NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
Side Stand Switch Operation
Side Stand
Gear
Position
Clutch
Lever
Engine
Start
Engine
Run
Up
Neutral
Released
Starts
Continue
running
Up
Neutral
Pulled in
Starts
Continue
running
Up
In Gear
Released
Does not
start
Continue
running
Up
In Gear
Pulled in
Starts
Continue
running
Down
Neutral
Released
Starts
Continue
running
Down
Neutral
Pulled in
Starts
Continue
running
Down
In Gear
Released
Does not
start
Stops
Down
In Gear
Pulled in
Does not
start
Stops
PERIODIC MAINTENANCE 2-67
Periodic Maintenance Procedures
If the side stand switch operation does not work, inspect
or replace the following parts.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 15 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Side Stand Switch (see Switch Inspection in the Electrical System chapter)
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Gear Position Sensor (see Gear Position Sensor Input
Voltage Inspection in the Fuel System (DFI) chapter)
Starter Lockout Switch (see Switch Inspection in the
Electrical System chapter)
Starter Relay (see Starter Relay Inspection in the Electrical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
If the all parts are good condition, replace the ECU (see
ECU Removal/Installation in the Fuel System (DFI) chapter).
Engine Stop Switch Operation Inspection
First Step
Turn the ignition switch on.
Set the gear position in the neutral position.
Turn the engine stop switch to stop position [A].
Push the starter button.
The engine does not start.
If the engine starts, inspect or replace the engine stop
switch (see Switch Inspection in the Electrical System
chapter).
•
•
•
•
•
Second Step
Turn the ignition switch on.
Set the gear position in the neutral position.
Turn the engine stop switch to run position [A].
Push the starter button and start the engine.
Turn the engine stop switch to stop position.
Immediately the engine should be stop.
If the engine does not stop, inspect or replace the engine
stop switch (see Switch Inspection in the Electrical System chapter).
If the engine stop switch is good condition, replace the
ECU (see ECU Removal/Installation in the Fuel System
(DFI) chapter).
•
•
•
•
•
•
2-68 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Spark Plug Replacement
the stick coils (see Stick Coil Removal in the
• Remove
Electrical System chapter).
the spark plugs using the 16 mm (0.63 in.) plug
• Remove
wrench [A] vertically.
• Replace the spark plugs with new ones.
Standard Spark Plug
Type:
NGK CR9EIA-9
the spark plug vertically into the spark plug hole
• Insert
with the spark plug installed in the plug wrench [A], and
finger-tighten it first.
NOTICE
If tightening the spark plug with the wrench inclined, the insulator of the spark plug may break.
• Tighten:
Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)
the stick coils (see Stick Coil Installation in the Elec• Install
trical System chapter).
installation, be sure the stick coils are installed se• After
curely by pulling up them lightly.
Others
Chassis Parts Lubrication
lubricating each part, clean off any rusty spots with
• Before
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
○Whenever
NOTE
the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubrication.
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Side Stand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
PERIODIC MAINTENANCE 2-69
Periodic Maintenance Procedures
Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cables
Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
•
the cable disconnected at both ends, the inner cable
• With
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Condition of Bolts, Nuts and Fasteners Tightness
Inspection
the tightness of the bolts and nuts listed here. Also,
• Check
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
2-70 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Bolt Locknut
Engine Mounting Bolts and Nuts
Exhaust Pipe Holder Nuts
Muffler Body Clamp Bolts
Muffler Body Mounting Bolts and Nuts
Premuffler Chamber Mounting Bolt
Radiator Bolts
Wheels:
Front Axle Clamp Bolts
Front Axle
Rear Axle Nut
Brakes:
Brake Lever Pivot Bolt Locknut
Brake Pedal Bolt
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolts and Nuts
Swingarm Pivot Shaft Nut
Tie-rod Nuts
Rocker Arm Nut
Steering:
Handlebar Holder Bolts
Steering Stem Head Bolt
Others:
Footpeg Bracket Bolts
Front Fender Mounting Bolts
Rear Frame Bolts
Side Stand Bolt
Side Stand Bracket Bolts
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)
Table of Contents
Exploded View...................................
DFI System........................................
DFI Components Naming ............
DFI Parts Location.............................
Specifications ....................................
Special Tools and Sealant .................
DFI Servicing Precautions .................
DFI Servicing Precautions ..............
Troubleshooting the DFI System .......
Outline ............................................
Inquiries to Rider.............................
DFI System Troubleshooting Guide ..
Self-Diagnosis ...................................
Self-Diagnosis Outline .................
Self-Diagnosis Procedures ..........
Service Code Reading .................
Service Code Erasing ..................
Backups .......................................
Main Throttle Sensor (Service Code
11) (DTC P0120, P0123) ................
Main Throttle Sensor
Removal/Adjustment .................
Main Throttle Sensor Input
Voltage Inspection.....................
Main Throttle Sensor Resistance
Inspection..................................
Main Throttle Sensor Output
Voltage Inspection.....................
Intake Air Pressure Sensor #1
(Service Code 12) (DTC P0105,
P0107) ............................................
Intake Air Pressure Sensor #1
Removal ....................................
Intake Air Pressure Sensor #1
Installation .................................
Intake Air Pressure Sensor #1
Input Voltage Inspection............
Intake Air Pressure Sensor #1
Output Voltage Inspection .........
Intake Air Temperature Sensor
(Service Code 13) (DTC P0110,
P0112) ............................................
Intake Air Temperature Sensor
Removal/Installation..................
Intake Air Temperature Sensor
Output Voltage Inspection .........
Intake Air Temperature Sensor
Resistance Inspection ...............
Water Temperature Sensor (Service
Code 14) (DTC P0115, P0117).......
3-4
3-10
3-12
3-19
3-22
3-24
3-26
3-26
3-28
3-28
3-32
3-35
3-40
3-40
3-41
3-43
3-43
3-45
3-48
3-48
3-48
3-49
3-49
3-52
3-52
3-52
3-53
3-54
3-58
3-58
3-58
3-59
3-61
Water Temperature Sensor
Removal/Installation..................
Water Temperature Sensor
Output Voltage Inspection .........
Water Temperature Sensor
Resistance Inspection ...............
Intake Air Pressure Sensor #2
(Service Code 16) (DTC P2226,
P2227, P2228)................................
Intake Air Pressure Sensor #2
Removal ....................................
Intake Air Pressure Sensor #2
Installation .................................
Intake Air Pressure Sensor #2
Input Voltage Inspection............
Intake Air Pressure Sensor #2
Output Voltage Inspection .........
Crankshaft Sensor (Service Code 21)
(DTC P0335)...................................
Crankshaft Sensor
Removal/Installation..................
Crankshaft Sensor Resistance
Inspection..................................
Crankshaft Sensor Peak Voltage
Inspection..................................
Rear Wheel Rotation Sensor (Service
Code 24) (DTC P2158)...................
Rear Wheel Rotation Sensor
Signal Inspection.......................
Gear Position Sensor (Service Code
25) (DTC P0914, P0915, P0916)....
Gear Position Sensor
Removal/Installation..................
Gear Position Sensor Input
Voltage Inspection.....................
Gear Position Sensor Output
Voltage Inspection.....................
Vehicle-down Sensor (Service Code
31) (DTC C0064) ............................
Vehicle-down Sensor Removal ....
Vehicle-down Sensor Installation .
Vehicle-down Sensor Input
Voltage Inspection.....................
Vehicle-down Sensor Output
Voltage Inspection.....................
Subthrottle Sensor (Service Code 32)
(DTC P0220, P0223) ......................
Subthrottle Sensor
Removal/Adjustment .................
3-61
3-62
3-63
3-64
3-64
3-64
3-65
3-66
3-68
3-68
3-68
3-68
3-69
3-69
3-71
3-71
3-71
3-72
3-74
3-74
3-74
3-75
3-76
3-79
3-79
3
3-2 FUEL SYSTEM (DFI)
Subthrottle Sensor Input Voltage
Inspection..................................
Subthrottle Sensor Output Voltage
Inspection..................................
Subthrottle Sensor Resistance
Inspection..................................
Oxygen Sensor - not activated
(Service Code 33) (DTC P0130,
P0132) ............................................
Oxygen Sensor Removal/Installation ............................................
Oxygen Sensor Inspection...........
Immobilizer Amplifier (Service Code
35, Equipped Models).....................
Antenna Resistance Inspection ...
Amplifier Input Voltage Inspection
Blank Key Detection (Service Code
36, Equipped Models).....................
Ignition Key Inspection.................
ECU Communication Error (Service
Code 39) .........................................
ECU Communication Line
Inspection..................................
Fuel Injectors (Service Code 41,
42, 43, 44) (DTC P0201, P0202,
P0203, P0204)................................
Fuel Injector Removal/Installation
Fuel Injector Audible Inspection...
Fuel Injector Resistance
Inspection..................................
Fuel Injector Power Source
Voltage Inspection.....................
Fuel Injector Output Voltage
Inspection..................................
Fuel Injector Fuel Line Inspection
Stick Coils #1, #2, #3, #4 (Service
Code 51, 52, 53, 54) (DTC P0351,
P0352, P0353, P0354) ...................
Stick Coil Removal/Installation.....
Stick Coil Primary Winding
Resistance Inspection ...............
Stick Coil Input Voltage
Inspection..................................
Radiator Fan Relay (Service Code
56) (DTC P0480) ............................
Radiator Fan Relay
Removal/Installation..................
Radiator Fan Relay Inspection.....
Subthrottle Valve Actuator (Service
Code 62) (DTC P2100)...................
Subthrottle Valve Actuator
Removal ....................................
Subthrottle Valve Actuator
Inspection..................................
Subthrottle Valve Actuator
Resistance Inspection ...............
3-79
3-80
3-82
3-83
3-83
3-83
3-86
3-86
3-86
3-87
3-87
3-88
3-88
3-89
3-89
3-89
3-89
3-90
3-91
3-92
3-94
3-94
3-94
3-94
3-96
3-96
3-96
3-97
3-97
3-97
3-97
Subthrottle Valve Actuator Input
Voltage Inspection.....................
Air Switching Valve (Service Code
64) (DTC P0410) ............................
Air Switching Valve
Removal/Installation..................
Air Switching Valve Inspection .....
Oxygen Sensor Heater (Service
Code 67) (DTC P0030)...................
Oxygen Sensor Heater
Removal/Installation..................
Oxygen Sensor Heater
Resistance Inspection ...............
Oxygen Sensor Heater Power
Source Voltage Inspection ........
Fuel Supply System (Service Code
94) (DTC P0170) ............................
Fuel Supply System Inspection....
Purge Valve (Service Code 3A,
Equipped Models) (DTC P0443).....
Purge Valve Removal/Installation
Purge Valve Inspection ................
Warning Indicator Light (LED) ...........
Yellow Engine Warning/Red
Warning Indicator Light (LED)
Inspection..................................
ECU ...................................................
ECU Identification ........................
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TSB/Document ID: 99924-1525-01
Replacement Service Bulletin Number:
MFR Communication Date: 2017-01-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
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