Download USE THIS MANUAL WITH: AN650 SERVICE MANUAL (99500
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AN650/A USE THIS MANUAL WITH: AN650 SERVICE MANUAL (99500-36111-01E) AN650/AK5 (’05-MODEL) 1 AN650/AK5 (’05-MODEL) This manual describes service data, service specifications, ABS and servicing procedures which differ from those of the AN650K3 (’03-model) and AN650AK4 (’04-model). NOTE: • Any differences between the AN650K3 (’03-model) and AN650K5 (’05-model), AN650AK4 (’04-model) and AN650AK5 (’05-model) in specifications and service data are indicated with an asterisk mark (*). • Please refer to the AN650K3 (’03-model) service manual and AN650AK4 (’04-model) service information for details which are not given in this manual. CONTENTS SPECIFICATION (AN650K5) .............................................................................. 3 SPECIFICATION (AN650AK5)............................................................................ 4 SERVICE DATA (AN650K5) ............................................................................... 5 SERVICE DATA (AN650AK5).............................................................................14 IMMOBILIZER (E-02, 19, 000) ............................................................................23 OPERATION...............................................................................................23 COMBINATION METER ......................................................................................25 TERMINAL ALIGNMENT ...........................................................................25 POWER WIND SCREEN (AN650AK5 E-02, 19, 000).........................................26 INSPECTION ..............................................................................................26 REMOVAL ..................................................................................................26 INSTALLATION..........................................................................................27 AMBIENT AIR TEMPERATURE SENSOR .........................................................28 INSPECTION ..............................................................................................28 FI SYSTEM WIRING DIAGRAM..........................................................................29 ECM COUPLERS ................................................................................................31 K4 MODEL ECM AND CVT CONTROL UNIT COUPLERS ......................31 K5 MODEL ECM COUPLERS ...................................................................31 MALFUNCTION CODE ..............................................................................33 ABS TROUBLESHOOTING (AN650AK5) ..........................................................34 MALFUNCTION CODE TROUBLESHOOTING.........................................34 WIND SCREEN CABLE ROUTING.....................................................................40 RADIATOR HOSE ROUTING .............................................................................41 EXTERIOR PARTS CONSTRUCTION................................................................42 CVT CONSTRUCTION ........................................................................................45 AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION ...........46 SPECIAL TOOLS ................................................................................................47 TIGHTENING TORQUE CHART .........................................................................47 WIRING DIAGRAM..............................................................................................49 A S E L P M 2 AN650/AK5 (’05-MODEL) COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE AN650K5 AN650AK5 E-03 E-28 E-33 E-02 E-19 E-24 000 E-02 E-19 000 COUNTRY or AREA U.S.A. Canada California (U.S.A.) U.K. E.U. Australia JAPAN U.K. E.U. JAPAN EFFECTIVE FRAME NO. JS1CP51A52 100001 – JS1BU111200100468 – JS1BU111100113619 – JS1BU121300100200 – !""!""!""!""! JS1BU132200100080 – JS1BU132100105119 – A S E L P M !""!""!""!""! AN650/AK5 (’05-MODEL) SPECIFICATION (AN650K5) DIMENSIONS AND DRY MASS Overall length ..................................................................................... 2 260 mm (89.0 in) Overall width....................................................................................... 810 mm (31.9 in) Overall height ..................................................................................... 1 435 mm (56.5 in) Wheelbase ......................................................................................... 1 595 mm (62.8 in) Ground clearance ............................................................................... 130 mm (5.1 in) Seat height ......................................................................................... 750 mm (29.5 in) Dry mass ............................................................................................ * 235 kg (518 lbs) ENGINE Type .................................................................................................... Number of cylinders ........................................................................... Bore.................................................................................................... Stroke ................................................................................................. Displacement...................................................................................... Compression ratio .............................................................................. Carburetion......................................................................................... Air cleaner .......................................................................................... Starter system .................................................................................... Lubrication system ............................................................................. Idle speed ........................................................................................... 4-stroke, liquid-cooled, DOHC 2 75.5 mm (2.972 in) 71.3 mm (2.807 in) 638 cm3 (38.9 cu. in) 11.2 : 1 Fuel injection Non-woven fabric element Electric Wet sump 1 200 ± 100 r/min DRIVE TRAIN Clutch ................................................................................................. Primary reduction ratio ....................................................................... Gearshift pattern................................................................................. Automatic transmission ratio .............................................................. Final reduction ratio ............................................................................ Drive system....................................................................................... Wet multi-plate, automatic, centrifugal type 1.333 (88/66) Automatic & Manual shift Variable change (1.800 – 0.465) 1.580 (32/31 × 31/32 × 34/31 × 49/34) Gear drive E L P M CHASSIS Front suspension ................................................................................ Rear suspension ................................................................................ Front fork stroke.................................................................................. Rear wheel travel................................................................................ Caster................................................................................................. Trail ..................................................................................................... Steering angle .................................................................................... Turning radius ..................................................................................... Front brake ......................................................................................... Rear brake.......................................................................................... Front tire size ...................................................................................... Rear tire size ...................................................................................... A S Telescopic, coil spring, oil damped Swingarm type, coil spring, oil damped 110 mm (4.3 in) 100 mm (3.9 in) 26° 10’ 106 mm (4.17 in) 41° (right and left) 2.7 m (8.9 ft) Disc brake, twin Disc brake 120/70R15M/C 56H, tubeless 160/60R14M/C 65H, tubeless ELECTRICAL Ignition type ........................................................................................ Ignition timing ..................................................................................... Spark plug .......................................................................................... Battery ................................................................................................ Generator ........................................................................................... Main fuse ............................................................................................ CVT fuse ............................................................................................ Fuse ................................................................................................... Electronic ignition (Transistorized) 10° B.T.D.C. at 1 200 r/min NGK CR8E or DENSO U24ESR-N 12 V 43.2 kC (12 Ah)/10 HR Three-phase A.C. generator 40 A 40 A 15/15/15/15/10/10/10 A ................................. E-02, 19 15/15/15/15/15/10/10 A ................................. E-03, 24, 28, 33 Headlight ............................................................................................ 12 V 60 + 55/55 + 55 (H4 + H7)..................... E-02, 19 12 V 60/55 W × 2 (H4 × 2) ............................. E-03, 24, 28, 33 Position/parking light .......................................................................... 12 V 5 W ........................................................ E-02, 19 Brake light/Taillight.............................................................................. 12 V 21/5 W × 2 License plate light............................................................................... 12 V 5 W Trunk light ........................................................................................... 12 V 5 W Turn signal light .................................................................................. 12 V 21 W Instrument panel light ......................................................................... 12 V 1.4 W × 2 Coolant temperature warning light ..................................................... 12 V 1.4 W Fuel injection warning light ................................................................. 12 V 1.4 W Oil pressure warning light ................................................................... 12 V 1.4 W Brake-lock warning light ..................................................................... 12 V 1.4 W High beam indicator light .................................................................... 12 V 1.4 W Turn signal indicator light.................................................................... 12 V 1.4 W × 2 Power mode indicator light ................................................................. 12 V 1.4 W Drive indicator light ............................................................................. 12 V 1.4 W Gear position indicator light ................................................................ 12 V 1.4 W × 5 Immobilizer indicator light ................................................................... * LED ................................................................ E-02, 19 Over drive indicator light..................................................................... * 12 V 1.4 W ..................................................... E-02, 19 CAPACITIES Fuel tank, including reserve .............................................................. Engine oil, oil change ........................................................................ with filter change ............................................................. overhaul........................................................................... Transmission oil, oil change .............................................................. overhaul ................................................................. Final gear oil, oil change .................................................................... overhaul....................................................................... Coolant ............................................................................................... 15.0 L (4.0/3.3 US/Imp gal) 2 600 ml (2.7/2.3 US/Imp qt) 2 900 ml (3.1/2.6 US/Imp qt) 3 400 ml (3.6/3.0 US/Imp qt) 360 ml (12.2/12.7 US/Imp oz) 400 ml (13.5/14.1 US/Imp oz) 300 ml (10.1/10.6 US/Imp oz) 430 ml (14.5/15.1 US/Imp oz) 1.6 L (1.7/1.4 US/Imp qt) 3 4 AN650/AK5 (’05-MODEL) SPECIFICATION (AN650AK5) DIMENSIONS AND DRY MASS Overall length ...................................................................................... 2 260 mm (89.0 in) Overall width ....................................................................................... 810 mm (31.9 in) Overall height ...................................................................................... 1 435 mm (56.5 in) Wheelbase .......................................................................................... 1 595 mm (62.8 in) Ground clearance................................................................................ 130 mm (5.1 in) Seat height .......................................................................................... 750 mm (29.5 in) Dry mass.............................................................................................* 243 kg (535 lbs) ENGINE Type..................................................................................................... Number of cylinders ............................................................................ Bore .................................................................................................... Stroke.................................................................................................. Displacement ...................................................................................... Compression ratio ............................................................................... Carburetion ......................................................................................... Air cleaner ........................................................................................... Starter system..................................................................................... Lubrication system .............................................................................. Idle speed ........................................................................................... 4-stroke, liquid-cooled, DOHC 2 75.5 mm (2.972 in) 71.3 mm (2.807 in) 638 cm3 (38.9 cu. in) 11.2 : 1 Fuel injection Non-woven fabric element Electric Wet sump 1 200 ± 100 r/min DRIVE TRAIN Clutch .................................................................................................. Primary reduction ratio........................................................................ Gearshift pattern ................................................................................. Automatic transmission ratio ............................................................... Final reduction ratio............................................................................. Drive system ....................................................................................... Wet multi-plate, automatic, centrifugal type 1.333 (88/66) Automatic & Manual shift Variable change (1.800 – 0.465) 1.580 (32/31 × 31/32 × 34/31 × 49/34) Gear drive CHASSIS Front suspension................................................................................. Rear suspension ................................................................................. Front fork stroke .................................................................................. Rear wheel travel ................................................................................ Caster ................................................................................................. Trail...................................................................................................... Steering angle ..................................................................................... Turning radius ..................................................................................... Front brake .......................................................................................... Rear brake .......................................................................................... Front tire size ...................................................................................... Rear tire size ....................................................................................... Telescopic, coil spring, oil damped Swingarm type, coil spring, oil damped 110 mm (4.3 in) 100 mm (3.9 in) 26° 10’ 106 mm (4.17 in) 41° (right and left) 2.7 m (8.9 ft) Disc brake, twin Disc brake 120/70R15M/C 56H, tubeless 160/60R14M/C 65H, tubeless ELECTRICAL Ignition type......................................................................................... Ignition timing ...................................................................................... Spark plug ........................................................................................... Battery................................................................................................. Generator ............................................................................................ Main fuse ............................................................................................ CVT fuse ............................................................................................. Fuse .................................................................................................... Headlight ............................................................................................. Position/parking light ........................................................................... Brake light/Taillight .............................................................................. License plate light ............................................................................... Trunk light............................................................................................ Turn signal light ................................................................................... Instrument panel light.......................................................................... Coolant temperature warning light ...................................................... Fuel injection warning light.................................................................. Oil pressure warning light ................................................................... Brake-lock warning light ...................................................................... High beam indicator light .................................................................... Turn signal indicator light .................................................................... Power mode indicator light .................................................................. Drive indicator light.............................................................................. Gear position indicator light ................................................................ ABS warning light................................................................................ Immobilizer indicator light....................................................................* Over drive indicator light .....................................................................* Electronic ignition (Transistorized) 10° B.T.D.C. at 1 200 r/min NGK CR8E or DENSO U24ESR-N 12 V 43.2 kC (12 Ah)/10 HR Three-phase A.C. generator 40 A 40 A 15/15/15/15/15/10/10/15/15 A 12 V 60 + 55/55 + 55 (H4 + H7) 12 V 5 W 12 V 21/5 W × 2 12 V 5 W 12 V 5 W 12 V 21 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W 12 V 1.4 W LED 12 V 1.4 W E L P M A S CAPACITIES Fuel tank, including reserve ................................................................ 15.0 L (4.0/3.3 US/Imp gal) Engine oil, oil change......................................................................... 2 600 ml (2.7/2.3 US/Imp qt) with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt) overhaul ........................................................................... 3 400 ml (3.6/3.0 US/Imp qt) Transmission oil, oil change ............................................................... 360 ml (12.2/12.7 US/Imp oz) overhaul .................................................................. 400 ml (13.5/14.1 US/Imp oz) Final gear oil, oil change..................................................................... 300 ml (10.1/10.6 US/Imp oz) overhaul ....................................................................... 430 ml (14.5/15.1 US/Imp oz) Coolant................................................................................................ 1.6 L (1.7/1.4 US/Imp qt) AN650/AK5 (’05-MODEL) 5 SERVICE DATA (AN650K5) VALVE + GUIDE Unit: mm (in) ITEM Valve diam. IN. EX. Tappet clearance (when cold) IN. EX. Valve guide to valve stem clearance IN. EX. Valve guide I.D. IN. & EX. Valve stem O.D. IN. STANDARD 29.5 (1.16) 25.0 (0.98) 0.10 – 0.20 (0.0039 – 0.0079) 0.20 – 0.30 (0.0079 – 0.0118) 0.010 – 0.040 (0.0004 – 0.0016) 0.030 – 0.060 (0.0012 – 0.0024) 4.500 – 4.515 (0.1772 – 0.1778) 4.475 – 4.490 (0.1762 – 0.1768) 4.455 – 4.470 (0.1754 – 0.1760) E L P M EX. LIMIT — — — — — — — — — Valve stem deflection IN. & EX. — Valve stem runout IN. & EX. — Valve head thickness IN. & EX. — 0.35 (0.014) 0.05 (0.002) 0.5 (0.02) IN. & EX. 0.9 – 1.1 (0.035 – 0.043) — IN. & EX. — IN. & EX. — 0.03 (0.001) 40.6 (1.60) IN. & EX. 136 – 156 N (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) at length 33.4 mm (1.31 in) Valve seat width Valve head radial runout A S Valve spring free length (IN. & EX.) Valve spring tension (IN. & EX.) — 6 AN650/AK5 (’05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM Cam height STANDARD 35.38 – 35.43 (1.393 – 1.395) 33.98 – 34.03 (1.338 – 1.340) 0.032– 0.066 (0.0013 – 0.0026) 24.012 – 24.025 (0.9454 – 0.9459) 23.959 – 23.980 (0.9433 – 0.9441) IN. EX. Camshaft journal oil clearance IN. & EX. Camshaft journal holder I.D. IN. & EX. Camshaft journal O.D. IN. & EX. Camshaft runout IN. & EX. 15th pin — CYLINDER + PISTON + PISTON RING E L P M ITEM Compression pressure STANDARD 1 500 – 1 900 kPa (15.0 – 19.0 kgf/cm2, 213 – 270 psi) Compression pressure difference Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Piston ring free end gap Piston ring end gap — 0.045 – 0.055 (0.0018 – 0.0022) 75.500 – 75.515 (2.9724 – 2.9730) * 75.470 – 75.485 (2.9705 – 2.9711) Measure at 15 mm (0.6 in) from the skirt end. A S R Approx. 11.6 (0.46) 2nd RN Approx. 8.6 (0.34) 2nd Piston ring to groove clearance Piston ring groove width — 1st 1st * 0.06 – 0.18 (0.002 – 0.005) * 0.06 – 0.18 (0.002 – 0.005) 1st — 2nd — 1st 1.01 – (0.040 – 1.01 – (0.040 – 2.01 – (0.079 – 2nd Oil — — 0.10 (0.004) — 0.10 (0.004) — Cam chain pin (at arrow “3”) Cylinder head distortion LIMIT 35.10 (1.382) 33.70 (1.327) 0.150 (0.0059) 1.03 0.041) 1.03 0.041) 2.03 0.080) Unit: mm (in) LIMIT 1 200 kPa (12 kgf/cm2, 171 psi) 200 kPa (2.0 kgf/cm2, 28 psi) 0.120 (0.0047) Nicks or scratches 75.380 (2.9677) 0.10 (0.004) 9.3 (0.37) 6.9 (0.27) 0.50 (0.020) 0.50 (0.020) 0.180 (0.007) 0.150 (0.006) — — — AN650/AK5 (’05-MODEL) ITEM Piston ring thickness 1st 2nd Piston pin bore Piston pin O.D. STANDARD 0.97 – 0.99 (0.038 – 0.039) 0.97 – 0.99 (0.038 – 0.039) 16.002 – 16.008 (0.6300 – 0.6302) 15.995 – 16.000 (0.6297 – 0.6299) CONROD + CRANKSHAFT 16.030 (0.6311) 15.980 (0.6291) — 0.05 (0.002) STANDARD Above 350 kPa (3.5 kgf/cm2 , 49.8 psi) Below 550 kPa (5.5 kgf/cm2, 78.2 psi) at 3 000 r/min LIMIT Crank pin width E L P M Conrod big end oil clearance Crank pin O.D. Crankshaft journal oil clearance Crankshaft runout — 0.080 (0.0031) Conrod big end width A S Crankshaft thrust clearance — STANDARD 16.010 – 16.018 (0.6303 – 0.6306) 0.10 – 0.20 (0.004 – 0.008) 19.950 – 20.000 (0.7854 – 0.7874) 20.100 – 20.150 (0.7913 – 0.7933) 0.032 – 0.056 (0.0013 – 0.0022) 44.976 – 45.000 (1.7707 – 1.7717) 0.018 – 0.045 (0.0007 – 0.0018) 47.985 – 48.000 (1.8892 – 1.8898) 2.025 – 2.175 (0.0797 – 0.0856) 0.10 – 0.15 (0.0039 – 0.0059) Conrod big end side clearance Crankshaft thrust bearing thickness LIMIT Unit: mm (in) ITEM Conrod small end I.D. Crankshaft journal O.D. LIMIT 16.040 (0.6315) 0.30 (0.012) — — — 0.080 (0.0031) — — — OIL PUMP ITEM Oil pressure (at 60 °C, 140 °F) 7 — 8 AN650/AK5 (’05-MODEL) CLUTCH Unit: mm (in) ITEM Drive plate thickness STANDARD 2.92 – 3.08 (0.115 – 0.121) 13.85 – 13.96 (0.545 – 0.550) 2.42 – 2.58 (0.095 – 0.102) Drive plate claw width Driven plate No. 2 thickness Driven plate distortion — Clutch spring free length 13.9 (0.547) 3.2 (0.126) 1 500 – 2 100 r/min 3 200 – 3 800 r/min Clutch plate concaved washer height Clutch engagement Clutch lock-up LIMIT 2.62 (0.103) 13.05 (0.514) 2.27 (0.089) 0.10 (0.004) 13.2 (0.520) 3.1 (0.12) — — INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM Injector resistance Fuel pump discharge amount Fuel pressure regulator operating set pressure FI/CVT-SENSORS ITEM CMP sensor resistance CMP sensor peak voltage CKP sensor resistance CKP sensor peak voltage IAP sensor input voltage IAP sensor output voltage TP sensor input voltage TP sensor resistance TP sensor output voltage ECT sensor input voltage ECT sensor resistance IAT sensor input voltage IAT sensor resistance AP sensor input voltage AP sensor output voltage TO sensor resistance TO sensor output voltage Injector voltage SPECIFICATION 11 – 13 Ω at 20 °C (68 °F) More than 0.9 L (0.95/0.79 US/Imp qt) For 30 sec. at 300 kPa (3.0 kgf/cm2, 43 psi) NOTE — Approx. 300 kPa (3.0 kgf/cm2, 43 psi) — A S E L P M SPECIFICATION 0.9 – 1.7 kΩ More than 0.5 V (When cranking) 150 – 300 Ω More than 2.0 V (When cranking) 4.5 – 5.5 V Approx. 2.6 V at idle speed 4.5 – 5.5 V Closed Approx. 1.1 kΩ Opened Approx. 4.2 kΩ Closed Approx. 1.1 V Opened Approx. 4.3 V 4.5 – 5.5 V Approx. 2.45 kΩ at 20 °C (68 °F) 4.5 – 5.5 V Approx. 2.45 kΩ at 20 °C (68 °F) 4.5 – 5.5 V Approx. 3.6 V at 100 kPa (760 mmHg) 19.1 – 19.7 kΩ Normal 0.4 – 1.4 V Leaning 3.7 – 4.4 V Battery voltage — NOTE +: B/Y, -: Br +: Bl, -: G +: B, -: B/Br +: B, -: B/Br AN650/AK5 (’05-MODEL) ITEM Ignition coil primary peak voltage SPECIFICATION More than 80 V (When cranking) NOTE #1 +: W/Bl, -: Ground #2 +: B/Y, -: Ground 4 – 5 Ω at 23 °C (73.4 °F) Idle speed Less than 0.4 V 3 000 r/min More than 0.6 V PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F) CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ Extended 0.2 – 1.0 kΩ Approx. 3.3 V CVT primary pulley position sensor 1st: Idle speed output voltage Approx. 1.3 V 3rd : 3 000 r/min th 5 : 3 000 r/min Approx. 0.5 V CVT secondary pulley revolution 400 – 600 Ω sensor resistance CVT secondary pulley revolution More than 5 V at idle speed sensor peak voltage HO2 sensor resistance HO2 sensor output voltage E L P M THROTTLE BODY ITEM I.D. No. Bore size Fast idle r/min Idle r/min Synchronizing screw opening IAC valve resistance Throttle cable play +: Y, -: W A S SPECIFICATION 10GO 32 mm (1.26 in) 1 300 – 1 600 r/min 1 200 ± 100 r/min 1 and 1/2 turns out Approx. 4 Ω at 20 – 24 °C (68 – 75 °F) 2.0 – 4.0 mm (0.08 – 0.16 in) THERMOSTAT + RADIATOR + FAN + COOLANT ITEM Thermostat valve opening temperature Thermostat valve lift Engine coolant temperature sensor resistance Radiator cap valve opening pressure Eclectic fan thermo-switch operating temperature Engine coolant type STANDARD/SPECIFICATION LIMIT Approx. 88 °C (190 °F) — Over 8.0 mm (0.3 20 °C (68 °F) 50 °C (122 °F) 80 °C (176 °F) 110 °C (230 °F) in) at 100 °C (212 °F) Approx. 2.45 kΩ Approx. 0.811 kΩ Approx. 0.318 kΩ Approx. 0.142 kΩ — — — — — 110 kPa (1.1 kgf/cm²) — ON 93 – 103 °C (199 – 217 °F) OFF 87 – 97 °C (188 – 206 °F) Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. — — — 9 10 AN650/AK5 (’05-MODEL) ITEM Engine coolant including reserve STANDARD/SPECIFICATION Reverse Approx. 250 ml tank side (0.264/0.220 US/Imp qt) Approx. 1 350 ml Engine side (1.427/1.188 US/Imp qt) ELECTRICAL Firing order Spark plug Type STD/SPEC. 1·2 NGK: CR8E DENSO: U24ESR-N 0.7 – 0.8 (0.028 – 0.031) Over 8.0 (0.3) at 1 atm. More than 2.0 V 0.8 – 2.5 Ω 8 – 18 kΩ Gap Spark performance CKP sensor peak voltage Ignition coil resistance Primary Secondary Ignition coil primary peak voltage E L P M More than 80 V Generator no-load voltage (When cold) Generator Max. output Regulated voltage Starter relay resistance Battery Fuse size — — Unit: mm (in) ITEM Generator coil resistance LIMIT CKP sensor Charging 150 – 300 Ω 0.1 – 1.0 Ω More than 50 V at 5 000 r/min Approx. 500 W at 5 000 r/min 14.0 – 15.5 V at 5 000 r/min 3–6Ω A S Type designation Capacity Head- LO light HI Fuel pump Ignition Turn signal Fan motor Main CVT Power source FTX14-BS 12 V 43.2 kC (12 Ah)/10 HR 15 A .......... E-03, 24, 28, 33 10 A .......... E-02, 19 15 A 10 A 15 A 15 A 15 A 40 A 40 A 10 A NOTE +: Bl, -:G #1 +: W/Bl, -: Ground #2 +: B/Y, -: Ground G – BI Y–Y AN650/AK5 (’05-MODEL) WATTAGE 11 Unit: W STD/SPEC. ITEM Headlight E-02, 19 60 + 55 55 5×2 21/5 × 2 21 × 4 5 1.4 × 2 1.4 1.4 1.4 1.4 1.4 1.4 × 2 1.4 1.4 1.4 × 5 5 LED 1.4 HI LO Parking or position light Brake light/Taillight Turn signal light License light Instrument panel light Engine coolant temp. indicator light FI indicator light Engine oil pressure indicator light Brake-lock indicator light High beam indicator light Turn signal indicator light Power mode indicator light Drive indicator light Gear position indicator light Trunk light * Immobilizer indicator light * Over drive indicator light BRAKE + WHEEL ITEM Brake disc thickness E L P M A S Front Rear Brake disc runout Master cylinder bore Front Front Rear Brake caliper cylinder bore Front Rear Brake caliper piston diameter Front Rear Brake fluid type STANDARD 4.5 ± 0.2 (0.177 ± 0.008) 5.5 ± 0.2 (0.217 ± 0.008) — Rear Master cylinder piston diameter E-03, 24, 28, 33 60 × 2 55 × 2 12.700 – 12.743 (0.5000 – 0.5017) 12.700 – 12.743 (0.5000 – 0.5017) 12.657 – 12.684 (0.4983 – 0.4994) 12.657 – 12.684 (0.4983 – 0.4994) 25.400 – 25.450 (1.0000 – 1.0020) 27.000 – 27.050 (1.0630 – 1.0650) 25.318 – 25.368 (0.9968 – 0.9987) 26.918 – 26.968 (1.0598 – 1.0617) DOT 4 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← Unit: mm (in) LIMIT 4.0 (0.16) 5.0 (0.20) 0.30 (0.012) — — — — — — — — — 12 AN650/AK5 (’05-MODEL) ITEM Wheel rim runout STANDARD Wheel axle runout Wheel rim size Axial — Radial — Front — Rear — Front Rear 15 M/C × MT3.50 14 M/C × MT4.50 SUSPENSION Unit: mm (in) ITEM Front fork stroke Front fork spring free length Front fork inner tube diam. TIRE ITEM A S Cold inflation tire pressure Solo riding Dual riding Tire size Tire type Tire tread depth (Recommended depth) LIMIT — 341 (13.4) SUZUKI FORK OIL G-10 (#10) or an equivalent fork oil 458 ml 151 (5.9) 41 (1.61) 100 (3.9) Front fork oil capacity (each leg) Front fork oil level Rear shock absorber spring adjuster STANDARD 110 (4.3) E L P M Front fork oil type Rear wheel travel LIMIT 2.0 (0.08) 2.0 (0.08) 0.25 (0.010) 0.25 (0.010) — — — LIMIT — Rear — Rear — STANDARD Front Front — — Front Rear Front Rear Rear — 2nd 225 kPa (2.25 kgf/cm2, 33 psi) 250 kPa (2.50 kgf/cm2, 36 psi) 225 kPa (2.25 kgf/cm2, 33 psi) 280 kPa (2.80 kgf/cm2, 41 psi) 120/70R15M/C 56H 160/60R14M/C 65H BRIDGESTONE TH01F BRIDGESTONE TH01R Front — — — — — — — — — 1.6 mm (0.06 in) 2.0 mm (0.08 in) AN650/AK5 (’05-MODEL) FUEL + OIL ITEM SPECIFICATION Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal) reserve Fuel meter mark Approx. 3.0 L (0.79/0.66 US/lmp gal) flickering Fuel meter mark and Approx. 1.5 L (0.40/0.33 US/lmp gal) LCD flickering Engine oil and transmission oil type * SAE 10W-40, API, SF/SG or SJ/SH with JASO MA Engine oil capacity 2.6 L Oil change (2.7/2.3 US/lmp qt) 2.9 L Filter change (3.1/2.6 US/lmp qt) 3.4 L Overhaul (3.6/3.0 US/lmp qt) Transmission oil capacity 360 ml Oil change (12.2/12.7 US/lmp oz) 400 ml Overhaul (13.5/14.1 US/lmp oz) Final gear oil type Hypoid gear oil SAE #90 API grade GL-5 Final gear oil capacity 300 ml Oil change (10.1/10.6 US/lmp oz) 430 ml Overhaul (14.5/15.1 US/lmp oz) A S E L P M NOTE E-03, 28, 33 The others 13 14 AN650/AK5 (’05-MODEL) SERVICE DATA (AN650AK5) VALVE + GUIDE Unit: mm (in) ITEM Valve diam. IN. EX. Tappet clearance (when cold) IN. EX. Valve guide to valve stem clearance IN. EX. Valve guide I.D. IN. & EX. Valve stem O.D. IN. E L P M EX. Valve stem deflection IN. & EX. Valve stem runout IN. & EX. Valve head thickness IN. & EX. Valve seat width Valve head radial runout A S Valve spring free length (IN. & EX.) Valve spring tension (IN. & EX.) IN. & EX. IN. & EX. STANDARD 29.5 (1.16) 25.0 (0.98) 0.10 – 0.20 (0.0039 – 0.0079) 0.20 – 0.30 (0.0079 – 0.0118) 0.010 – 0.040 (0.0004 – 0.0016) 0.030 – 0.060 (0.0012 – 0.0024) 4.500 – 4.515 (0.1772 – 0.1778) 4.475 – 4.490 (0.1762 – 0.1768) 4.455 – 4.470 (0.1754 – 0.1760) LIMIT — — — — — — — — — — 0.35 (0.014) 0.05 (0.002) 0.5 (0.02) 0.9 – 1.1 (0.035 – 0.043) — — 0.03 (0.001) 40.6 (1.60) — — IN. & EX. — IN. & EX. 136 – 156 N (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) at length 33.4 mm (1.31 in) — AN650/AK5 (’05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM Cam height IN. EX. Camshaft journal oil clearance IN. & EX. Camshaft journal holder I.D. IN. & EX. Camshaft journal O.D. IN. & EX. Camshaft runout IN. & EX. Cam chain pin (at arrow “3”) Cylinder head distortion STANDARD 35.38 – 35.43 (1.393 – 1.395) 33.98 – 34.03 (1.338 – 1.340) 0.032– 0.066 (0.0013 – 0.0026) 24.012 – 24.025 (0.9454 – 0.9459) 23.959 – 23.980 (0.9433 – 0.9441) — 15th pin — CYLINDER + PISTON + PISTON RING E L P M ITEM Compression pressure STANDARD 1 500 – 1 900 kPa (15.0 – 19.0 kgf/cm2, 213 – 270 psi) Compression pressure difference Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Piston ring free end gap Piston ring to groove clearance Piston ring groove width — 0.045 – 0.055 (0.0018 – 0.0022) 75.500 – 75.515 (2.9724 – 2.9730) * 75.470 – 75.485 (2.9705 – 2.9711) Measure at 15 mm (0.6 in) from the skirt end. A S Piston ring end gap — 1st R Approx. 11.6 (0.46) 2nd RN Approx. 8.6 (0.34) 2nd * 0.06 – 0.18 (0.002 – 0.005) * 0.06 – 0.18 (0.002 – 0.005) 1st — 2nd — 1st 1.01 – 1.03 (0.040 – 0.041) 1.01 – 1.03 (0.040 – 0.041) 2.01 – 2.03 (0.079 – 0.080) 1st 2nd Oil 15 LIMIT 35.10 (1.382) 33.70 (1.327) 0.150 (0.0059) — — 0.10 (0.004) — 0.10 (0.004) Unit: mm (in) LIMIT 1 200 kPa (12 kgf/cm2, 171 psi) 200 kPa (2.0 kgf/cm2, 28 psi) 0.120 (0.0047) Nicks or scratches 75.380 (2.9677) 0.10 (0.004) 9.3 (0.37) 6.9 (0.27) 0.50 (0.020) 0.50 (0.020) 0.180 (0.007) 0.150 (0.006) — — — 16 AN650/AK5 (’05-MODEL) ITEM Piston ring thickness 1st STANDARD 0.97 – 0.99 (0.038 – 0.039) 0.97 – 0.99 (0.038 – 0.039) 16.002 – 16.008 (0.6300 – 0.6302) 15.995 – 16.000 (0.6297 – 0.6299) 2nd Piston pin bore Piston pin O.D. CONROD + CRANKSHAFT — 0.05 (0.002) STANDARD Above 350 kPa (3.5 kgf/cm2, 49.8 psi) Below 550 kPa (5.5 kgf/cm2, 78.2 psi) at 3 000 r/min LIMIT Crank pin width E L P M Conrod big end oil clearance Crank pin O.D. Crankshaft journal oil clearance Crankshaft runout 16.030 (0.6311) 15.980 (0.6291) 0.080 (0.0031) Conrod big end width Crankshaft thrust clearance — STANDARD 16.010 – 16.018 (0.6303 – 0.6306) 0.10 – 0.20 (0.004 – 0.008) 19.950 – 20.000 (0.7854 – 0.7874) 20.100 – 20.150 (0.7913 – 0.7933) 0.032 – 0.056 (0.0013 – 0.0022) 44.976 – 45.000 (1.7707 – 1.7717) 0.018 – 0.045 (0.0007 – 0.0018) 47.985 – 48.000 (1.8892 – 1.8898) 2.025 – 2.175 (0.0797 – 0.0856) 0.10 – 0.15 (0.0039 – 0.0059) Conrod big end side clearance A S Crankshaft thrust bearing thickness — Unit: mm (in) ITEM Conrod small end I.D. Crankshaft journal O.D. LIMIT LIMIT 16.040 (0.6315) 0.30 (0.012) — — — 0.080 (0.0031) — — — OIL PUMP ITEM Oil pressure (at 60 °C, 140 °F) — AN650/AK5 (’05-MODEL) CLUTCH Unit: mm (in) ITEM Drive plate thickness STANDARD 2.92 – 3.08 (0.115 – 0.121) 13.85 – 13.96 (0.545 – 0.550) 2.42 – 2.58 (0.095 – 0.102) Drive plate claw width Driven plate No. 2 thickness Driven plate distortion — Clutch spring free length 13.9 (0.547) 3.2 (0.126) 1 500 – 2 100 r/min 3 200 – 3 800 r/min Clutch plate concaved washer height Clutch engagement Clutch lock-up LIMIT 2.62 (0.103) 13.05 (0.514) 2.27 (0.089) 0.10 (0.004) 13.2 (0.520) 3.1 (0.12) — — INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM Injector resistance Fuel pump discharge amount Fuel pressure regulator operating set pressure FI/CVT-SENSORS ITEM CMP sensor resistance CMP sensor peak voltage CKP sensor resistance CKP sensor peak voltage IAP sensor input voltage IAP sensor output voltage TP sensor input voltage TP sensor resistance TP sensor output voltage ECT sensor input voltage ECT sensor resistance IAT sensor input voltage IAT sensor resistance AP sensor input voltage AP sensor output voltage TO sensor resistance TO sensor output voltage Injector voltage 17 SPECIFICATION 11 – 13 Ω at 20 °C (68 °F) More than 0.9 L (0.95/0.79 US/Imp qt) For 30 sec. at 300 kPa (3.0 kgf/cm2 , 43 psi) NOTE — Approx. 300 kPa (3.0 kgf/cm2, 43 psi) — A S E L P M SPECIFICATION 0.9 – 1.7 kΩ More than 0.5 V (When cranking) 150 – 300 Ω More than 2.0 V (When cranking) 4.5 – 5.5 V Approx. 2.6 V at idle speed 4.5 – 5.5 V Closed Approx. 1.1 kΩ Opened Approx. 4.2 kΩ Closed Approx. 1.1 V Opened Approx. 4.3 V 4.5 – 5.5 V Approx. 2.45 kΩ at 20 °C (68 °F) 4.5 – 5.5 V Approx. 2.45 kΩ at 20 °C (68 °F) 4.5 – 5.5 V Approx. 3.6 V at 100 kPa (760 mmHg) 19.1 – 19.7 kΩ Normal 0.4 – 1.4 V Leaning 3.7 – 4.4 V Battery voltage — NOTE +: B/Y, -: Br +: Bl, -: G +: B, -: B/Br +: B, -: B/Br 18 AN650/AK5 (’05-MODEL) ITEM Ignition coil primary peak voltage SPECIFICATION More than 80 V (When cranking) 4 – 5 Ω at 23 °C (73.4 °F) Idle speed Less than 0.4 V 3 000 r/min More than 0.6 V PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F) CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ Extended 0.2 – 1.0 kΩ st Approx. 3.3 V CVT primary pulley position sensor 1 : Idle speed output voltage rd 3 : 3 000 r/min Approx. 1.3 V th : 3 000 r/min Approx. 0.5 V 5 CVT secondary pulley revolution 400 – 600 Ω sensor resistance CVT secondary pulley revolution More than 5 V at idle speed sensor peak voltage NOTE #1 +: W/Bl, -: Ground #2 +: B/Y, -: Ground HO2 sensor resistance HO2 sensor output voltage E L P M THROTTLE BODY ITEM I.D. No. Bore size Fast idle r/min Idle r/min Synchronizing screw opening IAC valve resistance Throttle cable play +: Y, -: W A S SPECIFICATION 10GO 32 mm (1.26 in) 1 300 – 1 600 r/min 1 200 ± 100 r/min 1 and 1/2 turns out Approx. 4 Ω at 20 – 24 °C (68 – 75 °F) 2.0 – 4.0 mm (0.08 – 0.16 in) THERMOSTAT + RADIATOR + FAN + COOLANT ITEM Thermostat valve opening temperature Thermostat valve lift Engine coolant temperature sensor resistance Radiator cap valve opening pressure Eclectic fan thermo-switch operating temperature Engine coolant type STANDARD/SPECIFICATION LIMIT Approx. 88 °C (190 °F) — Over 8.0 mm (0.3 in) at 100 °C (212 °F) 20 °C Approx. 2.45 kΩ (68 °F) 50 °C Approx. 0.811 kΩ (122 °F) 80 °C Approx. 0.318 kΩ (176 °F) 110 °C Approx. 0.142 kΩ (230 °F) — — — — — 110 kPa (1.1 kgf/cm²) — ON 93 – 103 °C (199 – 217 °F) OFF 87 – 97 °C (188 – 206 °F) Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. — — — AN650/AK5 (’05-MODEL) ITEM Engine coolant including reserve STANDARD/SPECIFICATION Reverse Approx. 250 ml tank side (0.264/0.220 US/Imp qt) Engine Approx. 1 350 ml side (1.427/1.188 US/Imp qt) ELECTRICAL LIMIT — — Unit: mm (in) ITEM Firing order Spark plug Type Gap Spark performance CKP sensor peak voltage Ignition coil resistance Primary Secondary Ignition coil primary peak voltage STD/SPEC. 1·2 NGK: CR8E DENSO: U24ESR-N 0.7 – 0.8 (0.028 – 0.031) Over 8.0 (0.3) at 1 atm. More than 2.0 V 0.8 – 2.5 Ω 8 – 18 kΩ E L P M More than 80 V Generator coil resistance CKP sensor Charging Generator no-load voltage (When cold) Generator Max. output Regulated voltage Starter relay resistance Battery Fuse size 19 150 – 300 Ω 0.1 – 1.0 Ω More than 50 V at 5 000 r/min A S Approx. 500 W at 5 000 r/min 14.0 – 15.5 V at 5 000 r/min 3–6Ω Type designation Capacity Head- LO light HI Fuel pump Ignition Turn signal Fan motor Main CVT Power source ABS FTX14-BS 12 V 43.2 kC (12 Ah)/10 HR 15 A 15 A 10 A 15 A 15 A 15 A 40 A 40 A 10 A 15 A × 2 NOTE +: Bl, -:G #1 +: W/Bl, -: Ground #2 +: B/Y, -: Ground G – BI Y–Y 20 AN650/AK5 (’05-MODEL) WATTAGE Unit: W STD/SPEC. ITEM Headlight E-02, 19 60 + 55 55 5×2 21/5 × 2 21 × 4 5 1.4 × 2 1.4 1.4 1.4 1.4 1.4 1.4 × 2 1.4 1.4 1.4 × 5 1.4 5 LED 1.4 HI LO Parking or position light Brake light/Taillight Turn signal light License light Instrument panel light Engine coolant temp. indicator light FI indicator light Engine oil pressure indicator light Brake-lock indicator light High beam indicator light Turn signal indicator light Power mode indicator light Drive indicator light Gear position indicator light ABS warning indicator light Trunk light * Immobilizer indicator light * Over drive indicator light BRAKE + WHEEL ITEM Brake disc thickness E L P M A S Front Rear Brake disc runout Master cylinder bore Front Front Rear Brake caliper cylinder bore Front Rear Brake caliper piston diameter Front Rear Brake fluid type STANDARD 4.5 ± 0.2 (0.177 ± 0.008) 5.5 ± 0.2 (0.217 ± 0.008) — Rear Master cylinder piston diameter E-03, 24, 28, 33 60 × 2 55 × 2 12.700 – 12.743 (0.5000 – 0.5017) 12.700 – 12.743 (0.5000 – 0.5017) 12.657 – 12.684 (0.4983 – 0.4994) 12.657 – 12.684 (0.4983 – 0.4994) 25.400 – 25.450 (1.0000 – 1.0020) 27.000 – 27.050 (1.0630 – 1.0650) 25.318 – 25.368 (0.9968 – 0.9987) 26.918 – 26.968 (1.0598 – 1.0617) DOT 4 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← Unit: mm (in) LIMIT 4.0 (0.16) 5.0 (0.20) 0.30 (0.012) — — — — — — — — — AN650/AK5 (’05-MODEL) ITEM Wheel rim runout STANDARD Wheel axle runout Wheel rim size Axial — Radial — Front — Rear — Front Rear 15 M/C × MT3.50 14 M/C × MT4.50 SUSPENSION Front fork spring free length Front fork oil capacity (each leg) Front fork oil level Front fork inner tube diam. A S Rear shock absorber spring adjuster ITEM Cold inflation tire pressure Solo riding Dual riding Tire size Tire type Tire tread depth (Recommended depth) STANDARD 110 (4.3) LIMIT — 341 (13.4) E L P M Front fork oil type TIRE LIMIT 2.0 (0.08) 2.0 (0.08) 0.25 (0.010) 0.25 (0.010) — — Unit: mm (in) ITEM Front fork stroke Rear wheel travel 21 SUZUKI FORK OIL G-10 (#10) or an equivalent fork oil 458 ml 151 (5.9) 41 (1.61) 100 (3.9) 2nd Front Rear Front Rear STANDARD 225 kPa (2.25 kgf/cm2, 33 psi) 250 kPa (2.50 kgf/cm2, 36 psi) 225 kPa (2.25 kgf/cm2, 33 psi) 280 kPa (2.80 kgf/cm2, 41 psi) 120/70R15M/C 56H 160/60R14M/C 65H BRIDGESTONE TH01F BRIDGESTONE TH01R Front — Rear — Front Rear Front Rear — — — — — — LIMIT — — — — — — — — 1.6 mm (0.06 in) 2.0 mm (0.08 in) 22 AN650/AK5 (’05-MODEL) FUEL + OIL ITEM SPECIFICATION Fuel type Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal) reserve Fuel meter mark Approx. 3.0 L (0.79/0.66 US/lmp gal) flickering Fuel meter mark and Approx. 1.5 L (0.40/0.33 US/lmp gal) LCD flickering Engine oil and transmission oil type * SAE 10W-40, API, SF/SG or SJ/SH with JASO MA Engine oil capacity 2.6 L Oil change (2.7/2.3 US/lmp qt) 2.9 L Filter change (3.1/2.6 US/lmp qt) 3.4 L Overhaul (3.6/3.0 US/lmp qt) Transmission oil capacity 360 ml Oil change (12.2/12.7 US/lmp oz) 400 ml Overhaul (13.5/14.1 US/lmp oz) Final gear oil type Hypoid gear oil SAE #90 API grade GL-5 Final gear oil capacity 300 ml Oil change (10.1/10.6 US/lmp oz) 430 ml Overhaul (14.5/15.1 US/lmp oz) A S E L P M NOTE AN650/AK5 (’05-MODEL) 23 IMMOBILIZER (E-02, 19, 000) • The immobilizer, an anti-theft system, is installed as a standard equipment. • The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start. • This system is same as the AN250/400K5. Immobilizer antenna Transponder Immobi-antenna Indicator light ECM E L P M ID OPERATION When the ignition switch is turned ON with the engine stop switch in ON and the side stand in up position, the immobi-antenna and ECM are powered ON. The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID. With the signal received, the transponder transmits the key ID signal to ECM so that ECM can make comparison with its own ID, and if it matches, the engine is made ready to start. A S Transponder Immobi-antenna Ignition switch ECM 24 AN650/AK5 (’05-MODEL) Also, when the ignition switch is turned ON, the indicator light flashes as many as the number of IDs registered in ECM. Thereafter, if the IDs are in agreement, the indicator light turns on for two seconds to notify of completion in successful communication. If the indicator light flashes fast, it notifies of communication error or disagreement of ID. Flashing 2 registered Normal 3 registered Normal Normal 4 registered Abnormal Fast flashing Approx. 1.6 sec. NOTE: If the indicator light flashes fast, turn the ignition switch OFF then ON to make judgment again as there is possible misjudgment due to environmental radio interference. # When the battery performance is lowered in winter (low temperature), the system may make a rejudgment at the time of beginning of the starter motor operation. In this case, the indicator light operation starts immediately after the starter motor operation. E L P M A S Lighting Approx. 2.0 sec. AN650/AK5 (’05-MODEL) 25 COMBINATION METER E L P M 1 AN650A only 2 E-02, 19, 000 only A S TERMINAL ALIGNMENT 1 2 3 4 5 6 7 8 9 0 Oil pressure switch (G/Y) — Speed sensor (O/R) Ignition (O/G) Battery (R/Bl) Speed sensor signal (W) Tachometer signal (Br/W) Oil level switch (Bl) FI (P/W) Signal ground (B/W) A B C D E F G H I J Turn signal L (B) Turn signal R (Lg) Illumination + (O/G) ABS (Br) [AN650A] Brake lock switch (V) High beam (Y) Immobilizer (E-02, 19, 000) Ambient air temperature sensor (Bl) Fuel pump (R/B) Power ground (B/W) 26 AN650/AK5 (’05-MODEL) POWER WIND SCREEN (AN650AK5 E-02, 19, 000) INSPECTION • Remove the lower leg shield. ($AN650K3 9-10) • Disconnect the wind screen regulator coupler 1. • Apply 12 V voltage to the terminals of the regulator coupler and check that the wind screen moves in the correct direction. Terminal – Terminal R+–-G G+–-R G Window screen UP DOWN • Repeat above inspection several times and replace the window screen regulator assembly if necessary. REMOVAL E L P M • Remove the wind screen. ($Page 42) • Remove the leg shield. ($AN650K3 9-10) • Remove the meter front lower panel 1. A S NOTE: Remove the bolts/screws behind the regulator by moving the regulator up or down. • Remove the meter front upper panel 2. R AN650/AK5 (’05-MODEL) • Remove the regulator mounting bolts. E L P M • Disconnect the couplers. A S • Disconnect the regulator coupler 4. • Remove the regulator motor mounting bolt and nuts. • Remove the wind screen regulator assembly. INSTALLATION Installation is in the reverse order of removal. Pay attention to the following point: • Rout the cables properly. ($Page 40) • Apply grease to the wires, pulleys and guide rails. 27 28 AN650/AK5 (’05-MODEL) AMBIENT AIR TEMPERATURE SENSOR INSPECTION • Turn the ignition switch to OFF. • Remove the AAT (Ambient Air Temperature) sensor by pushing off the clamp. • Check the AAT sensor coupler for loose or poor contacts. If OK, measure the AAT sensor resistance. % AAT sensor resistance: Approx. 2.12 kΩ at 20 °C (68 °F) (Terminal – Terminal) & 09900-25008: Multi-circuit tester set E L P M ' Tester knob indication: Resistance (Ω) Intake Air Temp 20 °C (68 °F) 25 °C (77 °F) 30 °C (86 °F) 40 °C (104 °F) Resistance Approx. 2.1 kΩ Approx. 1.7 kΩ Approx. 1.4 kΩ Approx. 0.9 kΩ A S NOTE: AAT sensor resistance measurement method is the same way as that of the ECT sensor. Refer to AN650K3 8-13 for details. • If neccesary, replace the AAT sensor with a new one. AAT sensor R/W Lg/Y Lg W/B Power sw. Center stand sw. s Mode sw. Brake sw. R G/W Shift down down sw. s Y Br/R Dg B/Bl BRK CSTD MODE POWER DOWN UP DON THA THW PA VCC PM E2 VTA +G -G +N -N Y/Bl Gr/W SDL SPR- SPR+ PPS MO- MO+ TXCK RXCK OX EXS E1 TS MS STA SS SPD IG1 IG2 VM GND PTC OXH SOL Gr/B #1 Ignition coil (IG coil) PTC heater O2 heater Solenoid valve Fan motor relay Fuel injector (FI) CVT motor Gr/R G/B G/R Bl B/R R/W Y/Bl B/O B/G B/W CVT unit Immobilizer Test select EXS sw. W/R B/Br B/Br Secondary pulley sensor Pulley position sensor Speed sensor Mode select W/Bl B/Y #2 B/Br Y/G G P Y/R B Br/B Y/W Y/W G/Bl O/W R/B VB +B Gr/Y FRL FP #2 #1 BATT (+B1) E L P M Shift up sw. Tip over sensor (TOS) Intake air temp. sensor (IATS) Engine coolant temp. sensor (ECTS) G/Y Lg/B R B P/B Br B/Y W/G W R/B A S Atomospheric pressure sensor (APS) Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Crankshaft position sensor (CKPS) Camshaft position sensor (CMPS) Combination meter Brake sw. Heated oxygen sensor (HO2S) Side stand sw. Side stand relay 15 A Engine stop sw. 10 A 40 A Starter sw. 30 A Main sw. (Ignition coil) Starter motor Starter relay Brake lamp 10 A Battery Fuel pump (PU) AN650/AK5 (’05-MODEL) FI SYSTEM WIRING DIAGRAM E-02, 19, 000 29 R/W Lg/Y Lg W/B Power sw. Center stand sw. s Mode sw. Brake sw. R G/W Shift down down sw. s Y Br/R Dg B/Bl BRK CSTD MODE POWER DOWN UP DON THA THW PA VCC PM E2 VTA +G -G +N -N VB FRL FP #2 #1 BATT (+B1) R/B B/Lg Gr/Y Y/Bl Gr/W Gr/B R/B SDL SPR- SPR+ PPS MO- MO+ E1 TS MS STA SS SPD IG1 IG2 VM GND PTC SOL AT +B Br/B G/Bl O/W #2 #1 Speed sensor Ignition coil (IG coil) PTC heater Solenoid valve Fan motor relay Fuel injector (FI) Gr/R G/B G/R CVT motor B/R R/W CVT unit Test select B/W Mode select W/R W/Bl B/Y B/Br Y/G G Y/R Side stand relay Secondary pulley sensor 15 A Brake sw. 40 A Fuel pump (PU) Starter sw. 30 A Main sw. (Ignition coil) Starter motor Starter relay Brake lamp 100 Ω 10 A Engine stop sw. 10 A Side-stand sw. Pulley position sensor E L P M Shift up sw. Tip over sensor (TOS) Intake air temp. sensor (IATS) Engine coolant temp. sensor (ECTS) G/Y Lg/B R B P/B Br B/Y W/G W A S Atomospheric pressure sensor (APS) Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Crankshaft position sensor (CKPS) Camshaft position sensor (CMPS) Combination meter Battery 30 AN650/AK5 (’05-MODEL) E-03, 28, 33 AN650/AK5 (’05-MODEL) 31 ECM COUPLERS K4 MODEL ECM AND CVT CONTROL UNIT COUPLERS ECM couplers CVT control unit couplers K5 MODEL ECM COUPLERS ECM couplers 9 8 7 6 5 4 3 2 E L P M 1 17 16 15 14 13 12 11 10 25 24 23 22 21 20 19 18 34 33 32 31 30 29 28 27 26 ECM TERMINAL NO. 1 2 3 4 5 6 7 8 9 0 A B C D E F 35 36 37 38 39 40 41 Ignition coil (IG1) Fuel injector (#1) Fuel injector (#2) Shift up switch (UP) Pulley position sensor (PPS) PTC heater (PTC) Speedometer (SPD) 61 64 63 53 52 51 50 49 48 60 59 58 57 56 55 54 A S CIRCUIT 62 47 46 45 44 43 42 Solenoid valve (SOL) Fuel pump relay (FP) Ignition coil (IG2) Fan motor relay (FRL) Power switch (POWER) Mode switch (MODE) Shift down switch (DOWN) CO and injection pulse width adjust box (COS1) CO and injection pulse width adjust box (COS2) ECM TERMINAL NO. G H I J K L M N O P Q R S T U V CIRCUIT Battery (+B) Center stand switch (CSTD) Side stand switch (SS) Brake switch (BRK) Mode select switch (MS) Test switch (TS) CO and injection pulse width adjust box (COV1) CO and injection pulse width adjust box (COV2) CO and injection pulse width adjust box (COV3) Ground (E03) Ground (E01) Starter relay (STA) Writing tool (RXD1) Writing tool (TXD1) SDL-KWP (SDL) Writing tool (FWE) 32 AN650/AK5 (’05-MODEL) ECM TERMINAL NO. W X Y Z [ \ ] ^ a b c d e f g h CIRCUIT Battery (BATT) Writing tool (RST) Ground (E1) CKP sensor (N-) CMP sensor (G+) OX heater (OXH) Immobilizer (TXCK) Immobilizer (RXCK) Immobilizer LED (LED) Injector power voltage (VM) CKP sensor (N+) CMP sensor (G-) O2 sensor (OX) Secondary pulley sensor (SPR-) Secondary pulley sensor (SPR+) Sensor power (VCC) ECM TERMINAL NO. i j k l m n o p q r s t u v w x CIRCUIT TP sensor (VTA) IAT sensor (THA) ECT sensor (THW) AP sensor (PA) O2 sensor control selector (EXS) Ground (E2) Tachometer (TACO) Meter (TECH) Writing tool (SCK) IAP sensor (PM) TO sensor (DON) Blank Battery (VB) Motor (MO+) Ground Motor (MO-) A S E L P M AN650/AK5 (’05-MODEL) MALFUNCTION CODE MALFUNCTION CODE C00 C11 C12 C13 C14 C15 C16 C21 C22 C23 C24 or C25 C32 or C33 C40 C41 C42 C44 C51 C52 C53 C54 C55 C58 DETECTED ITEM NO FAULT Camshaft position sensor Crankshaft position sensor Intake air pressure sensor Throttle position sensor Engine coolant temperature sensor Speed sensor Intake air temperature sensor Atmospheric pressure sensor Tip over sensor E L P M Ignition signal A S Fuel injector Intake air control (IAC) valve Fuel pump relay Ignition switch Heated oxygen sensor (HO2S) [E-02, 19] CVT motor CVT pulley position sensor CVT speed sensor CVT secondary pulley revolution sensor CVT engine revolution signal CVT reduction ratio disagreement ECM COUPLER TERMINALS TO CHECK K4 K5 ––––––––––– ––––––––––– [, d ← ($AN650K3 6-27) Z, c ← ($AN650K3 6-28) h, n, r ← ($AN650K3 6-30) h, i, n ← ($AN650K3 6-32) k, n ← ($AN650K3 6-33) ––––––––––– ––––––––––– j, n ← ($AN650K3 6-36) h, l, n ← ($AN650K3 6-38) h, n, s ← ($AN650K3 6-39) 4, 5, b ← ($AN650K3 6-40) 4, 5, b 2, 3, b ($AN650K3 6-40) ––––––––––– 9, b ($AN650K3 6-41) ––––––––––– G, \, e, n ($AN650K3 6-43) ––––––––––– 8, D, J (CVT control unit coupler) ($AN650K3 6-48) ––––––––––– ––––––––––– ← ––––––––––– ← ––––––––––– 5, Q, h ––––––––––– ––––––––––– ––––––––––– 3 (CVT control unit coupler) o (ECM coupler) ($AN650K3 6-53) o ––––––––––– ––––––––––– 33 34 AN650/AK5 (’05-MODEL) ABS TROUBLESHOOTING (AN650AK5) MALFUNCTION CODE TROUBLESHOOTING “41” Wheel speed sensor signal malfunction (F) POSSIBLE CAUSE • Poor contact on the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. 1) Inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. % Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm & 09900-20803: Thickness gauge 09900-20806: Thickness gauge Is the clearance OK? YES NO Go to step 2. Adjust the clearance. E L P M 2) Inspect the front wheel speed sensor rotor for damage and check that no foreign objects are caught in the rotor openings. Is the sensor rotor OK? YES NO Go to step 3. Clean or replace the sensor rotor. A S 3) Check that the front wheel speed sensor is mounted steadily. Is the sensor mounted steadily? YES NO Go to malfunction code “42”. ($Page 16). Tighten the mounting bolts or replace the bracket if necessary. AN650/AK5 (’05-MODEL) “42” Wheel speed sensor circuit open (F) POSSIBLE CAUSE • Poor contact on the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. • • • • Turn the ignition switch to OFF. Remove the leg shield. ($AN650K3 9-10) Remove the meter front lower panel. ($Page 8) Check the ABS control unit coupler and front wheel speed sensor coupler for looseness. If OK, disconnect the ABS control unit coupler. 1) Measure the resistance between B (B/R) and ground at the ABS control unit coupler. % Normal value: ∞ E L P M & 09900-25008: Multi circuit tester set 09900-25009: Needle pointed probe set ' Tester knob indication: Resistance (Ω) Is the resistance between B and ground OK? YES NO Go to step 3. Go to step 2. A S • Disconnect the front wheel speed sensor coupler. 2) Measure the resistance between A (B) and ground at the front wheel speed sensor coupler. % Normal value: ∞ ' Tester knob indication: Resistance (Ω) Is the resistance between A and ground OK? YES NO Inspect the wire harness. (Faulty B/R wire) Faulty front wheel speed sensor 3) Measure the resistance between 3 (W/R) and ground at the ABS control unit coupler. % Normal value: ∞ ' Tester knob indication: Resistance (Ω) Is the resistance between 3 and ground OK? YES NO Go to step 5. Go to step 4. 35 36 AN650/AK5 (’05-MODEL) 4) Measure the resistance between B (W) and ground at the front wheel speed sensor coupler. % Normal value: ∞ ' Tester knob indication: Resistance (Ω) Is the resistance between B and ground OK? YES NO Inspect the wire harness. (Faulty W/R wire) Faulty front wheel speed sensor 5) Check for continuity between B (B/R) on the ABS control unit coupler and C (B/R) on the front wheel speed sensor coupler. ( Tester knob indication: Continuity ()) Is there continuity between B and C? YES NO Go to step 6. Inspect the wire harness. (Faulty B/R wire) E L P M 6) Check for continuity between 3 (W/R) on the ABS control unit coupler and D (W/R) on the front wheel speed sensor coupler. ( Tester knob indication: Continuity ()) Is there continuity between 3 and D? YES NO A S Go to step 7. Inspect the wire harness. (Faulty W/R wire) • Connect the front wheel speed sensor coupler. 7) Connect three 1.5 V dry cells A in series as shown and make sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and B (B/ R) on the ABS control unit coupler. % Normal value: 3 – 14 mA * Tester knob indication: Current (+, 20 mA) Is the current OK? YES NO Replace the ABS control unit/HU. Faulty front wheel speed sensor. DCmA AN650/AK5 (’05-MODEL) “44” Wheel speed sensor signal malfunction (R) POSSIBLE CAUSE • Poor contact on the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. 1) Inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge. % Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm & 09900-20803: Thickness gauge 09900-20806: Thickness gauge Is the clearance OK? YES NO Go to step 2. Adjust the clearance. 2) Inspect the rear wheel speed sensor rotor for damage and check that no foreign objects are caught in the rotor openings. E L P M Is the sensor rotor OK? YES NO Go to step 3. Clean or replace the sensor rotor. A S 3) Check that the rear wheel speed sensor is mounted steadily. Is the sensor mounted steadily? YES NO Go to malfunction code “45”. ($Page 38) Tighten the mounting bolts or replace the bracket if necessary. 37 38 AN650/AK5 (’05-MODEL) “45” Wheel speed sensor circuit open (R) POSSIBLE CAUSE • Poor contact on the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. • • • • Turn the ignition switch to OFF. Remove the front box. ($AN650K3 9-18) Remove the trunk box cover. ($AN650K3 9-16) Check the ABS control unit/HU coupler and rear wheel speed sensor coupler for loose or poor contacts. If OK, then disconnect the ABS control unit/HU coupler 1) Check the resistance between terminal 2 (B/Y) on the ABS control unit coupler and ground. % Normal value: ∞ Ω (Infinity) E L P M & 09900-25008: Multi circuit tester set 09900-25009: Needle pointed probe set ' Tester knob indication: Resistance (Ω) Is the resistance OK? YES NO Go to step 3. Go to step 2. A S 2) Check the resistance between A (B) and ground. % Normal value: ∞ Ω (Infinity) ' Tester knob indication: Resistance (Ω) Is the resistance OK? YES NO Inspect the wire harness. (Faulty B/Y wire) Replace the rear wheel speed sensor. 3) Check the resistance between terminal H (W/Y) and ground. % Normal value: ∞ Ω (Infinity) ' Tester knob indication: Resistance (Ω) Is the resistance OK? YES NO Go to step 5. Go to step 4. AN650/AK5 (’05-MODEL) • Disconnect the rear wheel speed sensor coupler. 4) Check the resistance between B (W) and ground. % Normal value: ∞ Ω (Infinity) Is the resistance OK? YES NO Inspect the wire harness. (Faulty W/Y wire) Replace the rear wheel speed sensor. 5) Check the continuity between C (B/Y) and terminal 2. ! % Normal value: Continuity ()) ( Tester knob indication: Continuity test ()) Is the continuity OK? YES NO Go to step 6. Inspect the wire harness. (Faulty B/Y wire) E L P M 6) Check the continuity between D (W/Y) and terminal H. % Normal value: Continuity ()) ( Tester knob indication: Continuity test ()) Is the continuity OK? YES NO A S Go to step 7. Inspect the wire harness. (Faulty W/Y wire) • Connect the rear wheel speed sensor coupler. 7) Connect three 1.5 V dry cells A in series as shown and make sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and 2 (B/ Y) on the ABS control unit coupler. % Normal value: 3 – 14 mA & 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set * Tester knob indication: Current (+, 20 mA) Is the current OK? YES NO Replace the ABS control unit/HU. Replace the rear wheel speed sensor. DCmA ! 39 40 AN650/AK5 (’05-MODEL) WIND SCREEN CABLE ROUTING Cushion Speedometer Do not drop the cushion. E L P M Wind screen regulator Clamp Screen relay Tip over sensor A S ECM Pass through the cable back side of relay. ECM Clamp Air pressure sensor Fun motor relay Side stand relay Fuel pump relay Cushion Attach Screen relay Cushion AN650/AK5 (’05-MODEL) RADIATOR HOSE ROUTING Face the tip of clamp to the bottom. Reservoir inlet hose White mark Oil cooler inlet hose 14˚ E L P M Oil cooler outlet hose 10˚ White mark A S Radiator outlet hose Yellow mark Face the tip of clamp to the forward. Face the tip of clamps to the bottom. 41 42 AN650/AK5 (’05-MODEL) EXTERIOR PARTS CONSTRUCTION E L P M A S 1 2 3 4 5 Meter front upper panel Leg shield brace Meter cover Front panel Leg shield 6 7 8 9 0 Lower leg shield Floor mat Front box Wind screen Wind screen cover A B C D Wind screen regulator Meter front lower panel Front leg shield cover Lower bracket cover AN650/AK5 (’05-MODEL) E L P M A S 1 2 3 4 Maintenance lid Foot board Frame cover Leg side cover 5 6 7 8 Center frame cover Lower frame cover Rear fender Floor mat 9 Fuel tank inlet tray 0 Fuel tank inlet packing 43 44 AN650/AK5 (’05-MODEL) A S E L P M AN650/AK5 (’05-MODEL) CVT CONSTRUCTION K4 93 N·m (9.3 kgf-m, 67.5 lb-ft) K5 D FW E L P M A S 1 Secondary pulley shaft nut 2 Secondary pulley shaft adapter 3 O-ring 9 CVT belt 0 Primary pulley assembly A Shim G Secondary pulley fan H Bearing I Snap ring 4 Primary pulley shaft bolt 5 Primary pulley shaft adapter 6 CVT casing B O-ring C Bearing D Oil seal J Primary slide pulley idle gear K Secondary pulley revolution sensor L CVT motor 7 Bearing 8 O-ring E Washer F Secondary pulley assembly M CVT cover N CVT filter • Use new special tool for 4. ! 09924-51010: Primary pulley shaft bolt holder " Primary pulley shaft bolt: 93 N·m (9.3 kgf-m, 67.5 lb-ft) NOTE: Do not reuse the removed primary pulley shaft bolt. 45 46 AN650/AK5 (’05-MODEL) AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION Wind screen regulator motor Leg shield brace E L P M Ambient air temperature sensor A S Mirror drive relay (Electric mirror only) FWD AN650/AK5 (’05-MODEL) SPECIAL TOOLS 09900-20803 09900-20806 Thickness gauge 09900-25008 Multi circuit tester set 09900-25009 Needle pointed probe set 09924-51010 Primary pulley shaft 09930-82710 bolt holder Mode select switch TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter A (mm) 4 5 6 8 10 12 14 16 18 E L P M Conventional or “4” marked bolt N·m kgf-m 1.5 0.15 3 0.3 5.5 0.55 13 1.3 29 2.9 45 4.5 65 6.5 105 10.5 160 16.0 A S N·m 2.3 4.5 10 23 50 85 135 210 240 “7” marked bolt kgf-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21.0 24.0 A Conventional bolt “4” marked bolt “7” marked bolt 47 WIRING DIAGRAM AN650K5 (E-02, 19, 000) HI : HIGH BEAM INDICATOR LIGHT OI : OIL PRESSURE INDICATOR LIGHT FI : FI PILOT BRK : BRAKE-LOCK INDICATOR LIGHT TR : TURN SIGNAL INDICATOR LIGHT (R) TL : TURN SIGNAL INDICATOR LIGHT (L) WT : ENGINE COOLANT TEMP. INDICATOR LIGHT D : DRIVE MODE INDICATOR PM : POWER MODE INDICATOR IMO : IMMOBILIZER OD : OVER DRIVE INDICATOR LIGHT PM BRK BRK FI OI HI ABS PM WT HAZARD SWITCH SP/TA D 1 2 3 4 5 OFF ON FI OI HI IMO OD ENGINE STOP SWITCH OFF RUN SIDE-STAND SWITCH FRONT BRAKE SWITCH STARTER BUTTON IGNITION IGNITION COIL #1 COIL #2 PUSH FREE CENTER STAND SWITCH OFF ON PUSH ECM IMOBILIZER A.T-SENSOR IAC VALVE CVT MOTOR M Y B G R HANDLEBAR SWITCH (R) TR TL SOLENOID Br B/W W/Y B/W Br B/W POSITION LIGHT (L) W/R Gr/R B/W O/W Lg/B Br/R B/W W/G B/Y Y/W Y/Bl B/O O/Bl Y/R W Br B/G G/B G/R R P/B Dg B/Bl G/Y B/Br B/Br Br/W P/B R/Bl Gr/R R/B R/W B B/R Gr B/W W/B BRAKE LIGHT/TAILLIGHT (R) BRAKE LIGHT/TAILLIGHT (L) Gr B/W W/B B B/W Br B/W W/B B B B/W FRONT TURN SIGNAL LIGHT (L) HI LO PUSH L PUSH R PASSING DIMMER HORN SWITCH BUTTON LIGHT SWITCH TURN SIGNAL LIGHT SWITCH OFF ON FREE PUSH FREE PUSH UP FREE DOWN POWER REAR SWITCH UP/DOWN BRAKE SWITCH SWITCH D↔M SWITCH HANDLEBAR SWITCH (L) G/Y FAN MOTOR #1 #2 INJECTOR CVT REVOLUTION SENSOR ON OFF ON OFF OIL PRESSURE OIL LEVEL SWITCH SWITCH 1. HEAD HI 2. HEAD LO 3. FUEL 4. IGNITION 5. SIGNAL 6. FAN 15 A 10 A 10 A 15 A 15 A 15 A CVT FUEL PULLEY PUMP POSITION SENSOR TP SENSOR HO2 ECT IAT SENSOR SENSOR SENSOR REGULATOR/ RECTIFIER CMP SENSOR TO SENSOR GENERATOR MAIN FUSE STARTER (40 A) RELAY PUSH BATTERY STARTER MOTOR OFF ON TRUNK LIGHT SWITCH TRUNK LIGHT SEAT SWITCH Y/B Y/G B/W R/Bl G R R/W R B/W B B/W B/W B/W B B B/W R R/W Y/B Y/G R/W R Br/R B/Br W W/G B/Y Br R B/W O/W B/Br B/G Y/W Dg B/Br B/Bl B/Br O O/Bl R/B R/W B/Br G/Y R IAP AP (40 A) (10 A) SENSOR SENSOR POWER CTV SOURCE FUSE FUSE B B 3 Bl G Y Y Y 2 W Gr B W 1 B/Br Lg/B R M R P/B B/Br Y/R B/W R/B B/W 6 Y W 5 FUSE BOX ON OFF FAN MOTOR SWITCH 4 Bl Y B R /R Bl Bl B/Br BBr R Bl B Gr/B Y/R Gr/W Y/R G/R G/B Br Lbl O/G R B/O Y Y/W W/Y R/Bl B/R O/Y B Y/G O/W Y/R R/Bl FP RELAY R G O/W B/W Y/B SIDESTAND RELAY POWER SOURCE B PUSH B/W O/Bl Bl Bl/Y R/W Y/G Br/W G G/Y Lg/Y R/W Y B/W G/W B/G B/R B/O B O/G W/B W Y Y/W B/Bl B/W Lg Lbl B O/R FAN MOTOR RELAY Bl B W Y Y/W B/Bl B/W Lg Lbl B O HORN Gr/Y O/G B B/W O/G B/Bl O/Bl B/W REAR TURN SIGNAL LIGHT (L) B R/Bl B B/W REAR TURN SIGNAL LIGHT (R) B/W Lg Lg Br B/W W/B R HEAD LIGHT(L) B/W Gr A S Lg B/W Y B/W W HEAD LIGHT(R) LICENSE PLATE LIGHT B/W Lg B/W B/Y Gr/W Gr/B Y Bl B/Br P G/Bl B W/Bl Gr/Y R/W Lg/Y G/W L/G Bl/Y O/W Lg G W/B B/Br W/R Bl/W Bl/B Bl/G B/W B/W Y/G B/Br Bl/W Bl/B Bl/G Bl/R Bl/Y R Br/B O/W R/W B/R O/W G/Bl Lg B/W E L P M POSITION LIGHT (R) FRONT TURN SIGNAL LIGHT (R) Bl B/W Y/Bl B/W B/O O/Y B/W Y/W R B/W B B G B/W G B/W G B/W B B B O B O/W B/Y O/W W/Bl B/G B/Br O/Y O/W Y/G O Y O/G W/B B Lg Lbl O/G V O/Bl Bl B/W B O/G R/Bl O/G B/W O/R W R/B P/W Br/W Bl G/Y Lg Y V O/R W B/W ON OFF IGNITION SWITCH ON OFF LOCK P B B/R O/G P B/W BRAKELOCK SWITCH O/B O/W Y/G O/R Y/W B/R W/Bl SPEED SENSOR B Lg Lbl Gr P PUSH FREE TRUNK LIGHT DIODE AN650K5 (E-03, 24, 28, 33) HI : HIGH BEAM INDICATOR LIGHT OI : OIL PRESSURE INDICATOR LIGHT FI : FI PILOT BRK : BRAKE-LOCK INDICATOR LIGHT TR : TURN SIGNAL INDICATOR LIGHT (R) TL : TURN SIGNAL INDICATOR LIGHT (L) WT : ENGINE COOLANT TEMP. INDICATOR LIGHT D : DRIVE MODE INDICATOR PM : POWER MODE INDICATOR OD : OVER DRIVE INDICATOR LIGHT TR SIDE-STAND SWITCH CVT MOTOR SOLENOID HI LO PUSH L PUSH R PASSING DIMMER HORN SWITCH BUTTON LIGHT SWITCH TURN SIGNAL LIGHT SWITCH OFF ON FREE PUSH FREE PUSH UP FREE DOWN SWITCH HANDLEBAR SWITCH (L) G/Y B/W Y/W R B/W B B Br/B O/W R/W B/R O/W G/Bl #1 #2 INJECTOR CVT REVOLUTION SENSOR ON OFF ON OFF OIL PRESSURE OIL LEVEL SWITCH SWITCH 1. HEAD HI 2. HEAD LO 3. FUEL 4. IGNITION 5. SIGNAL 6. FAN 15 A 10 A 10 A 15 A 15 A 15 A CVT FUEL PULLEY PUMP POSITION SENSOR TP SENSOR ECT IAT SENSOR SENSOR CMP SENSOR REGULATOR/ RECTIFIER TO SENSOR GENERATOR Gr B/W W/B B B/W B/W B MAIN FUSE STARTER (40 A) RELAY PUSH BATTERY STARTER MOTOR OFF ON TRUNK LIGHT SWITCH TRUNK LIGHT SEAT SWITCH B/W R/Bl R/W R B/W B B B/W R R/W Y/B Y/G R/W R Br/R B/Br W W/G B/Y Br R B/W Dg B/Br B/Bl B/Br O O/Bl R/B R/W B/Br G/Y R IAP AP (40 A) (10 A) SENSOR SENSOR POWER CTV SOURCE FUSE FUSE B/W 3 B/W 2 B B 4 B/Br Lg/B R M Bl G Y Y Y 6 R P/B B/Br Y/R B/W R/B B/W 5 FUSE BOX ON OFF FAN MOTOR SWITCH 4 BRAKE LIGHT/TAILLIGHT (R) Bl Y B R /R Bl Bl B/Br BBr FP RELAY Gr B/W W/B REAR TURN SIGNAL LIGHT (L) R Bl B Y/G O/W Y/R R/Bl B/W O/Bl Bl G/Y B/O B FAN MOTOR POWER REAR SWITCH UP/DOWN BRAKE SWITCH SWITCH D↔M SIDESTAND RELAY POWER SOURCE B PUSH G O/W B/W Y/B FAN MOTOR RELAY REAR TURN SIGNAL LIGHT (R) B/W Lg Lg Br B/W W/B BRAKE LIGHT/TAILLIGHT (L) Bl B O/G W/B B/G B/R R Bl/Y R/W Y/G Br/W G Gr/Y O/G B B/W W Y Y/W B/Bl B/W Lg Lbl B O W Y Y/W B/Bl B/W Lg Lbl B O/R Lg/Y R/W Y B/W G/W O/G B/Bl O/Bl B/W HORN W/R B/W Gr Br B/W W/B B Gr/B Y/R B B/W FRONT TURN SIGNAL LIGHT (L) Gr/R B/W G B/W Lg B/W Bl B/W G B/W G B/W O/W B/Y O/W W/Bl O/G V B/Br Bl/W Bl/B Bl/G Bl/R Bl/Y R LICENSE PLATE LIGHT A S Gr/W Y/R Y B/W W G/R G/B HEAD LIGHT(L) Y W Y B/W W Br Lbl HEAD LIGHT(R) B B/W O/Bl Bl Lg B/W O/G R B/O Lg B/W E L P M R W Y Y/W W/Y R/Bl B/R O/Y FRONT TURN SIGNAL LIGHT (R) B/W B O/G R/Bl O/G B/W O/R W R/B P/W Br/W Bl G/Y Lg Y V O/R W B/W ON OFF IGNITION SWITCH ON OFF LOCK P B B/R B/Lg B/W B/G B/Br O/B O/W Y/G O/R Y/W B/R B/Bl O/Y O/W Y/G O Y O/G W/B O/G P B/W BRAKELOCK SWITCH B Lg Lbl Gr P SPEED SENSOR B Lg Lbl PUSH FREE O/W M Y/B Y/G CENTER STAND SWITCH OFF ON PUSH G R OFF RUN R OFF ON FI OI HI OD B R/Bl 5 B/W 4 Lg/B Br/R B/Lg R/B R/W B B/R 3 B/Br Br/W P/W 2 G/B G/R R P/B Dg B/Bl G/Y 1 ECM O/Bl Y/R W Br D PUSH FREE R/Bl SP/TA STARTER BUTTON IAC VALVE IGNITION IGNITION COIL #1 COIL #2 FRONT BRAKE SWITCH B/W W/G B/Y HAZARD SWITCH ENGINE STOP SWITCH Gr/R HANDLEBAR SWITCH (R) PM BRK BRK FI OI HI ABS PM WT B/Y Gr/W Gr/B Y Bl Br/B P G/Bl Y/G W/Bl Gr/Y R/W Lg/Y G/W Bl/R Bl/Y O/W Lg G W/B B/Br W/R Bl/W Bl/B Bl/G B/W B/W Y/G TL TRUNK LIGHT DIODE AN650AK5 (E-02, 19, 000) HI : HIGH BEAM INDICATOR LIGHT OI : OIL PRESSURE INDICATOR LIGHT FI : FI PILOT BRK : BRAKE-LOCK INDICATOR LIGHT TR : TURN SIGNAL INDICATOR LIGHT (R) TL : TURN SIGNAL INDICATOR LIGHT (L) WT : ENGINE COOLANT TEMP. INDICATOR LIGHT D : DRIVE MODE INDICATOR PM : POWER MODE INDICATOR IMO : IMMOBILIZER OD : OVER DRIVE INDICATOR LIGHT ABS : ABS INDICATOR LIGHT HANDLEBAR SWITCH (R) WINDSCREEN SWITCH ENGINESTOP SWITCH Y B G R Br B/W FRONT TURN SIGNAL LIGHT (R) Lg B/W HEADLIGHT (R) Y B/W W PASSING LIGHT SWITCH HI LO DIMMER SWITCH FREE PUSH OFF ON HORN BUTTON REAR BRAKE SWITCH L PUSH R • OPEN CLOSE POWER SWITCH FREE PUSH TURN SIGNAL LIGHT SWITCH B/R W/R B/Y W/Y B W B W O B/W R/B R R/B R Y/B Y/G B/W R/Bl R B R/Bl R/W B/W B/W B B B/W B/W MAIN FUSE STARTER (40 A) RELAY R R/W F-CUT SENSOR Y/B Y/G W W/G B/Y Br R B/W O/W B/Br B/G Y/W Dg B/Br B/Bl B/Br O O/Bl R/B R/W R/W D↔M SWITCH HANDLEBAR SWITCH (L) UP FREE DOWN UP/DOWN SWITCH MIRROR 1 2 G/Y 1. HEAD HI 2. HEAD LO 3. FUEL 4. IGNITION 5. SIGNAL 6. FAN 15 A 10 A 10 A 15 A 15 A 15 A FUEL PUMP CAM SENSOR REGULATOR/ RECTIFIER PUSH 12 V BATTERY GENERATOR STARTER MOTOR TRUNK BOX SWITCH G R B/W B B B Y Y Y Bl G W Gr B W BI Y B M.P A.P (40 A) (10 A) SENSOR SENSOR CTV POWER FUSE SOURCE W.T TP M.T O2 FUSE SENSOR SENSORSENSOR SENSOR DIODE R #1 #2 CVT INJECTOR PULLEY CVT POSITION REVOLUTION SENSOR SENSOR 3 FUSE BOX OIL PRESSURE SWITCH M Y W 6 B/W POWER SOURCE ON OFF ON OFF PUSH W/R Br B/W W/B B R Br/B B/Br L/Y R/W Y/G Br/W G G/R B/O G/B B/G B/R W Y Y/W B/Bl B/W Lg Lbl B O/R /R FAN MOTOR 5 R Bl B Bl B 4 B FAN MOTOR SWITCH PUSH Gr/R B/W O/W B/Y W/R W/B R R Gr/R Br B/R O O/Y W/Y B/W B/W R/B R/W B B/R Lg/B Br/R B/W W/G B/Y Y/W Y/Bl B/O O/Bl Y/R W Br B/G G/B O/R R P/B Dg B/Bl G/Y B/Br B/Br Br/W P/W R/Bl Gr/R BRAKE LIGHT/TAILLIGHT (L) ABS ABS FUSE MOT (15 A) FUSE (15 A) MODE SELECT COUPLER FVW RVW OFF ON TRUNK TRUNK BOX LIGHT BOX LIGHT SWITCH ON OFF OIL LEVEL SWITCH Gr B/W W/B B B/W REAR TURN SIGNAL LIGHT (L) B/Br G/Y R Br Lbl O/G R B/O F-P RELAY Y Y/W W/Y R/Bl B/R O/Y B O/W Y/R R/Bl SIDESTAND RELAY R G O/W B/W Y/B B/W O/Bl Bl G/Y B/O B Gr/Y O/G B B/W FAN MOTOR RELAY HORN M-RELAY REAR TURN SIGNAL LIGHT (R) BRAKE LIGHT/TAILLIGHT (R) OPTION MIRROR FUSE (3 A) B/W Gr B/W Lg Gr B/W W/B Lg Br B/W W/B Lg/Y R/W Y B/W G/W G/R O G/B W Y Y/W B/Bl B/W Lg Lbl B O B/G W/B O/G B/Bl O/BI B/W G/R Bl B/O B/W B G/B B/O O MIRROR-MOTOR (L) Y/R B/W R/B B/W B Bl R Bl B/Bl M B Bl Gr/B Y/R FRONT TURN SIGNAL LIGHT (L) Gr/W Y/R B B/W G/R O/R G/B O/B Br B/W POSITION LIGHT (L) B B/W LICENSE PLATE LIGHT A S W/Y B/W HEADLIGHT (L) B/Br Lg/B R Lg B/W B/Y Gr/W Gr/B Y Bl Br/B P G/Bl B W/Bl Gr/Y R/W Lg/Y G/W Bl/R Bl/Y O/W Lg G W/B B/Br W/R Bl/W Bl/B Bl/G B/W B/W Y/G E L P M B Bl POSITION LIGHT (R) R P/B B/Br B Bl O O SOLENOID MIRROR-MOTOR (R) M ABS-CONT B/Br Bl/W Bl/B Bl/G Bl/R Bl/Y R G B/W B B B B B O/W B/Y O/W W/Bl B/G B/Br O/B O/W Y/G O/R Y/W B/R B/Bl O/Y O/W Y/G O Y O/G W/B ON OFF LOCK P B B/R Bl B/W G B Lbl Lg Bl B/W G/B B Lbl Lg B/W B O/G R/Bl O/G B/W O/R W R/B P/W Br/W Bl G/Y Lg Y V Br O/Bl Bl O/G P B/W O/R W B/W O/G V ON OFF ECM M PUSH FREE PUSH FREE IGNITION SWITCH CVT MOTOR YBl B/W B/O O/Y SPEED SENSOR BRAKELOCK SWITCH CENTER STAND SWITCH SIDESTAND SWITCH M Bl B/W OFF ON S-RELAY R G 5 FI OI HI IMO OD IMOBILIZER SCREEN SCREEN FUSE MOTOR A.T-SENSOR PTC B/W Y/W R B/W B B 4 3 FRONT BRAKE LIGHT SWITCH G/B G B/W O R Bl OFF ON G B/W 2 1 IGNITION IGNITION COIL #1 COIL #2 HAZARD SWITCH SP/TA D PUSH Lg B/W BRK ABS PM BRK FI OI HI ABS PM WT STARTER BUTTON OFF RUN Br/B O/W R/W B/R O/W G/Bl TR TL O G B/W UP FREE DOWN WIRE COLORS B : Black Bl : Blue Br : Brown Dg : Dark green Dgr : Dark gray G : Green Gr : Gray Lbl : Light blue Lg : Light green O : Orange R : Red W : White : Yellow Y B/Bl : Black with Blue tracer B/R : Black with Red tracer B/W : Black with White tracer B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer O/B : Orange with Black tracer O/Bl : Orange with Blue tracer O/G : Orange with Green tracer O/R : Orange with Red tracer O/W : Orange with White tracer O/Y : Orange with Yellow tracer W/B : White with Black tracer Y/B : Yellow with Black tracer Y/G : Yellow with Green tracer Y/W : Yellow with White tracer E L P M Prepared by December, 2004 Part No. 99501-36110-01E Printed in Japan A S 48 Printed in Japan K5