teeth [C] aligned.
the timing rotor with the flywheel & pulley holder
• Holding
and tighten the 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 cover (see Crankshaft Sen• Install
sor Installation).

Stick Coil Removal

the air cleaner housing (see Air Cleaner Housing
• Remove
Removal in the Fuel System (DFI) chapter).
the stick coil connectors [A].
• Disconnect
Pull
out
the
coils [B] upward.
•○First, turn thestick
stick coil by 90 degrees, and then pull it out
by twisting the coil head to the left and right while holding
it securely by hand.

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

Stick Coil Installation

a thin coat of grease to the stick coils for easy in• Apply
stallation.
the stick coils so that the coil heads align with the
• Insert
lines [A] 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).

16-42 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:
0.85  1.15 Ω @20°C (68 °F)
Secondary Windings:

6.7  9.1 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).
•○Remove
Do 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:
-1449

57001

Connections:
Adapter (R, +) → Lead Wire-Peak Voltage Adapter (W)
Adapter (BK, –) → Lead Wire-Peak Voltage Adapter (R)

ELECTRICAL SYSTEM 16-43
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
Standard: 100 V or more

the test for the other stick coils.
• 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.
Standard Spark Plug
Type:
NGK SILMAR9B9

16-44 ELECTRICAL SYSTEM
Ignition System
Interlock Operation Inspection

• Raise the rear wheel off the ground with the stand [A].

1st 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 switch and diode array.
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, diode array 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 may not be stopped, inspect the gear position switch, side stand switch and diode array.
If their parts are normality, replace the ECU.

ELECTRICAL SYSTEM 16-45
Ignition System
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)

16-46 ELECTRICAL SYSTEM
Ignition System

ELECTRICAL SYSTEM 16-47
Ignition System
Ignition System Circuit

1. Ignition Switch
2. Engine Stop Switch
3. Spark Plugs
4. Stick Coils
5. Throttle Position Sensor
6. Crankshaft Sensor
7. Water Temperature Sensor
8. Vehicle-down Sensor
9. ECU
10. Gear Position Sensor
11. Side Stand Switch
12. Frame Ground (4)
13. Frame Ground (3)
14. Engine Ground
15. Battery 12 V 8.6 Ah
16. Main Fuse 30 A
17. ECU Fuse 15 A
18. Starter Relay
19. Ignition Fuse 15 A
20. Fuse Box (1)
21. Diode Array (Starter)
22. Joint Connector F
23. Starter Lockout Switch

16-48 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Removal

the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
the thermostat (see Thermostat Removal in the
• Remove
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 [C] with a new one.
• Replace
grease to the new O-ring.
• Apply
Tighten:
•
Torque - Starter Motor Mounting Bolts: 10 N·m (1.0 kgf·m,
89 in·lb)

the starter motor cable [A] as shown.
• Install
Tighten:
•
Torque - Starter Motor Cable Terminal Nut [B]: 6.0 N·m (0.61
kgf·m, 53 in·lb)

• Slide back the rubber cap to the original position.

Starter Motor Disassembly

the starter motor (see Starter Motor Removal).
• Remove
Take
off
the
motor through bolts [A] and remove
• the both end starter
covers [B].

ELECTRICAL SYSTEM 16-49
Electric Starter System

• Pull out the armature [A] out of the yoke [B].
NOTE

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

• Remove the starter motor terminal locknut [A].

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

Starter Motor Assembly

the positive brush assy [A] and the starter motor
• Install
terminal [B] as shown.
• Replace the O-ring [C] with a new one, and install it.

• Install:
Brush Springs [A]
Negative Brush Assy [B]

○Turn the stopper side [C] to inside.

• Tighten:

Torque - Brush Holder Screw: 3.8 N·m (0.39 kgf·m, 34 in·lb)

• Install the brushes onto the brush springs.

16-50 ELECTRICAL SYSTEM
Electric Starter System
the following parts to the starter motor terminal [A].
• Install
Collar [B]
Washer [C]
Starter Motor Terminal Locknut [D]
○Turn the flange of the collar to the locknut as shown.
Tighten:

•

Torque - Starter Motor Terminal Locknut:
kgf·m, 97 in·lb)

11 N·m (1.1

• 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].

the yoke [A] and the end covers [B] as shown.
• Assemble
“Y” Mark [C]
”I” Mark [D]

• Tighten:
Torque - Starter Motor Through Bolts [A]: 5.0 N·m (0.51
kgf·m, 44 in·lb)

ELECTRICAL SYSTEM 16-51
Electric Starter System
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 [B]
Standard:
12.05 mm (0.4744 in.)
Service Limit: 6.55 mm (0.258 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.

Armature Inspection

the resistance between any two commutator
• Measure
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 highest tester range, 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

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

16-52 ELECTRICAL SYSTEM
Electric Starter System
Right-hand End Cover Inspection

the resistance as shown.
• Measure
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

the front seat (see Front Seat Removal in the
• Remove
Frame chapter).
the battery negative (–) cable from the battery
• Remove
negative (–) terminal (see Battery Removal).
the starter relay [A] off the rear fender.
• Take
• Remove the cover [B].

• Remove:
Starter Motor Cable [A] and Spring Washer
•

Battery Positive (+) Cable [B] and Spring Washer
Disconnect the connector [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

ELECTRICAL SYSTEM 16-53
Electric Starter System
Electric Starter Circuit

1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
4. ECU
5. Joint Connector L
6. Gear Position Switch
7. Side Stand Switch
8. Frame Ground (4)
9. Frame Ground (3)
10. Frame Ground (2)
11. Engine Ground
12. Battery 12 V 8.6 Ah
13. Main Fuse 30 A
14. ECU Fuse 15 A
15. Starter Relay
16. Starter Motor
17. Fuse Box 1
18. Ignition Fuse 15 A
19. Diode Array (Starter)
20. Joint Connector F
21. Starter Circuit Relay
22. Starter Lockout Switch
23. Diode (Starter)

16-54 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

• Turn the cover [A] counterclockwise, and remove it.

the headlight connector [A].
• Disconnect
Open
the
clamp
[B], and remove the bulb.
•

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 with a new one.
• Replace
Install
the
[A].
•○Turn the tabnew[B]bulb
upward.
• Install the clamp [C].

ELECTRICAL SYSTEM 16-55
Lighting System
the headlight connector.
• Connect
Install
the
[A], and turn it clockwise until the mark
• [B] aligns tocover
the projection [C].
After
installation,
the headlight aim (see Headlight
• Aiming Inspectionadjust
in the Periodic Maintenance chapter).

○Another Bulb: Repeat the above steps.

Headlight Removal