Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

• Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench [A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

• Tighten:

Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft·lb)

• Install:

Stick Coils (see Stick Coil (Ignition Coil together with

Spark Plug Cap) Installation in the Electrical System chapter)

 

 

 

 

Fuel System (DFI)

Table of Contents

Exploded View........................................................................................................................ 3-4

DFI System............................................................................................................................. 3-10

DFI System............................................................................................................................. 3-12

DFI Parts Location.................................................................................................................. 3-15 3

Specifications......................................................................................................................... 3-16

Special Tools and Sealant...................................................................................................... 3-18

DFI Servicing Precautions...................................................................................................... 3-20

DFI Servicing Precautions................................................................................................ 3-20

Troubleshooting the DFI System............................................................................................ 3-22

Outline................................................................................................................................. 3-22

Outline............................................................................................................................... 3-22

Inquiries to Rider.................................................................................................................. 3-26

Inquiries to Rider............................................................................................................... 3-26

DFI System Troubleshooting Guide....................................................................................... 3-29

Self-Diagnosis........................................................................................................................ 3-37

Self-diagnosis Outline.......................................................................................................... 3-37

Self-diagnosis Outline....................................................................................................... 3-37

Self-diagnosis Procedures................................................................................................... 3-37

Self-diagnosis Procedures................................................................................................ 3-37

Service Code Clearing Procedures..................................................................................... 3-38

Service Code Clearing Procedures................................................................................... 3-38

How to Read Service Codes................................................................................................ 3-40

How to Read Service Codes............................................................................................. 3-40

How to Erase Service Codes............................................................................................... 3-40

How to Erase Service Codes............................................................................................ 3-40

Service Code Table.............................................................................................................. 3-41

Service Code Table........................................................................................................... 3-41

Backups............................................................................................................................... 3-42

Backups............................................................................................................................ 3-42

Main Throttle Sensor (Service Code 11)................................................................................ 3-44

Main Throttle Sensor Removal/Adjustment...................................................................... 3-44

Main Throttle Sensor Input Voltage Inspection................................................................. 3-44

Main Throttle Sensor Output Voltage Inspection.............................................................. 3-45

Main Throttle Sensor Resistance Inspection.................................................................... 3-46

Inlet Air Pressure Sensor (Service Code 12).......................................................................... 3-47

Inlet Air Pressure Sensor Removal................................................................................... 3-47

Inlet Air Pressure Sensor Installation................................................................................ 3-47

Inlet Air Pressure Sensor Input Voltage Inspection........................................................... 3-47

Inlet Air Pressure Sensor Output Voltage Inspection........................................................ 3-48

Inlet Air Temperature Sensor (Service Code 13).................................................................... 3-52

Inlet Air Temperature Sensor Removal/Installation........................................................... 3-52

Inlet Air Temperature Sensor Output Voltage Inspection.................................................. 3-52

Inlet Air Temperature Sensor Resistance Inspection........................................................ 3-53

Water Temperature Sensor (Service Code 14)...................................................................... 3-54

Water Temperature Sensor Removal/Installation............................................................. 3-54

Water Temperature Sensor Output Voltage Inspection..................................................... 3-54

Water Temperature Sensor Resistance Inspection........................................................... 3-55

Crankshaft Sensor (Service Code 21).................................................................................... 3-56

Crankshaft Sensor Removal/Installation........................................................................... 3-56

Crankshaft Sensor Inspection........................................................................................... 3-56

 

 

 

Speed Sensor (Service Code 24, 25)..................................................................................... 3-57

Speed Sensor Removal/Installation.................................................................................. 3-57

Speed Sensor Inspection.................................................................................................. 3-57

Speed Sensor Input Voltage Inspection............................................................................ 3-57

Speed Sensor Output Voltage Inspection......................................................................... 3-57

Vehicle-down Sensor (Service Code 31)................................................................................ 3-59

Vehicle-down Sensor Removal......................................................................................... 3-59

Vehicle-down Sensor Installation...................................................................................... 3-59

Vehicle-down Sensor Inspection....................................................................................... 3-59

Subthrottle Sensor (Service Code 32).................................................................................... 3-62

Subthrottle Sensor Removal/Adjustment.......................................................................... 3-62

Subthrottle Sensor Input Voltage Inspection..................................................................... 3-62

Subthrottle Sensor Output Voltage Inspection.................................................................. 3-63

Subthrottle Sensor Resistance Inspection........................................................................ 3-64

Oxygen Sensor-not activated (Service Code 33) (Europe Models)........................................ 3-66 Oxygen Sensor Removal/Installation................................................................................ 3-66

Oxygen Sensor Inspection................................................................................................ 3-66

Stick Coils #1, #2: (Service Code 51, 52).............................................................................. 3-68

Stick Coil Removal/Installation.......................................................................................... 3-68

Stick Coil Input Voltage Inspection.................................................................................... 3-68

Radiator Fan Relay (Service Code 56)................................................................................... 3-70

Radiator Fan Relay Removal/Installation.......................................................................... 3-70

Radiator Fan Relay Inspection.......................................................................................... 3-70

Subthrottle Valve Actuator (Service Code 62)........................................................................ 3-71

Subthrottle Valve Actuator Removal................................................................................. 3-71

Subthrottle Valve Actuator Audible Inspection.................................................................. 3-71

Subthrottle Valve Actuator Inspection............................................................................... 3-71

Subthrottle Valve Actuator Resistance Inspection............................................................ 3-71

Subthrottle Valve Actuator Input Voltage Inspection......................................................... 3-72 Air Switching Valve (Service Code 64)................................................................................... 3-73

Air Switching Valve Removal/Installation.......................................................................... 3-73

Air Switching Valve Inspection.......................................................................................... 3-73

Oxygen Sensor Heater (Service Code 67) (Europe Models)................................................. 3-74

Oxygen Sensor Heater Removal/Installation.................................................................... 3-74

Oxygen Sensor Heater Inspection................................................................................... 3-74

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)..................... 3-76 Oxygen Sensor Removal/Installation................................................................................ 3-76

Oxygen Sensor Inspection................................................................................................ 3-76

FI Indicator Light (LED).......................................................................................................... 3-78

FI Indicator Light (LED) Inspection................................................................................... 3-79 ECU........................................................................................................................................ 3-80

ECU Removal................................................................................................................... 3-80

ECU Installation................................................................................................................ 3-80

ECU Power Supply Inspection.......................................................................................... 3-81 Fuel Line................................................................................................................................. 3-83

Fuel Pressure Inspection.................................................................................................. 3-83

Fuel Flow Rate Inspection................................................................................................ 3-85

Fuel Pump.............................................................................................................................. 3-87

Fuel Pump Removal......................................................................................................... 3-87

Fuel Pump Installation...................................................................................................... 3-87

Fuel Pump Operation Inspection...................................................................................... 3-88

Fuel Pump Operating Voltage Inspection......................................................................... 3-88

Pressure Regulator Removal............................................................................................ 3-89

Pump Screen, Fuel Filter Cleaning................................................................................... 3-89 Fuel Injectors.......................................................................................................................... 3-91

Removal/Installation.......................................................................................................... 3-91

Audible Inspection............................................................................................................. 3-91

 

 

 

Fuel Injector Power Source Voltage Inspection................................................................ 3-91

Fuel Injector Output Voltage Inspection............................................................................ 3-92

Injector Signal Test............................................................................................................ 3-92

Injector Resistance Inspection.......................................................................................... 3-93

Injector Unit Test............................................................................................................... 3-94

Injector Fuel Line Inspection............................................................................................. 3-94

Throttle Grip and Cables........................................................................................................ 3-96

Throttle Grip Free Play Inspection.................................................................................... 3-96

Throttle Grip Free Play Adjustment................................................................................... 3-96

Throttle Cable Installation................................................................................................. 3-96

Throttle Cable Lubrication................................................................................................. 3-96

Throttle Body Assy................................................................................................................. 3-97

Idle Speed Inspection....................................................................................................... 3-97

Engine Vacuum Synchronization Inspection/Adjustment.................................................. 3-97 High Altitude Performance Adjustment............................................................................. 3-97

Throttle Body Assy Removal............................................................................................. 3-97

Throttle Body Assy Installation.......................................................................................... 3-98

Throttle Body Assy Disassembly...................................................................................... 3-99

Throttle Body Assy Assembly.................................................................................................. 3-100

Air Cleaner..................................................................................................................................... 3-101

Air Cleaner Element Removal/Installation............................................................................... 3-101

Air Cleaner Element Inspection............................................................................................... 3-101

Air Cleaner Oil Draining........................................................................................................... 3-101

Air Cleaner Housing Removal................................................................................................. 3-101

Air Cleaner Housing Installation............................................................................................... 3-102

Fuel Tank....................................................................................................................................... 3-103

Fuel Tank Removal.................................................................................................................. 3-103

Fuel Tank Installation............................................................................................................... 3-105

Fuel Tank and Cap Inspection................................................................................................. 3-106

Fuel Tank Cleaning.................................................................................................................. 3-107

Evaporative Emission Control System (California Model)............................................................ 3-108

Parts Removal/Installation....................................................................................................... 3-108

Hose Inspection....................................................................................................................... 3-108

Separator Inspection................................................................................................................ 3-108

Separator Operation Test......................................................................................................... 3-109

Canister Inspection.................................................................................................................. 3-109

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Fuel Pump Bolts	9.8	1.0	87 in·lb	L, S

2. FI Indicator Light (LED)

3. Throttle Cable (Accelerator)

4. Throttle Cable (Decelerator)

5. Throttle Body Assy

6. Injectors

7. Meter Unit (EX650B Models) CL: Apply cable lubricant.

EO: Apply engine oil. G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

S: Follow the specified tightening sequence.

 

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Water Temperature Sensor		1.2	106 in·lb
	Speed Sensor Bolt	7.8	0.80	69 in·lb	L
	Oxygen Sensor (Europe Models)	44.1	4.50	32.5

4. Inlet Air Pressure Sensor

5. Air Switching Valve

6. Inlet Air Temperature Sensor

7. Crankshaft Sensor

8. Battery

9. Relay Box

10. Stick Coil

11. Vehicle-down Sensor

12. ECU (Electronic Control Unit)

13. California Model G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

SS: Apply silicone sealant.

 

 

California Model

 

1. Tube (Green)

2. Tube (Blue)

3. Tube (White)

4. Tube (Blue)

5. Tube (Red)

 

DFI System

 

1. Ignition Switch

2. Starter Lockout Switch

3. Starter Relay

4. Tachometer

5. FI Indicator Light (LED)

6. Inlet Air Pressure Sensor

7. Spark Plug

8. Crankshaft Sensor

9. Injector

10. Main Throttle Sensor

11. Delivery Pipe

12. Subthrottle Sensor

13. Subthrottle Valve

14. Main Throttle Valve

15. Subthrottle Valve Actuator

16. Fuel Pump

17. Pressure Regulator

18. Fuel Tank

19. Air Cleaner Element

20. Air Switching Valve

21. Inlet Air Temperature Sensor

22. Air Cleaner Housing

23. Neutral Switch

24. Speed Sensor

25. Vehicle-down Sensor

26. Oxygen Sensor (Europe Models)

27. ECU (Electronic Control Unit)

28. Battery

29. Air Flow

30. Fuel Flow

31. Water Temperature Sensor

 

 

DFI System Wiring Diagram

 

Part Name

1. Oxygen Sensor (Europe Models)

2. Crankshaft Sensor

3. Inlet Air Temperature Sensor

4. Water Temperature Sensor

5. Water-proof Joint E

6. Injectors

7. Vehicle-down Sensor

8. Water-proof Joint D

9. Inlet Air Pressure Sensor

10. Main Throttle Sensor

11. Subthrottle Sensor

12. Subthrottle Valve Actuator

13. Speed Sensor

14. Air Switching Valve

15. Water-proof Joint C

16. Stick Coils

17. Fan Motor

18. Engine Stop Switch

19. Ignition Switch

20. FI Indicator Light (LED)

21. Water Temperature Gauge

22. Tachometer

23. Speedometer

24. Water-proof Joint A

25. Water-proof Joint B

26. Oxygen Sensor Heater Fuse 10 A

27. Radiator Fan Fuse 15 A

28. ECU Fuse 15 A

29. Ignition Fuse 10 A

30. Radiator Fan Relay

31. ECU Main Relay

32. Fuel Pump Relay

33. Relay Box

34. Main Fuse 30 A

35. Battery

36. Frame Ground

37. Fuel Pump

38. Diagnosis Connector

39. Self-diagnosis Terminal

40. Joint Connector

41. ECU

 

 

 

Terminal Names

1. Subthrottle Valve Actuator Drive Signal 2

2. Subthrottle Valve Actuator Drive Signal 1

3. Water Temperature Warning Light Signal

4. Unused

5. Oxygen Sensor Signal (Europe Models)

6. Speed Sensor Signal

7. Main Throttle Sensor Signal

8. Inlet Air Pressure Sensor Signal

9. Unused

10. Power Supply to Sensors

11. Vehicle-down Sensor Signal

12. Neutral Switch Signal

13. Crankshaft Sensor (+) Signal

14. Unused

15. Unused

16. Power Supply to ECU (from ECU Main Re- lay)

17. Power Supply to ECU (from Battery)

18. Subthrottle Valve Actuator Drive Signal 4

19. Subthrottle Valve Actuator Drive Signal 3

20. Water Temperature Sensor Signal

21. Unused

22. Self-diagnosis Terminal

23. Unused

24. Subthrottle Sensor Signal

25. Unused

26. Inlet Air Temperature Sensor Signal

 

27. Unused

28. Ground to Sensors

29. Oxygen Sensor Heater Signal (Europe Models)

30. Crankshaft Sensor (–) Signal

31. Unused

32. External Diagnosis System Signal

33. Unused

34. Ground to ECU

35. Engine Stop Switch Signal

36. Starter Lockout Switch Signal

37. Starter Button Signal

38. Unused

39. Fuel Pump Relay Signal

40. Air Switching Valve Signal

41. Fuel Injector #2 Signal

42. Fuel Injector #1 Signal

43. Stick Coil #1 Signal

44. Sidestand Switch Signal

45. Radiator Fan Relay Signal

46. External Communication Line (Mode Switch)

47. Tachometer Signal

48. FI Indicator Light (LED)

49. –

50. Ground for Fuel System

51. Ground for Ignition System

52. Stick Coil #2 Signal

 

 

DFI Parts Location

DFI: Digital Fuel Injection Parts

1. FI Indicator Light (LED)

2. Ignition Switch

3. Throttle Body Assy

4. Inlet Air Temperature Sensor

5. Injectors

6. Fuel Pump

7. Relay Box (ECU Main Relay, Fuel Pump Relay, Radiator Fan Relay)

8. Fuse Box (ECU Fuse 15 A, Oxygen Sen- sor Heater Fuse 10 A)

9. ECU

10. Battery

11. Oxygen Sensor (Europe Models)

12. Speed Sensor

13. Neutral Switch

14. Water Temperature Sensor

15. Subthrottle Sensor

16. Main Throttle Sensor

17. Subthrottle Valve Actuator

18. Stick Coils

19. Inlet Air Pressure Sensor

20. Diagnosis Connector

21. Self-diagnosis Terminal

22. Air Switching Valve

23. Crankshaft Sensor

24. Vehicle-down Sensor

 

 

Specifications

Item

Standard

Digital Fuel Injection System Idle Speed Throttle Assy: Type Bore ECU (Electronic Control Unit): Make Type Usable Engine Speed Fuel Pressure (High Pressure Line): Right after Ignition Switch ON After 3 Seconds from Ignition Switch ON With Engine Idling Fuel Pump: Type Discharge Fuel Injectors: Type Nozzle Type Resistance Main Throttle Sensor: Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Inlet Air Pressure Sensor: Input Voltage Output Voltage Inlet Air Temperature Sensor: Resistance Output Voltage at ECU Water Temperature Sensor: Resistance Output Voltage at ECU Speed Sensor: Input Voltage at Sensor Output Voltage at Sensor Vehicle-down Sensor: Detection Method Detection Angle

1 300 ±50 r/min (rpm) Two barrel type 38 mm (1.50 in.) Denso Digital memory type, with built in IC igniter, sealed with resin 100 ~ 11 000 r/min (rpm) (Europe Models) 100 ~ 11 160 r/min (rpm) (Other than Europe Models) 323 kPa (3.3 kgf/cm², 47 psi) with fuel pump running 265 kPa (2.7 kgf/cm², 38 psi) with fuel pump stopped 333 kPa (3.4 kgf/cm², 48 psi) with fuel pump running In-tank friction pump 60 mL or more for 3 seconds INP-287 One spray type with 12 holes About 11.7 ~ 12.3 Ω at 20°C (68°F) Non-adjustable and non-removable 4.75 ~ 5.25 V DC between BL and BR/BK leads 1.073 ~ 1.077 V DC between Y/W and BR/BK leads 4.29 ~ 4.49 V DC between Y/W and BR/BK leads 4 ~ 6 kΩ 4.75 ~ 5.25 V DC between BL and BR/BK leads 3.80 ~ 4.20 V DC at standard atmospheric pressure (see this text for details) 5.4 ~ 6.6 kΩ at 0°C (32°F) 0.29 ~ 0.39 kΩ at 80°C (176°F) About 2.25 ~ 2.50 V at 20°C (68°F) see Electrical System chapter About 2.80 ~ 2.97 V at 20°C (68°F) About 9 ~ 11 V DC at Ignition Switch ON About 0.05 ~ 0.07 V DC at Ignition Switch ON and 0 km/h Magnetic flux detection method more than 60 ~ 70° for each bank

 

Specifications

Item	Standard
Output Voltage	with the sensor tilted 60 ~ 70° or more: 0.65 ~ 1.35 V
	with sensor arrow mark pointed up: 3.55 ~ 4.45 V
Subthrottle Sensor:	Non-adjustable and non-removal
Input Voltage	4.75 ~ 5.25 V DC between BL and BR/BK leads
Output Voltage at Idle Throttle Opening	0.4 ~ 0.6 V DC between BL/W and BR/BK leads
Output Voltage at Full Throttle Opening	3.625 ~ 3.775 V DC between BL/W and BR/BK leads
Resistance	4 ~ 6 kΩ
Subthrottle Valve Actuator:
Resistance	About 5.5 ~ 7.5 Ω
Input Voltage	About 8.5 ~ 10.5 V DC
Oxygen Sensor (Europe Models):
Output Voltage (Rich)	0.7 V or more
Output Voltage (Lean)	0.2 V or less
Heater Resistance	11.7 ~ 14.5 Ω at 20°C (68°F)
Throttle Grip and Cables Throttle Grip Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)

 

Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm²: 57001-125