CONTENTS MOTORCYCLE. ISSUE NO.: M DATE: Oct. 19, 2004 PAGE: 1 OF 9

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1 MOTORCYCLE ISSUE NO.: M DATE: Oct. 19, 2004 PAGE: 1 OF 9 SUBJECT: CORRECTION AND ADDITIONAL INFORMATION OF THE SERVICE MANUAL APPLICABLE MODEL: LT-A700XK5 EFFECTIVE ENGINE OR FRAME NO.: REFERENCE: E-17, 24, 28, 33 This bulletin is to inform you of correction and additional information in the service manual for the above model. Please correct and add this information to the following service manual and send this information to your dealers. LT-A700X SERVICE MANUAL (Book): E (Pages 5-45 and 5-58) CONTENTS PAGE FI SYSTEM DIAGNOSIS... 2 C20 (P1752) DIFF-LOCK RELAY CIRCUIT MALFUNCTION.. 2 (5-45) C40 (P0505) ISC VALVE CIRCUIT MALFUNCTION... 5 (5-58)

FI SYSTEM DIAGNOSIS C20 (P1752) DIFF-LOCK RELAY CIRCUIT MALFUNCTION DETECTED CONDITION No voltage is applied to diff-lock motor, although ignition switch is turned ON, or voltage is applied to

2 FI SYSTEM DIAGNOSIS C20 (P1752) DIFF-LOCK RELAY CIRCUIT MALFUNCTION DETECTED CONDITION No voltage is applied to diff-lock motor, although ignition switch is turned ON, or voltage is applied to diff-lock motor, although ignition switch is turned OFF. POSSIBLE CAUSE Diff-lock relay circuit open or short. Diff-lock relay malfunction. ECM malfunction. ECM Diff-lock relay Y/B B/G Diff-lock relay O/Y B Ignition fuse Ignition switch Main fuse Transfer selecting switch W/Bl Br W Diff-lock motor INSPECTION Step 1 1) Remove the rear fender (!8-10). 2) Connect the disconnected couplers and battery. 3) Turn the ignition switch OFF. 4) Check the diff-lock relay coupler for loose or poor contacts. 5) If OK, then check the diff-lock relay insulation and continuity. (!9-23) Is the diff-lock relay OK? 1 YES NO Inspect the transfer selecting switch. (!9-37) Y/B wire open or shorted to ground, or poor K connection. If wire and connection are OK, intermittent trouble or faulty ECM. Recheck each terminal and wire harness for open circuit and poor connection. Replace the ECM with a known good one, and inspect it again. Replace the diff-lock relay with a new one. Wire harness side 5) After repairing the trouble, clear the DTC using SDS tool. (!5-23) 2

(Refer to the SDS operation manual for further details.) 3) Open the Data monitor.

3 SDS operation check (Transfer selecting switch) 1) Check that the transfer selecting switch (diff-lock position switch 1 and diff-lock switch 2) is turned OFF. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Open the Data monitor. 4) Check that both Differential lock position switch signal 3 and Differential lock switch signal 4 are Open. 3

4 5) Turn the transfer selecting switch (diff-lock position switch and diff-lock switch) ON position. 6) Check that both Differential lock position switch signal 5 and Differential lock switch signal 6 are GND. If the transfer selecting switch dose not function properly, inspect the transfer selecting switch for details. (!9-37) 4

C40 (P0505) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION No voltage is applied to ISC valve motor, although ignition switch is turned ON, or voltage is applied to ISC valve motor, although

ISC valve B/Lg R/B P/W ECM IS1A BATT IS1B M G W/Bl IS2A IS2B " Be careful not to disconnect at least 3 seconds after ignition switch is turned to OFF.

5 C40 (P0505) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION No voltage is applied to ISC valve motor, although ignition switch is turned ON, or voltage is applied to ISC valve motor, although ignition switch is turned OFF. POSSIBLE CAUSE ISC valve circuit open or short. ISC valve malfunction. ECM malfunction. ISC valve B/Lg R/B P/W ECM IS1A BATT IS1B M G W/Bl IS2A IS2B " Be careful not to disconnect at least 3 seconds after ignition switch is turned to OFF. If the ECM coupler is disconnected within 3 seconds after ignition switch is turned to OFF, there is a possibility of an usual value being written in ECM and causing an error of ISC valve operation. INSPECTION Step 1 1) Remove the left side cover. (!8-8) 2) Turn the ignition switch OFF. 3) Check the ISC valve coupler for loose or poor contacts. 4) If OK, then check the ISC valve lead wire continuity. 1 5) Disconnect the ISC valve coupler. 6) Check the continuity between terminals A and X, terminals B and 4, terminals C and G, terminals D and W, terminals E and 4 and terminals F and F. 1 # ISC valve wire continuity: Continuity ($) % : Multi-circuit tester set 5

(Terminal 1 Terminal 3) (Terminal 2 Terminal 4) Approx. 31 ± 3 kω (Terminal 3 Terminal 4) (Terminal 1 Terminal 2) Is the resistance OK?

6 Tester knob indication: Continuity test ($) Is the continuity OK? 1 YES NO Go to Step2 B/Lg, R/B, P/W, G or W/Bl wire open. Terminal side Step 2 Measure the resistance between terminals 1 and 2, terminals 3 and 4. 2 # ISC valve resistance: Approx. (Terminal 1 Terminal 3) (Terminal 2 Terminal 4) Approx. 31 ± 3 kω (Terminal 3 Terminal 4) (Terminal 1 Terminal 2) Is the resistance OK? 2 YES NO If wire is OK, intermittent trouble or faulty ECM. Replace the ISC valve with a new one. After repairing the trouble, clear the DTC using SDS tool. (!5-23) 6

ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running.

7 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Check that the Engine coolant/oil temperature is more than 70 C (158 F). 4) Click the Active control. 5) Click the ISC rpm control 1. 6) Check that the Spec 2 is rpm. 7) Check that the Desired idle speed 3 is rpm. 7

Check 2 1) Click the button 4 and decrease the Spec 2 to 1 000 rpm slowly. 2) Check that the Desired idle speed 3 is equal to the Spec 2.

8 Check 2 1) Click the button 4 and decrease the Spec 2 to rpm slowly. 2) Check that the Desired idle speed 3 is equal to the Spec 2. 3) Check that the Engine speed 5 is close to the Spec 2. 4) Click the button 1 and increase the Spec 2 slowly. 5) Check that the Desired idle speed 3 is equal to the Spec 2. 8

Check 3 1) Click the button 1 and increase the Spec 2 to 1 600 rpm slowly. 2) Check that the Desired idle speed 3 is equal to the Spec 2.

" Be careful not to increase the Spec to 1 650 rpm, or the Engine speed may reach the upper limit. Check 4 1) Check that the Spec 1 is 1 600 rpm.

9 Check 3 1) Click the button 1 and increase the Spec 2 to rpm slowly. 2) Check that the Desired idle speed 3 is equal to the Spec 2. 3) Check that the Engine speed 4 is close to the Spec 2. 4) Check that the ISC valve position 5 increases. " Be careful not to increase the Spec to rpm, or the Engine speed may reach the upper limit. Check 4 1) Check that the Spec 1 is rpm. 2) Check that the Desired idle speed 2 is rpm. 3) Check that the Engine speed 3 is close to rpm. If the ISC valve does not function propely, inspect the ISC valve for details. (!5-58) 9

BODY ELECTRICAL SYSTEM

BODY ELECTRICAL SYSTEM 8-1 SECTION 8 BODY ELECTRICAL SYSTEM WARNING: For vehicles equipped with Supplemental Restraint (Air Bag) System: Service on and around the air bag system components or wiring must