- •Foreword
- •A warning
- •General Information table of contents
- •Before Servicing
- •Before Servicing
- •Before Servicing
- •Model Identification
- •Model Identification
- •Periodic Maintenance table of contents
- •Special Tools
- •A warning
- •Idle Speed
- •Special Tool - Lead Wire-Peak Voltage Adapter: 57001-1449
- •Caution •
- •Caution
- •If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possibly causing an accident.
- •If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
- •A warning
- •If hard water is used in the system, it causes scales accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
- •Valve Clearance
- •Valve Clearance Adjustment
- •Valve clearance adjustment chart inlet valve
- •A warning
- •A warning
- •Mm (0.15 in.) (michelin) Service Limit: 1 mm (0.04 in.),
- •5.6 Mm (0.22 in.) (michelin) Service Limit: 2 mm (0.08 in.) (Up to 130 km/h)
- •3 Mm (0.12 in.) (Over 130 km/h)
- •A warning
- •A warning
- •A warning
- •A warning
- •Immediately blow the chain dry with compressed air after cleaning.
- •A warning
- •A warning
- •A warning
- •On the insulator, as shown. Other spark plugs will wear prematurely.
- •Fuel System (dfi) table of contents
- •Outline
- •Inquiries to Rider
- •Ignition sw off:
- •Ignition sw on:
- •43 (W) Terminal 12.5 V or more Battery Voltage (12.5 V or more)
- •Inspection Flow Chart
- •A warning
- •A warning
- •A warning
- •A warning
- •A warning
- •A warning
- •Standard- BatterY Voltage (12.5 V or more) for 3 seconds, and then 0 V.
- •Caution
- •Injector Resistance Connections to Injector
- •Idle Speed
- •It has been adjusted and set with precision at the factory.
- •Inlet Air Pressure Sensor Input Voltage Connections to ecu
- •Input Voltage at ecu Standard: 4.75 - 5.25 V dc
- •Inlet Air Pressure Sensor (Service Code 12)
- •Inlet Air Pressure Sensor Output Voltage Connection to Sensor
- •Inlet Air Pressure Sensor (Service Code 12)
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Resistance Standard: 1.6 - 3.7 kH at 20°c (68°f)
- •Inlet Air Temperature Sensor (Service Code 13)
- •Input Voltage at ecu
- •Input Voltage at Sensor Connector Standard: 4.75 - 5.25 V dc
- •Input Voltage at Sensor
- •Vehicle-down Sensor (Service Code 31)
- •Valve full opening to closing)
- •Input Voltage at ecu
- •Input Voltage at Sensor
- •A warning
- •Caution
- •If dirt gets into the engine, excessive engine wear and possible engine damage will occur. •
- •A warning
- •Air Line
- •A warning
- •A warning
- •In the tank cap. This could cause damage and clogging of the labyrinth in the cap.
- •A warning
- •A warning
- •A warning
- •Cooling System table of contents
- •Special Tool
- •6 Cooling system Coolant Flow Chart
- •If coolant must be added often, or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. * •
- •Radiator, Radiator Fan
- •A warning
- •Radiator, Radiator Fan
- •Radiator, Radiator Fan
- •Caution
- •Engine Top End table of contents
- •R marked side face up.
- •Rn marked side face up.
- •A marking hollow facing forward.
- •78.2: Horsepower 78.2 kW (106.3 ps) h: Honeycomb Type Catalyst
- •Caution
- •Caution •
- •Top Ring [d] Oil Ring Expander
- •Second Ring [e] Lower Oil Ring Steel Rail
- •Upper Oil Ring Steel Rail [f] Hollow
- •Muffler
- •A warning
- •Install the muffler body and exhaust pipe.
- •Clutch table of contents
- •If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. * •
- •Engine Lubrication System table of contents
- •Engine Oil Flow Chart
- •A warning
- •A warning
- •A warning
- •Engine Removal/lnstallation table of contents
- •A warning
- •Crankshaft / Transmission table of contents
- •Caution
- •A warning
- •Caution
- •Immediately dry the bolts and nuts with compressed air after cleaning.
- •Table of contents
- •A warning
- •Specia Tools
- •Inside Circlip Pliers : 57001-143
- •A warning
- •Valve Core (let out the air)
- •Inspect the rim and tire, and replace them if necessary.
- •Final Drive table of contents
- •G: Apply grease. Ho: Apply heavy oil.
- •Special Tools
- •Inside Circlip Pliers : Jack :
- •Special Tool * Inside Circlip Pliers: 57001-143 [b]
- •Special Tool - Inside Circlip Pliers: 57001-143
- •If the runout exceeds the service limit, replace the rear sprocket.
- •Brakes table of contents
- •Special Tools
- •Inside Circlip Pliers : 57001-143
- •Caution
- •Caution
- •Immediately wash away any brake fluid that spills. Note
- •Caution
- •Immediately wash away any brake fluid that spills.
- •A warning
- •A warning
- •A warning
- •Isopropyl alcohol, or ethyl alcohol.
- •A warning
- •A warning
- •Immediately wash away any brake fluid that spills. * •
- •18 Brakes Master Cylinder
- •Caution
- •Caution
- •Suspension table of contents
- •Exploded View
- •Special Tools
- •Inside Circlip Pliers : 57001-143
- •(From the top of the outer tube) note
- •If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube.
- •A warning
- •A warning
- •Caution * ★
- •24 Suspension
- •Steering table of contents
- •4 Steering Special Tools
- •A warning
- •Fairings
- •Insert the projection of rear fender rear under the rear fender front.
- •Install the front part of the flap under the rear fender rear.
- •Install the harness clamp in accordance with Harness Routing section in Appendix chapter.
- •A warning
- •Electrical System table of contents
- •Parts Location
- •Precautions
- •If by chance an excessive amount of gas is generated due to overcharging, the safety valve operates to keep the battery safe.
- •A warning
- •A warning
- •If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do standard charge later on.
- •If 24 volts is applied for more than a few seconds, the regulator/rectifier may be damaged.
- •Ignition System
- •Ignition System Troubleshooting
- •Ignition System
- •A warning
- •Ignition System
- •Ignition System
- •Ignition System
- •Ignition Coil Winding Resistance
- •Ignition System
- •A warning
- •If the reading is less than the specified value, check the following.
- •Insert the spark plug vertically into the plug hole with the plug [a] installed in the plug wrench [b],
- •Ignition System
- •Ignition System
- •Ignition System
- •1St Check
- •Interlock Operation Voltage Standard: 4 V or more
- •Ignition System
- •2Nd Check
- •Ignition System
- •Ignition System Circuit
- •Turn Signal Light Circuit
- •A warning
- •Caution
- •Appendix table of contents
- •Ic igniter in ecu trouble Fuel/air mixture incorrect:
- •Valve Seating Surface Width
- •Caution
FUEL
SYSTEM (DFI) 3-67
Main
Throttle Sensor (Service Code 11)
Output
Voltage Inspection
Measure
the output voltage at the ECU in the same way
as
input voltage inspection. Note the following.
Digital
Voltmeter [A]
Connector
[B]
Special
Tool - Needle Adapter Set: 57001-1457
Main
Throttle Sensor Output Voltage
Connections
to ECU
Meter
(+) -> Y/W lead (terminal 2)
Meter
(-) ->
BR/BK lead (terminal 14)
Start
the engine and warm it up thoroughly.
Check
idle speed to ensure throttle opening is correct.
Standard: 1
300 r/min (rpm)
If
the idle speed is out of the specified range, adjust the
idle
speed (see Idle Speed Inspection in Periodic Mainte-
nance
chapter).
Turn
the ignition switch OFF.
Measure
the output voltage with the engine stopped, and
with
the connector joined.
Turn
the ignition switch ON.
Measure
the output voltage when the throttle is fully
opened
or completely closed.
Output
Voltage at ECU
Standard: 1.02
- 4.62 V DC (at idle throttle opening
to
full throttle opening)
NOTE
o
The
throttle sensor is operating correctly if the following
voltages
are obtained:
•1.02
VDC (or slightly higher) with the throttle at the idle
position.
•
4.62
VDC (or slightly lower) with the throttle at the fully
open
position.
CAUTION ~
Do
not remove or adjust the main throttle sensor.
Never
drop the sensor can especially on a hard surface. A shock to
the sensor can damage it. *
•
If
the output voltage is within the standard range, check the ECU for
a good ground, and power supply (see this chapter). If the ground
and power supply are good, replace the ECU.
• If
the output voltage is far out of the standard range (e.g. when the
wiring is open, the reading is 0 V), check the output voltage again
at the sensor connector.
Idle Speed
It has been adjusted and set with precision at the factory.
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3-68
FUEL SYSTEM (DFI)
Main
Throttle Sensor (Service Code 11)
Disconnect
the main throttle sensor connector [A] and
connect
the harness adapter [B] between the harness
connector
and main throttle sensor connector.
Connect
a digital meter to the harness adapter leads.
Special
Tool - Throttle Sensor Harness Adapter :
57001-1538
Throttle
Sensor Output Voltage
Connections
to Sensor
Meter
(+) -> Y/W lead
Meter
(-) -> BR/BK lead
Measure
the sensor output voltage with the engine
stopped,
and with the connector joined.
Turn
the ignition switch ON.
Measure
the output voltage when the throttle is fully opened or completely
closed.
Output
Voltage at Sensor
Standard: 1.02
- 4.62 V DC (at idle throttle
opening
to full throttle opening)
NOTE
O
The
throttle sensor is operating correctly if the following voltages are
obtained:
1.02
VDC (or slightly higher) with the throttle at the idle position.
4.62
VDC (or slightly lower) with the throttle at the fully open
position.
CAUTION
Do
not remove or adjust the main throttle sensor. It has been adjusted
and set with precision at the factory.
Never
drop the sensor, especially on a hard surface. A shock to the sensor
can damage it.
NOTE
O
The
standard voltage marked with an asterisk refers to the value when
the voltage reading at the Input Voltage Inspection shows 5V
exactly. o
When
the input voltage reading shows other than 5V, derive a voltage
range as follows.
Example:
In
the case of a input voltage of 4.75 V.
1.02
x 4.75
+ 5.00
= 0.97
V 4.62 * 4.75 + 5.00 = 4.39 V Thus, the valid range is 0.97
- 4.39
V
After
throttle sensor voltage inspection, remove the harness
adapter.
If
the reading is out of the standard range, inspect the throttle
sensor resistance.
If
the output voltage is normal, check the wiring for continuity
(see next diagram).
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FUEL
SYSTEM (DFI) 3-69
Main
Throttle Sensor (Service Code 11)
Resistance
Inspection
Turn
the ignition switch OFF.
Disconnect
the main throttle sensor connector.
Connect
a digital meter [A] to the main throttle sensor connector [B].
Measure
the main throttle sensor resistance.
Main
Throttle Sensor Resistance
Connections: BL
lead [C] <—> BR/BK lead [D]
Standard: 4
- 6 kfi
If
the reading is out of the range, replace the throttle body assy.
If
the reading is within the range, but the problem still exists,
replace the ECU (see this chapter).
Subthrottle
Valve Actuator
Subthrottle
Sensor
Main
Throttle Sensor
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3-70
FUEL SYSTEM (DFI)
Inlet
Air Pressure Sensor (Service Code 12)
CAUTION
Never
drop the sensor, especially on a hard surface. Such a shock to the
part can damage it.
Removal
Turn
the ignition switch off.
Remove:
Air
Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Pressure
Sensor Connector [A]
Inlet
Air Pressure Sensor Screw [B]
Inlet
Air Pressure Sensor [C]
Vacuum
Hose [D]
Installation
NOTE
O
The
inlet air pressure sensor is the same part as the atmospheric
sensor except that the sensor has a vacuum hose and different
wiring.
•
Install:
Vacuum
Hose [A]
Inlet
Air Pressure Sensor [B]
Torque-Inlet
Air Pressure Sensor Screw: 4.9 N-m (0.50 kgf-m, 43 in-lb)
[C]
Vacuum Hoses
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