NHTSA ID Number: 10109090
Manufacturer Communication Number: 99924-1525-01
TSB/Document Date: 2017-08-01
Summary
Service Manual
Abnormal Engine Noise:
Knocking:
ECU trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Valve lifter worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring/groove clearance excessive
Piston ring worn, broken, or stuck
Piston ring groove worn
APPENDIX 17-77
Troubleshooting Guide
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mount loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Air switching valve damaged
Alternator rotor loose
Catalytic converter melt down due to muffler
overheating (KLEEN)
Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Balancer rubber damper damaged
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
Clutch housing/friction plate clearance excessive
Clutch housing gear worn
Wrong installation of outside friction plate
Transmission noise:
Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc.
not properly
mounted or tightened
Warning Indicator Light (Oil Pressure
Warning) Doesn’t Go OFF:
Engine oil pump damaged
Engine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearing worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
damaged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Brown smoke:
Air cleaner housing holder loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebars hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebars shakes or excessively
vibrates:
Tire worn
Swingarm pivot bearing worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar clamp bolt loose
Steering stem nut loose
Front, rear axle runout excessive
Engine mount loose
Handlebars pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering maladjusted
Front fork bent
17-78 APPENDIX
Troubleshooting Guide
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
cylinder
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery cable making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty
ZR900B with Immobilizer Models
Meter Unit
Water
Temperature
Sensor
*1: Equipped Models
Fuel Injectors
#2
#3
ON
BK
G
W
BL
BK
BK
G
BL/Y
BR/W
P/BK
OFF
BK/BL
G/W
Intake
Air
Temperature
Sensor
BL/R
Intake
VehicleAir
down
Pressure
Sensor #1 Sensor
BL/R
G
Y/BK
BK/O
P/BL
W/R
BL/G
W/R
BL/BK
Y
BK
Intake
Air
Pressure
Sensor #2
Subthrottle
Sensor
Main
Throttle
Sensor
Side
Stand
Switch
G
R/BK
G
Y/G
BL
BL
G
Y/BL
BL
G
G/W
BL
G
Y/W
BR/W
R/Y
BL
G
BL/W
R
BK/G
M
Y
Y/BK
Subthrottle
Valve
Actuator
LG
G
G/R
*1
Purge
Valve
Oxygen
Sensor
#4
BL
G
G/R
Stick
Coils
#1
G
#4
BR/W
R/BL
BK/Y
BL/W
BR/Y
BL/R
BK/W
R/BK
LED:Light Emitting Diode
#3
Air
Switching
Valve
R
BK
BK/R
BK/R
R/BK
R/BK
BK
BK
Y/R
R
BR/W
R
Right Switch Housing
1.Front Brake Light Switch
2.Engine Stop Switch
3.Starter Button
Fan
Motor
DP
DS
OFF
ON
#2
W/R
BL/O
#1
Oil
Pressure
Switch
Gear
Position
Sensor
W/G
3
2
R
BK/O
1
Crankshaft
Sensor
W/R
BL/R
Right Switch Housing
R
BK/R
Front Wheel
Rotation Sensor
W/G
1.Yellow ABS Indicator Light(LED)
2.Green Left Turn Signal Indicator Light(LED)
3.Green Right Turn Signal Indicator Light(LED)
4.Blue High Beam Indicator Light(LED)
5.Green Neutral Indicator Light(LED)
6.Yellow Engine Warning Indicator Light(LED)
7.Red Warning Indicator Light(LED)
(Oil Pressure/Battery/Water Temperature/Immobilizer)
8.Illumination Light(LED)
9.Speedometer
10.Tachometer
11.Odometer/Trip Meter/Mileage/Cruising Range
12.Clock
13.Fuel Level Gauge
14.Gear Position Indicator
OFF ON
Ignition
Switch
IGNITION
BATTERY
BR
W
BR
W
SIGNAL
BL
BL
Immobilizer
Amplifier
BR/W
BK/BL
V
P/BK
BK/W
BK
1
2
Immobilizer
Antenna
3
BK
BK/W
4
5
BK
BK/W
BK/R
Meter Unit
6
G
R/BK
7
1 1 1
10
11
111111
12
1111
13
E
BL/G
LG
R/Y
G
Y
BL/R
R/G
LG/BK
LG
GY
BL/Y
LB
P
BL/O
BL/R
8
9
ECU
BK/O
BK/Y
P/BK
R/BL
Y/BL
LB
BR/Y
G
BK/BL
R
BK
BK/G
BL/BK
BL/R
BL/O
BK/Y
BK/BL
Y/BK
G/R
R/BK
Fuse Box(1)
1
BK
BR/W
O
BR/W
2
GY
BR
BR
3
BR/Y
BR/Y
G
4
F
W
5
G/BK
O
1
6
BR
Front Right
Turn Signal
Light
12V10W
R
BL
2
R/Y
BK
BK
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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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