ST1100_Manual.pdf

SymbolsThe symbols used throughout this manual show specific service procedures. If supplementary information is required pertain-ing to these symbols, it would be explained specifically in the text without the use of the symbols.... Replace the partts] with new onets) before assembly.

Is :;O=ooLI Use special tool

Use optional tool. Use the same procedure you use to order parts.

C Torque specification. 10 Nm (1.0 kg-m, 7.2 ft-lb)10 (1.0, 7.2)

-:71 Use recommended engine oil, unless otherwise specified.-, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 1) .

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)..Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 orequivalent)Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.

Multi-purpose M-2 manufactured by Mitsubishi Oil Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 orequivalent)Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.

Honda Moly 60 (U.S.A. only)Rocol ASP manufactured by Rocol Limited. U.K.Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease

Om Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

Apply sealant

I Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.- Use Fork or Suspension Fluid.

16-B. ABS (After '95)Service Information

System Location

System Wiring Connections/Locations

Circuit Diagram

Service Information

CAUTION

168-1

16-6-2

16-6-3

16-6-4

Troubleshooting

Wheel Speed Sensor Air Gap Inspection

Front Modulator Removal/Installation

Rear Modulator Removal/Installation

16-8-5

16-B-34

16-B-36

16-B-38

Use a fully charged battery for troubleshooting. Do not diagnose the ABS with a charger connected to the battery.On removal and installation of the wheels and wheel speed sensors, be careful not to damage the wheel speed sensorsand pulser rings.

NOTE

Check the following before performing any ASS troubleshooting.- Pre-start self-diagnosis of ASS- ASS indicator lightIf an abnormality is found during the above checks, perform the ASS troubleshooting following the Symptom-to-System Chart (page 16-B-8). The ASS is normal if no trouble is found. Go to the checks on the other systems {e.g., LBSor basic brake system}.Troubles not resulting from a faulty ASS, l.e. brake disc squeak, unevenly worn brake pad, etc., cannot be recognized bythe ABS diagnosis system. (See the Common Service Manual.)Record the symptom of the problem and the problem code in MEMO before troubleshooting.When the ASS is faulty, the ABS indicator light blinks or it comes on. The ASS does not function at this time; take careduring the test ride.Do not disassembly the modulator assembly. If 'It is faulty, replace it an assembly.Refer to page 15-2 for brake fluid filling and bleeding. Note that there is no brake fluid in the modulator (except in themodulator head), because the modulator is the motor-driven hydraulic pressure type. Therefore, brake fluidreplacement and bleeding air from the modulator body is not necessary.When the wheel is removed, perform the air gap inspection (page 16-B-51).The ASS indicator light might blink in the following cases. If the indicator light blinks, clear the problem code andperform the pre-start self-diagnosis ofthe ABS (page 16-5). The ABS is normal if the ABS indicator light goes off.- The motorcycle has continuously run on the bumpy road.- The ABS control unit (ECU) was disrupted by extremely powerful radio were (Electromagnetic Interference).- After riding Ii.e. after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for more

than 30 seconds} with the motorcycle on the center stand.The ASS indicator light might blink in the following cases. If the indicator light blinks, service the faulty parts, clear theproblem code, and perform the pre-start self-diagnosis of the ABS (page 16-S-5}. The ASS is normal if the ABS indicatorlight goes off.- Incorrect tire pressure- Tires not recommended for the motorcycle were instailed.- Deformation ofthe wheelAfter troubleshooting, clear the problem code and perform the pre-start self-diagnosis again to be sure that the ASSindicator light is operating normally.

16-8-1

ABS (After '95)

System Location

(7) ASS INDICATOR LIGHT 2

(5) INDICATOR CONTROL UNIT

(8) ASS INDICATOR LIGHT 1(5) IGNITION SWITCH

(4) ABS,TCS INDICATOR LIGHT SWITCH

(3) BATIERY

(2) ASS FUSE CASE

(1) REAR WHEELSENSOR

(19) REAR PULSER RING

(18) REAR MODULATOR

(17) MOTOR DRIVER

(16) FRONT MODULATOR

(12) MODULATOR CONTROLMOTOR

(9) ASS CONTROL UNIT(ECU)

(13) CRANK ANGLE SENSOR

(10) FRONT MODULATOR CONTROLMOTOR RELAY

(11) REAR MODULATOR CONTROLMOTOR RELAY

(14) FRONT PULSER RING

(15) FRONT WHEEL SPEED SENSOR

16-B-2

System Wiring Connections/LocationsRefer to section 2, for the parts that must be removed for service.For example: ::1) CRANK ANGLE SENSOR -e-Maintenance part

-R. side cover (page 2-2)

ABS IAfter '95)

@INDICATOR (Black)

-Inner screen(page 2-7)

~

W.ID GiO

RiO Gr:'Bu

=

J) INDICATOR (White)-Inner screen (page 2-7)

G'iSe fl.: 0

(;..0 WiOLgiBI

v:(;, GI81G/81 ViG,

Lg..'B1rx

ASS INDICATORLIGHT 2-tnner screen

(page 2-7)

~'ASS INDICATORLIGHT 1-Inner screen(page 2-7)

Y.'O RiG

RiBr Br'Y

RiB, V..W

(fj) FRONT WHEEL SPEED SENSOR-Upper fairing (page 2-9}

ViO W:'Bu

(LZ' ECU (Black)-Upper fairing (page 2-9)

(]~, FRONT MODULATOR CONTROLMOTOR RELAY -Upper fairing

(page 2-9)

{,1' ECU (White)-Upper fairing (page 2-9)

::E' REAR MODULATOR CONTROLMOTOR RELAY -Upper fairing

(page 2-9)

,:[~~ FRONT MODULATOR CRANK ANGLESENSOR -Upper fairing (page 2-9)

~.>

~f- I~2!

R ,j', MOTOR DRIVER (12P)-Upper fairing(page 2-9)

= =c 'W

BIlG BliR

@, MOTOR DRIVER(4P Black)-Upper fairing

(page 2-9)

H' FRONT MODULATOR CONTROL MOTOR-Upper fairing (page 2-9)

16-B-3

ABS IAfter '95)

Circuit DiagramMODULATORCONTROL MOTOR RHAY

(FRONT) (REAR)

~~~~~~~ ~~~~

ASSFUSE,OX3 ,

1 lOA ASS MAIN2 30A FRONT MODULATOR CONTROL3 30A REAR MODULATOR CONTROL r

~RiBr

~RJBr

I-R/Br-

,--~--""---------,12P-BI

MOTOR DRIVER

f--Grlal---+\I---O/G--"r1--- Lg/O--"1----G'/'I--1---R/'I'----;f-- BuIGr---+f--BuIG--"1--- Bu/Lg,--"1--- '"/p---I---R/'"'---+

I

...L

CONNECTOR: 4P BI0- Bu

ABSCONT

2P-BI r- 2P-BI~

CONTROLMOTOR

CONNECTOR BIO-W

FRONT MODULATOR REAR MODULATOR

CRANK ANGLESENSOR

16-B-4

MAIN FUSE 30A

~/ 0:

Ell e );Ie 0L BATIERY4'

I II

"

$3PW'I

BLACK Be . BROWNYELLOW 0 ORANGEBLUE Lb LIGHT BLUEGREEN L9 . LIGHT GREENRED P PINKWHITE Ge GRAY

STARTER {f --G/BI----+---G!B'--/-~,,VABSfTCS INDICATOR LIGHTSWITCH

ABS (After '95)

TroubleshootingBefore Beginning Troubleshooting

Summary of ABS pre-start self-diagnosis systemThe ASS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator.When there is any abnormality, the problem and the problem part can be detected by outputting the problem code.

When the vehiclespeed is approximately 10 km/h (6 mile/h) or more, thewheel speed sensor signal is inputto the ASS controlunit (ECU), then the ASS pre-start self-diagnosis system operates the control motor inside the modulator, checks the crankangle condition with ASS control unit (ECU) and thereby it detects whether the modulator operation is normal, and itcompletes the pre-start self-diagnosis.

When the ASS is normal, the ASS indicator light goes off just after starting up indicating that the diagnosis is completed.If a problem is detected, the ASS indicator light blinks or comes on and stays on to notify the rider of the problem. The self-diagnosis is also made while the motorcycle is running, and the indicator light blinks when a problem is detected.When the indicator light blinks, the cause of the problem can be identified by retrieving the problem code following thespecified retrieval procedure. {page 16-S-6}

PRE-START SELF-DIAGNOSIS WHEN NORMAL

IGNITION SWITCH O~~ =.JCONTROL MOTOR RELAY O~~ =:J

ENGINE RUNNING -------------------r= STARTSTOP

__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~10 km h (6 mile/h) or aboveVEHICLE SPEED 0

CONTROL MOTORON nn__m__mmm n nnmm_m_11-

OFF

ASS INDICATOR

LIGHT 1 and 2ON::J

OFF LPre-start self-diagnosis completes

Pre-start self-diagnosis procedure (Everyday check-up)1. Turn the ignition switch ON.2. Be sure that the ABS indicator lights 1 and 2 come ON.3. Start the engine.4. Ride the motorcycle and raise the vehicle speed to approximately 10 km/h (pre-start self-diagsosis completes).5. The ABS is normal if both the ASS indicator light 1 and 2 go OFF.

~[ ASS I~

7 -"----~ASS INDICATOR LIGHT 1 ABS INDICATOR LIGHT 2

16-8-5

ABS IAfter '95)

Retrieval of/Clearing Problem Code ASS/Tes INDICATOR LIGHT SWITCH

NOTE

The ASS indicator light indicates the problem codeby its number of blinks (see the next page).The problem code is not cleared when the ignitionswitch is turned OFF during output of the problemcode. However, output cannot be restarted byturning the ignition switch ON. Restart the outputfollowing the problem code retrieval procedure.After retrieving the problem code, be sure to record itin MEMO, etc. Clear the problem code aftertroubleshoot! ng.

,\

Retrieval:1. Turn the ignition switch OFF.2. Turn the ignition switch ON while pressing the ASS/

TCS indicator light switch. The ASS indicator light 1and 2 should come ON. (The ASS indicator light 2 isOFF this ttrne.)

3. Hold the ASS/TCS indicator light switch pressed (forapproximately 5 seconds). The ASS indicator light 1should go OFF.

4. Release the ASS/TCS indicator light switchimmediately (within 1 second) after the ASS indicatorlight go OFF.

~. Output of the problem code starts and the ASSindicator light 1 blinks.

TCS ON/OFF SWITCH

Clearing:5. Press the ABS/TCS indicator light switch during output

of the problem code (while the ASS indicator light isblinking).

ABS (Afte' '951

Problem code indication pattern

Example: When the problem code is stored;

Latest problem code

tProblem code:

2

Previous timeproblem code

Problem code:6

Latest problem

Problem code start signal code t'" ProbleZm code:

ABS indicator light 1 ON, __ nm __ n __mm~~r----'~-~~-~'-~-

(> Pattern repeatedABS indicator light 1 OFF -----.,1/1---1*-- 3 sec.Release ABSjTCS indicator light switch. -'*--0.3 sec

-1-1---0.2 sec.

When the problem code not stored;

attern repeated

No output of code

--- ---- ----------- c'-

(> p

/' I--- 3 sec.

Problem code start signal

\ABS indicator light 1 ON_

ASS indicator light 1 OFF

Release ABSjTCS indicator light switch.

NOTE

The ECU can store up to two problem codes. The latest problem code is output first, then the previous one is output.When the two problem codes are output, diagnose on the latest problem code (i.e. code output first).After troubleshooting, perform the pre-start self-diagnosis again to be sure that there is no problem in the ABS indicatorlights and the problem code is cleared.See page 16-B-33 for the problems that are not represented with the problem codes.Check the following before performing ABS troubleshooting:- Pre-start self-diagnosis of ABS- ASS indicator lightIf an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-to-System Chart (see the following paqe). The ABS is normal if no trouble is found. Go on to the check the other basicsystems (e.g., LBS or basic brake system).

16-B-7

ABS (After '95)

Symptom-to System Chart

Problem Affected

Fuse Modulator

16-8-23

16-B-26

16-8-15

16-8-19

16-8-12

16-8-9

co~.

m cOn "c

00

00

00

00

00

00

oo

oo

o~cQ.o

!-:;;--=+=cr::1 ~

oo

ooo 0

oo

o

3as"

o

"CD

ABS IAfter '95)

Flowcharts

CAUTION

Use a fully charged battery. Do not diagnose with a charger connected to the battery.

NOTE

Turn the ignition switch OFF unless otherwise specified.When the ASS control unit (ECUl. motor driver or modulator is detected to be faulty, recheck the wire harnesses andconnectors connections closely before replacing the control unit, motor driver or modulator.After troubleshooting, perform the pre-start self-diagnosis again and be sure that the ASS indicator light is normal.The encircled numbers in the texts and connector diagrams indicate the connectors (see page 16-8-3). All connectorsdiagrams in the text are view from the terminal side.

Problem code 1: Faulty front modulator crank angle sensor system

Turn the ignition switch ON (but do not start theengine) and check the ABS indicator light.

1. Retrieve the problem code and record it. Clear theproblem code.

2. Perform the pre-start self-diagnosis (including rid-ing motorcycle I and check the ASS indicator light.

Light stays on( Does the ABS indicator light blink or come on ")__-"__'--__..'\ and stay on? /

I Light blinks,Turn the ignition switch OFF.

'------I Light goes

, --"O"-FF

Does the ASS indicator light blink or go off?

fight blinks

(Continue to the following page)

,,NormallTemporary problem)- Fine foreign matter in the modulator or the ECU

has been disrupted by an extremely powerful radiowave.

- Check the harness and connector for secure con-nection (page 15-B-3)

(

(Go to page 16-B-11)

Click\ sound/1Is there a sound in the front modulator?

Turn the ignition switch ON and check for the pre-start self-diagnosis sound (Le. click sound) from thefront modulator.

---,------

1. Disconnect the front modulator crank angle sensorconnector:@ with the ignition switch OFF.

2. Measure the output voltage between the mainwire harness side terminals of the sensor connec-tor)]' with the ignition switch ON.Standard: 4.5-5.5 V

~---~--

,View from terminal side

(Continue to the following page)j~

Green. Brown Black

'------@-JBlue

16-8-9

ABS (After '95)

(From the previous page: Measure theoutput voltage at the ':lit connector)

~'"0W_ Liqht Green

Repair open in the Black/Blue or Green/Brownharness between the modulator (angle sensorconnector) and ABS control unit (ECUjFaulty ASS control unit (ECU)

f~;

~CmJve;w;ught Green Yellow Light Green

~

Continuity

No continuity"/>_:C:C'::::,"::,"='-_.~~ . Repair open in the Yellow/Light Green harnessbetween the modulator tanq!e sensor connector)and ASS control unit (ECU)

--'--'--'--'----.~~ .Repair short in the Yellow/Light Green harness-------' between the modulator langle sensor connector)

and ABS control unit (ECUl

Normal

) Out of specification ~

-----

Is the voltage normal?

Is there continuity?

~""ity

Faulty front modulator

__LI

___L1. Disconnect the White connectnrqf of the ECU

with the ignition switch OFF.2. Check for continuity between the ECU connector

JJ' terminal and the main harness side terminal ofthe crank angle sensor connectorqe.

----

(, 15 there continuity?

l Continuity,I Check for continuity between the ECU connector

:t~ terminal and body ground.

r

(

(From the previous page: Light blinks]

I

1. Retrieve the problem code and record it.Clear the problem code.

2. Interchange the front and rear modulator with eachother (page 16-B-36 and 16-B-38).

3. Perform the pre-start self-diagnosis (including rid-ing motorcycle) and retrieve the problem code.

Is the problem code "2" )Problem code "2"

.. Faulty front modulator assembly

Problem code "1",Faulty ABS control unit (ECUI

16-B-10

(From page 16-6-9: Click sound)

1. Disconnect the front modulator control motorrelay connector 10 and connect the headlight relay

I

instead with the ignition switch OFF.2. Turn the ignition switch ON and check the ABS

L indicator light. -'

--,Does the ABS indicator light blink or come onand stay on?

Light stays on

ABS (After '951

HEADLIGHT RELAY

Faulty front modulator control motor relay

Light blinks

1. Disconnect the front and rear modulator controlmotor relay connector C!t/;ID and EeU Whiteconnector ,jJI with the ignition switch OFF.

2. Check for continuity between the connector :$)terminal and body ground.

c Is there continuity? ContinuityYellow

,, No continuity Faulty ABS control unit (ECUl

16-8-11

ABS (After '95)

Problem code 2: Faulty rear modulator crank angle sensor system

Turn the ignition switch ON (but do not start the lengine) and check the ABS indic8ctoc'cclig""htC. _

Does the ASS indicator light blink or come onand slay on?

Light blinks

Turn the ignition switch OFF.

,~

. Turn the engine stop switch OFF to deaden a fuelpump sound.

2. Turn the ignition switch ON and check for thepre-start self-diagnosis sound (i.e. click sound)from the modulator.

,Is there a sound in the rear modulator?

No sound

1. Disconnect the front modulator crank angle sensor Iconnector j) with the ignition switch OFF.

2. Measure the output voltage between the mainwire harness side terminals of the sensor connec-tor :l' with the ignition switch ON.Standard: 4.5-S.SV

Is the voltage normal?

Normal,(Continue to the following page)

16-8-12

Light stays on

Clicksound

(Go to page 16-8-14)

Out of specification

Light goes, OFF

ABS (After '95)

(From the previous page: Normal)

t1. Disconnect the White connector 'U' of the ECU


:jJ:terminal and the main harness side terminal ofthe crank angle sensor connector CD.

~~Blue Brown Blue Brown

~-~No continuity

Is there continuity? _/

Continuity

... Repair open in the Blue/Brown harnessbetween the modulator (connector anglesensor) and ASS control unit (ECUl,

Continuity>--------.~ .Repair short in the Blue/Brown harnessbetween the modulator (angle sensor----- connecter} and ASS control unit (ECUlNo continuity


,Faulty rear modulator

(From the previous page: Light blinks)

..1. Retrieve the problem code and record it.

Clear the problem code.2. Interchange the front and rear modulator with each

other (page 16-B-36and 16-B-38).3. Perform the pre-start self-diagnosis (including rid

ing motorcycle) and retrieve the problem code.

Is the problem code "1" ?

,Problem code "2"

" Problem code "1"

/ Faulty rear modulator assembly

,Faulty ASS control unit (ECU)

16-8-13

ABS (After '95)

(From page 16-8-12: Click sound)

rF.01;...-~-HEADLIGHTRELAY

.-===.-c-'C'--_ Faulty rear modulator control motor relay

I.r.,

r ig ht stays onDoes the ASS indicator light blink or comeon and stay on?

1

_ , . Disconnect the rear modulator control motor relayconnector i~) and connect the headlight relay in-stead with the ignition switch OFF.

2. Turn the ignition switch ON and check the ASS in-dicator light.

"-----~

~ Ugh< blinks _11~co nnect -'h-e--:fc-o-O-,-,-o-d~ce-,-r mod ulator control

motor relay connector @i:~) and ECU White conne-ctor ,n, with the ignition switch OFF.

2. Check for continuity between the connector C!ijterminal and body ground.

Yellow

Repair short in the Yellow/Orange harnessbetween the front/rear modulator controlmotor relay and ASS control unit (ECU).

ContinuityNo continuity

-'--------Is there continuity?c

, Faulty ASS control unit (ECU)

16-8-14

ABS (After '95)

Problem code 3: Faulty front modulator control motor system

Turn the ignition switch ON (but do not start theengine) and check the ASS indicator light.

IDoes the ASS indicator light blink or come onand stay on?

Light blinks Retrieve the latest problem code and record it.Clear the problem code.

Light stays on

Other___--' ,code

ASS FUSE CASE

l~: :~ Front modulator control motor fuseI.:~

1. Retrieve the problem code and record it.Clear the problem code.

2. Peform the pre-start self-diagnosis (includingriding motorcycle} and check the ASS indicatorlight.

__iGs the ASS Indicator light blink or go off?~

[ L,g" bliok,

--C-h-'-'-k-'-h,-',-o-o-'-m-O-d-,-',-'-or control motor fuse In the IASS tue case with the ignition switch OFF.

JProblem code "3"

Is the problem code "3"?

Faulty ASS control unit (ECU)

,Diagnose on the latest problem code

Replace the fuse and recheck.

Normal (Temporary problem}- Fine foreign matter in the modulator or the

ECU has been disrupted by an extremely power-ful radio wave.

- Check the harness and connector for secureconnection (page 16-8-3)

Burned out

Light goes off

-)>--=--,

Is the fuse normal?c _Normal,

1. Install the fuse in the fuse case.2. Disconnect the front modulator control motor relay

connector CID and connect the headlight relayinstead.

3. Perform the pre-start self-diagnosis (includingriding motorcycle) and check the ASS indicatorlight.

ABS IAfter '951

(From the previous page: Light blinks)

..1. Disconnect the front modulator control motor relay

connector (8) with the ignition switch OFF.2. Check for voltage between the relay connector (~)

terminal and body ground.

Does battery voltage register?

~ Vo"ogo

1.-DC,~-o-O-O-ed-C,"Co-m-o-,-o-'-dnver Blue connecto~2 Check for continuity between the relay con~~~tor I

(It and motor driver connector 'JV terminals. ~

No voltageRepair open in the Red or Red/Green harnessbetween the front modulator control motor relayand battery.

No continuity

Repair open in the Red/Brown harnessbetween the fuse case and front modulatorcontrol motor relay.

Rod

Repair open in the Yellow/Orange harnessbetween the ABS control unit (ECU) and frontmodulator control motor relay.

Repair open in the Brown/yellow harnessbetween the front modulator control motor relayand motor driver.

~ c~Yellow Orange Yellow/Oranqe

4:----J

---

,Is there continuity? )-

-~

Continuity

...No continuity


Continuity

--

Check for voltage between the relay connector@terminal and body ground with the ignitionswitch ON.

) No voltageDoes battery voltage register?Voltage

1. Disconnect the White connector ,11, of the ECU,


,n and relay connector (8) terminals.L -

(Continue to the following pagel

16-B-16

ASS (After '95)

(From the previous page: Continuity)

t1. Disconnect the front modulator control motor

[email protected]. Check for continuity between the motor connector

@and motor driver connector C]. terminals.

Repair open in the Black/Red or Black/Greenharness between the front modulator(control motor) and motor driver.

No continuity

Continuity


~ - ----'------'--------~----).-----==~

n~:,

GJG,eec~

Repair short in the Black/Green harnessbetween the front modulator (control motor)and motor driver.

Continuity

Check for continuity between the control motorconnector ,j5and body ground.

,

, ~--C ISthe~e continui~ ~r-"""""~'"'---"No continuity

~eGravvellcw GraYi'(ellow

ngeOrange. Green

Light GreenOrange

Orange iRed i

Gray.'

Orange

Repair open in the harness between theASS control unit (ECUj and motor driver.

,~,ow

'~,' ?reen Yell\w /Gray,pra1.2:: :J[

I I,

~

/ =- I">P

No continuityIs there continuity?

,

1. Disconnect the Black connector .:)} of the ECUand motor driver 12P connector '.

2. Check for continuity between the ECU connectors@/@'and connector@terminalsinthesameharness colors.

-- --------"

RedY II

Light GreenOrange

,~ ,

~ ~ j ,

~(4) PULSER RING

Adjust by following procedure:Turn the front wheel so one of the poles of the pulser ringand sensor face each other.Insert a feeler gauge 0.5 mm between the sensor andpole, then hold the sensor lightly against the pole.Tighten the sensor bracket bolt.

Torque: 12 Nm(1.2 kg-m. 9 ft-Ib)

Take off feeler gauge from the gap.Rotate the front wheel one full turn to make sure that thepulser ring does not interfere with the sensor.

If not still within specification, remove the sensormounting bolts and perform the shim adjustment.Adjust the air gap again.

(2) PULSER RING

(1) FEELERGAUGEO.5mm

\

(2) SENSOR

/

Rear

Place the motorcycle on its center stand.Measure the air gap between the wheel speed sensorand pulser ring all the way around while rotating the rearwheel by hand. It must be within the specification.

Standard: 0.8 ~:t mm (0.031 K~l,:inl

If not within specification, remove the sensor mountingbolts and perform the shim adjustment.Rotate the rear wheel one full turn to make sure that thepulser ring does not interfere with the sensor.

16-B-34

(1) REAR WHEEL SPEED SENSOR

(2) f1ULSER RING

(3) SHIM

MEMO

ABS (After '95)

16-B-35

AB5 (After '95)

Front Modulator Removal/Installation

if) 35 (3.5, 25)(61

(81

(4) 3P Blue

(5) 2P Black

(10)

(31

(2(

(1)

16-B-36

ABS (Afte, '95)

Check the brake system applying the lever and pedal brake after the air bleeding (page 3-13).

CAUTION

Avoid spilling fluid on a painted, plastic. or rubber parts. Place a rag over these parts whenever system is serviced.When removing the oil bolts, cover the end of the brake hose to prevent contamination. Do not allow foreign materialto enter the system.When removing and installing the modulator and motor driver, take care not to drop or strike the modulator.

NOTE

Note that there is no brake fluid in the modulator (except in the modulator head}, because the modulator is the motor-driven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body is notnecessary.Use only DOT 4 brake fluid from a sealed container.

Requisite Service

Lever and pedal brake line fluid draining/air bleeding (page 15-2)Upper fairing removal/installation (page 2-9)

Procedure O'tv Remarks

Removal Order Installation is in the reverse order of removal.(1) Motor driver connector 3{21 Motor driver mounting bolt 2(31 Motor driver 2(') Modulator crank angle sensor connector 1(5) Modulator control motor connector 1(6) Oil bolt ,{71 Sealing washer 8{81 Brake hose , NOTE. The reference nu-mbers are stamped on each brake hose

end and the modulator head. When installing, align eachnumbers (page 1-37)

(9) Modulator mounting bolt 3(10) Front modulator 1 CAUTION. Do not disassemble the modulator.

16-B-37

(After '95 J

ABS 1/lnstaliatlOnRear Modulator Remova

~ 35 (3.5, 25)(3)~

15)

17)

(1) 3P White

(2) 2P Black

16)

16-B-38

ABS (After '951

Check the brake system by applying the pedal brake after the air bleeding (page 3-13).

CAUTION

Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever system is serviced.When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material toenter the system.When removing and installing the modulator, take care not to drop or strike the modulator.

NOTE

Note that there is no brake fluid in the modulator (except in the modulator head), because the modulator is the motor-driven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body is notnecessary.Use only DOT 4 brake fluid from a sealed container.

Requisite Service

Pedal brake line fluid draining/air bleeding (page 15-2)Right side cover removal/installation (page 2-2)

Procedure Q'ty Remarks

Removal Order Installation is in the reverse order of removal.(1) Modulator crank angle sensor connector 1 Remove the sensor wire from the clamp and clip.(2) Modulator control motor connector 1(3) Oil bolt 4(4) Sealing washer 8(5) Brake hose 4 NOTE. The reference numbers are stamped on each brake hose

end and the modulator head. When installing, align eachnumbers (page 1-41),

(6) Modulator mounting bolt 3(7) Rear modulator 1 CAUTION. Do not disassemble the modulator.

16-8-39

SymbolsThe symbols used throughout this manual show specific service procedures. If supplementary information is required pertain-ing to these symbols, it would be explained specifically in the text without the use of the symbols.... Replace the partts] with new onets) before assembly.~


IOP~OOLI Use optional tool. Use the same procedure you use to order parts.


-:71 Use recommended engine oil, unless otherwise specified.-, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 1) .~ Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)..

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or

~equivalent)Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.


Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 orequivalent)

~ Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.Honda Moly 60 (U.S.A. only)Rocol ASP manufactured by Rocol Limited. U.K.Rocol Paste manufactured by Sumico Lubricant, Japan

~ Use silicone grease


"I~ Apply sealant


17. Charging System/AlternatorService Information 17-1

System Location 17-2

Troubleshooting 17-4

Charging System Inspection ('91-'95) 17-6(After-'951 17-9

Regulator/Rectifier ('91'95) 17-7

Alternator Inspection ('91-'95) 17-8(After '95) 17-10

Service Information

Battery Removal/Installation 17-12Stator Coil Removal/Installation

('91-'95) 17-13Alternator Removal/Installation

(After '95) 17-14Alternator Disassembly/Assembly

(After '95) 17-16Alternator Shaft Removal/Installation 17-18Alternator Shaft Disassembly/Assembly 17-20

The battery gives off explosive gases; keep sparks. flames, and cigarettes away_ Provide adequate ventilationwhen charging or using the battery in an enclosed space.

The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wearprotective clothing and a face shield.- If electrolyte gets on your skin. flush with water.- If electrolyte gets in your eyes. flush with water for at least 15 minutes and call a physician immediately.Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magne-sia or vegetable oil and call a physician.KEEP OUT OF REACH OF CHILDREN.

-------

Always turn off the ignition switch before disconnecting any electrical component.

CAUTIONI. So~e electrical components may be damaged if terminals or connectors are connected or disconnected whilethe ignition switch is ON and current is present.

For extended storage, remove the battery. give it a full charge. and store it in a cool, dry place. For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.

NOTE

The maintenance free battery must be replaced when it reaches the end of its service life.~~~~------

CAUTION

The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage thebattery.

Battery can be damaged if overcharged or undercharged, or if left to discharge for long periods.These same conditionscontribute to shortening the "lite span" of the battery. Even under normal use, the performance of a battery deterioratesafter 2-3 years.Battery voltage may recover after battery charging, but under heavy load. battery voltage will drop quickly andeventually die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge oftenresults from problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells isshorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Underthese conditions, the electrolyte level goes down quickly.Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the batteryis frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding themotorcycle.

The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeksto prevent sulfation from forming.

Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,always charge the battery. Also, the battery life is lengthened when it is initial-charged.

When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-4). For battery testing/charging, refer to section 22 of the Common Service Manual. For charging system location. see page 17-2.

17-1

Charging System/Alternator

System Location'91-'95

Standard model shown:

(1) IGNITIONSWITCH

(2) REGULATORRECTIFIER

(5) ALTERNATOR

(4) MAIN FUSE30A

(3) BATIERY

----- --

{1} IGNITION(6) FUSE lOA SWITCH

BI~R/BI~, W R (4) MAIN FUSE

30A

8(3) BATTERY

lZV lZA

(Z) REGULATORRECTIFIER

(5) ALTERNATOR

17-2

G

1


After '95

LBS-ABS/TCS model shown:

(5) MAIN FUSE 30A

(1) IGNITION SWITCH

(6) ALTERNATOR

--~l

/tarjl ,

(2) BATTERY

(4) ALTERNATOR FUSE 55A

,/,,--0:.=:J(1) IGNITION

SWITCH

(2) BATTERY

R--- --Red

BI Black

,

,(5)

MAINFUSE30A

~-,--.----~

"

"-m- (3) FUSE lOA---W-BI~RlBI

(4)ALTERNATORFUSE 55A(6) ALTERNATOR

~,

~

~ '0"-.i00-

-'nmc

~c

" ~ j .Q:f-SY ~ "0"L-

_ ri) RECTIFIER

17-3


Troubleshooting'91-'95

Battery Overcharging Faulty regulator/rectifier

Battery Undercharging

NOTE

In order to obtain accurate test readings when checking the charging system, the battery must be fully charged andin good condition. See Common Service Manual section 22 for checking the battery condition.

Measure the battery current leakage(Leak test) (page 17-6)

Incorrect

Check the regulator/rectifier unit inspection(page 17-7, 17-8)

Correct

Incorrect

L:Correct

IShorted wire harnessFaulty ignition switch

Faulty regulator/rectifier

Inspect the regulated voltage (page 17-6)Correct

AbnormalCheck the voltages of the regulator/rectifier battery, __:="""':-:c__charging line and ground line (page 17-6) r Open circuit in wire harness

I Poorly connected connectorsNormal

Not Charging

~-----:--L

Check the alternator (charging and field coils)resistance at the regulator/rectifier connector(page 17-7}

Abnormal Check the charging and field coils at alternator(page 17-7)

1-Normal

1__Abnormal

Abnormal Normal

IPoorly connected alternatorconnector

,--~.-. Faulty alternator


17-4


After '95

Inspect the following before diagnosis the system.- discharged battery- loose or corroded terminals of the connectors

NOTE

In order to obtain accurate test readings when charging system, the battery must be fully charged and in good condition.See Common Service Manual section 22 for checking the battery condition.

ICorrect

I


,Shorted wire harnessFaulty ignition switch

Faulty rotor coilFaulty stator coilWorn brushFaulty regulator/rectifier

Faulty battery

Open circuit in wire harnessLoose connectionsFaulty ignition switch

Open circuit in wire harnessLoose connectionsBurned out alternator fuse {55 A)

J-

---.1 Check the alternator (regulator/rectifier)(page 17-10)

1 ---

I Incorrect

Abnormal

Abnormal

Abnormal

Incorrect

=:J- More than 14.8 V14.2-14.8 V

_t,---

Normal_ L'~~~~Disassemble the alternator and inspect thefollowing:

stator coil (page 17-11)rotor coil (page 17-11)brush length (page 17-11)regulator/rectifier (page 17-10)

Normal

- , ,I

; Check the voltage of the battery charging line If--'-=='-='-_(page 26-152) J

llnspect the regulated voltage (page 17-9)

Lessthan 14.2 V------',Check the voltage of the regulator/rectifier input line (page 17-10)

Correct

Measure the battery current a~pere leakage !'-_'-='-::C'I {Leak test} (page 17-9)

17-5


Charging System Inspection ('91-'95)Current Leakage Test

Turn off the ignition switch, and disconnect the ground Hcable from the battery.

Connect the ammeter (+) probe to the ground cable and theammeter (-) probe to the battery (-) terminal.

With the ignition switch off, check for current leakage.

NOTE

I. When measuring current using a tester, set it to ahigh range, and then bring the range down to anappropriate level. Current flow larger than the rangeselected may blowout the fuse in the tester.While measuring current, do not turn the ignition on.A sudden surge of current may blowout the fuse inthe tester.

---------

Specified Current Leakage: 3 mA max.

If current leakage exceeds the specified value, a short circuitis likely.Locate the short by disconnecting connections one by oneand measuring the current.

(1) BATTERY GROUND CABLE

e

(2) BATTERYNEGATIVETERMINAL

Regulated Voltage/Ampere Inspection

NOTE

Before performing this test be sure that the battery isfully charged and that the voltage between its terminalsis greater than 12.6 V.

Remove the left side cover (page 2-2).Start the engine and warm it up to operating temperature,then turn the ignition switch OFF.-,-----If the engine must be running to do some work,

make sure the area is well-ventilated. Never run theengine in an enclosed area.

The exhaust contains poisonous carbon monoxidegas that may cause loss 01 consciousness and leadto death.

Connect a voltmeter between the battery terminals.

17-6

Charging SystemlAlternator

IS flOWing may damage the ammeter.

Disconnect the starter relay switch connector and remove(2) CONNECTOR ~

the main fuse.Reconnect the connector secoretv.

(11 MAIN FUSE ~n~lConnect the ammeter as shown.CAUTION ~ ~ +eo" ." Ir:

0 Be careful not to short any tester probes. '~~0 Although the current could be measured when the liLt'!!eammeter is connected between the battery positive !

terminal and the positive cable, a sudden surge of ~,~f~current to the startBr motor could damage the ammeter. Always turn the ignition off when conducting the,

test. Disconnecting the ammeter or wires when current (3) STARTER RELAY SWITCH

NOTE

Before making this test. all the lights and the otherelectrical equipment should be OFF.Use fully charged battery to make this test for correctmeasurement.

Start the engine and increase the engine speed gradually.

Regulated Voltage: 12.6-15.0 V/5,OOO rpmCharging Current: 0-1.0 A/5.000 rpm

(1) BATIERY POSITIVE(+)TERMINAL

~~~~--~~--(~2~1:B1ATIERY NEGATIVE(-)TERMINAL

Regulator/Rectifier ('91-'95)Wire Harness Inspection

Remove the left side cover (page 2-2).Disconnect the regulator/rectifier 6P connector and checkthe connector for loose or corroded terminals.

Measure the following between the connectors of the wireharness side.

Item Terminals Specification

Battery charging Red/White (+) Battery voltageline and ground should register.

Charging coil line Yellow and Yellow 0-1.0n.(20"C/68 F)

Field coil line White and 0-4_0n.Black 1120'C/68'FI

.------- (1) CONNECTOR,

17-7


Unit Inspection

Provided the circuits on the wire harness side are normal andthere are no loose connections at the connector, inspect theregulator!rectifier unit by measuring the resistance betweenthe terminals.

NOTE

You'll get false readings ifthe probes touch your fingers. Use the specified multlrneters. Using other equipment

may not allow you to obtain the correct results.This is due to the characteristic of semiconductors,which have different resistance values depending onthe applied voltage.

Unit' kg

\ + Probe Red/ .veuow 1 Yellow 2 Yellow 31 White- Probe " White ,

Charging System Inspection (After '951Current Leakage Test

Remove the left side cover (page 2-2).Turn off the ignition switch, and disconnect the ground (-)cable from the battery.

Connect the ammeter {+} probe to the ground cable and theammeter (-) probe to the battery (-) terminal.

With the ignition switch off, check for current leakage.

NOTE

When measuring current using a tester, set it to ahigh range, and then bring the range down to anappropriate level. Current flow larger than the rang],selected may blowout the fuse in the tester.While measuring current, do not turn the ignition on.A sudden surge of current may blowout the fuse inthe tester.

Specified Current Leakage: 2 mA max.

If current leakage exceeds the specified value, a short circuitis likely.Locate the short by disconnecting connections one by oneand measuring the current.

Regulated Voltage Inspection

NOTE

i. Before performing this test, be sure that the battery is! fully charged and that voltage between its terminals~greaterthan 12.6 V.

Start the engine and warm it up to operating temperature,then turn the ignition switch OFF.

H the engine must be running to do some work, makesure the area is well-ventilated. Never run the enginein an enclosed area. ,

The exhaust contains poisonous carbon monOXideJ' gas that may cause loss of consciousness and lead

to death.__ cc"'---__ _ _

CAUTION

i Be car~ul not to short any tester probes.

Connect a voltmeter between the battery terminals.Turn the headlight ON (High beam) and start the engine.Gradually increase the engine speed and check that thevoltage is regulated.

Regulated Voltage: 14.2-14.8 V/5,OOO mln-' (rpml


(1) BATTERY GROUND CABLE

(2) BATTERYNEGATIVETERMINAL

8

---------

17-9


Wire Harness Inspection

Disconnect the battery negative (-) cable.

Disconnect the battery negative cable from thebattery to prevent sparking when disconnecting the Ialternator cable.

Disconnect the alternator cable and White connector fromthe alternator.

Connect the battery negative (-) cable onto the battery.

Measure the voltage between each wire (wire harness side)and ground as indicated on the chart.

Disconnect the battery negative (-) cable to avoid sparki ngwhich would otherwise occur when connecting each wireto the alternator.

(1) WHITE CONNECTOR(Input line)

I -~::==J Li/"" - -I.'~ V,:1drL I $>,Ij~ooo

Stator

Check the resistance between each pair of terminals. Thereshould be minimal resistance.

Standard: 0.22 - 0.26 n (20C/68F)

Check for continuity between each terminal and the coilcore. There should be no continuity.

Rotor Coil

Check the slip rings for stepped wear.Measure the 0.0. of each slip ring.

Service limit: 12 mm (0.5 in)

Measure the resistance between the slip rings.

Standard: 2.6 - 3.2 n (20C/68Fl

Check for continuity between the slip ring and therotor or rotor shaft. There should be no continuity.

Brushes

Measure each brush length.

Service limit: 4.7 mm (0.19 in)


(1) TERMINALS

(l) BRUSHES

17-11


Battery Removal/Installation

(4)

{11

~(2)

(3)

Requisite Service

Left side cover removal/installation (page 2-2)

With the ignition switch "OFF", disconnect the negative (-) cable first, then the positive (+} cable.

Procedure Q'ty Remarksf--

Removal Order Installation is in the reverse order of removal.(1) Battery negative (-) cable 1 ,(2) Battery holder nut 1 After removing, open the battery holder.(3) Battery positive (+) cable 114) Battery 1

17-12


Stator Coil Removal/Installation ('91-'95)

(4)

{11

\ / (2)

~l~-~(3) {7)=!t"7J {6)~-~~

------~

(5)

Requisite Service

Swingarm removal/installation (page 14-8)


Removal Order Installation is in the reverse order of removal.(1) Lock nut 2 It is not necessary to remove, just loosen.(2) Gearshift pedal connecting rod 1.(3) Tube holder 1 After installation, route the tubes correctly (page 1-25).[4) Gearshift pedal 1(5) Alternator connector 2(6) Stator assembly 1[7) O-ring 1

17-13


Alternator Removal/Installation (After '95)

View from rear:

~1t:=~{41

Alternator base

Secure with a Bmm bolt

Mounting bosses

Alternator base (6)

~

-,Alternator shaft assembly

17-14

~Ti , ...c~


~servicing, disconnect the batlery negative cable from the batlery to prevent sparking when disconnecting thealternator cable.

Requisite Service

FueI tan k remova Vinstallation (page 2-12)Swingarm removal/installation (page 14-8)

Left pivot cover removal/installation (page 2-5}


Removal Order Installation is in the reverse order of removal.11) 2P {White} connector 1(2) Terminal nut 1 After tightening the terminal nut, install the terminal cap to

the terminal flange securely.(3) Alternator cable 1,(4) Mounting bolt 3 NOTE. Before removing the alternator, turn the alternator

clockwise and temporarily secure the alternator basewith a 8 mm bolt as shown.If the alternator base is not secured, it will cause thealternator shaft to come out with the alternator. If thisoccurs, oil pan removal will be necessary when

, reinstalling (page 17-18}.(5) Alternator 1 Pry the mounting bosses of the alternator using a

screwdriver.

iDisassembly/assembly (page 17-16)

(6) O-ring 1

17-15


Alternator Disassembly/Assembly (After '95)

17-16

----------

1 .., {3j

12(

cu )(10)

J

(5)

17(

1131qJ.~

141

------------

151

(9)

Requisite Service

Alternator removal/installation (page 17-14)


Procedure , Q'ty Remarks

Disassembly or der Assembly is in the reverse order of disassembly.11 } End cover screw 312} Nutfterminal insulator 1/1131 Rear end cover 1141 Terminal screw (pan-head) 2151 Terminal screw (flange) 3161 Regulator 1 ,,171 Brush assembly/holder insulator 1/118} Terminal screw (flange) 419} Rectifier 1(10) Housing nut 2(11) Rear housing , 1 Before installing, clean the slip rings thoroughly.(12) Rotor 1 NOTE:. Usea hydraulic press. Do not strike the slip ring ofthe

rotor shaft.(13) Oil seal 1(14), Retainer screw 4(15}i Bearing retainer 1(16} Front bearing (6202)/washer 1/1 i(H} Spacer ring/rear bearing (6002} 1/1 I

17-17


Alternator Shaft Removal/Installation'91-'95

131et,

Requisite Service

Engine removal/installation (page 7-2)Oil pan removal/installation (page 4-6)Stator coil removal/installation {page 17-13)

(t I

.{J/~Y 0 58 (5.8, 42)

121

6 mm bolt


Removal Order Installation is in the reverse order of removal.(t) Alternator shaft bolt 4 NOTE

Before removing, insert a 6 mm bolt in the holes in thealternator shaft driven gears for easy alternator shaftassembly installation. After installing, do not forget toremove the bolt.

121 Alternator shaft assembly t NOTEBefore installing, apply molybdenum disulfide grease to thealternator shaft driven gears. Disassembly/assembly {page17-20}

(31 O-ring t

17-18

After '95

et'l121

Requisite Service

Oil pan removal/installation (page 4-6)Alternator removal/installation {page 17-14}


I' 1

6mm bolt


Removal Order i Installation is in the reverse order of removal.NOTE. Before removing, insert a 6 mm bolt into the holes in

the alternator shaft driven gears for easy alternatorshaft assembly installation. After installing, do notforget to remove the 6 mm bolt.

I' 1 Alternator shaft assembly , NOTE. Before installing, apply molybdenum oil solution tothe alternator shaft driven gears.

Disassembly/assembly (page 17-21)(2) la-ring ,

17-19


Alternator Shaft Disassemlby/Assembly'91-'95

19}

110}

131 141 15}

IS}IS}

17}

Requisite Service

. Alternator shaft removal/installation (page 17-18).


Disassemlby Order Assembly is in the reverse order of disassembly.

11 } Alternator shaft nut 112} Washer 1

13} Bearing 114} Shaft collar 115} Cone washer 1 Install the washer with the tapered side facing to the

shaft nut.

IS} Alternator shaft driven gear 117} Damper spring 5IS} , Spring seat 12

19:}1Flywheel 1

110} Alternator shaft assembly 1

17-20

After '95

(51

(41

(31

Requisite Service

Alternator shaft removal/i nstauatron (page 17-19)

(11)

~IIII

(9(


Procedure Q'ty I Remarks

Disassembly Order Assembly is in the reverse order of disassembly.(1) , Alternator shaft nut 1(2( Washer 1(31 Bearing (6003) 1141 Shaft collar 1151 Cone washer 1 Install the washer with the tapered side facing to the shaft

nut.161 Alternator shaft driven gear 1171 Damper spring 4181 Spring seat 8(91 Flywheel 1

(10) Bolt 3(11) Retainer plate 1(12) Alternator base 1(13) Bearing (20 x 47 x 10.5) 1

17-21













"I~ Apply sealant


18. Ignition SystemService Information

System Location

Troubleshooting

Ignition System Inspection

Service Information

18-1

18-2

18-4

18-6

Ignition Coil

Ignition Pulse Generator Inspection

Ignition Pulse Generator Removal!Installation

Ignition Timing

18-8

18-9

18-10

18-11

When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 18-4).The digital transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can bemade to the ignition timing.

A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect. The ignition control module (leM) may be damaged if dropped. Also, if the connector is disconnected when current is

flowing, the excessive voltage may damage the unit. Always turn off the ignition switch bercre servicing.A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower enginecranking speed as well as no spark at the spark plugs.

Use spark plugs of the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.Refer to section 2 of the Common Service Manual.For neutral switch inspection, refer to section 25 of the Common Service Manual; for switch location, see page 18-2 or18-3 of this manual (System Location).For the ignition switch and engine stop switch inspection, check for continuity on the continuity chart of the WiringDiagram (section 22). Refer to page 21-4 for side stand switch inspection.

18-1

Ignition System

W/Y

,--'--y

(8) IGNITION PULSEGENERATOR

(13) ICM

(1) No. 2,4

V IGNITION COIL

(7) No.1,3 IGNITIONCOil

(9) BATIERY

(6) ENGINE STOPSWITCH

(4) BANK ANGLESENSOR RELAY

(5) BANK ANGLESENSOR

-0

/>-J{71 No. 1,3-~

IGNITION ICOIL -r-r

lOA

(6) ENGINE STOPS~TCH

{11} SIDE STANDSWITCH

(10) MAINFUSE30A

RjW

(4) BANK ANGLESENSOR RELAY

I

-;[...L

L--BI'-----I

W I G RIW


(12) NEUTRALSWITCH

(3) SIDE STANDINDICATOR LIGHT

(2) IGNITION SWITCH

(13) IGNITIONCONTROLMODULE{ICM}

System LocationStandard Model

(1) No. 2,4 IGNITION y;"COIL

/\

...".., R _ R/BI

(10) MAIN (2) IGNITIONFUSE SWITCH30A

FUSElOA

_L'-----=- (9) BATTERY

(11)SIDESTAND ISWITCH

TO TACHO-

(12) NEUTRALSWITCH

METERTO STARTERCIRCUIT

18-2

Ignition System

ABS/TCS or LBS-ABS/TCS Model ABS/TCS model shown:

(11) SIDE STANDSWITCH

(7) No.1, 3 IGNITIONCOIL

(4) BANK ANGLE SENSOR RELAY

(5) BANK ANGLE SENSOR

(6) ENGINE STOP SWITCH

~-~

(8) IGNITION PULSEGENERATOR

(9) BATTERY

(10) MAINFUSE30A

(12) NEUTRALSWITCH

(3) SIDE STANDINDICATOR LIGHT

(2} IGNITION SWITCH

(13) No. 2,4IGNITION COIL

(1) TCS/ignitioncontrol module(lCM) C~\ -

'---~

(4) BANK ANGLESENSOR RELAY (6) ENGINE STOP


BI/Y

L--BI----.J

(1) TCS/ICM

W/Y'-

T

(lOJ MAINFUSE30A

--=- (9) BATTERY

R _ R/BI _BI/BR = -(2) IGNITION FUSE (3) SIDESTANDlQI'-

SWITCH 10A INDIATOR

LIGHT

/(11)SIDESTAND J

SWITCHTO TACHO-

LG

~~o-~,

(12) NEUTRALSWITCH

METER (8) IGNITION PULSETO STARTER GENERATORCIRCUIT

18-3

Ignition System

TroubleshootingNo spark at all plugs (Faulty input system)

If there is no spark at all plugs, the problem could be at the input of the ignition system (ignition pulse generator. pow-er input circuit of the ignition control module (ICM), neutral switch, side stand switch or ICM).

Faulty ignition switchFaulty engine stop switch (except A8STCSmodel) For the engine stop switch inspection ofABS'TCS model, see page 18-1.Open circuit in wire harnessLoose or poor contact of related circuit con-nectorsFaulty bank angle sensor relayFaulty bank angle sensor

Poorly connected connector

Poorly connected connector

I Normal

jMeasure the ignition pulse generator resistance I Check the ignition pulse generator (page 18 7). Iat the lCM connector (page 18-6). Abnormal

Normal Abnormal

Faulty ignition pulse

Normal generator

Open circuit between the ICM and ignition pulsegenerator

Loose or poor contact of the ignition pulse gene-continuity at the I

rater connectorCheck the neutral switch for i Check the neutral switch.ICM connector (page 18-6).

AbnormalNormal Abnormal

1 Faulty neutral

switchNormal

Open circuit between the leM and neutralswitch

Loose or poor contact of the neutral switchCheck the side stand switch at the ICM connect-j

connectors

Check the side stand switch (page 21 4).i or (page 18-6). i Abnormal

!NormalNormal Abnormal

Faulty side stand. Faulty ICMswitch

Check for loose or poorly connected ICM con-Inector. I Abnormal1NormalCheck for loose or poorly connected ignition coil3P mini connector. Abnormal

~ Normal

I Check for battery voltage between the powerinput line (Black/White: standard model, Black/

'Yellow: ABSTCS model) and ground (Green) at the 'CM connector with the engine stop switch Abnormal

at RUN (except ABSTCS model) and the ignitionswitch ON (page 1B-6).,

Open circuit between the ICM and side standswitchLoose or poor contact of the side stand switchconnector

18-4

Ignition System

No spark at either ignition groupIf there is no spark at either group, the problem is suspected in the primary coil side of the ignition system (ignitioncoil, or ignition control module (ICM) and ignition coil circuit).

Switch the ignition coil primary terminal con-! nection between the faulty pair and good pair.i Try spark test again

U No Spark" conditionshifts to other pair

"No Spark"condition

remains withfaulty pair

..I Remove the faulty pair ignition coil and checkI the ignition coil resistance (page 18-7).

fFaulty Ignition coli" Faulty spark plug

wire

Abnormal

Measure resistance of the ignition primary coil I, ~.' .. " Poor or loose contact of ignition coil 3P miniat ICM connector (page 18-6).

_~"-__~ ~ connector

r Open circuit between the 1CM and ignition coilNormalFaulty ICM

No spark at one plug (Trouble in secondary coil side)" Faulty spark plug is most likely.

Normal

~ Conduct spark test on good ignition coil.

-.." Original spark plug no good.

_" Faulty ignition coil

Replace (suspected bad spark plug) with known Igood spark plug and conduct spark test. i Normal

Abnormal

Put the spark plug wire on and measure resistanceof ignition secondary coil (page 18-7). Normal

Abnormal

Remove the spark plug wire, and measure theresistance of the ignition secondary coil (page f--18-7) . Abnormal

~ NormalPoor contact of spark plug wireFaulty spark plug wire

Side stand switch does not function at all.

I

Side Stand Indicator:Check the side stand indicator for function.

Normal___" Faulty side stand switch

Open circuit in Green/White or Green wire

Abnormal

ISide Stand Switch:Check the side stand switch for continuity.

Normal-.." Loose or poor contact of related connectors

Open or short circuit in wire harnessBurnt indicator bulb

AbnormalFaulty side stand switch

18-5

Ignition System

Ignition System InspectionNOTE

Check the system components and lines step-by-stepaccording to the troubleshootinq chart on pages 1B-4and 18-5.

Standard model:Remove the left fairing pocket (page 2-6).

Remove the ignition control module (ICM} from the stay,disconnect the ICM connector and check it for loose orcorroded terminals.

ABS/TCS or LBS-ABSITCS model:Remove the middle fairing inner cover (page 2-7).Disconnect the TCS/ignition control module (ICM) 16P con-nector and check it for loose or corroded terminals.

Measure the data between the connector terminals usingthe following chart.

STANDARD MODEL:

(1) ICM

ASS/TCS or LBS-ABS/TCS MODEL:

(1) TCS/ICM

Item Terminals Standards (20"C/6B"F)

Battery voltage input line Black/white [ABS/TCS or LBS-ABS/TCS Battery voltage should registermodel: Black/Yellow] (+) and Ground (-)with the engine stop switch RUN (Standardmodel) and the ignition switch ON.

Ignition pulse generator line Yellow and White/yellow 405-495 Q

Ignition primary No. , ,3 Yellow/blue and Black/whitecoil line 2.16-3.19 Q

No. 2,4 Blue/yellow and Black/white

Neutral switch line Light green and Ground Continuity in neutralNo continuity in any gear

Side stand switch line Green/white and Ground Continuity with the stand upNo continuity with the stand down

Ground line Green and Ground Continuity

Tachometer line Yellow/green and Green wire connector of Continuity

( the harness side at the instruments I

18-6

Ignition System

Ignition CoilInspection

Remove the upper fairing (page 2-9).Disconnect the ignition primary coil 3P connector (white)and measure the primary coil resistance between each ignitioncoil.

Primary coil resistance:Standard: 2.16-3.19Q (20'C/6So F)

(1) 3P CONNECTOR

Disconnect the spark plug caps from the plugs and measurethe secondary coil resistance with the spark plug caps inplace,

Standard: 22.5-27.5kQ (20'C/6S" F)

(1lIGNITION COIL

OJl\-~(OJ (iiiiiii;,= 0

I ,

(2) IGNITION COIL

.~t:r0 iiiiiii

Q0

I I

(1) SPARK PLUG WIRES f

Standard: 13.5-16.5kQ (20C/6S" F)

If the resistance is out of the range, remove the spark plugcaps and measure the resistance between the secondarycoil terminals

18-7

Ignition System

Ignition Pulse Generator InspectionNOTE

It is not necessary to remove the ignition pulse gene-rator to make this inspection.

Standard model:

Remove the right side cover (page 2-2).

ABS/TCS or LBS-ABS/TCS model:

Remove the top shelter (page 2-5).

Disconnect the ignition pulse generator 4P connector andmeasure the resistance between the White/Yeliow andYellow wires.

Standard: 405-4950. (20e/68F)Refer to page 18-9 for ignition pulse generator replacement.

18-8

STANDARD MODEL:

w@

~--- ~~~~~~-~~~cccc~_D (G';"'--------------::;)~~q -;:-------r--

:----J V ~(1) IGNITION PULSE GENERATOR 4P CONNECTOR

ABS/TCS or LBS-ABS/TCS MODEL:

Ignition Pulse Generator Removal/Installation

Ignition System

ABS/TCS model shown:

(11

0'12 (1.2, 9)

.,('G1l!

(61

Clamp

0'12 (1.2, 9)

(21

Requisite Service Fuel tank Removal/Installation (page 2-12).

\ \ "

(31

(~,

Procedure my RemarksRemoval Order Installation is in the reverse order of removal.

111 Oil pressure switch terminal 1(21 Neutral switch connector 1 At installation, insert the neutral switch wire into the

clamp as shown.(3} Waterproof connector (4P) 114} Bolt 4151 Gasket 1(6} Dowel pin 2(7} Bolt 2(81 Ignition pulse generator 1

18-9













"I~ Apply sealant


Service Information

System location

System Wiring Connections/Locations

Service InformationCAUTION

19-1

19-2

19-3

Circuit Diagram

Troubleshooting

19. les19-4

19-5

Use the fully charged battery for troubleshooting. Do not diagnose the TeS with a charger connected to thebattery .On removal and installation of the wheel sensors/wheels. be careful not to damage the wheel sensors and pulserrings.

NOTE

Check the following before performing any TCS troubleshooting.- Pre-start self-diagnosis of res- Check on all lights and indicators of resIf an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-to-System Chart (page 19-6). The TCS is normal if no trouble is found. Go on to the check the other basic systems (e.g. fuel system, ignition system, etc.).Record the symptom of the problem and the problem code in MEMO before troubleshooting.When the TCS is faulty, the TCS indicator light blinks or it comes on. The TCS does not function this time; take careduring the test ride.The TCS OFF indicator turns on when the TCS ON/OFF switch connector is disconnected and then reconnected with ithe ignition switch ON. The TCS can be recovered this time by pushing the TCS ON/OFF switch. Take care whenremoving the left side pocket.When the rear wheel sensor or rear purser ring is replaced, perform the air gap inspection (16-51).The TCS indicator light might blink in the following cases. If the indicator light blinks, turn the ignition switch OFF andperform the pre-start self-diagnosis (page 19-5}. The TCS is normal if the TCS indicator light goes off.

The lCS/ignition control module was disrupted due to an extremely powerful radio wave (Electromagnetic Interfer-ence).

After riding (i.e. after the pre-start self- diagnosis), either front or rear wheel was stopped and the other wheel wasturned (for more than 10 seconds) with the engine kept running.Example:' Only the rear wheel was turned with the motorcycle set on the main stand.

o Only the front wheel was turned for inspection of the meter. When, after the test ride (i.e. after pre-start self- cnaancstsj.the motorcycle is set on the center stand with the engine

running and the throttle is opened quickly with the gear engaged (rear wheel idles), the ignition timing is retardedbecause of the difference in wheel speed between the front and rear wheels, which might cause afterfire and afterburn ..~

The TCS indicator light might blink under the following conditions. Turn the ignition switch OFF to return to the normal~condition and perform the pre-start self-diagnosis (page 19-5) of the TCS. The TCS is normal if the TCS indicator goesoff:

Improper tire air pressureTire not recommended for the motorcycle is installed.Deformation of the wheel

19-1

TCS

System LocationASS/les model shown:

(6) res INDICATOR LIGHT(7) res ACTIVATION LIGHTS

(12) FRONT WHEEL SENSOR

(10) BANK ANGLE SENSOR RELAY

(13) FRONT PULSER RING

(8) res OFF INDICATOR

(9) leS/IGNITION CONTROLMODULE

1~""'~~~~~~\\.,L-(11) BANK ANGLE SENSOR

(17)IGNITIONPULSE GENERATOR

(16) NEUTRAL SWITCH

(15) SIDE STAND SWITCH

(14) IGNITION COILS

(1S) REAR PULSER RING

(19)

REARWHEEL SENSOR

(4) res ON/OFF SWITCH

-------- -

(1) FUSE CASE

(3) ASS/leS INDICATOR LIGHT SWITCH

(2) BATTERY

19-2

System Wiring Connections/Locations(2)res ON/OFF SWITCH

-Top shelter

(page 2-5)

'J:: REAR WHEEL SENSOR-R. side coler (page 2-2)

. Refer to section2, (frame/body panelslexhaust system), for the parts thatmust be removed for service

For example::~ res SWITCH

TCS

F SWITCH

::j', ABS/TCS INDICATOR LIGHT SWITCH-Top shelter (page 2-5)

=Vj %Ala G!B

(1) reS/IGNITION CONTROLMODULE (leM) (16P)-Upper fairing (page 2-9)

:~: INDICATOR (WHITE)

-trmer screen (page 2-7)

=G/O V\joG~ RJ

ts u 0

(8: reS/IGNITION CONTROLMODULE (leM) (4P)

-Upper fairing (page 2-9)

m

($) INDICATOR (BLACK)

-Inner screen (page 2-7)

(~) BANK ANGLE SENSOR-Upper fairing (page 2-9)

TCS

Circuit Diagram

reS/IGNITION CONTROL MODULE

- -Z Z-i -im m,. ~ ~-n -n

': " "n - om IGNITION r- my- o Q~ ~

o nIY e e

" "

- -y. Z Z-i -i

m m~ ~

G -n ~

" TRACTION "O o e- om f- m8' Q

CONTROLQ

~ ~

n oe e-i "

G,

BulBIIBul

....--NEUTRAL SWIGNITION PULSE GENERATOR {:lllJ~I~~~~~G;

rBl-r---g* 6Y-::=====+. WIres SWITCH

2P- 81rB r-'i{~~'::::Y====l:HINDICATOR LIGHTSWITCH

01

SIDE STAND SW ....... ---.,

81 BLACK B, BROWNY YELLOW ,0 ORANGE

~BLUE Lb LIGHT BLUE

G GREEN Lg LIGHT GREENR REO P PINK

W WHITE Gr GRAY-

FRONT WHEELSENSOR

REAR WHEELSENSOR

ASS CONTROL UNIT

19-4

res OFF INDICATOR

-- TACHO

METER

res ACTIVATION L1G HT

~~CS INDICATOR LIGHT//~

: ~~fl ~R~AITERPD5 0 fe.~ a:l{.9 ~ Q.~~ iii): ~;: ~ II:

~W/O~R/O

t-Su/YI-Y/Bu~BIIY~LglO_

lOA

IGNITION SWITCH

9~-R

lrl-I-F~B~~R/W-=t..aBANK ANGLE

SENSOR RELAY3P-G

-+-----t=;~:::1J1::=~~r- RIW~/~BANK ANGLESENSOR

,.....-+-BIIW- _BIIW:===r~BIIW~-BIIY- -BIIY -BIIY-h::::U

ENGINE STOPSWITCH

-Y/G

TCS

Troubleshooting

Before Beginning Troubleshooting:

Summary of TCS pre-start self-diagnosis system

The TCS pre-start self-diagnosis system diagnoses inside the TCS/ignition control module (leM) and the electrical circuit

of the wheel sensors.

When the ignition switch is turned ON, the TCS starts the pre-start self-diagnosis to check inside the TCS/ICM for condi-tion. Then it g08S to the stand-by mode for the wheel sensor signal. After starting the motorcycle, the pre-start self-diag-nosis completes when the wheel sensor signal is transmitted to the TCSjlCM with the front/rear wheel rotating at the speedof approximately 10 km/h (6 mile/h) or above.

If the TCS is normal, the indicator light goes off after the motorcycle starts notifying the rider that the pre-start self-diagnosisis completed. When a problem is detected, the indicator light blinks or stays ON to notify the rider. The self-diagnosis is madewhile the motorcycle is moving, too, and the indicator light blinks when a problem is detected. (The TCS OFF indicatorcomes ON simultaneously.) The probable cause of the trouble can be detected from the lighting condition of the TCSindicator light, indicator, etc. (see the following page).

______/ 10 km/h (6 mile/h) or above

I"

(1) IGNITION SWITCH

(2) VEHICLE SPEED

(3) TCS INDICATOR LIGHT

(4) TCS OFF INDICATOR

(5) TCS ACTIVATION LIGHT

ONOFF

oON

OFFON

OFFON

OFF

.J

.J

.JC'=:J------; Pre start self diagnosisI completes.

Approx, 2 seconds(Check for blown out bulb)

Pre-start self-diagnosis procedure (Pre-start check-up)1. Turn the ignition switch ON.2. Be sure that the TCS OFF indicator and TCS activation light turn ON for approximately 2 seconds and then go OFF,

and be sure that the TCS indicator light stays ON.3. Start the engine and ride the motorcycle until the engine speed reaches approximately 10 km/h (6 mile/h).4. The TCS is normal if the TCS indicator light goes OFF.

(2) TCS ACTIVATION LIGHT

(1) TCS OFF INDICATOR

TCSACTIVE

NOTE

Check the following before performing TCS troubleshooting:- Pre-start self-diagnosis of TCS- Check all lights and indicators of TCS

If an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-to-System Chart (see the following page). The TCS is normal if no trouble is found. Go on to the check the other basic:systems (e.g., fuel system, ignition system). I

19-5

TCS

Symptom-to-System Chart

Affected

--< - l>Wheel 3-0 0_ t:::::'~o ~-< -~

- _z -" -n 0 0 -< -< -< ReferenceSymptom 0 '" ~- ~~

TCS

Flowcharts

NOTE

Turn the ignition switch OFF unless otherwise specified.

When the reS/ignition control module oeM) is found to be faulty, recheck the connectors before replacing the res;ICM.Atter troubleshooting, perform the pre-start self-diagnosis again and be sure that the indicator light of the res arenormal.The encircled numbers in the text and connector diagrams indicate the connectors (see page 19-3).

Lights and indicators of the leS do not turn on when the ignition switch is ON.

NOTE

The indicator lights of the res must turn on when the ignition switch is ON. The TeS activation light and Tes OFFindicator should go off approximately 2 seconds after the ignition switch is ON, while the res indicator light should notgo off unless the motorcycle starts to move.

TCS ACTIVATION LIGHT

I

L ,r( OSITION)11_ - IGNITION FUSELI~ r'IGN ACG STARTER")

~~

TCS OFF INDICATOR

L _//------f-= -

~. . . ~ TCSACTIVa T"" A ....

,-'=---


-/:=- -=:_-~ - " ~~:---:..~ICheck the indicator lights other than of TCS (e. /is.. neutral, fuel, and oil pressure switch indicator TCS INDICATOR LIGHTlights)

( Do the indicator lights come on or go off?Lights go off.


lights come on.

I Turn the ignition switch OFF. I Check the indicator fuse ("METER TAll POSI-TIOW).

I1 Check the ignition fuse ("IGN ACG STARTER") 1 < Is it normal?

< Burned out. Repair openJNormal Burned out.

Is it normal? , in the BLACK/BROWN harness

Normal between the indicator fuse and meter.

I~heck the 16P connector Cl) and 4P connector Replace the fuse and recheck.(:' of the TCS/ICM for secure connection.

-' Replace the fuse and recheck.< Are they connected securely? Poor connection Connect securely and recheck.,

Secure connection

r :-='1IDisconnect the 4P connector CS)of the TCS/ICM.II -' INDIC':-'TOR FUSE- "METER TAIL P .

FUSE CASE

19-7

TCS

(From the previous page)

Install the 4P connector '::': of the TCM/ICM. I

View from terminal side

GREffi~

YELLOW/GRAY

1-


.~


Repair open in the GREEN harness between theTCS/ICM and body ground, or poor grounding.

Repair open in the BLACK/YELLOW harnessbetween the bank angle sensor relay and leS/leMRepair open in the BLACK harness between theignition fuse and bank angle sensor relay.

TCS indicator light doesnot come on (See page19-7).

L __o (To the following page.)

II

TCS activation light andOFF indicator do notcome on (See page 19-7)

ICheck for continuity between the GREEN termi-nal of the TCS/ICM 4P ccnnectcr rg and bodyground.

< Is there continuity? No continuity ,Continuity

Disconnect the 16P connector


II Connect the 4P connector :]; of the TCSjICM. I

IDisconnect the BLACK/BROWN connector C1; ofthe TCS indicator light.

ITurn the ignition switch ON.

I! Check for voltage between the BLACK/BROWNi connector@ofthereS indicator light and bodyi ground.

< Does battery voltage register?No battery voltage

Battery voltage

I Turn the ignition switch OFF. II 7' View from term

Disconnect the RED/ORANGE connector @ of,~

the TeS indicator light. I I I I

I I I I ICheck for continuity between the RED/ORANGE

RED/Oterminal (4) of the res indicator light and the. RED/ORANGE terminal of the TCS/ICM 16P Iiconnector Ct,. ,

TCS

Repair open in the BLACK/BROWN harnessbetween the indicator fuse and meter.

inal side


Continuity

Connect the TCS/ICM 16P connector ,j)and con-nect the BLACK/BROWN and WHITE/ORANGEconnectors of the TCS indicator light.

Replace the LED of the TCS indicator light.

Turn the ignition switch ON and check the TCSindicator light.

Does the light come on?

Light goes off.

Faulty TCS/ICM

No continuity

Light comes on. ..

Repair open in the RED/ORANGE harnessbetween the TCS/ICM and meter.

TCS INDICATOR LIGHT LED

Faulty TCS indicator tight LED

19-9

TCS

Indicator lights of the TCS (except TCS indicator light) do not go off 2 seconds after the ignition switch is ON.

NOTE

The indicator lights of the res must come on when the ignition switch is ON. The res activation light and res OFFindicator should go off approximately 2 seconds after the ignition switch is ON, while the res indicator light should notgo off unless the motorcycle starts to move.


Disconnect the 16P connector mand 4P con-nector (~, of the TCS/ICM

Turn the ignition switch ON and check the resactivation light and res OFF indicator.

Do the lights come on or go off?

Lights go off.

Faulty TCS/ICM

Lights come onRepair short in the YELLOW/GRAY harness(TeS activation light) or WHITE/ORANGE har-ness (TeS OFF indicator) between the res/leM and meter .

TCS OFF INDICATOR TCS ACTIVATION LIGHT

TCS ACTIVE 1Tce I~

19-10

TCS

TCS indicator light does not go off after the motorcycle starts to move.

NOTE

If the res is normal, the wheel sensor system self checks and the res indicator light goes off after the motorcycle startsto move.

Turn the ignition switch OFF. res INDICATOR LIGHT

Check the l6P connector (]) and 4P connector.]) of the TCS/ICM for secure connection.

Are they connected securely]

Secure connection

Poor connection

'J) REAR:

Repair open in the GREEN harness between theTCSjlCM and body ground, or poor grounding


Connect securely and recheck.

~ ill)FRONT,

BLUE/GREE~EENL-@-J

~ cfbBLUE/BROWN BLUE/BROWNC@--J

No continuity

Continuity

jIs there continuity?

j

i

(Continue to th following page)

Disconnect the 4P connector () of theTCS/ICM,1

Check for continuity between the GREEN termi-nal of the TCS/ICM 4P connector (f{;: and bodyground

jCheck the wheel sensor connectors ({D for front,nd 0: for rear) for secure connection.

< Are they connected securely?Poor connection

Secure connection

Disconnect the ,6P connector ct, of the TCS/leM and the wheel sensor connectors (,n, for 'J)front and .'L for rear).

Check for continuity between the 16P connector(-t terminals of the TCS/ICM and the main har-ness side terminal of the wheel sensor cormec-tors eft: for front and CD for rear)

-~~~"":"'~"-_Connect securely and recheck.

Disconnect the 4P connector @oftheTCS/ICM.

Check for continuity between the GREEN termi Inal of the TCSjlCM 4P connector ca:, and body -ground.


Continuity

No continuityRepair open in the GREEN harness between theTCS/ICM and body ground. or poor grounding.



.. GREEN

n

19-15

TCS

(From the previous page) View from terminal side

-,ORANGEjYElLOW


Repair short in the ORANGE/YELLOW harnessbetween the TCS/ICM and TCS ON/OFF switch.

Repair open in the GREEN harness or ORANGE/YELLOW harness between the TCS/ICM andTCS ON/OFF switch connector.

~tBORANGE/YELL~EEN

jDisconnect the 16P connector ill and 4P con-nector () of the TCSjICM, and disconnect theres ON/OFF switch connector C?).

Check for continuity between the TCS/ICM 4Pconnector (~) terminal end main harness sideconnector (2:: terminal of the TCS ON/OFF swit- iJ)

ch, and between the TCS/ICM , 6P connector([; terminal and harness side connector ct, termi-nal of the TCS ON/OFF switch.

< Is there continuity? No continuityContinuity

With the TeS ON/OFF switch connector tj)disconnected, check for continuity between the16P connector (7) terminal and 4P connector ':IDof the TCS/ICM.

< Is there continuity ContinuityNo continuity

Faulty TCS/ICM

19-16

TCS

TCS indicator light blinks while riding and does not go off by operating ABS/TCS indicator light switch.

NOTE

When the TCS is faulty and the res indicator light blinks and TCS OFF indicator light comes on, the res indicator lightcan be turned off by operating the ABS!TCS indicator light switch. (However. the TCS OFF indicator cannot be turnedoff.)



View from terminal sidewtE

~

Faulty ABS/TCS indicator light switch


~". A

TCS INDICATOR LIGHT

1Secure connection

Check for continuity between the GREEN termi-~ nal of the rCS/ICM 4P connector :Je and body: ground.

: Disconnect the 4P connector ca; of the reS/ICM.

I Turn the ignition switch OFF. I - - - ---I ~=U=:4Check the ABS!TCS indicator light switch con-

nector (J) for secure connection. =--->- -

--------( Poor connectionIs it connected securely?Secure connection

Disconnect the ABS!TCS indicator light switchconnector (J).

ICheck for continuity between the switch sideconnector Q) terminals of the indicator lightswitch.Push: No continuityRelease: continuity

( AbnormalIs it normal?Normal

Check the 16P connector (f; and 4P connector(8~' of the TCS/ICM for secure connection.

( Poor connectionAre they connected securely?I


Continuity

No continuityRepair open in the GREEN harness between theTCS/ICM and body ground, or poor grounding.


19-17

TCS

.tpGRAY/YELLOW

I


Repair open in the GREEN harness or GRAY/YELLOW harness between the TCS/ICM andABS;TCS indicator light switch connector.

m~GR~EN


Repair short in the GRAY!yELLOW harness

between the TCS/ICM and ABS;TCS indicatorlight switch.

Y/yELLQWI

~tpAY/YELLQW GREEN


jDisconnect the l6P connector CD and 4P con-nector ,]::; of the TCS/ICM, and disconnect theABS/leS indicator light switch connector c:~_\

Check for continuity between the 4P connectorCit terminal of the TCS/ICM and the main har-ness side connector :,3) terminal of the ABS/leS (])indicator light switch, ,nd between the 16Pconnector oj) terminal of the TCS/ICM and themain harness side connector CJ" terminal of theASS/leS indicator light switch.

GRA

< Is there continuity? No continuityContinuity

Disconnect the WHITE_ connector of the ABS IXTCS/ICM (page 16-3-n_t,). :

,

IWith the ABS/leS indicator light switch con-nector C~: disconnected, check for continuity GRbetween the 16P connector CD terminal and 4Pconnector ;~!L terminal of the TCSjICM.

< Is there continuity? ContinuityNo continuity

Install the 4P connector :~; of the TCS/ICM and ithe WHITE connector (page 16-3-(C~') ofthe ABSECU. (Do not yet install the ABS/TCS indicatorlight switch connector ':1.:' and 16P connector CDof the TCSjICM.)

Turn the igntion switch ON.

I(Continue to the following page)

19-18


Check for voltage between the main harness sideconnector (j:: terminals of the ABS!TCS indicatorlight switch.

Is there approximately 5V?

jYesFaulty TCS/ICM

No


(~

GRAY/YELJEN

. Faulty ASS ECU

TCS

19-19













"I~ Apply sealant


Service Information

System Location

Troubleshooting

Service Information

20-1

20-2

20-4

20. Electric StarterStarter Motor Removal/Installatio

ST1100_Manual.pdf

Documents

Transcript of ST1100_Manual.pdf