NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
the throttle, confirm the output voltage will be
raise.
○The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
1.02 × 4.75 ÷ 5.00 = 0.969 V
1.06 × 4.75 ÷ 5.00 = 1.007 V
Thus, the valid range is 0.969 1.007 V
the ignition switch off.
• Turn
If the reading is out of the standard, replace the throttle
body assy (see Throttle Body Assy Removal/Installation).
If the reading is within the standard, replace the ECU and
check the wiring for continuity between main harness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Main Throttle Sensor Connector [B]
ECU Terminal 27 [C] ←→ Sensor Terminal [D]
ECU Terminal 49 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-51
Main Throttle Sensor (Service Code 11) (DTC P0120, P0123)
Main Throttle Sensor Circuit
1. Main Throttle Sensor
2. Subthrottle Sensor
3. ECU
3-52 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107)
Intake Air Pressure Sensor #1 Removal
NOTICE
Never drop the intake air pressure sensor #1 especially on a hard surface. Such a shock to the sensor
can damage it.
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Disconnect:
• Intake Air Pressure Sensor #1 Connector [A]
the intake air pressure sensor #1 [B] from the
• Remove
bracket [C].
the vacuum hose [A].
• Disconnect
the rubber damper [B] from the intake air pres• Remove
sure sensor #1 [C].
Intake Air Pressure Sensor #1 Installation
NOTE
○The intake air pressure sensor #1 is the same part as
the intake air pressure sensor #2.
is the reverse of removal.
• Installation
the intake air pressure sensor #1 [A] between the
• Position
projections [B] on the rubber damper.
• Install the rubber damper [A] on the bracket [B].
FUEL SYSTEM (DFI) 3-53
Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107)
Intake Air Pressure Sensor #1 Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
• Removal).the air cleaner housing (see Air Cleaner Housing
the intake air pressure sensor #1 connector
• Disconnect
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #1 [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Intake Air Pressure Sensor #1 Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Input Voltage
Standard: DC 4.75 5.25 V
the ignition switch off.
• Turn
If the reading is within the standard, check the output voltage (see Intake Air Pressure Sensor #1 Output Voltage
Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #1 Connector [B]
ECU Terminal 4 [C] ←→ Sensor Terminal [D]
ECU Terminal 49 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-54 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107)
Intake Air Pressure Sensor #1 Output Voltage
Inspection
the output voltage at the intake air pressure sen• Measure
sor #1 in the same way as input voltage inspection, note
the following.
○Disconnect the intake air pressure sensor #1 connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #1 [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #1 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor Y/BL) lead
Digital Meter (–) → BK (sensor G) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Output Voltage
Usable Range:
DC 3.80 4.20 V at standard
atmospheric pressure (101.32 kPa,
76 cmHg)
NOTE
○The output voltage changes according to local atmospheric pressure.
the ignition switch off.
• Turn
If the reading is out of the usable range, replace the sensor.
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #1 Connector [B]
ECU Terminal 18 [C] ←→ Sensor Terminal [D]
ECU Terminal 49 [E] ←→ Sensor Terminal [F]
FUEL SYSTEM (DFI) 3-55
Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107)
If the wiring is good, check the sensor for various vacuum.
Remove the intake air pressure sensor #1 [A] and disconnect the vacuum hose from the sensor.
Connect an auxiliary hose [B] to the intake air pressure
sensor #1.
Temporarily install the intake air pressure sensor #1.
○Connect a digital meter [C], vacuum gauge [D], the fork oil
level gauge [E] and the measuring adapter to the intake
air pressure sensor #1.
•
•
•
Special Tools - Fork Oil Level Gauge: 57001-1290
Vacuum Gauge: 57001-1369
Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #1 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor Y/BL) lead
Digital Meter (–) → BK (sensor G) lead
○Turn the ignition switch on.
○Measure the intake air pressure sensor #1 output voltage
from various vacuum readings, while pulling the handle of
the fork oil level gauge.
○Check the intake air pressure sensor #1 output voltage,
using the following formula and chart.
Suppose:
Pg: Vacuum Pressure (Gauge) of Throttle Body
Pl: Local Atmospheric Pressure (Absolute) measured by
a barometer
Pv: Vacuum Pressure (Absolute) of Throttle Body
Vv: Sensor Output Voltage (V)
then
Pv = Pl + Pg
For example, suppose the following data is obtained:
Pg = 8 cmHg (Vacuum Gauge Reading)
Pl = 54 cmHg (Barometer Reading)
Vv = 3.2 V (Digital Meter Reading)
then
Pv = 54 + 8 = 62 cmHg (Absolute)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.
Usable range = 3.08 3.48 V
Plot Vv (3.2 V) on the vertical line. → Point [3].
Results: In the chart, Vv is within the usable range and
the sensor is normal.
If the reading is out of the usable range, replace the sensor.
If the reading is within the usable range, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-56 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107)
ID: Idling
Ps: Standard Atmospheric Pressure (Absolute)
Pv: Throttle Vacuum Pressure (Absolute)
ST: Standard of Sensor Output Voltage (V)
TO: Throttle Full Open
UR: Usable Range of Sensor Output Voltage (V)
Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
FUEL SYSTEM (DFI) 3-57
Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107)
Intake Air Pressure Sensor #1 Circuit
1. Intake Air Pressure Sensor #2
2. Intake Air Pressure Sensor #1
3. ECU
3-58 FUEL SYSTEM (DFI)
Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112)
Intake Air Temperature Sensor Removal/Installation
NOTICE
Never drop the intake air temperature sensor especially on a hard surface. Such a shock to the sensor
can damage it.
the fuel tank (see Fuel Tank Removal).
• Remove
Disconnect
the intake air temperature sensor connector
• [A].
• Remove:
Intake Air Temperature Sensor Screw [B]
Intake Air Temperature Sensor [C]
sure to install the O-ring [A].
• Be
Install
• Tighten:the intake air temperature sensor.
•
Torque - Intake Air Temperature Sensor Screw: 1.2 N·m
(0.12 kgf·m, 11 in·lb)
the intake air temperature sensor connector.
• Connect
Install
the
fuel tank (see Fuel Tank Installation).
•
Intake Air Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
fuel tank (see Fuel Tank Removal).
• Disconnectthethe
air temperature sensor connector
• and connect theintake
measuring adapter [A] between these
connectors as shown.
Main Harness [B]
Intake Air Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Intake Air Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor R/BK) lead
Digital Meter (–) → BK (sensor G) lead
the output voltage with the engine stopped and
• Measure
the connector joined.
• Turn the ignition switch on.
Output Voltage
Standard: About DC 2.25 2.50 V @20°C (68°F)
NOTE
○The output voltage changes according to the intake air
temperature.
FUEL SYSTEM (DFI) 3-59
Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112)
the ignition switch off.
• Turn
If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Temperature Sensor Connector [B]
ECU Terminal 16 [C] ←→ Sensor Terminal [D]
ECU Terminal 49 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the intake air temperature sensor resistance (see Intake Air Temperature Sensor Resistance Inspection).
Intake Air Temperature Sensor Resistance
Inspection
the intake air temperature sensor (see Intake Air
• Remove
Temperature Sensor Removal/Installation).
the sensor [A] in a container of water so that the
• Suspend
heat-sensitive portion is submerged.
a thermometer [B] with the heat-sensitive por• Suspend
tion [C] located in almost the same depth with the sensor.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradually
• Place
raise the temperature of the water while stirring the water
•
gently for even temperature.
Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the following.
Intake Air Temperature Sensor Resistance
Standard: 5.4 6.6 kΩ @0°C (32°F)
0.29 0.39 kΩ @80°C (176°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
3-60 FUEL SYSTEM (DFI)
Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112)
Intake Air Temperature Sensor Circuit
1. Intake Air Temperature Sensor
2. ECU
FUEL SYSTEM (DFI) 3-61
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117)
Water Temperature Sensor Removal/Installation
NOTICE
Never drop the water temperature sensor especially
on a hard surface. Such a shock to the sensor can
damage it.
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Right Frame Cover (see Frame Cover Removal in the
•
•
•
•
Frame chapter)
Middle Front Engine Mounting Bolt [A]
Middle Engine Bracket Bolts [B]
Middle Engine Bracket [C]
Disconnect:
Water Temperature Sensor Connector [D]
Remove:
Water Temperature Sensor [E] with O-ring
Replace the O-ring with a new one.
Tighten:
Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106
in·lb)
the engine with coolant and bleed the air from the cool• Fill
ing system (see Coolant Change in the Periodic Maintenance chapter).
3-62 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117)
Water Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Disconnect
the water temperature sensor connector (see
• Water Temperature
Sensor Removal/Installation)
Connect
the
measuring
• nectors as shown. adapter [A] between these conSubharness [B]
Water Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Water Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor W/G) lead
Digital Meter (–) → BK (sensor G) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Output Voltage
Standard: About DC 2.80 2.97 V @20°C (68°F)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.
the ignition switch off.
• Turn
If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU and
check the wiring for continuity between main and subharness connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Subharness Connector [B]
ECU Terminal 3 [C] ←→ Connector Terminal [D]
ECU Terminal 49 [E] ←→ Connector Terminal [F]
FUEL SYSTEM (DFI) 3-63
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117)
Subharness Connector [A] ←→
Water Temperature Sensor Connector [B]
Connector Terminal [C] ←→ Sensor Terminal [D]
Connector Terminal [E] ←→ Sensor Terminal [F]
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).
Water Temperature Sensor Resistance Inspection
to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Water Temperature Sensor Circuit
1. Water Temperature Sensor
2. ECU
3-64 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)
Intake Air Pressure Sensor #2 Removal
NOTICE
Never drop the intake air pressure sensor #2 especially on a hard surface. Such a shock to the sensor
can damage it.
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Disconnect:
• Intake Air Pressure Sensor #2 Connector [A]
the intake air pressure sensor #2 [B] from the
• Remove
bracket [C].
the vacuum hose [A].
• Disconnect
the rubber damper [B] from the intake air pres• Remove
sure sensor #2 [C].
Intake Air Pressure Sensor #2 Installation
NOTE
○The intake air pressure sensor #2 is the same part as
the intake air pressure sensor #1.
is the reverse of removal.
• Installation
the intake air pressure sensor #2 [A] between the
• Position
projections [B] on the rubber damper.
• Install the rubber damper [A] on the bracket [B].
FUEL SYSTEM (DFI) 3-65
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)
Intake Air Pressure Sensor #2 Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch off.
• Turn
Remove
• Removal).the air cleaner housing (see Air Cleaner Housing
the intake air pressure sensor #2 connector
• Disconnect
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #2 [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Intake Air Pressure Sensor #2 Input Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BL) lead
Digital Meter (–) → BK (sensor G) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
Input Voltage
Standard: DC 4.75 5.25 V
the ignition switch off.
• Turn
If the reading is within the standard, check the output voltage (see Intake Air Pressure Sensor #2 Output Voltage
Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Intake Air Pressure Sensor #2 Connector [B]
ECU Terminal 4 [C] ←→ Sensor Terminal [D]
ECU Terminal 49 [E] ←→ Sensor Terminal [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-66 FUEL SYSTEM (DFI)
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)
Intake Air Pressure Sensor #2 Output Voltage
Inspection
the output voltage at the intake air pressure sen• Measure
sor #2 in the same way as input voltage inspection, note
the following.
○Disconnect the intake air pressure sensor #2 connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Pressure Sensor #2 [C]
Digital Meter [D]
Special Tool - Measuring Adapter: 57001-1700
Intake Air Pressure Sensor #2 Output Voltage
Connections to Adapter:
Digital Meter (+) → Y (sensor G/W) lead
Digital Meter (–) → BK (sensor G) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch on.
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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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