Starter Motor Brush Length Standard: 12 mm (0.47 in.)

Service Limit: 6.0 mm (0.24 in.)

Commutator Cleaning and Inspection

• Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves.

 

 

• Measure the diameter [A] of the commutator [B].

If the commutator diameter is less than the service limit,

replace the starter motor with a new one.

Commutator Diameter

Standard: 28 mm (1.10 in.)

Service Limit: 27 mm (1.06 in.)

 

Armature Inspection

• Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A].

Special Tool - Hand Tester: 57001-1394

If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.

• Using the highest hand tester range, measure the resis-

tance between the segments and the shaft [B].

If there is any reading at all, the armature has a short and the starter motor must be replaced.

 

NOTE

○Even if the foregoing checks show the armature to be

good, it may be defective in some manner not readily

detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.

Brush Lead Inspection

• Using the × 1 Ω hand tester range, measure the resis- tance as shown.

Terminal Bolt and Positive Brushes [A] Brush Plate and Negative Brushes [B]

Special Tool - Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assy and/or the brush plate assy.

 

Brush Plate and Terminal Bolt Inspection

• Using the highest hand tester range, measure the resis- tance as shown.

Terminal Bolt and Brush Plate [A]

Terminal Bolt and Negative Brush Holders [B] Terminal Bolt and Yoke [C]

Special Tool - Hand Tester: 57001-1394

If there is any reading, the brush plate assy and/or termi- nal bolt assy have a short. Replace the brush plate assy and the terminal bolt assy.

 

 

Starter Relay Inspection

• Remove:

Bolt [A] and Cover [B]

 

 

• Disconnect the connector [A].

• Disconnect the starter motor cable [B] and battery positive

CAUTION

The battery positive (+) cable with the rubber cap is connected directly to the battery positive (+) termi- nal even when the ignition switch off, so take care not to short the removed cable to chassis ground.

(+) cable [C] from the starter relay [D].

 

• Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown.

Special Tool - Hand Tester: 57001-1394

If the relay does not work as specified, the relay is defec- tive. Replace the relay.

Testing Relay

Tester Range: × 1 Ω range

Criteria: When battery is connected → 0 Ω

When battery is disconnected → ∞ Ω

 

Electric Starter Circuit

1. Ignition Switch

2. Water-proof Joint B

3. Starter Lockout Switch

4. Ignition Fuse 10 A

5. Fuse Box

6. Starter Circuit Relay

7. Relay Box

8. Starter Motor

9. Starter Relay

10. Main Fuse 30 A

11. Battery 12 V 10 Ah

12. Sidestand Switch

13. Frame Ground

14. Joint Connector

15. Neutral Switch

16. Water-proof Joint C

17. Starter Button

18. Engine Stop Switch

 

This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released.

Headlight Beam Horizontal Adjustment

• Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter.

Headlight Beam Vertical Adjustment

• Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter.

Headlight Bulb Replacement

• Remove:

Upper Inner Fairing (see Upper Inner Fairing Removal

in the Frame chapter) Headlight Connector [A] Headlight Bulb Dust Cover [B]

 

 

• Remove: Hook [A]

CAUTION

When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.

Headlight Bulb [B]

 

NOTE

○Clean off any contamination that inadvertently gets on

the bulb with alcohol or soap and water solution.

• Replace the headlight bulb.

• Fit the projection [A] of the bulb in the hollow [B] of the

headlight.

• Install the hook [C].

 

• Fit the dust cover [A] onto the bulb [B] firmly as shown. Good [C]

Bad [D]

• After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).

 

 

City Light Bulb Replacement (Europe Models)

• Remove the meter cover (see Meter Unit Removal/Instal- lation).

• Disconnect the connector [A].

• Pull out the socket [B] together with the bulb.

 

CAUTION

Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve.

• Pull the bulb [A] out of the socket.

 

• Replace the bulb with a new one.

 

 

Headlight Removal/Installation

• Remove:

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Mounting Bolts [A]

• Installation is the reverse of removal.

 

 

Tail/Brake Light Removal

• Remove:

Seat Covers (see Seat Cover Removal in the Frame

chapter)

• Disconnect the connector [A].

• Unscrew the mounting bolts [B].

• Remove the tail/brake light [C].

 

Tail/Brake Light Installation

• Installation is the reverse of removal.

 

 

License Plate Light Bulb Replacement

• Remove: Screws [A]

License Plate Light Cover [B]

• Push and turn the bulb counterclockwise and remove it.

 

• Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○Turn the bulb about 15°.

• Install the license plate light cover.

• Tighten:

Torque - License Plate Light Cover Screws: 0.90 N·m (0.090 kgf·m, 8 in·lb)

 

Headlight/Tail Light Circuit

1. Ignition Switch

2. Water-proof Joint A

3. Water-proof Joint B

4. Position Light

5. Headlight (High Beam)

6. Headlight (Low Beam)

7. Dimmer Switch

8. Passing Switch

9. Headlight Relay

10. Relay Box 11. Starter Relay

Turn Signal Light Bulb Replacement

• Unscrew the screw [A] and remove the lens [B].

○Turn the lens counterclockwise.

12. Main Fuse 30 A

13. Battery 12 V 10 Ah

14. Frame Ground

15. Tail/Brake Light

16. License Plate Light 12 V 5 W

17. Joint Connector

18. Water-proof Joint C

19. Regulator/Rectifier

20. Fuse Box

21. Headlight Fuse 10 A

22. Tail Light Fuse 10 A

 

 

• Push and turn the bulb [A] counterclockwise and remove it.

 

• Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○Turn the bulb about 15°.

• Install the projections of the lens to the dints of the turn signal light.

 

Turn Signal Relay Inspection

• Remove:

Left Upper Inner Fairing (see Upper Inner Fairing Re-

moval in the Frame chapter) Turn Signal Relay [A]

 

 

• Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights

flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C]

If the lights do not flash as specified, replace the turn sig- nal relay.

Testing Turn Signal Relay

Load	Flashing Times (c/m*)
The Number of Turn Signal Lights	Wattage (W)
1**	21 or 23	140 ~ 250
	42 or 46	75 ~ 95

(*): Cycle(s) per minute

(**): Corrected to “one light burned out”.

 

 

Turn Signal Light Circuit

1. Meter Unit

2. Water-proof Joint A

3. Water-proof Joint B

4. Front Right Turn Signal Light

5. Front Left Turn Signal Light

6. Turn Signal Relay

7. Hazard Button

8. Turn Signal Switch

9. Fuse Box

10. Turn Signal Relay Fuse 10 A

11. Main Fuse 30 A

12. Battery 12 V 10 Ah

13. Frame Ground

14. Rear Right Turn Signal Light

15. Rear Left Turn Signal Light

16. Joint Connector

17. Water-proof Joint C

18. Ignition Switch

19. Frame Ground

 

 

Air Switching Valve

Air Switching Valve Operation Test

• Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).

• Pull the air switching valve hose [A] out of the air cleaner

base.

 

 

• Take the air switching valve hose end outside of the frame.

• Reinstall the fuel tank (see Fuel Tank Installation in the

Fuel System (DFI) chapter).

• Start the engine and run it at idle speed.

• Plug [A] the air switching valve hose [B] end with your

finger and feel vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test).

• Apply a soap and water solution or rubber lubricant to the

end of the air switching hose and install the hose on the

fitting.

Air Switching Valve Unit Test

• Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

• Set the hand tester [A] to the × Ω range and connect it to

the air switching valve terminals as shown.