If the connector is clogged with mud or dust, blow it off with compressed air.
If the terminals of the main harness connectors are damaged, replace the main harness.
If the terminals of the ECU connectors are damaged, replace the ECU.
Gray Connector [A]
Special Tool - Hand Tester: 57001-1394
ECU Grounding Inspection
Connections:
(I) BK/Y leads (ECU terminal 40, 73 or 74) ←→ Battery (–) Terminal
(II) Engine Ground ←→ Battery (–) Terminal
Criteria: Both: 0 Ω
If no continuity, check the connectors, the engine ground lead, or main harness, and repair or replace them if necessary.
If the wiring is good, check the power source voltage of the ECU.
NOTE
Be sure the battery is fully charged.
Special Tool - Needle Adapter Set: 57001-1457
ECU Power Supply Inspection Connections:
(I) Digital Meter (+) → Terminal 41 (W/BK)
Digital Meter (–) → Battery (–) terminal
(II) Digital Meter (+) → Terminal 53 (BR/W)
Digital Meter (–) → Battery (–) terminal
(III) Digital Meter (+) → Terminal 54 (W/BK)
Digital Meter (–) → Battery (–) terminal
Ignition Switch OFF:
Terminal 41 (W/BK): Battery Voltage
Terminal 53 (BR/W): 0 V
Terminal 54 (W/BK): Battery Voltage
Ignition Switch ON:
All: Battery Voltage
If the reading is out of the specification, check the following.
Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter)
ECU Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
ECU Main Relay (see Relay Circuit Inspection in the Electrical System chapter)
Power Source Wiring (see wiring diagram in this section)
If the fuse, wiring and relay are good, replace the ECU (see ECU Removal/Installation).
Alternator Rotor Removal
Remove the alternator cover (see Alternator Cover Removal).
Clean off the oil from the outer circumference of the rotor.
Hold the alternator rotor steady with the rotor holder [A]
and suitable washer or plate [B].
Special Tools - Grip [C]: 57001-1591
Rotor Holder: 57001-1666
Flywheel P ...
Front Fork Inspection
Holding the brake lever, pump the
front fork up and down several times
to inspect smooth stroke.
Visually inspect the front fork for oil
leakage, scoring or scratches on the
outer surface of the inner tube.
If any doubt about the front fork, it
should be checked by an authorized
K ...
Piston Wear Inspection
Measure the outside diameter [A] of each piston 5 mm
(0.20 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the piston.
Piston Diameter
Standard: 75.959 75.974 mm
(2.9905 2.9911 in.)
...