NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
nector [B].
• Remove:
Meter Mounting Bolts [C]
Pull
• the meter unit [D] upward to clear the projection.
Meter Unit Installation
• Install:
Dampers [A]
•
•
Collars [B]
Install the grommet [C] with its larger diameter side [D]
facing upward [E], if removed.
Insert the projection [F] on the meter unit into the grommet.
the meter mounting bolts [A].
• Tighten
the meter connector [B], and install the dust
• Connect
cover [C].
the meter cover, and tighten its bolts together with
• Install
the washers.
Torque - Meter Cover Bolts: 0.5 N·m (0.05 kgf·m, 4.4 in·lb)
Meter Unit Disassembly/Assembly
• Remove:
Meter Unit (see Meter Unit Removal)
Meter Assembly Screws [A]
Lower Meter Cover [B]
16-70 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
the meter assembly [A] and upper meter cover
• Separate
[B].
• Assembly is the reverse of removal.
Meter Operation Inspection
Check 1: Meter Unit Switching Inspection
Display Mode Setting
Turn the ignition switch on and check the following.
By pushing the left meter button [A] or right meter button [B] each time, check that the display [C] changes as
shown.
Pushing Left Meter Button [D]
Pushing Right Meter Button [E]
If the display function does not work, replace the meter
assembly.
•
•
Unit Setting
Set the ODO mode by pushing the left meter button.
By pushing the right meter button each time while the left
meter button pushed in, check that the display changes
as shown.
•
•
○Mile/Km
NOTE
Display can alternate between English and
metric modes (mile and km) in the digital meter. Make
sure that km or mile according to local regulations is
correctly displayed before riding.
If the display function does not work, replace the meter
assembly.
ELECTRICAL SYSTEM 16-71
Meter, Gauge, Indicator Unit
Clock Setting
Set the clock display mode [A] by pushing the right meter
button [B].
•
the right meter button and hold it.
•○Push
The clock setting menu (hour and minute) should blink.
the right meter button and hold it.
•○Push
“12h” or “24h” display is appeared.
• Push the left meter button to select “12h” or “24h” [A].
the right meter button.
•○Push
The hour display [A] starts blinking.
pushing the left meter button each time, check that the
• By
hour display changes.
pushing the right meter button, check that the hour
• By
display decides and minute display [A] starts blinking.
pushing the left meter button each time, check that the
• By
minute display changes.
16-72 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
pushing the right meter button, check that the hour and
• By
minute display start blinking.
pushing the left meter button, check that the hour and
• By
minute display decide.
both hour and minute display is blinking, by pushing
• When
the right meter button, check that the hour display start
blinking. This blinking returns the hour setting display.
If the display function does not work, replace the meter
assembly.
Meter System Inspection
Check 2–1: Battery Warning Indicator Inspection
When the battery condition is low voltage (10.8 11.2 V or
less) or high voltage (15.5 16.5 V or more), the battery
warning indicator [A] and red warning indicator light (LED)
[B] go on.
If the battery warning indicator and red warning indicator light (LED) go on, inspect the charging voltage (see
Charging Voltage Inspection).
If the charging voltage is good, replace the meter assembly.
•
Check 2-2: Gear Position Indication Inspection
Turn the ignition switch on and shift the transmission gear
into neutral position.
○The green neutral indicator light (LED) [A] goes on, and
the gear position indicator is display the “N” [B].
•
the low gear position, and check that the display
• Set
changes to “1” mark [A] and the green neutral indicator
•
•
•
light (LED) [B] goes off.
Using the rear stand, raise the rear wheel off the ground.
Rotate the rear wheel by hand and change the gear position.
Check that the display corresponding to each gear position (1, N, 2, 3, 4, 5 or 6) appears.
If the display function does not work, check the following
parts.
Gear Position Sensor (see Gear Position Sensor Inspection)
Wiring (see Meter Unit Circuit)
If the above parts are good, replace the meter assembly
and/or ECU.
ELECTRICAL SYSTEM 16-73
Meter, Gauge, Indicator Unit
Meter Unit Inspection
the meter unit (see Meter Unit Removal).
• Remove
[1] Green Left Turn Signal Indicator Light (LED) (+)
[2] Blue High Beam Indicator Light (LED) (+)
[3] Unused
[4] Unused
[5] Fuel Level Gauge
[6] Green Neutral Indicator Light (LED) (–)
[7] Green Right Turn Signal Indicator Light (LED) (+)
[8] Yellow ABS Indicator Light (LED) (Equipped Models)
(–)
[9] Tachometer Signal
[10] Rear Wheel Rotation Sensor Signal
[11] Meter Communication Line
[12] Red Warning Indicator Light (LED), Oil Pressure
Warning Indicator (–)
[13] Unused
[14] Ground (–)
[15] Ignition (+)
[16] Battery (+)
NOTICE
Do not drop the meter unit. Do not short each terminals.
Check 3-1: Meter Unit Primary Operation Check
Using the auxiliary leads, connect the 12 V battery to the
meter unit connector as follows.
○Connect the battery positive (+) terminal to the terminal
[16].
○Connect the battery negative (–) terminal to the terminal
[14].
•
• Connect the terminal [15] to the battery (+) terminal.
16-74 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
the following items.
•○Check
The tachometer segments [A] sweeps to the maximum
reading, then sweeps back to the minimum reading.
○The LCD display and meter illuminations should turn on.
○All the LCD segments [B] appear for few seconds.
○The red warning indicator light (LED) [C] goes on for few
seconds.
○The yellow engine warning indicator light (LED) [D] and
yellow ABS indicator light (LED) [E] (if equipped) remains
on.
If the meter unit does not work properly, replace the meter
assembly.
NOTE
○This meter unit has a failure detection function of the
communication. When the communication error was
detected, the meter unit alerts the rider by the yellow
engine warning indicator light (LED) goes on.
○Make sure that the all fuel level gauge segments [A] and
indicator on the LCD start blinking approx. 5 seconds
after turning on the meter unit.
If the fuel level gauge does not work properly, replace the
meter assembly.
NOTE
○This meter unit has a failure detection function (for open
or short) of the fuel level gauge. When the fuel level
gauge is open or short, the meter unit alerts the rider by
the all fuel level gauge segments blink in the display.
○Make sure that the coolant temperature gauge segments
[A] and "- -" message [B] on the gear position indicator
start blinking approx. 10 seconds after turning on the meter unit.
NOTE
○This meter unit has a failure detection function (for open
or short) of the fuel level gauge. When the fuel level
gauge is open or short, the meter unit alerts the rider
by the all coolant temperature gauge segments blink in
the display.
If the fuel level gauge does not work properly, replace the
meter assembly.
Check 3-2: Meter Communication Line (Service Code
39) Check
Connect the leads in the same circuit as Check 3-1.
The yellow engine warning indicator light (LED) should
remains on.
•
•
ELECTRICAL SYSTEM 16-75
Meter, Gauge, Indicator Unit
the ODO mode [A] by pushing the left meter button
• Set
[B].
the left meter button and right meter button [C] si• Push
multaneously for more than 2 seconds.
the following items.
•○Check
The number “39” [A] in the display appears.
the left and right meter buttons again for more than
• Push
2 seconds.
the following items.
•○Check
The display returns ODO mode from number “39”.
If the meter unit does not work, replace the meter assembly.
NOTE
○The number “39” is service code of Self-Diagnosis (see
Fuel System (DFI) chapter). It is the service code of the
meter communication line error.
○The number “39” in the display disappear when the meter unit is connected to main harness of the normal motorcycle.
Check 3-3: Immobilizer Blinking Mode Inspection
(Equipped Models)
Connect the leads in the same circuit as Check 3-1.
Disconnect the terminal [15].
•
•
that the red warning indicator light (LED) [A] starts
• Check
blinking (Immobilizer Warning Indicator Blinking Mode).
the left meter button [B] and right meter button [C]
• Push
more than 2 seconds, within 20 seconds after the terminal
•
[15] disconnected.
Check that the red warning indicator light (LED) goes on
1 second, and then the indicator goes off (Immobilizer No
Blinking Mode).
○For this inspection,
NOTE
be sure the battery is 12.2 V or
more. Immobilizer Blinking Mode does not work, when
the battery voltage is less than 12 ±0.2 V.
16-76 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
the terminal [15] to the battery (+) terminal.
• Connect
And
then,
disconnect the terminal [15].
•
the left meter button [A] and right meter button [B]
• Push
more than 2 seconds, within 20 seconds after the terminal
•
[15] disconnected.
Check that the red warning indicator light (LED) [C] goes
on 1 second, and then the indicator starts blinking (Immobilizer Warning Indicator Blinking Mode).
If the meter function does not work, replace the meter
assembly.
Check 3-4: Blue High Beam Indicator Light (LED) Inspection
Connect the terminal [2] to the battery (+) terminal.
Connect the terminal [14] to the battery (–) terminal.
•
•
that the blue high beam indicator light (LED) [A]
• Check
goes on.
If the indicator light (LED) does not go on, replace the
meter assembly.
Check 3-5: Green Left Turn Signal Indicator Light (LED)
Inspection
Connect the terminal [1] to the battery (+) terminal.
Connect the terminal [14] to the battery (–) terminal.
•
•
ELECTRICAL SYSTEM 16-77
Meter, Gauge, Indicator Unit
that the green left turn signal indicator light (LED)
• Check
[A] goes on.
If the indicator light (LED) does not go on, replace the
meter assembly.
Check 3-6: Green Right Turn Signal Indicator Light
(LED) Inspection
Connect the terminal [7] to the battery (+) terminal.
Connect the terminal [14] to the battery (–) terminal.
•
•
that the green right turn signal indicator light (LED)
• Check
[A] goes on.
If the indicator light (LED) does not go on, replace the
meter assembly.
Check 3-7: Green Neutral Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 3-1.
Connect the terminal [6] to the battery (–) terminal.
•
•
that the green neutral indicator light (LED) [A] goes
• Check
on.
If the indicator light (LED) does not go on, replace the
meter assembly.
16-78 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 3-8: Yellow ABS Indicator Light (LED) Inspection
(Equipped Models)
Connect the leads in the same circuit as Check 3-1.
○The yellow ABS indicator light (LED) goes on.
Connect the terminal [8] to the battery (–) terminal.
•
•
that the yellow ABS indicator light (LED) [A] goes
• Check
off.
If the indicator light (LED) does not go off, replace the
meter assembly.
Check 3-9: Red Warning Indicator Light (LED) Inspection (Oil Pressure Warning)
Connect the leads in the same circuit as Check 3-1.
Connect the terminal [12] to the battery (–) terminal.
•
•
that the oil pressure warning indicator [A] and red
• Check
warning indicator light (LED) [B] go on.
If the oil pressure warning indicator and indicator light
(LED) does not go on, replace the meter assembly.
Check 3-10: Fuel Gauge Inspection
Connect the leads in the same circuit as Check 3-1.
○The all segments of the fuel gauge in the display will blink.
Connect the variable rheostat [A] between the terminal [5]
and the battery (–) terminal.
•
•
ELECTRICAL SYSTEM 16-79
Meter, Gauge, Indicator Unit
that the number of segments on the fuel level
• Check
gauge [A] matches the resistance value of the variable
rheostat.
○When the terminal [5] is connected, 1 segment in the fuel
level gauge should appear about every 15 seconds.
Variable Rheostat Resistance (Ω)
Display Segments
15
6 segments go on
40
5 segments go on
70
4 segments go on
100
3 segments go on
130
2 segments go on
180
1 segment goes on
220
1 segment and
fuel level warning
indicator blink
If the display function does not work, replace the meter
assembly.
Check 3-11: Speedometer Inspection
Connect the leads in the same circuit as Check 3-1.
The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave is input into terminal
[10].
○Indicates approximately 60 km/h if the input frequency is
approximately 388 Hz.
○Indicates approximately 60 mph if the input frequency is
approximately 625 Hz.
If the meter function does not work, replace the meter
assembly.
•
•
NOTE
○The input frequency of the oscillator adds the integrated
value of the odometer.
○The integrated value of the odometer cannot be reset.
Check 3-12: Odometer Check
Check the odometer with the speedometer check in the
same way.
If value indicated in the odometer is not added, replace
the meter assembly.
•
NOTE
○The data is maintained even if the battery is disconnected.
○When the figures come to 999999, they are stopped and
locked.
○The integrated value of the odometer cannot be reset.
16-80 ELECTRICAL SYSTEM
Meter, Gauge, Indicator Unit
Check 3-13: Trip A/B Meter Check
Check the trip meter with the speedometer in the same
way.
If value indicated in the trip meter is not added, replace
the meter assembly.
•
NOTE
○The integrated value of the odometer cannot be reset.
that when the right meter button is pushed for more
• Check
than two seconds, the figure display turns to 0.0.
If the figure display does not indicate 0.0, replace the meter assembly.
Check 3-14: Tachometer Inspection
Connect the leads in the same circuit as Check 3-1.
The engine speed (rpm) equivalent to the input frequency
is indicated in the oscillator [A], if the square wave is input
into terminal [9].
○Indicates approximately 6 000 rpm if the input frequency
is approximately 200 Hz.
If the meter function does not work, replace the meter
assembly.
•
•
Check 3-15: Other Inspection
○The following items are displayed while running.
AVERAGE
CURRENT
RANGE
ECO Mark
When the above item is faulty indication check the following items.
Wiring (see Wiring Inspection)
ECU Communication Line (see ECU Communication
Line Inspection in the Fuel System (DFI) chapter)
Fuel Injectors (see Fuel Injectors (Service Code 41, 42)
section in the Fuel System (DFI) chapter)
Rear Wheel Rotation Sensor (see Rear Wheel Rotation
Sensor (Service Code 24) section in the Fuel System
(DFI) chapter)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
If the above items are good, replace the meter assembly
and/or ECU.
•
Fuel Level Sensor Line Self-Diagnosis Mode
Inspection
NOTE
○Usually when the open or short of the fuel level sensor
circuit is detected, it becomes the Fuel Level Sensor
Line Self-Diagnosis Mode.
○The all segments of the fuel level gauge [A] and fuel level
warning indicator [B] in the display will blink. (This function is Fuel Level Sensor Line Self-Diagnosis Mode.)
If the meter enters the self-diagnosis mode when the meter is installed in the motorcycle, check the fuel level sensor (see Fuel Level Sensor Inspection) and wiring.
If the fuel level sensor and wiring are good, replace the
meter assembly.
ELECTRICAL SYSTEM 16-81
Meter, Gauge, Indicator Unit
Meter Circuit (ZR900A)
1. Ignition Switch
2. Crankshaft Sensor
3. Water Temperature Sensor
4. Gear Position Sensor
5. Oil Pressure Switch
6. ECU
7. Rear Wheel Rotation Sensor
8. Fuel Level Sensor
9. Frame Ground (2)
10. Engine Ground
11. Battery 12 V 8 Ah
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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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