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Kawasaki Ninja 650R, ER-6f ABS, ER-6f Motorcycle. Service Manual (2006-2008 year) - page 5

16-20 ELECTRICAL SYSTEM

Wiring Diagram (EX650B Models)

ELECTRICAL SYSTEM 16-21

Wiring Diagram (EX650B Models)

16-22 ELECTRICAL SYSTEM

Precautions

There are a number of important precautions that are

musts when servicing electrical systems. Learn and ob-

serve all the rules below.

○Do not reverse the battery cable connections. This will

burn out the diodes on the electrical parts.

○Always check battery condition before condemning other

parts of an electrical system. A fully charged battery is a

must for conducting accurate electrical system tests.

○The electrical parts should never be struck sharply, as

with a hammer, or allowed to fall on a hard surface. Such

a shock to the parts can damage them.

○To prevent damage to electrical parts, do not disconnect

the battery cables or any other electrical connections

when the ignition switch is on, or while the engine is

running.

○Because of the large amount of current, never keep the

starter button pushed when the starter motor will not turn

over, or the current may burn out the starter motor wind-

ings.

○Do not use a meter illumination bulb rated for other than

voltage or wattage specified in the wiring diagram, as the

meter or gauge panel could be warped by excessive heat

radiated from the bulb.

○Take care not to short the cables that are directly con-

nected to the battery positive (+) terminal to the chassis

ground.

○Troubles may involve one or in some cases all items.

Never replace a defective part without determining what

CAUSED the failure. If the failure was caused by some

other item or items, they must be repaired or replaced, or

the new replacement will soon fail again.

○Make sure all connectors in the circuit are clean and tight,

and examine wires for signs of burning, fraying, etc. Poor

wires and bad connections will affect electrical system op-

eration.

○Measure coil and winding resistance when the part is cold

(at room temperature).

○Color Codes:

BK: Black

G: Green

P: Pink

BL: Blue

GY: Gray

PU: Purple

BR: Brown

LB: Light Blue

R: Red

CH: Chocolate

LG: Light Green

W: White

DG: Dark Green

O: Orange

Y: Yellow

○Electrical Connectors

Female Connectors [A]

ELECTRICAL SYSTEM 16-23

Precautions

Male Connectors [B]

16-24 ELECTRICAL SYSTEM

Electrical Wiring

Wiring Inspection

• Visually inspect the wiring for signs of burning, fraying,

etc.

If any wiring is poor, replace the damaged wiring.

• Pull each connector [A] apart and inspect it for corrosion,

dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

is damaged, replace it.

• Check the wiring for continuity.

○Use the wiring diagram to find the ends of the lead which

is suspected of being a problem.

○Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

○Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Re-

place the lead or the wiring harness [B] if necessary.

ELECTRICAL SYSTEM 16-25

Battery

Battery Removal

• Remove:

Seat (see Seat Removal in the Frame chapter)

• Disconnect the negative (-) cable [A].

• Slide out the positive (+) terminal cap [B] and then discon-

nect the positive (+) cable.

CAUTION

Be sure to disconnect the negative (-) cable first.

• Remove the battery.

Battery Installation

• Put the battery into the rear fender front.

• Apply a light coat of grease on the terminals to prevent

corrosion.

• Install the positive (+) cable [A] first.

• Cover the positive (+) terminal with the cap [B].

• Install the negative (-) cable [C].

Battery Activation

Electrolyte Filling

• Make sure that the model name [A] of the electrolyte con-

tainer matches the model name [B] of the battery. These

names must be the same.

Battery Model Name for EX650A/B: YTX12-BS

CAUTION

Be sure to use the electrolyte container with the

same model name as the battery since the elec-

trolyte volume and specific gravity vary with the

battery type. This is to prevent overfilling of the

electrolyte, shorting the battery life, and deteriora-

tion of the battery performance.

CAUTION

Do not remove the aluminum sealing sheet [A] from

the filler ports [B] until just prior to use. Be sure to

use the dedicated electrolyte container for correct

electrolyte volume.

• Place the battery on a level surface.

• Check to see that the sealing sheet has no peeling, tears,

or holes in it.

• Remove the sealing sheet.

NOTE

○The battery is vacuum sealed. If the sealing sheet has

leaked air into the battery, it may require a longer initial

charge.

16-26 ELECTRICAL SYSTEM

Battery

• Remove the electrolyte container from the vinyl bag.

• Detach the strip of caps [A] from the container and set

aside, these will be used later to seal the battery.

NOTE

○Do not pierce or otherwise open the sealed cells [B] of

the electrolyte container. Do not attempt to separate

individual cells.

• Place the electrolyte container upside down with the six

sealed cells into the filler ports of the battery. Hold the

container level, push down to break the seals of all six

cells. You will see air bubbles rising into each cell as the

ports fill.

NOTE

○Do not tilt the electrolyte container

• Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or

if the container cells have not emptied completely, tap the

container [B] a few times.

• Keep the container in place for 20 minutes or more. Don’t

remove the container from the battery until it’s empty, the

battery requires all the electrolyte from the container for

proper operation.

CAUTION

Removal of the container before it is completely

empty can shorten the service life of the battery. Do

not remove the electrolyte container until it is com-

pletely empty and 20 minutes have elapsed.

• Gently remove the container from the battery.

• Let the battery sit for 30 minutes prior to charging to allow

the electrolyte to permeate into the plates for optimum

performance.

NOTE

○Charging the battery immediately after filling can

shorten service life. Let the battery sit for at least 30

minutes after filling.

ELECTRICAL SYSTEM 16-27

Battery

Initial Charge

• Place the strip [A] of caps loosely over the filler ports.

• Newly activated sealed batteries require an initial charge.

Standard Charge:

1.2 A × 5 ∼ 10 hours

If using a recommended battery charger, follow the

charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers

Optimate III

Yuasa 1.5 Amp Automatic Charger

Battery Mate 150-9

If the above chargers are not available, use equivalent

one.

NOTE

○Charging rates will vary depending on how long the

battery has been stored, temperature, and the type of

charger used. Let battery sit 30 minutes after initial

charge, then check voltage using a voltmeter. If it is

not at least 12.8 V, repeat charging cycle.

• After charging is completed, press down firmly with both

hands to seat the strip of caps [A] into the battery (don’t

pound or hammer.). When properly installed, the strip of

the caps will be level with the top of the battery.

CAUTION

Once the strip of the caps [A] is installed onto the

battery, never remove the caps, nor add water or

electrolyte to the battery.

NOTE

○To ensure maximum battery life and customer satisfac-

tion, it is recommended the battery be load tested at

three times its amp-hour rating for 15 seconds.

Re-check voltage and if less than 12.8 V repeat the

charging cycle and load test. If still below 12.8 V the

battery is defective.

16-28 ELECTRICAL SYSTEM

Battery

Precautions

1) No need of topping-up

No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying

off the seal cap to add water is very dangerous. Never do that.

2) Refreshing charge.

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been

discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification

(see Specifications).

When a fast charge is inevitably required, do it following precisely the maximum charge current

and time conditions indicated on the battery.

CAUTION

This battery is designed to sustain no unusual deterioration if refresh-charged according

to the method specified above. However, the battery’s performance may be reduced no-

ticeably if charged under conditions other than given above. Never remove the seal cap

during refresh charge.

If by chance an excessive amount of gas is generated due to overcharging, the relief valve

releases the gas to keep the battery normal.

3) When you do not use the motorcycle for months.

Give a refresh charge before you store the motorcycle and store it with the negative cable re-

moved. Give a refresh charge once a month during storage.

4) Battery life.

If the battery will not start the engine even after several refresh charges, the battery has ex-

ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob-

lem).

WARNING

Keep the battery away from sparks and open flames during charging, since the battery

gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,

connect the battery to the charger before turning on the charger.

This procedure prevents sparks at the battery terminals which could ignite any battery

gases.

No fire should be drawn near the battery, or no terminals should have the tightening loos-

ened.

The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If

touched, wash it off with liberal amount of water. Get medial attention if severe.

Interchange

A sealed battery can fully display its performance only when combined with a proper vehicle electric

system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with

a sealed battery.

Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original

equipment, the sealed battery’s life will be shortened.

ELECTRICAL SYSTEM 16-29

Battery

Charging Condition Inspection

○Battery charging condition can be checked by measuring

battery terminal voltage with a digital voltmeter [A].

• Remove:

Seat (see Seat Removal in the Frame chapter)

Battery Cable Cap (see Battery Removal)

• Disconnect the battery terminals.

CAUTION

Be sure to disconnect the negative (-) cable first.

• Measure the battery terminal voltage.

NOTE

○Measure with a digital voltmeter which can be read one

decimal place voltage.

If the reading is 12.8 V or more, no refresh charge is re-

quired, however, if the read is below the specified, refresh

charge is required.

Battery Terminal Voltage

Standard:

12.8 V or more

Terminal Voltage (V) [A]

Battery Charge Rate (%) [B]

Good [C]

Refresh charge is required [D]

Refreshing Charge

• Remove the battery [A] (see Battery Removal).

• Do refresh charge by following method according to the

battery terminal voltage.

WARNING

This battery is sealed type. Never remove sealing

cap [B] even at charging. Never add water. Charge

with current and time as stated below.

16-30 ELECTRICAL SYSTEM

Battery

Terminal Voltage: 11.5 ∼ less than 12.8 V

Standard Charge

1.2 A × 5 ∼ 10 h (see following chart)

Quick Charge

5A ×1 h

CAUTION

If possible, do not quick charge. If quick charge is

done unavoidably, do standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method

1.2 A × 20 h

NOTE

○Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge

for no more than 5 minutes at the increased voltage then

check if the battery is drawing current. If the battery

will accept current decrease the voltage and charge by

the standard charging method described on the battery

case. If the battery will not accept current after 5 min-

utes, replace the battery.

Battery [A]

Battery Charger [B]

Standard Value [C]

Current starts to flow [D]

• Determine the battery condition after refresh charge.

○Determine the condition of the battery left for 30 minutes

after completion of the charge by measuring the terminal

voltage according to the table below.

Criteria

Judgement

12.8 V or higher

Good

12.0 ∼ lower than 12.8 V

Charge insufficient → Recharge

lower than 12.0 V

Unserviceable → Replace

ELECTRICAL SYSTEM 16-31

Charging System

Alternator Cover Removal

• Remove:

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

Alternator Lead Connector [A]

• Place a suitable container under the alternator cover [A],

and remove the cover bolts [B].

• Pull the alternator cover outside.

Alternator Cover Installation

• Apply silicone sealant to the alternator lead grommet and

crankcase halves mating surface [A] on the front and rear

sides of the cover mount.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Check that dowel pins [B] are in place on the crankcase.

• Install a new gasket and the alternator cover.

• Tighten:

Torque - Alternator Cover Bolts:

9.8 N·m (1.0 kgf·m, 87

in·lb)

Stator Coil Removal

• Remove:

Alternator Cover (see Alternator Cover Removal)

Holding Plate Bolt [A] and Plate

Alternator Lead Grommet [B]

Stator Coil Bolts [C]

• Remove the stator coil [D] from the alternator cover.

16-32 ELECTRICAL SYSTEM

Charging System

Stator Coil Installation

• Apply a non-permanent locking agent to the threads of

the stator coil bolts and tighten them.

Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

• Secure the alternator lead with a holding plate, and

tighten the bolt.

○Apply a non-permanent locking agent to the threads of

the holding plate bolt.

Torque - Alternator Lead Holding Plate Bolt: 9.8 N·m (1.0

kgf·m, 87 in·lb)

• Apply silicone sealant to the circumference of the alter-

nator lead grommet, and fit the grommet into the notch of

the cover securely.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Install the alternator cover (see Alternator Cover Installa-

tion).

Alternator Rotor Removal

• Remove the alternator cover (see Alternator Cover Re-

moval).

• Remove the starter idle gear, torque limiter and shafts.

• Wipe oil off the outer circumference of the rotor.

• Hold the alternator rotor steady with the rotor holder [A],

and remove the rotor bolt [B] and washer.

Special Tools - Grip: 57001-1591

Rotor Holder: 57001-1658

• Using the flywheel puller [A], remove the alternator rotor

from the crankshaft.

Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×

1.5: 57001-1405

CAUTION

Do not attempt to strike the alternator rotor itself.

Striking the rotor can cause the magnets to lose

their magnetism.

Alternator Rotor Installation

• Using a cleaning fluid, clean off any oil or dirt on the fol-

lowing portions and dry them with a clean cloth.

Crankshaft Tapered Portion [A]

Alternator Rotor Tapered Portion [B]

• Apply a thin coat of molybdenum disulfide grease to the

crankshaft [C].

ELECTRICAL SYSTEM 16-33

Charging System

• Install the starter gear [A] and washer [B].

• Again, clean the crankshaft tapered portion [C] and dry

there.

• Install the alternator rotor [A] while turning [B] it counter-

clockwise.

• Install the washer [A].

NOTE

○Confirm the alternator rotor fit or not to the crankshaft

before tightening it with specified torque.

• Apply molybdenum disulfide oil solution to the threads

and seating surface of the rotor bolt.

• Install the rotor bolt [B] and tighten it with 70 N·m (7.0

kgf·m, 52 ft·lb) of torque.

• Remove the rotor bolt and washer.

• Check the tightening torque with flywheel puller.

If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15

ft·lb) of drawing torque, it is installed correctly.

If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15

ft·lb) of drawing torque, clean off any oil dirt or flaw of the

crankshaft and rotor tapered portion, and dry them with

a clean cloth. Then, confirm that it is not pulled out with

above torque.

• Tighten the alternator rotor bolt while holding the alterna-

tor rotor steady with the rotor holder.

Special Tools - Grip: 57001-1591

Rotor Holder: 57001-1658

Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114

ft·lb)

16-34 ELECTRICAL SYSTEM

Charging System

• Apply a thin coat of molybdenum disulfide grease to the

shafts [A], and install them.

• Install the torque limiter [B] and starter idle gear [C].

• Install the alternator cover (see Alternator Cover Installa-

tion).

Alternator Inspection

There are three types of alternator failures: short, open

(wire burned out), or loss in rotor magnetism. A short or

open in one of the coil wires will result in either a low output,

or no output at all. A loss in rotor magnetism, which may be

caused by dropping or hitting the alternator, by leaving it

near an electromagnetic field, or just by aging, will result in

low output.

• To check the alternator output voltage, do the following

procedures.

○Turn off the ignition switch.

○Disconnect the alternator lead connector [A].

○Connect the hand tester as shown in the table 1.

○Start the engine.

○Run it at the rpm given in the table 1.

○Note the voltage readings (total 3 measurements).

Table 1 Alternator Output Voltage

Tester

Connections

Reading

Range

Tester (+) to

Tester (-) to

at 4 000 rpm

250 V AC

One Black lead

Another Black lead

42 V or more

If the output voltage shows the value in the table, the al-

ternator operates properly.

If the output voltage shows a much higher than the value

in the table, the regulator/rectifier is damaged. A much

lower reading than that given in the table indicates that

the alternator is defective.

• Check the stator coil resistance as follows.

○Stop the engine.

○Connect the hand tester as shown in the table 2.

○Note the readings (total 3 measurement).

Table 2 Stator Coil Resistance

Tester

Connections

Reading

Range

Tester (+) to

Tester (-) to

× 1 Ω

One Black lead

Another Black lead

0.18 ∼ 0.27 Ω

ELECTRICAL SYSTEM 16-35

Charging System

If there is more resistance than shown in the table, or no

hand tester reading (infinity) for any two leads, the stator

has an open lead and must be replaced. Much less than

this resistance means the stator is shorted, and must be

replaced.

• Using the highest resistance range of the hand tester,

measure the resistance between each of the black leads

and chassis ground.

Any hand tester reading less than infinity (∞) indicates a

short, necessitating stator replacement.

If the stator coils have normal resistance, but the voltage

check showed the alternator to be defective; then the rotor

magnets have probably weakened, and the rotor must be

replaced.

Special Tool - Hand Tester: 57001-1394

Regulator/Rectifier Inspection

EX650A Models

• Remove:

Bolts [A]

• Disconnect the connector [A].

• Remove the regulator/rectifier [B].

EX650B Models

• Remove the bolts [A].

• Disconnect the connector [B].

• Remove the regulator/rectifier [C].

16-36 ELECTRICAL SYSTEM

Charging System

Rectifier Circuit Check

• Check conductivity of the following pair of terminals.

Rectifier Circuit Inspection

W/BL-BK1,

W/BL-BK2,

W/BL-BK3

Tester connection

BK/Y-BK1,

BK/Y-BK2,

BK/Y-BK3

The resistance should be low in one direction and more

than ten times as much in the other direction. If any two

leads are low or high in both directions, the rectifier is

defective and the regulator/rectifier must be replaced.

NOTE

○The actual meter reading varies with the meter used

and the individual rectifier, but, generally speaking the

lower reading should be from zero to one half the scale.

Regulator Circuit Check

To test the regulator out of circuit, use three 12 V batteries

and a test light (12 V 3 ∼ 6 W bulb in a socket with leads).

CAUTION

The test light works as an indicator and also a cur-

rent limiter to protect the regulator/rectifier from ex-

cessive current. Do not use an ammeter instead of

a test light.

• Check to be sure the rectifier circuit is normal before con-

tinuing.

• Do the 1st step regulator circuit test.

○Connect the test light and the 12 V battery to the regula-

tor/rectifier as shown.

○Check the BK1, BK2 and BK3 terminal respectively.

If the test light turns on, the regulator/rectifier is defective.

Replace it.

If the test light does not turn on, continue the test.

• Do the 2nd step regulator circuit test.

○Connect the test light and the 12 V battery in the same

manner as specified in the “Regulator Circuit Test-1st

Step”.

○Apply 12 V to the voltage BR terminal.

○Check the BK1, BK2 and BK3 terminal respectively.

If the test light turns on, the regulator/rectifier is defective.

Replace it.

If the test light does not turn on, continue the test.

ELECTRICAL SYSTEM 16-37

Charging System

• Do the 3rd step regulator circuit test.

○Connect the test light and the 12 V battery in the same

manner as specified in the “Regulator Circuit Test-1st

Step”.

○Momentarily apply 24 V to the voltage BR terminal by

adding a 12 V battery.

○Check the BK1, BK2 and BK3 terminals respectively.

CAUTION

Do not apply more than 24 V. If more than 24 V is ap-

plied, the regulator/rectifier may be damaged. Do

not apply 24 V more than a few seconds. If 24 V

is applied for more than a few seconds, the regula-

tor/rectifier may be damaged.

If the test light did not light when the 24 V was applied

momentarily to the voltage monitoring terminal, the regu-

lator/rectifier is defective. Replace it.

If the regulator/rectifier passes all of the tests described,

it may still be defective. If the charging system still does

not work properly after checking all of the components

and the battery, test the regulator/rectifier by replacing it

with a known good unit.

16-38 ELECTRICAL SYSTEM

Charging System

Charging Voltage Inspection

• Check the battery condition (see Charging Condition In-

spection).

• Warm up the engine to obtain actual alternator operating

conditions.

• Remove the seat (see Seat Removal in the Frame chap-

ter).

• Check that the ignition switch is turned off, and connect

the hand tester [A] to the battery terminals [B].

Special Tool - Hand Tester: 57001-1394

• Start the engine, and note the voltage readings at var-

ious engine speeds with the headlight turned on and

then turned off (To turn off the headlight, disconnect the

headlight connector on the headlight unit). The readings

should show nearly battery voltage when the engine

speed is low, and, as the engine speed rises, the read-

ings should also rise. But they must be kept under the

specified voltage.

Charging Voltage

Connections

Tester Range

Reading

Tester (+) to

Tester (-) to

25 V DC

Battery (+)

Battery (-)

14.2 ∼ 15.2 V

• Turn off the ignition switch to stop the engine, and discon-

nect the hand tester.

If the charging voltage is kept between the values given in

the table, the charging system is considered to be working

normally.

If the charging voltage is much higher than the values

specified in the table, the regulator/rectifier is defective

or the regulator/rectifier leads are loose or open.

If the charging voltage does not rise as the engine speed

increases, then the regulator/rectifier is defective or the

alternator output is insufficient for the loads. Check the

alternator and regulator/rectifier to determine which part

is defective.

ELECTRICAL SYSTEM 16-39

Charging System

Charging System Circuit

1. Ignition Switch

2. Alternator

3. Regulator/Rectifier

4. Water-proof Joint C

5. Main Fuse 30 A

6. Battery 12 V 10 Ah

7. Load

16-40 ELECTRICAL SYSTEM

Starter Motor Clutch

Starter Motor Clutch Removal/Installation

• Refer to the Alternator Rotor Removal/Installation.

Starter Motor Clutch Inspection

• Remove:

Alternator Cover (see Alternator Cover Removal)

Starter Idle Gear and Torque Limiter

Shafts

• Turn the starter motor clutch gear [A] by hand. The starter

motor clutch gear should turn clockwise [B] freely, but

should not turn counterclockwise [C].

If the starter motor clutch does not operate as it should or

if it makes noise, go to the next step.

• Disassemble the starter motor clutch, and visually inspect

the clutch parts.

If there is any worn or damaged part, replace it.

NOTE

○Examine the starter motor clutch gear as well. Replace

it if it worn or damaged.

Starter Motor Clutch Disassembly

• Remove:

Alternator Rotor (see Alternator Rotor Removal)

Starter Motor Clutch Bolts [A]

• Remove:

Starter Motor Clutch [A]

Starter Motor Clutch Assembly

• Apply a non-permanent locking agent to the threads of

the starter motor clutch bolts and tighten them.

Torque - Starter Motor Clutch Bolts: 34 N·m (3.5 kgf·m, 25

ft·lb)

ELECTRICAL SYSTEM 16-41

Ignition System

WARNING

The ignition system produces extremely high volt-

age. Do not touch the spark plugs or stick coils

while the engine is running, or you could receive

a severe electrical shock.

CAUTION

Do not disconnect the battery cables or any other

electrical connections when the ignition switch is

on, or while the engine is running. This is to prevent

ECU (Electric Control Unit) damage.

Do not install the battery backwards. The negative

side is grounded. This is to prevent damage to the

ECU.

Crankshaft Sensor Removal

• Remove:

Lower Fairing (see Lower Fairing Removal in the Frame

chapter)

Right Frame Cover (see Frame Cover Removal in the

Frame chapter)

Crankshaft Sensor Lead Connector [A]

• Remove:

Rubber Boot (Slide Out) [A]

Oil Pressure Switch Lead Terminal [B]

Clutch Cover (see Clutch Cover Removal in the Clutch

chapter)

• Remove:

Bolts [A]

Crankshaft Sensor [B]

• Pull out the grommet [C].

16-42 ELECTRICAL SYSTEM

Ignition System

Crankshaft Sensor Installation

• Route the crankshaft sensor lead correctly (see Cable,

Wire, and Hose Routing section in the Appendix chapter).

• Tighten:

Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.60 kgf·m, 53

in·lb)

• Apply silicone sealant [A] to the crankshaft sensor lead

grommet.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Install the removed parts (see appropriate chapters).

Crankshaft Sensor Inspection

• Remove:

Right Frame Cover (see Frame Cover Removal in the

Frame chapter)

Crankshaft Sensor Lead Connector [A]

• Set the hand tester to the × 100 Ω range and connect (+)

lead to the black lead and (-) lead to the yellow lead in

the connector.

Special Tool - Hand Tester: 57001-1394

If there is more resistance than the specified value, the

coil has an open lead and must be replaced. Much less

than this resistance means the coil is shorted, and must

be replaced.

Crankshaft Sensor Resistance: 376 ∼ 564 Ω

• Using the highest resistance range of the tester, measure

the resistance between the crankshaft sensor leads and

chassis ground.

Any tester reading less than infinity (∞) indicates a short,

necessitating replacement of the crankshaft sensor as-

sembly.

Crankshaft Sensor Peak Voltage Inspection

NOTE

○Be sure the battery is fully charged.

○Using the peak voltage adapter [A] is a more reliable

way to determine the condition of the crankshaft sen-

sor than crankshaft sensor internal resistance measure-

ments.

• Remove:

Crankshaft Sensor Lead Connector (see Crankshaft

Sensor Removal)

• Set the hand tester [B] to the × DC 10 V range, and con-

nect it peak voltage adapter.

• Connect the black lead of the adapter to yellow lead and

red lead to black lead in the crankshaft sensor connector.

• Turn the ignition switch and engine stop switch ON.

ELECTRICAL SYSTEM 16-43

Ignition System

• Pushing the starter button, turn the engine 4 ∼ 5 sec-

onds with the transmission gear in neutral to measure the

crankshaft sensor peak voltage.

• Repeat the measurement 5 or more times.

Crankshaft Sensor Peak Voltage

Standard:

1.9 V or more

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

If the tester reading is not specified one, check the crank-

shaft sensor.

Timing Rotor Removal

• Remove:

Clutch Cover (see Clutch Cover Removal in the Clutch

chapter)

Crankshaft Sensor (see Crankshaft Sensor Removal)

• Remove the timing rotor [A].

○Holding the timing rotor with the flywheel & pulley holder

[B] and unscrew the rotor bolt [C].

Special Tool - Flywheel & Pulley Holder: 57001-1605

Timing Rotor Installation

• Fit the rotor to the crankshaft.

• Tighten the rotor bolt.

Torque - Timing Rotor Bolt: 40 N·m (4.1 kgf·m, 30 ft·lb)

• Install the removed parts (see appropriate chapters).

Stick Coil (Ignition Coil together with Spark Plug

Cap) Removal

• Remove the air cleaner housing (see Air Cleaner Housing

Removal in the Fuel System (DFI) chapter).

• Disconnect the stick coil connectors [A].

• Pull the stick coils [B] off the spark plugs.

CAUTION

Do not pry the connector part of the coil while re-

moving the coil.

Stick Coil (Ignition Coil together with Spark Plug

Cap) Installation

• Insert the coil as shown being careful of the coil heads [A]

direction.

• Connect the connectors.

CAUTION

Do not tap the coil head while installing the coil.

• Run the hoses and harness correctly (see Cable, Wire,

and Hose Routing section in the Appendix chapter).

• Install the removed parts (see appropriate chapters).

16-44 ELECTRICAL SYSTEM

Ignition System

Stick Coil (Ignition Coil together with Spark Plug

Cap) Inspection

• Remove the stick coils (see Stick Coil (Ignition Coil to-

gether with Spark Plug Cap) Removal).

• Measure the primary winding resistance [A] as follows.

○Connect the hand tester between the coil terminals.

○Set the tester to the × 1 Ω range, and read the tester.

• Measure the secondary winding resistance [B] as follows.

○Connect the tester between the plug terminal and (-) coil

terminal.

○Set the tester to the × 1 kΩ range and read the tester.

Ignition Coil Winding Resistance

Primary Windings:

1.1 ∼ 1.5 Ω

Secondary Windings:

10.8 ∼ 16.2 kΩ

If the tester does not read as specified, replace the coil.

Stick Coil Primary Peak Voltage

NOTE

○Be sure the battery is fully charged.

• Remove the stick coils (see Stick Coil (Ignition Coil to-

gether with Spark Plug Cap) Removal), but do not remove

the spark plugs.

• Measure the primary peak voltage as follows.

○Install the new spark plug [A] into each stick coil [B], and

ground them onto the engine.

○Connect the peak voltage adapter [C] into the hand tester

[D] which is set to the × DC 250 V range.

○Connect the adapter to the lead wire-peak voltage

adapter [E] which is connected between the stick coil

connector and stick coil.

ECU [F]

Battery [G]

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Lead Wire-Peak Voltage Adapter:

57001

-1449

Primary Lead Connection

Adapter (R, +) to lead wire-peak voltage adapter (W)

Adapter (BK, -) to lead wire-peak voltage adapter (R)

16-46 ELECTRICAL SYSTEM

Ignition System

2nd Check

• Start the engine to the following conditions.

Condition

Transmission Gear → 1st Position

Clutch Lever → Pulled in

Sidestand → Up

○Turn the ignition switch ON and push the starter button.

○Then the starter motor should turn when the starter sys-

tem circuit is normality.

If the starter motor is not turn, inspect the starter lockout

switch, neutral switch and relay box.

If their parts are normality replace the ECU.

3rd Check

• Inspect the engine for its secure stop after the following

operations are completed.

• Run the engine to the following conditions.

Condition

Transmission Gear → 1st Position

Clutch Lever → Pulled in

Sidestand → Up

• Set the sidestand on the ground, then the engine will stop.

If whichever may not be stopped, inspect the neutral

switch, starter lockout switch, sidestand switch and relay

box.

If their parts are normality, replace the ECU.

IC Igniter Inspection

○The IC igniter is built in the ECU [A].

• Refer to the Interlock Operation Inspection, Ignition Sys-

tem Troubleshooting chart and Fuel System (DFI) chapter

for ECU Power Supply Inspection.

ELECTRICAL SYSTEM 16-47

Ignition System

16-48 ELECTRICAL SYSTEM

Ignition System

Ignition System Circuit

1. Ignition Switch

12. Water Temperature Sensor

22. Ignition Fuse 10 A

2. Engine Stop Switch

13. Neutral Switch

23. Fuse Box

3. Spark Plugs

14. Crankshaft Sensor

24. ECU Main Relay

4. Stick Coils

15. Oxygen Sensor

25. Relay Box

5. Water-proof Joint C

16. Meter Unit

26. Main Fuse 30 A

6. Speed Sensor

17. Water-proof Joint A

27. Starter Relay

7. Subthrottle Sensor

18. Water-proof Joint B

28. Battery 12 V 10 Ah

8. Main Throttle Sensor

19. Starter Lockout Switch

29. Frame Ground

9. Water-proof Joint D

20. Oxygen Sensor Heater Fuse

30. Sidestand Switch

10. Vehicle-down Sensor

10 A

31. Joint Connector

11. Water-proof Joint E

21. ECU Fuse 15 A

32. ECU

ELECTRICAL SYSTEM 16-49

Electric Starter System

Starter Motor Removal

CAUTION

Do not tap the starter motor shaft or body. Tapping

the shaft or body could damage the motor.

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Right Center Fairing (see Center Fairing Removal in the

Frame chapter)

• Slide back the rubber cap [A].

• Remove the starter motor cable terminal nut [B].

• Remove the mounting bolts [A].

• Pull out the starter motor [B].

Starter Motor Installation

CAUTION

Do not tap the starter motor shaft or body. Tapping

the shaft or body could damage the motor.

• When installing the starter motor, clean the starter mo-

tor legs [A] and crankcase [B] where the starter motor is

grounded.

• Replace the O-ring [A] with a new one.

• Apply grease to the O-ring.

• Apply a non-permanent locking agent to the threads of

the bolts and tighten the bolts.

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

• Install the starter motor cable.

• Tighten:

Torque - Starter Motor Cable Terminal Nut: 6.0 N·m (0.60

kgf·m, 53 in·lb)

16-50 ELECTRICAL SYSTEM

Electric Starter System

Starter Motor Disassembly

• Remove the starter motor (see Starter Motor Removal).

• Take off the starter motor through bolts [A] and remove

the both end covers [B] and pull the armature out of the

yoke [C].

• Remove:

Terminal Locknut and Washers

O-ring

• Remove the brush plate assy [A] from the yoke [B].

• Remove the brush plate [A] from the plate cover [B].

NOTE

○Do not remove the negative carbon brushes form the

brush plate.

Starter Motor Assembly

• Install the brush plate [A] to the plate cover [B] as shown.

• Install the brush plate assy to the yoke.

• Clamp the springs [A] with the clips [B].

• Fit the armature [C] to the brush plate assy [D].

• Remove the clips.

ELECTRICAL SYSTEM 16-51

Electric Starter System

• Install the new O-ring [A] as shown.

• Install:

Washers [B] and Terminal Locknut [C]

• Tighten:

Torque - Starter Motor Terminal Locknut:

11 N·m (1.1

kgf·m, 97 in·lb)

• Align the lines [A] on the yoke with the end cover lines [B].

• Tighten the through bolts.

Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m,

43 in·lb)

Brush Inspection

• Measure the length of each brush [A].

If any is worn down to the service limit, replace the brush

plate assy [B] and the terminal bolt assy [C].

Starter Motor Brush Length

Standard:

12 mm (0.47 in.)

Service Limit:

6.0 mm (0.24 in.)

Commutator Cleaning and Inspection

• Smooth the commutator surface [A] if necessary with fine

emery cloth [B], and clean out the grooves.

• Measure the diameter [A] of the commutator [B].

If the commutator diameter is less than the service limit,

replace the starter motor with a new one .

Commutator Diameter

Standard:

28 mm (1.10 in.)

Service Limit:

27 mm (1.06 in.)

16-52 ELECTRICAL SYSTEM

Electric Starter System

Armature Inspection

• Using the × 1 Ω hand tester range, measure the resis-

tance between any two commutator segments [A].

Special Tool - Hand Tester: 57001-1394

If there is a high resistance or no reading (∞) between any

two segments, a winding is open and the starter motor

must be replaced.

• Using the highest hand tester range, measure the resis-

tance between the segments and the shaft [B].

If there is any reading at all, the armature has a short and

the starter motor must be replaced.

NOTE

○Even if the foregoing checks show the armature to be

good, it may be defective in some manner not readily

detectable with the hand tester. If all other starter motor

and starter motor circuit components check good, but

the starter motor still does not turn over or only turns

over weakly, replace the starter motor with a new one.

Brush Lead Inspection

• Using the × 1 Ω hand tester range, measure the resis-

tance as shown.

Terminal Bolt and Positive Brushes [A]

Brush Plate and Negative Brushes [B]

Special Tool - Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an

open. Replace the terminal bolt assy and/or the brush

plate assy.

Brush Plate and Terminal Bolt Inspection

• Using the highest hand tester range, measure the resis-

tance as shown.

Terminal Bolt and Brush Plate [A]

Terminal Bolt and Negative Brush Holders [B]

Terminal Bolt and Yoke [C]

Special Tool - Hand Tester: 57001-1394

If there is any reading, the brush plate assy and/or termi-

nal bolt assy have a short. Replace the brush plate assy

and the terminal bolt assy.

ELECTRICAL SYSTEM 16-53

Electric Starter System

Starter Relay Inspection

• Remove:

Bolt [A] and Cover [B]

• Disconnect the connector [A].

• Disconnect the starter motor cable [B] and battery positive

(+) cable [C] from the starter relay [D].

CAUTION

The battery positive (+) cable with the rubber cap is

connected directly to the battery positive (+) termi-

nal even when the ignition switch off, so take care

not to short the removed cable to chassis ground.

• Connect the hand tester [A] and 12 V battery [B] to the

starter relay [C] as shown.

Special Tool - Hand Tester: 57001-1394

If the relay does not work as specified, the relay is defec-

tive. Replace the relay.

Testing Relay

Tester Range:

× 1 Ω range

Criteria:

When battery is connected → 0 Ω

When battery is disconnected → ∞ Ω

16-54 ELECTRICAL SYSTEM

Electric Starter System

Electric Starter Circuit

1. Ignition Switch

2. Water-proof Joint B

3. Starter Lockout Switch

4. Ignition Fuse 10 A

5. Fuse Box

6. Starter Circuit Relay

7. Relay Box

8. Starter Motor

9. Starter Relay

10. Main Fuse 30 A

11. Battery 12 V 10 Ah

12. Sidestand Switch

13. Frame Ground

14. Joint Connector

15. Neutral Switch

16. Water-proof Joint C

17. Starter Button

18. Engine Stop Switch

ELECTRICAL SYSTEM 16-55

Lighting System

This motorcycle adopt the daylight system and have a

headlight relay in the relay box. The headlight does not

go on when the ignition switch and the engine stop switch

are first turned on. The headlight comes on after the starter

button is released and stays on until the ignition switch is

turned off. The headlight will go out momentarily whenever

the starter button is pressed and come back on when the

button is released.

Headlight Beam Horizontal Adjustment

• Refer to the Headlight Aiming Inspection in the Periodic

Maintenance chapter.

Headlight Beam Vertical Adjustment

• Refer to the Headlight Aiming Inspection in the Periodic

Maintenance chapter.

Headlight Bulb Replacement

• Remove:

Upper Inner Fairing (see Upper Inner Fairing Removal

in the Frame chapter)

Headlight Connector [A]

Headlight Bulb Dust Cover [B]

• Remove:

Hook [A]

Headlight Bulb [B]

CAUTION

When handling the quartz-halogen bulb, never

touch the glass portion with bare hands. Always

use a clean cloth. Oil contamination from hands or

dirty rags can reduce bulb life or cause the bulb to

explode.

NOTE

○Clean off any contamination that inadvertently gets on

the bulb with alcohol or soap and water solution.

• Replace the headlight bulb.

• Fit the projection [A] of the bulb in the hollow [B] of the

headlight.

• Install the hook [C].

16-56 ELECTRICAL SYSTEM

Lighting System

• Fit the dust cover [A] onto the bulb [B] firmly as shown.

Good [C]

Bad [D]

• After installation, adjust the headlight aim (see Headlight

Aiming Inspection in the Periodic Maintenance chapter).

City Light Bulb Replacement (Europe Models)

• Remove the meter cover (see Meter Unit Removal/Instal-

lation).

• Disconnect the connector [A].

• Pull out the socket [B] together with the bulb.

• Pull the bulb [A] out of the socket.

CAUTION

Do not turn the bulb. Pull the bulb out to prevent

damage to the bulb. Do not use bulb rated for

greater wattage then the specified valve.

• Replace the bulb with a new one.

Headlight Removal/Installation

• Remove:

Upper Fairing (see Upper Fairing Removal in the Frame

chapter)

Mounting Bolts [A]

• Installation is the reverse of removal.

Tail/Brake Light Removal

• Remove:

Seat Covers (see Seat Cover Removal in the Frame

chapter)

• Disconnect the connector [A].

• Unscrew the mounting bolts [B].

• Remove the tail/brake light [C].

Tail/Brake Light Installation

• Installation is the reverse of removal.

ELECTRICAL SYSTEM 16-57

Lighting System

License Plate Light Bulb Replacement

• Remove:

Screws [A]

License Plate Light Cover [B]

• Push and turn the bulb counterclockwise and remove it.

• Insert the new bulb [A] by aligning its upper and lower pins

[B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○Turn the bulb about 15°.

• Install the license plate light cover.

• Tighten:

Torque - License Plate Light Cover Screws:

0.90

N·m

(0.090 kgf·m, 8 in·lb)

16-58 ELECTRICAL SYSTEM

Lighting System

Headlight/Tail Light Circuit

1. Ignition Switch

12. Main Fuse 30 A

2. Water-proof Joint A

13. Battery 12 V 10 Ah

3. Water-proof Joint B

14. Frame Ground

4. Position Light

15. Tail/Brake Light

5. Headlight (High Beam)

16. License Plate Light 12 V 5 W

6. Headlight (Low Beam)

17. Joint Connector

7. Dimmer Switch

18. Water-proof Joint C

8. Passing Switch

19. Regulator/Rectifier

9. Headlight Relay

20. Fuse Box

10. Relay Box

21. Headlight Fuse 10 A

11. Starter Relay

22. Tail Light Fuse 10 A

Turn Signal Light Bulb Replacement

• Unscrew the screw [A] and remove the lens [B].

○Turn the lens counterclockwise.

ELECTRICAL SYSTEM 16-59

Lighting System

• Push and turn the bulb [A] counterclockwise and remove

it.

• Insert the new bulb [A] by aligning its upper and lower pins

[B] with the upper and lower grooves [C] in the socket, and

turn the bulb clockwise.

○Turn the bulb about 15°.

• Install the projections of the lens to the dints of the turn

signal light.

Turn Signal Relay Inspection

• Remove:

Left Upper Inner Fairing (see Upper Inner Fairing Re-

moval in the Frame chapter)

Turn Signal Relay [A]

• Connect one 12 V battery and turn signal lights as indi-

cated in the figure, and count how may times the lights

flash for one minute.

Turn Signal Relay [A]

Turn Signal Lights [B]

12 V Battery [C]

If the lights do not flash as specified, replace the turn sig-

nal relay.

Testing Turn Signal Relay

Load

Flashing Times

The Number of Turn

Wattage (W)

(c/m*)

Signal Lights

1**

21 or 23

140 ∼ 250

2

42 or 46

75 ∼ 95

(*): Cycle(s) per minute

(**): Corrected to “one light burned out”.

16-60 ELECTRICAL SYSTEM

Lighting System

Turn Signal Light Circuit

1. Meter Unit

2. Water-proof Joint A

3. Water-proof Joint B

4. Front Right Turn Signal Light

5. Front Left Turn Signal Light

6. Turn Signal Relay

7. Hazard Button

8. Turn Signal Switch

9. Fuse Box

10. Turn Signal Relay Fuse 10 A

11. Main Fuse 30 A

12. Battery 12 V 10 Ah

13. Frame Ground

14. Rear Right Turn Signal Light

15. Rear Left Turn Signal Light

16. Joint Connector

17. Water-proof Joint C

18. Ignition Switch

19. Frame Ground

ELECTRICAL SYSTEM 16-61

Air Switching Valve

Air Switching Valve Operation Test

• Remove the fuel tank (see Fuel Tank Removal in the Fuel

System (DFI) chapter).

• Pull the air switching valve hose [A] out of the air cleaner

base.

• Take the air switching valve hose end outside of the

frame.

• Reinstall the fuel tank (see Fuel Tank Installation in the

Fuel System (DFI) chapter).

• Start the engine and run it at idle speed.

• Plug [A] the air switching valve hose [B] end with your

finger and feel vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for

leak. If there is no leak, check the air switching valve (see

Air Switching Valve Unit Test).

• Apply a soap and water solution or rubber lubricant to the

end of the air switching hose and install the hose on the

fitting.

Air Switching Valve Unit Test

• Remove the air switching valve (see Air Switching Valve

Removal in the Engine Top End chapter).

• Set the hand tester [A] to the × Ω range and connect it to

the air switching valve terminals as shown.

Special Tool - Hand Tester: 57001-1394

Air Switching Valve Resistance

Standard:

18 ∼ 22 Ω at 20°C (68°F)

If the resistance reading is except the specified value, re-

place it with a new one.

• Connect the 12 V battery [A] to the air switching valve

terminals as shown.

16-62 ELECTRICAL SYSTEM

Air Switching Valve

• Blow the air to the inlet air duct [A], and make sure does

not flow the blown air from the outlet air duct [B].

• Disconnect the 12 V battery.

• Blow the air to the inlet air duct [A], and make sure does

not flow the blown air from the outlet air duct [B].

If the air switching value does not operate as described,

replace it with a new one.

NOTE

○To check air flow through the air switching valve, just

blow through the air cleaner hose [C].

ELECTRICAL SYSTEM 16-63

Radiator Fan System

Fan Motor Inspection

• Disconnect the connector [A].

• Using an auxiliary leads, supply battery power to the fan

motor.

If the fan does not rotate, the fan motor is defective and

must be replaced.

Radiator Fan Circuit

1. Relay Box

10. Joint Connector

2. Radiator Fan Relay

11. ECU

3. ECU Main Relay

12. Water Temperature Sensor

4. Fuse Box

13. Water-proof Joint E

5. Fan Fuse 15 A

14. Water-proof Joint C

6. ECU Fuse 15 A

15. Radiator Fan

7. Main Fuse 30 A

16. Ignition Switch

8. Battery 12 V 10 Ah

17. Water-proof Joint A

9. Frame Ground

18. Water-proof Joint B

16-64 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

Meter Unit Removal/Installation

• Remove:

Windshield (see Windshield Removal in the Frame

chapter)

Upper Inner Fairings (see Upper Inner Fairing Removal

in the Frame chapter)

Screws [A] (Both Side) and Meter Cover [B]

• Slide the dust cover [A] and remove the connector [B].

• Remove the meter unit by taking off the mounting nuts

[C].

CAUTION

Place the meter unit so that the face is up. If a meter

unit is left upside down or sideways for any length

of time, it will malfunction.

• Installation is the reverse of removal.

• Insert the hooks [A] into the slots [B].

Meter, Gauge Disassembly

• Remove:

Meter Unit (see Meter Unit Removal/Installation)

Screws [A]

Lower Meter Cover [B]

• Separate the meter assembly [A] and upper meter cover

[B].

ELECTRICAL SYSTEM 16-65

Meter, Gauge, Indicator Unit

Electronic Combination Meter Unit Inspection

• Remove the meter unit [A] (see Meter Unit Removal/In-

stallation).

[1] Ignition

[2] Fuel Level Warning Indicator Light (LED) (-)

[3] Unused (EX650A Models)

ABS Indicator Light (LED)(-)(EX650B Models)

[4] Unused

[5] Neutral Indicator Light (LED) (-)

[6] FI Indicator Light (LED) (-)

[7] Tachometer Signal

[8] Water Temperature Sensor (-)

[9] Ground (-)

[10] Battery (+)

[11] Oil Pressure Warning Indicator Light (LED) (-)

[12] Speed Sensor Supply Voltage

[13] Right Turn Signal Indicator Light (LED) (+)

[14] Left Turn Signal Indicator Light (LED) (+)

[15] High Beam Indicator Light (LED) (+)

[16] Speed Sensor Signal

CAUTION

Do not drop the meter unit. Place the meter unit so

that it faces upward. If the meter unit is left upside

down or sideways for a long time or dropped, it will

malfunction. Do not short each terminals.

Liquid Crystal Display (LCD) Segment Check

• Using the auxiliary wires, connect the 12 V battery to the

meter unit connector as follows.

○Connect the battery positive terminal to the terminal [10].

○Connect the battery negative terminal to the terminal [9].

○The needles of the meter move.

• Connect the terminal [1] to the terminal [10].

16-66 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

○When the terminals are connected, the LCD segment [A]

and LED warning lights [B] appear.

If the LCD segment and LED warning lights will not ap-

pear, replace the meter assembly.

• Disconnect the terminal [1].

○The LCD segment and LED warning lights disappear.

If the segment do not disappear, replace the meter as-

sembly.

MODE AND RESET BUTTON Operation Check

• Connect the 12 V battery and terminals in the same man-

ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

• Check that the display change to the CLOCK, ODO, TRIP

A and TRIP B displays each time the MODE button [A] is

pressed.

○If the fuel level gauge flashed, display change to CLOCK,

FUEL, ODO, TRIP A and TRIP B.

If the display function does not work, replace the meter

assembly.

• Indicate the clock mode.

• Check that when the RESET button in CLOCK mode is

pushed for more than two seconds, the meter display

turns to the clock set mode.

○Both the hour and minute display start flashing.

ELECTRICAL SYSTEM 16-67

Meter, Gauge, Indicator Unit

• In the HOUR/MINUTE setting mode, press the RESET

button again to effect the HOUR setting mode.

○The hour display flashes on the display.

• Press the MODE button to set the hour.

• In the HOUR setting mode, press the RESET button to

effect the MINUTE setting mode.

○The minute display flashes on the display.

• Press the MODE button to set the minute.

• In the MINUTE setting mode, press the RESET button to

return to the HOUR/MINUTE setting mode.

• Press the MODE button to complete the time setting

process.

○The clock starts counting the seconds as soon as the

MODE button is pressed.

Speedometer Check

• Connect the 12 V battery and terminals in the same man-

ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

• The speed equivalent to the input frequency is indicated in

the oscillator [A], if the square wave (illustrated as shown)

would be input into the terminal [16].

○Indicates approximately 60 mph in case the input fre-

quency would be approximately 169.0 Hz.

○Indicates approximately 60 km/h in case the input fre-

quency would be approximately 105.6 Hz.

• If the oscillator is not available, the speedometer can be

checked as follows.

○Install the meter unit.

○Raise the rear wheel off the ground with stand.

○Turn on the ignition switch.

○Rotate the rear wheel by hand.

○Check that the speedometer shows the speed.

If the speedometer does not work, check the speed sen-

sor electric source voltage and speed sensor.

The electric source voltage and speed sensor are normal,

replace the meter assembly.

16-68 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

Speed Sensor Electric Source Check

• Connect the 12 V battery and terminals in the same man-

ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

• Set the hand tester to the DC 25 V range and connect it

to the terminals [12] and [9].

If the voltage is less than 8 V, replace the meter assembly.

Odometer Check

• Check the odometer with the speedometer in the same

way.

If value indicated in the odometer is not added, replace

the meter assembly.

NOTE

○The data is maintained even if the battery is discon-

nected.

○When the figures come to 999999, they are stopped and

locked.

Trip A/B Meter Check

• Check the trip A or B meters with the speedometer in the

same way.

If value indicated in the trip A/B meters is not added, re-

place the meter assembly.

• Check that when the RESET button is pushed for more

than two seconds, the figure display turns to 0.0.

If the figure display does not indicate 0.0, replace the me-

ter assembly.

Tachometer Check

• Connect the 12 V battery and terminals in the same man-

ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

• The revolutions per minute (rpm) equivalent to the input

frequency is indicated in the oscillator [A] if the square

wave (illustrated as shown) would be input into the termi-

nal [7].

○Indicates approximately 6 000 rpm in case the input fre-

quency would be approximately 200 Hz.

• If the oscillator is not available, the tachometer can be

checked as follows.

○Connect the 12 V battery and terminals in the same man-

ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

○Using an auxiliary wire, quick open and connect the ter-

minal [1] to the terminal [7] repeatedly.

○Then the tachometer needle [A] should flick [B].

If the needle does not flick, replace the meter assembly.

ELECTRICAL SYSTEM 16-69

Meter, Gauge, Indicator Unit

Indicator Lights Inspection

• Connect the 12 V battery and terminals in the same man-

ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments check”.

Neutral Indicator Light (LED) [A]

FI Indicator Light (LED) [B]

Oil Pressure Warning Indicator Light (LED) [C]

Right Turn Signal Indicator Light (LED) [D]

Left Turn Signal Indicator Light (LED) [E]

High Beam Indicator Light (LED) [F]

Fuel Level Warning Indicator Light (LED) [G]

Water Temperature Warning Indicator Light (LED)[H]

ABS Indicator Light (LED)(EX650B Models)[I]

• Using the auxiliary leads, connect a 12 V battery to the

meter unit connector as follows.

Water Temperature Warning Indicator Light (LED)

Battery Negative (-) Terminal to Terminal [8]

Oil Pressure Warning Indicator Light (LED)

Battery Negative (-) Terminal to Terminal [11]

Fuel Level Warning Indictor Light (LED)

Battery Negative (-) Terminal to Terminal [2]

16-70 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

High Beam Indicator Light (LED)

Battery Positive (+) Terminal to Terminal [15]

Neutral Indicator Light (LED)

Battery Negative (-) Terminal to Terminal [5]

Right and Left Turn Signal Indicator Light (LED)

For Right Turn Signal Indicator Light (LED)

Battery Positive (+) Terminal to Terminal [13]

For Left Turn Signal Indicator Light (LED)

Battery Positive (+) Terminal to Terminal [14]

FI Indicator Light (LED)

Battery Negative (-) Terminal to Terminal [6]

• If each lights (LED) does not go on, replace the meter

assembly.

ELECTRICAL SYSTEM 16-71

Meter, Gauge, Indicator Unit

EX650B Models

ABS Indicator Light (LED)

Battery Negative (-) Terminal to Terminal [3]

• If the light (LED) keeps going on, replace the meter as-

sembly.

16-72 ELECTRICAL SYSTEM

Meter, Gauge, Indicator Unit

Meter Circuit

1. Ignition Switch

11. Fuel Reserve Switch

2. Frame Ground

12. Joint Connector

3. Meter Unit

13. ECU

4. Water-proof Joint B

14. Oil Pressure Switch

5. ECU Fuse 15 A

15. Neutral Switch

6. Ignition Fuse 10 A

16. Water Temperature Sensor

7. Fuse Box

17. Water-proof Joint E

8. Main Fuse 30 A

18. Speed Sensor

9. Battery 12 V 10 Ah

19. Water-proof Joint C

10. Frame Ground

20. ABS Hydraulic Unit (EX650B Models)

ELECTRICAL SYSTEM 16-73

Switches and Sensors

Brake Light Timing Inspection

• Refer to the Brake Light Switch Operation Inspection in

the Periodic Maintenance chapter.

Brake Light Timing Adjustment

• Refer to the Brake Light Switch Operation Inspection in

the Periodic Maintenance chapter.

Switch Inspection

• Using a hand tester, check to see that only the con-

nections shown in the table have continuity (about zero

ohms).

○For the switch housings and the ignition switch, refer to

the tables in the Wiring Diagram.

If the switch has an open or short, repair it or replace it

with a new one.

Special Tool - Hand Tester: 57001-1394

Rear Brake Light Switch Connections

Sidestand Switch Connections

Neutral Switch Connections

Oil Pressure Switch Connections*

*: Engine lubrication system is in good condition.

16-74 ELECTRICAL SYSTEM

Switches and Sensors

Water Temperature Sensor Inspection

• Remove the water temperature sensor (see Removal/In-

stallation in the Fuel System (DFI) chapter).

• Suspend the sensor [A] in a container of coolant so that

the temperature-sensing projection [C] and threaded por-

tion [C] are submerged.

• Suspend an accurate thermometer [B] with temperature

-sensing projection located in almost the same depth.

NOTE

○The sensor and thermometer must not touch the con-

tainer side or bottom.

• Place the container over a source of heat and gradu-

ally raise the temperature of the coolant while stirring the

coolant gently.

• Using the hand tester, measure the internal resistance of

the sensor.

If the hand tester does not show the specified values, re-

place the sensor.

Water Temperature Sensor Resistance

Temperature

Resistance (kΩ)

–20°C (-4°F)

*18.80 ±2.37

0°C (32°F)

*(about 6.544)

40°C (104°F)

1.136 ±0.095

100°C (212°F)

0.1553 ±0.0070

*: Reference Information

Speed Sensor Removal

• Remove the left center fairing (see Center Fairing Re-

moval in the Frame chapter).

• Disconnect the speed sensor lead connector [A].

• Remove the engine sprocket cover (see Engine Sprocket

Removal in the Final Drive chapter).

• Remove:

Bolt [A]

Speed Sensor [B]

Speed Sensor Installation

• Installation is the reverse of removal.

• Apply a non-permanent locking agent to the sensor bolt,

and tighten it.

Torque - Speed Sensor Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)

ELECTRICAL SYSTEM 16-75

Switches and Sensors

Speed Sensor Inspection

• Remove the speed sensor (see Speed Sensor Removal).

• Connect the speed sensor connector [A] with the battery

[B], 10 kΩ resistor [C] and hand tester [D] as shown.

• Set the tester to the DC 25 V range.

Special Tool - Hand Tester: 57001-1394

• Trace [A] each side of the speed sensor surface with the

screw driver.

○Then the tester indicator should flick [B].

If the tester indicator does not flick, replace the speed

sensor.

Oxygen Sensor Removal (Europe Models)

• Remove:

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

• Disconnect the oxygen sensor lead connector [A].

• Remove the oxygen sensor [A].

Oxygen Sensor Installation (Europe Models)

CAUTION

Never drop the oxygen sensor [A], especially on a

hard surface. Such a shock to the unit can damage

it. Do not touch the sensing part [B] and filter holes

[C] of the sensor to prevent oil contact. Oil contami-

nation from hands can reduce sensor performance.

• Tighten:

Torque - Oxygen Sensor: 44.1 N·m (4.50 kgf·m, 32.5 ft·lb)

• Run the oxygen sensor lead correctly (see Cable, Wire,

and Hose Routing section in the Appendix chapter).

16-76 ELECTRICAL SYSTEM

Switches and Sensors

Oxygen Sensor Inspection (Europe Models)

• Refer to the Oxygen Sensor Inspection in the Fuel System

(DFI) chapter.

Fuel Reserve Switch Inspection

• Fill the fuel tank with fuel.

• Close the fuel tank cap surely.

• Remove the fuel tank (see Fuel Tank Removal in the Fuel

System (DFI) chapter).

• Connect the test light [A] (12 V 3.4 W bulb a socket with

leads) and the 12 V battery [B] to the fuel pump connector

[C].

Connections:

Battery (+) → 12 V 3.4 W Bulb (One Side)

12 V 3.4 W Bulb (Other Side) → BL Lead Terminal

Battery (-) → BK Lead Terminal

If the test light turn on, the reserve switch is defective.

Replace the fuel level sensor.

• Remove the fuel pump (see Fuel Pump Removal in the

Fuel System (DFI) chapter).

• Connect the test light (12 V 3.4 W bulb in a socket with

leads) and the 12 V battery to the fuel pump connector as

shown.

12 V Battery [A]

Test Light [B]

Fuel Pump Connector [C]

Fuel Reserve Switch [D]

If the test light doesn’t light, replace the fuel pump.

NOTE

○It may take a long time to turn on the test light in case

that the fuel reserve switch is inspected just after the

fuel pump is removed. Leave the fuel reserve switch

with leads for inspection connected for few minutes.

ELECTRICAL SYSTEM 16-77

Relay Box

The relay box [A] has relays and diodes. The relays and

diodes can not be removed.

Relay Box Removal

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

• Take out the relay box [A] and disconnect the connectors

[B].

Relay Circuit Inspection

• Remove the relay box (see Relay Box Removal).

• Check conductivity of the following numbered terminals

by connecting the hand tester and one 12 V battery to the

relay box as shown (see Relay Box Internal Circuit in this

section).

If the tester does not read as specified, replace the relay

box.

Relay Circuit Inspection (with the battery disconnected)

Tester Connection

Tester Reading (Ω)

Headlight Relay

1-3

∞

7-6

∞

ECU Main Relay

4-5

Not ∞*

7-8

∞

Fuel Pump Relay

9-10

Not ∞*

11-16

∞

Starter Circuit Relay

11-12

∞

17-20

∞

Fan Relay

18-19

Not ∞*

*: The actual reading varies with the hand tester used.

16-78 ELECTRICAL SYSTEM

Relay Box

Relay Circuit Inspection (with the battery connected)

Battery

Tester

Tester

Connection

Connection

Reading (Ω)

(+)

(-)

2-11

1-3

0

ECU Main Relay

4-5

7-6

0

Fuel Pump Relay

9-10

7-8

0

Fan Relay

18-19

17-20

0

Battery

Tester Connection

Tester

Connection

DC 25 V Range

Reading (V)

(+)

(-)

Starter

Battery

16-12

11-12

Circuit Relay

Voltage

(+): Apply positive lead.

(-): Apply negative lead.

Diode Circuit Inspection

• Remove the relay box (see Relay Box Removal).

• Check conductivity of the following pairs of terminals (see

Relay Box Internal Circuit in this section).

Diode Circuit Inspection

1-11, 2-11, 12-13, 12-15, 12-16, 13-14,

Tester Connection

13-15

The resistance should be low in one direction and more

than ten times as much in the other direction. If any diode

shows low or high in both directions, the diode is defective

and the relay box must be replaced.

NOTE

○The actual meter reading varies with the meter or tester

used and the individual diodes, but generally speaking,

the lower reading should be from zero to one half the

scale.

ELECTRICAL SYSTEM 16-79

Relay Box

Relay Box Internal Circuit

A: Headlight Relay

B: ECU Main Relay

C: Fuel Pump Relay

D: Starter Circuit Relay

E: Fan Relay

16-80 ELECTRICAL SYSTEM

Fuse

30 A Main Fuse Removal

• Remove:

Left Side Cover (see Side Cover Removal in the Frame

chapter)

Cover (see Starter Relay Inspection)

Connector [A]

• Pull out the main fuse [B] from the starter relay with needle

nose pliers.

Fuse Box Fuse Removal

• Remove the seat (see Seat Removal in the Frame chap-

ter).

• Unlock the hook [A] to lift up the lid [B].

• Pull the fuses [A] straight out of the fuse box with needle

nose pliers.

15 A ECU Fuse Removal

• Remove:

Seat (see Seat Removal in the Frame chapter)

• Unlock the hook [A] to pull the lid [B].

• Pull out the ECU fuse [A] from the fuse box.

ELECTRICAL SYSTEM 16-81

Fuse

Fuse Installation

• If a fuse fails during operation, inspect the electrical sys-

tem to determine the cause, and then replace it with a

new fuse of proper amperage.

• Install the fuse box fuses on the original position as spec-

ified on the lid.

Fuse Inspection

• Remove the fuse (see 30 A Main/Fuse Box /15 A ECU

Fuse Removal).

• Inspect the fuse element.

If it is blown out, replace the fuse. Before replacing a

blown fuse, always check the amperage in the affected

circuit. If the amperage is equal to or greater than the

fuse rating, check the wiring and related components for

a short circuit.

Housing [A]

Fuse Element [B]

Terminals [C]

Blown Element [D]

CAUTION

When replacing a fuse, be sure the new fuse

matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause

damage to wiring and components.

17-2 APPENDIX

Cable, Wire, and Hose Routing

17-4 APPENDIX

Cable, Wire, and Hose Routing

17-6 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

17-8 APPENDIX

Cable, Wire, and Hose Routing

17-10 APPENDIX

Cable, Wire, and Hose Routing

17-12 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

17-14 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

17-16 APPENDIX

Cable, Wire, and Hose Routing

17-18 APPENDIX

Cable, Wire, and Hose Routing

17-20 APPENDIX

Cable, Wire, and Hose Routing

17-22 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

17-24 APPENDIX

Cable, Wire, and Hose Routing

17-26 APPENDIX

Cable, Wire, and Hose Routing

17-28 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

17-30 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

17-32 APPENDIX

Cable, Wire, and Hose Routing

17-34 APPENDIX

Cable, Wire, and Hose Routing

17-36 APPENDIX

Cable, Wire, and Hose Routing

California Model

17-38 APPENDIX

Cable, Wire, and Hose Routing

17-40 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

17-42 APPENDIX

Cable, Wire, and Hose Routing

17-44 APPENDIX

Cable, Wire, and Hose Routing

EX650B Models

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