6.

FUEL SYSTEM (Programmed Fuel Injection)

COMPONENT LOCATION··· ....... ········ .... ······· 6-2

SERVICE INFORMATION·················--··········· 6-3

THROTTLE BODY ················ ......................... 5.72

PRIMARY INJECTOR .................................... 6-79

-
TROUBLESHOOTING··· ... ···························· .. 6-5 FAST IDLE WAX UNIT .................................6-81

SYSTEM LOCATION••--························· .. ······· 6-6 STARTER VALVE ..........................................6-82

SYSTEM DIAGRAM······································· 6-7 STARTER VALVE SYNCHRONIZATION ..... 6-86

PGM-FI SELF-DIAGNOSIS MAP SENSOR········ .. ···· ................................. 6-88

INFORMATION ······--··· ···· ··· ·························· ·· 6-8
IAT SENSOR ···················· .. ·····...................... 5.89
MIL CODE INDEx......................................... 6-12
ECT SENSOR ······ .. ······················ .................. 5.89
MIL TROUBLESHOOTING•·························· 6-15
CAM PULSE GENERATOR ........................... 5.90
DTC CODE INDEX········································ 6-33
TP SENSOR···················································6-91
DTC TROUBLESHOOTING•························· 6-37
BANK ANGLE SENSOR ······· .. ·········............. 6-93
FUEL LINE INSPECTION .. ··· ··· ······ ............ ··· 6-56
ENGINE STOP RELAY .................................. 6-94
FUEL PUMP UNIT ................ ············ .. ··· .... ··· 6-58
ENGINE CONTROL MODULE (ECM) ........... 5.94
FUEL CUT-OFF RELAY ................................ 6-60
PAIR CONTROL SOLENOID VALVE•···········6-96
FUEL TANK·········· ......................... ··· .... ········ 6-61
EVAP PURGE CONTROL SOLENOID VALVE
AIR CLEANER HOUSING ······ ··· ······· ............ 6-64 (California type only) ................................... 6-98

SECONDARY INJECTOR ............................. 6-67 Oz SENSOR (California type only) .............. 5.99

6-1
FUEL SYSTEM (Programmed Fuel Injection)
COMPONENT LOCATION

J
'
22 N-m (2.2 kgf-m, 16 ft-lb)

22 N-m (2.2 kgf-m, 16 ft-lb)

6-2
 FUEL SYSTEM (Programmed Fuel Injection)
SERVICE INFORMATION
GENERAL
• Be sure to relieve the fu el pressure while the engine is OFF.
Bending or twisting the control cables wi ll impair smooth operation and cou ld cause the cables to stick or bi nd, result-
ing in loss of vehicle control.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work a rea or where gasoli ne is stored can
cause a fire or explosion.
Do not apply commercially available carburetor cleaners to the inside of the t hrottle bore, which is coated with molyb-
denum.
Do not snap the throttle valve from fu ll open to fu ll c lose after the throttle cable has been removed. It may cause incor-
rect idle operation.
Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the int ake ports after
the throttle body has been rem oved.
Do not apply excessive force to the fue l pipe on the throttle body while removing o r installing the throttle body.
Do not damage the th rottle body. It may cause incorrect throttle and idle valve synchronization.
Prevent dirt and debris from entering the throttle bore, fuel tube and return tube, clean them using compressed air.
The throttle body is fact ory pre-set. Do not disassemble in a way other than shown in this manua l.
Do not push the fue l pump base under the fuel tank when the fuel tank is stored .
A lways replace the packing when the fuel pump is removed.
The programmed fue l injection (PGM-FI) system is equipped with the Self- Diagnostic System described (page 6-8). If
t he malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem.
When checking the PGM-FI, always follow the steps in the troubleshooting flow chart (page 6-15)(page 6-37).
The PGM-FI system is provided with fail-safe f unction to secure a minimum running capability even when there is any
trouble in the system. W hen any abnormality is detected by the self-diagnosis function, running capabil ity is secured by
using numerical values preset in advance in the program map. It must be remembered, however, that when any abnor-
mality is detected in 8 injectors and/or the ignition and cam pulse generator, the fail safe function stops the eng ine to
protect it from damage.
Refer to PGM-FI system location (page 6-6).
A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
Refer to procedures for fuel level sensor inspection (page 20-18).
The vehicle speed sensor sends digital pulse signal to the ECM (PGM-FI unit) and computation. Refer to p rocedures for
vehicle speed sensor inspection (page 20- 13).
When disassembling the programmed fuel injection parts, note the location of the O-r ings. Replace them with new ones
upon reassembly.
Before disconnecting the fuel hose, release the fue l pressure by loosening the f uel hose banjo bolt at the fue l tank.
A lways replace the sealing w ashers when the fuel hose banjo bolt is rem oved or loosened.
• Use a digita I tester for PGM-FI system inspection.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body 49 states, Canada type: GO63C
identification number California type: GO63B
Starter valve vacuum difference 20mm Hg
Base throttle valve for synchronization No. 3
Idle speed 1,300 ± 100 rpm
Throttle grip free p lay 2 - 4 mm (1/1 6 - 1/8 in)
Intake air temperature senso r re sistance (at 20°C/ 68° F) 1 - 4 kQ
Eng ine coolant temperat ure sensor resistance 2.3 - 2.6 kQ
(at 20°C/68°F) I
Fuel injection resistance Secondary injector 10.5 - 14.5 Q
(at 20°c /68°F) I Primary injector 10.5 - 14.5 Q
PAIR control solenoid valve resistance (at 20°C/ 68°F) 20 - 24 Q
Cam pulse generator peak voltage (at 20°C/68° F) 0.7 V m ini mum
Ignit ion p ulse generator peak voltage (at 20°C/ 68°F) I 0.7 V m inimum
Manifold absolute pressure at idle 150 - 250 mm Hg
Fuel pressure at idle 343 kPa (3.5 kgf/cm 2 , 50 psi)
3
Fuel pump f low (at 12V) 189 cm (6.4 US oz, 6.7 Imp oz) minimum/10 seconds

6-3
FUEL SYSTEM (Programmed Fuel Injection)
TORQUE VALUES
ECT (Engine Coolant Temperature) sensor 23 N-m (2.3 kgf-m, 17 lbf-ft)
Throttle body insulator band screw See page 1-15
Starter valve synchronization p late screw 0.9 N-m (0.09 kgf-m, 0.7 lbf-ft)
Starter va lve lock nut 1.8 N-m (0.18 kgf-m, 1.3 lbf-ft)
Fast idle wax unit link plate screw 0.9 N-m (0.09 kgf-m, 0.7 lbf-ft)
Fast idle wax unit mount ing screw 4.9 N-m (0.5 kgf-m, 3.6 lbf-ft)
Fuel filler cap socket bolt 1.8 N-m (0. 18 kgf-m , 1.3 lbf-ft)
Secondary injector bracket mounting bolt 5.4 N-m (0.55 kgf.m , 4 !bf-ft)
Fuel rail mounting bolt 9 .8 N-m (1.0 kgf-m, 7 lbf-ft)
Fuel f eed hose banjo bolt (fuel tank side) 22 N -m (2.2 kgf-m, 16 lbf-ft
Fuel hose sealing nut (throttle body side) 22 N-m (2.2 kgf-m, 16 lbf-ft)
Fuel pump mounting nut 12 N-m (1.2 kgf-m, 9 lbf-ft) See page 1-16 for tightening
sequence
O2sensor (Californ ia type on ly) 25 N-m (2.6 kgf-m, 19 lbf-ft)

TOOLS

Fuel pressure gauge, 100 psi Peak voltage adaptor ECM test harness
07 406-0040003 07HGJ-0020100 (not available in 070MZ-0010200
U.S.A.)

or 07406-0040002 (two required)

or 07406-004000A (U.S.A. only ) with commercially ava ilable digital
mu ltimete r (impedance 10 M Q/DCV
minimu m)

SCS service connector Ignition M ate peak voltage tester Vacuum gauge set
070PZ-ZY30100 MTP07-0286 (U.S.A. only) 07LMJ-001000A

6-4
 FUEL SYSTEM (Programmed Fuel Injection)
TROUBLESHOOTING
Engine won't start
Intake air leak
Fuel contaminated/deteriorated
Pinched or clogged fuel hose
Faulty fuel pump unit
• Clogged fuel filter/strainer
Clogged fue l injector filter
Sticking fuel injector needle
• Faulty fuel pump operating system
Engine stalls, hard to start, rough idling
Intake air leak
Fuel contaminated/deteriorated
• Pinched or clogged fuel hose
Idle speed m isadjusted
Starter valve synchronization m isadjusted
Backfiring or misfiring during acceleration
• Ignition system malfunction
Poor performance (drive ability) and poor fuel economy
Pinched or clogged fuel hose
• Faulty pressure regulator

6-5
 SYSTEM (Program~e~d!£F~u!e~II~n~je~c~t~io~n~)l.__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
FUEL M LOCATION
SYSTE IGNITION SWITCH

PAIR CONTROL SOLENOID VALVE

BANK ANGLE SENSOR

ECM
FUEL CUT-OFF RELAY

TP SENSOR

PURGE cor:-iTR OL
ALVE (Cal1forn1a
SOLENOID
. type on ly)

V SENSOR (VSS)
VEHICLE SPEED . e oolyl

0 2SENSOR (Californ ia typ FUEL PUMP

IGN ITION PULSE G ENERATOR

FULL NAME e sensor

·t Id absolut.:'.....!:.e::-::--;:;
P ressur : ;--
Mani o . ·on sensor
Throttle pos1t 1 ture-s-=---en=-=s-;;
orr - - , r-:r
Intake
. air tempetramperature
olant e sensor_7r:riijf
Engine co odu le
Engm. e:.....__
control
_ _ m

6-6
 FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM DIAGRAM
(2)

31
111 ~_J]::;._~_:::_:::---J
:::_L
:L---o
~--:~--:-:::-::~_:_":;'"_~-.-
---<-:14.J>-l
- _~-15)- -c
~ ;:;n~

~l
(71 - ~ I 191 _
132) L __ _ _____;;;____ _ __ __ __

H~
nII ii
w L

tt It tt ~• (23)

/ (~: { '~
I

~
i~
111)
' .:r ' lL
~-~
i=:;4) (25)

(12)
n ;l
]! I1~
'i,"

lrmJ ~~
JI ,-
-
I =

J
I==
ris)
-1171
- ,_
,_
~

114) 1-

i
~ = 18)
l ::E
u
121~ I~ 1211,
I --- LaJ
I---
<--

1311~
(27)
129)

w
Ii
• I
>-- (33)
1281 / :·,130)

I
-1..
(1) Engine stop relay (19) ECT sensor
(2) PGM-FI fuse (20A) (20) Ignition pulse generator
(3) Engine stop switch (21) 0 2 sensor (California type only)
(4) Sub-fuse (10A) (22) Water temperature LCD
(5) Ignition switch (23) Fuel cut-off re lay
(6) Main fuse A (30A) (24) Fuel pump unit
(7) Bank ang le sensor (25) Fuel indicator
(8) EVAP canister (California type) (26) Vehicle speed sensor
(9) Battery (27) Speedometer
(10) IAT sensor (28) Neutral switch
(11) Direct ignition coil/spa rk plug (29) Clutch switch
(12) PAIR control solenoid valve (30) Side stand switch
(13) TP sensor (31) Malfunction indicator lamp (M IL)
(14) MAP sensor (32) Data link connector
(15) Primary injector 133) Tachometer
( 16) Secondary injector (34) EVAP purge control solenoid valve
(17) Cam pulse generator (California type on ly)
(18) PAIR check valve

6-7
FUEL SYSTEM (Programmed Fuel Injection)
PGM-FI SELF-DIAGNOSIS
INFORMATION
SELF~DIAGNOSTIC PROCEDURE
Place t he motorcycle on its side stand.
MALFUNCTION INDICATOR LAMP (MIL)
Start the engine and let it idle.
NOTE:
If the engine will not start, turn the starter motor for
more than 10 seconds and check that the MIL b links.
The MIL will blink If the malf unction indicator lamp (MIL) does not
only with the side
stand down and
wilh the engine off
light or b link, the syst em has no memory of prob-
lem data .
']
lil
,~~
E
,._ ,_ 'F -1.
~
t I
' J
>

2 1 I -.,·,.--,
:,,_.-..,
a
u
mph

o,~,..,
~ ••~'l.t.•
/engine stop switch If the malfunction indicator blinks, note how many
is RUN/ or engine t imes the MIL blinks or read the Diagnosis Trouble cgirg~'="
l:C~•:;;·=S'=
l = = ~I
revs are below Code (DTC) with the Honda Diagnosis System (HDS)
5,000 rpm. In any Pocket Tester, and determine the cause of the prob-
other condition, the lem (page 6- 12, page 6-37).
MIL will illuminate
If you wish to read the PGM-FI memory for trouble
and stay on.
data, perform the following:

DTC (With the HDS Pocket Tester)

Turn the ignition switch OFF.
DATA LINK CONNECTOR
Remove the seat (page 3-4).
Connect the HDS Pocket Tester to the Data Link
Connector (DLC).
Turn the ignition switch ON and engine stop switch
"(:)".
Check the Diagnostic Trouble Code (OTC) and note
it. Also check the freeze data.
Refer to the OTC index (page 6-33) and begin the
appropriate troubleshooting procedure.
NOTE:
For specific operations, refer to t he user's manual ' - -- - - -- - -- - - - - -- - - -
that came with the HOS Pocket Tester.
MIL CODE (Without the HDS Pocket Tester)
Turn the ignition switch OFF.
Remove the seat (page 3-4).
Short the Data Link Connector (DLC) terminals using
the special tool.
TOOL:
SCS service connector 070PZ-ZY30100
Turn the ignition switch ON and engine stop switch
"(:)".

6-8
 FUEL SYSTEM (Programmed Fuel Injection)
Even if the PGM-FI If the ECM has no self diagnosis memory data, the
has memory dara, MIL wil l illuminate, when you turn the ignition MALFUNCTION INDICATOR LAMP (MIL)
the M IL does not switch ON.
blink w hen the
If the ECM has self diagnosis memory dat a, the MIL
engine is running.
will start blinking when you t urn the ignition switch
ON.
Note how many times the MIL blinks, and det ermine
the cause of the problem (page 6-1 2).
0 mph

::aa O
sc:.o

SELF-DIAGNOSIS RESET PROCEDURE

Reset the self-diagnosis memory data in either of 2
ways;
With the HDS
Use the HOS Pocket Tester to clear the ECU mem-
ory. See the HOS Pocket Tester user's manual for
specific instruction.
Without the HDS
1. Turn the engine stop switch "0" and ign ition
switch OFF.
2. Short the Data Link Connector (DLC) t erminals
using a special tool.

TOOL:
SCS service connector 070PZ-ZY30100
3. Turn t he ignit ion switch ON.
4. Remove the special tool from the Data Link Con-
nector (DLC).

SCS SERVICE CONNECTOR

5. The M IL lights about 5 seconds. While t he i ndica-
tor lights, short the Data Link Connector (DLC)
again with t he special tool.
Self -diagnosis memory data is erased, if the M IL
turns off and starts blinking.
The Data Link Connector (DLC) must be jumped
while t he indicator is lit. If not, the M IL wil l not
start bl inking.
Not e t hat t he self diagnosis memory data cannot
be erased if you turn off the ignition switch
before t he Ml L starts blinking.
If the MIL blinks 20 times, the data has not been
erased, so try again.

6-9
FUEL SYSTEM (Programmed Fuel Injection)
PEAK VOLTAGE INSPECTION PROCE-
DURE
Use this procedure for the ignition pu lse genera-
tor and cam pulse generator inspection.
Check all system connections before inspection.
If the system is disconnected, incorrect peak volt-
age might be measured.
Check cylinder compression and check t hat all
spark plugs are installed correctly.
Use the recommended digital mu ltimeter or
commercially available digital multimeter with
an impedance of 10 MQ/DCV mini mum.
If the Imrie diagnostic tester (model 625) is used,
follow the manufacturer's instruction.
The display value differs depending upon the
internal impedance of the multimeter.
Disconnect the fuel pump connector before
checking the peak voltage.
Lift and support the fuel tank (page 6-61 ).
Disconnect the fuel pump unit 3P (Black) connecto r.

Avoid touching the Connect the peak voltage adaptor to the digital mu l-
rester probes ro timeter.
DIGITAL MULTIMETER
prevent e!ecrric
shock.
TOOLS:
\/--,
lgnitionMate peak voltage tester MTP07-0286
(U.S.A. only) or ~
Peak voltage adaptor 07HGJ-0020100
(not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 M Q/DCV minimum)
0
PEAK VOLTAGE ADAPTOR· ....

TEST HARNESS CONNECTION

Remove the following:
- Fuel tank cover {page 3-15)
- ECM cover (page 6-94)
Disconnect the ECM 32P (Black) and 32P (Light gray)
connectors from the ECM.

6-10
 FUEL SYSTEM (Programmed Fuel Injection)
Connect the ECM test harnesses between t he mai n
wire harness and the ECM. ECM TEST HARNESSES

TOOLS:
ECM test harness 070MZ-0010200
(two required)

TEST HARNESS TERMINAL LAYOUT

T he ECM connector terminals are numbered as
shown. V IEW FROM WIRE HARNESS SIDE:

A :32P (BLACK}CON NECTOR

Al A 16 81 B16

orxJDDDDDDDO• ~•
=o••• DDDDDDD

A17 A32 B17 B32

B: 32P (LIGHT GRAY} CONNECTOR

The ECM test harness t erminals are same layout as
for the ECM connector t erminals as shown.

11 i ] C i i ' I ' ij II u lJ 1, J$ I' ~

0000000000000000
0000000000000000

FOR 32P (LIGHT GRAY) CONNECTOR

6-11
FUEL SYSTEM (Programmed Fuel Injection)
MIL CODE INDEX
The PGM-FI M IL denotes the failure codes (the number of blinks from Oto 49). When the indicator lights for 1.3 seconds,
it is equivalent to ten blinks. For example, a 1.3 second illumination and two blinks (0.5 second x 2) of the indicator
equals 12 blinks. Follow code 12 troubleshooting (page 6-24).
• When more than one failure occurs, the MIL shows the blinks in the orde r of lowest number to h ighest number. For
example if the indicator blinks once, then two times, two failures have occurred. Follow codes 1 (page 6- 15) and 2 (page
6-16) troubleshooting.

Refer
MIL
No blinks
I Function Failure
ECM malfunction . Faulty ECM
Causes Symptoms
to I
Engine does not start 6-94
No bl inks ECM power/ . Open circuit at the power input Engine does not start 6-94
i

ground circuits wire of the ECM

malf unction . Fau lty bank angle sensor
. Open circuit in bank angle sen-
sor related circuit
. Fault y engine stop relay
. Open circuit in engine stop relay
related wires
. Faulty engine stop switch
Open circuit in engine stop
switch related wires
Fau lty ignition switch
. Blown PGM-FI fuse (20 A)
. Blown sub-fuse (10A} (Starter,
Bank angle sensor)
No blinks ECM output line . ECM output voltage line (Yellow/ Engine does not start -
malfunction red wire) short circuit
No blinks MIL circuit mal- . Fau lty ECM Eng ine operates nor-
function . Open or short circuit in MI L wire mally
6-8

Stays lit Data link circuit . Short ci rcuit in data link connec- Eng ine operates nor- -
malfunction tor mal ly
. Faulty ECM
. Short circuit in data link connec-
tor wire
1 Blink MAP sensor cir- . Loose o r poor contact on MAP Engine operates nor- 6-15
cuit malfunction sensor connector mal ly
. Open or short circuit in MAP sen-
sor wire
. Fau lty MAP sensor
2 Blinks MAP sensor per- . Loose or poor connection of the Engine operates nor- 6-16
formance prob- MAP sensor vacuum hose ma lly
lem Faulty MAP sensor
7 Blinks ECT sensor cir- Loose or poor contact on ECT Hard start at a low tern- 6-17
cuit malfunction sensor perature (Simulate using
I . Open or short circuit in ECT sen- numerical values; 90 °C/
sor w ire 194 °F)
. Faulty ECT sensor
8 Blinks TP sensor circuit . Loose or poor contact on TP sen- Poor engine perfor- 6- 19
malfunction sor connector mance response and
. Open or short circuit in TP sen- when operating the
sor wire t hrottle quickly (Simu-
Fault y TP sensor

9 Blinks
I IAT sensor circuit Loose or poor contact on IAT .
late using numerical val-
ues; Throttle opens 0°)

malfunction sensor
Engine operates nor-
ma lly (Simulate using
6-21 I
. Open or short circuit in IAT sen- numerical values; 25 °C/
I
sor wire 77 °F}
. Fau lty IAT sensor
11 Blinks I Vehicle speed Loose or poor contact on vehicle Engine operates nor- 6-22
sensor circuit speed sensor connector mally
malfunction . Open o r short circuit in vehicle
speed sensor wire
I I . Faulty vehicle speed sensor

6-12
 FUEL SYSTEM (Programmed Fuel Injection)
Refer
MIL Function Failure Causes Symptoms
I to
12 Blinks No.1 Primary Loose or poor contact on No.1 Engine does not start 6-24
injector circuit Primary injector connector
malfu nction . Open or short circuit in No.1 Pri-
mary injector wire
. Faulty No.1 Primary injector
13 Blinks No.2 Primary . Loose or poor contact on No.2 . Engine does not start 6-25
injector circuit Primary injector connector
malfunction Open or short circuit in No.2 Pri-
mary injector wire
Faulty No.2 Primary inject or
14 Blinks No.3 Primary Loose or poor contact on No.3 Engine does not start 6-25
injector circuit Primary injector connector
malfunction . Open or short circuit in No.3 Pri-
mary injector wire
. Faulty No.3 Primary injector
15 Blinks No.4 Primary Loose or poor contact on No.4 Engine does not start 6-25
injector circuit Primary i njector connector
malfunction Open or short circuit in No.4 Pri-
ma ry injector wire
Faulty No.4 Primary injector
16 Blinks No.1 Secondary . Loose or poor contact on No.1 . Engine does not start 6-25
injector circuit Secondary injector connector
malfunction . Open or short circuit in No.1 Sec-
ondary injector wire
Faulty No.1 Secondary injector
17 Blinks No.2 Secondary . Loose or poor contact on No.2 Engine does not start 6-25
i njector circuit Secondary injector connector
malfunction Open or short circuit in No.2 Sec-
ondary injector wire
. Faulty No.2 Secondary injector
18 Blinks Cam pulse gener- . Loose or poor contact on cam Engine does not start 6-26
ator, no signa l pulse generator
. Open or short ci rcuit in cam
pulse generator
Faulty cam pulse generator
19 Blinks Ignition pulse Lo ose or poor contact on ignition . Engine does not start 6-27
generator, no sig- pulse generator
nal Open or short circuit in ignition
pu lse generator
I . Faulty ignition pulse generator
21 Bl inks No.1 0 2 sensor . Loose or poor contact on 0 2 sen- Engine operates nor- 6-28
circuit malfunc- sor connector mally
tion (California Short circuit in 0 2 sensor I
type only) Faulty 0 2 sensor
22 Blinks No.2 0 2 sensor Loose or poor contact on 0 2 sen- Engine operates nor- 6-29
circuit malfunc- sor connector mal ly
tion (California Short circuit in 02 sensor
type only) Faulty 0 2 sensor
23 Blinks No.1 02 sensor Loose or poor contact on 0 2 sen- . Engine operates nor- 6-30
heater malfunc- sor connector mally

I tion (California . Open or short circuit in 0 2 sensor

type only) heater
. Faulty 02 sensor
24 Blinks No.2 0 2 sensor . Loose or poor contact on 02 sen- Engine operates nor- 6-3 1
heater malfunc- sor connector mally
tion (California . Open or short circuit in 0 2sensor
type only) heater
. Faulty 0 2 sensor

6-13
FUEL SYSTEM (Programmed Fuel Injection)
I Refer
i 33 Blinks
I
MIL Function Failure
I
.
Causes
I . Symptoms
to
E2-PROM in ECM Faulty ECM Engine operates nor- 6-32

I I
malfunction I I
mal ly
Does not hold the self-
I I d iagnosis data
48 Blinks
I
I No.3 Secondary . Loose or poor contact on No.3
I Engine does not start 6-25
I i njector circuit Secondary injector connector

I I malfunction Open or short circuit in No.3 Sec-

ondary injector wire
Faulty No.3 Secondary injector
I I I
I
49 Blinks I No.4 Secondary Loose or poor contact on No.4 . Engine does not st art 6-25
i njector circuit
. Secondary injector connector I I
malfunction Open or short circuit in No.4 Sec-

I
!
'
ondary injector wire
Faulty No.4 Secondary injector I I

6-14
 FUEL SYSTEM (Programmed Fuel Injection)
MIL TROUBLESHOOTING
M IL 1 BLINK (MAP SENSOR)
• Before starting the inspection, check for loose or
poor contact on the MAP sensor connector and
recheck the M IL b linking.
1. MAP Sensor Output Voltage Inspection
Turn the ignition switch OFF.
Connect the ECM test harness to ECM connec-
tors (page 6-10).
It ? l J s' 1 i I 16 II 12 1l u 1!, If. f
Turn the ig nition switch ON ,rnd engine stop
switch" n ". 0000000000000000
000000000000 0000
Measure the voltage at the test harness termi- , ",, "'°'""',.
nals.
Is the voltage within 2. 7 - 3. 1V?
YES Interm ittent failure
Loose or poor contact on the ECM e 1----' ®
connectors
NO About 5 V
GO TO STEP 2.
About O V
GO TO STEP 3.
2. MAP Sensor Output Line Inspection
Turn the ign ition swit ch OFF.
Disconnect the MAP sensor 3P connector. MAP SENSOR 3P CON NECTOR

Turn the ignition switch ON and engine stop

switch" n ".
Measure the volt age at the wire harness side.

Connection: Light green/yellow (+) - Green/

orange(-)

Is the voltage within 4.75 - 5.25V?

YES - Fa ulty MAP sensor
NO Open circuit in Light green/yellow
wire
Open circuit in Green/orange wire
3. MAP Sensor Input Voltage Inspection
Measure the volt age at the wire harness side.
MAP SENSOR 3P CON NECTOR
Connection : Yellow/red (+) - Ground(-)

Is the voltage within 4. 75 - 5.25V? I II

-.,--
YES - GO TO STEP 4.
NO - GO T O STEP 5.

6-15
FUEL SYSTEM (Programmed Fuel Injection)
4. MAP Sensor Output Line Short Circuit Inspec-
t ion
Check for continuity between the MAP sensor 3P
con nector t erminal of the wire harness side and MAPSENSOR 3P CONNECTOR
ground.
Connection: Light green/yellow - Ground

Is there continuity?
YES - Short circuit in Light green/yellow/yel-
low wire
NO - Fault y MAP sensor

5. MAP Sensor Input Line Inspection

Turn the ignition switch OFF.
Disconnect the ECM 32P connectors.
Check for continuity at the Yellow/red wire
between the MAP sensor 3P connector terminal
816 Bl A16 Al
and the ECM 32P (Light gray) connector.

Connection: B18 - Yellow/red

Is there continuity?
YES - Replace the ECM with a known g ood
one, and recheck.
NO - Open circuit in Yellow/red wire

MIL 2 BLINKS (MAP SENSOR)

Before starting the inspection, check for loose or
poor contact on the MAP sensor connector and
recheck the M IL blinking.
1. MAP Sensor Hose Inspection
Turn the ignition switch OFF
Check for connection and install ation of the MAP
sensor vacuum hose.
Is the MAP sensor hose connection correct?
YES - GO TO STEP 2.
NO - Correct the hose connection or
installation

VACUUM HOSE

6-16
 FUEL SYSTEM (Programmed Fuel Injection)
2. MAP Sensor Output Voltage Inspection
Connect the ECM t est harness to ECM connec-
tors (page 6- 10).
T urn the ignit io n switch ON and engi ne stop 1, , , , s1 , , , ,o 11 u u1, 1~ u;1
sw it ch"()".
0000000000000000
M easure the voltage at the test harness t ermi- 0000000000000000
nals.

Connection: B15 (+) -B17 (-)

Is the voltage within 2. 7 - 3 . 1 V?

YES - GO TO STEP 3. 8
NO - Faulty MAP sensor

3. MAP Sensor Output Voltage Inspection At Idle

Start the engine.
Measu re t he voltage at t he test harness t ermi-
nals. JI i J , S I 1 8 I 1§ II if 13 t1151&i
Connection: B15 (+) -B17 (-) 0000000000000000
Standard: 2.7 V maximum 0000000000000000

Is the voltage less than 2. 7 V? S it it 28 ITTaDtJ

YES - Replace t he ECM w ith a known good

one, and recheck
NO - Faulty MAP sensor e

M IL 7 BLINKS (ECT SENSOR)

Before starting the inspection, check for loose or
poor cont act on t he ECT sensor connector and
recheck the M IL blin ki ng.
1. ECT Sensor Output Volt age Inspection
Tu rn the ig nition switch OFF.
Connect ECM the test harness to ECM con nec-
tors (page 6-10).
\ t l ; ! § t J i I JD It J2 1] ).I 1$ 16 I
Tu rn the ignition switch ON and engine stop
0000000000000000
switch" ()". 0000000000000000
Measu re th e volt age at the ECM test harness ter-
ln 1 r If nZJ VPZ'-
minals.

Connection: B27 (+ } -B 17 H
Standard: 2.7 - 3 .1 V (20°C/68°F)

Is the voltag e within 2.7 - 3. 1 V? e

YES - • Intermittent fai lure
• Loose or poor contact on t he ECM
connect o rs
NO - GO TO STEP 2.

6-17
FUEL SYSTEM (Programmed Fuel Injection}
2. ECT Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the ECT sensor 3P connector.
Turn the ignition switch ON and engine stop
switch" n ".
Measure the voltage at the wire harness side of
ECT sensor connector.

Connection: Pink (+) - Ground H

Is the voltage within 4.75 - 5.25V?
YES - Inspect the ECT sensor (page 20-16)
NO - GO TO STEP 3.

3. ECT Sensor Resistance Inspection

Turn the ignition switch OFF.
Disconnect the ECT sensor connector.
Measure the resistance at the ECT sensor termi-
nals.
Connection: Pink (+) - Green/orange H (sensor
side terminals)
Standard: 2.3 - 2.6 Q (20 °C/68 °F)
Is the resistance within 2.3 -2.6 Q 20 °C/68 "F)?
NO - Faulty ECT sensor.
YES - GO TO STEP 4.

4. ECT Sensor Open Circuit Inspection

Turn the ignition switch OFF.
Check for continuity at the Pink and Green/
orange wires between the ECT sensor 3P con-
nector terminal and the ECM 32P (Light gray)
connector terminal.

Connection: 817 - Pink

827 - Green/orange

Is there continuity?
YES - GO TO STEP 5.
NO Open circuit in Pink or Pink/white
wire
Open circuit in Green/orange w i re

5. ECT Sensor Output Line Short Circuit Inspection

Check for continuity between the ECT sensor 3P
connecto r term inal of the wire harness side and
ground. rg.:. 1'
Connection: Pink - Ground
Is there continuity?
YES - Short circuit in Pink w i re
I@
0 0

NO - Replace the ECM with a known good

one, and recheck.

6-18
 FUEL SYSTEM (Programmed Fuel Injection)
MIL 8 BLINKS (TP SENSOR)
Before starting the inspection, check for loose or
poor contact on the TP sensor connector and
recheck the M IL bli nking.
1. TP Sensor Output Voltage Inspection
Turn the ignition switch OFF.
Connect the ECM test harness to ECM connec-
tors (page 6-10).
Turn the ignition switch ON and engine stop
0000000000000000
switch"() ".
0000000000000000
Measure the TP sensor output voltage at the test
harness terminals.
'''''"''°''""''
Connection: B14 (+) - 817 (-)
Standard: *0.4 - 0.6 V (throttle fully closed)
*4.2 - 4.8 V (throttle fully opened) e
NOTE:
A voltage marked * refers to the va lue of the
ECM output voltage (STEP 1) when the volt- ~ - - - - - - -- - -- - -- - - - ~
age reading shows 5 V.
When the ECM output voltage reading shows
other than 5 V, derive the TP sensor output
voltage at the test harness as follows:
In the case of the ECM output voltage is 4.75
V:
0.4 X 4.75/ 5.0 = 0.38 V
0.6 X 4.75/ 5.0 = 0.57 V
Thus, the solution is "0.38 - 0.57 V" wit h the
throttle fully closed.
Replace 0.4 and 0.6 with 4.2 and 4.8 respec-
tively, in the above equations to determine
t he throttle ful ly opened range.
Is there standard voltage?
YES Intermittent fa il ure
• Loose or poor contact on t he ECM
connectors
NO - GO TO STEP 2.
2. TP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the TP sensor 3P connector. TPSENSOR3PCONNECTOR

Turn the ignition switch ON and engine stop

switch"()".
Measure the voltage at the wire harness side.
Connection: Yellow/red (+) - Green/orange (-)

Is the voltage within 4.75 - 5.25 V? 00

YES - GO TO STEP 4.
NO - GO TO STEP 3.

6-19
FUEL SYSTEM (Programmed Fuel Injection)
3. ECM Output Voltage Inspection
Turn the ignition switch OFF.
Connect the ECM test harness to ECM connec-
tors (page 6-10).
Turn the ignition switch ON and engine stop
0000000&00000000
switch"()". 1
000000 00000000
Measure the voltage at the test harness termi-
nals.
Connection: B18 (+) -B17 H
Is the voltage within 4. 75 - 5.25V?
YES - • Open circuit in Yellow/red wire
• Open circuit in Green/orange wire
NO - Replace the ECM with a known good
one, and recheck.
4. TP Sensor Output Line Inspection
Check for continuity between the T P sensor 3P
connector terminal of the wire harness side and
ECM 32P (Light gray) connector.
Connection: Red/yellow - B14

Is there continuity?
YES - GO TO STEP 5.
NO - Open circuit in Red/yellow wire

TP SENSOR
3P CONNECTOR

5. TP Sensor Output Line Short Circuit Inspection

Turn the ig nition switch OFF.
Check for continuity between the TP sensor 3P
connector terminal of the wire harness side and
ground.
Connection: Red/ yellow (+) - Ground H

Is there continuity?
YES - Short circu it in Red/yellow wire
NO - Faulty TP sensor

6-20
 FUEL SYSTEM (Programmed Fuel Injection)
MIL 9 BLINKS (IAT SENSOR)
Before starting the inspection, check for loose or
poor contact on the IAT sensor connector and
recheck the M IL b linking.
1. IAT Sensor Output Voltage Inspection
Turn the ignition switch OFF.
Connect the ECM test harness to ECM connec-
tors (page 6- 10).
11 , J , $ 1 , • e ,011 ,1 IJ ,, 1!, 1,1 11 :: , 4 ss , 1 t 1c11 nu u ,5 ,.1
Turn the ignit ion switch ON and engine stop
0000000000000000
switch" 0 ".
0000000000000000
M easure the volt age at the test harness termi-
nals. W...lUUiiUlV 24.25 26 21 2i 21 Mi It if I

Connection: B30 (+) - B17 (-)

Standard: 2.7 - 3.1 V (20°C/68°F)
Is the voltage within 2.7 - 3.1 V? e
YES Interm ittent fa ilure
• Loose or poor contact on the ECM
connectors
NO - GO TO STEP 2.
2. IAT Sensor Input Voltage Inspection
T urn the ignition switch OFF.
Disconnect the IAT sensor 2P connector.
Turn the ignition switch ON and engine stop
switch" 0 ".
Measure the voltage at the wire harness side of
IAT sensor connector.
I~

Connect ion: Gray/blue - Green/orange lo o

Is the voltage within 4. 75 - 5.25V?

YES - GO TO STEP 3.
NO - GO TO STEP 4.

3. IAT Sensor Resistance Inspection

T urn the ignition switch OFF.
Disconnect the IAT sensor 2P connector.
M easure the resist ance at the IAT sensor term i-
nals (at 20 - 30 °C/ 68 - 86 °F).

Standard: 1 - 4 kQ (20 - 30 °C/68 - 86 °F)

Is the resistance within 1 - 4 kQ? 00

NO - Faulty IAT sensor

YES - GO TO STEP 4.

6-21
FUEL SYSTEM (Programmed Fuel Injection)
4. IAT Sensor Open Circuit Inspection
Turn the ignition swit ch OFF.
Check for continuity at t he Gray/ blue and Green/
orange wires between t he IAT sensor 2P connec- cu:' •' 1 '••II ii•:.,,.., HI , . • ' • 11' • • .,,. •10 11 '' ,,,
tor terminal and the ECM 32P (Light gray) con-
nector.
Are there continuity?
YES - GO TO STEP 5.
NO - • Open circuit in Gray/ blue wire
• Open circuit in Green/ orange wire

5. IAT Sensor Output line Short Circuit Inspection

Check for continuity between the IAT sensor 2P
connector terminal of the wire harness side and
ground.
Connection: Gray/ blue - Ground
Is there continuity?
YES - Short circuit in Gray/blue wire
NO - Replace the ECM w ith a known good
one and recheck.

MIL 11 BLINKS (VEHICLE SPEED SEN-

SOR)
Before starting the inspection, check for loose or
poor contact on the veh icle speed sensor con -
nector and recheck the MIL b linking.
1. Vehicle Speed Sensor Pulse Inspection
Turn the ignition switch OFF.
Connect the ECM test harness to the ECM con-
nectors (page 6-10).
Support the motorcycle securely and place the
rear wheel off the ground. 0 00000000000
000000000000
Shift the transmission i nto gear.
Measure the voltage at the test harness termi-
nals with the ignition switch ON and engine st op
switch " () "while slowly turning the rear wheel
by hand. 9 .______.., V 1--- - ---' ·=B
Connection: B25 (+) - A4 (-)
Standard: Repeat Oto 5 V
Is there s tandard voltage?
YES - • Intermittent failure
• Loose or poor contact on the ECM
connectors
NO - GO TO STEP 2.

6-22
 FUEL SYSTEM (Programmed Fuel Injection)
2. Combination Meter Inspection
Check for operation of speed meter.
Does the speed meter operate normally?
YES - Open or short circuit in the Pink/green
wire
NO - GO TO STEP 3.

3. Vehicle Speed Sensor Input Voltage Inspection

Turn the ig nition swit ch OFF.
Disconnect the vehicle speed sensor 3P connec-
tor.
T urn the ignition switch ON and engine stop
sw itch" 0 ".
Measure the voltage at the w ire harness side.
Connection: Black (+) - Green H

Is there battery voltage?

YES - GO TO STEP 4.
NO Open circuit i n the Black or Black/
brown w ire
Open circuit in the Green or Green/
black w ire
4. Vehicle Speed Sensor Signal Line Short Circuit
Inspection
Turn the ignition switch OFF.
Check for cont inuity between the test harness
and the ground .

Connection: 825 - Ground 0000000000000000

0000000000000000
Is there continuity? I ·19 7?GJ1 lHlio5 Zfi fppQltj;n n l

YES - Short circu it in the Pink o r Pink/green

wire
NO - Inspect the vehicle speed sensor (page
2 0-13)

6-23
FUEL SYSTEM (Programmed Fuel Injection)
MIL 12 BLINKS (No.1 PRIMARY INJEC-
TOR) A:32P(BLACK) CONNECTOR

I MIL I INJEC- POWER SIGN AL SIGNAL POWER INPUT LINE

TOR INPUT LINE LINE ATECM
12 No.1 Black/white Pink/yellow A 11
Primary
13 No.2 Black/white Pink/blue A12
Primary
14 No.3 Black/white Pink/green A 13
Primary
15 No.4 Black/white Pink/black A14
Primary
16 No.1 Black/white Pink/yellow B1 B: 32P (LIGHT GRAY} CON NECTOR
i
Second-
ary
17 No.2 Black/white Pink/blue B2
Second-
ary
48 No.3 Black/white Pink/green B3
Second-
ary
49 No.4 Black/white Pink/black B4
Second-
ary I

1. Inject o r Circuit Resistance Inspection

Turn the ignition switch OFF.
Connect the ECM test harness to the ECM con-
nectors (page 6-10).
U 2 ~ • & , 1 I 4 j§ lj 1? ll 14 U Ii I I 12 J 4 S• t I DTTDnf.tiJDII
Measure the resista nce at the test harness termi- 0000000000 0000 000000000000000
nals. oo 000000 00000 ooooooobooooooo'
DI 1I 1• i& 1, n l3 0 U it LIDTIIDil
Connection: POW ER INPUT LINE - SIGNAL AT
ECM

Is there continuity?
YES - GO TO STEP 4.
NO - GO TO STEP 2.

2. Inject or Resistance Inspection

Disconnect the No.1 primary injector 2P connec-
tor and measure the resistance of the No.1 pri-
mary inject or 2P connector terminals.
Is the resista nce w ithin 11. 1 - 12.3 Q (20 °CI
68"F)7
YES - GO TO STEP 3.
NO - Fau lty injector

6-24
 FUEL SYSTEM (Programmed Fuel Injection)
3. Injector Input Voltage Inspection
Turn the ignition switch ON and engine stop
switch " n ". N0.1 PRIMARY INJECTOR 2P CONNECTOR

Measure the voltage between the No. 1 primary

injector connector of the wire harness side and
ground.

Connection: POWER INPUT LINE(+) - Ground(-)

Is there battery voltage?
YES - Open circuit in SIGNAL LINE wire
NO - Open circuit in POWER INPUT LINE wi re

4. Injector Signal Line Short Circuit Inspection

Check for continuity between the test harness
terminals and ground.

Connection: SIGNAL AT ECM - Ground

0000000000000000
Is there continuity? 0000 000000000000
YES - • Short circu it in the SIGNAL LINE wire
• Fau lty injector
NO - Replace the ECM with a known good
one, and recheck

MIL 13 BLINKS
(No.2 PRIMARY INJECTOR)
(page 6-24)

MIL 14 BLINKS
(No.3 PRIMARY INJECTOR)
(page 6-24)
MIL 15 BLINKS
(No.4 PRIMARY INJECTOR)
(page 6-24)

MIL 16 BLINKS
(No.1 SECONDARY INJECTOR)
(page 6-24)
MIL 17 BLINKS
(No.2 SECONDARY INJECTOR)
(page 6-24)

MIL 48 BLINKS
(No.3 SECONDARY INJECTOR)
(page 6-2 4)
MIL 49 BLINKS
(No.4 SECONDARY INJECTOR)
(page 6-24)

6-25
FUEL SYSTEM (Programmed Fuel Injection)
MIL 18 BLINKS (CAM PULSE GENERA-
TOR)
Before starting the inspection, check for loose or
poor contact on the cam pulse generator connec-
tor and rech eck the MIL blinking.
1. Cam Pulse Generator Peak Voltage Inspection at
ECM
Turn the ignition switch OFF.
Connect the ECM test harness to the ECM con-
nectors (page 6- 10).
Turn the ignition switch ON and engine stop
switch" () ".
Crank the engine w ith the starter motor, and
measure the cam pulse generator peak voltage
at the test harness terminals.

Connection: B10 (+ ) - A31 (-)

Is the voltage more than 0. 7 V (20 °C/68 °F)?
YES - • Intermittent failure
• Loose or poor contact o n t he ECM
connectors
NO - GO TO STEP 2.
2. Cam Pulse Generator Peak Voltage Inspection
Turn the ignition switch OFF.
Disconnect the cam pulse generator 2P connec-
tor.
Turn the ignition switch ON and engine stop
switch " () ".
Crank the engine with the starter motor, and
measure the cam pulse generator peak volta ge
at the cam pulse g enerator 2P connector.

Connection: Gray (+ ) - White/ yellow (-)

Is the voltage more than 0. 7 V (20 °C/68 °F)7
YES - Open or short circuit in the Green/
orange wire or Gray wire
NO - Faulty cam pulse generator

6-26
 FUEL SYSTEM (Programmed Fuel Injection)
MIL 19 BLINKS (IGNITION PULSE GEN-
ERATOR)
Before starting the inspection, check for loose o r
poor contact on the ignition pulse generator con-
nector and recheck t he MIL blinking.
1. Ignition Pulse Generator Peak Voltage Inspec-
tion at ECM
Turn the ignition switch OFF.
Connect the ECM test harness t o the ECM con-
nectors (page 6-10).
j I ' l 1 $ § J I ' '911 u ll J& 1$ ,, I
Turn the ignition switch ON and engine stop
00000000
switch "() ". 000,0 0000
Crank the engine with the starter motor, and
measure the ignition pulse generator peak volt-
age at the t est harness terminals.

Connection: B9 (+) - A31 (- )

Is the voltage more than 0.7 V (20 °C/68 °F)?
YES Intermittent failure
• Loose or poor contact on the ECM
connectors
NO - GO T O STEP 2.
2. Ignition Pulse Generator Peak Voltage Inspec-
tion
Turn t he ignition switch OFF.
Lift and support t he f uel tank (page 6-61 ). IGNITION PULSE GENERATOR
Disconnect the ignition pulse generator 2P (Red) 2P (RED) CONNECTOR
connector.
~I
Turn the ign ition switch ON and engine stop
switch"() ".
Crank the engine with the starter motor, and
measure the ignition pulse generator peak volt -
age at the ignition pu lse generator 2P (Red) con-
nect or.

Connection: Yellow{+ ) - Yellow/white(- )

Is the voltage more than 0.7 V (20 °C/68 °F}?

YES - Open o r short circuit i n the Yellow,
Green/orange or Yellow/wh ite w ire
NO - Faulty ignition pulse generator

6-27
FUEL SYSTEM (Programmed Fuel Injection)
MIL 21 BLINKS (No.1 0 2 SENSOR):
California type only
Before starting the inspection, check for loose or
poor contact on the 02 sensor connector and
recheck the MIL b linking.

I MIL 0 2 SEN-
SOR
GROUND SIGNAL
LINE LINE
SIGNAL
ATECM
21 No.1 0 2 Green/ Black/red 813

~
Sensor orange
No.2 02 Green/ Black/ B28
Sensor orange orange

GROUND LINE

B: 32P (LIGHT GRAY) CONNECTOR

1. 02 Sensor Output Voltage Inspection

Turn the ignition switch OFF.
Connect the ECM test harness to the ECM con-
nectors ( page 6-10).
f 1 l JI,.,! i !Pl •1n12,s111 o:::I...i.D I J I I ij i1 I) ;J i rS rq
Turn the ignition switch ON and engine stop
0000000000000000
switch"()". I
0000000000000000
Warm the engine until the coolant temperature
PHH! h H )oJfID
is 80 °C (176 °F).
Check the voltage at the test harness t erminal.

Connection: SIGNAL AT ECM {+} - B17 (-)

Standard: 0.1 - 0.3 V

Is the voltage as specified?

YES - Check the fuel pressure (page 6-56). If
the system is correct, GO TO STEP 4.
NO - GO TO STEP 2.
2. 0 2 Sensor Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the 0 2 sensor 4P connector.
11 2 J , s1 , 1 , 10 ,, if ,rmrn
Check the continuity between the t est harness 00,00000000000000
connector terminals and the 0 2 sensor 4P con- 00000 0000000000
nector. ,= ann &J9,nJ21
Connection: SIGNAL LINE - SIGNAL AT ECM
Is there continuity?
YES - GO TO STEP 3.
NO - Open circuit in the SIGNAL wire

6-28
 FUEL SYSTEM (Programmed Fuel Injection)
3. Oz Sensor Short Circuit Inspection
Connect the 0 2 Sensor 4P connector.
Check the conti nuity between the ECM connec-
tor terminal and ground.
Connection: SIGNAL AT ECM - Ground 0000000000000000
0000000000000000
Is there continuity?
YES - Short circuit in t he SIGNAL wire
NO - GO TO ST EP 4.

4. Oz Sensor Inspection
Replace the 02 sensor w ith a known good one
(page 6-99).
Reset the ECM {page 6-9).
Turn the ignition switch ON and engine stop
0000000000000000
switch"() ".
0000000000000000
Warm the engine u ntil the coolant temperature
is 80 °C (176 °C).
Check the voltage at the test harness terminal.

Connection: SIGNAL AT ECM (+) - B17 (-)

Standard: 0.1 - 0.3 V

Is the voltage as specified?
YES - Faulty 0 2 sensor
NO - Check the fue l su pply system (page 2-2).

MIL 22 BLINKS (No.2 02 SENSOR):

California type only
{page 6-28)

6-29
FUEL SYSTEM (Programmed Fuel Injection)
MIL 23 BLINKS (No. 1 0 2 SENSOR
HEATER): California type only
Before starting the inspection, check for loose or
poor contact on the 0 2 sensor connector and
recheck the MIL b li nking.

I MIL 0 2 Sensor POWER

INPUT
SIGNAL
LINE
I SIGNAL
ATECM I I
A: 32P (BLACK) CONNECTOR

i,~ :~••=•=
1 LINE
23 No.1 02 Black/ White A 10
Sensor white
24 No.2 02 Blacl</ White A9 rrm
L Sensor white

B: 32P (LIGHT GRAY) CONNECTOR

1. 0 2 Sensor Heater Resist a nee Inspection

Turn the ignition switch OFF.
Disconnect the 02 sensor connector ar;id mea-
sure t he resist ance at t he sensor side connector
white wire terminal and Green/ orange terminal.
Connection: White - Green/ orange
Is the resistance within 10 - 40 Q (20 °C/ 68"F)?
YES - GO TO STEP 2.
NO - Faulty 0 2 sensor

2. 0 2 Sensor Heater Open circuit Inspection

Connect the 02 sensor connector.
Measure the resistance at the test harness termi-
nals. ~ ' 1111 If 1J •! I~ 1[] I 3 LU .L..l [•~ II u !~ I• 1t 111

II
zl ' ' I
'I
I I
Connection: POWER INPUT LINE - SIGNAL AT
11000000000 ,ooooocgJ '000000000000000
ECM 1000000000 :,000000 1000000000000000 •I
Is the resistance within 10- 40 n (20 °C/ 68 °F)? ulBI ..
YES - GO TO STEP 3.
NO Open circuit in the Black/white wire
• Open circuit in the SIGNAL LINE wire
0

6-30
 FUEL SYSTEM (Programmed Fuel Injection)
3. 02 Sensor Heater Short Circuit Inspection 1
Disconnect the 02 sensor connector.
Check fo r continuity between the SIGNAL LI NE
wire term ina l at test harness and ground.
Connection: SIGNAL AT ECM - Ground

0000000000000000
YES - Short circuit in the SIGNAL LINE wire
BHU &&RJ1111
NO - GO TO STEP 4.

4. 0 2 Sensor Heater Short Circuit Inspection 2

Check for continuity between the 02 sensor con-
nector termina ls and ground. 0 2 SENSOR CONNECTOR
Connection : White - Ground

Is there continuity?
YES - Faulty 02 sensor
NO - Replace the ECM with a known good
one, and recheck.

1.====

MIL 24 BLINKS (No.2 02 SENSOR):

California type only
(page 6-30)

6-31
FUEL SYSTEM (Programmed Fuel Injection)
MIL 33 BLINKS (E2 -PROM)
1. Recheck Mil Blinks 1
Reset the self-diagnosis memory data (page 6-9).
Turn the ignition switch ON and engine stop
switch"() ".
Check that the MIL blinks.
Does the MIL blink 33 times?
YES - Replace the ECM with a known good
one, and recheck.
NO - GO TO STEP 2.
2. Recheck MIL Blinks 2
Turn the ignition switch OFF.
Short the data link connector w ith the SCS
service connector (070PZ-2Y30100).
Turn the ignition switch ON and engine st op
switch"()".
Check that the MIL blinks.
Does the MIL blink 33 times?
YES - GO TO STEP 3.
NO - Intermittent fa ilure

3. Recheck MIL Blinks 3

Reset the self-d iagnosis memo ry data (page 6-9).
Turn the ignition switch ON and engine stop
switch·()".
Check that the Mil blinks.
Does the MIL blink 33 times?
YES - Replace the ECM with a known good
one, and recheck.
NO - Intermittent failure

6-32
 FUEL SYSTEM (Programmed Fuel Injection)
DTC CODE INDEX
The Diagnostic Trouble Codes (DTC) are based upon Malfunction Indicator Lamp (MIL) codes and are displayed as
hyphenated numbers. The digits in front of the hyphen are equal t o an M IL code and indicate the Function Failure. The
d igit behind the hyphen details t he symptom. For example, in the case of the TP sensor, the ECM stores two levels of
information, a fun ction fai lu re and a detail of the symptom:
(08 - 1) =TP sensor voltage - lower tha n the specified value
or
(08 - 2) = TP sensor voltage - higherthan the specified value.
The MAP, ECT, TP and IAT sensor diag nosises wi ll be made according to the voltage output of the affected sensor.
If a failure occurs, the ECM deterrmines the Function Failure, compares the sensor voltage output to the standard value,
and then outputs the corresponding DTC to the HDS Pocket Test er
For example:
- If the input voltage line (A) on the MAP sensor is opened, the ECM det ects the output voltage is about 5 V, then the
DTC 1-2 (MAP sensor circuit h igh voltage) wil l be displyaed.
- If the input volta ge li ne (Bl on t he T P sensor is opened, the ECM detects the output voltage is O V, then the OTC 8-1 (TP
sensor circuit low voltage) will be d isplyaed.

5V
MAP SENSOR 5V
5V TP SENSOR

~ - - - -(B) ---<l--'
OUTPUT VOLTAGE

OUTPUT VOLTAGE

5V 5V
ECT SENSOR IAT SENSOR

OUTPUT VOLTAGE OUTPUT VOLTAGE

6-33
FUEL SYSTEM (Programmed Fuel Injection)
Refer
DTC Function Failure Causes Symptoms
to
ECM malfunction Faulty ECM Engine does not start 6-94
MIL does not blink
ECM power input Open circuit at the power input Engine does not start 6-9- 4- -
circuit malfunc-
tion
wire of the ECM
Faulty bank angle sensor I M IL does not blink

Open circuit in bank angle sensor

related circuit
Faulty engine stop relay
Open circuit in engine stop relay
related wires
Faulty engine stop switch
Open circuit in eng ine stop switch
related w ires
Faulty ignition switch
Blown PGM-FI fuse (20 A)
Blown sub-fuse (10 A) (Starter,
Bank ang le sensor)

n :.,~
ECM output line ECM output voltage line (Yellow/ • Engine does not short
malfunction red wire) short circuit
1 - - - - ---MIL circuit mal- Faulty ECM ngine operates nor-
function Open or short circuit in MIL wire mally
MIL does not blink
- - -- ----1-
Data link circuit S ho rt circu it in data link connector • Engine operates nor-
malfunction Faulty ECM mally
Short circuit in data link connector ~ MIL stays lit
w i re
1-1 MAP sensor c...,.ir-----+-- o=-p-en or short circuit in MAP sen- • Eng-in_e_o_p_e-ra_t_e_s_n_o_r__---+--6 ---37- -
cuit low voltage sor wire mally
Faulty MAP sensor __J
1-2 MAP sensor cir- Loose or poor contact on MAP Engine operates nor- 6-38
cuit high voltage sensor connector m
- ally
Open circuit in MAP sensor wire
• Faulty MAP sensor
2-1 MAP sensor per- Loose or poor connection of the I
formance prob- MAP sensor vacuum hose
lem Faulty MAP sen~s~o=r-- - -~ - -~ - -
7-1 ECT sensor cir- Short circu it in ECT sensor wire Hard start at a low t ern- 6-40
cuit low voltage Faulty ECT sensor perature (Simulate using
numerical values; 90 °C/
194 " F)
7-2 ECT sensor cir- Loose or poor contact on ECT sen- Hard start at a low tem- 6-40
cuit high voltage sor perature (Simulate using
Open circuit in ECT sensor wire numerical values; 90 °C/
Faulty ECT sensor 194 "Fl
8-1 TP sensor circuit Loose or poor contact on TP sen- Poor engine perfor- 6-42
low voltage sor connector mance and response
Open or short circuit in TP sensor when operating the
wire throttle quickly (Simu-
Faulty TP sensor late using numerical va l-
ues; Throttle opens 0°)
- -- -----:----:-----t----;c;: - - - - , - - ; - - ; - - - : : = - - - - - - : -- - - -- - - - - + - - - -- --i
8-2 TP sensor circuit Open circuit in TP sensor wire • Poor engine perfor- 6-43
high voltage Faulty TP sensor mance and response
when operating the
throttle quickly (Simu-
late using numerical va: t ·
f--~ ,--------,,-:-::--- ----:---:--+---=;-----,-----,-,----,-~- -- -- -- -- -·u es; Throttle opens 0°)
9-1 IAT sensor circuit Short circuit in IAT sensor wire • Engine operates nor- 6-44
low voltage Faulty IAT sensor mally (Simulate using
numerical values; 25 °C/
_J
I ., IAT sensor circuit
high voltage
Loose or poor contact on IAT sen-
sor
- ---cc77 °F) _ _ _
• Engine operates nor- T -45
J _ jmally (Simulate using
I
Open circuit in IAT sensor wire numerical values; 25 °C/
Faulty IAT senso r 77 "F) _ __ j

6-34
 FUEL SYSTEM (Programmed Fuel Injection)

DTC ' Function Failure Causes Symptoms

Refer
to
11-1 Vehicle speed . Loose or poor contact on veh icle Engine operates nor- 6-46
sensor no signal speed sensor connector mally
{circu it malfunc- . Open or short circuit in vehicle
t ion) speed sensor connector
Faulty vehicle speed sensor
12-1 No.1 Primary Loose or poor contact on No.1 Pri- Engi ne does not start 6-47
injector circuit
malfunction
mary injector connector
Open or short circuit in No. 1 Pri-
I
ma ry injector wire

13- 1 No.2 Primary

Faulty No.1 Primary i njector
Loose or poor contact on No.2 Pri- Engine does not start 6-49
I
injector circuit ma ry injector connector
malfunction Open or short circuit in No.2 Pri-
mary injector w ire
Faulty No.2 Primary injector
14- 1 No.3 Primary Loose or poor contact on No.3 Pri- Engi ne does not start 6-49
injector circuit ma ry injector con necto r
malfunction Open or short circuit in No.3 Pri-
mary injector wire
Faulty No.3 Primary injector
15- 1 No.4 Primary Loose or poor contact on No.4 Pri- Engine does not start 6-49
injector circuit ma ry injector connector
malfunction . Open or short circuit in No.4 Pri-
mary injector wire
Faulty No.4 Primary injector
16-1 No.1 Secondary Loose or poor contact on No. 1 . Engine does not start 6-49
injector circuit Secondary injector conn ector
malfunctiori . Open or short circuit in No.1 Sec-
ondary injector wire
Fau lty No.1 Secondary injector
17- 1 No.2 Secondary Loose o r poor contact on No.2 . Engine does not sta rt 6-49
injector circuit Secondary injector connector
m alfunction . Open or short circuit in No.2 Sec-
onda ry injector wire
Fau lty No.2 Secondary injector
18- 1 Cam pulse gener- Loose or poor contact on cam Engine does not start 6-50
ator no signal pulse generator
Open o r short circuit in cam p ulse
generator I
Faulty cam pulse generator I
19-1 Ignition pulse Loose or poor contact on ignition Engine does not start 6-51
generator no sig- p ulse generator
nal . Open or short circuit in ignition
p ulse generator
. Faulty ignition pu lse generator
21-1 No. 1 02 sensor . Loose or poor contact on 0 2 sen- . Engine operates nor- 6-52
circuit malfunc- so r connector mally
t ion {Ca lifornia . Short ci rcuit in 0 2 sensor
type only) . Faulty 0 2 sensor
22-1 No.2 02 sensor . Loose or poor contact on 0, sen- . Engine operates nor- 6-53
circuit malfunc- sor connector mally
tion (Ca lifornia Short circuit in 0 2 sensor

23-1
type o nly)
No.1 0 2 sensor
Fau lty Oz sensor I I
Loose or poor contact on 0 2 sen- Engine operates nor- 6-54
heater malf unc- sor connector mal ly
tion {California Open or short circuit in Oz sensor
type on ly) I heater
. Faulty Oz sensor
24- 1 No.2 0 2 sensor Loose o r poor contact on O, sen- Engi ne operates nor- 6-55
heater malfunc- sor connector mally
tion (Californ ia . Open or short circuit in 0 2 sensor
type only) heater
. Faulty 0 2 sensor

6-35
FUEL SYSTEM (Programmed Fuel Injection)

DTC I Function Failure Causes Symptoms

Refer
to
33-1 E2-PROM in ECM . Faulty ECM Engine operates nor- 6-55
malfunct ion m ally
I Does not hold the self -
diagnosis data
48-1 No.3 Secondary . Loose or poor contact on No.3 Engine does not start 6-49
injector circuit Secondary injector connector
malfunction . Open or short circuit in No.3 Sec-
ondary injector wire
. Fau lty No.3 Secondary injector
49-1 No.4 Secondary . Loose or poor contact on No.4 . Engine does not start 6-49
I injector circuit
malfunction . Secondary injector connector
Open or short circuit in No.4 Sec-
ondary injector wire
I . Faulty No.4 Secondary injector

6-36
 FUEL SYSTEM (Programmed Fuel Injection)
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW VOLT-
AGE)
1. MAP Sensor System Inspection
Tu rn the ignition switch ON and engine stop
switch " () ".
Check the MAP sensor with the HDS.
Is about O V or below indicated?
YES - GO TO STEP 2.
NO Intermittent fa i lure
• Loose or poor contact on the MAP
sensor connector
2. MAP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the MAP sensor 3P connector. MAPSENSOR3PCONNECT OR
Turn the ignit ion switch ON and engine stop
switch"()".
Measure the voltage at the wire harness side.
Connection: Yellow/red (+) - Green/orange H
Is the voltage within 4. 75 - 5.25V?
YES - GO TO STEP 4.
NO - GO TO STEP 3.

3. MAP Sensor Input Line Inspection

Turn the ignition switch OFF.
Disconnect the ECM 32P connectors.
Check for contin u ity at the Yellow/red wire
between the MAP sensor 3P connector terminal
81 6 B1 A16
and the ECM 32P (Light gray) connector. A1

Connection: B18 - Yellow/red

Is there continuity?
YES - Replace the ECM with a known good
one, and recheck.
NO - Open circuit in Yellow/red wire

4. MAP Sensor Output Line Short Circuit Inspec-

tion
Check for conti nuit y between the MAP sensor 3P
connector terminal of the wire harness side and
ground.
Connection: Light green/yellow - Ground
Is there continuity?
YES - Short ci rcui t in Light green/yellow w i re
NO - GO TO STEP 5.

6-37
FUEL SYSTEM (Programmed Fuel Injection)
5. MAP Sensor Inspection
Replace the MAP sensor with a known good one
(page 6-88).
Reset the ECM (page 6-9).
Turn the ignition switch ON and engine stop
switch"()".
Check the MAP sensor with the HOS.
Is DTC 1-1 indicated?
YES - Replace the ECM with a known good
one, and recheck
NO - Faulty original MAP sensor

OTC 1-2 (MAP SENSOR HIGH VOLT-

AGE)
Before starting the inspection, check for loose or
poor cont act on the MAP sensor con nector and
recheck the OTC.
1. MAP Sensor System Inspection 1
Turn the ignition switch ON and engine stop
switch " ()".
Check the MAP sensor with the HOS.
Is about 5 V indicated?
YES - GO TO ST EP 2.
NO Intermittent failure
• Loose or poor contact on the MAP
sensor connector
2. MAP Sensor System Inspection 2
Turn the ignition switch OFF.
Disconnect the MAP sensor 3P connector.
Connect the MAP sensor terminals at the wi re
harness side with a jumper w i re.
Connection: Light green/yellow - Green/orange
Turn the ignition switch ON and engine stop
switch "()".
Check the M AP sensor with the HOS.
Is about O Vindicated?
YES - Faulty MAP sensor
NO - GO TO STEP 3. '-....
JUMPER WIRE

3. MAP Sensor Input Voltage Inspection

Turn the ignition switch OFF.
Remove the jumper w ire.
Turn the ignition switch ON and engine stop
switch"()".
Measure the voltage at the wire harness side.
Connection: Yellow /red (+) - Green/orange(-)

Is the voltage within 4. 75 - 5.25V?

YES - GO TO STEP 4.
NO - Open circuit in Green/ orange wire

6-38
 FUEL SYSTEM (Programmed Fuel Injection)
4. MAP Sensor Output Line Open Circuit Inspec-
tion
Disconnect t he ECM 32P connectors.
Check for con tinu ity at the Light green/yellow
wire between t he MAP sensor 3P connector ter-
B16 B1 A76 Al
minal and the ECM 32P (Light gray) connector.

Connection: B15 - Light green/yellow

Is there continuity?
YES - Replace the ECM with a known good
one, and recheck
NO - Open c ircuit in Light green/yellow wire

DTC 2-1 (MAP SENSOR)

• Before sta rting t he inspection, check for loose or
poor contact on the MAP sensor connector and
recheck the OTC.
1. MAP Sensor System Inspection
Turn the ignition switch ON and engine stop
switch"(')".
Start the engine and check the MAP sensor w ith
the HDS at id le speed.
Is 1.6 Vindicated?
YES - Intermittent fail u re
NO - GO TO STEP 2.
2. Manifold Absolute Pressure Test
Turn the ign it ion switch OFF.
Check for connection and installation of the M AP
sensor vacuum hose.
Is the MAP sensor vacuum hose connection cor-
rect?
YES - GO TO STEP 3.
NO - Correct the hose instal lation

3. MAP Sensor System Inspection

Replace the MAP sensor with a known good one
(page 6-88).
T urn the ignition switch ON and engine stop
switch"(')".
Start t he engine and check the MAP sensor with
the HDS at idle speed.
/s 1.6 Vindicated?
YES - Fau lty o rig inal MAP sensor
NO - Replace t he ECM with a known good
one, and recheck.

6-39
FUEL SYSTEM (Programmed Fuel Injection)
DTC 7-1 (ECT SENSOR LOW VOLT-
AGE)
1. ECT Sensor System Inspection
Tu rn the ignition switch ON and engine stop
switch"() ".
Check t he ECT sensor with the HDS.
Is about O Vindicated?
YES - GO TO STEP 2.
NO Intermittent failu re
• Loose or poor contact on the ECT
sensor connector
2 . ECT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the ECT sensor 3P con nect o r.
Turn t he ign ition sw itch ON and engine stop
switch " () ".
Check t he ECT sensor with the HDS.
Is about O Vindicated?
YES - GO TO STEP 3.
NO - Faulty ECT sensor

3 . ECT Sensor Output Line Short Circuit Inspection

Turn t he ignition switch OFF.
Check fo r co ntinuity between t he ECT sensor 3P
con nector termina l of the wire harness side and
ground.
Connection: Pink - Ground
0 O
Is there continuity?
YES - Short circuit in Pink wire
NO - Replace t he ECM with a known g ood
one, and recheck.

DTC 7-2 (ECT SENSOR HIGH VOLT-

AGE)
Before starting the inspection, check for loose or
poor contact on the ECT sensor connector and
recheck t he DTC.
1. ECT Sensor System Inspection
Turn the ignition switch ON and engine sto p
switch"() ".
Check the ECT sensor with the HDS.
Is about 5 V indicated?
YES - GO T O STE P 2.
NO - • Intermittent failure
• Loose o r poor contact on the ECT
sensor connector

6-40
 FUEL SYSTEM (Programmed Fuel Injection)
2 . ECT Sensor Inspection
Turn the ign ition switch OFF.
Disconnect t he ECT sensor 3P connector.
Connect the ECT sensor terminals with a jumper
wire.
Connection: Pink - Green/ orange

Turn t he ig nition switch ON and engine stop

switch"()".
Check the ECT sensor wit h the HDS.
Is about O Vindicated?
YES - Inspect the ECT sensor (page 20-16)
NO - GO TO STEP 3.
JUMPER WIRE

3. ECT Sensor Output Line Inspection

Turn the ignition switch OFF.
Remove the jumper wire.
Disconnect the ECM 32P connectors.
816 81 A16
Check for continuity at the Pink (ECM side: Pink/
white) and Green/orange w ires between the ECT
sensor 3P connector terminal and the ECM 32P
(Light gray) connector.

Connection: B27 - Pink

B17 - Green/ orange

Are there continuity?

YES - Replace the ECM with a known good
one, and recheck
NO - • Open ci rcuit in Pink or Pink/white
wire
Open circuit in Green/orange wire

6-41
FUEL SYSTEM (Programmed Fuel Injection)
OTC 8-1 (TP SENSOR LOW VOLT AGE)
Before starting the inspection, check for loose o r
poor contact on t he TP sensor connector and
recheck the DTC.
1. TP Sensor Syst em Inspect ion
Turn the ignition switch ON and engine st op
switch " () ".
Check the TP sensor w ith the HDS when the
throttle fully closed.
Is about O V indicated?
YES Intermittent fa ilure
• Loose o r poor contact o n t he MAP
sensor connector
NO - GO TO STEP 2.
2. TP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the TP sensor 3P connector.
Turn the ignition switch ON and eng ine stop
switch " () ".
Measure the voltage at the wire harness side.
Co nnection: Yellow / red (+ ) - Green/ orange H

Is the voltage within 4. 75 - 5.25 V?

YES - GO TO STEP 4.
NO - GO TO STEP 3.

3. TP Sensor Circuit Inspection

Disconnect the ECM 32P connectors.
Check for continuity at the Yellow/ red wire
between the TP sensor 3P connector term inal
and t he ECM 32P (Light gray) connector.

Connection: B18 - Yellow/red B16 B1 A16 Al

Is there continuity?
YES - Replace the ECM w ith a known good
one, and recheck
NO - Open circui t in Yellow/ red wire

6-42
 FUEL SYSTEM (Programmed Fuel Injection)
4. TP Sensor Output Line Open Circuit Inspection
Check for continuity at the Red/yellow wire
between the TP sensor 3P connector terminal
and the ECM 32P (Light gray) connector.

Connection: B14 - Red/yellow 8 16 B1 A16 A1

ls there continuity?
YES - GO TO STEP 5 .
NO - Open circuit in Red/yellow wire

5. TP Sensor Output Line Short Circuit Inspection

Disconnect the TP sensor 3P connector.
Check for continuity between the TP sensor 3P
connector term inal of the wire harness side and
ground.
Connection: Red/yellow - Ground

Is there continuity?
YES - Short circu it in Red/yellow wire
NO - GO TO STEP 6.

6. TP Sensor Inspection
Replace the TP sensor with a known good one.
Reset the ECM (page 6-9).
Turn the ignition switch ON and engine stop
switch" n ".
Check the TP sensor with the HOS.
ls DTC 8-1 indicated?
YES - Replace the ECM with a known good
one, and recheck
NO - Faulty original TP sensor

DTC 8-2 (TP SENSOR HIGH VOLTAGE)

1. TP Sensor System Inspection
Turn the ignition switch ON and engine stop
switch" n ".
Check the TP sensor with the HOS.
Is about 5 Vindicated?
YES - GO TO STEP 2.
NO Intermittent failure
Loose or poor contact on the TP sen-
sor connector

6-43
FUEL SYSTEM (Programmed Fuel Injection)
2. TP Sensor Resistance Inspection
Turn the ignition switch OFF.
TP SENSOR 3P CONNECTOR
Disconnect the TP sensor 3P connector.
Measure the resistance at the TP sensor side.
Connection: Red/ yellow - Green/orange

ls the resistance within 0.4 - 0.6 Q?

YES - GO TO STEP 3.
NO - Fau lty TP sensor
Gr/O '

3. TP Sensor Input Voltage Inspection

Turn the ignition switch ON and engine stop
switch"()".
Measure the voltage at the wire harness side.

Connection: Yellow/ red (+) - Green/orange(-)

Is the voltage within 4. 75 - 5.25 V?
YES - Replace the ECM with a known good
one, and recheck
NO - Open circuit in Green/o range w ires

DTC 9-1 (IAT SENSOR LOW VOLTAGE)

1. IAT Sensor System Inspection
Turn the ignition switch ON and eng ine stop
switch"()".
Check the IAT sensor with the HDS.
Is about 0 Vindicated?
YES - GO TO STEP 2.
NO - • Intermittent fa ilure
• Loose o r poor contact on the IAT
sensor connector
2. IAT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the IAT sensor 2P connector. IAT SENSOR 2P CONNECTOR

Turn the ignition switch ON and engine stop

switch "()".
Check the IAT sensor with the HDS.
ls about 0 Vindicated ?
YES - GO TO STEP 3.
NO - Faulty IAT sensor

6-44
 FUEL SYSTEM (Programmed Fuel Injection)
3. IAT Sensor Output Line Short Circuit Inspection
Check for continuity between the IAT sensor 2P
connector term inal of t he w ire harness side and IAT SENSOR 2P CONNECTOR
ground.
Connection: Gray/blue - Ground

Is there continuity?
YES - Short circuit in Gray/blue wire
0 0
NO - Replace t he ECM with a known good
one, and recheck

OTC 9-2 (IAT SENSOR HIGH VOLTAGE)

• Before starting the inspection, check for loose or
poor contact on the IAT sensor connector and
recheck the OTC.
1. IAT Sensor System Inspection
Turn the ignition switch ON and engine stop
switch " () ".
Check the IAT sensor with the HOS.
Is about 5 Vindicated?
YES - GO TO STEP 2.
NO Intermittent fail ure
• Loose or poor contact on the IAT
sensor connector
2. IAT Sensor Inspection
Turn the ignition switch OFF.
IAT SENSOR 2P CONNECTOR
Disconnect the IAT sensor 2P connector.
Connect the IAT sensor t erminals with a jumper Jl /
wire.
Connection: Gray/blue - Green/orange

Turn the ignition swit ch ON and engine stop

switch" () ".
Check the IAT sensor with the HOS.
Is about O Vindicated?
YES - Faulty IAT sensor
NO - GO TO STEP 3.

3. IAT Sensor Output Line Inspection

Disconnect the ECM 32P connectors.
Check for continuity at the Gray/blue and Green/
orange wire between the IAT sensor 2P connec-
tor terminals and the ECM 32P (Light gray) con-
nector. 8 16 Bl A16 Al
Connection: B17 - Gray/ blue
B30 - Green/orange 0 0 0 0 0000000D00
000 00000000000
Are there continuity? A17

YES - Replace the ECM w ith a known good

o ne, and recheck.
NO Open circu it in Gray/blue wire
• Open circu it in Green/orange wire

6-45
FUEL SYSTEM (Programmed Fuel Injection)
DTC 11-1 (VEHICLE SPEED SENSOR)
Before starting the inspection, check for loose or
poor contact on the vehicle speed sensor con-
nector and recheck the OTC.
1. Vehicle Speed Sensor System Inspection
Support the motorcycle securely and p lace the
rear wheel off the ground.
Start the engine and shih the tran smission into
gear.
Check the vehicle speed sensor with the HOS at
10 km/h.
Is 10 km/ h indicated?
YES Interm ittent failure
• Loose or poor contact on the vehicle
speed sensor connector
NO - GO TO STEP 2.
2 . Combination Meter Inspection
Check for operation of speed meter.
SPEED METER
Does the speed meter operate normally?
YES - Open or short circuit in the Pink/green
wire
NO - GO TO STEP 3.

3. Vehicle Speed Sensor Input Voltage Inspection

Turn the ignition switch OFF.
Disconnect the vehicle speed sensor 3P connec-
tor.
Turn the ignition switch ON and eng ine stop
switch"()".
Measure the voltage at the w ire harness side.
Connection: Black (+ ) - Green (-)

Is there battery voltage?

YES - GO TO STEP 4.
NO - • Open circuit in the Black or Black/
brown w ire
• Open circuit in the Green o r Green/ .___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___.,
b lack wire

6-46
 FUEL SYSTEM (Programmed Fuel Injection)
4. Vehicle Speed Sensor Signal Line Short Circuit
Inspection
Turn t he ignition switch OFF.
Disconnect the ECM 32P connectors.
Check for continuity between the ECM 32P (Light
gray) connector terminal and the ground.
B16 81 A16 Al
Connection: 825 - Ground

Is there continuity?
YES - Short circuit i n the Pink or Pink/green
wire
NO - Inspect vehicle speed sensor (page 20-
13)

DTC 12-1 (No.1 PRIMARY INJECTOR)

Before st arti ng the inspection, check for loose or
poor contact on the Primary injector connectors
and recheck t he DTC.

DTC INJEC- POWER SIGNAL SIGNAL I

TOR INPUT LINE LINE ATECM
12-1 No. 1 Bl ack/white Pink/yellow A11
Primary i
13-1 No.2 Bl ack/white Pink/blue A1 2

14-1
Primary
No.3 Black/white Pink/green A13
I
Pri mary
15-1 No.4 Black/white Pink/black A14
Primary
16-1 No.1 Black/white Pink/yellow Bl
Sec-
ondary A:32P(BLACK) CONNECTOR
17-1 No.2 IBlack/white Pink/blue B2
Sec-
ondary
48-1 . No.3 Bl ack/wh ite Pink/green B3
Sec-
ondary
49-1 No.4 Black/white Pink/black B4
Sec-
ondary 1

1. Injector System Inspection

Reset the ECM (page 6-9).
Start the engine and check the injector with the
HOS.
Is the DTC 12-1 indicated?
YES - GO TO STEP 2.
NO Intermittent failure
Loose or poor contact o n the i njector
connector

6-47
FUEL SYSTEM (Programmed Fuel Injection)
2. Injector Circuit Resistance Inspection
Turn the ignition switch OFF.
Disconnect the ECM 32P connectors and m ea-
sure the resistance of the ECM 32P connector 616 Bl A16 Al
terminals.

Connection: POWER INPUT LINE - SIGNAL AT

ECM B17 A32 A17

Is there continuity?
YES
NO
- GO TO STEP 5.
- GO TO STEP 3.
'--------lo __ _.

3. Injector Resistance Inspection

Disconnect the primary injector 2P connector
and measure the resistance of the primary injec-
tor 2P connector terminals.
Is the resistance within 10.5 - 14.5 Q (20 °C/
68 °F)7
YES - GO TO STEP 4.
NO - Faulty injector

4. Injector Input Voltage Inspection

Turn the ignition switch ON and engine stop
switch"(')".
Measure the voltage between the primary injec-
tor connector of the wire harness side and
ground.

Connection: POWER INPUT LINE (+) - Ground (-)

Is there battery voltage?
YES - Open circuit in SIGNAL LINE wire
NO - Open circuit in POWER INPUT LI NE wire

6-48
 FUEL SYSTEM (Programmed Fuel Injection)
5. Injector Signal Line Short Circuit Inspection
Check for continuity between the ECM 32P con-
nector terminal and ground.

Connection: SIGNAL AT ECM - Ground

816 81 A 16 Al
Is there continuity?
DODOOOOODDDDD•
YES - • Short circuit in the SIGNAL LINE wire OOOODO• O• DODDD
• Faulty injector
832
NO - Replace the ECM with a known good
one, and recheck

DTC 13-1
(No.2 PRIMARY INJECTOR)
(page 6-47)
DTC 14-1
(No.3 PRIMARY INJECTOR)
(page 6-47)
DTC 15-1
(No.4 PRIMARY INJECTOR)
(page 6-47)
DTC 16-1
(No.1 SECONDARY INJECTOR)
(page 6-47)

DTC 17-1
(No.2 SECONDARY INJECTOR)
(page 6-47)

DTC 48-1
(No.3 SECONDARY INJECTOR)
(page 6-47)

DTC 49-1
(No.4 SECONDARY INJECTOR)
(page 6-47)

6-49
FUEL SYSTEM (Programmed Fuel Injection)
OTC 18-1 (CAM PULSE GENERATOR)
• Before starting the inspection, check for loose or
poor contact on the cam pulse generator connec-
tor and recheck the OTC.
1. Cam Pulse Generator Peak Voltage Inspection
Turn t he ignition switch OFF.
Disconnect the cam pulse generator 2P connec-
tor.
Turn the ignition swit ch ON and eng ine stop
switch" 0 ".
Crank the engine with the starter motor, and
measure the cam pulse generator peak voltage
at the cam pulse generator 2P connector.

Connection: Gray (+) - White/yeffow (-)

Is the voltage more than 0.7 V (20 "C/68 °F)?
YES - GO TO STEP 2.
NO - Faulty cam pulse generator
2. Cam Pulse Generator Circuit Inspection
Turn the ig nition switch OFF. ~ - - - - - - - - - -- - - - -----,
Disconnect the ECM 32P connectors.
Check for continuity at t he Grey and Green/ 01s 81 A16 Al
orange wire between the cam pulse generator ~ ; ;;;;;;;;:;:;;:;~ ~G:l h~+--If-=-u-==
- -===- -,::.-,=-==
- -=-,-r -=i.,.__
<s1

2P connector terminals and the ECM 32P con-

nectors terminals.
A17

Connection: B10 - Gray

A31 - Green/orange

ls there continuity?
YES - Short circuit in t he Gray wire
NO Open circuit in the Green/ orange
wire
• Open circuit i n the Gray w ire

6-50
 FUEL SYSTEM (Programmed Fuel Injection)
DTC 19-1 (IGNITION PULSE
GENERATOR)
Before starting the inspection, check for loose or
poor contact on the ignition pulse generator con -
nector and recheck the DTC.
1. Ignition Pulse Generator Peak Voltage Inspec-
tion
Turn the ign ition switch OFF.
Lift and support the fuel tank (page 6-61).
Disconnect the ignition pulse generator 2P (Red)
connector. IGNITION PULSE GENERATOR
2P(RED)CONNECTOR
Turn the ignition switch ON and engine stop =
switch"()·.
Crank the engine with the starter motor, and
measure the ignition pulse generator peak volt- 00
age at the ignition pu lse generator 2P (Red} con-
nector.

Connection: Yellow(+) - Yellow/white H

Is the voltage more than 0.7 V (20 °C/68 °F)?
YES - GO TO STEP 2.
NO - Fau lty ignition pulse generator
2. Ignition Pulse Generator Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM 32P connectors.
Check for contin uity at the Yellow and Green/ B16 Bl A16
orange wire between the ignition pulse genera-
tor 2P (Red) connector terminals and the ECM
connector termina ls.

Connection: B9 - Yellow
A31 - Yellow/white
Is there continuity?
YES - Short circuit in the Yellow wire
NO - • Open circuit in the Yellow wire
• Open circuit in the Green/orange
wire

6-51
FUEL SYSTEM (Programmed Fuel Injection)
OTC 21-1 (No.1 0 2 SENSOR) :
California type only
Before starting the inspection, check for loose or
poor contact on the 02 sensor connector and
recheck the DTC.

OTC 0 2 SEN-
SOR
IGROUND
LINE
l SIGNAL
LINE
SIGNAL
ATECM
121-1 ' No.1 0 2 Green/ Black/red B13
Sensor ora nge
1
22-1 No.2 0 2 Green/ Black/ B28
816
I Sensor orange orange
00• 0000000000
00000000000000
832 817 A32 A17

A, 32P (BLACK) CONN ECTOR I

1. 0 2 Sensor System Inspection 2
Turn the ignition switch ON and engine stop
switch " () ".
Warm the engine until the coolant temperature
is so •c (176 °F).
Check the 0 2 sensor with the HDS.

Standard: 0.1 - 0.3 V

Is the voltage as specified?
YES - Check the fuel pressure (page 6-56). If
the system is correct, GO TO STEP 4.
NO - GO TO STEP 2.
2. 0 2 Sensor Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the 02 senso r 4P connector and the
ECM connectors. 816 81 A16 Al

Check the continuity between the ECM connec-

tor terminals and the 02 sensor 4P connector. 0 0000•••• 0000•
00000•• 00• 000•
Connection: SIGNAL LINE - SIGNAL AT ECM A32 A17

Is there continuity?
YES - GO TO STEP 3.
NO - • Open circuit in the at SIGNAL LINE
w ire
Open circ uit in the GROUND LINE
wire

6-52
 FUEL SYSTEM (Programmed Fuel Injection)
3. 0 2 Sensor System Short Circuit Inspection
Connect the 02 sensor 4P connector and discon-
nect the ECM connectors.
Check the cont inuity between the ECM connec- s, e Bl A16 Al
tor term in a Is and ground. Fi~;;;;;;;;;~;;;;;;;;;;~;;;;~ ;:;:;;;;;;;;;;;;:;;;;;;;;;;;:;;;;t;:;
Connection: SIGNAL AT ECM - Ground

Is there continuity?
YES - Short circ uit in t he SIGNAL LINE wire
NO - GO TO STEP 4.

4. 0 2 Sensor Inspection
Replace the 02 sensor with a known good one
(page 6-99).
Reset the ECM (page 6-9).
8 16 81 A16 Al
Turn the ignition switch ON and engine stop
switch " n ". aoooa • o•• aaao•
o• oooooaaaoooo
Warm the engine until the coolant temperature
is 80 °C (176 °C). B32 A32 A17

Check the voltage at the test harness terminal.

Connection: SIGNAL AT ECM (+) - B17 (-)

8
Standard: 0.1 - 0.3 V
Is the voltage as specified?
YES - Faulty 0 2 sensor
NO - Check the fuel supply system (page 2-2).

OTC 22-1 (No.2 0 2 SENSOR):

California type only
(page 6-52)

6-53
FUEL SYSTEM {Programmed Fuel Injection)
OTC 23-1 (No.1 0 2 SENSOR HEATER):
California type only
Before starting the inspection, check for loo se or
poor contact on t he 02 sensor connector and
recheck t he DTC.

OTC 02 Sensor POWER I SIGNAL SIGNAL B: 32P (LIGHT GRAY) CO NNECTOR

INPUT LINE ATECM l POWER INPUT LINE

"'k;::;~~~
LINE
23- 1 No.1 02 Black/ Wh it e A 10
Sensor white
24-1 No.2 02 Black/ White A9
~;:;:::::;::;~~Al
Sensor white
•••00000::moo• o
000000=0•• 0 • 0
832 A17

A: 32P (BLA CK) CONNECTOR

1. 0 2 Sensor System Inspect ion

Reset the ECM (page 6-9).
Start t he engine and check the 0 2 sensor heater
with the HDS.
Is t he OTC 23-1 indicated?
YES - GO TO STEP 2.
NO Intermittent fai lu re
• Loose or poor cont act on the 0 2 sen-
sor connector
2. 0 2 Sensor Heater Resistance Inspect ion
Turn the ignition switch OFF.
Disconnect the 02 sensor connector and m ea-
sure the resistance at t he sensor side connector
white and Green/orange w ire terminals.
Connection: White - Whit e
Is the resistance w it hin 10 - 40 Q (20 °C/ 68 °F}?
YES - GO TO STEP 3.
NO - Fault y 02 sensor

3. 0 2 Sensor Heater Open circuit Inspection

Connect the 02 sensor connector.
Disconnect the ECM 32P connectors and mea-
sure t he resistance at the ECM terminal s. s,s Bl Al 6 Al
Connection: POWER INPUT LINE - SIGNAL r:;'.1;:;::;::::;::;:;::;:;::;:;::;:;:::;;;;;::::;::;":J,'.;:;
Is the resistance within 10 - 40 Q (20 °Cl 68°F}?
YES - GO TO STEP 4 . B17 A32 A17

NO Open circuit in the Black/white wire

• Open ci rcuit in the SIGNAL LINE wire

6-54
 FUEL SYSTEM (Programmed Fuel Injection)
4. 0 2 Sensor Heater Short Circuit Inspection 1
Disconnect the Oz sensor connector.
Check for continuity between the SIGNAL LINE
wire terminal at ECM 32P connectors and
g rou nd. 616 61 A 16 A1
Connection: SIGNAL AT ECM - Ground
Is there continuity?
••OOOODDDDODD
oco•• o• oo•• o
• DO
YES - Short circuit in the SIGNAL LINE w ire 832

NO - GO TO STEP 5.

5. 0 2 Sensor Heater Short Circuit Inspection 2

Check for continuity between the 02 sensor
heater connector terminal and ground.
Connection: White - Ground
Is there continuity?
YES - Faulty 0 2 sensor
NO - Replace the ECM with a known good
one, and recheck.

DTC 24-1 (No.2 0 2 SENSOR HEATER):

California type only
(page 6-54)

DTC 33-1 (E 2-PROM)

1. Recheck OTC
Reset the ECM (page 6-9).
Turn the ignition switch ON and engine st op
switch"() ".
Recheck the ECM E2-PROM
Is the DTC 33-1 indicated?
YES - Replace the ECM with a kn ow n good
one, and recheck.
NO - Intermittent fail u re

6-55
FUEL SYSTEM (Programmed Fuel Injection)
FUEL LINE INSPECTION
FUEL PRESSURE INSPECTION
Before d isconnecting f uel hoses, release the fuel
pressure by loosening the fue l feed hose banj o
bolt at the fuel tank.
Failure to release the fuel pressu re could result in
fuel spilling onto painted or plastic parts, which
will be damaged.
Always replace the sea ling washers when the
fuel feed hose banjo bolt is removed or
loosened.
Remove the seat (page 3-4).
Disconnect the battery negative cable from the
battery termina l.

Lift and support the fue l tank (page 6-61).

Cover the fuel hose banjo bolt with a rag or shop
towel.
Slowly loosen the fuel hose ban j o bolt and catch the
remaining fuel using an approved gaso line con -
tainer.

Remove the fuel h ose banjo bo lt and attach the fuel

pressure gauge with the fo llowing Honda genuine
parts.

Banjo bolt, 12 mm
Part No. 90008·PD6-010
Sealing washer, 12 mm
Part No. 90428-PDS-003
Sealing washer, 6 mm
Part No. 90430-PD-003

TOOL:
Fuel pressure gauge, 100 psi 07406-0040003 or
07406-0040002 or BANJO BOLT
07406-004000A
(U.S.A. only)

6-56
 FUEL SYSTEM (Programmed Fuel Injection)
Connect the battery negative cable.
Start the engine.
Measu re the fue l pressure at idle speed.
IDLE SPEED: 1,300::: 100 rpm
STANDARD: 343 kPa (3.5 kgf/cm 2 , 50 psi)

If the fuel pressure is h igher than specified, rep lace-

ment the fuel pump unit (page 6-59).
If the fue l pressure is lower than specified, inspect
t he fo llowing:
- Fuel line leaking
- Fuel strainer (page 6-60)

Always replace the After inspection, remove the banjo bolt and reinstall
sealing washer and tighten the o riginal fue l hose banjo bolt using FUEL HOSE
when che fuel feed new seali ng washers.
hose banjo bolt 1s \ \\'
removed or /oos- TORQUE: 22 N -m (2.2 kgf-m, 16 lbf-ft} \ \
ened. I
Remove the suitable support and close the fue l tank
(page 6-63).
Insta ll the removed parts in the reverse order of
removal.

FUEL FLOW INSPECTION

Remove the fol lowing:
- Lower cowls (page 3-6)
- Middle cowls (page 3-7)
Disconnect t he fue l c ut-off relay connector.

J ump t he Brown and Black/white wire terminals of

the wire harness side using a jumper wire.
Place an approved gasoline container and drain
the gasol ine.
Wipe off spilled out gasoline.

J UM PER W IRE CONNECTOR

6-57
FUEL SYSTEM (Programm ed Fuel Injection)
Do no1 apply exces- Hold the f uel pipe nut and remove the fuel hose
s,ve rorce or the sealing nut and sealing washers, then d isconnect
fuel rail may be the fuel hose.
damaged

Turn the ignition switch ON for 10 seconds.

Measure t he amount of fuel flow.
Amount of fuel flow:
189 cm 3 (6.4 US oz, 6.7 Imp oz) minimum
/ 10 seconds at 12 V
If t he fuel flow is less than specif ied, inspect t he fo l-
lowing:
- Pinched o r clogged fuel hose
- Fuel pump unit (page 6-58)
After inspecti on, install a new seal ing washers, fuel
hose sealing nut and connect the fuel hose.
TORQUE:
Fuel hose sealing nut: 22 N -m (2.2 kgf-m , 16 lbf-ft)

Start the eng ine and check for leaks.

FUEL PUMP UNIT

INSPECTION
Turn the ignition switch ON and confirm that the
fuel pump o perates for a few seconds.
If the fuel p ump does not operate, inspect as fo llow:
Lift and support the fuel tank {page 6-61 ).
Disconnect t he fuel pump unit 3P (Black) connector.

6-58
 FUEL SYSTEM (Programmed Fuel Injection)
Turn the ignition switch ON and measure the volt-
age between the terminals.

Connection: Brown (+) - Green (- )

There should be battery voltage for a few seconds.

If there is battery voltage a few seconds, repl ace the
fuel pump unit.
If there is no battery voltage, inspect the following:
- Main fuse 30A
- Sub fuse 10A
- Engine stop switch (page 20-20)
- Fuel cut-off relay {page 6-60)
- Engine stop relay (page 6-94)
- Bank angle sensor (page 6-93)
- ECM (page 6-95)
REMOVAL
Before disconnecting t he fuel line, release the
fuel pressure by loosen ing the fuel hose banjo
bolt at the fuel tank.
Failure to release the fuel pressure could resu lt in
fuel spil ling onto painted or plastic parts, which
will be damaged.
Always replace the sealing washers when the
fuel hose banjo bolt is removed or loosened.
Remove the fuel tank (page 6-61).
Remove the fuel p um p unit mounting nuts and
clamp.

Be careful not to Remove t he f uel pump unit and packing.

damage the pump FUEL PUMP UNIT
wire and fuel level
gauge.

PACKING

6-59
FUEL SYSTEM (Programmed Fuel Injection)
INSPECTION
Check the fuel pump unit for wear or damage,
replace it if necessary.
Clean the fuel strainer screen with non-flammable
or high flash point solvent.

INSTALLATION
Always replace the Place a new packing onto the fue l pump unit.
packing w,th a new FUEL PUMP UNIT
one.
Be careful not 10 Inst all the fuel pump unit into the f uel tank.
damage the pump
w ,re and fuel level
gauge.

Install the clamp and tighten the fuel pump mount-

ing nuts in the specified sequence as shown.

TORQUE: 12 N -rn (1.2 kgf-rn, 9 !bf.ft)

Install the fue l tank (page 6-62).

FUEL CUT-OFF RELAY

INSPECTION
Remove the following:
- Lower cowls (page 3-6)
- Middle cowls (page 3-7)
Disconnect the fuel cut-off relay 4P connector,
remove the fuel cut-off relay.

6-60
 FUEL SYSTEM (Programmed Fuel Injection)
Connect the o hmmet er to t he fue l cut-off relay con-
nector terminals. FUEL CUT-OFF RELAY BATTERY

Connection: A - B r;: : :'=====r11-----/-

Connect the 12V battery to the following fuel cut-off
relay connector terminals.
Connection: C {+) - D H
A C
LJ
There shou ld be continuity only when the 12V bat-
tery is connected. If there is no continuity wh en the
12V battery is connected, replace the fue l cut-off
relay.
le
B D

FUEL TANK
REMOVAL
Remove the fuel tank cover (page 3-15).
Remove the fuel tank mounting bolts.

Lift the fuel t ank and support it using a suitable sup-

port.

Disconnect the fue l pump u nit 3P (Black) connector.

6-61
FUEL SYSTEM (Programmed Fuel Injection)
Disconnect t he fuel tank air vent and overflow
hoses.
Cover the fu el hose banjo bolt with a rag or shop
towel.
Slow ly loosen the banjo bolt and catch the rem ain-
ing fuel using a approved gasoline container.
Remove the fu el hose ba njo bolt and sealing w ash-
ers, then d isconnect the fu el hose.
Before disconnecting fuel hoses, release the fu el
pressure by loosening the fuel hose banjo bolt at
the fue l tank.
Failure to release the fuel pressure could result in
fuel spilling onto painted o r plast ic parts, which
will be damaged.
Always replace the sealing washers when the
fuel hose banjo bolt is removed or loosened.
Remove the fue l tank pivot bolts, collars and fuel
tank.
Refer to procedures fo r fuel pump unit removal
(page 6-59).

INSTALLATION

FUEL TANK

AIR VENT HOSE

22 N-m (2.2 kgf-m, 16 lbf-ft

OVERFLOW HOSE

6-62
 FUEL SYSTEM (Programmed Fuel Injection)
Insta ll the fue l t ank, col lars and pivot bolts into the
frame and tighten the bolts securely.
Support the f uel tank using a suitable support.

A/Jgn 1he fuel hose Install the new sealing washers and tig hten the fue l
eyelet joint with the hose banjo bolt to the specified torque.
stopper on the fuel
pump mounting TORQUE: 22 N -m (2.2 kgf-m, 16 lbf-ft)
stay.

Route the hoses

properly /page 1- Connect the air vent and overflow hoses to the f ue l
22!. tank.

Connect the fuel pum p un it 3P (Black) connector.

Be careful not to Remove th e suitable support and close the fuel tank
damage the wire on the frame.
harness, fuel feed
hose, overflow
hose and air vent
hose.

Roure rhe harness,

wrres and hoses
properly (page 1-
22).

6-63
FUEL SYSTEM (Programmed Fuel Injection)
Install and tighten the mounting bolts and wire
clamp.
Install the f uel tank cover (page 3-15).

AIR CLEANER HOUSING

REMOVAL
Remove the following:
- Fuel tank (page 6-61 )
- ECM (page 6-94)
- Air cleaner cover (page 4-6)
Disconnect the secondary injector connectors.

Remove the five bolts and secondary injector

mounting bracket from the air cleaner housing.

Disconnect the MAP sensor connector and vacuu m

hose.
•li..'!lm•~

6-64
 FUEL SYSTEM (Programmed Fuel Injection)
Remove the eight screws and upper ai r cleaner
housing.

Remove the air funne l/air cleaner housing mounting

screw_s, then remove the ai r ·funnels.

Disconnect the PAIR air suction hose from the air

cleaner housing .

Disconnect the crankcase breather hose f rom the air

cleaner housing.
Remove the wire band clamp from the air cleaner
housing.
Remove the air cleaner housing.

6-65
FUEL SYSTEM (Programmed Fuel Injection)
INSTALLATION
Connect the crankcase breather hose to the air
cleaner housing.
Install the wire band and secure the wires.

Connect the PAIR air suction hose to the air cleaner

housing.
Install the ai r cleaner housing onto the throttle
body.

Install the air funnels in their proper locations.

Install and tighten the air fu nnel/ air cleaner housing
mounting screws .

Install the upper air cleaner housing and eight

screws.
Tighten the screws securely.

6-66
 FUEL SYSTEM (Programmed Fuel Injection)
Connect the MAP sensor connector and vacuum
hose.

Install the secondary injector mounting bracket onto

the air cleaner housing.
Tighten the bolts t o the specified torque.

TORQUE: 5.4 N-m (0.55 kgf-m , 4 lbf-ftl

Connect the secondary i njector connectors.

Install the removed parts in the reverse order of
rem oval.

SECONDARY INJECTOR
INSPECTION
Start the engine and let it id le.
Confirm the injector operating sounds with a sound-
i ng rod or stethoscope.
NOTE:
T he secondary injectors o perate with fo l lowing con-
d itions.
- Engine speed is over 5,500 rpm
- T hrottle opening is over 50°

6-67
FUEL SYSTEM (Programmed Fuel Injection)
REMOVAL
Before disconnecting the fue l l ine, release the
fuel pressure by loosening the fuel hose banjo
bolt.
Failure to release the fuel pressure could result in
fuel spil ling onto painted or p lastic parts, which
will be damaged.
Always replace the sealing washer when the fuel
hose banjo bolt is removed or loosened.
Remove the following:
- Fuel tank (page 6-61)
- ECM (page 6-94)
- Air cleaner cover (page 4-6)
Disconnect the secondary injector connectors.

Do nor apply exces- Hold the fuel rail nut and remove the fuel hose
sive force che fuel sealing nut and sealing washers, then disconnect
ra,1 the fuel hose.

Remove the five bolts and secondary injector

mounting bracket from the air cleaner housing.

6-68
 FUEL SYSTEM {Programmed Fuel Injection)
Remove the bolts and fuel rail/seco ndary injector
assembly from the mounting bracket.

FUEL RAIUSECONDARY INJECTOR

Rem ove the inject ors from the fue l rail.

INJ ECTOR

Remove the O-rin g . seal ri ng. cush ion ri ng and dust

seal. 0-RING

J SEAL RING

~-
0

CUSHION RING DUST SEAL

Rem ove the two bolts, fue l hose and O-ring.

FUEL HOSE

0-R ING

BOLTS

6-69
FUEL SYSTEM (Programmed Fuel Injection)
INSTALLATION
Apply oil to new O-ring and install it into the fuel
rail.
Install the fuel hose into the f uel rail.
711
. fi ,$!~ O-RING

Tighten the bolts securely.

BOLTS

Apply oil to a new O-ring.

O-RING
Replace the seal Install the new seal ring, cushion ring and O-ring, ~~
.......
ring, cushion nng being careful not to damage the O-ring.
nd
a O-ring wi
th
Check the dust seal for wear or damage, repl ace it if
J SEAL RING
new ones as a set
necessary. 0
Install the dust seal.

e~
CUSHION RING DUST SEAL

Install the fue l injectors into the fue l rail, being

careful not to damage the O-ring and cushion ring.

6-70
 FUEL SYSTEM (Programmed Fuel Injection)
Insta ll the fuel rail/secondary injector assembly onto
the mounting bracket, bei ng careful not to damage
the sea l rings and tighten the bolts to the specified
torque.

TORQUE: 9.8 N -m (1.0 kgf-m, 7 lbf-ft)

FUEL RAIL/SECONDARY INJECTOR

Install the secondary injector mount ing bracket onto

the air cleaner housing and tighten the bolts to the
specified torque.

TORQUE: 5.4 N-m (0.55 kgf-m, 4 lbf-ft}

Connect the fue l hose to the fuel rail with new seal-
ing w ashers.
Insta ll and tighten the sealing nut to the specified
torque.
TORQUE: 22 N-m (2.2 kgf-m, 16 lbf-ft)

Do not apply excessive force to the fuel rail.

Always hold the fue l rail nut while tightening the
fuel hose sealing nut.

Connect the secondary injector connecto rs.

Install the removed parts in the reverse order of
removal.

6-71
FUEL SYSTEM (Programmed Fuel Injection)
THROTTLE BODY
REMOVAL
Before disconnecting the fuel line, release the
fuel pressure by loosening the fuel hose banjo
bolt.
Failure to release the fuel pressure could result in
fuel spi lling onto painted or plastic parts, which
will be damaged.
Always replace the sealing washer when the fuel
hose banjo bolt is removed or loosened.
Drain the coolant from the cooling system (page 7- P--~~-r:ama::11111ms=
6).
Remove the fol lowing:
- Lower cowls (page 3-6)
- Middle cowls (page 3-7)
- Fuel tank (page 6-61 l
- Air cleaner housing (page 6-64)
Release the throttle stop screw knob fro m the
clamp.

CaMornia rypeonty. Disconnect the EVAP purge control solenoid va lve

hose from the 5-way joint.

Disconnect the primary injector connectors.

Disconnect the TP sensor connector.

6-72
 Loosen the hose clamp screws and disconnect the
fast idle wax unit water hoses from the wax unit.

Remove the bolt , stay and tool box from the frame.

Do nor hold 1he iuel Loosen the engine side insulator band screws using
rail on the throttle a long type phi Ilips screwdriver.
body ro remove 1he
Remove the throttle body from the cylinder head.
throttle body, or it
may be damaged.

Do nor snap the Loosen the lock nuts and disconnect the throttle
1hrottle valve from cable ends from the throttle drum.
fully open to fully
Seal the cylinder head intake ports w ith tape or a
closed afrer the
clean cloth to keep dirt and debris from entering
1hrottle cable has
the intake ports after the throttle body has been
been removed. ft
rem oved. If debris is allowed to enter the ports
may cause mcor-
t he engine may be damaged .
recr idle operation.

6-73
FUEL SYSTEM (Programmed Fuel Injection)
Loosen the insu lator band screws and remove the
insulators from the throttle body.

INSULATORS

Do not damage the throttle body. It may cause

incorrect throttle and idle valve synchronization.
The throttle body is factory pre-set. Do not disas-
semble in a way other than shown in this m an-
ual.
Do not loosen or tighten the white painted bolts
and screws of the throttle body. Loosening or
tightening them can cause throttle and idle va lve
synchronization failu re.
TOP V IEW:

9.8 N-m ( 1.0 kgf-m, 7 !bf-ft)

REAR V IEW:

0.9 N-m (0.09 kgf-m, 0.7 lbf-ft)

4.9 N-m (0.5 kgf-m, 3.6 lbf-ft)

6-74
 FUEL SYSTEM (Programmed Fuel Injection)
THROTTLE DRUM VIEW: RIGHT SIDE VIEW:

WHITE PAINTED W HIT E PAINTED

THROTTLE LINK VIEW: STARTER VALVE LINK VIEW:

0.9 N-m (0.09 kgf-m, 0.7 lbf-ft)

WHITE PAINTED

6-75
FUEL SYSTEM (Programmed Fuel Injection)
THROTTLE BODY VACUUM HOSE
ROUTING
Except California type:

California type:

6-76
 FUEL SYSTEM (Programmed Fuel Injection)
INSTALLATION
Check the insu lat or band angle.
Instal l the insulators onto the throttle body.

INSULATORS

Tighten the throttle bo dy side insulator band screw

so that the insulator band distance is 12 ± 1 mm (0.5 12 ± 1 mm(0.5 ± 0.04 in)
± 0.04 in).
Apply oil to the i nsulato r inside surfaces for ease of
throttle body insta llati on.

Route rhe throttle Connect the throttle cable ends to the throttle drum.
cables properly
(page 1-22).

Do nor hold the fuel Install the throttle body onto the cylinder head.
pipe on the throttle
body to install the
throttle body.

6 -77
FUEL SYSTEM (Programmed Fuel Injection)
Tighten the engine side insulator band so that the
insulator band distance is 10 :1: 1 mm (0.4 :1: 0.04 in). 10 ± 1 mm
~ - 4 :1: 0.04 in)

Install the tool box, stay and tighten the b olt

securely.

Connect the fast idle wax unit water hoses to the

wax unit and tighten the hose clamp screws.

Connect the TP sensor connector and primary

injector connectors.

6-78
 FUEL SYSTEM (Programmed Fuel Injection)
Caltforn,a type onIy: Connect the EVAP purge control solenoid va lve
hose from the 5-way joint.

Route the throttle stop screw properly, instal l the Pl_ _a,i_ _ _ __
throttl e stop screw knob to the clamp on the bypass
hose.
Install the removed parts in the reverse order of
removal.
After installation, adjust the throttle grip free play
(page 4-6).

PRIMARY INJECTOR
INSPECTION
Start the engine and let it idle. PRIMARY INJECTOR
Confirm the injector o perating sounds with a sound- SOUNDING ROD
ing rod or stethoscope.

REMOVAL
Remove the throttle body (page 6-72).
Remove the bolts and fuel rail/primary injector ,....,_-I.!______
assembly.

BOLTS

6-79
FUEL SYSTEM (Programmed Fuel Injection)
Remove the injectors from the fuel rail.

Remove the seal ring, 0-ring and cushion ring.

INSTALLATl ON
Apply oil to the new 0-ring.
Replace rhe seal Install the new seal ring, cushion ring and 0-ring,
nng, cush,on ring being careful not to damage the 0-ring.
and O-rmg v. 1h

·,
new ones as a ser

0-RING
g-, ~ SEAL RING

Install the fuel injectors into the fuel rail, being care-
ful not to damage the 0-ring and cushion ring. // ~ -
~ - 16

~ '{
' ~ l '~
"'~FUEL INJECTOR

Install the fuel rail/primary injector assembly onto

the throttle body, being careful not to damage the
seal rings.

6-80
 FUEL SYSTEM (Programmed Fuel Injection)
Tighten the fuel rail mounting bolts to the specified
t orque.
..,
TORQUE: 9.8 N-m (1.0 kgf-m, 7 lbf-ft)

Install the throttle body (page 6-77).

FAST IDLE WAX UNIT

REMOVAL/INSTALLATION
Do not loosen or Remove the th rottle body (page 6-72).
remove the wax WAX UNIT
Remove the wax unit mounting screws.
umt shah lock nur
and adjusting nur.

Release t he wax un it shaft joint piece from the wax

un it link arm, then remove the wax unit assembly.

Remove the boot.

Remove the snap ring from the wax unit assembly.

6-81
FUEL SYSTEM (Programmed Fuel Injection)
Tighten the wax unit mounting screws to the speci-
fied torque. WAX UNIT

TORQUE: 4.9 N-m (0.5 kgf,m, 3.6 lbf,ft)

STARTER VALVE
DISASSEMBLY
Remove the throttle body (page 6-72).
Remove the fuel rail and primary injectors (page 6- STARTER VALVE
79).
Turn each starter valve adjusting screw in,
recording the number of turns until it seats lightly.

No.1/2 starter valve:

Remove the starter valve arm screws and starter
valve arms.

No.3/4 starter valve:

Remove the fast idle wax unit (page 6-81 ).
Remove the starter valve arm screws and starter
valve arm.
Remove the screw and fast idle wax unit link arm.

Remove the starter valve shaft and three collars.

VALVE SHAFT

COLLAR S
•
6-82
 FUEL SYSTEM (Programmed Fuel Injection)
Mark the starrer Loosen the lock nut and remove the starter valv es.
valves during disas-
sembly so rhey can
be placed back in
che,r ongmal loca-
tions.

Check t he st art er va lve for scratches, scori ng or

other damage, replace it if necessary. STARTER VALVE

Do not apply com- Clean the starter valve bypasses using compressed
merc,ally available air.
carburetor cleaners
to the inside of the
rhrottle bore. which
,s coa1ed wi1h
molybdenum.

6-83
FUEL SYSTEM (Programmed Fuel Injection)
ASSEMBLY

0.9 N•m (0.09 kgf.m, 0.7

FAST IDLE WAX UNIT

5 N•m (0.5 kgf.m, 3.6 \bf.ft)

Install the starter valves into the valve holes.

T ighten the starter valve lock nut to the specified

torque.
TORQUE: 1.8 N •m (0.18 kgf,m, 1.3 !bf.ft)

6-84
 FUEL SYSTEM (Programmed Fuel Injection)
Install the three collars and starter valve shaft.
VALVE SHAFT

COLLARS

No.1 /2 starter valve:

•
Install the No.1/ 2 starter valve arm to the starter
valves. STARTER VALVE ARM
Install and tighten the starter valve arm mounting
screws to the specified torque.

TORQUE: 0.9 N-m (0.09 kgf-m, 0.7 lbf-ft)

No.3/4 starter valve:

Compress the thrust spring and install the No.3/ 4
starter valve arm onto the starter valves.
Install and tighten the starter valve arm mounting
screws to the specif ied torque.
TORQUE: 0.9 N-m (0.09 kgf-m, 0.7 lbf-ft}
Insta ll the fast idle wax unit link arm and tighten the
screw to the specified t orque.
TORQUE: 0.9 N-m (0.09 kgf-m, 0.7 lbf-ft)
Instal l the fast idle wax unit (page 6-81).
Turn the starter valve screw until it seats lightly,
then back it out as noted during remova l. STARTER VALVE
Install the throttle body (page 6-77).

6-85
FUEL SYSTEM (Programmed Fuel Injection)
STARTER VALVE SYNCHRONIZATION
Synchronize the starter valve with the engine at
normal operating temperature and with the
transmission in neutral.
Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate 50 rpm
change.
Lift and support the fuel tank (page 6-6 1).
Disconnect the each vacuum hose from the 5-way
joint.

Connect the vacuum hoses to the vacuum gauge.

VACUUM GAUGE
Connect a tachometer.
TOOL:
Vacuum gauge set 07 LMJ-001000A

Disconnect the PAIR air suction hoses from the reed

valve covers, then p lug the covers. AIR SUCTION HOSE
/J,

PAIR REED VALVE COVER

6-86
 FUEL SYSTEM (Programmed Fuel Injection)
Start the engine and adjust the idle speed with the
throttle stop screw.

IDLE SPEED: 1,300 ± 100 rpm

The No.3 srarter Match each intake vacuum pressure with the No.3
valve cannot be starter valve.
adjusted, 1t 1s the
base srarter valve. STARTER VALVE VACUUM DIFFERENCE:
20 mmHg

Remove the plugs and connect the PAIR air suction

hoses to the reed va lve covers.

Adjust the idle speed if the idle speed differs from

the specified speed.

IDLE SPEED: 1,300 ± 100 rpm

THROTTLE STOP SCREW KNOB

c:::=:r=......:-..:

6-87
FUEL SYSTEM (Programmed Fuel Injection)
Remove the vacuum gauge from the vacuum hoses.
Connect the each vacuum hoses to the 5-way joint.
Reset the ECM failure code (page 6-9).

MAP SENSOR
OUTPUT VOLTAGE INSPECTION
Connect the test harness to the ECM (page 6-10).
Measure the voltage at the test harness terminals
(page 6-1 1). (VI

Connection: B15 (+) - B17 H 3.5

STANDARD: 2.7 - 3.1 V
The MAP sensor output voltage (a bove) is mea- 3 .1
sured under the standard atmosphere (1 atm = 3 .0
1,013 hPa).
2.7
The MAP sensor output voltage is affected by the
distance above sea level, because the output volt- 2.5 2.5
age is changed by atmosphere.
Check the sea level measurement and be su re that
the measured voltage falls within the specified 2.1
2.0
value.

1.5

1.0

0.5

o 500 1,000 1,500 2,000 :m

(1,6501 (3,300) (4,9501 (6,600) (feetl

REMOVAL/INSTALLATION
Lift and support the fuel tank (page 6-6 1).
Disconnect the MAP sensor connector.
Disconnect the vacuum hose from the MAP sensor.
Remove the screw and MAP sensor from the air
cleaner housing.
Installation is in the reverse order of removal.

6-88
 FUEL SYSTEM (Programmed Fuel Injection)
IAT SENSOR
REMOVAL/INSTALLATION
Remove the air cleaner housing cover (page 4-6).
Remove the screws and IAT sensor from the air
cleaner housing cover.
Installation is in the reverse order of removal.

IAT SENSOR

ECT SENSOR
Replace the ECT REMOVAL/INSTALLATION
sensor while the Drain the coolant from the system (page 7-6).
engine 1s cold.
Disconnect the ECT sensor connector from the sen-
sor.
Remove the ECT sensor and sealing washer.

Always replace a Install a new sealing washer and ECT sensor.

sealing washer with Tighten the ECT sensor to the specified torque.
anew one.
TORQUE: 23 N-m (2.3 kgf-m, 17 lbf-ft)

Connect the ECT sensor connector.

Fill t he cooling system with recommended coolant
(page 7-6).

6-89
FUEL SYSTEM (Programmed Fuel Injection)
CAM PULSE GENERATOR
REMOVAL/ INSTALLATION
Remove the following:
- Lower cowls (page 3-6)
- Middle cow ls (page 3-7)
Lift and support the fuel tank (page 6-61).
Disconnect the cam pulse generator 2P (Natural)
connector.

Remove the bolt, clamp and cam pulse generator

from the cylinder head.

Apply oi l to a new 0-ring and i nstall it onto the cam - - - •

pulse generator.
Install the cam pulse generator into the cylinder
head.
Tighten the mounting bolt securely.

Route the cam pulse geoe,ato, wl,e prnpedy,

connect the 2P (Natural) connector.
I
Install the ,ernoved parts In the ,eve,se mde, of
removal.

6-90
 FUEL SYSTEM (Programmed Fuel Injection)
TP SENSOR
INSPECTION
Rem ov e the f uel t ank cover (page 3-15).
ECM TEST HAR NESS ECM
Disconnect the ECM 32P (Black) and 32P (Light gray)

~
connect ors.
Check the connector for loose or corro ded termi -
nals.
Connect the ECM test harness betw een the ECM
and main wire harness.
TOOL:
ECM test harness 070MZ-0010200
(two required )

INPUT VOLTAGE INSPECTION

Tu rn the ignition switch ON and measure and
record t he input voltage at the test harn ess termi-
nals using a digital mult imeter.

Connection: B1 8 (+) - B17 (-)

0000000000000000
0000000000000000
Standard: 4 .2- 4.8 V
tS20it8OJO J1 n I
If t he measurement is out of specification, check the
fo llowing:
- Loose connection of the ECM multi-connector
- Open circuit in wire harness 8 ,;B

OUTPUT VOLTAGE INSPECTION WITH THE THROT-

TLE FULLY OPENED
T urn t he ignition switch ON and measure and
record the out put voltage at the t est harn ess termi-
nals.

Connect ion: B14 (+) - B17 (-)

Iii l • I i t ti 1a111lll.i1.iiill I j t Ji $1 l I I ft·! 1;i)U 1 J,41

Measuring condition:
At throttle fully o pened 0000000000000000 oooooooooooooto,o
0000000000000000 000000000000~00
I· U KiS "I 'tiJ8i520i

6-91
FUEL SYSTEM (Programmed Fuel Injection)
OUTPUT V OLTAGE INSPECTION WITH THE THROT-
TLE FULLV CLOSED
Turn the ignition switch ON and measure and
record the output voltage with the throttle fully
closed.

Connection: B14 (+) - B17 H

Measuring condition:
000000,:,0 00000 0
At throttle fully closed 0
00000000 000000
1

8 +

CALCULATE RESULT COMPARISON

Compare the measurement to the result of the fo l-
lowing calculation.
With the throttle fully opened:
Measured input voltage X 0.824 = Vo
The sensor is normal if the measurement output
voltage is within 10% of Vo.
With the throttle fully closed:
Measured input voltage X 0.1 = Ve
The sensor is normal if the throttle closed output
voltage is with in 10% of Ve.
Using an analog meter, check that the needle of t he
voltmeter swings slowly when the throttle is opened
gradually.
CONTINUITY INSPECTION
Lift and support the fuel tank (page 6-61).
Disconnect the ECM 32P connectors and the TP sen-
sor 3P connector.
Check for continuity between the ECM 32P (Light
gray) connector and TP sensor 3P connector term i-
nal of the wire harness.
Connection: Yellow/red - B1 4
If there is no continuity, check the open o r short cir-
cu it in wire harness.

6-92
 FUEL SYSTEM (Programmed Fuel Injection)
BANK ANGLE SENSOR
INSPECTION
Remove the upper cowl (page 3-9) with the connec-
tors connected. BANK ANGLE SENSOR

Turn the ignition switch ON and engine stop switch

1! n ".
Measure the voltage between the following termi-
nals of the bank angle sensor connector with the
connector connected.

TERMINAL STANDARD I
White/black(+) - Green H Battery voltage I
Red/white{+) - Green (- ) 0-1V I
CONNECTOR

Do nor disconnect T urn the ignition switch OFF.

rhe bank angel sen-
Rem ove the screws, washer and bank ang le sensor.
sor connector dur-
mg mspection.

BANK ANGLE SENSOR

Place the bank angle sensor horizontal as shown,
60° BANK ANGLE POSITION
and turn the ignition switch ON.

6 ~
The bank angle sensor is normal if t he engine stop
relay clicks and power supply is closed.
Incline the bank angel sensor approximately 60
degrees to the left or r ight with the ignition switch
ON. NORMAL (approximate~
The bank angle sensor is normal if the engine stop POSITION

~
relay clicks and power supply is open.
If you repeat this t est, first turn the ignition switch

~
OFF, then turn the ignition switch ON.

:\ 60' (approximately)

REMOVAL/INSTALLATION
Disconnect the bank angle sensor 3P {Black) con·
nector.
Remove the two screws, washers and bank ang le
sensor.

6-93
FUEL SYSTEM (Programmed Fuel Injection)
lns tal the bank Installatio n is in the reverse order of removal.
angle sensor with
its . UP" rna'K 'ac- T ighten the mounting screws securely.
mgup.

ENGINE STOP RELAY

INSPECTION
Remove the foll owing:
- Lower cowls (page 3-6)
- Middle cowls (page 3-7)
Disconnect t he engine stop relay 4P connector,
remove the engine stop relay.

Connect the ohmmeter to the engine stop relay con-

nector terminals. ENGINE CONTROL RELAY BATTERY

Connection: A - B
Connect a 12 V battery to the following engine stop
relay connector terminals.
Connection: C (+) - D (-)

e
A C
There should be continuity only when the 12 V bat-
tery is connected.
If there is no continuity when the 12 V battery is
connected, replace the engine stop relay.
B D

ENGINE CONTROL MODULE (ECM)

REMOVAL/ INSTALLATION
Remove the fuel tank cover (page 3-15).
Remove the two screws and ECM cover.

6-94
 FUEL SYSTEM (Programmed Fuel Injection)
Disconnect t he ECM 32P {Black) and 32P (Light gray)
connectors. 32P (LIGHT GRAY) CONNE~TO~

Remove the ECM. ~"'- @i

Installation is in the reverse o rder of removal.

ECM POWER/GROUND LINE

INSPECTION
ENGINE DOES NOT START {MIL DOES NOT BLINK)
1. ECM Power Input Voltage Inspection
Disconnect t he ECM 32P {Black) and 32P {Light
gray) connect ors.
Turn the ignition switch ON and engi ne stop
Wi4 SI IJtlflll21B11$hi :, r , s , r ,
1 • 1:• ,. 11 n•w1
switch "() ".
Measure the voltage at the ECM 32P (Light gray) • DOOD• DDDDDDODOO
DDODDDDDDDD•••••
connector terminal and ground.

Connection: B16 (+) - Ground H

Is there battery voltage?
YES - GO TO STEP 2.
NO - GO TO STEP 3.

2 . ECM Ground Line Inspection

Turn the ignition swit ch OFF.
Check for continuity between the ECM 32P
(Black) connector t erminals and ground.

Connection: A4 (+) - Ground H

A18 (+) - Ground H
Are there continuities?
YES - Replace t he ECM with a know good one,
and recheck.
NO Open circuit in the Green/Pink (A18)
wire
Open circuit in the Green /Pink (A4)
wire

6-95
FUEL SYSTEM (Programmed Fuel Injection)
3. Engine Stop Relay Inspection 1
Turn the ignition switch OFF.
Disconnect the engine stop relay connector. ENG INE STOP RELAY
Turn the ignition switch ON and engine stop
switch" n ".
Measure the voltage at the engine stop relay
connector terminals.

Connection: Black (+ ) - Red /white (-)

Is there battery vo ltage?
YES - GO TO STEP 4.
NO - Inspect the bank angle sensor (page 6-
93)

4. Engine Stop Relay Inspection 2

Turn the ignition switch OFF.
Jump the eng ine stop relay connector terminals.

Connection: Red/white - Black/white

Turn the ignition switch ON.
M easure the voltage at the ECM connector ter-
minal and ground.

Connection: B16 (+ ) - Ground (- )

Is there battery voltage?
YES - Inspect the engine stop relay (page 6-
94)
NO - Open circuit in power input line (Black/ ~ - - -- - -- - -- - - - - -- ~
white or Red/white) between the battery
and the ECM

PAIR CONTROL SOLENOID VALVE

REMOVAL/ INSTALLATION
Remove the air cleaner housing (page 6-64).
PAIR CONTROL
Disconnect the PAIR control solenoid valve 2P SOLENOID VALVE
(Black} connector.
Disconnect the PAIR air suction hoses. #K/ "
Installation is in the reverse order of removal.

6-96
 FUEL SYSTEM (Programmed Fuel Injection)
INSPECTION
Remove the PAIR control solenoid valve.
Check that air flows (A) to (B} when the 12 V battery
is connected to the PAIR control solenoid valve ter- (Bl (B)
minals. Air shou ld not fl ow (A ) to (Bl when there is
no voltage applied to the PAIR valve terminals.
(A }

Check the resistance between the terminals of t he

PAIR control solenoid valve. PAIR SOLENOID VALVE

~
STANDARD: 20 - 24 Q (20 °C/68 °F)
If the resistance is out of specification, repla ce the ![g]I

~
PAIR control solenoid valve.

6-97
FUEL SYSTEM (Programmed Fuel Injection)
EVAP PURGE CONTROL SOLENOID
VALVE
{California type only)
REMOVAL/INSTALLATION
Remove the following:
- Lower cowls (page 3-6)
- Middle cowls (page 3-7) EVAP PURGE CONTROL
SOLENOID VALVE STAY
Remove the mounting bolts, fuse box stay and
EVAP purge control solenoid v alve stay.
FUSE BOX STAY
Disconnect the hoses and 2P connector from the
EVAP purge control solenoid valve.
Remove the bolts/ nuts and EVAP purge control
solenoid valve from the stay.
Instal lation in the reverse order of removal.

MOUNTING BOLT

EVAP PUR GE CONTROL SOLENOID VALVE

INSPECTION
Remove the EVAP purge control solenoid valve.
Check that air should not flow (A) to (B), only when
the 12V battery is connected to the EVAP purge con-
trol valve t erminals.

(B )

(A)

6-98
 FUEL SYSTEM (Programmed Fuel Injection)
Check t he resistance between the terminals of the
EVAP purge control solenoid valve.

STANDARD: 30 - 34 Q (20 °C/68 °F)

If the resistance is o ut of specification, replace the

EVAP purge control solenoid valve. 00

EVAP PURGE CONTRO L

SOLENOID VALVE

0 2 SENSOR (California type only)

REMOVAL
Handle the 0 2 sensor with care.
Do not get grease, oil or other materials in the 0 2
sensor air hole, or it may be damaged.
Do not service the 02 sensor while it is hot.
Remove the lower cowls (page 3-6).
Disconnect the 02 sensor 4P (Natural) connector.
Remove t he 0 2 sensor wire from the frame.

6-99
 Y STEM (Program
~ me ·t
FUEL S ~~~;F~u:e;l~I":.::i:.:e..:.c_ti_o_n_)_
the Q,sen,ornno. n,o, w;,e - ;:::=====~0~2~S~E;N~SD
O~R
~~U~N
~IT
~ - - - --

Remove damage the ,e h·le ,emovlng o,

Be careful not t_C:,,pact wren_ch w 'be dam aged.
Do not ng
installi use
t ha~12
e sensor, or it may

Install the 0 2 s~;t~o;h~n!~ecified torque.

Tighten the urn f m 19 lbf-ft)
TORQUE.. 25 N-m 12.6 kg . ,

Route theh020sensor wire

sensor 4P into t he frame.
(Natural) con nect or.
Connect t e 2

6-100