- •Foreword
- •General Information Table of Contents
- •Inspection
- •Instrument
- •Model Identification
- •Technical Information - Cassette Type Transmission
- •Technical Information - Inlet Air Pressure Sensor
- •Inlet Solenoid Valve
- •Unit Conversion Table Prefixes for Units:
- •Units of Power:
- •Periodic Maintenance Table of Contents
- •Idle Speed Inspection ....................................................................................................... 2-18
- •Idle Speed Adjustment...................................................................................................... 2-18
- •Valve Clearance Inspection .............................................................................................. 2-21
- •Valve Clearance Adjustment............................................................................................. 2-23
- •Periodic Inspection
- •Basic Torque for General Fasteners
- •Specifications
- •Special Tools
- •Inside Circlip Pliers: 57001-143
- •Fuel System (dfi)
- •Idle Speed Inspection
- •Idle Speed
- •Idle Speed Adjustment
- •Evaporative Emission Control System (California Model)
- •Cooling System
- •Air Suction System
- •Engine Top End
- •Valve Clearance Inspection
- •Valve clearance adjustment chart inlet valve
- •Valve clearance adjustment chart exhaust valve
- •Wheels/Tires
- •(Over 130 km/h (80 mph))
- •Drive Train
- •Brake System
- •Suspensions
- •Steering System
- •Electrical System
- •Replacement Parts
- •Viscosity: sae 10w-40
- •1.9 L (2.0 us qt) (when filter is removed)
- •2.4 L (2.5 us qt) (when engine is completely dry) note
- •It does not reach to this tightening torque.
- •Fuel System (dfi) Table of Contents
- •Inquiries to Rider.................................................................................................................. 3-26
- •Inquiries to Rider............................................................................................................... 3-26
- •Terminal Names
- •Dfi Parts Location
- •Specifications
- •Special Tools and Sealant
- •Dfi Servicing Precautions
- •Dfi Servicing Precautions
- •Inquiries to Rider
- •Inquiries to Rider
- •Sample Diagnosis Sheet
- •Engine Doesn’t Start, Starting Difficulty
- •Self-diagnosis Procedures
- •Service Code Clearing Procedures
- •How to Erase Service Codes
- •Backups
- •Idle Speed Standard: 1 300 ±50 r/min (rpm)
- •Inlet Air Pressure Sensor Removal
- •Inlet Air Pressure Sensor Installation
- •Inlet Air Pressure Sensor Input Voltage Inspection note
- •Inlet Air Pressure Sensor Input Voltage Connections to ecu
- •Inlet Air Pressure Sensor Output Voltage Inspection note
- •Inlet Air Pressure Sensor Output Voltage Connections to ecu
- •Inlet Air Pressure Sensor Output Voltage Connection to Adapter
- •Inlet Air Pressure Sensor Circuit
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Removal/Installation
- •Inlet Air Temperature Sensor Output Voltage Inspection note
- •Inlet Air Temperature Sensor Output Voltage Connections to ecu Connector
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Resistance Inspection
- •Inlet Air Temperature Sensor Circuit
- •Water Temperature Sensor (Service Code 14)
- •Water Temperature Sensor (Service Code 14)
- •Crankshaft Sensor (Service Code 21)
- •Speed Sensor (Service Code 24, 25)
- •Speed Sensor (Service Code 24, 25)
- •Vehicle-down Sensor (Service Code 31)
- •Vehicle-down Sensor Output Voltage Connections to Sensor
- •Vehicle-down Sensor Circuit
- •Oxygen Sensor-not activated (Service Code 33) (Europe Models)
- •Oxygen Sensor-not activated (Service Code 33) (Europe Models)
- •Stick Coils #1, #2: (Service Code 51, 52)
- •Stick Coil Removal/Installation
- •Input Voltage at ecu
- •Stick Coils #1, #2: (Service Code 51, 52)
- •Radiator Fan Relay (Service Code 56)
- •Subthrottle Valve Actuator (Service Code 62)
- •Subthrottle Valve Actuator (Service Code 62)
- •Input Voltage at Actuator
- •Air Switching Valve (Service Code 64)
- •Oxygen Sensor Heater (Service Code 67) (Europe Models)
- •Oxygen Sensor Heater (Service Code 67) (Europe Models)
- •Fi Indicator Light (led)
- •Inspection Flow Chart
- •Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
- •Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
- •Ignition Switch off: Terminal 16 (br/w): 0 V
- •Needle Adapter Set: 57001-1457
- •Standard: Battery Voltage (12.8 V or more) for 3 seconds, and then 0 V.
- •Injector Output Voltage Connections to Injector #1
- •Injector Wiring Inspection
- •Injector Signal Test
- •Injector Resistance Inspection
- •Injector Resistance Connections to Injector
- •#1: W/r ←→ bl/r Terminal #2: w/r ←→ bl/g Terminal
- •Injector Unit Test
- •Injector Fuel Line Inspection
- •Injector Fuel Line Maximum Pressure Standard: 333 kPa (3.4 kgf/cm², 48 psi)
- •Idle Speed Inspection
- •Throttle Body Assy
- •Throttle Body Assy
- •Air Cleaner
- •Air Cleaner
- •Evaporative Emission Control System (California Model)
- •Evaporative Emission Control System (California Model)
- •Cooling System Table of Contents
- •Exploded View
- •Coolant Flow Chart
- •Specifications
- •Coolant
- •Coolant
- •Water Pump
- •Impeller Assembly
- •Thermostat
- •Thermostat
- •Hose and Pipes
- •Water Temperature Sensor
- •Engine Top End Table of Contents
- •Exhaust System
- •Exhaust System
- •Specifications
- •Special Tools and Sealant
- •Clean Air System
- •Clean Air System
- •Cylinder Head Cover
- •Cylinder Head Cover
- •Camshaft Chain Tensioner
- •Inlet 36.44 mm (1.4346 in.)
- •Valve Guide Removal
- •Valve Guide Installation
- •Valve-to-Guide Clearance Measurement (Wobble Method)
- •Throttle Body Holder
- •Muffler
- •Muffler
- •Clutch Table of Contents
- •Exploded View
- •Specifications
- •Clutch Lever and Cable
- •Clutch Lever and Cable
- •Clutch Cover
- •Engine Lubrication System Table of Contents
- •Exploded View
- •Engine Oil Flow Chart
- •Engine Oil and Oil Filter
- •Oil Pressure Relief Valve
- •Oil Pump
- •Oil Pump
- •Oil Pressure Measurement
- •Oil Pressure Switch
- •Engine Removal/Installation Table of Contents
- •Exploded View
- •Crankshaft/Transmission Table of Contents
- •Balancer
- •Balancer
- •Balancer Shaft Bearing Insert Selection
- •Ball Bearing, Needle Bearing, and Oil Seal
- •Wheels/Tires Table of Contents
- •Exploded View
- •Specifications
- •Service Limit:
- •Hub Bearing
- •Hub Bearing
- •Final Drive Table of Contents
- •Exploded View
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Brakes Table of Contents
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Brake Lever, Brake Pedal
- •Brake Disc
- •Brake Fluid
- •Inquiries to Rider
- •Sample Diagnosis Sheet
- •Service Code Table
- •Suspension Table of Contents
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Special Tools
- •Viscosity: kayaba khl34-g10 or equivalent
- •Inner Tube Inspection
- •Rear Shock Absorber
- •Special Tools - Jack: 57001-1238
- •Rear Shock Absorber
- •Jack Attachment: 57001-1608
- •Steering Table of Contents
- •Exploded View
- •Special Tools
- •Steering
- •Handlebar
- •Handlebar
- •Frame Table of Contents
- •Inner Fairing Removal
- •Inner Fairing Installation
- •Side Covers
- •Seat Covers
- •Fenders
- •Fenders
- •Sidestand
- •Frame Cover
- •Electrical System Table of Contents
- •Specifications
- •Parts Location
- •Parts Location
- •Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)
- •Precautions
- •Electrical Wiring
- •Initial Charge
- •Interchange
- •Rotor Holder: 57001-1658
- •Interlock Operation Inspection
- •1St Check
- •2Nd Check
- •3Rd Check
- •Ic Igniter Inspection
- •Ignition System Circuit
- •Air Switching Valve
- •Air Switching Valve
- •Radiator Fan System
- •Indicator Lights Inspection
- •12 V 3.4 w Bulb (Other Side) → bl Lead Terminal Battery (–) → bk Lead Terminal
- •30 A Main Fuse Removal
- •15 A ecu Fuse Removal
- •Appendix Table of Contents
- •Engine Doesn’t Start, Starting Difficulty:
- •Poor Running at Low Speed:
- •Poor Running or No Power at High Speed:
- •Overheating:
- •Over Cooling:
- •Clutch Operation Faulty:
- •Gear Shifting Faulty:
- •Abnormal Engine Noise:
- •Valve noise:
- •Abnormal Drive Train Noise:
- •Battery Trouble:
- •Model application
Terminal Names
Subthrottle Valve Actuator Drive Signal 2
Subthrottle Valve Actuator Drive Signal 1
Water Temperature Warning Light Signal
Unused
Oxygen Sensor Signal (Europe Models)
Speed Sensor Signal
Main Throttle Sensor Signal
Inlet Air Pressure Sensor Signal
Unused
Power Supply to Sensors
Vehicle-down Sensor Signal
Neutral Switch Signal
Crankshaft Sensor (+) Signal
Unused
Unused
Power Supply to ECU (from ECU Main Re- lay)
Power Supply to ECU (from Battery)
Subthrottle Valve Actuator Drive Signal 4
Subthrottle Valve Actuator Drive Signal 3
Water Temperature Sensor Signal
Unused
Self-diagnosis Terminal
Unused
Subthrottle Sensor Signal
Unused
Inlet Air Temperature Sensor Signal
Unused
Ground to Sensors
Oxygen Sensor Heater Signal (Europe Models)
Crankshaft Sensor (–) Signal
Unused
External Diagnosis System Signal
Unused
Ground to ECU
Engine Stop Switch Signal
Starter Lockout Switch Signal
Starter Button Signal
Unused
Fuel Pump Relay Signal
Air Switching Valve Signal
Fuel Injector #2 Signal
Fuel Injector #1 Signal
Stick Coil #1 Signal
Sidestand Switch Signal
Radiator Fan Relay Signal
External Communication Line (Mode Switch)
Tachometer Signal
FI Indicator Light (LED)
49. –
Ground for Fuel System
Ground for Ignition System
Stick Coil #2 Signal
Dfi Parts Location
DFI: Digital Fuel Injection Parts
FI Indicator Light (LED)
Ignition Switch
Throttle Body Assy
Inlet Air Temperature Sensor
Injectors
Fuel Pump
Relay Box (ECU Main Relay, Fuel Pump Relay, Radiator Fan Relay)
Fuse Box (ECU Fuse 15 A, Oxygen Sen- sor Heater Fuse 10 A)
ECU
Battery
Oxygen Sensor (Europe Models)
Speed Sensor
Neutral Switch
Water Temperature Sensor
Subthrottle Sensor
Main Throttle Sensor
Subthrottle Valve Actuator
Stick Coils
Inlet Air Pressure Sensor
Diagnosis Connector
Self-diagnosis Terminal
Air Switching Valve
Crankshaft Sensor
Vehicle-down Sensor
Specifications
Item |
Standard |
Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type
Usable Engine Speed
Fuel Pressure (High Pressure Line): Right after Ignition Switch ON After 3 Seconds from Ignition Switch ON With Engine Idling Fuel Pump: Type Discharge Fuel Injectors: Type Nozzle Type Resistance Main Throttle Sensor: Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Inlet Air Pressure Sensor: Input Voltage Output Voltage
Inlet Air Temperature Sensor: Resistance
Output Voltage at ECU Water Temperature Sensor: Resistance Output Voltage at ECU Speed Sensor: Input Voltage at Sensor Output Voltage at Sensor
Vehicle-down Sensor: Detection Method Detection Angle |
1 300 ±50 r/min (rpm) Two barrel type
Denso Digital memory type, with built in IC igniter, sealed with resin 100 11 000 r/min (rpm) (Europe Models) 100 11 160 r/min (rpm) (Other than Europe Models)
323 kPa (3.3 kgf/cm², 47 psi) with fuel pump running 265 kPa (2.7 kgf/cm², 38 psi) with fuel pump stopped 333 kPa (3.4 kgf/cm², 48 psi) with fuel pump running
In-tank friction pump 60 mL or more for 3 seconds
INP-287 One spray type with 12 holes About 11.7 12.3 Ω at 20°C (68°F) Non-adjustable and non-removable 4.75 5.25 V DC between BL and BR/BK leads 1.073 1.077 V DC between Y/W and BR/BK leads 4.29 4.49 V DC between Y/W and BR/BK leads 4 6 kΩ
4.75 5.25 V DC between BL and BR/BK leads 3.80 4.20 V DC at standard atmospheric pressure (see this text for details)
5.4 6.6 kΩ at 0°C (32°F) 0.29 0.39 kΩ at 80°C (176°F) About 2.25 2.50 V at 20°C (68°F)
see Electrical System chapter About 2.80 2.97 V at 20°C (68°F)
About 9 11 V DC at Ignition Switch ON About 0.05 0.07 V DC at Ignition Switch ON and 0 km/h
Magnetic flux detection method more than 60 70° for each bank |
Specifications
Item |
Standard |
Output Voltage |
with the sensor tilted 60 70° or more: 0.65 1.35 V |
|
with sensor arrow mark pointed up: 3.55 4.45 V |
Subthrottle Sensor: |
Non-adjustable and non-removal |
Input Voltage |
4.75 5.25 V DC between BL and BR/BK leads |
Output Voltage at Idle Throttle Opening |
0.4 0.6 V DC between BL/W and BR/BK leads |
Output Voltage at Full Throttle Opening |
3.625 3.775 V DC between BL/W and BR/BK leads |
Resistance |
4 6 kΩ |
Subthrottle Valve Actuator: |
|
Resistance |
About 5.5 7.5 Ω |
Input Voltage |
About 8.5 10.5 V DC |
Oxygen Sensor (Europe Models): |
|
Output Voltage (Rich) |
0.7 V or more |
Output Voltage (Lean) |
0.2 V or less |
Heater Resistance |
11.7 14.5 Ω at 20°C (68°F) |
Throttle Grip and Cables Throttle Grip Free Play |
2 3 mm (0.08 0.12 in.) |
Special Tools and Sealant
Oil
Pressure Gauge, 5 kgf/cm²: 57001-125
Needle Adapter Set: 57001-1457
Fork
Oil Level Gauge: 57001-1290
Throttle Sensor Setting Adapter: 57001-1538
Hand
Tester: 57001-1394
Sensor Harness Adapter: 57001-1561
Throttle Sensor Setting Adapter #1: 57001-1400
Fuel Pressure Gauge Adapter: 57001-1593
Peak Voltage Adapter: 57001-1415
Fuel Hose: 57001-1607
