NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
11. Viewed from B
17-46 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-47
Cable, Wire, and Hose Routing
1. Crankshaft Sensor Lead
2. Rear Wheel Rotation Sensor Lead
3. Oxygen Sensor Lead
4. Rear Brake Light Switch Lead
5. Clamps (Hold the fuel tank breather hose.)
6. Fuel Tank Breather Hose
7. Fuel Tank Drain Hose
8. Run the fuel tank drain hose through the clamp.
9. Fuel Tank
10. Starter Motor Cable
11. Run the fuel tank breather hose between the starter motor cable and frame.
12. Run the fuel tank breather hose under the brake pipe. Run it to the upside of the rear brake light
switch lead.
13. Run the fuel tank breather hose outside the brake pipes. Run it to the inside of the oxygen
sensor lead, crankshaft sensor lead and rear wheel rotation sensor lead.
14. Brake Pipes
17-48 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-49
Cable, Wire, and Hose Routing
1. Fuel Tank Drain Hose
2. Side Stand Switch Lead
3. Run the fuel tank breather hose between the starter motor cable and frame.
4. Fuel Tank Breather Hose
5. Run the fuel tank breather hose outside the battery negative (–) cable.
6. Starter Motor Cable
7. Engine Subharness
8. Clamp (Hold the engine subharness, side stand switch lead, alternator lead, fuel tank drain hose
and fuel tank breather hose.)
9. Alternator Lead
10. Battery Negative (–) Cable
11. Breather Tank
12. Reserve Tank Overflow Hose
13. Run the side stand switch lead, engine subharness, fuel tank drain hose, fuel tank breather
hose and reserve tank overflow hose to the inside of the engine sprocket cover.
14. Breather Tank Hose
15. Run the side stand switch lead and engine subharness to inside of the fuel tank drain hose, fuel
tank breather hose and reserve tank overflow hose. Do not touch the harness to the bracket.
17-50 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-51
Cable, Wire, and Hose Routing
1. Front Brake Pipe (Front Master Cylinder ABS Hydraulic Unit)
2. Front Brake Pipe (ABS Hydraulic Unit Front Caliper)
3. Clamp (Hold the brake pipes.)
4. Left Switch Housing Leads
5. Ignition Switch Lead
6. Immobilizer Amplifier Lead (Equipped Models)
7. Run the brake pipes in front of the left switch housing lead.
8. Rear Brake Pipe (ABS Hydraulic Unit Rear Master Cylinder)
9. Rear Brake Pipe (ABS Hydraulic Unit Rear Caliper)
10. Fuel Hose
17-52 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-53
Cable, Wire, and Hose Routing
1. Front Brake Pipe (Front Master Cylinder ABS Hydraulic Unit)
2. Rear Brake Pipe (ABS Hydraulic Unit Rear Master Cylinder)
3. Clamp (Hold the brake pipes.)
4. Front Brake Pipe (ABS Hydraulic Unit Front Caliper)
5. Rear Brake Pipe (ABS Hydraulic Unit Rear Caliper)
6. Crankshaft Sensor Lead
7. Oxygen Sensor Lead
8. Rear Wheel Rotation Sensor Lead
9. Run the oxygen sensor lead, rear wheel rotation sensor lead and crankshaft sensor lead between the brake pipes.
17-54 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-55
Cable, Wire, and Hose Routing
1. Viewed from A
2. Clamps (Hold the front brake hose
.)
3. Clamp (Hold the front brake hose.)
4. Clamps (Hold the front brake hose.)
17-56 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-57
Cable, Wire, and Hose Routing
1. Front Brake Hose (Front Master Cylinder Left Front Caliper)
2. Clamp (Hold the front brake hose.)
3. Front Brake Hose (Left Front Caliper Right Front Caliper)
4. Clamp (Hold the front brake hose.)
5. Run the front brake hose between the main harness and left switch housing lead.
6. Clamp (Hold the front brake hose.)
17-58 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-59
Cable, Wire, and Hose Routing
1. Clamp (Hold the rear wheel rotation sensor lead.)
2. Clamp (Hold the rear wheel rotation sensor lead and rear brake hose.)
3. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
4. Clamp (Hold the rear wheel rotation sensor lead and rear brake hose.)
5. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
6. Clamp (Hold the rear wheel rotation sensor lead.)
7. Clamp (Hold the rear brake hose.)
8. Clamp (Hold the rear wheel rotation sensor lead and rear brake hose.)
9. Clamp (Hold the rear wheel rotation sensor lead.)
10. Viewed from A
11. Rear Wheel Rotation Sensor
17-60 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-61
Cable, Wire, and Hose Routing
1. Clamps (Hold the oxygen sensor lead, crankshaft sensor lead and rear wheel rotation sensor
lead.)
2. Rear Wheel Rotation Sensor Lead
3. Clamp (Hold the rear wheel rotation sensor lead.)
4. Rear Brake Light Switch Lead
5. Clamp (Hold the rear wheel rotation sensor lead.)
6. Clamp (Hold the rear wheel rotation sensor lead.)
7. Clamp (Hold the rear brake hose and rear wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces leftward.)
8. Clamp (Hold the rear wheel rotation sensor lead.)
9. Clamp (Hold the rear brake hose and rear wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces downward.)
10. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
11. Clamp (Hold the rear brake hose and rear wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces leftward.)
12. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
13. Mud Guard
14. Clamp (Hold the rear brake hose.)
15. Rear Brake Hose
17-62 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-63
Cable, Wire, and Hose Routing
1. Viewed from A
2. Clamp (Hold the front brake pipes.)
3. Viewed from B
4. Clamp (Hold the front brake pipes.)
5. Clamp (Hold the front brake hose.)
6. Clamp (Hold the front brake pipes.)
7. Clamp (Hold the front brake hose and front wheel rotation sensor lead.)
8. Front Wheel Rotation Sensor Lead
9. Clamp (Hold the front brake hose and front wheel rotation sensor lead.)
10. Clamp (Hold the front brake hose.)
11. Clamp (Hold the front brake hose.)
12. Clamp (Hold the front brake hose and front wheel rotation sensor lead.)
13. Front Wheel Rotation Sensor
14. Clamp (Hold the front brake pipes.)
15. Clamp (Hold the front brake hose.)
17-64 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-65
Cable, Wire, and Hose Routing
1. Front Brake Hose (Front Master Cylinder ABS Hydraulic Unit)
2. Clamp (Hold the front brake hose.)
3. Front Brake Hose (Left Front Caliper Right Front Caliper)
4. Clamp (Hold the front brake hose.)
5. Run the front brake hose to the outside of the right switch housing lead.
6. Front Brake Hose (Left Front Caliper ABS Hydraulic Unit)
7. Front Wheel Rotation Sensor Lead
8. Clamp (Hold the front brake hose and front wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces rightward.)
9. Clamp (Hold the front brake hose.)
10. Clamp (Hold the front brake hose and front wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces rightward.)
11. Front Wheel Rotation Sensor
17-66 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-67
Cable, Wire, and Hose Routing
1. Clamp (Hold the rear wheel rotation sensor lead.)
2. Clamp (Hold the rear wheel rotation sensor lead and rear brake hose.)
3. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
4. Clamp (Hold the rear wheel rotation sensor lead and rear brake hose.)
5. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
6. Clamp (Hold the rear wheel rotation sensor lead.)
7. Clamp (Hold the rear brake hose.)
8. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
9. Clamp (Hold the rear wheel rotation sensor lead and rear brake hose.)
10. Clamp (Hold the rear wheel rotation sensor lead.)
11. Clamp (Hold the rear brake pipes.)
12. Viewed from A
13. Rear Wheel Rotation Sensor
17-68 APPENDIX
Cable, Wire, and Hose Routing
ABS Equipped Models
APPENDIX 17-69
Cable, Wire, and Hose Routing
1. Clamps (Hold the oxygen sensor lead, crankshaft sensor lead and rear wheel rotation sensor
lead.)
2. Rear Wheel Rotation Sensor Lead
3. Clamp (Hold the rear wheel rotation sensor lead.)
4. Rear Brake Light Switch Lead
5. Clamp (Hold the rear wheel rotation sensor lead.)
6. Clamp (Hold the rear brake hose and rear wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces downward.)
7. This area of the rear wheel rotation sensor lead to avoid slack.
8. Clamp (Hold the rear brake pipes.)
9. Clamp (Hold the rear wheel rotation sensor lead.)
10. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
11. Clamp (Hold the rear wheel rotation sensor lead.)
12. Clamp (Hold the rear brake hose and rear wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces downward.)
13. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
14. Clamp (Hold the rear brake hose and rear wheel rotation sensor lead at the white paint of the
sensor lead. Position the clamp so that the open side faces leftward.)
15. Run the rear wheel rotation sensor lead and rear brake hose into the guide.
16. Mud Guard
17. Clamp (Hold the rear brake hose.)
18. Rear Brake Hose
17-70 APPENDIX
Cable, Wire, and Hose Routing
Evaporative Emission Control System Equipped Models
APPENDIX 17-71
Cable, Wire, and Hose Routing
1. Clamps
2. Throttle Body Assy
3. Purge Hose (Green Paint) (Purge Valve Throttle Body Assy)
4. Purge Hose (Green Paint) (Canister Purge Valve)
5. Fuel Tank Breather Hose (Blue Paint) (Fuel Tank Canister)
6. Purge Valve
7. Canister
17-72 APPENDIX
Cable, Wire, and Hose Routing
Evaporative Emission Control System Equipped Models
1. Run the fuel tank drain hose through the clamp.
2. Fuel Tank Drain Hose
3. Clamp (Hold the fuel pump lead, starter motor cable, battery negative (–) cable and fuel tank
drain hose.)
4. Starter Motor Cable
5. Fuel Pump Lead
6. Battery Negative (–) Cable
7. Fuel Hose
8. Fuel Tank
9. Fuel Tank Breather Hose (Fuel Tank Canister)
APPENDIX 17-73
Cable, Wire, and Hose Routing
Evaporative Emission Control System Equipped Models
1. Fuel Tank Drain Hose
2. Side Stand Switch Lead
3. Clamp (Hold the engine subharness, side stand switch lead, fuel tank drain hose and alternator
lead.)
4. Engine Subharness
5. Alternator Lead
6. Clamp (Hold the engine subharness and side stand switch lead.)
7. Reserve Tank Overflow Hose
8. Run the side stand switch lead, engine subharness, fuel tank drain hose and reserve tank overflow hose to the inside of the engine sprocket cover.
9. Run the side stand switch and engine subharness to inside of the fuel tank drain hose and
reserve thank overflow hose. Do not touch the harness to the bracket.
17-74 APPENDIX
Troubleshooting Guide
NOTE
○Refer to the Fuel System chapter for most
of DFI trouble shooting guide.
○This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:
Ignition and engine stop switch not on
Starter lockout switch or gear position sensor trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Starter system wiring shorted or open
Ignition switch trouble
Engine stop switch trouble
Main 30 A or ignition fuse blown
Starter motor rotating but engine doesn’t
turn over:
Vehicle-down sensor (DFI) coming off
Immobilizer system trouble (Equipped Models)
Starter clutch trouble
Starter idle gear trouble
Engine won’t turn over:
Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure
Balancer bearing seizure
No fuel flow:
No fuel in tank
Fuel pump trouble
Fuel tank air vent obstructed
Fuel filter clogged
Fuel line clogged
No spark; spark weak:
Vehicle-down sensor (DFI) coming off
Ignition switch not on
Engine stop switch turned to stop position
Clutch lever not pulled in or gear not in neutral
Battery voltage low
Immobilizer system trouble (Equipped Models)
Spark plug dirty, broken, or gap maladjusted
Spark plug incorrect
Stick coil shorted or not in good contact
Stick coil trouble
ECU trouble
Gear position sensor, starter lockout switch,
or side stand switch trouble
Crankshaft sensor trouble
Ignition switch or engine stop switch
shorted
Starter system wiring shorted or open
Main 30 A or ignition fuse blown
Fuel/air mixture incorrect:
Bypass screw maladjusted
Air passage clogged
Air cleaner clogged, poorly sealed, or missing
Leak from oil filler plug, crankcase breather
hose or air cleaner drain hose.
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
No valve clearance
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Immobilizer system trouble (Equipped Models)
Stick coil trouble
Stick coil shorted or not in good contact
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
ECU trouble
Crankshaft sensor trouble
Fuel/air mixture incorrect:
Bypass screw maladjusted
Air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or missing
Fuel tank air vent obstructed
Fuel pump trouble
Fuel to injector insufficient
APPENDIX 17-75
Troubleshooting Guide
Fuel line clogged
Throttle body assy holder loose
Air cleaner housing holder loose
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Camshaft cam worn
Run-on (dieseling):
Ignition switch trouble
Engine stop switch trouble
Fuel injector trouble
Carbon accumulating on valve seating surface
Engine overheating
Other:
ECU trouble
Throttle body assy not synchronizing
Engine oil viscosity too high
Drive train trouble
Brake dragging
Clutch slipping
Engine overheating
Air suction valve trouble
Air switching valve trouble
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
Stick coil shorted or not in good contact
Stick coil trouble
ECU trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Throttle body assy holder loose
Air cleaner housing holder loose
Water or foreign matter in fuel
Fuel to injector insufficient
Fuel tank air vent obstructed
Fuel line clogged
Fuel pump trouble
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface.)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
ECU trouble
Miscellaneous:
Throttle valve won’t fully open
Brake dragging
Clutch slipping
Engine overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Camshaft cam worn
Air suction valve trouble
Air switching valve trouble
Catalytic converter melt down due to muffler
overheating (KLEEN)
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
ECU trouble
Muffler overheating:
For KLEEN, do not run the engine even if
with only one cylinder misfiring or poor
running (Request the nearest service facility to correct it)
For KLEEN, do not push-start with a dead
battery (Connect another full-charged
battery with jumper cables, and start the
engine using the electric starter)
For KLEEN, do not start the engine under
misfire due to spark plug fouling or poor
connection of the stick coil
For KLEEN, do not coast the motorcycle
with the ignition switch off (Turn the ignition switch on and run the engine)
ECU trouble
Fuel/air mixture incorrect:
Throttle body assy holder loose
Air cleaner housing holder loose
Air cleaner poorly sealed, or missing
17-76 APPENDIX
Troubleshooting Guide
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Brake dragging
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Oil cooler incorrect (Equipped Models):
Oil cooler clogged
Water temperature meter incorrect:
Water temperature meter broken
Water temperature sensor broken
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Wrong coolant mixed ratio
Cooling system component incorrect:
Radiator fin damaged
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan relay trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged
Over Cooling:
Water temperature meter incorrect:
Water temperature meter broken
Water temperature sensor broken
Cooling system component incorrect:
Thermostat trouble
Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch hub or housing unevenly worn
No clutch lever play
Clutch inner cable trouble
Clutch release mechanism trouble
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
Sub clutch hub spline damaged
Clutch friction plate installed wrong
Clutch lever play excessive
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift ratchet assembly spring broken
Shift ratchet assembly broken
Shift pawl broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or broken
Shift ratchet assembly spring weak or broken
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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:
Previous TSB | Next TSB |
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