Interlock Operation Inspection

_• Raise the rear wheel off the ground with stand.

1St Check

_• Start the engine to the following conditions.

Condition

Transmission Gear → 1st Position Clutch Lever → Release Sidestand → Down or Up

○^{Turn the ignition switch ON and push the starter button.}

○^{Then the starter motor should not turn when the starter}

system circuit is normality.

If the engine is start, inspect the starter lockout switch, neutral switch and relay box.

If their parts are normality replace the ECU.

2Nd Check

_• Start the engine to the following conditions.

Condition

Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up

○^{Turn the ignition switch ON and push the starter button.}

○^{Then the starter motor should turn when the starter sys-}

tem circuit is normality.

If the starter motor is not turn, inspect the starter lockout switch, neutral switch and relay box.

If their parts are normality replace the ECU.

3Rd Check

_• Inspect the engine for its secure stop after the following operations are completed.

_• Run the engine to the following conditions.

Condition

Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up

_• Set the sidestand on the ground, then the engine will stop.

If whichever may not be stopped, inspect the neutral

switch, starter lockout switch, sidestand switch and relay box.

If their parts are normality, replace the ECU.

Ic Igniter Inspection

○^{The IC igniter is built in the ECU [A].}

_• Refer to the Interlock Operation Inspection, Ignition Sys- tem Troubleshooting chart and Fuel System (DFI) chapter

for ECU Power Supply Inspection.

Ignition System Circuit

1. Ignition Switch

2. Engine Stop Switch

3. Spark Plugs

4. Stick Coils

5. Water-proof Joint C

6. Speed Sensor

7. Subthrottle Sensor

8. Main Throttle Sensor

9. Water-proof Joint D

10. Vehicle-down Sensor

11. Water-proof Joint E

12. Water Temperature Sensor

13. Neutral Switch

14. Crankshaft Sensor

15. Oxygen Sensor

16. Meter Unit

17. Water-proof Joint A

18. Water-proof Joint B

19. Starter Lockout Switch

20. Oxygen Sensor Heater Fuse 10 A

21. ECU Fuse 15 A

22. Ignition Fuse 10 A

23. Fuse Box

24. ECU Main Relay

25. Relay Box

26. Main Fuse 30 A

27. Starter Relay

28. Battery 12 V 10 Ah

29. Frame Ground

30. Sidestand Switch

31. Joint Connector

32. ECU

Starter Motor Removal

_• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Right Center Fairing (see Center Fairing Removal in the Frame chapter)

_• Slide back the rubber cap [A].

_• Remove the starter motor cable terminal nut [B].

_• Remove the mounting bolts [A].

_• Pull out the starter motor [B].

Starter Motor Installation

_• When installing the starter motor, clean the starter mo- tor legs [A] and crankcase [B] where the starter motor is

grounded.

_• Replace the O-ring [A] with a new one.

_• Apply grease to the O-ring.

_• Apply a non-permanent locking agent to the threads of

the bolts and tighten the bolts.

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

_• Install the starter motor cable.

_• Tighten:

Torque - Starter Motor Cable Terminal Nut: 6.0 N·m (0.60

kgf·m, 53 in·lb)

Starter Motor Disassembly

_• Remove the starter motor (see Starter Motor Removal).

_• Take off the starter motor through bolts [A] and remove

the both end covers [B] and pull the armature out of the

yoke [C].

_• Remove:

Terminal Locknut and Washers

O-ring

_• Remove the brush plate assy [A] from the yoke [B].

_• Remove the brush plate [A] from the plate cover [B].

NOTE

○^{Do not remove the negative carbon brushes form the}

brush plate.

Starter Motor Assembly

_• Install the brush plate [A] to the plate cover [B] as shown.

_• Install the brush plate assy to the yoke.

_• Clamp the springs [A] with the clips [B].

_• Fit the armature [C] to the brush plate assy [D].

_• Remove the clips.

_• Install the new O-ring [A] as shown.

_• Install:

Washers [B] and Terminal Locknut [C]

_• Tighten:

Torque - Starter Motor Terminal Locknut: 11 N·m (1.1

kgf·m, 97 in·lb)

_• Align the lines [A] on the yoke with the end cover lines [B].

_• Tighten the through bolts.

Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m,

43 in·lb)

Brush Inspection

_• Measure the length of each brush [A].

If any is worn down to the service limit, replace the brush

plate assy [B] and the terminal bolt assy [C].

Starter Motor Brush Length Standard: 12 mm (0.47 in.)

Service Limit: 6.0 mm (0.24 in.)

Commutator Cleaning and Inspection

_• Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves.

_• Measure the diameter [A] of the commutator [B].

If the commutator diameter is less than the service limit,

replace the starter motor with a new one .

Commutator Diameter

Standard: 28 mm (1.10 in.)

Service Limit: 27 mm (1.06 in.)

Armature Inspection

_• Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A].

Special Tool - Hand Tester: 57001-1394

If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.

_• Using the highest hand tester range, measure the resis-

tance between the segments and the shaft [B].

If there is any reading at all, the armature has a short and the starter motor must be replaced.

NOTE

○^{Even if the foregoing checks show the armature to be}

good, it may be defective in some manner not readily

detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.

Brush Lead Inspection

_• Using the × 1 Ω hand tester range, measure the resis- tance as shown.

Terminal Bolt and Positive Brushes [A] Brush Plate and Negative Brushes [B]

Special Tool - Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assy and/or the brush plate assy.

Brush Plate and Terminal Bolt Inspection

_• Using the highest hand tester range, measure the resis- tance as shown.

Terminal Bolt and Brush Plate [A]

Terminal Bolt and Negative Brush Holders [B] Terminal Bolt and Yoke [C]

Special Tool - Hand Tester: 57001-1394

If there is any reading, the brush plate assy and/or termi- nal bolt assy have a short. Replace the brush plate assy and the terminal bolt assy.

Starter Relay Inspection

_• Remove:

Bolt [A] and Cover [B]

_• Disconnect the connector [A].

_• Disconnect the starter motor cable [B] and battery positive

(+) cable [C] from the starter relay [D].

_• Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown.

Special Tool - Hand Tester: 57001-1394

If the relay does not work as specified, the relay is defec- tive. Replace the relay.

Testing Relay

Tester Range: × 1 Ω range

Criteria: When battery is connected → 0 Ω

When battery is disconnected → ∞ Ω

Electric Starter Circuit

1. Ignition Switch

2. Water-proof Joint B

3. Starter Lockout Switch

4. Ignition Fuse 10 A

5. Fuse Box

6. Starter Circuit Relay

7. Relay Box

8. Starter Motor

9. Starter Relay

10. Main Fuse 30 A

11. Battery 12 V 10 Ah

12. Sidestand Switch

13. Frame Ground

14. Joint Connector

15. Neutral Switch

16. Water-proof Joint C

17. Starter Button

18. Engine Stop Switch

This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released.

Headlight Beam Horizontal Adjustment

_• Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter.

Headlight Beam Vertical Adjustment

_• Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter.

Headlight Bulb Replacement

_• Remove:

Upper Inner Fairing (see Upper Inner Fairing Removal

in the Frame chapter) Headlight Connector [A] Headlight Bulb Dust Cover [B]

_• Remove: Hook [A]

Headlight Bulb [B]

NOTE

○^{Clean off any contamination that inadvertently gets on}

the bulb with alcohol or soap and water solution.

_• Replace the headlight bulb.

_• Fit the projection [A] of the bulb in the hollow [B] of the

headlight.

_• Install the hook [C].

_• Fit the dust cover [A] onto the bulb [B] firmly as shown. Good [C]

Bad [D]

_• After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).

City Light Bulb Replacement (Europe Models)

_• Remove the meter cover (see Meter Unit Removal/Instal- lation).

_• Disconnect the connector [A].

_• Pull out the socket [B] together with the bulb.

_• Pull the bulb [A] out of the socket.

_• Replace the bulb with a new one.

Headlight Removal/Installation

_• Remove:

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Mounting Bolts [A]

_• Installation is the reverse of removal.

Tail/Brake Light Removal

_• Remove:

Seat Covers (see Seat Cover Removal in the Frame

chapter)

_• Disconnect the connector [A].

_• Unscrew the mounting bolts [B].

_• Remove the tail/brake light [C].

Tail/Brake Light Installation

_• Installation is the reverse of removal.

License Plate Light Bulb Replacement

_• Remove: Screws [A]

License Plate Light Cover [B]

_• Push and turn the bulb counterclockwise and remove it.

_• Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○^{Turn the bulb about 15°.}

_• Install the license plate light cover.

_• Tighten:

Torque - License Plate Light Cover Screws: 0.90 N·m (0.090 kgf·m, 8 in·lb)

Headlight/Tail Light Circuit

1. Ignition Switch

2. Water-proof Joint A

3. Water-proof Joint B

4. Position Light

5. Headlight (High Beam)

6. Headlight (Low Beam)

7. Dimmer Switch

8. Passing Switch

9. Headlight Relay

10. Relay Box 11. Starter Relay

Turn Signal Light Bulb Replacement

_• Unscrew the screw [A] and remove the lens [B].

○^{Turn the lens counterclockwise.}

12. Main Fuse 30 A

13. Battery 12 V 10 Ah

14. Frame Ground

15. Tail/Brake Light

16. License Plate Light 12 V 5 W

17. Joint Connector

18. Water-proof Joint C

19. Regulator/Rectifier

20. Fuse Box

21. Headlight Fuse 10 A

22. Tail Light Fuse 10 A

_• Push and turn the bulb [A] counterclockwise and remove it.

_• Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○^{Turn the bulb about 15°.}

_• Install the projections of the lens to the dints of the turn signal light.

Turn Signal Relay Inspection

_• Remove:

Left Upper Inner Fairing (see Upper Inner Fairing Re-

moval in the Frame chapter) Turn Signal Relay [A]

_• Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights

flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C]

If the lights do not flash as specified, replace the turn sig- nal relay.

Testing Turn Signal Relay

Load		Flashing Times (c/m*)
The Number of Turn Signal Lights	Wattage (W)
1**	21 or 23		140  250
2	42 or 46		75  95

(*): Cycle(s) per minute

(**): Corrected to “one light burned out”.

Turn Signal Light Circuit

1. Meter Unit

2. Water-proof Joint A

3. Water-proof Joint B

4. Front Right Turn Signal Light

5. Front Left Turn Signal Light

6. Turn Signal Relay

7. Hazard Button

8. Turn Signal Switch

9. Fuse Box

10. Turn Signal Relay Fuse 10 A

11. Main Fuse 30 A

12. Battery 12 V 10 Ah

13. Frame Ground

14. Rear Right Turn Signal Light

15. Rear Left Turn Signal Light

16. Joint Connector

17. Water-proof Joint C

18. Ignition Switch

19. Frame Ground