Suzuki SV1000 2003-2005 Service Manual 7 Electrical System

ELECTRICAL SYSTEM

CONTENTS

ELECTRICAL SYSTEM

7-1

CAUTIONS IN SERVICING

COUPLER
CLAMP
FUSE

SEMI-CONDUCTOR EQUIPPED PART
BATTERY

CONNECTING THE BATTERY
WIRING PROCEDURE

USING THE MULTI CIRCUIT TESTER

LOCATION OF ELECTRICAL COMPONENTS

CHARGING SYSTEM

TROUBLE SHOOTING

INSPECTION
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM

TROUBLE SHOOTING

STARTER MOTOR REMOVAL AND DISASSEMBLY
STARTER MOTOR INSPECTION
STARTER MOTOR REASSEMBLY
STARTER RELAY INSPECTION

SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS

INSPECTION

IGNITION SYSTEM

TROUBLESHOOTING
INSPECTION

COMBINATION METER

REMOVAL
PARTS NAME

OPERATING PROCEDURE
ENGINE COOLANT TEMPERATURE METER AND INDICATOR

LAMPS

RELAYS

~
HEADLIGHT AND POSITION LIGHT
BRAKE LIGHT/TAILLIGHT, TURN SIGNAL LIGHT AND

LICENCE PLATE LIGHT

TURN SIGNAL/SIDE-STAND RELAY
STARTER RELAY
FUEL PUMP RELA Y
SWITCHES

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~

~

~

~

~

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7- 3
7- 3
7- 3
7- 3
7- 3
7- 4
7- 4
7- 4
7- 4

7- 5

7- 7
7- 7
7- 9

7-12
7-12
7-13
7-14
7-15
7-16

7-17
7-20
7-20
7-22

7-25
7-25
7-26

7-26

~

7-28

7-31

7-31

7-32

7-33

7-33

7-33

7--33

7-34

7

7-2

ELECTRICAL

SYSTEM

ELECTRICAL SYSTEM

CONTENTS

BATTERY

SPECIFICATIONS
INITIAL CHARGING

SERVICING
RECHARGING OPERATION

~

~

7-36

~

~

~

7-36
7-36
7-37
7-38

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CAUTIONS IN SERVICING

COUPLER

•

With a lock type coupler, be sure to release the lock before
disconnecting it and push it in fully till the lock works when
connecting it

•

When disconnecting the coupler, be sure to hold the coupler

itself and do not pull the lead wires

•

Inspect each terminal on the coupler for being loose or bent

•

Inspect each terminal for corrosion and contamination

CLAMP

•

Clamp the wire harness at such positions as indicated in
"WIRE HARNESS ROUTING"

•

Bend the clamp properly so that the wire harness is clamped
securely

•

In clamping the wire harness, use care not to allow it to hang

down

.

•

Do not use wire or any other substitute for the band type

clamp

.

.

.

.

.

.

-

78-14)

(C"

.

ELECTRICAL SYSTEM 7-

3

FUSE

•

When a fuse blows, always investigate the cause, correct it
and then replace the fuse

•

Do not use a fuse of a different capacity

•

Do not use wire or any other substitute for the fuse

.

.

.

SEMI-CONDUCTOR EQUIPPED PART

•

Be careful not to drop the part with a semi-conductor built in

such as a ECM

•

When inspecting this part, follow inspection instruction strictly
Neglecting proper procedure may cause damage to this part

.

.

.

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7-4 ELECTRICAL SYSTEM

BATTERY

•

The MF battery used in this motorcycle does not require main­tenance (e.g.,

replenishment)

•

During normal charging, no hydrogen gas is produced

ever, if the battery is overcharged, hydrogen gas may be pro­duced

. Therefore, be sure there are no fire or spark sources

(e.g., short circuit) nearby when charging the battery

•

Be sure to recharge the battery in a well-ventilated and open

area

.

•

Note that the charging system for the MF battery is different

from that of a conventional battery
battery with a conventional battery

electrolyte level inspection, distilled water

.

. How-

.

. Do not replace the MF

.

CONNECTING THE BATTERY

•

When disconnecting terminals from the battery for disassem-

bly or servicing, be sure to disconnect the

wire, first

•

When connecting the battery lead wires, be sure to connect
theOObattery lead wire first

•

If the terminal is corroded, remove the battery, pour warm

water over it and clean it with a wire brush

•

After connecting the battery, apply a light coat of grease to the

battery terminals

•

Install the cover over the

.

.

.

.

battery terminal

O

battery lead

O

.

WIRING PROCEDURE

•

Properly route the wire harness according to the "WIRE HAR­NESS ROUTING" section

. (CJ8-14)

USING THE MULTI CIRCUIT TESTER

•

Properly use the multi circuit testerOand
Improper use can cause damage to the motorcycle and

tester

.

•

If the voltage and current values are not known, begin mea-

suring in the highest range

•

When measuring the resistance, make sure that no voltage is
applied

•

After using the tester, be sure to turn the switch to the OFF
position

CAUTION

Before using the multi circuit tester, read its instruc-

tion manual

. If voltage is applied, the tester will be damaged

.

.

.

e

probes

.

.

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ELECTRICAL SYSTEM 7-5

LOCATION OF ELECTRICAL COMPONENTS

~ 40

•

Fuel pump (C14-68)

02 CMP sensor (C'4-92)
~3 IAP sensor (=4-91)

Ignition coil (No

•

05 Horn

. 1)

® TO sensor (=4-93)
07 Gear position switch

Starter motor

•

Oil pressure switch

•

1o ECT sensor(f-

4-93)

4-93)

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~

~

~

~

~

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~

7-6 ELECTRICAL SYSTEM

90 Cooling fan thermo-switch

Cooling fan

•

Cooling fan motor switch coupler (=5-8)

•

•

Fuel injector

~5 TP sensor (=4-91)

STP sensor

•

Secondary throttle valve actuator (=4-51)

•

IAT sensor

•

(r

-

75-8)

(r

--

74-86)

(f"74-91)

(r

--

74-92)

(

F-75-9)

O

10 ECM (Engine Control Module)

5-8)

0

13 Starter relay
14 Side-stand/turn signal relay

4-51) 15 Fuse box

16 Mode selection switch coupler

Battery

11 Fuel pump relay

AP sensor (=4-93)

4-93)

17 Ignition coil (No

18 Regulator/rectifier

19 Generator

20 Speedometer sensor
21 CKP sensor
22 Side stand switch

. 2)

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j CHARGING SYSTEM

ELECTRICAL SYSTEM 7-7

4)

4)

Regulator/rectifier

Generator

I

TROUBLE SHOOTING

Battery runs down quickly

.

I
I

I

I

I

I

I

.,

~

SCR

I
I

is

Step 1

1) Check accessories which use excessive amounts of electricity

.

Are accessories being installed?

Ig

l

.switch

I N

m

a

m

0

J

40

YES

NO

Remove accessories

Go to Step 2

.

.

Step 2

1) Check the battery for current leaks

. (=7-9)

Is the battery for current leaks OK?

YES

NO

Go to Step 3

Short circuit of wire harness

•

•

Faulty electrical equipment

.

Step 3

1) Measure the charging voltage between the battery terminals

. (11r7-9)

Is the battery charging of voltage OK?

Faulty battery

YES

NO

•

•

Abnormal driving condition

Go to Step 4

.

<Continued on next page>

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7-8 ELECTRICAL SYSTEM

Step 4

1) Measure the resistance of the generator coil
Is the resistance of generator coil OK?

. (=7-1 0)

YES

NO

Step 5

1) Measure the generator no-load voltage
Is the generator no-load voltage OK?

YES

NO

Step 6

1) Inspect the regulator/rectifier
Is the regulator/rectifier OK?

YES
NO

Step 7

1) Inspect the wirings
Are the wirings OK?

YES

NO

Go to Step 5
Faulty

Go to Step 6
Faulty

Go to Step 7

Faulty regulator/rectifier

.

Faulty battery

Short circuit of wire harness

•

•

Poor contact of couplers

.

generator

.

generator

.(I"

77-11)

.

coilordisconnected

. (C_r7-10)

lead~^.iros

Battery overcharge

•

Faulty regulator/rectifier

•

Faulty battery

•

Poor contact of generator lead wire coupler

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ELECTRICAL SYSTEM

INSPECTION

j

BATTERY CURRENT LEAKAGE

Remove the front seat

•

•

Turn the ignition switch to the OFF position

•

Disconnect theObattery lead wire

Measure the current between the
battery lead wire using the multi circuit tester
exceeds the specified value, leakage is evident

Battery current (leak)

09900-25008

~j Tester knob indication

CAUTION

* Because the current leak might be large, turn the

tester to high range first to avoid tester damage

* Do not turn the ignition switch to the "ON" position

when measuring current

: Multi circuit tester set

. (=6-7)

: Under 3 mA

: Current

.

.

.

battery terminal and the

O

. If the reading

.

20 mA)

(-,

O

.

7-9

When checking to find the excessive current leakage, remove
the couplers and connectors, one by one, checking each part

REGULATED VOLTAGE

Remove the front seat.(r'6-7)

•

Start the engine and keep it running at 5 000 r/min with the

•

dimmer switch turned HI position

Measure the DC voltage between the
nals using the multi circuit tester

specified value, inspect the generator and regulator/rectifier
(r--r7-1

NOTE

When

charged condition

.

1)

:

making

Charging output (Regulated voltage)

.

09900-25008

Tester knob indication

this

test,besure

.

: Multi circuit tester set

.

and

O

. If the voltage is not within the

that

the

14.0- 15

: Voltage

(-)

battery termi-

O

battery is in fully-

:

.5 V at 5 000 r/m i n

.

.

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7

.10 ELECTRICAL SYSTEM

GENERATOR COIL RESISTANCE

•

Remove the front seat

•

Disconnect the generator coupler

Measure the resistance among the three lead wires
If the resistance is not specified value, replace the stator with a
new one

['~Generator coil resistance

. Also, check that the generator core is insulated

. (F-

76-7)

: 0.2- 0

D

.

.

(Yellow-Yellow)

.7 S2

-

S (Yellow-Ground)

.

09900-25008
Tester knob indication

ZJ

NOTE

:
When making above test, it is not necessary to remove the gen­erator

.

GENERATOR NO-LOAD PERFORMANCE

•

Disconnect the generator coupler

•

Don't disconnect the crankshaft position sensor coupler

•

Start the engine and keep it running at 5 000 r/min

Using the multi circuit tester, measure the voltage among the
three lead wires

If the tester reads under the specified value, replace the genera­tor with a new one

: Multi circuit tester set

: Resistance (S2)

. (Crabove)

.

.

.

.

A

A

A

Generator no-load performance

75 V and more at 5 000 r/min (When engine is cold)
09900-25008
Tester knob indication

: Multi circuit tester set

: Voltage

:

(-)

~

~

I

4)

REGULATOR/RECTIFIER

•

Disconnect the couplers and remove the regulator/rectifier

Measure the voltage among the terminals using the multi circuit
tester as indicated in the table below
the specified value, replace the regulator/rectifier with a new
one

.

09900-25008

~$

Tester knob indication

g

~'

B/R

131

0

B2
B3

a

B/W

OI

B

: Black, B/R

* More than 1

: Black with Red trancer

.4 V (tester's battery voltage)

: Multi circuit tester set

: Diode test

Probe of tester to

O

B/R

*
*

131

0.4-0.70.4-0.70.4-0.70.5-1

*

. If the voltage is not within

(-W)

:

B2 B3

*

*
*

.

Unit

: V

B/W

.2

0

.4-0

.7

0

.4-0

.7

0.4-0.7

ELECTRICAL SYSTEM

7-11

NOTE

:
If the tester reads under 1
connected, replace the battery of multi circuit tester

.4 V when the tester probes are not

.

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7-12 ELECTRICAL SYSTEM

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM

Engine stop
switch

0

Starter
motor

Starter relay

To ECM and

0

ignition coil

B/Y

Clutch lever
position switch

B/W

I

Y/G

Starter
button

W

TROUBLE SHOOTING

Starter motor will not run
Step 1

1) The transmission is in neutral
switch in the "RUN" position

2) Listen for a click from the starter relay when the starter button is pushed
Is a click sound heard?

.

. Grasp the clutch lever, turn on the

ignition switch with the engine stop

.

Ignition
switch

Fuse (30 A)

.

ro
m

A

rr

In

J

YES

NO

Step 2

1) Check if the starter motor runs when its terminal is connected to the
"wire" because a large amount of current flows

Go to Step 2
Go to Step 3

.
.

.)

battery terminal

O

. (Do not use thin

Does the starter motor run?

Faulty starter relay

YES

NO

•

•

Loose or disconnected starter motor lead wire

Faulty starter motor

<Continued on next page>

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Step 3

1) Measure the starter relay voltage at the starter
starter button is pushed

Is the voltage OK?

YES

NO

Step 4

1) Check the starter relay.(F-t
Is the starter relay OK?

.

Go to Step 4

•

Faulty ignition switch

•

Faulty engine stop switch

•

Faulty clutch lever position switch
Faulty gear position switch

•

•

Faulty turn signal/side-stand relay

•

Faulty starter button

•

Poor contact of connector

•

Open circuit in wire harness

.

7-1 6)

relay connectors (between Y/GO+and B/YO)when the

ELECTRICAL SYSTEM7-1

3

YES
NO

NOTE

:

Poor contact of the starter relay
Faulty starter relay

The starter motor runs when the transmission is in neutral with the side-stand up or down, but does not run
when the transmission is in any position other than neutral with the side-stand down

2) Check the side-stand switch
Is the side-stand switch OK?

YES

NO

Engine does not turn though the starter motor runs

•

Faulty starter torque limiter (=3-64)

Open circuit in wire harness

•

•

Poor contact of connector

Faulty side-stand switch

. (CIT7-17)

.

.

STARTER MOTOR REMOVAL AND
DISASSEMBLY

•

Remove the under cowling

•

Disconnect the starter motor lead wire

starter motor

.

. (=6-5)

6-5)

90 and remove the

~

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~

7-14 ELECTRICAL SYSTEM

•

Disassemble the starter motor as shown in the illustration

.

0-ring

T

Housing

02
©3

Armature
Washer

•

0-ring

O5

Starter motor case

•

07 Starter brush holder assembly

0-ring

•

STARTER MOTOR INSPECTION

CARBON BRUSH
Inspect the brushes for abnormal wear, cracks, or smoothness

in the brush holder
If any damages are found, replace the brush assembly with a
new one

.

.

i

V

COMMUTATOR

Inspect the commutator for discoloration, abnormal wear or
undercut

If abnormal wear is found, replace the armature with a new one

OA

.

.

If the commutator surface is discolored, polish it with #400 sand
paper and wipe it using a clean dry cloth

.

If there is no undercut, scrape out the insulator 10 with a saw
blade

.

ARMATURE COIL INSPECTION
Check for continuity between each segment, and between each

segment and the armature shaft using the multi circuit tester

.

If there is no continuity between the segments or there is conti­nuity between the segments and shaft, replace the armature

with a new one

09900-25008

i E

Tester knob indication

0

e

.

: Multi circuit tester set

: Continuity test

(

•I

)))

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~

ELECTRICAL SYSTEM 7-15

OIL SEAL INSPECTION
Check the oil seal lip for damage or leakage

If any damage is found, replace the housing end

.

.

J

STARTER MOTOR REASSEMBLY

l

Reassemble the starter motor in the reverse order of disassem-

bly

. Pay attention to the following points

•

Apply SUSUKI SUPER GREASE to the lip of the oil seal

:

.

99000-25030

99000-25010

•

Apply a small quantity of SUZUKI MOLY PASTE to the arma­ture shaft

Apply a small quantity of THREAD LOCK to the starter motor

•

housing bolts

•

Apply SUZUKI SUPER GREASE to the O-ring

.

99000-25140

99000-32050

99000-25030
99000-25010

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

: SUZUKI MOLY PASTE

.

: THREAD LOCK "1342"

.

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

Tighten the starter motor lead wire nut to the specified torque

•

: 5 N

.m (0

Starter motor lead wire nut

19

.5 kgf-m, 3

.7 Ib-ft)

.

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7-16 ELECTRICAL SYSTEM

STARTER RELAY INSPECTION

•

Remove the front seat.(F--r6-7)

•

Disconnect theObattery lead wire from the battery

•

Disconnect the starter relay coupler 1O

•

Remove the starter relay cover 02

.

.

.

•

Disconnect the starter motor lead wire

wire ®

•

Remove the starter relay 05

Apply 12 V to ® and © terminals and check for continuity
between the positive and negative terminals using the multi cir­cuit tester
relay is OK

CAUTION

Do not apply a battery voltage to the starter relay for
more than five seconds, since the relay coil may over­heat and damaged

.

.

. If the starter relay clicks and continuity is found, the

.
09900-25008
Tester knob indication

: Multi circuit tester set

: Continuity test (

.

and battery lead

(s

•~

l))

Measure the relay coil resistance between the terminals using
the multi circuit tester
value, replace the starter relay with a new one

Starter relay resistance

. .

09900-25008

~y Tester knob indication

. If the resistance is not within the specified

.

: 3 - 6

: Multi circuit tester set

: Resistance (SZ)

SZ

~

~

~

~

J

SIDE-STAND/IGNITION INTERLOCK
SYSTEM PARTS INSPECTION

Check the interlock system for proper operation

system does not operate properly, check each component for
damage or abnormalities
the component with a new one

SIDE-STAND SWITCH

•

Lift and support the fuel tank

•

Disconnect the side-stand switch coupler and measure the
voltage between Green and Black/Yellow lead wires

09900-25008

P71

i

Tester knob indication

ON

(Side-stand up)

OFF

(Side-stand down)

: Multi circuit tester set

. If any abnormality is found, replace

.

.

(

F-74-65)

: Diode test (-~W)

Green

(O+

Probe)

0 .4

-

1

.4 V and more

(Tester's battery voltage)

. If the interlock

.

Black/Yellow

Probe)

(O

0

.6 V

ELECTRICAL SYSTEM 7-

1

7

NOTE

:
If the tester reads under 1
connected, replace its battery

GEAR POSITION SWITCH

•

Lift and support the fuel tank

•

Disconnect the gear position switch coupler and check the
continuity between Blue and Black with the transmission in
"NEUTRAL"

ON (Neutral)

OFF (Expect neutral)

CAUTION

When disconnecting and connecting the gear position
switch coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged

.

.4 V when the tester probes are not

.

.

(r

-

74-65)

Blue

0

Black

0

.

Down

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~

7-18

ELECTRICAL SYSTEM

•

Connect the gear position switch coupler to the wiring har­ness

.

•

Turn the ignition switch to "ON" position and side-stand to
upright position

Measure the voltage between Pink and Black lead wires using
the multi circuit tester when shifting the gearshift lever from low
to top

.

.

Gear position switch voltage

(* Low to top gear position)

(*

Except neutral position)

09900-25008
09900-25009

1

711

Tester knob indication

TURN SIGNAL/SIDE-STAND RELAY

The turn signal/side-stand relay is composed of the turn signal

relay, and the side-stand relay and diode

•

Remove the front seat

•

Remove the turn signal/side-stand relay

SIDE-STAND RELAY INSPECTION

First check the insulation betweenOandOterminals with the

tester

. Then apply 12 V to terminalsODand ©
©) and check the continuity betweenODand
continuity, replace the turn signal/side-stand relay with a new
one

.

.

.

09900-25008

: Multi circuit tester set
: Needle pointed probe set

: Voltage

. (=6-7)

6-7)

: Multi circuit tester set

.6 V and more

: 0

(Pink-Black)

(--)

.

.

(

O+

toOandOto

(e

.

If there is no

Tester knob indication

e

0

: Continuity test

(•))))

~

~

ELECTRICAL SYSTEM 7-

DIODE INSPECTION

J

~

Measure the voltage between the terminals using the multi cir-

cuit tester

0

0

0
0

0-

go

NOTE
If the multi circuit tester reads under 1

probes are not connected, replace its battery

. Refer to the following table

Probe of tester to

©, ©

~

0

©, ©

0

.4-0

.6

09900-25008
Tester knob indication

:

: Multi circuit tester set

: Diode test

.

Unit

:

OO

More than 1
(Tester's battery

voltage)

(-W)

.4 V when the tester

.

.4 V

: V

iii

© OO

1 9

~

~

7-20

ELECTRICAL SYSTEM

IGNITION SYSTEM

Engine stop switch

0

CKP
sensor

I

I

1 0

I

Cam position
sensor

ECM

Power

source

circuit

0

Wave form
arrangement

circuit

Wave form
arrangement

circuit

Throttle
position

sensor

CPU

Engine
coolant temp

sensor

.

Gear
position

switch

Ignition
coil

0

t 0

a

00

0

°

o

'ta

Spark plug

#1

#2

m m

Side-

b

standstand

relay

Fuse

Ignition
switch

Fuse

Battery

V

NOTE

:

The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine

speed reaches 10 600 r/min, this circuit cuts off fuel at the fuel injector

.

. When engine

CAUTION

Under no load, the engine can run over 10 600 r/min, even if the fuel cut-off circuit is effective,
and it may cause engine damage
time

.

. Do not run the engine without load over 10 600 r/min at any-

TROUBLESHOOTING

NOTE

:
Check that the transmission is in neutral and the engine stop switch is in the "RUN" position
lever

. Check that the fuse is not blown and the battery is fully-charged before diagnosing

No spark or poor spark
Step 1

1) Check the ignition system couplers for poor connections

.

Is there connection in the ignition switch couplers?

YES

NO

Go to Step 2

.

Poor connection of couplers

. Pull the clutch

.

<Continued on next page>

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ELECTRICAL SYSTEM 7-21

Step 2

1) Measure the battery voltage between input lead wires (O/W and B/W) at the ECM with the ignition switch
in the "ON" position
Is the voltage OK?

.

YES

NO

Step 3

1) Measure the ignition coil primary peak voltage

NOTE

:

This inspection method is applicable only with the multi circuit tester and the peak volt adaptor

Is the peak voltage OK?

YES
NO

Step 4

1) Inspect the spark plugs
Are the spark plugs OK?

YES

NO

Go to Step 3

•

Faulty ignition switch
Faulty turn signal/side-stand relay

•

•

Faulty engine stop switch

•

Broken wire harness or poor connection of related circuit couplers

Go to Step 4
Go to Step 5

. (=2-6)

Poor connection of the spark plug cap

•

•

Go to Step 5

Faulty spark plug

.

.
.

2-6)

.

(-s)

.(f"

77-22)

.

(-s)

Step 5

1) Inspect the ignition coils
Are the ignition coils OK?

YES
NO

Step 6

1) Measure the crankshaft position sensor peak voltage and its resistance

NOTE

:

The crankshaft position

peak volt adaptor

Are the peak voltage and its resistance OK?

YES

NO

.

. (E177-23)

Go to Step 6
Faulty ignition coil

sensor

Faulty ECM

•

•

Poor connection of ignition couplers

Faulty crankshaft position sensor

.

(-s)

peak voltage inspection is applicable only with the mufti circuit tester and

.

~

~

~

~

~

~

~

~

~

~

7-22

ELECTRICAL SYSTEM

INSPECTION

IGNITION COIL PRIMARY PEAK VOLTAGE

•

Lift and support the fuel tank.(l1_,,--4-65)

•

Disconnect both of the spark plug caps.(f'72-6)

•

Connect new spark plugs to each spark plug cap and ground
them

.

NOTE

:
Make sure that all couplers and spark plugs are connected prop­erly and the battery used is in fully-charged condition

CAUTION

Avoid grounding the spark plugs and suppling the
electrical shock to the cylinder head cover (magne­sium parts) in order to prevent the magnesium mate­rial from damage

.

.

Measure the No
in the following procedure

Connect the multi circuit tester with peak voltage adaptor as

•

follows

No

.

. 1 ignition coil

. 1 and No

:OOProbe

•

No

. 2 ignition coil

:OOProbe

•

NOTE

:
Do not disconnect the ignition coil primary wire coupler

. .

09900-25008

CAUTION

Before using the multi circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual

•

Shift the transmission into neutral

•

Allow the engine to crank for a few seconds, and then mea­sure the ignition coil primary peak voltage

.

: Multi circuit tester set

. 2 ignition coils primary peak voltage

.

: Black terminal

Probe

: Ground
: White/Blue terminal

Probe

: Ground

.

.

.

r

In

•

Repeat the above procedure a few times and measure the
highest ignition coil primary peak voltage

Ignition coil primary peak voltage

Tester knob indication

WARNING

A

While testing, do not touch the tester probes and
spark plugs to prevent receiving an electric shock

•

If the peak voltage is lower than the specified values, inspect

the ignition coil.(F---r7-23)

: Voltage

.

: 200 V and more

(--)

.

~

~(~

~

~

~

ELECTRICAL SYSTEM 7-23

IGNITION COIL RESISTANCE

•

J

Disconnect the spark plug caps

Measure the ignition coil resistance in both the primary and sec-

ondary windings

range, replace the ignition coil with a new one

. If the resistance is not within the standard

.

.

1

Ignition coil resistance

Primary
Secondary

09900-25008
Tester knob indication : Resistance

CKP SENSOR PEAK VOLTAGE

•

Remove the front seat

•

Disconnect the ECM coupler

NOTE

:
Make sure that all of the couplers are connected properly and
the battery used is in fully-charged condition

: 2.8-4.2 S2

: 24 -

: Multi circuit tester set

((O

terminal -Sterminal)

36 kL2 (Plug cap

. (116-7)

.

-Oterminal)

(4)

.

Measure the CKP sensor peak voltage in the following proce­dures

.

•

Connect the multi circuit tester with peak volt adaptor as fol-

lows

.

O

Probe

: Green/Blue lead wire

Probe

9

. .

09900-25008

CAUTION

Before using the multi circuit tester and peak volt

adaptor, be sure to refer to the appropriate instruction

manual

: Green lead wire

: Multi circuit tester set

.

~

~

~

~

~

~

~

~

7-

2 4

ELECTRICAL SYSTEM

•

Shift the transmission into neutral

•

Allow the engine to crank for a few seconds, and then mea­sure the CKP sensor peak voltage

•

Repeat the above procedure a few times and measure the
highest peak voltage

[

CKP sensor peak voltage

I

rPli

Tester knob indication

If the peak voltage is lower than the specified values, check the
peak voltage at the CKP sensor lead wire coupler

•

Disconnect the CKP sensor lead wire coupler and connect the
multi circuit tester with the peak volt adaptor

•

Probe

: Green lead wire

Probe

•

•

Measure the CKP sensor peak voltage at the CKP sensor

lead wire coupler in the same manner as on the ECM coupler

: Blue lead wire

.

: Voltage

.

.

: 5

.0 V and more

(-)

(Z

.

.

.

CKP sensor peak voltage

Tester knob indication

~,~
If the peak voltage on the CKP sensor lead wire coupler is OK

but on the ECM coupler is out of specification, the wire harness
must be replaced

the CKP sensor must be replaced and re-checked

CKP SENSOR RESISTANCE

Measure the resistance between the lead wires and ground
the resistance is not specified value, the CKP sensor must be
replaced

.

CKP sensor resistance

09900-25008

Tester knob indication

. If both peak voltages are out of specification,

: Multi circuit tester set

: 5

.0 V and more

: Voltage

: 130 -

W Q (Green -

: Resistance (S2)

(-)

240 Q (Green-Blue)

Ground)

.

. If

~

~

~

~

COMBINATION METER

ELECTRICAL SYSTEM

J)

Conbination meter cover
Conbination meter unit

(2

7- 2

5

REMOVAL

•

Remove the body cowling

•

Remove the meter panel mounting bolts and disconnect the
meter coupler 1T

CAUTION

•

When disconnecting and connecting the combina­tion meter coupler, make sure to turn OFF the igni­tion switch, or electronic parts may get damaged

•

Do not attempt to disassemble the combination
meter unit

.

.

.

(r

--

r6-6)

.

~

~

~

~

~

~

~

7-26

ELECTRICAL SYSTEM

PARTS NAME

10 Turn signal indicator light

(2

Neutral indicator light

(3 Indicator light (Oil, Temp

•

SELECT button

•

Clock
Coolant temperature/Fl display

•

(7

Odo/Trip meter display

•

ADJUST button

~9 Fuel indicator light

1o High beam indicator light

., FI)

OPERATING PROCEDURE

INITIAL DISPLAY

When the ignition switch is turned to ON, the indicator light
andOcome on, then ©9 goes out two seconds later

NOTE

:

If the

power supply is cut (e, g, when the battery is replaced)

* The speedometer, tripmeter and clock are displayed after the

initial display appears

* Since the clock resets to

.

"1

:00",

it will need to be readjusted

CHANGE THE DISPLAY MODE
With each press of the SELECT button, the display changes

between odometer, tripmeter A and tripmeter B as shown

WARNING

A

Odometer

-n

Tripmeter A~~ Tripmeter

To avoid riding with only one hand, do not operate the

buttons while riding

.

ODOMETER

•

Displays the total distance travelled

.

:

.

.

B1-

1

TRIPMETER

•

Displays the distance travelled since the tripmeter was last
reset

NOTE

:

The tripmeters A and B can be used independently

Hold down the ADJUST button for two seconds to reset the

•

tripmeter

.

.

~

~

CLOCK

•

Displays the time (hours and minutes) on a 12-hour clock

•

Setting the time

10 Push the SELECT and ADJUST buttons simultaneously until

the hour display starts blinking

02 Adjust the hour display by pushing the ADJUST button
NOTE

:

.

.

When the ADJUST button is kept depressed for more than two

seconds, the display progresses continuously

03 Push the SELECT button

changed

.

. The setting that is blinking can be

.

ELECTRICAL SYSTEM 7-

ADJ

2 7

® Adjust the minute display by pushing the ADJUST button

($ Push the SELECT button to finish setting time

.

.

TACHOMETER

•

The tachometer pointer operates one time as shown below to
reset tachometer pointer, when connecting the
tachometer coupler

i

.

battery or

~

~

~

~

7-28 ELECTRICAL SYSTEM

ENGINE COOLANT TEMPERATURE METER

AND INDICATOR

•

Disconnect the engine coolant temperature sensor coupler

CAUTION

When connecting and disconnecting the engine cool­ant temp
OFF the ignition switch, or electronic parts may get
damaged

•

Connect the variable resistor

•

Turn the ignition switch "ON"

•

Check the LCD and LED operations when the resistance is
adjusted to the specified values

. sensor lead wire coupler, make sure to turn

.

between the terminals

OO

.

.

.

.

Engine
coolant

temp

.

Variable resister

sensor

Resistance

AO

Over 2

(Jumper wire)

If either one or all indications are abnormal, replace the combi-

nation meter with a new one

NOTE
If the engine stop switch is turned OFF while the ignition switch
is ON, the LCD displays "CHEC"
This condition implies that combination meter receives no signal
from the ECM
In that case, they are restored to ordinary indication by turning
the engine stop switch RUN

.45 kS

Approx

0

.811 kS2

Approx

0

.1 kS2
0c

:

LED © LCD ©

OFF

.

OFF

.

ON

ON

.

---

"50"

"120"-"139"

"HI"

.

. But it is not malfunction

.

LCD

0

-

Flicker

Flicker

Water

temperature
Under 19 °C

Approx

120-139

Over 140 °C

50 °C

.

.

0

C

~

~

~

~

1

FUEL LEVEL INDICATOR SWITCH INSPECTION

. (=4-69)

•

Remove the fuel pump assembly

•

Connect 12 V battery and test bulb (12 V, 3
level indicator switch as shown in the right illustrations
bulb should come on after several seconds if the switch is in
good condition

.

4-69)

.4 W) to the fuel

. The

ELECTRICAL SYSTEM 7-

29

•

When the switch is immersed in water under the above condi­tion, the bulb should go out
unit with a new one

FUEL LEVEL INDICATOR LIGHT INSPECTION
If the fuel level indicator light does not function properly, check

the fuel level indicator switch and its lead wire/coupler

If the fuel level indicator switch and its lead wire/coupler are all
right, replace the combination meter with a new one

OIL PRESSURE INDICATOR
NOTE

:
Before inspecting the oil pressure switch, check the engine oil
level.(rr2-15)

.

. If the bulb remains it, replace the

.

.

•

Remove the under cowling

•

Disconnect the oil pressure switch lead wire from the oil pres-

sure switch

•

Turn the ignition switch "ON" position

.

.(C7-6-5)

.

~

~

~

7

.30 ELECTRICAL SYSTEM

Check if the oil pressure indicator will light, when grounding the
lead wire
replace the meter with a new one after checking the connection
of couplers

SPEEDOMETER
If the speedometer, odometer or trip meter does not function

properly, inspect the speedometer sensor and connection of

coupler 1)

right, replace the meter with a new one

. If the oil pressure indicator does not function properly,

.

. If the speedometer sensor and connection are all

.

SPEEDOMETER SENSOR

•

Disconnect speedometer sensor coupler

•

Remove the speedometer sensor (2 by removing its mounting

bolt

.

•

Connect 12 V battery, 10 kQ resistor and the multi circuit
tester as shown in the right illustration

B/R

: Black with Red tracer

B/W

: Black with White tracer

B

: Black

:

.

09900-25008
Tester knob indication

•

Under above condition, if a suitable screwdriver touching the
pick-up surface of the speedometer sensor is moved, the

tester reading voltage changes (0 V

the tester reading voltage does not change, replace the
speedometer sensor with a new one

NOTE

:
The highest voltage reading in this test will be the same as that
of battery voltage

: Multi circuit tester set

: Voltage

.

.

.

(=)

- 12 V or 12 V -

.

0 V)

. If

~

~

~

~

LAMPS
HEADLIGHT AND POSITION LIGHT

ELECTRICAL SYSTEM7-3

10

Head light
12 V 60/55 W x 2

(2 Position light

12 V 5 W x 2

1

l

BULB REPLACEMENT
Headlight

•

Remove the headlight coupler and boot

•

Unhook the holder spring 9I and replace the headlight bulb

Position light

•

Open the lids

•

Remove the position light couplers 10

. (L & R)

.

. (L & R)

.

CAUTION

If you touch the bulb with your bare hands, clean the
bulb with a cloth moistened with alcohol or soapy

water to prevent premature bulb failure

.

~

~

7-32

ELECTRICAL

HEADLIGHT BEAM ADJUSTMENT

Adjust the headlight beam, both vertical and horizontal

•

Turn the adjuster

NOTE

:

To adjust the headlight beam, adjust the beam horizontally first,
then adjust the vertically

•

Turn the bolt © for the vertical adjustment

SYSTEM

for the horizontal adjustment

OA

.

.

.

.

BRAKE LIGHT/TAILLIGHT, TURN SIGNAL LIGHT AND LICENCE PLATE
LIGHT

RELAYS

TURN SIGNAL/SIDE-STAND RELAY

The turn signal/side-stand relay is composed of the turn signal

relay, side-stand relay and diode

INSPECTION
Before removing the turn signal/side-stand relay, check the

operation of the turn signal light
If the turn signal light does not illuminate, inspect the bulb, turn
signal switch and circuit connection
If the bulb, turn signal switch and circuit connection are OK, the

turn signal relay may be faulty

side-stand relay with a new one

NOTE

:

* Make sure that the battery is fully charged
* Refer to page 7-17 for the side-stand relay and diode inspec-

tion

.

.

.

.

; therefore, replace the turn signal/

.

.

ELECTRICAL SYSTEM 7-33

T)

SIDE-STAND RELAY

TURN

SIGNAL

RELAY

4)

STARTER RELAY
r -

77-1

6

FUEL PUMP RELAY

17'4-69

~

~

~

~

~

7-34

ELECTRICAL SYSTEM

SWITCHES

IGNITION SWITCH REMOVAL

•

Lift and support the fuel tank

•

Remove the air cleaner box.(F

•

Disconnect the ignition switch coupler

•

Remove the body cowling.(

•

Remove the ignition switch mounting bolts with the special
tools

.

. (=4-65)

74-75)

--

r -

76-6)

.

09930-11920
09930-11940

CAUTION

When reusing the ignition switch bolt, clean thread and

apply THREAD LOCK

99000-32050

: Torx bit JT40H
: Bit holder

.

: THREAD LOCK "1342"

~

~

ELECTRICAL SYSTEM 7.3 5

J

J

Inspect each switch for continuity with the multi circuit tester

tive switch assemblies with new ones

09900-25008

IGNITION

Position

ON

P

DIMMER SWITCH

Position

HI (=D)

LO (D)

TURN SIGNAL SWITCH

Position

L

PUSH

R

PASSING LIGHT SWITCH

Position

PUSH

ENGINE STOP SWICH

Position
OFF (>Z)

RUN (0)

STARTER BUTTON

Position

PUSH

HORN BUTTON

Position

PUSH

SWITCH

Color

Color

Color

Color

Color

Color

Color

: Multi circuit tester set

R

W

0 0

Lg

0

0

y
0 0

Lbl

0 0

0

0 Y

O/B

0

O/W

0

13/131

0

ON

.

Br

0

B

O/W

Y/G

B/W

. If any abnormality is found, replace the respec-

HAZARD

Color

Position

ON

OFF

FRONT BRAKE SWITCH

Color

Position

OFF

ON

REAR BRAKE SWITCH

Color

Position

OFF

ON

CLUTCH LEVER POSITION SWITCH

Color

Position

OFF

ON

OIL PRESSURE SWITCH

Color

Position

ON (engine

is stopped)

OFF (engine

is running)

NOTE

:
Before inspecting the oil pressure switch, check the
engine oil level

WIRE COLOR
B~:

Black

Br

: Brown

LbI

: Light blue

Lg

: Light green

0

:

Orange

R

:

Red

Y~:

Yellow

W

: White

Lg

0

B/R

O/G

B/Y

G/Y Ground

. (C72-15)

Lbl

0

0 0

W/B

0

O O

B/BI

: Black with Blue tracer

B/W

: Black with White tracer

B/Y

: Black with Yellow tracer

B/R

: Black with Red tracer

G/Y

: Green with Yellow tracer

O/B

: Orange with Black tracer

O/G

: Orange with Green tracer

O/W

: Orange with White tracer

ON

:Orange with Yellow tracer

W/B

: White with Black tracer

Y/G

: Yellow with Green tracer

B
0

B/BI

0

B/Y

~

~

~

~

~

~

~

~

~

7-36

ELECTRICAL SYSTEM

BATTERY

SPECIFICATIONS

Type designation

Capacity

Anode plates

•

Separator (fiberglass plate)

•

Cathode plates

•

Upper cover breather

•

12 V, 43

FTX14-BS

.2 kC (12 Ah)/10 HR

© Stopper

Filter

•

Terminal

•

•

Safety valve

INITIAL CHARGING

FILLING ELECTROLYTE

•

Remove the aluminum tape 10 sealing the battery electrolyte
filler holes 02

•

Remove the caps

.

(T

.

NOTE

:

* After filling the electrolyte completely, use the removed caps

O3 as the sealed caps of battery filler holes

* Do not remove or pierce the sealed areas ® of the electrolyte

container

•

Insert the nozzles of the electrolyte container ($ into the bat-

tery's electrolyte filler holes, holding the container firmly so

that it does not fall
fluid to spill

.

. Take precaution not to allow any of the

.

.

IN

V

~

~

~

ELECTRICAL SYSTEM7-37

•

Make sure air bubbles © are coming up each electrolyte con-

tainer, and leave in this position for about more than 20 min-

0

O

oV

0

0

J

°

0

L)

U

O

o

Vo

0

U

O

O

°

o

I

0

H,

I

U

0

O

o

0

U

G

V

0

Go

G

oU

0

0G

~`

1

utes

.

NOTE

:

If on air bubbles are coming up from a filler port, tap the bottom
of the electrolyte container two or three times
Never remove the container from the battery

•

After confirming that the electrolyte has entered the battery
completely, remove the electrolyte containers from the bat-

tery

. Wait for about more than 20 minutes

.

.

.

l

•

Insert the caps O7 into the filler holes, pressing in firmly so that

the top of the caps do not protrude above the upper surface of
the battery's top cover

CAUTION

•

Never use anything except the specified battery

•

Once install the caps to the battery

the caps

•

Do not tap the caps with a hammer when installing

them

.

.

.

.

; do not remove

~

~

~

~

~

~

~

~

7-

ELECTRICAL SYSTEM

3

8

•

For initial charging, use the charger specially designed for MF
battery

CAUTION

•

•

•

.

For charging the battery, make sure to use the
charger specially designed for MF battery
wise, the battery may be overcharged resulting in

shortened service life

Do not remove the cap during charging

Position the battery with the cap facing upward dur­ing charging

.

.

. Other-

.

SERVICING

Visually inspect the surface of the battery container
of cracking or electrolyte leakage from the sides of the battery

have occurred, replace the battery with a new one

terminals are found to be coated with rust or an acidic white
powdery substance, clean the battery terminals with sandpaper

. If any signs

. If the battery

.

RECHARGING OPERATION

•

Measure the battery voltage using the multi circuit tester

the voltage reading

battery with a battery charger

CAUTION

When recharging the battery, remove the battery from
the motorcycle

NOTE

:

While recharging, do not remove the caps on the top of the bat-

tery

.

Recharging time

CAUTION

Be careful not to permit the charging current to
exceed 6 A at any time

•

After recharging, wait at least 30 minutes and then measure
the battery voltage using the multi circuit tester

voltage is less than 12

battery voltage is still less than 12
replace the battery with a new one

•

When a battery is left unused for a long time, its voltage
needs to be regularly measured

used for more than one month (especially during the winter
season), measure the battery voltage at least once a month

is less

.

: 1

.4 A for 5 to 10 hours or 6 A for 1 hour

than the

.

.

.5 V, recharge the battery again

12 V

.5 V after recharging,

.

. When the motorcycle is not

recharge the

(DC),

. If the battery

. If

. If the

.

Charging period

(V)

18
17

16
15
14 ­13
12

0 10

Stop charging

20

30 40 50

Time

60

(Minutes)