CHAPTER 6
ELECTRONIC FUEL
INJECTION
ELECTRONIC FUEL INJECTION ............... 6-1
CHAPTER 7
CHASSIS
FRONT WHEEL AND BRAKE DISCS ........ 7-1
REAR WHEEL, BRAKE DISC, AND
REAR WHEEL SPROCKET ........................ 7-9
FRONT AND REAR BRAKES .................. 7-15
HYDRAULIC CLUTCH ............................. 7-43
FRONT FORK .......................................... 7-55
HANDLEBARS ......................................... 7-67
STEERING HEAD .................................... 7-72
REAR SHOCK ABSORBER
ASSEMBLY ............................................. 7-76
SWINGARM AND DRIVE CHAIN ........... 7-80
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS ................... 8-1
SWITCHES ................................................ 8-2
CHECKING THE SWITCHES ..................... 8-3
CHECKING THE BULBS AND
BULB SOCKETS ........................................ 8-4
IGNITION SYSTEM ................................... 8-7
ELECTRIC STARTING SYSTEM ............. 8-12
CHARGING SYSTEM .............................. 8-16
LIGHTING SYSTEM ................................ 8-19
SIGNALING SYSTEM ............................. 8-21
COOLING SYSTEM ................................. 8-24
ELECTRONIC FUEL INJECTION
SYSTEM .................................................. 8-28
ELECTRICAL CONTROL SYSTEM ......... 8-30
ELECTRICAL SPECIFICATIONSSPEC
2 - 15
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage12 V ----
Ignition system
Ignition system type C.D.I. ----
Ignition timing 5˚ BTDC at 1,100 r/min ----
Advanced timing 55˚ BTDC at 5,000 r/min ----
Advancer type Throttle position sensor and electrical ----
Pickup coil resistance/color 421 ~ 569 W / Gy–B ----
C.D.I. unit model (manufacturer) F8T19371 (MITSUBISHI) ----
Ignition coils
Model (manufacturer) F6T549 (MITSUBISHI) ----
Minimum ignition spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.16 ~ 0.21 W ----
Secondary coil resistance 5.0 ~ 6.8 kW ----
Throttle position sensor standard
resistance4 ~ 6 kW----
Charging system
System type AC magneto ----
Model (manufacturer) F4T254 (MITSUBISHI) ----
Nominal output 14 V / 22.5 A at 5,000 r/min ----
Stator coil resistance 0.38 ~ 0.46 W at 20˚C (68˚F) ----
Rectifier/regulator
Regulator type Semiconductor-short circuit ----
Model SH650D-11 (SHINDENGEN) ----
No-load regulated voltage 14.1 ~ 14.9 V ----
Capacity 18 A ----
Withstand voltage 200 V ----
Battery
Battery type GT9B-4 ----
Battery voltage/capacity 12V / 8AH ----
Headlight typeHalogen bulb
Indicator light type ´ quantityLED ´ 5
Bulbs (voltage/wattage ´ quantity)
Headlight R. 12 V 60 W ´ 1 / L. 12 V 51 W ´ 1 ----
Auxiliary light 12 V 5 W ´ 2 ----
Tail/brake light 12 V 5 W / 21 W ´ 1 ----
Front turn signal light 12 V 21 W ´ 2 ----
Rear turn signal light 12 V 21 W ´ 2 ----
Meter light 12 V 1.4 W ´ 2 ----
3 - 62
CHK
ADJ
REPLACING THE HEADLIGHT BULBS
EB305051
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of
the headlight bulbs.
1. Disconnect:
• headlight coupler 1
1
1
2. Remove:
• headlight bulb 1
WARNINGWARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
1
1
3. Install:
• headlight bulb
Secure the new headlight bulb with
the headlight bulb holder.
ACHTUNG:CAUTION:
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb and the luminous
flux will be adversely affected. If the
headlight bulb gets soiled, thoroughly
clean it with a cloth moistened with
alcohol or lacquer thinner.
4. Connect:
• headlight coupler
New
8 - 4
–+ELECCHECKING THE BULBS AND BULB SOCKETS
EB801020
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for dam-
age or wear, proper connections, and also
for continuity between the terminals.
Damage/wear ® Repair or replace the
bulb, bulb socket or both.
Improperly connected ® Properly con-
nect.
Incorrect continuity reading ® Repair or
replace the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are
shown in the illustration on the left.
• Bulbs A and B are used for headlights
and usually use a bulb holder which must
be detached before removing the bulb.
The majority of these bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulb C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs
D and E are used for meter and
indicator lights and can be removed from
their respective socket by carefully pulling
them out.
CHECKING THE CONDITION OF THE BULBS
The following procedure applies to all of
the bulbs.
1.Remove:
• bulb
8 - 5
–+ELECCHECKING THE BULBS AND BULB SOCKETS
WARNINGWARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the ter-
minal in the coupler.
• Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise the transparency of the glass, the
life of the bulb and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2.Check:
• bulb (for continuity)
(with the pocket tester)
No continuity ® Replace.
NOTE:
Before checking for continuity, set the
pocket tester to “0” and to the “W ´ 1”
range.
t t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Connect the tester positive probe to ter-
minal 1 and the tester negative probe to
terminal 2, and check the continuity.
b. Connect the tester positive probe to ter-
minal 1 and the tester negative probe to
terminal 3, and check the continuity.
c. If either of the readings indicate no conti-
nuity, replace the bulb.
s s s s s s s s s s s s s s s s s s s s s s s s s s s s
Pocket tester
90890-03112
8 - 6
–+ELECCHECKING THE BULBS AND BULB SOCKETS
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of
the bulb sockets.
1.Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity ® Replace.
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb sec-
tion; however, note the following.
t t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If
any of the readings indicate no continu-
ity, replace the bulb socket.
s s s s s s s s s s s s s s s s s s s s s s s s s s s s
CHECKING THE LEDs
The following procedure applies to all of
the LEDs.
1.Check:
LED (for proper operation)
t t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Disconnect the meter assembly coupler
(meter assembly side).
b. Connect two jumper leads 1 from the
battery terminals to the respective cou-
pler terminals as shown.
WARNINGWARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the
battery lead, otherwise the jumper lead
may burn.
• This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
c. When the jumper leads are connected to
the terminals the respective LED should
illuminate.
Does not light ® Replace the meter
assembly.
s s s s s s s s s s s s s s s s s s s s s s s s s s s s
Pocket tester
90890-03112
8 - 20
–+ELECLIGHTING SYSTEM
TROUBLESHOOTING
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
NOTE:
• Before troubleshooting, remove the following part(-s):
1) bottom cowling
2) front cowling
3) rear cowling
• Troubleshoot with the following special tool(-s).
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light
or meter light.
Check the main and headlight
fuses for continuity.Replace.
Check the condition of the bat-
tery.Recharge or replace.
Check the bulbs and bulb sockets. Replace.
Check the LED’s of the indicator
light.Replace the meter assembly.
Check the main switch. Replace.
Check the lights switch. Replace the left handlebar switch.
Check the dimmer switch. Replace the left handlebar switch.
Check the pass switch. Replace the left handlebar switch.
Check the entire lighting sys-
tem’s wiring.Repair or replace.
Pocket tester
90890-03112
No good
No good
No good
No good
No good
No good
No good
No good
No good
8 - 22
–+ELECSIGNALING SYSTEM
TROUBLE SHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
Check the main and signal system fuses
continuity.
Check the condition of the battery.
Check the main switch.
Check the entire signaling system’s wiring.
Check the bulbs and
bulb sockets.
Check the LED’s of
the indicator light.
Check the brake
switchs.
Replace the meter
assembly.
Check the neutral
switch.
Replace the meter
assembly. Check the relay unit.
Check the continuity of the thermistor in the fuel pump.OK
OK
OK
OK
OK
OK
OK
OK
OK
OKNo good
No good
No good
No goodReplace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.Recharge or replace.
Recharge or replace.
No goodNo good
No good
No good
No good
No good
No good
No good No good
No good OK
OK
BAD
OK Check the horn switch.
Check the horn. Replace.
Replace. Check the turn signal
switch.
Replace the turn
signal relay.
Replace the meter
assembly.
Replace the meter
assembly.
Replace the meter
assembly.Check the oil level
switch.
Replace the fuel
pump. Replace the left
handlebar switch.
Replace the
left handlebar
switch.