kgf·m, 97 in·lb)

11 N·m (1.1

• Install the brush springs [A] and insert the brushes [B].

• Apply thin coat of grease to the oil seal [A].

the O-rings [A] with new ones.
• Replace
Insert
the
[B] so that commutator side [C] faces
• hollow sidearmature
[D] of the yoke [E].

16-54 ELECTRICAL SYSTEM
Electric Starter System
the end cover [A] so that the stopper [B] is aligned
• Install
with the hollow [C] of the yoke.

the marks [A] to assembly the yoke and the end
• Align
covers [B].
• Tighten the through bolts.
Torque - Starter Motor Through Bolts: 5.0 N·m (0.51 kgf·m,
44 in·lb)

Brush Inspection

the length of each brush [A].
• Measure
If any is worn down to the service limit, replace the brush
assy.
Starter Motor Brush Length
Standard:
12 mm (0.47 in.)
Service Limit: 6.5 mm (0.26 in.)

Commutator Cleaning and Inspection

the metallic debris off the between commutator
• Clean
segments [A].

NOTE

○Do not use emery or sand paper on the commutator.
the commutator for damage or abnormal wear.
• Check
Replace the starter motor with a new one if there is any

•

damage or wear.
Visually inspect the commutator segments for discoloration.
Replace the starter motor with a new one if discoloration
is noticed.

ELECTRICAL SYSTEM 16-55
Electric Starter System
Armature Inspection

a tester, measure the resistance between any two
• Using
commutator segments [A].

•

If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
Using the tester, measure the resistance between the
segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.

NOTE

○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the tester. If all other starter motor and
starter motor circuit components check good, but the
starter motor still does not turn over or only turns over
weakly, replace the starter motor with a new one.
Brush Lead Inspection

a tester, measure the resistance as shown.
• Using
Terminal Bolt and Positive Brushes [A]
Right-hand End Cover and Negative Brushes [B]
If there is not close to zero ohms, the brush lead has an
open. Replace the brush plate assy.

Right-hand End Cover Inspection

a tester, measure the resistance as shown.
• Using
Terminal Bolt and Right-hand End Cover [A]
Terminal Bolt and Negative Brushes [B]
If there is any reading, the brush assy and/or terminal bolt
assy have a short. Replace the starter motor.

Starter Relay Inspection

• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Battery Negative (–) Cable (see Battery Removal)
Starter Relay Cover [A]

16-56 ELECTRICAL SYSTEM
Electric Starter System

• Disconnect:
Connector [A]
• Remove:
Cable Terminal Bolts [B]
Starter Relay [C]

a tester [A] and 12 V battery [B] to the starter
• Connect
relay [C] as shown.
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω

• Installation is reverse of removal.
Torque - Starter Relay Terminal Bolts: 3.9 N·m (0.40 kgf·m,
35 in·lb)

ELECTRICAL SYSTEM 16-57
Electric Starter System
Electric Starter Circuit

1. Engine Stop Switch
2. Starter Button
3. Gear Position Sensor
4. Side Stand Switch
5. ECU
6. Frame Ground (1)
7. Engine Ground
8. Battery 12 V 8 Ah
9. Starter Relay
10. Main Fuse 30 A

11. Starter Motor
12. Relay Box
13. Starter Circuit Relay
14. Joint Connector A
15. Starter Lockout Switch
16. Frame Ground (7)
17. Fuse Box (1)
18. Ignition Fuse 15 A
19. Ignition Switch

16-58 ELECTRICAL SYSTEM
Lighting System
This motorcycle adopt the daylight system and have a
headlight relay in the relay box. The headlight does not
go on when the ignition switch and the engine stop switch
are first turned on. The headlight comes on after the starter
button is released and stays on until the ignition switch is
turned off. The headlight will go out momentarily whenever
the starter button is pressed and come back on when the
button is released.

Headlight Beam Horizontal Adjustment

to the Headlight Aiming Inspection in the Periodic
• Refer
Maintenance chapter.

Headlight Beam Vertical Adjustment

to the Headlight Aiming Inspection in the Periodic
• Refer
Maintenance chapter.

Headlight Bulb Replacement

• Remove:
Headlight Unit (see Headlight Unit Removal)
Dust Cover [A]

the hook [A] from the stopper [B].
• Clear
Remove:
• Headlight Bulb [C]

NOTICE
When handling the quartz-halogen bulb, never
touch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands
or dirty rags can reduce bulb life or cause the bulb
to explode. Use the correct type of headlight bulb
with specified voltage and wattage only.

NOTE

○Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.
the headlight bulb.
• Replace
Fit
the
projection
[A] on the bulb in the cutout [B] on the
• headlight.

ELECTRICAL SYSTEM 16-59
Lighting System

• Install the hook [A] to the stopper [B].

the dust cover [A] onto the bulb [B] firmly as shown.
• FitGood
[C]

•
•

Bad [D]
Install the headlight unit (see Headlight Unit Installation).
After installation, adjust the headlight aim (see Headlight
Aiming Inspection in the Periodic Maintenance chapter).

Headlight Unit Removal

to the Upper Fairing Disassembly/Assembly in the
• Refer
Frame chapter.

Headlight Unit Installation

to the Upper Fairing Disassembly/Assembly in the
• Refer
Frame chapter.

City Light Bulb Replacement

the headlight unit (see Headlight Unit Removal).
• Remove
Pull
out
the
socket [A] from the headlight housing.
•

• Pull the bulb [A] out from the socket [B].
NOTICE
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage than the specified valve.
the bulb with a new one.
• Replace
Insert
the
socket into the headlight unit.
•

16-60 ELECTRICAL SYSTEM
Lighting System
Tail/Brake Light (LED) Unit Removal

• Remove:
Seat Cover (see Seat Cover Removal in the Frame
•

chapter)
Disconnect the tail/brake light lead connector [A].

• Remove:
Battery Case Bolts (Rear) [A]

• Remove:
Flap Bolts [A]
Tail/Brake Light Bolts [B] and Washers
Clamp [C]

the lock tab [A] of the rear fender and pull the rear
• Unlatch
fender [B] downward.
the tail/brake light (LED) unit [C] forward to pull off
• Slide
the bracket [D] from the slot [E] on the rear fender.
the tail/brake light (LED) unit from the rear
• Remove
fender.

Tail/Brake Light (LED) Unit Installation

the grommets [A] to the tail/brake light (LED) unit
• Install
[B] with its larger diameter side [C] facing upward [D].
the collars [E] from underside.
• Install
Install
the
rubber damper [F] to the bracket.
•

ELECTRICAL SYSTEM 16-61
Lighting System
the rubber damper [A] into the slot [B] to place the
• Insert
tail/brake light (LED) unit on the rear fender.

up the rear fender until the lock tab [A] latches to the
• Pull
frame.
the tail/brake light bolts [B] with the washers and
• Tighten
clamp [C].
the tail/brake light lead connector [D].
• Connect
Tighten
the
flap bolts [E] and battery case bolts (see Flap
• and Rear Fender
Installation in the Frame chapter).
Install
the
removed
parts (see appropriate chapters).
•

License Plate Light Bulb Replacement

• Remove:
License Plate Light Cover Screws [A]

License Plate Light Cover [B] and Lens

• Pull out the bulb [A] straight from the socket.
NOTICE
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage then the specified valve.
the bulb with a new one.
• Replace
Insert
the
bulb into the socket.
• Install the new
license
light cover.
• Tighten the licenseplate
plate light cover screws.
•

16-62 ELECTRICAL SYSTEM
Lighting System
Headlight/Tail Light Circuit

1. Ignition Switch
2. Fuse Box (1)
3. Headlight Relay Fuse 15 A
4. Brake Light/Horn Fuse 7.5 A
5. Tail/Brake Light (LED)
6. License Plate Light 12 V 5 W
7. Frame Ground (1)
8. Engine Ground
9. Battery 12 V 8 Ah
10. Starter Relay
11. Main Fuse 30 A

Turn Signal Light Bulb Replacement

• Remove:
Turn Signal Light Lens Screw [A]

Turn Signal Light Lens Housing [B]

12. Alternator
13. Relay Box
14. Headlight Circuit Relay
15. Passing Button
16. Dimmer Switch
17. Frame Ground (6)
18. Headlight (High) 12 V 55 W
19. Headlight (Low) 12 V 55 W
20. City Light 12 V 5 W
21. Meter Unit

ELECTRICAL SYSTEM 16-63
Lighting System
the socket [A] counterclockwise and remove the lens
• Turn
housing [B].
• Pull out the bulb [C] straight from the socket.

NOTICE
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage then the specified valve.

the bulb [A] with a new one.
• Replace
Push
the
bulb into the socket.
• Insert the new
socket by aligning its tabs [B] with the cutouts
• [C] of the lens.
• Turn the socket clockwise until it stops.

the lens housing [A] to the light case [B] by inserting
• Fit
the projection [C] on the lens housing to the inside of the

•

light case.
Tighten the turn signal light lens screw.
Torque - Turn Signal Light Lens Screw: 1.0 N·m (0.10 kgf·m,
8.9 in·lb)

Turn Signal Relay Inspection

• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
•

ter)
Remove the turn signal relay [A].
Disconnect the turn signal relay connector [B].

16-64 ELECTRICAL SYSTEM
Lighting System
one 12 V battery and turn signal lights as indi• Connect
cated, and count how many times the lights blink for one
minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not blink as specified, replace the turn signal relay.
Testing Turn Signal Relay
Load
The Number of Turn
Signal Lights

Wattage (W)

Blinking Times
(c/m*)

1**

10

140  250

2

20

75  95

(*): Cycle(s) per minute
(**): Correspond to “one light burned out.”

ELECTRICAL SYSTEM 16-65
Lighting System
Turn Signal Light Circuit

1. Ignition Switch
2. Fuse Box (2)
3. Turn Signal Relay Fuse 7.5 A
4. Rear Right Turn Signal Light 12 V 10 W
5. Rear Left Turn Signal Light 12 V 10 W
6. Frame Ground (1)
7. Engine Ground
8. Battery 12 V 8 Ah
9. Starter Relay

10. Main Fuse 30 A
11. Turn Signal Relay
12. Hazard Switch
13. Turn Signal Switch
14. Frame Ground (6)
15. Front Left Turn Signal Light 12 V 10 W
16. Front Right Turn Signal Light 12 V 10 W
17. Meter Unit

16-66 ELECTRICAL SYSTEM
Air Switching Valve
Air Switching Valve Operation Test

to the Air Suction System Damage Inspection in the
• Refer
Periodic Maintenance chapter.

Air Switching Valve Unit Test

the air switching valve (see Air Switching Valve
• Remove
Removal in the Engine Top End chapter).
a tester [A] to the air switching valve terminals
• Connect
as shown.
Air Switching Valve Resistance
Standard:
20  24 Ω @20°C (68°F)

If the resistance reading is out of the specified value, replace it with a new one.
the 12 V battery [A] to the air switching valve
• Connect
terminals as shown.

the air to the intake air duct [A], and make sure does
• Blow
not flow the blown air from the outlet air ducts [B].

the 12 V battery.
• Disconnect
the air to the intake air duct [A] again, and make sure
• Blow
flow the blown air from the outlet air duct [B].
If the air switching valve does not operate as described,
replace it with a new one.

NOTE

○To check air flow through the air switching valve, just
blow through the air switching valve hose (intake side)
[C].

ELECTRICAL SYSTEM 16-67
Air Switching Valve
Air Switching Valve Circuit

1. Ignition Switch
2. Air Switching Valve
3. Fuse Box (1)
4. Ignition Fuse 15 A
5. ECU
6. Joint Connector B
7. Engine Ground
8. Battery 12 V 8 Ah
9. Starter Relay
10. Main Fuse 30 A
11. ECU Fuse 15 A
12. Relay Box
13. ECU Main Relay
14. Frame Ground (7)
15. Frame Ground (6)

16-68 ELECTRICAL SYSTEM
Radiator Fan System
Fan Motor Inspection

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

in the Fuel System (DFI) chapter)
Disconnect the fan motor lead connector [A] behind the
air switching valve.
Using an auxiliary leads, apply a battery voltage to the fan
motor lead connector terminals.
If the fan does not rotate, the fan motor is defective and
must be replaced.

Radiator Fan Circuit

1. Ignition Switch
2. Fan Motor
3. Fuse Box (1)
4. Ignition Fuse 15 A
5. Fan Fuse 15 A
6. Water Temperature Sensor
7. ECU
8. Engine Ground
9. Battery 12 V 8 Ah
10. Starter Relay
11. Main Fuse 30 A
12. Relay Box
13. Radiator Fan Relay
14. Frame Ground (8)
15. Frame Ground (7)

ELECTRICAL SYSTEM 16-69
Meter, Gauge, Indicator Unit
Meter Unit Removal

• Remove:
Meter Cover Bolts [A] and Washers
Meter Cover [B]

the dust cover [A], and disconnect the meter con• Slide