NHTSA ID Number: 10109091
Manufacturer Communication Number: 99924-1509-03
TSB/Document Date: 2017-08-01
Summary
Service Manual
•
•
•
16-104 ELECTRICAL SYSTEM
Relay
Diode Inspection
Remove the diode (see Diode Removal).
Check conductivity of the following pairs of terminals.
•
•
Tester Connection
Diode (starter) and Diode
(Headlight) [A]
1-2, 2-3
Diode Array (starter) [B]
4-5, 6-7, 8-9
The resistance should be low in one direction and more
than 10 times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the diode must be replaced.
NOTE
○The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking,
the lower reading should be from zero to one half the
scale.
ELECTRICAL SYSTEM 16-105
Fuse
30 A Main/15 A ECU Fuse Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
•
ter)
Lift up the starter relay [A] with rubber protector to clear
the projection [B].
Remove the starter relay cover [C].
the fuses [A] off the starter relay with needle nose
• Take
pliers.
Fuse Box Fuse Removal
Fuse Box (1)
Remove the left inner fairing (see Upper Inner Fairing Removal in the Frame chapter).
Unlock the hook [A] to take off the fuse box (1) [B].
Unlock the hook [C] to lift up the lid.
•
•
•
the fuses [A] straight out of the fuse box (1) with nee• Pull
dle nose pliers.
Fuse Box (2)
Remove the front seat (see Front Seat Removal in the
Frame chapter).
Unlock the hook [A] to lift up the lid.
•
•
16-106 ELECTRICAL SYSTEM
Fuse
the fuses [A] straight out of the fuse box (2) with nee• Pull
dle nose pliers.
Fuse Installation
•
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a
new fuse of proper amperage.
Install the fuse box fuses on the original position as specified on the lid.
Fuse Inspection
the fuse.
• Remove
Inspect
the
element.
• If it is blownfuse
out, replace the fuse.
Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTICE
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
SELF-DIAGNOSIS SYSTEM 17-1
Self-Diagnosis System
Table of Contents
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Self-Diagnosis ........................................................................................................................
Self-Diagnosis Outline ......................................................................................................
Self-Diagnosis Procedures ...............................................................................................
Service Code Reading ......................................................................................................
Service Code Erasing .......................................................................................................
Backups ............................................................................................................................
Throttle Position Sensor (Service Code 11) (DTC P0120, P0121, P0122, P0220, P0223)....
Throttle Position Sensor Removal ....................................................................................
Throttle Position Sensor Input Voltage Inspection ............................................................
Throttle Position Sensor Output Voltage Inspection .........................................................
Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) ...............................
Intake Air Pressure Sensor #1 Removal...........................................................................
Intake Air Pressure Sensor #1 Installation........................................................................
Intake Air Pressure Sensor #1 Input Voltage Inspection...................................................
Intake Air Pressure Sensor #1 Output Voltage Inspection................................................
Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112)...............................
Intake Air Temperature Sensor Removal ..........................................................................
Intake Air Temperature Sensor Installation .......................................................................
Intake Air Temperature Sensor Output Voltage Inspection ...............................................
Intake Air Temperature Sensor Resistance Inspection .....................................................
Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) ....................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Output Voltage Inspection.....................................................
Water Temperature Sensor Resistance Inspection...........................................................
Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228)...................
Intake Air Pressure Sensor #2 Removal...........................................................................
Intake Air Pressure Sensor #2 Installation........................................................................
Intake Air Pressure Sensor #2 Input Voltage Inspection...................................................
Intake Air Pressure Sensor #2 Output Voltage Inspection................................................
Accelerator Position Sensor (Service Code 18) (DTC P2120, P2121, P2123, P2125,
P2128) .................................................................................................................................
Accelerator Position Sensor Removal ..............................................................................
Accelerator Position Sensor Input Voltage Inspection ......................................................
Accelerator Position Sensor Output Voltage Inspection ...................................................
Accelerator Position Sensor Resistance Inspection .........................................................
ABS Hydraulic Unit Communication Error (Service Code 1B, ZX1000S/Z) ...........................
ABS Hydraulic Unit Communication Line Inspection ........................................................
Crankshaft Sensor (Service Code 21) (DTC P0335)..............................................................
Crankshaft Sensor Removal/Installation...........................................................................
Crankshaft Sensor Resistance Inspection ........................................................................
Crankshaft Sensor Peak Voltage Inspection.....................................................................
Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158)...................................
Rear Wheel Rotation Sensor Signal Inspection................................................................
Gear Position Sensor (Service Code 25) (DTC P0914, P0917).............................................
Gear Position Sensor Removal/Installation ......................................................................
Gear Position Sensor Input Voltage Inspection ................................................................
Gear Position Sensor Output Voltage Inspection..............................................................
Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500) ..................................
17-5
17-7
17-8
17-8
17-10
17-13
17-13
17-16
17-22
17-22
17-22
17-23
17-26
17-26
17-26
17-26
17-28
17-32
17-32
17-32
17-32
17-34
17-35
17-35
17-35
17-36
17-38
17-38
17-38
17-38
17-40
17-42
17-42
17-42
17-43
17-44
17-46
17-46
17-48
17-48
17-48
17-48
17-49
17-49
17-52
17-52
17-52
17-53
17-56
17
17-2 SELF-DIAGNOSIS SYSTEM
Front Wheel Rotation Sensor Signal Inspection ...............................................................
Air Intake Solenoid Valve (Service Code 2D) (DTC P0660)...................................................
Air Intake Solenoid Valve Removal/Installation.................................................................
Air Intake Solenoid Valve Inspection.................................................................................
Vehicle-down Sensor (Service Code 31) (DTC C0064) .........................................................
Vehicle-down Sensor Removal .........................................................................................
Vehicle-down Sensor Installation ......................................................................................
Vehicle-down Sensor Input Voltage Inspection.................................................................
Vehicle-down Sensor Output Voltage Inspection ..............................................................
Oxygen Sensor - not activated (Service Code 33) (DTC P0130, P0132)...............................
Oxygen Sensor Removal/Installation................................................................................
Oxygen Sensor Inspection................................................................................................
Exhaust Butterfly Valve Actuator Sensor (Service Code 34) (DTC P048B, P048E) ..............
Exhaust Butterfly Valve Actuator Sensor Removal/Installation.........................................
Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection...................................
Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection ................................
Exhaust Butterfly Valve Actuator Sensor Resistance Inspection ......................................
Immobilizer Amplifier (Service Code 35, Equipped Models) ..................................................
Antenna Resistance Inspection ........................................................................................
Amplifier Input Voltage Inspection.....................................................................................
Blank Key Detection (Service Code 36, Equipped Models) ...................................................
Ignition Key Inspection......................................................................................................
ECU Communication Error (Service Code 39) (DTC U0001).................................................
ECU Communication Line Inspection ...............................................................................
Purge Valve (Service Code 3A, Other than US and CA Models) (DTC P0443) .....................
Purge Valve Removal/Installation .....................................................................................
Purge Valve Inspection .....................................................................................................
ESD ECU Communication Error (Service Code 3C) ..............................................................
ESD ECU Communication Line Inspection.......................................................................
Quick Shifter Sensor (Service Code 3E) (DTC P0826) ..........................................................
Quick Shifter Sensor Removal/Installation........................................................................
Quick Shifter Sensor Input Voltage Inspection..................................................................
Quick Shifter Sensor Output Voltage Inspection...............................................................
Quick Shifter Sensor Resistance Inspection.....................................................................
Primary Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201, P0202,
P0203, P0204).....................................................................................................................
Primary Fuel Injector Removal/Installation .......................................................................
Primary Fuel Injector Audible Inspection ..........................................................................
Primary Fuel Injector Resistance Inspection.....................................................................
Primary Fuel Injector Power Source Voltage Inspection...................................................
Primary Fuel Injector Output Voltage Inspection...............................................................
Primary Fuel Injector Fuel Line Inspection........................................................................
Fuel Pump Relay (Service Code 46) (DTC P0627)................................................................
Fuel Pump Relay Removal/Installation .............................................................................
Fuel Pump Relay Inspection .............................................................................................
Return Spring (Service Code 49) (DTC P2119) .....................................................................
Return Spring Removal.....................................................................................................
Return Spring Inspection ..................................................................................................
Secondary Fuel Injectors #1, #2, #3, #4 (Service Code 4A, 4B, 4C, 4D) (DTC P0205,
P0206, P0207, P0208) ........................................................................................................
Secondary Fuel Injector Removal/Installation...................................................................
Secondary Fuel Injector Audible Inspection......................................................................
Secondary Fuel Injector Resistance Inspection................................................................
Secondary Fuel Injector Power Source Voltage Inspection ..............................................
Secondary Fuel Injector Output Voltage Inspection..........................................................
Secondary Fuel Injector Fuel Line Inspection...................................................................
17-56
17-59
17-59
17-59
17-60
17-60
17-60
17-61
17-62
17-65
17-65
17-65
17-68
17-68
17-68
17-69
17-70
17-72
17-72
17-72
17-73
17-73
17-74
17-74
17-76
17-76
17-76
17-78
17-78
17-80
17-80
17-80
17-81
17-82
17-83
17-83
17-83
17-83
17-83
17-85
17-86
17-89
17-89
17-89
17-90
17-90
17-90
17-91
17-91
17-91
17-91
17-92
17-93
17-95
SELF-DIAGNOSIS SYSTEM 17-3
Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353,
P0354) .................................................................................................................................
Stick Coil Removal/Installation..........................................................................................
Stick Coil Primary Winding Resistance Inspection ...........................................................
Stick Coil Input Voltage Inspection....................................................................................
Radiator Fan Relay (Service Code 56) (DTC P0480) ............................................................
Radiator Fan Relay Removal/Installation..........................................................................
Radiator Fan Relay Inspection..........................................................................................
ETV Actuator (Service Code 58) (DTC P2100) ......................................................................
ETV Actuator Removal .....................................................................................................
ETV Actuator Input Voltage Inspection .............................................................................
ETV Actuator Relay Inspection .........................................................................................
Exhaust Butterfly Valve Actuator (Service Code 63) (DTC P0475) ........................................
Exhaust Butterfly Valve Actuator Removal .......................................................................
Exhaust Butterfly Valve Actuator Installation ....................................................................
Exhaust Butterfly Valve Actuator Inspection .....................................................................
Exhaust Butterfly Valve Actuator Resistance Inspection ..................................................
Air Switching Valve (Service Code 64) (DTC P0410).............................................................
Air Switching Valve Removal/Installation ..........................................................................
Air Switching Valve Inspection ..........................................................................................
Oxygen Sensor Heater (Service Code 67) (DTC P0030).......................................................
Oxygen Sensor Heater Removal/Installation ....................................................................
Oxygen Sensor Heater Resistance Inspection .................................................................
Oxygen Sensor Heater Power Source Voltage Inspection ...............................................
Fuel Supply System (Service Code 94) (DTC P0170) ...........................................................
Fuel Supply System Inspection.........................................................................................
Battery Voltage (Service Code 97) (DTC P0562) ...................................................................
Battery Voltage Inspection ................................................................................................
ETV Control Circuit (Service Code 98) (DTC P0607).............................................................
ETV Control Circuit Inspection..........................................................................................
ESD Actuator Error (Service Code E2E) ................................................................................
ESD Actuator Removal .....................................................................................................
ESD Actuator Installation ..................................................................................................
ESD Actuator Resistance Inspection ................................................................................
ESD Actuator Input Voltage Inspection.............................................................................
ESD ECU Error (Service Code E3B)......................................................................................
ESD ECU Removal...........................................................................................................
ESD ECU Installation........................................................................................................
ESD ECU Power Supply Inspection .................................................................................
ESD Calibration Error (Service Code E3F) ............................................................................
IMU (Inertial Measurement Unit) (Service Code E8E)............................................................
IMU Removal ....................................................................................................................
IMU Installation .................................................................................................................
IMU Power Supply Inspection...........................................................................................
IMU (Inertial Measurement Unit) Communication Error (Service Code E8F).........................
IMU Communication Line Inspection ................................................................................
ABS Service Codes (ZX1000S/Z) ..........................................................................................
Solenoid Valve Inspection (Service Code B13, B14, B17, B18) .......................................
ABS Solenoid Valve Relay Inspection (Service Code B19) ..............................................
Front, Rear Wheel Rotation Difference Abnormal Inspection (Service Code B25)...........
ABS Motor Relay Inspection (Service Code B35).............................................................
Front Wheel Rotation Sensor Signal Abnormal (Service Code B42)................................
Front Wheel Rotation Sensor Wiring Inspection (Service Code B43)...............................
Rear Wheel Rotation Sensor Signal Abnormal (Service Code B44) ................................
Rear Wheel Rotation Sensor Wiring Inspection (Service Code B45) ...............................
Power Supply Voltage Inspection (Low-Voltage) (Service Code B52)..............................
Power Supply Voltage Inspection (Over-Voltage) (Service Code B53).............................
17-97
17-97
17-97
17-97
17-99
17-99
17-99
17-101
17-101
17-101
17-102
17-103
17-103
17-103
17-103
17-103
17-105
17-105
17-105
17-106
17-106
17-106
17-106
17-109
17-109
17-110
17-110
17-111
17-111
17-112
17-112
17-112
17-112
17-112
17-114
17-114
17-114
17-114
17-116
17-117
17-117
17-117
17-117
17-119
17-119
17-121
17-121
17-121
17-121
17-121
17-122
17-123
17-123
17-124
17-124
17-125
17-4 SELF-DIAGNOSIS SYSTEM
ECU Inspection (Service Code B55).................................................................................
CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code
B57) CAN Communication (Reception) Monitor Inspection (Service Code B58)...........
ECU Communication Line Inspection (Service Code B62)...............................................
IMU Communication Line Inspection (Service Code B63)................................................
Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code B83) .......
Output Fluid Pressure Sensor (Front Brake) Offset Abnormal (Service Code B84) .........
Fluid Pressure Sensor Supply Voltage Inspection (Service Code B89)............................
IMU Inspection (Service Code B94)..................................................................................
17-125
17-125
17-126
17-127
17-127
17-127
17-128
17-128
SELF-DIAGNOSIS SYSTEM 17-5
Specifications
Item
Throttle Position Sensor:
Input Voltage
Output Voltage (1)
Output Voltage (2)
Intake Air Pressure Sensor #1/#2
Input Voltage
Output Voltage
Intake Air Temperature Sensor:
Output Voltage
Resistance
Water Temperature Sensor:
Output Voltage
Accelerator Position Sensor:
Input Voltage
Output Voltage (1)
Output Voltage (2)
Resistance
Gear Position Sensor:
Input Voltage
Output Voltage
Vehicle-down Sensor:
Input Voltage
Output Voltage
Oxygen Sensor:
Output Voltage (Rich)
Output Voltage (Lean)
Heater Resistance
Exhaust Butterfly Valve Actuator
Sensor:
Input Voltage
Output Voltage
Resistance
Immobilizer Antenna (Equipped
Models):
Resistance
Purge Valve (Other than US and
CA Models):
Resistance
Standard
DC 4.75 5.25 V
DC 1.20 1.60 V at full throttle opening (for reference)
DC 3.40 3.80 V at full throttle opening (for reference)
DC 4.75 5.25 V
DC 3.80 4.20 V at standard atmospheric pressure (101.32
kPa, 76 cmHg)
About DC 2.25 2.50 V @20°C (68°F)
5.4 6.6 kΩ @0°C (32°F)
0.29 0.39 kΩ @80°C (176°F)
About DC 2.80 2.97 V @20°C (68°F)
DC 4.75 5.25 V
DC 0.50 0.90 V at ordinary throttle position
DC 0.35 1.00 V at ordinary throttle position
4.5 6.5 kΩ
DC 4.75 5.25 V
In the text
DC 4.75 5.25 V
With sensor tilted 60 70° or more right or left: DC 0.65
1.35 V
With sensor arrow mark pointed up: DC 3.55 4.45 V
DC 0.8 V or more
DC 0.24 V or less
13 17 Ω @20°C (68°F)
DC 4.75 5.25 V
DC 3.46 3.76 V at pulley original position
4 6 kΩ
About 3.0 4.6 Ω
30 34 Ω @20°C (68°F)
17-6 SELF-DIAGNOSIS SYSTEM
Specifications
Item
Quick Shifter Sensor:
Input Voltage
Output Voltage
Resistance
Primary/Secondary Fuel Injectors:
Type
Nozzle Type
Resistance
ETV Actuator:
Input Voltage
Exhaust Butterfly Valve Actuator:
Resistance
ESD Actuator:
Input Voltage
Resistance
IMU:
Input Voltage
ABS (ZX1000S/Z)
ABS Hydraulic Unit:
Make
Wheel Rotation Sensor Air Gap:
Front
Rear
CAN Communication Line
Resistance
CAN Communication Line/Ground
Resistance
Standard
DC 4.75 5.25 V
DC 0.35 4.65 V
209 231 kΩ
EAT803
Fine atomizing type with 12 holes
About 11.7 12.3 Ω @20°C (68°F)
About DC 1 2 V or –1 –2 V
5 200 Ω (for reference)
About DC 9 11 V and then 0.1 V or About DC 9 11 V
About 23 29 Ω
Battery voltage
BOSCH
0.4 1.6 mm (0.02 0.06 in.)
0.4 1.6 mm (0.02 0.06 in.)
30 70 Ω
4 30 kΩ
SELF-DIAGNOSIS SYSTEM 17-7
Special Tools
Fork Oil Level Gauge:
57001-1290
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TSB/Document ID: 99924-1509-03
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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