16-76 ELECTRICAL SYSTEM

Switches and Sensors

•Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por-

•tion [E] are submerged.

Suspend an accurate thermometer [B] in the coolant.

NOTE

○The sensor and thermometer must not touch the container side or bottom.

•Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the

•coolant gently.

Using the hand tester, measure the internal resistance of the sensor.

○The sensor sends electric signals to the ECU (Electronic Control Unit) and coolant temperature gauge in the meter unit.

○Measure the resistance across the terminals and the body (for the gauge) at the temperatures shown in the table. If the hand tester does not show the specified values, replace the sensor.

Water Temperature Sensor

Resistance for ECU [C]

Speed• Sensor Inspection

Disconnect:

• Speed Sensor Connector [A]

Remove:

Engine Sprocket Cover [B] (see Final Drive chapter)

16-78 ELECTRICAL SYSTEM

Switches and Sensors

•Level Sensor Inspection

Remove:

•Fuel Tank (see Fuel System (DFI) chapter)

•Open the clamps [A]. Remove:

Bolts [B]

Fuel Level Sensor [C]

•Check that the float moves up and down smoothly without binding. It should go down under its own weight.

If the float does not move smoothly, replace the sensor. Float in Full Position [A]

Float in Empty Position [B] Float Arm Stoppers [C]

105.2112.2 mm (4.142 4.417 in.) from the Sensor Base Line [D]

33.640.6 mm (1.32 1.60 in.) from the Sensor Base Line [E]

Sensor Base Line [F]

•Using the hand tester [A], measure the resistance across the terminals in the fuel level sensor lead connector [B]. Black/Yellow [C]

White/Yellow [D]

Special Tool - Hand Tester: 57001–1394

If the tester readings are not as specified, or do not change smoothly according as the float moves up and down, replace the sensor.

Fuel Level Sensor Resistance

Standard: Full position: 4 10 Ω

Empty position [E]: 90 100

• Ω

Apply a non-permanent locking agent to the threads of the level sensor mounting bolts and tighten it.

Torque - Fuel Level Sensor Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

Fuel• Reserve Switch Inspection

•Fill the fuel tank with fuel.

•Close the fuel tank cap surely. Remove:

• Right Frame Cover (see Frame chapter) Disconnect the fuel level sensor connector [A].

ELECTRICAL SYSTEM 16-79

Switches and Sensors

•Connect the test light [A] (12 V 3.4 W bulb a socket with leads) and the 12 V battery [B] to the fuel level sensor connector [C].

Connections:

Battery (+) → 12 V 3.4 W Bulb (one side)

12 V 3.4 W Bulb (other side) → Blue Lead Terminal Battery (–) → BK/Y Lead Terminal

If the test light turn on, the reverse switch is defective. Replace the fuel level sensor.

•Remove:

• Fuel Level Sensor (see Fuel Level Sensor Inspection) Connect the test light (12 V 3.4 W bulb in a socket with leads) and the 12 V battery to the fuel pump connector as shown.

12 V Battery [A]

Test Light [B]

Fuel Pump Connector [C]

Fuel Reserve Switch [D]

If the test light doesn’t light, replace the fuel level sensor.

NOTE

○It may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel level sensor is removed. Leave the fuel reserve switch with leads for inspection connected for ten (10) minute.

Diode• (Rectifier) Inspection

•Remove the fairing (see Frame chapter)

•Cut the vinyl tape [A]. Disconnect the diode [B].

•Set the hand tester to the × 100 Ω range.

•Special Tool - Hand Tester: 57001–1394

Check the continuity between the diode terminals in both directions.

If there is continuity in one direction (forward direction) but no continuity (infinity) in the reverse direction, the diode is normal.

The diode is defective if there is continuity after changing the direction, or it if remains with no continuity.

NOTE

○The actual resistance measurement in the forward direction varies with the tester used and the individual diodes. Generally speaking, it is acceptable if the tester’s indicator swings approximately halfway.