Yamaha XV16 Road Star 1999-2003 Motorcycle Repair Manual

CARBURETOR CARB Order Job/Part Q’ty Remarks 6 9 1 Disconnect. Charcoal canister hose 10 (carburetor to charcoal canister) 2 Disconnect. 11 Carburetor heater connector 1 12 Carburetor 1 Fuel pump bracket assembly 13 (with fuel pump) 1 Disconnect. 14 Vacuum hose 1 Carburetor joint For installation, reverse the removal procedure. 6-2

CARBURETOR CARB EAS00483 6 Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. 1 Throttle stop screw 1 2 Vacuum chamber air vent hose 1 3 Fuel strainer 1 4 Throttle cable holder 1 5 Throttle position sensor bracket 1 6 Carburetor heater 1 7 Coasting enricher cover 1 8 Coasting enricher spring 1 9 Coasting enricher 1 6-3

CARBURETOR CARB Order Job/Part Q’ty Remarks 6 Vacuum chamber cover 1 0 Piston valve spring 1 A Jet needle holder 1 B Jet needle kit 1 C Piston valve 1 D Float chamber 1 E Float chamber rubber gasket 1 F Drain bolt 1 G Accelerator plunger 1 H Float pivot pin 1 I 6-4

CARBURETOR CARB 6 Order Job/Part Q’ty Remarks J Float 1 1 K Needle valve 1 1 L Needle valve seat 1 1 M Main jet 1 1 N Spacer 1 O Needle jet For assembly, reverse the disassembly procedure. P Pilot jet Q Starter jet R Pilot air jet 6-5

CARBURETOR CARB EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber • jet housing Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Wash the carburetor in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 3. Check: • float chamber body Dirt → Clean. 4. Check: • float chamber rubber gasket 1 Cracks/damage/wear → Replace. 5. Check: 6 • float Damage → Replace. 6. Check: • needle valve 1 • needle valve seat 2 Damage/obstruction/wear → Replace the needle valve, needle valve seat and O-ring as a set. 7. Check: • O-ring 3 Damage/wear → Replace the needle valve, needle valve seat and O-ring as a set. 6-6

CARBURETOR CARB 8. Check: • piston valve 1 Damage/scratches/wear → Replace. • piston valve diaphragm 2 Cracks/tears → Replace. 9. Check: • vacuum chamber cover 1 • piston valve spring 2 • jet needle holder 3 • jet needle spring 4 Cracks/damage → Replace. 10.Check: • jet needle kit 1 • main jet 2 • needle jet 3 • pilot jet 4 • starter jet 5 • pilot air jet 6 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 6 11.Check: • piston valve movement Insert the piston valve into the carbure- tor body and move it up and down. Tightness → Replace the piston valve. 12.Check: • starter plunger 1 • starter plunger spring 2 Bends/cracks/damage → Replace. • O-ring 3 Damage/wear → Replace. 6-7

CARBURETOR CARB 13.Check: • coasting enricher cover 1 • coasting enricher spring 2 Cracks/damage → Replace. • coasting enricher 3 Cracks/tears/damage → Replace. 14.Check: • accelerator plunger 1 • accelerator plunger spring 2 Bends/cracks/damage → Replace. • O-ring 3 Damage/wear → Replace. 15.Check: • fuel hose Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. CHECKING THE CARBURETOR JOINT 6 1. Check: • carburetor joint 1 Cracks/damage → Replace. • O-rings 2 Damage/wear → Replace the O-ring. EAS00487 ASSEMBLING THE CARBURETOR CAACUHTTIUONNG: : • Before assembling the carburetor, wash all the parts in a petroleum-based sol- vent. • Always use a new gasket. 6-8

CARBURETOR CARB 1. Install: • pilot air jet 1 2. Install: • starter jet 1 • pilot jet 2 3. Install: • needle jet 1 NOTE: Align the slot a on the needle jet with the projection b on the carburetor body. 6 4. Install: • spacer 1 • main jet 2 5. Install: • needle valve seat 1 6-9

CARBURETOR CARB 6. Install: • needle valve • float 1 • float pin 2 7. Install: • accelerator plunger 1 • drain bolt 2 • float chamber rubber gasket 3 8. Install: • float chamber 1 9. Install: 6 • piston valve 1 • jet needle kit • jet needle holder • piston valve spring • vacuum chamber cover 2 NOTE: • Install the end of the piston valve spring onto the spring guide on the vacuum chamber cover. • Align the tab a on the piston valve dia- phragm with the recess in the carburetor body. 6 - 10

T. R. CARBURETOR CARB 10.Install: • coasting enricher 1 • coasting enricher spring • coasting enricher cover 2 NOTE: Align the tab a on the coasting enricher with the recess b in the carburetor body. 11.Install: • terminal 1 • washer • carburetor heater 2 2.5 Nm (0.25 m · kg, 2.0 ft · lb) NOTE: Use “Heat Sinker” when installing the car- buretor heater. Heat Sinker 6 12.Install: • throttle position sensor bracket 1 • throttle cable holder 2 • vacuum chamber air vent hose 3 • fuel strainer 4 6 - 11

CARBURETOR CARB 13.Install: • throttle stop screw • drain hose INSTALLING THE CARBURETOR JOINTT. R. 1. Install: • carburetor joint 1 12 Nm (1.2 m · kg, 8.7 ft · lb) 2. Connect: • vacuum hose 2 EAS00492 INSTALLING THE CARBURETOR 1. Connect: • carburetor heater connectors 1 • charcoal canister hose (carburetor to charcoal canister) 2 2. Install: 6 • starter plunger 3. Connect: • starter cable 1 4. Install: • throttle position sensor NOTE: • Align the slot a of the throttle position sensor with the projection b of the throt- tle lever shaft. • For the correct installation, refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR”. 6 - 12

CARBURETOR CARB 5. Connect: • fuel hose 1 6. Connect: • throttle cables 1 7. Connect: • float chamber breather hose (carburetor to solenoid valve) 1 6 8. Hook: • throttle stop screw 1 9. Install: • carburetor NOTE: Align the projection a of the carburetor with slot of the carburetor joint. 10.Tighten: • carburetor joint clamp screw 1 6 - 13

CARBURETOR CARB 11.Adjust: • engine idling speed Engine idling speed 850 ~ 950 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 12.Adjust: 6 • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 4 ~ 8 mm (0.16 ~ 0.31 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level (above the float cham- ber mating surface) 4.0 ~ 5.0 mm (0.16 ~ 0.20 in) wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Install the fuel level gauge 1 onto the fuel drain pipe 2. Fuel level gauge YM-01312-A d. Loosen the fuel drain bolt. e. Measure the fuel level a. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 6 - 14

CARBURETOR CARB 2. Adjust: • fuel level wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Remove the carburetor. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slightly bending the float tang 1. e. Install the carburetor. f. Measure the fuel level again. g. Repeat steps (a) to (f) until the fuel level is within specification. vvvvvvvvvvvvvvvvvvvvvvvvvvvv EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sen- sor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor (installed on the carburetor) 6 wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Disconnect the throttle position sensor coupler from the wire harness. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor coupler. Positive tester probe → blue terminal 1 Negative tester probe → black terminal 2 c. Measure the maximum throttle position sensor resistance. Out of specification → Replace the throt- tle position sensor. Maximum throttle position sen- sor resistance 4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F) (blue — black) 6 - 15

CARBURETOR CARB d. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Positive tester probe → yellow terminal 3 Negative tester probe → black terminal 2 e. While slowly opening the throttle, check that the throttle position sensor resis- tance is within the specified range. NOTE: Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those spec- ified. Out of specification or the resistance changes abruptly → Go to step 2 below. Throttle position sensor resis- tance (520 ~ 900 Ω) ~ (4.0 ~ 6.0 kΩ) at 20 ˚C (68 ˚F) (yellow — black/blue) vvvvvvvvvvvvvvvvvvvvvvvvvvvv 2. Check: 6 • throttle position sensor (removed from the carburetor) wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Disconnect the throttle position sensor coupler from the wire harness. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Positive tester probe → blue terminal 1 Negative tester probe → black terminal 2 6 - 16

CARBURETOR CARB d. Measure the maximum throttle position sensor resistance. Out of specification → Replace the throt- tle position sensor. Maximum throttle position sen- sor resistance 4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F) (blue — black/blue) e. Connect the pocket tester (Ω × 1k) to the throttle position sensor coupler. Positive tester probe → yellow terminal 3 Negative tester probe → black terminal 2 f. While slowly opening the throttle, check that the throttle position sensor resis- tance is within the specified range. The resistance does not change or it changes abruptly → Replace the throttle position sensor. The slot is worn or broken → Replace the throttle position sensor. NOTE: Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those spec- ified. 6 Throttle position sensor resis- tance 0 ~ 5 ± 1.0 kΩ at 20 ˚C (68 ˚F) (yellow — black/blue) vvvvvvvvvvvvvvvvvvvvvvvvvvvv 6 - 17

CARBURETOR CARB 6 3. Adjust: • throttle position sensor angle wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Disconnect the throttle position sensor coupler from the wire harness. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor coupler. Positive tester probe → blue terminal 1 Negative tester probe → black terminal 2 c. Measure the throttle position sensor maximum resistance. d. Calculate the throttle position sensor maximum resistance when the throttle is fully closed. Throttle position sensor maximum resistance (throttle is fully closed) = Maximum resistance × (0.13 ~ 0.15) Example: If the maximum resistance = 5 kΩ, then the throttle position sensor’s maximum resis- tance when the throttle is fully closed should be: 5 kΩ × (0.13 ~ 0.15) = 650 ~ 750 Ω Lift the carburetor assembly slightly out of the intake manifolds. Loosen the throttle position sensor screws 4. Connect the pocket tester (Ω × 100) to the throttle position sensor. Positive tester probe → yellow terminal 3 Negative tester probe → black terminal 1 e. Adjust the throttle position sensor angle so that the measured resistance is within the specified range. Throttle position sensor resis- tance 650 ~ 750 Ω (yellow — black terminal) After adjusting the throttle position sensor angle, tighten the throttle position sensor screws. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 6 - 18

CARBURETOR CARB EAS00504 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Disconnect the fuel hose (fuel pump to carburetor) 2 from the carburetor. b. Place a container under the end of the fuel hose. c. Set the fuel cock to “ON” or “RES”. d. Start the engine and check if fuel flows from the fuel hose 2. Fuel flows. Fuel pump is OK. Fuel does not flow. Replace the fuel pump. e. Stop the engine and check if the fuel stops flowing from the fuel hose 2. Fuel stops flowing. Fuel pump is OK. Fuel flows. Replace the fuel pump. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 6 EAS00505 CHECKING THE FUEL COCK 1. Drain: • fuel (from the fuel tank) 2. Disconnect: • fuel hose (from the fuel cock) 3. Remove: • fuel cock 1 4. Check: • fuel cock Cracks/damage/wear → Replace. 5. Check: • fuel cock strainer 1 (with compressed air) Dirt/obstruction → Clean. Damage → Replace the fuel cock as a set. • rubber gasket 2 Cracks/damage/wear → Replace. 6 - 19

CARBURETOR CARB 6. Install: • fuel cock 7. Connect: • fuel hose EAS00506 CHECKING THE FUEL COCK OPERATION NOTE: After installing the fuel cock, check its oper- ation. 1. Set the fuel cock to “OFF”. 2. Disconnect: • fuel hose (from the fuel cock) 3. Check: • fuel cock operation wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Place a container under the end of the fuel cock. b. Check that the fuel cock lever is turned to “ON” or “RES”. Fuel flows. Fuel cock is OK. Fuel does not flow. Replace the fuel cock. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 6 4. Connect: • fuel hose 6 - 20

AIR INDUCTION SYSTEM CARB EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (sec- ondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allow- ing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approxi- mately 600 to 700 ˚C (1,112 to 1,292 ˚F). EAS00508 AIR CUTOFF VALVE The air cutoff valve is operated by the intake gas pressure through the piston valve diaphragm. Normally, the air cutoff valve is open to allow fresh air to flow into the exhaust port. During sudden decelera- tion (the butterfly valve suddenly closes), negative pressure is generated and the air cutoff valve is closed in order to prevent after-burning. 6 Additionally, at high engine speeds and when the pressure decreases, the air cutoff valve automatically closes to guard against a loss of performance due to self-EGR (Exhaust Gas Recirculation). 1 During normal operation, the air cutoff valve is open. 2 During sudden deceleration (the butterfly valve suddenly closes), the air cutoff valve closes. 3 At high engine speeds and when the pressure decreases, the air cutoff valve is closed. Å From the air cleaner ı To the reed valve Ç To the carburetor joint 6 - 21

AIR INDUCTION SYSTEM CARB EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve Å To the carburetor joint 2 Air cut valve ı To the front cylinder head 3 Air cleaner Ç To the rear cylinder head 4 Carburetor joint Î To the air cut valve 6 FWD 6 - 22

AIR INDUCTION SYSTEM CARB 6 Order Job/Part Q’ty Remarks Removing the air induction system Remove the parts in the order listed. fuel tank Refer to “FUEL TANK” in chapter 3. 1 Reed valve case to rear cylinder 1 head hose 2 Reed valve case to rear cylinder 1 head pipe 3 Reed valve case to front cylinder 1 head hose 4 Reed valve case to front cylinder 1 head hose 5 Gasket 2 6 Rectifier/regulator coupler 1 Disconnect. 7 Rectifier/regulator 1 8 Air filter bracket 1 6 - 23

AIR INDUCTION SYSTEM CARB Order Job/Part Q’ty Remarks 6 9 1 10 Air filter 1 11 Air filter cover 1 12 Air filter hose 1 13 Air cut valve to air filter hose 1 14 Plastic locking tie 1 15 Vacuum hose 1 16 Bracket 1 17 Air cut valve holder 1 18 Air cut valve 1 Air cut valve to reed valve cover 19 hose 1 20 Reed valve cover 1 Reed valve case 6 - 24

AIR INDUCTION SYSTEM CARB 6 Order Job/Part Q’ty Remarks 21 Reed valve base 1 2 22 Reed valve stopper 2 23 Reed valve For installation, reverse the removal procedure. 6 - 25

AIR INDUCTION SYSTEM CARB EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Check: • fibre reed 1 • fibre reed stopper • reed valve seat Cracks/damage → Replace the reed valve. 3. Measure: 6 • fibre reed bending a Out of specification → Replace the reed valve. Maximum fibre reed bending 0.4 mm (0.016 in) 1 Surface plate 4. Check: • air cutoff valve Cracks/damage → Replace. INSTALLING THE AIR INDUCTION SYSTEM 1. Install: • reed valves 1 • reed valve stoppers 2 • reed valve base 3 6 - 26

AIR INDUCTION SYSTEM CARB 2. Install: • reed valve case 1 • reed valve cover • bracket 2 3. Install: • air cut valve to reed valve cover hose 1 • air cut valve 2 • air cut valve holder 3 4. Install: • bracket (with the air cut valve and reed valve) 6 5. Install: • vacuum hose 1 • plastic locking tie 2 6. Install: • air cut valve to air filter hose 1 6 - 27

AIR INDUCTION SYSTEM CARB 7. Install: • air filter 1 • air filter hose 2 • air filter cover 3 8. Install: • air filter bracket 1 9. Install: • air filter case assembly 1 10.Install: 6 • rectifier/regulator 1 11.Connect: • rectifier/regulator coupler 2 12.Install: • gaskets • reed valve case to front cylinder head pipe 1 • reed valve case to front cylinder head hose • reed valve case to rear cylinder head pipe 2 • reed valve case to rear cylinder head hose 6 - 28

AIR INDUCTION SYSTEM CARB 13.Install: • fuel tank Refer to “FUEL TANK” in chapter 3. 6 6 - 29

ELEC – + CONTENTS ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ...................................................................... 7-1 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND 7 COUPLERS ................................................................................................ 7-2 SWITCHES .................................................................................................... 7-6 CHECKING SWITCH CONTINUITY ...................................................... 7-6 CHECKING THE SWITCHES ........................................................................ 7-7 CHECKING THE BULBS AND BULB SOCKETS .......................................... 7-9 TYPES OF BULBS ................................................................................. 7-9 CHECKING THE CONDITION OF THE BULBS .................................... 7-9 CHECKING THE CONDITION OF THE BULB SOCKETS ................... 7-11 CHECKING THE LEDs ......................................................................... 7-11

ELEC – + 7 IGNITION SYSTEM .................................................................................... 7-12 CIRCUIT DIAGRAM ............................................................................ 7-12 TROUBLESHOOTING ......................................................................... 7-13 ELECTRIC STARTING SYSTEM ................................................................. 7-17 CIRCUIT DIAGRAM ............................................................................ 7-17 STARTING CIRCUIT CUTOFF SYSTEM OPERATION ...................... 7-18 TROUBLESHOOTING ......................................................................... 7-19 STARTER MOTOR ...................................................................................... 7-23 CHECKING THE STARTER MOTOR .................................................. 7-25 ASSEMBLING THE STARTER MOTOR ............................................. 7-26 INSTALLING THE STARTER MOTOR ............................................... 7-27 CHARGING SYSTEM ................................................................................. 7-28 CIRCUIT DIAGRAM ............................................................................ 7-28 TROUBLESHOOTING ......................................................................... 7-29 LIGHTING SYSTEM .................................................................................... 7-31 CIRCUIT DIAGRAM ............................................................................ 7-31 TROUBLESHOOTING ......................................................................... 7-32 CHECKING THE LIGHTING SYSTEM ................................................ 7-33 SIGNALING SYSTEM ................................................................................. 7-37 CIRCUIT DIAGRAM ............................................................................ 7-37 TROUBLESHOOTING ......................................................................... 7-39 CHECKING THE SIGNALING SYSTEM ............................................. 7-40 FUEL PUMP SYSTEM ................................................................................ 7-46 CIRCUIT DIAGRAM ............................................................................ 7-46 FUEL PUMP CIRCUIT OPERATION ................................................... 7-47 TROUBLESHOOTING ......................................................................... 7-48 CHECKING THE FUEL PUMP ............................................................. 7-50 CARBURETOR HEATING SYSTEM ........................................................... 7-51 CIRCUIT DIAGRAM ............................................................................ 7-51 TROUBLESHOOTING ......................................................................... 7-52 SELF-DIAGNOSIS ....................................................................................... 7-55 TROUBLESHOOTING ......................................................................... 7-57

ELECTRICAL COMPONENTS ELEC – + ESA00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Wire harness A Battery K Stator coil assembly 2 Main switch B Starter relay L Rear brake light switch 3 Front brake light switch C Main fuse M Rectifier/regulator 4 Ignition coils D Thermo switch 5 Throttle position sensor E Fuse box 6 Clutch switch F Speed sensor 7 Decompression solenoid G Horns 8 Relay unit H Neutral switch 9 Turn signal relay I Sidestand switch 0 Ignitor unit J Pickup coil 7 FWD 7-1

ARRANGEMENT OF THE ELECTRICAL COMPONENTS ELEC – + AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 1 Right handlebar switch coupler, left handlebar switch couplers and front turn signal connectors 2 Headlight coupler 1 Tail/brake light connectors and rear turn signal connectors 7 7-2

ARRANGEMENT OF THE ELECTRICAL COMPONENTS ELEC – + AND COUPLERS 1 Spark plug cap #3 5 Carburetor heater sub-wire 8 Spark plug cap #2 2 Rear brake light switch cou- harness coupler 9 Spark plug cap #1 0 Fuel pump pler 6 Throttle position sensor A Fuel pump coupler 3 Ignition coil (front cylinder) coupler 4 Meter assembly couplers 7 Fuel sender coupler 1 Rear brake light switch lead 6 Horn coupler 2 Rectifier/regulator 7 Horn 3 Rectifier/regulator coupler 8 Pickup coil 4 Starter motor 9 Sidestand switch 5 Starter motor lead 7 7-3

ARRANGEMENT OF THE ELECTRICAL COMPONENTS ELEC – + AND COUPLERS 1 Fuse box 2 Stator coil coupler, decompression solenoid couplers, pickup coil coupler, speed sensor coupler, neutral switch connector and sidestand switch coupler 3 Battery negative lead 4 Battery positive lead 5 Battery 6 Ignitor unit 7 Tail/brake light and rear turn signal light sub-wire harness coupler 8 Starter relay 9 Main fuse 0 Starter relay coupler A Thermo switch B Thermo switch coupler C Horn D Horn coupler 7 7-4

ARRANGEMENT OF THE ELECTRICAL COMPONENTS ELEC – + AND COUPLERS 1 Carburetor heater 5 Main switch 9 Rear brake light switch 2 Throttle position sensor 6 Solenoid valve coupler 3 Ignition coil (rear cylinder) 7 Solenoid valve 4 Main switch coupler 8 Spark plug cap #4 1 Diode 5 Decompression solenoid 9 Turn signal relay coupler 2 Turn signal relay 6 Neutral switch 3 Relay unit 7 Speed sensor 4 Stator coil 8 Relay unit coupler 7 7-5

SWITCHES ELEC – + 7 EAS00730 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAACUHTTIUONNG: : Never insert the tester probes into the cou- pler terminal slots 1. Always insert the probes from the opposite end of the cou- pler, taking care not to loosen or damage the leads. Pocket tester YU-03112 NOTE: • Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range. • When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illus- tration. NOTE: “ ” indicates a continuity of electric- ity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between red and brown/ blue, and between blue/yellow and blue/ black when the switch is set to “ON”. 7-6

CHECKING THE SWITCHES ELEC – + EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch. 7 7-7

1 Dimmer switch CHECKING THE SWITCHES ELEC – + 2 Horn switch 3 Turn signal switch 9 Fuse 4 Clutch switch 0 Rear brake light switch 5 Engine stop switch A Sidestand switch 6 Start switch B Neutral switch 7 Front brake light switch 8 Main switch 7 7-8

CHECKING THE BULBS AND BULB SOCKETS ELEC – + EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for dam- age or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly con- nect. Incorrect continuity reading → Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left. • Bulbs A and B are used for the head- lights and usually use a bulb holder which must be detached before remov- ing the bulb. The majority of these bulbs can be removed from their respective socket by turning them counterclock- wise. • Bulb C is used for turn signal and tail/ brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. • Bulbs D and E are used for meter and 7 indicator lights and can be removed from their respective socket by carefully pulling them out. CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb 7-9

CHECKING THE BULBS AND BULB SOCKETS ELEC – + 7 WAWRNARINNGING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAACUHTTIUONNG: : • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the ter- minal in the coupler. • Avoid touching the glass part of the head- light bulb to keep it free from oil, other- wise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 2. Check: • bulb (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE: Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range. wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Connect the tester positive probe to ter- minal 1 and the tester negative probe to terminal 2, and check the continuity. b. Connect the tester positive probe to ter- minal 1 and the tester negative probe to terminal 3, and check the continuity. c. If either of the readings indicate no conti- nuity, replace the bulb. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 7 - 10

CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb sec- tion; however, note the following. wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continu- ity, replace the bulb socket. vvvvvvvvvvvvvvvvvvvvvvvvvvvv CHECKING THE LEDs The following procedure applies to all of the LEDs. 1. Check: LED (for proper operation) wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Disconnect the meter assembly coupler (meter assembly side). b. Connect two jumper leads 1 from the battery terminals to the respective cou- 7 pler terminals as shown. WAWRNARINNGING • A wire that is used as a jumper lead must have at least the same capacity of the battery lead, otherwise the jumper lead may burn. • This check is likely to produce sparks, therefore make sure that no flammable gas or fluid is in the vicinity. c. When the jumper leads are connected to the terminals the respective LED should illuminate. Does not light → Replace the meter assembly. 7 - 11 v v v v v v v v v v v v v v v v v v v v v v v v v v v v

EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM 73 Main switch IGNITION SYSTEM ELEC – + 4 Battery 7 - 125 Main fuse 9 Relay unit B Ignitor unit C Ignition coil D Spark plug F Pickup coil G Neutral switch a Engine stop switch i Ignition fuse k Sidestand switch l Diode

IGNITION SYSTEM ELEC – + EB802011 EB802401 TROUBLESHOOTING 2.Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses 2. battery Minimum open-circuit voltage 12.8 V or more at 20 ˚C (68 ˚F) 3. spark plugs • Is the battery OK? 4. ignition spark gap 5. spark plug cap resistance YES NO 6. ignition coil resistance 7. pickup coil resistance • Clean the battery 8. main switch terminals. 9. engine stop switch 10.neutral switch • Recharge or 11.sidestand switch replace the battery. 12.diode 13.relay unit (diode) 14.wiring (of the entire ignition system) EB802403 NOTE: 3.Spark plugs • Before troubleshooting, remove the fol- The following procedure applies to all of lowing part(s): the spark plugs. 1) rider seat • Check the condition of the spark plug. 2) fuel tank • Check the spark plug type. 3) side covers • Measure the spark plug gap. 4) ignition coils Refer to “CHECKING THE SPARK 5) headlight lens unit PLUGS” in chapter 3. • Troubleshoot with the following special Standard spark plug tool(s). DPR7EA-9 (NGK) X22EPR-U9 (DENSO) Dynamic spark tester Spark plug gap YM-34487 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) Pocket tester • Is the spark plug in good condition, is it of the correct type, and its gap within 7 YU-03112 specification? EB802400 1.Main and ignition fuses YES NO • Check the main and ignition fuses for continuity. Refer to “CHECKING THE FUSES” in Re-gap or replace chapter 3. the spark plug. • Are the main and ignition fuses OK? YES NO Replace the fuse(s). 7 - 13

EB802405 IGNITION SYSTEM ELEC – + 4.Ignition spark gap Spark plug cap resistance 10 kΩ at 20 ˚C (68 ˚F) The following procedure applies to all of the spark plugs. • Is the spark plug cap OK? • Disconnect the spark plug cap from the YES NO spark plug. • Connect the dynamic spark tester 1 as shown. 2 Spark plug cap • Set the main switch to “ON”. • Measure the ignition spark gap a. • Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs. Minimum ignition spark gap Replace the spark 6 mm (0.24 in) plug cap. • Is there a spark and is the spark gap EB802409 within specification? 6.Ignition coil resistance NO YES The following procedure applies to all of the ignition coils. • Disconnect the ignition coil connectors from the ignition coil terminals. • Connect the pocket tester (Ω × 1) to the ignition coil as shown. Tester positive probe → red/black Tester negative probe → orange (gray) The ignition system is OK. EB802407 7 5.Spark plug cap resistance The following procedure applies to all of • Measure the primary coil resistance. the spark plug caps. • Disconnect the spark plug cap from the Primary coil resistance 1.53 ~ 2.07 Ω at 20 ˚C (68 ˚F) spark plug. • Connect the pocket tester (Ω × 1k) to the • Connect the pocket tester (Ω × 1k) to the ignition coil as shown. spark plug cap as shown. • Measure the spark plug cap resistance. • Measure the secondary coil resistance. Tester positive probe → spark plug lead 1 Tester negative probe → spark plug lead 2 7 - 14

IGNITION SYSTEM ELEC – + EB802411 8.Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? YES NO Secondary coil resistance Replace the main 12 ~ 18 kΩ at 20 ˚C (68 ˚F) switch. • Is the ignition coil OK? EB802412 YES NO 9.Engine stop switch • Check the engine stop switch for conti- Replace the ignition coil. nuity. Refer to “CHECKING THE SWITCHES”. EB802410 • Is the engine stop switch OK? 7.Pickup coil resistance YES NO • Disconnect the pickup coil coupler from Replace the right the wire harness. handlebar switch. • Connect the pocket tester (Ω × 100) to EB802413 the pickup coil coupler. Tester positive probe → gray 1 10.Neutral switch Tester negative probe → black 2 • Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the neutral switch OK? YES NO 7 Replace the neutral switch. • Measure the pickup coil resistance. EB802414 Pickup coil resistance 248 ~ 372 Ω at 20 ˚C (68 ˚F) 11.Sidestand switch (between gray and black) • Check the sidestand switch for continu- • Is the pickup coil OK? ity. Refer to “CHECKING THE SWITCHES”. YES NO • Is the sidestand switch OK? YES NO Replace the pickup Replace the side- coil. stand switch. 7 - 15

IGNITION SYSTEM ELEC – + 12.Diode EB802415 13.Relay unit (diode) • Remove the diode from the coupler. • Remove the relay unit from the coupler. • Connect the pocket tester (Ω × 1) to the • Connect the pocket tester (Ω × 1) to the diode terminals as shown. relay unit terminals as shown. • Check the diode for continuity as fol- • Check the diode for continuity as fol- lows. lows. Tester positive probe → Tester positive probe → blue/white 1 Continu- sky blue 1 Continu- Tester negative probe → ity Tester negative probe → ity blue/yellow 2 blue/yellow 2 Tester positive probe → Tester positive probe → blue/yellow 2 No conti- blue/yellow 2 No conti- Tester negative probe → nuity Tester negative probe → nuity blue/white 1 sky blue 1 NOTE: NOTE: When you switch the tester’s positive When you switch the tester’s positive and negative probes, the readings in the and negative probes, the readings in the above chart will be reversed. above chart will be reversed. • Are the tester readings correct? • Are the tester readings correct? YES NO YES NO Replace the diode. Replace the relay unit. 7 EAS00754 14.Wiring • Check the entire ignition system’s wir- ing. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system’s wiring properly connected and without defects? YES NO Replace the ignitor Properly connect or unit. repair the ignition system’s wiring. 7 - 16

7 ELECTRIC STARTING SYSTEM ELEC – 7 - 17 EB803000 3 Main switch G Neutral switch ELECTRIC STARTING SYSTEM 4 Battery Y Clutch switch 5 Main fuse a Engine stop switch CIRCUIT DIAGRAM 6 Starter relay b Start switch 7 Starter motor i Ignition fuse 9 Relay unit k Sidestand switch B Ignitor unit l Diode E Decompression solenoid +

ELECTRIC STARTING SYSTEM ELEC – + 7 EB803010 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neu- tral switch is closed). • The clutch lever is pulled to the handle- bar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cutoff relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cutoff relay is open so current cannot reach the starter motor. When at least one of the above con- ditions has been met the starting circuit cut- off relay is closed and the engine can be started by pressing the start switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cutoff relay (relay unit) 7 Diode (relay unit) 8 Clutch switch 9 Sidestand switch 0 Diode A Neutral switch B Start switch C Ignitor unit D Starter relay E Starter motor F Decompression solenoid thermistor 7 - 18

ELECTRIC STARTING SYSTEM ELEC – + EB803020 EB802401 TROUBLESHOOTING 2.Battery • Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses 2. battery Open-circuit voltage 3. starter motor 12.8 V or more at 20 ˚C (68 ˚F) 4. relay unit (starting circuit cutoff relay) 5. relay unit (diode) • Is the battery OK? 6. starter relay 7. main switch YES NO 8. engine stop switch 9. neutral switch • Clean the battery 10.sidestand switch terminals. 11.diode 12.clutch switch • Recharge or 13.start switch replace the battery. 14.wiring EB803400 (of the entire starting system) 15.decompression solenoid 3.Starter motor • Connect the battery positive terminal 1 NOTE: • Before troubleshooting, remove the fol- and starter motor lead 2 with a jumper lead 3. lowing part(s): 1) rider seat 2) fuel tank 3) side covers 4) headlight lens unit • Troubleshoot with the following special tool(s). Pocket tester YU-03112 7 EB802400 WAWRNARINNGING 1.Main and ignition fuses • A wire that is used as a jumper lead • Check the main and ignition fuses for must have at least the same capacity of continuity. the battery lead, otherwise the jumper Refer to “CHECKING THE FUSES” in lead may burn. chapter 3. • This check is likely to produce sparks, • Are the main and ignition fuses OK? therefore make sure that no flammable YES NO gas or fluid is in the vicinity. • Does the starter motor turn? Replace the fuse(s). YES NO Repair or replace the starter motor. 7 - 19

ELECTRIC STARTING SYSTEM ELEC – + EB803402 EB803403 4.Relay unit (starting circuit cutoff relay) 5.Relay unit (diode) • Disconnect the relay unit from the cou- • Disconnect the relay unit from the cou- pler. pler. • Connect the pocket tester (Ω × 1) and • Connect the pocket tester (Ω × 1) to the battery (12 V) to the relay unit terminals relay unit terminals as shown. as shown. Battery positive terminal → red/black 1 • Check the diode for continuity as fol- Battery negative terminal → lows. black/yellow 2 Tester positive probe → Tester positive probe → blue 3 sky blue 1 Tester negative probe → blue/white 4 Tester negative probe → • Does the starting circuit cutoff relay black/yellow 2 Continu- have continuity between blue and blue/ white? Tester positive probe → ity sky blue 1 Tester negative probe → blue/yellow 3 Tester positive probe → black/yellow 2 Tester negative probe → sky blue 1 No conti- Tester positive probe → nuity blue/yellow 3 Tester negative probe → sky blue 1 YES NO Replace the relay unit. NOTE: 7 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. • Are the tester readings correct? YES NO Replace the relay unit. 7 - 20