Electrical System
Spark Plug Condition Inspection
• Remove the spark plugs (see Spark Plug Replacement).
• Visually inspect the spark plugs.
If the spark plug center electrode [A] and/or side elec-
trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated, replace the spark plug.
• Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap: 0.8 0.9 mm (0.03 0.04 in.)
• Use the standard spark plug or its equivalent.
Spark Plug: CR9EIA-9
Lights
and Switches Operation Inspection
First Step
• Turn on the ignition switch.
City Light [A] |
goes on |
Taillight [B] |
goes on |
License Plate Light [C] |
goes on |
Meter Panel LCD [D] |
goes on |
Neutral Indicator Light (LED) [E] |
goes on |
Oil Pressure Warning Indicator Light (LED) [F] |
goes on |
Water Temperature Warning Indicator Light (LED) [G] |
goes on |
FI Indicator Light (LED) [H] |
goes on (about 2 seconds) |
• The following lights should go on according to below table.
EX650B
Models
If the light does not go on, inspect or replace the following item.
Battery
(see Charging Condition Inspection in the Elec- trical System
chapter)
Applicable Bulb (see Wiring Diagram in the Electrical System chapter)
Meter Unit for Meter Panel LCD (see Electronic Com- bination Meter Unit Inspection in the Electrical System chapter)
Meter Unit for Neutral Indicator Light (LED) (see Elec- tronic Combination Meter Unit Inspection in the Electri- cal System chapter)
Meter Unit for Oil Pressure Warning Indicator Light (LED) (see Electronic Combination Meter Unit Inspec- tion in the Electrical System chapter)
Meter Unit for FI Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical Sys- tem chapter)
Meter Unit for Water Temperature Warning Indicator Light (LED) (see Electronic Combination Meter Unit Inspection in the Electrical System chapter)
Meter Unit for ABS Indicator Light (LED) (see ABS In- dicator Light (LED) Inspection in the Brakes chapter) (EX650B Models)
ECU (see ECU Power Supply Inspection in the Fuel Sys- tem (DFI) chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In- spection in the Electrical System chapter)
Ignition Switch (see Switch Inspection in the Electrical System chapter)
Neutral Switch (see Switch Inspection in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System chapter)
• Turn off the ignition switch.
• The all lights should go off.
If the light does not go off, replace the ignition switch.
Second Step
• Turn the ignition switch to P (Park) position.
• The city light, taillight and license plate light should go on.
If the light does not go on, inspect or replace the following
item.
Ignition Switch (see Switch Inspection in the Electrical System chapter)
Third
Step
• Turn on the turn signal switch [A] (left or right position).
• The left or right turn signal lights [B] (front and rear) ac-
cording to the switch position should flash.
• The turn signal indicator light (LED) [C] in the meter unit should flash.
If the each light does not flash, inspect or replace the following item.
Turn Signal Light Bulb (see Turn Signal Light Bulb Re- placement in the Electrical System chapter)
Meter
Unit for Turn Signal
Light Indicator Light (LED) (see
Electronic Combination
Meter Unit
Inspection in
the Electrical System
chapter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri- cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter)
Harness
(see Wiring Inspection in the Electrical
System chapter)
• Push the turn signal switch.
• The turn signal lights and indicator light (LED) should go
off.
If the light does not go off, inspect or replace the following item.
Turn Signal Switch (see Switch Inspection in the Electri- cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter)
Fourth
Step
• Set the dimmer switch [A] to low beam position.
• Start the engine.
• The low beam headlight should go on.
If the low beam headlight does not go on, inspect or re-
place the following item.
Headlight Low Beam Bulb (see Headlight Bulb Replace- ment in the Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electri- cal System chapter)
Dimmer Switch (see Switch Inspection in the Electrical System chapter)
Headlight Relay in Relay Box (see Relay Circuit Inspec- tion in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System chapter)
•
Set the dimmer switch to high beam position.
• The low beam [A] and high beam [B] headlights should
go on.
• The high beam indicator light (LED) [C] should go on.
If the high beam headlight and/or high beam indicator light
(LED) does not go on, inspect or replace the following item.
Headlight High Beam Bulb (see Headlight Bulb Replace- ment in the Electrical System chapter)
Dimmer
Switch (see Switch Inspection in the Electrical System chapter)
• Turn off the engine stop switch.
• The low beam and high beam headlights should stay go-
ing on.
If the headlights and high beam indicator light (LED) does go off, inspect or replace the following item.
Headlight Relay in Relay Box (see Relay Circuit Inspec- tion in the Electrical System chapter)
• Turn off the ignition switch.
• The headlights and high beam indicator light (LED) should
go off.
Headlight Aiming Inspection
• Inspect the headlight beam for aiming.
If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.
Headlight
Beam Horizontal Adjustment
• Turn the horizontal adjuster [A] on the headlight with the screwdriver in or out until the beam points straight ahead.
If the headlight beam points too low or high, adjust the vertical beam.
Headlight
Beam Vertical Adjustment
• Turn the vertical adjuster [A] on the headlight with the screwdriver in or out to adjust the headlight vertically.
NOTE
○ON high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an- gle according to local regulations.
○For US model, the proper angle is 0.4 degrees below
horizontal. This is 50 mm (2 in.) drop at 7.6 m (25
ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.
50
mm (2 in.) [A]
Center of Brightest Spot [B] 7.6 m (25 ft) [C]
Low Beam [D]
Height of Headlight Center [E] High Beam [F]
Sidestand
Switch Operation Inspection
• Inspect the sidestand switch [A] operation accordance to below table.
Sidestand Switch Operation
Sidestand |
Gear Position |
Clutch Lever |
Engine Start |
Engine Run |
Up |
Neutral |
Released |
Starts |
Continue running |
Up |
Neutral |
Pulled in |
Starts |
Continue running |
Up |
In Gear |
Released |
Doesn’t start |
Stops |
Up |
In Gear |
Pulled in |
Starts |
Continue running |
Down |
Neutral |
Released |
Starts |
Continue running |
Down |
Neutral |
Pulled in |
Starts |
Continue running |
Down |
In Gear |
Released |
Doesn’t start |
Stops |
Down |
In Gear |
Pulled in |
Doesn’t start |
Stops |
If the sidestand switch operation does not work, inspect or replace the following item.
Battery (see Charging Condition Inspection in the Elec- trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Ignition Switch (see Switch Inspection in the Electrical System chapter)
Sidestand Switch (see Switch Inspection in the Electrical System chapter)
Engine Stop Switch (see Switch Inspection in the Elec- trical System chapter)
Starter Button (see Switch Inspection in the Electrical System chapter)
Neutral Switch (see Switch Inspection in the Electrical System chapter)
Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System chapter)
If the all parts are good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chap- ter).
Engine
Stop Switch Operation Inspection
First Step
• Turn on the ignition switch.
• Set the neutral position.
• Turn the engine stop switch to stop position [A].
• Push the starter button.
• The engine does not start.
If the engine starts, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Elec- trical System chapter)
Second
Step
• Turn on the ignition switch.
• Set the neutral position.
• Turn the engine stop switch to run position [A].
• Push the starter button and run the engine.
• Turn the engine stop switch to stop position.
• Immediately the engine should be stop.
If the engine does not stop, inspect or replace the follow-
ing item.
Engine Stop Switch (see Switch Inspection in the Elec- trical System chapter)
If the engine stop switch is good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).
Others
Chassis Parts Lubrication
• Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri- cation.
Pivots: Lubricate with Grease.
Brake Lever Brake Pedal Clutch Lever
Rear Brake Joint Pin Sidestand
Points:
Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A] Throttle Inner Cable Upper and Lower Ends
Cables:
Lubricate with Rust Inhibitor.
Clutch Cable Throttle Cables
• Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
•
With the cable disconnected at both ends, the inner
cable should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
Bolts, Nuts and Fasteners Tightness Inspection
• Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the spec- ified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table. For each fastener, first loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Nut
Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts
Wheels: Front Axle
Front Axle Clamp Bolt Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Brake Lever Pivot Nut Brake Pedal Bolt
Brake Rod Joint Cotter Pin Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolt and Nut Swingarm Pivot Shaft Nut
Steering:
Steering Stem Head Bolt Handlebar Holder Bolts
Others:
Footpeg Stay Bolts Front Fender Bolts Sidestand Bolt