Page 698 of 794
6 - 10
–+ELECELECTRIC STARTING SYSTEM
DIODE INSPECTION
1. Remove the diode from wire harness.
2. Inspect:
•Diode continuity
Use pocket tester (tester selection posi-
tion Ω × 1)
Incorrect continuity → Replace. Tester (+)
→
Blue/Red terminal
1
Tester (–)
→
Sky blue terminal
2Continuous
Tester (+)
→
Blue/Red terminal
1
Tester (–)
→
Blue/Yellow terminal
3Continuous
Tester (+)
→
Sky blue terminal
2
Tester (–)
→
Blue/Red terminal
1No continuous
Tester (+)
→
Blue/Yellow terminal
3
Tester (–)
→
Blue/Red terminal
1No continuous
START SWITCH INSPECTION
1. Inspect:
•Start switch continuity
No continuous while being pushed → Replace.
Continuous while being freed → Replace.
2. Inspect:
•Rubber part a
Tears/damage → Replace. Tester (+) lead
→ Black lead
1
Tester (–) lead
→ Black lead
2
B
1 B
2 Tester selec-
tor position
PUSH IN
Ω
×
×× × 1
FREE
a
Page 720 of 794
6 - 19
–+ELECTPS (THROTTLE POSITION SENSOR) SYSTEM
HANDLING NOTE
CAUTION:
Do not loosen the screw {TPS (throttle
position sensor)}
1 except when changing
the TPS (throttle position sensor) due to
failure because it will cause a drop in
engine performance.
1
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
•Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
TPS COIL INSPECTION
1. Inspect:
•TPS coil resistance
Out of specification → Replace.
2. Loosen:
•Throttle stop screw 1
NOTE:
Turn out the throttle stop screw until the throt-
tle shaft is in the full close position.Tester (+) lead
→ Blue lead
1
Tester (–) lead
→ Black lead
2
TPS coil
resistanceTester selector
position
4 ~ 6 kΩ at
20 °C (68 °F)kΩ × 1
Page 726 of 794
6 - 22
–+ELECTPS (THROTTLE POSITION SENSOR) SYSTEM
10. Put the aligning marks a on the TPS and
carburetor.
11. Stop the engine.
12. Remove the carburetor.
a
13. Tighten:
•Screw (TPS) 1
NOTE:
Tighten the screw (TPS) using the T25 bit.
14. Install the carburetor.
1
EC694000
TPS INPUT VOLTAGE INSPECTION
1. Disconnect the TPS coupler.
2. Start the engine.
3. Inspect:
•TPS input voltage
Out of specification → Replace the CDI
unit.
Tester (+) lead
→ Blue lead
1
Tester (–) lead
→ Black/Blue lead
2
TPS input
voltageTester selector
position
4 ~ 6 V DCV-20
Page 732 of 794
6 - 24
–+ELECLIGHTING SYSTEM
CHECKING THE TAILLIGHT (LEDs)
1. Disconnect the taillight coupler.
2. Connect two jumper leads 1 from the bat-
tery terminals to the respective coupler ter-
minal as shown.
3. Check:
•LED (for proper operation)
Does not light → Replace the taillight
assembly.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
Battery (+) terminal →
Blue lead
2
Battery (–) terminal →
Black lead
3
AC MAGNETO INSPECTION
1. Inspect:
•Lighting coil resistance
Out of specification → Replace.
Tester (+) lead
→ Yellow lead
1
Tester (–) lead
→ Ground
2
Lighting coil
resistanceTester selector
position
0.224 ~ 0.336
Ω
at 20 °C (68 °F)Ω
× 1
Page 782 of 794
7 - 18
TUNSETTING
EC72Q000
Rear shock absorber setting parts
•Rear shock spring 1
NOTE:
The I.D. color a is marked at the end of the
spring.
TYPESPRING
RATESPRING
PART NUMBERI.D.
COLOR/
POINTSPRING
FREE
LENGTH
SOFT4.3
4.5
4.7
4.9
5.1
5.35UN-22212-00
5UN-22212-10
5UN-22212-20
5UN-22212-30
5UN-22212-40
5UN-22212-50Brown/1
Green/1
Red/1
Black/1
Blue/1
Yellow/1260
260
260
260
260
260
STD 5.5 5UN-22212-60 Pink/1 260
STIFF 5.7 5UN-22212-70 White/1 260
•Extent of adjustment (spring length)
SPRING FREE
LENGTHEXTENT OF
ADJUSTMENT
b
260 mm (10.24 in)238.5 ~ 258.5 mm
(9.39 ~ 10.18 in)