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8-25
NOYES
3. Charging voltage
Set the engine tachometer to the ignition coil
of cylinder #1.
Connect the pocket tester (DC 20 V) to the
battery as shown.
The charging circuit
is OK. Positive tester probe
positive battery terminal
Negative tester probe
negative battery terminal
Start the engine and let it run at approxi-
mately 5,000 r / min.
Measure the charging voltage.
Charging voltage
14 V at 5,000 r / min
Is the charging voltage within specification?
EAS00775
YESNO
Clean the battery
terminals.
Recharge or re-
place the battery.
Make sure the battery is fully charged.
NOTE:
Minimum open-circuit voltage
12.8 V or more at 20C (68F)
Is the battery OK?
CHARGING SYSTEMELEC
NOTE:
YESNO
1. Main fuse
Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.
Is the main fuse OK?
Replace the fuse.
2. Battery
Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
EAS00739 EAS00774
TROUBLESHOOTING
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil lead
5. stator coil resistance
6. wiring connections
(of the entire charging system)
Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
Troubleshoot with the following special tool(s).
Pocket tester
90890-03112, YU-3112
EAS00738
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8-26
CHARGING SYSTEMELEC
YESNO 5. Stator coil resistance
Remove the generator cover.
Connect the pocket tester (Ω 1) to the sta-
tor coils as shown.
Replace the stator
coil assembly.
EAS00776
Positive tester probe white
Negative tester probe white
Positive tester probe white
Negative tester probe white1
1
2
3
Measure the stator coil resistances.
Stator coil resistance
0.14 0.18 Ω at 20C (68F)
Is the stator coil OK?
YESNO 6. Wiring
Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
Is the charging system’s wiring properly con-
nected and without defects?
Properly connect or
repair the charging
system’s wiring.
EAS00779
Replace the rectifi-
er / regulator.
4. Stator coil lead
Disconnect stator coil lead coupler.
Connect the pocket tester (Ω 1) to the sta-
tor coil lead coupler as shown.
Positive tester probe
white
Negative tester probe
ground
3
Positive tester probe
white
Negative tester probe
ground
1
Positive tester probe
white
Negative tester probe
groundNo
continuity
2
YESNO
Replace the stator
coil lead. Are the tester readings correct?
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Page 433 of 457
8-40
SIGNALING SYSTEMELEC
YESNO
Replace the starting
circuit cut-off relay.
YESNO 4. Voltage
Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
The wiring circuit
from the main switch
to the meter assem-
bly coupler is faulty
and must be re-
paired. Positive tester probe brown
Negative tester probe ground
1
Turn the main switch to “ON”.
Measure the voltage (DC 12 V) of brown
at the meter assembly coupler (wire harness
side).
Is the voltage within specification?
This circuit is OK.
Are the tester readings correct?
YESNO 1. Oil level warning light (LEDs)
Check the oil level warning light for continu-
ity.
When the main switch is turn to “ON”, the oil
level warning light is come on.
Are the oil level warning light OK?
Replace the meter
assembly.
EAS00802
5. The oil level warning light fails to come on.
YESNO 2. Oil level switch
Drain the engine oil and remove the oil level
switch from the oil pan.
Connect the pocket tester (Ω 100) to the
oil level switch as shown.
Replace the oil level
switch. Positive tester probe
Connector (white)
Negative tester probe Body ground
1
12
Measure the oil level switch resistance.
Oil level switch resistance
114 126 Ω at 20C (68F)
484 536 Ω at 20C (68F)
1
2
Is the oil level switch OK?
2
When you switch the positive and negative
tester probes, the readings in the above
chart will be reversed.
NOTE:
1
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Page 447 of 457
8-54
SELF-DIAGNOSISELEC
L/B B
Lg
B
BG/W
B R/L
Y/LY/BR/G
Sb/W
W
G/W
G/W
R/L
B
R/W
LgLgB
Sb/WSb/WA
Br BrA
R/G R/GBB/R B/RBY/B Y/BBY/L Y/LBG/W G/WA
GY
14
3839
40
41
42
43
44
45
Repair or replace the
wire harness.
NO
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
2. Fuel pump thermistor
Check the fuel pump thermistor for continuity.
Refer to “The fuel level warning light fails to
come on”.
Is the fuel pump thermistor OK?
YES
Replace the fuel
pump.Replace the multi-
function meter.
NOTE:
14Fuel pump
45Multi-function meter
TROUBLESHOOTING
The warning light starts to indicate the
self-diagnosis sequence.
Check:
1. fuel pump thermistor
2. oil level switch
Before troubleshooting, remove the following
part(-s):
1. seat
2. fuel tank
Troubleshoot with the following special
tool(-s).
Pocket tester
90890-03112, YU-3112
1. Fuel pump thermistor
CIRCUIT DIAGRAM
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8-55
SELF-DIAGNOSISELEC
Replace the oil level
switch.
NO
2. Oil level switch
Check the oil level switch for continuity.
Refer to “The oil level warning light fails to
come on”.
Is the oil level switch OK?
YES
Repair or replace the
wire harness.
NO
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
Replace the multi-
function meter.
B/WWW
Y/LY/BR/G
Sb/W
W
WG/W
R/WSb/WSb/WA
Br BrA
R/G R/GBB/R B/RBY/B Y/BBY/L Y/L
Dg
Ch
BG/W G/WA
B/W B/W
GY
B
40
41
42
43
44
45
46
47
48
49
50
51
52
45Multi-function meter
52Oil level switch
2. Oil level switch
CIRCUIT DIAGRAM
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9-1
STARTING FAILURES
TRBL
SHTG
NOTE:
FUEL SYSTEM
Fuel tankEmpty fuel tank
Clogged fuel filter
Clogged fuel strainer
Clogged fuel tank drain hose
Deteriorated or contaminated fuel
Fuel pump Faulty fuel pump
Faulty fuel pump relay
Throttle body (-ies)
Deteriorated or contaminated fuel
Sucked-in air
Ignition coil(s) Cracked or broken ignition coil body
Broken or shorted primary or secondary
coils
Ignition system Faulty ECU
Faulty crankshaft position sensor
EAS00844
TROUBLESHOOTING
The following guide for troubleshooting does not cover all the possible \
causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure i\
n this manual for
checks, adjustments, and replacement of parts.
STARTING FAILURES
ENGINE
Cylinder(s) and cylinder head(s)
Loose spark plug
Loose cylinder head or cylinder
Damaged cylinder head gasket
Damaged cylinder gasket
Worn or damaged cylinder
Incorrect valve clearance
Improperly sealed valve
Incorrect valve-to-valve-seat contact
Incorrect valve timing
Faulty valve spring
Seized valve
Piston(s) and piston ring(s) Improperly installed piston ring
Damaged, worn or fatigued piston ring
Seized piston ring
Seized or damaged piston
Air filter Improperly installed air filter
Clogged air filter element
Crankcase and crankshaft Improperly assembled crankcase
Seized crankshaft
ELECTRICAL SYSTEMS
Battery Discharged battery
Faulty battery
Fuse(s) Blown, damaged or incorrect fuse
Improperly installed fuse
Spark plug(s)
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
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