1. Manuals
  2. Brands
  3. Excelsior-HENDERSON Manuals
  4. Motorcycle
  5. HCX 1999
  6. Service handbook

Excelsior-HENDERSON HCX 1999 Service Handbook

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the HCX 1999 and is the answer not in the manual?

Questions and answers

Related Manuals for Excelsior-HENDERSON HCX 1999

Summary of Contents for Excelsior-HENDERSON HCX 1999

  • Page 2 FOREWORD 6999-0003 7/15/99 All text, photographs, and illustrations in this handbook are based on the most current product information available at the time of publication. Product improvements or other changes may result in differences between this handbook and the motorcycle. Excelsior-Henderson reserves the right to make production changes at any time, without notice and without incurring any obligation to make the same or similar changes to motorcycles previously built.
  • Page 3 FOREWORD INTRODUCTION DEALER SUPPORT Notice NORTH/NORTHEAST REGIONAL SALES This is a preliminary draft of the Service PH 1-612-873-7032 Handbook. It is a subset of the information and FAX 1-612-873-7030 procedures that will appear in the final version. A WEST/NORTHWEST REGIONAL SALES limited number of photographs and illustrations appear in this draft;...

  • Page 4: Service Information

    FOREWORD REPLACEMENT PARTS SERVICE INFORMATION Use only genuine Excelsior-Henderson replacement Notice parts. This is your insurance the parts you are using • Use genuine Excelsior-Henderson replace- are specifically designed, engineered and ment parts and lubricants, or substitute parts manufactured for an Excelsior-Henderson motorcycle. and/or lubricants recommended by Excelsior- SERVICE BULLETINS Henderson.
  • Page 5 FOREWORD 6999-0003 7/15/99...

  • Page 6: Table Of Contents

    CONTENTS ROUTINE MAINTENANCE ... . . 1 BODY/EXHAUST ..... 2 LUBRICATION SYSTEM .
  • Page 7 6999-0003 7/15/99...

  • Page 8: Routine Maintenance

    ROUTINE MAINTENANCE 6999-0003 7/15/99...

  • Page 9: Routine Maintenance

    1. ROUTINE MAINTENANCE SERVICE INFORMATION ..1-1 HYDRAULIC CONTROLS ...1-6 TROUBLESHOOTING ... . . 1-2 FLUID LEVEL .

  • Page 10: Troubleshooting

    ROUTINE MAINTENANCE TROUBLESHOOTING MAINTENANCE INTERVALS 6999-0003 7/15/99...

  • Page 11: Engine Oil

    ROUTINE MAINTENANCE (StepNumber) ENGINE OIL (StepNumber) AIR FILTER ELEMENT (StepNumber) DRIVE BELT Check the drive belt condition . . . 6999-0003 7/15/99...

  • Page 12: Check Tension

    ROUTINE MAINTENANCE (StepNumber) CHECK TENSION 1. Mount the motorcycle and bring it to a vertical position. Notice • The motorcycle should be dry and at room temperature. • The rear suspension should be properly adjusted (see SHOCK ABSORBER ADJUSTMENT page 14-2).

  • Page 13: Throttle Cables

    ROUTINE MAINTENANCE (StepNumber) 3. Tighten the adjuster jam nuts. 4. Tighten the rear axle castle nut. Torque: 111 ft-lbs 5. Install a new rear axle cotter pin. Caution Always use a new cotter pin when installing the rear axle nut. 1.

  • Page 14: Oxygen Sensor

    ROUTINE MAINTENANCE (StepNumber) OXYGEN SENSOR (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) HYDRAULIC CONTROLS inspect all hoses and connections . . . Make sure the front and rear brake light switches . . . (StepNumber) FLUID LEVEL (StepCaptionHold) “For demonstration only”...

  • Page 15: Brake Pads

    ROUTINE MAINTENANCE (StepNumber) BRAKE PADS (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) SPARK PLUGS (StepNumber) STEERING HEAD BEARINGS Turn bars side to side . . . Lift and . . . front to back To adjust, refer to Front Suspension Chapter.

  • Page 16: Tires

    ROUTINE MAINTENANCE (StepNumber) TIRES (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) WHEELS AND SPOKES (StepNumber) SIDESTAND (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) NUTS/BOLTS/FASTENERS 6999-0003 7/15/99...

  • Page 17: Road Test

    ROUTINE MAINTENANCE (StepNumber) ROAD TEST (StepNumber) (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” 6999-0003 7/15/99...
  • Page 18 ROUTINE MAINTENANCE 1-10 6999-0003 7/15/99...
  • Page 19 ROUTINE MAINTENANCE 1-11 6999-0003 7/15/99...
  • Page 20 ROUTINE MAINTENANCE NOTES 1-12 6999-0003 7/15/99...
  • Page 21 ROUTINE MAINTENANCE 1-13 6999-0003 7/15/99...
  • Page 22 BODY/EXHAUST 6999-0003 7/15/99...

  • Page 23: Body/Exhaust

    2. BODY/EXHAUST SERVICE INFORMATION ..2-1 FRONT FENDER ....2-8 TROUBLESHOOTING ... . . 2-2 REMOVAL .

  • Page 24: Troubleshooting

    BODY/EXHAUST TROUBLESHOOTING Excessive exhaust noise Poor performance • Broken exhaust system components • Dents of kinks in exhaust header • Exhaust leak • Exhaust leak • Plugged muffler 6999-0003 7/15/99...

  • Page 25: Saddle

    BODY/EXHAUST (StepNumberStart) SADDLE REMOVAL 1. Remove the tandem saddle screw. Lift the back of the tandem saddle slightly and pull it rearward, out from the mounting posts. 10187 1. TANDEM SADDLE 3. POSTS 2. SCREW (StepNumber) 2. Remove the rider’s saddle screws and tandem saddle posts.

  • Page 26: Draining

    BODY/EXHAUST (StepNumber) DRAINING USING THE EXAMINATOR DIAGNOSTIC TOOL 1. Remove the rider’s saddle and tandem saddle (see Chapter 2. BODY/EXHAUST). 2. Remove the rear fuel tank mounting screw and isolator. 10190 1. REAR TANK MOUNT (StepNumber) 3. Place a rag between the front of the fuel tank and the top triple clamp to protect the tank finish.
  • Page 27 BODY/EXHAUST (StepNumber) USING THE FUEL PUMP POWER JUMPER WIRE 1. Remove the saddle(s) (see SADDLE REMOVAL page 2-3). 2. Remove the rear fuel tank mounting screw and isolator. 3. Remove the instrument cluster from the fuel tank (see Chapter 18. LIGHTS/GAUGES/SWITCHES).

  • Page 28: Removal

    BODY/EXHAUST (StepNumber) 11. Connect the fuel pump power jumper wire to the wiring harness and the fuel pump. 12. Attach the ground clamp to motorcycle ground. Tool: Fuel Pump Power Jumper Wire EH-6999-0040A 1. FUEL PUMP POWER JUMPER WIRE (StepNumber) 13.

  • Page 29: Installation

    BODY/EXHAUST (StepNumber) 7. Place a rag between the front of the fuel tank and the triple clamp to protect the tank. 8. Lift the rear of the fuel tank two or three inches and disconnect the tank vent tube. Caution Lifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging the finish.

  • Page 30: Front Fender

    BODY/EXHAUST (StepNumber) 3. Place a rag between the front of the fuel tank and the triple clamp to protect the tank. Caution Lifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging the finish.
  • Page 31 BODY/EXHAUST (StepNumber) Disconnect the brake hose from the brake caliper. Pass the brake hose upward and out of the front fender. Caution Cover or plug exposed brake fluid passages to prevent foreign objects from entering the brake system. Remove the caliper rod mount from the rigid fork and set the brake caliper assembly aside.

  • Page 32: Installation

    BODY/EXHAUST (StepNumber) INSTALLATION Slide the fender upward onto the struts and the rigid fork. Install the fender mounting screws. Install the brake caliper assembly by attaching the caliper rod mount to the rigid fork. Torque: Pass the brake hose through the front fender grommet and connect it to the caliper assembly.

  • Page 33: Installation

    BODY/EXHAUST (StepNumber) 3. Remove the fender extension screw. 4. Support the fender, and remove front fender support mounting screws. Remove the fender assembly. 1. FENDER EXTENSION 3. MOUNTING SCREWS SCREW 2. FENDER SUPPORT (StepNumber) 5. Remove the screws that secure the fender supports to the fender and remove the supports.
  • Page 34 BODY/EXHAUST (StepNumber) Gently pull the oxygen sensor wire out from under the side cover and disconnect the wire at the harness connecter. Notice Remove oxygen sensor from the exhaust header only if exhaust header will be replaced. 1. OXYGEN SENSOR 2.

  • Page 35: Inspection

    BODY/EXHAUST (StepNumber) INSPECTION Inspect the condition of the exhaust headers. Severe dents, kinks, and cracks in the pipe will reduce the engines ability to evacuate exhaust gasses properly, reducing engine performance. Check the condition of the exhaust header mounting studs. Make sure they are not bent, and that the threads are not damaged.
  • Page 36 BODY/EXHAUST (StepNumber) Connect the oxygen sensor wire, and push the connector under the side cover. Replace any wire ties previously removed. Notice Make sure all wires are secure from vibration and direct contact to high temperature surfaces. Install all exhaust system heat shields and tighten the heat shield clamps.
  • Page 37 BODY/EXHAUST 2-15 6999-0003 7/15/99...
  • Page 38 LUBRICATION SYSTEM 10732 6999-0003 7/15/99...

  • Page 39: Lubrication System

    3. LUBRICATION SYSTEM SERVICE INFORMATION ..3-1 OIL SCAVENGE PUMP... . .3-7 TROUBLESHOOTING ... . . 3-2 REMOVAL .

  • Page 40: Troubleshooting

    LUBRICATION SYSTEM OIL FLOW 10734 SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Oil system pressure 45 - 75 psi Oil pressure pump Gerotor tip clearance 0.008 in Gerotor body clearance 0.009 in Gerotor end play 0.0035 in Oil scavenge pump Gerotor tip clearance 0.008 in Gerotor body clearance 0.009 in...

  • Page 41: Oil Pressure Switch

    LUBRICATION SYSTEM (StepNumber) OIL PRESSURE SWITCH The oil pressure switch is located on the right side of the crankcase behind the timing gear cover. The switch is powered through the Lights fuse and the low oil pressure indicator lamp. At startup, the oil pressure switch is closed and the low oil pressure indicator lamp is illuminated.

  • Page 42: Removal

    LUBRICATION SYSTEM (StepNumber) REMOVAL 1. Drain the engine oil and remove the oil filter (see ENGINE OIL page 1-3). 2. Remove the front exhaust header and muffler (see EXHAUST SYSTEM REMOVAL page 2-11). 3. Remove the pump cover screws and the pump cover. 4.

  • Page 43: Inspection

    LUBRICATION SYSTEM (StepNumber) 4. Remove the housing alignment pins. 5. Remove the gerotor assembly. Caution The georotor assembly must be reinstalled exactly as it was removed from the oil pump. Use a permanent marker to identify the inner and outer surfaces of the gerotor components.

  • Page 44: Assembly

    LUBRICATION SYSTEM (StepNumber) 4. Use a straight edge and a feeler gauge to measure the gerotor end clearance. Service Limit: 0.0035 in Replace components that are worn, damaged, or exceed their service limits. 10750 1. FEELER GAUGE 3. GEROTOR 2. STRAIGHT EDGE (StepNumber) ASSEMBLY 1.

  • Page 45: Installation

    LUBRICATION SYSTEM (StepNumber) INSTALLATION 1. Install new O-rings onto the relief valve. Notice Always use new O-rings during installation. 2. Coat the relief valve with clean engine oil and push it into the engine case. 10738 1. RELIEF VALVE engine oil (StepNumber) 3.

  • Page 46: Disassembly

    LUBRICATION SYSTEM (StepNumber) 4. Remove the scavenge pump mounting screws and carefully pull the pump straight out of the engine case. 5. Iff applicable, remove the scavenge pump drive coupling. 6. Remove and discard the O-rings from the pump ports. 10745 1.

  • Page 47: Assembly

    LUBRICATION SYSTEM (StepNumber) 4. Use a straight edge and a feeler gauge to measure the gerotor end clearance. Service Limit: 0.0035 in Notice Make sure to inspect both gerotor assemblies and their respective pump bodies. Replace components that are worn, damaged, or exceed their service limits.

  • Page 48: Installation

    LUBRICATION SYSTEM (StepNumber) INSTALLATION 1. Place new O-rings in the pump ports. 2. Install the pump drive coupling. 3. Position the scavenge pump onto the engine case and install the mounting screws. Torque: 8 ft-lbs 10745 1. SCAVENGE PUMP 3. O-RINGS 2.
  • Page 49 LUBRICATION SYSTEM NOTES 3-11 6999-0003 7/15/99...
  • Page 50 ENGINE CONTROL SYSTEM 6999-0003 7/15/99...

  • Page 51: Engine Control System

    4. ENGINE CONTROL SYSTEM SERVICE INFORMATION ..4-1 AIR CLEANER ....4-139 TROUBLESHOOTING ... . . 4-3 THROTTLE BODY .
  • Page 52 ENGINE CONTROL SYSTEM SPECIFICATIONS Unit: inch ITEM STANDARD SERVICE LIMIT 820Ω @ 120° F Air temperature sensor resistance 1210Ω @ 100° F 1830Ω @ 80° F 2840Ω @ 60° F 3500Ω @ 50° F Engine temperature sensor resistance 150Ω @ 230° F 422Ω...
  • Page 53 ENGINE CONTROL SYSTEM TOOLS Examinator Diagnostic Tool ... . 6999-0009 Fuel Pump Power Jumper Wire ..EH-6999-0040A Fuel Pump Puller ....EH-6999-0039A TROUBLESHOOTING Engine Will Not Crank...

  • Page 54: System Operation

    ENGINE CONTROL SYSTEM SYSTEM OPERATION The fuel injection system is a port sequential, closed devices that do the work, such as the fuel pump, fuel loop type. This means the system delivers fuel to each injectors, and ignition coils. cylinder in sequence and that fueling and ignition are The ECM performs the following tasks: adjusted based on the combustion efficiency.
  • Page 55 ENGINE CONTROL SYSTEM CALCULATING AIR FLOW The throttle body is equipped with an idle air control (IAC) valve and stepper motor assembly. This valve pro- The ECM uses air pressure, air temperature, engine vides a path for air flow during startup and at low engine speed, and throttle position to calculate the air flow.
  • Page 56 ENGINE CONTROL SYSTEM CONTROLLING FUEL VAPOR While the engine is not running, vapor pressure that builds in the fuel tank is released and trapped in the The evaporative system provides a path for fuel canister. When the engine is running, the ECM vapors to escape from the fuel tank.
  • Page 57 ENGINE CONTROL SYSTEM CONTROLLING FUEL FLOW and releasing fuel into the intake port. The engine tem- perature sensor enables the ECM to adjust the injection Fuel flow depends on constant fuel pressure and the duration and thus the fuel flow for all operating tempera- amount of time that the fuel injector is open (injection tures.
  • Page 58 ENGINE CONTROL SYSTEM CONTROLLING INJECTION TIMING AND bustion process, the ECM matches injection timing and the rapid decrease in engine speed that accompanies IGNITION TIMING the number 1 cylinder compression stroke. The road The ECM controls fuel injection and ignition timing speed sensor, located on top of the transmission case, based on information it receives from the crankshaft generates voltage pulses as the teeth of the fifth gear...
  • Page 59 ENGINE CONTROL SYSTEM OPTIMIZING COMBUSTION increasing or decreasing the injection duration based on these signals. This causes the calculated air-to-fuel ratio Oxygen content in the exhaust is a measure of combus- to rise and fall about the ideal air-to-fuel ratio for the cur- tion efficiency.
  • Page 60 ENGINE CONTROL SYSTEM MANAGING SYSTEM DIAGNOSTICS When fault-producing conditions cease, and after a suf- ficient number of warm-up cycles, the ECM will extin- Each sensor or component has an acceptable operating guish the check engine lamp and clear fault codes from voltage or resistance range that the ECM recognizes.
  • Page 61 ENGINE CONTROL SYSTEM DIAGNOSING FAULTS Using the Examinator™ diagnostic tool, you can read Pins are identified by number or letter as labeled on the fault codes stored in memory and display other engine connector. For example, power to the throttle position performance information.
  • Page 62 ENGINE CONTROL SYSTEM FAULT CODE P0105 BAROMETRIC PRESSURE SENSOR CIRCUIT FAULT (StepNumber) DESCRIPTION Out-of-range barometric pressure reading. Possible causes: • Plugged ECM vent tube • ECM malfunction. DISPLAY FAULT HISTORY DATA Make note of the air pressure value. (StepNumber) INSPECT AIR PRESSURE SENSOR TUBE Remove and inspect the ECM vent tube.
  • Page 63 ENGINE CONTROL SYSTEM FAULT CODE P0112 AIR TEMPERATURE SENSOR CIRCUIT FAULT: SHORT TO GROUND Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DESCRIPTION Low voltage in the air temperature sensor circuit interpreted as a high air temperature condition. Possible causes: •...
  • Page 64 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from the air temperature sensor (P8). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 65 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Air Temp Disconnect the harness from the air temperature sensor (P8). Is there continuity between Air Temp and motorcycle ground? •...
  • Page 66 ENGINE CONTROL SYSTEM FAULT CODE P0113 AIR TEMPERATURE SENSOR CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO POWER Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DESCRIPTION High voltage condition in the air temperature sensor circuit interpreted as a low temperature condition. Possible open circuit or short a 5 or 12 volt power source.
  • Page 67 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from the air temperature sensor (P8). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 68 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR OPEN CIRCUIT Air Temp Is there continuity between Air Temp and P8B-1? between Sensor Gnd and P8B-2? •...
  • Page 69 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR SHORT TO +12V Was the air temperature sensor voltage greater than 5.5 volts? • Yes - Trace air temperature sensor signal wiring (Gn/W) for a short to +12 volts. Repair wiring. Reconnect the harness, clear the fault codes, and run the engine.
  • Page 70 ENGINE CONTROL SYSTEM FAULT CODE P0117 ENGINE TEMPERATURE SENSOR CIRCUIT FAULT: SHORT TO GROUND Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DESCRIPTION Low voltage in the engine temperature sensor circuit interpreted as a high engine temperature condition. Possible short to ground.
  • Page 71 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from the engine temperature sensor (P5). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, disconnect the harness from the sensor and continue.
  • Page 72 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Engine Temp Disconnect the harness from the engine temperature sensor (P5).
  • Page 73 ENGINE CONTROL SYSTEM FAULT CODE P0118 ENGINE TEMPERATURE SENSOR CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO POWER Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DESCRIPTION High voltage condition in the engine temperature sensor circuit interpreted as a low temperature condition. Possible open circuit or short to a 5 or 12 volt power source.
  • Page 74 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from the air temperature sensor (P8). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, disconnect the harness from the sensor and continue.
  • Page 75 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR OPEN CIRCUIT Engine Temp Disconnect the harness from the engine temperature sensor (P5).
  • Page 76 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR SHORT TO +12V Was the engine temperature sensor voltage greater than 5.5 volts? • Yes - Trace engine temperature sensor signal wiring (Pk/Y) for a short to +12 volts. Repair wiring. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, contact dealer service.
  • Page 77 ENGINE CONTROL SYSTEM FAULT CODE P0119 ENGINE TEMPERATURE SENSOR CIRCUIT FAULT: VOLTAGE TOO HIGH Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DESCRIPTION High voltage in the engine temperature sensor circuit interpreted as a low engine temperature condition. Possible short to a 5 volt power supply.
  • Page 78 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from the engine temperature sensor (P5). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, disconnect the harness from the sensor and continue.
  • Page 79 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR INTERNAL SHORT Sensor Engine Temp Disconnect the harness from the engine temperature sensor (P5).
  • Page 80 ENGINE CONTROL SYSTEM FAULT CODE P0122 THROTTLE POSITION SENSOR CIRCUIT FAULT: LOW INPUT VOLTAGE Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DESCRIPTION Low voltage in the throttle position sensor circuit interpreted as a larger throttle opening. Possible open or short circuit. DISPLAY FAULT HISTORY DATA Make note of the throttle position value.
  • Page 81 ENGINE CONTROL SYSTEM (StepNumber) TEST THROTTLE POSITION SENSOR Use the Examinator diagnostic tool to display the throttle position. While observing the throttle position value, slowly roll the throttle from fully closed to fully open. Does the value increase steadily? • Yes - Continue. •...
  • Page 82 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Throttle Disconnect the harness from the throttle position sensor (P7). Is there continuity between Throttle and motorcycle ground.
  • Page 83 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR INTERNAL SHORT Sensor Throttle Is there continuity between Throttle and Sensor Gnd? • Yes - Repair wiring. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, contact dealer service. •...
  • Page 84 ENGINE CONTROL SYSTEM FAULT CODE P0123 THROTTLE POSITION SENSOR CIRCUIT FAULT: HIGH INPUT VOLTAGE Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DESCRIPTION High voltage in throttle position sensor circuit interpreted as a smaller throttle opening. Possible short to a power source. DISPLAY FAULT HISTORY DATA Make note of the throttle position value.
  • Page 85 ENGINE CONTROL SYSTEM (StepNumber) TEST THROTTLE POSITION SENSOR Use the Examinator diagnostic tool to display the throttle position. While observing the throttle position value, slowly roll the throttle from fully closed to fully open. Does the value increase steadily? • Yes - Continue. •...
  • Page 86 ENGINE CONTROL SYSTEM (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? • Yes - Continue. • No - Fasten the ECM connectors. Clear the fault codes and run the engine. If the fault reoccurs, continue. 10270 (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2).
  • Page 87 ENGINE CONTROL SYSTEM FAULT CODE P0170, 1171 AIR/FUEL FEEDBACK FAULT: MAXIMUM RICH 10233 (StepNumber) DESCRIPTION Calculated fuel demand has reached the maximum limit. Possible causes: • Incorrect engine tune • Engine tune variables out of range • Intake or exhaust air leak •...
  • Page 88 ENGINE CONTROL SYSTEM (StepNumber) DISPLAY SENSOR DATA Run the engine and record the following data: • Short term fuel trim • Long term fuel trim • Oxygen sensor voltage • Engine temperature and sensor voltage • Throttle position and sensor voltage •...
  • Page 89 ENGINE CONTROL SYSTEM (StepNumber) CHECK FUEL LEVEL Is there sufficient fuel in the fuel tank? • Yes - Continue. • No - Fill fuel tank and continue. (StepNumber) INSPECT OXYGEN SENSOR Is the oxygen sensor fastened properly? Is the connector (P4) intact and fastened properly? •...
  • Page 90 ENGINE CONTROL SYSTEM (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? • Yes - Continue. • No - Fasten the ECM connectors. Clear the fault codes and run the engine. If the fault reoccurs, continue. 10270 (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2).
  • Page 91 ENGINE CONTROL SYSTEM (StepNumber) INSPECT BRACKET FASTENERS Inspect the fasteners on the throttle body and fuel rail brackets. Are the brackets fastened securely? • Yes - Continue. • No - Tighten bracket screws as needed. (StepNumber) INSPECT INTAKE COLLARS Inspect the intake collars, seals, and fasteners? Are the intake collars fastened securely to the cylinder heads? •...
  • Page 92 ENGINE CONTROL SYSTEM (StepNumber) MEASURE FUEL PRESSURE Connect a pressure gauge to the Schrader valve on the fuel rail. Run the fuel pump and measure the fuel pressure. Is the value in range? Standard: 45 - 51 psi • Yes - Inspect fuel hose for blockage. If none is found, replace the fuel pump.
  • Page 93 ENGINE CONTROL SYSTEM (StepNumber) INSPECT EXHAUST PIPES AND MUFFLERS Inspect exhaust pipes for air leaks, particularly the number 2 exhaust on which the oxygen sensor is mounted. Are repairs needed? • Yes - Make necessary repairs. Clear the fault codes and run the engine.
  • Page 94 ENGINE CONTROL SYSTEM FAULT CODE P0170, 1172 AIR/FUEL FEEDBACK FAULT: MAXIMUM LEAN 10233 (StepNumber) DESCRIPTION Calculated fuel demand has reached the minimum limit. Possible causes: • Incorrect engine tune • Engine tune variables out of range • Insufficient air flow •...
  • Page 95 ENGINE CONTROL SYSTEM (StepNumber) DISPLAY SENSOR DATA Run the engine and record of the following data: • Short term fuel trim • Long term fuel trim • Oxygen sensor voltage • Engine temperature and sensor voltage • Throttle position and sensor voltage •...
  • Page 96 ENGINE CONTROL SYSTEM (StepNumber) INSPECT OXYGEN SENSOR Is the oxygen sensor fastened properly? Is the connector (P4) intact and fastened properly? • Yes - Continue. • No - Secure sensor and connector. Clear the fault codes and run the engine. If the fault reoccurs, continue. (StepNumber) TEST FOR SHORT TO +12V Does the fault history data or the sensor data show an...
  • Page 97 ENGINE CONTROL SYSTEM (StepNumber) INSPECT IAC VALVE Inspect the idle air control for obstructions. Are repairs needed? • Yes - Make repairs. Clear the fault codes and run the engine. If the fault reoccurs, continue. • No - Continue. (StepNumber) MEASURE FUEL PRESSURE Connect a pressure gauge to the Schrader valve on the fuel rail.
  • Page 98 ENGINE CONTROL SYSTEM (StepNumber) REPLACE FUEL INJECTORS Replace the fuel injectors. Reconnect the harness, clear the fault codes, and run the engine. Does the fault reoccur? • Yes - Reinstall the original fuel injectors and continue. • No - Repair complete. (StepNumber) REPLACE ECM Replace the ECM and load the current engine tune.
  • Page 99 ENGINE CONTROL SYSTEM FAULT CODE P0170, 1178 AIR/FUEL FEEDBACK FAULT: MAXIMUM AIR LEAKAGE ADAPTION 10233 (StepNumber) DESCRIPTION Calculated air demand has reached the maximum limit. Possible causes: • Incorrect engine tune • Engine tune variables out of range • Insufficient air flow •...
  • Page 100 ENGINE CONTROL SYSTEM (StepNumber) DISPLAY SENSOR DATA Run the engine and warm it to closed loop operation. Record of the following data: • Short term fuel trim • Long term fuel trim • Oxygen sensor voltage • Engine temperature and sensor voltage •...
  • Page 101 ENGINE CONTROL SYSTEM (StepNumber) INSPECT OXYGEN SENSOR Is the oxygen sensor fastened properly? Is the connector (P4) intact and fastened properly? • Yes - Continue. • No - Secure sensor and connector. Clear the fault codes and run the engine. If the fault reoccurs, continue. (StepNumber) TEST FOR SHORT TO +12V Does the fault history data or the sensor data show an...
  • Page 102 ENGINE CONTROL SYSTEM (StepNumber) INSPECT IAC VALVE Inspect the idle air control for obstructions. Are repairs needed? • Yes - Make repairs. Clear the fault codes and run the engine. If the fault reoccurs, continue. • No - Continue. (StepNumber) MEASURE FUEL PRESSURE Connect a pressure gauge to the Schrader valve on the fuel rail.
  • Page 103 ENGINE CONTROL SYSTEM (StepNumber) REPLACE FUEL INJECTORS Replace the fuel injectors. Reconnect the harness, clear the fault codes, and run the engine. Does the fault reoccur? • Yes - Reinstall the original fuel injectors and continue. • No - Repair complete. (StepNumber) REPLACE ECM Replace the ECM and load the current engine tune.
  • Page 104 ENGINE CONTROL SYSTEM FAULT CODE P0170, 1179 AIR/FUEL FEEDBACK FAULT: MINIMUM AIR LEAKAGE ADAPTION 10233 (StepNumber) DESCRIPTION Calculated air demand has reached the minimum limit. Possible causes: • Incorrect engine tune • Engine tune variables out of range • Excess air flow •...
  • Page 105 ENGINE CONTROL SYSTEM (StepNumber) DISPLAY SENSOR DATA Run the engine and record of the following data: • Short term fuel trim • Long term fuel trim • Oxygen sensor voltage • Engine temperature and sensor voltage • Throttle position and sensor voltage •...
  • Page 106 ENGINE CONTROL SYSTEM (StepNumber) CHECK FUEL LEVEL Is there sufficient fuel in the fuel tank? • Yes - Continue. • No - Fill fuel tank and continue. (StepNumber) INSPECT OXYGEN SENSOR Is the oxygen sensor fastened properly? Is the connector (P4) intact and fastened properly? •...
  • Page 107 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Oxygen Disconnect the harness from the oxygen sensor (P4). Is there continuity between Oxygen and motorcycle ground? •...
  • Page 108 ENGINE CONTROL SYSTEM (StepNumber) INSPECT INTAKE COLLARS Inspect the intake collars and fasteners? Are the intake collars fastened securely to the cylinder heads? • Yes - Continue. • No - Tighten the intake collar screws as needed. (StepNumber) INSPECT THROTTLE BODY Remove the air cleaner cover and inspect the air cleaner.
  • Page 109 ENGINE CONTROL SYSTEM (StepNumber) INSPECT INTAKE MANIFOLD Remove the intake manifold and inspect for air leaks around the injectors and the intake collar seals. Are repairs needed? • Yes - Make repairs. Clear the fault codes and run the engine. If the fault reoccurs, continue. •...
  • Page 110 ENGINE CONTROL SYSTEM (StepNumber) REPLACE ECM Replace the ECM and load the current engine tune. Reset closed throttle position, long term fuel trim, and IACV adaption values. Run the engine. Does the fault reoccur? • Yes - Reinstall the original ECM and continue. •...
  • Page 111 ENGINE CONTROL SYSTEM FAULT CODE P0201, P1201 INJECTOR 1 CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND R/Gy A B C D E F 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) DISPLAY FAULT HISTORY DATA Make note of the injector pulse time.
  • Page 112 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from fuel injector 1 (P10). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 113 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Injectors Disconnect the harness from fuel injector 1 (P10). Is there continuity between Injector 1 and motorcycle ground? •...
  • Page 114 ENGINE CONTROL SYSTEM FAULT CODE P0201, P1205 INJECTOR 1 CIRCUIT FAULT: SHORT TO +12V R/Gy A B C D E F 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) MEASURE INJECTOR 1 RESISTANCE Disconnect the harness from injector 1 (P10). Measure the resistance between across the injector terminals.
  • Page 115 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected. 10271 (StepNumber) TEST FOR SHORT TO +12V Power Relay Injectors Disconnect the harness from injector 1 (P10). Is there continuity between Injector 1 and Power Relay Output? Output Coil...
  • Page 116 ENGINE CONTROL SYSTEM FAULT CODE P0202, P1202 INJECTOR 2 CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND R/Gy A B C D E F 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) DISPLAY FAULT HISTORY DATA Make note of the injector pulse time.
  • Page 117 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from fuel injector 2 (P11). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 118 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Injectors Disconnect the harness from fuel injector 2 (P11). Is there continuity between Injector 2 and motorcycle ground? •...
  • Page 119 ENGINE CONTROL SYSTEM FAULT CODE P0202, P1206 INJECTOR 2 CIRCUIT FAULT: SHORT TO +12V A B C D E F R/Gy 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) MEASURE COMPONENT RESISTANCE Disconnect the harness from injector 2 (P11). Measure the resistance between across the injector terminals.
  • Page 120 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected. 10271 (StepNumber) TEST FOR SHORT TO +12V Power Relay Injectors Disconnect the harness from injector 2 (P11). Is there continuity between Injector 2 and Power Relay Output? Output Coil...
  • Page 121 ENGINE CONTROL SYSTEM FAULT CODE P0335 CRANKSHAFT SENSOR CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND W/Be 10235 (StepNumber) DISPLAY FAULT HISTORY DATA Make note of the Ignition Timing and the Target Dwell values. (StepNumber) INSPECT CRANKSHAFT SENSOR Is the crankshaft position sensor fastened properly? Is the connector (P6) intact and fastened properly? •...
  • Page 122 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from crankshaft position sensor (P6). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 123 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Crankshaft Disconnect the harness from the crankshaft sensor (P6). Is there continuity between Crankshaft Pos and motorcycle ground? between Crankshaft Neg and motorcycle ground? •...
  • Page 124 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR OPEN CIRCUIT Crankshaft Disconnect the harness from the crankshaft position sensor (P6). Is there continuity between Crankshaft Pos and P6B- 2? between Crankshaft Neg and P6B-1? • Yes - Continue. • No - Repair or replace the crankshaft position sensor cable. Reconnect the harness, clear the fault codes, and run the engine.
  • Page 125 ENGINE CONTROL SYSTEM FAULT CODE P0335, P1335 CRANKSHAFT SENSOR CIRCUIT FAULT: SIGNAL FAULT W/Be 10235 (StepNumber) INSPECT CRANKSHAFT POSITION GEAR Is the crankshaft position gear free from damage and debris? Is the clearance between the sensor and the timing tooth in range? Standard: 0.039 inches...
  • Page 126 ENGINE CONTROL SYSTEM FAULT CODE P0351, P1351 IGNITION COIL 1 CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND A B C D E F R/Gy 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) DISPLAY FAULT HISTORY DATA (StepNumber) INSPECT IGNITION COIL 1 Is ignition coil 1 fastened properly? Is the connector (P12)
  • Page 127 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from ignition coil 1 (P12). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 128 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Coils Disconnect the harness from ignition coil 1 (P12). Is there continuity between Coil 1 and motorcycle ground? •...
  • Page 129 ENGINE CONTROL SYSTEM FAULT CODE P0351, P1355 IGNITION COIL 1 CIRCUIT FAULT: SHORT TO +12V R/Gy A B C D E F 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from ignition coil 1 (P12). Are the pins and sockets intact and secure? •...
  • Page 130 ENGINE CONTROL SYSTEM (StepNumber) • Yes - Continue. • No - Replace ignition coil 1. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue. (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue.
  • Page 131 ENGINE CONTROL SYSTEM FAULT CODE P0352, P1352 IGNITION COIL 2 CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND A B C D E F R/Gy 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) DISPLAY FAULT HISTORY DATA (StepNumber) INSPECT IGNITION COIL 2 Is ignition coil 2 fastened properly? Is the connector (P13)
  • Page 132 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from ignition coil 2 (P13). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 133 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Coils Disconnect the harness from ignition coil 2 (P13). Is there continuity between Coil 2 and motorcycle ground? •...
  • Page 134 ENGINE CONTROL SYSTEM FAULT CODE P0352, P1356 IGNITION COIL 2 CIRCUIT FAULT: SHORT TO +12V A B C D E F R/Gy 30 86 Y/Be +12V W/Bk W/Bk Be/O 1 2 3 4 5 6 (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from ignition coil 2 (P13). Are the pins and sockets intact and secure? •...
  • Page 135 ENGINE CONTROL SYSTEM (StepNumber) • Yes - Continue. • No - Replace ignition coil 2. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue. (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue.
  • Page 136 ENGINE CONTROL SYSTEM FAULT CODE P0444 PURGE VALVE CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND A B C D E F 30 86 +12V Pk/Be 11 12 W/Bk 1 2 3 (StepNumber) DISPLAY SENSOR DATA Make note of the purge valve duty cycle. (StepNumber) INSPECT PURGE VALVE Is the purge valve fastened properly? Is the connector (P3)
  • Page 137 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from purge valve (P3). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 138 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR SHORT TO GROUND Purge Disconnect harness from the purge valve (P3). Is there continuity between Purge and motorcycle ground. • Yes - Repair wiring. Reconnect the harness, clear the fault codes, and run purge valve component test. If the fault reoccurs, continue.
  • Page 139 ENGINE CONTROL SYSTEM FAULT CODE P0445 PURGE VALVE CIRCUIT FAULT / SHORT TO +12V A B C D E F 30 86 +12V Pk/Be 11 12 W/Bk 1 2 3 (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from purge valve (P3). Are the pins and sockets intact and secure? •...
  • Page 140 ENGINE CONTROL SYSTEM (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? • Yes - Continue. • No - Fasten the ECM connectors. Clear the fault codes and run the engine. If the fault reoccurs, continue. 10270 (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2).
  • Page 141 ENGINE CONTROL SYSTEM FAULT CODE P0500 ROAD SPEED SENSOR CIRCUIT FAULT A B C D E F 30 86 +12V Pk/Be 11 12 W/Bk 1 2 3 (StepNumber) DISPLAY FAULT HISTORY DATA Make note of road speed value. (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? •...
  • Page 142 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Speedometer Disconnect the harness from the road speed sensor (P37). Is there continuity between Speedometer and motorcycle ground? •...
  • Page 143 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR INTERNAL SHORT Power Relay Speedometer Is there continuity between Speedometer (P2-D1) and Power Relay Output (P1-H4)? Output Coil • Yes - Repair wiring. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue. •...
  • Page 144 ENGINE CONTROL SYSTEM FAULT CODE P0505 IDLE AIR CONTROL (IAC) VALVE STEPPER MOTOR CIRCUIT FAULT 10 12 A B C D 10237 (StepNumber) DISPLAY FAULT HISTORY DATA DISPLAY SENSOR DATA Make note of the IACV Stepper Position value. (StepNumber) INSPECT IAC VALVE Is the IAC valve fastened properly? Is the connector (P9) intact and fastened properly? •...
  • Page 145 ENGINE CONTROL SYSTEM (StepNumber) INSPECT COMPONENT CONNECTOR Disconnect the harness from idle air control (P9). Are the pins and sockets intact and secure? • Yes - Continue. • No - Repair connector. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue.
  • Page 146 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Idle Air Control Disconnect the harness from the IAC valve (P9).
  • Page 147 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR OPEN CIRCUIT ABCD Idle Air Disconnect the harness from the IAC valve (P9). Is there continuity between Idle Air Control A and P9B-A? between Idle Air Control B and P9B-B? ABCD Idle Air 10332 (StepNumber) Is there continuity between Idle Air Control C and P9B-C? ABCD...
  • Page 148 ENGINE CONTROL SYSTEM FAULT CODE P0562 LOW SYSTEM VOLTAGE A B C A B C D E F +12V O/Be Be/Gy R/Gy 1 2 3 10238 (StepNumber) DISPLAY SENSOR DATA Make note of the Battery Voltage. (StepNumber) MEASURE BATTERY VOLTAGE Clean the battery posts and cable terminals if necessary.
  • Page 149 ENGINE CONTROL SYSTEM (StepNumber) MEASURE IGNITION FUSE VOLTAGE Remove the cover on fuse connector P30 and remove the ignition fuse. Clean the fuse blades and sockets if necessary. Measure the voltage between P30B-E and motorcycle ground. Is the value less than the measured battery voltage? •...
  • Page 150 ENGINE CONTROL SYSTEM (StepNumber) Disconnect main harness from the lights/control harness at connector P40. Is there continuity between the tilt switch output (P17B-2) and P40B-B? • Yes - Reconnect the harness to the tilt switch and continue. • No - Repair wiring. Reconnect the harness, clear the fault codes, and run the engine.
  • Page 151 ENGINE CONTROL SYSTEM (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? • Yes - Continue. • No - Fasten the ECM connectors. Clear the fault codes and run the engine. If the fault reoccurs, continue. 10270 (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2).
  • Page 152 ENGINE CONTROL SYSTEM FAULT CODE P0563 HIGH SYSTEM VOLTAGE A B C A B C D E F +12V O/Be Be/Gy R/Gy 1 2 3 10238 (StepNumber) MEASURE ALTERNATOR OUTPUT VOLTAGE Measure the alternator output voltage. Is the voltage acceptable? •...
  • Page 153 ENGINE CONTROL SYSTEM FAULT CODE P0230, P1231 FUEL PUMP CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND A B C A B C D E F 30 86 +12V R/Gy R/Bk O/Be 1 2 3 4 5 6 1 3 5 1 2 3 10239 (StepNumber)
  • Page 154 ENGINE CONTROL SYSTEM (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? • Yes - Continue. • No - Fasten the ECM connectors. Clear the fault codes and run the engine. If the fault reoccurs, continue. 10270 (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2).
  • Page 155 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR OPEN CIRCUIT Fuel Pump Disconnect the harness from the fuel pump (P18). Is there continuity between Fuel Pump and P18A-2? between the fuel pump fuse input (P31B-C) and P18A-1? between P18A-3 and motorcycle ground? •...
  • Page 156 ENGINE CONTROL SYSTEM (StepNumber) TEST IGNITION RELAY CIRCUIT Disconnect the ignition relay from the harness (P26). Is there continuity between the ignition relay output (P26B-87) and fuel pump fuse input (P31B-C)? between the ignition relay coil output (P26B-85) and motorcycle ground? •...
  • Page 157 ENGINE CONTROL SYSTEM FAULT CODE P0230, 1232 FUEL PUMP CIRCUIT FAULT: SHORT TO +12V A B C A B C D E F 30 86 +12V R/Gy R/Bk O/Be 1 2 3 4 5 6 1 3 5 1 2 3 10239 (StepNumber) INSPECT FUEL PUMP...
  • Page 158 ENGINE CONTROL SYSTEM • Main switch On - For the first 10 seconds, any voltage indicates a short with the fuel pump power circuit. After 10 seconds, any voltage indicates a short with a switched power circuit other than the fuel pump power circuit. •...
  • Page 159 ENGINE CONTROL SYSTEM FAULT CODE P1386 TACHOMETER CIRCUIT FAULT: SHORT TO GROUND A B C A B C D E F 30 86 +12V Y/Be O/Be 10240 (StepNumber) DISPLAY SENSOR DATA Make note of the Engine Speed value. When the engine is running does the tachometer work? DISPLAY FAULT HISTORY DATA Make note of the Engine Speed value.
  • Page 160 ENGINE CONTROL SYSTEM (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue. 10271 (StepNumber) TEST FOR SHORT TO GROUND Tachometer Reconnect the harness to the instrument cluster. Is there continuity between Tachometer and motorcycle ground? •...
  • Page 161 ENGINE CONTROL SYSTEM FAULT CODE P1387 TACHOMETER CIRCUIT FAULT: SHORT TO +12V A B C A B C D E F 30 86 +12V Y/Be O/Be 10240 (StepNumber) DISPLAY SENSOR DATA Make note of the Engine Speed value. When the engine is running does the tachometer work.
  • Page 162 ENGINE CONTROL SYSTEM (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? • Yes - Continue. • No - Fasten the ECM connectors. Clear the fault codes and run the engine. If the fault reoccurs, continue. 10270 (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2).
  • Page 163 ENGINE CONTROL SYSTEM FAULT CODE P1560 SENSOR SUPPLY VOLTAGE FAULT Pk/Y Gn/W Gy/V 10 12 9 12 A B C 10232 (StepNumber) DISPLAY SENSOR DATA Make note of the Sensor Reference Voltage. (StepNumber) CONNECT BREAKOUT BOX Disconnect the harness from the ECM (P1 and P2). Connect P1B and P2B to the breakout box leaving the ECM disconnected, then continue.
  • Page 164 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR SHORT TO GROUND Sensor Disconnect the harness from the throttle position sensor (P7). Is there continuity between Sensor 5V and Sensor Gnd? • Yes - Repair wiring. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue. •...
  • Page 165 ENGINE CONTROL SYSTEM FAULT CODE 1601 CHECK ENGINE LAMP CIRCUIT FAULT: OPEN CIRCUIT / SHORT TO GROUND A B C A B C D E F 30 86 +12V Y/Be O/Be Y/Bk 11 12 Be/R 10249 (StepNumber) INSPECT FUSES Remove the cover from the fuse connector (P30) and inspect the lights and ignition fuses.
  • Page 166 ENGINE CONTROL SYSTEM (StepNumber) TEST COMPONENT FOR CONTINUITY Disconnect the harness from the instrument cluster (P20). Is there continuity between the power input (P20A-2) and the check engine lamp (P20A-9)? • Yes - Continue. • No - Inspect the instrument cluster wiring and the check engine lamp bulb.
  • Page 167 ENGINE CONTROL SYSTEM (StepNumber) TEST FOR SHORT TO GROUND Check Engine Reconnect the harness to the instrument cluster. Is there continuity between Check Engine and motorcycle ground? • Yes - Repair wiring. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue. •...
  • Page 168 ENGINE CONTROL SYSTEM (StepNumber) TEST RELAY COIL OUTPUT Disconnect the harness from the accessory relay (P16). Is there continuity between the coil output (P16B-85) and motorcycle ground? • Yes - Continue. • No - Repair wiring and continue. (StepNumber) MEASURE RELAY SWITCH VOLTAGE Measure the voltage at the relay switch input (P16B-30).
  • Page 169 ENGINE CONTROL SYSTEM (StepNumber) MEASURE MAIN SWITCH ACCESSORY VOLTAGE Disconnect the harness from the main switch. Move the main switch to Acc. Measure the voltage at the accessory output (P29B-B). Is the value 11 - 14 volts? • Yes - Contact dealer service. •...
  • Page 170 ENGINE CONTROL SYSTEM FAULT CODE 1602 CHECK ENGINE LAMP CIRCUIT FAULT: SHORT TO +12V A B C A B C D E F 30 86 +12V Y/Be O/Be Y/Bk 11 12 Be/R 10249 (StepNumber) INSPECT ECM CONNECTORS Are the ECM connectors fastened properly? •...
  • Page 171 ENGINE CONTROL SYSTEM TEST FOR SHORT TO +12V Check Engine Is there continuity between Check Engine and the potential power sources on the instrument cluster connector (P20B)? • Yes - Repair wiring. Reconnect the harness, clear the fault codes, and run the engine. If the fault reoccurs, continue. •...
  • Page 172 ENGINE CONTROL SYSTEM (StepNumberStart) ENGINE CONTROL MODULE REMOVAL 1. Disconnect the battery beginning with the negative battery cable (see Chapter 16. BATTERY/CHARGING SYSTEM). 2. Jack the rear of the motorcycle a few inches. 3. Remove the upper belt guard (see Chapter 2. BODY/ EXHAUST).
  • Page 173 ENGINE CONTROL SYSTEM (StepNumber) INSPECTION Inspect for dirt, debris or bent pins in the connector bodies. Gently clean away any dirt or debris. Carefully straighten bent pins. Inspect the ECM vent tube for obstructions. This tube leads to the barometric sensor. Caution Do not apply compressed air to the vent tube or the sensor port.
  • Page 174 ENGINE CONTROL SYSTEM (StepNumber) FUEL TANK The following sections describe how to drain, remove, and install the fuel tank. The Super X fuel tank can be removed without draining the fuel from the tank. Use care when removing a tank with fuel in it.
  • Page 175 ENGINE CONTROL SYSTEM (StepNumber) WARNING The fuel hose is under pressure. Wear eye protection and use a rag to cover the disconnection point to prevent fuel spray. 5. Disconnect the hose from the fuel pump. Wipe up any spilled fuel. 1.
  • Page 176 ENGINE CONTROL SYSTEM (StepNumber) USING THE FUEL PUMP POWER JUMPER WIRE 1. Remove the rider’s saddle and tandem saddle (see Chapter 2. BODY/EXHAUST). 2. Remove the rear fuel tank mounting screw and isolator. 3. Remove the instrument cluster from the fuel tank (see Chapter 18.
  • Page 177 ENGINE CONTROL SYSTEM (StepNumber) 11. Connect the fuel pump power jumper wire to the wiring harness and the fuel pump. 12. Attach the ground clamp to motorcycle ground. Tool: Fuel Pump Power Jumper Wire EH-6999-0040A 1. FUEL PUMP POWER JUMPER WIRE (StepNumber) 13.
  • Page 178 ENGINE CONTROL SYSTEM (StepNumber) 7. Place a rag between the front of the fuel tank and the triple clamp to protect the tank. 8. Lift the rear of the fuel tank two or three inches and disconnect the tank vent tube. Caution Lifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging...
  • Page 179 ENGINE CONTROL SYSTEM (StepNumber) 3. Place a rag between the front of the fuel tank and the triple clamp to protect the tank. Caution Lifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging the finish.
  • Page 180 ENGINE CONTROL SYSTEM (StepNumber) PRESSURE TESTING Remove the air cleaner (see AIR CLEANER REMOVAL page 4-139) Remove the cap from the Schrader valve on the fuel rail. Connect a fuel pressure gauge to the valve. Move the main switch to the On position. Observe the gauge. The fuel pressure should rise to the operating pressure while the pump is running, then fall slightly after it stops.
  • Page 181 ENGINE CONTROL SYSTEM (StepNumber) INSPECTION Use the Examinator diagnostic tool to perform an operational test. See the Examinator Handbook for information about running component tests. Inspect the fuel pump and connector for damage. Repair or replace as needed. (StepNumber) Notice The following electrical tests can be done without removing the fuel the pump.
  • Page 182 ENGINE CONTROL SYSTEM (StepNumber) FUEL LEVEL SENSOR REMOVAL 1. Drain the fuel tank (see FUEL TANK DRAINING page 4- 124). 2. Remove the fuel tank (see FUEL TANK REMOVAL page 4-127). (StepNumber) WARNING Some fuel will always remain in the tank. Use care when removing the fuel level sensor to avoid spilling fuel.
  • Page 183 ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION Install the fuel level sensor with a new rubber gasket. Tighten the five screws evenly in a star pattern. Torque: 46 in-lbs Install the fuel tank (see FUEL TANK INSTALLATION page 4- 128). (StepNumber) PURGE VALVE California Models Only REMOVAL 1.
  • Page 184 ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION 1. Install the purge valve with the molded arrow pointing to the rear of the motorcycle. 2. Connect the vent tubes to the purge valve. 3. Connect the wiring harness to the purge valve. 4. Install the fuel tank (see FUEL TANK INSTALLATION page 4-128).
  • Page 185 ENGINE CONTROL SYSTEM (StepNumber) ROLLOVER VALVE REMOVAL 1. Pull the rollover valve and clip from the mounting panel. 1. ROLLOVER VALVE 2. TANK VENT TUBE (StepNumber) 2. While holding the rollover valve and clip, remove the upper tube from the rollover valve inlet. 3.

  • Page 186: Fuel Injectors

    ENGINE CONTROL SYSTEM (StepNumber) FUEL INJECTORS REMOVAL 1. Remove the fuel tank(see FUEL TANK REMOVAL page 4-127). 2. Remove the air cleaner(see AIR CLEANER REMOVAL page 4-139). (StepNumber) 3. Remove the retaining clips that hold the fuel rail on the tops of the injectors.
  • Page 187 ENGINE CONTROL SYSTEM (StepNumber) INSPECTION Inspect the fuel injector, collar, and connectors for damage. Repair or replace as needed. 1. COLLAR 2. CONNECTOR (StepNumber) Measure the resistance across the injector terminals. If the value is not in range, replace the injector. 11.75 - 12.25Ω...

  • Page 188: Throttle Control

    ENGINE CONTROL SYSTEM (StepNumber) THROTTLE CONTROL REMOVAL 1. Remove the fuel tank (see FUEL TANK REMOVAL page 4-127). 2. Remove the air cleaner (see AIR CLEANER REMOVAL page 4-139). (StepNumber) 3. Slide the rubber covers off both cable adjusters, and loosen both adjuster jam nuts.

  • Page 189: Air Cleaner

    ENGINE CONTROL SYSTEM (StepNumber) 3. Adjust the throttle cables (see THROTTLE CONTROL ADJUSTMENT page 4-139). 4. Slide the rubber covers on to the cable adjusters. 5. Install the fuel tank (see FUEL TANK INSTALLATION page 4-128). 6. Install the air cleaner (see AIR CLEANER INSTALLATION page 4-140).

  • Page 190: Throttle Body

    ENGINE CONTROL SYSTEM (StepNumber) INSPECTION To remove large particles from the element, strike the open face of the element sharply against a clean, flat surface. To remove smaller particles from the element, use low- pressure air and blow from the inside out. WARNING •...
  • Page 191 ENGINE CONTROL SYSTEM (StepNumber) 8. Remove the two screws that secure the throttle body bracket to the cylinder heads 9. Slide the throttle body and bracket off the studs. 10. Remove the throttle body seal and discard it. 1. BRACKET 2.
  • Page 192 ENGINE CONTROL SYSTEM (StepNumber) 5. Install the air cleaner backplate and gasket onto the intake manifold mounting studs and fasten the four nuts. Torque: 8 ft-lbs 6. Install the air cleaner (see AIR CLEANER INSTALLATION page 4-140). (StepNumber) INTAKE MANIFOLD REMOVAL 1.
  • Page 193 ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION 1. Install the intake manifold and intake collars with new seals. Fasten intake collar screws. Torque: 18 ft-lbs (StepNumber) 2. Connect the wiring harness to the fuel injectors. 3. Install the throttle body (see THROTTLE BODY INSTALLATION page 4-141).
  • Page 194 ENGINE CONTROL SYSTEM (StepNumber) Measure the resistance across the sensor terminals. If the resistance is out of range, replace the sensor. Standard: 820Ω @ 120° F 1210Ω @ 100° F 1830Ω @ 80° F 2840Ω @ 60° F 3500Ω @ 50° F Ω...
  • Page 195 ENGINE CONTROL SYSTEM (StepNumber) INSPECTION Inspect the sensor and connector for damage. Repair or replace as needed. Inspect the gap between the crankshaft position sensor and the crankshaft position gear. Standard: 0.039 inches (StepNumber) Measure the resistance across the sensor terminals. If the value is not in range, replace the crankshaft position sensor.
  • Page 196 ENGINE CONTROL SYSTEM (StepNumber) ENGINE TEMPERATURE SENSOR REMOVAL WARNING Cylinder heads can be very hot. Allow the engine to cool before removing the engine temperature sensor. 1. Disconnect the wiring harness from the engine temperature sensor. 2. Remove the engine temperature sensor from the front cylinder head.
  • Page 197 ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION 1. Install the engine temperature sensor in the front cylinder head. Torque: 8 in-lbs 2. Connect the wiring harness to the engine temperature sensor. (StepNumber) OXYGEN SENSOR REMOVAL 1. Disconnect the wiring harness from the oxygen sensor. 2.
  • Page 198 ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION 1. Apply a high temperature anti-seize lubricant to the oxygen sensor threads and Install the sensor. Torque: 20 ft-lbs 2. Connect the wiring harness to the oxygen sensor. (StepNumber) ROAD SPEED SENSOR REMOVAL 1. Remove the exhaust and muffler assembly (see Chapter BODY/EXHAUST).
  • Page 199 ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION 1. Install the road speed sensor with an new o-ring and fasten the two screws. Torque: 8 ft-lbs 2. Connect the wiring harness to the road speed sensor. 3. Install the electronics cover and fasten the three screws. Torque: 5 ft-lbs (StepNumber) 4.

  • Page 200: Tilt Switch

    ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION 1. Install the throttle position sensor on the throttle spindle and fasten the two screws. Torque: 18 in-lbs (StepNumber) 2. Install the throttle body (see THROTTLE BODY INSTALLATION page 4-141). 3. Install the air cleaner (see AIR CLEANER INSTALLATION page 4-140).
  • Page 201 ENGINE CONTROL SYSTEM (StepNumber) INSPECTION Inspect the tilt switch and connector for damage. Remove the tilt switch from the motorcycle. Connect the tilt switch ground (P17A-1) to ground and apply 12 volts to the power input (P17A-3). Measure the voltage between the tilt switch output (P17A-2) and ground within 60°...
  • Page 202 ENGINE CONTROL SYSTEM (StepNumber) 2. Disconnect the wiring harness from the idle air control. 3. Remove the two screws and washers that secure the idle air control to the throttle body 4. Remove the idle air control and discard the o-ring. 1.
  • Page 203 ENGINE CONTROL SYSTEM (StepNumber) INSTALLATION 1. Install the idle air control with a new o-ring in the throttle body and fasten the screws and washers. Torque: 26 in-lbs (StepNumber) 2. Install the throttle body (see THROTTLE BODY INSTALLATION page 4-141). 3.
  • Page 204 ENGINE CONTROL SYSTEM (StepNumber) 5. Remove the ignition coil from the spark plug by pulling up on the coil. 6. Disconnect the wiring harness from the ignition coil. Press the connector release tab down and remove the connector. (StepNumber) 7. To prevent debris from entering the engine through the spark plug hole, use pressurized air to blow clean the area around each spark plug.
  • Page 205 ENGINE CONTROL SYSTEM (StepNumber) IGNITION COILS Inspect the ignition coil and connector for damage. Repair or replace as needed. Measure the resistance across the ignition coil terminals. If the value is not in range, replace the ignition coil. Ω Standard: 0.8 - 1.5Ω...
  • Page 206 ENGINE REMOVAL/INSTALLATION 6999-0003 7/15/99...

  • Page 207: Engine Removal/Installation

    5. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ..5-1 ENGINE REMOVAL....5-3 TROUBLESHOOTING ... . . 5-2 ENGINE INSTALLATION.
  • Page 208 ENGINE REMOVAL/INSTALLATION TROUBLESHOOTING 6999-0003 7/15/99...
  • Page 209 ENGINE REMOVAL/INSTALLATION (StepNumber) ENGINE REMOVAL 1. Drain the engine oil (see ENGINE OIL page 1-3). 2. Remove the battery (see BATTERY REMOVAL page 16-3). 3. Remove the fuel tank (see FUEL TANK page 2-3). 4. Remove the left and right side foot board support screws, and remove the foot boards.
  • Page 210 ENGINE REMOVAL/INSTALLATION (StepNumber) 19. Disconnect the alternator wire from the voltage regulator. Remove the cable tie if necessary. 20. Remove the banjo bolt, clutch hose, and sealing washers from the outer primary cover. Discard the sealing washers. 1. ALTERNATOR WIRE 3.
  • Page 211 ENGINE REMOVAL/INSTALLATION (StepNumber) 34. Remove the engine control module (ECM) bracket to frame screws. 35. Pull the two fuse holders from the battery box bracket. 36. Remove the diagnostic connector from the battery box bracket. 37. Remove the battery box and bracket. 38.

  • Page 212: Engine Installation

    ENGINE REMOVAL/INSTALLATION (StepNumber) 44. Remove the rear engine mount nuts. 45. Loosen and either rear engine mount screw. Remove the screw, washer, and carefully push or pull the engine mount shaft from the engine case. 46. Remove the left and right side engine mount spacers and engine mounts.
  • Page 213 ENGINE REMOVAL/INSTALLATION (StepNumber) 2. Slide the engine lift fixture rods under the exhaust ports from the right side of the engine. Tool: Engine lift fixture EH-6999-0101 Notice Make sure the engine lift fixture is securely installed on the engine lift. 3.
  • Page 214 ENGINE REMOVAL/INSTALLATION (StepNumber) 5. Install the left front engine isolator bracket onto the engine (isolator bracket with threaded holes). 6. Thread the studs into the engine isolator bracket, install a washer first, and to locknuts on each stud. Thread the studs into the engine isolator bracket, thread them in until the head of each stud is flush with the bracket.
  • Page 215 ENGINE REMOVAL/INSTALLATION (StepNumber) 14. Install the right rubber engine mount, onto the right engine isolator mounting bracket. 15. Align the hole in the right rubber engine mount, with the alignment pin, on the engine isolator mounting bracket. 16. Install the right front engine mounting bracket. Install the bolts and tighten hand tight.
  • Page 216 ENGINE REMOVAL/INSTALLATION (StepNumber) 3. Tighten both of the front rubber engine mount bolts, to a torque of 20 ft-lb. 1. RUBBER ENGINE 2. ENGINE MOUNT BOLTS MOUNTS (StepNumber) 4. Install the chrome engine mount cover nuts. 5. Tighten the engine mount cover nuts, to a torque of 20 ft-lb.
  • Page 217 ENGINE REMOVAL/INSTALLATION (StepNumber) Connect Neutral Switch 1. Attach the neutral switch connector to the neutral switch. 1. NEUTRAL SWITCH 2. NEUTRAL CONNECTOR (StepNumber) Connect the Oil Pressure Switch 1. Attach the oil pressure connector to the oil pressure switch 1. OIL PRESSURE SWITCH. 2.
  • Page 218 ENGINE REMOVAL/INSTALLATION (StepNumber) Install the Wiring Tray and Battery Box Before starting this procedure make sure you have the battery box, wiring tray, battery box spacer, mounting bolts, and flange nuts, in close proximity to the battery box working area. 1.
  • Page 219 ENGINE REMOVAL/INSTALLATION (StepNumber) Notice You will need connect the two ground wires before installing the flange nuts. Install both ground wires on the center mounting bolt. 5. On the electronics cover support bracket side. Install the mounting bolts and flange nuts. 6.
  • Page 220 ENGINE REMOVAL/INSTALLATION (StepNumber) 3. Loop the drive belt around the engine drive sprocket, and the rear wheel driven sprocket. 1. DRIVE BELT 3. REAR WHEEL DRIVEN 2. DRIVE SPROCKET SPROCKET (StepNumber) 4. Move the rear wheel back, until there is tension on the belt. 5.
  • Page 221 ENGINE REMOVAL/INSTALLATION (StepNumber) Install and Adjust Throttle Cables 1. Install the ball end of the opening cable (cable ball with the yellow end) into the cable guide, of the throttle body. 2. Install the barrel end of the closing cable into the cable guide, of the throttle body.
  • Page 222 ENGINE REMOVAL/INSTALLATION (StepNumber) Wire Connections FUEL INJECTORS 2. Install the fuel injector electrical connector labeled #1 on the front (#1) cylinder. 3. Install the fuel injector electrical connector labeled #2 on the front (#2) cylinder. 1. #1 FUEL INJECTOR 3. #2 FUEL INJECTOR CONNECTOR CONNECTOR 2.
  • Page 223 ENGINE REMOVAL/INSTALLATION (StepNumber) CRANKSHAFT POSITION SENSOR 6. Connect the crankshaft sensor wire. 1. CRANKSHAFT SENSOR (StepNumber) VOLTAGE REGULATOR 5. Connect the voltage regulator plug connector. 1. VOLTAGE REGULATOR 2. VOLTAGE REGULATOR PLUG CONNECTOR (StepNumber) ALTERNATOR 8. Connect the alternator connector to the connector on the voltage regulator.
  • Page 224 ENGINE REMOVAL/INSTALLATION (StepNumber) Install Throttle Body and Air Cleaner Assembly AIR TEMPERATURE SENSOR CONNECTOR 1. Run the wires for the air temperature in between the cylinders. They will need to be available at the bottom right of the throttle body support bracket. 2.
  • Page 225 ENGINE REMOVAL/INSTALLATION (StepNumber) IDLE AIR CONTROL VALVE AND AIR TEMPERATURE SENSOR 4. Connect the idle air control valve connector to the idle air control valve connector on the throttle body. 5. Position the air cleaner backplate in front of the throttle body, and the connect air temperature sensor and breather line.
  • Page 226 ENGINE REMOVAL/INSTALLATION (StepNumber) AIR CLEANER COVER 13. Install the air cleaner cover. 14. Apply a drop of loctite to the threads of the three (3) air cleaner mounting bolts. 15. Install the air filter mounting bolts. 16. Tighten the mounting bolts to a torque of 8 ft-lb. 1.
  • Page 227 ENGINE REMOVAL/INSTALLATION (StepNumber) Bleed Clutch Notice Make sure the clutch reservoir is full before starting this procedure. Use only DOT 5 hydraulic fluid. See adding hydraulic fluid. 1. Remove the clutch cylinder cover. 2. Pull in the clutch handle. 3. Install a clear plastic tube over the bleeder nipple, with the open end of the tube pointed upward.

  • Page 228: Oil Filter

    ENGINE REMOVAL/INSTALLATION (StepNumber) Electronics Cover 1. Place the electronics cover into position over the oil fill tube. 2. Install the three mounting fasteners and tighten the fasteners to a torque of 7 ft-lb. 3. Install the oil dipstick. 1. ELECTRONICS COVER 3.
  • Page 229 ENGINE REMOVAL/INSTALLATION (StepNumber) Install Front Exhaust Pipe If the exhaust was removed as an assembly, reinstall the exhaust system, install new exhaust gaskets, tighten and torque the flanged exhaust nuts and muffler mounting bolts. Complete Installation Instructions 1. Install the front exhaust first, start with the front head pipe. Notice The upper heat shields must be loosely installed on the head pipes, before the pipes are attached to the heads.
  • Page 230 ENGINE REMOVAL/INSTALLATION (StepNumber) 12. Tighten the front and rear exhaust flange nuts in equal increments to a torque of 20 ft-lb. 13. Tighten the front and rear muffler mounting bolts to the support bracket. Tighten the bolts to a torque of 30 ft-lb. 14.
  • Page 231 ENGINE REMOVAL/INSTALLATION (StepNumber) 4. Pull the wires for the fuel pump, fuel gauge, instrument cluster and vent tube through the hole in the gas tank that the wires pass through. 5. Connect the wires for the fuel pump, fuel gauge, instrument cluster.
  • Page 232 ENGINE REMOVAL/INSTALLATION (StepNumber) Align Rear Wheel This procedure involves using the Excelsior-Henderson rear wheel alignment gauge, part no. EH-6999-0037, which is designed specifically for aligning the rear wheel. Before aligning the rear wheel, loosen the rear axle castle nut, and make sure the rear axle moves easily from front to back.
  • Page 233 ENGINE REMOVAL/INSTALLATION (StepNumber) Drive Belt CHECK DRIVE BELT TENSION This procedure involves using the Excelsior-Henderson belt tension gauge, part no. EH-6999-0038, which is designed specifically for measuring drive belt tension. This procedure can be performed from either the right or left side of the motorcycle.
  • Page 234 ENGINE REMOVAL/INSTALLATION (StepNumber) Adjust Drive Belt Tension Notice Before adjusting drive belt tension, be sure the rear axle is properly aligned. 1. Remove and discard the rear axle cotter pin. Loosen the rear axle castle nut and the rear axle adjuster jam nuts. 2.
  • Page 235 ENGINE REMOVAL/INSTALLATION 5-29 6999-0003 7/15/99...
  • Page 236 ENGINE REMOVAL/INSTALLATION 5-30 6999-0003 7/15/99...
  • Page 237 ENGINE REMOVAL/INSTALLATION 5-31 6999-0003 7/15/99...
  • Page 238 ENGINE REMOVAL/INSTALLATION 5-32 6999-0003 7/15/99...
  • Page 239 ENGINE REMOVAL/INSTALLATION 5-33 6999-0003 7/15/99...
  • Page 240 ENGINE REMOVAL/INSTALLATION 5-34 6999-0003 7/15/99...
  • Page 241 ENGINE REMOVAL/INSTALLATION 5-35 6999-0003 7/15/99...
  • Page 242 ENGINE REMOVAL/INSTALLATION 5-36 6999-0003 7/15/99...
  • Page 243 ENGINE REMOVAL/INSTALLATION 5-37 6999-0003 7/15/99...
  • Page 244 ENGINE REMOVAL/INSTALLATION 5-38 6999-0003 7/15/99...
  • Page 245 ENGINE REMOVAL/INSTALLATION NOTES 5-39 6999-0003 7/15/99...
  • Page 246 CYLINDER HEAD/CAM DRIVE 6999-0003 7/15/99...

  • Page 247: Cylinder Head/Cam Drive

    6. CYLINDER HEAD/CAM DRIVE SERVICE INFORMATION ..6-1 INSPECTION ..... . 6-9 VALVE GUIDE REPLACEMENT .
  • Page 248 CYLINDER HEAD/CAM DRIVE SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Cylinder compression Pressure 125 - 175 psi Variance 0 - 10% Cylinder head distortion 0.003 in Valve spring Free length 1.428 in Compression 118 lbs/in Valve & valve guide Valve guide I.D. Intake = 0.2745 - 0.2755 Intake = 0.2765 in Exhaust = 0.2745 - 0.2755...

  • Page 249: Troubleshooting

    CYLINDER HEAD/CAM DRIVE TROUBLESHOOTING Cylinder head problems usually affect overall engine performance. These can be diagnosed by performing a compression test (see COMPRESSION TEST page 6-4) or by tracing top-end noise. Compression low, difficult starting, poor low speed Excessive exhaust smoke performance •...

  • Page 250: Compression Test

    CYLINDER HEAD/CAM DRIVE (StepNumberStart) COMPRESSION TEST Notice The ECM will record fault codes if the main switch is placed in the On position or if the engine is cranked while certain electrical components are disconnected. The ECM automatically clears these fault codes after the components are reconnected (see Managing System diagnostics page...

  • Page 251: Cylinder Head/Cam Drive

    CYLINDER HEAD/CAM DRIVE (StepNumber) 13. If the compression readings are low or differ by more than 10%, pour about 1/2 oz. of clean engine oil into each cylinder through the spark plug hole and recheck the compression on both cylinders. –...
  • Page 252 CYLINDER HEAD/CAM DRIVE (StepNumber) 7. Remove the cam bearing caps and the camshafts. CAM BEARING CAP 2. CAMSHAFT (StepNumber) 8. Remove the timing cover and discard the cover gasket. 9. Clean any remaining gasket material from the timing cover and the engine case. 10.
  • Page 253 CYLINDER HEAD/CAM DRIVE (StepNumber) 17. Remove the idler gear spindle and sealing washer. Let the upper cam chain idler gear rest in the cam chain tunnel. 1. SPINDLE 2. UPPER IDLER GEAR (StepNumber) 18. Remove the lower cam chain idler gear. 19.

  • Page 254: Disassembly

    CYLINDER HEAD/CAM DRIVE (StepNumber) DISASSEMBLY Notice Mark all components during disassembly so they can be installed in their original location. 1. Remove the hydraulic lifters and set them upside down. Using a small suction cup or valve lapping tool may ease lifter removal.

  • Page 255: Inspection

    CYLINDER HEAD/CAM DRIVE (StepNumber) INSPECTION CYLINDER HEAD 1. Check the spark plug hole and valve openings for cracks. 2. Using a straight edge and a feeler gauge measure the head gasket surface for warpage. Service Limit: 0.003 in – Warpage in excess of the service limit may be correctable.
  • Page 256 CYLINDER HEAD/CAM DRIVE (StepNumber) 2. Measure and record the inside diameter of each valve guide. Service Limit: Intake = 0.2765 in Exhaust = 0.2770 in 1. VALVE GUIDE (StepNumber) 3. Clean each valve stem thoroughly to remove all carbon deposits. 4.
  • Page 257 CYLINDER HEAD/CAM DRIVE (StepNumber) 4. Measure the valve head margin. Service Limit: 0.02 in 5. Replace if necessary. 10130 1. VALVE HEAD MARGIN (StepNumber) 6. Apply a light coat of dye to the valve face. Insert the valve in its respective seat and tap the valve several times without rotating it.
  • Page 258 CYLINDER HEAD/CAM DRIVE (StepNumber) CAMSHAFT 1. Measure the cam lobe height. Service Limit: Intake = 1.477 in Exhaust = 1.517 in Notice The camshafts are stamped either "IN" for intake, or "EX" for exhaust on the end opposite the camshaft gear. 10133 1.
  • Page 259 CYLINDER HEAD/CAM DRIVE (StepNumber) – Install the camshaft bearing cap and measure the inside diameter of the camshaft bearing holder and cap. Service Limit: 1.001 in – Replace the camshaft or cylinder head depending on which item exceeds its service limit. 1.
  • Page 260 CYLINDER HEAD/CAM DRIVE (StepNumber) 3. Measure the diameter of the idler gear spindle in the area shown. Service Limit: 0.623 in 4. Replace if necessary. 1. IDLER GEAR SPINDLE 2. MEASUREMENT AREA (StepNumber) 5. Inspect the idler gear and sprocket teeth for wear and damage.
  • Page 261 CYLINDER HEAD/CAM DRIVE (StepNumber) CAM CHAIN 1. Inspect the cam chain for wear, damage or excessive chain stretch. 2. Replace if necessary. (StepNumber) CAM CHAIN TENSIONER 1. Inspect the cam chain tensioner and its spring for wear or damage. 2. Release the ratchet and check that the rod moves freely in the housing.
  • Page 262 CYLINDER HEAD/CAM DRIVE (StepNumber) IDLER BEARING CARRIER & BEARINGS 1. Inspect the idler bearing carrier for wear and damage. 2. Inspect the idler bearings in the carrier and in the engine case. Turn the inner race with your finger. The race should turn smoothly and quietly without excess play.

  • Page 263: Valve Guide Replacement

    CYLINDER HEAD/CAM DRIVE (StepNumber) VALVE GUIDE REPLACEMENT 1. Chill the new valve guides in a freezer for at least 1 hour. 2. Using a hot plate or oven, heat the cylinder head to 275° - 290°F. Notice Use temperature indicator labels to insure proper cylinder head heating.

  • Page 264: Valve Seat Refacing

    CYLINDER HEAD/CAM DRIVE (StepNumber) 7. Finish the valve guide bores. Use liberal amounts of cutting oil to prevent ream chatter. Tool: Valve guide reamer EH-6999-0032 Notice Insert the reamer form the combustion chamber side of the valve guide. Rotate the reamer clockwise. 8.
  • Page 265 CYLINDER HEAD/CAM DRIVE (StepNumber) 4. Use a 32° cutting tool to remove the outer 25% of the old valve seat width. 10150 1. OLD SEAT WIDTH (StepNumber) 5. Use a 60° cutting tool to remove the inner 25% of the old valve seat width.

  • Page 266: Assembly

    CYLINDER HEAD/CAM DRIVE (StepNumber) ASSEMBLY 1. Install the valve spring seat. 2. Lubricate the new valve seal and press into position. Tool: Valve seal socket EH-6999-0025-3 Tool: Valve guide driver EH-6999-0025-1 1. VALVE SPRING SEAT 3. VALVE SEAL SOCKET 2. VALVE SEAL 4.

  • Page 267: Camshaft/Gear Replacement

    CYLINDER HEAD/CAM DRIVE (StepNumber) CAMSHAFT/GEAR REPLACEMENT Notice The camshafts are stamped either "IN" for intake, or "EX" for exhaust on the end opposite the camshaft gear. 1. Remove the screw that fastens the camshaft gear to the camshaft and remove the camshaft gear from the camshaft. 2.

  • Page 268: Cylinder Timing

    CYLINDER HEAD/CAM DRIVE (StepNumber) 3. Check that cylinder barrel is squarely seated in crankcase. 4. Install dowel pins. 5. Install the dowel orifice with a new O-ring. 6. Place head gasket over dowel pins with part number stamping up. 7. Align cylinder head squarely over dowel pins and gently rock cylinder head into position.
  • Page 269 CYLINDER HEAD/CAM DRIVE (StepNumber) 15. Place the cam chain on the idler gear and place them in the cam chain tunnel of front cylinder. 16. Rotate the idler gear until F| mark on the left side of the idler gear is at 12 o’clock. 17.
  • Page 270 CYLINDER HEAD/CAM DRIVE (StepNumber) 27. Lubricate the camshaft journals with a molybdenum oil solution. Lubricate the camshaft journal holder and bearing caps with engine oil. 28. Place the camshafts in their respective journal holders and align the camshaft timing marks with the idler gear timing NEED ART marks as shown.
  • Page 271 CYLINDER HEAD/CAM DRIVE (StepNumber) 32. Place the cam chain on the idler gear and place them in the cam chain tunnel of rear cylinder. 33. Rotate the idler gear until R| mark on the left side of the idler gear is at 12 o’clock. 34.
  • Page 272 CYLINDER HEAD/CAM DRIVE (StepNumber) 44. Lubricate the camshaft journals with a molybdenum oil solution. Lubricate the camshaft journal holder and bearing caps with engine oil. 45. Place the camshafts in their respective journal holders and align the camshaft timing marks with the idler gear timing NEED ART marks as shown.
  • Page 273 CYLINDER HEAD/CAM DRIVE (StepNumber) 54. Clean any remaining gasket material from the cylinder head and lower cam cover. Use a new gasket and install the lower cam cover. Torque: 8 ft-lbs 55. Use a new gasket and install the upper cam cover. Tighten the mounting bolts in a crisscross pattern starting in the center.
  • Page 274 CYLINDER/PISTON 6999-0003 7/15/99...

  • Page 275: Cylinder/Piston

    7. CYLINDER/PISTON SERVICE INFORMATION ..7-1 PISTONS ..... . .7-10 TROUBLESHOOTING ... . . 7-3 REMOVAL .
  • Page 276 CYLINDER/PISTON SPECIFICATIONS Unit: inch ITEM STANDARD SERVICE LIMIT Cam chain guide rail 0.000 Cylinder taper 0.000 Cylinder head warp 0.006 in Cylinder base warp .0.008 in Cylinder boring sizes 0.000 in. (Standard) 0.000 in. (.010 in. Oversize) 0.000 in. (.020 in. Oversize) Cylinder honing sizes 0.000 in.

  • Page 277: Troubleshooting

    CYLINDER/PISTON TROUBLESHOOTING Cylinder problems usually affect overall engine performance. These can be diagnosed by performing a compression test or by tracing piston noise. Compression low, difficult starting, poor low speed Excessive exhaust smoke performance • Worn cylinder, piston, or piston rings •...

  • Page 278: Cylinder

    CYLINDER/PISTON (StepNumberStart) CYLINDER REMOVAL 1. Remove the engine from the frame (see ENGINE REMOVAL page 5-3). 2. Remove the throttle body (see THROTTLE BODY REMOVAL page 4-140). 3. Remove the cylinder heads, timing cover and gears (see REMOVAL REMOVAL page 6-5).

  • Page 279: Inspection

    CYLINDER/PISTON (StepNumber) 7. Lift the movable cam chain guide and moveable cam chain guide holder, from the crankcase. Notice Repeat these procedures for the opposite cylinder. 1. MOVABLE CAM CHAIN 2. MOVABLE CAM CHAIN GUIDE GUIDE HOLDER (StepNumber) INSPECTION CAM CHAIN GUIDES 1.
  • Page 280 CYLINDER/PISTON (StepNumber) CYLINDERS 1. Remove any gasket material from the machined surfaces of the cylinder. 2. Clean the cylinders in non-volatile cleaning solvent. 1. GASKET MATERIAL 2. MACHINED SURFACES 3. CYLINDERS (StepNumber) 3. Inspect the cylinder bore for burned spots, scoring, grooves, scratches, scuffing, or uneven wear in the ring path area.

  • Page 281: Measurement

    CYLINDER/PISTON (StepNumber) 6. Inspect the cylinder for cracks. If cracks are found in the cylinder, replace the cylinder. 7. Clean the cylinders in non-volatile cleaning solvent. Make sure that all traces of filings or dye have been removed. 8. Wash the cylinder bore with dish washing soap and warm water to remove any abrasive particles or debris.

  • Page 282: Deglazing

    CYLINDER/PISTON (StepNumber) CYLINDER GASKET SURFACES Use a metal scale and a feeler gauge to check the cylinder gasket surfaces for warping. If the warp exceeds the service limit, replace the cylinder and piston. 1. Place the metal scale across the cylinder head gasket surface from head bolt to head bolt.

  • Page 283: Boring

    CYLINDER/PISTON (StepNumber) BORING If a cylinder needs boring, take the cylinder to an authorized Excelsior-Henderson Dealer or a machine shop for service. Pistons and rings are available in three sizes. Standard: 0.000 in. (Standard) 0.000 in. (.010 in. Oversize) 0.000 in. (.020 in. Oversize) Notice Bore the cylinder to 0.003 in.

  • Page 284: Pistons

    CYLINDER/PISTON (StepNumber) PISTONS REMOVAL 1. Remove the cylinders (see CYLINDER REMOVAL page 7-4) 2. Place a clean rag over the crankcase cylinder opening to prevent the piston pin clip from entering the crankcase. (StepNumber) DISASSEMBLY 1. Remove the first and second compression rings from the piston using a piston ring expander.
  • Page 285 CYLINDER/PISTON (StepNumber) Caution • Never use a wire brush to remove carbon deposits from the piston. Scratches or other marks on the piston could score the cylinder bore resulting in engine damage. • Do not bead blast pistons to remove carbon deposits from the piston.
  • Page 286 CYLINDER/PISTON (StepNumber) PISTON RINGS 1. Apply clean engine oil to the three piston ring grooves. 2. Install the compression rings into the first and second ring grooves. Install the compression ring in the second groove with the dot toward the top. Install the oil control expander ring into the third ring groove.
  • Page 287 CYLINDER/PISTON (StepNumber) PISTON PINS AND PIN BORES Install the piston pins into the piston pin bores. The piston pins should slide in and out of the piston pin bores smoothly, without pivoting or rocking. 1. Measure the piston pin hole inner diameter at two perpendicular points (X &...
  • Page 288 CYLINDER/PISTON (StepNumber) ASSEMBLY PISTON PIN BUSHING Notice Place clean lint free shop rags in and around the crankcase bore. This will prevent metal chips and shavings and from falling into the crankcase. 1. Install the piston pin bushing tool into the connecting rod bushing and press out the old bushing.

  • Page 289: Installation

    CYLINDER/PISTON (StepNumber) PISTON RINGS 1. Apply clean engine oil to the three piston ring grooves. 2. Install the compression rings into the first and second ring grooves. Install the compression ring in the second groove with the dot toward the top. Caution Installing the second ring upside down will scrape oil into the cylinder bore and combustion chamber, causing...
  • Page 290 CYLINDER/PISTON (StepNumber) 4. Clean the gasket surface of the crankcase thoroughly. Caution Be careful not to damage the gasket surface of the crankcase. Do not allow gasket material to enter the crankcase during cleaning. 1. CRANKCASE (StepNumber) 5. Install the movable cam chain guide into the crankcase. Torque: Movable cam chain guide 20 ft-lb 6.
  • Page 291 CYLINDER/PISTON (StepNumber) 10. Install the stationary cam chain guide. Caution Make sure the lower mounting posts of the stationary cam chain guide are properly seated. 11. Install the cylinder heads (see CYLINDER HEAD/CAM DRIVE INSTALLATION page 6-21). 1. STATIONARY CAM CHAIN GUIDE (StepNumber) (StepCaptionHold) “For demonstration only”...
  • Page 292 CRANKCASE/CRANKSHAFT 6999-0003 7/15/99...

  • Page 293: Crankcase/Crankshaft

    8. CRANKCASE/CRANKSHAFT SERVICE INFORMATION ..8-1 CRANKSHAFT ....8-11 TROUBLESHOOTING ... . . 8-1 CONNECTING RODS .
  • Page 294 CRANKCASE/CRANKSHAFT (StepNumberStart) CRANKCASE PREPERATION Before starting to take the crankcase apart, it is important to make sure the following sensors and switch have been removed from the crankcase. • Road Speed Sensor • Crankshaft Position Sensor • Neutral Switch 1. ROAD SPEED SENSOR 3.
  • Page 295 CRANKCASE/CRANKSHAFT (StepNumberStart) Remove all fasteners from the left side of the crankcase holding the crankcase halves together. Tilt the complete crankcase toward the oil filter side. This will ease the removal of the left crankcase half. (StepCaptionHold) “For demonstration only” 1.
  • Page 296 CRANKCASE/CRANKSHAFT (StepNumber) Notice It is important that the rod assemblies are returned to the same side on the crankshaft as from which they were removed. Make sure to mark (with different color paint or different numbers) the out side of the right and left rods before removing them from the crankshaft.
  • Page 297 CRANKCASE/CRANKSHAFT (StepNumber) CRANKSHAFT INSPECTION Caution Make sure to clean parts in solvent before beginning any inspection. Failure to clean parts can cause inaccurate readings during part inspection. RUNOUT Measure the crankshaft runout using V-Blocks and a dial indicator with a free standing base. Standard: 0.0000 Service Limit: 0.0000...
  • Page 298 CRANKCASE/CRANKSHAFT (StepNumber) Inspect the cam drive (Right Case) side crankshaft main bearing journal for scratches, wear or damage. Measure the main bearing journal using a 1-2 in. micrometer. The first measurement should be taken at the 12 and 6 O’clock position. The second measurement should be taken at the 3 and 9 O’clock position.
  • Page 299 CRANKCASE/CRANKSHAFT (StepNumber) Inspect the crankcase cam drive (Left Case) side main bearing for scratches, wear or damage. Measure the main bearing using a telescoping bore gauge and a 1-2 in. micrometer. The first measurement should be taken at the 2 and 8 O’clock position.
  • Page 300 CRANKCASE/CRANKSHAFT (StepNumber) Install the crankshaft bearing remover onto the universal handle driver. Using a small hand torch heat the crankcase casting area around the bearing for approximately 4 to 5 minutes. Insert the crankshaft bearing remover and universal handle driver into the main bearing. Press or drive the main bearing out of the crankcase.
  • Page 301 CRANKCASE/CRANKSHAFT (StepNumber) Notice The primary and cam bearings must be installed from the inside of the case outward. The bearings can be installed with the universal driver and a hammer or an arbor press an arbor press is recommended. To install the crankcase primary drive (Left Case) or cam drive (Right Case) side main bearing.
  • Page 302 CRANKCASE/CRANKSHAFT (StepNumber) INSPECTION ROD BEARING JOURNAL (CRANKSHAFT) Inspect the both sides crankshaft rod bearing journals for scratches, wear or damage. Measure the rod bearing journals using a 2-3 in. micrometer. The first measurement should be taken at the 12 and 6 O’clock position.
  • Page 303 CRANKCASE/CRANKSHAFT (StepNumber) (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) MAIN BEARING REPLACEMENT (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) ASSEMBLY (StepCaptionHold) “For demonstration only”...
  • Page 304 CRANKCASE/CRANKSHAFT (StepNumber) INSPECTION (StepNumber) CAM GEAR REPLACEMENT (StepNumber) OIL PUMP GEAR REPLACEMENT (StepNumber) INSTALLATION 8-12 6999-0003 7/15/99...
  • Page 305 CRANKCASE/CRANKSHAFT (StepNumber) CONNECTING RODS REMOVAL (StepNumber) INSPECTION OIL CLEARANCE (StepNumber) WRIST PIN CLEARANCE (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) BEARING SELECTION 8-13 6999-0003 7/15/99...
  • Page 306 CRANKCASE/CRANKSHAFT (StepNumber) INSTALATION (StepNumber) (StepNumber) (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) 8-14 6999-0003 7/15/99...
  • Page 307 CRANKCASE/CRANKSHAFT (StepNumber) (StepNumber) (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) (StepNumber) 8-15 6999-0003 7/15/99...
  • Page 308 PRIMARY DRIVE 10794 6999-0003 7/15/99...

  • Page 309: Primary Drive

    9. PRIMARY DRIVE SERVICE INFORMATION ..9-1 TORSIONAL COMPENSATOR ..9-4 TROUBLESHOOTING ... . . 9-1 REMOVAL .

  • Page 310: Outer Primary Cover

    PRIMARY DRIVE (StepNumberStart) OUTER PRIMARY COVER REMOVAL 1. Drain the engine oil (see ENGINE OIL page 1-3). 2. Remove gear shifter assembly (see GEAR SHIFTER REMOVAL page 11-3). 3. Remove the clutch cover screws and the clutch cover. 4. Hold the clutch adjustment screw with a flat blade screwdriver and remove the outer jam nut.

  • Page 311: Inspection

    PRIMARY DRIVE (StepNumber) INSPECTION 1. Clean the outer primary cover with solvent and carefully remove any remaining gasket material. 2. Inspect the outer primary cover for chips, cracks, and stripped threads. Replace the outer cover if necessary. (StepNumber) ASSEMBLY 1. Install the outer primary cover insert and tighten the insert mounting screws.

  • Page 312: Torsional Compensator

    PRIMARY DRIVE (StepNumber) 6. Start the inner jam nut onto the clutch adjustment screw, and turn the screw counter-clockwise until the inner jam nut is captured by the slave cylinder. Continue turning the adjustment screw until the slave cylinder piston bottoms out. 7.

  • Page 313: Inspection

    PRIMARY DRIVE (StepNumber) 4. Use an impact wrench to remove the torsional compensator spring retainer. Tool: Torsional compensator socket EH-6999-0041 5. Remove the compensator springs, drive ramp, driven ramp, and the crankshaft sleeve. Notice To release the sprag clutch, rotate the starter gear clockwise as you remove the crankshaft sleeve.

  • Page 314: Installation

    PRIMARY DRIVE (StepNumber) INSTALLATION 1. Coat the sprag inner race with an assembly lubricant and slide the crankshaft sleeve all the way onto the crankshaft splines. Notice To ease assembly of sleeve into starter gear, rotate the starter gear clockwise (release sprag clutch) as you install the crankshaft sleeve.

  • Page 315: Inspection

    PRIMARY DRIVE (StepNumber) INSPECTION 1. Clean the inner primary cover with solvent and carefully remove any remaining gasket material. 2. Inspect the inner primary cover for chips, cracks, and stripped threads. Replace the inner cover if necessary. (StepNumber) INSTALLATION 1. Clean any remaining gasket material from the engine case and inner primary cover.
  • Page 316 CLUTCH 10758 10-0 6999-0003 7/15/99...

  • Page 317: 10. Clutch

    10. CLUTCH SERVICE INFORMATION ..10-1 SLAVE CYLINDER ....10-7 TROUBLESHOOTING ... . 10-2 REMOVAL .

  • Page 318: Troubleshooting

    CLUTCH SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Diaphragm spring height .189 in. - .229 in. warpage .008 in. Friction disc thickness (blue tab) .142 in. (green tab) .110 in. (brown tab) .142 in. (damper) .142 in. Clutch plate warpage .008 in. thickness .059 in.

  • Page 319: Bleeding Clutch System

    CLUTCH (StepNumberStart) BLEEDING CLUTCH SYSTEM Air trapped in the clutch system adversely effects clutch system performance. Air can enter the clutch system during system service or from clutch fluid contamination. Bleeding the clutch system removes air from the system. The following procedure can also be used to flush or replace clutch fluid at the prescribed maintenance intervals (see Chapter 1.

  • Page 320: Adjusting Clutch Freeplay

    CLUTCH (StepNumber) 11. Fill the reservoir to within 1/4" of the top with new DOT 5 hydraulic fluid from a clean container. 12. Check the operation of the clutch before riding the motorcycle, and again at low speed before returning the motorcycle to normal use.

  • Page 321: Disassembly

    CLUTCH (StepNumber) DISASSEMBLY 1. Clean the area around the reservoir cap and remove the reservoir cap, plate, and diaphragm. Empty the reservoir of any remaining hydraulic fluid. 2. Remove the lever bolt, and lever assembly. 3. Clamp the master cylinder securely in a padded vise. 4.

  • Page 322: Assembly

    CLUTCH (StepNumber) ASSEMBLY 1. Clamp the master cylinder securely in a padded vise. 2. Insert a new piston return spring into the master cylinder with the larger windings toward the clutch hose port. Caution For proper master cylinder operation, always use a new piston kit when assembling the master cylinder.

  • Page 323: Installation

    CLUTCH (StepNumber) INSTALLATION 1. Position the master cylinder assembly and clamp on the handlebar. Install clamp screws finger tight. 2. Install the clutch hose banjo bolt, clutch hose, and new sealing washers. Torque: 18 ft-lbs Caution For proper clutch system operation, always use new sealing washers.

  • Page 324: Disassembly

    CLUTCH (StepNumber) 7. Remove the slave cylinder mounting screws and the slave cylinder. 8. Remove and discard the O-ring. 10778 1. SLAVE CYLINDER 2. O-RING (StepNumber) DISASSEMBLY 1. Remove the piston retaining ring. 2. Blow low pressure compressed air (10 - 15 psi) into the fluid port and push the piston from the cylinder housing.

  • Page 325: Inspection

    CLUTCH (StepNumber) INSPECTION 1. Clean all cylinder parts and blow out all fluid ports with compressed air. Caution Do not use mineral base solvents to clean clutch parts. 2. Visually inspect the cylinder bore. If there is evidence or scoring, pitting, or corrosion, replace the caliper assembly. 3.

  • Page 326: Installation

    CLUTCH (StepNumber) INSTALLATION 1. Use a new O-ring and install the slave cylinder. Tighten the mounting screws. Torque: 8 ft-lbs 10778 1. SLAVE CYLINDER 2. O-RING (StepNumber) 2. Place a new O-ring on the slave cylinder supply tube and feed the tube up through the outer primary cover. 3.

  • Page 327: Disassembly

    CLUTCH (StepNumber) 5. Hold the clutch basket stationary and remove the clutch mounting nut. Tool: Clutch basket wrench EH-6999-0030 6. Remove the belleville washer and pull the clutch basket and clutch collar off of the transmission input shaft. 10782 1. MOUNTING NUT 3.

  • Page 328: Inspection

    CLUTCH (StepNumber) 3. Remove the spring retainer, diaphragm springs, spring seat, and pressure plate. 4. Remove the friction discs and clutch plates. 5. Remove the clutch hub and thrust washer. Notice The clutch hub includes a damper assembly beneath the clutch plates and friction discs.
  • Page 329 CLUTCH (StepNumber) PRESSURE PLATE 1. Inspect the pressure plate contact surface for grooves, pitting, or uneven wear. Replace the pressure plate if necessary. 10786 1. CONTACT SURFACE (StepNumber) FRICTION DISCS 1. Inspect the friction discs for scoring and discoloration. 2. Measure friction disc thickness as shown. Service Limit: (blue tab) .142 in.

  • Page 330: Assembly

    CLUTCH (StepNumber) CLUTCH BASKET AND COLLAR 1. With the clutch collar installed in the clutch basket, turn the collar with your finger. The collar should turn smoothly and quietly without excess play. 2. The outer race of the clutch basket bearing should fit tightly in the clutch basket, and the clutch collar should slide easily into the bearing without excess play.
  • Page 331 CLUTCH (StepNumber) 4. Coat the thrust washer with clean engine oil. 5. Place the thrust washer and the clutch hub into the clutch basket. 6. Coat the remaining friction discs with clean engine oil. 7. Install a friction disc (brown tab) followed by a clutch plate.

  • Page 332: Installation

    CLUTCH (StepNumber) INSTALLATION 1. Lubricate the clutch collar and the clutch basket bearing with assembly lubricant, and slide the collar and clutch basket all the way onto the transmission input shaft. Notice Make sure the clutch and starter gear teeth mesh before tightening the clutch mounting nut.
  • Page 333 CLUTCH NOTES 10-17 6999-0003 7/15/99...
  • Page 334 TRANSMISSION 10822 11-0 6999-0003 7/15/99...

  • Page 335: 11. Transmission

    11. TRANSMISSION SERVICE INFORMATION ..11-1 TRANSMISSION (continued) TROUBLESHOOTING ... . 11-2 INSPECTION ..... 11-7 ASSEMBLY .

  • Page 336: Troubleshooting

    TRANSMISSION SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Gear inside diameters Input - 4th gear somethingI4 Input - 5th gear somethingI5 Output - 1st gear somethingO1 Output - 2nd gear somethingO2 Output - 3rd gear somethingO3 Input & output shaft diameters Input - main bearing somethingIB Input - 4th gear somethingI4...

  • Page 337: Gear Shifter

    TRANSMISSION (StepNumberStart) GEAR SHIFTER REMOVAL 1. Remove the left side foot board and supports. 2. Remove the acorn nuts from the shift rod ball joints. 3. Remove the front and rear ball joints from the shift levers. 4. Remove the pivot bracket screws and the pivot bracket assembly.

  • Page 338: Assembly

    TRANSMISSION (StepNumber) ASSEMBLY 1. Install both foot peg levers on the shift shaft as shown. 2. Install the pinch screws with one drop of Loctite 242 thread locker. Torque: 8 ft-lbs 3. Slide the shift shaft into the pivot bracket. 4.

  • Page 339: Transmission

    TRANSMISSION (StepNumber) TRANSMISSION REMOVAL 1. Remove the outer primary cover (see OUTER PRIMARY COVER REMOVAL page 9-2). 2. Remove the torsional compensator (see TORSIONAL COMPENSATOR REMOVAL page 9-4). 3. Remove the clutch (see CLUTCH REMOVAL page 10-10) 4. Remove the output sprocket (see OUTPUT SPROCKET REMOVAL page 11-14).
  • Page 340 TRANSMISSION (StepNumber) 5. Remove the shift fork shafts and the shift forks. Notice Mark the shift forks to ensure they are reinstalled in their original location. 6. Remove the shift drum, drum bearing retainer, and shift drum bearing. Notice The shift drum bearing has a slip fit, and should not require additional tools for removal.

  • Page 341: Inspection

    TRANSMISSION (StepNumber) 14. Remove the retaining ring, needle bearing, washer, and 1st gear from the output shaft. 15. Remove 4th gear from the output shaft. 16. Remove the retaining ring, washer, and 3rd gear from the output shaft. 10832 1. RETAINING RING 5.
  • Page 342 TRANSMISSION (StepNumber) 3. Inspect the output main bearing (in right side engine case). Turn the inner race with your finger. The race should turn smoothly and quietly without excess play. 4. The outer race of the output main bearing should fit tightly in the engine case, and the output shaft should slide easily into the bearing without excess play.
  • Page 343 TRANSMISSION (StepNumber) GEARS 1. Inspect the gear dogs, dog holes, and gear teeth on each gear for damage and excessive wear. 2. Inspect internal splines by placing the gear in position on it’s respective shaft and trying to rotate the gear in either direction.

  • Page 344: Assembly

    TRANSMISSION (StepNumber) SHIFT DRUM 1. Inspect the shift drum bearing surfaces and shift fork grooves for damage and abnormal wear. 2. Measure the shaft diameter in the locations shown. Service Limit: Gear selector end somethingSDG Service Limit: Neutral cam end somethingSDN Replace the shift drum if necessary.
  • Page 345 TRANSMISSION (StepNumber) 1. Press a new input bearing onto the input shaft until it contacts the shaft gear. Tool: Input shaft tool EH-6999-0058 2. Install the input bearing outer retainer onto the cassette plate. Torque: 8 ft-lbs 3. Press the input bearing and shaft assembly into the cassette plate until the bearing contacts the retainer.
  • Page 346 TRANSMISSION (StepNumber) 10. Install 2nd/3rd gear on the input shaft. 11. Install 2nd gear, the washer, and the retaining ring on the output shaft. 10830 1. RETAINING RING 3. 2ND GEAR - OUTPUT 2. WASHER 4. 2ND/3RD GEAR - INPUT (StepNumber) 12.

  • Page 347: Installation

    TRANSMISSION (StepNumber) 19. Use a drop of Loctite 242 thread locker on the detent arm screw, and install the detent spring and detent arm. Torque: 8 ft lbs 20. Install the gear selector assembly. Torque: 8 ft-lbs 21. Hold the shift pawl away from the gear selector and push the shift shaft assembly into the cassette plate.

  • Page 348: Output Sprocket

    TRANSMISSION (StepNumber) 9. Install the output sprocket (see OUTPUT SPROCKET INSTALLATION page 11-15). 10. Install the clutch (see CLUTCH INSTALLATION page 10-16) 11. Install the torsional compensator (see TORSIONAL COMPENSATOR INSTALLATION page 9-6). 12. Install the outer primary cover (see OUTER PRIMARY COVER INSTALLATION page 9-3).

  • Page 349: Inspection

    TRANSMISSION (StepNumber) INSPECTION 1. Inspect the splines by placing the sprocket on the transmission output shaft and trying to rotate the sprocket in either direction. There should be no rotary movement. 2. Inspect the sprocket for cracked or bent side plates. The side plates must be firmly attached to the sprocket hub.

  • Page 350: Final Drive Belt

    TRANSMISSION (StepNumber) 6. Place the drive belt on the output sprocket. 7. Turn the rear axle adjusters in until they seat in the adjuster collars. 8. Align the rear wheel (see REAR WHEEL ALIGNMENT page 12-11). 1. ADJUSTER 2. ADJUSTER COLLAR (StepNumber) 9.

  • Page 351: Installation

    TRANSMISSION (StepNumber) 5. Support the rear of the engine from underneath. 6. Remove the rear engine mount nuts. 7. Loosen an engine mount screw. • If the right side engine mount screw loosens first, remove the screw and washer. Use a length of 5/8" dia. stock as a push rod to drive the engine mount shaft into the engine case.
  • Page 352 WHEELS 10736 12-0 6999-0003 7/15/99...

  • Page 353: 12. Wheels

    12. WHEELS SERVICE INFORMATION ..12-1 REAR WHEEL (cont.) TROUBLESHOOTING ... . 12-2 INSTALLATION ....12-10 ALIGNMENT .

  • Page 354: Troubleshooting

    WHEELS SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Tires Size Front Tire = Dunlop 491 Elite II MT90B16 1/16" minimum tread with 36 psi cold depth Rear Tire = Dunlop 491 Elite II MU90B16 1/16" minimum tread with 40 psi cold depth Runout Radial = 0.00 - 0.09"...

  • Page 355: Front Wheel

    WHEELS (StepNumberStart) FRONT WHEEL REMOVAL 1. Raise the wheel off the ground by supporting the frame securely. 2. Loosen both axle pinch screws. 3. Remove the right side axle bolt and bevel washer. 4. Remove the brake caliper mounting screws. 5.

  • Page 356: Disassembly

    WHEELS (StepNumber) 1. Place the wheel in a truing stand and measure the runout. Spin the wheel slowly and read the runout using a dial indicator. To adjust rim runout (see TRUING WHEEL page 12-14). Notice Actual runout is 1/2 the total indicator reading. Standard: Radial = 0.00 - 0.02"...

  • Page 357: Assembly

    WHEELS (StepNumber) 3. Insert a punch into the hub from the stamped text side. With the tip of the punch on the inner race of the opposite bearing, tap out the bearing retainer and bearing. Notice If bearings are removed, they must be replaced with new ones.

  • Page 358: Installation

    WHEELS (StepNumber) 6. Install the hub cap and hub cap screws. Torque: 10 ft-lbs 7. Install the brake rotor using new rotor screws. Torque: 50 ft-lbs WARNING Do not get grease on the brake rotor or stopping power will be reduced. Clean the brake rotor with brake cleaner or lacquer thinner before installing the wheel.

  • Page 359: Inspection

    WHEELS (StepNumber) 6. Remove and discard the rear axle cotter pin, and remove the castle nut. 7. Loosen the rear axle adjuster jam nuts and turn the adjusters out as far as possible. Slide the rear wheel and axle all the way forward. 8.

  • Page 360: Disassembly

    WHEELS (StepNumber) 1. Place the wheel in a truing stand and measure the runout. Spin the wheel slowly and read the runout using a dial indicator. To adjust rim runout (see TRUING WHEEL page 12-14). Notice Actual runout is 1/2 the total indicator reading. Standard: Radial = 0.00 - 0.02"...

  • Page 361: Assembly

    WHEELS (StepNumber) 3. Insert a punch into the hub from the stamped text side. With the tip of the punch on the inner race of the opposite bearing, tap out the bearing retainer and bearing. Notice If bearings are removed, they must be replaced with new ones.

  • Page 362: Installation

    WHEELS (StepNumber) Install the rear sprocket and the sprocket screws. Torque: 55 ft-lbs 10031 1. SPROCKET SCREWS 2. SPROCKET (StepNumber) 6. Install the brake rotor using new rotor screws. Torque: 50 ft-lbs WARNING Do not get grease on the brake rotor or stopping power will be reduced.

  • Page 363: Alignment

    WHEELS (StepNumber) 8. Place the drive belt on the rear sprocket and install the rear belt guard. 9. Install the left adjuster collar and castle nut. Tighten the castle nut finger tight. 10. Turn the axle adjusters in until they seat into the adjuster collars.

  • Page 364: Lacing Wheel

    WHEELS (StepNumber) LACING WHEEL A complete spoke set includes twenty inner spokes, twenty outer spokes, and 40 spoke nipples. Inner spokes have heads that angle away from the spoke shaft, outer spokes have heads that angle toward the spoke shaft. Notice When properly installed, inner spoke shafts reside inside the hub flange, and outer spoke shafts reside outside the...
  • Page 365 WHEELS (StepNumber) 7. Place the rim on two 7/8" spacers and center it over the hub assembly. Notice • When lacing the front wheel, position the valve stem opening toward the lower hub flange. • When lacing the rear wheel, position the valve stem opening toward the upper hub flange.

  • Page 366: Truing Wheel

    WHEELS (StepNumber) 15. Lace an upper flange inner spoke through the one hole in a spoke hole group that points toward the spoke. 16. Lubricate the threads, and screw a spoke nipple onto the end of the upper flange inner spoke a few turns. 17.
  • Page 367 WHEELS (StepNumber) EXAMPLE: If the offset measurement is too short, loosen the two spokes attached to the hub near the stamped text flange, then tighten the two spokes attached to the opposite flange. Turn all four spokes an equal number of turns. Caution Always loosen the appropriate spokes before tightening the opposite spokes.

  • Page 368: Tires & Inner Tubes

    WHEELS (StepNumber) 12. Adjust the truing stand gauge to the edge of the rim. 13. Spin the rim slowly. If the rim contacts the gauge near a marked spoke group, loosen the spokes in the group on the opposite side of the rim. Tighten the spokes in the group that is nearest the gauge.

  • Page 369: Removal

    WHEELS (StepNumber) Notice • When installing a new tire, always use a new inner tube. • Inner tubes can be patched, but only as an emergency measure. Replace a damaged or patched inner tube as soon as possible. 10061 (StepNumber) REMOVAL 1.

  • Page 370: Installation

    WHEELS (StepNumber) INSTALLATION 1. Clean the inside of the tire, the inner tube, and the rim. WARNING • Use the correct tire and inner tube specified. Use of non-standard parts can adversely affect motorcycle handling. • Always check tire sidewalls for arrows indicating proper tire rotation for the application.

  • Page 371: Radial Runout

    WHEELS (StepNumber) RADIAL RUNOUT 1. Mount the wheel assembly in a truing stand. Slowly turn the wheel assembly and measure the amount of radial runout from a point near the center of the tire tread. Standard: Radial = 0.00 - 0.09" Notice Make sure tire bead is properly seated.

  • Page 372: Wheel Balance

    WHEELS (StepNumber) WHEEL BALANCE WARNING Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check wheel balance before reinstalling the wheel. 1. Mount the wheel assembly in an inspection stand. Notice If possible, balance wheels with brake rotor, sprocket, or hub cap properly attached.
  • Page 373 WHEELS NOTES 12-21 6999-0003 7/15/99...
  • Page 374 FRONT SUSPENSION/STEERING 13-0 6999-0003 7/15/99...

  • Page 375: 13. Front Suspension/Steering

    13. FRONT SUSPENSION/STEERING SERVICE INFORMATION ..13-1 STRUTS (cont.) TROUBLESHOOTING ... . 13-2 ASSEMBLY ..... . 13-9 INSTALLATION .

  • Page 376: Troubleshooting

    FRONT SUSPENSION/STEERING TOOLS Strut spring compressor - - - - - - XXXX-XXX4 Retaining nut socket - - - - - - - - XXXX-XXX6 Bearing sleeve - - - - - - - - - - - XXXX-XXX1 Bearing driver - - - - - - - - - - - XXXX-XXX2 Bearing driver - - - - - - - - - - - XXXX-XXX2 TROUBLESHOOTING Hard steering...

  • Page 377: Handlebar

    FRONT SUSPENSION/STEERING (StepNumberStart) HANDLEBAR REMOVAL Release all cables, wires and hoses from cable retainers. Remove left control assembly. Carefully allow the control assembly to hang by its harness. Remove clutch lever assembly. Carefully allow the assembly to hang by its harness. 1.

  • Page 378: Installation

    FRONT SUSPENSION/STEERING (StepNumber) INSTALLATION Install isolation mounts in the risers. Install risers on top triple clamp. Torque: Handlebar riser screws 1.00 ft-lbs. Center handlebar knurled areas on the risers. Install clamps and clamp screws finger tight. Position handlebar in desired location.

  • Page 379: Struts

    FRONT SUSPENSION/STEERING (StepNumber) Turn both throttle cable adjusters to remove almost all of the slack in the cables. Standard: 1/16 - 3/16 in Notice Make sure cables are adjusted to allow throttle valve complete movement from rest to stop. Tighten adjuster lock nuts. (StepNumber) Install clutch lever assembly.
  • Page 380 FRONT SUSPENSION/STEERING (StepNumber) Wrap a clean cloth around the lower portion of each strut spring. (StepNumber) Cover the inner surface of each strut below the fender mounting screws with tape. Remove the fender screws. Slide the fender assembly downward off both struts and the rigid fork. Notice To prevent damaging plated and painted surfaces, make sure the fender grommets remain in position as the...

  • Page 381: Disassembly

    FRONT SUSPENSION/STEERING (StepNumber) DISASSEMBLY Remove socket head screws and strut cap. 10079 1. SOCKET HEAD SCREWS 2. STRUT CAP (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) Compress the strut spring. Tool: Strut spring compressor XXXX-XXX4 Slide the spring retainer out from underneath the damper unit...
  • Page 382 FRONT SUSPENSION/STEERING (StepNumber) STRUT BEARINGS Check the strut bearing for axial or radial movement. Replace the bearing if lateral movement is detected in any direction. 1. STRUT BEARING 3. RADIAL MOVEMENT 2. AXIAL MOVEMENT (StepNumber) SPRING Measure the spring free length. Replace if necessary. Service Limit: 15.50 - 15.25 in Inspect each spring isolator for cracks, tears, and brittleness.

  • Page 383: Assembly

    FRONT SUSPENSION/STEERING (StepNumber) ASSEMBLY Stabilize the lower strut. Use the flats at the base of the damper unit to screw it into the lower strut. Torque: Damper unit 3.00 ft-lbs. Install the lower spring isolator. 10081 1. LOWER SPRING 2. LOWER STRUT ISOLATOR 3.
  • Page 384 FRONT SUSPENSION/STEERING (StepNumber) Pass the strut axle all the way through the first strut assembly and the top triple clamp. Install any washers and the strut axle end bolt. Torque: Strut axle end bolt 5.00 ft-lbs. 10077 1. STRUT AXLE 3.

  • Page 385: Fork

    FRONT SUSPENSION/STEERING (StepNumber) FORK REMOVAL Remove the front wheel assembly (see FRONT WHEEL REMOVAL page 12-3). Remove both struts (see STRUTS REMOVAL page 13-5) Remove fuel tank (see FUEL TANK page 2-3) 1. FORK (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency”...

  • Page 386: Inspection

    FRONT SUSPENSION/STEERING (StepNumber) Remove fork studs. Remove acorn nut and washer. Remove top triple clamp. 1. FORK STUDS (2) 3. WASHER 2. ACORN NUT 4. TOP TRIPLE CLAMP (StepNumber) Support fork. Remove lock nut and retaining nut. Slide fork down and out of steering head. 1.
  • Page 387 FRONT SUSPENSION/STEERING (StepNumber) LOWER STEERING HEAD BEARING (see STEERING HEAD BEARINGS INSPECTION page 13- 1. LOWER STEERING HEAD BEARING (StepNumber) FORK Place the fork on a flat work surface. Position spacers of equal height beneath the upper bars of the fork. Gently add some weight to the upper bars so the entire fork rests squarely on the spacers.

  • Page 388: Installation

    FRONT SUSPENSION/STEERING (StepNumber) INSTALLATION Apply a thin film of wheel bearing grease to the steering stem and slide it through the steering head. Start the retaining nut and the lock nut on the steering stem. Slowly tighten the retaining nut while rocking the fork in a front-to-rear motion until any movement is just eliminated.

  • Page 389: Steering Head Bearings

    FRONT SUSPENSION/STEERING (StepNumber) Connect the horn wires to the back of the horn assembly. Install the headlamp/horn bracket. Safely route the headlamp wires around the steering head and connect them to the main wire harness. 1. HEADLAMP/HORN ASSEMBLY (StepNumber) STEERING HEAD BEARINGS INSPECTION Turn the upper bearing inner race with your finger.

  • Page 390: Installation

    FRONT SUSPENSION/STEERING (StepNumber) Drive the lower bearing race from the steering head with a drift or large punch. 1. DRIFT OR LARGE PUNCH (StepNumber) Install the top triple clamp acorn nut on the steering stem to protect the threads during bearing removal. Cover the top surface of the lower triple clamp near the steering stem.
  • Page 391 FRONT SUSPENSION/STEERING (StepNumber) Drive the upper steering head bearing into the steering head. Contact only the outer race of the bearing, pressing it squarely into the head until it seats. Tool: Bearing driver XXXX-XXX3 1. UPPER BEARING 3. BEARING DRIVER (StepCaptionHold) “For demonstration only”...
  • Page 392 REAR SUSPENSION 14-0 6999-0003 7/15/99...

  • Page 393: 14. Rear Suspension

    14. REAR SUSPENSION SERVICE INFORMATION ..14-1 SHOCK ABSORBER....14-2 TROUBLESHOOTING ... . 14-1 SWING CAGE .

  • Page 394: Shock Absorber

    REAR SUSPENSION (StepNumberStart) SHOCK ABSORBER ADJUSTMENT (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) REMOVAL (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) INSPECTION (StepNumber)
  • Page 395 REAR SUSPENSION (StepNumber) ASSEMBLY (StepNumber) INSTALLATION (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) SWING CAGE REMOVAL (StepNumber) INSPECTION 14-3 6999-0003 7/15/99...
  • Page 396 REAR SUSPENSION (StepNumber) PIVOT BEARING REPLACEMENT (StepNumber) INSTALLATION (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) (StepNumber) 14-4 6999-0003 7/15/99...
  • Page 397 REAR SUSPENSION (StepNumber) (StepNumber) (StepCaptionHold) “For demonstration only” (StepCaptionHold) “These are BLIND (white text) (StepCaptionHold) “Used to hold table height consistency” (StepNumber) (StepNumber) 14-5 6999-0003 7/15/99...
  • Page 398 REAR SUSPENSION (StepNumber) 14-6 6999-0003 7/15/99...
  • Page 399 REAR SUSPENSION 14-7 6999-0003 7/15/99...
  • Page 400 BRAKES 15-0 6999-0003 7/15/99...

  • Page 401: 15. Brakes

    15. BRAKES SERVICE INFORMATION ..15-1 REAR MASTER CYLINDER ..15-11 TROUBLESHOOTING ... . 15-2 REMOVAL ..... . 15-11 DISASSEMBLY .

  • Page 402: Troubleshooting

    BRAKES SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Brake pad friction material thickness 1/16" or less Brake rotor thickness as marked on rotor TORQUE VALUES Front master cylinder banjo bolt ... . 18 ft-lbs Front caliper housing screws .

  • Page 403: Bleeding Brake System

    BRAKES (StepNumberStart) BLEEDING BRAKE SYSTEM Air trapped in the brake system adversely effects brake system performance. Air can enter the brake system during system service or from hydraulic fluid contamination. Bleeding the brake system removes air from the system. The following procedure can also be used to flush or replace hydraulic fluid at the prescribed maintenance intervals (see Chapter 1.

  • Page 404: Front Master Cylinder

    BRAKES (StepNumber) FRONT MASTER CYLINDER REMOVAL 1. Loosen the mirror lock nut and remove the right mirror. 2. Loosen the turn signal gimbal nut and remove the turn signal assembly. 3. Disconnect the brake light wire harness. 4. Remove the banjo bolt, brake hose, and sealing washers. Discard the sealing washers.

  • Page 405: Inspection

    BRAKES (StepNumber) INSPECTION 1. Clean all cylinder parts and blow out all fluid ports with compressed air. Caution Do not use mineral base solvents to clean brake parts. 2. Visually inspect the cylinder bore. If there is evidence of scoring, pitting, or corrosion, replace the master cylinder assembly.

  • Page 406: Installation

    BRAKES (StepNumber) 7. Install the brake light switch. 8. Install the lever bolt and lever. 9. Install the diaphragm, plate, and reservoir cap. 1. CAP 4. LEVER BOLT 2. PLATE 5. LEVER 3. DIAPHRAGM 6. BRAKE LIGHT SWITCH (StepNumber) INSTALLATION 1.

  • Page 407: Front Caliper

    BRAKES (StepNumber) FRONT CALIPER PAD REPLACEMENT 1. Remove the front wheel (see FRONT WHEEL REMOVAL page 12-3). 2. Use a large flat blade screwdriver or small pry bar against the old brake pads and spread the caliper pistons as far apart as possible.

  • Page 408: Removal

    BRAKES (StepNumber) REMOVAL 1. Remove the front wheel (see FRONT WHEEL REMOVAL page 12-3). 2. Remove the banjo bolt, brake hose, and sealing washers. Discard the sealing washers. 3. Remove the nut and washer from the caliper rod and remove the caliper assembly. 1.

  • Page 409: Inspection

    BRAKES (StepNumber) 9. Remove and discard the dust seal and wiper seal from each cylinder bore. Caution Be extremely careful not to scratch the cylinder bore when removing the piston seals. 10. Remove the bleed valve cover and the bleed valve. 1.

  • Page 410: Assembly

    BRAKES (StepNumber) 6. Inspect the brake rotor. A warped or heavily scored rotor should be replaced. 7. Measure the thickness of the rotor in the brake pad contact area. Replace the rotor if it has worn beyond the minimum thickness dimension stamped on the rotor. 8.

  • Page 411: Installation

    BRAKES (StepNumber) INSTALLATION 1. Slide the caliper assembly onto the caliper rod and install the washer and nut. Torque: 30 ft-lbs 2. Install the banjo bolt, brake hose, and new sealing washers. Torque: 18 ft-lbs Caution For proper brake system operation, always use new sealing washers.

  • Page 412: Disassembly

    BRAKES (StepNumber) DISASSEMBLY 1. Clean the area around the reservoir cap and remove the reservoir cap, plate, and diaphragm. Empty the reservoir of any remaining hydraulic fluid. 1. CAP 3. DIAPHRAGM 2. PLATE (StepNumber) 2. Clamp the master cylinder securely in a padded vise. 3.

  • Page 413: Inspection

    BRAKES (StepNumber) INSPECTION 1. Clean all cylinder parts and blow out all fluid ports with compressed air. Caution Do not use mineral base solvents to clean brake parts. 2. Inspect the cylinder bore. If there is evidence of scoring, pitting, or corrosion, remove the adapter plate and replace the master cylinder assembly.

  • Page 414: Installation

    BRAKES (StepNumber) 7. Install the jam nut on the piston rod. 8. Slide the cylinder end spring washer onto the master cylinder. 9. Install the spring and clevis end spring washer 10. Turn the rod clevis onto the piston rod until one or two threads are visible inside the clevis.

  • Page 415: Rear Caliper

    BRAKES (StepNumber) 4. Install the rear brake pedal. Torque: 50 ft-lbs 5. Install the brake pedal clevis pin and a new clevis cotter pin. 6. Install the foot support assembly. Torque: 25 ft-lbs 7. Bleed the rear brake system (see BLEEDING BRAKE SYSTEM page 15-3).

  • Page 416: Removal

    BRAKES (StepNumber) 8. Check to make sure the anti-rattle spring is in position and undamaged. Replace the anti-rattle spring if necessary. 9. Place the new brake pads in position. 10. Drive the pad retaining pin into the caliper from the outboard side.

  • Page 417: Inspection

    BRAKES (StepNumber) 8. Blow low pressure compressed air (10 - 15 psi) into the cross port to push the pistons from each caliper housing. WARNING The pistons may eject from the caliper housing with great force, resulting in damage to the piston or personal injury. Point the caliper away from you or others and wear heavy gloves or wrap the caliper housing in a heavy towel before removing the pistons.

  • Page 418: Assembly

    BRAKES (StepNumber) 5. Inspect each brake pad for damage or wear. Replace any brake pad that has less than the recommended amount of friction material. Service Limit: 1/16" or less WARNING To preserve consistent braking performance, always replace brake pads in complete sets. 1.

  • Page 419: Installation

    BRAKES (StepNumber) INSTALLATION 1. Slide the caliper onto the rotor and over the mounting bracket. Install the two mounting screws. Torque: 35 ft-lbs 2. Install the banjo bolt, brake hose, and new sealing washers. Torque: 18 ft-lbs Caution For proper brake system operation, always use new sealing washers.
  • Page 420 BATTERY/CHARGING SYSTEM 16-0 6999-0003 7/15/99...

  • Page 421: 16. Battery/Charging System

    16. BATTERY/CHARGING SYSTEM SERVICE INFORMATION ..16-1 ALTERNATOR ....16-7 TROUBLESHOOTING ... . 16-2 ROTOR REMOVAL .

  • Page 422: Troubleshooting

    BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Battery model YTX20L-BS Battery voltage (loaded) 9.6 volts Battery voltage (unloaded) 12.8 V or more Regulated voltage 14.0 - 14.8 V @ 3,000 rpm Current leakage 1.0 mA or less Stator resistance 0.5 ohms or less Alternator output 60 to 70 VAC TORQUE VALUES...

  • Page 423: Battery

    BATTERY/CHARGING SYSTEM (StepNumberStart) BATTERY REMOVAL 1. Remove the screw that secures the battery cover strap and remove the strap. 2. Remove the battery cover. 3. Disconnect the negative ( - ) battery cable. 4. Disconnect the positive ( + ) battery cable. WARNING Disconnecting the positive cable first can produce an electric shock that could result in damage or injury.

  • Page 424: Charging

    BATTERY/CHARGING SYSTEM (StepNumber) CHARGING WARNING • The battery may contain explosive gases. • Keep sparks, cigarettes, or open flame away from the battery. • Protect eyes, skin, clothing when handling or working near the battery. • Make sure ventilation is adequate when charging or using the battery in an enclosed space.

  • Page 425: Charging System Tests

    BATTERY/CHARGING SYSTEM (StepNumber) CHARGING SYSTEM TESTS Notice In order to obtain accurate test readings, the battery must be fully charged (see BATTERY CHARGING page 16-4). REGULATED VOLTAGE 1. Start the engine and warm it to operating temperature. When the engine is warm, move the main switch to the Off position.

  • Page 426: Alternator Stator

    BATTERY/CHARGING SYSTEM (StepNumber) ALTERNATOR STATOR 1. Disconnect the alternator from the voltage regulator connector. 2. Measure the resistance between the each of the stator leads. Standard: 0.5 ohms or less 3. Test for continuity between each stator lead and motorcycle ground. There should be no continuity. If the resistance is out of range or there is continuity between the stator and ground, replace the stator.

  • Page 427: Alternator

    BATTERY/CHARGING SYSTEM (StepNumber) 4. Remove the tandem and rider’s saddles (see SADDLE REMOVAL page 2-3) 5. Remove the boot from the main breaker and attach the load tester positive lead to the main breaker post. 6. Start the engine and run it at 3000 rpm. 7.

  • Page 428: Rotor Inspection

    BATTERY/CHARGING SYSTEM (StepNumber) 3. Thread the alternator puller into the rotor and tighten the puller clockwise until the rotor is free from the crankshaft. Tool: Alternator rotor puller EH-6999-0028 1. ALTERNATOR PULLER 2. ROTOR (StepNumber) ROTOR INSPECTION 1. Inspect the inside of the rotor for cracks, damage or unusual wear.

  • Page 429: Stator Removal

    BATTERY/CHARGING SYSTEM (StepNumber) STATOR REMOVAL 1. Remove the stator wire clip and fastener from the outer primary cover. 2. Remove the stator mounting screws and the stator. 1. WIRE CLIP 3. STATOR 2. MOUNTING SCREWS (StepNumber) STATOR INSPECTION 1. Inspect the stator for damage or unusual wear. 2.

  • Page 430: Installation

    BATTERY/CHARGING SYSTEM (StepNumber) INSTALLATION 1. Position the voltage regulator on the mounting bracket and install the mounting screws and locknuts. Torque: 8 ft-lbs 2. Connect the regulator to the alternator and to the wire harness. 3. Secure the connectors to the bottom frame tube with a new cable strap.
  • Page 431 BATTERY/CHARGING SYSTEM NOTES 16-11 6999-0003 7/15/99...
  • Page 432 STARTER 10722 17-0 6999-0003 7/15/99...

  • Page 433: 17. Starter

    17. STARTER SERVICE INFORMATION ..17-1 STARTER RELAY ....17-6 TROUBLESHOOTING ... . 17-2 ONBOARD TEST .

  • Page 434: Troubleshooting

    STARTER TROUBLESHOOTING Starter motor does not run Starter motor runs slowly • Discharged battery • Low battery voltage • Faulty starter relay • Faulty starter motor connection • Faulty starter relay connection • Faulty starter relay connection • Faulty starter motor connection •...

  • Page 435: Starter Motor

    STARTER (StepNumberStart) STARTER MOTOR CURRENT DRAW TEST Measure the starter motor current draw using an induction ammeter. The motorcycle should be at room temperature and the battery should be fully charged. 1. Verify that the transmission is in neutral and remove the ignition coils from the spark plugs.

  • Page 436: Inspection

    STARTER (StepNumber) 3. Remove the armature and the front cover. Remove the front cover O-ring. Caution Keep the armature clean. Avoid transferring dirt and skin oils to the commutator. 1. FRONT COVER 2. ARMATURE (StepNumber) 4. Remove the starter motor terminal and washers. 5.

  • Page 437: Assembly

    STARTER (StepNumber) ARMATURE 1. Inspect the shaft for worn or damaged drive gear teeth. 2. Inspect armature bearings. The bearings should rotate smoothly and quietly with no axial movement. 3. Test for continuity between the armature core and any commutator segment. Standard: No continuity 4.

  • Page 438: Installation

    STARTER (StepNumber) INSTALLATION 1. Install a new O-ring on the front starter cover boss. Lightly lubricate the O-ring to ease assembly. 2. Install the starter motor and fasten the mounting screws. Torque: 8 ft-lbs 3. Connect the starter cable. 4. Connect the battery, positive cable first (see BATTERY INSTALLATION page 16-4).

  • Page 439: Inspection

    STARTER (StepNumber) INSPECTION 1. Inspect the switch and coil connections for dirt or corrosion. Clean as needed. 2. Apply 12 volts to the relay coil (terminals 85 and 86). Test for continuity across the relay switch (terminals 30 and 87). If the test fails, replace the starter relay.

  • Page 440: Inspection

    STARTER (StepNumber) 6. Remove the inner primary cover screws and the inner primary cover. 7. Remove and discard the inner primary cover gaskets. 10805 1. INNER PRIMARY COVER (StepNumber) 8. Remove starter idler gear and idler gear shaft. 1. IDLER GEAR 2.

  • Page 441: Installation

    STARTER (StepNumber) INSTALLATION 1. Clean any remaining gasket material from the engine case and inner primary cover. 2. Install the starter idler gear shaft and gear into the crankcase. 1. IDLER GEAR 2. IDLER GEAR SHAFT (StepNumber) 3. Make sure the two alignment pins are in position. 4.
  • Page 442 STARTER (StepNumber) 7. Lubricate the crankshaft bearing race with an assembly lubricant and install the starter gear/sprag clutch assembly on the crankshaft. 8. Install the clutch (see CLUTCH INSTALLATION page 10-16). 9. Install the torsional compensator (see TORSIONAL COMPENSATOR INSTALLATION page 9-6).
  • Page 443 STARTER NOTES 17-11 6999-0003 7/15/99...
  • Page 444 LIGHTS/GAUGES/SWITCHES 18-0 6999-0003 7/15/99...

  • Page 445: 18. Lights/Gauges/Switches

    18. LIGHTS/GAUGES/SWITCHES SERVICE INFORMATION ..18-2 TURN SIGNAL LAMPS ...18-16 TROUBLESHOOTING ... . 18-3 BULB REPLACEMENT .

  • Page 446: Service Information

    LIGHTS/GAUGES/SWITCHES SERVICE INFORMATION GENERAL • For additional information on the engine control module and related sensors (see Chapter 4. ENGINE CONTROL SYSTEM). • Refer to the wiring schematic for wire and connector conventions (see Chapter 19. WIRING SCHEMATIC). • For electric starter motor and starter relay information (see Chapter 17.

  • Page 447: Troubleshooting

    LIGHTS/GAUGES/SWITCHES TROUBLESHOOTING Headlamp low beam or high beam does not work Tail lamp does not work • Faulty bulb • Faulty bulb • Faulty dimmer switch • Blown Lights fuse • Faulty wiring • Faulty wiring Neither high beam nor low beam works Brake lamp does not work •...

  • Page 448: Right Handlebar Control

    LIGHTS/GAUGES/SWITCHES (StepNumberStart) RIGHT HANDLEBAR CONTROL The right handlebar control houses the following: • Engine stop/run switch - powered by the tilt switch and controls power to the starter button and the ECM. • Hazard switch - switches hazard input to the turn signal control module to ground, activating the hazard flashers.

  • Page 449: Inspection

    LIGHTS/GAUGES/SWITCHES (StepNumber) Notice Separate the control body halves carefully to avoid loosing the throttle cable end keepers. 8. Remove the screws that secure the handlebar control body and separate the control body halves. 9. Remove the throttle cables from the control body and remove the control.

  • Page 450: Installation

    LIGHTS/GAUGES/SWITCHES (StepNumber) FRONT BRAKE LAMP SWITCH Test for continuity between the switch input and switch output with the front brake on and off. If the test fails, replace the front brake lamp switch. Standard: On - Continuity Off - No Continuity 1.

  • Page 451: Left Handlebar Control

    LIGHTS/GAUGES/SWITCHES (StepNumber) LEFT HANDLEBAR CONTROL The left handlebar control houses the following: • Headlamp dimmer switch - powered through the Lights fuse and controls power to the headlamp high and low beam. • Turn signal switch - switches turn signal control module inputs to ground activating or canceling the turn signals.

  • Page 452: Inspection

    LIGHTS/GAUGES/SWITCHES (StepNumber) INSPECTION Inspect handlebar control connectors for damage or corrosion. Clean or repair as needed. HEADLAMP DIMMER SWITCH Test for continuity between the following: • Switch position: Low beam. – Switch power (P23B-A) – Low beam output (P23B-B) • Switch position: High beam –...

  • Page 453: Installation

    LIGHTS/GAUGES/SWITCHES (StepNumber) HORN BUTTON Test for continuity between the switch input (P22B-A) and switch output (P22B-B) with the button on and off. If the test fails, replace the left handlebar control. Standard: On - Continuity Off - No Continuity (StepNumber) INSTALLATION 1.

  • Page 454: Inspection

    LIGHTS/GAUGES/SWITCHES (StepNumber) 3. Disconnect the wiring harness from the main switch (P29). 4. Remove the screws that secure the main switch bracket and remove the switch and bracket assembly. 1. BRACKET 3. SWITCH 2. LOCK ASSEMBLY (StepNumber) INSPECTION 1. The switch should move freely from Off to On to Acc. 2.

  • Page 455: Installation

    LIGHTS/GAUGES/SWITCHES (StepNumber) INSTALLATION 1. Install the bracket and main switch assembly. Torque: 7 ft-lbs 2. Connect the main switch to the wiring harness. 3. Install the fuel tank (see FUEL TANK INSTALLATION page 4-123). 4. Connect the battery, positive cable first (see BATTERY INSTALLATION page 16-4).

  • Page 456: Rear Brake Switch

    LIGHTS/GAUGES/SWITCHES (StepNumber) REAR BRAKE SWITCH The rear brake switch is located on the left side of the motorcycle near the kickstand bumper. It is a hydraulic switch operated by the brake pedal. The rear brake switch is powered by the Lights fuse and controls the brake lamp. REMOVAL 1.

  • Page 457: Removal

    LIGHTS/GAUGES/SWITCHES (StepNumber) Lift the lamp from the headlamp bucket, and disconnect the wire terminal from the back of the lamp. 3. Connect the new lamp and test for proper operation. Standard: ANSI #6054 4. Reinstall the headlamp bezel and screw. (StepNumber) ADJUSTMENT 1.

  • Page 458: Installation

    LIGHTS/GAUGES/SWITCHES (StepNumber) INSTALLATION 1. Install the headlamp and fasten the mounting screw. Torque: 35 ft-lbs 2. Route the headlamp harness and connect the headlamp to the wiring harness. 3. Install the fuel tank (see FUEL TANK INSTALLATION page 4-123). 4. Connect the battery, positive cable first (see BATTERY INSTALLATION page 16-4).

  • Page 459: Installation

    LIGHTS/GAUGES/SWITCHES (StepNumber) 4. Unfasten the tail lamp wiring harness from the wire clips. 5. Remove the mounting screws on the inside of the fender and remove the tail lamp assembly. 1. WIRE CLIPS 2. MOUNTING SCREWS (StepNumber) INSTALLATION 1. Install the tail lamp assembly and fasten the mounting screws.

  • Page 460: Installation

    LIGHTS/GAUGES/SWITCHES (StepNumber) 3. Disconnect the wiring harness from the turn signal control module. 4. Remove the turn signal control module. 1. TURN SIGNAL CONTROL MODULE (StepNumber) INSTALLATION 1. Install the turn signal control module. 2. Connect the wiring harness to the turn signal control module.

  • Page 461: Front Turn Signal

    LIGHTS/GAUGES/SWITCHES (StepNumber) FRONT TURN SIGNAL REMOVAL 1. Disconnect the battery, negative cable first (see BATTERY REMOVAL page 16-3). 2. Remove the fuel tank (see FUEL TANK REMOVAL page 4-122). 3. Unfasten the wire clips on the handle bars. 4. Remove the steering head harness clip and separate the front turn signal harness.

  • Page 462: Rear Turn Signals

    LIGHTS/GAUGES/SWITCHES (StepNumber) REAR TURN SIGNALS REMOVAL 1. Disconnect the battery, negative cable first (see BATTERY REMOVAL page 16-3). 2. Remove the rear fender (see REAR FENDER REMOVAL page 2-10). 3. Disassemble the tail lamp connector. Remove the locking wedge. Unlock the pin tangs and remove the following pins: –...

  • Page 463: Horn

    LIGHTS/GAUGES/SWITCHES (StepNumber) 4. Assemble the tail lamp connector. Install the pins and the locking wedge. – Pin 3 - Violet - left turn signal – Pin 6 - Black - left turn signal ground. – Pin 4 - Violet - right turn signal (taped) –...

  • Page 464: Neutral Switch

    LIGHTS/GAUGES/SWITCHES (StepNumber) NEUTRAL SWITCH The neutral switch is powered by the ECM through the neutral indicator lamp and grounds to the engine case. The switch is normally open. When the transmission is placed in neutral, the switch actuator rides up on the neutral switch cam, closes the switch, and illuminates the neutral indicator lamp.

  • Page 465: Installation

    LIGHTS/GAUGES/SWITCHES (StepNumber) INSTALLATION 1. Install the neutral switch with a new seal washer. Torque: 12 ft-lbs 2. Connect the wiring harness to the neutral switch. (StepNumber) OIL PRESSURE SWITCH The oil pressure switch is located on the right side of the crankcase behind the timing gear cover.

  • Page 466: Inspection

    LIGHTS/GAUGES/SWITCHES (StepNumber) INSPECTION 1. Inspect the connector and switch. Clean as needed. 2. Turn the main switch to the On position. 3. If the indicator lamp does not illuminate, disconnect the oil pressure switch wire and ground it to the engine or frame. 4.

  • Page 467: Bulb Replacement

    LIGHTS/GAUGES/SWITCHES (StepNumber) BULB REPLACEMENT 1. Remove the instrument cluster (see INSTRUMENT CLUSTER REMOVAL page 18-22). 2. Locate the burned out bulb. Grasp the corresponding wires and pull the rubber socket plug from the instrument cluster. 3. Replace the bulb and insert the rubber socket in the instrument cluster.

  • Page 468: Main Breaker

    LIGHTS/GAUGES/SWITCHES (StepNumber) MAIN BREAKER The electrical system is protected by a 50 amp thermal circuit breaker. The breaker is located under the electronics cover. REMOVAL 1. Disconnect the battery, negative cable first (see BATTERY REMOVAL page 16-3). 2. Remove the exhaust and muffler assembly (see EXHAUST SYSTEM REMOVAL page 2-11).

  • Page 469: Fuses

    LIGHTS/GAUGES/SWITCHES (StepNumber) NOTES FUSES Fuses are located under the rider’s saddle and protect the following circuits: • Electronic fuel injection (EFI) - including ECM, injectors, ignition coils, road speed sensor, and purge valve. • Fuel pump • Ignition - including the main switch and odometer. •...

  • Page 470: Removal

    LIGHTS/GAUGES/SWITCHES (StepNumber) NOTES REMOVAL 1. Remove the tandem and rider’s saddles (see SADDLE REMOVAL page 2-3). 2. Remove the exhaust and muffler assembly (see EXHAUST SYSTEM REMOVAL page 2-11). 3. Remove the screws that secure the electronics cover and remove the cover. 4.

  • Page 471: Continuity Test

    LIGHTS/GAUGES/SWITCHES (StepNumber) CONTINUITY TEST 1. Remove the relay (see RELAYS REMOVAL page 18-26). 2. Apply 12 volts across the relay coil (pins 85 and 86) and test for continuity between the relay switch input (pin 30) and the output (pin 87). If there is no continuity, replace the relay. (StepNumber) INSTALLATION 1.
  • Page 472 LIGHTS/GAUGES/SWITCHES 18-28 6999-0003 7/15/99...

  • Page 473: 19. Wiring Schematic

    WIRING SCHEMATIC 19. WIRING SCHEMATIC Alternator Turn Signal Main Switch Fuse Power Ignition Accessory Fuse Voltage Starter Relay Starter Motor Brake Control Block B Relay Block A Regulator Light Latch Relay Relay Switch Main Breaker Engine Chassis Be/R Light Bar Ground Ground A B C D E F...
  • Page 474 WIRING SCHEMATIC NOTES 19-2 6999-0003 7/15/99...

Table of Contents

Save PDF