Category Archives: ANUAL SERVICE M

TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START

1. Fuel Line Inspection

Check fuel flow to carburetor.

Does fuel reach the carburetor?

IMO — • Clogged fuel hose or fuel strainer

• Clogged fuel valve

• Clogged fuel tank breather hose

YES — GO TO STEP 2.

2. Spark Plug Inspection Remove and inspect spark plug.

Is the spark plug wet?

YES — • Flooded carburetor

• Throttle valve open

• Dirty air cleaner

• Improperly adjusted pilot screw

NO — GO TO STEP 3.

3. Spark Test Perform spark test.

Is there weak or no spark?

YES — • Faulty spark plug

• Fouled spark plug

• Loose or disconnected ignition system wires

• Broken or shorted ignition coil wire

• Faulty ignition coil

• Faulty igniting pulse generator

• Faulty exciter coil

• Faulty engine stop button

• Faulty ignition control module (ICM)

NO — GO TO STEP 4.

4. Engine Starting Condition

Start engine by normal procedure.

Does the engine start then stops?

YES — • Improper choke operation

• Incorrectly adjusted carburetor

• Leaking carburetor insulator

• Improper ignition timing (Faulty ICM or ignition pulse generator)

• Contaminated fuel

• Improper hot start operation

NO — GO TO STEP 5.

5. Cylinder Compression Inspection

Test cylinder compression.

Is the compression low?

YES — • Valve clearance too small

• Valve stuck open

• Worn cylinder and piston rings

• Damaged cylinder head gasket

• Seized valve

• Improper valve timing

• ’05 — ’07: Faulty decompressor cam

• After ’07: Faulty decompressor shaft



[1] If the engine runs rich exiting a corner, turn the pilot screw clockwise to lean the mixture.

• If the engine runs lean exiting a corner, turn the pilot screw counterclockwise to richen the mix­ture.

WIRING DIAGRAM



WIRING DIAGRAM

WIRING DIAGRAM




WIRING DIAGRAM



STARTER SWITCH

INSPECTION

’05 — ’07:

STARTER SWITCH

Remove the front visor.

— ’05 -’07: (page 3-5)

— After ’07: (page 3-6)

Disconnect the starter switch 2P (Black) connector.

STARTER SWITCH

STARTER SWITCH

Check for continuity between the starter switch con­nector terminals (Yellow/red and Black).

There should be continuity with the starter switch pushed and no continuity with the switch released.


TRIPMETER

STARTER SWITCH

REMOVAL/INSTALLATION

Remove the front visor.

— ’05 — ’07: (page 3-5)

— After ’07: (page 3-6)

Loosen the lock nut and disconnect the tripmeter cable.

’05- ’07: Remove the nuts, washers and tripmeter.

After ‘07 Remove the nuts, cable guide and tripmeter.

Installation is in the reverse order of removal.


TAIL LIGHT

INSPECTION

Start the engine and check the tail light illumination.

TAIL LIGHT

If any LED does not turn on, replace the tail light unit.



CLAMPS STAY



CONNECTORS



TAIL LIGHT



SCREWS



TAIL LIGHT UNIT



REMOVAL/INSTALLATION

Remove the following:

— Seat (page 3-3)

— Side covers (page 3-3)

Disconnect the tail light wire connectors. Remove the screws and wire clamps.

Remove the screws, stay and tail light unit.

Installation is in the reverse order of removal.

TORQUE:

Tail light mounting screw:

4.2 N m (0.4 kgf-m, 3.1 lbf-ft)

Tail light wire clamp screw:

0.7 N m (0.1 kgf-m, 0.5 lbf-ft)



ENGINE STOP BUTTON

TAIL LIGHT

3P (BLACK) CONNECTOR

INSPECTION

Remove the front visor.

— ’05-’07: (page 3-5)

— After ’07: (page 3-6)

TAIL LIGHT

(BLACK) CONNECTOR ’05 — ’07 shown: ^ ENGINE STOP BUTTON

TAIL LIGHT

Check for continuity between the Black/white termi­nal and Black/green terminal.

There should be continuity with the engine stop but­ton depressed, and no continuity with the button released.


Disconnect the engine stop button 3P (Black) con­nector.


CLUTCH SWITCH

INSPECTION

’05 — ’07:

TAIL LIGHT

Remove the front visor.

— ’05-’07: (page 3-5)

— After ’07: (page 3-6)

Disconnect the engine stop button 3P (Black) con­nector and clutch switch wire (Black/red) connector.

Check for continuity between the Black/brown ter­minal and Black/red wire connector.

There should be continuity with the clutch lever squeezed, and no continuity with the clutch lever released.

If the continuity is abnormal, remove the clutch switch (page 20-8).


TAIL LIGHT


REMOVAL/INSTALLATION

Remove the boot.

SCREW

CONNECTORS

TAIL LIGHT

Remove the screw, stay, clutch switch and discon — CLUTCH^MTCH nect the connectors.


Check for continuity between the clutch switch ter­minals.

CLUTCH SWITCH

TAIL LIGHT

There should be no continuity with the switch pushed, and there should be continuity with the switch is released.

If the continuity at the connectors is abnormal and the continuity at the clutch switch terminal is nor­mal, check the connectors for loose connection and the wire harness for an open circuit or loose con­nection.