NHTSA ID Number: 10109087
Manufacturer Communication Number: 99924-1519-01_ZX
TSB/Document Date: 2017-08-01
Summary
Service Manual
2-11
1-3
0
ECU Main Relay
4-5
7-6
0
9-10
7-8
0
18-19
17-20
0
Battery
Connection
(+) (–)
Tester
Connection
(+) (–)
Tester Reading
(V)
16-12
11-12
Starter
Circuit Relay
(+): Apply positive lead.
(–): Apply negative lead.
Diode Circuit Inspection
the relay box (see Relay Box Removal).
• Remove
Check
conductivity
of the following pairs of terminals (see
• Relay Box Internal Circuit
in this section).
Diode Circuit Inspection
Tester Connection
1-11, 2-11, 12-13, 12-15, 12-16, 13-14,
13-15
The resistance should be low in one direction and more
than 10 times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the relay box must be replaced.
NOTE
○The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking,
the lower reading should be from zero to one half the
scale.
16-110 ELECTRICAL SYSTEM
Relay Box
Relay Box Internal Circuit
A. Headlight Circuit Relay
B. ECU Main Relay
C. Fuel Pump Relay
D. Starter Circuit Relay
E. Fan Relay
ELECTRICAL SYSTEM 16-111
Fuse
30 A Main/15 A ECU Fuse Removal
• Remove:
Starter Relay Cover (see Starter Relay Inspection)
Pull
the fuses [A] from the starter relay with needle
• noseoutpliers.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Unlock the hook [A] to lift up the lid.
Fuse Box (1) [B]
Fuse Box (2) [C]
the fuses [A] straight out of the fuse box with needle
• Pull
nose pliers.
Fuse Installation
•
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a
new fuse of proper amperage.
Install the fuse box fuses on the original position as specified on the lid.
Fuse Inspection
the fuse (see 30 A Main/15 A ECU/Fuse Box
• Remove
Fuse Removal).
the fuse element.
• Inspect
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTICE
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
APPENDIX 17-1
Appendix
Table of Contents
Cable, Wire, and Hose Routing ..............................................................................................
Troubleshooting Guide ...........................................................................................................
17-2
17-44
17
17-2 APPENDIX
Cable, Wire, and Hose Routing
1. Clamp (Hold the main harness.)
2. Clamp (Hold the left front turn signal light lead to the left upper fairing.)
3. Left Front Turn Signal Light Lead
4. Clamp (Hold the right front turn signal light lead to the right upper fairing.)
5. Right Front Turn Signal Light Lead
6. Run the left front turn signal light lead into the hole of the left upper fairing.
7. Run the right front turn signal light lead into the hole of the right upper fairing.
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Clamp (Hold the right front turn signal light lead to the meter bracket.)
2. Meter Lead
3. Clamp (Hold the main harness to the meter bracket.)
4. Turn Signal Relay
5. Horn
6. Install the horn connectors to the horn as shown.
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Clamp (Run the clutch cable and left switch housing lead in order from the inside of the motorcycle.)
2. Clutch Cable
3. Left Switch Housing Lead
4. Clamp (Hold the clutch cable and left switch housing lead.)
5. Run the ignition switch lead, immobilizer antenna lead (equipped models), left switch housing
lead and clutch cable to the inside of the front fork.
6. Ignition Switch Lead
7. Immobilizer Antenna Lead (Equipped Models)
8. Run the ignition switch lead and immobilizer antenna lead (equipped models) through the clamp.
9. Run the ignition switch lead, immobilizer antenna lead (equipped models) and left switch housing lead to the inside of the clamp.
10. Run the clutch cable to the inside of the radiator mounting position. Run the clutch cable under
the other leads.
17-6 APPENDIX
Cable, Wire, and Hose Routing
1. Throttle Cable (Decelerator)
2. Throttle Cable (Accelerator)
3. Clamp (Run the brake hose
, throttle cable (decelerator), throttle cable (accelerator) and right
switch housing lead in order from the outside of the motorcycle.)
4. Clutch Cable
5. Run the brake hose to the front side of the right switch housing lead and throttle cables. Run
the right switch housing lead to the rear side of the brake hose and throttle cables.
6. Run the throttle cables, clutch cable, right switch housing lead and purge valve lead (equipped
models) through this point to the inside of the frame.
7. Purge Valve Lead (Equipped Models)
8. Right Switch Housing Lead
9. Brake Hose
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Canister (Equipped Models)
2. Install the front wheel rotation sensor to the windshield bracket assembly.
3. Right Front Turn Signal Light Lead
4. Clutch Cable
5. Clamp (Hold the clutch cable.)
6. Quick Rivet (Hold the front heat insulation rubber plate to the bracket.)
7. Front Heat Insulation Rubber Plate
8. Viewed from A
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Run the purge hose (equipped models) to left side of the stick coil #2 lead.
2. Air Switching Valve
3. Run the purge hose (equipped models) under the air switching valve hose.
4. Air Switching Valve Hose
5. Run the purge hose (equipped models) above the bracket.
6. Stick Coil Lead
7. Hold the breather hose (equipped models) and the water hose with the clamp. Run the breather
hose (equipped models) inside of the water hose.
8. Run the air switching valve hose to the upside of the stick coil lead.
9. Breather Hose (Equipped Models)
10. Run the breather hose (equipped models) under the crankshaft sensor lead, wheel rotation sensor lead and alternator lead.
11. Crankshaft Sensor Lead
12. Alternator Lead
13. Rear Wheel Rotation Sensor Lead
14. Intake Air Temperature Sensor Lead
15. Run the intake air temperature sensor lead under the crankshaft senor lead, rear wheel rotation
sensor lead and alternator lead.
16. Clamps (Hold the fuel injector lead.)
17. Fuel Tank Breather Hose
18. Run the fuel injector lead in front of the fuel tank breather hose.
19. Run the subharness between the throttle body assy holder #1 and #2. Do not pinch the subharness with the throttle body assy.
20. Subharness
21. Run the right switch housing lead under the other leads and cables.
22. Clamp (Hold the vacuum hose and main harness at the white tape position of the main harness.)
23. Vacuum Hose
24. Main Harness
17-10 APPENDIX
Cable, Wire, and Hose Routing
1. Run the ignition switch lead and immobilizer antenna lead (equipped models) under the left
switch housing lead.
2. Left Switch Housing Lead
3. Ignition Switch Lead
4. Immobilizer Antenna Lead (Equipped Models)
5. Main Harness
6. Run the main harness between the bracket and frame.
7. Install the clamps to the frame as shown.
8. 5 mm (0.20 in.)
9. 3 mm (0.12 in.)
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Crankshaft Sensor Lead Connector (Install it to the connector bracket.)
2. Connector Bracket (Install it to the air cleaner housing.)
3. Rear Wheel Rotation Sensor Lead Connector (Install it to the connector bracket.)
4. Alternator Lead Connector (Install it to the connector bracket.)
5. Run the radiator overflow hose between the main throttle sensor and subthrottle sensor.
6. Radiator Overflow Hose
7. Battery Negative (–) Cable
8. Run the starter motor cable to the outside of the battery negative (–) cable.
9. Starter Motor Cable
10. Clamp (Face the open side of the clamp upward and install it to the frame. Then hold the breather
hose (equipped models) at the blue paint position of the breather hose (equipped models).)
11. Side Stand Switch Lead
12. Run the side stand switch lead to the rear side of the fuel tank breather hose. Run the alternator
lead and crankshaft sensor lead to the front side of the fuel tank breather hose.
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Regulator/Rectifier
2. Immobilizer Amplifier (Equipped Models)
3. Regulator/Rectifier Lead Connector
4. Run the regulator/rectifier lead to the inside of the main harness.
5. Main Harness
6. Cover the right switch housing lead connector, ignition switch lead connector, radiator fan motor
lead connector and immobilizer antenna lead connector (equipped models) with the dust cover.
7. Band (Hold the dust cover. Cut the band excess length after holding the dust cover.)
8. Clamp (Hold the right switch housing lead, ignition switch lead, radiator fan motor lead and
immobilizer antenna lead (equipped models).)
9. Radiator Fan Motor Lead
10. Ignition Switch Lead
11. Right Switch Housing Lead
12. Run the subharness under the bracket, cables and other leads.
13. Install the clamp to the bracket as shown.
14. Immobilizer Antenna Lead (Equipped Models)
17-14 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Air Cleaner Drain Hose
2. Alternator Lead
3. Side Stand Switch Lead
4. Run the starter motor cable to the inside of the other hoses, alternator lead and side stand switch
lead.
5. Clamp (Hold the reserve tank overflow hose, side stand switch lead, alternator lead, fuel tank
chain hose and subharness.)
6. Reserve Tank Overflow Hose
7. Clamp (Hold the side stand switch lead and subharness.)
8. Fuel Tank Drain Hose
9. Run the alternator lead to the inside of the subharness.
10. Starter Motor Cable
11. Subharness
17-16 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Idle Adjusting Cable
2. Clamp (Hold the alternator lead and side stand switch lead, and face the open side of the clamp
forward.)
3. Fuel Hose
4. Run the fuel hose, battery negative (–) cable, starter motor cable and fuel tank drain hose in
order from the inside of the frame.
5. Battery Negative (–) Cable
6. Side Stand Switch Lead
7. Alternator Lead
8. Fuel Tank Drain Hose
9. Reserve Tank Overflow Hose
10. Run the reserve tank overflow hose and side stand switch lead to the inside of the engine
sprocket cover.
11. Air Cleaner Drain Hose
12. Starter Motor Cable
13. Run the idle adjusting cable to the under of the air cleaner drain hose. Run the idle adjusting
cable to the front side of the side stand switch lead and alternator lead. Run the idle adjusting
cable to the outside of the air cleaner drain hose.
17-18 APPENDIX
Cable, Wire, and Hose Routing
1. Radiator Overflow Hose
2. Breather Hose (Equipped Models)
3. Run the water hose, breather hose (equipped models), radiator overflow hose and air bleeder
hose in order from the outside of the frame.
4. Water Hose
5. Air Bleeder Hose
6. Clutch Cable
7. Run the clutch cable through the clamp of the crankshaft sensor cover.
8. Crankshaft Sensor Lead
9. Oxygen Sensor Lead
10. Clamp (Hold the oxygen sensor lead and crankshaft sensor lead.)
APPENDIX 17-19
Cable, Wire, and Hose Routing
This page intentionally left blank.
17-20 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-21
Cable, Wire, and Hose Routing
1. Run the alternator lead and crankshaft sensor lead through this point.
2. Rear Wheel Rotation Sensor Lead
3. Run the rear wheel rotation sensor lead through this point.
4. Clamp (Hold the main harness and heat insulation rubber plate, and face the open side of the
clamp to the right side.)
5. Main Harness
6. Rivets (Hold the heat insulation rubber plate to the battery case.)
7. Crankshaft Sensor Lead
8. Alternator Lead
9. Battery Negative (–) Cable
10. Run the breather hose (equipped models) to right side of the battery negative (–) cable.
11. Run the breather hose (equipped models) under the battery negative (–) cable.
12. Clamp (Face the open side of the clamp upward and install it to the frame. Then hold the
breather hose (equipped models) at the blue paint position of the breather hose.)
13. Fuel Tank Drain Hose
14. Run the breather hose (equipped models) under the fuel tank drain hose.
15. Run the fuel tank drain hose into the hole of the heat insulation rubber plate.
16. Breather Hose (Equipped Models) (Run it above the heat insulation rubber plate.)
17. Run the fuel hose into the hole of the heat insulation rubber plate.
18. Fuel Hose
19. Run the fuel tank breather hose (US and CA models) and battery negative (–) cable into the
hole of the heat insulation rubber plate.
17-22 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-23
Cable, Wire, and Hose Routing
1. Main Harness
2. Crankshaft Sensor Lead
3. Run the oxygen sensor lead, crankshaft sensor lead and rear brake light switch lead to the
outside of the main harness.
4. Clamp (Hold the rear wheel rotation sensor lead.)
5. Rear Wheel Rotation Sensor Lead
6. Oxygen Sensor Lead
7. Clamp (Hold the oxygen sensor lead, crankshaft sensor lead and rear brake light switch lead.)
8. Rear Brake Light Switch Lead
9. Run the oxygen sensor lead and crankshaft sensor lead between the clamp and frame.
10. Clamp (Hold the reserve tank overflow hose.)
11. Reserve Tank Overflow Hose
12. Radiator Overflow Hose
13. Run the radiator overflow hose through the clamps.
14. Run the radiator overflow hose to the inside of the reserve tank overflow hose.
17-24 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-25
Cable, Wire, and Hose Routing
1. Spring Preload Adjuster Hose
2. Rear Wheel Rotation Sensor Lead
3. Run the rear wheel rotation sensor lead to the outside of the brake pipes.
4. Run the rear brake light switch lead to the inside of the brake pipes.
5. Brake Pipes
6. Run the spring preload adjuster hose to the inside of the brake pipes.
7. Run the spring preload adjuster hose between the frame and clamp.
8. Rear Brake Light Switch Lead
9. Run the rear brake light switch lead and rear wheel rotation sensor lead to the outside of the
spring preload adjuster hose.
10. Clamp (Hold the rear brake light switch lead and rear wheel rotation sensor lead.)
11. Run the brake pipe to the inside of the rear brake light switch lead.
12. Crankshaft Sensor Lead
13. Oxygen Sensor Lead
14. Bend the clamp rearward to hold the crankshaft sensor and oxygen sensor lead.
17-26 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-27
Cable, Wire, and Hose Routing
1. Fuel Pump Lead
2. Main Harness
3. Install the clamp to the battery case as shown.
4. Run the fuel pump lead to the upside of the main harness.
5. Run the fuel pump lead and main harness to the outside of the fuse boxes.
6. Clamp (Hold the fuel pump lead and main harness.)
7. Install the fuel pump lead connector to the bracket.
8. Battery Positive (+) Cable
9. Run the starter motor cable to the inside of the battery positive (+) cable.
10. Starter Relay
11. Starter Motor Cable
12. Run the starter motor cable between the starter relay and battery.
13. Run the starter motor cable to the upside of the main harness.
14. Battery
15. Fuse Boxes
16. Install the clamp to the frame as shown.
17-28 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-29
Cable, Wire, and Hose Routing
1. Hold the right rear turn signal light lead connector and left rear turn signal light lead connector
to the bracket.
2. Left Rear Turn Signal Light Lead Connector
3. Main Harness
4. Run the main harness to the right side of the rear turn signal light lead connectors.
5. Right Rear Turn Signal Light Lead Connector
6. License Plate Light Lead
7. Relay Box
8. Clamp (Hold the license plate light lead, tail/brake light lead and rear turn signal light leads.
When installing the clamp, bended portion of the clamp faces to inside.)
9. Seat Lock Cable
10. Run the seat lock cable to the front side of the rib. Run the seat lock cable to the upside of the
license plate light lead, tail/brake light lead and rear turn signal light leads.
11. Left Rear Turn Signal Light Lead
12. Right Rear Turn Signal Light Lead
13. Clamp (Hold the rear turn signal light leads, and face the open side of the clamp rearward.)
14. Tail/Brake Light Lead
15. Run the license plate light lead through this point.
16. Put the tail/brake light lead connector in this position. Do not pinch the tail/brake light lead with
the rear fender.
17. Bend the clamp upward to hold the tail/brake light lead.
18. Run the rear turn signal light leads through this point.
19. ECU
20. Run the ECU leads to the front side of the rib.
21. ECU Leads
22. ABS Kawasaki Diagnosis System Connector
23. Kawasaki Diagnostic System Connector
17-30 APPENDIX
Cable, Wire, and Hose Routing
1. Right Rear Turn Signal Light Lead
2. Run the license plate light lead, left rear turn signal light lead and right rear turn signal light lead
to the upside of the flap.
3. Clamp (Hold the license plate light lead, left rear turn signal light lead and right rear turn signal
light lead.)
4. License Plate Light Lead
5. Left Rear Turn Signal Light Lead
APPENDIX 17-31
Cable, Wire, and Hose Routing
1. Water Temperature Sensor Lead
2. Subharness
3. Clamp (Hold the gear position sensor/oil pressure switch lead. Attach the clamp to the upside
of the water pipe branch.)
4. Run the gear position sensor/oil pressure switch lead to the rear side of the water pipe branch.
5. Connect the gear position sensor lead to the gear position sensor. Do not stretch the lead after
connected.
6. Run the oil pressure switch lead to the inside of the water hose.
7. Cover the oil pressure switch with the switch cover.
8. Water Pipe
9. Viewed from A
17-32 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-33
Cable, Wire, and Hose Routing
1. Front Heat Insulation Rubber Plate
2. Stick Coil Connectors
3. Throttle Body Assy Holder #3 and #4
4. Fuel Hose
5. Rear Heat Insulation Rubber Plate (Install the rear heat insulation rubber plate to the throttle
body assy holder #2 and #3.)
6. Breather Hose
17-34 APPENDIX
Cable, Wire, and Hose Routing
1. Install the clamps as shown.
2. Water Hoses
3. Air Bleeder Hose
4. Radiator Overflow Hose
5. Reserve Tank Overflow Hose
6. Coolant Reserve Tank
APPENDIX 17-35
Cable, Wire, and Hose Routing
This page intentionally left blank.
17-36 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-37
Cable, Wire, and Hose Routing
1. Water Hoses
2. Install the clamps as shown.
3. Install the water hose so that the white paint mark faces upward.
4. Install the water hose so that the white paint mark faces outward.
5. Align the yellow paint mark of the water hose with the projection on the water pipe.
6. Install the water hose until the rised portion of the water pipe.
7. Install the water hose until the half of the punch mark is hidden.
8. Air Bleeder Hose
9. Install the air bleeder hose above the thermostat cover bolt.
10. Viewed from A
11. Viewed from B
12. Viewed from C
13. Install the clamp so that the tab of the clamp faces rearward.
14. Breather Hose
15. Install the breather hose so that the white paint mark faces rearward.
17-38 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-39
Cable, Wire, and Hose Routing
1. Front Brake Hose
2. Front Wheel Rotation Sensor Lead
3. Clamp (Hold the front wheel rotation sensor lead.)
4. Clamp (Hold the front wheel rotation sensor lead.)
5. Clamps (Hold the front brake hose.)
6. Clamps (Hold the front brake hose and front wheel rotation sensor lead.)
7. Clamps (Hold the brake pipes.)
8. Front Wheel Rotation Sensor
9. About 90°
10. About 50°
17-40 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-41
Cable, Wire, and Hose Routing
1. Rear Brake Hose
2. Run the rear wheel rotation sensor lead through the clamp.
3. Rear Wheel Rotation Sensor Lead
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TSB/Document ID: 99924-1519-01_ZX
Replacement Service Bulletin Number:
MFR Communication Date: 2016-12-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
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- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
Last update on 2026-07-02 / Affiliate links / Images from Amazon Product Advertising API
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