Service Manual: S&T Motors Co., LTD

S&T Motors Co., Ltd.
SERVICE MANUAL
SERVICE MANUAL
99000-51320
FOREWORD GROUP INDEX
This manual contains an introductory description on

HYOSUNG『』&『
and procedures for its inspection / service and
』 GENERAL INFORMATION 1
overhaul of its main components.
It covers the differences from Carburetor type and
please refer to the service manual of『
EI SYSTEM DIAGNOSIS 4-1
(99000-51210)』,『 &
(99000-94910)』 and『 (99000-94810)』
for others which are not covered in this manual.
Other information considered as generally known is
FUEL SYSTEM AND THROTTLE BODY 4-2
not included.
Read GENERAL INFORMATION section to
familiarize yourself with outline of the vehicle and
MAINTENANCE and other sections to use as a guide
ELECTRICAL SYSTEM 6
for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum SERVICING INFORMATION 8
and quick service.
This manual has been prepared on the basis

of the latest specification at the time of
publication.
If modification has been made since then,
difference may exist between the content of
this manual and the actual vehicle.
Illustrations in this manual are used to show
the basic principles of operation and work
procedures.
They may not represent the actual vehicle
exactly in detail.
WARNING
This manual is intended for those who have
enough knowledge and skills for servicing
HYOSUNG vehicles. Without such knowledge and
skills, you should not attempt servicing by relying
on this manual only.
Instead, please contact your nearby authorized
HYOSUNG motorcycle dealer.
NOTE
『』model :
『』model :
COPYRIGHT S&T Motors Co., Ltd.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE
LOOKING FOR :
1. The text of this manual is divided into sections.
2. As the title of these sections are listed on the previous
page as GROUP INDEX, select the section where you
are looking for.
3. Holding the manual as shown at the right will allow you
to find the first page of the section easily.
4. On the first page of each section, its contents are listed.
Find the item and page you need.
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing.
The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Apply THREAD LOCK“1324”
.
Data beside it indicates specified torque.
Apply oil.
Apply or use brake fluid.
Use engine oil unless otherwise specified.
Apply SUPER GREASE“A”

. Measure in voltage range.
Apply SUPER GREASE“C”

. Measure in resistance range.
Apply SILICONE GREASE. Measure in current range.
Apply MOLY PASTE. Measure in diode test range.
Apply BOND“1215”
. Measure in continuity test range.
Use fork oil. Use special tool.
Use engine coolant.
2
ABBREVIATIONS USED IN THIS MANUAL
A L
ABDC : After Bottom Dead Center LCD : Liquid Crystal Display
AC : Alternating Current LED : Light Emitting Diode
API : American Petroleum Institute LH : Left Hand
ATDC : After Top Dead Center
M
B
Max : Maximum
BBDC : Before Bottom Dead Center Min : Minimum
BDC : Bettom Dead Center
BTDC : Before Top Dead Center O
O2 Sensor : Oxygen Sensor (O2S)
D
DC : Direct Current R
DOHC : Double Over Head Camshaft
RH : Right Hand
RO Switch : Roll Over Switch
E
ECU : Engine Control Unit, S
EI Control Unit SAE : Society of Automotive Engineers
EI : Electric fuel Injection, SAV Solenoid : Secondary Air Valve Solenoid
Electric fuel Injector
T
F TDC : Top Dead Center
FP : Fuel Pump TP Sensor : Throttle Position Sensor (TPS)
G W
GP Switch : Gear Position Switch WT Sensor : Water Temperature Sensor
(WTS)
I
IAP Sensor : Intake Air Pressure Sensor
(IAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
ISC Solenoid : Idle Speed Control Solenoid
3
WIRE COLOR
B : Black Gr : Gray Sb : Light blue

L : Blue Lg : Light green W : White
Br : Brown O : Orange Y : Yellow
G : Green R : Red
BL : Black with Blue tracer BBr : Black with Brown tracer
BG : Black with Green tracer BO : Black with Orange tracer
BR : Black with Red tracer BW : Black with White tracer
BY : Black with Yellow tracer LB : Blue with Black tracer
LG : Blue with Green tracer LR : Blue with Red tracer
LW : Blue with White tracer LY : Blue with Yellow tracer
BrB : Brown with Black tracer BrW : Brown with White tracer
GB : Green with Black tracer GR : Green with Red tracer
GY : Green with Yellow tracer GrB : Gray with Black tracer
GrR : Gray with Red tracer GrW : Gray with White tracer
OB : Orange with Black tracer OL : Orange with Blue tracer
OG : Orange with Green tracer OR : Orange with Red tracer
OW : Orange with White tracer OY : Orange with Yellow tracer
RB : Red with Black tracer RW : Red with White tracer
WB : White with Black tracer WL : White with Blue tracer
WR : White with Red tracer YB : Yellow with Black tracer
YL : Yellow with Blue tracer YG : Yellow with Green tracer
YR : Yellow with Red tracer
4
GENERAL INFORMATION
1
CONTENTS
EXTERIOR PHOTOGRAPH ………………………………………………………… 6 (1-7-1)
EXTERIOR ILLUSTRATION~ ₩………………………………… 7 (1-7-2)

EXTERIOR ILLUSTRATION~ ₩……………………………… 8 (1-7-3)
EXTERIOR ILLUSTRATION~ ₩……………………………… 9 (1-7-4)
SPECIFICATIONS~ & ₩ ………………… 10 (1-8-1)
SPECIFICATIONS~ & ₩ …………… 12 (1-9-1)
FUNCTION OF EI SENSOR ………………………………………………………… 14 (1-9-3)
5
1-7-1 GENERAL INFORMATION
EXTERIOR PHOTOGRAPH
6
GENERAL INFORMATION 1-7-2
EXTERIOR ILLUSTRATION~ ₩
Rear turn signal lamp
Brake / Tail lamp

Rear
reflector License plate lamp
(WIDTH)
Head lamp Front turn signal lamp
Passenger footrests
(HEIGHT)
(WHEEL BASE)
(LENGTH)
7
Rear
reflector Rear turn signal lamp
Brake / Tail lamp
License plate lamp
(WIDTH)
Passenger footrests
(HEIGHT)
(WHEEL BASE)
(LENGTH)
8
(WIDTH)
Rear turn signal lamp
Brake / Tail lamp
Rear License plate lamp
Passenger footrests
reflector
(HEIGHT)
(WHEEL BASE)
(LENGTH)
9
SPECIFICATIONS~ & ₩
⊙ DIMENSIONS AND MASS

ITEM
Overall length 2,430 mm (95.7 in) 2,095 mm (82.5 in)
Overall width 890 mm (35.0 in) 785 mm (30.9 in)
Overall height 1,155 mm (45.5 in) 1,125 mm (44.3 in)
Wheelbase 1,665 mm (65.6 in) 1,445 mm (56.9 in)
Ground clearance 160 mm (6.3 in) 185 mm (7.3 in)
Mass 220 kg (485 lbs) 210 kg (463 lbs)
⊙ ENGINE
ITEM
Type Four-stroke, DOHC, Liquid-cooled ←
Number of cylinder V-2 cylinder ←
Bore 81.5 mm (3.21 in) ←
Stroke 62.0 mm (2.44 in) ←
Piston displacement 647 ㎤ (39.5 in3 ) ←
Fuel system Electric fuel Injection ←
Starter system Electric starter ←
Lubrication system Wet sump ←
⊙ TRANSMISSION
ITEM
Clutch Wet multi-plate type ←
Transmission 5-speed constant mesh 6-speed constant mesh
Gearshift pattern 1-down, 4-up 1-down, 5-up
Final reduction 2.69 2.93
1st 2.46 2.46
2nd 1.78 1.60
3rd 1.38 1.32
Gear ratio
4th 1.13 1.13
5th 0.96 0.96
6th - 0.85
Drive belt / chain Poly chain belt RK525XSO 108 links
10
⊙ CHASSIS
ITEM
Front suspension Telescopic type ←
Rear suspension Swingarm type ←
Steering angle 35˚(right & left) 30˚(right & left)
Caster 35˚ 25.5˚
Trail 160 mm (6.3 in) 85 mm (3.35 in)
Front brake Double disk brake ←
Rear brake Disk brake ←
Front tire size 120/70 - ZR 18 59W 120/60 - ZR 17 55W
Rear tire size 180/55 - ZR 17 73W 160/60 - ZR 17 69W
Front fork stroke 130 mm (5.12 in) 120 mm (4.72 in)
⊙ ELECTRICAL
ITEM
Ignition type ECU ←
Ignition timing 5˚B.T.D.C. at 2,000 rpm ←
Spark plug CR8E ←
Battery 12 V 12 Ah (MF) ←
Main 30 A ←
Fuse
Head lamp 15 A ←
HI 12 V - H4 : 60 W ×1 ←
Head lamp
LO 12 V - H4 : 55 W ×1 ←
Position 12 V - W5 W ×1 ←
Turn signal lamp 12 V - RY10 W × 4 ←
Brake / Tail lamp LED type ←
License plate lamp 12 V - W5 W × 1 ←
Illumination lamp - LED type
High beam indicator lamp LED type ←
Turn signal indicator lamp(right & left) LED type ←
Neutral indicator lamp LED type ←
Fuel indicator lamp LED type (Level type) ←
Coolant temperature indicator lamp LED type (Level type) ←
“FI”(Fuel Injection) check lamp LED type ←
⊙ CAPACITIES
ITEM
Fuel tank 16.0 ℓ 17.0 ℓ
Oil change 3,000 ㎖ ←
Engine oil Oil and filter change 3,200 ㎖ ←
Engine overhaul 3,400 ㎖ ←
Front fork oil capacity (One side) 420 cc 400 cc
NOTE
The specifications are subject to change without notice.
11
SPECIFICATIONS~ & ₩
⊙ DIMENSIONS AND MASS

ITEM
Overall length 2,095 mm (82.5 in) ←
Overall width 785 mm (30.9 in) 700 mm (27.6 in)
Overall height 1,135 mm (44.7 in) ←
Wheelbase 1,445 mm (56.9 in) ←
Ground clearance 185 mm (7.3 in) 165 mm (6.5 in)
Mass 210 kg (463 lbs) 215 kg (474 lbs)
⊙ ENGINE
ITEM
Type Four-stroke, DOHC, Liquid-cooled ←
Number of cylinder V-2 cylinder ←
Bore 81.5 mm (3.21 in) ←
Stroke 62.0 mm (2.44 in) ←
Piston displacement 647 ㎤ (39.5 in3 ) ←
Fuel system Electric fuel Injection ←
Starter system Electric starter ←
Lubrication system Wet sump ←
⊙ TRANSMISSION
ITEM
Clutch Wet multi-plate type ←
Transmission 6-speed constant mesh ←
Gearshift pattern 1-down, 5-up ←
Final reduction 2.93 ←
1st 2.46 ←
2nd 1.60 ←
3rd 1.32 ←
Gear ratio
4th 1.13 ←
5th 0.96 ←
6th 0.85 ←
Drive chain RK525XSO 108 links ←
12
⊙ CHASSIS
ITEM
Front suspension Telescopic type ←
Rear suspension Swingarm type ←
Steering angle 27˚(right & left) ←
Caster 25.5˚ ←
Trail 74 mm (2.91 in) ←
Front brake Double disk brake ←
Rear brake Disk brake ←
Front tire size 120/60 - ZR 17 55W ←
Rear tire size 160/60 - ZR 17 69W ←
Front fork stroke 120 mm (4.72 in) ←
⊙ ELECTRICAL
ITEM
Ignition type ECU ←
Ignition timing 5˚B.T.D.C. at 2,000 rpm ←
Spark plug CR8E ←
Battery 12 V 12 Ah (MF) ←
Main 30 A ←
Fuse
Head lamp 15 A ←
HI 12 V - H1 : 55 W ×1 ←
Head lamp
LO 12 V - H3 : 55 W ×1 ←
Position 12 V - W5 W ×1 ←
Turn signal lamp 12 V - RY10 W × 4 ←
Brake / Tail lamp LED type ←
License plate lamp 12 V - W5 W × 1 ←
Illumination lamp LED type ←
High beam indicator lamp LED type ←
Turn signal indicator lamp(right & left) LED type ←
Neutral indicator lamp LED type ←
Fuel indicator lamp LED type (Level type) ←
Coolant temperature indicator lamp LED type (Level type) ←
“FI”(Fuel Injection) check lamp LED type ←
⊙ CAPACITIES
ITEM
Fuel tank 17.0 ℓ ←
Oil change 3,000 ㎖ ←
Engine oil Oil and filter change 3,200 ㎖ ←
Engine overhaul 3,400 ㎖ ←
Front fork oil capacity (One side) 400 cc ←
NOTE
The specifications are subject to change without notice.
13
FUNCTION OF EI SENSOR
★ ECU (Engine Control Unit, EI Control Unit)
: ECU decide the fuel injection volume and ignition time to adjust the fuel injector opening and closing rate
which is considered the engine speed, intake air pressure, intake air volume, engine temperature, oxygen
volume and throttle opening angle, etc.
★ EI (Electric fuel Injector)

: EI spray the fuel to intake pipe by ECU’s injection signal.
Fuel which is needed combustion in the combustion chamber is supplied from the fuel tank.
★ GP switch (Gear Position Switch)

: GP switch is used when start / stop and control ECU as the converted electrical signal of the gear position is
supplied ECU.
★ IAP sensor (Intake Air Pressure Sensor : IAPS)

: IAP sensor measure the pressure which is generated from the intake pipe and compare with the provided
absolute pressure, then analogize the air volume indirectly and help to work the fuel injector properly.
★ IAT sensor (Intake Air Temperature Sensor : IATS)

: IAT sensor perceive the atmospheric temperature and is located the air cleaner case.
★ ISC solenoid (Idle Speed Control Solenoid)

: ISC solenoid is interlocked with the throttle body, so ECU control the engine idle speed.
★ O2 sensor (Oxygen Sensor : O2S)

: O2 sensor measure the oxygen volume from the exhaust gas and convert the oxygen volume into voltage
value, then communicate the output voltage to ECU.
★ Pick-up Coil
: Pick-up coil perceive the front and rear cylinder’s engine speed and realtime of piston position.
★ RO switch (Roll Over Switch)

: RO switch is the fuel cut-off system when the motorcycle is leaned over 60°for upset accident.
★ SAV solenoid (Secondary Air Valve Solenoid)

: SAV solenoid supply the fresh air to the exhaust pipe for decrease of the exhaust gas.
★ TP sensor (Throttle Position Sensor : TPS)

: TP sensor detect the throttle opening angle and is located the throttle body.
It decide the fuel injection volume and compensate the ignition time as inform idle·acceleration·
deceleration condition and throttle full opening etc. to ECU.
★ WT sensor (Water Temperature Sensor : WTS)

: WT sensor is located on the cylinder block’s water jacket, the intake pipe or the cylinder head coolant
passage’s thermostat part for contact with the coolant.
WT sensor is the NTC (Negative Temperature Coefficient) resister that measure the coolant temperature and
inform ECU.
14
EI SYSTEM DIAGNOSIS
CONTENTS
PRECAUTIONS IN SERVICING ……………………………………… 16 (4-1-1)
4 -1
EI SYSTEM TECHNICAL FEATURES ……………………………… 20 (4-1-5)
SELF-DIAGNOSIS FUNCTION ……………………………………… 27 (4-1-12)
EI SYSTEM TROUBLESHOOTING ………………………………… 30 (4-1-15)
CUSTOMER COMPLAINT ANALYSIS………………………………… 30 (4-1-15)
SELF-DIAGNOSTIC PROCEDURES ………………………………… 32 (4-1-17)
SELF-DIAGNOSIS RESET PROCEDURE …………………………… 33 (4-1-18)
MALFUNCTION CODE AND DEFECTIVE CONDITION …………… 34 (4-1-19)
“C12”PICK-UP COIL CIRCUIT MALFUNCTION …………………… 36 (4-1-21)
“C14”TP SENSOR CIRCUIT MALFUNCTION ……………………… 37 (4-1-22)
“C15”WT SENSOR CIRCUIT MALFUNCTION ……………………… 40 (4-1-25)
“C17”o“
r C18”IAP SENSOR CIRCUIT MALFUNCTION …………… 42 (4-1-27)
“C21”IAT SENSOR CIRCUIT MALFUNCTION ……………………… 44 (4-1-29)
“C22”OXYGEN SENSOR CIRCUIT MALFUNCTION ……………… 46 (4-1-31)
“C23”RO SWITCH CIRCUIT MALFUNCTION ……………………… 47 (4-1-32)
“C24”o“
r C25”IGNITION COIL MALFUNCTION …………………… 48 (4-1-33)
“C31”GP SWITCH CIRCUIT MALFUNCTION ……………………… 49 (4-1-34)
“C32”o“
r C33”FUEL INJECTOR CIRCUIT MALFUNCTION ……… 50 (4-1-35)
“C41”FUEL PUMP RELAY CIRCUIT MALFUNCTION ……………… 52 (4-1-37)
SENSORS ………………………………………………………………… 53 (4-1-38)
15
4-1-1 EI SYSTEM DIAGNOSIS
PRECAUTIONS IN SERVICING
When handling the component parts or servicing the
EI system, observe the following points for the safety
of the system.
⊙ ELECTRICAL PARTS
▣ CONNECTOR / COUPLER
● When connecting a connector, be sure to push it
in until a click is felt.
● With a lock type coupler, be sure to release the
lock when disconnecting, and push it in fully till the
works when connecting it.
● When disconnecting the coupler, be sure to hold
the coupler body and do not pull the lead wires.
● Inspect each terminal on the connector / coupler
for looseness or bending.
● Inspect each terminal for corrosion and

contamination.
The terminals must be clean and free of any
foreign material which could impede proper
terminal contact.
● Inspect each lead wire circuit for poor connection

by shaking it by hand lightly. If any abnormal
condition is found, repair or replace.
● When taking measurements at electrical

connectors using a tester probe, be sure to insert
the probe from the wire harness side (backside) of
the connector / coupler.
16
EI SYSTEM DIAGNOSIS 4-1-2
● When connecting meter probe from the terminal

side of the coupler (connection from harness side
not being possible), use extra care not to force
and cause the male terminal to bend or the female
terminal to open.
Connect the probe as shown to avoid opening of
female terminal.
Never push in the probe where male terminal is
supposed to fit.
● Check the male connector for bend and female
connector for excessive opening. Also check the
coupler for locking (looseness), corrosion, dust,
etc.
⊙ FUSE
● When a fuse blows, always investigate the cause
to correct it and then replace the fuse.
● Do not use a fuse of a different capacity.
● Do not use wire or any other substitute for the
fuse.
⊙ ECU / VARIOUS SENSORS

● Since each component is a high-precision part,
great care should be taken not to apply any sharp
impacts during removal and installation.
● Be careful not to touch the electrical terminals of

the ECU.
The static electricity from your body may damage
this part.
17
● When disconnecting and connecting the ECU,

make sure to turn “OFF” the ignition switch, or
electronic parts may get damaged.
● Battery connection in reverse polarity is strictly

prohibited.
Such a wrong connection will damage the
components of the EI system instantly when
reverse power is applied.
● Removing any battery terminal of a running

engine is strictly prohibited.
The moment such removal is made, damaging
counter electromotive force will be applied to the
ECU which may result in serious damage.
● Before measuring voltage at each terminal, check

to make sure that battery voltage is 11V or higher.
Terminal voltage check at low battery voltage will
lead to erroneous diagnosis.
18
● Never connect an ohmmeter to the ECU with its

coupler connected. If attempted, damage to the
ECU or sensors may result.
● Be sure to use a specified voltmeter / ohmmeter.
Otherwise, accurate measurements may not be
obtained and personal injury may result.
⊙ USING TESTERS
● Use well-charged batteries in the tester.
● Be sure to set the tester to the correct testing
range.
▣ USING THE TESTER

● Incorrectly connecting the and probes may
cause the inside of the tester to burnout.
● If the voltage and current are not known, make
measurements using the highest range.
● After using the tester, turn the power off.
19
EI SYSTEM TECHNICAL FEATURES

⊙『』&『』EI SYSTEM’S CONTROL
DIAGRAM
ECU
IAT Sensor AIR FUEL
AIR CLEANER FUEL TANK
TP Sensor ISC Solenoid FUEL PUMP
THROTTLE BODY
SAV Solenoid
IAP Sensor INTAKE PIPE
FUEL INJECTOR
WT Sensor
Pick-up Coil CYLINDER
O2 Sensor EXHAUST PIPE
: Electrical signal flow

MUFFLER
: Air flow EXHAUST GAS
: Fuel flow
: Exhaust gas flow
20
⊙ INJECTION TIME (INJECTION VOLUME)

The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of
intake air pressure, engine speed and throttle opening angle, and various compensations.
These compensations are determined according to the signals from various sensors that detect the engine and
driving conditions.
ECU
Intake Air Pressure Sensor Intake air pressure signal

(IAP Sensor)
Basic
Engine speed signal fuel
Pick-up coil
injection
time
Throttle Position Sensor Throttle opening signal
(TP Sensor)
Various signals
Various Sensors Compensation
Ultimate
Injection signal fuel
Injectors
injection
time
21
⊙ COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensation of the fuel injection time
(volume).
SIGNAL DESCRIPTION
WATER COOLANT TEMPERATURE When engine coolant temperature is low, injection time (volume)
SENSOR SIGNAL is increased.
INTAKE AIR TEMPERATURE SENSOR When intake air temperature is low, injection time (volume) is
SIGNAL increased.
ECU operates on the battery voltage and at the same time, it
monitors the voltage signal for compensation of the fuel injection
BATTERY VOLTAGE SIGNAL time (volume). A longer injection time is needed to adjust
injection volume in the case of low voltage.
ENGINE RPM SIGNAL At high speed, the injection time (volume) is increased.
When starting engine, additional fuel is injected during cranking
STARTING SIGNAL engine.
During acceleration, the fuel injection time (volume) is increased
ACCELERATION SIGNAL / in accordance with the throttle opening speed and engine rpm.
DECELERATION SIGNAL During deceleration, the fuel injection time (volume) is
decreased.
⊙ INJECTION STOP CONTROL

SIGNAL DESCRIPTION
When the motorcycle rolls over, the roll over switch sends a
ROLL OVER SWITCH SIGNAL
signal to the ECU. Then, this signal cuts OFF current supplied to
(FUEL CUT-OFF)
the fuel pump, fuel injector and ignition coil.
The fuel injectors stop operation when engine rpm reaches rev.
OVER-REV. LIMITER SIGNAL
limit rpm.
22
⊙ EI SYSTEM PARTS LOCATION~ ₩
5
2 ECU
4 6
9 3
8
7
① Speedometer ⑥ Fuel injector, NO.2

② Fuel pump relay ⑦ GP switch
③ Fuel injector, NO.1 ⑧ Pick-up coil
④ TP sensor ⑨ Ignition coil, NO.1
⑤ IAT sensor
23
1 2 13
ECU
10 11
14
15
⑩ RO switch ⑬ IAP sensor, NO.1

⑪ Ignition coil, NO.2 ⑭ WT sensor
⑫ IAP sensor, NO.2 ⑮ Oxygen sensor
24
⊙ EI SYSTEM PARTS LOCATION~ ₩
ECU
8 5
2 4
3
7
6
① Speedometer ⑤ IAT sensor

② Fuel injector, NO.1 ⑥ GP switch
③ TP sensor ⑦ Pick-up coil
④ Fuel injector, NO.2 ⑧ Ignition coil, NO.1
25
9
ECU
13 11
12
10
14
15
⑨ Fuel pump relay ⑬ IAP sensor, NO.2

⑩ RO switch ⑭ WT sensor
⑪ Ignition coil, NO.2 ⑮ Oxygen sensor
⑫ IAP sensor, NO.1
26
SELF-DIAGNOSIS FUNCTION
The self-diagnosis function is incorporated in the ECU.
The function has two modes, “USER MODE” and “DEALER MODE”.
The user can only be notified by the LCD(DISPLAY) panel ① and the “FI” check lamp “ ” ②.
To check the function of the individual EI system devices, the dealer mode is prepared.
In this check, the special tool is necessary to read the code of the malfunction items.
⊙ USER MODE
LCD (DISPLAY) “FI” CHECK LAMP INDICATION
MALFUNCTION
INDICATION ① INDICATION ② MODE
“NO” Speedometer - -
“YES” Speedometer “FI” check lamp Each 2 sec.
and comes on. Speedometer or “FI”
“FI” letters letters is indicated.
Engine can start A
Engine can not “FI” letters “FI” check lamp comes “FI” letters is indicated
start B on and blinks. continuously.
A
When one of the signals is not received by the ECU, the fail-safe circuit works and injection is not stopped.
In this case, “FI” letters and speedometer are indicated in the LCD panel ① and motorcycle can run.
B
The injection signal is stopped, when the pick-up coil signal, roll over switch signal, NO.1 & NO.2 ignition signals,
NO.1 & NO.2 injector signals, fuel pump relay signal or ignition switch signal is not sent to the ECU.
In this case, “FI” letters is indicated in the LCD panel ① continuously. Motorcycle does not run.
“CHE” : The LCD panel ① indicates “CHE” letters when no communication signal from the ECU is received for 3
seconds.
For example, The ignition switch is turned “ON” position, and the engine stop switch is turned “ ” position.
In this case, the speedometer does not receive any signal from the ECU, and the LCD panel ① indicates “CHE”
letters.
If “CHE” letters is indicated, the LCD panel ① does not indicate the trouble code.
The possible cause of this indication is as follows, Engine stop switch is in “ ” position. Ignition fuse is burnt.
It is necessary to check the wiring harness between the ECU and speedometer couplers.
② ① ①
27
⊙ DEALER MODE
The defective function is memorized in the ECU.
Use the special tool’s coupler to connect to the dealer mode coupler. (Refer to page 4-1-17)
The memorized malfunction code is displayed on LCD (DISPLAY) panel .
Malfunction means that the ECU does not receive signal from the devices.
These affected devices are indicated in the code form.
Mode select switch : 09900-27000
28
CAUTION
Do not disconnect the ECU lead wire couplers, before checking the malfunction code, or the malfunction
code memory is erased and the malfunction code can not be checked.
Confirm the malfunction code after turn the ignition switch “ON” position or cranking the engine for few
seconds.
LCD (DISPLAY) “FI” CHECK LAMP INDICATION

MALFUNCTION
INDICATION INDICATION MODE
“NO” C -
C** code is indicated “FI” check lamp

goes off. For each 2 sec.,
“YES” from small numeral to
code is indicated.
large one.
CODE MALFUNCTION PART REMARKS

C None No defective part
C12 Pick-up coil
C14 Throttle position sensor (TPS)
C15 Water temperature sensor (WTS)
C17 Intake air pressure sensor (IAPS), NO.1 For NO.1 cylinder
C18 Intake air pressure sensor (IAPS), NO.2 For NO.2 cylinder
C21 Intake air temperature sensor (IATS)
C22 Oxygen sensor (O2S)
C23 Roll over switch (RO switch)
C24 Ignition coil, NO.1 For NO.1 cylinder
C25 Ignition coil, NO.2 For NO.2 cylinder
C31 Gear position switch (GP switch)
C32 Fuel injector, NO.1 For NO.1 cylinder
C33 Fuel injector, NO.2 For NO.2 cylinder
C41 Fuel pump relay
In the LCD (DISPLAY) panel , the malfunction code is indicated from small code to large code.
29
EI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper
analysis and diagnosis.
▣ EXAMPLE : CUSTOMER PROBLEM INSPECTION FORM

User name : Model : VIN :
Date of issue : Date Reg. : Date of problem : Mileage :
“FI” Check lamp Always ON Sometimes ON Always OFF Good condition
Malfunction display / code

No code Malfunction code ( )
(LCD panel)
PROBLEM SYMPTOMS
Difficult Starting Poor Driveability
No cranking Hesitation on acceleration
No initial combustion Back fire / After fire
No combustion Lack of power
Poor starting at Surging
( cold warm always) Abnormal knocking
Other Engine rpm jumps briefly
Other
Poor Idling Engine Stall when

Poor fast Idle Immediately after start
Abnormal idling speed Throttle valve is opened
( High Low) ( rpm) Throttle valve is closed
Unstable Load is applied
Hunting ( rpm. to rpm) Other
Other
OTHERS :
30
MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather Fair Cloudy Rain Snow Always Other
Temperature Hot Warm Cool Cold ( °F / °C) Always
Frequency Always Sometimes ( times / day, month) Only once
Under certain condition
Road Urban Suburb Highway Mountainous ( Uphill Downhill)
Tarmacadam Gravel Other
Motorcycle condition
Engine condition Cold Warming up phase Warmed up Always Other at starting
Immediately after start Racing without load Engine speed ( rpm)
Motorcycle condition During driving : Constant speed Accelerating Decelerating

Right hand corner Left hand corner At stop
Motorcycle speed when problem occurs ( km/h, Mile/h)
Other
NOTE
The above form is a standard sample.
If should be modified according to conditions characteristic of each market.
31
SELF-DIAGNOSTIC PROCEDURES
Don’t disconnect couplers from ECU, battery cable
from battery, ECU ground wire harness from engine
or main fuse before confirming malfunction code
(self-diagnostic trouble code) stored in memory.
Such disconnection will erase memorized information
in ECU memory.
Malfunction code stored in ECU memory can be
checked by the special tool.
To check malfunction code, read SELF-DIAGNOSIS
FUNCTION “DEALER MODE” (Refer to page
4-1-13, 14) carefully to have good understanding as
to what functions are available and how to use it.
Be sure to read “PRECAUTIONS for Electrical Circuit

Service” (Refer to page 4-1-1) before inspection and
observe what is written there.
● Remove the seat. ( )
● Remove the rear seat. ( )
● Connect the special tool to the dealer mode
coupler at the wiring harness, and the ignition
switch is set to “ON” position.
● Turn the special tool’s switch “ON” position and
check the malfunction code to determine the
malfunction part.
Mode select switch : 09900-27000
NOTE
The dealer mode coupler is located under the
seat. ( )
The dealer mode coupler is located under the
rear seat. ( )
32
SELF-DIAGNOSIS RESET PROCEDURE

● After repairing the trouble, turn the ignition switch
“OFF” position and turn “ON” position again. ①
● If “C ”(LCD INDICATION ①) is indicates, the
malfunction codes are cleared.
● Disconnect the special tool from the dealer mode
coupler.
33
MALFUNCTION CODE AND DEFECTIVE CONDITION

MALFUNCTION DETECTED FAILURE CONDITION
DETECTED ITEM
CODE CHECK FOR
C NO FAULT -
After ECU receiving the ignition switch signal, the pick-up coil
signal does not reach ECU for more than 3 sec..
C12 Pick-up coil In this case, the code C12 is indicated.
Pick-up coil wiring and mechanical parts.

(Pick-up coil, lead wire coupler connection)
The sensor should produce following voltage.

Throttle position sensor 0.1 V sensor output voltage 4.8 V
C14 Without the above range for 2 sec. and more, C14 is indicated.
(TPS)
Throttle position sensor, lead wire / coupler connection.
The sensor voltage should be the following.

Water temperature 0.08 V sensor output voltage 4.65 V
sensor (WTS)
Water temperature sensor, lead wire / coupler connection.
Intake air pressure 0.40 V sensor output voltage 4.75 V
C17 / C18 sensor (IAPS), Without the above range for 6 sec. and more, C17 or C18 is
indicated.
NO.1 / NO.2
Intake air pressure sensor, lead wire / coupler connection.

Intake air temperature 0.08 V sensor output voltage 4.75 V
sensor (IATS)
Intake air temperature sensor, lead wire / coupler connection.
After the engine run, the oxygen sensor signal is inputted in
ECU since then 600 sec..
C22 Oxygen sensor (O2S) When this is the case, ECU not receive the signal, C22 is
indicated.
Oxygen sensor, lead wire / coupler connection.
After holding the motorcycle vertically and the ignition switch
turns “ON” position, the switch resistance should be the
Roll over switch following for more than 3 sec..
C23 switch resistance ∞Ω(Infinity)
(RO switch)
Without the above value for 3 sec. and more, C23 is indicated.
Roll over switch, lead wire / coupler connection.
34

DETECTED ITEM
CODE CHECK FOR
Ignition signal is interrupted continuous by 31 times or more
when ECU confirm ignition surge at each combustion chamber.
Ignition coil (IG coil),
C24 / C25 In this case, the code C24 or C25 is indicated.
NO.1 / NO.2
Ignition coil, wiring / coupler connection, power supply from the
battery.
It judges from gear position voltage, engine speed and throttle
position by ECU, 0.15 V < Gear position switch output voltage <
3.93 V for more 5 sec..
Gear position switch
C31 If gear position switch voltage get out of the above voltage, C31
(GP switch)
is indicated.
Gear position switch, wiring / coupler connection, gearshift cam
etc.
Injector signal is interrupted continuous for more than 1 sec.

when ECU confirm injector running surge at each combustion
Fuel injector,
C32 / C33 chamber, C32 or C33 is indicated.
NO.1 / NO.2
Injector, wiring / coupler connection, power supply to the
injector.
Voltage is applied continuous for more than 5 sec., battery
voltage 3.2 V when the fuel pump relay is “OFF” position or
battery voltage < 1.5 V when the fuel pump relay is “ON”
C41 Fuel pump relay position.
In this case, the code C41 is indicated.
Fuel pump relay, connecting lead wire, power source to fuel
pump relay, fuel injector.
35
“C12” PICK-UP COIL CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
After ECU receiving the ignition switch signal, the ● Metal particles or foreign materiel being attached
pick-up coil signal does not reach ECU for more than on the pick-up coil and rotor tip.
3 sec.. ● Pick-up coil circuit open or short.
● Pick-up coil malfunction.
● ECU malfunction.
▣ INSPECTION
1) Remove the frame cover.
2) Turn the ignition switch “OFF” position. ①
3) Check the pick-up coil coupler ① for loose or poor
contacts.
If OK, then measure the pick-up coil resistance.
4) Disconnect the pick-up coil coupler ① and

measure the resistance.
110 ~ 140 Ω
Pick-up coil resistance
(G - L)
Ω)
Tester knob indication : Resistance (Ω
5) If OK, then check the continuity between each

terminal and ground.
∞ Ω (Infinity)
Pick-up coil continuity (G - Ground)
(L - Ground)
Ω)
Are the resistance and continuity OK?

J2
● L or G wire open or shorted to
ground, or poor J2 or J3
connection of ECU coupler.
● If wire and connection are OK,
YES
intermittent trouble or faulty ECU.
● Recheck each terminal and wire
harness for open circuit and poor
connection.
● Loose or poor contacts on the pick-
up coil coupler or ECU coupler. J3
NO ECU Coupler
● Replace the pick-up coil with a new
one.
36
“C14” TP SENSOR CIRCUIT MALFUNCTION

Output voltage is out of the specified range for 2 sec. ● TP sensor circuit open or short.
and more.
0.1 V Sensor output voltage 4.8 V ● TP sensor malfunction.
▣ INSPECTION
◈ Step 1
1) Turn the ignition switch “OFF” position.
2) Check the TP sensor coupler for loose or poor
contacts.
If OK, then measure the TP sensor input voltage.
3) Disconnect the TP sensor coupler ①.
4) Turn the ignition switch “ON” position.

5) Measure the voltage at the OB wire and ground.
6) If OK, then measure the voltage at the OB wire
and GR wire.
4.9 ~ 5.1 V
TP sensor input
( OB - Ground )
voltage
( OB - GR )
Tester knob indication : Voltage ( )
Is the input voltage OK?
YES Go to Step 2.
● Loose or poor contacts on the
ECU coupler.
NO
● Open or short circuit in the OB
wire or GR wire.
37
◈ Step 2
3) Disconnect the TP sensor coupler.
4) Check the continuity between (LY) and ground.
TP sensor continuity ∞ Ω (Infinity)

( - Ground)
Ω)
Ground
Is the continuity OK?

YES Go to Step 3.
Replace the TP sensor with a new
NO
one.
38
◈ Step 3
1) Connect the TP sensor coupler.
2) Insert the needle pointed probes to the lead wire
coupler.
Measure the TP sensor output voltage at the
coupler~between ( : LY) and ( : GR)₩
by turning the throttle grip.
TP sensor output voltage

Throttle valve is closed Approx. 1.02 ~ 1.22 V
Throttle valve is opened Approx. 4.30 ~ 4.70 V
Is the output voltage OK?

● OB, LY or GR wire open or
shorted to ground, or poor B2 , B2
F3 , or B4 connection of ECU
coupler.
YES
intermittent trouble or faulty
ECU.
harness for open circuit and
poor connection. F3 B4
ECU Coupler
If check result is not satisfactory,
NO replace the TP sensor with a new
one.
39
“C15” WT SENSOR CIRCUIT MALFUNCTION

Output voltage is out of the specified range for 2 sec. ● WT sensor circuit open or short.
and more. ● WT sensor malfunction.
0.08 V Sensor output voltage 4.65 V
▣ INSPECTION
2) Check the WT sensor coupler for loose or poor
contacts.
If OK, then measure the WT sensor resistance.
☞ Refer to the service manual『
(99000-51210)』page 5-7
(99000-94810)』page 5-7
3) Disconnect the WT sensor coupler.

4) Measure the resistance between the terminals ①
and ③.
0.1163 ~ 48.1400 ㏀
~When Water
WT sensor resistance temperature is
-40℃ ~ 120℃
(-40℉ ~ 248℉) ₩
Tester knob indication : Resistance (㏀)

Water
① ③
40
WT sensor resistance
Engine Coolant Temp. Resistance (To ECU)
-40 ℃ (-40 ℉) Approx. 48.140 ㏀
0 ℃ (32 ℉) Approx. 5.790 ㏀
20 ℃ (68 ℉) Approx. 2.450 ㏀
40 ℃ (104 ℉) Approx. 1.148 ㏀
60 ℃ (140 ℉) Approx. 0.586 ㏀
80 ℃ (176 ℉) Approx. 0.322 ㏀
120 ℃ (248 ℉) Approx. 0.1163 ㏀
Is the resistance OK?

● G or GR wire open or shorted to
G1
ground, or poor G1 or C4
( )
● Br or GR wire open or shorted to
ground, or poor G1 or C4
YES
( )
intermittent trouble or faulty C4
ECU Coupler
ECU.
poor connection.
Replace the WT sensor with a new
NO
one.
41
“C17” or “C18” IAP SENSOR CIRCUIT MALFUNCTION

IAP sensor output voltage is out of the specified range ● Clogged vacuum passage between throttle body
for 6 sec. and more. and IAP sensor.
0.40 V Sensor output voltage 4.75 V ● Air being drawn from vacuum passage between
NOTE : throttle body and IAP sensor.
Note that atmospheric pressure varies depending on ● IAP sensor circuit open or shorted to ground.
weather conditions as well as altitude. ● IAP sensor malfunction.
Take that into consideration when inspecting voltage. ● ECU malfunction.
▣ INSPECTION
◈ Step 1
1) Remove the fuel tank. ①
3) Check the IAP sensor NO.1 coupler ① and NO.2
coupler ② for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
4) Disconnect the IAP sensor couplers NO.1 ③ and

NO.2 ④.
6) Measure the input voltage at the OB wire and
ground.
If OK, then measure the input voltage at the OB
wire and GR wire.
4.5 ~ 5.5 V
IAP sensor input
( OB - Ground )
voltage ( OB - GR ) ②
Is the input voltage OK?
YES Go to Step 2.
● Loose or poor contacts on the ECU
coupler.
NO ● Open or short circuit in the OB wire
or GR wire. ③ ④
42
◈ Step 2
1) Connect the IAP sensor couplers NO.1 ① and ①
NO.2 ②.
2) Insert the needle pointed probes to the lead wire
coupler.
3) Start the engine at idle speed.
4) Measure the IAP sensor output voltage at the wire
side coupler (between BL~ NO.1₩or BY~NO.2₩
and GR wires).
Approx. 2.7 V at idle speed

IAP sensor
~NO.1₩
( BL - GR,
output voltage
~NO.2₩ BY - GR)
Is the voltage OK?

● OB(NO.1), OB(NO.2), BL(NO.1),
BY(NO.2) or GR wire open or ②
shorted to ground, or poor A1
(NO.1), A2 (NO.2), F1 (NO.1),
G2 (NO.2), B4 connection of G2 F1
YES
ECU coupler. A1
intermittent trouble or faulty
ECU. A2
poor connection.
If check result is not satisfactory,
NO replace the IAP sensor with a new
ECU Coupler B4
one.
Output voltage
(Input voltage 5 V, ambient temp. 25 °C, 77 °F)
ALTITUDE ATMOSPHERIC OUTPUT
(Reference) PRESSURE VOLTAGE
(ft) (m) (mmHg) kPa (V)
0 0 760 100
Approx.
3.7 ~ 3.9
2 000 610 707 94
2 001 611 707 94
Approx.
3.3 ~ 3.7
5 000 1 524 634 85
5 001 1 525 634 85
Approx.
3.0 ~ 3.3
8 000 2 438 567 76
8 001 2 439 567 76
Approx.
2.7 ~ 3.0
10 000 3 048 526 70
43
“C21” IAT SENSOR CIRCUIT MALFUNCTION

Output voltage is out of the specified range for 2 sec. ● IAT sensor circuit open or short.
and more. ● IAT sensor malfunction.
0.08 V Sensor output voltage 4.75 V
▣ INSPECTION
1) Remove the fuel tank.
3) Check the IAT sensor coupler for loose or poor
contacts.
If OK, then measure the IAT sensor resistance.
4) Disconnect the IAT sensor coupler.
5) Measure the resistance between the terminals ①

and ②.
0.081 ~ 48.352 ㏀ ①
~When Intake air ②
IAT sensor resistance temperature is
-40℃ ~ 130℃
(-40℉ ~ 266℉) ₩
NOTE
IAT sensor resistance measurement method is
the same way as that of the WT sensor.
(99000-51210)』page 5-7
(99000-94810)』page 5-7
44
IAT sensor resistance

Intake Air Temp. Resistance
-40 ℃ (-40 ℉) 44.642 ㏀ ± 5%
-20 ℃ (-4 ℉) 14.958 ㏀ ± 5%
0 ℃ (32 ℉) 5.734 ㏀ ± 5%
20 ℃ (68 ℉) 2.438 ㏀ ± 5%
40 ℃ (104 ℉) 1.141 ㏀ ± 5%
60 ℃ (140 ℉) 0.579 ㏀ ± 5%
80 ℃ (176 ℉) 0.315 ㏀ ± 5%
100 ℃ (212 ℉) 0.182 ㏀ ± 5%
120 ℃ (248 ℉) 0.111 ㏀ ± 5%
130 ℃ (266 ℉) 0.088 ㏀ ± 5%
● Lg or GR wire open or shorted to

ground, or poor G3 or B4
YES intermittent trouble or faulty
ECU.
poor connection.
ECU Coupler G3 B4
Replace the IAT sensor with a new
NO
one.
45
“C22” OXYGEN SENSOR CIRCUIT MALFUNCTION

After the engine run, the oxygen sensor signal is not ● Oxygen sensor, Oxygen sensor heater circuit open
inputted in ECU since then 600 sec.. or short.
● Oxygen sensor, Oxygen sensor heater malfunction.
▣ INSPECTION
1) Remove the seat.
3) Check the Oxygen sensor coupler for loose or
poor contacts.
Is OK?
H1
● B or GR wire open or shorted to
ground, or poor H1 or C4
(Sensor side)
● OB or B wire open or shorted to
ground, or poor C3 or H3
YES
(Heater side) C3
intermittent trouble or faulty H3 ECU Coupler C4
ECU.
poor connection.
Replace the Oxygen sensor with a
NO
new one. Sensor side Heater side
GR B B OB
46
“C23” RO SWITCH CIRCUIT MALFUNCTION

After holding the motorcycle vertically and the ignition ● RO switch circuit short or leaned more than 60。
.
switch turns “ON” position, the switch resistance ● RO switch malfunction.
should be the following for more than 3 sec..
Switch resistance ∞Ω(Infinity)
▣ INSPECTION
1) Remove the seat.
3) Check the RO switch coupler for loose or poor
contacts.
If OK, then measure the RO switch resistance.
4) Disconnect the RO switch coupler.
5) Measure the resistance at the wire coupler (switch

side) between BW and YL wires of the RO switch
at horizontal place.
∞ Ω (Infinity)
RO switch resistance at normal condition
( BW - YL )
Also, measure the resistance when leaning of the
motorcycle.
6) Measure the resistance when it is leaned more

than 60。
, left and right, from the horizontal level.
0 Ω
RO switch resistance at leaned more than 60。
( BW - YL )
Ω)
47

E2
● B or GR wire open or shorted to
ground, or poor E2 or C4
YES intermittent trouble or faulty
ECU.
connection.
● Loose or poor contacts on the ECU Coupler C4
ECU coupler.
● Open or short circuit in the B
NO
wire or GR wire.
● Replace the RO switch with a
new one.
“C24” or “C25” IGNITION COIL MALFUNCTION

Refer to the IGNITION COIL for details.
[Refer to the service manual『 (99000-51210)』page 6-5,
Refer to the service manual『 (99000-94810)』page 6-5]
48
“C31” GP SWITCH CIRCUIT MALFUNCTION

GP switch output voltage is out of the specified range ● GP switch circuit open or short.
for 5 sec. and more. ● GP switch malfunction.
0.15 V < Switch output voltage < 3.93 V ● ECU malfunction.
▣ INSPECTION
3) Check the GP switch coupler for loose or poor
contacts.
If OK, then measure the GP switch resistance.
4) Park the motorcycle on a firm, flat surface

vertically.
5) Turn the side-stand to up-right position.
6) Make sure the engine stop switch is in the “ ”
position.
7) Insert the needle pointed probes to the GP switch
coupler.
9) Measure the resistance at the wire side coupler
between GL wire and L wire, when shifting the
gearshift lever from 1st to Top.
GP switch resistance 100 Ω ~ 2.0 ㏀

(GL - L)

● GL or L wire open or shorted to F2
ground, or poor F2 or E3
YES
connection.
Open or short circuit in the GL or L
NO E3
wire. ECU Coupler
49
“C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION

Injector signal is interrupted continuous for more than ● Injector circuit open or short.
1 sec. when ECU confirm injector running surge at ● Injector malfunction.
each combustion chamber. ● ECU malfunction.
▣ INSPECTION
◈ Step 1
1) Remove the fuel tank and frame cover.
2) Turn the ignition switch “OFF” position. ①
3) Check the injector couplers NO.1 ① and NO.2 ②
for loose or poor contacts.
If OK, then measure the injector resistance.
4) Disconnect the injector couplers NO.1 ① and

NO.2 ② and measure the resistance between
terminals.
Injector resistance 11.4 ~ 12.6 Ω

at 20℃ (68℉)
Tester knob indication : Resistance ( Ω) ②
5) If OK, then check the continuity between injector

terminals and ground.
Injector continuity ∞ Ω (Infinity)

Tester knob indication : Resistance ( Ω)
Are the resistance and continuity OK?

YES Go to Step 2
Replace the Injector with a new
NO
one.
50
◈ Step 2
2) Measure the injector voltage between YR(NO.1) or
RB(NO.2) wire and ground.
Battery voltage
Injector voltage ~NO.1₩
( YR - Ground,
~NO.2₩ RB - Ground )
NOTE NO.1
Injector voltage can be detected only 3
seconds after ignition switch is turned “ON”
position.
NO.2
Is the voltage OK?

L1
● YR(NO.1), RB(NO.2) wire open or
shorted to ground, or poor L1
(NO.1), L2 (NO.2) connection of
ECU coupler.
YES ● If wire and connection are OK,
● Recheck each terminal and wire L2
connection.
Inspect the fuel pump or fuel pump ECU Coupler
NO
relay. (Refer to page 4-2-5)
51
“C41” FUEL PUMP RELAY CIRCUIT MALFUNCTION

Voltage is applied continuous for more than 5 sec., ● Fuel pump relay circuit open or short.
battery voltage 3.2 V when the fuel pump relay is ● Fuel pump relay malfunction.
“OFF” position or battery voltage < 1.5 V when the ● ECU malfunction.
fuel pump relay is “ON” position.
▣ INSPECTION
3) Check the fuel pump relay coupler for loose or
poor contacts.
If OK, then check the insulation and continuity.
Refer to page 4-2-5 for details.
Is the Fuel pump relay OK?

E1
● GW or BBr wire open or shorted
to ground, or poor L4 or E1
YES
connection.
● Inspect the fuel injectors.
(Refer to page 4-1-35) L4 ECU Coupler
Replace the fuel pump relay with a
NO
new one.
52
SENSORS ①
⊙ PICK-UP COIL INSPECTION
The pick-up coil ① is installed in the magneto cover.
(Refer to page 4-1-21)
⊙ PICK-UP COIL REMOVAL AND

INSTALLATION
● Remove the magneto cover.
● Install the magneto cover in the reverse order of
removal.
⊙ IAP SENSOR INSPECTION

The intake air pressure (IAP) sensors NO.1 ② and ②
NO.2 ③ are installed at the downside of the air
cleaner. (Refer to page 4-1-27)
⊙ IAP SENSOR REMOVAL AND

INSTALLATION
● Remove the fuel tank.
● Remove the IAP sensor from the downside of the
air cleaner.
● Install the IAP sensor in the reverse order of
removal.
⊙ TP SENSOR INSPECTION
The throttle position (TP) sensor ④ is installed at the
left side of the throttle body. (Refer to page 4-1-22)
⊙ TP SENSOR REMOVAL AND ④

INSTALLATION
CAUTION
Never remove or adjust the TP sensor.
53
⊙ WT SENSOR INSPECTION
The water temperature (WT) sensor ① is installed at
the rear side of the thermostat case.
⊙ WT SENSOR REMOVAL AND

INSTALLATION ①
● Remove the WT sensor.
● Install the WT sensor in the reverse order of
removal.
·m (0.5 ~ 0.8 kgf·
WT sensor : 5 ~ 8 N· ·m)
⊙ IAT SENSOR INSPECTION

The intake air temperature (IAT) sensor ② is ②
installed at the downside of the air cleaner case.
⊙ IAT SENSOR REMOVAL AND

INSTALLATION
● Remove the IAT sensor from the air cleaner case.
● Install the IAT sensor in the reverse order of
removal.
⊙ RO SWITCH INSPECTION,
REMOVAL AND INSTALLATION ③
The roll over (RO) switch ③ is located in the
downside of the fuel tank mounting bolts.
● Romove the seat.
● Remove the RO switch from the frame.
● Install the RO switch in the reverse order of
removal.
54
FUEL SYSTEM AND THROTTLE BODY
CONTENTS
FUEL SYSTEM …………………………………………………………… 56 (4-2-1)
REMOVAL AND DISASSEMBLY ………………………………………… 58 (4-2-3)
REASSEMBLY AND INSTALLATION …………………………………… 59 (4-2-4)
FUEL PRESSURE OF FUEL PUMP INSPECTION …………………… 60 (4-2-5)
4 -2
FUEL PUMP RELAY INSPECTION ……………………………………… 60 (4-2-5)
FUEL MESH FILTER INSPECTION AND CLEANING ………………… 61 (4-2-6)
FUEL GAUGE INSPECTION……………………………………………… 61 (4-2-6)
THROTTLE BODY……………………………………………………… 62 (4-2-7)
REMOVAL ………………………………………………………………… 63 (4-2-8)
CLEANING ………………………………………………………………… 64 (4-2-9)
INSPECTION ……………………………………………………………… 64 (4-2-9)
INSTALLATION …………………………………………………………… 64 (4-2-9)
CAUTION
Gasoline must be handled carefully in an area well ventilated and away from fire or spark.
55
4-2-1 FUEL SYSTEM AND THROTTLE BODY
FUEL SYSTEM
56
FUEL SYSTEM AND THROTTLE BODY 4-2-2
57
REMOVAL AND DISASSEMBLY

● Remove the seat. ( )
● Remove the front seat. ( )
● Remove the fuel tank mounting bolts and fuel tank

bracket mounting bolt. ( )
● Remove the fuel tank mounting bolts and take off
the hooks. ( )
● Disconnect the fuel gauge coupler ①.
● Remove the fuel pump coupler ②.

● Remove the fuel injector hose ③.
CAUTION
After disconnecting the fuel injector hose ③,
insert a blind plug into the end to stop fuel ③
leakage.
58
● Remove the fuel tank rearward.
CAUTION
As gasoline leakage may occur in this operation,
keep away from fire and sparks.
● Remove the fuel pump assembly ① by removing

its mounting bolts diagonally.
WARNING ①
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
● Remove the fuel gauge ②.
REASSEMBLY AND INSTALLATION

Reassembly and installation the fuel tank in the
reverse order of removal and disassembly.
● When installing the fuel pump assembly, first
tighten all the fuel pump assembly mounting bolts
lightly in diagonal stages, and then tighten them
in the above tightening order.
NOTE
Apply a small quantity of the THREAD LOCK
“1324” to the thread portion of the fuel pump
mounting bolt.
THREAD LOCK “1324”
59
FUEL PRESSURE OF FUEL

PUMP INSPECTION
● Remove the seat.
● Place a rag under the fuel injector hose.
● Disconnect the fuel injector hose from the fuel
hose joint.
● Install the special tool between the fuel tank and
fuel hose joint.
Fuel pump pressure gauge
: 09915-54510
Turn the ignition switch “ON” position and check the

fuel pressure of the fuel pump.
Fuel pressure Approx. 2.96 ~ 3.16 kgf/cm2

of fuel pump (290 ~ 310 kPa, 42.06 ~ 44.96 psi)
If the fuel pressure is lower than the specification,

inspect the following items :
* Fuel hose leakage
* Clogged fuel filter
* Pressure regulator
* Fuel pump
If the fuel pressure is higher than the specification,

inspect the following items :
* Fuel pump check valve
* Pressure regulator
WARNING
● Before removing the special tool, turn the
ignition switch to “OFF” position and release
the fuel pressure slowly.
● Gasoline is highly flammable and explosive.
Keep heat, sparks and flame away.
FUEL PUMP RELAY INSPECTION

Fuel pump relay is located the left side of the frame. ①
● Remove the frame cover.
● Remove the fuel pump relay ①.
60
First, check the insulation between ① and ②

terminals with pocket tester. Then apply 12 volts to ① ③
③ and ④ terminals, to ③ and to ④, and check
the continuity between ① and ②.
If there is no continuity, replace it with a new one.
② ④
FUEL MESH FILTER INSPECTION

AND CLEANING
● If the fuel mesh filter is clogged with sediment or
rust, fuel will not flow smoothly and loss in engine
power may result.
● Blow the fuel mesh filter with compressed air.
NOTE
If the fuel mesh filter is clogged with many
sediment or rust, replace the fuel filter cartridge
with a new one.
FUEL GAUGE INSPECTION

● Measure resistance between the terminals when
float is at the position instead below.
Fuel float position Resistance between terminals

F Approx. 90 ~ 100 Ω
1/2 Approx. 38 Ω
E Approx. 4 ~ 10 Ω
● If the resistance measured is out of the

specification, replace the gauge with a new one.
● Inspect the fuel level meter.
61
THROTTLE BODY
62
REMOVAL
● Disconnect the fuel hoses.
● Remove the all couplers to related the throttle
body.
● Loosen the throttle body clamp screws.
● Remove the air cleaner box.

● Disconnect the throttle cables from their drum.
● Dismount the throttle body assembly.
CAUTION
Be careful not to damage the throttle cable
bracket when dismounting or remounting the
throttle body assembly.
After disconnecting the throttle cables, do not
snap the throttle valve from full open to full
close. It may cause damage to the throttle
valve and throttle body.
63
CLEANING
● Clean all passageways with a spray-type throttle
body cleaner and blow dry with compressed air.
WARNING
Some throttle body cleaning chemicals,
especially dip-type soaking solutions, are very
corrosive and must be handled carefully. Always
follow the chemical manufacturer’s instructions
on proper use, handling and storage.
CAUTION
Do not use wire to clean passageways. Wire can
damage passageways. If the components cannot
be cleaned with a spray cleaner it may be
necessary to use a dip-type cleaning solution and
allow them to soak. Always follow the chemical
manufacturer’s instructions for proper use and
cleaning of the throttle body components. Do not
apply throttle body cleaning chemicals to the
rubber and plastic materials.
INSPECTION
● Check following items for any damage or clogging.
* O-ring * Throttle body
①
* Injector cushion seal * Fuel injector
* Throttle valve * Vacuum hose
* Intake pipe
* Throttle shaft bushing and seal
Check fuel injector filter for evidence of dirt and
contamination. If present, clean and check for
presence of dirt in the fuel lines and fuel tank.
INSTALLATION
Installation is in the reverse order of removal.
Pay attention to the following points :
CAUTION
Never operate the idle screw ① to avoid
variations of the carburetion setting.
● Connect the throttle cable to the throttle cable

drum.
● Adjust the throttle cable play with the cable
adjusters.
64
ELECTRICAL SYSTEM
CONTENTS
LOCATION OF ELECTRICAL COMPONENTS ………………… 66 (6-1)

IGNITION SYSTEM ……………………………………………………… 68 (6-3)
CHARGING SYSTEM …………………………………………………… 69 (6-7)
65
6-1 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
④ ⑥ ⑦ ⑧ ⑩
⑤ ⑨ ⑬
① ⑪
② ③
① Ignition coil NO.1 ④ Cooling fan motor relay ⑨ Fuel pump relay ⑪ Battery
② Main fuse (30A) ⑤ Head lamp relay ⑩ Turn signal relay ⑫ ECU
③ Head lamp fuse (15A) ⑥ Regulator / Rectifier ⑬ RO switch
⑦ Side stand relay
⑧ Main relay
⑭ ⑮
⒕
⒃
⑭ TP sensor ⑮ IAT sensor ⒃ Magneto
⒔ Pick-up coil
⒕ GP switch
66
ELECTRICAL SYSTEM 6-2
⒖ (23)
⒗
(22)
(24)
(21)
⒖ SAV solenoid ⒗ IAP sensor NO.2 (23) Starter motor relay
(21) Ignition coil NO.2 (24) ISC solenoid
(22) IAP sensor NO.1
(25)
(27)
(26)
(25) Oxygen sensor (26) Fuel injector NO.2 (27) Fuel injector NO.1
67
6-3 ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SWITCH
ENGINE STOP SWITCH
Y
IGNITION COIL, NO.1
IGNITION COIL, NO.2 G FUSE

REGULATOR
Y
ECU /
RECTIFIER
L
BATTERY
Y
12V 12Ah
⊙ INSPECTION
▣ MAGNETO
Using the pocket tester, measure the resistance Charging coil
between the lead wires in the following table.
If the resistance is not within the specified value,
replace the stator coil, with a new one.
Stator coil resistance Standard

Pick-up coil G-L 110 ~ 140 Ω
Pick-up coil
Charging coil Y-Y 0.2 ~ 0.4 Ω
Tester knob indication : Resistance ( Ω)
CAUTION
When mounting the stator on magneto cover,
apply a small quantity of THREAD LOCK “1324”
to the threaded parts of screws.
THREAD LOCK“1324”
”
68
ELECTRICAL SYSTEM 6-7
CHARGING SYSTEM
Regulator / Rectifier
Ignition switch
A. C generator
Battery
IC
LOAD
▣ REGULATOR / RECTIFIER
Disconnect the regulator / rectifier couplers.
Measure the voltage between the terminals using the
pocket tester as indicated in the table below.
If the voltage is not within the specified value, replace
the regulator / rectifier with a new one.
Unit : V
Tester probe
① ② ③ ④ ⑤
Tester probe
① 0 0 0 0.4~0.7
② 0 0 0 0.4~0.7
③ 0 0 0 0.4~0.7
④ 0.4∼0.7 0.4∼0.7 0.4∼0.7 0.5~1.2 ①
⑤ 0 0 0 0 ④
Tester knob indication : Diode test (+ )
②
③
⑤
69
70
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING ………………………………………………… 72 (8-1-1)
SPECIAL TOOLS ……………………………………………………… 81 (8-9)
TIGHTENING TORQUE ……………………………………………… 82 (8-12)
SERVICE DATA ………………………………………………………… 83 (8-18)
WIRING DIAGRAM~ ₩……………………………… 86 (8-30-1)
WIRING DIAGRAM~ ₩………………………………… 88 (8-30-3)
WIRING DIAGRAM~ & ₩ ……… 90 (8-30-5)
8
71
8-1-1 SERVICING INFORMATION
TROUBLESHOOTING
⊙ MALFUNCTION CODE AND DEFECTIVE CONDITION
DETECTED ITEM
CODE CHECK FOR
C NO FAULT -
After ECU receiving the ignition switch signal, the pick-up coil
signal does not reach ECU for more than 3 sec..
C12 Pick-up coil In this case, the code C12 is indicated.
Pick-up coil wiring and mechanical parts.

(Pick-up coil, lead wire coupler connection)

Throttle position sensor 0.1 V sensor output voltage 4.8 V
(TPS)
Throttle position sensor, lead wire / coupler connection.

Water temperature 0.08 V sensor output voltage 4.65 V
sensor (WTS)
Water temperature sensor, lead wire / coupler connection.
Intake air pressure 0.40 V sensor output voltage 4.75 V
C17 / C18 sensor (IAPS), Without the above range for 6 sec. and more, C17 or C18 is
indicated.
NO.1 / NO.2
Intake air pressure sensor, lead wire / coupler connection.

Intake air temperature 0.08 V sensor output voltage 4.75 V
sensor (IATS)
Intake air temperature sensor, lead wire / coupler connection.
After the engine run, the oxygen sensor signal is inputted in
ECU since then 600 sec..
C22 Oxygen sensor (O2S) When this is the case, ECU not receive the signal, C22 is
indicated.
Oxygen sensor, lead wire / coupler connection.
After holding the motorcycle vertically and the ignition switch
turns “ON” position, the switch resistance should be the
Roll over switch following for more than 3 sec..
C23 switch resistance ∞Ω(Infinity)
(RO switch)
Without the above value for 3 sec. and more, C23 is indicated.
Roll over switch, lead wire / coupler connection.
72
SERVICING INFORMATION 8-1-2

DETECTED ITEM
CODE CHECK FOR
Ignition signal is interrupted continuous by 31 times or more
when ECU confirm ignition surge at each combustion chamber.
Ignition coil (IG coil),
C24 / C25 In this case, the code C24 or C25 is indicated.
NO.1 / NO.2
Ignition coil, wiring / coupler connection, power supply from the
battery.
It judges from gear position voltage, engine speed and throttle
position by ECU, 0.15 V < Gear position switch output voltage <
3.93 V for more 5 sec..
Gear position switch
C31 If gear position switch voltage get out of the above voltage, C31
(GP switch)
is indicated.
Gear position switch, wiring / coupler connection, gearshift cam
etc.
Injector signal is interrupted continuous for more than 1 sec.

when ECU confirm injector running surge at each combustion
Fuel injector,
C32 / C33 chamber, C32 or C33 is indicated.
NO.1 / NO.2
Injector, wiring / coupler connection, power supply to the
injector.
Voltage is applied continuous for more than 5 sec., battery
voltage 3.2 V when the fuel pump relay is “OFF” position or
battery voltage < 1.5 V when the fuel pump relay is “ON”
C41 Fuel pump relay position.
In this case, the code C41 is indicated.
Fuel pump relay, connecting lead wire, power source to fuel
pump relay, fuel injector.
73
⊙ ENGINE
Complaint Symptom and possible causes Remedy
Engine will not Compression too low
start or is hard to 1. Tappet clearance out of adjustment. Adjust.
start. 2. Worn valve guides or poor seating of valves. Repair or replace.
3. Mistimed valves. Adjust.
4. Excessively worn piston rings. Replace.
5. Worn-down cylinder bore. Replace.
6. Starter motor cranks too slowly. See electrical section.
7. Poor seating of spark plugs. Retighten.
Plug not sparking

1. Fouled spark plugs. Clean.
2. Wet spark plugs. Clean and dry.
3. Defective ignition coils. Replace.
4. Open or short in high-tension cord. Replace.
5. Defective pick-up coil. Replace.
6. Defective ECU. Replace.
7. Open-circuited wiring connections. Repair or replace.
No fuel reaching the intake manifold

1. Clogged fuel filter or fuel hose. Clean or replace.
2. Defective fuel pump. Replace.
3. Defective fuel pressure regulator. Replace.
4. Defective fuel injector. Replace.
5. Defective fuel pump relay. Replace.
7. Open-circuited wiring connections. Check and repair.
Incorrect fuel/air mixture

1. TP sensor out of adjustment. Adjust.
4. Defective TP sensor. Replace.
6. Defective IAP sensor. Replace.
8. Defective WT sensor. Replace.
9. Defective IAT sensor. Replace.
74

Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust.
2. Poor seating of valves. Replace or repair.
3. Defective valve guides. Replace.
4. Worn down camshafts. Replace.
5. Too wide spark plug gaps. Adjust or replace.
11. Imbalanced throttle valve or SAV solenoid. Adjust.
12. Damaged or cracked vacuum hose. Replace.
Engine stalls Incorrect fuel / air mixture

often. 1. Defective IAP sensor or circuit. Repair or replace.
2. Clogged fuel filter. Clean or replace.
6. Defective thermostat. Replace.
8. Damaged or cracked vacuum hose. Replace.
Fuel injector improperly operating

1. Defective fuel injectors. Replace.
2. No injection signal from ECU. Repair or replace.
3. Open or short circuited wiring connection. Repair or replace.
4. Defective battery or low battery voltage. Replace or recharge.
Control circuit or sensor improperly operating

7. Defective fuel pump relay. Replace.
Engine internal parts improperly operating

1. Fouled spark plugs. Clean.
2. Defective pick-up coil or ECU. Replace.
3. Clogged fuel hose. Clean.
4. Tappet clearance out of adjustment. Adjust.
75

Noisy engine. Excessive valve chatter
1. Too large tappet clearance. Adjust.
2. Weakened or broken valve springs. Replace.
3. Worn tappet or cam surface. Replace.
4. Worn and burnt camshaft journal. Replace.
Noise seems to come from piston

1. Worn down pistons or cylinders. Replace.
2. Combustion chambers fouled with carbon. Clean.
3. Worn piston pins or piston pin bore. Replace.
4. Worn piston rings or ring grooves. Replace.
Noise seems to come from cam chain

1. Stretched chain. Replace.
2. Worn sprockets. Replace.
3. Tension adjuster not working. Repair or replace.
Noise seems to come from clutch

1. Worn splines of countershaft or hub. Replace.
2. Worn teeth of clutch plates. Replace.
3. Distorted clutch plates, driven and drive. Replace.
4. Worn clutch release bearing. Replace.
5. Weakened clutch dampers. Replace the primary driven gear.
Noise seems to come from crankshaft

1. Rattling bearings due to wear. Replace.
2. Worn and burnt big-end bearings. Replace.
3. Worn and burnt journal bearings. Replace.
Noise seems to come from transmission

1. Worn or rubbing gears. Replace.
2. Worn splines. Replace.
3. Worn bearings. Replace.
4. Worn or rubbing primary gears. Replace.
Noise seems to come from water pump

1. Too much play on pump shaft bearing. Replace.
2. Worn or damaged impeller shaft. Replace.
3. Worn or damaged mechanical seal. Replace.
4. Contact between pump case and impeller. Replace.
76

Engine runs poorly Defective engine internal / electrical parts
in high speed range. 1. Weakened valve springs. Replace.
2. Worn camshafts. Replace.
3. Valve timing out of adjustment. Adjust.
4. Too narrow spark plug gaps. Adjust.
5. Ignition not advanced sufficiently due to poorly working timing Replace ECU.
advance circuit.
9. Clogged fuel hose, resulting in inadequate fuel supply to injector. Clean and prime.
12. Defective SAV solenoid. Replace.
13. Clogged air cleaner element. Clean.
Defective air flow system

1. Clogged air cleaner element. Clean or replace.
2. Defective throttle valve. Adjust or replace.
3. Sucking air from throttle body joint. Repair or replace.
Defective control circuit or sensor

1. Low fuel pressure. Repair or replace.
77

Engine lacks Defective engine internal / electrical parts
power. 1. Loss of tappet clearance. Adjust.
2. Weakened valve springs. Replace.
3. Valve timing out of adjustment. Adjust.
4. Worn piston rings or cylinders. Replace.
5. Poor seating of valves. Repair.
6. Fouled spark plugs. Clean or replace.
7. Incorrect spark plugs. Adjust or replace.
8. Clogged injectors. Clean.
10. Clogged air cleaner element. Clean.
11. Sucking air from throttle valve or vacuum hose. Retighten or replace.
12. Too much engine oil. Drain out excess oil.
13. Defective fuel pump or ECU. Replace.
14. Defective pick-up coil and ignition coils. Replace.
Defective control circuit or sensor

1. Low fuel pressure. Repair or replace.
8. Defective GP switch. Replace.
Engine overheats. Defective engine internal parts

1. Heavy carbon deposit on piston crowns. Clean.
2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Replace or clean.
4. Sucking air from intake pipes. Retighten or replace.
5. Use incorrect engine oil. Change.
6. Defective cooling system. See radiator section.
Lean fuel / air mixture

1. Short-circuited IAP sensor / lead wire. Repair or replace.
2. Short-circuited IAT sensor / lead wire. Repair or replace.
3. Sucking air from intake pipe joint. Repair or replace.
4. Defective fuel injectors. Replace.
6. Defective cooling system. Consult radiator section.
The other factors

1. Ignition timing too advanced due to defective timing advance Replace.
system (WT sensor, pick-up coil, GP switch and ECU).
2. Drive belt / chain is too tight. Adjust.
78

Dirty or heavy 1. Too much engine oil in the engine. Check with inspection win-
exhaust smoke. dow, drain out excess oil.
2. Worn piston rings or cylinders. Replace.
3. Worn valve guides. Replace.
4. Cylinder wall scored or scuffed. Replace.
5. Worn valves stems. Replace.
6. Defective stem seals. Replace.
7. Worn side rails. Replace.
Slipping clutch. 1. Weakened clutch springs. Replace.

2. Worn or distorted pressure plates. Replace.
3. Distorted clutch plates or pressure plates. Replace.
Dragging clutch. 1. Some clutch springs weakened while others are not. Replace.
2. Distorted pressure plates or clutch plates. Replace.
Transmission will 1. Broken gearshift cam. Replace.

not shift. 2. Distorted gearshift forks. Replace.
3. Worn gearshift pawl. Replace.
Transmission will 1. Broken return spring on shift shaft. Replace.

not shift back. 2. Rubbing or sticky shift shaft. Repair or replace
3. Distorted or worn gearshift forks. Replace.
Transmission 1. Worn shifting gears on driveshaft or countershaft. Replace.

jumps out of 2. Distorted or worn gearshift forks. Replace.
gear. 3. Weakened stopper spring on gearshift stopper. Replace.
79
8-5 SERVICING INFORMATION
⊙ ELECTRICAL
No sparking or 1. Defective ignition coils or spark plug caps. Replace.
poor sparking. 2. Defective spark plugs. Replace.
5. Defective RO switch. Replace.
6. Open-circuited wiring connections. Check and repair.
Spark plug soon 1. Mixture too rich. Inspect EI system.

become fouled 2. Idling speed set too high. Inspect EI system.
with carbon. 3. Incorrect gasoline. Change.
4. Dirty element in air cleaner. Clean or replace.
5. Spark plugs too cold. Replace by hot type plug.
Spark plug 1. Worn piston rings. Replace.

become fouled 2. Pistons or cylinders worn. Replace.
too soon. 3. Excessive clearance of valve stems in valve guides. Replace.
4. Worn stem oil seal. Replace.
Spark plug 1. Spark plugs too hot. Replace by cold type plug.
electrodes 2. The engine overheats. Tune up.
overheat or burn. 3. Spark plugs loose. Retighten.
4. Mixture too lean. Inspect EI system.
Magneto charge, 1. Lead wires tend to get shorted or open-circuited or loosely Repair or retighten.
but charging connected at terminals.
rate is below the 2. Grounded or open-circuited stator coils of magneto. Replace.
specification. 3. Defective regulator / rectifier. Replace.
4. Defective cell plates in the battery. Replace the battery.
Magneto 1. Internal short - circuit in the battery. Replace the battery.

overcharges. 2. Resistor element in the regulator / rectifier damaged or defective. Replace.
3. Regulator / rectifier poorly grounded. Clean and tighten ground
connection.
Magneto does not 1. Open - or short - circuited lead wirse, or loose lead connections. Repair or replace or retighten.
charge. 2. Short - circuited, grounded or open stator coil. Replace.
3. Short - circuited or punctured regulator / rectifier. Replace.
Unstable charging. 1. Lead wire insulation frayed due to vibration resulting in Repair or replace
intermittent shorting.
2. Magneto internally shorted. Replace.
3. Defective regulator / rectifier. Replace.
Starter switch is 1. Battery run down. Recharge or replace.

not effective. 2. Defective switch contacts. Replace.
3. Brushes not seating properly on commutator in starter motor. Repair or replace.
4. Defective starter relay / ignition interlock switch. Replace.
5. Defective main fuse. Replace.
80
SERVICING INFORMATION 8-9
SPECIAL TOOLS
·Part Name·
Special tools Part Number· ·Description
09900-27000
Mode select switch
Inspect EI system sensor.
09915-54510
Fuel pump pressure gauge
Measure fuel pressure of fuel pump.
81
TIGHTENING TORQUE
⊙ EI SYSTEM PARTS
ITEM ·m
N· ·m
kgf·
Water temperature sensor (WT sensor) 5~8 0.5 ~ 0.8
Fuel injector bolt 5~8 0.5 ~ 0.8
Intake air temperature sensor (IAT sensor) 5~8 0.5 ~ 0.8
82
SERVICE DATA
⊙ EI SENSORS
ITEM SPECIFICATION NOTE
IAP sensor input voltage 4.5 ~ 5.5 V
IAP sensor output voltage Approx. 2.7 V at idle speed
TP sensor input voltage 4.9 ~ 5.1 V
Closed Approx. 1.02 ~ 1.22 V
TP sensor output voltage
Opened Approx. 4.30 ~ 4.70 V
0.081 ~ 48.352 ㏀
IAT sensor resistance ~When Intake air temperature is
-40℃ ~ 130℃ (-40℉ ~ 266℉)₩
IAT sensor resistance (each temperature) Refer to page 45 (4-1-30)
∞ Ω (Infinity) at normal condition
RO switch resistance
0 Ω at leaned more than 60。
GP switch resistance 100 Ω ~ 2.0 ㏀
Oxygen sensor heater voltage Battery voltage
⊙ THROTTLE BODY
Bore size 39
Idle rpm 1,300 ~ 1,500 rpm
Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in)
⊙ FUEL INJECTOR + FUEL PUMP

Fuel injector resistance 11.4 ~ 12.6 Ω at 20℃ (68℉)
Fuel injector voltage Battery voltage
Fuel pressure of fuel pump Approx. 2.96 ~ 3.16 kgf/cm2 (290 ~ 310 kPa, 42.06 ~ 44.96 psi)
83
⊙ THERMOSTAT + COOLING FAN + COOLANT

ITEM STANDARD LIMIT
Valve opening 88℃ (190℉)
Thermostat valve operating temperature Valve full open 100℃ (212℉)
Valve closing 83℃ (181℉)
Thermostat valve lift Over 8 mm (0.32 in) / 100℃ (212℉)
0.1163 ~ 48.1400 ㏀
WT sensor resistance ~When Water temperature is
-40℃ ~ 120℃ (-40℉ ~ 248℉)₩
-40℃ (-40℉) Approx. 48.140 ㏀
0℃ (32℉) Approx. 5.790 ㏀
20℃ (68℉) Approx. 2.450 ㏀
WT sensor resistance~To ECU₩
(each temperature) 40℃ (104℉) Approx. 1.148 ㏀
60℃ (140℉) Approx. 0.586 ㏀
80℃ (176℉) Approx. 0.322 ㏀
120℃ (248℉) Approx. 0.1163 ㏀
Cooling fan thermo-switch operating OFF→ON Approx. 95℃ (203℉)
temperature ON→OFF Approx. 88℃ (190℉)
Use an antifreeze/coolant compatible with
Engine coolant type aluminum radiator, mixed with distilled water only,
at the ratio of 50 : 50
Reserve tank side 230 ㎖

Engine coolant capacity Radiator side 430 ㎖
Engine side 940 ㎖
84
⊙ ELECTRICAL Unit : mm (in)
ITEM STANDARD NOTE

Ignition timing BTDC 5°/ 2,000 rpm
Type CR8E
Gap 0.7 ~ 0.8 (0.028 ~ 0.032)
Spark plug Hot type CR7E
Standard type CR8E
Cold type CR9E
Spark performance Over 8 mm (0.32 in)
Ignition coil primary peak voltage 150 V and more
Primary 3.5 ~ 5.5 Ω
Ignition coil resistance
Secondary 20 ~ 31 ㏀
Pick-up coil 110 ~ 140 Ω G-L
Stator coil resistance
Charging coil 0.2 ~ 0.4 Ω Y-Y
Magneto no-load voltage Over 70 V / 5,000 rpm
Battery standard charging voltage 13.5 ~ 15.0 V / 5,000 rpm
Type STX14-BS
Capacity 12V 12Ah
Battery
Standard
1.320 at 20℃ (68℉)
electrolyte S.G.
Main 30A
Fuse size
Head lamp 15A
85
WIRING DIAGRAM~ ₩
86
87
WIRING DIAGRAM~ ₩
88
89
WIRING DIAGRAM~ & ₩
90
91
Prepared by
1st Ed. JUN. 2009.
Manual No. 99000-51320

Printed in Korea
S&T Motors Co., Ltd.
SERVICE MANUAL
SERVICE MANUAL
99000-51320

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SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Apply SUPER GREASE“A”

Apply SUPER GREASE“C”

Apply SILICONE GREASE. Measure in current range.

Apply MOLY PASTE. Measure in diode test range.

Use fork oil. Use special tool.

Use engine coolant.

B : Black Gr : Gray Sb : Light blue

BL : Black with Blue tracer BBr : Black with Brown tracer

BG : Black with Green tracer BO : Black with Orange tracer

BR : Black with Red tracer BW : Black with White tracer

BY : Black with Yellow tracer LB : Blue with Black tracer

LG : Blue with Green tracer LR : Blue with Red tracer

LW : Blue with White tracer LY : Blue with Yellow tracer

GB : Green with Black tracer GR : Green with Red tracer

GY : Green with Yellow tracer GrB : Gray with Black tracer

OB : Orange with Black tracer OL : Orange with Blue tracer

OG : Orange with Green tracer OR : Orange with Red tracer

OW : Orange with White tracer OY : Orange with Yellow tracer

RB : Red with Black tracer RW : Red with White tracer

WB : White with Black tracer WL : White with Blue tracer

WR : White with Red tracer YB : Yellow with Black tracer

YL : Yellow with Blue tracer YG : Yellow with Green tracer

YR : Yellow with Red tracer

EXTERIOR PHOTOGRAPH ………………………………………………………… 6 (1-7-1)

EXTERIOR ILLUSTRATION~ ₩………………………………… 7 (1-7-2)

Rear turn signal lamp

Brake / Tail lamp

Head lamp Front turn signal lamp

Head lamp Front turn signal lamp

⊙ DIMENSIONS AND MASS

⊙ DIMENSIONS AND MASS

★ EI (Electric fuel Injector)

★ GP switch (Gear Position Switch)

★ IAP sensor (Intake Air Pressure Sensor : IAPS)

★ IAT sensor (Intake Air Temperature Sensor : IATS)

★ ISC solenoid (Idle Speed Control Solenoid)

★ O2 sensor (Oxygen Sensor : O2S)

★ RO switch (Roll Over Switch)

★ SAV solenoid (Secondary Air Valve Solenoid)

★ TP sensor (Throttle Position Sensor : TPS)

★ WT sensor (Water Temperature Sensor : WTS)

● Inspect each terminal for corrosion and

● Inspect each lead wire circuit for poor connection

● When taking measurements at electrical

● When connecting meter probe from the terminal

⊙ ECU / VARIOUS SENSORS

● Be careful not to touch the electrical terminals of

● When disconnecting and connecting the ECU,

● Battery connection in reverse polarity is strictly

● Removing any battery terminal of a running

● Before measuring voltage at each terminal, check

● Never connect an ohmmeter to the ECU with its

▣ USING THE TESTER