TOOL: Spoke wrench 5.8 x 6.1 mm 07701-0020300

 

TORQUE: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)

 

STEERING HEAD BEARINGS

 

Support the motorcycle using a safety stand or hoist, raise the front wheel off the ground.

 

Check that the handlebar moves freely from side to side. Make sure the control cables do not interfere with the handlebar rotation.

 

Check for steering stem bearings by grabbing the fork legs and attempting to move the front fork forward to backward.

 

If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (page 16-21).

 

3-20

PGM-FI SYSTEM

 

 

SERVICE INFORMATION·····························4-2 PGM-FI SYSTEM LOCATION·······················4-2 PGM-FI SYSTEM DIAGRAM·························4-3

 

PGM-FI TROUBLESHOOTING INFORMATION··············································4-4

 

PGM-FI SYMPTOM TROUBLESHOOTING···································4-6

 

DTC INDEX····················································4-7

 

SENSOR UNIT POWER LINE

INSPECTION ·················································4-8

 

DTC TROUBLESHOOTING························4-10 MIL TROUBLESHOOTING ·························4-29 MIL CIRCUIT TROUBLESHOOTING ·········4-43 SENSOR UNIT ············································4-44 ECT SENSOR ·············································4-46

O2 SENSOR·················································4-47

 

BANK ANGLE SENSOR·····························4-48

 

ECM·····························································4-49

 

 

4-1

PGM-FI SYSTEM

SERVICE INFORMATION

 

GENERAL

 

• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before proceeding.

• When disassembling the PGM-FI system parts, note the location of the O-rings. Replace them with new ones upon reassembly.

 

• Use a digital tester for PGM-FI system inspection.

• The following color codes are used throughout this section.

 

Bu = Blue	G = Green	Lb = Light Blue	O = Orange	R = Red	Y = Yellow
Bl = Black	Gr = Gray	Lg = Light Green	P = Pink	W = White	Br = Brown

 

PGM-FI SYSTEM LOCATION

 

 

IGNITION SWITCH	ENGINE STOP SWITCH

 

 

ECM

 

DLC

 

BANK ANGLE SENSOR

 

FUEL PUMP

 

INJECTOR

 

IACV

 

 

O2 SENSOR

 

			SENSOR UNIT:
ECT SENSOR			VS SENSOR
		– MAP SENSOR
		CKP SENSOR
		– IAT SENSOR

– TP SENSOR

 

4-2

PGM-FI SYSTEM

PGM-FI SYSTEM DIAGRAM

 

R/W

FAN FUSE (10 A)

Bl/W

IGNITION SWITCH

ENGINE STOP SWITCH

ALTERNATOR

R/W

R/W

FI, IGN FUSE (10 A)

Bl/G

Bl/Bu

Bl/R

METER, TAIL

R/W

R/W

FUSE (10 A)

Bl

Y

Y Y

G

STARTER

RELAY

REGULATOR/

SWITCH

MAIN

STARTER SWITCH

RECTIFIER

FUSE

G/R

(30 A)

Y/R

Bl/Bu

CKP SENSOR

STARTER

MOTOR

Br

Bl/Bu

BATTERY

G

Bl/W

Y/R

Br/R

Bl/Bu

FUEL

G/R

PUMP

RELAY

Lg/R

G/R

G/R

NLSW

Br

FLR

FUEL PUMP UNIT

DIODE

CLUTCH

Bl/Bu

NEUTRAL

IGP

SWITCH

SWITCH

SPEEDOMETER

Bl

G

UP

Bl

FI-IND

W/Bu

G/W

G/O

G/O

SSTAND

MIL

G

DOWN

TW-IND

G/Bu

SIDESTAND SWITCH

(11)

HIGH COOLANT

ECM

TEMPERATURE INDICATOR

Bu/Y

VS SENSOR

W/Y

PCP

G/Bl

G

PCM

Bl/R

Bl

P

W/R

 

(54)	Bl/Bu					Bl/W	Bl/W
					FAN
				Bl/G
R/Bu					CONTROL
BANK ANGLE		BA	FANC
		RELAY
SENSOR					W/R
				VSP	Bu	G
	SENSOR UNIT
				Bl/Bu	(12)
(1)
			INJ	P/W
Lg/Bl		PB		Bl
MAP SENSOR		INJECTOR
(8)					IGNITION COIL	SPARK PLUG
				Bl/Bu
Y		THL		G/R
TP SENSOR		IGPLS

 

(9)		Gr/Bu		TA			O/G		Bl/Bu
				EX-AI
IAT SENSOR		Y/Bu						PAIR CONTROL
(7)			TW				SOLENOID VALVE	Bl/Bu
				K-LINE		Y		SCS CONNECTOR
ECT SENSOR		G/W
		SG	SCS
		Y/R	Bu
			VCC
						G
					Bu/W
					IACV1A			DLC
					Bu/Bl
(21)					IACV1B
Bl	Bl/W			Br/W	IACV
	O2	IACV2A
O2 SENSOR					IACV2B		Br/Bl

 

		PG1 10 PG2		LG	(29)
	G	G	G/Bl
					Br: Brown
					Bl: Black
(): MIL number				Y: Yellow
				Bu: Blue
: Engine does not start					G: Green
				R: Red
when detecting MIL					W: White
:Short terminals for					O: Orange
				Lg: Light green
reading MIL
	ECM 33P (BLACK) CONNECTOR	Gr: Gray
		P: Pink
		(ECM side of the male terminals)

 

4-3

PGM-FI SYSTEM

PGM-FI TROUBLESHOOTING INFORMATION

 

GENERAL TROUBLESHOOTING

 

Intermittent Failure

 

The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out, the original problem may be intermittent.

 

Opens and Shorts

 

"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With ECMs this can something mean something work, but not the way it’s supposed to.

 

If the MIL has come on

 

Refer to DTC READOUT (page 4-5).

 

If the MIL did not stay on

 

If the MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 4-6).

 

SYSTEM DESCRIPTION

 

SELF-DIAGNOSIS SYSTEM

 

The PGM-FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system, the ECM turns on the MIL and stores a DTC in its erasable memory.

 

FAIL-SAFE FUNCTION

 

The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by pre-programed value in the simulated program map. When any abnormality is detected in the injector, the fail-safe function stops the engine to protect it from damage.

 

MIL Blink Pattern

 

• DTC can be read from the ECM memory by the MIL blink pattern.

• The MIL will blink the current DTC, in case the ECM detects the problem at present, when the ignition switch ON and engine stop switch " " or idling. The MIL will stay ON when the engine speed is over 2,100 min^-1 (rpm).

 

• The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for 1.3 seconds, the short blinking lasts for 0.3 seconds. One long blink is the equivalent of ten short blinks. For example, when two long blinks are followed by five short blinks, the MIL is 25 (two long blinks = 20 blinks, plus five short blinks).

 

• When the ECM stores more than one DTC, the MIL will indicate them by blinking in the order from the lowest number to highest number.

 

MIL Check

 

When the ignition switch is turned ON and engine stop switch " " the MIL will stay on for a few seconds, then go off. If the MIL does not come on, troubleshoot the MIL circuit (page 4-43).

 

CURRENT DTC/STORED DTC

 

The DTC is indicated in two ways according to the failure status.

 

• In case the ECM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC when the sidestand is lowered. It is possible to readout the MIL blink pattern as the current DTC.

• In case the ECM does not detect any problem at present but has a problem stored in its memory, the MIL will not light and blink. If it is necessary to retrieve the past problem, readout the stored DTC by following the DTC readout procedure (page 4-5).

 

4-4

PGM-FI SYSTEM