Service information of fuel system General Be sure to relieve the fuel pressure with the ignition switch turned to "OFF". Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. Work in a...
Troubleshooting of fuel system Engine won't start Intake air leak Fuel contaminated/deteriorated Pinched or clogged fuel hose Faulty fuel pump Clogged fuel filter Clogged fuel injector filter Sticking fuel injector needle Faulty fuel pump operating system Engine stall, hard to...
Fuel system location FULL NAME ABBREVIATIONS Manifold absolute pressure sensor MAP sensor Throttle position sensor TP sensor Intake air temperature sensor IAT sensor Engine coolant temperature sensor ECT sensor Engine control module ECM
PGM-FI (programmed fuel injection) system Self-diagnostic procedure Place the motorcycle on its side stand. Start the engine and let it idle. If the malfunction indicator lamp (MIL) does not light or blink, the system has no memory of problem data. If the MIL blinks, note how many times the...
PGM-FI self-diagnosis malfunction indicator failure codes The PGM-FI malfunction indicator denotes the failure codes (the number of blinks from 0 to 33). When the indicator lights for 1.3 seconds it is equivalent to 10 blinks. For example, a 1.3 second illumination and two blinks (0.5 second x 2) of the...
PGM-FI MIL 1 blink (MAP sensor) Turn the ignition switch to "OFF". ↓ Disconnect the MAP sensor 3P black connector. Check for loose or poor contact on the MAP sensor connector. ↓ Connect the MAP sensor 3P black connector. Place the motorcycle on its side stand. Start the engine and...
PGM-FI MIL 2 blinks (MAP sensor) Turn the ignition switch to "OFF". ↓ Remove the MAP sensor. Connect the vacuum gauge between the throttle body and the MAP sensor. Start the engine and measure the manifold absolute pressure at idle speed. Standard: 150-250 mm Hg Out of range →...
PGM-FI MIL 7 blinks (ECT sensor) Turn the ignition switch to "OFF". ↓ Disconnect the ECT sensor 3P connector. Check for loose or poor contact on the ECT sensor connector. ↓ Connect the ECT sensor 3P connector. Place the motorcycle on its side stand. Turn the ignition switch to...
PGM-FI MIL 8 blinks (TP sensor) Turn the ignition switch to "OFF". ↓ Disconnect the TP sensor 3P gray connector. Check for loose or poor contact on the TP sensor 3P gray connector. ↓ Connect the TP sensor 3P gray connector. Place the motorcycle on its side stand. Start the engine...
PGM-FI MIL 9 blinks (IAT sensor) Turn the ignition switch to "OFF". ↓ Disconnect the IAT sensor 2P connector. Check for loose or poor contact on the IAT sensor connector. ↓ Connect the IAT sensor 2P connector. Place the motorcycle on its side stand. Turn the ignition switch to...
PGM-FI MIL 10 blink (BARO sensor) Turn the ignition switch to "OFF". ↓ Disconnect the BARO sensor 3P connector. Check for loose or poor contact on the BARO sensor connector. ↓ Connect the BARO sensor 3P connector. Place the motorcycle on its side stand. Start the engine and check...
PGM-FI MIL 11 blinks (vehicle speed sensor) Turn the ignition switch to "OFF". ↓ Disconnect the vehicle speed sensor 3P connector. Check for loose or poor contact on the vehicle speed sensor connector. ↓ Connect the vehicle speed sensor 3P connector. Start the engine. Place the side stand up...
PGM-FI MIL 12 blinks (rear injector) Turn the ignition switch to "OFF". ↓ Disconnect the rear injector 2P gray connector. Check for loose or poor contact on the rear injector 2P brown connector. ↓ Connect the rear injector 2P brown connector. Place the motorcycle on its side stand....
PGM-FI MIL 13 blinks (front injector) Turn the ignition switch to "OFF". ↓ Disconnect the front injector 2P brown connector. Check for loose or poor contact on the front injector 2P gray connector. ↓ Connect the front injector 2P gray connector. Place the motorcycle on its side stand....
PGM-FI MIL 18 blinks (cam pulse generator) Turn the ignition switch to "OFF". ↓ Disconnect the cam pulse generator 2P black connector. Check for loose or poor contact on the cam pulse generator 2P black connector. ↓ Connect the cam pulse generator 2P black connector. Place the motorcycle on...
PGM-FI MIL 19 blinks (ignition pulse generator) Turn the ignition switch to "OFF". ↓ Disconnect the ignition pulse generator 2P connector. Check for loose or poor contact on the ignition pulse generator 2P connector. ↓ Connect the ignition pulse generator 2P connector. Place the motorcycle on its...
PGM-FI MIL 21 blinks (O2 sensor/California type only) Turn the ignition switch to "OFF". ↓ Disconnect the О2 sensor 4P connector. Check for loose or poor contact on the O2 sensor 4P connector. ↓ Disconnect the ECM connectors. Connect the test harness to ECM connectors. ↓ Check the continuity between...
PGM-FI MIL 23 blinks (O2 sensor heater/California type only) Turn the ignition switch to "OFF". ↓ Disconnect the O2 sensor 4P connectors. Check for loose or poor contact on the O2 sensor 4P connector. ↓ Connect the O2 sensor connector. Short the service check connector ( page 5-6 ). Start the engine and check...
PGM-FI MIL 33 blinks (E2-prom) Turn the ignition switch to "OFF". ↓ Disconnect the ECM connectors. Check for loose or poor contact of the ECM connectors. ↓ Connect the ECM connectors. Short the service check connector with a jumper wire ( page 5-6 ). Turn the ignition switch to...
Fuel pressure inspection Remove the seat ( page 2-2 ). Disconnect the battery negative cable from the battery terminal. Open and support the rear end of the fuel tank ( page 3-4 ). Disconnect the pressure regulator vacuum hose and plug the vacuum hose. Cover the fuel hose...
Fuel flow inspection Open and support the rear end of the fuel tank ( page 3-4 ). Disconnect the fuel cut-off relay 4P connector. Jump the Brown and Black/white wire terminals of the wire harness side using a jumper wire. When the fuel return hose is disconnected,...
Fuel pump — removal and installation Inspection Turn the ignition switch to "ON" and confirm that the fuel pump operates for a few seconds. If the fuel pump does not operate, inspect as follows: Open and support the front end of the fuel tank ( page 3-4 ). Disconnect the fuel pump 3P...
Fuel cut-off relay Remove the right side cover ( page 2-2 ). Disconnect the fuel cut-off relay 4P connector, then remove the fuel cut-off relay. Connect the ohmmeter to the fuel cut-off relay connector terminals. Connection: Black/white - Brown. Connect the 12-V...
Fuel tank — removal and installation Removal Disconnect the fuel pump 3P black connector. Open and support the rear end of the fuel tank ( page 3-4 ). Notice. Do not apply excessive force to the fuel pipe. Disconnect the fuel tank breather from the fuel tank. Disconnect the fuel return...
Air cleaner housing — removal and installation Removal Open and support the front end of the fuel tank ( page 3-4 ). Remove the air cleaner element ( page 3-5 ). Disconnect the intake duct control hose. Remove the screws and air funnel from the air cleaner housing. Remove the tab on the air...
Throttle body removal Drain the coolant from the cooling system ( page 6-6 ). Remove the following: Fuel tank ( page 5-50 ) Air cleaner housing ( page 5-51 ) Remove the throttle stop screw from the guide. Always replace the sealing washers when the fuel hose banjo bolt...
Intake manifold removal Remove the throttle body ( page 5-52 ). Disconnect the front injector 2P black connector and rear injector 2P gray connector. Disconnect the intake duct control solenoid valve hose from the intake manifold. Loosen the rear insulator band screw....
Intake manifold installation Check the collars for wear or damage. Check the rubbers for wear or damage. Replace them if necessary. Install a new О-rings to the front and rear insulator grooves. Install the front insulator to the cylinder head and tighten the bolts securely....
Throttle body installation Check that the О-ring is in good condition, replace if necessary. Connect the water hose and tighten the band screw securely. Connect the throttle cables to the throttle drum. Install the throttle body and clamp. Tighten the bolts securely. Install...
Injectors — removal and installation Inspection Start the engine and let it idle. Confirm the injector operating sounds with a sounding rod or stethoscope. If the injector does not operates, replace the injector. Removal Remove the intake manifold ( page 5-54 ). Disconnect the vacuum...
Starter valve — disassembly and assembly Disassembly Remove the throttle body ( page 5-52 ). Remove the screws and starter valve assembly from the throttle body. Remove the starter valve assembly from the throttle body. Clean the starter valve bypass using compressed air. Do not apply...
Air screw synchronization Synchronize the air screw with the engine at the normal operating temperature and with the transmission in neutral. Open and support the rear end of the fuel tank ( page 3-4 ). Remove the air cleaner housing ( page 5-51 ). Disconnect the intake duct...
BARO and MAP sensor — removal and installation Output voltage inspection Connect the test harness to the ECM ( page 5-8 ). Measure the voltage at the test harness terminals ( page 5-9 ). CONNECTION: BARO sensor: B1 (+) - B8 (-) MAP sensor: B1 (+) - B7 (-) STANDARD: 2.7 - 3.1 V The BARO and MAP...
IAT sensor — removal and installation Remove the air cleaner housing ( page 5-51 ). Disconnect the IAT sensor 2P connector. Remove the screws and IAT sensor from the air cleaner housing. Installation is in the reverse order of removal.
ECT sensor — removal and installation Drain the coolant from the system ( page 6-4 ). Remove the throttle body ( page 5-52 ). Disconnect the ECT sensor 3P connector from the sensor. Replace the ECT sensor while the engine is cold. Remove the ECT sensor and sealing washer. Install the...
Cam pulse generator — removal and installation Removal Open and support the rear end of the fuel tank ( page 3-4 ). Disconnect the cam pulse generator 2P black connector. Remove the bolt and cam pulse generator. Remove the О-ring from the cam pulse generator groove. Installation Installation is...
TP sensor — removal and installation Inspection Remove the seat ( page 2-2 ). Disconnect the ECM 22P black and 22P gray connectors. Check the connector for loose or corroded terminals. Connect the ECU test harness between the ECM and main wire harness. Tool: ECU test harness...
Bank angle sensor — removal and installation Support the motorcycle on a level surface. Remove the seat ( page 2-2 ). Turn the ignition switch to "ON" and measure the voltage between the following terminals of the bank angle sensor 3P green connector with the connector connected. TERMINAL...
Engine stop relay — inspection Disconnect the engine stop relay 4P connector, remove the engine stop relay. Connect the ohmmeter to the engine stop relay connector terminals. Connection: Red/white - Black/white. Connect the 12-V battery to the following engine stop relay...
ECM (Engine Control Module) — removal and installation Removal/installation Remove the seat ( page 2-2 ). Remove the rubber band and remove the ECM from the battery tray cover. Disconnect the ECM 22P black and 22P gray connectors. Power/ground line inspection Connect the test harness between the main...
Intake duct control solenoid valve — inspection Removal/installation Remove the fuel tank ( page 5-50 ). Disconnect the intake duct control solenoid valve 2P connector. Disconnect the vacuum hoses from the intake duct control solenoid valve. Remove the bolt and intake duct control solenoid valve....
Pair solenoid valve — removal and installation Removal/installation Remove the intake duct control solenoid valve ( page 5-73 ). Disconnect the PAIR solenoid valve 2P connector. Disconnect the PAIR air suction hoses. Remove the bolt and PAIR solenoid valve. Installation is in the reverse order...
Pair check reed valve — removal and installation Removal/installation Remove the fuel tank ( page 5-50 ). Remove the front and rear ignition coils ( page 17-5 ). Remove the bolts and PAIR check reed valve cover. Remove the PAIR check reed valve. Installation is in the reverse order of removal....
EVAP purge control valve (California type only) Removal Disconnect the EVAP purge control valve 2P black connector. Disconnect the air hoses from the EVAP purge control valve. Remove the bolt and EVAP purge control valve bracket assembly. Installation is in the reverse order of removal....
O2 sensor (California type only) — removal Removal Notice: Handle the O2 sensor with care. Do not get grease, oil or other materials in the O2 sensor air hole. Do not service the O2 sensor while it is hot. Remove the seat ( page 2-2 ). Disconnect the O2 sensor 4P connector. Remove the O2...