ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INCORRECT ENGINE IDLING SPEED9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE9-2 . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY GEAR SHIFTING9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY CLUTCH9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH SLIPS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH DRAGS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHEATING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERCOOLING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR BRAKING PERFORMANCE9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY FRONT FORK LEGS9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKING OIL 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNSTABLE HANDLING9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY LIGHTING OR SIGNALING SYSTEM9-6 . . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL / BRAKE LIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . .
TAIL / BRAKE LIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com
2-15
ELECTRICAL SPECIFICATIONSSPEC
ELECTRICAL SPECIFICATIONS
ItemStandardLimit
System voltage12 V
Ignition system
Ignition system type
Ignition timing
Crankshaft position sensor
resistance / color
T.C.I. unit model (manufacturer)
DC. T.C.I.
5 BTDC at 1,050 r / min
336 504 Ω at 20C (68F) / Gy-B
F8T822 (MITSUBISHI) (USA)
F8T823 (MITSUBISHI) (CAL)
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
F6T558 (MITSUBISHI)
6 mm (0.24 in)
1.19 1.61 Ω at 20C (68F)
8.5 11.5 kΩ at 20C (68F)
Charging system
System type
Model (manufacturer)
Normal output
Stator coil resistance / color
A.C. magneto
F4T850 (MITSUBISHI)
14 V / 560 W at 5,000 r / min
0.14 0.18 Ω at 20C (68F) / W-W
Rectifier / regulator
Regulator type
Model (manufacture)
Semi conductor short circuit
FH011AA (SHINDENGEN)
()
No-load regulated voltage
Rectifier capacity
Withstand voltage
()
14.3 15.1 V
50 A
100 V
Battery
Battery type
Battery voltage / capacity
Specific gravity
Manufacturer
Ten hour rate amperage
YTZ10S
12 V / 8.6 Ah
1.310
YUASA
0.8 A
Headlight typeHalogen bulb
Bulbs (voltage / wattage quantity)
Headlight
Auxiliary light
Tail / brake light
Front turn signal light / position light
Rear turn signal light
Licence plate light
Meter light
12 V 55 W 4
12 V 5 W 2
LED 1
12 V 21 W / 5 W 2
12 V 21 W 2
12 V 5 W 1
LED 1
ProCarManuals.com
8-5
CHECKING THE BULBS AND BULB SOCKETSELEC
WARNING
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage / wear Repair or replace the bulb,
bulb socket or both.
Improperly connected Properly connect.
No continuity 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 the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The ma-
jority of these types of bulbs can be removed
from their respective socket by turning them
counterclockwise.
Bulbs
C are used for turn signal and
tail / brake lights and can be removed from
the socket by pushing and turning the bulb
counterclockwise.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
bulb
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
When changing the tail / brake light bulb,
confirm that the frame has cooled accord-
ing to the warning label and change the
tail / brake light bulb.
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8-33
LIGHTING SYSTEMELEC
EAS00791
4. The auxiliary light fails to come on.
YESNO 1. Auxiliary light and socket
Check the auxiliary light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the auxiliary light .bulb and socket OK?
Replace the auxiliary
light bulb, socket or
both.
YESNO 2. Voltage
Connect the pocket tester (DC 20 V) to the
auxiliary light coupler (auxiliary light side) as
shown.
The wiring circuit
from the main switch
to the auxiliary light
coupler is faulty and
must be repaired. Positive tester probe blue / red
Negative tester probe black
1
Turn the main switch to “ON”.
Measure the voltage (DC 12 V) of blue / red
on the auxiliary light coupler (auxiliary
light side).
Is the voltage within specification?
2
This circuit is OK.
2
5. The turn signa l/ position light fails to come on.
YESNO 1. Turn signal / position light and socket
Check the turn signal / position light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the turn signal / position light bulb and
socket OK?
Replace the turn sig-
nal / position light
bulb, socket or both.
YESNO 2. Voltage
Connect the pocket tester (DC 20 V) to the
turn signal / position light coupler (wire har-
ness side) as shown.
The wiring circuit from
the main switch to the
turn signal / position
light coupler is faulty
and must be repaired. Turn the main switch to “ON”.
Measure the voltage (DC 12 V) of blue or
blue on the turn signal / position light cou-
pler (wire harness side).
Is the voltage within specification?
3
This circuit is OK.
Left turn signal / position light
Positive tester probe blue
Negative tester probe black
Right turn signal / position light
Positive tester probe blue
Negative tester probe black
1
2
A
Left turn signal / position light
Right turn signal / position light
B
A
B
3
4
1
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8-37
SIGNALING SYSTEMELEC
YESNO 1. Tail / brake light bulb and socket
Check the tail / brake light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the tail / brake light bulb and socket OK?
Replace the tail /
brake light bulb,
socket or both.
EAS007972. The tail / brake light fails to come on.
YESNO 2. Brake light switches
Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake light switch OK?
Replace the brake
light switch.
3. Voltage
Connect the pocket tester (DC 20 V) to the
tail / brake light coupler (wire harness side)
as shown.
Positive tester probe yellow
Negative tester probe black
1
2
Turn the main switch to “ON”.
Pull in the brake lever or push down on the
brake pedal.
Measure the voltage (DC 12 V) of yellow
on the tail / brake light coupler (wire harness
side).
Is the voltage within specification?
1
YESNO 2. Voltage
Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
The wiring circuit
from the main switch
to the horn connec-
tor is faulty and must
be repaired. Positive tester probe black / white
Negative tester probe ground
1
Turn the main switch to “ON”.
Push the horn switch.
Measure the voltage (DC 12 V) of
black / white at the horn terminal.
Is the voltage within specification?
NOYES 3. Horn
Disconnect the black connector at the horn
terminal.
Connect a jumper lead to the horn termi-
nal and ground the jumper lead.
Turn the main switch to “ON”.
Push the horn switch.
Does the horn sound?
The horn is OK.
1
Replace the horn.
ProCarManuals.com
8-42
SIGNALING SYSTEMELEC
YESNO 2. 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 green / white
Negative tester probe black / white
1
2
Turn the main switch to “ON”.
Measure the voltage (DC 12 V) of
green / white and black / white at the
meter assembly coupler.
Is the voltage within specification?
This circuit is OK.
12
Replace the multi-
function meter.
NO
1. Multi-function meter bulb socket
Check the multi-function meter bulb socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Is the multi-function meter bulb socket OK?
YES
EAS008067. The speedometer fails to come on.
2. Speed sensor
Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
Replace the speed
sensor.
NOYES
Positive tester probe white / yellow
Negative tester probe black / blue1
2
Set the main switch to “ON”.
Elevate the rear wheel and slowly rotate it.
Measure the voltage (DC 5 V) of white / yel-
low and blue. With each full rotation of the
rear wheel, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
Does the voltage reading cycle correctly?
This circuit is OK.
ProCarManuals.com
9-6
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
TURN SIGNAL DOES NOT COME ON
Faulty turn signal switch
Faulty turn signal relay
Burnt-out turn signal bulb
Incorrect connection
Damaged or faulty wire harness
Improperly grounded circuit
Faulty battery
Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
Faulty turn signal relay
Faulty main switch
Faulty turn signal switch
Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
Faulty turn signal relay
Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
Incorrect turn signal bulb
Faulty turn signal relay
Burnt-out turn signal bulb
HORN DOES NOT SOUND
Improperly adjusted horn
Damaged or faulty horn
Faulty main switch
Faulty horn switch
Faulty battery
Blown, damaged or incorrect fuse
Faulty wire harness
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON
Wrong headlight bulb
Too many electrical accessories
Hard charging
Incorrect connection
Improperly grounded circuit
Poor contacts (main or light switch)
Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb
Faulty battery
Faulty rectifier / regulator
Improperly grounded circuit
Faulty main switch
Faulty light switch
Headlight bulb life expired
TAIL / BRAKE LIGHT DOES NOT COME ON
Too many electrical accessories
Incorrect connection
TAIL / BRAKE LIGHT BULB BURNT OUT
Faulty battery
Incorrectly adjusted rear brake light switch
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