SUZUKI

SERVICE MANUAL
 TABLE OF CONTENTS
Precautions ............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Service Data........................................................... 0C-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Emission Control Devices ...................................... 1B-1
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System.......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 11-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension ................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis.............................. 2A-1
Front Suspension................................................... 2B-1
Rear Suspension.................................................... 2C-1
Wheels and Tires ................................................... 2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Chain/ Drive Train/ Drive Shaft ................... 3A-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis .................... 4A-1
Front Brakes........................................................... 48-1
Rear Brakes ........................................................... 4C-1
ABS ........................................................................ 4E-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Manual Transmission ............................................. 5B-1
Clutch ..................................................................... 5C-1
Steering ....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering/ Handlebar .............................................. 6B-1
Body and Accessories ............................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems.................................................... 9B-1
Combination Meter/ Fuel Meter/ Horn.................. 9C-1
Exterior Parts ......................................................... 90-1
Body Structure ....................................................... 9E-1
Control Systems....................................................... 10-i
Precautions ............................................................ 10-1
Cruise Control System .........................................10A-1
Immobilizer Control System .................................10C-1
Communication System .......................................10H-1
 Table of Contents 00- i

Section 00

Precautions
CONTENTS

Precautions ............................................... 00-1 Intermittent Malfunction Inspection ..................... 00-7

Precautions ........................................................... 00-1 Precautions for Circuit Tester .............................. 00-8
General Precautions ........................................... 00-1 Precautions for SDS-II ........................................ 00-9
Precautions for Catalytic Converter .................... 00-1 Precautions for Identification ............................... 00-9
Precautions for Electrical Circuit Service ............ 00-2
00-1 Precautions:
Precautions
Precautions
General Precautions
BENM1 0L30000001
• Proper service and repair procedures are
important for the safety of the service
mechanic and the safety and reliability of
the motorcycle.
• When 2 or more persons work together,
pay attention to the safety of each other.
• When it is necessary to run the engine
indoors, make sure that exhaust gas is
forced outdoors.
• When working with toxic or flammable
materials, make sure that the area you
work in is well ventilated and that you
follow all of the material manufacturer's
instructions.
• To avoid getting burned, do not touch the
engine, engine oil and exhaust system
until they have cooled.
NOTICE
• Never use gasoline as a cleaning solvent.
• After servicing the fuel, oil, exhaust or
brake systems, check all lines and fittings
related to the system for leaks.
• If parts replacement is necessary, replace
the parts with Suzuki Genuine Parts or
their equivalent.
• When removing parts that are to be reused,
keep them arranged in an orderly manner
so that they may be reinstalled in the
proper order and orientation.
• Be sure to use special tools when
instructed.
• Make sure that all parts used in
reassembly are clean. Lubricate them
when specified.
• Use the specified lubricant, bond, or
sealant.
• When removing the battery, disconnect the
negative(-) cable first and then the
positive(+) cable.
• When reconnecting the battery, connect
the positive(+) cable first and then the
negative(-) cable, and replace the terminal
cover on the positive(+) terminal.
• When performing service to electrical
parts, if the service procedures do not
require use of battery power, disconnect
the negative (-) cable from the battery.
• When tightening the cylinder head or case
bolts and nuts, tighten the larger sizes
first. Always tighten the bolts and nuts
diagonally from the inside toward outside
and to the specified tightening torque.
• Whenever you remove oil seals, gaskets,
packing, 0-rings, locking washers, self­
locking nuts, cotter pins, circlips and
certain other parts as specified, be sure to
replace them with new ones. Also, before
installing these new parts, be sure to
remove any left over material from the
mating surfaces.
• Never reuse a circlip. When installing a
new circlip, take care not to expand the
end gap larger than required to slip the
circlip over the shaft. After installing a
circlip, always ensure that it is completely
seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners
to the specified torque. Wipe off grease
and oil if a thread is smeared with them.
• After reassembling, check parts for
tightness and proper operation.
• To protect the environment, do not
unlawfully dispose of used motor oil and
other fluids: batteries, and tires.
• To protect Earth's natural resources,
properly dispose of used motorcycle and
parts.
Precautions for Catalytic Converter
BENM10L30000002
As this vehicle is equipped with a catalytic converter, use
only unleaded fuel and be careful not to let a large
amount of unburned fuel enter the converter, or it can be
damaged.
• Conduct a spark jump test only when necessary to the
shortest possible time without opening the throttle.
• Conduct engine compression checks within the
shortest possible time.
• Avoid any situations which can result in engine
misfire. (e.g. starting the engine when the fuel tank is
nearly empty.)
 Precautions: 00-2

Precautions for Electrical Circuit Service • Inspect each lead wire circuit for poor connection by
BENM10L30000003
shaking it by hand lightly. If any abnormal condition is
When handling the electrical parts or servicing the
found, repair or replace.
electric system, observe the following points for the
safety of the system.

Electrical Parts
Connector I Coupler
• Faulty electrical system is often related to poor
electrical contact of connector/coupler. Before
servicing individual electrical part, check electrical
contact of the connector/coupler.
• When connecting a connector, be sure to push it in
until a click is felt.
131OG1000003-02

• When taking measurements at electrical coupler (1)

using a tester probe (2), be sure to insert the probe
from the wire harness side (rear) of the coupler.

I310G1000001-01

• With a lock type coupler, be sure to release the lock

when disconnecting, and push it in fully to engage the
lock when connecting.
IF04K1000002-02
• When disconnecting the coupler, be sure to hold the
coupler body and do not pull the lead wires. • When connecting meter probe (2) from the terminal
side of the coupler ( 1) because it cannot be connected
• Inspect each terminal on the connector/coupler for
from harness side, use extra care not to bend the
looseness or bending.
male terminal of coupler of force its female terminal
• Push in the coupler straightly. An angled or skewed open for connection.
insertion may cause the terminal to be deformed, In case of such coupler as shown connect probe as
possibly resulting in poor electrical contact. shown to avoid opening female terminal.
• Inspect each terminal for corrosion and Never connect probe where male terminal is
contamination. The terminals must be clean and free supposed to fit.
of any foreign material which could impede proper
terminal contact.
• Before refitting the sealed coupler, make sure its seal
rubber is positioned properly. The seal rubber may
possibly come off the position during disconnecting
work and if the coupler is refitted with the seal rubber
improperly positioned, it may result in poor water
sealing.

ID26J1000014-01

• Avoid applying grease or other similar material to

connector/coupler terminals to prevent electric
trouble.

I31DG1000002-01
00-3 Precautions:

Clamp ECM / CDI UNIT/ ABS control unit/ HU/ Various

• Clamp the wire harness at such positions as indicated sensors
in "Wiring Harness Routing Diagram" in Section 9A • Since each component is a high-precision part, great
(Page 9A-13). care should be taken not to apply any severe impacts
• Bend the clamp properly so that the wire harness is during removal and installation.
clamped securely.
• In clamping the wire harness, use care not to allow it
to hang down.
• Do not use wire or any other substitute for the band
type clamp.

IH17K1000002-01

IH17K1000001-01

Fuse
• When a fuse is blown, always investigate the cause to
correct it and then replace the fuse.
• Do not use a fuse of different capacity.
• Do not use wire or any other substitute for the fuse.

IH17K1000003-01

• Be careful not to touch the electrical terminals of the

electrical parts (ECM / CDI UNIT, etc.). The static
electricity from your body may damage them.

l649G1000001-02

Switch
Never apply grease material to switch contact points to
prevent damage.

IH17K1000004-01
 Precautions: 00-4
• When disconnecting and connecting the coupler, Battery
make sure to turn OFF the ignition switch (1 ), or • Select the same type MF battery when replacing the
electrical parts may get damaged. battery.
• Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
components of the Fl system and ABS instantly when
reverse power is applied.

IE39J1000001-01

• Never allow dust or water to contact the ABS control

unit/ HU.

I718H1000004-01

• Removing any battery terminal of a running engine is

strictly prohibited. The moment such removal is made,
damaging counter electromotive force will be applied
to the electronic unit which may result in serious
damage.

IH17K1000005-01

• The ABS control unit/ HU cannot be disassembled.

Replace the whole unit with a new one.

IH17K1000007-01

• Before measuring voltage at each terminal, check to

make sure that battery voltage is 11 V or higher.
Terminal voltage check with a low battery voltage will
lead to erroneous diagnosis.
IH17K1000006-01

• Never connect any tester (voltmeter, ohmmeter, or

whatever) to the electronic unit when its coupler is
disconnected. Otherwise, damage to electronic unit
may result.
• Never connect an ohmmeter to the electronic unit with
its coupler connected. If attempted, damage to ECM/
CDI UNIT/ ABS control unit/ HU or sensor may
result.
• Be sure to use a specified voltmeter/ohmmeter. I310G1000012-02

Otherwise, accurate measurements may not be

obtained and personal injury may result.
00-5 Precautions:
Electrical Circuit Inspection Procedure
While there are various methods for electrical circuit
inspection, described here is a general method to check
for open and short circuit using an ohmmeter and a
voltmeter.
Open circuit check
Possible causes for the open circuit are as follows. As
the cause can exist in the connector/coupler or terminal,
they need to be checked carefully.
• Loose connection of connector/coupler
• Poor contact of terminal (due to dirt, corrosion or rust,
poor contact tension, entry of foreign object etc.)
• Wire harness being open.
• Poor terminal-to-wire connection.
When checking system circuits including an electronic
control unit such as ECM, etc., it is important to perform
careful check, starting with items which are easier to
check.
1) Disconnect the negative (-) cable from the battery.
2) Check each connector/coupler at both ends of the
circuit being checked for loose connection. Also
check for condition of the coupler lock if equipped.
IE02K1000004-01
[A]: Check for loose connection
1. Sensor
2. Electrical part
3) Using a test male terminal, check the female
terminals of the circuit being checked for contact
tension.
Check each terminal visually for poor contact
(possibly caused by dirt, corrosion, rust, entry of
foreign object, etc.). At the same time, check to
make sure that each terminal is fully inserted in the
coupler and locked.
If contact tension is not enough, rectify the contact to
increase tension or replace. The terminals must be
clean and free of any foreign material which could
impede proper terminal contact.
IE02K1000005-01
[A]: Check contact tension by inserting and removing.
[BJ: Check each terminal for bend and proper alignment.
4) Using continuity inspect or voltage check procedure
as described below, inspect the wire harness
terminals for open circuit and poor connection.
Locate abnormality, if any.
[B]
ID26J1000005-03
[A]: Looseness of crimping
(BJ: Open
(CJ: Thin wire (A few strands left)
 Precautions: 00-6

Continuity check Voltage check

1) Measure resistance across coupler [B] (between [A]
and [CJ in the figure).
If no continuity is indicated (infinity or over limit), the
circuit is open between terminals [A] and [C].
IE02K1000007-01
1. Electrical part
If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
1) With all connectors/couplers connected and voltage
applied to the circuit being checked, measure
voltage between each terminal and body ground.
2) If measurements were taken as shown in the figure
and results were listed in the following, it means that
the circuit is open between terminals [A] and [B].
Voltage between
[A] and body ground: 0 V
[BJ and body ground: Approx. 5 V
[C] and body ground: Approx. 5 V
3) Also, if measured values are as listed following, a
resistance (abnormality) exists which causes the
voltage drop in the circuit between terminals [A] and
[BJ.

,
Voltage between

:
2) Disconnect the coupler [BJ and measure resistance
[A] and body ground: 3 V - 2 V voltage drop
between couplers [A] and [B-1].
[BJ and body ground: Approx. 5 V

1
If no continuity is indicated, the circuit is open
[C] and body ground: Approx. 5 V
between couplers [A] and [B-1]. If continuity is
indicated, there is an open circuit between couplers
[B-2] and [C] or an abnormality in coupler [B-2] or
coupler [C].

D!, , I I
V
- + : :
__ ,_,

IE02K1000008-01

1. Electrical part

ID26J1000008-05
00-7 Precautions:
Short circuit check (Wire harness to ground)
1) Disconnect the negative (-) cable from the battery.
2) Disconnect the connectors/couplers at both ends of
the circuit to be checked.
NOTE
If the circuit to be checked branches to other
parts as shown, disconnect all connectors/
couplers of those parts. Otherwise, diagnosis
will be wrong.
3) Measure resistance between terminal at one end of
circuit ([AJ terminal in the figure) and body ground. If
continuity is indicated, there is a short circuit to
ground between terminals [AJ and [CJ.
IF04K1000003-01
[DJ: To other parts [E]: Other parts
4) Disconnect the connector/coupler included in circuit
(coupler [BJ) and measure resistance between
terminal [A] and body ground. If continuity is
indicated, the circuit is shorted to the ground
between terminals [AJ and [BJ.
IF04K1000001-01
[DJ: To other parts
Twist Pair Wire Harness
NOTE
For locations where twist pair wire harness
are used, refer to "How to Read Terminal
Nos." in Section 9A (Page 9A-1).
• A twist (1) in the twist pair wire harnesses except
around the connectors (2) should be within 100 mm
(3.9 in.). Excessively-loose lines can be affected by
electric noise.
IL06L 1000002-01
• Do not connect twist pair line terminals using a bypass
wire (1). Doing so makes the twist pair line receive
electric noise interference.
IL06L1000001-01
Intermittent Malfunction Inspection
BENM10L30000004
Since most intermittent failures are caused by faulty
electrical connections or wiring, it is necessary to check
the wiring part suspected of failure. Perform the following
inspections depending on the suspected cause.
Failure Caused by Vibration
Lightly vibrate the electrical part, sensor, connector or
lead wire with fingers to check if the failure is
reproduced.
IM10L1000001-01
 Precautions: 00-8

Failure Caused by Rain or High Humidity

A CAUTION
Do not splash water directly on electrical
parts, as this may damage them.

IM10L1000003-02
Splash water on the vehicle to check if the failure is
reproduced.

Failure Caused by High Electrical Load

Turn on all electrical equipment to check if the failure is
reproduced.

Precautions for Circuit Tester

BENM10L30000005
IM10L1000002-02 Read the instruction manual to use the tester correctly.

Failure Caused by Temperature Fluctuation Symbols

If a failure is suspected at low or high temperatures, Symbol Definition
perform the following inspections.

A WARNING
-
-n
-- - DC
AC
Resistance
To avoid the risk of being burned, do not •Ill Continuity
touch the heated part. -I+ Diode
Do not heat electrical components above 60
oc (140 °F).

A CAUTION
Do not heat or cool electrical components in
disassembled form, as this may damage
them.

• Heat an electrical component with a hair dryer to

check if the failure is reproduced.
• Cool an electrical component with a cold spray to
check if the failure is reproduced.

IM10L1000004-01
00-9 Precautions:

Precautions for SDS-11

BENM1 0L30000006
• In some models of the SUZUKI motorcycles, the OTC
can be confirmed by using SOS-II.
• Read the instruction manual when using SOS-II and
operate it properly.
Special tool
(A): 09904-41031
09904-41041

{A)

D
ri�.........
===========��so s.�� ===
11

IH18K1000002-01

Precautions for Identification

BENM10L30000007
When viewed from the state in sitting on the seat, the
cylinders of this engine are identified as No. 1 (1 ), No. 2
(2), No. 3 (3) and No. 4 (4), counting from left to right.
The sensor, actuator, etc. in No. 1 cylinder are identified
as #1 and the ones in No. 2, No. 3 and No. 4 cylinder are
as #2, #3 and #4 respectively.

Section 0
General Information
CONTENTS
General Information ................................ 0A-1
Service Manual Information ................................... 0A-1
General Description.............................................0A-1
Abbreviations ...................................................... 0A-1
SAE-to-Former SUZUKI Term ............................ 0A-2
Symbols .............................................................. 0A-3
Wire Color Symbols ............................................ 0A-4
How to Read Terminal Numbers......................... 0A-5
SDS-II ................................................................. 0A-6
Applicable Model/ VIN ........................................ 0A-7
Vehicle Side View ............................................... 0A-8
Vehicle Identification Number ............................. 0A-8
Warning, Caution and Information Labels
Location ............................................................ 0A-9
Component Location.........................................0A-10
Electrical Components Location ....................... 0A-10
Technical Features................................................ 0A-12
General Description...........................................0A-12
Engine Control System Description .................. 0A-12
Electric Throttle Control System Description..... 0A-13
Suzuki Drive Mode Selector Alpha (SDMS-a)
Description ...................................................... 0A-15
Launch Control System Description .................. 0A-17
Easy Start System Description.....................� .... 0A-17
Crankcase Emission Control System
Description ...................................................... 0A-18
Exhaust Emission Control System
Description ...................................................... 0A-19
Evaporative Emission Control System
Description (if equipped) ................................. 0A-20
Fuel System Description ................................... 0A-21
ABS ................................................................... 0A-22
IMU ................................................................... 0A-24
Motion Track Brake System .............................. 0A-24
Hill Hold Control System ................................... 0A-25
Slope Dependent Control System ..................... 0A-27
Emergency Stop Signal (ESS) Description ....... 0A-27
Combination Meter System Description............ 0A-28
Service Reminder Indicator Description ............ 0A-32
Cruise Control System Description ................... 0A-33
Active Speed Limiter Description ...................... 0A-35
Immobilizer Control System Description (If
Equipped) ........................................................ 0A-37
CAN Communication System Description......... 0A-38
Table of Contents 0- i
Maintenance and Lubrication ................. 0B-1
Precautions...........................................................0B-1
Precautions for Maintenance .............................. 08-1
Scheduled Maintenance ......................................0B-1
Periodic Maintenance Schedule Chart ................ 08-1
Repair Instructions ..............................................0B-3
Air Cleaner Element ............................................ 08-3
Exhaust Pipe Bolt and Muffler Mounting Bolts .... 0B-3
Valve Clearance .................................................. 08-4
Spark Plugs ......................................................... 0B-7
Fuel Hose ............................................................ 08-8
Evaporative emission control system .................. 08-8
Engine Oil.......................................................... 08-11
Engine Oil Filter................................................. 08-12
Throttle Cable Play............................................ 08-12
PAIR (air supply) System .................................. 0B-13
Throttle Bore Cleaning ...................................... 0B-14
Throttle Valve Synchronization ......................... 0B-15
Engine Coolant.................................................. 0B-16
Radiator Hose ................................................... 08-17
Clutch Fluid ....................................................... 08-17
Clutch Hose....................................................... 0B-18
Drive Chain ....................................................... 08-18
Brakes ............................................................... 08-20
Brake Fluid ........................................................ 08-22
Brake Hose ....................................................... 08-25
Front Brake Hose Removal and Installation...... 08-25
Rear Brake Hose Removal and Installation ...... 0B-25
Tires .................................................................. 0B-26
Steering ............................................................. 08-26
Front Forks ........................................................ 08-27
Rear Suspension............................................... 08-28
Chassis Bolts and Nuts ..................................... 0B-29
Lubrication......................................................... 0B-32
Specifications.....................................................0B-33
Tightening Torque Specifications ...................... 08-33
Special Tools and Equipment...........................0B-34
Recommended Service Material ....................... 0B-34
Special Tool ...................................................... 0B-34
Service Data ............................................. 0C-1
Precautions...........................................................0C-1
Precautions for Service Data .............................. 0C-1
Specifications.......................................................0C-1
0-ii Table of Contents

Specifications ...................................................... 0C-1 Special Tools and Equipment ........................... OC-16

Service Data ........................................................ 0C-2 Fuel/ Oil/ Fluid/ Coolant Recommendation .... 0C-16
Fasteners Information ......................................... 0C-6 Special Tool ...................................................... 0C-18
Tightening Torque List ........................................ 0C-9
 General Information: Service Manual Information OA-1

General Information
Service Manual Information

General Description
Abbreviations GEN: Generator
BENM10L30111001
GND: Ground
A:
GP: Gear Position
AAT: Ambient Air Temperature
H:
ABDC: After Bottom Dead Center
HC: Hydrocarbons
ABS: Anti-lock Brake System
HI: High
AC: Alternating Current
H02: Heated Oxygen
ACL: Air Cleaner
HU: Hydraulic Unit
AKI: Anti-knock Index
I:
AP: Atmospheric Pressure
IAP: Intake Air Pressure
API: American Petroleum Institute
IAT: Intake Air Temperature
ATDC: After Top Dead Center
I.D.: Inside Diameter
A/F: Air Fuel Ratio
IG: Ignition
B: IMU: Inertial Measurement Unit
BBDC: Before Bottom Dead Center
IN.: Intake
BTDC: Before Top Dead Center
ISC: Idle Speed Control
B+: Battery Positive Voltage
J:
C:
JASO: Japanese Automobile Standards Organization
CAN: Controller Area Network
J/C: Junction Coupler
COi: Capacitive Discharge Ignition
L:
CKP: Crankshaft Position
LCD: Liquid Crystal Display
CKT: Circuit
LED: Light Emitting Diode
CLP: Clutch Lever Position
LH: Left Hand
CMP: Camshaft Position
LO: Low
CO: Carbon Monoxide
M:
CPU: Central Processing Unit
Max: Maximum
CVT: Continuously Variable Transmission
MIL: Malfunction Indicator Light
D:
Min.: Minimum
DC: Direct Current
N:
DOHC: Double Over Head Camshaft
NOx: Nitrogen Oxides
DRL: Daytime Running Light
0:
OTC: Diagnostic Trouble Code
02: Oxygen
E:
OBD: On-Board Diagnostic System
ECM: Engine Control Module
OHC: Over Head Camshaft
ECT: Engine Coolant Temperature
O.D.: Outside Diameter
ECU: Electronic Control Unit P:
EEPROM: Electrically Erasable Programmable Read
PAIR: Pulsed Secondary Air Injection
Only Memory
PCV: Positive Crankcase Ventilation
ESS: Emergency Stop Signal
PP: Pulley Position
ET: Engine Temperature R:
ETV: Electric Throttle Valve
EVAP: Evaporative Emission
RH: Right Hand
ROM: Read Only Memory
EX.: Exhaust
RON: Research Octane Number
EXCV: Exhaust Control Valve
RPM: Engine Speed
EXCVA: Exhaust Control Valve Actuator
S:
F:
SAE: Society of Automotive Engineers
Fl: Fuel Injection, Fuel Injector
SDMS: Suzuki Drive Mode Selector
FP: Fuel Pump
SDS: Suzuki Diagnosis System
FPR: Fuel Pressure Regulator SRAD: Suzuki Ram Air Direct
FTPC: Fuel Tank Pressure Control STCS: Secondary T hrottle Control System
FWD: Forward STD: Standard
G: STP: Secondary T hrottle Position
0A-2 General Information: Service Manual Information

STV: Secondary Throttle Valve H:

STVA: Secondary Throttle Valve Actuator
T:
TC: Traction Control
TDC: Top Dead Center
TO: Tip-over
TP: T hrottle Position
TPS: Throttle Position Sensor
V:
WT: Variable Valve Timing
SAE-to-Former SUZUKI Term
BENM10L30111010
This list shows SAE (Society of Automotive Engineers)
J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations,
as well as their former SUZUKI names.
Ex. SAE term (Abbreviation): Former SUZUKI term
A:
Air Cleaner (ACL): Air Cleaner, Air Cleaner Box
B:
Barometric Pressure (BARO): Barometric Pressure,
Atmospheric Pressure (APS, AP Sensor)
Battery Positive Voltage (B+): Battery Voltage, +B
C:
Camshaft Position Sensor (CMP Sensor): Camshaft
Position Sensor (CMPS)
Crankshaft Position Sensor (CKP Sensor):
Crankshaft Position Sensor (CKPS), Crank Angle
D:
Data Link Connector (DLC): Dealer Mode Coupler
Diagnostic Test Mode (DTM): -
Diagnostic Trouble Code (DTC): Diagnostic C ode,
Malfunction Code
E:
Electronic Ignition (El): -
Engine Control Module (ECM): Engine Control
Module (ECM), Fl Control Unit, Engine Control Unit
(ECU)
Engine Coolant Level (ECL): Coolant Level
Engine Coolant Temperature (ECT): Coolant
Temperature, Engine Coolant Temperature, Water
Temperature
Engine Speed (RPM): Engine Speed (RPM)
Evaporative Emission (EVAP): Evaporative Emission
Evaporative Emission Canister (EVAP Canister): -
(Canister)
Exhaust Control System: EXC System (EXCS)
Exhaust Control Valve: EXC Valve (EXCV)
Exhaust Control Valve Actuator: EXCV Actuator
(EXCVA)
F:
Fan Control (FC): -
Fuel Level Sensor: Fuel Level Sensor, Fuel Level
Gauge
Fuel Pump (FP): Fuel Pump (FP)
G:
Generator (GEN): Generator
Ground (GND): Ground (GND, GRD)
Hydrocarbons (HC): Hydrocarbons
Heated Oxygen Sensor (HO2S): Heated Oxygen
Sensor (HO2S), 02 sensor
I:
Intake Air Temperature (IAT): Intake Air Temperature
(IAT), Air Temperature
Idle Speed Control (ISC): -
Ignition Control (IC): Electronic Spark Advance (ESA)
Ignition Control Module (ICM): -
M:
Malfunction Indicator Lamp (MIL): LED Light,
Malfunction Indicator Light (MIL)
Manifold Absolute Pressure (MAP): Intake Air
Pressure (IAP), Intake Vacuum
Mass Air Flow (MAF): Air Flow
0:
On-Board Diagnostic (OBD): Self-Diagnosis Function,
Diagnostic
Open Loop (OL): -
P:
Power Control Module (PCM): -
Programmable Read Only Memory (PROM):
Pulsed Secondary Air Injection (PAIR): Pulse Air
Control (PAIR)
Purge Valve (Purge Valve): Purge Valve (SP Valve)
R:
Random Access Memory (RAM): -
Read Only Memory (ROM): ROM
S:
Secondary Air Injection (AIR): -
Secondary Throttle Control System (STCS): STC
System (STCS)
Secondary Throttle Valve (STV): ST Valve (STV)
Secondary Throttle Valve Actuator (STVA): STV
Actuator (STVA)
T:
Throttle Body (TB): Throttle Body (TB)
Throttle Body Fuel Injection (TBI): Throttle Body Fuel
Injection (TBI)
Throttle Position Sensor (TP Sensor): T P Sensor
(TPS)
Tank Pressure Control Valve: T PC Valve (TPCV)
Traction Control (TC): Traction Control
V:
Voltage Regulator (VR): Voltage Regulator
Volume Air Flow (VAF): Air Flow
 General Information: Service Manual Information 0A-3

Symbols
BENM10L30111002
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The
meaning of each symbol is also included in the table.
NOTE
The table below shows generally used symbols, and includes some symbols not used in this manual.

Symbol Definition
Torque control required.
�
Data beside it indicate specified torque.
-mi Apply oil.
Use engine oil unless otherwise specified.

1m1 Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 5 : 1 ).
Apply SUZUKI SUPER GREASE A.
)©! 99000-25011
Apply SUZUKI SUPER GREASE C.
)©t 99000-25030
Apply SUZUKI MOLYBDENUM GREASE L.
,fu 99000-25280
Apply SUZUKI MOLY PASTE.
� 99000-25140
Apply SUZUKI SILICONE GREASE.
� 99000-25100
Apply SUZUKI WATER RESISTANT GREASE EP2.
}®I 99000-25350
Apply SUZUKI BOND 1207B.
l(im] 99000-31140
Apply SUZUKI BOND 1215.
,cm:] 99000-31110
11112168]
Apply SUZUKI BOND 1216B.
99000-31230
Apply THREAD LOCK CEMENT 1303B.
� 99000-32030
Apply THREAD LOCK CEMENT 1322D.
tJmmJ 99000-32150
Apply THREAD LOCK CEMENT 1342H.
� 99000-32160
Apply THREAD LOCK CEMENT 1360.
� 99000-32130
Use SUZUKI SUPER LONG LIFE COOLANT (BLUE).
99000-99032-20X
� Use SUZUKI LONG LIFE COOLANT (GREEN).
99000-99032-12X
imEI Apply or use fork oil.
ill Apply or use brake fluid.
IIWI Use special tool.
� Do not reuse.
� Note on reassembly.
C Inserting position of resin remover

e Holding position with hands

OA-4 General Information: Service Manual Information

Wire Color Symbols

BENM10L30111003

Symbol Wire Color Symbol Wire Color

B Black Lbl Light blue
Be Beige Lg Light green
Bl Blue 0 Orange
Br Brown p Pink
Dbr Dark brown R Red
Dg Dark green V Violet
G Green w White
Gr Gray y Yellow

There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored
(striped) wire.
The single-colored wire uses only one color symbol (i.e. G). The dual-colored wire uses two color symbols (i.e. G/Y).
The first symbol represents the base color of the wire and the second symbol represents the color of the stripe.

ID26.J1010224-02

1. G (Base color) 3. G (Base Color)

2. Y (Stripe color)
 General Information: Service Manual Information 0A-5

How to Read Terminal Numbers

BENM10L30111004
• The coupler section is described in an illustration viewed from terminal side. However, when using illustration
viewed from harness side, the coupler illustration is described together with the symbol mark (1).
• For the visual direction of coupler such as ECM and ABS CONTROL UNIT/ HU with many terminals, symbol mark
(1) is also described together.
• The coupler information is expressed in terminal layout, lock position (2) and terminal numbers (3).
• The terminal numbers in this manual are described using "T".

NOTE
Molded terminal numbers that are different from the above can be found on some connectors in rare
cases. These molded numbers are not applied in this manual.

t:;> [BJ

�
[A)?J
IJ27K1010012-01

[A]: View terminal side [B]: View harness side

� 2

□
r-' I

8 7 6 5 4 3 2

15 14 13 12 11 10 9

IJ27K1010001-02

Female Terminal
Bounds of the coupler shape are expressed in a single line. The terminal numbers are described with an integer from
1 sequentially from the top left corner.

2 3 4
-
5 6 7 8
IJ27K1010002-01

Male Terminal
Bounds of the coupler shape are expressed in a double line. The terminal numbers are described with an integer from
1 sequentially from the top right corner.

4 3 2 -
8 7 6 5
IJ27K1010003-01
0A-6 General Information: Service Manual Information

Controller I Sensor
In the case of simple substance of sensors without wiring harness, they are described as shown in the illustration
below.

IJ27K1010004-04

1. Controller/sensor 3. Coupler "B"

2. Coupler "A" 4. View

B A

I II I I
24 23 22121 20 19 2 1
4 I 3 I
6 5
30 29 28 27 26 25 12 11 10 9 8 7
36 35 34 33 32 31 18 17 16 15 14 13

IJ27K1010008-01

SDS-11
BENM10L30111005
SDS-11 Function
NOTE
For details of each SDS-11 function, referring to the SDS-11 operation manual.

Function Description
Data monitor ECU data can be displayed and the displayed data can be saved.
OTC inspection Current OTC, past OTC and pending OTC can be displayed.
Show failure data
.
"Show failure data" can be displayed.

.
Active control Various actuators can be operated .

Utility . The learned value of various systems can be reset.

Vehicle information can be displayed .
• The status of "System Readiness Test" can be displayed .
Reprogramming T he ECM and ABS control unit/ HU can be programmed.
 General Information: Service Manual Information 0A-7

Corresponding ECU
NOTE
The item of the available "Active control" and "Utility" varies according to the type of the vehicle.

DTC Show failure Reprogrammi

ECU Data monitor Active control Utility
inspection data ng
ECM Available Available Available Available *1 Available *2 Available
ABS control unit/ HU Available Available Not available Available * 1 Available *2 Available
Combination meter Not available Not available Not available Not available Available *2 Available

* 1: Active control
. .
.
PAIR control solenoid drive control Cooling fan relay control

. .
Steering damper solenoid operating control • EVAP purge valve operating control

. STV I ETV drive control Long term fuel trim reset

.
TP fully closed learned value reset • MIL

.
ECM
.
Exhaust valve drive control Reset closed accel position

. .
ISC rpm control Reset IMU learning value

.
ISC aperture learned value reset Reset gear position learned value
ISC air volume control
ABS control unit/ HU • ABS HU operating 2

*2: Utility
. .
ECM
ABS . Vehicle information
Vehicle information
Readiness test results

Combination meter • Vehicle information

Applicable Model / VIN

BENM10L30111006
Applicable Model
GSX1300R

Applicable VIN

NOTE
• "#" indicates any check digit from 0 to 9 and X.
• "@" indicates the year of manufacture or the month and year of manufacture.

Applicable Model VIN Number Country or Area

JS1 EJ11B#M7100001 - U.S.A. except for California State
GSX1300RM2
JS1EJ11D#M7100001 California State
0A-8 General Information: Service Manual Information

Vehicle Side View

BENM 1OL30111007
SUZUKI GSX1300R

IM10L1011001-01

Vehicle Identification Number

BENM10L30111008
The frame serial number or V.I.N. (Vehicle Identification
Number) (1) is stamped on the steering head tube. The
engine serial number (2) is located on the crankcase
assembly.
u ;j
�
1-�-� ­

·.". '.�
-· �•
•.• •
• I

',

/�

IM10l1011007-01

IM10L1011003-01
 General Information: Service Manual Information 0A-9

Warning, Caution and Information Labels Location

BENM10L30111009

[A] [BJ [CJ

i .':;,_·.
" '
> '• ·. ,.

[E)

.,,,....-��-:<�·,-:'k,ii"•
.

-
/ .•
.
. . � ... .. ,
.

""

[G) [G)

11

12
. let!;
.>..ff-
0�

[HJ [I]
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_,,,,.c:.__/'
--------
�-

_,..-- .. ,. -

/(''
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?_
//
1/ • .

c)

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IM10L1011004-02

[A]: Fuel tank cover
[BJ: Meter panel (left side)
[C]: Rear fender (front)
[D]: Windscreen
[E]: Swing arm
[F]: Frame (right side)
[G]: Frame (left side)
[H]: Frame cover (left side)
(I]: Meter panel (right side) 8. Tire information label
1. Gasoline label 9. Information label (If equipped)
2. General warning label 10. EPA noise label or Un noise label (If
equipped)
3. General warning label or Helmet label or Clutch 11. Manufacturer label (If equipped)
fluid label
4. Vacuum hose routing label (If equipped) 12. Safety plate or I.D. plate (If equipped)
5. Manual notice label (If equipped) 13. Brake fluid label (If equipped)
6. Recycle label (if equipped)
7. Cowling label (if equipped)
0A-10 General Information: Service Manual Information

Component Location
Electrical Components Location BENM10L30113001

IM10L1011008-02

1. AP sensor 8. Battery 15. H02 sensor #1

2. Starter relay I Main fuse
3. Mode select coupler (6P)
4. Fuel pump
5. Fuel level gauge
6. IAT sensor
7. ECM
9. Left handle switch 16. CKP sensor
10. Clutch lever position switch 17. Generator rotor
11. Gearshift sensor 18. Fuse box
12. Rectifier 19. FP relay
13. GP sensor 20. Cooling fan relay
14. Side-stand switch 21. Starter sub relay
 General Information: Service Manual Information 0A-11

•• 1

'
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,:
,�. ''
'I �. .'
'
,· '
� /4
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IM10L 1011006-02

[Al With immobilizer control system 8. ABS control unit/ HU 16. Horn
1. Combination meter 9. P rimary fuel injector 17. Cooling fan
2. Immobilizer antenna (If equipped) 10. Secondary fuel injector 18. Starter motor
3. Ignition switch 11. IAP sensor 19. Accelerator body assembly (incorporating
accelerator position sensor (main and sub)
and cruise control cancel switch)
4. PAIR control solenoid valve 12. ECT sensor 20. EVAP system purge control solenoid valve
(If equipped)
5. Ignition coil 13. Front brake switch 21. H02 sensor #2
6. CMP sensor 14. Right handle switch 22. Front wheel speed sensor
7. Throttle body (incorporating TP sensor (main 15. IMU 23. Rear wheel speed sensor
and sub) and throttle valve motor)
0A-12 General Information: Technical Features

Technical Features
General Description
Engine Control System Description
BENM10L30121001

• T he engine control in this motorcycle is controlled by ECM.

Item
Injection control
Ignition control
Fuel pump relay control
Electronic throttle control
Starter relay control
Cooling fan relay control
EVAP system purge control
solenoid valve control (if
equipped)
PAIR control solenoid valve
control
HO2 sensor heater control
SDMS-a function
Launch control
Cruise control
Active speed limiter function
Immobilizer control (if equipped)
CAN communication function
Description
ECM controls fuel injector and injects fuel of the most suitable quantity in the
most suitable timing. Also, ECM stops the fuel injector control based on the
engine and driving conditions.
ECM controls ignition coil and ignition of the spark plug in the most suitable
ignition timing based on the engine and driving conditions. (e.g. engine cranking,
idle speed, normal driving, accelerating, decelerating, etc.)
ECM controls ON or OFF of the fuel pump relay to operate the fuel pump based
on the ignition switch position and engine operating conditions.
Refer to "Electric T hrottle Control System Description": Technical Features (Page
.
0A-13).
ECM controls ON or OFF of the starter relay to operate the starter motor
corresponding to the state of the ignition switch and actuation of the engine
stop/ starter switch ("START" position).
• ECM controls easy start system. Refer to "Easy Start System Description":
Technical Features (Page 0A-17).
ECM controls ON or OFF of the cooling fan relay to operate the cooling fan based
on the engine coolant temperature condition.
ECM performs the EVAP system purge control solenoid valve ON/ OFF control
based on the engine and driving conditions.
ECM performs the PAIR control solenoid valve ON/ OFF control based on the
engine and driving conditions.
ECM controls the heater in the HO2 sensor and performs the early activation of
-
the HO2 sensor. '
Refer to "Suzuki Drive Mode Selector Alpha (SDMS-a) Description": Technical
Features (Page 0A-15).
Refer to "Launch Control System Description": Technical Features (Page 0A-17).
Refer to "Cruise Control System Description": Technical Features (Page 0A-33).
Refer to "Active Speed Limiter Description": Technical Features (Page 0A-35).
Refer to "Immobilizer Control System Description (If Equipped)": Technical
Features (Page 0A-37).
ECM uses CAN communication to communicate with combination meter, ABS
control unit/ HU (with motion track brake system), IMU (with motion track brake
system) and SDS-II tool. Refer to "CAN Communication System Description":
Technical Features (Page 0A-38).

ECM has a self-diagnosis function which detects a malfunction in this system. When detecting any malfunction,
ECM performs fail-safe function based on the level of the malfunction.
- Self-diagnosis function: -(Page 1A-1)
- Fail-safe function: "(Page 1A-19)
• ECM receives vehicle speed signal using front and rear wheel speed sensor signal from ABS control unit/ HU.
 General Information: Technical Features OA-13

Engine Control System Input/ Output Diagram

Input Control module Output

ECM

lqnition switch siqnal I Injection control I 11Primarv fuel injector II

ilizer antenna I Ignition control I ::secondary fuel iniector II
�
or Fuel pump relay
control ::ignition coil II
CMP sensor N
"
IAP sensor I Electronic throttle !Fuel 12um12 relay Ii
control
II
I AP sensor I !Throttle valve motor II
TP sensor (Main/ Sub) I Starter relay controlI
!Starter relay II
IAT sensor Cooling fan relay
control !Cooling fan relay
Accelerator position sensor Ii

I
(Main / Sub) [B] EVAP system
purge control ll[B] EVAP system purge control
IECT sensor I llsolenoid valve
solenoid valve
!HO2 sensor #1 / #2 I control 1 PAIR control solenoid valve
I 11
Clutch lever position switch PAIR control
::HO2 sensor heater #1 / #2 II
IGP sensor {Neutral / GP signal} I solenoid valve
!Gearshift sensor control ::�A] Immobilizer antenna I
I
HO2 sensor
Engine stop/ starter switch
heater control 1l[A] Immobilizer indicator light Ii
("RUN"/ "ENGINE STOP"
/ "START" position) I SDMS-a function I
Side-stand switch II
H I Launch control I
!Fuel pump relay I I Cruise control I
ABS control unit/HU Active speed limiter
(Vehicle speed signal) function
[A] Immobilizer
control
CAN communication
Combination meter Combination meter II
function W
ABS control unit/HU rr--, ABS control unit/HU II
IMU - ---- - - - - - - --- - - - - -- - ----
�
I Fail-safe function I
!Mode select switch I Self-diagnosis [A] : With immobilizer control system
function [B]: With EVAP system
..,.: CAN communication
IM10L1012001--04

Electric Throttle Control System Description

The electric throttle control system consists of the following:
BENM10L30121002

• Throttle body incorporating the throttle valve, throttle valve motor and TP sensors (main and sub)
• Accelerator body assembly incorporating accelerator position sensors (main and sub)
• ECM
OA-14 General Information: Technical Features

Operation Description
• ECM ( 1) detects opening angle of the throttle grip based on the signal voltage of the accelerator position sensor (2).
Using that data and engine operation condition, ECM calculates the optimum throttle valve opening. On the other
hand, it detects the throttle valve opening based on the signal voltage of the TP sensor (3) and compares this value
with the above calculated optimum throttle valve opening. When there is a difference between them, ECM changes
the duty ratio of throttle valve motor according to this difference to drive the throttle valve motor (4). When there is
no difference, ECM fixes the duty ratio of throttle valve motor to maintain the throttle valve opening. In this way, the
throttle valve (5) is opened and closed to achieve the optimum throttle valve opening.
• In this system, TP sensor and accelerator position sensor have 2 sensors (main and sub) each to assure highly
accurate and reliable control and abnormality detection. When ECM detects an abnormality in the system, it stops
controlling the throttle valve motor.
• This throttle body is not equipped with ISC valve for idle speed control. Idle speed control is performed by the
throttle valve motor by adjusting the throttle valve opening.
• Accelerator body (6) assembly has a cruise control cancel switch (7). ECM performs cancel of the cruise control,
when turning the throttle grip beyond the fully closed position.

' ·,
,---------------------------------7
-���= '
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i
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6__,__

l_ _________________________________ _j

10

8
12

13

14

IM10L1012002-01
8. CPU 12. TP sensor (main) signal circuit 16. Throttle grip
9. Throttle valve motor driver 13. TP sensor (sub) signal circuit 17. Throttle cable
10. Accelerator position sensor (main) signal 14. Drive circuit of throttle valve motor 18. Fully closed position
circuit
11. Accelerator position sensor (sub) signal 15. Throttle body 19. Cruise control cancel switch position
circuit
 General Information: Technical Features 0A-15

Suzuki Drive Mode Selector Alpha (SDMS-a) Description

BENM10L30121003

• SDMS-a (1) is the function that can change the modes of "power mode" (2), "motion track traction control system"
(3), "engine brake control" (4), "anti-lift control" (5) and "bi-directional quick shift system" (6) at once.
• The 6 modes can be selected by the mode switch (7) and select switch (8).
- [A]: Mode A, B and C cannot change the mode of each system.
- [B]: Mode U1, U2 and U3 can change the mode of each system optionally and can save.

SDMS-a (1) PW(2) TC (3) EB (4) LF (5) QS (6)

A [A] [AJ [A] [A] [AJ �1
(
N \\
B [AJ [AJ [A] [AJ [AJ
C [A] [A] [AJ [AJ [AJ (
2�-Jillr'
U1 [B] [BJ [B] [B] [B]
U2 [BJ [BJ [B] [B] [BJ
U3 [BJ [B] [B] [B] [BJ iPTI==:__,� 1 r� 1

-�\
6 5 4
7

IM10L1012003-02

Power Mode
• Power mode is the function that can change engine power characteristics optionally.
• The 3 driving modes (from mode 1 to mode 3) can be selected by the mode switch and select switch.

Motion Track Traction Control System

• When the motion track traction control system senses rear wheel spin (revolution difference between the front
· wheel and rear wheel) during start up or acceleration, the system regulates the engine torque to restore gripping
power of the rear wheel and insure the running stability. An IMU adopted in the motion track traction control system
senses inclination of the motorcycle and the system has realized the traction control at cornering in high accuracy.
• The system senses the condition of rear wheel rotation by the signals sent from front and rear wheel speed sensors,
accelerator position sensor, CKP sensor, GP sensor and IMU. When the rear wheel spin has been detected, ECM
reduces engine power output to prevent its spin by controlling ignition timing and throttle valve motor.
• The motion track traction control status (ON / OFF) and levels can be selected by the mode switch and select
switch.
• There are 10 steps of motion track traction control levels (from mode 1 to mode 10) and the higher figure has higher
effect of the control. If "OFF" is selected, the engine output is not regulated even when the rear wheel spins freely.
Traction control indicator:
• The traction control indicator (1) comes on when the ignition switch is turned "ON" and goes off after the vehicle
speed exceeds 10 km/h (6 mile/h). After that the indicator light does not come on after the vehicle speed decreases
to less than 10 km/h (6 mile/h).
• The traction control indicator blinks when controlling the engine torque by the motion track traction control system.
• The traction control indicator. comes on and remains on when the motion track traction control system is not working
due to a system malfunction.
0A-16 General Information: Technical Features

IM10L1012004-01

Engine Brake Control

• Engine brake control is a function to control effect of the engine brake in the deceleration.
• The engine brake control status (ON / OFF) and levels can be selected by the mode switch and select switch.
• There are 3 steps of engine brake control levels (from mode 1 to mode 3) and the higher figure has lower effect of
the engine brake. If "OFF" is selected, the effect of engine brake is not regulated.
• The effect of the engine brake is regulated by control of the following.
- F uel cut of 1 or 2 cylinder is stopped.
- Throttle valve opening control depending on the mode.

Anti-Lift Control
• Anti-lift control is a function to prevent the lift of the front wheel in the acceleration.
• During anti-lift control, the ECM regulates the engine output according to the driving conditions (e.g. vehicle speed,
engine speed, gear position, etc.) and the amount of throttle grip operation. The engine output is also regulated
when lifting of the front wheel is detected.
• The anti-lift control status (ON / OFF) and levels can be selected by the mode switch and select switch.
• There are 10 steps of anti-lift control levels (from mode 1 to mode 10) and the higher figure has lower effect of the
control. If "OFF" is selected, the engine output is not regulated even when the front wheel lifted.

Bi-Directional Quick Shift System

• The bi-directional quick shift system allows the rider to upshift and downshift without using the clutch or throttle
operation.
• The gearshift sensor on the gearshift-linkage monitors a gearshift lever motion and ECM controls the ignition timing,
throttle valve opening and the fuel injection volume to be injected.
• The ECM monitors gearshift-linkage stroke and the GP sensor to adjust the engine speed.
• The bi-directional quick shift system provides OFF, mode 1 and mode 2.
- Mode 1: The quick shift is available. The gearshift lever stroke required for the shift change is set larger and the
gearshift lever operation is set heavier than those of mode 2.
- Mode 2: The quick shift is available. The gearshift lever stroke required for the shift change is set smaller and the
gearshift lever operation is set lighter than those of mode 1.
Upshift:
• When the gearshift sensor senses an upshift motion, the system automatically reduces the power in a short time by
controlling the ignition timing and throttle valve opening in order to unload the transmission gear dogs and allows a
smooth upshift.
• This system enables upshift at full throttle condition and realizes almost uninterrupted acceleration.
Downshift:
• When the gearshift sensor senses a downshifl motion, the system automatically opens the throttle valve instantly in
order to rise the engine speed properly for lower gear position.
• The system monitors gearshift-linkage stroke and GP sensor as well as engine speed.
• This system enables quicker and smoother downshift without blipping the throttle grip or using the clutch, and the
system automatically opens the throttle valves just enough to increase engine speed and adapts the engine speed
to the lower gear.
 General Information: Technical Features 0A-17

Launch Control System Description

BENM10L30121004
• The launch control system makes it easier for a rider to get a fast start in closed-course competition.
• Once the rider selects the launch control using the engine stop/ starter switch ("START' position) on the right
handlebar, the system controls the throttle valve opening and ignition timing in order to limit the engine rpm
automatically and to optimize torque delivery while the rider holds the throttle grip wide open.
• Therefore, the rider can concentrate on feeling to in the clutch lever.
• The launch control system is controlled by pushing the engine stop/ starter switch ("START" position) (1) for 1
second or more, after the engine starts and when the vehicle is stationary.
• When the launch control is set, ignition timing, power mode, motion track traction control and anti-lift control are
shifted to dedicated mode for the launch control and the LCD indication will change to the launch control dedicated
display (2).
• The launch control levels can be selected by the select switch (3).
• There are 3 steps of launch control levels (from mode 1 to mode 3) and the higher figure, the higher the engine
speed limited at vehicle start.
• This control is automatically canceled under the condition that the gear is shifted up to 4th or the vehicle is
decelerated by releasing the throttle grip or applying the brake.

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IM10L1012005-02

4. Mode 1 5. Mode 2 6. Mode 3

Easy Start System Description

BENM10L30121005
This model has adopted easy start system which operates cranking continuously for specified time without continuous
pushing of the engine stop/ starter switch ("START" position).
• ECM monitors various signals and one-push of the engine stop/ starter switch ("START' position) makes the starter
relay to ON to operate the starter motor until the engine is started. However, if the engine cannot be started within
the specified time, the ECM sets the starter relay to OFF.
• When the ignition switch is ON and, judging conditions of all of the following factors, ECM controls the starter relay
to set ON. However, responding to either of the following conditions, ECM sets the starter relay to OFF.
- Status of GP sensor or clutch lever position switch
Status of side-stand switch
Status of engine stop/ starter switch ("START" position)
- Status of engine start
NOTE
When the engine might not start easily, grasp the clutch lever with neutral position and pushing the
engine stop/ starter switch ("START" position) continually enable continuous cranking.
0A-18 General Information: Technical Features

Crankcase Emission Control System Description

BENM10L30121006
The engine is equipped with a PCV system.
Blow-by gas in the engine is constantly drawn into the crankcase (1), which is returned to the combustion chamber
through the PCV hose (2), air cleaner box (3) and throttle body (4).

4 -.....__,,_____

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3

.....______.,,.5
¢:::::J [A]

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IM10L1012006-01
[A]: Fresh air [C]: Blow-by gas [E]: Exhaust gas
(BJ: Fuel/Air mixture [D]: Air/Blow-by gas mixture 5. PCV reed valve
 General Information: Technical Features 0A-19

Exhaust Emission Control System Description

BENM10L30121007
The exhaust emission control system is composed of the PAIR system and three-way catalyst system.
• The fresh air is drawn into the exhaust ports through the PAIR control solenoid valve (1) and PAIR reed valve (2).
The PAIR control solenoid valve is controlled by the ECM (3), based on the engine and driving conditions. And the
PAIR reed valve is operated by the exhaust-pulse.
• The three-way catalyst (4) is emission control device added to the exhaust system to lower the levels of
hydrocarbon (HC), carbon monoxide (CO) and nitrogen oxides (NOx) pollutants in exhaust gases.

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i
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i
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[A]: PAIR control solenoid valve is OFF (open) [C]: Fresh air [E]: Exhaust gas I Fresh air mixture
(BJ: PAIR control solenoid valve is ON (close) (D]: Exhaust gas
0A-20 General Information: Technical Features

Evaporative Emission Control System Description (if equipped)

BENM10L30121008
The evaporative emission control system is composed of the EVAP system.
The EVAP system restrains hydrocarbons namely HC vapors from emitting into the atmosphere. The HC vapors'
pressure in the fuel tank (1) may rise affected by change of ambient temperature, barometric pressure or refueling,
and the pressurized vapors are conducted into the EVAP canister (2) through the fuel shut-off valve (3) so as to
maintain the tank pressure normal. Active carbon (4) in the EVAP canister absorbs the hydrocarbons and storing
them.
The active carbon stores the hydrocarbons until the engine is able to consume them. When the EVAP system purge
control solenoid valve (5) is turned ON by the ECM (6), fresh air flow into the EVAP canister due to negative intake
pressure, then the HC vapors are pulled apart from the active carbon and sucked into the throttle body (7).

NOTE
• When tank pressure is excessive high, the pressurized vapors are discharged into the atmosphere
through the fuel relief valve (8) so as to maintain the tank pressure normal.
• When motorcycle is tipping over, the fuel shut-off valve prevents the fuel that may flow out to the
EVAP line because check ball (9) shuts the EVAP line.

11
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IM10L 1012007-02

[A]: Tank pressure is excessive high. [C]: Fresh air 10. Fuel
[BJ: Motorcycle is tipping over. (D]: Fuel vapor 11. Fuel tank cap
 General Information: Technical Features 0A-21

Fuel System Description

BENM10L30121009
Fuel System
The fuel delivery system consists of the fuel tank (1 ), fuel pump (2) (incorporating fuel pressure regulator (3) and fuel
filter (4), fuel feed hose (5), primary fuel delivery pipe (6), primary fuel injectors (7), secondary fuel delivery pipe (8)
and secondary fuel injectors (9). There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump
and pressurized fuel flows into the injectors installed in the fuel delivery pipes. Fuel pressure is regulated by the fuel
pressure regulator. As the fuel pressure applied to the fuel injectors through the fuel delivery pipes is always kept at
the specified level, the fuel is injected into the throttle body below the throttle valve and funnel in conic dispersion
when each injector opens according to the injection signal from the ECM. Secondary fuel injectors are mounted in the
air cleaner box and activated at high rpm.
The fuel relieved by the fuel pressure regulator flows back into the fuel tank.

<:===i [A]
.... [BJ
-<·---------, [C]

IM10L1170051-01
[A]: Before-pressurized fuel [BJ: Pressurized fuel [C]: Relieved fuel
0A-22 General Information: Technical Features

ABS
BENM10L30121010
General Description
• ABS control unit calculates signals from wheel speed sensors, pressure sensors, IMU and ECM. And transmits
control signals to HU. HU controls braking force based on the control signals.
• ABS control unit/ HU uses CAN communication to communicate with IMU, ECM and combination meter. For details
of CAN communication system, referring to the "CAN Communication System Description": Technical Features
(Page 0A-38).
• This ABS is equipped with the following function and systems.
Motion track brake system: -(Page 0A-24)
- Hill hold control system: -(Page 0A-25)
Slope dependent control system: c]P(Page 0A-27)
- Emergency stop signal: c]P(Page 0A-27)

r·-·-·-· . ·-·-·
7 ·-·-·-·-·-· 9-,
18

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24 25
IM10L 1012027-01
 General Information: Technical Features OA-23

1. Brake lever / master cylinder 10. Rear brake caliper pressure sensor 19. ABS control unit
2. Brake pedal / master cylinder 11. Suction return flow pump 20. IMU
3. Inlet valve 12. Check valve 21. ECM
4. Outlet valve 13. Accumulator 22. Combination meter
5. Switching valve 14. Front brake caliper 23. ABS indicator light
6. High pressure switch valve 15. Rear brake caliper 24. Front system
Front brake master cylinder pressure Front wheel speed sensor Rear system
sensor
7. 16. 25.

8. Front brake caliper pressure sensor 17. Rear wheel speed sensor
9. Rear brake master cylinder pressure sensor 18. HU

ABS Control Input/ Output Table

INPUT Device (or signal) OUTPUT Device (or signal)

ABS control unit/HU

HU

ABS control unit

II F
ront brake master cylinder pressure sensor ➔ I� CPU
Inlet solenoid valve/

II
Front brake caliper pressure sensor
1�.. Outlet solenoid valve /
Solenoid valve relay control rfc)> Solenoid valve relay ➔ High pressure switch valve/
Switching valve
ear brake master cylinder pressure sensor
II R

II Rear brake caliper pressure sensor p,,

Pump motor relay control f4 Pump motor relay �-➔
I Pump motor

r
II Batte y power supply ::

heel speed sensor ::

II W

Wheel speed signal ,II ECM II

output control II

CAN communication
IMU II - ECM

I
I
II II function II II

II ECM II -I Combination meter

II , II II
-----------------------------
Ir-
II
Combination meter
I Fail - safe function
I
I Self diagnosis
I
..,.: CAN communication
IM10L1012016-02
0A-24 General Information: Technical Features

IMU
BENM10L30121011
• IMU (1) is located under the front seat.
• IMU consists of 3-axis G sensor and 3-axis gyro sensor. These sensors detect the longitudinal acceleration, lateral
acceleration, vertical acceleration, pitch rate, roll rate and yaw rate of the motorcycle, and transmit their signals to
ABS control unit/ HU through CAN communication.

IM10L1012017-02

[A]: Longitudinal acceleration [C): Vertical acceleration [E]: Roll rate

[BJ: Lateral acceleration [D): Pitch rate [F]: Yawrate

Motion Track Brake System

BENM10L30121012
This system has a following control.
Combined brake control:
Combined Brake Control is linked control of the brakes on the front and rear wheels.
Even when the rider operates the brake lever and not the brake pedal, the ABS control unit/ HU activates the pump
motor and boosts the rear brake caliper pressure automatically. This improves deceleration of the motorcycle even
when only the brake lever is operated. The ABS control unit/ HU alters the braking distribution between the front and
rear brakes according to the lean angle, with the proportion allocated to the rear braking decreasing as the lean angle
increases.

[DJ ... [El

IM10L1012018-04

[AJ: When only the front brake lever is operated [DJ: Brake input
[BJ: When only the rear brake pedal is operated [E]: Brake output
[C]: When the front brake lever and rear brake pedal is operated
 General Information: Technical Features 0A-25

Cornering Brake Control:

Cornering Brake Control is control of the front and rear caliper pressure based on the amount of lean angle. The ABS
control unit/ HU utilizes internal solenoid valves, with the ABS beginning to operate as the lean angle increases and
the wheel slip rate is small. This prevents wheel lock within defined parameters when the rider applies excessive
braking during cornering.

Hill Hold Control System

BENM10L30121013
System Description
• This system is a function that prevents the motorcycle from moving backwards when starting after stopping on an
uphill slope [A] and assists with pulling away smoothly.
• When the system operates, it controls the rear brake for about 30 seconds to prevent the motorcycle from moving
backward without any operation of the brake lever or the brake pedal.
About 3 seconds before the system is deactivated, the hill hold indicator starts blinking and the rear caliper pressure
is gradually reduced accordingly until the system is fully deactivated.

[A]

\{(�\{( IM10L1012019-03

Effective Conditions for Control

If all of the following conditions are met, hill hold control system is in on-standby. And when brake lever and brake
pedal are released, ABS control unit/ HU controls the rear caliper pressure of rear brake for about 30 seconds.
NOTE
When hill hold control system is available, hill hold indicator is OFF, and when its system is operating ,
hill hold indicator is ON or blinks. For details of hill hold indicator, referring to "Hill Hold Indicator":
Technical Features (Page 0A-26)

• "HILL HOLD SET" is "ON".

NOTE
The selected item is highlighted (1 ).

IM10L1012020-01
0A-26 General Information: Technical Features

• Motorcycle stopped on an uphill slope.

• Brake lever and/or pedal are operated.
• Gear position is other than neutral.
• Side stand is retracted.
• No DTC related to the control is detected.

System Cancel Conditions

Hill hold control is canceled under one of the following conditions.
• Motorcycle is started.
• About 30 seconds elapses after the brake lever and brake pedal are released.
• Brake lever is grasped 2 times quickly.
• Gear position is neutral.
• Side stand on the ground.

Hill Hold Indicator

NOTE
When DTC related to the control is detected, the "HILL!" (6) is indicated by the display of the LCD.

Hill Hold Control System Conditions Hill Hold Indicator (1)

"HILL HOLD SET' is "OFF" (7).
ON (2) ("OFF" display)
OTC related to the control is detected.
"HILL HOLD SET' is "ON" (8).
OFF (3)
Hill hold control system is in on-standby.
After the brake lever and brake
ON for about 27 seconds (4)
pedal are released.
Hill hold control system is operating.
Before rear caliper pressure
Blinks for about 3 seconds (5)
reduces.

IM10L 1012021-02
 General Information: Technical Features OA-27

Slope Dependent Control System

BENM10L30121014
This system controls front and rear caliper pressure to restrain rear wheel lift up, when operating the brake lever and/
or brake pedal in a downhill slope [A].

[A]

IM10L1012022-03

Emergency Stop Signal (ESS) Description

BENM10L30121015
When the execution condition is satisfied, the ABS controller transmits an emergency stop signal request to the
combination meter by CAN communication. The combination meter drives the turn signal circuit to blink the hazard
lights at twice the normal rate.

NOTE
• The operation of the hazard lamp SW (hazard lamp control) has priority over the ESS control.
• ESS control cannot be turned OFF.

Execution condition
The ABS controller executes control when all of the following conditions are satisfied.
• Brake lever or brake pedal is operated forcefully when the speed of the motorcycle is at least 55 km/h
• ABS is activated or brake is operated forcefully such that ABS would activate

-+ -+

� - - - [BJ - - - � �--- [CJ ---�

., ________ ., .. ________ .,
IM10L 1012023-01

[A]: Running at or above the [BJ: The rider operated the brakes. [C]: Detects excessive deceleration [D]: Hazard lamp blinks at high
speeified speed. or activates ABS. speed.

Release condition
The ABS controller releases control when any of the following conditions is satisfied.
• Speed significantly decreases
• Brake pedal or brake lever is released
• ABS activation stops
• Hazard switch is turned on
0A-28 General Information: Technical Features

Combination Meter System Description

BENM10L30121016

• This combination meter mainly consists of the stepping motor, TFT LCD (Thin Film Transistor Liquid Crystal
Display) and LED (Light Emitting Diode).
• Combination meter uses signals (information) sent from each control module by CAN communication to ECM and
ABS control unit. For more information on CAN communication data received by combination meter, refer to "CAN
Communication System Description": Technical Features (Page 0A-38).
• The combination meter drives the turn signal light according to the state of the turn signal swtich and the hazard
switch.
The turn signal light is driven in response to an ESS signal by CAN communication from the ABS controller.
In response to the "P" (parking) position of the ignition switch, the combination meter illuminates the position light,
tail light and the license plate light.

11

14 16 15

[A] 22 23 21 [B] 22 24 23
17 18 19 20 21
32

25

29

27 28 26 31

[C] 33 [D]
LF:1 EB:1

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100000 3
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IM10L1012024-02
 General Information: Technical Features 0A-29

(A]: "SDMS-a" screen 10. Oil pressure indicator light 23. ETC indicator and ERR indicator (If equipped)
[B]: "Active data" screen 11. Speedometer 24. Forward acceleration
[C]: Riding assistance system indicator list and 12. Engine coolant temperature indicator light 25. Engine rpm indicator
Information window (one-row display)
[DJ: Information window (two-row display) 13. Engine coolant temperature meter 26. Hill hold indicator
1. Fuel meter 14. Neutral indicator light 27. Riding assistance system indicator
2. Fuel indicator light 15. High beam indicator light 28. Gear position indicator
3. Tachometer 16. Multifunction display 29. Throttle opening
4. Turn signal indicator light 17. Clock 30. Brake pressure (Front and Rear)
5. ABS indicator light 18. Diagnosis display 31. Bank angle
6. Master warning indicator light 19. Freeze indicator 32. Maximum bank angle and Bank angle Peak
hold bar
7. Engine rpm indicator light 20. Thermometer 33. Riding assistance system indicator list
8. Malfunction indicator light 21. Service reminder indicator 34. Information window
9. Traction control indicator light 22. SDMS (Suzuki Drive Mode Selector)-a
indicator

Combination Meter Display Table

Display
Display Function
indication
Analog The fuel level indicator indicates the amount of fuel remaining in
Fuel meter
meter the fuel tank.
This indicator comes on when the fuel level drops below approx.
Fuel indicator light LED
5.0 L (5.3/4.4 US/Imp qt).
Analog The tachometer indicates the engine speed in revolutions per
Tachometer
meter minute (r/min).
Operating the right or left turn signal causes the turn signal

.
Turn signal indicator light LED
indicator to blink.
This indicator normally comes on when the ignition switch is
turned "ON" and goes off after the motorcycle speed exceeds 5

.
km/h (3 mph).
ABS indicator light LED
If there is a problem with the ABS (Antilock Brake System), this
indicator light comes on. The ABS does not operate when the
ABS indicator light is on.

.
The indicators come on when the following malfunctions occur.

. Low battery voltage (Red)

Master warning indicator light LED

. ECM malfunction (Yellow)
ABS control unit malfunction (Yellow)

..
• Handle switch malfunction (Yellow)
Ambient air temperature sensor malfunction (Yellow)

.
It works when the setting is on .
Engine rpm indicator light LED As the engine speed approaches the set value, the engine rpm
indicator light comes on or blinks in conjunction with the rpm
indicator to indicate when to change gears up.
The indicator light comes on or blink when the fuel injection
Malfunction indicator light LED
system malfunction.
The traction control indicator light "TC" blinks when the traction
Traction control indicator light LED
control system is controlling engine power output.
When the ignition switch is turned on, this indicator come on, and
normally, will turn off when the engine starts.
Oil pressure indicator light LED
.
The indicator comes on when the following malfunctions occur.
Engine oil pressure drops
Analog The speedometer indicates the road speed in miles per hour or
Speedometer
meter kilometers per hour
This indicator comes on when the engine coolant temperature
Engine coolant temperature indicator
LED exceeds 123 °C (253 °F) and turn off once the temperature falls to
light
120 °c (248 °F).
.,
Analog
Engine coolant temperature meter This meter indicates coolant temperature meter.
meter
0A-30 General Information: Technical Features

Display
Display Function
indication
The green indicator light will come on when the transmission is in
Neutral indicator light LED
neutral.
This indicator light will be lit when the headlight high beam is
High beam indicator light LED
turned on.
Clock LCD (TFT) The time is displayed using a 12-hour, AM/PM system.
This display shows the current failure information as the following.
• "CHEC": When the malfunction of communication system, this

.
indication is displayed.
'TO!": If the motorcycle tips over or the ECM detects a TO
sensor circuit malfunction, this indication is displayed.
• Figure of key mark: This mark is displayed when the ECM
detects a malfunction of the ignition switch (without immobilizer
control system) or when the key IDs do not match (With

. Immobilizer control system).

"Fl": When the ECM detects a malfunction of engine control

.
Diagnosis system, "Fl" is displayed.
LCD (TFT)
display "HILL!": When the ABS control unit / HU detects a malfunction

.
of hill hold control function, "HILL" is displayed.
"AIR!": When the combination meter detects a malfunction of

.
ambient air temp sensor, this indication is displayed.
"SW!": When the combination meter detects a malfunction of

.
handle switch, this indication is displayed.
Figure of battery mark: When the battery voltage is low, this

. indication appears.
OTC: OTC is displayed by using a special tool. The OTC that
can be displayed are P-codes (ECM), C-codes (ABS) and U-
codes (CAN).
Multifunction display The freeze mark appears on the main screen whenever the
Freeze ambient temperature falls below 3° C (38 ° F). If you press the
LCD (TFT)
indicator MODE/SET switch or the select switches (Up and Down) while
freeze mark is displayed, this indicator appears.
The thermometer shows the ambient temperature. The
temperature display range is from -10 °C to 50 °C (14 ° F to 122
°
Thermometer LCD (TFT) F). The meter displays "Lo" when the ambient air temperature is
below - 10 ° C (14 °F). The thermometer displays "HI" when the
ambient air temperature is above 50 °c (122 ° F).
"Service Reminder" is a function that tells you when the next
service is due by a date and distance indication and an service
Service reminder indicator light.
reminder LCD (TFT) The service reminder indicator are indicated when the set date or
indicator distance has been reached.
Refer to "Service Reminder Indicator Description": Technical
Features (Page OA-32).
"SDMS-a" is a feature that offers the rider a selection of 6 riding
assistance system modes with 5 different control levels.
SDMS (Suzuki Use these modes in accordance with riding conditions and
Drive Mode desired use, such as weather, speed, road conditions, and level
LCD (TFT)
Selector)-a of traffic. The available modes include A, 8, C, U1, U2, and U3.
indicator This indicator displays the currently selected mode.
Refer to "Suzuki Drive Mode Selector Alpha (SDMS-a)
Description": Technical Features (Page OA-15).
ETC and ERR The ETC indicator is displayed on vehicles equipped with ETC.
indicator (If LCD (TFT) An error mark "ERR" is displayed when there is an error in ETC
equipped) related parts.
 General Information: Technical Features 0A-31

Display
Display Function
indication
The information displayed here changes in accordance with the
Forward
LCD (TFT) rate of acceleration during acceleration and deceleration
acceleration
operations.
Engine rpm This indicator appears when the engine rpm indicator light (LED)
LCD (TFT)
indicator is set to blinking or on.
The hill hold indicator in the LCD display indicates the hill hold

.
operation status, as follows.

.
Hill hold Hill Hold ON indicator: System controlling brakes
LCD (TFT)
indicator Hill Hold ON indicator brinking: Advance notification of brake

.
control release
Hill Hold OFF indicator: System off, System failure
Riding
assistance You can set one riding assistance system mode each on the L
LCD (TFT)
system side and R side.
indicator
Gear position The gear position indicator indicates gear position. This indicator
LCD (TFT)
indicator displays "N" when the transmission is in neutral.
Throttle The throttle opening is highlighted in accordance with throttle
LCD (TFT)
opening operation.
Brake pressure The brake pressure for the front brake and rear brake is
(Front and LCD (TFT) highlighted in accordance with the operation of the front brake
Multifunction display
Rear) and rear brake.
The bank angles are highlighted in accordance with the bank
Bank angle LCD (TFT)
angle of the motorcycle as you are riding.
Maximum bank
The maximum bank angles are displayed in numeric format while
angle and
LCD (TFT) riding. The deepest bank angle is displayed by the peak hold
Bank angle
bars.
Peak hold bar
Riding
assistance This area displays the configured state of all control systems
LCD (TFT)
system configurable as riding assistance system indicators.
indicator list

.
This window displays the following items.

.
Odometer
Trip meter
• Average fuel consumption meter (km/L, L/100km or MPG US,
Information
.
LCD (TFT) MPG IMP)
window
Cumulative time
• Voltmeter
• Instantaneous fuel consumption meter
• Driving range meter
0A-32 General Information: Technical Features

Service Reminder Indicator Description

BENM10L30121017
When 1 month or 1000 km (600 mile) remains before the set date or distance, advance notice of the service interval
(inspection date, remaining distance) (1) is indicated for 2 seconds when the ignition switch is turned ON.

IM10L1012025-01
When the set date or distance for the service maintenance has been reached, an alarm screen (2) is indicated for 2
seconds when the ignition switch is turned ON. And on the main display, service reminder indicator (3) appears.

D
'111r '[ill]
3 10•00 AIR 30•c
5DIV1S

IM10L1012026-01
Once this service reminder indicator is displayed, it remains displayed until you reset the service reminder. The service
reminder is set using the mode select switch (special tool). Refer to "Service Reminder Reset" in Section 9C (Page
9C-9).
Special tool
(A): 09930-83130

IL06L1110161-01
 General Information: Technical Features OA-33

Cruise Control System Description

BENM10L30121018
System Description
• Cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.g. on a
highway. It allows the driver to drive at a constant speed of approximately 30 km/h (19 mile/h)* to 200 km/h ( 124
mile/h) without opening the throttle grip. (*: Vehicle speed varies depending on gear position. Refer to "Effective
Conditions for Control": Technical Features (Page 0A-33).
• T he system mainly consists of ECM, throttle body, cruise control switch, select switch ("RES / UP" and "SET /
DOWN"), mode switch, accelerator body assembly (incorporating cruise control cancel switch) and combination
meter.
• ECM performs control of the cruise control system. ECM controls throttle valve opening to keep actual vehicle
speed at set (target) speed.

Effective Conditions for Control

If all of the following conditions are met, it is possible to set the cruise control system.
• Cruise control switch (1) is ON state. (Cruise control system is in on-standby. Refer to "Cruise Control Indicator":
Technical Features (Page 0A-35).
NOTE
• Cruise control switch has a momentary contact type button. When ignition switch is turned "ON"
again, the system comes OFF.
• When the cruise control system enters the on-standby state by pushing the cruise control switch,
the LCD switches to the cruise control system dedicated display.
• The active speed limiter is switched to the on-standby state by pressing the "MODE" switch (2) for a
long time, when the cruise control system is in the on-standby state.

IM10L1012008-01

• Motorcycle is running at approximately 30 km/h (19 mile/h)* to 200 km/h (124 mile/h).
*: Vehicle speed varies depending on gear position, referring to the following table.
Gear position 2nd 3rd 4th 5th 6th
Approx. 30 km/h Approx. 40 km/h Approx. 50 km/h Approx. 55 km/h Approx. 60 km/h
Vehicle speed
(19 mile/h) (25 mile/h) (31 mile/h) (34 mile/h) (37 mile/h)

• Gear position is 2nd, 3rd, 4th, 5th or 6th.

• Clutch lever is released.
• Brake lever and pedal are released.
• Rear wheel does not wheel spin.
• No OTC related to the control is detected.
0A-34 General Information: Technical Features

Speed Set Function

When "SET/ DOWN" switch (1) is pressed in execution state of the control, the speed obtained when the switch is
pressed is stored as a set speed and the cruise control system starts control.

IM10L1012009-01

Acceleration / Deceleration Function

• When "RES/ UP" switch (1) is pushed momentarily, the vehicle speed is set to approximately 1 km/h (0.6 mile/h)
high.
When the switch is pushed for a long time, acceleration continues for pushing the switch. And when the switch is
released, the vehicle speed is set.
• When "SET/ DOWN" switch (2) is pushed momentarily, the vehicle speed is set to approximately 1km/h (0.6 mile/h)
low.
When the switch is pushed for a long time, deceleration continues for pushing the switch. And when the switch is
released, the vehicle speed is set.

NOTE
When control of the cruise control system, the vehicle speed can be accelerated by opening the
throttle grip. And when the throttle grip released, decelerate and keep the vehicle speed according to
the set speed by ECM.

IM10L1012010-01

Cancel / Resume Function

NOTE
*: Vehicle speed varies depending on gear position. Refer to "Effective Conditions for Control":
Technical Features (Page 0A-33).

• When throttle grip is turned adversely under the control of the cruise control system, the control is canceled and the
system becomes in a state of on-standby.
NOTE
Accelerator body assembly has a cruise control cancel switch. Refer to "Electric Throttle Control
System Description": Technical Features (Page 0A-13).

• When the cruise control is in on-standby state by cancel operation while the motorcycle is running at approximately
30 km/h (19 mile/h)* or higher speed, pressing "RES/ UP" switch (1) allows the system to resume motorcycle
running at the speed set before the control is canceled.
 General Information: Technical Features OA-35

IM10L1012011-01

• Cruise control is canceled under one of the following conditions.

Conditions Resume Function
Throttle grip is turned adversely. Available
Gear position is 1st and neutral. Available
Clutch lever is grasped. Available
Brake lever is grasped or brake pedal is depressed. Available
Cruise control switch is turned OFF. Not available
Motorcycle is running at lower than approximately 30 km/h (19 mile/h)* Not available
Rear wheel is wheel spin. Available
The actual vehicle speed does not reach target vehicle speed for specified time. Available
DTC related to the control of the cruise control system is detected. Not available

Cruise Control Indicator

• When the cruise control is in on-standby, cruise control indicator (1) is ON.
• When the cruise control is in set, "SET' indicator (2) is ON.
• When the resume function is available, a preset vehicle speed indicator (3) is displayed on the LCD.

PW: 1 TC: 1 LF: 1 ES: 1

QS: 1

IM10L1012012-01

Active Speed Limiter Description

BENM10L30121019
• Active speed limiter is a function to prevent the vehicle speed from exceeding a preset vehicle speed even when a
throttle grip is fully opened.
• Active speed limiter is in on-standby by pushing the cruise control switch (1).
NOTE
• Cruise control switch has a momentary contact type button. When ignition switch is turned "ON"
again, the system comes OFF.
• When the active speed limiter enters the on-standby state by pushing the cruise control switch, the
LCD switches to the active speed limiter dedicated display.
• The cruise control system is switched to the on-standby state by pushing the "MODE" switch (2) for
a long time, when the active speed limiter is in the on-standby state.

• The active speed limiter can be set once the ECM detects the vehicle speed after the ignition switch is turned ON.
• The method of changing the set vehicle speed is as follows. And the vehicle speed range that can be set is from 40
(25 mile/h) km/h to 200 km/h (124 mile/h).
- When "RES/ UP" switch (3) is pushed momentarily, the vehicle speed is set to 1 km/h (0.6 mile/h) high.
OA-36 General Information: Technical Features

When this switch is pushed for a long time, the set speed increases in increments of 5 km/h (3 mile/h) while the
switch is pushed. And when the switch is released, the vehicle speed is set.
- When "SET/ DOWN" switch (4) is pushed momentarily, the vehicle speed is set to 1 km/h (0.6 mile/h) low.
When this switch is pushed for a long time, the set speed decrease in increments of 5 km/h (3 mile/h) while the
switch is pushed. And when the switch is released, the vehicle speed is set.

: . . 2
MOD

,...,,,,,,,:i"' l

IM10L1012013-01

• When "MODE" switch is pushed under the control of the active speed limiter, the control is canceled and the active
speed limiter becomes in a state of on-standby. And when the active speed limiter is in on-standby state by cancel
operation, the set vehicle speed before cancellation becomes valid again by pushing the "MODE" switch.
• When cruise control switch is pushed under the control of the active speed limiter, the active speed limiter is OFF.
NOTE
When the throttle grip is open, the active speed limiter cannot be canceled or turned OFF by operating
the "MODE" switch or cruise control switch.

• Active speed limiter can be temporarily cancelled by quickly opening the throttle grip during the active speed limiter
set.

Active speed limiter Indicator

• When the active speed limiter is in on-standby, active speed limiter indicator (1) is ON.
• When the active speed limiter is in set, "SET" indicator (2) is ON.
• When ECM detects a malfunction in this system, active speed limiter indicator is blinks.
• When the active speed limiter is temporarily cancelled state, a preset vehicle speed indicator (3) is blinks.

PW: 1 re: 1 LF: 1 ES: 1

os:1

IM10L1012014-01
 General Information: Technical Features OA-37

Immobilizer Control System Description (If Equipped)

BENM10L30121020
System Description
• The immobilizer control system verifies that the key ID of transponder agrees with key ID already registered in ECM
by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system
makes the engine ready to start.
• The ignition key incorporates the transponder which stored key ID.

Operation Description
Operation procedure of immobilizer control system is as follows.
1) When the ignition switch is turned ON, the immobilizer antenna (1) and ECM (2) are powered ON.
2) The ECM transmits a signal (3) to the transponder (4) through the immobilizer antenna.
3) With the signal received, the transponder transmits the key ID signal (5) to the ECM through the immobilizer
antenna.
4) ECM compares this key ID with the key ID that has already been registered in ECM.
• If both key IDs agree, the ECM makes the engine ready to start. At the same time, ECM activates the indicator
light (6) of immobilizer antenna.
• If both key IDs do not agree, ECM causes fuel pump, fuel injector and ignition coil to be suspended. At the same
time, ECM activates the indicator light of immobilizer antenna.
NOTE
For details of indicator light, referring to "Indicator Light Description": Technical Features (Page OA-
38).

. . . .
5
----
: Permit : Inhibit : l41---------'"--
: engine : engine :
: starting :
..
: starting :
, ___________

IL06L1012017-01
0A-38 General Information: Technical Features

Indicator Light Description

When the ignition switch is turned ON , the indicator light (1) flashes as many as the number of key IDs registered in
ECM. Thereafter, if the key IDs are in agreement, the indicator light turns on for two seconds to notify of completion in
successful communication.
If the indicator light flashes fast, it notifies of communication error or disagreement of key ID.

ON

{®)(IGNITION 1

IE31J1180004-01

iii
Flashing Lighting

2 registered Normal

3 registered Normal

4 registered

--------
Fast flashing
Normal

Abnormal

Approx. 1.6 sec. ...,- Approx. 2.0 sec.---,

I705H1180006-01

CAN Communication System Description

BENM10L30121021
System Description
• Communication between each control module and device is established through continuous input/ output of ON/
OFF digital signals to exchange various data items. Transmitting / receiving these data is called as serial
communication interface. Types of serial communication interface with protocols (communication standards) such
as UART, CAN and LIN have been adopted for in-vehicle communication system.
• In this motorcycle, the following control devices transmit/ receive data through a twist pair of two communication
lines (CAN High (1) and CAN Low (2)) connected through CAN communication. Data obtained by a specific control
module can be shared with every control module. Communication speed of CAN system is fast and the system is
suitable for high-speed control data processing by ECM etc.
ECM (3)
Combination meter (4)
- ABS control unit/ HU (5)
- IMU (6)

NOTE
The SDS-11 communicates with ECM and ABS control unit/ HU by CAN communication.

4 3 6 5

�
2 2
'
2 ?'

8 1

.................................... ·•· ..................•...................

I I I
I I I ■
1 I I I

IM10L1012015-01
7. Mode select coupler (6P) 8. J/C
 General Information: Technical Features 0A-39

CAN Communication Signal

CANcommunication is established as shown below with 2.5 Vas the reference level for both CANHigh signal (1)and
CANLow signal (2). The range of CANHigh signal is from 2.5 Vto about 3.5 Vand that of CANLow signal is from 2.5
Vto about 1.5 V. When both are at 2.5 V, signal is judged as OFF. When CANHigh signal is 3.5 Vand CANLow signal
is 1.5 V {that is , when the difference between High voltage and Low voltage is more than about 2V), signal is judged
as ON. F or this reason, a feature of CANcommunication signal is that the signal waveform between CANHigh and
CANLow signals is symmetrical with respect to 2.5 Vlevel. CANcommunication fails when the symmetrical signal
form collapses.

3.5 v--

2·5 V ----1�1�u-1-u~rn u 1 1 mm I m !!!!!!! 1 111!111

11. 1.i iiiirn.11.. 1t :ttrn i...ii.l
.......
::::::: :
. . .. .. .....
. . . . . . . ... ..
.......
....
:::::::
..
.. ..
1.5 v -�
2

ov IL06L1012019-01
OB-1 Maintenance and Lubrication:

Maintenance and Lubrication

Precautions
Precautions for Maintenance
BENM10L30200001
The "Periodic Maintenance Schedule Chart" lists the recommended intervals for all the required periodic service work
necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed
in terms of kilometers, miles and months for your convenience.
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed
emission standards and it will also ensure the reliability and performance of the motorcycle.

NOTE
More frequent servicing may be required on motorcycles that are used under severe conditions.

Scheduled Maintenance
Periodic Maintenance Schedule Chart
BENM10L30205001
NOTE
I = Inspect and clean, adjust, replace or lubricate as necessary.
R = Replace.
T = Tighten.

Interval
months 2 12 24 36 48
Item
km 1000 6000 12000 18000 24000
miles 600 3750 7500 11250 15000
Air cleaner element w(Page 0B-3) - I I R I
Exhaust pipe bolts and muffler bolts w(Page 0B-3) T - T - T
Valve clearance w(Page 08-4) - - - - I
Spark plugs "1°(Page 0B-7) - I R I R
Fuel hose w(Page 0B-8) - I I I I
Evaporative emission control system (california model - - -
I I
only) w(Page 0B-8)
Engine oil w(Page 0B-11) R R R R R
Engine oil filter c,F(Page 0B-12) R - - R -
Throttle cable play @"(Page 0B-12) I I I I I
PAIR (air supply) system w(Page 0B-13) - - I - I
Throttle bore cleaning w(Page 0B-14) - - I - I
Throttle valve synchronization ce-(Page 08-15) I - I - I
"SUZUKI SUPER
LONG LIFE COOLANT" Replace every 4 years or 48000 km (30000 miles)
(Blue)
"SUZUKI LONG LIFE
Engine coolant w(Page 0B-16) COOLANT" (Green) or
an engine coolant other - - -
R R
than "SUZUKI SUPER
LONG LIFE COOLANT"
(Blue)
Radiator hose c,F(Page 0B-17) - I I I I
- I I I I
Clutch fluid w(Page 0B-17)
Replace every 2 years
- I I I I
Clutch hose w(Page 0B-18)
Replace every 4 years
Drive chain w(Page 0B-18)
I I I I I
Clean and lubricate every 1000 km (600 miles)
 Maintenance and Lubrication: 0B-2

Interval
months 2 12 24 36 48
Item
km 1000 6000 12000 18000 24000
miles 600 3750 7500 11250 15000
Brakes cF(Page OB-20) I I I I I
- I I I I
Brake fluid w(Page OB-22)
Replace every 2 years
- I I I I
Brake hose <?(Page OB-25)
Replace every 4 years
Tires <?(Page OB-26) - I I I I
Steering <7(Page OB-26) I - I - I
Front forks w(Page OB-27) - - I - I
Rear suspension <7(Page OB-28) - - I - I
Chassis bolts and nuts <?(Page 08-29) T T T T T
Lubrication w(Page OB-32) Lubricate every 1000 km (600 miles)
0B-3 Maintenance and Lubrication:

Repair Instructions
Air Cleaner Element •

BENM1OL30206001
-- . ·- �W>

\
Inspection
. ' . . .

Refer to "Replacement" (Page 08-3).

1) Inspect the air cleaner element for clogging. If it is
clogged with dirt, replace it with a new one.

NOTICE
• Do not blow the air cleaner element with
compressed air.
• If driving under dusty conditions, replace
the air cleaner element more frequently. IM10L1020004-02
Make sure that the air cleaner is in good 4) Install the new air cleaner element (1) to the air
condition at all times. Life of the engine cleaner box.
depends largely on this component.
5) Tighten the air cleaner element screws (2) to the
specified torque.
Tightening torque
Air cleaner element screw (a): 1.2 N·m (0.12 kgf­
m, 0.90 lbf-ft)

IM10L1020001-03

2) Remove the drain plug (1) and drain water from the
air cleaner box.

IM10L 1020078-01

6) Install the air cleaner cover. <1r(Page 1 D-6)

7) Install the fuel tank. <1r(Page 1G-12)

Exhaust Pipe Bolt and Muffler Mounting Bolts

BENM10L30206002
Tighten
IM10L 1020002-01 Check the exhaust pipe bolts, muffler connector bolt and
3) Install the drain plug to the air cleaner box. muffler support bolt are tightened to their specified
torque.
Replacement Tightening torque
1) Lift and support the fuel tank. w (Page 1G-12) Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
2) Remove the air cleaner cover. <1r(Page 10-6) Exhaust pipe support bolt (b): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
3) Remove the air cleaner element screws (1) and air
Muffler connector bolt (c): 18 N·m (1.8 kgf-m, 13.5
cleaner element (2) from the air cleaner box.
lbf-ft)
Muffler support bolt (d): 30 N·m (3.1 kgf-m, 22.5 lbf­
ft)
 Maintenance and Lubrication: OB-4

IM10L1020010-01

Valve Clearance
BENM 1 OL30206003
Refer to "Cylinder Head Cover Removal and Installation"
in Section 1D (Page 1D-15) and "Spark Plug Removal
and Installation" in Section 1 H (Page 1 H-5).

Inspection
Valve clearance adjustment must be checked and
adjusted, a) at the time of periodic inspection, b) when
the valve mechanism is serviced, and c) when the
camshafts are removed for servicing.
IM10L1020007-01
NOTE
• The cam must be at positions, (1) or (2),
when checking or adjusting the valve
clearance. Clearance readings should not
be taken with the cam in any other position
than these two positions.
• The valve clearance should be taken when
each cylinder is at Top Dead Center (TDC)
of compression stroke.
• The clearance specification is for COLD
state.
IM10L1020008-01
• To turn the crankshaft for valve clearance
checking, be sure to use a wrench, and
rotate in the normal running direction.

."
· =r-r,,•.-·
r rr r .,:;
,
r

,
r
'
�

I
IM10L1020096-01

IF04K1140093-01

1) Remove the valve timing inspection cap (1) and

starter clutch cover cap (2) from the starter clutch
cover.
0B-5 Maintenance and Lubrication:

"�l
o
I <l -

L �-'
IM10L 1020014-02

2) Turn the crankshaft clockwise to bring the line (1) on 3) In this condition, read the valve clearance at the
the starter clutch to the slit (2) of valve timing valves (1) (IN and EX of#4 cylinder, EX of#3 and IN
inspection hole and also to bring the cams to the of#2). If the clearance is out of specification, adjust
position as shown in the figure. the clearance.
Valve clearance
When engine cold
Intake [Standard]: 0.08 - 0.18 mm (0.0031 -
0.0070 in)
Exhaust [Standard]: 0.18 - 0.28 mm (0.0070-
0.0110 in)
Special tool
09900-20803

-
t
\-:..:("'.• - ,- �
;,�·��,.ih•. ,. � - -
'

.
�---- ...f
1"( \
-�--
2
y.:�
-.- � J -

;, J
IM10L1020015-01

IM10L1020013-04

IM10L1020016-01
°
4) Turn the crankshaft 360 degrees (one rotation) to
bring the line on the starter clutch to the slit of cap
hole thread and also to bring the cams to the position
as shown in the figure.
 Maintenance and Lubrication: 0B-6

I •""'I

-�
'
.,
�\
- ,

IL41 K1140050-01
IM10L1020017--02
b) Calculate the thickness of new shim by the
5) Read the clearance at the rest of the valves (1) and following formula.
adjust the clearance if necessary.
• Intake:

t
A= B + C - 0.15 mm (0.0059 in.)
• Exhaust:
A= B + C - 0.25 mm (0.0098 in.)
• A: Thickness of new shim
• B: Thickness of removed shim
I;�� �..u�,_·. ... --:;
;_· "·f
r=====r.
- • C: Measured valve clearance
,�-,•
NOTE
;-. The figures indicate the thickness of the
.
-;; !. shim, as illustrated, a total of 25 sizes of shim
are available ranging from 2.300 to 3.500 mm
in steps of 0.050 mm.
7'
IM10L1020018-01

Adjustment
The clearance is adjusted by replacing the existing
tappet shim with a thicker or thinner shim.
1) Remove the intake camshaft or exhaust camshaft. I837H1020014-01
<7(Page 1 D-18)
2) Remove the tappet (1) and shim (2) by fingers or c) Select new shim closest to calculated value from
magnetic hand. available size.
Indicated figure Thickness
230 2.300 mm
235 2.350 mm
240 2.400 mm
245 2.450 mm
250 2.500 mm
255 2.550 mm
260 2.600 mm
265 2.650 mm
270 2.700 mm
275 2.750 mm
IM10L1020019-01 280 2.800 mm
3) Select proper size of tappet as follows to adjust valve 285 2.850 mm
clearance to specification. 290 2.900 mm
295 2.950 mm
a) Using a micrometer, measure the thickness of
300 3.000 mm
the removed shim (1 ).
305 3.050 mm
310 3.100 mm
315 3.150 mm
320 3.200 mm
325 3.250 mm
330 3.300 mm
0B-7 Maintenance and Lubrication:

Indicated figure Thickness

335 3.350 mm
340 3.400 mm
345 3.450 mm
350 3.500 mm

4) Fit the selected shim (1) to the valve stem end.

NOTE
• Apply engine oil to tappet shim top and
bottom faces.
• When seating the tappet shim, be sure the I823H1020005-01

figure printed surface faces the tappet.

I
!
\.S
ll tl

i
a

ID26J1180010-03

NOTICE
IE31J1140061-01 Confirm the thread size and reach when
5) Install the intake camshaft or exhaust camshaft. replacing the plug. If the reach is too short,
<lr"(Page 1D-18) carbon will be deposited on the screw
portion of the plug hole and engine damage
6) Rotate the engine so that the tappet is depressed
may result.
fully. This will squeeze out oil trapped between the
shim and the tappet that could cause an incorrect
measurement, then check the clearance again to Heat Range
confirm that it is within the specified range. Check spark plug heat range by observing electrode
color. If the electrode of the spark plug is wet appearing
7) After finishing the valve clearance adjustment, check
or dark color, replace the spark plug with hotter type one.
the engine for smooth starting and free from any
If it is white or glazed appearing, replace the spark plug
abnormal noise.
with colder type one.
Spark Plugs Heat range
BENM10L30206004
Inspection Hot type Cold type
Standard
Refer to "Replacement" (Page 08-7). (Option) (Option)
NGK CR8EIA-9 CR9EIA-9 CR10EIA-9
Spark Plug Inspection DENSO IU24D IU27D IU31D
Check spark plug for:
• Electrode wear
Replacement
Refer to "Ignition Coil Removal and Installation" in
• Carbon deposits Section 1H (Page 1H-4).
• Insulator damage 1) Remove the spark plugs with a spark plug wrench.
• Spark plug gap "a"
If any abnormality is found, replace the spark plug with a Special tool
new one. (A): 09930-10121

Spark plug
Type [Standard]: NGK: CR9EIA-9 / DENSO: IU27D
Gap [Standard]: 0.8 - 0.9 mm (0.032 - 0.035 in)
 Maintenance and Lubrication: 0B-8

3) After finishing the fuel feed hose inspection, install

the removed parts.

Replacement
1) Lift and support the fuel tank. w(Page 1G-12)
2) Disconnect the fuel feed hose joints (1) from the fuel
pump, primary fuel delivery pipe and secondary fuel
delivery pipe. r:u-(Page 1G-7)

IM10L1020020-01

2) Screw the new spark plugs into the cylinder head

with fingers, and then tighten them to the specified
torque.
NOTICE
Do not cross thread or over tighten the spark
plug, or such an operation will damage the
aluminum threads of the cylinder head.
IM10L1020023-01

Special tool 3) Install the new fuel feed hose in the reverse order of
(A): 09930-10121 removal.

Tightening torque Evaporative emission control system

Spark plug: 11 N·m (1.1 kgf-m, 8.5 lbf-ft) BENM10L30206006
Refer to "EVAP System Removal and Installation" in
Section 18 (Page 18-8).

Hose
1) Lift and support the fuel tank. cc-(Page 1 G-12)
2) Remove the Frame cover assembly: r:u-(Page 9D-51)
3) Inspect the EVAP hoses (1) for wear or damage.
If it is worn or damage, replace the EVAP hose with a
new one. <r(Page 18-8)

IM10L 1020021-01

Fuel Hose
BENM10L30206005
Inspection
1) Lift and support the fuel tank. cc-(Page 1G-12)
2) Inspect the fuel feed hose (1) for damage and fuel
leakage. If any defects are found, the fuel feed hose
(1) must be replaced.

IM10L1020022-01
0B-9 Maintenance and Lubrication:
IM10L1020072-01
2. EVAP system purge control solenoid valve
3. EVAP canister
4) Check that the EVAP hoses are securely connected.
(u"(Page 1 B-2)
EVAP Canister
Gasoline and gasoline vapor is toxic. A small
amount of fuel remains in the EVAP canister
when checking it.
Do not swallow the fuel when blowing the
EVAP canister.
Check EVAP canister as follows.
If faulty condition is found, replace EVAP canister.
1) Remove the EVAP canister. cr(Page 1 B-8)
2) Check EVAP canister body for damage to the body.
3) Check that there is no restriction of flow through
purge port (1) and air port (2) when specified air
pressure (3) is blown into tank port (4).
EVAP canister blowing air pressure
[Standard]: 2.0 kPa (0.02 kgf/cm2, 0.29 psi)
IM10l1020073-01
EVAP System Purge Control Solenoid Valve
Gasoline and gasoline vapor is toxic. A small
amount of fuel remains in the EVAP system
purge control solenoid valve when checking
it.
Do not swallow the fuel when blowing the
EVAP system purge control solenoid valve.
1) Check the resistance between the terminals of the
EVAP system purge control solenoid valve (1 ). If the
resistance is not within the standard range, replace
the EVAP system purge control solenoid valve with a
new one.
EVAP system purge control solenoid valve
resistance
20 °C (68 °F) [Standard]: 22 - 26 Q
IL06l1020051-01
2) Check the EVAP system purge control solenoid
valve as follows. If faulty condition is found, replace
the EVAP system purge control solenoid valve with a
new one.
a) Connect clean hose (2) to air inlet port (1).
b) Check that there is no air flow to air outlet port
(4) when air (3) is blown into air inlet port.
IJ10K1120016-01
c) Connect the 12 V battery to the terminals of the
EVAP system purge control solenoid valve (1 ).
d) Check that there is no restriction of flow through
air outlet port (4) when air (3) is blown into air
inlet port (2).
 Maintenance and Lubrication: 0B-10

t=J¢3
IL06L1020052-01

Fuel Shut-off Valve

Check fuel shut-off valve as follows.
If faulty condition is found, replace fuel tank cap.
�(Page 1G-12)
1) Hold the fuel tank cap so that the fuel tank cap
breather hole (1) is aligned with and closely contacts
the packing breather port (2) and align the fuel tank
cap tip (3) at the same height as the fuel tank cap IM10L1020075-01
outer upper surface (4).
3) Keep the step 1), connect the vacuum pump gauge
to the breather port (1) with the fuel tank cap turned
upside down, and give negative pressure to check
that air cannot pass through.
Special tool
(A): 09917-47020

IM10L1020074--01

2) Keep the step 1), connect the vacuum pump gauge

to the breather port (1) with the fuel tank cap turned
upright, and give positive pressure to check that air
can pass through.
Special tool
(A): 09917-47020

IM1OL1020076-01
0B-11 Maintenance and Lubrication:

Engine Oil
BENM10L30206007
Inspection
Engine Oil Leakage Inspection
Visually check the cylinder, crankcase, etc. for oil
leakage.

Engine Oil Level Inspection

1) Keep the motorcycle upright on a level surface.
2) Start the engine at idle speed for a few minutes. Turn
off the engine and wait for about three minutes.
3) Check the oil level and deterioration through the
inspection window. If the oil level is below lower line IM10L1020026-01
(1 ), add new oil up to upper line (2). However, if the 5) Install the new gasket washer (1) to the oil drain plug
oil is deteriorated or discoloration, replace it. (2) and tighten the oil drain plug to the specified
torque.
NOTE
The sharp edge (3) of gasket must face the oil
drain plug side.

Tightening torque
Oil drain plug (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)

IM10L1020024-01

Replacement
1) Keep the motorcycle upright on a level surface.
2) Start the engine at idle speed for a few minutes and
then turn off the engine.
3) Place an oil pan under the engine and remove the oil 2, (a)
filler cap (1 ). IH13K1150048-01

6) Pour new oil through the oil filler hole.

IM10L 1020025-01
4) Drain engine oil by removing the oil drain plug (1).
A CAUTION
To avoid getting burned, do not touch the
engine, engine oil and exhaust system.
Necessary amount of engine oil
Oil change [Standard]: 3200 ml (3.38 US qt, 2.82
Imp qt)
Oil and filter change [Standard]: 3400 ml (3.59 US
qt, 2.99 Imp qt)
Engine overhaul [Standard]: 4100 ml (4.33 US qt,
3.61 Imp qt)
7) Install the oil filer cap
8) Start the engine and check for oil leakage.
9) Stop the engine and check the engine oil level again.
Refer to "Inspection" under "Engine Oil" (Page 08-
11).
 Maintenance and Lubrication: 0B-12

Engine Oil Filter

BENM10L30206008
Replacement
1) Drain the engine oil. Refer to "Replacement" under
"Engine Oil" (Page 0B-11).
2) Remove the right under cowling. ar-(Page 9D-42)
3) Remove the oil filter (1) using the special tool.

NOTICE
Detach the special tool once the oil filter has
come loose, and then remove the filter by ID26J1150014-03
hand.
6) Add new engine oil. Refer to "Replacement" under
Special tool "Engine Oil" (Page 0B-11).
(A): 09915-40620 7) Check the engine oil level. Refer to "Inspection"
under "Engine Oil" (Page 0B-11 ).

Throttle Cable Play

BENM10L30206009
Inspection
Turn the throttle grip slowly and inspect the throttle cable
play "a" at the periphery of the grip.
Throttle cable play
[Standard): 2.0 - 4.0 mm (0.08 - 0.16 in)

4) Apply engine oil lightly to the O-ring of new oil filter

(1) before installation.
NOTICE
ONLY USE A GENUINE SUZUKI
MOTORCYCLE OIL FILTER. IJ27K1140010-01

Other manufacturer's oil filters may differ in

Adjustment
thread specifications (thread diameter and
pitch), filtering performance and durability 1) Slid the rubber boots (1).
which may lead to engine damage or oil 2) Loosen the lock-nut (2) of the throttle cable No.1.
leaks. Also, do not use a genuine Suzuki 3) Turn the adjuster (3) in or out until the throttle cable
automobile oil filter on this motorcycle. play (at the throttle grip) is within the specification.
5) Install a new oil filter. Turn it by hand until you feel Throttle cable play
that the oil filter O-ring contacts the oil filter mounting [Standard]: 2.0 - 4.0 mm (0.079 - 0.16 in)
surface. Then, tighten the oil filter two full turns (or to
4) Tighten the lock-nut (2) while holding the adjuster
specified torque) with the special tool.
(3).
NOTICE
To properly tighten the oil filter, use the
special tool. Never tighten the oil filter by After the adjustment is completed, check that
hand only. handlebar movement does not raise the
engine idle speed and that the throttle grip
Special tool returns smoothly and automatically.
(A): 09915-40620
Tightening torque
Oil filter (a): 20 N·m (2.0 kgf-m, 15.0 lbf-ft)
0B-13 Maintenance and Lubrication:

PAIR Control Solenoid Valve

1) Remove the PAIR control solenoid valve, if
necessary. <:r(Page 18-5)
2) Check that air flows through the air inlet port to the
air outlet ports. If air does not flow out, replace the
PAIR control solenoid valve with a new one.
2 3
IE31J1130081-01

5) Reinstall the rubber boot.

PAIR (air supply) System

BENM10L30206010
PAIR Hose
1) Remove the air cleaner box. """(Page 1 D-6)
2) Inspect the PAIR hoses (1) for wear or damage.
If it is worn or damaged, replace the PAIR hose with
a new one. """(Page 18-5)
IF31J1120011-01

3) Connect the 12 V battery to the PAIR control

solenoid valve terminals and check the air flow. If air
does not flow out, the solenoid valve is in normal
condition.

IM10l.1020077-01

2. PAIR control solenoid valve

3) Check that the PAIR hoses are securely connected.

"""(Page 18-1)
IF31J1120012-01

PAIR Reed Valve
1) Remove the PAIR reed valve. """(Page 18-4)
2) Inspect the reed valves for carbon deposit.
If carbon deposit is found on the reed valve, replace
the PAIR reed valve with a new one.
4) Check the resistance between the terminals of the
PAIR control solenoid valve. If the resistance is out
of the specified valve, replace the PAIR control
solenoid valve with a new one.
PAIR control solenoid valve resistance
20 - 30 °c (68 - 86 °F) [Standard]: 20 - 24 n

1947H1120018-01
IF31J1120013-01
3) Install the PAIR reed valve. """(Page 18-4)
5) Reinstall the PAIR control solenoid valve. -(Page
18-5)

Throttle Bore Cleaning
BENM 1 0L30206011
Refer to "Air Cleaner Box Removal and Installation" in
Section 1D (Page 1D-6).
Inspection
1) Remove the funnel bolts (1) and remove the funnel
(2).
NOTE
When removing funnels, be careful that the
injector gets caught.
2) Shift the transmission into neutral.
3) Turn the ignition switch ON.
4) Set the anti-lift control "OFF".
NOTE
If the anti-lift control is not turned off, the
throttle valve will not fully open.
O peration Procedure
Make sure either the riding assistance system
indicator (1) is highlighted. Then, press and hold the
MODE/SET switch for 2 seconds to display the riding
assistance system indicator list (2).
After making a selection, use the select switches (Up
and Down) to set the anti-lift control "OFF".
NOTE
Set the SDMS to either A, B, or C, then turn
lift control "OFF". When the finished, reset
the lift control setting by turning the ignition
switch OFF.
\M10L1020090-01
5) Keep the throttle grip in the fully-opened position.
Maintenance and Lubrication: OB-14
NOTICE
Do not snap the throttle valve from the open
to full close. It may cause damage to the gear
inside the throttle body.
6) Inspect the main bore and throttle valve for carb?n
deposit. If carbon deposit is found, clean the main
bore and throttle valve.
Cleaning
1) Clean the location (1) shown in the figure with a
cotton swab moistened with carbon cleaner.
IM10L1020091-01
NOTICE
• Some cleaning chemicals are very
corrosive. Always follow the chemical
manufacturer's instructions for proper use,
handling and storage.
• Do not dip the throttle body in a cleaning
chemical or do not splay the cleaning
chemical directly to the throttle valve.
• Cleaning chemical will penetrate into
electronic parts resulting in cause of
malfunction.
• Do not use wire to clean passages. Wire
may damage them.
• Do not apply any cleaning chemical to
parts made of rubber and plastic materials.
Cleaning chemical may damage these
parts.
2) Install the removed parts.
3) Restore SDMS to its original setting.
4) After finishing the throttle bore cleaning, reset the
ISC aperture learned value.
NOTE
If you do not reset the ISC aperture learned
value, the idle speed may increase.
0B-15 Maintenance and Lubrication:

Throttle Valve Synchronization Adjustment

BENM 1 0L30206012
Check and adjust the throttle valve synchronization 1) Equalize the vacuum of the cylinders as follows:
among four cylinders. a) Check that the engine idle speed is within the
specified value.
Inspection
NOTICE
1) Start the engine and run it in idling condition for
warming up. A cylinder with the white painted
synchronizing screw is fixed to the specified
2) Stop the warmed-up engine.
vacuum (default setting). Do not turn the
3) Lift and support the fuel tank. <:ir"(Page 1G-12) synchronizing screw with the white paint.
4) Disconnect the respective vacuum hoses from
vacuum nipples on the throttle body. NOTE
5) Disconnect the IAP sensor coupler (1) from the IAP Cylinder position with the white painted
sensor. synchronizing screw depends on the throttle
6) Connect the respective vacuum tester hoses (2) to body.
the vacuum nipples.
b) Equalize the vacuum of the cylinders by turning
each synchronizing screw (1) except the one
with the white paint.

NOTE
Always set the engine rpm at idle rpm.

IM10l.1020030-02

7) Set up the SDS-11 tool referring to the SDS-11

operation manual for further details.
8) Start the engine.
9) Click "Data monitor".
10) Warm up the engine enough.
IM10L1020032-01
11) Click "Active control".
2) If the adjustment is not yet correct, inspect and clean
12) Click "ISC air volume control".
the throttle body. <?(Page 0B-14)
13) Click "ON" to fix the ISC air volume of four cylinders.
3) Repeat the procedures from 1) to 2).
NOTE 4) Close the SDS-11 tool and turn the ignition switch
When making this synchronization, be sure OFF.
that the engine coolant temperature is over 5) Disconnect the vacuum tester and install the
80 °C (176 °F). removed parts.
6) After completing the throttle valve synchronization,
14) Check for the synchronization of vacuum from #1 to clear the OTC and reset the ISC aperture learned
#4 cylinders. value. w-(Page 1C-3)

IM10L1020031-02
 Maintenance and Lubrication: 0B-16

Engine Coolant 5) Disconnect the water pump inlet hose (1) and drain
BENM10L30206013 engine coolant.
Inspection
1) Keep the motorcycle upright.
2) Remove the side cowling assembly. w(Page 9D-37)
3) Check the engine coolant level by observing the full
(1) and lower (2) lines on the engine coolant
reservoir tank. If the level is below the lower line, add
engine coolant to the bottom of full line from the
engine coolant reservoir tank filler.

6) Flush the radiator with fresh water if necessary.

IM10L1020033-01
4) Install the reservoir tank cap by aligning the match
mark (1) and reservoir tank overflow hose (2).
5) Install the removed parts.
Replacement
Refer to "Engine Coolant Description" in Section 1 F
(Page 1F-1).
1) Support the motorcycle upright.
2) Remove the side cowling assembly. w(Page 9D-37)
3) Lift and support the fuel tank. w(Page 1 G-12)
4) Remove the radiator cap (1).
7) Connect the water pump inlet hose. w(Page 1 F-2)
8) Pour the specified engine coolant up to the radiator
inlet.
Engine coolant
Engine side [Standard]: Approx. 2700 ml (2.9 US
qt, 2.4 Imp qt)
Reservoir tank side [Standard]: Approx. 200 ml
(0.21 US qt, 0.17 Imp qt)
9) Slowly swing the motorcycle, right and left, to bleed
the air trapped in the cooling circuit.
10) Add engine coolant up to the radiator inlet.
11) Close the radiator cap securely.
12) Start up the engine at idle speed for few minutes.
13) Stop the engine and wait until the engine cools down
fully.
14) Open the radiator cap and add engine coolant up to
the radiator inlet.
15) Repeat the 9)- 14) procedures until no air bleeds
from the radiator inlet.
16) Loosen the thermostat cover air bolt (1) and check
the engine coolant flows out.

--��
·:-,_
IM10L1020037-01

17) Install the new gasket to the thermostat cover air

bolt.
18) Tighten the thermostat cover air bolt to the specified
torque.
Tightening torque
Thermostat cover air bolt: 6.0 N·m (0.61 kgf-m,
IM10L 1160020-02
4.45 lbf-ft)
0B-17 Maintenance and Lubrication:

19) Install the radiator cap. Clutch Fluid

BENM10L30206015
20) After warming up and cooling down the engine Inspection
several times, add the engine coolant up to the full
1) Keep the motorcycle upright and place the
level of the reservoir. Refer to "Inspection" under the
"Engine Coolant" (Page 0B-16). handlebar straight.
21) Install the removed parts. 2) Check the clutch fluid level by observing the lower
limit line (1 ). When the clutch fluid level is below the
lower limit line, replenish with clutch fluid that meets
Radiator Hose the following specification.
BENM10L30206014
1) Remove the side cowling assembly. cr(Page 9D-37) Brake fluid (DOT 4)
2) Lift and support the fuel tank. cr(Page 1 G-12)
3) Check the radiator hoses (1) for crack, damage or
engine coolant leakage. If any defect is found,
replace the radiator hose with a new one.
4) Any leakage from the connecting section (2) should
be corrected by proper tightening. cr(Page 1 F-2)

IM10L1020042-01

Replacement
1) Remove the side cowling assembly. cr(Page 9D-37)
2) Place the motorcycle on a level surface and keep the
handlebar straight.
IM10L1020038-01 3) Remove the clutch fluid reservoir cap screws (1),
clutch fluid reservoir cap (2) and diaphragm from the
clutch master cylinder.

IM10L1020039-01

5) After finishing the radiator hose inspection, install the

removed parts. IM10L1020043-01

4) Suck up the old clutch fluid as much as possible.

IM10L 1020044-01

5) Fill the reservoir with new clutch fluid.

Brake fluid (DOT 4)
 Maintenance and Lubrication: 0B-18

6) Attach a clear hose (1) to the air bleeder valve (2)

and insert the free end of the hose into a receptacle.

Replacement
7) Loosen the air bleeder valve, squeeze and release
the clutch lever and drain the old clutch fluid out of
the clutch system.
NOTE
While bleeding the clutch system, replenish
the reservoir with the clutch fluid as
necessary to keep the fluid above the lower
level.
1) Remove the fuel tank. w(Page 1G-12)
2) Drain the clutch fluid. Refer to "Replacement" under
"Clutch Fluid" (Page 08-17).
3) Remove the clutch hose as shown in the clutch hose
routing diagram. Refer to "Clutch Hose Routing
Diagram" in Section 5C (Page 5C-3).
4) Install the new clutch hose and clamps. Refer to
"Clutch Hose Routing Diagram" in Section 5C (Page
5C-3).
5) Bleed air from the clutch system. Cu'(Page 5C-6)

Drive Chain
BENM10L30206017
Inspection
Drive chain
1) With the transmission in neutral, support the
motorcycle with a jack and turn the rear wheel slowly
by hand.
2) Visually check the drive chain for the possible
IM10L1020046-01
defects listed as follows. If any defects are found, the
8) Bleed the air from the clutch system. w(Page 5C-6) drive chain must be replaced. w(Page 3A-8)

Clutch Hose NOTE

BENM10L30206016
When replacing the drive chain, replace the
Inspection
drive chain and sprockets as a set.
1) Remove the fuel tank. Cu'(Page 1G-12)
2) Inspect the clutch hose (1) for clacks, damage and • Loose pins
clutch fluid leakage. If defects are found, replace • Damaged rollers
clutch hose with a new one. • Dry or rusted links
• Kinked or binding links
Excessive wear
Improper chain adjustment
• Missing seal rings
0B-19 Maintenance and Lubrication:

Drive chain Length

1) Place the motorcycle on the side-stand.
2) Loosen the rear axle nut (1).
3) Loosen the left and right chain adjuster lock-nuts (2).
4) Give tension to the drive chain fully by turning both
chain adjuster bolts (3).

\) ..... - , I649G1020036-02
'
)
.,,,, � ... 4i,

Gear shift cover protector

I�\ Check the gear shift cover protector (1) for wear or
', damage. If contacting surface (2) is worn or damaged,
.... ,.,,,
�t ( \-
1
\ l replace the gear shift cover protector with a new one.
,,.,
fl)
--
,r"

J
w(Page 3A-5)
��, -.
_,�'ll'l'
-.:I'·- ' 1
.,, a
) "I ) • ) /
) ) .
IM10L1310002-02

5) Count out 21 pins (20 pitches) on the chain and

measure the distance between the two points. If the
distance exceeds the service limit, the chain must be
replaced. w(Page 3A-8)
Drive chain 20-pitch length
[Limit]: 319.4 mm (12.57 in)
IM10L2020021-01
1 2 3
Adjustment

f
1) Place the motorcycle on the side-stand.
.. 2) Loosen the rear axle nut (1).
3) Loosen the left and right chain adjuster lock-nuts (2).
4) Loosen or tighten both chain adjuster bolts (3) until
I649G 1 020034-02
there is a slack "a" at the middle of the chain
between the engine and rear sprockets.
6) After finishing the drive chain length inspection,
adjust the drive chain slack. NOTICE

Drive chain slack The reference marks (4) on both sides of the
swingarm and the edge of each chain
Inspect the drive chain slack "a" at the middle of the
chain between the engine and rear sprockets. Adjust the adjuster must be aligned to ensure that the
front and rear wheels are correctly aligned.
drive chain slack if necessary.
NOTICE Drive chain slack
On side-stand
If you ride the motorcycle while the chain
[Standard]: 20 - 30 mm (0.79-1.18 in)
slack is outside the range of the specified
values, damage to the parts around the chain
may results.

Drive chain slack

On side-stand
Standard: 20-30 mm (0.79-1.18 in)
 Maintenance and Lubrication: 0B-20

7) Lubricate both front and back plates of the drive

chain (1).
8) Wipe off excess lubricant after lubricating all around
of the drive chain (1).

"a"
- --�. . . � ..
.. . .-
Q
,'

I649G1020036-02

5) After adjusting the drive chain, tighten the rear axle

nut to the specified torque.
Tightening torque
Rear axle nut: 100 N·m (10.2 kgf-m, 74.0 lbf-ft)
6) Recheck the drive chain slack after tightening the
axle nut.
IM10L1310004-01
7) Tighten both chain adjuster lock-nuts to the specified
torque.
Brakes
Tightening torque BENM10L30206018

Chain adjuster lock-nut: 22 N·m (2.2 kgf-m, 16.5 Brake Pad

lbf-ft) Front Brake Pad Inspection
The extent of brake pads (1) wear can be checked by
Cleaning and Lubrication observing the grooved limit line "a" on the pads. When
1) Place the motorcycle on the side-stand. the wear exceeds the grooved limit line, replace the
pads with new ones. <7(Page 4B-2)
2) Remove dirt and dust from the drive chain (1). Be
careful not to damage the seal ring.
3) Clean the drive chain (1) with a sealed drive chain
cleaner, or water and neutral detergent.

NOTICE
Cleaning the drive chain improperly can
damage seal rings and ruin the drive chain.
• Do not use a volatile solvent such as paint
thinner, kerosene and gasoline. \j
"a"
• Do not use high pressure cleaner to clean
the drive chain. IM10L1020047-03
• Do not use wire brush to clean the drive
chain. Rear Brake Pad Inspection
The extent of brake pads (1) wear can be checked by
4) Use a soft brush to clean the drive chain (1). Be observing the grooved limit line "a" on the pads. When
careful not to damage the seal ring even through the wear exceeds the grooved limit line, replace the
using a soft brush. pads with new ones.
5) Wipe off water and neutral detergent.
6) Lubricate with a motorcycle sealed drive chain
lubricant or high viscosity oil.
NOTICE
Some drive chain lubricant contains solvents
and additives which could damage the seal
rings in the drive chain.
Use sealed drive chain lubricant which is
specifically intended for use with sealed \j
"a"
drive chains.
IM1OL1020048-02
0B-21 Maintenance and Lubrication:

Brake Disc Special tool

Front Brake Disc Inspection (A): 09912-66310
Brake Disc Thickness
Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if defect is found.
Front brake disc thickness
[Limit]: 5.0 mm (0.197 in)
Special tool
(A): 09912-66310
ID26J1420029-01

Brake Disc Runout

1) Dismount the rear brake pads. Refer to "Rear Brake
Pad Inspection" in Section 4C (Page 4C-2).
2) Measure the runout using the dial gauge. Replace
the disc if the runout exceeds the service limit.
Rear brake disc runout
[Limit]: 0.30 mm (0.012 in)
ID26J1420029-01 Special tool
(A): 09900-20607
Brake Disc Runout (A): 09900-20701
1) Dismount the front brake pads. Refer to "Front Brake
Pad Replacement" in Section 48 (Page 48-2).
2) Measure the runout using the dial gauge. Replace
the disc if the runout exceeds the service limit.
Front brake disc runout
[Limit]: 0.30 mm (0.012 in)
Special tool
(A): 09900-20607
09900-20701
ID26J1420030-04

3) Remount the rear brake pads. Refer to "Rear Brake

Pad Replacement" in Section 4C (Page 4C-2).

Brake Light Switch

Front Brake Light Switch Inspection
1) Disconnect the front brake light switch coupler (1)
from the front brake light switch.

ID26J1420030-04

3) Remount the front brake pads. Refer to "Front Brake

Pad Replacement" in Section 48 (Page 48-2).

Rear Brake Disc Inspection

Brake Disc Thickness
Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if defect is found.
IM10L1020049-02
Rear brake disc thickness 2) Inspect the front brake light switch for continuity with
[Limit]: 5.0 mm (0.197 in) a circuit tester. If any abnormality is found, replace
the switch with a new one. Refer to "Front Brake
 Maintenance and Lubrication: 0B-22

Master Cylinder Assembly / Brake Lever 5) Install the removed parts.

Disassembly and Reassembly" in Section 4A (Page
4A-16). Brake Pedal Height
1) Inspect the brake pedal height "a" between the pedal
T1 T2 top face and footrest. Adjust the brake pedal height if
necessary.
Free
Grasped Brake pedal height
IM10L1020050-01 [Standard]: 50 - 60 mm (2.0 - 2.4 in)
3) Connect the front brake light switch coupler (1) to the
front brake light switch.

2) Loosen the lock-nut (1).

IM10L1020049-02
Rear Brake Light Switch Inspection
1) Lift up the fuel tank. w(Page 1G-12)
2) Disconnect the rear brake light switch coupler (1).
3) Turn the push rod (2) in or out until the brake pedal
height is within the specification.
4) Tighten the lock-nut (1) to the specified torque.
Tightening torque
Rear brake master cylinder rod lock-nut (a): 18
N·m (1.8 kgf-m, 13.5 lbf-ft)

3) Inspect the rear brake light switch for continuity with

a tester. If any abnormality is found, replace the 5) After finishing the brake pedal height inspection and
switch with a new one. Refer to "Rear Brake Light adjustment, check the rear brake light switch. Refer
Switch Removal and Installation" in Section 4A to "Brake light switch" under "Brakes" (Page 08-20).
(Page 4A-9).
Brake Fluid
BENM10L30206019
Inspection
1) Keep the motorcycle upright and place the
handlebars straight.
IM10L1020052-01
2) Check the brake fluid level by observing the lower
I
l�
limit lines (1) on the front and rear brake fluid
T1 T2
reservoirs. When the brake fluid level is below the
lower limit line, inspect for brake pad wear and leaks
Free and replenish with brake fluid that meets the
Depressed 0 -0 following specification.
IM10L1020053-01
Brake fluid (DOT 4)
4) Connect the rear brake light switch coupler.
0B-23 Maintenance and Lubrication:

Front brake Brake fluid (DOT 4)

5) Attach a clear hose (1) to the front brake caliper air
bleeder valve (2) and insert the free end of the hose
into a receptacle.
6) Loosen the front brake caliper air bleeder valve,
squeeze and release the brake lever and drain the
old brake fluid out of the brake system.

NOTE
While replacing the brake system, replenish
the reservoir with the brake fluid as
necessary to keep the fluid above the lower
level.
Rear brake

IJ27K1410061-01

7) Bleed the air from the front brake system. <:Jr>(Page

4A-11)
Replacement
Front Brake Rear Brake
1) Place the motorcycle on a level surface and keep the 1) Place the motorcycle on a level surface.
handlebars straight.
2) Remove the front seat. <:Jr>(Page 9D-34)
2) Remove the reservoir cap and diaphragm.
3) Remove the reservoir tank bracket bolt (1 ).
3) Suck up the old brake fluid as much as possible.

4) Move the reservoir tank with reservoir tank bracket

4) Fill the reservoir with new brake fluid. to outside of the frame.
 Maintenance and Lubrication: 0B-24

5) Remove the reservoir cap screws (1), reservoir cap

(2) and diaphragm from the rear brake master
cylinder reservoir.

IM10L1020070-01

10) Bleed the air from the rear brake system. cu-(Page
4A-11)
IM10L1020067-02
11) Install the diaphragm and reservoir cap (1).
6) Suck up the old brake fluid as much as possible.
12) Tighten the reservoir cap screws (2) to the specified
torque.
Tightening torque
Rear master cylinder reservoir cap screw (a):
1.5 N·m (0.15 kgf-m, 1.10 lbf-ft)

IM10L1020068-02

7) Fill the reservoir with new brake fluid.

Brake fluid (DOT 4)
8) Attach a clear hose (1) to the rear brake caliper air
bleeder valve (2) and insert the free end of the hose IM10L1410024-03

into a receptacle.
9) Loosen the rear brake caliper air bleeder valve (1)
and pump the brake pedal until the old brake fluid
flows out of the brake system.
NOTE
While replacing the brake system, replenish
the reservoir with the brake fluid as
necessary to keep the fluid above the lower
level.
13) Install the reservoir tank inside of the frame.
14) Tighten the reservoir tank bracket bolt (1) to the
specified torque.
Tightening torque
Rear brake master cylinder reservoir tank
bracket bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

IM10L1020093-01
08-25 Maintenance and Lubrication:

Brake Hose
BENM1OL30206020
Inspection
1) Remove the fuel tank. CiF(Page 1G-12)
2) Inspect the brake hoses and hose joints for crack,
damage or brake fluid leakage. If any defects are
found, replace the brake hose with a new one. Refer
to "Replacement" (Page 0B-25).

IM1OL1020060-01

IM10L1020056-01

Replacement
Front Brake Hose
Refer to "Front Brake Hose Routing Diagram" in Section
4A (Page 4A-2).
1) Drain the brake fluid. CiF(Page 08-22)
2) Remove the fuel tank. w(Page 1G-12)
3) Remove the front brake hoses.
4) Install the new front brake hose.
5) Install the fuel tank. CiF(Page 1G-12)
6) Bleed air from the front brake system. CiF(Page 0B-
22)

Rear Brake Hose

1) Drain the brake fluid. CiF(Page 0B-22)
2) Remove the fuel tank. CiF(Page 1G-12)
3) Remove the rear brake hose.
4) Install the new brake hose.
5) Install the fuel tank. CiF(Page 1G-12)
6) Bleed air from the front brake system.

Front Brake Hose Removal and Installation

BENM10L30206021
Refer to "Replacement" under the "Brake Hose" (Page
08-25).

Rear Brake Hose Removal and Installation

BENM 1 OL30206022
Refer to "Replacement" under the "Brake Hose" (Page
0B-25).
IM10L1020059-01
 Maintenance and Lubrication: 0B-26

Tires Tire pressure

BENM1 OL30206023 If the tire pressure is too high or too low, steering will be
Wipe the tire clean and check for the following points: adversely affected and tire wear increased. Therefore,
• Nick and rupture on side wall maintain the correct tire pressure for good roadability or
• Tread separation shorter tire life will result. Cold inflation tire pressure is as
• Abnormal, uneven wear on tread follows.
• Surface damage on bead
Cold inflation tire pressure
• Localized tread wear due to skidding (Flat spot) Front Rear
• Abnormal condition of inner liner [Standard] [Standard]
Solo 290 kPa 290 kPa
Tire size
riding (2.90 kgf/cm2, 42 psi) (2.90 kgf/cm2, 42 psi)
Front [Standard]: 120/70ZR17M/C (58W), tubeless
Dual 290 kPa 290 kPa
Rear [Standard]: 190/50ZR17M/C (73W), tubeless
riding (2.90 kgf/cm2 , 42 psi) (2.90 kgf/cm2 , 42 psi)
Tire type
Front [Standard]: BRIDGESTONE / S22F L
Rear [Standard]: BRIDGESTONE / S22R L

I310G1020069-02
I649G1240042-02

Tire tread condition Steering

BENM10L30206024
Operating the motorcycle with excessively worn tires will Inspection
decrease riding stability and consequently invite a Steering should be adjusted properly for smooth turning
dangerous situation. It is highly recommended to replace of handlebars and safe running. Overtighten steering
a tire when the remaining depth of tire tread reaches the prevents smooth turning of the handlebars and too loose
following specification. steering will cause poor stability.
Tire tread depth 1) Check that there is no play in the steering stem.
Recommend depth a) Support the motorcycle with its front wheel off
Front [Limit]: 1.6 mm (0.06 in) the ground, grasp the bottoms of the front forks
Rear [Limit]: 2.0 mm (0.08 in) and move the forks back-and-forth to check
Special tool there is no play in the stem bearings.
09900-20805

,.----,
I '
/ I

:�:
\'' ...½,'
__ ... ,. ,

I310G1020068-02 IM10L1020080-01

b) With the front wheel on the ground and applying

the front brake(s), move the handlebar backand­
forth and up-and-down to check there is no play
in the stem bearings.
0B-27 Maintenance and Lubrication:

IM10L1020094-01

2) If play is found, adjust the steering tension.
Adjustment
1) By supporting the motorcycle with a jack, lift the front
wheel until it is off the floor 20 - 30 mm (0.8 - 1.2 in).
2) Remove the steering damper. ""(Page 68-11)
3) Check to make sure that the cables and wire
harnesses are properly routed.
4) With the front wheel in the straight ahead state, hitch
the spring scale on one handlebar grip end as shown
in the figure and read the graduation when the
handlebar start moving.
Steering tension initial force
[Standard]: 2 - 5 N (0.21 - 0.50 kgf, 0.45 - 1.12 lbf)
d) Tighten the steering stem lock-nut to the
specified torque and install the removed parts.
@'(Page 6B-3)
Tightening torque
Steering stem lock-nut: 80 N·m (8.2 kgf-m,
59.0 lbf-ft)
Steering stem top nut: 90 N·m (9.2 kgf-m,
66.5 lbf-ft)
e) Make sure that the initial force is within the
specified range and the steering is not loose.

IM10L 1020081-01

Front Forks
BENM10L30206025
IF04K1620033-01
Inspect the front forks for oil leakage, scoring or
5) Do the same on the other grip end. scratches on the outer surface of the inner tubes (1).
6) If the initial force reading on the scale when the Replace any defective parts, if necessary. c:r(Page 28-5)
handlebar starts turning is either too heavy or too
light, adjust the tension until it satisfies the
specification as follows.
a) Remove the body cowling. w(Page 9D-43)
b) Remove the handlebars and steering upper
bracket. <:r(Page 6B-3)
c) Remove the steering stem lock-nut, and then
adjust the steering stem adjust-nut (1) by
loosening or tightening it.
Special tool
(A): 09940-14911 IM10L1020082-01
(B): 09940-14960
 Maintenance and Lubrication: 0B-28

Rear Suspension
BENM10L30206026
Inspect the rear shock absorber ( 1) for oil leakage and
check that there is no play in the swingarm (2).
Replace any defective parts, if necessary.
• Rear shock absorber replace: <?(Page 2C-4)
• Swingarm pivot shaft and bearing inspection: w(Page
2C-11)
• Cushion lever inspection: <?(Page 2C-6)
• Cushion rod inspection: <7(Page 2C-8)
• Swingarm inspection: <?(Page 2C-11)

IM10L1020084-01
08-29 Maintenance and Lubrication:
Chassis Bolts and Nuts
Check that all chassis bolts and nuts are tightened to their specified torque.
1. Steering stem top nut
2. Steering stem lock-nut
3. Front fork upper clamp bolt
4. Front fork lower clamp bolt
5. Front brake master cylinder mounting bolt
6. Brake hose union bolt
7. Clutch master cylinder mounting bolt
8. Clutch hose union bolt
9. Swingarm pivot nut
10. Front footrest bracket bolt
(a): 90 N-m (9.2 kgf-m, 66.5 lbf-ft)
(b): 23 N-m (2.3 kgf-m, 17.0 lbf-ft)
BENM10L30206027
(�)
�
IM 1OL1020085-03
(c): 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
(d): 100 N-m (10.2 kgf-m, 74.0 lbf-ft)
(e): 26 N-m (2.7 kgf-m, 19.5 lbf-ft)
(f): 80 N-m (8.2 kgf-m, 59.0 lbf-ft)
 Maintenance and Lubrication: 0B-30

,.JS•f""' 1
"
. . (, . (,

,, 10, (g)
'
;,\'"
/

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'ti

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'

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t ��
�..:.. .,
13, (i)
- ,... .
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IM 1OL1020086-03

1. Rear shock absorber upper mounting nut
2. Brake pipe flare nut
3. Rear shock absorber lower mounting nut
4. Front axle nut
5. Front axle stopper bolt
6. Brake hose union bolt
7. Front brake disc bolt
8. Front brake caliper mounting bolt
9. Front brake caliper air bleeder valve (d): 8.5 N-m (0.87 kgf-m, 6.30 lbf-ft)
10. Rear brake disc bolt (e): 100 N-m (10.2 kgf-m, 74.0 lbf-ft)
11. Rear brake caliper air bleeder valve (f): 39 N-m (4.0 kgf-m, 29.0 lbf-ft)
12. Rear axle nut (g): 35 N-m (3.6 kgf-m, 26.0 lbf-ft)
13. Chain adjuster lock-nut (h): 8.0 N-m (0.82 kgf-m, 5.90 lbf-ft)
(a) 50 N-m (5.1 kgf-m, 37.0 lbf-ft) (i): 22 N-m (2.2 kgf-m, 16.5 lbf-ft)
(b): 15 N-m (1.5 kgf-m, 11.0 lbf-ft) U): 16 N-m (1.6 kgf-m, 12.0 lbf-ft)
(c): 23 N-m (2.3 kgf-m, 17.0 lbf-ft)
0B-31 Maintenance and Lubrication:

:.:? '"

/ !_
,./ �-
_�
..

., '

.. . 1, (

\\-. "_ r, f.,

���_'ll!.· (Q - /-' -- /�
�
,.-�
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....•
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IM10L1020087-01

1. Brake pipe flare nut 6. Cushion rod mounting nut (d): 18 N-m ( 1.8 kgf-m, 13.5 lbf-ft)
2. Brake hose union bolt 7. Seat rail mounting bolt (e): 78 N-m (8.0 kgf-m, 57.5 lbf-ft)
3. Rear brake master cylinder mounting bolt (a): 15 N-m (1.5 kgf-m, 11.0 lbf-ft) (f): 50 N-m (5.1 kgf-m, 37.0 lbf-ft)
4. Rear brake master cylinder rod lock-nut (b): 23 N-m (2.3 kgf-m, 17.0 lbf-ft)
5. Cushion lever mounting bolt (c): 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
 Maintenance and Lubrication: 0B-32

Lubrication
BENM10L30206028
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated as follows.
NOTE
• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
• Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the
motorcycle has been operated under wet or rainy conditions.

IM10L1020088-07
1. Clutch lever holder r..ii 5. Drive chain
: Lubricate with a motorcycle sealed drive
)®!: Apply grease.

chain lubricant or high viscosity oil.

2. Gearshift lever pivot 6. Brake lever holder �: Apply silicone grease.
3. Side-stand pivot and spring hook 7. Brake pedal pivot
4. Footrest pivot 8. Pillion footrest
0B-33 Maintenance and Lubrication:

Specifications
Tightening Torque Specifications
BENM1 0L30207001

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Air cleaner element screw 1.2 0.12 0.90 <7(Page 0B-3)
Exhaust pipe bolt 23 2.3 17.0 <7(Page 0B-3)
Exhaust pipe support bolt 23 2.3 17.0 """(Page 08-3)
Muffler connector bolt 18 1.8 13.5 <7(Page 0B-3)
Muffler support bolt 30 3.1 22.5 w(Page 08-3)
Spark plug 11 1.1 8.5 Clr'(Page OB-8)
Oil drain plug 23 2.3 17.0 Clr"(Page 08-11)
Oil filter 20 2.0 15.0 <lr'{Page 0B-12)
Thermostat cover air bolt 6.0 0.61 4.45 <lr'{Page 08-16)
Rear axle nut 100 10.2 74.0 cy-(Page 08-20)
Chain adjuster lock-nut 22 2.2 16.5 cy-(Page 0B-20)
Rear brake master cylinder rod lock-nut 18 1.8 13.5 w(Page 08-22)
Rear master cylinder reservoir cap screw 1.5 0.15 1.10 """(Page 0B-24)
Rear brake master cylinder reservoir tank -(Page 08-24)
10 1.0 7.5
bracket bolt
Steering stem lock-nut 80 8.2 59.0 w(Page 08-27)
Steering stem top nut 90 9.2 66.5 (Page 0B-27)
17

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Fasteners Information" in Section 0C (Page OC-6)
 Maintenance and Lubrication: 0B-34

Special Tools and Equipment

Recommended Service Material
BENM10L30208001
Material SUZUKI recommended product or Specification Note
Brake fluid DOT4 - w(Page 08-17) / w(Page
08-17) / w(Page 08-22) /
<?(Page 0B-23) I <?(Page
08-24)

NOTE
Required service material(s) is also described in:
"Lubrication" (Page 0B-32)

Special Tool
BENM10L30208002
09900-20607 09900-20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
<7(Page 0B-21) / <7(Page 0B-21) /
w(Page 0B-21) <7(Page 0B-21)

09900-20803 09900-20805
Thickness gauge Tire depth gauge
<7(Page 0B-5) w(Page 08-26)

09912-66310 09915-40620
Micrometer (0 - 25 mm) Oil filter wrench
w(Page 08-21) / @>(Page 0B-12) /
w(Page 0B-21) w(Page 0B-12)

09917-47020 09930-10121
Vacuum pump gauge set Spark plug socket set
w(Page 08-10) / w(Page 08-7) /
w(Page 08-10) w(Page 0B-8)

09940-14911 09940-14960
Steering stem nut socket Steering stem nut socket
wrench
w(Page 0B-27) w(Page 0B-27)
0C-1 Service Data:

Service Data
Precautions
Precautions for Service Data
BENM10L30300001
NOTE
Specifications and service data are subject to change without notice.

Specifications
Specifications
BENM10L30307001

Dimensions and curb mass

Overall length
Item Specification
2180mm (85.8 in) -
Remark

Overall width 735mm (28.9 in) -

1165mm (45.9 in) -
Overall height
1205 mm (47.4 in)
-
With option
Wheelbase
Ground clearance
1480mm (58.3 in)
125 mm (4.9 in) -
-
Seat height
Curb mass
800 mm (31.5 in)
264 kg (582 lbs) -
Engine

Type
Item Specification
4-stroke, liquid-cooled -
Remark

-
Number of cylinders
Bore
4
81.0 mm (3.189 in) -
Stroke 65.0 mm (2.559 in) -
Displacement 1340 cm3 (81.8 cu. in) -
-
Compression ratio 12.5: 1
-
Fuel system
Air cleaner
Fuel injection system
Paper element -
-
Starter system
Idle speed
Electric
1050 -1250 r/min -
Drive train

Clutch
Item Specification
Wet multi-plate --
Remark

Transmission
Gearshift pattern
6-speed constant mesh
1-down, 5-up -
Primary reduction ratio 1.596 (83/52) -
-
Low
2nd
2.615 (34/13)
1.937(31/16) -
3rd 1.526 (29/19) -
Gear ratios -
4th
5th
1.285 (27/21)
1.136 (25/22) -
-
Top
Final reduction ratio
1.043 (24/23)
2.388 (43/18) --
Drive chain RKGB50GSVZ5, 114 links

Chassis

Front suspension
Item Specification
Telescopic, coil spring, oil damped -
Remark

Rear suspension Link type, coil spring, oil damped -

Front fork stroke 120mm (4.7 in) -
 Service Data: 0C-2

Item Specification
140mm (5.5 in) -
Remark
Rear wheel travel
Steering angle 30 ° (right & left) -
23° 00' -
Caster
-
Trail 90mm (3.54 in)
-
Turning radius 3.3 m (10.8 ft)
-
Front brake
Rear brake
Disc brake, twin
Disc brake --
Front tire 120/70ZR17M/C (58W), tubeless
Rear tire 190/50ZR17M/C (73W), tubeless -
Electrical

Ignition type
Item Specification
Electronic ignition (Transistorized) -
Remark

Spark plug
DENSO: IU27D -
NGK: CR9EIA-9
Battery 12V 40.3 kC (11.2 Ah)/10 HR -
Capacities
Item Specification Remark
Fuel tank 20.0 L (5.3 US gal, 4.4 Imp gal)

Service Data
BENM10L30307002
Emission Control Devices
Item Specification Standard Limit / Note
PAIR control solenoid valve resistance 20-30 °C (68-86 °F) 20-24 0

Engine Electrical Devices

Item Specification Standard Limit / Note
Idle speed (When engine is warmed) 1050-1250 r/min -
Fast idle speed 2100-2300 r/min -
0 °C (32 °F) 5400-6600 0 -
IAT sensor resistance
80 °C (176 °F) 290-390 0 -
-20 °C (--4 °F) 13840-16330 0 -
ECT sensor resistance 20 °C (68 °F) 2320-2590 0 -
80 °C (176 °F) 310-326 0 -
HO2 sensor heater resistance 23 °C (73.4 °F) 11.5-17.5 0 -
Throttle body 1.0. No. 10L1 -
Throttle body bore size 43 mm (1.69 in) -

Engine Mechanical
Item Specification Standard Limit / Note
1400 -1900 kPa Limit: 1000 kPa (10
Compression pressure
(14 - 19 kgf/cm2, 203 - 276 psi) kgf/cm2, 145 psi)
IN. 36.58 - 36.62 mm (1.440-1.442 in) 36.28 mm (1.429 in)
Cam height
EX. 36.83-36.87 mm (1.450-1.452 in) 36.53 mm (1.439 in)
Camshaft journal oil clearance IN. &EX. 0.032-0.066 mm (0.0013-0.0026 in) 0.150 mm (0.0059 in)
Camshaft runout IN.&EX. - 0.10 mm (0.004 in)
Valve clearance (When engine is IN. 0.08-0.18 mm (0.0031 - 0.0070 in) -
cold) EX. 0.18-0.28 mm (0.0070-0.0110 in) -
IN. 4.975-4.990 mm (0.1959-0.1965 in) -
Valve stem 0.0. -
EX. 4.955-4.970 mm (0.1951-0.1957 in)
IN. 0.9-1.1 mm (0.036-0.043 in) -
Valve seat width -
EX. 0.9 - 1.1 mm (0.036 -0.043 in)
Valve guide 1.0. IN.&EX. 5.000-5.012 (0.1969-0.1973) -
Valve guide to valve stem IN. 0.010-0.037 (0.0004-0.0015) -
clearance EX. 0.030-0.057 (0.0012-0.0022) -
Valve spring free length IN. &EX. - 42.0 mm (1.653 in)
0C-3 Service Data:

Item Specification Standard Limit/ Note

Cylinder head distortion - 0.20 mm (0.0078 in)
Cylinder distortion - 0.20 mm (0.0078 in)
No nicks or
Cylinder bore 81.000-81.015 mm (3.1890-3.1896 in)
Scratches
80.970-80.985 mm (3.1878-3.1884 in)
80.850 mm (3.1831
Piston diameter Measure at 8.5 mm (0.33 in) from the skirt
in)
end.
1st - 0.180 mm (0.0070 in)
Piston ring to groove clearance -
2nd 0.150 mm (0.0059 in)
1st 0.06-0.18 mm (0.002-0.007 in) 0.50 mm (0.019 in)
Piston ring end gap
2nd 0.06-0.18 mm (0.002-0.007 in) 0.50 mm (0.019 in)
18.030 mm (0.7098
Piston pin bore I.D. 18.002 -18.008 mm (0.7087-0.7090 in)
in)
Piston pin O.D. 17.995-18.000 mm (0.7085-0.7087 in) 17.98 mm (0.7079 in)
Conrod big end side clearance 0.10-0.20 mm (0.004-0.008 in) 0.30 mm (0.011 in)
Conrod big end oil clearance 0.032-0.056 mm (0.0013-0.0022 in) 0.080 mm (0.0031 in)
Crankshaft journal O.D. 39.982-40.000 mm (1.5741-1.5748 in) -
Crankshaft journal oil clearance 0.010-0.028 mm (0.0004-0.0011 in) 0.080 mm (0.0031 in)
Crankshaft runout - 0.05 mm (0.002 in)

Engine Lubrication System

Item Specification Standard Limit/ Note
Oil pressure (at 60 °C, 140 °F) 3000 r/min
200-500 kPa
(2.0-5.1 kgf/cm2, 29.0-72.5 psi)
-
Oil change 3200 ml (3.4 US qt, 2.8 Imp qt) -
Necessary amount of engine oil Oil and filter change 3400 ml (3.6 US qt, 3.0 Imp qt) -
Engine overhaul 4100 ml (4.3 US qt, 3.6 Imp qt) -
Cooling System
Item Specification Standard Limit/ Note
Approx. 200 ml (0.21 US qt, 0.17
Reservoir tank side
Imp qt)
Engine coolant
Engine side
Approx. 2700 ml (2.9 US qt, 2.4
Imp qt)
-
108.0-137.4 kPa (1.1-1.4 kgf/ -
Radiator cap valve opening pressure
cm2, 15.7-19.9 psi)
Cooling fan operating temperature
ON-OFF Approx. 100 °C (212 °F) -
OFF-ON Approx. 105 °C (221 °F) -
Thermostat valve opening -
Approx. 82 °C (179.6 °F)
temperature
8 mm (0.3 in) or more at At 95 °C -
Thermostat valve lift
(203 °F)

Fuel System
Item Specification Standard Limit/ Note
289 -299 kPa (2.95 - 3.04 kgf/cm2 ,
Fuel pressure
42.0-43.3 psi)

Ignition System
Item Specification Standard Limit/ Note
Firing order 1•2•4•3 -
Spark plug Type DENSO: IU27D -
NGK: CR9EIA-9
Gap 0.8-0.9 mm (0.031 -0.035 in) -
 Service Data: 0C-4

Charging System
Item Specification Standard Limit/ Note
Battery leakage current 3m A or less -
Regulated voltage (charging output) 5000r/min 13.5-15.0V -
Generator coil resistance 0.2-0.70 -
Generator no-load voltage (When
50 00r/min 70V (AC) or more -
engine is cold)
Generator maximum output 5000r/min Approx . 375 W -
Type designation FTZ14S
Battery -
Capacity 12V 40.3kC (11.2 Ah)/10 HR

Front Suspension
Item Specification Standard Limit/ Note
Front fork inner tube O.D . 43mm (1.7in) -
Front fork oil level (Without spring,
88mm (3.5in)
inner tube fully compressed)
Front fork spring free length 264mm (10.4in) 258mm (10.2in)
Front fork oil capacity (Each leg) 521ml (17.62 USoz, 18.34 Imp oz) -
Adjustable range:
Front fork spring adjuster 10mm (0.39in) 4 -14mm (0.16-
0.55in)
8clicks counterclockwise from stiffest Adjustable range:
Rebound
position 0-11clicks
Front fork damping force adjuster
2 turns counterclockwise from stiffest Adjustable range:
Compression
position 0-3turns

Rear Suspension
Item Specification Standard Limit/ Note
Adjustable range:
Rear shock absorber spring pre-set
195mm (7.68in) 190-200mm
length
(7.48-7.87 in)
8clicks counterclockwise from stiffest Adjustable range:
Rebound
Rear shock absorber damping force position 0-18clicks
adjuster 1.5turns counterclockwise from stiffest Adjustable range:
Compression
position 0- 1.8turns

Wheels and Tires

Item Specification Standard Limit/ Note
Axial& -
Front 2.0mm (0.08in)
Radial
Wheel rim runout
Axial & -
Rear 2.0mm (0.08 in)
Radial
Tire size
Front 120/70ZR17M/C (58W) -
Rear 190/ 50ZR 17M/C (73W) -
Front BRIDGESTONE: S 22F L -
Tire type -
Rear B RIDGESTONE: S22R L
Tire tread depth (Recommended Front - 1.6mm (0.06in)
depth) Rear - 2.0 mm (0.08 in)
Cold inflation tire pressure (Solo Front 290kPa (2.90 kgf/cm 2 , 42psi) -
riding) Rear 290kPa (2.90 kgf/cm 2 , 42psi) -
Cold inflation tire pressure (Dual Front 290kPa (2.90kgf/cm 2 , 42psi) -
riding) Rear 290 kPa (2.90kgf/cm 2 , 42psi) -
Front 17 M/C x MT 3.50 -
Wheel rim size
Rear 17 M/C x MT 6.00 -
0C-5 Service Data:
Drive Chain/ Drive Train/ Drive Shaft
Item Specification Standard Limit/ Note
Type RKGB50GSVZ5 -
Drive chain Links 114 links -
20-pitch length - 319.4 mm (12.57 in)
Drive chain slack (on side-stand) 20 -30 mm (0.8-1.2 in) -
Brake Control System and Diagnosis
Item Specification Standard Limit/ Note
Rear brake pedal height 50-60 mm (2.0 - 2.4 in) -
Front Approx. 17.5 mm (0.69 in) -
Master cylinder bore / piston diameter -
Rear Approx. 14.0 mm (0.55 in)

Front Brakes
Item Specification Standard Limit/ Note
Brake disc thickness 5.3-5.7 mm (0.21 - 0.22 in) 5.0 mm (0.20 in)
Brake disc runout - 0.30 mm (0.012 in)
Brake caliper cylinder bore / piston -
Approx. 30.0 mm (1.18 in)
diameter

Rear Brakes
Item Specification Standard Limit/ Note
Brake disc thickness 5.3-5.7 mm (0.21-0.22 in) 5.0 mm (0.20 in)
Brake disc runout - 0.30 mm (0.012 in)
Brake caliper cylinder bore / piston -
Approx. 38.2 mm (1.50 in)
diameter

Manual Transmission
Item Specification Standard Limit/ Note
Gearshift fork thickness No.1, 2 4.8-4.9 mm (0.189- 0.193 in)

Clutch
Item Specification Standard Limit/ Note
Drive plate thickness No.1 2.92-3.08 mm (0.115-0.121 in) 2.62 mm (0.103 in)
No. 2 3.72-3.88 mm (0.146-0.153 in) 3.42 mm (0.135 in)
Driven plate distortion No.1, 2, 3, 4 - 0.10 mm (0.004 in)
Clutch spring free length 46.52 mm (1.831 in) 44.2 mm (1.74 in)
Master cylinder bore I piston diameter Approx. 12.7 mm (0.500 in) -
Release cylinder bore / piston -
Approx. 33.6 mm (1.32 in)
diameter

Steering/ Handlebar
Item Specification Standard Limit/ Note
Steering tension initial force 2-5 N (0.2-0.5 kgf, 0.4- 1.1 lbf)

Wiring Systems
Item Specification Standard Limit/ Note
Hi 7.5A -
Headlight :
Lo 7.5A -
Fuel 10A -
Ignition 10A -
Signal 10A
Fuse size
Fan 15A -
Main 30A -
Park 10A -
ABS motor 30A -
ABS valve 15A -
 Service Data: OC-6

Lighting Systems
Item Specification Standard Limit/ Note
Hi LED -
Headlight -
Lo LED
Position light LED -
Turn signal light LED -
Brake light/Tail light LED -
License plate light LED -

Combination Meter I Fuel Meter I Horn

Item Specification Standard Limit/ Note
Fuel indicator light LED -
Turn signal indicator light LED -
Traction control indicator light LED -
Engine coolant temperature indicator -
LED
light
Oil pressure indicator light LED -
Hi beam indicator light LED -
Master warning indicator light LED -
Malfunction indicator light LED -
Neutral indicator light LED -
ABS indicator light LED -
-20 °C (--4 °F) 13779- 19083 0 -
-10 °C (14 °F) 8100 -10609 0 -
0 °C (32 °F) 4928-6125 0 -
Ambient air temperature sensor 10 °C (50 °F) 3089-3656 0 -
resistance 20 °C (68 °F) 1992-2251 0 -
25 °C (77 °F) 1615-1785 0 -
30 °C (86 °F) 1290-1456 0 -
40 °C (104 °F) 838-986 0 -

Fasteners Information NOTICE

BENM1 0L30307003
Metric Fasteners
Most of the fasteners used for this vehicle are JIS­
defined and ISO-defined metric fasteners. When
replacing any fasteners, it is most important that
replacement fasteners are of the correct diameter,
thread pitch and strength.
Combining male and female fasteners with
different thread pitches will damage both
fasteners.
It is important to note that, even when the
nominal diameter (1) of the threads is the
same, JIS-defined and ISO-defined fasteners
may be different in thread pitch (2) or width
across flats (3). Refer to the following table
for these differences.
Before installing a fastener, check it for
correct thread pitch and then, screw it in or
on the mating fastener by hand. If the
fastener is too tight to turn by hand, its
thread pitch may be different from that of the
mating fastener.

JIS-TO-ISO main fasteners comparison table

Nominal diameter
MG MS M10 M12 M14
Thread pitch 1.0 1.25 1.25 1.25 1.5
JIS
Width across flats 10 12 14 17 19
T hread pitch 1.0 1.25 1.5 1.5 1.5
ISO
Width across flats 10 13 16 18 21
OC-7 Service Data:

01
replacement fasteners of the correct diameter and
thread pitch. Correct replacement bolts and nuts are
available as SUZUKI spare parts.
Metric bolts and nuts: Strength class numbers or marks
(The larger the number, the greater the strength).

11111111
IE31J1030001-02

Fastener Strength Identification

Most commonly used strength classes of metric
fasteners are 4T, 6.8, 7T and 8.8. Strength class is
indicated by a number or radial line(s) embossed on the
head of each bolt. Some metric nuts have a punched
number, 6 or 8 on their end surfaces. Figure shows
different strength markings.
When replacing metric fasteners, use bolts and nuts of
the same strength class as or higher class than the
original bolts and nuts. It is also important to select
IE31J1030002-01

1. Nut strength identification

Standard Tightening Torques

Each fastener should be tightened to the torque specified in each section. If no torque description or specification is
provided in the relevant section, refer to the following tightening torque chart for the applicable torque for each
fastener. When a fastener of greater strength than the original one is used, use the torque specified for the original
fastener.
NOTE
• For flanged bolts, flanged nuts and self-locking nuts of the 4T and 7T strength classes, add 10% to
the applicable tightening torques given in the following chart.
• The following chart is applicable only where the fastened parts are made of steel or light alloy.

Tightening torque chart

Thread diameter (Nominal diameter) (mm)
Strength Unit
4 5 6 8 10 12 14 16 18
Fastener of strength class equivalent to N-m 1.5 3.0 5.5 13 29 45 65 105 160
4T kgf-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16
lbf-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0

� ✓ IE31J1030003-01
Fastener of strength class equivalent to N-m 2.4 4.7 8.4 20 42 80 125 193 280
6.8 kgf-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28
lbf-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5

�
�
IE31J1030004-01
 Service Data: 0C-8

Thread diameter (Nominal diameter) (mm)

Strength Unit 16 18
4 5 6 8 10 12 14
Flanged fastener of strength class N-m 2.4 4.9 8.8 21 44 84 133 203 298
equivalent to 6.8 kgf-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8
*: Self-locking nut (6 strength) lbf-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5

f!fd ti� IE31J1030005-01

Fastener of strength class equivalent to N-m 2.3 4.5 10 23 50 85 135 210 240
7T kgf-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24

✓ ✓
lbf-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0

IE31J1030006-01
Fastener of strength class equivalent to N-m 3.1 6.3 11 27 56 105 168 258 373
8.8 (bolt) or 8 (nut) kgf-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3

✓✓
lbf-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0

IE31J1030007-01
Flanged fastener of strength class N-m 3.2 6.5 12 29 59 113 175 270 395
equivalent to 8.8 (bolt) or 8 (nut) kgf-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5
-- lbf-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0

�
�
"
IE31J1030008-01

Width across flats Thread diameter Unit

Small crown shape bolt
"b" [mm] "a" [mm] N-m kgf-m lbf-ft
7 5 4.5 0.45 3.5
8 6 10 1.0 7.5

ID26J1030004-01

*: Self-locking nut
0C-9 Service Data:

Tightening Torque-List
BENM10L30307004
Maintenance and Lubrication
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Air cleaner element screw 1.2 0.12 0.90 cr(Page 08-3)
Exhaust pipe bolt 23 2.3 17.0 cr(Page 08-3)
Exhaust pipe support bolt 23 2.3 17.0 cr(Page 08-3)
Muffler connector bolt 18 1.8 13.5 cr(Page 08-3)
Muffler support bolt 30 3.1 22.5 cr(Page 08-3)
Spark plug 11 1.1 8.5 cr(Page 08-8)
Oil drain plug 23 2.3 17.0 <?(Page 08-11)
Oil filter 20 2.0 15.0 w(Page 08-12)
Thermostat cover air bolt 6.0 0.61 4.45 <?(Page 08-16)
Rear axle nut 100 10.2 74.0 cr(Page 08-20)
Chain adjuster lock-nut 22 2.2 16.5 cr(Page 08-20)
Rear brake master cylinder rod lock-nut 18 1.8 13.5 w(Page 08-22)
Rear master cylinder reservoir cap screw 1.5 0.15 1.10 cr(Page 08-24)
Rear brake master cylinder reservoir tank cr(Page 08-24)
10 1.0 7.5
bracket bolt
Steering stem lock-nut 80 8.2 59.0 cr(Page 08-27)
Steering stem top nut 90 9.2 66.5 cr(Page 08-27)

Emission Control Devices

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
PAIR reed valve cover bolt 10 1.0 7.5 w(Page 18-4)
PAIR control solenoid valve bracket bolt 5.5 0.56 4.05 cr(Page 18-5)
PCV cover bolt 10 1.0 7.5 er (Page 18-7)
PCV reed valve cover bolt 10 1.0 7.5 cr(Page 18-7)
EVAP system purge control solenoid valve nut 6.7 0.68 4.95 cr(Page 18-9)
Accelerator body assembly bracket bolt 10 1.0 7.5 cr(Page 18-10)

Engine Electrical Devices

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
IAP sensor screw 1.3 0.13 0.95 c:r(Page 1C-5)
IAT sensor screw 1.3 0.13 0.95 cr(Page 1C-6)
ECT sensor 18 1.8 13.5 w-(Page 1C-7)
HO2 sensor 25 2.5 18.5 cr(Page 1C-10)
CMP sensor bolt 10 1.0 7.5 cr(Page 1C-11)
Accelerator body assembly bolt 10 1.0 7.5 w-(Page 1C-14)

Engine Mechanical
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Fuel tank bracket bolt (front side) 10 1.0 7.5 cr(Page 1D-7)
Fuel tank bracket bolt (rear side) 5.5 0.56 4.05 cr(Page 1D-7)
Funnel bolt 4.3 0.44 3.20 cr(Page 1D-7)
Air cleaner cover bolt 1.8 0.18 1.35 c:r(Page 1D-7)
Intake pipe clamp screw cr(Page 1D-10) /
1.5 0.15 1.10
w(Page 1D-13)
Delivery pipe screw 3.5 0.36 2.60 w(Page 1D-12)
Cylinder head cover bolt 12 1.2 9.0 w(Page 1D-15)
CMP sensor bolt 10 1.0 7.5 c:r(Page 1D-16)
Cam chain guide No.2 bolts 10 1.0 7.5 cr(Page 1D-21)
Camshaft journal holder bolt <?(Page 1D-22) /
10 1.0 7.5
w(Page 1D-25)
Cam chain tension adjuster bolt 10 1.0 7.5 cr(Page 1D-23)
 Service Data: 0C-10

Tightening torque Note

Fastening part N-m kgf-m lbf-ft
Valve timing inspection cap 23 2.3 17.0 <T(Page 1D-24)
Starter clutch cover cap 11 1.1 8.5 <T(Page 1D-24)
Engine mounting thrust adjuster 10 1.0 7.5 w(Page 1D-30)
Engine mounting thrust adjuster lock-nut 45 4.6 33.5 <T(Page 1D-30)
Side-stand bracket bolt 95 9.7 70.0 w(Page 1D-33)
Oil pressure switch lead wire bolt 1.5 0.15 1.10 <T(Page 1D-33)
Gearshift link arm bolt 10 1.0 7.5 w(Page 1D-33)
°
Cylinder head bolt (L180) 28 N-m - turn counterclockwise 270 -10 w(Page 10-36)
N-m- 25 N-m -51 N-m (2.9 kgf-m- turn
counterclockwise 270° - 1.0 kgf-m -2.5
kgf-m- 5.2 kgf-m, 21.0 lbf-ft- turn
counterclockwise 270° -7.5 lbf-ft- 18.5
lbf-ft -38.0 lbf-ft)
Cylinder head bolt (L55) 10 1.0 7.5 <T(Page 10-37)
Cylinder head bolt (L30) 10 1.0 7.5 <T(Page 10-37)
Cylinder nut 10 1.0 7.5 <T(Page 10-37)
Cylinder head side bolt 14 1.4 10.5 <T(Page 10-37)
Oil hose union bolt (cam chain tension adjuster) 18 1.8 13.5 <T(Page 10-38)
Oil hose union bolt (cylinder head) 20 2.0 15.0 <:7(Page 1D-38)
Cylinder head plug 23 2.3 17.0 w(Page 1D-45)
Oil gallery bolt (Cylinder head) 10 1.0 7.5 <T(Page 1D-45)
Water bypass union 12 1.2 9.0 <T(Page 1D-46)
Clamp screw 1.5 0.15 1.10 <T(Page 1D-46)
Thermostat cover bolt 10 1.0 7.5 w(Page 1D-46)
ECT sensor 18 1.8 13.5 <T(Page 1D-47)
Water inlet connector bolt 10 1.0 7.5 <T(Page 1D-54)
Balancer shaft arm bolt 10 1.0 7.5 <T(Page 1D-62)
Balancer shaft mounting bolt 10 1.0 7.5 <T(Page 1D-63)
Oil separator cover bolt 10 1.0 7.5 <T(Page 1D-63)
Oil pipe bolt 10 1.0 7.5 <T(Page 1D-63)
Oil pipe union bolt 24 2.4 18.0 w(Page 1D-63)
Oil filter stand 15 1.5 11.0 <T(Page 1D-64)
Gearshift cam stopper bolt 10 1.0 7.5 <?(Page 1D-64)
Gearshift cam plate stopper bolt 13 1.3 9.5 <D""(Page 1D-64)
Gearshift cover bolt 10 1.0 7.5 w(Page 1D-65)
Cam chain tensioner bolt 23 2.3 17.0 <7(Page 1D-65)
Oil hose union plug 25 2.5 18.5 <?(Page 1D-74)
Piston cooling oil gallery plug 10 1.0 7.5 <7(Page 1D-74)
Upper crankcase plug 23 2.3 17.0 w(Page 1D-74)
Transmission cooling oil gallery plug 10 1.0 7.5 <?(Page 1D-74)
Oil gallery plug (M10) 18 1.8 13.5 <?(Page 1D-75)
Oil gallery plug (M6) 10 1.0 7.5 <7(Page 1D-75)
Oil gallery plug (M8) 10 1.0 7.5 <T(Page 1D-75)
Crankcase bolt (M9) 22 N-m- turn clockwise 30° (2.2 kgf-m- <;iF(Page 10-77) /
turn clockwise 30° , 16.5 lbf-ft _, turn w(Page 1D-84)
clockwise 30° )
Crankcase bolt (M10) 50 5.1 37.0 <T(Page 1D-77)
Crankcase bolt (M8) 26 2.7 19.5 (y'(Page 1D-77)
Crankcase bolt (M6) 11 1.1 8.5 <:7 (Page 1D-78)
Conrod cap bolt 25 N-m- turn clockwise 90° (2.5 kgf-m- "'"(Page 1D-80) /
turn clockwise 90 ° , 18.5 lbf-ft -turn "'"(Page 1D-82)
clockwise 90° )
0C-11 Service Data:

Engine Lubrication System

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Oil gallery plug (M16) 35 3.6 26.0 <F(Page 1E-4)
Oil strainer bolt 10 1.0 7.5 .:r(Page 1E-7)
Breather pipe bolt 10 1.0 7.5 .:r(Page 1E-7)
Oil pan bolt 10 1.0 7.5 <7(Page 1 E-7)
Oil cooler outlet hose bolt 10 1.0 7.5 <F(Page 1 E-7)
Oil cooler bolt 5.5 0.56 4.05 <r(Page 1 E-9)
Oil cooler hose bolt 10 1.0 7.5 cr(Page 1E-9)
Oil pressure switch 13 1.3 9.5 w(Page 1E-11)
Oil pressure switch lead wire connecting screw 1.5 0.15 1.10 <7(Page 1E-11)
Piston cooling oil jet bolt 10 1.0 7.5 <F(Page 1E-12)
Oil jet 1.0 0.10 0.75 w(Page 1E-12)
Oil gallery jet 35 3.6 26.0 <,j"(Page 1E-13)
Oil pump bolt 10 1.0 7.5 .:r(Page 1E-15)

Engine Cooling System

Tightening torque
Fastening part Note
N-m kgf-m lbf.ft
Radiator assembly bolt 10 1.0 7.5 <F(Page 1F-10)
Oil cooler bolt 5.5 0.56 4.05 <F(Page 1F-10)
Radiator reservoir tank bolt 5.5 0.56 4.05 <F(Page 1F-10)
Thermostat cover bolt 10 1.0 7.5 w-(Page 1F-14)
Water pump bolt 10 1.0 7.5 w(Page 1F-16)
Impeller securing bolt 8.0 0.82 5.90 <7'(Page 1F-19)
Water pump case screw 6.0 0.61 4.45 w(Page 1F-19)

Fuel System
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Fuel tank cap bolt 3.0 0.31 2.25 w(Page 1G-12)
Fuel tank rear bolt 10 1.0 7.5 <7(Page 1G-13)
Fuel tank rear bracket bolt 10 1.0 7.5 <7'(Page 1G-13)
Rear brake master cylinder reservoir tank <F(Page 1G-13)
10 1.0 7.5
bracket bolt
Fuel tank front bolt 5.5 0.56 4.05 w(Page 1G-13)
Fuel pump mounting bolt 10 1.0 7.5 w-(Page 1G-18)
Fuel delivery pipe mounting screw <?(Page 1 G-22) /
3.5 0.36 2.60
w(Page 1G-23)

Ignition System
Tightening torque
Fastening part
N-m I kgf-m I lbf.ft
Note
Ignition switch mounting bolt 23 I 2.3 l 17.0 .:r(Page 1 H-8)

Starting System
Tightening torque
Fastening part Note
N-m kgf-m lbf•ft
Starter motor housing bolt 4.7 0.48 3.50 w(Page 11-6)
Starter relay terminal bolt 4.5 0.46 3.35 <er(Page 11-8)
Starter clutch bolt 54 5.5 40.0 c:,r-(Page 11-11)
Starter clutch cover bolt 10 1.0 7.5 w-(Page 11-12)
Starter torque limiter cover bolt 10 1.0 7.5 <:r(Page 11-12)
 Service Data: 0C-12

Charging System
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Generator stator bolt 11 1.1 8.5 <H"(Page 1J-6)
CKP sensor bolt 6.5 0.66 4.80 <Jr(Page 1J-6)
Generator rotor bolt 120 12.2 88.5 <Jr(Page 1J-6)
Generator cover bolt 10 1.0 7.5 <r(Page 1J-6)
Regulator/rectifier bolt 8.8 0.90 6.50 @>(Page 1J-7)
Regulator/rectifier bracket bolt 10 1.0 7.5 <H"(Page 1J-7)

Exhaust System
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Exhaust pipe bolt 23 2.3 17.0 w(Page 1K-5)
Exhaust pipe support bolt 23 2.3 17.0 c,;-,(Page 1K-5)
Muffler rear cover bolt 6.5 0.66 4.80 <u"(Page 1K-6)
Muffler cover bolt 5.5 0.56 4.05 <H"(Page 1K-6)
Muffler support bolt (except for India) 30 3.1 22.5 <:r(Page 1K-7)
Muffler support bolt (for India) 25 2.5 18.5 <u"(Page 1K-7)
Exhaust pipe cover bolt 5.5 0.56 4.05 <u"(Page 1K-7)
Muffler connector bolt 18 1.8 13.5 <r(Page 1K-7)

Front Suspension
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Front fork cap bolt 23 2.3 17.0 <r(Page 28-3)
Front fork lower clamp bolt 23 2.3 17.0 <Jr(Page 2B-3)
Front fork upper clamp bolt 23 2.3 17.0 <H"(Page 2B-3)
Front fork damper rod bolt 23 2.3 17.0 c,;-,(Page 2B-8)
Front fork inner rod lock-nut 15 1.5 11.0 w(Page 2B-10)

Rear Suspension
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Adjuster lock nut 30 3.1 22.5 <u"(Page 2C-3)
Rear shock absorber mounting nut <:r(Page 2C-4) I
50 5.0 36.0
<u"(Page 2C-6)
Cushion lever mounting nut w(Page 2C-4) I
78 8.0 57.5
w(Page 2C-6)
Cushion rod mounting nut w(Page 2C-6) I
78 8.0 57.5
<r(Page 2C-8)
Plate bolt 5.5 0.56 4.05 w(Page 2C-9)
Chain case bolt 5.5 0.56 4.05 <:r(Page 2C-9)
Chain buffer bolt 5.5 0.56 4.05 c,;-,(Page 2C-9)
Swingarm pivot shaft 15 1.5 11.0 <u"(Page 2C-10)
Swingarm pivot nut 100 10.2 74.0 <?(Page 2C-10)
Swingarm pivot lock-nut 90 9.2 66.5 w(Page 2C-10)

Wheels and Tires

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Front axle nut 100 10.2 74.0 c,;-,(Page 2D-4)
Front axle pinch bolt <T(Page 2D-4) I
23 2.3 17.0
cr(Page 2D-4)
0C-13 Service Data:

Drive Chain / Drive Train / Drive Shaft

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Engine sprocket nut 150 15.3 111.0 @>(Page 3A-4)
Engine sprocket cover bolt 10 1.0 7.5 w(Page 3A-4)
Engine sprocket cover bolt 5.5 0.56 4.05 Ci?(Page 3A-4)
Gear shift cover protector bolt 10 1.0 7.5 @>(Page 3A-5)
Rear sprocket nut 60 6.1 44.5 @>(Page 3A-5)

Brake Control System and Diagnosis

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Rear brake master cylinder rod lock-nut 18 1.8 13.5 w(Page 4A-10)
Front footrest bolt w(Page 4A-10) /
26 2.7 19.5
@>(Page 4A-22)
Rear brake master cylinder mounting bolt w(Page 4A-10) /
10 1.0 7.5
w(Page 4A-21)
Front footrest guard bolt Ci?(Page 4A-10) /
5.0 0.51 3.70
w(Page 4A-22)
Front brake master cylinder air bleeder valve @>(Page 4A-11) /
6.0 0.61 4.45
<?(Page 4A-17)
Front brake caliper air bleeder valve 8.5 0.87 6.30 @>(Page 4A-12)
Front reservoir cap screw 1.5 0.15 1.10 <7(Page 4A-12)
Rear brake caliper air bleeder valve 8.0 0.82 5.90 <?(Page 4A-13)
Rear master cylinder reservoir cap screw 1.5 0.15 1.10 <7(Page 4A-13)
Rear brake master cylinder reservoir tank <?(Page 4A-13)
10 1.0 7.5
bracket bolt
Front brake master cylinder holder bolt 10 1.0 7.5 w(Page 4A-15)
Brake hose union bolt w(Page 4A-16) /
23 2.3 17.0
<7(Page 4A-21)
Front brake light switch screw 1.2 0.12 0.90 w(Page 4A-18)
Brake lever pivot bolt 1.0 0.10 0.75 w(Page 4A-18)
Brake lever pivot bolt lock-nut 5.9 0.60 4.35 @"(Page 4A-18)
Brake hose connector screw 1.5 0.15 1.10 <7(Page 4A-23)

Front Brakes
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Front brake caliper mounting bolt w(Page 48-2) I
39 4.0 29.0
<7(Page 4B-3)
Brake hose union bolt 23 2.3 17.0 W"(Page 48-3)
Brake air bleed valve 8.5 0.87 6.30 <7(Page 4B-5)
Brake disc bolt 23 2.3 17.0 w(Page 48-6)

Rear Brakes
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Rear brake caliper mounting bolt 17 1.7 12.5 @"(Page 4C-2)
Rear brake pad mounting pin 15 1.5 11.0 w(Page 4C-2)
Brake hose union bolt 23 2.3 16.5 <7(Page 4C-3)
Rear brake caliper sliding pin bolt 32 3.3 24.0 <lr'(Page 4C-4)
Brake disc bolt 35 3.6 26.0 w(Page 4C-6)
 Service Data: 0C-14

ABS
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
ABS control unit/ HU mounting bolt 8.0 0.82 5.90 cr(Page 4E-51)
Tightening torque ABS control unit/ HU w(Page 4E-51)
12 1.2 9.0
mounting bolt
Brake pipe flare nut 16 1.6 11.5 w-(Page 4E-51)
IMU holder nut 6.5 0.66 4.80 w(Page 4E-52)
IMU bolt 6.5 0.66 4.80 @'(Page 4E-52)
Wheel speed sensor bolt <7(Page 4E-53) I
10 1.0 7.5
w(Page 4E-54)
Front brake disc bolt 23 2.3 17.0 <7(Page 4E-54)
Wheel speed sensor rotor bolt 6.5 0.66 4.80 w(Page 4E-55)

Manual Transmission
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Gearshift cam bearing retainer screw 8.4 0.86 6.20 w(Page 5B-5)
GP sensor nut 6.0 0.61 4.45 w(Page 5B-15)
Gearshift link rod nut 10 1.0 7.5 <7(Page 5B-18)
Gear shift sensor lock-nut 10 1.0 7.5 @'(Page 5B-19)
Gearshift link arm bolt 10 1.0 7.5 @'(Page 5B-20)

Clutch
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Clutch air bleeder valve 5.4 0.55 4.00 w(Page 5C-7)
Reservoir cap screw 1.5 0.15 1.10 <r(Page 5C-7)
Clutch master cylinder mounting bolt 10 1.0 7.5 w-(Page 5C-9)
Clutch hose union bolt <7(Page 5C-10) I
23 2.3 17.0
<7(Page 5C-14)
Clutch lever position switch screw 1.2 0.12 0.90 <7(Page 5C-12)
Clutch lever pivot bolt 1.0 0.10 0.75 w(Page SC-12)
Clutch lever pivot bolt lock-nut 5.9 0.60 4.35 w(Page 5C-12)
Clutch release cylinder mounting bolt 10 1.0 7.5 w(Page 5C-14)
Clutch sleeve hub nut 150 15.3 111.0 <7(Page 5C-20)
Clutch spring set bolt 10 1.0 7.5 w(Page 5C-22)
Clutch cover bolt 10 1.0 7.5 w(Page 5C-22)

Steering / Handlebar
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
handlebar bolt 23 2.3 17.0 cr(Page 6B-5)
Handlebar holder bolt 23 2.3 17.0 @'(Page 6B-5)
Front fork upper clamp bolt 23 2.3 17.0 w(Page 6B-5)
Steering stem top nut r:r(Page 6B-5) /
90 9.2 66.5
w(Page 68-15)
Handlebar balancer screw w(Page 6B-6) I
23 2.3 17.0
w(Page 6B-6)
Throttle grip screw 3.0 0.31 2.25 <7(Page 6B-8)
Left handle switch screw 3.0 0.31 2.25 <7(Page 6B-10)
Steering damper mounting bolt 23 2.3 17.0 w(Page 6B-12)
Steering damper rod end nut 23 2.3 17.0 w(Page 6B-12)
Steering stem adjust-nut 20 N-m (2.0 kgf-m, 15.0 lbf-ft) -+ turn <:?(Page 6B-14)
counterclockwise 0 - 1/4
Steering stem lock-nut 80 8.2 59.0 -(Page 6B-15)
0C-15 Service Data:

Exterior Parts
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Rear view mirror nut 12 1.2 9.0 17 (Page 9D-34)
Striker support bracket bolt 8.8 0.90 6.50 cir(Page 9D-36)
Front fender bolt 10 1.0 7.5 "°°(Page 9D-36)
Horn bolt 5.5 0.56 4.05 17 (Page 9D-37)

Lower bracket cover bolt 10 1.0 7.5 "°°(Page 9D-37)

Side cowling assembly bolt "°°(Page 9D-39) /
10 1.0 7.5 17 (Page 9D-50)

Side cowling assembly screw "°°(Page 9D-39) I

1.8 0.18 1.35
w(Page 9D-50)
Side front cowling No.1 screw 1.8 0.18 1.35 w(Page 9D-41)
Side rear cover screw 1.8 0.18 1.35 "°°(Page 9D-41)
Side cover screw 1.8 0.18 1.35 <7(Page 90-41)
Side front cowling No.2 screw 1.8 0.18 1.35 "°°(Page 9D-42)
Under cowling bolt cr(Page 9D-43) /
10 1.0 7.5
w(Page 90-50)
Under cowling screw 1.8 0.18 1.35 w(Page 90-43)
Cowling brace bolt 23 2.3 17.0 w(Page 90-46)
Regulator I rectifier bracket bolt 10 1.0 7.5 "°°(Page 9D-46)
Combination meter bolt 5.5 0.56 4.05 w(Page 9D-46)
Meter panel (center) screw 1.8 0.18 1.35 w(Page 9D-46)
Windscreen bolt 0.4 0.04 0.30 @"'(Page 9D-47)
Body center cowling screw 1.8 0.18 1.35 w(Page 9D-48)
Meter front panel screw 1.8 0.18 1.35 @"'(Page 9D-48)
Headlight screw 1.8 0.18 1.35 <7(Page 9D-48)
Cowling brace screw 1.8 0.18 1.35 <ir(Page 9D-48)
Front turn signal light screw 1.8 0.18 1.35 @"'(Page 9D-48)
Fuel tank front cover bolt 4.0 0.41 2.95 w(Page 9D-50)
Side cowling assembly screw No.2 4.5 0.46 3.35 w(Page 90-50)
Fuel tank cap cover bolt 5.5 0.56 4.05 w(Page 90-50)
Frame cover assembly screw 5.5 0.56 4.05 w(Page 90-52)
Frame cover assembly bolt 10 1.0 7.5 @"'(Page 90-52)
Frame center cover screw 2.0 0.20 1.50 @"'(Page 9D-52)
Frame cover screw 2.0 0.20 1.50 w(Page 9D-53)
Rear fender (rear) upper bolt 12 1.2 9.0 "°°(Page 9D-54)
Rear fender (rear) under bolt 12 1.2 9.0 @"'(Page 9D-54)
Frame under cover screw 0.8 0.08 0.60 <7(Page 90-54)

Cruise Control System

Tightening torque
Note
Fastening part
N-m I kgf-m I lbf-ft
Cruise control cancel switch screw 0.28 I 0.03 I 0.20 @"'(Page 10A-7)

Immobilizer Control System

Tightening torque
Note
Fastening part
N-m I kgf-m I lbf-ft
Immobilizer antenna bolt 4.5 I 0.46 I 3.35 @"'(Page 10C-6)
 Service Data: OC-16

Special Tools and Equipment

Fuel / Oil / Fluid / Coolant Recommendation Suzuki does not recommend the use of engine oils
BENM10L30308002 which have an "ENERGY CONSERVING" or
Fuel "RESOURCE CONSERVING" indication in the API
NOTICE service symbol for any of its motorcycles/ ATVs.
They can affect the engine life and the clutch
Do not use leaded gasoline. If it is used, the performance.
engine and the emission control system will
be damaged.

Use unleaded gasoline with an octane rating of 95 RON

(90 AKI) or higher.
Unleaded gasoline containing up to 5% or 10% ethanol
by volume may be used. Use the recommended
gasoline according to a gasoline label (if equipped). I D26J1030005-02

Engine Oil Brake Fluid

Suzuki recommends the use of SUZUKI Genuine Oil or Specification and classification: DOT 4
Equivalent Engine Oil.
A WARNING
SUZUKI Genuine Oil
Since the brake system of this motorcycle is
Standard filled with a glycol-based brake fluid by the
Oil
SAE JASO manufacturer, do not use or mix different
ECSTAR types of fluid such as silicone-based and
10W-40 MA
R9000 petroleum-based fluid for refilling the
ECSTAR
10W-40 MA system, otherwise serious damage will
R7000 result.
ECSTAR Do not use any brake fluid taken from old or
10W-40 MA
R5000 used or unsealed containers.
Never reuse brake fluid left over from a
Equivalent Engine Oil
previous servicing, which has been stored
Equivalent Engine Oil means engine oil that meets the
for a long period.
following standards.
Engine oil
API service classification SJ, SL, SM or SN Engine Coolant
JASO T903 standard MA (MA1, MA2) Suzuki recommends the use of SUZUKI LONG LIFE
Viscosity SAE 10W-40 COOLANT or SUZUKI SUPER LONG LIFE COOLANT.
Coolant 99000-99032-12X (SUZUKI LONG LIFE
If SAE 1 0W-40 engine oils are not available, select oils
COOLANT (GREEN))
of an appropriate viscosity grade according to the
Coolant 99000-99032-20X (SUZUKI SUPER LONG
following chart.
LIFE COOLANT (BLUE))
NOTICE If SUZUKI COOLANT is not available, use an anti­
When 10W-30 engine oil is used, use only SJ, freeze/engine coolant compatible with an aluminum
SL API classification. If there are not used radiator, mixed with distilled water only.
API classification engine oils, the engine will
be damaged.

ENGINE OIL
•
'.'.
-·• ,.._,. • •
• •
•
• •
·c -30-20-10 0 10 20 30 40
TEMP. "f -22 -4 14 32 50 68 86 104
IF04K1030001-01
0C-17 Service Data:

For SUZUKI LONG LIFE COOLANT For SUZUKI SUPER LONG LIFE COOLANT

NOTICE NOTICE
• Use a high quality ethylene glycol base • Ethanol or methanol base coolant or water
anti-freeze, mixed with distilled water. Do alone should not be used in cooling
not mix an alcohol base anti-freeze and system at any time as damage to cooling
different brands of anti-freeze. system could occur.
• Do not put in more than 60% anti-freeze or • Do not mix the distilled water, SUZUKI
less than 50%. (Refer to Fig. 1 and 2.) LONG LIFE COOLANT (coolant color:
Green) or equivalent.
The 50:50 mixture of distilled water and ethylene glycol
anti-freeze will provide the optimum corrosion protection SUZUKI SUPER LONG LIFE COOLANT will provide the
and excellent heat protection, and will protect the cooling optimum corrosion protection and excellent heat
system from freezing at temperatures above -31 °c (- protection, and will protect the cooling system from
24 °F). freezing at temperatures above -36 °C (-33 °F).
If the vehicle is to be exposed to temperatures below -
Anti-freeze concentration table
31 °C (-24 °F), this mixing ratio should be increased up
to 55% or 60% according to the figure. Anti-freeze density Freezing point
50% -36 oc (-33 °F)
Anti-freeze Proportioning Chart
Anti-freeze density Freezing point Water for mixing
50% -31 oc (-24 °F) Use distilled water only. Water other than distilled water
55% -40 oc (-40 °F) can corrode and clog the aluminum radiator.
60% -55 °C (-67 °F) For engine coolant mixture information, refer to "Engine
Coolant" (Page 0C-16).
Fig.1: Engine coolant density-freezing point curve
NOTICE
( O F) ( O C) Mixing of anti-freeze/engine coolant should
32 0 be limited to 60%. Mixing beyond it would
reduce its efficiency. If the anti-freeze/engine
I\
32 -10
coolant mixing ratio is below 50%, rust
1: -4 -20 inhabiting performance is greatly reduced.
·5
Be sure to mix it above 50% even though the
Ol -22 -30
atmospheric temperature does not go down

I
"f:j -40 -40
to the freezing point.
-58 -50
-76 -60 ..
I Anti-freeze / Engine coolant
-94 -70 .. I I
• I The engine coolant perform as a corrosion and rust
inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the
20 40 60 80 100 atmospheric temperature in your area does not go down
Density(%) to freezing point.
I310G1160001-02
Suzuki recommends the use of SUZUKI COOLANT anti­
freeze/engine coolant. If this is not available, use an
Fig.2: Engine coolant density-boiling point curve
equivalent which is compatible with an aluminum
(OF) (O C) radiator.
302 150 .---.----,--r---,--....----,
Front Fork Oil
284 140 1----t---i--+---+--t--::,,....., 1.5 Use SUZUKI FORK OIL L-01.
C �
"g_ 266 130 0.9 � Fork oil 99000-99044-L01 (SUZUKI FORK OIL L-01)
Ol �
§ 248 120 0.5 c.
Ol
Q)

� 15
�

230 110 0
c.,
212 100 1--==---1--+--+-+----I

0 10 20 30 40 50 60
Density(%)
I310G1160002-02
 Service Data: 0C-18

Special Tool
BENM10L30308003
NOTE
Torx® is the registered trademark of Camcar Division of Textron inc. U.S.A.

09900-06104 09900-06107 09900-06108 09900-18740 09900-20202

Snap ring pliers Snap ring pliers Snap ring pliers Hexagon bit socket Micrometer (25 - 50
(External: Bent nose) (External) (Internal) (24 mm: 1/2 sq.) mm)

09900-20203 09900-20530 09900-20602 09900-20605 09900-20607

Micrometer (50 - 75 Cylinder gauge set Dial gauge (1 x 0.001 Dial calipers (10 - 34 Dial gauge (10 x 0.01
mm) mm) mm) mm)

09900-20701 09900-20803 09900-20805 09900-20806 09900-21304

Dial gauge chuck Thickness gauge Tire depth gauge Thickness gauge V blocks

09900-22303 09900-22304 09900-22401 09900-22403 09904-41031

Plastigage (0.025 - Plastigage (0.051 - Small bore gauge (10 Small bore gauge (18 SDS-11 set
0.076 mm) 0.152 mm) - 18 mm) - 35 mm)

✓
09904-41041 09904-41051 09904-41071 09912-66310 09913-50121
SDS-11 (oscilloscope) Conversion cable Conversion cable Micrometer (0 - 25 Oil seal remover
set (ISO) mm)
OC-19 Service Data:

09913-70210 09915-40620 09915-41510 09915-63311 09915-64512

Bearing installer set Oil filter wrench Oil filter stand remover Compression gauge Compression gauge
adapter set (2500 kPa)

09915-74511 09915-74540
/
09916-10912 09916-14510 09916-14522
Oil pressure gauge set Oil pressure gauge Valve lapper Valve lifter Valve lifter attachment
(600 kPa) attachment

09916-34542 09916-34570 09916-34580 09916-44310 09916-53350

Reamer handle Valve guide reamer Valve guide reamer Valve guide installer / Valve guide installer
(05.0) (010.8) remover attachment

0i H�
..n.t A A
09916-74521 09916-74550 09916-84511 09917-47020 09918-78211
Piston ring holder Piston ring holder Tweezers Vacuum pump gauge Radiator cap tester kit
handle band (073 - 85) set

09919-28620
'/
09920-31020 09920-31021 09920-34830 09920-53740
Sleeve protector Extension handle Extension handle Starter clutch rotor Clutch sleeve hub
holder holder
 Service Data: 0C-20

09921-20240 09922-22712 09923-74511 09924--84510 09924--84521

Bearing remover set Drive chain cut/ rivet Bearing remover (020 Bearing installer set Bearing installer set
tool set - 35)

09925-18011 09930-10121 09930-11920 09930-11940 09930-30104

Bearing installer Spark plug socket set Ton<® bit (JT40H) Ton<® bit holder (3/8 Rotor remover sliding
sq.) shaft

09930-30450 09930-44530 09930-73140 09930-73170 09930-83130

Rotor remover bolt Rotor holder Starter torque limiter Starter torque limiter Mode selection switch
socket holder (ISO)

'
09940-14911 09940-14960 09940-14970 09940-14990 09940-30221
Steering stem nut Steering stem nut Swingarm pivot Engine mounting Front fork cylinder
socket socket wrench adjuster wrench adjuster wrench holder

09940-40211
t;;:::
�

09940-40220
'
09940-52841
@ .

�
�

' f!J
09940-52861
(;
{
!. ,;

,.___(2) �

09940-63110
Fuel pressure gauge Fuel pressure gauge Front fork inner rod Front fork oil seal Tooc® bit (ES)
adapter attachment holder installer set
0C-21 Service Data:

09940-93110 09940-94922 09940-94930 09941-34513 09943-74111

Fork spring Front fork spring Front fork spacer Bearing installer set Front fork oil level
compressor stopper plate holder gauge

Section 1
Engine
CONTENTS
Precautions ................................................. 1-1
Precautions............................................................. 1-1
Precautions for Engine .......................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
Precautions........................................................... 1A-1
Precautions for DTC Trouble Shooting ............... 1A-1
General Description ............................................. 1A-1
Self-Diagnosis Function ...................................... 1A-1
Schematic and Routing Diagram ........................1A-6
Engine Control System Wiring Diagram.............. 1A-6
Component Location ........................................... 1A-8
Engine Control System Component Location ..... 1A-8
Diagnostic Information and Procedures ............ 1A-9
Engine Control System Check ............................ 1A-9
DTC Check ....................................................... 1A-11
DTC Clearance ................................................. 1A-12
DTC Table......................................................... 1A-13
Fail-Safe Table.................................................. 1A-19
Scan Tool Data ................................................. 1A-20
Visual Inspection ............................................... 1A-24
Engine Symptom Diagnosis .............................. 1A-25
MIL Inspection................................................... 1A-30
Master Warning Indicator Inspection................. 1A-31
DTC P0030 ....................................................... 1A-32
DTC P0050 ....................................................... 1A-34
DTC P0069 ....................................................... 1A-36
DTC P0110/P0111 /P0112 ............................ 1A-38
OTC P0115 / P0116 / P0117 ............................ 1A-40
DTC P0120/P0123 .......................................... 1A-42
DTC P0130/P0132/P0133 ............................ 1A-44
DTC P0150/P0152 /P0153 ............................ 1A-46
DTC P0171/P0172/P0174/ P0175 ............... 1A-48
DTC P0201/P0202/P0203/P0204 ............... 1A-50
DTC P0220 I P0223 .......................................... 1A-52
DTC P0232/P023F .......................................... 1A-55
DTC P0300 I P0301/P0302/P0303/P0304 .. 1A-57
DTC P0335 ....................................................... 1A-59
DTC P0340 ....................................................... 1A-61
DTC P0351/P0352/P0353/P0354 ............... 1A-63
DTC P0410 ....................................................... 1A-64
DTC P0412 ....................................................... 1A-65
DTC P0444 ....................................................... 1A-67
Table of Contents 1- i
DTC P0480 ....................................................... 1A-69
DTC POS00 ....................................................... 1A-71
DTC P0508 ....................................................... 1A-73
DTC P0602 ....................................................... 1A-73
DTC P0607 ....................................................... 1A-73
DTC P0826 I P0828 .......................................... 1A-74
DTC P0830 ....................................................... 1A-76
DTC P0850 ....................................................... 1A-78
DTC P0914/P0915/P0916............................. 1A-80
DTC P1105/P1106/P1107............................. 1A-82
DTC P1201/P1202/P1203/P1204 ............... 1A-84
DTC P1610 ....................................................... 1A-86
DTC P1622 ....................................................... 1A-88
DTC P1650 ....................................................... 1A-88
DTC P2101 ....................................................... 1A-89
DTC P2102 ....................................................... 1A-91
DTC P2120/P2123 .......................................... 1A-92
DTC P2125/P2128 .......................................... 1A-94
DTC P2135 ....................................................... 1A-96
DTC P2138 ....................................................... 1A-97
DTC P2158 ....................................................... 1A-98
DTC P2226/P2228 ........................................ 1A-100
DTC P2505 ..................................................... 1A-1 02
DTC P2A00 ..................................................... 1A-103
DTC P2A03 ..................................................... 1A-104
DTC U0073 ..................................................... 1A-105
DTC U0121 ..................................................... 1A-105
DTC U0123 ..................................................... 1A-105
DTC U0155 ......................................... : ........... 1A-105
Engine Control System Circuits Inspection ..... 1A-105
ECM Power Supply and Ground Circuit
Check ............................................................ 1A-113
Special T ools and Equipment .........................1A-117
Special Tool .................................................... 1A-117
Emission Control Devices ...................... 1 B-1
Precautions ...........................................................1 B-1
Precautions for Emission Control Devices .......... 18-1
Schematic and Routing Diagram ........................1 B-1
PAIR System Hose Routing Diagram ................. 18-1
PCV Hose Routing Diagram ............................... 18-2
EVAP Canister Hose Routing Diagram ............... 1 B-2
Repair Instructions .............................................. 1 B-4
PAIR Reed Valve Removal and Installation ........ 18-4
1-ii Table of Contents
PAIR Control Solenoid Valve Removal and
Installation ......................................................... 1 B-5
PAIR System Inspection ..................................... 1 B-5
PAIR Hose Removal and Installation .................. 1 B-5
PCV Hose Inspection .......................................... 1 B-6
PCV Hose Removal and Installation ................... 1 B-6
PCV Reed Valve/ PCV Cover Removal and
Installation ......................................................... 1 B-6
PCV Reed Valve/ PCV Cover lnspection ........... 18-7
EVAP System Removal and Installation ............. 18-8
EVAP System Inspection .................................. 18-10
Specifications .....................................................1 B-1O
Tightening Torque Specifications ...................... 1 B-10
Special Tools and Equipment ...........................1 B-1 O
Recommended Service Material . ...................... 1 B-1O
Engine Electrical Devices ....................... 1 C-1
Precautions ........................................................... 1C-1
Precautions for Engine Electrical Device ............1C-1
Precautions for Electric Throttle Control
System .............................................................. 1C-1
Component Location ........................................... 1C-1
Engine Electrical Components Location ............. 1C-1
Diagnostic Information and Procedures ............ 1C-1
Engine Symptom Diagnosis ................................1C-1
Repair Instructions .............................................. 1C-2
ECM Removal and Installation ............................ 1C-2
ECM Learned Value Reset ................................. 1C-3
AP Sensor Inspection.......................................... 1C-3
AP Sensor Removal and lnstallation................... 1C-3
IAP Sensor Inspection......................................... 1C-4
IAP Sensor Removal and lnstallation.................. 1C-5
IAT Sensor Inspection ......................................... 1C-5
IAT Sensor Removal and lnstallation .................. 1C-5
ECT Sensor Inspection .......................................1C-6
ECT Sensor Removal and Installation ................ 1C-6
TP Sensor lnspection .......................................... 1C-7
HO2 Sensor Inspection .......................................1C-8
HO2 Sensor Removal and Installation ................ 1C-9
CMP Sensor Inspection .................................... 1C-11
CMP Sensor Removal and Installation ............. 1C-11
CKP Sensor lnspection .....................................1C-12
CKP Sensor Removal and Installation ..............1 C-13
Accelerator Position Sensor Inspection ............ 1C-13
Accelerator Position Sensor Removal and
Installation .......................................................1C-14
Throttle Valve Motor Inspection ........................ 1C-15
GP Sensor Inspection ....................................... 1C-15
GP Sensor Removal and Installation ................ 1C-15
Gearshift Sensor Inspection.............................. 1C-15
Gearshift Sensor Removal and Installation ....... 1C-15
Specifications ..................................................... 1C-16
Tightening Torque Specifications ...................... 1C-16
Special Tools and Equipment ........................... 1C-16
Special Tool ......................................................1C-16
Engine Mechanical .................................. 1 D-1
Precautions........................................................... 1 D-1
Precautions for Engine Mechanical.....................1 D-1
Schematic and Routing Diagram ........................1 D-2
Throttle Cable Routing Diagram..........................1 D-2
Diagnostic Information and Procedures ............ 1 D-3
Engine Mechanical Symptom Diagnosis .............1 D-3
Compression Pressure Check ............................1 D-3
Repair Instructions .............................................. 1D-5
Intake System Construction ................................1 D-5
Air Cleaner Element Removal and Installation ....1 D-6
Air Cleaner Box Removal and Installation ...........1 D-6
Throttle Body Components .................................1 D-8
Throttle Cable Play On-Vehicle Inspection
and Adjustment .................................................1 D-9
Engine Idle Speed Inspection .............................1 D-9
Throttle Cable Removal and Installation ............. 1 D-9
Throttle Body Removal and Installation ..............1 D-9
Throttle Body Disassembly and Reassembly ....1 D-11
Throttle Body Inspection and Cleaning .............1D-12
Throttle Valve Synchronization .........................1D-12
Intake Pipe Removal and Installation ................1 D-12
Cylinder Head Cover Components ................... 1 D-14
Cylinder Head Cover Removal and
Installation .......................................................1 D-15
Cylinder Head Cover Inspection .......................1 D-16
Cam Chain Tension Adjuster/ Camshaft
Components ....................................................1 D-17
Cam Chain Tension Adjuster/ Camshaft
Removal ..........................................................1 D-18
Cam Chain Tension Adjuster/ Camshaft
Installation .......................................................1 D-19
Camshaft Inspection .........................................1 D-24
Cam Chain Tension Adjuster Inspection ...........1 D-26
Cam Chain Guide Inspection ............................ 1 D-26
Valve Clearance Inspection and Adjustment ....1 D-26
Engine Assembly Removal ...............................1 D-27
Engine Assembly Installation ............................1 D-30
Cylinder head Components...............................1 D-34
Cylinder Head Removal ....................................1 D-35
Cylinder Head Installation .................................1 D-36
Valve and Cylinder Head Components .............1 D-39
Valve/ Valve Spring Removal and Installation ..1 D-40
Valve Inspection ................................................1 D-41
Valve Seat Repair .............................................1 D-44
Valve Spring Inspection ....................................1 D-44
Cylinder Head Disassembly and Reassembly ..1 D-44
Cylinder Head Inspection ..................................1 D-47
Valve Guide Replacement ................................1 D-47
Cylinder/ Cam Chain Guide No.1/ Piston/
Piston Ring Components ................................1 D-49
Cam Chain Guide No.1/ Cylinder / Piston
Removal .......................................................... 1 D-50
Cam Chain Guide No.1/ Cylinder/ Piston
Installation .......................................................1 D-51
Cylinder Disassembly and Reassembly ............ 1 D-54
Cylinder Inspection ............................................1 D-54
Piston/ Piston Ring Inspection ......................... 1 D-55
Crank Balancer/ Cam Chain Tensioner/ Oil
Filter/ Oil Filter Stand/ Oil Pipe Components ..1 D-57
Crank Balancer/ Cam Chain Tensioner/ Oil
Filter/ Oil Filter Stand/ Oil Pipe Removal. ......1 D-58

Crank Balancer/ Cam Chain Tensioner/ Oil
Filter/ Oil Filter Stand Installation ................... 1 D-61
Cam Chain Tensioner Inspection ...................... 1 D-67
Crank Balancer Disassembly and
Reassembly ....................................................1 D-67
Crank Balancer Inspection ................................ 1 D-68
Crankcase / Crankshaft/ Crankshaft journal
bearing / Oil Jet / Oil gallery plug
Components .................................................... 1 D-70
Crankcase/ Crankshaft Removal ..................... 1 D-71
Crankcase I Crankshaft Installation .................. 1 D-74
Conrod I Conrod Crank Pin Bearing
Components .................................................... 1 D-79
Conrod/ Conrod Crank Pin Bearing Removal
and Installation ................................................1 D-80
Conrod I Crankshaft Inspection ........................ 1 D-81
Conrod Crank Pin Bearing Inspection and
Selection ......................................................... 1 D-82
Crankshaft Journal Bearing Inspection and
Selection ......................................................... 1 D-84
Crankshaft Thrust Clearance Inspection and
Selection ......................................................... 1 D-86
Specifications..................................................... 1 D-88
Tightening Torque Specifications ...................... 1 D-88
Special Tools and Equipment........................... 1D-90
Recommended Service Material ....................... 1 D-90
Special Tool ......................................................1 D-90
Engine Lubrication System .................... 1 E-1
Precautions........................................................... 1E-1
Precautions for Engine Oil .................................. 1 E-1
Schematic and Routing Diagram........................ 1E-2
Engine Lubrication System Chart Diagram ......... 1 E-2
Diagnostic Information and Procedures............ 1 E-3
Engine Lubrication Symptom Diagnosis ............. 1 E-3
Oil Pressure Check ............................................. 1 E-4
Repair Instructions .............................................. 1E-5
Engine Oil Inspection .......................................... 1 E-5
Engine Oil Replacement ..................................... 1 E-5
Oil Filter Replacement ........................................ 1 E-5
Oil Pan / Oil Pressure Regulator/ Breather
Pipe / Oil Strainer .............................................. 1E-5
Oil Pan/ Oil Strainer/ Oil Pressure Regulator
Removal and Installation................................... 1 E-6
Oil Pressure Regulator / Oil Strainer
Inspection.......................................................... 1E-8
Oil Cooler Components ....................................... 1 E-8
Oil Cooler/ Oil Cooler Hose Removal and
Installation ......................................................... 1E-9
Oil Cooler/ Oil Cooler Hose Inspection and
Cleaning .......................................................... 1 E-10
Oil Pressure Switch Removal and Installation .. 1 E-11
Oil Pressure Switch Inspection ......................... 1 E-11
Oil Jet/ Oil Gallery Jet Removal and
Installation ....................................................... 1 E-12
Oil Jet/ Oil Gallery Jet Inspection ..................... 1 E-13
Oil Pump Components ...................................... 1E-14
Oil Pump Removal and Installation ................... 1 E-14
Oil Pump lnspection .......................................... 1E-16
Table of Contents 1-iii
Specifications..................................................... 1E-16
Tightening Torque Specifications ...................... 1 E-16
Special Tools and Equipment........................... 1E-17
Recommended Service Material ....................... 1 E-17
Special Tool ...................................................... 1E-17
Engine Cooling System ........................... 1 F-1
Precautions........................................................... 1F-1
Precautions for Engine Cooling System.............. 1F-1
Precautions for Engine Coolant .......................... 1F-1
General Description............................................. 1F-1
Engine Coolant Description ................................. 1 F-1
Schematic and Routing Diagram........................ 1F-1
Cooling Circuit Diagram ...................................... 1F-1
Water Hose Routing Diagram ............................. 1 F-2
Diagnostic Information and Procedures............ 1F-5
Engine Cooling Symptom Diagnosis ................... 1F-5
Repair Instructions .............................................. 1F-6
Cooling System Components.............................. 1F-6
Engine Coolant Level Inspection ......................... 1F-6
Engine Coolant Replacement ............................. 1F-6
Engine Cooling System Inspection ..................... 1F-7
Radiator Cap Inspection ...................................... 1F-7
Cooling Fan On-Vehicle Inspection..................... 1 F-8
Radiator Hose Inspection .................................... 1F-8
Radiator/ Cooling Fan Motor Removal and
Installation ......................................................... 1F-8
Radiator Inspection and Cleaning ..................... 1F-11
Radiator Reservoir Tank Inspection .................. 1F-11
Radiator Reservoir Tank Removal and
Installation ....................................................... 1 F-11
Water Hose Inspection ...................................... 1F-11
Water Hose Removal and lnstallation ............... 1F-12
Cooling Fan Relay Removal and Installation .... 1F-12
Cooling Fan Relay Inspection ........................... 1F-13
Thermostat Cover I Thermostat Removal and
lnstallation ....................................................... 1F-13
Thermostat lnspection....................................... 1F-14
Water Pump Components ................................. 1F-15
Water Pump Removal and lnstallation .............. 1F-15
Water Pump Disassembly and Assembly ......... 1 F-17
Water Pump Related Parts Inspection .............. 1F-19
Specifications..................................................... 1 F-21
Tightening Torque Specifications ...................... 1F-21
Special Tools and Equipment........................... 1F-21
Recommended Service Material ....................... 1 F-21
Special Tool ...................................................... 1 F-21
Fuel System ............................................. 1 G-1
Precautions.......................................................... 1G-1
Precautions for Fuel System .............................. 1 G-1
Schematic and Routing Diagram....................... 1G-2
Fuel Tank Water Drain Hose and Fuel Tank
Breather Hose Routing Diagram ...................... 1 G-2
Diagnostic Information and Procedures........... 1G-6
Fuel System Symptom Diagnosis ...................... 1 G-6
Repair Instructions ............................................. 1G-6
Fuel Pressure Inspection ................................... 1 G-6
Fuel Discharge Amount Inspection .................... 1G-6
1-iv Table of Contents
Fuel Pressure Relief Procedure......................... 1G-7
Fuel Feed Hose Disconnection and
Reconnection ................................................... 1G-7
Fuel Hose Inspection ......................................... 1G-7
Fuel Feed Hose Removal and Installation ......... 1G-8
Fuel Tank Construction...................................... 1G-9
Fuel Tank Cap Removal and Installation ......... 1G-12
Fuel Tank Removal and Installation................. 1G-12
Fuel Pump Assembly Components.................. 1G-14
Fuel Level Gauge Construction........................ 1G-15
Fuel Pump On-Vehicle Inspection.................... 1G-16
Fuel Pump Assembly/ Fuel Level Gauge
Removal and Installation................................ 1G-16
Fuel Pump Disassembly and Reassembly....... 1G-18
Fuel Filter Inspection........................................ 1G-20
Fuel Level Gauge Inspection ........................... 1G-20
Fuel Pump Relay Removal and Installation ..... 1G-20
Fuel Pump Relay Inspection ............................ 1G-21
Fuel Injector On-Vehicle Inspection ................. 1G-21
Fuel Injector/ Fuel Delivery Pipe Removal
and Installation ............................................... 1G-21
Fuel Injector Inspection and Cleaning.............. 1G-23
Specifications.................................................... 1G-24
Tightening Torque Specifications..................... 1G-24
Special Tools and Equipment.. ........................ 1G-24
Recommended Service Material...................... 1G-24
Special Tool ..................................................... 1G-24
Ignition System ........................................ 1 H-1
Schematic and Routing Diagram........................ 1H-1
Ignition System Diagram ..................................... 1 H-1
Component Location ........................................... 1H-2
Ignition System Components Location................ 1 H-2
Diagnostic Information and Procedures............ 1H-2
Ignition System Symptom Diagnosis................... 1 H-2
No Spark or Poor Spark...................................... 1 H-3
Repair Instructions .............................................. 1H-4
Ignition Coil Removal and Installation.................1 H-4
Spark Plug Removal and Installation .................. 1 H-5
Spark Plug Inspection ......................................... 1 H-5
Ignition Coil Inspection........................................ 1 H-5
Engine Stop/ Starter Switch Inspection..............1 H-6
Ignition Switch lnspection .................................... 1 H-6
Ignition Switch Removal and lnstallation.............1 H-7
Specifications....................................................... 1H-9
Tightening Torque Specifications........................ 1 H-9
Special Tools and Equipment............................. 1H-9
Special Tool ........................................................1 H-9
Starting System ......................................... 11-1
Schematic and Routing Diagram......................... 11-1
Starting System Diagram ..................................... 11-1
Component Location............................................ 11-2
Starting System Components Location................ 11-2
Diagnostic Information and Procedures............. 1I-2
Starting System Symptom Diagnosis................... 11-2
Starter Motor Will Not Run ................................... 11-3
Repair Instructions ............................................... 11-5
Starter Motor Components................................... 11-5
Starter Motor Removal and Installation................ 11-6
Starter Motor Disassembly and Assembly ........... 11-6
Starter Motor Inspection....................................... 11-7
Starter Relay Removal and Installation ................ 11-8
Starter Relay Inspection....................................... 11-8
Starter Sub Relay Removal and Installation ........ 11-9
Starter Sub Relay Inspection ............................... 11-9
Starter Interlock System Parts Inspection............ 11-9
Starter Torque Limiter/ Starter Clutch
Removal and Installation.................................. 11-10
Starter Torque Limiter Inspection....................... 11-12
Starter Clutch Inspection.................................... 11-13
Specifications................................................·...... 11-14
Tightening Torque Specifications....................... 1I-14
Special Tools and Equipment ............................ 1I-14
Recommended Service Material ........................ 11-14
Special Tool ....................................................... 11-14
Charging System ...................................... 1J-1
Schematic and Routing Diagram........................ 1J-1
Charging System Diagram .................................. 1J-1
Component Location ........................................... 1J-1
Charging System Components Location............. 1J-1
Diagnostic Information and Procedures............ 1J-1
Charging System Symptom Diagnosis................ 1J-1
Battery Runs Down Quickly ................................ 1J-2
Repair Instructions .............................................. 1J-3
Battery Current Leakage Inspection.................... 1J-3
Regulated Voltage Inspection ............................. 1J-3
Generator Inspection........................................... 1J-4
Generator Removal............................................. 1J-4
Generator Installation.......................................... 1J-6
Regulator/ Rectifier Construction ....................... 1J-7
Regulator/ Rectifier Removal and Installation .... 1J-7
Battery Charging ................................................. 1J-8
Battery Removal and Installation ........................ 1J-8
Battery Visual Inspection..................................... 1J-9
Specifications..................................................... 1J-10
Tightening Torque Specifications...................... 1J-10
Special Tools and Equipment........................... 1J-10
Special Tool ...................................................... 1J-10
Exhaust System ....................................... 1 K-1
Precautions........................................................... 1K-1
Precautions for Exhaust System ......................... 1 K-1
Repair Instructions .............................................. 1K-1
Exhaust System Components............................. 1 K-1
Exhaust Pipe/ Muffler Removal.......................... 1 K-2
Exhaust Pipe/ Muffler Installation....................... 1 K-5
Exhaust System Inspection................................. 1 K-7
Specifications....................................................... 1K-8
Tightening Torque Specifications........................ 1 K-8
 Precautions: 1-1

Precautions
Precautions
Precautions for Engine
BENM10L31000001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Catalytic Converter" in Section 00 (Page
00-1 ), "Precautions for Electrical Circuit Service" in Section 00 (Page 00-2), "Precautions for Circuit Tester" in Section
00 (Page 00-8) and "Precautions for SDS-11" in Section 00 (Page 00-9).
1A-1 Engine General Information and Diagnosis:

Engine General Information and Diagnosis

Precautions
Precautions for DTC Trouble Shooting
BENM10L31100001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Electrical Circuit Service" in Section 00
(Page 00-2), "Precautions for Circuit Tester" in Section 00 (Page 00-8) and "Precautions for SDS-II" in Section 00
(Page 00-9).

NOTE
After repairing the trouble, clear the OTC using the special tool. "(Page 1A-12)

General Description
Self-Diagnosis Function
BENM10L31101001
The self-diagnosis function is incorporated in the ECM. T he function has two modes, "User mode" and "Dealer mode".

User Mode
• The ECM warns riders to turn the MIL (1) on or blink it depending on the failure place or its content.
And the ECM turns the MIL off when detecting 3 DIC-correct continuously after detecting the first abnormality.
• For some malfunctions, ECM adopts the 3 driving cycle detection logic to prevent erroneous detection.
With this logic, MIL is turned on when the same malfunction is detected for 3 consecutive driving cycles.

NOTE
• The MIL blinking only when detecting a misfire which can cause damage to the catalyst.
• When some DTCs are detected, the ECM turns the master warning indicator (2) on.
And the ECM turns the master warning indicator off when detecting 1 DIC-correct after detecting the
first abnormality.
• The combination meter controls the each indicator based on the CAN communication signal
received from ECM.
• When lowering of the battery is detected, the master warning indicator is turned red ON.
• For LCD indication (3), referring to "Combination Meter System Description": Technical Features in
Section OA (Page OA-28).

Malfunction part MIL (1) Master warning indicator (2)

Other than following malfunction parts ON or blink -
FP relay - ON
Cooling fan relay - ON
Ignition switch (without Immobilizer control - ON
system)
Key is not registered. (with Immobilizer - ON
control system)
Gearshift sensor - ON
IMU - ON
ECM (Data programming error/ ROM error) - ON
CAN communication system - ON
 Engine General Information and Diagnosis: 1A-2

IM10L1110001-01

Supplementation
• In the case that the engine control system is in normal condition, the combination meter lights up the MIL and the
master warning indicator when the ignition switch is turned ON, and then, about 3 seconds after the ignition switch
is turned ON, it turns the MIL and the master warning indicator OFF.

NOTE
If master warning indicator is on continuously after turning the ignition switch ON although the battery
voltage is normal, a malfunction may be detected except for engine control system.

• The driving cycle (O/C) means the cycle beginning from turning the ignition switch ON through starting the engine
until turning the ignition switch OFF. The 3 driving cycles are the term repeating 3 times of the above mentioned
cycle.
• The ECM erases the registered failure data when not detecting the same one during 40 times of warm up cycle.
And the warm up cycle means the cycle of engine warm up operation that the engine coolant temperature reaches
more than approximately 70 °C (158 °F) and also rises more than approximately 20 ° C (36 °F) from the one at
engine starting.
• 3 driving cycle detection logic:
The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending OTC) but MIL or
master warning indicator does not light at this time. ECM causes the MIL or master warning indicator to light up
when it detects third time the same malfunction in the next two driving cycle.
• Pending DTC:
"Pending OTC" is relevant to those OTCs to which the 3 driving cycle detection logic is applied. If such a OTC is
detected and stored temporarily during the first of three consecutive driving cycles, the OTC is called pending OTC.
1A-3 Engine General Information and Diagnosis:

Dealer Mode
To check the function of the individual engine control system devices, the dealer mode is provided. In this check, the
special tool is necessary to read the code of the malfunction items.
• The defective function is memorized in the ECM. Use the special tool's coupler to connect to the mode select
coupler (6P).
Special tool
09930-83130
• The memorized malfunction code (1) is indicated by the display of the LCD.

Ji..:.L.,JF-1 a,,

'--'-'------'°
IM10L1110125-02

• Malfunction means that the ECM does not receive normal signal from the devices. These affected devices are
indicated in the code form.
NOTE
• Before checking the malfunction code, do not disconnect the ECM coupler.
If the coupler from the ECM is disconnected, the malfunction code memory is erased and the
malfunction code can not be checked.
• Some DTCs do not display malfunction code on the LCD.
• Pending DTC can be checked only by using the SDS-11.
 Engine General Information and Diagnosis: 1A-4

Diagnostic coupler location

Mode select coupler (6P) (1) is located under the rear seat. This coupler can use SDS-II tool and OBD conversion
cable.
Special tool
09904-41051
09904-41071

IM10L1110126-02

Show Failure Data

ECM stores the engine and driving conditions at the moment of the detection of a malfunction in its memory. This data
is called "Show failure data".
Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the
motorcycle was running or stopped) when a malfunction was detected by checking the "Show failure data". This "Show
failure data" function can record the maximum of two Diagnostic Trouble Codes in the ECM.
Also, ECM has a function to store each "Show failure data" for two different malfunctions in the order of occurrence as
the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been
detected. Its use is helpful when rechecking or diagnosing a trouble.
For details of "Show failure data" that can be read from ECM, refer to the table below.
DTC
Calculated LOAD value
Engine coolant temperature
Short term fuel trim (Bank1)
Long term fuel trim (Bank1)
Manifold absolute pressure "A"
Engine speed
Vehicle speed sensor
Intake air temperature
Absolute throttle position angle bank1
Battery voltage
Gear position

Show failure data clearance

When a DTC is cleared, the "Show failure data" for the malfunction represented by this DTC is also cleared.
1A-5 Engine General Information and Diagnosis:

System Readiness Test (If Equipped)

The system readiness test is performed for the purpose of checking that each of the exhaust-emission-related
systems fulfills the conditions that allow ECM to detect a malfunction if it occurs and to set the corresponding OTC.
The test is carried out by monitoring the specific items (components) using a SDS-11. When the test shows that the
conditions pre-established for the tested system are met, ECM performs an on-board diagnosis of the system,
changes the status of the system readiness test from "Not Complete" to "Completed", and causes the "Completed"
status to be displayed on the scan tool.
The "Completed" status is maintained until OTC clearance operation is performed using the scan tool.

NOTE
• The system readiness test status may change from "Completed" to "Not Complete" if any of the
following service operations is performed.
- Disconnection of battery (-) lead wire
- Disconnection of ECM couplers
- Removal of ECM power supply fuse
• The items (components) indicated in the table below are monitored in the system readiness test to
check the readiness for detecting the DTCs listed beside each monitoring item.
• The "Completed" or "Not Complete" status identified through the system readiness test does not
mean the "Normal" or "Abnormal" result of on-board diagnosis.

Monitoring item of system readiness test

NOTE
SDS-11 displays "monitoring item" except the following table. And statuses of those "monitoring item"
are always displayed with "Completed".

Monitoring item DTC related to monitoring item

P0133
H02 Sensor
P0153
PAIR system P0410
 Engine General Information and Diagnosis: 1A-6

Schematic and Routing Diagram

Engine Control System Wiring Diagram
BENM10L31102001

---------------- -------------�' T100 R

/W
22
'
._____....,,G"-lr T27 - RNJ

----'----------------------- ----------- ---

G T18
':
:[A]
R/Y T2
, 2 61
1------�G"-' T60

0,.�::: +
r
'
--------------------------- -------------�
G/W

Gr/B
3
� T89

T881-=:::..:...__---+Jlllfl..+:..=_-�
G rlY

66
T98 l-=� -----+JNI'\..+:..=...-�
L9

/W
T97 Lg
5 1 T96 L
g/B

6 I. T95
Lg/R

T106 Y/R
�
7
l
8
ri-'lPl�l----+--t--�<C.JT42 __ J...__
J.
41

T9 4 W/B
9 42
T28 7tr 60
T24
10 --;r­
W/BI
t---+-t'V'-'lrl-l----+--t- -�--iT79 _ T83
r-,__
44
T82 i-: B,:________;_.::;'----'
�
11 70
45
T81 1-'-----'
y
46
I r-- TSO �G,e_______
�""---
�
B/Lg
TTS
T84 P/W

12 L T51 1-JRc,____1-.----r­
47

13
L T49 lJR1Y3If______J:::;=,7 58
P/W
52
BIBI
51
T1

i
53 59
W/B T1 7

54
T36
___L
Y/G
BI/ B --;r--
T47

BI/W T4
5 ___L
T86 B/Y

�-�l-d'"�----'G"'-lT35 --I-+--+- 711T �

T91
B/W
r-- T107 l-'B"'-/W
'-'--------1
_
't: 12V
0--------..-BB�r T72 ___J...__, 711Tm,
T108 l-'"'-'-'--------1
8/W
i': 5V

IM10L 1110003-02
1A-7 Engine General Information and Diagnosis:

[A]: With immobilizer control system 17. ABS control unit/ HU
[BJ: Without immobilizer control 18. Front wheel speed sensor
system
[CJ: To[c] 19. Rear wheel speed sensor
1. ECM 20. Side-stand switch
2. Immobilizer antenna 21. Clutch lever position switch
3. CKP sensor 22. Fuel fuse (1 O A)
4. CMP sensor 23. Ignition switch
5. IAP sensor 24. Ignition fuse (10 A)
6. AP sensor 25. Engine stop/ starter switch
("RUN/ STOP" position)
7. Gearshift sensor 26. FP relay
8. ECT sensor 27. Fuel pump
9. IAT sensor 28. Primary fuel injector #1
10. HO2 sensor #1 29. Primary fuel injector #2
11. HO2 sensor #2 30. Primary fuel injector #3
12. GP sensor 31. Primary fuel injector #4
13. Combination meter 32. Secondary fuel injector #1
14. Neutral indicator light 33. Secondary fuel injector #2
15. Mode select coupler (6P) 34. Secondary fuel injector #3
16. IMU 35. Secondary fuel injector #4
36. Cooling fan relay
37. Fan (RH) fuse (15 A)
38. Cooling fan motor (RH)
39. Fan (LH) fuse (15 A)
40. Cooling fan motor (LH)
41. EVAP system purge control
solenoid valve (If equipped)
42. PAIR control solenoid valve
43. Ignition coil #1
44. Ignition coil #2
45. Ignition coil #3
46. Ignition coil #4
47. Throttle body
48. Throttle valve motor
49. TP sensor (main)
50. TP sensor (sub)
51. Accelerator body assembly
52. Accelerator position sensor
(main)
53. Accelerator position sensor (sub)
54. Engine stop/ starter switch
("START" position)
55. Starter relay
56. Starter sub relay
57. Starter motor
58. Main fuse (30 A)
59. Battery
60. CPU
61. Immobilizer antenna
communication and indicator
light drive circuit
62. HO2 sensor heater drive circuit
63. CAN driver
64. Power supply circuit
65. Fuel pump relay drive circuit
66. Fuel injector drive circuit
67. Cooling fan relay drive circuit
68. EVAP system purge control
solenoid valve drive circuit (If
equipped)
69. PAIR control solenoid valve drive
circuit
70. Ignition coil drive circuit
71. Throttle valve motor drive circuit
72. Starter relay drive circuit

Terminal Arrangement of ECM Coupler

IM10L 1110004-01
[A]: ECM coupler (View[al) 1. Coupler "A" 2. Coupler "B" 3. Coupler "C"
 Engine General Information and Diagnosis: 1A-8

Component Location
Engine Control System Component Location
BENM10L31103001

3 2

¢, i.Jc;J;.; ¢

'1�11

IM10L1110127-02
1A-9 Engine General Information and Diagnosis:

1. Combination meter 12. Primary fuel injector 23. ECM

2. MIL 13. Secondary fuel injector 24. IATsensor
3. Master warning indicator 14. IAP sensor 25. Clutch lever position switch
4. Ignition switch 15. ECT sensor 26. Gearshift sensor
5. Immobilizer antenna (If equipped) 16. IMU 27. GP sensor
6. Engine stop/ starter switch 17. Accelerator body assembly (incorporating 28. Side-stand switch
accelerator position sensor (main and sub) and
cruise control cancel switch)
7. PAIR control solenoid valve 18. EVAP system purge control solenoid valve (If 29. HO2 sensor #1
equipped)
8. Ignition coil 19. HO2 sensor #2 30. CKP sensor
9. CMP sensor 20. Mode select coupler (6P) 31. FP relay
10. Throttle body (incorporating TP sensor (main 21. AP sensor 32. Cooling fan relay
and sub) and throttle valve motor)
11. ABS control unit I HU 22. Starter relay 33. Starter sub relay

Diagnostic Information and Procedures

Engine Control System Check Is there any faulty condition?
BENM10L31104001
Refer to the following items for the details of each step. Yes Repair or replace defective part, and go to
Step 5.
Step 1
Customer complaint analysis No Go to Step 4.
1) Perform customer complaint analysis. w(Page
Step4
1A-9)
Trouble symptom confirmation
Was customer complaint analysis performed? 1) Check trouble symptom. <:r(Page 1A-11)
Yes Go to Step 2. Is trouble symptom identified?
No Perform customer complaint analysis. Yes Perform "Engine Symptom Diagnosis"
(Page 1A-25), and go to Step 5.
Step2
DTC check No Perform "Intermittent Malfunction
1) Check for DTCs (including pending DTCs). Inspection" in Section 00 (Page 00-7), and
w(Page 1A-11) go to Step 5.

Is there any DTC(s)? Steps

Final confirmation test
Yes Check and repair according to applicable
OTC troubleshooting, and go to Step 5. 1) Perform final confirmation test. c:r(Page 1A-11)
Does the trouble recur?
No Go to Step 3.
Yes Go to Step 2.
Step 3
Visual inspection No End.
1) Perform visual inspection. w(Page 1A-11)

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form such as following will facilitate collecting information to the point required for proper
analysis and diagnosis.
NOTE
This form is a standard sample. The form should be modified according to conditions and
characteristic of each market.
 Engine General Information and Diagnosis: 1A-10

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name: Model: VIN:
Date of issue: Date Reg.: Date of problem: Mileage:

MIL condition
□Always ON/□Sometimes ON/□Always OFF/□Good condition
Master warning indicator
□ Always ON/□ Sometimes ON/□ Always OFF/□Good condition
condition
Malfunction display/code User mode: □No display/□ Malfunction display ( )
Dealer mode: □No code/□ Malfunction code ( )

PROBLEM SYMPTOMS
□ Difficult Starting □ Poor Driveability
□ No cranking □Hesitation on acceleration
□ No initial combustion □ Back fire/ □ After fire
□No combustion □Lack of power
□ Poor starting at □ Surging
(□cold/□warm/□always) □ Abnormal knocking
□Other □Engine rpm jumps briefly
□ Other

□ Poor Idling □ Engine Stall when

□ Poor fast Idle □ Immediately after start
□Abnormal idling speed □ Throttle valve is opened
(□ High/□ Low) ( r/min) □ Throttle valve is closed
□ Unstable □ Load is applied
□ Hunting ( r/min to r/min) □ Other
□Other

□OTHERS:

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather □ Fair/ □ Cloudy/ □ Rain/□Snow/□Always/□Other
Temperature □ Hot /□ Warm / □ Cool I□Cold ( ° C/ °F) /□Always
Frequency □Always/□Sometimes ( times/ day, month)/□Only once
o Under certain condition
Road o Urban/ o Suburb/□ Highway/□ Mountainous (□ Uphill/ □ Downhill)
□Tarmacadam/□Gravel /□ Other
Motorcycle condition
Engine condition □ Cold/□ Warming up phase/ □ Warmed up/ □ Always/ □ Other at starting
□ Immediately after start/ □ Racing without load/ □ Engine speed ( r/min)
Motorcycle condition During driving: □Constant speed/ □ Accelerating/□ Decelerating
o Right hand corner I□Left hand corner
□ At stop/□ Motorcycle speed when problem occurs ( km/h, mile/h)
□ Other:
IM41K1112061-01
1A-11 Engine General Information and Diagnosis:

Step 2: OTC Check

First, check DTC (including pending DTCs). '6'"(Page 1A-
11)

Step 3: Visual Inspection

As a preliminary step, perform visual check of the items
that support proper function of the engine. c,r(Page 1A-
24)

Step 4: Trouble Symptom Confirmation

Based on information obtained in "Step 1: Customer
Complaint Analysis" (Page 1A-9), check trouble
symptoms.

Step 5: Final Confirmation Test

Check that the problem symptom has gone and engine
is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the
DTC referring to "OTC Clearance" (Page 1A-12) and
confirm that the OTC is not indicated, based on
information obtained in "Step 1: Customer Complaint
Analysis" (Page 1A-9).
IL06L1110160-02

5) Turn the ignition switch ON.

OTC Check
BENM10L31104002
NOTE
• Do not disconnect the coupler from ECM,
battery cable from battery, ECM ground
wire from engine or fuse before confirming
OTC stored in memory. Such
disconnection will erase memorized
information in ECM memory.
• Before checking OTC, read "User Mode
and Dealer Mode" under "Self-Diagnosis
Function" (Page 1A-1) carefully to have
good understanding as to what functions
are available and how to use it.
Use of SDS-11
1) Turn the ignition switch OFF.
2) Remove the rear seat. '6'"(Page 90-34)
3) Connect the conversion cable (ISO) to mode select
coupler (6P) (1 ).
Special tool
(A): 09904-41071
4) Connect the SOS-II to conversion cable (ISO).
Special tool
(B): 09904-41031
09904-41041
10) Install the removed parts.
6) Read OTC according to instructions displayed on
SOS-II and print it or write it down. Refer to SOS-II
operation manual for further details.
NOTE
• If communication between SDS-11 and ECM
is not possible, perform the following
checks.
- Check wire harness between mode
select coupler (6P) and ECM coupler.
- Check DIG-cable between mode select
coupler (6P) and SDS-11. If necessary,
check DIG-cable and conversion cable
(ISO) by substituting a known-good
cable.
- Check CAN communication system.
cr(Page 1 OH-4)
- Check ECM power circuit and ground
circuit. <r(Page 1A-113)
• Not only SDS-11 used for detecting DTCs
but also for reproducing and checking on
screen the failure condition as described
by customers using the trigger.
How to use trigger referring to the SDS-11
operation manual for further details.
7) Close the SDS-II and turn the ignition switch OFF.
8) Disconnect the SOS-II from conversion cable (ISO).
9) Disconnect the conversion cable (ISO) from mode
select coupler (6P).
 Engine General Information and Diagnosis: 1A-12

Use of Mode Select Switch DTC Clearance

BENM10L31104003
1) Remove the rear seat. w(Page 90-34) NOTE
2) Connect the special tool to the mode select coupler
The malfunction code is memorized in the
(6P) (1) at the wiring harness.
ECM also when the lead wire coupler of any
Special tool sensor is disconnected. Therefore, when a
(A): 09930-83130 lead wire coupler has been disconnected in
the diagnosis, erase the stored past DTC.
(A)
1) Turn the ignition switch OFF.
2) Remove the rear seat. <:?(Page 9D-34)
3) Connect the conversion cable (ISO) to mode select
IL06L1110161-01
coupler (6P) (1).
3) Start the engine or crank the engine for more than 4
seconds. Special tool
(A): 09904-41071
4) Turn the special tool's switch ON.
4) Connect the SDS-II to conversion cable (ISO).
Special tool
(B): 09904-41031
09904-41041

IJ10K1110012-01

5) Check the OTC (1) to determine the malfunction

part. <:?(Page 1A-13)

A 1
�:::;�

tWlTI
�-=-� I �(�t�l
� ! ""RE
·�·i·IJ8.Jll"1 .,1

-..;.,.�-0

�----
- �
0--7
IM10L1110125-02

(B)
IL0SL1110160-02

5) Turn the ignition switch ON.

6) Clear DTC according to instructions displayed on
SOS-II. Refer to SOS-II operation manual for further
details.
1A-13 Engine General Information and Diagnosis:

NOTE 8) Disconnect the SDS-11 from conversion cable (ISO).

If communication between SDS-11 and ECM is 9) Disconnect the conversion cable (ISO) from mode
not possible, perform the following checks. select coupler (6P).
• Check wire harness between mode select 10) Install the removed parts.
coupler (6P) and ECM coupler.
• Check DIG-cable between mode select
coupler (6P) and SDS-I1. If necessary,
check DIG-cable and conversion cable
(ISO) by substituting a known-good cable.
• Check CAN communication system.
rr(Page 10H-4)
• Check ECM power circuit and ground
circuit. <r(Page 1A-113)

7) Close the SDS-11 and turn the ignition switch OFF.

DTC Table
BENM10L31104004
NOTE
• When DTC P0300 / P0301 / P0302 / P0303 / P0304 is detected, MIL blinks or lights up according to
detecting condition.
• "1 D/C / 3 DIC" in "DTC detection logic" column of table below means DTC detecting logic varies
depending on DTC.
• *1: Display on the LCD only. (If the ECM is normal but the ABS detects OTC, ABS-related DTC(s) is
displayed.)
• Some DTCs do not display malfunction code on the LCD.

DTC Master
DTC DTC name DTC detecting condition detection MIL warning
logic indicator
00000 *1 None - - OFF OFF
HO2 Sensor Heater Control Circuit HO2 sensor #1 heater circuit is
P0030
Bank 1 Sensor 1 <?(Page 1A-32) shorted to ground or open.
3 DIC ON OFF
HO2 Sensor Heater Control Circuit HO2 sensor #2 heater circuit is
P0050
Bank 2 Sensor 1 Ci?(Page 1A-34) shorted to ground or open.
3 DIC ON OFF
Difference between measured
Manifold Absolute Pressure - value by AP sensor and measured
P0069 Barometric Pressure Correlation value by IAP sensor is higher than 3 DIC ON OFF
Ci?(Page 1A-36) specified value although the engine
is stopped.
IAT sensor output voltage is higher
P0110 IAT Sensor 1 Circuit w(Page 1A-38)
than 4.90V.
3 DIC ON OFF

IAT Sensor 1 Circuit Response

IAT sensor output voltage does not
P0111
Malfunction w(Page 1A-38)
change, under the specified 3 DIC ON OFF
condition.
IAT Sensor 1 Circuit Low ""(Page IAT sensor output voltage is lower
P0112
1A-38) than 0.10V.
3 DIC ON OFF
ECT sensor output voltage is higher
P0115 ECT Sensor Circuit Ci?(Page 1A-40)
than 4.90V.
1 DIC ON OFF
ECT sensor output voltage does not
ECT Sensor Circuit Response
P0116
Malfunction ""(Page 1A-40)
change, under the specified 3 DIC ON OFF
condition.
ECT Sensor Circuit Low -(Page 1A- ECT sensor output voltage is lower
P0117
40) than 0.10V.
3 DIC ON OFF
TP Sensor I Switch "A" Circuit TP sensor (main) output voltage is
P0120
""(Page 1A-42) lower than 0.20 V.
1 DIC ON OFF
TP Sensor I Switch "A" Circuit High TP sensor (main) output voltage is
P0123
w(Page 1A-42) higher than 4.80 V.
1 DIC ON OFF
 Engine General Information and Diagnosis: 1A-14

OTC Master
DTC DTC name DTC detecting condition detection MIL warning
logic indicator
02 Sensor Circuit Bank 1 Sensor 1
P0130
w(Page 1A-44)
HO2 sensor #1 is not activated. 3 DIC ON OFF
02 Sensor Circuit High Voltage Bank HO2 sensor #1 output voltage is
P0132
1 Sensor 1 w(Page 1A-44) higher than 4.90 V.
3 DIC ON OFF
Shifting time between rich and lean
02 Sensor Circuit Slow Response
P0133
(Bank1 Sensor1) w(Page 1A-44)
of HO2 sensor #1 is longer than 3 DIC ON OFF
specified time.
02 Sensor Circuit Bank 2 Sensor 1
P0150
c:,;=(Page 1A-46)
HO2 sensor #2 is not activated 3 DIC ON OFF
02 Sensor Circuit High Voltage Bank HO2 sensor #2 output voltage is
P0152
2 Sensor 1 w(Page 1A-46) higher than 4.90 V.
3 DIC ON OFF
Shifting time between rich and lean
02 Sensor Circuit Slow Response
P0153
(Bank2 Sensor1) c:,;=(Page 1A-46)
of HO2 sensor #2 is longer than 3 DIC ON OFF
specified time.
Fuel trim correction is higher than
System Too Lean Bank 1 -(Page
P0171
1A-48)
specified value for specified time 3 DIC ON OFF
under the specified condition.
Fuel trim correction is lower than
System Too Rich Bank 1 c:,;=(Page
P0172
1A-48)
specified value for specified time 3 DIC ON OFF
under the specified condition.
Fuel trim correction is higher than
System Too Lean Bank 2 (j;P(Page
P0174
1A-48)
specified value for specified time 3 DIC ON OFF
under the specified condition.
Fuel trim correction is lower than
System Too Rich Bank 2 """(Page
P0175
1A-48)
specified value for specified time 3 DIC ON OFF
under the specified condition.
Primary fuel injector #1 signal is
Injector Circuit I Open - Cylinder 1 interrupted by 20 times or more
P0201
c:,;=(Page 1A-50) continuity although CKP signal is
1 DIC ON OFF
detected.
Primary fuel injector #2 signal is
Injector Circuit I Open - Cylinder 2 interrupted by 20 times or more
P0202
w(Page 1A-50) continuity although CKP signal is
1 DIC ON OFF
detected.
Primary fuel injector #3 signal is
Injector Circuit I Open - Cylinder 3 interrupted by 20 times or more
P0203
w(Page 1A-50) continuity although CKP signal is
1 DIC ON OFF
detected.
Primary fuel injector #4 signal is
Injector Circuit I Open - Cylinder 4 interrupted by 20 times or more
P0204
w(Page 1A-50) continuity although CKP signal is
1 D/C ON OFF
detected.
T P Sensor / Switch "B" Circuit T P sensor (sub) output voltage is
P0220
c:,;=(Page 1A-52) lower than 0.20 V.
1 DIC ON OFF
T P Sensor/ Switch "B" Circuit High TP sensor (sub) output voltage is
P0223
w(Page 1A-52) higher than 4.80 V.
1 DIC ON OFF
FP Secondary Circuit High <r{Page Voltage is input to ECM although
P0232
1A-55) the FP relay is OFF.
1 DIC OFF ON
FP Secondary Circuit I Open No voltage is input to ECM although
P023F
c:,;=(Page 1A-55) the FP relay is ON.
1 DIC OFF ON
1A-15 Engine General Information and Diagnosis:

OTC Master
DTC DTC name DTC detecting condition detection MIL warning
logic indicator
Any of the following conditions is

.
met.
Misfire, which causes damage to
the catalyst, is detected at 2 or
more cylinders, under the
Random I Multiple Cylinder Misfire
P0300
Detected c,r-(Page 1A-57)
specified condition. (The MIL 3 DIC ON OFF

.
blinks)
Misfire, which affects exhaust
emission adversely, is detected
at 2 or more cylinders, under the
specified condition.
Any of the following conditions is

.
met.
Misfire, which causes damage to
the catalyst, is detected at
Cylinder 1 Misfire Detected c,r-(Page cylinder #1, under the specified
DIC ON
.
P0301 3 OFF
1A-57) condition. (The MIL blinks)
Misfire, which affects exhaust
emission adversely, is detected
at cylinder #1, under the
specified condition.
Any of the following conditions is
met.
• Misfire, which causes damage to
the catalyst, is detected at
Cylinder 2 Misfire Detected w(Page cylinder #2, under the specified
DIC ON
.
P0302 3 OFF
1A-57) condition. (The MIL blinks)
Misfire, which affects exhaust
emission adversely, is detected
at cylinder #2, under the
specified condition.
Any of the following conditions is

.
met.
Misfire, which causes damage to
the catalyst, is detected at
Cylinder 3 Misfire Detected c,r-(Page cylinder #3, under the specified
DIC ON
.
P0303 3 OFF
1A-57) condition. (The MIL blinks)
Misfire, which affects exhaust
emission adversely, is detected
at cylinder #3, under the
specified condition.
Any of the following conditions is

.
met.
Misfire, which causes damage to
the catalyst, is detected at
Cylinder 4 Misfire Detected c,r-(Page cylinder #4, under the specified
P0304 3 DIC ON OFF
.
1A-57) condition. (The MIL blinks}
Misfire, which affects exhaust
emission adversely, is detected
at cylinder #4, under the
specified condition.
 Engine General Information and Diagnosis: 1A-16

DTC Master
DTC DTC name DTC detecting condition detection MIL warning
logic indicator
CKP sensor signal is not input to
CKP Sensor "A" Circuit cr(Page 1A- ECM for a few seconds or more, ON OFF
P0335 1 D/C
59) after receiving the starter relay ON
signal.
No CMP signal is detected,
CMP Sensor "A" Circuit Bank 1 or ON OFF
P0340 although the CKP signal is input to 1 D/C
Single Sensor 17 (Page 1A-61)
ECM.
Ignition coil #1 signal is interrupted
Ignition Coil "A" Primary / Secondary
P0351 by 20 times or more continuity 1 D/C ON OFF
Circuit cr(Page 1A-63)
although CKP signal is detected.
Ignition coil #2 signal is interrupted
Ignition Coil "B'' Primary / Secondary
P0352 by 20 times or more continuity 1 D/C ON OFF
Circuit Cs"(Page 1A-63)
although CKP signal is detected.
Ignition coil #3 signal is interrupted
Ignition Coil "C" Primary / Secondary
P0353 by 20 times or more continuity 1 D/C ON OFF
Circuit 17 (Page 1A-63)
although CKP signal is detected.
Ignition coil #4 signal is interrupted
Ignition Coil "D" Primary / Secondary
P0354 by 20 times or more continuity 1 D/C ON OFF
Circuit Cs"(Page 1A-63)
although CKP signal is detected.
PAIR air flow volume is out of the
P0410 PAIR System Cli"(Page 1A-64) specified range, under the specified 3 DIC ON OFF
condition.
PAIR System Switching Valve "A" PAIR control solenoid valve drive
P0412
Circuit <r(Page 1A-65) circuit is shorted to ground or open.
3 DIC ON OFF
EVAP System Purge Control Valve EVAP system control solenoid valve
P0444
Circuit Open r:ir(Page 1A-67) circuit is shorted to ground or open.
3 DIC ON OFF
Cooling fan relay drive circuit is
P0480 Fan 1 Control Circuit 17 {Page 1A-69)
shorted to ground or open.
3 DIC OFF ON
Any of the following conditions is

.
met.
Front wheel speed is 0 km/h (0
mile/h) for a few seconds at

.
motorcycle deceleration.
Vehicle Speed Sensor "A" <1r(Page
P0500
1A-71) Front wheel speed is 0 km/h (0 3 DIC ON OFF
mile/h) for a few seconds or more
although the rear wheel speed is

.
higher than 10km/h (6 mile/h).
Front wheel speed signal does
not become stable
Cold Start Ignition Timing Ignition timing for catalystwarming
P0S0B 3 D/C ON OFF
Performance -(Page 1A-73) up is out of the specified range.
Control Module Programming Error ECM internal failure (data
P0602
e1r(Page 1A-73)
1 D/C OFF ON
programming error).
Control Module Performance
P0607
r:ir(Page 1A-73)
ECM internal processor failure. 1 D/C ON OFF
Up and Down Shift Switch Circuit Gearshift sensor output voltage is
P0826
Cli"(Page 1A-74) lower than 0.10 V.
3 DIC OFF ON
Up and Down Shift Switch Circuit Gearshift sensor output voltage is
P0828
High <lr'{Page 1A-74) higher than 4.90 V.
3 DIC OFF ON
Clutch lever position switch is
Clutch Switch "A" Circuit <?(Page 1A- continuity ON for more than
P0830
76)
3 D/C ON OFF
specified time with motorcycle
running.
Neutral switch is continuity ON for
Park/ Neutral Switch Input Circuit
POSSO more than specified time with 3 D/C ON OFF
e1r(Page 1A-78)
motorcycle running.
1A-17 Engine General Information and Diagnosis:

DTC Master
OTC OTC name DTC detecting condition detection MIL warning
logic indicator
GP sensor output voltage is higher
P0914 GP Sensor Circuit w(Page 1A-80) than 4.90 V for 3 sec. or more 3 DIC ON OFF
continuity.
Any of the following conditions is
met.
• GP sensor output voltage is out

.
GP Sensor Circuit Range/ of the specified range.
P0915 3 DIC ON OFF
Performance w(Page 1A-80) Difference between measured
gear position and estimated gear
position is out of the specified
range.
GP sensor output voltage is lower
GP Sensor Circuit Low w(Page 1A-
P0916
80)
than 0.10 V for 3 sec. or more 3 DIC ON OFF
continuity.
IAP Sensor Circuit Bank 2 w(Page IAP sensor output voltage is higher
P1105
1A-82) than 4.80 V.
3 DIC ON OFF
Any of the following conditions is

.
met.
IAP sensor vacuum hose has
IAP Sensor Circuit Range I
DIC ON
.
P1106 come off. 3 OFF
Performance Bank2 <7(Page 1A-82)
IAP sensor output voltage does
not change, under the specified
condition.
IAP Sensor Circuit Low Bank2 IAP sensor output voltage is lower
P1107
w(Page 1A-82) than 0.10 V.
3 DIC ON OFF
Secondary fuel injector #1 signal is
Secondary Injector Circuit I Open - interrupted by 20 times or more
P1201
Cylinder 1 w(Page 1A-84) continuity although CKP signal is
3 DIC ON OFF
detected.
Secondary fuel injector #2 signal is
Secondary Injector Circuit I Open - interrupted by 20 times or more
P1202
Cylinder 2 w(Page 1A-84) continuity although CKP signal is
3 DIC ON OFF
detected.
Secondary fuel injector #3 signal is
Secondary Injector Circuit I Open - interrupted by 20 times or more
P1203
Cylinder 3 w(Page 1A-84) continuity although CKP signal is
3 DIC ON OFF
detected.
Secondary fuel injector #4 signal is
Secondary Injector Circuit I Open - interrupted by 20 times or more
P1204
Cylinder 4 w(Page 1A-84) continuity although CKP signal is
3 DIC ON OFF
detected.
Without immobilizer control
system
Ignition switch signal is not input to
P1610 Ignition Switch Signal Circuit the ECM. w(Page 1A-86) 1 D/C OFF ON
With immobilizer control system
Refer to "OT C Table" in Section 1QC
(Page 10C-3).
Control Module ROM Error w-(Page
P1622
1A-88)
EEPROM in ECM is corrupted. 1 D/C ON OFF
Inertial Measurement Unit w(Page ECM receives abnormal signal from
P1650 3 D/C OFF ON
1A-88) IMU.
 Engine General Information and Diagnosis: 1A-18

OTC Master
OTC OTC name OTC detecting condition detection MIL warning
logic indicator
Any of the following conditions is

.
met.
Throttle valve motor and/or its

.
circuit malfunction is detected.

.
Throttle valve sticking is detected
Difference between measured
throttle valve position and
targeted throttle valve position is
Throttle Actuator "A" Control Motor
.
out of the specified range.
P2101 Circuit Range / Performance <?(Page 1 D/C ON OFF
The target value of throttle valve

.
1A-89)
position does not become stable.
Throttle valve motor power
supply circuit malfunction is

. detected.
Throttle valve does not become

.
fully closed position.
TP sensor malfunction is
detected.
Difference between power supply
Throttle Actuator "A" Control Motor voltage to throttle valve motor and
P2102 1 D/C ON OFF
Circuit Low <?(Page 1A-91) battery voltage is out of the
specified range.
TP Sensor / Switch "D" Circuit Accelerator position sensor (main)
P2120 1 D/C ON OFF
-(Page 1A-92) output voltage is lower than 0.10 V.
TP Sensor / Switch "D" Circuit High Accelerator position sensor (main)
P2123 1 D/C ON OFF
-(Page 1A-92) output voltage is higher than 4.90 V.
TP Sensor / Switch "E" Circuit Accelerator position sensor (sub)
P2125 1 D/C ON OFF
<7(Page 1A-94) output voltage is lower than 0.10 V.
TP Sensor / Switch "E" Circuit High Accelerator position sensor (sub}
P2128 1 D/C ON OFF
-(Page 1A-94) output voltage is higher than 4.90 V.
Difference between TP sensor
TP Sensor / Switch "A" / "B" Voltage
P2135
Correlation 17 (Page 1A-96)
(main) value and TP sensor (sub) 1 D/C ON OFF
value is out of the specified range.
Difference between accelerator
TP Sensor / Switch "D" / "E" Voltage position sensor (main) value and
P2138
Correlation cr(Page 1A-97) accelerator position sensor (sub)
1 D/C ON OFF
value is out of the specified range.
Any of the following conditions is

.
met, at motorcycle deceleration.
Rear wheel speed is 0 km/h (0
mile/h) for a few seconds or

.
more, at motorcycle deceleration.
Vehicle Speed Sensor "B" w(Page
P2158
1A-98) Rear wheel speed is 0 km/h (0 3 D/C ON OFF
mile/h) for a few seconds or more
although the front wheel speed is

.
higher than 10km/h (6 mile/h).
Rear wheel speed signal does
not become stable.
AP sensor output voltage is higher
P2226 AP Sensor Circuit w(Page 1A-100)
than 4.80 V.
3 DIC ON OFF
AP Sensor Circuit Low <:ir(Page 1A- AP sensor output voltage is lower
P2228
100) than 0.10 V.
3 DIC ON OFF
ECM Power Input Signal "'"(Page Power source for ECM is not
P2505 1 D/C ON OFF
1A-102) supplied.
1A-19 Engine General Information and Diagnosis:

OTC Master
OTC OTC name OTC detecting condition detection MIL warning
logic indicator
02 Sensor Circuit Range /
HO2 sensor #1 output voltage is
P2A00 Performance Bank 1 Sensor 1 3 DIC ON OFF
stayed for specified time or more.
w(Page 1A-103)
02 Sensor Circuit Range /
HO2 sensor #2 output voltage is
P2A03 Performance Bank 2 Sensor 1 3 D/C ON OFF
stayed for specified time or more.
w(Page 1A-104)
Control Module Communication Bus
U0073 1 D/C OFF ON
Off
Refer to "CAN OT C (Lost
Lost Communication With ABS
U0121 Communication and 1 D/C OFF ON
Control Module
Communication Bus Off) Table" in
U0123 Lost Communication With IMU 1 D/C OFF ON
Section 10H (Page 10H-5).
Lost Communication With Instrument
U0155 1 D/C OFF ON
Panel Cluster (IPC) Control Module

Fail-Safe Table
BENM10L31104005
Engine control system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a
minimum performance necessary even under malfunction condition.

NOTE
• *1: When the clutch lever is grasped, starting ability is "YES".
• *2: Depending on the timing of OTC detection, the starting ability may become "NO".

Item
. Fail-safe mode
ECM stops controlling HO2 sensor
Starting ability Running ability

HO2 sensor heater

.I heater.
Feedback compensation is inhibited. (Air
fuel ratio is fixed to normal.)
"YES" "YES"

Intake air pressure value is fixed to 101.3

IAP sensor "YES" "YES"
kPa (760 mmHg).
Atmospheric pressure value is fixed to 101.3
AP sensor "YES" "YES"
kPa (760 mmHg).
Intake air temperature value is fixed 25.0 °C
IAT sensor "YES" "YES"
.
(77 °F).
Engine coolant temperature value is fixed
ECT sensor
. to 80 °C (176 °F).
Cooling fan is fixed to on state.
One of the TP sensor (main) or TP sensor
"YES" "YES"

T P sensor (sub) is normal: "YES" "YES"

.
ECM uses normal sensor side signal.
ECM stops controlling HO2 sensor
heater.
HO2 sensor "YES" "YES"
Feedback compensation is inhibited. (Air
I fuel ratio is fixed to normal.)
"YES" "YES"
Ignition coil #1 Cylinder #1 fuel-cut
Cylinder #2, #3 & #4 can run
"YES" "YES"
Ignition coil #2 Cylinder #2 fuel-cut
Cylinder #1, #3 & #4 can run
"YES" "YES"
Ignition coil #3 Cylinder #3 fuel-cut
Cylinder #1, #2 & #4 can run
"YES" "YES"
Ignition coil #4 Cylinder #4 fuel-cut
Cylinder #1, #2 & #3 can run
ECM stops controlling PAIR control solenoid
PAIR control solenoid valve "YES" "YES"
valve.
EVAP system purge control ECM stops controlling EVAP system purge
solenoid valve "YES" "YES"
control solenoid valve.
 Engine General Information and Diagnosis: 1A-20

Item Fail-safe mode Starting ability Running ability

Cooling fan relay ECM stops controlling cooling fan relay. "YES" "YES"
Clutch lever position switch Clutch lever position switch is fixed to OFF. "YES" "YES"
It is either following depending on a failed

.
state.
Gear position signal is fixed to specified
GP sensor "NO" *1 "YES"
.
gear position.
Gear position signal is fixed to the
position before occurrence of failure.
Throttle grip opening value is fixed to fully "NO"
Accelerator position sensor "YES"
closed position.
Throttle valve motor ECM stops controlling throttle valve motor. "YES" *2 "YES"
Front wheel speed sensor Front vehicle speed is fixed to O km/h (0 "YES"
"YES"
mile/h).
Rear wheel speed sensor Rear vehicle speed is fixed to O km/h (0
"YES" "YES"
mile/h).

Scan Tool Data

BENM10L31104006
As the data values are standard values estimated on the basis of values obtained from the normally operating
motorcycles using a SDS-11, use them as reference values.
Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each
specified data range. Therefore, judgment as abnormal should not be made depending on these data alone.

NOTE
• If communication between SDS-11 and ECM is not possible, perform the following checks.
- Check wire harness between mode select coupler (6P) and ECM coupler.
- Check DIG-cable between mode select coupler (6P) and SDS-11. If necessary, check DIG-cable and
conversion cable (ISO) by substituting a known-good cable.
- Check CAN communication system. <r(Page 10H-4)
- Check ECM power circuit and ground circuit. 17 (Page 1A-113)
• *1: The value of throttle position displayed on SDS-11 is different from value of mechanical throttle
valve opening.
- Mechanical throttle valve opening (Ignition switch: ON):
- Throttle grip is fully close position: Approx. 6.1 - 8.5°
- Throttle grip is fully open position: Approx. 90.0°

Normal condition /
Scan tool data
Reference value
Short term fuel trim (Bank1) Approx. -25 - 50%
Long term fuel trim (Bank1) Approx. -25 - 50%
Short term fuel trim (Bank2) Approx. -25 - 50%
Long term fuel trim (Bank2) Approx. -25 - 50%
Almost the same as
Vehicle speed sensor front
combination meter reading.
Almost the same as
Vehicle speed sensor rear
combination meter reading.
Engine speed Approx. 1150 r/min
Approx. 100 kPa
Manifold absolute pressure "A"
Approx. 60 kPa
Almost the same as
Barometric pressure
measured value.
Almost the same as
Intake air temperature
measured value.
Almost the same as
Ambient air temperature
measured value.
Engine coolant temperature Approx. 80 - 105 °C
Learned IAC actuator position (ETV) Approx. 1.8 °
Motorcycle condition
Engine: Idle speed after warming up
Engine: Idle speed after warming up
Engine: Idle speed after warming up
Engine: Idle speed after warming up
Riding condition: While running
Riding condition: While running
Engine: Idle speed after warming up
Engine: Stopped
Engine: Idle speed after warming up
The barometric pressure is measured and
compared with scan tool data reading.
The intake air temperature is measured and
compared with scan tool data reading.
The ambient air temperature is measured and
compared with scan tool data reading.
Engine: Idle speed after warming up
Engine: Idle speed after warming up
1A-21 Engine General Information and Diagnosis:
Scan tool data
Shift sensor output voltage
Gear position
Throttle position sensor A output
voltage
Throttle position sensor B output
voltage
Accelerator position sensor D output Approx. 0.5 - 0.7 V
voltage
Accelerator position sensor E output Approx. 0.8 - 1.0 V
voltage
Absolute throttle position angle bank1
Absolute accelerator position angle
Throttle motor voltage (Bank1)
Battery voltage
Oxygen sensor1 (Bank1)
Oxygen sensor2 (Bank2)
Inertial sensor output Ox
Inertial sensor output Oy
Inertial sensor output Oz
Engine stop / starter switch
Radiator fan
EVAP canister
PAIR control solenoid valve
Neutral switch
Test switch
Anti-theft type
Normal condition /
Motorcycle condition
Reference value
Approx. 4.48-4.65 V Gearshift lever: Fully upped
Approx. 2.38-2.62 V Gearshift lever: Neutral position
Approx. 0.35 - 0.52 V Gearshift lever: Fully downed
N Gear position: Neutral
1 Gear position: 1st
2 Gear position: 2nd
3 Gear position: 3rd
4 Gear position: 4th
5 Gear position: 5th
6 Gear position: 6th
Approx. 3.6 - 3.8 V Throttle grip: Fully close position
Approx. 0. 7 V Throttle grip: Fully open position
Approx. 4.2 - 4.4 V Throttle grip: Fully close position
Approx. 1.3 V Throttle grip: Fully open position
Throttle grip: Fully close position
Approx. 3.5 V Throttle grip: Fully open position
Throttle grip: Fully close position
Approx. 4.6 V Throttle grip: Fully open position
Approx. 40.5 ° *1 Throttle grip: Fully close position
Approx. 118.0° *1 Throttle grip: Fully open position
Approx. 15.5° Throttle grip: Fully close position
Approx. 100.5 ° Throttle grip: Fully open position
Battery voltage -
Approx. 12 - 15 V Engine: Running
Approx. 0 - 1.0 V Engine: Idle speed after warming up
Approx. 0 - 1.0 V Engine: Idle speed after warming up
Side-stand position with steering fully
3.12 to -3.12 deg/s Static
turned to left side.
Numerical value increases
Raise to upright position from side-
to the positive or negative Dynamic
stand position. (While raising)
side.
Side-stand position with steering fully
3.12 to-3.12 deg/s Static
turned to left side.
Numerical value increases
Raise to upright position from side-
to the positive or negative Dynamic
stand position. (While raising)
side.
Side-stand position with steering fully
3.12 to -3.12 deg/s Static
turned to left side.
Numerical value increases Raise to upright position from side-
Dynamic
to the negative side. stand position. (While raising)
Engine stop / starter switch ("STOP" position):
Stop
ON
Run
Engine stop/ starter switch ("STOP" position):
OFF
On Cooling fan: Running
Off Cooling fan: Stopped
On EVAP system purge control solenoid valve: ON
Off EVAP system purge control solenoid valve: OFF
On PAIR control solenoid valve: ON
Off PAIR control solenoid valve: OFF
GND Gear position: Neutral
Open Gear position: Other than neutral
Special Tool (Mode selection switch): Connected
on· .c
to the mode select coupler (6P), and ON
Special Tool (Mode selection switch): Not
Off
connected to the mode select coupler (6P)
Normal OTC P1610: Not detected
Abnormal OTC P1610: Detected
 Engine General Information and Diagnosis: 1A-22

Normal condition /
Scan tool data Motorcycle condition
Reference value
On Motorcycle condition: Leaning 45 ° or more
Tip over sensor
Off Motorcycle condition: Normal
On Clutch lever: Grasped
Clutch switch
Off Clutch lever: Released
Engine stop/ starter switch ("START" position):
On
Pushed
Starter switch
Engine stop/ starter switch ("START" position):
Off
Released
ECM sends HO2 sensor heater drive signal to
On
HO2 sensor.
Oxygen sensor heater1
ECM does not send HO2 sensor heater drive
Off
signal to HO2 sensor.
On "MODE" switch: Pushed (For a short time)
Set switch (Short)
Off "MODE" switch: Released
On "MODE" switch: Pushed (For a long time)
Set switch (Long)
Off "MODE" switch: Released
On "RES/ UP" switch: Pushed (For a short time)
Up switch (Short)
Off "RES/ UP" switch: Released
On "RES/ UP" switch: Pushed (For a long time)
Up switch (Long)
Off "RES/ UP" switch: Released
On "SET/ DOWN" switch: Pushed (For a short time)
Down switch (Short)
Off "SET/ DOWN" switch: Released
On "SET/ DOWN" switch: Pushed (For a long time)
Down switch (Long)
Off "SET/ DOWN" switch: Released
On Cruise control switch: Pushed
Speed control switch (Raw value)
Off Cruise control switch: Released
Throttle grip: Cruise control cancel switch
On
position
Cruise cancel switch
Throttle grip: Other than cruise control cancel
Off
switch position
On "MODE" switch: Pushed
Set switch (Raw value)
Off "MODE" switch: Released
On "RES/ UP" switch: Pushed
Up switch (Raw value)
Off "RES/ UP" switch: Released
On "SET/ DOWN" switch: Pushed
Down switch (Raw value)
Off "SET/ DOWN" switch: Released
On Engine: Decelerating
Fuel cut flag1
Off Engine: Idle speed
On Engine: Decelerating
Fuel cut flag2
Off Engine: Idle speed
On Engine: Decelerating
Fuel cut flag3
Off Engine: Idle speed
On Engine: Decelerating
Fuel cutflag4
Off Engine: Idle speed
On "RES/ UP" switch: Pushed (For a short time)
Cruise resume switch (Short)
Off "RES/ UP" switch: Released
On "RES/ UP" switch: Pushed (For a long time)
Cruise resume switch (Long)
Off "RES/ UP" switch: Released
On "RES/ UP" switch: Pushed
Cruise resume switch (Raw value)
Off "RES/ UP" switch: Released
On "SET/ DOWN" switch: Pushed (For a short time)
Cruise set switch (Short)
Off "SET/ DOWN" switch: Released
On "SET/ DOWN" switch: Pushed (For a long time)
Cruise set switch (Long)
Off "SET/ DOWN" switch: Released
On "SET/ DOWN" switch: Pushed
Cruise set switch (Raw value)
Off "SET/ DOWN" switch: Released
1A-23 Engine General Information and Diagnosis:

Normal condition /
Scan tool data Motorcycle condition
Reference value
Approx. 1.0 - 1.3 V Gear position: Neutral
Approx. 0.5 - 0.8 V Gear position: 1st
Approx. 1.6 - 1.8 V Gear position: 2nd
Gear position voltage Approx. 2.2-2.5 V Gear position: 3rd
Approx. 2.9 - 3.2 V Gear position: 4th
Approx. 3.6- 3.8 V Gear position: 5th
Approx. 4.2 - 4.5 V Gear position: 6th
CAN status (ABS) 1 Any condition
CAN status (IPC) 1 Any condition
CAN status (IMU) 1 Any condition
Traction control mode 0 Motion track traction control system: OFF
1 SDMS-a: Mode A
2 SDMS-a: Mode B
3 SDMS-a: Mode C
OMS mode
4 SDMS-a: Mode U1
5 SDMS-a: Mode U2
6 SDMS-a: Mode U3
1 Power mode: Mode 1
Power mode 2 Power mode: Mode 2
3 Power mode: Mode 3
0 Motion track traction control system: OFF
1 Motion track traction control system: Mode 1
2 Motion track traction control system: Mode 2
3 Motion track traction control system: Mode 3
4 Motion track traction control system: Mode 4
Traction control mode 5 Motion track traction control system: Mode 5
6 Motion track traction control system: Mode 6
7 Motion track traction control system: Mode 7
8 Motion track traction control system: Mode 8
9 Motion track traction control system: Mode 9
10 Motion track traction control system: Mode 10
0 Bi-directional quick shift system: Mode 0
Quick shift mode 1 Bi-directional quick shift system: Mode 1
2 Bi-directional quick shift system: Mode 2
0 Anti-lift control: Mode 0
1 Anti-lift control: Mode 1
2 Anti-lift control: Mode 2
3 Anti-lift control: Mode 3
4 Anti-lift control: Mode 4
Lift control mode 5 Anti-lift control: Mode 5
6 Anti-lift control: Mode 6
7 Anti-lift control: Mode 7
8 Anti-lift control: Mode 8
9 Anti-lift control: Mode 9
10 Anti-lift control: Mode 10
0 Engine brake control: Mode O
1 Engine brake control: Mode 1
Engine-brake control mode
2 Engine brake control: Mode 2
3 Engine brake control: Mode 3
1 Launch control: Mode 1
Launch mode 2 Launch control: Mode 2
3 Launch control: Mode 3
Desired speed (Cruise Controller) Approx. 30 - 200 km/h Cruise control system: ON
Desired speed (Speed Limiter) Approx. 40 - 200 km/h Active speed limiter: ON
0% Riding condition: While stopped
Spin rate (Traction Control)
Approx. 0 -100% Riding condition: While running
Number of reprogramming According to number of times the
0-255
"Reprogramming" is performed.
 Engine General Information and Diagnosis: 1A-24

Normal condition /
Scan tool data Motorcycle condition
Reference value
Side-stand position with steering fully turned to
3.78 to 0.73 m/s2
left side.
Inertial sensor output Ax axis
Numerical value increases
Upright position.
to the negative side.
Side-stand position with steering fully turned to
10.96 to 8.71 m/s2
left side.
Inertial sensor output Ay axis
Numerical value increases
Upright position.
to the positive side.
Side-stand position with steering fully turned to
1.47 to-1.61 m/s2
left side.
Inertial sensor output Az axis
Numerical value does not Upright position.
change.

Visual Inspection
BENM10L31104007
Prior to diagnosis using the SDS-11 or mode select switch, perform the following visual inspections. The reason for
visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of
SDS-11 or mode select switch.
Inspection item Referring section
Level "Engine Oil Inspection" in Section 1E
Engine oil
Leakage (Page 1E-5)
"Engine Coolant Level Inspection" in
Level
Section 1 F (Page 1 F-6)
Engine coolant
"Engine Cooling System Inspection" in
Leakage
Section 1 F (Page 1 F-7)
Level -
Fuel "Fuel Hose Inspection" in Section 1 G
Leakage
(Page 1G-7)
Dirt "Air Cleaner Element Removal and
Air cleaner element
Clogging Installation" in Section 1D (Page 1 D-6)
"Battery Visual Inspection" in Section
Battery Corrosion of terminal
1J (Page 1J-9)
"Precautions for Electrical Circuit
Fuse Burning
Service" in Section 00 (Page 00-2)
MIL
Operation "Self-Diagnosis Function" (Page 1A-1)
Master warning indicator
Each indicator light Operation "Combination Meter On-Vehicle
Inspection" in Section 9C (Page 9C-9)
Combination meter Operation "Combination Meter On-Vehicle
Inspection" in Section 9C (Page 9C-9)
Leakage of exhaust gas "Exhaust System Inspection" in
Exhaust system
Noise Section 1 K (Page 1 K-7)
Disconnection "Precautions for Electrical Circuit
Harness coupler
Poor contact Service" in Section 00 (Page 00-2)
1A-25 Engine General Information and Diagnosis:
Engine Symptom Diagnosis
Condition Possible cause
Engine will not start or is Valve clearance out of adjustment.
hard to start Worn valve guides or poor seating of
(Compression too low) valves.
Mistimed valves.
Excessively worn piston rings.
Worn-down cylinder bores.
Too slow starter motor cranking.
Poor seating of spark plugs.
Engine will not start or is Defective spark plugs.
hard to start (Plug not Too wide spark plug gap.
sparking) Fouled spark plugs.
Wet spark plugs.
Defective ignition coils.
Defective CKP sensor.
Defective ECM.
Open-circuited wiring connections.
Engine will not start or is Clogged fuel filter or fuel hose.
hard to start (No fuel
reaching the intake port)
Defective fuel pump.
Defective fuel pump relay.
Defective fuel pressure regulator.
Defective fuel injectors.
Defective ECM.
Defective engine stop switch signal
circuit.
Open-circuited wiring connections.
Engine will not start or is Defective fuel pump.
hard to start {Incorrect Defective fuel pressure regulator.
fuel/air mixture) Defective TP sensor.
Defective CKP sensor.
Defective IAP sensor.
Defective ECM.
Defective ECT sensor.
Defective IAT sensor.
Defective throttle valve motor.
BENM10L31104008
Correction I Reference Item
Adjust. t?(Page 10-26)
Repair or replace. ,r(Page 10-44)
Adjust. t?(Page 1 D-26)
.
Replace.
Removal: t?(Page 1D-50)
• Installation: t?(Page 1D-51)
Replace.
•
.
Removal: t?(Page 10-50)
Installation: t?(Page 10-51)
Repair or replace.
• Repair: t?(Page 11-7)
. Replace: or(Page 11-6)
Retighten. -(Page 1 H-5)
Replace. t?(Page 1H-5)
Replace. cr(Page 1 H-5)
Replace. -(Page 1H-5)
Dry or replace. or(Page 1H-5)
Replace. t?(Page 1H-4)
.
Replace.
.
Removal: cr(Page 1J-4)
Installation: w(Page 1J-6)
Replace. or(Page 1C-2)
Repair or replace. t?(Page 9A-5)
.
Clean or replace.
.
Fuel filter: -(Page 1G-20)
Fuel hose: w(Page 1G-8)
Replace. t?(Page 1G-16)
Replace. ,r(Page 1G-20)
Replace. ,r(Page 1G-18)
Replace. w(Page 1G-21)
.
Replace. t?(Page 1C-2)
Repair or replace: Engine stop switch signal
. wire. w(Page 9A-5)
Replace: ECM. cr(Page 1C-2)
Repair and replace. w(Page 9A-5)
Replace. -(Page 1 G-16)
Replace. w(Page 1G-18)
Replace. <r(Page 10-9)
.
Replace.
.
Removal: w(Page 1J-4)
Installation: t?(Page 1J-6)
Replace. -(Page 1C-5)
Replace. w(Page 1 C-2)
Replace. <r(Page 1C-6)
Replace. <r(Page 1C-5)
Replace. w(Page 10-9)
 Engine General Information and Diagnosis: 1A-26

Condition Possible cause Correction I Reference Item

Engine idles poorly Valve clearance out of adjustment. Adjust. <?(Page 10-26)
Poor seating of valves. Repair. <?(Page 10-44)
Defective valve guides. Replace. <?(Page 10-44)

.
Worn down camshafts and/or cam Replace.
surfaces. Removal: <?(Page 10-18)
• Installation: <?(Page 10-19)
Too wide spark plug gap. Replace. <?(Page 1H-5)
Defective ignition coil. Replace. <?(Page 1H-4)
Defective CKP sensor. Replace.
• Removal: <?(Page 1J-4)
. Installation: w(Page 1J-6)
Defective ECM. Replace. <?(Page 1C-2)
Defective TP sensor. Replace. <?(Page 10-9)
Defective fuel pump. Replace. <?(Page 1G-16)
Imbalanced throttle valve. Adjust. <?(Page 08-15)
Damaged or cracked vacuum hose. Replace.
Defective throttle valve motor. Replace. -(Page 10-9)
Dirty throttle body. Clean. -(Page 10-12)
Throttle valve system incorrect leaning. Reset learned value. -(Page 1C-3)
Engine stalls often Defective IAP sensor or circuit. Repair or replace. <?(Page 1C-5)
(Incorrect fuel/air mixture) Clogged fuel filter. Replace. <r(Page 1G-20)
Defective fuel pump. Replace. <?(Page 1G-16)
Defective fuel pressure regulator. Replace. -(Page 1G-18)
Defective ECT sensor. Replace. -(Page 1C-6)
Defective thermostat. Replace. rr(Page 1F-13)
Defective IAT sensor. Replace. cr(Page 1C-5)
Damaged or cracked vacuum hose. Replace.
Defective throttle valve motor. Replace. <?(Page 10-9)
Engine stalls often (Fuel Defective fuel injectors. Replace. -(Page 1G-21)
injector improperly No injection signal from ECM. Repair or replace. -(Page 1A-50)
operating) Open or short circuited wiring Repair or replace. -(Page 9A-5)
connections.
Defective battery or low battery voltage. Replace or recharge. rr(Page 1J-8)
Engine stalls often Defective ECM. Replace. -(Page 1 C-2)
(Control circuit or sensor Defective fuel pressure regulator. Replace. -(Page 1G-18)
improperly operating) Defective TP sensor. Replace. -(Page 10-9)
Defective IAT sensor. Replace. -(Page 1C-5)
Defective CKP sensor. Replace.

.
• Removal: -(Page 1J-4)
Installation: w(Page 1J-6)
Defective CMP sensor. Replace. -(Page 1C-11)
Defective ECT sensor. Replace. -(Page 1C-6)
Defective fuel pump relay. Replace. -(Page 1 G-20)
Defective throttle valve motor. Replace. w(Page 10-9)
Throttle valve system incorrect leaning. Reset learned value. -(Page 1C-3)
Engine stalls often Fouled spark plug. Replace. -(Page 1H-5)

.
(Engine internal parts Defective CKP sensor. Replace.
improperly operating)
.
Removal: -(Page 1J-4)
Installation: w(Page 1J-6)
Defective ECM. Replace. w(Page 1C-2)
Clogged fuel hose. Clean or replace. w(Page 1G-8)
Valve clearance out of adjustment. Adjust. -(Page 10-26)
Dirty throttle body. Clean. <r(Page 10-12)
1A-27 Engine General Information and Diagnosis:

Condition Possible cause Correction I Reference Item

Noisy engine (Excessive Too large valve clearance. Adjust. -(Page 10-26)
valve chatter) Weakened or broken valve springs. Replace. -(Page 10-40)

.
Worn tappets and/or cam surfaces. Replace.

. Removal: -(Page 10-18)

Installation: -(Page 10-19)

.
Worn or burnt camshaft journals. Replace.
Removal: -(Page 10-18)
• Installation: -(Page 10-19)

.
Noisy engine (Noise Worn down pistons or cylinders. Replace.
seems to come from Piston:
piston)
- Removal: w-(Page 10-50)

.
- Installation: -(Page 10-51)
Cylinder
- Removal: w(Page 10-50)
- Installation: -(Page 10-51)
Combustion chamber fouled with Clean. t?(Page 10-47)
carbon.

.
Worn piston pins or piston pin bores.Replace.

.
Removal: -(Page 10-50)
Installation: -(Page 10-51)

.
Worn piston rings or ring grooves. Replace.

.
Removal: w(Page 10-50)
Installation: -(Page 10-51)

.
Noisy engine (Noise Stretched cam chain. Replace.
seems to come from cam
.
Removal: -(Page 10-58)
chain)
Installation: -(Page 10-61)

.
Worn sprockets. Replace.

.
Removal: w(Page 10-58)
Installation: t?(Page 10-61)

. Removal: w-(Page 10-58)

Cam chain tension adjuster not working. Repair or replace.

. Installation: w(Page 10-61)

. Removal: -(Page 10-71)
Noisy engine (Noise Rattling bearing due to wear. Replace.
seems to come from
crankshaft) . Installation: -(Page 10-74)
. Removal: -(Page 10-71)
Worn or burnt crank pin bearings. Replace.

. Installation: ir(Page 10-74)

Worn or burnt journal bearings.
Noisy engine (Noise Too much play on pump shaft bearing.
seems to come from Worn or damaged impeller shaft.
water pump) Worn or damaged mechanical seal.
Contact between pump case and
impeller.
Replace.
•
.
Removal: w-(Page 10-71)
Installation: -(Page 10-74)
Replace. w-(Page 1F-17)
Replace. t?(Page 1F-17)
Replace. -(Page 1F-17)
Replace. -(Page 1F-17)
 Engine General Information and Diagnosis:
Condition Possible cause
Engine runs poorly in Weakened valve springs.
high speed range Worn camshafts.
(Defective engine interna/J
electrical parts)
Valve clearance out of adjustment.
Too narrow spark plug gaps.
Ignition not advanced sufficiently due to Replace ECM. w(Page 1C-2)
poorly working timing advance circuit.
Defective ignition coils.
Defective CKP sensor.
Defective ECM.
Clogged air cleaner element.
Clogged fuel hose, resulting in
inadequate fuel supply to injector.
Defective fuel pump.
Defective T P sensor.
Defective accelerator position sensor.
Defective throttle valve motor.
Engine runs poorly in Clogged air cleaMr element.
high speed range Sucking air from throttle body joint or
(Defective air flow intake pipe joint.
system)
Defective ECM.
Defective throttle valve motor.
Unbalancing throttle valve
synchronization.
Defective accelerator position sensor.
Engine runs poorly in Low fuel pressure.
high speed range Defective TP sensor.
(Defective control circuit Defective IAT sensor.
or sensor) Defective IAP sensor.
Defective CKP sensor.
Defective CMP sensor.
Defective ECM.
Defective accelerator position sensor.
Defective throttle valve motor.
1A-28
Correction I Reference Item
Replace. "(Page 10-40)
.
Replace.
.
Removal: <r(Page 10-18)
Installation: <r(Page 10-19)
Adjust. cr(Page 10-26)
Replace. w(Page 1H-5)
Replace. w(Page 1H-4)
.
Replace.
Removal: cr(Page 1J-4)
- Installation: <r(Page 1J-6)
Replace. <?(Page 1C-2)
Replace. "(Page 10-6)
Clean and prime.
Replace. @>(Page 1G-16)
Replace. <?(Page 10-9)
Replace. cr(Page 1C-14)
Replace. "(Page 10-9)
Rgplacg_ {?(Page 10-6)
.
Repair or replace.
.
Throttle body joint: @>(Page 10-9)
Intake pipe joint: w-(Page 10-12)
Replace. <?(Page 1C-2)
Replace. -(Page 10-9)
Adjust. <?(Page 08-15)
Replace. -(Page 10-9)
Clean or replace.
Replace. "(Page 10-9)
Replace. -(Page 1C-5)
Replace. <?(Page 1C-5)
.
Replace.
.
Removal: @>(Page 1J-4)
Installation: @>(Page 1J-6)
Replace. <?(Page 1C-11)
Replace. "(Page 1C-2)
Replace. <?(Page 1C-14)
Replace. cr(Page 10-9)
1A-29 Engine General Information and Diagnosis:

Condition Possible cause Correction I Reference Item

Engine lacks power Weakened valve springs. Replace. w(Page 10-40)
(Defective engine internal/ Valve clearance out of adjustment. Adjust. w(Page 10-26)
electrical parts) Worn piston rings or cylinders.
.
Replace.
Piston ring:
- Removal: w(Page 10-50)
- Installation: w(Page 10-51)
• Cylinder
- Removal: w(Page 10-50)
- Installation: w(Page 10-51)
Poor seating of valves. Repair. w(Page 10-44)
Fouled spark plugs. Replace. w(Page 1H-5)
Incorrect spark plugs. Replace. w(Page 1H-5)
Clogged fuel injector. Clean or replace. w(Page 1G-23)
Clogged air cleaner element. Replace. w(Page 1D-6)

.
Sucking air from throttle body joint or Repair or replace.
intake pipe joint.
.
Throttle body joint: w(Page 10-9)
Intake pipe joint: -(Page 10-12)
Too much engine oil. Drain out excess oil.
Defective fuel pump. Replace. w(Page 1G-16)
Defective ECM. Replace. w(Page 1C-2)

.
Defective CKP sensor. Replace.

. Removal: -(Page 1J-4)

Installation: w(Page 1J-6)
Defective ignition coils. Replace. -(Page 1H-4)
Defective accelerator position sensor. Replace. w(Page 1C-14)
Defective throttle valve motor. Replace. -(Page 10-9)
Engine lacks power Low fuel pressure. Repair or replace.

.
(Defective control circuit • Fuel feed hose: w(Page 1G-8)
or sensor)
Fuel pump: -(Page 1G-16)
Defective TP sensor. Replace. -(Page 10-9)
Defective IAT sensor. Replace. <?>(Page 1C-5)
Defective CKP sensor.
.
Replace.
Removal: <?>(Page 1J-4)
• Installation: w(Page 1J-6)
Defective IAP sensor. Replace. -(Page 1C-5)
Defective ECM. Replace. <?>(Page 1C-2)
Defective accelerator position sensor. Replace. <?>(Page 1C-14)
Defective throttle valve motor. Replace. <?>(Page 10-9)
Engine overheats Heavy carbon deposit on piston crown. Clean.
(Defective engine internal Not enough oil in the engine. Add oil. <?(Page 1E-5)
parts) Defective oil pump or clogged oil circuit. Replace or clean. !?(Page 1E-14)
Use of incorrect engine oil. Replace. -(Page 1E-5)

.
Sucking air from throttle body joint or Repair or replace.

.
intake pipe joint. Throttle body joint: <?(Page 1D-9)
Intake pipe joint: <?"(Page 1D-12)

Defective cooling system
Engine overheats (Lean Short-circuited IAP sensor/lead wire.
fuel/air mixture) Short-circuited IAT sensor/lead wire.
.
• Engine cooling system: -(Page 1 F-5)
Engine oil cooling system: i:r(Page 1E-3)
Repair or replace. <?>(Page 1C-5)
Repair or replace. -(Page 1C-5)

.
Sucking air from throttle body joint or Repair or replace.
intake pipe joint.
.
Throttle body joint: i:r(Page 10-9)
Intake pipe joint: -(Page 1D-12)
Defective fuel injectors. Replace. i:r(Page 1G-21)
Defective ECT sensor. Replace. w(Page 1C-6)
 Engine General Information and Diagnosis: 1A-30

Condition Possible cause Correction I Reference Item

Engine overheats (Other
factors)
Dirty or heavy exhaust
smoke
Ignition timing is too advanced due to Replace.
defective timing advance system (ECT
sensor, CKP sensor or ECM).
Too much engine oil. Drain out excess oil.
Worn piston rings or cylinders. Replace.
• Piston ring:
- Removal: <Y{Page 1D-50)
- Installation: w(Page 1D-51)
• Cylinder
- Removal: -r(Page 1D-50)
- Installation: w(Page 10-51)
Worn valve guides. Replace. or(Page 1D-47)
Scored or scuffed cylinder walls.
.
Replace.

Worn valve stems.

. Removal: w(Page 1D-50)
Installation: w(Page 1D-51)
Replace. or(Page 1D-40)
Defective valve stem oil seal. Replace. or(Page 1D-40)
Worn oil ring side rails.
.
Replace.

.
Removal: or(Page 1D-50)
Installation: -(Page 1D-51)

MIL Inspection No Check the combination meter power

BENM10L31104009 supply and ground circuit.
Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page If combination meter power supply and
1A-6). ground circuit is in good condition, replace
the combination meter. <?(Page 9C-13)
Troubleshooting
Step 3
Step 1 (The MIL lights up)
1) Check if the MIL (1) lights up when turning the 1) Check if the MIL go off about 3 seconds later of
ignition switch ON. ignition switch ON.
Does the MIL go off?

Yes Go to Step 4.

No • DTC output. <?(Page 1A-11)

• If DTC can not be output, check the
combination meter. -(Page 9C-9)
If combination meter is in good
condition, replace the ECM and inspect
it again. <7(Page 1C-2)
IM10L 1110005-01
Step4
Does the MIL light up?
Is "- - - - -" or "CHEC" displayed to LCD?
Yes Go to Step 3.
Yes Perform the "CAN Communication Check"
No Go to Step 2. in Section 1 OH (Page 1OH-4).

Step 2 No Normal. (No DTC exists)

(The MIL dose not lights up)
1) Check the other indicator light. w(Page 9C-9)
Is check result OK?
Yes Replace the combination meter. w(Page
9C-13)
1A-31 Engine General Information and Diagnosis:

Master Warning Indicator Inspection Step 3

BENM10L31104010
Wiring Diagram (The master warning indicator lights up)
Refer to "Engine Control System Wiring Diagram" (Page 1) Check if the master warning indicator go off about
1A-6). 3 seconds later of ignition switch ON.
Does the master warning indicator go off?
Troubleshooting
Yes Normal.
Step 1
1) Check if the master warning indicator (1) lights up No Go to Step 4.
when turning the ignition switch ON.
Step4
Is battery mark, "Air!" or "SW!" displayed to LCD?
Yes Check the battery voltage or go to
troubleshooting for "Multifunction Display
indicates "Air!"" in Section 9C (Page 9C-4)
or "Multifunction Display indicates "SW!""
in Section 9C (Page 9C-6).
No • OTC output.
IM10L1110006-01
- ECM: <F(Page 1A-11)

Does the master warning indicator light up? - ABS control unit/ HU: <F(Page 4E-
15)
Yes Go to Step 3. • If OTC can not be output, go to Step 5.
No Go to Step 2.
Step 5
Step 2 Is "- - - - -" or "CHEC" displayed to LCD?
(The master warning indicator dose not lights up)
Yes Perform the "CAN Communication Check"
1) Check the other indicator light. <F(Page 9C-9)
in Section 1OH (Page 10H-4).
Is check result OK?
No Replace the combination meter. <?'(Page
Yes Replace the combination meter. <r(Page 9C-13)
9C-13) If the master warning indicator is abnormal
No Check the combination meter power even after replacing the combination
supply and ground circuit. meter, replace the ECM or ABS control
unit/ HU and inspect it again.
If combination meter power supply and
ground circuit is in good condition, replace • ECM: <r(Page 1C-2)
the combination meter. <F(Page 9C-13) • ABS control unit/ HU: <F(Page 4E-50)
 Engine General Information and Diagnosis: 1A-32

DTC P0030 BENM10L31104011

OTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area
P0030: H02 Sensor Heater Control Circuit Bank1
Sensor1
HO2 sensor #1 heater circuit is shorted to ground or
. HO2 sensor #1 heater
HO2 sensor #1 heater circuit
• ECM
open.
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

w W/Y

5
w Bl T79--GJ

i·
B B1/G T24
7 T
Gr B/Br T28�

IM10L 1110007-01

1. HO2 sensor #1 4. Ignition switch 7. Battery

2. ECM 5. Main fuse (30 A)
3. HO2 sensor heater drive circuit 6. Ignition fuse (10 A)

Troubleshooting No Repair or replace the "T4" wire at the HO2

sensor #1 coupler.
Step 1
H02 sensor #1 heater power supply circuit check Step 2
1) Turn the ignition switch OFF. H02 sensor #1 heater circuit check
2) Disconnect the HO2 sensor #1 coupler. @"(Page 1) Turn the ignition switch OFF.
1C-9) 2) Disconnect the ECM coupler "C". @"(Page 1C-2)
3) Check for proper terminal connection to the HO2 3) Check for proper terminal connection to the ECM
sensor #1 coupler (1). coupler "C".
4) If connections are OK, turn the ignition switch ON. 4) If connections are OK, check the following points.
5) Measure the voltage between "T4" and ground. • Resistance
H02 sensor heater power supply voltage - Between "T3" at the HO2 sensor #1 coupler
[Standard]: Battery voltage (1) and "T79" at the ECM coupler "C" (2):
less than 1 n

4 3

IL41K1110009-01

Is check result OK?

Yes Go to Step 2.
1A-33 Engine General Information and Diagnosis:

No Repair or replace the "T3" wire at the HO2

sensor #1 coupler.
2
Step3
H02 sensor #1 heater check
4 3
1) Measure the HO2 sensor #1 heater resistance.
Refer to "HO2 Sensor Heater Resistance" under
"HO2 Sensor Inspection" in Section 1C (Page 1C-
8).
Is check result OK?
Yes Replace the ECM and inspect it again.
(g"(Page 1C-2)
No Replace the HO2 sensor #1. (g"(Page 1C-
9)
·-----------------------, ,----------------------

- Between "T3" at the HO2 sensor #1 coupler

(1) and ground: infinity

IL41 K1110011-01

- Between "T3" and other terminal at HO2

sensor #1 coupler (1): infinity

IL41K1110012-01

• Voltage
- Turn the ignition switch ON.
- Between ''T3" at the HO2 sensor #1 coupler
(1) and ground: approx. 0 V

4 3

IL41K1110013-01

Is check result OK?

Yes Go to Step 3.
 Engine General Information and Diagnosis: 1A-34

DTC P0050
BENM10L31104012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
•
.
P0050: H02 Sensor Heater Control Circuit Bank 2 H02 sensor #2 heater
Sensor1
.
H02 sensor #2 heater circuit
H02 sensor #2 heater circuit is shorted to ground or
ECM
open.
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

4
6
2

w W/Y

5
w w T78-0

B WIG T40
7 .,.. J;�
Gr B/Br T28�

IM10L1110009-01

1. HO2 sensor #2 4. Ignition switch 7. Battery

2. ECM 5. Main fuse (30 A)
3. HO2 sensor heater drive circuit 6. Ignition fuse (10 A)

Troubleshooting No Repair or replace the "T4" wire at the H02

sensor #2 coupler.
Step 1
H02 sensor #2 heater power supply circuit check Step2
1) Turn the ignition switch OFF. H02 sensor #2 heater circuit check
2) Disconnect the H02 sensor #2 coupler. <7(Page 1) Turn the ignition switch OFF.
1C-9) 2) Disconnect the ECM coupler "C". 07 (Page 1C-2)
3) Check for proper terminal connection to the H02 3) Check for proper terminal connection to the ECM
sensor #2 coupler ( 1). coupler "C".
4) If connections are OK, turn the ignition switch ON. 4) If connections are OK, check the following points.
5) Measure the voltage between "T4" and ground. • Resistance
H02 sensor heater power supply voltage - Between 'T3" at the H02 sensor #2 coupler
[Standard]: Battery voltage (1) and 'T78" at the ECM coupler "C" (2):
less than 1 0

4 3

IL41K1110009-01

Is check result OK?

Yes Go to Step 2.
1A-35 Engine General Information and Diagnosis:

No Repair or replace the "T3" wire at the H02

sensor #2 coupler.
2
.Step 3
HO2 sensor #2 heater check
4 3
1) Measure the H02 sensor #2 heater resistance.
Refer to "H02 Sensor Heater Resistance" under
"H02 Sensor Inspection" in Section 1C (Page 1C-
8).
Is check result OK?
Yes Replace the ECM and inspect it again.
17 (Page 1C-2)

No Replace the H02 sensor #2. -(Page 1C-

9)
L-----------------------, ,----------------------

- Between "T3" at the H02 sensor #2 coupler

(1) and ground: infinity

IL41K1110011-01

- Between "T3" and other terminal at H02

sensor #2 coupler (1): infinity

IL41K1110012-01

• Voltage
- Turn the ignition switch ON.
- Between "T3" at the H02 sensor #2 coupler
(1) and ground: approx. 0 V

4 3

IL41K1110013-01

Is check result OK?

Yes Go to Step 3.
 Engine General Information and Diagnosis: 1A-36

DTC P0069
BENM10L31104013
DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area

.
P0069: Manifold Absolute Pressure - Barometric IAP sensor vacuum hose or AP sensor vacuum hose
Pressure Correlation
.
IAP sensor or AP sensor
Difference between measured value by AP sensor and
.
IAP sensor or AP sensor circuit
measured value by IAP sensor is higher than specified
value although the engine is stopped. ECM
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

3
5V
5V
R T12__J

G/8 TB •
B/Br T28�

I
'--
5V

G/Y T9 •

IM10L1110011-01
1. IAP sensor 2. AP sensor 3. ECM
1A-37 Engine General Information and Diagnosis:

Troubleshooting

Step _1
OTC check
Is OTC P1105, P1106, P1107, P2226 and/or P2228
detected?

Yes Go to troubleshooting for applicable DTC.

No Go to Step 2.

Step 2
IAP sensor vacuum hose and AP sensor vacuum
hose check
• Check that the IAP sensor vacuum hose and AP
sensor vacuum hose are connected correctly.
-(Page 1 D-5)
• Check the IAP sensor vacuum hose and AP sensor
vacuum hose for wear and damage.
Is check result OK?

Yes Go to Step 3.
No Repair or replace the IAP sensor vacuum
hose and AP sensor vacuum hose.

Step 3
IAP sensor and AP sensor circuit check
1) Check the IAP sensor and AP sensor circuit.
• IAP sensor: Refer to "Step 2" - "Step 4" under
"DTC P1105 / P1106 / P1107" (Page 1A-82)
• AP sensor: Refer to "Step 1" - "Step 3" under
"DTC P2226 / P2228" (Page 1A-100)
Is check result OK?

Yes Go to Step 4.

No Repair or replace defective parts.

Step4
IAP sensor and AP sensor check
1) Check the IAP sensor and AP sensor.
• IAP sensor: -(Page 1 C-4)
• AP sensor: (lj"(Page 1C-3)

Is check result OK?

Yes Replace the ECM and inspect it again.

(lj"(Page 1C-2)

No Repair or replace defective parts.

• IAP sensor: Clr'(Page 1C-5)
• AP sensor: Cll"(Page 1C-3)
 Engine General Information and Diagnosis: 1A-38

DTC P0110 / P0111 / P0112

BENM10L31104014
DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area

.
P0110: IAT Sensor 1 Circuit IAT sensor
The sensor output voltage is higher than 4.90 V.
.
IAT sensor circuit
(3 D/C detection logic)
ECM
P0111: IAT Sensor 1 Circuit Response Malfunction
IAT sensor output voltage does not change, under the specified
condition.
(3 D/C detection logic)
P0112: IAT Sensor 1 Circuit Low
The sensor output voltage is lower than 0.10 V.
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

I ..
5V

T26

T28�

IM10L1110012-01

1. IAT sensor 2. ECM

Troubleshooting

Step 1
©-1--
IAT sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". <7(Page 1C-2)
3) Check for proper terminal connection to the ECM -----------------------------·----· ----------------
coupler "A". ''

4) If connections are OK, check the following points.

• Resistance
- Between 'T1" at the IAT sensor coupler (1)
and "T26" at the ECM coupler "A" (2): less
than 1 O ----------------------- , ------------------------�
,, ,
- Between "T2" at the IAT sensor coupler and 2 ,',,'
"T28" at the ECM coupler "A": less than 1 0

�:-:,:,:,\,:,:-�-:-:,:,:,:,;;) �:1:1�1:1@ �:1:1:1�1:1:1:�

IM10L1110013-01

- Between "T1" at the IAT sensor coupler (1)

and ground: infinity
- Between "T2" at the IAT sensor coupler and
ground: infinity
- Between "T1" and "T2" at IAT sensor coupler:
infinity
1A-39 Engine General Information and Diagnosis:

IL06L 1110017-01

• Voltage
- Turn the ignition switch ON.
- Between "T1" at the IAT sensor coupler (1)
and ground: approx. 0 V
- Between "T2" at the IAT sensor coupler and
ground: approx. 0 V

IL06L1110018-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the defective wire

harness.

Step2
IAT sensor resistance check
1) Turn the ignition switch OFF.
2) Measure the IAT sensor resistance. w-(Page 1 C-
5)
Is check result OK? I

Yes Replace the ECM and inspect it again.

w-(Page 1 C-2)
No Replace the IAT sensor. w-(Page 1 C-5)
 Engine General Information and Diagnosis: 1A-40

DTC P0115 / P0116 / P0117

BENM10L31104015
OTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area
P0115: ECT Sensor Circuit
. ECT sensor

.
ECT sensor output voltage is higher than 4.90 V. ECT sensor circuit
(1 D/C detection logic) ECM
P0116: ECT Sensor Circuit Response Malfunction
ECT sensor output voltage does not change, under the
specified condition.
(3 DIC detection logic)
P0117: ECT Sensor Circuit Low
ECT sensor output voltage is lower than 0.10 V.
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

I
5V

T42 •
T28
�
IM10L1110014-01

1. ECT sensor 2. ECM

Troubleshooting

Step 1
ECT sensor signal circuit check ffi-1 ----,
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". <F(Page 1C-2)
3) Check for proper terminal connection to the ECM
coupler "A".
4) If connections are OK, check the following points.
• Resistance
- Between "T1" at the ECT sensor coupler (1)
and "T42" at the ECM coupler "A" (2): less
than 1 n L _'-_-_-_-
_ _-_
_ -__-__-_-_-_-
_ __ -_-
__-_-_ -__-_-__-_-__-__-_-__-_-__-_-__-_-- ---

�•: •: •t:, •�•: •: •:h-

, ,,
- Between "T2" at the ECT sensor coupler and ', '
2 ','
"T28" at the ECM coupler "A": less than 1 0

@:1):1:1:� �:1:1:1):1:1:1:�
IM10L1110015-01

- Between "T2" at the ECT sensor coupler (1)

and ground: infinity
- Between "T1" at the ECT sensor coupler and
ground: infinity
- Between 'T2" and "T1" at the ECT sensor
coupler: infinity
1A-41 Engine General Information and Diagnosis:

IL06L 1110022-01

• Voltage
- Turn the ignition switch ON.
- Between "T2" at the ECT sensor coupler (1)
and ground: approx. 0 V
- Between "T1" at the ECT sensor coupler and
ground: approx. 0 V

IL06L 1110023-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the defective wire

harness.

Step2
ECT sensor resistance check
1) Turn the ignition switch OFF.
2) Measure the ECT sensor resistance. c7(Page 1 C-
6)
Is check result OK?
Yes Replace the ECM and inspect it again.
<?(Page 1 C-2)
No Replace the ECT sensor. (Q'(Page 1 C-6)
 Engine General Information and Diagnosis: 1A-42

OTC P0120 / P0123

BENM10L31104016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area

.
P0120: TP Sensor I Switch "A" Circuit • TP sensor (main)
TP sensor (main) output voltage is lower than 0.20 V.
.
TP sensor (main) circuit
(1 0/C detection logic) ECM
P0123: TP Sensor/ Switch "A" Circuit High
TP sensor (main) output voltage is higher than 4.80 V.
(1 0/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

R/W T92

B/Lg T75
P/W T84 ;15V
R T51 1"
4 B T57

7
w
G
T?O
T63
�
J;;
8 T

IM10L1110016-01

1. TP sensor (main) 4. Throttle body 7. Main fuse (30 A)

2. TP sensor (sub) 5. Throttle valve motor drive circuit 8. Battery
3. Throttle valve motor 6. Fuel fuse (10 A) 9. ECM

Troubleshooting No Go to Step 2.

Step 1 Step2
TP sensor power supply circuit check TP sensor ground circuit check
1) Turn the ignition switch OFF. 1) Measure the voltage between the "T2" at the TP
2) Disconnect the TP sensor coupler (1 ). w-(Page sensor coupler (1) and ground.
1D-9) TP sensor power supply voltage
3) Check for proper terminal connection to the TP [Standard]: 4.5 - 5.5 V
sensor coupler (1).
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the "T2" and 'T4".
TP sensor power supply voltage
[Standard]: 4.5 - 5.5 V

IM10L1110018-01

Is check result OK?

Yes Repair or replace the "T4" wire at the TP
sensor coupler.
IM10L 1110017-01
No Repair or replace the "T2" wire at the TP
Is check result OK? sensor coupler.
Yes Go to Step 3.
1A-43 Engine General Information and Diagnosis:

- Between "T1" at the TP sensor coupler (1)

Step 3
and ground: approx. 0 V
TP sensor (main) signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "B". �(Page 1C-2)
3) Check for proper terminal connection to the ECM
coupler "B".
4) If connections are OK, check the following points.
• Resistance
IM10L1110022-01
- Between "T1" at the TP sensor coupler (1)
and "T57" at the ECM coupler "B" (2): less Is check result OK?
than 1 0
Yes Go to Step 4.
No Repair or replace the 'T1" wire at the TP
sensor coupler.

Step4
TP sensor (main) output voltage check
------------------- ------------------------------�' 1) Measure the TP sensor (main) output voltage.
'
'' �(Page 1C-7)
'
'
'' Is check result OK?
Yes Replace the ECM and inspect it again.
�(Page 1C-2)

No Replace the throttle body. <7(Page 1D-9)

w
'' _______
·--------------------- __,
\ ------------------------�
'
'
'

t•:•:•:•:•:•:•:•�•:•:•:•:•:•:•:•J·. �:1:1:1�1:1:1:�
IM10L 1110019-01

- Between 'T1" at the TP sensor coupler (1)

and ground: infinity

IM10L 1110020-01

- Between ''T1" and other terminal at the TP

sensor coupler (1 ): infinity

IM10L1110021-01

• Voltage
- Turn the ignition switch ON.
1A-45 Engine General Information and Diagnosis:

Troubleshooting

�tep 1
HO2 sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the H02 sensor #1 coupler and ECM
coupler.
• H02 sensor #1: <:iF(Page 1C-9)
IL41K1110021-01
• ECM: w(Page 1C-2)
- Between ''T2" and other terminal at H02
3) Check for proper terminal connection to the H02 sensor #1 coupler (1 ): infinity
sensor #1 coupler and ECM coupler "A".
4) If connections are OK, check the following points.
• Resistance
- Between "T1" at the H02 sensor #1 coupler
(1) and "T24" at the ECM coupler "A" (2):
less than 1 n
- Between "T2" at the H02 sensor #1 coupler
and "T28" at the ECM coupler "A": less than
10 IL41K1110022-01

• Voltage
- Turn the ignition switch ON.
- Between each of ''T1" and "T2" at the H02
sensor #1 coupler (1) and ground: approx. 0
4 3 V

----------------------- ·--------------------------�
'
'

IL41K1110023-01

Is check result OK?

------------------------' ' ,------------------------�
'
'' , ,
','
Yes Go to Step 2.
2
No Repair or replace the defective wire

t-:-:-:-:-L-�-:-:-:-:-:,;�i- @,:,�,:,:� �:,:,:,�,:,:,:�

IM10L1110023-01 Step 2
harness.

- Between each of ''T1" and ''T2" at the H02 HO2 sensor #1 output voltage check
sensor #1 coupler (1) and ground: infinity 1) Turn the ignition switch OFF.
2) Connect the ECM coupler "A" and H02 sensor #1
coupler.
2 ) Warm up the engine enough.
3
4 3
4) Measure the H02 sensor #1 output voltage. Refer
to "H02 Sensor Output Voltage" under "H02
IL41K1110020-01 Sensor Inspection" in Section 1C (Page 1C-8).
- Between ''T1" and other terminal at H02 Is check result OK?
sensor #1 coupler (1): infinity
Yes Replace the ECM and inspect it again.
w(Page 1C-2)

No Replace the H02 sensor #1. <:iF(Page 1C-

9)
 Engine General Information and Diagnosis: 1A-46

OTC P0150 / P0152 / P0153

BENM10L31104018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area

.
P0150: 02 Sensor Circuit Bank 2 Sensor 1 • H02 sensor #2
H02 sensor #2 is not activated. H02 sensor #2 circuit
(3 DIC detection logic) • ECM
P0152: 02 Sensor Circuit High Voltage Bank 2 Sensor
1
H02 sensor #2 output voltage is higher than 4.90 V.
(3 DIC detection logic)
P0153: 02 Sensor Circuit Slow Response (Bank2
Sensor1)
Shifting time between rich and lean of H02 sensor #2 is
longer than specified time.
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

w W/Y

5
w w T78----0

B WIG T40
7 -,- J; �
Gr B/Br T28
--i,.

IM10L 1110009-01
1. H02 sensor #2 4. Ignition switch 7. Battery
2. ECM 5. Main fuse (30 A)
3. H02 sensor heater drive circuit 6. Ignition fuse (10 A)
1A-47 Engine General Information and Diagnosis:

Troubleshooting

Step 1
HO2 sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the HO2 sensor #2 coupler and ECM
coupler.
• HO2 sensor #2: �(Page 1C-9)
IL41K1110021-01
• ECM: (jr'(Page 1C-2)
- Between "T2" and other terminal at HO2
3) Check for proper terminal connection to the HO2
sensor #2 coupler (1): infinity
sensor #2 coupler and ECM coupler "A".
4) If connections are OK, check the following points.
• Resistance
- Between "T1" at the HO2 sensor #2 coupler
(1) and "T40" at the ECM coupler "A" (2):
less than 1 n
- Between "T2" at the HO2 sensor #2 coupler
and "T28" at the ECM coupler "A": less than
1 n IL41K1110022-01

• Voltage
- Turn the ignition switch ON.
- Between each of "T1" and "T2" at the HO2
sensor #2 coupler (1) and ground: approx. 0
4 3 V

',
------------------------�-------------------------�
:' 2
''
'
4 3

IL41K1110023-01

Is check result OK?

------------------------, , ,------------------------�
, , Yes Go to Step 2.
,, ,
2 ,'/
No Repair or replace the defective wire
harness.
�:,:,:,:.\.:.:,�,:,:,:,:,:,;�� �:1:1�1:1:� �:1:1:1�1:1:1:�
IM10L1110024-01 Step2
- Between each of "T1" and "T2" at the HO2 HO2 sensor #2 output voltage check
sensor #2 coupler (1) and ground: infinity 1) Turn the ignition switch OFF.
2) Connect the ECM coupler "A" and HO2 sensor #2
coupler.
3) Warm up the engine enough.
4) Measure the HO2 sensor #2 output voltage. Refer
to "HO2 Sensor Output Voltage" under "HO2
IL41K1110020-01 Sensor Inspection" in Section 1C (Page 1C-8).
- Between "T1" and other terminal at HO2 Is check result OK?
sensor #2 coupler (1): infinity
Yes Replace the ECM and inspect it again.
w(Page 1C-2)
No Replace the HO2 sensor #2. <?"(Page 1C-
9)
 Engine General Information and Diagnosis: 1A-48

DTC P0171 / P0172 / P0174 / P0175

BENM10L31104019
DTC Detecting Condition and Trouble Area
DTC detecting condition
P0171: System Too Lean Bank 1 . Fuel system
Trouble area

Fuel trim correction is higher than specified value for • Air intake system
specified time under the specified condition. •
.
Exhaust system
(3 DIC detection logic)
P0172: System Too Rich Bank 1
. Emission control system

.
Fuel trim correction is lower than specified value for H02 sensor #1
specified time under the specified condition.
.
H02 sensor #1 circuit
(3 DIC detection logic)
P0174: System Too Lean Bank 2 . ECM
Fuel system
Fuel trim correction is higher than specified value for
.
• Air intake system
specified time under the specified condition.
.
Exhaust system
(3 DIC detection logic)
P0175: System Too Rich Bank 2 Emission control system
•
.
Fuel trim correction is lower than specified value for H02 sensor #2
specified time under the specified condition.
.
H02 sensor #2 circuit
(3 DIC detection logic) ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

5
7
3

6 T79----<

T24-x-•

T28� 4

T78----,

T40--x..--•►

IM10L1110025-01
1. HO2 sensor #1 4. HO2 sensor heater drive circuit 7. Ignition fuse (10 A)
2. HO2 sensor #2 5. Ignition switch 8. Battery
3. ECM 6. Main fuse (30 A)
1A-49 Engine General Information and Diagnosis:

Troubleshooting
Step4
H02 sensor circuit signal check
"Step 1: ..
DTC check 1) Check HO2 sensor signal circuit.
• HO2 sensor #1: "Step 1" under "DTC P0130 /
Is there any DTC(s) other than P0171 P0172, P0174
P0132 / P0133" (Page 1A-44)
and P0175?
• HO2 sensor #2: "Step 1" under "OTC P0150 /
Yes Go to troubleshooting for applicable DTC. P0152 / P0153" (Page 1A-46)
No Go to Step 2. Is check result OK?

Step2 Yes Go to Step 5.

Fuel system and emission control system check No Repair or replace the defective wire
1) Check the following points related to fuel and harness.
emission control systems.
• Fuel pressure: "'"(Page 1 G-6) Step 5
• Fuel injector circuit: Refer to "OTC P0201 / DTC recheck
P0202 I P0203 / P0204" (Page 1A-50) and 1) Replace the HO2 sensor #1 and HO2 sensor #2.
"OTC P1201 / P1202 / P1203 / P1204" (Page (q'(Page 1 C-9)
1A-84). 2) Perform "DTC Check" (Page 1A-11) and recheck
• Fuel injector: w-(Page 1G-23) OTC.
• IAP sensor: <ir(Page 1C-4) Is DTC P0171 P0172, P0174 and/or P0175 still
• PCV hose: <ir(Page 18-6) detected?
• PAIR system: (q'(Page 18-5) Yes Replace the ECM and inspect it again.
• EVAP system (If equipped): ClP{Page 18-10) w-(Page 1C-2)
Is check result OK? No End.
Yes Go to Step 3.
No Repair or replace defective parts.

Step 3
Exhaust system and air intake system check
1) Check exhaust system and air intake system for
clogging and leakage.
• Exhaust system: (q'(Page 1 K-7)
• Check air intake system for clogging and
leakage.

IM10L 1110128-04

Is check result OK?

Yes Go to Step 4.

No Repair or replace defective parts.

 Engine General Information and Diagnosis: 1A-50

DTC P0201 / P0202 / P0203 / P0204

BENM10L31104020
DTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area
P0201: Injector Circuit/ Open - Cylinder 1
Primary fuel injector #1 signal is interrupted by 20 . Primary fuel injector #1

.
Primary fuel injector #1 circuit
times or more continuity although CKP signal is
ECM
detected.
(1 D/C detection logic)
•
.
P0202: Injector Circuit/ Open - Cylinder 2 Primary fuel injector #2
Primary fuel injector #2 signal is interrupted by 20 Primary fuel injector #2 circuit
times or more continuity although CKP signal is • ECM
detected.
(1 D/C detection logic)
.
.
P0203: Injector Circuit/ Open - Cylinder 3 Primary fuel injector #3
Primary fuel injector #3 signal is interrupted by 20 Primary fuel injector #3 circuit
times or more continuity although CKP signal is • ECM
detected.
(1 D/C detection logic)
P0204: Injector Circuit/ Open - Cylinder 4 . Primary fuel injector #4
Primary fuel injector #4 signal is interrupted by 20 •
.
Primary fuel injector #4 circuit
times or more continuity although CKP signal is
ECM
detected.
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

10

14
'-------- Y/B T103-----0
Y/R
�
T90-

2
Gr/B T89-
T
11

1 3
Gr/Y T88-
9

4
Gr/R T87-
-

IM10L1110026-01
1. Primary fuel injector #1 6. Ignition switch 11. Battery
2. Primary fuel injector #2 7. Engine stop/ starter switch ("RUN / STOP" 12. Main fuse (30 A)
position)
3. Primary fuel injector #3 8. Fuel pump relay drive circuit 13. Ignition fuse (10 A)
4, Primary fuel injector #4 9. Fuel injector drive circuit 14. Fuel fuse (10 A)
5. FP relay 10. ECM
1A-51 Engine General Information and Diagnosis:

Troubleshooting Between ''T1" at the primary fuel injector

coupler and "T87" at the ECM coupler "C":
Step 1 less than 1 0
Primary fuel injector power supply circuit check
1) Turn the ignition switch OFF.
2) Disconnect the primary fuel injector coupler.
<?(Page 1G-21)
' ' .'
3) Check for proper terminal connection to the
primary fuel injector coupler (1). i l-i l :
4 If connections are OK, turn the ignition switch ON.
)
' '
5) Measure the voltage between ''T2" and ground. 75 76 77 78'
84 85 86
�,....,.....�
NOTE
92 93 94
Primary fuel injector power supply voltage 100101 02 0
can be detected only for a few seconds after
ignition switch is turned ON.

Primary fuel injector power supply voltage --- -- 2

(,;,;,;,;,;,;,;,�,;,;,;,;,;,;,;,J
[Standard]: Battery voltage
�:1:1�1:1:���1:1�1:1:'.:�
IM10L1110027-01

- Between ''T1" at the primary fuel injector

coupler (1) and ground: infinity

IL41K1110025-01

Is check result OK?

Yes Go to Step 2.
No Repair or replace the ''T2" wire at the IL41 K1110027-01

primary fuel injector #1 coupler. - Between "T1" and "T2" at the primary fuel
injector coupler (1): infinity
Step 2
Primary fuel injector drive circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "C". w-(Page 1C-2)
3) Check for proper terminal connection to the ECM
coupler "C". IL41K1110028-01

• Voltage
4) If connections are OK, check the following points.
• Resistance - Turn the ignition switch ON.
- Primary fuel injector #1: - Between ''T1" at the primary fuel injector
Between ''T1" at the primary fuel injector coupler (1) and ground: approx. 0 V
coupler (1) and ''T90" at the ECM coupler "C"
(2): less than 1 0
- Primary fuel injector #2:
Between ''T1" at the primary fuel injector
coupler and ''T89" at the ECM coupler "C":
less than 1 0
IL41K1110029--01
Primary fuel injector #3:
Between "T1" at the primary fuel injector Is check result OK?
coupler and ''T88" at the ECM coupler "C":
Yes Go to Step 3 .
less than 1 0
- Primary fuel injector #4: No Repair or replace the "T1" wire at the
primary fuel injector coupler.
 Engine General Information and Diagnosis: 1A-52

Is check result OK?

Step 3
Primary fuel injector resistance check Yes Replace the ECM and inspect it again.
1) Turn the ignition switch OFF. <T(Page 1 C-2)
2) Measure the primary fuel injector resistance. No Replace the primary fuel injector. <1r'(Page
cr(Page 1 G-21) 1G-21)

DTC P0220 / P0223

BENM10L31104021
OTC Detecting Condition and Trouble Area
OTC detecting condition Trouble area
P0220: TP Sensor/ Switch "B" Circuit • TP sensor (sub)
TP sensor (sub) output voltage is lower than 0.20 V.
.
• TP sensor (sub) circuit
(1 D/C detection logic)
ECM
P0223: TP Sensor/ Switch "B" Circuit High
TP sensor (sub) output voltage is higher than 4.80 V.
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

�----------------R/W T92

r-----:======:::i,.-----8/Lg T75
----,------P/W T84 � 5V
T51 j

J;
4 B T57
w T70
7 G T63
7!!TJ;
8 "T"

IM10L 1110016-01

1. TP sensor (main) 4. Throttle body 7. Main fuse (30 A)

2. TP sensor (sub) 5. Throttle valve motor #1 drive circuit 8. Battery
3. Throttle valve motor 6. Fuel fuse (10 A) 9. ECM
1A-53 Engine General Information and Diagnosis:

Troubleshooting Step 3
TP sensor #1 (sub) signal circuit check
Step 1
TP sensor #1 power supply circuit check 1) Turn the ignition switch OFF.
1) Turn the ignition switch OFF. 2) Disconnect the ECM coupler "B". 17 (Page 1C-2)
2) Disconnect the TP sensor coupler (1). w(Page 3) Check for proper terminal connection to the ECM
1 D-9) coupler "B".
3) Check for proper terminal connection to the TP 4) If connections are OK, check the following points.
sensor coupler (1). • Resistance
4) If connections are OK, turn the ignition switch ON. - Between "T3" at the throttle body #1 coupler
5) Measure the voltage between the 'T2" and "T4". (1) and "T70" at the ECM coupler "B" (2):
less than 1 n
TP sensor power supply voltage
[Standard]: 4.5 - 5.5 V

8I
4

2 3
I ·] ---------------�'

(i5!)) IM10L1110017-01
''

Is check result OK?

Yes Go to Step 3.
No Go to Step 2.

Step2 •---------------------, \ ------------------

[,:,:,:,:,:,:,:fo:,:,:,:,:,:,i -w�:1,1,'�1:1:1,�
TP sensor ground circuit check
1) Measure the voltage between the "T2" at the TP
sensor coupler (1) and ground.
TP sensor power supply voltage IM10L1110028-01
[Standard]: 4.5 - 5.5 V
- Between 'T3" at the TP sensor coupler (1)
and ground: infinity

IM10l1110018-01
IM10L 1110029-01
Is check result OK?
- Between 'T3" and other terminal at the TP
Yes Repair or replace the "T4" wire at the TP sensor coupler (1 ): infinity
sensor coupler.
No Repair or replace the "T2" wire at the TP
sensor coupler.

IM10L 1110030-01
 Engine General Information and Diagnosis: 1A-54

• Voltage
- Turn the ignition switch ON.
- Between "T3" at the TP sensor coupler (1)
and ground: approx. 0 V

IM10L1110031-01

Is check result OK?

Yes Go to Step 4.

No Repair or replace the "T3" wire at the TP

sensor coupler.

Step4
TP sensor (sub) output voltage check
1) Measure the TP sensor (sub) output voltage.
w(Page 1C-7)
Is check result OK?

Yes Replace the ECM and inspect it again.

w(Page 1C-2)
No Replace the throttle body. w(Page 1 D-9)
1A-55 Engine General Information and Diagnosis:

DTC P0232 / P023F

BENM10L31104022
DTC Detecting Condition and Trouble Area
DTC detecting condition
. F uel pump relay Trouble area
P0232: FP Secondary Circuit High
Voltage is input to ECM although the FP relay is OFF. . FP relay circuit
(1 D/C detection logic)
P023F: FP Secondary Circuit/ Open
. ECM
No voltage is input to ECM although the FP relay is
ON.
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

W/R
R/W
5
3

9
Y/8 T103-G
[A]

Y/R T106
---;r

6 i

IM10L 1110032-01

[A]: To fuel pump, primary fuel injectors and 4. Fuel pump relay drive circuit 8. Ignition fuse (10 A)
secondary fuel injectors
1. FP relay 5. ECM 9. Fuel fuse (10 A)
2. Ignition switch 6. Battery
3. Engine stop/ starter switch ("RUN/ STOP" 7. Main fuse (30 A)
position)

Troubleshooting
�
Step 1 2
,_______,�-----'-T-_3
FP relay power supply circuit check
1) Turn the ignition switch OFF.
2) Remove the fuel pump relay. w(Page 1G-21) 5 (±)ve
3) Check for proper terminal connection to the FP
relay couplers. IM10L1110033-01

4) If connections are OK measure the voltage Is check result OK?

between "TS" at the FP relay coupler (1) and
Yes Go to Step 2.
ground.
5) If OK, turn the ignition switch ON. No Repair or replace the defective wire
6) Measure the voltage between "T3" at the FP relay harness.
coupler and ground.
Step 2
FP relay power supply voltage FP relay check
[Standard]: Battery voltage 1) Check the FP relay. <?(Page 1G-21)
Is check result OK?
Yes Go to Step 3.
 Engine General Information and Diagnosis: 1A-56

No Replace the FP relay.

Step 3
FP relay drive circuit and signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "C". ""(Page 1C-2)
3) Check for proper terminal connection to the ECM
coupler "C".
4) If connections are OK, check the following points.
• Resistance IM10L 1110036-01

• Voltage
- Between "T1" at the FP relay coupler (1) and
"T103" at the ECM coupler "C" (2): less than - Turn the ignition switch ON.
1n - Between "T1" at the FP relay coupler (1) and
- Between "T4" at the FP relay coupler and ground: approx. 0 V
"T106" at the ECM coupler "C": less than 1 n - Between "T4" at the FP relay coupler and
ground: approx. 0 V
2 3
1 2 3
4

�:�
5

--------------------- ---------- -------------------

' IM10L1110037-01

Is check result OK?

Yes Replace the ECM and inspect it again.
""(Page 1C-2)

No Repair or replace the defective wire

harness.
-----------------------,, ,,--------------------- I

- - 2

�,:,:,:,:,:,:,:,�,:,:,:,:,:,:,:,J @1:1):1:1:���.1�1:1:'.:�
IM10L1110034-01

- Between 'T1" at the FP relay coupler (1) and

ground: infinity
- Between 'T4" at the FP relay coupler and
ground: infinity

1 2 3

�:�
- Between ''T1" and other terminal at FP relay
IM10L1110035-01

coupler (1): Infinity

- Between "T4" and other terminal at FP relay
coupler: Infinity
1A-57 Engine General Information and Diagnosis:

DTC P0300 / P0301 / P0302 / P0303 / P0304

BENM10L31104023
DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area

.
P0300: Random / Multiple Cylinder Misfire Fuel system
Detected
.
Air intake system

. Misfire, which causes damage to the catalyst, is .

Any of the following conditions is met.
Exhaust system

.
Emission control system
detected at 2 or more cylinders, under the specified

. Misfire, which affects exhaust emission adversely, is .

condition. (The MIL blinks) Ignition system
Engine compression
detected at 2 or more cylinders, under the specified • Valve clearance
condition. • Valve timing
(3 DIC detection logic) .
.
Drive chain
P0301: Cylinder 1 Misfire Detected
ECM
.
Any of the following conditions is met.
Misfire, which causes damage to the catalyst, is
detected at cylinder #1, under the specified

. condition. {The MIL blinks)

Misfire, which affects exhaust emission adversely, is
detected at cylinder #1, under the specified
condition.
(3 DIC detection logic)
P0302: Cylinder 2 Misfire Detected

.
Any of the following conditions is met.
Misfire, which causes damage to the catalyst, is
detected at cylinder #2, under the specified

.
condition. {The MIL blinks)
Misfire, which affects exhaust emission adversely, is
detected at cylinder #2, under the specified
condition.
(3 DIC detection logic)
P0303: Cylinder 3 Misfire Detected
Any of the following conditions is met.
Misfire, which causes damage to the catalyst, is
detected at cylinder #3, under the specified condition.
(The MIL blinks)
Misfire, which affects exhaust emission adversely, is
detected at cylinder #3, under the specified condition.
(3 DIC detection logic)
P0304: Cylinder 4 Misfire Detected
Any of the following conditions is met.
Misfire, which causes damage to the catalyst, is
detected at cylinder #4, under the specified condition.
(The MIL blinks)
Misfire, which affects exhaust emission adversely, is
detected at cylinder #4, under the specified condition.
(3 DIC detection logic)
 Engine General Information and Diagnosis: 1A-58

Troubleshooting Step 5 _ . . .
Exhaust system and air intake system check
Step 1
Fuel level check 1) Check exhaust system and air intake system for
clogging and leakage.
1) Check fuel level by fuel level indicator.
• Exhaust system: eu-(Page 1K-7)
Does it indicate "E" level (empty)? • Check air intake system for clogging and
Yes Add fuel, and perform the "Step 5: Final leakage.
Confirmation Test" of "Engine Control
System Check" (Page 1A-9) and recheck
DTC.

No Go to Step 2.

Step 2
Fuel quality check
1) Check fuel in fuel tank for smell, color and quality.
Is check result OK?

Yes Go to Step 3.

No Replace fuel with correct type fuel, and Is check result OK?
perform the "Step 5: Final Confirmation
Yes Go to Step 6.
Test" of "Engine Control System Check"
(Page 1A-9) and recheck OTC. No Repair or replace defective parts.
Step3 Step6
Drive chain check Engine mechanical system check
1) Check the drive chain slack. eu-(Page 3A-3) 1) Check the following points.
Is check result OK? • Engine compression: w-(Page 10-3)
• Valve clearance: eu-(Page 10-26)
Yes Go to Step 4.
• Valve timing: e7(Page 10-51)
No Adjust the drive chain slack or replace the
drive chain, and perform the "Step 5: Final Is check result OK?
Confirmation Test" of "Engine Control Yes Check ECM power supply and ground
System Check" (Page 1A-9) and recheck circuits. w(Page 1A-113)
OTC.
If circuit is OK, replace the ECM and
Step4 inspect it again. w(Page 1C-2)
Fuel system and emission control system check
No Repair or replace defective parts.
1) Check the following points related to fuel and
emission control systems.
• Fuel pressure: w-(Page 1G-6)
Fuel injector circuit: Refer to "OTC P0201 /
P0202 I P0203 I P0204" (Page 1A-50) and/or
"OTC P1201 / P1202 / P1203 / P1204" (Page
1A-84).
• Fuel injector: eu-(Page 1G-23)
• PCV hose: w(Page 1B-6)
• PAIR system: <;y'(Page 1B-5)
• EVAP system (If equipped): <;y'(Page 1B-10)
Is check result OK?
Yes Go to Step 5.
No Repair or replace defective parts.
1A-59 Engine General Information and Diagnosis:

DTC P0335
BENM10L31104024
DTC Detecting Condition and Trouble Area
DTC detecting condition
P0335: CKP Sensor "A" Circuit . Trouble area
Metal particles or foreign material being stuck on the

.
CKP sensor signal is not input to ECM for a few seconds CKP sensor and rotor tip

.
or more, after receiving the starter relay ON signal. CKP sensor
(1 DIC detection logic)
.
CKP sensor circuit
ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

T16+

T31

IM10L1110038-01
[A]: To regulator/rectifier 2. Generator
1. CKP sensor 3. ECM

Troubleshooting

Step 1
CKP sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the CKP sensor lead wire coupler and
ECM coupler "A". ------------------------------------------- . . -----�
• CKP sensor: cr(Page 1C-12)
• ECM: �(Page 1C-2)
3) Check for proper terminal connection to the CKP
sensor lead wire coupler and ECM coupler "A".
4) If connections are OK, check the following points. ----------------
---- ------,, , ,------------------------�
• Resistance ,
,, ,
2 ,,,,,
- Between "T1" at the CKP sensor lead wire
coupler (1) and "T16" at the ECM coupler "A" ] �
(2): less than 1 0 (,:,:,:, :, ,;,:,�,:,:,:,:,:,; ] @i:1):1;1:� �:1;1:I),1;1:I:�
- Between "T2" at the CKP sensor lead wire IM10L 1110039-01

coupler and ''T31" at the ECM coupler "A": - Between "T1" at the CKP sensor lead wire
less than 1 n coupler (1) and ground: infinity
- Between "T2" at the CKP sensor lead wire
coupler and ground: infinity

IM10L 1110040-01
 Engine General Information and Diagnosis: 1A-60

- Between "T1" and "T2" at the CKP sensor 3) Check that end face of the CKP sensor (1) and
lead wire coupler (1): infinity generator rotor teeth (2) are free from any metal
particles and damage.

IM10L1110041-01

• Voltage
- Turn the ignition switch ON.
- Between 'T1" at the CKP sensor lead wire
coupler (1) and ground: approx. 0 V
- Between "T2" at the CKP sensor lead wire
coupler and ground: approx. 0 V

Is check result OK?

Yes Replace the ECM and inspect it again.
rr(Page 1C-2)
IM10L1110042-01 No Clean or replace defective parts.
Is check result OK?
Yes Go to Step 2.
No Repair or replace the defective wire
harness.

Step2
CKP sensor resistance check
1) Turn the ignition switch OFF.
2) Measure the CKP sensor resistance. Refer to
"CKP Sensor Resistance" under "CKP Sensor
Inspection" in Section 1C (Page 1C-12).
Is check result OK?
Yes Go to Step 3.
No Replace the CKP sensor. ""(Page 1C-13)

Step 3
CKP sensor peak voltage check
1) Connect the ECM coupler.
2) Crank the engine several seconds with the starter
motor, and measure the CKP sensor peak voltage
with the peak volt adapter. Refer to "CKP Sensor
Peak Voltage" under "CKP Sensor Inspection" in
Section 1C (Page 1C-12).
Is check result OK?
Yes Replace the ECM and inspect it again.
""(Page 1C-2)
No Go to Step 4.

step4
CKP sensor and generator rotor check
1) Turn the ignition switch OFF.
2) Remove the generator cover. w(Page 1J-4)
1A-61 Engine General Information and Diagnosis:

DTC P0340
BENM10L31104025
DTC Detecting Condition and Trouble Area
DTC detecting condition
P0340: CMP Sensor "A" Circuit Bank 1 or Single . Trouble area
Metal particles or foreign material being stuck on the CMP
Sensor sensor and intake camshaft dent
No CMP signal is detected, although the CKP signal is • CMP sensor
input to ECM. • CMP sensor circuit
(1 D/C detection logic)
ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

2
--,_ 5V
5V
Bl R T12__]

,____ w ----------< B/Y T32 •

B B/Br T28
-__,.
�

IM10L 1110044-01

1. CMP sensor 2. ECM

Troubleshooting

Step 1
CMP sensor power supply circuit check
1) Turn the ignition switch OFF. IM10L1110046-01

2) Disconnect the CMP sensor coupler. �(Page 1C- Is check result OK?
11)
Yes Repair or replace the "T3" wire at the CMP
3) Check for proper terminal connection to the CMP
sensor coupler (1). sensor coupler.

4) If connections are OK, turn the ignition switch ON. No Repair or replace the "T1" wire at the CMP
5) Measure the voltage between the 'T1" and 'T3". sensor coupler.

CMP sensor power supply voltage Step 3

[Standard]: 4.5 - 5.5 V CMP sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". w(Page 1C-2)
3) Check for proper terminal connection to the ECM
coupler "A".
4) If connections are OK, check the following points.
• Resistance
IM10L1110045-0 1
- Between "T2" at the CMP sensor coupler (1)
Is check result OK?
and 'T32" at the ECM coupler "A" (2): less
Yes Go to Step 3. than 1 n
No Go to Step 2.

Step2
CMP sensor ground circuit check
1) Measure the voltage between the 'T1" at the CMP
sensor coupler (1) and ground.
CMP sensor power supply voltage
[Standard]: 4.5 - 5.5 V
 Engine General Information and Diagnosis: 1A-62

Step 5
CMP sensor and camshaft check
1) Turn the ignition switch OFF.
--------------------------------------------------� 2) Check that end face of the CMP sensor (1) and
intake camshaft (2) are free from any metal
particles and damage.

'------------------,
------------------------' '------------------------�
'' ' '

(,:, :, i.:, �,: ,: ,:,;�J,

2 :/

@:I�I:I:� �:I:1:1�1:1:I:�
IM10L1110047-01

- Between "T2" at the CMP sensor coupler (1)

and ground: infinity IM10L 1110051--01

Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. w(Page 1C-2)
IM10L1110048-01

- Between "T2" and other terminal at the CMP No Clean or replace defective parts.
sensor coupler (1): infinity

IM10L 1110049-01

• Voltage
- Turn the ignition switch ON.
- Between "T2" at the CMP sensor coupler (1)
and ground: approx. O V

IM10L 1110050-01

Is check result OK?

Yes Go to Step 4.
No Repair or replace the "T2" wire at the CMP
sensor coupler.

Step 4
CMP sensor check
1) Check the CMP sensor. w(Page 1C-11)
Is check result OK?

Yes Go to Step 5.
No Replace the CMP sensor with a new one.
er (Page 1 C-11)
1A-63 Engine General Information and Diagnosis:

OTC P0351 / P0352 / P0353 / P0354

BENM10L31104026
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0351: Ignition Coil "A" Primary/ Secondary Refer to "No Spark or Poor Spark" in Section 1 H (Page 1 H-3).
Circuit
Ignition coil #1 signal is interrupted by 20 times or
more continuity although CKP signal is detected.
(1 0/C detection logic)
P0352: Ignition Coil "B" Primary/ Secondary
Circuit
Ignition coil #2 signal is interrupted by 20 times or
more continuity although CKP signal is detected.
(1 0/C detection logic)
P0353: Ignition Coil "C" Primary/ Secondary
Circuit
Ignition coil #3 signal is interrupted by 20 times or
more continuity although CKP signal is detected.
(1 D/C detection logic)
P0354: Ignition Coil "D" Primary/ Secondary
Circuit
Ignition coil #4 signal is interrupted by 20 times or
more continuity although CKP signal is detected.
(1 D/C detection logic)
 Engine General Information and Diagnosis: 1A-64

DTC P0410
BENM10L31104027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0410: PAIR System • PAIR system
PAIR air flow volume is out of the specified range, under • ECM
the specified condition.
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

T94--G

T 7

IM10L1110052-02
1. PAIR control solenoid valve 4. Ignition switch 7. Battery
2. ECM 5. Ignition fuse (10 A)
3. PAIR control solenoid valve drive circuit 6. Main fuse (30 A)

Troubleshooting No Repair or replace defective wire harness.

Step 1
DTC check
1) Perform "DTC Check" (Page 1A-11 ).
Is OTC P0412 detected?
Yes Go to troubleshooting for applicable OTC.
No Go to Step 2.

Step 2
PAIR system check
1) Check the PAIR system. w(Page OB-13)
Is check result OK?
Yes Go to Step 3.
No Repair or replace defective parts.

Step 3
PAIR control solenoid valve circuit check
1) Check the PAIR control solenoid valve power
supply and drive circuits. Refer to step "Step 1" -
"Step 2" in ''Troubleshooting" under "DTC P0412"
(Page 1A-65).
Is check result OK?
Yes Replace the ECM and inspect it again.
<:r(Page 1C-2)
1A-65 Engine General Information and Diagnosis:

DTC P0412
BENM10L31104028
DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area
P0412: PAIR System Switching Valve "A" Circuit
PAIR control solenoid valve drive circuit is shorted to . PAIR control solenoid valve

.
PAIR control solenoid valve circuit
ground or open.
ECM
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

T94--EJ

T 1

IM10L111 0052-02
1. PAIR control solenoid valve 4. Ignition switch 7. Battery
2. ECM 5. Ignition fuse (10 A)
3. PAIR control solenoid valve drive circuit 6. Main fuse (30 A)

Troubleshooting
Step2
PAIR control solenoid valve drive circuit check
Step 1
PAIR control solenoid valve power supply circuit 1) Turn the ignition switch OFF.
check 2) Disconnect the ECM coupler "C". 07 (Page 1C-2)
1) Turn the ignition switch OFF. 3) Check for proper terminal connection to the ECM
2) Disconnect the PAIR control solenoid valve coupler "C".
coupler. -(Page 18-5) 4) If connections are OK, check the following points.
3) Check for proper terminal connection to the PAIR • Resistance
control solenoid valve coupler (1). - Between "T1" at the PAIR control solenoid
4) If connections are OK, turn the ignition switch ON. valve coupler (1) and "T94" at the ECM
5) Measure the voltage between "T2" and ground. coupler "C" (2): less than 1 0

PAIR control solenoid valve power supply

voltage
[Standard]: Battery voltage

IL06L1110052-01

Is check result OK?

Yes Go to Step 2.
No Repair or replace the "T2" wire at the PAIR
control solenoid valve coupler.
 Engine General Information and Diagnosis: 1A-66

Step 3
PAIR solenoid valve resistance check
1) Turn the ignition switch OFF.
2) Measure the PAIR control solenoid valve
,----------------- -- ------ -----------
- resistance. Refer to step 4) in "PAIR Control
' :
Solenoid Valve" under "PAIR (air supply) System"
in Section OB (Page 0B-13).
Is check result OK?

Yes Replace the ECM and inspect it again.

«F"(Page 1C-2)

No Replace the PAIR control solenoid valve.

' '
--------------
�------------------------ ,,---------------------J
<:r(Page 1B-5)
- - 2

(,:,:,:,:,:,:,:,�,:,:,:,:,:,:,:,J @1:1):1:I:��»:1:(1:,,;,�
IM10L 1110053-01

Between "T1" at the PAIR control solenoid

valve coupler (1) and ground: infinity

IL06L 1110054-01

- Between "T1" and ''T2" at the PAIR control

solenoid valve coupler (1): infinity

IL06L 1110055-02

• Voltage
- Turn the ignition switch ON.
- Between "T1" at the PAIR control solenoid
valve coupler (1) and ground: approx. 0 V

IL06L 1110056-01

Is check result OK?

Yes Go to Step 3.

No Repair or replace the "T1" wire at the PAIR

control solenoid valve coupler.
1A-67 Engine General Information and Diagnosis:

OTC P0444
BENM10L31104029
DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area

.
P0444: EVAP System Purge Control Valve Circuit EVAP system purge control solenoid valve
Open
.
EVAP system purge control solenoid valve circuit
EVAP system purge control solenoid valve circuit is
ECM
shorted to ground or open.
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

T101-G

T 7

IM10L1110054-02
1. EVAP system purge control solenoid valve 4. Ignition switch 7. Battery
2. ECM 5. Ignition fuse ( 10 A)
3. EVAP system purge control solenoid valve 6. Main fuse (30 A)
drive circuit

Troubleshooting No Repair or replace the 'T1" wire at the

EVAP system purge control solenoid valve
Step 1 coupler.
EVAP system purge control solenoid valve power
supply circuit check Step2
1) Turn the ignition switch OFF. EVAP system purge control solenoid valve drive
circuit check
2) Disconnect the EVAP system purge control
solenoid valve coupler. ""(Page 1 B-8) 1) Turn the ignition switch OFF.
3) Check for proper terminal connection to the EVAP 2) Disconnect the ECM coupler "C". ""(Page 1 C-2)
system purge control solenoid valve coupler (1). 3) Check for proper terminal connection to the ECM
4) If connections are OK, turn the ignition switch ON. coupler "C".
5) Measure the voltage between "T1" and ground. 4) If connections are OK, check the following points.
• Resistance
EVAP system purge control solenoid valve
power supply voltage - Between "T2" at the EVAP system purge
[Standard]: Battery voltage control solenoid valve coupler (1) and "T101"
at the ECM coupler "C" (2): less than 1 O

IL06L1110057-01

Is check result OK?

Yes Go to Step 2.
 Engine General Information and Diagnosis: 1A-68

No Repair or replace the "T2" wire at the

EVAP system purge control solenoid valve
coupler.

Step 3
,--------------
'
----------------------------------- EVAP system purge control solenoid valve
' resistance check
'
1) Turn the ignition switch OFF.
2) Measure the EVAP system purge control solenoid
valve resistance. Refer to step 1) in "EVAP
System Purge Control Solenoid Valve" under
"Evaporative emission control system" in Section
OB (Page OB-8).
'
-----------------------, ,,---------------------J Is check result OK?
- - 2
Yes Replace the ECM and inspect it again.
w(Page 1C-2)
��
(,:,:,:,:,:,:,:,�,:,:,:,:,:,:,:� �:1:1),1:I; :�:1):I:I:'.:� No Replace the EVAP system purge control
IM10L1110055-03 solenoid valve. <?(Page 18-8)
- Between "T2" at the EVAP system purge
control solenoid valve coupler (1) and
ground: infinity

IL06L 1110061-01

- Between "T2" and "T1" at the EVAP system

purge control solenoid valve coupler (1):
infinity

IL06L1110055-02

• Voltage
- Turn the ignition switch ON.
- Between "T2" at the EVAP system purge
control solenoid valve coupler (1) and
ground: approx. 0 V

IL06L1110062-01

Is check result OK?

Yes Go to Step 3.
1A-69 Engine General Information and Diagnosis:

OTC P0480
BENM10L31104030
OTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area
P0480: Fan 1 Control Circuit
Cooling fan relay drive circuit is shorted to ground or
open.
. Cooling fan relay
Cooling fan relay circuit
• ECM
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

3
7
'-------- G/R------- T93-G
5
...._ _____.....

9 T
IM10L1110056-02
1. Cooling fan relay 4. Cooling fan relay drive circuit 7. Ignition fuse (1 0 A)
2. Cooling fan 5. Ignition switch 8. Cooling fan fuse (15 A)
3. ECM 6. Main fuse (30 A) 9. Battery

Troubleshooting
Step2
Cooling fan relay check
Step 1
Cooling fan relay power supply circuit check 1) Check the cooling fan relay. w(Page 1F-13)
1) Turn the ignition switch OFF. Is check result OK?
2) Remove the cooling fan relay. w(Page 1F-13). Go to Step 3.
Yes
3) Check for proper terminal connection to the
cooling fan relay coupler. No Replace the cooling fan relay.
4) If connections are OK, turn the ignition switch ON.
Step3
5) Measure the voltage between "T3" at the cooling Cooling fan relay drive circuit check
fan relay coupler (1) and ground.
1) Turn the ignition switch OFF.
Cooling fan relay power supply voltage 2) Disconnect the ECM coupler "C". w(Page 1C-2)
[Standard]: Battery voltage
3) Check for proper terminal connection to the ECM
coupler "C".
4 ) If connections are OK, check the following points.
• Resistance
1---,-1---:.....i..-3-� - Between "T1" at the cooling fan relay coupler
5 (1) and ''T93" at the ECM coupler "C" (2):
less than 1 0
IM10L1110057-01

Is check result OK?

Yes Go to Step 2.
No Repair or replace the 'T3" wire at the
cooling fan relay coupler.
 Engine General Information and Diagnosis: 1A-70

Yes Replace the ECM and inspect it again.

-(Page 1 C-2)
1 2 3
No Repair or replace the "T1" wire at the
4
cooling fan relay coupler.
5

75 76 77 78 79 80 81 82 83
84 85 86 87 88 89 90 91
92 93 94 95 96 97 98 99

�»:
- - 2

�
�:,:,:,:,:,:,:,�,:,:,:,:,:,:,:,) �:I:1�1:1: I).1:1 :::�
IM10L 1110058-01

- Between ''T1" at the cooling fan relay coupler

(1) and ground: infinity

2 3

5
IM10L1110059-01

- Between "T1" and other terminal (2) at

cooling fan relay coupler (1): Infinity

IM10L1110060-01

• Voltage
- Turn the ignition switch ON.
- Between "T1" at the cooling fan relay coupler
(1) and ground: approx. 0 V

2 3

5
IM10L 1110061-01

Is check result OK?

1A-71 Engine General Information and Diagnosis:

DTC P0S00
BENM10L31104031
DTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area
POSOO: Vehicle Speed Sensor "A"

.
Any of the following conditions is met.
Front wheel speed is O km/h (0 mile/h) for a few
. Front wheel speed sensor
Front wheel speed sensor circuit
• ABS control unit / HU

.
seconds or more, at motorcycle deceleration. • ECM
Front wheel speed is O km/h (0 mile/h) for a few
seconds or more although the rear wheel speed is

.
higher than 10km/h (6 mile/h).
Front wheel speed signal does not become stable
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

5V
f"I.__J

.r
I I BI/B----1 T47 ___ I.__.
5V

Bltw----1 T45--I.-....

Lr
IM10L 1110062-01

1. Front wheel speed sensor 3. ABS control unit/ HU

2. Rear wheel speed sensor 4. ECM

Troubleshooting - Between 'T12" at the ABS control unit / HU

coupler (1) and "T47" at the ECM coupler "A"
Step 1 (2): less than 1 0
ABS OTC check.
1) Check that OTC is detected in ABS. w(Page 4E-
15)
Is the OTC detected?
Yes Go to troubleshooting for DTCs. Refer to
"OTC Table" in Section 4E (Page 4E-18).

No Go to Step 2.

Step 2
Speed sensor signal circuit check (From ABS
control unit to ECM)
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A" and ABS control
unit/ HU coupler.
• ECM coupler "A": -(Page 1C-2)
• ABS control unit I HU coupler: <:r(Page 4E-50)
3) Check for proper terminal connection to the ECM
coupler "A" and ABS control unit / HU coupler.
4) If connections are OK, check the following points.
• Resistance
 Engine General Information and Diagnosis: 1A-72

[ill [I]
[DJ 0c.,...+,+----•>))i----�
B] m
B] [TI
lHl rn :__
-_-__-___
- -__-_-__-__-_-_-_
_-__
-__-_--
__-__-_-__-_-
__-__-_-
__
- __
-,i_ __
--_- -
B]] [I]
.J

'
'
ff§] [zJ '' '
[fl � '
'
''
,,
B]] @] ,,
2 ::

t,:,:,:,;,i,;.;,�,:,:,:,:,/,J @1:1�1:1:� �:1:1:1�1:1:1�IM10L 1110065-0 1

• Voltage
- Turn the ignition switch ON.
-----------------------'' , '------------------------� - Between "T47" at the ECM coupler "A" (1)
,
'' , and ground: approx. 0 V

I frnl�
2 :/
F --------------------------------------------------

�,:,:,:,:,:,:,:,�,:,:,:,:,:,:,:,J ��
1

--------'----'-------:
IM10L 1110063-01

- Between "T47" at the ECM coupler "A" (1)

and ground: infinity

I
:__-_-__-_-
__-__-_-
__-_ -__-_-_
_ __
- -_-_-_-
_ __-__-_-_-_-
_ __-
__-_-__-_-
__1-_------- -

Is check result OK?

Yes Replace the ECM and inspect it again.
<?(Page 1C-2)
If this DTC is detected again, replace the
ABS control unit/ HU and recheck DTC.
No Repair or replace the "T47" wire at the
ECM coupler "A".
1A-73 Engine General Information and Diagnosis:

OTC POS0B
BENM10L31104032
DTC Detecting Condition and Trouble Area
DTC detecting condition
P050B: Cold Start Ignition Timing Performance
Ignition timing for catalyst warming up is out of the
. ECM
Trouble area

specified range.
(3 D/C detection logic)

Troubleshooting Is DTC P050B still detected?

Step 1 Yes Replace the ECM and inspect it again.

DTC recheck .,,.(Page 1C-2)
1) Perform "OTC Clearance" (Page 1A-12). No End.
2) Perform "OTC Check" (Page 1A-11) and recheck
OTC.

OTC P0602
BENM10L31104033
DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area

.
P0602: Control Module Programming Error Reprogramming failure of ECM
ECM internal failure (data programming error). ECM
(1 D/C detection logic)

Troubleshooting Yes Execute reprogramming of ECM correctly

once again.
Step 1 If this OTC is detected again, replace the
ECM reprogramming check ECM. .,,.(Page 1C-2)
Was reprogramming of ECM executed?
No Execute reprogramming of ECM.

OTC P0607
BENM10L31104034
NOTE
When DTC P0607 is detected, perform the Troubleshooting of DTC P0607 first even if other DTC is
detected.

DTC Detecting Condition and Trouble Area

DTC detecting condition
. Trouble area

.
P0607: Control Module Performance ECM coupler connection
ECM internal processor failure. ECM
(1 D/C detection logic)

Troubleshooting Yes Replace the ECM and inspect it again.

.,,.(Page 1C-2)
Step 1
ECM coupler connection check No End.
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. .,,.(Page 1C-2)
3) Check for proper terminal connection to the ECM
couplers.
4 If connections are OK, reconnect the ECM
)
couplers.
5) Perform "OTC Check" (Page 1A-11) and check
OTC
Is DTC P0607 still detected?
 Engine General Information and Diagnosis: 1A-74

DTC P0826 I P0828

BENM1DL31104035
OTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area
P0826: Up and Down Shift Switch Circuit
Gearshift sensor output voltage is lower than 0.10 V.
(3 DIC detection logic)
. Gearshift sensor
Gearshift sensor circuit
• ECM
P0828: Up and Down Shift Switch Circuit High
Gearshift sensor output voltage is higher than 4.90 V.
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

2
5V
Bl ------, R T12__J

I
G ---<
G/B T11 •
---<
B B/Br T28
�Lr
*

IM10L1110067-01
1. Gearshift sensor 2. ECM

Troubleshooting Gearshift sensor power supply voltage

[Standard]: 4.5 - 5.5 V
Step 1
Gearshift sensor power supply circuit check
17±ffi
1) Turn the ignition switch OFF. 1 2
2) Disconnect the gearshift sensor coupler. <?(Page
58-19)
34�
3) Check for proper terminal connection to the IM10L1110069-01
gearshift sensor coupler (1).
Is check result OK?
4) If connections are OK, turn the ignition switch ON.
Yes Repair or replace the "T1" wire at the
5) Measure the voltage between the ''T4" and ''T1".
gearshift sensor coupler.
Gearshift sensor power supply voltage
[Standard]: 4.5 - 5.5 V No Repair or replace the "T4" wire at the
gearshift sensor coupler.

Step 3
Gearshift sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". c:v-(Page 1C-2)
3) Check for proper terminal connection to the ECM
IM10L1110068-01 coupler "A".
Is check result OK? 4) If connections are OK, check the following points.
• Resistance
Yes Go to Step 3.
- Between "T2" at the gearshift sensor coupler
No Go to Step 2. (1) and "T11" at the ECM coupler "A" (2): less
than 1 0
Step2
Gearshift sensor ground circuit check
1) Measure the voltage between the "T4" at the
gearshift sensor coupler (1) and ground.
1A-75 Engine General Information and Diagnosis:

No Replace the gearshift sensor with a new

one. �(Page 5B-19)
1rill

rrGj
,------------------------------ -------------------�

------- - -- - - -, , ,-
,
--
,, , ,

t,;,;,;,;,i,;,;,�,;,;,;,:,:/� �:1:I),1:I:� �:1:1:I),I:1:1:�

2 ,'/

IM10L1110070-01

- Between "T2" at the gearshift sensor coupler

(1) and ground: infinity

IM10L1110071-01

- Between "T2" and other terminal at the

gearshift sensor coupler (1): infinity

IM10L1110072-01

• Voltage
- Turn the ignition switch ON.
- Between 'T2" at the gearshift sensor coupler
(1) and ground: approx. 0 V

IM10L1110073-01

Is check result OK?

Yes Go to Step 4.
No Repair or replace the "T2" wire at the
gearshift sensor coupler.

Step4
Gearshift sensor check
1) Check the gearshift sensor. <:7(Page SB-20)
Is check result OK?
Yes Replace the ECM with a known good one,
and inspect it again. ar(Page 1 C-2)
 Engine General Information and Diagnosis: 1A-76

DTC P0830 BENM10L31104036

DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0830: Clutch Switch "A" Circuit • Clutch lever position switch
Clutch lever position switch is continuity ON for more •
.
Clutch lever position switch circuit
than specified time with motorcycle running.
.
Left handle switch
(3 DIC detection logic)
ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

---fl-
12V

� B B � B, - T72 ___ J__..

-LJ-
stw stw---Q]--stw ...,________--1
--;},,
IM10L 1110074-02

[A]: To starter sub relay 2. ECM

1. Clutch lever position switch 3. Left handle switch

Troubleshooting
1
Step 1 ---cJ=J
Clutch lever position switch check
1) Turn the ignition switch OFF.
2) Check the clutch lever position switch. <7(Page
5C-6) 4 3 2 1

Is check result OK? 8 7 6 5

IL06L3110028-01
Yes Go to Step 2.
• Between ''T1" (B wire) at the clutch lever
No Replace the clutch lever position switch. position switch connector (1) and ground:
<7(Page 5C-10) infinity

Step 2 1
Clutch lever position switch signal circuit check ---cJ=J
(left handle switch)
1) Check for proper terminal connection to the clutch
lever position switch connectors or coupler.
2) If connections are OK, disconnect the left handle IL06L 1110076-01
• Between "T1" (B wire) at the clutch lever
switch couplers. (U'(Page 68-9)
position switch connector (1) and "T1" (B/W
3) Check for proper terminal connection to the left
wire) at the clutch lever position switch
handle switch couplers.
connector (2): infinity
4) If connections are OK, check the resistance.
• Between "T1" (B wire) at the clutch lever 1 2
---cJ=J ---cJ=J
position switch connector (1) and "T2" at the left
handle switch coupler (8P) (2): less than 1 n

IL06L 1110077-0 1

Is check result OK?

Yes Go to Step 3.
1A-77 Engine General Information and Diagnosis:

No Repair the left handle switch lead wire or

replace the left handle switch. w-(Page 68-
9) 2 3 4

Step3 5 Ii 7 8
Clutch lever position switch signal circuit check
(main harness) 2

1) Disconnect the ECM coupler "B''. CS"(Page 1C-2)

2) Check for proper terminal connection to the ECM 3
coupler "B".
6
3) If connections are OK, check the resistance.
IL06L 1110081-01
• Between "T2" at the left handle switch coupler
(8P) (1) and 'T72" at the ECM coupler "B" (2): Is check result OK?
less than 1 n
Yes Replace the ECM and inspect it again.
-(Page 1C-2)
1 2 3 4 No Repair or replace the "T2" wire at the left
handle switch coupler (8P).
5 Ii 7 8

�---------------------------- ---------------------,
'''

' '
I - - - - - - - - - - - - - - - - - - - - - - - , - - - - - - - - - - - - - - - - - - - - - - -
1

',
' 1' 2

�:1:1:I�1:1:I:�
(,:,:,:,:,:,:,:,): :,:,:,:,:,:,:,) IM10L 1110075-01

• Between "T2" at the left handle switch coupler

(8P) (1) and ground: infinity

2 3 4

5 Ii 7 8

IL06L 1110080-01
• Between "T2" at the left handle switch coupler
(8P) ( 1) and "T4" at the left handle switch
coupler (6P) (2): infinity
 Engine General Information and Diagnosis: 1A-78

OTC P0850
BENM10L31104037
DTC Detecting Condition and Trouble Area
DTC detecting condition
P0850: Park/ Neutral Switch Input Circuit GP sensor . Trouble area

.
Neutral switch is continuity ON for more than specified • GP sensor circuit
time with motorcycle running.
ECM
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

2
[A]

5V
R SV
R T12_1
-,_

p sv
p T43l

Bl Bl T20 I ..
>-----B/W B/Br T28
-L....r
�

IM1 0L1110076-02
[A]: To combination meter and starter sub relay I 1. GP sensor 2. ECM

Troubleshooting GP sensor power supply voltage

[Standard]: 4.5 - 5.5 V
Step 1
GP sensor power supply circuit check
1) Turn the ignition switch OFF.
2) Disconnect the GP sensor coupler. w(Page 58-
14) IM10L1110078-02
3) Check for proper terminal connection to the GP Is check result OK?
sensor coupler (1).
4) If connections are OK, turn the ignition switch ON. Yes Repair or replace the "T4" wire at the
gearshift sensor coupler.
5) Measure the voltage between the "T1" and "T4".
GP sensor power supply voltage No Repair or replace the "T1" wire at the
[Standard]: 4.5 - 5.5 V gearshift sensor coupler.

Step 3
GP sensor (neutral) signal circuit check
1) Disconnect the GP sensor coupler, ECM coupler
"A", combination meter coupler and starter sub
relay.
• GP sensor coupler: w(Page 58-14)
IM10L1110077-02
• ECM coupler: w(Page 1C-2)
Is check result OK? • Combination meter coupler: Clr'(Page 9C-13)
• Remove the starter sub relay. w(Page 11-9)
Yes Go to Step 3.
2) Check for proper terminal connection to the GP
No Go to Step 2. sensor coupler and ECM coupler "A".
3) If connections are OK, check the resistance.
Step 2
• Resistance
GP sensor ground circuit check
- Between "T2" at the GP sensor coupler (1)
1) Measure the voltage between the "T1" at the GP
and 'T20" at the ECM coupler "A" (2): less
sensor coupler (1) and ground.
than 1 0
1A-79 Engine General Information and Diagnosis:

No Replace the GP sensor. <?(Page 58-14)

,--------------------------------------------------�
' '
'

:1��--1------�----­
:,,,----t------'---''--------------..
'
'
']'--,--���1-.,.;....L,,-J.......-L..,.--'---.-��__,_.,.;....L,,-J.......-L..,.-.J....,
'
'
'
'
''

------------------------ , ------------------------
, ,
,, ,
2 :/

(,:,:,:,:,\,:,:,�,:,:,:,:,:,;;) �:1:I�I:1:� �:1:1:I),1:1:1:�

IM10L 1110079-01

- Between "T2" at the GP sensor coupler (1)

and ground: infinity

IM10L 1110080-01

- Between "T2" and other terminal at the GP

sensor coupler (1): infinity

IM10L 1110081--01

• Voltage
- Turn the ignition switch ON.
- Between "T2" at the GP sensor coupler (1)
and ground: approx. 0 V

IM10L1110082--01

Is check result OK?

Yes Go to Step 4.

No Repair or replace the "T2" wire at the GP

sensor coupler.

Step4
GP sensor check
1) Turn the ignition switch OFF.
2) Check the neutral switch of GP sensor. Refer to
"'"(Page 58-13)
Is check result OK?
Yes Replace the ECM and inspect it again.
<?(Page 1 C-2)
 Engine General Information and Diagnosis: 1A-80

DTC P0914 / P0915 / P0916

BENM10L31104038
DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area
P0914: GP Sensor Circuit
GP sensor output voltage is higher than 4.90 V for 3 . GP sensor
GP sensor circuit
sec. or more continuity. • ECM
(3 D/C detection logic)
P0915: GP Sensor Circuit Range/Performance

.
Any of the following conditions is met.
GP sensor output voltage is out of the specified
range.
• Difference between measured gear position and
estimated gear position is out of the specified range.
(3 D/C detection logic)
P0916: GP Sensor Circuit Low
GP sensor output voltage is lower than 0.10 V for 3
sec. or more continuity.
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

[A]
2
5V
__J SV
-,_

sv
R R T12

p p T43l

Bl Bl T20 I •
t----B/W B/Br T28*
-Lr

IM10L1110076-02

[A): To combination meter and starter sub relay 1. GP sensor 2. ECM

Troubleshooting Is check result OK?

Step 1 Yes Go to Step 3.

GP sensor power supply circuit check
No Go to Step 2.
1) Turn the ignition switch OFF.
2) Disconnect the GP sensor coupler. -(Page 5B- Step 2
14) GP sensor ground circuit check
3) Check for proper terminal connection to the GP 1) Measure the voltage between the "T1" at the GP
sensor coupler (1). sensor coupler (1) and ground.
4) If connections are OK, turn the ignition switch ON. GP sensor power supply voltage
5) Measure the voltage between the "T1" and "T4". [Standard]: 4.5 - 5.5 V
GP sensor power supply voltage
[Standard]: 4.5 - 5.5 V

IM10L1110078-02

Is check result OK?

Yes Repair or replace the 'T4" wire at the

gearshift sensor coupler.
IM10L1110077-02
1A-81 Engine General Information and Diagnosis:

No Repair or replace the 'T1" wire at the

gearshift sensor coupler.

Step 3
GP sensor (gear position) signal circuit check
1) Turn the ignition switch OFF. IM10L1110086-01

2) Disconnect the ECM coupler "A". w(Page 1C-2) Is check result OK?
3) Check for proper terminal connection to the ECM
Yes Go to Step 4.
coupler "A".
4) If connections are OK, check the following points. No Repair or replace the "T3" wire at the GP
• Resistance sensor coupler.
- Between "T3" at the GP sensor coupler (1)
Step4
and "T43" at the ECM coupler "A" (2): less
GP sensor check
than 1 0
1) Turn the ignition switch OFF.
2) Check the neutral switch of GP sensor. w(Page
SB-13)
Is check result OK?

Yes Replace the ECM and inspect it again.

w(Page 1C-2)

- - - - - - - - - - -, :, ,- - - - -1- - - - - - -
No Replace the GP sensor. w(Page 5B-14)

t,: ,: ,L:,�:, :, -:.�i-

2 ,,

�:1:1X1:1:� @1:1:1X1:1:1:�
IM10L 1110083-01
I
- Between "T3" at the GP sensor coupler (1)
and ground: infinity

IM10L 1110084-01

- Between "T3" and other terminal at the GP

sensor coupler (1 ): infinity

1110085-01IM10L
• Voltage
- Turn the ignition switch
ON.
- Between "T3" at the GP
sensor coupler (1)
and ground: approx. o v
 Engine General Information and Diagnosis: 1A-82

OTC P1105 / P1106 / P1107

BENM10l31104039
DTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area

.
P1105: IAP Sensor Circuit Bank 2 Vacuum passage between throttle body and IAP sensor

.
IAP sensor output voltage is higher than 4.80 V. IAP sensor
(3 D/C detection logic)
.
IAP sensor circuit
P1106: IAP Sensor Circuit Range/ Performance
Bank2 ECM
Any of the following conditions is met.
•
.
IAP sensor vacuum hose has come off.
IAP sensor output voltage does not change, under
the specified condition.
(3 D/C detection logic)
P1107: IAP Sensor Circuit Low Bank2
IAP sensor output voltage is lower than 0.10 V.
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

3
5V
5V
R T12_j

G/B TB ..
B/Br T28
�

I ..
,___ 5V

G/Y T9

IM10L1110011-01
1. IAP sensor 2. AP sensor 3. ECM

Troubleshooting
Step2
NOTE IAP sensor power supply circuit check
When DTC P1106 is not detected, start with 1) Turn the ignition switch OFF.
Step 2. 2) Disconnect the IAP sensor coupler. cr(Page 1 C-5)
3) Check for proper terminal connection to the IAP
Step 1 sensor coupler (1).
IAP sensor vacuum hose check 4) If connections are OK, turn the ignition switch ON.
• Check that the IAP sensor vacuum hose is 5) Measure the voltage between the "T3" and "T1".
connected correctly. w(Page 1D-5)
IAP sensor power supply voltage
• Check the IAP sensor vacuum hose for wear and
[Standard]: 4.5 - 5.5 V
damage.
Is check result OK?
Yes Go to Step 2.

No Repair or replace the IAP sensor vacuum

hose.
IM06L1110001-01

Is check result OK?

1A-83 Engine General Information and Diagnosis:

Yes Go to Step 3. - Between "T2" and other terminal at IAP

sensor coupler (1): infinity
No Go to Step 2.

Step 3
IAP sensor ground circuit check
1) Measure the voltage between the "T3" at the IAP
sensor coupler (1) and ground.
IAP sensor power supply voltage
[Standard]: 4.5 - 5.5 V
IM0SL 1110004-01

• Voltage
- Turn the ignition switch ON.
- Between 'T2" at the IAP sensor coupler (1)
and ground: approx. 0 V

IM0SL1110002-01

Is check result OK?

Yes Repair or replace the "T1" wire at the IAP
sensor coupler.
IM06L1110005-01
No Repair or replace the "T3" wire at the IAP
sensor coupler. Is check result OK?

Step4 Yes Go to Step 5.

IAP sensor signal circuit check No Repair or replace the "T2" wire at the IAP
1) Turn the ignition switch OFF. sensor coupler.
2) Disconnect the ECM coupler "A". -(Page 1 C-2)
Steps
3) Check for proper terminal connection to the ECM
IAP sensor output voltage at idle speed check
coupler "A".
1) Turn the ignition switch OFF.
4) If connections are OK, check the following points.
2) Measure the IAP sensor voltage. Refer to "IAP
• Resistance
Sensor Output Voltage" under "IAP Sensor
- Between "T2" at the IAP sensor coupler (1) Inspection" in Section 1C (Page 1C-4).
and "T8" at the ECM coupler "A" (2): less
than 1 0 Is check result OK?

Yes Replace the ECM and inspect it again.

-(Page 1C-2)

No Replace the IAP sensor. -(Page 1C-5)

,---------------------------------------------------

�-'_-__-_-
__-_-
__-__-_-
__-_-
__-_- __-_-
__-_-_-
' ,
, ,
__-_-
__-_-
_- -_--- �
___-_- _-__ -
__ ____
' ,

�•:•:•:•:l•:•:•:1�1:1:,:,:,:,:,//
frnl �
:,J �� IM10L1110087-01

- Between "T2" at the IAP sensor coupler (1)

and ground: infinity
 Engine General Information and Diagnosis: 1A-84

OTC P1201 / P1202 / P1203 / P1204

BENM10L31104040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area

1
Secondary fuel injector #1 signal is interrupted by 20
..
P1201: Secondary Injector Circuit/ Open - Cylinder • Secondary fuel injector #1
Secondary fuel injector #1 circuit
ECM
times or more continuity although CKP signal is
detected.
(3 DIC detection logic)
P1202: Secondary Injector Circuit/ Open - Cylinder • Secondary fuel injector #2
2 • Secondary fuel injector #2 circuit
Secondary fuel injector #2 signal is interrupted by 20 •
ECM
times or more continuity although CKP signal is
detected.
(3 DIC detection logic)

.
P1203: Secondary Injector Circuit/ Open - Cylinder • Secondary fuel injector #3
3
.
Secondary fuel injector #3 circuit
Secondary fuel injector #3 signal is interrupted by 20
ECM
times or more continuity although CKP signal is
detected.
(3 DIC detection logic)
P1204: Secondary Injector Circuit/ Open - Cylinder
4 . Secondary fuel injector #4

.
Secondary fuel injector #4 circuit
Secondary fuel injector #4 signal is interrupted by 20
ECM
times or more continuity although CKP signal is
detected.
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

10

14
T103--G
Y/R

Lg T98-

2
T97-
11 T
9
3
T96-

4
T95-
-
IM10L t110088-01
1A-85 Engine General Information and Diagnosis:

1. Secondary fuel injector #1 6. Ignition switch 11. Battery

2. Secondary fuel injector #2
3. Secondary fuel injector #3
4. Secondary fuel injector #4
5. FP relay
7. Engine stop/ starter switch ("RUN / STOP" 12. Main fuse (30 A)
position)
8. Fuel pump relay drive circuit 13. Ignition fuse (10 A)
9. Fuel injector drive circuit 14. Fuel fuse (10 A)
10. ECM

Troubleshooting Between "T1" at the secondary fuel injector

coupler and 'T96" at the ECM coupler "C":
Step 1 less than 1 0
Secondary fuel injector power supply circuit check - Secondary fuel injector #4:
1) Turn the ignition switch OFF. Between ''T1" at the secondary fuel injector
2) Disconnect the secondary fuel injector coupler. coupler and "T95" at the ECM coupler "C":
<:ll"(Page 1 G-21) less than 1 0
3) Check for proper terminal connection to the
secondary fuel injector coupler (1). 1--GrJ

4) If connections are OK, turn the ignition switch ON.

.. - - . - -..... -
. .
.,.
5) Measure the voltage between "T2" and ground.
I
NOTE :-:
I I
�
I
:

Secondary fuel injector power supply voltage

can be detected only for a few seconds after
ignition switch is turned ON.

Secondary fuel injector power supply voltage

[Standard]: Battery voltage

------------------------ ,,--------------------- I

, __ :: ,_ 2
_

��
(,:,:,:,:,:,:,:,�,:,:,:,:,:,:,:,) �:I:I).1:I; �I:I).1:I:'.:�
IM10L 1110089-01
IL41K1110025-01
- Between "T1" at the secondary fuel injector
Is check result OK? coupler (1) and ground: infinity
Yes Go to Step 2.

No Repair or replace the "T2" wire at the

secondary fuel injector coupler.

Step 2
Secondary fuel injector drive circuit check IL41K1110027-01

1) Turn the ignition switch OFF. - Between ''T1" and "T2" at the secondary fuel
2) Disconnect the ECM coupler "C". (g'(Page 1 C-2) injector coupler (1): infinity

3) Check for proper terminal connection to the ECM

coupler "C".
4) If connections are OK, check the following points.
• Resistance
- Secondary fuel injector #1: IL41K1110028-01
Between "T1" at the secondary fuel injector • Voltage
coupler (1) and "T98" at the ECM coupler "C"
(2): less than 1 0 - Turn the ignition switch ON.
- Secondary fuel injector #2: - Between "T1" at the secondary fuel injector
Between "T1" at the secondary fuel injector coupler (1) and ground: approx. O V
coupler and "T97" at the ECM coupler "C":
less than 1 0
- Secondary fuel injector #3:
 Engine General Information and Diagnosis: 1A-86

_Step 3
Secondary fuel injector resistance check
1) Turn the ignition switch OFF.
2) Measure the secondary fuel injector resistance.
"""(Page 1 G-21)
IL41K1110029-01 Is check result OK?
Is check result OK? Yes Replace the ECM and inspect it again.
Yes Go to Step 3. cy-(Page 1C-2)

No Repair or replace the ''T1" wire at the No Replace the secondary fuel injector.
secondary fuel injector coupler. cy-(Page 1 G-21)

DTC P1610
BENM10L31104041
NOTE
For model with immobilizer control system, refer to "DTC P1610" in Section 10C (Page 10C-4).

DTC Detecting Condition and Trouble Area

DTC detecting condition
. Trouble area

.
P1610: Ignition Switch Signal Circuit Ignition switch
Ignition switch signal is not input to the ECM.
.
Ignition switch circuit
(1 D/C detection logic)
ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

Gr --------1 T27---

4 T

IM10L1110090-01
[A]: To ignition fuse (10 A) 2. ECM 4. Battery
1. Ignition switch 3. Main fuse (30 A)

Troubleshooting

Step 1 _
Ignition switch power supply circuit check
1) Turn the ignition switch OFF. 6 5 4
2) Disconnect the ignition switch coupler. <lf>(Page
1H-7) IM10L 1110091-01

3) Check for proper terminal connection to the Is check result OK?

ignition switch coupler ( 1 ).
Yes Go to Step 2.
4) If connections are OK, measure the voltage
between the 'T1" and ground. No Repair or replace the 'T1" wire at the
ignition switch coupler.
Ignition switch power supply voltage
[Standard]: Battery voltage
1A-87 Engine General Information and Diagnosis:

Step 2 - Between "T2" at the ignition switch coupler

Ignition switch signal circuit check (1) and ground: approx. 0 V
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". w(Page 1 C-2)
3 2
3) Check for proper terminal connection to the ECM
coupler "A". 6 ..
,. 4
4) If connections are OK, check the following points.
• Resistance
- Between "T2" at the ignition switch coupler
(1) and "T27" at the ECM coupler "A" (2):
less than 1 0 IM10L1110095-01

Is check result OK?

Yes Go to Step 3.
3 2
No Repair or replace the 'T2" wire at the
6 4 ignition switch coupler.

Step3
Ignition switch check
-------------------------------- -------------------
'
'' 1) Replace the ignition switch. w(Page 1 H-7)
'' 2) Connect the ECM coupler "A". (lr>(Page 1 C-2)
'
'
''
3) Perform "OTC Check" (Page 1A-11) and check
L...,-L....,-1--.--J...,.....L-.-J-,..-'-,,....L--,--L._,-...1.-,-.L...,-'--r,J'--T--',--,--J--,-J--,-L..., ' OTC.
Is OTC P1610 still detected?
------------------------ -------------------------

t .//��
' ', Yes Replace the ECM with a known good one,
'' ,
and inspect it again. w(Page 1 C-2)

�,:,:,:,;,:,;,:,�,:,:,:,:,:,:,:,J ��
No End.

iM10L1110092-01

- Between "T2" at the ignition switch coupler

(1) and ground: infinity

3 2

6 .,
j'
4

tM10L 1110093-01

- Between "T2" and other terminal (1) at the

ignition switch coupler (2): infinity

3 2

6 5 4

tM10L1110094-01

• Voltage
 Engine General Information and Diagnosis: 1A-88

DTC P1622
BENM10L31104042
OTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1622: Control Module ROM Error • ECM coupler connection
EEPROM in ECM is corrupted. • ECM
(1 D/C detection logic)

Troubleshooting 5) Perform "DTC Check" (Page 1A-11) and check

DTC.
Step 1
Is OTC P1622 still detected?
ECM coupler connection check
1) Turn the ignition switch OFF. Yes Replace the ECM and inspect it again.
2) Disconnect the ECM couplers. <?(Page 1C-2) @>(Page 1C-2)
3) Check for proper terminal connection to the ECM No End.
couplers.
4) If connections are OK, reconnect the ECM
couplers.

OTC P1650
BENM10L31104043
OTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area

.
P1650: Inertial Measurement Unit IMU
ECM receives abnormal signal from IMU.
.
IMU circuit
(3 D/C detection logic)
ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page
1A-6).

Troubleshooting

·step 1
ABS OTC check
1) Check that DTC is detected in ABS. w(Page 4E-
15)
Is the OTC detected?
Yes Go to troubleshooting for DTCs. Refer to
"DTC Table" in Section 4E (Page 4E-18).
No Perform troubleshooting of "DTC C1762 I
C1763 / C1764 I C1765 I C1766 I C1767"
in Section 4E (Page 4E-41).
If check result is OK, replace the ECM and
inspect it again. <?(Page 1C-2)
1A-89 Engine General Information and Diagnosis:

DTC P2101
BENM10L31104044
DTC Detecting Condition and Trouble Area
OTC detecting condition Trouble area
•
.
P2101: Throttle Actuator "A" Control Motor Circuit Throttle valve motor
Range / Performance
.
Throttle valve motor circuit
Any of the following conditions is met.
.
Throttle valve sticking
• Throttle valve motor and/or its circuit malfunction is

. .
Throttle valve motor power supply circuit
detected.
TP sensor
.
Throttle valve sticking is detected

.
TP sensor circuit
Difference between measured throttle valve position
and targeted throttle valve position is out of the ECM

.
specified range.
The target value of throttle valve position does not

.
become stable.
Throttle valve motor power supply circuit malfunction is

. detected.

.
Throttle valve does not become fully closed position .
TP sensor malfunction is detected .
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

R/W T92

B/Lg
P/W
R
T75
T84
T51
;b 5V
j
4
I,
B T57
w T70
7 G T63
�I,
8 "T"

IM10L1110016-01

1. TP sensor (main) 4. Throttle body 7. Main fuse (30 A)

2. TP sensor (sub) 5. Throttle valve motor drive circuit 8. Battery
3. Throttle valve motor 6. Fuel fuse (10 A) 9. ECM

Troubleshooting • Throttle valve motor coupler: w-(Page 1 D-9)

• ECM coupler "C": <T(Page 1C-2)
Step 1
3) Check for proper terminal connection to the
DTC check throttle valve motor coupler and ECM coupler "C".
Is there any DTC(s) other than P2101? 4) If connections are OK, check the following points.
Yes Go to troubleshooting for applicable DTC. • Resistance
- Between "T1" at the throttle valve motor
No Go to Step 2. coupler (1) and "T84" at the ECM coupler "C"
(2): less then 1 0
Step2
Throttle valve motor drive circuit check - Between "T2" at the throttle valve motor
coupler and "T75" at the ECM coupler "C":
1) Turn the ignition switch OFF. less then 1 0
2) Disconnect the throttle valve motor coupler and
ECM coupler "C".
 Engine General Information and Diagnosis: 1A-90

Step 3 .. .
Throttle valve and throttle valve motor check
1) Check the following points. <7(Page 1C-15)
• Throttle valve operation:
• Throttle valve motor resistance:
Is check result OK?

Yes Go to Step 4.
No Replace the throttle body. ""(Page 10-9)

Step4
Throttle valve motor power supply circuit check
1) Check the throttle valve motor #1 power supply
circuit. Refer to "Step 1" under "OTC P2102"
(Page 1A-91).
Is check result OK?
Yes Go to Step 5.
- Between "T1" at the throttle valve motor No Repair or replace the defective wire
coupler (1) and ground: infinity harness.
- Between 'T2" at the throttle valve motor
coupler and ground: infinity Steps
- Between "T1" and T2 at the throttle valve TP sensor circuit check
motor coupler: infinity 1) Check the TP sensor circuit.
• TP sensor (main) circuit: Refer to "Step 1" -
"Step 3" under "OTC P0120 / P0123" (Page 1A-
42)
• TP sensor (sub) circuit: Refer to "Step 1" -
"Step 3" under "OTC P0220 / P0223" (Page 1A-
52)
Is check result OK?
Yes Go to Step 6.
IL06L1110022-01

• Voltage No Repair or replace the defective wire

harness.
- Turn the ignition switch ON.
- Between "T1" at the throttle valve motor Step 6
coupler (1) and ground: approx. 0 V TP sensor output voltage check
- Between "T2" at the throttle valve motor 1) Measure the TP sensor output voltage. "(Page
coupler and ground: approx. O V 1C-7)
Is check result OK?

Yes Replace the ECM and inspect it again.

"(Page 1 C-2)

No Replace the throttle body. "(Page 10-9)

IL06L 1110023-01

Is check result OK?

Yes Go to Step 3.

No Repair or replace the defective wire

harness.
1A-91 Engine General Information and Diagnosis:

DTC P2102
BENM10L31104045
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2102: Throttle Actuator "A" Control Motor Circuit • Throttle valve motor power supply circuit
Low • ECM
Difference between power supply voltage to throttle valve
motor and battery voltage is out of the specified range.
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

R/W T92

B/Lg T75
P/W T84 �
¥
r
R T51
4 B T57
w T?O
7 G T63
7rr;
8 "T"

IM10L1110016-01

1. TP sensor (main) 4. Throttle body 7. Main fuse (30 A)

2. TP sensor (sub) 5. Throttle valve motor drive circuit 8. Battery
3. Throttle valve motor 6. Fuel fuse (10 A) 9. ECM

Troubleshooting

Step 1
Throttle valve motor power supply circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "C". w(Page 1 C-2)
3) Check for proper terminal connection to the ECM
coupler "C".
4) If connections are OK, measure the voltage
between "T92" at the ECM coupler "C" (1) and
ground.
Throttle valve motor power supply voltage
[Standard]: Battery voltage

Is check result OK?

Yes Replace the ECM and inspect it again.
<?(Page 1C-2)
No Repair or replace the "T92" wire at the
ECM coupler "C".
 Engine General Information and Diagnosis: 1A-92

DTC P2120 / P2123

BENM10L31104046
OTC Detecting Condition and Trouble Area
OTC detecting condition
P2120: TP Sensor/ Switch "D" Circuit Accelerator.position
Trouble area
sensor (main)
Accelerator position sensor (main) output voltage is lower • Accelerator position sensor (main) circuit
than 0.10 V.
(1 DIC detection logic)
ECM .
P2123: TP Sensor/ Switch "D" Circuit High
Accelerator position sensor (main) output voltage is
higher than 4.90 V.
(1 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

5V
------- R/Y T49 i
t-------- P/W T56

t--------Br/W T68�
3 5V
t-------- RIG T59 j
2 o-------B/BI T65
1--------B/Lg T71�

IM10L 1110098-03

1. Accelerator position sensor (main) 3. Accelerator body assembly

2. Accelerator position sensor (sub) 4. ECM

Troubleshooting No Go to Step 2.

Step 1 Step2
Accelerator position sensor (main) power supply Accelerator position sensor (main) ground circuit
circuit check check
1) Turn the ignition switch OFF. 1) Measure the voltage between the "T6" at the
2) Disconnect the accelerator position sensor accelerator position sensor coupler (1) and
coupler (1). <?(Page 1C-13) ground.
3) Check for proper terminal connection to the Accelerator position sensor power supply
accelerator position sensor coupler (1 ). voltage

4) If connections are OK, turn the ignition switch ON. [Standard]: 4.5 - 5.5 V

5) Measure the voltage between the "T6" and "TS".

Accelerator position sensor power supply
voltage
[Standard]: 4.5 - 5.5 V

IM10L 1110100-01

Is check result OK?

Yes Repair or replace the "T5" wire at the
IM10L 1110099-01
accelerator position sensor coupler.
Is check result OK? No Repair or replace the "T6" wire at the
accelerator position sensor coupler.
Yes Go to Step 3.
1A-93 Engine General Information and Diagnosis:

Step 3
Accelerator position sensor (main) signal circuit
check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "B". w(Page 1C-2)
3) Check for proper terminal connection to the ECM IM10L1110104-01
coupler "B".
Is check result OK?
4) If connections are OK, check the following points.
• Resistance Yes Go to Step 4.
- Between "T 4" at the accelerator position No Repair or replace the "T4" wire at the
sensor coupler (1) and "T56" at the ECM accelerator position sensor coupler.
coupler "B'' (2): less than 1 O
Step4
Accelerator position sensor (main) output voltage
check
1) Measure the accelerator position sensor (main)
output voltage. cr(Page 1C-13)
Is check result OK?
Yes Replace the ECM and inspect it again.
w(Page 1C-2)
No Replace the accelerator body assembly.
w(Page 1C-14)

W
''
:_____________________ ,------------------------J

t,:,:,:,:,:,:,:,�,:,:-:,:,:-:,:,i _ _ �:1:1:1�1:1:1:�
IM10L1110101-01

- Between "T4" at the accelerator position

sensor coupler (1) and ground: infinity

IM10L1110102-01

- Between "T4" and other terminal (2) at the

accelerator position sensor coupler (1 ):
infinity

IM10L1110103-01

• Voltage
- Turn the ignition switch ON.
- Between "T4" at the accelerator position
sensor coupler (1) and ground: approx. 0 V
 Engine General Information and Diagnosis: 1A-94

OTC P2125 / P2128

BENM10L31104047
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2125: TP Sensor/ Switch "E" Circuit • Accelerator position sensor (sub)
Accelerator position sensor (sub) output voltage is lower • Accelerator position sensor (sub) circuit
than 0.10V.
ECM
(1 DIC detection logic)
P2128: TP Sensor/ Switch "E" Circuit High
Accelerator position sensor (sub) output voltage is higher
than 4.90V.
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

5V
t-------- R/Y T49 j
t--------P/W T56
t--------Br/W T68�
3 5V
,________ RIG T59 f
2 1-------- BIBI T65
1--------B/Lg T71�

IM10L 1110098-03
1. Accelerator position sensor (main) 3. Accelerator body assembly
2. Accelerator position sensor (sub) 4. ECM

Troubleshooting No Go to Step 2.

Step 1 Step 2
Accelerator position sensor (sub) power supply Accelerator position sensor (sub) ground circuit
circuit check check
1) Turn the ignition switch OFF. 1) Measure the voltage between the "T3" at the
2) Disconnect the accelerator position sensor accelerator position sensor coupler (1) and
coupler (1). W"(Page 1C-13) ground.
3) Check for proper terminal connection to the Accelerator position sensor power supply
accelerator position sensor coupler (1). voltage
4) If connections are OK, turn the ignition switch ON. [Standard]: 4.5 - 5.5 V

5) Measure the voltage between the "T3" and "T2".

Accelerator position sensor power supply
voltage
[Standard]: 4.5 - 5.5 V

IM10L1110107-01

Is check result OK?

Yes Repair or replace the "T2" wire at the
IM10L1110106-01
accelerator position sensor coupler.
Is check result OK? No Repair or replace the 'T3" wire at the
accelerator position sensor coupler.
Yes Go to Step 3.
1A-95 Engine General Information and Diagnosis:

Step 3 .
Accelerator position sensor (sub) signal circuit
check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "B". <r(Page 1 C-2)
3) Check for proper terminal connection to the ECM IM10L1110111-01
coupler "B".
Is check result OK?
4) If connections are OK, check the following points.
• Resistance Yes Go to Step 4.
- Between ''T1" at the accelerator position No Repair or replace the "T1" wire at the
sensor coupler (1) and "T65" at the ECM accelerator position sensor coupler.
coupler "8" (2): less than 1 0
Step4
Accelerator position sensor (sub) output voltage
check
1) Measure the accelerator position sensor (sub)
output voltage. w-(Page 1C-13)
Is check result OK?
Yes Replace the ECM and inspect it again.
i:r(Page 1C-2)
No Replace the accelerator body assembly.
w-(Page 1C-14)

'
''
_________________________ J

',, \ 2

t,:,:,:,:,:,:,:,�,:,:,:,:,:,:,:0 ��:1:1:1�1:1:1:�
IM10L1110108-01

- Between "T1" at the accelerator position

sensor coupler (1) and ground: infinity

IM10L1110109-01

- Between ''T1" and other terminal (2) at the

accelerator position sensor coupler (1):
infinity

IM10L1110110-01

• Voltage
- Turn the ignition switch ON.
- Between "T1" at the accelerator position
sensor coupler (1) and ground: approx. 0 V
 Engine General Information and Diagnosis: 1A-96

DTC P2135
BENM10L31104048
DTC Detecting Condition and Trouble Area
DTC detecting condition
P2135: TP Sensor/ Switch "A"/ "B" Voltage . TP sensor
Trouble area

Correlation • TP sensor circuit

Difference between TP sensor (main) value and TP • ECM
sensor (sub) value is out of the specified range.
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

�----------------R/W T92

�-�======.:::t"-1-------B/Lg
�--ir------P/W
R
T75
T84
T51
;1 5V
T
I
4 B T57

7
w
G
T70
T63 7,,I
8 -,-

IM10L1110016-01

1. TP sensor (main) 4. Throttle body 7. Main fuse (30 A)

2. TP sensor (sub) 5. Throttle valve motor drive circuit 8. Battery
3. Throttle valve motor 6. Fuel fuse (10 A) 9. ECM

Troubleshooting
Step3
TP sensor output voltage check
Step 1
DTC check 1) Measure the TP sensor output voltage. w(Page
1 C-7)
Is there any DTC(s) other than P2135?
Is check result OK?
Yes Go to troubleshooting for applicable OTC.
Yes Replace the ECM and inspect it again.
No Go to Step 2. w(Page 1C-2)

Step 2 No Replace the throttle body. w(Page 1 D-9)

TP sensor circuit check
1) Check the TP sensor circuit.
• TP sensor (main) circuit: Refer to "Step 1" -
"Step 3" under "OTC P0120 / P0123" (Page 1A-
42).
• TP sensor (sub) circuit: Refer to "Step 1" -
"Step 3" under "OTC P0220 / P0223" (Page 1A-
52).
Is check result OK?

Yes Go to Step 3.
No Repair or replace the defective wire
harness.
1A-97 Engine General Information and Diagnosis:

DTC P2138
BENM10L31104049
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
•
.
P2138: TP Sensor/ Switch "D" / "E" Voltage Accelerator position sensor

.
Correlation Accelerator position sensor circuit
Difference between accelerator position sensor (main)
ECM
value and accelerator position sensor (sub) value is out
of the specified range.
(1 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

r
5V
,________ R/Y T49

I
-------P/W T56
-------Br/W T68�
3 5V
,________ RIG T59 j

T65
I
2 t--------8/81
o-- ---- --8/Lg T71�

IM10l 1110098-03
1. Accelerator position sensor (main) 3. Accelerator body assembly
2. Accelerator position sensor (sub) 4. ECM

Troubleshooting
Step3
Accelerator position sensor output voltage check
Step 1
DTC check 1) Measure the accelerator position sensor output
voltage. <7(Page 1C-13)
Is there any DTC(s) other than P2138?
Is check result OK?
Yes Go to troubleshooting for applicable DTC.
Yes Replace the ECM and inspect it again.
No Go to Step 2. <ir(Page 1C-2)

Step 2 No Replace the accelerator body assembly.

Accelerator position sensor circuit check <7(Page 1C-14)
1) Check the accelerator position sensor circuit.
• Accelerator position sensor (main) circuit: Refer
to "Step 1" - "Step 3" under "DTC P2120 /
P2123" (Page 1A-92).
• Accelerator position sensor (sub) circuit: Refer
to "Step 1" - "Step 3" under "DTC P2125 /
P2128" (Page 1A-94).
Is check result OK?
Yes Go to Step 3.

No Repair or replace the defective wire

harness.
 Engine General Information and Diagnosis: 1A-98

DTC P2158 BENM10L31104050

DTC Detecting Condition and Trouble Area
DTC detecting condition
. Trouble area

.
P2158: Vehicle Speed Sensor "B" Rear wheel speed sensor
Any of the following conditions is met, at motorcycle Rear wheel speed sensor circuit

. .
deceleration. • ABS control unit / HU
Rear wheel speed is 0 km/h (0 mile/h) for a few

.
ECM
seconds or more, at motorcycle deceleration.
Rear wheel speed is 0 km/h (0 mile/h) for a few
seconds or more although the front wheel speed is
higher than 10km/h (6 mile/h).
• Rear wheel speed signal does not become stable .
(3 DIC detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

I I�.
1 5V
I"\ I
L_J I B1/B----t T47--.....

U'
5V
...
I��
2

B1/W---t T45--.....

..,.
IM10L 1110062--01

1. Front wheel speed sensor 3. ABS control unit/ HU

2. Rear wheel speed sensor 4. ECM

Troubleshooting • Resistance
- Between "T12" at the ABS control unit / HU
Step 1 coupler (1) and "T45" at the ECM coupler "A"
ABS DTC check. (2): less than 1n
1) Check that DTC is detected in ABS. <?(Page 4E-
15)
Is the DTC detected?
Yes Go to troubleshooting for DTCs. Refer to
"OTC Table" in Section 4E (Page 4E-18).
No Go to Step 2.

Step2
Speed sensor signal circuit check (From ABS
control unit to ECM)
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A" and ABS control
unit / HU coupler.
• ECM coupler "A": '°"(Page 1C-2)
• ABS control unit / HU coupler: <F(Page 4E-50)
3) Check for proper terminal connection to the ECM
coupler "A" and ABS control unit / HU coupler.
4) If connections are OK, check the following points.
1A-99 Engine General Information and Diagnosis:

---------------------------------------------------'
'
[ill DJ ----------'----'----------- ''
'
[TI] [I] ''
��
Gll
lHl
rnrn L..,-L-,-L--,-L..,,--J--,-.......,_"--.-'-.-'--,-L-...-L-r--'---r--'--r-'--,-L---r-L-,......_, I '
LC.......1."-'-----'-_,__...,___..____,____,____._-'---'--..._I-'----'-�--' I ,
·�----------�-_____,,
''
'
'
I-----•-----------------' '•••••-------- •---------•.J
B]] []] '' '''

fill [I]
B]] IT] '' ' ''
,
,' , 1
'''',
,,
B]] � 2 ,','

t,:,:,:,:,\,:,:,�,:,:,:,:,:,::'.':J �:1:1):1:I:� �:I:1:I):1:1:I:�

IM10L1110114-01

• Voltage
- Turn the ignition switch ON.
-----------------------' ' '------------------------�

t,:,:,:,:,\,:,:,�,: ,: ,:;�i-
- Between "T45" at the ECM coupler "A" (1)
'' '
:/ and ground: approx. 0 V
2

�:I:I�I:I:� @1:1:1:(I:1:1:�
1-------------------------------------------------- '
' ''

IM10L1110112-01

- Between "T45" at the ECM coupler "A" (1)

and ground: infinity
---------------------------------------------------'
''' '' ''
----------------------- _____________ ___________ .J

'' ' '''

''' ' ''
'' '
' '':
'
,,

(,:,:,:,:,\,:,:,�,:,:,:,:,:,:,-;,J @:I):1:I:� �:1:I:I):I:I:1:�

1 //
·�----------�-_____,,
' '
' '------------- ----------.J
I-----------------------
'' '''
'' ' ''
'
'' :
IM10L1110115-01

'''' Is check result OK?

,,
1 ,,:,,
Yes Replace the ECM and inspect it again.

t,:,:,:, :,t:,:,�,:,:,:,:,:,::�-,J �:1: I):I:I:� �:I:1: I):1:I:I:�

c:r(Page 1C-2)
If this OTC is detected again, replace the
IM10L1110113-01 ABS control unit/ HU and recheck OTC.
- Between 'T45" and other terminal (1) at ECM
coupler "A" (2): infinity No Repair or replace the "T45" wire at the
ECM coupler "A".
 Engine General Information and Diagnosis: 1A-100

DTC P2226 I P2228

BENM10L31104051
DTC Detecting Condition and Trouble Area
OTC detecting condition Trouble area
P2226: AP Sensor Circuit
AP sensor output voltage is higher than 4.80 V. .
• AP sensor

.
AP sensor circuit
(3 D/C detection logic) ECM
P2228: AP Sensor Circuit Low
AP sensor output voltage is lower than 0.10 V.
(3 D/C detection logic)

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

3
5V
5V
R T12__j

G/8 TB •
B/Br T28�

I•
- 5V

G/Y T9

IM10L1110011-01

1. IAP sensor 2. AP sensor 3. ECM

Troubleshooting
Step2
AP sensor ground circuit check
Step 1
AP sensor power supply circuit check 1) Measure the voltage between the "T3" at the AP
sensor coupler (1) and ground.
1) Turn the ignition switch OFF.
2) Disconnect the AP sensor coupler. <7(Page 1C-3) AP sensor power supply voltage
[Standard]: 4.5 - 5.5 V
3) Check for proper terminal connection to the AP
sensor coupler (1).
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the "T3" and "T1".
AP sensor power supply voltage
[Standard]: 4.5 - 5.5 V
IM06L1110002-01

Is check result OK?

Yes Repair or replace the "T1" wire at the AP

sensor coupler.
IM06L1110001-01 No Repair or replace the "T3" wire at the AP
Is check result OK? sensor coupler.

Yes Go to Step 3. Step3

AP sensor signal circuit check
No Go to Step 2.
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". <7(Page 1C-2)
1A-101 Engine General Information and Diagnosis:

3) Check for proper terminal connection to the ECM Step 4

coupler "A". AP sensor output voltage at idle speed check
4) If connections are OK, check the following points. 1) Turn the ignition switch OFF.
• Resistance 2) Measure the AP sensor voltage. Refer to "AP
- Between "T2" at the AP sensor coupler (1) Sensor Output Voltage" under <1F'(Page 1C-3).
and "T9" at the ECM coupler "A" (2): less
than 1 n Is check result OK?
Yes Replace the ECM and inspect it again.
-(Page 1C-2)
No Replace the AP sensor. w(Page 1C-3)

,------------------------- -------------------------
I
'

-----------------------,' , ,------------------------�
,
,' ,

t /,, frnl �
�,;,;,;,;,;,;,;,�,;,;,:,:,:,:,:,J �� iM10L1110116-01

- Between 'T2" at the AP sensor coupler (1)

and ground: infinity
- Between 'T2" and other terminal at AP/
sensor coupler (1): infinity

iM06L111 0004-01

• Voltage
- Turn the ignition switch ON.
- Between "T2" at the AP sensor coupler (1)
and ground: approx. 0 V

iM06L1110005-01

Is check result OK?

Yes Go to Step 5.
No Repair or replace the 'T2" wire at the AP
sensor coupler.
 Engine General Information and Diagnosis: 1A-102

DTC P2505
BENM10L31104052
OTC Detecting Condition and Trouble Area
DTC detecting condition
P2505: ECM Power Input Signal . Trouble area
ECM back-up power supply circuit
Power source for ECM is not supplied. • Fuel fuse (10 A)
(1 DIC detection logic) • ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

I
4
[A]
[B]

� R/W-------1� T100 �

3 .,..

IM10L1110117-01
[A]: To FP relay 2. Main fuse (30 A) 5. Power supply circuit
[BJ: To ignition switch and cooling fan relay 3. Battery
1. Fuel fuse (10 A) 4. ECM

Troubleshooting Yes Replace the ECM and inspect it again.

w(Page 1C-2)
Step 1
ECM power supply voltage check No Check fuel fuse (10 A) for blowout.
1) Turn the ignition switch OFF. • If fuel fuse (1O A) is not blown, check
2) Disconnect the ECM coupler "C". w(Page 1C-2) "T100" wire at the ECM coupler "C" for
open.
3) Check for proper terminal connection to the ECM
coupler "C". • If fuel fuse (10 A) is blown, check
"T100" wire at the ECM coupler "C" for
4) If connections are OK, measure the voltage
open and short circuit to ground.
between "T100" at the ECM coupler "C" (1) and
ground.
ECM power supply voltage
[Standard]: Battery voltage

Is check result OK?

1A-103 Engine General Information and Diagnosis:

OTC P2AOO
BENM10L31104053
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2A00: 02 Sensor Circuit Range I Performance Bank • Air intake system
1 Sensor 1 .
Exhaust system

.
H02 sensor #1 output voltage is stayed for specified time •
H02 sensor #1
or more.

.
(3 D/C detection logic) H02 sensor #1 circuit
ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

w W/Y

5 w Bl T79�

B 81/G
J; •
T24
7 T
Gr 8/Br T28
�

IM10L1110007--01
1. H02 sensor #1 4. Ignition switch 7. Battery
2. ECM 5. Main fuse (30 A)
3. H02 sensor heater drive circuit 6. Ignition fuse (10 A)

Troubleshooting

Step 1
DTC check
Is there any DTC(s) other than P2A00?

Yes Go to troubleshooting for applicable DTC.

No Go to Step 2.

Step2
Exhaust system and air intake system check
IM10L1110128-04
1) Check exhaust system and air intake system for
clogging and leakage. Is check result OK?
• Exhaust system: w(Page 1 K-7) Yes Go to Step 3.
• Check air intake system for clogging and
leakage. No Repair or replace defective parts.

Step 3
H02 sensor #1 signal circuit check
1) Check H02 sensor #1 signal circuit. Refer to
"Step 1" under "DTC P0130 / P0132 / P0133"
(Page 1A-44).
Is check result OK?
Yes Go to Step 4.
 Engine General Information and Diagnosis: 1A-104

No Repair or replace the defective wire Step 5

harness. OTC recheck
Step4 1) Replace the HO2 sensor #1. <r(Page 1C-9)
HO2 sensor #1 heater circuit check 2) Perform "DTC Check" (Page 1A-11) and recheck
1) Check HO2 sensor #1 heater circuit. Refer to DTC.
"Step 1" - "Step 2" under "DTC P0030" (Page 1A- Is DTC P2A00 still detected?
32).
Yes Replace the ECM and inspect it again.
Is check result OK? r:v-(Page 1C-2)
Yes Go to Step 5. End.
No
No Repair or replace the defective wire
harness.

OTC P2A03
BENM10L31104054
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2A03: 02 Sensor Circuit Range/ Performance Bank • Air intake system
2 Sensor 1 .
.
Exhaust system
HO2 sensor #2 output voltage is stayed for specified time
HO2 sensor #2
or more.
•
.
(3 DIC detection logic) HO2 sensor #2 circuit
ECM

Wiring Diagram
Refer to "Engine Control System Wiring Diagram" (Page 1A-6).

4
6
2

5 T78----0

T40--x..--►►
7 "T"

T28�

IM10L 1110009-01
1. HO2 sensor #2 4. Ignition switch 7. Battery
2. ECM 5. Main fuse (30 A)
3. HO2 sensor heater drive circuit 6. Ignition fuse (10 A)
1A-105 Engine General Information and Diagnosis:

Troubleshooting Step 3
HO2 sensor #2 signal circuit check
Step 1
·oTC check 1) Check H02 sensor #2 signal circuit. Refer to
"Step 1" under "OTC P0150 / P0152 / P0153"
Is there any DTC(s) other than P2A03? (Page 1A-46).
Yes Go to troubleshooting for applicable OTC. Is check result OK?
No Go to Step 2. Yes Go to Step 4.

Step2 No Repair or replace the defective wire

Exhaust system and air intake system check harness.
1) Check exhaust system and air intake system for
Step4
clogging and leakage.
HO2 sensor #2 heater circuit check
Exhaust system: w(Page 1 K-7)
1) Check H02 sensor #2 heater circuit. Refer to
• Check air intake system for clogging and "Step 1" - "Step 2" under "OTC P0050" (Page 1A-
leakage. 34).
Is check result OK?
Yes Go to Step 5.

No Repair or replace the defective wire

harness.

Step 5
DTC recheck
1) Replace the H02 sensor #2. <:lF(Page 1C-9)
2) Perform "DTC Check" (Page 1A-11) and recheck
IM10L1110128-04 OTC.
Is check result OK? Is DTC P2A03 still detected?
Yes Go to Step 3. Yes Replace the ECM and inspect it again.
<:lF(Page 1C-2)
No Repair or replace defective parts.
No End.

DTC U0073
BENM10L31104055
Refer to "Troubleshooting for Communication Bus Off' in Section 1 OH (Page 1OH-13).

DTC U0121
BENM 1OL31104056
Refer to "Troubleshooting for Lost Communication" in Section 1OH (Page 1OH-9).

DTC U0123
BENM10L31104057
Refer to ''Troubleshooting for Lost Communication" in Section 1 OH (Page 1 OH-9).

DTC U0155
BENM10L31104058
Refer to "Troubleshooting for Lost Communication" in Section 1OH (Page 1 OH-9).

Engine Control System Circuits Inspection

BENM10L31104059
Refer to "Precautions for Electrical Circuit Service" in Section 00 (Page 00-2).
Refer to "Precautions for Circuit Tester" in Section 00 (Page 00-8).
 Engine General Information and Diagnosis: 1A-106

Voltage and Signal Check

- [a
]
Q

IM10L 1110004-01

[A]: ECM coupler (View [al) 1. Coupler "A" 2. Coupler "B" 3. Coupler "C"

ECM terminal standard voltage table (reference)

NOTICE
Failure to observe "Precautions for Electrical Circuit Service" and "Precautions for Circuit Tester" may
cause damage to motorcycle or parts when measuring voltage.
Read "Precautions for Electrical Circuit Service" in Section 00 (Page 00-2) and "Precautions for Circuit
Tester" in Section 00 (Page 00-8) before starting the operations described below and follow all of the
instructions provided.

NOTE
• As each terminal voltage is affected by battery voltage, check that battery voltage is 12 V or more
when ignition switch is "ON".
• Voltage with asterisk(*) cannot be measured with voltmeter because it is pulse signal. Use
oscilloscope for its check.

Terminal No. Wire color Circuit Normal voltage Condition

Approx. 2.5 V
T1* BIBI CAN signal (Low) H Ignition switch: ON
Approx. 1.5 V
Immobilizer
T2 R/Y communication (If - -
equipped)
T3 - - - -
T4 - - - -
TS - - - -
T6 - - - -
T7 - - -
.
.
-
Ignition switch: ON
Engine: Stopped
Approx. 3.4 - 4.0 V
Barometric pressure: 100 kPa, 760
T8 G/B IAP sensor signal
. mmHg
Engine: Idle speed after warming
up
Approx. 0.79 - 4.0 V
• Barometric pressure: 100 kPa, 760
. mmHg

.
Ignition switch: ON
Approx. 3.4 - 4.0 V Barometric pressure: 100 kPa, 760
T9 G/Y AP sensor signal
mmHg
Approx. 0 V Ignition switch: OFF
T10 - - - -
1A-107 Engine General Information and Diagnosis:

Terminal No. Wire color Circuit Normal voltage Condition

.
Approx. 4.48 - 4.65 • Ignition switch: ON
V Gearshift lever: Fully upped

T11 G/B
Gearshift sensor
signal
Approx. 0.35 - 0.52 •
V .Ignition switch: ON
Gearshift lever: Fully downed

.
Approx. 2.38 - 2.62 • Ignition switch: ON
V Gearshift lever: Neutral position
Power source for Approx. 5 V Ignition switch: ON
T12 R
sensors Approx. 0 V Ignition switch: OFF
T13 - - - -
T14 - - - -
T15 - - - -
Approx. 6 V
CKP sensor signal
T16* G/W i! Engine: Idle speed after warming up
(+) Approx. -6 V
Approx. 3.5 V
T17* W/8 CAN signal (High) i! Ignition switch: ON
Approx. 2.5 V
Immobilizer
T18 G communication (If - -
equipped)
- -
.
T19 - -

.
Ignition switch: ON
Approx. 12 V
. Gear position: Other than neutral

.
T20 Bl Neutral signal
Ignition switch: ON
Approx. 0 V
Gear position: Neutral
T21 - - - -
T22 - - - -
T23 - - - -
Approx. 0 V
T24* B1/G HO2 sensor #1 signal i! Engine: Idle speed after warming up
Approx. 1 V
- - - -
T25
.
.
Ignition switch: ON

.
Approx. 3.3 V
IAT: 0 °C(32 °F)
T26 Dg IAT sensor signal Approx. 2.3 V
.. Ignition switch: ON
IAT: 20 °C (68 °F)
Approx. 0.5 V
Ignition switch signal Approx. 1 - 12 V
. Ignition switch: ON
IAT: 80 °C(176 °F)
Ignition switch: ON
T27 Gr
(If equipped) Approx. 0 V Ignition switch: OFF
T28 B/Br Sensor ground(E2) Approx. 0 V Any condition
T29 - - - -
T30 - - - -
T31 G/BI CKP sensor signal(-) Approx. 0 V Any condition
Approx. 5 V
T32* B/Y CMP sensor signal i! Engine: Running
Approx. 0 V
T33 - - - -
- - - -
T34
.
.
Ignition switch: ON
Approx. 12 V
T35 G
Side-stand switch
signal
Approx. 0 V
. Side-stand: On the ground
Ignition switch: ON
Side-stand: Retracted
 Engine General Information and Diagnosis: 1A-108

Terminal No. Wire color Circuit Normal voltage

. Condition
Ignition switch: ON
Approx. 12 V • Engine stop/ starter switch
T36 Y/G Starter switch signal ("START" position): Pushed
Engine stop/ starter switch: Other
Approx. 0 V
than "START" position
T37 - - - -
T38 - - - -
• Ignition switch: ON
Approx. 5 V
T39 W/R
Mode select coupler
. Mode select switch: OFF

.
(6P) Ignition switch: ON
Approx. 0 V
Mode select switch: ON
Approx. 0 V
T4 0* WIG HO2 sensor #2 signal H Engine: Idle speed after warming up
Approx. 1 V
- - - -
T4 1
.
.
Ignition switch: ON
Approx. 3.3 V
. ECT: 0 °C (32 °F)

.
Ignition switch: ON
T4 2 BIBI ECT sensor signal Approx. 2.3 V
. ECT: 20 °C (68 °F)

.
Ignition switch: ON
Approx. 0.5 V
. ECT: 80 °C (176 °F)
Approx. 0.6 V
.• Ignition switch: ON
Gear position: 1st
Approx. 1.2 V
.• Ignition switch: ON
Gear position: Neutral
Ignition switch: ON
Approx. 1. 7 V
• Gear position: 2nd

.
• Ignition switch: ON
T43 p GP sensor signal Approx. 2.4 V
. Gear position: 3rd
Ignition switch: ON

.
Approx. 3. 0 V
Gear position: 4 th
Ignition switch: ON
Approx. 3.7 V
•
. Gear position: 5th

.
Ignition switch: ON
Approx. 4.4 V
Gear position: 6th
T44 - - - -
Approx. 5 V
Rear wheel speed
T45* 81/W
sensor signal H Riding condition: W hile running
Approx. 0 V
T4 6 - - - -
Approx. 5 V
Front wheel speed
T47* BI/B
sensor signal H Riding condition: W hile running
Approx. 0 V
T4 8 - - - -
Power source for Approx. 5 V Ignition switch: ON
T4 9 R/Y accelerator position
Approx. 0 V Ignition switch: OFF
sensor (main)
.
.
Ignition switch: ON
Approx. 12 V Engine stop/ starter switch: "RUN"
TSO W/R
Engine stop switch
. position

.
signal Ignition switch: ON
Approx. 0 V Engine stop/ starter switch:
"STOP" position
P ower source for TP Approx. 5 V Ignition switch: ON
T51 R
sensor Approx. 0 V Ignition switch: OFF
1A-109 Engine General Information and Diagnosis:

Terminal No. Wire color Circuit Normal voltage Condition

T52 - - - -
T53 - - - -
T54 - - - -
Battery voltage Ignition switch: ON

.
T55 W/Y Power source
Approx. O V Ignition switch: OFF

.
Approx. 0.485- Ignition switch: ON
Accelerator position 0.635 V Throttle grip: Released
T56 P/W •
.
sensor (main) signal Ignition switch: ON
Approx. 3.51 V

Approx. 3.635- . Throttle grip: Fully open position

Ignition switch: ON
TP sensor (main) 3.785 V • Throttle grip: Released
T57 B
signal • Ignition switch: ON
Approx. 0.70 V
Throttle grip: Fully open position
T58 - - - -
Power source for Approx. 5 V Ignition switch: ON
T59 RIG accelerator position
Approx. 0 V Ignition switch: OFF
sensor (sub)
.
.
Ignition switch: ON
Approx. 12 V
Immobilizer indicator
. Immobilizer indicator: OFF

.
T60 Gr
(If equipped) Ignition switch: ON
Approx. 0 V
Immobilizer indicator: ON
T61 - - - -
T62 - - - -
T63 G TP sensor ground Approx. 0 V Any condition
T64 - - -
Approx. 0.825 - . -
Ignition switch: ON
Accelerator position 0.975 V • Throttle grip: Released
T65 BIBI •
.
sensor (sub) signal Ignition switch: ON
Approx. 4.59 V
Throttle grip: Fully open position
T66 - - - -
T67 - - - -
Accelerator position
T68 Br/W Approx. 0 V Any condition
sensor (main) ground
- - - -
T69
.
.
Approx. 4.235- Ignition switch: ON

T70 w TP sensor (sub) 4.385 V

. Throttle grip: Released

.
signal Ignition switch: ON
Approx. 1.30 V
Throttle grip: Fully open position
Accelerator position
T71 B/Lg Approx. 0 V Any condition
sensor(sub)ground
• Ignition switch: ON
Approx. 12 V • Clutch lever position switch: OFF
T72 Br
Clutch lever position
. (Clutch lever is released)

.
switch signal Ignition switch: ON
Approx. 0 V Clutch lever position switch: ON
(Clutch lever is grasped)
T73 - - - -
- - - -
T74
.
.
Ignition switch: ON
Approx. 0 V
Throttle grip: Fully closed position
T75* B/Lg
Throttle valve motor
Approx. 12 V .
.
(open) Ignition switch: ON
u Throttle grip: Fully opened position
Approx. 0 V
T76 - - - -
T77 - - - -
 Engine General Information and Diagnosis: 1A-110

Terminal No. Wire color Circuit Normal voltage Condition

HO2 sensor heater Approx. 12 V Ignition switch: ON
T78 w #2 Approx. OV Ignition switch: OFF
HO2 sensor heater Approx. 12 V Ignition switch: ON
T79 Bl Ignition switch: OFF
#1 Approx. 0V
Approx. 0V
T80* G Ignition coil #41 H Engine: Running
Approx. 12 - 14 V
Approx. 0 V
T81* y Ignition coil #31 u Engine: Running
Approx. 12 - 14 V
Approx. 0 V
T82* B Ignition coil #21 i! Engine: Running
Approx. 12 - 14 V
Approx. 0 V
T83* W/BI Ignition coil #11 i! Engine: Running
Approx. 12 - 14 V
.
.
Approx. 12 V Ignition switch: ON
i!
T84* P/W
Throttle valve motor Approx. 0 V
. Throttle grip: Fully closed position

.
(close) Ignition switch: ON
Approx. 0 V
Throttle grip: Fully opened position
T85 - - - -
Approx. 12 V Ignition switch: ON
T86 B/Y Starter relay
Approx. 0 V
.
Starter motor: Running
Engine stop / starter switch: "RUN"
position
Approx. 12 V . Ignition switch: For a few seconds
T87* Gr/R
Primary fuel injector
#4
Approx. 12 V
. after turned ON
Engine: Stopped

u Engine: Running
Approx. 0 V
. Engine stop / starter switch: "RUN"

.
position
Approx. 12 V Ignition switch: For a few seconds

.
Primary fuel injector after turned ON
T88* Gr/Y
#3 Engine: Stopped
Approx. 12 V
i! Engine: Running
Approx. 0 V
. Engine stop / starter switch: "RUN"
position
Approx. 12 V • Ignition switch: For a few seconds
T89* Gr/B
Primary fuel injector
#2
Approx. 12 V
. after turned ON
Engine: Stopped

i! Engine: Running
Approx. 0 V
• Engine stop / starter switch: "RUN"

.
position
Approx. 12 V Ignition switch: For a few seconds
T90* Gr/W
Primary fuel injector
#1
Approx. 12 V
. after turned ON
Engine: Stopped

i! Engine: Running
Approx. 0 V
1A-111 Engine General Information and Diagnosis:

Terminal No. Wire color Circuit Normal voltage Condition

Ignition system
T91 8/W Approx. 0 V Any condition
ground (E03)
Power source for
T92 R/W Battery voltage Any condition
throttle body
Approx. 12 V
.
Ignition switch: ON

. Cooling fan: Running

T93 G/R Cooling fan relay Ignition switch: ON
Approx. 0 V
Approx. 12 V
. Ignition switch: ON
Ignition switch: ON

PAIR control solenoid

. PAIR control solenoid valve: ON
T94 W/8 (PAIR control solenoid valve is
valve Approx. 0 V
operated using "PAIR control
solenoid drive control" on "Active

. control" of SDS-I1.)
Engine stop / starter switch: "RUN"

.
position
Approx. 12 V Ignition switch: For a few seconds

.
.
after turned ON
Engine: Stopped

.
Engine: 4800 r/min or more
Secondary fuel
T95* Lg/R Throttle position angle: 38% or
injector#4
more (The throttle position angle
Approx. 12 V
(Absolute throttle position angle
i! bank1) can be checked with the
Approx. 0 V
.
"Data monitor" function of SDS-I1.)
Gear position: Other than neutral

. position
Engine stop / starter switch: "RUN"

Approx. 12 V . position
Ignition switch: For a few seconds

.
after turned ON

. Engine: Stopped

.
Engine: 4800 r/min or more
Secondary fuel
T96* Lg/8 Throttle position angle: 38% or
injector#3
more (The throttle position angle
Approx. 12 V
(Absolute throttle position angle
i! bank1) can be checked with the
Approx. 0 V
"Data monitor" function of SDS-II.)
• Gear position: Other than neutral

. position
Engine stop / starter switch: "RUN"

. Ignition switch: For a few seconds

position
Approx. 12 V

. Engine: Stopped
after turned ON

. Engine: 4800 r/min or more

T97* Lg/W
Secondary fuel
injector #2 . Throttle position angle: 38% or
more (The throttle position angle
Approx. 12 V
(Absolute throttle position angle
i! bank1) can be checked with the
Approx. 0 V
.
"Data monitor" function of SDS-II.)
Gear position: Other than neutral
position
 Engine General Information and Diagnosis: 1A-112

Terminal No. Wire color Circuit Normal voltage

. Condition
Engine stop / starter switch: "RUN"
position
Approx. 12 V • Ignition switch: For a few seconds

.
.
after turned ON
Engine: Stopped

T98* Lg
Secondary fuel
injector #1
. Engine: 4800 r/min or more
Throttle position angle: 38% or
more (The throttle position angle
Approx. 12 V
(Absolute throttle position angle
H bank1) can be checked with the
Approx. 0 V
.
"Data monitor" function of SDS-II.)
Gear position: Other than neutral
position
T99 - - - -
Power source for
T100 R/W Battery voltage Any condition
back-up
Approx. 12 V Ignition switch: ON
• Ignition switch: ON
. EVAP system purge control
EVAP system purge solenoid valve: ON (EVAP system
T101 G
control solenoid valve Approx. 0 V purge control solenoid valve is
operated using "EVAP purge valve
operating control" on "Active
control" of SDS-I1.)
T102 - - -
. -
Engine stop/ starter switch: "RUN"

T103 Y/8 FP relay

Approx. 12 V . position
Ignition switch: A few seconds

.
after turning ON
Engine: Stopped
Approx. 0 V Engine: Running
T104 - - - -
- - - -
T105
. Engine stop/ starter switch: "RUN"

T106 Y/R
Power source for fuel
injectors and fuel
Approx. 0 V . position
Ignition switch: A few seconds

.
after turning ON
pump
Engine: Stopped
Approx. 12 V Engine: Running
General power
T107 8/W Approx. O V Any condition
ground (E01)
T108 B/W
Control circuit ground Approx. 0 V Any condition
(E1)
1A-113 Engine General Information and Diagnosis:

ECM Power Supply and Ground Circuit Check BENM10L31104060

Circuit Diagram

19
15
T100 1-'RJW..:..:..:.____________________----<:r-..
RJW -----_.J
T92 1---

J.
2
r7--------<....---'- R"--l T12 _j
BfY T3Z TSS W /Y
(J)
L-..1--- T84 1-'P-'-N/
'-'--------lf---� 20
3 G/B TB L T51 l--'R.,___ _--1--p------j�
13
17
4 G/Y TS
22
G/B T11 18
5

21 B/Br T28
9
l
,_ _______ '--< T43
P
6
8 1
l--------= "--i T20

"t: 12V
"f: 5V
-[a]
Q

IM10L1110119-01
[A]: ECM coupler (View [al) 8. Accelerator position sensor (sub} 17. Main fuse (30 A)
[8]: T o [b] 9. Accelerator body assembly 18. Battery
1. ECM 10. TP sensor (main) 19. To FP relay
2. CMP sensor 11. TP sensor (sub) 20. To HO2 sensor, Engine stop/ starter switch
("RUN / STOP" position}, cooling fan relay,
EVAP system purge control solenoid valve
(If equipped) and PAIR control solenoid
valve
3. IAP sensor 12. T hrottle valve motor 21. To each sensor
4. AP sensor 13. Throttle body 22. CPU
5. Gearshift sensor 14. Ignition switch 23. Power supply circuit
6. GP sensor 15. Fuel fuse (10 A) 24. T hrottle valve motor drive circuit
7. Accelerator position sensor (main) 16. Ignition fuse (10 A)
______________________ ___________________ -
Troubleshooting
Engine General Information and Diagnosis:
....;;,
1A-114

NOTE ',-----------
• As each terminal voltage is affected by
battery voltage, check that battery voltage
is 12 V or more when ignition switch is
"ON".
• Before performing, check that related
fuses of ECM power circuit have not blown
out.
'
If any fuse has blown out, replace the fuse ----------- �--------------�'
and check circuits connected to the blown ',, \ 1 2
fuse for short circuit to ground.

[,:,:,:,:,:,:,:,�,:,:,:,:,:,:,:, �::,I�1:/0 �:1:1:l�I:/1:�

J
Step 1
ECM power supply circuit check .:
.,,
., .. ;�
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "B" and ECM coupler
"C". w(Page 1C-2)
3) Check for proper terminal connection to ECM
coupler "B" and ECM coupler "C".
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the following
terminal at the ECM coupler "B'' (1) and ECM
coupler "C" (2).
• Between the "T55" and ''T91". IM10L 1110120-01
• Between the "T55" and ''T107". Is check result OK?
• Between the ''T55" and "T108".
Yes Go to Step 3.
ECM power supply voltage
[Standard]: Battery voltage No Go to Step 2.

Step2
ECM ground circuit check
1) Measure the voltage between "T55" at the ECM
coupler "B" (1) and ground.
ECM power supply voltage
[Standard]: Battery voltage

I- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

------------
'
----------------
'

[,:,:,:,:,:,:,:,�1:,:,:,:,:,:,::J. :�:1:1 :(1:1:0 �:1:1:1 :(1:1:I:�

IM10L1110121-01

Is check result OK?

1A-115 Engine General Information and Diagnosis:

Yes Repair or replace defective ground wire • GP sensor: w(Page 1C-15)

harness. • Gearshift sensor: c;r (Page 1 C-15)
No Check "T55" wire for open, short circuit to 4) Check for proper terminal connection to each
battery and short circuit to ground. If "T55" sensor couplers.
wire is in good condition, check the 5) If connections are OK, turn the ignition switch ON.
following parts. 6) Measure the sensor power supply voltage.
• Wire for open, short circuit to battery
Sensor power supply voltage
and short circuit to ground of the wire
[Standard]: 4.5 - 5.5 V
harness between battery and ignition
switch. • IAP sensor coupler (1): Between the "T3" and
• Fuses "T1".

• Ignition switch

Step 3
ECM back-up power supply circuit check
1) Turn the ignition switch OFF.
!M06L1110001-01
2) Measure the voltage between "T100" at the ECM
• AP sensor coupler (1): Between the 'T3" and
coupler "C" (1) and ground.
"T1".
ECM power supply voltage
[Standard]: Battery voltage

�------------------------------------
'

!M06L1110001-01

• Accelerator position sensor coupler (1)

- Accelerator position sensor (main): Between
the "T6" and "T5" .
- Accelerator position sensor (sub): Between
the ''T3" and "T2".
,----------------

�Vg
t,:,:,:,:,:,:V,:1�1:,:,:,:,:,:,:,J �� !M10L1110122-01

Is check result OK?

IM10L111012,J-01
Yes Go to Step 4.
• TP sensor coupler (1 ): Between the 'T2" and
No Check 'T100" wire for open and short "T4".
circuit to ground. If "T100" wire is in good
condition, check the fuse.

Step4
Sensor power supply circuit check
1) Turn the ignition switch OFF.
2) Connect the ECM coupler "B" and ECM coupler IM10L1110017-01
"C". c:r(Page 1C-2)
• CMP sensor coupler ( 1): Between the "T1" and
3) Disconnect the following sensor couplers. "T3".
• IAP sensor: c;r(Page 1C-4)
• AP sensor: w(Page 1C-3)
• Accelerator position sensor: c;r(Page 1C-13)
• TP sensor: w(Page 1C-7)
• CMP sensor: cir-(Page 1C-11)
 Engine General Information and Diagnosis: 1A-116

- Accelerator position sensor (main): Between

the "T6" and ground.
- Accelerator position sensor (sub): Between
the ''T3" and ground.

11 I [+] 16)
IM10L1110045-01
1 2 5

J18®®1 �
• GP sensor coupler (1): Between the "T1" and
"T4".

IM10L1110124-01

• TP sensor coupler (1): Between the "T2" and

ground.

IM10L1110077-02

• Gearshift sensor coupler (1): Between the "T4"

and "T1".

IM10L 1110018-01

• CMP sensor coupler (1): Between the "T1" and

ground.

IM10L 1110068-01

Is check result OK?

IM10L1110046-01
Yes ECM power supply and ground circuits are
in good condition. • GP sensor coupler (1): Between the ''T1" and
ground.
No Go to Step 5.

Step 5
Sensor ground circuit check
1) Measure the sensor power supply voltage. IM10L1110078-02

• Gearshift sensor coupler ( 1 ): Between the "T4"

Sensor power supply voltage
and ground.
[Standard]: 4.5 - 5.5 V
• IAP sensor coupler (1): Between the "T3" and
ground. 1 2

1lfffi
34�
IM10L1110069-01

Is check result OK?

Yes Repair or replace the defective ground

IM06L1110002-01 wire harness.
• AP sensor coupler (1): Between the ''T3" and
No Check defective sensor power supply
ground.
circuit wire for open, short circuit to battery
and short circuit to ground. If sensor
power supply circuit wire is in good
condition, replace the ECM and recheck
ECM power supply and ground circuits.
�(Page 1C-2)

IMOSL1110002-01

• Accelerator position sensor coupler (1)

1A-117 Engine General Information and Diagnosis:

Special Tools and Equipment

Special Tool
BENM10L31108001

09904-41031 09904-41041
SDS-11 set SDS-II (oscilloscope) set
w(Page 1A-11) / w(Page 1A-11) /
w(Page 1A-12) w(Page 1A-12)

09904-41051 09904-41071
Conversion cable Conversion cable (ISO)
w(Page 1A-4) c:u-(Page 1A-4) /
w(Page 1A-11) /
w(Page 1A-12)

09930-83130
Mode selection switch (ISO)
w(Page 1A-3) /
<:r(Page 1A-12)
 Emission Control Devices: 1 B-1

Emission Control Devices

Precautions
Precautions for Emission Control Devices
BENM10L31200001
Refer to "General Precautions" in Section 00 (Page 00-1 ).

Schematic and Routing Diagram

PAIR System Hose Routing Diagram
BENM10L31202001

r - - -
[A] ---' - ---[BJ - -- [C] --- -D ---
[ J
T - - - r- - - 7

+
I
"b"
I I I� "b"

"Q[�i
[FJ iiB"b "b "
i-tr.. ¢
I I I I
L - - - - - - - -•- - - - - - - - � - - - - - - - _1_ - - - - - - - J

� -�������
-----------------------
I [EJ 7
FWD

----------------------�
IM1 0L1120003--01
1 B-2 Emission Control Devices:

[A]: View [a] lijj[I]: Face the yellow mark to backward of the PAIR 7. PAIR reed valve plate
control solenoid valve.
[BJ: View [bl fijj [J] Push in the PAIR reed valve plate until the two 8. PAIR control solenoid valve bracket
points contact the cylinder head cover.
[C]: View[c] 1. PAIR hose (to air cleaner box) "a": Approx. 45°
[DJ: View [d] 2. PAIR hose (to left PAIR reed valve cover) "b": Approx. o•
[E]: View[e] 3. PAIR hose (to right PAIR reed valve cover) �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
[ F]: Upper side 4. PAIR control solenoid valve C!lml: 5.5 N-m (0.56 kgf-m, 4.05 lbf-ft)
fijj [G]: Face the white mark upward. 5. PAIR reed valve cover
fijj [H]: Face the white mark to right side. 6. PAIR reed valve

PCV Hose Routing Diagram

BENM10L31202002
Refer to "Intake System Construction" in Section 1 D (Page 1 D-5).

EVAP Canister Hose Routing Diagram

BENM10L31202003

r.i [E]

C •.. 2
r.l �I

IM10L2120001-01
 Emission Control Devices: 1 B-3

[AJ: View[aJ �[MJ: Face the white mark to right side. � 10. Clamp
: Face the locked part of clamp to right
side.
Face the tip of clamp downward.
[BJ: View[bJ �[NJ: Face the yellow mark upward. 11. Main harness
[CJ: View[ cJ f,.jj[O]: Face the white mark to left side. 12. Battery minus lead wire
[DJ: Upper side 1. EVAP surge No.1 hose 13. Rear wheel speed sensor lead wire
�[EJ: Align the EVAP canister No. 1 bracket with the 2. EVAP surge No.2 hose 14. Rear brake light switch lead wire
edge of the rear seat cushion plate.
fllll[F]: Align the EVAP canister No.2 bracket with the 3. EVAP purge No.1 hose 15. Seat rail tube
seat rail tube.
f,.jj[GJ: Do not intersect the EVAP surge No.2 hose 4. EVAP purge No.2 hose 16. Fuel tank
with the EVAP purge No.1 hose.
f,.jj [H]: Pass the EVAP surge No.2 hose and EVAP 5. EVAP canister 17. To throttle body
purge No.1 hose under the battery minus lead
wire and main harness.
(ij[IJ: The EVAP hose must not be visible in hole of 6. EVAP canister No.1 bracket f..ii 18. Clamp
the frame cover. : Clamp the starter motor lead wire
and protector part of the EVAP purge
No.2 hose.
r.ii [J]: Face the clamp end to right side. 7. EVAP canister No.2 bracket 19. Starter motor lead wire
rij [KJ: Face the clamp end upward. 8. EVAP system purge control solenoid valve �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
rij[LJ: Face the clamp end to left side. �9. Clamp
: Face the locked part of clamp to left side.
Face the tip of clamp to left side.
1B-4 Emission Control Devices:

Repair Instructions
PAIR Reed Valve Removal and Installation
BENM10L31206001
Refer to "PAIR System Hose Routing Diagram" (Page
1 B-1).

Removal
1) Remove the air cleaner box. """(Page 1 D-6)
2) Disconnect the PAIR hoses (1) from the PAIR reed
valve covers.

Installation
Install the PAIR reed valve in the reverse order of
removal. Pay attention to the following points:
• Push in the PAIR reed valve plate (1) until the two
points (2) contact the cylinder head cover.

-� IM10L 1120005-01

3) Remove the bolts (1) and PAIR reed valve covers

(2).

IM10L1120012-01
• Tighten PAIR reed valve cover bolts (1) to the
specified torque.
Tightening torque
PAIR reed valve cover bolt (a): 10 N·m (1.0 kgf-m,
IM10L1120009-01
7.5 lbf-ft)
4) Remove the PAIR reed valves (1).

IM10L1120010-01
• Connect the PAIR hoses properly. Refer to "PAIR
5) Remove the PAIR reed valve plates (1).
System Hose Routing Diagram" (Page 1 B-1).
 Emission Control Devices: 1 B-5

PAIR Control Solenoid Valve Removal and

Installation
BENM10L31206002
Refer to "PAIR System Hose Routing Diagram" (Page
1 B-1).

Removal
1) Remove the air cleaner box. <7(Page 1 0-6)
2) Disconnect the PAIR control solenoid valve coupler
(1).

Installation
Install the PAIR control solenoid valve in the reverse
order of removal. Pay attention to the following point:
• Tighten the PAIR control solenoid valve bracket bolts
(1) to the specified torque.
Tightening torque
PAIR control solenoid valve bracket bolt (a): 5.5
N·m (0.56 kgf-m, 4.05 lbf-ft)

3) Disconnect the PAIR hoses (1) from PAIR control

solenoid valve.

IM10L1120018-01

2. PAIR control solenoid valve bracket

IM10L1120015-01
• Connect the PAIR hoses properly. Refer to "PAIR
4) Remove the PAIR control solenoid valve (1) from its
System Hose Routing Diagram" (Page 1 B-1).
bracket.
PAIR System Inspection
BENM10L31206003
Refer to "PAIR (air supply) System" in Section OB (Page
08-13).

PAIR Hose Removal and Installation

BENM10L31206004
Refer to "PAIR System Hose Routing Diagram" (Page
18-1).

IM10L1120016-01
5) Remove the PAIR control solenoid valve bracket as
follows, if necessary.
a) Remove the radiator heat shield. <7(Page 1 F-8)
b) Remove the bolts (1) and PAIR control solenoid
valve bracket (2).
Removal
1) Remove the air cleaner box. w(Page 10-6)
2) Disconnect the PAIR hoses (1) from the PAIR reed
valve covers (2).
3) Disconnect the PAIR hoses from PAIR control
solenoid valve (3).
1 B-6 Emission Control Devices:
IM10L1120019-01
4) Remove the PAIR hoses.
Installation
Install the PAIR hoses in the reverse order of removal.
Pay attention to the following points:
• Connect the PAIR hoses properly. Refer to "PAIR
System Hose Routing Diagram" (Page 18-1).
PCV Hose Inspection
BENM10L31206005
1) Lift and support the fuel tank. <T(Page 1G-12)
2) Inspect the PCV hose (1) for wear and damage.
If it is worn or damaged, replace the PCV hose with
a new one.
3) Check that the PCV hose is securely connected.
IM10L1120020-01
4) After finishing the PCV hose inspection, install the
removed parts.
PCV Hose Removal and Installation
BENM10L31206006
Refer to "Intake System Construction" in Section 1 D
(Page 1 D-5).
Removal
1) Lift and support the fuel tank. <T(Page 1G-12)
2) Disconnect the PCV hose (1) from air cleaner box
(2).
3) Disconnect the PCV hose from PCV reed valve
cover (3).
IM10L1120021-01
4) Remove the PCV hose.
Installation
Install the PCV hose in the reverse order of removal. Pay
attention to the following points:
• Connect the PCV hose properly. Refer to "Intake
System Construction" in Section 1 D (Page 10-5).
PCV Reed Valve / PCV Cover Removal and
Installation
BENM10L31206007
Removal
1) Lift and support the fuel tank. <T(Page 1G-12)
2) Disconnect the PCV hose from PCV reed valve
cover. <:ir(Page 18-6)
3) Remove the bolts (1) and PCV reed valve cover (2).
IM10L 1120022-01
4) Remove the PCV reed valve (1).
IM10L1120023-01
5) Remove the bolts (1) and PCV cover (2).
 Emission Control Devices: 1B-7

• Tighten the PCV reed valve cover bolts (1) to the

specified torque.
Tightening torque
PCV reed valve cover bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

IM10L1120024-01

3. Ground wire harness

Installation
Installation is in the reverse order of removal.
Pay attention to the following points:
• Apply sealant to the mating surface of the PCV cover
(1 ).
NOTE
• Make surfaces free from moisture, oil dust
and other foreign materials.
• Spread on surface thinly to form an even
layer and assemble the PCV cover within a
few minutes.
Sealant 99000-31140 (SUZUKI BOND 1207B)
• Connect the PCV hose properly. Refer to "Intake
System Construction" in Section 1 D (Page 1 D-5).
PCV Reed Valve / PCV Cover Inspection
BENM10L31206008
PCV Reed Valve
1) Remove the PCV reed valve. Refer to "PCV Reed
Valve/ PCV Cover Removal and Installation" (Page
18-6).
2) Inspect the PCV reed valve for carbon deposit. If
carbon deposit is found in the PCV reed valve,
replace the PCV reed valve with a new one.

"A"

IM10L1120025-01

• Tighten the PCV cover bolts (1) to the specified IM10L1120028-01

torque.
PCV Cover
Tightening torque
1) Remove the PCV cover. Refer to "PCV Reed Valve/
PCV cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf.ft)
PCV Cover Removal and Installation" (Page 1 B-6).
2) Inspect the PCV cover for carbon deposit. If carbon
1, (a)
deposit is found in the PCV cover, remove the
carbon.

1, (a)
IM10L 1120026-01

2. PCVcover 3. Ground wire harness

1 B-8 Emission Control Devices:

8) Disconnect the EVAP surge No.1 hose and EVAP

surge No.2 hose from EVAP hose joint (2), if
necessary.

IM10L1120029-01

EVAP System Removal and Installation

BENM10L31206009
Refer to "EVAP Canister Hose Routing Diagram" (Page
1 B-2).
Hose
Removal
1) Lift and support the fuel tank. w(Page 1G-12)
2) Remove the frame cover assembly: w(Page 90-51)
3) Disconnect the EVAP purge No.1 hose (1) and EVAP
purge No.2 hose (2) from EVAP system purge
control solenoid valve (3).
4) Disconnect the EVAP purge No.2 hose from vacuum
line of throttle body.
5) Disconnect the EVAP surge No.1 hose (4) from fuel
tank.
9) Remove the EVAP hoses.
Installation
Install the EVAP hoses in the reverse order of removal.
Pay attention to the following points:
• Connect the EVAP hoses properly. Refer to "EVAP
Canister Hose Routing Diagram" (Page 1 B-2).
EVAP Canister
Removal
1) Remove the frame cover assembly. @°(Page 90-51)
2) Disconnect the EVAP surge No.2 hose (1) and EVAP
purge No.1 hose (2) from EVAP canister (3).

IM10L 1120031-02

3) Remove the EVAP canister (1) from its bracket.

6) Disconnect the EVAP surge No.2 hose (1) and EVAP
purge No.1 hose (2) from EVAP canister (3).

7) Release the clamps (1).


Installation
Install the EVAP canister in the reverse order of removal.
Pay attention to the following point
• Connect the EVAP surge No.2 hose and EVAP purge
No.1 hose to EVAP canister as shown in the "EVAP
Canister Hose Routing Diagram" (Page 1B-2).
EVAP System Purge Control Solenoid Valve
Removal
1) Lift and support the fuel Tank. <7(Page 1G-12)
2) Remove the clamps (1) from accelerator body
assembly bracket.
3) Disconnect the EVAP purge No.1 hose (1) and EVAP
purge No.2 hose (2) from EVAP system purge
control solenoid valve (3).
4) Disconnect the EVAP system purge control solenoid
valve coupler (1 ).
5) Remove the accelerator body assembly bracket
bolts (1).
Emission Control Devices: 1 B-9
NOTE
Do not drop the accelerator body assembly
bracket spacers.
6) Move the accelerator body assembly bracket outside
of the motorcycle.
7) Remove the nut (1) and remove the EVAP system
purge control solenoid valve (2) from its bracket.
NOTE
Be careful not to expose the accelerator body
assembly to an excessive shock.
Installation
Install the EVAP system purge control solenoid valve in
the reverse order of removal. Pay attention to the
following point:
• Tighten the EVAP system purge control solenoid valve
nut (1) to the specified torque.
Tightening torque
EVAP system purge control solenoid valve nut
(a): 6.7 N·m (0.68 kgf-m, 4.95 lbf-ft)
1 B-1 O Emission Control Devices:

IM10L1120039-01

• Tighten the accelerator body assembly bracket bolts • Connect the EVAP purge No.1 hose and EVAP purge
(1) to the specified torque. No.2 hose as shown in the "EVAP Canister Hose
Routing Diagram" (Page 1 B-2).
Tightening torque
Accelerator body assembly bracket bolt (a): 10
Fuel Shut-off Valve
N·m (1.0 kgf-m, 7.5 lbf-ft)
For fuel tank cap removal and installation, refer to
<T(Page 1 G-12).

EVAP System Inspection

BENM10L31206010
Refer to "Evaporative emission control system" in
Section OB (Page 08-8).

Specifications
Tightening Torque Specifications
BENM10L31207001
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
PAIR reed valve cover bolt 10 1.0 7.5 <?'(Page 18-4)
PAIR control solenoid valve bracket bolt 5.5 0.56 4.05 '7(Page 18-5)
PCV cover bolt 10 1.0 7.5 <7(Page 18-7)
PCV reed valve cover bolt 10 1.0 7.5 (r'(Page 1B-7)
EVAP system purge control solenoid valve nut 6.7 0.68 4.95 <?'(Page 18-9)
Accelerator body assembly bracket bolt 10 1.0 7.5 cr(Page 1B-10)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"PAIR System Hose Routing Diagram" (Page 1B-1)
"EVAP Canister Hose Routing Diagram" (Page 1B-2)
"Fasteners Information" in Section 0C (Page OC-6)

Special Tools and Equipment

Recommended Service Material
BENM10L31208001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI BOND 12078 P/No.: 99000-31140 <T(Page 1B-7)
 Engine Electrical Devices: 1C-1

Engine Electrical Devices

Precautions
Precautions for Engine Electrical Device
BENM1 0L31300001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Electrical Circuit Service" in Section 00
(Page 00-2), "Precautions for Circuit Tester" in Section 00 (Page 00-8) and "Precautions for SDS-11" in Section 00
(Page 00-9).

Precautions for Electric Throttle Control System

BENM10L31300002
A CAUTION
If you touch the throttle valve with your finger when the ignition switch is "ON" and the throttle grip is
opened, your finger may be pinched in the gap between the throttle valve and throttle body housing
when the throttle grip is released.
Never touch the throttle valve with your finger when the ignition switch is "ON" and the throttle grip is
opened.

NOTICE
• Failure to take proper precautions when handling the throttle body may lead to malfunction of the
throttle body or damage to its components.
- Do not disassemble the throttle body.
- Do not drop or otherwise expose the throttle body to large shock.
- Keep the throttle body housing and/or throttle valve free of dust, metallic particles or other
foreign materials.
- Do not apply undue forces to the throttle valve when checking operation of the throttle valve or
performance of the TP sensor.
• Failure to take proper precautions when handling the accelerator body assembly may lead to
malfunction of the accelerator body assembly or damage to its components.
- Do not remove the accelerator position sensor from the accelerator body assembly.
- Do not drop or otherwise expose the accelerator body assembly to large shock.

Component Location
Engine Electrical Components Location
BENM10L31303001
Refer to "Electrical Components Location": Service Manual Information in Section 0A (Page 0A-10).

Diagnostic Information and Procedures

Engine Symptom Diagnosis
BENM10L31304001
Refer to "Engine Symptom Diagnosis" in Section 1A (Page 1A-25).
1C-2 Engine Electrical Devices:

Repair Instructions
ECM Removal and Installation
BENM1 0L31306001
Removal
NOTICE
Be careful not to disconnect the ECM coupler
at least 5 seconds after ignition switch is
turned to OFF. If the ECM coupler is
disconnected within 5 seconds after ignition
switch is turned to OFF, there is a possibility
of an unusual valve position being written in
ECM and causing an error of throttle valve IM10L1130004-01
operation. 5) Remove the ECM.
1) Remove the front seat. eu-(Page 9D-34) Installation
2) Disconnect the battery(-) lead wire. eu-(Page 1J-8) Install the ECM in the reverse order of removal. Pay
3) Detach the band(1). attention to the following point:
4) Disconnect the ECM couplers from the ECM. At this • Connect the ECM coupler "A" as follows.
time, disconnect the ECM coupler "A"(2) as follows. a. Make sure that lock lever(1) are in unlock
position.
b. Insert ECM coupler "A"(2) to ECM(3) until they
stop with lock lever in unlocked position.

a) Push the lock(1) to release locking of the lock

lever(2). IM10L1130005-01

c. Turn the lock lever(1) in direction of arrow to lock

the ECM coupler "A" securely.

IM10L1130002-01

b) Turn the lock lever(1) in arrow direction until it IM10L1130006-01

stops. d. Make sure that lock lever(1) are in lock position.

IM10L1130003-01

c) Disconnect the ECM coupler "A" (1) from ECM IM10L1130007-01

(2).
 Engine Electrical Devices: 1C-3

• After ECM is replaced with new one, perform the If the voltage is not within the specified value,
following procedure. replace the AP sensor. cir(Page 1C-3)
a. Perform the "Reprogramming" to ECM. Referring Special tool
to the Suzuki SDS-11 reprogramming software (A): 09917-47020
operator's manual for further details.
b. Perform the key registration.(if equipped)

ECM Learned Value Reset

BENM 1OL31306002
Perform ECM learned value reset whenever one of the
following operations has been performed.
Operation Item to reset
Throttle body is replaced TP fully closed learned
value reset
ISC aperture learned value
reset
Accelerator body assembly Reset closed accel position
is replaced
HO2 sensor is replaced Long term fuel trim reset
(HO2 sensor feedback
learned value)
IM10L1130008-02
IMU is replaced Reset IMU learning value
GP sensor is replaced Reset gear position learned
ATOMOSPHERIC OUTPUT
value ALTITUDE (Reference) PRESSURE VOLTAGE
m ft kPa mmHg V

1) Turn the ignition switch OFF. 0-610 0- 2001 100-94 760-705 3.4 -4.0
611-1524 2005-5000 94-85 705-638 3.0-3.7
2) Remove the rear seat. w(Page 9D-34) 1525-2438 5003-7999 85-76 638-570 2.6-3.4
3) Set up the SDS-11 referring to the SDS-11 operation 2439-3048 8002-10000 76-70 570-525 2.4-3.1
IF04K1130058-02
manual for further details.
6) After finishing the AP sensor inspection, install the
Special tool removed parts.
09904-41031
09904-41041 AP Sensor Removal and Installation
09904-41071 BENM10L31306004
Removal
4) Turn the ignition switch ON.
1) Remove the frame cover assembly. cr(Page 9D-51)
5) Click the "Active control".
2) Disconnect the AP sensor coupler(1 ).
6) Click the item depending on operation and follow
instructions displayed on SDS-I1.
7) Close the SDS-11 and turn the ignition switch OFF.
NOTE
The ECM learned value initialization is
automatically started after the ignition switch
is turned OFF position.

AP Sensor Inspection
BENM10L31306003
1) Turn the ignition switch OFF.
2) Remove the AP sensor. cir(Page 1C-3) 3) Remove the AP sensor(1) from sensor holder(2).
3) Connect the vacuum pump gauge to the vacuum
port of the AP sensor(1 ).
4) Arrange 3 new 1.5 V batteries(2) in series(check
that total voltage is 4.5 - 5.0 V) and connect(-)
terminal to the "T1" and(+) terminal to the 'T3".
5) Measure the voltage between "T2" and "T1". Also,
check if voltage reduces when vacuum is applied
using the vacuum pump gauge.
1C-4 Engine Electrical Devices:

5) Measure the voltage between "T2" and "T1". Also,

check if voltage reduces when vacuum is applied
using the vacuum pump gauge.
If the voltage is not within the specified value,
replace the IAP sensor. '1F(Page 1C-5)
Special tool
(A): 09917-47020

IM10L1130010-01

Installation
Install the AP sensor in the reverse order of removal.

IAP Sensor Inspection

BENM 10L31306005
IAP Sensor Output Voltage at Idle Speed
1) Check the IAP sensor power supply voltage.
c:u-(Page 1 A-82)
2) Turn the ignition switch OFF.
3) Connect the IAP sensor coupler and ECM couplers.
4) Connect the circuit tester to the wire harness as IM10L1130008-02

shown in the figure.

5) Start the engine and at idle speed, measure the IAP ALTITUDE (Reference) ATOMOSPHERIC
PRESSURE
OUTPUT
VOLTAGE
sensor output voltage between the G/B wire and B/ m ft kPa mmHg V
Br wire. If the voltage is not within the specified 0-610 0-2001 100-94 760-705 3.4-4.0
value, replace the IAP sensor. cr(Page 1C-5) 611-1524 2005-5000 94-85 705-638 3.0-3.7
1525-2438 5003- 7999 85-76 638-570 2.6-3.4
IAP sensor output voltage 2439-3048 8002-10000 76-70 570-525 2.4-3.1
IF04K1130058-02
Idle speed at 1 atm.
[Standard]: Approx. 0.789 - 4.0 V 6) After finishing the IAP sensor inspection, install the
removed parts.

2
R
IM10L 1130011-01

1. IAP sensor 2. ECM

6) After finishing the IAP sensor inspection, install the

removed parts.

IAP Sensor Output Voltage

1) Turn the ignition switch OFF.
2) Remove the IAP sensor. 17 (Page 1C-5)
3) Connect the vacuum pump gauge to the vacuum
port of the IAP sensor ( 1 ).
4) Arrange 3 new 1.5 V batteries (2) in series (check
that total voltage is 4.5 - 5.0 V) and connect(-)
terminal to the "T1" and (+) terminal to the "T3".
 Engine Electrical Devices: 1C-5

IAP Sensor Removal and Installation IAT Sensor Inspection

BENM10L31306006 BENM10L31306007
Removal 1) Turn the ignition switch OFF.
1) Lift and support the fuel tank. <?(Page 1 G-12) 2) Remove the IAT sensor. c:lP{Page 1C-5)
2) Disconnect the IAP sensor coupler (1) and vacuum 3) Measure the IAT sensor (1) resistance between the
hose (2). terminals of the IAT sensor. If the resistance is out of
the specified value, replace the IAT sensor. <?(Page
1C-5)
IAT sensor resistance
o c (32 °f) [Standard]: 5400 - 6600 n
0

so 0 c (176 °f) (Standard]: 290- 390 a

IL06L1130003-01

3) Remove the IAP sensor screw (1) and IAP sensor 4) After finishing the IAT sensor inspection, install the
(2) from the air cleaner box. removed parts.

IAT Sensor Removal and Installation

◄ BENM10L31306008
Removal
1) Lift and support the fuel tank. <:r(Page 1G-12)
2) Disconnect the IAT sensor coupler (1).

IM10L1130013-01

Installation
Install the IAP sensor in the reverse order of removal.
Pay attention to the following point:
• Tighten the IAP sensor screw (1) to the specified
torque.
Tightening torque 3) Remove the IAT sensor screw (1) and IAT sensor (2)
IAP sensor screw (a): 1.3 N·m (0.13 kgf-m, 0.95 from the air cleaner box.
lbf-ft)

IM10L1130014-01
Installation
2. IAP sensor
Install the IAT sensor in the reverse order of removal.
Pay attention to the following point:
• Install the new 0-ring (1) to the IAT sensor (2).
1C-6 Engine Electrical Devices:

(Q)
(5740)

2320 - 2590

(1150)
(584)
310-326
0 20 60 80 (°C)
1D26J1130061-02
IL06l1130005-01

• Tighten the IAT sensor screw (1) to the specified

torque.
Tightening torque
IAT sensor screw (a): 1.3 N·m (0.13 kgf-m, 0.95
lbf-ft)

1D26J1130060-01

3. Heater

ECT Sensor Removal and Installation

BENM10L31306010
Removal
1) Drain engine coolant. w(Page 1 F-6)
2) Lift and support the fuel tank. <?(Page 1G-12)
2. IAT sensor
3) Disconnect the ECT sensor coupler (1).

ECT Sensor Inspection

BENM10L31306009
Refer to "ECT Sensor Removal and Installation" (Page
1 C-6).
Measure the resistance between terminals of the ECT
sensor (1). Make sure that the resistance value
decreases as temperature increase. If measured
resistance does not change as specified, replace ECT
sensor with a new one.

NOTICE
• Handle the ECT sensor carefully as it will 4) Remove the ECT sensor (1) and its gasket (2) from
easily be broken if it receives excessively the cylinder head.
large shocks or forces.
• Keep the ECT sensor and thermometer (2)
not in contact with the heater's water
container.

ECT sensor resistance

-20 °c (-4 °F) [Standard]: 13840 - 16330 a
20 °c (68 °F) [Standard]: 2320 - 2590 a
80 °c (176 °F) [Standard]: 310 - 326 a
 Engine Electrical Devices: 1C-7

NOTICE
Take special care when handling the ECT
sensor. It may cause damage if it gets an
excessive impact.

4) Measure the output voltage of TP sensor main and

sub signals as follows.
If faulty condition is found, replace the throttle body
with a new one. w(Page 1 D-9)
a) Arrange 3 new 1.5 V batteries(1) in series
(check that total voltage is 4.5 - 5.0 V) and
Installation connect(-) terminal to the "T4" and(+) terminal
Install the ECT sensor in the reverse order of removal. to the 'T2".
Pay attention to the following points:
b) Connect the voltmeter between the following
• Install the new gasket(1). terminal.
• Install the ECT sensor(2) and tighten it to the • TP sensor(main): between the "T1" and "T4"
specified torque. • TP sensor(sub): between the "T3" and "T4"
Tightening torque
ECT sensor (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)

[B]
I I _...- 2
{ililiB

jJ
TP Sensor Inspection
BENM10L31306011
Refer to "Precautions for Electric Throttle Control
System" (Page 1C-1).

NOTICE
Do not snap the throttle valve from the open
to full close. It may cause damage to the gear
inside the throttle body.
IM10L1130022-01

1) Turn the ignition switch OFF. [A]: TP sensor (main) 2. TP sensor

[BJ: TP sensor (sub)
2) Remove the air cleaner box. w(Page 1 D-6)
3) Disconnect the TP sensor coupler(1). c) Check that voltage varies depending on throttle
opening angle as shown in the following graph
while throttle valve is opened and closed
manually.
TP sensor (main) output voltage
Closed [Standard]: 3.635 - 3.785 V
1C-8 Engine Electrical Devices:

Opened [Standard]: Approx. 0.70 V H02 sensor #1

TP sensor (sub) output voltage
Closed [Standard]: 4.235 - 4.385 V
Opened [Standard]: Approx. 1.30 V

IM10L1130025-03

H02 sensor #2

[a]

4.235 - 4.385 .... ...

3.635 - 4.385 .. .....

A rox. 1.30 ·· •······ ···································

pp
A rox. 0.70 •· •······ ··········································· IM10L 1130026-03
pp
4) Measure the H02 sensor (1) output voltage between
the 'T1" and "T2", in idling condition.
[d) [e) 5) If OK, then pinch the PAIR hose (2) with a proper
IM10L1130024-02
hose clamp.
[a]: Voltage (V) 6) Measure the H02 sensor output voltage while
(b]: Throttle valve opening
holding the engine speed at 6000 r/min.
[c]: Angle obtained when throttle valve is fully opened manually
(d]: Fully closed position H02 sensor output voltage
(e]: Fully opened position Idle speed [Standard]: Approx. 0 V
1. TP sensor (main) output voltage 6000 r/min [Standard]: Approx. 1 V
2. TP sensor (sub) output voltage

5) After finishing the TP sensor inspection, install the ___<±l_+-1 V ....e__....,

removed parts.

H02 Sensor Inspection

BENM10L31306012
2
H02 Sensor Output Voltage
1) Remove the following parts. 3 4
• For H02 sensor #1, remove the side cowling
IL41K1130014-01
assembly (LH). <rr(Page 9D-37)
• For H02 sensor #2, lift and support the fuel tank.
c;,-(Page 1G-12)
2) Start the engine and warm up the engine enough.
3) Disconnect the H02 sensor coupler (1).
 Engine Electrical Devices: 1C-9

H02 sensor heater resistance

23 °c (73.4 °F) [Standard]: 11.5-17.5 n

3 4

..___ n I-----'

IL41K1130015-01
7) If the H02 sensor output voltage is not within the
4) After finishing the H02 sensor inspection, install the
standard range, replace the H02 sensor with a new
removed parts.
one. w(Page 1C-9)
8) After finishing the H02 sensor inspection, install the
removed parts.
H02 Sensor Removal and Installation
BENM10L31306013

H02 Sensor Heater Resistance

1) Remove the following parts. Do not remove the H02 sensor while it is hot.
• For H02 sensor #1, remove the side cowling
assembly (LH). w(Page 9D-37) NOTICE
• For H02 sensor #2, lift and support the fuel tank. • Be careful not to expose the H02 sensor to
w(Page 1G-12) excessive shock.
2) Disconnect the H02 sensor coupler (1). • Do not use an impact wrench when
H02 sensor #1 removing or installing the H02 sensor.
• Be careful not to twist or damage the
sensor lead wire.

Removal
1) Remove the side cowling assembly. '°"(Page 9D-37)
2) Lift and support the fuel tank. w(Page 1G-12)
3) Disconnect the H02 sensor coupler (1).
H02 sensor #1

IM10L1130025-03

H02 sensor #2

IM10L 1130025-03

IM1 OL 1130026-03

3) Measure the H02 sensor heater resistance between

the "T3" and 'T4" of the H02 sensor. If the resistance
is out of the specified value, replace the H02 sensor
(1) with a new one. w(Page 1C-9)
1C-10 Engine Electrical Devices:

H02 sensor #2 H02 sensor #2

IM10L 1130026-03

4) Release the clamps (1).

H02 sensor #1 Installation
Install the H02 sensor in the reverse order of removal.
Pay attention to the following points:
• Apply nickel based anti seize to the thread part of
H02 sensor.
• Tighten the H02 sensor (1) to the specified torque.
Tightening torque
H02 sensor (a): 25 N•m (2.5 kgf-m, 18.5 lbf-ft)

H02 sensor #1

IM10L1130056-01

H02 sensor #2

IM10L1130032-01

H02 sensor #2

5) Remove the H02 sensor (1) from exhaust pipe.

H02 sensor #1

• Clamp the H02 sensor #1 lead wire, referring to

"Wiring Harness Routing Diagram" in Section 9A
(Page 9A-13).
IM10L1130031-01
• Pass the H02 sensor #2 lead wire (1) under (2) the oil
pressure switch lead wire (3).
• Do not twist H02 sensor #2 lead wire and oil pressure
switch lead wire.
 Engine Electrical Devices: 1C-11

CMP Sensor Removal and Installation

BENM10L31306015
Removal
1) Remove the fuel tank front cover. <?(Page 9D-49)
2) Disconnect the CMP sensor coupler (1 ).

IM10L1130034-01

• Reset the long term fuel trim when replacing the HO2
sensor. <?(Page 1C-3)

CMP Sensor Inspection

BENM10L31306014 IM10L1130036-01

1) Turn the ignition switch OFF. 3) Remove the bolt (1 ).

2) Remove the CMP sensor. cr(Page 1C-11) 4) Remove the CMP sensor(2) from cylinder head
3) Arrange 3 new 1.5 V batteries (1) in series(check cover.
that total voltage is 4.5 - 5.0 V), 1000 0 resistor(2)
and connect(-) terminal to the 'T3" and(+) terminal
to the "T1".

IM10L1130037-01

IM10L1130035-01
Installation
Install the CMP sensor in the reverse order of removal.
3. CMP sensor
Pay attention to the following points:
4) Under this condition, if a suitable screwdriver • Check the O-ring(1) for damage.
touching the pick-up surface of the CMP sensor is If check result is not OK, replace the CMP sensor with
moved, the tester reading voltage changes (0.8 V a new one.
and less - 4.3 V and more).
If the voltage reading does not change, replace the
CMP sensor with a new one. w-(Page 1c-11)

IM10L 1130038-01
• When installing the CMP sensor, make sure to clean
the sensor surface.
1823\--\1110007-01
• Tighten the CMP sensor bolt (1) to the specified
torque.
Tightening torque
CMP sensor bo\t (a): '\O N·m {'\.O kgf-m, 7 .5 \bf-ft)
1C-12 Engine Electrical Devices:

IM10L1130042-01

6) Measure the CKP sensor peak voltage in the

following procedures:
IM10L1130039-01
a) Shift the transmission to the neutral and turn the
CKP Sensor Inspection ignition switch ON.
BENM10L31306016 b) Grasp the clutch lever.
CKP Sensor Peak Voltage
c) Push the engine stop/ starter switch to the
NOTE "START' position and allow the engine to crank
Be sure that all the couplers are connected for a few seconds, and then measure the CKP
properly and the battery used is in fully­ sensor peak voltage.
charged condition. 7) Repeat the c) procedure several times and measure
the highest peak voltage.
1) Remove the meter panel (LH). w(Page 9D-37) If the voltage is lower than standard range, inspect
2) Remove the fuel fuse (10 A) (1) to stop the fuel for coupler connection and metal particles or foreign
injection. material being stuck on the CKP sensor and
generator rotor.
If the peak voltage is within the standard range,
check the continuity between the CKP sensor
coupler and ECM coupler.
CKP sensor peak voltage
When cranking [Standard]: 2 V or more
8) After finishing the CKP sensor inspection, install the
removed parts.

CKP Sensor Resistance

3) Remove the side cowling assembly (LH). w(Page
9D-37)
4) Disconnect the CKP sensor coupler ( 1 ).
1) Remove the side cowling assembly (LH). w(Page
9D-37)
2) Disconnect the CKP sensor coupler (1).

IM10L1130041-02

3) Measure the resistance between the terminals of the

IM10L1130041-02
CKP sensor (1).
5) Connect the multi circuit tester with the peak voltage If the resistance is not within the standard range,
adapter (1) as follows. replace the CKP sensor with a new one. -(Page
1C-13)
CKP sensor - circuit tester connection
(+) ; obe (-) Probe CKP sensor resistance
� / 20 °c (68 °F) (Standard]: 180 - 280 n
/ CKP sensor ( / T2
 Engine Electrical Devices: 1C-13

[A]

2 ----------

ri
�s1�
4,, 3 �
,
2 1l I
IM10L1130043-01
�<t? e 8
1
4) After finishing the CKP sensor inspection, install the
removed parts. V
CKP Sensor Removal and Installation [BJ
BENM10L31306017
Refer to "Generator Removal" in Section 1J (Page 1J-4)
and "Generator Installation" in Section 1J (Page 1J-6).

Accelerator Position Sensor Inspection

BENM10L31306018
Refer to "Precautions for Electric Throttle Control
System" (Page 1C-1).
1) Check that the throttle cable play is within the
specification. w-(Page 1 D-9) IM10L1130045-01

2) Lift and support the fuel tank. w-(Page 90-49)
3) Remove the air cleaner box. w-(Page 1D-6)
4) Disconnect the accelerator position sensor coupler
(1).
5) Measure the output voltage of accelerator position
sensor main and sub signals as follows.
If faulty condition is found, replace the accelerator
body assembly with a new one. w-(Page 1C-14)
a) Arrange 3 new 1.5 V batteries(1) in series, and
check that total voltage is 4.5 - 5.0 V.
IL,.:...,·
b) Connect 3 new 1.5 V batteries terminal to the
accelerator position sensor terminal as follows.
• Accelerator position sensor (main): connect(­
) terminal to the "T5" and(+) terminal to the
"T6"
• Accelerator position sensor(sub): connect(-)
terminal to the "T2" and(+) terminal to the "T3"
c) Connect the voltmeter between the following
terminal.
• Accelerator position sensor (main): between
the "T4" and "T5"
[A]: Accelerator position sensor 2. Accelerator position sensor
(main)
[B]: Accelerator position sensor
(sub)
d) Check that voltage varies depending on throttle
grip opening angle as shown in the following
graph.
Accelerator position sensor (main) output
voltage
Closed [Standard]: 0.485 - 0.635 V
Opened [Standard]: Approx. 3.51 V
Accelerator position sensor (sub) output
voltage
Closed [Standard]: 0.825 - 0.975 V
Opened [Standard]: Approx. 4.59 V
[a]
Approx. 4.59·· ········································ ···············
Approx. 3.51-- •····················•················· •········ ·····
2
0.825 - 0.975-
0.485 - 0.635· ·· ··········•···•·······•··•···•···•···················
i-----------+-[b]
[c) [d]
IM10L1130046-02
[a]: Voltage(V)
[b]: Throttle grip opening angle
[c]: Throttle grip: Fully closed position
[d]: Throttle grip: Fully opened position
1. Accelerator position sensor (main) output voltage
2. Accelerator position sensor (sub) output voltage

• Accelerator position sensor (sub): between

the "T1" and ''T2" 6) After finishing the accelerator position sensor
inspection, install the removed parts.
1C-14 Engine Electrical Devices:

Accelerator Position Sensor Removal and

Installation
BENM10L31306019
Refer to "Precautions for Electric Throttle Control
System" (Page 1C-1).

Removal
1) Lift and support the fuel tank. <?(Page 1 G-12)
2) Disconnect the accelerator position sensor coupler
(1) and cruise control cancel switch coupler (2).

IM10L1130054-01

Installation
Install the accelerator body assembly in the reverse
order of removal.
Pay attention to the following point:
• Connect the throttle cables to the accelerator body
assembly and clamp. Refer to "Throttle Cable Routing
Diagram" in Section 1 D (Page 1 D-2).
• Tighten the accelerator body assembly bolts (1) to the
specified torque.
3) Remove the accelerator body assembly bolts (1).
Tightening torque
Accelerator body assembly bolt (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)

IM10L1130052-01

4) Disconnect the throttle cables (1) from the clamp (2).

IM10L1130055-01

• Check the throttle cable play and proper operation.

(g'(Page 1 D-9)
• Reset the accelerator position sensor fully closed
learned value when replacing the accelerator body
assembly. w(Page 1C-3)

IM10L1130053-01

5) Move the accelerator body assembly outside of the

motorcycle.
6) Disconnect the throttle cables (1) from the
accelerator body assembly (2).
 Engine Electrical Devices: 1C-15

Throttle Valve Motor Inspection Throttle Valve Motor Check

BENM10L31306020
Refer to "Precautions for Electric Throttle Control 1) Turn the ignition switch OFF.
System" (Page 1C-1). 2) Remove the air cleaner box. c:r-(Page 1 D-6)
3) Disconnect the throttle valve motor coupler (1).
Throttle Valve Operation Check

NOTICE
Do not snap the throttle valve from the open
to full close. It may cause damage to the gear
inside the throttle body.

1) Turn the ignition switch OFF.

2) Remove the air cleaner box. c:r-(Page 1 D-6)
3) Check throttle valve operation as follows.
If faulty condition is found, replace throttle body with
a new one. c:r-(Page 1D-9)
a) Check that throttle valve (1) moves smoothly to
both fully closed position and fully open position
when pressed manually.
4) Measure the throttle valve motor resistance between
the "T1" and "T2" of the throttle valve motor (1).
If faulty condition is found, replace throttle body with
a new one. <r(Page 1 D-9)
Throttle valve motor resistance
20 °c (68 °F) [Standard]: 0.3 -100 n

��
/
� ' -
",
/ �
-...,

IM10L1130050-01

5) After finishing the throttle valve motor inspection,

IM 1 0L1130023-02
install the removed parts.
b) Check throttle valve (1) returns to fully closed
position when finger pressure on throttle valve is GP Sensor Inspection
BENM10L31306021
released slowly at fully open position. Refer to "GP Sensor Inspection" in Section 58 (Page 58-
13).

GP Sensor Removal and Installation

BENM10L31306022
Refer to "GP Sensor Removal and Installation" in
Section 58 (Page 58-14).

Gearshift Sensor Inspection

BENM10L31306023
Refer to "Gearshift Sensor Inspection" in Section 5B
IL06L1130015-01 (Page 5B-13).
4) After finishing the throttle valve motor inspection,
install the removed parts. Gearshift Sensor Removal and Installation
BENM10L31306024
Refer to "GP Sensor Removal and Installation" in
Section 58 (Page 58-14).
1 C-16 Engine Electrical Devices:

Specifications
Tightening Torque Specifications
BENM10L31307001
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
IAP sensor screw 1.3 0.13 0.95 w(Page 1C-5)
IAT sensor screw 1.3 0.13 0.95 w(Page 1C-6)
ECT sensor 18 1.8 13.5 w(Page 1C-7)
HO2 sensor 25 2.5 18.5 "'"'(Page 1C-10)
CMP sensor bolt 10 1.0 7.5 w(Page 1 C-11)
Accelerator body assembly bolt 10 1.0 7.5 w(Page 1C-14)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Fasteners Information" in Section 0C (Page 0C-6)

Special Tools and Equipment

Special Tool
BENM10L31308001
09904-41031 09904-41041
SDS-11 set SDS-11 (oscilloscope) set
cr(Page 1C-3) cr(Page 1C-3)

09904-41071 09917-47020
Conversion cable (ISO) Vacuum pump gauge set
w(Page 1C-3) w(Page 1C-3) /
w(Page 1C-4)
 Engine Mechanical: 1 D-1

Engine Mechanical
Precautions
Precautions for Engine Mechanical
BENM10L31400001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Electrical Circuit Service" in Section 00
(Page 00-2) and "Precautions for SDS-11" in Section 00 (Page 00-9).
NOTE
Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake,
exhaust) so that they can be reinstalled in their original positions.
1 D-2 Engine Mechanical:

Schematic and Routing Diagram

Throttle Cable Routing Diagram
BENM10L31402001

,_.[A]

4 ,_.[B]
2

ri.[G]
7 - - -
- ,_. [A]
?-� -· -
.·e----- -
.
8
.i-----
1 ,·

2�

,__ [I]
IM10L1140001-03
 Engine Mechanical: 1 D-3

�[A]: Pass the throttle cable No. 1 to the outside of
throttle cable No. 2 at the upper side of the
frame.
f..- [B]: Pass the throttle cables to the lower side of wire
harness guide.
f..-[H]: Pass the throttle cable No.1 to the lower side 6. Cable guide
of the throttle cable No.2.
f..- [I]: Pass the throttle cables to under the fuel 7. Fuel tank front cover
tank cover and outside the fuel tank bracket.

f..- [CJ: Pass the throttle cable No.2 to the inside of 1. Throttle cable No.1 8. Fuel tank bracket
throttle cable No.1.
f..- [DJ: The distance between the adjustment nut and 2. Throttle cable No.2 9. Accelerator body assembly
the lock nut shall not exceed one rotation back.
f..- [E]: The throttle cables is clamped to prevent tension 3, Frame (!W]: 4.5 N-m (0.46 kgf-m, 3.35 lbf-ft)
or looseness.
Fasten throttle cable No.1 to the upper side and
throttle cable No.2 to the lower side.
f..- [F]: Pass the throttle cables to the front side of the 4. Wire harness guide C!llm 2.5 N-m (0.25 kgf-m, 1.85 lbf-ft)
front brake hose.
f..- [G] Pass the throttle cables to the inside of the front 5. Front brake hose
brake pipe.

Diagnostic Information and Procedures

Engine Mechanical Symptom Diagnosis
BENM10L31404001
Refer to "Engine Symptom Diagnosis" in Section 1A
(Page 1A-25).

Compression Pressure Check

BENM10L31404002
The compression pressure reading of a cylinder is a
good indicator of its internal condition.
The decision to overhaul the cylinder is often based on
the results of a compression test. Periodic maintenance
records kept at your dealership should include
compression readings for each maintenance service. IM10L1140002-01

6) Set the anti-lift control "OFF". <7(Page 0B-14)

NOTE
7) Keep the throttle grip in the fully-opened position.
• Before checking the engine for
compression pressure, make sure that the
cylinder head bolts are tightened to the
specified torque values and the valves are
properly adjusted.
• Make sure that the battery is in fully­
charged condition.

1) Warm up the engine.

2) Remove the air cleaner box. c:r(Page 1 D-6)
3) Remove the spark plugs. <7(Page 1 H-5)
4) Disconnect the primary and secondary fuel injector IM10L1140003-01

couplers. Refer to "Fuel Injector/ Fuel Delivery Pipe 8) Grasp the clutch lever.
Removal and Installation" in Section 1 G (Page 1 G- 9) Push the engine stop/ starter switch to the "START"
21). position and crank the engine for a few seconds.
5) Install the compression gauge and adapter in the Record the maximum gauge reading as the cylinder
spark plug hole. Make sure that the connection is compression.
tight. 10) Repeat this procedure with the other cylinders.
Special tool Compression pressure
(A): 09915-64512 [Standard]: 1400 -1900 kPa (14-19 kgf/cm2 , 203
(B): 09915-63311 - 276 psi)
[Limit]: 1000 kPa (10 kgf/cm2 , 145 psi)
Compression pressure difference
[Limit]: 200 kPa (2 kgf/cm2 , 29 psi)
1 D-4 Engine Mechanical:

If compression pressure is less than the service

limit, it is considered any of the following
reasons:
• Excessively worn cylinder walls
• Worn piston or piston rings
• Piston rings stuck in grooves
• Poor valve seating
• Ruptured or otherwise defective cylinder head
gasket
Overhaul the engine in the following cases:
• Compression pressure in one of the cylinders is
1000 kPa (10 kgf/cm2, 145 psi) and less.
• The difference in compression pressure between
any two cylinders is 200 kPa (2 kgf/cm2, 29 psi)
and more.
• All compression pressure readings are below
1400 kPa (14 kgf/cm2 , 203 psi) even when they
measure 1000 kPa (10 kgf/cm2 , 145 psi) and
more.
11) After checking the compression pressure, install the
removed parts.
 Engine Mechanical: 1 D-5

Repair Instructions
Intake System Construction BENM10L31406001

� >r �\l�I
tf�tf�
��re
"a"
�

8 9�

11
(iii[B]

f..il[C]
IM10L1140297-01

f,.jj[A]: Face the clamp end to the left side. 6. Throttle body assembly �: 1.8 N•m (0.18 kgf-m, 1.35 lbf-ft)
flllli[BJ: Pass the breather hose to upper side of the 7. Air cleaner element (!D: 4.3 N-m (0.44 kgf-m, 3.20 lbf-ft)
cruise control cancel switch coupler.
� [CJ: Pass the breather hose to right side of the
starter motor lead wire.
8. Air cleaner box m: 3.5 N-m (0.36 kgf-m, 2.60 lbf-ft)

1. Air cleaner cover 9. IATsensor 1.5 N-m (0.15 kgf-m, 1.10 lbf-ft)
m:
�:
2. Funnel 10. IAP sensor 1.3 N-m (0.13 kgf-m, 0.95 lbf-ft)
3. Secondary fuel injector 11. Breather hose "a": 35° - 55°
4. Fuel feed hose 12. Cruise control cancel switch coupler
5. Intake pipe 13. Starter motor lead wire
1 D-6 Engine Mechanical:

Air Cleaner Element Removal and Installation 5) Disconnect the IAP sensor coupler (1 ), IAT sensor
BENM10L31406002 coupler (2) and hoses (3).
For removal and installation procedure, refer to "Air
Cleaner Element" in Section OB (Page OB-3). And if
necessary, replace the air cleaner element with a new
one.

Air Cleaner Box Removal and Installation

BENM10L31406003

Removal
1) Remove the fuel tank. w(Page 1G-12)
2) Remove the air cleaner cover screws (1) and air
cleaner cover (2) from the air cleaner box.
IM10L1140008-01

6) Disconnect PAIR hose (1) and crankcase breather

(PCV) hose (2) from the air cleaner case.

IM1 0L1140005-01

3) Remove the fuel feed hose (1) and secondary fuel

injector couplers (2).
IM10L1140009-01

7) Remove the fuel tank bracket bolts (1 ), fuel tank

bracket (2) and air cleaner box (3).

IMWL1140006-01

4) Remove the funnel bolts (1) and funnels (2) from the
air cleaner box.
IM10L1140010-01
NOTE
When removing funnels, be careful that the
injector gets caught.
 Engine Mechanical: 1 D-7

Installation • Tighten the air cleaner cover bolts ( 1) to the specified

Install the air cleaner box in the reverse order of torque.
removal. Pay attention to the following points:
Tightening torque
• Route the hoses properly. Refer to "Intake System Air cleaner cover bolt (a): 1.8 N·m (0.18 kgf-m,
Construction" (Page 1 D-5). 1.35 lbf-ft)
• Tighten the fuel tank bracket bolts (1) to the specified
torque.
Tightening torque
Fuel tank bracket bolt (front side) (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)
Fuel tank bracket bolt (rear side) (b): 5.5 N·m (
0.56 kgf-m, 4.05 lbf-ft)

1
.
")

1, (b)1

) __ �

--- /'!>..,
•
IM10L1140011-01
• Install the funnel (1), and then tighten the funnel bolts
(2) to the specified torque.
Tightening torque
Funnel bolt (a): 4.3 N·m (0.44 kgf-m, 3.20 lbf-ft)

-\
�I
. /

;r:
--�•

fl_-
'111:,•• , � . �
IM10L1140012-02
• Before installing the air cleaner cover, inspect the air
cleaner cover gasket (1) for damage or cracks. If any
defect is found, replace the air cleaner gasket with a
new one.

IM10L1140292-01
1D-8 Engme Meehan·1cal:

Throttle Body C omponents

BENM10L31406004

13

IM10L1140294-01
 Engine Mechanical: 1 D-9

1. Throttle body 7. Cushion seal 13. Purge hose (if equipped)

2. O-ring 8. Fuel injector (!ml: 3.5 N-m (0.36 kgf-m, 2.60 lbf-ft)

fl':
3. Washer 9. O-ring Apply engine oil.

4. Spring 10. Fuel delivery pipe �: Do not reuse.

5. Synchronizing screw 11. O-ring
6. Vacuum hoses 12. Nipple joint

Throttle Cable Play On-Vehicle Inspection and Throttle Body Removal and Installation
BENM10L31406008
Adjustment
BENM10L31406005
Refer to 'Throttle Cable Play" in Section OB (Page 08- Removal
12). 1) Remove the air cleaner box. <lr'{Page 1D-6)
2) Remove the clamps (1), and then disconnect the
Engine Idle Speed Inspection primary fuel injector couplers (2).
BENM10L31406006
1) Turn the ignition switch OFF.
2) Remove the rear seat. CS"'(Page 9D-34)
3) Set up the SDS-11 referring to the SOS-II operation.
4) Start the engine.
5) Click "Data monitor".
6) Check the engine idle speed. If the engine idle
speed is out of the specified range, check the air
suction, throttle valve etc.
NOTE
IM10L1140016-01
The engine idle speed is automatically
adjusted by the throttle valve. Therefore, no 3) Remove the clamp (1), and then disconnect the
adjuster is provided. throttle valve motor coupler (2) and TP sensor
coupler (3).
Engine idle speed
When engine warmed
(Standard]: 1150 ± 100 r/min
7) Close the SDS-11 tool and turn the ignition switch
OFF.
8) Install the removed parts.

Throttle Cable Removal and Installation

BENM10L31406007
Removal
1) Remove the fuel tank. CS"'(Page 9D-49)
IM10L1140017-01
2) Remove the right handle switch. CS"'(Page 68-3)
4) Disconnect the purge hose No.2 (1) (if equipped).
3) Disconnect the throttle cables from the accelerator
body assembly. <lr'(Page 1 C-14)
4) Remove the throttle cables as shown in the cable
routing diagram. Refer to "Throttle Cable Routing
Diagram" (Page 1D-2).

Installation
Install the throttle cables in the reverse order of removal.
Pay attention to the following points:
• Install the throttle cables as shown in the cable routing
diagram. Refer to "Throttle Cable Routing Diagram"
(Page 1D-2). IM10L1140018-02
• Check the throttle cable play and proper operation. 5) Loosen the intake pipe clamp screws (1 ), and then
<lr'(Page 1D-9) remove the throttle body.
1D-10 Engine Mechanical:

NOTICE Installation
• Do not snap the throttle valve from the
open to full close. It may cause damage to
the gear inside the throttle body.
• If foreign materials like mud and sand are
adhered to the intake pipe or the throttle
body, they are likely to get into the intake
port. When foreign materials like mud or
sand are adhered, remove them before
starting the work.
1) Install the throttle body (1) to the intake pipe.
2) Tighten the intake pipe clamp screws (2) to the
specified torque.
Tightening torque
Intake pipe clamp screw (a): 1.5 N·m (0.15 kgf­
m, 1.10 lbf-ft)

IM10L1140020-02

3) Connect the purge hose No.2 (1) (if equipped).

IM10L1140019-01

IM10L 1140018-02

4) Connect the throttle valve motor coupler (1), TP

sensor coupler (2) and primary fuel injector couplers
(3).
5) Install the clamps (4).

IM10L 1140021-01
 Engine Mechanical: 1D-11

• The screw (1) is factory-adjusted at the

time of delivery and therefore avoid
removing of turning it unless otherwise
necessary.

IM10L 1140284-01

6) Install the air cleaner box. i:r(Page 1 D-6)

Throttle Body Disassembly and Reassembly

BENM10L31406009
Refer to "Throttle Body Removal and Installation" (Page • Do not turn or remove the synchronizing
1 D-9). screw with white paint (one in four). The
white painted screw is fixed in the factory
Disassembly default setting.
NOTE
1) Remove the delivery pipe screws (1 ), delivery pipe
• Identify the position of each removed part. (2) and primary fuel injectors (3) from the throttle
Organize the parts in their respective body.
groups so that they can be reinstalled in
their original positions.
• Do not apply the battery voltage to the
throttle valve motor (1) directly.
Otherwise the gear inside the throttle body
may get damaged.
• Never remove the throttle valve motor (1).

3
'
IM10L1140026-01

2) Disconnect the vacuum hoses (1 ).

3) Disconnect the purge hoses (2). (If equipped)

IM10L 1140023-01

• Never remove the throttle valves (1) and TP

sensor (2).

IM10L1140027-01

4) Before removing the synchronizing screws without

white paint, make sure the setting by turning each
one clockwise slowly and count the number of turns
until the screw is lightly seated.
This counted number is important when
reassembling synchronizing screw to the original
IM10L1140024-01 position.
1 D-12 Engine Mechanical:

5) Remove the synchronizing screws without white

paint.

IM10L1140030-01

IM10L 1140028-01 Throttle Body Inspection and Cleaning

BENM10L31406010
6) Remove the O-ring (1), washer (2) and spring (3).
Refer to "Throttle Bore Cleaning" in Section OB (Page
0B-14).

Throttle Valve Synchronization

BENM10L31406011
Refer to "Throttle Valve Synchronization" in Section OB
(Page 08-15).

Intake Pipe Removal and Installation

BENM10L31406012
Refer to "Throttle Body Removal and Installation" (Page
1 D-9).

Removal
Reassembly 1) Loosen the intake pipe clamp screw (1).
Reassemble the throttle body in the reverse order of 2) Remove the intake pipes (2).
disassembly. Pay attention to the following point:
• Apply engine oil to the new O-ring (1).
• Install the new O-ring (1), washer (2) and spring (3).

• Tighten the delivery pipe screws (1) to specified

torque.
Tightening torque
Delivery pipe screw (a): 3.5 N·m (0.36 kgf-m, 2.60
lbf-ft)
 · Engine Mechanical: 1D-13

Installation
Install the intake pipe in the reverse order of removal. Pay attention to the following points:
• Face the up mark (1) on the intake pipe to upper.
• Set the clamp screws as shown in the figure.

[A]

[CJ y - ¢ [D]

"a" "a" Uall " ll

a

[B]
IM10L1140141-01

[AJ: Front [BJ: Rear (CJ: Left [DJ: Right "a": 35° - 55°

• Tighten the intake pipe clamp screws (2) to the specified torque.
Tightening torque
Intake pipe clamp screw (a): 1.5 N·m (0.15 kgf-m, 1.10 lbf-ft)
1 D-14 Engine Mechanical:

Cylinder Head Cover Components BENM10L31406013

IM10L1140033--03

f..iii 1 Cylinder head cover bolt 5. CMP sensor bolt "Wm]: Apply SUZUKI BOND 1207B
: When install the cylinder head bolt, clean the cylinder head
bolt threads and matching surface.
2. Washer 6. CMP sensor
"ir: Apply engine oil.

3. Cylinder head cover �: 12 N-m (1.2 kgf-m, 9.0 lbf-ft) �: Do not reuse.
4. Cylinder head cover gasket C!lmJ:
10 N-m (1.0 kgf-m, 7.5 lbf-ft)
 Engine Mechanical: 10-15

Cylinder Head Cover Removal and Installation "A": Sealant 99000-31140 (SUZUKI BOND
BE:NM10L31406014 1207B)
Refer to "Throttle Body Removal and Installation" (Page
1 D-9).

Removal
1) Remove the ignition coils. -(Page 1 H-4)
2) Disconnect the PAIR hose. -(Page 18-4)
3) Disconnect the CMP sensor coupler (1), and then
remove the CMP sensor bolt (2) and CMP sensor (3)
from the cylinder head cover.

IM10L1140036-03

IM10L1140034-01
4) Remove the cylinder head cover bolts (1) and
cylinder head cover (2) from the cylinder head.
3) Place the cylinder head cover on the cylinder head.
4) Clean the cylinder head bolt threads and matching
surface.
5) Set the new gaskets (1) to each cylinder head cover
bolt and coat the both sides of the gasket with
engine oil.

IM10L1140035-01

5) Remove the gaskets (1) from the cylinder head

covers.
IM10L 1140037-01

6) Tighten the cylinder head cover bolts (1) to the

specified torque.
Tightening torque
Cylinder head cover bolt (a): 12 N·m (1.2 kgf-m,
9.0 lbf-ft)
•. -- . . -;
,'
::;;:;;�;;;;:::::;:::::;;::;:::: _. .

IM10L1140291-01

Installation
1) Install new gaskets (1) to the cylinder head cover.
2) Apply sealant to the cam end cap points of the
gasket and cylinder head as shown.
IM10L 1140038-01
1 D-16 Engine Mechanical:

7) Install the CMP sensor (1) to the cylinder head, and

then tighten the CMP sensor bolt (2) to the specified
torque.
Tightening torque
CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf­
ft)
8) Connect the CMP sensor coupler (3) to the CMP
sensor.

9) Install the ignition coil. <lr'(Page 1 H-4)

Cylinder Head Cover Inspection

BENM10L31406015
Refer to "Cylinder Head Cover Removal and Installation"
(Page 1 D-15).
Clean and check the gasket grooves (1).
If there is anything unusual, replace the cylinder head
cover with a new one.

IM10L1140040-01
 Engine Mechanical: 1 D-17

Cam Chain Tension Adjuster/ Camshaft Components BENM10L31406016

r.i 2

IM10L1140041-03

1. Cam chain guide bolt f-iii 7. Camshaft journal holder bolt (L45) 13. Cam chain tensioner adjuster bolt
: For tightening order, refer to "Cam
Chain Tension Adjuster/ Camshaft
Installation" (Page 1D-19).
f,,jj 2 Cam chain guide 8. Intake camshaft journal holder 14. Cam chain tensioner adjuster
: Stamped mark facing up side.
3. Cylinder head oil pipe bolt 9. Exhaust camshaft journal holder 15. Cam chain tensioner adjuster gasket
4. Gasket washer 10. Dowel pin �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)

-mi:
5. Cylinder head oil pipe 11. Intake camshaft Apply engine oil.

f-iii 6. Camshaft journal holder bolt (L39)

: For tightening order, refer to "Cam Chain Tension
12. Exhaust camshaft t): Do not reuse.
Adjuster/ Camshaft Installation" (Page 1D-19).
1D-18 Engine Mechanical:

Cam Chain Tension Adjuster/ Camshaft

Removal
BENM10L31406017
Refer to "Cylinder Head Cover Removal and Installation"
(Page 1D-15).
1) Remove the spark plugs. c:r-(Page 1 H-5) 2
2) Remove the valve timing inspection cap (1) and
starter clutch cover cap (2) from the starter clutch
cover.

IM10L1140042-01

3) Turn the crankshaft clockwise to bring the line (1) on

the starter clutch to the slit (2) of the valve timing
inspection hole and also to bring the cams to the
position as shown in the figure.

IM10L 1140045--01

4) Remove the cam chain tension adjuster bolts (1),

cam chain tension adjuster (2) and gasket (3).
IM10L1140043-01
NOTE
Do not disassemble the cam chain tension
adjuster.

IM10L1140046-01
 Engine Mechanical: 1 D-19

NOTICE
Be sure to loosen the camshaft journal
holder bolts evenly by shifting the wrench in
the descending order of numbers.

Fl 0
F �"
--=·
---.:�-_ ---
I
IM10L 1140286-01

S)'R.e,move the cylinder head oil pipe bolts (1 ), washers

an·-a cylinder head oil pipe (2) from the camshaft
housing.

8) Remove the dowel pins (1) from the cylinder head.

9) Remove the intake camshaft (2) and exhaust
camshaft (3) .

2
...........��t � IM10L1140048-01

6) Remove the cam chain guide bolts (1) and cam

chain guide (2) from the camshaft housing.

IM.10L1140051-01

Cam Chain Tension Adjuster/ Camshaft

Installation
BENM10L31406018
1) Apply engine oil to the camshaft journals and cam
faces.

NOTICE
IM10L1140049-02 Identify the camshafts according to the
7) Remove the camshaft journal holder bolts (1) intake following embosses letters.
camshaft journal holder (2) and exhaust camshaft Intake camshaft (1): [A]
journal holder (3) from the cylinder head. Exhaust camshaft (2): [BJ

IM10L1140052-01

[A]: IN [BJ: EX
1 D-20 Engine Mechanical:

2) Turn the crankshaft clockwise and align the line (1)

on the starter clutch to the slit (2) of cap hole thread
while keeping the cam chain pulled upward.

NOTICE
• Pull the cam chain upward, or the chain
will be caught between crankcase and cam
drive sprocket.
• To adjust the camshaft timing correctly, be
sure to align the line (1) with slit (2) and
hold this position when installing the
camshafts. IM10L1140055-01

5) Engage the cam chain (1) with the exhaust camshaft

sprocket.
NOTICE
• Before installing the camshaft, check that
the tappets are installed correctly.
2
• Align the C-ring (2) of the exhaust
camshaft bearing with the groove (3) in the
cylinder head.

6) Bind the cam chain and the sprocket with a proper

clamp (4) to prevent the cam chain disengagement
while installing the camshaft journal holders.

IM10L1140056-01

7) The other arrow marked "2" (1) should now be

pointing straight up. Starting from the roller pin that is
directly above the arrow marked "2" (1), count out 15
roller pins (from the exhaust camshaft side going
towards the intake camshaft side).
8) Engage the 15th roller pin (2) on the cam chain with
the arrow marked "3" on the intake sprocket.

IM10L 1140054-01

3) Pull the cam chain lightly.

4) Turn the exhaust camshaft so that the arrow is
aligned with the gasket surface of the cylinder head.
(The exhaust camshaft sprocket has an arrow
marked "1" (1).)
 Engine Mechanical: 1D-21

NOTE
• Before installing the camshaft, check that
the tappets are installed correctly.
Align the C-ring (3) of the intake camshaft
bearing with the groove (4) in the cylinder
head.

11) Install the camshaft journal holders (1) and camshaft

journal holder bolts (2).
12) Have the camshaft journal holders seated evenly by
IM10L1140057-02 tightening the camshaft journal holder bolts lightly, in
the ascending order of numbers.

NOTICE
Damage to head or camshaft journal holder
thrust surfaces may result if the camshaft
journal holders (1) are not drawn down
evenly.

NOTE
• Each camshaft journal holder is identified
with a cast-on letters.
• The ascending order of numbers are
9) Bind the cam chain and the sprocket with a proper
indicated on the camshaft journal holders.
clamp (1) to prevent the cam chain disengagement
while installing the camshaft journal holders.
NOTE
The cam chain should now be on all three
sprockets. Be careful not to move the
crankshaft until the camshaft journal holders
and cam chain tension adjuster are secured.

13) Install the cam chain guide No.2 (1) with the
stamped mark (2) facing up side.
14) Tighten the cam chain guide bolts (3) to the specified
torque.
Tightening torque
10) Install the dowel pins (1) to the cylinder head. Cam chain guide No.2 bolts (a): 10 N·m (1.0 kgf­
m, 7.5 lbf-ft)
1 D-�2 Engine Mechanical:

IM10L1140062-01

15) Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque.
Tightening torque
Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
NOTICE
Temporary tighten in order the camshaft journal holder bolt "1 - 2", and then tighten in order the bolt
"3 - 12" to the specified torque.

NOTE
The camshaft journal holder bolts are made of a special material and much superior in strength,
compared with other types of high strength bolts.
Take special care not to use other types of bolts.

IM10L1140063-02
 Engine Mechanical: 1 D-23

16) Remove the clamps (1).

IM10L1140047-02

20) Install the cam chain tension adjuster (1), and then
17) Holding the cam chain tension adjuster (1), tighten the bolts (2) to the specified torque.
compress the plunger (2) by turning the adjuster
Tightening torque
body until the groove (4) reaches the outer circlip (3).
Cam chain tension adjuster bolt (a): 10 N·m (1.0
NOTICE kgf-m, 7.5 lbf-ft)
When turning the adjuster body, do not make
the groove (4) to cross the outer circlip (3). If
the inner circlip (5) is caught in the groove
(4), plunger may not come out automatically
from the adjuster body even if pushing force
is applied on the head. In such a case, it
needs to be replace.

IM10L 1140065-01

21) Release the lock of the cam chain tensioner adjuster

by turning the crankshaft 30 degrees "a"
counterclockwise.

NOTE
Before turning the crankshaft, confirm the
spark plugs has been removed.
IH17K1140067-01

18) Turn the plunger head (1) clockwise more than 90 °

to make a little play in the inner thread mechanism.

IM 1 0L 1140066-02

22) Confirm the cam chain tensioner adjuster for proper

operation by checking the cam chain slack.
19) Fit a new gasket (1).
1 D-24 Engine Mechanical:

28) Install the removed parts.

Camshaft Inspection
BENM10L31406019
Refer to "Cam Chain Tension Adjuster/ Camshaft
Removal" (Page 1 D-18) and "Cam Chain Tension
Adjuster/ Camshaft Installation" (Page 1 D-19).

Camshaft Identification
The camshafts can be identified by the embossed letter.

23) Check that the crankshaft rotates smoothly by

rotating the crankshaft (some turns) and recheck the
valve timing.

IM10L1140070-01

[A]: IN (Intake camshaft) [BJ: EX (Exhaust camshaft}

IM10L1140068-01

[A]: Intake side [BJ: Exhaust side Cam Wear

Check the camshaft for wear or damage.
24) Check and adjust the valve clearance. w(Page 1 D- Measure the cam height "a" with a micrometer.
26) Replace a camshaft if the cams are worn to the service
25) Apply engine oil to the new O-ring (1), and then limit.
install the new O-ring to the starter clutch cover cap.
Cam height
26) Install the new gasket (2) to the valve timing Intake [Limit]: 36.28 mm (1.429 in)
inspection cap. Exhaust [Limit]: 36.53 mm (1.439 in)
27) Tighten the valve timing inspection cap (3) and
Special tool
starter clutch cover cap (4) to the specified torque.
09900-20202
Tightening torque
Valve timing inspection cap {a): 23 N·m (2.3 kgf­
m, 17.0 lbf-ft)
Starter clutch cover cap {b): 11 N·m (1.1 kgf-m, "a"
8.5 lbf-ft)

I649G1140199-03

Camshaft Runout
Measure the runout using the dial gauge. Replace the
camshaft if the runout exceeds the limit.
Camshaft runout
Intake & Exhaust [Limit]: 0.10 mm (0.004 in)
Special tool
{A): 09900-20607
{B): 09900-20701
{C): 09900-21304

t "' '
�- �
� - -

�-- -, �,. - .:__ '- J"

IM10L1140069-01
 Engine Mechanical: 1 D-25

IF04K1140086-01

1947H1140066-01
Camshaft Journal Wear
Inspect the camshaft journal wear in the following
5) Remove the camshaft journal holders and measure
the width of the compressed plastigage using the
procedures:
envelope scale.
1) Determine whether or not each journal is worn down
6) This measurement should be taken at the widest
to the limit by measuring the oil clearance with the
part of the compressed plastigage.
camshaft installed in place.
2) Use the plastigage to read the clearance at the Camshaft journal oil clearance
widest portion, which is specified as follows. Intake [Limit]: 0.150 mm (0.0059 in)
Exhaust [Limit]: 0.150 mm (0.0059 in)
Special tool
(A): 09900-22303
(B): 09900-22304

1947H1140067-01

7) If the camshaft journal oil clearance exceeds the

IF04K1140087-01
limit, measure the inside diameter of the camshaft
3) lnst�!I each camshaft journal holder to its original journal holder and the outside diameter of the
posItIon. Refer to "Cam Chain Tension Adjuster/ camshaft journal. Replace the camshaft or the
Camshaft Installation" (Page 1 D-19). cylinder head depending upon which one exceeds
4) Tighten the camshaft journal holder bolts in the specification.
ascending order of numbers to the specified torque.
Refer to "Cam Chain Tension Adjuster/ Camshaft Camshaft journal holder I.D.
Installation" (Page 1 D-19).. Intake [Standard]: 24.012 - 24.025 mm (0.9454 -
0.9459 in)
NOTE Exhaust [Standard]: 24.012 - 24.025 mm (0.9454
Do not rotate the camshafts with the -0.9459 in)
plastigage in place. Camshaft journal O.D.
Intake [Standard): 23.959 - 23.980 mm (0.9433 -
Tightening torque 0.9441 in)
Camshaft journal holder bolt: 10 N·m (1.0 kgf­ Exhaust [Standard]: 23.959 - 23.980 mm (0.9433
m, 7.5 lbf-ft) - 0.9441 in)
Special tool
(A): 09900-20602
(B): 09900-22403
(C): 09912-66310
1 D-26 Engine Mechanical:

=----

0,L
·-·----
IF04K1140088-01

IH17K1140081-02

2) Check that the plunger goes out automatically when

its head (1) is tapped. If it does not work smoothly,
replace the cam chain tension adjuster with a new
one.

IF04K1140089-01

Camshaft Sprocket
Inspect the teeth of each camshaft sprocket (1) for wear
or damage.
If they are worn or damaged, replace the sprocket/
camshaft assembly and cam chain as a set.
IH17K1140082-01

Cam Chain Guide Inspection

BENM10L31406021
Refer to "Cam Chain Tension Adjuster/ Camshaft
Removal" (Page 1 D-18), "Cam Chain Tension Adjuster/
Camshaft Installation" (Page 1 D-19), "Crank Balancer/
Cam Chain Tensioner/ Oil Filter/ Oil Filter Stand / Oil
Pipe Removal" (Page 1 D-58) and "Crank Balancer/
Cam Chain Tensioner/ Oil Filter/ Oil Filter Stand
Installation" (Page 1 D-61).
Check the contacting surface of the cam chain guides. If
IM10L1140071-01 it is worn or damaged, replace it with a new one.

Cam Chain Tension Adjuster Inspection

BENM10L31406020
Refer to "Cam Chain Tension Adjuster/ Camshaft
Removal" (Page 10-18) and "Cam Chain Tension
Adjuster/ Camshaft Installation" (Page 1 D-19).
1) Turn the plunger (1) into the adjuster body until the
groove (3) reaches the outer circlip (2). Refer to
"Cam Chain Tension Adjuster/ Camshaft
Installation" (Page 1 D-19).

IM10L1140287-01

Valve Clearance Inspection and Adjustment

EiENM10L31406022
Refer to "Valve Clearance" in Section OB (Page 08-4).
 Engine Mechanical: 1 D-27

Engine Assembly Removal

BENM10L31406023
Before taking the engine out of the frame, wash the
engine using a steam cleaner. Engine removal is
sequentially explained in the following steps:
1) Remove the seat. w(Page 90-34)
2) Disconnect the battery(-) lead wire. w(Page 1 J-8)
3) Jack up the motorcycle and fix it for safety.
4) Drain engine oil. w(Page 0B-11)
5) Drain engine coolant. w(Page 0B-16)
6) Remove the throttle body assembly. w(Page 1 D-9)
7) Remove the radiator and radiator heat shield.
<?(Page 1 F-8)
8) Remove the oil cooler. w(Page 1 E-9)
9) Remove the exhaust system components. w(Page
1K-2)
10) Remove the clutch release cylinder holder, push rod
(1), engine sprocket nut(2), washer(3), sprocket
cover protector(4) and engine sprocket(5). w(Page
3A-3)

IM10L1140288-01

14) Disconnect the side-stand switch lead wire coupler

(1 ), gear shift sensor lead wire coupler(2), CKP
sensor lead wire coupler(3), generator lead wire
coupler(4), and GP sensor lead wire coupler(5).

IM10L 1140073-01

11) Mark the gearshift shaft head at which the gearshift

link arm slit is set for correct reinstall.
12) Remove the gear shift link arm bolt(1) and gearshift
link arm(2) from the gear shift shaft.

15) Remove the side-stand bracket bolt (1) and side­

stand(2) with its bracket from the frame.

� (�
,:r:�·-
rj-==--·.__

13) Release the clamps(1).

IM10L1140076-01
1 D-28 Engine Mechanical:

16) Remove the oil pressure switch lead wire bolt (1), 20) Support the engine with a proper jack.
and then disconnect the oil pressure switch lead wire 21) Remove the engine mounting bolts (1) and (2) from
(2) from the oil pressure switch. the cylinder head .

17) Disconnect the ECT sensor lead wire coupler (1) 22) Loosen the engine mounting pinch bolt (1).
from the ECT sensor.
23) Remove the engine mounting bolts (2) and (3) from
the cylinder head.

18) Disconnect the starter motor lead wire (1) and

engine ground lead wire (2).
24) Loosen the engine mounting thrust adjuster lock-nut
(1) with the special tool.
25) Loosen the engine mounting thrust adjuster (2) fully.
Special tool
(A): 09940-14990

19) Disconnect the CMP sensor lead wire coupler ( 1 ),

ignition coil / plug cap lead wire couplers (2) and 2
PAIR hoses (3). IM10L 1140088-01

r.

IM10L1140081-02
 Engine Mechanical: 1 D-29

[BJ

IM10L1140095-02

[A]: Rear upper side [B]: Rear lower side

26) Remove the engine mounting nuts (1) and (2).

27) Loosen the engine mounting thrust adjuster lock­

nuts (1) and (2) with the special tool.
28) Loosen the engine mounting thrust adjusters (3) and
(4)fully.
Special tool
(A): 09940-14990
NOTE
Do not remove the engine mounting bolts at
this stage.

[A]

IM10L1140092-01

IM10L1140093-02
1 D-30 Engine Mechanical:

IM10L1140091-01 IM10L1140097-01

29) Remove the engine mounting bolts and gradually

lower the front side of the engine.
Then, take off the driven chain from the drive shaft.
30) Remove the engine assembly.

Engine Assembly Installation

BENM10L31406024
Install the engine in the reverse order of engine removal.
Pay attention to the following points:
• Gradually raise the rear side of the engine assembly,
and then put the drive chain on the driveshaft.
NOTICE
Be careful not to catch the wiring harness
between the frame and the engine.

• Tighten the engine mounting thrust adjuster lock-nuts

·I.::> (1) to the specified torque with the special tool.
IM1 OL1140096-01 Special tool
• Install all engine mounting bolts and spacers, then (A): 09940-14990
tighten them temporarily.
Tightening torque
• Tighten the engine mounting thrust adjusters (1) to the Engine mounting thrust adjuster lock-nut (a): 45
specified torque. N·m (4.6 kgf-m, 33.5 lbf-ft)
Tightening torque
Engine mounting thrust adjuster (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)

IM10L 1140100-02
 Engine Mechanical: 1 D-31

• Tighten all engine mounting bolts and nuts to the

specified torque.
NOTE
The engine mounting nuts are self-locking.
Once the nuts have been removed, they are
no longer of any use.

• Tighten the engine mounting pinch bolt to the

specified torque.
1 D-32 Engine Mechanical:

LH ¢:i ¢ RH �
1"b"

A p---it�-�B

L. t!Jll

�---+--++---+--�□ .\
1"a"�

t?L
�
1· I �1"b"

/
1"a"�
11

11 �
1- 3"h"r'l"IIII
�

4�
11

E
l l � Y
,I
1 "c"
I.
11 �
r
\�3"9"t!]!ll

il 4�

/.,. r
�H

I I �3•g•t!Jll

�
�
D �

�- �h" t!Jll
t!Jll

I815H1140131-02

�.
"c": 320 mm (12.60 in)
1, Bolt �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
2. Spacer "d": 47 mm (1.85 in) 45 N-m (4.6 kgf-m, 33.5 lbf-ft)
3. Adjuster "e": 37.5 mm (1 .48 in) �: 55 N-m (5.6 kgf-m, 40.5 lbf-ft)
4. Nut "f': 243 mm (9.56 in) �: 75 N-m (7_6 kgf-m, 55.5 lbf-ft)
"a": 45 mm (1.77 in) "g": 43 mm (1.59 in) �: 35 N•m (3.6 kgf-m, 26.0 lbf-ft)
"b": 60 mm (2.36 in) "h": 39 mm (1.54 in)
 Engine Mechanical: 1 D-33

• Install the side-stand(1), and then tighten the new

side-stand bracket bolt(2) to the specified torque.
Tightening torque
Side-stand bracket bolt (a): 95 N·m (9.7 kgf-m,
4
70.0 lbf-ft)
.-- •
�
r�
·--:::1-

r.;
.' �--•·"·•-�
.,
"

IM10L1140103-01

• Connect the oil pressure switch lead wire(1), and

then tighten the oil pressure switch lead wire bolt(2)
to the specified torque.
Tightening torque
Oil pressure switch lead wire bolt (a): 1.5 N·m (
0.15 kgf-m, 1.10 lbf-ft) • Install the clutch release cylinder holder. <7(Page 3 A-
3)
• Connect the ignition coil / plug cap lead wire couplers
and PAIR hoses. Refer to "Ignition Coil Removal and
Installation" in Section 1 H(Page 1 H-4) and "PAIR
Reed Valve Removal and Installation" in Section 1 B
(Page 1 B-4).
• Connect the CMP sensor lead wire coupler. <7(Page
1 C-11)
Connect the starter motor lead wire and engine
ground lead wire. cjj"'(Page 9A-13)
IM10L1140289-01 • Connect the side-stand switch lead wire coupler, CKP
• Align the mark(1) on the gear shift shaft with the slit sensor lead wire coupler, generator lead wire coupler,
(2) of the gearshift link arm. GP sensor lead wire coupler and gearshift sensor
lead wire coupler. cjj"'(Page 9A-13)
• Align the center of hole(3) of the gearshift link arm
with the groove(4) of the gearshift shaft. • Connect the ETC sensor lead wire coupler.
• Tighten the gearshift link arm bolt(5) to the specified • Fill the engine oil. cjj"'(Page 0B-11)
torque. • Fill the engine coolant. <7(Page 0B-16)
Tightening torque • Install the radiator heat shield and radiator. w(Page
Gearshift link arm bolt (a): 10 N·m (1.0 kgf-m, 7.5 1 F-8)
lbf-ft) • Install the oil cooler. cjj"'(Page 1 E-9)
• Install the exhaust system components. w(Page 1 K-
2)
• After finishing the engine installation, check the
following items.
- Throttle valve synchronization w(Page 0B-15)
- Drive chain slack w(Page 0B-18)
- Engine oil and coolant leakage "Engine Oil" in
Section OB(Page 08-11) and "Radiator Hose" in
Section OB(Page 08-17).
• Connect the battery(-) lead wire. w(Page 1J-8)
• Install the seat. cjj"'(Page 9D-34)
1 D-34 Engine Mechanical:

Cylinder head Components

BENM10L31406025

l
1 �

'

IM10L1140106-02

1. Oil hose union bolt
(cam chain tension adjuster)
2. Gasket
3. Oil hose (cam chain tension adjuster)
4. Oil hose union bolt (Cylinder head)
5. Oil hose (cylinder head)
6. Cylinder head side bolt
8. Cylinder head bolt (L55)
9. Cylinder head bolt (L30)
10. Cylinder head bolt (L180)
: For tightening order, refer to "Cylinder
Head Installation" (Page 10-36).
11. Cylinder head
12. Cylinder head gasket
13. Dowel pin
(!IQ]: 18 N-m (1.8 kgf-m, 18.5 lbf-ft)
C!lml: 20 N-m (2.0 kgf -m, 15.0 lbf-ft)
t!IG): 14 N-m (1.4 kgf-m, 10.5 lbf-ft)
�: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
�: Cylinder head bolt (L180) (a): 28 N-m -
turn counterclockwise 270' - 10 N-m -, 25
N-m -, 51 N-m (2.9 kgf-m-, turn
counterclockwise 270' -, 1.0 kgf-m--. 2.5
kgf-m--, 5.2 kgf-m, 21.0 lbf-ft-, turn
counterclockwise 270° --, 7.5 lbf-ft-, 18.5
lbf-ft _, 38.0 lbf-ft)
"il1: Apply engine oil to bolt thread and seat.

7. Gasket 14. Water bypass hose 0: Do not reuse.

 Engine Mechanical: 1 D-35

Cylinder Head Removal

BENM 1 0L31406026
Refer to "Engine Assembly Removal" (Page 1 D-27) and
"Cam Chain Tension Adjuster/ Camshaft Removal"
(Page 1 D-18).
1) Remove the water bypass hose (1) from the cylinder
head.

5) Remove the cylinder head bolts (L55) (1) and

cylinder head bolt (L30) (2) from the cylinder.
6) Loosen the cylinder nuts (3).

2) Release the clamp (1 ).

3) Remove the oil hose bolts (2), oil hose (cam chain
tension adjuster) (3) and oil hose (cylinder head) (4)
from the cylinder head and upper crankcase.

_:,J
IM10L1140111-02

7) Remove cylinder head bolts (1).

NOTE
When loosening the cylinder head bolts,
loosen each bolt little by little diagonally.

8) Remove the cylinder head (2) from the cylinder.

. '
IM10L1140108-02

IM10L1140112-01

9) Remove the dowel pins (1) and cylinder head gasket

(2) from the cylinder.

IM10L1140109-03

4) Remove the cylinder head side bolt (1) and gasket

(2) from the cylinder head.
1 D-36 Engine Mechanical:

·- ,
IM10L1140113-02
,_ _j
IM10L1140113-02

2) Place the cylinder head on the cylinder.

Cylinder Head Installation
BENM10L31406027 NOTE
1) Install the dowel pins (1) and a new cylinder head When installing the cylinder head, keep the
gasket (2) to the cylinder. cam chain taut.

3) Install the cylinder head bolts (L180) to the cylinder according to the following procedure.
a) Apply engine oil to the both side of the washers "A" and thread portion "B'' of the bolts before installing the
cylinder head bolts.

"B"

"A"
IF04K1140331-03

b) Tighten the cylinder head bolt to 28 N-m (2.9 kgf-m, 21.0 lbf-ft) in numerical order "1" - "12".
c) In the same manner as in Step b), turn counterclockwise them to 270° .
d) In the same manner as in Step b), tighten them to 10 N-m (1.0 kgf-m, 7.5 lbf-ft).
e) In the same manner as in Step b), tighten them to 25 N-m (2.5 kgf-m, 18.5 lbf-ft), and then tighten to 51 N-m
(5.2 kgf-m, 38.0 lbf-ft).
Tightening torque
Cylinder head bolt (L180) (a): 28 N-m-+ turn counterclockwise 270° -+ 10 N-m-+ 25 N-m - 51 N-m (2.9
kgf-m - turn counterclockwise 270° - 1.0 kgf-m - 2.5 kgf-m - 5.2 kgf-m, 21.0 lbf-ft - turn
counterclockwise 270° - 7.5 lbf-ft - 18.5 lbf-ft-+ 38.0 lbf-ft)
 Engine Mechanical: 1 D-37

�-�-
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-t
r.="7", (

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JIU•
,.,.,.,.,,., '--"-

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. •�""' r-,,,:-.,.__-., I'!'!' •

,=.Ji...,�
-

"10",.....-I
1 1
(a)
--•

IM10L 1140114-02

4) Tighten the cylinder head bolt (1), (2) and cylinder 6) Install the new gasket (1) and cylinder head side bolt
nuts (3) to specified torque. (2) to the cylinder head, and then tighten the bolt to
the specified torque.
Tightening torque
Cylinder head bolt (L55) (a): 10 N·m (1.0 kgf-m, Tightening torque
7.5 lbf-ft) Cylinder head side bolt (a): 14 N·m (1.4 kgf-m,
Cylinder head bolt (L30) (b): 10 N·m (1.0 kgf-m, 10.5 lbf-ft)
7.5 lbf-ft)
Cylinder nut (c): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) NOTE
Install the cylinder head side bolt between
the cam chain.

-�
IM10L1140115-02

5) Apply engine oil to the both side of the new gasket

(1).

7) Install the oil hoses (1) and (2) with new gaskets and
oil hose union bolts (3) and (4), and then tighten the
oil hose union bolts to specified torque.
NOTE
Pass the oil hose (1) between the water hose
(5) and cylinder.

8) Clamp the oil hose (1) and water hose (5).

IM10L1140116-01
1 D-38 Engine Mechanical:

Tightening torque
Oil hose union bolt (cam chain tension adjuster)
(a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
Oil hose union bolt (cylinder head) (b): 20 N·m (
2.0 kgf-m, 15.0 lbf-ft)

IM10L1140119-01

9) Install the water bypass hose (1) to the cylinder

head.
 Engine Mechanical: 10-39

Valve and Cylinder Head Components

BENM10L31406028

,: 2 7

A
· · ··
-.;._;·;:
,

IM10L 1140120-02

r.-[A]: Face the small-pitch portion to the cylinder

head.
10. Cylinder head plug m: 23 N-m (2.3 kgf-m. 17.0 lbf-ft)

(.iii [BJ: The air bleeder hole of the thermostat faces 11. Gasket �: 10 N-m (1.0 kgf-m. 7.5 lbf-ft)
upside.
1. Tappet 12. Oil gallery bolt C!lGl 18 N-m (1.8 kgf-m, 13.5 lbf-ft)
2. Shim 13. ECT sensor �: 6 N-m (0.61 kgf-m, 4.45 lbf-ft)
3. Valve spring retainer 14. Thermostat cover bolt �: 1.5 N-m (0.15 kgf-m, 1.10 lbf-fl)
4. Valve cotter 15. Thermostat cover �: 12 N-m (1.2 kgf-m, 9.0 lbf-ft)

"111:
5. Valve spring 16. Thermostat Apply engine oil.

6. Oil seal

7. Valve spring seat

17. Thermostat cover air bolt

18. Intake pipe clamp

-w:0: Apply molybdenum oil.

Do not reuse.
8. Exhaust valve 19. Intake pipe
9. Intake valve 20. Water bypass union
1D-40 Engine Mechanical:

Valve / Valve Spring Removal and Installation

BENM10L31406029
Refer to "Cylinder Head Removal" (Page 1 D-35) and
"Cylinder Head Installation" (Page 1 D-36).

Removal
1) Remove the tappet (1) and shim (2) by fingers or
magnetic hand.

6) Remove the oil seal (1) and spring seat (2).

7) Remove the other valves in the same manner as
described previously.

IM10L1140121-01

2) Insert the special tool between the valve springs and

l
i�
cylinder head.
3) Using the special tools, compress the valve springs
and remove the two cotter halves ( 1) from the valve
stem.

NOTICE
Be careful not to damage the tappet sliding
' - .�
IM10L1140124-01

surface with the special tool.

Installation
Special tool 1) Install the valve spring seat (1).
(A): 09919-28620 2) Apply engine oil to the new oil seal (2), and press-fit
(B): 09916-14522 it into the position.
(C): 09916-14510
09916-84511

3) Insert the valve, with its stem coated with

IM10L1140122-03
molybdenum oil solution all around and along the full
4) Remove the valve spring retainer ( 1) and valve
stem length without any break.
spring (2).
5) Pull out the valve (3) from the combustion chamber NOTICE
side. When inserting the valve, take care not to
damage the lip of the oil seal.

"A": Assembly lubrication (Molybdenum oil

solution)
 Engine Mechanical: 1 D-41

2
3

"A"
IF04K1140149-01

4) Install each valve spring with the small-pitch portion

(1) facing cylinder head. IE31J1140175-02

3. Valve spring retainer 4. Cotter

4
7) Apply engine oil to the tappets (2).
3 8) Install the tappet shims (1) and the tappets (2) to

t their original positions.

NOTE
When seating the tappet shim, be sure the
IF04K1140150-01 figure printed surface faces the tappet.
2. Large-pitch portion 4. Paint
3. Upward

5) Put on the valve spring retainer (1), and using the

special tools, press down the springs, fit the cotter
halves (2) to the stem end, and release the lifter to
allow the cotter halves to wedge in between retainer
and stem.
NOTICE
• Be sure to restore each spring and valve to
their original positions.
IM10L1140127-01
• Be careful not to damage the valve and
valve stem when handling it.
Valve Inspection
• Compressing of the valve spring must be BENM10L31406030
limited to the extent only necessary to Refer to "Valve/ Valve Spring Removal and Installation"
prevent the spring from fatigue. (Page 1 D-40).

Special tool Valve Stem Runout

(A): 09916-14510 Support the valve using V blocks, as shown in the figure,
(B): 09916-14522 and check its runout using the dial gauge. If the runout
(C): 09919-28620 exceeds the service limit, replace the valve.
09916-84511
Valve stem runout
Intake & Exhaust [Limit]: 0.05 mm (0.0019 in)
Special tool
(A): 09900-20607
(B): 09900-20701
(C): 09900-21304

IM10L1140126-03

6) Be sure that the rounded lip (1) of the cotter fits

snugly into the groove (2) in the stem end.
1D-42 Engine Mechanical:

Valve Stem Deflection

Lift the valve about 10 mm (0.39 in) "a" from the valve
seat. Measure the valve stem deflection in two
directions, (1) and (2), perpendicular to each other,
positioning the dial gauge as shown. If the deflection
measured exceeds the limit, then determine whether the
valve or valve guide should be replaced with a new one.
Valve stem deflection
Intake & Exhaust
0.25 mm (0.010 in)
Special tool
IF04K1140154-01
(A): 09900-20607
09900-20701
Valve Head Radial Runout
Place the dial gauge at a right angle to the valve head (A)
face and measure the valve head radial runout. If it
measures more than the service limit, replace the valve.
Valve head radial runout
Intake & Exhaust [Limit]: 0_03 mm (0.0011 in)
Special tool
(A): 09900-20607
(B): 09900-20701
(C): 09900-21304
-------- - ...____,,
(A) IH18K1140324-02

Valve Stem Wear

IF04K1140155-01
Valve Face Wear
Visually inspect each valve face for wear. Replace any
valve with an abnormally worn face. The thickness of the
valve face decreases as the face wears. Measure the
valve head "a". If it is out of specification replace the
valve with a. new one.
Measure the valve stem O.D. using the micrometer. If it
is out of specification, replace the valve with a new one.
If the valve stem O.D. is within specification but the valve
stem deflection is not, replace the valve guide. After
replacing the valve or valve guide, recheck the
deflection.
Valve stem O.D.
Intake [Standard]: 4.975- 4.990 mm (0.1959 - 0.1965
in)
Exhaust [Standard]: 4.955- 4.970 mm (0.1951 -
0.1957 in)
Special tool
(A): 09912-66310

+
Valve head thickness
Intake & Exhaust [Limit]: 0.5 mm (0.019 in)

IF04K1140158-01
l649G1140233-02
 Engine Mechanical: 1 D-43

Valve Seat Width Valve Seat Sealing Condition

1) Visually check for valve seat width on each valve
face. If the valve face has worn abnormally, replace
the valve.
2) Coat the valve seat with a red lead (Prussian Blue)
and set the valve in place.
3) Rotate the valve with light pressure.
1) Clean and assemble the cylinder head and valve
components.
2) Fill the intake and exhaust ports with gasoline to
check for leaks. If any leaks occur, inspect the valve
seat and face for burrs or other things that could
prevent the valve from sealing. <r(Page 1 D-44)

Special tool
(A): 09916-10912

IM10L1140129-01

IM10L 1140128-01

4) Check that the transferred red lead (blue) on the

valve face is uniform all around and in center of the
valve face.
If the seat width "a" measured exceeds the standard
value, or seat width is not uniform reface the seat
using the seat cutter. CiF(Page 1 D-44)
Valve seat width
Intake [Standard]: 0.9 -1.1 mm (0.036 - 0.043 in)
Exhaust [Standard]: 0.9 - 1.1 mm (0.036 - 0.043
in)

I649G1140246-02
10-44 Engine Mechanical:

Valve Seat Repair Check the valve springs for proper strength by
BENM10L31406031 measuring its free length and also by the force required
The valve seats (1) for both the intake and exhaust to compress it. If the spring length is less than the
valves are machined to three different angles. The seat service limit or if the force required to compress the
contact surface is cut at 45° . spring does not fall within the range specified, replace
NOTICE spring as a set.

• The valve seat contact area must be Valve spring free length
inspected after each cut. Intake & Exhaust [Limit]: 42.0 mm (1.653 in)
• Do not use lapping compound after the Valve spring pre-load
final cut is made. The finished valve seat When compressed to 36.8 mm (1.449 in)
should have a velvety smooth finish but Intake & Exhaust [Standard]
not a highly polished or shiny finish. This 149 -171 N (15.2 -17.4 kgf, 33.5 - 38.4 lbf)
will provide a soft surface for the final
seating of the valve which will occur
during the first few seconds of engine
operation.
• The titanium valves are coated with an
oxidized membrane treatment to resist
wear but the membrane tend to removed if
IK34K2140017-01
lapped after valve seat servicing.

NOTE
After servicing the valve seats, be sure to
check the valve clearance after the cylinder
head has been reinstalled. 17 (Page 1 D-26)

ID26J1140263-01

Cylinder Head Disassembly and Reassembly

BENM10L31406033
Refer to "Cylinder Head Removal" (Page 1D-35) and
"Cylinder Head Installation" (Page 1D-36).
[A] [BJ
IF04K1140326-02
Disassembly
[A]: Intake valve [BJ: Exhaust valve
1) Remove the ECT sensor (1) and gasket from the
cylinder head.
Intake Exhaust
Seat angle 30°/45°/60° 15 °/45°/60°
0.9-1.1 mm
Seat width +-
(0.036 - 0.043 in)
Valve 33 mm 27.5 mm
diameter (1.30 in) (1.08 in)
Valve guide 5.000 - 5.012 mm
+-
I.D. (0.1969 - 0.1973 in)

Valve Spring Inspection

BENM10L31406032
Refer to "Valve/ Valve Spring Removal and Installation"
(Page 1D-40). IM10L1140130-01
The force of the coil spring keeps the valve seat tight.
2) Remove the thermostat cover bolts (1) and
Weakened spring results in reduced engine power
thermostat cover (2) from the cylinder head.
output and often accounts for the chattering noise
coming from the valve mechanism.
 Engine Mechanical: 1 D-45

6) Remove the oil gallery bolt (1) and gasket from the
cylinder head.

-,.., 11

IM10L1140132-01

3) Remove the thermostat (1) from the cylinder head.

IM10L1140136-01

7) Remove the cylinder head plug (1) and gasket from

the cylinder head.

IM10L1140133-01

4) Loosen the intake pipe clamp screws (1), and then

remove the intake pipes (2) from the cylinder head.
IM10l11401 3 7 -01

2 Assembly
Assembly is in the reverse order of disassembly. Pay
attention to the following points:
• Install the cylinder head plug (1) and oil gallery bolt (2)
with the new gasket, and then tighten the oil gallery
bolt and cylinder head plug.
Tightening torque
Cylinder head plug (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
IM10L1140134-01 Oil gallery bolt (Cylinder head) (b): 10 N·m (1.0
5) Remove the water bypass union (1) from the cylinder kgf-m, 7.5 lbf-ft)
head.

IM10L1140138-01
IM10L1140135-01
1 D-46 Engine Mechanical:

Tightening torque
Water bypass union (a): 12 N·m (1.2 kgf-m, 9.0
lbf-ft)

IM10L1140139-01

• Install the new water bypass union (1) to the cylinder

head, and then tighten the specified torque.
IM10L1140140-01

• Set the clamp screws as shown in the figure.

[A]

ti
- ¢ [D]

"a" uan Ila" Uall

[B]
IM10L1140141-01

[AJ: Front [BJ: Rear [C]: Left [DJ: Right "a": 35° - 55°

• Tighten the clamp screw (1) to the specified torque. NOTE

Tightening torque The air bleeder hole (2) of the thermostat
Clamp screw (a): 1.5 N·m (0.15 kgf-m, 1.10 lbf-ft) faces upside.

. ... .. · .­

l... ..::,,
"'
,. .
.. '

,.l J<

. . . . "'
. .,

IM10L1140142-01

• Install the thermostat (1) to the cylinder head. IM10L 1140143-01

• Install the thermostat cover (1), and then tighten the
thermostat cover bolts (2) to the specified torque.
Tightening torque
Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
i.

Engine Mechanical: 1 D-47

Valve Guide Replacement

BENM10L31406035
Refer to "Valve/ Valve Spring Removal and Installation"
(Page 1 D-40).
1) Using the valve guide remover, drive the valve guide
out toward the intake or exhaust camshaft side.
Special tool
(A): 09916-44310

NOTE
• Discard the removed valve guide sub­
IM10L1140144-01 assemblies.
• Install the ECT sensor with new gasket to the cylinder • Only oversized valve guides are available
head, and then tighten the ECT sensor (1) to the as replacement parts. (Part No. 11115-
specified torque. 15H70)
Tightening torque
ECT sensor (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)

IM10L1140145-01
IM10L1140147-03

Cylinder Head Inspection 2) Refinish the valve guide holes in the cylinder head
BENM10L31406034 using the reamer and handle.
Refer to "Cylinder Head Removal" (Page 1 D-35) and 3) Remove the special tools by turning clockwise and
"Cylinder Head Installation" (Page 1 D-36). raising them at the same time.
1) Decarbonize the combustion chambers.
2) Check the gasket surface of the cylinder head for NOTICE
distortion with a straightedge and thickness gauge, Never turn the special tools
taking a clearance reading at several places as counterclockwise, as this will dull the blades.
indicated. If the largest reading at any position of the
straightedge exceeds the limit, replace the cylinder Special tool
head. (A): 09916-34580
(B): 09916-34542
Cylinder head distortion
[Limit]: 0.20 mm (0.0078 in)
Special tool
09900-20803

IM10L1140148-03

4) Cool down the new valve guides in a freezer for

about one hour and heat the cylinder head to 100 -
150 °C (212 - 302 °F) with a hot plate.

IM10L 1140146-01
1D-48 Engine Mechanical:

NOTICE 7) After installing the valve guides, refinish their guiding

Do not use a burner to heat the valve guide bores using the reamer. Be sure to clean and oil the
hole to prevent cylinder head distortion. guides after reaming.

NOTE
5) Apply engine oil to each valve guide and valve guide
hole. • Be sure to cool down the cylinder head to
6) Drive the guide into the guide hole using the valve ambient air temperature.
guide installer. • Insert the reamer from the combustion
chamber and always turn the reamer
NOT/CE
handle clockwise.
Failure to oil the valve guide hole before
driving the new guide into place may result in Special tool
a damaged guide or head. (A): 09916-34542
(B): 09916-34570
Special tool
(A): 09916-44310
(B): 09916-53350

IM10L1140151-03

IM10L1140150-01

1. Cylinder head "a": 18.0 mm (0.71 in)

IM10L1140149-03
 Engine Mechanical: 1 D-49

Cylinder/ Cam Chain Guide No.1 / Piston / Piston Ring Components

BENM10L31406036
NOTE
The components of the piston are the same from # 1 to # 4.

13

� 14-ri

'"" ""
'-, V

. /'\_

"'-,V _/,
12
"" ""
"" ""

U
--p
5-

IM10L1140152-03
1. Cam chain guide 7. Piston pin 13. Water inlet connector
2. Cylinder nut 8. Piston �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
3. Cylinder 9. Oil ring
-mi: Apply oil.

4. Cylinder gasket

5. Dowel pin
10. 2nd ring

11. 1st ring

111., Apply molybdenum oil.

Do not reuse.
6. Piston pin circlip 12. Water hose
1 D-50 Engine Mechanical:

Cam Chain Guide No.1 / Cylinder / Piston

Removal
BENM10L31406037
Refer to "Cylinder Head Removal" (Page 1 D-35).
Refer to "Cylinder Head Installation" (Page 1 D-36).

Cam Chain Guide No.1

1) Remove the cam chain guide No.1 (1) from the
cylinder.

IM10L1140156-02

Piston
1) Place a clean rag over the cylinder base so as not to
drop the piston pin circlips into the crankcase.
2) Remove the piston pin circlip (1) from the piston.

IM10L1140153-02

Cylinder
1) Remove the water hose (1) from the cylinder.

IM10l1140157-01

3) Draw out the piston pin (1) and remove the piston
(2).
NOTE
Scribe the cylinder number on the piston
head.
IM10l1140154-01

2) Remove the cylinder nuts (1), and then remove the

cylinder (2).

IM10L1140158-01

3) Remove the dowel pins (1) and cylinder gasket (2).

 Engine Mechanical: 1D-51

Piston ring
1) Carefully spread the ring opening with your thumbs
and then push up the opposite side of the 1st ring to
remove it.
NOTE
Do not expand the piston ring excessively
since it is apt to be broken down.

[B]
IH17K1140241-01

[A]: Incorrect I [BJ: Correct

b) Install the 2nd ring (1) and 1st ring (2) to piston.
NOTE
• 1st ring (2) and 2nd ring (1) differ in shape.
• Face the side with the stamped mark
upward when assembling.
I837H1140181-01

2) Remove the 2nd ring and oil ring in the same

manner.
J
1·
t-2

s
Cam Chain Guide No.1 / Cylinder/ Piston
�
Installation
BENM10L31406038

L
Piston ring
t-1
NOTE
• When installing the piston ring, be careful IM10L1140159-01

not to damage the piston.

• Do not expand the piston ring excessively
since it is apt to be broken down.

1) Install the piston rings in the order of the oil ring, 2nd
ring and 1st ring.
a) The first member to go into the oil ring groove is
the spacer (1).
After placing the spacer, fit the two side rails (2).
NOTICE I823H1140148-03

When installing the spacer, be careful not to 2) Position the gaps of the piston rings and side rails as
allow its two ends to overlap in the groove. shown. Before inserting piston into the cylinder,
check that the gaps are so located.

IF04K1140328-02
1 D-52 Engine Mechanical:

NOTE
[A]
• Be sure to install the pistons in the
cylinders from which they were removed in
disassembly, refer to the cylinder
numbers, #1 through #4, scribed on the
piston.
• When installing the pistons, the indent (3)
on the piston head must be faced to
exhaust side.

3
[BJ
IH18K1140213-01

[A]: EX.
[BJ: IN.
1. 2nd ring and lower side rail
2. Upper side rail
3. 1st ring and spacer
"a": 120°

Piston
1) Apply a small quantity of molybdenum oil solution to
the piston pin (1) and sliding surface of the pistons
(2). 3) Install the new piston pin circlip (1).

"A": Assembly lubrication (Molybdenum oil NOTE

solution) • Place a clean rag over the cylinder base so
as not to drop the piston pin circlips into
the crankcase.
• End gap of the circlip should not be
aligned with the cutaway (2) in the piston
pin bore.

IM10L1140160-01

2) Install the piston (1 ), piston pin (2).

IM10L1140162-01

Cylinder
1) Fit the dowel pins (1) and a new gasket (2) to the
upper crankcase.
 Engine Mechanical: 1 D-53

NOTE
Some light resistance must be overcome to
lower the cylinder.

5) After inserting the No. 2 and No. 3 pistons in place,

IM10L1140156-02
2) Apply a small quantity of molybdenum oil solution to
the sliding surface of the pistons (1).
6) Install the cylinder (1), and then tighten he cylinder
"A": Assembly lubrication (Molybdenum oil
solution)
insert the No. 1 and No. 4 pistons in the same
manner of the No. 2 and No. 3 pistons.
NOTE
When installing the cylinder block, keep the
cam chain taut. The cam chain must not be
caught between cam drive sprocket and
crankcase when turning the crankshaft.
nuts (2) temporary.

IM10L1140163-01

3) Install special tools to the No. 2 and No. 3 pistons. Cam Chain Guide No.1
Special tool 1) Install the cam chain guide No.1 (1) to the cylinder.
(A): 09916-74521
(B): 09916-74550
NOTE
Do not over tighten the bands, or the piston
installation into the cylinders will be difficult.

IM10L1140153-02

IM10L1140164-01

4) Insert the No. 2 and No. 3 pistons into the cylinder.

1 D-54 Engine Mechanical:

Cylinder Disassembly and Reassembly Cylinder Inspection

BENM10L31406039 BENM10L31406040
Refer to "Cam Chain Guide No.1/Cylinder/ Piston Refer to "Cam Chain Guide No.1/Cylinder/ Piston
Removal" (Page 1 D-50). Removal" (Page 1 D-50).
Refer to "Cam Chain Guide No.1/ Cylinder/ Piston Refer to "Cam Chain Guide No.1/Cylinder/ Piston
Installation" (Page 1 D-51). Installation" (Page 1 D-51).

Disassembly Cylinder Distortion

1) Remove the water inlet connector bolts (1) and water Check the gasket surface of the cylinder for distortion.
inlet connector (2). Use a straightedge and thickness gauge. Take clearance
readings at several places. If any reading exceeds the
service limit, replace the cylinder.
Special tool
09900-20803
Cylinder distortion
[Limit]: 0.20 mm (0.008 in)

IM10L1140166-01

Reassembly
Assembly is in the reverse order of disassembly. Pay
attention to the following points:
• Apply engine coolant to new O-ring (1) of water inlet
connector (2).
I823H1140144-01

Cylinder Bore
Check the cylinder wall for any scratches, nicks or other
damage. Measure the cylinder bore diameter at six
places.
2
Special tool
(A): 09900-20530
Cylinder bore
[Standard]: 81.000- 81.015 mm (3.1890- 3.1896 in)
[Limit]: No nicks or Scratches
IM10L 1140169-01

• Tighten the water inlet connector bolts (1) to the

specified torque.
Tightening torque
Water inlet connector bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

IM10L1140171-01

IM10L 1140170-01
 Engine Mechanical: 1 D-55

Piston to Cylinder Clearance

Subtract the piston diameter from the cylinder bore
diameter. If the piston to cylinder clearance exceeds the
service limit, replace both the cylinder and the piston.
Piston to cylinder clearance
[Limit]: 0.120 mm (0.0047 in)

Piston Ring to Groove Clearance

I823H1140146-02
Measure the side clearances of the 1st and 2nd piston
rings using the thickness gauge. If any of the clearances
Piston-to-cylinder Clearance exceed the limit, replace both the piston and piston
Refer to "Piston/ Piston Ring Inspection" (Page 1D-55). rings.
Piston ring to groove clearance
Piston / Piston Ring Inspection 1st [Limit]: 0.180 mm (0.0070 in)
BENM10L31406041
2nd [Limit]: 0.150 mm (0.0059 in)
Refer to "Cam Chain Guide No.1/ Cylinder / Piston
Removal" (Page 1 D-50) and "Cam Chain Guide No.1/ Piston ring groove width
Cylinder/ Piston Installation" (Page 1D-51). 1st [Standard] "a": 0.83 - 0.85 mm (0.0327 -0.0335
in)
Piston Diameter 1st [Standard] "b": 1.30-1.32 mm (0.0512- 0.0520
Measure the piston diameter using the micrometer at 8.5 in)
mm (0.3 in) "a" from the skirt end. If the piston diameter 2nd [Standard]: 1.01 - 1.03 mm (0.0398 - 0.0406 in)
is less than the service limit, replace the piston. Oil [Standard]: 2.01 - 2.03 mm (0.0791 - 0.0799 in)
Piston diameter
Measure at 8.5 mm (0.3 in) from the skirt end. "b"
"a ll
[Limit]: 80.850 mm (3.1831 in)
Special tool
t
(A): 09900-20203

I823H1140580-02

Piston ring thickness

1st [Standard] "a": 0.76 - 0.81 mm (0.0299 - 0.0319
in)
IF04K1140240-01
1st [Standard] "b": 1.08 - 1.10 mm (0.0425- 0.0433
in)
2nd [Standard]: 0.97 - 0.99 mm (0.0382 - 0.0390 in)
Special tool
(A): 09900-20803
(B): 09912-66310

"a"

J
IF04K1140241-01

"b"
I
IM10L 1140173-01
1D-56 Engine Mechanical:

(A)

IF04K1140242-01

IM10L1140174-01

Piston Pin and Pin Bore

Measure the piston pin bore inside diameter using the
small bore gauge. If either is out of specification or the
difference between these measurements surpass limits,
replace the piston.
Piston pin bore I.D.
[Limit]: 18.030 mm (0.7098 in)
Special tool
IF04K1140243-01
(A): 09900-20602
Piston Ring Free End Gap and Piston Ring End Gap (B): 09900-22401
Measure the piston ring free end gap using vernier
calipers. Next, fit the piston ring squarely into the
cylinder and measure the piston ring end gap using the
thickness gauge. If any of the measurements exceed the
service limit, replace the piston ring with a new one.
Piston ring free end gap
1st [Limit]: 5.2 mm (0.20 in)
2nd [Limit]: 7.2 mm (0.28 in)
IF04K1140246-01
Piston ring end gap Measure the piston pin outside diameter at three
1st [Limit]: 0.50 mm (0.019 in) positions using the micrometer. If any of the
2nd [Limit]: 0.50 mm (0.019 in) measurements are out of specification, replace the
Special tool piston pin.
(A): 09900-20803 Piston pin O.D.
[Limit]: 17.98 mm (0.7079 in)
Special tool
(A): 09912-66310

IK46K1140139-01

IF04K1140323-02
 Engine Mechanical: 1 D-57

Crank Balancer/ Cam Chain Tensioner/ Oil Filter/ Oil Filter Stand / Oil Pipe Components
BENM10L31406042

.-.,:
. ,•

4 �
�·,r• if?;':
<
1cv,
......_
· ,,,
,......____
......____
/
/
3 �
/
8 _
/
9� _/-

10 -......._ ' _/-

"-- '✓ - /

�7�
IM10L1140175-01

1. Cam chain tensioner bolt 11. Oil separator bolt 21. Damper
2. Cam chain tensioner 12. Oil separator 22. Crank balancer
3. Oil filter 13. Balancer shaft mounting bolt �: 23 N-m (2.3 kgf-m, 17.0 lbf-ft)
4. Oil filter stand 14. Balancer shaft arm bolt �: 20 N-m (2.0 kgf-m, 15.0 lbf-fl)
5. Oil pipe union bolt 15. Balancer shaft arm C!IBJ: 15 N·m (1.5 kgf-m, 11.0 lbf-ft)
6. Gasket 16. Balancer shaft C!mE: 24 N-m (2.4 kgf-m, 18.0 lbf-ft)
7. Oil pipe bolt 17. Washer �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)

-a1:
8. Oil pipe 18. Bearing Apply engine oil.

9. O-ring 19. Spacer �: Apply SUZUKI SUPER GREASE A.

10. Cushion 20. Balancer gear �: Do not reuse.
1 D-58 Engine Mechanical:

Crank Balancer/ Cam Chain Tensioner/ Oil

Filter/ Oil Filter Stand / Oil Pipe Removal
BENM 1 0L31406043
• Refer to "Engine Assembly Removal" (Page 1 D-27).
• Refer to "Cam Chain Guide No.1 / Cylinder / Piston
Removal" (Page 1 D-50).
• Refer to "Cam Chain Guide No.1 / Cylinder / Piston
Installation" (Page 1 D-51).

PCV Cover
Remove the PCV hose (1) and cover (2). <lr(Page 1 B-6)
IM10L 1140179-02

Cam Chain
Remove the cam chain (1) and cam chain drive sprocket
(2).

IM10L1140176-02

Cam Chain Tensioner

Remove the cam chain tensioner bolt (1), cam chain
tensioner (2), cam chain guide retainer bolt (3) and cam
chain guide retainer (4).

IM10L1140177-02

Starter Motor
Remove the starter motor (1). Cs"'(Page 11-6)

IM10L1140181-01

·1M10L1140178-02

Starter Torque Limiter / Starter Clutch

Remove the starter torque limiter (1) and starter clutch
(2). <7(Page 11-10)
 Engine Mechanical: 10-59

Clutch
Remove the clutch component parts (1). w(Page 5C-17)

'(
IM10L1140185-02

IM10L114018 2-02 Water Pump

Remove the water pump (1). <?(Page 1F-15)
Oil Pump
Remove the oil pump (1). c:u-(Page 1 E-14)

p---· W, (�
,::..--::;- ·

--
�
.�

•I - ..
IM10L1140183-02 Gearshift System
IM10L1140186-04

1) Remove the oil seal retainer bolts (1) and oil seal
GP Sensor retainer (2) from the upper crankcase and lower
.Remove the GP sensor (1). c:u-(Page 58-14) crankcase.

IM10L1140184-02 IM10L1140187-01

2) Remove the gearshift cover bolts (1) and gearshift

Generator
cover (2) from the lower crankcase.
Remove the generator component parts (1). (g'>(Page 1 J-
4)

IM10L1140188-01
1 D-60 Engine Mechanical:

3) Remove the dowel pins (1) and gasket (2) from the Oil Filter/ Oil Filter Stand
lower crankcase. 1) Remove the oil filter (1). <:lr'(Page 08-1 2)

IM10L1140193-01
4) Remove the gearshift assembly (1) from the lower 2) Remove oil filter stand from the lower crankcase
crankcase. using special tool and wrenches, if necessary.
Special tool
(A): 09915-41510

==---��
(A)
)

,, ' - --------� I
� I {
5) Remove the gearshift cam plate stopper bolt (1),
gearshift cam plate stopper (2) and gearshift cam
\:�
plate (3). IM10L1140194-03

Oil Pipe
1) Remove the oil pipe bolts (1), union bolt (2), gaskets
and oil pipe (3).
2) Remove the cushion (4).

6) Remove the gearshift cam stopper bolt (1), gearshift

cam stopper (2), washer and spring (3) from the
lower crankcase.

IM10L1140195-01

Oil Pressure Switch

Remove the oil pressure switch (1) from the lower
crankcase. .,,..(Page 1 E-11)
 Engine Mechanical: 1 D-61

4) Remove the crank balancer assembly (1) and

Oil Pan/ Oil Pressure Regulator/ Oil Strainer/ washers (2) from the lower crankcase.
Breather Pipe
1) Remove the following parts. i:r(Page 1 E-6)
Oil pan
• Oil strainer
• Breather pipe

Crank Balancer
1) Remove the oil separator bolt (1) and oil separator
(2) from the lower crankcase.

IM10L1140200-01

Crank Balancer/ Cam Chain Tensioner/ Oil

Filter/ Oil Filter Stand Installation
BENM10L31406044
Crank Balancer
1) Temporarily install the cam chain drive sprocket,
starter clutch and starter clutch cover. i:r(Page 11-10)
2) Turn the crankshaft to bring the line (1) on starter
.� clutch to the slit (2) of the valve timing inspection
IM10L1140197-01
hole.
2) Remove the balancer shaft arm bolt (1), balancer
shaft mounting bolt (2) and balancer shaft arm (3).

IM10L1140198-02

3) Remove the balancer shaft (1) from the crank

balancer assembly.
1 D-62 Engine Mechanical:

NOTE
Make sure that the positions of #1 piston and
#4 piston are at top dead center (TDC) of the
compression stroke.
NOTE
Make sure that the engraved line (2) on the
crank balancer, the punch mark (3) on the
balancer gear, and the triangle mark (4) on
the crankcase are aligned.

IM10L1140203-01

5) Install the balancer shaft(1) to the crank balancer

assembly.

3) Apply engine oil to the washers(1), and then install

the washers to the crank balancer assembly(2).

IM1 0L1140204-01

6) Install the balancer shaft arm(1) to the balancer

shaft, and then tighten the new balancer shaft arm
bolt(2) to the specified torque.
Tightening torque
Balancer shaft arm bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

IM10L1140202-02

4) Hold the crankshaft and install the crank balancer

assembly(1).

IM10L1140205-01

7) Slowly turn the balancer shaft(1) clockwise until it

stops(position(2)) with a(-) screwdriver.
8) From this position, turn the balancer shaft (1)
counterclockwise by 1.5 - 2 graduations(3), and
then tighten the bolt(4) to the specified torque.
From(2) to(3): 1.5 - 2 graduations.
 - ------Engine Mechanical: 1 D-63

NOTE • Breather pipe

If the balancer gear is noisy after starting the
engine, turn in or out the balancer shaft Oil Pressure Switch
Install the oil pressure switch (1). <ir(Page 1E-11)
within 1 graduation from standard setting to
reduce the gear noise.

Tightening torque
Balancer shaft mounting bolt (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)

Oil Pipe
1) Apply grease to the new O-ring (1), and then install
the new O-ring to the oil pipe.
"A": Grease 99000-25011 (SUZUKI SUPER
GREASE A)

IM10l1140207-01

9) Install the oil separator cover (1), and then tighten
the oil separator cover bolt (2) to the specified
torque.
Tightening torque
Oil separator cover bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
5) Tighten the oil pipe bolt (4) and oil pipe union bolt (1)
IM10l1140209-01
2) Apply engine oil to the oil pipe union bolt (1) threads.
3) Install the oil pipe (2), new gaskets (3), new oil pipe
bolt (4) and oil pipe union bolt (1) to the upper
crankcase and lower crankcase.
4) Install the cushion (5) to the oil pipe.
to the specified torque.
Tightening torque
Oil pipe bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Oil pipe union bolt (b): 24 N·m (2.4 kgf-m, 18.0
lbf-ft)

2
b)

IM10l1140208-01

Oil Pan/ Oil Pressure Regulator I Oil Strainer/

Breather Pipe
1) Install the following parts. c,r(Page 1E-6)
• Oil pan
• Oil strainer
1 D-64 Engine Mechanical:

Oil Filter / Oil Filter Stand 4) When installing the gearshift cam plate (1), align the
1) Install the oil filter stand (1) to the lower crankcase, gearshift cam pin (2) with the hole (3) of gearshift
and then tighten the oil filter stand with special tool to cam plate.
the specified torque.
Special tool
(A): 09915-41510
Tightening torque
Oil filter stand (a): 15 N·m (1.5 kgf-m, 11.0 lbf-ft)

IM10L1140293-01

5) When installing the gearshift cam stopper (1), align

the projection (2) of gearshift cam stopper with the
groove (3) of gearshift cam plate (4).
6) Tighten the gearshift cam plate stopper bolt (5) to the
specified torque.
IM10L1140211-03 Tightening torque
2) Install the oil filter (1 ). w(Page 0B-12) Gearshift cam plate stopper bolt (a): 13 N·m (1.3
kgf-m, 9.5 lbf-ft)

Gearshift System
1) Install the gearshift cam stopper (1), spring (2) and
gearshift cam stopper bolt (3).
2) Tighten the gearshift cam stopper bolt (3) to the
specified torque.
Tightening torque
Gearshift cam stopper bolt (a): 10 N·m (1.0 kgf­
m, 7.5 lbf-ft)

7) Install the gearshift assembly (1) to the lower

crankcase.

IM10L1140212-01

3) Degrease the thread of gearshift cam plate stopper

bolt (1).
 Engine Mechanical: 1 D-65

8) Install the dowel pins (1) and new gasket (2) to the
lower crankcase. Generator
Install the generator component parts (1). w(Page 1 J-6)

1
IM10L1140185-02
9) Install the gearshift cover (1) and gearshift cover
bolts (2) to the lower crankcase, and then tighten the
Cam Chain Tensioner
gearshift cover bolts to the specified torque.
Install the cam chain tensioner (1) and cam chain
Tightening torque tensioner bolt (2) to the upper crankcase, and then
Gearshift cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 tighten the cam chain tensioner bolt to the specified
lbf-ft) torque.
Tightening torque
Cam chain tensioner bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

IM10L1140216-01

Water Pump
Install the water pump (1). (D"'(Page 1F-15)
IM10L1140217-01
1 D-66 Engine Mechanical:

Cam Chain Oil Pump

1) Install the cam chain drive sprocket (1) to the Install the oil pump (1). Clr'(Page 1E-14)
crankshaft.
F� ·.
NOTE
Align the wide spline tooth (2) of cam chain
drive sprocket and that of crankshaft.
•.

--•
.;)
!)
··., ··,.

�IM10L1140183-02

Clutch
Install the clutch component parts (1). Clr'(Page 5C-17)

'I! I
V) ✓/
I), I
2) Install the cam chain (1) onto the cam chain drive
sprocket. . '
•

IM10L1140182-02

Starter Torque Limiter/ Starter Clutch

Install the starter torque limiter (1) and starter clutch (2).
<F(Page 11-10)
IM10L1140219-01

GP Sensor
Install the GP sensor (1). Clr'(Page 58-14)

IM10L1140179-02

IM10L1140184-02
 Engine Mechanical: 1 D-67

Starter Motor
Install the starter motor (1). or(Page 11-6)

IM10L1140290-01

Crank Balancer Disassembly and Reassembly

BENM10L31406046

PCV Cover Refer to "Crank Balancer/ Cam Chain Tensioner / Oil

Install the PCV cover (2) and hose (1). Cl!"(Page 1 B-6) Filter/ Oil Filter Stand/ Oil Pipe Removal" (Page 1 D-58)
and "Crank Balancer/ Cam Chain Tensioner/ Oil Filter/
Oil Filter Stand Installation" (Page 10-61 ).

Disassembly
1) Remove the washers (1), bearings (2) and spacer
(3) from the crank balancer.

IM10L1140177-02

IM10L1140220-02

2) Remove the balancer gear (1) along with the

dampers (2) from the crank balancer.
3) Remove the dampers (2) from the balancer gear (1).

IM10L 1140176-02

• Refer to "Cam Chain Guide No.1/ Cylinder/ Piston

Removal" (Page 1 D-50).
• Refer to "Cam Chain Guide No.1 / Cylinder/ Piston
Installation" (Page 1 D-51).
• Refer to "Engine Assembly Installation" (Page 1 D-30).

Cam Chain Tensioner Inspection

BENM10L31406045
Refer to "Crank Balancer I Cam Chain Tensioner/ Oil IM10L 1140221-01

Filter/ Oil Filter Stand/ Oil Pipe Removal" (Page 10-58)

and "Crank Balancer/ Cam Chain Tensioner/ Oil Filter/
Oil Filter Stand Installation" (Page 1 D-61).
Check the contacting surface of the cam chain tensioner.
If it is worn or damaged, replace it with a new one.
1 D-68 Engine Mechanical:
,
Assembly
1) Apply engine oil to the dampers (1 ).

IM10L1140220-02

IM10L1140222-01 Crank Balancer Inspection

BENM10L31406047
2) Install the crank balancer (1) to the balancer gear Refer to "Crank Balancer Disassembly and Reassembly"
(2). (Page 10-67).
NOTE
Damper
• Align the portion (3) of the crank balancer Inspect the damper for wear and damage, replace it if
with between the dampers (4). any defects are found.
• Align the engraved line (5) on the crank
balancer with the punched mark (6) on the
balancer gear.

I
!
L I823H1140273-01

Bearing and Washer

Inspect the bearings (1) and the washers (2) for wear or
IM10L 1140223-01
damage. Replace the bearing or the washer if there is
anything unusual.

IM10L1140224-02
IM10L1140225-01
3) Apply engine oil to the washers (1), bearings (2) and
spacer (3).
4) Install the washers (1), bearings (2) and spacer (3) to
the crank balancer.
 Engine Mechanical: 1 D-69

Balancer Shaft
Inspect the balancer shaft for wear or damage. Replace
the balancer shaft if there is anything unusual.

I823H1140275-01
1 D-70 Engine Mechanical:

Crankcase/ Crankshaft/ Crankshaft journal bearing/ Oil Jet/ Oil gallery plug Components
BENM10L31406048

0
17 � �/

'"'-1
�

i 'I��
�9�

o
�f.ji[A]

13-----'-=\
,j � □ qi
. ·�-
\
'. I)
I

A
,,,. \

19�

IM10L1140226-02
 Engine Mechanical: 1 D-71

f.i[A]: The new gasket is installed in the direction 11. Upper crankcase �: 22 N-m-+ turn clockwise 30° (2.2 kgf-m
shown in the figure. -+ turn clockwise 30° , 16.5 lbf-ft-+ turn
clockwise 30° )
1. Crankcase bolt (M6 x L40) 12. Dowel pin �: 25 N-m (2.5 kgf-m, 18.5 lbf-ft)
2. Crankcase bolt (M6 x LSD) 13. Crankshaft assembly �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
3. Crankcase bolt (M6 x L60) fii,14. Thrust bearing r!IO] 18 N-m (1.8 kgf-m, 13.5 lbf-ft)
: Install thrust bearing with oil grooves
facing crankshaft.
4. Crankcase bolt (MB x LBO) 15. Crankshaft journal bearing (without oil �: 23 N-m (2.3 kgf-m, 17.0 lbf-ft)
groove)
5. Crankcase bolt (MB x L65) 16. Crankshaft journal bearing (with oil groove) �: 50 N-m (5.1 kgf-m, 37.0 lbf-ft)
6. Crankcase bolt (MB x L60) 17. Oil gallery plug (M14) •12018] Apply sealant.

1111:
7. Crankcase bolt (MB x LSO) 18. Oil hose union plug Apply molybdenum oil.

lii, 8 Lower crankcase bolt (M9 x L 115) 19. Upper crankcase plug 0: Do not reuse.
: For tightening order, refer to "Crankcase/
Crankshaft Installation" (Page 10-74).
lii, 9 Lower crankcase bolt (M9xL95) �: 11 N-m (1.1 kgf-m, 8.5 lbf-ft)
: For tightening order, refer to "Crankcase/
Crankshaft Installation" (Page 10-74).
10. Lower crankcase �: 26 N-m (2.7 kgf-m, 19.5 lbf-ft)

Crankcase / Crankshaft Removal

BENM10L31406049
3
Lower crankcase [B]
1) Remove the crankcase bolts from the upper
crankcase and lower crankcase.

[A] 2

J_=
\�
,-- '
· '· ?"'
==--::;

IM10L 1140228-01

[A]: Upper side

[BJ: Lower side
1. Crankcase bolt (M6 x L60)
IM10L1140227-01 2. Crankcase bolt (M6 x L50)
3, Crankcase bolt (M6 x L40)

2) Remove the crankcase bolts from the upper

crankcase and lower crankcase.
1 D-72 Engine Mechanical:

[A]

IM10L1140231-01
IM10L1140229-02
2. Crankcase bolt (M9 x L 115)
3. Crankcase bolt (M9 x L95)
[BJ 4. Washer

4) Make sure that all of the bolts are removed. Then,

tap the sides of the lower crankcase using a plastic
hammer to separate the upper and lower crankcase
halves and then lift the lower crankcase off of the
upper crankcase.
5) Remove the dowel pins (1) from the upper
crankcase.

-� -:�

t . .. ? ;

IM10L 1140230-01

[A]: Upper side

[B]: Lower side
1. Crankcase bolt (MB x LBO)
2. Crankcase bolt (MB x L65)
3. Crankcase bolt (MB x L60)
4. Crankcase bolt (MB x L50)
5. Washer
Crankshaft assembly
3) Remove the crankcase bolts (M10) (1) and 1) Remove the crankshaft assembly (1) from the upper
crankcase bolts (MS) in numerical order ("1" - "11 "). crankcase.

NOTE
Remove the conrod if necessary. Refer to
"Conrod I Conrod Crank Pin Bearing
Removal and Installation" (Page 1 D-80).

2) Remove the thrust bearings (2) from the crankcase.

 Engine Mechanical: 1 D-73

IM1 0L1140233-01 IM10L1140235-01

2. Upper crankcase 3. Lower crankcase

Transmission
Remove the transmission components. <?(Page 5B-3) Oil Jet
Crankshaft journal bearing 1) Remove the piston cooling oil jets (1). <?(Page 1E-
Remove the crankshaft journal bearings (1) from the 12)
upper crankcase and lower crankcase.
NOTICE
• When removing the crankshaft journal
bearings, be careful not to scratch the
crankcase and the crankshaft journal
bearings.
• Do not touch the bearing surfaces with
your hands. Grasp the bearings by their
edges.

NOTE
2) Remove the oil jet (for transmission oil spray) (1).
• Do not remove the crankshaft journal W"(Page 1E-12)
bearings unless absolutely necessary.
• Make a note of where the crankshaft
journal bearings are removed from so that
they can be reinstalled in their original
positions.

IM10L1140237-01

3) Remove the oil jet (for transmission) (1 ). cr(Page

1E-12)

IM10L 1140234-01

IM10L1140238-01
1 D-74 Engine Mechanical:

4) Remove the oil gallery jet (1). <F(Page 1E-12)

IM10L1140242-02
IM10L1140239-01 7. Lower crankcase
6. Upper crankcase

Oil gallery plug

Crankcase / Crankshaft Installation
1) Remove the following parts. BENM 1 0L31406050

• Piston cooling oil gallery plug (1) Oil gallery plug

• Oil hose union plug (2) _ the new _ gas�et (1) to the oil hose union plug
1) lnstall
(2) m correct d1rect1on as shown in the figure.
• Transmission cooling oil gallery plug (3)
2) Install the piston cooling oil gallery plug (3).
• Upper crankcase plug (4)
3) Tighten the plugs to the specified torque.
• Oil gallery plug (5)
Tightening torque
Oil hose union plug (a): 25 N·m (2.5 kgf-m ' 18.5
lbf-ft)
Piston cooling oil gallery plug (b): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)

IM10L1140240-02

IM10L1140243-02

4) Install the new gaskets (1) to the upper crankcase

plug (2) in correct direction as shown in the figure.
5) Install the transmission cooling oil gallery plug (3).
IM10L1140241-02
6) Tighten the plugs to the specified torque.
Tightening torque
Upper crankcase plug (a): 23 N·m (2.3 kgf-m
17.0 lbf-ft)
Transmission cooling oil gallery plug (b): 10
N·m (1.0 kgf-m, 7.5 lbf-ft)
 Engine Mechanical: 1 D-75

Crankshaft journal bearing

1) Apply molybdenum oil solution to the crankshaft
journal bearing.
"A": Assembly lubrication (Molybdenum oil
solution)
2) Install the crankshaft journal bearings to the upper
and lower crankcases, be sure to fix the stopper part
(1) first and press the other end.

NOTE
• Do not touch the bearing surfaces with
your hands. Grasp by the edge of the
bearing shell.
• There are two types of bearing halves in
the crankshaft journal bearing with oil
groove (2) and without oil groove (3).
• Inspect and select the crankshaft journal
IM10L1140244-02 bearing if necessary. Refer to "Crankshaft
7) Install the new gaskets to the oil gallery plugs. Journal Bearing Inspection and Selection"
(Page 1 D-84).
NOTE
Only the gasket (1) is installed in the
direction shown in the figure.

8) Tighten the oil gallery plugs (2) to the specified

torque.
Tightening torque
Oil gallery plug (M10) (a): 18 N·m (1.8 kgf-m,
13.5 lbf-ft)
'Oil gallery plug (M6) (b): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
Oil gallery plug (MS) (c): 10 N•m (1.0 kgf-m, 7.5
lbf-ft) IM10L1140246-01

IM10L1140247-01

IM10L 1140245-02

Oil Jet
Install the oil jets. w-(Page 1 E-12)
1 D-76 Engine Mechanical:

NOTE
• Right-thrust bearing has green painting.
• Inspect and select the crankshaft thrust
clearance if necessary. Refer to
"Crankshaft Thrust Clearance Inspection
and Selection" (Page 1D-86).

IM10L1140248-01

4. Upper crankcase 5. Lower crankcase

Transmission
Install the transmission components. w(Page 58-4)

Crankshaft assembly
1) Apply engine oil to inner surface of crankshaft IM10L 1140251-01
journal bearings (1).
Lower crankcase
1) Install the dowel pins (1) to the upper crankcase.

IM10L 1140249-01

IM10L1140252-01

2) Clean the mating surfaces of upper and lower

crankcase halves. Apply sealant to the mating
surface of the lower crankcase (1).
NOTE
• Apply sealant to the portion (2) of the
upper and lower crankcases.
• Make surfaces free from moisture, oil, dust
and other foreign materials.
IM10L 1140250-01
• Spread on surfaces thinly to form an even
2. Upper crankcase 3. Lower crankcase
layer, and assemble the crankcases within
few minutes.
2) Install the crankshaft assembly (1) to the upper
crankcase. • Take extreme care not to apply any sealant
to the oil hole, oil groove and bearing.
3) Install thrust bearings (2) with oil grooves (3) facing
crankshaft assembly (1). • Apply to distorted surfaces as it forms a
comparatively thick film.

"A": Sealant 99000-31140 (SUZUKI BOND

1207B)
 Engine Mechanical: 1D-77

Tightening torque
Crankcase bolt (M10) (b): 50 N·m (5.1 kgf-m,
37.0 lbf-ft)

1, (b)
- I �;;=;;==;
;;;.,,.I

., \
3,4,"10", (a) 3, "2", (a) - , 3,4, "8", (a)

'\::.=1'
2

IM10L1140253-02
;
·
r::..i-._....� ;_._
,_J
' ��.,1.1;�:
; ·· 2""3", (a)
f!J}}
3) Match the upper and lower crankcase. 3,4, "9", (� ) 2, "1", (a) 3,4, "7", (a)
IM10L1140255-01
NOTE
2. Crankcase bolt (M9 x L115)
Align each gearshift fork (1) with its groove 3. Crankcase bolt (M9 x L95)
(2) of the driveshaft and countershaft. 4. New washer

7) Tighten the crankcase bolts (M8) (1) to the specified

torque.
Tightening torque
Crankcase bolt (MS) (a): 26 N·m (2.7 kgf-m, 19.5
lbf-ft)
1•• ;

, 1, [A]
t
�
- --- -----
1, (a) · • ·
·. . .. · - .. :.._

e§�
2 . - ._.L--- 2, (a)
1, 5, (a
·.:
. r-' �tri%i:±_ __ ;·(:; (a)
I
�iJ \
: r- ' f.JF-i;��
.,: . -�
., =· -. . . L '· , • .! : ..... _ • 1 i ·1_ ' � '

-.....,..,,
►-
�
1 ;:
ri

I J· -
,� ...
. ., ' '•• -=
"7'"----..-. . ' 1I==- -•.
.,..,..,, . JJJJ]
' ,._
IM10L 1140254-01
IM10L1140256-02
4) Tighten the crankcase bolts (M9) to the specified
torque in numerical order ("1" - "10").
5) Additionally tighten the crankcase bolts (M9) with the
specified angles gradually in numerical order "1" -
"1 O" using an angular torque gauge.
Tightening torque
Crankcase bolt (M9) (a): 22 N-m - turn
clockwise 30 ° (2.2 kgf-m - turn clockwise 30° ,
16.5 lbf-ft - turn clockwise 30° )
6) Tighten the crankcase bolt (M10) (1) to the specified
torque.
1 D-78 Engine Mechanical:

[BJ
[BJ

-
l
-1
-· I

\
___ \

. . \i
. 1, (a)
!•--

4, (a).
.
-::
,--
' ' �::
������ -? . �-- ��ga;�t""�
,-- '
- _;_,-;,
. .,, �
. o ,-•··

r
L' ·.J, (a) • ( )
-. . . �.I � { �- (
, . ,-�,. 1
"'-<,-..X.
I \l'J
IM10L1140257-01
'
IM10L1140259-01
[A]: Upper crankcase
[A]: Upper crankcase
[BJ: Lower crankcase
[BJ: Lower crankcase
1. Crankcase bolt (MB x LB0)
1. Crankcase bolt (MS x LSD)
2. Crankcase bolt (MB x LS5)
2. Crankcase bolt (MS x L50)
3. Crankcase bolt (MB x LSD) (New bolt)
3. Crankcase bolt (MS x L40)
4. Crankcase bolt (MB x L50) (New bolt)
5. New washer
- 9) After crankcase bolts have been tightened, check
8) Tighten the crankcase bolts (M6) to the specified that the crankshaft rotates smoothly.
torque. 10) Also check that the driveshaft and countershaft
rotate smoothly.
Tightening torque
Crankcase bolt(M6)(a): 11 N·m(1.1 kgf-m, 8.5
lbf-ft)

[A] 2, (a)

lM10L1140260-01

IM10L1140258-01

IM10L1140261-01
 Engine Mechanical: 1 D-79

Conrod I Conrod Crank Pin Bearing Components

BENM10L31406051
NOTE
# 1 to # 4 conrod have the same parts composition.

-m:
IM10L1140262-02
"1. Conrod cap bolt r.ii 4. Conrod crank pin bearing Apply molybdenum oil.
: For tightening order, refer to "Conrod / : Refer to "Conrod I Conrod Crank Pin
Conrod Crank Pin Bearing Removal and Bearing Removal and Installation" (Page
Installation" (Page 10-80). 10-80).
2. Conrod cap �: 25 N-m _. turn clockwise go• (2.5 kgf-m _. Do not reuse.
�:
turn clockwise go•, 18.5 lbf-ft _. turn
clockwise go•)

-mi:
3. Conrod Apply engine oil.
1 D-80 Engine Mechanical:

Conrod I Conrod Crank Pin Bearing Removal

and Installation
BENM10L31406052

1) Remove the crankshaft assembly from the

crankcase. Refer to "Crankcase / Crankshaft
Removal" (Page 1D-71).
2) Remove the conrod cap bolts (1 }, conrod cap (2) and
conrod (3).

IM10L1140265-01

3) When fitting the conrod cap (1), make sure that I.D.
code (2) on each conrod faces intake side.
4) Apply engine oil to the flange and thread portion of
the new conrod cap bolts (3).

IM10L 1140263-01

3) Remove the bearings (1) from the conrod cap and

conrod.

IM10L1140267-01

[A]: Intake side

5) Tighten the conrod cap bolt by using a 10 mm, 12

point socket wrench in the following two steps.

IM10L1140264-01 Tightening torque

Conrod cap bolt (a): 25 N-m ---+ turn clockwise
Installation 90° (2.5 kgf-m---+ turn clockwise 90° , 18.5 lbf-ft---+
1) Install the crank pin bearings (1) to the conrod and turn clockwise 90°)
conrod cap, be sure to fix the stopper part (2) first
and press the other end.
NOTE
Inspect and select the conrod crank pin
bearing if necessary. Refer to "Conrod Crank
Pin Bearing Inspection and Selection" (Page
1D-82).

2) Apply molybdenum oil solution to the inner surface of

the crank pin bearings (1).
"A": Assembly lubrication (Molybdenum oil
solution)
 Engine Mechanical: 1D-81

Conrod Big End Side Clearance

1) Check the conrod big end side clearance using the
thickness gauge.
Conrod big end side clearance
[Limit]: 0.3 mm (0.011 in)
Special tool
(A): 09900-20803

"a": 90°

6) Apply engine oil to the conrod big end side surfaces

(1 ).

,..., -
IF04K1140292-01

2) If the clearance exceeds the limit, remove the conrod

and measure the conrod big end width and crank pin
width. Refer to "Conrod/ Conrod Crank Pin Bearing
Removal and Installation" (Page 1 D-80). If any of the
measurements are out of specification, replace the
conrod or crankshaft.
Conrod big end width
IM10L 1140270-01 [Standard]: 20.95 - 21.00 mm (0.8248 - 0.8268 in)
Crank pin width
Conrod I Crankshaft Inspection [Standard]: 21.10 - 21.15 mm (0.8307 - 0.8327 in)
BENM10L31406053
Refer to "Conrod I Conrod Crank Pin Bearing Removal Special tool
and Installation" (Page 1 D-80). (A): 09912-66310
(B): 09900-20605
Conrod Small End I.D.
Measure the conrod small end inside diameter using the
small bore gauge.
If the conrod small end inside diameter exceeds the
service limit, replace the conrod.
Conrod small end I.D.
[Limit]: 18.050 mm (0.7106 in)
Special tool
(A): 09900-20602
(8): 09900-22401

IF04K 1140293-01

Crankshaft Runout
Support the crankshaft using V blocks as shown, with
(B) the two end journals resting on the blocks. Set up the
dial gauge as shown, and rotate the crankshaft slowly to
read the runout. Replace the crankshaft if the runout
exceeds the service limit.
Crankshaft runout
IF04K1140291-01
[Limit]: 0.05 mm (0.0019 in)
Special tool
(A): 09900-20607
(B): 09900-20701
1D-82 Engine Mechanical:

(C): 09900-21304 3) Tighten the conrod cap bolts to the specified torque,
in two stages.

NOTE
• When installing the conrod cap bolts to the
crank pin, make sure that I.D. code (1) on
the conrod faces towards the intake side.
• Never rotate the crankshaft or conrod
when a piece of plastigage is installed.

Tightening torque
Conrod cap bolt (a): 25 N-m --+ turn clockwise
IM10L1140271-01 90° (2.5 kgf-m --+ turn clockwise 90° , 18.5 lbf-ft --+
turn clockwise 90°)
Conrod Crank Pin Bearing Inspection and
Selection
BENM10L31406054
Refer to "Conrod / Conrod Crank Pin Bearing Removal
and Installation" (Page 1 D-80).

Inspection
1) Inspect the bearing surfaces for any signs of fusion,
pitting, burn or flaws. If any, replace them with a
specified set of bearings.

IF04K1140296-01

4) Remove the conrod cap bolts and measure the width

� of the compressed plastigage using the envelope

f]J::=::m111::m1 1 � scale. This measurement should be taken at the

widest part of the compressed plastigage.
I718H1140285-01 If the oil clearance exceeds the service limit, select
2) Place the plastigage axially along the crank pin, the specified bearings from the bearing selection
avoiding the oil hole, as shown in the figure. table.
Special tool Conrod big end oil clearance
(A): 09900-22303 [Standard]: 0.032 - 0.056 mm (0.0013 - 0.0022 in)
[Limit]: 0.080 mm (0.0031 in)
Special tool
(A): 09900-22303

IF04K1140295-01

(A)
IF04K1140297-01
 Engine Mechanical: 1D-83

Selection Special tool

1) Check the corresponding conrod I.D. code numbers (A): 09900-20202
([1] or[2]) (1).

T IF04K1140298-01 4) Select the specified bearings from the bearing

IF04K1140300-01

Conrod big end I.D. selection table.

[Standard]: 41.000-41.016 mm (1.6142 -1.6148 NOTICE
in)
The bearings should be replaced as a set.
Conrod I.D. specification
Code (1) I.D. specification
Bearing selection table
41.000-41.008 mm
1
(1.6142 - 1.6145 in) Crank pin O.D.
41.008-41.016 mm

I
2 Code 1 2 3
(1.6145-1.6148 in)
Conrod 1 Green Black Brown
2) Check the corresponding crank pin O.D. code 1.0. 2 Black Brown Yellow
numbers ([1 ], [2] or [3]) ( 1). IF04K1140333-03

Crank pin bearing thickness

[Standard]: 1.480-1.496 mm (0.0583-0.0589 in)
Bearing thickness specification
Color (Part No.) Thickness
Yellow 1.492-1.496 mm
(12164-10L00-0D0) (0.0587 - 0.0589 in)
Brown 1.488-1.492 mm
(12164-10L00-0C0) (0.0586-0.0587 in)
Black 1.484 -1.488 mm
(12164-10L00-0B0) (0.0584 - 0.0585 in)
Green 1.480 -1.484 mm
IM10L1140272-01
(12164-10LOO-0A0) (0.0583-0.0584 in)
3) Measure the conrod crank pin O.D. with the special
tool. If any of the measurements are out of
specification, replace the crankshaft.
Crank pin O.D.
[Standard]: 37.976-38.000 mm (1.4951-1.4961
in)
Crank pin O.D. specification
Code O.D. specification
37.992- 38.000 mm
1
(1.4957 -1.4960 in)
37.984-37.992 mm
2 IF04K1140301-01
(1.4954 - 1.4957 in)
37.976-37.984 mm 1. Color code
3
(1.4951-1.4954 in)
1 D-84 Engine Mechanical:

Crankshaft Journal Bearing Inspection and 4) Mate the lower crankcase with the upper crankcase.
Selection 5) Tighten the crankcase bolt (M9) (1) to the specified
BENM10L31406055
torque in numerical order ("1" - "10").
Refer to "Crankcase/ Crankshaft Removal" (Page 10-
71) and "Crankcase/ Crankshaft Installation" (Page 10- 6) Additionally tighten the crankcase bolts (M9) (1) with
74). the specified angles gradually in numerical order "1"
- "1 0" using an angular torque gauge.
Inspection NOTE
1) Inspect each upper and lower crankcase bearing (1)
Do not rotate the crankshaft when a piece of
for any damage.
plastigage is installed.

Tightening torque
Crankcase bolt (M9) (a): 22 N-m - turn
clockwise 30° (2.2 kgf-m - turn clockwise 30° ,
16.5 lbf-ft --+ turn clockwise 30°)

IM10L1140273-01
1, "10", (a)
rr· _J , .
i-p;", (a)
.

. 't
• ��-

�
��- 1,�. -_
���=:;�-;::� \ ;_;:;;_-
.,
-.a

i � ;:

::;, �
��
'---- ,
1.-.:C...
' . ,
V
, a 11--rL ='
�

1, "9",'(a)' 1, "1", (a) 1, "7", (a)

IM10L1140276-01
7) Remove the lower crankcase and measure the width
of compressed plastigage using the envelope scale.
IM10L 1140274-01 This measurement should be taken at the widest
2) Set the crankshaft onto the upper crankcase. part of the compressed plastigage. If the oil
3) Install the plastigage onto each crankshaft journal. clearance exceeds the service limit, select the
specified bearings from the bearing selection table.
Special tool
09900-22303 Crankshaft journal oil clearance
[Standard]: 0.010 - 0.028 mm (0.0004 - 0.0011 in)
. ' [Limit]: 0.080 mm (0.0031 in)

·. ''·•1=
�
w
i;/il'

IM10L1140275-01

IM10L1140277-01
 Engine Mechanical: 1D-85

Selection Special tool

1) Check the corresponding crankcase journal I.D. (A): 09900-20202
codes ([A], [B] or [Cl) (1), which are stamped on the
upper crankcase.

4) Select the specified bearings from the bearing

IM1 0L1140278-01 selection table.
Bearing selection table
Crankcase journal I.D.
[Standard]: 43.000 - 43.018 mm (1.6929 -1.6936
Crankshaft 0.0.
in)
Code A B C
Crankcase journal I.D. specification A Green Black Brown
Code (1) I.D. specification Crankcase
B Black Brown Yellow
43.000 -43.006 mm I.D.
A C Brown Yellow Blue
(1.6929 -1.6931 in) IF04K1140310-01
43.006 -43.012 mm
B Crankcase journal bearing thickness
(1.6931 -1.6933 in)
43.012 - 43.018 mm [Standard]: 1.492 -1.507 mm (0.0588 -0.0593 in)
C
(1.6933 -1.6936 in) Bearing thickness specification
Color (Part No.) Thickness
2) Check the corresponding crankshaft journal O.D.
Blue
codes ([A], [B] or [Cl) ( 1 ), which are stamped on the 1.504 -1.507 mm
(12229-10L00-0E0)
crankshaft. (0.05922 -0.05933 in)
(12229-15H10-0E0)
Yellow
1.501 -1.504 mm
(12229-10L00-0D0)
(0.0591 -0.0592 in)

t�".;
(12229-15H10-0D0)
Brown
1.498 -1.501 mm
(12229-10L00-0C0)
(0.05898 -0.05909 in)
it:.:: {12229-15H10-0C0)
� ...
Black
"'

\__ 1.495 -1.498 mm

(12229-1 0L00-0B0)
1.......

(0.05886 -0.05897 in)

(12229-15H10-0B0)
Green
1.492 -1.495 mm
(12229-10L00-0A0)
(0.05874 -0.05885 in).
IM10L 1140279-01 ( 12229-15H 10-0AO)
3) Measure the crankshaft O.D. with the special tool. If
any of the measurements are out of specification,
replace the crankshaft.
CrankshaftjournalO.D.
[Standard]: 39.982 -40.000 mm (1.5741 -1.5748
in)
Crankshaft journalO.D. specification
Code (1) O.D. specification
39.994 -40.000 mm
A
(1.5746 -1.5748 in)
39.988 -39.994 mm
B
(1.5743 -1.5746 in) IF04K1140311-01

C 39.982 -39.988 mm 1. Color code

(1.5741 -1.5743 in)
1 D-86 Engine Mechanical:

Crankshaft Thrust Clearance Inspection and

Selection "a"
BENM10l31406056
Refer to "Crankcase/ Crankshaft Removal" (Page 1 D-
71) and "Crankcase/ Crankshaft Installation" (Page 1 D-
74).

Inspection
1) With the crankshaft's right-side and left-side thrust
bearings inserted into the upper crankcase.
2) Measure the thrust clearance "a" between the left­
side thrust bearing and crankshaft using the
thickness gauge. If the thrust clearance exceeds the
standard range, adjust the thrust clearance.
NOTE
Pull the crankshaft to the left (generator side)
so that there is no clearance on the right-side
thrust bearing.

Crankshaft thrust clearance

[Standard]: 0.060 - 0.110 mm (0.0024- 0.0043 in)
Special tool IM10L1140282-01

(A): 09900-20803 "a": Clearance

Selection
1) Remove the right-side thrust bearing and measure
its thickness using the micrometer. If the thickness of
the right-side thrust bearing is below standard,
replace it with a new bearing and measure the thrust
clearance again, as described in Inspection 1) and
2).
Camshaft thrust bearing thickness
Right side [Standard]: 2.425 - 2.450 mm (0.0954-
0.09646 in)
IM10L1140281-01
Left side [Standard]: 2.350 - 2.500 mm (0.0925 -
[A): Front side 1. Right-side thrust bearing 0.0984 in)
[BJ: left side 2. left-side thrust bearing
Special tool
(A): 09912-66310

IF04K1140314-01

2) If the right-side thrust bearing is within the standard

range, reinsert the right-side thrust bearing and
remove the left-side thrust bearing.
3) With the left-side thrust bearing removed, measure
the clearance "a" using the thickness gauge as
shown.
 Engine Mechanical: 1D-87

Special tool
(A): 09900-20803
"a"

',. �.
IM10L1140283-01

4) Select a left-side thrust bearing from the selection table.

NOTE
Right-side thrust bearing has the same specification as the GREEN (12228-24F00-0D0) of left-side
thrust bearing.

Left-side thrust bearing selection table

Clearance before inserting
Color "A" (Part No.) Thrust bearing thickness Thrust clearance
the left-side thrust bearing
2.560 - 2.585 mm White 2.475 - 2.500 mm
(0.1008 - 0.1018 in) (12228-24F00-0F0) (0.0974 - 0.0984 in)
2.535 - 2.560 mm Yellow 2.450 - 2.475 mm
(0.0998 - 0.1008 in) (12228-24F00-0E0) (0.0965 - 0.0974 in)
2.510 - 2.535 mm Green 2.425 - 2.450 mm 0.060 - 0.110 mm
(0.0988 - 0.0998 in) (12228-24F00-0D0) (0.0955 - 0.0965 in) (0.0024 - 0.0043 in)
2.485 - 2.510 mm Blue 2.400 - 2.425 mm
(0.0978 - 0.0988 in) (12228-24F00-0C0) (0.0945 - 0.0955 in)
2.460 - 2.485 mm Black 2.375 - 2.400 mm
(0.0969 - 0.0978 in) (12228-24F00-0B0) (0.0935 - 0.0945 in)
2.430 - 2.460 mm Red 2.350 - 2.375 mm 0.055 - 0.110 mm
(0.0957 - 0.0969 in) (12228-24F00-0A0) (0.0925 - 0.0935 in) (0.0022 - 0.0043 in)

IF04K1140316-01

1. Color code

5) After selecting a left-side thrust bearing, install it and then measure the thrust clearance again.
1 D-88 Engine Mechanical:

Specifications
Tightening Torque Specifications
BENM10L31407001

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Fuel tank bracket bolt (front side) 10 1.0 7.5 @'(Page 1D-7)
Fuel tank bracket bolt (rear side) 5.5 0.56 4.05 w(Page 1D-7)
Funnel bolt 4.3 0.44 3.20 @'(Page 1D-7)
Air cleaner cover bolt 1.8 0.18 1.35 w-(Page 1D-7)
Intake pipe clamp screw w-(Page 1D-10) /
1.5 0.15 1.10
w-(Page 1D-13)
Delivery pipe screw 3.5 0.36 2.60 <:r(Page 1D-12)
Cylinder head cover bolt 12 1.2 9.0 w(Page 1D-15)
CMP sensor bolt 10 1.0 7.5 w(Page 1D-16)
Cam chain guide No.2 bolts 10 1.0 7.5 @'(Page 1D-21)
Camshaft journal holder bolt @'(Page 1D-22) I
10 1.0 7.5
sr(Page 1D-25)
Cam chain tension adjuster bolt 10 1.0 7.5 Qr'(Page 1D-23)
Valve timing inspection cap 23 2.3 17.0 c:r(Page 1D-24)
Starter clutch cover cap 11 1.1 8.5 Qr'(Page 1D-24)
Engine mounting thrust adjuster 10 1.0 7.5 -(Page 1D-30)
Engine mounting thrust adjuster lock-nut 45 4.6 33.5 -(Page 1D-30)
Side-stand bracket bolt 95 9.7 70.0 <T(Page 1D-33)
Oil pressure switch lead wire bolt 1.5 0.15 1.10 w(Page 1D-33)
Gearshift link arm bolt 10 1.0 7.5 @'(Page 1D-33)
Cylinder head bolt (L180) 28 N-m - turn counterclockwise 270 ° - 10 w-(Page 1D-36)
N-m - 25 N-m - 51 N-m (2.9 kgf-m - turn
counterclockwise 270 ° - 1.0 kgf-m - 2.5
kgf-m - 5.2 kgf-m, 21.0 lbf-ft - turn
counterclockwise 270 ° - 7.5 lbf-ft - 18.5
lbf-ft - 38.0 lbf-ft)
Cylinder head bolt (L55) 10 1.0 7.5 w(Page 1D-37)
Cylinder head bolt (L30) 10 1.0 7.5 17 (Page 1D-37)

Cylinder nut 10 1.0 7.5 -(Page 1D-37)

Cylinder head side bolt 14 1.4 10.5 17 (Page 1D-37)

Oil hose union bolt (cam chain tension adjuster) 18 1.8 13.5 17 (Page 1D-38)
Oil hose union bolt (cylinder head) 20 2.0 15.0 cir(Page 1D-38)
Cylinder head plug 23 2.3 17.0 cr(Page 1D-45)
Oil gallery bolt (Cylinder head) 10 1.0 7.5 cr(Page 10-45)
Water bypass union 12 1.2 9.0 cir(Page 1D-46)
Clamp screw 1.5 0.15 1.10 w-(Page 10-46)
Thermostat cover bolt 10 1.0 7.5 w(Page 1D-46)
ECT sensor 18 1.8 13.5 "'"(Page 10-47)
Water inlet connector bolt 10 1.0 7.5 w(Page 1D-54)
Balancer shaft arm bolt 10 1.0 7.5 cr(Page 10-62)
Balancer shaft mounting bolt 10 1.0 7.5 w(Page 1D-63)
Oil separator cover bolt 10 1.0 7.5 c?(Page 1D-63)
Oil pipe bolt 10 1.0 7.5 CiF(Page 10-63)
Oil pipe union bolt 24 2.4 18.0 c?(Page 1D-63)
Oil filter stand 15 1.5 11.0 w(Page 1D-64)
Gearshift cam stopper bolt 10 1.0 7.5 c;r(Page 10-64)
Gearshift cam plate stopper bolt 13 1.3 9.5 (s"(Page 1D-64)
Gearshift cover bolt 10 1.0 7.5 "'"(Page 1D-65)
Cam chain tensioner bolt 23 2.3 17.0 w(Page 1D-65)
Oil hose union plug 25 2.5 18.5 "'""(Page 10-74)
Piston cooling oil gallery plug 10 1.0 7.5 c:s-(Page 1D-74)
Upper crankcase plug 23 2.3 17.0 w(Page 1D-74)
Transmission cooling oil gallery plug 10 1.0 7.5 CiF(Page 1D-74)
Oil gallery plug (M10) 18 1.8 13.5 <7(Page 1D-75)
 Engine Mechanical: 1 D-89

Tightening torque
Fastening part N-m kgf-m lbf-ft
Note
Oil gallery plug (M6) 10 1.0 7.5 <:u>(Page 1D-75)
Oil gallery plug (M8) 10 1.0 7.5 w(Page 1D-75)
Crankcase bolt (M9) 22 N-m ---+- turn clockwise 30° (2.2 kgf-m ---+- w(Page 1D-77)/
turn clockwise 30° , 16.5 lbf-ft---+- turn <7(Page 1D-84)
clockwise 30° )
Crankcase bolt (M10) 50 5.1 37.0 <?(Page 1D-77)
Crankcase bolt (M8) 26 2.7 19.5 <?(Page 1D-77)
Crankcase bolt (MS) 11 1.1 8.5 <r(Page 1D-78)
Conrod cap bolt 25 N-m ---+- turn clockwise 90° (2.5 kgf-m ---+- <?(Page 1D-80)/
turn clockwise 90° , 18.5 lbf-ft ---+- turn <?(Page 1D-82)
°
clockwise 90 )

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"T hrottle Cable Routing Diagram" (Page 1D-2)
"Intake System Construction" (Page 1D-5)
''Throttle Body Components" (Page 1D-8)
"Cylinder Head Cover Components" (Page 1D-14)
"Cam Chain Tension Adjuster/ Camshaft Components" (Page 1D-17)
"Engine Assembly Installation" (Page 1D-30)
"Cylinder head Components" (Page 1D-34)
"Valve and Cylinder Head Components" (Page 1D-39)
"Cylinder/ Cam Chain Guide No.1/ Piston / Piston Ring Components" (Page 1D-49)
"Crank Balancer/ Cam Chain Tensioner/ Oil Filter/ Oil Filter Stand/ Oil Pipe Components" (Page 1D-57)
"Crankcase/ Crankshaft/ Crankshaft journal bearing/ Oil Jet/ Oil gallery plug Components" (Page 1D-70)
"Conrod I Conrod Crank Pin Bearing Components" (Page 1D-79)
1D-90 Engine Mechanical:

Special Tools and Equipment

Recommended Service Material
BENM10L31408001

Material SUZUKI recommended product or Specification Note

Assembly lubrication Molybdenum oil solution - <:Jr"(Page 1D-40) / <:lr"(Page
1 D-52) / <T(Page 1 D-53) /
<:lr"(Page 1 D-75) / w(Page
1 D-80)
Grease SUZUKI SUPER GREASE A P/No.: 99000-25011 <F(Page 1 D-63)
Sealant SUZUKI BOND 12078 P/No.: 99000-31140 <F(Page 1D-15) / <F(Page
1D-76)

NOTE
Required service material(s) is also described in:
"Throttle Body Components" (Page 1D-8)
"Cylinder Head Cover Components" (Page 1D-14)
"Cam Chain Tension Adjuster/ Camshaft Components" (Page 1D-17)
"Cylinder head Components" (Page 1D-34)
"Valve and Cylinder Head Components" (Page 1D-39)
"Cylinder/ Cam Chain Guide No.1 I Piston/ Piston Ring Components" (Page 1D-49)
"Crank Balancer / Cam Chain Tensioner / Oil Filter/ Oil Filter Stand/ Oil Pipe Components" (Page 1D-
57)
"Crankcase I Crankshaft/ Crankshaft journal bearing/ Oil Jet/ Oil gallery plug Components" (Page 1D-
70)
"Conrod I Conrod Crank Pin Bearing Components" (Page 1D-79)

Special Tool
BENM10L31408002
09900-20202 09900-20203
Micrometer (25 - 50 mm) Micrometer (50 - 75 mm)
w(Page 1D-24) / w(Page 10-55)
<F(Page 10-83) /
<:lr"(Page 10-85)

09900-20530 09900-20602
Cylinder gauge set Dial gauge (1 x 0.001 mm)
<:Jr"(Page 1D-54) <T(Page 10-25) I
<F(Page 10-56) I
<:lr"(Page 10-81)

09900-20605 09900-20607
Dial calipers (10 - 34 mm) Dial gauge (10 x 0.01 mm)
<:R'"(Page 10-81) w(Page 1D-24) /
<ir(Page 10-41) /
<7(Page 10-42) /
<7(Page 1 D-42) /
<T(Page 10-81)
 Engine Mechanical: 10-91

09900-20701 09900-20803
Dial gauge chuck Thickness gauge
<u>(Page 1D-24) / w(Page 1D-47) /
w(Page 1D-41) / Cv'(Page 10-54) /
w(Page 1D-42) / @'(Page 1D-55) /
w(Page 1D-42) / @'(Page 1D-56) /
-(Page 1D-81) -(Page 1D-81) /
@'(Page 1D-86) I
-(Page 1D-87)
09900-21304 09900-22303
V blocks Plastigage (0.025 - 0.076
mm)
-(Page 1D-24) I (u"(Page 1D-25) /
@'(Page 10-41) / '"'"(Page 1D-82) /
-(Page 10-42) / w(Page 1D-82) /
@'(Page 10-82) w(Page 1D-84)
09900-22304 09900-22401
Plastigage (0.051 - 0.152 Small bore gauge (10 - 18
mm) mm)
w(Page 10-25) w(Page 1D-56) /
'"'"(Page 1D-81)

09900-22403 09912-66310
Small bore gauge (18 - 35 Micrometer (O - 25 mm)
mm)
w(Page 10-25) <lr'(Page 1D-25) /
'"'"(Page 10-42) /
@'(Page 10-55) I
@'(Page 10-56) /
@'(Page 10-81) /
cu-(Page 10-86)
09915-41510 09915-63311
Oil filter stand remover Compression gauge adapter
w(Page 10-60) / @"(Page 1 D-3)
w(Page 10-64)

09915-64512 09916-10912
Compression gauge set Valve lapper
(2500 kPa)
1. Gauge 2. Hose (Adapter) w(Page 1D-43)
-(Page 10-3)

09916-14510 09916-14522
Valve lifter Valve lifter attachment
1. Main unit 2. Attachment cu-(Page 1D-40) /
Cv'(Page 10-40) I '"'"(Page 1D-41)
-(Page 1D-41)
1 D-92 Engine Mechanical:

09916-34542 09916-34570
Reamer handle Valve guide reamer (05.0)
w(Page 1 D-47) / w(Page 1 D-48)
t7(Page 1 D-48)

09916-34580 09916--44310
Valve guide reamer (010.8) Valve guide installer /
remover
w(Page 1 D-47) w-(Page 1 D-47) /
w(Page 1 D-48)

09916-53350 09916-74521
Valve guide installer Piston ring holder handle
attachment
w(Page 1 D-48) This tool is included in
Piston ring holder set
(09916-74512).
<r(Page 1 D-53)
09916-74550 09916-84511
Piston ring holder band (073 Tweezers
- 85)
�(Page 1 D-53) <lF(Page 1 D-40) I
t7(Page 1 D-41)

09919-28620 09940-14990
Sleeve protector Engine mounting adjuster
wrench
w(Page 1 D-40) / w(Page 1 D-28) /
w-(Page 1 D-41) @>(Page 1 D-29) /
w(Page 1 D-30)
 Engine Lubrication System: 1 E-1

Engine Lubrication System

Precautions
Precautions for Engine Oil
BENM10L31500001
Refer to "Fuel I Oil/ Fluid/ Coolant Recommendation" in Section OC (Page OC-16).
1E-2 Engine Lubrication System:

Schematic and Routing Diagram

Engine Lubrication System Chart Diagram
BENM10L31502001

CAMSHAFT JOURNALS,

.,,,
CAMFACES AND TAPPETS

' , ' ..
INTAKE CAMSHAFT ,-----�'-----, ,,., RH-BEARING AND
INTAKE CAMSHAFT CAM CHAIN

�----
HOUSING CAM SPROCKET
OIL PIPE TENSION
ADJUSTER

'
EXHAUST CAMSHAFT RH-BEARING AND
EXHAUST CAMSHAFT t---.i

' '
HOUSING CAM SPROCKET

''"
II

,,,.
II
''"
II

I CAM DRIVE CHAIN

CYLINDER HEAD CAMSHAFT JOURNALS,

'
CAMFACES AND TAPPETS

''"
II

SUB GALLERY STATER

CLUTCH

#1 PISTON #2PISTON #3PISTON #4PISTON OIL HOSE

. .
COOLING COOLING COOLING COOLING

''"' ' '

OIL JET OIL JET OIL JET OIL JET

,,,. '
''"
' '"'
II II

.',,', , .',,', , .''",, .',",,

#1 PISTON AND #2PISTON AND #3PISTON AND #4PISTON AND OIL PIPE 1-----�
CYLINDER WALL CYLINDER WALL CYLINDER WALL CYLINDER WALL

#1 CRANKSHAFT #2CRANKSHAFT #3CRANKSHAFT #4CRANKSHAFT

PIN BEARING PIN BEARING PIN BEARING PIN BEARING

#1 CRANKSHAFT #2 CRANKSHAFT #3 CRANKSHAFT #4 CRANKSHAFT #5 CRANKSHAFT

OIL JET JOURNAL BEARING JOURNAL BEARING JOURNAL BEARING
JOURNAL BEARING JOURNAL BEARING

I GENERATOR I MAIN GALLERY

OIL JET

' ••' ••'

,,.,•• ,,.,
OIL JET BALANCER
,,,, SHAFT
DRIVESHAFT DRIVESHAFT OIL PRESSURE
GEARS AND -----; RIGHT-SIDE SWITCH
BUSHINGS BEARING

COUNTERSHAFT COUNTERSHAFT
GEARS AND 14--------l LEFT-SIDE
OIL COOLER
BUSHINGS BEARING

.
PRIMARY DRIVEN CLUTCH PUSH

''
GEAR BEARING PIECE
OIL PRESSURE
REGULATOR

.
I II'
CLUTCH PLATES OIL STRAINER
•
'
I II'

_OIL PAN
IM10L11 50051-01

Diagnostic Information and Procedures
Engine Lubrication Symptom Diagnosis
Condition Possible cause
Engine overheats Insufficient amount of engine oil.
Defective oil pump.
Clogged oil circuit.
Incorrect engine oil.
Clogged oil cooler.
Exhaust smoke is dirty or Excessive amount of engine oil.
thick
Engine lacks power Excessive amount of engine oil.
Engine Lubrication System: 1E-3
BENM10L31504001
Correction I Reference Item
Add engine oil. <7(Page 1E-5)
Replace. -(Page 1E-14)
Clean.
Change. -(Page 1E-5)
Replace. w(Page 1 E-9)
Drain out excess engine oil. w-(Page 1 E-5)
Drain out excess engine oil. <7(Page 1 E-5)
1E-4 Engine Lubrication System:

Oil Pressure Check 5) Warm up the engine as follows:

BENM10L31504002 Summer: 10 min. at 2000 r/min
Check the engine oil pressure periodically. This will give Winter: 20 min. at 2000 r/min
a good indication of the condition of the moving parts.
6) After warm up, increase the engine speed to 3000 r/
NOTE min and read the oil pressure gauge.
Before checking the oil pressure, check the If the oil pressure is lower or higher than the
following: specification, the following causes may be
considered.
• Oil level: -r(Page 1E-5)
• Oil leaks (If leak is found, repair it.) Oil pressure
At 60 °C (140 °F), 3000 r/min
• Oil quality (If oil is discolored or
[Standard]: 200 - 500 kPa (2.0 - 5.1 kgf/cm2, 29.0
deteriorated, replace it.)
- 72.5 psi)
1) Remove the side cowling assembly (RH). w(Page High oil pressure Low oil pressure
9D-37)
• Engine oil viscosity is • Clogged oil filter
2) Start the engine and check if the oil pressure
too high • Oil leakage from the oil
indicator light is turned on. If the light stays on, check
• Clogged oil passage passage
the oil pressure indicator light circuit. If the circuit is • Combination of the • Damaged O-ring
OK, check the oil pressure in the following manner. above items • Defective oil pump
3) Remove the oil gallery plug (M16) (1) and washer. • Combination of the
above items

7) Stop the engine and remove the oil pressure gauge

and attachment.

t1!+'413WUeJ
1

To avoid the risk of being burned, remove the

oil pressure gauge when the oil has cooled.

8) Install the new gasket to the oil gallery plug (M16)

(1).
IM 10L1150003-02
9) Install the oil gallery plug (M16) and tighten it to the
4) Install the oil pressure gauge and attachment into specified torque.
the oil gallery.
Tightening torque
Special tool Oil gallery plug (M16) (a): 35 N·m (3.6 kgf-m,
(A): 09915-74511 26.0 lbf-ft)
(B): 09915-74540

IM 1 0L 1150005-02

10) Check the engine oil level. cv-(Page 1 E-5)

11) Install the removed parts.
IM10L1150004-02
 Engine Lubrication System: 1 E-5

Repair Instructions
Engine Oil Inspection Oil Filter Replacement
BENM10L31506001 BENM10L31506003
Refer to "Engine Oil" in Section OB (Page 08-11 ). Refer to "Engine Oil Filter" in Section OB (Page OB-12).

Engine Oil Replacement

BENM10L31506002
Refer to "Engine Oil" in Section OB (Page OB-11 ).

Oil Pan / Oil Pressure Regulator/ Breather Pipe/ Oil Strainer

BENM10L31506004

,-
: -'-'r.: "'"( !r
��\,)_; I �
�

4�

IM10L1150052-04
f,jjj[AJ: The new gasket is install in the direction 5. Oil strainer �: 23 N-m (2.3 kgf-m, 17.0 lbf-ft}
shown in the figure.
1. Oil cooler outlet hose bolt 6. 0-ring �: Do not reuse.

fl1:
2. Oil pan 7. Breather pipe Apply engine oil.

3. Oil pan gasket 8. Oil pressure regulator �: Apply SUZUKI SUPER GREASE A

4. Oil drain plug (!IEE: 10 N-m (1.0 kgf-m, 7.5 !bf-ft)

1E-6 Engine Lubrication System:

Oil Pan/ Oil Strainer/ Oil Pressure Regulator 7) Remove the O-ring (1).
Removal and Installation
BENM 1 0L31506005
Removal
1) Drain the engine oil. <lr'{Page 08-11)
2) Remove the side cowling assembly. <lr'{Page 9D-37)
3) Remove the exhaust pipe assembly. <?'(Page 1 K-2)
4) Remove the oil cooler outlet hose bolts (1) from the
oil pan.

Installation
1) Apply grease to the new O-ring (1).
"A": Grease 99000-25011 (SUZUKI SUPER
GREASE A)

IM10L 1150007-01

5) Remove the oil pan (1) and gasket from the lower
crankcase.
1, "A"

IM10L 1150011-01

2) Apply engine oil to the oil pressure regulator hole (1)

of the lower crankcase.

2. Oil pan bolt (M6 x L30)

3. Oil pan bolt (with washer) (M6 x L30)

���------�
4. Oil pan bolt (M6 x L40)
-::?"
�
6) Remove the following parts. �
• Oil strainer bolt (1)

.:
• Oil strainer (2)
• Breather pipe bolt (3) �
IM10L 1150054-01
• Breather pipe (4)
3) Install the oil pressure regulator (1) to the lower
• Oil pressure regulator (5) crankcase.
 Engine Lubrication System: 1E-7

.,:::::"1
�
�

:� IM10L1150013-01

4) Apply engine oil to the oil strainer hose (1) of the
lower crankcase.
8) Install the new gasket and oil pan (1) to the lower
crankcase.
9) Tighten the oil pan bolt to specified torque.
NOTE
First, after the new oil pan bolt (with washer)
(3) is tightened, another bolt is tightened.

Tightening torque
Oil pan bolt (a): 10 N·m (1_0 kgf-m, 7.5 lbf-ft)

5) Apply grease to the new O-ring (1 ).

"A": Grease 99000-25011 (SUZUKI SUPER
GREASE A)

IM10L1150056-02

2. Oil pan bolt (M6 x L30)

3. Oil pan bolt (with washer)
4. Oil pan bolt (M6 x L40)

10) Install the oil cooler outlet hose bolts (1) to the oil
pan.
11) Tighten the oil cooler outlet hose bolts to specified
torque.
6) Install the oil strainer (1 ), and then tighten the oil
strainer bolts (2) to specified torque. Tightening torque
Oil cooler outlet hose bolt (a): 10 N·m (1.0 kgf­
Tightening torque m, 7.5 lbf-ft)
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
7) Install the breather pipe (3) to lower crankcase, and
then tighten the breather pipe bolt (4) to specified
torque.
Tightening torque
Breather pipe bolt (b): 10 N·m (1.0 kgf-m, 7.5 lbf­
ft)

IM10L1150017-01
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 Engine Cooling System: 1F-18

Reassembly
1) Install the new oil seal (1) with the special tool.

NOTE
The stamped mark on the oil seal should face
mechanical seal side.

Special tool
(A): 09913-70210

I823H1160042-01

4) Apply molybdenum solution to the impeller shaft (1)

and washer (2).
"A": Assembly lubrication (Molybdenum oil
solution)
5) Install the impeller shaft (1) and washer (2) to the
water pump body.

IM10L1160056-01

2) Apply a small quantity of the grease to the oil seal

lip.
"A": Grease 99000-25011 (SUZUKI SUPER
GREASE A)

IM10L1160059-01

6) Install the rubber seal (1) into the impeller (2).

7) After wiping off the oily or greasy matter from the
mechanical seal ring (3), install it into the impeller.

NOTE
IM10L 1160057-01 The paint marked side of mechanical seal
3) Install a new mechanical seal using a suitable size ring faces the rubber seal.
socket wrench.
NOTE
On new mechanical seals, the sealer "A" has
been applied.

\_
IM10L 1160060-01

8) Install the washer (1) and seal washer (2) onto the
"A"
impeller securing bolt.

IM10L 1160058-01
1F-19 Engine Cooling System:

NOTE Tightening torque

The metal side of seal washer and the curved Water pump case screw (a): 6.0 N·m (0.61 kgf­
side of washer face the impeller securing bolt m, 4.45 lbf-ft)
head.

IM10L1160064-01

IM10L1160061-01
Water Pump Related Parts Inspection
9) Install the impeller and tighten the impeller securing BENM10L31606021
bolt (1) to the specified torque. Refer to "Water Pump Disassembly and Assembly"
(Page 1F-17).
Tightening torque
Impeller securing bolt (a): 8.0 N·m (0.82 kgf-m, Mechanical Seal
5.90 lbf-ft) Visually inspect the mechanical seal for damage, with
particular attention given to the sealing face.
Replace the mechanical seal that shows indications of
leakage.

IM10L1160062-01

10) Install new O-rings.

NOTE
I823H1160049-01

• Apply engine coolant to the O-ring (1 ).

• Apply grease to the O-ring (2).
"A": Grease 99000-25011 (SUZUKI SUPER
GREASE A)
Oil Seal
Visually inspect the oil seal for damage, with particular
attention given to the lip.
Replace the oil seal that shows indications of leakage.

I823H1160050-01

11) Fit the water pump case and tighten the water pump
case screws (1) to the specified torque.
 Engine Cooling System: 1 F-20

Seal Washer
Visually inspect the seal washer for damage, with
particular attention given to the sealing face.
Replace the seal washer that shows indications of
leakage.

1a23H11soos1-01

Impeller / Shaft
Visually inspect the impeller and its shaft for damage.
Replace the impeller or shaft if necessary.

1823H1160052-01

Impeller Shaft Journal

Visually inspect the journal for damage or scratch.
Replace the water pump body if necessary.

1823H1160053-01
1F-21 Engine Cooling System:

Specifications
Tightening Torque Specifications
BENM10L31607001
Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Radiator assembly bolt 10 1.0 7.5 cr(Page 1F-10)
Oil cooler bolt 5.5 0.56 4.05 cr(Page 1F-10)
Radiator reservoir tank bolt 5.5 0.56 4.05 w(Page 1F-10)
Thermostat cover bolt 10 1.0 7.5 w(Page 1 F-14)
Water pump bolt 10 1.0 7.5 -(Page 1F-16)
Impeller securing bolt 8.0 0.82 5.90 cr(Page 1F-19)
Water pump case screw 6.0 0.61 4.45 cr(Page 1F-19)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Water Hose Routing Diagram" (Page 1F-2)
"Cooling System Components" (Page 1F-6)
"Water Pump Components" (Page 1F-15)

Special Tools and Equipment

Recommended Service Material
BENM10L31608001
Material SUZUKI recommended product or Specification Note
Assembly lubrication Molybdenum oil solution - "'"(Page 1F-18)
Grease SUZUKI SUPER GREASE A P/No.: 99000-25011 "'"(Page 1F-16) / "'"(Page
1F-18) / -(Page 1F-19)

NOTE
Required service material(s) is also described in:
"Cooling System Components" (Page 1 F-6)
"Water Pump Components" (Page 1F-15)

Special Tool
BENM10L31608002
09913-70210 09918-78211
Bearing installer set Radiator cap tester kit
"'"(Page 1F-18) "'"(Page 1F-7) I
cr(Page 1F-7)

09921-20240
Bearing remover set
cr(Page 1 F-17)
 Fuel System: 1G-1

Fuel System
Precautions
Precautions for Fuel System
BENM10L31700001

• Keep away from fire or spark.

• During disassembling, use care to minimize spillage of gasoline.
• Spilled gasoline should be wiped off immediately.
• Work in a well-ventilated area.
• Before loosening or disconnecting the fuel feed line, relieve the fuel system of fuel pressure by
following "Fuel Pressure Relief Procedure" (Page 1G-7).

A CAUTION
• To prevent the fuel system (fuel tank, fuel hose, etc.) from contamination with foreign particles, blind
all openings.
• After removing the throttle body, tape the cylinder intake section to prevent foreign particles from
entering.
1G-2 Fuel System:

Schematic and Routing Diagram

Fuel Tank Water Drain Hose and Fuel Tank Breather Hose Routing Diagram
BENM10L31702001
Without EVAP Control System

ii!I

9
5 \
II
a
ll

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8
-
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4
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[DJ

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r..[A]

3
4

r..[H]
IM10L1170052-02
 Fuel System: 1G-3

�[A] Pass the fuel tank drain hose and fuel tank �[J]: Clamp the fuel tank drain hose and fuel tank 9. Fuel tank breather hose No.3
breather hose No.1 to the upper side of breather hose No.2 on the both side of breather
clutch release cylinder holder. hose clamp.
�[BJ: Pass the fuel tank drain hose to the rear 1. Fuel tank 10. 3-way joint
side of frame.
[CJ: Front side 2. Frame 11. Starter motor lead wire
[DJ: Upper side 3. Clutch release master cylinder holder 12. Wiring harness
[EJ: Right side 4. Fuel tank drain hose 13. Side-stand switch lead wire/ GP
sensor lead wire/ HO2 sensor
lead wire/ Gearshift sensor lead
wire
� [F]: Face the white mark of the hoses to front 5. Fuel tank breather hose No.2 "a": 30-40 mm (1.18-1.57 in)
side.
�[G]: Pass the fuel tank drain hose and fuel tank 6. Clamp "b": 0-5 mm (0-0.20 in)
breather hose No.1 to between the frame
and wiring harness.
�[HJ: Face the projection of clamp to right side. 7. Fuel tank breather hose No.1 "c": 50 mm(1.97 in)
[I]: Left side 8. Breather hose clamp "d": 0-10 mm(0-0.3gin)
1G-4 Fuel System:

With EVAP Control System

''a" 2

,-------L ),
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IM10l1170053-02
 Fuel System: 1G-5

fllij[A]: Pass the fuel tank drain hose to the upper side of [I]: Right side 6. Surge hose No.1
clutch release cylinder holder.
fllii [BJ: Pass the fuel tank drain hose to the rear side of
frame.
(iii [J]: Clamp the fuel tank drain hose on the both side
of breather hose clamp.
7. Starter motor lead

[CJ: Front side fllii [K]: Adhere the clamp to the fuel tank drain hose. 8. Wiring harness
[D]: Upper side 1. Fuel tank 9. Frame
(iii [E]: Pass the fuel tank drain hose to the between the 2. Fuel tank drain hose 10. Side stand switch lead wire/ GP
wiring harness and frame. sensor lead wire/ HO2 sensor
lead wire/ Gear shift sensor lead
wire
fllii [F]: Face the white mark of the fuel tank drain hose 3. Clamp "a": 50 mm (1.97 in)
to front side.
fllij[G]: Face the projection of clamp to right side. 4. White stripe "b": 0-5 mm (0-0.20 in)
[HJ: Left side 5. Clamp "c ": 0-10 mm (0-0.39 in)
1G-6 Fuel System:

Diagnostic Information and Procedures

Fuel System Symptom Diagnosis
BENM10L31704001
Refer to "Engine Symptom Diagnosis" in Section 1A (Page 1A-25).

Repair Instructions
Fuel Pressure Inspection Fuel pressure
BENM1 0L31706001 [Standard]: 289 - 299 kPa (2.95 - 3.04 kgf/cm2,
1) Lift and support the fuel tank. "'"(Page 1 G-12) 42.0 - 43.3 psi)
2) Place a clean rag under the fuel feed hose (1) and
5) Remove the special tools.
disconnect the fuel feed hose from the fuel pump.
w (Page 1 G-7)

Before removing the special tools, turn the

ignition switch OFF and release the fuel
pressure slowly.

6) After finishing the fuel pressure inspection, install the

removed parts.

Fuel Discharge Amount Inspection

BENM10L31706002
1) Lift and support the fuel tank. "'"(Page 1 G-12)
IM 1 0L1170054-03 2) Place a clean rag under the fuel feed hose (1) and
3) Install the special tools between the fuel pump and disconnect the fuel feed hose from the fuel delivery
fuel delivery pipe. pipe. w(Page 1 G-7)
Special tool
(A): 09940-40211
(B): 09940-40220
(C): 09915-74511

IM 1 0L1170054-03

3) Place the measuring cylinder (1) and insert the fuel

feed hose (2) into the measuring cylinder.

IM 1 0L1170050-02

4) Turn the ignition ON and check for fuel pressure.

If the fuel pressure is lower than the specification,
check for the followings:
• Fuel hose leakage
• Clogged fuel filter 1 ___,_

• Pressure regulator
• Fuel pump
If the fuel pressure is higher than the specification, IK31 K1170043-01

check for the followings:

• Fuel pump
• Pressure regulator
 Fuel System: 1G-7

4) Disconnect the fuel pump coupler (1 ). 4) After servicing, install the removed parts.

Fuel Feed Hose Disconnection and

Reconnection
BENM10L31706004
Disconnection
1) Lift and support the fuel tank. @"(Page 1G-12)
2) Place a rag over the fuel feed hose.
3) Relieve fuel pressure. @"(Page 1 G-7)
4) Pull the retainer (1).
5) Disconnect the fuel feed hose joint (2) from fuel pipe.
IM10L 1170002-02

5) Connect proper lead wires to the fuel pump.

Apply12 V to fuel pump (between ''T1" and ''T2") for
10 seconds and measure the amount of fuel
discharged.
If the discharge amount is out of the specification,
the following cause maybe considered. IE31J1170034-01

Possible cause Correction

Clogged fuel filter Replace Reconnection
Defective fuel pump Replace 1) Insert the fuel feed hose joint (1) to fuel pipe.
2) Lock the retainer (2).
Battery(+) terminal - "T1"
Battery(-) terminal - "T2"

NOTE
The battery must be in fully charged
condition.

FP discharge amount IE31J1170035-01

Per 10 seconds [Standard]: 223 ml (7.54 US oz, 3) Confirm that fuel feed hose joint is not disconnected
7.85 Imp oz) or more by hand.

Fuel Hose Inspection

BENM10L31706005
Refer to "Fuel Hose" in Section 08 (Page 08-8).

IM 10L 1170003-02

6) After finishing the fuel discharge inspection, reinstall

the removed parts.

Fuel Pressure Relief Procedure

BENM10L31706003
NOTICE
Performing this procedure when the engine
is still hot can damage the catalyst.
Wait until the engine has cooled down before
performing this procedure.

1) Check that the engine is cold.

2) Disconnect the fuel pump coupler. <F(Page 1 G-12)
3) Start the engine and run it until the engine stops for
lack of the fuel. Repeat cranking the engine 2 - 3
times for about 3 seconds each time to dissipate the
fuel pressure in line.
Fuel connections are now safe for servicing.
1G-8 Fuel System:

Fuel Feed Hose Removal and Installation

BENM 1 0L31706006
Removal
1) Lift and support the fuel tank. 07 (Page 1 G-12)
2) Place a clean rag under the fuel feed hose (1 ).
3) Disconnect the fuel feed hose joints (2) and remove
the fuel feed hose. 17 (Page 1G-7)

IM10L1170004-02

Installation
Install the fuel feed hose in the reverse order of removal.
 Fuel System: 1G-9

Fuel Tank Construction

BENM10L31706007
Fuel Tank Cover
Refer to "Fuel Tank Front Cover/ Fuel Tank Bracket Construction" in Section 9D (Page 9D-13).

Fuel Tank

2 4

fi,[A]

'
5

�
� _4{ '\If

>\,,
,,,.�
'

1 ---.....::�\.
✓

:,;,'/,;--7\------
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_>(____'
I _.,,.,.,---- '
8 11 __
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fi,[D] fi,[E]
.... - __....._--::...

�I 7
I
[CJ � ', 0 /,

8
,,.-1,--T·----+--'-
1/ �/-
'•/
._ · ,
0 �

IM10L1170055-02
1G-10 Fuel System:

�[AJ: The arrow mark on the fuel tank rear bracket 2. Fuel tank rear bracket No.2 8. Fuel tank vessel
No.2 is facing forward.
�[BJ: The arrow mark on the fuel tank rear bracket 3. Fuel tank front bracket �: 5.5 N-m (0.56 kgf-m, 4.05 lbf-ft)
No.3 is facing forward.
[C]: Forward 4. Fuel tank rear bracket No.3 C!lm]: 3.0 N-m (0.31 kgf-m, 2.25 lbf-ft)
�[DJ: Make sure that the lower end of the fuel tank 5. Fuel tank front bracket C!ImJ: 10 N-m (1.0 k g f m
- , 7.5 lbf-ft)
container does not protrude outside the sealing
surface of the fuel tank.
�[
El Align the groove of the fuel tank vessel with the 6. Fuel tank (!ME: 23 N•m (2.3 kgf-m, 17.0 lbf-ft)
protrusion of the fuel tank.
1. Fuel tank cap 7. Fuel tank rear bracket No.1
 - � ��:·
System·
Fuel� 1G -11
-------------- -
Fuel tank cushion and heat shiel d-

[F]

[A] ¢::J ¢ [BJ

(ijjj[C] (.ii [C]

IM10L 1170056-02
1G-12 Fuel System:

[AJ: Front side [IJ: Lower side f.ij 4. Fuel tank fastener
: Stick the fastener aligning with the
groove of the fuel tank.
Clean the adhesive surface before
sticking the fastener.
Press the fastener after sticking.
[BJ: Rear side f.ij [JJ: Stick the fuel tank side cushion align the f.ij 5. Fuel tank side cushion
projection on the fuel tank. : Stick the cushion aligning with the
groove of the fuel tank.
Clean the adhesive surface before
sticking the cushion.
Press the cushion after sticking.
f.ij [C]: Clean the adhesive surface before f.ij [K]: The thick side of the fuel tank molding 6. Fuel tank
sticking the fuel tank heat shield. faces inward.
Press the fuel tank heat shield after
sticking.
f.ij [DJ: Stick the fuel tank heat shield No.2 under f.ij [L]: Apply adhesive to the inside of fuel tank 7. Clamp
the fuel tank heat shield No.1. flange and fuel tank molding.
f..iil[E]: Face the clamp end to rearward. f..iil[MJ: Apply adhesive to the inside of fuel tank 8. Fuel tank front bracket nut
flange and fuel tank side cushion.
f.ij[F]: Hook the fuel tank front cover nut to the 1. Fuel tank heat shield No.1 9. Fuel tank molding
hole of the fuel tank heat shield No.2.
[GJ: Upper side 2. Fuel tank heat shield No.2 10. Fuel tank side cushion
[HJ : Left side f..iil 3 Fuel tank cover fastener
: Stick the fastener aligning with the
groove of the fuel tank.
Clean the adhesive surface before
sticking the fastener.
Press the fastener after sticking.

Fuel Tank Cap Removal and Installation

BENM 10L31706008
Removal
1) Remove the fuel tank front cover. w(Page 9D-49)
2) Open the fuel tank cap with the ignition key.
3) Remove the fuel tank cap bolts (1) and fuel tank cap
(2) from the fuel tank.

1, (a

IM10L1170006-02

Fuel Tank Removal and Installation

BENM10L31706009
Removal
1) Remove the fuel tank front cover. w(Page 9D-49)
2) Remove the fuel tank front bracket bolts (1) from the
IM10L1170005-02 frame.

Installation
Install the fuel tank cap in the reverse order of removal.
Pay attention to the following point:
• Tighten the fuel tank cap bolts (1) to the specified
torque.
Tightening torque
Fuel tank cap bolt (a): 3.0 N·m (0.31 kgf-m, 2.25
lbf-ft)

IM10L1170007-02

3) Lift and support the fuel tank.

4) Disconnect the fuel pump coupler (1) from the fuel
pump.
5) Place a clean rag under the fuel feed hose (2) and
disconnect the fuel feed hose from the fuel pump.
 Fuel System: 1G-13

6) Disconnect the surge hose or fuel tank breather Tightening torque

hose (3) and fuel tank water drain hose (4) from the Fuel tank rear bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf­
fuel tank. ft)

IM10L1170008-03
7) Remove the fuel tank rear bracket bolts (1) and rear
brake master cylinder reservoir tank bracket bolt (2).
IM10L1170011-02
• Tighten the fuel tank rear bracket bolts (1) and rear
brake master cylinder reservoir tank bracket bolt (2) to
the specified torque.
Tightening torque
Fuel tank rear bracket bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
Rear brake master cylinder reservoir tank bracket
bolt (b): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

8) Lift up the rear side of fuel tank, and then remove the
fuel tank rear bolt (1) and fuel tank(2).

• Tighten the fuel tank front bolts (1) to the specified

torque.
Tightening torque
Fuel tank front bolt (a): 5.5 N·m (0.56 kgf-m, 4.05
lbf-ft)

IM10L 1170058-01

Installation
Install the fuel tank in the reverse order of removal. Pay
attention to the following points:
NOTICE
Be sure not to bend or twist the hoses when
installing.

• Connect the fuel tank water drain hose and surge

hose or fuel tank breather hose. w-(Page 1 G-2)
• Tighten the fuel tank rear bolt (1) to the specified
torque.
1G-14 Fuel System:

Fuel Pump Assembly Components

BENM 1OL31706010

©
©

�
�-mi�
I 1 1...,__2

©--- "tr

� - ,
d�
�

IM10L1170060-03

"111:
1. Fuel pump 5. Fuel feed hose Apply engine oil.

2. Fuel filter 6. Fuel pump inner plate �: Do not reuse.

3. Fuel level gauge 7. Fuel pump outer plate
4. Fuel pressure regulator �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
 Fuel System: 1G-15

Fuel Level Gauge Construction

BENM10L31706011

fijji [A],"1" 1 fijji [A], "2"

2 _.--;;;

Ir-ii [C]

Ir-ii [DJ

IM10L1170014-02

!r..[AJ: Install the fuel level gauge and fuel level gauge attachment to the fuel pump 2. Fuel level gauge attachment
assembly in order of "1" _, "2".
r_. [BJ: Pass the lead wires into the hole of fuel level gauge attachment. 3. Fuel pump assembly
Route the lead wires as shown in the figure.
r_. [CJ: Set the fuel level gauge to the fuel level gauge attachment until the hook is
locked firmly.
4. Fuel level gauge(+) lead wire (R)

�[DJ: Set the fuel level gauge attachment to the fuel pump assembly until the hook 5. Fuel level gauge(-) lead wire(BJ
is locked firmly.
The terminals must be below this line.
1. Fuel level gauge �6. Terminal
: Connect the terminal firmly.
1G-16 Fuel System:

Fuel Pump On-Vehicle Inspection

BENM10L31706012
Turn the ignition switch ON and check that the fuel pump
operates for a few seconds.
If the fuel pump motor does not make operating sound,
inspect the fuel pump circuit connections and fuel pump
relay. w (Page 1G-21)
If the fuel pump circuit connections is OK, the fuel pump
may be faulty, replace the fuel pump assembly with a
new one. "'"(Page 1G-16)

Fuel Pump Assembly / Fuel Level Gauge

Removal and Installation IM10L1170017-02

BENM10L31706013 5) Disconnect the fuel level gauge lead wires (1) from
Refer to "Fuel Tank Removal and Installation" (Page 1 G- the fuel pump.
12).

Removal
1) Remove the fuel pump mounting bolts (1) diagonally.
2) Remove the fuel pump outer plate (2) from the fuel
tank.

6) Unhook the hooks (1) and slide the fuel level sender
gauge (2) arrow direction as shown in the figure.

IM10L1170015-02

3) Remove the fuel pump inner plate (1) and fuel pump
assembly (2) form the fuel tank.

7) Unhook the hooks (1) and slide the fuel level sender
gauge (2) from the fuel level sender gauge
attachment (3) arrow direction as shown in the
figure.

IM10L1170016-02

4) Remove the fuel tank vessel (1) from the fuel tank.
 Fuel System: 1G-17

Installation
1) Install the fuel level gauge to the fuel level gauge
attachment. Then install the fuel level gauge
assembly to the fuel pump assembly. Refer to "Fuel
Level Gauge Construction" (Page 1G-15).
2) Align the groove (1) of the fuel tank vessel with the
protrusion (2) of the fuel tank.

IM10L1170064-01
>
5) Install the new O-ring (1) to the fuel pump assembly.

'f},
IM10L 1170021-02

IJ13K3170003-01

6) When install the fuel pump to the fuel tank, set the
fuel pump terminal (1) between the projections (2) of
fuel tank vessel.

IM10L 1170022-02

3) Install the fuel tank vessel (1) to the fuel tank, and
then make sure that the lower end (2) of the fuel tank
container does not protrude outside the sealing
surface (3) of the fuel tank.

IM10L1170024-02

7) Align the boss (1) of fuel pump assembly with the

punch mark (2) on fuel pump inner plate and install
them.

IM10L1170023-02

4) Install the fuel pump inner plate (1) to the fuel tank.

IM10L1170025-02

8) Install the fuel pump outer plate (1) aligning the boss
(2) of fuel pump assembly with the groove (3) of fuel
pump outer plate.
1G-18 Fuel System:

IH13K1170052-01

9) Install the fuel pump mounting bolt (1). 2. Hooked point

10) Tighten all the fuel pump mounting bolts lightly in the
ascending order and then tighten them to the 3) Remove the fuel filter (1) and fuel pressure regulator
specified torque in the figure. (2).
Tightening torque
Fuel pump mounting bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

"2"

1, (a) IH13K1170053-01

4) Remove the fuel pump (1).

IM10L 1170027-02

Fuel Pump Disassembly and Reassembly

BENM10L31706014
Refer to "Fuel Pump Assembly/ Fuel Level Gauge
Removal and Installation" (Page 1G-16).

Disassembly
1) Disconnect the fuel pump lead wire connectors (1).

IH13K1170054-02

5) Remove the fuel pump lead wires (1) and collar (2).

IH13K1170051-01

2) Remove the flange (1). 2

IH13K1170055-03
 Fuel System: 1G-19

Reassembly
1) Install the fuel pump(+) lead wire(1), fuel pump(-)
lead wire(2) and collar (3).

IH 13K1170059-02

6) Align the boss(1) of fuel pump with the groove(2) of

3
fuel filter and install the fuel filter(3).
IH13K1170056-01

2) Apply engine oil lightly to the new O-rings(1) and

install them.

IH13K1170060-01

7) Apply engine oil lightly to the new O-ring(1) and

install it.
IH13K1170057-01

3) Install the fuel pump(1) and route the fuel pump lead
wires as shown in the figure.

IH13K1170061-01

8) Install the flange(1) until the hooks(2) into the

locked position.
IH13K1170058-02

2. Fuel pump(+) lead wire(Bl)

3. Fuel pump (-) lead wire (B)

4) Apply engine oil lightly to the new O-ring(1) of the

new fuel pressure regulator(2). I

5) Install the fuel pressure regulator(2).

IH13K1170062-01

9) Connect the fuel pump(+) lead wire(1) and fuel

pump(-) lead wire(2).
1G-20 Fuel System:

"a"

IH13K1170063-01

Fuel Filter Inspection

BENM10L31706015
Refer to "Fuel Pump Disassembly and Reassembly"
(Page 1G-18).
Inspect the fuel filter for clogging. If the fuel filter is "b"
clogged with dirt, replace the fuel filter with a new one.

IM1 0L1170033-03

Fuel Pump Relay Removal and Installation

BENM10L31706017
Removal
1) Turn the ignition switch OFF.
2) Remove the meter panel. <7(Page 9D-37)
IH13K1170064-01
3) Remove the fuel pump relay (1).
Fuel Level Gauge Inspection
BENM10L31706016
Refer to "Fuel Pump Assembly/ Fuel Level Gauge
Removal and Installation" (Page 1G-16).
Measure the resistance at each fuel level gauge in float
position. If the resistance is incorrect, replace fuel level
gauge with a new one.
Float position Resistance
"a" 76.9 - 85.9 mm
8-12 0
(3.027 - 3.381)
"b" 161.9-170.9 mm
337-343 0
(6.374-6.728 in) IM10L1170031-03

Installation
Install the fuel pump relay in the reverse order of
removal.
 Fuel System: 1G-21

Fuel Pump Relay Inspection

BENM10L31706018
Refer to "F uel Pump Relay Removal and Installation"
(Page 1 G-20).
Check the fuel pump relay in the following procedures. If
abnormality is found, replace the fuel pump relay with a
new one.
1) Check that there is no continuity between terminals IL41K1170014-01
"T4" and "TS". 5) After finishing the fuel injector inspection, install the
2) Check that there is continuity between terminals "T1" removed parts.
and "T3".
3) Connect battery positive(+) terminal and negative(­ Fuel Injector/ Fuel Delivery Pipe Removal and
) terminal between terminals "T1" and 'T3" and Installation
check for continuity between terminals "T4" and "TS". BENM10L31706020
If there is no continuity when the relay is connected NOTE
to the battery, replace the fuel pump relay. The fuel injector can be removed without
removing the throttle body.
T5 T3
Primary side
Removal
1) Remove the air cleaner box. w(Page 1 D-6)
2) Remove the clamps(1), and then disconnect the fuel
injector couplers(2) from the fuel injectors.

T4 T1
IL41K1150036-02

Fuel Injector On-Vehicle Inspection

BENM10L31706019
1) Lift and support the fuel tank. w(Page 1G-12)
2) Turn the ignition switch OFF.
3) Disconnect the fuel injector coupler from the fuel
injector.

IM1 0L1170035-03

3) Remove the fuel delivery pipe assembly bolt(1) and

fuel delivery pipe assembly (2).

IM10L1170063-01

1. Primary fuel injector coupler

2. Secondary fuel injector coupler

4) Measure the fuel injector resistance between

terminals using the circuit tester. If resistance is out IM10L1170036-03

of specification, replace the fuel injector(1) with a 4) Remove the fuel injectors(1) from the fuel delivery
new one. w(Page 1G-21) pipes.

Fuel injector resistance

20 °c (68 °F) [Standard]: 11.5 -12.5 n
1G-22 Fuel System:
• Install the fuel delivery pipe assembly (1) to the
throttle body.

NOTICE
Never turn the fuel injectors while installing
them.

Tighten the fuel delivery pipe mounting screws (2) to

the specified torque.
Tightening torque
Fuel delivery pipe mounting screw (a): 3.5 N·m (
IM10L 1170037-03 0.36 kgf-m, 2.60 lbf-ft)
5) Remove the nipple joint (1) and O-rings (2) from the
fuel delivery pipes (3).

3
IM10L 1170041-03
IM10L1170065-02

Installation Secondary side

Install the fuel injector and fuel delivery pipe in the
reverse order of removal. Pay attention to the following
points:
• Apply engine oil to the new O-ring.
• Install the nipple joint (1) and new O-rings (2) to the
fuel delivery pipes (3).
Removal
1) Remove the fuel tank. i:o=(Page 1G-12)
2) Place a clean rag under the fuel feed hose (1) and
disconnect the fuel feed hose (1). <:lr"(Page 1G-7)

3
IM10L1170042-02
IM10L 1170065-02

• Apply a thin coat of engine oil to the new O-rings (1) 3) Disconnect the fuel injector couplers (1) from the fuel
and new cushion seals (2). injectors.

IM10L 1170043-02

4) Remove the fuel delivery pipe assembly bolt (1) and

fuel delivery pipe assembly (2).
 Fuel System: 1G-23

• Apply a thin coat of engine oil to the new O-rings (1)

and new cushion seals (2).

IM10L1170044-02

5) Remove the fuel injectors (1) from the fuel delivery

pipes. IM10L117-0047-02

• Install the fuel delivery pipe assembly (1) to the air

cleaner box.
NOTICE
Never turn the fuel injectors while installing
them.

• Tighten the fuel delivery pipe mounting screws (2) to

the specified torque.
Tightening torque
Fuel delivery pipe mounting screw (a): 3.5 N·m (
0.36 kgf-m, 2.60 lbf-ft)
IM10L1170045-02

6) Remove the nipple joint cover (1), nipple joint (2) and
O-rings (3) from the fuel delivery pipes (4).

4
IM10L1170066-02

Fuel Injector Inspection and Cleaning

Installation BENM10L31706021

Install the fuel injector and fuel delivery pipe in the
reverse order of removal. Pay attention to the following
points:
• Apply engine oil to the new O-rings.
• Install the nipple joint cover (1), nipple joint (2) and
new O-ring (3) to the fuel delivery pipes (4).
Refer to "Fuel Injector/ Fuel Delivery Pipe Removal and
Installation" (Page 1 G-21 ).
Check the fuel injector filter for evidence of dirt and
contamination. If present, clean and check for presence
of dirt in the fuel line and fuel tank.

4
IM10L1170066-02
1G-24 Fuel System:

Specifications
Tightening Torque Specifications
BENM10L31707001
Tightening torque
Fastening part Note
N•m kgf-m lbf-ft
Fuel tank cap bolt 3.0 0.31 2.25 w(Page 1G-12)
Fuel tank rear bolt 10 1.0 7.5 w(Page 1G-13)
Fuel tank rear bracket bolt 10 1.0 7.5 w-(Page 1G-13)
Rear brake master cylinder reservoir tank w(Page 1G-13)
10 1.0 7.5
bracket bolt
Fuel tank front bolt 5.5 0.56 4.05 w(Page 1G-13)
Fuel pump mounting bolt 10 1.0 7.5 w(Page 1G-18)
Fuel delivery pipe mounting screw es=(Page 1G-22) /
3.5 0.36 2.60
w(Page 1G-23)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Fuel Tank Construction" (Page 1G-9)
"Fuel Pump Assembly Components" (Page 1G-14)

Special Tools and Equipment

Recommended Service Material
BENM10L31708001
NOTE
Required service material(s) is also described in:
"Fuel Pump Assembly Components" (Page 1G-14)

Special Tool
BENM10L31708002
09915-74511 09940-40211
Oil pressure gauge set (600 Fuel pressure gauge
kPa) adapter
1. Gauge 2. Hose Discontinued
(U"(Page 1G-6) w(Page 1G-6)

09940-40220
Fuel pressure gauge
attachment
w(Page 1G-6)
   



  
   



 
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9C-13 Combination Meter I Fuel Meter I Horn:

Combination Meter Removal and Installation

BENM1 OL39306007
[AJ [BJ Refer to "Body Cowling Assembly Removal and
Installation" in Section 9D (Page 9D-44).

Combination Meter Disassembly and

Reassembly
BENM10L39306008
Approx. 8110 Disassemble/reassemble the combination meter as
shown in the combination meter components. w-(Page
9C-8)

ECT Sensor Removal and Installation

BENM10L39306009
Refer to "ECT Sensor Removal and Installation" in
Section 1 C (Page 1C-6).

Approx. 1420 Fuel Meter Inspection

BENM10L39306010
1) Disconnect the fuel pump coupler. w-(Page 1 G-16)
2) Connect a variable resistor (1) between the T3 and
T4 of the fuel pomp coupler.

Approx. 1110

IL06L1930038-01

3) Turn the ignition switch ON.

4) Check the fuel meter (1) and indicator light (2)
operations when the resistance is adjusted to the
specified values.
If either one or both indications are abnormal,
[CJ replace the combination meter with a new one. Refer
to "Combination Meter Removal and Installation"
(Page 9C-13).
NOTE
IM10L1930014-04
It takes approx. 40 seconds that the fuel level
[A): Resistance [CJ: When data cannot be indicator indicates the detected fuel level.
received or abnormal data is
received.
[B]: Engine coolant temperature [DJ: ON
meter

5) After finishing the ECT indicator inspection, reinstall

the removed parts.

IM10L1930027-01
9C-15 Combination Meter I Fuel Meter I Horn:

Speed Sensor Inspection

BENM10L39306014
Refer to "Wheel Speed Sensor and Sensor Rotor
Inspection" in Section 4E (Page 4E-55).

NOTE
The combination meter receives the signal of
the front wheel speed sensor and displays
the vehicle speed.

Ambient Air Temperature Sensor Removal and

Installation
BENM10L39306015
1) Remove the body cowl cover. <?(Page 90-43)
2) Disconnect the ambient air temperature sensor
coupler (1).

IM10L1930015-01
9C-17 Combination Meter I Fuel Meter I Horn:

[A] [BJ [CJ

[DJ
'
[F]
I

AIR 3 ° c
AIR 38 ° F
/
ON

* tt
[D] [E]
/ ' ° °
5 C(41 F)

*
OFF 3 °C (38 °F)
AIR 5 ° c
[E]
AIR 41 ° F
�
IM10L1930018-01

[A]: Thermometer [DJ: When decreasing the temperature

[BJ: Freeze indicator [E]: When increasing the temperature
[C]: Ambient air temperature [F]: Flicker

5) Install the removed parts.

Ambient Air Temperature Sensor Inspection Oil Pressure Indicator Inspection

BENM10L39306017 BENM1 0L39306018
Refer to "Freeze Indicator Light/ Thermometer 1) Remove the under cowling (LH). w(Page 9D-42)
Inspection" (Page 9C-16).
2) Disconnect the oil pressure switch lead wire (1) from
Measure the resistance between terminals of ambient air
the oil pressure switch.
temperature sensor.
If any abnormality is found, replace the ambient air
temperature sensor with a new one.

NOTE
Ambient air temperature sensor resistance
measurement method is the same way as
that of the ECT sensor. 17 (Page 1C-6)

3) Turn the ignition switch ON.

4) Check if the oil pressure indicator light (LED) (2) will
light up when grounding the lead wire (1 ).
IL06L1930043-01 If the oil pressure indicator light does not light up,
replace the combination meter with a new one after
Ambient air temperature sensor resistance
checking the wiring and connection of couplers.
Temperature Standard resistance
-20 oc (-4 °f) 13779 -19083 0
-10 oc (14 °f) 8100 -10609 0
0 oc (32 °f) 4928-6125 0
10 oc (50 °f) 3089 -3656 0
20 oc (68 °f) 1992-2251 0
25 oc (77 °f) 1615- 1785 0
30 oc (86 °f) 1290 - 1456 n
40 oc (10 4 °f) 838-986 n

IM10L1930020-01

5) Install the removed parts.

9D-1 Exterior Parts:

Exterior Parts
Precautions
Precautions for Exterior Parts
BENM10L39400001
• In the absence of specific instructions, the same procedure applies to both sides.
• Clean the adhesive surface before sticking the cushion, tape and protector.

Schematic and Routing Diagram

Seat Lock Cable Routing Diagram
BENM10L39402001

4 �[A]

�[C]

[BJ

5 4 3
IM10L1940001-01

(iii [A]: Set the seat lock cable firmly to guide of frame rear cover 1. Striker support bracket 6. Seat lock cable guide
(LH)
[BJ: Spherical cable end 2. Striker support bracket bolt 7. Seat lock cable plate
rlllli[CJ: Set the seat lock cable firmly to seat lock cable guide. 3. Frame rear cover (LH) 8. Seat lock assembly
[D]: Cylindrical cable end 4. Seat lock cable C!Iml 8.8 N•m (0.90 kgf-m, 6.50 lbf-ft)
(iii[E]: Align the rib of seat lock assembly and groove of each part. 5. Rear fender (front)

Exterior Components Location
21
4
s�t..���;_,,_
6
7 /'
/
/ ----
10
------------------ �
34
1. Windscreen .r(Page 9D-44)
2. Rear view mirror <r(Page 9D-34)
3. Body center cowling ""(Page 9D-47)
4. Body cowling ""(Page 9D-47)
5. Intake center cover "'"(Page 9D-47)
6. Intake rear cover <r(Page 9D-47)
7. Front fender <r(Page 9D-36)
8. Body cowl cover <r(Page 9D-43)
9. Under inner cowling "'"(Page 9D-43)
10. Under center cowling "'"(Page 9D-42)
11. Under cowling <>-(Page 9D-42)
12. Air intake inner pipe "'"(Page 9D-48)
Component Location
26
16
15
- ,/.
13. Air intake outer pipe "'"(Page 9D-48)
14. Frame cover "'"(Page 9D-51)
15. Frame rear cover <>-(Page 9D-51)
16. Frame center cover '""(Page 9D-51)
17. Pillion rider handle "'"(Page 9D-36)
18. Rear seat "'"(Page 9D-34)
19. Front seat "'"(Page 9D-34)
20. Fuel tank front cover <>-(Page 9D-49)
21. Meter front panel No.1 "'"(Page 9D-47)
22. Meter panel (center) "'"(Page 9D-44)
23. Meter panel "'"(Page 9D-37)
24. Frame under cover ""(Page 9D-54)
Exterior Parts: 9D-2
BENM10L39403001
IM 1 0L 1940004-03
25. Rear fender (rear) <>-(Page 9D-53)
26. Rear fender (front) "'"(Page 9D-53)
27. Side front cowling No.2 "'"(Page 9D-40)
28. Side rear cowling "'"(Page 9D-40)
29. Meter front panel No.2 "'"(Page go-40)
30. Side cover w(Page 9D-40)
31. Side rear cover <r(Page 9D-40)
32. Side front cowling No.1 "'"(Page 9D-40)
33. Fuel tank cap cover "'"(Page 9D-49)
34. Lower bracket cover <>-(Page 9D-37)
35. Frame cover lid "'"(Page 9D-51)
9D-3 Exterior Parts:

Exterior Component Removal Chart

• This chart shows removal procedures for exterior component. Carry out each process following the arrow from left
to right.
• Indicated number in the chart corresponds to the number in "Exterior Components Location" (Page 9D-2).
• The part shown by circled number (e.g. CD) can be removed from the vehicle individually.
• Adjoining part can be removed as a unit.
• Small white circle ( O ) indicates joining of the arrows.
For removal of a part pointed by an arrow from a small white circle, all the part(s) in starting point of arrow(s) to the
small white circle must be removed beforehand.
• Small black circle ( • ) indicates branching of the arrows.
For removal of parts pointed by arrow(s) from a small black circle, choose an arrow corresponding to a target part to
be removed.

�-- 2 1----------....f '------ �

12
13
�
5 6

19

18
1. Windscreen ""(Page 9D-44)
2. Rear view mirror -(Page 9D-34)
3. Body center cowling ""(Page 9D-47)
4. Body cowling "'"(Page 9D-47)
5. Intake center cover "'"(Page 9D-47)
6. Intake rear cover <r(Page 9D-47)
7. Front fender ""(Page 9D-36)
8. Body cowl cover ""(Page 9D-43)
9. Under inner cowling <r{Page 9D-43)
10. Under center cowling a-(Page 9D-42)
11. Under cowling <r(Page 9D-42)
12. Air intake inner pipe ""(Page 9D-48)
17
13. Air intake outer pipe ""(Page 9D-48)
14. Frame cover ""(Page 9D-51)
15. Frame rear cover <7(Page 9D-51)
16. Frame center cover <r(Page 9D-51)
17. Pillion rider handle ""(Page 9D-36)
18. Rear seat ""(Page 9D-34)
19. Front seat "'"(Page 9D-34)
20. Fuel tank front cover "'"(Page 9D-49)
21. Meter front panel No.1 "'"(Page 9D-47)
22. Meter panel (center) ""(Page 9D-44)
23. Meter panel "'"(Page 9D-37)
24. Frame under cover "'"(Page 9D-54)
34
IM10L2940001-01
25. Rear fender (rear) "'"(Page 9D-53)
26. Rear fender (front) a-(Page 9D-53)
27. Side front cowling No.2 <7(Page 9D-40)
28. Side rear cowling "'"(Page 90-40)
29. Meter front panel No.2 "'"(Page 9D-40)
30. Side cover a-(Page 9D-40)
31. Side rear cover '"'(Page 9D-40)
32. Side front cowling No.1 .r(Page 9D-40)
33. Fuel tank cap cover "'"(Page 9D-49)
34. Lower bracket cover "'"(Page 9D-37)
35. Frame cover lid ""(Page 9D-51)
 Exterior Parts: 9D-4

Repair Instructions
Rear View Mirror Construction
BENM10L39406001

,.

@
� �>� /2

·� ��3
IM10L2940002-01

1. Rear view mirror 4. Rear view mirror nut t!lm]: 12 N-m (1.2 kgf-m, 9.0 lbf-ft)
2. Body cowling 5. Cowling brace
3. Brace cowling cushion 6. Windscreen brace
9D-5 Exterior Parts:

Front Fender Construction

BENM10L39406002

' V" [A]

°" (§) /;
\ �

9 �

f.il[B] .--_

IM10L 1940006-03
[A]: View [a] 2. Front fender front bolt 7. Front side reflex reflector bracket
r,..[B]: Stick the tape so as not to block a hole. 3. Front fender rear bolt 8. Front side reflex reflector
[CJ: For U.S.A., Canada and California State. 4. Front side reflex reflector nut �: 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
[DJ: Except for U.S.A., Canada, California
State. Japan and Thailand.
5. Front side reflex reflector bracket C!llm:
2.5 N-m (0.25 kgf-m, 1.85 lbf-ft)

1. Front fender 6. Front side reflex reflector t): Do not reuse.

 Exterior Parts: 9D-6

� �1
Cowling c onstruction
BENM10L39406003

��

I'--. �

�7
�_____:__

'j
,�-
"C
--,---···�,

/i
/

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@ (I)
V
9

C!ll
9D-7 Exterior Parts:
Body Cowling Construction
[A): From meter panel (center)
[BJ: From headlight
(C]: To cowling brace
1. Windscreen
2. Body cowling
BENM10L39406004
3
IM10L1940008-02
3. Body center cowling g: 0.4 N-m (0.04 kgf-m, 0.30 lbf-ft)
4. Meter front panel No.1 �: 1.8 N-m (0.18 kgf-m, 1.35 lbf-ft)
�5. Windscreen bolt 'a": 3.0-4.0 mm (0.12 - 0.16 in)
: Tighten the windscreen bolt to the specified torque or
tighten so that the protruding amount of the screw is "a".
6. Windscreen nut
7. Cowling brace
 Exterior Parts: 9D-8

[B]
2
[C] [B]

-5,'fJ [B]
--�----
-- [B] [C]
[A] .-,
,-...------------
_;<�;�------=
t' .....::-. ·;�
r··: ..._-�

•...._\_: � '3
® CE)

body cowling ide cowling assembly 3 . Body cowl cover

headlight enter cover .
4_ Under ·1nner cowling
turn signal light rear cover
go.g Exterior Parts:

-- :.. -=-@
i
�� � . ·· .

m:
IM10L1940010-03

[A]: To intake rear cover
[BJ: To meter front panel No.1
[C]: To body center cowling
[DJ: From windscreen
1. Headlight
2. Intake pipe assembly 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
3. Turn signal light � : 23 N-m (2.3 kgf-m, 17.0 lbf-ft)
4. Brace assembly (!IGJ: 1.8 N-m (0.18 kgf-m, 1.35 lbf-ft)
5. Combination meter t): Do not reuse.
6. Meter panel (center)
 Exterior Parts: 9D-10

Windscreen Brace Construction

BENM 1 0L39406005

IM10L1940011-01
9D-11 Exterior Parts:

Side Cowling Assembly Construction

BENM10L39406006
NOTE
The following figure shows the right side. The same procedure applies to the other side except in
some cases.

"1"

"4"

IM10L 1940012--03
 Exterior Parts: 9D-12

[A]: Left side only 1. Side rear cowling 5. Side front cowling No.2
[B]: Assembling direction of the clip 2. Side front cowling No.1 6. Meter front panel No.2
irlllf[C]: First, assemble side rear cowling and side 3. Side rear cover 7. Hook
front cowling No.1.
(jj[D]: Align the boss on A with the hole on B, and 4. Side cover �: 1.8 N-m (0.18 kgf-m, 1.35 lbf-ft)
then secure the hook.
9D-13 Exterior Parts:

Fuel Tank Front Cover I Fuel Tank Bracket Construction

BENM10L39406007

"1"

[A]
��

�1
.. �1<d>

IM10L1940013-02
 Exterior Parts: 9D-14

[A]: View[a] 4. Fuel tank cover rubber 9. Meter panel (RH)

[BJ: Top side 5. Fuel tank front bracket 10. Air cleaner box
�1. Cushion 6. Throttle cables 11. Frame
: Stick the cushion aligning with emboss
line.
�2 Fastener 7. Clip �: 5.5 N-m (0.56 kgf-m, 4.05 lbf-ft)
: Stick the fastener aligning with emboss
line.
3. Fuel tank front cover 8. Cushion rubber �: 4.0 N·m (0.41 kgf-m, 2.95 !bf-ft)

Frame Cover Assembly Construction

BENM10L39406008

C!lLm
�/
2

�1---l
. i i'> I'

,;�' @�>�r1
/4
@ I�\ �
@ r..ii [A) t.!111!

�
�

/)"·�\' //
:p /
. /

... ·1·
J
1 I� ·fl
l ! /
,.,.-
.r 0

·�"'""'
�
.@
:,.

�
-
', I �

IM10L1940014-02

f..il[A]: Firmly insert into the protrusion inside the 2. Frame cover assembly �: 5.5 N-m (0.56 kgf-m, 4.05 lbf-ft)
cover
1. Frame cover lid �: 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
9D-15 Exterior Parts:

Frame Cover Construction

BENM1 0L39406009

[G]

2
is

f..i[F] [a]

(J

�
r..i [J]
D]r'"l""!I -
��

17 -�:) �j
3
v
_/ [c]�

·. r- 3

4
)- �
/
)A�
. '

IM10L 1940015-03

[AJ: View[aJ [HJ: Thin riiis Cushion

: Stick the cushion aligning with
emboss line. (LH only)
[BJ: View [b] [I]: Thick f.ii 6. Cushion
: Stick the cushion matching with
seating surface.
[CJ: View[cJ riii [J]: Be aware of the difference in thickness. f.ii 7. Cushion
: Stick the cushion matching with rib.
riij [DJ: Tighten the boss securely fitted. 1. Frame center cover �: 2.0 N·m (0.20 kgf-m, 1.50 lbf-ft)
"a": 0 - 2 mm (0 - 0.078 in)
riii [E]: Match the corners. 2. Cushion
riij [FJ:
Stiel< the cushion aligning with cover edge 3. Frame rear cover
and R end of rib.
(GJ: Top side 4. Frame cover
 Exterior Parts: 9D-16

Rear Fend er Construction

BENM10L39406010

IM10L2940003-01
9D-17 Exterior Parts:

[A]: View[a] 1. Seat rail 11. Cushion

[B]: View [b] 2. Rear fender bracket 12. Cushion
[C]: View[c] 3. Rear fender (front) 13. Cushion
[D]: View(d] 4. Fuel tank lower bracket �: 12 N-m (1.2 kgf-m, 9.0 lbf-ft)
�[E]: Stick the cushion aligning with the emboss 5. Battery front shield �: 0.8 N-m (0.08 kgf-m, 0.60 lbf-ft)
line.
f,.jj[F]: Fit the cushion according to the shape of 6. Rear fender (front) brace t!lG.l 10 N-m (1.0 kgf-m, 7.5 lbf-ft)
part.
[G]: Drain hole 7. Rear fender mudguard "a": 0 - 2 mm (0 - 0.079 in)

[HJ: Top side 8. Rear fender (rear) "b": 1.5 - 3.5 mm (0.059 - 0.13)
f,.jj [I]: Except for india. 9. Frame under cover t!i: Do not reuse.
f..ii (J]: Tighten this screw first. 10. Cushion

Pillion Rider Handle Construction

BENM10L39406011

__,,,:5�:��)
�- ,\ ' \
.:::--... �:..:�·-l\ \ I'�--: "-=<= .
-
I

'

,, I
:/jj \'
,/ ¥ I 1
I I

/
,.
\
. [)
,. .·' 1'
.. '-. \ .

5 10

IM10L1940017-01
1. Pillion rider handle 7. Washer 13. Washer
2. Pillion rider handle bolt 8. Cushion 14. Cushion (LH only)
3. Washer 9. Cushion 15. Cushion
4. Frame rear cover 10. Washer �: 25 N-m (2.5 kgf-m, 18.5 lbf-ft)
5. Seat rail 11. Cushion
6. Cushion 12. Cushion
 Exterior Parts: 9D-18

Windscreen Cushion Construction

BENM10L39406012

"a"
'
_'· ��--=:----:-::_-.

"b"
IM10L1940018-01

f.i, [A]: Press the cushion after sticking. 2. Cushion "b": 2.5 - 5.5 mm 0.099 -0.21 in)
1. Windscreen "a": 0 -1 mm (0- 0.039 in)
9D-19 Exterior Parts:

Body Center Cowling Cushion Construction

BENM10L39406013

� ��h
-
/

.
F
i
\"'·

ff'
_ff-'

IM10L1940019-01

f,,.[A]: Stick the cushion or tape within 1 mm (0.039 1. Body center cowling 3. Fastener
in) for inside of emboss line.
Press the cushion after sticking.
!r..-[B]: Stick the cushion or tape within 1 mm (0.039 2. Cushion 4. Tape
in) for inside of emboss line.
 Exterior Parts: 9D-20

Body Cowling Cushion Construction

BENM10L39406014

r.i[B]

"a"

[C]

1
��·E::)-,�___ r..._cA--1-1,-3 �

. j3) //
� � 0/
� (7/

�=====--E:i� )

r.i[B]

IM10L1940020-01

f.i,[A]: Stick the cushion or tape within 1mm (0.039 [D]: Emboss line 3. Cushion
in) for inside of emboss line.
Press the cushion after sticking.
(,.j[B]: Stick the tape aligning with the end of 1. Body cowling
curved surface.
[C]: Emboss line 2. Tape
9D-21 Exterior Parts:

Intake Cover Cushion Construction

BENM10L39406015

r.iia[A], 2

IM10L1940021-01

f.i [A): Stick the cushion within 1 mm (0.039 in) for 1. Intake center cover 2. Cushion
inside of emboss line.
Press the cushion after sticking.
 Exterior Parts: 90_22

Intake Cover C h"ion Construction No.2

BENM10L39406016

(.ii [A], 2

✓
C-C

B-B

�[A], 2

A-A

(.ii [A], 2
(.ii [A], 2
D-D

'\

o.O
-✓

, :/ �
E
1ffl',.
�
r�I�)
..',"'.';
'
@/ /�
(11�,���
E-E

(.ii [A], 2
IM10L1940022-02
[A]: Stick the cushion within 1 mm (0.039 in) for 1. Intake rear cover 2. Cushion
inside of emboss Jin .
Press th e cushion
. after
e sticking.
9D-23 Exterior Parts:

Intake Pipe Cushion Construction

BENM10L39406017

A-A

" " �[A], 2

a
[B] ---

r-7�
B-B
�[A], 3

D-D

llaO

IM10L 1940023-01

f.-[A]: Stick the cushion or tape within 1 mm (0.039 1. Intake pipe assembly 3. Cushion
in) for inside of emboss line.
Press the cushion after sticking.
(BJ: Emboss line 2. Cushion Ila": 0 -1 mm (0 - 0.039 in)
 Exterior Parts: 9D-24

Meter Panel Cushion Construction

BENM10L39406018

A-A B-B C-C

�[Bl, 2 �[BJ, 3 �[BJ, 4

_____ )

fr
[a)
D - D (E - E)

IM10L 1940024-02

[A]: View[a] 2. Cushion 5. Cushion

"a": 0 -1 mm (0 - 0.039 in)
(ii[B]: Stick the cushion within 1 mm (0.039 in) for inside of emboss line. 3. Cushion
Press the cushion after sticking.
1. Meter panel 4. Cushion "b": -1 - 0 mm (-0.039- 0 in)
9D-25 Exterior Parts:

Meter Panel Cushion Construction No.2

BENM10L39406019

� [A], 3 -,.__

f.ii[C]

f.ii [C], 5

IM 1 0L 1940025--02

f.ij[A]: Stick the cushion within 1mm (0.039 in) for inside of emboss line. 1. Meter panel (center) 4. Cushion
Press the cushion after sticking.
f.ii [BJ: Stick the cushion aligning with the end of curved surface. 2. Cushion 5. Cushion
f.ii [CJ: Press the cushion after sticking. 3. Cushion 6. Cushion
 Exterior Parts: 9D-26

Under Cowl Cushion Construction

BENM10L39406020

rii. [A], 2

(�-···· . ..•�

.
/' ·. '
\

IM10L1940026·01

� [A]: Stick the cushion aligning with the emboss line. 1. Under center cowling 2. Cushion

Body Cowl Cover Cushion Construction

BENM10L39406021

(iii [A], 2

+ +

D D

D
FWD
IM10L1940027-01

fiil [A]: Stick the cushion within 1 mm (0.039 in) for inside of 1. Body cowl cover 2. Cushion
emboss line.
9D-27 Exterior Parts:

Side Cowling Assembly Cushion Construction

BENM10L39406022

C-C

�
2

�[N]

(.ii[F]

(.ii [T] (.ii [I]

[D] 6

--·
�[J]
Yi==
L-
/

IM10L1940028-03
 Exterior Parts: 9D-28

[A]: View[a] (.i[L]: In this range, adhered all around. 3. Cushion

[B]: View[b] (.i[M): No permit distortion all around. 4. Cushion

[CJ: View[cJ f.il [NJ: Match the cushion with rib. 5. Cushion
[D]: View[dJ (.i[OJ: Cushion does not extend from the edge. 6. Molding
[E]: Long side (.i [P]: Stick the cushion to the edge. 7. Cushion (LH only)
(.i [FJ: Stick the cushion aligning with emboss line. [Q]: View[q] 8. Molding
[G]: Bonded surface [RJ: Left side 9. Cushion
f.il [HJ: Stick the cushion aligning with the edge of the part. [SJ: Right side 10. Cushion
f.il [IJ: Do not run aground. f.il [T]: Stick the molding aligning with the mark. 11. Molding
f.il [J]: Align the molding with the edge. 1. Side cowling assembly 12. Cushion
f.il [KJ: Allow overlap. 2. Cushion

Under Inner Cowling Cushion Construction

BENM10L39406023

r..[A], 4
,_
0 ----
' .._.,_ .

- I
l'��
o /
-ri
. -
2

IM10l 1940029-01

f.il [AJ: Stick the cushion within 1mm (0.039 in) for 2. Under inner cowling (LH) 4. Cushion
inside of emboss line.
Press the cushion after sticking.
1. Under inner cowling (RH) 3. Cushion
9D-29 Exterior Parts:

Battery and ECM Cushion Construction

BENM 1 0L39406024

\a�-.:::.:::::::::===--= �G
@

cQ
-�-P.a,------;.=--t-
, ___-·
_ · .. ·---
lla" a
"a"
11 ,,-
8

(iii [A], (iii 5

IM10L1940030-02

f.ij[A]: Align the edge of protector with the end of curved 2. Cushion Ir.ii5. Protector
surface. ; Press the protector after stii;lling.
�[BJ: Allow the protector to hit the corner. 3. Rear fender (front) "a": 0 - 3 mm (0 - 0.11 in)
1. Battery Ir.ii 4, Protector
: Press the protector after sticking.
"b": 0 -1 mm (0 - 0 039 in)
.
 Exterior Parts: 90-30

·� c:e:s:saa. ::u ZL -�-·

-1•□ fr

f"c"
[ ]

"a �Jl,
y---�
B tcf-.ji[�

[C] r-----, "c" �[G]

__,?-J• f-.ji [G]

��- �U
[D]
-"b----+--"

f-.ji [I] , 2

r,1J
lld"
'ir---.;

[E] [ F] [H]
�- :· .

"e"

"f"
� _r'
�[I], 5 f.iij[H] (iii [I] ,4
IM10L1940031-01
"a": 0-3mm(0-0.11 in)
[Al: View [a] r...11J: Press the cushion or protector after sticking.
[BJ: View (b]
"b": 50 - 60 mm (2.0-2.3 in)
fllii[JJ: Fold the cushion and stick ii.
Press the cushion after sticking.
[CJ: View[cJ 1. Rear fender (front) "c": 2 - 8 mm (0.079 - 0.31 in)
[DJ: View[d] 2. Cushion "d": 0-2 mm(0 - 0.078 in)
[E]: View[eJ 3. Cushion "e": 13-16 mm(0.52 -0.62 in)
[F]: View[f] 4. Cushion "e": 0-5 mm(0-0.19 in)
�[G]: Stick the protector so that it does not 5. Cushion
protrude from the battery holder.
r,.. [HJ: Align the edge of protector with the end of 6. Cushion
curved surface .
9D-31 Exterior Parts:

Frame Rear Cover Tape Construction

BENM 1 OL39406025

-
0

B-B
(iii [C], 3

-� ;�
J'
�
IJ D]

IM10L1940032-01

f.iiil [A]: Align the edge of cushion with the end of (D]: Emboss line 3. Tape
curved surface.
1. Frame cover assembly "a": 0 - 1.5 mm (0 - 0.059 in)
f.iiil [B]: Stick the cushion aligning with the edge of
the part.
f.iiil [C]: Fold the tape inward and stick it.
Press the tape after sticking.
r... 2. Cushion
: Press the cushion after sticking.
'b": 0 - 1 mm (0 - 0.039 in)
 Exterior Parts: 9D-32

Pillion Rider Handle Cushion Construction

BENM10L39406026

(iji[A]

�- '

4 \

� \

"a" 4
IM 1 0L 1940033-02

f,jj[A]: Stick the cushion away from this area. 2. Cushion "a": 7 - 13 mm (0.28 - 0.051 in)
f,jj[BJ: Align the edge of cushion with the end of 3. Cushion
curved surface.
1. Pillion rider handle 4. Cushion (LH only)
9D-33 Exterior Parts:

Clip Removal and Installation Type2

BENM1 0L39406027
Removal
Type 1
Removal 1) Pull up the ce.nter piece.
. 2) Remove the chp.
1) Depress the hea. d 0f clip center pIece (1).
2) Pull out the clip (2).

ID26J1940171-02

.
Installation
1) Keep the Pin. puIIed out to close the claws.
. .mto the fitting hole
2) Set the clip
.
ID26J1940192-01 3) Push 1·n the center pI·ece .

Installation
1) L t the center pIec . e stick out toward the head so that
th: c laws (1_) d ;
ose

2) lnse rt the clip mto e installation hole

.
NOTE
-��;::�
o preven hhee ppawl (1)
::..:..__=�tHt: ;.;;���-m
from damage, �se
ID26J1940172-02

T � rt�
the clip all the w,a�y�i:nto
� � th e ·nstallation hole.
� ::_:_:: _•_____

Installation
_ ( 1) into the gate (2) as shown .m the figure
Insert the clip .
 Exterior Parts: 9D-34

Rear View Mirror Removal and Installation

BENM10L39406028

Removal
1) Remove the meter panel (center) and combination
meter. w(Page 9D-44)
2) Remove the rear view mirror bolts (1) and rear view
mirror (2).

. /
IM10L1940034-01

Installation
Install the rear view mirror in the reverse order of
removal. Pay attention to the following point:
IM10L1940037-01
• Tighten the rear view mirror nuts (1) to the specified
torque. Installation
Tightening torque 1) Slide the front seat (1) into bracket and tighten the
Rear view mirror nut (a): 12 N·m (1.2 kgf-m, 9.0 front seat bolts (2).
lbf-ft)

IM10L1940038-01
IM10L1940035-01

Seat Removal and Installation

BENM 1 0L39406029 2-@
Front Seat
Removal
1) Remove the front seat bolts (1) and front seat (2).
.,,� '\
2
, ~·

/ �,✓-�,

IM10L1940039-01

- - ---- - ------ -
-
9D-35 Exterior Parts:

Rear Seat Seat Lock Cable/ Seat Lock Assembly/ Striker

Removal Support Bracket Removal and Installation
BENM1 0L39406030
1) Unlock the seat lock (1) with the ignition key.
2) Remove the rear seat (2). Seat Lock Cable
Removal
1) Remove the rear seat. <lr(Page 9D-34)
2 2) Remove the frame cover assembly. <lr(Page 9D-51)
3) Disconnect the seat lock cable (1) from the seat lock
assembly (2) and striker support bracket (3).

�
/J_ ,�-
\, _____
IM10L1940040-02

Installation
Slide the rear seat hook into the seat hook guide and
push down firmly until the seat snaps into the locked
position.
IM10L1940042-01

Installation
Install the seat lock cable in the reverse order of
removal. Pay attention to the following point:
• Install the seat lock seat lock cable. Refer to "Seat
Lock Cable Routing Diagram" (Page 9D-1).

Seat Lock Assembly

Removal
1) Disconnect the seat lock cable from the seat lock
IM10L1940041-01 assembly. Refer to "Seat Lock Cable" under "Seat
Lock Cable / Seat Lock Assembly / Striker Support
Bracket Removal and Installation" (Page 90-35).
2) Remove the seat lock cable plate (1), seat lock cable
guide (2) and seat lock assembly (3).

IM10L1940127-02

IM10L1940043-01

Installation
Install the seat lock assembly in the reverse order of
removal. Pay attention to the following point:
• Install the seat lock assembly. Refer to "Seat Lock
Cable Routing Diagram" (Page 9D-1).
 Exterior Parts: 9D-36

Striker Support Bracket Front Fender Removal and Installation

BENM10L39406032
Removal
1) Remove the rear seat. w(Page 9D-34) Removal
2) Disconnect the seat lock cable from the striker 1) Remove the front fender ( 1).
support bracket. Refer to "Seat Lock Cable" under
"Seat Lock Cable I Seat Lock Assembly/ Striker
Support Bracket Removal and Installation" (Page
9D-35).
3) Remove the striker support bracket (1 ).

IM10L1940046-01

Installation
Install the front fender in the reverse order of removal.
Pay attention to the following points:
IM10L1940044-01 • Install the front fender with front side reflex reflector (if
equipped). Refer to "Front Fender Construction"
Installation (Page 9D-5).
Install the striker support bracket in the reverse order of
• Tighten the front fender bolts (1) to the specified
removal. Pay attention to the following point:
torque.
• Tighten the striker support bracket bolts (1) to the
specified torque. Tightening torque
Front fender bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Tightening torque
Striker support bracket bolt (a): 8.8 N·m (0.90 kgf­
m, 6.50 lbf-ft)

1, (a)- �
. . . -
�·,,.,,. •· I
.
.'•

,...�

\ " 1:
'
. � '

�< 0 f'
\ II"
-.
1, (a)
IM10L1940148-01

IM10L1940045-01

Pillion Rider Handle Removal and Installation

BENM10L39406031

Removal
1) Remove the rear seat. -(Page 9D-34)
2) Remove the pillion rider handle. Refer to "Pillion
Rider Handle Construction" (Page 9D-17).

Installation
Install the pillion rider handle in the reverse order of
removal.
9D-37 Exterior Parts:

Lower Bracket Cover Removal and Installation

BENM10L39406033

Removal
1) Remove the body cowling assembly. <7(Page 9D-44)
2) Disconnect the lead wire (1) and remove the horn
(2).
l . I
� ...

@§) . - ;;�
IM10L1940049-01

-y---�
\ -- '
Side Cowling Assembly Removal and
Installation
BENM10L39406034
1

Removal
1) Remove the front seat. <?(Page 9D-34)
3) Remove the lower bracket cover (1). 2) Remove the body cowl cover and under inner cowl.
<?(Page 9D-43)
3) Remove the under cowling. <7(Page 9D-42)
4) Remove the fasteners and bolt from the meter panel
(1).

IM10L1940048-01

Installation
Install the lower bracket cover in the reverse order of
removal. Pay attention to the following points:
IM10L1940050-01
• Tighten the horn bolt (1) to the specified torque.
5) Remove the meter panel (1) in the direction as

�l �
Tightening torque shown in the figure with unhooking the hooks.
Horn bolt (a): 5.5 N·m (0.56 kgf-m, 4.05 lbf-ft)

1, (a)
'<.��
•:---;;: �-.:

I lir. ,
�-
. . .:Iii
. :·:-..

IM10L1940128--02

• Tighten the lower bracket cover bolts ( 1) to the

specified torque. IM10L1940138-01

Tightening torque
Lower bracket cover bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
 Exterior Parts: 9D-38

IM10l1940051-02

6) Remove the fastener, screws and bolt from the side

cowling assembly (1).

10l1940055-02

8) Tilt the side cowling assembly (1).

IM10l1940056-01

9) Pull the side cowling assembly (1) backward to

unhook the hooks and remove it.
IM10L1940052-02

IM10L1940053-01

7) Unhook the hook, protrusion and fasteners (1) as

shown in the figure.

IM10L1940057-01
9D-39 Exterior Parts:

NOTICE
To prevent damage to the frame when
installing the side cowling assembly(1),
remove the nut (2) from the side cowling
assembly.

IM10L1940058-01

• Tighten the side cowling assembly bolt (1) and screws

(2) to the specified torque.
Tightening torque
Side cowling assembly bolt (a): 10 N·m (1.0 kgf­
m, 7.5 lbf-ft)
Side cowling assembly screw (b): 1.8 N·m (0.18
kgf-m, 1.35 lbf-ft)
IM10L1940139-01

Installation
Install the side cowling assembly in the reverse order of
removal. Pay attention to the following points:
• After installing the side cowling assembly (1) on
vehicle, attach the nut (2) removed in advance to side
cowling assembly.
-1 __ 1,(a)
@
IM10L1940059-01

IM10L1940140-01

• Pass the reservoir tank over flow hose to hole of side

cowling assembly (2).

IM10L1940060-02
 Exterior Parts: 9D-40

Side Cowling Assembly Disassembly and

Reassembly

e:A.: :{_ t.
BENM 1 0L39406035

Disassembly -1� - 2
t�� " - -�--�V-
-
·:
1) Remove the side cowling assembly. <?(Page 9D-37)

·-·
..
2) Remove the meter front panel No.2 (1). �
',

® � _.0
��
1
...
,:�

-
., - - Ir,,,,
,,
✓ "

') .._ '

,)
IM10L1940062-01

3) Remove the side front cowling No.2 (1).

IM10L1940063-01

[A): LH

5) Remove the side rear cover (1) from the side cover
(2).

I \
2�\c

��✓ -

IM10L1940061-01

4) Remove the side cover (1) and side rear cover (2) as
a assembly.

IM10L1940064-01

[A]: LH

6) Remove the side rear cowling (1) from the side front
cowling No.1 (2).
9D-41 Exterior Parts:

IM10L1940065-01

Reassembly
Reassemble the side cowling assembly in the reverse
order of removal. Pay attention to the following points:
• Tighten the side front cowling No.1 screw (1) to the
specified torque.
Tightening torque
Side front cowling No_ 1 screw (a): 1.8 N·m (0.18
kgf-m, 1.35 lbf-ft)

IM10L1940067-01

[A]: LH

• Tighten the side cover screws (1) to the specified

torque.
�
Tightening torque
� Side cover screw (a): 1.8 N·m (0.18 kgf-m, 1.35
1, (a)
lbf-ft)
IM10L1940066-01

• Tighten the side rear cover screws (1) to the specified

torque.
Tightening torque
Side rear cover screw (a): 1.8 N·m (0.18 kgf-m,
1.35 lbf-ft)

[A]

IM10L1940068-01

[A]: LH
 Exterior Parts: 9D-42

• Tighten the side front cowling No.2 screws (1) to the

specified torque and install the clip as shown in the
figure.
Tightening torque
Side front cowling No.2 screw (a): 1.8 N·m (0.18
kgf-m, 1.35 lbf-ft)

IM10L1940141-01

3) Unhook the hooks inserting the remover in the

hatched area.

IM10L1940069-01

Under Center Cowling/ Under Cowling Removal

and Installation
BENM10L39406036

Removal
1) Remove the fasteners (1).
c: Inserting position of resin remover
IM10L1940071-02

4) Pull the under cowling (1) outside to remove the

protrusions.
5) Remove the under center cowling (2).

IM10L1940070-01

2) Remove the under cowling bolt (1) and unhook the

hook.

IM10L1940072-01

6) Remove the under cowling screw (1 ).

9D-43 Exterior Parts:

�
I
2, (b)

IM10L1940073-02 IM10L1940077-02

7) Unhook the hooks by holding the hatched areas "1"

with hands as shown in the figure, and then remove Body Cowl Cover/ Under Inner Cowling
the under cowling (1). Removal and Installation
BENM10l39406037

Removal
1) Remove the fasteners and ambient air temperature
sensor (1) from body cowl cover.

o:
IM10L1940074-03

Holding position with hands

8) Remove the other side using the same procedure.

Installation
Install the under center cowling and under cowling in the
reverse order of removal. Pay attention to the following
points:
• Tighten the under cowling bolt (1) and screw (2) to the
specified torque.
Tightening torque
Under cowling bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf­
ft)
Under cowling screw (b): 1.8 N·m (0.18 kgf-m, IM10l1940142-01
1.35 lbf-ft) 2) Pull body cowl cover (1) inserting the remover in the
hatched area.

IM10L1940076-03
 Exterior Parts: 9D-44

C, : Inserting position of resin remover

3) Move the body cowl cover (1) backward and move

downward.

IM10L1940082-01

• Attach the ambient air temperature sensor (1) to the

body cowl cover (2) before install the body cowl cover
to the vehicle.

IM10L1940080-01

4) Remove the fasteners.

5) Remove the under inner cowling (1) inserting the
remover in the hatched area.

IM10L1940143-01

Body Cowling Assembly Removal and

Installation
BENM 1 OL39406038

Removal
1) Remove the fasteners from the meter panel (center)
(1).

IM10L 1940081-02

Inserting position of resin remover

Installation
Install the body cowling and under inner cowling in the
reverse order of removal. Pay attention to the following
point:
• When installing the under inner cowling, pass the
projection of the radiator (1) through the hole of the
under inner cowling (2).
2) Remove the windscreen screws and remove the
windscreen (1) in the direction as shown in the
figure.
9D-45 Exterior Parts:

IM10L1940085-02

7) Remove the bolts and remove the combination

meter (1 ).

3) Remove the meter panel and side cowling assembly.

-(Page 9D-37)
4) Remove the body cowl cover. <:7(Page 9D-43)
5) To avoid damaging meter panel (center) (1 ), cover it
or peripheral part with clothes or the like.
NOTICE
In particular, be careful as the hatched area
shown in the figure are easily damaged. IM10L1940086-01

8) Remove the rear view mirror. C7(Page 9D-34)

9) Remove the regulator/ rectifier bracket (1 ).

IM10L1940144-01

6) Remove the fasteners and screws and remove the

meter panel (center) (1 ).
10) Remove the clamps, electrical parts and disconnect
the couplers from the body cowling assembly. Refer
to "Wiring Harness Routing Diagram" in Section 9A
(Page 9A-13).
11) Remove the body cowling assembly (1 ).
 Exterior Parts: 90-46

IM10L1940088-01 IM10L1940091-01

12) Remove the fastener and remove the intake pipe • Tighten the combination meter bolts (1) to the
assembly (1). specified torque.
Tightening torque
Combination meter bolt (a): 5.5 N·m (0.56 kgf-m,
4.05 lbf-ft)

IM 10L1940089-01

Installation
Install the body cowling assembly in the reverse order of
IM10l1940092-01
removal. Pay attention to the following points:
• Tighten the meter panel (center) screws (1) to the
• Tighten the new cowling brace bolts (1) to the
specified torque.
specified torque.
Tightening torque
Tightening torque
Meter panel (center) screw (a): 1.8 N·m (0.18 kgf­
Cowling brace bolt (a): 23 N·m (2.3 kgf-m, 17.0
m, 1.35 lbf-ft)
lbf-ft)

1, (

1, (a)

IM10L1940090-01

• Tighten the new regulator/ rectifier bracket bolts (1) to

the specified torque.
Tightening torque
Regulator I rectifier bracket bolt (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)
IM10L1940093-02

• Tighten the windscreen bolts (1) to the specified

torque or tighten so that the protruding amount of the
screw is "a".
9D-47 Exterior Parts:

Tightening torque
Windscreen bolt (a): 0.4 N·m (0.04 kgf-m, 0.30 lbf­
ft)

IM10L1940096-01

3) Remove the headlight (1 ).

IM10L1940097-01

IM 1OL1940094-02 4) Remove the screws and disassemble into the meter

"a": 3.0-4.0mm(0.12-0.16in) front panel No.1 (1), body center cowling (2) and
body cowling (3).
• Adjust the headlight beam. Refer to "Headlight Beam
Adjustment" in Section 98 (Page 98-4).

Body Cowling Assembly Disassembly and

Reassembly
BENM 1 OL39406039

Disassembly
1) Remove the front turn signals (1).

IM10L1940098-01

..
IM10L1940095-01 ------=:::: - ;.
2) Remove the cowling brace (1).
6,JK2 .

IM10L1940099-01

5) Disassemble into the Intake center cover (1) and

intake rear cover (2).
 Exterior Parts: 9D-48

Tightening torque
Cowling brace screw(a): 1.8 N·m(0.18 kgf-m,
1.35 lbf-ft)

IM10L1940100--01
IM10L1940103-01

• Tighten the front turn signal light screws (1) to the

Reassembly
specified torque.
Reassemble the body cowling assembly in the reverse
order of removal. Pay attention to the following points: Tightening torque
• Tighten the body center cowling screws (1) and meter Front turn signal light screw(a): 1.8 N·m(0.18
front panel screws (2) to the specified torque. kgf-m, 1.35 lbf-ft)
Tightening torque
Body center cowling screw(a): 1.8 N·m(0.18 kgf­
m, 1.35 lbf-ft)
Meter front panel screw(b): 1.8 N·m(0.18 kgf-m,
1.35 lbf-ft)

2, (b

IM10L1940104-01
1, (a)

Intake Pipe Assembly Removal and Installation

BENM10L39406040

Removal
IM10L1940101-01
1) Remove the intake pipe assembly. w(Page 9D-44)
• Tighten the headlight screws (1) to the specified 2) If necessary, disassemble the intake pipe assembly.
torque.
Tightening torque
Headlight screw(a): 1.8 N·m(0.18 kgf-m, 1.35 lbf­
ft)

®
-
IM10L1940105-01

IM10L1940102-01 Installation
• Tighten the cowling brace screws (1) to the specified Install the intake pipe assembly in the reverse order of
torque. removal.
9D-49 Exterior Parts:

Fuel Tank Cap Cover I Fuel Tank Front Cover

Removal and Installation
BENM 1 0L39406041

Removal
1) Remove the fuel tank cap cover bolts and remove
the fuel tank cap cover (1).
2) Remove the front seat. w(Page 9D-34)

IM10L1940145-01

IM10L1940129-01 6) Reinsert the hook as shown in the figure.

3) Remove the meter panel. w(Page 9D-37)
4) Remove the screw, hook, fasteners (1) and bolts as
shown in the figure.

IM10L 1940147-01

7) Remove the fuel tank front cover bolts (1).

8) Open the side cowling assembly (2) in the direction
IM10L1940131-02
as shown in the figure to open the space and remove
the fasteners (3).
NOTICE
Do not spread the side cowling assembly too
wide as it may damage the side cowling
assembly.

NOTE
Be careful not to drop the fastener (3).

IM10L1940132-02

5) Unhook the side cowling assembly (1) from the

protrusion (2) of the bracket.

IM10L 1940133-01
 Exterior Parts: 9D-50

9) Unhook the hooks and disconnect the fasteners (1)

to remove the fuel tank front cover (2).

IM10L1940137-01

• Tighten the under cowling bolt (1) and side cowling

assembly bolt (2) to the specified torque.
Tightening torque
Under cowling bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf­
ft)
Side cowling assembly bolt (b): 10 N·m (1.0 kgf­
m, 7.5 lbf-ft)
IM10L1940135-01

Installation
Install the fuel tank front cover in the reverse order of
removal.
Pay attention to the following point:
• Tighten the fuel tank front cover bolts (1) to the
specified torque.
Tightening torque
Fuel tank front cover bolt (a): 4.0 N·m (0.41 kgf­
m, 2.95 lbf-ft)
M_ @-2,(b)
\@) 1, (a)
IM10L1940136-01

• Tighten the fuel tank cap cover bolts (1) to the

specified torque.
Tightening torque
Fuel tank cap cover bolt (a): 5.5 N·m (0.56 kgf-m,
4.05 lbf-ft)

• Tighten the side cowling assembly screws (1) and ..,.

J. side cowling assembly bolt No.2 to the specified
torque.
Tightening torque
Side cowling assembly screw (a): 1.8 N·m (0.18
kgf-m, 1.35 lbf-ft)
Side cowling assembly screw No.2 (b): 4.5 N·m (

I,
0.46 kgf-m, 3.35 lbf-ft)
...,,,....:,..,;,
IM10L1940130-01

I
9D-51 Exterior Parts:

Frame Cover Assembly Removal and

Installation
BENM10L39406042

Removal
1) Remove the front seat and rear seat. <:u>(Page 9D-
34)
2) Remove the pillion rider handle. 17 (Page 9D-36)
3) Remove the frame cover rid (1).

4) Disconnect the seat lock cable (1) from the frame

cover assembly.

IM10L1940111-01

6) Spread opening end of frame cover assembly (1) in

arrow "2" direction by holding the hatched areas "1"
with hands.
7) Unhook the hooks and move frame cover assembly
(1) in arrow "3" direction.

5) Remove the frame cover screws, bolts and

fasteners.

o: Holding position with hands

IM10L1940112-01

I
 Exterior Parts: 9D-52

Installation
Install the frame cover assembly in the reverse order of
removal. Pay attention to the following point: Frame Cover Assembly Disassembly and
• When installing the frame cover assembly, fit the Reassembly
BENM 1 0L39406043
projections (1) of the rear combination light into the
grooves (2) of the frame cover assembly.
Disassembly
1) Remove the screws and remove the frame cover (1).

IM10L1940115-01

2) Remove the screws and disassemble in to the frame

rear cover (1) and frame center cover (2).

IM10L 1940146-01

• Tighten the frame cover assembly screws (1) and

bolts (2) to the specified torque.
Tightening torque IM10L1940116-01

Frame cover assembly screw (a): 5.5 N·m (0.56

Reassembly
kgf-m, 4.05 lbf-ft)
Frame cover assembly bolt {b): 10 N·m (1.0 kgf­ Reassemble the frame cover assembly in the reverse
order of removal. Pay attention to the following points:
m, 7.5 lbf-ft)
• Tighten the frame center cover screws (1) to the
specified torque.
Tightening torque
Frame center cover screw (a): 2.0 N·m (0.20 kgf­
m, 1.50 lbf-ft)
9D-53 Exterior Parts:

Installation
Install the rear fender (rear) in the reverse order of
removal.

Rear Fender (Front)

Removal
1) Remove the front seat, rear seat and frame cover
assembly and rear fender (rear). Refer to "Rear
Fender (Rear)" under "Rear Fender Removal and
Installation" (Page 9D-53).
2) Remove the battery. @"(Page 1J-8)
IM10L1940117-01
3) Remove the ECM. w-(Page 1C-2)
• Tighten the frame cover screws (1) to the specified
4) Remove the seat lock assembly. Refer to "Seat Lock
torque.
Assembly" under "Seat Lock Cable/ Seat Lock
Tightening torque Assembly/ Striker Support Bracket Removal and
Frame cover screw (a): 2.0 N·m (0.20 kgf-m, 1.50 Installation" (Page 9D-35).
lbf-ft) 5) Remove the muffler support bolt. w-(Page 1 K-2)
6) Remove the pillion footrest from the seat rail.
w-(Page 9E-5)
7) Remove the bolts and rear fender (front) bracket (1 ).

IM10L1940118-01

Rear Fender Removal and Installation

BENM10L39406044

Rear Fender (Rear)

Removal
1) Remove the frame cover assembly. @"(Page 9D-51)
2) Disconnect the license plate light coupler and
remove the clamps. Refer to "Rear Lighting System
Construction" in Section 98 (Page 98-5).
3) Remove the license plate light (1) and Rear reflex
reflector (2) from the rear fender (rear) (3). Refer to
"Rear Lighting System Construction" in Section 98
(Page 9B-5). IM10L1940120-01

8) Unhook the hooks (1) of the battery front shield.

IM10L1940119-01

IM10L1940121-01
 Exterior Parts: 9D-54

9) Disconnect the couplers and remove the clamps and
sensors from the rear fender (front) (1 ).
10) Remove the rear fender (front) (1) in the direction as
shown in the figure.
Frame Under Cover Removal and Installation
BENM 10L39406045
Removal
1) Remove the frame cover assembly. w(Page 9D-51)
2) Remove the rear combination light. w(Page 9B-7)
3) Remove the screws and remove the frame under
cover (1).

11) If necessary, remove the battery front shield by

removing the fuel tank rear bracket No.2. w(Page
1G-12)
IM10L1940125-01

Installation
Install the rear fender (front) in the reverse order of Installation
removal. Pay attention to the following points: Install the frame under cover in the reverse order of
removal. Pay attention to the following point:
• Tighten the rear fender (front) bracket upper bolts (1 ).
• Tighten the frame under cover screws (1) in numerical
Tightening torque order ("1" - "2") to the specified torque.
Rear fender (rear) upper bolt (a): 12 N·m (1.2 kgf­
m, 9.0 lbf-ft) Tightening torque
Frame under cover screw (a): 0.8 N·m (0.08 kgf­
m, 0.60 lbf-ft)
1, (a)
---

IM10L1940123-01

• Tighten the new rear fender (front) bracket under bolts

(1 ). IM10l2940004-02

Tightening torque Rear Fender Mudguard Removal and

Rear fender (rear) under bolt (a): 12 N·m (1.2 kgf­ Installation
m, 9.0 lbf-ft) BENM10L39406046
Refer to "Rear Fender Construction" (Page 9D-16).

,.
�

1, (a)
/"
..t1
IM10L1940124-01
9D-55 Exterior Parts:

Specifications
Tightening Torque Specifications
BENM10L39407001

Tightening torque
Fastening part Note
N-m kgf-m lbf-ft
Rear view mirror nut 12 1.2 9.0 w(Page 9D-34)
Striker support bracket bolt 8.8 0.90 6.50 <l:F(Page 9D-36)
Front fender bolt 10 1.0 7.5 <l:F(Page 9D-36)
Horn bolt 5.5 0.56 4.05 c,P(Page 9D-37)
Lower bracket cover bolt 10 1.0 7.5 c,P(Page 90-37)
Side cowling assembly bolt <7(Page 9D-39) I
10 1.0 7.5
c,P(Page 9D-50)
Side cowling assembly screw c:u-(Page 90-39) /
1.8 0.18 1.35
<7(Page 9D-50)
Side front cowling No.1 screw 1.8 0.18 1.35 <7(Page 9D-41)
Side rear cover screw 1.8 0.18 1.35 w(Page 9D-41)
Side cover screw 1.8 0.18 1.35 <7(Page 9D-41)
Side front cowling No.2 screw 1.8 0.18 1.35 <7(Page 90-42)
Under cowling bolt (b'"(Page 90-43) /
10 1.0 7.5
Clr'(Page 9D-50)
Under cowling screw 1.8 0.18 1.35 (b'"(Page 9D-43)
Cowling brace bolt 23 2.3 17.0 c,P(Page 9D-46)
Regulator/ rectifier bracket bolt 10 1.0 7.5 <lr'{Page 9D-46)
Combination meter bolt 5.5 0.56 4.05 <lr'(Page 9D-46)
Meter panel (center) screw 1.8 0.18 1.35 Cb'"(Page 90-46)
Windscreen bolt 0.4 0.04 0.30 <:r(Page 9D-47)
Body center cowling screw 1.8 0.18 1.35 <r{Page 9D-48)
Meter front panel screw 1.8 0.18 1.35 <7(Page 9D-48)
Headlight screw 1.8 0.18 1.35 <lr'{Page 9D-48)
Cowling brace screw 1.8 0.18 1.35 c:r(Page 9D-48)
Front turn signal light screw 1.8 0.18 1.35 -(Page 9D-48)
Fuel tank front cover bolt 4.0 0.41 2.95 c:r(Page 9D-50)
Side cowling assembly screw No.2 4.5 0.46 3.35 c:r(Page 9D-50)
Fuel tank cap cover bolt 5.5 0.56 4.05 <l:F(Page 9D-50)
Frame cover assembly screw 5.5 0.56 4.05 w(Page 9D-52)
Frame cover assembly bolt 10 1.0 7.5 c:r(Page 9D-52)
Frame center cover screw 2.0 0.20 1.50 w(Page 9D-52)
Frame cover screw 2.0 0.20 1.50 -(Page 9D-53)
Rear fender (rear) upper bolt 12 1.2 9.0 cr(Page 9D-54)
Rear fender (rear) under bolt 12 1.2 9.0 cr(Page 9D-54)
Frame under cover screw 0.8 0.08 0.60 <?(Page 9D-54)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Seat Lock Cable Routing Diagram" (Page 9D-1)
"Rear View Mirror Construction" (Page 90-4)
"Front Fender Construction" (Page 90-5)
"Cowling Construction" (Page 90-6)
"Body Cowling Construction" (Page 9D-7)
"Side Cowling Assembly Construction" (Page 9D-11)
"Fuel Tank Front Cover I Fuel Tank Bracket Construction" (Page 90-13)
"Frame Cover Assembly Construction" (Page 9D-14)
"Frame Cover Construction" (Page 90-15)
"Rear Fender Construction" (Page 90-16)
"Pillion Rider Handle Construction" (Page 9D-17)
"Fasteners Information" in Section 0C (Page 0C-6)
 Body Structure: 9E-1

Body Structure
Repair Instructions
Body Frame Construction
BENM10L39506001

, •. •.-c::::,,_'>
"
.
·• •

/-'

"/,
/''i
":-. c:�
[BJ •

� \,·· � 2

IM10L1950001-02

[A): To[B) 4, Spacer �: 10 N-m (1.0 kgf-m, 7.0 lbf-ft)

[BJ: From[A) 5, Adjuster �: 45 N-m (4.5 kgf-m, 32.5 lbf-ft)
1. Frame 6, Adjuster locK-nut �: 35 N-m (3.5 kgf-m,25.5 lbf-ft)
2, Seat rail 7, Engine mounting pinch bolt
3. Seat rail bolt m: 50 N-m (5 0 kgf-m, 36.0 lbf-fl)
9E-2 Body Structure:

Front Footrest Construction BENM10L39506002

2 1

"a"- C=\
IM--4-c::::::---i�--,--- 4

---��----- 5 3 12�

-
IM10L 1950002-05

[A]: View [a] 7. Front footrest bar �: 26 N,m (2.7 kgf-m, 19.5 lbf-ft)
1. Frame 8. Footrest bar screw ua": Press fit dimensions of the bush
2.0 mm (0.08 in)
2. Washer 9. Bank sensor bolt No. 1 )@t: Apply grease to sliding surface.
3. Washer 10. Bank sensor bolt No. 2 �: Apply thread lock to the thread part.
4. Bush �: 3.0 N-m (0.31 kgf-m, 2.25 lbf-ft) 0: Do not reuse.
5. Front footrest bracket C!Iml 13 N-m (1.3 kgf-m, 9.5 lbf-ft)
6. Footrest rubber �: 18 N-m (1.8 kgf-m, 13.5 lbf-ft)
 Body Structure: 9E-3

Front Footrest Removal and Installation BENM10L39506003

Refer to "Front Footrest Construction" (Page 9E-2).

Side-stand Construction BENM10L39506004

(
2

IM10L1950003-04

1. Side-stand bracket 5. Side-stand bolt �: 50 N-m (5.0 kgf-m, 36.0 lbf-ft)

2. Side-stand 6. Side-stand springs (Inner and outer) �: Apply grease to sliding surface.
3. Side-stand bracket bolt �: 95 N-m (9.5 kgf-m. 68.5 lbf-ft) �: Do not reuse.
4. Side-stand nut �: 40 N-m (4.1 kgf-m, 29.5 lbf-ft)

Side-stand Removal and Installation

BENM10L39506005

Removal
1) Support the motorcycle with a jack or wooden block.
A.CAUTION

• Do not support the motorcycle with the exhaust pipes.

• Make sure that the motorcycle is supported securely.

2) Remove the side-stand. w-(Page 9E-3)

Installation
Install the side-stand in the reverse order of removal.
9E-4 Body Structure:

Pillion Footrest Construction BENM10L39506006

IM10L1950004-04
1. Seat rail 7. Footrest bar screw �: 3.0 N-m (0.31 kgf-m, 2.25 lbf-ft)
2. Pillion footrest bracket 8. Spring J@i: Apply grease to sliding surface.
3. Pillion footrest bracket bolt 9. Ball �: Apply thread lock to the thread part.
4. Pin 10. Plate 0: Do not reuse.
5. Footrest rubber 11. E-ring
6. Pillion footrest bar �: 35 N-m (3.5 kgf-m, 25.5 lbf-ft)
 Body Structure: 9E-5

Pillion Footrest Removal and Installation

BENM10L39506007

Removal
1) Remove the muffler support bolt to remove the muffler from the pillion footrest. Refer to "Exhaust Pipe/ Muffler
Removal" in Section 1 K (Page 1 K-2).
2) Remove the pillion footrest. w-(Page 9E-4)

Installation
Install the pillion footrest in the reverse order of removal.

Seat Rail Tape Construction

BENM10L39506008

IM10L1950005-01
"c": 0 mm(0 in)
f,,jjj[A]: The same procedures are f,,jjj 2. Tape
applicable to both the right and left : Clean the adhesive surface before sticking
tapes. the tape. Press the tape after sticking.
f,,jjj [BJ: Stick the tape using the weld bead "a": -5-5 mm(-0.19-0.19 in)
as a guide.
1. Seat rail "b": 8 mm(0.31 in) max

Specifications
Tightening Torque Specifications
BENM10L39507001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Body Frame Construction" (Page 9E-1)
"Front Footrest Construction" (Page 9E-2)
"Side-stand Construction" (Page 9E-3)
"Pillion Footrest Construction" (Page 9E-4)

Special Tools and Equipment

Recommended Service Material
BENM10L39508001
NOTE
Required service material(s) is also described in:
"Front Footrest Construction" (Page 9E-2)
"Side-stand Construction" (Page 9E-3)
"Pillion Footrest Construction" (Page 9E-4)
9E-6 Body Structure:

Section 10
Control Systems
CONTENTS
Precautions ............................................... 10-1
Precautions ........................................................... 10-1
Precautions for Engine ........................................ 10-1
Cruise Control System .......................... 10A-1
Precautions......................................................... 10A-1
Precautions for Cruise Control System ............. 10A-1
Schematic and Routing Diagram ...................... 10A-1
Cruise Control System Wiring Diagram ............ 10A-1
Component Location ......................................... 10A-1
Cruise Control System Component Location .... 10A-1
Diagnostic Information and Procedures .......... 10A-2
Cruise Control System/ Active Speed Limiter
Check .............................................................. 10A-2
Scan Tool Data ................................................. 10A-4
Cruise Control System Symptom Diagnosis ..... 10A-4
Active Speed Limiter Symptom Diagnosis ........ 10A-5
Cruise Control System Circuits Inspection........ 10A-5
Repair Instructions ............................................ 10A-6
Cruise Control Switch Inspection ...................... 10A-6
Cruise Control Switch Removal and
Installation ....................................................... 10A-6
Communication System ........................ 10H-1
"RES/ UP" Switch/ "SET/ DOWN" Switch
Inspection ........................................................ 1 0A-6
"RES/ UP" Switch/ "SET/ DOWN" Switch
Removal and Installation ................................. 10A-6
Cruise Control Cancel Switch Inspection .......... 10A-6
Cruise Control Cancel Switch Removal and
Installation ....................................................... 1 0A-6
Mode Switch Inspection .................................... 10A-7
Mode Switch Removal and Installation ............. 10A-7
Specifications ..................................................... 10A-7
Tightening Torque Specifications ...................... 10A-7
Immobilizer Control System ................. 10C-1
Precautions ......................................................... 10C-1
Precautions for DTC Trouble Shooting ............. 10C-1
Precautions for Immobilizer System.................. 1 0C-1
General Description ........................................... 10C-1
Self-Diagnosis Function .................................... 10C-1
Table of Contents 10- i
Schematic and Routing Diagram ...................... 10C-1
Immobilizer Control System Wiring Diagram .... 10C-1
Component Location ......................................... 10C-1
Immobilizer Control System Component
Location........................................................... 10C-1
Diagnostic Information and Procedures .......... 10C-2
Immobilizer Control System Check ................... 10C-2
OTC Check........................................................ 10C-3
OTC Clearance ................................................. 10C-3
OTC Table ......................................................... 10C-3
Fail-Safe Table .................................................. 10C-3
OTC P1610 ....................................................... 10C-4
Immobilizer Control System Circuits
lnspection ........................................................ 10C-6
Repair Instructions ............................................ 10C-6
Immobilizer Antenna Removal and
Installation ....................................................... 10C-6
Ignition Key Registration ................................... 10C-6
Specifications ..................................................... 10C-7
Tightening Torque Specifications ...................... 10C-7
Precautions......................................................... 10H-1
Precautions for OTC Trouble Shooting ............. 10H-1
General Description ........................................... 10H-1
Self-Diagnosis Function .................................... 10H-1
Schematic and Routing Diagram ...................... 10H-2
CAN Communication System Wiring Diagram ..10H-2
Component Location ......................................... 10H-3
CAN Communication System Component
Location........................................................... 1 OH-3
I
Diagnostic Information and Procedures .......... 10H-4
CAN Communication Check ............................. 10H-4
OTC Check........................................................ 10H-4
OTC Clearance ................................................. 10H-4 1
CAN OTC (Lost Communication and
Communication Bus Off) Table ....................... 10H-5
CAN Signal Reference Waveform ..................... 10H-6
Troubleshooting for Lost Communication ......... 1 0H-9
Troubleshooting for Communication Bus Off .. 10H-13
10-1 Precautions:

Precautions
Precautions
Precautions for Engine
BENM10L3A000001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Electrical Circuit Service" in Section 00
(Page 00-2), "Precautions for Circuit Tester" in Section 00 (Page 00-8) and "Precautions for SDS-11" in Section 00
(Page 00-9).
 Cruise Control System: 10A-1

Cruise Control System

Precautions
Precautions for Cruise Control System
BENM10L3A100001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Electrical Circuit Service" in Section 00
(Page 00-2), "Precautions for Circuit Tester" in Section 00 (Page 00-8) and "Precautions for SDS-II" in Section 00
(Page 00-9).

NOTE
• Cruise control system is controlled by ECM. If cruise control system is abnormal condition, a
malfunction may be detected by engine control systems. 17 (Page 1A-9)
• ECM receives following signal from ABS control unit I HU and combination meter by CAN
communication.
- ABS control unit/ HU: Front brake master cylinder pressure sensor, front brake caliper pressure
sensor, rear brake master cylinder pressure sensor and rear brake caliper pressure sensor signal.
- Combination meter: Cruise control switch signal, select switch ("RES/ UP" and "SET/ DOWN")
signal, mode switch signal and cruise control cancel switch signal.

Schematic and Routing Diagram

Cruise Control System Wiring Diagram
BENM10L3A102001
Refer to "Engine Control System Wiring Diagram" in Section 1A (Page 1A-6).

Component Location
Cruis� Control System Component Location
BENM10L3A103001
Refer to "Engine Control System Component Location" in Section 1A (Page 1A-8).
1 0A-2 Cruise Control System:

Diagnostic Information and Procedures

Cruise Control System I Active Speed Limiter
Check
BENM10L3A104001
Refer to the following items for the details of each step.

Step 1
Customer complaint analysis
1) Perform customer complaint analysis. w(Page
10A-3)
Was customer complaint analysis performed?

Yes Go to Step 2.
No Perform customer complaint analysis.

Step2
DTC check
1) Check for DTCs.
• ECM: refer to "OTC Check" in Section 1A (Page
1A-11)
• ABS control unit/ HU: refer to "OTC Check" in
Section 4E (Page 4E-15)
Is there any DTC(s)?

Yes Check and repair according to applicable

OTC troubleshooting, and go to Step 4.
No Go to Step 3.

Step3
Trouble symptom confirmation
1) Check trouble symptom. @"(Page 10A-4)
Is trouble symptom identified?

Yes Perform "Cruise Control System Symptom

Diagnosis" (Page 10A-4) or "Active Speed
Limiter Symptom Diagnosis" (Page 1 OA­
S), and go to Step 4.

No Perform "Intermittent Malfunction

Inspection" in Section 00 (Page 00-7), and
go to Step 4.

Step4
Final confirmation test
1) Perform final confirmation test. @"(Page 10A-4)
Does the trouble recur?

Yes Go to Step 2.
No End.
 Cruise Control System: 10A-3

Step 1: Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form such as following will facilitate collecting information to the point required for proper
analysis and diagnosis.

NOTE
This form is a standard sample. The form should be modified according to conditions and
characteristic of each market.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name: Model: VIN:
Date of issue: Date Reg.: Date of problem: Mileage:

MIL condition
□ Always ON/□ Sometimes ON/□ Always OFF/□ Good condition
Master warning indicator
□ Always ON/□ Sometimes ON /□ Always OFF /□ Good condition
condition
Malfunction display/code User mode: □ No display/□ Malfunction display ( )
Dealer mode: □ No code I□ Malfunction code ( )

PROBLEM SYMPTOMS
□ Cruise control cannot be on-standby
□ Cruise control cannot be set
□ Cruise control cannot be canceled
□ Set speed cannot be changed
□ Cruise control indicator and/or cruise control indicator light (if equipped) dose not turn ON or OFF
□ OTHERS:

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather □ Fair/□ Cloudy/ □ Rain/□ Snow/ □ Always/□ Other
Temperature □ Hot/□ Warm/□ Cool/□ Cold (° C/ ° F)/□ Always
Frequency □ Always/□ Sometimes (times I day, month)/□ Only once
□ Under certain condition
Road □ Urban/ o Suburb/□ Highway/□ Mountainous (□ Uphill /□ Downhill)
o Tarmacadam /□ Gravel/□ Other
Motorcycle condition
Engine condition □ Cold/□ Warming up phase/ □ Warmed up/□ Always /□ Other at starting
□ Immediately after start/ o Racing without load/□ Engine speed ( r/min)
Motorcycle condition During driving: □ Constant speed/□ Accelerating/□ Decelerating
□ Right hand corner/ o Left hand corner
□ At stop/□ Motorcycle speed when problem occurs ( km/h, mile/h)
□ Other:
IM10L1A10001-01
10A-4 Cruise Control System:

Step 2: OTC Check Step 4: Final Confirmation Test

First, check DTC of ECM. w(Page 1A-11)
Step 3: Trouble Symptom Confirmation
Based on information obtained in "Step 1: Customer
Complaint Analysis" (Page 10A-3), check trouble
symptoms.
Check that the problem symptom has gone and cruise
control system is free from any abnormal conditions. If
what has been repaired is related to the malfunction
DTC, clear the OTC referring to "OTC Clearance" in
Section 1A (Page 1A-12) and confirm that the DTC is not
indicated, based on information obtained in "Step 1:
Customer Complaint Analysis" (Page 10A-3).

Scan Tool Data

BENM10L3A104002
The associated data values of the cruise control system can be confirmed using a SDS-11. Refer to "Scan Tool Data" in
Section 1A (Page 1A-20).

Cruise Control System Symptom Diagnosis

BENM10L3A104003
NOTE
Cruise control system is controlled by ECM. Before performing symptom diagnosis, check that no
OTC is detected in ECM.

Condition Possible cause Correction I Reference Item

Cruise control cannot be Faulty cruise control switch.
on-standby Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Cruise control cannot be Faulty "SET/ DOWN" switch.
set Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Cruise control cannot be Faulty cruise control cancel switch.
canceled
Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Set speed cannot be Faulty "RES/ UP" Switch and "SET/
changed DOWN" Switch.
Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Cruise control indicator Faulty cruise control switch.
dose not turn ON or OFF Faulty "SET/ DOWN" switch.
Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Check cruise control switch. -(Page 10A-6)
Repair or replace.
Check combination meter. <r(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. -(Page 1 C-2)
Check "SET I DOWN" switch. <r(Page 10A-6)
Repair or replace.
Check combination meter. <?(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty -(Page 1 C-2)
Check cruise control cancel switch. -(Page
10A-6)
Repair or replace.
Check combination meter. <?(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. -(Page 1C-2)
Check "RES I UP" Switch and "SET I DOWN"
Switch. w(Page 10A-6)
Repair or replace.
Check combination meter. -(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty -(Page 1 C-2)
Check cruise control switch. <r(Page 10A-6)
Check "SET I DOWN" switch. w(Page 10A-6)
Repair or replace.
Check combination meter. rr(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. w(Page 1 C-2)

Active Speed Limiter Symptom Diagnosis
NOTE
Active speed limiter is controlled by ECM. Before performing symptom diagnosis, check that no DTC
is detected in ECM.
Condition Possible cause
Active speed limiter Faulty cruise control switch.
cannot be on-standby Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Active speed limiter Faulty "SET/ DOWN" switch.
cannot be set Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Active speed limiter Faulty mode switch.
cannot be canceled Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Set speed cannot be Faulty "RES / UP" Switch and "SET/
changed DOWN" switch.
Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Active speed limiter Faulty cruise control switch.
indicator dose not turn Faulty mode switch.
ON or OFF Faulty wiring or grounding.
Faulty combination meter.
Faulty ECM.
Cruise Control System Circuits Inspection
Refer to "Engine Control System Circuits Inspection" in Section 1A (Page 1A-105).
Cruise Control System: 10A-5
BENM10L3A104004
Correction I Reference Item
Check cruise control switch. w-(Page 10A-6)
Repair or replace.
Check combination meter. w-(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. <r(Page 1 C-2)
Check "SET I DOWN" switch. <r{Page 10A-6)
Repair or replace.
Check combination meter. w(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. <r{Page 1C-2)
Check mode switch. <r(Page 10A-7)
Repair or replace.
Check combination meter. w(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. <r{Page 1 C-2)
Check "RES I UP" Switch and "SET I DOWN"
switch. <r{Page 10A-6)
Repair or replace.
Check combination meter. w(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. <r{Page 1 C-2)
Check cruise control switch. <r{Page 10A-6)
Check mode switch. w-(Page 10A-7)
Repair or replace.
Check combination meter. <r(Page 9C-9)
Replace ECM after checking that none of
above parts is faulty. <r{Page 1 C-2)
BENM10L3A104005
10A-6 Cruise Control System:

Repair Instructions
Cruise Control Switch Inspection
BENM10L3A106001
Refer to"Right Handle Switch Inspection" in Section 6B Position
T2
(Page 6B-7).
Fully closed position: [A]
Cruise control cancel
Cruise Control Switch Removal and Installation switch position: [BJ
BENM10L3A106002
Refer to "Right Handle Switch Removal and Installation"
in Section 6B (Page 6B-7).

"RES/ UP" Switch/ "SET I DOWN" Switch

Inspection
BENM10L3A106003
Refer to "Left Handle Switch Inspection" in Section 6B
(Page 6B-9).

"RES/ UP" Switch/ "SET/ DOWN" Switch

Removal and Installation
BENM10L3A106004
Refer to "Left Handle Switch Removal and Installation" in
Section 6B (Page 6B-9). IM10L 1130048-01

Cruise Control Cancel Switch Inspection
BENM10L3A106005
Refer to "Precautions for Electric Throttle Control
System" in Section 1C (Page 1C-1).
1) Lift and support the fuel tank. Cl>""(Page 9D-49)
2) Check that throttle cable No.2 has been connected
to accelerator body assembly properly. w-(Page 1D-
2)
If any defect is found, repair or replace the throttle
cable No.2 before proceeding to the next step.
3) Disconnect the cruise control cancel switch coupler
( 1 ).
Cruise Control Cancel Switch Removal and
Installation
BENM10L3A106006
Refer to "Precautions for Electric Throttle Control
System" in Section 1C (Page 1C-1).
Removal
1) Move the accelerator body assembly outside of the
motorcycle. w-(Page 1C-14)
2) Remove the cruise control cancel switch screw (1 ).
3) Remove the cruise control cancel switch (2) from the
accelerator body assembly.

IM10L2A10003-01
4) Inspect the cruise control cancel switch (1) for
continuity between "T1" and "T2" with the tester.
If any abnormality is found, replace the cruise control
cancel switch with a new one. -(Page 1 0A-6)
 Cruise Control System: 10A-7

Installation Mode Switch Inspection

BENM10L3A106007
Install the cruise control cancel switch in the reverse
Refer to "Left Handle Switch Inspection" in Section 6B
order of removal.
(Page 68-9).
Pay attention to the following point:
• Tighten the new cruise control cancel switch screw (1)
to specified torque.
Mode Switch Removal and Installation
BENM10L3A106008
Refer to "Left Handle Switch Removal and Installation" in
Tightening torque
Section 68 (Page 68-9).
Cruise control cancel switch screw (a): 0.28 N·m (
0.03 kgf-m, 0.20 lbf-ft)

IM10l2A10004-01

• After finishing the accelerator body assembly

installation, inspect the cruise control cancel switch.
-(Page 1 OA-6)

Specifications
Tightening Torque Specifications
BENM10L3A107001
Tightening torque
Fastening part Note
N-m I kgf-m I lbf-ft
Cruise control cancel switch screw 0.28 I 0.03 I 0.20 <r(Page 10A-7)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Fasteners Information" in Section 0C (Page 0C-6)
10C-1 Immobilizer Control System:

Immobilizer Control System

Precautions
Precautions for DTC Trouble Shooting
BENM10L3A300001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Electrical Circuit Service" in Section 00
(Page 00-2), "Precautions for Circuit Tester" in Section 00 (Page 00-8) and "Precautions for SDS-11" in Section 00
(Page 00-9).

NOTE
• Immobilizer control system is controlled by ECM.
• After repairing the trouble, clear the OTC using the special tool. r:r(Page 10C-3)

Precautions for Immobilizer System

BENM10L3A300002
• Ignition key incorporates the transponder. T herefore, it is necessary to register the key ID to ECM, when ignition key
is replaced or added.
• Do not turn ON ignition switch with ignition key in contact with or very close to another key. Or, the immobilizer
control system may detect some abnormal condition and prevent the engine from starting.
• Do not turn ON ignition switch using ignition key with any type of metal wrapped around its grip or in contact with
key. Or, the immobilizer control system may detect some abnormal condition and prevent the engine from starting.
• Do not leave ignition key in a place where temperature is high. High temperature may cause damage to the
transponder built in the ignition key.
• Do not turn ignition switch to "ON" position by bringing radio antenna close to immobilizer antenna. Or, the
immobilizer control system may detect some abnormal condition and prevent the engine from starting.

General Description
Self-Diagnosis Function
BENM10L3A301001
Refer to "Self-Diagnosis Function" in Section 1A (Page 1A-1 ).

Schematic and Routing Diagram

Immobilizer Control System Wiring Diagram
BENM1 0L3A302001
Refer to "Engine Control System Wiring Diagram" in Section 1A (Page 1A-6).

Component Location
Immobilizer Control System Component Location
BENM10L3A303001
Refer to "Engine Control System Component Location" in Section 1A (Page 1A-8).
 Immobilizer Control System: 10C-2

Diagnostic Information and Procedures

Immobilizer Control System Check Step4
BENM 1 0L3A304001
Engine start check
Step 1 1) Start engine.
Indicator light operation check
Does engine start?
1) When turning the ignition switch ON, check if the
indicator light (1) of immobilizer antenna operates Yes Check indicator light circuit. If indicator
as shown in figure. light circuit is in good condition, replace
the immobilizer antenna. <:ir'(Page 10C-6)
Flashing Lighting No Go to Step 5.
2 key IDs registered in ECM
3 key IDs registered in ECM Step 5
DTC check
4 key IDs registered in ECM
Is there any DTC(s)?
Approx. 1.6 sec. Approx. 2.0 sec.
Yes Go to troubleshooting for applicable OTC.
No Perform "Engine Control System Check"
in Section 1A (Page 1A-9).

IL06L 1A30001-01

Is check result OK?

Yes Go to Step 2.
No Go to Step 3.

Step2
Engine start check
1) Start engine.
Does engine start?
Yes Immobilizer control system is in good
condition.

No Go to Step 5.

Step 3
DTC check
Is DTC P1610 detected?
Yes Go to troubleshooting for "OTC P1610"
(Page 10C-4).
No Go to Step 4.
10C-3 Immobilizer Control System:

DTC Check
BENM1 OL3A304002
Refer to "OTC Check" in Section 1A (Page 1A-11 ).

DTC Clearance
BENM10L3A304003
Refer to "OTC Clearance" in Section 1A (Page 1A-12).

DTC Table
BENM10L3A304004
NOTE
*1: Display on the LCD only. (If the ECM is normal but the ABS detects DTC, ABS-related DTC(s) is
displayed.)

DTC OTC name DTC detecting condition

00000 *1 None -

.Any of the following conditions is met.

Verification error of key ID between ignition key and

.
P1610 Ignition Switch Signal Circuit cy,(Page 1 OC-4) ECM.
Communication error between immobilizer antenna
and ECM.

Fail-Safe Table
BENM1 OL3A304005
Refer to "Fail-Safe Table" in Section 1A (Page 1A-19).
 Immobilizer Control System: 10C-4

OTC P1610
BENM10L3A304006
OTC Detecting Condition and Trouble Area
OTC detecting condition
. Trouble area
P1610: Ignition Switch Signal Circuit
. Key ID is not registered in ECM

.
Any of the following conditions is met. Immobilizer antenna
• Verification error of key ID between ignition key and Immobilizer antenna circuit

.
ECM.
ECM
Communication error between immobilizer antenna
and ECM.

Wiring Diagram
Refer to "Immobilizer Control System Wiring Diagram" (Page 10C-1).

3
R W/Y I
6
Bl Gr T60l

2
G G .. T18--
7 T y R/Y T2
B B/W
;),,
IM10L1A30001-01

1. ECM 4. Ignition switch 7. Battery

2. Immobilizer antenna communication and 5. Ignition fuse (10 A)
indicator light drive circuit
3. Immobilizer antenna 6. Main fuse (30 A)

Troubleshooting

Step1
3
Engine start check
1) Start engine using the spare ignition key. 6
Does engine start? IL06L1A30003-01

Yes End. (Ignition key was not registered) Is check result OK?
No Go to Step 2. Yes Go to Step 4.

Step2 No Go to Step 3.
Immobilizer antenna power supply circuit check
Step 3
1) Turn the ignition switch OFF.
Immobilizer antenna ground circuit check
2) Disconnect the immobilizer antenna coupler.
1) Measure the voltage between 'TS" at the
w-(Page 10C-6)
immobilizer antenna coupler (1) and ground.
3) Check for proper terminal connection to the
immobilizer antenna coupler (1).
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between "TS" and 'T2".
Immobilizer antenna power supply voltage
[Standard]: Battery voltage
10C-5 Immobilizer Control System:

3 2 3 2

6 5 4 6 5 4

IL06L1A30004-01 IL06L 1A30006-01

Is voltage specified range in Step 2? - Between "T6" and other terminal (2) at
immobilizer antenna coupler (1 ): infinity
Yes Repair or replace the "T2" wire at the - Between "T3" and other terminal at
immobilizer antenna coupler. immobilizer antenna coupler: infinity
No Repair or replace the "T5" wire at the
immobilizer antenna coupler. 2

Step4
Immobilizer antenna signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". w(Page 1C-2)
3) Check for proper terminal connection to the ECM
coupler "A".
2
4) If connections are OK, check the following points.
I L06L 1 A30007-02
• Resistance • Voltage
- Between "TS" at the immobilizer antenna a. Turn the ignition switch ON.
coupler ( 1) and "T18" at the ECM coupler "A"
b. Check the following points
(2): less than 1 0
- Between 'T6" at the immobilizer antenna
- Between "T3" at the immobilizer antenna
coupler (1) and ground: approx. 0 V
coupler and 'T2" at the ECM coupler "A":
less than 1 0 - Between "T3" at the immobilizer antenna
coupler and ground: approx. 0 V

IL06L1A30008-01
Is check result OK?
-----· ------------------' , ------------------------� Yes Go to Step 5.
' ,

t,: ,: ,i.:, �,: ,: ;,: ; J �:1:I�I:I:� �:1;1;1�1; :I:�

•>)) 2 // No Repair or replace the defective wire
harness.

IM10L 1A30002-01

- Between 'T6" at the immobilizer antenna

coupler (1) and ground: infinity
- Between "T3" at the immobilizer antenna
coupler and ground: infinity
 Immobilizer Control System: 10C-6

Is OTC P1610 still detected?

Step 5
Immobilizer antenna check Yes Replace the ECM and inspect it again.
1) Replace the immobilizer antenna. r:r(Page 10C-6) 17 (Page 1C-2)

2) Recheck DTC. No End. (Immobilizer antenna was faulty)

Immobilizer Control System Circuits Inspection

BENM10L3A304007
Refer to "Engine Control System Circuits Inspection" in Section 1A (Page 1A-105).

Repair Instructions
Immobilizer Antenna Removal and Installation Tightening torque
BENM10L3A306001 Immobilizer antenna bolt (a): 4.5 N·m (0.46 kgf­
NOTICE m, 3.35 lbf-ft)
The immobilizer antenna is a precision unit
and can be easily damaged.
Handle the immobilizer antenna carefully and
do not expose it to a large shock.

Removal
1) Remove the meter panel (RH). <T(Page 9D-37)
2) Disconnect the immobilizer antenna coupler (1).

(a)
IM10L1A30004-01

Ignition Key Registration

BENM10L3A306002
• It is necessary to perform ignition key registration
when carrying out any of the following points.
- ECM is replaced.
- Ignition switch is replaced.
IM10L1A30006-01
- All ignition keys are lost.
3) Remove the ignition switch. <T(Page 1H-7)
4) Remove the bolts (1) and immobilizer antenna (2) NOTE
from steering stem upper bracket (3). • If the ECM is replaced, at least 2 ignition
keys must be registered into the ECM.
• If all ignition keys are lost, ECM should be
replaced with a new one.

• It is possible to register 4 ignition keys in ECM.

IM10L1 A30003-01

Installation
Install the immobilizer antenna in the reverse order of
removal. Pay attention to the following point:
• Tighten the immobilizer antenna bolts to the specified
torque.
10C-7 Immobilizer Control System:

Specifications
Tightening Torque Specifications
BENM10L3A307001
Tightening torque
Note
Fastening part
N-m I kgf-m I lbf-ft
Immobilizer antenna bolt 4.5 I 0.46 I 3.35 <7(Page 1 0C-6)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
"Fasteners Information" in Section 0C (Page 0C-6)
 Communication System: 10H-1

Communication System
Precautions
Precautions for OTC Trouble Shooting
BENM10L3A800001
Refer to "General Precautions" in Section 00 (Page 00-1 ), "Precautions for Electrical Circuit Service" in Section 00
(Page 00-2), "Precautions for Circuit Tester" in Section 00 (Page 00-8) and "Precautions for SDS-II" in Section 00
(Page 00-9).

NOTE
• Diagnosing target control module / sensor only is not enough to accurately diagnose any trouble of
CAN communication system. Check if other control module / sensor detected CAN DTC.
• It is possible that CAN system has trouble because of blown fuse or low battery voltage. Before
troubleshooting, check that fuse, battery voltage and charging system condition are normal.
• CAN communication error is detected if coupler of control modules or sensors being connected to
CAN communication line or applicable fuse is connected / disconnected when ignition switch is ON.
• Check that no equipment or option other than original parts is connected onto CAN bus. If any of
those items are connected, disconnect it before troubleshooting.
• If any DTCs together with "Lost Communication" (Reception error) and/or "Communication Bus
Off" are displayed, start troubleshooting of CAN communication first.
• Before diagnosing trouble, check equipment of motorcycle being serviced as well as control
modules and sensors connected to CAN communication line.
• After repairing the trouble, clear the DTC using the special tool. cr(Page 10H-4)

General Description
Self-Diagnosis Function
BENM10L3A801001
• ECM: refer to "Self-Diagnosis Function" in Section 1A (Page 1A-1 ).
• ABS control unit/ HU: refer to "Self-diagnosis Function" in Section 4E (Page 4E-3).
10H-2 Communication System:

Schematic and Routing Diagram

CAN Communication System Wiring Diagram
BENM10L3A802001

rr rr
2 4 5

3
T19T20 T17 T1 T2 TS T2 T3 TB T17

BIBI

8 BIBI BIBI BIBI BIBI

9
_J-------1 W/B WIB WIB WIB

p:,
W/B

IM10L1A80001-01

1. Combination meter 4. IMU 7. J/C

2. ECM 5. ABS control unit/ HU 8. Wire harness No.2 coupler
3. Mode select coupler (6P) 6. CAN driver 9. Main harness cob!pler

Terminal Arrangement of Wiring Harness Coupler (View [a])

[a]-[\_
[A] [D] [E]
[C]
��

E] 0
1 2 3 �

5
0
@] 0
4 6

GJ

[B]

I I I
I I
1 2 3 ! 4IsI6I7I8I9I10j11l12l13l14l1sl16I [!]
J I I J I I I J J I I I I I I I I
17 1 s 19 20 21 22 23 24 2s 26 21 2a 29 30 31 32
@] 0 IM10L1A80002-03

[A]: ECM coupler (Coupler "A") [CJ: Mode select coupler (6P) [E]: IMU coupler
[BJ: Combination meter coupler (D]: ABS control unit/ HU coupler
 Communication System: 10H-3

Component Location
CAN Communication System Component Location
BENM1 0L3A803001

IM10L 1A80003-01

1. Combination meter 3. Mode select coupler (6P) 5. IMU

2. ECM 4. ABS control unit/ HU

-,
1 0H-4 Communication System:

Diagnostic Information and Procedures

CAN Communication Check
BENM 1 0L3A804001
Troubleshooting Selection Procedure
1) Turn the ignition switch ON.
2) Check if the SDMS-a indicator and/or each indicators are displayed normally on the LCD (1).

IM10L1A80004-01

3) Check that communication between SDS-11 and ECM is possible.

4) Check that communication between SDS-11 and ABS control unit/ HU is possible.
5) Perform the troubleshooting according to the following table.
Check result
Communication
Communication
between SDS-11 Troubleshooting
SDMS-a indicator between SDS-11
and ABS control
and ECM
unit/ HU
. Perform the "Troubleshooting for Lost Communication"

.
(Page 10H-9).
Possible
Possible When CAN-DTC is not detected, CAN communication
system is good condition.
Perform the "Troubleshooting for Lost Communication"
Not possible
(Page 10H-9).
Normal Perform the "Troubleshooting for Lost Communication"
Possible
(Page 10H-9).
Check CAN communication circuit between mode select
coupler (6P) and ECM coupler for open circuit.
Not possible
If CAN communication circuit is in good condition, check
Not possible
DIG-cable between mode select coupler (6P) and SDS-I1.
If necessary, check DIG-cable and conversion cable
(ISO) by substituting a known-good cable.
Perform the "Troubleshooting for Lost Communication"
Possible
(Page 1 0H-9).
Possible
Perform the "Troubleshooting for Lost Communication"
Not possible
Abnormal
(Page 1 0H-9).
Perform the "Troubleshooting for Lost Communication"
Possible
(Page 10H-9).
Not possible
Perform the 'Troubleshooting for Communication Bus
Not possible
Off' (Page 10H-13).

DTC Check
BENM10L3A804002
• ECM: refer to "DTC Check" in Section 1A (Page 1A-11).
• ABS control unit/ HU: refer to "OTC Check" in Section 4E (Page 4E-15).

DTC Clearance
BENM 1 0L3A804003
• ECM: refer to "OTC Clearance" in Section 1A (Page 1A-12).
• ABS control unit I HU: refer to "OTC Clearance" in Section 4E (Page 4E-16).
 Communication System: 10H-5

CAN OTC (Lost Communication and Communication Bus Off) Table

BENM 1 0L3A804004
NOTE
If communication between SDS-11 and each controller is not possible, perform the "CAN
Communication Check" (Page 10H-4).
• CAN DTC may not be displayed on the LCD, when the CAN circuit is abnormal.
DTC DTC name DTC detecting condition
ECM
Control Module Communication Bus Off w(Page ECM fails to transmit and receive the data via CAN for
U0073
10H-13) specified time continuously.
Lost Communication With ABS Control Module Receiving error of the data from ABS control unit/ HU
U0121
w(Page 10H-9) via CAN for specified time continuously.
Receiving error of the data from IMU via CAN for
U0123 Lost Communication With IMU w(Page 1 0H-9)
specified time continuously.
Lost Communication With Instrument Panel Receiving error of the data from combination meter via
U0155
Cluster (IPC) Control Module w(Page 1 0H-9) CAN for specified time continuously.
ABS control unit/ HU
Control Module Communication Bus Off w(Page ABS control unit/ HU fails to transmit and receive the
U0073
10H-13) data via CAN for specified time continuously.
Receiving error of the data from ECM via CAN for
U0100 Lost Communication With ECM w(Page 10H-9)
specified time continuously.
Receiving error of the data from IMU via CAN for
U0123 Lost Communication With IMU w(Page 10H-9)
specified time continuously.
Lost Communication With Instrument Panel Receiving error of the data from combination meter via
U0155
Cluster (IPC) Control Module w(Page 10H-9) CAN for specified time continuously.
10H-6 Communication System:

CAN Signal Reference Waveform

BENM10L3A804005
• "Normal Waveform" (Page 1 0H-6) and "Examples of Abnormal Waveforms" (Page 1 OH-7) of CAN signal are shown
for reference.

NOTE
Waveforms in "Examples of abnormal waveforms" are selected examples of CAN communication
waveforms seen when an abnormal condition occurs. However, these waveforms may not be exactly
the same in appearance as observed waveforms. Therefore, to identify an abnormal condition, select
the waveform that is most similar to the observed waveform from "Examples of Abnormal Waveforms"
(Page 10H-7).

• Observe the waveform according to the following procedure.

a. Turn the ignition switch OFF.
b. Connect the oscilloscope (1) to mode select coupler (6P) (2).
c. Turn the ignition switch ON.
d. Observe the waveform.
Oscilloscope
Circuit Terminal No.
Channel Probe
+ "T2"
CAN High signal 1 - Ground
+ "T5"
CAN Low signal 2 - Ground

2 ----;--,--JL.......L..,------._
,....;......::........,.. 2 3
· ---·--·--------'
1ffl, (i)_roo
........,........,
4 5 6

IL06L1A80006-01

Normal Waveform
Normal waveform Description
Reference voltages for both
CAN High signal and CAN
Low signal are 2.5 V.
Waveform of CAN High
signal is 2.5 - 3.5 V and that
of CAN Low signal is 2.5 -
1.5 V.

IL06L1A80003-01
[A]: Ground level of each channel [D]: Waveform of channel 1 (CAN High signal)
[BJ: VOLT/DIV of each channel [E]: Waveform of channel 2 (CAN Low signal)
[C]: TIME/DIV of each channel
 Communication System: 10H-7
Examples of Abnormal Waveforms
Characteristic waveform
Possible cause Description
CAN High signal CAN Low signal
Shorted to ground ,,........��.,,.,...._,,_,.,.,��0·�· _,..,. �,.,.........� In case CAN High signal
wire is shorted to ground
circuit
Both of CAN High signal and
ti-fllllflllMHIBlr>+t+<-�'1
CAN Low signal are fixed to
GND level (0 V).
In case CAN Low signal
wire is shorted to ground
circuit
1.00V ch',�.,� A ch• r , ., V) Reference voltages for both
1LosL1Aaooos-01
of CAN High signal and CAN
Low signal are GND level (0
V) and CAN High signal
waveform oscillates
irregularly.
• CAN High signal: Between
0 Vand 3.5 V
• CAN Low signal: Fixed to
ov
Opened In case CAN High signal
wire is open
Reference voltages for both
CAN High signal and CAN
t1ii.-1it111HH1tt1HH�at Low signal are 2.5 V and
these waveforms oscillate
irregularly.
• CAN High signal: Between
4.0 Vand 1.0 V
2.20V1 •
.00V M� A Chl
IL06L1A80007-01 IL06L1A80008-01
CAN Low signal: Between
2.5 Vand 1.0 V
In case CAN Low signal
wire is open
Reference voltages for both
of CAN High signal and CAN
Low signal are 2.5 Vand
these waveforms oscillate
irregularly.
• CAN High signal: Between
2.5 Vand 4.0 V
• CAN Low signal: Between
1.0 Vand 4.0 V
Shorted to power ���������� In case CAN High signal
supply circuit (12 V) wire is shorted to power
supply circuit (12 V)
CAN High signal is fixed to
..-.++<-++t-~+<�<+H-1-f+H+I 12 Vand CAN Low signal is
t fixed to 11 V.
In case CAN Low signal
. +

Di­
[
ID] 2.00 V
· • · . · ·•• · · · f . · . . ·
· · J+ wire is shorted to power
suppl� cir�uit (1_2 �)
�e:"·2_l,fil_JM_illi!i) � ch; r ·,.•,yi CAN High signal Is fixed to 11
ILOGL1A80009-01 ILooL1Aaoo10-01
v and CAN Low signal is
fixed to 12 V.
10H-8 Communication System:

Characteristic waveform
Possible cause Description
Shorted to power ����������� In case CAN High signal
supply circuit (5 V) wire is shorted to power
supply circuit (5 V)
Reference voltages for both
l'l'H�-i-++++-1 CAN High signal and CAN
f+++++--+>+-H-t+.....+-,-fll+_.,.
Low signal are 4.5 V and
these waveforms oscillate
irregularly.
• CAN High signal: Between
_..,..,,,..,-i-'-ie_..,.,,..,,............,_,....,....,,,...,....,,....,,.,,;-rl 5.5 V and 3.5 V
IL06L 1A80012-01
• CAN Low signal: Between
5.0 V and 1.0 V
In case CAN Low signal
wire is shorted to power
supply circuit (5 V)
Reference voltage is 4.5 V
and phase is the same for
both CAN High signal and
CAN Low signal, and
waveforms oscillate
irregularly between 6.0 V and
1.0 V.
CAN High signal Both of CAN High signal and
and CAN Low signal CAN Low signal are fixed to
wires are shorted to near 2.5 V.
each other

IL06L1A80013-01
 Communication System: 10H-9

Troubleshooting for Lost Communication

BENM10L3A804006
NOTE
Perform "CAN Communication Check" (Page 10H-4): before performing this troubleshooting.

Wiring Diagram

n n
2 4 5

T19T20 T17 T1 T2 T5 T2 T 3 T8 T17

----------, - -- ------ --- ------
BIBI :ca) :cc] :[d]

BIBI BIBI BIBI 8181

Wl8 WIB WIB WIB

-----------------

IM10L1A80005--02

[a] to [d]: CAN communication line (linked with diagnosis flows [a] to [d] of 4. !MU 8. Wire harness No.2
"Diagnosis Flow Selection Table")
1. Combination meter 5. ABS control unit/ HU 9. Main harness coupler
2. ECM 6. CAN driver
3. Mode select coupler (6P) 7. J/C

Terminal arrangement of wiring harness coupler (View [a])

[\
[a]-
[AJ [DJ [EJ
(CJ
r
3
' �[2]
G0
1 2 �

4 5 6
,, Ci]
0 0
[BJ
I I
I
11 213141 s I 6I7I a I g l10l11l12l13i14i1sl16l �0
I I I I I I I I I I I I I
11 1 a 19I20 21 22 23 24 2s 26 27 2a 29 30 131 I32 I E] 0 IM10L1A80002-03

[Al: ECM coupler (Coupler "l'i') [CJ'. Mode select coupler (6P) [E]: !MU coupler
lB\: Combination meter coupler [D]: ABS control unit/ HU coupler
10H-10 Communication System:

Diagnosis Flow Selection Table

NOTE
• If an individual control module or sensor fails to communicate, check whether power supply circuit
or ground circuit of control module or sensor is in good condition, referring to system circuit
diagram, etc. before diagnosing trouble with flow chart.
• Diagnosis flows [a] to [d) link with CAN communication lines [a) to [d] of "Wiring Diagram" (Page
10H-9).
• Occurrence of multiple troubles is not included in the scope of this trouble diagnosis.
• Combination meter in itself does not have a function to diagnose CAN communication error in DTC.

CAN OTC detecting control module / sensor Diagnosis flow

U0100
ABS control unit/ HU (When communication between SDS-11 and ECM is
"Diagnosis flow: [d)" (Page 10H-12)
possible.)
ABS control unit/ HU (When communication between SDS-11 and ECM is
"Diagnosis flow: [a]" (Page 10H-11)
not possible.)
U0121
ECM (When communication between SDS-11 and ABS control unit/ HU is
"Diagnosis flow: [a]" (Page 10H-11)
possible.)
ECM (When communication between SDS-11 and ABS control unit/ HU is
"Diagnosis flow: [d]" (Page 10H-12)
not possible.)
U0123
ECM "Diagnosis flow: [a]" (Page 10H-11)
ABS control unit/ HU "Diagnosis flow: [d]" (Page 10H-12)
ECM and ABS control unit/ HU "Diagnosis flow: [c]" (Page 10H-12)
U0155
ECM "Diagnosis flow: [a]" (Page 10H-11)
ABS control unit/ HU "Diagnosis flow: [d]" (Page 10H-12)
ECM and ABS control unit/ HU "Diagnosis flow: [b]" (Page 10H-11)
 Communication System: 10H-11

Troubleshooting 4) Check for proper terminal connection to the

Diagnosis flow: [a]
Step 1
CAN communication circuit [a] check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler "A". cr(Page 1C-2)
3) Check for proper terminal connection to the ECM
coupler "A".
4) If connections are OK, measure the resistance
between the mode select coupler (6P) and ECM
coupler "A" as follows.
• Between ''T2" at the mode select coupler (6P)
(1) and "T17" at the ECM coupler "A" (2): less
than 1 0
• Between "TS" at the mode select coupler (6P)
and "T1" at the ECM coupler "A": less than 1 n
combination meter coupler, sub harness coupler
and main harness coupler.
5) If connections are OK, connect the sub harness
coupler to the main harness coupler.
6) Measure the resistance between the mode select
coupler (6P) and combination meter coupler as
follows.
• Between "T2" at the mode select coupler (6P)
(1) and "T19" at the combination meter coupler
(2): less than 1 n
• Between "TS" at the mode select coupler (6P)
and "T20" at the combination meter coupler:
less than 1 n

1 ---,-------,--�----,-------.
3

IM10L1A80007-01

Is check result JK?

Yes Replace the combination meter and
inspect it again. <?(Page 9C-13)
No Repair or replace the defective wire
------------------------' ------------------------

t,: ,: ,\.:.:,�, :, :, ;:i·

, harness.
, ,,
,, ,
2 , ,'

�:1:1�1:1:� �:1:1:1�1:1:1:�
IM10L 1A80006-01

Is check result OK?

Yes Replace the ECM and inspect it again.
cr(Page 1C-2)
No Repair or replace the defective wire
harness.

Diagnosis flow: [b]

Step 1
CAN communication circuit (b] check
1) Turn the ignition switch OFF.
2) Disconnect the combination meter coupler.
-(Page 9C-13)
3) Disconnect the sub harness coupler from main
harness coupler.
10H-12 Communication System:

Diagnosis flow: [c] Diagnosis flow: [d]

Step 1 Step 1
CAN communication circuit [c] check CAN communication circuit [d] check
1) Turn the ignition switch OFF. 1) Turn the ignition switch OFF.
2) Disconnect the IMU coupler. Clr{Page 4E-51) 2) Disconnect the ABS control unit/ HU coupler.
w(Page 4E-50)
3) Check for proper terminal connection to the IMU
coupler. 3) Check for proper terminal connection to the ABS
4) If connections are OK, measure the resistance control unit/ HU coupler.
between the mode select coupler (6P) and IMU 4) If connections are OK, measure the resistance
coupler as follows. between the mode select coupler (6P) and ABS
• Between "T2" at the mode select coupler (6P) control unit/ HU coupler as follows.
(1) and "T2" at the IMU coupler (2): less than 1 • Between "T2" at the mode select coupler (6P)
n (1) and "T8" at the ABS control unit/ HU
• Between "T5" at the mode select coupler (6P) coupler (2): less than 1n
and ''T3" at the IMU coupler: less than 1 n • Between "T5" at the mode select coupler (6P)
and 'T17" at the ABS control unit/ HU coupler:
less than 1 0

� [iJ
4
2
EJ
0
IL06L1A80019-01
� 0
Is check result OK?
� 0 ,;
Yes Replace the IMU and inspect it again.
c:Jr(Page 4E-51) E] IT]
No Repair or replace the defective wire
harness.
2
�
V

I�!�
0
4 5
�
V

�
IM10L1A80008-01

Is check result OK?

Yes Replace the ABS control unit/ HU and

inspect it again. w(Page 4E-50)

No Repair or replace the defective wire

harness.
 Communication System: 10H-13

Troubleshooting for Communication Bus Off

BENM10L3A804007
NOTE
Perform "CAN Communication Check" (Page 10H-4): before performing this troubleshooting.

Wiring Diagram

2 4 5

3
�
T19T20 T17 T1 T2 T5 T2 T3 TB T17

:[a]
BIBI
;[b] :[d]
I
I

BIBI BIBI BIBI BIBI

I
'
:a
_J----1 WIB WIB WIB WIB
i 9

fsTs1
W/8
:______, ·-- -----"

IM10L1A80005-02

(a] to (d]: CAN communication line (linked with diagnosis flows [a] to [d] of 4. IMU 8. Wire harness No.2 coupler
"Diagnosis Flow Selection Table")
1. Combination meter 5. ABS control unit/ HU 9. Main harness coupler
2. ECM 6. CAN driver
3. Mode select coupler (SP) 7. J/C

Terminal arrangement of wiring harness coupler (View [a])

[a]-ct [A] [DJ [E]

[CJ
/ ' ��
1 3
�0
2

6
4 5
�0
�0
�0
�0
[B]
�0
I I I I I
I I
11 1 2 1 3 1 4 1 s 1 6 1 7 1 a 1 9 1101 11 j 12 13 14 1s 16 @] 0
I I I I I I I I I
17 1a 19 20 21 22 23 24 j 2s 26 j 27 2a 29 j 30 31 j 32 I I I I @] 0 IM10L1A80002-03

[A]: ECM coupler (Coupler "A") [C]: Mode select coupler (SP) [E]: IMU coupler
[B]: Combination meter coupler [DJ: ABS control unit/ HU coupler
10H-14 Communication System:

Troubleshooting

NOTE
2
Diagnosis flows [a] to [d] link with CAN
communication lines [a] to [d] of "Wiring 4 5 6
Diagram" (Page 10H-13).

Diagnosis flow: [a] to [d]

Step 1 IL06L 1A80021-01

CAN communication circuit check
Is check result OK?
1) Turn the ignition switch OFF.
2) Disconnect couplers from all the control modules Yes Go to Step 2.
and sensors communicating by CAN.
No Repair or replace the defective wire
• ECM: @"(Page 1C-2) harness.
• Combination meter: -(Page 9C-13)
• ABS control unit/ HU: w(Page 4E-50) Step2
Combination meter CAN termination resistor
• IMU: w(Page 4E-51) check
3) Disconnect the sub harness coupler from the main 1) Connect the combination meter coupler. @"(Page
harness coupler. 9C-13)
4) Check for proper terminal connection to the 2) Measure the resistance between the 'T2" and "T5"
couplers, which was disconnected in step 2) and of mode select coupler (6P) (1).
3).
5) If connections are OK, connect the sub harness
coupler to the main harness coupler.
6) Check the following points.
• Resistance 4
- Between "T2" at the mode select coupler IL0BL1A80025-06
(6P) (1) and ground: infinity
Is resistance 114 -134 n?
- Between "T5" at the mode select coupler
(6P) and ground: infinity Yes Go to Step 3.

No Replace the combination meter and

inspect it again. W"(Page 9C-13)
2 ..!..__.;:;:::-+--- ---,

Step 3
4 5 6 ECM CAN termination resistor check
1) Disconnect the combination meter coupler.
cr(Page 9C-13)
2) Connect the ECM coupler "A". <1r(Page 1C-2)
IL06L1A80020-01
3) Measure the resistance between the "T2" and "T5"
- Between "T2" and "T5" at the mode select
of mode select coupler (SP) (1 ).
coupler (6P) (1): infinity

4
IL06L1A80025-06
IL06L1A80014-07

• Voltage Is resistance 114-134 n?

- Turn the ignition switch ON. Yes Go to Step 4.
- Between "T2" at the mode select coupler
No Replace the ECM and inspect it again.
(6P) (1) and ground: approx. 0 V
<7(Page 1C-2)
- Between "TS" at the mode select coupler
(SP) (1) and ground: approx. 0 V
 Communication System: 10H-15

Step4
SDS-11 communication check
1) Check that communication between SDS-11 and
ECM is possible.
Is communication possible?
Yes Go to Step 5.

No Replace the ECM and inspect it again.

w(Page 1C-2)

Steps
SDS-11 communication check
1) Turn the ignition switch OFF.
2) Connect the combination meter coupler. <?(Page
SC-13)
3) Check that communication between SDS-11 and
ECM is possible.
Is communication possible?
Yes Go to Step 6.

No Replace the combination meter and

inspect it again. w(Page 9C-13)

Step 6
SDS-11 communication check
1) Turn the ignition switch OFF.
2) Connect the ABS control unit/ HU coupler.
CS"(Page 4E-50)
3) Check that communication between SDS-11 and
ECM is possible.
Is communication possible?
Yes Replace the IMU and inspect it again.
w(Page 4E-51)

No Replace the ABS control unit/ HU and

inspect it again. CS"(Page 4E-50)
 :-
, .

'S_

Prepared by
SUZUKI MOTOR CORPORATION

March, 2021
Part No. 99500-10L00-03E
Printed in U.S.A.

836

..