CONTENTS TROUBLESHOOTING 8- 2 Fl SYSTEM MALFUNCTION
Contents
1. ITEM STANDARD LIMIT Thermostat valve opening tem 86 5 89 5 C perature 188 193 F Thermostat valve lift Over 8 0 mm 0 31 in at 100 C 212 F Radiator cap valve opening e i pressure 110 kPa 1 1 kgf cm 15 6 psi Cooling fan thermo switch oper OFF ON Approx 105 C 221 F _ ating temperature ON OFF Approx 100 C 212 F Engine coolant temperature 20 C PES sensor resistance 68 F Approx 2 45 kQ 40 C 104 F Approx 1 15 60 140 F Approx 0 58 80 C 176 F Approx 0 32 Engine coolant type Use an anti freeze coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50 50 Engine coolant Reservoir Approx 250 ml tank side 0 3 0 2 US Imp qt Engine Approx 1 950 ml side 2 1 1 7 US Imp qt DRIVE TRAIN Unit mm in Except ratio ITEM STANDARD LIMIT Primary reduction ratio 1 838 57 31 Final reduction ratio 2 352 40 17 Gear ratio Low 2 666 32 12 2nd 1 933 29 15 3rd 1 500 27 18 4th 1 227 27 22 5th 1 086 25 23 1 000 24 24 Shift fork to groove clearance 0 1 0 3 0 50 0 004 0 012 0 020 Shift fork groove width 5 0 5 1 0 197 0 201 Shift fork thickness 48 4 9 E 0 189 0 193 Drive chain Type RK530SMOZ1 Links 108 links ENDLESS 20 s 319 4 length 12 6 Drive chain slack 20 30 0 8 1 2 Gearshift lever height 65 ES2. B up side B left side up side touching to the stopper tighten the union bolt r After the brake hose union touching to the stopper tighten the union bolt After positioning the clamp with the stopper lighten the clamp bolt Insert the clamp to the hole of the front fender fully N SECT A The green paint is on the right side and faces upside After the brake hose union touching to the stopper tighten the union boit SNILNOY ISOH 3HVH9 LNOHJ 528 NOLLVINHOSNI 9NIOIAH3S Face the clamp ends backward Ts Be careful not to contact the seat rail and 20 reservoir tank when installing The white paint faces outside Face the clamp ends backward es After the brake hose union touching to the stopper tighten the union bolt After the brake hose union touching to the stopper tighten the union bolt SNILNOY 3SOH HV3H NOLLVNHOSNI 5 928 SERVICING INFORMATION 8 25 FUEL TANK DRAIN HOSE ROUTING 8 26 SERVICING INFORMATION FUEL TANK INSTALLATION Apply adhesive agent to the cushion rubber D 9 DJ SERVICING INFORMATION 8 27 PAIR AIR SUPPLY SYSTEM HOSE ROUTING Matching mark White Re e SN eS
3. 4 RADIATOR COOLING SYSTEM SERVICING INFORMATION 8 9 Complaint Symptom and possible causes Remedy Engine overheats 1 Not enough engine coolant Add engine coolant 2 Radiator core clogged with dirt or scale Clean 3 Faulty cooling fan Repair or replace 4 Defective cooling fan thermo switch Replace 5 Clogged water passage Clean 6 Air trapped in the cooling circuit Bleed air 7 Defective water pump Replace 8 Use of incorrect engine coolant Replace 9 Defective thermostat Replace Engine overcools 1 Defective cooling fan thermo switch Replace 2 Extremely cold weather Put on radiator cover 3 Defective thermostat Replace 8 10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Noisy rear suspen sion Loose nuts or bolts on rear suspension Worn swingarm and suspension bearings Retighten Heavy steering 1 Overtightened steering stem nut Adjust 2 Broken bearing in steering stem Replace 3 Distorted steering stem Replace 4 Not enough pressure in tires Adjust Wobbly handlebars 1 Loss of balance between right and left front forks Replace 2 Distorted front fork Repair or replace 3 Distorted front axle or crooked tire Replace 4 Loose steering stem nut Adjust 5 Worn or incorrect tire or wrong tire pressure Adjust or replace 6 Worn b
4. 4 Improperly set rear suspension adjuster Adjust 5 Improperly set damping force adjuster Adjust 1 2 SERVICING INFORMATION 8 11 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1 Leakage of brake fluid from hydraulic system Repair or replace power 2 Worn pads Replace 3 Oil adhesion on friction surface of pads shoe Clean disc and pads 4 Worn disc Replace 5 Air in hydraulic system Bleed air 6 Not enough brake fluid in the reservoir Replenish Brake squeaking 1 Carbon adhesion on pad surface Repair surface with sandpaper 2 Tilted pad Correct pad fitting or replace 3 Damaged wheel bearing Replace 4 Loose front wheel axle or rear wheel axle Tighten to specified torque 5 Worn pads or disc Replace 6 Foreign material in brake fluid Replace brake fluid 7 Clogged return port of master cylinder Disassemble and clean master Cylinder Excessive brake lever 1 Air in hydraulic system Bleed air stroke 2 Insufficient brake fluid Replenish fluid to specified level bleed air 3 Improper quality of brake fluid Replace with correct fluid Leakage of brake 1 Insufficient tightening of connection joints Tighten to specified torque fluid 2 Cracked hose Replace 3 Worn piston and or cup Replace piston and or cup Brake drags 1 Rusty part Clean and lubricate 2 Insufficient brake lever or brake pedal pivot lubrication Lubricate 8 12 SERVICING INFORMA
5. NN 4 25 UN Ue N MN Sf 3 S i e 27 e Bo UR ee Matching mark White Yellow Es Z 410 Nm 1 0 7 01 4 VJ OA ES lt NS PAIR read valve 8 28 SERVICING INFORMATION SEAT LOCK CABLE ROUTING SERVICING INFORMATION 8 29 SIDE STAND SET UP D I 40 Nm 4 0 kgf m 29 0 Ib ft 10 0 kgf m 72 5 Ib ft BRAKE PEDAL FOOTREST SET UP Footrest bracket Sy ke light switch Bree light euo Mom CN Rear brake master cylinder i Va Cotter pin AT d 22 S XY Footrest Z holder VIEW Brake pedal d Brake pedal Footrest bracket Frame VIEW 8 30 SERVICING INFORMATION SPECIAL TOOLS mud SSS To 09900 00410 09900 06107 Snap ring pliers 09900 06108 09900 18740 Hexagon wrench Hexagon wrench set 09900 20101 or 09900 20102 Vernier calipers 09900 20202 Micrometer 09900 20204 Micrometer 75 100 mm 09900 20205 Micrometer 0 25 mm 09900 20602 Dial gauge 1 1 1 000 mm 1 mm 09900 20607 Dial gauge 1 100 mm 10 mm 25 50 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 22301 09900 22302 Plastigauge 09900 22403 Small bore gauge 18 35 mm 09900 25008 Multi circuit tester set 09900 250
6. SERVICING INFORMATION 8 1 SERVICING INFORMATION CONTENTS P TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ENGINE RADIATOR COOLING SYSTEM CHASSIS BRAKES ELECTRICAL BATTERY WIRE HARNESS CABLE AND HOSE ROUTING WIRE HARNESS ROUTING ENGINE ELECTRICAL PARTS SET UP REGULATOR RECTIFIRE INSTALLATION THROTTLE CABLE ROUTING THROTTLE BODY INSTALLATION HOSE ROUTING CRANKCASE BREATHER HOSE ROUTING CLUTCH HOSE ROUTING COOLING SYSTEM HOSE ROUTING FRONT BRAKE HOSE ROUTING REAR BRAKE HOSE ROUTING FUEL TANK DRAIN HOSE ROUTING FUEL TANK INSTALLATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING SEAT LOCK CABLE ROUTING SIDE STAND SET UP BRAKE PEDAL FOOTREST SET UP SPECIAL TOOLS TIGHTENING TORQUE 7 ENGINE FI SYSTEM PARTS CHASSIS TIGHTENING TORQUE CHART SERVICE DATA 8 2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR coo NO FAULT C11 Camshaft position sen sor The signal does not reach ECM for more than 3 sec after receiving the starter signal The camshaft position sensor wiring and mechanical parts Camshaft position sensor intake cam pin wiring coupler con nection C12 Crankshaft position sensor The signal does not reach ECM for more than
7. Air temperature sensor 8 t amp Nm 1 8 kgf m 13 15 4 down side amp The clamp bolt head faces B The ends of the clamp face 8 20 SERVICING INFORMATION CRANKCASE BREATHER HOSE ROUTING The clamp bolt head faces B The ends of the clamp face right side Mig Breather hose Marking amp up side JE CLUTCH HOSE ROUTING tighten the union bolt SECT B Clamp the clutch hose firmly SERVICING INFORMATION 8 21 After the clutch cable hose union touching to the stopper Pass through the clutch hose outside of the guide After the clutch hose union touching to the stopper tighten the union bolt 8 22 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Pass through the reservoir hose right side of the breather hose and high tension cord i bottom side B b Ca right side o9 B bottom side N right lt b I under side gt 32 Marking 3 2 kgf m 23 Ib ft 9 23 Nm 2 3 kgf m 16 5 Ib ft fro hose notch heat shield di m Pass through the reservoir The ends of the clamp face B The clamp bolt head faces nt side of Press fitting position of bearing surface of clutch cover Marking amp ves VA back side Tighten the clamp bolt to the specified torque 2 0 2 kg m 1 5 lb ft
8. output Approx 400 W at 5 000 r min Generator no load voltage When engine is cold Regulated voltage 14 0 15 5 V at 5 000 r min 75 and more AC at 5 000 r min Starter relay resistance 3 60 Battery Type designation FTX14 BS gt Capacity 12 V 43 2 12 Ah 10 HR 1 Fuse size HI 15 A Headlight LO 15A Fuel 10A Ignition 15A 5 9 Turn signal 10A Fan motor 15A Main 30A 8 44 SERVICING INFORMATION WATTAGE Unit W ITEM SPECIFICATION Headlight HI 60 x 2 LO 55 x2 Position light 5x2 Brake light Taillight LED Turn signal light 21 4 Speedometer Tachometer light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED Fuel indicator light LED Coolant temperature oil pres sure FI indicator light LED License light 5 BRAKE WHEEL Unit mm in ITEM STANDARD LIMIT Rear brake pedal height e 55 956 Brake disc thickness 5 0 0 2 4 5 Front 0 197 0 008 0 18 5 0 0 2 4 5 Rear 0 197 0 008 0 18 Brake disc runout m 0 30 Front amp Rear 0 012 Master cylinder bore Front 0 8248 5213 14 000 14 043 Rear 0 5512 0 5529 Master cylinder piston diam Front nd 06242 13 957 13 984 Rear 0 5495 0 5506 seer T HE Front va 33 960 34 010 Trailing 1 3370 1 3
9. 2 56 It 8 42 SERVICING INFORMATION INJECTOR FUEL PUMP FUEL PRESSURE REGURATOR ITEM SPECIFICATION NOTE Injector resistance 11 13 Q at 20 C 68 F Fuel pump discharge amount 168 ml and more 5 7 5 9 US Imp oz for 10 seconds at 300 kPa 3 0 kgf cm 43 psi operat Approx 300 kPa 3 0 kgf cme 43 psi FI SENSORS ITEM SPECIFICATION NOTE CMP sensor peak voltage 3 7 V and more CKP sensor resistance 130 2400 CKP sensor peak voltage 5 0 V and more When cranking IAP sensor input voltage 45 55V IAP sensor output voltage Approx 2 5 V at idle speed TP sensor input voltage 4 5 5 5 sensor resistance Closed Approx 1 12 kQ Opened Approx 4 26 TP sensor output voltage Closed Approx 1 12 V Opened Approx 4 26 V ECT sensor input voltage 45 55V ECT sensor resistance Approx 2 45 kQ at 20 C 68 F IAT sensor input voltage 4 5 5 5 IAT sensor resistance Approx 2 45 at 20 C 68 F AP sensor input voltage 4 5 5 5 sensor output voltage Approx 4 0 V at 100 kPa 760 mmHg TO sensor resistance 19 1 19 7 TO sensor voltage 1 4 V and less GP switch voltage 0 6 V and more From 1st to top Injector voltage Battery voltage sation coil primary peak volt 200 V and more When cranking STP sensor input voltage 45 5
10. 3 5 25 5 Rear axle nut For E 03 28 33 100 10 0 72 5 For the others 120 12 0 87 0 Rear sprocket nut 60 6 0 43 5 Seat rail bolt 55 5 5 40 0 Steering damper bolt 23 23 16 5 Steering damper nut 23 23 16 5 Steering stem nut 45 4 5 32 5 TIGHTENING TORQUE CHART For other bolts and nuts listed previously refer to this chart SERVICING INFORMATION 8 37 Bolt Diameter Conventional or 4 marked bolt 7 marked bolt amp mm Nam kgf m Ib ft N m kgf m Ib ft A 1 5 0 15 1 0 2 3 0 23 15 5 3 0 3 2 0 45 0 45 3 0 6 5 5 0 55 40 10 10 70 8 13 1 3 9 5 23 23 165 10 29 2 9 21 0 50 50 360 12 45 4 5 32 5 85 8 5 61 5 14 65 65 47 0 135 13 5 975 16 105 105 76 0 210 21 0 152 0 18 160 16 0 115 5 240 240 1735 PAN Conventional bolt 4 marked bolt 7 marked bolt 8 38 SERVICING INFORMATION SERVICE DATA VALVE GUIDE Unit mm in Ww ITEM STANDARD LIMIT Valve diam IN 36 zd i 1 42 33 EX 1 30 En v Tappet clearance when cold IN 0 10 0 20 Sa 0 004 0 008 0 20 0 30 0 008 0 012 Valve guide to valve stem clear 0 010 0 046 T ance IN 0 0004 0 0018 0 030 0 066 2 X 0 0012 0 0026 Valve guide D 5 500 5 512 IN amp EX 0 2165 0 2170 Valve stem O D IN 5 475 5 4
11. 4 Open or short in high tension cords 5 Defective crankshaft position sensor 6 Defective ECM 7 Open circuited wiring connections No fuel reaching the intake manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective ECM 7 Open circuited wiring connection Incorrect fuel air mixture Adjust Repair or replace Adjust Replace Replace See electrical section Retighten Clean or replace Clean and dry Replace Replace Replace Replace Repair or replace Clean or replace Replace Replace Replace Replace Replace Check and repair 1 Throttle position sensor out of adjustment Adjust 2 Defective fuel pump Replace 3 Defective fuel pressure regulator Replace 4 Defective throttle position sensor Replace 5 Defective crankshaft position sensor Replace 6 Defective intake air pressure sensor Replace 7 Defective atmospheric pressure sensor Replace 8 Defective ECM Replace 9 Defective engine coolant temp sensor Replace 10 Defective intake air temp sensor Replace 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 camshaft Replace 5 Too wide spark plug gaps Adjust or replace 6 Defective ignition coil Replace 7 Defective crankshaft position sensor Repla
12. Defective camshaft position sensor Defective crankshaft position sensor Defective gear position switch Defective intake air pressure sensor Defective atmospheric pressure sensor Defective ECM Imbalanced throttle valve synchronization Throttle position sensor out of adjustment Defective secondary throttle position sensor and or secondary throttle valve actuator Adjust Replace Adjust Replace Repair Clean or replace Adjust or replace Clean or replace Adjust Clean or replace Adjust Retighten or replace Drain out excess oil Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Replace Replace Adjust Adjust Replace 8 8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts Heavy carbon deposit on piston crowns Not enough oil in the engine Defective oil pump or clogged oil circuit Sucking air from intake pipes Use of incorrect engine oil Defective cooling system Lean fuel air mixture 1 Short circuited intake air pressure sensor lead wire 2 Short circuited intake air temp sensor lead wire 3 Sucking air from intake pipe joint 4 Defective fuel injector 5 Defective engine coolant temp sensor The other factors 1 Ignition timing too advanced due to defective timing advance system engine coolant temp s
13. TIGHTENING TORQUE ENGINE ITEM Nm kgf m Ib ft Cylinder head cover bolt 14 1 4 10 0 Spark plug 11 1 1 8 0 Camshaft journal holder bolt 10 1 0 7 0 Cam chain tension adjuster bolt F 23 23 16 5 R 7 0 7 5 0 Cam chain tension adjuster mounting bolt 10 1 0 7 0 Cam drive idle gear sprocket shaft 40 4 0 29 0 chain tensioner mounting bolt 10 1 0 7 0 Cylinder head nut M 8 25 2 5 18 0 6 10 1 0 7 0 Cylinder head 10 47 47 34 0 6 10 10 7 0 PAIR read valve cover bolt 10 1 0 7 0 Cylinder nut 6 10 1 0 7 0 Water drain 6 BE 0 55 4 0 Clutch sleeve hub nut 95 9 5 68 5 Clutch spring set bolt 10 1 0 7 0 Clutch spring support bolt 23 23 16 5 Cam drive idle gear sprocket nut 70 7 0 50 5 Primary drive gear nut 115 155 83 0 Generator cover plug 15 1 5 11 0 Valve timing inspection plug 23 2 3 16 5 Generator rotor bolt 140 14 0 101 0 Starter clutch bolt 25 2 5 18 0 Generator stator set bolt 12 12 8 5 Generator stator clamp bolt 6 5 0 65 4 7 Crankshaft position sensor set bolt 6 5 0 65 4 7 Gear position sensor mounting bolt 6 5 0 65 47 Gearshift cam stopper bolt 10 1 0 7 0 Gearshift cam stopper plate bolt 10 1 0 7 0 Gearshift arm stopper bolt 23 2 3 16 5 Oil pressure switch 14 1 4 10 0 Crankcase bolt M 6 11 1 1 8 0 M 8 26 2 6 19 0 Generator cover bolt M 6 11 14 8 0 Clutch cover bolt M 6 T 14 8 0 Gearshift cover bolt M 6 11 14 8 0 Water pump case bolt M 6 10 1 0 7 3 Oil gallery plug
14. control circuit or sensor o Low fuel pressure Defective throttle position sensor Defective intake air temp sensor Defective camshaft position sensor Defective crankshaft position sensor Defective gear position switch Defective intake air pressure sensor Defective atmospheric pressure sensor Defective ECM Throttle position sensor out of adjustment Defective secondary throttle position sensor and or secondary throttle valve actuator Clean or replace Adjust or replace Adjust or replace Repair or replace Replace Adjust Repair or replace Replace Replace Replace Replace Replace Replace Replace Replace Adjust Replace Engine lacks power Defective engine internal electrical parts 1 2 3 4 5 6 Be 8 9 10 11 12 13 14 15 Loss of tappet clearance Weakened valve springs Valve timing out of adjustment Worn piston rings or cylinders Poor seating of valves Fouled spark plug Incorrect spark plug Clogged injector Throttle position sensor out of adjustment Clogged air cleaner element Imbalanced throttle valve synchronization Sucking air from throttle valve or vacuum hose Too much engine oil Defective fuel pump or ECM Defective crankshaft position sensor and ignition coil Defective control circuit or sensor Low fuel pressure Defective throttle position sensor Defective intake air temp sensor
15. ft Steering stem head nut 90 9 0 65 0 Steering stem lock nut 80 8 0 58 0 Front fork upper clamp bolt 23 23 16 5 Front fork lower clamp bolt 23 23 16 5 Front fork cap bolt 23 23 16 5 Front fork inner rod lock nut 15 1 5 11 5 Front fork damper rod bolt 23 2 3 16 5 Front axle 100 10 0 72 5 Front axle pinch bolt 23 2 3 16 5 Handlebar clamp bolt 23 2 3 16 5 Front brake master cylinder mounting bolt 10 1 0 7 0 Front brake caliper mounting bolt 26 2 6 19 0 Front brake caliper housing bolt 23 2 3 16 5 Front brake pad mounting pin 16 1 6 11 5 Brake hose union bolt 23 2 3 16 5 Clutch master cylinder mounting bolt 10 1 0 7 0 Clutch hose union bolt 23 23 16 5 Air bleeder valve Clutch 5 4 0 54 4 0 bleeder valve Front 7 5 0 75 5 5 Air bleeder valve Rear 6 0 6 4 4 Front brake disc bolt 23 2 3 16 5 Rear brake caliper mounting bolt 23 2 3 16 5 Rear brake caliper sliding pin 27 2 7 20 5 Rear brake master cylinder mounting bolt 10 1 0 7 0 Rear brake master cylinder rod lock nut 18 1 8 13 0 Rear brake pad mounting pin 18 1 8 13 0 Rear brake pad mounting pin plug 2 5 0 25 1 8 Front footrest bracket mounting bolt 23 2 3 16 5 Front footrest bolt 39 3 9 28 0 Swingarm pivot shaft 15 1 5 11 0 Swingarm pivot nut 100 10 0 70 0 Swingarm pivot shaft lock nut 90 9 0 65 0 Rear shock absorber mounting nut Upper and lower 50 5 0 36 0 Cushion lever mounting nut Front 78 7 8 56 5 Cushion rod mounting nut Upper and lower 78 7 8 56 5 Rear brake disc bolt 35
16. or open circuited stator coils or generator Defective regulator rectifier Defective cell plates in the battery Repair or retighten Replace Replace Replace the battery Generator over charges Naja n Internal short circuit in the battery Damaged or defective resistor element in the regulator rectifier Poorly grounded regulator rectifier Replace the battery Replace Clean and tighten ground con nection Unstable charging Lead wire insulation frayed due to vibration resulting in intermittent short circuiting Repair or replace B Brushes not seating properly on starter motor commu tator Defective starter relay starter interlock switch Defective main fuse 2 Internally short circuited generator Replace 3 Defective regulator rectifier Replace Starter button is not 1 Run down battery Repair or replace effective 2 Defective switch contacts Replace 3 Repair or replace Replace Replace 9 BATTERY SERVICING INFORMATION 8 12 E Complaint Symptom and possible causes Remedy Sulfation acidic Cracked battery case Replace the battery white powdery sub 2 Battery has been left in a run down condition for a long Replace the battery stance or spots on time surfaces of cell plates Battery runs down 1 Trouble in charging system Check the generator regulator quickly rectifier and cir
17. 09 Needle pointed probe set 09913 10750 Compression gauge adapter 09913 13121 Carburetor balancer set 09913 50121 Oil seal remover 09913 60210 Journal bearing 09913 60230 Journal bearing remover installer set remover installer 09913 60240 Journal bearing holder pb SERVICING INFORMATION 8 31 09915 72410 09913 70210 09915 40610 09915 64512 Oil pressure gauge 09915 74511 Bearing installer set Oil filter wrench Compression gauge attachment Oil pressure gauge Vy WV E 09915 74521 09915 74532 09915 77331 09916 14510 Oil pressure gauge Oil pressure gauge Meter for high pres 09916 10911 Valve spring com hose adaptor sure Valve lapper set pressor 09916 24480 09916 14910 Valve seat cutter Valve spring com 09916 21111 Solid pilot head 09916 34542 pressor attachment Valve seat cutter set N 140 5 5 See page 3 42 Reamer handle N 09916 34550 09916 34580 09916 44910 Valve guide reamer Valve guide reamer Valve guide 09916 53340 09916 84511 5 5 mm remover installer Tweezers Muo 09917 47010 Vacuum pump gauge 10 8 mm 09920 13120 Crankcase separat ing tool 09920 53740 Clutch sleeve hub holder Y Attachment 09921 20240 Bearing remover set 09923 73210 Bearing remover 8 32 SERVICING INFORMATION 09923 74511 Bearing
18. 14 kgf cm 142 199 psi en Compression pressure differ 200 kPa ence c 2 kgf cm 28 psi Piston to cylinder clearance 0 015 0 025 0 12 0 0006 0 0010 0 0047 Oylinder bore 98 000 98 015 Nicks or 3 8583 3 8589 Scratches Piston diam 97 980 97 995 8 8575 3 8581 80850 at 10 0 4 in from the skirt end Cylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 8 8 0 35 625 2nd Approx 10 1 0 40 32 Piston ring end gap ist 0 15 0 35 0 7 0 006 0 014 0 03 0 30 0 45 0 7 2nd 0 012 0 018 0 03 Piston ring to groove clearance 0 18 1st 0 0071 0 15 2nd 0 0059 Piston ring groove width 0 0 6374 ES 155 1 57 E 0 0610 0 0618 1 01 1 03 2nd 0 0398 0 0406 2 51 2 53 0 0988 0 0996 Piston ring thickness ones 0 036 x 034 0 03 18 1 38 1 40 0 054 0 055 0 97 0 99 2nd 0 038 0 039 y Piston pin bore I D 22 002 22 008 22 030 0 8662 0 8665 0 8673 Piston pin O D 21 993 22 000 21 980 0 8658 0 8661 0 8654 8 40 SERVICING INFORMATION CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end D 22 010 22 018 22 040 0 8665 0 8668 0 8677 Conrod big end side clearance 0 17 0 32 0 50 0 007 0 013 0 020 Conro
19. 2 sec after receiving the starter signal The crankshaft position sensor wiring and mechanical parts Crankshaft position sensor wiring coupler connection C13 Intake air pressure sensor The sensor should produce following voltage 0 50 V lt sensor voltage lt 4 85 V Without the above range C13 is indicated Intake air pressure sensor wiring coupler connection C14 Throttle position sen sor The sensor should produce following voltage 0 20 V lt sensor voltage lt 4 80 V Without the above range C14 is indicated Throttle position sensor wiring coupler connection C15 Engine coolant tem perature sensor The sensor voltage should be the following 0 15 V lt sensor voltage 4 5 V Without the above range C15 is indicated Engine coolant temperature sensor wiring coupler connection C21 Intake air temperature sensor The sensor voltage should be the following 0 15 V lt sensor voltage 4 5 V Without the above range C21 is indicated Intake air temperature sensor wiring coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following 0 50 V lt sensor voltage lt 4 5 V Without the above range C22 is indicated Atm pressure sensor wiring coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec after ignition switch turns ON 0 20 V lt sensor
20. 389 38 180 38 230 Rear 1 5031 1 5051 Giedel Lomo ate TR kroni 33 901 33 934 eng 1 3346 1 3360 Rear 38 115 38 148 1 5005 1 5019 Brake fluid type DOT 4 9 D 9 D 9 0 l SERVICING INFORMATION 8 45 ITEM STANDARD LIMIT Wheel rim runout 2 0 Front amp Rear Axial 0 08 e 2 0 Radial 0 08 Wheel axle runout 0 25 Front 0 010 0 25 Rear 0 010 Wheel rim size Front 17 x MT 3 50 17M C x MT 3 50 Rear 17 x MT 5 50 17M C x MT 5 50 Tire size Front 120 70 ZR17M C 58W tubeless Rear 180 55 ZR17M C 73W tubeless Tire type Front MICHELIN PILOT SPORT E Rear MICHELIN PILOT SPORT L Tire tread depth 1 6 Front 0 06 2 0 Rear 0 08 SUSPENSION Unit mm in ITEM STANDARD LIMIT Front fork stroke 120 4 72 Front fork spring free length 296 3 290 11 7 11 4 Front fork oil level 162 without spring inner tube fully 6 4 compressed Front fork spring adjuster groove from top Front fork damping force Rebound 1 turn out from stiffest position adjuster z Compras 1 turn out from stiffest position Rear shock absorber spring pre 199 5 set length 7 85 Rear shock absorber damping Rebound 3 4 turn out from stiffest position eg f d
21. 5V STP sensor resistance Closed Approx 0 58 kQ Opened Approx 4 38 STP sensor output voltage Closed Approx 0 58 V at input voltage is 5 0 V Opened Approx 4 38 V at input voltage is 5 0 V STV actuator resistance 7 140 Heated oxygen sensor output 0 4 V and less at idle speed Except for USA voltage 0 6 V and more at 3 000 r min Except for USA Heated oxygen sensor resis 4 5 Q at 23 C 73 4 F Except for USA tance PAIR solenoid valve resistance 20 24 Q at 20 C 68 F SERVICING INFORMATION 8 43 b 1 9 THROTTLE BODY ITEM SPECIFICATION ID No 1660 For E 02 19 1661 For E 33 16G2 For E 03 24 28 E 19 UD UF Bore size 52mm b Fast idle r min 1 900 2 500 r min at 25 C 77 F Idle r min 1 200 gt 100 r min Warmed engine Throttle cable play 2 0 4 0 mm 0 08 0 16 in 9 ELECTRICAL Unit mm in ITEM SPECIFICATION NOTE Firing order 1 2 Spark plug CR8EK Type DENSO U24ETR 0 6 0 7 Gap 0 024 0 028 Spark performance Over 8 0 3 at 1 atm Crankshaft position sensor resistance 130 2400 BI G Ignition coil resistance Primary 28 420 tap 2 tap Secondary 24 36 kQ tap Plug cap Crankshaft position sensor peak voltage 5 0 V and more When cranking dion coil primary peak volt 200 V and more When cranking Generator coil resistance 02 070 Y Y Generator Max
22. 90 m 0 2156 0 2161 EX 5 455 5 470 ES 0 2148 0 2154 Valve stem deflection 0 35 IN amp EX 0 014 Valve stem runout 0 05 IN SEX 0 002 Valve head thickness 0 5 w IN amp EX 0 02 Valve seat width 0 9 1 1 IN amp EX 0 035 0 043 Valve head radial runout 0 03 1 IN amp EX 0 001 Valve spring free length 41 2 IN amp EX 1 69 Valve spring tension 197 227 N IN amp EX 20 1 23 1 kgf 44 3 51 0 lbs at length 35 6 mm 1 40 in CAMSHAFT CYLINDER HEAD Unit mm in ITEM STANDARD LIMIT height 37 78 37 82 37 48 e 1 487 1 489 1 476 36 38 36 42 36 08 i 1 432 1 434 1 420 Camshaft journal oil clearance 0 019 0 053 0 150 IN amp EX 0 0007 0 0021 0 0059 Camshaft journal holder 22 012 22 025 IN amp EX 0 8666 0 8671 Camshaft journal O D 21 972 21 993 IN amp EX 0 8650 0 8659 Camshaft runout IN amp EX 0 10 li 0 004 LL SERVICING INFORMATION 8 39 ITEM STANDARD LIMIT Cam drive idle gear sprocket 0 15 0 29 e thrust clearance 0 006 0 011 Cylinder head distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in L ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 800 kPa i s e i f cm Automatic de comp actuated 10
23. M 16 35 3 5 25 5 M 8 18 1 8 13 0 SERVICING INFORMATION 8 35 ITEM Nm kgf m Ib ft Oil drain plug 23 23 16 5 Piston cooling oil nozzle screw 8 0 8 6 0 Oil pump mounting bolt 10 1 0 7 0 Conrod bearing cap bolt Initial 35 3 5 25 5 After tightening to the above torque tighten 1 4 of Final y a turn 90 Muffler mounting bolt and exhaust pipe bolt 23 2 3 16 5 Muffler mounting nut 25 2 5 18 0 Oil cooler mounting bolt 10 1 0 7 3 Oil cooler hose union bolt 23 2 3 16 5 Engine sprocket nut 115 11 5 83 0 Engine mounting pinch bolt 23 23 16 5 Engine mounting bolt nut M 12 93 9 3 67 6 M 10 55 5 5 40 0 Engine mounting thrust adjuster 12 1 2 8 5 Engine mounting thrust adjuster lock nut 45 4 5 32 5 Cooling fan thermo switch 17 4 7 12 5 FI SYSTEM PARTS ITEM N m kgf m Ib ft ECTS 18 1 8 13 0 IATS 18 1 8 13 0 CMPS mounting bolt 10 1 0 73 2 sensor For E 02 19 47 5 4 75 34 3 Fuel delivery pipe mounting screw 5 0 5 3 7 Fuel pump mounting bolt 10 1 0 1 7 3 Throttle body connecting bolt 5 0 5 3 7 Actuator motor cover nut 2 0 2 1 5 TPS mounting screw 3 5 0 35 2 5 STPS mounting screw 2 0 2 1 5 8 36 SERVICING INFORMATION CHASSIS ITEM kgf m Ib
24. Replace Replace Replace Clean Replace Clean Adjust Repair or replace Clean or replace Repair or replace Repair or replace Replace or recharge 8 6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy 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 timing chain 1 Stretched chain Replace 2 Worn sprockets Replace 3 Tension adjuster not working Repair or replace DON 2 3 4 Noise seems to come from clutch Worn splines of countershaft or hub Worn teeth of clutch plates Distorted clutch plates driven and drive Worn clutch release bearing Weakened clutch dampers Noise seems to come from crankshaft 1 Rattling bearings due to wear Worn and burnt big end bearings Worn and burnt journal bearings Too large thrust clearance Noise seems to come from transmission Replace Replace Replace Replace Replace the primary driven gear Replace Replace Replace Replace thrust bearing ator 1 Worn or rubbing gears Re
25. TION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1 Defective ignition coil or camshaft position sensor Replace sparking 2 Defective spark plugs Replace 3 Defective crankshaft position sensor Replace 4 Defective ECM Replace 5 Defective tip over sensor Replace 6 Open circuited wiring connections Check and repair Spark plugs soon 1 Mixture too rich Consult FI system become fouled with 2 Idling speed set too high Adjust fast idle or throttle stop carbon Screw 3 Incorrect gasoline Change 4 Dirty air cleaner element Clean or replace 5 Too cold spark plugs Replace with hot type plugs Spark plugs become 1 Worn piston rings Replace fouled too soon 2 Worn piston or cylinders Replace 8 Excessive clearance of valve stems in valve guides Replace 4 Worn stem oil seal Replace Spark plug electrodes 1 Too hot spark plugs Replace with cold type plugs overheat or burn 2 Loose spark plugs Retighten 3 Too lean mixture Consult Fl system Generator does not 1 Open or short circuited lead wires or loose lead con Repair or replace or retighten charge on nection Short circuited grounded or open generator coils Short circuited or punctured regulator rectifiers Replace Replace Generator does charge but charging rate is below the specification Lead wires tend to get short or open circuited or loosely connected at terminals Grounded
26. ce 8 Defective ECM Replace 9 Defective throttle position sensor Replace 10 Defective fuel pump Replace 11 Imbalanced throttle valve Adjust 12 Damaged or cracked vacuum hose Replace SERVICING INFORMATION 8 5 Complaint Symptom and possible causes Remedy Engine stalls often Incorrect fuel air mixture 1 Defective intake air pressure sensor or circuit Clogged fuel filter Defective fuel pump Defective fuel pressure regulator Damaged or cracked vacuum hose Defective engine coolant temp sensor Defective thermostat Defective intake air temp sensor ONAMRON Fuel injector improperly operating 1 Defective fuel injector 2 No injection signal from ECM 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operating Defective ECM Defective fuel pressure regulator Defective throttle position sensor Defective intake air temp sensor Defective camshaft position sensor Defective crankshaft position sensor Defective engine coolant temp sensor Defective fuel pump relay Engine internal parts improperly operating 1 Fouled spark plugs 2 Defective crankshaft position sensor or ECM 3 Clogged fuel hose 4 Tappet clearance out of adjustment ONDAN Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace
27. cuit connections and make necessary adjust ments to obtain specified charging operation 2 Cell plates have lost much of their active material as a Replace the battery and cor result of overcharging rect the charging system 3 Internal short circuit in the battery Replace the battery 4 Too low battery voltage Recharge the battery fully 5 Too old battery Replace the battery Battery sulfation 1 Incorrect charging rate Replace the battery When not in use battery should be checked at least once a month to avoid sulfation 2 The battery was left unused in a cold climate for too Replace the battery if badly long sulfated 8 14 SERVICING INFORMATION WIRE HARNESS CABLE AND HOSE ROUTING WIRE HARNESS ROUTING Set the coupler to the center of the frame Wiring harness Set the speed sensor coupler under the clutch hose Throttle cables Harness e Handle switch L Magneto Clutch hose Side atand ewitch Side stand switch Clamp Speed sensor Cable guide lala Clamp Clamp Handle switch Ignition switch Clamp the lead wire under the frame Set A mark to the exhaust side HO sensor For E 02 19 SERVICING INFORMATION 8 15 Clamp Wiring harness Neutral switch Clamp the harness without contacting to the bracket Harness Rear turn signal light L Licence lamp Set the connector and harness b
28. d big end width 21 95 22 00 0 864 0 866 Crank pin width 44 17 44 22 1 739 1 741 Conrod big end oil clearance 0 040 0 064 0 080 0 0016 0 0025 0 0031 Crank pin O D 44 976 45 000 1 7707 1 7717 Crankshaft journal oil clearance 0 002 0 029 0 080 0 0008 0 0011 0 0031 Crankshaft journal O D 47 985 48 000 MN 1 8892 1 8898 Crankshaft runout 0 05 0 002 OIL PUMP ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 350 kPa 3 5 kgf cm 50 psi Below 650 kPa 6 5 kgf cm 92 psi at 3 000 CLUTCH Unit mm in ITEM STANDARD Drive plate thickness No 1 2 92 3 08 2 62 0 115 0 121 0 103 3 72 3 88 3 42 No 2andaj 0 146 0 153 0 135 Drive plate claw width No 1 13 85 13 96 13 05 0 545 0 550 0 514 13 90 14 00 13 10 No 2 and 3 0 547 0 551 0 516 Driven plate distortion 0 10 0 004 Clutch spring free length 28 1 26 7 1 11 1 05 Clutch master cylinder 14 000 14 043 0 5512 0 5528 Clutch master cylinder piston 13 957 13 984 _ diam 0 5495 0 5505 Clutch release cylinder bore 35 700 35 762 D 1 4055 1 4079 Clutch release cylinder piston 35 650 35 675 diam 1 4035 1 4045 Clutch fluid type DOT 4 SERVICING INFORMATION 8 41 THERMOSTAT RADIATOR FAN COOLANT
29. earing race in steering stem Replace Wobbly front wheel 1 Distorted wheel rim Replace 2 Worn front wheel bearings Replace 3 Defective or incorrect tire Replace 4 Loose axle or axle pinch bolt Retighten 5 Incorrect front fork oil level Adjust Front suspension too 1 Weakened springs Replace soft 2 Not enough fork oil Replenish 3 Wrong viscous fork oil Replace 4 Improperly set front fork spring adjuster Adjust 5 Improperly set front fork damping force adjuster Adjust Front suspension too 1 Too viscous fork oil Replace stiff 2 Too much fork oil Drain excess oil 3 Improperly set front fork spring adjuster Adjust 4 Improperly set front fork damping force adjuster Adjust 5 Bent front axle Replace Noisy front suspen 1 Not enough fork oil Replenish sion 2 Loose bolts on suspension Retighten Wobbly rear wheel 1 Distorted wheel rim Replace 2 Worn rear wheel bearing or swingarm bearings Replace 3 Defective or incorrect tire Replace 4 Worn swingarm and rear suspensions Replace 5 Loose nuts or bolts on rear suspensions Retighten Rear suspension too 1 Weakened spring of shock absorber Replace soft 2 Leakage of oil from shock absorber Replace 3 Improperly set rear spring unit adjuster Adjust 4 Improperly set damping force adjuster Adjust Rear suspension too 1 Bent shock absorber shaft Replace stiff 2 Bent swingarm pivot shaft Replace 3 Worn swingarm and suspension bearings Replace
30. ensor gear position switch crankshaft position sensor and ECM 2 Drive chain too tight Clean Add oil Replace or clean Retighten or replace Change See radiator section Repair or replace Repair or replace Repair or replace Replace Replace Replace Adjust Dirty or heavy exhaust smoke Too much engine oil in the engine Check with the inspection win dow Drain excess oil 2 Worn piston rings or cylinders Replace 3 Worn valve guides Replace 4 Scored or scuffed cylinder walls Replace 5 Worn valves stems Replace 6 Defective stem seal Replace 7 Worn oil ring side rails Replace Slipping clutch 1 Weakened clutch springs Replace 2 Worn or distorted pressure plate Replace 3 Distorted clutch plates or clutch plate Replace Dragging clutch 1 Some clutch spring weakened while others are not Replace 2 Distorted pressure plate or clutch plate Replace Transmission will not 1 Broken gearshift cam Replace shift 2 Distorted gearshift forks Replace 3 Worn gearshift pawl Replace Transmission will not 1 Broken return spring on shift shaft Replace shift back 2 Rubbing or sticky shift shaft Repair or replace 3 Distorted or worn gearshift forks Replace Transmission jumps 1 Worn shifting gears on driveshaft or countershaft Replace out of gear 2 Distorted or worn gearshift forks Replace 3 Weakened stopper spring on gearshift stopper Replace
31. etween the frame and the reservoir tank Set surely Set the coupler inside of the triangle area between Taping clamp Set A markto Set the high tension cord the frame and fender backward as much as possible h be the exhaust side ithout contacting to the fuel tank Head lamp Taping clamp 8 16 SERVICING INFORMATION ENGINE ELECTRICAL PARTS SET UP Apply bond to the groove of the grommet 8 6 5 0 65 kgf m 4 7 Ib ft 8 12 Nm 1 2 kgf m 8 5 Ib ft Apply bond to the groove of the grommet 1 0 kgf m 7 3 lb ft SA 2 Cylinder SERVICING INFORMATION 8 17 REGULATOR RECTIFIRE INSTALLATION 8 18 SERVICING INFORMATION THROTTLE CABLE ROUTING Throttle cable pull Throttle cable return pu Harness e Handle switch L Cable guide Throttle cable guide pull Throttle cable guide return SERVICING INFORMATION 8 19 THROTTLE BODY INSTALLATION HOSE ROUTING cn Lj Intake pipe side 15 25 Marking right side Sr Fs VIEW OF TOP Throttle body clamp position Breather hose GA 4 Ex 1 15 251 Marking ids Ww NT 25 Air cleaner side up side Y A down side KIZ Pass through the boost hose upward of the PAIR hose Water temperature sensor 9 18 Nm 1 8 kgf m 13 Ib ft
32. justi 3 At ied compras 2 1 4 turns out from stiffest position Rear wheel travel 129 on 5 08 Swingarm pivot shaft runout m 0 3 0 01 TIRE PRESSURE COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa kgf cm psi kPa kgf cm psi FRONT 250 2 50 36 250 2 50 36 REAR 250 2 50 36 290 2 90 42 8 46 SERVICING INFORMATION FUEL OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl E 03 28 33 Tertiary Butyl Ether less than 10 ethanol or less js than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Tente Fuel tank 16 L 4 2 3 5 US Imp gal E 33 17 L 4 5 3 7 US Imp gal The others Engine oil type SAE 10W 40 API SF or SG Engine oil capacity 00 ml 27 Change 2 9 2 4 US Imp at 2 900 Filter change 3 1 2 6 US Imp qt Overhaul 3 300 ml 3 5 2 9 US Imp qt Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil Front fork oil capacity each leg 494 ml 16 69 17 39 US Imp oz
33. ler connection power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON or voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay connecting lead power source to fuel pump relay C42 Ignition switch Ignition switch signal is not input in the ECM Ignition switch lead wire coupler C44 Heated oxygen sensor HO2S For 02 19 During O2 feedback control O2 sensor voltage is higher or lower than the specification No signal is detected during engine operation or no electrical power is supplied from the battery 25 lead wire coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve PAIR valve When no operating voltage is supplied from the ECM C49 is indicated PAIR valve can not operate PAIR valve lead wire coupler 8 4 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start or is hard to start Compression too low 1 Tappet clearance out of adjustment 2 Worn valve guides or poor seating of valves 3 Mistimed valves 4 Excessively worn piston rings 5 Worn down cylinder bores 6 Starter motor cranks too slowly 7 Poor seating of spark plugs Plugs not sparking 1 Fouled spark plugs 2 Wet spark plugs 3 Defective ignition coil or camshaft position sensor
34. place 2 Worn splines Replace 3 Worn or rubbing primary gears Replace 4 Worn bearings 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 Engine runs poorly in mice engine internal electrical parts high speed range Weakened valve springs Replace 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 Replace ECM timing advance circuit 6 Defective ignition coil Replace 7 Defective crankshaft position sensor Replace 8 Defective ECM Replace 9 Clogged air cleaner element Clean or replace 10 Clogged fuel hose resulting in inadequate fuel supply Clean and prime to injector 11 Defective fuel pump Replace 12 Defective throttle position sensor Replace 13 Defective secondary throttle position sensor or its actu Replace bos b e SERVICING INFORMATION 8 7 Complaint Symptom and possible causes Remedy Engine runs poorly in high speed range Defective air flow system Clogged air cleaner element Defective throttle valve Defective secondary throttle valve Sucking air from throttle body joint Defective ECM Imbalanced throttle valve synchronization Defective
35. puller 09924 74570 Final drive gear bearing installer remover 09924 84510 Bearing installer set 09924 84521 Bearing installer set 09925 18011 Steering bearing installer L 09930 10121 09930 11950 Spark plug wrench 09930 11920 09930 11940 09930 11960 09930 30102 set Torx bit JT40H Bit holder Torx wrench Sliding shaft kis 09930 73110 09930 73120 09930 82720 09930 30450 09930 44541 Starter torque limiter Starter torque limiter Mode selection Rotor remover bolt Rotor holder holder socket switch 09940 14940 09940 14990 09940 14911 Swingarm pivot 09940 14960 Engine mounting 09940 30250 Steering stem nut thrust adjuster Steering nut wrench thrust adjuster Front fork assem wrench socket wrench socket socket wrench bling tool 09940 40211 Fuel pressure gauge adapter 09940 40220 Fuel pressure gauge hose attachment 09940 52841 Front fork inner rod holder 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 9 e SERVICING INFORMATION 8 33 wo 09941 34513 Steering race 09943 74111 installer Fork oil level gauge NOTE When ordering a special tool please confirm whether it is available or not 8 34 SERVICING INFORMATION
36. voltage lt 4 80 V Without the above value C23 is indicated Tip over sensor wiring coupler connection C24 or C25 Ignition signal Crankshaft position sensor signal is produced and ECM deter mines the ignition signal but signal from ignition coil is inter rupted continuous by 4 times or more In this case the code C24 or C25 is indicated Ignition coil wiring coupler connection power supply from the battery C28 Secondary throttle valve actuator SERVICING INFORMATION 8 3 No operating voltage is supplied from the ECM C28 is indi cated STVA can not operate STVA lead wire coupler STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage 0 10 V lt sensor voltage 4 90 V Without the above range C29 is indicated Secondary throttle position sensor wiring coupler connection C31 Gear position signal Gear position signal voltage should be higher than the following for more than 2 seconds Gear position switch voltage z 0 6 V Without the above value C31 is indicated Gear position sensor wiring coupler connection gearshift cam etc C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM deter mines the injection signal but fuel injection signal is interrupted continuous by 4 times or more In this case the code C32 or C33 is indicated Injector wiring coup
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