Air Switching Valve

Air Switching Valve Operation Test

_• Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).

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

base.

_• Take the air switching valve hose end outside of the frame.

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

Fuel System (DFI) chapter).

_• Start the engine and run it at idle speed.

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

finger and feel vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test).

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

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

fitting.

Air Switching Valve Unit Test

_• Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

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

the air switching valve terminals as shown.

Special Tool - Hand Tester: 57001-1394

Air Switching Valve Resistance Standard: 18  22 Ω at 20°C (68°F)

If the resistance reading is except the specified value, re- place it with a new one.

_• Connect the 12 V battery [A] to the air switching valve terminals as shown.

Air Switching Valve

_• Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air duct [B].

_• Disconnect the 12 V battery.

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

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

If the air switching value does not operate as described, replace it with a new one.

NOTE

○^{To check air flow through the air switching valve, just}

blow through the air cleaner hose [C].

Radiator Fan System

Fan Motor Inspection

_• Disconnect the connector [A].

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

motor.

If the fan does not rotate, the fan motor is defective and must be replaced.

Radiator Fan Circuit

1. Relay Box

2. Radiator Fan Relay

3. ECU Main Relay

4. Fuse Box

5. Fan Fuse 15 A

6. ECU Fuse 15 A

7. Main Fuse 30 A

8. Battery 12 V 10 Ah

9. Frame Ground

10. Joint Connector 11. ECU

12. Water Temperature Sensor

13. Water-proof Joint E

14. Water-proof Joint C

15. Radiator Fan

16. Ignition Switch

17. Water-proof Joint A

18. Water-proof Joint B

Meter Unit Removal/Installation

_• Remove:

Windshield (see Windshield Removal in the Frame

chapter)

Upper Inner Fairings (see Upper Inner Fairing Removal in the Frame chapter)

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

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

_• Remove the meter unit by taking off the mounting nuts

[C].

_• Installation is the reverse of removal.

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

Meter, Gauge Disassembly

_• Remove:

Meter Unit (see Meter Unit Removal/Installation)

Screws [A]

Lower Meter Cover [B]

_• Separate the meter assembly [A] and upper meter cover [B].

Electronic Combination Meter Unit Inspection

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

[1] Ignition

[2] Fuel Level Warning Indicator Light (LED) (–) [3] Unused (EX650A Models)

ABS Indicator Light (LED)(–)(EX650B Models) [4] Unused

[5] Neutral Indicator Light (LED) (–) [6] FI Indicator Light (LED) (–)

[7] Tachometer Signal

[8] Water Temperature Sensor (–) [9] Ground (–)

[10] Battery (+)

[11] Oil Pressure Warning Indicator Light (LED) (–) [12] Speed Sensor Supply Voltage

[13] Right Turn Signal Indicator Light (LED) (+) [14] Left Turn Signal Indicator Light (LED) (+) [15] High Beam Indicator Light (LED) (+)

[16] Speed Sensor Signal

Liquid Crystal Display (LCD) Segment Check

_• Using the auxiliary wires, connect the 12 V battery to the meter unit connector as follows.

○^{Connect the battery positive terminal to the terminal [10].}

○^{Connect the battery negative terminal to the terminal [9].}

○^{The needles of the meter move.}

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

○^{When the terminals are connected, the LCD segment [A]} and LED warning lights [B] appear.

If the LCD segment and LED warning lights will not ap- pear, replace the meter assembly.

_• Disconnect the terminal [1].

○^{The LCD segment and LED warning lights disappear.}

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

sembly.

MODE AND RESET BUTTON Operation Check

_• Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

_• Check that the display change to the CLOCK, ODO, TRIP A and TRIP B displays each time the MODE button [A] is

pressed.

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

FUEL, ODO, TRIP A and TRIP B.

If the display function does not work, replace the meter assembly.

_• Indicate the clock mode.

_• Check that when the RESET button in CLOCK mode is

pushed for more than two seconds, the meter display

turns to the clock set mode.

○^{Both the hour and minute display start flashing.}

_• In the HOUR/MINUTE setting mode, press the RESET button again to effect the HOUR setting mode.

○^{The hour display flashes on the display.}

_• Press the MODE button to set the hour.

_• In the HOUR setting mode, press the RESET button to effect the MINUTE setting mode.

○^{The minute display flashes on the display.}

_• Press the MODE button to set the minute.

_• In the MINUTE setting mode, press the RESET button to return to the HOUR/MINUTE setting mode.

_• Press the MODE button to complete the time setting

process.

○^{The clock starts counting the seconds as soon as the}

MODE button is pressed.

Speedometer Check

_• Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

_• The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave (illustrated as shown)

would be input into the terminal [16].

○^{Indicates approximately 60 mph in case the input fre-}

quency would be approximately 169.0 Hz.

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

quency would be approximately 105.6 Hz.

_• If the oscillator is not available, the speedometer can be checked as follows.

○^{Install the meter unit.}

○^{Raise the rear wheel off the ground with stand.}

○^{Turn on the ignition switch.}

○^{Rotate the rear wheel by hand.}

○^{Check that the speedometer shows the speed.}

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

sor electric source voltage and speed sensor.

The electric source voltage and speed sensor are normal, replace the meter assembly.

Speed Sensor Electric Source Check

_• Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

_• Set the hand tester to the DC 25 V range and connect it to the terminals [12] and [9].

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

Odometer Check

_• Check the odometer with the speedometer in the same way.

If value indicated in the odometer is not added, replace the meter assembly.

NOTE

○^{The data is maintained even if the battery is discon-}

nected.

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

locked.

Trip A/B Meter Check

_• Check the trip A or B meters with the speedometer in the same way.

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

_• Check that when the RESET button is pushed for more

than two seconds, the figure display turns to 0.0.

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

Tachometer Check

_• Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg-

ments Check”.

_• The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square

wave (illustrated as shown) would be input into the termi- nal [7].

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

quency would be approximately 200 Hz.

_• If the oscillator is not available, the tachometer can be checked as follows.

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

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

ments Check”.

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

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

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

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