30 A Main Fuse Removal

_• Remove:

Left Side Cover (see Side Cover Removal in the Frame

chapter)

Cover (see Starter Relay Inspection) Connector [A]

_• Pull out the main fuse [B] from the starter relay with needle

nose pliers.

Fuse Box Fuse Removal

_• Remove the seat (see Seat Removal in the Frame chap- ter).

_• Unlock the hook [A] to lift up the lid [B].

_• Pull the fuses [A] straight out of the fuse box with needle nose pliers.

15 A ecu Fuse Removal

_• Remove:

Seat (see Seat Removal in the Frame chapter)

_• Unlock the hook [A] to pull the lid [B].

_• Pull out the ECU fuse [A] from the fuse box.

Fuse

Fuse Installation

_• If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a

new fuse of proper amperage.

_• Install the fuse box fuses on the original position as spec- ified on the lid.

Fuse Inspection

_• Remove the fuse (see 30 A Main/Fuse Box /15 A ECU Fuse Removal).

_• Inspect the fuse element.

If it is blown out, replace the fuse. Before replacing a

blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.

Housing [A]

Fuse Element [B] Terminals [C] Blown Element [D]

Appendix Table of Contents

Cable, Wire, and Hose Routing .............................................................................................. 17-2

Troubleshooting Guide 17-46

17

1. Clamp (From the on sequentially, through the ignition switch lead, left switch housing lead and main harness.)

2. Left Switch Housing Lead Connector

3. Clamp (Insert the clamp from air cleaner side.)

4. Air Switching Valve Lead Connector

5. Main Harness

6. Clamp

7. Clamp (Insert the clamp in the frame.)

8. Clamp (Insert the clamp in the frame.)

9. Clamp

10. Inlet Temperature Sensor Lead Connector

11. Clamp (Insert the clamp from air cleaner side.)

12. Ignition Switch Lead Connector

13. Clamp (Clamp the left switch housing lead (main harness side), ignition switch lead (main har- ness side) and air switching valve lead.)

14. Through the air switching valve lead on the left switch housing lead.

1. Relay Box

2. Main Harness

3. Clamp (Insert the clamp in the bracket.)

4. Battery Negative Cable

5. Battery Positive Cable

6. ECU Connectors

7. Clamp

8. Clamp

9. Tail Light Connector

10. License Plate Light Connector

11. Rear Left Turn Signal Light Connector

12. Rear Right Turn Signal Light Connector

13. Clamp (Insert the clamp in the rear fender rear.)

14. Frame Ground

15. Clamp

16. Water-proof Joint

17. Clamp

18. Fuse Box

19. Clamp

20. Clamp

21. Band

22. Band

23. Clamp

24. To the Vehicle-down Sensor, Crankshaft Sensor and Rear Brake Switch

25. Clamp (Clamp the regulator/rectifier lead, and insert the clamp in the rear fender front.)

26. Battery Negative Lead Connector

27. Fuel Pump Lead

28. Starter Motor Cable

29. To Starter Relay

30. Regulator/Rectifier Lead

31. View A

EX650B Models

1. To Main Harness

2. Battery Positive Cable

3. ABS Kawasaki Self-diagnosis System Connector (Insert the connector to the bracket.)

4. ABS Motor Relay Fuse

5. ABS Solenoid Valve Relay Fuse

1. Inlet Pressure Sensor

2. Turn Signal Relay

3. Air Cleaner Drain Tube

4. From this side, through the fuel tank drain tube, corrugated tube and air cleaner drain tube between chain guide and engine.

5. To the Water Temperature Sensor

6. Oxygen Sensor Lead Connector

7. Clamp (Through the sidestand switch lead and oxygen sensor lead in the clamp.)

8. Oxygen Sensor Lead

9. Clamp (Through the drain hose in the clamp.)

10. Drain Hose

11. Sidestand Switch Lead

12. Corrugated Tube

13. Alternator Lead Connector

14. Sidestand Switch Lead Connector

15. Speed Sensor Lead Connector

16. Main Throttle Sensor Lead Connector

17. Tube

18. Neutral Switch Lead

19. Drain Hose (Through the drain hose between main harness and air cleaner.)

20. Clamp (Insert the clamp in the cross pipe.)

1. Clamp (Through the right switch housing lead, and insert the clamp in the frame.)

2. Clutch Cable

3. Throttle Cables

4. Clamp

5. Right Switch Housing Lead

6. Clamp (Through the clutch cable in the clamp.)

7. Frame (Through the coolant hose in the frame.)

8. Coolant Hose

9. Clamp

1. Brake Hose

2. Clutch Cable

3. Throttle Cables

4. Clamp

5. Right Switch Housing Lead

6. Clamp (Through the clutch cable in the clamp.)

7. Frame (Through the coolant hose in the frame.)

8. Coolant Hose

9. Clamp

10. Clamp (Clamp the right switch housing lead connector.)

11. Bracket

12. Throttle Cables

13. Through the brake hose at the right side of the throttle cables.

1. Right Switch Housing Lead

2. Throttle Cable (Decelerator)

3. Throttle Cable (Accelerator)

4. Through the brake hose at the right side of the throttle cables.

1. Crankshaft Sensor Lead Connector

2. Clamp (Insert the clamp in the bracket.)

1. Tail Light Connector

2. License Plate Light Connector

3. Rear Right Turn Signal Light Connector

4. Rear Left Turn Signal Light Connector

5. Clamp (Insert the clamp in the rear fender rear.)

6. Clamp (Insert the clamp in the rear fender rear.)

7. Diagnosis Connector

8. Clamp (Insert the clamp in the rear fender front.)

9. Rear Brake Light Switch Lead

10. Band (Clamp the main harness with the frame.)

11. Band

12. ABS Kawasaki Self-diagnosis System Connector (EX650B Models)

5. Brake Hose

6. Clamp

7. Ignition Switch Lead

8. Main Harness

9. Left Switch Housing Lead

10. Clutch Cable

11. Clamp (Insert the clamp to the inner fairing.)

12. Clamp

13. Clamp

14. Clamp (Clamp the left switch housing lead and ignition switch lead.) 15. 20 mm (0.79 in.)

16. 50 mm (1.97 in.)

EX650B Models

5. Brake Hose (Through the brake hose at the right side of the throttle cables.)

6. Clamp

7. Ignition Switch Lead

8. Main Harness

9. Left Switch Housing Lead

10. Clutch Cable

11. Clamp (Insert the clamp to the inner fairing.)

12. Clamp

13. Clamp

14. Front Wheel Rotation Sensor Lead

15. Front

16. Baffle Plate

17. Clamp (Insert the clamp to the baffle plate.)

18. Front Wheel Rotation Sensor Lead Connector

19. Clamp (Clamp the left switch housing lead and ignition switch lead.) 20. 20 mm (0.79 in.)

21. 50 mm (1.97 in.)

1. Clamp

2. Clamp

3. Clamp

4. Clamp (Clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe.)

5. Ground Lead

6. Clamp

7. Subthrottle Sensor Lead Connector

8. Subthrottle Valve Actuator Lead Connector

9. Clamp (Clamp the harness.)

10. Clamp 11. Clamp

12. Stick Coil Lead Connector

13. Clamp (Clamp the stick coil lead.)

14. Clamp (Push the subthrottle valve actuator lead, and clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe.)

1. Regulator/Rectifier Lead

2. Clamp (Insert the clamp in the frame.)

3. Rear Brake Light Switch Lead Connector

4. Through the rear brake light switch lead and vehicle-down sensor lead from the front side of the rear shockabsorber installation part.

5. Through the regulator/rectifier lead to the front opening of the rear fender front.

6. Vehicle-down Sensor Lead

7. Fuel Pump Lead Connector

8. Through the fuel pump lead to the hook of the rear fender front (Routing is done so that there is no slack.).

9. Through the fuel pump lead to the slit of the cover.

1. ABS Hydraulic Unit Lead (ECU) (Through the lead to the forward of frame cross pipe.)

2. ABS Hydraulic Unit

3. Through the rear wheel rotation sensor lead upper the starter motor cable and engine ground cable.

4. Through the regulator/rectifier lead in the clamp.

5. Through the rear wheel rotation sensor lead upper the brake hose.

6. Rear Wheel Rotation Sensor Lead

7. Through the regulator/rectifier lead under the brake fluid reservoir hose.

8. Through the vehicle-down sensor lead under the brake hose.

9. Clamp (Clamp the brake hose and rear wheel rotation sensor lead.)

10. Through the rear wheel rotation sensor lead upper the rear brake light switch lead.

11. Through the rear wheel rotation sensor lead under the brake hose.

1. Front Wheel Rotation Sensor Lead

2. Ignition Switch Lead

3. Left Switch Housing Lead

4. Clamp (Clamp the front wheel rotation sensor lead.)

5. Main Harness

6. Clamp (Clamp the front wheel rotation sensor lead.)

1. To Meter Unit

2. Clamp

3. To Front Right Turn Signal Light Lead

4. Left Switch Housing Lead

5. Ignition Switch Lead

6. Main Harness

7. To Front Left Turn Signal Light Lead

1. Clamp

2. Clamp (Insert the clamp to the inner fairing.)

3. Clamp (Insert the clamp to the upper fairing bracket.)

California Model

1. Through the hose between main harness and air cleaner housing.

2. To Fuel Tank (Red)

3. To Fuel Tank (Blue)

4. Left Side View

5. Through the hose between main harness and air cleaner housing.

6. Front

7. Lower Side View

3. Clamp

4. Clamp

EX650B Models

EX650B Models

4. Clamp

NOTE

○^{Refer to the Fuel System chapter for most}

of DFI trouble shooting guide.

○^{This is not an exhaustive list, giving every}

possible cause for each problem listed. It

is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.