- •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
Input Voltage at Actuator
Standard: About 8.5 10.5 V DC
If the reading is within the standard but the actuator doesn’t operate, replace it.
If the reading is out of the range, check the wiring to ECU (see wiring diagram in this section).
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
Subthrottle Valve Actuator Circuit
ECU
Subthrottle Valve Actuator
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation
• Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter.
Air Switching Valve Inspection
• Refer to the Air Switching Valve Operation Test/Unit Test in the Electrical System chapter.
• Remove the fuel tank (see Fuel Tank Removal) and check
the wiring continuity, using the following diagram.
Air
Switching Valve Circuit
ECU
Air Switching Valve
Water-proof Joint C
Ignition Switch
Water-proof Joint A
ECU Fuse 15 A
ECU Main Relay
Relay Box
Main Fuse 30 A
Battery
Frame Ground
Joint Connector
Oxygen Sensor Heater (Service Code 67) (Europe Models)
Oxygen Sensor Heater Removal/Installation
The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
Oxygen
Sensor Heater Inspection
• Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter).
• Disconnect the oxygen sensor lead connector [A].
•
Set the hand tester [A] to the × 1 Ω range and connect it to
the terminals in the oxygen sensor lead connector [B].
Black [C] Black [D]
Special Tool - Hand Tester: 57001-1394
Oxygen Sensor Resistance
Standard: 11.7 14.5 Ω at 20°C (68°F)
If the tester reading is not as specified, replace the oxygen sensor with a new one.
If
the tester reading is specified, check the power source voltage
Inspection.
NOTE
○Be sure the battery is fully charged.
• Connect a digital voltmeter [A] to the oxygen sensor con- nector [B], using the needle adapter [C].
Special Tool - Needle Adapter Set: 57001-1457
• Measure the power source voltage with the engine stopped, and with the oxygen sensor connector joined.
Oxygen Sensor Power Source Voltage Connections to Oxygen Sensor Connector
Tester (+) → W/Y lead [D]
Tester (−) → Battery (−) Terminal [E]
Standard: Battery Voltage (12.8 V or more)
Oxygen Sensor [F]
If the reading is incorrect, check the following. Battery
Main Fuse 30 A
Oxygen Sensor Heater Fuse 10 A
If the reading is good, the power source voltage is normal, Inspect the Red/Black lead between the oxygen sensor connector and the ECU for continuity, using the following diagram.
If the wiring is good, inspect the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Oxygen Sensor Heater (Service Code 67) (Europe Models)
Oxygen Sensor Circuit
ECU
Oxygen Sensor
Water-proof Joint E
Water-proof Joint D
Oxygen Sensor Heater Fuse 10 A
Main Fuse 30 A
Battery
Frame Ground
Joint Connector
