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Excelsior-HENDERSON HCX 1999, Service Handbook

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Excelsior-HENDERSON HCX 1999 Service Handbook Download Page 473

19. WIRING SCHEMATIC

6999-0003 7/15/99

19-1

Engine Managment Harness

Main Harness

Lights/Controls

Harness

1

2

W

Be

/W

1

2

Pk

/B

e

Tilt

Switch

Engine Control

Module (ECM)

P19

P18

P11

P10

P13

P12

P41

P42

P43

2

1

1

2

3

4

5 6 

Bk

/W

Bk

/W

Bk

/R

Bk

/R

P41

1

2

3

4

5 6 

CONNECTORS

Connector
 Number

Pin

Name

Male (P41A) 

Female (P41B)

WIRE CONVENTIONS

Power

Signal

Ground

Cable 

Connector gender is determined by pin type.

Pk
R
O
Y
Gn
Be
V
Tn
Bn
Gy
Bk
W

Pink
Red
Orange
Yellow
Green
Blue
Violet
Tan
Brown
Gray
Black
White

Fuel

Level

Sensor

Be

Y

1
2
3
4
5
6
7
8

V

Bn
Bk
Bk
Bk

O

V

Pk/Y

R/W

Gn/W
Y/Bk
Be/Gn
Bn/R

Gy/V

Bk

O

Bk/Pk

Pk/Be

W/Bk

R/Bk

R/Gy
Y/Be

O/W

Pk

W

Gy/Y

Bk

Bk

Bk

Gn

Tn

Be/Gy

W/Bk

Be/O

Tn

R/Gy

4 7 15 16

Gn

O/

W

Bk

V

Be

/R

Y/R

Y/

Bk

Bn/

R

Gn

/W

R/

W

Pk/

B

e

Pk

/Y

Gy

/V

O

Bk

/P

k

Gy

Be/

R

O/

W

 

Bk

Gn

W

Pk

Be

O/

B

e

Tn

Bk

/W

O/

Bk

Be/

G

n

Be/

O

R/Gy

Y/

Be

Y/

R

O/

W

R/

Bk

A B C

1

2

1

2

3

4

5 6 

7 8

9 10 11 12

1

2

3

1

2

3

1

2

1

2

1

2

3

4

5 6 

7

8

9 10 11 12

1

2

3

4

5 6 

7 8

9 10 11 12

O/

W

O/

W

O/

W

Be/

O

R/Gy

Y/

Be

Y/

R

R/

B

k

Bk

O/

B

e

V

V

W/

B

k

W/

B

k

Be/

G

n

O/

B

k

Bk

Tn

Be

Pk

W

Gn

Bk

Bk/

W

Bk

Y/

Bk

Gy

Bk

/P

k

O

Gy

/V

Pk

/Y

R/

W

Bn

/R

Gn

/W

O/

W

 

R

Be/

R

R

O/

Be

R

W/

B

k

R

W/

B

k

O

R

R

Bk

R/Gy

R

R

R/

W

Bk

Y/

Be

Be

R

R/

Bk

R

O

Bk

O

d

om

et

er

 M

e

m

o

ry

Switc

h

e

d

 Po

we

r

Ta

ch

om

e

ter

Spe

edo

m

e

te

r

F

u

el

 L

e

v

e

l G

a

ug

e

G

rou

nd

Ne

u

tr

a

l L

a

mp

C

h

e

c

k

 En

gi

ne

 La

m

p

O

il P

res

su

re

 La

m

p

H

igh

 Be

am

 L

a

m

p

Tu

rn

 Si

g

nal

 L

a

m

p

Lo

w

 Fu

el

 La

m

p

Bk

Bk

R

R

R

Y

A B C D E F

A

u

xi

liar

y

 L

Igh

ts

 1

0

A

Fu

el

 Pu

m

p

 1

0

A

EF

I 1

5

A

30 85

87

86

30 85

87

86

Li

ght

s 1

5

A

H

o

rn

 10A

Ig

ni

ti

on

 5

A

A B C D E F

Alternator

M

85

86

Bk

Bk

Bk

Bk

Bk

Be

Battery

Chassis

Ground

Engine

Ground

R/

Bk

Bk

Tail Light

Brake Light
Turn Signal Left
Turn Signal Right

Ground

D4

A1

A2
B1
B2
B3
B4
D1

G1

E1
E2
E3
E4

F1
F2
F4

H4

G4

H1

H2
H3

D2

A1
A2
B2

C4
D1

E1

F3

G3

H4

G4
H1

1 2 3

1 2

A

B C

D

86 87

85

30

K

J

H

G

F

E

D

C

B

A

Be
Be

Bk/R
R/Bk

Gn

O/Be

Gy
Bk
Bk

Be/R

W

W/Be

3

2

1

Bk

R/Gy

K

J

H

G

F

E

D

C

B

A

Be/Gy

O

R/Gy

R/W

Bn

Y

W

V

Bk

Be/Gy

O

R/Gy

R/W

Be
Be

Bk/R
R/Bk

Gn

O/Be

Gy
Bk
Bk

Be/R

Horn

Bk

Y

Bn/W

Pk

Bk

V/W

Y

R/Bk

W

Y

Be

Bk

V

Be

Bk

W

Y

Bk

W

Bk/R

Be

Be

O

Y

Be

Headlight

Bk

Bn

Be

Bk

Be/R

2

1

B

A

H

G

F 

E

D

C

B

A

C

2

1

3

2

1

3

2

1

3

Bn

Y

W

V

Bk

B

A

H

G

F 

E

D

C

O/

W

 

Main

Breaker

50A

Voltage

Regulator

Road

Speed

Sensor

Oxygen

Sensor

Oil

Pressure

Switch

Crankshaft

Position

Sensor

P4

P3

Purge

Valve

Idle Air
Control

Valve

P9

Engine

Temperature

Sensor

P5

Throttle

Position

Sensor

P7

Air

Temperature

Sensor

P8

Instrument

Cluster

P20

1

2

1

2

Ignition

Coil 1

Ignition

Coil 2

Fuel

Injector

 1

Fuel

Injector

 2

Fuel

Pump

P21

Dimmer

Switch

Left

Handlebar

Control

P22

P23

Left Turn

Signal

P24

P35

P25

Right

Handlebar

Control

Right Turn

Signal

P27

P38

Light Bar

Ground

Turn Lamp

Running Lamp

Ground

High Beam

Low Beam

Ground

Turn Lamp

Running Lamp

High Beam

Low Beam

Power

Right Turn Out

Auto Reset

Ground

Left Turn Out

 

Horn Out

Horn In

Po

we

r

A

c

c

e

ss

or

y

On

Bk

Gy

W

V/

W

Bn

/W

Pk

Gn

Be

V

Bn

O/

Be

O/

Be

R/

W

R/

G

y

C

B

A

12

11

10

9

8

7

6 

5

4

3

2

1

Turn Signal

Control

Main Switch

P28

P29

Power

Latch

Relay

P15

Ignition

Relay

P26

Accessory

Relay

P16

Fuse

Block A

P30

P36 

P33 

Starter Relay

Starter Motor

Brake

Light

Switch

P34 

Rear

Lights

P17

P1

P2

                              

Fuse

Block B

P30

Ground

Hazard Auto

Start Button Out

Start Button In

Stop/Run Switch Out

Stop/Run Switch In

Brake Light Out

Brake Light In

T1

P14

P37

P6

P32

Neutral

Switch

Diagnostic
Connector

P40

P39

Bk

W

Gy

/Y

Be

/R

10459

WIRING SCHEMATIC

19

Summary of Contents for HCX 1999

Page 1: ......

Page 2: ...out incurring any obligation to make the same or similar changes to motorcycles previously built EXCELSIOR HENDERSON MOTORCYCLE MANUFACTURING COMPANY 805 HANLON DRIVE BELLE PLAINE MINNESOTA 56011 TELE...

Page 3: ...l attention to information in the Handbook that begins with this symbol The following terms have special meaning in the Handbook Be certain you understand the meaning of each term as the terms communi...

Page 4: ...Notice Use genuine Excelsior Henderson replace ment parts and lubricants or substitute parts and or lubricants recommended by Excelsior Henderson Special tools should be used as service procedures rec...

Page 5: ...FOREWORD 6999 0003 7 15 99 iii...

Page 6: ...L SYSTEM 4 ENGINE REMOVAL INSTALLATION 5 CYLINDER HEAD CAM DRIVE 6 CYLINDER PISTON 7 CRANKCASE CRANKSHAFT 8 PRIMARY DRIVE 9 CLUTCH 10 TRANSMISSION 11 WHEELS 12 FRONT SUSPENSION STEERING 13 REAR SUSPEN...

Page 7: ...6999 0003 7 15 99 v...

Page 8: ...1 0 6999 0003 7 15 99 ROUTINE MAINTENANCE 1...

Page 9: ...3 DRIVE BELT 1 3 CHECK TENSION 1 4 ADJUST TENSION 1 4 THROTTLE CABLES 1 5 FUEL HOSE RAIL 1 5 EMISSION CONTROL SYSTEM 1 5 OXYGEN SENSOR 1 6 HYDRAULIC CONTROLS 1 6 FLUID LEVEL 1 6 LEVERS AND PEDAL 1 6...

Page 10: ...1 2 6999 0003 7 15 99 ROUTINE MAINTENANCE TROUBLESHOOTING MAINTENANCE INTERVALS...

Page 11: ...ROUTINE MAINTENANCE 6999 0003 7 15 99 1 3 StepNumber StepNumber StepNumber ENGINE OIL 1 2 AIR FILTER ELEMENT 1 2 DRIVE BELT Check the drive belt condition 1 2...

Page 12: ...4 Push the plunger upward until the small O ring touches the tension gauge body Make sure the tension gauge is seated squarely against the drive belt and move the large O ring until it aligns with th...

Page 13: ...nuts 4 Tighten the rear axle castle nut Torque 111 ft lbs 5 Install a new rear axle cotter pin Caution Always use a new cotter pin when installing the rear axle nut 1 COTTER PIN 2 CASTLE NUT 3 ADJUST...

Page 14: ...istency 1 2 HYDRAULIC CONTROLS inspect all hoses and connections Make sure the front and rear brake light switches 1 2 FLUID LEVEL StepCaptionHold For demonstration only StepCaptionHold These are BLIN...

Page 15: ...PADS StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 2 SPARK PLUGS 1 2 STEERING HEAD BEARINGS Turn bars side...

Page 16: ...monstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 2 WHEELS AND SPOKES 1 2 SIDESTAND StepCaptionHold For demonstration only StepCaption...

Page 17: ...AINTENANCE 6999 0003 7 15 99 1 9 StepNumber StepNumber ROAD TEST 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consist...

Page 18: ...1 10 6999 0003 7 15 99 ROUTINE MAINTENANCE...

Page 19: ...ROUTINE MAINTENANCE 6999 0003 7 15 99 1 11...

Page 20: ...ROUTINE MAINTENANCE NOTES 6999 0003 7 15 99 1 12...

Page 21: ...ROUTINE MAINTENANCE 6999 0003 7 15 99 1 13...

Page 22: ...2 0 6999 0003 7 15 99 BODY EXHAUST 2...

Page 23: ...can explode Insufficient safeguards when handling gasoline can result in severe personal injury death and or property damage TORQUE VALUES Rear fender strut bolts Exhaust header flange nut Muffler cl...

Page 24: ...2 2 6999 0003 7 15 99 BODY EXHAUST TROUBLESHOOTING Excessive exhaust noise Broken exhaust system components Exhaust leak Poor performance Dents of kinks in exhaust header Exhaust leak Plugged muffler...

Page 25: ...e post at the rear of the fuel tank Install the tandem saddle posts and fasten the rider s saddle screws Torque 18 ft lbs 2 Slide the tandem saddle into the posts at the rear of the rider s saddle and...

Page 26: ...hose from the fuel pump 1 FUEL HOSE 6 Connect a drain hose to the fuel tank at the fuel pump connection 7 Run the drain hose into a suitable container up to 6 5 gallons 8 Be sure to secure the hose wh...

Page 27: ...ifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging the finish 6 Lift the rear of the fuel tank two or three inches to expose the fue...

Page 28: ...ion Stop the fuel pump before it runs dry Running the fuel pump without fuel will damage the pump REMOVAL 1 Disconnect the battery negative cable first see BATTERY REMOVAL page 16 3 2 Open the right g...

Page 29: ...e disconnection point to prevent fuel spray 9 Wrap a rag around the fuel hose connection point and disconnect the hose from the fuel pump Wipe up any spilled fuel 1 FUEL HOSE 10 Remove the two nuts an...

Page 30: ...sor Tuck the connectors under the tank electrical connectors 8 Install the instrument cluster see INSTRUMENT CLUSTER INSTALLATION page 18 23 9 Install the rear fuel tank screw and isolator 10 Tighten...

Page 31: ...ssembly aside 1 BRAKE HOSE 2 CALIPER ROD MOUNT 3 BRAKE CALIPER ASSEMBLY 4 RIGID FORK Wrap a clean cloth around the lower portion of each strut spring Cover the inner surface of each strut below the fe...

Page 32: ...e are BLIND white text StepCaptionHold Used to hold table height consistency 1 BRAKE HOSE 2 BRAKE CALIPER ASSEMBLY 3 CALIPER ROD MOUNT 4 RIGID FORK Install both suspension rockers Torque Remove any cl...

Page 33: ...ve the spacers For additional tail lamp service information see TAIL LAMP page 18 14 For additional turn signal lamp service information see TURN SIGNAL LAMPS page 18 16 1 FENDER SUPPORT 2 MOUNTING SC...

Page 34: ...DN 7 15 Remove rear exhaust header flange nuts Support the rear muffler and remove the muffler mounting bolts Remove the rear exhaust assembly by sliding the assembly rearward off of the exhaust studs...

Page 35: ...flange over the exhaust studs Start the header mounting nuts onto the exhaust studs Start the muffler mounting bolts into the muffler 1 EXHAUST GASKET 2 EXHAUST STUD Slide the rear exhaust assembly o...

Page 36: ...place any wire ties previously removed Notice Make sure all wires are secure from vibration and direct contact to high temperature surfaces Install all exhaust system heat shields and tighten the heat...

Page 37: ...BODY EXHAUST 6999 0003 7 15 99 2 15...

Page 38: ...3 0 6999 0003 7 15 99 LUBRICATION SYSTEM 3 10732...

Page 39: ...ifters and cam chains of both cylinders The oil then drains through the cam chain tunnel into the timing gear area of the crankcase where it is drawn into the outer scavenge pump The scavenge pump ret...

Page 40: ...lve stuck open Pressure pump gerotor pin sheared Pressure pump drive gear s damaged Worn or damaged pressure pump gerotor Oil draining from air cleaner Oil level too high Oil pressure too high Pressur...

Page 41: ...e indicator lamp does not illuminate at startup inspect the oil pressure switch see OIL PRESSURE SWITCH INSPECTION page 18 22 If the low pressure indicator lamp remains lit while the engine is running...

Page 42: ...MP COVER 2 PUMP 7 Remove the timing gear cover screws and the timing gear cover 8 Remove and discard the cover gasket and O rings 9 Pull the idler shaft from the crankcase and discard the O ring 10 Re...

Page 43: ...es should rotate smoothly and quietly Replace any worn or damaged components 1 IDLER SHAFT 2 IDLER GEAR 3 SPACER 4 NEEDLE BEARING RELIEF VALVE 1 Push in the relief valve plunger to make sure it moves...

Page 44: ...actly as they were removed from the oil pump housing Notice Coat all components with clean engine oil before assembly 1 RETAINING RING 2 OIL PUMP SHAFT 3 BACKPLATE 2 Install the dowel pin into the oil...

Page 45: ...e timing cover and tighten the mounting screws Torque 8 ft lbs 1 TIMING GEAR COVER 2 IDLER SHAFT 3 IDLER GEAR 7 Place a new O ring in the pump port 8 Install the pump and tighten the mounting screws T...

Page 46: ...G RING 4 Remove the gerotor assemblies Caution The georotor assemblies must be reinstalled exactly as it was removed from the oil pump Use a permanent marker to identify the inner and outer surfaces o...

Page 47: ...moved from the oil pump housing Notice Coat all components with clean engine oil before assembly 1 RETAINING RING 2 PUMP SHAFT 3 BACKPLATE 2 Install the first dowel pin into the oil pump shaft 3 Place...

Page 48: ...13 1 TIMING GEAR COVER CRANKCASE REED VALVE REMOVAL 1 Remove the inner primary cover see INNER PRIMARY COVER REMOVAL page 9 6 2 Remove the starter idler gear 3 Remove the starter crankshaft gear 4 Re...

Page 49: ...LUBRICATION SYSTEM NOTES 6999 0003 7 15 99 3 11...

Page 50: ...4 0 6999 0003 7 15 99 ENGINE CONTROL SYSTEM 4...

Page 51: ...pump has a built in pressure regulator and filter SERVICE INFORMATION 4 1 TROUBLESHOOTING 4 3 SYSTEM OPERATION 4 4 DIAGNOSING FAULTS 4 11 ENGINE CONTROL MODULE 4 122 FUEL TANK 4 124 FUEL PUMP FILTER 4...

Page 52: ...t switch screw 5 ft lbs Idle air control screw 26 in lbs Spark plug 15 ft lbs SPECIFICATIONS Unit inch ITEM STANDARD SERVICE LIMIT Air temperature sensor resistance 820 120 F 1210 100 F 1830 80 F 2840...

Page 53: ...function Fuel injector malfunction Faulty crankshaft position sensor Closed throttle position needs resetting EFI fuse open Oxygen sensor contaminated Engine Stalls Hard to Start Rough Idle Intake air...

Page 54: ...n to the ECM which it uses to make adjustments to these basic parameters The ECM generates signals that drive the devices that do the work such as the fuel pump fuel injectors and ignition coils The E...

Page 55: ...ed to be reset periodically as parts wear and seat together Use the Examinator diagnostic tool to reset the closed throttle position The throttle body is equipped with an idle air control IAC valve an...

Page 56: ...uel On California models an emissions canister captures the fuel vapors and passes them through a purge valve to the throttle body While the engine is not running vapor pressure that builds in the fue...

Page 57: ...essure of 48 psi The ECM applies a voltage to the fuel injector solenoid for a specific time period opening the valve and releasing fuel into the intake port The engine tem perature sensor enables the...

Page 58: ...he crankcase This generates voltage pulses that the ECM uses to calculate engine speed To determine piston position in the 4 cycle com bustion process the ECM matches injection timing and the rapid de...

Page 59: ...al for high oxygen content 0 5V or a rich signal for low oxygen content 0 5V The ECM compensates by increasing or decreasing the injection duration based on these signals This causes the calculated ai...

Page 60: ...ult P0117 Engine Temperature Sensor Short to Ground P0352 Ignition Coil 2 Circuit Fault P0118 Eng Temp Sensor Open Circuit Short to Power P1352 Ignition Coil 1 Open Circuit Short to Ground P0119 Engin...

Page 61: ...er as labeled on the connector For example power to the throttle position sensor is applied to pin P7A A The Examinator diagnostic tool displays a variety of engine data that can help you determine th...

Page 62: ...LT HISTORY DATA Make note of the air pressure value INSPECT AIR PRESSURE SENSOR TUBE Remove and inspect the ECM vent tube Is the tube clogged Caution Do not apply compressed air to the vent tube or th...

Page 63: ...ground Temperature above 160 F INSPECT AIR TEMPERATURE SENSOR Is the connector P8 fastened Is the air temperature sensor probe tip intact Yes Continue No Fasten the connector Replace the air temperat...

Page 64: ...lt reoccurs continue MEASURE COMPONENT RESISTANCE Measure the resistance across the sensor terminals Is the value in range Standard 820 120 F 1210 100 F 1830 80 F 2840 60 F 3500 50 F Yes Continue No R...

Page 65: ...between Air Temp and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs contact dealer service No Contact dealer service TEST FOR...

Page 66: ...T HISTORY DATA Make note of the air temperature DISPLAY SENSOR DATA Make note of the air temperature sensor voltage INSPECT AIR TEMPERATURE SENSOR Is the connector P8 fastened Is the air temperature s...

Page 67: ...lt reoccurs continue MEASURE COMPONENT RESISTANCE Measure the resistance across the sensor terminals Is the value in range Standard 820 120 F 1210 100 F 1830 80 F 2840 60 F 3500 50 F Yes Continue No R...

Page 68: ...tinuity between Air Temp and P8B 1 between Sensor Gnd and P8B 2 Yes Continue No Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue TEST FOR SHO...

Page 69: ...the air temperature sensor voltage greater than 5 5 volts Yes Trace air temperature sensor signal wiring Gn W for a short to 12 volts Repair wiring Reconnect the harness clear the fault codes and run...

Page 70: ...gine temperature condition Possible short to ground INSPECT ENGINE TEMPERATURE SENSOR Is the engine temperature sensor fastened properly Is the connector P5 intact and fastened properly Yes Continue N...

Page 71: ...and continue MEASURE COMPONENT RESISTANCE Disconnect the harness from the engine temperature sensor P5 Measure the resistance across the sensor terminals Is the value in range Standard 150 230 F 422 1...

Page 72: ...tinuity between Engine Temp and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR INTERNAL SHORT Di...

Page 73: ...wer source DISPLAY FAULT HISTORY DATA Make note of the engine temperature DISPLAY SENSOR DATA Make note of the engine temperature sensor voltage INSPECT ENGINE TEMPERATURE SENSOR Is the engine tempera...

Page 74: ...d continue MEASURE COMPONENT RESISTANCE Disconnect the harness from the engine temperature sensor P5 Measure the resistance across the sensor terminals Is the value in range Standard 150 230 F 422 160...

Page 75: ...re sensor P5 Is there continuity between Engine Temp and P5B 1 between Sensor Gnd and P5B 2 Yes Continue No Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault re...

Page 76: ...engine temperature sensor voltage greater than 5 5 volts Yes Trace engine temperature sensor signal wiring Pk Y for a short to 12 volts Repair wiring Reconnect the harness clear the fault codes and r...

Page 77: ...mperature condition Possible short to a 5 volt power supply INSPECT ENGINE TEMPERATURE SENSOR Is the engine temperature sensor fastened properly Is the connector P5 intact and fastened properly Yes Co...

Page 78: ...and continue MEASURE COMPONENT RESISTANCE Disconnect the harness from the engine temperature sensor P5 Measure the resistance across the sensor terminals Is the value in range Standard 150 230 F 422 1...

Page 79: ...leaving the ECM disconnected then continue TEST FOR INTERNAL SHORT Disconnect the harness from the engine temperature sensor P5 Is there continuity between Engine Temp and Sensor Gnd Yes Repair wiring...

Page 80: ...A Make note of the throttle position value DISPLAY SENSOR DATA Make note of the throttle position and throttle position sensor voltage values INSPECT THROTTLE POSITION SENSOR Is the throttle position...

Page 81: ...e throttle position sensor P7 Are the pins and sockets intact and secure Yes Continue No Repair connector Reconnect the harness clear the fault codes and run the engine If the fault reoccurs disconnec...

Page 82: ...Is there continuity between Throttle and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CI...

Page 83: ...EST FOR INTERNAL SHORT Is there continuity between Throttle and Sensor Gnd Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs contact dealer service...

Page 84: ...Make note of the throttle position value DISPLAY SENSOR DATA Make note of the throttle position sensor voltage with the throttle closed and open INSPECT THROTTLE POSITION SENSOR Is the throttle positi...

Page 85: ...e throttle position sensor P7 Are the pins and sockets intact and secure Yes Continue No Repair connector Reconnect the harness clear the fault codes and run the engine If the fault reoccurs disconnec...

Page 86: ...isconnected then continue TEST FOR SHORT TO 5V Is there continuity between Throttle and Sensor 5V Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs...

Page 87: ...mber DESCRIPTION Calculated fuel demand has reached the maximum limit Possible causes Incorrect engine tune Engine tune variables out of range Intake or exhaust air leak Insufficient fuel flow Sensor...

Page 88: ...isplay the engine tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes...

Page 89: ...ly Yes Continue No Secure sensor and connector Clear the fault codes and run the engine If the fault reoccurs continue Start the engine and allow it to warm to closed loop operation Use the Examinator...

Page 90: ...ving the ECM disconnected then continue TEST FOR SHORT TO GROUND Disconnect the harness from the oxygen sensor P4 Is there continuity between Oxygen and motorcycle ground Yes Repair wiring Reconnect t...

Page 91: ...needed INSPECT THROTTLE BODY Remove the air cleaner cover and inspect the air cleaner Clean or replace the air cleaner if necessary Open the throttle bore and inspect the butterfly valve the injector...

Page 92: ...leaks around the injectors and the intake collar seals Are repairs needed Yes Make repairs Reset closed throttle position long term fuel trim and IACV adaption Clear the fault codes and run the engin...

Page 93: ...e position long term fuel trim and IACV adaption values Run the engine Does the fault reoccur Yes Reinstall the original ECM and continue No Repair complete MEASURE CYLINDER COMPRESSION Measure compre...

Page 94: ...r DESCRIPTION Calculated fuel demand has reached the minimum limit Possible causes Incorrect engine tune Engine tune variables out of range Insufficient air flow Excess fuel flow Sensor malfunction Fa...

Page 95: ...tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes and run the engine...

Page 96: ...volt Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue REPLACE OXYGEN SENSOR Replace the oxygen sensor Reconnect the harness c...

Page 97: ...ndard 45 51 psi Yes Replace the fuel pump Clear the fault codes and run the engine If the fault reoccurs continue No Continue INSPECT INTAKE MANIFOLD Remove the intake manifold and inspect for obstruc...

Page 98: ...load the current engine tune Reset closed throttle position long term fuel trim and IACV adaption values Run the engine Does the fault reoccur Yes Reinstall the original ECM and continue No Repair co...

Page 99: ...StepNumber DESCRIPTION Calculated air demand has reached the maximum limit Possible causes Incorrect engine tune Engine tune variables out of range Insufficient air flow Excess fuel flow Sensor malfun...

Page 100: ...he engine tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes and run...

Page 101: ...arness clear the fault codes and run the engine If the fault reoccurs continue No Continue REPLACE OXYGEN SENSOR Replace the oxygen sensor Reconnect the harness clear the fault codes and run the engin...

Page 102: ...ndard 45 51 psi Yes Replace the fuel pump Clear the fault codes and run the engine If the fault reoccurs continue No Continue INSPECT INTAKE MANIFOLD Remove the intake manifold and inspect for obstruc...

Page 103: ...load the current engine tune Reset closed throttle position long term fuel trim and IACV adaption values Run the engine Does the fault reoccur Yes Reinstall the original ECM and continue No Repair co...

Page 104: ...pNumber StepNumber DESCRIPTION Calculated air demand has reached the minimum limit Possible causes Incorrect engine tune Engine tune variables out of range Excess air flow Insufficient fuel flow Senso...

Page 105: ...tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes and run the engine...

Page 106: ...he fault reoccurs continue Start the engine and allow it to warm to closed loop operation Use the Examinator diagnostic tool to monitor the short term fuel trim Raise the engine speed to 2000 RPM for...

Page 107: ...Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from the oxygen sensor P4 Is there...

Page 108: ...hrottle position long term fuel trim and IACV adaption values Clear the fault codes and run the engine No Continue Remove the throttle body assembly Inspect for air leaks around the butterfly valve th...

Page 109: ...d fastened properly Yes Continue No Secure fuel injectors and connectors Clear the fault codes and run the engine If the fault reoccurs continue REPLACE FUEL INJECTORS Replace the fuel injectors Recon...

Page 110: ...epair complete MEASURE CYLINDER COMPRESSION Measure compression on both cylinders Is the value in range Standard 185 205 psi Yes Continue No Make necessary repairs Clear the fault codes and run the en...

Page 111: ...of the injector pulse time INSPECT FUEL INJECTOR 1 Is fuel injector 1 fastened properly Is the connector P10 intact and fastened properly Yes Continue No Secure fuel injector 1 and connector Clear th...

Page 112: ...the harness from injector 1 P10 Measure the resistance across the injector terminals Is the value in range Standard 11 75 12 25 68 F Notice Use an ohmeter with sufficient accuracy for this measuremen...

Page 113: ...and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from fuel...

Page 114: ...5 68 F Notice Use an ohmeter with sufficient accuracy for this measurement instead of the Examinator diagnostic tool Yes Reconnect the harness clear the fault codes and run the engine If the fault reo...

Page 115: ...ing the ECM disconnected TEST FOR SHORT TO 12V Disconnect the harness from injector 1 P10 Is there continuity between Injector 1 and Power Relay Output Yes Repair wiring Reconnect the harness clear th...

Page 116: ...ote of the injector pulse time INSPECT FUEL INJECTOR 2 Is injector 2 fastened properly Is the connector P11 intact and fastened properly Yes Continue No Secure the injector 2 and connector Clear the f...

Page 117: ...esistance between across the injector terminals Is the value in range Standard 11 75 12 25 68 F Notice Use an ohmeter with sufficient accuracy for this measurement instead of the Examinator diagnostic...

Page 118: ...and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from fuel...

Page 119: ...8 F Notice Use an ohmeter with sufficient accuracy for this measurement instead of the Examinator diagnostic tool Yes Reconnect the harness clear the fault codes and run the engine If the fault reoccu...

Page 120: ...ut box leaving the ECM disconnected TEST FOR SHORT TO 12V Disconnect the harness from injector 2 P11 Is there continuity between Injector 2 and Power Relay Output Yes Repair wiring Reconnect the harne...

Page 121: ...note of the Ignition Timing and the Target Dwell values INSPECT CRANKSHAFT SENSOR Is the crankshaft position sensor fastened properly Is the connector P6 intact and fastened properly Yes Continue No...

Page 122: ...t reoccurs continue MEASURE COMPONENT RESISTANCE Disconnect the crankshaft position sensor from the harness P6 Measure the resistance across the sensor terminals Is the value in range Standard 532 588...

Page 123: ...inue TEST FOR SHORT TO GROUND Disconnect the harness from the crankshaft sensor P6 Is there continuity between Crankshaft Pos and motorcycle ground between Crankshaft Neg and motorcycle ground Yes Rep...

Page 124: ...epair or replace the crankshaft position sensor cable Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue TEST FOR INTERNAL SHORT Is there continuity between...

Page 125: ...Is the crankshaft position gear free from damage and debris Is the clearance between the sensor and the timing tooth in range Standard 0 039 inches Yes Contact dealer service Yes Clean or replace cran...

Page 126: ...OIL 1 Is ignition coil 1 fastened properly Is the connector P12 intact and fastened properly Yes Continue No Secure the ignition coil 1 and connector Clear the fault codes and run the engine If the fa...

Page 127: ...the harness from ignition coil 1 Measure the resistance across the ignition coil terminals Is the value in range Standard 0 8 1 5 Notice Use an ohmeter with sufficient accuracy for this measurement i...

Page 128: ...ycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from ignition coil...

Page 129: ...ult codes and run the engine If the fault reoccurs continue MEASURE COIL 1 RESISTANCE Disconnect the harness from ignition coil 1 Measure the resistance across the ignition coil terminals Is the value...

Page 130: ...e harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Disconnect the harness from the ignition coil P12 Is there con...

Page 131: ...OIL 2 Is ignition coil 2 fastened properly Is the connector P13 intact and fastened properly Yes Continue No Secure the ignition coil 2 and connector Clear the fault codes and run the engine If the fa...

Page 132: ...the harness from ignition coil 2 Measure the resistance across the ignition coil terminals Is the value in range Standard 0 8 1 5 Notice Use an ohmeter with sufficient accuracy for this measurement i...

Page 133: ...l 2 and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from...

Page 134: ...t codes and run the engine If the fault reoccurs continue MEASURE COMPONENT RESISTANCE Disconnect the harness from ignition coil 2 Measure the resistance across the ignition coil terminals Is the valu...

Page 135: ...he harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Disconnect the harness from ignition coil 2 P13 Is there cont...

Page 136: ...cycle INSPECT PURGE VALVE Is the purge valve fastened properly Is the connector P3 intact and fastened properly Yes Continue No Secure the purge valve and connector Clear the fault codes and run the e...

Page 137: ...P3 Measure the resistance between across the purge valve terminals Is the value in range Standard 26 Yes Continue No Replace the purge valve Reconnect the harness clear the fault codes and run purge v...

Page 138: ...d run purge valve component test If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect harness from the purge valve P3 Is there continuity between Purge and P3B 2 between Power R...

Page 139: ...engine If the fault reoccurs continue MEASURE PURGE VALVE RESISTANCE Disconnect the harness from the purge valve P3 Measure the resistance between across the purge valve terminals Is the value in rang...

Page 140: ...the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Disconnect the harness from the purge valve P3 Is there cont...

Page 141: ...of road speed value INSPECT ECM CONNECTORS Are the ECM connectors fastened properly Yes Continue No Fasten the ECM connectors Clear the fault codes and run the engine If the fault reoccurs continue 1...

Page 142: ...etween Speedometer and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Is there cont...

Page 143: ...or Clear the fault codes and run the engine If the fault reoccurs continue INSPECT COMPONENT CONNECTOR Disconnect the harness from road speed sensor P37 Are the pins and sockets intact and secure Yes...

Page 144: ...PLAY SENSOR DATA Make note of the IACV Stepper Position value INSPECT IAC VALVE Is the IAC valve fastened properly Is the connector P9 intact and fastened properly Yes Continue No Secure the sensor an...

Page 145: ...NT RESISTANCE Disconnect the harness from the IAC valve P9 Measure the resistance between P9A A and P9A D and between P9A B and P9A C Are the values in range Standard 47 7 58 3 73 F Yes Continue No Re...

Page 146: ...l C and ground between Idle Air Control D and ground Yes Repair wiring Reconnect the harness and clear the fault code Run the IAC valve component test If the fault reoccurs continue No Continue TEST F...

Page 147: ...between Idle Air Control B and P9B B Is there continuity between Idle Air Control C and P9B C between Idle Air Control D and P9B D Yes Contact dealer service No Repair wiring Reconnect the harness an...

Page 148: ...cable terminals if necessary Measure the battery voltage Is the voltage 11 14 volts Yes Make note of the voltage and continue No Charge or replace the battery Clear the fault codes and run the engine...

Page 149: ...Is the value less than the measured battery voltage Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue INSPECT MAIN SWITCH With...

Page 150: ...continue No Move the main switch to the Off position Reconnect connector P40 and continue MEASURE ENGINE STOP RUN SWITCH VOLTAGE Disconnect the harness from the right handle bar controls P25 Move the...

Page 151: ...P2B to the breakout box leaving the ECM disconnected then continue MEASURE SYSTEM VOLTAGE Move the main switch to the On position Move the engine stop run switch to Run Measure the voltage between Ki...

Page 152: ...asure the alternator output voltage Is the voltage acceptable Yes Contact dealer service No Repair alternator Clear the fault codes and run the engine If the fault reoccurs contact dealer service 1023...

Page 153: ...fuse Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue TEST FOR CONTINUITY Disconnect the harness from the fuel pump P18 Is there continuity between P18B 1...

Page 154: ...reoccurs continue CONNECT BREAKOUT BOX Disconnect the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected TEST FOR SHORT TO GROUND Disconnect the harnes...

Page 155: ...pair wiring Reconnect the harness clear the fault codes and run the fuel pump prime component test If the fault reoccurs contact dealer service MEASURE FUEL PUMP FUSE VOLTAGE Measure the voltage at th...

Page 156: ...ay fuel pump fuse and fuse connector cover Clear the fault codes and run the engine If the fault reoccurs continue MEASURE IGNITION RELAY VOLTAGE Move the main switch to the On position Measure the vo...

Page 157: ...des and run fuel pump prime test If the fault reoccurs continue TEST FOR SHORT TO POWER Measure the voltage between the fuel pump signal line P18B 2 and motorcycle ground under the following condition...

Page 158: ...10 seconds any voltage indicates a short with a switched power circuit other than the fuel pump power circuit Main switch On Engine stop run switch Run Any voltage indicates a short with the ECM powe...

Page 159: ...he tachometer work DISPLAY FAULT HISTORY DATA Make note of the Engine Speed value INSPECT ECM CONNECTORS Are the ECM connectors fastened properly Yes Continue No Fasten the ECM connectors Clear the fa...

Page 160: ...air wiring Reconnect the harness clear the fault codes and run the tachometer component test If the fault reoccurs repair or replace the instrument cluster No Repair or replace instrument cluster Disc...

Page 161: ...gine Speed value INSPECT INSTRUMENT CLUSTER CONNECTOR Disconnect the harness from the instrument cluster P20 Are the pins and sockets intact and secure Yes Continue No Repair connector Reconnect the h...

Page 162: ...ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Is there continuity between Tachometer and the potential power sources on the ins...

Page 163: ...Y SENSOR DATA Make note of the Sensor Reference Voltage CONNECT BREAKOUT BOX Disconnect the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then con...

Page 164: ...e No Continue MEASURE SENSOR VOLTAGE Attach the breakout box Y cable female connectors to the ECM Move the main switch to the On position Move the Engine Stop Run switch to the Run position Measure th...

Page 165: ...lace or secure the fuses Clear the fault codes and run the engine If the fault reoccurs continue INSPECT INSTRUMENT CLUSTER CONNECTOR Is the instrument cluster connector P20 intact and fastened proper...

Page 166: ...and the check engine lamp bulb Repair wiring or replace the bulb Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue INSPECT ECM CONNECTORS Are the ECM connec...

Page 167: ...arness from the instrument cluster Is there continuity between the check engine lamp P20A 3 and ground P20A 7 Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fa...

Page 168: ...alue 11 14 volts Yes Continue No Repair wiring and continue MEASURE RELAY COIL VOLTAGE Move the main switch to Acc Measure the voltage at the relay coil input P16B 86 Is the value 11 14 volts Yes Move...

Page 169: ...sconnect the harness from the main switch Move the main switch to Acc Measure the voltage at the accessory output P29B B Is the value 11 14 volts Yes Contact dealer service No Repair wiring Reconnect...

Page 170: ...Fasten the ECM connectors Clear the fault codes and run the engine If the fault reoccurs continue CONNECT BREAKOUT BOX Disconnect the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout...

Page 171: ...onnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue Is there continuity between P20A 2 and the potential power sources on the instrument cluster conn...

Page 172: ...lt guard see Chapter 2 BODY EXHAUST 1 UPPER BELT GUARD 4 Remove the four screws and washers that secure the electronics guard 5 Remove the electronics guard between the rear fender and the wheel d tab...

Page 173: ...the two screws Torque 22 in lbs Caution Do not apply grease to the ECM connectors Grease prevents moisture from escaping the connector body This can cause corrosion of the pins and sockets leading to...

Page 174: ...uel tank and the fuel hose may retain some residual pressure WARNING Gasoline is extremely flammable and can be explosive under certain conditions Always work in a well ventilated area Keep sparks and...

Page 175: ...8 Be sure to secure the hose while running the pump to prevent the hose from coming out of the container 1 DRAIN HOSE 9 Connect the Examinator diagnostic tool to the diagnostic connector on the wirin...

Page 176: ...he tank Caution Lifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging the finish 6 Lift the rear of the fuel tank two or three inches...

Page 177: ...top the fuel pump before it runs dry Running the fuel pump without fuel will damage the pump REMOVAL 1 Disconnect the battery beginning with the negative battery cable see Chapter 16 BATTERY CHARGING...

Page 178: ...ver the disconnection point to prevent fuel spray 9 Wrap a rag around the fuel hose connection point and disconnect the hose from the fuel pump Wipe up any spilled fuel 1 FUEL HOSE 10 Remove the two n...

Page 179: ...ctor through the hole and connect it 7 Connect the wiring harness to the fuel pump and the fuel level sensor Tuck the connectors under the tank electrical connectors 8 Install the instrument cluster s...

Page 180: ...4 124 Be sure the battery is well charged Run the fuel pump for 15 seconds and measure the volume of fuel Multiply the measured value by four to obtain gallons per minute If the flow volume is out of...

Page 181: ...cross the input P18B 1 and output P18B 2 terminals of the fuel pump If there is no continuity replace the fuel pump Test for continuity between the ground terminal P18B 3 and the fuel pump casing If t...

Page 182: ...ot pour from the fuel level sensor opening 4 Remove the five screws from the fuel level sensor 5 Carefully remove the fuel level sensor and rubber gasket 1 FUEL LEVEL SENSOR INSPECTION Inspect the fue...

Page 183: ...alve 3 Disconnect the vent tubes from the purge valve 4 Remove the purge valve 1 PURGE VALVE 2 VENT TUBES INSPECTION While installed on the motorcycle the purge valve should be oriented so that the ar...

Page 184: ...he canister vent tube from the canister 3 Disconnect the rollover vent tube from the canister 4 Remove the screw on the canister strap lift the strap and remove the canister 1 PURGE VENT TUBE 2 CANIST...

Page 185: ...Discard the clip 1 DRAIN TUBE INSPECTION Inspect the rollover valve openings for obstructions Hold the valve with the inlet up Blow air low pressure through the inlet Air should flow freely If not rep...

Page 186: ...ake manifold 1 CLIP 2 FUEL RAIL WARNING There may be a small amount of fuel in the fuel hose and fuel rail Use a rag when removing the fuel rail to absorb any fuel 5 Using the fuel rail mounting stem...

Page 187: ...TALLATION 1 Install a new injector o ring Lubricate the o ring with a small amount of silicon grease 2 Install the injector into the intake manifold Be sure the collar is in place 3 Using the fuel rai...

Page 188: ...es from the throttle body 5 Remove the cable retainer underneath the switch assembly 6 Separate the halves of the right hand switch control and remove the throttle grip 1 CABLE ADJUSTERS 2 JAM NUTS IN...

Page 189: ...Turn the cable adjuster on the throttle opening cable out until the throttle free play is between 1 16 and 3 16 1 CABLE ADJUSTERS 2 JAM NUTS 4 Hold the throttle control grip at the fully closed posit...

Page 190: ...s Torque 8 ft lbs THROTTLE BODY REMOVAL 1 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 2 Remove the four nuts on the air cleaner backplate 3 Pull the air cleaner backplate from the mounti...

Page 191: ...for proper operation Notice On California models inspect the vent tube and coupling for cracks Repair or replace as needed INSTALLATION 1 Fit the throttle body with a new throttle body seal 2 Install...

Page 192: ...ank see FUEL TANK REMOVAL page 4 127 2 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 3 Remove throttle body see THROTTLE BODY REMOVAL page 4 140 WARNING There may be a small amount of fuel...

Page 193: ...Install the fuel tank see FUEL TANK INSTALLATION page 4 128 AIR TEMPERATURE SENSOR REMOVAL 1 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 2 Remove the four nuts on the air cleaner backpla...

Page 194: ...ss 2 Install the air cleaner backplate on the mounting studs and fasten the four nuts Torque 8 ft lbs 3 Install the air cleaner see AIR CLEANER INSTALLATION page 4 140 CRANKSHAFT POSITION SENSOR REMOV...

Page 195: ...and the crankshaft position gear Standard 0 039 inches Measure the resistance across the sensor terminals If the value is not in range replace the crankshaft position sensor Standard 532 588 68 F INS...

Page 196: ...nect the wiring harness from the engine temperature sensor 2 Remove the engine temperature sensor from the front cylinder head 1 ENGINE TEMPERATURE SENSOR INSPECTION Inspect the engine temperature sen...

Page 197: ...or OXYGEN SENSOR REMOVAL 1 Disconnect the wiring harness from the oxygen sensor 2 Remove the oxygen sensor from the rear exhaust pipe INSPECTION Inspect the oxygen sensor and connector for damage Repa...

Page 198: ...the output sprocket cover and remove the cover 1 OUTPUT SPROCKET 3 Remove the three screws from the electronics cover and remove the cover 4 Disconnect the wiring harness from the road speed sensor 5...

Page 199: ...screws and grommets Torque 22 in lbs 5 Install the exhaust and muffler system see Chapter 2 BODY EXHAUST THROTTLE POSITION SENSOR REMOVAL 1 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 2...

Page 200: ...nstall the air cleaner see AIR CLEANER INSTALLATION page 4 140 4 Install the fuel tank see FUEL TANK INSTALLATION page 4 128 5 Reset the closed throttle position Tool Examinator Diagnostic Tool 6999 0...

Page 201: ...or a tilt angle greater than 60 If the values are not in range replace the tilt switch Standard Within 60 11 14 volts Greater than 60 0 8 volts INSTALLATION 1 Install the tilt switch and fasten the tw...

Page 202: ...o ring 1 IDLE AIR CONTROL 2 O RING INSPECTION Remove the air cleaner and inspect the valve movement while running the idle air control valve component test See the Examinator Handbook for information...

Page 203: ...8 5 Use the Examinator diagnostic tool to reset the idle air control valve adaption and the long term fuel trim Tool Examinator Diagnostic Tool 6999 0009 IGNITION COILS SPARK PLUGS REMOVAL 1 Remove th...

Page 204: ...Both spark plugs should have light or medium tan color deposits on the insulator around the electrode tip The spark plug electrode tip and bridge should have sharp square edges Damaged electrodes can...

Page 205: ...erminals If the value is not in range replace the ignition coil Standard 0 8 1 5 INSTALLATION 1 Install the spark plug in to the cylinder head Thread by hand then tighten Torque 15 ft lbs 2 Install th...

Page 206: ...5 0 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION 5...

Page 207: ...sembly should be removed and installed from the right side of the motorcycle TORQUE VALUES TOOLS Engine lift fixture EH 6999 0101 Engine stand adapter EH 6999 0102 SERVICE INFORMATION 5 1 TROUBLESHOOT...

Page 208: ...5 2 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION TROUBLESHOOTING...

Page 209: ...em over the top tube of the frame 8 Disconnect the main switch wire 9 Remove the switch bracket screws and the main switch assembly 10 Remove the output sprocket see OUTPUT SPROCKET REMOVAL page 11 14...

Page 210: ...AFT POSITION SENSOR 24 Remove the air cleaner cover and the air cleaner element 25 Remove the air cleaner backplate and gasket 26 Disconnect the crankcase breather hose 27 Disconnect the air temperatu...

Page 211: ...KET 4 DIAGNOSTIC CONNECTOR 5 BATTERY BOX 39 Disconnect the engine ground wires 1 GROUND WIRE 40 Support the engine from underneath 41 Remove the front engine mount nuts 42 Remove both front mount scre...

Page 212: ...lift fixture EH 6999 0101 Notice Make sure the engine lift fixture is securely installed on the engine lift 1 LIFT FIXTURE 48 Raise the engine until it clears the lower frame rail 49 Tip the engine s...

Page 213: ...e support Notice Make sure the drive belt is not pinched behind the engine during engine installation 7 Remove the engine lift fixture Install Motor Mounts and Regulator 8 Install one of the rear engi...

Page 214: ...cknut from the engine isolator bracket lower stud and tighten the lower stud locknut to a torque of 20 ft lb 1 REMOVE LOCKNUT 2 UPPER STUD 3 LOWER STUD 9 Install the right front engine isolator bracke...

Page 215: ...solator mounting bracket 18 Align the hole in the left rubber engine mount with the alignment pin on the left engine isolator mounting bracket 19 Install the left front engine mounting bracket Install...

Page 216: ...torque of 20 ft lb 1 ENGINE MOUNT COVER NUTS Install Brake Pedal 1 Align the brake pedal with the brake mounting bracket 2 Insert the brake pedal pivot bolt and tighten hand tight 3 Tighten the brake...

Page 217: ...the oil pressure switch 1 OIL PRESSURE SWITCH 2 OIL PRESSURE CONNECTOR Connect the Road Speed Sensor 1 Attach the road speed connector to the road speed sensor 1 ROAD SPEED SENSOR 2 ROAD SPEED CONNEC...

Page 218: ...X 2 WIRING TRAY 3 MOUNTING BOLTS 4 FLANGE NUTS 1 Insert the wiring tray into it s installation location 2 insert the battery box into it s installation location 3 From the battery box side insert one...

Page 219: ...NGE NUTS 7 Plug In the electrical connectors for the fuse holders 8 Install the small mounting bolts 9 Install the battery spacer 1 ELECTRICAL CONNECTOR 2 SMALL MOUNTING BOLTS 3 BATTERY SPACER Install...

Page 220: ...h a constant belt tension Notice Do not finish tighten the axle adjustment locknuts axle nut or drive pulley nut this will be completed in later procedures 1 MOVE REAR WHEEL BACK 2 REAR WHEEL ADJUSTER...

Page 221: ...play as necessary to achieve 1 16 in to 3 16 in of free play 1 RUBBER COVERS 2 CABLE ADJUSTER JAM NUT 3 CABLE ADJUSTER 4 CABLE GUIDES 5 THROTTLE OPENING CABLE 6 THROTTLE CLOSING CABLE Install the Sta...

Page 222: ...l the fuel injector electrical connector labeled 2 on the front 2 cylinder 1 1 FUEL INJECTOR CONNECTOR 2 FRONT 1 CYLINDER 3 2 FUEL INJECTOR CONNECTOR 4 REAR 2 CYLINDER ENGINE TEMPERATURE SENSOR 4 Conn...

Page 223: ...ect the crankshaft sensor wire 1 CRANKSHAFT SENSOR VOLTAGE REGULATOR 5 Connect the voltage regulator plug connector 1 VOLTAGE REGULATOR 2 VOLTAGE REGULATOR PLUG CONNECTOR ALTERNATOR 8 Connect the alte...

Page 224: ...the wires for the air temperature in between the cylinders They will need to be available at the bottom right of the throttle body support bracket 2 Install the throttle body onto the four 4 manifold...

Page 225: ...AIR CONTROL VALVE 2 THROTTLE BODY 3 AIR CLEANER BACKPLATE 4 AIR TEMPERATURE SENSOR 5 BREATHER LINE AIR CLEANER BACKING PLATE 6 Slide the backplate onto the manifold studs 7 Install the four 4 hex fla...

Page 226: ...lave Supply Line 1 Remove the acorn nut This acorn nut is from the shifter linkage rear bolt that is covering the clutch slave cylinder supply line banjo bolt 2 Install new crush washers Notice Anytim...

Page 227: ...ng 5 Close bleeder and repeat steps 1 thru 4 6 Remove the plastic tube wipe up any excess fluid 7 Install the clutch access cover and fasteners when complete 8 Tighten the fasteners to a torque of 8ft...

Page 228: ...OUNTING FASTENERS 4 OIL DIPSTICK Oil Filter 1 Using a new oil filter apply a light coating of oil to the gasket surface of the oil filter 2 Thread the oil filter onto the oil filter adaptor stem 3 Tur...

Page 229: ...e 5 Install the two 2 exhaust flange fasteners and tighten hand tight Always replace the exhaust sealing gaskets whenever the exhaust pipes are removed from the engine 1 FRONT HEAD PIPE 2 EXHAUST SEAL...

Page 230: ...to a torque of 55 ft lb 16 Tighten the muffler mounting bracket bolts to a torque of 30 ft lb 17 Position heat shields and tighten them to a torque of 8ft lb 1 EXHAUST FLANGE NUTS 2 MUFFLER MOUNTING B...

Page 231: ...instrument pod bolts 8 Install the front gas tank isolator mounts and mounting bolts tighten the front and rear tank mounting bolts handtight 9 Tighten the front and rear tank mounting bolts to a torq...

Page 232: ...nter along the rod until pointer tip rests in the center dimple of the rear axle Tighten the pointer thumb screw 3 Move the alignment gauge to the opposite location on the other side of the motorcycle...

Page 233: ...own directly over the 10 lb mark on the plunger 5 Have an assistant complete steps 6 9 6 Place the base of the tension gauge bracket squarely against the lower strand of the drive belt at the front of...

Page 234: ...sion and install a new rear axle cotter pin WARNING Do not reuse a cotter pin because it may fail causing the wheel to loosen and you to lose control of the motorcycle 1 COTTER PIN 2 CASTLE NUT 3 ADJU...

Page 235: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 29...

Page 236: ...5 30 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Page 237: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 31...

Page 238: ...5 32 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Page 239: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 33...

Page 240: ...5 34 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Page 241: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 35...

Page 242: ...5 36 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Page 243: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 37...

Page 244: ...5 38 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Page 245: ...ENGINE REMOVAL INSTALLATION NOTES 6999 0003 7 15 99 5 39...

Page 246: ...6 0 6999 0003 7 15 99 CYLINDER HEAD CAM DRIVE 6...

Page 247: ...self adjusting hydraulic lifters to open the valves Notice To gain access to the cylinder head valves camshafts and cam drive components the engine must be removed from the frame see Chapter 5 ENGINE...

Page 248: ...EH 6999 0062 Idler bearing remover installer EH 6999 0056 Universal driver EH 6999 0043 SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Cylinder compression Pressure 125 175 psi Variance 0 10 Cylinder hea...

Page 249: ...seat Burnt or bent valve Valve stuck open Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Compression too high Carbon build up on piston or combustion chamber...

Page 250: ...n with air 4 Remove the spark plugs 5 Connect a compression gauge to the front cylinder 1 COMPRESSION GAUGE 6 Make sure the transmission is in neutral 7 Make sure the engine Run Stop switch is set to...

Page 251: ...body see THROTTLE BODY REMOVAL page 4 140 Notice Mark all components during disassembly so they can be installed in their original location 1 Blow the area around the spark plug clean with air and rem...

Page 252: ...and the idler shaft O ring 1 TIMING COVER 2 COVER O RING 3 IDLER SHAFT O RING 11 Remove the oil scavenge pump 12 Remove and discard the input and output port O rings 13 Remove idler bearing carrier 1...

Page 253: ...R IDLER GEAR 2 REAR LOWER IDLER GEAR 20 Remove the cam chain tunnel bolts 21 Loosen the cylinder head bolts gradually 1 8 1 4 turn increments in a cross pattern and remove them 22 Separate and remove...

Page 254: ...remove the valve keepers and remove the valve keepers Tool Valve spring compressor EH 6999 0026 1 VALVE SPRING COMPRESSOR 3 Remove the valve spring retainer spring spring seat and valve 4 Remove the...

Page 255: ...hold table height consistency 1 STRAIGHT EDGE 2 FEELER GAUGE 3 Inspect the lifter bores for wear or damage 4 Blow clean all oil passages making sure they are not plugged 1 OIL PASSAGE VALVE SPRING 1 M...

Page 256: ...take 0 0030 in Exhaust 0 0045 in 1 VALVE STEM 2 If the valve to valve guide clearance exceeds the service limit determine if a new valve guide with standard dimensions would bring the clearance within...

Page 257: ...rea 1 UNEVEN SEAT WIDTH 2 FACE DAMAGE 3 CONTACT AREA LOW 4 CONTACT AREA HIGH 8 Measure the valve seat width Notice Valve seat width should be even all the way around the valve Service Limit 0 045 in 9...

Page 258: ...ginal location Tighten the bearing cap screws gradually and evenly in a diagonal pattern Torque 90 in lbs Notice Do not rotate the camshaft while using plastigauge 1 PLASTIGUAGE 2 CAMSHAFT JOURNAL 3 B...

Page 259: ...e wear or damage or if any measurements are past the service limits see CAMSHAFT GEAR REPLACEMENT page 6 21 5 Inspect the cam gear teeth for wear and damage Replace if necessary see CAMSHAFT GEAR REPL...

Page 260: ...ar and idler gear 1 GEAR TEETH 2 THICKNESS 8 Measure and record the gap between the idler gear bosses of the cylinder head 9 Subtract the idler gear thickness from the boss gap to determine the idler...

Page 261: ...TENSIONER 1 Inspect the cam chain tensioner and its spring for wear or damage 2 Release the ratchet and check that the rod moves freely in the housing 3 Replace if necessary 1 SPRING 2 RATCHET 3 ROD 4...

Page 262: ...etaining ring to remove a bearing from the bearing carrier Use the following tools to remove the inner bearings from the engine case Tool Inner idler bearing remover EH 6999 0063 Tool Transmission end...

Page 263: ...o avoid injury use insulated gloves when handling a heated cylinder head 3 Drive the old valve guides out from the combustion chamber side of the cylinder head Tool Valve guide driver EH 6999 0025 1 1...

Page 264: ...the seat Refinish the seat to the specified seat width with a 45 finish cutter Caution Grind the seat only as much as necessary to obtain the desired specification 2 Lap valve seat see LAPPING VALVE...

Page 265: ...Caution Grind the seat only as much as necessary to obtain the desired specification 7 Lap valve seat see LAPPING VALVE SEAT page 6 19 1 NEW SEAT WIDTH LAPPING VALVE SEAT 1 Apply lapping compound to t...

Page 266: ...m oil solution and carefully insert the valves into the valve guides Caution To avoid damaging the valve seal rotate the valve slowly while inserting 1 VALVE STEM 4 Install the valve spring and valve...

Page 267: ...from cam lobe Rear intake 90 degrees from cam lobe 1 INTAKE CAM LOBE 2 FRONT CAM DOWEL POSITION 3 REAR CAM DOWEL POSITION Front exhaust in line with cam lobe Rear exhaust 70 degrees from cam lobe 5 In...

Page 268: ...CHAIN TUNNEL BOLTS 2 9 Tighten the head bolts in the order shown to the initial torque Torque 10 ft lbs 10 Continue tightening the head bolts in the order shown to the intermediate torque Torque 20 ft...

Page 269: ...move any slack in the cam chain and check the alignment of the timing index marks Adjust idler gear in the cam chain if necessary 1 IDLER GEAR TIMING MARK 2 INDEX MARK 22 Reset the cam chain tensioner...

Page 270: ...ll the camshaft bearing caps and tighten the mounting bolts evenly in a diagonal sequence Torque 90 in lbs Notice To aid in returning the camshaft bearing caps to their original location they are cast...

Page 271: ...e any slack in the cam chain and check the alignment of the timing index marks Adjust idler gear in the cam chain if necessary 1 IDLER GEAR TIMING MARK 2 INDEX MARK 39 Reset the cam chain tensioner by...

Page 272: ...ring caps to their original location they are cast with a number that matches a number location cast in the cylinder head The arrow head near the number on the bearing cap should point toward the cams...

Page 273: ...gasket and install the upper cam cover Tighten the mounting bolts in a crisscross pattern starting in the center Torque 12 ft lbs 56 Install spark plugs and ignition coils see IGNITION COILS SPARK PLU...

Page 274: ...7 0 6999 0003 7 15 99 CYLINDER PISTON 7...

Page 275: ...s of the cylinder or the piston during disassembly or assembly When servicing cylinders and pistons mark the disassembled parts to ensure they are reinstalled in their original location When reassembl...

Page 276: ...000 in Standard 0 000 in 010 inch Oversize 0 000 in 020 inch Oversize Piston outer diameter 0 000 in Cylinder to piston clearance 0 000 in Piston ring clearance Compression ring 0 008 in Oil ring 0 00...

Page 277: ...e Leaking cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder and or piston Compression too high Carbon build up on piston or combustion chamber Excessive exhaust smoke Worn...

Page 278: ...tionHold Used to hold table height consistency 4 Remove the fixed and movable cam chain guides Notice Mark all components during disassembly Front or Rear so they can be installed in their original lo...

Page 279: ...in guide for deformed mounting holes and posts Replace as required 2 Inspect the tensioner pad portion of the movable cam chain guide for deformation Replace as required 1 MOUNTING HOLE 2 MOUNTING POS...

Page 280: ...volatile cleaning solvent 1 GASKET MATERIAL 2 MACHINED SURFACES 3 CYLINDERS 3 Inspect the cylinder bore for burned spots scoring grooves scratches scuffing or uneven wear in the ring path area 1 INSP...

Page 281: ...bore and or hone the cylinder to the next larger standard piston size This also requires refitting the cylinder with the next standard size piston and piston rings 1 Measure from front to rear and fro...

Page 282: ...ead bolt Insert the feeler gauge between the metal scale and the cylinder base surface Repeat this measurement for each pair of adjacent head bolts Service Limit 0 008 in 1 CYLINDER BASE SURFACE 2 MET...

Page 283: ...ls hone the bore to create an angular crosshatch pattern of 60 Caution An improper crosshatch pattern or too fine a hone may result in high engine oil consumption and piston seizure 1 Coat the cylinde...

Page 284: ...n clips Caution Do not reuse piston pin clips The removal process can weaken them causing them to break or dislodge resulting in engine damage 5 Using the piston pin puller remove the piston pin from...

Page 285: ...ing or melting burning and scoring 2 Inspect the edges of the piston domes for nicks or burrs Remove any defects with a light filing of the edge of the piston dome and buff smooth with a steel wool pa...

Page 286: ...te text StepCaptionHold Used to hold table height consistency 1 OIL RING 2 COMPRESSION RING 1 3 COMPRESSION RING 2 4 Use a piston to press each piston ring squarely into the cylinder bore Remove the p...

Page 287: ...ameter from the piston pin hole inner diameter Service Limit 0 000 in 1 PISTON PIN HOLE 2 PISTON PIN CONNECTING ROD PISTON PIN BUSHING 1 Measure and record the inner diameter of the piston pin bushing...

Page 288: ...new piston pin bushing into the connecting rod and install the piston pin bushing tool into the connecting rod 3 Press in the new piston pin bushing 4 Drill 7 64 inch oil holes in top of bushing 5 Re...

Page 289: ...xpander ring into the third ring groove StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 COMPRESSION RINGS 2 OI...

Page 290: ...onHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 MOVABLE CAM CHAIN GUIDE 2 DOWEL PINS 3 CYLINDER BASE GASKET 7 Apply clean engine oil to the cylinder walls and...

Page 291: ...are properly seated 11 Install the cylinder heads see CYLINDER HEAD CAM DRIVE INSTALLATION page 6 21 1 STATIONARY CAM CHAIN GUIDE StepCaptionHold For demonstration only StepCaptionHold These are BLIND...

Page 292: ...8 0 6999 0003 7 15 99 CRANKCASE CRANKSHAFT 8...

Page 293: ...L TORQUE VALUES TOOLS TROUBLESHOOTING SERVICE INFORMATION 8 1 TROUBLESHOOTING 8 1 Remove all fasteners from the left side of the crankcase holding the crankcase halves together 8 3 CRANKSHAFT 8 11 CON...

Page 294: ...onsistency 1 ROAD SPEED SENSOR 2 CRANKSHAFT POSITION SENSOR 3 NEUTRAL SWITCH CRANKCASE SEPERATION Remove all fasteners from the right side of the crankcase holding the crankcase halves together Remove...

Page 295: ...the way around the crankcase to loosen the bond between the mating surfaces of the crankcases to separate the crankcase halves StepCaptionHold For demonstration only StepCaptionHold These are BLIND wh...

Page 296: ...kshaft Disassemble the rods from the crankshaft 1 OUTER SIDE RIGHT ROD 2 OUTER SIDE RIGHT ROD Install the rod cap onto the same rod immediately after removal with dimple on rod in alignment with dimpl...

Page 297: ...need to be replaced 1 V BLOCKS 2 CRANKSHAFT 3 DIAL INDICATOR AND FREE STANDING BASE INSPECTION MAIN BEARING CRANKSHAFT Inspect the primary drive Left Case side crankshaft main bearing journal for scr...

Page 298: ...damaged it will need to be turned down or replaced 1 12 AND 6 POSITION 2 3 AND 9 POSITION INSPECTION MAIN BEARING CRANKCASE Inspect the crankcase primary drive Left Case side main bearing for scratche...

Page 299: ...mit or has scratches wear or is damaged it will need to be replaced and new bearings installed 1 TELESCOPING GAUGE 2 MICROMETER 3 2 AND 8 POSITION 4 4 AND 11 POSITION REPLACEMENT MAIN BEARING CRANKCAS...

Page 300: ...RING REMOVER 2 UNIVERSAL DRIVER 3 HAND TORCH 4 PRESS OR HAMMER REPLACEMENT MAIN BEARING CRANKCASE INSTALLATION PRIMARY OR CAM DRIVE BEARING Caution The Crankshaft Bearing Installer has two different d...

Page 301: ...ORT 2 MAIN BEARING Install the crankshaft bearing installer onto the universal handle driver Using a small hand torch heat the crankcase casting area around the bearing for approximately 4 to 5 minute...

Page 302: ...cratches wear or is damaged it will need to be turned down or replaced and new bearings installed Rod bearings are available in the following sizes 0 00 in Standard 0 10 in 0 20 in 1 MICROMETER 2 12 A...

Page 303: ...old Used to hold table height consistency 1 2 MAIN BEARING REPLACEMENT StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consi...

Page 304: ...8 12 6999 0003 7 15 99 CRANKCASE CRANKSHAFT StepNumber StepNumber StepNumber StepNumber INSPECTION 1 2 CAM GEAR REPLACEMENT 1 2 OIL PUMP GEAR REPLACEMENT 1 2 INSTALLATION 1 2...

Page 305: ...er StepNumber StepNumber CONNECTING RODS REMOVAL 1 2 INSPECTION OIL CLEARANCE 1 2 WRIST PIN CLEARANCE StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold...

Page 306: ...NKCASE CRANKSHAFT StepNumber StepNumber StepNumber StepNumber INSTALATION 1 2 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table h...

Page 307: ...6999 0003 7 15 99 8 15 StepNumber StepNumber StepNumber StepNumber 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height cons...

Page 308: ...9 0 6999 0003 7 15 99 PRIMARY DRIVE 9 10794...

Page 309: ...tion see Chapter 17 STARTER For additional Alternator service information see Chapter 16 BATTERY CHARGING SYSTEM For additional Clutch service information see Chapter 10 CLUTCH Caution Cleanliness is...

Page 310: ...ator Remove the cable tie if necessary 7 If servicing the hydraulic clutch system remove the banjo bolt clutch hose and sealing washers Discard the sealing washers 8 Remove the outer primary cover scr...

Page 311: ...see STATOR INSTALLATION page 16 9 1 INSERT INSTALLATION 1 Clean any remaining gasket material from the inner and outer primary covers 2 Make sure the two alignment pins are in position 3 Using a new...

Page 312: ...0 3 10 Adjust the clutch freeplay see ADJUSTING CLUTCH FREEPLAY page 10 4 11 Install gear shifter assembly see GEAR SHIFTER INSTALLATION page 11 4 12 Fill the engine case with oil see ENGINE OIL page...

Page 313: ...driven ramps Each ramp face should have a smooth gradual slope without ridges grooves or steps 2 Position the driven ramp on the crankshaft sleeve The ramp should rotate smoothly and evenly around th...

Page 314: ...the four compensator springs are identical they must be installed in the orientation shown 5 Using an impact wrench install the spring retainer Tool Torsional compensator socket EH 6999 0041 Torque 80...

Page 315: ...the engine case and inner primary cover 2 Make sure the two alignment pins are in position 3 Using new gaskets install the inner primary cover and tighten the cover mounting screws Torque 8 ft lbs No...

Page 316: ...10 0 6999 0003 7 15 99 CLUTCH 10 10758...

Page 317: ...the hydraulic system can damage brake system componants Do not use mineral based products to clean clutch cylinder parts Use only denatured alcohol DOT 5 hydrau lic fluid or a solvent specifically rec...

Page 318: ...ufficient fluid in the master cylinder Contaminated hydraulic fluid System leak Clutch freeplay out of adjustment Clutch lever feels spongy when applied Air in the hydraulic system Contaminated hydrau...

Page 319: ...ESERVOIR CAP 2 PLATE 3 DIAPHRAGM 5 Remove the clutch cover 6 Push one end of a piece of 3 16 I D clear tubing over the slave cylinder bleed valve Place the other end of the tube in a container filled...

Page 320: ...esistance is felt piston is against outer retaining ring 5 Hold the inner jam nut and turn the adjustment screw counter clockwise until the inner jam nut is captured by the slave cylinder Continue tur...

Page 321: ...PLATE 3 DIAPHRAGM 4 LEVER BOLT 5 LEVER ASSEMBLY 6 DUST BOOT 7 PUSH ROD 8 RETAINING RING 9 PISTON ASSEMBLY 10 RETURN SPRING INSPECTION 1 Clean all cylinder parts and blow out all fluid ports with compr...

Page 322: ...ush the piston past the retaining ring groove in the cylinder bore 5 Install a new retaining ring with retaining ring pliers Notice Make sure the retaining ring is completely seated in the cylinder bo...

Page 323: ...to the left side steering stop Adjust the turn signal assembly to the desired position and tighten the gimbal nut 6 Bleed the clutch system see BLEEDING CLUTCH SYSTEM page 10 3 1 GIMBAL NUT 2 BANJO B...

Page 324: ...caliper housing with great force resulting in damage to the piston or personal injury Point the caliper away from you or others and wear heavy gloves or wrap the caliper housing in a heavy towel befor...

Page 325: ...d port the clutch hose and both ends of the supply tube The machined surfaces must be absolutely free of damage If any damage is observed replace the component 1 CYLINDER BORE 2 PISTON 3 FLUID PORT 4...

Page 326: ...system operation always use new sealing washers 5 Tighten the supply tube hex nut Torque 35 ft lbs Notice Make sure the head of the slave cylinder supply tube is properly seated in the outer primary c...

Page 327: ...1 With the clutch collar installed in the clutch basket compress the diaphragm springs Tool Valve spring compressor EH 6999 0026 Tool Clutch compression adaptors EH 6999 0027 2 Remove the spring retai...

Page 328: ...asteners for wear cracks or damage Replace components as necessary LIFT PLATE BEARING 1 Turn the inner race of the lift bearing with your finger The bearing should turn smoothly and quietly without ex...

Page 329: ...ISC CLUTCH PLATES 1 Inspect the clutch plates for scoring and discoloration 2 Use a surface plate and a feeler gauge to measure the plate warpage Service Limit 008 in 3 Measure the clutch plate thickn...

Page 330: ...tached to the clutch basket 1 COLLAR 2 CLUTCH BASKET 3 CLUTCH GEAR 5 Inspect the clutch basket dogs for scoring nicks notches or abnormal wear caused by the friction discs Replace components as necess...

Page 331: ...tch basket 1 THRUST WASHER 2 HUB 3 CLUTCH BASKET 4 FRICTION DISC BROWN TAB 5 CLUTCH PLATE 6 FRICTION DISC GREEN TAB 7 FRICTION DISC BLUE TAB 8 SHALLOW DOG 11 Install the pressure plate spring seat and...

Page 332: ...the belleville washer should contact the spring retainer 3 Hold the clutch basket stationary and install the clutch mounting nut Tool Clutch basket wrench EH 6999 0030 Torque 90 ft lbs 1 MOUNTING NUT...

Page 333: ...CLUTCH NOTES 6999 0003 7 15 99 10 17...

Page 334: ...11 0 6999 0003 7 15 99 TRANSMISSION 11 10822...

Page 335: ...and cause serious eye injury To Avoid injury when removing or installing retaining rings always use the correct size and type retaining ring pliers and be sure the tips are not worn or damaged Notice...

Page 336: ...ller EH 6999 0061 Shift shaft bearing tool EH 6999 0060 Output shaft seal installer EH 6999 0057 TROUBLESHOOTING Excessive noise Worn seized or damaged transmission gear Worn or damaged transmission b...

Page 337: ...KET DISASSEMBLY 1 Remove the pinch screw from the front shift lever and remove the shift lever 2 Remove the shifter shaft from the pivot bracket 3 Remove the pinch screws from the foot peg levers and...

Page 338: ...ker Torque 8 ft lbs 1 FOOT PEG LEVER 2 SHIFT SHAFT 3 FRONT SHIFT LEVER INSTALLATION 1 Install the rear shift lever on the transmission shift shaft as shown 2 Install the pinch screw with one drop of L...

Page 339: ...ever and remove the shift lever 1 ACORN NUT 2 BALL JOINT 3 SHIFT LEVER 4 PINCH SCREW 8 Remove the transmission cassette plate screws 9 Carefully tap on the end of the output shaft with a wooden or pla...

Page 340: ...from the output shaft 8 Remove the retaining ring needle bearing and washer from the input shaft 9 Remove the retaining ring washer and 5th gear from the input shaft 1 5TH GEAR OUTPUT 2 RETAINING RING...

Page 341: ...transmission parts in solvent prior to inspection BEARINGS 1 Inspect the input end bearing race in right side engine case and the output end bearing race in cassette plate for grooves scoring or gall...

Page 342: ...PUT MAIN BEARING 2 BEARING RETAINER 5 Inspect the shift drum bearing The inner race should turn smoothly and quietly and the shift drum should slide easily into the bearing without excess play 6 The o...

Page 343: ...Output 3rd gear somethingO3 1 DOG 2 DOG HOLE 3 SPLINE 4 MEASURE I D SHAFTS 1 Check the spline grooves bearing surfaces and gear shoulders for damage and abnormal wear 2 Measure the shaft diameter in t...

Page 344: ...Limit something 3 Inspect the shift fork shafts for deformation and abnormal wear Replace components as necessary 1 SHIFT CLAW 2 SHIFT DRUM PIN SHIFT MECHANISM 1 Inspect the stop stud detent arm all...

Page 345: ...3 OUTER RETAINER 4 INNER RETAINER 5 CASSETTE PLATE Notice Coat the bearing surface of all gears bearings shafts and the shift drum grooves prior to assembly 5 Install 3rd gear the washer and the reta...

Page 346: ...1 5TH GEAR OUTPUT 2 RETAINING RING 3 NEEDLE BEARING 4 WASHER 5 RETAINING RING 6 WASHER 7 5TH GEAR INPUT 15 Install the shift drum bearing Notice The shift drum bearing has a slip fit and should not re...

Page 347: ...nput shaft and output shaft with an assembly lubricant 3 Carefully slide the transmission assembly into the engine case and install the cassette plate screws Torque 18 ft lbs Notice Make sure the cass...

Page 348: ...ely 4 Remove the lower belt guard 1 SPROCKET COVER 2 LOWER BELT GUARD 5 Remove and discard the rear axle cotter pin 6 Loosen the castle nut 7 Loosen the rear axle adjuster jam nuts and turn the adjust...

Page 349: ...ves scratches and pitting Replace components as necessary 1 SPLINES 2 SIDE PLATE 3 TEETH 4 SPACER 5 Inspect the sprocket cover grommets for cracks and brittleness Replace grommets as necessary 1 COVER...

Page 350: ...2 ADJUSTER COLLAR 9 Install the lower belt guard Torque 5 ft lbs 10 Install the sprocket cover Torque 8 ft lbs 11 Install the exhaust system see EXHAUST SYSTEM INSTALLATION page 2 13 1 SPROCKET COVER...

Page 351: ...unt aligned 8 Remove the right side mount spacer and mount 9 Remove the drive belt 1 NUT 2 SCREW 3 SHAFT 4 SPACER 5 MOUNT INSTALLATION 1 Place the drive belt on the front sprocket and feed it out the...

Page 352: ...12 0 6999 0003 7 15 99 WHEELS 12 10736...

Page 353: ...n those used on the front WARNING Riding on damaged wheels or tires impairs safe operation of this vehicle For brake system service see Chapter 15 BRAKES SERVICE INFORMATION 12 1 TROUBLESHOOTING 12 2...

Page 354: ...ed tire and wheel Loose axle fasteners Faulty swing cage pivot bearings see Chapter 14 REAR SUSPENSION Wheel rotation difficult Faulty wheel bearings Bent axle Brake drag see Chapter 15 BRAKES SPECIFI...

Page 355: ...pacers and caliper bracket Notice Do not operate the front brake while the front wheel is removed Doing so will cause difficulty reinstalling the brake rotor between the brake pads 1 AXLE PINCH SCREW...

Page 356: ...Standard Lateral 0 00 0 08 1 DIAL INDICATOR RADIAL 2 DIAL INDICATOR LATERAL BRAKE ROTOR 1 Place the wheel in a truing stand and measure the brake rotor runout Spin the wheel slowly and read the runou...

Page 357: ...remove the spokes and rim from the hub 1 STAMPED TEXT 2 PUNCH ASSEMBLY 1 If hub was removed from wheel see LACING WHEEL page 12 12 2 Install a new bearing in the stamped text side of the hub with the...

Page 358: ...pads during front wheel installation 3 Coat the axle with a thin film of molybdenum grease 4 Slide the axle all the way through the bevel washer rockers spacers bracket and wheel from the left side o...

Page 359: ...cause difficulty reinstalling the brake rotor between the brake pads 10 Support the rear wheel from underneath and carefully push or pull the axle out to the right 11 Hold the caliper bracket in posit...

Page 360: ...ateral 0 00 0 08 1 DIAL INDICATOR RADIAL 2 DIAL INDICATOR AXIAL BRAKE ROTOR 1 Place the wheel in a truing stand and measure the brake rotor runout Spin the wheel slowly and read the runout using a dia...

Page 361: ...remove the spokes and rim from the hub 1 STAMPED TEXT 2 PUNCH ASSEMBLY 1 If hub was removed from wheel see LACING WHEEL page 12 12 2 Install a new bearing in the stamped text side of the hub with the...

Page 362: ...he brake caliper bracket slot is in position on the swing cage tab 3 Place the axle spacers in position on the wheel Lift the rear wheel and spacers into the swing cage from behind Support the wheel f...

Page 363: ...GAUGE 2 POINTER 3 Move the alignment gauge to the opposite location on the other side of the motorcycle 4 Without moving the alignment gauge pointer turn the rear axle adjuster in or out until the ce...

Page 364: ...flange inner spokes counterclockwise as far as possible 3 Insert an outer spoke in each remaining lower flange spoke hole Swing all lower flange outer spokes clockwise as far as possible 1 STAMPED TEX...

Page 365: ...hat point inward toward each other 1 RIM 2 SPOKE HOLE GROUP 10 9 Lace a lower flange outer spoke through the one hole in a spoke hole group that points toward the spoke 10 Lubricate the threads and sc...

Page 366: ...age 12 14 1 UPPER FLANGE OUTER SPOKE HOLE 2 SPOKE HOLE GROUP 10 TRUING WHEEL 1 Mark the center of one of the ten spoke groups with a piece of tape 2 Mark the center of the spoke group directly across...

Page 367: ...for all four marked spoke groups 1 SPOKE HOLE GROUP 2 SPOKES TO STAMPED TEXT FLANGE 9 Adjust the truing stand gauge to the tire bead seat 10 Spin the rim slowly If the rim contacts the gauge near a ma...

Page 368: ...t the valve stem hole lubricate and tighten the remaining spoke nipples one turn at a time Torque 40 in lbs 1 GAUGE R Caution Do not tighten spokes too tight or damage to rim hub spokes or nipples may...

Page 369: ...langes with a tire lubricant or liquid soap 5 Using tire irons and rim protectors start the upper bead over the edge of the rim at the valve stem Continue all around rim until first bead is entirely o...

Page 370: ...sidewall it is the tire balance mark heaviest point and should be located next to the valve stem when the tire is mounted 4 Beginning at the valve stem hole place the first bead into the rim well Work...

Page 371: ...is within the specified tolerance the tire is at fault and should be replaced 1 GAUGE LATERIAL RUNOUT 1 Mount the wheel assembly in a truing stand Slowly turn the wheel assembly and measure the amount...

Page 372: ...p properly attached 2 Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel 3 Repeat this procedure two or three times to verify the heaviest area If the wheel is balanced it...

Page 373: ...WHEELS NOTES 6999 0003 7 15 99 12 21...

Page 374: ...13 0 6999 0003 7 15 99 FRONT SUSPENSION STEERING 13...

Page 375: ...5 00 ft lbs Caliper rod mount screws 6 00 ft lbs Brake hose banjo bolt 7 00 ft lbs Suspension rocker bolts 8 00 ft lbs Steering stem lock nut 9 00 ft lbs Top triple clamp acorn nut 10 00 ft lbs Fork...

Page 376: ...not track straight Damaged or loose steering head bearings Bent front fork Bent front struts Bent front axle Front wheel installed incorrectly Bent frame Worn or damaged front wheel bearings Worn or...

Page 377: ...turn both cable adjusters to create slack in the cables Disconnect the cables from the hand grip and slide the hand grip off the handlebar Carefully allow the control assembly to hang by the throttle...

Page 378: ...d or personal injury StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 RISER 2 HANDLEBAR KNURLED AREA 3 CLAMP Ti...

Page 379: ...adequate travel Failure to insure proper operation could result in damage to the motorcycle and or personal injury 1 CABLE RETAINER 2 LEFT CONTROL ASSEMBLY 3 CLUTCH LEVER ASSEMBLY STRUTS REMOVAL Remov...

Page 380: ...1 STRUT 2 FENDER MOUNTING SCREWS 4 3 TAPE Remove one of the strut axle end bolts Support the strut assembly opposite the remaining strut axle end bolt Pull the strut axle out only enough to release t...

Page 381: ...TAINER 3 DAMPER UNIT HEAD 4 UPPER STRUT COVER 5 UPPER SPRING ISOLATOR Remove the lower spring isolator Stabilize the lower strut Use the flats at the base of the damper unit to unscrew it from the low...

Page 382: ...ring isolator for cracks tears and brittleness Replace as needed 1 FREE LENGTH STRUT AXLE Place the strut axle in V blocks and measure the runout Notice Actual runout is 1 2 the total indicator readin...

Page 383: ...ng upper spring isolator and upper strut cover Slide the spring retainer between upper spring cover and the damper unit head Decompress the strut spring 1 STRUT SPRING 2 SPRING RETAINER 3 DAMPER UNIT...

Page 384: ...height consistency 1 STRUTS 2 RIGID FORK 3 TAPE 4 FENDER MONTING SCREWS 4 Install the brake caliper assembly by attaching the caliper rod mount to the rigid fork Torque Caliper rod mount screws 6 00 f...

Page 385: ...tion only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 FORK Release any headlamp wire retainers and disconnect the headlamp wire from the main wir...

Page 386: ...G HEAD INSPECTION TOP TRIPLE CLAMP Inspect the top triple clamp bushings Blow the bushings clean and dislodge any abrasive particles imbedded in the bushings A straight strut axle should pass easily t...

Page 387: ...rests squarely on the spacers Measure the distance from the work surface to the bottom of one fork leg at the fork bearing center Label this dimension D1 Measure the remaining fork in the same manner...

Page 388: ...uced vehicle control resulting in personal injury Hold the retaining nut and tighten the lock nut Tool Retaining nut socket XXXX XXX6 Torque Steering stem lock nut 9 00 ft lbs Check that the bearing p...

Page 389: ...ary Inspect the lower bearing and lower bearing race for signs of wear such as cracks galling flat spots and metal filings mixed with the bearing grease Replace the lower bearing and race if necessary...

Page 390: ...alent tool Be careful not to damage the fork or steering stem 1 ACORN NUT 2 STEERING STEM 3 LOWER TRIPLE CLAMP 4 LOWER BEARING SEAL 5 CHISEL INSTALLATION Pack the new lower bearing seal with wheel bea...

Page 391: ...g head Contact only the outer race of the bearing pressing it squarely into the head until it seats Tool Bearing driver XXXX XXX3 StepCaptionHold For demonstration only StepCaptionHold These are BLIND...

Page 392: ...14 0 6999 0003 7 15 99 REAR SUSPENSION 14...

Page 393: ...999 0003 7 15 99 14 1 SERVICE INFORMATION GENERAL TORQUE VALUES TOOLS TROUBLESHOOTING SERVICE INFORMATION 14 1 TROUBLESHOOTING 14 1 SHOCK ABSORBER 14 2 SWING CAGE 14 3 SPECIFICATIONS Unit inch ITEM ST...

Page 394: ...epCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 2 REMOVAL StepCaptionHold For demonstration only StepCaptionHold...

Page 395: ...Number StepNumber StepNumber StepNumber ASSEMBLY 1 2 INSTALLATION StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistenc...

Page 396: ...N StepNumber StepNumber StepNumber StepNumber PIVOT BEARING REPLACEMENT 1 2 INSTALLATION StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold...

Page 397: ...999 0003 7 15 99 14 5 StepNumber StepNumber StepNumber StepNumber 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consis...

Page 398: ...14 6 6999 0003 7 15 99 REAR SUSPENSION StepNumber 1 2...

Page 399: ...REAR SUSPENSION 6999 0003 7 15 99 14 7...

Page 400: ...15 0 6999 0003 7 15 99 BRAKES 15...

Page 401: ...nation Use only DOT 5 silicone based hydraulic fluid from a sealed clean container Using the wrong hydraulic fluid or allowing contaminants into the hydraulic system can damage brake system componants...

Page 402: ...ot yet seated Caliper piston seized or sticking Excessive brake pedal or lever travel Air in the hydraulic system Insufficient fluid in the master cylinder Contaminated hydraulic fluid System leak Act...

Page 403: ...push one end of a piece of 3 16 I D clear tubing over the bleed valve Place the other end of the tube in a container filled with enough hydraulic fluid to cover the end of the tube 6 Pump the brake p...

Page 404: ...4 BANJO BOLT 5 BRAKE HOSE 6 SEALING WASHER 7 HANDLEBAR CLAMP DISASSEMBLY 1 Clean the area around the reservoir cap and remove the reservoir cap plate and diaphragm Empty the reservoir of any remaining...

Page 405: ...Clamp the master cylinder securely in a padded vise 2 Insert a new piston return spring into the master cylinder with the larger windings toward the brake hose port Caution For proper master cylinder...

Page 406: ...w sealing washers 3 Connect the brake light wire harness 4 Install the turn signal assembly and tighten the turn signal gimbal nut finger tight 5 Install the mirror 6 Rotate the master cylinder assemb...

Page 407: ...G PIN 4 BRAKE PAD 6 Inspect the brake rotor A heavily scored rotor should be replaced 7 Measure the thickness of the rotor in the brake pad contact area Replace the rotor if it has worn beyond the min...

Page 408: ...ousing screws 5 Remove the caliper from the padded vise and separate the caliper housing 6 Remove the anti rattle spring 7 Remove and discard the cross port O ring StepCaptionHold For demonstration on...

Page 409: ...re If there is evidence or scoring pitting or corrosion replace the caliper assembly 3 Inspect each piston If there is evidence of scoring pitting or corrosion replace the piston set 4 Inspect the bra...

Page 410: ...r bore 2 Install a new dust seal in each cylinder bore 3 Lubricate each piston with clean DOT 5 hydraulic fluid and with the cupped end facing toward the brake pad carefully press the piston into the...

Page 411: ...E 3 SEALING WASHER 4 CALIPER ROD 5 CALIPER ASSEMBLY REAR MASTER CYLINDER REMOVAL 1 Remove the front right foot support assembly 2 Remove the brake pedal clevis pin and cotter pin Discard the cotter pi...

Page 412: ...UST SEAL 3 RESERVOIR CONNECTOR 4 RETAINING RING 5 SUPPLY PORT O RING 7 Remove the spring bellows 8 While compressing the spring loosen the jam nut and remove the rod clevis 9 Remove the clevis end spr...

Page 413: ...aphragm piston dust boot and bellows for cuts tears and deterioration Replace items if necessary 1 SUPPLY PORT 2 BRAKE HOSE PORT 3 BRAKE HOSE FITTING 4 DIAPHRAGM 5 DUST BOOT 6 BELLOWS ASSEMBLY 1 Clamp...

Page 414: ...er cylinder 14 Install a new retaining ring with retaining ring pliers 15 Install a new dust seal and connector O ring 16 Attach the diaphragm plate and cap to the fluid reservoir StepCaptionHold For...

Page 415: ...the hose or caliper could occur 2 Use a large flat blade screwdriver or small pry bar against the old brake pads and spread the caliper pistons as far apart as possible 3 Remove the retaining ring and...

Page 416: ...ting screws and slide the caliper forward and off of the brake rotor 1 BANJO BOLT 2 BRAKE HOSE 3 SEALING WASHER 4 MOUNTING SCREWS DISASSEMBLY 1 Clean brake dust from the caliper 2 Clamp the caliper se...

Page 417: ...careful not to scratch the cylinder bore when removing the piston seals 10 Remove the bleed valve cover and the bleed valve 1 DUST SEAL 2 WIPER SEAL INSPECTION 1 Clean all caliper parts and blow out...

Page 418: ...n procedures see REAR WHEEL DISASSEMBLY page 12 8 and see REAR WHEEL ASSEMBLY page 12 9 ASSEMBLY 1 Install a new wiper seal in each cylinder bore 2 Install a new dust seal in each cylinder bore 3 Lubr...

Page 419: ...tall the two mounting screws Torque 35 ft lbs 2 Install the banjo bolt brake hose and new sealing washers Torque 18 ft lbs Caution For proper brake system operation always use new sealing washers 3 Bl...

Page 420: ...16 0 6999 0003 7 15 99 BATTERY CHARGING SYSTEM 16...

Page 421: ...ttery specifically designed for use in the Super X motorcycle Follow manufacturers instructions for proper preparation of the battery before installation WARNING The battery contains sulfuric acid whi...

Page 422: ...current leakage and locate short if readings are high Test regulated voltage Test alternator output and inspect alternator stator and rotor if readings are low Test current balance Battery overchargin...

Page 423: ...R 3 NEGATIVE CABLE 4 POSITIVE CABLE INSPECTION 1 Inspect the battery for leaks cracks or damage to the case Replace the battery if necessary Notice Over time the ends of the battery case may bow inwar...

Page 424: ...w the battery to sit 1 2 hours before checking the charge Use a voltmeter to check the charge Repeat the charging cycle if the charge is less than the minimum Standard 12 8 V or more 1 BATTERY CHARGER...

Page 425: ...RNATOR OUTPUT page 16 5 1 DC VOLTMETER 2 POSITIVE TERMINAL 3 NEGATIVE TERMINAL ALTERNATOR OUTPUT 1 Disconnect the wiring harness from the voltage regulator connector 2 Check the connector for corrosio...

Page 426: ...ative battery cable 5 Connect the negative probe of the ammeter to the negative battery terminal Caution When using an ammeter set it to a high range initially Current that is higher than the selected...

Page 427: ...ickup over the alternator wire 13 Start the engine run it at 3000 rpm Increase the load on the load tester as required to obtain a constant 13 0 volts 14 Record the current output The current output s...

Page 428: ...nets 4 Clean the rotor using a petroleum based solvent and a clean dry cloth 1 ROTOR INSIDE 2 ROTOR TAPERED BORE ROTOR INSTALLATION 1 Slide the rotor onto the crankshaft WARNING When installing the ro...

Page 429: ...sistance see ALTERNATOR STATOR page 16 6 1 STATOR STATOR INSTALLATION 1 Position the stator on the outer primary cover and route the stator wire above the stator as shown 2 Install the stator mounting...

Page 430: ...bracket and install the mounting screws and locknuts Torque 8 ft lbs 2 Connect the regulator to the alternator and to the wire harness 3 Secure the connectors to the bottom frame tube with a new cable...

Page 431: ...BATTERY CHARGING SYSTEM NOTES 6999 0003 7 15 99 16 11...

Page 432: ...17 0 6999 0003 7 15 99 STARTER 17 10722...

Page 433: ...starts the crankshaft accelerates and overtakes the starter crankshaft gear disen gaging the sprag clutch WARNING Disconnect the battery before servicing the starter motor or the starter relay TORQUE...

Page 434: ...pen circuit Faulty ground Starter motor runs slowly Low battery voltage Faulty starter motor connection Faulty starter relay connection Faulty engine ground connection Faulty starter motor Starter mot...

Page 435: ...n the starter motor while observing the ammeter Ignore the initial peak current value If the value is out of range a starter malfunction is likely Remove and inspect the starter motor see STARTER MOTO...

Page 436: ...NDING BRUSHES INSPECTION Make sure no engine oil is present inside the starter motor casing COMMUTATOR 1 Clean with crocus cloth if needed Measure the diameter of the commutator in the brush contact a...

Page 437: ...continuity between the brush holder base and each of the two field winding brush housings If the test fails replace the brush holder Standard No continuity 1 BRUSH HOLDER BASE 2 INSULATOR 3 FIELD WIN...

Page 438: ...that the transmission is in neutral and remove the ignition coils from the spark plugs 4 Move the engine run stop switch to the Run position and the main switch to the On position 5 Press the starter...

Page 439: ...cables and wiring harness to the starter relay 3 Install the electronics cover and mounting screws Torque 5 ft lbs 4 Install the muffler and exhaust assembly see EXHAUST SYSTEM INSTALLATION page 2 13...

Page 440: ...ree of grooves or brinelling chatter marks 2 Inspect the sprag cams They should move freely in all directions The sprag housing should retain the cams at all times 1 SPRAG INNER RACE 2 SPRAG OUTER RAC...

Page 441: ...PIN 3 GASKET 4 INNER PRIMARY COVER 5 If removed assemble the starter gear and sprag outer race if required and fasten the screws Torque 55 in lbs 6 Lightly lubricate the sprag cams with an assembly lu...

Page 442: ...install the starter gear sprag clutch assembly on the crankshaft 8 Install the clutch see CLUTCH INSTALLATION page 10 16 9 Install the torsional compensator see TORSIONAL COMPENSATOR INSTALLATION page...

Page 443: ...STARTER NOTES 6999 0003 7 15 99 17 11...

Page 444: ...18 0 6999 0003 7 15 99 LIGHTS GAUGES SWITCHES 18...

Page 445: ...LATION 18 14 TAIL LAMP 18 14 BULB REPLACEMENT 18 14 REMOVAL 18 14 INSTALLATION 18 15 TURN SIGNAL CONTROL MODULE18 15 REMOVAL 18 14 INSTALLATION 18 16 TURN SIGNAL LAMPS 18 16 BULB REPLACEMENT 18 16 FRO...

Page 446: ...g screw 35 ft lbs Tail lamp mounting screw 7 ft lbs Front turn signal gimbal nut 10 ft lbs Rear turn signal mounting screw 20 ft lbs Horn cover nut 8 ft lbs Horn mounting screw 22 in lbs Neutral switc...

Page 447: ...not work Faulty horn Blown horn fuse Faulty wiring Turn signals do not work Faulty bulb Faulty turn signal control module Faulty wiring Fault turn signal switch Tail lamp does not work Faulty bulb Blo...

Page 448: ...DLEBAR CONTROL REMOVAL 1 Disconnect the battery negative cable first see BATTERY REMOVAL page 16 3 2 Remove the fuel tank see FUEL TANK REMOVAL page 4 127 3 Remove the handlebar wire clips and steerin...

Page 449: ...for continuity between the switch input P25A C and ground P25A D with the switch set to Run and Stop If the test fails replace the right handlebar control Standard Run Continuity Stop No Continuity 1...

Page 450: ...Install the control body on the handlebar and fasten the screws Torque 20 in lbs Notice Place the tab on the control body into the hole in the handlebar 1 ALIGNMENT HOLE 2 Route the handlebar control...

Page 451: ...als Horn button powered through the horn fuse and controls power to the horn REMOVAL 1 Disconnect the battery negative cable first see BATTERY REMOVAL page 16 3 2 Remove fuel tank see FUEL TANK REMOVA...

Page 452: ...beam Switch power P23B A Low beam output P23B C If the test fails replace the left handlebar control Standard Continuity 1 LOW BEAM 2 HIGH BEAM TURN SIGNAL SWITCH Test for continuity between the foll...

Page 453: ...fasten the harness P clip 3 Connect the wiring harness to the left handlebar control left turn signal and head lamp dimmer switch 1 HARNESS ROUTING 4 Move handlebars from stop to stop to verify free...

Page 454: ...sion or damage Clean or repair as needed 3 Test for continuity Switch position Off If the test fails replace the main switch Switch power P29B A and Accessory P29B B Switch power P29B A and On P29B C...

Page 455: ...r The front brake switch is powered by the Lights fuse and controls the brake lamp REMOVAL 1 Disconnect the two wires from the brake switch 2 Remove the screw that secures the switch to the front brak...

Page 456: ...ake lines Add brake fluid or bleed the brakes if necessary see BLEEDING BRAKE SYSTEM page 15 3 1 With the switch mounted on the motorcycle disconnect the two wires Test for continuity between the swit...

Page 457: ...5 feet away from a wall 2 Turn the motorcycle main switch to On and the headlamp dimmer switch to high beam 3 The headlamp beam should shine straight ahead with the top of the beam even with the cente...

Page 458: ...or is located under the seat BULB REPLACEMENT 1 Remove the lens screws and lens from the brake lamp housing 2 Remove the tail lamp bulb or license plate lamp bulb 3 Install the new tail lamp bulb Stan...

Page 459: ...ail lamp housing Torque 7 ft lbs 2 Route the tail lamp harness and fasten it to the wire clips 3 Assemble the tail lamp connector Install the pins and the locking wedge Pin 1 Blue tail lamp Pin 2 Yell...

Page 460: ...3 Install the fuel tank see FUEL TANK INSTALLATION page 4 123 4 Connect the battery positive cable first see BATTERY INSTALLATION page 16 4 TURN SIGNAL LAMPS The front turn signal lamps are combinatio...

Page 461: ...rn signal gimbal nut and remove the turn signal Remove harness ties as needed under the fuel tank and remove the turn signal lamp 1 TURN SIGNAL 2 TURN SIGNAL CONNECTOR INSTALLATION 1 Install the turn...

Page 462: ...n 3 Violet left turn signal Pin 6 Black left turn signal ground Pin 4 Violet right turn signal taped Pin 5 Black right turn signal ground taped 1 PIN 3 VIOLET 2 PIN 4 VIOLET 3 PIN 5 BLACK 4 PIN 6 BLAC...

Page 463: ...STALLATION page 2 11 6 Connect the battery positive cable first see BATTERY INSTALLATION page 16 4 HORN REMOVAL 1 Disconnect the wiring harness from the horn 2 Remove the screws that secure the horn a...

Page 464: ...e and inspect the neutral switch see NEUTRAL SWITCH INSPECTION page 18 20 If the neutral indicator lamp does not illuminate inspect the instrument cluster wiring and the neutral indicator lamp bulb se...

Page 465: ...closed and the low oil pressure indicator lamp is illuminated As the oil pressure rises to normal operating levels the switch opens and extinguishes the indicator lamp While the engine is running if...

Page 466: ...cator lamp does not illuminate inspect the oil pressure switch wiring and the indicator bulb see INSTRUMENT CLUSTER BULB REPLACEMENT page 18 23 INSTALLATION 1 Install the oil pressure switch Torque 12...

Page 467: ...ANSI 1061 Fuel gauge lighting Standard ANSI 1061 Low Fuel Indicator Standard ANSI 1063 4 Install the instrument cluster see INSTRUMENT CLUSTER INSTALLATION page 18 23 1 SPEEDOMETER 2 INDICATOR LAMPS 3...

Page 468: ...t secure the electronics cover and remove the cover 4 Open the circuit breaker boot and disconnect the circuit breaker wires Clean ring connectors and breaker posts as needed 5 Remove the screws that...

Page 469: ...tach the fuse block to the frame 5 Install the tandem and rider s saddle see SADDLE INSTALLATION page 2 3 1 FUSE BLOCK COVER 2 LIGHTS 15A 3 HORN 10A 4 IGNITION 5A 5 AUXILIARY LIGHTS 10A 6 FUEL PUMP 10...

Page 470: ...12 volts remove the accessory relay and perform a continuity test see RELAYS CONTINUITY TEST page 18 27 1 MAIN SWITCH 2 LIGHTS FUSE IGNITION RELAY 1 With the engine stop run switch in the Stop positio...

Page 471: ...witch input pin 30 and the output pin 87 If there is no continuity replace the relay INSTALLATION 1 Apply a small amount of silicon grease to the terminals and insert the relay in the connector 2 Inst...

Page 472: ...18 28 6999 0003 7 15 99 LIGHTS GAUGES SWITCHES...

Page 473: ...Light Brake Light Turn Signal Left Turn Signal Right Ground D4 A1 A2 B1 B2 B3 B4 D1 G1 E1 E2 E3 E4 F1 F2 F4 H4 G4 H1 H2 H3 D2 A1 A2 B2 C4 D1 E1 F3 G3 H4 G4 H1 1 2 3 1 2 A B C D 86 87 85 30 K J H G F E...

Page 474: ...WIRING SCHEMATIC NOTES 19 2 6999 0003 7 15 99...

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