Yamaha 2002 FZS600 Supplementary Service Manual Download

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MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item

Standard

Limit

Carburetor:

I.D. mark
Main jet

(M.J)

Main air jet

(M.A.J)

Jet needle

(J.N)

Needle jet

(N.J)

Pilot air jet

(P.A.J.1)

Pilot outlet

(P.O)

Pilot jet

(P.J)

Bypass 1

(B.P.1)

Bypass 2

(B.P.2)

Bypass 3

(B.P.3)

Pilot screw

(P.S)

Valve seat size

(V.S)

Starter jet

(G.S.1)

Starter jet

(G.S.2)

Throttle valve size

(TH.V)

Fuel level

(F.L) (with
special tool)

Engine idle speed
Intake vacuum

5DM1 01
#115
#80
5D86-3 / 5
P-0M
#130
0.95
#12.5
0.9
0.8
0.8
2-1 / 2
1.0
0.6
0.8
#110
3.5 mm

1,150

1,250 r / min

31.7

34.3 kPa (238

257 mmHg)

SSS

TIGHTENING TORQUES

ENGINE

Part to be tightened

Part name

Thread

size

Q’ty

Tightening

torque

Remarks

size

Radietor cover

Bolt

0.7

Summary of Contents for 2002 FZS600

Page 1: ......

Page 2: ...essary to use this Supplemen tary Service Manual together with the following manual FZS600 SERVICE MANUAL 5DM1 AE1 FZS600 SUPPLEMENTARY SERVICE MANUAL 5DM1 AE2 FZS600 P 2002 SUPPLEMENTARY SERVICE MANUAL E2001 by Yamaha Motor Co Ltd First Edition August 2001 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...e all its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Aler...

Page 4: ...spections and Adjustments where the sub section title s appear In Chapter 3 Periodic Inspections and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 ...

Page 5: ...ooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearin...

Page 6: ...NK 24 CHASSIS 25 ADJUSTING THE FRONT BRAKE 25 ELECTRICAL SYSTEM 25 REPLACING THE HEADLIGHT BULBS 25 ADJUSTING THE HEADLIGHT BEAMS 26 ENGINE CYLINDER HEAD 27 CLUTCH 28 INSTALLING THE CLUTCH 30 AC MAGNETO AND STARTER CLUTCH 32 STARTER CLUTCH 32 COOLING SYSTEM RADIATOR 33 THERMOSTAT 34 ASSEMBLING THE THERMOSTAT 35 WATER PUMP 36 DISASSEMBLING THE WATER PUMP 37 CHECKING THE WATER PUMP 37 ASSEMBLING THE...

Page 7: ... 49 CHECKING SWITCHES 51 SWITCH POSITION AND TERMINAL CONNECTION 51 LIGHTING SYSTEM 52 CIRCUIT DIAGRAM 52 LIGHTING SYSTEM CHECK 53 SIGNAL SYSTEM 56 CIRCUIT DIAGRAM 56 SIGNAL SYSTEM CHECK 58 COOLING SYSTEM 60 CIRCUIT DIAGRAM 60 TROUBLESHOOTING 61 FZS600 P 2002 WIRING DIAGRAM ...

Page 8: ...unleaded gasoline 22 L 3 6 L Tire Type Size front rear Manufacturer front rear Type front rear Tubeless 110 70ZR 17 M C 54W 110 70ZR 17 54W 160 60ZR 17 M C 69W 160 60ZR 17 69W BRIDGESTONE DUNLOP BRIDGESTONE DUNLOP BT 57F D207F BT 57R D207J Tire pressure Maximum load except motorcycle Loading condition A front rear Loading condition B front rear High speed riding front rear 183 kg 0 X 90 kg 225 kPa...

Page 9: ...rn signal light Meter light Indicator light Neutral indicator light High beam indicator light Oil level warning light Turn signal indicator light Fuel level warning light Engine temperature warning light 12 V 60 W 55 W 2 12 V 5 W 2 12 V 5 W 21 W 2 12 V 21 W 2 12 V 21 W 2 14 V 14 W 3 12 V 1 4 W 1 12 V 1 4 W 1 12 V 1 4 W 1 12 V 1 4 W 2 12 V 2 W 1 LED ...

Page 10: ...t size V S Starter jet G S 1 Starter jet G S 2 Throttle valve size TH V Fuel level F L with special tool Engine idle speed Intake vacuum 5DM1 01 115 80 5D86 3 5 P 0M 130 0 95 12 5 0 9 0 8 0 8 2 1 2 1 0 0 6 0 8 110 3 5 mm 1 150 X 1 250 r min 31 7 X 34 3 kPa 238 X 257 mmHg SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS TIGHTENING TORQUES ENGINE Part to be tightened Part ...

Page 11: ...d output Stator coil resistance A C magneto F4T377 MITSUBISHI 14 V 21 A at 5 000 r min 0 28 X 0 34 Ω at 20_C W W SSS SSS SSS SSS Rectifier Model manufacture Capacity Withstand voltage SH650C 11 SHINDENGEN 18 A 200 V SSS SSS SSS Fuel gauge Model manufacture Sender unit resistance full empty 5RT NIPPON SEIKI 4 X 10 Ω 122 5 X 128 5 Ω SSS SSS SSS Amperage for individual circuit Main Headlight Signal I...

Page 12: ... 5 LUBRICATION POINT AND LUBRICATION TYPES SPEC LUBRICATION POINT AND LUBRICATION TYPES ENGINE Lubrication Point Symbol Cylinder head tightening nut washer ...

Page 13: ...adiator outlet hose 9 Radiator 10 Radiator inlet hose 1 Engine outlet hose 2 Engine outlet hose 3 Carburetor inlet hose 4 Carburetor outlet hose 5 Water pump 6 Coolant drain bolt 7 Water pump outlet hose EB203000 COOLING SYSTEM DIAGRAMS ...

Page 14: ... 7 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Water pump outlet hose 3 Oil cooler inlet hose 4 Oil cooler outlet hose 5 Carburetor outlet hose ...

Page 15: ...he bottom of protector A Using clamp left handlebar switch lead to crimpled part of clutch cable fitting After clamp ing cut excessive portion from tip B Using clamp bundle S Left handlebar switch lead S Clutch cable S Starter cable C 30 mm or less from the top of protector 1 Throttle cables 2 Clutch cable 3 Left handlebar switch lead 4 Starter cable 5 Main switch 6 Main switch lead 7 Brake hose 8...

Page 16: ...4 Starter relay 15 Battery positive lead 16 Seat lock cable 17 Seat lock stay 18 Cross tube 3 19 A C magneto lead 20 Starter motor lead 21 Cross tube 22 Air filter case drain hose 23 Sidestand switch lead 24 Neutral switch 25 Oil level switch lead 26 Radiator 1 Main switch lead 2 Starter cable 3 Left handlebar switch lead 4 Clutch cable 5 Horn lead 6 Rectifier regulator 7 Box 8 Air guide 9 Radiato...

Page 17: ...and neutral switch lead pass the over cross tube 3 F Using clamp fix wire harness to the frame G Using clamp fix wire harness to the frame H After connecting coupler push then on the inside of lock stay on the frame I Using clamp fix to bracket on the frame A Using clamp fix S Left handlebar switch lead S Main switch lead S Clutch cable S Starter cable In so doing locate main switch lead innermost...

Page 18: ...Stater motor lead S Sidestand switch lead S Oil level switch lead S Neutral switch lead Locate wire harness outermost Locate clamp with its tip down ward and cut off excessive length K Pass air filter drain hose through clamp on engine L Air filter case drain hose in front of swingarm pivot shaft and in rear of cross tube CABLE ROUTING SPEC Q Pass on the outside of spark plug lead 1 S Clutch cable...

Page 19: ...r tube V Pass speed sensor lead along brake hose on the outside of frame and fix it with clamp at 3 positions W To stop switch X To battery negative lead Y To starter relay Z Pass only starter motor lead be hind wire harness branch CABLE ROUTING SPEC ...

Page 20: ...ch lead 6 Radiator reservoir tank 7 Rear brake light switch lead 8 Battery 9 Radiator reservoir tank breather hose 10 Battery negative lead 11 Cross tube 3 12 Radiator reservoir tank breather hose 13 Air filter 14 Throttle position sensor lead 15 Box 16 Speed sensor lead 17 Engine bracket 3 18 Swingarm bracket ...

Page 21: ...under S Throttle cable 2 pcs S Right handlebar switch lead S Speed sensor lead And them into box at right side In so doing give leads some slack E Pass throttle cable under box F Pass through holder on frame S Radiator reservoir tank breath er hose S Fuel tank breather hose G To reservoir tank H Pass battery negative lead on the inside of radiator reservoir tank breather hose I Using clamp fix sto...

Page 22: ...m bracket on frame with a clamp S Fuel tank drain hose S Fuel tank breather hose S Radiator reservoir tank breathe hose N Fuel tank drain hose install so that it is not bent or slack O After passing throttle position sensor lead as shown install cover 2 to air filter K Pass through hole in bracket bat tery and clamp rear brake light switch lead L Pass on the inside of air filter bracket on frame S...

Page 23: ...8 Starter motor lead CABLE ROUTING SPEC 1 Throttle cables 2 Speed sensor lead 3 Right handlebar switch lead 4 Thermostat housing 5 Carburetor heater hot water hose 6 Radiator reservoir tank breather hose 7 Fuel pump 8 Fuel filter 9 Fuel tank breather hose 10 Fuel tank drain hose 11 Pipe 2 12 Fuel hose 13 Throttle position sensor lead 14 Fuel pipe 15 Fuel sender coupler 16 Battery negative lead 17 ...

Page 24: ...r lead 41 Rectifier regulator lead 42 Left handlebar switch lead 43 Main switch lead 44 Clamp 29 Starter relay 30 Turn signal relay 31 Starting circuit cut off relay 32 Wire harness 33 Fuel pump lead coupler 34 Ignition coil 35 Clutch cable 36 Starter cable CABLE ROUTING SPEC ...

Page 25: ...ke light switch lead and battery negative lead under ra diator reservoir tank and be tween radiator reservoir hose and battery and connect them at right side of battery CABLE ROUTING SPEC A Pass radiator reservoir tank breather hose at left side of ther mostat housing B Do not fix 4 spark plug lead with a band C Using clamp fix 3 and 4 spark plug lead and pass them under radiator reservoir tank br...

Page 26: ...amp fastened to wire har ness onto T stud on frame U Pass wire harenss through cut in box rear and connect it inside box V Using clamp fix wire harness to bracket at 2 positions J Pass wire harness on the inside of vehicle from rear fender rib K Pass wire harness under starter relay L Pass starter motor lead under branched harness and put it up ward M Fit fuel sender coupler onto cross pipe on fra...

Page 27: ...witch lead and speed sensor lead through cut in box front and connect them inside box Y Using clamp fix wire harness af ter making sure to pass it under taillight bracket Z To taillight AA Bend AB Into turn signal light AC No slack is permitted AD Clamp rear turn signal light leads L and R without slack AE Mate turn signal light reads L and R at coupler position bend them and clamp them to gether ...

Page 28: ...e S Check fuel hoses for cracks or damage 2 Fuel filter S Check condition 3 Spark plugs S Check condition S Clean and regap p p g S Replace 4 Valves S Check valve clearance S Adjust Every 40 000 km 5 Air filter element S Clean 5 Air filter element S Replace 6 Clutch S Check operation S Adjust 7 Front brake S Check operation fluid level and vehicle for fluid leakage S Replace brake pads Whenever wo...

Page 29: ...tors S Check starter choke operation S Adjust engine idling speed and synchronization 23 Engine oil S Change S Check oil level and vehicle for oil leakage 24 Engine oil filter cartridge S Replace 25 Cooling system S Check coolant level and vehicle for coolant leakage g y S Change Every 3 years 26 Front and rear brake switches S Check operation 27 Moving parts and cables S Lubricate 28 Lights signa...

Page 30: ...re NOTE Order Job name Part name Q ty Remarks 1 2 3 4 5 6 Removing the front cowling Rear view mirror left right Inner panel left right Cowling stay Headlight sub harness Front cowling Headlight assembly 1 1 1 1 1 1 1 1 33 Nm 3 3 mSkg FRONT COWLING CHK ADJ FRONT COWLING SEAT SIDE COVER FUEL TANK FRONT COWLING ...

Page 31: ... Fuel tank Fuel sender lead coupler Fuel tank breather hose Fuel tank drain hose Fuel hose Side cover left right Grab bar Plate Rear cowling 1 1 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Disconnect the couplers For installation reverse the removal procedure NOTE 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg 19 Nm 1 9 mSkg SEAT SIDE COVER AND FUEL TANK ...

Page 32: ...g dial with the arrow mark 2 Position 1 Distance is the largest Position 5 Distance is the smallest After adjusting the brake lever position make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial ELECTRICAL SYSTEM EB305051 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Disconnect Sheadlight lead 1 2 Remo...

Page 33: ...ned with alcohol or lacquer thinner 5 Install Sheadlight bulb holder 6 Connect Sheadlight lead EB305061 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Adjust Sheadlight beam vertically a Turn the adjusting screw 1 3 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust Sheadlight beam horizontally a Turn the a...

Page 34: ...inder head gasket Dowel pin 2 4 1 1 1 2 Remove the parts in the order listed Refer to CAMSHAFT section in chapter 4 Manual No 5DM1 AE1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CYLINDER HEAD section in chapter 4 Manual No 5DM1 AE1 20 Nm 2 0 mSkg 35 Nm 3 5 mSkg 20 Nm 2 0 mSkg CYLINDER HEAD ENG ENGINE CYLINDER HEAD ...

Page 35: ...h push rod O ring Ball Long clutch push rod Friction plate 1 Clutch plate Friction plate 2 Friction plate large Clutch spring plate Nut 6 1 1 1 1 1 6 8 2 1 1 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE CLUTCH section Refer to INSTALLING THE CLUTCH section 70 Nm 7 0 mSkg 8 Nm 0 8 mSkg CLUTCH ENG CLUTCH ...

Page 36: ...Spacer Bearing Clutch housing Thrust washer Spacer 1 1 1 1 1 1 1 1 Refer to INSTALLING THE CLUTCH section For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CLUTCH section Refer to REMOVING INSTALLING THE CLUTCH section Refer to INSTALLING THE CLUTCH section 70 Nm 7 0 mSkg 8 Nm 0 8 mSkg ...

Page 37: ...er 2 tighten the clutch boss nut Universal clutch holder 90890 04086 3 Bend the lock washer 3 tab along a flat side of the nut 4 Lubricate Slong clutch push rod 1 Sball 2 Sshort clutch push rod 3 SO ring 4 with the recommended lubricant Recommended lubricant Lithium soap base grease 5 Install Slong clutch push rod Sball Sshort clutch push rod along with a new O ring 4 6 Lubricate Sfriction plates ...

Page 38: ...iction plate large of inside dia and clutch plate c Install a friction plate and then alternate between a clutch plate and a friction plate 8 Install Spressure plate 1 Sclutch springs 2 Sclutch spring bolts 3 SWhen installing the clutch springs alternate between long and short clutch springs STighten the clutch spring bolts in stages and in a crisscross pattern 9 Install Sclutch cover 1 Sclutch co...

Page 39: ...r Shaft Primary Starter idle gear primary Shaft Secondary Starter idle gear secondary Shaft drive gear 1 2 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE STARTER CLUTCH section in chapter 4 Manual No 5DM1 AE1 For installation reverse the removal procedure 12 Nm 1 2 mSkg 80 Nm 8 0 mSkg AC MAGNETO AND STARTER CLUTCH ENG AC MAGNETO AND STARTER CLUTCH STARTER C...

Page 40: ...ose Radiator Fan 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT COWLING SEAT SIDE COVER FUEL TANK section in chapter 3 Manual No 5DM1 AE1 Refer to CHANGING THE COOLANT section in chapter 3 Manual No 5DM1 AE1 Disconnect the coupler For installation reverse the removal procedure NOTE 7 Nm 0 7 mSkg 7 Nm 0 7 mSkg 7 Nm 0 7 mSkg RADIATOR COOL COOLING SYSTEM RADIATOR ...

Page 41: ... engine temperature Thermostat housing cover O ring Thermostat Thermostat housing 1 1 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure Refer to ASSEMBLING THE THERMOSTAT section 1 2 3 4 5 6 23 Nm 2 3 mSkg 8 Nm 0 8 mSkg 10 Nm 1 0 mSkg THERMOSTAT COOL THERMOSTAT ...

Page 42: ...rmostat 2 SO ring New 3 Sthermostat housing cover 4 Sthermostat housing cover bolt Install the thermostat with its breather hole a facing up 2 Install Sthermo switch fan motor 1 Sthermo unit engine temperature 2 Use extreme care when handling the ther mo switch and temperature sender Replace any part that was dropped or subjected to a strong impact ...

Page 43: ... ty Remarks Disassembling the water pump Circrip Impeller shaft Water pump seal Oil seal Bearing 1 1 1 1 2 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 WATER PUMP COOL WATER PUMP ...

Page 44: ...l from the out side of the water pump housing 3 3 Remove Srubber damper holder 1 Srubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaft EAS00473 CHECKING THE WATER PUMP 1 Check Swater pump housing cover 1 Swater pump housing 2 Simpeller 3 Srubber damper 4 Srubber damper holder 5 2 Check Swater pump seal Soil seal Swater pump inlet pipe Crack damage w...

Page 45: ...pply tap water or coolant onto its outer surface 2 Install Swater pump seal New 1 Never apply oil or grease onto the water pump seal surface SInstall the water pump seal with the water pump seal installers SBefore installing the water pump seal apply Yamaha bond No 1215 to the water pump housing 2 Water pump seal installer 3 90890 04078 Middle driven shaft bearing driver 4 90890 04058 Yamaha bond ...

Page 46: ...der New 2 Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure Stilt Out of specification Repeat steps 3 and 4 Make sure that the rubber damper and rubber damper holder are flush with the impeller Tilt limit 0 15 mm 1 Straightedge 2 Impeller ...

Page 47: ...INSTALLING THE FRONT FORK LEGS section For installation reverse the removal procedure Order Job name Part name Q ty Remarks 1 2 3 4 5 Removing the front fork Front wheel Front brake calipers Front fender Bolt upper bracket Cap bolt Bolt lower bracket Front fork assembly left right 1 2 2 2 1 1 Refer to REMOVING INSTALLING THE FRONT FORK LEGS section 30 Nm 3 0 mSkg 7 Nm 0 7 mSkg 30 Nm 3 0 mSkg FRONT...

Page 48: ...ch bolt 3 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove Sfront fork leg EB703710 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Sfront fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the handlebar holder 2 Tighten S...

Page 49: ... housing Throttle cable Grip end Grip assembly Clutch cable Clutch switch Handle bar switch left Starter cable Grip end 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to INSTALLING THE HANDLEBAR section in chapter 7 Manual No 5DM1 AE1 Refer to INSTALLING THE HANDLEBAR section in chapter 7 Manual No 5DM1 AE1 7 Nm 0 7 mSkg 10 Nm 1 0 mSkg 23 Nm 2 3 mSkg 7 Nm 0 7 mSkg HANDLEBAR C...

Page 50: ...ebar holder Handle bar 1 1 2 1 Refer to REMOVING THE HANDLEBAR section in chapter 7 Manual No 5DM1 AE1 For installation reverse the removal procedure Refer to INSTALLING THE HANDLEBAR section in chapter 7 Manual No 5DM1 AE1 7 Nm 0 7 mSkg 10 Nm 1 0 mSkg 23 Nm 2 3 mSkg 7 Nm 0 7 mSkg HANDLEBAR CHAS ...

Page 51: ...ut lower 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL section in chapter 7 Manual No 5DM1 AE1 Refer to FRONT FORK section in chapter 7 Manual No 5DM1 AE1 Refer to HANDLEBAR section in chapter 7 Manual No 5DM1 AE1 Disconnect the coupler NOTE Refer to FRONT COWUNG SEAT SIDE COVER FUEL TANK section Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD section...

Page 52: ...1 12 13 Lower bracket Ball race cover Ball bearing Rubber washer 1 Ball bearing 1 1 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE STEERING HEAD section in chapter 7 Manual No 5DM1 AE1 18 Nm 1 8 mSkg 52 Nm 5 2 mSkg 110 Nm 11 0 mSkg 2nd 1st ...

Page 53: ...ve chain guide Pivot shaft Swingarm 1 2 1 1 1 1 1 Removing the parts in the order listed Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET section in chapter 7 Manual No 5DM1 AE1 Refer to REMOVING THE ENGINE section in chapter 4 Manual No 5DM1 AE1 Refer to REAR SHOCK ABSORBER AND RELAY ARM section in chapter 7 Manual No 5DM1 AE1 115 Nm 11 5 mSkg 23 Nm 2 3 mSkg 7 Nm 0 7 mSkg SWINGARM AND DRIVE...

Page 54: ...AND DRIVE CHAIN CHAS Order Job name Part name Q ty Remarks 8 9 10 11 12 Drive chain Cover Spacer Bearing Washer 1 2 1 2 2 For installation reverse the removal procedure 115 Nm 11 5 mSkg 23 Nm 2 3 mSkg 7 Nm 0 7 mSkg ...

Page 55: ...two seconds 2 When the hour digits start flashing push the RESET button 2 to set the hours 3 Push the SELECT button 1 to change the minutes 4 When the minute digits start flashing push the RESET button 2 to set the minutes 5 Push the SELECT button 1 to start the clock After setting the clock be sure to push the SELECT button 1 before turning the main switch to OFF otherwise the clock will not be s...

Page 56: ... 49 CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM ...

Page 57: ...ebar switch 47 Pass switch 48 Dimmer switch 49 Horn switch 50 Clutch switch 51 Hazard switch 52 Turn signal switch 53 Horn 54 Turn signal relay 55 Thermo switch 56 Radiator fan motor 57 Headlight relay on off 58 Headlight relay dimmer 59 Tail brake light 60 Auxiliary light 61 Headlight 62 Front turn signal light left 63 Front turn signal light right 64 Rear turn signal light left 65 Rear turn sign...

Page 58: ...itches as shown in the left page and check for the correct terminal connections closed circuit according to the color combinations shown in the chart Poor connection fault Repair or replace CHECKING SWITCHES ELEC YP SWITCH POSITION AND TERMINAL CONNECTION ...

Page 59: ... 29 Meter light 37 Signal system fuse 38 Headlight fuse 42 Light switch 47 Pass switch 48 Dimmer switch 57 Headlight relay on off 58 Headlight relay dimmer 59 Tail brake light 60 Auxiliary light 61 Headlight LIGHTING SYSTEM CHAS EB905000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 60: ...ester lead Black lead High beam indicator light Tester lead Black Yellow lead Tester lead Black lead 1 STurn the main switch to ON STurn the light switch to ON STurn the dimmer switch to LO or HI SCheck the voltage 12 V of the Black Yel low Black Green and Black Yellow leads on the bulb socket connector The wiring circuit from the main switch to the bulb socket connector is faulty repair it MEETS ...

Page 61: ...Battery terminal Blue Black terminal Battery terminal Black terminal Tester lead Black Blue terminal Tester lead Red Yellow terminal 1 2 3 4 EB803023 SCheck the headlight relay for continuity Battery terminal Yellow terminal Battery terminal Black terminal 1 2 CONTINUITY NO CONTINUITY Tester lead Black Blue terminal Tester lead Black Yellow terminal Tester lead Black Blue terminal Tester lead Blac...

Page 62: ...ns of the entire lighting system Refer to CIRCUIT DIAGRAM Properly connect the lighting system CONTINUITY POOR CONNECTION EB803023 This circuit is not foulty EB808022 Replace the headlight relay Dimmer NO CONTINUITY SCheck the headlight relay for continuity CONTINUITY ...

Page 63: ... 56 SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 64: ... warning light 25 Fuel meter 26 Speedometer 28 Turn signal indicator light 31 Thermo unit 32 Wire lead 33 Neutral switch 34 Oil level switch 35 Fuel sender 37 Signaling system fuse 41 Front brake light switch 45 Rear brake light switch 49 Horn switch 51 Hazard switch 52 Turn signal switch 53 Horn 54 Turn signal relay 59 Tail brake light 62 Front turn signal light left 63 Front turn signal light ri...

Page 65: ...el sender coupler from the wire harness SConnect the pocket tester Ω 1 to the fuel sender SCheck the fuel sender for continuity MEETS SPECIFICATION Replace the fuel sender OUT OF SPECIFICATION 1 2 SMeasure the fuel sender resistance 3 4 2 3 Voltage SConnect the pocket tester DC 20 V to the meter assembly coupler S Drain the fuel S Turn the main switch to ON S Check the voltage 12 V The wiring circ...

Page 66: ...harness SMove the float to UP or DOWN Replace the fuel meter DOES NOT MOVE STurn the main switch to ON SCheck the fuel gauge needle moves F or E 1 2 Before reading the meter stay put the float for more than three minutes respectively at UP or DOWN Float position Needle moves Float UP F Float DOWN E MOVE This circuit is not faulty NOTE ...

Page 67: ... 60 1 Main switch 3 Backup fuse 5 Battery 6 Main fuse 31 Thermo unit 39 Radiator fan motor fuse 55 Thermo switch 56 Radiator fan motor COOLING SYSTEM ELEC EB807000 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 68: ...e at 20_C EB802012 2 Battery SCheck the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Manual No 5DM1 AE1 SClean the batery terminals SRecharge or replace the battery CORRECT INCORRECT EB807010 TROUBLESHOOTING IF THE FAN MOTOR FAILS TO TURN IF THE COOLANT TEMPERTATURE METER FAILS TO MOVE WHEN THE ENGINE IS WARM Procedure Check 1 Fuses main signal and fan 2 Battery 3 Main switch 4 Fan m...

Page 69: ...n Blue SDisconnect the fan motor coupler SConnect the battery 12 V as shown 2 EB802017 3 Main switch Replace the main switch CONTINUITY NO CONTINUITY EB807011 The fan motor is faulty replace it MOVES DOES NOT MOVE 4 Fan motor Battery lead Black terminal Battery led Black terminal S Check the operation of the fan motor 2 1 1 ...

Page 70: ...r to record the temperatures 2 EB802017 5 Thermo switch Replace the thermo switch GOOD CONDITION BAD CONDITION THERMO SWITCH ON THERMO SWITCH OFF 1 Handle the thermo switch with special care Never subject it to strong shocks or allow it to be dropped Should it be dropped it must be replaced Tests 1 2 Heat up tests Tests 3 4 Cool down tests f Continuity No continuity A B Test step Good condition 1 ...

Page 71: ...ture indicated in the table SCheck the thermo unit for continuity at the temperatures indicated in the table Replace the thermo unit GOOD CONDITION BAD CONDITION 7 Coolant temperature warning light SCheck the LED for continuity CONTINUITY Replace the meter assembly NO CONTINUITY 2 8 Voltage SConnect the pocket tester DC 20 V to the meter coupler STurn the main switch to ON SCheck the voltage 12 V ...

Page 72: ... COOLING SYSTEM ELEC SCheck the connections of the entire cooling system Refer to CIRCUIT DIAGRAM This circuit is not faulty 9 Wiring connections Properly connect the cooling system CORRECT POOR CONNECTION ...

Page 73: ... switch 43 Engine stop switch 44 Start switch 45 Rear brake light switch 46 Left handlebar switch 47 Pass switch 48 Dimmer switch 49 Horn switch 50 Clutch switch 51 Hazard switch 52 Turn signal switch 53 Horn 54 Turn signal relay 55 Thermo switch 56 Radiator fan motor 57 Headlight relay on off 58 Headlight relay dimmer 59 Tail brake light 60 Auxiliary light 61 Headlight 62 Front turn signal light ...

Page 74: ...ake light switch 40 Engine stop switch 41 Start switch 42 Rear brake light switch 43 Left handlebar switch 44 Pass switch 45 Dimmer switch 46 Horn switch 47 Clutch switch 48 Turn signal switch 49 Horn 50 Turn signal relay 51 Thermo switch 52 Radiator fan motor 53 Headlight relay dimmer 54 Tail brake light 55 Headlight 56 Front turn signal light left 57 Front turn signal light right 58 Rear turn si...

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