TRX520

SHOP MANUAL
TRX520
TRX520FM1/FM2/FE1/FE2/FM6/FA6/FA7L
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30. TRX520FM1/FM2/FE1/FE2/FM6/FA6/FA7-L ADDENDUM
30
A Few Words About Safety ·················· 30-2 DCT DTC TROUBLESHOOTING
(FA models) ······································ 30-37
INTRODUCTION ·································· 30-3
TR SENSOR (FA models) ···················· 30-44
SERVICE RULES································· 30-4
NEUTRAL SWITCH (FA models)··········· 30-44
MODEL IDENTIFICATION ····················· 30-5
SHIFT VALVE BODY (FA models)········· 30-45
SPECIFICATIONS································ 30-7
ENGINE REMOVAL/INSTALLATION······ 30-45
TORQUE VALUES ······························30-11
REAR BRAKE LEVER
LUBRICATION & SEAL POINTS ···········30-12 (FE1/FE2/FA6/FA7) ····························· 30-48
CABLE & HARNESS ROUTING ············30-12 FRONT DRIVE SHAFT························· 30-49
CENTER MUDGUARD ·························30-18 REAR DRIVE SHAFT

(FM6/FA6/FA7 models) ······················· 30-54
FRONT FENDER/CARRIER ··················30-20
ASSIST HEADLIGHT (FM models) ········ 30-59
PGM-FI SYSTEM LOCATION
(FE/FA models) ··································30-21 COMBINATION METER ······················· 30-59
PGM-FI SYSTEM DIAGRAM ·················30-23 ESP COMPONENT LOCATION

(FE models)······································· 30-61
PGM-FI SYSTEM DTC INDEX ···············30-26
ESP SYSTEM DIAGRAM
(FE models)······································· 30-62
PGM-FI SYSTEM DTC
TROUBLESHOOTING ·························30-28
ESP DTC INDEX (FE models)··············· 30-63
ELECTRIC STARTER
TROUBLESHOOTING ·························30-30 ESP DTC TROUBLESHOOTING
(FE models)······································· 30-64
ELECTRIC STARTER COMPONENT
LOCATION (FE/FA models) ·················30-31 SHIFT SPINDLE ANGLE SENSOR
(FE models)······································· 30-70
ELECTRIC STARTER SYSTEM DIAGRAM
(FE/FA models) ··································30-32 TR SENSOR (FE models) ···················· 30-70
DCT COMPONENT LOCATION NEUTRAL SWITCH (FE models)··········· 30-71

(FA models) ······································30-33
WIRING DIAGRAMS ··························· 30-73
DCT DIAGRAM (FA models) ················30-34
DCT DTC INDEX (FA models) ··············30-35
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TRX520FM1/FM2/FE1/FE2/FM6/FA6/FA7-L ADDENDUM
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe

condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service or repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
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INTRODUCTION
This addendum contains information for TRX520FM1/FE1/FM2/FE2/FM6/FA6/FA7-L.
Refer to TRX500 SHOP MANUAL (No. 62HR4000, 62HR400Z and 62HR400Y) for service procedures and data not included in this
addendum.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: June, 2019
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SERVICE RULES
ABBREVIATION
Throughout this manual, the following abbreviation are used to identify the respective parts or systems.
Abbrev. term Full term
2WD 2 Wheel Drive
4WD 4 Wheel Drive
CKP sensor Crankshaft Position sensor
DCT Dual Clutch Transmission
DLC Data Link Connector
DTC Diagnostic Trouble Code
ECM (FM models) Engine Control Module
ECT sensor Engine Coolant Temperature sensor
ECU Electric Control Unit
EEPROM Electrically Erasable Programmable Read Only Memory
EPS Electric Power Steering
ESP Electric Shift Program
IACV Idle Air Control Valve
IAT sensor Intake Air Temperature sensor
LCD Liquid Crystal Display
MAP sensor Manifold Absolute Pressure sensor
MCS Motorcycle Communication System
MIL Malfunction Indicator Lamp
PCM (FE/FA models) Powertrain Control Module
PGM-FI Programmed Fuel Injection
SCS service connector Service Check Short service connector
TP sensor Throttle Position sensor
TR sensor Transmission Range sensor
VS sensor Vehicle Speed sensor
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MODEL IDENTIFICATION
This manual covers 7 types of TRX520 models:
ED:
Model name FM2 FM6 FE2 FA6
Manual transmission O O O –
DCT – – – O
Left foot operated gearshift O O – –
ESP – – O –
EPS O O O O
Independent rear suspension – O – O
Rear hydraulic disc brake – O – O
U:
Model name FM1 FM2 FM6 FE1 FE2 FA6 FA7
Manual transmission O O O O O – –
DCT – – – – – O O
Left foot operated gearshift O O O – – – –
ESP – – – O O – –
EPS – O O – O O O
Independent rear suspension – – O – – O O
Rear hydraulic disc brake – – O – – O O
Aluminum wheel – – – – – – O
Be sure to refer to the procedure that pertains to the appropriate version of the TRX520.
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SERIAL NUMBERS/LABELS
The Vehicle Identification Number (VIN) [1] is stamped on the The throttle body identification number [1] is stamped on the
front the frame. lower side of the throttle body.
Remove the radiator cap lid (page 2-3).
FA models
shown:
[1]
[1]
FM/FE models: FA models:

The engine serial number [1] is stamped on the left side of The engine serial number [1] is stamped on the upper side of
the rear crankcase. the rear crankcase.
[1]
[1]
The color label [1] is attached on the left front frame down The certification label [1] (U type) is attached on the left front
pipe. When ordering color-coded parts, always specify the frame pipe.
designated color code.
[1]
[1]
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SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length FM1/FM2/FE1/FE2 2,106 mm (82.9 in)
FM6/FA6/FA7 2,185 mm (86.0 in)
Overall width 1,205 mm (47.4 in)
Overall height FM1/FM2/FE1/FE2 1,213 mm (47.8 in)
FM6 1,238 mm (48.7 in)
FA6/FA7 1,237 mm (48.7 in)
Wheelbase FM1/FM2/FE1/FE2 1,269 mm (50.0 in)
FM6/FA6/FA7 1,294 mm (50.9 in)
Front tread FM1/FM2/FE1/FE2 905 mm (35.6 in)
FM6 915 mm (36.0 in)
FA6/FA7 917 mm (36.1 in)
Rear tread FM1/FM2/FE1/FE2/FM6 920 mm (36.2 in)
FA6/FA7 921 mm (36.3 in)
Seat height FM1/FM2/FE1/FE2 ED: 878 mm (34.6 in)
U: 877 mm (34.5 in)
FM6 ED: 925 mm (36.4 in)
U: 924 mm (36.4 in)
FA6/FA7 ED: 923 mm (36.3 in)
U: 922 mm (36.3 in)
Footpeg FM1/FM2/FE1/FE2 ED: 367 mm (14.4 in)
height U: 366 mm (14.4 in)
FM6 ED: 387 mm (15.2 in)
U: 386 mm (15.2 in)
FA6/FA7 ED: 384 mm (15.1 in)
U: 383 mm (15.1 in)
Ground FM1/FM2/FE1/FE2 190 mm (7.5 in)
clearance FM6 ED: 251 mm (9.9 in)
U: 250 mm (9.8 in)
FA6/FA7 ED: 248 mm (9.8 in)
U: 247 mm (9.7 in)
Curb weight FM1 290 kg (639 lbs)
FE1 291 kg (642 lbs)
FM2/FE2 297 kg (655 lbs)
FM6 318 kg (701 lbs)
FA6 331 kg (730 lbs)
FA7 328 kg (723 lbs)
Maximum FM1/FM2/FE1/FE2 ED: 219 kg (483 lbs)
weight U: 250 kg (551 lbs)
capacity FM6/FA6/FA7 ED: 227 kg (500 lbs)
U: 260 kg (573 lbs)
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ITEM SPECIFICATIONS
FRAME Frame type Double cradle
Front suspension Double wishbone
Front wheel travel 185 mm (7.3 in)
Front damper Double tube
Rear suspension FM1/FM2/FE1/FE2 Swingarm (trailing type)
FM6/FA6/FA7 Double wishbone
Rear wheel travel FM1/FM2/FE1/FE2 185 mm (7.3 in)
FM6/FA6/FA7 215 mm (8.5 in)
Rear damper Double tube
Front tire size AT25 x 8-12
Rear tire size AT25 x 10-12
Front rim size 12 x 6.0 AT
Rear rim size 12 x 7.5 AT
Front tire brand FM1/FM2/FE1/FE2 M975 (MAXXIS)
FM6/FA6/FA7 MU25 (MAXXIS)
Rear tire brand FM1/FM2/FE1/FE2 M978 (MAXXIS)
FM6/FA6/FA7 MU26 (MAXXIS)
Front brake FM6/FA6/FA7 Hydraulic disc brake
Rear brake FM1/FM2/FE1/FE2 Mechanical drum brake
FM6/FA6/FA7 Hydraulic disc brake
Caster angle FM1/FM2/FE1/FE2 2°
FM6/FA6/FA7 1°
Trail length FM1/FM2/FE1/FE2 5.0 mm (0.20 in)
FM6/FA6/FA7 – 1.0 mm (– 0.04 in)
Front camber angle FM1/FM2/FE1/FE2 0.1°
FM6/FA6/FA7 0°
Rear camber angle FM6/FA6/FA7 – 0.5°
Fuel tank capacity 14.7 liters (3.88 US gal, 3.23 Imp gal)
Fuel tank reserve capacity 4.9 liters (1.29 US gal, 1.08 Imp gal)
ENGINE Cylinder arrangement Single cylinder, longitudinally
installed
Bore and stroke 96.0 x 71.5 mm (3.78 x 2.81 in)
Displacement 518 cm3 (31.6 cu-in)
Compression ratio 9.5:1
Valve train OHV
Intake opens: at 1 mm (0.04 in) lift 5° BTDC
valve closes: at 1 mm (0.04 in) lift 50° ABDC
Exhaust opens: at 1 mm (0.04 in) lift 42° BBDC
valve closes: at 1 mm (0.04 in) lift 8° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Oiled double urethane foam
Engine dry weight FM1/FM2 51.5 kg (113.5 lbs)
FM6 51.7 kg (114.0 lbs)
FE models 52.8 kg (116.4 lbs)
FA models 62.1 kg (136.9 lbs)
FUEL DELIVERY Type PGM-FI
SYSTEM Throttle bore 36 mm (1.4 in)
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ITEM SPECIFICATIONS
DRIVE TRAIN Clutch system Centrifugal and multi-plate, wet
(FM/FE models) Clutch operation system Automatic
Transmission Constant mesh, 5-speeds with
reverse
Primary reduction 2.103 (61/29)
Secondary reduction 1.875 (30/16)
Final reduction Front 3.230 (42/13)
Rear 3.153(41/13)
Gear ratio 1st 4.230 (55/13)
2nd 2.388 (43/18)
3rd 1.608 (37/23)
4th 1.178 (33/28)
5th 0.848 (28/33)
Reverse 5.743 (48/13 x 28/18)
Gearshift pattern Pattern R–N–1–2–3–4–5
FM models Left foot operated return system
FE models Electric shift (left hand operated)
return system
DRIVE TRAIN Clutch system Centrifugal and 2 multi-plate wet
(FA models) clutches
Clutch operation system Automatic
Transmission Automatic, 5-speeds with reverse
Primary reduction 2.680 (67/25)
Secondary reduction 1.520 (38/25)
Final reduction Front 3.230 (42/13)
Rear 3.153 (41/13)
Transmission gear ratio 1st 3.058 (52/17)
2nd 2.157 (41/19)
3rd 1.588 (27/17)
4th 1.181 (26/22)
5th 0.848 (28/33)
Reverse 3.996 (45/16 x 27/19)
Transmission gearshift pattern R–N–1–2–3–4–5
Automatic and Electric shift (left hand
operated) return system
Sub transmission gear ratio L 2.187 (35/16)
D 1.520 (38/25)
Sub transmission gearshift pattern L–D
Lever operated system
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor and emergency
recoil stater
Charging system Triple phase output alternator
Regulator/rectifier FET shorted, triple phase full wave
rectification
Lighting system Battery
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Throttle body identification number GQ3DC
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 96.000 – 96.010 (3.7795 – 3.7799) 96.10 (3.783)
Piston, Piston O.D. at 15 (0.6) from bottom
piston pin, 95.965 – 95.985 (3.7781 – 3.7789) 95.89 (3.775)
piston ring
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FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
Cold tire FM1/ ED: Standard 32.5 kPa (0.33 kgf/cm2, 4.7 psi) –
pressure FM2/ With cargo 32.5 kPa (0.33 kgf/cm2, 4.7 psi) –
FE1/ U: Standard 30 kPa (0.30 kgf/cm2, 4.4 psi) –
FE2 With cargo 30 kPa (0.30 kgf/cm2, 4.4 psi) –
FM6/ ED: Standard 35 kPa (0.35 kgf/cm2, 5.1 psi) –
FA6/ With cargo 35 kPa (0.35 kgf/cm2, 5.1 psi) –
FA7 U: Standard 30 kPa (0.30 kgf/cm2, 4.4 psi) –
With cargo 30 kPa (0.30 kgf/cm2, 4.4 psi) –
Toe FM1/FM2/FE1/ Toe-out: 9.0 ± 15 (0.35 ± 0.6)
–
FE2
FM6 Toe-out: 1.0 ± 15 (0.04 ± 0.6) –
FA5/FA6/FA7 Toe-out: 8.0 ± 15 (0.31 ± 0.6) –
REAR WHEEL/SUSPENSION SPECIFICATIONS

Cold tire FM1/ ED: Standard 32.5 kPa (0.33 kgf/cm2, 4.7 psi) –
pressure FM2/FE1/ With cargo 32.5 kPa (0.33 kgf/cm2, 4.7 psi) –
FE2 U: Standard 30 kPa (0.30 kgf/cm2, 4.4 psi) –
FM6/FA6/ ED: Standard 35 kPa (0.35 kgf/cm2, 5.1 psi) –
FA7 With cargo 35 kPa (0.35 kgf/cm2, 5.1 psi) –
U: Standard 30 kPa (0.30 kgf/cm2, 4.4 psi) –
BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Battery Capacity U type 12 V – 16 Ah (10 HR)
ED type 12 V 16 Ah (10 HR)/16.8 Ah (20 HR)
Current FM1/FM2/FE1/FE2 0.31 mA max.
leakage
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Assist headlight FM1/FM2/FE1/FE2 12 V - 50 W
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TORQUE VALUES
ENGINE & FRAME TORQUE VALUES
• Torque specifications listed below are for important fasteners.
• Others should be tightened to standard torque values listed above.
DUAL CLUTCH TRANSMISSION (FA models)
THRE
TORQUE
AD
ITEM Q’TY REMARKS
DIA. N·m (kgf·m,
(mm) lbf·ft)
Gear shift spindle return spring pin 1 8 26 (2.7, 19) Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
(0.12 – 0.16 in) from tip
Shift drum center bolt 1 8 31 (3.2, 23) Apply locking agent to the threads.
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
(0.12 – 0.16 in) from tip
Shift drum guide plate bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
(0.26 ± 0.04 in) except 1.0 – 3.0 mm
(0.04 – 0.12 in) from tip
TR sensor mounting bolt 1 6 12 (1.2, 9)
Neutral switch 1 10 13 (1.3, 10)
EOT sensor 1 10 14.5 (1.5, 11)
SUB-TRANSMISSION (FA models)

THREAD TORQUE
ITEM Q’TY N·m (kgf·m, REMARKS
DIA.(mm)
lbf·ft)
Rear sub-frame lower mounting bolt 2 12 120 (12.2, 89) Lock nut: replace with a new one.
Rear sub-frame rear mounting nut 1 12 75 (7.6, 55) Lock nut: replace with a new one.
REAR WHEEL/SUSPENSION
THREAD TORQUE
DIA. (mm)
lbf·ft)
Swingarm pivot bolt (FM1/FM2/FE1/ 2 12 120 (12.2, 89) Self-lock nut.
FE2)
BRAKE SYSTEM
THREAD TORQUE
DIA. (mm)
lbf·ft)
Rear brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Rear brake lever pivot nut 1 6 5.9 (0.6, 4.4)
ELECTRIC SHIFT PROGRAM (ESP: FE models)
THREAD TORQUE
DIA. (mm)
lbf·ft)
TR sensor mounting bolt 1 6 12 (1.2, 9)
Neutral switch 1 10 13 (1.3, 10)
OTHERS
THREAD TORQUE
DIA. (mm)
lbf·ft)
Front reflex reflector 2 6 1.5 (0.2, 1.1) Lock nut: replace with a new one.
Rear reflex reflector 4 6 1.5 (0.2, 1.1) Lock nut: replace with a new one.
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LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Engine oil Inside of oil filter cover
Locking agent Cam chain tensioner lifter bolt threads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except
1.0 – 3.0 mm (0.04 – 0.12 in)
from tip
Camshaft bearing setting plate bolt threads Apply locking agent to the threads.
(0.20 - 0.31 in) except
2.0 - 4.0 mm (0.08 - 0.16 in)
from tip
Recoil starter assembly mounting bolt threads Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except
1.0 – 2.0 mm (0.04 – 0.08 in)
from tip
FRAME
MATERIAL LOCATION REMARKS
G.A. Besmoly CE Front drive shaft outboard joint inside FM and FE models
(Brugarolas) 50 – 70 g (1.8 – 2.5 oz)
Front drive shaft inboard joint inside FM and FE models
65 – 85 g (2.3 – 3.0 oz)
Oilstomoly 2 LN 584 LO Rear drive shaft outboard/inboard joint inside 70 – 90 g (2.5 – 3.2 oz)
(Castrol)
CABLE & HARNESS ROUTING

FM6/FA6/FA7:
RIGHT HANDLEBAR COMBINATION METER

THROTTLE CABLE 16P CONNECTOR
SWITCH WIRE
IGNITION
SWITCH WIRE
FRONT BRAKE
HOSE A
ASSIST HEADLIGHT
2P CONNECTOR
FRONT SUB
LEVER REAR (PARKING)
HARNESS
BRAKE CABLE
REVERSE SELECTOR
CABLE (FM6 only)
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FA models:
VS SENSOR 3P O2 SENSOR 4P
(Black) CONNECTOR CONNECTOR
CRANKCASE
BREATHER
HOSE
RANGE SELECT CABLE REAR BRAKE HOSE
FA models:
ALTERNATOR BATTERY NEGATIVE REAR BRAKE LIGHT SWITCH
WIRE (–) CABLE (Pedal side) 2P (Black) CONNECTOR
GROUND CABLE CKP SENSOR 2P

(Engine-to-frame) (Gray) CONNECTOR
FINAL GEAR CASE

BREATHER HOSE
ENGINE SUB
HARNESS
STARTER
MOTOR SENSOR
CABLE HARNESS
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FE models:
REAR BRAKE LIGHT

BATTERY NEGATIVE
SWITCH WIRE
(–) CABLE
SENSOR HARNESS
VS SENSOR WIRE
ALTERNATOR WIRE
GROUND CABLE
(Engine-to-frame)
STARTER MOTOR CABLE

STARTER MOTOR CABLE
SENSOR HARNESS
VS SENSOR WIRE BATTERY NEGATIVE LEVER REAR (PARKING)

(–) CABLE BRAKE CABLE
NEUTRAL SWITCH
CONNECTOR
GROUND CABLE
(Engine-to-frame)
TR SENSOR
SHIFT SPINDLE ANGLE SENSOR

3P (Gray) CONNECTOR
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FA models:
SUB-TRANSMISSION
DRIVE SWITCH
45°
45°
STARTER MOTOR CABLE
SUB-TRANSMISSION
LOW SWITCH
ENGINE SUB HARNESS
SENSOR HARNESS TR SENSOR

3P (Gray) CONNECTOR

3P (Gray) CONNECTOR
NEUTRAL SWITCH
CONNECTOR
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FE models:
NEUTRAL SWITCH
SENSOR HARNESS 8P CONNECTOR
(Black) CONNECTOR
CKP SENSOR 2P
(Gray) CONNECTOR ENGINE SUB
HARNESS 6P (Black)
CONNECTOR
GROUND POINT
REAR BRAKE LIGHT

SWITCH (Pedal side) 2P
BRAKE CABLE
(Black) CONNECTOR
FA models:
WHITE MARK SUB-TRANSMISSION LOW
SWITCH CONNECTOR
REAR BRAKE LIGHT
SWITCH (Pedal side) 2P SUB-TRANSMISSION DRIVE
(Black) CONNECTOR SWITCH CONNECTOR
NEUTRAL SWITCH
CKP SENSOR 2P CONNECTOR
(Gray) CONNECTOR
SENSOR HARNESS
8P (Black)
CONNECTOR

GROUND POINT BRAKE CABLE
REAR BRAKE LIGHT

SWITCH WIRE
(Pedal side)
REAR BRAKE HOSE
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All models:
Inside of front fender:

HEADLIGHT SUB
HARNESS
30-17
dummyhead
CENTER MUDGUARD
REMOVAL/INSTALLATION
LEFT CENTER MUDGUARD
• Take care not to scratch the front and rear fenders

when removing and installing the center mudguard.
Remove the tank cover assembly (page 2-4).
Remove the following:
– setting bolts [1] and step [2]
– trim clips [3], socket bolts [4] and nuts [5]
– left center mudguard [6]
Installation is in the reverse order of removal.
[5]
[4]
[5]
[4]
[1]
[6]
[2]
[3]
30-18
dummyhead
RIGHT CENTER MUDGUARD
• Take care not to scratch the front and rear fenders

when removing and installing the center mudguard.
– tank cover assembly (page 2-4)
– setting bolts [1] and step [2]
– trim clips [3], socket bolts [4] and nuts [5]
– right center mudguard [6]
Release the water hose [7] and bleed hose [8] from the
guides [9] of the right center mudguard.
[8] [9]
[9] [7]
[5]
[5]
[4]
[3] [4]
[1]
[2]
[6]
30-19
dummyhead
FRONT FENDER/CARRIER
ASSEMBLY
Remove the following: [1]
[1]
– front fender/carrier assembly (page 2-4)
– pocket lid [1]
– rubber seal [2]
• Installing the rubber seal as shown. [2]
[2]
FM1/FM2/FE1/FE2: Release the center cover rubber [1] from the hook [2]
and boss [3] of the front center cover [4]. [1]
Remove the front carrier and front carry pipe assembly
(page 2-6). [4]
Install the removed parts in the reverse order of

removal.
[3]
[2]
30-20
dummyhead
PGM-FI SYSTEM LOCATION (FE/FA
models)
FE models:
FE2 shown:
ENGINE STOP SWITCH
FUSE BOX: IGNITION SWITCH

– ES FUSE (30 A)
– MAIN 2 FUSE (10 A)
COMBINATION METER:
– ACC FUSE (20 A)
PCM/ECM – MIL
– IGN FUSE (20 A)
BANK ANGLE SENSOR
FUEL INJECTOR DLC

MAIN 1 FUSE (40 A) O2 SENSOR
FUEL PUMP
RELAY BOX:
– FUEL PUMP
RELAY
IGNITION COIL
ECT SENSOR
IACV
SENSOR UNIT:
– MAP SENSOR
– TP SENSOR CKP SENSOR
VS SENSOR
IAT SENSOR
TR SENSOR NEUTRAL SWITCH
30-21
dummyhead
FA models:
IGNITION SWITCH
ENGINE STOP SWITCH
FUSE BOX: COMBINATION METER:

– FAN FUSE (20 A) – MIL
– ES FUSE (30 A)
BANK ANGLE SENSOR
– MAIN 2 FUSE (10 A)
PCM/ECM
– ACC FUSE (20 A) DLC
– IGN FUSE (20 A)
FUEL INJECTOR
FUEL PUMP
MAIN 1 FUSE (40 A) O2 SENSOR
RELAY BOX:
– FUEL PUMP
RELAY
FRONT VS
SENSOR
IGNITION COIL
ECT SENSOR
IACV
SENSOR UNIT: TR SENSOR

– MAP SENSOR
– TP SENSOR CKP SENSOR
REAR VS SENSOR
IAT SENSOR NEUTRAL SWITCH
30-22
dummyhead
PGM-FI SYSTEM DIAGRAM
FM models:
MAIN POWER REGULATOR/

RELAY RECTIFIER
IGNITION SWITCH IGN FUSE (20A) R/Bl R R
R Bl Bl/R Bl/R V/W

BATTERY
R R/Bl R/Bl P W/Bl
MAIN 1 FUSE (40A) ACC FUSE (20A)
R/Bl R/Y R
FAN FUSE (20A)
MAIN FUSE 2 (10A) DIODE
R/W
ENGINE STOP SWITCH

Bl/R Bl/W
Bl/R B1 MAIN PRC B31 V/W
CKP Bu/Y B23 PCP

SENSOR G
FUEL PUMP RELAY

FLR B20 Gr/R Bl/W
SENSOR UNIT
Bl/R
TP Br/W B3 VCC
SENSOR Bu/Bl B14 TH
Br G
(8) G/W G/W B2 SG
MAP PCM/ECM (33)

M
SENSOR Lg B25 PB
(1)
FUEL PUMP
INJ B33 G/Bl Bl/R
BANK ANGLE FUEL

SENSOR Br/W INJECTOR
Bl/G B6 BA
(54) G/W (12)
IGN1 B11 G/Y Bl/R

IAT Gr B26 TA
SENSOR G/W IGNITION
(9) COIL
G/W
Bl/Bu B27 TW
SPARK
PLUG
ECT
SENSOR IACV-1A B8 Y
M
(7) IACV-1B B5 Y/G IACV
IACV-2A B30 Y/Bu (29)
IACV-2B B9 Br/Y
COMBINATION METER
G/W
MIL IGN Bl/R
M-TXDRXD A21 P SERIAL GND
SP
Gr Bl Y/R A10 O2 P/G G
RR VSP B16 P/G
Bl/R W W G/O A11 O2HT
SEN VB A5 Bl/R Bl/W P
O2 SENSOR G
(21,23) VS SENSOR
(11)
Lb/W A13 GP 5 W/Bl

K - LINE B17 O/W
Y A2 GP 4 SCS B29 Br/R
G
4 Bu A26 GP 3
5 3 DLC SCS SERVICE CONNECTOR
2 W/R A27 GP 2 FAN C3 G/Bl

M R/W
R
N
1 W/G A24 GP 1 COOLING FAN MOTOR
LG B13 G
Lg/R A17 GP N
PG1 B21 G
Gr A25 GP R PG2 B10 G
GEAR POSITION PG3 C5 G

SWITCH
(41)
PCM/ECM C-1 C-3

A-1 A-11 B-1 B-11
A-12 A-22 B-12 B-22
( ): MIL Blink
: Engine does not start
when detecting DTC
: Short terminals for
reading DTC
C-4 C-5 A-23 A-33 B-23 B-33
5P (Black) CONNECTOR 33P (Black) CONNECTOR 33P (Gray) CONNECTOR
30-23
dummyhead
FE models:
ES FUSE (30 A)
R R/W

RELAY RECTIFIER
R Bl Bl/R Bl/R V/W

BATTERY
R R/Bl R/Bl P W/Bl
MAIN 1 FUSE (40A) ACC FUSE (20A)
R/Bl R/Y R
ENGINE STOP SWITCH

Bl/R Bl/W
Bl/R B1 MAIN PRC B31 V/W
FLR B20
CKP Bu/Y B23 PCP

SENSOR G
PCM/ECM
(33) FUEL PUMP RELAY
SENSOR UNIT PCM/ECM
FLR B20 Gr/R Bl/W
TP Br/W B3 VCC Bl/R
SENSOR Bu/Bl B14 TH
(8) G/W B2 SG
Br G
INJ B33
MAP
SENSOR Lg B25 PB
M
FUEL PUMP
(1)
BANK ANGLE INJ B33

IGNI B11 G/Bl Bl/R
SENSOR Br/W
Bl/G B6 BA
G/W FUEL
(54) INJECTOR
(12)
IAT Gr B26 TA
SENSOR G/W IGN1 B11 G/Y Bl/R
(9)
G/W IGNITION
Bl/Bu B27 TW IACV-1A B8 COIL
IACV-1B B5
ECT IACV-2A B30 SPARK
SENSOR IACV-2B B9 PLUG
(7)
IACV-1A B8 Y
M
IACV-1B B5 Y/G IACV
IACV-2A B30 Y/Bu (29)
G/W IACV-2B B9 Br/Y
COMBINATION METER
MIL IGN Bl/R
Gr Bl Y/R A10 O2
M-TXDRXD A21
M-TXDRXD A21 P SERIAL GND G
Bl/R W W G/O A11 O2HT
SP
O2 SENSOR
P/G
(21,23) RR VSP B16 P/G
SEN VB A5 Bl/R Bl/W P

G
A13 GP 5 K - LINE B17 VS SENSOR
VCC Br SCS B29
(66)
A2 GP 4
GND G/W
Bu A26 GP
DRUM
3 POS W/Bl
OUT K - LINE B17 O/W
SCS
FAN B29
C3 Br/R
TR SEMSOR A27 GP 2 G
DLC SCS SERVICE CONNECTOR
FAN C3 G/Bl
M R/W
A24 GP 1 COOLING FAN MOTOR

LG B13 G
Lg Lg/R A17 DP
GP N
PG1 B21 G
A25 GP R PG2 B10 G
NEUTRAL
SWITCH PG3 C5 G
PCM/ECM C-1 C-3

A-1 A-11 B-1 B-11
A-12 A-22 B-12 B-22
( ): MIL Blink
when detecting DTC
reading DTC
C-4 C-5 A-23 A-33 B-23 B-33
30-24
dummyhead
FA models:
ES FUSE (30 A)
R R/W
REGULATOR/
MAIN RECTIFIER
RELAY
R Bl Bl/R Bl/R V/W

BATTERY MAIN FUSE 1 (40 A)
R R/Bl R/Bl P W/Bl
ACC FUSE (20A)
R/Bl R/Y R

O2 SENSOR
Bl/R
HEATER
(23) W W G/O A11 O2HT MAIN B1 Bl/R
O2 SENSOR Gr Bl Y/R A10 O2
PRC B31 V/W
(21) G/W
CKP Bu/Y B23 PCP

SENSOR G
FUEL PUMP RELAY
FLR B20 Gr/R Bl/W Bl/R

Bl/G B6 BA
G/W Bl/R ENGINE STOP
BANK SWITCH
Br/W
ANGLE
SENSOR Br G
(54)
FUEL PUMP
SENSOR UNIT M
TP Br/W B3 VCC INJ B33 G/Bl Bl/R
SENSOR Bu/Bl B14 TH
FUEL
(8) G/W B2 SG
INJECTOR
(12)
MAP
SENSOR Lg B25 PB
IG B11 G/Y Bl/R
(1)
IGNITION
IAT Gr B26 TA COIL
SENSOR G/W
(9) PCM/ECM (33) SPARK
G/W PLUG
Bl/Bu B27 TW
ECT IACV 1A B8 Y
SENSOR IACV1B B5 Y/G IACV
IACV2A B30 Y/Bu M (29)
(7)
IACV 2B B9 Br/Y
VCC Br
MIL
TR SEMSOR GND
IGN Bl/R
G/W
M-TXD A21 P UART
OUT Bu A26 DP GND G
COMBINATION METER
Lg Lg/R A17 DP N
NEUTRAL SWITCH
W/G Bl/R A5 SEN VB W/Bl
P P/G B16 RR VSP K - LINE B17 O/W
Bl/Y B15 FR VSP SCS B29 Br/R
G
REAR VS G
SENSOR DLC SCS SERVICE CONNECTOR
(66) W B22 2POS SUB TRANS L
Bl A15 2POS SUB TRANS D
FAN C3 G/Bl G M Bu R/W
Bl/R
COOLING FAN MOTOR
LG B13 G
FRONT VS G PG1 B21 G

SENSOR
PG2 B10 G
(67)
PG3 C5 G
SUB-TRANSMISSION SUB-TRANSMISSION
LOW SWITCH DRIVE SWITCH
(81) (81)
PCM C-1 C-3

A-1 A-11 B-1 B-11
A-12 A-22 B-12 B-22
( ): MIL Blink
when detecting DTC
reading DTC
C-4 C-5 A-23 A-33 B-23 B-33
30-25
dummyhead
PGM-FI SYSTEM DTC INDEX
• If not using the MCS, perform all inspections according to the relevant main code.
DTC Function Failure Symptom/Fail-safe function Refer to
MAP sensor circuit low voltage (less than 0.195 V) • Engine operates normally
1-1 4-9
• MAP sensor or its circuit malfunction • Pre-program value: 64 kPa
MAP sensor circuit high voltage (more than 3.804 V) • Engine operates normally
1-2 • Loose or poor contact of the MAP sensor connector • Pre-program value: 64 kPa 4-10
• MAP sensor or its circuit malfunction
ECT sensor circuit low voltage (less than 0.078 V) • Hard to start at a low
• ECT sensor or its circuit malfunction temperature
7-1 • Pre-program value: 69.9°C/ 4-12
157.8°F
• Cooling fan turns on
ECT sensor circuit high voltage (more than 4.922 V) • Hard to start at a low
• Loose or poor contact of the ECT sensor connector temperature
7-2 • ECT sensor or its circuit malfunction • Pre-program value: 69.9°C/ 4-13
157.8°F
• Cooling fan turns on
TP sensor circuit low voltage (less than 0.225 V) • Poor engine acceleration
• Loose or poor contact of the TP sensor connector • Pre-program value: 0°
8-1 4-14
• TP sensor or its circuit malfunction • ESP does not work (FE
model only)
TP sensor circuit high voltage (more than 4.922 V) • Poor engine acceleration
• TP sensor or its circuit malfunction • Pre-program value: 0°
8-2 4-16
• ESP does not work (FE
model only)
IAT sensor circuit low voltage (less than 0.078 V) • Engine operates normally
9-1
• IAT sensor or its circuit malfunction • Pre-program value: 32.9°C/ 4-17
91.2°F
IAT sensor circuit high voltage (more than 4.922 V) • Engine operates normally
9-2 • Loose or poor contact of the IAT sensor connector • Pre-program value: 32.9°C/ 4-18
• IAT sensor or its circuit malfunction 91.2°F
11-1 (FM VS sensor no signal • Engine operates normally
models • Loose or poor contact of the VS sensor connector • Gear position indicator 23-9
only) • VS sensor or its circuit malfunction blinks "–"
Fuel Injector circuit malfunction • Engine does not start
12-1 • Loose or poor contact of the fuel injector connector • Fuel Injector, fuel pump and 4-19
• Fuel Injector or its circuit malfunction ignition shut down
O2 sensor malfunction • Engine operates normally
21-1 • Loose or poor contact of the O2 sensor connector 4-21
• O2 sensor or its circuit malfunction
O2 sensor heater circuit malfunction • Engine operates normally
23-1 • Loose or poor contact of the O2 sensor heater connector 4-22
• O2 sensor heater or its circuit malfunction
IACV circuit malfunction • Engine stalls, hard to start,
29-1 • Loose or poor contact of the IACV connector rough idling 4-24
• IACV or its circuit malfunction
PCM/ECM EEPROM malfunction • Rough idling
33-2 * • Does not hold the self- 30-29
diagnosis data
Gear position switch malfunction • Engine operates normally
41-1 (FM
• Loose or poor contact of the gear/shift drum position
models 23-17
switch connector
only)
• Gear position switch or its circuit malfunction
Bank angle sensor circuit low voltage (less than 0.352 V) • Engine operates normally
54-1 • Bank angle sensor or its circuit malfunction • Bank angle sensor stops the 4-26
control
Bank angle sensor circuit high voltage (more than 4.531 V) • Engine operates normally
• Loose or poor contact of the bank angle sensor • Bank angle sensor stops the
54-2 4-27
connector control
• Bank angle sensor or its circuit malfunction
66-1 (66) VS sensor no signal • Engine operates normally
(FE • Loose or poor contact of the VS sensor connector • Gear position indicator
23-9
models • VS sensor or its circuit malfunction blinks "–"
only) • EPS does not work
30-26
dummyhead
DTC Function Failure Symptom/Fail-safe function Refer to
Rear VS sensor no signal • Engine operates normally
66-1 (66)
• Loose or poor contact of the rear VS sensor connector • Gear position indicator
(FA
• Rear VS sensor or its circuit malfunction blinks "–" 26-78
models
• Gearshift function does not
only)
work
Front VS sensor no signal • Gear position indicator
67-1 (67)
• Loose or poor contact of the front VS sensor connector blinks "–"
(FA
• Front VS sensor or its circuit malfunction • Engine operates normally 26-79
models
• Gearshift function does not
only)
work
81-1 (FA Sub-transmission position switches malfunction • Gearshift function does not
models • Sub-transmission position switch or its circuit work 26-135
only) malfunction
* The MIL does not blink (DTC can be readout/erased only by MCS).
30-27
dummyhead
PGM-FI SYSTEM DTC
TROUBLESHOOTING
DTC 12-1 (FUEL INJECTOR)
• Before starting the inspection, check for loose or
poor contact on the fuel injector 2P (Black)
connector and PCM/ECM 33P connectors, and
recheck the DTC.
From IGNITION
SWITCH
FUEL
INJECTOR
Bl/R
PCM/
ECM
G/Bl
Probable cause
• Open circuit in Black/red wire between the ignition
switch and fuel injector
• Open or short circuit in Green/black wire between
the fuel injector and PCM/ECM
• Faulty fuel injector
• Faulty PCM/ECM
1. Fuel Injector System Inspection
Erase the DTCs (page 4-6).
Check the fuel injector with the MCS.
Is the DTC 12-1 indicated?
YES – GO TO STEP 2.
NO – • Intermittent failure.
• Loose or poor contact of the connected
fuel injector 2P (Black) connector.
2. Fuel Injector Resistance Inspection
Disconnect the fuel injector 2P (Black) connector
[1]
(page 7-23).
Measure the resistance between the fuel injector
side connector [1] terminals.
Standard: 11.1 – 12.3 Ω (20°C/68°F)
Is the resistance within 11.1 – 12.3 Ω (20°C/
68°F)?
NO – Faulty fuel injector.
30-28
dummyhead
3. Fuel Injector Input Voltage Inspection
Turn the ignition switch ON.
[1]
Measure the voltage between the wire harness side
fuel injector 2P (Black) connector [1] terminal and
ground.
Connection: Black/red(+) – Ground (–)
Bl/R
Is there battery voltage?
NO – Open circuit in the Black/red wire.
4. Fuel Injector Signal Line Short Circuit Inspection

Turn the ignition switch OFF.
[1]
Check for continuity between the wire harness side
fuel injector 2P (Black) connector [1] terminal and
ground.
Connection: Green/black – Ground
G/Bl
Is there continuity?
YES – Short circuit in the Green/black wire.
NO – GO TO STEP 5.
5. Fuel Injector Signal Line Open Circuit Inspection

Disconnect the PCM/ECM 33P (Gray) connector
[2] [1]
(page 4-33).
fuel injector 2P (Black) connector [1] and PCM/ECM
33P (Gray) connector [2] terminals.
Connection: B33 – Green/black
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110 B33 G/Bl
YES – Replace the PCM/ECM with a known good
one (page 4-33), and recheck.
NO – Open circuit in the Green/black wire.
DTC 33-2 (EEPROM)

1. Recheck DTC
Erase the DTC (page 4-6).
Recheck the PCM/ECM EEPROM with the MCS.
Is DTC 33-2 indicated?
YES – Replace the PCM/ECM with a known good
one (page 4-33) and recheck.
NO – Intermittent failure
30-29
dummyhead
ELECTRIC STARTER TROUBLESHOOTING
Unusual condition Probable cause (Check in numerical order)
Starter motor Starter motor does not turn 1. Weak battery
2. Loose connection or open circuit in the battery cable(s)
3. Loose connection or open circuit in the starter motor cable
4. Faulty starter relay switch (page 6-7)
5. Open circuit in starter relay switch ground circuit (page 6-6)
6. Faulty starter relay switch power input line (page 6-7)
– Faulty circuit between the battery and IGN fuse (page 4-33)
– Open circuit between the fuse box and engine stop switch
– Faulty handlebar switch (engine stop switch and/or starter/
override switch)
– Open circuit between the starter/override switch and starter
inhibitor relay
– Faulty override inhibitor relay (page 19-19) or its circuits
– Open circuit between the override inhibitor relay and starter relay
switch
7. Faulty starter motor
8. FM models: Faulty gear position switch or its circuits
FE models: Faulty TR sensor or its circuits
FA models: Faulty TR sensor or its circuits
9. FE/FA models: Faulty neutral switch or its circuits
10.Faulty front brake inhibitor switch or its circuits
11.Faulty PCM/ECM
Starter motor turns slowly 1. Low battery voltage
2. Poorly connected battery cable terminal(s)
3. Poorly connected starter motor cable
4. Faulty starter motor
5. Poorly connected battery (–) cable ground terminal
Starter motor turns, but engine 1. Faulty starter clutch assembly
does not turn 2. Damaged or faulty starter driven gear
3. Damaged or faulty starter reduction gear
4. Damaged or faulty starter motor pinion gear
Starter relay switch "Clicks", 1. Crankshaft does not turn due to engine problems
but engine does not turn over
30-30
dummyhead
ELECTRIC STARTER COMPONENT
LOCATION (FE/FA models)
FE2 shown:
STARTER/
OVERRIDE SWITCH IGNITION SWITCH
ENGINE STOP SWITCH

FRONT BRAKE
INHIBITOR SWITCH
FUSE BOX:
– IGN FUSE (20 A)
– LIGHT FUSE (20 A)
– MAIN 2 FUSE (10 A) PCM/ECM
– DIODE (R/Y, G)
MAIN 1 FUSE (40 A)
STARTER RELAY
SWITCH
BATTERY
STARTER MOTOR
NEUTRAL SWITCH
TR SENSOR
RELAY BOX:
– OVERRIDE INHIBITOR RELAY
– DIODE (Y/R, G)
– IN-GEAR START DIODE (Lg/R, Br/W)
CKP SENSOR
30-31
dummyhead
ELECTRIC STARTER SYSTEM DIAGRAM (FE/FA models)
FE/FA models:
BATTERY
Y/R MAIN 1 FUSE R/Bl

Lg/R (40 A)
R/Bl R/Y R
STARTER RELAY
OVERRIDE MAIN 2 FUSE IGNITION
SWITCH DIODE
INHIBITOR (10 A) SWITCH
RELAY STARTER/ Bl
ENGINE STOP SWITCH IGN FUSE
G Y/R OVERRIDE SWITCH
(20 A)
G Bu Bl/W Bl/R
DIODE
Y/R Bl/Br P
FRONT BRAKE LIGHT
Br/W Bu FUSE
INHIBITOR SWITCH
Lg/R Lg (20 A)
IN-GEAR CKP
STARTER START SENSOR
DIODE PCM/ECM
MOTOR Bu/Y
G
G/W Br/W
NEUTRAL SWITCH
Bu Br
TR SENSOR
30-32
dummyhead
DCT COMPONENT LOCATION (FA
models)
COMBINATION METER
REVERSE SWITCH – GEAR POSITION INDICATOR
UPSHIFT SWITCH
IGNITION SWITCH
DOWNSHIFT SWITCH
DRIVE MODE
SELECT SWITCH
PCM
RELAY BOX
– MAIN POWER RELAY
DLC
SHIFT SOLENOID VALVE
SENSOR UNIT (TP SENSOR)
FRONT VS
SUB-TRANSMISSION DRIVE SWITCH
SENSOR
FUSE BOX
– MAIN FUSE 1 (40 A)
– MAIN FUSE 2 (10 A)
– IGN FUSE (20 A)
– ACC FUSE (20 A)
– DIODE
BATTERY
SHIFT CONTROL
MOTOR
SUB-TRANSMISSION
LOW SWITCH
EOT SENSOR
REAR VS SENSOR
DUAL CLUTCH PC
TR SENSOR SOLENOID VALVE
SHIFT SPINDLE ANGLE CKP SENSOR

SENSOR
NEUTRAL SWITCH
30-33
dummyhead
DCT DIAGRAM (FA models)
ES FUSE (30 A)
R R/W
REGULATOR/
MAIN RECTIFIER
IGNITION RELAY
SWITCH IGN FUSE
(20A) R/Bl R R
R Bl Bl/R Bl/R V/W

BATTERY MAIN FUSE 1 (40A)
R R/Bl R/Bl P W/Bl
ACC FUSE
(20A)
LIGHT FUSE
FRONT BRAKE (20A)
Bl/Br Y/R
LIGHT SWITCH
R/Bl R/Y R
REAR BRAKE MAIN FUSE 2 (10A) DIODE
LIGHT SWITCH Bl/Br G/Y
(LEVER)
REAR BRAKE PRC B31 V/W
LIGHT SWITCH Bl G/Y A14 STOP LAMP SW
(PEDAL) UP
MAIN B1 Bl/R Bl/R
G/Bl W/Bu A6 SFT UP

GEARSHIFT Br/W DOWN ES
SWITCH AT-ES SW A18 Br/Bl Bl/G
Br/W Lg/Y W/Y A16 SFT DOWN AT
(42)
Br/W
DRIVE MODE
REVERSE Br/W G/W W/R B19 RVS HDLE SW
SELECT SWITCH
SWITCH
Br/W
CKP Bu/Y B23 PCP MIL

SENSOR G IGN Bl/R
M-TXD A21 P UART
GEAR
GND G
SENSOR UNIT POSITION
INDICATOR
TP Br/W Br/W Br/W B3 VCC COMBINATION METER
SENSOR Bu/Bl B14 TH
(8) G/W G/W B2 SG
W/Bl
Bu/Y B28 TO K - LINE B17 O/W
G/W SCS B29 Br/R
G
EOT DLC SCS SERVICE CONNECTOR
SENSOR PCM (33)
(44)
PVB C4 R/W
SHIFT SHIFT CONTROL

Bl/W SMOP C1 R
SPINDLE
ANGLE
G/Y G/Bu A23 ANGLE SMOM C2 Bl M MOTOR
(24, 31)
G/R G/W
SENSOR PG3 C5 G
(21, 22, 23)
TR VCC Br
SEMSOR SFTSOL A B7 Br/W SHIFT SOLENOID
(27, 51, 57) GND G/W VALVE
Bu A26 DP G (15)
OUT
Lg Lg/R A17 DP N
LSOLP A8 Bl/W DUAL CLUTCH PC
NEUTRAL SWITCH SOLENOID VALVE
(52) LSOLM A9 W/Y (4)
W/G Bl/R A5 SEN VB1
P P/G B16 RR VSP
REAR VS
SENSOR G FAIL-SAFE
RELAY
(66)
(32)
2POS SUB TRANS L B22 W SUB-TRANSMISSION
Bl/R LOW SWITCH
Bl/Y B15 FR VSP (81)
FRONT VS 2POS SUB TRANS D A15 Bl SUB-TRANSMISSION

SENSOR G DRIVE SWITCH
LG B13 G (81)
(67) PG1 B21 G
PG2 B10 G
PCM C-1 C-3

A-1 A-11 B-1 B-11
A-12 A-22 B-12 B-22
( ): Gear position
indicator blink
( ): MIL Blink

reading DTC
C-4 C-5 A-23 A-33 B-23 B-33
30-34
dummyhead
DCT DTC INDEX (FA models)
• When the gear position indicator shows "–" constantly, but no problem code is indicated and retrievable, refer to the symptom
troubleshooting (page 26-54).
DTC Refer to
Function Failure Symptom/Fail-safe Function
("–" blinks) page
Dual clutch PC solenoid valve Low input • Gearshift function does not
• Loose or poor contact of the dual clutch PC solenoid work
4-1 (4) valve connector 26-65
• Dual clutch PC solenoid valve or its circuit
malfunction
Dual clutch PC solenoid valve High input • Gearshift function does not
4-2 (4) • Dual clutch PC solenoid valve or its circuit work 26-66
malfunction
Dual clutch PC solenoid valve drive circuit • Gearshift function does not
4-3 (4) • Dual clutch PC solenoid valve or its circuit work 26-65
malfunction
TP sensor circuit Low voltage • Poor engine acceleration
8-1 (8) • TP sensor or its circuit malfunction • Gearshift function does not 4-14
• Loose or poor contact of the TP sensor connector work
TP sensor circuit High voltage • Poor engine acceleration
8-2 (8) • TP sensor or its circuit malfunction • Gearshift function does not 4-16
work
Shift solenoid valve circuit • Gearshift function does not
• Loose or poor contact of the shift solenoid valve work
15-1 (15) 26-67
connector
• Shift solenoid valve or its circuit malfunction
Shift spindle angle sensor circuit Low voltage (less than • Gearshift function does not
0.215 V) work
21-1 (21) • Loose or poor contact of the shift spindle angle 26-68
sensor connector
• Shift spindle angle sensor or its circuit malfunction
Shift spindle angle sensor circuit High voltage (more • Gearshift function does not
21-2 (21) than 4.619 V) work 26-69
Shift spindle operation malfunction (while operating • Gearshift function does not
gearshift mechanism) work
22-1 (22) 26-70
• Control motor or its circuit malfunction
Shift spindle operation malfunction (after operating • Gearshift function does not
gearshift mechanism) work
23-1 (23) 26-71
• Shift spindle angle sensor installation problem
Shift control motor drive circuit • Gearshift function does not
• Loose or poor contact of the shift control motor work
24-1 (24) connector 26-72
• Control motor drive circuit malfunction
Shift drum position malfunction • Gearshift function does not
• TR sensor malfunction work
27-1 (27) 30-37
• Gearshift mechanism malfunction
• Faulty PCM
Shift control motor low voltage • Gearshift function does not
• Fail safe relay in the PCM work (2nd gear only)
31-1 (31) • ES fuse (30 A) • Creep cut does not work 30-38
• Loose or poor contact of the PCM 33P (Gray)
connector
Fail-safe relay circuit • Gearshift function does not
32-1 (32) 26-73
• Fail-safe relay circuit malfunction work
PCM EEPROM malfunction • Does not hold and erase
33-2 * 30-29
the self-diagnosis data.
Gearshift switch circuit • Gearshift function does not
42-1 (42) 30-39
• Gearshift switch or its circuit malfunction work
EOT sensor circuit low voltage (less than 0.059 V) • Gearshift function works
44-1 (44) 26-76
• EOT sensor or its circuit malfunction normally
30-35
dummyhead
DTC Refer to
Function Failure Symptom/Fail-safe Function
("–" blinks) page
EOT sensor circuit high voltage (more than 4.922 V) • Gearshift function works
44-2 (44) • Loose or poor contact of the EOT sensor connector normally 26-77
• EOT sensor or its circuit malfunction
TR sensor low voltage (less than 0.410 V) • Gearshift function does not
51-1 (51) • Loose or poor contact of the TR sensor connector work 30-40
• TR sensor or its circuit malfunction
TR sensor high voltage (more than 4.702 V) • Gearshift function does not
51-2 (51) 30-42
• TR sensor or its circuit malfunction work
Neutral switch stuck OFF • Gearshift function does not
52-1 (52) • Loose or poor contact of the neutral switch connector work 30-42
• Neutral switch or its circuit malfunction
Neutral switch stuck ON • Gearshift function does not
52-2 (52) 30-43
• Neutral switch or its circuit malfunction work
Gearshift mechanism malfunction • Gearshift function does not
57-1 (57) • Gearshift mechanism malfunction work 30-43
Gear position malfunction (jumps out of gear) • Gearshift function does not
57-2 (57) • Gearshift mechanism malfunction work 30-43
Rear VS sensor no signal • Gearshift function does not
• Loose or poor contact of the Rear VS sensor work
66-1 (66) 26-78
connector
• Rear VS sensor or its circuit malfunction
Front VS sensor no signal • Gearshift function does not
• Loose or poor contact of the Front VS sensor work
67-1 (67) 26-79
connector
• Front VS sensor or its circuit malfunction
Sub-transmission switches malfunction (Low and drive • Gearshift function does not
switches remain on simultaneously for more than 1.5 work
81-1 (81) 26-135
seconds)
• Sub-transmission switch or its circuit malfunction
30-36
dummyhead
DCT DTC TROUBLESHOOTING (FA
models)
DTC 27-1 (SHIFT DRUM POSITION
MALFUNCTION)
1. TR Sensor System Inspection
Check the TR sensor with the MCS.
Is Low voltage (about 0 V) or High voltage (about
5 V) indicated?
YES – • About 0 V: See DTC 51-1 (page 30-40).
• About 5 V: See DTC 51-2 (page 30-42).
2. Shift Control Motor/Reduction gear condition
Check the shift control motor and reduction gears
are installed properly and are not damaged.
Are the shift control motor and reduction gears
in normal condition?
NO – Install the shift control motor and reduction
gears properly or replace faulty parts.
3. Shift Control Motor Condition Inspection
Remove the shift control motor (page 26-95).
Connect a fully charged 12 V battery [1] to the
control motor [2] 2P connector terminals to check
the motor operation.
Change the battery connection to check the reverse
operation.
Does the shift control motor turn in both
directions?
NO – Faulty shift control motor
[2] [1]

Remove the TR sensor with the connector
connected (page 30-44).
While turning the TR sensor shaft, check the TR
sensor voltage with the MCS.
When turning the sensor shaft clockwise:
Voltage increase
When turning the sensor shaft
counterclockwise:
Voltage decrease
Does the voltage vary properly?
NO – Faulty TR sensor
5. TR Sensor Condition Inspection
Check that the TR sensor is installed properly and is
not damaged.
Is the TR sensor in normal condition?
NO – Install the TR sensor properly.
30-37
dummyhead
6. DTC Recheck
Recheck the DTC with the MCS.
YES – Replace the PCM with a known good one,
and recheck.
DTC 31-1 (SHIFT CONTROL MOTOR

LOW VOLTAGE)

poor contact on the shift control motor 2P (Black)
and PCM 5P (Black) connectors, and recheck the
DTC.
1. DTC Recheck
Erase the DTCs (page 4-6).
Check the DTC with the MCS.
YES – DTC 32-1 indicated (page 26-73).
2. Shift Control Motor Line Open Circuit Inspection
Disconnect the PCM 5P (Black) connector and shift
[1] C1
control motor 2P (Black) connector.
shift control motor 2P (Black) connector [1] and Bl
PCM 5P (Black) connector [2] terminals.
Connection: Red – C1
Black – C2
TOOL:
Test probe 07ZAJ-RDJA110 C2
R
YES – Replace the PCM with a known good one, [2]
and recheck.
NO – • Open circuit in the Red wire
• Open circuit in the Black wire
30-38
dummyhead
DTC 42-1 (GEARSHIFT SWITCH
CIRCUIT)
• Before starting the troubleshooting, check the
handlebar switch 14P (Gray) connector for loose
contacts or corroded terminals, and recheck the
DTC.
1. Shift Switch Status Inspection
Check the shift switch status and voltage in the Data
List Menu of MCS as follows:
UP DOWN
"Up" ON 2.78 – 4.10 V 0.70 – 2.25 V
"Down" ON 0.70 – 2.25 V 2.78 – 4.10 V
Both ON 3.17 – 4.32 V 3.17 – 4.32 V
Both OFF 0 – 0.41 V 0 – 0.41 V
Is the shift switch status normal?
YES – Intermittent failure
2. Shift Switch Inspection at PCM connector
Disconnect the PCM 33P connectors (page 4-33). [1] A6
Check for continuity between the wire harness side B3
33P (Black) connector [1] and (Gray) connector [2]
terminals while pushing each switch.
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
Connection:
With the upshift switch pushed:
A6 – B3
With the downshift switch pushed:
A16 – B3
A16 [2]
30-39
dummyhead
3. Gearshift Switch Inspection at Handlebar Switch
Connector
Remove the left handlebar switch 14P (Gray)
connector from the frame and disconnect it (page W/Bu
22-12). W/Y
Check for continuity between the switch side 14P
(Gray) connector [1] terminals while pushing each
switch.
Connection:
With the upshift switch pushed [1]
Brown/white – White/blue
With the downshift switch pushed
Brown/white – White/yellow
Is there continuity? Br/W
YES – Open circuit in the following wire between
the PCM and handlebar switch
connectors:
• Brown/white wire
• White/blue wire
• White/yellow wire
NO – Faulty gearshift switch (Replace the
handlebar switch.)
4. Recheck DTC
Connect the PCM 33P (Black) connector and
handlebar switch 14P (Gray) connector.
Recheck the current DTC with the MCS.
YES – Replace the PCM with a known good one
(page 4-33) and recheck.
DTC 51-1 (TR SENSOR LOW

VOLTAGE)
poor contact of the TR sensor 8P (Black) and PCM
33P connectors, and recheck the DTC.
Is about 0 V indicated?
2. TR Sensor Input Voltage Inspection
Disconnect the TR sensor 8P (Black) connector [1]
(page 30-44).
Measure the voltage at the wire harness side 8P
(Black) connector [1]. G/W
Br/W
Connection: Brown/white (+) – Green/white (–)
Is the voltage within 4.75 – 5.25 V?
30-40
dummyhead
3. TR Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF. [1]
Disconnect the PCM 33P (Gray) connector (page 4-
33).
Check for continuity between the wire harness side Br/W
33P (Gray) connector [1] and 8P (Black) connector
[2].
TOOL:
Test probe, 2 packs 07ZAJ-RDJA110
Connection: B3 – Brown/white
YES – GO TO STEP 4. [2]
B3
NO – Open circuit in the Brown/white wire
4. TR Sensor Ground Line Open Circuit Inspection
[2].
G/W
TOOL:
Connection: B2 – Green/white
NO – Open circuit in the Green/white wire
[2] B2 [1]
5. TR Sensor Signal Line Open Circuit Inspection

[1] [2]
Disconnect the PCM 33P (Black) connector (page
4-33).
33P (Black) connector [1] and 8P (Black) connector
[2].
TOOL:
Connection: A26 – Blue Bu

A26
NO – Open circuit in the Blue wire
6. TR Sensor Output Line Short Circuit Inspection
8P (Black) connector [1] and ground. [1]
Connection: Blue – ground
YES – Short circuit in the Blue wire
Bu
30-41
dummyhead
7. TR Sensor Inspection
Replace the TR sensor with a known good one
(page 30-44).
Connect the 8P (Black) connector and 33P (Black)
connector.
NO – Faulty original TR sensor
DTC 51-2 (TR SENSOR HIGH

VOLTAGE)
(page 30-44).
Turn the ignition switch ON (I).
DTC 52-1 (NEUTRAL SWITCH STUCK

OFF)

poor contact on the neutral switch and PCM 33P
(Black) connector, and recheck the DTC.
1. DTC Recheck
2. Neutral Switch Line Open Circuit Inspection
[1] A17 [2]
Disconnect the PCM 33P (Black) connector and
neutral switch connector.
PCM 33P (Black) connector [1] and neutral switch
connector [2] terminals.
Connection: A17 – Light green/red
TOOL: Lg/R
Test probe 07ZAJ-RDJA110
NO – Open circuit in the Light green/red wire
30-42
dummyhead
3. Neutral Switch Inspection
Replace the neutral switch with a known good one
(page 30-44).
and recheck.
NO – Faulty original neutral switch

ON)
1. Neutral Switch Line Short Circuit Inspection
Disconnect the neutral switch connector.
Check for continuity between the neutral switch
connector terminal and ground.
Connection: Light green/red – Ground
YES – Short circuit in the Light green/red wire.
(page 30-44).
Connect the neutral switch connector.
and recheck.
DTC 57-1 (GEARSHIFT MECHANISM

MALFUNCTION)
See DTC 27-1 (page 30-37).
DTC 57-2 (GEAR POSITION

MALFUNCTION; JUMPS OUT OF
GEAR)
See DTC 27-1 (page 30-37).
30-43
dummyhead
TR SENSOR (FA models)
[1] [2]
– engine guard (page 2-5)
– right center mudguard (page 30-18)
Disconnect the following:
– sensor harness 8P (Black) connector [1]
– neutral switch wire connector [2]
Remove the harness band [3].
[3]
Release the harness crip [1].
[1]
Disconnect the following: [4]
– spindle angle sensor 3P (Gray) connector [2]
– neutral switch wire connector [3] [2] [5]
Remove the bolt [4] and TR sensor [5] from the rear
crankcase cover.
[3]
Coat a new O-ring [1] with engine oil and install it into
the TR sensor [2] groove. [2]
[1]
Install the TR sensor by aligning the flat surface of the
sensor hole and shift drum [3] end.
Install the bolt and tighten it.
TORQUE:
TR sensor mounting bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the removed part in the reverse order of removal.
Align [3]
NEUTRAL SWITCH (FA models)

– engine guard (page 2-5) [3]
Disconnect the neutral switch connector [1].
[1]
Remove the neutral switch [2] and sealing washer [3].
• Replace the sealing washer with a new one.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft) [2]
30-44
dummyhead
SHIFT VALVE BODY (FA models)
EMERGENCY VALVE FUNCTION
• The emergency valve is used when the hydraulic

pressure is shut off by the faulty dual clutch PC
solenoid (stuck; mechanical lock), and the vehicle is
prevented from running. Open the bypass oil circuit
manually to supply hydraulic pressure.
The stopper bolt [1] that operates the emergency valve
is secured with the lock plate [2]. [3]
When trouble occurs, loosen the lock plate bolt [3].
Remove the oil check lid (page 2-3).
Release the lock plate bolt fixing the lock plate with the
gear change lever tool [4].
Turn the stopper bolt all the way in to activate the
emergency valve.
[1]
[2]
[3]
[1]
[4]
ENGINE REMOVAL/INSTALLATION
FM/FE models:
FM models:
– center mudguards (page 30-18)
Drain the engine oil (page 3-12).
Drain the coolant (page 8-4).
– fuel tank (page 7-17)
– throttle body (page 7-18)
– exhaust system (page 2-10)
– battery (–) cable (page 21-4)
Remove the pinch bolt [1] and gearshift pedal [2].
[2] [1]
30-45
dummyhead
Remove the trim clips [1].
Unhook
Unhook and remove the heat protector [2] and release
the water hose [3]. [2]
[1]
[3]
Disconnect the stator 3P (Gray) connector [1]. [1]

[3]
Unlock the wire clamp [2], remove the wire band [3] and
release the stator wire [4].
[2] [4]

[1] [2]
– CKP sensor 2P (Gray) connector [3]
Remove the engine (page 15-3).
removal.
[3]
30-46
dummyhead
FA models:
Unhook
– center mudguards (page 30-18)
– engine guard (page 2-5) [2]
Drain the engine oil (page 3-12).
Drain the coolant (page 8-4).
[1]
– fuel tank (page 7-17)
– throttle body (page 7-18)
– range select cable cover (page 26-38)
– exhaust system (page 2-10)
– battery (–) cable (page 21-4)
Remove the trim clips [1].
Unhook and remove the heat protector [2] and release
the water hose [3].
[3]
Disconnect the stator 3P (Gray) connector [1]. [1]

[3]
Unlock the wire clamp [2], remove the wire band [3] and
release the stator wire [4].
[2] [4]

[5]
– sub-transmission low switch connector [3]
– sub-transmission drive switch connector [4] [6]
– CKP sensor 2P (Gray) connector [5]
– wire band [6]
– engine ( 26-147)
[3]
Installation is in the reverse order of removal. [1]
[2] [4]
30-47
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REAR BRAKE LEVER (FE1/FE2/FA6/
FA7)
Remove the rear brake lever switch (page 22-13).
[2]
Loosen the rear brake cable adjuster (page 26-39).
– pivot nut [1]
– wire holder plate [2] (by releasing the brake lever
switch wire [3])
[3]
[1]
Align
– pivot bolt [1]

– spring [2] [2]
Remove the rear brake lever [3] with rear brake cable
[4].
Disconnect the rear brake cable from the rear brake [1]
lever.
• Apply grease to the rear brake cable end.
• Hook the spring ends as shown.
• Install the wire holder plate by aligning its hole with
the lever holder boss.
• Tighten the pivot nut while holding the pivot bolt.
TORQUE:
[2]
Rear brake lever pivot bolt:
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
Rear brake lever pivot nut:
5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)
Adjust the rear brake cable (page 26-39).
[4] [3]
30-48
dummyhead
FRONT DRIVE SHAFT
DISASSEMBLY
Check the boots [1] for cuts or other damage.
[1]
Check the drive shaft joints [2] for excessive play or
noise by moving the joints in a circular direction.
If the outboard joint seems to be worn or damaged, the
drive shaft must be replaced. Inboard Outboard
• To replace the outboard boot, first remove the

inboard boot as described in following steps.
Then remove bands and the outboard boot off the
inboard end of the shaft.
• The outboard joint can not be disassembled.
[2] [2]
Replace the band Cut off and remove the boot bands [1] from inboard
[1]
with new ones boot [2].
whenever removing
Remove the boot from the inboard joint.
them.
[2]

[2]
– stopper ring [1]
– inboard joint [2] [1]
FM and FE models: Remove the balls [1] from the bearing cage [2] and
[1]
inner race [3] by tilting the cage as shown.
Slide the bearing cage down into the inboard boot. [2]
[3]
30-49
dummyhead
FM and FE models: While holding the drive shaft [1], press it out of the inner
[1]
race [2] using a suitable tool as shown.
[2]
FM and FE models: Remove the stopper ring [1], inner race [2] and inboard
[2]
boot [3] from the drive shaft.
[3] [1]
Replace these Check the following for wear or damage.
[4]
components as an
– bearing cage [1]
assembly.
– race [2]
[3]
– steel balls [3]
– inboard joint [4]
[1] [2]
Replace the bands Cut off and remove the boot bands [1] from outboard
whenever removing [1]
Remove the outboard boot.
them.
[2]
30-50
dummyhead
ASSEMBLY
DRIVE SHAFT
SHAFT BOOT BAND
INBOARD JOINT
OUTBOARD BOOT
OUTBOARD JOINT
OUTBOARD BOOT BAND
STOPPER RING
BEARING
STOPPER RING
INBOARD BOOT BAND
INBOARD BOOT
Pack the inboard and outboard joint insides with specified grease. SHAFT BOOT BAND
The outboard boot [1] is larger than the inboard boot [2].
Do not interchange them.
[2] [1]
Each band has following identification number [1]. Do

outboard band shown: [1]
not interchange them.
INBOARD SHAFT BOOT BAND: 23.75

INBOARD BOOT BAND: 64
OUTBOARD SHAFT BOOT BAND: 0255
OUTBOARD BOOT BAND: 0710
30-51
dummyhead
Pack the outboard joint with specified grease.
[1] [2]
Specified grease: G.A. Besmoly CE (Brugarolas)
Volume: 50 – 70 g (1.8 – 2.5 oz)
Install the following:
– outboard boot [1]
– inboard boot [2]
Do not tighten the bands at this time.
Specified grease
FM and FE models: Install the bearing cage [1] with the small O.D. facing
[1]
the drive shaft.
Install a new stopper ring [2] into the drive shaft groove.
[2]
FM and FE models: Install the inner race [1] with the chamfered I.D. [2]
facing the drive shaft (ring groove [3] side facing
opposite side). [3]
Drive the shaft with a copper hammer until the stopper
ring seats in the ring groove.
[2] [1]
FM and FE models: Assemble the bearing cage [1] and six balls [2] onto the
inner race [3]. [2]
[1] [3]
30-52
dummyhead
Pack the inboard joint with specified grease.
Specified
Specified grease: G.A. Besmoly CE (Brugarolas) grease
[2]
Volume: 65 – 85 g (2.3 – 3.0 oz)
Install the inboard joint over the bearing.
Install the stopper ring [2] into the groove in the inboard
joint properly.
Install the boot over the inboard joint.
[1]
Adjust the length of the drive shaft to the figure given

below.
DRIVE SHAFT LENGTH:

FM1/FM2/FE models/FA models
Left:: 494.5 mm (19.47 in)
Right: 508.8 mm (20.03 in)
Note the installation Install new shaft boot band [1] and inboard boot band
[4]
direction of the [2] onto the inboard boot [3].
band (page 30-51). Lock the boot bands using the following tool.
TOOL:
[4] CV Joint Band Pliers OET 14100134 or
equivalent
Lock
[1]
[3]
[2]
Install new shaft boot band [1] and outboard boot band
[2] onto the outboard boot [3]. Lock
[3]
• Installation direction of the band (page 30-49).
Lock the boot bands.
[2]
[1]
30-53
dummyhead
REAR DRIVE SHAFT (FM6/FA6/FA7
models)
DISASSEMBLY
Check the boots [1] for cuts or other damage.
Check the drive shaft joints [2] for excessive play or [1]
noise by moving the joints in a circular direction.
If the outboard joint seems to be worn or damaged, the
drive shaft must be replaced.
Inboard Outboard
• To replace the outboard boot, first remove the

inboard boot as described in following steps.
Then remove bands and the outboard boot off the
inboard end of the shaft.
• The outboard joint cannot be disassembled.
[2] [2]
Replace the band Cut off and remove the boot bands [1] from inboard
[1]
whenever removing
Remove the boot from the inboard joint.
them.
[2]

[2]
– stopper ring [1]
– inboard joint [2] [1]
Remove the balls [1] from the bearing cage [2] and
[1]
inner race [3] by tilting the cage as shown.
Slide the bearing cage down into the inboard boot. [2]
[3]
30-54
dummyhead
While holding the drive shaft [1], press it out of the inner
[1]
race [2] using a suitable tool as shown.
[2]
Remove the stopper ring [1], inner race [2] and inboard
[2]
boot [3] from the drive shaft.
[3] [1]
Replace these Check the following for wear or damage.
[4]
components as an
– bearing cage [1]
assembly.
– race [2]
[3]
– steel balls [3]
– inboard joint [4]
[1] [2]
Replace the bands Cut off and remove the boot bands [1] from outboard
whenever removing [1]
Remove the outboard boot.
them.
[2]
30-55
dummyhead
ASSEMBLY
DRIVE SHAFT
SHAFT BOOT BAND
INBOARD JOINT
OUTBOARD BOOT
OUTBOARD JOINT
OUTBOARD BOOT BAND
STOPPER RING
BEARING
STOPPER RING
INBOARD BOOT BAND
INBOARD BOOT
Pack the inboard and outboard joint insides with specified grease. SHAFT BOOT BAND
The outboard boot [1] is larger than the inboard boot [2].
Do not interchange them.
[2] [1]
Each band has following identification number. Do not

outboard band shown: [1]
interchange them.
INBOARD SHAFT BOOT BAND: 25.5

INBOARD BOOT BAND: 66.8
OUTBOARD SHAFT BOOT BAND: 0248
OUTBOARD BOOT BAND: 0755
30-56
dummyhead
Pack the outboard joint with specified grease.
[1] [2]
Specified grease: Oilstomoly 2 LN 584 LO (Castrol)
Volume: 70 – 90 g (2.5 – 3.2 oz)
– outboard boot [1]
– inboard boot [2]
Do not tighten the bands at this time.
Specified grease
Install the bearing cage [1] with the small O.D. facing
[1]
the drive shaft.
Install a new stopper ring [2] into the drive shaft groove.
[2]
Install the inner race [1] with the chamfered I.D. [2]
facing the drive shaft (ring groove [3] side facing
opposite side).
Drive the shaft with a copper hammer until the stopper [3]
ring seats in the ring groove.
[2] [1]
Assemble the bearing cage [1] and six balls [2] onto the
inner race [3].
[2]
[1] [3]
30-57
dummyhead
Pack the inboard joint with specified grease.
Specified
Specified grease: Oilstomoly 2 LN 584 LO (Castrol) grease
[2]
Volume: 70 – 90 g (2.5 – 3.2 oz)
Install the inboard joint [1] over the bearing.
Install the stopper ring [2] into the groove in the inboard
joint properly.
Install the boot over the inboard joint.
[1]
Adjust the length of the drive shaft to the figure given

below.
REAR DRIVE SHAFT LENGTH:

Left/Right: 519.5 mm (20.45 in)
Install new shaft boot band [1] and inboard boot band
[4]
[2] onto the inboard boot [3].

Lock the boot bands using the following tool.
TOOL: Lock
[4] CV Joint Band Pliers OET 14100134 or
equivalent [1]
[3]
[2]
Install new shaft boot band [1] and outboard boot band
[2] onto the outboard boot [3]. Lock
[3]
Lock the boot bands.
[2]
[1]
30-58
dummyhead
ASSIST HEADLIGHT (FM models)
Remove the screws [1] and trim clips [2].
Remove the assist headlight cover/unit and disconnect
[1]
the 3P connector [3].
Remove the screws [4] and assist headlight unit [5]
from the cover [6].
Install the assist headlight unit and removed parts in the
reverse order of removal.
[3]
[2]
[4]
[5]
[6]
BULB REPLACEMENT
Remove the assist headlight unit/cover (page 30-59).
Remove the assist headlight bulb [1] by rotating it
counterclockwise.
Avoid touching halogen headlight bulb. Fingerprints can

create hot spots that cause a bulb to break.
• Install the assist headlight bulb by aligning the bulb
tabs with the grooves of the assist headlight.
removal.
[1]
COMBINATION METER
SERIAL COMMUNICATION LINE
Gear position indicator continuously blinks "–",
MIL, reverse, neutral, differential lock and high
coolant temperature indicators come on
1. PCM/ECM Power Input Inspection
Check that the engine can be started normally.
Can the engine start?
NO – Check the PCM/ECM power/ground line
(page 4-33).
30-59
dummyhead
2. Connector Inspection
Check the combination meter 16P (Gray) connector
and PCM/ECM 33P (Black) connector for loose
contacts or corroded terminals.
Are the connectors in good condition?
NO – Loose or poor contacts at the combination
meter 16P (Gray) connector or PCM/ECM
33P (Black) connector.
3. Combination Meter Serial Line Short Circuit
Inspection
Disconnect the PCM/ECM 33P (Black) connector
[1]
(page 4-33).
PCM/ECM 33P (Black) connector [1] terminal and
ground.
TOOL:
P (A21)
Connection: Pink (A21) – ground
YES – Short circuit in the Pink wire.
4. Combination Meter Serial Line Open Circuit

Inspection
Disconnect the combination meter 16P (Gray)
[2]
connector (page 22-6).
Check the continuity between the PCM/ECM 33P
(Black) connector [1] and combination meter 16P
(Gray) connector [2] terminals.
TOOL:
P (A21)
Connection: Pink (A21) – Pink
P
NO – Open circuit in the Pink and/or Violet wire. [1]
5. PCM/ECM Circuit Inspection

Connect the PCM/ECM 33P (Black) connector.
[1]
Turn the ignition switch ON and wait 5 seconds or P
more. Measure resistance at the combination meter
16P (Gray) connector [1] terminals.
Connection: Pink – Green
Is the resistance 0.1 kΩ – 100 kΩ?
YES – Replace the combination meter with a
known good one, and recheck.
G
NO – Replace the PCM/ECM with a known good
one, and recheck.
30-60
dummyhead
ESP COMPONENT LOCATION (FE models)
REVERSE SWITCH
UPSHIFT SWITCH
COMBINATION METER:
DOWNSHIFT SWITCH – GEAR POSITION INDICATOR
ENGINE STOP SWITCH
FUSE BOX:
– ES FUSE (30 A) DLC
– ACC FUSE (20 A)
– MAIN 2 FUSE (10 A) PCM
– IGN FUSE (10 A)
MAIN 1
FUSE (40 A)
BATTERY SHIFT CONTROL MOTOR
VS SENSOR NEURAL SWITCH

SENSOR UNIT:
– MAP SENSOR TR SENSOR
– TP SENSOR
30-61
dummyhead
ESP SYSTEM DIAGRAM (FE models)
ES FUSE
(30A)
R/W

RELAY RECTIFIER
R R/Bl R R
IGNITION SWITCH IGN FUSE (20A)
MAIN 1 FUSE R Bl Bl/R Bl/R V/W
(40A)
BATTERY
R R/Bl R/Bl P W/Bl
ACC FUSE (20A)
R/Bl R/Y R
Up
GEAR G/Bl W/Bu A6 SFT UP PRC B31 V/W
SHIFT SWITCH Br/W
(42) Dwon
Lg/Y W/Y A16 SFT DWN
Br/W PVB C4 R/W
REVESE SWITCH G/W W/R B19 RVS HDLE SW

MAIN B1 Bl/R
MOM C2 Bl SHIFT CONTROL

MOP C1 R MOTOR
(22) (27) (57)
Br/W Br/W B3 VCC

TP
Bu/Bl B14 TH
SENSOR
G/R G/W B2 SG
(8)
PCM/ECM
(33)
W/Bl
SHIFT SPINDLE Bl/W K - LINE B17 O/W
ANGLE SENSOR G/Y G/Bu A23 ANGLE SCS B29 Br/R
(21)(22) G/R G
DLC SCS SERVICE CONNECTOR
VCC Br
TR SEMSOR
(27)(51) (57) GND G/W
MIL
OUT Bu A26 DRUM POS
LCD
Lg Lg/R A17 DP N
M-TXDRXD A21 P SERIAL IGN Bl/R
SP GND
NEUTRAL SWITCH G
(52) P/G COMBINATON
G B13 LG METER
RR VSP B16 P/G
G B21 PG1 P
SEN VB A5 Bl/R Bl/W
G B10 PG2
G C5 PG3
G
VS SENSOR
(11)
PCM C-1 C-3

A-1 A-11 B-1 B-11
A-12 A-22 B-12 B-22
( ): Gear position indicator
(each gear position)
blink
reading DTC
C-4 C-5 A-23 A-33 B-23 B-33

30-62
dummyhead
ESP DTC INDEX (FE models)
• When the gear position indicator "–" is blinking constantly (and the MIL and coolant temperature indicator lights are dark), but no
DTC is indicated or retrievable, check the serial communication line (page 22-7).
• There are some DTCs (21-1 thru 23-1) related to the shift spindle angle sensor circuit that have different conditions of
malfunction detection. In case of the low voltage (about 0 V) or high voltage (about 5 V) in the shift spindle angle sensor circuit,
DTC 22-2 will be indicated when the control motor does not operate.
• If not using the MCS, perform all inspections according to the relevant main code.
Refer
DTC Function Failure Symptom/Fail-safe function
to
TP sensor circuit Low voltage (less than 0.225 V) • Poor engine acceleration
8-1 • TP sensor or its circuit malfunction • ESP does not work 4-14
• Loose or poor contact of the TP sensor connector
TP sensor circuit High voltage (more than 4.922 V) • Poor engine acceleration
8-2 4-16
• TP sensor or its circuit malfunction • ESP does not work
VS sensor no signal • Engine operates normally
11-1 • Loose or poor contact of the VS sensor connector • ESP does not work 23-9
• VS sensor or its circuit malfunction
Shift spindle angle sensor circuit Low voltage (less than • ESP does not work
21-1 0.215 V) 23-11
Shift spindle angle sensor circuit High voltage (more than • ESP does not work
4.619 V)
21-2 • Loose or poor contact of the shift spindle angle sensor 23-12
connector
Shift spindle operation malfunction (while operating • ESP does not work
gearshift mechanism)
22-1 23-13
Shift spindle operation malfunction (after operating gearshift • ESP does not work
mechanism)
23-1 23-14
• Shift spindle angle sensor installation problem
Shift control motor drive circuit • ESP does not work
24-1 • Control motor or its circuit malfunction 23-15
• Control motor drive circuit malfunction
Shift drum position malfunction • ESP does not work
27-1 • TR or its circuit malfunction 30-64
• Faulty gearshift mechanism
Fail-safe relay circuit • ESP does not work
32-1 23-16
• Fail-safe relay circuit malfunction
PCM EEPROM malfunction • Does not hold the self-diagnosis
33-2 * 30-29
data
Gearshift (UP/DOWN) switch circuit • ESP does not work
42-1 30-39
• Gearshift (UP/DOWN) switch circuit malfunction (Short)
TR sensor low voltage (less than 0.410 V) • ESP does not work
51-1 • Loose or poor contact of the TR sensor connector 30-66
TR sensor high voltage (more than 4.702 V) • ESP does not work
51-2 30-68
Neutral switch stuck OFF • ESP does not work
52-1 • Loose or poor contact of the neutral switch connector 30-68
Neutral switch stuck ON • ESP does not work
52-2 30-69
Gearshift mechanism malfunction • ESP does not work
57-1 • TR sensor malfunction 30-69
• Faulty shifter mechanism
Gear position malfunction (jumps out of gear) • ESP does not work
57-2 • TR sensor malfunction 30-69
• Faulty shifter mechanism
30-63
dummyhead
ESP DTC TROUBLESHOOTING (FE
models)
DTC 27-1 (SHIFT DRUM POSITION
MALFUNCTION)
Is Low voltage (about 0 V) or High voltage (about
5 V) indicated?
YES – • About 0 V: See DTC 51-1 (page 30-66).
• About 5 V: See DTC 51-2 (page 30-68).
2. Shift Control Motor/Reduction gear condition
Check the shift control motor and reduction gears
are installed properly and are not damaged.
Are the shift control motor and reduction gears
in normal condition?
NO – Install the shift control motor and reduction
gears properly or replace faulty parts.
3. Shift Control Motor Condition Inspection
Remove the shift control motor (page 23-22).
Connect a fully charged 12 V battery [1] to the shift
control motor [2] 2P connector terminals to check
the motor operation.
Change the battery connection to check the reverse
operation.
Does the shift control motor turn in both
directions?
NO – Faulty shift control motor
[2] [1]

Remove the TR sensor with the connector
connected (page 30-70).
While turning the TR sensor shaft, check the TR
sensor voltage with the MCS.
When turning the sensor shaft clockwise:
Voltage increase
When turning the sensor shaft
counterclockwise:
Voltage decrease
Does the voltage vary properly?
NO – Faulty TR sensor
5. TR Sensor Condition Inspection
Check that the TR sensor is installed properly and is
not damaged.
Is the TR sensor in normal condition?
NO – Install the TR sensor properly.
30-64
dummyhead
6. DTC Recheck
and recheck.
DTC 42-1 (GEARSHIFT SWITCH

CIRCUIT)
• Before starting the troubleshooting, check for loose

or poor contact of the following connectors, and
recheck the DTC (page 23-9).
– handlebar switch 14P (Gray)
– PCM 33P (Black and Gray)
1. Gearshift Switch Inspection
Check the gearshift switch status with the MCS data
list menu.
UP DOWN
"Up" ON 2.78 – 4.10 V 0.70 – 2.25 V
"Down" ON 0.70 – 2.25 V 2.78 – 4.10 V
Both ON 3.17 – 4.32 V 3.17 – 4.32 V
Both OFF 0 – 0.41 V 0 – 0.41 V
Is the gearshift switch status normal?
YES – Intermittent failure
2. Gearshift Switch Inspection at Handlebar Switch
Connector
Disconnect the handlebar switch 14P (Gray)
connector [1].
Check for continuity between the handlebar switch
side 14P (Gray) connector terminals while pushing W/Bu
the gearshift switch.
Connection: W/Y
With the upshift switch pushed: Br/W
Brown/white – White/blue
Brown/white – White/yellow
Br/W
NO – Faulty handlebar switch.
30-65
dummyhead
3. Gearshift Switch Inspection at PCM Connector
Connect the handlebar switch 14P (Gray) connector
and disconnect the PCM 33P connectors (page 4-
33).
PCM 33P (Black) connector [1] and PCM 33P A6 B3
(Gray) connector [2] terminals while pushing the
gearshift switch.
TOOL:
A16 B3
Connection:
With the upshift switch pushed:
B3 – A6
[1] [2]
B3 – A16
NO – Open circuit in the Brown/white, White/blue
or White/yellow wire between the switch
and PCM.
4. Recheck DTC
Connect the PCM 33P connectors.
Erase the DTC (page 4-6).
Check the shift operation and the DTC with the
MCS.
Is the DTC 42-1 indicated?
(page 4-33), and recheck.
NO – Intermittent failure.
DTC 51-1 (TR SENSOR LOW

VOLTAGE)
poor contact of the TR sensor 8P (Black) and PCM
33P connectors, and recheck the DTC.
2. TR Sensor Input Voltage Inspection
Disconnect the TR sensor 8P (Black) connector [1]
(page 30-70).
Measure the voltage at the wire harness side 8P
(Black) connector [1].
Connection: Brown/white (+) – Green/white (–)
G/W Br/W
Is the voltage within 4.75 – 5.25 V?
30-66
dummyhead
3. TR Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF. [1]
Disconnect the PCM 33P (Gray) connector (page 4-
33).
[2].
Br/W
TOOL:
Connection: B3 – Brown/white
B3
NO – Open circuit in the Brown/white wire
4. TR Sensor Ground Line Open Circuit Inspection
[2].
TOOL:
G/W
Connection: B2 – Green/white
NO – Open circuit in the Green/white wire
[2] B2 [1]
5. TR Sensor Signal Line Open Circuit Inspection

[1] [2]
Disconnect the PCM 33P (Black) connector (page
4-33).
33P (Black) connector [1] and 8P (Black) connector
[2].
TOOL:
Bu
Connection: A26 – Blue
A26
NO – Open circuit in the Blue wire
6. TR Sensor Output Line Short Circuit Inspection
8P (Black) connector [1] and ground. [1]
Connection: Blue – ground
YES – Short circuit in the Blue wire
NO – GO TO STEP 7. Bu
30-67
dummyhead
(page 30-70).
Connect the 8P (Black) connector and 33P (Black)
connector.
DTC 51-2 (TR SENSOR HIGH

VOLTAGE)
(page 30-70).

OFF)

poor contact on the neutral switch and PCM 33P
(Black) connector, and recheck the DTC.
1. DTC Recheck
2. Neutral Switch Line Open Circuit Inspection
[1] A17 [2]
Disconnect the PCM 33P (Black) connector and
PCM 33P (Black) connector [1] and neutral switch
connector [2] terminals.
Connection: A17 – Light green
TOOL: Lg
Test probe 07ZAJ-RDJA110
NO – Open circuit in the Light green wire
30-68
dummyhead
(page 30-71).
and recheck.

ON)
1. Neutral Switch Line Short Circuit Inspection
Disconnect the neutral switch connector.
Check for continuity between the neutral switch
connector terminal and ground.
Connection: Light green – Ground
YES – Short circuit in the Light green wire.
(page 30-71).
Connect the neutral switch connector.
and recheck.
DTC 57-1 (GEARSHIFT MECHANISM

MALFUNCTION)
See DTC 27-1 (page 30-64).
DTC 57-2 (GEAR POSITION

MALFUNCTION; JUMPS OUT OF
GEAR)
See DTC 27-1 (page 30-64).
30-69
dummyhead
SHIFT SPINDLE ANGLE SENSOR (FE
models)
REMOVAL
[2]
– two bolts [1]
– two collars [2]
– sensor cover [3]
– shift spindle angle sensor (page 23-21) [1]
[3]
INSTALLATION
[3] [1]
– shift spindle angle sensor (page 23-21)
– two collars [1]
– sensor cover [2]
– two bolts [3] [2]
• Install the sensor cover as shown.

[1]
[3]
[2]
TR SENSOR (FE models)

[1] [2]
– sensor cover (page 30-70)
30-70
dummyhead
Remove the harness band [1].
[1]
Release the harness crip [2].
– spindle angle sensor 3P (Gray) connector [3]
– neutral switch connector [4]
Remove the socket bolt [5] and TR sensor [6] from the
rear crankcase cover. [4]
[6]
[5]
[3] [2]
Coat a new O-ring [1] with engine oil and install it into
the TR sensor [2] groove.
Install the TR sensor by aligning the flat surface of the
sensor hole and shift drum end [3]. [1]
Install the socket bolts and tighten them.
TORQUE:
TR sensor mounting bolt:
12 N·m (1.2 kgf·m, 8.9 lbf·ft)
[2]
[3]
Align
NEUTRAL SWITCH (FE models)

[1]
Disconnect the neutral switch connector [1].
Remove the neutral switch [2] and washer [3].
• Replace the washer with a new one.
TORQUE: 13 N·m (1.3 kgf·m, 9.6 lbf·ft)

[2]/[3]
30-71
dummyhead
MEMO
dummytext
FM1 model
HORN SWITCH
ACCESSORY
Lg Lg P SOCKET
HORN ECM
Y
G STARTER
ALTERNATOR
W/Bl
W/Bl
STOP SIG SW
RELAY SWITCH
DL PER RLY
DL 4WD SW
DL PUL RLY
M-TXDRXD
JOINT CONNECTOR 2 JOINT CONNECTOR 1
DL FUSER
DL OP SW
BANK ANGLE
SEN VB1
DL MOM
DIODE DIODE
INH RLY
IACV 2B
IACV 1A
DL MOP
RR VSP
G
DL POS
DL POT
IACV2A
IACV1B
OR SW
Y Y
K-LINE
ST SENSOR R
O2HT
MAIN
GP R
GP N
IGN1
GP 2
GP 3
GP 1
GP 5
GP 4
JOINT
PRC
VCC
SCS
PCP
PG3
PG1
PG2
DL>4 4WD DL>4 OR
FAN
FLR
INU
TW
STOP MOP MOM ST
SG
PB
TH
LG
BA
O2
TA
POS POS ACT SW
W/Bl
JOINT DIODE REGULATOR
B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11
A-11
CONDENSOR
Lg/R
C-5
C-4
C-3
C-2
C-1
B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
3P
/RECTIFIER
O/W
Br/Y
G
33P Gr 33P Bl
Gr
Gr
24P 12P Bl 5P BATTERY
JOINT
O/W
O/W
4P Bl
Y/R
G/W
Y/Bl
Y/Bl
G/Y
G/Y
Bl/G
Y/R
W 12 V - 16 AH
Gr
Gr
Bu
Bu
O
O
Bu
ENGINE
Bu/Bl
Bl/Bu
Lb/W
Bu/Y
Bu/Y
Br/W
Br/W
Br/W
Gr/W
Lg/R
Y/Bu
Br
Br/R
G/W
W/G
G/Bl
G/Bl
Bl/G
P/G
R
V/W
Y/R
Br/W
Br/W
Br/W
G/O
Bl/R
Bl/R
Bl/R
Bl/R
Y/R
Bu
Bu
Bu
Lg
W/Bl
Br/R
Y
G
Y
GROUND ENGINE
O/W
Br/W
G/Y
G/Y
Y/R
Y/R
Y/Bl
Gr
O
Bu
Bu
Bu
2P
Y/Bu
GROUND
Gr/R
Bl/G
O/W
2P
Br/Y
Br/W
W/R
Bl/R
Bl/R
3P
Bl/Y
3P
Bl/R
Bl/R
Bl/R
Y/Bl
G/Y
Y/G
O/W
Y/R
Gr
G/Y
Lb
Gr
G
P
G
Gr Bl G
R
R
R
Y
Y
Y
G
R
R
G
STARTER
Y/R
G
MOTOR
R
R
R/Bl
MAIN 1
(40A)
IGNITION SWITCH R/Bl A
4P R/W
R/Bl B
BAT1 R R R/Y
BAT Bl Bl Bl C
Bl/R
BAT2 R/Bl R/Bl P D
DC P P Bl/Br
P E
R/Y
16P P F
8P Gr W/Bl
FUEL( + ) Y/W Y/W
FUEL( - ) G/Y G/Y
UART V P R/Y
COMBINATION SP P/G P/G R G
METER IGN Bl/R Bl/R

BATT R/Y R/Y
GND G G
FUSE BOX
A: FAN (20 A)
B: MAIN 2 (10 A)
C: IGN (20 A)
D: LIGHT (20 A)
ASSIST
HEADLIGHT Bu/Bl E: DIF (10 A)
G
(50W) F: ACC (20 A)
LEFT HANDLEBAR G: DIODE
SWITCH
IG Bl/W 8P G G/Y BRAKE/TAILLIGHT
STARTER/OVERRIDE/ ST Bu G
BAT3 Bl/Br Bl/W Br
LIGHTING/DIMMER/ BAT4 Bl/R Bu
ENGINE STOP SWITCH TL Br G/Y 3P
HI Bu/Bl Y/R
LO W Bl/Br Bl
REAR BRAKE LIGHT SWITCH G/Y

(LEVER SIDE) Bl/Br
Bl/R
FRONT BRAKE Y/R
INHIBITOR SWITCH Bl/Br
Br
G
Bu/Bl 3P
W
HEADLIGHT G
(12 V - 35/35W x 2)
Bu/Bl
W
G
ENGINE FRAME
GROUND GROUND
DL TO 4WD O O
DL TO BOTH Br Br
DL OP SW Bl/Y Bl/Y
GND G G
BACKWARD Bl/R Bl/R
2WD TO 4WD W W
FORWARD Bl Bl
PERMISSION Bl/G Bl/G
8P
DIFFERENTIAL LOCK O
SWITCH
G/W
Y/Bu
Bl/Bu
Gr/W
Y
Bl/R
Bl
Bl/Bu
Br/Y
Y/G
Bl/R
Bl/R
Bu/Y
G
Bl/G
G/W
G/W
Gr
Lg
R/W
Lg/R
O
Bl/Br
G/W
W/R
P/G
G/Y
G/O
2P
G
Bl/Bu
Bl/Bu
Bl/Bu
Bl/Bu
Gr
4P
Br/W
Br/W
Y
Bl/R
Bl/R
R/Bl
Bl/R
Bl/W
R/Y
R/Y
Bu/Y
Y/R
Gr
Bu
G/Bl
Bl
Br
G/Y
O
Bu
Gr
R
G/W
G/W
G/W
W
Lb
Bu/Bl
Bl
Gr
Br/W
Lb/W
W/G
G/Bl
8P
Y/W
Bl/R
2P
Br
Bu
Bl/R
G
Y/R
G/Y
G
G
G
G
G
G
5P
G
G
G
G
G
Bl/Bu
Bl/Bu
Bl/Bu
Bl
Y/Bu
Lg/R
Gr/R
Br/W
Bl/R
Bl/R
Bl/R
O/W
R/Y
V/W
Y/Bl
3P
Y/R
Bu
Bu
Bu
Br/Y
Bl/G
O/W
Bl
Y/Bl
G/W
G/W
G/W
G
Bl
G
2P 2P 8P Bl 2P
G
G
G
G
G
G
4P 2P
G
G
G
G
G
G
Bl
Bu
Bl ECT Gr Bl Gr
Bu/Y
Bl
Lg/R
W/R
SENSOR
Gr
P
10P
Y
G
IACV
Gr
W
G/Y
Lb/W
W/G
Bl/W
4P
Bu
W
Bl
IAT SENSOR
G
Bu
Gr
Lb
W
Gr
JOINT JOINT JOINT JOINT
COOLING FAN FRAME GROUND
SNSR GND( - )
HEATER( + )
HEATER( - )
SNSR SIG( + )
REAR BRAKE MOTOR MAP

5 4 ENGINE
Br
Bl
G
O
3
LIGHT SWITCH 2 GROUND CKP
PERMISSION PULL BACK A SENSOR R N1 SENSOR
RELAY RELAY (PEDAL SIDE)
FUEL PUMP
DL MOP
DL POT
DL TO 4WD
4WD
4WD TO BOTH
2WD TO 4WD
DL MOM
DL POS
GND
FAIL-SAFE MAIN FUEL PUMP TP SENSOR FUEL INJECTOR

PULL BACK B RELAY RELAY RELAY UNIT
RELAY O2 VS SENSOR
DIFFLOCK DRIVE DIFFLOCK DRIVE OVERRIDE SENSOR FUEL FUEL SENSOR UNIT IGNITION COIL
A RELAY B RELAY INHIBITOR PUMP LEVEL GEAR POSITION
RELAY SENSOR SWITCH
SWITCH CONTINUITY DIFFLOCK ACTUATOR
REAR BRAKE REAR BRAKE

IGNITION LIGHTING DIMMER ENGINE STOP STARTER/OVERRIDE FRONT BRAKE LIGHT SWITCH LIGHT SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH INHIBITOR SWITCH (LEVER SIDE) (PEDAL SIDE)
STOP STOP STOP
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V LAMP 12V LAMP 12V LAMP Bl Black O Orange
ON ON LO OFF FREE FREE FREE FREE
Br Brown P Pink
Bu Blue R Red
OFF OFF (N) RUN PUSH PUSH PUSH PULL
G Green V Violet
COLOR R/Bl P R Bl COLOR Bl/Br Br HI COLOR Bl/R Bl/W COLOR Bl/W Bu COLOR Bl/Br Y/R COLOR Bl/Br G/Y COLOR Bl G/Y Gr Gray W White
COLOR W Bu/Bl Lb Light Blue Y Yellow
Lg Light Green
30-73
dummytext
FE1 model
HORN SWITCH
ACCESSORY
Lg Lg P SOCKET PCM/ECM
HORN
STOP_LAMP_SW
Y
G STARTER
ALTERNATOR
W/Bl
W/Bl
RVS HDLE SW
DIFF PER RLY

STOP SIG SW
DIFF PUL RLY

PVB+SUB VB
RELAY SWITCH
DIFF OP SW
DRUM POS
SFT DOWN
DIFF MOM
DIFF MOP
DIFF ENG
BANK ANGLE
DIFF POT
DIFF FSR
DIODE DIODE
INH RLY
IACV 2B
IACV 1A
RR VSP
SEN VB
G
IACV2A
IACV1B
SFT UP
OR SW
ANGLE
Y Y
K-LINE
R
M-TXD
SENSOR
SMOM
SMOP
ST
O2HT
MAIN
DP N
JOINT R
PRC
VCC
SCS
PCP
PG3
PG1
PG2
DL>4 4WD DL>4 K- OR
FAN
FLR
INU
TW
VSP MOP MOM STOP LINE SCS ST
SG
R
PB
TH
LG
BA
O2
TA
POS POS ACT SW
IG
W/Bl
JOINT REGULATOR
B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11
A-11
CONDENSOR
Lg/R
C-5
C-4
C-3
C-2
C-1
B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
3P
/RECTIFIER
O/W
Br/Y
G
DIODE 33P Gr 33P Bl
Gr
Gr
JOINT
P/G
O/W
O/W
O/W
Br/R
4P Bl
Y/R
G/W
Y/Bl
Y/Bl
G/Y
G/Y
Bl/G
Y/R
W W 12 V - 16 AH
Gr
Gr
Bu
Bu
O
O
Bu
ENGINE
Lg/R
W/Bu
Bu/Bl
Bl/Bu
Bu/Y
Bu/Y
Br/W
Gr/W
Y/Bu
Br
Br/R
G/W
G/Bl
G/Bl
Bl/G
P/G
R
V/W
Y/R
Br/W
Br/W
Br/W
G/O
Bl/R
Bl/R
Bl/R
Bl/R
Bu
Bu
Lg
W/Bl
W/R
Br/R
G
R
G
Y
GROUND ENGINE
P/G
P/G
Br/R
O/W
O/W
Br/W
G/Y
G/Y
Y/R
Y/R
Y/Bl
Gr
O
Bu
Bu
Bu
2P
Y/Bu
GROUND
R/W
Bl/G
O/W
2P
Br/Y
Br/W
Y/R
Bl/R
G/Y
W/Y
Bl/R
3P
Bl/Y
3P
Bl/R
Bl/R
Bl/R
Y/Bl
G/Y
Y/G
Gr/R
O/W
Y/R
Gr
G/Y
Bl
Bu
Lb
G
P
Br/W
Br/W
Br/W
G
Gr Bl G
R
R
R
Y
Y
Y
G
EPS FUSE
R
R
R
(40A)
G
STARTER
Y/R
MOTOR
R
R
R/Bl
MAIN 1
(40A)
IGNITION SWITCH R A
4P R/W
R/Bl B
BAT1 R R R/Y
BAT Bl Bl Bl C
Bl/R
BAT2 R/Bl R/Bl P D
DC P P Bl/Br
P E
R/Y
16P P F
8P Gr W/Bl
FUEL( + ) Y/W Y/W
FUEL( - ) G/Y G/Y
UART P P R/Y
METER IGN Bl/R Bl/R

BATT R/Y R/Y
GND G G
FUSE BOX
A: ES (30 A)
B: MAIN 2 (10 A)
C: IGN (20 A)
D: LIGHT (20 A)
ASSIST
G
(50W) F: ACC (20 A)
SWITCH IG Bl/W
ST Bu
BAT3 Bl/Br 14P G G/Y BRAKE/TAILLIGHT
STARTER/OVERRIDE/ BAT4 Bl/R G
TL Br Bl/W Br
LIGHTING/DIMMER/ HI Bu/Bl Bu
ENGINE STOP SWITCH LO W G/Y 3P
Y/R
Bl/Br Bl
VCC Br/W Br/W
GEAR SHIFT S/D Lg/Y W/Y
VCC Br/W
SWITCH S/U G/Bl W/Bu
REVERSE SWITCH VCC Br/W
RVS G/W W/R
Bl/Br
(LEVER SIDE) Bl/R
FRONT BRAKE Y/R
Bl/Br
INHIBITOR SWITCH Br
G
Bu/Bl 3P
W
HEADLIGHT G
(12 V - 35/35W x 2)
Bu/Bl
W
G
ENGINE FRAME
GROUND GROUND
DL TO 4WD O O
DL TO BOTH Br Br
DL OP SW Bl/Y Bl/Y
GND G G
BACKWARD Bl/R Bl/R
2WD TO 4WD W W
FORWARD Bl Bl
8P
DIFFERENTIAL LOCK O
SWITCH
G/W
Y/Bu
Lg/R
Bl/Bu
Gr/W
Y
Bl/R
Bu
Bl
G/Y
Bl/Bu
Br/W
Br/W
Br/Y
G/W
Y/G
Bl/R
Bl/R
Bu/Y
G
Bl/G
8P
G/W
G/W
Gr
Lg
R/W
O
Bl/Br
G/W
P/G
G/Y
G/O
2P Bl
G
Bl/Bu
Bl/Bu
Bl/Bu
Bl/Bu
4P
Br/W
Br/W
Bl/R
Bl/R
R/Bl
Bl/R
Bl/W
R/Y
R/Y
Bu/Y
Y/R
Gr
Bu
G/Bl
Bl
Br
G/Y
O
Bu
Gr
R
G/W
G/W
G/W
G/W
W
Lb
Bu/Bl
Bl
Gr
Br/W
G/Bl
8P Y/W
Bl/R
Br
Bl/R
G
2P
Y/R
G/Y
G
G
G
G
G
G
G
G
G
G
G
Bl/Bu
Bl/Bu
Bl/Bu
Y/Bu
Gr/R
Bl/R
Bl/R
Bl/R
O/W
Lg/R
Br/W
R/Y
V/W
Y/Bl
Bl
Br/W
Y/R
Bu
Bu
Bu
G/R
Br/Y
Bl/G
5P
O/W
Bl
Y/Bl
G/W
G/W
G/W
G/W
Bu
G
Bl
2P 2P 2P
G
G
G
G
G
G
4P
G
G
G
G
G
Bl
Bu ECT 3P 2P
R
Bl
G/W
Bu/Y
Bl
2P
G/Y
Br
SENSOR Bl
P
10P
Lg
Gr
W
G
IACV Bl
G/Y
Gr
Bl/W
W
Bl
4P IAT SENSOR
G
Bu
Gr
Lb
W
Gr
GND
VCC
SNSR GND( - )
HEATER( + )
HEATER( - )
SNSR SIG( + )
COOLING FAN FRAME

MAP
Br
GROUND
Bl
G
O
REAR BRAKE MOTOR CKP

PERMISSION PULL BACK A LIGHT SWITCH SENSOR SHIFT SENSOR
RELAY RELAY (PEDAL SIDE) CONTROL
OUT
GND
VCC
FUEL PUMP MOTOR
DL MOP
DL POT
DL TO 4WD
4WD
4WD TO BOTH
2WD TO 4WD
DL MOM
DL POS
GND

RELAY O2
PUMP LEVEL TR SENSOR
A RELAY B RELAY INHIBITOR
RELAY SENSOR
NEUTRAL
REAR BRAKE SWITCH
REAR BRAKE
LIGHTING DIMMER ENGINE STOP STARTER/OVERRIDE GEAR SHIFT REVERSE FRONT BRAKE LIGHT SWITCH LIGHT SWITCH SHIFT
IGNITION SPINDLE
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH INHIBITOR SWITCH (LEVER SIDE) (PEDAL SIDE) ANGLE
STOP STOP STOP SENSOR VS SENSOR
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D RVS VCC 12V LAMP 12V LAMP 12V LAMP Bl Black O Orange
ON ON LO OFF FREE UP FREE FREE FREE FREE
Br Brown P Pink
Bu Blue R Red
OFF OFF (N) RUN PUSH DOWN PUSH PUSH PUSH PULL
G Green V Violet
COLOR R/Bl P R Bl COLOR Bl/Br Br HI COLOR Bl/R Bl/W COLOR Bl/W Bu COLOR G/Bl Br/W Lg/Y COLOR G/W Br/W COLOR Bl/Br Y/R COLOR Bl/Br G/Y COLOR Bl G/Y Gr Gray W White
Lg Light Green
30-74
dummytext
FM2 model/FM6 model
HORN SWITCH
ACCESSORY
Lg Lg P SOCKET
HORN ECM
Y
G ALTERNATOR STARTER
W/Bl
STOP SIG SW
W/Bl
EPS ECU RELAY SWITCH
DL PER RLY
DL 4WD SW
DL PUL RLY
M-TXDRXD
DL FUSER
DL OP SW
TORQUE
SEN VB1
EPS
DL MOM
DIODE DIODE
INH RLY
IACV-2A
IACV-2B
IACV-1A
IACV-1B
M( + )
DL MOP
M( - )
RR VSP
DL POS
DL POT
BANK ANGLE
NEP
VSP
G
PG
+B
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE
EPS IND
4WD IND1
TACHO
OR SW
Y Y
K-LINE
SENSOR ST R
O2HT
MOTOR
MAIN
GP R
GP N
IGN1
GP 2
GP 3
GP 1
GP 5
GP 4
JOINT
PRC
VCC
SCS
PCP
DL>4 4WD DL>4 K- SENSOR
PG3
PG1
PG2
OR
FAN
FLR
INU
TW
STOP VSP MOP MOM LINE SCS ST
SG
R
PB
TH
LG
BA
O2
TA
POS POS ACT SW
JOINT
W/Bl
DIODE
T/S GND
REGULATOR
B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11
A-11
CONDENSOR
Lg/R
C-5
C-4
C-3
C-2
C-1
B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
/RECTIFIER
VS2
VS1
O/W
Br/Y
2P 21P
Bl
2P
G
R
33P Gr 33P Bl
Gr
Gr
24P 12P 3P 5P BATTERY
Gr JOINT
P/G
P/G
O/W
O/W
O/W
Br/R
Br/R
3P 4P Bl
Y/R
Y/Bl
Y/Bl
G/Y
G/Y
Bl
Y/R
W 12 V - 16 AH
Gr
Gr
Br/W
Bu
Bu
O
O
Bu
W/R
G/O
O/W
Bl/R
P/G
ENGINE
Bu/Bl
Bl/Bu
Bu/Bl
Bu
Bl
Lb/W
Bu/Y
Bu/Y
G/W
Br/W
2P
Br/W
Gr/W
Lg/R
Bl/G
Y/Bu
Br
Br/R
G/W
W/G
G/Bl
G/Bl
Bl/G
P/G
R
V/W
Y/R
Br/W
Br/W
Br/W
G/O
Bl/R
Bl/R
Bl/R
Bl/R
Bu
Y/R
Bu
Bu
Bu
Lg
W/Bl
Br/R
Y
G
Y
GROUND ENGINE
P/G
P/G
Br/R
O/W
O/W
O/W
G/O
Y/R
G/Y
G/Y
Y/R
Y/R
Y/Bl
Gr
O
Bu
Bu
Bu
W/Bu
Bu/Bl
2P
Br/W
Y/Bu
Br/R
GROUND
Gr/R
Y/G
Y/R
Bl/G
O/W
2P
Bl
Br/Y
Br/W
W/R
Bl/R
G
Bl/R
3P
Bl/Y
3P
Bl/R
Bl/R
Bl/R
Bl/R
Y/Bl
G/Y
Y/G
O/W
Y/R
Gr
G/Y
Lb
Gr
G
P
G
G
W/Bu Gr Bl G
R
R
R
Y
Y
Y
G
EPS FUSE
R
R
R
(40A)
G
STARTER
Y/R
MOTOR
R
W/R
R
R/Bl
MAIN 1
(40A)
IGNITION SWITCH R/Bl A
4P R/W
R/Bl B
BAT1 R R R/Y
BAT Bl Bl Bl C
Bl/R
BAT2 R/Bl R/Bl P D
DC P P Bl/Br
P E
R/Y
16P P F
8P Gr W/Bl
FUEL( + ) Y/W Y/W
FUEL( - ) G/Y G/Y
UART P P R/Y
METER EPS Y/G Y/G

IGN Bl/R Bl/R
BATT R/Y R/Y
GND G G
FUSE BOX
A: FAN (20 A)
B: MAIN 2 (10 A)
C: IGN (20 A)
D: LIGHT (20 A)
ASSIST
G
(50W) F: ACC (20 A)
LEFT HANDLEBAR 8P G: DIODE
SWITCH FM2:G
IG Bl/W FM6:Gr G/Y BRAKE/TAILLIGHT
STARTER/OVERRIDE/ ST Bu G
BAT3 Bl/Br Bl/W Br
LIGHTING/DIMMER/ BAT4 Bl/R Bu
ENGINE STOP SWITCH TL Br G/Y 3P
HI Bu/Bl Y/R
LO W Bl/Br Bl

(LEVER SIDE) Bl/Br
Bl/R
FRONT BRAKE Y/R
INHIBITOR SWITCH Bl/Br
Br
G
Bu/Bl 3P
W
HEADLIGHT G
(12 V - 35/35W x 2)
Bu/Bl
W
G
ENGINE FRAME
GROUND GROUND
DL TO 4WD O O
DL TO BOTH Br Br
DL OP SW Bl/Y Bl/Y
GND G G
BACKWARD Bl/R Bl/R
2WD TO 4WD W W
FORWARD Bl Bl
8P
DIFFERENTIAL LOCK O
SWITCH
G/W
Y/Bu
Bl/Bu
Gr/W
Y
Bl/R
Bl
Bl/Bu
Br/Y
Y/G
Bl/R
Bl/R
Bu/Y
G
Bl/G
G/W
G/W
Gr
Lg
R/W
Lg/R
O
Bl/Br
G/W
W/R
P/G
Bl/R
G/Y
G/O
G
Bl/Bu
Bl/Bu
Bl/Bu
Bl/Bu
Gr
2P 4P
Br/W
Y
Bl/R
Bl/R
R/Bl
Bl/R
Bl/W
Br/W
R/Y
R/Y
Bu/Y
Y/R
Gr
Bu
G/Bl
Bl
Br
G/Y
O
W
Bu
Gr
R
G/W
G/W
G/W
Lb
Bu/Bl
Bl
Gr
Br/W
Lb/W
W/G
G/Bl
Y/W
Bl/R
8P
Br
Bu
G/Y
Bl/R
G
Y/R
G/Y
2P
G
G
G
G
G
G
5P
G
G
G
G
G
Bl/Bu
Bl/Bu
Bl/Bu
Y/Bu
Gr/R
Bl/R
Bl/R
Bl/R
O/W
R/Y
Lg/R
Br/W
V/W
Y/Bl
Y/R
Bu
Bu
Bu
Bl
Br/Y
Bl/G
O/W
Bl
Y/Bl
G/W
G/W
G/W
G
Bl
G
2P 2P 2P 8P 3P 2P
G
G
G
G
G
G
2P
G
G
G
G
G
G
4P
Bu
Bl Bl ECT Bl Gr
Bu/Y
Bl
Bl
Bl
Lg/R
W/R
SENSOR
Gr
P
10P
Gr
Y
W
G
IACV
G/Y
G/Y
Lb/W
W/G
Bl/W
W
Bl
Bu
4P IAT SENSOR
G
Bu
Gr
Lb
W
Gr
SNSR GND( - )
HEATER( + )
HEATER( - )
SNSR SIG( + )

MOTOR MAP
5 4 ENGINE
Br
Bl
G
O
3
GROUND CKP
PERMISSION PULL BACK A FM6: SENSOR
2
SENSOR
R N1
RELAY RELAY REAR BRAKE
LIGHT SWITCH FUEL PUMP
DL MOP
DL POT
DL TO 4WD
4WD
4WD TO BOTH
2WD TO 4WD
DL MOM
DL POS
GND

PULL BACK B RELAY RELAY RELAY (PEDAL SIDE) UNIT
RELAY O2 VS SENSOR
FM2: PUMP LEVEL
A RELAY B RELAY INHIBITOR REAR BRAKE GEAR POSITION
RELAY SENSOR SWITCH
LIGHT SWITCH
SWITCH CONTINUITY DIFFLOCK ACTUATOR (PEDAL SIDE)
REAR BRAKE REAR BRAKE

IGNITION LIGHTING DIMMER ENGINE STOP STARTER/OVERRIDE FRONT BRAKE LIGHT SWITCH LIGHT SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH INHIBITOR SWITCH (LEVER SIDE) (PEDAL SIDE)
STOP STOP STOP
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V LAMP 12V LAMP 12V LAMP Bl Black O Orange
ON ON LO OFF FREE FREE FREE FREE
Br Brown P Pink
Bu Blue R Red
OFF OFF (N) RUN PUSH PUSH PUSH PULL
G Green V Violet
COLOR R/Bl P R Bl COLOR Bl/Br Br HI COLOR Bl/R Bl/W COLOR Bl/W Bu COLOR Bl/Br Y/R COLOR Bl/Br G/Y COLOR Bl G/Y Gr Gray W White
Lg Light Green
30-75
dummytext
FE2 model
HORN SWITCH
ACCESSORY
Lg Lg P SOCKET
HORN PCM/ECM
STOP_LAMP_SW
Y
G STARTER
ALTERNATOR
W/Bl
W/Bl
RVS HDLE SW
DIFF PER RLY

STOP SIG SW
DIFF PUL RLY

PVB+SUB VB
RELAY SWITCH
DIFF OP SW
EPS ECU
DRUM POS
SFT DOWN
DIFF MOM
DIFF MOP
DIFF 4WD
DIFF ENG
TORQUE BANK ANGLE
DIFF POT
DIFF FSR
EPS DIODE DIODE
INH RLY
IACV 2B
IACV 1A
M( + )
M( - )
RR VSP
SEN VB
IACV2A
IACV1B
SFT UP
NEP
VSP
PG
+B
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE
EPS IND
4WD IND1
TACHO
ANGLE
OR SW
Y Y
K-LINE
R
M-TXD
SENSOR SENSOR
SMOM
SMOP
ST
O2HT
MOTOR
MAIN
DP N
JOINT R
PRC
VCC
SCS
PCP
PG3
PG1
PG2
DL>4 4WD DL>4 K- OR
FAN
FLR
INU
TW
SG
R
PB
TH
LG
BA
O2
TA
POS POS ACT SW
IG
W/Bl
JOINT
T/S GND
REGULATOR
B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11
A-11
CONDENSOR
Lg/R
C-5
C-4
C-3
C-2
C-1
B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
/RECTIFIER
VS2
VS1
3P
O/W
Br/Y
G
2P 21P
Bl
2P DIODE
R
33P Gr 33P Bl
Gr
Gr
Gr JOINT
P/G
P/G
O/W
O/W
O/W
Br/R
Br/R
3P 4P Bl
Y/R
G/W
Y/Bl
Y/Bl
G/Y
G/Y
Bl/G
Y/R
W 12 V - 16 AH
Gr
Gr
Br/W
Bu
Bu
O
O
Bu
W/R
G/O
O/W
Bl/R
P/G
ENGINE
Lg/R
W/Bu
Bu/Bl
Bl/Bu
Bu/Bl
Bu
Bu
Bl
Bu/Y
Bu/Y
Br/W
2P
Br/W
Gr/W
Y/Bu
Br
Br/R
G/W
G/Bl
G/Bl
Bl/G
P/G
R
V/W
Y/R
Br/W
Br/W
Br/W
Gr
G/O
Bl/R
Bl/R
Bl/R
Bl/R
Bu
Bu
Lg
W/Bl
W/R
Br/R
G
R
G
Y
GROUND ENGINE
P/G
P/G
Br/R
O/W
O/W
O/W
G/O
Y/R
Br/W
G/Y
G/Y
Y/R
Y/R
Y/Bl
Gr
O
Bu
Bu
Bu
W/Bu
Bu/Bl
2P
Y/Bu
Br/R
GROUND
Y/G
Y/R
R/W
Bl/G
O/W
2P
Bl
Br/Y
Br/W
Y/R
Bl/R
G
W/Y
Bl/R
3P
Bl/Y
3P
R
Bl/R
Bl/R
Bl/R
Bl/R
G/Y
Y/Bl
G/Y
Y/G
Gr/R
O/W
Y/R
Gr
G/Y
Bl
Bu
Lb
G
P
Br/W
Br/W
Br/W
G
Gr Bl G
W/Bu
R
R
R
Y
Y
Y
G
EPS FUSE
R
R
R
(40A)
G
STARTER
Y/R
MOTOR
R
W/R
R
R/Bl
MAIN 1
(40A)
IGNITION SWITCH R A
4P R/W
R/Bl B
BAT1 R R R/Y
BAT Bl Bl Bl C
Bl/R
BAT2 R/Bl R/Bl P D
DC P P Bl/Br
P E
R/Y
16P P F
8P Gr W/Bl
FUEL( + ) Y/W Y/W
FUEL( - ) G/Y G/Y
UART P P R/Y
METER EPS Y/G Y/G

IGN Bl/R Bl/R
BATT R/Y R/Y
GND G G
FUSE BOX
A: ES (30 A)
B: MAIN 2 (10 A)
C: IGN (20 A)
D: LIGHT (20 A)
ASSIST
G
(50W) F: ACC (20 A)
SWITCH IG Bl/W
ST Bu
BAT3 Bl/Br 14P G G/Y BRAKE/TAILLIGHT
STARTER/OVERRIDE/ BAT4 Bl/R G
TL Br Bl/W Br
LIGHTING/DIMMER/ HI Bu/Bl Bu
ENGINE STOP SWITCH LO W G/Y 3P
Y/R
Bl/Br Bl
VCC Br/W Br/W
GEAR SHIFT S/D Lg/Y W/Y
VCC Br/W
REVERSE SWITCH VCC Br/W
RVS G/W W/R
Bl/Br
(LEVER SIDE) Bl/R
FRONT BRAKE Y/R
Bl/Br
INHIBITOR SWITCH Br
G
Bu/Bl 3P
W
HEADLIGHT G
(12 V - 35/35W x 2)
Bu/Bl
W
G
ENGINE FRAME
GROUND GROUND
DL TO 4WD O O
DL TO BOTH Br Br
DL OP SW Bl/Y Bl/Y
GND G G
BACKWARD Bl/R Bl/R
2WD TO 4WD W W
FORWARD Bl Bl
8P
DIFFERENTIAL LOCK O
SWITCH
G/W
Y/Bu
Lg/R
Bl/Bu
Gr/W
Y
Bl/R
Bu
Bl
G/Y
Bl/Bu
Br/W
Br/W
Br/Y
G/W
Y/G
Bl/R
Bl/R
Bu/Y
G
Bl/G
8P
G/W
G/W
Gr
Lg
R/W
O
Bl/Br
G/W
P/G
2P
G/Y
G/O
Bl
G
Bl/Bu
Bl/Bu
Bl/Bu
Bl/Bu
4P
Br/W
Br/W
Bl/R
Bl/R
R/Bl
Bl/R
Bl/W
R/Y
R/Y
Bu/Y
Y/R
Gr
Bu
G/Bl
Bl
Br
G/Y
O
Bu
Gr
R
G/W
G/W
G/W
G/W
W
Lb
Bu/Bl
Bl
Gr
Br/W
G/Bl
8P Y/W
Bl/R
Br
Bl/R
G
2P
Y/R
G/Y
G
G
G
G
G
G
G
G
G
G
G
Bl/Bu
Bl/Bu
Bl/Bu
Y/Bu
Gr/R
Bl/R
Bl/R
Bl/R
O/W
Lg/R
Br/W
R/Y
V/W
Y/Bl
Bl
Br/W
Y/R
Bu
Bu
Bu
G/R
Br/Y
Bl/G
5P
O/W
Bl
Y/Bl
G/W
G/W
G/W
G/W
Bu
G
Bl
2P 2P 2P
G
G
G
G
G
G
4P
G
G
G
G
G
G
Bl Bu 3P 2P
ECT
R
Bl
G/W
Bu/Y
Bl
2P
G/Y
Br
SENSOR Bl
P
10P
Lg
Gr
W
G
IACV Bl
G/Y
Gr
Bl/W
W
Bl
4P IAT SENSOR
G
Bu
Gr
Lb
W
Gr
GND
VCC
SNSR GND( - )
HEATER( + )
HEATER( - )
SNSR SIG( + )

MAP
Br
Bl
G
O
REAR BRAKE MOTOR CKP

PERMISSION PULL BACK A LIGHT SWITCH SENSOR SHIFT SENSOR
RELAY RELAY (PEDAL SIDE) CONTROL
OUT
GND
VCC
FUEL PUMP MOTOR
DL MOP
DL POT
DL TO 4WD
4WD
4WD TO BOTH
2WD TO 4WD
DL MOM
DL POS
GND

RELAY O2
PUMP LEVEL TR SENSOR
A RELAY B RELAY INHIBITOR
RELAY SENSOR
NEUTRAL
REAR BRAKE SWITCH
REAR BRAKE
LIGHTING DIMMER ENGINE STOP STARTER/OVERRIDE GEAR SHIFT REVERSE FRONT BRAKE LIGHT SWITCH LIGHT SWITCH SHIFT
IGNITION SPINDLE
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH INHIBITOR SWITCH (LEVER SIDE) (PEDAL SIDE) ANGLE
STOP STOP STOP SENSOR VS SENSOR
Br Brown P Pink
Bu Blue R Red
G Green V Violet
Lg Light Green
30-76
dummytext
FA6 model/FA7 model
HORN SWITCH ACCESSORY SOCKET
PCM
Lg Lg P
2 POS SUB TRANS D

2 POS SUB TRANS L
HORN
Y
G ALTERNATOR STARTER
STOPLAMP SW
W/Bl
W/Bl
RVS HDLE SW
DIFF PER RLY

STOP SIG SW
DIFF PUL RLY

PVB+SUB VB
RELAY SWITCH
DIFF OP SW
EPS ECU
SFT DOWN
DIFF MOM
DIFF MOP
SFTSOL A
DIFF 4WD
AT ES SW
DIFF ENG
TORQUE BANK ANGLE
DIFF POT
DIFF FSR
EPS DIODE DIODE
INH RLY
IACV 2B
IACV 1A
M( + )
M( - )
RR VSP
SEN VB
G
LSOL M
FR VSP
IACV2A
IACV1B
SFT UP
NEP
VSP
PG
+B
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE
EPS IND
4WD IND1
LSOL P
TACHO
OR SW
ANGLE
Y Y
K-LINE
R
M-TXD
SENSOR SENSOR
SMOM
SMOP
ST
O2HT
MOTOR
MAIN
DP N
JOINT R
PRC
VCC
SCS
PCP
PG3
PG1
PG2
DL>4 4WD DL>4 K- OR
FAN
FLR
INU
TW
SG
DP
TO
R
PB
TH
LG
BA
O2
TA
POS POS ACT SW
IG
W/Bl
JOINT DIODE
T/S GND
REGULATOR
B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11
A-11
CONDENSOR
Lg/R
C-5
C-4
C-3
C-2
C-1
A-2
B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-1
/RECTIFIER
VS2
VS1
3P
O/W
Br/Y
2P 21P
Bl
2P
G
R
33P Gr 33P Bl
Gr
Gr
24P 12P 5P BATTERY
Gr JOINT
P/G
O/W
O/W
O/W
Br/R
Br/R
P/G
3P 4P Bl
Y/R
G/W
Y/Bl
Y/Bl
G/Y
G/Y
Bl/G
Y/R
W 12 V - 16 AH
Gr
Gr
Br/W
Bu
Bu
O
O
Bu
W/R
G/O
O/W
Bl/R
P/G
ENGINE
W/Bu
Bu/Bl
Bl/Bu
Bu/Bl
Bu
Bu
Bl
Bu/Y
Bu/Y
Br/Bl
Br/W
2P
Br/W
Gr/W
Bl/W
Y/Bu
W/Y
Br
Br/R
G/W
G/Bl
G/Bl
Bl/G
P/G
R
V/W
Y/R
Br/W
Br/W
Br/W
Br/W
G/Y
Gr
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Y/R
Y/R
Bu
Bu
Lg
W/Bl
Br/R
G
R
G
Bu
Y
GROUND ENGINE
P/G
P/G
Br/R
O/W
O/W
O/W
G/O
Y/R
Br/W
G/Y
G/Y
Y/R
Y/R
Y/Bl
Gr
O
Bu
Bu
Bu
W/Bu
Bu/Bl
2P
Y/Bu
Bu/Y
Br/R
GROUND
Gr/R
Y/G
Lg/R
Y/R
R/W
Bl/G
O/W
2P
Bl
W/R
Br/Y
Br/W
Br/W
G/Y
G/O
Bl/R
G
W/Y
Bl/R
3P
Bl/Y
Bl/Y
3P
Bl/R
Bl/R
Bl/R
Bl/R
Y/Bl
G/Y
Y/G
O/W
Gr
Bl
G/Y
Bl
Lb
G
P
Br/W
Br/W
G
Gr Bl G
W/Bu
R
R
R
Y
Y
Y
G
EPS FUSE
R
R
R
(40A)
G
STARTER
Y/R
MOTOR
R
W/R
DRIVE MODE SELECT SWITCH 2P R

R/Bl
Bl
Bl/G Bl/R MAIN 1
Br/Bl Br/Bl (40A)
IGNITION SWITCH R A
4P R/W
R/Bl B
BAT1 R R R/Y
BAT Bl Bl Bl C
Bl/R
BAT2 R/Bl R/Bl P D
DC P P Bl/Br
P E
R/Y
16P P F
8P Gr W/Bl
FUEL( + ) Y/W Y/W
FUEL( - ) G/Y G/Y
UART P P R/Y
METER EPS Y/G Y/G

IGN Bl/R Bl/R
BATT R/Y R/Y
GND G G FUSE BOX
A: ES (30 A)
B: MAIN 2 (10 A)
C: IGN (20 A)
D: LIGHT (20 A)
ASSIST E: DIF (10 A)
HEADLIGHT Bu/Bl
G F: ACC (20 A)
(50W)
G: DIODE
LEFT HANDLEBAR
SWITCH IG Bl/W
ST Bu
BAT3 Bl/Br 14P G
STARTER/OVERRIDE/ BAT4 Bl/R
TL Br Bl/W
LIGHTING/DIMMER/ HI Bu/Bl Bu G/Y
W G/Y G
ENGINE STOP SWITCH LO
Y/R Br
Bl/Br
VCC Br/W Br/W 3P
GEAR SHIFT S/D Lg/Y W/Y Bl
VCC Br/W
REVERSE SWITCH VCC Br/W BRAKE/TAILLIGHT
RVS G/W W/R
Bl/Br
(LEVER SIDE) Bl/R
FRONT BRAKE Y/R
Bl/Br
INHIBITOR SWITCH Br
G
Bu/Bl 3P
W
HEADLIGHT G
(12 V - 35/35W x 2)
Bu/Bl
W
G
ENGINE FRAME
GROUND GROUND
DL TO 4WD O O
DL TO BOTH Br Br
DL OP SW Bl/Y Bl/Y
GND G G
BACKWARD Bl/R Bl/R
2WD TO 4WD W W
FORWARD Bl Bl
8P
DIFFERENTIAL LOCK O
SWITCH
P/G
G/W
Y/Bu
Bl/Bu
Gr/W
G/W
Bl/R
Bu
Bl/W
W
Bl
Bl
G/Y
Bl/Bu
Bl/R
Br/W
G
Br/W
Br/Y
Bu/Y
G/W
Y/G
Bl/R
Bl/R
W/Y
Bu/Y
G
Bl/G
8P
G/W
G/W
Gr
Lg
R/W
O
Bl/Br
G/W
G/Y
G/O
2P Bl
G
Bl/Bu
Bl/Bu
Bl/Bu
Bl/Bu
4P
Br/W
3P
Br/W
Bl/R
Bl/R
R/Bl
Bl/R
Bl/W
R/Y
R/Y
Bl/Y
Bu/Y
G
Y/R
Gr
Bu
G/Bl
Bl
Br
G/Y
O
Bu
Gr
R
G/W
G/W
G/W
G/W
W
Lb
Bu/Bl
Bl Bl
W
Gr
Bl
Br/W
G/Bl
Y/W
8P
Br
Bl/R
Y/R
G/Y
2P
G
G
G
G
G
G
G
Br/W
2P
Bl/R
P
5P 2P
G
G
G
G
G
IGNITION
Bl/Bu
Bl/Bu
Bl/Bu
Y/Bu
Gr/R
Bl/R
Bl/R
Bl/R
O/W
Lg/R
Br/W
R/Y
V/W
Y/Bl
Br/W
Y/R
Bl
Bu
Bu
Bu
Br/Y
Bl/G
G/R
O/W
Bl
Bl
Y/Bl
Bu
G
Bl COIL Bl
G
Bl
2P
G/W
G/W
G/W
G/W
G/W
2P
W/G
2P
G
G
G
G
G
G
4P 2P
G
G
G
G
G
G
G
3P Bl
Bu
ECT Gr
R
Bl Bl
Lg
G/W
Bu/Y
Bl 2P
G/Y
Br
10P SENSOR
Gr
W
G
IACV Bl
Bl
G/Y
2P Gr
W
Bl
FRONT Br 4P IAT SENSOR EOT
G
Bu
Gr
Lb
W
VS Gr REAR VS SENSOR
JOINT JOINT JOINT SENSOR JOINT
SENSOR
SNSR GND( - )
HEATER( + )
HEATER( - )
SNSR SIG( + )

MAP ENGINE DUAL
Br
Bl
G
O
REAR BRAKE MOTOR GROUND CKP

PERMISSION PULL BACK A SHIFT LIGHT SWITCH SENSOR SHIFT SENSOR CLUTCH PC
OUT
GND
VCC
RELAY RELAY SOLENOID (PEDAL SIDE) CONTROL SOLENOID
FUEL PUMP MOTOR
DL MOP
DL POT
DL TO 4WD
4WD
4WD TO BOTH
2WD TO 4WD
DL MOM
DL POS
GND
FAIL-SAFE MAIN FUEL PUMP VALVE TP SENSOR VALVE

PULL BACK B RELAY RELAY RELAY UNIT FUEL INJECTOR
RELAY O2 TR SENSOR
DIFFLOCK DRIVE DIFFLOCK DRIVE OVERRIDE SENSOR FUEL FUEL SENSOR UNIT SUB-TRANSMISSION
A RELAY B RELAY INHIBITOR PUMP LEVEL NEUTRAL DRIVE SWITCH
RELAY SENSOR SWITCH
DIFFLOCK ACTUATOR SUB-TRANSMISSION
SWITCH CONTINUITY SHIFT SPINDLE LOW SWITCH
ANGLE
REAR BRAKE REAR BRAKE SENSOR
IGNITION LIGHTING DIMMER ENGINE STOP STARTER/OVERRIDE GEAR SHIFT REVERSE FRONT BRAKE LIGHT SWITCH LIGHT SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH INHIBITOR SWITCH (LEVER SIDE) (PEDAL SIDE)
STOP STOP STOP
Br Brown P Pink
Bu Blue R Red
G Green V Violet
Lg Light Green
30-77
dummytext
MEMO
Honda Motor Co., Ltd. 2019
Published by Honda Motor Co., Ltd. Book number : 62HR400X
Printed in Japan 2019.06

TRX520

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SHOP MANUAL

30. TRX520FM1/FM2/FE1/FE2/FM6/FA6/FA7-L ADDENDUM

CABLE & HARNESS ROUTING ············30-12 FRONT DRIVE SHAFT························· 30-49

CENTER MUDGUARD ·························30-18 REAR DRIVE SHAFT

PGM-FI SYSTEM DIAGRAM ·················30-23 ESP COMPONENT LOCATION

DCT COMPONENT LOCATION NEUTRAL SWITCH (FE models)··········· 30-71

DCT DTC INDEX (FA models) ··············30-35

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

© Honda Motor Co., Ltd.

FM/FE models: FA models:

FUEL SYSTEM SPECIFICATIONS

REAR WHEEL/SUSPENSION SPECIFICATIONS

BATTERY/CHARGING SYSTEM SPECIFICATIONS

SUB-TRANSMISSION (FA models)

CABLE & HARNESS ROUTING

RIGHT HANDLEBAR COMBINATION METER

RANGE SELECT CABLE REAR BRAKE HOSE

GROUND CABLE CKP SENSOR 2P

FINAL GEAR CASE

REAR BRAKE LIGHT

STARTER MOTOR CABLE

VS SENSOR WIRE BATTERY NEGATIVE LEVER REAR (PARKING)

SHIFT SPINDLE ANGLE SENSOR

STARTER MOTOR CABLE

ENGINE SUB HARNESS

SENSOR HARNESS TR SENSOR

SHIFT SPINDLE ANGLE SENSOR

SHIFT SPINDLE ANGLE SENSOR

REAR BRAKE LIGHT

LEVER REAR (PARKING)

REAR BRAKE LIGHT

REAR BRAKE HOSE

Inside of front fender:

• Take care not to scratch the front and rear fenders

• Take care not to scratch the front and rear fenders

• Installing the rubber seal as shown. [2]

Install the removed parts in the reverse order of

ENGINE STOP SWITCH

FUSE BOX: IGNITION SWITCH

FUEL INJECTOR DLC

TR SENSOR NEUTRAL SWITCH

FUSE BOX: COMBINATION METER:

SENSOR UNIT: TR SENSOR

MAIN POWER REGULATOR/

IGNITION SWITCH IGN FUSE (20A) R/Bl R R

R Bl Bl/R Bl/R V/W

ENGINE STOP SWITCH

Bl/R B1 MAIN PRC B31 V/W

CKP Bu/Y B23 PCP

FUEL PUMP RELAY

MAP PCM/ECM (33)

BANK ANGLE FUEL

IGN1 B11 G/Y Bl/R

Lb/W A13 GP 5 W/Bl

2 W/R A27 GP 2 FAN C3 G/Bl

GEAR POSITION PG3 C5 G

PCM/ECM C-1 C-3