1-iv Table of Contents
Schematic and Routing Diagram....................... 1G-3
Fuel Tank Drain Hose and Breather Hose
Routing Diagram .............................................. 1G-3
Diagnostic Information and Procedures........... 1G-4
Fuel System Diagnosis ...................................... 1G-4
Repair Instructions ............................................. 1G-5
Fuel Pressure Inspection ................................... 1G-5
Fuel Pump Inspection ........................................ 1G-6
Fuel Discharge Amount Inspection .................... 1G-6
Fuel Pump Relay Inspection .............................. 1G-7
Fuel Hose Inspection ......................................... 1G-7
Fuel Level Gauge Inspection ............................. 1G-7
Fuel Tank Construction...................................... 1G-8
Fuel Tank Removal and Installation................... 1G-9
Fuel Pump Components .................................. 1G-10
Fuel Pump Disassembly and Assembly........... 1G-11
Fuel Mesh Filter Inspection and Cleaning........ 1G-13
Fuel Injector / Fuel Delivery Pipe / T-joint
Removal and Installation................................ 1G-13
Fuel Injector Inspection and Cleaning.............. 1G-13
Specifications.................................................... 1G-14
Service Data..................................................... 1G-14
Tightening Torque Specifications..................... 1G-14
Special Tools and Equipment.......................... 1G-15
Recommended Service Material...................... 1G-15
Special Tool ..................................................... 1G-15
Ignition System........................................ 1H-1
General Description.............................................1H-1
Immobilizer Description (For E-02, 19, 24, 51) ....1H-1
Drive Mode Selector Description.........................1H-2
Schematic and Routing Diagram........................1H-3
Ignition System Diagram.....................................1H-3
Ignition System Components Location................1H-3
Diagnostic Information and Procedures............1H-4
Ignition System Symptom Diagnosis...................1H-4
No Spark or Poor Spark......................................1H-5
Repair Instructions ..............................................1H-6
Ignition Coil and Spark Plug Removal and
Installation.........................................................1H-6
Spark Plug Inspection and Cleaning...................1H-7
Ignition Coil Inspection........................................1H-7
CKP Sensor Inspection.......................................1H-9
CKP Sensor Removal and Installation..............1H-10
Engine Stop Switch Inspection..........................1H-10
Ignition Switch Inspection..................................1H-10
Ignition Switch Removal and Installation...........1H-11
Drive Mode Selector Inspection ........................1H-12
Specifications.....................................................1H-13
Service Data......................................................1H-13
Tightening Torque Specifications......................1H-13
Special Tools and Equipment...........................1H-14
Recommended Service Material.......................1H-14
Special Tool ......................................................1H-14
Starting System.........................................1I-1
Schematic and Routing Diagram......................... 1I-1
Starting System Diagram ..................................... 1I-1
Component Location ............................................ 1I-1
Starting System Components Location................ 1I-1
Diagnostic Information and Procedures............. 1I-1
Starting System Symptom Diagnosis................... 1I-1
Starter Motor Will Not Run ................................... 1I-2
Starter Motor Runs But Does Not Crank The
Engine................................................................ 1I-2
Repair Instructions ............................................... 1I-3
Starter Motor Components................................... 1I-3
Starter Motor Removal and Installation................ 1I-4
Starter Motor Disassembly and Assembly ........... 1I-4
Starter Motor Inspection....................................... 1I-5
Starter Relay Removal and Installation................ 1I-6
Starter Relay Inspection....................................... 1I-6
Turn Signal / Side-stand Relay Removal and
Installation.......................................................... 1I-7
Side-stand / Ignition Interlock System Parts
Inspection........................................................... 1I-7
Starter Torque Limiter Removal and
Installation.......................................................... 1I-9
Starter Torque Limiter Inspection....................... 1I-10
Starter Clutch Removal and Installation............. 1I-10
Starter Clutch Inspection.................................... 1I-11
Starter Button Inspection.................................... 1I-12
Specifications...................................................... 1I-12
Service Data....................................................... 1I-12
Tightening Torque Specifications....................... 1I-12
Special Tools and Equipment ............................ 1I-13
Recommended Service Material........................ 1I-13
Special Tool ....................................................... 1I-13
Charging System......................................1J-1
Schematic and Routing Diagram........................ 1J-1
Charging System Diagram.................................. 1J-1
Component Location ........................................... 1J-1
Charging System Components Location............. 1J-1
Diagnostic Information and Procedures............ 1J-1
Charging System Symptom Diagnosis................ 1J-1
Battery Runs Down Quickly ................................ 1J-2
Repair Instructions .............................................. 1J-3
Battery Current Leakage Inspection.................... 1J-3
Regulated Voltage Inspection ............................. 1J-3
Generator Inspection........................................... 1J-3
Generator Removal and Installation.................... 1J-4
Regulator / Rectifier Construction ....................... 1J-7
Regulator / Rectifier Removal and Installation .... 1J-7
Regulator / Rectifier Inspection........................... 1J-8
Battery Components ........................................... 1J-9
Battery Charging ................................................. 1J-9
Battery Removal and Installation ...................... 1J-11
Battery Visual Inspection................................... 1J-12
Specifications..................................................... 1J-12
Service Data...................................................... 1J-12
Tightening Torque Specifications...................... 1J-12
Special Tools and Equipment ........................... 1J-13
Recommended Service Material....................... 1J-13
Special Tool ...................................................... 1J-13
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys
email: info@motomatrix.co.uk / www.motomatrix.co.uk
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