NOTICE
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
ECU damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
ECU.

Crankshaft Sensor Removal
NOTICE
Never drop the sensor, especially on a hard surface.
Such a shock to the sensor can damage it.

• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main•
•

tenance chapter)
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Disconnect the crankshaft sensor lead connector [A] and
free its lead [B] from the clamp [C].

the crankshaft sensor lead from the clamps [A] at
• Clear
right side of the frame.

the crankshaft sensor lead from the clamps [A] near
• Clear
the swingarm pivot.

16-42 ELECTRICAL SYSTEM
Ignition System
the crankshaft sensor lead [A] from the clamp [B]
• Clear
under the clutch cover.

• Remove:
Crankshaft Sensor Cover Bolts [A]
Crankshaft Sensor Cover Bolt [B] (with a Dent on the
Bolt Head)
Crankshaft Sensor Cover [C]

• Remove:
Crankshaft Sensor Bolts [A]
Crankshaft Sensor [B]

Crankshaft Sensor Installation

the crankshaft sensor.
•○Install
When installing the sensor which is fastened by bolts,

•

tighten the bolts after placing the sensor on the bottom
surface completely.
Tighten:
Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.61 kgf·m, 53
in·lb)

ELECTRICAL SYSTEM 16-43
Ignition System
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them

•

with a clean cloth.
Apply liquid gasket [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and
rear sides of the crankshaft sensor cover mount.
Sealant - Liquid Gasket, TB1211F: 92104-0004

• Replace the O-ring [A] with a new one.
NOTE

○Do not apply a liquid gasket or a sealant to the groove
for O-ring.

• Install:
Crankshaft Sensor Cover [A]
Apply
a non-permanent locking agent to the threads of
• the crankshaft
sensor cover bolt [B] which has a dent on
•

the bolt head.
Tighten the crankshaft sensor cover bolts [B] [C].
Torque - Crankshaft Sensor Cover Bolts:
kgf·m, 106 in·lb)

12 N·m (1.2

the crankshaft sensor lead and clutch cable correctly
• Run
(see Cable, Wire, and Hose Routing section in the Appen-

•

dix chapter).
Install the removed parts (see appropriate chapters).

16-44 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Inspection

the crankshaft sensor lead connector (see
• Disconnect
Crankshaft Sensor Removal).
a tester [A], and connect it to the crankshaft sensor
• Set
lead connector [B].
Special Tool - Needle Adapter Set [C]: 57001-1457
Crankshaft Sensor Resistance
Connections:
Tester (+) → Y lead
Tester (–) → BK lead
Standard:

•

376  564 Ω @20°C (68°F)

If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Measure the resistance between the crankshaft sensor
leads and chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the crankshaft sensor.

Crankshaft Sensor Peak Voltage Inspection
NOTE

○Be sure the battery is fully charged.
○Using the peak voltage adapter [A] is more reliable way
to determine the condition of the crankshaft sensor than
crankshaft sensor internal resistance measurements.
the crankshaft sensor lead connector [B] (see
• Disconnect
Alternator Cover Removal).
a tester [C], and connect it to the peak voltage
• Set
adapter.
Special Tools - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Needle Adapter Set [D]: 57001-1457

the adapter to the terminals of the crankshaft
• Connect
sensor lead connector.
Connections:
Crankshaft
Sensor Lead

Peak Voltage
Adapter

Tester

Y lead

←

R lead

→

(+)

BK lead

←

BK lead

→

(–)

the engine stop switch to run position.
• Turn
Turn
the ignition switch on.
• Pushing
starter button, turn the engine 4  5 sec• onds withthe
the transmission gear in neutral to measure the

•

crankshaft sensor peak voltage.
Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
3.0 V or more
Standard:

If the reading is less than the standard, inspect the crankshaft sensor (see Crankshaft Sensor Inspection).

ELECTRICAL SYSTEM 16-45
Ignition System
Timing Rotor Removal

the crankshaft sensor (see Crankshaft Sensor
• Remove
Removal).
the timing rotor with the flywheel & pulley holder
• Holding
[A] and remove the timing rotor bolt [B].
Special Tool - Flywheel & Pulley Holder: 57001-1605

• Remove the timing rotor [C].
Timing Rotor Installation

the timing rotor [A] on the crankshaft [B] with their
• Install
teeth [C] aligned.
the timing rotor with the flywheel & pulley holder
• Holding
and tighten the timing rotor bolt.
Torque - Timing Rotor Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
Special Tool - Flywheel & Pulley Holder: 57001-1605

the crankshaft sensor (see Crankshaft Sensor In• Install
stallation).

Stick Coil Removal
NOTICE
Never drop the stick coils, especially on a hard surface.
Such a shock to the stick coils can damage it.

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
•

in the Fuel System (DFI) chapter)
Disconnect the connectors from the stick coils [A] and pull
out the stick coils.

NOTICE
Do not pry the connector part of the coil while removing the coil.

Stick Coil Installation

the stick coils [A] so that the coil heads align with
• Insert
the lines [B] on the cylinder head cover.

NOTICE
Do not tap the coil head while installing the coil.
installation, be sure the stick coils are installed se• After
curely by pulling up them lightly.
the leads correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

16-46 ELECTRICAL SYSTEM
Ignition System
Stick Coil Inspection

the stick coils (see Stick Coil Removal).
• Remove
the primary winding resistance [A] as follows.
•○Measure
Connect a tester between the coil terminals.
the secondary winding resistance [B] as follows.
•○Measure
Connect the tester between the plug terminal and (–) coil
terminal.
Stick Coil Winding Resistance
Primary Windings:
1.11  1.50 Ω @20°C (68°F)
Secondary Windings:

6.4  9.6 kΩ @20°C (68°F)

If the tester does not read as specified, replace the coil.

Stick Coil Primary Peak Voltage Inspection
NOTE

○Be sure the battery is fully charged.
the stick coils (see Stick Coil Removal), but do
• Remove
not remove the spark plugs.
the primary peak voltage as follows.
•○Measure
Install the new spark plug [A] into each stick coil [B], and
ground them onto the engine.

○Connect the peak voltage adapter [C] into a tester [D].
○Connect the adapter to the lead wire-peak voltage
adapter [E] which is connected between the stick coil
connector and stick coil.
ECU [F]
Battery [G]
Special Tools - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Lead Wire - Peak Voltage Adapter: 57001
-1449
Primary Lead Connection
Adapter (R, +) to lead wire-peak voltage adapter (W)
Adapter (BK, –) to lead wire-peak voltage adapter (R)

ELECTRICAL SYSTEM 16-47
Ignition System
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
the engine stop switch to run position.
• Turn
the ignition switch on.
• Turn
Pushing
starter button, turn the engine 4  5 seconds
• with the the
transmission in neutral to measure the primary

•

peak voltage.
Repeat the measurements 5 times for one stick coil.
Stick Coil Primary Peak Voltage
95 V or more
Standard:

the test for the other stick coil.
• Repeat
If the reading is less than the specified value, check the
following.
Stick Coils (see Stick Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)

Spark Plug Removal

to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.

Spark Plug Installation

to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.

Spark Plug Condition Inspection

the spark plugs (see Spark Plug Replacement in
• Remove
the Periodic Maintenance chapter).
inspect the spark plugs.
• Visually
If the spark plug center electrode [A] and/or side elec-

•

trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.
Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap:

0.8  0.9 mm (0.031  0.035 in.)

• Use the standard spark plug or its equivalent.
Spark Plug:

NGK CR9EIA-9

16-48 ELECTRICAL SYSTEM
Ignition System
Interlock Operation Inspection

the rear wheel off the ground with the stand.
• Raise
the engine stop switch on (run position).
•1stTurn
Check
• Start the engine to the following conditions.
Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Side Stand → Down or Up

○Turn the ignition switch on and push the starter button.
○Then the starter motor should not turn when the starter
system circuit is normality.
If the engine is start, inspect the starter lockout switch,
gear position sensor and relay box.
2nd Check
Start the engine to the following conditions.

•

Condition:
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Side Stand → Up

○Turn the ignition switch on and push the starter button.
○Then the starter motor should turn when the starter system circuit is normality.
If the starter motor is not turn, inspect the starter lockout
switch, side stand switch, relay box, and starter relay.
3rd Check
Inspect the engine for its secure stop after the following
operations are completed.
Run the engine to the following conditions.

•
•

Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Side Stand → Up

the side stand on the ground, then the engine will
• Set
stop.
If the engine does not stop, inspect the gear position sensor, side stand switch and relay box.
If their parts are normality, replace the ECU.

IC Igniter Inspection

○The IC igniter is built in the ECU [A].

to the following items.
• Refer
Interlock Operation Inspection (see Interlock Operation
Inspection)
Ignition System Troubleshooting (see Ignition System
section)
ECU Power Supply Inspection (see ECU Power Supply
Inspection in the Fuel System (DFI) chapter)

ELECTRICAL SYSTEM 16-49
Ignition System

16-50 ELECTRICAL SYSTEM
Ignition System
Ignition System Circuit

1. Engine Stop Switch
2. Spark Plugs
3. Stick Coils
4. Crankshaft Sensor
5. Main Throttle Sensor
6. Subthrottle Sensor
7. Vehicle-down Sensor
8. Water Temperature Sensor
9. Gear Position Sensor
10. Side Stand Switch
11. ECU
12. Joint Connector B
13. Engine Ground

14. Battery 12 V 8 Ah
15. Starter Relay
16. Main Fuse 30 A
17. ECU Fuse 15 A
18. Relay Box
19. ECU Main Relay
20. Joint Connector A
21. Starter Lockout Switch
22. Frame Ground (9)
23. Frame Ground (7)
24. Frame Ground (6)
25. Fuse Box (1)
26. Ignition Fuse 15 A
27. Ignition Switch

ELECTRICAL SYSTEM 16-51
Electric Starter System
Starter Motor Removal

the coolant reserve tank (see Coolant Reserve
• Remove
Tank Removal in the Cooling System chapter).
out the rubber cap [A].
• Slide
Remove:
• Starter Motor Cable Terminal Nut [B]
Starter Motor Mounting Bolts [C]
Starter Motor [D]

Starter Motor Installation
NOTICE
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
the starter motor legs [A] and crankcase [B] where
• Clean
the starter motor is ground.

the O-ring [A] with a new one.
• Replace
Apply
grease
to the O-ring.
• Install the starter
motor on the crankcase.
•

• Tighten the starter motor mounting bolts [A].
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)

the starter motor cable [B] to the terminal and
• Connect
position it vertically [C] as shown.
• Tighten the starter motor cable terminal nut [D].
Torque - Starter Motor Cable Terminal Nut: 5.9 N·m (0.60
kgf·m, 52 in·lb)

back the rubber cap to the original position.
• Slide
Install
the removed parts (see appropriate chapters).
•

Starter Motor Disassembly

• Remove:
Starter Motor (see Starter Motor Removal)
Starter Motor Through Bolts [A]
End Covers [B]

16-52 ELECTRICAL SYSTEM
Electric Starter System

• Remove the armature [A] from the commutator side.
NOTE

○Do not remove the circlip [B] from the shaft.

• Remove:
Starter Motor Terminal Locknut [A]
Washer [B]
Collar [C]
O-ring [D]

out the brushes from the brush holder [A].
• Pull
Remove:
• Brush Springs [B]
Starter Motor Terminal [C]
Positive Brush Assy [D]
Brush Holder Screw [E]
Negative Brush Assy [F]
Brush Holder

Starter Motor Assembly

the hole [A] of the brush holder [B] to the boss [C]
• Align
of the right-hand end cover [D].

the stoppers [A] of the negative brush assy [B] to
• Align
the grooves [C] of the brush holder [D].
• Tighten:
Torque - Brush Holder Screw: 3.8 N·m (0.39 kgf·m, 34 in·lb)

ELECTRICAL SYSTEM 16-53
Electric Starter System
the hole [A] of the positive brush assy [B] with the
• Align
hole [C] of the brush holder [D].
• Insert the starter motor terminal through the holes.

the O-ring [A] with a new one.
• Replace
Install
the
following parts to the starter motor terminal [B].
• New O-ring
Collar [C]
Washer [D]
Starter Motor Terminal Locknut [E]
○Install the collar so that stepped side faces outward.
Tighten:

•

Torque - Starter Motor Terminal Locknut: