ANUAL SERVICE M

IGNITION CONTROL MODULE (ICM)

REMOVAL/INSTALLATION

Remove the left side cover (page 3-3).

Disconnect the ICM connectors.

Remove the ICM from the rear fender.

Installation is in the reverse order of removal.

IGNITION COIL

INSPECTION

Remove the fuel tank (page 3-8).

Remove the spark plug cap.

Disconnect the ignition coil primary wire.

Measure the ignition coil resistance between the primary terminal and body ground.

STANDARD: 0.1 - 0.3 П (20cC/68 F)

If the resistance is out of specification, replace the ignition coil.

Measure the ignition secondary coil resistance between the primary terminal and plug cap.

STANDARD: 9 - 16 kii (20 C/68 F)

If resistance is out of range, remove the spark plug cap and measure the ignition secondary coil resis­tance between the primary terminal and spark plug wire.

STANDARD: 4 - 8 k£i (20°C/68 F)

If the resistance is out of specification, replace the ignition coil.

BOLT/CLAMP

IGNITION COIL

REMOVAL/INSTALLATION (After '07)

Remove the following:

- Fuel tank (page 3-8)

- Left radiator grill (page 7-8)

- Spark plug cap (page 4-12)

Remove the left radiator lower mounting bolt and slide the left radiator forward.

Release the siphon hose from the ignition coil stay clamp.

Disconnect the ignition coil primary wire connector. Remove the bolt and ground wire.

Remove the ignition coil/stay by unhooking the igni­tion coil stay boss from the left radiator lower mount.

IGNITION TIMING

NOTE:

• The ignition timing is factory preset and only needs to be checked when an electrical system component is replaced.

Warm up the engine to normal operating tempera­ture.

Stop the engine and remove the timing hole cap. Connect the timing light to the spark plug wire.

Attach a tachometer according to its manufacture's instructions.

Read the instruction for timing light operation.

Start the engine and hold it at 1,800 ±100 rpm while pointing the timing light towards the index notch.

The ignition timing is correct if the "F" mark on the flywheel aligns with the index notch in the left crankcase cover.

F" MARK

Check that the O-ring is in good condition, replace it if necessary.

Apply oil to the O-ring and install it onto the timing hole cap.

Apply grease to the timing hole cap threads.

Install the timing hole cap and tighten it to the spec­ified torque.

TORQUE: 10 N m (1.0 kgf-m, 7 Ibf ft)

O-RING

THROTTLE POSITION SENSOR INSPECTION

Remove the fuel tank (page 3-8).

Disconnect the throttle position sensor 3P (Black) connector.

Measure the resistance between the Blue and Black wire terminals of the sensor side connector.

STANDARD: 4 - 6 k£2 (20 C/68; F)

Check that the resistance between the Yellow and Black wire terminals varies with the throttle position while operating the throttle grip.

Fully closed-Fully open position:

Resistance increases Fully open-Fully closed position:

Resistance decreases

If both measurements are abnormal, replace the throttle position sensor (page 6-26).

ELECTRIC STARTER

COMPONENT LOCATION

'05 - '07 shown:

SYSTEM DIAGRAM

SERVICE INFORMATION

GENERAL

NOTICE

If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged.

• The starter motor can be serviced with the engine in the frame.

• When checking the electric starter system, always follow the steps in the troubleshooting (page 19-4).

• Always disconnect the negative cable at the battery before servicing the starter motor. The motor could suddenly start, causing serious injury.

• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.

Refer to the following components information.

- Engine stop button (page 20-7)

- Starter switch (page 20-9)

- Clutch switch (page 20-8)

- Starter clutch (page 11-19)

SPECIFICATION

TORQUE VALUE

Starter motor case bolt 3.4 N m (0.3 kgf-m, 2.5 lbf-ft)

TROUBLESHOOTING

Starter motor does not turn

1. Fuse Inspection

Check for blown fuse (15 A).

Is the fuse blown?

YES - Replace the fuse.

NO - GO TO STEP 2.

2. Battery Inspection

Make sure the battery is fully charged and in good condition.

Is the battery in good condition?

YES - GO TO STEP 3.

NO - Charge or replace the battery (page 17-6).

3. Starter Relay Switch Operation

Check the starter relay switch operation.

You should hear the relay "CLICK" when the starter switch is depressed and pull the clutch lever.

Is there a "CLICK"?

YES - GO TO STEP 4.

NO - GO TO STEP 5.

4. Starter Motor Inspection

Apply battery voltage directly to the starter motor and check the operation.

Does the starter motor turn?

YES - • Poorly connected starter motor cable

• Faulty starter relay switch

NO - Faulty starter motor.

5. Relay Coil Ground Line Inspection

Disconnect the starter relay switch connector, then check for continuity between the green wire ter­minal of the wire harness side and body ground.

Is there continuity?

NO - • Open circuit in wire harness

• Loose or poor contact connector

YES - GO TO STEP 6.

6. Starter Relay Switch Input Line Inspection

Connect the starter relay switch connector.

Pull the clutch lever and engine starter switch is pushed, measure the voltage at the starter relay switch connector (between Yellow/red (+) and body ground (-)).

Is the input line normal?

YES - GO TO STEP 7.

NO - • Faulty clutch switch (page 20-8)

• Faulty engine starter switch (page 20-9)

• Loose or poor contact of the related connector terminal

• Open circuit in the wire harness

7. Starter Relay Switch Continuity Inspection

Connect the starter relay switch connector.

Pull the clutch lever and engine starter switch is pushed, check for continuity at the starter relay switch.

Is there continuity7

YES - Loose or poor contact of the starter relay switch connector.

NO - Faulty starter relay switch.

Starter motor turns engine slowly

• Low battery voltage

• Poorly connected battery cable

• Poorly connected starter motor cable

• Faulty starter motor

• Poorly connected ground cable terminal

Starter motor turns, but engine does not turn

• Starter motor is running backwards - Case assembled improperly

• Faulty starter clutch

• Damaged starter gear train

Starter relay switch clicks, but engine does not turn over

• Crankshaft does not turn due to engine problems