Stick Coil Primary Peak Voltage Standard: 88 V or more

• Repeat the test for the other stick coil.

If the reading is less than the specified value, check the

following.

Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection)

Crankshaft Sensor (see Crankshaft Sensor Inspection) ECU (see ECU Power Supply Inspection in the Fuel Sys- tem (DFI) chapter)

Spark Plug Removal

• Refer to the Spark Plug Replacement in the Periodic Maintenance chapter.

Spark Plug Installation

• Refer to the Spark Plug Replacement in the Periodic Maintenance chapter.

Spark Plug Condition Inspection

• Refer to the Spark Plug Condition Inspection in the Peri- odic Maintenance chapter.

Interlock Operation Inspection

• Raise the rear wheel off the ground with stand.

1st Check

• Start the engine to the following conditions.

Condition

Transmission Gear → 1st Position Clutch Lever → Release Sidestand → Down or Up

○Turn the ignition switch ON and push the starter button.

○Then the starter motor should not turn when the starter

system circuit is normality.

If the engine is start, inspect the starter lockout switch, neutral switch and relay box.

If their parts are normality replace the ECU.

 

 

2nd Check

• Start the engine to the following conditions.

Condition

Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up

○Turn the ignition switch ON and push the starter button.

○Then the starter motor should turn when the starter sys-

tem circuit is normality.

If the starter motor is not turn, inspect the starter lockout switch, neutral switch and relay box.

If their parts are normality replace the ECU.

3rd Check

• Inspect the engine for its secure stop after the following operations are completed.

• Run the engine to the following conditions.

Condition

Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up

• Set the sidestand on the ground, then the engine will stop.

If whichever may not be stopped, inspect the neutral

switch, starter lockout switch, sidestand switch and relay box.

If their parts are normality, replace the ECU.

IC Igniter Inspection

○The IC igniter is built in the ECU [A].

• Refer to the Interlock Operation Inspection, Ignition Sys- tem Troubleshooting chart and Fuel System (DFI) chapter

for ECU Power Supply Inspection.

 

 

 

 

Ignition System Circuit

1. Ignition Switch

2. Engine Stop Switch

3. Spark Plugs

4. Stick Coils

5. Water-proof Joint C

6. Speed Sensor

7. Subthrottle Sensor

8. Main Throttle Sensor

9. Water-proof Joint D

10. Vehicle-down Sensor

11. Water-proof Joint E

12. Water Temperature Sensor

13. Neutral Switch

14. Crankshaft Sensor

15. Oxygen Sensor

16. Meter Unit

17. Water-proof Joint A

18. Water-proof Joint B

19. Starter Lockout Switch

20. Oxygen Sensor Heater Fuse 10 A

21. ECU Fuse 15 A

22. Ignition Fuse 10 A

23. Fuse Box

24. ECU Main Relay

25. Relay Box

26. Main Fuse 30 A

27. Starter Relay

28. Battery 12 V 10 Ah

29. Frame Ground

30. Sidestand Switch

31. Joint Connector

32. ECU

Starter Motor Removal

CAUTION

Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Right Center Fairing (see Center Fairing Removal in the Frame chapter)

• Slide back the rubber cap [A].

• Remove the starter motor cable terminal nut [B].

• Remove the mounting bolts [A].

• Pull out the starter motor [B].

 

CAUTION

Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.

Starter Motor Installation

• When installing the starter motor, clean the starter mo- tor legs [A] and crankcase [B] where the starter motor is

grounded.

 

• Replace the O-ring [A] with a new one.

• Apply grease to the O-ring.

• Apply a non-permanent locking agent to the threads of

the bolts and tighten the bolts.

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Install the starter motor cable.

• Tighten:

Torque - Starter Motor Cable Terminal Nut: 6.0 N·m (0.60

kgf·m, 53 in·lb)

 

Starter Motor Disassembly

• Remove the starter motor (see Starter Motor Removal).

• Take off the starter motor through bolts [A] and remove

the both end covers [B] and pull the armature out of the

yoke [C].

 

 

• Remove:

Terminal Locknut and Washers

O-ring

• Remove the brush plate assy [A] from the yoke [B].

 

 

• Remove the brush plate [A] from the plate cover [B].

NOTE

○Do not remove the negative carbon brushes form the

brush plate.

Starter Motor Assembly

• Install the brush plate [A] to the plate cover [B] as shown.

• Install the brush plate assy to the yoke.

 

• Clamp the springs [A] with the clips [B].

• Fit the armature [C] to the brush plate assy [D].

• Remove the clips.

 

 

• Install the new O-ring [A] as shown.

• Install:

Washers [B] and Terminal Locknut [C]

• Tighten:

Torque - Starter Motor Terminal Locknut: 11 N·m (1.1

kgf·m, 97 in·lb)

• Align the lines [A] on the yoke with the end cover lines [B].

• Tighten the through bolts.

Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m,

43 in·lb)

Brush Inspection

• Measure the length of each brush [A].

If any is worn down to the service limit, replace the brush

plate assy [B] and the terminal bolt assy [C].