VL1500.K5 (ID=1709).pdf

VL1500

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VL1500 SERVICE MANUAL (99500-39166-01E)

VL1500K5 (’05-MODEL) 1

VL1500K5 (’05-MODEL)

This manual describes service specifications, service data and servicing procedures which dif-

fer from those of the VL1500K4 (’04-model).

NOTE:

• Any differences between the VL1500K4 (’04-model) and VL1500K5 (’05-model) in

specifications and service data are indicated with an asterisk mark (*).

• Please refer to the VL1500 service manual for details which are not given this manual.

CONTENTS

ABBREVIATIONS USED IN THIS MANUAL .................................................... 3

SPECIFICATIONS ............................................................................................. 5

PERIODIC MAINTENANCE SCHEDULE ......................................................... 7

MAINTENANCE AND TUNE-UP PROCEDURES ............................................ 8

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ................ 13

ENGINE REMOVAL AND INSTALLATION ...................................................... 14

ENGINE DISASSEMBLY AND

REASSEMBLY .................................................................................................. 17

ENGINE COMPONENTS INSPECTION AND SERVICING .............................. 18

PRECAUTIONS IN SERVICING........................................................................ 19

FI SYSTEM TECHNICAL FEATURES .............................................................. 26

FUEL DELIVERY SYSTEM ............................................................................... 28

FI SYSTEM PARTS LOCATION ....................................................................... 29

FI SYSTEM WIRING DIAGRAM........................................................................ 31

ECM TERMINAL................................................................................................ 32

SELF-DIAGNOSIS FUNCTION ......................................................................... 33

FAIL-SAFE FUNCTION ..................................................................................... 37

FI SYSTEM TROUBLESHOOTING................................................................... 38

FUEL SYSTEM .................................................................................................. 93

THROTTLE BODY.............................................................................................102

SENSORS..........................................................................................................118

EXTERIOR PARTS............................................................................................121

FRONT FORK....................................................................................................122

LOCATION OF ELECTRICAL COMPONENTS ................................................127

CHARGING SYSTEM ........................................................................................129

AUTOMATIC DECOMPRESSION SYSTEM/STARTER SYSTEM AND

SIDE-STAND IGNITION INTERLOCK SYSTEM ..............................................131

IGNITION SYSTEM ...........................................................................................133

SPEEDOMETER................................................................................................138

RELAYS.............................................................................................................141

2 VL1500K5 (’05-MODEL)

SWITCHES........................................................................................................ 142

BATTERY.......................................................................................................... 143

WIRING HARNESS, CABLE AND HOSE ROUTING....................................... 144

EXTERIOR PARTS INSTALLATION................................................................ 153

SPECIAL TOOLS.............................................................................................. 157

TIGHTENING TORQUE .................................................................................... 158

SERVICE DATA................................................................................................ 159

EMISSION CONTROL SYSTEMS .................................................................... 168

PAIR (AIR SUPPLY) SYSTEM INSPECTION .................................................. 172

PAIR (AIR SUPPLY) SYSTEM DIAGRAM ....................................................... 174

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................................ 175

HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24) .......... 176

WIRING DIAGRAM ........................................................................................... 177

COUNTRY AND AREA CODES

The following codes stand for the applicable country (-ies) and area (-s).

CODE

COUNTRY or AREA

EFFECTIVE FRAME NO.

E-03

E-19

E-24

E-28

E-33

U.S.A. (Except for California)

Australia

Canada

California (U.S.A.)

JS1VY52A 52100001 –

JS1AL211100105237 –

JS1AL211300100688 –

JS1VY52A 52100001 –

VL1500K5 (’05-MODEL) 3

ABBREVIATIONS USED IN THIS

MANUAL

ABDC : After Bottom Dead Center

AC : Alternating Current

ACL : Air Cleaner, Air Cleaner Box

API : American Petroleum Institute

ATDC : After Top Dead Center

ATM Pressure: Atmospheric Pressure

Atmospheric Pressure Sensor

(APS)

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

EOT Sensor : Engine Oil Temperature

Sensor (EOTS), Oil Temp.

Sensor

EVAP : Evaporative Emission

EVAP Canister : Evaporative Emission

Canister (Canister)

A/F

: Air Fuel Mixture

BBDC

: Before Bottom Dead Center

: Fuel Injection, Fuel Injector

BTDC

: Before Top Dead Center

: Fuel Pump

B+

: Battery Positive Voltage

FPR

: Fuel Pressure Regulator

FP Relay

: Fuel Pump Relay

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

GEN

: Generator

GND

: Ground

GP Switch

: Gear Position Switch

: Carbon Monoxide

HC : Hydrocarbons

HO2 Sensor : Heated Oxygen Sensor (HO2S)

CPU

: Central Processing Unit

: Direct Current

DMC

: Dealer Mode Coupler

IAP Sensor : Intake Air Pressure Sensor (IAPS)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

DOHC

: Double Over Head Camshaft

DRL

: Daytime Running Light

: Ignition

LCD

: Liquid Crystal Display

LED

: Light Emitting Diode

(Malfunction Indicator Lamp)

: Left Hand

4 VL1500K5 (’05-MODEL)

MAL-Code

: Malfunction Code

(Diagnostic Code)

Max

: Maximum

MIL

: Malfunction Indicator Lamp

(LED)

Min

: Minimum

NOx

: Nitrogen Oxides

OHC

: Over Head Camshaft

OPS

: Oil Pressure Switch

PCV

: Positive Crankcase

Ventilation (Crankcase Breather)

: Right Hand

ROM

: Read Only Memory

SAE : Society of Automotive Engineers

STC System : Secondary Throttle Control

System (STCS)

STP Sensor : Secondary Throttle Position

Sensor (STPS)

ST Valve : Secondary Throttle Valve (STV)

STV Actuator : Secondary Throttle Valve Actuator

(STVA)

TO Sensor : Tip Over Sensor (TOS)

TP Sensor

: Throttle Position Sensor (TPS)

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