MOTORCYCLE

DATE: Dec., 17, 2003

PAGE: 1 OF 26

SUBJECT: SERVICE INFORMATION

APPLICABLE MODEL:DL1000K4
EFFECTIVE ENGINE OR FRAME NO.:
REFERENCE: E-02, 03, 19, 24, 28, 33

This bulletin is to inform you of the service information for the DL1000K4 model. Please use
the following service manual along with the information contained in this bulletin for proper
servicing.

DL1000 SERVICE MANUAL: 99500-39230-01E

99500-39231-03E
99500-39231-01F
99500-39230-01G
99500-39230-01B

We hope that this information will be useful in your service activities.

CONTENTS
PAGE
SPECIFICATIONS.................................................................................... 2
SERVICE DATA ....................................................................................... 3
SPECIAL TOOL ....................................................................................... 12
PERIODIC MAINTENANCE CHART ....................................................... 13
ENGINE INSTALLATION......................................................................... 14
FI SYSTEM............................................................................................... 15
COMBINATION METER .......................................................................... 16
WIRE HARNESS ROUTING .................................................................... 22
COWLING SETUP ................................................................................... 24
WIRING DIAGRAM .................................................................................. 25

NOTE:
Asterisk mark (*) indicated the New K4 model specifications.
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 295 mm (90.4 in)
Overall width........................................................................................* 910 mm (35.8 in)
Overall height ......................................................................................* 1 395 mm (54.9 in)
Wheelbase .......................................................................................... 1 535 mm (60.4 in)
Ground clearance................................................................................ 165 mm (6.5 in)
Seat height .......................................................................................... 840 mm (33.1 in)
Dry mass .............................................................................................* 208 kg (458 lbs)
* 210 kg (462 lbs) ..... E33

ENGINE
Type..................................................................................................... 4-stroke, Liquid-cooled, DOHC, 90° degree V-twin
Number of cylinders ............................................................................ 2
Bore..................................................................................................... 98.0 mm (3.858 in)
Stroke .................................................................................................. 66.0 mm (2.598 in)
Displacement ...................................................................................... 996 cm 3 (60.8 cu. in)
Compression ratio ............................................................................... 11.3 : 1
Fuel system ......................................................................................... Fuel injection system
Air cleaner ........................................................................................... Non-woven fabric element
Starter system ..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed............................................................................................ 1 200 ± 100 r/min

DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................ 1-down, 5-up
Primary reduction ratio ........................................................................ 1.838 (57/31)
Gear ratios, Low ................................................................................ 3.000 (36/12)
2nd ................................................................................ 1.933 (29/15)
3rd ................................................................................. 1.500 (27/18)
4th ................................................................................. 1.227 (27/22)
5th ................................................................................. 1.086 (25/23)
Top................................................................................. 0.913 (21/23)
Final reduction ratio............................................................................. 2.411 (41/17)
Drive chain .......................................................................................... RK525 SMOZ7, 112 links

CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front suspension stroke ...................................................................... 160 mm (6.3 in)
Rear wheel travel ................................................................................ 159 mm (6.3 in)
Caster.................................................................................................. 26° 30’
Trail...................................................................................................... 111 mm (4.4 in)
Steering angle ..................................................................................... 40° (right & left)
Turning radius...................................................................................... 2.7 m (8.86 ft)
Front brake .......................................................................................... Disk brake, twin
Rear brake........................................................................................... Disk brake
Front tire size....................................................................................... 110/80 R19M/C 59H, tubeless
Rear tire size ....................................................................................... 150/70 R17M/C 69H, tubeless

ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 4° B.T.D.C. at 1 200 r/min
Spark plug ........................................................................................... NGK CR8EK or DENSO U24ETR
Battery................................................................................................. 12V 43.2 kC (12Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse............................................................................................. 30A
Fuse ....................................................................................................* 10/10/15/15/15/15A
Headlight ............................................................................................. 12V 60/55W × 2 (H4 × 2)
Position/Parking light ........................................................................... 12V 5W × 2 Except E-03, 24, 28, 33
Brake light/Taillight .............................................................................. 12V 21/5W × 2
License plate light ............................................................................... 12V 5W
Turn signal /Hazard light......................................................................* 12V 21W
Speedometer light ............................................................................... LED
Tachometer light .................................................................................. LED
Turn signal indicator light..................................................................... LED
Neutral indicator light........................................................................... LED
High beam indicator light..................................................................... LED
Fuel injection warning light.................................................................. LED
(Coolant temperature, Oil pressure)

CAPACITIES
Fuel tank ............................................................................................. 22 L (5.81/4.84 US/Imp gal)
Engine oil, oil change......................................................................... 2 700 ml (2.9/2.4 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul............................................................................ 3 300 ml (3.5/2.9 US/Imp qt)
Coolant................................................................................................ 2.2 L (2.3/1.9 US/Imp qt)

–2–
SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 36 —
(1.42)
EX. 33 —
(1.30)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem clear- IN. 0.010 – 0.037 —
ance (0.0004 – 0.0015)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
Valve guide I.D. IN. & EX. 5.500 – 5.512 —
(0.2165 – 0.2170)
Valve stem O.D. IN. 5.475 – 5.490 —
(0.2156 – 0.2161)
EX. 5.455 – 5.470 —
(0.2148 – 0.2154)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length IN. & EX. — 39.6
(1.56)
Valve spring tension 197 – 227 N
IN. & EX. (20.1 – 23.1 kgf, 44.3 – 51.0 lbs) —
at length 35.6 mm (1.40 in)

–3–
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height IN. 36.28 – 36.32 35.98
(1.428 – 1.430) (1.417)
EX. 35.68 – 35.72 35.38
(1.405 – 1.406) (1.393)
Camshaft journal oil clearance IN. & EX. 0.019 – 0.053 0.150
(0.0007 – 0.0021) (0.0059)
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —
(0.8666 – 0.8671)
Camshaft journal O.D. IN. & EX. 21.972 – 21.993 —
(0.8650 – 0.8659)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam drive idle gear/sprocket 0.15 – 0.29 —
thrust clearance (0.006 – 0.011)
Cylinder head distortion — 0.05
(0.002)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 000 – 1 400 kPa 800 kPa
(Automatic de-comp. actuated) (10 – 14 kgf/cm², 142 – 199 psi) (8 kgf/cm²,
114 psi)
Compression pressure differ- — 200 kPa
ence (2 kgf/cm², 28 psi)
Piston to cylinder clearance 0.015 – 0.025 0.12
(0.0006 – 0.0010) (0.0047)
Cylinder bore 98.000 – 98.015 Nicks or
(3.8583 – 3.8589) Scratches
Piston diam. 97.980 – 97.995 97.880
(3.8575 – 3.8581) (3.8535)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion — 0.05
(0.002)
Piston ring free end gap 1st Approx. 8.8 (0.35) 7.0
(0.28)
2nd Approx. 10.1 (0.40) 8.1
(0.32)
Piston ring end gap 1st 0.15 – 0.35 0.5
(0.006 – 0.014) (0.02)
2nd RN 0.30 – 0.45 0.7
(0.012 – 0.018) (0.03)
Piston ring to groove clearance 1st — 0.18
(0.0071)
2nd — 0.15
(0.0059)

–4–
 ITEM STANDARD LIMIT
Piston ring groove width 0.93 – 0.95 —
(0.0366 – 0.0374)
1st
1.55 – 1.57 —
(0.0610 – 0.0618)
2nd 1.01 – 1.03 —
(0.0398 – 0.0406)
Oil 2.51 – 2.53 —
(0.0988 – 0.0996)
Piston ring thickness 0.86 – 0.91 —
(0.034 – 0.036)
1st
1.38 – 1.40 —
(0.054 – 0.055)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore I.D. 22.002 – 22.008 22.030
(0.8662 – 0.8665) (0.8673)
Piston pin O.D. 21.992 – 22.000 21.980
(0.8658 – 0.8661) (0.8654)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 22.010 – 22.018 22.040
(0.8665 – 0.8668) (0.8677)
Conrod big end side clearance 0.17 – 0.32 0.50
(0.007 – 0.013) (0.020)
Conrod big end width 21.95 – 22.00 —
(0.864 – 0.866)
Crank pin width 44.17 – 44.22 —
(1.739 – 1.741)
Conrod big end oil clearance 0.040 – 0.064 0.080
(0.0016 – 0.0025) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.002 – 0.029 0.080
(0.0008 – 0.0011) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft journal holder width 25.2 – 25.4
(0.99 – 1.00) —
Crankshaft journal width 25.50 – 25.55
(1.004 – 1.006) —
Crankshaft runout — 0.05
(0.004)

–5–
OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60°C, 140°F) Above 400 kPa (4.0 kgf/cm², 57 psi)
Below 700 kPa (7.0 kgf/cm², 100 psi) —
at 3 000 r/min

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness No.1 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
No.2 and 3 3.72 – 3.88 3.42
(0.146 – 0.153) (0.135)
Drive plate claw width No.1 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
No.2 and 3 13.90 – 14.00 13.10
(0.547 – 0.551) (0.516)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 61.5 – 62.5 59.4
(2.42 – 2.46) (2.34)
Clutch master cylinder bore 14.000 – 14.043 —
(0.5512 – 0.5528)
Clutch master cylinder piston 13.957 – 13.984 —
diam. (0.5495 – 0.5505)
Clutch release cylinder bore 35.700 – 35.762 —
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675 —
diam. (1.4035 – 1.4045)

THERMOSTAT + RADIATOR + FAN

ITEM STANDARD LIMIT
Thermostat valve opening tem- 86.5 – 89.5 °C —
perature (188 – 193 °F)
Thermostat valve lift Over 8 mm (0.31 in) at 100 °C (212 °F) —
Radiator cap valve opening 110 kPa (1.1 kgf/cm², 15.6 psi) —
pressure
Cooling fan ther- ON→OFF Approx. 105 °C (221 °F) —
moswitch operating
temperature ON→OFF Approx. 100 °C (212 °F) —
Engine coolant tem- 20 °C Approx. 2.45 kΩ —
perature sensor (68 °F)
resistance 40 °C
(104 °F) Approx. 1.148 kΩ —
60 °C Approx. 0.587 kΩ —
(140 °F)
80 °C Approx. 0.322 kΩ —
(176 °F)

–6–
DRIVE TRAIN Unit: mm (in) Expect ratio
ITEM STANDARD LIMIT
Primary reduction ratio 1.838 (57/31) —
Final reduction ratio 2.411 (41/17) —
Gear ratio Low 3.000 (36/12) —
2nd 1.933 (29/15) —
3rd 1.500 (27/18) —
4th 1.227 (27/22) —
5th 1.086 (25/23) —
Top 0.913 (21/23) —
Shift fork to groove clearance 0.1 – 0.3 0.50
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1 —
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9 —
(0.189 – 0.193)
Drive chain Type RK525SMOZ7 —
Links 112 links, ENDLESS —
20-pitch length — 319.4
(12.6)
Drive chain slack 20 – 30 —
(0.8 – 1.2)
Gearshift lever height 25 —
(1.0)

INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR

ITEM SPECIFICATION NOTE
Injector resistance 12 – 18 Ω at 20 °C (68 °F)
Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/lmp qt)
for 1 minute at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operat- Approx. 300 kPa (3.0 kgf/cm², 43 psi)
ing set pressure

–7–
FI-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor output voltage More than 3.7 V
CKP sensor resistance 130 – 240 Ω
CKP sensor peak voltage More than 3.7 V (When cranking)
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.5 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.3 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor reisitance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input volatage 4.5 – 5.5 V
IAT sensor resistance Approx 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 4.0 V at 760 mmHg (100kPa)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage Approx. 0.4 – 1.4 V
GP switch voltage More than 1.0 V (From 1st to top)
Injector voltage Battery voltage
Ignition coil primary peak volt- More than 150 V (When cranking)
age
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.3 kΩ
STP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
STV actuator resistance 4.8 – 7.2 Ω
Heated oxygen sensor output Less than 0.4 V at idle speed
voltage (After warming up)
Heated oxygen sensor resis- European
tance 4 – 5 Ω at 23 °C (73.4 °F) markets
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)

THROTTLE BODY
ITEM SPECIFICATION
ID No. * 06G3 (For E-02, 19), 06G4 (For E-33), 06G5 (For E-03, 24, 28)
Bore size 45 mm
Fast idle r/min 1 500 – 2 100 r/min at 25 °C (77 °F)
Idle r/min 1 200 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 r/min
(0.08 – 0.16 in)

–8–
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Ignition timing 4° B.T.D.C. at 1 200 r/min
Firing order 1·2
Spark plug Type NGK: CR8EK
Denso: U24ETR
Gap 0.6 – 0.7
(0.024 – 0.028)
Spark performance Over 8 (0.3) at 1 atm.
Crankshaft position sensor 130 – 240 Ω Bl – G
resistance
Ignition coil resistance Primary 2–5Ω + tap – - tap
Secondary 24 – 37 kΩ + tap – Plug cap
Crankshaft position sensor peak More than 3.7 V When cranking
voltage
Ignition coil primary peak volt- More than 150 V When cranking
age
Generator coil resistance 0.2 – 0.5 Ω Y–Y
Generator Max. output Approx. 400 W at 5 000 r/min
Generator no-load voltage More than 75 V (AC) at 5 000 r/min
(When engine is cold)
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size HI 15 A
Headlight
LO 15 A
Turn signal 15 A
Ignition * 10 A
Fan motor 15 A
Meter 10 A
Main 30 A

–9–
WATTAGE Unit: W
SPECIFICATION
ITEM
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light * 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./Fuel injection warning LED ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 20 – 30 —
(0.8 – 1.2)
Brake disc thickness
Front 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)
Rear 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)
Brake disc runout
— 0.30
(Front & Rear) (0.012)
Master cylinder bore Front 15.870 – 15.913 —
(0.6248 – 0.6265)
Rear 14.000 – 14.043 —
(0.5512 – 0.5529)
Master cylinder piston diam. Front 15.827 – 15.854 —
(0.6231 – 0.6242)
Rear 13.957 – 13.984 —
(0.5495 – 0.5506)
Brake caliper cylinder bore
Front 30.230 – 30.306 —
(1.1902 – 1.1931)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
Brake caliper piston diam.
Front 30.150 – 30.200 —
(1.1870 – 1.1890)
Rear 38.098 – 38.148 —
(1.4999 – 1.5019)
Wheel rim runout 2.0
(Front & Rear) Axial — (0.08)
Radial — 2.0
(0.08)

– 10 –
 ITEM STANDARD LIMIT
Wheel axle runout
Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 19M/C × MT 2.50 —
Rear 17M/C × MT 4.00 —
Tire size Front 110/80R19M/C 59H —
Rear 150/70R17M/C 69H —
Tire type Front BRIDGESTONE: TW101 F —
Rear BRIDGESTONE: TW152 F —
Tire tread depth Front — 1.6
(0.06)
Rear — 2.0
(0.08)

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 160 —
(6.3)
Front fork spring free length 433.6 424
(17.07) (16.7)
Front fork oil level (without spring, 140.0 —
inner tube fully compressed) (5.51)
Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil
Front fork oil capacity (each leg) 496.0 ml
(16.76/17.46 US/lmp oz)
Front fork spring adjuster 3rd groove from top —
Rear shock absorber spring 2nd groove from bottom —
adjuster
Rear shock absorber damping Rebound 7/8 turn out from stiffest position —
force adjuster
Rear wheel travel 159 —
(6.3)
Swingarm pivot shaft runput — 0.3
(0.01)

TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kgf/cm² psi kPa kgf/cm² psi
FRONT 250 2.50 36 250 2.50 36
REAR 250 2.50 36 280 2.80 41

– 11 –
FUEL + OIL + ENGINE COOLANT
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by the
research method. Gasoline containing MTBE (Methyl
E-03, 28, 33
Tertiary Butyl Ether), less than 10% ethanol, or less
than 5% methanol with appropriate cosolvents and
corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or higher.
The others
An unleaded gasoline is recommended.
Fuel tank 17 L
(4.5/3.7 US/lmp gal)
Engine oil type SAE 10W-40, API SF or SG
Engine oil capacity Change 2 700 ml
(2.9/2.4 US/lmp qt)
Filter change 2 900 ml
(3.1/2.6 US/lmp qt)
Overhaul 3 300 ml
(3.5/2.9 US/lmp qt)
Brake fluid type DOT 4
Engine coolant type Use an anti-freeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio of
50:50.
Engien coolant Reserve tank Approx. 250 ml
side (0.3/0.2 US/lmp qt)

Engine side Approx. 1 950 ml

(2.1/1.7 US/lmp qt)

SPECIAL TOOL

09930-82720
Mode select switch

– 12 –
PERIODIC MAINTENANCE CHART
Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 2 12 24 36 48
Air cleaner element — I I R I
Exhaust pipe bolts and muffler bolts T — T — T
Valve clearance — — — — I
Spark plugs — I R I R
Fuel hose — I I I I
Replace every 4 years
Engine oil R R R R R
Engine oil filter R — — R —
Idle speed I I I I I
Throttle cable play I I I I I
Throttle valve synchronization I — I — I
(E-33 only)
Evaporative emission control system — — I — I
(E-33 only) Replace vapor hose every 4 years
PAIR(air supply)system — — I — I
Engine coolant Replace every 2 years.
Radiator hose — I I I I
Clutch hose — I I I I
Replace every 4 years
Clutch fluid — I I I I
Replace every 2 years
Drive chain I I I I I
Clean and lublicate every 1 000 km (600 miles)
Brakes I I I I I
Brake hose — I I I I
Replace every 4 years
Brake fluid — I I I I
Replace every 2 years
Tires — I I I I
Steering I — I — I
Front fork — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T T T T T
NOTE:
I=Inspect and clean, adjust, replace or lubricate as necessary;
R=Replace; T=Tighten

– 13 –
ENGINE INSTALLATION
Remount the engine in the reverse order of engine removal.
Pay attention to the following points:
NOTE:
* The engine mounting nuts are self-locking.
* Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them
to the specified torque.

LH RH

D
FW

RH ITEM N·m kgf-m lb-ft

LH
ABDE 55 5.5 40.0
JKL 23 2.3 16.5
FH 12 1.2 8.5
GI 45 4.5 32.5
C 75 7.5 54.0

– 14 –
FI SYSTEM
• ECM terminals have been change is as following.
• To inspect the sensors according to the FI malfunction codes,
refer to the following. (DL1000 service manual !4-32 to 4-50)
" 09930-82720: Mode select switch
DL1000K3 model

DL1000K4 model

1 Ignition coil #1 F PM U GP
2 Ignition coil #2 G PA V FP
3 Ground H CLT W AT
4 Tachometer I TPS X E2
5 Fuel injector #1 J MO+ Y Ground
6 Fuel injector #2 K STA Z THW
7 SOL L MO– [ TECH
8 HO2 (OXH) M — \ —
9 — N HO2 (OX) ] TS
0 VCC O Ground ^ NT
A — P N+ a DON
B G+ Q — b —
C Ground R VM c —
D THA S — d STPS
E +B T N–

– 15 –
COMBINATION METER
REMOVAL AND DISASSEMBLY
• Disconnect the battery - lead wire.
• Remove the combination meter panel.
• Remove the combination meter 1.
#
When disconnecting and connecting the combination
meter coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.

• Disassemble the combination meter as follows.

#
Do not attempt to disassemble the combination meter
unit.

1 Combination meter cover

2 Combination meter unit

– 16 –
INSPECTION
LED (LIGHT EMITTING DIODE)
Check that the LED lights immediately after turning the ignition switch on.
If the LED fails in operation, replace the combination meter unit with a new one after checking its wire har-
ness/coupler.
STEPPING MOTOR
Check that the pointer calibrates itself immediately after turning the ignition switch on and stops at starting
point.
If abnormal condition is found, replace the combination meter unit with a new one after checking its wire har-
ness/coupler.

NOTE:
The pointer may not return to the proper position even turning the ignition switch on under low temperature
condition. In that case, you can reset the pointer to the proper position by following the instruction below:
1) With the ADJ switch A pressed, turn the ignition switch on.
2) Keep pushing the ADJ switch A for 3 to 5 seconds.
3) Push the ADJ switch A twice (within 1 second). → Reset
* Complete the operation within 10 seconds after the ignition switch has been turned on.

Time Ignition switch ADJ switch

OFF PUSH
0 ON
•
•
3 sec
•
5 sec Release
• Push
•
• Push → Reset
•
10 sec ADJ SWITCH

Pointer will return to the starting point right after the completion of the operation. In the case of the pointer
not returning to the proper position after doing above, replace the combination meter unit.

– 17 –
ODOMETER
The odometer indicates “------” when the odometer is faulty.
Replace the combination meter unit with a new one.

TRIP METER
The trip meter indicates “----.-” when the trip meter is faulty.
In case the odometer works normaly, perform the trip meter
reset. If the trip meter isn’t restored after above reset, replace
the combination meter unit with a new one.

TRIP METER RESET PROCEDURE

1. Turn the ignition “ON”.
2. Select the trip meter by pushing the SEL switch A.
3. Push the ADJ switch B for 2 seconds.

– 18 –
INDICATORS
ENGINE COOLANT TEMPERATURE METER INSPECTION
• Disconnect the ECT sensor coupler 1.
#
When connecting and disconnecting the ECT sensor
lead wire coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.

• Connect the variable resistor A between the terminals.

• Turn the ignition switch “ON”.
• Check the display of engine coolant temperature meter as
shown below. If any abnormality is found, replace the combi-
nation meter with a new one.
A Variable resister
B ECT sensor

Water temperateure 39 ˚C and below 40 – 59 ˚C 60 – 79 ˚C 80 – 111 ˚C

1.148 kΩ
Resistance 1.148 – 0.587 kΩ 0.587 – 0.188 kΩ 0.188 – 0.140 kΩ
and more

Engine coolant
temperature meter

Water temperateure 112 – 119 ˚C 120 ˚C and over 122 ˚C and over
0.116 kΩ 0.111 kΩ
Resistance 0.140 – 0.116 kΩ
and less and less

Engine coolant
temperature meter

– 19 –
FUEL LEVEL GAUGE INSPECTION
• Remove the fuel tank. (!4-52)
• Remove the fuel pump. (!4-55)

Measure the resistance at each fuel level gauge float position. If

the resistance is incorrect, replace the fuel level gauge with a
new one.

Float position Resistance

A “F” (Full) Approx. 4 Ω
B “E” (Empty) Approx. 182 Ω

" 09900-25008: Multi circuit tester set

$Tester knob indication: Resistance (Ω
Ω)

• Install the fuel pump. (!4-58)

– 20 –
FUEL LEVEL METER INSPECTION
• Remove the fuel tank left side cover.
• Disconnect the fuel pump lead wire coupler.

• Connect the each resistor between the Yellow/Black and

Black/White lead wires at the wire harness.
• Turn the ignition switch “ON” position and wait for approx. 40
seconds.
Check the display of fuel meter as shown below, If any abnor-
mality is found, replace the combination meter with a new one.

More than 6.5 Ω

Resistance 87.5 – 167.0 Ω 50.0 – 87.5 Ω 26.0 – 50.0 Ω 6.5 – 26.0 Ω
167.0 Ω and less

Fuel level
meter

– 21 –
 Handlebar switch coupler (R) HO2 sensor coupler
Ignition switch coupler ECT sensor
CMP sensor Fuse box
ECM FP relay
Clamp TO sensor

Clamp

AP sensor
Handlebar switch Clamp
coupler (L) Clamp Starter relay
STPS coupler Speed sensor Fuel pump coupler Seat lock cable
coupler
Injector coupler
WIRE HARNESS ROUTING

Starter relay
Fuse box
Handlebar switch (L) Throttle cables
lead wires

– 22 –
Fixed clamp
Clamp Clamp

Regulator/rectifier

Clamp
Fixed clamp

Ignition coil

Clamp
 Clamp

IAT sensor

IAP sensor

CMP sensor

Fixed clamp

Fixed clamp

HO2 sensor

Clamp

Fixed clamp

Clamp

Headlight

– 23 –
COWLING SETUP

1 Screen
2 Cowling brace
3 Combination meter panel
4 Cowling body
5 Right cowling
6 Left cowling
7 Left side cowling
8 Right side cowling
9 Inner cowling
0 Engine under cover
A Cowling brace mounting bolt

@
ITEM N·m kgf-m lb-ft
A 35 3.5 25.5

– 24 –
WIRING DIAGRAM
E-02, 19
ENGINE
STOP FRONT BRAKE
SWITCH SWITCH OIL PRESSURE
OFF OFF SWITCH
(OPTIONAL PARTS) RUN ON
STARTER
GRIP HEATER IGNITION SWITCH SWITCH OFF
ON
ON
OFF PUSH FUEL PUMP REAR BRAKE
SP : SPEEDOMETER LIGHT
TA
LOCK O2 SENSOR SWITCH
: TACHOMETER LIGHT P
FUEL ECM

B
N : NEUTRAL INDICATOR LIGHT SPEEDOMETER ON
M
PUMP TO
SENSOR AP
OFF
H : HIGH BEAM INDICATOR LIGHT IGNITION IGNITION RELAY

B/W
O/Y
SENSOR

Or
Br

O/W

B/Bl
O

O/B
R

B/R

Y/G

W/B
O : OIL PRESSURE INDICATOR LIGHT

B/Lg
B/W
COIL #1 COIL #2

Y/R
Gr
W

O
B
IL L R IL
R : TURN SIGNAL INDICATOR LIGHT(R)
SP FI W TA
L : TURN SIGNAL INDICATOR LIGHT(L)
FI : FI INDICATIOR LIGHT OD O
OD

Gr/W
Br/W
: OD INDICATOR LIGHT

Br/W
W/Bl

Bl/W

W/Bl
Gr/R

Gr/B

Bl/W
B/Br

Br/R
Br/B

Gr/R
B/Br

B/Br

Bl/G

G/Bl
O/Bl
B/Br

B/Br
O/W

W/G

Bl/B

B/Bl

Bl/R

Bl/G
B/W

O/W

W/G

B/W

O/W
O/W

R/W
B/W

Bl/Y

W/R

W/B
B/W

B/W

B/W

Bl/B

Bl/R
W/B

R/W
W/B

Y/W

P/W
W/B

Bl/Y
O/G

W/R

B/W
O/R

B/O
O/G

O/R

G/B
O/B

B/G
O/G

O/G
B/W

O/B

G/Y

R/B

B/R

Y/G
G/Y

Y/R

Y/B
Y/G

Y/R

B/Y

Y/B
G/Y
Y/B

Y/R
O/G

Dg
Br

Br
Bl
N H

G
O
R

B
R

P
R

R
W : ECT INDICATOR LIGHT

Br/B

Bl/B
R/W

B/W
P/W

O/G
B/G

O/R

G/Y

Y/B
Lg
B

FRONT TURN SIGNAL LIGHT (R)

B Lg
B/W B/W

POSITION LIGHT (R) Br/B Br/B

Br Br G/Y G/Y
B/W B/W P/W P/W
O/R O/R
REAR TURN SIGNAL LIGHT (R)
Lg
R/W R/W B/W
Y B/G B/G
HEADLIGHT (R) B/W Y/B Y/B Gr
B/Bl O/G O/G B/W
Bl/B Bl/B W/B
Lg
BRAKE LIGHT/
Y TAILLIGHT
HEADLIGHT (L) B/W Lg Lg Br Gr
B/Bl B/W B/W B/W B/W
Y Y W/B W/B
B
Br Br
Gr LICENSE
Br Br B B B/W LIGHT
B/W B/W B/Bl W
B/W
POSITION LIGHT (L) B
B B
B/W
REAR TURN SIGNAL LIGHT (L)
B/W

FRONT TURN SIGNAL LIGHT (L)

B/W
P/W
O/R
O/Bl
B/W

Gr/W
W/Bl

Gr/B

W/Bl

B/Br
B/Br

B/Br

B/Br

B/Br

G/Bl
B/W
B/Bl

O/Bl
O/W

B/W

R/W
Bl/B
Y/W

B/W

R/W

B/W
B/W
B/W

Y/Bl

B/W

Y/Bl
P/W

R/W

B/W
O/G
O/Y

Y/G
O/B

G/B

B/Y
O/Y

O/Y
Y/R
B/Y

B/R
R/B
Lbl

Lbl

Dg
Lg

Br

Bl

Br
Bl
W

G
G
O

B
B
B
B
B
P

R
O
R

R
B

Y
R

R
Y

B/W
O/G
B/R

P
Bl

HORN

B/W
B/W
B
B
B
R
R
B/W

Y/W
O/R

B/Y
B/Y
Lbl

B/R
Lg

B/W

B/W
W

Bl
B

Y
Y
Y
G
B/W
4 5 6 SPEEDOMETER
R
Y

Bl
1

P
ON
Gr/W
B
B

Gr/B

B/Br
P/W
Y/R

IAP SENSOR
R

OFF
STP
B/Bl

CMP SENSOR CKP

FAN MOTOR SENSOR SENSOR FREE
PUSH SENSOR REGULATOR/ STARTER 1:MAIN 30A
SWITCH FAN ECT 1 2 3 IAT
MOTOR STV SENSOR GEAR SENSOR RECTIFIER MOTOR STARTER BATTERY
ON FREE ACTUATOR POSITION SIDE STAND GENERATOR RELAY
PUSH OFF PUSH PAIR SWITCH SWITCH
FUSE BOX 1. HEAD HI 15A
HORN HAZARD PASSING CLUTCH SOLENOID 2. HEAD LO 15A
BUTTON SWITCH LIGHT LEVER 3. METER 10A
SWITCH POSITION 4. IGNITION 10A
5. SIGNAL 15A
L HI SWITCH 6. FAN 15A
PUSH LO
R
Gr/W

Gr/B
B/Br
P/W

Y/R

Y/R

DIMMER
R

TURN SIGNAL SWITCH

SWITCH

HANDLEBAR SWITCH (L)

TP
SENSOR
#1 #2
E-03, 24, 28, 33
HANDLEBAR SWITCH (R)

ENGINE
STOP FRONT BRAKE
SWITCH SWITCH
OFF OFF
(OPTIONAL PARTS) RUN STARTER ON
GRIP HEATER IGNITION SWITCH SWITCH
ON
OIL
PRESSURE
SP : SPEEDOMETER LIGHT OFF PUSH
SWITCH FUEL PUMP REAR BRAKE
LOCK SWITCH
TA : TACHOMETER LIGHT P
SPEEDOMETER OFF ON FUEL ECM
N : NEUTRAL INDICATOR LIGHT M
PUMP TO
ON OFF AP
H : HIGH BEAM INDICATOR LIGHT IGNITION IGNITION RELAY SENSOR SENSOR

B/W
O/Y

Or
Br

O/W

B/Bl
O

O/B
R

B/R

Y/G

B/Lg
B/W

W/B
O : OIL PRESSURE INDICATOR LIGHT

Y/R
COIL #1 COIL #2

O
IL L R IL
R : TURN SIGNAL INDICATOR LIGHT(R)
SP FI W TA
L : TURN SIGNAL INDICATOR LIGHT(L)
FI : FI INDICATIOR LIGHT OD O
OD : OD INDICATOR LIGHT

Gr/W
Br/W

Br/W
W/Bl

Bl/W
Bl/W

W/Bl

Gr/R
Br/R
Gr/R

Gr/B

B/Br
B/Br

O/Bl
B/Br

Br/B
B/Br

Bl/G
O/W

W/G

Bl/G

G/Bl
B/W

Bl/B

Bl/R

O/W
B/W

O/W
O/W

W/B
O/W

Bl/B

B/Bl

Bl/R

Bl/Y

W/R

B/W
R/W
W/B

W/B

R/W
B/W

Bl/Y

W/R

B/W

B/W
O/G

G/Y
O/Y

Y/W

P/W
O/R

B/O
O/G

O/B
O/G
B/W

O/B

O/R

G/B

B/G
Y/R

Y/B
Y/G

G/Y
G/Y

R/B

B/R

Y/G
Y/B

Y/R

Y/R

B/Y

Y/B
O/G

Dg
Br

Bl
N H

O
R

R
R

B
R

P
W : ECT INDICATOR LIGHT

Br/B

Bl/B
R/W

B/W
P/W

O/G
B/G

O/R

G/Y

Y/B
Lg
B

FRONT TURN SIGNAL LIGHT (R)

B Lg
B/W B/W

Br/B Br/B
G/Y G/Y
P/W P/W REAR TURN SIGNAL LIGHT (R)
O/R O/R Lg
R/W R/W B/W
Y B/G B/G
HEADLIGHT (R) B/W Y/B Y/B Gr
B/Bl O/G O/G B/W
Bl/B Bl/B W/B
Lg
BRAKE LIGHT/
Y TAILLIGHT
HEADLIGHT (L) B/W Lg Lg Br Gr
B/Bl B/W B/W B/W B/W
Y Y W/B W/B
B
B/Bl Br
Gr LICENSE
B B B/W LIGHT
B/Bl W
B/W
B
B B REAR TURN SIGNAL LIGHT (L)
B/W B/W

FRONT TURN SIGNAL LIGHT (L)

B/W
P/W
O/R
O/Bl
B/W

Gr/W
W/Bl

Gr/B

W/Bl

B/Br
B/Br

B/Br

B/Br

B/Br

G/Bl
B/W

O/Bl
B/Bl

B/W

R/W
Bl/B
Y/W

B/W

R/W

B/W
B/W
B/W

Y/Bl

B/W

Y/Bl
P/W

R/W

B/W
O/G
O/Y

Y/G
O/B

G/B

B/Y
O/Y

O/Y
Y/R
B/Y

B/R
R/B
Lbl

Lbl

Dg
Lg

Bl

Br
Bl
W

G
G
O

R
P

R
O

G
R

R
B

Y
R

R
Y

B/W
O/G
B/R

P
Bl

HORN

B/W
B/W
B
B
B
R
R
B/W

Y/W
O/R

B/Y
B/Y
Lbl

B/R
Lg

B/W

B/W
W

Bl
B

Y
Y
Y
G
B/W
4 5 6 SPEEDOMETER
R
Y

Bl
1

P
ON
Gr/W
Gr/B

B/Br
P/W
Y/R

IAP SENSOR
R

OFF
B/Bl

CAM STP SENSOR CKP

FAN MOTOR FAN SENSOR SENSOR FREE
PUSH SENSOR REGULATOR/ 1:MAIN 30A
SWITCH MOTOR ECT 1 2 3 IAT STARTER
STV SENSOR GEAR SENSOR RECTIFIER MOTOR STARTER BATTERY
ON FREE ACTUATOR POSITION SIDE STAND GENERATOR RELAY
PUSH OFF PUSH SWITCH FUSE BOX 1. HEAD HI 15A SWITCH
2. HEAD LO 15A
HORN HAZARD PASSING CLUTCH 3. METER 10A
BUTTON SWITCH LIGHT LEVER 4. IGNITION 10A
SWITCH POSITION 5. SIGNAL 15A
L HI SWITCH 6. FAN 15A
PUSH LO
R
Gr/W

Gr/B
B/Br
P/W

Y/R

Y/R

DIMMER
R

TURN SIGNAL SWITCH

SWITCH

HANDLEBAR SWITCH (L)

TP
SENSOR
#1 #2
INJECTOR