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S[[ S1AN[ SW1H
CABLE & HARNESS ROUTING
9
PP EPAK[ AE|[
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S[A1 |OK AE|[
HH 1[NSON OP[
S[[ S1AN[ SlW
S1AP1[P MO1OP
O| PUMP AE|[
1HPO11|[ AE|[
O| PASS 1UE[
O| 1UE[
AU1O EYS1AP1[P OP[
FU[| 1UE[
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FU[| AU1O OK ASS'Y
FU[| S1PAN[P
FU[| 1ANK
FU[| v[N1 1UE[
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|H PP WNK[P |H1
PH PP WNK[P |H1
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FU[| UN1
1A| |H1 ONN[1N ONN[1OP
[ UN1 ASS'Y
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AU1O EYS1AP1[P
ONN[1N OUP|[P
A ONN[1N OUP|[P
A OP[ |AMP
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|AMP N 1H[ POS1ON OF 1H[ |AMP FPM|Y
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l O|
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WP[ HAPN[SS
S1AP1[P P[A|Y ASS'Y
[NN[ [AP1H
1H1 A1 1H[ SAM[ 1M[
W1H 1H[ S1AP1N MO1OP
PP[SS 1O A11AH 1H[
S[| S[1ON 1O 1H[ PP[
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5. INSPECTION /
MAINTENANCE
1) FUEL UNIT
REMOVAL
Remove the luggage box.
Remove the fuel unit wire from the wire harness.
Turn the fuel unit set cap complete to the left, and
remove it.
INSTALLATION
Install the base packing to the fuel tank.
Install the fuel unit.
Remove the base packing.
NOTE
NOTE
10
Be careful of prevention the fuel unit wire from
damaging.
When disassembling, be careful of prevention the
thermistor from damaging.
Check the base packing for damage.
NOTE
Install it aligning the part of the fuel unit with the
loop part of fuel tank.
Check the fuel leakage.
FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT
FUEL UNIT
FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT
FUEL UNIT
FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT
FUEL UNIT
THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR
THERMISTOR
BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING
BASE PACKING
INSPECTION/MAINTENANCE
BLACK
FUSE
GREEN YELLOW/WHITE
FUEL WARNING INDICATOR
LEVEL SENSOR
(THERMISTOR)
RED GREEN
MAIN SWITCH
11
FUEL UNIT INSPECTION
INFORMATION
Remove the fuel unit and check for proper operation in
the air and gasoline.
- Connect additional bulb between terminals of the fuel
unit and battery sides and check that the bulb is
illuminating.
(ADDITIONAL BULB CAPACITY : 14V 3W)
Check for battery voltage between the fuel level sensor
connector terminals.
The bulb must be illuminated within 3minutes after the
thermistor of the fuel unit is exposed in the air.
The bulb must not be illuminated within 3 minutes
after immersing the thermistor of the fuel unit.
FUEL WARNING INDICATOR
A thermistor is built into the fuel level sensor in the
fuel tank and the fuel warning light turns on due to
the thermistors self radiation of heat.
When the thermistor is in the gasoline, radiation of
heat increases and the self heating action is reduced.
As the resistance increases and the current does not
flow at this time, the fuel warning light does not turn
on.
When the thermistor is out of gasoline, i.e.fuel level is
low, radiation of heat decreases and the self heating
increases. As the resistance is low at this time, current
flows and the fuel warning light turns on.
FUEL UNIT
GREEN GREEN
BATTERY
YELLOW/WHITE
YELLOW/WHITE
BLACK
BULB (14V 3W)
COUPLER
TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER
TESTER
FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT
FUEL UNIT
BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB
BULB
FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT
FUEL UNIT
INSPECTION/MAINTENANCE
12
STARTER SWITCH
FREE
PUSH
CORD COLOR
ST
LIGHTING SWITCH
P
(N)
H
CORD COLOR
CI TL HL RE
YELLOW/RED
YELLOW BROWN PINK BLUE/WHITE
GREEN
E
WINKER SWITCH
L
N
R
CORD COLOR
R L WIN
SKY BLUE ORANGE GRAY
DIMMER SWITCH
LO
N
HI
CORD COLOR
HI HL LO
BLUE BLUE/WHITE WHITE
HORN SWITCH
FREE
PUSH
CORD COLOR
HO BAT
LIGHT GREEN BLACK
2) HANDLE SWITCH INSPECTION
Remove the front cover.
Remove the handle switch coupler, connector, and
inspect continuity of each terminal.
If abmormal, inspect the switch.
There should be continuity between the
positions on the continuity chart.
WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY
WINKER RELAY
DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH
DIMMER SWITCH
WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH WINKER SWITCH
WINKER SWITCH
HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH
HORN SWITCH
LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH
LIGHTING SWITCH
STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH
STARTER SWITCH
TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER TESTER
TESTER
INSPECTION/MAINTENANCE
13
3) SPEEDOMETER REPLACEMENT
Remove the front cover.
Loosen the 2 washer bolts, and remove the wind
screen.
Remove the speedometer cable from the meter.
Remove the speedometer coupler connected to the
wire harness.
Remove the speedometer wiring from the steering
handle cable guide.
Loosen the 2 flange bolts securing the steering handle
stay.
Remove the speedometer from the steering handle.
Install in the reverse order of removal.
NOTE
Check the each switch for proper operation.
The wire and cable must be connected accurately.
WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN WIND SCREEN
WIND SCREEN
FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER
FRONT COVER
SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE
SPEEDOMETER CABLE
SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER SPEEDOMETER COUPLER
SPEEDOMETER COUPLER
FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS
FLANGE BOLTS
INSPECTION/MAINTENANCE
14
4) PILOT BOX SET BULB REPLACEMENT
Remove the front cover.
Loosen the 2 tapping screws and remove the pilot box
base.
5) FRONT MINI COVER REMOVAL
Remove the front cover.
Loosen the 2 flange nuts and 2 special screws securing
the front under cover.
Remove the front mini cover.
Install in the reverse order of removal.
Remove the bulb from the socket, and replace with a
new bulb.
WEDGE BASE BULB T6.5 : 14V 3W
TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW
TAPPING SCREW
TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW
TAPPING SCREW
BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB BULB
BULB
SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS
SPECIAL SCREWS
INSPECTION/MAINTENANCE
15
6) LUGGAGE CARRIER REMOVAL
Loosen 3 flange bolts securing the top of the body
cover.
Remove the luggage carrier.
7) HANDLE LEVER PROTECTOR REMOVAL
[LEFT]
Loosen the 2 washer bolts, remove the LH. handle
lever protector.
Install in the reverse order of removal.
[RIGHT]
Loosen the handle lever bolt and wire band, remove
the RH. handle lever protector.
Install in the reverse order of removal.
Install in the reverse order of removal.
BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT
BOLT
BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT
BOLT
BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS
BOLTS
BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS
BOLTS
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
HANDLE LEVER
PROTECTOR
WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND WIRE BAND
WIRE BAND
WIRING DIAGRAM
1 1
6. WIRING DIAGRAM
MEMO
18
19
MEMO
20
MEMO
SERVICE MANUAL
2002. 5. PRINTED
2002. 5. PUBLICATION
NO COPY