Honda 1986 GoldWing GL1200A, Manual

Page 1: ... this are based on the latest pnx llCt availablf at the time of for r i tiYln Honda Motor Co Inc reserves tile mak e h nnt Q at any irn6 without m t c and without tion whatever Sections 1 3 4 1a describe accor t oioc ition 8 sure to rel er to the Maintenance h rl I i9C Or 3 Wh 7nf V H a GL 200A BE l is in ror service Use tl16 schedule to know what tht vehicle needs to in condition and within EPA 1...

Page 2: ...General Information Service Safety 1 2 Important Safety Notice 1 2 Model Identification 1 3 Emission Control Systems 1 4 Metric Conversions 1 7 ...

Page 3: ... cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please under stand that those warnings could not cover all conceivable ways in which service whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceivable way nor could Honda in vestigate all such ways Anyone using service procedures or tools whether or not re...

Page 4: ...Model Identification GL1200A GOLD WING ASPENCADE SE i 1 3 ...

Page 5: ...pply system as well as other systems to reduce carbon monoxide and hydrocarbons Exhaust Emission Control System Secondary Air Supply System The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system Th...

Page 6: ... vapor from the fuel tank is routed into a charcoal canister where it is adsorbed and stored while the engine is stopped When the motorcycle is running and the purge control diaphragm valve IS open fuel vapor in the charcoal canister is drawn Into the engine No adjustments to the evaporative emiSSion control system are necessary however periodic inspection of the hoses and canister is recommended ...

Page 7: ...any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those...

Page 8: ...am Sq centimeter 14 22 PoundS Sq inch kg cml psi Pounds Sq inch psi 0 0703 Kilogram Sq centimeter kg cml Temperature Centigrade CC CO 1 8 32 Fahrenheit FO Fahrenheit FO F0 32 1 8 Centigrade CO Capacity Liter I 0 2642 Gallon gal Liter I 1 0568 Quart qt Quart qt 0 9463 Liter I Gallon gal 3 785 Liter I Volume Cubic centimeter CC 0 061 Cubic inches cu in Cubic inches cu in 16 39 Cubic centimeters cc W...

Page 9: ...Specifications General 2 2 CFI 2 3 Electrical 2 4 Standards Service Limits 2 5 Torque Values 2 8 ...

Page 10: ...clearance Idle speed SPECIAL EDITION Gl1200 ASPENCADE 2 505 mm 98 6 in 970 mm 38 2 In 1 510 mm 59 4 Inl 1 610 mm 63 4 In 780 mm 30 7 Inl 140 mm 5 5 In 355 kg 783 Ib California type 356 kg 784 Ib 380 kg 838 Ib California type 381 kg 840 Ib Double cradle TelescopIc 140 mm 5 5 in 0 1 0 kglcm2 0 14 psi Swing arm 105 mm 4 1 In 2 0 6 5 kgfcm2 28 92 psi 130 90 16 67H 2 25 kglcm2 32 psi 150 90 1574H 2 25 ...

Page 11: ...tended high NGK OPR9EA 9 speed riding ND X27EPR U9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Firing order 1 3 2 4 Fuses 3A lOA 15A and 30A Imain and sub main tuses CFIS ystem Item Standard Fuel pressure Ignition switch ON 2 4 2 7 kg cm2 34 38 psi At Idle speed 2 0 2 4 kgtcm2 28 34 pSI Injector cOil resistance 1 55 1 85 Ohms 20 C 68 F PB sensor output voltage atmosphenc 358 4 02V pressure test 100 m...

Page 12: ...arged 1 280 12 t 3V At 20 C 68 F Normal reaoing 1 260 11 12V Needs Charging 1 200 below 1211 Battery charging rate 2A max 3 000 rpm Altarnator 47QW S OOO rpm Regulatorlrectlfier Type Translstonzed Regulated voltage 14 15V Charging starts 1 000 1 200 rpm Bectrica Starter motor Brush length 12 13 mm 0 47 0 51 in umit 7 5 mm 0 30 In Brush spring tension 560 680 g 119 8 24 0 ozl umlh 40 9 15 5 oz 011 ...

Page 13: ... 27000 27021 11 0630 1 0638 2705 1 0651 Bearing clearance Center 0050 0 087 00020 0 0034 014 0 006 8 th ends o 030 0 067 0 0012 0 0026 0 14 0 006 Standards Service Limits C Cylinder Piston Crankshaft Cylinoer Cylinder compression 1 15 kg1cm2 1156 213 pSI 10 kg cm2 142psi Cylinder InSide Diameter 75500 75 515 2 9724 2 9730 75 60 12 976 Out ol round o 15 0 006 Taper 0 05 0 0021 Warpage across top of...

Page 14: ...5 1 2215 3105 1222 C2 G3 31 000 31 033 1 2205 12218 31 06 1 223 M4 25 020 25 041 0 9850 0 9859 25 0S 0_98l M5 28 020 28 04 11 1 1031 11040 28 0611 105 Gear bushing 0 0 C1 C2 C3 30950 30 975112185 12195 30 90 1217 M5 27959 2798011 1007 1 101S 2790 1098 Gear to bushing clearance Cl 0 025 0075 0 0010 00030 015 0 006 C2 C3 0 025 0 083 O 0010 0 0033 016 0 006 M5 0040 0 082 0 0016 0 0032 016 0 006 Gear ...

Page 15: ...l gear assembly preload 2 0 4 0 kQ cm il 7 3 5 In Itl AlnQ gear to case stopper clearance 0 3 0 6 0 01 0 021 B I rakes Front orake master cylinder Cylinder 1 0 12700 12 743 0 5000 0 5017 12 755 0 5022 Piston 0 0 12 684 12 65710 4994 04983 12 645 0 4978 Front brake Cylinder 1 0 Right caliper 25400 25 490 1 0000 1 0035 25 460 1 0024 caliper Left caliper 32 030 32 080 1 2610 2630 32 090 1 2634 Piston...

Page 16: ...m lOCk bolt 1 8 26 19 Gearshift fork lock bolt 1 7 16 12 ali filter bolt 1 12 30 22 all drain plug 1 14 38 27 Alternator dnve shaft holder bolt 5 6 12 9 0 1 pressure sWitch 1 12 9 NOTE 4 Starter clutch outer torx bolt 3 8 25 18 NOTE 2 Coolant temperature sensor 1 23 17 NOTE 4 Thermostatic fan motor switch 1 28 20 NOTE 4 Oli pipe bolt 3 14 10 Spark plug 4 12 16 12 Timing belt cover bolt 4 6 12 9 Cy...

Page 17: ...t brake disc bolt 5 8 30 22 Front brake caliper bracket upper 2 10 35 25 lower 2 8 23 16 Brake caliper pivot bolt 3 12 28 20 Brake caliper bolt 3 8 23 17 Brake hose oil bolt 4 10 30 22 Brake metal line jOint 6 10 17 12 Front brake master cylinder holder bolt 2 6 12 9 Rear braKe disc nut 5 8 30 22 Rear braKe master cylinder bolt 2 8 27 19 Rear brake rod joint lock nut 1 8 18 13 Rear axle nut 1 18 9...

Page 18: ... Rear fender mounting bolt Seat bolt Standard Torque Values 1 6 2 1 3 3 6 3 2 2 4 2 4 2 1 1 1 2 2 6 8 10 16 12 10 8 10 12 10 8 10 8 8 10 8 6 8 8 12 26 48 110 60 35 22 35 60 40 18 40 22 18 22 22 10 14 22 9 18 35 80 43 25 16 25 43 29 13 29 16 13 16 16 7 10 16 Item 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 2 10 Torque Values 5 Nom 4 ft Ib 10 Nom 7 ft ...

Page 19: ...Maintenance Maintenance Schedule i 3 2 Fuel Filter 3 3 I Air Cleaner 3 4 Throttle Valve Synchronization 3 5 I Cruise Valve Element 3 6 ...

Page 20: ...L SYSTEM FINAL DAIVE OIL I I A BAnERY MONTH I I I I I I BRAKE FLUID 2 YEARS R I I R I I R BRAKE PAD WEAR I I I I I I Ul 2 BRAKE SYSTEM 1 I I I w 1 BRAKE LIGHT SWITCH I I I 0 HEADLIGHT AIM I I W f 5 CLUTCh FLUID 2 YEARS R I I R I I R w CLUTCH SYSTEM I I I a z SIDE STAND I I I 0 iii SUSPENSION I I I Ul CRUISE VALVE ELEMENT A 3 6 w Z AIR PUMP ELEMENT C 0 AIR DRIER I I I z NUTS BOLTS FASTENERS I I I I...

Page 21: ...bolts slowly to drain the lines and filter and to keep gasoline from spraying out Remove the banjo bolts to disconnecl the fuel lines Loosen the 6 mm clamp bolt and remove the filter from its bracket Install the new filter in the filter bracket Connect the fuel lines NOTE Use new sealing washers Align the fuel line with the filter stopper Tighten the banjo bolts Torque 22 N m 16 ft Ib Tightel the ...

Page 22: ...ner cover Remove the air cleaner cover TI SENSOR COUPLER BREATHER HOSE COUPLER HOLDER Remove and discard the air cleaner element Install the new element with the breather hose grommet facing the rear Install the air cleaner cover by inserting the T1 sensor In the forward grommet on the element Tignten the cover with the wing nut and connect the breather hose Install parts in the reverse order of r...

Page 23: ...le Differences in vacuum readings between these cylinders is probably due to car bon build up on the throttle valve To clean the throttle valves remove the cleaning hole plugs from the intake pipes Remove the spark plugs NOTES Decarbonizethe throttle valve with the highest vacuum reading first the lowest last Use a cleaner containing a rust inhibitor Spray carburetor cleaner into the intake pipes ...

Page 24: ...allation or the cruise control will not disengage Install the new element and assemble the parts in reverse order of removal Remove the element cover Remove and discard the cruise valve element Maintenance Cruise Valve Element Remove the seat side covers and top compartment 3 6 ...

Page 25: ...Engine Removal Installation Removal 4 2 Installation 4 6 ...

Page 26: ... electrical couplers remove the fairing Remove the radiator Remove the exhaust pipes and engine guards Remove the air chamber assembly see page 10 34 Disconnect the starter motor cable at the starter Remove the crankcase breather tank Disconnect the alternator coupler Remove the fuel pump and right footpeg bracket bolt Remove the foot peg and support the fuel pump with str ing or wire 4 2 ...

Page 27: ...e 2P yellow white wires coupler Disconnect the GAlGL sensor wire white 4P coupler Release the wires from the wire band Disconnect the oil pressure sensor yellow waterproof 3P coupler Disconnect the Tw sensor blue waterproof 2P coupler Release the wires from the wire bands Release the engine sub harness shift sensor wire Ns sensor wire and fan motor wires from the wire bands and wire clamps cont d ...

Page 28: ...the clutch lever in and tie it to the handlebar grip This prevents overextension of the slave cylinder piston Remove the two bolts from the top of the front engine mount bracket Remove the two bolts from the bracket front Remove the fan shroud and the front bracket Remove the left engine mount bolt and the cap nuts then remove the subframe ...

Page 29: ...inually adjusted as mounting bolts are removed to relieve stress trom re maining bolts Remove the right engine mount bolts Remove the triangular engine mount bracket from each side Release the clutch hose from the hose clamp With the aJd of another person to steady the engine ad just the jack while you raise the right rear engine mount boss out of the trame tabs cont d 4 5 ...

Page 30: ... while align ing the output shaft with the universal joint CAUTION Be careful not to damage the brake lines during Installation Sl1de the output shaft back into the universal joint CAUTION Car fully align mounting points with the Jack to prevent damage to mounting bolt threads wire harnesses and cables Hand tighten mounting bolts and nuts land Install parts noted In this order 1 The left and then ...

Page 31: ... and torque the m n ountlng bolts In the se 1 60 N m 43 ft lb 2 35 N m 25 ft lb Left side only N m 43 ft lb Left side only 5 22 m 43 ft lb 6 35 m 16 ft lb 7 35 25 ft lb 8 22 25 fHb N m 16 ft Ib Remove the jack 4 7 ...

Page 32: ... Frame Suspension Handlebar Replacement 5 2 Front Fork Illustration 5 3 Rear Shock Illustration 5 3 ...

Page 33: ...ndlebar switch Release the handlebar cover by removing two screws Remove the two 6 mm locating bolts and four handlebar mount bolts Remove the set plate and handlebar Installation Install the handlebar in the reverse order of removal Torque Handlebar mount bolt 10 mm 35 N m 26 ft Ib Handlebar locatIng bolt 6 mm 10 N m 7 ft Ib 5 2 ...

Page 34: ...________ PISTON RING OILSEPA ATO iiP LOWER SPRING The GL1200 SE i has an extra piston ring and an oil separator between the upper and lower fork springs Rear Shock Illustration The GL1200SE i has a check valve at each rear shock absorber 5 3 ...

Page 35: ...Brakes Front Master Cylinder 6 2 ...

Page 36: ...e brake light cruise cancel switch from the master cylinder by loosening the screw SCREW Installation Align the gap between the holder and the master cylinder with the arrow on the handlebar Install the brake light crUise cancel switch by aligning the switch pin with the master cylinder hole Tighten the screw securely 6 2 ...

Page 37: ... Ignition Service Information 7 2 Troubleshooting 7 4 Ignition Timing 7 5 Ignition Coil 7 6 Spark Unit 7 7 Spark Unit Resister 7 8 ...

Page 38: ...before troubleshooting the ignition system Measuring outputs at coupler pms Insert the tester probes from behind the coupler pins to avoid bending or prying them open Be careful not to short out pins Disconnecting a coupler or connector Turn the ignition switch OFF Positive and negative sides are so mar1 ed Do not remove waterproof grommets from the couplers Fuses Relays ECU Coupler Pin Numbers IG...

Page 39: ...are connected properly Each pair of spark plugs 1 2 3 4 has its own ignition circuit Faulty plug No Spark at One Pair of Plugs 1 2 or 3 4 Engine does not start or Is hard to start No Spark at r All Plugs SPARK TEST Remove spark plugs and 1 Go to CFI check for spark at each cylinder Troubleshooting Fuel system indicator does not light page 10 7 L r No Spark at One Plug PLUG CAPS AND LEADS Measure r...

Page 40: ...ING Check continuity from W with Y tube wire to ECU coupler pin 7 and from G with Bu tube plus W tube wire to pin 8 Continuity IGNITION COIL Inspect ignition coil see Abnormal page 7 4 Normal CAMSHAFT ANGLE SENSORS Inspect Abnormal Gr GI sensors see page 10 29 Normal Open circuit between spark unit and Ignition coil primary terminal Poor contact at couplers Open circuit Poor contact at couplers Fa...

Page 41: ...park plug wire Start the engine and let it idle Idle speed 1000 t 100 rpm The timing is correct if the flywheel F1 mark aligns with the inspection cap center index mark at idle Timing advance is correct if when the engine speed is raised the F1 mark moves up and disappears Connect the timing light to the No 3 or No 4 cylinder spark plug wire and repeat the procedure using the F2 mark If the timing...

Page 42: ...its Remove the two bolts and the throttle cable guide Pull the Ignition coli toward the air cleaner Remove the Ignition coil screws and disconnect the ter minal wires Remove the ignition coil NOTE When installing the coils the BIJW and YIBu wires go to the left coil 1 2 The BI W and BulY wires go to the right coil 3 4 Coil polarity has no effect on pertor mance Inspection See the base manual for I...

Page 43: ... fender If there is no continuity the wir ng harness has an open Check for battery voltage between the coupler BVW and G terminals If there is no voltage check for continuity between the 21 P black coupler W terminal on the fuse box and the spark unit coupler 81fW terminal If there is no continuity the wiring harness has an open Check for battery voltage between the coupler Y and G terminals If th...

Page 44: ...k unit NOTE The No 1 2 cylinder spark unit 4P coupler is red The No 3 4 cylincler coupler is black Install the spark units in the reverse order of removal Spark Unit Resister Inspection Disconnect the coupler and measure resistance between the white and black wire terminals Resistance 2 9 3 2 ohms If resistance is outside lhese limits install a new resister 7 8 ...

Page 45: ...truments Service Information 8 2 Troubleshooting 8 3 Turn Signal Cornering Lights 8 11 Front Brake Light Switch 8 12 Oil Pressure Warning Switch 8 12 Oil Pressure Sensor 8 13 Tail Light Relay 8 13 Handlebar Switches 8 14 ...

Page 46: ...Lights Switches Instruments Service Information Refer to the base manual for disassembly assembly procedures 8 2 ...

Page 47: ... C2e 13P S c Pler oVolts Battery Voltage 11 5 to 13 5 V Continuity Sl Sr wire shorted No Continuity Faulty meter POWER TO FUSEJRELAY BOX Measure voltage between BllBr terminal of fuse relay box 9P black coupler and battery negative terminal oVolts FUSEIRELAY BOX Measure voltage between each 01 two BI terminals of fuseIrelay box 4P black coupler and battery negative terminal o Volts IGNITION SWITCH...

Page 48: ...of adapter About 5 V o Volts Abnormal Voltage About 5 V Open or short cirCUit In SI Sr or G BI wire between meter and sensor couplers Poor contact at meter or left fairing coupler oVolts FaUlty meter SENSOR SIGNAL Measure voltage be tween W and R leads of inspection adapter Voltage should be 0 7 1 3V oVolts SIGNAL WIRE TO METER Check for con tinuity between BulY terminal of meter white 20P coupler...

Page 49: ...ery 15 seconds Also check that temperature decreases by one segment every 15 seconds by separating the sensor terminal from ground SENSOR WIRE Disconnect meter white 20P coupler Check for continuity between sensor wire terminal and body ground Normal Abnormal Continuity Short circuit in engine sub hamess main harness or fairing sub harness Above 200 n Poor contact at left fairing coupler or sensor...

Page 50: ...inuity between BltBr and BI Y terminals of harness side coupler and sensor black 3P coupler Battery Voltage SENSOR SIGNAL Measure voltage between BIIY and G BI terminals of meter white 13P coupler Rotate front wheel Slowly High above 3 5 V and Low below 1 5 V pulses should appear ETC must be connected Normal 8 6 Abnormal Continuity Short circuit In harness Normal Faulty sensor Check for poor conta...

Page 51: ...r Check for poor contact at ETC unit coupler If coupler is OK ETC unit printed circuit board is faulty Water Temperature Fuel Gauge Will Not Shift to 011 Temperature Pressure Gauge METER Short LbiW terminal of meter Display Does white 20P coupler to G BI terminal of Not Shift meter white 1 3P coupler Meter is normal if display shifts Display Shifts ETC UNIT WIRING Short Lb W terminal of Display Do...

Page 52: ...te 13P coupler Meter is normal if it resets Meter Resets ETC UNIT WIRING Disconnect meter No white 20P coupler and ECU white 17P Continuity coupler Check for continuity between RIG terminals of both couplers Normal 8 8 Check for poor contact at meter coupler If coupler is OK meter IS faUlty Open or short circuit in wire hamess Poor contact at left fairtng coupler Check for poor contact at ETC unit...

Page 53: ...attery Voltage Open circuit in fuse relay box SIGNAL TO RELAY With left handlebar switch couplers connected measure voltage between Lb W or OIW brown 9P and G black 9P terminals of switch couplers under rubber cover next to left fairing pocket Battery voltage should be present between these terminals IBattery Voltage Open circuit in fuse relay box SWitch position R LbIW G OV O W G 12V IFuse Fuse O...

Page 54: ...ING Measure voltage between 8r 8u tennlna of right handlebar switch red 9P coupler and body ground o Volts WIRING FUSE RELAY BOX Measure voltage between 8r 8u terminal of fuse relay box black 9P coupler and body ground oVolts 8 10 Battery Voltage Battery Voltage Poor contact at left Faulty handlebar L handlebar switch switch coupler Short circuit In wire harness Lb W or Q W wire Open circuit In wi...

Page 55: ...MAIN RELAY TURN SIGNAL CA lC L CONTROllihlT SUS F S S i I dl ioS GliAL LAY Br Bu I W G 1lI1 ll 1IlI G tI G I B IL LI luIJf J RELAY a 0 Il L _ t i F f t r rG I I I Q IlJ I OTO O I 0 0 Q l O 0 0 I Off PUS allOl FlJSES f1lGI T TURN SIGNAL POSITI lI TS RE LAY Q No LABEL 1 STOP 1 OR i TURN TAllLIUriT II No I LABEL 6 I L CORNERING LIGHT 7 I R CORNERING LIGHT Ql ...

Page 56: ...the switch side coupler Lever released No continuity Lever pulled Continuity Check continuity at the switch tenninals and replace the switch if continuity Is abnonnal Oil Pressure Warning Switch Installation The oil pressure wamlng switch is behind the charcoal canister on the Califomla model Torque 12 N m 9 It Ib NOTE Make sure the switch wire doesn t contact the clutch cable after Installation 8...

Page 57: ...switch threads Install and tighten the switch Torque 12 N m 9 ft Ib Connect the sensor coupler and air vent tube Install the air cleaner cover Main Relay Inspection Remove the shelter The relay is just to the left of the radiator cap Remove the relay from the bracket and pull off the rubber cover Depress the catch on the coupler with a long screwdriver and pull the relay out Check for no continuit...

Page 58: ...es Instruments Handlebar Switches Turn Signal Switch Remove the left side fairing pocket and shelter Inspect at the black and brown gp couplers behind the rubber cover Starter Button Inspect at the gp red coupler on the right inner side of the fairing Test for continuity between the color coded wires BVLg VIR BI A Bu W FREE 0 PUSH 8 14 ...

Page 59: ...Accessories Fairing Lower Covers 9 2 ...

Page 60: ...he five screws and collars to release the fairing lower cover Remove the air ventilator panel from the fairing Hold the lower cover while you disconnect the cornering light wires then remove the cover Release the inner cover by removing the screws 9 2 ...

Page 61: ...ooting 10 7 Fuel Pressure Inspection 10 20 Fuel Injectors 10 20 Pressure PB Sensors 10 22 Throttle 0th Sensor 10 24 Crankshaft Angle NS Sensor 10 27 Camshaft Angle GR GL Sensors10 28 Air Temperature T1 Sensor 10 29 Coolant Temperature TW Sensor 10 30 Fuel Pump 10 31 CFI Electronic Control Unit ECU 10 33 Air Valve 10 34 Air Chamber 10 34 ...

Page 62: ...o avoid bending or prying them open Be careful not to short out pins Disconnecting B coupler or connector Turn the ignition switch OFF_Positive and negative sides are so marked Do not remove waterproof grommets from the couplers Fuses Relays ECU Coupler Pin Numbers CFI MAIN RELA V FUEL PUMP RELA V V jj 0 IGNITIOt REGULATOR CFf CRUISE HEIGHT FUSE 10AI CONTROL FUSE 15AI Parts Location I T1 SENSOR I ...

Page 63: ...System Diagram FUEL SYSTEM f 1 INDICATOR r I nSEN k PO SENSORS f FfFr THROTTLE II II __ SENSOR Functions Parts ...

Page 64: ...CFI System Service Information cont d System Wiring Diagram I _ I J I l rt l c J Lj rJ 10 4 ...

Page 65: ...onnectors 0 I 0 10 28 1ubInQ c o o 0 ECU un 0 0 C 0 ThrolllE valve syn hrol1 zatlon 0 0 1 1Q 33 Spark plugs Spark plug I WP o o o o c 3 5 o o v o o o IQMlon 0 1 U 1 4 4 4 1 ____11___ 1 1 Spark un 0 0 0 c o I W lr e c o n n ec Io r 5 n o I 0 1 0 1 4 1 7 7 1 zl T t f t t f t T l o Sattery 0 0 0 7 2 f r 4 l I 4 z GRiGL sensor 0 0 0 N s se n 5 0 r I 4 c 1 I o o 4 o 4 4 4 O 2 7 l Plug gao o o c o o a a...

Page 66: ...tion and Ignition timing are both fixed O OO e ECU Faulty ECU IP sensor PI IS fixed to 760 mm 30 in Hg P1 sensor O O e T sensor Open CIfCUlt Tl IS fixed to 25 C 77 F Shorted signal wife O O e Tw sensor Open CIfCUlt Tw s fixed to 85 C 185 F Shorled signal wife O e 2 4 cylinder Open or short CIfCUlt Injectors NOTE 11 Fuel inJection and Ignition liming are both stopped NOTE 2 OOO e 1t1 3 cylinder Ope...

Page 67: ... voltage between ECU coupler terminals 1 l land2 Battery Voltage Eeu Check ECU coupler for loose contact o Volts No Good Poor contact Good Faulty ECU POWER TO RELAY BOX Measure voltage between W I and G I terminals of fuselrelay box 21 P black coupler 2 P black coupler RELAY Replace CFI main relay in fuse relay box WIth a known good relay Recheck indicator Battery Voltage Good Poor contact at blac...

Page 68: ...ENSOR Check fuel pump shut off No Good sensor see page 10 32 Good Faulty ignition switch Faulty engine stop switch Broken or loose subfuse 5 Poor contact at couplers Open or short circuit in harness Broken or loose sUbfuse 91 or 30A fuse Open or short circuit in wire harness W wlrel Open or short circuit in fuse relay box W R wire Poor contact at couplers Faulty fuel pump shut off sensor Damaged f...

Page 69: ...utput Normal Isee page 10 31 Low FUEL FILTER Replace fuel tilter and Nonnal recheck fuel pump output Low Abnormal fuel pressure only at Idle VACUUM HOSE Repair leaking or blocked regulator vacuum hose High fuel pressure engine OFF Faulty pressure regulator Repair as necessary Faulty pressure regulator Blocked filter Faulty fuel pump RETURN LINE Check fuel return line for pinching or blockage Norma...

Page 70: ...y ECU Try with known good ECU Remove spark plugs and check for spark No Spark Go to IGNITION SYSTEM at each cylinder TROUBLESHOOTING Spark OK see page 7 3 Pump FUEL PUMP Check that FUEL PUMP Operates operates for about 3 seconds after Go to FUEL PRESSURE ignition switch is turned ON TROUBLESHOOTING see page 10 9 Does Not Operate Pump Won t FUEL PUMP Disconnect fuel pump Operate coupler and apply b...

Page 71: ...ttery Voltage POWER TO ECU Measure ECU input I 0 Volts voltage see page 10 7 Battery Voltage WIRING Disconnect ECU coupler Measure voltage between terminals 30 oVolts and 2 Battery voltage should appear when ignition switch is ON and starter button is pushed Battery Voltage cont d Open circuit in wires between 21 P black coupler and fuel pump coupler Open circuit in wires between 13P black coupler...

Page 72: ...Normal PB SENSORS Inspect PB sensors see page 10 22 Normal THROTTLE SENSOR Measure output voltage of throttle sensor see page 10 24 r L_E_O_ S_O_N_ I FAULTY PART Inspect system or parts I indicated tNormal Faulty ECU Try with a known good ECU Abnormal f Faulty injector or signal lines Abnormal r l Go to IGNITION TROUBLESHOOTING see page 7 3 Abnormal Faulty PB sensor Abnormal Faulty or incorrectly ...

Page 73: ...E Measure fuel pressure see page 10 20 Normal THROTILE SENSOR Inspect throttle sensor see page 10 24 Normal PB SENSOR Inspect each PB sensor see page 10 22 Normal Abnormal Abnormal Abnormal Abnormal Faulty Injector or wires Go to FUEL PRESSURE TROUBLESHOOTING see page 10 9 Faulty or incorrectly adjusted throttle sensor Faulty PB sensor HOSES Inspect PB sensor hoses for blockage rClear B I oc k e d...

Page 74: ...ING Check ignition timing see Abnormal SENSORS Check ignition timing related page 7 5 sensors PBR PBL Ns f th GR GL TW sensors Normal Normal Faulty ECU Try with a known goodl ECU FUEL PRESSURE Check fuel pressure Abnormal Isee page 10 20 Go to FUEL PRESSURE TROUBLESHOOTING Normal see page 10 9 HOSES Check PB sensor hoses for Abnormal blockage With vacuum pump see Follow procedures page 10 l8 on pa...

Page 75: ...ensor hoses for Abnormal blockage with a vacuum pump see Follow procedures on page 10 1 8 page 10 18 Normal AIR LEAKS Check for leaky parts in Leaking intake system between throttle valve and Too lean a mixture due to secondary cylinder head air leak Not Leaking Not Synchronized THROTTLE VALVES Inspect After synchronization 01 throttle valves Adjust Adjustment throttle valve synchronization it vac...

Page 76: ...ls of air valve see page 10 34 65 100n AIR VALVE Pinch air bypass hoses between air valve and air chamber air valve and reed valves Recheck idle speed Idle speed should decrease Idle Speed Air oypass hoses I Decreases To air a chamber _ 1 I Air Vallie 1 Not Decreased COOLING Check water bypass hoses Blocked between air valve and thermostat hOUSing There should be no blocking lClear AIR LEAKS Check...

Page 77: ... 10 20 Faulty injector or wires Normal FUEL PRESSURE Check fuel pressure Abnormal see page 10 20 See page 10 9 Normal HOSES Check P8 sensor hoses for Blocked blockape with a vacuum pump Too rich a fuel mixture due to see page 10 18 incorrect pressure to PB sensors Clear SENSORS Check the following sensors Abnormal PB sensor see page 10 22 Faulty sensor TW sensor see page 10 30 Normal Loose or WIRI...

Page 78: ... or wires Incorrect pressure applied to PB sensor Connect a vacuum pump as shown Start engine and check PB sensor hoses for blockage Vacuum gauge should indicate intake manifold vacuum Vacuum 3 way iOlnt Normal Abnormal Check and repair PB hose Correct AIR JETS Inspect vacuum air jets at each intake pipe for blockage see page 10 24 Blocked Incorrect PB SENSOR Inspect each PB sensor see page 10 22 ...

Page 79: ... cleaner see page 3 5 Then recheck synchronization Abnormal REED VALVES Apply pressure to each reed valve air hose Pressure should hold Abnormal I j Secondary air leaking at intake system Normal 1 Excessive carbon built up on throttle valves Pressure Bleeds Faulty reed valve or loose connection at reed valve case Pressure Holds Faulty throttle body 10 19 ...

Page 80: ... 2 2 4 kg em 2 28 34 psi If pressure is not within specification replace the fuel pressure regulator NOTE Install a new aluminum washer when you recon nect the fuel line Fuel Injectors Operation Inspection With the engine stopped turn the ignition switch ON and quickly open the throttle You should hear the injector click LED Inspection The LED s will indicate trouble by cylinder banks Discon nect ...

Page 81: ... take pipe mating face Use only dowel bolts to install the Injector cap Shim Selection O RING COLOR CODE STAMP SHIM SELECTION TABLE Unit mm ln INJECTOR NOTE Injectors must be adjusted with shims when any of the following parts are replaced Fuel injector Fuel delivery pIpe Fuel injector cap Throttle body Intake pipe Shim only the affected Injector Determine the Injector color code Measure the dista...

Page 82: ...ck the sensor coupler for loose or poorly contacted terminals Input Output Voltage Inspection t L 1 000 IT 2 000 IT 3 000 m 4 000 m 3 300 III 16 600 III 19 843 hi 113 000 III 700 400 a UNCORRECTED I TMOSPHERIC PRESSURE TEMP ALTlTUDE PZ M Hgl J r l t _l j 1 _ l 1 r I I 1 Compensate the voltage reading for pz uSing this for mula EXAMPLE Conditions Altitude 1500 m 5000 ft Temperature 20 C 68 0 F Outp...

Page 83: ...age readings are correct install a new ECU PBSENSOR COUPLERS PBR SENSOR INSPECTION ADAPTER RED LEAD DIGITAL CIRCUIT TESTER Disconnect the vacuum tube from the PB sensor Turn the Ignition switch ON Measure the output voltage bet ween the white and green inspection adapter leads Output voltage under atmospheric pressure 3 58 4 02 V Connect a hand vacuum pump to the PB sensor and apply vacuum Turn th...

Page 84: ...e 0th Sensor LED Inspection Connect the inspection adapter between the ECU and throttle sensor couplers and measure the input voltage see page 10 13 Check for continuity between the white adapter lead and the 11 ECU coupler terminal With the sensor coupler disconnected check for no continuity between the 11 ECU coupler terminal and the body ground GREEN LEAD 117 11 1 1 I f DIGITAL CIRCUIT TESTER I...

Page 85: ...ge between the No 1 2 ECU coupler terminals If the voltage Is OK in stall a new ECU INSPECTION ADAPTER DIGITAl CIRCUIT TESTER With the ignition switch ON measure the output voltage between the white and green I adapter leads while gradually opening the throttle Replace the sensor if the voltage does not rise smoothly as the throttle is opened Loosen the Idle adjustment screw and insert a 2 9 mm 0 ...

Page 86: ...lt Break the head off the bolt by drilling a 9 mm 0 35 In hole through the marked location Install a new sensor on the throttle body using new break head bolts NOTE Do not break the heads off the bolts until after ad justing the sensor Install the throttle body on the engine Insert the 2 9 mm gauge between the throttle valve ann and stop screw Turn the sensor until the output voltage is 0 475 0 49...

Page 87: ...terminal and ground or other terminals Check the sensor coupler for poor contact at the ter minals Coil Resistance Inspection Remove the ignition coil from the frame see page 7 5 Remove the Ns sensor white 2P coupler from the holder Measure the resistance between the yellow and white coupler terminals Resistance 297 363 ohms Check for no continuity between each of the two ter minals and body groun...

Page 88: ...nd the No 24 terminal With the sensor coupler disconnected check for no con tinuity between the No 7 and No 8 ECU coupler ter minals and ground or other terminals Check the sensor coupler for poor contact at the ter minals Coli Resistance Inspection Remove the fainng Remove the GR GL white 4P sensor coupler from the holder Measure the GL sensor coil resistance between the W with Y tube and Y termi...

Page 89: ...iring harness for an open circUit Check for continuity between the sensor negative 1 terminal and the NO 3 ECU terminal bet ween the positive terminal and the No 10 ECU ter minal Disconnect the coupler from the sensor and measure voltage between the terminals Voltage should be 4 75 5 25 V with the ignition switch ON Air Temperature T1 Sensor LED Inspection With the sensor coupler disconnected chec...

Page 90: ...terproof 2P blue coupler Connect the Inspection adapter to the hamess side coupler Turn the Ignition ON There should be 4 75 5 25 V across the red and green 1 adapter leads If there is no voltage check the wIring harness Check for no continuity between the red lead and the No 28 ECU terminal and between the green lead and the NO 3 terminal Continuity indicates an open circuit With the sensor coupl...

Page 91: ... c Main Fuel Pump Relay Inspection Fuel pump capacity 630 cc 21 3 oz lmlnute minimum Measure the amount of fuel discharged Engage the transmission With the clutch lever out and push the starter button so the starter motor will not work Out the fuel pump operates Fuel Pump Operation Inspection _ Turn the ignition OFF Disconnect Ihe fuel line from the left fuel delivery pipe by removing the joint nu...

Page 92: ...cated on the rear fender Remove the pump cover bolts and the cover Wrap a shop towel around the fuel line and fitting Loosen the fuel hose banjo nut slowly then disconnect the hose Remove the nght footpeg bracket bolt and the fuel pump Disconnect the fuel lines from the pump Remove the mounting bracket Install in the reverse order of removal Torque values Fuel hose banjo nut 28 N m 20 ft lb Footpe...

Page 93: ...ct the coupler from the ECU NOTES Do not pry the coupler open or bend the terminals Keep water oil and dirt away from the terminals Do not attempt to disassemble the ECU InstallatIon Attach the ECU coupler to the ECU hinge and push it in until the lock engages Slide the ECU into its case and install the dust cover CAUTION If the dust cover Is not Installed the ECU may be damaged by water or dust P...

Page 94: ...erse order of removal Air Chamber Removal NOTES Keep the intake pipes injectors and caps in their original sets and install them in their original locations Adjust the injectors with shims whenever you install these new parts injector cap delivery pipe throttle body and intake pipe Turn the ignition OFF and disconnect the fuel pump coupler Remove the fuel filter from the left engIne mount bracket ...

Page 95: ...the Injector cap bolts and caps Plug each injec tor port to keep out dirt Disconnect the spark plug wires Disconnect the PB and cruise control vacuum hoses Remove the intake pipe mounting bolts pipes and the in Jector cover bracket Disconnect the crankcase breather tube Disconnect the secondary air supply tubes from the cylinder heads and engine case holders Disconnect the cruise control throttle ...

Page 96: ...tle cables NOTE If the left fairing bracket interferes with with the air chamber remove the left fuel delivery pipe Disassembly NOTE See the base manual for service of the secondary elr supply reed valves and the purge control valve Remove the primary reed valve set plate Disconnect the air hoses from the housing Remove the reed valve covers Check the reeds for signs of damage or fatigue and repla...

Page 97: ...UPPLY SYSTEM I I REED VALVE I f1r 0 1 Wi J __J Qtt J 6 A H 1 SENSOR Q PRIMARY REED VALVES NOTES Use new O rings and sealing washers Clean all parts in solvent Install the air chamber cover with the front mark lacing forward Connect the throttle link to the throttle arm install the washer and a new cotter pin cont d FRONT MARK AI R CHAMBER COVER 10 37 ...

Page 98: ...REGULATOR VACUUM HOSE L REED VALVE AIR HOSE AIR VALVE OUTLET AIR HOSE SECONDARY AIR SUPPLY HOSES California Model 1 SECONDARY AIR SUPPLY 0 TUBES 10 38 PRESSURE REGULATOR PURGE AIR SUPPLY HOSE VACUUM HOSE PC PORT VACUUM HOSE UPPER PB POR 1 VACUUM HOSE AIR VALVE OUTLET AIR HOSE SEE A VE I t I 0 o PURGE AIR REED VALVE SUPPLY HOSE REED VALVE AIR HOSE ...

Page 99: ...t caught on surrounding parts and disconnected Apply a thin coat of clean engine oil to the pressure regulator a rings and install the right fuel delivery pipe Connect the vacuum hoses to the pressure regulator Connect the air outlet and inlet hoses to the air chamber On California models connect the purge aJr hose to the purge control valve Connect the secondary air supply hoses to the cylinder h...

Page 100: ... breather tube to the ooglne Connect the vacuum hose to the intake pipe Connect the sparX plug leads Connect the fuel line to the left fuel delivery pipe and tighten the banjo nut Torque 22 N m 18 ft Ib Connect the throttle sensor and cruise control throttle grip cancel switch couplers Install the air cleaner case and air cleaner Connect the fuel pump coupler pressurize the system by turning the I...

Page 101: ...Electronic Travel Computer Service Information 11 2 Troubleshooting 11 4 Removal 11 12 Disassembly 11 12 Assembly 11 14 ...

Page 102: ...e or resistance Make sure all related couplers or wires are connected securely Disconnecting a coupler or connector Tum the ignition switch OFF Positive I and negative sides are so marl ed Fuses Relays CFI CRUISE HEIGHT CONT 15A METER 10A PARKING 10A Parts Location I 7 I 1 1 1 t j I r INJECTOR RADIO CASSETTE DECK ___ FUSEJRELAY BOX I E T C CONTROLLER CONNECTORS llll I I L i FUEL L EVEL 1 SENSOR _ ...

Page 103: ...ystem Wiring Diagram o L J L L l LJ J L L L l J L L Ie a fi I I 1 3 j ti r l i l2 J lLJ J I E u I u i 1 di I J I ll _ di 3 w Jz a t Q J a r 11 o f I L E l malt l 11 3 1 lI3ur8 r O lllllll il c f l J 11 3 ...

Page 104: ...E Check 7 5 A fuse under left fainng pocket Blown Fuse Short circuit between fuse and ETC unit Fuse OK WIRING Remove 7 5 A fuse from fuse holder Check for continuity between the fuse wire and R of ETC unit 17P coupler A 17P WHITE COUPLER No Continuity Continuity Poor contact at fuse terminal I Loose or poor contact at left fairing coupler 20P black coupler Open circuit between fuse and ETC unit Ba...

Page 105: ...ER and measure voltage between tuse positive terminal and battery negative terminal with ignition switch in the ACC position o Volts IGNITION SWITCH Check ignition sWltcn for continuity see base manual Normal ADnormal Poor contact at Faulty ignition ignition switch switch coupler or fuse box coupler Open coupler In harness between ignition switch and fuse terminal Battery Voltage WIRING Check for ...

Page 106: ...switch ON Measure voltage between W and G SI terminals of 17P White coupler o Volts Check the fuel system indicator The fuel system indicator shOUld come on for about 3 seconds when the ignition is switched ON Battery Voltage SPEEDOMETER ODOMETER Check speedometer and odometer functions Abnormal cont d next page SENSOR SIGNAL Measure voltage between SIIY terminal of the instrument 20P black couple...

Page 107: ...olume function Open circuit Faulty instrument between instrument and ignition switch Poor contact at fairing 13P white coupler coupler Not OK r Conl d OK Faulty ETC unit try with known good ETC unit SENSOR SIGNAL Measure voltage between W SI and G SI terminals of ETC unit 17P white coupler with ignition sWitch ON Volt meter should indicate from o to about 9V alternately when the front wheel is rot...

Page 108: ...More than 10 Liters FUEL GAUGE Check fuel gauge LCD ShOuld light more than 3 segments Yes LOW FUEL INDICATOR Check low fuel Indicator Indicator should go oN about 3 seconds after ignition is switched ON Yes No No SENSOR Check fuel level sensor see base manual OK Faulty fuel level sensor SENSOR SIGNAL Measure voltage between W Bu and GlBI terminals of the fuel level sensor terminals Volt meter shou...

Page 109: ... Open or short circuit in wire harness Correct Faulty ETC unit Below 5 Liters FUEL LEVEL Check amount of fuel in fuel 1 3 gal Fill tank with more than 5 liters 1 3 gal tank with ignition switch OFF Recheck display with ignition switch ON More than 5 Liters 1 3 gal tAbnormal Normal COUPLER Check fuel level sensor Fuel level was too coupler for poor contact Then check fuel Abnormal low Poor contact ...

Page 110: ...WIRING Check for continuity between body ground and G SI terminal of the sensor coupler Ohmmeter should indicate no continuity Faulty ETC unit try with a known good ETC unit Poor contact at 17P coupler No Fuel consumption does not decrease on display SIGNAUETC UNIT Disconnect white 3P coupler resistor on the rear fender Check fuel consumption function with ignition sWitch ON Fuel consumption displ...

Page 111: ... between Lg BI Br W Br and G terminals of 17P white coupler at each Ignition sWitch position Battery voltage should be indicated as shown Oft Wire Position P Ace ON Color Lock Lg BI G 12V OV 12V 12V Br 1 GI 12V OV OV OV Br W l j G I ov OV OV 12V COUPLERS Check contact at ETC 17P and Ignition switch couplers Normal Open or short circuit In wire harness Faulty ignition switch Poor contact at coupler...

Page 112: ...ve the four mounting nuts which secure the E T C unit SCREWS COVER SCREWS Unscrew the six cover mounting screws Disassembly CAUTION Keep water and dirt away from the printed board and other parts Press the wire grommet down into the cover Remove the cover Remove the illumination bulbs by turning the sockets counterclockwise 11 12 ...

Page 113: ...sassembly Do not remove the base printed board Disconnect the black LCD indicator coupler from the printed board Release the LCD Indicator from the case by removing the seven self tapping screws Remove the screws radio controller and fader Remove the screws which secure the printed boards Remove the water shield and buttons from the case NOTE Record the button colors and note the location of paper...

Page 114: ...Electronic Travel Computer Assembly Assemble In the reverse order of disassembly PANEL 11 14 KNOBS FADER LCD DISPL A Y D I S PlAlNTED BD MPUTER PR NTED BOARD ...

Page 115: ...ng Rear Suspension Service Information 12 2 Troubleshooting 12 4 Air Pump Relay 12 17 Suspension Control Switch 12 17 Air Distributor 12 18 Pressure Relief Valve 12 23 Suspension Computer 12 23 Height Sensor 12 24 ...

Page 116: ...ecting a coupler or connector Tum the ignition switch OFF Positive and negative sides are so marked Fuses Relay Box AIR PUMP RELAY CFt MAIN RELAY n l t O III DJ10 ul 11 0 6 1 1LJ STOP HORN TURN I L J AIR PUMP C 10 A 1SA IGNITIONI REGULATOR C TOARIUN 10A PARKING C F I CRUISE HEIGHT CONTROL 15A 10A 1SA Parts Location SENSOR CONNECTING ROD r J Z h REAR HEIGHT N i I I I I y J J __ 1 I r v f I I J 0 I ...

Page 117: ...Wiring Diagram o BAntRY l GROUND LAIl L___ I e EEJ SILICON FlECTlI 1ER DRIER 9 ro ROIIT FORl S tb __ TO REAli SHOCKS SlON COMPUTER SUSPEN 11 G Y j t ll w 12 3 ...

Page 118: ... Measure voltage between Battery computer battery negative terminal and GiY Voltage terminal of suspension computer 20P Short Circuit in wire harness coupler Voltage should not appear with Ignition switch ON o Volts POWER Measure voltage between W I o Volts COUPLER Check right fairing 24P coupler and G terminals of computer 20P for poor contact coupler Battery voltage should be indicated with igni...

Page 119: ...Inspect height sensor see page 12 24 Open circUit In wire harness Abnormal Poor contact at right fairing 24P or at sWitch coupler Faulty sWitches Reconnect 20P coupler and measure vollage between terminals Voltage should be above 10 V with ignition switch ON and handlebar switctl in neutral Y R 1 WIG I j n Y R i to G 1 cJEJooD D8W G toGI D D nD W R to G Y WI I toG G 1 WIR 1 Y W 1 Normal Abnormal c...

Page 120: ...nttion sWitch ON NOTE Seal pin holes when done Below 3 0 Volts LCD DISPLAY Disconnect LCD coupler Apply battery voltage to display side as shown LCD should show three bars COUPLER T r I I I I I I I Abnormal EEE Indicated Faulty LCD display Normal COUPLER Reconnect LCD 6P water proof coupler and recheck display OlE Not Indicated Connector was loose IE Indicated COUPLER Check suspension computer 20P...

Page 121: ...d solenoid valve 4P couplers Check G Br W Br R and BrN wires for continuity Abnormal oetween RHC unit and solenoid valve couplers of wire harness Between same COlor Continuity Between different colors No continuity Normal SOLENOID VALVE Connect suspension computer coupler Measure resistance at 4P coupler of solenoid valves with coupler Abnormal disconnected BrlR G 79 9 3Q Br Y G 79 9 3 Q Br W G 13...

Page 122: ... 2 3 Volts SENSOR SIGNAL Measure voltage Normal between Lb and G terminals of 3P red coupler with coupler connected There should be below 0 3 V whefl ignition switch is ON oVolts PRESSURE SENSOR Inspect the air Abnormal pressure sensor refer to On Board Air Compressor System in base manual Normal RELIEF VALVE Check air pressure relief Abnormal valve operation see page 12 23 Normal C cont d Blocked...

Page 123: ...ure voltage between terminals on wire harness side as shown Battery voltage should be indicated with Ignition switch ON Battery Voltage COUPLER Check 6P coupler for poor contact If coupler is secure install new LCD display I __ _ 1 1 i oVolts DIsplay untt coupler wire harness Side SYSTEM OPERATION Check auto leveling system operation Does Not Operate WIRING Disconnect right fairing 24P coupler Mea...

Page 124: ... Remove grommet from LCD 6P water proof coupler Measure voltages between W BI and G BI 1 and Wry 1 and G SI without disconnecting coupler Voltage should be above 3 V Check W SI and W Y wires between this coupler and suspension computer coupler Tt 1ere should be continuity between same colors o Volts Faulty suspension computer COMPUTER Check voltage between W SI i and GiSI wires while pushing the I...

Page 125: ...erate 24P coupler Open circuit in main Go to SYSTEM DOES NOT OPERATE page 12 4 wire harness Faul rela Pump does not operate g p Air leaking past air hose joints a HOSES Disconnect front and rear air hoses Air Flow HOSES Check air pump inlet and pump to under right fairing Check If air flows out distributor air hoses for blockage or pinching lhrough each air hose jOint by operating air pump Normal ...

Page 126: ...ks past mating surfaces of solenoid valve and Faulty solenoid valve a ring distributor No Air Leaks HOSES Check air hoses for blockage Clear DISTRIBUTOR PORT Check air distributor between air pump and air distributor port for blockage Not Blocked Blocked Check air relief valve Check for air leaks past air relief valve or pressure sensor AIR INTAKE Check air inlet hose and air Blocked element for b...

Page 127: ...g cm 28 psi has been reached Go to SYSTEM DOES NOT OPERATE page 12 4 Open CIrcuit In main or fairing sub wire harness Poor contact at right fairing 24P or switch coupler Faulty switch Faulty suspension computer E EEE or TROUBLE CODES Check LCD display Displayed Normal SWITCH Disconnect suspension computer 20P coupler Check Abnormal IncreaselDecrease switch for continuity see page 12 17 Normal SUSP...

Page 128: ...N BI FRONT or REM Br W G above 9 V Normal Click SOLENOID VALVE Check solenoid valves Not Heard for operation by applying battery voltage to solenoid valve terminals Click Heard SENSOR Check air pressure sensor see Abnormal base manual Nonnal RELIEF VALVE Check pressure relief Abnonnal valve of air distributor for blockage see page 2 201 Normal Check solenoid valve Nonnal operation see page 12 19 F...

Page 129: ... 6 kg em 9 pSI front and 5 5 kg em 78 psi rear This is normal operation TEST SUPPOr1 motorcycle on its center More Than stand Increa e rear suspension pressure 4 Seconds to 6 5 kg cm 92 psi Measure time for pressure to decrease rom 6 5 kg cm2 92 psi to 2 0 kg cm 28 psi Less Than 4 Seconds CHECK VALVE Disconnect air pump hose Air Flows that goes to air distributor at air pump Check for air flow thr...

Page 130: ...there has been excessive 011 leakage Clean the air hoses and air distributor betore inspecting the system SEPARATORS Check front fork oil Abnormal separators for damage Normal CHECK VALVES Inspect rear shock Abnormal check lIallies for damage or blockage Normal Oil LEVEL Check suspension oil level Abnormal Faulty oil separator disassemble and clean fork Incorrect check valve operation Incorrect oi...

Page 131: ...DECREASE SELECT SWITCH R SWITCH POSITION CODE Y R G y W INCREASE NEUTRAL DECREASE AUTO lEVELJPRESSURE CHECK SWITCH r _ CODE W Bu G COLOA W R G WIG I W1TCH POSITI IN 2 DE AUTO LEVEL NEUTRAL P CHECK If tests indicate no continUity check for a loose switch coupler or right fairing coupler and tor an open or short circuit in the wire harness or fairing sub harness INCREASE DECREASE SELECT SWITCH Disco...

Page 132: ...Disconnect the front and rear suspension air hoses trom the air distributor NOTE Use a wrench to keep the hose joint from turning while loosening the hose joint nut Remove hoses slowly to allow pressure to bleed from air lines Free the air rehef hose tram the wire band Lift the air distributor out of the fairing Disconnect the air drier hose NOTE The hose joint contains a steel ball spring seat an...

Page 133: ...valve s If pressure remains steady even when the solenoid valve is activated clean the air passage in the air distributor Repeat the above procedure for the rear Side applying battery voltage between the BrtY and G terminals of the valve coupler PRESSURE PUMP Apply vacuum to the air distributor relief port If vacuum does not remain steady remove the solenoid valve and replace the rubber seat at th...

Page 134: ...the rubber seat at the end of each valve rod Replace damaged or deteriorated seats Remove the pressure relief valve and air valve AIR DISTRIBUTOR RELIEF SOLENIOD VALVE __ RUBBER SEAT CONTROL NEEDLE Check the O nngs for damage or deterioration Check that the air valve moves freely Disassemble the pressure relief valve Check the O rings for damage or deterioration Check the air passages for obstruct...

Page 135: ...l a rings Make sure the rubber solenoid valve seats are in place dunng assembly Check each valve for proper seating Torque the parts as indicated t 55 m 41 ft Ib SENSOR BRACKET AIR PRESSURE SENSOR Q LLJ l t RELIEF HOSE RELIEF SOLENOID VALVE loO white mark AIR VALVE PRESSURE RELIEF VALVE BODY FRO T SUSPENSION SOLENOID VALVE r d mark cont d 12 21 ...

Page 136: ... forward fairing hole Position the hose ioints onto the fairing grommets Use a chemlcellubricant CRC 5 56 or equivalent to help posi tion the hose jOints Route the air relief hose NOTE Be careful not to pinch the air relief hose If the hose is blocked or restricted the RHC reacts as if the pressure sensor IS faulty and shuts the system down Connect the front and rear air hoses to the air distribut...

Page 137: ... Install new parts as necessary Install the relief valve components Tighten the hose fitting Torque 55 N m 41 ft lb RUBBER SEAT PISTON PISTON O RING L OSE FITTING Suspension Computer Removal Remove the top compartment and right fairing pocket Disconnect the 20P black coupler Remove the two bolts and case lid Remove the computer from the case NOTE To remove the computer case the fairing must be rem...

Page 138: ...n Reconnect lhe sensor wire to the wiring harness Measure the voltage between the Lg R l and GIS l terminals of the sensor coupler with the ignition switch ON If there is no voltage check the black 13P coupler on the rear fender for looseness If the coupler is OK check the wire harness for an open circuit With the ignition switch ON measure voltage between the sensor terminals in each of lhe three...

Page 139: ... sensor coupler Connect the sensor arm to the connecting rod Tighten the 8 mm bolt Torque 21 N m 15 t Ib Adjustment Support the motorcycle on Its center stand Loosen the adjusting rod pinch bolts Tum the adjusting rod to align the end of the sensor arm with the sensor case index mark Tighten the adjusting rod pinch bolts Torque 12 N m 9 ft Ib Install parts in the reverse order of removal SENSOR AR...

Page 140: ...ng 13 4 Cruise Valve Relay 13 13 Cruise Actuator 13 13 Vacuum Hose 13 14 One Way Valve 13 15 Cruise Control Valve 13 15 Cruise Cancel Switches 13 16 Cruise Control Switches 13 18 Junction Box 13 19 Throttle Operation 13 21 Throttle Cable Adjustment 13 22 ...

Page 141: ...t out pins Testing for continuity or measuring a voltage or resistance Make sure all related couplers or wires are connected securely Disconnecting a coupler or connector Tum the ignition switch OFF Positive and negative sides are so marked Fuses Relays lONITION REGULATOR flO A Parts Location C F I MAIN FUSEJRELAY BOX CORNERINO STOP LIOHT 10 A FRONT BRAKE CANCEL SWITCH I J J 13 2 ...

Page 142: ...1TCH r c la _ r t i _ SUlIUSES G rlll I y y a V T J R IJIV 1 IlELUG Ir t t I_IlELlY G I rf C T PI W SHJT OFF TU IWt UlHT 5DlSOIl 7 n I I I a J JTT IIIlMf a O a 1 L t F ISU II LJIl1 IIETEJl I IGliITION en C1USLI IafT l l Im lXIII STOP Il UYS II LAIEl 1 SToP JIIIP 3 CllIJ5 V CFlIWll AUTO ClilUSl SYSTB 4 W W ...

Page 143: ...indicator light Go to CRUISE INDICATOR LIGHT DOES comes on for a few seconds then goes NOT COME ON WHEN IGNITION SWITCH off IS TURNED ON troubleshooting Normal Isee page 13 9 Check cruise indicator light for function Not Lit Check auto leveling suspension display for with ignition switch ON operation Lit _t Abnormal BRAKELIGHT WIRING Is brakellght Normal Go to LCD DOES NOT DISPLAY turned ON with i...

Page 144: ...witch or open circuit in wire o Volts harness Loose or impropeny connected terminals Note ChecK that front brake and front brake cancel switches are connected properly POWER TO RELAY With Ignition switch and cruise sWitch ON check that there IS battery I oltage between Gi81 and G I terminals of ECU coupler o Volts RELAY Check Cruise Valve Relay see page 13 13 Normal Faulty relay Battery Voltage Op...

Page 145: ...ntinuity Blown lamp Open circuit in meter Open circUit of W wire in right fairing pocket No Continuity Open circuit Poorly con nected 13P white coupler of right fairing coupler Is there battery voltage between BUY and G terminals of control unit coupler with ignition and cruise control switches ON o Volts L Faulty cruise set switch Open circuit in harness or poor contact at coupler 13 6 ...

Page 146: ...dication of gear position indicator normal Normal GEARSHIFT SENSOR WIRING Disconnect cruise control unit coupler and check for continuity between R W and G J terminals There should be continuity only when the transmission IS in 4th gear Check for continuity between G O and G terminal There should be continuity only when transmission is in 00 Normal SWITCHES Check cruise and resume switches See pag...

Page 147: ...from about 9V to less than 1V alternately when front wheel IS rotated slowly Normal HOSES Check vacuum hoses for damage or clogging Normal o Volts Open Circuit In wire harness Abnormal I I t I Check speed sensor see base manual Abnormal tNormal Faulty speed Short or open cir sensor cui in wire harness Poor contact at coupler Abnormal Faulty vaquum circuit ACTUATOR Check actuator see page 13 13 Nor...

Page 148: ...tween BllBr and G terminals of the terminal of Indicator light check relay Indicator light check relay coupler coupler and battery negative terminal Battery oVolts Voltage Battery Voltage Open circuit in wire Open circuit in wire harness G wire harness BI Br wire WIRING Short wires between BulO and WIRING Short wires between BulO and G BulR and G terminals of indicator light Abnormal G Bu R and G ...

Page 149: ... and cruise switch ON and engine stop switch in RUN measure voltage between W Bu and G terminals of ECU coupler coupler connected Battery voltage should appear when resume switch is pressed Battery Voltage Abnormal o Volts I I Go to Cruise Control Does Not Function at All see page 13 4 Start engine lWon t Start Go to Fuel System Starts Indicator Does Not Light of CFI troubleshooting see page 10 7 ...

Page 150: ... Faulty actuator Abnormal I Faulty cruise control valve unit Abnormal 1 Faulty one way valve l Try with a known good ECU Cruise Control Is Cancelled Accidently SENSOR SIGNAL With ignition switch ON measure voltage between BIIY and G terminals to ECU coupler Voltage should change tram about 9V to less than 1V alternately when rotating front wheel slowly BI Y 1 Abnormal Abnormal Faulty speed sensor ...

Page 151: ...m hoses for Abnormal clogging or damage Normal CABLES Check throttle cables and Abnormal junction box for smooth movement by turning throttle gnp Normal ACTUATOR Check actuator operation Abnormal see page 13 13 Normal CONTROL VALVE Check cruise Abnormal control valve unit see page 13 15 Normal RElA Y Check cruise valve relay Abnormal see page 13 13 Normal Faulty vacuum circuit Stiff throttle cable...

Page 152: ...inuity between terminals 1 and 2 If there is no continUity Install a new relay Cruise Actuator Inspection Remove the top compartment Disconnect the vacuum hose from the actuatorI and con nect a vacuum pump to the actuator Apply vacuum If vacuum does not remain steady install a new actuator If the throttle gnp does not rotate with vacuum applied check the following Throttle Operation Junction box o...

Page 153: ...racket Loosen the cable joint nut and disconnect the cable from the junction box Pull the vacuum hose oH the actuator Be careful not to puncture the hose Vacuum Hose Inspection Disconnect the vacuum hose from the intake pipe of the No 4 cylinder Connect a vacuum pump to the hose and apply vacuum If vacuum does not remain steady check the vacuum hose for damage deterioration or loose connection 13 ...

Page 154: ...ross the coupler terminals shown in the table on the right Test each pair of terminals wires with the actuator hose port open and then blocked with a plugged hose CAUTION Avoid touching the positive battery test wire to the negative test wire If a test involves two or more negative wires first connect all negative wires to the negative battery wire then connect the positive wire to the positive ba...

Page 155: ...CHANGE Disconnect the black 4P coupler behind the nght handlebar Check for continuity between the BllBu and G W wire terminals Brake lever released Continuity Brake lever pulled in No continUIty If unable to obtain the above results check for continuity at the switch terminal If switch continuity is normal check the sub harness tor continuity If continuity IS abo normal install a new sWitch Remove...

Page 156: ...ft of the crUIse control unit Throttle closed Continuity Further return No continuity To adjust remove the fuel strainer from the left engine mount bracket Disconnect the left throttle link arm from the throttle arm Loosen the adjusting bolt lock nut Connect an ohmmeter to the switch wires and turn the adjusting bolt until continuity shifts to no continuity Back off the adjusting bolt 2 1 3 rotati...

Page 157: ...nUity Back the adjusting nut oH 1 2 turn toward the brake pedal and tighten the lock nut NOTE Replace the switch if continuity or no continuity falls to shift Cruise Control Switches Cruise Switch Remove the cruise control unit dust cover Measure voltage between the BliY and G terminals of the coupler NOTE Do not confuse this wire with the BI Y speed sen sor wire The switch is normal if battery vo...

Page 158: ...d discon nect the brown 6P right handlebar switch coupler Check for continuity between the terminals UPPER CABLE LOWER CABLE o J C i Ll t6 CABLE DRUM WASHER Remove the cable drum from the cable ends Remove the circlip and washer Remove the mount bolts and junction box from its bracket Remove the cover from the junction box Remove the actuator cable and loosen the throttle cable lock nuts Junction ...

Page 159: ...he cable drum and drum shaft with grease Insert the ends of the throttle cables into the slots in the cable drum Install the cable drum In the case NOTE Install the cable drum wIth the stopper facing the inside Connect the cables to the cable drum with the stopper contacting the control arm Install the washer and a new circlip on the drum shaft In stall the circlip with the sharp edge facing out B...

Page 160: ...e inner cable condition Replace them if they are frayed or kinked Make sure throttle gnp free play IS 2 6 mm 1 8 1 4 In at the throttle grip flange Make minor adjustments with the throttle grip adjuster Make major throttle grip free play adjustments with the middle cable adjuster after removing the top compart ment To adJust loosen the lock nut tum the adjuster as re quired and tighten the lock nu...

Page 161: ...the actuator mount nuts Loosen the upper throttle cable adjusters to allow play In the upper throttle cable Tum the lower throttle cable adjuster to align the index mark on the cable drum with the arrow mark on the case Tighten the throttle cable adjuster lock nut Tighten the upper cable lock nut NOTE Adjust throttle grip free play and check operation of the throttle grip and cancel switch Recheck...

Page 162: ...AZZARD SWI TCH TLl E w 0 It OF t g g i I i G 1 P I X 0 B _ I r 0 0 f I t 5rARTI G MOTOO _ I TLI I ACC ll BI 1 0 9_ o I B lb IG B BlAe B BROWN f YELl 0 ORANGE B BLUE Lo LIGHT BLUE G G E 1 i Lg lIGJ lT GREE R R e P PIN W WI TE G GRAY 811 IGNITION S NI ret lOCI M lP Wj BRA E LIGHT RELAv rupfol SIGNAL SWITe ACe _5e L Pus COLOR G lo 1 COLOR 0 BI SilI l Tel CONTINUITY AL f PNATOR IG 1 rIO COli S II FUSE...

Page 163: ...Index Index 14 2 ...

Page 164: ... Fuel Pump GR GL Sensor Handlebar Replacement Handlebar Switches Height Sensor Ignition Coil Ignition System Ignltiol Timing Ignition Troubleshooting LightS SwitcheS Instruments Maintenance Schedule Metric Conversions 14 2 12 4 10 34 3 4 12 18 12 17 10 29 0 34 2 10 1 10 33 10 5 10 6 0 7 10 28 10 30 8 11 10 27 13 13 13 16 13 1 13 4 13 15 13 19 13 18 3 14 3 6 13 13 11 14 11 2 11 12 11 4 10 33 1 1 4 ...