Service manual

Information Summary and Preparation

prior to a connector removed or connected.

3. During any operation to simulate the thermal state of one defective unit or increase temperatures,

the temperature of the electronic control unit shall be less than 80 degrees Celsius.

4. All fuel hoses shall be high pressure-tolerant pipes in virtue of the high fuel pressure in the

Electronic Management System (300kPa or so) or even at the engine stopped. As a result, the fuel

hose during maintenance shall not be disassembled arbitrarily. In the case of maintaining the fuel

system, the pressure in the fuel system shall be released prior to removal of a fuel hose shown as

follows: Remove the fuel pump relay; start the engine; keep the engine at the idle speed until the

engine stops. The operation of removal of a fuel hose and replacement of a clamp shall be

executed by a professional mechanic in a well-ventilated place.

5. The power supplied to the electric fuel pump which is being removed from the fuel tank shall be

disconnected beforehand to prevent any spark or fire.

6. The fuel pump to be tested shall not be empty or refilled by water or the service life will be

curtailed. On the other hand, the positive and negative poles of the fuel pump shall be properly

connected.

7. Unless otherwise required, the spark test shall not be conducted or be completed quickly during

inspections of the ignition system. Additionally, the air throttle shall be kept closed during

inspections or the incompletely ignited gasoline will be fed into the exhauster and damage the

three-way catalytic converter.

8. The idle speed has been adjusted by the Electronic Management System in advance and not

changed manually. The initial position of the throttle stop screw adjusted by Motive Power shall

not be changed by a user without permission unless otherwise demanded.

9. The cables to be connected to the positive and negative poles on a battery shall be correctly linked

or the electronic devices will be damaged. The minus earth is used in the system.

10. Any cable connected to a battery shall not be disconnected during the engine running.

11. The battery shall be removed from the motorcycle for a charge separately conducted but not be

directly charged with the battery fixed on the vehicle for convenience.

12. The cables connected to the battery’s positive & negative poles and the electronic control unit

shall be removed from the motorcycle prior to any electrical welding operation.

13. Do not cut a cable’s cover layer to test any signal imported to or exported from one device.

1-5 Torque

Rated values

Type Torque (kg-m) Type Torque (kg-m)

5mm bolt 0.4~0.5kg-m 6mm nut 1.0~1.4kg-m

6mm bolt 0.9~1.1kg-m 8mm nut 2.0~3.0kg-m

8mm bolt 1.8~2.5kg-m 10mm nut 3.0~4.0kg-m

10mm bolt 3.0~4.0kg-m Pin / bolt 1.5~2.0kg-m

12mm bolt 5.0~6.0kg-m