GV650 GT650 Delphi Service Manual PDF

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VHUYLFH#PDQXDO
SERVICE MANUAL
<<333KE<843
FOREWORD GROUP INDEX
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This manual contains an introductory description on
HYOSUNG 『
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』 and procedures for its

GENERAL INFORMATION 1
inspection / service and overhaul of its main components.
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It covers the differences

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from Carburetor type and
please refer to the
(99000-51210)』,
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『
service manual of 『
&
EI SYSTEM DIAGNOSIS 4-1
(99000-94910)』 and 『 (99000-94810)』
for others which are not covered in this manual.
Other information considered as generally known is FUEL SYSTEM AND THROTTLE BODY 4-2
not included.
R e a d G E N E R A L I N F O R M AT I O N s e c t i o n t o
familiarize yourself with outline of the vehicle and
MAINTENANCE and other sections to use as a guide
ELECTRICAL SYSTEM 6
for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum
and quick service.
CHASSIS 7
❖ This manual has been prepared on the basis
of the latest specification at the time of SERVICING INFORMATION 8
publication.
If modification has been made since then,
difference may exist between the content of
this manual and the actual vehicle.
❖ Illustrations in this manual are used to show
the basic principles of operation and work
procedures.
They may not represent the actual vehicle
exactly in detail.
WARNING
This manual is intended for those who have
enough knowledge and skills for servicing
HYOSUNG vehicles. Without such knowledge and
skills, you should not attempt servicing by relying
on this manual only.
Instead, please contact your nearby authorized
HYOSUNG motorcycle dealer.
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model :
❖『』 model
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Ⓒ COPYRIGHT S&T Motors Co., Ltd.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE

LOOKING FOR :
1. The text of this manual is divided into sections.
2. As the title of these sections are listed on the previous
page as GROUP INDEX, select the section where you
are looking for.
3. Holding the manual as shown at the right will allow you
to find the first page of the section easily.
4. On the first page of each section, its contents are listed.
Find the item and page you need.
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing.
The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Apply or use brake fluid.
Data beside it indicates specified torque.
Apply oil.
Measure in voltage range.
Use engine oil unless otherwise specified.
Apply GREASE. Measure in resistance range.
Apply SILICONE GREASE. Measure in current range.
Apply MOLY PASTE. Measure in diode test range.
Apply GASKET BOND Measure in continuity test range.
Use fork oil. Use special tool.
Apply THREAD LOCK Use engine coolant.
2
ABBREVIATIONS USED IN THIS MANUAL
A L
ABDC : After Bottom Dead Center LCD : Liquid Crystal Display
AC : Alternating Current LED : Light Emitting Diode
API : American Petroleum Institute LH : Left Hand
ATDC : After Top Dead Center
M
B
Max : Maximum
BBDC : Before Bottom Dead Center Min : Minimum
BDC : Bottom Dead Center
BTDC : Before Top Dead Center O
O2 Sensor : Oxygen Sensor (O2S)
D
DC : Direct Current R
DOHC : Double Over Head Camshaft
RH : Right Hand
RO Switch : Roll Over Switch
E
ECU : Engine Control Unit, S
EI Control Unit SAE : Society of Automotive
EI : Electric fuel Injection, Engineers
Electric fuel Injector S/W : Switch
F T
FP : Fuel Pump TDC : Top Dead Center
TP Sensor : Throttle Position Sensor (TPS)
G
GP Switch : Gear Position Switch W
WT Sensor : Water Temperature Sensor
I (WTS)
IAP Sensor : Intake Air Pressure Sensor

(IAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS) NOTE
IG : Ignition ❖ NO.1 : For Front Cylinder
ISC Solenoid : Idle Speed Control Solenoid ❖ NO.2 : For Rear Cylinder
3
WIRE COLOR
B : Black Gr : Gray Sb : Light blue

L : Blue Lg : Light green W : White
Br : Brown O : Orange Y : Yellow
G : Green R : Red
BL : Black with Blue tracer BBr : Black with Brown tracer
BG : Black with Green tracer BO : Black with Orange tracer
BR : Black with Red tracer BW : Black with White tracer
BY : Black with Yellow tracer LB : Blue with Black tracer
LG : Blue with Green tracer LR : Blue with Red tracer
LW : Blue with White tracer LY : Blue with Yellow tracer
BrB : Brown with Black tracer BrW : Brown with White tracer
GB : Green with Black tracer GR : Green with Red tracer
GY : Green with Yellow tracer GrB : Gray with Black tracer
GrR : Gray with Red tracer GrW : Gray with White tracer
OB : Orange with Black tracer OL : Orange with Blue tracer
OG : Orange with Green tracer OR : Orange with Red tracer
OW : Orange with White tracer OY : Orange with Yellow tracer
RB : Red with Black tracer RW : Red with White tracer
WB : White with Black tracer WL : White with Blue tracer
WR : White with Red tracer YB : Yellow with Black tracer
YL : Yellow with Blue tracer YG : Yellow with Green tracer
YR : Yellow with Red tracer
4
GENERAL INFORMATION
1
CONTENTS
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EXTERIOR ILLUSTRATION & PHOTOGRAPH ……………… 6 [1-7-1]
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SPECIFICATIONS d@ ……………………………
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10 [1-8-1]
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SPECIFICATIONS d@
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& d@ ……
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SPECIFICATIONS d@ & d@ … 14 [1-9-3]
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FUNCTION OF EI SENSOR …………………………………………
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5
1-7-1 GENERAL INFORMATION
EXTERIOR ILLUSTRATION & PHOTOGRAPH
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6
GENERAL INFORMATION 1-7-2
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8
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SPECIFICATIONS d@
◉ DIMENSIONS AND MASS

ITEM d@
Overall length 2,330 mm (91.7 in)

Overall width 840 mm (33.1 in) d@
Overall height 1,150 mm (45.3 in)
Wheelbase 1,670 mm (65.8 in)
Ground clearance 160 mm (6.3 in)
Mass 240 kg (529 lbs)
◉ ENGINE
ITEM d@
Type Four-stroke, DOHC, Liquid-cooled

Number of cylinder V-2 cylinder d@
Bore 81.5 mm (3.21 in)
Stroke 62.0 mm (2.44 in)
Piston displacement 647 ㎤ (39.5 in )
3
Fuel system Electric fuel Injection

Starter system Electric starter
Lubrication system Wet sump
◉ TRANSMISSION
ITEM d@
Clutch Wet multi-plate type

Transmission 5-speed constant meshd@
Gearshift pattern 1-down, 4-up
Final reduction 2.69
1st 2.46
2nd 1.78
3rd 1.38
Gear ratio
4th 1.13
5th 0.96
6th -
Drive belt Poly chain belt
10
◉ CHASSIS
ITEM d@
Front suspension Telescopic type

Rear suspension Swingarm type d@
Steering angle 35˚(right & left)
Caster 35˚
Trail 160 mm (6.3 in)
Front brake Double disk brake
Rear brake Disk brake
Front tire size 120/70 - ZR 18 59W
Rear tire size 180/55 - ZR 17 73W
Front fork stroke 130 mm (5.12 in)
◉ ELECTRICAL
ITEM d@
Ignition type ECU

Ignition timing 5˚B.T.D.C. at 2,000 rpmd@
Spark plug CR8E
Battery 12 V 12 Ah (MF)
Main 30 A
Fuse
ECU 15 A
HI
12 V - H4 : 60 / 55 W × 1
Head lamp LO
Position 12 V - W5 W × 1
Turn signal lamp 12 V - RY10 W × 4
Brake / Tail lamp LED type
License plate lamp 12 V - W5 W × 1
Tachometer lamp -
High beam indicator lamp LED type
Turn signal indicator lamp(right & left) LED type
Neutral indicator lamp LED type
Fuel indicator lamp LCD type (Level type)
Coolant temperature indicator lamp LCD type (Level type)
“FI”(Fuel Injection) check lamp LED type
◉ CAPACITIES
ITEM d@
Fuel tank 16.0 ℓ

Oil change 3,000 ㎖ d@
Engine oil Oil and filter change 3,200 ㎖
Engine overhaul 3,400 ㎖
Front fork oil capacity (One side) 420 cc
NOTE
The specifications are subject to change without notice.
11
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SPECIFICATIONS d@ & d@
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◉ DIMENSIONS AND MASS d@ d@ d@
ITEM d@
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Overall length 2,090 mm (82.3 in) d@ ←

Overall width 785 mm (30.9 in) ←
Overall height 1,125 mm (44.3 in) d@ 1,095 mm (43.1 in)
Wheelbase 1,435 mm (56.5 in) ← d@
Ground clearance 175 mm (6.9 in) d@ ←
Mass 210 kg (463 lbs) ← d@
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◉ ENGINE d@ d@
ITEM d@ d@
Type Four-stroke, DOHC, Liquid-cooled

d@ ←
Number of cylinder V-2 cylinder ←
Bore 81.5 mm (3.21 in) d@ ←
Stroke 62.0 mm (2.44 in) ←
3
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Fuel system Electric fuel Injection ←
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Starter system Electric starter ←
Lubrication system Wet sump ← d@
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◉ TRANSMISSION d@ d@
ITEM d@ d@
Clutch Wet multi-plate type d@ ←

Transmission 6-speed constant mesh ←
Gearshift pattern 1-down, 5-up d@ ←
Final reduction 2.93 ←
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1st 2.46 ←
2nd 1.60 ←
3rd 1.32 ←
Gear ratio
4th 1.13 ←
5th 0.96 ←
6th 0.85 ←
Drive chain RK525XSO 108 links ←
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◉ CHASSIS d@ d@
ITEM d@ d@
Front suspension Telescopic type d@ ←

Rear suspension Swingarm type ←
Steering angle 30˚(right & left) d@ ←
Caster 25.5˚ ←
Trail 85 mm (3.35 in) d@ ←
Front brake Double disk brake ← d@
Rear brake Disk brake ←
Front tire size 120/60 - ZR 17 55W ← d@
Rear tire size 160/60 - ZR 17 69W ←
Front fork stroke 120 mm (4.72 in) ← d@
◉ ELECTRICAL d@ d@
ITEM d@ d@
Ignition type ECU d@ ←

Ignition timing 5˚B.T.D.C. at 2,000 rpm ←
Spark plug CR8E d@ ←
Battery 12 V 12 Ah (MF) ←
Main 30 A d@ ←
Fuse
ECU 15 A ←
HI
12 V - H4 : 60 / 55 W × 1 ←
Head lamp LO
Position 12 V - W5 W × 1 12 V - W5 W × 2
Turn signal lamp 12 V - RY10 W × 4 ←
Brake / Tail lamp LED type ←
License plate lamp 12 V - W5 W × 1 ←
Tachometer lamp LED type ←
High beam indicator lamp LED type ←
Turn signal indicator lamp(right & left) LED type ← d@
Neutral indicator lamp LED type ←
Fuel indicator lamp LCD type (Level type) ← d@
Coolant temperature indicator lamp LCD type (Level type) ←
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“FI”(Fuel Injection) check lamp LED type ←
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◉ CAPACITIES d@
ITEM d@ d@
Fuel tank 17.0 ℓ d@ ←

Oil change 3,000 ㎖ ←
Engine oil Oil and filter change 3,200 ㎖ d@ ←
Engine overhaul 3,400 ㎖ ←
Front fork oil capacity (One side) 380 cc d@ ←
NOTE
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SPECIFICATIONS d@ & d@
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◉ DIMENSIONS AND MASS d@ d@
ITEM d@ d@
Overall length 2,090 mm (82.3 in) ← d@

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Overall width 785 mm (30.9 in) 700 mm (27.6 in)
Overall height 1,135 mm (44.7 in) d@ ←
Wheelbase 1,435 mm (56.5 in) ←
Ground clearance 175 mm (6.9 in) 165 mm (6.5 in)
Mass 210 kg (463 lbs) 215 kg (474 lbs) d@
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◉ ENGINE d@
ITEM d@ d@
Type Four-stroke, DOHC, Liquid-cooled ← d@

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Number of cylinder V-2 cylinder ←
Bore 81.5 mm (3.21 in) d@ ←
Stroke 62.0 mm (2.44 in) ←
3
←
Fuel system Electric fuel Injection ←
Starter system Electric starter ←
Lubrication system Wet sump ←
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◉ TRANSMISSION d@
ITEM d@ d@
Clutch Wet multi-plate type ← d@

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Transmission 6-speed constant mesh ←
Gearshift pattern 1-down, 5-up d@ ←
Final reduction 2.93 ←
1st 2.46 ←
2nd 1.60 ←
3rd 1.32 ←
Gear ratio
4th 1.13 ←
5th 0.96 ←
6th 0.85 ←
Drive chain RK525XSO 108 links ←
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◉ CHASSIS d@
ITEM d@ d@
Front suspension Telescopic type ← d@

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Rear suspension Swingarm type ←
Steering angle 27˚(right & left) ←
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Caster 25.5˚ ←
Trail 74 mm (2.91 in) ←
Front brake Double disk brake ←
Rear brake Disk brake ←
Front tire size 120/60 - ZR 17 55W ← d@
Rear tire size 160/60 - ZR 17 69W ←
Front fork stroke 120 mm (4.72 in) d@ ← d@
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◉ ELECTRICAL d@
ITEM d@ d@
Ignition type ECU ← d@

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Ignition timing 5˚B.T.D.C. at 2,000 rpm ←
Spark plug CR8E ←
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Battery 12 V 12 Ah (MF) ←
Main 30 A ←
Fuse
ECU 15 A ←
HI 12 V - H1 : 55 W × 1 ←
Head lamp LO 12 V - H3 : 55 W × 1 ←
Position 12 V - W5 W × 1 ←
Turn signal lamp 12 V - RY10 W × 4 ←
Brake / Tail lamp LED type ←
License plate lamp 12 V - W5 W × 1 ←
Tachometer lamp LED type ←
High beam indicator lamp LED type ←
Turn signal indicator lamp(right & left) LED type ←
Neutral indicator lamp LED type ←
Fuel indicator lamp LCD type (Level type) ← d@
Coolant temperature indicator lamp LCD type (Level type) ←
“FI”(Fuel Injection) check lamp LED type d@ ← d@
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◉ CAPACITIES d@
ITEM d@ d@
Fuel tank 17.0 ℓ ← d@

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Oil change 3,000 ㎖ ←
Engine oil Oil and filter change 3,200 ㎖ d@ ←
Engine overhaul 3,400 ㎖ ←
Front fork oil capacity (One side) 380 cc 481 cc
NOTE
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FUNCTION OF EI SENSOR
★ ECU (Engine Control Unit, EI Control Unit)
: ECU decide the fuel injection volume and ignition time to adjust the fuel injector opening and closing rate
which is considered the engine speed, intake air pressure, intake air volume, engine temperature, oxygen
volume and throttle opening angle, etc.
★ EI (Electric fuel Injector)

: EI spray the fuel to intake pipe by ECU’s injection signal.
Fuel which is needed combustion in the combustion chamber is supplied from the fuel tank.
★ GP switch (Gear Position Switch)

: GP switch is used when start / stop and control ECU as the converted electrical signal of the gear position is
supplied ECU.
★ IAP sensor (Intake Air Pressure Sensor : IAPS)

: IAP sensor measure the pressure which is generated from the intake pipe and compare with the provided
absolute pressure, then analogize the air volume indirectly and help to work the fuel injector properly.
★ IAT sensor (Intake Air Temperature Sensor : IATS)

: IAT sensor perceive the atmospheric temperature and is located the air cleaner case.
★ ISC solenoid (Idle Speed Control Solenoid)

: ISC solenoid is interlocked with the throttle body, so ECU control the engine idle speed.
★ O2 sensor (Oxygen Sensor : O2S)

: O2 sensor measure the oxygen volume from the exhaust gas and convert the oxygen volume into voltage
value, then communicate the output voltage to ECU.
★ Pick-up Coil
: Pick-up coil perceive the front and rear cylinder’s engine speed and realtime of piston position.
★ RO switch (Roll Over Switch)

: RO switch is the fuel cut-off system when the motorcycle is leaned over 60°for upset accident.
★ TP sensor (Throttle Position Sensor : TPS)

: TP sensor detect the throttle opening angle and is located the throttle body.
It decide the fuel injection volume and compensate the ignition time as inform
idle・acceleration・deceleration condition and throttle full opening etc. to ECU.
★ WT sensor (Water Temperature Sensor : WTS)

: WT sensor is located on the cylinder block’s water jacket, the intake pipe or the cylinder head coolant
passage’s thermostat part for contact with the coolant.
WT sensor is the NTC (Negative Temperature Coefficient) resister that measure the coolant temperature and
inform ECU.
16
EI SYSTEM DIAGNOSIS
CONTENTS
PRECAUTIONS IN SERVICING ……………………………………… 18 [4-1-1] 4-1

EI SYSTEM TECHNICAL FEATURES …………………………… 22 [4-1-5]
SELF-DIAGNOSIS FUNCTION ……………………………………… 29 [4-1-12]

EI SYSTEM TROUBLESHOOTING ………………………………… 41 [4-1-24]
CUSTOMER COMPLAINT ANALYSIS ……………………………… 41 [4-1-24]
SELF-DIAGNOSTIC PROCEDURES ………………………………… 43 [4-1-26]
SELF-DIAGNOSIS RESET PROCEDURE ………………………… 46 [4-1-29]

MALFUNCTION CODE AND DEFECTIVE CONDITION ………… 48 [4-1-31]
“0031”, “0032”, “0037” or “0038”
OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION &
“0131”, “0132”, “0137” or “0138”
OXYGEN SENSOR CIRCUIT MALFUNCTION ………………… 52 [4-1-35]
“0107” or “0108” IAP SENSOR CIRCUIT MALFUNCTION …… 54 [4-1-37]

“0112” or “0113” IAT SENSOR CIRCUIT MALFUNCTION ……… 56 [4-1-39]
“0117” or “0118” WT SENSOR CIRCUIT MALFUNCTION ……… 58 [4-1-41]
“0122” or “0123” TP SENSOR CIRCUIT MALFUNCTION ……… 60 [4-1-43]
“0201” or “0202” FUEL INJECTOR CIRCUIT MALFUNCTION … 63 [4-1-46]

“0230” or “0232” FUEL PUMP RELAY CIRCUIT MALFUNCTION 65 [4-1-48]
“0336” or “0337” PICK-UP COIL CIRCUIT MALFUNCTION …… 66 [4-1-49]
“0351” or “0352” IGNITION COIL MALFUNCTION ……………… 68 [4-1-51]
“0500” SPEEDO SENSOR MALFUNCTION ……………………… 69 [4-1-52]

“0505” ISC SOLENOID RANGE ABNORMAL ……………………… 70 [4-1-53]
“0562” or “0563” BATTERY VOLTAGE MALFUNCTION ………… 71 [4-1-54]

“0650” “FI” CHECK LAMP CIRCUIT MALFUNCTION …………… 72 [4-1-55]
“0850” GP or CLUTCH LEVER SWITCH CIRCUIT MALFUNCTION
………………………………………………………………………… 73 [4-1-56]
SENSORS …………………………………………………………………… 75 [4-1-58]
17
4-1-1 EI SYSTEM DIAGNOSIS
PRECAUTIONS IN SERVICING
When handling the component parts or servicing the
EI system, observe the following points for the safety
of the system.
◉ ELECTRICAL PARTS
▒ CONNECTOR / COUPLER
● When connecting a connector, be sure to push it in
until a click is felt.
● With a lock type coupler, be sure to release the
lock when disconnecting, and push it in fully till the
works when connecting it.
● When disconnecting the coupler, be sure to hold
the coupler body and do not pull the lead wires.
● Inspect each terminal on the connector / coupler
for looseness or bending.
● Inspect each terminal for corrosion and

contamination.
The terminals must be clean and free of any
foreign material which could impede proper
terminal contact.
● Inspect each lead wire circuit for poor connection

by shaking it by hand lightly. If any abnormal
condition is found, repair or replace.
● When taking measurements at electrical

connectors using a tester probe, be sure to insert
the probe from the wire harness side (backside) of
the connector / coupler.
18
EI SYSTEM DIAGNOSIS 4-1-2
● When connecting meter probe from the terminal

side of the coupler (connection from harness side
not being possible), use extra care not to force
and cause the male terminal to bend or the female
terminal to open.
Connect the probe as shown to avoid opening of
female terminal.
Never push in the probe where male terminal is
supposed to fit.
● Check the male connector for bend and female
connector for excessive opening. Also check the
coupler for locking (looseness), corrosion, dust,
etc.
◉ FUSE
● When a fuse blows, always investigate the cause
to correct it and then replace the fuse.
● Do not use a fuse of a different capacity.
● Do not use wire or any other substitute for the
fuse.
◉ ECU / VARIOUS SENSORS

● Since each component is a high-precision part,
great care should be taken not to apply any sharp
impacts during removal and installation.
● Be careful not to touch the electrical terminals of

the ECU.
The static electricity from your body may damage
this part.
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● When disconnecting and connecting the ECU,

make sure to turn “OFF” the ignition switch, or
electronic parts may get damaged.
● Battery connection in reverse polarity is strictly

prohibited.
Such a wrong connection will damage the
components of the EI system instantly when
reverse power is applied.
● Removing any battery terminal of a running engine

is strictly prohibited.
The moment such removal is made, damaging
counter electromotive force will be applied to the
ECU which may result in serious damage.
● Before measuring voltage at each terminal, check

to make sure that battery voltage is 11V or higher.
Terminal voltage check at low battery voltage will
lead to erroneous diagnosis.
20
● Never connect an ohmmeter to the ECU with its

coupler connected. If attempted, damage to the
ECU or sensors may result.
● Be sure to use a specified voltmeter / ohmmeter.
Otherwise, accurate measurements may not be
obtained and personal injury may result.
ᶇ USING TESTERS
● Use well-charged batteries in the tester.
● Be sure to set the tester to the correct testing
range.
▒ USING THE TESTER

● Incorrectly connecting the ⊕ and ⊖ probes may
cause the inside of the tester to burnout.
● If the voltage and current are not known, make
measurements using the highest range.
● After using the tester, turn the power off.
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EI SYSTEM TECHNICAL FEATURES
◉『 d@ 』&『 d@ 』
EI SYSTEM’S CONTROL DIAGRAM d@
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ECU d@
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AIR FUEL
IAT Sensor
AIR CLEANER FUEL TANK
TP Sensor ISC Solenoid FUEL PUMP
THROTTLE BODY
IAP Sensor
INTAKE PIPE
FUEL INJECTOR
WT Sensor
Pick-up Coil CYLINDER
O2 Sensor EXHAUST PIPE
: Electrical signal flow

MUFFLER
: Air flow EXHAUST GAS
: Fuel flow
: Exhaust gas flow
22
◉ INJECTION TIME (INJECTION VOLUME)

The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of
intake air pressure, engine speed and throttle opening angle, and various compensations.
These compensations are determined according to the signals from various sensors that detect the engine and
driving conditions.
ECU
Intake Air Pressure Sensor Intake air pressure signal

(IAP Sensor)
Basic
Engine speed signal fuel
Pick-up coil
injection
time
Throttle Position Sensor Throttle opening signal
(TP Sensor)
Various signals
Various Sensors Compensation
Ultimate
Injection signal fuel
Injectors
injection
time
23
◉ COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensation of the fuel injection time
(volume).
SIGNAL DESCRIPTION
WATER COOLANT TEMPERATURE When engine coolant temperature is low, injection time (volume)
SENSOR SIGNAL is increased.
INTAKE AIR TEMPERATURE SENSOR When intake air temperature is low, injection time (volume) is
SIGNAL increased.
ECU operates on the battery voltage and at the same time, it
monitors the voltage signal for compensation of the fuel injection
BATTERY VOLTAGE SIGNAL time (volume). A longer injection time is needed to adjust
injection volume in the case of low voltage.
ENGINE RPM SIGNAL At high speed, the injection time (volume) is increased.
When starting engine, additional fuel is injected during cranking
STARTING SIGNAL engine.
During acceleration, the fuel injection time (volume) is increased
ACCELERATION SIGNAL / in accordance with the throttle opening speed and engine rpm.
DECELERATION SIGNAL During deceleration, the fuel injection time (volume) is
decreased.
◉ INJECTION STOP CONTROL

SIGNAL DESCRIPTION
When the motorcycle rolls over, the roll over switch sends a
ROLL OVER SWITCH SIGNAL
signal to the ECU. Then, this signal cuts OFF current supplied to
(FUEL CUT-OFF)
the fuel pump, fuel injector and ignition coil.
The fuel injectors stop operation when engine rpm reaches rev.
OVER-REV. LIMITER SIGNAL
limit rpm.
24
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◉ EI SYSTEM PARTS LOCATION d@
5
9
2 ECU
4 6
3
8
7
① Speedometer ⑥ Fuel injector, NO.2

② Fuel pump relay ⑦ GP switch
③ Fuel injector, NO.1 ⑧ Pick-up coil
④ TP sensor ⑨ Ignition coil, NO.1
⑤ IAT sensor
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ECU 12
10 11
13
14
15
⑩ RO switch ⑬ WT sensor
⑪ Ignition coil, NO.2 ⑭ Oxygen sensor, NO.2
⑫ IAP sensor ⑮ Oxygen sensor, NO.1
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◉ EI SYSTEM PARTS LOCATION d@
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1 d@
ECU
8 5
2 4
3
7
6
① Speedometer ⑤ IAT sensor

② Fuel injector, NO.1 ⑥ GP switch
③ TP sensor ⑦ Pick-up coil
④ Fuel injector, NO.2 ⑧ Ignition coil, NO.2
27
9
ECU
11
10
12
13
14
15
⑨ Fuel pump relay ⑬ WT sensor

⑩ RO switch ⑭ Oxygen sensor, NO.2
⑪ Ignition coil, NO.1 ⑮ Oxygen sensor, NO.1
⑫ IAP sensor
28
SELF-DIAGNOSIS FUNCTION
The self-diagnosis function is incorporated in the ECU.
The function has two modes, “USER MODE” and “DEALER MODE”.
The user can be notified by the LCD display panel Ⓑ and the “FI” check lamp “ ” Ⓒ.
To check the function of the individual EI system devices, the dealer mode is prepared.
In this check, the special tool and additional operations is necessary to read the code of the malfunction items.
◉ USER MODE d@
d@
d@
d@ d@
Ⓒ Ⓑ Ⓐ
d@ d@
d@ d@ d@
d@ d@
d@ & d@ &
d@ d@
d@
d@ d@
Ⓒ d@
Ⓒ
d@
Ⓓ Ⓓ
d@
Ⓑ Ⓐ Ⓑ Ⓐ
29
The LCD display panel Ⓑ indicates “FI” letters and speedometer alternately, and the “FI” check lamp “ ” Ⓒcomes on
and remains lit when the ignition switch is set to “ON” position with the engine stopped as a test of injection system
operation.
As soon as the engine starts, the LCD display panel Ⓑindicates speedometer continuously and “FI” check lamp “ ” Ⓒ
should go out.
If the fuel injection system fails,

A the LCD display panel Ⓑdoes not indicate “FI” letters and speedometer alternately, and the “FI” check lamp “ ” Ⓒ
does not come on
when the ignition switch is set to “ON” position with the engine stopped.
B the LCD display panel Ⓑindicates “FI” letters and speedometer alternately, and the “FI” check lamp “ ” Ⓒcomes
on and remains lit
after the engine start.
LCD (DISPLAY) “FI” CHECK LAMP

CLASSIFICATION MALFUNCTION REMARKS
INDICATION Ⓑ INDICATION Ⓒ
Indicates “FI” letters and “FI” check lamp comes on

“NO”
speedometer alternately. continually.
IGNITION SWITCH “ON”
POSITION
Indicates “FI” letters and “FI” check lamp comes on
“YES”
“NO” Indicates speedometer. “FI” check lamp goes off.
ENGINE RUNNING
Indicates “FI” letters and “FI” chek lamp comes on
“YES”
30
◉ DEALER MODE
The defective function is memorized in the ECU.
The memorized malfunction code is displayed on the clock screen Ⓐ or with blinks signal of the “FI” check lamp “ ” Ⓒ.
Malfunction means that the ECU does not receive signal from the devices or fault signal received.
These affected devices are indicated in the code form on the clock screen Ⓐ or displayed with blinks signal of the “FI”
check lamp “ ” Ⓒ.
▒ A. LCD (DISPLAY) PANEL d@

To confirm the memorized malfunction code through the clock screen Ⓐ :
1-1. Remove the front seat. [ d@ ]
1-2. Remove the rear seat. [ d@ ]
2. Connect the special tool to the dealer moded@

coupler at the wiring harness, and the ignition switch is set to the “ON”
position.
d@
Mode select switch : 09900-27000d@

3. Turn the special tool’s switch to the “ON” position.
d@
4. Press the select switch Ⓓ (in the normal mode) for 2 seconds to the clock screen Ⓐ isŵthe clock reset modeŶ.
In that state, continuously pressing the select switch Ⓓ for 3 seconds, the clock screen Ⓐ is displayed ŵ the
malfunction code modeŶ-
NOTE
This time, if not connect the special tool correctly, the LCD display panel Ⓑ indicates the “cHE” letters.
Pressing the select switch Ⓓ for 0.6 ~ 1 seconds, the “cHE” letters disappear.
5. The memorized malfunction code is displayed in the code form on the clock screen Ⓐ.
6. Start the engine and repeat the above procedure.
7. Check the malfunction code to determine the malfunction part.
8. Pressing the select switch Ⓓ (in the malfunction code mode) for 0.6 ~ 1 seconds,ŵthe malfunction code modeŶis
changed into the CLOCK.
NOTE
The malfunction code of the clock screen Ⓐ is displayed the current code(s).
31
d@
d@
d@
Ⓒ Ⓑ d@ Ⓐ d@
d@ d@
d@ d@ d@
d@ d@
d@ & d@ &
d@ d@
d@
d@ d@
Ⓒ d@ Ⓒ
d@
Ⓓ
d@
Ⓓ
Ⓑ Ⓐ Ⓑ Ⓐ
32
CAUTION
⎃ Confirm the malfunction code after turning the ignition switch “ON” position and starting the engine
d@
separately.
⎃ The dealer mode coupler of the wiring harness is located under the front seat. [ d@ ]
The dealer mode coupler of the wiring harness is located under the rear seat.
[ d@ ]
d@
d@
d@
CLOCK SCREEN “FI” CHECK LAMP INDICATION
CLASSIFICATION MALFUNCTION
d@ INDICATION Ⓐ INDICATION Ⓒ MODE
“FI” check lamp comes

“NO” noEr
IGNITION on continually.
SWITCH
“ON”
For each 2 sec.,
POSTION
“YES” **** code is indicated in “FI” check lamp comes
order of occurrence. on continually. code is indicated.
“FI” check lamp

“NO” CLOCK
goes off.
ENGINE
RUNNING
code is indicated in “FI” check lamp comes For each 2 sec.,
“YES” ****
order of occurrence. on continually. code is indicated.
NOTE
Pressing the select switch Ⓓ (in the “noEr” display state) for 0.6 ~ 1 seconds, it is changed into the CLOCK.
33
▒ B. “FI” CHECK LAMP

To confirm the memorized malfunction code through the “FI” check lamp “ ”Ⓒ:
1. Turn the ignition switch alternately, “ON” and “OFF” position, for 2 seconds by three times.
CAUTION
Take special care when operating above procedure.
If the ignition switch is turned alternately, “ON” and “OFF” position, for 2 seconds by five times, the ECU is
initialized.
2. The memorized malfunction code is displayed with blinks signal of the “FI” check lamp “ ” Ⓒ.
3. Check the malfunction code to determine the malfunction part.
NOTE
The malfunction code of the “FI” check lamp Ⓒ is displayed both the current code(s) and history code(s).
d@
d@
d@
Ⓒ Ⓑ
NH\
d@
d@
d@
d@
d@ &
d@
d@
Ⓒ d@
d@
NH\
34
d@
d@ EI SYSTEM DIAGNOSIS 4-1-18

d@ d@
d@
d@ &
d@
d@
d@
Ⓒ
d@
Ⓑ
NH\
MALFUNCTION LCD (DISPLAY) INDICATION Ⓑ “FI” CHECK LAMP INDICATION Ⓒ
“NO” “FI” check lamp comes on continually.

Indicates “FI” letters
and speedometer alternately. Malfunction code is blinked
“YES”
in order of occurrence.
35
B CODE
A CODE
MALFUNCTION PART REMARKS
0031
[ 0 0 3 1 0 0 3 1 ]
NO.1 O2 S heater Circuit Low Voltage For NO.1 cylinder
0032
[ 0 0 3 2 0 0 3 ]
NO.1 O2 S heater Circuit High Voltage For NO.1 cylinder
0037
[ 0 0 3 7 0 0 ]
NO.2 O2 S heater Circuit Low Voltage For NO.2 cylinder
0038
[ 0 0 3 8 0 0 ]
NO.2 O2 S heater Circuit High Voltage For NO.2 cylinder
0107
[ 0 1 0 7 0 1 0 ]
IAPS Circuit Low Voltage or Open
0108
[ 0 1 0 8 0 1 0 ]
IAPS Circuit High Voltage
0112
[ 0 1 1 2 0 1 1 2 0 1 1 2 ]
IATS Circuit Low Voltage
0113
[ 0 1 1 3 0 1 1 3 0 1 1 ]
IATS Circuit High Voltage or Open
※ A CODE : For LCD (DISPLAY) indication

B CODE : For “FI” check lamp indication
36
B CODE
A CODE
0117
[ 0 1 1 7 0 1 1 7 ]
WTS Circuit Low Voltage
0118
[ 0 1 1 8 0 1 1 8 ]
WTS Circuit High Voltage or Open
0122
[ 0 1 2 2 0 1 2 2 0 1 2 ]
TPS Circuit Low Voltage or Open
0123
[ 0 1 2 3 0 1 2 3 0 1 ]
TPS Circuit High Voltage
0131
[ 0 1 3 1 0 1 3 1 0 1 3 ]
NO.1 O2 S Circuit Low Voltage For NO.1 cylinder
0132
[ 0 1 3 2 0 1 3 2 0 1 ]
NO.1 O2 S Circuit High Voltage For NO.1 cylinder
0137
[ 0 1 3 7 0 1 3 7 ]
NO.2 O2 S Circuit Low Voltage For NO.2 cylinder
0138
[ 0 1 3 8 0 1 3 8 ]
NO.2 O2 S Circuit High Voltage For NO.2 cylinder

37
B CODE
A CODE
0201
[ 0 2 0 1 0 2 0 1 ]
NO.1 Fuel injector Circuit Malfunction For NO.1 cylinder
0202
[ 0 2 0 2 0 2 0 2 ]
NO.2 Fuel injector Circuit Malfunction For NO.2 cylinder
0230
[ 0 2 3 0 0 2 3 ]
Fuel pump relay Circuit Low Voltage or Open
0232
[ 0 2 3 2 0 2 3 2 0 ]
Fuel pump relay Circuit High Voltage
0336
[ 0 3 3 6 0 3 3 6 ]
Pick-up coil Noisy Signal
0337
[ 0 3 3 7 0 3 3 7 ]
Pick-up coil No Signal
0351
[ 0 3 5 1 0 3 5 1 ]
NO.1 IG coil Malfunction For NO.1 cylinder
0352
[ 0 3 5 2 0 3 5 2 ]
NO.2 IG coil Malfunction For NO.2 cylinder

38
B CODE
A CODE
0500
[ 0 5 0 0 0 5 ]
Speedo sensor Malfunction
0505
[ 0 5 0 5 0 5 ]
ISC Error
0562
[ 0 5 6 2 0 5 6 2 ]
Battery Voltage Low
0563
[ 0 5 6 3 0 5 6 3 ]
Battery Voltage High
0650
[ 0 6 5 0 0 6 ]
“FI” check lamp Circuit Malfunction
0850
[ 0 8 5 0 0 8 ]
GP or Clutch lever Switch Circuit Malfunction

39
▒ LCD (DISPLAY) INDICATION

In the clock screen ≶, the malfunction code is indicated in order of occurrence.
▒ “FI” CHECK LAMP INDICATION

In the “FI” check lamp “ ” ≸, the malfunction code is blinked in order of occurrence.
d@
d@
d@
d@ d@
Ⓒ Ⓐ
d@ d@
d@ d@ d@
d@ d@
d@ & d@ &
d@ d@
d@
d@ d@
Ⓒ d@ Ⓒ
d@
d@
Ⓐ Ⓐ
40
EI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper
analysis and diagnosis.
▒ EXAMPLE : CUSTOMER PROBLEM INSPECTION FORM

User name : Model : VIN :
Date of issue : Date Reg. : Date of problem : Mileage :
“FI” Check lamp □@Always ON □ Sometimes ON □ Always OFF □ Good condition
Malfunction display / code

(LCD panel) or
□ No code □ Malfunction code ( )
Blinks signal
( “FI” check lamp)
PROBLEM SYMPTOMS
□ Difficult Starting □ Poor Driveability
□ No cranking □ Hesitation on acceleration
□ No initial combustion □ Back fire / □ After fire
□ No combustion □ Lack of power
□ Poor starting at □ Surging
(□ cold □ warm □ always) □ Abnormal knocking
□ Other □ Engine rpm jumps briefly
□ Other
□ Poor Idling □ Engine Stall when
□ Poor fast Idle □ Immediately after start
□ Abnormal idling speed □ Throttle valve is opened
(□ High □ Low) ( rpm) □ Throttle valve is closed
□ Unstable □ Load is applied
□ Hunting ( rpm. to rpm) □ Other
□ Other
□ OTHERS :
41
MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather □ Fair □ Cloudy □ Rain □ Snow □ Always □ Other
Temperature □ Hot □ Warm □ Cool □ Cold ( °F / °C) □ Always
Frequency □ Always □ Sometimes ( times / day, month) □ Only once
□ Under certain condition
Road □ Urban □ Suburb □ Highway □ Mountainous (□ Uphill □ Downhill)
□ Tarmacadam □ Gravel □ Other
Motorcycle condition
Engine condition □ Cold □ Warming up phase □ Warmed up □ Always □ Other at starting
□ Immediately after start □ Racing without load □ Engine speed ( rpm)
Motorcycle condition □ Constant speed □ Accelerating □ Decelerating

During driving :
□ Right hand corner □ Left hand corner □ At stop
□ Motorcycle speed when problem occurs ( km/h, Mile/h)
□ Other
NOTE
The above form is a standard sample.
If should be modified according to conditions characteristic of each market.
42
SELF-DIAGNOSTIC PROCEDURES
Don’t disconnect couplers from ECU, battery cable from battery, ECU ground wire harness from engine or main
fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory.
The memorized malfunction code is displayed in the code form on the clock screen Ⓐ or with blinks signal of the
“FI” check lamp “ ” Ⓒ.
To check malfunction code, read SELF-DIAGNOSIS FUNCTION “DEALER MODE” (Refer to page 31 ~ 40 [4-1-14
~ 23]) carefully to have good understanding as to what functions are available and how to use it.
Be sure to read “PRECAUTIONS for Electrical Circuit Service” (Refer to page 18 [4-1-1]) before inspection and
observe what is written there.
d@
d@
d@
d@ d@
Ⓒ Ⓐ
d@ d@
d@ d@ d@
d@ d@
d@ & d@ &
d@ d@
d@
d@ d@
Ⓒ d@
Ⓒ
d@
d@
Ⓐ Ⓐ
43
▒ LCD (DISPLAY) INDICATION

Refer to page 31 [4-1-14]
▒ “FI” CHECK LAMP INDICATION

d@
Refer to page 34 [4-1-17]
d@
NH\
44
d@
d@ d@
d@ d@ DIAGNOSIS 4-1-28

EI SYSTEM
d@ d@ d@
d@ d@
d@ & d@ &
d@ d@
d@
d@ d@
d@ d@
d@
NH\
NH\
45
SELF-DIAGNOSIS RESET PROCEDURE

▒ LCD (DISPLAY) PANEL Ⓐ
● After repairing the trouble, refer to page 31 [4-1-14], move toŵthe malfunction code modeŶ.
● If the clock screen Ⓐ indicates the “noEr” letters, the malfunction codes are cleared.
● Disconnect the special tool from the dealer mode coupler at the wiring harness.
d@
d@
d@
d@ d@
Ⓒ Ⓐ
d@ d@
d@ d@ d@
d@ d@
d@ & d@ &
d@ d@
d@
d@ d@
Ⓒ d@ Ⓒ
d@
d@
Ⓐ Ⓐ
46
▒ “FI” CHECK LAMP Ⓒ

● Repair the trouble.
Turn the ignition switch to the “OFF” position and return to the “ON” position, and then wait for 10 seconds.
Repeat the above procedure 30 times.
In this case, the malfunction codes are cleared.
d@
d@
d@
d@ NH\ d@
d@ d@
d@ d@ d@
d@ d@
d@ & d@ &
d@ d@
d@
d@ d@
d@ d@
d@
NH\
NH\
47
MALFUNCTION CODE AND DEFECTIVE CONDITION

MALFUNCTION DETECTED FAILURE CONDITION
DETECTED ITEM
CODE CHECK FOR
noEr NO FAULT -
After engine running, if oxygen sensor heater signal open or is

happened the ground short fault for 1 second by 10 times in 12
0031 Low Voltage times test cycle, the code 0031 is indicated.
NO.1 Oxygen sensor, lead wire / coupler connection.

O2 S heater
Circuit After engine running, if oxygen sensor heater signal is
happened the high short fault for 1 second by 10 times in 12
0032 High Voltage times test cycle, the code 0032 is indicated.
Oxygen sensor, lead wire / coupler connection.


O2 S heater
The sensor should produce following voltage.

Low Voltage 0.15 V ≦ Sensor output voltage
0107 Without the above range for 2.2 sec. and more, 0107 is indicated.
or Open
Intake air pressure sensor, lead wire / coupler connection.
IAPS Circuit
Sensor output voltage ≦ 5 V
0108 High Voltage Without the above range for 10.0 sec. and more, 0108 is
indicated.
The sensor voltage should be the following.

0.1 V ≦ Sensor output voltage
0112 Low Voltage Without the above range for 6.25 sec. and more, 0112 is indicated.
Intake air temperature sensor, lead wire / coupler connection.

IATS Circuit
High Voltage Sensor output voltage ≦ 4.9 V
or Open
48

DETECTED ITEM
CODE CHECK FOR
Water temperature sensor, lead wire / coupler connection.

WTS Circuit
High Voltage Sensor output voltage ≦ 5 V
or Open

or Open
Throttle position sensor, lead wire / coupler connection.
TPS Circuit
Sensor output voltage ≦ 4.9 V
0123 High Voltage Without the above range for 7.8 sec. and more, 0123 is indicated.

After engine running, the oxygen sensor signal is inputted in ECU
since then 300 sec.
In this case, the sensor voltage should be the following.
0131 Low Voltage 30 mV ≦ Sensor output voltage
Without the above range for 28.1 sec. and more, 0131 is indicated.

O2 S Circuit After engine running, the oxygen sensor signal is inputted in ECU
since then 300 sec.
0132 High Voltage Sensor output voltage ≦ 1.0 V
since then 300 sec.

since then 300 sec.
49

DETECTED ITEM
CODE CHECK FOR
After engine running, if NO.1 fuel injector signal open or is
NO.1 Fuel Injector happened the high / ground short fault for 1 second by 5 times
0201 in 10 times test cycle, the code 0201 is indicated.
Circuit Malfunction
Injector, wiring / coupler connection, power supply to the injector.

NO.2 Fuel Injector happened the high / ground short fault for 1second by 5 times in
0202 10 times test cycle, the code 0202 is indicated.
Circuit Malfunction
After engine running, if fuel pump relay signal open or is

Low Voltage
0230 times test cycle, the code 0230 is indicated.
or Open
Fuel pump relay, connecting lead wire, power source to fuel
Fuel pump pump relay, fuel injector.
relay Circuit
After engine running, if fuel pump relay signal is happened the
high short fault for 1 second by 10 times in 20 times test cycle,
0232 High Voltage the code 0232 is indicated.
pump relay, fuel injector.
After engine running, if the magneto rotor tooth’s error is

happened continuously by 10 times in 100 times test cycle, the
0336 Noisy Signal code 0336 is indicated.
Pick-up coil wiring and mechanical parts. (Pick-up coil, lead wire
coupler connection)
Pick-up coil
After engine running, if the pick-up coil signal does not reach
ECU for more than 0.5 sec., the code 0337 is indicated.
0337 No Signal
coupler connection)
After engine running, if NO.1 ignition coil signal open or is

happened the high / ground short fault for 1 second by 5 times
0351 NO.1 IG coil Malfunction in 10 times test cycle, the code 0351 is indicated.
Ignition coil, wiring / coupler connection, power supply from the

battery.


battery.
50

DETECTED ITEM
CODE CHECK FOR
Motorcycle speed ＜ 10 km/h
Water temperature ＜ 20 ℃
IAPS pressure ＞ 40 kPa
Speedo sensor 20% ＜ TPS open angle ＜ 100%
0500 2,000 rpm ＜ Engine speed ＜ 6,000 rpm
Malfunction
If the above conditions are maintained for more than 1 second,
the code 0500 is indicated.
Speedo sensor, wiring / coupler connection to ECU.
After engine running, if idle speed is different to 500 rpm from

the specified range in 25 seconds test cycle, the code 0505 is
0505 ISC Error indicated.
Idle speed control solenoid, wiring / coupler connection.
The battery voltage should be the following.

9 V ≦ Battery voltage
0562 Low Without the above range for 3.125 sec. and more, 0562 is indicated.
Battery Battery, wiring / coupler connection to ECU.

Voltage
Battery voltage ≦ 16 V
0563 High Without the above range for 3.125 sec. and more, 0563 is indicated.
Battery, wiring / coupler connection to ECU.
After engine running, if “FI” check lamp signal open or is

“FI” check lamp happened the high / ground short fault for 1 second by 40 times
Circuit Malfunction
“FI” check lamp, wiring / coupler connection.
If gear position or clutch lever switch signal feedback is not

active in continuous by 20 times in fully power down cycles, the
GP or Clutch lever Switch code 0850 is indicated.
0850 (Fully power down cycle : Ignition switch “ON” ơ “OFF” position)
Circuit Malfunction
Gear position or clutch lever switch, wiring / coupler connection,
gearshift cam etc.
51
“0031”, “0032”, “0037” or “0038”

OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION &
“0131”, “0132”, “0137” or “0138”
OXYGEN SENSOR CIRCUIT MALFUNCTION
LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION
0031
[ 0 0 3 1 0 0 3 1 ]
0032
[ 0 0 3 2 0 0 3 ]
0037
[ 0 0 3 7 0 0 ]
0038
[ 0 0 3 8 0 0 ]
0131
[ 0 1 3 1 0 1 3 1 0 1 3]
0132
[ 0 1 3 2 0 1 3 2 0 1 ]
0137
[ 0 1 3 7 0 1 3 7 ]
0138
[ 0 1 3 8 0 1 3 8 ]
DETECTED CONDITION POSSIBLE CAUSE
● Oxygen sensor, Oxygen sensor heater circuit open

or short.
☞ Refer to page 48, 49 [4-1-31, 32]
● Oxygen sensor, Oxygen sensor heater malfunction.
● ECU malfunction.
※ Ⓐ : NO.1 O 2 S
Ⓑ : NO.2 O 2 S
Ⓑ Ⓐ
52
▒ INSPECTION
1) Remove the front seat and frame cover.
2) Turn the ignition switch to the “OFF” position.
3) Check the Oxygen sensor coupler for loose or
poor contacts.
/0
/0
Is OK? J8 J7 E:
or GR (NO.1 O 2 S) / R or GR
●B
(NO.2 O 2 S) wire open or shorted
to ground, or poor B17 or B10
(NO.1 O 2 S) / G5 or B10
(NO.2 O 2 S) connection of ECU
coupler. [Sensor side]
Gray E4: Black E43
W (NO.1 O 2 S heater) /
L (NO.2 O 2 S heater) wire open
or shorted to ground, or poor ECU Coupler
B7 (NO.1 O 2 S heater)
YES / G4 (NO.2 O 2 S heater)
connection of ECU coupler.
YL coupler open or shorted to Sensor side Heater side
the wiring harness (main relay
output side).
[Heater side] GR B W YL
If wire and connection are OK,
intermittent trouble or faulty ECU.
Recheck each terminal and wire NO.1 O2 S
harness for open circuit and poor
connection.
NO Replace the Oxygen sensor with a

new one. Sensor side Heater side
GR R L YL
NO.2 O2 S
53
“0107” or “0108” IAP SENSOR CIRCUIT MALFUNCTION

0107
[ 0 1 0 7 0 1 0 ]
0108
[ 0 1 0 8 0 1 0 ]

●C logged vacuum passage between throttle body
☞ Refer to page 48 [4-1-31]
and IAP sensor.
● Air being drawn from vacuum passage between
NOTE :
throttle body and IAP sensor.
Note that atmospheric pressure varies depending on
● IAP sensor circuit open or shorted to ground.
weather conditions as well as altitude.
● IAP sensor malfunction.
Take that into consideration when inspecting voltage.
▒ INSPECTION
◈ Step 1
1) Remove the fuel tank.
3) Check the IAP sensor coupler ① for loose or poor
contacts. ①
If OK, then measure the IAP sensor input voltage.
4) Disconnect the IAP sensor coupler ②.

5) Turn the ignition switch to the “ON” position.
6) Measure the input voltage at the OB wire and
ground.
If OK, then measure the input voltage at the OB
wire and GR wire.
4.5 ~ 5.5 V
IAP sensor input
( ⊕ OB - ⊖ Ground )
voltage ( ⊕ OB - ⊖ GR ) ②
Tester knob indication : Voltage ( )
Is the input voltage OK?
YES Go to Step 2.
●L oose or poor contacts on the ECU
coupler.
NO
● Open or short circuit in the OB wire
or GR wire.
54
◈ Step 2
1) Connect the IAP sensor coupler ①.
2) Insert the needle pointed probes to the lead wire
coupler.
4) Measure the IAP sensor output voltage at the wire
side coupler (between BL and GR wires). ①
IAP sensor Approx. 2.7 V at idle speed
output voltage (⏍ BL - ⏎ GR)
Is the output voltage OK?
● OB, BL or GR wire open or

shorted to ground, or poor B16 ,
B11 or B10 connection of ECU
coupler.
YES ● If wire and connection are OK,
● Recheck each terminal and wire E49
Gray Black E44 E43
connection.
ECU Coupler
If check result is not satisfactory,
NO replace the IAP sensor with a new
one.
Output voltage
(Input voltage 5 V, ambient temp. 25 °C, 77 °F)
ALTITUDE ATMOSPHERIC OUTPUT
(Reference) PRESSURE VOLTAGE
(ft) (m) (mmHg) kPa (V)
0 0 760 100
Approx.
3.7 ~ 3.9
2 000 610 707 94
2 001 611 707 94
Approx.
3.3 ~ 3.7
5 000 1 524 634 85
5 001 1 525 634 85
Approx.
3.0 ~ 3.3
8 000 2 438 567 76
8 001 2 439 567 76
Approx.
2.7 ~ 3.0
10 000 3 048 526 70
55
“0112” or “0113” IAT SENSOR CIRCUIT MALFUNCTION

<
<

● IAT sensor circuit open or short.
☞@ Refer to page 48 [4-1-31] ● IAT sensor malfunction.
▒ INSPECTION
1) Remove the fuel tank.
3) Check the IAT sensor coupler for loose or poor
contacts.
If OK, then measure the IAT sensor resistance.
4) Disconnect the IAT sensor coupler.

5) Measure the resistance between the terminals ①
and ②.
0.081 ~ 48.352
[ When Intake air
IAT sensor resistance temperature is
-40℃ ~ 130℃
(-40℉ ~ 266℉) ]
Tester knob indication : Resistance (㏀)
NOTE
IAT sensor resistance measurement method is
the same way as that of the WT sensor.
@
Refer to the service manual @ " @ @ @ @ @ @ @ @ @ @ @ @ @ @
(99000-51210) #@ page 5-7
@
Refer to the service manual @ " @ @ @ @ @ @ @ @ @ @ @ @ @ @
(99000-94810) #@ page 5-7
56
IAT sensor resistance

Intake Air Temp. Resistance
-40 ℃ (-40 ℉) 44.642 ㏀ ± 5%
-20 ℃ (-4 ℉) 14.958 ㏀ ± 5%
0 ℃ (32 ℉) 5.734 ㏀ ± 5%
20 ℃ (68 ℉) 2.438 ㏀ ± 5%
40 ℃ (104 ℉) 1.141 ㏀ ± 5%
60 ℃ (140 ℉) 0.579 ㏀ ± 5%
80 ℃ (176 ℉) 0.315 ㏀ ± 5%
100 ℃ (212 ℉) 0.182 ㏀ ± 5%
120 ℃ (248 ℉) 0.111 ㏀ ± 5%
130 ℃ (266 ℉) 0.088 ㏀ ± 5%
Is the resistance OK?
● Lg or GR wire open or shorted to E;

ground, or poor B8 or B10
● I f wire and connection are OK,
YES
● Recheck each terminal and wire
Gray Black E43
connection.
Replace the IAT sensor with a new ECU Coupler

NO
one.
57
“0117” or “0118” WT SENSOR CIRCUIT MALFUNCTION

0117
[ 0 1 1 7 0 1 1 7 ]
0118
[ 0 1 1 8 0 1 1 8 ]

● WT sensor circuit open or short.
☞ Refer to page 49 [4-1-32] ● WT sensor malfunction.
▒ INSPECTION
1) Turn the ignition switch “OFF” position.
2) Check the WT sensor coupler for loose or poor
contacts.
If OK, then measure the WT sensor resistance.
☞@Refer to the service manual ᴢ@@
(99000-51210)ᴣpage 5-7
☞@Refer to the service manualᴢ@@
(99000-94810)ᴣpage 5-7
3) Disconnect the WT sensor coupler.

4) Measure the resistance between the terminals ①
and ③.
0.1163 ~ 48.1400 ㏀
When Water
WT sensor resistance temperature is
-40℃ ~ 120℃
(-40℉ ~ 248℉)

Water
③
① ③
58
WT sensor resistance
Engine Coolant Temp. Resistance (To ECU)
-40 ℃ (-40 ℉) Approx. 48.140 ㏀
0 ℃ (32 ℉) Approx. 5.790 ㏀
20 ℃ (68 ℉) Approx. 2.450 ㏀
40 ℃ (104 ℉) Approx. 1.148 ㏀
60 ℃ (140 ℉) Approx. 0.586 ㏀
80 ℃ (176 ℉) Approx. 0.322 ㏀
120 ℃ (248 ℉) Approx. 0.1163 ㏀
Is the resistance OK?
● G or GR wire open or shorted to

ground, or poor B14 or B10
● If wire and connection are OK,
YES intermittent trouble or faulty
ECU.
harness for open circuit and Gray * Black *
poor connection.
ECU Coupler
Replace the WT sensor with a new
NO
one.
59
“0122” or “0123” TP SENSOR CIRCUIT MALFUNCTION

0122
[ 0 1 2 2 0 1 2 2 0 1 2 ]
0123
[ 0 1 2 3 0 1 2 3 0 1 ]

● TP sensor circuit open or short.
☞ Refer to page 49 [4-1-32] ● TP sensor malfunction.
▒ INSPECTION
◈ Step 1
2) Check the TP sensor coupler for loose or poor
contacts.
If OK, then measure the TP sensor input voltage.
3) Disconnect the TP sensor coupler ①.

5) Measure the voltage at the OB wire and ground.
6) If OK, then measure the voltage at the OB wire
and GR wire.
4.9 ~ 5.1 V
TP sensor input
( ⊕ OB - ⊖ Ground )
voltage
( ⊕ OB - ⊖ GR )
Is the input voltage OK?
YES Go to Step 2.
● Loose or poor contacts on the
ECU coupler.
NO
● Open or short circuit in the OB
wire or GR wire.
60
◈ Step 2
1) Remove the frame cover.
3) Disconnect the TP sensor coupler.
4) Check the continuity between Ⓐ (LY) and ground.
TP sensor continuity ∞ Ω (Infinity)

(Ⓐ - Ground)
Tester knob indication : Resistance (Ω)

Ground
Is the continuity OK?

YES Go to Step 3.
Replace the TP sensor with a new
NO
one.
◈ Step 3
1) Connect the TP sensor coupler.
2) Insert the needle pointed probes to the lead wire
coupler.
Measure the TP sensor output voltage at the
coupler [between Ⓐ (⊕ : LY) and Ⓒ (⊖ : GR)] by
turning the throttle grip.
TP sensor output voltage

Throttle valve is closed Approx. 1.07 ~ 1.17 V
Throttle valve is opened Approx. 4.30 ~ 4.70 V
61
Is the output voltage OK?

E49 E45
● O B , LY o r G R w i r e o p e n o r
shorted to ground, or poor ,
or connection of ECU
coupler.
Gray Black E43
connection.
ECU Coupler
If check result is not satisfactory,
NO replace the TP sensor with a new
one.
62
“0201” or “0202” FUEL INJECTOR CIRCUIT MALFUNCTION

0201
[ 0 2 0 1 0 2 0 1 ]
0202
[ 0 2 0 2 0 2 0 2 ]

● Injector circuit open or short.
☞ Refer to page 50 [4-1-33] ● Injector malfunction.
▒ INSPECTION
◈ Step 1
1) Remove the fuel tank and frame cover.
3) Check the injector couplers NO.1 ① and NO.2 ②
for loose or poor contacts.
If OK, then measure the injector resistance.
※ Ⓐ : NO.1 FUEL INJECTOR
(white taping)
Ⓑ : NO.2 FUEL INJECTOR Ⓐ Ⓑ
4) Disconnect the injector couplers NO.1 ① and

NO.2 ② and measure the resistance between
terminals.
11.4 ~ 12.6 Ω
Injector resistance
at 20℃ (68℉)
② ①
5) If OK, then check the continuity between injector

terminals and ground.
Injector continuity ∞ Ω (Infinity)

Are the resistance and continuity OK?
YES Go to Step 2
Replace the Injector with a new
NO
one.
63
◈ Step 2
2) Measure the injector voltage between YL(NO.1 &
NO.2) wire and ground.
Battery voltage
Injector voltage ( [NO.1] ⊕ YL - ⊖ Ground,
[NO.2] ⊕ YL - ⊖ Ground )
NO.1 NO.2
NOTE
Injector voltage can be detected only 3
seconds after ignition switch is turned “ON”
position.
Is the voltage OK?

● YR(NO.1), RB(NO.2) wire open or E9 E8
shorted to ground, or poor
(NO.1), (NO.2) connection of
ECU coupler.
harness for open circuit and poor Gray Black
connection.
Inspect the fuel pump or fuel pump
ECU Coupler
NO
relay. (Refer to page 82 [4-2-5])
64
“0230” or “0232” FUEL PUMP RELAY CIRCUIT MALFUNCTION

0230
[ 0 2 3 0 0 2 3 ]
0232
[ 0 2 3 2 0 2 3 2 0 ]

● Fuel pump relay circuit open or short.
☞ Refer to page 50 [4-1-33] ● Fuel pump relay malfunction.
▒ INSPECTION
3) Check the fuel pump relay coupler for loose or
poor contacts.
If OK, then check the insulation and continuity.
Refer to page 82 [4-2-5] for details.
※ Ⓐ : Side stand relay

Ⓑ : Main relay
Ⓒ : Fuel pump relay
Ⓐ Ⓑ Ⓒ Ⓓ
Ⓓ : Turn signal relay
Is the Fuel pump relay OK?

E<
● GW wire open or shorted to
ground, or poor connection of
ECU coupler.
YES
connection. Gray Black
● Inspect the fuel injectors.
(Refer to page 63 [4-1-46]) ECU Coupler
Replace the fuel pump relay with a
NO
new one.
65
“0336” or “0337” PICK-UP COIL CIRCUIT MALFUNCTION

0336
[ 0 3 3 6 0 3 3 6 ]
0337
[ 0 3 3 7 0 3 3 7 ]

● Metal particles or foreign materiel being attached
on the pick-up coil and rotor tip.
☞ Refer to page 50 [4-1-33] ● Pick-up coil circuit open or short.
● Pick-up coil malfunction.
▒ INSPECTION
2) Turn the ignition switch to the “OFF” position. ①
3) Check the pick-up coil coupler ① for loose or poor
contacts.
If OK, then measure the pick-up coil resistance.
4) Disconnect the pick-up coil coupler ① and

measure the resistance.
110 ~ 140 Ω
Pick-up coil resistance
(G - L)

5) If OK, then check the continuity between each
terminal and ground.
∞ Ω (Infinity)
Pick-up coil continuity (G - Ground)
(L - Ground)
66
Are the resistance and continuity OK?

● L or G wire open or shorted to E7
ground, or poor or
YES
Gray Black E4 6
connection.
● Loose or poor contacts on the pick-
up coil coupler or ECU coupler. ECU Coupler
NO
● Replace the pick-up coil with a new
one.
67
“0351” or “0352” IGNITION COIL MALFUNCTION

☞ Refer to the IGNITION COIL for details.
(See page 91 ~ 92 [6-4 ~ 5])
0351
[ 0 3 5 1 0 3 5 1 ]
0352
[ 0 3 5 2 0 3 5 2 ]
68
“0500” SPEEDO SENSOR MALFUNCTION

0500
[ 0 5 0 0 0 5 ]

● Speedo sensor circuit open and short.
☞ Refer to page 51 [4-1-34] ● Speedo sensor malfunction.
▒ INSPECTION
◈ Step 1
1) Driving the motorcycle and check the speedometer of the instrument panel for works.
Is the Speedometer OK?
YES Go to step 2
Replace the speedo sensor with a

NO
new on.
◈ Step 2
1) Check the continuity between G wire of the
speedo sensor coupler (3 pins) ① and of the
ECU coupler.
Speedo sensor
0Ω
continuity

①
Is OK?

YES
● Replace the speedo sensor or
ECU with a new one.
Recheck each terminal and wire

NO harness for open circuit and poor
connection. J48 Gray Black
ECU Coupler
69
“0505” ISC SOLENOID RANGE ABNORMAL

0505
[ 0 5 0 5 0 5 ]

● ISC solenoid malfunction.
☞ Refer to page 51 [4-1-34] ● ISC solenoid’s step is out of the specified range.
▒ INSPECTION
3) Check the ISC solenoid coupler for loose or poor
contacts.
4) Turn the ignition switch “ON” position to check the
ISC solenoid operation.
[ When Ignition switch “OFF” ]
[ When Ignition switch “ON” ]
Is OK?
● LY, G, BBr or YL wire loose or J4
poor contacts on the ISC solenoid
coupler, or poor , , or
harness for open circuit and poor J46 Gray J45 J44 Black
connection.
Replace the ISC solenoid with a new
ECU Coupler
NO
one.
70
“0562” or “0563” BATTERY VOLTAGE MALFUNCTION

0562
[ 0 5 6 2 0 5 6 2 ]
0563
[ 0 5 6 3 0 5 6 3 ]

● Battery voltage circuit open and short.
☞ Refer to page 51 [4-1-34] ● Battery malfunction.
▒ INSPECTION
1) Remove the front seat.
3) Using the pocket tester, measure the DC voltage
between the battery (+) and (-) terminal.
Battery voltage 11 ~ 16 V
Is the battery voltage OK?

J< E5
● OB, BW, BW or RB wire open or
shorted to ground, or poor B15 , G9 ,
B2 or B18 connection of ECU
coupler.
● Recheck each terminal and wire E4; E48
Gray Black
connection.
ECU Coupler
NO Replace the battery with a new one.
71
“0650” “FI” CHECK LAMP CIRCUIT MALFUNCTION

0650
[ 0 6 5 0 0 6 ]

● “FI” check lamp circuit open and short.
☞ Refer to page 51 [4-1-34] ● “FI” check lamp malfunction.
▒ INSPECTION
2) Turn the ignition switch
d@
to the “OFF” position.
3) Disconnect the instrument panel lead wires.
4-1) d@
Connect the battery ⊕ terminal to the O (9 pins

coupler) wire of the instrument panel and the
battery ⊖ terminal to the BW (9 pins coupler)
wire of the instrument panel.
And then connect the LY (3 pins coupler) wire of
the instrument paneld@ to the battery ⊖ terminal
directly. d@ d@
d@ d@
4-2) d@
& d@
Connect the battery ⊕

d@
d@ terminal to the R (9 pins coupler) wire and O (9 pins coupler) wire of the instrument
d@
d@battery ⊖ terminal to the BW (3 pins coupler) wire of the head lamp.

d@
panel and the
And then connect d@ the LY (3 pins coupler) wire of the instrument panel to the battery ⊖ terminal directly.
d@ d@
4-3) &
d@ d@
Connect the battery ⊕ terminal to d@the R (4 pins coupler) wire and O (9 pins coupler) wire of the instrument
panel and the battery ⊖ terminal to d@
the BW (9 pins coupler) wire of the instrument panel.
d@
And then connect the LY (4 pins coupler) wire of the instrument panel to the battery ⊖ terminal directly.
Is the “FI” check lamp lit?

J6
● LY or OB wire open or shorted to
ground, or poor G3 or B15
YES
Gray E48 Black
connection.
Replace the instrument panel with a ECU Coupler
NO
new one.
72
“0850” GP or CLUTCH LEVER SWITCH CIRCUIT MALFUNCTION

0850
[ 0 8 5 0 0 8 ]

● GP switch circuit open or short.
● GP switch malfunction.
☞ Refer to page 51 [4-1-34] ● Clutch lever switch circuit open or short.
● Clutch lever switch malfunction.
▒ INSPECTION
1) Remove the frame cover. ①
3) Check the GP switch and clutch lever switch
coupler for loose or poor contacts.
If OK, then measure the GP switch and the clutch
lever switch resistance.
4) Park the motorcycle on a firm, flat surface

vertically.
5) Disconnect the GP switch coupler ① and then
check the continuity between L wire and ground
when gearshift lever is shifted from the neutral
state.
0Ω
GP switch continuity
(L Ground)
73
6) Disconnect the clutch lever switch coupler ② and

then check the continuity between GR wire and Br ②
wire when the squeezing the clutch lever.
Clutch lever 0Ω
switch continuity (GR Br)
7) Measure the voltage between G18 of the ECU and

the LY wire of the wiring harness’s GP switch
coupler, and measure the voltage between G18 of
the ECU and the GR wire of the wiring harness’s
clutch lever switch coupler.
If the measurement is out of 0.4 ~ 0.7 V, replacce
the DIODE #3 with a new one
Tester knob indication : Diode test ( )
gQX Gray Black
ECU Coupler
Is OK?
YES ● Recheck each terminal and wire
connection.
Replace the GP switch or Clutch
NO
lever switch with a new one.
74
SENSORS ①
◉ PICK-UP COIL INSPECTION
The pick-up coil ① is installed in the magneto cover.
(Refer to page 66 [4-1-49])
◉ PICK-UP COIL REMOVAL

AND INSTALLATION
● Remove the magneto cover.
● Install the magneto cover in the reverse order of
removal.
◉ IAP SENSOR INSPECTION

The intake air pressure (IAP) sensor ② is installed on ②
the left side of the throttle body.
◉ IAP SENSOR REMOVAL

AND INSTALLATION
● Remove the fuel tank.
● Remove the IAP sensor from the left side of the
throttle body.
● Install the IAP sensor in the reverse order of
removal.
◉ TP SENSOR INSPECTION
The throttle position (TP) sensor ③ is installed on
the left side of the throttle body.
◉ TP SENSOR REMOVAL AND

INSTALLATION
③
CAUTION
Never remove or adjust the TP sensor.
75
◉ WT SENSOR INSPECTION
The water temperature (WT) sensor ① is installed on
the rear side of the thermostat case.
◉ WT SENSOR REMOVAL AND ①

INSTALLATION
● Remove the WT sensor.
● Install the WT sensor in the reverse order of
removal.
WT sensor : 5 ~ 8 N · m (0.5 ~ 0.8 kgf · m)
◉ IAT SENSOR INSPECTION

The intake air temperature (IAT) sensor ② is installed
under the air cleaner case. ②
◉ IAT SENSOR REMOVAL AND

INSTALLATION
● Remove the IAT sensor from the air cleaner case.
● Install the IAT sensor in the reverse order of
removal.
◉RO SWITCH REMOVAL AND

INSTALLATION
The roll over (RO) switch ③ is located below the fuel
tank mounting bolts.
● Romove the front seat.
● Remove the RO switch from the frame.
● Install the RO switch in the reverse order of
removal. ③
76
FUEL SYSTEM AND THROTTLE BODY
CONTENTS
FUEL SYSTEM ……………………………………………………………… 78 [4-2-1]

REMOVAL AND DISASSEMBLY ………………………………………… 80 [4-2-3]
REASSEMBLY AND INSTALLATION …………………………………… 81 [4-2-4] 4-2
FUEL PRESSURE OF FUEL PUMP INSPECTION …………………… 82 [4-2-5]
FUEL PUMP RELAY INSPECTION ……………………………………… 82 [4-2-5]
FUEL MESH FILTER INSPECTION AND CLEANING ………………… 83 [4-2-6]

FUEL GAUGE INSPECTION ……………………………………………… 83 [4-2-6]
THROTTLE BODY ………………………………………………………… 84 [4-2-7]

REMOVAL……………………………………………………………………… 85 [4-2-8]
CLEANING …………………………………………………………………… 86 [4-2-9]
INSPECTION ………………………………………………………………… 86 [4-2-9]

INSTALLATION ……………………………………………………………… 86 [4-2-9]
CAUTION
Gasoline must be handled carefully in an area well ventilated and away from fire or spark.
77
4-2-1 FUEL SYSTEM AND THROTTLE BODY
FUEL SYSTEM d@
d@
78
FUEL SYSTEM AND THROTTLE BODY 4-2-2
d@
d@
d@
d@
d@
79
REMOVAL AND DISASSEMBLY

● Remove the front seat.
d@
● Remove the fuel tank mounting bolts and fuel tank
bracket mounting bolt. ( d@ )
● Remove the fuel tank mounting bolts and take off the
hooks. ( d@ )
d@
d@
d@
d@
● Disconnect the fuel gauge coupler ①.
● Remove the fuel pump coupler ②.

● Remove the fuel injector hose ③.
CAUTION
After disconnecting the fuel injector hose ③,
insert a blind plug into the end to stop fuel ③
leakage.
80
● Remove the fuel tank rearward.
CAUTION
As gasoline leakage may occur in this operation,
keep away from fire and sparks.
● Remove the fuel pump assembly ① by removing

its mounting bolts diagonally.
WARNING ①
❖ Gasoline is highly flammable and explosive.
❖ Keep heat, spark and flame away.
● Remove the fuel gauge ②.
REASSEMBLY AND INSTALLATION

Reassembly and installation the fuel tank in the
reverse order of removal and disassembly.
● When installing the fuel pump assembly, first
tighten all the fuel pump assembly mounting bolts
lightly in diagonal stages, and then tighten them in
the above tightening order.
NOTE
When installing the fuel pump assembly, apply a
small quantity of the THREAD LOCK to the thread
portion of the fuel pump mounting bolt.
THREAD LOCK
81
FUEL PRESSURE OF FUEL

PUMP INSPECTION
● Remove the front seat.
● Place a rag under the fuel injector hose.
● Disconnect the fuel injector hose from the fuel
hose joint.
● Install the special tool between the fuel tank and
fuel hose joint.
Fuel pump pressure gauge

: 09915-54510
Turn the ignition switch “ON” position and check the

fuel pressure of the fuel pump.
Fuel pressure Approx. 2.25 ~ 2.50 kgf/cm²

of fuel pump (220 ~ 245 kPa, 32.0 ~ 35.6 psi)
If the fuel pressure is lower than the specification,

inspect the following items :
* Fuel hose leakage
* Clogged fuel filter
* Pressure regulator
* Fuel pump
If the fuel pressure is higher than the specification,

inspect the following items :
* Fuel pump check valve
* Pressure regulator
WARNING
⎃ Before removing the special tool, turn the
ignition switch to “OFF” position and release
the fuel pressure slowly.
⎃ Gasoline is highly flammable and explosive.
Keep heat, sparks and flame away.
FUEL PUMP RELAY INSPECTION

Fuel pump relay is located the left side of the frame. ①
● Remove the frame cover.
● Remove the fuel pump relay ①.
82
First, check the insulation between ① and ②

terminals with pocket tester. Then apply 12 volts to ① ③
③ and ④ terminals, ⊕ to ③ and ⊖ to ④, and check
the continuity between ① and ②.
If there is no continuity, replace it with a new one.
② ④
FUEL MESH FILTER INSPECTION

AND CLEANING
● If the fuel mesh filter is clogged with sediment or
rust, fuel will not flow smoothly and loss in engine
power may result.
● Blow the fuel mesh filter with compressed air.
NOTE
If the fuel mesh filter is clogged with many
sediment or rust, replace the fuel filter cartridge
with a new one.
FUEL GAUGE INSPECTION

● Measure resistance between the terminals when
float is at the position instead below.
Fuel float position Resistance between terminals

F Approx. 90 ~ 100 Ω
1/2 Approx. 38 Ω
E Approx. 4 ~ 10 Ω
● If the measured resistance is out of the specification,

replace the gauge with a new one.
● Inspect the fuel level meter.
83
THROTTLE BODY
84
REMOVAL
● Remove the air cleaner box.
● Disconnect the fuel hoses.
● Remove the all couplers is related to the throttle
body.
● Loosen the throttle body clamp screws.
● Disconnect the throttle cables from their drum.

● Dismount the throttle body assembly.
CAUTION
❖ Be careful not to damage the throttle cable
bracket when dismounting or remounting the
throttle body assembly.
❖ After disconnecting the throttle cables, do not
snap the throttle valve from full open to full
close. It may cause damage to the throttle
valve and throttle body.
85
CLEANING
● Clean all passageways with a spray-type throttle
body cleaner and blow dry with compressed air.
WARNING
Some throttle body cleaning chemicals,
especially dip-type soaking solutions, are very
corrosive and must be handled carefully. Always
follow the chemical manufacturer’s instructions
on proper use, handling and storage.
CAUTION
Do not use wire to clean passageways. Wire can
damage passageways. If the components cannot
be cleaned with a spray cleaner it may be
necessary to use a dip-type cleaning solution
and allow them to soak. Always follow the
chemical manufacturer’s instructions for proper
use and cleaning of the throttle body
components. Do not apply throttle body cleaning
chemicals to the rubber and plastic materials.
INSPECTION
● Check following items for any damage or clogging.
* O-ring * Throttle body
①
* Injector cushion seal * Fuel injector
* Throttle valve * Vacuum hose
* Intake pipe
* Throttle shaft bushing and seal
Check fuel injector filter for evidence of dirt and
contamination. If present, clean and check for
presence of dirt in the fuel lines and fuel tank.
INSTALLATION
Installation is in the reverse order of removal.
Pay attention to the following points :
CAUTION
The idle screw ① adjustment affect the control of
the ECU. It can cause start-up off.
So should never adjust.
● Connect the throttle cable to the throttle cable

drum.
● Adjust the throttle cable play with the cable
adjusters.
86
ELECTRICAL SYSTEM
CONTENTS
LOCATION OF ELECTRICAL COMPONENTS ………………… 88 [6-1]
IGNITION SYSTEM …………………………………………………………… 90 [6-3]
CHARGING SYSTEM ……………………………………………………… 93 [6-7]
STARTER SYSTEM AND SIDE STAND

IGNITION INTERLOCK SYSTEM …………………………………… 95 [6-11]
6
87
6-1 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
④ ⑥ ⑦ ⑧ ⑩ ⑫ ⑬
⑤ ⑨
⑪
① ② ③
① Ignition coil NO.1 ④ Cooling fan motor relay ⑨ Fuel pump relay ⑪ Battery
② Main fuse (30 A) ⑤ Head lamp relay ⑩ Turn signal relay ⑫ ECU
③ ECU fuse (15 A) ⑥ Regulator / Rectifier ⑬ RO switch
⑦ Side stand relay
⑧ Main relay
⑮
⑭
⑱
⑯
⑭ TP sensor ⑮ IAT sensor ⑯ Magneto
⑰ Pick-up coil
⑱ GP switch
88
ELECTRICAL SYSTEM 6-2
⑳
⑲ IAP sensor ⑳ Ignition coil NO.2 Starter motor relay
ISC solenoid
Oxygen sensor NO.1 WT sensor Fuel injector NO.1

Oxygen sensor NO.2 Fuel injector NO.2
89
IGNITION SYSTEM
IGNITION SWITCH
ENGINE STOP SWITCH
Y
IGNITION COIL, NO.1
IGNITION COIL, NO.2 G

30A 15A
FUSE FUSE
REGULATOR
Y
ECU /
RECTIFIER
L
BATTERY
Y
12V 12Ah
◉ INSPECTION
▒ MAGNETO
Using the pocket tester, measure the resistance
Charging coil
between the lead wires in the following table.
If the resistance is not within the specified value,
replace the stator coil, with a new one.
Stator coil resistance Standard

Pick-up coil G-L 110 ~ 140 Ω
Charging coil Y-Y 0.2 ~ 0.4 Ω Pick-up coil
NOTE
When making above test, it is not necessary to
remove the magneto.
90
▒ IGNITION COIL PRIMARY PEAK

VOLTAGE INSPECTION
● Remove the fuel tank and frame cover.
● Disconnect the two spark plug caps.
● With the spark plug cap connected, place a new
spark plug on the engine to ground it.
NOTE
❖ Check that all the couplers are connected.
❖ Check that the all battery is fully charged.
Measure the NO.1 and NO.2 ignition coil primary

peak voltage using the tester in the following
procedure.
● Connect the tester as follows.
NO.1 Ignition coil
⇒ ⊕ Probe : BY lead wire terminal
⊖ Probe : Ground
NO.2 Ignition coil
⇒ ⊕ Probe : WL lead wire terminal
⊖ Probe : Ground
NOTE
Do not disconnect the ignition coil / plug cap lead
wire couplers.
● Shift the transmission into the neutral and then

turn the ignition switch to the “ON” position.
● Squeeze the clutch lever.
● Press the starter switch and allow the engine to
crank for a few seconds, and then measure the
ignition coil primary peak voltage.
● Repeat the above procedure a few times and
measure the highest ignition coil primary peak
voltage.
Ignition coil primary peak voltage 400 V and more Ignition coil NO.1
WARNING
While testing, do not touch the tester probes and
spark plugs to prevent receiving an electric shock.
If the peak voltage is lower than the specified values,

inspect the ignition coil. (Refer to the next page.)
Ignition coil NO.2
91
▒ IGNITION COIL RESISTANCE

INSPECTION
● Disconnect the ignition coil read wire.
Measure the ignition coil resistance in bolt the primary
and secondary windings. If the resistance is not within
the standard range, replace the ignition coil with a new
one.
IGNITION COIL / PLUG CAP RESISTANCE

Primary 0.52 ~ 0.64 Ω (⊕ Terminal - ⊖ Terminal)
Secondary 6.4 ~ 7.8 ㏀ (Plug cap - ⊕ Terminal)
Tester z indication : Resistance (㏀)
⊕ ⊖
92
CHARGING SYSTEM
Regulator / Rectifier
Ignition switch
A. C generator
Battery
IC
LOAD
◉ INSPECTION
▒ CHARGING OUTPUT CHECK
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the DC voltage
between the battery terminal ⊕ and ⊖.
If the voltage is not within the specified value, check the
magneto no-load performance and regulator / rectifier.
CAUTION
When making this test, be sure that the battery is
full-charged condition.
IG. switch
Standard charge 13.5 ~ 15.0 V (at 5,000 rpm)
Tester knob indication : Voltage ( ) Regulator

Rectifier
Battery DCV
93
▒ MAGNETO NO-LOAD PERFOR-MANCE

Disconnect the three lead wires from the magneto
terminal.
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the AC voltage
between the three lead wires.
If the voltage is under the specified value, replace the
magneto with a new one.
Standard NO-load perfor-

Over 70 V (at 5,000 rpm)
mance of magneto
▒ REGULATOR / RECTIFIER
Disconnect the regulator / rectifier couplers.
Measure the voltage between the terminals using the
pocket tester as indicated in the table below.
If the voltage is not within the specified value, replace
the regulator / rectifier with a new one.
Unit : V
⊕ Tester probe
① ② ③ ④ ⑤
⊖ Tester probe
① 0 0 0 0.4~0.7
② 0 0 0 0.4~0.7
③ 0 0 0 0.4~0.7
④ 0.4~0.7 0.4~0.7 0.4~0.7 0.5~1.2 ①
⑤ 0 0 0 0
④
Tester knob indication : Diode test (+ )
②
③
⑤
94
STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK

SYSTEM
◉ STARTER SYSTEM DESCRIPTION
The starter system consists of the following components : the starter motor, starter relay, clutch lever switch,
side stand switch, GP switch, starter switch, engine stop switch, ignition switch and battery.
Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact
points to close, thus completing the circuit from the starter motor to the battery.
STARTER
SWITCH IGNITION SWITCH
FUSE
ENGINE NEUTRAL
STOP INDICATOR
BATTERY
SWITCH GP SWITCH
SIDE STAND
RELAY SIDE STAND
START START RELAY SWITCH
MOTOR CLUTCH LEVER
SWITCH
◉ SIDE STAND / IGNITION INTERLOCK SYSTEM DESCRIPTION

This side stand / ignition interlock system prevents the motorcycle from being started with side stand down.
The system is operated by an electric circuit provided between the battery and ignition coil.
The circuit consists of the neutral indicator light and switches.
The ignition coils will send voltage to the spark plugs depending on what gear the transmission is in and
whether the side stand is either up or down.
The gear position and side stand switches work together in this system.
The ignition coil work only in two situations as follows.
SIDE STAND MAIN RELAY

RELAY
IGNITION SWITCH
BATTERY IGNITION COIL
BATTERY
NEUTRAL
INDICATOR LIGHT
DIODE
GP SWITCH SIDE STAND SWITCH
95
▒ TRANSMISSION : Neutral -䭵 ON䭶

Side stand - Down
Clutch lever - Squeeze
SIDE STAND RELAY MAIN RELAY

IGNITION SWITCH 䭵ON䭶
䭵ON䭶 BATTERY IGNITION COIL
BATTERY
NEUTRAL
INDICATOR LAMP
DIODE
GP SWITCH䭵ON䭶
SIDE STAND SWITCH
SIDE STAND
䭵DOWN POSITION䭶
▒ TRANSMISSION : Neutral -䭵 OFF䭶

Side stand - Up
Clutch lever - Squeeze
SIDE STAND RELAY MAIN RELAY

䭵ON䭶
IGNITION SWITCH
䭵ON䭶 BATTERY IGNITION COIL
BATTERY
NEUTRAL
INDICATOR LAMP
DIODE
SIDE STAND SWITCH

GP SWITCH 䭵OFF䭶 SIDE STAND
䭵UP-RIGHT POSITION䭶
d@
䭿 d@ 䮀)䭿 d@ 䮀are equipped with the side stand ignition interlock
system. d@
If the transmission is in neutral or side standd@

up, you can only start the engine by squeezing in the clutch lever.
# NO.# Neutral switch# Clutch lever# d@ #
Side stand Engine Start
1 䮡䮡䮧 d@
Possible
NOTE
2 䮧䮡䮡 Possible
䮡 On, Squeeze or Up
3 䮡䮧䮧 Impossible
䮧 Off, Release or Down
4 䮧䮡䮧 Impossible
5 䮧䮧䮡 Impossible
96
CHASSIS
CONTENTS d@
d@
EXTERIOR PARTS ………………………………………………………

d@
98 [7-1-1]
FRONT FORK [ d@ 2013 model ] …………… 100 [7-15]

d@
97
7-1-1 CHASSIS d@
d@
EXTERIOR PARTS d@
◉ SIDE COWLING INNER [ d@ 2013 model]

d@
98
d@
d@
CHASSIS 7-1-2
d@ d@
d@
The 『 d@ 』 &
『 d@ 』 have the “side cowling

d@
❸
inner ①” at the rightside and leftside.
d@
Use the “side cowling inner RH (Right Hand)” to ❹
d@
operate the radiator cap ②.
To disassemble the “side cowling inner RH (Right

Hand)”, remove the scrivet ③ from the inside and
❶
unhook the hook ④ , ⑤ , ⑥ .
❻
❺
WARNING
You can be injured by scalding fluid or steam if
you open the radiator cap when the engine is
hot.
After the engine cools, wrap a thick cloth
around cap and carefully remove the cap by
turning it a quarter to allow pressure to escape
and then turn the cap all the way off.
❷
99
d@
d@
7-15 CHASSIS
d@
FRONT FORK [ d@ 2013 model ]

d@
100
CHASSIS 7-16
◉ REMOVAL AND DISASSEMBLY

●@Remove the body cowling.
●@Remove the front fender.
●@Take off the front wheel.
●@@L oosen the handlebar clamp bolts ① , right and

left.
●@Loosen the front fork upper ② and lower ③

clamp bolts, right and left.
●@Remove the front brake hose clamp.
●@Pull down the right and left front forks.
②
●@Remove the front fork cap bolt ④#from the inner rod
by loosening the lock nut ⑤. ⑥
CAUTION ⑤
Do not disassemble the front fork cap ⑥.
④
101
7-17 CHASSIS
●@Remove the spacer ①, spring retainer ②, spring ③

and spring guide ④. ② ①
④
●@Remove the outer tube ⑤ from the inner tube.
●@Invert the front fork and stroke the inner rod several
times to let out fork oil.
●@@Under the inverted condition of front fork, drain oil to
hold it for a few time.
102
CHASSIS 7-18
●@Remove the dust seal ① and the oil seal stopper ring
②. ②
●@Remove the oil seal ③# and oil seal retainer 土 by

using the special tool.
Oil seal remover : 09913-50121 ①
CAUTION
The removed oil seal must be replaced with a
new one.
②
◉ INSPECTION
■ INNER AND OUTER TUBES
Inspect the inner tube outer surface and inner tube slide
metal ⑤/#outer tube slide metal ⑥#face for scratches.
If any defects are found, replace them with a new one.
■ FORK SPRING
Measure the fork spring free length.
If it is shorter than the service limit, replace it with a new
one.
683#pp#+461;#lq,
Front fork spring free Service limit
length 350 mm (13.8 in)
103
7-19 CHASSIS
◉ REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order of removal and disassembly.
Pay attention to the following points :
CAUTION
❖@Thoroughly wash all the component parts being assembled.
Insufficient washing can result in oil leakage or premature wear of the parts.
❖@When reassembling the front fork, use new fork oil.
❖ Use the specified fork oil for the front fork.
❖@When reassembling, replace the oil seal and dust seal with new ones.
● On the inner tube, assemble the following parts.

① Dust seal
② Oil seal stopper ring
③ Oil seal
④ Oil seal retainer
⑤ Outer tube slide metal ①
⑥ Inner tube slide metal Ⓐ ②
③
CAUTION ④
❖ When installing the dust seal ① and oil seal ③
⑤
onto the inner tube, protect their seal lips with ⑥
a vinyl film Ⓐ to prevent oil seal damage.
❖ Do not use solvents for washing to prevent oil
seal damage.
■ OUTER TUBE
●@@Install the outer tube to the inner tube.
CAUTION
Be careful not to damage the dust seal lip and
the oil seal lip, when installing the outer tube.
■ OIL SEAL AND DUST SEAL

●@@Apply GREASE to the new oil seal and dust seal lips
lightly before installing it.
GREASE
●@@Install the oil seal retainer ④, oil seal ③, oil seal
stopper ring ② and dust seal ① to the outer tube.
CAUTION ⑤
❖ When installing the oil seal to outer tube, ④
be careful not to damage the oil seal lip.
❖ Do not use solvents for washing to prevent ③
oil seal damage.
❖ Apply fork oil to the outer tube slide metal ⑤. ②
❖ Make sure that the oil seal stopper ring ② ①
has been fitted securely.
104
CHASSIS 7-20
■ FORK OIL
●@@Place the front fork vertically without spring.
●@@Compress it fully.
●@@Pour specified front fork oil up to the top level of the
outer tube.
●@@Move the inner rod slowly more than ten times until
bubbles do not come out from the oil.
NOTE
Refill front fork oil up to the top of the outer tube
to find bubbles while bleeding air.
●@Refill specified front fork oil up to the top level of the

outer tube again. Move the outer tube up and down
several strokes until bubbles do not come out from
the oil.
●@Keep the front fork vertically and wait 5 ~ 6 minutes.
NOTE
⎆ Always keep oil level over the tube top end, or
air may enter the tube during this procedure.
# Take extreme attention to pump out air com-
pletely.
●@@Hold the front fork vertically and adjust fork oil level
with the special tool.
NOTE
When adjusting the fork oil level, remove the fork
spring and compress the outer tube fully.
Each leg
Front fork oil capacity
481 ± 2 cc
Standard
Front fork
100 mm (3.9 in) from end of outer tube
oil level
(when maximum compressed without spring)
Front fork oil specification : TOP #15,

SAE0W or an equivalent fork oil
Front fork oil level gauge : 09943-74111
105
7-21 CHASSIS
■ FRONT FORK CAP BOLT

●@@When installing the spring adjuster ① to the front fork
① ①
cap bolt@ ②L@ set the upper surface of the front fork
cap bolt@ ②@ with the upper surface of the spring ② ②
adjuster@①@horizontally.
●@@Hold the front fork cap bolt ② and tighten the inner
rod lock nut ③ to the specified torque.
@@@@@@@@@@Inner rod lock nut
: 17.5 ~ 22.5 N呇m (1.75 ~ 2.25 kgf呇m) ③
●@Tighten the front fork cap bolt ② to the specified
torque. ②
@@@@@@@@@@Front fork cap bolt
: 30 ~ 40 N呇m (3.0 ~ 4.0 kgf呇m)
● When installing the front fork to the steering stem

upper bracket ④, install the steering stem upper
④
bracket ④ to the front fork cap bolt under 5 mm (0.2 in). 5 mm
●@@Tighten the front fork upper ⑤# and lower ⑥# clamp ⑤
bolts to the specified torque, right and left.
@@@@@@@@@@Front fork upper clamp bolt
: 22 ~ 35 N呇m (2.2 ~ 3.5 kgf呇m)
@@@@@@@@@@Front fork lower clamp bolt ⑥
: 22 ~ 35 N呇m (2.2 ~ 3.5 kgf呇m)
●@Tighten the handlebar clamp bolts ⑦, right and left.

@@@@@@@@@@Handlebar clamp bolt
: 22 ~ 35 N呇m (2.2 ~ 3.5 kgf呇m)
106
CHASSIS 7-22
●@@Install the right front fork in the same manner as the

left one.
●@@Install the front fender and tighten its mounting bolts
with finger.
●@Install the front wheel.
●@Install the brake calipers.
●@Swing the motorcycle up and down several times.
●@Tighten the front fender mounting bolts.
●@Install the brake hose securely.
●@Install the body cowling.
◉ FRONT FORK SETTING

After installing the front fork, adjust the rebound and
compression damping force as follows.
▒ DAMPING FORCE ADJUSTMENT
1. Rebound damping force
To adjust the rebound damping force turn in the adjuster
①#fully for呓S呔or呓H呔direction. ❶
Count the number of clicks from the fully turned-in posi-
tion.
Fully turned-in呓H呔direction provides stiffest rebound
damping force and turning呓S呔direction the adjuster
will soften rebound damping force.
Standard
Front fork rebound
12 clicks out from end of
damping force adjuster
呓H呔direction
2. Compression damping force

To adjust the compression damping force turn in the
adjuster ②#fully for呓S呔or呓H呔direction.
Count the number of clicks from the fully turned-in
position.
Fully turned-in呓H呔direction provides stiffest
compression damping force and turning呓S呔direction ❷
the adjuster will soften compression damping force.
Standard
Front fork compression
10 clicks out from end
damping force adjuster
of呓H呔direction
STANDARD FRONT FORK DAMPING FORCE

Rebound Compression
Softer Turn to呓S呔direction Turn to呓S呔direction
Solo riding Standard 12 clicks out from end of呓H呔direction 10 clicks out from end of 呓 H呔direction
Stiffer Turn to呓 H呔direction Turn to呓 H呔direction
Dual riding 12 clicks out from end of呓H呔direction 10 clicks out from end of呓H呔direction
WARNING
Be sure to adjust the rebound and compression damping force on both front fork legs equally.
107
MEMO
108
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING …………………………………………………… 110 [8-1-1]

SPECIAL TOOLS …………………………………………………………… 121 [8-9]
TIGHTENING TORQUE ………………………………………………… 122 [8-12]
d@
SERVICE DATA ………………………………………………………………
d@
d@ 123 [8-18-1]
d@
WIRING DIAGRAM [ d@

d@
d@
] j j j j j j128
j [8-30-1]
j j j
d@
WIRING DIAGRAM [ d@

d@
] j j j j j j130
j [8-30-3]
j j j
d@
WIRING DIAGRAM [ d@ ] j j j j j j132
j [8-30-5]
j j j
109
8-1-1 SERVICING INFORMATION
MALFUNCTION CODE AND DEFECTIVE CONDITION

DETECTED ITEM
CODE CHECK FOR
noEr NO FAULT -


O2 S heater


O2 S heater

or Open
IAPS Circuit
Sensor output voltage ≦ 5 V
0108 High Voltage Without the above range for 10.0 sec. and more, 0108 is
indicated.


IATS Circuit
High Voltage Sensor output voltage ≦ 4.9 V
or Open
110
SERVICING INFORMATION 8-1-2

DETECTED ITEM
CODE CHECK FOR

WTS Circuit
High Voltage Sensor output voltage ≦ 5 V
or Open

or Open
TPS Circuit
Sensor output voltage ≦ 4.9 V
0123 High Voltage Without the above range for 7.8 sec. and more, 0123 is indicated.

since then 300 sec.

since then 300 sec.
since then 300 sec.

since then 300 sec.
111

DETECTED ITEM
CODE CHECK FOR
NO.1 Fuel Injector happened the high / ground short fault for 1 second by 5 times
Circuit Malfunction

NO.2 Fuel Injector happened the high / ground short fault for 1second by 5 times in
0202 10 times test cycle, the code 0202 is indicated.
Circuit Malfunction
After engine running, if fuel pump relay signal open or is

Low Voltage
0230 times test cycle, the code 0230 is indicated.
or Open
Fuel pump pump relay, fuel injector.
relay Circuit
After engine running, if fuel pump relay signal is happened the
high short fault for 1 second by 10 times in 20 times test cycle,
0232 High Voltage the code 0232 is indicated.
pump relay, fuel injector.
After engine running, if the magneto rotor tooth’s error is

happened continuously by 10 times in 100 times test cycle, the
0336 Noisy Signal code 0336 is indicated.
coupler connection)
Pick-up coil
After engine running, if the pick-up coil signal does not reach
ECU for more than 0.5 sec., the code 0337 is indicated.
0337 No Signal
coupler connection)


battery.


battery.
112

DETECTED ITEM
CODE CHECK FOR
Motorcycle speed ＜ 10 km/h
Water temperature ＜ 20 ℃
IAPS pressure ＞ 40 kPa
Speedo sensor 20% ＜ TPS open angle ＜ 100%
0500 2,000 rpm ＜ Engine speed ＜ 6,000 rpm
Malfunction
If the above conditions are maintained for more than 1 second,
the code 0500 is indicated.
Speedo sensor, wiring / coupler connection to ECU.
After engine running, if idle speed is different to 500 rpm from

the specified range in 25 seconds test cycle, the code 0505 is
0505 ISC Error indicated.
Idle speed control solenoid, wiring / coupler connection.

9 V ≦ Battery voltage
0562 Low Without the above range for 3.125 sec. and more, 0562 is indicated.
Battery Battery, wiring / coupler connection to ECU.

Voltage
Battery voltage ≦ 16 V
0563 High Without the above range for 3.125 sec. and more, 0563 is indicated.
Battery, wiring / coupler connection to ECU.
After engine running, if “FI” check lamp signal open or is

“FI” check lamp happened the high / ground short fault for 1 second by 40 times
Circuit Malfunction
“FI” check lamp, wiring / coupler connection.
If gear position or clutch lever switch signal feedback is not

active in continuous by 20 times in fully power down cycles, the
GP or Clutch lever Switch code 0850 is indicated.
0850 (Fully power down cycle : Ignition switch “ON” ơ “OFF” position)
Circuit Malfunction
Gear position or clutch lever switch, wiring / coupler connection,
gearshift cam etc.
113
◉ ENGINE
Complaint Symptom and possible causes Remedy
Engine will not Compression too low
start or is hard 1. Tappet clearance out of adjustment. Adjust.
to start. 2. Worn valve guides or poor seating of valves. Repair or replace.
3. Mistimed valves. Adjust.
4. Excessively worn piston rings. Replace.
5. Worn-down cylinder bore. Replace.
6. Starter motor cranks too slowly. See electrical section.
7. Poor seating of spark plugs. Retighten.
Plug not sparking

1. Fouled spark plugs. Clean.
2. Wet spark plugs. Clean and dry.
3. Defective ignition coils. Replace.
4. Open or short in high-tension cord. Replace.
5. Defective pick-up coil. Replace.
6. Defective ECU. Replace.
7. Open-circuited wiring connections. Repair or replace.
No fuel reaching the intake manifold

1. Clogged fuel filter or fuel hose. Clean or replace.
2. Defective fuel pump. Replace.
3. Defective fuel pressure regulator. Replace.
4. Defective fuel injector. Replace.
5. Defective fuel pump relay. Replace.
7. Open-circuited wiring connections. Check and repair.
Incorrect fuel/air mixture

3. Defective TP sensor. Replace.
5. Defective IAP sensor. Replace.
7. Defective WT sensor. Replace.
8. Defective IAT sensor. Replace.
114

Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust.
2. Poor seating of valves. Replace or repair.
3. Defective valve guides. Replace.
4. Worn down camshafts. Replace.
5. Too wide spark plug gaps. Adjust or replace.
11. Imbalanced throttle valve. Adjust.
12. Damaged or cracked vacuum hose. Replace.
Engine stalls Incorrect fuel / air mixture

often. 1. Defective IAP sensor or circuit. Repair or replace.
2. Clogged fuel filter. Clean or replace.
6. Defective thermostat. Replace.
8. Damaged or cracked vacuum hose. Replace.
Fuel injector improperly operating

1. Defective fuel injectors. Replace.
2. No injection signal from ECU. Repair or replace.
3. Open or short circuited wiring connection. Repair or replace.
4. Defective battery or low battery voltage. Replace or recharge.
Control circuit or sensor improperly operating

7. Defective fuel pump relay. Replace.
Engine internal parts improperly operating

1. Fouled spark plugs. Clean.
2. Defective pick-up coil or ECU. Replace.
3. Clogged fuel hose. Clean.
4. Tappet clearance out of adjustment. Adjust.
115

Noisy engine. Excessive valve chatter
1. Too large tappet clearance. Adjust.
2. Weakened or broken valve springs. Replace.
3. Worn tappet or cam surface. Replace.
4. Worn and burnt camshaft journal. Replace.
Noise seems to come from piston

1. Worn down pistons or cylinders. Replace.
2. Combustion chambers fouled with carbon. Clean.
3. Worn piston pins or piston pin bore. Replace.
4. Worn piston rings or ring grooves. Replace.
Noise seems to come from cam chain

1. Stretched chain. Replace.
2. Worn sprockets. Replace.
3. Tension adjuster not working. Repair or replace.
Noise seems to come from clutch

1. Worn splines of countershaft or hub. Replace.
2. Worn teeth of clutch plates. Replace.
3. Distorted clutch plates, driven and drive. Replace.
4. Worn clutch release bearing. Replace.
5. Weakened clutch dampers. Replace the primary driven gear.
Noise seems to come from crankshaft

1. Rattling bearings due to wear. Replace.
2. Worn and burnt big-end bearings. Replace.
3. Worn and burnt journal bearings. Replace.
Noise seems to come from transmission

1. Worn or rubbing gears. Replace.
2. Worn splines. Replace.
3. Worn bearings. Replace.
4. Worn or rubbing primary gears. Replace.
Noise seems to come from water pump

1. Too much play on pump shaft bearing. Replace.
2. Worn or damaged impeller shaft. Replace.
3. Worn or damaged mechanical seal. Replace.
4. Contact between pump case and impeller. Replace.
116

Engine runs poorly Defective engine internal / electrical parts
in high speed 1. Weakened valve springs. Replace.
range. 2. Worn camshafts. Replace.
3. Valve timing out of adjustment. Adjust.
4. Too narrow spark plug gaps. Adjust.
5. Ignition not advanced sufficiently due to poorly working timing Replace ECU.
advance circuit.
9. Clogged fuel hose, resulting in inadequate fuel supply to injector. Clean and prime.
12. Clogged air cleaner element. Clean.
Defective air flow system

1. Clogged air cleaner element. Clean or replace.
2. Defective throttle valve. Adjust or replace.
3. Sucking air from throttle body joint. Repair or replace.
Defective control circuit or sensor

1. Low fuel pressure. Repair or replace.
117

Engine lacks Defective engine internal / electrical parts
power. 1. Loss of tappet clearance. Adjust.
2. Weakened valve springs. Replace.
3. Valve timing out of adjustment. Adjust.
4. Worn piston rings or cylinders. Replace.
5. Poor seating of valves. Repair.
6. Fouled spark plugs. Clean or replace.
7. Incorrect spark plugs. Adjust or replace.
8. Clogged injectors. Clean.
10. Clogged air cleaner element. Clean.
11. Sucking air from throttle valve or vacuum hose. Retighten or replace.
12. Too much engine oil. Drain out excess oil.
13. Defective fuel pump or ECU. Replace.
14. Defective pick-up coil and ignition coils. Replace.
Defective control circuit or sensor

1. Low fuel pressure. Repair or replace.
7. Defective GP switch. Replace.
Engine overheats. Defective engine internal parts

1. Heavy carbon deposit on piston crowns. Clean.
2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Replace or clean.
4. Sucking air from intake pipes. Retighten or replace.
5. Use incorrect engine oil. Change.
6. Defective cooling system. See radiator section.
Lean fuel / air mixture

1. Short-circuited IAP sensor / lead wire. Repair or replace.
2. Short-circuited IAT sensor / lead wire. Repair or replace.
3. Sucking air from intake pipe joint. Repair or replace.
4. Defective fuel injectors. Replace.
6. Defective cooling system. Consult radiator section.
The other factors

1. Ignition timing too advanced due to defective timing advance Replace.
system (WT sensor, pick-up coil, GP switch and ECU).
2. Drive belt / chain is too tight. Adjust.
118

Dirty or heavy 1. Too much engine oil in the engine. Check with inspection win-
exhaust smoke. dow, drain out excess oil.
2. Worn piston rings or cylinders. Replace.
3. Worn valve guides. Replace.
4. Cylinder wall scored or scuffed. Replace.
5. Worn valves stems. Replace.
6. Defective stem seals. Replace.
7. Worn side rails. Replace.
Slipping clutch. 1. Weakened clutch springs. Replace.

2. Worn or distorted pressure plates. Replace.
3. Distorted clutch plates or pressure plates. Replace.
Dragging clutch. 1. Some clutch springs weakened while others are not. Replace.
2. Distorted pressure plates or clutch plates. Replace.
Transmission will 1. Broken gearshift cam. Replace.

not shift. 2. Distorted gearshift forks. Replace.
3. Worn gearshift pawl. Replace.
Transmission will 1. Broken return spring on shift shaft. Replace.

not shift back. 2. Rubbing or sticky shift shaft. Repair or replace
3. Distorted or worn gearshift forks. Replace.
Transmission 1. Worn shifting gears on driveshaft or countershaft. Replace.

jumps out of gear. 2. Distorted or worn gearshift forks. Replace.
3. Weakened stopper spring on gearshift stopper. Replace.
119
8-5 SERVICING INFORMATION
◉ ELECTRICAL
No sparking or 1. Defective ignition coils or spark plug caps. Replace.
poor sparking. 2. Defective spark plugs. Replace.
5. Defective RO switch. Replace.
6. Open-circuited wiring connections. Check and repair.
Spark plug soon 1. Mixture too rich. Inspect EI system.

become fouled 2. Idling speed set too high. Inspect EI system.
with carbon. 3. Incorrect gasoline. Change.
4. Dirty element in air cleaner. Clean or replace.
5. Spark plugs too cold. Replace by hot type plug.
Spark plug 1. Worn piston rings. Replace.

become fouled 2. Pistons or cylinders worn. Replace.
too soon. 3. Excessive clearance of valve stems in valve guides. Replace.
4. Worn stem oil seal. Replace.
Spark plug 1. Spark plugs too hot. Replace by cold type plug.
electrodes 2. The engine overheats. Tune up.
overheat or burn. 3. Spark plugs loose. Retighten.
4. Mixture too lean. Inspect EI system.
Magneto charge, 1. Lead wires tend to get shorted or open-circuited or loosely Repair or retighten.
but charging connected at terminals.
rate is below the 2. Grounded or open-circuited stator coils of magneto. Replace.
specification. 3. Defective regulator / rectifier. Replace.
4. Defective cell plates in the battery. Replace the battery.
Magneto 1. Internal short - circuit in the battery. Replace the battery.

overcharges. 2. Resistor element in the regulator / rectifier damaged or defective. Replace.
3. Regulator / rectifier poorly grounded. Clean and tighten ground
connection.
Magneto does not 1. Open - or short - circuited lead wirse, or loose lead connections. Repair or replace or retighten.
charge. 2. Short - circuited, grounded or open stator coil. Replace.
3. Short - circuited or punctured regulator / rectifier. Replace.
Unstable charging. 1. Lead wire insulation frayed due to vibration resulting in Repair or replace
intermittent shorting.
2. Magneto internally shorted. Replace.
3. Defective regulator / rectifier. Replace.
Starter switch is 1. Battery run down. Recharge or replace.

not effective. 2. Defective switch contacts. Replace.
3. Brushes not seating properly on commutator in starter motor. Repair or replace.
4. Defective starter relay / ignition interlock switch. Replace.
5. Defective main fuse. Replace.
120
SERVICING INFORMATION 8-9
SPECIAL TOOLS
Special tools Part Number・Part Name・Description
09900-27000
Mode select switch
Inspect EI system sensor.
09915-54510
Fuel pump pressure gauge
Measure fuel pressure of fuel pump.
121
TIGHTENING TORQUE
◉ EI SYSTEM PARTS
ITEM N・m kgf・m
Water temperature sensor (WT sensor) 5~8 0.5 ~ 0.8
Fuel injector 5~8 0.5 ~ 0.8
Intake air temperature sensor (IAT sensor) 5~8 0.5 ~ 0.8
122
SERVICE DATA
◉ EI SENSORS
ITEM SPECIFICATION NOTE
IAP sensor input voltage 4.5 ~ 5.5 V
IAP sensor output voltage Approx. 2.7 V at idle speed
TP sensor input voltage 4.9 ~ 5.1 V
Closed Approx. 1.07 ~ 1.17 V
TP sensor output voltage
Opened Approx. 4.30 ~ 4.70 V
0.081 ~ 48.352 ㏀
IAT sensor resistance [When Intake air temperature is
-40℃ ~ 130℃ (-40℉ ~ 266℉)]
IAT sensor resistance (each temperature) Refer to page 57 [4-1-40]
123
◉ THROTTLE BODY
Bore size 39
Idle rpm 1,400 ~ 1,600 rpm
Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in)
◉ FUEL INJECTOR + FUEL PUMP

Fuel injector resistance 11.4 ~ 12.6 Ω at 20 ℃ (68 ℉)
Fuel injector voltage Battery voltage
Fuel pressure of fuel pump Approx. 2.25 ~ 2.50 kgf/cm² (220 ~ 245 kPa, 32.0 ~ 35.6 psi)
124
◉ THERMOSTAT + COOLING FAN + COOLANT

ITEM STANDARD LIMIT
Valve opening 88℃ (190℉)
Thermostat valve operating temperature Valve full open 100℃ (212℉)
Valve closing 83℃ (181℉)
Thermostat valve lift Over 8 mm (0.32 in) / 100℃ (212℉)
0.1163 ~ 48.1400 ㏀
WT sensor resistance [When Water temperature is
-40℃ ~ 120℃ (-40℉ ~ 248℉)]
-40℃ (-40℉) Approx. 48.140 ㏀
0℃ (32℉) Approx. 5.790 ㏀
20℃ (68℉) Approx. 2.450 ㏀
WT sensor resistance [To ECU]
40℃ (104℉) Approx. 1.148 ㏀
(each temperature)
60℃ (140℉) Approx. 0.586 ㏀
80℃ (176℉) Approx. 0.322 ㏀
120℃ (248℉) Approx. 0.1163 ㏀
Cooling fan thermo-switch operating OFF → ON Approx. 95℃ (203 ℉)
temperature ON → OFF Approx. 88℃ (190 ℉)
Use an antifreeze/coolant compatible with

Engine coolant type aluminum radiator, mixed with distilled water only,
at the ratio of 50 : 50
Reserve tank side 230 ㎖

Engine coolant capacity Radiator side 430 ㎖
Engine side 940 ㎖
125
◉ ELECTRICAL Unit : mm (in)
ITEM STANDARD NOTE

Ignition timing BTDC 5˚/ 2,000 rpm & BTDC 35˚/ 7,000rpm
Type CR8E
Gap 0.7 ~ 0.8 (0.028 ~ 0.032)
Spark plug Hot type CR7E
Standard type CR8E
Cold type CR9E
Spark performance Over 8 mm (0.32 in)
Ignition coil primary peak voltage 400 V and more
Primary 0.52 ~ 0.64 Ω
Ignition coil / Spark plug cap resistance
Secondary 6.4 ~ 7.8 ㏀
Pick-up coil 110 ~ 140 Ω G-L
Stator coil resistance
Charging coil 0.2 ~ 0.4 Ω Y-Y
Magneto no-load voltage Over 70 V / 5,000 rpm
Battery standard charging voltage 13.5 ~ 15.0 V / 5,000 rpm
Type STX14-BS
Battery Capacity 12V 12Ah

Standard
1.320 at 20℃ (68℉)
electrolyte S.G.
Main 30 A
Fuse size
ECU 15 A
126
d@
d@
d@
◉ SUSPENSION [ d@ 2013 model ] Unit : mm (in)

ITEM STANDARD
d@ LIMIT
Front fork stroke 120 (4.72) ———
Front fork spring free length 335 (14.0) 350 (13.8)
Front fork oil type TOP #15, SAE0W or an equivalent fork oil ———
100 mm (3.9 in) from end of outer tube

Front fork oil level ———
(when maximum compressed without spring)
Front fork oil capacity (each leg) 481 ± 2 cc ———
STANDARD FRONT FORK DAMPING FORCE

Rebound Compression
Softer Turn to呓 S 呔direction Turn to呓 S 呔direction
Solo riding Standard 12 clicks out from end of呓H呔direction 10 clicks out from end of 呓 H呔direction
Stiffer Turn to呓H呔direction Turn to呓H呔direction
Dual riding 12 clicks out from end of呓H呔direction 10 clicks out from end of呓H呔direction
127
d@
WIRING DIAGRAM [ d@ ]
128
129
d@
d@
d@

d@
130
131
d@
d@
d@
d@
132
133
Prepared by
1st Ed. OCT. 2012.
Manual NO. 99000HB9510

Printed in Korea
S&T Motors Co., Ltd.

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d@ 

』 and procedures for its

It covers the differences

Ⓒ COPYRIGHT S&T Motors Co., Ltd.

TO LOCATE WHAT YOU ARE

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Apply GREASE. Measure in resistance range.

Apply SILICONE GREASE. Measure in current range.

Apply MOLY PASTE. Measure in diode test range.

Apply GASKET BOND Measure in continuity test range.

Use fork oil. Use special tool.

Apply THREAD LOCK Use engine coolant.

IAP Sensor : Intake Air Pressure Sensor

B : Black Gr : Gray Sb : Light blue

BL : Black with Blue tracer BBr : Black with Brown tracer

BG : Black with Green tracer BO : Black with Orange tracer

BR : Black with Red tracer BW : Black with White tracer

BY : Black with Yellow tracer LB : Blue with Black tracer

LG : Blue with Green tracer LR : Blue with Red tracer

LW : Blue with White tracer LY : Blue with Yellow tracer

GB : Green with Black tracer GR : Green with Red tracer

GY : Green with Yellow tracer GrB : Gray with Black tracer

OB : Orange with Black tracer OL : Orange with Blue tracer

OG : Orange with Green tracer OR : Orange with Red tracer

OW : Orange with White tracer OY : Orange with Yellow tracer

RB : Red with Black tracer RW : Red with White tracer

WB : White with Black tracer WL : White with Blue tracer

WR : White with Red tracer YB : Yellow with Black tracer

YL : Yellow with Blue tracer YG : Yellow with Green tracer

YR : Yellow with Red tracer

EXTERIOR ILLUSTRATION & PHOTOGRAPH

EXTERIOR ILLUSTRATION & PHOTOGRAPH

EXTERIOR ILLUSTRATION & PHOTOGRAPH

EXTERIOR ILLUSTRATION & PHOTOGRAPH

◉ DIMENSIONS AND MASS

Overall length 2,330 mm (91.7 in)

Type Four-stroke, DOHC, Liquid-cooled

Fuel system Electric fuel Injection

Clutch Wet multi-plate type

Front suspension Telescopic type

Ignition type ECU

Fuel tank 16.0 ℓ

◉ DIMENSIONS AND MASS d@  d@  d@ 

Overall length 2,090 mm (82.3 in) d@  ←

◉ ENGINE d@  d@ 

ITEM d@  d@ 

Type Four-stroke, DOHC, Liquid-cooled

◉ TRANSMISSION d@  d@ 

ITEM d@  d@ 

Clutch Wet multi-plate type d@  ←

◉ CHASSIS d@  d@ 

ITEM d@  d@ 

Front suspension Telescopic type d@  ←

◉ ELECTRICAL d@  d@ 

ITEM d@  d@ 

Ignition type ECU d@  ←

ITEM d@  d@ 

Fuel tank 17.0 ℓ d@  ←

d@

◉ DIMENSIONS AND MASS d@ d@ d@

Overall length 2,090 mm (82.3 in) d@ ←

◉ ENGINE d@ d@

ITEM d@ d@

◉ TRANSMISSION d@ d@

ITEM d@ d@

Clutch Wet multi-plate type d@ ←

◉ CHASSIS d@ d@

ITEM d@ d@

Front suspension Telescopic type d@ ←

◉ ELECTRICAL d@ d@

ITEM d@ d@

Ignition type ECU d@ ←

ITEM d@ d@

Fuel tank 17.0 ℓ d@ ←

ITEM d@ d@

Overall length 2,090 mm (82.3 in) ← d@

ITEM d@ d@

Type Four-stroke, DOHC, Liquid-cooled ← d@

ITEM d@ d@

Clutch Wet multi-plate type ← d@

ITEM d@ d@

Front suspension Telescopic type ← d@

ITEM d@ d@

Ignition type ECU ← d@

ITEM d@ d@

Fuel tank 17.0 ℓ ← d@

◉ EI SYSTEM PARTS LOCATION d@

◉ EI SYSTEM PARTS LOCATION d@

◉ USER MODE d@

d@ d@ d@

▒ A. LCD (DISPLAY) PANEL d@

1-2. Remove the rear seat. [ d@ ]

2. Connect the special tool to the dealer moded@

Mode select switch : 09900-27000d@

d@ d@ d@