ELECTRIC STAR T ER

COMPONENT LOCATION

FA2 model shown : STARTER SWITCH

IGNITION SWITCH

ENGINE STOP SWITCH _ _

_ _ _ _ FRONT BRAKE SWITCH

FUSE BOX :

MAIN F USE 1 ( 30 A )

- MAIN F USE 2 ( 10 A )

IGN FUSE (20 A)

O I ODE

PCM / ECM

---4;"':'~

RELAY

S T ARTER INH IBI T OR RELAY

S T ARTER RELAY SWITCH DIODE

STARTER

SW IT CH

STARTER MOTOR

Except FA lIfA2 : GEAR POSITION SWITCH

FA lIFA2 : SHIFT DRUM POSITION SWITCH

SYSTEM DIAGRAM

o

8

BATTERY

Lg / R

Y / R , -

STARTER RELAY

SWITCH

MAl

N 1 FUSE RlBI

(40

AI

1-

RlBI .

-

-------

-f;:;::::~ -_, o..ro-

RIY

MAIN2FUSE

~

DIODE SWITCH ( 10 A )

STARTER

INHIBITOR

*'

G

G

M STARTER

MOTOR

~

/ R

DIODE

RELAY STARTER

SWITCH

Bu

--0'--0-

ENGINE STOP SWI T CH

811\'V --0

~~~~ \ USE

81

I

~

1

B,/W

0

vv v

Bu

~-----'

-

,-

Y / R

-----o ~Bl / Br ~p

'1--

LgIR

FRONT BRAKE

INHIBITOR SWITCH

- - - - - - - - + 0 -

P

0

2

9

0

UGHT

FUSE

~

( 20 A )

PCMlECM

BuiY

-Il

G

..;..

O R

~;ARPOSITION

(NEUTRAL )

SWITCH

6·3

ELECTRIC STARTER

5T ARTER MOTOR

REMOVAUINSTALLA TION

Rem ove the air cleaner housing (page 7-17) .

Disconnecllhe battery negative H cable (page 22-5) .

Remove the following :

terminal nul (1] (open the rubber cap (2])

slarter motor cable [3]

two mounting bolts (4) and ground cable [5)

Remove the starter motor [1] from t he rear crankcase ..,, ~~::" cover .

Remove the O-ring (2) from t he slarter moior.

Coat a new a·ring with engine oil and install it into the starter motor groove.

Apply molybdenum oil solution to the starter motor shaft splines [3).

Install the removed parts in the reverse order of removal.

OISASSEMBL YIASSEMBL Y

I

NOTICE

I

The anna/ure coil may be damaged if the magnet in the motor case pulls t he annature against t he case .

ARMATURE

SEAL RING

Ell

MOTOR CASE

6-4

NUT

Align

,OIL SEAL

~

WASHER

BRUSH

TERMINAL

STOPPER

REAR COVER

BRUSH HOLDER

SPRINGS

J

Af/{;¢ ,

NEGATIVEBRUSHSET~

POSITIVE i

Align

TERMINAL V

BOLT

3.7 N ' m (004 kgf -m, 2 .

7Ibf-ft)

FRONTC~

4 .9 N 'm (0.5 kgf-m, 3.6 Ibf-ft)

INSPECTION

Check the oil seal [1] and ball bearing [2] in the front cover for wear or damage.

ELECTRIC STARTER

[21

Check the commutator bars [I] for damage or abnormal wear.

Check the commutator bars of the arma t ure [2) for discoloration .

Clean any metal debris from between commutator bars .

NOTE :

• Do not use emery or sand paper on the commuta t or.

Check for continuity between pairs of commutator bars

11 I·

There should be continuity .

CONTINUITY :

[1]

11]

Check for continuity between each commutator bar [I] and the armature shaft {2].

There should be no continuity .

NO CONTINUITY : [2]

6-5

ELECTRIC STARTER

Check for continuity between the starter motor cable terminal 11] and positive brushes 12].

There should be continuity.

Check for continuity between the positive brushes [1J and the rear cover (2].

~======:;:~==~~===== ~

There should be no continuity.

Check for continuity between the negative brushes [31 and the rear cover.

There should be continuity.

Check for continuity between the positive and negative brushes.

There should be no continuity.

STARTER RELAY SWITCH

OPERATION INSPECTION

Remove the rear fender cover (pa ge 2-8).

Turn the ignition switch ON and engine stop swi t ch "O~.

Shift the transmission into neutral or apply front brake .

Push the starter switch.

The relay coil is normal if the starter relay switch [1] clicks.

If you don't hear the switch "CLICK" , inspect the relay switch using the procedure below .

CIRCUIT INSPECTION

Ground Line :

Disconnect the starter relay switch 2P (Green) , - - - - - - - - - - - - - - - - - , connector (page 6-7).

Check for continuity between the wire harness side 2P

(Green) connector [1J terminal and ground .

Con nec t i on : Gr ee n Gr o und

There should be continuity at all limes. j

,

,

6-6

ELECTRIC STARTER

Power I nput Line ;

Disconnect the starter relay switch 2P ( Green ) - - - - - - - - - - connec t or ( page 6-7 ) . [1)

Turn the ignition swi t ch ON and engine stop sWitch yt .

Shift the transmission into neutral or apply front brake .

Measure the voltage between the Wife harness side 2P

( Green) connector 111 terminal and ground .

Connection : Ye llo w / red (+) Ground

H

There should be battery vol la ge only when t he starter switch IS pushed . L

CONTINUITY INSPECTION

Remove the s t a rt er relay swi t ch [1J (page 6 7) .

Connect the fully cha rged 12 V [2) battery to the starter relay switch 2 P (G reen) connector [3J terminals .

Connection: Battery (+) terminal - Yellow / red

Battery ( -) terminal Light green / r ed

There should be continuity between the cable terminals while the battery is connecte d , and no continuity when the battery is d i sconnected.

Lg / R

11 1

®

REMOVALIINSTALLA TION

Disconneclthe battery negative H cable ( page 22 5) .

Disconnect the starter relay switch 2P (Green) connec t or [1].

Remove the terminal nuts [2) . spring washers [3) . battery positive (+) cable [4) and starter motor cable [5] .

Remove th e starter relay switch [6] fr om the rear f ender with t he shoc k rubber (71.

Remove the starter relay switch from the shock rubbe r .

Installation is in the reverse order of removal.

(31 121

6-7

ELECTRIC STARTER

STARTER INHIBITOR RELAY/STARTER

RELAY SWITCH DIODE

INSPECTION

Remove the PCM f ECM from the ECM stay (page 4-36) .

Remove the screws [1] and relay box lid [2J.

Remove the starter inhibitor relay [1) and starter relay switch diode [2).

1

Connect an ohmmeter to the starter Inhibitor relay [1] , - - - - - , - , - - - - - - - - - - - - - , terminals as shown and check for continuity. {1 J

There should be continuity. \

Connect a 12 V battery to Ihe relay terminals as shown.

There should be no continuity only when the 12 V battery is connected.

,

Check for continuity between the terminals of the diode

III

~=========== ====~

III

When Ihere is continuity, a small resistance value will register .

If there is continuity in one direction . the diode is normal.

•

; j j j

I

6·8

7. FUEL SYSTEM

SERVICE INFORMATION · ······ · ·· · ··· ······· ······ ·· 7-2

SYSTEM COMPONENTS· ········· ····················7-3

FUEL LINE TROUBLESHOOTING·· ············· 7-4

FUEL LINE INSPECTION ······························7-5

FUEL PUMP UNIT ······ ·································7-11

FUEL TANK · ···· · ··· · ···· · ····· · ···························716

AIR CLEANER HOUSING .......................... 7-17

THROTILE BODy ...................................... 7-18 lAC V .... _ ....

.. _ _ ...... _._ ....... _. 7-21

FUEL INJECTOR · .... · .... ·· .... ··· .... · .. ····· .. · .. ····7-22

7-1

FUEL SYSTEM

SERVICE INFORMATION

GENERAL

This section covers service of the mechanical system of the PGMF I system and the fuel supply system. For electrical system service of the PGM-FI system, see PGM-Ft System section (page 4-2) .

Before disconnecting the fuel feed hose , relieve pressure from the system (page 7-5) .

Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend , resulting in loss of vehicle control.

Work in a well ventilated area . Smoking or allowing flames or sparks in the work area or where gasoline is sto r ed can cause a fire or explosion .

Do nOI snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle operation .

Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering the intake port after the throttle body has been removed.

Do not damage t he throttle body. It may cause incorrect throttle valve operation .

Prevent dirt and debris from entering the throttle bore, I ACV, sensor hole and fuel feed hose . Clean them using compressed air.

The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.

Do not loosen or tighten the white painted screws and nut of the throttle body . loosening or tightening them can cause throttle body malfunction.

Tighten the yellow pain t ed screws of the throttle body to the specified torque.

When disassembling the fuel system parts, note the location of the O-rings. Replace t hem with new ones upon reassembly .

When servicing the fuel feed hose , be careful nolto bend or kink it.

TOOLS

Fuel connector remover

070MF-HP50200

Fuel pressure gauge

0740B-0040004

Pressure gauge manifold

07ZAJ-S5A0111 (not available in

U.S.A.)

1 , or 07AMF-001A100 (U .

S.A. only ~ or

07406-004000C or 07406-0040008

Hose attachment , 9 mm/9 mm

(U.S

.

A. only)

Pressure manif' ol"d ~ h ~ o ~ ,~e ------1 ---C A"d<-,~p~le~,~, ~m~'~le ;--------~

07ZAJ-S5A0120 (not available in

U,SA)

07AMJ-HW3A100 (U.S.A. only) 07AA J -S6MA200 (U .

S.A. only)

1

•

•

j

Adapter , female

07AAJ-SBMA400 (U .

S .

A . only)

7-2