposits.

3. Speed Sensor/Pulser Ring Fit Inspection Check installation condition of the pulser ring and speed sensor for looseness. Did pulser ring and speed sensor have proper fit? NO

– Install properly or replace the faulty part.

YES

– GO TO STEP 4.

4. Speed Sensor/Pulser Ring Damage Inspection Check the pulser ring for deform ation or dam age (e.g., chipped teeth) and the speed sensor tip for dam age. Was deformation or damage found? NO

– GO TO STEP 5.

YES

– Replace the faulty part.

5. ABS Indicator Function Inspection Retrieve the problem code and erase it. With the ignition sw itch turned “ ON” (do not operate the ignition sw itch after erasing the problem code), turn the rear w heel by hand (vehicle speed: approxim ately 4 km /h [2.5 m ph] or above) and check the ABS indicator. Is the indicator blinking?

16-12

YES

– GO TO STEP 6.

BRAKE SYSTEM (ABS) 6. Speed Sensor Line Short Circuit Inspection at ABS Control Unit Disconnect the ABS control unit 12P connector (8). Check for continuity betw een the Black/ orange or Blue/yellow term inal of the connector (8) and ground.

(8)

Is there continuity? NO (NORMAL) – GO TO STEP 8. YES

– GO TO STEP 7.

7. Speed Sensor Line Short Circuit Inspection at Sensor Connector Disconnect the rear w heel speed sensor connector (6). Check for continuity betw een either term inal of the sensor side connector (6) and ground in the sam e m anner as the previous step.

(6)

Is there continuity? NO

– Short circuit in the w ire betw een the ABS control unit and speed sensor.

YES

– Faulty rear w heel speed sensor.

8. Wire Harness Continuity Inspection Disconnect the rear w heel speed sensor connector (6). Short the term inals of the connector (6) w ith a jum per w ire. Check for continuity betw een the Black/orange and Blue/yellow term inals of the connector (8). Is there continuity? NO

– Open circuit in the w ire betw een the ABS control unit and speed sensor.

YES

– GO TO STEP 9.

(6)

(8)

9. Check Indicator Function Again Rem ove the rear w heel speed sensor and replace it w ith a new one. Connect the control unit 12P connector (8). Perform the pre-start selfdiagnosis and check the ABS indicator. Is indicator blinking? NO

– Faulty rem oved w heel speed sensor.

YES

– Faulty ABS control unit.

16-13

BRAKE SYSTEM (ABS) Problem Code 4: Front modulator control motor system 1. Motor Fuse No. 3 Inspection Check the front control m otor fuse (No. 3; 30A).

(10)

Is the fuse blown?

NO YES

– GO TO STEP 3.

– GO TO STEP 2.

–

2. Short Circuit Inspection Between Fuse Box and ABS Control Unit Disconnect the ABS control unit 5P connector (9). Check for continuity betw een the Red/blue term inal of the connector (9) and ground w ith the No. 3 fuse rem oved.

(9)

Is there continuity? NO

– Tem porary failure (install a spare fuse and check again).

YES

– Short circuit in the w ire betw een the fuse box and ABS control unit.

3. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform the pre-start self-diagnosis and check the ABS indicator. Is indicator blinking? YES

– GO TO STEP 4.

– Norm al (tem porary failure). Fine foreign m atter in m odulator, or the ABS unit has been disrupted by and extrem ely pow erful radio w ave. Check the connector and w ire harness for loose connection.

4. ABS Control Unit Battery Voltage Inspection Disconnect the ABS control unit 5P connector (9). M easure the voltage betw een the Red/blue term inal (+) of the connector (9) and the ground (–). There should be battery voltage at all tim es.

(9)

Is there battery voltage? NO

– Open circuit in the w ire betw een the fuse box and ABS control unit.

YES

– GO TO STEP 5.

V 16-14

BRAKE SYSTEM (ABS) 5. Modulator Motor Ground Circuit Inspection at ABS Control Unit Check for continuity betw een the Green term inal of the connector (9) and ground.

(9)

Is there continuity? NO

– Open circuit in the Green w ire (ground).

YES

– GO TO STEP 6.

6. Modulator Motor Short Circuit Inspection at Modulator Connector Disconnect the front m odulator control m otor connector (2). Check for continuity betw een the Brow n/yellow term inal of the connector (2) and ground, and betw een the Green/yellow term inal of the connector (2) and ground.

(2)

Is there continuity? NO

– GO TO STEP 8.

YES

– Short circuit in the w ire betw een the ABS control unit and m odulator (control m otor).

7. Open Circuit Inspection Between ABS Control Unit and Front Modulator Short the Brow n/yellow and Green/yellow term inal of the connector (9) w ith a jum per w ire. Check for continuity betw een the Brow n/yellow and Green/yellow term inals of the connector (2). Is there continuity? YES

– GO TO STEP 8.

– Open circuit in the w ire betw een the ABS control unit and m odulator (control m otor).

(9)

(2)

16-15

BRAKE SYSTEM (ABS) 8. Modulator Motor Inspection by Removing Front and Rear Modulators Connect the control unit 5P connector (9). Disconnect the (3), (4) and (5) connectors from the front and rear m odulators. Connect the (5) and (4) connectors to the front m odulator, and the (2) and (3) connectors to the rear m odulator conversely. Perform the pre-start self-diagnosis and retrieve the problem code and record it. Is any problem code indicated?

(5)

(2)

CODE 4 – Faulty ABS control unit. CODE 5 – Faulty front m odulator assem bly.

(3)

(4)

Problem Code 5: Rear modulator control motor system 1. Front Control Motor Fuse No. 4 Inspection Check the front control m otor fuse (No. 4; 30A).

(10)

Is the fuse blown?

NO YES

– GO TO STEP 3.

– GO TO STEP 2.

+ –

2. Short Circuit Inspection Between Fuse Box and ABS Control Unit Disconnect the ABS control unit 5P connector (7). Check for continuity betw een the Red/green term inal of the connector (7) and ground w ith the No. 4 fuse rem oved. Is there continuity? YES

– Short circuit in the w ire betw een the fuse box and ABS control.

– Tem porary failure (install a spare fuse and recheck).

3. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform the pre-start self-diagnosis and check the ABS indicator. Is the indicator blinking?

16-16

– Norm al (tem porary failure). Fine foreign m aterial in m odulator or the ABS control unit has been disrupted by an extrem ely pow erful radio w ave. Check the connector and w ire harness for loose connection.

YES

– GO TO STEP 4.

(7)

17 18

BRAKE SYSTEM (ABS) 4. ABS Control Unit Battery Voltage Inspection • Disconnect the ABS control unit 5P connector (7). M easure the voltage betw een the Red/ green term inal (+) of the connector (7) and ground (–). There should be battery voltage at all tim es.

(7)

Is there battery voltage? NO

– Open circuit in the w ire betw een the fuse box and ABS control unit.

YES

– GO TO STEP 5.

V 5. Modulator Motor Ground Circuit Inspection at ABS Control Unit Check for continuity betw een the Green term inal of the connector (7) and ground.

(7)

Is there continuity? NO

– Open circuit betw een in the Green w ire.

YES

– GO TO STEP 6.

6. Modulator Motor Short Circuit Inspection at Modulator Connector Disconnect the rear m odulator control m otor connector (5). Check for continuity betw een the Brow n/light green term inal of the connector (5) and ground, and betw een the Red/black term inal of the connector (5) and ground.

(5)

Is there continuity? NO

– GO TO STEP 7.

YES

– Short circuit in the w ire betw een the ABS control unit and m odulator (control m otor).

16-17

BRAKE SYSTEM (ABS) 7. Wire Harness Open Circuit Inspection Between ABS Control Unit and Rear Modulator Short the Brow n/light green and Red/black term inals of the connector (7) w ith a jum per w ire. Check for continuity betw een the Brow n/light green and Red/black term inals of the connector (5).

(7)

(5)

Is there continuity? NO

– Open circuit in the w ire betw een the ABS control unit and m odulator (control m otor).

YES

– GO TO STEP 8.

8. Modulator Motor Inspection by Replacing Front and Rear Modulators Connect the control unit 5P connector (7). Disconnect the (2), (3) and (4) connectors from the front and rear m odulators. Connect the (2) and (3) connectors to the rear m odulator and the (5) and (4) connectors to the front m odulator conversely. Perform the pre-start self-diagnosis and retrieve the problem code and record it. Is there a problem code 4 or 5?

(5)

(2)

CODE 4 – Faulty rear m odulator assem bly. CODE 5 – Faulty ABS control unit.

(3) Problem Code 6: Front modular crank angle sensor system 1. ABS Indicator Checking Turn the ignition sw itch “ ON” and check the ABS indicator. Is the indicator blinking? NO

– GO TO STEP 2.

YES

– GO TO STEP 3.

2. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform pre-start self-diagnosis and check the ABS indicator. Is the indicator blinking?

16-18

YES

– GO TO STEP 3.

(4)

BRAKE SYSTEM (ABS) 3. Crank Angle Sensor Input Voltage Inspection Disconnect the front m odulator crank angle sensor connector (3). M easure the voltage betw een the Orange/green (+) and Pink/black (–) term inals of the connector (3) w ith the ignition sw itch turned to “ ON.” Standard: 4.5 – 5.5V.

(3)

Is voltage within standard range? NO

– GO TO STEP 7.

YES

– GO TO STEP 4.

V 4. Crank Angle Sensor Short Circuit Inspection at ABS Control Unit Connector • Disconnect the ABS control unit 12P connector (8). Check for continuity betw een the White/red term inal of the connector (3) and ground.

(3)

Is there continuity? NO

– GO TO STEP 5.

YES

– Short circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

5. Open Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator Ground the White/red term inal of the connector (8) w ith a jum per w ire. Check for continuity betw een the White/red term inal of the connector (3) and ground.

(8)

(3)

Is there continuity? NO

– Open circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

YES

– GO TO STEP 6.

16-19

BRAKE SYSTEM (ABS) 6. Modulator Inspection by Replacing the Front and Rear Modulators Connect the control unit 12P connector (8). Disconnect the (2), (4) and (5) connectors from the front and rear m odulators. Connect the (5) and (4) connectors to the front m odulator, and the (2) and (3) connectors to the rear m odulator conversely. Perform the pre-start self-diagnosis and retrieve the problem code, and record it. Is there a problem code 6 or 7?

(5)

(2)

CODE 6 – Faulty ABS control unit. CODE 7 – Faulty front m odulator assem bly.

(3)

(4)

7. Short Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator Disconnect the ABS control unit 12P connector (8). Check for continuity betw een the Orange/ green term inal of the connector (3) and ground, and betw een the Pink/black term inal of the connector (3) and ground.

(3)

Is there continuity? NO

– GO TO STEP 8.

YES

– Short circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

8. Open Circuit Inspection Between ABS Control Unit and Modulator Short the Orange/green and Pink/black term inals of the connector (8) w ith a jum per w ire. Check for continuity betw een the Orange/green and Pink/black term inals of the connector (3). Is there continuity?

16-20

– Open circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

YES

– Faulty ABS control unit.

(8)

(3)

BRAKE SYSTEM (ABS) Problem Code 7: Rear modulator crank angle sensor system 1. ABS Indicator Checking Turn the ignition sw itch to “ ON” and check the ABS indicator. Is the indicator blinking? NO

– GO TO STEP 2.

YES

– GO TO STEP 3.

2. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform the pre-start self-diagnosis and check the ABS indicator. Does indicator go off or blink? GOES OFF – Norm al (tem porary failure). Fine foreign m aterial in m odulator or the ABS control unit has been disrupted by an extrem ely pow erful radio w ave. Check the connector and w ire harness for loose connection. YES

– GO TO STEP 3.

3. Crank Angle Sensor Input Voltage Inspection • Disconnect the rear m odulator crank angle sensor connector (4). M easure the voltage betw een the Orange/w hite (+) and Pink/w hite (–) term inals of the connector (4) w ith the ignition sw itch turned to “ ON.” Standard: 4.5 – 5.5V.

(4)

Is voltage within standard value? NO

– GO TO STEP 6.

YES

– GO TO STEP 4.

V 4. Short Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator Disconnect the ABS control unit 12P connector (8). Check for continuity betw een the White/blue term inal of the connector (4) and ground.

(4)

Is there continuity? NO

– GO TO STEP 5.

YES

– Short circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

16-21

BRAKE SYSTEM (ABS) 5. Open Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator Ground the White/blue term inal of the connector (8) w ith a jum per w ire. Check for continuity betw een the White/blue term inal of the connector (4) and ground.

(8)

(4)

Is there continuity? NO

– Open circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

YES

– GO TO STEP 6.

6. Modulator Inspection by Replacing the Front and rear Modulators Connect the control unit 12P connector (8). Disconnect the (2), (3), and (5) connectors from the front and rear m odulators. Connect the (2) and (3) connectors to the rear m odulator, and the (5) and (4) connectors to the front m odulator conversely. Perform the pre-start self-diagnosis and retrieve the problem code and record it. Is any problem code indicated?

(5)

(2)

CODE 6 – Faulty rear m odulator assem bly. CODE 7 – Faulty ABS control unit.

(3)

(4)

7. Short Circuit Inspection Between the ABS Control Unit and Angle Sensor Modulator Disconnect the ABS control unit 12P connector (8). Check for continuity betw een the Orange/ w hite term inal of the connector (4) and ground, and betw een the Pink/w hite term inal of the connector (4) and ground. Is there continuity?

16-22

– GO TO STEP 8.

YES

– Short circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

(4)

BRAKE SYSTEM (ABS) 8. Open Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator or Faulty ABS Control Unit Short the Orange/w hite and Pink/w hite term inals of the connector (8) w ith a jum per w ire. Check for continuity betw een the Orange/w hite and Pink/w hite term inals of the connector (4). Is there continuity? NO

– Open circuit in the w ire betw een the ABS control unit and m odulator (angle sensor).

YES

– Faulty ABS control unit.

(8)

(4)

Problem Code 10: ABS control unit (front relay circuit) 1. ABS Indicator Checking • The ABS indicator blinks or com es on and stays on w hen the ABS control unit has been disrupted by an extrem ely pow erful radio w ave (electrom agnetic interference). This is just a tem porary sym ptom . Erase the problem code and the ABS control unit is norm al unless the sym ptom occurs again. Turn the ignition sw itch to “ ON” and check the ABS indicator. Is the indicator blinking? NO

– GO TO STEP 2.

YES

– GO TO STEP 3.

2. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform the pre-start self-diagnosis and check the ABS indicator. Is the indicator blinking? NO

– Norm al (tem porary failure). Fine foreign m atter in m odulator or the ABS control unit has been disrupted by an extrem ely pow erful radio w ave. Check the connector and w ire harness for loose connection.

YES

– GO TO STEP 3.

3. Check Problem Code Retrieve the problem code and record the latest problem code. Is the problem code 10 or other? CODE 10 – GO TO STEP 4. OTHER THAN CODE 10 – Diagnose at the latest problem code.

16-23

BRAKE SYSTEM (ABS) 4. Modulator Inspection by Replacing the Front and Rear Modulators Disconnect the (2), (3), (4) and (5) connectors from the front and rear m odulators. Connect the (5) and (4) connectors to the front m odulator, and the (2) and (3) connectors to the rear m odulator conversely. Perform the pre-start selfdiagnosis and retrieve the problem code, and record it. Is any problem code indicated?

(5)

(2)

CODE 10 – Faulty ABS control unit. CODE 11 – Faulty front m odulator assem bly.

(3) Problem Code 11: ABS control unit (rear relay circuit) 1. ABS Indicator Checking • The ABS indicator blinks or com es on and stays on w hen the ABS control unit has been disrupted by an extrem ely pow erful radio w ave (electrom agnetic interference). This is just a tem porary sym ptom . Erase the problem code and the ABS control unit is norm al unless the sym ptom occurs again. Turn the ignition sw itch to “ ON” and check the ABS indicator. Is the indicator blinking? NO

– GO TO STEP 2.

YES

– GO TO STEP 3.

2. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform the pre-start self-diagnosis and check the ABS indicator. Is the indicator blinking? NO

YES

– GO TO STEP 3.

3. Check Problem Code Retrieve the problem code and record the latest problem code. Is any problem code indicated? CODE 11 – GO TO STEP 4. OTHER THAN CODE 11 – Diagnose at the latest problem code.

16-24

(4)

BRAKE SYSTEM (ABS) 4. Modulator Inspection by Replacing the Front and Rear Modulators Disconnect the (2), (3), (4) and (5) connectors from the front and rear m odulators. Connect the (5) and (4) connectors to the front m odulator, and the (2) and (3) connectors to the rear m odulator conversely. Perform the pre-start self-diagnosis and retrieve the problem code, and record it. Is any problem code indicated?

(5)

(2)

CODE 10 – Faulty rear m odulator assem bly. CODE 11 – Faulty ABS control unit.

(3)

(4)

Problem Code 12 and 13: ABS control unit (front and rear motor driver circuit) 1. ABS Indicator Checking • The ABS indicator blinks or com es on and stays on w hen the ABS control unit has been disrupted by an extrem ely pow erful radio w ave (electrom agnetic interference). This is just a tem porary sym ptom . Erase the problem code and the ABS control unit is norm al unless the sym ptom occurs again. Turn the ignition sw itch to “ ON” and check the ABS indicator. Is the indicator blinking? NO

– GO TO STEP 2.

YES

– GO TO STEP 3.

2. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform the pre-start self-diagnosis and check the ABS indicator. Is the indicator blinking? NO

YES

– GO TO STEP 3.

3. Check Problem Code Retrieve the problem code and record the latest problem code. Is the problem code 12, 13 or other? CODE 12 or 13 – Faulty ABS control unit. OTHER THAN CODE 12 or 13 – Diagnose at the latest problem code.

16-25

BRAKE SYSTEM (ABS) Problem Code 14: Power circuit 1. Battery Charging System Inspection • Ask the rider about the follow ing w hen the m otorcycle is brought in for inspection. This problem code w ill light up to indicate battery discharge. – Ask w hether the m otorcycle has been run w ith large capacity electric load accessories. – Ask w hether the m otorcycle has been left for long tim e w ith the ignition sw itch turned to “ ON” (after the pre-start self-diagnosis). • Check to see w hether the indicated idle speed m atches the specified idle speed. Check the battery for charging condition. Is the charging system normal? NO (low or no voltage) – Check the charging system (section 16). YES

battery

– GO TO STEP 2.

2. ABS Indicator Function Inspection Retrieve the problem code and erase it. Perform the pre-start self-diagnosis and check the ABS indicator.

(9)

Is the indicator blinking? NO (ON) – GO TO STEP 3. NO (OFF) – Norm al (tem porary failure). The ABS control unit has been disrupted by an extrem ely pow erful radio w ave. Check the connector and w ire harness for loose connection. YES

– GO TO STEP 4.

3. Input Voltage Inspection Disconnect the ABS control unit 5P connector (9) and (7). M easure the voltage betw een the Red/ blue (+) and Green (–) term inals of the connector (9), and betw een the Red/green (+) and Green (–) term inals of the connector (7). There should be voltage at all tim es. Standard: 10 – 17V.

(7)

Is the voltage within the standard value? NO

– Check the w ire betw een the battery and fuse box for open or short circuit. If the w ire harness is OK, check the charging system (section 16).

YES (normal 10 – 17 V at both connectors) – • Faulty ABS control unit. 4. Check Voltage After Replacing Battery Retrieve the problem code and verify that the problem code is “ 14.” Erase the problem code. Replace the battery w ith a new fully charged battery. Perform the pre-start self-diagnosis and check the ABS indicator. Is the indicator blinking?

16-26

YES

– Faulty ABS control unit.

– Faulty rem oved battery.

BRAKE SYSTEM (ABS) Problems Not Detected by ABS Control Unit (ABS indicator stays on) 1. Check Battery System Check the battery for charging condition. Is voltage within standard range? NO (low or no voltage) – Check the charging system (section 16). YES

– GO TO STEP 2.

2. ABS Main Fuse No. 13 Inspection Check the ABS m ain fuse (No. 13; 5A).

(10)

Is the fuse blown?

NO YES

– GO TO STEP 5.

– GO TO STEP 3.

+ –

17 18

3. Short Circuit Inspection Between Fuse Box and ABS Control Unit Disconnect the ABS control unit 5P connector (7). Check for continuity betw een the Red/blue term inal of the connector (7) and ground w ith the No. 13 fuse rem oved.

(7)

Is there continuity? NO

– Tem porary failure (install a spare fuse and recheck).

YES

– Short circuit in the w ire betw een the fuse box and ABS control unit.

4. Open Circuit Inspection Between Fuse Box and ABS Control Unit Install the fuse. Disconnect the ABS control unit (7). M easure the voltage betw een the Red/blue term inal (+) of the connector (7) and ground (–) w ith the ignition system turned to “ ON.”

(7)

Is there voltage? NO

– Open circuit in the w ire betw een the fuse box and ABS control unit.

YES

– GO TO STEP 5.

16-27

BRAKE SYSTEM (ABS) 5. Open Circuit Inspection Between ABS Control Unit and Indicator Connect the 5P connector (7). Disconnect the ABS control unit 5P connector (9). M easure the voltage betw een the Yellow /blue term inal (+) of the connector (9) and ground (–) w ith the ignition sw itch turned to “ ON.” Standard: 1 – 3V.

(9)

Is there voltage? NO

– Open circuit in the w ire betw een the ABS control unit and com bination m eter (ABS indicator).

YES (normal voltage) – GO TO STEP 6.

6. Open or Short Circuit Inspection Between ABS Control Unit and Wheel Speed Sensor Connect the 5P connector (9). Disconnect the front and rear w heel speed sensor connectors (1) and (6). M easure the voltage betw een each connector (1) and (6), term inal (+) and ground (–) as show n w ith the ignition sw itch turned to “ ON.”

(1)

(6)

Is there voltage? NO

– Open or short circuit in the w ire betw een the ABS control unit and front or rear w heel speed sensor.

YES

– GO TO STEP 7.

7. Open Circuit Inspection Between ABS Control and Wheel Speed Sensor Disconnect the ABS control unit 12P connector (8). Ground the Green/orange and Blue/yellow term inals of the connector (8) w ith jum per w ires. Check for continuity between each connector (1) and (6) and ground as show n.

(8)

Is there continuity? NO

– Open circuit in the w ire betw een the ABS control unit and front or rear w heel speed sensor.

YES

– GO TO STEP 8.

(1)

16-28

(6)

BRAKE SYSTEM (ABS) 8. ABS Indicator Checking Perform the pre-start self-diagnosis and check the ABS indicator. Does the indicator go off or stay on? GOES OFF–Norm al (tem porary failure). The ABS control unit has been disrupted by an extrem ely pow erful radio w ave. Check the connector and w ire harness for loose connection. STAYS ON–Faulty ABS control unit.

WHEEL SPEED SENSOR AIR GAP INSPECTION Front sensor: Rear sensor:

Raise the front w heel off the ground. Rem ove the rear fender A (page 2-13). M easure the clearance (air gap) betw een the sensor and pulser ring at several points by turning the w heel slow ly. It m ust be w ithin specification. STANDARD: Front/rear: 0.4 – 1.2 mm (0.02 – 0.05 in) The sensor air gap cannot be adjusted. If it is not w ithin specification, check each installation part for deform ation, looseness and dam age.

REPLACEMENT FRONT SENSOR Rem ove the follow ing: – right front fender cover (page 2-6) – center inner fairing (page 2-10) Disconnect the sensor 2P (orange) connector.

16-29

BRAKE SYSTEM (ABS) Rem ove the sensor w ire from the clam ps and clips. Rem ove the tw o bolts, clam p and speed sensor. Route the wire properly (page 1-23).

Installation is in the reverse order of rem oval. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) After installation, check the air gap (page 16-29).

REAR SENSOR Rem ove the follow ing: – right saddle bag (page 2-15) – fuel tank (page 5-56) Disconnect the sensor 2P (gray) connector. Rem ove the sensor w ire from the clam ps and clips. Rem ove the tw o bolts and the speed sensor. Route the wire properly (page 1-23).

Installation is in the reverse order of rem oval. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) After installation, check the air gap (page 16-29).

16-30

BRAKE SYSTEM (ABS)

ABS MODULATOR REMOVAL

Drain the hydraulic brake system (page 15-6). Rem ove the ignition coils (page 18-8). Disconnect the control m otor 2P (black) and crank angle sensor 3P (gray) connectors from each m odulator. When loosening the joint nuts, cover the ends of the brake pipe to prevent contamination.

Loosen the joint nuts to disconnect the brake pipe from each m odulator.

Be careful not to bend or damage the brake pipe and stay.

– m odulator/stay assem bly from fram e – three m ounting bolts and each m odulator from the stay

Rem ove the follow ing: – spark plug w ire clip from stay – tw o stay bolts

16-31

BRAKE SYSTEM (ABS) INSTALLATION Route the wires properly (page 1-23).

Install the m odulators onto the stay w ith the m ounting bolts. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the m odulator/stay assem bly, being careful not to interfere w ith the brake pipes and tighten the tw o stay bolts. TORQUE: 17 N·m (1.7 kgf·m, 12 lbf·ft) Install the clip of the spark plug w ires into the stay. Set the brake pipes into the m odulator ports and m ake sure that the paint color on the brake pipes are aligned w ith the m arks on the m odulators.

Be careful not to cross-thread the joint nuts.

Apply brake fluid to the joint nut threads on the brake pipes. Tighten the joint nuts to connect the brake pipes. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Connect the connectors to the m odulators properly. Install the ignition coils (page 18-8). Fill and bleed (page 15-6).

16-32

the

hydraulic

brake

system

17. BATTERY/CHARGING SYSTEM

SYSTEM LOCATION···································· 17-2

BATTERY·······················································17-6

SYSTEM DIAGRAM····································· 17-2

CHARGING SYSTEM INSPECTION·············17-9

SERVICE INFORMATION ···························· 17-3

ALTERNATOR·············································17-10

TROUBLESHOOTING ·································· 17-5

17-1

BATTERY/CHARGING SYSTEM

SYSTEM LOCATION BATTERY/CHARGING SYSTEM

SYSTEM DIAGRAM

17-2

BATTERY/CHARGING SYSTEM

SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flam es and cigarettes away. Provide adequate ventilation w hen charging. • The battery contains sulfuric acid (electrolyte). Contact w ith skin or eyes m ay cause severe burns. Wear protective clothing and a face shield. – If electrolyte gets on your skin, flush w ith water. – If electrolyte gets in your eyes, flush w ith water for at least 15 m inutes and call a physician im m ediately. • Electrolyte is poisonous. – If swallow ed, drink large quantities of water or m ilk and call your local Poison Control Center or a physician im m ediately. • Alw ays turn off the ignition sw itch before disconnecting any electrical com ponent. • Som e electrical com ponents m ay be dam aged if term inals or connectors are connected or disconnected w hile the ignition sw itch is turned to “ ON” and current is present. • For extended storage, rem ove the battery, give it a full charge, and store it in a cool, dry place. • For a battery rem aining in a stored m otorcycle, disconnect the negative battery cable from the battery. • The battery sealing caps should not be rem oved. Attem pting to rem ove the sealing caps from the cells m ay dam age the battery. • The m aintenance free (M F) battery m ust be replaced w hen it reaches the end of its service life. • The battery can be dam aged if overcharged or undercharged, or if left to discharge for long periods. These sam e conditions contribute to shortening the “ life span” of the battery. Even under norm al use, the perform ance of the battery deteriorates after 2–3 years. • Battery voltage m ay recover after battery charging, but under heavy load, the battery voltage w ill drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem . Battery overcharge often results from problem s in the battery itself, w hich m ay appear to be an overcharging sym ptom . If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes dow n quickly. • Before troubleshooting the charging system , check for proper use and m aintenance of the battery. Check if the battery is frequently under heavy load, such as having the headlight and taillight on for long periods of tim e w ithout riding the m otorcycle. • The battery w ill self-discharge w hen the m otorcycle is not in use. For this reason, charge the battery every 2 w eeks to prevent sulfation from occurring. • Filling a new battery w ith electrolyte w ill produce som e voltage, but in order to achieve its m axim um perform ance, alw ays charge the battery. Also, the battery life is lengthened w hen it is initially charged. • When checking the charging system , alw ays follow the steps in the troubleshooting flow chart (page 17-5). • The regulator/rectifier is located in the alternator. • The alternator service m ay be done w ith the engine in the fram e. For alternator driven gear rem oval/installation, see section 10. BATTERY CHARGING • This m odel com es w ith a m aintenance free (M F) battery. Rem em ber the follow ing about M F batteries. – Use only the electrolyte that com es w ith the battery. – Use all of the electrolyte. – Seal the battery properly. – Never open the seals after installation. • For battery charging, do not exceed the charging current and tim e specified on the battery. Using excessive current or extending the charging tim e m ay dam age the battery. BATTERY TESTING Refer to the battery tester’s Operation M anual for the recom m ended battery testing procedure. The recom m ended battery tester puts a “ load” on the battery so the actual battery condition of the load can be m easured. Recommended battery tester

BM-210-AH, BM-210 or BATTERY MATE

17-3

BATTERY/CHARGING SYSTEM SPECIFICATIONS Battery

Alternator

ITEM Capacity Current leakage Voltage (20° C/68° F) Charging current

Fully charged Needs charging Norm al Quick

Capacity Stator coil resistance (20° C/68° F) Rotor coil resistance (20° C/68° F) Rotor coil slip ring O.D.

STANDARD 12 V – 18 Ah 5 m A m ax. 13.0 – 13.2 V Below 12.3 V 1.8 A x 5 – 10 h 9.0 A x 1.0 h 1 kW @ 2,400 m in –1 (rpm ) 0.07 – 0.09 Ω 2.5 – 2.9 Ω 22.7 m m (0.89 in)

SERVICE LIMIT – – – – – – – – – 21.2 m m (0.83 in)

TORQUE VALUES Alternator m ounting bolt Alternator term inal nut

29 N·m (3.0 kgf·m , 22 lbf·ft) 8 N·m (0.8 kgf·m , 5.8 lbf·ft)

TOOLS Driver 07749-0010000

Attachm ent, 20 m m I.D. 07746-0020400

17-4

Pilot, 20 m m 07746-0040500

Driver, 22 m m I.D. 07746-0020100

BATTERY/CHARGING SYSTEM

TROUBLESHOOTING Battery is damaged or weak 1. Battery Inspection Rem ove the battery (page 17-6). Check the battery condition using the recom m ended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH, BM-210 or BATTERY MATE Is the battery voltage within 13.0–13.2 V? NO

– Faulty battery.

YES

– GO TO STEP 2.

2. Battery Current Leakage Inspection Install the battery (page 17-6). Check the battery current leakage (CURRENT LEAKAGE TEST: page 17-9). SPECIFIED CURRENT LEAKAGE: 5 mA max. Is the current equal to or less than the specified value? NO

– Shorted w ire harness.

YES

– GO TO STEP 3.

3. Battery Connection Inspection Check the battery term inals, alternator cable term inal, and alternator 4P connector for loose or poor contacts. Are all battery connections tight? NO

– Loose or poor contact term inal or connector.

YES

– GO TO STEP 4.

4. Charging Voltage Inspection M easure and record the battery voltage using a digital m ultim eter (page 17-6). Start the engine. M easure the charging voltage (page 17-7). Com pare the m easurem ents to the result of the follow ing calculation. MEASURED BATTERY VOLTAGE < MEASURED CHARGING VOLTAGE < 15.5 V Do the battery and charging voltages satisfy the calculation? YES

– Faulty battery.

– GO TO STEP 5.

5. Wire Harness Inspection Perform the w ire harness inspection (page 17-10). Is battery voltage present when tested as described? NO

– Open circuit in w ire harness.

YES

– GO TO STEP 6.

6. Alternator Inspection Rem ove the alternator (page 17-10). Disassem ble the alternator and inspect the follow ing: – rotor coil (page 17-12) – brush length (page 17-13) – stator coil (page 17-13) Does the alternator test OK? NO

– • Faulty rotor coil. • Worn brush. • Faulty stator coil.

YES

– Faulty regulator/rectifier.

17-5

BATTERY/CHARGING SYSTEM

BATTERY REMOVAL/INSTALLATION Rem ove the left side cover (page 2-5). Rem ove the trim clip and battery plate.

Rem ove the bolt and low er the battery holder. With the ignition sw itch turned to “ OFF,” disconnect the negative (–) cable first, then disconnect the positive (+) cable. Rem ove the battery from the battery case. Install the battery in the reverse order of rem oval. • Connect the positive (+) cable first, then connect the negative (–) cable. • After connecting the battery cables, coat the term inals w ith grease.

VOLTAGE INSPECTION Rem ove the left side cover (page 2-5). M easure the battery voltage using a com m ercially available digital m ultim eter. VOLTAGE (20° C/68° F): Fully charged: 13.0 – 13.2 V Under charged: Below 12.3 V

17-6

BATTERY/CHARGING SYSTEM BATTERY TESTING Rem ove the battery (page 17-6). For accurate test results, be sure the tester’s cables and clamps are in good working condition and that a secure connection can be made at the battery.

Securely connect the tester’s positive (+) cable first, then connect the negative (–) cable. TOOL: Battery tester

BATTERY

BM-210-AH or BM-210 (U.S.A. only)

TESTER

RED BLACK

Set the tem perature sw itch to “ HIGH” or “ LOW” depending on the am bient tem perature.

For the first check, DO NOT charge the battery before testing; test it in an “as is” condition.

Push in the appropriate test button for 3 seconds and read the condition of the battery on the m eter.

TEST BUTTONS

• To avoid damaging the tester, only test batteries with an amperage rating of less than 30 Ah. • Tester damage can result from overheating when: – The test button is pushed in for more than 3 seconds. – The tester is used without being allowed to cool for at least 1 minute when testing more than one battery. – More than ten consecutive tests are performed without allowing at least a 30-minute cooldown period. The result of a test on the m eter scale is relative to the am p. hour rating of the battery. Any battery reading in the green zone is OK. Batteries should only be charged if they register in the YELLOW or RED zone.

17-7

BATTERY/CHARGING SYSTEM BATTERY CHARGING Rem ove the battery (page 17-6). â&#x20AC;˘ M ake sure the area around the charger is w ell ventilated, clear of flam m able m aterials, and free from heat, hum idity, w ater and dust. â&#x20AC;˘ Clean the battery term inals and position the battery as far aw ay from the charger as the leads w ill perm it. â&#x20AC;˘ Do not place batteries below the charger â&#x20AC;&#x201C; gases from the battery m ay corrode and dam age the charger. â&#x20AC;˘ Do not place batteries on top of the charger. Be sure the air vents are not blocked. 1. Turn the â&#x20AC;&#x153; POWERâ&#x20AC;? sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Turn the power ON/ OFF at the charger, not at the battery terminals.

2. Set the SWITCHâ&#x20AC;? charged.

â&#x20AC;&#x153; BATTERY AM P. HR. SELECTOR for the size of the battery being

TOOL: Christie battery charger

MC1012/2 (U.S.A. only)

!" 3. Set the â&#x20AC;&#x153; TIM ERâ&#x20AC;? to the position indicated by the Honda Battery Tester; RED-3, RED-2 or YELLOW-1. If you are charging a new battery, set the sw itch to the NEW BATT position. 4. Attach the clam ps to the battery term inals: red to positive, black to negative. Connecting the cables with the POWER switch turned to â&#x20AC;&#x153;ONâ&#x20AC;? can produce a spark which could ignite or explode the battery.

Connect the battery cables only w hen the â&#x20AC;&#x153; POWERâ&#x20AC;? sw itch is turned to â&#x20AC;&#x153; OFFâ&#x20AC;? .

5. Turn the â&#x20AC;&#x153; POWERâ&#x20AC;? sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? . The charger will automatically switch to the "Trickle" mode after the set charging time has elapsed.

6. When the tim er reaches the â&#x20AC;&#x153; Trickleâ&#x20AC;? position, the charging cycle is com plete. Turn the â&#x20AC;&#x153; POWERâ&#x20AC;? sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the clam ps. 7. Let the battery cool for at least 10 m inutes or until gassing subsides after charging. 8. Retest the battery using the Honda battery tester and recharge if necessary using the above steps.

17-8

BATTERY/CHARGING SYSTEM

CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Rem ove the left side cover (page 2-5). Turn the ignition sw itch to “ OFF,” and disconnect the negative (–) cable from the battery. Connect the am m eter (+) probe to the negative (–) cable and the am m eter (–) probe to the battery (–) term inal. With the ignition sw itch turned to “ OFF,” check for current leakage. • When m easuring current using a tester, set it to a high range, and then bring the range dow n to an appropriate level. Current flow higher than the range selected m ay blow the fuse in the tester. • While m easuring current, do not turn the ignition sw itch to “ ON.” A sudden surge of current m ay blow the fuse in the tester. SPECIFIED CURRENT LEAKAGE: 5 mA maximum If current leakage exceeds the specified value, a shorted circuit is the probable cause. Locate the short by disconnecting connections one by one and m easuring the current.

CHARGING VOLTAGE INSPECTION • M ake sure the battery is in good condition before perform ing this test. Rem ove the left side cover (page 2-5). Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.

Start the engine and w arm it up to the operating tem perature; then stop the engine. Connect the m ultim eter betw een the positive and negative term inals of the battery. • To prevent a short, m ake absolutely certain w hich are the positive and negative term inals or cable. With the headlight on high beam , restart the engine. M easure the voltage on the m ultim eter w hen the engine runs at 2,000 rpm . STANDARD: Measured battery voltage (page 17-6) < Measured charging voltage (page 17-9) < 15.5 V

17-9

BATTERY/CHARGING SYSTEM WIRE HARNESS INSPECTION 4P CONNECTOR

Rem ove the left side cover (page 2-5). Rem ove the left engine side cover (page 2-5). Be sure to disconnect the battery negative cable to prevent sparking when disconnecting or connecting the alternator cable.

Disconnect the battery negative (–) cable from the battery. Pull the rubber cap off the alternator term inal, rem ove the nut and disconnect the alternator cable. Disconnect the alternator 4P connector. Connect the battery negative cable to the battery and check the follow ing at the w ire harness side: BATTERY CHARGING LINE M easure the voltage betw een the alternator cable term inal (+) and ground (–). There should be battery voltage at all tim es.

NUT, CABLE

BATTERY VOLTAGE LINE M easure the voltage betw een the Black/yellow w ire term inal (+) of the alternator 4P connector and ground (–). There should be battery voltage w ith the ignition sw itch turned to “ ON” and the engine stop sw itch turned to “ .” Install the rem oved parts in the reverse order of rem oval.

ALTERNATOR REMOVAL Rem ove the left engine side cover (page 2-5). Rem ove the fuel tank (page 5-56).

4P CONNECTOR

Disconnect the alternator 4P connector. Pull the rubber cap off the alternator term inal, rem ove the nut and disconnect the alternator cable.

NUT, CABLE Rem ove the alternator.

three

m ounting

bolts

and

the

17-10

BATTERY/CHARGING SYSTEM Rem ove the O-ring from the alternator.

O-RING

DISASSEMBLY M ark the front and rear housings before disassem bly to identify their original position. Rem ove the four bolts and separate the front housing/rotor from the rear housing/stator.

Rem ove the four screw s and separate the rotor from the front housing.

OIL SEAL

SCREWS

Rem ove the oil seal from the front housing.

ROTOR Rem ove the term inal cap, nut and term inal set from the rear housing.

17-11

BATTERY/CHARGING SYSTEM Rem ove the spring w asher from the rear housing. Rem ove the three screw s and separate the stator coil and regulator/rectifier assem bly from the rear housing.

SPRING WASHER

SCREWS

INSPECTION ROTOR COIL Inspect the slip rings for discoloration. M easure the O.D. of the slip rings. SERVICE LIMIT: 21.2 mm (0.83 in)

M easure the rotor coil resistance betw een the slip rings. STANDARD: 2.5 – 2.9 Ω

Check for continuity betw een the slip ring and rotor shaft. There should be no continuity.

17-12

SLIP RINGS

BATTERY/CHARGING SYSTEM ROTOR BEARING Turn the outer race of each bearing w ith your finger. The bearings should turn sm oothly and quietly. Also check that the bearing inner race fits tightly on the rotor shaft. Replace the bearings if the races do not turn sm oothly, quietly, or if they fit loosely on the shaft (page 17-15).

BRUSH LENGTH Always replace the Replace the brushes if they are w orn to or near the brushes in pairs. w ear lines.

If replacem ent is necessary, rem ove the insulator and cap, m elt the solder securing the brushes, and pull the brushes out of the brush holder.

Install new brushes in the brush holder w ith their m arked side facing to the front housing. Set the brushes at the installed length as show n. INSTALLED LENGTH: 1.5 mm (0.06 in)

17-13

BATTERY/CHARGING SYSTEM Work quickly to avoid heat damage to the regulator/rectifier.

Heat the soldering iron (capacity: about 32 W) and use a low -tem perature (180° – 200° C) solder to solder the brushes.

• Make sure that solder does not enter the brush holder or the brush will not operate properly. • Do not apply excess solder; align the solder end with the brush holder surface as shown. Cut off the surplus brush w ires.

STATOR COIL Work quickly to avoid heat-damage to the regulator/rectifier. Hold the stator coil wire with pliers to dissipate heat.

M elt the solder and separate the stator coil from the regulator/rectifier.

Melt the solder

REGULATOR/RECTIFIER

STATOR COIL M easure the resistance betw een the stator coil w ires. STANDARD: 0.07 – 0.09Ω at 20° C (68° F)

Put the tester probe on the silver color part of the core.

Check for continuity betw een the stator coil w ire and stator core. There should be no continuity. For stator coil assem bly, see page 17-14.

17-14

BATTERY/CHARGING SYSTEM RECTIFIER See the w ire diagram on page 17-2 for term inal locations. Check for continuity in each direction betw een: â&#x20AC;&#x201C; B and P term inals â&#x20AC;&#x201C; E (ground) and P term inals All diodes should have continuity in only one direction. If any of the diodes fail, replace the regulator/ rectifier assem bly.

ROTOR BEARING REPLACEMENT Rem ove the front and rear rotor bearings using a bearing puller.

Be sure to center the attachment with the bearing.

Drive a new front bearing onto the rotor shaft using the special tools. TOOLS: Driver, 22 mm I.D. Attachment, 20 mm I.D.

07746-0020100 07746-0020400

Drive a new rear bearing onto the rotor shaft using the special tools. TOOLS: Driver Pilot, 20 mm

07749-0010000 07746-0040500

DRIVER REAR BEARING

PILOT

17-15

BATTERY/CHARGING SYSTEM ASSEMBLY

Heat a high-am perage soldering iron (capacity: about 110 W). Work quickly to avoid heat damage to the regulator/ rectifier.

Join with solder

REGULATOR/RECTIFIER

Using a high-tem perature (300Â° C), high lead content solder, join the stator and regulator/rectifier by soldering the stator coil w ires on the diode term inals.

STATOR COIL Push the brushes in the brush holder and insert an appropriate pin into the brush holder to hold the brushes.

17-16

BATTERY/CHARGING SYSTEM Install the stator coil and regulator/rectifier assem bly into the rear housing, w hile inserting the pin holding the brushes into the hole in the housing. Align the m arks on the rear housing and stator.

HOLE

REAR HOUSING

PIN Install the three screw s and tighten them securely.

5+4-95

Install the term inal and nut, and tighten the nut.

TORQUE: 8 N路m (0.8 kgf路m, 5.8 lbf路ft) Install the term inal cap.

Apply grease to a new oil seal lip and install it into the front housing.

OIL SEAL

17-17

BATTERY/CHARGING SYSTEM Install the rotor into the front housing. Install the four screw s and tighten them securely.

OIL SEAL

SCREWS

ROTOR

Install the spring w asher into the rear housing.

Install the front housing/rotor into the rear housing/ stator, w hile aligning the m arks on the front housing and stator. Rem ove the pin holding the brushes from the rear housing. Install the four bolts and tighten them securely.

SPRING WASHER

M ake sure the bolt holes in the rear housing align w ith the gaps betw een the stator core ridges. â&#x20AC;˘ M ake sure the bolt holes in the rear housing align w ith the gaps betw een the stator core ridges.

INSTALLATION Coat a new O-ring w ith oil and install it into the alternator groove.

17-18

O-RING

BATTERY/CHARGING SYSTEM Install the alternator into the rear case and tighten the three m ounting bolts. TORQUE: 29 N路m (3.0 kgf路m, 22 lbf路ft)

Connect the alternator cable and tighten the term inal nut securely. Install the rubber cap properly. Connect the alternator 4P connector.

4P CONNECTOR

Install the fuel tank (page 5-56). Install the left engine side cover (page 2-5).

NUT, CABLE

17-19

MEMO

18. IGNITION SYSTEM

SYSTEM LOCATION···································· 18-2

IGNITION COIL ·············································18-7

SYSTEM DIAGRAM····································· 18-2

IGNITION PULSE GENERATOR···················18-9

SERVICE INFORMATION ···························· 18-3

PGM-FI IGNITION RELAY ··························18-11

TROUBLESHOOTING ·································· 18-4

BANK ANGLE SENSOR ·····························18-13

IGNITION SYSTEM INSPECTION ··············· 18-5

IGNITION TIMING ······································18-14

18-1

IGNITION SYSTEM

SYSTEM LOCATION IGNITION SYSTEM

SYSTEM DIAGRAM

18-2

IGNITION SYSTEM

SERVICE INFORMATION GENERAL • Som e electrical com ponents m ay be dam aged if term inals or connectors are connected or disconnected w hile the ignition sw itch is “ ON” and current is present. • When servicing the ignition system , alw ays follow the steps in the troubleshooting table on page 18-4. • This m otorcycle’s Ignition Control M odule (ICM ) is built into the Engine Control M odule (ECM ). • The transistorized ignition system uses an electrically controlled ignition tim ing system . No adjustm ents can be m ade to the ignition tim ing. • The ECM varies ignition tim ing according to the engine speed. • The ECM m ay be dam aged if dropped. Also, if the connector is disconnected w hen current is flow ing, the excessive voltage m ay dam age the ECM . Alw ays turn the ignition sw itch to “ OFF” before servicing. • A faulty ignition system is often related to poor connections. Check those connections before proceeding. • M ake sure the battery is adequately charged. Using the starter m otor w ith a w eak battery results in a slow er engine cranking speed as w ell as no spark at the spark plugs. • This m otorcycle’s ignition coil is equipped w ith an ignitor. The ignition coil signal voltage from the ECM is converted to the high voltage in the ignition coil. • For spark plug inspection, see section 3. • See section 19 for the follow ing com ponents: – Ignition sw itch – Engine stop sw itch – Gear position sw itch – Side stand sw itch

SPECIFICATIONS Spark plug

ITEM Standard For cold clim ate (below 5° C/41° F) For extended high speed riding

Spark plug gap Ignition coil signal peak voltage Ignition pulse generator peak voltage Ignition tim ing (“ F” m ark)

SPECIFICATIONS BKR6E-11 (NGK), K20PR-U11 (DENSO) BKR5E-11 (NGK), K16PR-U11 (DENSO) BKR7E-11 (NGK), K22PR-U11 (DENSO) 1.0 – 1.1 m m (0.039 – 0.043 in) 2.5 – 5.0 V 0.7 V m inim um 0° BTDC at idle

TORQUE VALUES Ignition pulse generator bolt

12 N·m (1.2 kgf·m , 9 lbf·ft)

TOOL IgnitionM ate peak voltage tester M TP07-0286 (U.S.A. only)

Peak voltage adaptor 07HGJ-0020100

Test harness set 07WM Z-M BGA000

(not available in U.S.A.) w ith com m ercially available digital m ultim eter (im pedance 10 MΩ/DCV m inim um )

18-3

IGNITION SYSTEM

TROUBLESHOOTING • Inspect the follow ing before diagnosing the system . – Faulty spark plug. – Loose spark plug cap or spark plug w ire connections. – Water in the spark plug cap (Leaking the ignition coil secondary voltage). • If there is no spark at any cylinder, tem porarily exchange the ignition coil w ith a know n-good one and perform the spark test. If there is spark, the exchanged ignition coil is faulty.

No spark at spark plugs UNUSUAL CONDITION No peak voltage Ignition coil signal voltage

Ignition pulse generator

Peak voltage is norm al, but no spark. Low peak voltage

No peak voltage

18-4

PROBABLE CAUSE (check in numerical order) 1. The m ultim eter im pedance is too low ; below 10 MΩ/DCV. 2. Cranking speed is too low (battery is undercharged). 3. The sam pling tim ing of the tester and m easured pulse w ere not synchronized. (System is norm al if the m easured voltage is over the standard voltage at least once.) 4. Faulty side stand sw itch or gear position (neutral) sw itch. 5. An open circuit or loose connection in No. 4 related circuit w ires. – Side stand sw itch line: Green/w hite w ire – Neutral sw itch line: Blue/red and Light green/red w ires 6. Open or short circuit in the ignition coil signal w ire (No. 1 & 2: Yellow / w hite, No. 3 & 4: Yellow /blue, No. 5 & 6: Yellow /red). 7. Faulty peak voltage adaptor. 8. Faulty engine control m odule (ECM ) (w hen No. 1 through 7 are norm al). 1. Open circuit in ignition coil pow er input or ground line (page 18-5). 2. Ignition coil is leaking secondary current am perage. 3. Faulty spark plug w ire 1. The m ultim eter im pedance is too low ; below 10 M Ω/DCV. 2. Cranking speed is too slow (battery is undercharged). 3. The sam pling tim ing of the tester and m easured pulse w ere not synchronized. (System is norm al if the m easured voltage is over the standard voltage at least once.) 4. Faulty ignition pulse generator (w hen causes No. 1 through 3 are norm al). 1. Faulty peak voltage adaptor. 2. Faulty ignition pulse generator.

IGNITION SYSTEM

IGNITION SYSTEM INSPECTION • If there is no spark present at the plugs, check all connections for loose or poor contact before m easuring the peak voltage. • Use a com m ercially available digital m ultim eter (im pedance 10 M Ω/DCV m inim um ). • The display value differs depending upon the internal im pedance of the m ultim eter. Connect the peak voltage adaptor to the digital m ultim eter.

DIGITAL MULTIMETER

TOOLS: Peak voltage tester (U.S.A. only) or 07HGJ-0020100 Peak voltage adaptor (not available in U.S.A.) with commercially available digital multimeter (impedance 10 MΩ/DCV minimum)

PEAK VOLTAGE ADAPTOR Rem ove the seat (page 2-5).

FUEL PUMP 5P CONNECTOR

Disconnect the fuel pum p 5P connector.

IGNITION COIL SIGNAL PEAK VOLTAGE • Check all system connections before perform ing this inspection. Loose connectors can cause incorrect readings. • Check that the cylinder com pression is norm al for each cylinder and the spark plug is installed correctly in the cylinder head. Rem ove the center inner fairing (page 2-10). Disconnect the ignition coil 4P connector.

No. 3 & 4 COIL CONNECTOR No. 1 & 2 COIL No. 5 & 6 COIL CONNECTOR CONNECTOR

18-5

IGNITION SYSTEM Connect the peak voltage tester or adaptor probes to the w ire harness side connector term inal and ground.

CONNECTION: No. 1 & 2 ignition coil: Yellow/white (+) â&#x20AC;&#x201C; Ground (â&#x20AC;&#x201C;) No. 3 & 4 ignition coil: Yellow/blue (+) â&#x20AC;&#x201C; Ground (â&#x20AC;&#x201C;) No. 5 & 6 ignition coil: Yellow/red (+) â&#x20AC;&#x201C; Ground (â&#x20AC;&#x201C;) Shift the transm ission into neutral. Make sure the engine stop switch is turned to â&#x20AC;&#x153; .â&#x20AC;?

Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;?

Crank the engine w ith the starter m otor and m easure the ignition coil signal peak voltage. PEAK VOLTAGE: 2.5 â&#x20AC;&#x201C; 5.0 V â&#x20AC;˘ Although m easured values are different for each ignition coil, they are norm al as long as voltage is higher than the specified value. If the peak voltage is low er than the standard value, follow the checks described in the troubleshooting chart on page 18-4.

IGNITION PULSE GENERATOR PEAK VOLTAGE â&#x20AC;˘ Check that the cylinder com pression is norm al for each cylinder and the spark plug is installed correctly in the cylinder head. Connect the test harnesses set to the ECM connectors (page 5-11). TOOLS: Test harness set

07WMZ-MBGA000

No. 21 PEAK VOLTAGE ADAPTOR

Connect the peak voltage tester or adaptor probes to the test pin box term inals. CONNECTION: No. 41 (+) â&#x20AC;&#x201C; No. 21 (â&#x20AC;&#x201C;) Shift the transm ission into neutral. Make sure the engine stop switch is turned to â&#x20AC;&#x153; .â&#x20AC;?

Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Crank the engine w ith the starter m otor and m easure â&#x20AC;&#x153; the ignition pulse generator peak voltage PEAK VOLTAGE: 0.7 V minimum If the voltage m easured at the ECM connector is abnorm al, m easure the peak voltage at the ignition pulse generator connector. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Rem ove the air cleaner housing (page 5-57).

18-6

No. 41

IGNITION SYSTEM Disconnect the ignition pulse generator 2P red connector and connect the peak voltage tester or adaptor probes to the ignition pulse generator side connector term inals. CONNECTION: Yellow (+) – White/yellow (–) In the sam e m anner as at the ICM connector, m easure the peak voltage and com pare it to the voltage m easured at the ECM connector. • If the peak voltage m easured at the ECM connector is abnorm al and the m easurem ent at the ignition pulse generator connector is norm al, the Yellow or White/yellow w ire has an open or short circuit, or loose connections. • If both peak voltages are abnorm al, follow the checks described in the troubleshooting chart on page 18-4.

2P RED CONNECTOR

IGNITION COIL POWER/GROUND LINE INSPECTION • If the ignition coil signal voltage is norm al but there is no spark at the plug, perform this inspection. Rem ove the center inner fairing (page 2-10). Turn the ignition sw itch “ OFF.” Disconnect the ignition coil 4P connector.

No. 3 & 4 COIL CONNECTOR No. 1 & 2 COIL No. 5 & 6 COIL CONNECTOR CONNECTOR

POWER INPUT LINE Make sure the engine stop switch is turned to “ .”

1. Turn the ignition sw itch “ ON” and check the PGM -FI m alfunction indicator lam p (M IL). • If the M IL stays on, check the PGM -FI ignition relay circuits (page 18-11). • If the M IL com es on for a few seconds and goes off, go to step 2.

MIL

18-7

IGNITION SYSTEM 2. M easure the voltage betw een the Black/yellow w ire term inal (+) of the ignition coil 4P connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

â&#x20AC;˘ If there is no voltage, repair the open circuit in the Black/yellow w ire betw een the ignition coil and PGM -FI ignition relay.

GROUND LINE Check for continuity betw een the Green w ire term inal of the ignition coil 4P connector and ground. There should be continuity.

â&#x20AC;˘ If there is no continuity, repair the open circuit in the Green w ire betw een the ignition coil and ground term inal.

REPLACEMENT

Rem ove the center inner fairing (page 2-10). Rem ove the evaporative em ission (EVAP) purge control solenoid valve from the stay. Disconnect the ignition coil 4P connectors.

Disconnect the spark plug w ires from the ignition coils. Rem ove the bolts and ignition coils from the stay. Connect the spark plug wires to the ignition coils properly (page 1-23).

Install the ignition coils in the reverse order of rem oval.

18-8

IGNITION SYSTEM SPARK PLUG WIRE Disconnect the spark plug w ires from the ignition coils. Rem ove the No. 3 & 4 ignition coil. Rem ove the w ire clam p from the stay and rem ove the stay from the No. 2 and No. 5 spark plug w ires.

SPARK PLUG WIRES No. 3 & 4 IGNITION COIL

WIRE CLAMP Rem ove the cylinder head side covers (page 3-7). Disconnect the spark plug caps from the plugs (page 3-8).

Rem ove the bolts, front low er inner cover, w ire clam ps and the spark plug w ires. Route the spark plug w ires properly (page 1-23) and install the rem oved parts in the reverse order of rem oval.

IGNITION PULSE GENERATOR REPLACEMENT Rem ove the follow ing: â&#x20AC;&#x201C; front low er fairing (page 2-6) â&#x20AC;&#x201C; air cleaner housing (page 5-57) Disconnect the ignition pulse generator 2P red connector.

2P RED CONNECTOR Rem ove the 12 bolts and the crankcase front cover.

Rem ove the dow el pins and gasket.

18-9

IGNITION SYSTEM Rem ove the tw o bolts, w ire retainer, grom m et and the ignition pulse generator from the front crankcase cover.

GROMMET

BOLTS

Clean the gasket m ating surfaces of the crankcase and cover thoroughly, being careful not to dam age them . Apply sealant to the grom m et seating surface of a new ignition pulse generator. Apply locking agent to the bolt threads. Install the ignition pulse generator, grom m et and w ire retainer onto the crankcase cover and tighten the bolts. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

WIRE RETAINER

IGNITION PULSE GENERATOR

Install the dow el pins and a new gasket.

Apply sealant to the m ating surface of the crankcase as show n.

Install the front crankcase cover and tighten the 12 bolts.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

18-10

IGNITION SYSTEM Connect the ignition pulse generator 2P red connector securely. Install the follow ing: – air cleaner housing (page 5-57) – front low er fairing (page 2-6)

2P RED CONNECTOR

PGM-FI IGNITION RELAY SYSTEM INSPECTION • If the PGM -FI m alfunction indicator lam p (M IL) stays on and there is no ignition coil input voltage, perform this inspection.

Rem ove the seat (page 2-5). Rem ove the tw o screw s and rem ove the relay box. Rem ove the relay blocks from the relay box.

1. Turn the ignition sw itch to “ OFF” and exchange the PGM -FI ignition relay w ith the other good one. Turn the ignition sw itch to “ ON” and check the M IL. • If the M IL com es on for a few seconds and goes off, replace the PGM -FI ignition relay w ith a new one. • If the M IL stays on, go to step 2.

MIL

18-11

IGNITION SYSTEM 2. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the PGM -FI IGNITION relay. Turn ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Black w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

â&#x20AC;˘ If there is no battery voltage, go to step 3. â&#x20AC;˘ If there is battery voltage, go to step 4.

Make sure the engine stop switch is turned to â&#x20AC;&#x153; .â&#x20AC;?

3. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Rem ove the right side cover (page 2-5). Rem ove the fuse box cover. Check the No. 17 fuse (20 A). â&#x20AC;˘ If the fuse is OK, repair the open circuit in the Black w ire betw een the fuse box and relay box. â&#x20AC;˘ If the fuse is blow n, replace it w ith a new one, install the PGM -FI ignition relay and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? If the fuse blow s again, check for a short circuit in the related w ires.

FUSE BOX COVER 4. M easure the voltage betw een the Black/w hite w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

â&#x20AC;˘ If there is no battery voltage, check the Black/ w hite w ire at the engine stop sw itch (page 20-35). â&#x20AC;˘ If there is battery voltage, go to step 5.

5. Check for continuity betw een the Red/w hite w ire term inal of the relay connector and ground. There should be continuity w ith the ignition sw itch turned to â&#x20AC;&#x153; ON.â&#x20AC;?

â&#x20AC;˘ If there is continuity, the system is OK; check for loose contacts or corroded term inals. â&#x20AC;˘ If there is no continuity, check the bank angle sensor (page 18-13).

18-12

IGNITION SYSTEM

BANK ANGLE SENSOR INSPECTION 1. Rem ove the front fairing (page 2-10). Check for continuity between the Green w ire term inal of the w ire harness side bank angle sensor 3P green connector and ground. There should be continuity.

BANK ANGLE SENSOR 3P GREEN CONNECTOR

• If there is no continuity, check for an open circuit in the Green w ire betw een the bank angle sensor connector and ground term inal. • If there is continuity, go to step 2.

2. Turn the ignition sw itch to “ ON.” M easure the voltage betw een the Red/w hite w ire term inal (+) of the w ire harness side connector and ground (–). There should be battery voltage.

BANK ANGLE SENSOR CONNECTOR (viewed from the terminal side)

• If there is no voltage, check for an open circuit in the Red/w hite w ire. • If there is battery voltage, go to step 3. 3. M easure the voltage betw een the White w ire term inal (+) of the w ire harness side connector and ground (–). There should be battery voltage. • If there is no voltage, check for an open circuit in the White w ire. • If there is battery voltage, go to step 4. 4. Rem ove the tw o screw s and the bank angle sensor assem bly from the right headlight.

Red/white

White

Green

SCREWS

BANK ANGLE SENSOR 5. Turn the ignition sw itch to “ OFF.” Connect the bank angle sensor connector. M easure the voltage betw een the Red/w hite (+) and Green (–) w ire term inals. • Place the bank angle sensor horizontal and turn the ignition sw itch to “ ON.” There should be 0 – 1 V. • Angle the sensor approxim ately 43 degrees to the left or right w ith the ignition sw itch to “ ON.” There should be battery voltage. • If you repeat this test, first turn the ignition sw itch to “ OFF,” then back to “ ON” before you try the test again.

18-13

IGNITION SYSTEM

IGNITION TIMING Start the engine, w arm it up to norm al operating tem perature and stop it. Rem ove the left or right cylinder head side cover (page 3-8) Rem ove the tim ing hole cap (page 3-9). Read the manufacturers instructions for timing light operation.

Connect the tim ing light to the No. 1 or No. 2 spark plug w ire. Start the engine, let it idle and check the ignition tim ing.

The tim ing is correct if the F1.2 m ark on the ignition pulse generator rotor aligns w ith the index m ark on the front crankcase cover.

INDEX MARK

F1.2 MARK Connect the tim ing light to the No. 3 or No. 4 spark plug w ire and check the ignition tim ing as previously described by observing the F3.4 m ark.

F1.2 MARK

INDEX MARK

F3.4 MARK

F5.6 MARK

INDEX MARK

Check the No. 5 or No. 6 cylinder ignition tim ing in the sam e w ay, using the F5.6 m ark. Rem ove the tim ing light and install the follow ing: â&#x20AC;&#x201C; cylinder head side cover (page 3-7) â&#x20AC;&#x201C; tim ing hole cap (page 3-9)

18-14

19. STARTER/REVERSE SYSTEM

SYSTEM LOCATION···································· 19-2

REVERSE SWITCH ·····································19-27

STARTER SYSTEM DIAGRAM ··················· 19-2

REVERSE REGULATOR ASSEMBLY·········19-28

REVERSE SYSTEM DIAGRAM ··················· 19-3

REVERSE RESISTOR ASSEMBLY ·············19-30

SERVICE INFORMATION ···························· 19-4

POWER CONTROL RELAY·························19-31

TROUBLESHOOTING ·································· 19-6

SPEED LIMITER RELAY······························19-33

STARTER/REVERSE MOTOR ··················· 19-17

REVERSE SHIFT RELAY·····························19-34

STARTER RELAY SWITCH A ···················· 19-24

REVERSE SHIFT ACTUATOR ····················19-36

STARTER RELAY SWITCH B····················· 19-25

CRUISE/REVERSE CONTROL MODULE ·····················································19-39

REVERSE RELAY ······································· 19-26 REVERSE SHIFT MECHANISM··················19-42

19-1

STARTER/REVERSE SYSTEM

SYSTEM LOCATION STARTER/REVERSE SYSTEM

STARTER SYSTEM DIAGRAM

19-2

STARTER/REVERSE SYSTEM

REVERSE SYSTEM DIAGRAM

19-3

STARTER/REVERSE SYSTEM

SERVICE INFORMATION GENERAL • Alw ays turn the ignition sw itch to “ OFF” before servicing the starter/reverse m otor. The m otor could suddenly start, causing serious injury. • The starter/reverse m otor can be serviced w ith the engine in the fram e. • When checking the starter/reverse system , alw ays follow the steps in the troubleshooting flow chart (page 19-6). • A w eak battery m ay be unable to turn the starter/reverse m otor quickly enough, or supply adequate ignition current. • If current flow s through the starter/reverse m otor to turn it w hile the engine is not cranking over, the starter/reverse m otor m ay be dam aged. • When the speed lim iter is activated during reverse running, follow ed by the electrical m otor brake, the m otorcycle stops running in reverse and the reverse indicator goes out. To use reverse again, it is necessary to push the reverse shift sw itch to “ OFF,” then push it to “ ON.” • See section 10 for starter clutch servicing. • See section 19 for follow ing com ponents: – ignition sw itch – engine stop sw itch – starter/reverse sw itch – reverse shift sw itch – clutch sw itch – side stand sw itch – gear position sw itch

SPECIFICATIONS ITEM Starter/reverse m otor brush length Reverse resistor Red and black term inal resistance (20° C/68° F) White term inal

STANDARD 12.5 m m (0.49 in) 0.20 – 0.25 Ω 0.15 – 0.20 Ω

SERVICE LIMIT 6.0 m m (0.24 in) – –

TORQUE VALUES Starter/reverse m otor m ounting bolt Reverse sw itch Reverse sw itch term inal nut Shift drum lock arm bolt Reverse shifter shaft bolt Reverse shifter cable holder bolt

19-4

29 N·m (3.0 kgf·m , 22 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft) 2 N·m (0.2 kgf·m , 1.4 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft) 14 N·m (1.4 kgf·m , 10 lbf·ft) 12 N·m (1.2 kgf·m , 9 lbf·ft)

Apply locking agent to the threads. Apply locking agent to the threads. Apply locking agent to the threads.

STARTER/REVERSE SYSTEM TOOLS Driver 07749-0010000

Attachm ent, 24 x 26 m m 07746-0010700

Attachm ent, 32 x 35 m m 07746-0010100

Attachm ent, 37 x 40 m m 07746-0010200

Attachm ent, 20 m m I.D. 07746-0020400

Pilot, 20 m m 07746-0040500

or equivalent com m ercially available in U.S.A. Pin driver, 3.5 m m 07744-0010300

Fork seal driver 07947-4630100

Assem bly collar 07965-VM 00100

or equivalent com m ercially available in U.S.A.

19-5

STARTER/REVERSE SYSTEM

TROUBLESHOOTING Starter/reverse motor will not turn for starting 1. Battery Power to Starter Relay Switch A Inspection • Check that the battery is fully charged and in good condition. • M ake sure the reverse shift sw itch is pushed to “ OFF” (neutral position). • Check for a blow n No. 8 ST. KILL fuse, No. 10 RVS START fuse (5 A) or No. 12 RVS fuse B (5 A). Rem ove the left saddlebag (page 2-15). Check for a loose or poorly connected battery cable, and an open circuit in the battery cable betw een the battery and starter relay sw itch A. Are all connections between the battery and the starter relay good? NO

– • Poorly connected battery cable. • Open circuit in the battery cable.

YES

– GO TO STEP 2.

2. Starter Relay Switch A Connection Inspection Check for loose or poorly connected cable term inal at starter relay sw itch A. Is the cable connection good? NO

– Poorly connected term inals.

YES

– GO TO STEP 3.

3. Starter Relay Switch B Power Supply and Connection Inspection Check for loose or poorly connected cable term inals at starter relay sw itch B, and an open circuit in the starter relay sw itch cable betw een starter relay sw itches A and B. Are all connections between starter relay switches A and B good? NO

– • Poorly connected term inals. • Open circuit in the starter relay sw itch cable.

YES

– GO TO STEP 4.

4. Starter Relay Switches A & B Operation Inspection With the ignition sw itch turned to “ ON” and the engine stop sw itch to “ ” , push the starter/reverse sw itch and check for a “ click” sound from starter relay sw itches A and B. Both sw itches should click. Do both switches click? NO

– • If both relay sw itches do not click, GO TO STEP 7. • If starter relay sw itch A clicks but switch B does not click, GO TO STEP 10.

YES

– GO TO STEP 5.

5. Starter Motor Power Supply and Connection Inspection Rem ove the fuel tank (page 5-56). Check for loose or poorly connected cable term inals at the starter m otor, and an open circuit in the starter m otor cable betw een starter relay sw itch B and the starter m otor. Is the circuit between the starter relay switch B and the starter motor, and all connections at the starter motor good? NO

– • Poorly connected term inal. • Open circuit in the starter m otor cable.

YES

– GO TO STEP 6.

6. Starter Motor Operation Inspection Connect the starter m otor term inal directly to the battery positive term inal. (Because a large am ount of current flow s, DO NOT USE A THIN WIRE.) Does the motor turn?

19-6

– Faulty starter m otor.

YES

– Faulty starter relay sw itch B.

STARTER/REVERSE SYSTEM 7. Starter Relay Switch A Relay Coil Control Line Continuity Inspection Check the relay coil ground line of starter relay sw itch A (page 19-24). Is there continuity? NO

– • Open circuit in the Brow n/red w ire betw een starter relay sw itch A and the reverse relay. • Loose or poor contact of the reverse relay connector. • Faulty reverse relay or its circuits (page 19-26)

YES

– GO TO STEP 8.

8. Starter Relay Switch A Relay Coil Voltage Line Inspection Check the relay coil input voltage line of starter relay sw itch A (page 19-24). Is battery voltage present when the starter/reverse switch is pushed in? NO

– • Open circuit in the Yellow /red w ire betw een starter relay sw itch A and right handlebar sw itch. • Loose or poor contact of the handlebar sw itch connector. • Faulty right handlebar (starter/reverse) sw itch (page 20-35). • Open circuit in the White w ire betw een the right handlebar sw itch and fuse box (No. 8 ST. KILL fuse).

YES

– GO TO STEP 9.

9. Starter Relay Switch A Operation Inspection Check the operation of starter relay sw itch A (page 19-24). Is there continuity between the cable terminals while the battery is connected, and no continuity when the battery is disconnected? NO

– Faulty starter relay sw itch A.

YES

– Loose or poor contact of the starter relay sw itch A 2P red connector.

19-7

STARTER/REVERSE SYSTEM 10. Starter Relay Switch B Relay Coil Control Line Continuity Inspection Check the relay coil ground line of starter relay sw itch B (page 19-25). Is there continuity? NO

– • Open circuit in the Green/red w ire betw een starter relay sw itch B and reverse regulator assem bly. • Open circuit in the Green/orange w ire betw een the reverse regulator assem bly and reverse sw itch. • Loose or poor contact of the reverse regulator assem bly connector. • Faulty reverse regulator assem bly (diode) (page 19-28). • Faulty reverse sw itch (page 19-27).

YES

– GO TO STEP 11.

11. Starter Relay Switch B Relay Coil Voltage Line Inspection Check the relay coil input voltage line of starter relay sw itch B (page 19-25). Is battery voltage present only when the starter/reverse switch is pushed in? NO

– • Open circuit in the Red w ire betw een starter relay sw itch A and the fuse box (No. 12 reverse fuse B) • Open circuit in the Yellow /red w ire betw een starter relay sw itch B and the fuse box (No. 12 reverse fuse B). • Faulty starter relay sw itch A.

YES

– GO TO STEP 12.

12. Starter Relay Switch B Operation Inspection Check the operation of starter relay sw itch B (page 19-25). Is there continuity between the cable terminals while the battery is connected, and no continuity when the battery is disconnected? NO

– Faulty starter relay sw itch B.

YES

– Loose or poor contact of the starter relay sw itch B 2P w hite connector.

Starter motor turns slowly • Weak battery • Poorly connected battery cable • Poorly connected starter m otor cable • Faulty starter m otor Starter motor turns, but engine does not turn • Faulty starter clutch (section 10) Starter relay switch “clicks,” but engine does not turn over • Crankshaft does not turn due to engine problem • Faulty starter drive or driven gear • Faulty starter idle gear

19-8

STARTER/REVERSE SYSTEM Reverse shift actuator will not turn to the reverse position when the reverse shift switch is pushed to “ON” 1. Reverse Shift Actuator Operation Inspection • Check for a blow n No. 23 RVS SHIFT fuse A (15 A). • Check that the neutral indicator com es on w hen the ignition sw itch is turned to “ ON” w ith the transm ission in neutral. • Check that the reverse shift actuator cables are adjusted properly (page 19-36). • M ake sure the m otorcycle is stopped. With the m otorcycle stopped, shift the transm ission into neutral and turn the ignition sw itch to “ ON.” Push the reverse shift sw itch to “ ON” and check that the reverse actuator operates. Does the reverse actuator operate? YES

– GO TO STEP 13.

– GO TO STEP 2.

2. Reverse Indicator Operation Inspection Check that the reverse indicator is blinking. Does the reverse indicator blink? NO

– GO TO STEP 10.

YES

– GO TO STEP 3.

3. Reverse Shift Relay Inspection Check the reverse shift relay system (page 19-34). Does the reverse shift relay system test OK? NO

– Faulty reverse shift relay(s) or related circuit.

YES

– GO TO STEP 4.

4. Reverse Shift Relay 1 Coil Control Line Voltage Inspection Check the reverse shift relay 1 coil (No. 40) circuit at the cruise/reverse control m odule (page 19-39). Is battery voltage present when tested as described? NO

– Open circuit in the Blue/black w ire betw een the control m odule and reverse shift relay 1.

YES

– GO TO STEP 5.

5. Reverse Shift Relay 2 Coil Voltage/Control Line Continuity Inspection Check the reverse shift relay 2 coil (No. 34) circuit at the cruise/reverse control m odule (page 19-39). Is continuity correct? NO

– • Open circuit in the Blue/w hite w ire betw een the control m odule and reverse shift relay 2. • Open circuit in the Red w ire betw een reverse shift relays 1 and 2.

YES

– GO TO STEP 6.

6. Reverse Shift Relay 3 Coil Control Line Continuity Inspection Check the reverse shift relay 3 coil (No. 27) circuit at the cruise/reverse control m odule (page 19-39). Is continuity correct? NO

– Short circuit in the Yellow /w hite w ire betw een the control m odule and reverse shift relay 3.

YES

– GO TO STEP 7.

7. Reverse Actuator/Shift Relay Ground Line Continuity Inspection Check the reverse shift m otor (+) (No. 1) circuit at the cruise/reverse control m odule (page 19-39). Is there continuity? NO

– Open circuit in the Pink w ire betw een the control m odule and reverse shift relay 3.

YES

– GO TO STEP 8.

19-9

STARTER/REVERSE SYSTEM 8. Reverse Shift Motor Ground Line Continuity Inspection Check the reverse shift m otor (–) (No. 8) circuit at the cruise/reverse control m odule (page 19-39). Is there continuity? NO

– Open circuit in the Green w ire betw een the control m odule and ground term inal.

YES

– GO TO STEP 9.

9. Reverse Shift Actuator Motor Inspection Check the reverse shift actuator (page 19-36) Does the reverse shift actuator test OK? NO

– Faulty reverse shift actuator m otor and related circuits.

YES

– Faulty cruise/reverse control m odule.

10. Gear Position Neutral Line Continuity Inspection Check the gear position (neutral) sw itch (No. 47) circuit at the cruise/reverse control m odule (page 19-39). Is there continuity? NO

– Open circuit in the Light green/red w ire betw een the control m odule and gear position sw itch.

YES

– GO TO STEP 11.

11. Reverse Shift Switch Line Voltage Inspection Check the reverse shift sw itch (No. 23) circuit at the cruise/reverse control m odule (page 19-39). Is battery voltage present? NO

– • Open circuit in the Yellow /w hite w ire betw een the control m odule and right handlebar sw itch. • Faulty right handlebar sw itch (reverse shift sw itch).

YES

– GO TO STEP 12.

12. Cruise/Reverse Control Module Ground Line Continuity Inspection Check the ground (No. 20 and 52) circuits at the cruise/reverse control m odule (page 19-39). Is there continuity?

19-10

– Open circuit in the Green w ire betw een the control m odule and ground term inal.

YES

– Faulty cruise/reverse control m odule.

STARTER/REVERSE SYSTEM 13. Reverse Indicator Operation Inspection Check the reverse indicator. Does the reverse indicator light blink? NO

– If the indicator light com es on and does not blink, the system is norm al. – If the indicator light does not com e on, perform the troubleshooting on page 19-11.

YES

– GO TO STEP 14.

14. Reverse Position Switch Signal Line Voltage Inspection Check the reverse position sw itch (No. 25) circuit at the cruise/reverse control m odule page 19-39. Is battery voltage present? NO

– Open circuit in the White/blue w ire betw een the control m odule and reverse shift actuator.

YES

– GO TO STEP 15.

15. Reverse Switch Line Continuity Inspection Check the reverse sw itch (No. 17) circuit at the cruise/reverse control m odule (page 19-39). Is continuity correct? NO

– Short circuit in the Green/orange w ire betw een the control m odule and reverse sw itch.

YES

– Faulty cruise/reverse control m odule.

Reverse shift actuator operates but the reverse indicator does not come on 1. Oil Pressure and Side Stand Indicator Operation Inspection Check for blow n speed lim iter fuse (70 A). Check that the oil pressure and side stand indicators function properly. Do the oil pressure and side stand indicators function properly? NO

– Check the com bination m eter pow er input line (page 20-17).

YES

– GO TO STEP 2.

2. Reverse Indicator Operation Inspection Check the reverse indicator (No. 24) circuit at the cruise/reverse control m odule (page 19-39). Does the reverse indicator come on? NO

– • Open circuit in the White/red w ire betw een the cruise/reverse control m odule and com bination m eter. • Loose or poor contact of the related connectors. • Faulty com bination m eter.

YES

– GO TO STEP 3.

3. Speed Limiter Line Continuity Inspection Check the speed lim iter fuse (No. 19) circuit at the cruise/reverse control m odule (page 19-39). Is there continuity? NO

– Open circuit in the Yellow w ire betw een the control m odule and fuse box (reverse lim iter fuse).

YES

– Faulty cruise/reverse control m odule.

19-11

STARTER/REVERSE SYSTEM Reverse shift actuator will not turn to the neutral position when the reverse shift switch is pushed to â&#x20AC;&#x153;OFFâ&#x20AC;? 1. Neutral Indicator Operation Inspection Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and push the reverse shift sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that the reverse shift actuator turns to the neutral position and the neutral indicator com es on. Does the neutral indicator come on? YES

â&#x20AC;&#x201C; The system is norm al.

â&#x20AC;&#x201C; GO TO STEP 2.

2. Reverse Actuator Operation Inspection - Reverse Position Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the center inner fairing (page 2-10). Return the reverse shift actuator to the neutral position by turning the pulley clockw ise using a 22 m m w rench. If the pulley cannot be turned, check the reverse shift actuator (page 19-36). If the actuator is OK, check the reverse shift m echanism (page 19-42). Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and push the reverse shift sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? position. Check that the reverse actuator turns to the reverse position and the reverse indicator com es on. Does the reverse actuator turn to the reverse position and the reverse indicator light come on? NO

â&#x20AC;&#x201C; Perform the troubleshooting on page 19-9.

YES

â&#x20AC;&#x201C; GO TO STEP 3.

3. Reverse Shift Relay 3 Coil Control Line Continuity Inspection Check the reverse shift relay 3 coil (No. 27) circuit at the cruise/reverse control m odule (page 19-39). Is continuity correct? NO

â&#x20AC;&#x201C; â&#x20AC;˘ Open circuit in the Yellow /w hite w ire betw een the control m odule and reverse shift relay 3. â&#x20AC;˘ Open circuit in the Red w ire betw een reverse shift relays 1 and 3.

YES

â&#x20AC;&#x201C; GO TO STEP 4.

4. Reverse Shift Relay 2 Coil Control Line Continuity Inspection Check the reverse shift relay 2 coil (No. 34) circuit at the cruise/reverse control m odule (page 19-39). Is continuity correct?

19-12

â&#x20AC;&#x201C; Short circuit in the Blue/w hite w ire betw een the control m odule and reverse shift relay 2.

YES

â&#x20AC;&#x201C; Faulty cruise/reverse control m odule.

STARTER/REVERSE SYSTEM Starter motor turns for starting but will not turn for reverse running 1. Side Stand Switch Signal Line Continuity Inspection • M ake sure the follow ing conditions are satisfied for reverse running: – engine is running – transm ission is in neutral – side stand is retracted – reverse shift sw itch is pushed to “ ON” and the reverse indicator illum inates. • When the speed lim iter is activated during reverse running, follow ed by the electrical m otor brake or w hen the m otor is overloaded m ore than 3 seconds, the reverse system is turned off and the reverse indicator goes out. To use reverse again, it is necessary to push the reverse shift sw itch to “ OFF,” then push it to “ ON.” Check the side stand sw itch (No. 11) circuit at the cruise/reverse control m odule (page 19-39). Is continuity correct? NO

– Open circuit in the Green/w hite w ire betw een the cruise/reverse control m odule and side stand sw itch.

YES

– GO TO STEP 2.

2. Oil Pressure Switch Signal Line Continuity Inspection Check the oil pressure sw itch (No. 48) circuit at the cruise/reverse control m odule (page 19-39). Is continuity correct? NO

– • Short circuit in the Blue or Blue/red w ire betw een the control m odule and oil pressure sw itch. • Faulty oil pressure sw itch diode (D18) (page 20-13).

YES

– GO TO STEP 3.

3. Starter Relay Switch B Cable Continuity Inspection Rem ove the left saddlebag (page 2-15). Check for continuity betw een the cable term inals at starter relay sw itch B. There should be continuity. Is there continuity? NO

– • Open circuit in the Red w ire betw een starter relay sw itch B and reverse resistor assem bly. • Open circuit in the Black w ire betw een starter relay sw itch B and reverse resistor assem bly. • Loose or poor contact of the related connectors and term inal. • Faulty reverse resistor assem bly (page 19-30).

YES

– GO TO STEP 4.

4. Starter Relay Switch A Relay Coil Voltage Line Inspection M easure the regulated voltage of the reverse regulator assem bly at the starter relay sw itch A 2P connector (page 19-28). Is battery voltage present? NO

– GO TO STEP 5.

YES

– Tem porary failure; the system is norm al.

5. Starter Reverse Switch Signal Line and Reverse Relay Coil Control Line Voltage Inspection Check the starter/reverse sw itch (No. 18) circuit and reverse relay (No. 43) circuit at the cruise/ reverse control m odule (page 19-39). Is battery voltage present? NO

– • Open circuit in the Yellow /red w ire betw een the cruise/reverse control m odule and starter/reverse sw itch. • Open circuit in the Yellow /red w ire betw een the cruise/reverse control m odule and reverse relay. • Loose or poor contact of the related connectors.

YES

– GO TO STEP 6.

19-13

STARTER/REVERSE SYSTEM 6. Reverse Regulator Circuit Inspection Check the reverse regulator circuits (page 19-29). Do the reverse regulator circuits test OK? NO

– • Open circuit in the Light blue w ire betw een the reverse regulator assem bly and cruise/ reverse control m odule. • Open circuit in the Green w ire betw een the reverse regulator assem bly and ground term inal. • Open circuit in the White/blue w ire betw een the reverse regulator assem bly and reverse position sw itch (in the reverse shift actuator). • Open circuit in the Brow n/red w ire betw een the reverse regulator assem bly and starter relay sw itch A. • Loose or poor contact of the related connectors.

YES

– GO TO STEP 7.

7. Reverse Regulator Inspection Replace the reverse regulator assem bly w ith a know n-good one and check the regulated voltage again. Is the regulated voltage correct?

19-14

– • Loose or poor contact of the cruise/reverse control m odule connectors. • Faulty cruise/reverse control m odule.

YES

– Faulty original reverse regulator assem bly.

STARTER/REVERSE SYSTEM Reverse running speed too slow (below 0.6 mph (1.0 km/h) on a flat road), lack of uphill power 1. Battery voltage Inspection Check the battery (page 17-6). Is battery voltage within the specified value? NO

– • Under charged battery. • Faulty battery.

YES

– GO TO STEP 2.

2. Power Control Relay Inspection Check the pow er control relay system (page 19-31). Does the power control relay system test OK? NO

– • Faulty pow er control relay circuits. • Faulty pow er control relay.

YES

– GO TO STEP 3.

3. Reverse Resistor Assembly Inspection Check the reverse resistor assem bly (page 19-30). Is the resistance correct? NO

– Faulty reverse resistor assem bly. – Faulty cruise/reverse control m odule.

Speed limiter system will not works when the reverse running speed is above 1.6 mph (2.5 km/h) 1. Speed Limiter Relay System Inspection Check the speed lim iter relay system (page 19-33). Does the speed limiter relay system test OK? NO

– • Faulty speed lim iter relay circuits. • Faulty speed lim iter relay.

YES

– GO TO STEP 2.

2. Speed Limiter Line Continuity Inspection Check the Yellow w ire for continuity betw een the speed lim iter relay connector and speed lim iter fuse term inal in the fuse box. There should be continuity Is there continuity? NO

– Open circuit in the Yellow w ire betw een the speed lim iter relay and fuse box.

YES

– GO TO STEP 3.

3. Reverse Resistor Assembly Inspection Check the reverse resistor assem bly (page 19-30). Is the resistance correct? NO

– Faulty reverse resistor assem bly.

YES

– Faulty cruise/reverse control m odule.

19-15

STARTER/REVERSE SYSTEM Motorcycle starts reverse running but stops immediately 1. Voltage to Starter Motor Signal Line Continuity Inspection Check for a blow n No. 11 RVS fuse A (5 A). Check the starter/reverse m otor (No. 12) circuit at the cruise/reverse control m odule (page 19-39). Is there continuity? NO

– • Check for open circuit in the Pink w ire betw een starter relay sw itch B and reverse fuse A in the fuse box. • Check for an open circuit in the Pink/w hite w ire betw een the cruise/reverse control m odule and reverse fuse B in the fuse box.

YES

– • Loose or poor contact of the cruise/reverse control m odule connectors. • Faulty cruise/reverse control m odule.

System enters the reverse mode before all reverse running conditions are satisfied 1. Side Stand Switch and Oil Pressure Switch Signal Line Continuity Inspection Check the side stand sw itch (No. 11) and oil pressure sw itch (No. 48) circuits at the cruise/reverse control m odule (page 19-39). Is the continuity correct?

19-16

– • Check for a short circuit in the Green/w hite w ire betw een the cruise/reverse control m odule and side stand sw itch. • Faulty side stand sw itch. • Check for an open circuit in the Blue or Blue/red w ire betw een the cruise/reverse control m odule and oil pressure sw itch, or faulty diode. • Faulty oil pressure sw itch.

YES

– Faulty cruise/reverse control m odule.

STARTER/REVERSE SYSTEM

STARTER/REVERSE MOTOR REMOVAL Rem ove the follow ing: – fuel tank (page 5-56). – reverse shift arm (page 19-42) Slide the rubber cap off the starter m otor term inal and rem ove the term inal nut and starter/reverse m otor cable. Rem ove the three starter/reverse m otor m ounting bolts.

Rem ove the starter/reverse m otor from the rear crankcase cover as show n and rem ove the O-ring from the starter m otor.

DISASSEMBLY/INSPECTION Rem ove the three starter/reverse m otor case bolts.

Rem ove the follow ing: – reduction gear case – seal ring – gear base w asher – gear base – w asher

GEAR CASE

SEAL RING

GEAR BASE

19-17

STARTER/REVERSE SYSTEM – – – –

rear cover w asher seal ring arm ature

ARMATURE Check the com m utator bars of the arm ature for discoloration. • Do not use em ery or sand paper on the com m utator.

Check for continuity betw een pairs of com m utator bars. There should be continuity.

Check for continuity betw een each com m utator bar and the arm ature shaft. There should be no continuity.

19-18

STARTER/REVERSE SYSTEM BRUSH/MOTOR CASE M easure the brush length. SERVICE LIMIT: 6.0 mm (0.24 in)

Check for continuity betw een the insulated brush and cable term inal. There should be continuity.

Check for continuity betw een the insulated brush and m otor case. There should be no continuity.

Rem ove the follow ing if necessary: â&#x20AC;&#x201C; brush holder

19-19

STARTER/REVERSE SYSTEM â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C; â&#x20AC;&#x201C;

nut w asher insulator w ashers O-ring cable term inal insulated brush insulator

REDUCTION GEAR CASE Check the reverse drive gear for excessive or abnorm al w ear. Rem ove the snap ring and w ashers from the starter shaft.

Rem ove the reduction gears and dow el pin.

Check the starter reduction gears for excessive or abnorm al w ear. Rem ove the three screw s.

Separate the starter and reverse reduction gear cases.

GEAR HOLDER

Rem ove the seal ring. Rem ove the gear holder. Check the reverse reduction gears for excessive or abnorm al w ear.

REDUCTION GEARS

19-20

SEAL RING

STARTER/REVERSE SYSTEM ASSEMBLY

Apply m olybdenum disulfide grease to the reverse reduction gears. Install the gear holder, aligning the groove w ith the dow el pin. Install a new seal ring. Assem ble the reduction gear cases, aligning the groove w ith the dow el pin.

Install the three screw s and tighten them securely.

Install the dow el pin and starter reduction gears, aligning the groove in the large outer gear w ith the pin. Apply m olybdenum disulfide grease to the starter reduction gears.

19-21

STARTER/REVERSE SYSTEM Install the w ashers and snap ring onto the starter shaft.

Install the follow ing: â&#x20AC;&#x201C; insulator â&#x20AC;&#x201C; insulated brush â&#x20AC;&#x201C; cable term inal â&#x20AC;&#x201C; new O-ring â&#x20AC;&#x201C; insulator w ashers â&#x20AC;&#x201C; w asher â&#x20AC;&#x201C; nut

BRUSH O-RING

TERMINAL

INSULATOR WASHERS

NUT

WASHER

INSULATOR

Install the brush holder, aligning the tab w ith the groove in the case, and w ire grooves w ith the insulated brush w ires.

The coil may be damaged if the magnet pulls the armature against the case.

Push and hold the brushes inside the brush holder, and install the arm ature through the m otor case and brush holder. When installing the arm ature into the m otor case, hold the arm ature tightly to prevent the m agnet of the case from pulling the arm ature against it. Install the w asher and a new seal ring. Install the rear cover, aligning the slot w ith the brush holder tab.

19-22

STARTER/REVERSE SYSTEM Install the w asher. Install the gear base and gear base w asher, aligning the grooves w ith the m otor case lug. Install a new seal ring. Install the reduction gear case, aligning the groove in the large outer gear w ith the m otor case lug.

GEAR CASE

SEAL RING Install the three case bolts and tighten them securely.

LUG AND GROOVE

GEAR BASE

CASE BOLTS

INSTALLATION Coat a new O-ring w ith oil and install it into the starter/reverse m otor groove. Install the starter/reverse m otor into the rear crankcase cover as show n.

Install the three m ounting bolts and tighten them . TORQUE: 29 N·m (3.0 kgf·m, 22 lbf·ft) Connect the starter m otor cable. Install and tighten the term inal nut securely. Pull the rubber cap onto the term inal securely. Install the follow ing: – reverse shift arm (page 19-49) – fuel tank (page 5-56).

19-23

STARTER/REVERSE SYSTEM

STARTER RELAY SWITCH A M ake sure the engine stop sw itch is turned to “ and the reverse shift sw itch is pushed to “ OFF.” Rem ove the left saddlebag (page 2-15).

”

INSPECTION Shift the transm ission into neutral. Turn the ignition sw itch to “ ON” and check that the neutral indicator com es on. Push the starter/reverse sw itch. The coil is norm al if starter relay sw itch A clicks. If you don’t hear the sw itch “ click,” turn the ignition sw itch to “ OFF,” disconnect the 2P red connector of starter relay sw itch A and check the follow ing: RELAY COIL GROUND LINE Turn the ignition sw itch to “ ON.” Check for continuity betw een the Brow n/red w ire (ground line) term inal of the w ire harness side connector and ground. If there is continuity w hen the transm ission is in neutral, or w hen the clutch is disengaged and the side stand is retracted, the ground line is norm al. (There is a slight resistance due to the diode.) RELAY COIL INPUT VOLTAGE LINE Turn the ignition sw itch to “ ON.” M easure the voltage betw een the Yellow /red w ire term inal (+) of the w ire harness side connector and ground (–). If battery voltage is present only w hen the starter/ reverse sw itch is pushed in, the input voltage line is norm al. OPERATION CHECK Disconnect the battery and starter relay sw itch cables from starter relay sw itch A. Connect a fully charged 12-V battery to the connector term inals of starter relay sw itch A.

Yellow/red

CONNECTION: Battery (+) terminal – Yellow/red wire terminal Battery (–) terminal – Green/red wire terminal There should be continuity betw een the cable term inals w hile the battery is connected, and no continuity w hen the battery is disconnected.

19-24

Green/red

STARTER/REVERSE SYSTEM

STARTER RELAY SWITCH B • Check that starter relay sw itch A operates properly before inspecting starter relay sw itch B. M ake sure that the engine stop sw itch is turned to “ ” and the reverse shift sw itch is pushed to “ OFF.” Rem ove the left saddlebag (page 2-15).

INSPECTION Shift the transm ission into neutral. Turn the ignition sw itch to “ ON” and push the starter/ reverse sw itch. The coil is norm al if starter relay sw itch B clicks. If you don’t hear the sw itch “ click,” turn the ignition sw itch to “ OFF,” disconnect the 2P w hite connector of starter relay sw itch B and check the follow ing: RELAY COIL GROUND LINE Check for continuity betw een the Green/red w ire (ground line) term inal of the w ire harness side connector and ground. If there is continuity, the ground line is norm al. (There is a slight resistance due to the diode.) RELAY COIL INPUT VOLTAGE LINE Turn the ignition sw itch to “ ON.” M easure the voltage betw een the Yellow /red w ire term inal (+) of the w ire harness side connector and ground (–). If battery voltage is present only w hen the starter/ reverse sw itch is pushed in, the input voltage line is norm al. OPERATION CHECK Disconnect the starter relay sw itch and starter/ reverse m otor cables from starter relay sw itch B. Connect a fully charged 12-V battery to the connector term inals of starter relay sw itch B.

Yellow/red

Green/red

19-25

STARTER/REVERSE SYSTEM

REVERSE RELAY SYSTEM INSPECTION M ake sure that the engine stop sw itch is turned to â&#x20AC;&#x153; â&#x20AC;? and the reverse shift sw itch is pushed to â&#x20AC;&#x153; OFF.â&#x20AC;? Check that the neutral indicator operates properly (page 20-26). Rem ove the seat (page 2-5). Rem ove the tw o screw s and rem ove the relay box. Rem ove the relay blocks from the relay box.

1. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and exchange the reverse relay w ith the other good one. Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Push the starter/reverse sw itch and check starter relay sw itch A. â&#x20AC;˘ If starter relay sw itch A clicks, replace the reverse relay w ith a new one. â&#x20AC;˘ If starter relay sw itch A does not click, GO TO STEP 2.

2. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the reverse relay. Turn ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Yellow /red w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

â&#x20AC;˘ If there is battery voltage, GO TO STEP 3. â&#x20AC;˘ If there is no voltage, check the follow ing: â&#x20AC;&#x201C; open circuit in the Yellow /red and Black/red w ires betw een the reverse relay and reverse shift sw itch â&#x20AC;&#x201C; loose or poor contact of the related connector â&#x20AC;&#x201C; faulty diode (D7) in the reverse regulator assem bly (page 19-28) 3. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Check for continuity betw een the Black/red w ire term inal of the relay connector and ground. There should be continuity. â&#x20AC;˘ If there is continuity, GO TO STEP 4. â&#x20AC;˘ If there is no continuity, check the follow ing: â&#x20AC;&#x201C; open circuit in the Black/red w ire betw een the reverse relay and reverse regulator assem bly â&#x20AC;&#x201C; faulty diode (D4 or D5) in the reverse regulator assem bly (page 19-28) â&#x20AC;&#x201C; open circuit in the Green/orange w ire betw een the reverse regulator assem bly and reverse sw itch â&#x20AC;&#x201C; faulty reverse sw itch

19-26

STARTER/REVERSE SYSTEM 4. Check for continuity betw een the Blue/green w ire term inal of the relay connector and ground. There should be continuity w hen the transm ission is in neutral, or w hen the clutch is disengaged and the side stand is retracted. â&#x20AC;˘ If there is continuity, the system is OK; check for loose contacts or corroded term inals. â&#x20AC;˘ If there is no continuity, check the follow ing: â&#x20AC;&#x201C; open circuit in the Blue/green w ire betw een the reverse relay and reverse regulator assem bly â&#x20AC;&#x201C; faulty diode (D2, D3 or D11) in the reverse regulator assem bly (page 19-28) â&#x20AC;&#x201C; open circuit in the Green/red w ire betw een the reverse regulator assem bly and clutch sw itch â&#x20AC;&#x201C; faulty clutch sw itch â&#x20AC;&#x201C; open circuit in the Green/w hite betw een the clutch sw itch and side stand sw itch â&#x20AC;&#x201C; faulty side stand sw itch

REVERSE SWITCH REMOVAL/INSTALLATION Rem ove the right engine side cover (page 2-5).

Pull the rubber cap off the reverse sw itch. Rem ove the term inal nut and reverse sw itch w ire. Rem ove the reverse sw itch from the crankcase.

Install the reverse sw itch w ith a new sealing w asher and tighten it.

WIRE TERMINAL

TORQUE: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft) Install the sw itch w ire and tighten the term inal nut. TORQUE: 2 NÂˇm (0.2 kgfÂˇm, 1.4 lbfÂˇft) Install the rubber cap on the reverse sw itch. Install the right engine side cover (page 2-5).

SEALING WASHER

REVERSE SWITCH

19-27

STARTER/REVERSE SYSTEM INSPECTION Check that the sw itch shaft m oves sm oothly by pushing it. Check for continuity betw een the sw itch term inal and shaft. There should be continuity.

REVERSE REGULATOR ASSEMBLY REMOVAL/INSTALLATION REVERSE REGULATOR ASSEMBLY

Rem ove the left saddlebag (page 2-15). Rem ove the reverse regulator assem bly from rear fender B. Disconnect the 20P connector and rem ove the reverse regulator assem bly. Install the reverse regulator assem bly in the reverse order of rem oval.

20P CONNECTOR

DIODE INSPECTION Rem ove the (page 19-28).

reverse

regulator

assem bly

â&#x20AC;˘ The 11 diodes are integrated in the assem bly. They are used in the follow ing circuits: D1:

Ground of starter relay sw itch B coil Ground of reverse relay (neutral position side) Gear position (neutral) signal of engine D2: control m odule (ECM ) Ground of reverse relay (clutch sw itch and D3: side stand sw itch side) Ground of reverse relay coil (reverse D4: sw itch side) Ground of reverse relay coil (neutral posiD5: tion side) D6: Ground of neutral indicator D7: Pow er source of reverse relay coil Pow er source of headlight and headlight D8: relay in reverse running D9: Gear position (overdrive) signal of ECM D10: Gear position (4th) signal of ECM D11: Ground of reverse relay

19-28

STARTER/REVERSE SYSTEM Check the continuity for each diode betw een the follow ing term inals: Diode Term inal (+) Term inal (â&#x20AC;&#x201C;)

D1 12 11

D2 18 13

D3 18 16

D4 1 11

D5 1 13

Diode Term inal (+) Term inal (â&#x20AC;&#x201C;)

D7 2 3

D8 4 5

D9 7 17

D10 8 6

D11 15 18

D6 14 13

When there is continuity, a sm all resistance value w ill register. If there is continuity in one direction, the diode is good.

REGULATED VOLTAGE INSPECTION Rem ove the left saddlebag (page 2-15). Shift the transm ission into neutral and retract the side stand. Raise the rear w heel off the ground by placing the m otorcycle on its center stand. Start the engine, push the reverse shift sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and m ake sure that the reverse indicator com es on. M easure the voltage at the starter relay sw itch A 2P red connector w ith the connector connected. CONNECTION: Brown/red wire terminal (+) â&#x20AC;&#x201D; Ground (â&#x20AC;&#x201C;) The rear wheel starts turning if the reverse system functions properly.

Push the starter/reverse sw itch. The voltage should be approxim ately 0 V for the first 0.3 second, then a m inim um of 4.0 V should register. Push the reverse shift sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and stop the engine.

REVERSE REGULATOR CIRCUIT INSPECTION Rem ove the (page 19-28).

reverse

regulator

assem bly

Check the follow ing at the w ire harness side connector of the reverse regulator assem bly: GROUND LINE Check for continuity betw een the Green w ire term inal and ground. There should be continuity at all tim es.

19-29

STARTER/REVERSE SYSTEM REVERSE POSITION SWITCH LINE Connect the reverse regulator 20P connector. Shift the transm ission into neutral and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Push the reverse shift sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that the reverse indicator com es on. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the reverse regulator 20P connector. Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the White/blue w ire term inal (+) of the w ire harness side 20P connector and ground (â&#x20AC;&#x201C;). There should be battery voltage. After inspection, turn the reverse shift actuator to the neutral position. STARTER RELAY SWITCH LINE Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Disconnect the 2P red connector of starter relay sw itch A. Check for continuity betw een the Brow n/red w ire term inals of the reverse regulator and starter relay sw itch A connectors. There should be continuity.

CONTROL MODULE LINE Rem ove the top shelter (page 2-11) Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Disconnect cruise/reverse control m odule 26P gray connector. Check for continuity betw een the Light blue w ire term inals of the reverse regulator and control m odule connectors. There should be continuity.

REVERSE RESISTOR ASSEMBLY REMOVAL/INSTALLATION Rem ove the battery case (page 5-56). Disconnect the reverse resistor 3P connector. Rem ove the nut and cable from the reverse resistor term inal. Rem ove the tw o bolts and reverse resistor assem bly.

19-30

! " #

STARTER/REVERSE SYSTEM Rem ove the three screw s and stay from the reverse resistor assem bly. Install the reverse resistor assem bly in the reverse order or rem oval.

INSPECTION M easure the resistance betw een the 3P connector w ire term inals and cable term inal of the resistor.

STANDARDS at 20Â° C (68Â° F) Red â&#x20AC;&#x201C; Cable terminal: 0.20 â&#x20AC;&#x201C; 0.25â&#x201E;Ś White â&#x20AC;&#x201C; Cable terminal: 0.15 â&#x20AC;&#x201C; 0.20â&#x201E;Ś Black â&#x20AC;&#x201C; Cable terminal: 0.20 â&#x20AC;&#x201C; 0.25â&#x201E;Ś

POWER CONTROL RELAY SYSTEM INSPECTION Rem ove the follow ing: â&#x20AC;&#x201C; top shelter (page 2-11) â&#x20AC;&#x201C; left saddlebag (page 2-15)

CRUISE/REVERSE CONTROL M ODULE

Shift the transm ission into neutral and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Push the reverse shift sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that the reverse indicator com es on. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the cruise/reverse control m odule 26P gray connector.

26P GRAY CONNECTOR POWER CONTROL RELAY 1 1. Ground the Orange w ire term inal of the control m odule connector w ith a jum per w ire. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that pow er control relay 1 clicks.

â&#x20AC;˘ If the relay clicks, the relay coil is norm al; go to step 3. â&#x20AC;˘ If the relay does not click, go to step 2.

! "

19-31

STARTER/REVERSE SYSTEM 2. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Power control relay 1 is the same part as power control relay 2 and the speed limiter relay.

Exchange pow er control relay 1 w ith the other good one and check again. â&#x20AC;˘ If the relay clicks, replace pow er control relay 1 w ith a new one and go to step 3. â&#x20AC;˘ If the relay does not click, check the follow ing: â&#x20AC;&#x201C; open circuit in the Orange w ire betw een pow er control relay 1 and cruise/reverse control m odule â&#x20AC;&#x201C; open circuit in the White/blue w ire betw een pow er control relay 1 and reverse shift actuator (reverse position sw itch)

3. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the reverse resistor connector. With the jum per w ire ground, turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Check for continuity betw een the Red and Black w ire term inals of the w ire harness side reverse resistor connector. There should be continuity. â&#x20AC;˘ If there is no continuity, check for open circuit in Red and Black w ires betw een pow er control relay 1 and reverse resistor.

POWER CONTROL RELAY 2 1. Ground the White w ire term inal of the control m odule connector w ith a jum per w ire. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that pow er control relay 2 clicks.

â&#x20AC;˘ If the relay clicks, the relay coil is norm al; go to step 3. â&#x20AC;˘ If the relay does not click, go to step 2.

! " 2. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Power control relay 2 is the same part as power control relay 1 and the speed limiter relay.

19-32

Exchange pow er control relay 2 w ith a know ngood one and check again. â&#x20AC;˘ If the relay clicks, replace pow er control relay 2 w ith a new one and go to step 3. â&#x20AC;˘ If the relay does not click, check the follow ing: â&#x20AC;&#x201C; open circuit in the White w ire betw een pow er control relay 2 and the cruise/ reverse control m odule â&#x20AC;&#x201C; open circuit in the White/blue w ire betw een pow er control relay 2 and reverse shift actuator (reverse position sw itch)

STARTER/REVERSE SYSTEM 3. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the reverse resistor connector. With the jum per w ire ground, turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Check for continuity betw een the Red and White w ire term inals of the w ire harness side reverse resistor connector. There should be continuity. â&#x20AC;˘ If there is no continuity, check for an open circuit in the Red and White w ires betw een pow er control relay 2 and the reverse resistor.

REVERSE RESISTOR CONNECTOR

OPERATION CHECK Rem ove the pow er control relay. Connect an ohm m eter and a fully charged 12-V battery to the relay term inals as show n. There should be continuity w hile the battery is connected, and no continuity w hen the battery is disconnected.

SPEED LIMITER RELAY SYSTEM INSPECTION Rem ove the follow ing: â&#x20AC;&#x201C; top shelter (page 2-11) â&#x20AC;&#x201C; left saddlebag (page 2-15)

CRUISE/REVERSE CONTROL MODULE

22P GRAY CONNECTOR 1. Ground the Gray w ire term inal of the control m odule connector w ith a jum per w ire. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that the speed lim iter relay clicks.

â&#x20AC;˘ If the relay clicks, the relay coil is norm al; go to step 3. â&#x20AC;˘ If the relay does not click, go to step 2.

! "

19-33

STARTER/REVERSE SYSTEM 2. Turn the ignition sw itch to “ OFF.” The speed limiter relay is the same part as power control relays 1 and 2.

Exchange the speed lim iter relay w ith a know ngood one and check again. • If the relay clicks, replace the speed lim iter relay w ith a new one and go to step 3. • If the relay does not click, check the follow ing: – open circuit in the Gray w ire betw een the speed lim iter relay and cruise/reverse control m odule. – open circuit in the White/blue w ire betw een the speed lim iter relay and reverse shift actuator (reverse position sw itch)

SPEED LIMITER RELAY

3. Turn the ignition sw itch to “ OFF” and disconnect the reverse resistor connector. Check for continuity betw een the White w ire term inals of the speed lim iter relay and reverse resistor connectors. There should be continuity.

REVERSE RESISTOR CONNECTOR

OPERATION CHECK Rem ove the speed lim iter relay. Connect an ohm m eter and a fully charged 12-V battery to the relay term inals as show n. There should be continuity w hile the battery is connected, and no continuity w hen the battery is disconnected.

REVERSE SHIFT RELAY Check that the neutral indicator com es on w hen the ignition sw itch is turned to “ ON” w ith the transm ission in neutral. Rem ove the seat (page 2-5). Rem ove the tw o screw s and rem ove the relay box. Rem ove the relay blocks from the relay box.

19-34

STARTER/REVERSE SYSTEM 1. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and exchange reverse shift relay 1 w ith a know n-good one. Shift the transm ission into neutral and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Turn the reverse shift sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? â&#x20AC;˘ If the reverse shift actuator operates, replace reverse shift relay 1 w ith a new one. â&#x20AC;˘ If the reverse shift actuator does not operate, go to step 2. 2. Push the reverse shift sw itch to â&#x20AC;&#x153; OFF,â&#x20AC;? turn the ignition sw itch to â&#x20AC;&#x153; OFF,â&#x20AC;? and exchange reverse shift relay 2 w ith a know n-good one. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and push the reverse shift sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? â&#x20AC;˘ If the reverse shift actuator operates, replace reverse shift relay 2 w ith a new one and check again using original reverse shift relay 1. â&#x20AC;˘ If the reverse shift actuator does not operate, go to step 3. 3. Push the reverse shift sw itch to â&#x20AC;&#x153; OFF,â&#x20AC;? turn the ignition sw itch to â&#x20AC;&#x153; OFF,â&#x20AC;? and exchange reverse shift relay 3 w ith a know n-good one. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and push the reverse shift sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? â&#x20AC;˘ If the reverse shift actuator operates, replace reverse shift relay 3 w ith a new one and check again using original reverse shift relays 1 and 2. â&#x20AC;˘ If the reverse shift actuator does not operate, go to step 4. 4. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove reverse shift relay 1. M easure the voltage betw een the Red/black w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;). â&#x20AC;˘ If there is battery voltage, go to step 5. â&#x20AC;˘ If there is no voltage, check for an open circuit in the Red/black w ire betw een the relay box and fuse box (No. 23 fuse).

5. Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Brow n w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;).

â&#x20AC;˘ If there is battery voltage, go to step 6. â&#x20AC;˘ If there is no voltage, check for an open circuit in the Brow n w ire betw een the relay box and fuse box (No. 10 fuse). 6. Check the Red w ires for continuity betw een relays 1 and 2, and betw een relays 1 and 3. â&#x20AC;˘ If there is continuity, follow the troubleshooting flow chart on page 19-9. â&#x20AC;˘ If there is no continuity, repair the open circuit in the Red w ire.

19-35

STARTER/REVERSE SYSTEM

REVERSE SHIFT ACTUATOR MOTOR INSPECTION 1. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the reverse shift relays 2 and 3 (page 19-34). 2. Shift the transm ission into neutral. Connect a fully charged 12-V battery to the relay connector term inals.

CONNECTION: Positive (+) â&#x20AC;&#x201C; Blue of relay 2 Negative (â&#x20AC;&#x201C;) â&#x20AC;&#x201C; Blue/red of relay 3 â&#x20AC;˘ If the reverse shift actuator operates, the m otor is norm al. â&#x20AC;˘ If the actuator does not operate, go to step 3.

3. Rem ove the air cleaner housing (page 5-57). Disconnect the reverse shift actuator 2P w hite connectors. Connect a fully charged 12-V battery to the actuator side connector term inals. CONNECTION: Positive (+) â&#x20AC;&#x201C; Blue Negative (â&#x20AC;&#x201C;) â&#x20AC;&#x201C; Blue/red â&#x20AC;˘ If the actuator operates, check the follow ing: â&#x20AC;&#x201C; open circuit in the Blue w ire betw een reverse shift relay 2 and the actuator â&#x20AC;&#x201C; open circuit in the Blue/red w ire betw een reverse shift relay 3 and the actuator â&#x20AC;˘ If the actuator does not operate, go to step 4. 4. Disconnect the reverse shift actuator cables from the actuator (page 19-38) and check again. â&#x20AC;˘ If the actuator operates, check the reverse shift m echanism (page 19-42). â&#x20AC;˘ If the actuator does not operate, replace the actuator w ith a new one.

REVERSE POSITION SWITCH INSPECTION Rem ove the air cleaner housing (page 5-57). Disconnect the reverse shift actuator 3P red and 2P w hite connectors.

19-36

2P WHITE CONNECTOR

STARTER/REVERSE SYSTEM INPUT VOLTAGE CHECK Tem porarily install the battery. Turn the ignition to â&#x20AC;&#x153; ONâ&#x20AC;? and m easure the voltage betw een the Brow n w ire term inal (+) of the w ire harness side 3P connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

! "

â&#x20AC;&#x201C; If there is no voltage, check for an open circuit in the Brow n w ire betw een the reverse shift actuator and fuse box (No. 10 fuse).

OPERATION CHECK M ake sure the reverse shift actuator is in the neutral position. Check for continuity betw een the Brow n and Black/ w hite w ire term inals of the actuator side 3P connector. There should be continuity.

Turn the actuator to the reverse position by connecting a fully charged 12-V battery to the actuator side 2P connector term inals. CONNECTION: Positive (+) â&#x20AC;&#x201C; Blue Negative (â&#x20AC;&#x201C;) â&#x20AC;&#x201C; Blue/red

REVERSE SHIFT ACTUATOR PULLEY (NEUTRAL POSITION)

REVERSE SHIFT ACTUATOR PULLEY (REVERSE POSITION)

Check for continuity betw een the Brow n and White/ blue w ire term inals of the actuator side 3P connector. There should be continuity.

REMOVAL/INSTALLATION Rem ove the follow ing: â&#x20AC;&#x201C; right engine side cover (page 2-5) â&#x20AC;&#x201C; ABS m odulators (page 16-31)

Loosen the lock nuts and adjusting nuts on the reverse shift actuator cables fully.

19-37

STARTER/REVERSE SYSTEM Rem ove the nuts and reverse shift actuator cables from the cable holder, and disconnect the cables from the actuator pulley. Rem ove the three bolts and the reverse shift actuator from the crankcase.

N CABLE

“N” MARK

PULLEY

Install the reverse shift actuator onto the crankcase and tighten the three bolts securely. Connect the R (reverse) cable to the pulley on the “ R” m ark side and N (neutral) cable on the “ N” m ark side. Install and tighten the lock nuts. Adjust the actuator cables. Install the follow ing: – ABS m odulators (page 16-31) – right engine side cover (page 2-5)

R CABLE

“R” MARK

BOLTS

REVERSE SHIFT ACTUATOR CABLE ADJUSTMENT Rem ove the follow ing: – right engine side cover (page 2-5) – center inner fairing (page 2-10) Check that the reverse shift actuator pulley is in the neutral position as show n.

REVERSE SHIFT ACTUATOR PULLEY (REVERSE POSITION)

Check the N cable clearance betw een the cable outer end and cable holder. CLEARANCE: 0 mm (0 in) Check the R cable clearance betw een the cable outer end and cable holder. CLEARANCE: 0.3 – 0.8 mm (0.01 – 0.03 in)

Loosen each lock nut and adjust the clearance by turning each adjusting nut as required.

19-38

STARTER/REVERSE SYSTEM Shift the transm ission into neutral and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Push the reverse shift sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? to m ove the reverse actuator pulley to the reverse position.

REVERSE SHIFT ACTUATOR PULLEY (REVERSE POSITION)

M ake sure there is clearance betw een the reverse shift arm and lost m otion plate as show n. Push the reverse shift sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? to return the reverse actuator pulley to the neutral position. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and install the follow ing: â&#x20AC;&#x201C; center inner fairing (page 2-6) â&#x20AC;&#x201C; right engine side cover (page 2-5)

CRUISE/REVERSE CONTROL MODULE SYSTEM INSPECTION Rem ove the top shelter (page 2-11). Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the 26P black and gray connectors from the cruise/ reverse control m odule.

Check the reverse system circuits at the w ire harness side connector term inals by referring to the chart on page 19-40.

19-39

STARTER/REVERSE SYSTEM • To turn the reverse shift actuator from the neutral position to the reverse position, follow the steps below : – Turn the ignition sw itch to “ OFF,” and connect the control m odule connectors. – Shift the transm ission into neutral and turn the ignition sw itch to “ ON.” – Push the reverse shift sw itch to “ ON.” The reverse position sw itch turns to the reverse position and reverse indicator com es on. – Turn the ignition sw itch to “ OFF” and disconnect the control m odule connectors. • To m ove the reverse shift actuator from the reverse position to the neutral position, follow the steps below : – Turn the ignition sw itch to “ OFF,” and connect the control m odule connectors. – Turn the ignition sw itch to “ ON.” – Turn the reverse shift sw itch to “ OFF.” The reverse position sw itch turns to the neutral position and neutral indicator com es on. – Turn the ignition sw itch to “ OFF” and disconnect the control m odule connectors. 1

Terminal No. & Circuit Reverse shift m otor (+)

8 11

Reverse shift m otor (–) Side stand sw itch

Wire Color & Connection Pink and Pink of the control m odule and reverse shift relays 2, 3 connectors Green and ground Green/w hite and ground

Conditions Rem ove reverse shift relays 2 and 3 (page 19-34) and check for continuity betw een the sam e color w ire term inals. – Side stand retracted Side stand extended

Starter/reverse m otor

Reverse sw itch

Pink/w hite and starter/ reverse m otor cable term inal of starter relay sw itch B Green/orange and ground

Starter/reverse sw itch

Yellow /red (+) and ground (–)

Speed lim iter fuse Ground

Yellow and ground

20 23

Green and ground

Reverse shift sw itch Reverse indicator

Yellow /w hite (+) and ground (–) White/red (+) and ground (–)

Reverse position sw itch

White/blue (+) and ground (–)

Reverse shift relay 3

Yellow /w hite and Yellow / w hite of the control m odule and reverse shift relay 3 Yellow /w hite and ground

Pow er control relay 1

Orange (+) and ground (–)

Speed lim iter relay

Gray (+) and ground (–)

19-40

Rem ove the left saddlebag (page 2-15). Reverse shift actuator in the neutral position Reverse shift actuator in the reverse position Ignition sw itch “ ON” Engine stop sw itch to “ ” Starter/reverse sw itch pushed – – Ignition sw itch “ ON” Reverse shift sw itch to “ ON” Ground it w ith a jum per w ire and turn the ignition sw itch “ ON.” Reverse shift actuator in the reverse position Ignition sw itch “ ON” Rem ove reverse shift relay 3 (page 19-34) and check for continuity betw een the sam e color w ire term inals. – Reverse shift actuator in the reverse position Ignition sw itch “ ON” Reverse shift actuator in the reverse position Ignition sw itch “ ON”

Specification There should be continuity.

There should continuity. There should continuity. There should continuity. There should continuity.

be be be no be

There should be continuity. There should be no continuity. There should be battery voltage. There should be continuity. There should be continuity. There should be battery voltage. Reverse indicator should com e on. There should be battery voltage. There should be continuity. There should be no continuity. There should be battery voltage. There should be battery voltage.

STARTER/REVERSE SYSTEM Terminal No. & Circuit 34 Reverse shift relay 2

Wire Color & Connection Blue/w hite and Blue/w hite of the control m odule and reverse shift relay 2 Blue/w hite and ground

Reverse regulator

Light blue and Light blue of the control m odule and reverse regulator

Reverse shift relay 1 Reverse relay

Blue/black (+) and ground (–) Yellow /red (+) and ground (–) White (+) and ground (–)

43 46

Pow er control relay 2

Neutral sw itch

Oil pressure sw itch

Light green/red and ground Blue and ground

Conditions Rem ove reverse shift relay 2 (page 19-34) and check for continuity betw een the sam e color w ire term inals. – Rem ove the reverse regulator (page 19-28) and check for continuity betw een the sam e color w ire term inals. Ignition sw itch “ ON” Ignition sw itch “ ON” Reverse shift actuator in the reverse position Ignition sw itch “ ON” Transm ission in neutral – Start the engine and let it idle.

Ground

Green and ground

–

Specification There should be continuity. There should be no continuity. There should be continuity. There should be battery voltage. There should be battery voltage. There should be battery voltage. There should continuity. There should continuity. There should continuity. There should continuity.

be be be no be

19-41

STARTER/REVERSE SYSTEM

REVERSE SHIFT MECHANISM REVERSE SHIFT ARM REMOVAL Rem ove the rear brake m aster cylinder (page 15-19). Rem ove the tw o bolts, ground cable and reverse shift actuator cable holder.

Rem ove the follow ing: – bolt – w asher – collar – lost m otion spring – reverse shift arm w ith the cables and holder

– – – – –

lost m otion plate reverse shift arm spring bushing spring collar O-ring from the collar

– needle bearing – w asher – oil seal

19-42

STARTER/REVERSE SYSTEM REVERSE SHIFTER/SHIFT DRUM LOCK ARM REMOVAL Rem ove the rear crankcase cover (page 10-11). Rem ove the follow ing: – starter reduction gear and shaft – w asher – reverse idle gear

REDUCTION GEAR

GEAR SHAFT – reverse shifter shaft assem bly

REVERSE IDLE GEAR

WASHER

– three bolts – starter drive gear holder – tw o dow el pins

– bolt – shift drum lock arm assem bly

19-43

STARTER/REVERSE SYSTEM DISASSEMBLY/INSPECTION

SHIFTER ASSEMBLY

Rem ove the roller pin and reverse shifter assem bly from the shaft. Check the reverse shifter shaft for w ear or dam age.

SHIFTER SHAFT

ROLLER PIN

Rem ove the snap ring and disassem ble the shifter assem bly. Check the shifter gear, needle bearings and shifter for w ear or dam age.

Check the drive gear teeth for w ear or dam age. Turn the drive gear and check the bearing condition. The bearing should turn sm oothly and quietly. Also check that the outer race of the bearing fits tightly in the holder. Replace the bearing if the drive gear does not turn sm oothly, quietly, or if the outer race fits loosely in the holder.

Check the reverse shifter shaft bearing for w ear or dam age.

Check the shift drum lock arm assem bly for distortion, dam age or w ear.

19-44

STARTER/REVERSE SYSTEM BEARING REPLACEMENT STARTER DRIVE GEAR BEARING Support the gear holder and press the starter drive gear out of the bearing using the special tools. TOOLS: Pilot, 20 mm Assembly collar

07746-0040500 07965-VM00100

Press the bearing out of the gear holder using the special tools. TOOLS: Driver Attachment, 32 x 35 mm Fork seal driver

07749-0010000 07746-0010100 07947-4630100

Support the gear holder and press the bearing into the holder using the special tools. TOOLS: Driver Attachment, 37 x 40 mm Pilot, 20 mm Attachment, 20 mm I.D.

Use the small I.D. of the special tool to support the bearing inner race.

07749-0010000 07746-0010200 07746-0040500 07746-0020400

Support the bearing inner race w ith the special tool and press the starter drive gear into the bearing. TOOL: Attachment, 20 mm I.D.

07746-0020400

REVERSE SHIFTER SHAFT BEARING Rem ove the starter drive gear. Drive the reverse stopper shaft and collar out of the gear holder. TOOL: Pin driver, 4 mm

07944-SA00000 or equivalent commercially available in U.S.A.

19-45

STARTER/REVERSE SYSTEM Press the reverse shifter shaft bearing out of the gear holder using a suitable tool. Press a new needle bearing into the gear holder using the special tool. TOOLS: Driver Attachment, 24 x 26 mm

07749-0010000 07746-0010700

Drive the reverse stopper shaft w ith its collar into the gear holder so that the height from the holder is 6.7 – 7.3 m m (0.26 – 0.29 in).

6.7–7.3 mm (0.26–0.29 in)

COLLAR

SHIFT DRUM LOCK ARM/REVERSE SHIFTER INSTALLATION Apply m olybdenum disulfide grease to the lock arm pivot. Apply locking agent to the shift drum lock arm bolt threads. Install the shift drum lock arm assem bly and tighten the bolt. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Apply oil to the starter drive gear bearing and install the drive gear into the gear holder. Apply oil to the reverse shifter shaft bearing. Apply m olybdenum oil solution to the reverse stopper shaft and collar.

19-46

STOPPER SHAFT

STARTER/REVERSE SYSTEM Install the tw o dow el pins into the crankcase.

Install the starter drive gear holder and tighten the three bolts securely.

Apply oil to the needle bearings. Apply m olybdenum oil solution to the shifter guide (holes), groove and shifter gear splines.

Install the w asher, needle bearings, shifter gear and w asher onto the reverse shifter.

Install the snap ring w ith the cham fered side facing in.

SNAP RING

Check that the shifter gear turns sm oothly.

SNAP RING

SHIFTER GEAR

19-47

STARTER/REVERSE SYSTEM Coat the reverse shifter shaft w ith m olybdenum oil solution. Install the reverse shifter assem bly onto the shaft. Coat the roller pin w ith grease. Install the roller pin into the hole in the shaft through the guide holes in the shifter.

Install the reverse shifter shaft assem bly into the shift drum lock arm w hile aligning the flat on the shaft end w ith the flat in the lock arm hole.

Further insert the shifter shaft assem bly w hile aligning the shifter groove w ith the stopper shaft

Install the reverse idle gear w ith the “ OUT” m ark facing out. Install the w asher.

REDUCTION GEAR

REVERSE IDLE GEAR “OUT” MARK

Coat the starter reduction gear shaft w ith m olybdenum oil solution and install it into the gear holder. Install the starter reduction gear onto the shaft. Install the rear crankcase cover (page 10-24).

GEAR SHAFT

19-48

WASHER

STARTER/REVERSE SYSTEM REVERSE SHIFT ARM INSTALLATION

Apply grease to the lip of a new oil seal and install the seal into the rear crankcase cover. Coat the needle bearing w ith m olybdenum oil solution and install the w asher and needle bearing onto the reverse shifter shaft.

Coat a new O-ring w ith oil and install it into the spring collar. Install the spring collar onto the reverse shifter shaft.

19-49

STARTER/REVERSE SYSTEM Apply m olybdenum disulfide grease to the inner and outer surfaces of the spring bushing. Install the bushing, reverse shift arm spring and lost m otion plate.

Install the reverse shift arm and lost m otion spring over the shaft and plate w hile hooking the spring ends properly as show n.

LOST MOTION SPRING ENDS

ARM SPRING END Apply locking agent to the reverse shifter shaft bolt threads. Install the collar, w asher and shaft bolt, and tighten the bolt. TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)

Apply locking agent to the cable holder bolt threads. Install the cable holder, ground cable term inal and holder bolts, and tighten the bolts. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Check the reverse shift actuator cables and adjust them if necessary (page 19-38). Install the rear brake m aster cylinder (page 15-19).

19-50

ARM SPRING END

20. LIGHTS/METERS/SWITCHES

SYSTEM LOCATION···································· 20-2

OIL PRESSURE INDICATOR ······················20-27

SERVICE INFORMATION ···························· 20-3

TURN SIGNAL RELAY································20-27

TROUBLESHOOTING ·································· 20-4

TURN SIGNAL CANCEL UNIT ···················20-28

HEADLIGHT·················································· 20-8

POSITION LIGHT RELAY····························20-31

HEADLIGHT ADJUSTER ····························· 20-9

HAZARD SWITCH·······································20-32

FRONT TURN SIGNAL LIGHT··················· 20-13

OPEN AIR TEMPERATURE SENSOR ········20-33

SADDLEBAG COMBINATION LIGHT ······· 20-14

IGNITION SWITCH ·····································20-34

TRUNK BRAKE/TAILLIGHT······················· 20-15

HANDLEBAR SWITCH································20-35

LICENSE LIGHT·········································· 20-15

BRAKE SWITCH··········································20-37

RELAY BOX················································ 20-16

CLUTCH SWITCH ·······································20-37

COMBINATION METER····························· 20-17

GEAR POSITION SWITCH··························20-38

SPEEDOMETER ········································· 20-20

SIDE STAND SWITCH ································20-39

TACHOMETER ··········································· 20-21

MULTI-DISPLAY CONTROL SWITCH········20-40

COOLANT TEMPERATURE GAUGE/ ECT SENSOR ············································· 20-22

HORN ··························································20-40 FAN CONTROL RELAY·······························20-41

FUEL GAUGE/LOW FUEL INDICATOR ···· 20-24 POWER TRUNK LOCK SYSTEM················20-42 NEUTRAL INDICATOR ······························ 20-26

20-1

LIGHTS/METERS/SWITCHES

SYSTEM LOCATION LIGHTS/METERS/SWITCHES

20-2

LIGHTS/METERS/SWITCHES

SERVICE INFORMATION GENERAL A halogen headlight bulb becomes very hot while the headlight is on, and remains hot for a while after it is turned off. Be sure to let it cool down before servicing. • Use an electric heating elem ent to heat the w ater/coolant m ixture for the therm osensor inspection. Keep all flam m able m aterials aw ay from the electric heating elem ent. Wear protective clothing, insulated gloves and eye protection. • Note the follow ing w hen replacing the halogen headlight bulb. – Wear clean gloves w hile replacing the bulb. Do not put fingerprints on the headlight bulb, as they m ay create hot spots on the bulb and cause it to fail. – If you touch the bulb w ith your bare hands, clean it w ith a cloth m oistened w ith alcohol to prevent an early failure. – Be sure to install the dust cover after replacing the bulb. • Check the battery condition before perform ing any inspection that requires proper battery voltage. • A continuity test can be m ade w ith the sw itches installed on the m otorcycle. • When checking the turn signal/hazard system , alw ays follow the steps in the troubleshooting flow chart (page 20-5). • The follow ing color codes used are indicated throughout this section. Bl: Black Br: Brow n Bu: Blue

G: Green Gr: Gray Lb: Light Blue

Lg: Light Green O: Orange P: Pink

R: Red W: White Y: Yellow

SPECIFICATIONS Bulbs

Fuse

ITEM Headlight (high beam ) Headlight (low beam ) Brake/taillight License light Front turn signal/running light Rear turn signal light M ain fuse A M ain fuse B Reverse speed lim iter fuse Sub-fuse

ECT sensor resistance

M odulator fuse (ABS m odel) At 80° C (176° F) At 120° C (248° F)

SPECIFICATIONS 12 V – 55 W x 2 12 V – 55 W x 2 12 V – 21/5 W x 6 12 V – 3CP (5W) 12 V – 21/5 W x 2 12 V – 21 W x 2 30A 100A 70A 20A x 3, 15A x 8, 10A x 3, 5A x 4 (ABS m odel: 5A x 5) 30 A x 2 47 – 57Ω 14 – 18Ω

TORQUE VALUES Side stand sw itch bolt Ignition sw itch m ounting bolt

12 N·m (1.2 kgf·m , 9 lbf·ft) 25 N·m (2.5 kgf·m , 18 lbf·ft)

TOOL IgnitionM ate peak voltage tester M TP07-0286 (U.S.A. only)

Peak voltage adaptor 07HGJ-0020100

Fuel sender/pum p w rench 07ZM A-M CAA201 (U.S.A. only)

(not available in U.S.A.) w ith com m ercially available digital m ultim eter (im pedance 10 MΩ/DCV m inim um )

or 07ZM A-M CAA200 (U.S.A. only)

20-3

LIGHTS/METERS/SWITCHES

TROUBLESHOOTING • Check the follow ing before troubleshooting: – faulty or under-charged battery – blow n m ain fuse B (100 A) and No. 2 m ain fuse A (30 A) – Check the ignition sw itch and its circuit if all system s do not function w hen the ignition sw itch is turned to “ ON.” • Check for open circuit in the Green (ground) w ire for each part.

LIGHTING SYSTEM • The headlights go off w hen the starter/reverse sw itch is pushed for starting. • The low beam headlights rem ain on w hen the starter/reverse sw itch is pushed for reverse running. Low beam headlights do not light with the ignition switch turned to “ON” • Faulty bulbs • Faulty HEADLIGHT LO relay (page 20-16) • Faulty starter/reverse sw itch (page 20-35) • Faulty diode (D21) • Blow n No. 9 fuse or No. 26 fuse (Check for a short circuit in the related w ires if the fuse is blow n again.) • Loose or poor contact of related connectors • Open circuit in related w ires Low beam headlights go off during reverse running • Open circuit in the Blue w ire betw een the headlight LO relay and reverse regulator assem bly • Faulty diode (D8) (page 19-28) • Open circuit in the White/blue w ire betw een the reverse position sw itch and reverse regulator assem bly • Loose or poor contact of related connectors Both high beam headlights do not light with the dimmer switch pushed to “ ” • Faulty dim m er sw itch (page 20-36) • Open circuit in the Blue/w hite w ire betw een the starter/reverse sw itch and dim m er sw itch Left high beam headlight does not light with the dimmer switch pushed to “ • Faulty bulb • Open circuit in the Blue w ire betw een the left headlight and dim m er sw itch • Loose or poor contact of related connectors

”

Right high beam headlight does not light with the dimmer switch pushed to “ ” • Faulty bulb • Faulty HEADLIGHT HI relay (page 20-16) • Blow n No. 24 fuse (Check for a short circuit in the related w ires if the fuse is blow n again.) • Loose or poor contact of related connectors • Open circuit in related w ires Taillights and meter lights do not light with the ignition switch turned to “ON” • Faulty TAIL relay (page 20-16) • Blow n No. 5 fuse (Check for a short circuit in the related w ires if the fuse is blow n again.) • Loose or poor contact of related connectors • Open circuit in related w ires Brake lights do not come on when the brake is applied with the ignition switch turned to “ON” • Faulty brake light sw itch (page 20-37) • Faulty STOP LIGHT relay (page 20-16) • Faulty HORN TURN relay (page 20-16) • Blow n No. 18 fuse (Check for a short circuit in the related w ires if the fuse is blow n again.) • Loose or poor contact of related connectors • Open circuit in related w ires

20-4

LIGHTS/METERS/SWITCHES TURN SIGNAL/HAZARD LIGHT SYSTEM • The turn signal lights blink faster than norm al if one bulb is burnt out. All turn signal lights do not operate 1. Turn Signal Switch Inspection Check the turn signal sw itch (page 20-28). Is the turn signal switch operating properly? NO

– Faulty turn signal sw itch.

YES

– GO TO STEP 2.

2. Turn Signal Relay Power Input Voltage Inspection Check the turn signal relay pow er input line (page 20-27). Is there battery voltage? NO

– • Open circuit in the Light green/black w ire betw een the turn signal relay and ACC relay. • Loose or poor contact of the related connectors. • Faulty ACC relay or its circuits (page 20-16).

YES

– GO TO STEP 3.

3. Turn Signal Light Inspection Connect the Light green/black and Gray w ire term inals of the m eter 3P connector w ith a jum per w ire. Turn the ignition sw itch to “ ON” and operate the turn signal sw itch.

METER 3P CONNECTOR

Light green/black

Do the turn signal lights come on? NO

– • Open circuit in the Gray w ire betw een the turn signal relay and turn signal sw itch. • Loose or poor contact of the related connectors.

YES

– GO TO STEP 4.

Gray 4. Turn Signal Relay Inspection Check the turn signal relay (page 20-27). Is the turn signal relay operating properly? NO

– Faulty turn relay.

YES

– GO TO STEP 5.

5. Turn Signal Cancel Unit Inspection Perform the turn signal cancel unit system inspection (page 20-28). Does the turn signal system pass the inspection? NO

– • Open or short circuit in the w ire harness (page 20-28). • Loose or poor contact of the related connectors.

YES

– Faulty turn signal cancel unit.

20-5

LIGHTS/METERS/SWITCHES Turn signals do not cancel automatically 1. Angle Sensor Inspection Check the angle sensor of the turn signal cancel unit (page 20-30). Does the angle sensor rotate freely? NO

– Dam aged or im properly installed angle sensor plate.

YES

– GO TO STEP 2.

2. Speed Pulse Signal Line Inspection Check the speed pulse signal line of the turn signal cancel unit (page 20-29). Is the voltage within specified value? NO

– • Open or short circuit in the White/black w ire betw een the turn signal cancel unit and com bination m eter. • Loose or poor contact of the related connectors. • Faulty com bination m eter.

YES

– Faulty turn signal cancel unit.

Turn signals do not cancel manually 1. Turn Signal Switch Inspection Check the turn signal sw itch (page 20-27). Is the turn signal switch operating properly? NO

– Faulty turn signal sw itch.

YES

– GO TO STEP 2.

2. Turn Signal Off Signal Line Inspection Check the turn signal off signal line of the turn signal cancel unit (page 20-28). Is there continuity? NO

– • Open circuit in the Light green/w hite w ire betw een the turn signal cancel unit and turn signal sw itch. • Loose or poor contact of the related connectors.

YES

– Faulty turn signal cancel unit.

Position lights do not light with the ignition switch turned to “ON” • Faulty turn signal sw itch (page 20-27) • Open circuit in the Brow n/w hite w ire betw een the TAIL relay and turn signal sw itch • Open circuit in the Light blue/w hite or Orange/white w ire betw een the turn signal sw itch and turn signal light • Faulty position light relay and its circuits (page 20-31) Opposite position light does not go off when the turn signal switch is operated • Faulty turn signal sw itch (page 20-27) • Faulty position light relay and its circuits (page 20-31) • Faulty diode (D20) (page 20-33)

20-6

LIGHTS/METERS/SWITCHES Turn signal system operates properly but hazard system does not operate 1. Hazard Switch Inspection Check the hazard sw itch (page 20-32). Is the hazard switch operating properly? NO

– Faulty hazard sw itch; replace the left panel sw itch assem bly (page 20-32).

YES

– GO TO STEP 2.

2. Hazard Switch Ground Line Continuity Inspection Check for continuity betw een the Green w ire term inal of the w ire harness side panel sw itch 14P connector and ground. Is there continuity? NO

– Open circuit in the Green w ire betw een the hazard sw itch and ground term inal.

YES

– GO TO STEP 3.

3. Hazard Switch Line Continuity Inspection Disconnect the com bination m eter 3P connector (page 20-17). Check for continuity of the follow ing w ires betw een the panel sw itch 14P connector and m eter 3P connector. – Gray – Blue/green Is there continuity? NO

– • Open circuit in the follow ing w ires: – Gray – Blue/green

YES

– • Faulty diodes (D12, D13) (page 20-33). • Open circuit in the Pink/w hite w ire betw een the hazard sw itch and diodes. • Open circuit in the Orange or Light blue w ire.

20-7

LIGHTS/METERS/SWITCHES

HEADLIGHT BULB REPLACEMENT A halogen headlight bulb becom es very hot w hile the headlight is on, and w ill rem ain hot for a w hile after it is turned off. Be sure to let it cool dow n before servicing.

LOW BEAM HEADLIGHT

ARROW MARK

For high beam bulb, rem ove the fairing pocket (page 2-11). Disconnect the headlight connector. Rem ove the dust cover. Unhook the bulb retainer, rem ove the bulb socket and replace the headlight bulb w ith a new one.

Avoid touching a halogen headlight bulb. Finger prints can create hot spots that cause a bulb to break. If you touch the bulb w ith your bare hands, clean it w ith a cloth m oistened w ith alcohol to prevent an early failure.

CONNECTOR

BULB

DUST COVER

Install the bulb/socket into the headlight and hook the bulb retainer properly as show n. Install the dust cover properly onto the headlight w ith the arrow m ark facing up. Connect the headlight connector. Install the fairing pocket (page 2-11).

BULB RETAINER

REMOVAL/INSTALLATION Rem ove the front fairing (page 2-10). Rem ove the tw o screw s and bank angle sensor assem bly from the right headlight.

HEADLIGHT JOINT PLATE

Rem ove the tw o bolts, nuts and joint plate. Rem ove the four bolts and the headlight unit from the front fairing. Install the headlight unit in the reverse order of rem oval. Perform the sam e procedure for the left headlight; how ever, there is no bank angle sensor.

BANK ANGLE SENSOR

20-8

LIGHTS/METERS/SWITCHES

HEADLIGHT ADJUSTER SYSTEM INSPECTION Headlight adjuster does not operate 1. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that the headlight low beam s go on. â&#x20AC;˘ If the headlights are on, go to step 2. â&#x20AC;˘ If the headlights do not light, check the No. 9 fuse in the fuse box. 2. Turn the ignition sw itch â&#x20AC;&#x153; OFF.â&#x20AC;? Rem ove the inner fairings (page 2-10). Disconnect the 3P gray connector from each headlight adjuster and check for loose contacts or corroded term inals.

3. Check for continuity betw een the Green w ire term inal and ground. There should be continuity.

â&#x20AC;˘ If there is continuity, go to step 4. â&#x20AC;˘ If there is no continuity, check for an open circuit in the Green w ire betw een the headlight adjuster and ground term inal.

4. Start the engine and let it idle. M easure the voltage betw een the Brow n/red w ire term inal (+) and ground (â&#x20AC;&#x201C;). There should be battery voltage. â&#x20AC;˘ If there is battery voltage, go to step 5. â&#x20AC;˘ If there is no voltage, check for: â&#x20AC;&#x201C; open circuit in the Brow n/red and Brow n w ires betw een the headlight adjuster and relay â&#x20AC;&#x201C; headlight adjuster relay system (page 20-11)

! "

20-9

LIGHTS/METERS/SWITCHES 5. Connect the voltm eter betw een the Light green w ire term inal (+) and ground (â&#x20AC;&#x201C;). Check that the voltage varies w ith the headlight adjusting sw itch position w hile operating the sw itch.

! !

STANDARD: 1.2â&#x20AC;&#x201D;10.8 V â&#x20AC;˘ If the voltage is norm al, replace the headlight adjuster (page 20-9). â&#x20AC;˘ If the voltage is abnorm al, check for: â&#x20AC;&#x201C; open or short circuit in the Light green w ire betw een the headlight adjuster and adjusting sw itch â&#x20AC;&#x201C; headlight adjusting sw itch system (page 20-9)

REPLACEMENT Rem ove the inner fairing (page 2-10). Disconnect the headlight adjuster 3P gray connector. Right headlight adjuster: Turn the adjuster clockw ise. Left headlight adjuster: Turn the adjuster counterclockw ise. Turn the adjusting bolt counterclockw ise and rem ove the headlight adjuster from the headlight.

Install the headlight adjuster in the reverse order of rem oval. Adjust the headlight beam (page 3-19).

HEADLIGHT ADJUSTING SWITCH SYSTEM INSPECTION 1. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? Rem ove the left fairing pocket (page 2-11). Disconnect the left panel sw itch assem bly 14P gray connector and check for loose contacts or corroded term inals.

2. M easure the resistance betw een the Yellow /red and Blue/green w ire term inals of the sw itch side connector.

STANDARD: 4.0â&#x20AC;&#x201D;6.0 kâ&#x201E;Ś â&#x20AC;˘ If the resistance is norm al, go to step 3. â&#x20AC;˘ If the resistance is abnorm al, replace the panel sw itch assem bly (page 20-32).

20-10

LIGHTS/METERS/SWITCHES 3. Check that the resistance betw een the Yellow / blue and Blue/green w ire term inals varies w ith the headlight adjusting sw itch position w hile operating the sw itch.

Clockwise (from Lo to Hi position): Resistance increases Counterclockwise (from Hi to Lo position): Resistance decreases â&#x20AC;˘ If the m easurem ents are norm al, go to step 4. â&#x20AC;˘ If the m easurem ents are abnorm al, replace the panel sw itch assem bly (page 20-32).

4. Check for continuity betw een the Green w ire term inal of the w ire harness side connector and ground. There should be continuity.

! "

WIRE HARNESS SIDE CONNECTOR (viewed from the terminal side)

â&#x20AC;˘ If there is continuity, go to step 5. â&#x20AC;˘ If there is no continuity, check for an open circuit in the Green w ire betw een the panel sw itch connector and ground term inal.

Green 5. Start the engine and let it idle. M easure the voltage betw een the Brow n/red w ire term inal (+) and ground (â&#x20AC;&#x201C;). There should be battery voltage.

WIRE HARNESS SIDE CONNECTOR (viewed from the terminal side)

â&#x20AC;˘ If there is battery voltage, the system is OK. â&#x20AC;˘ If there is no battery voltage, check for: â&#x20AC;&#x201C; open circuit in the Brow n/red w ire betw een the panel sw itch connector and headlight adjuster relay â&#x20AC;&#x201C; headlight adjuster relay system

Brown/red HEADLIGHT ADJUSTER RELAY SYSTEM INSPECTION 1. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check that the oil pressure indicator com es on. Start the engine and check that the oil pressure indicator goes off. â&#x20AC;˘ If the indicator goes off, go to step 2. â&#x20AC;˘ If the indicator rem ains on, check the oil pressure sw itch (page 20-13).

20-11

LIGHTS/METERS/SWITCHES 2. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the seat (page 2-5). Rem ove the tw o screw s and rem ove the relay box. Rem ove the relay blocks from the relay box.

3. Exchange the headlight adjuster relay w ith the other good one. Start the engine, let it idle and operate the headlight adjusting sw itch.

â&#x20AC;˘ If the headlight adjuster functions properly, replace the headlight adjuster relay w ith a new one. â&#x20AC;˘ If the headlight adjuster does not function, go to step 4.

4. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the headlight adjuster relay. Check for continuity betw een the Blue/w hite w ire term inal of the relay connector and ground. Start the engine and let it idle. There should be no continuity.

â&#x20AC;˘ If there is no continuity, go to step 5. â&#x20AC;˘ If there is continuity, check for: â&#x20AC;&#x201C; short circuit in the Blue/w hite w ire betw een the headlight adjuster relay and oil pressure sw itch diode (D17) â&#x20AC;&#x201C; faulty diode (D17)

5. Stop the engine then turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Brow n/red w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;). There should be battery voltage. â&#x20AC;˘ If there is battery voltage, the system is OK; check for loose contacts or corroded term inals. â&#x20AC;˘ If there is no voltage, check for an open circuit in the Brow n/red w ire betw een the headlight adjuster relay and fuse box (No. 9 fuse).

20-12

LIGHTS/METERS/SWITCHES OIL PRESSURE SWITCH DIODE Rem ove the seat (page 2-5). Rem ove the oil pressure sw itch diode from the w ire harness. Check for continuity betw een the diode term inals. When there is continuity, a sm all resistance value w ill register. If there is continuity in one direction, the diode is norm al.

FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Rem ove the screw and m irror from the rearview m irror housing by releasing the tw o tabs.

TAB

M IRROR

SCREW

Rem ove the bulb socket from the turn signal light by turning it counterclockw ise. Pull the bulb out of the socket and replace it w ith a new one. Install the rem oved parts in the reverse order of rem oval.

REPLACEMENT Rem ove the rearview m irror cover (page 2-7). Disconnect the turn signal light connector. Rem ove the m irror from the m irror housing. Rem ove the three screw s, base cover and turn signal light assem bly.

20-13

LIGHTS/METERS/SWITCHES

SADDLEBAG COMBINATION LIGHT BULB REPLACEMENT Open the saddlebag lid. Rem ove the three nuts and the com bination light from the saddlebag.

REAR TURN SIGNAL LIGHT Rem ove the bulb socket from the com bination light by turning it counterclockw ise. Pull the turn signal light bulb out of the socket and replace it w ith a new one. Install the rem oved parts in the reverse order of rem oval.

TURN SIGNAL LIGHT BULB SOCKET

BRAKE/TAILLIGHT Rem ove the bulb socket from the com bination light by turning it counterclockw ise. Pull the brake/taillight bulb out of the socket and replace it w ith a new one.

Install the rem oved parts in the reverse order of rem oval.

20-14

LIGHTS/METERS/SWITCHES

TRUNK BRAKE/TAILLIGHT BULB REPLACEMENT Open the trunk lid.

Rem ove the three nuts and the brake/taillight from the trunk.

Rem ove the bulb socket from the brake/taillight by turning it counterclockw ise. Pull the bulb out of the socket and replace it w ith a new one. Install the rem oved parts in the reverse order of rem oval.

BULB

SOCKET

LICENSE LIGHT BULB REPLACEMENT Rem ove the tw o screw s and license light lens. Pull the bulb out of the socket and replace it w ith a new one. Install the license light lens and tighten the tw o screw s.

BULB LENS

SCREWS

20-15

LIGHTS/METERS/SWITCHES

RELAY BOX RELAY INSPECTION Rem ove the relay blocks (page 20-12). The fourteen 4-term inal relays are the sam e parts and the six 5-term inal relays are the sam e parts. Check the relay function by exchanging it w ith the other good one.

BLANK

4-TERMINAL RELAYS 4-TERMINAL RELAY CHECK Check for continuity betw een the No. 1 and No. 2 term inals. Connect the fully charged 12-V battery (+) term inal to the relay No. 3 term inal and the (–) term inal to the No. 4 term inal.

No. 2

No. 1

No. 3

No. 4

• There should be continuity w hile the battery is connected. • There should be no continuity w hen the battery is disconnected.

5-TERMINAL RELAY CHECK Check for continuity betw een the No. 1 and No. 2 term inals, and betw een No. 1 and No. 4 term inals. Connect the fully charged 12-V battery (+) term inal to the relay No. 3 term inal and the (–) term inal to the No. 5 term inal.

No. 2

No. 1

• There should be continuity betw een the No. 1 and No. 2 term inals w hile the battery is connected. • There should be continuity betw een the No. 1 and No. 4 term inals w hen the battery is disconnected.

No. 3 No. 4

20-16

No. 5

5-TERMINAL RELAYS

LIGHTS/METERS/SWITCHES

COMBINATION METER REMOVAL/INSTALLATION Rem ove the front fairing (page 2-10). Rem ove the three com bination m eter m ounting nuts.

Rem ove the connector boots from the com bination m eter. Disconnect the 20P black, 16P black, 20P blue and 3P w hite connectors and rem ove the com bination m eter from the stay.

20P BLUE

20P BLACK

16P BLACK

Install the com bination m eter in the reverse order of rem oval.

3P WHITE

POWER/GROUND LINE INSPECTION Rem ove the com bination m eter (page 20-17). Check the follow ing at the w ire harness side connector term inals: POWER SOURCE LINE M easure the w ire term inal ground (–). There should sw itch turned

voltage betw een the Brow n/w hite (+) of the 20P blue connector and be battery voltage w ith the ignition to “ ON.”

If there is no voltage, check for: – open circuit in the Brow n/w hite w ire betw een the com bination m eter and TAIL relay – TAIL relay (page 20-16) – loose or poor contact of related connectors

Brown/white

METER 20P BLUE CONNECTOR (viewed from the terminal side)

20-17

LIGHTS/METERS/SWITCHES ACCESSORY POWER LINE M easure the voltage betw een the Light green/black w ire term inal (+) of the 20P blue connector and ground (–). There should be battery voltage w ith the ignition sw itch turned to “ ON” or “ ACC.” If there is no voltage, check for: – open circuit in the Light green/black w ire betw een the com bination m eter and ACC relay – ACC relay (page 20-16) – loose or poor contact of related connectors

Light green/black

METER 20P BLUE CONNECTOR (viewed from the terminal side)

BACK-UP POWER LINE M easure the voltage betw een the Red/yellow w ire term inal (+) of the 20P blue connector and ground (–). There should be battery voltage at all tim es.

Red/yellow

If there is no voltage, check for: – open circuit in the Red/yellow w ire betw een the com bination m eter and fuse box (No. 22 fuse) – blow n No. 22 fuse – loose or poor contact of related connectors

METER 20P BLUE CONNECTOR (viewed from the terminal side) GROUND LINE Check for continuity betw een the Green w ire term inal of the 20P black connector and ground. There should be continuity at all tim es.

Green

If there is no continuity, check for open circuit in the Green w ire betw een the com bination m eter and ground term inal.

METER 20P BLACK CONNECTOR (viewed from the terminal side) SENSOR GROUND LINE Check for continuity betw een the Green w ire term inal of the 20P blue connector and ground. There should be continuity at all tim es. If there is no continuity, check for open circuit in the Green w ire betw een the com bination m eter and ground term inal.

Green

METER 20P BLUE CONNECTOR (viewed from the terminal side)

20-18

LIGHTS/METERS/SWITCHES DISASSEMBLY Rem ove the six tapping screw s, m eter lens and visor.

METER LENS

Rem ove the four tapping screw s, disconnect the connector and rem ove the LCD assem bly.

SCREWS

LCD ASSEMBLY

SCREWS Rem ove the eight tapping screw s and rem ove the m eter/gauge assem bly from the low er case.

Rem ove the three term inal screw s and turn signal relay circuit board. Rem ove the tapping screw , w ire clam p and turn signal relay w ire.

5+4-95

WIRE CLAMP

TAPPING SCREW TERMINAL SCREWS

20-19

LIGHTS/METERS/SWITCHES ASSEMBLY Assem ble the com bination m eter in the reverse order of disassem bly.

METER LENS

METER VISOR

LOWER CASE

METER/GAUGE ASSEMBLY

TURN SIGNAL RELAY WIRE

LCD ASSEMBLY TURN SIGNAL RELAY CIRCUIT BOARD

WIRE CLAMP

SPEEDOMETER INSPECTION Speedometer does not operate 1. Check that the tachom eter, coolant tem perature gauge and fuel gauge operate properly. â&#x20AC;˘ If they do not function, check the pow er source line and sensor ground line (page 20-17). â&#x20AC;˘ If they function properly, go to step 2. 2. Check that the engine control m odule (ECM ) stores failure code 11 (page 5-16). â&#x20AC;˘ If the ECM stores failure code 11, perform the troubleshooting on page 5-28. â&#x20AC;˘ If the ECM does not store failure codes, go to step 3. 3. Rem ove the com bination m eter (page 20-17). Place the m otorcycle on its center stand, shift the transm ission into neutral and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the White/black (+) and Green (â&#x20AC;&#x201C;) w ire term inals of the com bination m eter 20P black connector. There should be 0 V to 5 V pulse voltage w hile slow ly turning the rear w heel by hand. â&#x20AC;˘ If the pulse voltage appears, replace the m eter/gauge assem bly (page 20-19). â&#x20AC;˘ If the pulse voltage does not appear, check for: â&#x20AC;&#x201C; open circuit in the White/black w ire betw een the com bination m eter and speed sensor â&#x20AC;&#x201C; loose or poor contact in the related connectors

20-20

! "# # $ %

LIGHTS/METERS/SWITCHES

TACHOMETER INSPECTION Tachometer does not operate 1. Check that the speedom eter, coolant tem perature gauge and fuel gauge operate properly. â&#x20AC;˘ If they do not function, check the pow er source line and sensor ground line (page 20-17). â&#x20AC;˘ If they function properly, go to step 2. 2. Rem ove the com bination m eter (page 20-17). Connect the peak voltage tester or adaptor probes to the Yellow /green (+) and Green (â&#x20AC;&#x201C;) w ire term inals of the com bination m eter 20P black connector. TOOLS: Peak voltage tester (U.S.A. only) or Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter (impedance 10 Mâ&#x201E;Ś/DCV minimum) Start the engine and m easure the tachom eter signal peak voltage.

! " #

PEAK VOLTAGE: 10.5 V minimum â&#x20AC;˘ If the m easured value is m ore than 10.5 V, replace the m eter/gauge assem bly (page 20-19). â&#x20AC;˘ If the m easured value is less than 10.5 V, replace the engine control m odule (ECM ). â&#x20AC;˘ If there is no voltage, go to step 3. 3. Rem ove the top shelter (page 2-12). Disconnect the engine control m odule (ECM ) 22P gray connector.

4. Check the Yellow /green w ire for open or short circuit as follow s: â&#x20AC;&#x201C; Check for continuity betw een the com bination m eter and ECM connectors. There should be continuity. â&#x20AC;&#x201C; Check for continuity to ground. There should be no continuity.

ECM 22P GRAY CONNECTOR

â&#x20AC;˘ If the Yellow /green w ire is OK, replace the ECM .

20-21

LIGHTS/METERS/SWITCHES

COOLANT TEMPERATURE GAUGE/ ECT SENSOR SYSTEM INSPECTION 1. Check that the tachom eter, speedom eter and fuel gauge operate properly. â&#x20AC;˘ If they do not function, check the pow er source line and sensor ground line (page 20-17). â&#x20AC;˘ If they function properly, go to step 2. 2. Rem ove the left radiator stay (page 5-71). Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the ECT sensor 3P connector.

3. Ground the Green/black w ire term inal of the ECT sensor connector w ith a jum per w ire. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check the coolant tem perature gauge. The gauge needle should m ove to â&#x20AC;&#x153; H.â&#x20AC;? â&#x20AC;˘ If the needle m oves, check the ECT sensor. â&#x20AC;˘ If the needle does not m ove, go to step 4.

4. Rem ove the com bination m eter (page 20-17). Check the Green/black w ire for continuity betw een the com bination m eter 20P blue connector and ECT sensor connector.

! " #

There should be continuity. â&#x20AC;˘ If there is continuity, replace the m eter/gauge assem bly (page 20-19).

20-22

LIGHTS/METERS/SWITCHES ECT SENSOR INSPECTION ECT SENSOR

Rem ove both radiators (page 6-8). Rem ove the tw elve intake m anifold bolts and raise the m anifold to access the ECT sensor. Disconnect the ECT sensor connector. Rem ove the ECT sensor and sealing w asher from the left cylinder head.

SEALING WASHER Keep all flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection.

Suspend the ECT sensor in a pan of coolant (1:1 m ixture) on an electric heating elem ent and m easure the resistance betw een the therm osensor term inal and body as the coolant heats up. • Soak the ECT sensor in coolant up to its threads w ith at least 40 m m (1.57 in) from the bottom of the pan to the bottom of the sensor. • Keep the tem perature constant for 3 m inutes before testing. A sudden change of tem perature w ill result in incorrect readings. Do not let the therm om eter or ECT sensor touch the pan. Tem perature Resistance

80° C (176° F) 47 – 57

120° C (248° F) 14 – 18

ECT SENSOR

Replace the ECT sensor if it is out of specifications by m ore than 10% at any tem perature listed.

ECT SENSOR

Install the ECT sensor w ith a new sealing w asher and tighten it. TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft) Connect the ECT sensor connector. Install the rem oved parts. Fill and bleed the cooling system (page 6-6).

SEALING WASHER

20-23

LIGHTS/METERS/SWITCHES

FUEL GAUGE/LOW FUEL INDICATOR SYSTEM INSPECTION 1. Check that the tachom eter, speedom eter and coolant tem perature gauge operate properly. â&#x20AC;˘ If they do not function, check the pow er source line and sensor ground line (page 20-17). â&#x20AC;˘ If they function properly, go to step 2.

2P CONNECTOR

2. Rem ove the seat (page 2-5). With the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? disconnect the fuel level sensor 2P connector.

3. Turn the ignition sw itch to â&#x20AC;&#x153; ON,â&#x20AC;? and check the low fuel indicator and fuel level gauge. The indicator should com e on and the gauge needle should m ove to â&#x20AC;&#x153; E.â&#x20AC;?

FUEL GAUGE

LOW FUEL INDICATOR 4. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and ground the Gray/black w ire term inal of the sensor 2P connector w ith a jum per w ire. Turn the ignition sw itch to â&#x20AC;&#x153; ON,â&#x20AC;? and check the low fuel indicator and fuel level gauge. The indicator should not com e on and the gauge needle should m ove to â&#x20AC;&#x153; F.â&#x20AC;? â&#x20AC;˘ If the indicator and gauge function properly, check the fuel level sensors. â&#x20AC;˘ If one of the indicator or gauge functions properly but the other does not function, replace the m eter/gauge assem bly (page 20-19). â&#x20AC;˘ If the indicator and gauge do not function, go to step 5. 5. Rem ove the com bination m eter (page 20-17). Check the Gray/black w ire betw een the com bination m eter and fuel level sensor connectors. â&#x20AC;&#x201C; Check for continuity betw een the com bination m eter and fuel level sensor connectors. There should be continuity. â&#x20AC;&#x201C; Check for continuity to ground. There should be no continuity. â&#x20AC;˘ If the Gray/black w ire is OK, replace the m eter/ gauge assem bly (page 20-19).

20-24

! "

LIGHTS/METERS/SWITCHES FUEL LEVEL SENSOR INSPECTION

Disconnect the fuel level sensor connector. Rem ove the tw o bolts and shelter setting stay.

Rem ove the fuel level sensor retainer by turning it counterclockw ise w ith the special tool. TOOL: Fuel sender/pump wrench

07ZMA-MCAA201 or 07ZMA-MCAA200

Rem ove the fuel level sensor and base gasket from the fuel tank.

M easure the resistance betw een the fuel level sensor connector term inals w ith the float at top (FULL) and bottom (EM PTY) positions.

FLOAT

RESISTANCE (20Â° C/68Â° F): 1.5 â&#x20AC;&#x201C; 2.5â&#x201E;Ś with the float at FULL position 61.4 â&#x20AC;&#x201C; 63.4â&#x201E;Ś with the float at EMPTY position

EMPTY POSITION

Install a new base gasket. Install the fuel level sensor in the fuel tank and align the lugs on the sensor base w ith grooves in the fuel tank. Install the retainer and turn it clockw ise w ith the special tool until it stops.

GROOVES

BASE GASKET

Install the rem oved parts in the reverse order of rem oval.

20-25

LIGHTS/METERS/SWITCHES FUEL PUMP SIDE LEVEL SENSOR Rem ove the fuel pum p assem bly (page 5-60). M easure the resistance betw een the fuel level sensor term inals of the fuel pum p connector w ith the float at the top (FULL) and bottom (EM PTY) positions. RESISTANCE (20Â° C/68Â° F): 1.5 â&#x20AC;&#x201C; 2.5â&#x201E;Ś with the float at FULL position 28.6 â&#x20AC;&#x201C; 30.6â&#x201E;Ś with the float at EMPTY position

FLOAT

Install the fuel pum p assem bly (page 5-62).

EMPTY POSITION

NEUTRAL INDICATOR SYSTEM INSPECTION 1. Shift the transm ission into neutral and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? The neutral indicator should com e on. â&#x20AC;˘ If the indicator com es on, the system is OK. â&#x20AC;˘ If the indicator does not com e on, go to step 2.

2. Rem ove the com bination m eter (page 20-17). Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Black/w hite w ire term inal (+) of the com bination m eter 20P black connector and ground (â&#x20AC;&#x201C;). There should be battery voltage. â&#x20AC;˘ If there is no battery voltage, go to step 3. â&#x20AC;˘ If there is voltage, check for: â&#x20AC;&#x201C; reverse position sw itch (page 19-30) â&#x20AC;&#x201C; reverse shift sw itch (page 20-35) â&#x20AC;&#x201C; open circuit in the Black/w hite, Black/red and Black/brow n w ires betw een the com bination m eter and reverse position sw itch â&#x20AC;&#x201C; loose or poor contact of related connectors 3. Check for continuity betw een the Light green w ire term inal of the com bination m eter 20P black connector and ground. There should be continuity. â&#x20AC;˘ If there is continuity, replace the m eter/gauge assem bly (page 20-19). â&#x20AC;˘ If there is no continuity, check for: â&#x20AC;&#x201C; faulty gear position sw itch (page 20-38) â&#x20AC;&#x201C; faulty diode (D6) (page 19-28) â&#x20AC;&#x201C; open circuit in the Light green and Light green/red w ires betw een the com bination m eter and gear position sw itch

20-26

! "

LIGHTS/METERS/SWITCHES

OIL PRESSURE INDICATOR INSPECTION Rem ove the left front exhaust pipe protector (page 2-18).

OIL PRESSURE SWITCH WIRE

Rem ove the rubber cap, and disconnect the oil pressure sw itch w ire by rem oving the term inal screw .

RUBBER CAP

TERMINAL SCREW

Indicator does not come on with the ignition switch turned to â&#x20AC;&#x153;ONâ&#x20AC;? Ground the w ire term inal to the engine w ith a jum per w ire. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and check the oil pressure indicator. The indicator should com e on. â&#x20AC;˘ If the indicator com es on, replace the oil pressure sw itch. â&#x20AC;˘ If the indicator does not com e on, check for an open circuit in the Blue/red w ire betw een the oil pressure sw itch and com bination m eter. Indicator stays on while the engine is running Check for continuity betw een the oil pressure sw itch w ire term inal and ground. There should be no continuity.

OIL PRESSURE INDICATOR

â&#x20AC;˘ If there is continuity, check for short circuit in the Blue/red w ire betw een the oil pressure sw itch and com bination m eter â&#x20AC;˘ If there is no continuity, check the oil pressure (page 4-6). If the oil pressure is norm al, replace the oil pressure sw itch.

TURN SIGNAL RELAY Rem ove the com bination m eter (page 20-17).

POWER INPUT LINE INSPECTION Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? or â&#x20AC;&#x153; ACC.â&#x20AC;? M easure the voltage betw een the Light green/black w ire term inal (+) of the com bination m eter 3P connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

! ! " #

20-27

LIGHTS/METERS/SWITCHES FUNCTION CHECK Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and connect the com bination m eter 3P connector. Ground the Blue/green w ire term inal w ith a jum per w ire. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? or â&#x20AC;&#x153; ACCâ&#x20AC;? and operate the turn signal sw itch. The turn signal lights should blink.

TURN SIGNAL CANCEL UNIT SYSTEM INSPECTION Rem ove the front fairing (page 2-10).

6P GRAY CONNECTOR

Disconnect the 6P gray connector at the right connector holder. Check the connector for loose contacts or corroded term inals. Check the follow ing at the m ain w ire harness side 6P gray connector.

RIGHT CONNECTOR HOLDER GROUND LINE Check for continuity betw een the Green w ire term inal and ground. There should be continuity at all tim es.

MAIN WIRE HARNESS SIDE CONNECTOR (viewed from the terminal side)

â&#x20AC;˘ If there is no continuity, check for an open circuit in the Green w ire betw een the 6P gray connector and ground term inal. TURN SIGNAL ON SIGNAL LINE Check for continuity betw een the Pink w ire term inal and ground. There should be continuity w hen the turn signal sw itch is turned to â&#x20AC;&#x153; â&#x20AC;? or â&#x20AC;&#x153; .â&#x20AC;? â&#x20AC;˘ If there is no continuity, check for an open circuit in the Pink w ire betw een the 6P gray connector and left handlebar sw itch. TURN SIGNAL OFF SIGNAL LINE Check for continuity betw een the Light green/w hite w ire term inal and ground. There should be continuity w hen the turn signal sw itch is pushed. â&#x20AC;˘ If there is no continuity, check for an open circuit in the Light green/w hite w ire betw een the 6P gray connector and left handlebar sw itch.

20-28

Green Pink Light green/white

LIGHTS/METERS/SWITCHES POWER INPUT LINE M easure the voltage betw een the White/green w ire term inal (+) and ground (–). There should be battery voltage w ith the ignition sw itch turned to “ ON.”

White/green

• If there is no voltage check the follow ing: – open circuit in the White/green w ire betw een the 6P gray connector and HORN TURN relay – HORN TURN relay

MAIN WIRE HARNESS SIDE CONNECTOR (viewed from the terminal side) SPEED PULSE SIGNAL LINE M ake sure the speedom eter operates properly before inspection.

White/black

Connect the 6P gray connector. Place the m otorcycle on its center stand, shift the transm ission into neutral and turn the ignition sw itch to “ ON.” M easure the voltage betw een the White/black w ire term inal (+) and ground (–). There should be 0 V to 5 V pulse voltage w hile slow ly turning the rear w heel by hand. • If the pulse voltage is not present, check the follow ing: – open or short circuit in the White/black w ire betw een the 6P gray connector and com bination m eter – loose or poor contact in related connectors

MAIN WIRE HARNESS SIDE CONNECTOR (viewed from the terminal side)

CANCEL SIGNAL LINE M ake sure the ground, turn signal on/off signal and pow er input lines are OK before inspection. Connect the 6P gray connector and turn the ignition sw itch to “ ON.” M easure the voltage betw een the Blue/black w ire term inal (+) and ground (–). There should be no voltage w hen the turn signal sw itch is pushed to “ ” or “ .” There should be battery voltage w hen the turn signal sw itch is pushed. • If there is battery voltage in both conditions, replace the turn signal cancel unit. • If there is no voltage in both conditions, check the follow ing: – open or short circuit in the Blue/black and Blue/ green w ires betw een the 6P gray connector and com bination m eter 3P connector (turn signal relay) – faulty diode (D19) (page 20-32) – loose or poor contact in related connectors

Blue/black

MAIN WIRE HARNESS SIDE CONNECTOR (viewed from the terminal side)

20-29

LIGHTS/METERS/SWITCHES ANGLE SENSOR INSPECTION Check the angle sensor plate for dam age or deform ation. Rem ove the screw attaching the angle sensor plate. Check that the angle sensor rotates sm oothly by turning the angle sensor plate. Install and tighten the screw securely.

REMOVAL/INSTALLATION

Rem ove the m eter panel (page 2-7).

Rem ove the tw o screw s and handlebar center cover.

Rem ove the steering stem nut cap and disconnect the turn signal cancel unit 7P connector.

CAP

7P CONNECTOR Rem ove the three screw s and turn signal cancel unit from the steering stem .

Installation is in the reverse order of rem oval.

20-30

LIGHTS/METERS/SWITCHES

POSITION LIGHT RELAY SYSTEM INSPECTION â&#x20AC;˘ The position light relay is sam e part as the 5-term inal relays in the relay box. Rem ove the front fairing (page 2-10).

Rem ove the position light relay. Check the follow ing at the w ire harness side 5P connector.

1. Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the White/green w ire term inal (+) of the w ire harness side 5P connector and ground (â&#x20AC;&#x201C;). There should be battery voltage. â&#x20AC;˘ If there is battery voltage, go to step 2. â&#x20AC;˘ If there is no voltage, check the follow ing: â&#x20AC;&#x201C; HORN TURN relay â&#x20AC;&#x201C; open circuit in the White/green w ire 2. M easure the voltage betw een the Light blue/ w hite w ire term inal (+) and ground (â&#x20AC;&#x201C;). There should be battery voltage and no voltage w hen the turn signal sw itch is pushed to â&#x20AC;&#x153; .â&#x20AC;? â&#x20AC;˘ If the m easurem ents are norm al, go to step 3. â&#x20AC;˘ If there is no voltage, check the follow ing: â&#x20AC;&#x201C; faulty turn signal sw itch â&#x20AC;&#x201C; open circuit in the Light blue/w hite w ire

3. M easure the voltage betw een the Orange/w hite w ire term inal (+) and ground (â&#x20AC;&#x201C;). There should be battery voltage and no voltage w hen the turn signal sw itch is pushed to â&#x20AC;&#x153; .â&#x20AC;? â&#x20AC;˘ If the m easurem ents are norm al, go to step 4. â&#x20AC;˘ If there is no voltage, check the follow ing: â&#x20AC;&#x201C; faulty turn signal sw itch â&#x20AC;&#x201C; open circuit in the Orange/w hite w ire 4. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the turn signal diode 3P connector. Check the Blue/w hite w ire for continuity betw een the position light relay and turn signal diode connectors. There should be continuity.

20-31

LIGHTS/METERS/SWITCHES TURN SIGNAL DIODE CHECK Check for continuity betw een the diode term inals. When there is continuity, a sm all resistance value w ill register. If there is continuity in one direction, the diode is norm al.

(+)

HAZARD SWITCH INSPECTION Rem ove the left fairing pocket (page 2-11). Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and disconnect the left panel sw itch assem bly 14P gray connector. Check for loose contacts or corroded term inals.

Check for continuity betw een the sw itch side connector term inals. Continuity should exist betw een the color coded w ires as show n in the chart.

$ %

! " # $

LEFT PANEL SWITCH REPLACEMENT Disconnect the left panel sw itch assem bly 14P gray connector (page 20-32).

Rem ove the left fairing m olding (page 2-10). Rem ove the screw attaching the sw itch assem bly. Release the three tabs and the sw itch assem bly from the top shelter. Install new panel sw itch assem bly and rem oved parts in the reverse order of rem oval.

20-32

LIGHTS/METERS/SWITCHES HAZARD SWITCH DIODE Rem ove the seat (page 2-5). Rem ove the hazard sw itch diode from the w ire harness.

(+)

Check for continuity betw een the diode term inals. When there is continuity, a sm all resistance value w ill register. If there is continuity in one direction, the diode is norm al.

( ) DIODE

OPEN AIR TEMPERATURE SENSOR SYSTEM INSPECTION Rem ove the top shelter (page 2-11). Disconnect the open air tem perature sensor 2P w hite connector.

AIR TEMPERATURE SENSOR CONNECTOR 1. Turn the ignition sw itch to “ ON” and m easure the voltage betw een the Yellow /blue (+) and Green/black w ire term inal of the w ire harness side sensor connector. There should be approxim ately 5 V. • If there is approxim ately 5 V, go to step • if there is no voltage, check for an open in the Yellow /blue and Green/black betw een the sensor and com bination connectors.

2. circuit w ires m eter

2. Turn the ignition sw itch to “ OFF” and m easure the resistance betw een the sensor side connector term inals. Ambient temperature – 5° C (23° F) 0° C (32° F) 10° C (50° F) 20° C (68° F) 30° C (86° F) 40° C (104° F)

WIRE HARNESS SIDE SENSOR CONNECTOR (viewed from the terminal side)

Yellow/blue

Green/black

Resistance Approx. 21 kΩ Approx. 16 kΩ Approx. 10 kΩ Approx. 6 kΩ Approx. 4 kΩ Approx. 2.5 kΩ

20-33

LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION

AIR DUCT

Rem ove the front fairing (page 2-10). Rem ove the right upper air duct by releasing the grom m et from the boss.

GROMMET AND BOSS Rem ove the screw and open air tem perature sensor from the air duct.

Install the open air tem perature sensor in the reverse order of rem oval.

IGNITION SWITCH INSPECTION Rem ove the top shelter (page 2-11).

Disconnect the ignition sw itch 4P w hite connector. Check for continuity betw een the sw itch side connector term inals in each sw itch position. Continuity should exist betw een the color coded w ires as show n in the chart.

Color Position LOCK OFF ON ACC

20-34

Lg/Bl

Bu/O

LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Disconnect the ignition sw itch connector. Rem ove the m ulti-display control sw itch 4P connector from the stay on the ignition sw itch.

IGNITION SWITCH

Rem ove the tw o m ounting bolts and the ignition sw itch. Install the ignition sw itch and tighten the m ounting bolts. TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft) Install the rem oved parts in the reverse order of rem oval. BOLTS

HANDLEBAR SWITCH INSPECTION Rem ove the front fairing (page 2-10).

18P CONNECTOR

Disconnect the follow ing: ‘01 – ‘03: – right handlebar sw itch 18P green connector – left handlebar sw itch 12P green connector – left handlebar sw itch 14P blue connector After ‘03: – right handlebar sw itch 18P blue connector – left handlebar sw itch 12P blue connector – left handlebar sw itch 14P gray connector Check for continuity betw een the connector term inals in each sw itch position. Continuity should exist betw een the color coded w ires as show n below .

14P CONNECTOR

RIGHT HANDLEBAR SWITCH

12P CONNECTOR

ENGINE STOP SWITCH

• For cruise control sw itch inspection, see section 21. Starter/reverse switch

Color Position

Bl/W

Y/R

Br/W

Bu/W

FREE PUSH

REVERSE SHIFT SWITCH

Engine stop switch

Color Position

STARTER/REVERSE SWITCH

Bl/W

OFF RUN OFF Reverse shift switch

Color Position

Y/W

Bl/Br

Bl/R

FREE PUSH

20-35

LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCH

DIMMER SWITCH • For audio sw itch inspection, see section 21. Dimmer switch

Color Position

Bu/W

LO TURN SIGNAL SWITCH

(N) HI

HORN SWITCH

Horn switch

Color Position

W/G

FREE PUSH Turn signal switch

Color

Position

Br/W

Lb/W

O/W

Lg/W

R L PUSH

DISASSEMBLY/ASSEMBLY ORNAM ENT PLATE A

ORNAM ENT PLATE A

UPPER LENS

AUDIO LENS

LOWER LENS A

UPPER LENS A

UPPER LENS B

BULB C

BULB C ORNAM ENT PLATE C

BULB C BULB B ORNAM ENT PLATE B BULB C BULB B LOWER LENS B RIGHT HANDLEBAR SWITCH

20-36

ORNAM ENT PLATE D LOWER LENS

BULB B BULB A LEFT HANDLEBAR SWITCH

LIGHTS/METERS/SWITCHES

BRAKE SWITCH FRONT â&#x20AC;˘ The upper (sm all) term inals are the brake light sw itch term inals. Disconnect the front brake sw itch connectors and check for continuity betw een the sw itch term inals. There should be continuity w ith the front brake lever squeezed and no continuity w ith the lever released.

REAR Rem ove the top shelter (page 2-11). There should be continuity w ith the rear brake pedal depressed and no continuity w ith the pedal released. Disconnect the rear brake light sw itch 3P w hite connector and check for continuity betw een the sw itch side connector term inals.

CLUTCH SWITCH â&#x20AC;˘ The upper sw itch is the clutch sw itch. Disconnect the clutch sw itch w ire connectors and check for continuity betw een the sw itch term inals. There should be continuity w ith the clutch lever squeezed and no continuity w ith the lever released.

20-37

LIGHTS/METERS/SWITCHES

GEAR POSITION SWITCH INSPECTION Rem ove the air cleaner housing (page 5-65).

GEAR POSITION SWITCH CONNECTOR

Disconnect the gear position sw itch connector.

Check for continuity at the sw itch side connector term inals. There should be continuity in each gear position as follow s: GEAR POSITION Neutral 1st 2nd 3rd 4th Overdrive

CONTINUITY Light green/red to ground â&#x20AC;&#x201C; Black/yellow to ground White/red to ground Red/white to ground Green/orange to ground

!" #

REPLACEMENT Rem ove the air cleaner housing (page 5-65). Disconnect the gear position sw itch connector. Rem ove the gear position sw itch from the gearshift linkage cover (page 10-8). Install a new gear position sw itch onto the gearshift linkage cover and install the cover (page 10-9). Connect the gear position sw itch connector. Install the air cleaner housing (page 5-65).

20-38

GEAR POSITION SWITCH CONNECTOR

LIGHTS/METERS/SWITCHES

SIDE STAND SWITCH INSPECTION 3P CONNECTOR

Rem ove the left engine side cover (page 2-5). Disconnect the side stand sw itch 3P connector. Check for continuity betw een the sw itch side connector term inals in each side stand position. There should be continuity as follow s:

Color Position Extended Retracted

G/W

Y/Bl

BOLT

SIDE STAND SWITCH

REPLACEMENT 3P CONNECTOR

Rem ove the left engine side cover (page 2-5). Disconnect the side stand sw itch 3P connector. Rem ove the side stand sw itch bolt and the sw itch.

BOLT Install a new side stand sw itch by aligning the sw itch pin w ith the hole in the side stand and the sw itch groove w ith the bracket pin.

Install the side stand sw itch bolt and tighten it. TORQUE: 10 NÂˇm (1.0 kgfÂˇm, 7 lbfÂˇft) Connect the side stand sw itch 3P connector. Install the left engine side cover (page 2-5).

20-39

LIGHTS/METERS/SWITCHES

MULTI-DISPLAY CONTROL SWITCH REMOVAL/INSTALLATION Rem ove the m eter panel (page 2-7). Rem ove the tw o screw s and m ulti-display control sw itch. Installation is in the reverse order of rem oval.

INSPECTION Check for continuity betw een the sw itch connector term inals.

CONNECTOR

MODE SWITCH There should be continuity betw een the Black/ yellow and Green/yellow w ire term inals w hen the “ M ODE” sw itch is depressed. TRIP SWITCH There should be continuity betw een the Brow n/ yellow and Green/yellow w ire term inals w hen the “ TRIP” sw itch is depressed. DISP SWITCH There should be continuity betw een the Blue/yellow and Green/yellow w ire term inals w hen the “ DISP” sw itch is depressed.

DISP SWITCH

MODE SWITCH

TRIP SWITCH HORN CONNECTORS

Rem ove the front low er fairing (page 2-6). Disconnect the w ire connectors from the horn. Connect a 12-V battery to the horn term inals. The horn is norm al if it sounds w hen the 12-V battery is connected across the horn term inals.

HORN

20-40

LIGHTS/METERS/SWITCHES

FAN CONTROL RELAY INSPECTION Check that the engine control m odule (ECM ) stores failure code 7 before inspection (page 5-16). If the ECM stores failure code 7, perform the troubleshooting on page 5-19. Fan motor does not start 1. Rem ove the relay blocks (page 20-16). Turn the ignition sw itch to “ OFF” and rem ove the fan control relay.

FAN CONTROL RELAY

2. Turn the ignition sw itch to “ ON” and m easure the voltage betw een the Black/blue w ire term inal (+) and ground (–). There should be battery voltage. • If there is battery voltage, go to step 3. • If there is no voltage, check the follow ing: – blow n No. 7 fuse – open circuit in the Black/blue w ire 3. Turn the ignition sw itch to “ OFF” and connect the Blue and Black/blue w ire term inals w ith a jum per w ire. Turn the ignition sw itch to “ ON.” The cooling fan should start.

FAN CONTROL RELAY CONNECTOR Black/blue

JUMPER WIRE

Blue

– If the cooling fans start, go to step 4. – If the cooling fans do not start, check the follow ing: – faulty cooling fan – open circuit in the Blue and Green w ires 4. Exchange the fan control relay w ith a know ngood one. Start the engine and w arm it up and check the cooling fans. • If the cooling fans start, replace the fan control relay. • If the cooling fans do not start, check for an open circuit in the Black/red w ire betw een the relay and engine control m odule.

20-41

LIGHTS/METERS/SWITCHES

POWER TRUNK LOCK SYSTEM â&#x20AC;˘ The turn signal lights blink tw ice w hen the trunk opener unit is unlocked using the transm itter w ith the ignition sw itch turned to â&#x20AC;&#x153; OFFâ&#x20AC;? or â&#x20AC;&#x153; LOCK.â&#x20AC;? â&#x20AC;˘ The turn signal lights blink once w hen the trunk opener unit is locked using the transm itter w ith the ignition sw itch turned to â&#x20AC;&#x153; OFFâ&#x20AC;? or â&#x20AC;&#x153; LOCK.â&#x20AC;? â&#x20AC;˘ The horns sound tw ice and the turn signal lights blink tw ice w hen the â&#x20AC;&#x153; CALLâ&#x20AC;? button is pushed for m ore than 0.5 second. â&#x20AC;˘ The trunk opener unit can be unlocked or locked using the transm itter w ith the ignition sw itch turned to â&#x20AC;&#x153; ONâ&#x20AC;? or â&#x20AC;&#x153; ACC,â&#x20AC;? but the turn signal lights do not blink. â&#x20AC;˘ The â&#x20AC;&#x153; POP UPâ&#x20AC;? and â&#x20AC;&#x153; CALLâ&#x20AC;? functions do not w ork w ith the ignition sw itch turned to â&#x20AC;&#x153; ONâ&#x20AC;? or â&#x20AC;&#x153; ACC.â&#x20AC;? â&#x20AC;˘ If any of the lids are open, the trunk opener unit cannot be locked using the transm itter and the turn signal lights blink ten tim es w hen the lock button is pushed. â&#x20AC;˘ If the trunk opener unit is unlocked using the transm itter but any of the lids is not opened w ithin 30 seconds, the trunk is locked autom atically.

TRANSMITTER REGISTRATION â&#x20AC;˘ The codes of up to three transm itters can be registered into the trunk lock control unit m em ory. (If a fourth code is stored, the code w hich w as registered first w ill be erased.) â&#x20AC;˘ M ake sure to keep the tim ing betw een 1 and 4 seconds for each action. Too fast or too slow w ill cause the control unit to lose the stored codes. 1. Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? Betw een 1 and 4 seconds, press the trunk opener button on the transm itter w hile aim ing transm itter at the trunk. Betw een 1 and 4 seconds, turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? 2. Betw een 1 and 4 seconds, turn the ignition sw itch back to â&#x20AC;&#x153; ON.â&#x20AC;? Betw een 1 and 4 seconds, press the trunk opener button on the transm itter w hile aim ing transm itter at the trunk. Betw een 1 and 4 seconds, turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? 3. Betw een 1 and 4 seconds, turn the ignition sw itch back to â&#x20AC;&#x153; ON.â&#x20AC;? Betw een 1 and 4 seconds, press the trunk opener button on the transm itter w hile aim ing transm itter at the trunk. Betw een 1 and 4 seconds, turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;? 4. Betw een 1 and 4 seconds, turn the ignition sw itch back to â&#x20AC;&#x153; ON.â&#x20AC;? Betw een 1 and 4 seconds, press the trunk opener button on the transm itter w hile aim ing transm itter at the trunk. Confirm that the turn signal lights blink tw ice. Leave the ignition sw itch â&#x20AC;&#x153; ON.â&#x20AC;? 5. Within 10 seconds, aim the transm itters (up to three) that you w ant to store codes in at the trunk and press the trunk opener button once on each transm itter. Confirm that the turn signal lights blink tw ice. Turn the ignition sw itch to â&#x20AC;&#x153; OFF.â&#x20AC;?

20-42

LIGHTS/METERS/SWITCHES 6. Confirm proper operation of each transm itter w ith the new codes.

TROUBLESHOOTING Power trunk lock system does not function with the transmitter 1. Check for w ater leakage into the transm itter. • If there is w ater leakage, replace transm itter. • If there is no w ater leakage, go to step 2.

the

2. Replace the battery (CR2025) w ith a new one and check if the system functions w ith the transm itter. • If the system functions properly, the transm itter is OK. • If the system does not function, go to step 3. 3. Rew rite the transm itter code (page 20-42) and check if the system functions w ith the transm itter. • If the system functions properly, the transm itter is OK. • If the system does not function, go to step 4. 4. Register the good know n transm itter and check that the system functions properly. • If the system functions properly, replace the transm itter. • If the system does not function, go to step 5. 5. Rem ove the trunk lid inner cover and disconnect the trunk lock control unit 18P w hite connector (page 20-46). Check for continuity between the Green w ire term inal and ground. There should be continuity at all tim es.

18P WHITE CONNECTOR (viewed from the terminal side)

• If there is continuity, go to step 6. • If there is no continuity, check for an open circuit in the Green w ire.

Green 6. M easure the voltage betw een the Red/yellow w ire term inal (+) and ground (–). There should be battery voltage at all tim es.

Red/yellow

• If there is battery voltage, replace the trunk lock control unit (page 20-46). • If there is no voltage, check the follow ing: – blow n No. 22 fuse. – open circuit in the Red/yellow w ire.

18P WHITE CONNECTOR (viewed from the terminal side)

20-43

LIGHTS/METERS/SWITCHES Trunk opener unit cannot be locked and unlocked with the transmitter 1. Rem ove the trunk lid inner cover and disconnect the trunk lock control unit 18P w hite connector (page 20-46). 2. Unlock the trunk opener unit w ith the ignition key. Connect a 12-V battery (+) term inal to the Yellow w ire term inal and (–) term inal to the Red w ire term inal m om entarily. The trunk opener unit should be locked. • If the trunk opener unit is locked, go to step 3. • If the trunk opener unit is not locked, check the follow ing: – lock/unlock actuator (page 20-47) – open circuit in the Red and Yellow w ires – loose or poor contact of related connectors

Red

Yellow

18P WHITE CONNECTOR (viewed from the terminal side)

3. Connect a 12-V battery (+) term inal to the Red w ire term inal and (–) term inal to the Yellow w ire term inal m om entarily. The trunk opener unit should be unlocked. • If the trunk opener unit is unlocked, replace the trunk opener unit (page 20-48). • If the trunk opener unit is not unlocked, replace the trunk lock control unit (page 20-46). Trunk opener unit can be unlocked but cannot be locked with the transmitter M ake sure all trunk and saddlebag lids are closed com pletely. 1. Rem ove the trunk lid inner cover and disconnect the trunk lock control unit 18P w hite connector (page 20-46). 2. Check for continuity betw een the Brow n/red w ire term inal and ground. There should be no continuity. • If there is no continuity, go to step 3. • If there is continuity, check the follow ing: – trunk and saddlebag open sw itches (pages 20-48 and 20-49) – short circuit in the Brow n/red, Red/w hite, White/red and Blue/red w ires betw een the trunk control unit and open sw itches 3. Unlock the trunk opener unit w ith the ignition key. Check for continuity betw een the White w ire term inal and ground. There should be no continuity. • If there is no continuity, replace the trunk lock control unit (page 20-46). • If there is continuity, check the follow ing: – lock/unlock sw itch (page 20-47) – short circuit in the White w ire

20-44

18P WHITE CONNECTOR (viewed from the terminal side)

Brown/red

White

LIGHTS/METERS/SWITCHES Trunk opener unit can be locked but cannot be unlocked with the transmitter 1. Rem ove the trunk lid inner cover and disconnect the trunk lock control unit 18P w hite connector (page 20-46). 2. Lock the trunk opener unit w ith the ignition key. Check for continuity betw een the Black w ire term inal and ground. There should be no continuity. • If there is no continuity, replace the trunk lock control unit (page 20-46). • If there is continuity, check the follow ing: – lock/unlock sw itch (page 20-47) – short circuit in the Black w ire

18P WHITE CONNECTOR (viewed from the terminal side)

Trunk opener unit can be locked with the transmitter although one of the lids is open

Black

• Faulty trunk or saddlebag open sw itch (pages 20-48 and 20-49) • Faulty open sw itch diode (page 20-49) • Open circuit in the Brow n/red, Red/w hite, White/ red and Blue/red w ires betw een the trunk control unit and open sw itches • Loose or poor contact of related connectors • Faulty trunk control unit Trunk opener unit can be locked and unlocked with the transmitter but the turn signal lights do not blink M ake sure that: – the turn signal/hazard system functions properly. – ignition sw itch is turned to “ OFF” or “ LOCK.” 1. Rem ove the trunk lid inner cover and disconnect the trunk lock control unit 18P w hite connector (page 20-46). 2. Rem ove the hazard sw itch diode (page 20-33). Check the Pink/w hite w ire for continuity betw een the trunk lock control unit and hazard sw itch diode. There should be continuity. • If there is continuity, check the hazard sw itch diode (page 20-33). If the diode is OK, replace the trunk lock control unit (page 20-46). • If there is no continuity, check for: – open circuit in the Pink/w hite w ire – loose or poor contact of related connectors

Pink/white

18P WHITE CONNECTOR (viewed from the terminal side)

20-45

LIGHTS/METERS/SWITCHES Horns do not sound when the “CALL” button is pushed M ake sure that: – the horns sound w hen the horn sw itch is pushed w ith the ignition sw itch is turned to “ ON” or “ ACC.” – the ignition sw itch is turned to “ OFF” or “ LOCK.” 1. Rem ove the trunk lid inner cover and disconnect the trunk lock control unit 18P w hite connector (page 20-46). 2. Ground the Pink w ire term inal w ith a jum per w ire. The horns should sound.

Pink

• If the horns sound, replace the trunk lock control unit (page 20-46). • If the horns do not sound, check the follow ing: – HORN (CALL) relay (page 20-16) – open circuit in the Pink, Red/yellow and Light green w ires Trunk lid cannot be opened with the transmitter • Ignition sw itch is turned to “ ON” or “ ACC” • Faulty trunk lid opener actuator (page 20-47) • Open circuit in the Blue w ire betw een the trunk control unit and opener actuator • Open circuit in the Green w ire betw een the opener actuator and ground term inal • Loose or poor contact in related connectors • Faulty trunk control unit

18P WHITE CONNECTOR (viewed from the terminal side)

Trunk and saddlebag lid open indicator does not function when one of the lids is open • Faulty trunk or saddlebag open sw itch (pages 20-48 and 20-49) • Open circuit in the follow ing w ires: – Brow n/red w ire (for the trunk lid) – White/red and Brow n/red w ires (for the right saddlebag) – Blue/red and Brow n/red w ires (for the left saddlebag)

TRUNK LOCK CONTROL UNIT REMOVAL/INSTALLATION Open the trunk lid. Rem ove the four screw s and tw o trunk strikers. Rem ove the 15 tapping screw s and trunk lid inner cover. Disconnect the 18P w hite connector from the trunk lock control unit. Rem ove the tw o screw s and control unit from the inner cover.

Install the trunk lock control unit in the reverse order of rem oval.

20-46

LIGHTS/METERS/SWITCHES TRUNK OPENER UNIT INSPECTION Rem ove the trunk low er cover (page 2-14).

Disconnect the trunk opener unit 8P connector.

LOCK/UNLOCK ACTUATOR Unlock the trunk opener unit w ith the ignition key. Connect a 12-V battery (+) term inal to the Yellow w ire term inal and (â&#x20AC;&#x201C;) term inal to the Red w ire term inal m om entarily. The trunk opener unit should be locked.

Connect a 12-V battery (+) term inal to the Red w ire term inal and (â&#x20AC;&#x201C;) term inal to the Yellow w ire term inal m om entarily. The trunk opener unit should be unlocked.

LOCK/UNLOCK SWITCH Check for continuity betw een the White and Green w ire term inals. There should be continuity w ith the opener unit locked, and no continuity w ith the unit unlocked.

Check for continuity betw een the Black and Green w ire term inals. There should be continuity w ith the opener unit unlocked, and no continuity w ith the unit locked.

TRUNK LID OPENER ACTUATOR Close the trunk lid. Connect a 12-V battery (+) term inal to the Blue w ire term inal and (â&#x20AC;&#x201C;) term inal to the Green w ire term inal m om entarily. The trunk lid should open (pop up).

20-47

LIGHTS/METERS/SWITCHES TRUNK OPEN SWITCH Check for continuity betw een the Brow n/red and Green w ire term inals. There should be continuity w ith the trunk lid open and no continuity w ith the lid closed.

TRUNK OPENER UNIT REMOVAL/ INSTALLATION Rem ove the trunk low er cover (page 2-14).

Rem ove the trunk and saddlebag opener rods from the snap joints of the opener unit.

Rem ove the tw o bolts and the trunk/saddlebag lid opener lever assem bly.

Disconnect the trunk opener unit 8P connector.

Rem ove the three screw s and the trunk opener unit from the trunk.

5+4-95

20-48

LIGHTS/METERS/SWITCHES Rem ove the retainer plate and lock cylinder from the trunk opener unit.

LOCK CYLINDER

Installation is in the reverse order of rem oval.

RETAINER PLATE

SADDLEBAG OPEN SWITCH INSPECTION Rem ove rear fender A (page 2-13). Disconnect the saddlebag sub-w ire harness 2P and 3P connectors (left: red connectors, right: blue connectors).

Check for continuity betw een the Brow n/red and Green w ire term inals of the saddlebag side connectors. There should be continuity w ith the saddlebag lid open, and no continuity w ith the lid closed.

OPEN SWITCH DIODE INSPECTION Rem ove the seat (page 2-5). Rem ove the trunk/saddlebag open sw itch diode from the w ire harness. Check for continuity betw een the diode term inals. When there is continuity, a sm all resistance value w ill register.

DIODE (+)

If there is continuity in one direction, the diode is norm al.

( )

20-49

MEMO

21. CRUISE CONTROL SYSTEM

SYSTEM LOCATION···································· 21-2

IGNITION CRUISE RELAY··························21-11

SERVICE INFORMATION ···························· 21-3

CRUISE CONTROL SWITCH ······················21-13

TROUBLESHOOTING ·································· 21-4

CRUISE CANCEL SWITCH ·························21-14

CRUISE/REVERSE CONTROL MODULE ······················································ 21-9

CRUISE ACTUATOR···································21-16

21-1

CRUISE CONTROL SYSTEM

SYSTEM LOCATION CRUISE CONTROL SYSTEM

21-2

CRUISE CONTROL SYSTEM

SERVICE INFORMATION GENERAL • The cruise control can be set w hen the m otorcycle is running betw een 30 and 100 m ph (48 and 160 km /h) w ith the transm ission in 4th or overdrive. • The electric cruise actuator is used to control the throttle valve in this cruise control system . • The cruise control m odule is integrated w ith the reverse control m odule. • When checking the cruise control system , alw ays follow the steps in the troubleshooting flow chart (page 21-4).

SPECIFICATIONS Cruise actuator coil resistance (20° C/68° F)

ITEM Clutch coil Step m otor coil

STANDARD 35 – 45 Ω 3–7Ω

SERVICE LIMIT – –

21-3

CRUISE CONTROL SYSTEM

TROUBLESHOOTING Cruise â&#x20AC;&#x153;ONâ&#x20AC;? indicator does not come on when the cruise main switch is pushed to â&#x20AC;&#x153;ONâ&#x20AC;? 1. Fuse Inspection â&#x20AC;˘ The cruise â&#x20AC;&#x153; ONâ&#x20AC;? indicator should com e on w hen the cruise m ain sw itch is pushed to â&#x20AC;&#x153; ONâ&#x20AC;? w ith the ignition sw itch turned to â&#x20AC;&#x153; ONâ&#x20AC;? and the engine stop sw itch to â&#x20AC;&#x153; â&#x20AC;? . â&#x20AC;˘ M ake sure the reverse system functions properly. Check for blow n No. 19 fuse. Is fuse No. 19 blown? YES

â&#x20AC;&#x201C; Replace the fuse w ith a new one and turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? If the fuse blow s again, check for a short circuit in the related w ires.

â&#x20AC;&#x201C; GO TO STEP 2.

2. Cruise Power Input Line Check the cruise pow er input (No. 14) line at the cruise/reverse control m odule (page 21-9). Does the cruise power input (No. 14) line function as specified? NO

â&#x20AC;&#x201C; â&#x20AC;˘ Faulty ignition cruise relay or its circuits (page 21-11). â&#x20AC;˘ Open circuit in the Black/yellow w ire betw een the cruise/reverse control m odule and ignition cruise relay.

YES

â&#x20AC;&#x201C; GO TO STEP 3.

3. Cruise â&#x20AC;&#x153;ONâ&#x20AC;? Indicator Line Check the cruise â&#x20AC;&#x153; ONâ&#x20AC;? indicator (No. 13) line at the cruise/reverse control m odule (page 21-9). Does the cruise â&#x20AC;&#x153;ONâ&#x20AC;? indicator (No. 13) line function as specified? NO

â&#x20AC;&#x201C; GO TO STEP 7.

YES

â&#x20AC;&#x201C; GO TO STEP 4.

4. Cruise Main Switch Line Check the cruise m ain sw itch (No. 9) line at the cruise/reverse control m odule (page 21-9). Does the cruise main switch (No. 9) line function as specified? YES

â&#x20AC;&#x201C; Faulty cruise/reverse control m odule.

â&#x20AC;&#x201C; GO TO STEP 5.

5. Cruise Main Switch Check the cruise m ain sw itch (page 21-13). Does the cruise main switch function? NO

â&#x20AC;&#x201C; Faulty cruise m ain sw itch; replace the right handlebar sw itch.

YES

â&#x20AC;&#x201C; GO TO STEP 6.

6. Right Handlebar Wiring Harness Voltage Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? w ith the engine stop sw itch to â&#x20AC;&#x153; .â&#x20AC;? M easure the voltage betw een the Black/yellow w ire term inal (+) of the w ire harness side right handlebar sw itch connector and ground (â&#x20AC;&#x201C;).

Is there battery voltage?

21-4

â&#x20AC;&#x201C; Open circuit in the Black/yellow w ire betw een ignition cruise relay and right handlebar sw itch.

YES

â&#x20AC;&#x201C; â&#x20AC;˘ Open circuit in the Black/yellow w ire betw een the cruise/reverse control m odule and right handlebar sw itch. â&#x20AC;˘ Loose or poor contact of the related connectors.

! " # $

CRUISE CONTROL SYSTEM 7. Combination Meter and Cruise/Reverse Module Rem ove the com bination m eter (page 20-17). Check the Blue-orange w ire for continuity betw een the m eter 20P blue connector and cruise/reverse control m odule 26P black connector.

!"# $ % & '( ' &# )#$ *

Is there continuity? NO

â&#x20AC;&#x201C; â&#x20AC;˘ Open circuit in the Blue/orange w ire. â&#x20AC;˘ Loose or poor contact of the related connectors.

YES

â&#x20AC;&#x201C; GO TO STEP 8.

8. Combination Meter Voltage Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Black/yellow w ire term inal (+) of the m eter 20P blue connector and ground. Is there battery voltage? NO

â&#x20AC;&#x201C; Open circuit in the Black/yellow w ire betw een the com bination m eter and ignition cruise relay.

YES

â&#x20AC;&#x201C; Faulty m eter/gauge assem bly; replace it (page 20-19).

Cruise â&#x20AC;&#x153;ONâ&#x20AC;? indicator blinks when the cruise main switch is pushed to â&#x20AC;&#x153;ONâ&#x20AC;? 1. Relay Coil Line â&#x20AC;˘ If the cruise actuator relay is faulty, the system w ill enter the fail-safe m ode, and the cruise â&#x20AC;&#x153; ONâ&#x20AC;? indicator w ill blink w hen the cruise m ain sw itch is pushed to â&#x20AC;&#x153; ONâ&#x20AC;? w ith the ignition sw itch turned to â&#x20AC;&#x153; ON and the engine stop sw itch to â&#x20AC;&#x153; .â&#x20AC;&#x153; Check the cruise actuator relay coil (No. 50) line at the cruise/reverse control m odule. Does the relay coil (No. 50) line function as specified? NO

â&#x20AC;&#x201C; â&#x20AC;˘ Faulty cruise actuator relay (page 21-16). â&#x20AC;˘ Open circuit in the Black/yellow w ire betw een the ignition cruise and actuator relays. â&#x20AC;˘ Open or short circuit in the Green/black w ire betw een the cruise/reverse control m odule and cruise actuator relay.

YES

â&#x20AC;&#x201C; GO TO STEP 2.

2. Cruise Actuator Relay Signal Line Check the cruise actuator relay signal (No. 32) line at the cruise/reverse control m odule (page 21-9). Does the cruise actuator relay signal (No. 32) line function as specified? NO

â&#x20AC;&#x201C; â&#x20AC;˘ Faulty cruise actuator relay (page 20-16). â&#x20AC;˘ Open circuit in the Black/yellow w ire betw een the ignition cruise and actuator relays. â&#x20AC;˘ Open circuit in the Brow n/w hite w ire betw een the cruise/reverse control m odule and cruise actuator relay.

YES

â&#x20AC;&#x201C; Faulty cruise/reverse control m odule.

21-5

CRUISE CONTROL SYSTEM Cruise “SET” indicator starts blinking when the vehicle speed reaches above 25km/h (16 mph) with the main switch pushed to “ON” 1. Cruise Actuator Clutch Line • The control m odule self-diagnoses the actuator clutch w hen the vehicle speed reaches above 25 km /h (16 m ph) w ith the cruise m ain sw itch pushed to “ ON,” and the system w ill enter fail-safe m ode if the actuator clutch is faulty. Check the cruise actuator clutch (No. 30) line at the cruise/reverse control m odule (page 21-9). Does cruise actuator clutch (No. 30) line function as specified? NO

– • Faulty cruise actuator clutch (page 21-16). • Open or short circuit in the Brow n/black w ire betw een the cruise/reverse control m odule and cruise actuator. • Open circuit in the Green w ire betw een the cruise actuator and ground term inal.

YES

– Faulty cruise/reverse control m odule.

Cruise control cannot be set 1. Gear Position Switch Line Check the follow ing before proceeding: • The cruise “ ON” indicator com es on w hen the cruise m ain sw itch is pushed to “ ON.” • The cruise actuator cable is adjusted properly (page 21-17). • The speedom eter and tachom eter operate properly. Check the gear position (overdrive) sw itch (No. 2) line at the cruise/reverse control m odule (page 21-9). Does gear position switch (No. 2) line function as specified? NO

– • Faulty gear position sw itch (page 20-38). • Open circuit in the Green/orange w ire betw een the cruise/reverse control m odule and gear position sw itch.

YES

– GO TO STEP 2.

2. Gear Position (4th) Switch Line Check the gear position (4th) sw itch (No. 3) line at the cruise/reverse control m odule (page 21-9). Does gear position (4th) switch (No. 3) line function as specified? NO

– • Faulty gear position sw itch. • Open circuit in the Red/w hite w ire betw een the cruise/reverse control m odule and gear position sw itch.

YES

– GO TO STEP 3.

3. Clutch Cruise Cancel Switch Line Check the clutch cruise cancel sw itch (No. 4) line at the cruise/reverse control m odule. Does the clutch cruise cancel switch (No. 4) line function as specified? YES

– Faulty clutch cruise cancel sw itch (page 21-14).

– GO TO STEP 4.

4. “SET/DECEL” Switch Line Check the cruise “ SET/DECEL” sw itch (No. 6) line at the cruise/reverse control m odule (page 21-9). Does the “SET/DECEL” switch (No. 6) line function as specified? NO

– • Faulty cruise “ SET/DECEL” sw itch (page 21-13). • Open circuit in the White/yellow w ire betw een the cruise/reverse control m odule and right handlebar sw itch.

YES

– GO TO STEP 5.

5. Speed Sensor Line Check the speed sensor (No. 7) line at the cruise/reverse control m odule (page 21-9). Does the speed sensor (No. 7) line function as specified?

21-6

– • Open circuit in the White/black w ire betw een the cruise/reverse control m odule and speed sensor.

YES

– GO TO STEP 6.

CRUISE CONTROL SYSTEM 6. Engine Speed Pulse Line Check the engine speed pulse (No. 21) line at the cruise/reverse control m odule (page 21-9). Does the engine speed pulse (No. 21) line function as specified? NO

– Open circuit in the Yellow /green w ire betw een the cruise/reverse m odule and engine control m odule (ECM ).

YES

– GO TO STEP 7.

7. Cruise Actuator Clutch Line Check the cruise actuator clutch (No. 30) line at the cruise/reverse control m odule (page 21-9). Does the cruise actuator clutch (No. 30) line function as specified? NO

YES

– GO TO STEP 8.

8. Cruise Cancel Switch Line Check the cruise cancel sw itch (No. 31) line at the cruise/reverse control m odule (page 21-9). Does the cancel switch (No. 31) line function as specified? NO

– GO TO STEP 13.

YES

– GO TO STEP 9.

9. Brake Light Line Check the brake light (No. 35) line at the cruise/reverse control m odule (page 21-9). Does the brake light (No. 35) line unction as specified? NO

– Faulty brake light system .

YES

– GO TO STEP 10.

10. Cruise Actuator Motor A Line Check the cruise actuator m otor A (No. 33) line at the cruise/reverse control m odule (page 21-9). Does the cruise actuator motor A (No. 33) line function as specified? NO

– • Faulty cruise actuator m otor (page 21-16). • Open circuit in the Blue w ire betw een the cruise/reverse control m odule and cruise actuator. • Open circuit in the Brow n/w hite w ire betw een the cruise/reverse control m odule and cruise actuator.

YES

– GO TO STEP 11.

11. Cruise Actuator Motor B Line Check the cruise actuator m otor B (No. 39) line at the cruise/reverse control m odule (page 21-9). Does the cruise actuator motor B (No. 39) line function as specified? NO

– • Faulty cruise actuator m otor (page 21-16). • Open circuit in the Yellow w ire betw een the cruise/reverse control m odule and cruise actuator.

YES

– GO TO STEP 12.

12. Cruise Actuator Motor C Line Check the cruise actuator m otor C (No. 45) line at the cruise/reverse control m odule (page 21-9). Does the cruise actuator motor C (No. 45) line function as specified? NO

– • Faulty cruise actuator m otor (page 21-16). • Open circuit in the Light green w ire betw een the cruise/reverse control m odule and cruise actuator.

YES

– Faulty cruise/reverse control m odule.

21-7

CRUISE CONTROL SYSTEM 13. Front Brake Cruise Cancel Switch Check the front brake cruise cancel sw itch (page 21-14). Does the front brake cruise cancel switch function? NO

– • Faulty front brake cruise cancel sw itch. • Open circuit in the Black/yellow w ire.

YES

– GO TO STEP 14.

14. Throttle Grip Cruise Cancel Switch Check the throttle grip cruise cancel sw itch (page 21-14). Does the throttle grip cruise cancel switch function? NO

– • Faulty throttle grip cruise cancel sw itch. • Open circuit in the Green/w hite w ire betw een the front brake cruise cancel sw itch and throttle grip cruise cancel sw itch.

YES

– GO TO STEP 15.

15. Rear Brake Cruise Cancel Switch Check the rear brake cruise cancel sw itch (page 21-16). Does the rear brake cruise cancel switch function? NO

– • Faulty rear brake cruise cancel sw itch. • Open circuit in the Green/w hite w ire betw een the throttle grip cruise cancel sw itch and rear brake cruise cancel sw itch.

YES

– Open circuit in the Brow n/red w ire betw een the cruise/reverse control m odule and rear brake cruise cancel sw itch.

Cruise control cannot be cancelled 1. Clutch Cruise Cancel Switch Line • M ake sure that the brake lights operate properly. Check the clutch cruise cancel sw itch (No. 4) line at the cruise/reverse control m odule (page 21-9). Does the clutch cruise cancel switch (No. 4) line function as specified? NO

– • Faulty clutch cruise cancel sw itch (page 21-14). • Open circuit in the Green/blue w ire betw een the cruise/reverse control m odule and clutch cruise cancel sw itch. • Open circuit in the Black/yellow w ire betw een the clutch cruise cancel sw itch and cruise m ain sw itch.

YES

– GO TO STEP 2.

2. Cruise Cancel Switch Line Check the cruise cancel sw itch (No.31) line at the cruise/reverse control m odule (page 21-9). Does the cruise cancel switch (No. 31) line function as specified? NO

– • Faulty front brake cruise cancel sw itch (page 21-14). • Faulty throttle grip cruise cancel sw itch (page 21-14). • Faulty rear brake cruise cancel sw itch (page 21-16).

YES

– GO TO STEP 3.

3. Brake Light Line Check the brake light (No. 35) line at the cruise/reverse control m odule (page 21-9). Does the brake light (No. 35) line function as specified?

21-8

– Open circuit in the Green/red w ire betw een the cruise/reverse control m odule and stop light relay.

YES

– Faulty cruise/reverse control m odule.

CRUISE CONTROL SYSTEM Cruise control cannot be resumed 1. Cruise RESUME/ACCEL Switch Line • The cruise control system is turned off (m em ory is erased) w hen both the “ SET/DECEL” sw itch and “ RESUM E/ACCEL” sw itch are pushed sim ultaneously. Check the cruise “ RESUM E/ACCEL” sw itch (No. 5) line at the cruise/reverse control m odule (page 21-9). Does the cruise “RESUME/ACCEL” switch (No. 5) line function as specified? NO

– • Faulty cruise “ RESUM E/ACCEL sw itch (page 21-13). • Open circuit in the White/blue w ire betw een the cruise/reverse control m odule and right handlebar sw itch.

YES

– Faulty cruise/reverse control m odule.

Cruise control cannot be set but the cruise “SET” indicator does not come on 1. Cruise “SET” Switch Line Check the cruise “ SET” indicator (No. 26) line at the cruise/reverse control m odule (page 21-9). Does the cruise “SET” indicator (No. 26) line function as specified? NO

– Faulty cruise/reverse control m odule.

YES

– GO TO STEP 2.

2. Combination Meter and Cruise/Reverse Control Module Rem ove the com bination m eter (page 20-17). Check the Blue/w hite w ire for continuity betw een the m eter 20P blue connector and cruise/reverse control m odule 26P black connector. Is there continuity? NO

– • Open circuit in the Blue/w hite w ire. • Loose or poor contact of the related connectors.

YES

– Faulty m eter/gauge assem bly; replace it (page 20-19).

CRUISE/REVERSE CONTROL MODULE SYSTEM INSPECTION Rem ove the top shelter (page 2-11). Turn the ignition sw itch “ OFF” and disconnect 26P black and gray connectors from the cruise/reverse control m odule.

Be sure that the engine stop sw itch is turned to “

.”

Check the cruise control system circuits at the w ire harness side connector term inals by follow ing the chart on the next page.

7 6 5 4 3 2 1 9 8 13 12 11 14 19 18 17 26 25 24 23 21 20

33 32 31 30 29 28 27 39 37 35 34 40 45 43 52 49 48 47 46

26P BLACK

26P GRAY

WIRE HARNESS SIDE CRUISE/REVERSE CONTROL MODULE CONNECTORS (viewed from the terminal side)

21-9

CRUISE CONTROL SYSTEM Terminal No. & Circuit 2 Gear position sw itch (Overdrive)

Wire Color & Connection Green/orange and ground

Gear position sw itch (4th)

Red/w hite and ground

Clutch cruise cancel sw itch

Green/blue (+) and ground (–)

“ RESUM E/ ACCEL” sw itch

“ SET/DECEL” sw itch

Speed sensor

Cruise m ain sw itch CRUISE ON indicator Cruise pow er input Ground Engine speed pulse CRUISE SET indicator Cruise actuator clutch

13 14 20 21 26 30

Cruise cancel sw itch

White/blue (+) and ground (–)

White/yellow (+) and ground (–)

White/black (+) and ground (–) Black/yellow (+) and ground (–) Blue/orange Black/yellow (+) and ground (–) Green and ground Yellow /green (+) and ground (–) Blue/w hite Brow n/black and ground Brow n/red (+) and ground (–)

Cruise actuator relay output

Brow n/w hite (+) and ground (–)

Cruise actuator m otor A

Blue and No. 32 Brow n/w hite

21-10

Conditions Transm ission shifted into the overdrive gear Transm ission shifted into any gear except overdrive gear Transm ission shifted into 4th gear Transm ission shifted into any gear except 4th gear Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” Clutch lever squeezed Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” Clutch lever free Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” “ RESUM E/ACCEL” sw itch pushed Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” “ RESUM E/ACCEL” sw itch free Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” “ SET/DECEL” sw itch pushed Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” “ SET/DECEL” sw itch free Ignition sw itch turned to “ ON” Rear w heel turned slow ly Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” Ground w ire w ith a jum per w ire and turn the ignition sw itch to “ ON.” Ignition sw itch turned to “ ON” – Crank the engine w ith the starter m otor. Ground it w ith a jum per w ire and turn the ignition sw itch to “ ON.” – Connect the 12-V battery (+) to Brow n/ black and (–) to ground. Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” Brake lever and pedal free Ignition sw itch turned to “ ON” Cruise m ain sw itch turned to “ ON” Brake lever squeezed or brake pedal depressed Ignition sw itch turned to “ ON” Ground the No. 50 Green/black w ith a jum per w ire and turn ignition sw itch to “ ON.” –

Specification There should be continuity. There should continuity. There should There should continuity. There should voltage.

be no be continuity. be no be battery

There should be no voltage. There should be battery voltage. There should be no voltage. There should be battery voltage. There should be no voltage. 0 to 5 V pulse voltage should appear. There should be battery voltage. CRUISE ON indicator should com e on. There should be battery voltage. There should be continuity. * There should be 10.5 V or m ore. CRUISE SET indicator should com e on. There should be 35 – 45Ω. Actuator clutch should click. There should be battery voltage. There should be no voltage.

There should be no voltage. There should be battery voltage. There should be 3 – 7Ω.

CRUISE CONTROL SYSTEM Terminal No. & Circuit 35 Brake light

Wire Color & Connection Green/red (+) and ground (–)

Conditions Ignition sw itch turned to “ ON” Brake lever and pedal free Ignition sw itch turned to “ ON” Brake lever squeezed or brake pedal depressed –

Specification There should be no voltage. There should be battery voltage.

There should be 3 – 7Ω. Cruise actuaYellow and No. 32 Brow n/w hite tor m otor B 45 Cruise actuaLight green and No. – There should be 3 – 7Ω. tor m otor C 32 Brow n/w hite 50 Cruise actuaGreen/black (+) and Ignition sw itch turned to “ ON” There should be battery tor relay coil ground (–) voltage. 52 Ground Green and ground – There should be continuity. * M easure the voltage using the peak voltage tester (U.S.A. only) or peak voltage adaptor (07HGJ-0020100/not available in U.S.A.) w ith com m ercially available digital m ultim eter (im pedance 10 M Ω/DCV m inim um ). 39

IGNITION CRUISE RELAY INSPECTION Rem ove the seat (page 2-5).

Rem ove the tw o screw s and rem ove the relay box. Rem ove the relay blocks from the relay box.

1. Turn the ignition sw itch to “ OFF” and rem ove the ignition cruise relay and cruise actuator relay.

2. Check the Black/yellow w ire for continuity betw een the ignition cruise relay and cruise actuator relay. There should be continuity.

21-11

CRUISE CONTROL SYSTEM 3. Exchange the ignition cruise relay w ith the a know n-good one. Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;?

M easure the voltage betw een the Black/yellow w ire term inal (+) of the cruise actuator relay connector and ground (â&#x20AC;&#x201C;). There should be battery voltage. â&#x20AC;˘ If there is battery voltage, replace the ignition cruise relay w ith a new one. â&#x20AC;˘ If there is no voltage, go to step 4.

4. Turn the ignition sw itch to â&#x20AC;&#x153; OFFâ&#x20AC;? and rem ove the ignition cruise relay. Check for continuity betw een the Green w ire term inal of the relay connector and ground.

There should be continuity. â&#x20AC;˘ If there is continuity, go to step 5. â&#x20AC;˘ If there is no continuity, repair the open circuit in the green w ire.

5. M easure the voltage betw een the Yellow w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

â&#x20AC;˘ If there is battery voltage, go to step 6. â&#x20AC;˘ If there is no voltage, check for an open circuit in the Yellow w ire betw een the ignition cruise relay and fuse box (No. 19 fuse).

6. Turn the ignition sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Black/yellow w ire term inal (+) of the relay connector and ground (â&#x20AC;&#x201C;).

There should be battery voltage. â&#x20AC;˘ If there is battery voltage, the system is OK; check for loose contacts or corroded term inals. â&#x20AC;˘ If there is no voltage, check for an open circuit in the Black/yellow w ire betw een the ignition cruise relay and the PGM -FI ignition relay.

21-12

CRUISE CONTROL SYSTEM

CRUISE CONTROL SWITCH Rem ove the front fairing (page 2-10).

18P CONNECTOR

Disconnect the right handlebar sw itch 18P green (After â&#x20AC;&#x2DC;03: blue) connector. Check for continuity betw een the connector term inals in each sw itch position. Continuity should exist betw een the color coded w ires as show n in the charts below .

CRUISE MAIN SWITCH

SET/DECEL SWITCH

Color White/yellow Black/yellow Position FREE PUSH

RESUME/ACCEL SWITCH

Color Position FREE PUSH

White/blue Black/yellow $% ! "#$% $& '

21-13

CRUISE CONTROL SYSTEM

CRUISE CANCEL SWITCH CLUTCH • The low er sw itch is the clutch cruise cancel sw itch. Disconnect the clutch sw itch w ire connectors and check for continuity betw een the sw itch term inals. There should be continuity w ith the clutch lever squeezed and no continuity w ith the lever released. Turn the ignition sw itch to “ ON” and push the cruise m ain sw itch to “ ON.” M easure the voltage betw een the Black/yellow w ire term inal (+) and ground (–). There should be battery voltage.

FRONT BRAKE • The low er (large) term inals are the cruise cancel sw itch term inals. Disconnect the front brake sw itch connectors and check for continuity betw een the sw itch term inals. There should be no continuity w ith the front brake lever squeezed and continuity w ith the lever released. Turn the ignition sw itch to “ ON” and push the cruise m ain sw itch to “ ON.” M easure the voltage betw een the Black/blue w ire term inal (+) and ground (–). There should be battery voltage.

THROTTLE GRIP Rem ove the air cleaner housing (page 5-57). Disconnect the throttle grip cruise cancel sw itch 2P blue connector. Check for continuity betw een the sw itch side connector term inals. There should be continuity w ith the throttle grip in any position. Turn the throttle grip to open the throttle, hold the throttle drum then close the throttle grip. There should be no continuity. Turn the ignition sw itch to “ ON” and push the cruise m ain sw itch to “ ON.” M easure the voltage betw een the Green/w hite w ire w ithout the brow n tube term inal (+) of the w ire harness side connector and ground (–). There should be battery voltage.

21-14

2P BLUE CONNECTOR

CRUISE CONTROL SYSTEM SWITCH REPLACEMENT Disconnect the throttle grip cruise cancel sw itch 2P blue connector.

2P BLUE CONNECTOR

Rem ove the return side throttle cable from the cable stay and disconnect it from the throttle drum . Rem ove the left radiator (page 6-10).

RETURN SIDE THROTTLE CABLE Rem ove the tw o bolts and proportional control valve (PCV) from the stay. Rem ove the stay m ounting bolt.

STAY

PCV Rem ove the tw o socket bolts and stay from the cancel sw itch.

Rem ove the center bolt and sw itch cover.

21-15

CRUISE CONTROL SYSTEM

Disconnect the throttle cables from the sw itch drum s and rem ove them from the sw itch housing. Apply grease to the sliding portions of the switch.

Install a new throttle grip cruise cancel sw itch and rem oved parts in the reverse order of rem oval. TORQUE: PCV mounting bolt: 12 NÂˇm (1.2 kgfÂˇm, 9 lbfÂˇft) After installation check the throttle grip free play and adjust as necessary (page 3-5).

REAR BRAKE Rem ove the top shelter (page 2-11).

2P RED CONNECTOR

Disconnect the rear brake cruise cancel sw itch 2P red connector and check for continuity betw een the sw itch side connector term inals. There should be no continuity w ith the rear brake pedal depressed and continuity w ith the pedal released. Turn the ignition sw itch to â&#x20AC;&#x153; ONâ&#x20AC;? and push the cruise m ain sw itch to â&#x20AC;&#x153; ON.â&#x20AC;? M easure the voltage betw een the Green/w hite w ire term inal (+) of the w ire harness side connector and ground (â&#x20AC;&#x201C;). There should be battery voltage.

CRUISE ACTUATOR INSPECTION Rem ove the top shelter (page 2-11). Disconnect the cruise actuator 6P black connector. Check the connector for loose contacts or corroded term inals.

6P BLACK CONNECTOR ACTUATOR CLUTCH Connect a 12-V battery (+) term inal to the No. 6 term inal of the actuator connector and battery (â&#x20AC;&#x201C;) term inal to the No. 3 term inal.

The actuator clutch should click. ACTUATOR MOTOR M easure the m otor coil resistances betw een the No. 1 and No. 2 term inals, the No. 1 and No. 4 term inals, and the No. 1 and No. 5 term inals. STANDARD: 3 â&#x20AC;&#x201C; 5â&#x201E;Ś

21-16

CRUISE CONTROL SYSTEM REPLACEMENT

Rem ove the air cleaner housing (page 5-57). Rem ove the cruise actuator cable from the cable stay, and disconnect it from the actuator drum .

Rem ove the three tapping screw s and the cruise actuator unit from the control unit holder. Install a new cruise actuator unit onto the control unit holder and tighten the three tapping screw s.

Connect the cruise actuator cable to the actuator drum and install it onto the cable stay. Adjust the cable position w ith the nuts so that the distance betw een the cable cap screw end and stay is 34 m m (1.34 in) as show n.

Install the air cleaner housing (page 5-57).

ACTUATOR CABLE ADJUSTMENT

Rem ove the top shelter (page 2-11). Check that the projection of the actuator drum aligns w ith the groove of the throttle drum by looking through the hole as show n w ith a light.

21-17

CRUISE CONTROL SYSTEM Loosen the lock nut and adjust the cruise actuator cable by turning the adjusting nut as required.

Install the top shelter (page 2-11).

21-18

22. AUDIO SYSTEM

SYSTEM LOCATION···································· 22-2

AUDIO SWITCH ············································22-9

SERVICE INFORMATION ···························· 22-3

ANTENNA ···················································22-11

TROUBLESHOOTING ·································· 22-4

SPEAKER·····················································22-12

AUDIO UNIT················································· 22-6

HEADSET JUNCTION WIRE ······················22-12

22-1

AUDIO SYSTEM

SYSTEM LOCATION AUDIO SYSTEM

22-2

AUDIO SYSTEM

SERVICE INFORMATION GENERAL • • • •

When checking the audio system , alw ays follow the steps in the troubleshooting flow chart (page 22-4). All m em orized radio channels are erased w hen the battery cable is disconnected. The AM frequency m oves in sequence in 10 kHz steps. The FM frequency m oves in sequence in 0.2 M Hz steps. The “ am bience” (AM B) circuit blends and boosts certain frequencies from both channels for a “ live perform ance” effect. AM B m ay be used for stereo program s from the FM radio. How ever, the am bience circuit m ay m ake w eak FM stereo signals sound w orse.

TORQUE VALUE Antenna base m ounting bolt

14 N·m (1.4 kgf·m , 10 lbf·ft)

22-3

AUDIO SYSTEM

TROUBLESHOOTING • Check the radio reception by tuning to a station know n to have a strong signal. • Check that the follow ing fuses are good: – No. 21 fuse (15 A) – No. 22 fuse (20 A) • Check that the m ulti-display indication function operates properly. No sound from speakers 1. Audio Unit Connections Inspection • Select the speaker w ith the “ AUDIO” button w hen the audio system output is headset. Rem ove the top shelter (page 2-12). Check the audio unit 34P black and gray connectors for loose or poor contact. Do all wires make good contact? NO

– Correct the faulty part.

YES

– GO TO STEP 2.

2. Audio Back-up Line Inspection Check the audio back-up line (page 22-6). Is battery voltage present? NO

– Open circuit in the Red/yellow w ire betw een the audio unit and fuse.

YES

– GO TO STEP 3.

3. Accessory Power Line Inspection Check the accessory pow er line (page 22-6). Is battery voltage present? NO

– Open circuit in the Light green/black w ire betw een the audio unit and relay.

YES

– GO TO STEP 4.

4. Audio Ground Line Inspection Check the ground line (page 22-6). Is there continuity? NO

– Open circuit in the Green w ire betw een the audio unit and ground term inal.

YES

– GO TO STEP 5.

5. Speaker Output Voltage Inspection M easure the speaker output voltage (page 22-6). Is voltage present?

22-4

– • Open or short circuit in the w ire betw een the audio unit and speaker. • Faulty audio unit.

YES

– Faulty speaker(s).

AUDIO SYSTEM Radio works, but audio switch does not function 1. Audio Switch Inspection Check the audio sw itch that does not function (page 22-9). Does the switch test OK? NO

– Faulty audio sw itch.

YES

– GO TO STEP 2.

2. Audio Switch Line Inspection Check the related audio sw itch lines (page 22-7). Is continuity correct? NO

– Open or short circuit in w ire betw een the audio sw itch and audio unit.

YES

– • Loose or poor related connection. • Faulty audio unit.

Weak or noisy reception 1. Antenna Connection Inspection • Use of the am bience (AM B) circuit m ay cause w eak FM signals. • As FM stereo reception becom es w eaker, special circuits in the radio gradually blend the sound tow ard m onaural to m aintain som e sound quality, even though the “ STEREO” indication rem ains on. Rem ove the seat (page 2-5). Check for loose or poor antenna connection. Are all antenna connections good? NO

– Correct the faulty part.

YES

– GO TO STEP 2.

2. Antenna Base Inspection Check the antenna base (page 22-11). Is continuity correct? NO

– Faulty antenna base.

YES

– • Loose or poor related connection. • Faulty condenser in the alternator or cooling fan m otor. • Faulty audio unit.

AVC (Auto Volume Control) does not work at all 1. Speedometer Inspection Check that the speedom eter operates properly. Is the speedometer operating properly? NO

– Check the speedom eter (page 20-20).

YES

– GO TO STEP 2.

2. Speed Pulse Signal Line Inspection Check the speed pulse signal line (page 22-8). Is the voltage within the specified voltage? NO

– Open or short circuit in White/black w ire betw een the com bination m eter and audio unit.

YES

– • Loose or poor related connection. • Faulty audio unit.

Radio works, but audio display does not appear 1. Audio Display Signal Line Inspection Check the audio display signal lines (page 22-7). Is continuity correct? NO

– Open or short circuit in the w ire betw een the com bination m eter and audio unit.

YES

– • Loose or poor related connection. • Faulty audio unit.

22-5

AUDIO SYSTEM

AUDIO UNIT POWER/GROUND LINE INSPECTION Rem ove the top shelter (page 2-12). Check the follow ing at the audio unit 34P black connector term inals. BACK-UP LINE M easure the voltage betw een the Red/yellow w ire term inal (+) and ground (–). There should be battery voltage at all tim es. ACCESSORY POWER LINE M easure the voltage betw een the Light green/black w ire term inal (+) and ground (–). There should be battery voltage w ith the ignition sw itch turned to “ ON” or “ ACC.” GROUND LINE Check for continuity betw een the Green w ire term inal and ground. There should be continuity at all tim es.

SPEAKER OUTPUT VOLTAGE INSPECTION Rem ove the speakers (page 22-12). Select the AC range on the tester. The voltage should increase or decrease in accordance with the volume.

M easure the voltage betw een the connector term inals at each speaker. CONNECTIONS: LEFT SPEAKER: Blue/green (+) – Gray/black (–) RIGHT SPEAKER: Red/green (+) – Brown/black (–) There should be voltage w ith the radio turned on.

22-6

SPEAKER CONNECTORS

AUDIO SYSTEM MAIN WIRE HARNESS INSPECTION Rem ove the top shelter (page 2-12). AUDIO SWITCH LINES Rem ove the front fairing (page 2-10). Disconnect the left handlebar sw itch connectors. â&#x20AC;&#x2DC;01 â&#x20AC;&#x201C; â&#x20AC;&#x2DC;03: â&#x20AC;&#x201C; 14P blue â&#x20AC;&#x201C; 12P green After â&#x20AC;&#x2DC;03: â&#x20AC;&#x201C; 14P gray â&#x20AC;&#x201C; 12P blue

12P CONNECTOR

14P CONNECTOR Check for continuity betw een the audio unit 34P and handlebar (audio) sw itch connectors as show n. There should be continuity betw een the sam e color w ire term inals.

34P (black):

34P (gray):

Also, check for a short circuit betw een each connector term inal and ground. There should be no continuity. 34P (black) â&#x20AC;&#x201C; 14P No. 11: Orange No. 12: White No. 19: Green No. 20: Brow n No. 21: Black No. 28: Red No. 29: Yellow

â&#x20AC;&#x2DC;01 â&#x20AC;&#x201C; â&#x20AC;&#x2DC;03: 10

12 11

14P: 28

â&#x20AC;&#x2DC;01 â&#x20AC;&#x201C; â&#x20AC;&#x2DC;03: 34P (gray) â&#x20AC;&#x201C; 14P After â&#x20AC;&#x2DC;03: 34P (gray) â&#x20AC;&#x201C; 12P No. 10: Light green

19 29 20 (View ed from the term inal side)

Check for continuity betw een the Green w ire term inal of the handlebar (audio) sw itch 12P connector and ground. There should be continuity.

Green

After â&#x20AC;&#x2DC;03: 10

14P:

(View ed from the term inal side)

AUDIO DISPLAY SIGNAL LINES Rem ove the com bination m eter (page 20-17). Check for continuity betw een the audio unit 34P black and m eter 16P connectors. There should be continuity betw een the sam e color w ire term inals.

Also, check for a short circuit betw een each connector term inal and ground. There should be no continuity.

No. 1: Red No. 2: Black No. 3: Shield No. 10: Green No. 18: White

22-7

AUDIO SYSTEM SPEED PULSE SIGNAL LINE Place the m otorcycle on its center stand, then shift the transm ission into neutral. M easure the voltage betw een the White/black w ire term inal (+) of the audio unit 34P (gray) connector and ground (–) w ith the ignition sw itch turned to “ ON.” There should be 0 V to 5 V pulse voltage w hile slow ly turning the rear w heel by hand.

STARTER/REVERSE SWITCH LINE M easure the voltage betw een the Yellow /red w ire term inal (+) of the audio unit 34P gray connector and ground (–) w ith the ignition sw itch turned to “ ON” and the engine stop sw itch turned to “ .” There should be battery voltage w hen the starter/ reverse sw itch is pushed If there is no voltage, check the follow ing: – open or short circuit in the Yellow /red w ire – loose or poor contact in related connectors

REMOVAL/INSTALLATION Rem ove the top shelter (page 2-12). Rem ove the ten screw s and separate the front and rear top shelters.

Rem ove the tw o screw s and audio unit. Install the audio unit in the reverse order of rem oval.

22-8

AUDIO SYSTEM

AUDIO SWITCH INSPECTION Rem ove the front fairing (page 2-10). Disconnect the left handlebar sw itch connectors. ‘01 – ‘03: – 14P blue – 12P green After ‘03: – 14P gray – 12P blue Check for continuity betw een the connector term inals in each sw itch position. Continuity should exist betw een the color coded w ire term inals as follow s:

14P CONNECTOR

TERMINAL ARRANGEMENT AND SWITCH LOCATION

12P CONNECTOR 12P:

14P:

CB-VOL SWITCH

Color Position Up Free Down

Black Orange

Red

(View ed from the term inal side) No. 1: No. 2: No. 3: No. 5:

Orange White Black Light green (‘01 – ‘03) No. 7: Red No. 8: Yellow No. 9: Brow n No. 10: Green2

CB-CH SWITCH

Color Brown Orange Position Up Free Down

Red

No. 3: Light green (After ‘03) No. 5: Green1

TALK

CB-VOL

VOLUM E

CB-SQL SWITCH

Color Green2 Orange Position Up Free Down

Red

CB-CH CB-SQL

TUNE/DISC M UTE

VOLUME SWITCH

Color Position Up Free Down

Black

White Yellow

22-9

AUDIO SYSTEM TUNE/DISC SWITCH

Color Position Up Free Down

Black

White Yellow

MUTE SWITCH

Color Light Green1 green Position Free Push TALK SWITCH

Color Green2 Yellow Position Free Push

22-10

AUDIO SYSTEM

ANTENNA REMOVAL/INSTALLATION Loosen the lock nut and rem ove the antenna from the base by turning it counterclockw ise. Rem ove the seat (page 2-5).

Open the trunk lid, and rem ove the four screw s and right trunk side pocket. Rem ove the w ire band. Disconnect the antenna connector located under the fram e cross-m em ber and rem ove the antenna w ire out of the fram e. Rem ove the three bolts, stay and antenna base assem bly. Route the wires properly (page 1-23).

Installation is in the reverse order of rem oval.

TORQUE: Antenna base bolt: 14 NÂˇm (1.4 kgfÂˇm, 10 lbfÂˇft)

INSPECTION Rem ove the seat (page 2-5).

Disconnect the antenna connector. Rem ove the antenna from the antenna base (page 22-11). Check for continuity betw een the antenna connector and base as show n.

B A: Continuity B: No continuity

22-11

AUDIO SYSTEM

SPEAKER REMOVAL/INSTALLATION Rem ove the m eter panel (page 2-7). Rem ove the four m ounting screw s. Disconnect the connectors to rem ove the speaker. Install the speaker in the reverse order of rem oval.

INSPECTION Select smallest range on the ohmmeter.

Connect an analogue ohm m eter to the speaker term inals. The speaker is norm al if the speaker clicks at the m om ent w hen the ohm m eter probes are connected to the speaker term inals.

HEADSET JUNCTION WIRE INSPECTION Front headset:

Rem ove the left fairing pocket (page 2-11).

Rear headset:

Rem ove the seat (page 2-5). Disconnect the junction w ire 6P red connector. Check for continuity betw een the sam e color (num ber) w ire term inals of the 6P connector and junction connector. There should be continuity.

5: Red

4: Yellow 3: Black

22-12

1: White 2

1 2: Shield

4 5

23. WIRING DIAGRAM

SERVICE INFORMATION ···························· 23-3

STARTER/REVERSE SYSTEM···················23-12

FUSE BOX ···················································· 23-3

LIGHTING SYSTEM····································23-13

SUSPENSION LEVEL CONTROL SYSTEM 23-5

TURN SIGNAL LIGHTS/HORN ··················23-14

ABS······························································· 23-7

COMBINATION METER ·····························23-15

FUEL SYSTEM (Programmed Fuel Injection) ····················· 23-9

ACC/TRUNK LOCK CONTROL SYSTEM ··23-17 CRUISE CONTROL SYSTEM ·····················23-20

COOLING/CHARGING/IGNITION SYSTEM ····················································· 23-11

AUDIO SYSTEM ·········································23-22

23-1

WIRING DIAGRAM

SERVICE INFORM ATION WIRING DIAGRAM

GENERAL • The follow ing abbreviations are used to identify w ire colors in this section. Bl: Black Br: Brow n Bu: Blue G: Green

FUSE BOX FUSE NUM BER

23-3

Gr: Gray Lb: Light blue Lg: Light green O: Orange

P: Pink R: Red S: Shield w ire W: White

Y: Yellow

24. TECHNICAL FEATURES

IDLE AIR CONTROL (IAC) VALVE··············· 24-2

ELECTRIC REAR SUSPENSION SPRING PRELOAD ADJUSTMENT SYSTEM ············24-6

HYDRAULICALLY ASSISTED CLUTCH ······ 24-4 ANTI-LOCK BRAKE SYSTEM (ABS)············24-7 BRAKE SERVO-PRESSURE SENSING ANTI-DIVE SYSTEM ···································· 24-5

IGNITION COIL WITH BUILT-IN IGNITER ·24-12

24-1

TECHNICAL FEATURES

IDLE AIR CONTROL (IAC) VALVE TECHNICAL FEATURES

SUMMARY The IAC valve is the electro-m agnetic variable valve that controls the idle speed of the engine by passing air around the throttle valves w hen they are fully closed. It controls the fluctuation of the idle speed and adjusts it to the basic idle speed by supplying air to the intake m anifold according to the engine coolant tem perature, engine load, and the condition of the throttle valves. When the coolant tem perature is low , the IAC valve functions as the fast idle valve, too.

STRUCTURAL PRINCIPLE As the IAC valve shaft rotates, the IAC valve opens and closes the air passage to control the air flow volum e.

A m agnet is m ounted at the end of the shaft, i.e., in the oval hole in the iron core. Because the m agnet is set at the center of the oval hole, the m agnetic force from the N-pole and the S-pole attracts the iron core of the narrow est air gap part to the m agnet, bringing the m agnet to the position show n. The iron core is w ound w ith a coil. Therefore, it turns into an electro-m agnet w hen electric current flow s through the coil.

24-2

TECHNICAL FEATURES When electric current flow s through the coil turning the iron core into an electro-m agnet, the N and S poles of the m agnet and the N and S poles of the electro-m agnet attract each other causing the m agnet on the valve shaft to rotate. To change the rotating direction of the valve, current flow is reversed. This sw itches the N and S poles of the electro-m agnet and the rotating direction of the valve reverses.

OPERATION CONTROL The IACâ&#x20AC;&#x2122;s drive signal is output from the ECM to turn the IAC valve side voltage on and off. As the IAC valve is required to control the intake air flow volum e by continuously changing its valve angle, the digital drive signal turns the voltage on and off at a constant frequency, w ith the signal being a PWM (Pulse Width M odulation) type that changes the on tim e ratio per cycle. This is referred to as the duty ratio (duty cycle). The average current changes sm oothly, just as the analog type does, in accordance w ith the changes of the duty ratio. The IAC valve has a built-in drive circuit. With the 50% of the duty ratio used as a reference point of 0 (zero), the drive circuit judges the duty ratio below the reference point as the close-circuit direction and the duty ratio (duty cycle) above the reference point as the open-circuit direction. The IAC sw itches the open and close circuit direction by changing the direction of the current flow through the coil. FI IGN RELAY

IAC VALVE ECM

DRIVE CIRCUIT

Duty Ratio (duty cycle)

24-3

TECHNICAL FEATURES

HYDRAULICALLY ASSISTED CLUTCH SUMMARY The hydraulically assisted clutch uses engine oil to boost the engagem ent force against the pressure plate. This clutch increases the friction force betw een the clutch plates and discs (pressure force against the pressure plate) w ithout the need for heavy clutch springs. This allow s the use of a sm all and lightw eight clutch, w hich results in a light clutch lever feel. High pressure oil is pum ped from the oil pum p through the crankcase oil passage. Oil flow s through the oil passage and is regulated by the regulator valve. The oil then travels through the oil passage in the clutch cover and joint piece, and goes to the clutch.

CONSTRUCTION AND OPERATION When the clutch is engaged: The pressurized oil flow s through the oil passage in the joint piece and m ainshaft, and enters an oil cham ber w hich is form ed by the clutch piston, pressure plate, and clutch center. Because the clutch piston and clutch center are fixed by the lock nut via the spring guide, oil pressure m oves the pressure plate tow ards the clutch center. The clutch spring is forced against the pressure plate via lifter plate B. Therefore, the clutch plates and discs are pressed together by oil pressure and spring force.

OIL PASSAGE PRESSURE PLATE REGULATOR VALVE CLUTCH CENTER

MAIN SHAFT OIL CHAMBER

CLUTCH PISTON CLUTCH COVER JOINT PIECE SPRING GUIDE CLUTCH SPRING

When the clutch is disengaged: The oil outlet ports in the pressure plate are sealed by lifter plate B. Lifter plate B is pressed against the pressure plate by the force of the clutch spring. When lifter plate A is pushed out by the lifter rod via the joint piece and bearing, the spring force, w hich acts on the pressure plate via lifter plate B, is released.

This opens the outlet ports sealed by lifter plate B and oil pressure in the oil cham ber is released. Therefore, oil pressure and spring force are rem oved, the friction force betw een the clutch plates and discs is relieved, and the clutch is disengaged.

The lifter spring presses lifter plate B against the pressure plate lightly to prevent the oil in the cham ber from leaking.

24-4

TECHNICAL FEATURES

BRAKE SERVO-PRESSURE SENSING ANTI-DIVE SYSTEM This m otorcycle is equipped w ith the Linked Brake System (LBS). This system operates the anti-dive system on the left front fork by utilizing fluid pressure generated in the secondary m aster cylinder. The secondary m aster cylinder responds to braking forces generated by the lever and/or pedal. When either brake is applied, the plunger is pushed by pressure from the secondary m aster cylinder and the anti-dive piston valve in the fork oil passage m oves to block the passage. As the flow of the fork fluid is reduced by m ovem ent of the piston valve, the system reduces com pression of the front fork and thereby controls the nose dive of the vehicle.

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24-5

TECHNICAL FEATURES

ELECTRIC REAR SUSPENSION SPRING PRELOAD ADJUSTMENT SYSTEM This system adjusts the rear suspension spring preload by operating a hydraulic jacking system that is driven by an electric m otor. The shock absorber and actuator are connected w ith an oil hose. The piston in the actuator is operated by the control m otor, w hile the shock absorber piston is operated by hydraulic pressure. The piston stroke is detected by the angle sensor and the m otor is controlled w ith the control unit (ECU) inside the com bination m eter. Preload can be adjusted by operating the â&#x20AC;&#x153; Upâ&#x20AC;? and â&#x20AC;&#x153; Dow nâ&#x20AC;? sw itch w hile m onitoring the preload condition on the m ulti-display. Tw o preload settings can be stored and retrieved by operating the m em ory buttons on the control panel.

" # #

24-6

TECHNICAL FEATURES

ANTI-LOCK BRAKE SYSTEM (ABS) SUMMARY The ABS is designed to help prevent w heel lock-up during hard braking or braking on loose or slippery surfaces. ABS m om entarily reduces the brake caliper fluid pressure w hen the w heel is about to lock. When the system senses that the tendency for w heel lock is reduced, brake caliper fluid pressure is restored. ABS repeats this cycle as required for secure brake perform ance w ith m inim um possibility of w heel lock. In this ABS, brake fluid pressure is directly controlled by the m otorâ&#x20AC;&#x2122;s regulation of the rotational angle of the piston-crank m echanism , w hich in turn controls the brake fluid. Therefore, in com parison w ith other ABSs, the m odulator size, num ber of parts, and w eight are all substantially reduced. In addition, the fluid pressure can be regulated continuously, unlike ABSs w hich have staged control. This ABS has a higher accuracy of control in a m ore sim plified system .

COMPONENT LOCATIONS (1) (2) (3) (4) (5)

ABS indicator: Blinks or stays on w hen a problem occurs in the ABS. Pulser rings (front/rear): Rotates w ith the w heel and detects w heel speed using the w heel speed sensor. Wheel speed sensors (front/rear): Inputs the pulse signal, generated proportionally to the rotating speed of the pulser ring in the ABS control unit. M odulators (front/rear): Adjusts the caliper fluid pressure. ABS control unit (ECU): Controls the ABS by m onitoring the input signals of each sensor.

24-7

TECHNICAL FEATURES SYSTEM CONSTRUCTION

! " MOTOR DRIVEN MODULATOR The m odulator controls the brake fluid pressure that is essential for ABS operation. This m otorcycle is equipped w ith separate and independent front and rear m odulators. At the sam e tim e, in order to com bine w ith the Linked Brake System (LBS), a single m odulator controls tw o routes for brake fluid pressure, as tw o routes for braking input are given respectively to the front and rear w heels. The m odulator consists of the follow ing parts: â&#x20AC;&#x201C; Control piston: Operates in accordance w ith the change of the crankshaft angle and adjusts the caliper fluid pressure. Because each m odulator m ust provide sim ultaneous control over tw o separate system s, each features tw o sets of control pistons. â&#x20AC;&#x201C; Crankshaft: Turns w ith the control m otor via the reduction gears to change the piston position. â&#x20AC;&#x201C; Back-up spring: Pushes the control pistons up (holds the cut-off valve open) by w ay of the crankshaft. â&#x20AC;&#x201C; Control m otor: Drives the crankshaft and adjusts the pressure in the system . â&#x20AC;&#x201C; Crank angle sensor: Detects the crankshaft angle. â&#x20AC;&#x201C; Cut-off valve* : Shuts off the hydraulic pressure to the brake caliper (see page 24-9).

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24-8

( (

TECHNICAL FEATURES * 3-STAGE CUT-OFF VALVE A 3-stage cut-off valve w as created by adding a spring-loaded orifice valve on top of a spring-loaded ball-type cut-off valve. By positioning the orifice valve in-line w ith the cut-off valve w e obtain three stages of operation. Stage 1: When the ABS is engaged, the control piston m oves dow n to cut off flow to both the cut-off valve and orifice valve, elim inating hydraulic flow betw een the m aster cylinder and brake caliper. Stage 2: The control piston m oves up slightly to open the cut-off valve, leaving the orifice valve closed. This stage perm its only a sm all am ount of hydraulic pressure to flow through the orifice valve to the brake caliper. Stage 3: The control piston returns to its norm al, upperm ost position, opening both the cut-off valve and orifice valve, and restoring full hydraulic pressure for conventional brake operation.

WHEEL SPEED SENSOR/PULSER RING The w heel speed sensor is a contactless sensor that detects front and rear w heel speed. The sensor consists of a perm anent m agnet and Hall elem ent, and is connected to the ABS control unit. When the projection on the pulser ring (that is rotating w ith the w heel) passes across the w heel speed sensor, voltage pulses are generated at the sensor. The ABS control unit detects the w heel speed as it receives the pulse signal, because the frequency of the signal increases proportionally to the w heel speed.

Rear wheel sensor shown: PULSER RING

At low speed

At high speed

PULSE SIGNALS

WHEEL SPEED SENSOR

24-9

TECHNICAL FEATURES ABS CONTROL UNIT • M odulator m otor control: The ABS control unit m onitors both the tw o w heel speed sensors and the tw o m odulator crank angle sensors that provide precise readings of each m odulator’s crankshaft positioning (i.e., control piston position). The ABS control unit directs its m otor driven control signals (control unit w ith the built-in m otor driver) to deliver high-am perage electrical output to the control m otors and thus operates the system . • Self-diagnosis function: The dual-CPU configuration ensures instant recognition of com puter-related m alfunctions, since the tw o CPUs run constant checks on each other w henever the ignition sw itch is turned to “ ON.” When the ignition sw itch is turned to “ ON,” the ABS control unit evaluates its internal circuits. The indicator blinks w hen an abnorm ality is detected in the system . When the system is norm al, the ABS indicator stays on indicating that the ABS control unit is in the stand-by m ode for the w heel speed sensor and m odulator crank angle sensor signals. The w heel speed sensors send signals to the control unit after the m otorcycle starts to m ove (approxim ately 10 km /h or above), then the control unit evaluates the system condition by activating the m odulator control m otors and receiving signals from the crank angle sensors. The ABS indicator goes off w hen the system is found to be norm al. The control unit m onitors its m ain functions w hile the m otorcycle is m oving, w hether the brakes are engaged or not. When it detects a problem , the ABS indicator blinks. • Change-over function: When the ABS control unit detects a problem through its self-diagnosis function, it stops the ABS function. The back-up spring in the m odulator pushes the control piston autom atically to open the cut-off valve and restore conventional brake operation. • Problem code storage function: Problem codes can be m em orized and stored in the ABS control unit (up to tw o codes), and can be retrieved and indicated by the num ber of tim es the ABS indicator blinks.

ABS CONTROL UNIT

ABS Control Unit

Front Speed Sensor

CPUs

ABS Indicator

Rear Speed Sensor Front Angle Sensor Rear Angle Sensor

24-10

Motor Driver

Front Control Motor Rear Control Motor

TECHNICAL FEATURES MODULATOR OPERATION • Pressure DECREASE: When the ABS control unit detects any tendency tow ards w heel lock, it rapidly reduces hydraulic pressure to the brake caliper by rotating the crankshaft to low er the control piston, closing the cut-off valve. • Pressure HOLD: Follow ing a predeterm ined decom pression interval, the crankshaft is rotated up slightly to m ove the control piston into the pressure hold position, w hich perm its the slipping w heel to recover its rotational speed. • Pressure INCREASE: Once the ABS control unit detects full w heel-speed recovery, it rotates the crankshaft back into its highest position. This rapid cycle of pressure DECREASE, HOLD, and INCREASE m akes possible nearly instantaneous correction of changes in w heel rotation w hile ensuring highly accurate control of hydraulic pressure to both independent sets of brake caliper pistons.

ABS DEACTIVATED: MOTOR From master cylinder

GEARS

To caliper

PISTON

Pressure DECREASE:

Pressure INCREASE:

BACK-UP SPRING

CRANKSHAFT

Caliper

24-11

TECHNICAL FEATURES

IGNITION COIL WITH BUILT-IN IGNITER Each ignition coil has a built-in igniter that boosts the ignition signal (5V) from the engine control m odule (ECM ) to generate the prim ary side voltage.

24-12

25. TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START ········································· 25-2

POOR PERFORMANCE AT LOW AND IDLE SPEED···················································25-5

ENGINE LACKS POWER ····························· 25-3

POOR PERFORMANCE AT HIGH SPEED ····25-6 POOR HANDLING·········································25-6

25-1

TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START TROUBLESHOOTING

1. Spark Plug Inspection Rem ove and inspect spark plugs. Are the spark plugs in good condition? NO

– • Incorrect spark plug heat range • Incorrect spark plug gap • Dirty air cleaner

YES

– GO TO STEP 2.

2. Spark Test Perform spark test. Is the spark quality good? NO

– • • • • • • • •

Faulty spark plug Loose or disconnected ignition system w ires Faulty ignition coil Broken or shorted spark plug w ire Faulty ignition pulse generator Faulty engine stop sw itch Faulty PGM -FI IGNITION relay Faulty engine control m odule (ECM )

YES

– GO TO STEP 3.

3. Programmed Fuel Injection System Inspection Check the fuel injection system . Is the fuel injection system normal? NO

– Faulty fuel injection system (section 5)

YES

– GO TO STEP 4.

4. Cylinder Compression Inspection Test the cylinder com pression. Is the compression as specified? NO

– • • • • •

Valve stuck open Worn cylinder and piston rings Dam aged cylinder head gasket Seized valve Im proper valve tim ing

YES

– GO TO STEP 5.

5. Engine Start Condition Start by follow ing the norm al procedure. Does the engine start but stop? YES

25-2

– • • • •

Leaking intake m anifold gasket Faulty idle air control valve Im proper ignition tim ing (Faulty ECM or ignition pulse generator) Contam inated fuel

TROUBLESHOOTING

ENGINE LACKS POWER 1. Drive Train Inspection Raise w heel off the ground and spin by hand. Does the wheel spin freely? NO

– • Brake dragging • Worn or dam aged final gear bearings

YES

– GO TO STEP 2.

2. Tire Pressure Inspection Check the tire pressure. Are the tire pressures correct? NO

– • Faulty tire valve • Punctured tire

YES

– GO TO STEP 3.

3. Clutch Inspection Accelerate rapidly low to second. Does the engine speed change accordingly when clutch is released? NO

– • • • • • •

Clutch slipping Worn clutch discs/plates Warped clutch discs/plates Weak clutch spring Faulty hydraulic assist system Additive in engine oil

YES

– GO TO STEP 4.

4. Engine Performance Inspection Accelerate lightly. Does the engine speed increase? NO

– • Clogged air cleaner • Restricted fuel flow • Clogged m uffler

YES

– GO TO STEP 5.

5. Spark Plug Inspection Rem ove and inspect spark plugs. Are the spark plugs in good condition? NO

– • Plugs not serviced frequently enough • Incorrect spark plug heat range

YES

– GO TO STEP 6.

6. Engine Oil Inspection Check the oil level and condition. Is the engine oil in good condition? NO

– • Oil level too high • Oil level too low • Contam inated oil

YES

– GO TO STEP 7.

7. Ignition Timing Inspection Check the ignition tim ing. Is the ignition timing as specified? NO

– • Faulty engine control m odule (ECM ) • Faulty ignition pulse generator

YES

– GO TO STEP 8.

25-3

TROUBLESHOOTING 8. Cylinder Compression Inspection Test the cylinder com pression. Is the compression as specified? NO

– • • • •

Valve clearance too sm all Worn cylinder and piston rings Dam aged cylinder head gasket Im proper valve tim ing

YES

– GO TO STEP 9.

9. Programmed Fuel Injection System Inspection Check the fuel injection system . Is the fuel injection system normal? NO

– Faulty fuel injection system (section 5)

YES

– GO TO STEP 10.

10. Lubrication Inspection Rem ove cylinder head cover and inspect lubrication. Is the valve train lubricated properly? NO

– Clogged oil passage

YES

– GO TO STEP 11.

11. Overheating Inspection Check for engine overheating. Is the engine overheating? YES

– • • • • • • •

Coolant level too low Fan m otor not w orking (Faulty fan m otor or ECM ) Therm ostat stuck closed Excessive carbon build-up in com bustion cham ber Use of poor quality fuel Clutch slipping Wrong type of fuel

– GO TO STEP 12.

12. Engine Knocking Inspection Accelerate or run at high speed. Is the engine knocking?

25-4

YES

– • • • •

Worn piston and cylinder Wrong type of fuel Excessive carbon build-up in com bustion cham ber Ignition tim ing too advanced (Faulty ECM )

– Engine does not knock

TROUBLESHOOTING

POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Intake Manifold Gasket Inspection Check for leaking intake m anifold gasket. Is the intake manifold gasket leaking? YES

– • Loose intake m anifold m ounting bolts • Dam aged intake m anifold gasket

– GO TO STEP 2.

2. Spark Test Perform spark test. Is the spark quality good? NO

– • • • • • • •

Faulty spark plug Fouled spark plug Loose ignition system w ires Broken or shorted spark plug w ire Faulty ignition pulse generator Faulty ignition coil Faulty engine control m odule (ECM )

YES

– GO TO STEP 3.

3. Ignition Timing Inspection Check the ignition tim ing. Is the ignition timing as specified? NO

– • Faulty engine control m odule (ECM ) • Faulty ignition pulse generator

YES

– GO TO STEP 4.

4. Programmed Fuel Injection System Inspection Check the fuel injection system . Is the fuel injection system normal? NO

– Faulty fuel injection system (section 5)

25-5

TROUBLESHOOTING

POOR PERFORMANCE AT HIGH SPEED 1. Ignition Timing Inspection Check the ignition tim ing. Is the ignition timing as specified? NO

– • Faulty engine control m odule (ECM ) • Faulty ignition pulse generator

YES

– GO TO STEP 2.

2. Programmed Fuel Injection System Inspection Check the fuel injection system . Is the fuel injection system normal? NO

– Faulty fuel injection system (section 5)

YES

– GO TO STEP 3.

3. Valve Timing Inspection Check the valve tim ing. Is the valve timing correct? NO

– Cam shafts not installed properly

YES

– GO TO STEP 4.

4. Valve Spring Inspection Check the valve springs. Is the valve spring free length as specified? NO

– Faulty valve spring

YES

– Not w eak

POOR HANDLING Steering is heavy • Steering bearing adjustm ent nut too tight • Dam aged steering head bearings Either wheel is wobbling • Excessive w heel bearing play • Excessively w orn sw ingarm pivot bearings • Excessive final gear bearing play • Bent fram e The motorcycle pulls to one side • Front and rear w heels not aligned • Bent fork • Bent sw ingarm • Bent axle • Bent fram e

25-6

26. INDEX ABS M ODULATOR······················································ 16-31 AIR CLEANER ·································································· 3-6 AIR CLEANER HOUSING ·············································· 5-57 ALTERNATOR······························································ 17-10 ANTENNA ···································································· 22-11 ANTI-LOCK BRAKE SYSTEM (ABS)····························· 24-7 AUDIO SWITCH····························································· 22-9 AUDIO UNIT ·································································· 22-6 BANK ANGLE SENSOR ·············································· 18-13 BARO/M AP SENSORS ·················································· 5-67 BATTERY ······································································· 17-6 BATTERY/CHARGING SYSTEM SPECIFICATIONS ·························································· 1-10 BEFORE STARTING TROUBLESHOOTING ················· 16-5 BEFORE TROUBLESHOOTING····································· 16-8 BODY PANEL LOCATIONS············································· 2-3 BRAKE FLUID ································································ 3-16 BRAKE FLUID REPLACEM ENT/AIR BLEEDING··········· 15-6 BRAKE LIGHT SWITCH ················································· 3-18 BRAKE PAD WEAR························································ 3-17 BRAKE PAD/DISC························································ 15-13 BRAKE SERVO-PRESSURE SENSING ANTI-DIVE SYSTEM ······················································ 24-5 BRAKE SWITCH··························································· 20-37 BRAKE SYSTEM ···························································· 3-18 BRAKE SYSTEM SPECIFICATIONS ····························· 1-10 CABLE & HARNESS ROUTING ···································· 1-23 CAM CHAIN INSTALLATION········································ 8-26 CAM CHAIN REM OVAL ················································ 8-12 CAM SHAFT POSITION SENSOR ································· 5-67 CAM SHAFT INSTALLATION ········································ 8-28 CAM SHAFT REM OVAL··················································· 8-7 CASE BEARING REPLACEM ENT ······························· 12-14 CHARGING SYSTEM INSPECTION······························ 17-9 CLUTCH ········································································· 9-14 CLUTCH FLUID ······························································ 3-19 CLUTCH FLUID REPLACEM ENT/AIR BLEEDING ·········· 9-7 CLUTCH M ASTER CYLINDER ········································ 9-8 CLUTCH SLAVE CYLINDER·········································· 9-12 CLUTCH SPECIFICATIONS ············································· 1-7 CLUTCH SWITCH ························································ 20-37 CLUTCH SYSTEM ························································· 3-19 COM BINATION M ETER ·············································· 20-17 COM PONENT LOCATION CLUTCH······································································· 9-2 COOLING SYSTEM ····················································· 6-2 CYLINDER HEAD/VALVE············································ 8-2 CYLINDER/PISTON/CRANKSHAFT·························· 11-2 ENGINE REM OVAL/INSTALLATION ························· 7-2 FINAL DRIVE ····························································· 12-2 FRONT WHEEL/SUSPENSION/STEERING·············· 13-2 FUEL SYSTEM (Program m ed Fuel Injection)··········· 5-2 GEARSHIFT LINKAGE/TRANSM ISSION ················· 10-2 REAR WHEEL/SUSPENSION ··································· 14-2 COOLANT REPLACEM ENT············································· 6-6 COOLANT TEM PERATURE GAUGE/ECT SENSOR······································································· 20-22 COOLING SYSTEM ······················································· 3-14 COOLING SYSTEM SPECIFICATIONS··························· 1-6 CRANKCASE ASSEM BLY··········································· 11-22 CRANKCASE BREATHER················································ 3-7 CRANKCASE COVER BEARING REPLACEM ENT······ 10-19 CRANKCASE SEPARATION ········································· 11-6 CRANKPIN BEARING ·················································· 11-11 CRANKSHAFT INSTALLATION ·································· 11-16 CRANKSHAFT REM OVAL··········································· 11-13 CRUISE ACTUATOR···················································· 21-16 CRUISE CANCEL SWITCH ·········································· 21-14 CRUISE CONTROL SWITCH ······································· 21-13 A

CRUISE CONTROL SYSTEM SPECIFICATIONS ·········· 1-11 CRUISE/REVERSE CONTROL M ODULE CRUISE CONTROL SYSTEM ···································· 21-9 STARTER/REVERSE SYSTEM ································ 19-39 CYLINDER COM PRESSION ············································ 8-6 CYLINDER HEAD ASSEM BLY ······································ 8-22 CYLINDER HEAD COVER INSTALLATION··················· 8-32 CYLINDER HEAD COVER REM OVAL ····························· 8-6 CYLINDER HEAD DISASSEM BLY ································ 8-16 CYLINDER HEAD INSTALLATION ································ 8-24 CYLINDER HEAD REM OVAL ········································ 8-14 CYLINDER HEAD/VALVES SPECIFICATIONS················ 1-7 CYLINDER/PISTON/CRANKSHAFT SPECIFICATIONS····························································· 1-8 DELAY VALVE······························································ 15-38 ECM (ENGINE CONTROL M ODULE)···························· 5-71 ELECTRIC REAR SUSPENSION SPRING PRELOAD ADJUSTM ENT SYSTEM ····························· 24-6 EM ISSION CONTROL INFORM ATION LABELS ·········· 1-72 EM ISSION CONTROL SYSTEM S ································· 1-69 ENGINE IDLE SPEED····················································· 5-88 ENGINE INSTALLATION ··············································· 7-11 ENGINE OIL ··································································· 3-11 ENGINE OIL FILTER······················································· 3-12 ENGINE REM OVAL ························································· 7-5 ENGINE SIDE COVER······················································ 2-5 EVAPORATIVE EM ISSION (EVAP) CONTROL SYSTEM ········································································· 5-74 EVAPORATIVE EM ISSION CONTROL SYSTEM ·········· 3-15 EXHAUST SYSTEM ······················································· 2-18 FAN CONTROL RELAY················································ 20-41 FINAL DRIVE ASSEM BLY ··········································· 12-17 FINAL DRIVE DISASSEM BLY/INSPECTION ················ 12-9 FINAL DRIVE INSTALLATION····································· 12-22 FINAL DRIVE OIL ··························································· 3-15 FINAL DRIVE REM OVAL ··············································· 12-7 FINAL DRIVE SPECIFICATIONS······································ 1-9 FORK ············································································ 13-24 FRONT BRAKE CALIPER············································· 15-27 FRONT FAIRING ···························································· 2-10 FRONT FENDER COVERS ··············································· 2-6 FRONT LOWER FAIRING ················································ 2-6 FRONT M ASTER CYLINDER······································· 15-15 FRONT TURN SIGNAL LIGHT ···································· 20-13 FRONT WHEEL ···························································· 13-16 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS····························································· 1-9 FUEL GAUGE/LOW FUEL INDICATOR······················· 20-24 FUEL INJECTORS·························································· 5-61 FUEL LINE········································································ 3-5 FUEL LINE INSPECTION ··············································· 5-52 FUEL PUM P ··································································· 5-54 FUEL PUM P RELAY······················································· 5-66 FUEL SYSTEM (Program m ed Fuel Injection) SPECIFICATIONS····························································· 1-6 FUEL TANK ···································································· 5-63 GEAR POSITION SWITCH··········································· 20-38 GEARSHIFT LINKAGE··················································· 10-8 GEARSHIFT LINKAGE/TRANSM ISSION SPECIFICATIONS····························································· 1-8 HANDLEBAR·································································· 13-7 HANDLEBAR SWITCH················································· 20-35 HAZARD SWITCH························································ 20-32 HEADLIGHT ··································································· 20-8 HEADLIGHT ADJUSTER ··············································· 20-9 HEADLIGHT AIM ··························································· 3-19 HEADSET JUNCTION WIRE ······································· 22-12 HORN ··········································································· 20-40 HYDRAULICALLY ASSISTED CLUTCH ························ 24-4 D

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INDEX IAT SENSOR ·································································· 5-68 IDLE AIR CONTROL (IAC) VALVE································· 24-2 IGNITION COIL ······························································ 18-7 IGNITION COIL WITH BUILT-IN IGNITER ·················· 24-12 IGNITION CRUISE RELAY··········································· 21-11 IGNITION PULSE GENERATOR···································· 18-9 IGNITION SWITCH ······················································ 20-34 IGNITION SYSTEM INSPECTION ································· 18-5 IGNITION SYSTEM SPECIFICATIONS ························· 1-11 IGNITION TIM ING ······················································· 18-14 INNER FAIRING ····························································· 2-10 KNOCK SENSOR ··························································· 5-69 LICENSE LIGHT ··························································· 20-15 LIGHTS/M ETERS/SWITCHES SPECIFICATIONS ········· 1-11 LUBRICATION & SEAL POINTS ··································· 1-19 LUBRICATION SYSTEM SPECIFICATIONS ··················· 1-6 M AIN JOURNAL BEARING········································· 11-14 M AINTENANCE SCHEDULE··········································· 3-4 M ETER PANEL································································· 2-7 M ODEL IDENTIFICATION ··············································· 1-2 M ULTI-DISPLAY CONTROL SWITCH························· 20-40 NEUTRAL INDICATOR ················································ 20-26 NUTS, BOLTS, FASTENERS········································· 3-21 O2 SENSOR ··································································· 5-69 OIL PRESSURE CHECK ··················································· 4-5 OIL PRESSURE INDICATOR ······································· 20-27 OIL PUM P ········································································ 4-7 OIL STRAINER/PRESSURE RELIEF VALVE···················· 4-6 OPEN AIR TEM PERATURE SENSOR ························· 20-33 PGM -FI (PROGRAM M ED FUEL INJECTION) SYSTEM ···········································································5-8 PGM -FI IGNITION RELAY ··········································· 18-11 PGM -FI SELF-DIAGNOSIS M ALFUNCTION INDICATOR FAILURE CODES······································· 5-13 PGM -FI TROUBLESHOOTING ······································ 5-16 PISTON/CONNECTING ROD INSTALLATION ··········· 11-17 PISTON/CONNECTING ROD REM OVAL······················ 11-7 POSITION LIGHT RELAY············································· 20-31 POWER CONTROL RELAY·········································· 19-31 POWER TRUNK LOCK SYSTEM ································· 20-42 PRIM ARY GEARS/OUTPUT SHAFT INSTALLATION···························································· 10-20 PRIM ARY GEARS/OUTPUT SHAFT REM OVAL········· 10-13 PROPORTIONAL CONTROL VALVE (PCV) ················ 15-39 RADIATOR COOLANT··················································· 3-13 RADIATOR/COOLING FAN ············································· 6-8 REAR BRAKE CALIPER················································ 15-34 REAR CRANKCASE COVER INSTALLATION············· 10-24 REAR CRANKCASE COVER REM OVAL ····················· 10-11 REAR FENDER A···························································· 2-13 REAR FENDER B···························································· 2-16 REAR M ASTER CYLINDER/BRAKE PEDAL················ 15-19 REAR WHEEL······························································· 14-14 REARVIEW M IRROR························································ 2-7 RELAY BOX ································································· 20-16 REVERSE OPERATION ·················································· 3-20 REVERSE REGULATOR ASSEM BLY·························· 19-28 REVERSE RELAY ························································· 19-26 REVERSE RESISTOR ASSEM BLY ······························ 19-30 REVERSE SHIFT ACTUATOR······································ 19-36 REVERSE SHIFT M ECHANISM ··································· 19-42 REVERSE SHIFT RELAY ·············································· 19-34 REVERSE SWITCH······················································· 19-27 SADDLEBAG COM BINATION LIGHT ························· 20-14 SADDLEBAG/TRUNK STAY·········································· 2-17 SADDLEBAGS ······························································· 2-15 SEAT ················································································ 2-5 SECONDARY AIR SUPPLY SYSTEM ··················· 3-14,5-84 SECONDARY M ASTER CYLINDER ···························· 15-24 I

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SERVICE INFORM ATION AUDIO SYSTEM ························································22-3 BATTERY/CHARGING SYSTEM ·······························17-3 BRAKE SYSTEM (ABS) ·············································16-3 BRAKE SYSTEM (Standard) ·····································15-3 CLUTCH ·······································································9-4 COOLING SYSTEM ·····················································6-3 CRUISE CONTROL SYSTEM ····································21-3 CYLINDER HEAD/VALVE ············································8-3 CYLINDER/PISTON/CRANKSHAFT ··························11-3 ENGINE REM OVAL/INSTALLATION ··························7-3 FINAL DRIVE······························································12-3 FRAM E/BODY PANELS/EXHAUST SYSTEM ·············2-2 FRONT WHEEL/SUSPENSION/STEERING ··············13-3 FUEL SYSTEM (Program m ed Fuel Injection) ···········5-3 GEARSHIFT LINKAGE/TRANSM ISSION ··················10-4 IGNITION SYSTEM ···················································18-3 LIGHTS/M ETERS/SWITCHES ···································20-3 LUBRICATION SYSTEM ·············································4-3 M AINTENANCE···························································3-2 REAR WHEEL/SUSPENSION ····································14-3 STARTER/REVERSE SYSTEM ··································19-4 WIRING DIAGRAM ····················································23-3 SERVICE RULES·······························································1-2 SHOCK ABSORBER ·····················································14-16 SIDE COVER·····································································2-5 SIDE STAND···································································3-20 SIDE STAND SWITCH ·················································20-39 SPARK PLUG····································································3-8 SPEAKER······································································22-12 SPECIFICATIONS ·····························································1-4 SPEED LIM ITER RELAY ···············································19-33 SPEEDOM ETER····························································20-20 STARTER RELAY SWITCH A·······································19-24 STARTER RELAY SWITCH B·······································19-25 STARTER/REVERSE M OTOR ······································19-17 STARTER/REVERSE SYSTEM SPECIFICATIONS ········1-11 STEERING HEAD BEARINGS········································3-22 STEERING STEM ·························································13-41 SUSPENSION·································································3-21 SUSPENSION LEVEL RELAY ······································14-29 SUSPENSION LINKAGE··············································14-18 SWINGARM ·································································14-22 SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM ·······························17-2 FUEL SYSTEM (Program m ed Fuel Injection) ···········5-7 IGNITION SYSTEM ···················································18-2 LUBRICATION ·····························································4-2 REVERSE SYSTEM ····················································19-3 STARTER SYSTEM ···················································19-2 SYSTEM LOCATION AUDIO SYSTEM ························································22-2 BATTERY/CHARGING SYSTEM ·······························17-2 BRAKE SYSTEM (ABS) ·············································16-2 BRAKE SYSTEM (Standard) ·····································15-2 CRUISE CONTROL SYSTEM ····································21-2 FUEL SYSTEM (Program m ed Fuel Injection) ···········5-6 IGNITION SYSTEM ···················································18-2 LIGHTS/M ETERS/SWITCHES ···································20-2 STARTER/REVERSE SYSTEM ··································19-2 SYSTEM TESTING···························································6-5 SYSTEM WIRING CONNECTIONS/LOCATIONS ·········16-4 TACHOM ETER ·····························································20-21 THROTTLE BODY···························································5-58 THROTTLE OPERATION ··················································3-5 TOP SHELTER ································································2-11 TORQUE VALUES ENGINE & FRAM E·····················································1-12 STANDARD································································1-12 T

INDEX TRANSM ISSION ASSEM BLY····································· 10-33 TRANSM ISSION DISASSEM BLY······························· 10-26 TROUBLESHOOTING, GENERAL ENGINE DOES NOT START OR IS HARD TO START ································································· 25-2 ENGINE LACKS POWER ·········································· 25-3 POOR HANDLING ····················································· 25-6 POOR PERFORM ANCE AT HIGH SPEED ················ 25-6 POOR PERFORM ANCE AT LOW AND IDLE SPEED······························································· 25-5 TROUBLESHOOTING, SPECIFIC·································· 16-8 AUDIO SYSTEM ······················································· 22-4 BATTERY/CHARGING SYSTEM ······························ 17-5 BRAKE SYSTEM (ABS) ·········································· 16-10 BRAKE SYSTEM (Standard) ···································· 15-5 CLUTCH······································································· 9-6 COOLING SYSTEM ····················································· 6-4 CRUISE CONTROL SYSTEM ···································· 21-4 CYLINDER HEAD/VALVE············································ 8-5 CYLINDER/PISTON/CRANKSHAFT·························· 11-5 FINAL DRIVE ····························································· 12-6 FRAM E/BODY PANELS/EXHAUST SYSTEM ············ 2-2 FRONT WHEEL/SUSPENSION/STEERING·············· 13-6 FUEL SYSTEM (Program m ed Fuel Injection)··········· 5-5 GEARSHIFT LINKAGE/TRANSM ISSION ················· 10-7 IGNITION SYSTEM ··················································· 18-4 LIGHTS/M ETERS/SWITCHES··································· 20-4 LUBRICATION SYSTEM ············································· 4-4 REAR WHEEL/SUSPENSION ··································· 14-5

STARTER/REVERSE SYSTEM ··································19-6 TRUNK············································································2-13 TRUNK BRAKE/TAILLIGHT ·········································20-15 TRUNK LOWER COVER·················································2-13 TURN SIGNAL CANCEL UNIT ····································20-28 TURN SIGNAL RELAY ·················································20-27 VALVE CLEARANCE ························································3-9 VALVE GUIDE REPLACEM ENT·····································8-19 VALVE SEAT INSPECTION/REFACING ························8-19 VEHICLE SPEED SENSOR·············································5-81 WATER PUM P/THERM OSTAT······································6-17 WHEEL SPEED SENSOR ·············································16-29 WHEELS/TIRES ······························································3-22 WINDSHIELD····································································2-8 WIRING DIAGRAM ABS ············································································23-7 ACC/TRUNK LOCK CONTROL SYSTEM ················23-17 AUDIO SYSTEM ······················································23-22 COM BINATION M ETER ··········································23-15 COOLING/CHARGING/IGNITION SYSTEM ···········23-11 CRUISE CONTROL SYSTEM ··································23-20 FUEL SYSTEM (Program m ed Fuel Injection) ·········23-9 FUSE BOX··································································23-3 LIGHTING SYSTEM ·················································23-13 STARTER/REVERSE SYSTEM ································23-12 SUSPENSION LEVEL CONTROL SYSTEM ··············23-5 SUSPENSION LEVEL CONTROL SYSTEM ··················································23-5 TURN SIGNAL LIGHTS/HORN ·······························23-14 V

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