Suzuki VL1500K4 Supplementary Service Manual

VL1500

USE THIS MANUAL WITH:

VL1500 SERVICE MANUAL (99500-39166-01E)

VL1500K5 (’05-MODEL)

VL1500K5 (’05-MODEL) 1

This manual describes service specifications, service data and servicing procedures which differ from those of the VL1500K4 (’04-model).

NOTE:

• Any differences between the VL1500K4 (’04-model) and VL1500K5 (’05-model) in specifications and service data are indicated with an asterisk mark (*).

• Please refer to the VL1500 service manual for details which are not given this manual.

CONTENTS

ABBREVIATIONS USED IN THIS MANUAL .................................................... 3

SPECIFICATIONS ............................................................................................. 5

PERIODIC MAINTENANCE SCHEDULE ......................................................... 7

MAINTENANCE AND TUNE-UP PROCEDURES ............................................ 8

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ................ 13

ENGINE REMOVAL AND INSTALLATION ...................................................... 14

ENGINE DISASSEMBLY AND

REASSEMBLY .................................................................................................. 17

ENGINE COMPONENTS INSPECTION AND SERVICING .............................. 18

PRECAUTIONS IN SERVICING........................................................................ 19

FI SYSTEM TECHNICAL FEATURES .............................................................. 26

FUEL DELIVERY SYSTEM ............................................................................... 28

FI SYSTEM PARTS LOCATION ....................................................................... 29

FI SYSTEM WIRING DIAGRAM........................................................................ 31

ECM TERMINAL................................................................................................ 32

SELF-DIAGNOSIS FUNCTION ......................................................................... 33

FAIL-SAFE FUNCTION ..................................................................................... 37

FI SYSTEM TROUBLESHOOTING................................................................... 38

FUEL SYSTEM .................................................................................................. 93

THROTTLE BODY.............................................................................................102

SENSORS..........................................................................................................118

EXTERIOR PARTS............................................................................................121

FRONT FORK....................................................................................................122

LOCATION OF ELECTRICAL COMPONENTS ................................................127

CHARGING SYSTEM ........................................................................................129

AUTOMATIC DECOMPRESSION SYSTEM/STARTER SYSTEM AND

SIDE-STAND IGNITION INTERLOCK SYSTEM ..............................................131

IGNITION SYSTEM ...........................................................................................133

SPEEDOMETER................................................................................................138

RELAYS.............................................................................................................141

© COPYRIGHT SUZUKI MOTOR CORPORATION 2004

2 VL1500K5 (’05-MODEL)

SWITCHES........................................................................................................ 142

BATTERY.......................................................................................................... 143

WIRING HARNESS, CABLE AND HOSE ROUTING....................................... 144

EXTERIOR PARTS INSTALLATION................................................................ 153

SPECIAL TOOLS.............................................................................................. 157

TIGHTENING TORQUE .................................................................................... 158

SERVICE DATA ................................................................................................ 159

EMISSION CONTROL SYSTEMS .................................................................... 168

PAIR (AIR SUPPLY) SYSTEM INSPECTION .................................................. 172

PAIR (AIR SUPPLY) SYSTEM DIAGRAM ....................................................... 174

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................................ 175

HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24) .......... 176

WIRING DIAGRAM ........................................................................................... 177

COUNTRY AND AREA CODES

The following codes stand for the applicable country (-ies) and area (-s).

CODE

E-03

E-19

E-24

E-28

E-33

COUNTRY or AREA

U.S.A. (Except for California)

EU

Australia

Canada

California (U.S.A.)

EFFECTIVE FRAME NO.

JS1VY52A 52100001 –

JS1AL211100105237 –

JS1AL211300100688 –

JS1VY52A 52100001 –

JS1VY52A 52100001 –

VL1500K5 (’05-MODEL) 3

ABBREVIATIONS USED IN THIS

MANUAL

A

ABDC

AC

ACL

API

: After Bottom Dead Center

: Alternating Current

: Air Cleaner, Air Cleaner Box

: American Petroleum Institute

ATDC : After Top Dead Center

ATM Pressure : Atmospheric Pressure

A/F

Atmospheric Pressure Sensor

(APS)

: Air Fuel Mixture

E

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

EOT Sensor : Engine Oil Temperature

Sensor (EOTS), Oil Temp.

Sensor

EVAP : Evaporative Emission

EVAP Canister : Evaporative Emission

Canister (Canister)

B

BBDC

BTDC

B+

: Before Bottom Dead Center

: Before Top Dead Center

: Battery Positive Voltage

F

FI

FP

FPR

FP Relay

: Fuel Injection, Fuel Injector

: Fuel Pump

: Fuel Pressure Regulator

: Fuel Pump Relay

C

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

CO

CPU

(Clutch Switch)

: Carbon Monoxide

: Central Processing Unit

G

GEN

GND

: Generator

: Ground

GP Switch : Gear Position Switch

H

HC : Hydrocarbons

HO2 Sensor : Heated Oxygen Sensor (HO2S)

D

DC

DMC

DOHC

DRL

: Direct Current

: Dealer Mode Coupler

: Double Over Head Camshaft

: Daytime Running Light

I

IAP Sensor : Intake Air Pressure Sensor (IAPS)

IAT Sensor : Intake Air Temperature Sensor

IG

(IATS)

: Ignition

L

LCD

LED

LH

: Liquid Crystal Display

: Light Emitting Diode

(Malfunction Indicator Lamp)

: Left Hand

4 VL1500K5 (’05-MODEL)

M

MAL-Code : Malfunction Code

(Diagnostic Code)

Max

MIL

: Maximum

: Malfunction Indicator Lamp

Min

(LED)

: Minimum

N

NOx

O

OHC

OPS

: Nitrogen Oxides

: Over Head Camshaft

: Oil Pressure Switch

P

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

R

RH

ROM

: Right Hand

: Read Only Memory

S

SAE : Society of Automotive Engineers

STC System : Secondary Throttle Control

System (STCS)

STP Sensor : Secondary Throttle Position

ST Valve

Sensor (STPS)

: Secondary Throttle Valve (STV)

STV Actuator : Secondary Throttle Valve Actuator

(STVA)

T

TO Sensor : Tip Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................

2 525 mm (99.4 in)

Overall width........................................................ * 995 mm (40.2 in) ............... E-24

Overall width........................................................ * 1 020 mm (40.2 in) ............... Others

Overall height ...................................................... * 1 125 mm (44.3 in)

Wheelbase ..........................................................

1 700 mm (66.9 in)

Ground clearance................................................ * 140 mm ( 5.5 in)

Seat height ..........................................................

700 mm (27.6 in)

Dry mass ............................................................. * 302 kg (665 lbs)

ENGINE

Type.....................................................................

4-stroke, Air-cooled, OHC

Number of cylinders ............................................

2

Bore.....................................................................

96 mm (3.780 in)

Stroke ..................................................................

101 mm (3.976 in)

Displacement ......................................................

1 462 cm

3

(89.2 cu. in)

Compression ratio ...............................................

8.5 : 1

Fuel system ......................................................... * Fuel injection

Air cleaner ...........................................................

Non-woven fabric element

Starter system .....................................................

Electric

Lubrication system ..............................................

Wet sump

Idle speed............................................................

1 000 ± 100 r/min

DRIVE TRAIN

Clutch ..................................................................

Wet multi-plate type

Transmission .......................................................

5-speed constant mesh

Gearshift pattern .................................................

1-down, 4-up

Primary reduction ratio ........................................

1.490 (76/51)

Secondary reduction ratio ...................................

0.852 (29/34)

Gear ratios, Low ..................................................

3.000 (36/12)

2nd ..................................................

1.823 (31/17)

3rd ...................................................

1.333 (28/21)

4th ...................................................

1.041 (25/24)

Top...................................................

0.884 (23/26)

Final reduction ratio.............................................

2.666 (19/19 × 32/12)

Drive system .......................................................

Shaft drive

VL1500K5 (’05-MODEL) 5

6 VL1500K5 (’05-MODEL)

CHASSIS

Front suspension ................................................. Telescopic, coil spring, oil damped

Rear suspension .................................................. Link type, coil spring, oil damped

Front suspension stroke....................................... 140 mm (5.5 in)

Rear wheel travel ................................................. 118 mm (4.6 in)

Caster .................................................................. 32°

Trail ...................................................................... 138 mm (5.43 in)

Steering angle...................................................... 39° (right & left)

Turning radius ...................................................... 3.1 m (10.2 ft)

Front brake ........................................................... Disc brake, twin

Rear brake ........................................................... Disc brake

Front tire size ....................................................... 150/80-16 M/C 71H, tubeless

Rear tire size ........................................................ 180/70-15 M/C 76H, tubeless

ELECTRICAL

Ignition type.......................................................... Electronic ignition (Transistorized)

Ignition timing....................................................... * 9° B.T.D.C. at 1 000 r/min

Spark plug............................................................ NGK DPR7EA-9 or DENSO X22EPR-U9

Battery ................................................................. * 12 V 64.8 kC (18 Ah)/10 HR

Generator............................................................. Three-phase A.C. generator

Main fuse ............................................................. 30 A

Fuse ..................................................................... 10/10/10/15/15/10 A

Headlight.............................................................. 12 V 60/55 W (H4)

Position/Parking light............................................* 12 V 5 W .....................Except E-03, 24, 28, 33

Brake light/Taillight ............................................... 12 V 21/5 W

Front turn signal light ........................................... 12 V 21/5 W ................E-03, 28, 33

12 V 21 W ...................Others

Rear turn signal light ............................................ 12 V 21 W

Speedometer light................................................ * LED

Turn signal indicator light ..................................... * LED

Neutral indicator light ........................................... * LED

High beam indicator light ..................................... * LED

Oil pressure indicator light ................................... LED

FI warning light .................................................... * LED

CAPACITIES

Fuel tank .............................................................. * 14.0 L (3.7/3.1 US/Imp gal)

Engine oil, oil change ......................................... 3 700 ml (3.9/3.3 US/Imp qt) with filter change............................... 4 300 ml (4.5/3.8 US/Imp qt) overhaul ............................................ 5 000 ml (5.3/4.4 US/Imp qt)

Final gear oil ........................................................ 200 – 220 ml (6.8/7.0 – 7.4/7.7 US/Imp oz)

VL1500K5 (’05-MODEL) 7

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, miles and time for your convenience.

NOTE:

More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

Interval

Item

Air cleaner element

* Exhaust pipe nuts and muffler bolts

Spark plugs

* Fuel hose km miles months

Engine oil

Engine oil filter

* Engine idle speed

* Throttle cable play

Automatic decompression cable

* Throttle valve synchronization

* Evaporative emission control system

(E-33 only)

* PAIR (air supply) system

Clutch hose

Clutch fluid

Final gear oil

Brakes

Brake hose

Brake fluid

Tires

Steering

Front forks

Rear suspension

Chassis bolts and nuts

1 000 6 000 12 000 18 000

600

2

—

T

—

—

4 000

12

I

I

I

—

7 500

24

R

I

I

T

11 000

36

I

I

R

—

R

R

I

—

R

Replace every 4 years.

R R

—

I

—

I

R

I

I

I

I

(E-33 only)

—

I

I

—

I

I

I

I

I

—

— I —

Replace vapor hose every 4 years.

—

—

—

I I

I

I


I I

—

I

R

I

—

—

—

I

—

—

T

—

—

—

T

I

I


— I —

I

I I

I

I


I I

I


I I

I

T

I

I —

—

—

T

24 000

14 500

48

R

I

I

T

R

—

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

T

NOTE:

* I = Inspect and clean, adjust, replace or lubricate as necessary; R = Replace; T = Tighten

* Item marked with asterisk (*) is exclusive to VL1500K5 (’05-MODEL).

8 VL1500K5 (’05-MODEL)

MAINTENANCE AND TUNE-UP PRO-

CEDURES

This section describes the servicing procedures for each Periodic Maintenance item which differ from those of the VL1500K4

(’04-MODEL).

For details other than the following items, refer to the chapter 2 of Service Manual.

FUEL HOSE

Inspect every 6 000 km (4 000 miles, 12 months).

Replace every 4 years.

• Remove the seats

1. (

!Page 121)

• Remove the speedometer and fuel inlet cover

2.

(

!VL1500 Service Manual 6-3)

• Remove the left frame head cover

3 and left frame upper cover

4. (


Inspect the fuel feed hose

A for damage and fuel leakage. If any defect is are found, the fuel feed hose must be replaced.

ENGINE IDLE SPEED

Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months).

NOTE:

Warm up the engine before adjusting the engine idle speed.

• Adjust the throttle cable play.(

!Below)

• Remove the left frame upper cover.

(


• Start the engine, turn the throttle stop screw

1 and set the engine idle speed as follows.

• Connect the multi-circuit tester to the high-tension cord.

" Engine idle speed: 1 000 ± 100 r/min

# 09900-25008: Multi-circuit tester set

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Adjust the throttle cable play

A with the following three steps.

MINOR ADJUSTMENT

First step:

• Loosen the lock-nut

1 of the throttle returning cable 2 and turn in the adjuster

3 fully into the threads.

Second step:


4 of the throttle pulling cable 5.

• Turn the adjuster

6 in or out until the throttle cable play A (at the throttle grip) is between 2.0 – 4.0 mm (0.08 – 0.16 in).

• Tighten the lock-nut

4 while holding the adjuster 6.

Third step:

• While holding the throttle grip at the fully closed position, slowly turn out the adjuster

3 of the throttle returning cable 2 until resistance is felt.


1 while holding the adjuster 3.

" Throttle cable play

A: 2.0 – 4.0 mm (0.08 – 0.16 in)

$

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.

NOTE:

Major adjustment can be made by the throttle body side adjuster.

VL1500K5 (’05-MODEL) 9

10 VL1500K5 (’05-MODEL)

MAJOR ADJUSTMENT

• Remove the air cleaner box. (

!Page 103)

• Loosen the locknut

1 of the throttle returning cable.

• Turn the returning cable adjuster

2 to obtain proper cable play.


3 of the throttle pulling cable.

• Turn the pulling cable adjuster

4 in or out until the throttle cable play

A (at the throttle grip) is between 2.0 – 4.0 mm

(0.08 – 0.16 in).


3 securely while holding the adjuster 4.

"%Throttle cable play

A: 2.0 – 4.0 mm (0.08 – 0.16 in)

• While holding the throttle grip at the fully closed position, slowly turn the returning cable adjuster

2 to obtain a slack of

1.0 mm (0.04 in).


1 securely.

$

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.

THROTTLE VALVE SYNCHRONIZATION

Inspect initially at 1 000 km (600 miles, 2 month) (E-33 only) and every 12 000 km (7 500 miles, 24 months).

Inspect the throttle valve synchronization periodically.

(

!Page 114)

PAIR (AIR SUPPLY) SYSTEM

Inspect every 12 000 km (7 500 miles, 24 months).

Inspect the PAIR (air supply) system periodically.

(

!Page 172)

EXHAUST PIPE BOLTS AND MUFFLER

BOLTS

Tighten initially at 1 000 km (600 miles, 2 month) and every 12 000 km (7 500 miles, 24 months) thereafter.

• Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.

VL1500K5 (’05-MODEL) 11

Apply PERMATEX 1372.

A Gasket

B Exhaust pipe connector


&

ITEM

7

N·m kgf-m lb-ft

12458

25

36

23

55

2.5

2.3

5.5

18.0

16.5

40.0

12 VL1500K5 (’05-MODEL)

CHASSIS BOLTS AND NUTS

Tighten initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to VL1500 Service

Manual 2-18 for the locations of the following nuts and bolts.)

ITEM

Front axle

Front axle pinch bolt

Brake disc bolt (Front and Rear)

*Front fork cap bolt

A

*Front fork upper clamp bolt

B

Front fork lower clamp bolt

Steering stem head nut

Front brake master cylinder mounting bolt

Front brake caliper mounting bolt

Front brake caliper housing bolt

Brake hose union bolt

Front brake hose joint nut

Front brake hose adaptor

Air bleeder valve

* Handlebar set bolt

* Handlebar holder nut

C

Front footrest bolt

Rear brake master cylinder rod lock nut

Rear brake pedal bolt

Rear brake master cylinder mounting bolt

Clutch hose union bolt

Clutch

master cylinder mounting bolt

Rear swingarm pivot bolt (Left)

Rear swingarm pivot bolt (Right)

Rear swingarm pivot

lock nut

Rear shock absorber mounting nut

(Upper and Lower)

Rear cushion lever/rod mounting nut

Rear axle nut

Rear caliper mounting bracket bolt/nut

Rear

brake caliper mounting bolt

Rear

brake caliper housing bolt

Final gear case mounting nut

50

135

110

60

35

33

40

NOTE:

* Item marked with asterisk (*) is exclusive to VL1500K5 (’05-MODEL).

* Refer to page 126 for the

A, B and C tightening.

16

10

23

10

23

70

50

18

100

9.5

100

23

15

23

7.5

90

10

35

35

N·m

65

23

23

23

23

23

5.0

13.5

11.0

6.0

3.5

3.3

4.0

1.6

1.0

2.3

1.0

2.3

7.0

5.0

1.8

10.0

0.95

10.0

9.0

1.0

3.5

3.5

2.3

1.5

2.3

0.75

kgf-m

6.5

2.3

2.3

2.3

2.3

2.3

36.0

97.5

79.5

43.5

25.5

24.0

29.0

16.5

50.5

36.0

13.0

11.5

7.0

16.5

7.0

72.5

7.0

72.5

65.0

7.0

25.5

25.5

16.5

11.0

16.5

5.5

lb-ft

47.0

16.5

16.5

16.5

16.5

16.5

VL1500K5 (’05-MODEL) 13

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions.

ENGINE LEFT SIDE

PARTS

Secondary case

Secondary driven bevel gear

* Gear position switch body

Clutch release cylinder

Starter torque limiter

Starter idle gear

Starter clutch

Gearshift lever and linkage

Generator

REMOVAL

3-24, 4-5

3-25, 4-5

17

6-59

3-27, 3D-1

3-17, 3D-1

3-27, 3D-1, 3D-5

3-26, 3E-1

3-27, 3D-1

INSTALLATION

3-41, 4-10

3-40, 4-10

17

6-61

3-36, 3D-6

3-60, 3D-6

3-38, 3D-5, 3D-6

3-38, 3E-5

3-38, 3D-6

ENGINE RIGHT SIDE

PARTS

Clutch cover

Clutch pressure, drive and driven plates

Clutch sleeve hub

Clutch housing

Oil pump drive gears

Oil pump driven gears

Oil pressure switch

Oil pressure regulator

* EOT sensor

Back torque limiter

Rear clutch cover

ENGINE CENTER

PARTS

* Throttle body

Oil filter

Oil cooler

Starter motor

REMOVAL

3-20, 3C-1

3-20, 3C-1

3-21, 3C-1

3-22, 3C-2

3-22, 3C-2

3-23

3-24, 3G-5

3-23, 3G-3

17

3-22, 3C-2

3-6

REMOVAL

104

2-6

3G-5

7-14

INSTALLATION

3-50, 3C-5

3-48, 3C-5

3-46, 3C-5

3-46, 3C-4

3-46, 3C-4

3-45

3-43, 3G-7

3-45, 3G-4

17

3-46, 3C-5

3C-6

INSTALLATION

110

2-7

3-13

7-17

14 VL1500K5 (’05-MODEL)

ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL

The engine removal procedure is different from that of the

VL1500K4 (’04-MODEL). For details other than the removal procedure, refer to the VL1500 Service Manual.

• Remove the seats. (

!Page 121)

• Remove the PAIR cover

1.

• Disconnect the PAIR hoses

2 from the pipes.

• Remove the PAIR control solenoid valve nuts

3.

• Disconnect the PAIR control solenoid valve coupler

4 and

PAIR hose

5.

• Remove the PAIR control solenoid valve

6.

• Remove the PAIR device bracket

7.

• Remove the No. 1 and No. 2 PAIR pipes.


!Page 103)

• Remove the throttle body. (

!Page 104)

VL1500K5 (’05-MODEL) 15

16 VL1500K5 (’05-MODEL)

ENGINE INSTALLATION

Installation is in the reverse order of removal procedure.

• Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.


'

Replace the gaskets with the new ones.

• Adjust the following items to the specification.

* Engine oil (


* Throttle valve synchronization (

!Page 114)

* Throttle cable play (

!Page 9)

* Engine idle speed (

!Page 8)

* Automatic decompression cable (


* Clutch air bleeding (


* Wiring harness, cables and hoses (

!Page 144)


ENGINE DISASSEMBLY AND

REASSEMBLY

The engine disassembly and reassembly procedures are different from those of the VL1500K4 (’04-MODEL). For details other than the following parts, refer to the VL1500 Service Manual.

GEAR POSITION SWITCH REMOVAL

• Remove the gear position switch

1.

GEAR POSITION SWITCH REASSEMBLY

• Apply SUZUKI SUPER GREASE “A” to the O-ring.

• When installing the gear position switch

1, align the pin A with the hole

B in the gearshift cam retainer 2.

'

Use a new O-ring to prevent oil leakage.

( 99000-25030: SUZUKI SUPER GREASE “A” (USA)

99000-25010: SUZUKI SUPER GREASE “A” (Others)

EOT SENSOR REMOVAL

• Place an oil pan below the EOT sensor.

• Disconnect the EOT sensor coupler

1 and remove the EOT sensor

2.

$

Do not remove the EOT sensor when the engine is hot.

EOT SENSOR REASSEMBLY

• Install a new gasket washer

1.

• Tighten the EOT sensor to the specified torque.

'

Take special care when handling the temperature sensor. It may cause damage if it gets a sharp impact.

& EOT sensor: 22 N·m (2.2 kgf-m, 16.0 lb-ft)

VL1500K5 (’05-MODEL) 17

18 VL1500K5 (’05-MODEL)

ENGINE COMPONENTS INSPECTION

AND SERVICING

CAMSHAFT

For details other than the following, refer to the VL1500 Service

Manual.

Each camshaft I.D. code has been changed which is stamped on the camshaft end.

I.D. code

Front cylinder

B

Rear cylinder

C

CAM WEAR

" Cam height

H

Service Limit (IN) : 35.02 mm ( 1.379 in)

(EX) : 36.58 mm (1.440 in)

# 09900-20202: Micrometer (25 – 50 mm)

I.D.

Front cylinder Rear cylinder

PRECAUTIONS IN SERVICING

When handling the FI component parts or servicing the FI system, observe the following points for the safety of the system.

CONNECTOR/COUPLER

• When connecting a connector, be sure to push it in until a click is felt.

• With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.

• When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.

• Inspect each terminal on the connector/coupler for looseness or bending.

• Inspect each terminal for corrosion and contamination.

The terminals must be clean and free of any foreign material which could impede proper terminal contact.

• Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.

• When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler

VL1500K5 (’05-MODEL) 19

Click

Click

Coupler

Probe

20 VL1500K5 (’05-MODEL)

• When connecting meter probe from the terminal side of the coupler where (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open.

Connect the probe as shown to avoid opening of female terminal.

Never push in the probe where male terminal is supposed to fit.

• Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.

FUSE

• When a fuse blows, always investigate the cause to correct it and then replace the fuse.

• Do not use a fuse of a different capacity.

• Do not use wire or any other substitute for the fuse.

Coupler

Probe

Where male terminal fits

ECM/ VARIOUS SENSORS

• Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and installation.

INCORRECT

• Be careful not to touch the electrical terminals of the ECM.

The static electricity from your body may damage this part.

• When disconnecting and connecting the ECM couplers, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

VL1500K5 (’05-MODEL) 21

Ignition S/W

INCORRECT

• Battery connection in reverse polarity is strictly prohibited.

Such a wrong connection will damage the components of the

FI system instantly when reverse power is applied.

• Removing any battery terminal of a running engine is strictly prohibited.

The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in serious damage.

• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagnosis.

• Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECM when its coupler is disconnected. Otherwise, damage to the ECM may result.

• Never connect an ohmmeter to the ECM with its coupler connected. If attempted, damage to the ECM or sensors may result.

• Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.

V

22 VL1500K5 (’05-MODEL)

ELECTRICAL CIRCUIT INSPECTION

PROCEDURE

While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

• Loose connection of connector/coupler

• Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.)

• Wire harness being open

• Poor terminal-to-wire connection

• Disconnect the negative cable from the battery.

• Check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock if equipped.

Sensor

Check for loose connection

ECM

• Using a test male terminal, check the female terminals of the circuit being checked for contact tension.

Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the coupler and locked.

If contact tension is not enough, rectify the contact to increase tension or replace.

The terminals must be clean and free of any foreign material which could impede proper terminal contact.

• Using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection. Locate abnormality, if any.

Check contact tension by inserting and removing.

Check each terminal for bend and proper alignment.

Looseness of crimping

Open

Thin wire (a few strands left)

VL1500K5 (’05-MODEL) 23

Continuity check

• Measure resistance across coupler

B (between A and C in the figure).

If no continuity is indicated (infinity or over limit), the circuit is open between terminals

A and C.

• Disconnect the coupler

B and measure resistance between couplers

A and B.

If no continuity is indicated, the circuit is open between couplers

A and B. If continuity is indicated, there is an open circuit between couplers

B’ and C or an abnormality in coupler

B’ or coupler C.

VOLTAGE CHECK

If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.

• With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.

If measurements were taken as shown in the figure at the right and results are as listed below, it means that the circuit is open between terminals

A and B.

Voltage Between:

C and body ground: Approx. 5 V

B and body ground: Approx. 5 V

A and body ground:

0 V

Also, if measured values are as listed below, a resistance

(abnormality) exists which causes the voltage drop in the circuit between terminals

A and B.

Voltage Between:

C and body ground: Approx. 5 V

B and body ground: Approx. 5 V

A and body ground:

3 V

2 V voltage drop

0 V

5 V

5 V

5 V

ECM

ECM

24 VL1500K5 (’05-MODEL)

SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)

• Disconnect the negative cable from the battery.

• Disconnect the connectors/couplers at both ends of the circuit to be checked.

NOTE:

If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts. Otherwise, diagnosis will be misled.

• Measure resistance between terminal at one end of circuit (

A terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals

A and C.

To other parts

Other parts

5 V

• Disconnect the connector/coupler included in circuit (coupler

B) and measure resistance between terminal A and body ground.

If continuity is indicated, the circuit is shorted to the ground between terminals

A and B.

To other parts

ECM

VL1500K5 (’05-MODEL) 25

USING THE MULTI-CIRCUIT TESTER

• Use the Suzuki multi-circuit tester (09900-25008).

• Use well-charged batteries in the tester.

• Be sure to set the tester to the correct testing range.

USING THE TESTER

• Incorrectly connecting the

+ and - probes may cause the inside of the tester to burnout.

• If the voltage and current are not known, make measurements using the highest range.

• When measuring the resistance with the multi-circuit tester,

∞ will be shown as 10.00 M

Ω and “1” flashes in the display.

• Check that no voltage is applied before making the measurement. If voltage is applied, the tester may be damaged.

• After using the tester, turn the power off.


NOTE:

* When connecting the multi-circuit tester, use a needle pointed probe set to the back side of the lead wire coupler and connect the probes of tester to them.

* Use a needle pointed probe set to prevent the rubber of the water proof coupler from damage.

# 09900-25009: Needle pointed probe set

MULTI-CIRCUIT TESTER

NEEDLE POINTED PROBE SET

26 VL1500K5 (’05-MODEL)

FI SYSTEM TECHNICAL FEATURES

INJECTION TIME (INJECTION VOLUME)

The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.

These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

ECM

Intake Air Pressure

Sensor (IAP Sensor)

Crankshaft Position

Sensor (CKP Sensor)

Throttle Position

Sensor (TP Sensor)

Various

Sensors

Intake air pressure signal

Engine speed signal

Throttle opening signal

Various signals

Basic fuel injection time

Compensation

Injectors

Injection signal

Ultimate fuel injection time

VL1500K5 (’05-MODEL) 27

COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensation of the fuel injection time (volume).

SIGNAL

ENGINE OIL TEMPERATURE SENSOR

SIGNAL

INTAKE AIR TEMPERATURE SENSOR

SIGNAL

HEATED OXYGEN SENSOR SIGNAL

(FOR E-02, 19, 24)

BATTERY VOLTAGE SIGNAL

ENGINE RPM SIGNAL

STARTING SIGNAL

ACCELERATION SIGNAL/

DECELERATION SIGNAL

DESCRIPTION

When engine oil temperature is low, injection time (volume) is increased.

When intake air temperature is low, injection time (volume) is increased.

Air/fuel ratio is compensated to the theoretical ratio from density of oxygen in exhaust gasses. The compensation occurs in such a way that more fuel is supplied if detected air/fuel ratio is lean and less fuel is supplied if it is rich.

ECM operates on the battery voltage and at the same time, it monitors the voltage signal for compensation of the fuel injection time (volume). A longer injection time is needed to adjust injection volume in the case of low voltage.

At high speed, the injection time (volume) is increased.

When starting engine, additional fuel is injected during cranking engine.

During acceleration, the fuel injection time (volume) is increased, in accordance with the throttle opening speed and engine rpm. During deceleration, the fuel injection time

(volume) is decreased.

INJECTION STOP CONTROL

SIGNAL

TIP-OVER SENSOR SIGNAL

(FUEL SHUT-OFF)

OVER-REV. LIMITER SIGNAL

DESCRIPTION

When the motorcycle tips over, the tip-over sensor sends a signal to the ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors and ignition coils.

The fuel injectors stop operation when engine rpm reaches rev. limit rpm.

28 VL1500K5 (’05-MODEL)

FUEL DELIVERY SYSTEM

The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe

(including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.

Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector (the fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of 300 kPa (3.0 kgf/cm²,

43 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM.

The fuel relieved by the fuel pressure regulator flows back to the fuel tank.

1 Fuel tank

2 Fuel filter (For high pressure)

3 Fuel pressure regulator

4 Fuel injector

5 Fuel feed hose

6 Fuel mesh filter (For low pressure)

7 Fuel pump

A Before-pressurized fuel

B Pressurized fuel

C Relieved fuel

FI SYSTEM PARTS LOCATION

VL1500K5 (’05-MODEL) 29

ECM

A Speedometer

B Starter relay

C Starter motor

D Intake air pressure sensor #1 (IAPS)

E Fuel pump relay (FP RELAY)

F Fuel pump

G Tip-over sensor (TOS)

H Gear position switch

I HO2 sensor (HO2S) [For E-02, 19, 24]

J Crankshaft position sensor (CKPS)

K Fuel injector #2 (FI)

L Fuel injector #1 (FI)

M Ignition coil #1 (IG COIL)

30 VL1500K5 (’05-MODEL)

ECM

N Intake air pressure sensor #2 (IAPS)

O Secondary throttle position sensor (STPS)

P Throttle position sensor (TPS)

Q Secondary throttle valve actuator (STVA)

R Decompression relay

S Decompression solenoid

T Intake air temperature sensor (IATS)

U Ignition coil #2 (IG COIL)

V PAIR solenoid valve

W Engine oil temperature sensor (EOTS)

FI SYSTEM WIRING DIAGRAM

VL1500K5 (’05-MODEL) 31

32 VL1500K5 (’05-MODEL)

ECM TERMINAL

8

9

0

A

B

C

D

E

F

G

TERMINAL

NO.

1

2

3

4

5

CIRCUIT

Blank

Power source for sensors (VCC)

6

GP switch signal (GP)

IAT sensor signal (IAT)

Rear cylinder IAP sensor signal (IAP. R)

STP sensor signal (STP)

7

HO2 sensor signal (HO2S)

[For E-02, 19, 24]

Clutch lever position switch (CLP)

TERMINAL

NO.

H

I

J

K

L

M

N

CIRCUIT

Ignition switch signal (AT)

EOT sensor signal (EOT)

TO sensor signal (TOS)

TP sensor signal (TP)

Front cylinder IAP sensor signal (IAP. F)

HO2 control selector (EXS)

[For E-02, 19, 24]

Mode select switch (MS)

Starter switch (STA)

Neutral switch (NT)

CKP sensor signal (CKP-)

Power source for fuel injector (VM)

Power source (B+1)

Power source for back-up (B+2)

ECM ground (E1)

Sensors ground (E2)

–

–

–

O

P

Q

R

S

T

U

V

W

X

CKP sensor signal (CKP+)

Blank

Blank

–

Serial data for speedometer (TECH)

Serial data for self-diagnosis (SDL)

–

–

TERMINAL

NO.

Y

Z

CIRCUIT

STVA signal (STVA. 1B)

HO2 sensor heater (HO2. H)

[For E-02, 19, 24] a b c

[

\

]

^

STVA signal (STVA. 1A)

Blank

Ground (E01)

Rear cylinder Fuel injector (#1)

Front cylinder Fuel injector (#2)

Blank

Front cylinder Ignition coil (IG2)

TERMINAL

NO.

d

CIRCUIT

STVA signal (STVA. 2B)

Fuel pump relay (FP Relay) e j k l f g h i

STVA signal (STVA. 2A)

PAIR control solenoid valve (PAIR)

Ground (E02)

Decomp. solenoid (DRL)

Starter relay (STR)

Blank

Rear cylinder Ignition coil (IG1)

VL1500K5 (’05-MODEL) 33

SELF-DIAGNOSIS FUNCTION

The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and

“Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared. In this check, the special tool is necessary to read the code of the malfunction items.

USER MODE

MALFUNCTION

“NO”

“YES”

LCD (DISPLAY)

INDICATION

A

Odometer

*1

Odometer (*1) and

“FI” letters

*2 Engine can start

Engine can not start “FI” letter

*3

FI LIGHT

INDICATION

B

----

FI light turns ON.

FI light turns ON and blinks.

INDICATION MODE

----

Each 2 sec. Odometer

(*1) and “FI” are indicated alternately.

“FI” is indicated continuously.

*1

Current letter displayed any one of the Odometer, Tripmeter or

Clock.

*2

When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case, “FI” and

Odometer (*1) are indicated in the LCD panel and motorcycle can run.

However, when starter relay signal is not received by ECM, the engine can not be restarted.

*3

The injection signal is stopped, when the crankshaft position sensor signal, tip-over sensor signal, both #1/#2 ignition signals, both #1/#2 injector signals, fuel pump relay signal or ignition switch signal is not sent to ECM. In this case, “FI” is indicated in the LCD panel. Motorcycle does not run.

“CHEC”: The LCD panel indicates “CHEC” when no communication signal from the ECM is received for 5 seconds.

For Example

: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from ECM, and the panel indicates “CHEC”.

If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the wiring harness between ECM and speedometer couplers.

The possible cause of this indication is as follows;

Engine stop switch is in OFF position. Side-stand/ignition inter-lock system is not working. Ignition fuse is burnt.

NOTE:

Until starting the engine, the FI light turns ON.

The FI light is also turned ON when engine temperature is high or oil pressure is low.

34 VL1500K5 (’05-MODEL)

DEALER MODE

The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on the LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

# 09930-82720: Mode select switch

'

Before checking the malfunction code, do not disconnect the ECM lead wire couplers.

If the couplers from the ECM are disconnected, the malfunction code memory is erased and the malfunction code can not be checked.

MALFUNCTION

“NO”

“YES”

LCD (DISPLAY)

INDICATION

C00

C** code is indicated from small numeral to large one.

FI LIGHT

INDICATION

FI light turns OFF.

INDICATION MODE

—

For each 2 sec., code is indicated.

VL1500K5 (’05-MODEL) 35

C31

C32

C33

C41

C42

C44

C49

CODE

C17

C18

C19

C21

C23

C24

C00

C12

C13

C14

C15

C25

C28

C29

MALFUNCTION PART

None

Crankshaft position sensor (CKPS)

Intake air pressure sensor #2 (IAPS #2)

Throttle position sensor (TPS)

Engine oil temp. sensor (EOTS)

Intake air pressure sensor #1 (IAPS #1)

Decomp. control system

Starter control system

Intake air temp. sensor (IATS)

Tip-over sensor (TOS)

Ignition signal #1 (IG coil #1)

Ignition signal #2 (IG coil #2)

Secondary throttle valve actuator (STVA)

Secondary throttle valve position sensor

(STPS)

Gear position signal (GP switch)

Injector signal #1 (FI #1)

Injector signal #2 (FI #2)

Fuel pump control system (FP control system)

Ignition switch signal (IG switch signal)

Heated oxygen sensor (HO2S)

PAIR control solenoid valve (PAIR valve)

REMARKS

No defective part

Pick-up coil signal, signal generator

For Front cylinder

*1

For Rear cylinder

For Rear cylinder

For Front cylinder

*2

For Rear cylinder

For Front cylinder

Fuel pump, fuel pump relay

Anti-theft

For E-02, 19, 24

In the LCD (DISPLAY) panel, the malfunction code is indicated from small code to large code.

*1

To get the proper signal from the throttle position sensor, the sensor basic position is indicated in the LCD

(DISPLAY) panel. The malfunction code is indicated in three digits. In front of the three digits, a line appears in any of the three positions, upper, middle or lower line. If the indication is upper or lower line when engine rpm is 1 000 r/min, slightly turn the throttle position sensor and bring the line to the middle.

In the normal condition, the throttle valve stop screw pushes throttle valves slightly, and middle line will be indicated.

*2

When the secondary throttle valve actuator and secondary throttle position sensor signals are not sent to

ECM. In this case, C28 and C29 are indicated alternately.

36 VL1500K5 (’05-MODEL)

TPS ADJUSTMENT

1. Warm up the engine and adjust the engine idle speed to 1 000

± 100 r/min. (

!Page 8)

2. Connect the special tool (Mode select switch) and select the dealer mode.

3. Remove the right frame upper cover.

(


4. Loosen the screws and turn the throttle position sensor

1 and bring the line to the middle.

5. Then, tighten the screws to fix the throttle position sensor.

# 09930-11950: Torx wrench

09930-82720: Mode select switch

The LCD displays the line for 0.4 sec. at a time, and when such a display repeats two times, it indicates the current position where the sensor is fixed.

A Incorrect

B Correct position

VL1500K5 (’05-MODEL) 37

FAIL-SAFE FUNCTION

FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.

ITEM

STARTING

ABILITY

RUNNING

ABILITY

IAP sensor

TP sensor

EOT sensor

IAT sensor

Ignition signal

FAIL-SAFE MODE

Intake air pressure is fixed to

760 mmHg.

The throttle opening is fixed to full open position.

Ignition timing is also fixed.

Engine oil temperature value is fixed to 80 °C (176 °F).

Intake air temperature value is fixed to 40 °C (104 °F).

#1 Ignition-off and #1 Fuel-cut

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

Injection signal

#2 Ignition-off and #2 Fuel-cut

#1 Fuel-cut

#2 Fuel-cut

“YES” “YES”

#2 cylinder can run.

“YES” “YES”


“YES” “YES”


“YES” “YES”


STV actuator

STP sensor

Gear position signal

Secondary throttle valve is fixed in any position.When motor disconnection or lock occurs, power from ECM is shut off.

Secondary throttle valve is fixed in any position.

Gear position signal is fixed to 5th gear.

HO2 sensor

(For E-02, 19, 24)

Feedback compensation is inhibited.

(Air/fuel ratio is fixed to normal.)

PAIR control solenoid valve O2 feedback control is stopped and

PAIR valve is fixed to open position.

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

The engine can start and can run even if the above signal is not received from each sensor. But, the engine running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.

When two ignition signals or two injector signals are not received by ECM, the fail-safe circuit can not work and ignition or injection is stopped.

38 VL1500K5 (’05-MODEL)

FI SYSTEM TROUBLESHOOTING

CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name:

Date of issue:

Model:

Date Reg.

VIN:

Date of problem: Mileage:

Malfunction indicator lamp condition (LED)

Malfunction display/code

(LCD)

Always ON Sometimes ON Always OFF Good condition

User mode:

Dealer mode:

No display

No code

Malfunction display ( )

Malfunction code ( )

Difficult Starting

No cranking

No initial combustion

No combustion

Poor starting at

( cold warm always)

Other

Poor Idling

Poor fast idle

Abnormal idling speed

(

High Low) ( r/min)

Unstable

Hunting ( r/min to r/min)

Other

OTHERS:

PROBLEM SYMPTOMS

Poor Driveability

Hesitation on acceleration

Back fire/ After fire

Lack of power

Surging

Abnormal knocking

Engine rpm jumps briefly

Other

Engine Stall when

Immediately after start

Throttle valve is opened

Throttle valve is closed

Load is applied

Other

VL1500K5 (’05-MODEL) 39

Weather

Temperature

Frequency

Road

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition

Fair Cloudy Rain Snow Always Other

Hot Warm Cool Cold ( °C/ °F) Always

Always Sometimes ( times/ day, month) Only once

Under certain condition

Urban Suburb Highway Mountainous ( Uphill Downhill)

Tarmacadam Gravel Other

Motorcycle condition

Engine condition Cold Warming up phase Warmed up Always Other at starting

Immediately after start Racing without load Engine speed ( r/min)

Motorcycle condition

During driving: Constant speed Accelerating Decelerating

Right hand corner Left hand corner

At stop Motorcycle speed when problem occurs ( km/h, mile/h)

Other

NOTE:

The above form is a standard sample. The form should be modified according to conditions and characteristics of each market.

VISUAL INSPECTION

• Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.

* Engine oil level and leakage (


* Fuel level and leakage (

!Page

8 )

* Clogged air cleaner element (


* Battery condition (


* Throttle cable play (

!Page 9)

* Vacuum hoses looseness, bend and disconnection

* Broken fuse

* FI light operation (

!Page 33 and 140)

* Each warning light operation (

!Page 140)

* Speedometer operation (

!Page 141)

* Exhaust gas leakage and noise (

!Page 11)

* Each coupler disconnection

* Clogged oil cooler fins (

!VL1500 Service Manual 3G-6)

40 VL1500K5 (’05-MODEL)

SELF-DIAGNOSTIC PROCEDURES

NOTE:

* Don’t disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

* Malfunction code stored in ECM memory can be checked by the special tool.

* Before checking malfunction code, read SELF-DIAGNOSIS

FUNCTION “USER MODE and DEALER MODE” (

!Page 33

and 36) carefully to have good understanding as to what functions are available and how to use it.

* Be sure to read “PRECAUTIONS IN SERVICING” (

!Page 19)

before inspection and observe what is written there.

• Remove the left frame head cover.

(


• Connect the special tool to the dealer mode coupler

A at the wiring harness, and start the engine or crank the engine for more than 4 seconds.

• Turn the special tool’s switch ON and check the malfunction code to determine the malfunction part.

# 09930-82720: Mode select switch

SELF-DIAGNOSIS RESET PROCEDURE

• After repairing the trouble, turn OFF the ignition switch and turn ON again.

• If the malfunction code indicates (C00), the malfunction is cleared.

• Disconnect the special tool from the dealer mode coupler.

NOTE:

* Even though the malfunction code (C00) is indicated, the previous malfunction history code still remains stored in the ECM.

Therefore, erase the history code memorized in the ECM using

SDS.

* The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.

USE OF SDS DIAGNOSTIC PROCEDURES

* Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

* Malfunction code stored in ECM memory can be checked by the SDS.

* Be sure to read “PRECAUTIONS IN SERVICING” (

!Page 19)

before inspection and observe what is written there.

• Remove the left side frame head cover.

(


• Set up the SDS tool. (Refer to the SDS operation manual for further details)

• Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaying data at the time of DTC) according to instructions displayed on SDS.

• Not only is SDS used for detecting Diagnostic Trouble Codes but also for reproducing and checking on screen the failure condition as described by customers using the trigger.

• How to use trigger. (Refer to the SDS operation manual for further details.)

# 09904-41010: SDS set tool

09904-41030-004: CD-ROM Ver. 4

VL1500K5 (’05-MODEL) 41

42 VL1500K5 (’05-MODEL)

USE OF SDS DIAGNOSIS RESET PROCE-

DURE

• After repairing the trouble, turn OFF the ignition switch and turn ON again.

• Click the DTC inspection button

1.

• Check the DTC.

• The previous malfunction history code (Past DTC) still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS tool.

NOTE:

The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.

• Click “Clear”

2 to delete history code (Past DTC).

• Follow the displayed instructions.

• Check that both “Current DTC”

3 and “Past DTC” 4 are deleted (NIL).

VL1500K5 (’05-MODEL) 43

SHOW DATA WHEN TROUBLE

(DISPLAING DATA AT THE TIME OF DTC)

ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”.

Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble. This show data when trouble function can record the maximum of two Diagnostic Trouble

Codes in the ECM.

Also, ECM has a function to store each show data when trouble for two different malfunctions in the order as the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been detected. lts use is helpful when rechecking or diagnosing a trouble.

• Click “Show data when trouble”

1 to display the data. By clicking the drop down button 2, either “Failure

#1” or “Failure #2” can be selected.

44 VL1500K5 (’05-MODEL)

MALFUNCTION CODE AND DEFECTIVE CONDITION

DTC No.

C00

C12

P0335

C13/C17

P1750/P0105

C14

P0120

C15

P0115

C18

P1751

C19

P0615

H

L

H

L

DETECTED

ITEM

DETECTED FAILURE CONDITION

NO FAULT –––––––––––

CKP sensor The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

CHECK FOR

–––––––––––

CKP sensor wiring and mechanical parts.

CKP sensor, lead wire/coupler connection.

IAP sensor, lead wire/coupler connection.

IAP sensor The sensor should produce following voltage.

TP sensor

0.1 V sensor voltage < 4.8 V

In other than the above range, C13

(P1750) or C17 (P0105) is indicated.

The sensor should produce following voltage.

TP sensor, lead wire/coupler connection.

EOT sensor



(P0120) is indicated.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

The sensor voltage should be the following.

TP sensor circuit shorted to

VCC or ground circuit open.

TP sensor circuit open or shorted to ground or VCC circuit open.

EOT sensor, lead wire/coupler connection.






Decomp. relay Decomp relay signal is not input to

ECM.

Starter relay Starter relay signal is not input to

ECM.

EOT sensor circuit open or ground circuit open.

EOT sensor circuit shorted to ground.

Decomp. relay, lead wire/coupler connection.

Starter relay, lead wire/coupler connection.

VL1500K5 (’05-MODEL) 45

DTC No.

C21

P0110

C23

P1651

C24/C25

P0351/P0352

C28

P1655

C29

P1654

H

L

H

L

H

L

DETECTED

ITEM

IAT sensor

DETECTED FAILURE CONDITION CHECK FOR

TO sensor

Ignition signal

The sensor voltage should be the following.






The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.

0.2 V sensor voltage 4.6 V

In other than the above value, C23



IAT sensor, lead wire/coupler connection.

IAT sensor circuit open or ground circuit open.

IAT sensor circuit shorted to ground.

TO sensor, lead wire/coupler connection.


CKP sensor (pick-up coil) signal is produced, but signal from ignition coil is interrupted 8 times or more continuously. In this case, the code C24

(P0351) or C25 (P0352) is indicated.

When no actuator control signal is Secondary throttle valve actuator supplied from the ECM, communication signal does not reach ECM or operation voltage does not reach

STVA motor, C28 (P1655) is indicated.

STVA can not operate.

STP sensor The sensor should produce following voltage.

TO sensor circuit open or shorted to VCC or ground circuit open.

TO sensor circuit shorted to ground or VCC circuit open.

Ignition coil, lead wire/coupler connection, power supply from the battery.

STVA motor, STVA lead wire/ coupler.

STP sensor, lead wire/coupler connection.






STP sensor circuit shorted to

VCC or ground circuit open.

STP sensor circuit open or shorted to ground or VCC circuit open.

46 VL1500K5 (’05-MODEL)

DTC No.

C31

P0705

C32/C33

P0201/P0202

C41

P0230

C42

P1650

C44

P0130

C44

P0135

C49

P1656

DETECTED

ITEM

Gear position signal

DETECTED FAILURE CONDITION


Fuel injector CKP sensor (pickup coil) signal is produced, but fuel injector signal is interrupted 4 times or more continuously. In this case, the code C32 (P0201) or

C33 (P0202) is indicated.

Fuel pump relay

Gear position signal voltage should be higher than the following for 3 seconds and more.

Gear position sensor voltage > 0.6 V

If lower than the above value, C31

Ignition switch

HO2 sensor

(For E-02,

19, 24)

No voltage is applied to the fuel pump, although fuel pump relay is turned ON, or voltage is applied to fuel pump, although fuel pump relay is turned

OFF.

Ignition switch signal is not input to

ECM.

HO2 sensor output voltage is not input to ECM during engine operation and running condition.

PAIR control solenoid valve

(Sensor voltage 0.1 V)

In other than the above value, C44


The heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit, C44


PAIR control solenoid valve voltage is not input to ECM.

CHECK FOR

GP switch, lead wire/coupler connection, gearshift cam, etc.

Fuel injector, wiring/coupler connection, power supply to the injector.

Fuel pump relay, lead wire/coupler connection, power source to the fuel pump relay and fuel injectors.

Ignition switch, lead wire/coupler.

HO2 sensor circuit open or shorted to ground.

HO2 sensor, lead wire/coupler connection.

Battery voltage supply to the

HO2 sensor.

PAIR control solenoid valve, lead wire/coupler.

VL1500K5 (’05-MODEL) 47

“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION

The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

POSSIBLE CAUSE

• Metal particles or foreign material being stuck on the CKP sensor and rotor tip.

• CKP sensor circuit open or short.

• CKP sensor malfunction.

• ECM malfunction.

CKP sensor

G

BI

G/Y

Br

ECM

CKP

CKP

To Regulator/Rectifier

GEN.

INSPECTION

Step 1

1) Remove the seats. (

!Page 121)

2) Remove the left and right frame upper covers.

(


3) Remove the speedometer and fuel inlet cover.

(


4) Turn the ignition switch OFF.

5) Check the CKP sensor coupler for loose or poor contacts.

If OK, then measure the CKP sensor resistance.

6) Disconnect the CKP sensor coupler and measure the resistance.

" CKP sensor resistance: 178 – 242 Ω

(Green – Blue)

1

1

48 VL1500K5 (’05-MODEL)

7) If OK, then check the continuity between each terminal and ground.

" CKP sensor continuity: ∞ Ω (Infinity)

(Blue – Ground)

(Green – Ground)


) Tester knob indication: Resistance (Ω)

Are the resistance and continuity OK?

YES

NO

Go to step 2.

Replace the CKP sensor with a new one.

8) After repairing the trouble, clear the DTC using SDS tool.

(

!Page 42)

1

Step 2

1) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler.

2) Repeat the above test procedure a few times and measure the highest peak voltage.

" CKP sensor peak voltage: 2.4 V and more

(

+ Green – - Blue)


* Tester knob indication: Voltage (+)

1 Peak volt adaptor

.

Is the voltage OK?

YES

NO

• G/Y or Brown wire open or shorted to ground.

• Loose or poor contacts on the CKP sensor coupler or ECM coupler (terminal

9 or Q).

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

• Inspect that metal particles or foreign material stuck on the CKP sensor and rotor tip.

• If there are no metal particles and foreign material, then replace the CKP sensor with a new one.


(

!Page 42)

2

2

ECM coupler (Harness side)

V

VL1500K5 (’05-MODEL) 49

“C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION


IAP sensor voltage low or high

(0.1 V Sensor voltage < 4.8 V)

NOTE:

Note that atmospheric pressure varies depending on weather conditions as well as altitude.

Take that into consideration when inspecting voltage.

POSSIBLE CAUSE

• Clogged vacuum passage between throttle body and IAP sensor.

• Air being drawn from vacuum passage between throttle body and IAP sensor.

• IAP sensor circuit open or shorted to ground.

• IAP sensor malfunction.


ECM

VCC

IAP. F

E2

IAP sensor #2 (Front cylinder)

R

G/B

B/Br

R

G/W

B/Br

IAP sensor #1 (Rear cylinder)

INSPECTION

Step 1

(When indicating C13/P1750 for IAP sensor #2)

1) Remove the right frame upper cover.

(


For the other inspection procedures are the same as C17/

P0105.

(When indicating C17/P0105 for IAP sensor #1)

1) Remove the left frame upper cover.

(



3) Check the IAP sensor coupler (Front cylinder side

1 or Rear cylinder side

2) for loose or poor contacts.

If OK, then measure the IAP sensor input voltage.

4) Disconnect the IAP sensor coupler.

5) Turn the ignition switch ON.

6) Measure the voltage at the Red wire

3 and ground.

7) Also, measure the voltage at the Red wire

3 and B/Br wire 4.

" IAP sensor input voltage: 4.5 – 5.5 V

(

+ Red – - Ground)

(

+ Red – - B/Br)



1

1

V

IAP. R

1

50 VL1500K5 (’05-MODEL)

Is the voltage OK?

YES

NO

Go to Step 2.

• Loose or poor contacts on the ECM coupler

(terminal

6 or D).

• Open or short circuit in the Red wire or B/Br wire.


(

!Page 42)

Step 2

1) Connect the IAP sensor coupler.

2) Insert the needle pointed probes to the lead wire coupler.

3) Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler.

(Front cylinder side: between G/B and B/Br wires)

(Rear cylinder side: between G/W and B/Br wires)

" IAP sensor output voltage: Approx. 2.53 V at idle speed

(Front cylinder side:

+ G/B – - B/Br)

(Rear cylinder side:

+ G/W – - B/Br)


09900-25009: Needle pointed probe set


Is the voltage OK?

YES

NO

Go to Step 3.

• Check the vacuum hose for crack or damage.

• Open or short circuit in the G/B wire.

(Front cylinder side)

• Open or short circuit in the G/W wire.

(Rear cylinder side)

• If vacuum hose and wire are OK, replace the

IAP sensor with a new one.


(

!Page 42)

2

V

VL1500K5 (’05-MODEL) 51

Step 3


2) Remove the IAP sensor. (

!Page 118)

3) Connect the vacuum pump gauge to the vacuum port of the

IAP sensor.

4) Arrange 3 new 1.5 V batteries in series

1 (check that total voltage is 4.5 – 5.0 V) and connect

- terminal to the ground terminal

2 and + terminal to the Vcc terminal 3.

5) Check the voltage between Vout

4 and ground. Also, check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge. (

!Page 52)

# 09917-47011: Vacuum pump gauge

09900-25008: Multi-circuit tester set


3

Is the voltage OK?

YES

NO

• Red, B/Br or G/B wire open or shorted to ground, or poor

6, D or L connection.


• G/W, Red or B/Br wire open or shorted to ground, or poor

3, 6 or D connection.





If check result is not satisfactory, replace the IAP sensor with a new one.


(

!Page 42)

3


52 VL1500K5 (’05-MODEL)

Output voltage (Vcc voltage 4.5 – 5.0 V, ambient temp. 20 –

30 °C, 68 – 86 °F)

ALTITUDE

(Reference)

(ft)

0



2 000

2 001



5 000

5 001



8 000

8 001



10 000

(m)

0



610

611



1 524

1 525



2 438

2 439



3 048

ATMOSPHERIC

PRESSURE

(mmHg)

760



707

707



634

634



567

567



526 kPa

100



94

94



85

85



76

76



70

OUTPUT

VOLTAGE

(V)

3.4 – 4.0

2.8 – 3.7

2.6 – 3.4

2.4 – 3.1

VL1500K5 (’05-MODEL) 53

“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION

C14

P0120

H

L


Output voltage is not within the following range.

Difference between actual throttle opening and opening calculated by ECM is larger than specified value.

0.1 V Sensor voltage < 4.8 V



POSSIBLE CAUSE

• TP sensor maladjusted.

• TP sensor circuit open or short.

• TP sensor malfunction.


• TP sensor circuit shorted to VCC or ground circuit open.

• TP sensor circuit open or shorted to ground or

VCC circuit open.

ECM

TP sensor

R VCC

BI/B

B/Br

TP

E2

INSPECTION

Step 1 (When indicating C14:)


(



3) Check the TP sensor coupler for loose or poor contacts.

If OK, then measure the TP sensor input voltage.

4) Disconnect the TP sensor coupler.



B and ground.


B and B/Br wire C.

" TP sensor input voltage: 4.5 – 5.5 V

(

+ Red – - Ground)

(

+ Red – - B/Br)



Is the voltage OK?

YES

NO

Go to Step 2.


(terminal

6 or D).


1

1

V

54 VL1500K5 (’05-MODEL)

Step 1 (When indicating P0120-H:)


(




If OK, then check the TP sensor lead wire continuity.

1


5) Check the continuity between BI/B wire

A and Red wire B.

If the sound is not heard from the tester, the circuit condition is

OK.

1

!

6) Remove the left frame upper cover (

!VL1500 Service

Manual 6-3) and disconnect the ECM coupler.


A and terminal K.

8) Also, check the continuity between B/Br wire

C and terminal D.

" TPS lead wire continuity: Continuity (,)



- Tester knob indication: Continuity test (,)

Is the continuity OK?

YES

NO

Go to Step 2.

BI/B wire shorted to VCC, or B/Br wire open.


(

!Page 42)

1


!

VL1500K5 (’05-MODEL) 55

Step 1 (When indicating P0120-L:)


(




If OK, then measure the TP sensor lead wire continuity.

1



A and ground.

6) Also, check the continuity between BI/B wire

A and B/Br wire

C. If the sound is not heard from the tester, the circuit condition is OK.

1

!

7) Remove the left frame upper cover. (

!VL1500 Service



A and terminal K.

9) Also, check the continuity between Red wire

B and terminal 6.

" TPS lead wire continuity: Continuity (,)





YES

NO

Go to Step 1 (

!Page 53) and Go to Step 2.

Red wire or BI/B wire open, or BI/B wire shorted to ground.

10)After repairing the trouble, clear the DTC using SDS tool.

(

!Page 42)

1


!

56 VL1500K5 (’05-MODEL)

Step 2



3) Install the test harness to the TP sensor.

4) Check the continuity between terminal

A and ground.

" TP sensor continuity: ∞ Ω (Infinity)

(Terminal

A – Ground)

2

5) If OK, then measure the TP sensor resistance at the test harness terminals (between terminal

A and terminal B).

6) Turn the throttle grip and measure the resistance.

" TP sensor resistance

Throttle valve is closed: Approx. 1.12 k

Ω

Throttle valve is opened: Approx. 4.41 k

Ω

2

2

TPS

7) If OK, then measure the TP sensor resistance at the test harness terminals (between terminal c and terminal D).

" TP sensor resistance: Approx. 4.66 kΩ

(Terminal

C – Terminal D)


09900-28630: TPS test wire harness


2

Are the continuity and resistance OK?

YES

NO

Go to Step 3.

• Reset the TP sensor position correctly.

• Replace the TP sensor with a new one.


(

!Page 42)

2

TPS

BI/B

R

B/Br

ECM

BI/B

R

B/Br

ECM

Step 3

1) Connect the TP sensor coupler

1 to the test harness.


3) Measure the TP sensor output voltage at the coupler

(between

+ BI/B and - B/Br) by turning the throttle grip.

3

VL1500K5 (’05-MODEL) 57

V

" TP sensor output voltage

Throttle valve is closed: Approx. 1.12 V

Throttle valve is opened: Approx. 4.41 V



3

TPS

BI/B

R

B/Br

ECM

Is the voltage OK?

YES

NO

• R, B/Br or BI/B wire open or shorted to ground, or poor

6, D or K connection.




If check result is not satisfactory, replace TP sensor with a new one.


(

!Page 42)

3


58 VL1500K5 (’05-MODEL)

“C15” (P0115-H/L) EOT SENSOR CIRCUIT MALFUNCTION

C15

P0115

H

L



0.1 Sensor voltage < 4.6 V



POSSIBLE CAUSE

• EOT sensor circuit open or short.

• EOT sensor malfunction.


• EOT sensor circuit open or ground circuit open.

• EOT sensor circuit shorted to ground.

EOT sensor

ECM

Sub harness

W

W

B/BI

B/G

B/BI

B/Br

EOT

E2

INSPECTION



2) Check the EOT sensor coupler for loose or poor contacts.

If OK, then measure the EOT sensor voltage at the wire side coupler.

3) Disconnect the EOT sensor coupler and turn the ignition switch ON.

4) Measure the voltage between B/Bl wire terminal

1 and ground.

5) Also, measure the voltage between B/Bl wire terminal

1 and

B/G wire terminal

2.

" EOT sensor input voltage: 4.5 – 5.5 V

(

+ B/Bl – - Ground)

(

+ B/Bl – - B/G)



Is the voltage OK?

YES

NO

Go to Step 2.


(terminal

D or I) or sub harness coupler.

• Open or short circuit in the B/Bl wire or B/Br wire or sub harness.

1

1

V

VL1500K5 (’05-MODEL) 59




If OK, then check the EOT sensor lead wire continuity.

1

7


(


4) Disconnect the EOT sensor coupler and ECM coupler.

5) Check the continuity between B/Bl wire

A and terminal I.

6) Also, check the continuity between B/G wire

B and terminal D.

" EOTS lead wire continuity: Continuity (,)





YES

NO

Go to Step 2.

• B/BI, B/Br wire or sub harness (B/BI or B/G wire) open.

• Loose or poor contacts on the sub harness coupler.


(

!Page 42)

1

1

EOT


Sub harness

B/BI

B/G

B/BI

B/Br

!

ECM

60 VL1500K5 (’05-MODEL)




If OK, then check the EOT sensor lead wire continuity.

1

3) Disconnect the EOT sensor coupler.

4) Check the continuity between B/Bl wire

1 and ground.


OK.


1

5) Connect the EOT sensor coupler and turn the ignition switch

ON.

6) Measure the voltage between B/Bl wire

1 and ground.

" EOT sensor output voltage: 0.1 – 4.6 V

(

+ B/BI – - Ground)




Are the continuity and voltage OK?

YES

NO

Go to Step 2.

• B/BI wire or sub harness (B/BI wire) shorted to ground.

• If wire and sub harness are OK, go to Step 2.


(

!Page 42)

1

V

!

VL1500K5 (’05-MODEL) 61

Step 2


2) Disconnect the EOT sensor coupler.

3) Measure the EOT sensor resistance.

" EOT sensor resistance:

Approx. 61.3 k

Ω at 20 °C (68 °F)

(White – White)



Refer to next page for details.

Is the resistance OK?

YES

NO

• B/Bl or B/Br wire open or shorted to ground, or poor

D or I connection.

• Open or short circuit in the sub harness, or sabharness connection.




Replace the ECT sensor with a new one.


(

!Page 42)

" EOT sensor specification

Engine Oil Temp

20 °C (68 °F)

50 °C (122 °F)

80 °C (176 °F)

110 °C (230 °F)

Resistance

Approx. 61.3 k

Ω

Approx. 17.8 k

Ω

Approx. 6.2 k

Ω

Approx. 2.5 k

Ω

2

2


62 VL1500K5 (’05-MODEL)

EOT SENSOR INSPECTION

• Remove the EOT sensor. (

!Page 119)

• Check the EOT sensor by testing it at the bench as shown in the figure. Connect the EOT sensor

1 to a circuit tester and place it in the oil

2 contained in a pan, which is placed on a stove.

• Heat the oil to raise its temperature slowly and read the column thermometer

3 and the ohmmeter.

• If the EOT sensor ohmic value does not change in the proportion indicated, replace it with a new one.

" EOT sensor specification

Engine Oil Temp

20 °C (68 °F)

50 °C (122 °F)

80 °C (176 °F)

110 °C (230 °F)

Resistance

Approx. 61.3 k

Ω

Approx. 17.8 k

Ω

Approx. 6.2 k

Ω

Approx. 2.5 k

Ω



If the resistance is noted to show infinity or too much different resistance value, replace the EOT sensor with a new one.

'

* Take special care when handling the EOT sensor. It may cause damage if it gets a sharp impact.

* Do not contact the EOT sensor and the column thermometer with a pan.

VL1500K5 (’05-MODEL) 63

“C18” (P1751) DECOMP. RELAY CIRCUIT MALFUNCTION


Decomp. relay signal is not input to ECM.

POSSIBLE CAUSE

• Decomp. system circuit open or short.


ECM

DRL G/R

Decomp. relay

W

O/W

R

Engine stop switch

Side-stand relay

To GP switch

Ignition switch

Decomp. solenoid

INSPECTION

Step 1


(



3) Check the Decomp. relay coupler for loose or poor contacts.

If OK, then check the Decomp. relay.

(Refer to VL1500 Service Manual 7-20 for details.)

1

Is the Decomp. relay OK?

YES

• O/W or G/R wire open or shorted to ground, or poor i connection.




Replace the Decomp. relay with a new one.

NO


(

!Page 42)

1


64 VL1500K5 (’05-MODEL)

ACTIVE CONTROL INSPECTION

1) Set up the SDS tool. (Refer to the SDS operation manual for further details)


3) Click “Decomp. solenoid operating control”

1.

4) With the engine starter button pushed, click “On” button

2.

At this time, if an operation sound is heard from the decomp.

solenoid valve, the function is normal.

NOTE:

Decomp. solenoid valve can be operated about one second after button is turned “On”.

VL1500K5 (’05-MODEL) 65

“C19” (P0615) STARTER RELAY CIRCUIT MALFUNCTION


Starter relay signal is not input to ECM.

POSSIBLE CAUSE

• Starter system circuit open or short.


ECM

STRL

Y/G

STARTER

RELAY

O/W

Engine stop switch

Side-stand relay

To GP switch

STARTER

MOTOR

Ignition switch

INSPECTION

Step 1


(



3) Check the Starter relay coupler for loose or poor contacts.

If OK, then inspection the Starter relay.

(Refer to VL1500 Service Manual 7-17 for details.)

1

Is the Starter relay OK?

YES

• O/W and Y/G wire open or shorted to ground, or poor j connection.




Replace the Starter relay with a new one.

NO


(

!Page 42)

1


66 VL1500K5 (’05-MODEL)

“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION

C21

P0110

H

L






POSSIBLE CAUSE

• IAT sensor circuit open or short.

• IAT sensor malfunction.


• IAT sensor circuit open or ground circuit open.

• IAT sensor circuit shorted to ground.

ECM

IAT sensor

Dg

B/Br

IAT

E2

INSPECTION

Step 1(When indicating C21:)


(



3) Check the IAT sensor coupler for loose or poor contacts.

If OK, then measure the IAT sensor voltage at the wire side coupler.

4) Disconnect the IAT sensor coupler and turn the ignition switch

ON.

5) Measure the voltage between Dg wire terminal

1 and ground.

6) Also, measure the voltage between Dg wire terminal

1 and

B/Br wire terminal

2.

" IAT sensor input voltage: 4.5 – 5.5 V

(

+ Dg – - Ground)

(

+ Dg – - B/Br)



Is the voltage OK?

YES

NO

Go to Step 2.


(terminal

2 or D).

• Open or short circuit in the Dg wire or B/Br wire.

1

1

V

VL1500K5 (’05-MODEL) 67



(




If OK, then check the IAT sensor lead wire continuity.

1


(


5) Disconnect the IAT sensor coupler and ECM coupler.

6) Check the continuity between Dg wire

A and terminal 2.


B and terminal D.

" IATS lead wire continuity: Continuity (,)





YES

NO

Go to Step 2.

Dg wire or B/Br wire open.


(

!Page 42)

1


!

68 VL1500K5 (’05-MODEL)



(




If OK, then check the IAT sensor lead wire continuity.

1

4) Disconnect the IAT sensor coupler.

5) Check the continuity between Dg wire

1 and ground. If the sound is not heard from the tester, the circuit condition is OK.


1

6) Connect the IAT sensor coupler and turn the ignition switch

ON.

7) Measure the voltage between Dg wire

1 and ground.

" IAT sensor output voltage: 0.1 – 4.6 V

(

+ Dg – - Ground)




Are the continuity and voltage OK?

YES

NO

Go to Step 2.

• Dg wire shorted to ground.

• If wire is OK, go to Step 2.


(

!Page 42)

1

!

V

VL1500K5 (’05-MODEL) 69

Step 2


2) Measure the IAT sensor resistance.

" IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F)

(Terminal – Terminal)



1


YES

NO

• Dg or B/Br wire open or shorted to ground, or poor

2 or D connection.




Replace the IAT sensor with a new one.

" IAT sensor specification

Intake Air Temp

20 °C (68 °F)

40 °C (104 °F)

60 °C (140 °F)

80 °C (176 °F)

Resistance

Approx. 2.45 k

Ω

Approx. 1.148 k

Ω

Approx. 0.587 k

Ω

Approx. 0.322 k

Ω

NOTE:

IAT sensor resistance measurement method is the same way as that of the EOT sensor. Refer to page 62 for details.

1


70 VL1500K5 (’05-MODEL)

“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION

C23

P1651

H

L


The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.




POSSIBLE CAUSE

• TO sensor circuit open or short.

• TO sensor malfunction.


• TO sensor circuit open or shorted to VCC or ground circuit open.

• TO sensor circuit shorted to ground or VCC circuit open.

TO SENSOR

R

Br/W

B/Br

ECM

VCC

TOS

E2

INSPECTION



!Page 121)


3) Check the TO sensor coupler for loose or poor contacts.

If OK, then measure the TO sensor resistance.

4) Disconnect the TO sensor coupler.

1

5) Measure the resistance between terminal

A and terminal C.

" TO sensor resistance: 19.1 – 19.7 kΩ

(Terminal

A – Terminal C)




YES

NO

Go to Step 2.

Replace the TO sensor with a new one.

1

VL1500K5 (’05-MODEL) 71 step 1 (When indicating P1651-H:)


!Page 121)



If OK, then check the TO sensor lead wire continuity.

1


5) Check the continuity between Red wire

A and Br/W wire B.


OK.

1

!


!VL1500 Service


7) Check the continuity between Br/W wire

B and terminal J.


C and terminal D.

" TOS lead wire continuity: Continuity (,)





YES

NO

Go to Step 2.

Br/W wire shorted to VCC, or B/Br wire open.


(

!Page 42)

1


!

72 VL1500K5 (’05-MODEL)



!Page 121)



If OK, then check the TO sensor lead wire continuity.

1


5) Check the continuity between Br/W wire

B and ground.

6) Also, check the continuity between Br/W wire

B and B/Br wire


1

!


!VL1500 Service


8) Check the continuity between Red wire

A and terminal 6.

9) Also, then check the continuity between Br/W wire

B and terminal

J.

" TOS lead wire continuity: Continuity (,)





YES

NO

Go to Step 2.

Red or Br/W wire open, or Br/W wire shorted to ground.


(

!Page 42)

1


!

VL1500K5 (’05-MODEL) 73

Step 2

1) Connect the TO sensor coupler.

2) Insert the needle pointed probes to the lead wire coupler.


4) Measure the voltage at the wire side coupler between Black and B/Br wires.

" TO sensor voltage (Normal): 0.4 – 1.4 V

(

+ Br/W – - B/Br)

1

Also, measure the voltage when leaning the motorcycle.

5) Dismount the TO sensor from its bracket and measure the voltage when it is leaned 65° and more, left and right, from the horizontal level.

" TO sensor voltage (Leaning): 3.7 – 4.4 V

(

+ Br/W – - B/Br)




Is the voltage OK?

YES

NO

• Red, Br/W or B/Br wire open or shorted to ground, or poor

6, D or J connection.




• Loose or poor contacts on the ECM coupler.

• Open or short circuit.

• Replace the TO sensor with a new one.


(

!Page 42)

1

1

V

65 ˚


V

“C24” (P0351) or “C25” (P0352) IGNITION SYSTEM MALFUNCTION

(When indicating C24/P0351 for IG coil #1)

(When indicating C25/P0352 for IG coil #2)

* Refer to the IGNITION SYSTEM for details. (

!Page 133)

74 VL1500K5 (’05-MODEL)

“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION


The operation voltage does not reach the STVA.

ECM does not receive communication signal from the STVA.

POSSIBLE CAUSE

• STVA malfunction.

• STVA circuit open or short.

• STVA motor malfunction.

STVA

B

P

G

W/B

B/Lg

P/W

G

W/B

ECM

STVA. 1B

STVA. 1A

STVA. 2B

STVA. 2A

INSPECTION

Step 1

1) Remove the air cleaner box. (

!Page 103)


3) Check the STVA lead wire coupler for loose or poor contacts.

1

4) Turn the ignition switch ON to check the STV operation.

(STV operating order: 95% open

→ Full open → 95% open)

1

Is the operating OK?

YES

NO

Go to Step 2.

• Loose or poor contacts on the STVA coupler.

• Open or short circuit in the B/Lg, P/W, W/B or

Green wires.

• If wire and connection are OK, go to Step 2.


(

!Page 42)

VL1500K5 (’05-MODEL) 75

Step 2


2) Disconnect the STVA lead wire coupler.

3) Check the continuity between each terminal and ground.

" STVA continuity: ∞ Ω (Infinity)

(Terminal – Ground)

2

4) If OK, then measure the STVA resistance (between Black wire

A and Pink wire B) and (between Green wire C and W/

B wire

D).

" STVA resistance: Approx. 6.5 Ω

(Black

A – Pink B)

(Green

C – W/B D)




YES

NO

• B/Lg, P/W, Green and W/B wire open or shorted to ground, or poor

Y, [, d and f connection.




• Loose or poor contacts on the ECM coupler.

• Replace the STVA with a new one.


(

!Page 42)

2

2


76 VL1500K5 (’05-MODEL)




3) Click “Secondary throttle operating control”

1.

4) Click each button

2.

At this time, if an operation sound is heard from the STVA, the function is normal.

VL1500K5 (’05-MODEL) 77

“C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION

C29

P1654

H

L


Signal voltage is not within the following range.

Difference between actual throttle opening and opening calculated by ECM is larger than specified value.

0.1 V Sensor voltage < 4.8 V



POSSIBLE CAUSE

• STP sensor maladjusted.

• STP sensor circuit open or short.

• STP sensor malfunction.


• STP sensor circuit shorted to VCC or ground circuit open.

• STP sensor circuit open or shorted to ground or

VCC circuit open.

ECM

VCC

STP

E2

BI

Y

B

R

Y/W

B/Br

STP sensor

INSPECTION



!Page 103)


3) Check the STP sensor coupler for loose or poor contacts.

If OK, then measure the STP sensor input voltage.

4) Disconnect the STP sensor coupler.



A and ground.


A and B/Br wire C.

" STP sensor input voltage: 4.5 – 5.5 V

(

+ Red – - Ground)

(

+ Red – - B/Br)



Is the voltage OK?

YES

NO

Go to Step 2.


(terminal

6 or D).

)


1

1

V

78 VL1500K5 (’05-MODEL)



!Page 103)



If OK, then check the STP sensor lead wire continuity.

1


5) Check the continuity between Y/W wire

B and Red wire A.


OK.

1

!


!VL1500 Service



B and terminal 4.


C and terminal D.

" STPS lead wire continuity: Continuity (,)





YES

NO

Go to Step 2.

Y/W wire shorted to VCC, or B/Br wire open.


(

!Page 42)

1


!

VL1500K5 (’05-MODEL) 79



!Page 103)



If OK, then check the STP sensor lead wire continuity.

1



B and ground.

6) Also, check the continuity between Y/W wire

B and B/Br wire


1

!


!VL1500 Service



B and terminal 4.

9) Also, check the continuity between Red wire

A and terminal 6.

" STPS lead wire continuity: Continuity (,)





YES

NO

Go to Step 1 (

!Page 77) and Go to Step 2.

Red or Y/W wire open, or Y/W wire shorted to ground.


(

!Page 42)

1


!

80 VL1500K5 (’05-MODEL)

Step 2



!Page 103)


4) Check the continuity between each terminal and ground.

" STP sensor continuity: ∞ Ω (Infinity)


2

5) If OK, then measure the STP sensor resistance at the wire terminals (between Yellow wire

A and Black wire B).

6) Close and open the secondary throttle valve by finger, and measure the valve closing and opening resistance.

2

" STP sensor resistance

Secondary throttle valve is closed : Approx. 0.5 k

Ω

Secondary throttle valve is opened: Approx. 3.9 k

Ω

(Yellow

A – Black B)

2

7) If OK, then measure the STP sensor resistance at the wire terminals (between Blue wire c and Black wire B).

" STP sensor resistance: Approx. 4.69 kΩ



Are the continuity and resistance OK?

YES

NO

Go to Step 3.

• Reset the STP sensor position correctly.

• Replace the STP sensor with a new one.


(

!Page 42)

2

2

VL1500K5 (’05-MODEL) 81

Step 3


2) Connect the STP sensor coupler.

3) Insert the needle pointed probes to the STP sensor coupler.

4) Disconnect the STVA lead wire coupler.


6) Measure the STP sensor output voltage at the coupler

(between

+ Y/W wire and - B/Br wire) by turning the secondary throttle valve (close and open) with a finger.

" STP sensor output voltage

Secondary throttle valve is closed: Approx. 0.5 V

Secondary throttle valve is opened: Approx. 3.9 V



) Tester knob indication: Voltage (+)

3

3

3

Is the voltage OK?

YES

NO

• Red, Y/W or B/Br wire open or shorted to ground, or poor

4, 6 or D connection.




If check result is not satisfactory, replace STP sensor with a new one.


(

!Page 42)

3


82 VL1500K5 (’05-MODEL)

“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION


No Gear Position switch voltage.

Switch voltage is not within the following range.

Switch voltage > 0.6 V

POSSIBLE CAUSE

• Gear Position switch circuit open or short.

• Gear Position switch malfunction.


ECM

GP

R/B

B/G

BI

R

B

4

To engine stop switch

Side-stand relay

5

GP switch

N

1

Neutral indicator light

3

2

Side-stand switch

Ignition switch

INSPECTION

Step 1

1) Remove the secondary gear case cover.

(



3) Check the GP switch coupler for loose or poor contacts.

If OK, then measure the GP switch voltage.

1

4) Support the motorcycle with a jack.

5) Fold the side-stand to up position.

6) Make sure the engine stop switch is in the “RUN” position.

7) Insert the needle pointed probe to the lead wire coupler.


9) Measure the voltage at the wire side coupler between R/B wire and B/G wire, when shifting the gearshift lever from 1st to

Top.

" GP switch voltage: 0.6 V and more

(

+ R/B – - B/G)



) Tester knob indication: Voltage (+)

1

V

VL1500K5 (’05-MODEL) 83

Is the voltage OK?

YES

NO

• Red or R/B wire open or shorted to ground.




• R/B or B/G wire open, or R/B or Red wire shorted to ground.


(terminal

1).

• If wire and connection are OK, replace the GP switch with a new one.


(

!Page 42)

1


84 VL1500K5 (’05-MODEL)

“C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION


CKP signals produced but fuel injector signal is interrupted continuous by 4 times or more.

POSSIBLE CAUSE

• Injector circuit open or short.

• Injector malfunction.


ECM

Y/R

Fuel pump relay

To engine stop switch

#1

#2

Gr/W

Gr/B

(Front cylinder) (Rear cylinder)

Fuel injector

INSPECTION

(When indicating C32/P0201 for fuel injector #1)

(When indicating C33/P0202 for fuel injector #2)

Step 1


!Page 103)


3) Check the injector coupler (Front cylinder side

1 or Rear cylinder side

2) for loose or poor contacts.

If OK, then measure the injector resistance.

4) Disconnect the injector coupler and measure the resistance between terminals.

" Injector resistance: Approx. 11.7 Ω at 20 °C (68 °F)

(Terminal – Terminal)

1

1

VL1500K5 (’05-MODEL) 85


" STP sensor continuity: ∞ Ω (Infinity)



Are the resistance and continuity OK?

YES

NO

Go to Step 2.

Replace the injector with a new one.

(

!Page 111)


(

!Page 42)

1

Step 2


2) Measure the injector voltage between Y/R wire and ground.

" Injector voltage: Battery voltage

(

+ Y/R – - Ground)

NOTE:

Injector voltage can be detected only 3 seconds after ignition switch is turned ON.



Is the voltage OK?

YES

• Gr/B wire open or shorted to ground, or poor a connection.


• Gr/W wire open or shorted to ground, or poor

^ connection.





Open circuit in the Y/R wire.

NO


(

!Page 42)

2

2


V

86 VL1500K5 (’05-MODEL)

“C41” (P0230) FP RELAY CIRCUIT MALFUNCTION


No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump, although fuel pump relay is turned OFF.

POSSIBLE CAUSE

• Fuel pump relay circuit open or short.

• Fuel pump relay malfunction.


ECM

VM

FP Relay

Y/R

Y

M

Fuel pump

Fuel pump relay

R/W

O/W

Engine stop switch

To GP switch

Side-stand relay

Ignition switch

INSPECTION

Step 1


(



3) Check the FP relay coupler for loose or poor contacts.

If OK, then check the FP relay.

(Refer to page 96 for details.)

1

Is the FP relay OK?

YES

NO

• Yellow or O/W wire open or shorted to ground, or poor e connection.

• Y/R or R/W wire open or poor

0 connection.




Replace the FP relay with a new one.

1

4)After repairing the trouble, clear the DTC using SDS tool. (

!Page 42)


“C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION


Ignition switch signal is not input in the ECM.

POSSIBLE CAUSE

• Ignition system circuit open or short.


INSPECTION

*Refer to the IGNITION SWITCH INSPECTION for details. (

!Page 142)

VL1500K5 (’05-MODEL) 87

“C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION

(FOR E-02, 19, 24)

C44

(P0130)

C44

(P0135)


HO2 sensor output voltage is not input to ECM during engine operation and running condition.

(Sensor voltage 0.7 V)

POSSIBLE CAUSE

• HO2 sensor circuit open or shorted to ground.

• Fuel system malfunction.


The heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit.

• Battery voltage supply to the HO2 sensor.

ECM

E2

HO2S

HO2. H

B/Br

W/G

W/B

Engine stop switch

Side-stand relay

O/W

To GP switch

Ignition switch

HO2 sensor

INSPECTION

Step 1 (When indicating C44/P0130:)


!Page 121)


3) Check the HO2 sensor for loose or poor contacts.

If OK, then check the HO2 sensor lead wire continuity.

1

4) Disconnect the HO2 sensor coupler

5) Check the continuity between W/G wire

A and ground.

6) Also, check the continuity between W/G wire

A and B/Br wire

B. If the sound is not heard from the tester, the circuit condition is OK.



1

!

88 VL1500K5 (’05-MODEL)

7) Remove the left frame upper cover. (

!VL1500 Service


8) Check the continuity between W/G wire

A and terminal 7.


B and terminal D.

" HO2S lead wire continuity: Continuity (,)





YES

NO

Go to Step 2. (When indicating C44/P0130:)

W/G wire shorted to ground, or W/G or B/Br wire open.


(

!Page 42)


1) Connect the ECM coupler and HO2 sensor coupler.

2) Warm up the engine enough.

3) Measure the HO2 sensor output voltage between W/G wire and B/Br wire, when idling condition.

" HO2 sensor output voltage at idle speed:

0.4 V and less (

+ W/G – - B/Br)

1

2


!

V

4) If OK, then pinch the PAIR hose

1 with a proper hose clamp.

5) Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r/min.

" HO2 sensor output voltage at 5 000 r/min:

0.6 V and more (

+ W/G – - B/Br)




2

VL1500K5 (’05-MODEL) 89

Is the voltage OK?

YES

• W/G wire or B/Br wire open or shorted to ground, or poor

7 or D connection.




Replace the HO2 sensor with a new one.

NO


(

!Page 42)



!Page 121)


3) Check the HO2 sensor for loose or poor contacts.

If OK, then measure the HO2 sensor resistance.

2

1


4) Disconnect the HO2 sensor coupler and measure the resistance between terminals.

" HO2 heater resistance: 6.5 - 8.9 Ω at 23 °C (73.4 °F)


NOTE:

* Temperature of the sensor affects resistance value largely.

* Make sure that the sensor heater is at correct temperature.



Is the voltage OK?

YES

NO

Go to Step 2.

Replace the HO2 sensor with a new one.


(

!Page 42)

1

90 VL1500K5 (’05-MODEL)


1) Connect the HO2 sensor coupler.

2) Insert the needle pointed probes to the HO2 sensor coupler.

3) Turn the ignition switch ON and measure the heater voltage between W/B wire and ground.

4) If the tester voltage indicates the battery voltage, it is good condition.

" Heater voltage: Battery voltage

(

+ W/B – - Ground)

NOTE:

Battery voltage can be detected only before starting the engine.




Is the voltage OK?

YES

NO

• O/W or W/B wire open or shorted to ground, or poor

Z connection.




• Open or short circuit in the W/B wire or O/W wire.


(terminal

Z) or HO2 sensor coupler.


(

!Page 42)

2

2


V

VL1500K5 (’05-MODEL) 91

“C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION


PAIR control solenoid valve voltage is not input to

ECM.

POSSIBLE CAUSE

• PAIR valve circuit open or short.

• PAIR valve malfunction.


ECM

SOL

Br/B

Engine stop switch

Side-stand relay

O/W

To GP switch

Ignition switch

PAIR control solenoid valve

INSPECTION

Step 1


2) Check the PAIR control solenoid valve coupler for loose or poor contacts.

If OK, then measure the PAIR control solenoid valve resistance.

1

3) Disconnect the PAIR control solenoid valve coupler.

4) Measure the resistance between Black and Black wire terminals.

" PAIR valve resistance:

20 – 24

Ω at 20 – 30 °C (68 – 86 °F)

(Black – Black)




" PAIR valve resistance: ∞ Ω (Infinity)




YES

NO

Go to Step 2.

Replace the PAIR valve with a new one.

1

1

92 VL1500K5 (’05-MODEL)


(

!Page 42)

Step 2


2) Measure the voltage between O/W wire and ground.

" PAIR valve voltage: Battery voltage

(

+ O/W – - Ground)



2

Is the voltage OK?

YES

• Br/B wire open or shorted to ground, or poor g connection.




Open or short circuit in the O/W wire.

NO


(

!Page 42)

2




3) Click “PAIR Sol operating control”

1.


V

4) Click each button

2.

At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.

FUEL SYSTEM

FUEL TANK REMOVAL


1. (

!Page 121)


2.

(


• Remove the frame head covers

3 and frame upper covers 4.

(


• Remove the frame covers

5.

(


• Remove the PAIR cover, PAIR control valve and PAIR bracket. (

!Page 14)

• Remove the exhaust pipes and mufflers

6.

(


• Remove the heat shield bolt and fuel tank mounting bolts.

(


• Remove the right frame handle grip

7 and seat frame 8.

(


• Remove the fuel feed hose

A, fuel tank breather hose B and fuel drain hose

C.

• Disconnect the TO sensor coupler

D and fuel pump coupler

E.

• Remove the fuel tank

9.

$

Gasoline is highly flammable and explosive.

Keep heat, spark and flame away.

VL1500K5 (’05-MODEL) 93

94 VL1500K5 (’05-MODEL)

FUEL PRESSURE INSPECTION


!Page 121)

• Remove the speedometer and fuel inlet cover.

(


• Remove the left frame head cover and left frame upper cover.

(


• Place a rag under the fuel feed hose.


1.

• Install the special tools between the fuel tank and fuel delivery pipe.

# 09940-40211: Fuel pressure gauge adaptor

09940-40220: Fuel pressure gauge hose attachment

09915-74511: Oil pressure gauge set

Turn the ignition switch ON and check the fuel pressure.

" Fuel pressure: Approx. 300 kPa (3.0 kgf/cm

2

, 43 psi)

If the fuel pressure is lower than the specification, inspect the following items:

* Clogged fuel filter

* Pressure regulator

* Fuel pump

If the fuel pressure is higher than the specification, inspect the following items:

* Fuel pump check valve

* Pressure regulator

$

* Before removing the special tools, turn the ignition switch to OFF position and release the fuel pressure slowly.

* Gasoline is highly flammable and explosive. Keep heat, sparks and flame away.

A To fuel tank.

B To fuel delivery pipe.

VL1500K5 (’05-MODEL) 95

FUEL PUMP INSPECTION

Turn the ignition switch ON and check that the fuel pump operates for few seconds.

If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor.

If the fuel pump relay, tip-over sensor and fuel pump circuit connections are OK, the fuel pump may be faulty, replace the fuel pump with a new one.

FUEL DISCHARGE AMOUNT INSPECTION

$




!Page 121)


(


• Remove the left frame head cover and left frame upper cover.

(


• Disconnect the fuel feed hose

1 from the fuel delivery pipe.

• Place the measuring cylinder and insert the fuel feed hose end into the measuring cylinder.

• Disconnect the fuel pump lead wire coupler

2.

96 VL1500K5 (’05-MODEL)

• Connect a proper lead wire into the fuel pump lead wire coupler (fuel pump side) and apply 12 volts to the fuel pump

(between Y/R wire and B/W wire) for 10 seconds and measure the amount of fuel discharged.

Battery

+ terminal

(Yellow with red tracer)

Battery

- terminal

(Black with white tracer)

If the pump does not discharge the amount specified, it means that the fuel pump is defective or that the fuel filter is clogged.

" Fuel discharge amount: 168 ml and more/10 sec.

(5.7/5.9 US/Imp oz)/10 sec.

NOTE:

The battery must be in fully charged condition.

FUEL PUMP RELAY INSPECTION

Fuel pump relay is located at the right side of the ECM.

• Remove the left frame head cover.

(


• Remove the fuel pump relay.

First, check the insulation between

A and B terminals with pocket tester. Then apply 12 volts to

C and D terminals, + to

C and - to D, and check the continuity between A and B.

If there is no continuity, replace it with a new one.

FUEL PUMP ASSEMBLY REMOVAL


1. (

!Page 121)


2.

(


• Remove the left frame head cover

3 and left frame upper cover

4. (

!VL1500%Service Manual 6-3)


5.

$



• Remove the fuel pump coupler

6.

• Remove the mounting bolts diagonally.

• Lift up the rear part

A and turn the fuel pump mounting plate counterclockwise to approx. 90°.

• Pull out the fuel pump mounting plate until the pressure regulator

7 comes out from the fuel tank.

• Turn the fuel pump mounting plate counterclockwise to approx. 35°.

VL1500K5 (’05-MODEL) 97

98 VL1500K5 (’05-MODEL)

• Pull the fuel pump mounting plate until the fuel filter


• Set the fuel pump mounting plate to the horizontal line.

• Turn the fuel pump mounting plate counterclockwise to approx. 90°.

• Pull the fuel pump mounting plate until the fuel pump band


• Remove the fuel pump assembly.

'

Be careful not to bend the fuel level gauge.

FUEL PUMP DISASSEMBLY

CONSTRUCTION

VL1500K5 (’05-MODEL) 99

1 Band

2 Fuel pump

3 Rubber cushion

4 Fuel pump holder

5 O-ring

A Fuel pump mounting bolt

&

ITEM N·m kgf-m lb-ft

A

10 1.0

7.0

100 VL1500K5 (’05-MODEL)

DISASSEMBLY

• Remove the fuel pump holder

1.

• Disconnect the fuel pump coupler

2.

• Remove the band

3, rubber cushion 4 and fuel pump 5.

FUEL MESH FILTER INSPECTION AND

CLEANING

If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

• Blow the fuel mesh filter with compressed air.

NOTE:

If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one.

REASSEMBLY

• Reassembly the fuel pump in the reverse order of disassembly, and pay attention to the following points:

• Apply thin coat of engine oil to the new bushing and install it to the fuel joint pipe.

'

Use the new bushing to prevent fuel leakage.

INSTALLATION

• Install the fuel pump in the reverse order of removal, and pay attention to the following points:

• Install the new O-ring and apply grease to it.

$

The O-ring must be replaced with a new one to prevent fuel leakage.



• Install the fuel pump assembly.

'

Be careful not to bend the fuel level gauge.

• When installing the fuel pump assembly, first tighten all the fuel pump assembly mounting bolts lightly and then to the specified torque, in the ascending order of numbers.

.

& Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.3 lb-ft)

NOTE:

Apply a small quantity of the THREAD LOCK to the thread portion of the fuel pump mounting bolt.

. 99000-32050: THREAD LOCK “1342”

VL1500K5 (’05-MODEL) 101

102 VL1500K5 (’05-MODEL)

THROTTLE BODY

CONSTRUCTION

1 STP sensor

2 TP sensor

3 Fuel delivery pipe

4 Fuel delivery pipe joint hose

5 Fuel injector

6 O-ring

7 Cushion seal

8 Throttle stop screw

9 Fast idle screw

0 IAP sensor

A STP sensor mounting screw

B TP sensor mounting screw

C

Fuel delivery pipe joint hose mounting screw

D

Fuel delivery pipe mounting screw

&


A

3.5

0.35

2.5

B

3.5

0.35

2.5

C

3.5

0.35

2.5

D

3.5

0.35

2.5

AIR CLEANER BOX REMOVAL


1. (

!Page 121)


2, frame head covers

3, and frame upper covers 4.

(


• Loosen the throttle body clamp screws.

• Disconnect the IAT sensor coupler

5.

• Disconnect the PCV hose

6 and PAIR hose 7.

VL1500K5 (’05-MODEL) 103

104 VL1500K5 (’05-MODEL)

THROTTLE BODY REMOVAL


!Page 103)

• Disconnect the throttle cables from their drum.

'

After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body.

• Disconnect the STP sensor coupler

1 and STVA coupler 2.

• Place a rag under the fuel feed hose and disconnect the fuel feed hose

3 from the delivery pipe.

• Disconnect the fuel injector couplers.

• Loosen the throttle body clamp screws at the intake pipe side.

• Disconnect the TP sensor coupler

4 and IAP sensor vacuum hoses

5.

• Remove the throttle body assembly.

THROTTLE BODY DISASSEMBLY

• Remove the fuel delivery pipe joint hose

1.

• Remove the fuel delivery pipes

2

• Remove the fuel injectors.

VL1500K5 (’05-MODEL) 105

106 VL1500K5 (’05-MODEL)

• Remove the TP sensor

3 and STP sensor 4 with the special tool.

# 09930-11950: Torx wrench

NOTE:

Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation.

'

Never remove the STVA

5 from the throttle body.

'

Never remove the secondary throttle valve

6 and

throttle valve

7.

'

Avoid removing the throttle valve adjuster

8 unless

absolutely necessary.

'

The fast idle screw

9 is factory-adjusted at the time of

delivery and therefore avoid removing or turning it unless otherwise necessary.

THROTTLE BODY CLEANING

$

Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage.

• Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.

'

Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the throttle body components. Do not apply carburetor cleaning chemicals to the rubber and plastic materials.

INSPECTION

Check following items for any damage or clogging.

* O-ring

* Throttle valve

* Secondary throttle valve

* Vacuum hose

* Delivery pipe joint hose

* Injector cushion seal

VL1500K5 (’05-MODEL) 107

108 VL1500K5 (’05-MODEL)

THROTTLE BODY REASSEMBLY

Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:

• With the STV fully open, install the STP sensor

1 and tighten the STP sensor mounting screw to the specified torque.

NOTE:

* Apply thin coat of the engine oil to the new O-ring.

* Align the secondary throttle shaft end

A with the groove B of

STP sensor.

* Apply SUZUKI SUPER GREASE “A” to the secondary throttle shaft end

A if necessary.



# 09930-11950: Torx wrench

& STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)

NOTE:

* Make sure the STP valve open or close smoothly.

* If the STP sensor adjustment is necessary, refer to page 110 for STP sensor setting procedure.

• With the throttle valve fully closed, install the TP sensor

2 and tighten the TP sensor mounting screw to the specified torque.

NOTE:

* Apply thin coat of the engine oil to the new O-ring.

* Align the throttle shaft end

C with the groove D of TP sensor.

* Apply SUZUKI SUPER GREASE “A” to the throttle shaft end

C if necessary.



# 09930-11950: Torx wrench

& TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)

NOTE:

* Make sure the throttle valve open or close smoothly.

* TP sensor setting procedure. (

!Page 36)

• Apply thin coat of the engine oil to the new fuel injector cushion seal

3, and install it to the fuel injector.

'

Replace the cushion seal and O-ring with the new ones.

• Install the O-ring

4 to the fuel injector.

• Apply thin coat of the engine oil to the new O-ring

4.

• Install the fuel injector

5 by pushing it straight to the delivery pipe

6.

NOTE:

Align the boss

E of the injector with the groove F of the delivery

pipe.

'

Never turn the injector while pushing it.

• Install the fuel delivery pipes

7 along with the fuel injectors.

'

Never turn the fuel injectors while installing them.

• Tighten the fuel delivery pipe mounting screws to the specified torque.

& Fuel delivery pipe mounting screw:

3.5 N·m (0.35 kgf-m, 2.5 lb-ft)

• Apply thin coat of the engine oil to the new O-rings.

'

Replace the O-rings with the new ones.

• Install the fuel delivery pipe joint hose

8 to the delivery pipes.

• Tighten the fuel delivery pipe hose mounting screws to the specified torque.

& Fuel delivery pipe joint hose mounting screw:

3.5 N·m (0.35 kgf-m, 2.5 lb-ft)

VL1500K5 (’05-MODEL) 109

110 VL1500K5 (’05-MODEL)

THROTTLE BODY INSTALLATION

Installation is in the reverse order of removal. Pay attention to the following points:

• Connect the throttle pulling cable

1 and throttle returning cable

2 to the throttle cable drum.

• Loosen each throttle cable lock-nut.

• Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance is 0 – 2 mm (0 – 0.08 in).

• Tighten each lock-nut.

• Adjust the throttle cable play.

Refer to page 9 for details.

AIR CLEANER BOX INSTALLATION

Installation is in the reverse order of removal. Pay attention to the following points:

• Install the air cleaner box and tighten the throttle body clamp screws as shown in the illustration.

LEFT

SIDE

0 – 2 mm

(0 – 0.08 in)

Foward

0 – 2 mm

(0 – 0.08 in)

RIGHT

SIDE

VIEW OF TOP

STP SENSOR ADJUSTMENT

If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor position as follows:


!Page 103)

• Disconnect the STVA coupler and STP sensor coupler.

(

!Page 74 and 77)

• Close the secondary throttle valve by finger, and measure the

STP sensor resistance.

" STP sensor setting resistance

ST valve is fully closed: Approx. 0.5 k

Ω

(

+ Yellow – - Black)



Yellow

Black

• If the STP sensor resistance is out of specification, loosen the

STP sensor mounting screw and adjust the STP sensor resistance to specification.

• Tighten the STP sensor mounting screw.

# 09930-11950: Torx wrench

& STP sensor mounting screw: 3.5 N·m

(0.35 kgf-m, 2.5 lb-ft)

FUEL INJECTOR REMOVAL


!Page 103)

• With battery negative cable disconnected, disconnect the injector couplers.

• Remove the fuel delivery pipe hose and pipes.

(

!Page 105)

• Remove the fuel injectors #1 and #2. (

!Page 105)

FUEL INJECTOR INSPECTION

Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank.

NOTE:

The fuel injector can be checked without removing it from the throttle body.

Refer to page 84 for details.

FUEL INJECTOR INSTALLATION

• Apply thin coat of the engine oil to new injector cushion seal and O-rings. (

!Page 109)

• Install the injector by pushing it straight to the throttle body.

Never turn the injector while pushing it. (

!Page 109)

VL1500K5 (’05-MODEL) 111

112 VL1500K5 (’05-MODEL)

FAST IDLE

The fast idle system is automatic type.

When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed.

When the engine has warmed up, depending on the oil temperature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.

Ambient Temp.

–5 °C (23 °F)

15 °C (59 °F)

25 °C (77 °F)

Fast idle rpm

Fast idle cancelling time

1 400 – 2 000 rpm Approx. 100 sec.

1 400 – 2 000 rpm Approx. 40 sec.

1 400 – 2 000 rpm Approx. 30 sec.

FAST IDLE ADJUSTMENT


!Page 121)

• Remove the speedometer and fuel inlet cover, frame head covers and frame upper covers.

(


• Start up the engine and run it in idling condition for warming up.

• Connect a tachometer and set the idle rpm to 1 000 rpm by the throttle stop screw

1.

• Check and adjust the TP sensor. (

!Page 36)

• Turn the ignition switch OFF.

• Disconnect the TP sensor coupler

2 and install the test harness.

• Start up the engine.

• Measure the TP sensor output voltage at the wire terminals

(between

+ Red and - Black).

" TP sensor output voltage at idle position: Approx. 1.12 V

# 09900-28630: TPS test wire harness

09900-25008: Multi-circuit tester set


• Turn the ignition switch OFF.


!Page 103)

• Disconnect the STVA coupler

3.

• Turn the ignition switch ON.

• Open the secondary throttle valve fully by turning it with your finger.

• With the secondary throttle valve held at this position, measure the output voltage of the TP sensor as shown.

• Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened.

Example: TP sensor output voltage with the STV fully open

Minus TP sensor output voltage at idle is 0.08 V

STV fully open

Idle

1.20 V

- 1.12 V

0.08 V

" TP sensor output voltage variation: 0.064 – 0.096 V

• If the voltage variation is out of specification, turn in or out the fast idle adjust screw

4 to adjust the voltage to specification.

'

The fast idle screw is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary.

• Cool down the engine to ambient air temperature and start the engine to check the fast idle rpm comes within the specified rpm.

" Standard

Fast idle rpm: 1 400 – 2 000 r/min (Cold engine)

Idle rpm : 1 000 ± 100 r/min (Warmed engine)

• If it is not at the specified rpm, the cause may possibly be short-circuit in oil temperature sensor or wiring harness or

STVA.

VL1500K5 (’05-MODEL) 113

114 VL1500K5 (’05-MODEL)

THROTTLE VALVE SYNCHRONIZATION

Check and adjust the throttle valve synchronization among two cylinders.

USE OF DIGITAL VACUUM TESTER

Step 1


!Page 121)

• Remove the speedometer and fuel inlet cover, frame head covers and upper frame covers.

(



• Stop the warmed-up engine.

• Disconnect the IAP sensor couplers

1.

• Disconnect the IAP sensor vacuum hoses

2 from each throttle body.

• Connect the vacuum tester hoses

3 to each vacuum nipple on the throttle body.

Step 2

• Connect a tachometer and start up the engine.

• Bring the engine rpm to 1 000 r/min by the throttle stop screw

4.

• Check the vacuum of the two cylinders. If the adjustment is necessary, proceed to the next step.

NOTE:

During balancing the throttle valves, always set the engine rpm at 1 000 r/min, using throttle stop screw.

Step 3

• Turn in all the idle air screws to the complete close position.

• Check for difference of vacuum between No. 1 and No. 2.

• Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower.

• Check for the synchronization adjustment. If the adjustment is not yet correct, remove each idle air screw and clean them with a spray-type carburetor cleaner and blow dry with a compressed air.

• Also, clean the idle air screw passageways.

NOTE:

* Slowly turn the idle air screw in clockwise and count the number of turns until the screw is lightly seated.

* Make a note of how many turns were made so the screw can be reset correctly after cleaning.

* After balancing the two valves, set the idle rpm to 1 000 r/min by the throttle stop screw.

Step 4

Repeat the above procedure (Step 3) until the correct condition.

USE OF VACUUM BALANCER GAUGE

Calibrating each vacuum gauge


!Page 121)


(



• Stop the warmed-up engine.

• Disconnect the IAP sensor couplers. (

!Page 49)

• Disconnect the IAP sensor vacuum hose

1 from the No. 1 throttle body.

VL1500K5 (’05-MODEL) 115

116 VL1500K5 (’05-MODEL)

• Connect one of the vacuum balancer gauge hose

2 to the vacuum nipple on the No. 1 throttle body.

# 09913-13121: Vacuum balancer gauge

• Connect a tachometer.

• Start up the engine and keep it running at 1 000 r/min by turning throttle stop screw

3.


• Turn the air screw

4 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball

5 in the tube to the center line

6.

NOTE:

The vacuum gauge is positioned approx. 45° from the horizontal level.

• After making sure that the steel ball stays steady at the center line, disconnect the hose from the No.1 throttle body vacuum nipple and connect the next hose to this vacuum nipple.

• Turn air screw to bring the other steel ball

7 to the center line.

The balancer gauge is now ready for use in balancing the throttle valves.

Throttle valve synchronization

Using the vacuum balancer gauge, inspect the throttle valve synchronization in the same manner as the digital vacuum tester. Pay attention to the following points:

The vacuum gauge is positioned approx. 45° from the horizontal level, and in this position the two balls should be within one ball dia. If the difference is larger than one ball, turn the idle air screw on the throttle body and bring the ball to the same level.

A correctly adjusted throttle valve synchronization has the balls in the No. 1 and No. 2 at the same level.

# 09913-13121: Vacuum balancer gauge

NOTE:

* During balancing the throttle valves, always set the engine rpm at 1 000 r/min, using throttle stop screw.

* After balancing the four valves, set the idle rpm to 1 000 r/min by the throttle stop screw.

THROTTLE POSITION SENSOR (TPS) SETTING

After all adjustments are completed, check or adjust the TPS setting condition. (

!Page 36)

VL1500K5 (’05-MODEL) 117

45 ˚

118 VL1500K5 (’05-MODEL)

SENSORS

IAP SENSOR INSPECTION

The intake air pressure sensor is located at the rear side of the air cleaner box. (

!Page 49)

IAP SENSOR REMOVAL/INSTALLATION

• Remove the frame head covers and frame upper covers.

(


• Remove the IAP sensors

1 and disconnect the couplers 2 and vacuum hoses

3.

• Installation is in the reverse order of removal.

TP SENSOR INSPECTION

The throttle position sensor is installed on the No. 2 throttle body. (

!Page 53)

TP SENSOR REMOVAL/INSTALLATION

• Remove the right frame head cover and right frame upper cover. (


• Remove the TP sensor and disconnect the coupler

1.

# 09930-11950: Torx wrench

• Install the TP sensor to the No. 2 throttle body.

(

!Page 108)

• TP sensor setting procedure. (

!Page 36)

STP SENSOR INSPECTION

The secondary throttle position sensor is installed on the No. 2 throttle body. (

!Page 77)

STP SENSOR REMOVAL/INSTALLATION




1 and remove the STP sensor 2.

# 09930-11950: Torx wrench

• Install the STP sensor to the No. 2 throttle body.

(

!Page 108)

• STP sensor setting procedure. (

!Page 110)

CKP SENSOR INSPECTION

The signal rotor is mounted on the generator rotor and crankshaft position sensor is installed at the inside of the generator cover.

(


CKP SENSOR REMOVAL/INSTALLATION

(

!VL1500%Service Manual 3D-4)

VL1500K5 (’05-MODEL) 119

IAT SENSOR INSPECTION

The intake air temperature sensor is installed at the front right side of the air cleaner box. (

!Page 66)

IAT SENSOR REMOVAL/INSTALLATION



• Disconnect the IAT sensor coupler

1 and remove the IAT sensor.


& IAT sensor: 20 N·m (2.0 kgf-m, 14.4 lb-ft)

EOT SENSOR INSPECTION

The engine oil temperature sensor is installed at the right crankcase. (

!Page 62)

EOT SENSOR REMOVAL/INSTALLATION

• Disconnect the EOT sensor coupler

1 and remove the EOT sensor

2.


& EOT sensor: 22 N·m (2.2 kgf-m, 16.0 lb-ft)

120 VL1500K5 (’05-MODEL)

TO SENSOR INSPECTION

The tip-over sensor is located under the front seat.

(

!Page 70)

TO SENSOR REMOVAL/INSTALLATION


!Page 121)


1 and remove the TO sensor.


NOTE:

When installing the TO sensor, bring the “UPPER” letter

A on it

to the top.

HO2 SENSOR INSPECTION

(FOR E-02, 19, 24)

The heated oxygen sensor is installed on the pre-muffler.

(

!Page 87)

HO2 SENSOR REMOVAL/INSTALLATION


!Page 121)


1 and remove the HO2 sensor unit.

$

Do not remove the HO2 sensor while it is hot.

'

Be careful not to expose it to excessive shock.

Do not use an impact wrench while removing or installing the HO2 sensor unit.

Be careful not to twist or damage the sensor lead wire.


'

Do not apply oil or other materials to the sensor air hole.

• Tighten the sensor unit to the specified torque.

& HO2 SENSOR: 25 N·m (2.5 kgf-m, 18.0 lb-ft)

• Route the HO2 sensor lead wire properly.

(

!Page 145 and 146)

EXTERIOR PARTS

SEAT REMOVAL

This section gives only exterior parts removal procedure which differ from that of the VL1500K4 (’04-MODEL). For details refer to the chapter 6 of Service Manual.

• Remove the rear seat

1.

'

Be careful not to scratch the rear fender.

• Remove the seat bracket

2 and front seat 3.

VL1500K5 (’05-MODEL) 121

SEAT INSTALLATION

Installation is in the reverse order of removal.

Pay attention the following points:

• With the recessed part

1 of the rear seat engaged with the tongue

2 of the front seat bracket, install the rear seat.

122 VL1500K5 (’05-MODEL)

FRONT FORK

CONSTRUCTION

1 O-ring

2 Front fork spring

3 Damper rod ring

4 Rebound Spring

5 Damper rod

6 Inner tube

7 Slide metal

8 Dust seal

9 Oil seal stopper ring

0 Oil seal

A Oil seal retainer

B Oil lock piece

C Inner tube cover guide

D Outer tube

E Upper inner tube cover

F Rubber

G Washer

H lower inner tube cover

I Inner tube cover stopper

A Front fork cap bolt

B Front axle pinch bolt

C Damper rod bolt

&


A

23 2.3

16.5

B

C

23

20

2.3

2.0

16.5

14.5

REMOVAL AND DISASSEMBLY

The front fork removal and disassembly procedures are different from those of the VL1500K4 (’04-MODEL). For details other than the following, refer to the VL1500 Service Manual.

• Remove the front wheel, front fender and front brake calipers.

(

!VL1500%Service Manual 6-7 and 6-12)

• Loosen the steering stem head nut

1.

• Loosen the front fork upper clamp bolts

2, left and right.

NOTE:

Slightly loosen the front fork cap bolts

3 before loosening the

lower clamp bolts to facilitate later disassembly.

• Loosen the front lower clamp bolts

4, left and right.

NOTE:

Hold the front fork by the hand to prevent it from falling down.

• Remove the front forks, left and right.

• Remove the upper inner tube covers

5, washers and rubbers, left and right.

• Remove the front fork lower inner tube cover

6, washer 7 and rubber

8.

VL1500K5 (’05-MODEL) 123

124 VL1500K5 (’05-MODEL)

• Remove the front fork cap bolts

7.

INSPECTION

For details other than the following, refer to the VL1500 Service

Manual.

FORK SPRING

" Front fork spring free length

Service Limit: 589 mm (23.2 in)

REASSEMBLY AND REMOUNTING

The front fork reassembly and remounting procedures are different from those of the VL1500K4 (’04-MODEL). For details other than the following, refer to the VL1500 Service Manual.

FORK OIL

" Capacity (each leg): 416 ml (14.1/14.6 US/lmp oz)

" Fork oil level: 192 mm (7.56 in)

# 09943-74111: Front fork oil level gauge

• Install the front fork cap bolt.

• Install the inner tube cover stopper

1 at 284.3 mm (11.19 in)

A from the upper surface of the inner tube.

• Set the washer

2 and rubber 3 to the inner tube.

• Install the upper inner tube cover

4.

NOTE:

When installing the front fork inner tube upper cover, align the hole

C in the front fork inner tube upper cover and protrusion B

on the steering stem lower bracket.

VL1500K5 (’05-MODEL) 125

126 VL1500K5 (’05-MODEL)

• When installing the front fork assembly, align the upper surface

D of the inner tube with the surface E of the steering upper bracket.

• Tighten the front fork lower clamp bolts

5 to the specified torque.

& Front fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Tighten the front fork cap bolt


& Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Tighten the front fork upper clamp bolt


& Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Tighten the steering stem head nut


& Steering stem head nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft)

LOCATION OF ELECTRICAL COMPONENTS

VL1500K5 (’05-MODEL) 127

1 Fuel pump and level gauge (

!Page 95)

2 TP sensor (

!Page 53)

3 IAP sensor (Front) (

!Page 49)

4 Ignition coil (#2)

5 Horn (**

Except for E-03, 24, 28 and 33)

6 Automatic decompression relay

7 Fuse box

8 Side-stand/turn signal relay

9 TO sensor (

!Page 70)

0 Starter motor

A Oil pressure switch

B EOT sensor (

!Page 58)

C IAT sensor (

!Page 66)

D Speed sensor (

!Page 141)

E Battery

F Automatic decompression solenoid

(**): Horn is located under the ECM.

128 VL1500K5 (’05-MODEL)

1 Fuel injector (#1 & #2)(

!Page 84)

2 STP sensor (

!Page 77)

3 STV actuator (

!Page 74)

4 IAP sensor (Rear) (

!Page 49)

5 ECM (Engine Control Module)

6 Fuel pump relay (

!Page 96)

7 Starter relay/Main fuse

8 Side-stand switch

9 GP switch (

!Page 82)

0 HO2 sensor (For E-02, 19, 24) (

!Page 87)

A Ignition coil (#1)

B Regulator/rectifier

C Generator

D CKP sensor (

!Page 47)

E Mode selection switch coupler

F Ignition switch

VL1500K5 (’05-MODEL) 129

CHARGING SYSTEM

INSPECTION

GENERATOR COIL RESISTANCE


!Page 121)


(


• Disconnect the generator coupler

1.

• Measure the resistance among the three lead wires.

If the resistance is not specified value, replace the stator with a new one. Also, check that the generator core is insulated.

" Generator coil resistance: 0.1 – 1.0 Ω (White – White)

∞ Ω (White – Ground)



NOTE:

When making above test, it is not necessary to remove the generator.

GENERATOR NO-LOAD PERFORMANCE

• Disconnect the generator coupler. (

!Above)

• Start the engine and keep it running at 5 000 r/min.

• Using the multi-circuit tester, measure the voltage among the three lead wires.

If the tester reads under the specified value, replace the generator with a new one.

" Generator no-load performance:

80 V and more at 5 000 r/min (When engine is cold)


* Tester knob indication: Voltage (∼)

W

W

W

W

W

W

130 VL1500K5 (’05-MODEL)

REGULATOR/RECTIFIER

• Remove the secondary gear case cover.

(


• Disconnect the couplers and remove the regulator/rectifier

1.

• Measure the voltage between the terminals using the multi circuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.


/ Tester knob indication: Diode test (0)

Unit: V

B/R

+ Probe of tester to:

B1 B2 B3 B/W

B/R

B1

B2

B3

B/W

✽

✽

✽

✽

0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2

✽

✽

✽

✽

✽

✽

B: Black, B/R: Black with Red, B/W: Black with White tracer

✽ 1.4 V and more (tester’s battery voltage)

✽

✽

✽

0.4 – 0.7

0.4 – 0.7

0.4 – 0.7

B/R

B2

B3

B/W

B1

NOTE:

If the tester reads 1.4 V and below when the tester probes are not connected, replace the battery of the multi-circuit tester.

VL1500K5 (’05-MODEL) 131

AUTOMATIC DECOMPRESSION SYSTEM/STARTER SYSTEM

AND SIDE-STAND IGNITION INTERLOCK SYSTEM

Fuse 30A

Starter relay

IG. switch

Automatic decompression relay

Fuse 15A

Turn signal/ side-stand relay

O/B

Engine stop switch

Fuse 15A

Y/G

M

Starter motor

G/R

Automatic decompression solenoid


O/R

O/W

Neutral indicator light switch

Sidestand switch

Battery

ECM

Clutch lever position switch

Starter button

G/Y

Br

Signal generator

132 VL1500K5 (’05-MODEL)

SIDE-STAND/IGNITION INTERLOCK SYSTEM

PARTS INSPECTION

Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one.

GEAR POSITION SWITCH

• Remove the secondary gear case cover.

(


• Disconnect the gear position switch coupler

1 and check the continuity between Blue and Black with the transmission in

“NEUTRAL”.



Blue Black

ON (Neutral)

OFF (Other than neutral)

'

When disconnecting and connecting the gear position switch coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

• Connect the gear position switch coupler to the wiring harness.

• Turn the ignition switch to “ON” position and side-stand to upright position.

• Insert the needle pointed probes to the gear position switch coupler.

• Measure the voltage between Red/Black and Black/Green lead wires using the multi-circuit tester when shifting the gearshift lever from low to top.

" GP switch voltage: 0.6 V and more (

+ R/B – - B/G)

(* Low to top gear positions except neutral position.)




'

Use the special tool to prevent the rubber of the water proof coupler from damage.

V

VL1500K5 (’05-MODEL) 133

IGNITION SYSTEM

ECM

CKP sensor

Wave form arrangement circuit

Power source circuit

CPU

Engine stop switch

Ignition coil

Spark plug

#1

#2

Sidestand relay

Fuse

Ignition switch

Fuse

Battery

Throttle position sensor

Engine oil temp.

sensor

Gear position switch

NOTE:

The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 5 800 – 6 000 r/min during running, this circuit cuts off fuel at the fuel injector.

TROUBLESHOOTING

No spark or poor spark

NOTE:

Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Squeeze the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing.

Step 1

1) Check the ignition system couplers for poor connections.

Is there connection in the ignition switch couplers?

YES

NO

Go to Step 2.

Poor connection of couplers

134 VL1500K5 (’05-MODEL)

Step 2

1) Measure the battery voltage between input lead wires at the ECM with the ignition switch in the “ON” position. (E-02, 19, 24: O/G and B/W, E-03, 28, 33: O/W and B/W)

Is the voltage OK?

YES

NO

Go to Step 3.

• Faulty ignition switch

• Faulty turn signal/side-stand relay

• Faulty engine stop switch

• Broken wire harness or poor connection of related circuit couplers

Step 3

1) Measure the ignition coil primary peak voltage. (

!Page 135)

NOTE:

This inspection method is applicable only with the multi circuit tester and the peak volt adaptor.

Is the peak voltage OK?

YES

NO

Go to Step 4.

Go to Step 5.

Step 4

1) Check the plug caps for poor contacts.

2) If OK, then inspect the spark plugs. (


Are the spark plugs OK?

YES

NO

Go to Step 5.

Faulty spark plug (-s)

Step 5

1) Inspect the ignition coils. (

!Page 136)

Are the ignition coils OK?

YES

NO

Go to Step 6.

Faulty ignition coil (-s)

Step 6

1) Measure the CKP sensor peak voltage and its resistance. (

!Page 136 and 137)

NOTE:

The CKP peak voltage inspection is applicable only with the multi-circuit tester and peak volt adaptor.

Are the peak voltage and its resistance OK?

YES

NO

• Faulty ECM

• Open or short circuit in wire harness

• Poor connection of ignition couplers

• Faulty CKP sensor

• Metal particles or foreign material being stuck on the CKP sensor and rotor tip

VL1500K5 (’05-MODEL) 135

INSPECTION

IGNITION COIL PRIMARY PEAK VOLTAGE


(


• Remove the cylinder head side caps and disconnect the spark plug caps. (


• Connect new spark plugs to each spark plug cap and ground them to the cylinder head.

NOTE:

Make sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition.

Measure the #1 and #2 ignition coils primary peak voltage in the following procedure.

• Connect the multi-circuit tester with peak voltage adaptor as follows.

#1 ignition coil:

# 2 ignition coil:

+ Probe: White terminal

- Probe: Ground

+ Probe: Black/Yellow terminal

- Probe: Ground

NOTE:

Do not disconnect the ignition coil primary wire coupler.


'

Before using the multi-circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.

• Shift the transmission into neutral and turn ignition switch

“ON”.

• Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage.

• Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage. If the peak voltage is lower than the specified values, inspect the ignition coil.

" Ignition coil primary peak voltage: 180 V and more

*Tester knob indication: Voltage (+)

$

Avoid touching the tester probes and spark plugs to prevent an electric shock while testing.

Peak volt adaptor

ECM

W or B/Y

Ignition coil

New spark plug

Battery

136 VL1500K5 (’05-MODEL)

IGNITION COIL RESISTANCE


(


• Remove the cylinder head side caps and disconnect the spark plug caps. (


• Measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.

" Ignition coil resistance

Primary: 1 – 7

Ω (

+ terminal – - terminal)

Secondary: 18 – 28 k

Ω (Plug cap –

+ terminal)



Ω k

Ω

CKP SENSOR PEAK VOLTAGE


!Page 121)


(


NOTE:

Make sure that all of the couplers are connected properly and the battery used is in fully-charged condition.

• Measure the CKP sensor peak voltage in the following procedures.

• Disconnect the CKP sensor lead wire coupler

1.

• Connect the multi-circuit tester with the peak volt adaptor as follows.

+ Probe: Green lead wire

- Probe: Blue lead wire

'

Before using the multi-circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.

CKP sensor

CKP sensor coupler

Peak volt adaptor

VL1500K5 (’05-MODEL) 137

• Shift the transmission into the neutral and turn ignition switch

“ON”.

• Crank the engine a few seconds with the starter motor by depressing starter button and check the CKP sensor peak voltage.

• Repeat the above procedure a few times and measure the highest peak voltage.

" CKP sensor peak voltage: 2.4 V and more

(Green – Blue)



If the peak voltage on the CKP sensor lead wire coupler is OK but on the ECM coupler is out of specification, the wire harness must be replaced. If both peak voltages are out of specification, the CKP sensor must be replaced and re-checked.

CKP SENSOR RESISTANCE


!Page 121)


(


• Disconnect the CKP sensor lead wire coupler

1.

• Measure the resistance between the lead wires and ground. If the resistance is not specified value, the CKP sensor must be replaced.

" CKP sensor resistance: 178 – 242 Ω (Green – Blue)

∞ Ω (Blue – Ground)



CKP sensor coupler

CKP sensor

138 VL1500K5 (’05-MODEL)

SPEEDOMETER

DESCRIPTION

This speedometer mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This speedometer is light, thin and of high response compared to those currently in use because of this composition.

The speedometer pointer is driven by the stepping motor.

The LCD indicates Odo/Trip A/Trip B/Clock/FI and Fuel level respectively.

NOTE:

If the engine stop switch is turned OFF while the ignition switch is ON, the LCD displays “CHEC”. But it is not a malfunction.

This condition implies that combination meter receives no signal from the ECM.

In that case, they are restored to normal indication by turning the engine stop switch to RUN position.

LED (Light Emitting Diode)

LED is used for the illumination light and each indicator light.

LED is maintenance free. LED is less electric-power consuming and stronger to vibration resistance compared to the bulb.

1 Select switch (Odo/Trip/clock)

2 Reset switch

3 Speedometer

4 LCD (Odo/Trip A/Trip B/Clock/FI)

5 LCD (Fuel level)

6 LED (High-beam indicator light)

7 LED (FI indicator light)

8 LED (Turn signal indicator light)

9 LED (Oil pressure indicator light)

0 LED (Neutral indicator light)

REMOVAL AND DISASSEMBLY


!Page 121)


(


• Remove the speedometer

1.

'

When disconnecting and reconnecting the speedometer coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

• Disassemble the speedometer as follows.

VL1500K5 (’05-MODEL) 139

1 Select switch cover

2 Reset switch cover

'

3 Speedometer cover

4 Speedometer unit

Do not attempt to disassemble the Speedometer unit

4.

5 Speedometer case

140 VL1500K5 (’05-MODEL)

INSPECTION

LED (LIGHT EMITTING DIODE)

Check that the LEDs illuminate (FI light and Oil pressure indicator light) immediately after turning the ignition switch on. Also, check the other LEDs for their lighting (Neutral indicator light,

High-beam indicator light and Turn signal indicator light) in accordance with their switch positions.

If the LED fails in operation, replace the speedometer unit with a new one after checking its wire harness/coupler.

FUEL LEVEL GAUGE INSPECTION

• Remove the fuel pump assembly. (

!Page 96)

• Measure the resistance at each fuel level gauge float position.

If the resistance is incorrect, replace the fuel level gauge with a new one.

Float position

34.8 mm (1.37 in)

142.9 mm (5.63 in)

Resistance

4 – 10

Ω

90 – 100

Ω

FUEL LEVEL INDICATOR

If the fuel level indicator

B does not function properly, check the fuel level gauge and its lead wire/coupler.

If the fuel level gauge and its lead wire/coupler are functioning properly, replace the speedometer with a new one.

34.8 mm

142.9 mm

OIL PRESSURE INDICATOR

NOTE:

Before inspecting the oil pressure switch, check if the engine oil level is correct. (

!VL1500 Service Manual 2-6)

• Disconnect the oil pressure switch lead wire from the oil pressure switch.

• Turn the ignition switch ON.

• Check if the oil pressure indicator

C will light, when grounding the lead wire.

If any indications are abnormal, replace the combination meter with a new one after checking connection of couplers.

SPEEDOMETER

If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of coupler

1. If the speedometer sensor and connection are all right, replace the meter with a new one.

SPEEDOMETER SENSOR

• Remove the right frame cover.

(

! VL1500 Service Manual 6-2)

• Remove the rear clutch cover.

(

! VL1500 Service Manual 3-6)

• Disconnect the speed sensor lead wire coupler

1.

• Remove the speedometer sensor

2 by removing its mounting bolt.

VL1500K5 (’05-MODEL) 141

• Connect 12 V battery, 10 k

Ω resistor and the multi-circuit tester as shown in the right illustration.

R/B: Red with Black tracer

B/W: Black with White tracer

P: Pink



V

• Under above condition, if a suitable screwdriver touching the pick-up surface of the speedometer sensor is moved, the tester voltage reading should change (0 V

→ 12 V or 12 V →

0 V). If the tester voltage reading does not change, replace the speedometer sensor with a new one.

NOTE:

The highest voltage reading in this test will be the same as that of battery voltage.

(Battery voltage)

10 k

Ω

B/W

12V

P R/B

Speed sensor

RELAYS

FUEL PUMP RELAY

!Page 96

142 VL1500K5 (’05-MODEL)

SWITCHES

inspect each switch for continuity with the multi-circuit tester. If any abnormality is found, replace the respective switch assemblies with new ones.


IGNITION SWITCH

Color

R O O/Y Gr Br

Position

P

LOCK

OFF

ON

DIMMER SWITCH

Color

Position

HI (

µ)

LO (

¶)

W

TURN SIGNAL SWITCH

Color

Position

L

Lg

PUSH

R

PASSING LIGHT SWITCH

Color

Position

O/R

Y

Lbl

Y

Y/W

B

HAZARD

Color

Position

OFF

ON

B Lbl

FRONT BRAKE SWITCH

Color

Position

OFF

B/R

ON

REAR BRAKE SWITCH

Color

Position

ON

OFF

O

B/Bl

W/B

CLUTCH LEVER POSITION SWITCH

Color

Position

FREE

B/Y B/Y

Lg

PUSH

ENGINE STOP SWITCH

Color

Position

OFF (

À)

RUN (

¾)

O/B

STARTER BUTTON

O/W

O/W Y/G Y/W O/R

Position

OIL PRESSURE SWITCH

Color

Position

ON (engine is stopped)

OFF (engine is running)

B/Y Ground

NOTE:

Before inspecting the oil pressure switch, check the engine oil level. (

:

VL1500 Service Manual 2-6)

PUSH

HORN BUTTON

Color

Position

B/Bl

PUSH

B/W

WIRE COLOR

B : Black

Br : Brown

Gr : Gray

Lbl : Light blue

Lg : Light green

O : Orange

R : Red

Y : Yellow

W : White

B/Bl : Black with Blue tracer

B/W : Black with White tracer

B/Y : Black with Yellow tracer

B/R : Black with Red tracer

O/B : Orange with Black tracer

O/R : Orange with Red tracer

O/W : Orange with White tracer

O/Y : Orange with Yellow tracer

W/B : White with Black tracer

Y/G : Yellow with Green tracer

Y/W : Yellow with White tracer

BATTERY

SPECIFICATIONS

Type designation

Capacity a Anode plates b Separator (fiberglass plate) c Cathode plates d Upper cover breather

FTZ16-BS-1

12 V, 64.8 kC (18 Ah)/10 HR e Stopper f Filter g Terminal h Safety valve

VL1500K5 (’05-MODEL) 143

144 VL1500K5 (’05-MODEL)

WIRING HARNESS, CABLE AND HOSE ROUTING

WIRING HARNESS ROUTING

Starter motor

6 N.m

(0.6 kgf-m, 4.5 lb-ft)

Ground wire

Speed sensor

6 N.m

(0.6 kgf-m, 4.5 lb-ft)

Oil pressure switch

14 N.m

(1.4 kgf-m,

10.0 lb-ft)

160 N.m

(16.0 kgf-m,

115.5 lb-ft)

Side-stand switch

Secondary gear case cover

Gear position switch

CKP sensor

Regulator/rectifier

11 N.m

(1.1 kgf-m, 8.0 lb-ft)

VL1500K5 (’05-MODEL) 145

Clamp

Wiring harness

HO2 sensor

(For E-02, 19, 24)

Clutch hose

High-tension cord

Frame

Clamp

Wiring harness

Set the clamp between the

IAP sensor and horn bracket.

Clamp

Generator coupler

Wiring harness

(Except TO sensor)

Don’t set lead wire on pipe.

Pass through the high-tension cord inside of the breather hose.

Ignition coil

TO sensor

Set the “ UP ” mark to the top.

Brake hose

Decomp relay

IAP sensor

Clamp

STVA

Wiring harness

Decomp solenoid

Plate approval mark

(Except for E-03, 24, 28, 33)

Horn (For E-02, 19)

Clamp

Battery

Wiring harness

Stop lamp switch

Speed sensor

Clamp

Fuse box

Turn signal/ side-stand relay

Stop lamp switch

Be careful not to contact the wire harness to the clutch cover.

Stop lamp switch

Battery

OIL pressure switch

Clamp

Frame

Frame

Stop lamp switch

146 VL1500K5 (’05-MODEL)

Clamp

Handle switch (R, L)

Clamp

Wiring harness

Front turn (R, L)

Clamp

Handle switch

Brake hose

Clutch hose

Boots

Horn lead wire

(For E-02, 19)

Handle switch (R, L)

Clamp

Horn lead wire

(For E-03, 24, 28, 33)

Clamp

Horn (For E-03, 24, 28, 33)

Generator lead wire

Ignition switch

IAP sensor

Fuel pump relay

Put lead wire into the space.

HO2 sensor lead wire

(For E-02, 19, 24)

Starter motor

Battery

Horn (For E-02, 19)

Clamp

Horn

(Except for E-03, 24, 28, 33)

Clamp

Starter motor

Battery

Clamp

ECM

Clamp

Battery

Clamp

Wiring harness

Clutch pipe

CABLE AND HOSE ROUTING

Wiring harness Throttle cable No. 2

Wiring harness

Brake hose

40 mm

(1.57 in)

160 mm

(6.30 in)

Throttle cable No. 1

Clutch hose

VL1500K5 (’05-MODEL) 147


Clutch hose


Wiring harness


Clutch hose

50 mm

(1.97 in)

Clamp

Clamp


Wiring harness

Clamp

Throttle cables and wiring harness must be passed under the clutch hose.

148 VL1500K5 (’05-MODEL)

FRONT BRAKE HOSE ROUTING

35 ˚

1

After the brake hose union has contacted the stopper, tighten the union bolt to the specified torque.

4

2

After positioning the hose clamp with stopper, tighten the clamp bolt.

3 Clamp the brake hose firmly.

5

Pass through the brake hose inside of the hose guide.

Bind the brake hose together with the wire harness by the wire clamp.

REAR BRAKE HOSE ROUTING

VL1500K5 (’05-MODEL) 149

42 ˚

1

After the brake hose union has contacted the stopper, tighten the union bolt.

Brake hose must be passed over the brake support

2 boss and caliper bracket.

3 Reservoir tank

4 Clamp

5

6

After positioning the clamp with the stopper, tighten the clamp bolt.

Brake hose

7 Wire harness

8 Frame

150 VL1500K5 (’05-MODEL)

FUEL SYSTEM HOSE ROUTING

1 Fuel feed hose

2 IAP sensor vacuum hose (Rear cylinder)

3 IAP sensor vacuum hose (Front cylinder)

4 Purge hose (E-33 only)

5 Surge hose (E-33 only)

6 EVAP canister (E-33 only)

7 Throttle body

8 PCV (Breather) hose

9 Air cleaner box

0 IAT sensor

A IAP sensor (Front cylinder)

B IAP sensor (Rear cylinder)

C EOT sensor

&


0

20 2.0

14.4

C

22 2.2

16.0

VL1500K5 (’05-MODEL) 151

The ends of the clamp should face left side.

The ends of the clamp should face right side.

The clamp bolt head

sould face downward.

15 N.m

(0.15 kgf-m, 1.0 lb-ft)

10 N.m

(1.0 kgf-m, 7.0 lb-ft)

Clamp

Water drain hose

5 N.m

(0.5 kgf-m,

3.7 lb-ft)

Fuel feed hose

TPC valve

Water drain hose

The ends of the clamp should face right side.

Apply an adhesive agent.

Clamp

152 VL1500K5 (’05-MODEL)

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING

*1

*2

20 – 40 mm

(0.79 – 1.57 in) 20 – 40 mm

(0.79 – 1.57 in)

*3

1

PAIR control solenoid valve with PAIR reed valve

*1

Connect the air hose to the air cleaner box.

2 Cushion seat (Apply an adhesive agent to the cushion seat.)

*2 Matching mark (Yellow)

3

Wiring harness

*3 Matching mark (White)

EXTERIOR PARTS INSTALLATION

METER/FUEL INLET COVER INSTALLATION

VL1500K5 (’05-MODEL) 153

*1

*2

1 Frame upper cover (L)

2 Frame upper cover (R)

3 Speedometer/Fuel inlet cover

4

Speedometer switch cover

(USA)

(Others)

(USA)

(Others)

5 Fuel lid hinge bracket

6 Fuel lid

7 Fuel lid cover

*1 Outside

*2 Apply an adhesive agent.

154 VL1500K5 (’05-MODEL)

FRAME UPPER COVER INSTALLATION

1 Cushion seat

2 Apply an adhesive agent.

3 Cushion rubber

4

Molding

5 Bend up the stay.

6 50 mm (2.0 in)

FRAME HEAD COVER INSTALLATION

VL1500K5 (’05-MODEL) 155

1 Cushion seat

2 Apply an adhesive agent.

3 3 mm (0.12 in)

156 VL1500K5 (’05-MODEL)

GREASE-UP POINTS

BRAKE PEDAL INSTALLATION

50 N.m

(5.0 kgf-m, 36.0 lb-ft)

H

×

×

×

H Brake pedal height: 98 mm (3.86 in)

×

Apply an adhesive agent.

VL1500K5 (’05-MODEL) 157

SPECIAL TOOLS

09900-25009

Needle pointed probe set

09900-28630

TPS test wire harness

09904-41010

SDS set tool

09904-41030-004

CD-ROM Ver. 4

09915-74511

Oil pressure gauge

09940-40211

Fuel pressure gauge adapter

09940-40220

Fuel pressure gauge hose attachment

09930-11950

Torx wrench

09930-82720

Mode selection switch

NOTE:

When order the special tool, please confirm whether it is available or not.

158 VL1500K5 (’05-MODEL)

TIGHTENING TORQUE

* FI SYSTEM AND INTAKE AIR SYSTEM

ITEM

IAT sensor

HO2 sensor (For E-02, 19, 24)

EOT sensor

Fuel pump mounting bolt

STPS mounting screw

TPS mounting screw

Fuel delivery pipe mounting screw

Fuel delivery pipe hose mounting screw

* CHASSIS

Front fork cap bolt

Front fork upper clamp bolt

Handlebar set bolt

Handlebar holder nut

ITEM N·m

23

23

23

70

N·m

20

25

22

10

3.5

3.5

5

5

kgf-m

2.0

2.5

2.2

1.0

0.35

0.35

0.5

0.5

kgf-m

2.3

2.3

2.3

7.0

lb-ft

16.5

16.5

16.5

50.5

lb-ft

14.4

18.0

16.0

7.0

2.5

2.5

3.5

3.5

SERVICE DATA

VALVE + GUIDE

Valve diam.

ITEM

Lash-adjuster plunger stroke

Valve guide to valve stem clearance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

(INTAKE)

Valve spring free length

(EXHAUST)

Valve spring tension (INTAKE)

Valve spring tension (EXHAUST)

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN. & EX.

IN.

EX.

IN.

STANDARD

33

(1.3)

40

(1.6)

0 – 0.5

(0 – 0.02)

0.010 – 0.037

(0.0004 – 0.0015)

0.040 – 0.070

(0.0016 – 0.0028)

—

5.500 – 5.512

(0.2165 – 0.2170)

7.000 – 7.015

(0.2756 – 0.2762)

5.475 – 5.490

(0.2156 – 0.2161)

6.945 – 6.960

(0.2734 – 0.2740)

—

—

—

—

0.9 – 1.1

(0.035 – 0.043)

1.0 – 1.2

(0.039 – 0.047)

—

EX.

IN. & EX.

INNER

OUTER

—

—

—

INNER

OUTER

53 –65 N (5.3 – 6.5 kgf)

(11.68 – 14.33 Ibs) at length 28.0 mm (1.10 in)

140 – 142 N (14.0 – 14.2 kgf)


203 – 233 N (20.3 – 23.3 kgf)


VL1500K5 (’05-MODEL) 159

Unit: mm (in)

LIMIT

—

—

—

—

—

0.35

(0.014)

—

—

—

—

0.03

(0.001)

35.0

(1.38)

37.8

(1.49)

40.6

(1.60)

—

0.05

(0.002)

0.5

(0.02)

2.5

(0.10)

2.2

(0.09)

—

—

—

—

160 VL1500K5 (’05-MODEL)

CAMSHAFT + CYLINDER HEAD

Cam height

ITEM

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

IN.

EX.

IN. & EX.

STANDARD

* 35.320 – 35.370

(1.3905 – 1.3925)

36.880 – 36.930

(1.4521 – 1.4537)

0.032 – 0.066

(0.0013 – 0.0026)

Front head right side, rear head left side

Front head left side, rear head right side

Front head right side, rear head left side

Front head left side, rear head right side

20.012 – 20.025

(0.7879 – 0.7884)

25.012 – 25.025

(0.9847 – 0.9852)

19.959 – 19.980

(0.7858 – 0.7866)

24.959 – 24.980

(0.9826 – 0.9835)

Camshaft runout

Front & Rear —

Rocker arm I.D.

Rocker arm shaft O.D.

IN.

EX.

IN.

EX.

14.000 – 14.018

(0.5511 – 0.5519)

16.000 – 16.018

(0.6299 – 0.6303)

13.966 – 13.984

(0.5498 – 0.5506)

15.966 – 15.984

(0.6286 – 0.6293)

Cylinder head distortion

—

Cylinder head cover distortion

—

CYLINDER + PISTON + PISTON RING

ITEM

Compression pressure

(Automatic de-compression actuated)

Compression pressure difference

STANDARD

1 000 – 1 400 kPa

(10 – 14 kgf/cm

2

, 142 – 199 psi)

—

Piston to cylinder clearance

Cylinder bore

Piston diam.

Cylinder distortion

0.02 – 0.03

(0.0008 – 0.0012)

96.000 – 96.015

(3.7795 – 3.7801)

95.975 – 95.990

(3.7785 – 3.7791)

Measure at 16 mm (0.6 in) from the skirt end.

—

Piston ring free end gap

1st T Approx. 13.5 (0.53)

2nd T Approx. 14.0 (0.55)

—

0.10

(0.004)

—

—

—

—

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

LIMIT

* 35.02

(1.379)

36.58

(1.440)

0.150

(0.0060)

—

—

—

Unit: mm (in)

LIMIT

—

200 kPa

(2 kgf/cm

2

,

28 psi)

0.120

(0.0047)

Nicks or

Scratches

95.88

(37.7748)

0.05

(0.002)

10.8

(0.43)

11.2

(0.44)

ITEM

Piston ring end gap

Piston ring to groove clearance

Piston ring groove width

Piston ring thickness

Piston pin bore

Piston pin O.D.

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod big end side clearance

Conrod big end width

Crank pin width

Conrod big end oil clearance

Crank pin O.D.

Crankshaft journal oil clearance

Crankshaft journal O.D.

Crankshaft journal I.D.

Crankshaft thrust bearing thickness

Crankshaft thrust clearance

Crankshaft runout

2nd

1st

2nd

1st

2nd

1st

Oil

1st

2nd

STANDARD

23.015 – 23.023

(0.9061 – 0.9064)

0.10 – 0.20

(0.004 – 0.008)

21.95 – 22.00

(0.864 – 0.866)

22.10 – 22.15

(0.870 – 0.872)

0.024 – 0.042

(0.0009 – 0.0017)

49.982 – 50.000

(1.9678 – 1.9685)

0.020 – 0.050

(0.0008 – 0.0020)

51.965 – 51.980

(2.0459 – 2.0465)

52.000 – 52.015

(2.0472 – 2.0478)

1.925 – 2.175

(0.0758 – 0.0856)

0.05 – 0.10

(0.002 – 0.004)

—

STANDARD

0.30 – 0.45

(0.012 – 0.018)

0.45 – 0.60

(0.018 – 0.024)

—

—

1.210 – 1.230

(0.0476 – 0.0484)

1.510 – 1.530

(0.0594 – 0.0602)

2.810 – 2.830

(0.1106 – 0.1114)

1.160 – 1.175

(0.0457 – 0.0463)

1.470 – 1.490

(0.0579 – 0.0587)

23.002 – 23.008

(0.9056 – 0.9058)

22.992 – 23.000

(0.9052 – 0.9055)

VL1500K5 (’05-MODEL) 161

Unit: mm (in)

LIMIT

23.040

(0.9071)

0.3

(0.012)

—

—

0.080

(0.0031)

—

0.080

(0.0031)

—

—

—

—

0.05

(0.002)

LIMIT

0.70

(0.028)

1.00

(0.039)

0.180

(0.007)

0.150

(0.006)

—

—

—

—

—

23.030

(0.9067)

22.980

(0.9047)

162 VL1500K5 (’05-MODEL)

OIL PUMP

ITEM

Oil pump reduction ratio

Oil pressure (at 60 °C, 140 °F)

CLUTCH

ITEM

Drive plate thickness

Drive plate claw width

Driven plate distortion

Clutch spring free length

Clutch master cylinder bore

Clutch master cylinder piston diam.

Clutch release cylinder bore

Clutch release cylinder piston diam.

DRIVE TRAIN

ITEM

Primary reduction ratio

Secondary reduction ratio

Final reduction ratio

Gear ratios Low

2nd

3rd

4th

Top

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

Damper spring free length

Gearshift lever height

Secondary bevel gear backlash

Final bevel gear backlash

STANDARD

1.154 (76/51 × 31/40)

Above 350 kPa (3.5 kgf/cm 2 , 50 psi)

Below 650 kPa (6.5 kgf/cm

2

, 92 psi) at 3 000 r/min

STANDARD

2.90 – 3.10

(0.114 – 0.122)

15.6 – 15.8

(0.614 – 0.622)

—

34.47

(1.357)

14.000 – 14.043

(0.5512 – 0.5529)

13.957 – 13.984

(0.5495 – 0.5506)

33.600 – 33.662

(1.3228 – 1.3253)

33.550 – 33.575

(1.3209 – 1.3218)

STANDARD

1.490 (76/51)

0.852 (29/34)

2.666 (19/19 × 32/12)

3.000 (36/12)

1.823 (31/17)

1.333 (28/21)

1.041 (25/24)

0.884 (23/26)

0.1 – 0.3

(0.004 – 0.012)

5.50 – 5.60

(0.217 – 0.220)

5.30 – 5.40

(0.209 – 0.213)

—

82

(3.23)

0.03 – 0.15

(0.001 – 0.006)

0.03 – 0.64

(0.001 – 0.025)

LIMIT

—

—

Unit: mm (in) Except ratio

LIMIT

—

—

—

—

—

—

—

—

0.5

(0.020)

—

—

73.6

(2.90)

—

—

—

Unit: mm (in)

LIMIT

2.60

(0.102)

14.8

(0.583)

0.10

(0.004)

32.7

(1.29)

—

—

—

—

VL1500K5 (’05-MODEL) 163

* INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR

ITEM

Injector resistance

Fuel pump discharge amount

SPECIFICATION

Approx. 11.7

Ω at 20 °C (68 °F)

168 ml (5.7/5.9 US/lmp oz) and more/10 sec.

Fuel pressure regulator operating set pressure

Approx. 300 kPa (3.0 kgf/cm 2 , 43 psi)

* FI-SENSORS

ITEM

CKP sensor resistance

CKP sensor peak voltage

IAP sensor input voltage

IAP sensor output voltage

TP sensor input voltage

TP sensor resistance

TP sensor output voltage

EOT sensor input voltage

EOT sensor output voltage

EOT sensor resistance

IAT sensor input voltage

IAT sensor output voltage

IAT sensor resistance

TO sensor resistance

TO sensor voltage

GP switch voltage

Injector voltage

STP sensor input voltage

STP sensor resistance

STP sensor output voltage

STV actuator resistance

Heated oxygen sensor output voltage

Heated oxygen sensor resistance

PAIR solenoid valve resistance

Closed

Opened

Closed

Opened

Normal

SPECIFICATION

178 – 242

Ω

2.4 V and more (When cranking)

4.5 – 5.5 V

Approx. 2.53 V at idle speed

4.5 – 5.5 V

Approx. 4.66 k

Ω

Approx. 1.12 k

Ω

Approx. 4.41 k

Ω

Approx. 1.12 V

Approx. 4.41 V

4.5 – 5.5 V

0.1 – 4.6 V

Approx. 61.3 k

Ω at 20 °C (68 °F)

4.5 – 5.5 V

0.1 – 4.6 V

Approx. 2.45 k

Ω at 20 °C (68 °F)

19.1 – 19.7 k

Ω

0.4 – 1.4 V

Leaning 3.7 – 4.4 V

Closed

Opened

Closed

Opened

0.6 V and more (From 1st to top)

Battery voltage

4.5 – 5.5 V

Approx. 4.69 k

Ω

Approx. 0.5 k

Ω

Approx. 3.9 k

Ω

Approx. 0.5 V

Approx. 3.9 V

Approx. 6.5

Ω

0.4 V and less at idle speed

0.6 V and more at 5 000 r/min

6.5 – 8.9

Ω at 23 °C (73.4 °F)

20 – 24

Ω at 20 – 30 °C (68 – 86 °F)

NOTE

NOTE

When leaning 65 °

For E-02, 19, 24

164 VL1500K5 (’05-MODEL)

* THROTTLE BODY

ITEM

ID No.

Bore size

Fast idle r/min

Idle r/min

Throttle cable play

SPECIFICATION

10F0 (For E-02, 19, 03, 24, 28), 10F1 (For E-33)

36 mm

1 400 – 2 000 r/min When cold engine

1 000 ± 100 r/min

2.0 – 4.0 mm

(0.08 – 0.16 in)

ELECTRICAL

Firing order

Spark plug

ITEM

Spark performance

* CKP sensor resistance

* CKP sensor peak voltage

Ignition coil resistance

Ignition coil primary peak voltage

Generator coil resistance

Generator Max. output

Generator no-load voltage

(when engine is cold)

Regulated voltage

Decomp. solenoid resistance

Fuel pump resistance

Starter relay resistance

* GP switch voltage

Battery

Fuse size

Type designation

Capacity

HI

Headlight

LO

Signal

Ignition

Fuel

Power source

Main

Type

Gap

Primary

Secondary

SPECIFICATION

R · F

NGK: DPR7EA-9

DENSO: X22EPR-U9

0.8 – 0.9

(0.031 – 0.035)

Over 8 (0.3) at 1 atm.

178 – 242

Ω

2.4 V and more

1 – 7

Ω

18 – 28 k

Ω

Front

Rear

* 180 V and more

* 180 V and more

0.1 – 1.0

Ω

*Approx. 375 W at 5000 r/min

80 V (AC) and more at 5 000 r/min

13.5 – 15.0 V at 5 000 r/min

0.1 – 1.5

Ω

70 – 110

Ω

3 – 6

Ω

0.6 V and more (From 1st to top)

* FTZ16-BS-1

* 12 V 64.8 kC (18 Ah)/10 HR

10 A

10 A

15 A

15 A

10 A

10 A

30 A

Unit: mm (in)

NOTE

Bl – G

Terminal –

Terminal

Plug cap –

Terminal

B/Y –

Ground

W – Ground

* W – W

WATTAGE

ITEM

Headlight HI

LO

Position/Parking light

Brake light/Taillight

Turn signal light

Speedometer light

Turn signal indicator light

High beam indicator light


Oil pressure indicator light

* FI indicator light

BRAKE + WHEEL

ITEM

Rear brake pedal height

Brake disc thickness

Front

Rear

Front

Rear

E-03, 28, 33

60

55

21/5

21/5

21

* LED

* LED

* LED

* LED

LED

LED

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial

Radial

Front

Rear

SPECIFICATION

E-24

←

←

←

21

←

←

←

←

←

←

←

STANDARD

98

(3.86)

4.8 – 5.2

(0.189 – 0.205)

6.6 – 7.0

(0.260 – 0.276)

—

15.870 – 15.913

(0.6248 – 0.6265)

12.700 – 12.743

(0.5000 – 0.5017)

15.827 – 15.854

(0.6231 – 0.6242)

12.657 – 12.684

(0.4983 – 0.4994)

30.230 – 30.306

(1.1902 – 1.1931)

30.230 – 30.306

(1.1902 – 1.1931)

30.150 – 30.200

(1.1870 – 1.1890)

30.150 – 30.200

(1.1870 – 1.1890)

—

—

—

—

VL1500K5 (’05-MODEL) 165

Unit: W

Others

←

←

* 12/5

←

←

←

←

←

←

←

←

←

—

—

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

Unit: mm (in)

LIMIT

—

4.5

(0.18)

6.3

(0.25)

0.30

(0.012)

—

—

—

—

—

166 VL1500K5 (’05-MODEL)

Wheel rim size

ITEM

Tire size

Tire tread depth

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Front fork oil level

Rear shock absorber spring set length

Rear wheel travel

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT

REAR

FUEL + OIL

ITEM

Fuel type

Fuel tank

Engine oil type

Engine oil capacity

Front fork oil type

Front

Front

Front

Rear

STANDARD

140

(5.5)

* 601.5

(23.68)

*192

(7.56)

222.0

(8.74)

118

(4.6)

STANDARD

16 × MT3.50, 16M/C × MT3.50

150/80-16 71H, 150/80-16M/C 71H

—

—

LIMIT

—

* 589

(23.2)

—

—

—

LIMIT

—

—

—

—

1.6

(0.06)

2.0

(0.08)

Unit: mm (in)

NOTE

kPa

200

250

SOLO RIDING kgf/cm 2

2.00

2.50

psi

29

36 kPa

200

250

DUAL RIDING kgf/cm 2

2.00

2.50

psi

29

36

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE

(Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.

Change

* 14.0 L

(3.7/3.1 US/Imp gal)

SAE 10W-40, API SF or SG

3 700 ml

(3.9/3.3 US/lmp qt)

4 300 ml

(4.5/3.8 US/lmp qt)

Filter change

Overhaul

5 000 ml

(5.3/4.4 US/lmp qt)

SUZUKI FORK OIL SS-08 (#10) or equivalent fork oil

LIMIT

E-03, 28, 33

The others

ITEM

Front fork oil capacity (each leg)

Bevel gear oil type

Bevel gear oil capacity

Brake fluid type

Final

STANDARD

*416 ml

(14.1/14.6 US/lmp oz)

Hypoid Gear oil #90 API GL-5

200 – 220 ml

(6.8/7.0 – 7.4/7.7 US/lmp oz)

DOT 4

VL1500K5 (’05-MODEL) 167

LIMIT

168 VL1500K5 (’05-MODEL)

EMISSION CONTROL SYSTEMS

FUEL INJECTION SYSTEM

VL1500K5 motorcycles are equipped with a fuel injection system for emission level control.

This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits.

1 Fuel tank

2 Fuel filter (For high pressure)

3 Fuel pressure regulator

4 Fuel delivery pipe

5 Fuel injector

6 Fuel feed hose

7 Fuel mesh filter (For low pressure)

8 Fuel pump

A Before-pressurized fuel

B Pressurized fuel

C Relieved fuel

VL1500K5 (’05-MODEL) 169

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body.

1 PAIR control solenoid valve

2 PCV hose

A FRESH AIR

B EXHAUST GAS

C

FUEL/AIR MIXTURE

D BLOW-BY GAS

170 VL1500K5 (’05-MODEL)

EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)

The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system (For E-02, 19, 24 and 33). The fresh air is drawn into the exhaust port through the PAIR solenoid valve and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, EOTS, IATS, IAPS and CKPS.


2 PAIR reed valve

3 Fresh air from air cleaner box.

4 Fuel injector

5 ECM

6 HO2 sensor (E-02, 19, 24)

7

Three-way catalyst (E-02, 19, 24, 33)

A FRESH AIR

B EXHAUST GAS

VL1500K5 (’05-MODEL) 171

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or

2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:

• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases.

• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air.

• Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label.

172 VL1500K5 (’05-MODEL)

PAIR (AIR SUPPLY) SYSTEM INSPECTION

HOSES AND PIPES

• Remove the PAIR cover. (

!Page 14)

• Inspect the hoses for wear or damage.

• Inspect that the hoses for secure connection.

PAIR REED VALVE

• Remove the PAIR control solenoid valve. (

!Page 14)

• Remove the reed valve case

1 and PAIR reed valve 2.

• Inspect the reed valve for the carbon deposit.

• If the carbon deposit is found in the reed valve, replace the

PAIR reed valve with a new one.

• Install the reed valve

A and its case B with outlet pipes C the facing the PAIR control solenoid valve

D.

PAIR CONTROL SOLENOID VALVE

• Remove the PAIR control solenoid valve. (

!Page 14)

• Check that air flows through the air inlet port to the air outlet ports.

• If air does not flow out, replace the PAIR control solenoid valve with a new one.

Air flow

Air flow

• Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow.

• If air does not flow out, the solenoid valve is in normal condition.

• Check the resistance between the terminals of the PAIR control solenoid valve.

" Resistance: 20 – 24 Ω at 20 – 30 °C (68 – 86 °F)



If the resistance is not within the standard range, replace the

PAIR control solenoid valve with a new one.

Installation is in the reverse order of removal.

• Connect the lead wire coupler of the PAIR control solenoid valve and PAIR hoses securely.

PAIR system hose routing. (

!Page 175)

VL1500K5 (’05-MODEL) 173

Ω

174 VL1500K5 (’05-MODEL)

PAIR (AIR SUPPLY) SYSTEM DIAGRAM

*1

*3

*2

A FRESH AIR

B EXHAUST GAS


2 PAIR reed valve

3 No. 1 cylinder

4 No. 2 cylinder

*1

From air cleaner

*2 To No. 1 cylinder

*3 To No. 2 cylinder

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING

*1

VL1500K5 (’05-MODEL) 175

*2

20 – 40 mm

(0.79 – 1.57 in) 20 – 40 mm

(0.79 – 1.57 in)

*3

1

PAIR control solenoid valve with PAIR reed valve

*1

Connect the air hose to the air cleaner box.

2 Cushion seat (Apply adhesive agent to the cushion seat) *2 Matching mark (yellow).

3

Wiring harness.

*3 Matching mark (white).

176 VL1500K5 (’05-MODEL)

HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24)

The HO2 sensor coupler is located at the rear side of the fuel tank. (

!Page 87)

• Inspect the HO2 sensor and its circuit referring to flow table of the malfunction code C44 (P0130/P0135).

• Check the resistance between the terminals of the HO2 sensor.

" Resistance: 6.5 – 8.9 Ω at 23 °C (73.4 °F)




If the resistance is not within the standard range, replace the

HO2 sensor with a new one.

NOTE:

* Temperature of the sensor affects resistance value largely.

* Make sure that the sensor heater is at correct temperature.

$

Do not remove the HO2 sensor while it is hot.

'

Be careful not to expose it to excessive shock.

Do not use an impact wrench while removing or installing the HO2 sensor unit.

Be careful not to twist or damage the sensor lead wire.

White

White

WIRING DIAGRAM

E-02, 19, 24

TU

HI

OI

NU

IL

FI

: TURN SIGNAL INDICATOR LIGHT

: HIGH BEAM INDICATOR LIGHT

: OIL PRESSURE INDICATOR LIGHT

: NEUTRAL INDICATOR LIGHT

: ILLUMINATION

: FI INDICATOR LIGHT

SPEEDOMETER

FI

HANDLEBAR SWITCH (R)

HAZARD

SWITCH

OFF

ON

SPEED

SENSOR

ENGINE STOP

SWITCH

OFF

RUN PUSH

STARTER

BUTTON

FRONT BRAKE

LIGHT SWITCH

OFF

ON

TP

SENSOR

IGNITION

COIL #1

IGNITION

COIL #2

SIDE-STAND

SWITCH

HO2

SENSOR

REAR BRAKE

LIGHT SWITCH

ON

OFF

PUSH

FREE

DECOMP

RELAY

DECOMP

SOLENOID

TO

SENSOR

FUEL PUMP

M

FUEL PUMP

RELAY

ECM

FRONT TURN SIGNAL LIGHT (R)

HEADLIGHT

FRONT TURN SIGNAL LIGHT (L)

POSITION LIGHT

(For E-02, 19)

SA

MP

LE

(Only for E-24)

OPTION

HORN HORN-H

HORN-L

PUSH

HORN

BUTTON

L

PUSH

R

TURN SIGNAL

LIGHT SWITCH

PUSH

PASSING

LIGHT

SWITCH

HI

LO

DIMMER

SWITCH

FREE

CLUTCH

LEVER

POSITION

SWITCH

P

LOCK

OFF

ON

IGNITION SWITCH

HANDLEBAR SWITCH (L)

GP

SWITCH

IAP

SENSOR

FRONT

IAP

SENSOR

REAR

STV ACTUATOR

INJECTOR

#1

INJECTOR

#2

IAT

SENSOR

ON

OFF

EOT

SENSOR

OIL

PRESSURE

SWITCH

4 5 6

1 2 3

FUSE BOX

1. HEAD HI

2. HEAD LO

3. FUEL

10 A

10 A

10 A

4. IGNITION

5. SIGNAL

15 A

15 A

6. P-SOURCE 10 A

1

GENERATOR

REGULATOR/

RECTIFIER

PAIR

SOLENOID

VALVE

STARTER

MOTOR

1: MAIN (30 A)

STARTER

RELAY

BATTERY

BRAKE LIGHT/

TAILLIGHT

E-03, 28, 33

TU

HI

OI

NU

IL

FI

: TURN SIGNAL INDICATOR LIGHT

: HIGH BEAM INDICATOR LIGHT

: OIL PRESSURE INDICATOR LIGHT

: NEUTRAL INDICATOR LIGHT

: ILLUMINATION

: FI INDICATOR LIGHT

SPEEDOMETER

FI

HANDLEBAR SWITCH (R)

HAZARD

SWITCH

OFF

ON

SPEED

SENSOR

ENGINE STOP

SWITCH

OFF

RUN PUSH

STARTER

BUTTON

FRONT BRAKE

LIGHT SWITCH

OFF

ON

TP

SENSOR

IGNITION

COIL #1

IGNITION

COIL #2

SIDE-STAND

SWITCH

REAR BRAKE

LIGHT SWITCH

ON

OFF

PUSH

FREE

DECOMP

RELAY

DECOMP

SOLENOID

TO

SENSOR

FUEL PUMP

M

FUEL PUMP

RELAY

ECM

FRONT TURN SIGNAL LIGHT (R)

HEADLIGHT

FRONT TURN SIGNAL LIGHT (L)

SA

MP

LE

OPTION

HORN-L

PUSH

HORN

BUTTON

L

PUSH

R

TURN SIGNAL

LIGHT SWITCH

PUSH

PASSING

LIGHT

SWITCH

HI

LO

DIMMER

SWITCH

FREE

CLUTCH

LEVER

POSITION

SWITCH

P

LOCK

OFF

ON

IGNITION SWITCH

HANDLEBAR SWITCH (L)

GP

SWITCH

STV ACTUATOR

INJECTOR

#1

INJECTOR

#2

IAT

SENSOR

IAP

SENSOR

FRONT

IAP

SENSOR

REAR

ON

OFF

EOT

SENSOR

OIL

PRESSURE

SWITCH

4 5 6

1 2 3

FUSE BOX

1. HEAD HI

2. HEAD LO

3. FUEL

10 A

10 A

10 A

4. IGNITION

5. SIGNAL

15 A

15 A

6. P-SOURCE 10 A

1

GENERATOR

REGULATOR/

RECTIFIER

PAIR

SOLENOID

VALVE

STARTER

MOTOR

1: MAIN (30 A)

STARTER

RELAY

BATTERY

BRAKE LIGHT/

TAILLIGHT

Prepared by

May, 2004

Part No. 99501-39550-01E

Printed in Japan

176

Printed in Japan

K5

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