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SHOP MANUAL
CRF1000A/A2/AL/AL2/
D/D2/DL/DL2
CRF1000A/A2/AL/AL2/D/D2/DL/DL2
J
26-1
26
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26. CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
A Few Words About Safety ·······················26-2
INTRODUCTION··········································26-3
SERVICE RULES ········································26-4
MODEL IDENTIFICATION ··························26-5
SPECIFICATIONS ·······································26-7
TORQUE VALUES ····································26-13
LUBRICATION & SEAL POINTS··············26-16
CABLE & HARNESS ROUTING ···············26-17
TECHNICAL FEATURE ····························26-38
BODY PANEL LOCATIONS ·····················26-39
WINDSCREEN···········································26-41
MIDDLE COWL ·········································26-42
FRONT COVER ·········································26-44
INNER PANEL COVER ·····························26-45
SKID PLATE··············································26-46
FRONT SIDE PIPE ····································26-47
SEAT CATCH STAY ·································26-48
ETC TRAY ·················································26-49
SIDE COVER ·············································26-49
REAR SIDE INNER BODY ························26-51
REAR CARRIER········································26-52
CARRIER BRACKET ································26-53
REAR CENTER COWL ·····························26-54
REAR FENDER A······································26-54
REAR FENDER B······································26-56
MUFFLER/EXHAUST PIPE·······················26-58
SIDESTAND ··············································26-60
FRONT NUMBER STAY
(IN model only) ·········································26-60
MAINTENANCE SCHEDULE····················26-61
THROTTLE OPERATION··························26-63
SPARK PLUG············································26-63
PGM-FI SYSTEM LOCATION ···················26-64
PGM-FI SYSTEM DIAGRAM·····················26-65
PGM-FI DTC INDEX ··································26-67
PGM-FI DTC TROUBLESHOOTING·········26-70
MIL CIRCUIT TROUBLESHOOTING······26-115
ECM (CRF1000A/A2/AL/AL2)/
PCM (CRF1000D/D2/DL/DL2)
(PGM-FI SYSTEM) ··································26-115
GRIP APS/
RIGHT HANDLEBAR SWITCH ···············26-116
TBW RELAY············································26-122
IGNITION SYSTEM
SYSTEM DIAGRAM ································26-123
IGNITION SYSTEM INSPECTION ··········26-124
IGNITION COIL········································26-124
ELECTRIC STARTER SYSTEM
DIAGRAM················································26-127
FUEL TANK ············································ 26-128
AIR CLEANER HOUSING ······················26-128
THROTTLE BODY ··································26-128
EVAP CANISTER
(ED/KO/TH/FO/MA models) ···················26-131
RADIATOR·············································· 26-132
RIGHT CRANKCASE COVER
(CRF1000A2/AL2)···································26-133
DCT SYSTEM DIAGRAM ······················· 26-134
DCT DTC INDEX ····································· 26-135
DCT DTC TROUBLESHOOTING ··········· 26-140
A/M SWITCH TROUBLESHOOTING ····· 26-177
RIGHT CRANKCASE COVER
(CRF1000D2/DL2)···································26-178
ENGINE REMOVAL ································ 26-178
ENGINE INSTALLATION························ 26-180
SWINGARM ············································26-181
FRONT BRAKE CALIPER······················ 26-182
ABS SYSTEM DIAGRAM ······················· 26-183
ABS DTC INDEX·····································26-184
ABS DTC TROUBLESHOOTING ··········· 26-186
ABS MODULATOR································· 26-195
BATTERY/CHARGING SYSTEM SERVICE
INFORMATION ······································· 26-197
BATTERY/CHARGING SYSTEM
TROUBLESHOOTING ···························· 26-198
BATTERY················································ 26-199
CHARGING SYSTEM INSPECTION ······ 26-200
TURN SIGNAL LIGHT/RELAY ··············· 26-201
COMBINATION METER ·························26-204
GEAR POSITION SENSOR
(CRF1000A/A2/AL/AL2) ························· 26-205
NEUTRAL SWITCH
(CRF1000A/AL/A2/AL2) ························· 26-206
SHIFT SPINDLE SWITCH
(CRF1000A/AL/A2/AL2) ························· 26-206
GRIP HEATER
(CRF1000A2/AL2/D2/DL2) ····················· 26-207
IMMOBILIZER SYSTEM (HISS) SYSTEM
DIAGRAM················································26-218
IMMOBILIZER SYSTEM (HISS)
TROUBLESHOOTING ···························· 26-220
ECM (CRF1000A/A2/AL/AL2)/
PCM (CRF1000D/D2/DL/DL2) (HISS) ···· 26-222
IMMOBILIZER RECEIVER······················ 26-222
WIRING DIAGRAM
(CRF1000A/A2/AL/AL2) ························· 26-225
WIRING DIAGRAM
(CRF1000D/D2/DL/DL2) ························· 26-226
26-2
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
26-3
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
INTRODUCTION
This addendum contains information for the CRF1000A/D/A2/D2/AL/DL/AL2/DL2-J.
Refer to CRF1000/A/D-G, H SHOP MANUAL (No. 62MJP00) and CRF1000/A/D-H, J SHOP MANUAL (No. 62MJP01Z) for service
procedures and data not included in this addendum.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: November, 2017
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
26-4
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design
specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 26-17).
9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
ABS Anti-lock Brake System
APS Accelerator Position Sensor
CAN Controller Area Network
CKP sensor Crankshaft Position sensor
DCT Dual Clutch Transmission
DLC Data Link Connector
DTC Diagnostic Trouble Code
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
EEPROM Electrically Erasable Programmable Read Only Memory
EOP sensor Engine Oil Pressure sensor
EOT sensor Engine Oil Temperature sensor
ESS Emergency Stop Signal
EVAP Evaporative Emission
GST Generic Scan Tool
HSTC Honda Selectable Torque Control
IACV Idle Air Control Valve
IAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MCS Motorcycle Communication System
MIL Malfunction Indicator Lamp
PAIR Pulse Secondary Air Injection
PCM Powertrain Control Module
PGM-FI Programmed Fuel Injection
SCS short connector Service Check Signal short connector
TBW Throttle By Wire
TP sensor Throttle Position sensor
TR sensor Transmission Range Sensor
VS sensor Vehicle Speed sensor
26-5
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DESTINATION CODE
Throughout this manual, the following codes are used to identify individual models for each region.
MODEL IDENTIFICATION
SERIAL NUMBER
DESTINATION CODE REGION
BR, IIBR, IIIBR, IVBR Brazil
CH, IICH, IVCH China
ED, IIED, IIIED, IVED European direct sales
GS, IIGS, IIIGS, IVGS Gulf countries
II-IN, III-IN, IV-IN Indonesia
KO, IIKO, IIIKO, IVKO Korea
RU, IIRU, IIIRU Russia
TH, IITH, IIITH, IVTH Thailand
U, IIU, IIIU, IVU Australia, New Zealand
IIFO, IIIFO Taiwan
IIIMA, IVMA Malaysia
CRF1000D2 shown:
The throttle body identification number [1] is stamped on the
upper front left side of the throttle body as shown.
[1]
26-6
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
TYPES
TYPE CODE DESTINATION
CODE
Manual
Transmission
DCT ABS HSTC EVAP ACCESSORY
SOCKET
CRF1000A ED, IIED, IIIED – –
IIFO, IIIFO – –
GS, IIGS, IIIGS – – –
IIKO, IIIKO – –
U, IIU, IIIU – – –
CRF1000A2 IVED –
IVGS – –
IVU – –
CRF1000AL IIIMA – –
III-IN – – –
TH, IITH, IIITH – –
CRF1000AL2 IVMA –
IVTH –
CRF1000D ED, IIED, IIIED – –
GS, IIGS, IIIGS – – –
IIKO, IIIKO – –
U, IIU, IIIU – – –
CRF1000D2 IVED –
IVGS – –
IVKO –
IVU – –
CRF1000DL IIIMA – –
III-IN – – –
TH, IITH, IIITH – –
CRF1000DL2 IVMA –
IV-IN – –
IVTH –
26-7
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length CRF1000A//D 2,330 mm (91.7 in)
CRF1000A2//D2 2,340 mm (92.1 in)
CRF1000AL/AL2/DL/DL2 2,310 mm (90.9 in)
Overall width 930 mm (36.6 in)
Overall height CRF1000A/D 1,475 mm (58.1 in)
CRF1000A2/D2 1,570 mm (61.8 in)
CRF1000AL/DL 1,435 mm (56.5 in)
CRF1000AL2/DL2 1,510 mm (59.4 in)
Wheelbase CRF1000A/D Except FO models 1,575 mm (62.0 in)
FO model 1,570 mm (61.8 in)
CRF1000A2/D2 1,580 mm (62.2 in)
CRF1000AL/
AL2/DL/DL2
Except IN models 1,560 mm (61.4 in)
IN model 1,555 mm (61.2 in)
Seat height CRF1000A/D Standard position 870 mm (34.3 in)
Low position 850 mm (33.5 in)
CRF1000A2/
D2
Standard position 920 mm (36.2 in)
Low position 900 mm (35.4 in)
CRF1000AL/DL 830 mm (32.7 in)
CRF1000AL2/DL2 860 mm (33.9 in)
Footpeg height CRF1000A/D 352 mm (13.9 in)
CRF1000A2/D2 372 mm (14.6 in)
CRF1000AL/AL2/DL/DL2 313 mm (12.3 in)
Ground clearance CRF1000A/D 250 mm (9.8 in)
CRF1000A2/D2 270 mm (10.6 in)
CRF1000AL/AL2/DL/DL2 210 mm (8.3 in)
Curb
weight
CRF1000A U/GS models 229 kg (505 lbs)
ED/KO/FO models 230 kg (507 lbs)
CRF1000A2 U/GS models 242 kg (534 lbs)
ED model 243 kg (536 lbs)
CRF1000AL 229 kg (505 lbs)
CRF1000AL2 242 kg (534 lbs)
CRF1000D U/GS/ models 239 kg (527 lbs)
ED/KO models 240 kg (529 lbs)
CRF1000D2 ED model 253 kg (558 lbs)
KO model 255 kg (562 lbs)
GS/U models 252 kg (556 lbs)
CRF1000DL IN model 240 kg (529 lbs)
MA/TH models 239 kg (527 lbs)
CRF1000DL2 252 kg (556 lbs)
Maximum weight capacity CRF1000A/AL/D/DL 213 kg (470 lbs)
CRF1000A2/D2/AL2/DL2 195 kg (430 lbs)
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRAME Frame type Semi double cradle
Front suspension Telescopic fork
Front axle travel CRF1000A/AL/D/DL 204 mm (8.0 in)
CRF1000A2/AL2/D2/DL2 224 mm (8.8 in)
Rear suspension Swingarm
Rear axle travel CRF1000A/AL/D/DL 220 mm (8.7 in)
CRF1000A2/AL2/D2/DL2 240 mm (9.4 in)
Front tire size 90/90-21M/C 54H
Rear tire size 150/70R18M/C 70H
Front tire brand D610FW (DUNLOP)
A41F G (BRIDGESTONE)
Rear tire brand D610W (DUNLOP)
A41R G (BRIDGESTONE)
Front brake Hydraulic double disc
Rear brake Hydraulic single disc
Caster angle 27° 30’
Trail length CRF1000A/AL/D/DL 113 mm (4.4 in)
CRF1000A2/AL2/D2/DL2 111 mm (4.4 in)
Fuel tank capacity CRF1000A/AL/D/DL 18.8 liters
(4.97 US gal, 4.14 Imp gal)
CRF1000A2/AL2/D2/DL2 24.2 liters
(6.39 US gal, 5.32 Imp gal)
ENGINE Cylinder arrangement 2 cylinders in-line, slant
angle 22.5°
Bore and stroke Except TH model 92.0 x 75.1 mm
(3.62 x 2.96 in)
TH models 92.000 x 75.148 mm
(3.6220 x 2.9586 in)
Displacement Except TH model 998 cm
3
(60.9 cu-in)
TH model 999.11 cm
3
(60.946 cu-in)
Compression ratio 10.0 : 1
Valve train Chain driven, OHC with
valve lifter and rocker arm
Intake
valve
opens at 1 mm (0.04 in) lift 5° BTDC
closes at 1 mm (0.04 in) lift 40° ABDC
Exhaust
valve
opens at 1 mm (0.04 in) lift 40° BBDC
closes at 1 mm (0.04 in) lift 5° ATDC
Lubrication system Forced pressure and dry
sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper element
Engine dry weight 76.4 kg (168.4 lbs)
Firing order 1 - 2
FUEL
DELIVERY
SYSTEM
Type PGM-FI
Throttle bore
44 mm (1.73 in)
DRIVE TRAIN
(CRF1000A/A2/
AL/AL2)
Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission Constant mesh, 6-speeds
Primary reduction 1.733 (78/45)
Final reduction Except FO/IN models 2.625 (42/16)
FO/IN models 2.470 (42/17)
Gear ratio 1st 2.866 (43/15)
2nd 1.888 (34/18)
3rd 1.480 (37/25)
4th 1.230 (32/26)
5th 1.100 (33/30)
6th 0.968 (31/32)
Gearshift pattern Left foot operated return
system,
1 - N - 2 - 3 - 4 - 5 - 6
ITEM SPECIFICATIONS
26-9
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FUEL SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
DRIVE TRAIN
(CRF1000D/D2/
DL/DL2)
Clutch system 2 Multi-plate wet clutches
Clutch operation system Automatic
Transmission Constant mesh, 6-speeds
Primary reduction 1.883 (81/43)
Final reduction Except IN models 2.625 (42/16)
IN model 2.470 (42/17)
Gear ratio 1st 2.562 (41/16)
2nd 1.761 (37/21)
3rd 1.375 (33/24)
4th 1.133 (34/30)
5th 0.972 (36/37)
6th 0.882 (30/34)
Gearshift pattern Automatic and electric shift
(left hand operated) return
system,
N - 1 - 2 - 3 - 4 - 5 - 6
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output
alternator
Regulator/rectifier FET shorted/triple phase
full wave rectification
Lighting system Battery
ITEM SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identification
number
Except GS/U/IN
models
GNH3A
GS/U/IN models GNH3B
Engine idle speed 1,250 ± 100 min
-1
(rpm)
Fuel pressure at idle 324 – 367 kPa (3.3 – 3.7 kgf/cm
2
, 47 – 53 psi)
Fuel pump flow (at 12 V) 319 cm
3
(10.8 US oz, 11.2 Imp oz) minimum/10 seconds
ITEM SPECIFICATIONS
Coolant
capacity
Radiator and engine 1.65 liters (1.74 US qt, 1.45 Imp qt)
Reserve tank 0.33 liter (0.35 US qt, 0.29 Imp qt)
Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm
2
, 16 – 20 psi)
Thermostat Begin to open 80 – 84°C (176 – 183°F)
Fully open 95°C (203°F)
Valve lift 8 mm (0.3 in) minimum
Recommended
antifreeze
Except IN/TH/MA models High quality ethylene glycol antifreeze containing
silicate-free corrosion inhibitors
IN/TH/MA models Honda PRE-MIX coolant
Standard coolant
concentration
Except IN/TH/MA models
1:1 mixture with distilled water
26-10
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire
pressure
Driver only CRF1000A/AL/D/DL 200 kPa (2.00 kgf/cm
2
, 29 psi) –
CRF1000A2/AL2/D2/
DL2
225 kPa (2.25 kgf/cm
2
, 33 psi) –
Driver and passenger 225 kPa (2.25 kgf/cm
2
, 33 psi) –
Axle runout – 0.2 (0.01)
Wheel rim
runout
Radial – 1.0 (0.04)
Axial – 1.0 (0.04)
Wheel hub-to-rim distance 28.5 – 30.5 (1.12 – 1.20) –
Wheel balance weight – 60 g (2.1 oz) max.
Fork Spring free
length
CRF1000A/D 433.7 (17.07) 425.0 (16.73)
CRF1000A2/D2 465.7 (18.33) 456.4 (17.97)
CRF1000AL/AL2/DL/
DL2
394.2 (15.52) 386.3 (15.21)
Recommended fork fluid Honda Ultra Cushion Oil 10W –
Fluid level CRF1000A/D 95.0 (3.74) –
CRF1000A2/D2 110.0 (4.33) –
CRF1000AL/AL2/DL/
DL2
104.0 (4.09) –
Fluid
capacity
CRF1000A/D 721 ± 2.5 cm
3
(24.4 ± 0.1 US oz,
25.4 ± 0.1 Imp oz)
–
CRF1000A2/D2 695 ± 2.5 cm
3
(23.5 ± 0.1 US oz,
24.5 ± 0.1 Imp oz)
–
CRF1000AL/AL2/DL/
DL2
710 ± 2.5 cm
3
(24.0 ± 0.1 US oz,
25.0 ± 0.1 Imp oz)
–
Pre-load
adjuster
standard
position
CRF1000A/A2/AL/DL 5 turns from the full soft position –
CRF1000D/D2 8.5 turns from the full soft position –
CRF1000AL2/DL2 10.5 turns from the full soft position –
Rebound
adjuster
standard
position
CRF1000A/A2/D/D2 2 1/4 turns from maximum position –
CRF1000AL/AL2/DL/
DL2
2 1/2 turns from maximum position –
Compression
adjuster
standard
position
CRF1000A/D 8 clicks from maximum position –
CRF1000A2/D2 4 clicks from maximum position –
CRF1000AL/AL2/DL/
DL2
10 clicks from maximum position –
Steering head bearing pre-load 9.8 – 14.7 N (1.0 – 1.5 kgf, 2.2 – 3.3 lbf) –
26-11
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit: mm (in)
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Cold tire
pressure
Driver only CRF1000A/AL/D/DL 250 kPa (2.50 kgf/cm
2
, 36 psi) –
CRF1000A2/AL2/D2/DL2 280 kPa (2.80 kgf/cm
2
, 41 psi) –
Driver and passenger 280 kPa (2.80 kgf/cm
2
, 41 psi) –
Axle runout – 0.2 (0.01)
Wheel rim runout Radial – 1.0 (0.04)
Axial – 1.0 (0.04)
Wheel hub-to-rim distance 5.2 – 7.2 (0.205 – 0.283) –
Wheel balance weight – 60 g (2.1 oz) max.
Drive
chain
Slack CRF1000A/AL/D/DL 35 – 45 (1.4 – 1.8) –
CRF1000A2/AL2/D2/DL2 45 – 55 (1.8 – 2.2) –
Size/link DID525HV3-124LE –
Shock
absorber
Pre-load adjuster standard position 7 clicks from minimum position
(first click is "0" position)
–
Rebound
adjuster
standard
setting
CRF1000A/D 9 clicks from maximum position –
CRF1000A2/D2 13 clicks from maximum position –
CRF1000AL/DL/AL2/DL2 17 clicks from maximum position
–
Compress
ion
adjuster
standard
position
CRF1000A/D 14 clicks from maximum position –
CRF1000A2/D2 19 clicks from maximum position –
CRF1000AL/DL/AL2/DL2 13 clicks from maximum position –
ITEM SPECIFICATIONS
Battery Type HY110
Capacity 12 V – 6.0 Ah (20 HR)
Current leakage 0.66 mA max.
Voltage
(20°C/68°F)
Fully charged 13.5 – 14.0 V
Needs charging Below 10.8 V
Alternator Capacity 0.49 kW/5,000 min
-1
(rpm)
Charging coil resistance (20°C/68°F) 0.1 – 1.0
26-12
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight Hi LED
Lo LED
Brake/taillight LED
Position light LED
Front turn signal light LED
Rear turn signal light LED
License light 12 V – 5 W
Instrument light LED
Turn signal indicator LED
High beam indicator LED
Neutral indicator LED
Low oil pressure indicator LED
Fuel reserve indicator LED
MIL LED
High coolant temperature indicator LED
HISS indicator LED
ABS indicator LED
Rear ABS indicator LED
Parking brake indicator
(CRF1000D/D2/DL/DL2)
LED
Torque control indicator LED
Torque control off indicator LED
Fuse Main fuse 30 A
FI fuse 15 A
ABS M fuse 30 A
ABS FSR fuse 30 A
DCT M fuse (CRF1000D/D2/DL/DL2) 30 A
Sub
fuse
CRF1000A/A2/AL/AL2 20 A x 2, 10 A x 6
CRF1000D/D2/DL/DL2 20 A x 2, 10 A x 7
ECT sensor resistance 40°C (104°F) 1.0 – 1.3 k
100°C (212°F) 0.14 – 0.18 k
Open air temperature sensor resistance 25°C (77°F) 4.9 – 5.1 k
Fuel level sensor resistance Full 6.4 – 10.4
Empty 204.8 – 210.8
26-13
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
TORQUE VALUES
ENGINE & FRAME TORQUE VALUES
FRAME BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm)
N·m (kgf·m,
lbf·ft)
Windscreen mounting screw 4 5 0.42 (0.04, 0.3)
Skid plate mounting bolt 3 8 26 (2.7, 19)
Front side cover mounting screw
(CRF1000A2/D2/AL2/DL2)
6 5 0.42 (0.04, 0.3)
Left rear cover mounting bolt 2 6 12 (1.2, 9)
Pillion step bracket mounting bolt 4 8 32 (3.3, 24)
Brake hose oil bolt 2 10 34 (3.5, 25)
Brake pipe joint 2 10 14 (1.4, 10) Apply brake fluid to the threads.
Exhaust pipe cover C pan screw 3 6 9.0 (0.9, 6.6)
Exhaust outer cover screw 1 6 9.0 (0.9, 6.6)
Exhaust pipe joint nut 4 8 20 (2.0, 15)
Exhaust pipe cover A pan screw 1 6 9.0 (0.9, 6.6)
Exhaust pipe cover B front band
screw
1 – 1.2 (0.1, 0.9)
Exhaust pipe cover B rear band
screw
1 – 3.5 (0.4, 2.6)
Muffler band bolt 2 8 17 (1.7, 13)
Muffler cover pan screw 2 6 9.0 (0.9, 6.6)
Tail cap cover bolt 2 6 9.0 (0.9, 6.6)
Exhaust pipe stud bolt 4 8 – See page 2-18
Sidestand pivot nut 1 10 42 (4.3, 31) See page 26-60
Self-lock nut
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm)
N·m (kgf·m,
lbf·ft)
Air cleaner element mounting screw 4 5 1.1 (0.1, 0.8) Tapping screw
Air cleaner cover screw 8 5 1.1 (0.1, 0.8) Tapping screw
Spark plug 4 10 22 (2.2, 16)
Valve adjusting screw lock nut 4 5 10 (1.0, 7) Apply engine oil to the threads and
seating surface.
Timing hole cap 1 14 6.0 (0.6, 4.4) Apply grease to the threads.
Crankshaft hole cap 1 30 8.0 (0.8, 5.9) Apply grease to the threads.
Engine oil drain bolt 2 12 30 (3.1, 22)
Oil filter boss (crankcase side) 1 20 – Apply locking agent to the threads.
See page 3-12
Engine oil filter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads.
Clutch oil filter cover bolt
(CRF1000D/D2/DL/DL2)
2 6 12 (1.2, 9)
Rear axle nut 1 18 100 (10.2, 74) Self-lock nut
Drive chain adjuster lock nut 2 8 27 (2.8, 20) UBS-nut
Drive sprocket bolt 1 10 54 (5.5, 40)
Driven sprocket nut 5 12 100 (10.2, 74) Apply engine oil to the threads and
seating surface.
Self-lock nut
Parking brake adjuster lock nut
(CRF1000D/D2/DL/DL2)
1 8 17.2 (1.8, 13)
Front spoke 36 BC 3.5 3.7 (0.4, 2.7)
Rear spoke 32 BC 3.5 3.7 (0.4, 2.7)
26-14
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ENGINE REMOVAL/INSTALLATION
LIGHTS/METERS/SWITCHES
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m,
lbf·ft)
Right lower frame bolt 4 10 44 (4.5, 32)
Swingarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and
seating surface.
Self-lock nut
Rear lower nut (10 mm) 1 10 44 (4.5, 32)
Front lower nut (10 mm) 1 10 44 (4.5, 32)
Front middle nut (8 mm) 2 8 32 (3.3, 24)
Front middle nut (10 mm) 1 10 44 (4.5, 32)
Front upper bolt 3 8 32 (3.3, 24)
Rear upper bolt (8 x 25 mm) 2 8 32 (3.3, 24)
Rear upper nut (8 mm) 1 8 32 (3.3, 24)
Drive sprocket bolt 1 10 54 (5.5, 40)
EOT sensor
(CRF1000D/D2/DL/DL2)
1 10 15 (1.5, 11)
Clutch EOP sensor wire stay bolt
(CRF1000D/D2/DL/DL2)
1 6 12 (1.2, 9)
Clutch EOP sensor cover bolt
(CRF1000D/D2/DL/DL2)
2 6 10 (1.0, 7)
Shift spindle switch terminal nut
(CRF1000A/A2/AL/AL2)
1 4 1.7 (0.2, 1.3)
Neutral switch terminal nut
(CRF1000A/A2/AL/AL2)
1 4 1.7 (0.2, 1.3)
Neutral switch terminal nut
(CRF1000D/D/DL/DL2)
1 4 1.7 (0.2, 1.3)
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m,
lbf·ft)
License light cover screw 2 5 3.8 (0.4, 2.8)
Combination meter mounting screw/
washer
4 5 1.0 (0.1, 0.7) Tapping screw
EOP switch
(CRF1000A/A2/AL/AL2)
1 PT 1/8 12 (1.2, 9) Apply sealant to the threads.
See page 22-19
EOP switch terminal bolt/washer
(CRF1000A/A2/AL/AL2)
1 4 2.0 (0.2, 1.5)
EOP sensor
(CRF1000D/D2/DL/DL2)
1 10 22 (2.2, 16)
Ignition switch mounting bolt 2 8 26 (2.7, 19) Replace with a new one.
Sidestand switch mounting bolt 1 6 10 (1.0, 7) Replace with a new one.
Gear position sensor mounting bolt
(CRF1000A/A2/AL/AL2)
1 6 12 (1.2, 9)
Neutral switch
(CRF1000A/A2/AL/AL2)
1 10 12 (1.2, 9)
Neutral switch terminal nut
(CRF1000A/A2/AL/AL2)
1 4 1.7 (0.2, 1.3)
Shift spindle switch
(CRF1000A/A2/AL/AL2)
1 10 12 (1.2, 9)
Shift spindle switch terminal nut
(CRF1000A/A2/AL/AL2)
1 4 1.7 (0.2, 1.3)
26-15
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
OTHERS
*1: Apply locking agent to the threads as shown.
*2: Apply locking agent to the threads as shown.
ITEM Q'TY THREAD TORQUE REMARKS
DIA. (mm) N·m (kgf·m,
lbf·ft)
Clutch lever pivot bolt
(CRF1000A/A2/AL/AL2)
1 6 1.0 (0.1, 0.7)
Clutch lever pivot nut
(CRF1000A/A2/AL/AL2)
1 6 5.9 (0.6, 4.4) Self-lock nut
Lower crankcase sealing bolt
(18 mm)
(After '17 except BR model)
2 18 29 (3.0, 21) Apply locking agent to the threads.
Coating width:5 ± 1 mm (0.2 ± 0.04
in) except 2 ± 1 (0.1 ± 0.04 in) from
bolt end
2.0 ± 1.0 mm
(0.08 ± 0.04 in)
Do not apply this area.
6.5 ± 1.0 mm
(0.26 ± 0.04 in)
Apply this area.
The bolt shown is typical.
6.5 ± 1.0 mm
(0.26 ± 0.04 in)
The bolt shown is typical.
Apply this area.
26-16
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
LUBRICATION & SEAL POINTS
FRAME
MATERIAL LOCATION REMARKS
Urea based multi-purpose
extreme pressure grease
NLGI #2 (EXCELITE EP2
manufactured by KYODO
YUSHI CO., LTD. or
equivalent)
Steering head bearing rolling contact surface 3 – 5 g (0.1 – 0.2 oz)
Steering head dust seal lips
Lithium based multi-purpose
grease NLGI #2 or equivalent
Seat catch hook sliding area
Gearshift pedal pivot sliding area (grease groove)
(CRF1000A/A2/AL/AL2)
Throttle cable end and throttle grip pipe flange groove
Wheel dust seal lips
Rear wheel hub O-ring (driven flange side)
Rear brake middle arm pivot sliding surface
Parking brake stopper stay teeth and lock lever pivot
sliding surface (CRF1000D/D2/DL/DL2)
Parking brake lever pivot sliding surface
(CRF1000D/D2/DL/DL2)
Clutch lever pivot sliding area (CRF1000A/A2/AL/AL2)
Throttle pipe-to-APS contacting area See page 26-116
Molybdenum disulfide grease
(containing more than 3%
molybdenum disulfide, NLGI
#2 or equivalent)
Sidestand collar outer surface
Sidestand pivot sliding surface
Swingarm pivot dust seal lips
Swingarm pivot needle bearings
Cushion arm dust seal lips
Cushion arm needle bearings
Cushion connecting rod needle bearings
Cable lubricant Seat lock cable outer inside
Honda Bond A or an
equivalent
Handlebar grip rubber inside
ThreeBond 1521 or an
equivalent
Swingarm cap mating surface
Rear brake pad retainer mating surface
Silicone grease Front brake lever pivot bolts sliding surface 0.10 g (0.004 oz) minimum
Front brake lever-to-master piston contacting area 0.10 g (0.004 oz) minimum
Rear brake master cylinder push rod sliding surface 0.10 g (0.004 oz) minimum
Rear brake master cylinder push rod boot fitting area 0.10 g (0.004 oz) minimum
Rear brake pad pin stopper ring
Brake caliper dust seals
Rear brake caliper sleeve sliding surface 0.4 g (0.01 oz) minimum
Rear brake caliper pin bolt sliding surface 0.4 g (0.01 oz) minimum
Parking brake push rod rolling surface
(CRF1000D/D2/DL/DL2)
0.4 g (0.01 oz) minimum
Parking brake piston sliding surface
(CRF1000D/D2/DL/DL2)
0.4 g (0.01 oz) minimum
Parking brake shaft threads (CRF1000D/D2/DL/DL2) 0.4 g (0.01 oz) minimum
Parking brake shaft boot lips (CRF1000D/D2/DL/DL2) 0.4 g (0.01 oz) minimum
Parking brake pin bolt sliding surface
(CRF1000D/D2/DL/DL2)
0.4 g (0.01 oz) minimum
Parking brake caliper bracket pin sliding surface
(CRF1000D/D2/DL/DL2)
0.4 g (0.01 oz) minimum
DOT 4 brake fluid Brake master piston and cups
Brake caliper piston
Brake caliper piston seals
Rear master cylinder reservoir hose joint O-ring
Fork fluid Fork cap O-ring
Fork dust seal and oil seal lips
Dive chain lubricant designed
specifically for O-ring chains
or SAE #80-90 gear oil
Drive chain whole surface
26-17
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CABLE & HARNESS ROUTING
CRF1000A/A2/AL/AL2: CLUTCH CABLE
CRF1000D/D2/DL/DL2: PARKING BRAKE CABLE
LEFT HANDLEBAR
SWITCH WIRE
FRONT BRAKE HOSE A
LEFT HANDLEBAR
SWITCH WIRE
5 mm (0.2 in)
maximum
Front
RIGHT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
CLAMP
(Clamp to brake hose end)
RIGHT HANDLEBAR
SWITCH WIRE
26-18
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
100 – 120 mm
(3.9 – 4.7 in)
70 mm (2.8 in)
RIGHT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
FRONT BRAKE HOSE A
FRONT BRAKE HOSE D
LEFT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
IGNITION
SWITCH WIRE
IMMOBILIZER
RECEIVER WIRE
RIGHT HANDLEBAR
SWITCH WIRE
RIGHT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
RIGHT HANDLEBAR
SWITCH WIRE
LEFT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
RIGHT HANDLEBAR
SWITCH WIRE
Front
CLAMP
(Clamp on a cable protector)
RIGHT HANDLEBAR
SWITCH WIRE
CRF1000A/A2/AL/AL2: CLUTCH CABLE
CRF1000D/D2/DL/DL2: PARKING BRAKE CABLE
FRONT BRAKE HOSE A
LEFT HANDLEBAR
SWITCH WIRE
Front
FRONT BRAKE HOSE A
RIGHT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
RIGHT HANDLEBAR
SWITCH WIRE
Front
26-19
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRONT SUB HARNESS 2
12P (GRAY) CONNECTOR
FRONT SUB HARNESS 3
12P (BLACK) CONNECTOR
FRONT SUB HARNESS 1
12P (BLACK) CONNECTOR
ACCESSORY SOCKET
2P (BLACK) CONNECTOR
(CRF1000A2/AL2/D2/DL2)
RIGHT FRONT
TURN SIGNAL
2P (LIGHT BLUE)
CONNECTOR
OPEN AIR TEMPERATURE SENSOR
2P (BLACK) CONNECTOR
FRONT OPTION
4P CONNECTOR
CRF1000A/A2/AL/AL2:
REAR ABS SWITCH 2P (BLACK) CONNECTOR
CRF1000D/D2/DL/DL2:
REAR ABS/G SWITCH 4P (BLACK) CONNECTOR
COMBINATION METER
32P (GRAY) CONNECTOR
HEADLIGHT 1
2P CONNECTOR
HEADLIGHT 2
2P (BLACK)
CONNECTOR
Front
Up
FRONT COWL STAY
FRONT SUB
HARNESS
CRF1000A2/AL2/D2/DL2:
Install the wire band on
the white tape.
26-20
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRONT BRAKE HOSE D
MAIN WIRE
HARNESS
HORN WIRE
IGNITION
SWITCH WIRE
FRONT WHEEL SPEED
SENSOR WIRE
LEFT HANDLEBAR
SWITCH WIRE
IMMOBILIZER
RECEIVER WIRE
LEFT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
80° - 100°
HORN WIRE
FRONT SUB HARNESS 1
12P (BLACK) CONNECTOR
FRONT SUB HARNESS 2
12P (GRAY) CONNECTOR
LEFT HANDLEBAR
SWITCH WIRE
LEFT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
Right
Up
FRONT BRAKE
HOSE D
FRONT WHEEL SPEED
SENSOR WIRE
26-21
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
GROUND
TERMINALS
ECT SENSOR
2P (BLACK) CONNECTOR
No.1 CYLINDER SUB PLUG CAP
MAIN WIRE HARNESS
IMMOBILIZER
RECEIVER WIRE
LEFT
HANDLEBAR
SWITCH WIRE
MAIN WIRE HARNESS
LEFT FAN MOTOR
2P (BLACK)
CONNECTOR
HORN WIRE
MAIN WIRE HARNESS
LEFT GRIP HEATER
2P (BLACK) CONNECTOR
(CRF1000A2/AL2/D2/DL2)
LEFT GRIP HEATER
4P (BLACK) CONNECTOR
(CRF1000A2/AL2/D2/DL2)
LEFT HANDLEBAR SWITCH
10P CONNECTOR
CRF1000A/A2/AL/AL2:
LEFT HANDLEBAR SWITCH
8P CONNECTOR
CRF1000D/D2/DL/DL2:
LEFT HANDLEBAR SWITCH
12P CONNECTOR
IGNITION
SWITCH WIRE
26-22
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
EOP SENSOR
3P (BLACK)
CONNECTOR
ALTERNATOR
ASSEMBLY WIRE
RADIATOR
RESERVE TANK
DRAIN HOSE
ALTERNATOR
ASSEMBLY WIRE
ALTERNATOR
ASSEMBLY WIRE
FUEL TANK
DRAIN HOSE
SIDESTAND
SWITCH WIRE
SIDESTAND
SWITCH WIRE
ED/KO/TH/FO/MA models:
CANISTER DRAIN HOSE
GS/U/IN models:
FUEL TANK BREATHER HOSE
To VS sensor
SIDESTAND
SWITCH WIRE
CRF1000A/A2/AL/AL2:
ALTERNATOR
ASSEMBLY WIRE
EOP SWITCH
CRF1000D Shown:
EOP SWITCH
TERMINAL
26-23
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
30 – 50 mm
(1.2 – 2.0 in)
FRONT WHEEL SPEED
SENSOR WIRE
CRF1000A/A2/AL/AL2:
CLUTCH CABLE
CRF1000D/D2/DL/DL2:
PARKING BRAKE CABLE
FRONT BRAKE HOSE A
FRONT BRAKE HOSE D
FRONT WHEEL SPEED
SENSOR WIRE
FRONT BRAKE HOSE E
RIGHT HANDLEBAR
SWITCH WIRE
RIGHT GRIP HEATER WIRE
(CRF1000A2/AL2/D2/DL2)
26-24
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
SIPHON HOSE
APS 8P (BLACK)
CONNECTOR
RIGHT FAN MOTOR
2P (BLACK)
CONNECTOR
No.2 CYLINDER
SUB PLUG CAP
FRONT BRAKE PIPE D
STARTER RELAY
SWITCH
FUSE CASE
FRONT BRAKE
PIPE C
LINEAR SOLENOID VALVE
4P (BLACK) CONNECTOR
(CRF1000D/D2/DL/DL2)
PARKING BRAKE CABLE
(CRF1000D/D2/DL/DL2)
LINEAR SOLENOID
VALVE WIRE
(CRF1000D/D2/DL/DL2)
AIR CLEANER
HOUSING DRAIN HOSE
MAIN WIRE
HARNESS
SPARK PLUG WIRE
RIGHT HANDLEBAR SWITCH
8P (GRAY) CONNECTOR
CRF1000D shown:
RIGHT GRIP HEATER
2P (BLACK) CONNECTOR
(CRF1000A2/AL2/D2/DL2)
LINEAR SOLENOID
VALVE WIRE
(CRF1000D/D2/DL/DL2)
MAIN WIRE HARNESS
AIR CLEANER HOUSING
DRAIN HOSE
CRF1000D/D2/DL/DL2:
LINEAR SOLENOID
VALVE WIRE
CRF1000A/A2/AL/AL2:
SPARK PLUG WIRE
Front
Right
LINEAR SOLENOID
VALVE WIRE
(CRF1000D/D2/DL/DL2)
RIGHT HANDLEBAR
SWITCH
8P (BLACK) CONNECTOR
(CRF1000D/D2/DL/DL2)
PARKING BRAKE CABLE
(CRF1000D/D2/DL/DL2)
CRF1000A/A2/AL/AL2:
Do not touch the clutch
cable with the insulator.
CLUTCH CABLE
INSULATOR
26-25
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
No.2 CYLINDER
SUB PLUG CAP
O2 SENSOR
4P (BLACK)
CONNECTOR
REAR BRAKE
SWITCH
EOT SENSOR
3P (BLACK) CONNECTOR
(CRF1000D/D2/DL/DL2)
LINEAR SOLENOID
VALVE WIRE
(CRF1000D/D2/DL/DL2)
MAIN WIRE HARNESS
No.1 CLUTCH EOP
SENSOR
(CRF1000D/D2/DL/DL2)
No.2 CLUTCH EOP
SENSOR
(CRF1000D/D2/DL/DL2)
PARKING BRAKE
CABLE
(CRF1000D/D2/DL/DL2)
CLUTCH LINE EOP
SENSOR
(CRF1000D/D2/DL/DL2)
Front
Up
Front
Right
STARTER
MOTOR
STARTER
MOTOR CABLE
CRF1000D shown:
SHIFT SPINDLE ANGLE
SENSOR
(CRF1000D/D2/DL/DL2)
45° ± 10°
26-26
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
IGNITION COIL SUB HARNESS
FRONT BRAKE PIPE C
FRONT BRAKE PIPE D
No.2 CYLINDER
SUB IGNITION COIL
No.2 CYLINDER
MAIN IGNITION
COIL
No.1 CYLINDER
SUB IGNITION COIL
No.1 CYLINDER MAIN
IGNITION COIL
IGNITION SWITCH WIRE
IAT SENSOR
2P (BLUE) CONNECTOR
MAIN WIRE
HARNESS
CRANKCASE
BREATHER HOSE
AIR SUCTION HOSE
TBW UNIT
6P (BLACK)
CONNECTOR
IGNITION COIL SUB HARNESS
BLACK WIRE
BLACK WIRE
GREEN WIRE
BLACK WIRE
BLACK WIRE
GREEN WIRE
GREEN WIRE
GREEN WIRE
IGNITION COIL SUB HARNESS
6P CONNECTOR
GRAY TAPE
(CRF1000D/D2/DL/DL2)
26-27
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRONT WHEEL SPEED SENSOR
2P (BLACK) CONNECTOR
IAT SENSOR
No.2 CYLINDER MAIN PLUG WIRE
PAIR CONTROL
SOLENOID VALVE
2P (BLACK) CONNECTOR
No.1 CYLINDER SUB PLUG WIRE
No.1 CYLINDER MAIN PLUG WIRE
26-28
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ECM/PCM
33P (Blue) CONNECTOR
ECM/PCM
33P (Black) CONNECTOR
ECM/PCM
33P (Gray) CONNECTOR
MAIN WIRE
HARNESS
IGNITION COIL SUB HARNESS
6P CONNECTOR
FRONT
BRAKE PIPE D
ED/KO/TH/FO/MA models:
FUEL TANK-to-CANISTER HOSE
ED/KO/TH/FO/MA models:
CANISTER-to-EVAP PURGE
CONTROL SOLENOID
VALVE HOSE
ED/KO/TH/FO/MA models:
EVAP PURGE CONTROL
SOLENOID VALVE-to-
THROTTLE BODY HOSE
ED/KO/TH/FO/MA models:
FUEL TANK-to-CANISTER
HOSE
FRONT
BRAKE PIPE C
ED/KO/TH/FO/MA models:
EVAP PURGE CONTROL
SOLENOID VALVE
2P (BLACK) CONNECTOR
MAIN WIRE
HARNESS
FUEL FEED
HOSE
FUEL TANK
DRAIN HOSE
MAP SENSOR
3P (BLACK) CONNECTOR
PCM 33P (Brown)
CONNECTOR
(CRF1000D/D2/DL/DL2)
FUEL LEVEL SENSOR
2P (Black) CONNECTOR
26-29
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FUEL PUMP
3P (BLACK) CONNECTOR
SEAT LOCK CABLE
MAIN WIRE
HARNESS
REAR BRAKE
HOSE A
REAR BRAKE
HOSE B
REAR WHEEL
SPEED SENSOR WIRE
REAR WHEEL SPEED SENSOR
2P (BLACK) CONNECTOR
FUSE BOX 1
FUSE BOX 2
FUSE BOX 3
(CRF1000D/D2/DL/DL2)
HISS 2P (RED)
CONNECTOR
TBW RELAY
26-30
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ALTERNATOR
ASSEMBLY WIRE
FUEL TANK
DRAIN HOSE
BATTERY
BATTERY
NEGATIVE (-)
CABLE
BATTERY
POSITIVE (+)
CABLE
PARKING BRAKE CABLE
(CRF1000D/D2/DL/DL2)
REAR BRAKE HOSE B
ED/KO/TH/FO/MA models:
CANISTER DRAIN HOSE
ED/KO/TH/FO/MA models:
EVAP CANISTER-to-PURGE CONTROL
SOLENOID VALVE HOSE
MAIN WIRE
HARNESS
26-31
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
JUNCTION 2
JUNCTION 1
SIDESTAND SWITCH
2P (BLACK) CONNECTOR
REAR BRAKE
LIGHT SWITCH
2P (GRAY)
CONNECTOR
PARKING BRAKE
CABLE
O2 SENSOR WIRE
SIPHON HOSE
ALTERNATOR ASSEMBLY
6P (BLACK) CONNECTOR
INNER MAINSHAFT SENSOR
3P (BLACK) CONNECTOR
FUEL TANK
BREATHE HOSE
FUEL TANK
DRAIN HOSE
ALTERNATOR
ASSEMBLY WIRE
REAR BRAKE LIGHT
SWITCH
SHIFT SPINDLE ANGLE SENSOR
3P (BLUE) CONNECTOR
TR SENSOR
3P (BLACK) CONNECTOR
NEUTRAL
SWITCH
MAIN WIRE
HARNESS
FUEL LEVEL SENSOR
2P (Black) CONNECTOR
CRF1000D/D2/DL/DL2:
26-32
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
SIDESTAND SWITCH
2P (BLACK) CONNECTOR
REAR BRAKE
LIGHT SWITCH
2P (GRAY)
CONNECTOR
O2 SENSOR
WIRE
SIPHON
HOSE
ALTERNATOR ASSEMBLY
6P (BLACK) CONNECTOR
GEAR POSITION SENSOR
3P (BLACK) CONNECTOR
REAR BRAKE
LIGHT
SWITCH WIRE
SHIFT SPINDLE
SWITCH
SHIFT STROKE
SENSOR
(OPTIONAL)
4P CONNECTOR
NEUTRAL
SWITCH
CRF1000A/A2/AL/AL2:
JUNCTION 2
JUNCTION 1
FUEL LEVEL SENSOR
2P (Black) CONNECTOR
26-33
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FUEL TANK-to-CANISTER HOSE
EVAP PURGE CONTROL SOLENOID VALVE
2P (BLACK) CONNECTOR
CANISTER-to-EVAP PURGE CONTROL
SOLENOID VALVE HOSE
EVAP CANISTER
EVAP PURGE CONTROL SOLENOID VALVE
-to-THROTTLE BODY HOSE
CANISTER DRAIN HOSE
ED/KO/TH/FO/MA models:
26-34
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FUEL PUMP RELAY
HEADLIGHT RELAY
DLC
IN model:
REAR OPTION 4P CONNECTOR
Except IN model:
REAR OPTION 6P CONNECTOR
FAN CONTROL RELAY
HISS 2P (RED)
CONNECTOR
GRIP HEATER CONTROLLER
10P (BLACK) CONNECTOR
(CRF1000A2/AL2/D2/DL2)
OPTION 10P (BLACK)
CONNECTOR
(CRF1000A/AL/D/DL)
RELAY BOX
– FI RELAY
– ENGINE STOP RELAY
STARTER RELAY
(CRF1000D/D2/DL/DL)
DIODE
(CRF1000A/A2/AL/AL2)
RESISTOR
(CRF1000A/A2/AL/AL2)
LEFT REAR TURN
SIGNAL LIGHT
2P (ORANGE)
CONNECTOR
LICENSE LIGHT
2P CONNECTOR
RIGHT REAR TURN
SIGNAL LIGHT
2P (LIGHT BLUE)
CONNECTOR
WIRE BAND
Wire band is rear
from this line
BRAKE/TAILLIGHT
3P (BLACK) CONNECTOR
BRAKE/TAILLIGHT
HARNESS
The brake/tail light
harness should pass
under the frame
26-35
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
REAR
BRAKE
HOSE B
REAR
BRAKE
HOSE A
Up
Right
REAR WHEEL
SPEED SENSOR WIRE
REAR BRAKE HOSE B
REAR WHEEL
SPEED SENSOR
WIRE
REAR BRAKE HOSE B
REAR BRAKE HOSE B
PARKING BRAKE CABLE
(CRF1000D/D2/DL/DL2)
PARKING BRAKE CABLE
(CRF1000D/D2/DL/DL2)
REAR BRAKE HOSE B
PARKING BRAKE CABLE
(CRF1000D/D2/DL/DL2)
REAR BRAKE
RESERVE TANK
REAR WHEEL
SPEED SENSOR WIRE
PARKING BRAKE CABLE
(CRF1000D/D2/DL/DL2)
SIPHON HOSE
REAR BRAKE
LIGHT SWITCH
REAR WHEEL
SPEED SENSOR WIRE
REAR WHEEL
SPEED SENSOR WIRE
Right
Up
26-36
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Rear
45°
Lower
Left
Left
45°
45°
Lower
Left
RADIATOR
HOSE B
Blue paint
White paint
Yellow paint
Insert the radiator upper hose
onto the radiator pipe round
corner end.
RADIATOR
UPPER HOSE
45°
40°
Right
Front
RADIATOR
LOWER HOSE
RADIATOR
HOSE B
White paint
Prevent the water
hose band from
interfering with the
radiator stay.
Yellow paint
45°
Left
Lower
White paint
26-37
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
45°
Lower
Rear
45°
Lower
Rear
WATER BOTTOM
HOSE
Insert the hose to the index mark.
Yellow paint
White paint
RADIATOR HOSE A
White paint
Blue paint
30°
Lower
Rear
Insert the
hose to the
punch mark.
Insert the hose to the index mark.
Insert the hose to the punch mark.
30°
Rear
Lower
26-38
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
TECHNICAL FEATURE
ESS (Emergency Stop Signal) (Except KO model)
The ESS is such a function that activates all turn indicators to blink fast when the motorcycle decelerates rapidly under certain
conditions to alert following drivers/riders. With the ABS full-cycling, issuing/halting of ESS logic signal is conducted in accordance
with the deceleration as per the ESS protocol. The ABS modulator constantly monitors the ESS logic signal, hazard switch signal,
and the speed to trigger ESS. When the ESS is triggered, all turn signal lights are activated to blink at a high frequency (4 ± 1 Hz).
The ABS modulator triggers ESS when the motorcycle is running above 53 km/h, the brake is applied, and a quick deceleration (6
m/s
2
or higher) is detected. When the ESS is triggered, all the turn signal lights are activated to blink faster than the usual rate 1.3 –
1.5 Hz. The vehicle speed signals are sent to the ABS modulator from the front and rear wheel speed sensors. The ESS is
cancelled when the deceleration decreases to under 2.5 m/s
2
, the hazard switch is turned on or the brake is released. This system
is applicable only in countries that allow blinking of light in a hazard. For quick inspection, all turn indicators can be checked for
quick blinking by short-circuiting SCS and grabbing the brake with the ignition switch at ON. It can also be checked that all the
blinking turn signal lights go off when the brake is released.
As the SCS is shorted and the brake is
grabbed with the ignition switch at ON to send
the deliberately issued ESS logic signal, all
turn signal lights and other indicators blink
fast at 4 ± 1 Hz.
Ignition switch
Front/rear wheel speed
sensor
Front/rear brake light
switch
Hazard switch
ESS system
ESS control
ABS modulator
Issues/halts
ESS logic signal
Judges ESS
trigger
Output for fast
blinking of turn
signal lights
Turn signal relay
Left front turn signal light
Right front turn signal light
Left rear turn signal light
Right rear turn signal light
Indicator in
combination meter
Turn signal blink fast
26-39
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
BODY PANEL LOCATIONS
CRF1000A/AL/D/DL
BODY PANEL REMOVAL CHART
This chart shows the removal order of the frame covers by following the arrow.
[1]
[11]
[20]
[12]
[2][3][4][6]
[7]
[8]
[5]
[21]
[9] [13]
[14]
[15]
[16][17][18][19]
[10]
[22]
[23]
[1] Front cover (page 26-44) [13] Rear fender B (page 26-56)
[2] Windscreen (page 2-5) [14] Side cover (page 2-11)
[3] Tank front cover (page 2-9) [15] Rear fender A (page 26-54)
[4] Knuckle guard (page 2-5) [16] Pillion seat (page 2-11)
[5] ETC tray (page 26-49) [17] Main seat (page 2-4)
[6] Rear carrier (page 26-52) [18] Tank rear cover (page 2-10)
[7] Muffler/exhaust pipe (page 2-16) [19] Inner panel cover (page 26-45)
[8] Tank side cover (page 2-9) [20] Middle cowl (page 2-6)
[9] Inner cover (page 2-8) [21] Front fender (page 2-9)
[10] Front spoiler (page 2-7) [22] Rear center cowl (page 26-54)
[11] Skid plate (page 2-10) [23] Seat catch stay (page 26-48)
[12] Left rear cover (page 2-10)
[16] Pillion seat
[19] Inner panel cover
[1] Front cover
[14] Side cover
[11] Skid plate
[4] Knuckle guard [12] Left rear cover
[9] Inner cover
[13] Rear fender B
[3] Tank front cover
[21] Front fender
[22] Rear center cowl
[23] Seat catch stay
[18] Tank rear cover
[6] Rear carrier
[5] ETC tray
[8] Tank side cover
[20] Middle cowl
[2] Windscreen
[7] Muffler/exhaust
pipe
[15] Rear fender A
[10] Front spoiler
[17] Main seat
26-40
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000A2/AL2/D2/DL2
BODY PANEL REMOVAL CHART
This chart shows the removal order of the frame covers by following the arrow.
[6]
[11]
[4]
[18]
[3][14][9][20]
[25]
[10]
[8] [24]
[23]
[2]
[1]
[17][7]
[5]
[22]
[21]
[19]
[13]
[16]
[12]
[15]
[1] Main seat (page 2-4) [14] Tank front cover (page 2-9)
[2] Pillion seat (page 2-11) [15] Tank rear cover (page 2-10)
[3] Windscreen (page 26-41) [16] Seat catch stay (page 26-48)
[4] Middle cowl (page 26-42) [17] ETC tray (page 26-49)
[5] Front spoiler (page 2-7) [18] Side cover (page 26-49)
[6] Front cover (page 26-44) [19] Rear side inner body (page 26-51)
[7] Inner panel cover (page 26-45) [20] Rear carrier (page 26-52)
[8] Inner cover (page 2-8) [21] Carrier bracket (page 26-53)
[9] Knuckle guard (page 2-5) [22] Rear center cowl (page 26-54)
[10] Front fender (page 2-9) [23] Rear fender A (page 26-54)
[11] Left rear cover (page 2-10) [24] Rear fender B (page 26-56)
[12] Skid plate (page 26-46) [25] Muffler/exhaust pipe (page 26-58)
[13] Front side pipe (page 26-47)
[11] Left rear cover[10] Front fender
[9] Knuckle guard
[1] Main seat
[2] Pillion seat
[20] Rear carrier
[22] Rear center cowl
[21] Carrier bracket
[23] Rear fender A
[18] Side cover
[19] Rear side inner body
[15] Tank rear cover
[16] Seat catch stay
[17] ETC tray
[24] Rear fender B
[25] Muffler/exhaust pipe
[12] Skid plate
[3] Windscreen
[13] Front side pipe
[4] Middle cowl
[5] Front spoiler
[6] Front cover
[7] Inner panel cover
[14] Tank front cover
[8] Inner cover
26-41
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
WINDSCREEN
CRF1000A2/AL2/D2/DL2
REMOVAL/INSTALLATION
Remove the following:
– Socket bolts [1]
– Plastic washers [2]
– Rubber washers [3]
– Windscreen [4]
Remove the well nuts [5] and cowl stay covers [6] if
necessary.
Installation is in the reverse order of removal.
• When installing the cowl stay cover, set the cowl
stay cover boss [7] into the front cowl stay hole [8].
TORQUE: 0.42 N·m (0.04 kgf·m, 0.3 lbf·ft)
[1]
[2]
[3]
[4]
[6]
[5]
[6]
[7]
[8]
[2]
26-42
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
MIDDLE COWL
CRF1000A2/AL2/D2/DL2
REMOVAL/INSTALLATION
Remove the front side pipe (page 26-47).
Remove the socket bolts [1], plastic washers [2], rubber
washers [3] and trim clips [4].
Release the bosses [5].
Remove the middle cowl [6] by releasing the tabs [7].
Installation is in the reverse order of removal.
[6]
[4]
[5]
[7]
[1]
[2]
[3]
[1]
[2]
[3]
26-43
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DISASSEMBLY/ASSEMBLY
Remove the middle cowl (page 26-42).
Remove the screws [1] and front side cover [2] from the
middle cowl [3].
Remove the front side cover mounting screws [1] and
front side cover [2] from the middle cowl [3].
Installation is in the reverse order of removal.
[3]
[2] [1]
TORQUE:
Front side cover mounting screw:
0.42 N·m (0.04 kgf·m, 0.3 lbf·ft)
[3]
[2][1] [1]
26-44
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRONT COVER
REMOVAL/INSTALLATION
Remove the following:
– Front spoiler (page 2-7)
– Windscreen
– CRF1000A/AL/D/DL (page 2-5)
– CRF1000A2/AL2/D2/DL2 (page 26-41)
Remove the twist clips [1] and trim clips [2].
Remove the socket bolts [3].
Remove the front cover [4] while pulling it forward.
Installation is in the reverse order of removal.
[2]
[4]
[2]
[3]
[1]
[3]
CRF1000D2 shown:
26-45
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
INNER PANEL COVER
REMOVAL/INSTALLATION
(RIGHT SIDE)
Remove the front cover (page 26-44).
Disconnect the front turn signal light 2P (Light blue)
connector [1].
Disconnect the rear ABS switch 2P (Black) connector
[2].
Disconnect the rear ABS/G switch 4P (Black) connector
[2].
Remove the socket bolt [3], trim clip [4] and right inner
panel cover [5].
Installation is in the reverse order of removal.
REMOVAL/INSTALLATION
(LEFT SIDE)
Remove the front cover (page 26-44).
Disconnect the front turn signal light 2P (Orange)
connector [1].
Disconnect the accessory socket 2P (Black) connector
[2].
Remove the wire band [3].
Remove the socket bolt [4], trim clips [5] and left inner
panel cover [6].
Installation is in the reverse order of removal.
CRF1000A/A2/AL/
AL2:
CRF1000D/D2/DL/
DL2:
[4]
[5]
[1]
[2]
[3]
CRF1000A2/D2/
AL2/DL2:
[6]
[5]
[5]
[2]
[1][4]
[3]
26-46
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DISASSEMBLY/ASSEMBLY
Remove the socket bolt [1].
Remove the front turn signal cover [2] from the inner
panel cover [3].
Assembly is in the reverse order of disassembly.
SKID PLATE
CRF1000A2/AL2/D2/DL2
REMOVAL/INSTALLATION
Remove the bolts [1], washers [2] and collar [3].
Remove the skid plate [4].
Installation is in the reverse order of removal.
• Align the right rear grommet [5] of the skid plate with
the boss [6] of frame.
[1]
[2] [3]
TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft)
[3]
[6]
[4]
[5]
[1]
[1]
[1]
[2]
[2]
26-47
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRONT SIDE PIPE
REMOVAL/INSTALLATION
Remove the skid plate (page 26-46).
Remove the following:
– Bolts [1]
–Washers [2]
– Bolt/washers [3]
– Front side pipe [4]
Remove the collars [5] from the front side pipe.
Remove the collars [6] from the front side pipe stay.
Installation is in the reverse order of removal.
FRONT SIDE PIPE STAY REMOVAL/
INSTALLATION
Remove the front side pipe (page 26-47).
Remove the socket bolts [1] and front side pipe stay [2].
Installation is in the reverse order of removal.
LOWER CROSS PIPE REMOVAL/
INSTALLATION
Remove the bolt/washers [1] and lower cross pipe [2].
Remove the collars [3] from the lower cross pipe
bracket.
Installation is in the reverse order of removal.
[4]
[3]
[6]
[1]/[2]
[1]/[2]
[5]
[2] [1]
[2]
[1]
[3]
26-48
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
SEAT CATCH STAY
REMOVAL/INSTALLATION
Remove the tank rear cover (page 2-10).
Remove the bolts [1] and pull up the seat catch stay [2].
Disconnect the seat lock cable [3] from the seat catch
stay.
Remove the seat lock cover [4].
Remove the bolt [1] and seat catch hook [2] from the
seat catch stay [3].
Installation is in the reverse order of removal.
• Apply grease to the seat catch hook sliding area.
• Align the seat catch hook boss with the stay hole.
• Align the grooves of the ETC tray with the tabs of the
seat lock cover.
[4]
[2]
[3]
[1]
[3]
[1]
[2]
26-49
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ETC TRAY
REMOVAL/INSTALLATION
Remove the seat catch stay (page 26-48).
Release the following:
– Fuse box 1/2 [1]
– Fuse box 3 [2]
– Trim clip [3]
Remove the ETC tray [4] by releasing the boss [5].
Installation is in the reverse order of removal.
• Route the wire harnesses properly (page 26-17).
SIDE COVER
REMOVAL/INSTALLATION
RIGHT SIDE
Remove the pillion seat (page 2-11).
Remove the screws [1] and socket bolts [2].
Release the tabs [3] of side cover from the carrier
bracket.
Remove the side cover [4] by releasing the snap fit clip
[5] and tabs [6].
Installation is in the reverse order of removal.
[1]
[2]
[4]
[3]
[5]
[2]
[4]
[5]
[3]
[6][2]
[3][1]
[6]
[6]
26-50
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
LEFT SIDE
Remove the pillion seat (page 2-11).
Remove the socket bolts [1] and left pillion step bracket
[2].
Remove the socket bolts [1] and right rear side lid [2].
Remove the screws [3] and socket bolts [4].
Release the tabs [5] of side cover from the carrier
bracket.
Remove the side cover [6] by releasing the snap fit clip
[7] and tabs [8].
Installation is in the reverse order of removal.
[1]
[2]
TORQUE:
Pillion step bracket mounting bolt:
32 N·m (3.3 kgf·m, 24 lbf·ft)
[2] [4]
[5]
[1]
[4]
[5] [3]
[8]
[7]
[6]
[8][8]
[8]
26-51
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
REAR SIDE INNER BODY
REAR SIDE INNER BODY A
REMOVAL/INSTALLATION
Remove the side cover (page 26-49).
Remove the bolt [1], collar [2] and rear side inner body
A [3].
Installation is in the reverse order of removal.
LEFT REAR SIDE INNER BODY B
REMOVAL/INSTALLATION
Remove the following:
– Seat catch stay (page 26-48)
– Rear side inner body A (page 26-51)
Release the grip heater controller [1] from the left rear
side inner body B [2].
Remove the screws [3] and seat lock cylinder [4].
Remove the trim clip [5] and socket bolts [6].
Remove the left rear side inner body B by releasing its
tab [7].
Installation is in the reverse order of removal.
[1]
[2]
[3]
Left side shown:
[1]
[7]
[3] [3][4]
[2]
[5][6]
[6]
26-52
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
RIGHT REAR SIDE INNER BODY B
REMOVAL/INSTALLATION
Remove the rear side inner body A (page 26-51).
Remove the socket bolts [1] and right rear side inner
body B [2].
Installation is in the reverse order of removal.
REAR CARRIER
CRF1000A/AL/D/DL
REMOVAL/INSTALLATION
Remove the side covers (page 2-11).
Remove the following:
– Flange bolts [1]
–Collars [2]
–Washers [3]
– Rear carrier [4]
Installation is in the reverse order of removal.
[2]
[1]
[2]
[1][1]
[3]
[1]
[3]
[4]
26-53
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000A2/AL2/D2/DL2
REMOVAL/INSTALLATION
Remove the pillion seat (page 2-11).
Remove the bolts [1] and rear carrier [2].
Remove the carrier rubbers [3] from the rear carrier.
Installation is in the reverse order of removal.
CARRIER BRACKET
REMOVAL/INSTALLATION
Remove the rear center cowl (page 26-54).
Remove the following:
– Bolts [1]
–Collars [2]
–Washers [3]
– Carrier bracket [4]
Installation is in the reverse order of removal.
[1]
[2]
[3]
[1]
[3]
[1]
[1]
[1]
[3]
[2][2]
[3]
[1]
[4]
26-54
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
REAR CENTER COWL
REMOVAL/INSTALLATION
CRF1000A/AL/D/
DL:
Remove the rear carrier (page 26-52).
Remove the following:
– Side cover (page 26-49)
– Rear carrier (page 26-52)
Remove the socket bolts [1] and rear center cowl [2].
Remove the well nuts [3] from the carrier bracket.
Installation is in the reverse order of removal.
REAR FENDER A
REMOVAL/INSTALLATION
CRF1000A/AL/D/
DL:
Remove the rear center cowl (page 26-54).
Remove the carrier bracket (page 26-53).
Disconnect the brake/taillight 3P (Black) connector [1].
Remove the nuts [2], collars [3] and brake/taillight [4].
CRF1000A2/AL2/
D2/DL2:
CRF1000D2 shown: [2][1]
[3]
[3]
CRF1000A2/AL2/
D2/DL2:
[3]
[4]
[3]
[2]
[1]
26-55
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Remove the wire band [1].
Disconnect the license light 2P (White) connector [2].
Remove the socket bolts [3] and rear fender A [4].
Installation is in the reverse order of removal.
• Route the wires properly (page 26-17).
DISASSEMBLY/ASSEMBLY
Remove the rear fender A (page 26-54).
Remove the following parts from the rear fender A [1]:
– Socket bolt [2]
– Bolts [3]
–Collars [4]
– Nuts [5]
– Fender cover bracket [6]
– Rear fender A cover [7]
Remove the nuts [8], collars [9], license light rubber [10]
and license light [11].
Remove the nut [12] and reflector [13].
Assembly is in the reverse order of disassembly.
[4]
[2]
[3]
[1]
[5]
[6] [5] [8] [9]
[12]
[10]
[11]
[7]
[1]
[13]
[3]
[2]
[4]
26-56
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
REAR FENDER B
SEAT LOCK CYLINDER
(CRF1000A/AL/D/DL/DL)
REMOVAL/INSTALLATION
Remove the ETC tray (page 26-49).
Disconnect the seat lock cable [1] from the seat lock
cylinder [2] and stay [3].
Remove the lock spring [4], cylinder, and stay.
Installation is in the reverse order of removal.
• Align the lug [5] of the cylinder with the grooves [6]
of the rear fender B, lock spring, and stay.
REMOVAL/INSTALLATION
Remove the following:
– Rear fender A (page 26-54)
– Muffler
– CRF1000A/AL/D/DL (page 2-16)
– CRF1000A2/AL2/D2/DL2 (page 26-58)
– Regulator/rectifier (page 21-8)
– ABS modulator (page 26-195)
Remove the seat lock cylinder (page 26-56).
Remove the following:
– Rear side inner body (page 26-51)
– ETC tray (page 26-49)
Remove the EVAP canister (page 26-131).
Disconnect the following:
– Rear turn signal light 2P (Light blue) connector [1]
– Rear turn signal light 2P (Orange) connector [2]
– Turn signal light relay 18P (Black) connector (page
2-13)
Release the following:
– TBW relay [3]
– Rear wheel speed sensor 2P (Black) connector [4]
– Fan control relay [5]
– DLC [6]
– CKP sensor 2P (Red) connector [7]
Release the option 4P connector [8].
Release the option 6P connector [9].
Release the resistor [10] and diode [11].
[2]
[4]
[5]
[1] [3]
[6]
CRF1000A/A2/AL/
AL2:
CRF1000D/D2/DL/
DL2:
ED/KO/TH/FO/MA
models:
IN model:
Except IN model:
CRF1000A/A2/AL/
AL2:
[3]
[4]
[2]
[1]
[5]
[6]
[7]
[8]/[9]
[10]
[11]
26-57
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Remove the screw [1] and mud guard [2].
• Move the mud guard to the left to release the mud guard tab [3].
Remove the socket bolts [4].
Remove the rear fender B [5] by pulling it rearward.
Remove the turn signal light relay from the rear fender B (page 22-9).
Installation is in the reverse order of removal.
• Place the hooks of rear fender B [6] onto the frame.
• Route the wires, pipes and hoses properly (page 26-17).
[5]
[1]
[2]
[3]
[4]
[4]
[6]
26-58
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
MUFFLER/EXHAUST PIPE
MUFFLER
DISASSEMBLY/ASSEMBLY
Remove the muffler (page 2-16).
• Align the slots of the muffler cover with the bosses of the muffler.
EXHAUST PIPE
REMOVAL/INSTALLATION
Remove the following:
– Skid plate (page 26-46)
– Muffler (page 2-16)
Release the O
2 sensor wire clip [1] and disconnect the
4P (Black) connector [2].
TAIL CAP COVER
MUFFLER COVER
MUFFLER
PAN SCREW
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
RUBBER WASHER
TAIL CAP COVER BOLTS
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
RUBBER WASHERS
[2]
[1]
26-59
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Remove the pan screw [1] and exhaust pipe cover A [2].
Loosen the band screw and remove the band [3] and exhaust pipe cover B [4].
Remove the mounting bolt [5], collar [6], and mounting nut [7].
Remove the exhaust pipe joint nuts [8], gaskets [9], and exhaust pipe [10].
Installation is in the reverse order of removal.
• Always replace the gaskets with new ones.
• When installing the exhaust pipe, loosely install all of the exhaust pipe fasteners.
• Always tighten the joint nuts first, then tighten the mounting bolt.
• Align the slots of the exhaust pipe cover A/B with the bosses of the exhaust pipe.
•For O
2 sensor removal/installation (page 4-42)
[1]
[2]
[4]
[3]
[10]
[8]
[7]
[6]
[5]
6° ± 10°
58°
[3]
[9]
TORQUE:
Exhaust pipe joint nut:
20 N·m (2.0 kgf·m, 15 lbf·ft)
Exhaust pipe cover A pan screw:
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
Exhaust pipe cover B front band screw:
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
Exhaust pipe cover B rear band screw:
3.5 N·m (0.4 kgf·m, 2.6 lbf·ft)
26-60
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
SIDESTAND
REMOVAL/INSTALLATION
Remove the sidestand switch (page 22-27) (not
necessary to disconnect the connector).
Support the motorcycle securely using a hoist or
equivalent.
Remove the sidestand return springs [1].
Remove the sidestand pivot nut [2] and bolt [3], then
remove the sidestand [4] and collar [5].
Apply molybdenum disulfide grease to the sidestand
pivot bolt sliding surface and collar outer surface.
Install the sidestand and collar.
Install and tighten the pivot bolt.
Install and tighten the sidestand pivot nut to the
specified torque while holding the sidestand pivot bolt.
Install the sidestand and return springs in the direction
as shown.
Install the sidestand switch (page 22-27).
FRONT NUMBER STAY (IN model only)
CRF1000A2/AL2/D2/DL2
REMOVAL/INSTALLATION
Remove the bolts [1] and front number bracket [2] from
the front side pipe.
Installation is in the reverse order of removal.
• The number plate guard [3] must be removed and
installed from the front number bracket together with
the number plate.
TORQUE: 42 N·m (4.3 kgf·m, 31 lbf·ft)
[2]
[3]
[1]
[4]
Up
Rear
[5]
[3]
[1][2]
26-61
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
MAINTENANCE SCHEDULE
CRF1000A/AL/AL2 FO/MA Models
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult a dealer.
* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replacement requires mechanical skill.
ITEM NOTE
FREQUENCY (NOTE 1)
ANNUAL
CHECK
REGULAR
REPLACE
REFER TO
PAGE
x 1,000 km 1 6 12 18 24 30 36
x 1,000 mi 0.6 4 8 12 16 20 24
* FUEL LINE I I I I 3-3
* THROTTLE OPERATION I I I I 26-63
* AIR CLEANER NOTE 2 R R 3-4
CRANKCASE BREATHER NOTE 3 CCCCCC 3-5
* SPARK PLUG
EVERY 24,000 km (16,000 mi): I
EVERY 48,000 km (32,000 mi): R
3-5
26-63
* VALVE CLEARANCE I 3-8
ENGINE OIL R R R R R 3-11
ENGINE OIL FILTER R R 3-12
RADIATOR COOLANT NOTE 5 I I I I 3 years 3-14
* COOLING SYSTEM I I I I 3-15
*
SECONDARY AIR SUPPLY
SYSTEM
I3-15
*
EVAPORATIVE EMISSION
CONTROL SYSTEM
I 25-21
DRIVE CHAIN NOTE 4 EVERY 1,000 km (600 mi): I, L 3-16
DRIVE CHAIN SLIDER NOTE 4 I I I 3-19
BRAKE FLUID NOTE 5 I I IIII I 2 years 3-19
BRAKE PADS WEAR I I IIII I 3-20
BRAKE SYSTEM I I I I 3-20
BRAKE LIGHT SWITCH I I I I 3-21
HEADLIGHT AIM I I I I 3-22
CLUTCH SYSTEM I I IIII I 3-22
SIDESTAND I I I I 3-23
* SUSPENSION I I I I 3-23
* NUTS, BOLTS, FASTENERS NOTE 4 I I I I 3-25
**WHEELS/TIRES NOTE 4 IIIIII I 3-26
** STEERING HEAD BEARINGS I I I I 3-26
26-62
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000DL/DL2 MA Model
Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult a dealer.
* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replacement requires mechanical skill.
ITEM NOTE
FREQUENCY (NOTE 1)
ANNUAL
CHECK
REGULAR
REPLACE
REFER TO
PAGE
x 1,000 km 1 6 12 18 24 30 36
x 1,000 mi0.6 4 8 12162024
* FUEL LINE I I I I 3-3
* THROTTLE OPERATION I I I I 26-63
* AIR CLEANER NOTE 2 R R 3-4
CRANKCASE BREATHER NOTE 3 CCCCCC 3-5
* SPARK PLUG
EVERY 24,000 km (16,000 mi): I
EVERY 48,000 km (32,000 mi): R
3-5
26-63
* VALVE CLEARANCE I 3-8
ENGINE OIL R R R R R 3-11
ENGINE OIL FILTER R R 3-12
CLUTCH OIL FILTER R R 3-14
RADIATOR COOLANT NOTE 5 I I I I 3 years 3-15
* COOLING SYSTEM I I I I 3-15
*
SECONDARY AIR SUPPLY
SYSTEM
I3-3
*
EVAPORATIVE EMISSION
CONTROL SYSTEM
I 25-21
DRIVE CHAIN NOTE 4 EVERY 1,000 km (600 mi): I, L 3-16
DRIVE CHAIN SLIDER NOTE 4 I I I 3-19
BRAKE FLUID NOTE 5 I I I I I I I 2 years 3-19
BRAKE PADS WEAR I I I I I I I 3-20
BRAKE SYSTEM I I I I 3-20
BRAKE LIGHT SWITCH I I I I 3-21
* BRAKE LOCK OPERATION I I I I I I 3-21
HEADLIGHT AIM I I I I 3-22
SIDESTAND I I I I 3-23
* SUSPENSION I I I I 3-23
* NUTS, BOLTS, FASTENERS NOTE 4 I I I I 3-25
**WHEELS/TIRES NOTE 4 IIIIII I 3-26
** STEERING HEAD BEARINGS I I I I 3-26
26-63
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
THROTTLE OPERATION
Check for smooth operation of the throttle grip [1] and
that it returns automatically to the fully closed position
from any open position and from any steering position.
Clean and apply grease the throttle pipe-to-APS
contacting area if throttle operation is not smooth (page
26-116).
SPARK PLUG
PULL THE RADIATOR TO OUTSIDE
RIGHT SIDE
Remove the inner cover (page 2-8).
Remove the bolts [1] and washers [2].
Release the siphon hose [1].
Release the connector clip [2] from the radiator shroud.
Release the clamps [1] from the radiator shroud.
Pull the right radiator to outside.
Installation is in the reverse order of removal.
• Route the hose and wire properly (page 26-17).
[1]
[1]/[2]
[1]
[2]
[1]
[1]
26-64
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
PGM-FI SYSTEM LOCATION
DLC
SIDESTAND
SWITCH
VS SENSOR
IGNITION SWITCH
ECM/PCM
ECT SENSOR
FUEL PUMP UNIT
IAT SENSOR
FRONT WHEEL
SPEED SENSOR
MAP SENSOR
CKP SENSOR
O2 SENSOR
EOP SENSOR
(CRF1000D/D2/DL/DL2)
No.2 FUEL INJECTOR
No.1 FUEL INJECTOR
TBW UNIT
– TBW MOTOR
– TP SENSOR
REAR WHEEL
SPEED SENSOR
BANK ANGLE
SENSOR
APS
TBW RELAY
RELAY BOX
– FI RELAY
– ENGINE STOP RELAY
STARTER RELAY
SWITCH
– FI 15 A
26-65
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
PGM-FI SYSTEM DIAGRAM
CRF1000A/A2/AL/AL2
BATTERY
MAIN
FUSE
30A
FI FUSE 15A
FI RELAY
FAN
CONTROL
RELAY
FUEL
PUMP
RELAY
IGP A11
ENG_STOP C20
IGP A22
PCS C12
EX-AI C23
FLR C2
FAN C1
INJ1 D8
INJ2 D7
IG2 A1
IG1 A2
IG3 A12
IG4 A23
K-LINE D3
SCS D18
FVW D22
RVW C27
CANL D10
VSP D21
CANH D11
SSTAND D33
CLUTCH D31
TMOP A10
TMOM A9
TPS1 C13
TPS2 C24
VCC3 D27
SG3 D25
PAIR CONTROL
SOLENOID VALVE
FUEL
PUMP
SPARK
PLUGS
No. 1-1
No. 1-2
No. 2-1
No. 2-2
CKP SENSOR
IMMOBILIZER
RECEIVER
ABS
MODULATOR
O
2 SENSOR
PCM
PCP
IMOID
IMOAU
O2HT1
O2-1
PB
BA
VCC4
TA
TW
C28
C7
C17
C6
C3
A20
DRUMANGA30
SPINDLED30
C15
D12
D28
TBWRLYC5
TBW+BA7
TBW+BA8
APS1C14
APS2C25
VCC1D16
VCC2D17
SG1D14
SG2D15
SSTRKA14
PGA4
PGA26
PGA5
PGA27
PGA15
PGD23
PGD24
LGA33
SG4D26
C31
C21
HISS
INDICATOR
COMBINATION METER
MIL
SPINDLE
SWITCH
ECM
MAP
SENSOR
BANK ANGLE
SENSOR
IAT
SENSOR
ECT
SENSOR
No. 1
FUEL
INJECTOR
No. 2
FUEL
INJECTOR
APS
FRONT WHEEL
SPEED SENSOR
REAR WHEEL
SPEED SENSOR
VS SENSOR
IGNITION SWITCH
ENGINE STOP SWITCH
REGULATOR/
RECTIFIER
DLC
TBW FUSE
10A
ABS_M FUSE 30A
FAN FUSE 20A
ILLUMI_STOP HORN FUSE 10A
ABS MAIN FUSE 10A
ENG STOP
FUSE 10A
ECM 33P (Blue) CONNECTOR A
(ECM SIDE)
ECM 33P (Black) CONNECTOR C
(ECM SIDE)
ECM 33P (Gray) CONNECTOR D
(ECM SIDE)
CLOCK_TURN FUSE 10A
STARTER SWITCH
STARTER
RELAY
SWITCH
GEAR
POSITION
SENSOR
CLUTCH SWITCH
DIODE
SIDESTAND SWITCH
STARTER
MOTOR
TBW
RELAY
RESISTOR
TP
SENSOR
TBW
MOTOR
ENGINE
STOP
RELAY
EVAP PURGE CONTROL
SOLENOID VALVE
(ED/KO/TH/FO/MA models)
Bu/Bl
Y/R
G
Y/Bl
Y/Bu
Br/Bl
Gr/Bu
Y/W
GBlY/W
WR/W
P/Bl
P/Bu
Bu/Bl
Bu/W
Bu/R
Bu/Y
W
W/Y
Bu/Y
Bu/Bl
Y
P
Bu/O
W
W
Gr
Bl
Lg
Br/R
Lg/Bl
Y/R
Gr/Bl
R/Bu
Bl/Gr Bl
G
G
Gr/Bu
Bu/Y
Br
P
Y
W
Lg
Bu/W
Y/R
Y/Bl
Gr
W/R
W/Bl
Br/Bl
Bl/W
Br/Bl
W
Bu
W
Bu
P
Bl
Bl/R
Bu/R
Bu
Bu/Bl
Bu/W
Y
Lg
G/Bu
Y/W
Br/G
Br/G
G
G
G
G
G
G
G
G/Bu
Bl
Br
Bu
G
Gr
Lg
: Black
: Brown
: Blue
: Green
: Gray
: Light green
O
P
R
W
Y
: Orange
: Pink
: Red
: White
: Yellow
R/Bu
R/BuBr/Bl
R
RR/Bu
R/Bl
Bl/R
R/G
R
R/Y W
G
G
G
Bl/R
R/W
G/W
G/W
G/R
G/Y
Br/Bl
R/Bu
Y/W
R/W
Br/Bl
Y/W Y/W
Br/Bl
26-66
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000D/D2/DL/DL2
BATTERY
MAIN FUSE
30A
FI FUSE 15A
FI RELAY
FAN
CONTROL
RELAY
FUEL
PUMP
RELAY
IGP A11
ENG_STOP C20
PCS C12
EX-AI C23
FLR C2
FAN C1
INJ1 D8
INJ2 D7
IG2 A1
IG1 A2
IG3 A12
IG4 A23
K-LINE D3
SCS D18
FVW D22
RVW C27
CANL D10
VSP D21
CANH D11
TMOP A10
TMOM A9
TPS1 C13
TPS2 C24
VCC3 D27
SG3 D25
PAIR CONTROL
SOLENOID VALVE
FUEL
PUMP
SPARK
PLUGS
No. 1-1
No. 1-2
No. 2-1
No. 2-2
CKP SENSOR
IMMOBILIZER
RECEIVER
ABS
MODULATOR
O
2
SENSOR
PCM
PCP
IMOID
IMOAU
O2HT1
O2-1
PB
BA
VCC4
TA
TW
C28
C7
C17
C6
C3
A20
SSTANDD33
C15
D12
D28
TBWRLYC5
TBW+BA7
TBW+BA8
APS1C14
APS2C25
VCC1D16
VCC2D17
SG1D14
SG2D15
PGA4
PGA26
PGA5
PGA27
PGA15
PGD23
PGD24
LGA33
SG4D26
C31
C21
HISS
INDICATOR
COMBINATION METER
MIL
SIDESTAND
SWITCH
PCM
MAP
SENSOR
BANK ANGLE
SENSOR
IAT
SENSOR
ECT
SENSOR
No. 1
FUEL INJECTOR
No. 2
FUEL INJECTOR
APS
FRONT WHEEL
SPEED SENSOR
REAR WHEEL
SPEED SENSOR
VS SENSOR
IGNITION
SWITCH
ENGINE STOP SWITCH
REGULATOR/
RECTIFIER
DLC
TBW FUSE
10A
ABS_M FUSE 30A
FAN FUSE 20A
ILLUMI_STOP HORN FUSE 10A
ABS MAIN FUSE 10A
ENG STOP
FUSE 10A
TBW
RELAY
PCM 33P (Brown) CONNECTOR B
(PCM SIDE)
PCM 33P (Blue) CONNECTOR A
(PCM SIDE)
PCM 33P (Black) CONNECTOR C
(PCM SIDE)
PCM 33P (Gray) CONNECTOR D
(PCM SIDE)
CLOCK_TURN FUSE 10A
POILC8
EOP SENSOR
TP SENSOR
TBW MOTOR
ENGINE
STOP
RELAY
EVAP PURGE CONTROL
SOLENOID VALVE
(BR/CH/ED/KO/TH/FO models)
IGP A22
Bu/Bl
Y/R
G
Y/Bl
Y/Bu
Br/Bl
Gr/Bu
Y/W
GBlY/WR/Bl
W
P/Bl
P/Bu
Bu/Bl
Bu/W
Bu/R
Bu/Y
W
W/Y
Bu/Y
Bu/Bl
G/W
Y
P
Bu/O
W
Gr
Bl
Lg
Br/R
Lg/Bl
Y/R
Gr/Bl
R/Bu
Bl/Gr Bl
GG
Gr/Bu
Bu/Y
Br
P
Y
W
Be
Bu/W
Y/R
Y/Bl
Gr
W/R
W/Bl
Br/Bl
Bl/W
Br/Bl
W
Bu
W
Bu
P
Bl
Bl/R
Bu/R
Bu
Bu/Bl
Bu/W
Y
Lg
G/Bu
Y/W
Br/G
Br/G
G
G
G
G
G
G
G
G/Bu
Bl
Br
Bu
G
Gr
Lg
: Black
: Brown
: Blue
: Green
: Gray
: Light green
O
P
R
W
Y
Be
: Orange
: Pink
: Red
: White
: Yellow
: Beige
R/BuR/W
R/BuBr/Bl
R
RR/Bu
R/Bl
R/Bl Bl/R
R/G
R
Bl R/Y
G
G
G
Bl
R/W
W
G
G
Br/Bl
26-67
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
PGM-FI DTC INDEX
• If the MCS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the Honda
code.
• The main code of Honda code (the number in front of hyphen) can be indicated as MIL blinking.
• About Diagnostic Trouble Codes (P code) other than in this DTC INDEX, refer to DCT SYSTEM DTC INDEX (page 26-135).
DTC
(Honda
code)
Function Failure Symptom/Fail-safe function
Refer
to
page
P0107
(1-1)
MAP sensor circuit low voltage (less than 0.029 V)
• MAP sensor or its circuit malfunction
• Engine operates normally
26-70
P0108
(1-2)
MAP sensor circuit high voltage (more than 3.809 V)
• Loose or poor contact of the MAP sensor connector
• MAP sensor or its circuit malfunction
• Engine operates normally
26-71
P1002
(2-1)
MAP sensor performance problem
• Loose or poor contact of the MAP sensor hose
• MAP sensor malfunction
• Engine operates normally
26-72
P0117
(7-1)
ECT sensor circuit low voltage (less than 0.049 V)
• ECT sensor or its circuit malfunction
• Hard start at a low temperature
26-73
P0118
(7-2)
ECT sensor circuit high voltage (more than 4.946 V)
• Loose or poor contact of the ECT sensor connector
• ECT sensor or its circuit malfunction
• Hard start at a low temperature
26-73
P0112
(9-1)
IAT sensor circuit low voltage (less than 0.049 V)
• IAT sensor or its circuit malfunction
• Engine operates normally
26-74
P0113
(9-2)
IAT sensor circuit high voltage (more than 4.946 V)
• Loose or poor contact of the sensor unit connector
• IAT sensor or its circuit malfunction
• Engine operates normally
26-75
P0500
(11-1)
VS sensor malfunction
• Loose or poor contact of the VS sensor connector
• VS sensor or its circuit malfunction
• Engine operates normally
26-76
P0201
(12-1)
No. 1 (left) fuel injector malfunction
• Loose or poor contact of the fuel injector connector
• Fuel injector or its circuit malfunction
• Engine does not start
• Fuel injector, fuel pump and ignition
coil shut down
26-78
P0202
(13-1)
No. 2 (right) fuel injector malfunction
• Loose or poor contact of the fuel injector connector
• Fuel injector or its circuit malfunction
• Engine does not start
• Fuel injector, fuel pump and ignition
coil shut down
P0131
(21-1)
O
2 sensor circuit low voltage (less than 0.059 V)
•O
2 sensor or its circuit malfunction
• Engine operates normally
26-79
P0132
(21-2)
O
2 sensor circuit high voltage (more than 3.008 V)
• Loose or poor contact of the O
2 sensor connector
•O
2 sensor or its circuit malfunction
• Engine operates normally
26-80
P0135
(23-1)
O2 sensor heater malfunction
• Loose or poor contact of the O
2 sensor connector
•O
2 sensor heater or its circuit malfunction
• Engine operates normally
26-81
P062F
(33-2)
ECM/PCM EEPROM malfunction • Engine operates normally
• Does not hold the self-diagnosis
data
26-83
P1702
(41-1)*
1
Gear position sensor malfunction
• Loose or poor contact of the gear position sensor
connector
• Gear position sensor or its circuit malfunction
• ECM malfunction
• Engine operates normally
• HSTC does not operate
26-83
P1000
(54-1)
Bank angle sensor circuit low voltage
(less than 0.020 V)
• Bank angle sensor or its circuit malfunction
• Engine operates normally
• Engine stop function does not
operate
26-85
P1001
(54-2)
Bank angle sensor circuit high voltage
(more than 4.976 V)
• Loose or poor contact of the bank angle sensor
connector
• Bank angle sensor or its circuit malfunction
• Engine operates normally
• Engine stop function does not
operate 26-86
P2158
(66-1)
Rear wheel speed sensor malfunction
• Loose or poor contact of the rear wheel speed
sensor connector
• Faulty rear wheel speed sensor or its circuit
malfunction
• Engine operates normally
26-87
26-68
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
P1500
(67-1)
Front wheel speed sensor malfunction
• Loose or poor contact of the front wheel speed
sensor connector
• Faulty front wheel speed sensor or its circuit
malfunction
• Engine operates normally
26-88
P0122
(71-1)
TP sensor 1 low voltage
• TP sensor 1 or its circuit malfunction
• Vehicle speed limit: approximately
120 km/h (75 mph)
• HSTC does not operate
26-89
P0123
(71-2)
TP sensor 1 high voltage
• Loose or poor contact of the TP sensor 1 connector
• TP sensor 1 or its circuit malfunction
• Vehicle speed limit: approximately
120 km/h (75 mph)
• HSTC does not operate
26-90
P0222
(72-1)
TP sensor 2 low voltage
• TP sensor 2 or its circuit malfunction
• Vehicle speed limit: approximately
120 km/h (75 mph)
• HSTC does not operate
26-91
P0223
(72-2)
TP sensor 2 high voltage
• Loose or poor contact of the TP sensor 2 connector
• TP sensor 2 or its circuit malfunction
• Vehicle speed limit: approximately
120 km/h (75 mph)
• HSTC does not operate
26-92
P2135
(73-1)
TP sensors 1 and 2 voltage correlation malfunction
• TP sensor or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate
26-93
P2135
(73-2)
TP sensors 1 and 2 short circuit
• TP sensor or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate
P2122
(74-1)
APS 1 (TCP) low voltage
• Loose or poor contact of the APS connector
• APS 1 or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate 26-94
P2123
(74-2)
APS 1 (TCP) high voltage
• APS 1 or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate
26-95
P2127
(75-1)
APS 2 (TCP) low voltage
• Loose or poor contact of the APS connector
• APS 2 or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate 26-96
P2128
(75-2)
APS 2 (TCP) high voltage
• APS 2 or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate
26-97
P2138
(76-1)
APS 1 – 2 (TCP) voltage correlation malfunction
• APS or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate
26-98
P1684
(77-1)
TBW return spring malfunction • Vehicle speed limit: approximately
120 km/h (75 mph)
• HSTC does not operate
26-99
P2118
(78-1)
TBW motor malfunction
• TBW motor circuit malfunction
• Engine operates at idle speed
• HSTC does not operate
26-100
P2101
(79-1)
TP sensor 2 low voltage
• TP sensor 2 or its circuit malfunction
• Vehicle speed limit: approximately
120 km/h (75 mph)
• HSTC does not operate
26-101
P055C
(83-1)*
2
EOP sensor low voltage (less than 0.059 V)
• EOP sensor or its circuit malfunction
• Engine operates normally
26-101
P055D
(83-2)*
2
EOP sensor high voltage (more than 4.883 V)
• Loose or poor contact of the EOP sensor connector
• EOP sensor or its circuit malfunction
• Engine operates normally
26-102
P0606
(84-1)
CPU in the ECM/PCM malfunction
• Faulty ECM/PCM
• Engine operates normally
26-103
P1658
(85-1)
TBW relay failure (ON side)
• TBW relay or its circuit malfunction
• Vehicle speed limit: approximately
120 km/h (75 mph)
• HSTC does not operate
26-103
P1659
(85-2)
TBW relay failure (OFF side)
• TBW relay or its circuit malfunction
• Engine operates at idle speed
• HSTC does not operate
P0443
(88-1)*
3
EVAP purge control solenoid valve malfunction
• Loose or poor contact of the EVAP purge control
solenoid valve connector
• EVAP purge control solenoid valve or its circuit
malfunction
• Engine operates normally
26-105
P0412
(89-1)
PAIR control solenoid valve malfunction
• Loose or poor contact of the PAIR control solenoid
valve connector
• PAIR control solenoid valve or its circuit malfunction
• Engine operates normally
26-106
DTC
(Honda
code)
Function Failure Symptom/Fail-safe function
Refer
to
page
26-69
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
•*
1
: CRF1000A/A2/AL/AL2
•*
2
: CRF1000D/D2/DL/DL2
•*
3
: ED/KO/TH/FO/MA models
P0351
(91-1)
No.1-1 (No.1 cylinder main) ignition coil circuit
malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.1 Injector and main ignition coil
shut down
26-108
P0352
(92-1)
No.2-1 (No.2 cylinder main) ignition coil circuit
malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.2 Injector and main ignition coil
shut down
P0353
(93-1)
No.1-2 (No.1 cylinder sub) ignition coil circuit
malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.1 Injector and sub ignition coil
shut down
P0354
(94-1)
No.2-2 (No.2 cylinder sub) ignition coil circuit
malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.2 Injector and sub ignition coil
shut down
U0001
(103-1)
CAN communication malfunction
• ECM/PCM failure
• Combination meter failure
• CAN communication circuit malfunction
• Engine operates normally
• HSTC does not operate
26-110
U0155
(103-2)
CAN communication malfunction
• Combination meter failure
• CAN communication circuit malfunction
• Engine operates normally
• HSTC does not operate 26-111
P170D
(107-1)*
1
Shift stroke sensor circuit low voltage
• Loose or poor contact of the Shift stroke sensor
connector
• Shift stroke sensor or its circuit malfunction
• Engine operates normally
• Quickshifter (Optional) does not
operate
26-112
P1708
(108-1)*
1
Shift spindle switch circuit low voltage
• Shift spindle switch or its circuit malfunction
• Engine operates normally
• Quickshifter (Optional) does not
operate
26-113
P0704
(113-1)*
1
Clutch switch circuit low voltage
• Clutch switch or its circuit malfunction
• Engine operates normally
• Quickshifter (Optional) does not
operate
26-114
DTC
(Honda
code)
Function Failure Symptom/Fail-safe function
Refer
to
page
26-70
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
PGM-FI DTC TROUBLESHOOTING
• If the ECM/PCM is replaced, perform the Key
Registration Procedure (page 23-3).
• CRF1000D/D2/DL/DL2: If the PCM is replaced,
perform the Clutch Initialize Learning Procedure
(page 13-82).
DTC P0107 (MAP SENSOR LOW
VOLTAGE)
1. MAP sensor system inspection
Check the MAP sensor with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. MAP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the MAP sensor 3P (Black) connector
(page 26-128).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P
(Black) connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 4.
NO – GO TO STEP 3.
3. MAP Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Open circuit in the Yellow/red wire
Connection: Yellow/red (+) – Gray/black (–)
[1]
Y/RGr/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
[1]
Y/R Y/R
[2]
26-71
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. MAP Sensor Signal Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between 3P (Black) connector
[1] and ground.
Is there continuity?
YES – Short circuit in the Light green/black wire
NO – GO TO STEP 5.
5. MAP Sensor Inspection
Replace the MAP sensor with a known good one
(page 26-128).
Connect the 33P (Gray) connector.
Erase the DTC (page 25-25).
Check the MAP sensor with the GST or MCS.
Is DTC P0107 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original MAP sensor
DTC P0108 (MAP SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the MAP sensor 3P (Black), ECM/
PCM 33P (Black) and 33P (Gray) connectors, and
recheck the DTC.
1. MAP sensor system inspection
Check the MAP sensor with the GST or MCS.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. MAP Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the MAP sensor 3P (Black) connector
(page 26-128).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P
(Black) connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – Open circuit in the Gray/black wire
Connection: Light green/black – Ground
[1]
Lg/Bl
Connection: Yellow/red (+) – Gray/black (–)
[1]
Y/RGr/Bl
26-72
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. MAP Sensor System Inspection with Jumper
Wire
Turn the ignition switch OFF.
Connect the wire harness side 3P (Black) connector
[1] terminals with a jumper wire [2].
Check the MAP sensor with the GST or MCS.
Is about 0 V indicated?
YES – Faulty MAP sensor
NO – GO TO STEP 4.
4. MAP Sensor Signal Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Black) connector
[2].
Is there continuity?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Open circuit in the Light green/black wire
DTC P1002 (MAP SENSOR
PERFORMANCE PROBLEM)
1. MAP Sensor System Inspection
Connect the GST or MCS.
Start the engine and check the MAP sensor with the
MCS at idle speed.
Is the reading changed?
YES – Intermittent failure
NO – GO TO STEP 2.
2. MAP Sensor Hose Inspection
Turn the ignition switch OFF.
Check that the hose [1] is connected to the MAP
sensor [2] properly.
Is the hose connected properly?
YES – GO TO STEP 3.
NO – Correct the hose connection
Connection: Light green/black – Gray/black
[2]
[1]
Gr/Bl Lg/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection:
Light green/black – Light green/black
[2]
Lg/Bl
Lg/Bl
[1]
[2] [1]
26-73
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. MAP Sensor System Inspection
Replace the MAP sensor with a known good one
(page 26-128).
Connect the GST or MCS.
Start the engine and check the MAP sensor with the
MCS at idle speed.
Has the reading changed?
YES – Faulty original MAP sensor
NO – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
DTC P0117 (ECT SENSOR LOW
VOLTAGE)
1. ECT Sensor System Inspection
Check the ECT sensor with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. ECT Sensor System Inspection with Connector
Disconnected
Turn the ignition switch OFF.
Disconnect the ECT sensor 2P (Black) connector
(page 4-41).
Check the ECT sensor with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 3.
NO – Faulty ECT sensor
3. ECT Sensor Output Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Light green wire
NO – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
DTC P0118 (ECT SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the ECT sensor 2P (Black), ECM/
PCM 33P (Black) and 33P (Gray) connectors, and
recheck the DTC.
1. ECT Sensor System Inspection
Check the ECT sensor with the GST or MCS.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
Connection: Light green – Ground
[1]
Lg
26-74
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. ECT Sensor System Inspection with Jumper
Wire
Turn the ignition switch OFF.
Disconnect the ECT sensor 2P (Black) connector
(page 4-41).
Connect the wire harness side 2P (Black) connector
[1] terminals with a jumper wire [2].
Check the ECT sensor with the GST or MCS.
Is about 0 V indicated?
YES – Faulty ECT sensor
NO – GO TO STEP 3.
3. ECT Sensor Output Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Black) connector [1] and 33P (Black) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Light green wire
4. ECT Sensor Ground Line Open Circuit
Inspection
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Open circuit in the Gray/black wire
DTC P0112 (IAT SENSOR LOW
VOLTAGE)
1. IAT Sensor System Inspection
Check the IAT sensor with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
Connection: Light green – Gray/black
[2]
[1]
Gr/Bl
Lg
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Light green – Light green
[1]
Lg
Lg
[2]
Connection: Gray/black – Gray/black
Gr/Bl
[1]
[2]
Gr/Bl
26-75
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. IAT Sensor System Inspection with Connector
Disconnected
Turn the ignition switch OFF.
Disconnect the IAT sensor 2P (Blue) connector
(page 7-11).
Check the IAT sensor with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 3.
NO – Faulty IAT sensor
3. IAT Sensor Output Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Blue) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Brown/red wire
NO – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
DTC P0113 (IAT SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the IAT sensor 2P (Blue), ECM/PCM
33P (Black) and 33P (Gray) connectors, and
recheck the DTC.
1. IAT Sensor System Inspection
Check the IAT sensor with the GST or MCS.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. IAT Sensor System Inspection with Jumper Wire
Turn the ignition switch OFF.
Disconnect the IAT sensor 2P (Blue) connector
(page 7-11).
Connect the wire harness side 2P (Blue) connector
[1] terminals with a jumper wire [2].
Check the IAT sensor with the GST or MCS.
Is about 0 V indicated?
YES – Faulty IAT sensor
NO – GO TO STEP 3.
Connection: Brown/red – Ground
[1]
Br/R
Connection: Brown/red – Gray/black
[2]
[1]
Gr/Bl Br/R
26-76
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. IAT Sensor Output Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Blue) connector [1] and 33P (Black) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Brown/red wire
4. IAT Sensor Ground Line Open Circuit Inspection
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Blue) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Open circuit in the Gray/black wire
DTC P0500 (VS SENSOR)
• Before starting the inspection, check for loose or
poor contact on the VS sensor 3P (Black) and ECM/
PCM 33P (Gray) connectors, and recheck the DTC.
1. DTC Recheck
Erase the DTC (page 25-25).
Test-ride the motorcycle above 3,400 min
-1
(rpm).
Stop the engine.
Check the DTC with the GST or MCS.
Is DTC P0500 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. VS Sensor Ground Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the VS sensor 3P (Black) connector
(page 4-42).
Check for continuity between the wire harness side
3P (Black) connector [1] and ground.
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Green wire
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Brown/red – Brown/red
[1]
Br/R
Br/R
[2]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
Gr/Bl
[1]
[2]
Gr/Bl
Connection: Green – Ground
[1]
G
26-77
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. VS Sensor Input Line Open Circuit Inspection
Temporarily install the removed electrical parts in
the reverse order of removal.
Turn the ignition switch ON.
Measure the voltage between the wire harness side
3P (Black) connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 4.
NO – • Open circuit in the Black/red wire
(CRF1000A/A2/AL/AL2)
• Open circuit in the Black and Black/red
wire (CRF1000D/D2/DL/DL2)
4. VS Sensor Signal Line Short Circuit Inspection
Turn the ignition switch OFF.
Check for continuity between the wire harness side
3P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Pink wire
NO – GO TO STEP 5.
5. VS Sensor Signal Line Open Circuit Inspection
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 6.
NO – Open circuit in the Pink wire
6. VS Sensor Inspection
Replace the VS sensor with a known good one
(page 4-42).
Connect the 33P (Gray) connector.
Erase the DTC (page 25-25).
Test-ride the motorcycle above 3,400 min
-1
(rpm).
Stop the engine.
Check the DTC with the GST or MCS.
Is the DTC P0500 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original VS sensor
Connection:
CRF1000A/A2/AL/AL2:
Black/red (+) – Green (–)
CRF1000D/D2/DL/DL2:
Black (+) – Green (–)
[1]
G
CRF1000A/A2/AL/AL2: Bl/R
CRF1000D/D2/DL/DL2: Bl
Connection: Pink – Ground
[1]
P
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Pink – Pink
[1]
P
P
[2]
26-78
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC P0201 (No. 1 FUEL INJECTOR)/
DTC P0202 (No. 2 FUEL INJECTOR)
• Before starting the inspection, check for loose or
poor contact on the fuel injector 2P (No.1: Black/
No.2: Blue) and ECM/PCM 33P (Gray) connectors,
and recheck the DTC.
1. DTC Recheck
Erase the DTC (page 25-25).
Check the DTC with the GST or MCS.
Is the DTC P0201 or P0202 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Fuel Injector Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the fuel injector 2P (No.1: Black/No.2:
Blue) connector (page 26-128).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
2P connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 3.
NO – Open circuit in the Brown/black wire
3. Fuel Injector Resistance Inspection
Turn the ignition switch OFF.
Measure the resistance at the injector side 2P
connector [1].
Is the resistance within 11 – 13 (20°C/68°F)?
YES – GO TO STEP 4.
NO – Faulty fuel injector
Connection: Brown/black (+) – Ground (–)
[1]
Br/Bl
[1]
26-79
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Fuel Injector Signal Line Open Circuit Inspection
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between the wire harness side
No.1 fuel injector 2P connector [1] and 33P (Gray)
connector [2].
Check for continuity between the wire harness side
No.2 fuel injector 2P connector [3] and 33P (Gray)
connector.
Is there continuity?
YES – GO TO STEP 5.
NO – • Open circuit in the Pink/black wire
• Open circuit in the Pink/blue wire
5. Fuel Injector Signal Line Short Circuit Inspection
Check for continuity between the wire harness side
2P connector [1] and ground.
Is there continuity?
YES – • Short circuit in the Pink/black wire
• Short circuit in the Pink/blue wire
NO – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
DTC P0131 (O2 SENSOR LOW
VOLTAGE)
1. DTC Recheck
Erase the DTC (page 25-25).
Start the engine and warm it up until the coolant
temperature is 80°C (176°F).
Stop the engine.
Check the DTC with the GST or MCS.
Is the DTC P0131 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection:
No.1: Pink/black – Pink/black
No.2: Pink/blue – Pink/blue
[2]
[1]
P/Bl
P/Bu
[2]
[3]
Connection:
No.1: Pink/black – Ground
No.2: Pink/blue – Ground
[1]
No.1: P/Bl
No.2: P/Bu
26-80
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. O2 Sensor Output Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the O2 sensor 4P (Black) connector
(page 26-58).
Check for continuity between the wire harness side
4P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Black wire
NO – GO TO STEP 3.
3. O
2 Sensor Inspection
Replace the O
2 sensor with a known good one
(page 4-42).
Erase the DTC (page 25-25).
Start the engine and warm it up until the coolant
temperature is 80°C (176°F).
Stop the engine.
Check the O
2 sensor with the GST or MCS.
Is the DTC P0131 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original O
2 sensor
DTC P0132 (O2 SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the O
2 sensor 4P (Black), ECM/PCM
33P (Blue) and 33P (Gray) connectors, and recheck
the DTC.
1. DTC Recheck
Erase the DTC (page 25-25).
Start the engine and warm it up until the coolant
temperature is 80°C (176°F).
Stop the engine.
Check the DTC with the GST or MCS.
Is the DTC P0132 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
Connection: Black – Ground
Bl
[1]
26-81
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. O2 Sensor Output Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the O
2 sensor 4P (Black) connector
(page 26-58).
Disconnect the ECM/PCM 33P (Blue) connector
(page 4-39).
Check for continuity between the wire harness side
4P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Black wire
3. O
2 Sensor Ground Line Open Circuit Inspection
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between the wire harness side
4P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Gray or Gray/black wire
4. O
2 Sensor Inspection
Replace the O
2 sensor with a known good one
(page 4-42).
Connect the ECM/PCM 33P (Blue and Gray)
connectors.
Erase the DTC (page 25-25).
Start the engine and warm it up until the coolant
temperature is 80°C (176°F).
Stop the engine.
Check the O
2 sensor with the GST or MCS.
Is the DTC P0132 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original O
2 sensor
DTC P0135 (O2 SENSOR HEATER)
• Before starting the inspection, check for loose or
poor contact on the O
2 sensor 4P (Black) and ECM/
PCM 33P (Black) connectors, and recheck the DTC.
1. DTC Recheck
Erase the DTC (page 25-25).
Start the engine and check the DTC with the GST or
MCS.
Is DTC P0135 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Black – Black
[2]
[1]
Bl
Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray – Gray/black
Gr/Bl
[1]
[2]
Gr
26-82
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. O2 Sensor Heater Resistance Inspection
Turn the ignition switch OFF.
Disconnect the O2 sensor 4P (Black) connector
(page 26-58).
Measure the resistance at the sensor side 4P
(Black) connector [1].
Is the resistance within 6.7 – 10.5 (20°C/68°F)?
YES – GO TO STEP 3.
NO – Faulty O
2 sensor
3. O
2 Sensor Heater Input Voltage Inspection
Turn the ignition switch ON.
Measure the voltage between the wire harness side
4P (Black) connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 4.
NO – Open circuit in the Brown/black wire
4. O
2 Sensor Heater Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
4P (Black) connector [1] and 33P (Black) connector
[2].
Is there continuity?
YES – GO TO STEP 5.
NO – Open circuit in the White wire
5. O
2 Sensor Heater Line Short Circuit Inspection
Check for continuity between the wire harness side
4P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the White wire
NO – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
Connection:
CRF1000A/A2/AL/AL2:
White – White
CRF1000D/D2/DL/DL2:
Red/white – White
[1]
W
CRF1000A/A2/AL/AL2: W
CRF1000D/D2/DL/DL2: R/W
Connection: Brown/black (+) – Ground (–)
[1]
Br/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: White – White
W
[2]
[1]
W
Connection: White – Ground
W
[1]
26-83
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC P062F (ECM/PCM EEPROM)
1. Recheck DTC
Erase the DTC (page 25-25).
Check the DTC with the GST or MCS.
Is the DTC P062F indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Intermittent failure
DTC P1702 (GEAR POSITION
SENSOR) (CRF1000A/A2/AL/AL2)
• Before starting the inspection, check for loose or
poor contact on the gear position sensor 3P (Black),
PCM 33P (Blue) and 33P (Gray) connectors, and
recheck the DTC.
1. Gear Position Sensor System Inspection
Check the gear position sensor with the GST or
MCS.
Is about 0 V or 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Gear Position Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the gear position sensor 3P (Black)
connector (page 26-205).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P
(Black) connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 5.
NO – GO TO STEP 3.
3. Gear Position Sensor Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the ECM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Yellow/red wire
Connection: Yellow/red (+) – Gray/black (–)
Gr/BlY/R
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
[2][1]
Y/R
Y/R
26-84
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Gear Position Sensor Ground Line Open Circuit
Inspection
Check for continuity between the wire harness side
33P (Gray) connector [1] and 3P (Black) connector
[2].
Is there continuity?
YES – Replace the ECM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Gray/black wire
5. Gear Position Sensor Signal Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the ECM 33P (Blue) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Blue) connector
[2].
Is there continuity?
YES – GO TO STEP 6.
NO – Open circuit in the White wire
6. Gear Position Sensor Output Line Short Circuit
Inspection
Check for continuity between the wire harness side
3P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the White wire
NO – GO TO STEP 7.
7. Gear Position Sensor Inspection
Replace the gear position sensor with a known good
one (page 26-205).
Connect the 3P (Black) connector, 33P (Blue)
connector and 33P (Gray) connector.
Check the gear position sensor with the GST or
MCS.
Is about 0 V or 5 V indicated?
YES – Replace the ECM with a known good one
and recheck (page 4-39).
NO – Faulty original gear position sensor
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
Gr/Bl
[2]
Gr/Bl
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: White – White
[1]
W
W
[2]
Connection: White – Ground
[1]
W
26-85
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC P1000 (BANK ANGLE SENSOR
LOW VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the bank angle sensor 2P (Black)
and ECM/PCM 33P (Gray) connectors, and recheck
the DTC.
1. Bank Angle Sensor System Inspection
Erase the DTC (page 25-25).
Check the bank angle sensor with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Bank Angle Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the bank angle sensor 2P (Black)
connector (page 22-4).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
2P (Black) connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 3.
NO – Open circuit in the Black/white or Red/
white wire
3. Bank Angle Sensor Signal Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Gray) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Red/blue wire
Connection:
CRF1000A/A2/AL/AL2:
Black/white (+) – Ground (–)
CRF1000D/D2/DL/DL2:
Red/white (+) – Ground (–)
[1]
CRF1000A/A2/AL/AL2: Bl/W
CRF1000D/D2/DL/DL2: R/W
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Red/blue – Red/blue
[2]
[1]
R/Bu
R/Bu
26-86
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Bank Angle Sensor Signal Line Short Circuit
Inspection
Check for continuity between the wire harness side
2P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Red/blue wire
NO – GO TO STEP 5.
5. Bank Angle Sensor Inspection
Replace the bank angle sensor with a known good
one (page 4-42).
Connect the ECM/PCM 33P (Gray) connector.
Erase the DTC (page 25-25).
Check the DTC with the GST or MCS.
Is DTC P1000 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original bank angle sensor
DTC P1001 (BANK ANGLE SENSOR
HIGH VOLTAGE)
1. Bank Angle Sensor System Inspection
Erase the DTC (page 25-25).
Check the bank angle sensor with the GST or MCS.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Bank Angle Sensor Inspection
Replace the bank angle sensor with a known good
one (page 4-42).
Erase the DTC (page 25-25).
Check the DTC with the GST or MCS.
Is DTC P1001 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original bank angle sensor
Connection: Red/blue – Ground
[1]
R/Bu
26-87
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC P2158 (REAR WHEEL SPEED
SENSOR SIGNAL)
1. DTC Recheck
Erase the DTC (page 25-25).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 20 seconds.
Stop the engine.
Check the DTC with the GST or MCS.
Is DTC P2158 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. ABS DTC Check
Check the ABS DTC (page 20-6).
Does the ABS modulator have any DTC?
YES – Follow the ABS DTC index (page 26-184).
NO – GO TO STEP 3.
3. Rear Wheel Speed Sensor Signal Output Line
Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the following:
– ABS modulator 18P (Black) connector (page 20-
6)
– ECM/PCM 33P (Black) connector (page 4-39)
Check for continuity between the wire harness side
18P (Black) connector [1] and 33P (Black)
connector [2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Blue/black wire
4. Rear Wheel Speed Sensor Signal Output Line
Short Circuit Inspection
Check for continuity between the wire harness side
33P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Blue/black wire
NO – GO TO STEP 5.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/black – Blue/black
[2]
[1]
Bu/Bl
Bu/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/black – Ground
[1]
Bu/Bl
26-88
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. ECM/PCM Inspection
Replace the ECM/PCM with a known good one
(page 4-39).
Connect the ABS modulator 18P (Black) connector.
Erase the DTC (page 25-25).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 20 seconds.
Stop the engine.
Check the DTC with the GST or MCS.
Is DTC P2158 indicated?
YES – Replace the ABS modulator with a known
good one and recheck (page 26-195).
NO – Faulty original ECM/PCM
DTC P1500 (FRONT WHEEL SPEED
SENSOR SIGNAL)
1. DTC Recheck
Erase the DTC (page 25-25).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 30 seconds.
Stop the engine.
Check the DTC with the GST or MCS.
Is DTC P1500 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. ABS DTC Check
Check the ABS DTC (page 20-6).
Does the ABS modulator have any DTC?
YES – Follow the ABS DTC index (page 26-184).
NO – GO TO STEP 3.
3. Front Wheel Speed Sensor Signal Output Line
Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the following:
– ABS modulator 18P (Black) connector (page 20-
6)
– ECM/PCM 33P (Gray) connector (page 4-39)
Check for continuity between the wire harness side
18P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Blue/yellow wire
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/yellow – Blue/yellow
[2]
[1]
Bu/Y
Bu/Y
26-89
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Front Wheel Speed Sensor Signal Output Line
Short Circuit Inspection
Check for continuity between the wire harness side
33P (Gray) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Blue/yellow wire
NO – GO TO STEP 5.
5. ECM/PCM Inspection
Replace the ECM/PCM with a known good one
(page 4-39).
Connect the ABS modulator 18P (Black) connector.
Erase the DTC (page 25-25).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 30 seconds.
Stop the engine.
Check the DTC with the GST or MCS.
Is DTC P1500 indicated?
YES – Replace the ABS modulator with a known
good one and recheck (page 26-195).
NO – Faulty original ECM/PCM
DTC P0122 (TP SENSOR 1 LOW
VOLTAGE)
1. TP Sensor 1 System Inspection
Erase the DTC (page 25-25).
Check the TP sensor with the GST or MCS.
Is about 0.096 V and below indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TP Sensor 1 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the TBW unit 6P (Black) connector
(page 26-128).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the TBW unit
connector [1] terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 3.
NO – • Open or short circuit in the Yellow wire
• If the wire is OK, replace the ECM with
a known good one, and recheck.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/yellow – Ground
[1]
Bu/Y
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow (+) – Light green (–)
[1]
YLg
26-90
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. TP Sensor 1 Output Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the TBW unit
connector [1] terminal at the harness side and
ground.
Is there continuity?
YES – Short circuit in the Blue/Black wire
NO – GO TO STEP 4.
4. TP Sensor 1 Inspection
• If the TP sensor 1 is faulty, replace the throttle
body/TBW unit assembly.
Replace the throttle body (page 26-128).
Connect the ECM and TBW unit connectors.
Erase the DTC (page 25-25).
Turn the ignition switch ON with the engine stop
switch " ".
Check the TP sensor 1 with the MCS.
Is DTC P0122 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original TBW unit (TP Sensor)
DTC P0123 (TP SENSOR 1 HIGH
VOLTAGE)
1. TP Sensor 1 System Inspection
Erase the DTC (page 25-25).
Check the TP sensor with the GST or MCS.
Is about 4.762 V and above indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TP Sensor 1 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the TBW unit 6P (Black) connector
(page 26-128).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the TBW unit
connector [1] terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 3.
NO – • Open circuit in the Light green wire
• If the wire is OK, replace the ECM/PCM
with a known good one and recheck
(page 4-39).
Connection: Blue/Black – Ground
Bu/Bl
[1]
Connection: Yellow (+) – Light green (–)
YLg
[1]
26-91
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. TP Sensor 1 Output Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the TBW unit
connector [1] and ECM/PCM connector [2] terminals
at the wire side.
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Blue/Black wire
4. TP Sensor 1 Inspection
• If the TP sensor 1 is faulty, replace the throttle
body/TBW unit assembly.
Replace the throttle body (page 26-128).
Connect the ECM/PCM and TBW unit connectors.
Erase the DTC (page 25-25).
Check the TP sensor 1 with the GST or MCS.
Is DTC P0123 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original TBW unit (TP Sensor)
DTC P0222 (TP SENSOR 2 LOW
VOLTAGE)
1. TP Sensor 2 System Inspection
Erase the DTC (page 25-25).
Check the TP sensor with the GST or MCS.
Is about 0.063 V and below indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TP Sensor 2 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the TBW unit 6P (Black) connector [1]
(page 26-128).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the TBW unit
connector [1] terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 3.
NO – • Open or short circuit in the Yellow wire
• If the wire is OK, replace the ECM/PCM
with a known good one and recheck
(page 4-39).
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/Black – Blue/Black
[1]
Bu/Bl
[2]
Bu/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow (+) – Light green (–)
YLg
[1]
26-92
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. TP Sensor 2 Output Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the TBW unit
connector terminal at the harness side and ground.
Is there continuity?
YES – Short circuit in the Blue/white wire
NO – GO TO STEP 4.
4. TP Sensor 2 Inspection
• If the TP sensor 2 is faulty, replace the throttle
body/TBW unit assembly.
Replace the throttle body (page 26-128).
Connect the ECM/PCM and TBW unit connectors.
Erase the DTC (page 25-25).
Check the TP sensor 2 with the GST or MCS.
Is DTC P0222 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original TBW unit (TP Sensor)
DTC P0223 (TP SENSOR 2 HIGH
VOLTAGE)
1. TP Sensor 2 System Inspection
Erase the DTC (page 25-25).
Check the TP sensor with the GST or MCS.
Is about 4.761 V and above indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TP Sensor 2 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the TBW unit 6P (Black) connector [1]
(page 26-128).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the TBW unit
connector [1] terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 3.
NO – • Open circuit in the Light green wire
• If the wire is OK, replace the ECM/PCM
with a known good one and recheck
(page 4-39).
Connection: Blue/white – Ground
Bu/W
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow (+) – Light green (–)
YLg
[1]
26-93
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. TP Sensor 2 Output Line Open Circuit
Inspection
Turn the ignition switch OFF.
Check for continuity between the TBW sensor
connector [1] and ECM/PCM connector [2] terminals
at the harness side.
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Blue/white wire
4. TP Sensor 2 Inspection
• If the TP sensor 2 is faulty, replace the throttle
body/TBW unit assembly.
Replace the throttle body (page 26-128).
Connect the ECM/PCM and TBW unit connectors.
Erase the DTC (page 25-25).
Turn the ignition switch ON with the engine stop
switch " ".
Check the TP sensor 2 with the GST or MCS.
Is DTC P0223 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original TBW unit (TP Sensor)
DTC P2135 (TP SENSOR 1 and 2
VOLTAGE CORRELATION FAILURE)
DTC P2135 (TP SENSOR 1 and 2
SHORT CIRCUIT)
1. TP Sensor 1 and 2 System Inspection
Erase the DTC (page 25-25).
Check the TP sensor with the GST or MCS.
Is the DTC P2135 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Throttle Valve Operation Inspection
Turn the ignition switch OFF.
Remove the air cleaner housing (page 26-128).
Turn the ignition switch ON with the engine stop
switch " ".
Visually check the throttle valve operation.
Is the valve operation normal?
YES – Clean the throttle bores and valves
carefully. (Do not apply commercially
available carburetor cleaners to the inside
of the throttle bore, which is coated with
molybdenum.)
NO – GO TO STEP 3.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/white – Blue/white
Bu/W
[2]
Bu/W
[1]
26-94
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. TP Sensor Line Short Circuit Inspection
Disconnect the ECM/PCM 33P (Black) connector [1]
(page 4-39).
Disconnect the TBW unit 6P (Black) connector
(page 26-128).
Check for continuity between the ECM/PCM
connector terminals at the harness side.
Is there continuity?
YES – GO TO STEP 4.
NO – Short circuit of the Blue/black to Blue/white
wire
4. TP Sensor Inspection
• If the TP sensor 1 and 2 is faulty, replace the
throttle body/TBW unit assembly.
Replace the throttle body (page 26-128).
Connect the ECM/PCM and TBW unit connectors.
Erase the DTC (page 25-25).
Turn the ignition switch ON with the engine stop
switch " ".
Check the TP sensor 1 and 2 with the GST or MCS.
Is DTC P2135 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original TBW unit (TP Sensor)
DTC P2122 (APS 1 LOW VOLTAGE)
1. APS 1 System Inspection
Erase the DTC (page 25-25).
Check the APS 1 sensor with the GST or MCS.
Is about 0.137 V and below indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. APS 1 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the APS 8P (Black) connector (page 26-
116).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the APS connector [1]
terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 3.
NO – • Open or short circuit in the Brown wire
• If the wire is OK, replace the ECM/PCM
with a known good one and recheck
(page 4-39).
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/black – Blue/white
[1]
Bu/W
Bu/Bl
Connection: Brown (+) – Pink (–)
[1]
BrP
26-95
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. APS 1 Output Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the APS 8P (Black) connector (page 26-
116).
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the APS connector [1]
and ECM/PCM connector [2] terminals at the
harness side.
Is there continuity?
YES – Open circuit in the Blue/yellow wire
NO – GO TO STEP 4.
4. APS 1 Output Line Short Circuit Inspection
Check for continuity between the APS connector
terminal at the harness side and ground.
Is there continuity?
YES – Short circuit in the Blue/yellow wire
NO – GO TO STEP 5.
5. APS 1 Inspection
• If the APS 1 is faulty, replace the APS.
Replace the APS (page 26-116).
Connect the ECM/PCM and APS connectors.
Erase the DTC (page 25-25).
Check the APS 1 with the GST or MCS.
Is DTC P2122 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original APS
DTC P2123 (APS 1 HIGH VOLTAGE)
1. APS 1 System Inspection
Erase the DTC (page 25-25).
Check the APS 1 with the GST or MCS.
Is about 4.902 V and above indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/yellow – Blue/yellow
[2]
Bu/Y
[1]
Bu/Y
Connection: Blue/yellow – Ground
[1]
Bu/Y
26-96
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. APS 1 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the APS 8P (Black) connector (page 26-
116).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the APS connector [1]
terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 3.
NO – • Open circuit in the Brown wire
• If the wire is OK, replace the ECM/PCM
with a known good one and recheck
(page 4-39).
3. APS 1 Inspection
• If the APS 1 is faulty, replace the APS.
Replace the APS (page 26-116).
Connect the APS connector.
Erase the DTC (page 25-25).
Check the APS 1 with the MCS.
Is DTC P2123 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original APS
DTC P2127 (APS 2 LOW VOLTAGE)
1. APS 2 System Inspection
Erase the DTC (page 25-25).
Check the APS 2 with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. APS 2 Output Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Disconnect the APS 8P (Black) connector (page 26-
116).
Check for continuity between the APS [1] connector
terminal at the harness side and ground.
Is there continuity?
YES – Short circuit in the Yellow wire
NO – GO TO STEP 3.
Connection: Brown (+) – Pink (–)
[1]
BrP
Connection: Yellow – Ground
[1]
Y
26-97
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. APS 2 Output Line Open Circuit Inspection
Check for continuity between the APS connector [1]
and ECM/PCM connector [2] at the harness side.
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Yellow wire
4. APS 2 Input Voltage Inspection
Connect the ECM/PCM connector.
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the APS connector [1]
terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 5.
NO – • Open or short circuit in the White wire
• Open circuit in the Light green wire
(CRF1000A/A2/AL/AL2)
• Open circuit in the Beige wire
(CRF1000D/D2/DL/DL2)
• If the wires are good condition, replace
the ECM/PCM with a known good one
and recheck (page 4-39).
5. APS 2 Inspection
• If the APS 2 is faulty, replace the APS.
Replace the APS (page 26-116).
Connect the APS connector.
Erase the DTC (page 25-25).
Check the APS 2 with the MCS.
Is DTC P2127 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original APS
DTC P2128 (APS 2 HIGH VOLTAGE)
1. APS 2 System Inspection
Erase the DTC (page 25-25).
Check the TP sensor with the GST or MCS.
Is about 4.902 V and above indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow – Yellow
[2]
[1]
Y
Y
Connection:
CRF1000A/A2/AL/AL2:
White (+) – Light green (–)
CRF1000D/D2/DL/DL2:
White (+) – Beige (–)
[1]
CRF1000A/A2/AL/AL2: Lg
CRF1000D/D2/DL/DL2: Be
W
26-98
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. APS 2 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the APS 8P (Black) connector (page 26-
116).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the APS connector [1]
terminals at the harness side.
Is about 5 V indicated?
YES – GO TO STEP 3.
NO – • Open circuit in the Light green wire
(CRF1000A/A2/AL/AL2)
• Open circuit in the Beige wire
(CRF1000D/D2/DL/DL2)
• If the wire is OK, replace the ECM/PCM
with a known good one and recheck
(page 4-39).
3. APS 2 Inspection
• If the APS 2 is faulty, replace the APS.
Replace the APS (page 26-116).
Connect the APS connector.
Erase the DTC (page 25-25).
Check the APS 2 with the GST or MCS.
Is DTC P2128 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original APS
DTC P2138 (APS 1 and 2 VOLTAGE
CORRELATION FAILURE)
1. APS System Inspection
Erase the DTC (page 25-25).
Open the throttle and check the APS 1 and 2 with
the GST or MCS.
Is the DTC P2138 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
Connection:
CRF1000A/A2/AL/AL2:
White (+) – Light green (–)
CRF1000D/D2/DL/DL2:
White (+) – Beige (–)
[1]
CRF1000A/A2/AL/AL2: Lg
CRF1000D/D2/DL/DL2: Be
W
26-99
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. APS Line Short Circuit Inspection
Disconnect the ECM/PCM 33P (Black) connector [1]
(page 4-39).
Check for continuity between the ECM/PCM
connectors at the harness side.
Is there continuity?
YES – GO TO STEP 3.
NO – Short circuit of the Blue/yellow wire to
Yellow wire
3. APS Inspection
• If the APS is faulty, replace the APS.
Replace the APS (page 26-116).
Connect the ECM/PCM 33P connectors.
Erase the DTC (page 25-25).
Check the APS with the GST or MCS.
Is DTC P2138 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original APS
DTC P1684 (TBW RETURN SPRING
FAILURE)
1. Throttle Valve and Return Spring Inspection
• Be careful not to damage the throttle valves.
• The return spring cannot be replaced. If the
return spring is faulty, replace the throttle body/
TBW unit assembly.
Remove the throttle body (page 26-128).
Open the throttle valve [1] with your finger.
Does the throttle valve open and return
smoothly?
YES – GO TO STEP 2.
NO – Faulty throttle body (throttle valve and/or
return spring)
2. Throttle Body Inspection
Check the throttle bores [1] and valves visually for
fixed carbon.
Is there contamination?
YES – Clean the throttle bores and valves
carefully. (Do not apply commercially
available carburetor cleaners to the inside
of the throttle bore, which is coated with
molybdenum.)
NO – GO TO STEP 3.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/yellow – Yellow
[1]
Bu/Y
Y
[1]
[1] [1]
26-100
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. TBW System Inspection
Install the throttle body (page 26-128).
Erase the DTC (page 25-25).
Start the engine and let it idle, and then stop the
engine and wait 10 seconds.
Check the TBW unit with the GST or MCS.
Is the DTC 77-1 indicated?
YES – • Replace the throttle body (page 26-
128).
• If the ECM/PCM still detects a problem,
replace the ECM/PCM with a known
good one and recheck (page 4-39).
NO – Intermittent failure
DTC P2118 (TBW MOTOR FAILURE)
1. TBW Motor System Inspection
Erase the DTC (page 25-25).
Check the TBW motor with the GST or MCS.
Is the DTC P2118 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TBW Motor Line Open Circuit Inspection
Disconnect the ECM/PCM 33P (Blue) connector
(page 4-39).
Disconnect the TBW unit 6P (Black) connector
(page 26-128).
Check for continuity between the ECM/PCM
connector [1] and TBW unit connector [2] terminals
at the harness side.
Is there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in the Blue/red wire
• Open circuit in the Blue wire
3. TBW Motor Inspection
• The TBW motor cannot be replaced. If the TBW
motor is faulty, replace the throttle body/TBW
unit assembly.
Replace the throttle body (page 26-128).
Connect the ECM/PCM and TBW unit connectors.
Erase the DTC (page 25-25).
Check the TBW motor with the GST or MCS.
Is the DTC P2118 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original TBW unit (TBW motor)
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/red – Blue/red
Blue – Blue
[2]
Bu/R
Bu
Bu/R
Bu
[2]
[1]
[1]
26-101
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC P2101 (TBW SYSTEM CONTROL
CORRELATION FAILURE)
1. TBW System Inspection
Erase the DTC (page 25-25).
Check the TBW system with the GST or MCS.
Is the DTC P2101 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TBW Motor Line Open Circuit Inspection
Disconnect the ECM/PCM 33P (Blue) connector [1]
(page 4-39).
Check for continuity between the ECM/PCM
connector at the harness side.
Is there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in the Blue wire
• Open circuit in the Blue/red wire
3. TBW Unit Inspection
Replace the throttle body (page 26-128).
Erase the DTC (page 25-25).
Check the TBW system with the MCS.
Is the DTC P2101 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original TBW unit (TBW control
system)
DTC P055C (EOP SENSOR LOW
VOLTAGE) (CRF1000D/D2/DL/DL2)
1. EOP Sensor System Inspection
Connect the MCS and start the engine.
Check the EOP sensor with the GST or MCS.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. EOP Sensor Inspection
Stop the engine.
Disconnect the CKP sensor/EOP sensor 6P (Black)
connector (page 22-10).
Turn the ignition switch ON.
Check the EOP sensor with the MCS.
Is about 0 V indicated?
YES – GO TO STEP 3.
NO – Faulty EOP sensor
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue – Blue/red
[1]
Bu
Bu/R
26-102
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. EOP Sensor Input Line Open Circuit Inspection
Measure the voltage at the wire harness side 6P
(Black) connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 4.
NO – Open circuit in the Yellow/red wire
4. EOP Sensor Output Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector (page
4-39).
Check for continuity between the wire harness side
6P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the White wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC P055D (EOP SENSOR HIGH
VOLTAGE) (CRF1000D/D2/DL/DL2)
• Before starting the inspection, check for loose or
poor contact on the CKP sensor/EOP sensor 6P
(Black), PCM 33P (Black) and 33P (Gray)
connectors, and recheck the DTC.
1. EOP Sensor System Inspection
Check the EOP sensor with the GST or MCS.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. EOP Sensor Inspection
Turn the ignition switch OFF.
Disconnect the CKP sensor/EOP sensor 6P (Black)
connector (page 22-10).
Connect the wire harness side 6P (Black) connector
[1] terminals with a jumper wire [2].
Turn the ignition switch ON.
Check the EOP sensor with the MCS.
Is about 0 V indicated?
YES – Faulty EOP sensor
NO – GO TO STEP 3.
Connection: Yellow/red (+) – Gray/black (–)
Gr/Bl
Y/R
[1]
Connection: White – Ground
W
[1]
Connection: White – Gray/black
[2]
W
Gr/Bl
[1]
26-103
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. EOP Sensor Ground Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
sensor 6P (Black) connector [1] and 33P (Gray)
connector [2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Gray/black wire
4. EOP Sensor Output Line Open Circuit
Inspection
Disconnect the PCM 33P (Black) connector (page
4-39).
Check for continuity between the wire harness side
6P (Black) connector [1] and 33P (Black) connector
[2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the White wire
DTC P0606 (CPU IN THE PCM)
1. DTC Recheck
Erase the DTC (page 25-25).
Check the DTC with the GST or MCS.
Is DTC P0606 indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Intermittent failure
DTC P1658 (TBW RELAY FAILURE -
ON SIDE)
DTC P1659 (TBW RELAY FAILURE -
OFF SIDE)
1. TBW Relay System Inspection
Inspect the TBW relay (page 26-122).
Erase the DTC (page 25-25).
Check the TBW relay with the GST or MCS.
Is the DTC P1658 or P1659 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
[2]
[1]
Gr/Bl
Gr/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: White – White
W
[2]
[1]
W
26-104
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. TBW Relay Input Voltage Inspection
Turn the ignition switch OFF.
Remove the TBW relay (page 26-122).
Measure the voltage at the TBW relay terminal [1]
and ground.
Is about 12 V indicated?
YES – GO TO STEP 3.
NO – • Open circuit in Red/blue wire
• Open circuit in Green wire
• Blown TBW 10 A fuse
3. TBW Relay Line Open Circuit Inspection
Disconnect the ECM/PCM 33P (Blue) connector [1]
and ECM/PCM 33P (Black) connector [2] (page 4-
39).
Check for continuity between the ECM/PCM
connector and TBW relay terminals [3] at the
harness side.
Is there continuity?
YES – GO TO STEP 4.
NO – • Open circuit in the Brown/green wire
• Open circuit in the Yellow/white wire
4. TBW Relay Line Short Circuit Inspection
Check for continuity between the ECM/PCM (Blue)
connector [1] and (Black) connector [2] terminals at
the harness side and ground.
Is there continuity?
YES – • Short circuit in the Brown/green wire
• Short circuit in the Yellow/white wire
NO – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
Connection: Red/blue (+) – Green (–)
[1]
R/Bu
G
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Brown/green – Brown/green
Brown/green – Brown/green
Yellow/white – Yellow/white
[2]
Y/W
Br/G
[3]
[1]
Br/G
[1]
Br/G
Br/G
Y/W
[3]
[3]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Brown/green – Ground
Brown/green – Ground
Yellow/white – Ground
[2]
[1]
Br/GBr/G
Y/W
26-105
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC P0443 (EVAP PURGE CONTROL
SOLENOID VALVE) (ED/KO/TH/FO/MA
models)
• Before starting the inspection, check for loose or
poor contact on the EVAP purge control solenoid
valve 2P (Black) and ECM/PCM 33P (Black)
connectors, and recheck the DTC.
1. EVAP Purge Control Solenoid Valve System
Inspection
Erase the DTCs (page 25-25).
Start the engine and check the EVAP purge control
solenoid valve with the GST or MCS.
Is the DTC P0443 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. EVAP Purge Control Solenoid Valve Input
Voltage Inspection
Turn the ignition switch OFF.
Disconnect the EVAP purge control solenoid valve
2P (Black) connector (page 25-58).
Turn the ignition switch ON and engine stop switch
"".
Measure the voltage between the wire harness side
2P (Black) connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 3.
NO – Open circuit in the Brown/black wire
3. EVAP Purge Control Solenoid Valve Signal Line
Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Black) [1] and 33P (Black) [2] connectors.
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Yellow/black wire
Connection: Brown/black (+) – Ground (–)
[1]
Br/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/black – Yellow/black
[1]
[2]
Y/Bl
Y/Bl
26-106
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. EVAP Purge Control Solenoid Valve Signal Line
Short Circuit Inspection
Check for continuity between the 2P (Black)
connector [1] and ground.
Is there continuity?
YES – Short circuit in the Yellow/black wire
NO – GO TO STEP 5.
5. EVAP Purge Control Solenoid Valve Resistance
Inspection
Measure the resistance between the solenoid valve
side 2P (Black) connector [1] terminals.
Is the resistance within 30 – 34 (20°C/68°F)?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty EVAP purge control solenoid valve
DTC P0412 (PAIR CONTROL
SOLENOID VALVE)
• Before starting the inspection, check for loose or
poor contact on the PAIR control solenoid valve 2P
(Black) and ECM/PCM 33P (Black) connectors, and
recheck the DTC.
1. PAIR Control Solenoid Valve System Inspection
Erase the DTCs (page 25-25).
Start the engine and check the PAIR control
solenoid valve with the GST or MCS.
Is the DTC P0412 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
Connection: Yellow/black – Ground
Y/Bl
[1]
[1]
26-107
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. PAIR Control Solenoid Valve Input Voltage
Inspection
Turn the ignition switch OFF.
Disconnect the PAIR control solenoid valve 2P
(Black) connector (page 25-58).
Turn the ignition switch ON and engine stop switch
"".
Measure the voltage between the wire harness side
2P (Black) connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 3.
NO – Open circuit in the Brown/black wire
3. PAIR Control Solenoid Valve Signal Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector
(page 4-39).
Check for continuity between the wire harness side
2P (Black) [1] and 33P (Black) [2] connectors.
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Yellow/blue wire
4. PAIR Control Solenoid Valve Signal Line Short
Circuit Inspection
Check for continuity between the 2P (Black)
connector [1] and ground.
Is there continuity?
YES – Short circuit in the Yellow/blue wire
NO – GO TO STEP 5.
Connection: Brown/black (+) – Ground (–)
[1]
Br/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/blue – Yellow/blue
[1]
[2]
Y/Bu
Y/Bu
Connection: Yellow/blue – Ground
Y/Bu
[1]
26-108
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. PAIR Control Solenoid Valve Resistance
Inspection
Measure the resistance between the solenoid valve
side 2P (Black) connector [1] terminals.
Is the resistance within 24 – 28 (20°C/68°F)?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty PAIR control solenoid valve
DTC P0351
(No.1-1 [No1 CYLINDER MAIN]
IGNITION COIL CIRCUIT)/
DTC P0352
(No.2-1 [No.2 CYLINDER MAIN]
IGNITION COIL CIRCUIT)/
DTC P0353
(No.1-2 [No.1 CYLINDER SUB]
IGNITION COIL CIRCUIT)/
DTC P0354
(No.2-2 [No.2 CYLINDER SUB]
IGNITION COIL CIRCUIT)
1. Ignition Coil Primary Circuit System Inspection
Erase the DTCs (page 25-25).
Start the engine and check the ignition coil primary
circuit with the GST or MCS.
Is the DTC P0351, P0352, P0353, or P0354
indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Ignition Coil Primary Coil Input Voltage
Inspection
Disassemble the ignition coil tray (page 26-124).
Connect the Ignition coil sub harness 6P connector
(page 26-124).
Turn the ignition switch ON and engine stop switch
"".
Measure the voltage between the wire harness side
wire connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 3.
NO – Open circuit in the Brown/black wire
[1]
Connection: Brown/black (+) – Ground (–)
[1]
Br/Bl
26-109
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Ignition Coil Primary Coil Signal Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Blue) connector
(page 4-39).
Check the continuity between the wire harness side
wire connector [1] and 33P (Blue) connector [2].
Is there continuity?
YES – GO TO STEP 4.
NO – • Open circuit in the Blue/black wire
• Open circuit in the Blue/white wire
• Open circuit in the Blue/red wire
• Open circuit in the Blue/yellow wire
4. Ignition Coil Primary Coil Signal Line Short
Circuit Inspection
Check for continuity between the ignition coil wire
connector [1] and ground.
Is there continuity?
YES – • Short circuit in the Blue/black wire
• Short circuit in the Blue/white wire
• Short circuit in the Blue/red wire
• Short circuit in the Blue/yellow wire
NO – GO TO STEP 5.
5. Ignition Coil Primary Peak Voltage Inspection
Connect the ECM/PCM 33P (Blue) connector.
Inspect the ignition coil primary peak voltage (page
26-124).
Is the peak voltage normal?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – GO TO STEP 6.
6. Ignition Coil Inspection
Replace the Ignition coil with a known good one
(page 26-124).
Erase the DTCs (page 25-25).
Check the ignition coil with the GST or MCS.
Is DTC P0351 (91-1) or P0352 (92-1) indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original ignition coil
TOOL:
Test probe 07ZAJ-RDJA110
Connection:
No.1-1 ignition coil: Blue/black – Blue/black
No.1-2 ignition coil: Blue/white – Blue/white
No.2-1 ignition coil: Blue/red – Blue/red
No.2-2 ignition coil: Blue/yellow – Blue/yellow
Bu/Bl
Bu/Y
Bu/R
Bu/W
[2]
[1]
Connection:
No.1-1 ignition coil: Blue/black – Ground
No.1-2 ignition coil: Blue/white – Ground
No.2-1 ignition coil: Blue/red – Ground
No.2-2 ignition coil: Blue/yellow – Ground
[1]
No.1-1: Bu/Bl
No.1-2: Bu/W
No.2-1: Bu/R
No.2-2: Bu/Y
26-110
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC U0001 (CAN)
1. CAN System Inspection
Erase the DTC (page 25-25).
Check the CAN with the GST or MCS.
Is DTC U0001 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. CAN Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the following:
– ECM 33P (Gray) connector [1] (page 4-39)
– Combination meter 32P (Gray) connector [2]
(page 22-12)
Check the continuity between the wire harness side
32P (Gray) and 33P (Gray) connectors terminals.
Is there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire
3. CAN Line Short Circuit Inspection
Check for continuity between the wire harness side
33P (Gray) connector [1] terminals and ground.
Is there continuity?
YES – • Short circuit in the Black/red wire
• Short circuit in the Black wire
NO – GO TO STEP 4.
4. ECM Inspection
Replace the ECM/PCM with a known good one.
Disconnect the combination meter 32P (Gray)
connector [2] (page 22-12).
Erase the DTC (page 25-25).
Check the CAN with the GST or MCS.
Is DTC U0001 indicated?
YES – GO TO STEP 5.
NO – Faulty original ECM/PCM
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Black/red – Black/red
Black – Black
[2]
[1]
Bl/R
Bl
Bl
Bl/R
Connection: Black/red – Ground
Black – Ground
TOOL:
Test probe 07ZAJ-RDJA110
[1]
Bl
Bl/R
26-111
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. Combination meter Inspection
Replace the combination meter with a known good
one.
Erase the DTC (page 25-25).
Check the CAN with the GST or MCS.
Is DTC U0155 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original combination meter
DTC U0155 (CAN_METER)
1. CAN System Inspection
Erase the DTC (page 25-25).
Check the CAN with the GST or MCS.
Is DTC U0001 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. CAN Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the following:
– ECM 33P (Gray) connector [1] (page 4-39)
– Combination meter 32P (Gray) connector [2]
(page 22-12)
Check the continuity between the wire harness side
32P (Gray) and 33P (Gray) connectors terminals.
Is there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire
3. CAN Line Short Circuit Inspection
Check for continuity between the wire harness side
33P (Gray) connector [1] terminals and ground.
Is there continuity?
YES – • Short circuit in the Black/red wire
• Short circuit in the Black wire
NO – GO TO STEP 4.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Black/red – Black/red
Black – Black
[2]
[1]
Bl/R
Bl
Bl
Bl/R
Connection: Black/red – Ground
Black – Ground
TOOL:
Test probe 07ZAJ-RDJA110
[1]
Bl
Bl/R
26-112
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Combination meter Inspection
Replace the combination meter with a known good
one.
Erase the DTC (page 25-25).
Check the CAN with the GST or MCS.
Is DTC U0155 indicated?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Faulty original combination meter
DTC P170D (SHIFT STROKE SENSOR
LOW VOLTAGE) (CRF1000A/A2/AL/
AL2)
1. Shift Stroke Sensor System Inspection
Check the shift stroke sensor with the GST or MCS.
Is the indicated voltage within 0.5 – 4.5 V?
YES – Intermittent failure
NO – GO TO STEP 2.
2. Shift Stroke Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the shift stroke sensor 4P connector.
Turn the ignition switch ON and engine stop switch
"".
Measure the voltage between the wire harness side
4P connector terminals.
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 4.
NO – GO TO STEP 3.
3. Shift Stroke Sensor Circuit Inspection
Turn the ignition switch OFF.
Disconnect the ECM 33P (Gray) connector.
Check for continuity between the wire harness side
4P [1] and ECM 33P (Gray) [2] connectors
terminals.
Is there continuity?
YES – Replace the ECM with a known good one
and recheck (page 4-39).
NO – Open circuit in Yellow/red wire
Connection: Yellow/red (+) – Gray/black (–)
Gr/Bl
Y/R
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
[1]
Y/R
Y/R
[2]
26-113
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Shift Stroke Sensor Output Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the ECM 33P (Blue) connector.
Check for continuity between the wire harness side
4P [1] and 33P (Blue) [2] connectors terminals.
Is there continuity?
YES – GO TO STEP 5.
NO – Open circuit in Black/blue wire
5. Shift Stroke Sensor Output Line Short Circuit
Inspection
Connect the ECM 33P connectors.
Check for continuity between the wire harness side
4P connector [1] and ground.
Is there continuity?
YES – Short circuit in Black/blue wire
NO – GO TO STEP 6.
6. Shift Stroke Sensor Inspection
Replace the shift stroke sensor with a known good
one.
Erase the DTC (page 25-25).
Check the shift stroke sensor with the GST or MCS.
Is DTC P170D indicated?
YES – Replace the ECM with a known good one
and recheck (page 4-39).
NO – Faulty original shift stroke sensor
DTC P1708 (SHIFT SPINDLE SWITCH
HIGH VOLTAGE) (CRF1000A/A2/AL/
AL2)
1. Shift Spindle Switch System Inspection
Erase the DTC (page 25-25).
Check the shift spindle switch with the GST or MCS.
Is DTC P1708 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Black/blue – Black/blue
Bl/Bu
Bl/Bu
[1]
[2]
Connection: Black/blue – Ground
Bl/Bu
[1]
26-114
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Shift Spindle Switch Input Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the shift spindle switch terminal.
Check for continuity between the wire harness side
switch terminal and ground.
Is there continuity?
YES – Short circuit in Yellow/white wire
NO – GO TO STEP 3.
3. Shift Spindle Switch Inspection
Replace the shift spindle switch with a known good
one.
Erase the DTC (page 25-25).
Check the shift spindle switch with the GST or MCS.
Is DTC P1708 indicated?
YES – Replace the ECM with a known good one
and recheck (page 4-39).
NO – Faulty original shift spindle switch
DTC P0704 (CLUTCH SWITCH)
(CRF1000A/A2/AL/AL2)
1. Clutch Switch System Inspection
Erase the DTC (page 25-25).
Check the clutch switch with the GST or MCS.
Is DTC P0704 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Clutch Switch Input Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the left handlebar switch 10P (Gray)
connector.
Check for continuity between the wire harness side
10P (Gray) [1] connector and ground.
Is there continuity?
YES – Short circuit in Green/Yellow wire
NO – GO TO STEP 3.
Connection: Yellow/white – Ground
Bu
[1]
Connection: Green/yellow – Ground
[1]
G/Y
26-115
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Clutch Switch Inspection
Replace the clutch switch with a known good one.
Erase the DTC (page 25-25).
Check the clutch switch with the GST or MCS.
Is DTC P0704 indicated?
YES – Replace the ECM with a known good one
and recheck (page 4-39).
NO – Faulty original clutch switch
MIL CIRCUIT TROUBLESHOOTING
When The Engine Starts But The MIL
Does Not Go Off Within A Few
Seconds
• If the engine stop switch is in " ", the MIL will stay
on even when the system is normal.
If the MIL stays on, check the combination meter
indication when the CAN line is abnormal (page 26-67).
If the indication is not according to above condition,
check as follows.
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Gray) connector (page
4-39).
Check for continuity between the wire harness side
ECM/PCM 33P (Gray) connector [1] and ground.
If there is continuity, check for short circuit in the Gray/
blue wire between the DLC and ECM/PCM.
If there is no continuity, replace the ECM/PCM with a
known good one and recheck (page 4-39).
ECM (CRF1000A/A2/AL/AL2)/
PCM (CRF1000D/D2/DL/DL2)
(PGM-FI SYSTEM)
POWER/GROUND LINE INSPECTION
POWER INPUT LINE
Disconnect the ECM/PCM 33P (Blue) connector (page
4-39).
Measure the voltage between the wire harness side
ECM/PCM 33P (Blue) connector [1] and ground.
There should be battery voltage with the ignition switch
turned ON and engine stop switch " ".
If there is no voltage, check the following:
– Open circuit in the Brown/black wire between the
ECM/PCM and FI relay
– FI relay and related circuit (page 4-43)
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION: Gray/blue – Ground
Gr/Bu
[1]
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION: Brown/black (+) – Ground (–)
Brown/black (+) – Ground (–)
Br/Bl
[1]
Br/Bl
26-116
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
GROUND LINE
Disconnect the ECM/PCM 33P (Blue) and (Gray)
connectors (page 4-39).
Check for continuity between the ECM/PCM (Blue)
connector [1] and (Gray) connector [2] terminals at the
harness side and ground.
There should be continuity at all times.
If there is no continuity, check for open circuit in the
Green/blue or Green wire.
GRIP APS/RIGHT HANDLEBAR
SWITCH
APS INSPECTION
• Before starting the inspection, check for loose or
poor contact on the APS connector and ECM
connector, then recheck the DTC.
1. APS 1 and 2 Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the APS 8P (Black) connector [1] (page
26-117).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage at the harness side.
Is the voltage about 5 V?
YES – GO TO STEP 2.
NO – Open or short circuit in the White or Brown
wire. If the wires are OK, replace the ECM/
PCM with a known good one and recheck
(page 4-39).
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION: Green (A4) – Ground
Green (A5) – Ground
Green (A15) – Ground
Green (A26) – Ground
Green (A27) – Ground
Green/blue (A33) – Ground
Green (D23) – Ground
Green (D24) – Ground
G
(A15)
G
(A26)
G
(A4)
G
(A5)
G
(A27)
G/Bu
(A33)
G
(D23)
G
(D24)
[2]
[1]
Connection: White (+) [VCC 2] – Ground
Brown (+) [VCC 1] – Ground
[1]
Br
W
26-117
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. APS 1 and 2 System Inspection
Erase the DTC (page 25-25).
Check the APS 1 and 2 with the MCS.
Note the APS 1 and 2 output voltage.
Is the voltage within standard?
YES – Intermittent failure
NO – GO TO STEP 3.
3. APS System Inspection
Connect a 5 V battery to the APS connector
terminals at the APS side as shown.
Measure the voltage at the APS side.
Is the voltage within standard?
YES – Replace the ECM/PCM with a known good
one and recheck (page 4-39).
NO – Replace the APS with a known good one
and recheck (page 26-117).
REMOVAL
• The parts of the grip APS not shown in this manual
should not be disassembled.
Remove the following:
– Right knuckle guard (page 2-5)
– Right rearview mirror (page 17-4)
Pull the right radiator to out side (page 26-63).
Disconnect the follow:
– APS 8P (Black) connector [1]
– Right handlebar switch 8P (Gray) connector [2]
Calculate the 5 V / input voltage x output voltage.
Standard (at throttle opened):
APS 1: 4.433 – 4.567 V
APS 2: 2.183 – 2.317 V
Standard (at throttle closed):
APS 1: 0.433 – 0.567 V
APS 2: 0.183 – 0.317 V
Connection: Gray (+) – White/black (–)
Blue/white (+) – Yellow/black (–)
Calculate the 5 V / input voltage x output voltage.
Standard (at throttle opened):
APS 1: 4.488 – 5.512 V
APS 2: 2.238 – 2.262 V
Standard (at throttle closed):
APS 1: 0.488 – 0.512 V
APS 2: 0.238 – 0.262 V
W/Bl
Gr
W/R
Y/R
Y/Bl
5 V
BATTERY
5 V
BATTERY
Bu/W
Y/Bl
W/Bl
[1] [2]
26-118
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Release the harness clips [1] from the stays.
Remove the clamps [1].
Disconnect the front brake light switch connectors [1].
Remove the following:
– Lower front brake master cylinder holder bolt [2]
– Upper front brake master cylinder holder bolt [3]
– Stay [4]
–Holder [5]
– Front brake master cylinder [6]
• Keep the brake master cylinder reservoir upright to
prevent air from entering the hydraulic system.
Remove the following:
– Lower right handlebar switch housing screw/
washers [1]
– Upper right handlebar switch housing screw/
washers [2]
– Right handlebar switch cover [3]
[1]
[1]
[1]
[6]
[1]
[3]
[2]
[5]
[4]
[3] [2]
[1]
26-119
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Remove the screws [1] and throttle grip [2].
Remove the screw [1] and unhook the tab of the stay [2]
from the hole of the handlebar.
Remove the right handlebar switch/APS [3] from the
handlebar [4].
INSTALLATION
CRF1000A2/AL2/
D2/DL2:
When replacing the right handlebar switch/APS, install
the wire band to the following procedure:
1. Remove the wire band [1].
2. Mark [2] the right grip heater wire as shown.
3. Install a new wire band by aligning the blue tape [3]
of the right handlebar switch/APS wire and the
marking of the right grip heater wire.
[2] [1]
[1]
[1]
[2]
[4]
[3]
[1]
230 ± 10 mm
(9.1 ± 0.4 in)
[2]
[2]
[3]
[3]
26-120
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Install the right handlebar switch/APS [1] to the
handlebar [2].
Align the tab of the stay with the hole [3] of the
handlebar.
Install and tighten the screw [4].
Apply grease to the throttle pipe [1] and APS [2] contact
area as shown.
Install the throttle grip [1].
• Align the tab of throttle grip with the groove of APS
[2].
[4]
[3]
[2]
[1]
5 mm
(0.2 in)
3 mm
(0.1 in)
3 mm
(0.1 in)
5 mm
(0.2 in)
3 mm
(0.1 in)
5 mm
(0.2 in)
5 mm
(0.2 in)
3 mm
(0.1 in)
3 mm
(0.1 in)
5 mm
(0.2 in)
5 mm
(0.2 in)
3 mm
(0.1 in)
5 mm
(0.2 in)
3 mm
(0.1 in)
3 mm
(0.1 in)
5 mm
(0.2 in)
[2]
[1]
[2][1]
Align
26-121
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Install and tighten the screws [1].
Install the following:
– Right handlebar switch cover [1]
– Upper right handlebar switch housing screw/washer
[2]
– Lower right handlebar switch housing screw/washer
[3]
Tighten the upper right handlebar switch housing
screw/washer first, then the lower right handlebar
switch housing screw/washer to the specified torque.
Install the following:
– Front brake master cylinder [1]
–Holder [2]
–Stay [3]
– Upper front brake master cylinder holder bolt [4]
– Lower front brake master cylinder holder bolt [5]
Tighten the upper front brake master cylinder holder
bolt first, then the lower front brake master cylinder
holder bolt to the specified torque.
• Align the front brake master cylinder end with the
paint mark [6] on the handlebar.
• Holder "UP" mark [7] to facing upward.
Connect the front brake light switch connectors [8].
Install the clamps [1].
• Position the clamps properly (page 26-17).
[1]
[1]
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
[1] [2]
[3]
TORQUE: 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
[1]
[8]
[4]
[5]
[2]
[3]
[6][7]
[1]
26-122
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Install the harness clips [1] to the stays.
Connect the follow:
– APS 8P (Black) connector [1]
– Right handlebar switch 8P (Gray) connector [2]
Install the following:
– Right knuckle guard (page 2-5)
– Right rearview mirror (page 17-10)
– Right radiator (page 26-63)
Check the throttle operation.
TBW RELAY
REMOVAL/INSTALLATION
Remove the fuel tank (page 26-128).
Remove the TBW relay [1] from the relay connector.
Installation is in the reverse order of removal.
RELAY INSPECTION
Remove the TBW relay (page 26-122).
Refer to FI relay inspection (page 4-43).
[1]
[1]
[1] [2]
[1]
26-123
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
IGNITION SYSTEM
SYSTEM DIAGRAM
Bl: Black
G: Green
Gr: Gray
R: Red
Y: Yellow
W: White
Bu: Blue
Lg: Light green
Br: Brown
BANK
ANGLE
SENSOR
ECM
CKP
SENSOR
No.2-2
SIDESTAND
SWITCH
ENGINE
STOP 10 A
ENGINE STOP
RELAY
MAIN
FUSE
30 A
IGNITION
SWITCH
BATTERY
W/Y
R/Bl
Bl/Gr
R/W
G
Lg
Bu/Bl
Y
G
Bu/W
Bu/R
Bl
Bl
Bl/W
R/Bu
R
G/W
Bu/Y
Y/W
FI FUSE
15 A
FI RELAY
No.2-1
No.1-2
No.1-1
Bl
NEUTRAL
SWITCH
ENGINE
STOP
SWITCH
Br/Bl
W
R/Bl
R/Bl
G
G
R/Bu
26-124
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
IGNITION SYSTEM INSPECTION
CKP SENSOR PEAK VOLTAGE
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
Turn the ignition switch OFF.
Disconnect the ECM/PCM 33P (Black) connector [1]
(page 4-39).
Connect the peak voltage tester or adaptor probes to
the wire harness side 33P connector terminals.
Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch " ".
Crank the engine with the starter motor and measure
the CKP sensor peak voltage.
If the peak voltage measured at the ECM/PCM 33P
connectors are abnormal, measure the peak voltage at
the CKP sensor connector.
IGNITION COIL
IGNITION COIL TRAY
REMOVAL/INSTALLATION
Disconnect the spark plug cap (page 3-5).
Remove the throttle body (page 26-128).
Remove the wire band [1].
Disconnect the Ignition coil sub harness 6P connector
[2].
Disconnect and release the following connectors from
the ignition coil tray:
– Ignition switch 2P (Brown) connector [3]
– Immobilizer receiver 4P (Black) connector [4]
TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor [2] 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 M/DCV minimum)
Test probe 07ZAJ-RDJA110
CONNECTION: Yellow (+) – White/yellow (–)
CRF1000A/A2/AL/
AL2:
PEAK VOLTAGE: 0.7 V minimum
[2]
[1]
W/Y
Y
[2] [4]
[3]
[1]
26-125
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Disconnect the air supply hose [1] from the PAIR
control solenoid valve [2].
Releasing the bosses [1] from the grommets [2] by
pulling the ignition coil tray assembly [3] rearward.
Disconnect the PAIR control solenoid valve 2P (Black)
connector [4].
Remove the ignition coil tray assembly.
Installation is in the reverse order of removal.
• Route the wires properly (page 26-17).
• Tighten the insulator band screws (throttle body
side) to the specified range (page 26-128).
[1]
[2]
[3]
[4]
[2]
[1]
26-126
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DISASSEMBLY/ASSEMBLY
Remove the ignition coil tray assembly (page 26-124)
Remove the PAIR control solenoid valve [1].
Release the wire clip [2] and ignition coil sub harness
6P connector [3].
Remove the bolts [4].
Disconnect the ignition coil connectors [5].
Remove the following parts from the ignition tray [6]:
– No.1 cylinder main ignition coil [7]
– No.1 cylinder sub ignition coil [8]
– No.2 cylinder main ignition coil [9]
– No.2 cylinder sub ignition coil [10]
– Ignition coil sub harness [11]
Installation is in the reverse order of removal.
• Route the wire harness properly (page 26-17).
[1]
[2]
[3]
[11]
[6]
[8]
[7]
[9]
[10]
[4]
[4]
[5]
[4]
[4]
26-127
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ELECTRIC STARTER SYSTEM
DIAGRAM
CRF1000A/A2/AL/AL2:
CRF1000D/D2/DL/DL2:
Bl: Black
G: Green
R: Red
Y: Yellow
W: White
Gr: Gray
Bu: Blue
Lg: Light green
ENGINE
STOP
SWITCH
STARTER
SWITCH
IGNITION
SWITCH
MAIN
FUSE
30 A
BATTERY
SIDESTAND
SWITCH
NEUTRAL
SWITCH
STARTER
MOTOR
CLUTCH
SWITCH
R
Bl/Gr
R/Bl
W
Y/W
Lg
G/R
G/YG/W
Bl
Bl
NEUTRAL
DIODE
STARTER
RELAY
SWITCH
ENGINE
STOP 10 A
G
Bl/BrBl/Bu
W: White
Gr: Gray
Bu: Blue
Lg: Light green
ENGINE STOP
SWITCH
STARTER
SWITCH
IGNITION
SWITCH
STARTER
RELAY
SWITCH
MAIN
FUSE
30 A
BATTERY
STARTER
RELAY
STARTER
MOTOR
R/Bl
Y/W
Bl/Gr
W
G
G/R
Y/W
R
Bl
Bl
ENG STOP
10 A
Bl
Bl: Black
G: Green
R: Red
Y: Yellow
FRONT BRAKE
LIGHT SWITCH
REAR BRAKE
LIGHT SWITCH
A/M SWITCH
ILLUMI_STOP
HORN
10 A
Bl/R
Bl
Bl
Bl/G
Bl/Bu
Lg
R/Bl
Bl/R
PCM
R/Bl
Y/W
Y/W
G/Y
NEUTRAL
SWITCH
26-128
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FUEL TANK
REMOVAL/INSTALLATION
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
• Install the fuel tank breather hose [1] so that the
hose end is 9.0 mm (0.35 in) from the fuel tank [2]
(GS/U/IN models).
• Install the fuel tank-to-canister hose [1] so that the
hose end is 9.0 mm (0.35 in) from the fuel tank [2]
(ED/KO/TH/FO/MA models).
AIR CLEANER HOUSING
REMOVAL/INSTALLATION
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
• Install the crankcase breather hose [1] so that the
hose end is 2.0 mm (0.08 in) from the air cleaner
housing [2].
THROTTLE BODY
REMOVAL
Remove the following:
– Air cleaner housing (page 26-128)
– Tool box (page 26-199)
Disconnect the fuel feed hose (fuel rail side) (page 7-4).
Disconnect the EVAP purge control solenoid valve-to-
throttle body hose (page 25-58).
Disconnect the following:
– MAP sensor 3P (Black) connector [1]
– TBW unit 6P (Black) connector [2]
9.0 mm
(0.35 in)
[1]
[2]
2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
[1]
[2]
ED/KO/TH/FO/MA
models:
[2]
[1]
26-129
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Loosen the band screws (throttle body side) [1].
Disconnect the throttle body by pulling it upward.
Disconnect the following:
– Fuel injector 2P (Black) connector [1]
– Fuel injector 2P (Blue) connector [2]
• Do not loosen or tighten the white painted screws
[1], nut [2] and screws [3] of the throttle body.
Loosening or tightening any of these can cause
throttle valve and idle control failure.
INSTALLATION
Connect the following:
– Fuel injector 2P (Black) connector [1]
– Fuel injector 2P (Blue) connector [2]
[1]
Left side: Right side:
[1]
[2]
[1]
[3][2]
[1]
[2]
[1]
26-130
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Install the throttle body [1].
• Align the insulator grooves with the throttle body
lugs.
Tighten the insulator band screws (throttle body side)
[1] to the specified range as shown.
• Make sure that the insulator band screws (throttle
body side) are in the position as shown.
Connect the following:
– MAP sensor 3P (Black) connector [1]
– TBW unit 6P (Black) connector [2]
Connect the fuel feed hose (fuel rail side) (page 7-4).
Connect the EVAP purge control solenoid valve-to-
throttle body hose (page 25-58).
Install the following:
– Air cleaner housing (page 26-128)
– Tool box (page 26-199)
[1]
Align
Align
14 ± 1.0 mm
(0.6 ± 0.04 in)
14 ± 1.0 mm
(0.6 ± 0.04 in)
Front
[1] [1]
[1]
Left side: Right side:
[1]
ED/KO/TH/FO/MA
models:
[2]
[1]
26-131
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
EVAP CANISTER
(ED/KO/TH/FO/MA models)
REMOVAL/INSTALLATION
Remove the following:
– Fuel tank (page 26-128)
– ETC tray (page 26-49)
Disconnect the EVAP canister-to-purge control solenoid
valve hose [1] from the EVAP purge control solenoid
valve [2].
Release the fuel tank-to-EVAP canister hose [3] from
the clamps [4].
Disconnect the EVAP canister drain hose [1].
Remove the screws [2].
Release the band [3] from the rear fender B stay [4] by
turning the EVAP canister [5].
Remove the EVAP canister.
[1]
[2]
[3]
[4]
[1]
[3]
[5]
[2]
[4]
26-132
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Installation is in the reverse order of removal.
• When installing the EVAP canister [1], check the
canister mounting rubber [2] is correct position as
shown.
• Route the hoses properly (page 26-17).
RADIATOR
REMOVAL/INSTALLATION
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
Installation is in the reverse order of removal.
• Tighten the water hose band screws to the specified
range as shown.
• Route the hoses and wires properly (page 26-17).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-4).
[1]
[2]
34 mm
(1.34 in)
90°
[2]
[1]
0 – 0.5 mm (0 – 0.02 in)
26-133
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
RIGHT CRANKCASE COVER
(CRF1000A2/AL2)
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
REMOVAL
Remove the bolts [1].
Remove the right skid plate bracket [2].
Remove the right crankcase cover [3] while turning the
clutch lifter lever [4] counterclockwise to disengage the
lifter lever slit from the clutch lifter pin.
INSTALLATION
Install the right crankcase cover [1] by holding the
clutch lifter lever [2].
Install the right skid plate bracket [3].
Install the bolts [4] and tighten it in a crisscross pattern
in 2 or 3 steps to the specified torque.
Be careful not to
drop the return
spring.
[3]
[1]
[4][2]
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[1]
[4]
[2][3]
26-134
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DCT SYSTEM DIAGRAM
1
12
23
2
13
24
3
14
25
4
15
26
5
16
27
6
17
28
7
18
29
8
19
30
9
20
31
10
21
32
11
22
33
1
12
23
2
13
24
3
14
25
4
15
26
5
16
27
6
17
28
7
18
29
8
19
30
9
20
31
10
21
32
11
22
33
1
12
23
2
13
24
3
14
25
4
15
26
5
16
27
6
17
28
7
18
29
8
19
30
9
20
31
10
21
32
11
22
33
DOWN UP
UP
DOWN
1
12
23
2
13
24
3
14
25
4
15
26
5
16
27
6
17
28
7
18
29
8
19
30
9
20
31
10
21
32
11
22
33
R/BlR/Bl
R/BuW
R
BlBl/Gr
W
Bl
G
G
Br/Bl
Lg
Bl/R
Bl
P
Lg/R
W/Y
G/Bu
Bu/Bl
Bu/Y
Bu/Bl
Bu
Bl
Bl/R
W
Bu
W
Lg
R/G
Gr/Bl
W
W
P
P
Bu/G
W
Y/W
Lg/Y
Bu
Y/G
Bl/G
Y/R
Bl/Br
G
G/Bu
G/W
W
Y
Bl
Br/Bl
W/R
Bu
Y/W
Gr
G/Y
Bl/W
P/Bu
P/Bu
Y/Bu
Y/Bu
Br/Bl
Br/Bl
Gr/Bu
G/Bu
Bl/RBl/R
Bl/R
Y/W
G/Y
G/Y
Br/Bl
Bl/W
R/W
R/W
R/W
R/W
G
G/R
Y
Gr
G
G
G
G
G
G
G
G
Bu/Bl
G/Bl
G
DCT MAIN
10A
DCT_M 30A
MAIN
FUSE
30A
ENGINE STOP SWITCH
STARTER
RELAY
From
STARTER
RELAY
SWITCH
FRONT BRAKE LIGHT SWITCH
REAR BRAKE LIGHT SWITCH
ENG STOP
10A
ILLUMI/STOP
10A
IGNITION
SWITCH
CLUTCH
LINE EOP
SENSOR
No.1 CLUTCH
EOP SENSOR
EOT SENSOR
INNER MAINSHAFT
SENSOR
OUTER MAINSHAFT
SENSOR
TR SENSOR
SHIFT SPINDLE
ANGLE SENSOR
No.2 CLUTCH
EOP SENSOR
PCM 33P
(
Brown
)
CONNECTOR B
(PCM SIDE)
PCM 33P
(
Blue
)
CONNECTOR A
(PCM SIDE)
FRONT WHEEL
SPEED SENSOR
REAR WHEEL
SPEED SENSOR
CKP SENSOR
PCM 33P
(
Black
)
CONNECTOR C
(PCM SIDE)
PCM 33P
(
Gray
)
CONNECTOR D
(PCM SIDE)
ABS
MODULATOR
COMBINATION
METER
NEUTRAL
SWITCH
No.1 LINEAR SOLENOID
VALVE
No.2 LINEAR SOLENOID
VALVE
SHIFT CONTROL
MOTOR
SHIFT SWITCH
SIDESTAND
SWITCH
N-D SWITCH
A/M SWITCH
DLC
FI RELAY
VS SENSOR
Bl
Br
Bu
G
Gr
Lg
P
R
W
Y
: Black
: Brown
: Blue
: Green
: Gray
: Light green
: Pink
: Red
: White
: Yellow
ENG STOP C20
CANHD11
CANLD10
NLSWB5
VSPD21
FVWD22
RVWC27
PCPC7
PCMC28
SFTDOWNB6
GMODESWC29
SFTUPB29
SEL-DB17
SEL-NB30
MODE SWB28
PLINEB32
SG4D26
VCC4D28
PC1B19
PC2B20
SPDLANGA32
DRUMANGA30
NM2PB27
VSENSE2B25
NM1PB2
VSENSE1B4
TOB31
STOP B15
LSOL2M B9
LSOL2P B8
LSOL1M B11
LSOL1P B10
SMOM B18
SMOM B7
SMOP B14
SMOP B3
ST-INH D13
SCS D18
K-LINE D3
IGP A11
IGP A22
SUBVB B22
SUBVB B33
PVB B12
PVB B1
PG
PG
PG
A27
LG A33
SSTAND D33
D23
D24
PG A26
PG A15
PG A5
PG A4
G MODE
SWITCH
PCM
FI
FUSE
30A
ENGINE
STOP
RELAY
26-135
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DCT DTC INDEX
• If the MCS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the DTC.
• The DTCs related to emission control, have P code and if the PCM detects them, MIL illuminates simultaneously.
Honda
code
(DTC)
Function Failure Symptom/Fail-safe function Refer
to
page
1-1
Shift pedal angle sensor (Optional) malfunction
• Shift pedal angle sensor or its circuit malfunction
• DCT shift pedal (Optional) mechanism malfunction
• Loose or poor contact of the shift pedal angle sensor
connector
• Faulty PCM
• DCT shift pedal (Optional)
function does not work
26-140
7-1
(P0117)
ECT sensor circuit low voltage (less than 0.049 V)
• ECT sensor or its circuit malfunction
• Hard start at a low
temperature
26-73
7-2
(P0118)
ECT sensor circuit high voltage (more than 4.946 V)
• Loose or poor contact of the ECT sensor connector
• ECT sensor or its circuit malfunction
• Hard start at a low
temperature 26-73
8-1
TP sensor low voltage
• TP sensor 1 or its circuit malfunction
• TP sensor 2 or its circuit malfunction
• Vehicle speed limit:
approximately 120 km/h (75
mph)
• HSTC does not operate
26-142
8-2
TP sensor high voltage
• Loose or poor contact of the TP sensor 1 connector
• Loose or poor contact of the TP sensor 2 connector
• TP sensor 1 or its circuit malfunction
• TP sensor 2 or its circuit malfunction
• Vehicle speed limit:
approximately 120 km/h (75
mph)
• HSTC does not operate
26-142
9-1
Clutch line EOP sensor low voltage (less than 0.298 V)
• Clutch line EOP sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work 26-142
9-2
Clutch line EOP sensor high voltage (more than 4.702 V)
• Loose or poor contact of the clutch line EOP sensor
connector
• Clutch line EOP sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-143
11-1
(P0500)
VS sensor malfunction
• Loose or poor contact of the VS sensor connector
• VS sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
works
26-76
19-1
CKP sensor no signal
• Loose or poor contact of the CKP sensor connector
• Electromagnetic interference at CKP sensor
• CKP sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
• Engine does not operate 26-144
21-1
(P1708)
Shift spindle angle sensor low voltage (less than 0.308 V)
• Loose or poor contact of the shift spindle angle sensor
connector
• Shift spindle angle sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-145
21-2
(P1709)
Shift spindle angle sensor high voltage (more than 4.976 V)
• Shift spindle angle sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work 26-147
22-1
Shift spindle operation malfunction (after operating gearshift
mechanism)
• Gearshift mechanism malfunction
• Shift spindle angle sensor malfunction
• Gearshift function does not
work
26-148
23-1
Shift spindle operation malfunction (while operating gearshift
mechanism)
• Gearshift mechanism malfunction
• Shift spindle angle sensor malfunction
• Gearshift function does not
work
26-149
24-1
(P170A)
Shift control motor drive circuit
• Shift control motor or its circuit malfunction
• Shift control motor drive circuit in the PCM malfunction
• Gearshift function does not
work 26-150
27-1
Shift drum position malfunction
• TR sensor malfunction
• Gearshift mechanism malfunction
• Faulty PCM
• Gearshift function does not
work
26-151
26-136
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
31-1
(P170B)
Shift control motor low voltage (less than 9.016 V)
• Ignition hold relay circuit in the PCM malfunction
• Blown fuse DCT M 30 A
• Loose or poor contact of the PCM 33P (Blue) connector
• Gearshift function does not
work
26-152
32-1
Fail safe relay circuit malfunction
• PCM (DCT drive circuit) power input line malfunction
• Blown fuse DCT M 30 A
• Fail safe relay in the PCM malfunction
• Gearshift function does not
work
26-153
37-1
(P0562)
Ignition hold relay malfunction
• PCM (DCT drive circuit) sub power input line malfunction
• Blown sub fuse DCT MAIN 10 A
• Ignition hold relay in the PCM malfunction
• Gearshift function does not
work
26-153
41-1
N-D switch malfunction
• Loose or poor contact of the N-D switch connector
• N-D switch or its circuit malfunction
• Faulty PCM
• N-D switch does not work
26-154
42-1
(P0826)
Shift switch malfunction
• Loose or poor contact of the shift switch connector
• Shift switch or its circuit malfunction
• Faulty PCM
• Shift switch does not work
26-155
44-1
(P0197)
EOT sensor low voltage (less than 0.088 V)
• EOT sensor or its circuit malfunction
• Faulty PCM
• Gearshift function works
normally 26-157
44-2
(P0198)
EOT sensor high voltage (more than 4.903 V)
• Loose or poor contact of the EOT sensor connector
• EOT sensor or its circuit malfunction
• Faulty PCM
• Gearshift function works
normally
26-158
47-1
(P1704)
No.1 clutch EOP sensor low voltage (less than 0.298 V)
• No.1 clutch EOP sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work 26-159
47-2
(P1705)
No.1 clutch EOP sensor high voltage (more than 4.702 V)
• Loose or poor contact of the No.1 clutch EOP sensor
connector
• No.1 clutch EOP sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-160
48-1
(P1706)
No.2 clutch EOP sensor low voltage (less than 0.298 V)
• No.2 clutch EOP sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work 26-159
48-2
(P1707)
No.2 clutch EOP sensor high voltage (more than 4.702 V)
• Loose or poor contact of the No.2 clutch EOP sensor
connector
• No.2 clutch EOP sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-160
49-1
Clutch line low oil pressure (when clutch is engaged)
• Engine oil level low
• Faulty oil pump
• Faulty clutch oil circuit
• Clutch line EOP sensor malfunction
• Faulty PCM
• Gearshift function does not
work
26-161
49-2
Clutch line low oil pressure (when engine is running)
• Engine oil level low
• Faulty oil pump
• Faulty clutch oil circuit
• Clutch line EOP sensor malfunction
• Faulty PCM
• Gearshift function does not
work
26-161
51-1
(P1702)
TR sensor low voltage (less than 0.117 V)
• Loose or poor contact of the TR sensor connector
• TR sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-162
51-2
(P1703)
TR sensor high voltage (more than 4.976 V)
• TR sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work 26-164
Honda
code
(DTC)
Function Failure Symptom/Fail-safe function Refer
to
page
26-137
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
52-1
Neutral switch stuck OFF
• Loose or poor contact of the neutral switch connector
• Neutral switch or its circuit malfunction
• Faulty PCM
• Gearshift function works
normally
• Shift indicator blinking
26-164
52-2
Neutral switch stuck ON
• Neutral switch or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work 26-165
53-1
(P0715)
Inner mainshaft speed low
• Loose or poor contact of the inner mainshaft sensor
connector
• Inner mainshaft sensor or its circuit malfunction
• Electromagnetic interference
• Faulty PCM
• Gearshift function does not
work
26-165
54-1
(P2765)
Outer mainshaft speed low
• Loose or poor contact of the outer mainshaft sensor
connector
• Outer mainshaft sensor or its circuit malfunction
• Electromagnetic interference
• Faulty PCM
• Gearshift function does not
work
26-168
55-1
(P0745)
No.1 linear solenoid valve current failure
• Loose or poor contact of the No.1 linear solenoid valve
connector
• No.1 linear solenoid valve or its circuit malfunction
• No.1 linear solenoid valve drive circuit in the PCM
malfunction
• Faulty PCM
• Gearshift function does not
work
26-170
55-2
(P0745)
No.1 linear solenoid valve driver in the PCM failure
• Loose or poor contact of the No.1 linear solenoid valve
connector
• Loose or poor contact of the PCM 33P connector
• No.1 linear solenoid valve or its circuit malfunction
• No.1 linear solenoid valve drive circuit in the PCM
malfunction
• Faulty PCM
• Gearshift function does not
work
26-170
56-1
(P0775)
No.2 linear solenoid valve current failure
• Loose or poor contact of the No.1 linear solenoid valve
connector
• No.2 linear solenoid valve or its circuit malfunction
• No.2 linear solenoid valve drive circuit in the PCM
malfunction
• Faulty PCM
• Gearshift function does not
work
26-171
56-2
(P0775)
No.2 linear solenoid valve driver in the PCM failure
• Loose or poor contact of the No.2 linear solenoid valve
connector
• Loose or poor contact of the PCM 33P connector
• No.2 linear solenoid valve or its circuit malfunction
• No.2 linear solenoid valve drive circuit in the PCM
malfunction
• Faulty PCM
• Gearshift function does not
work
26-171
57-1
Gearshift mechanism malfunction
• Gearshift mechanism malfunction
• TR sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-172
57-2
Gear position malfunction (jumps out of gear)
• Gearshift mechanism malfunction
• TR sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-172
58-1
No.1 clutch does not disengage (when shifting gear)
• No.1 clutch sticking
• Faulty clutch oil circuit
• Gearshift function does not
work
• Engine does not operate
26-172
59-1
No.2 clutch does not disengage (when shifting gear)
• No.2 clutch sticking
• Faulty clutch oil circuit
• Gearshift function does not
work
• Engine does not operate
26-172
Honda
code
(DTC)
Function Failure Symptom/Fail-safe function Refer
to
page
26-138
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
61-1
No.1 clutch oil pressure malfunction (at clutch initial diagnosis)
• No.1 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• Faulty PCM
• Gearshift function does not
work
26-173
61-2
No.1 clutch no oil pressure
• No.1 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.1 linear solenoid valve or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-173
61-3
No.1 clutch oil pressure degradation
• No.1 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.1 linear solenoid valve malfunction
• Faulty PCM
• Gearshift function does not
work
26-173
61-4
No.1 clutch oil pressure canceling malfunction
• No.1 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• Loose or poor contact of the No.1 linear solenoid valve and
clutch EOP sensor connectors
• No.1 linear solenoid valve malfunction
• Faulty PCM
• Gearshift function does not
work
• Engine does not operate
26-173
62-1
No.1 clutch oil pressure high
• No.1 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.1 linear solenoid valve malfunction
• Faulty PCM
• Gearshift function does not
work
26-173
62-2
No.1 clutch oil pressure high (Prevention of motorcycle
creeps)
• No.1 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.1 linear solenoid valve malfunction
• Faulty PCM
• Gearshift function does not
work
26-173
63-1
No.2 clutch oil pressure malfunction (at clutch initial diagnosis)
• No.2 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• Faulty PCM
• Gearshift function does not
work
26-174
63-2
No.2 clutch no oil pressure
• No.2 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.2 linear solenoid valve or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-174
63-3
No.2 clutch oil pressure degradation
• No.2 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.2 linear solenoid valve malfunction
• Faulty PCM
• Gearshift function does not
work
26-174
63-4
No.2 clutch oil pressure canceling malfunction
• No.2 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• Loose or poor contact of the No.2 linear solenoid valve and
clutch EOP sensor connectors
• No.2 linear solenoid valve or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
• Engine does not operate
26-174
64-1
No.2 clutch oil pressure high
• No.2 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.2 linear solenoid valve malfunction
• Faulty PCM
• Gearshift function does not
work
26-174
64-2
No.2 clutch oil pressure high (Prevention of motorcycle
creeps)
• No.2 clutch EOP sensor malfunction
• Faulty clutch oil circuit
• No.2 linear solenoid valve malfunction
• Faulty PCM
• Gearshift function does not
work
26-174
Honda
code
(DTC)
Function Failure Symptom/Fail-safe function Refer
to
page
26-139
dummyheaddummyhead
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
65-1
(P170C)
Front and rear wheel speed signal malfunction
• Front wheel speed sensor or its circuit malfunction
• VS sensor or its circuit malfunction
• Faulty ABS modulator
• Faulty PCM
• Gearshift function does not
work
26-174
66-1
(P2158)
Rear wheel speed sensor no signal
• Rear wheel speed sensor or its circuit malfunction
• Loose or poor contact of the rear wheel speed sensor
connector
• Electromagnetic interference at rear wheel speed sensor
• Faulty ABS modulator
• Faulty rear pulser ring
• Faulty PCM
• Gearshift function does not
work
26-87
67-1
(P1500)
Front wheel speed sensor no signal
• Front wheel speed sensor or its circuit malfunction
• Loose or poor contact of the front wheel speed sensor
connector
• Electromagnetic interference at front wheel speed sensor
• Faulty ABS modulator
• Faulty front pulser ring
• Faulty PCM
• Gearshift function does not
work
26-88
68-1
No.1 clutch operation malfunction (clutch slips)
• VS sensor malfunction
• Faulty No.1 clutch
• Faulty PCM
• Gearshift function does not
work
26-175
69-1
No.2 clutch operation malfunction (clutch slips)
• VS sensor malfunction
• Faulty No.2 clutch
• Faulty PCM
• Gearshift function does not
work
26-176
71-1
(P1700)
Inner mainshaft/countershaft speed ratio failure
• VS sensor or its circuit malfunction
• Inner mainshaft sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-176
72-1
(P1701)
Outer mainshaft/countershaft speed ratio failure
• VS sensor or its circuit malfunction
• Outer mainshaft sensor or its circuit malfunction
• Faulty PCM
• Gearshift function does not
work
26-176
84-1
(P0606)
CPU in the PCM malfunction
• Faulty PCM
• Gearshift system stops
26-176
91-1
(P0351)
No.1-1 (No.1 cylinder main) ignition coil circuit malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.1 Injector and main
ignition coil shut down 26-108
92-1
(P0352)
No.2-1 (No.2 cylinder main) ignition coil circuit malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.2 Injector and main
ignition coil shut down 26-108
93-1
(P0353)
No.1-2 (No.1 cylinder sub) ignition coil circuit malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.1 Injector and sub ignition
coil shut down 26-108
94-1
(P0354)
No.2-2 (No.2 cylinder sub) ignition coil circuit malfunction
• Loose or poor contact of the ignition coil connector
• Ignition coil or its circuit malfunction
• No.2 Injector and sub ignition
coil shut down 26-108
103-1
(U0001)
CAN communication malfunction
• PCM failure
• Combination meter failure
• CAN communication circuit malfunction
• Engine operates normally
• HSTC does not operate
26-110
Honda
code
(DTC)
Function Failure Symptom/Fail-safe function Refer
to
page
26-140
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DCT DTC TROUBLESHOOTING
• If the PCM is replaced, perform the following:
– Key Registration Procedure (page 23-3)
– Clutch Initialize Learning Procedure (page 13-82)
DTC 1-1 (SHIFT PEDAL ANGLE
SENSOR (OPTIONAL) MALFUNCTION)
1. Recheck the DTC
Erase the DTCs (page 25-25).
Turn the ignition switch ON and engine stop switch
"".
Operate the DCT shift pedal up and down several
times with the engine stopped.
Recheck the DTC with the MCS or GST.
Is the DTC 1-1 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Shift Pedal Angle Sensor Input Voltage
Inspection
Turn the ignition switch OFF.
Disconnect the shift pedal angle sensor 3P (Black)
connector [1].
Turn the ignition switch ON and engine stop switch
"".
Measure the voltage between the wire harness side
shift pedal angle sensor 3P (Black) connector
terminals.
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 4.
NO – GO TO STEP 3.
3. Shift Pedal Angle Sensor Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector [1] (page
4-39).
Check for continuity between the wire harness side
shift pedal angle sensor 3P (Black) connector [2]
and PCM 33P (Gray) connector terminals.
Is there continuity?
YES – Replace the PCM with a known good one,
and recheck (page 4-39).
NO – • Open circuit in Yellow/red wire
• Open circuit in Gray/black wire
Connection: Yellow/red (+) – Gray/black (–)
Y/R Gr/Bl
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
Gray/black – Gray/black
[2] [1]
Y/R
Gr/Bl
Gr/BlY/R
26-141
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Shift Pedal Angle Sensor Output Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector [1]
(page 4-39).
Check for continuity between the wire harness side
shift pedal angle sensor 3P (Black) connector [2]
and PCM 33P (Brown) connector terminals.
Is there continuity?
YES – GO TO STEP 5.
NO – Open circuit in Yellow/black wire
5. Shift Pedal Angle Sensor Output Line Short
Circuit Inspection
Check for continuity between the wire harness side
shift pedal angle sensor 3P (Black) connector [1]
and ground.
Is there continuity?
YES – Short circuit in Yellow/black wire.
NO – GO TO STEP 6.
6. Shift Pedal Angle Sensor Resistance Inspection
Measure the resistance at the sensor side shift
pedal angle sensor 3P (Black) connector [1]
terminals.
Operate the DCT shift pedal to check that the
resistance changes in accordance with the pedal
operation.
Are the resistance inspections normal?
YES – Replace the PCM with a known good one,
and recheck (page 4-39).
NO – Faulty shift pedal angle sensor, replace
the DCT shift pedal as an assembly.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/black – Yellow/black
[1]
Y/Bl
[2]
Y/Bl
Connection: Yellow/black – Ground
[1]
Y/Bl
Connection: Yellow/red – Blue/green
Standard: 4 – 6 k (20°C/68°F)
Connection: Yellow/blue – Blue/green
When moving the pedal up:
Resistance increases
When moving the pedal down:
Resistance decreases
[1]
Y/R Bu/G
Y/Bu Bu/G
[1]
26-142
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 8-1 (TP SENSOR LOW VOLTAGE)
Refer to PGM-FI DTC P0122 (page 26-89).
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
Refer to PGM-FI DTC P0123 (page 26-90).
DTC 9-1 (CLUTCH LINE EOP SENSOR
LOW VOLTAGE)
1. Clutch line EOP Sensor System Inspection
Connect the MCS or GST and start the engine.
Check the clutch line EOP sensor with the MCS or
GST.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Clutch Line EOP Sensor Inspection
Stop the engine.
Disconnect the clutch line EOP sensor 3P (Gray)
connector (page 13-80).
Turn the ignition switch ON.
Check the clutch line EOP sensor with the MCS or
GST.
Is about 0 V indicated?
YES – GO TO STEP 3.
NO – Faulty clutch line EOP sensor
3. Clutch Line EOP Sensor Input Voltage
Inspection
Measure the voltage between the wire harness side
3P connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 5.
NO – GO TO STEP 4.
4. Clutch Line EOP Sensor Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
3P connector [1] and 33P (Gray) connector [2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Yellow/red wire
Connection: Yellow/red (+) – Gray/black (–)
Gr/Bl Y/R
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
Y/R
[2][1]
Y/R
26-143
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. Clutch Line EOP Sensor Output Line Short
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
sensor 3P connector [1] and ground.
Is there continuity?
YES – Short circuit in the Yellow/green wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 9-2 (CLUTCH LINE EOP SENSOR
HIGH VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the clutch line EOP sensor 3P
(Gray), and PCM 33P (Brown) and 33P (Gray)
connectors, and recheck the DTC.
1. Clutch line EOP Sensor System Inspection
Check the clutch line EOP sensor with the MCS or
GST.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Clutch Line EOP Sensor Inspection
Turn the ignition switch OFF.
Disconnect the clutch line EOP sensor 3P connector
(page 13-80).
Short the wire harness side 3P connector [1]
terminals with a jumper wire [2].
Turn the ignition switch ON.
Check the clutch line EOP sensor with the MCS or
GST.
Is about 0 V indicated?
YES – Faulty clutch line EOP sensor
NO – GO TO STEP 3.
Connection: Yellow/green – Ground
[1]
Y/G
Connection: Red/green – Gray/black
[2]
[1]
Gr/Bl R/G
26-144
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Clutch Line EOP Sensor Ground Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
clutch line EOP sensor 3P connector [1] and PCM
33P (Gray) connector [2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Gray/black wire
4. Clutch Line EOP Sensor Output Line Open
Circuit Inspection
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
clutch line EOP sensor 3P connector [1] and 33P
(Brown) connector [2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Red/green wire
DTC 19-1 (CKP SENSOR NO SIGNAL)
1. CKP sensor Peak Voltage Inspection
Disconnect the alternator assembly 6P (Black)
connector (page 14-4).
Temporarily connect the battery cables.
Turn the ignition switch ON with the engine stop
switch " ".
Crank the engine with the starter motor and
measure the CKP sensor peak voltage at the CKP
sensor side 6P (Black) connector [1].
Is the voltage more than 0.7 V?
YES – GO TO STEP 2.
NO – Faulty CKP sensor
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
Gr/Bl
[2][1]
Gr/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Red/green – Red/green
R/G
[1]
R/G
[2]
TOOLS:
Peak voltage adaptor [2] 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 M/DCV minimum)
Connection: Yellow (+) – White/yellow (–)
[2]
[1]
W/Y
Y
26-145
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. CKP sensor Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Black) connector (page
4-39).
Check for continuity between the wire harness side
6P (Black) connector [1] and 33P (Black) connector
[2].
Is there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in the Yellow wire
• Open circuit in the White/yellow wire
3. CKP sensor Line Short Circuit Inspection
Check for continuity between the wire harness side
6P (Black) connector [1] and ground
Is there continuity?
YES – Short circuit in the Yellow wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 21-1 (P1708) (SHIFT SPINDLE
ANGLE SENSOR LOW VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the shift spindle angle sensor 3P
(Blue), PCM 33P (Black) and 33P (Gray)
connectors, and recheck the DTC.
1. Shift Spindle Angle Sensor System Inspection
Check the shift spindle angle sensor with the MCS
or GST.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow – Yellow
White/yellow – White/yellow
[1]
[2]
Y
W/Y
Connection: Yellow – Ground
[1]
Y
26-146
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Shift Spindle Angle Sensor Input Voltage
Inspection
Turn the ignition switch OFF.
Disconnect the shift spindle angle sensor 3P (Blue)
connector (page 13-79).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P
(Black) connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 5.
NO – GO TO STEP 3.
3. Shift Spindle Angle Sensor Input Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Yellow/red wire
4. Shift Spindle Angle Sensor Ground Line Open
Circuit Inspection
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Gray/black wire
Connection: Yellow/red (+) – Gray/black (–)
Y/R Gr/Bl
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
Y/R
[2][1]
Y/R
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
Gr/BlGr/Bl
[1] [2]
26-147
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. Shift Spindle Angle Sensor Signal Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Blue) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Blue) connector [1] and 33P (Blue) connector
[2].
Is there continuity?
YES – GO TO STEP 6.
NO – Open circuit in the White wire
6. Shift Spindle Angle Sensor Output Line Short
Circuit Inspection
Check for continuity between the wire harness side
3P (Blue) connector [1] and ground.
Is there continuity?
YES – Short circuit in the White wire
NO – GO TO STEP 7.
7. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a known
good one (page 13-79).
Connect the 3P (Blue) connector, 33P (Blue)
connector and 33P (Gray) connector.
Check the shift spindle angle sensor with the MCS
or GST.
Is about 0 V indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original shift spindle angle sensor
DTC 21-2 (P1709) (SHIFT SPINDLE
ANGLE SENSOR HIGH VOLTAGE)
1. Shift Spindle Angle Sensor System Inspection
Check the shift spindle angle sensor with the MCS
or GST.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
TOOL:
Test probe 07ZAJ-RDJA110
Connection: White – White
W
W
[1] [2]
Connection: White – Ground
[1]
W
26-148
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a known
good one (page 13-79).
Check the shift spindle angle sensor with the MCS
or GST.
Is about 5 V indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original shift spindle angle sensor
DTC 22-1 (SHIFT SPINDLE
OPERATION MALFUNCTION: AFTER
OPERATING GEARSHIFT
MECHANISM)
1. Shift Spindle Angle Sensor System Inspection
Check the shift spindle angle sensor with the MCS.
Is Low voltage (about 0 V) or High voltage (about
5 V) indicated?
YES – • About 0 V: See DTC 21-1 (page 26-
145).
• About 5 V: See DTC 21-2 (page 26-
147).
NO – GO TO STEP 2.
2. Shift Control Motor/Reduction Gear Condition
Check the shift control motor and reduction gears
are installed properly and are not damaged (page
13-71).
Are the shift control motor and reduction gears
in normal condition?
YES – GO TO STEP 3.
NO – Install the shift control motor and reduction
gears properly or replace faulty parts.
3. Shift Control Motor Inspection
Remove the shift control motor (page 13-71).
Connect a fully charged 12 V battery [1] to the shift
control motor [2] 2P connector to check the motor
operation.
Change the battery connection to check the reverse
operation.
Does the shift control motor turn in both
directions?
YES – GO TO STEP 4.
NO – Faulty shift control motor
[2] [1]
26-149
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Shift Spindle Angle Sensor System Inspection
Remove the shift spindle angle sensor with the
connector connected (page 13-79).
Turn the ignition switch ON.
While turning the shift spindle angle sensor shaft,
check the shift spindle angle sensor voltage with the
MCS.
Does the voltage vary properly?
YES – GO TO STEP 5.
NO – Faulty shift spindle angle sensor
5. Shift Spindle Angle Sensor Condition Inspection
Check that the shift spindle angle sensor is installed
properly and is not damaged.
Is the shift spindle angle sensor in normal
condition?
YES – GO TO STEP 6.
NO – Install the shift spindle angle sensor
properly or replace it (page 13-79).
6. DTC Recheck
Recheck the DTC with the MCS.
Is DTC 22-1 indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Intermittent failure
DTC 23-1 (SHIFT SPINDLE
OPERATION MALFUNCTION: WHILE
OPERATING GEARSHIFT
MECHANISM)
Refer to DTC 22-1 (page 26-148).
When turning the shaft clockwise:
Voltage increase
When turning the shaft counterclockwise:
Voltage decrease
26-150
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 24-1 (SHIFT CONTROL MOTOR
DRIVE CIRCUIT)
1. Shift Control Motor Line Open Circuit Inspection
Disconnect the following:
– PCM 33P (Brown) connector (page 4-39)
– Shift control motor 2P (Black) connector (page
13-71)
Check for continuity between the wire harness side
2P (Black) connector [1] and PCM 33P (Brown)
connector [2].
Is there continuity?
YES – GO TO STEP 2.
NO – • Open circuit in the Pink/blue wire
• Open circuit in the Yellow/blue wire
2. Shift Control Motor Line Short Circuit Inspection
Check for continuity at the wire harness side shift
control motor 2P (Black) connector [1] terminals and
ground.
Is there continuity?
YES – • Short circuit in the Pink/blue wire
• Short circuit in the Yellow/blue wire
NO – GO TO STEP 3.
3. Shift Control Motor Inspection
Remove the shift control motor (page 13-71).
Connect a fully charged 12 V battery [1] to the shift
control motor [2] 2P connector to check the motor
operation.
Change the battery connection to check the reverse
operation.
Does the shift control motor turn in both
directions?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty shift control motor
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Pink/blue – Pink/blue
Pink/blue – Pink/blue
Yellow/blue – Yellow/blue
Yellow/blue – Yellow/blue
Y/Bu
P/Bu
Y/Bu
P/Bu
Y/Bu
P/Bu
P/Bu
Y/Bu
[1] [2]
[1]
[2]
Connection: Pink/blue – Ground
Yellow/blue – Ground
Y/Bu
[1]
P/Bu
[2] [1]
26-151
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 27-1 (SHIFT DRUM POSITION
MALFUNCTION)
1. TR Sensor System Inspection
Check the TR sensor with the MCS or GST.
Is Low voltage (about 0 V) or High voltage (about
5 V) indicated?
YES – • About 0 V:
See DTC 51-1 (P1702) (page 26-162).
• About 5 V:
See DTC 51-2 (P1703) (page 26-164).
NO – GO TO STEP 2.
2. Shift Control Motor/Reduction gear condition
Check the shift control motor and reduction gears
are installed properly and are not damaged (page
13-71).
Are the shift control motor and reduction gears
in normal condition?
YES – GO TO STEP 3.
NO – Install the shift control motor and reduction
gears properly or replace faulty parts.
3. Shift Control Motor Inspection
Remove the shift control motor (page 13-71).
Connect a fully charged 12 V battery [1] to the shift
control motor [2] 2P connector to check the motor
operation.
Change the battery connection to check the reverse
operation.
Does the shift control motor turn in both
directions?
YES – GO TO STEP 4.
NO – Faulty shift control motor
4. TR Sensor System Inspection
Remove the TR sensor with the connector
connected (page 13-79).
Turn the ignition switch ON.
While turning the TR sensor shaft, check the TR
sensor voltage with the MCS.
Does the voltage vary properly?
YES – GO TO STEP 5.
NO – Faulty TR sensor
5. TR Sensor Condition Inspection
Check that the TR sensor is installed properly and is
not damaged.
Is the TR sensor in normal condition?
YES – GO TO STEP 6.
NO – Install the TR sensor properly or replace it
(page 13-79).
[2] [1]
When turning the shaft clockwise:
Voltage increase
When turning the shaft counterclockwise:
Voltage decrease
26-152
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
6. DTC Recheck
Recheck the DTC with the MCS.
Is DTC 27-1 indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Intermittent failure
DTC 31-1 (P170B) (SHIFT CONTROL
MOTOR LOW VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the shift control motor 2P (Black)
and PCM 33P (Brown) connectors, and recheck the
DTC.
1. DTC Recheck
Erase the DTCs (page 25-60).
Check the DTC with the MCS or GST.
Is DTC 32-1 or 37-1 indicated?
YES – • DTC 32-1 indicated (page 26-153).
• DTC 37-1 (P0562) indicated (page 26-
153).
NO – GO TO STEP 2.
2. Shift Control Motor Line Open Circuit Inspection
Disconnect the following:
– PCM 33P (Brown) connector (page 4-39)
– Shift control motor 2P (Black) connector (page
13-71)
Check for continuity between the wire harness side
2P (Black) connector [1] and PCM 33P (Brown)
connector [2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – • Open circuit in the Pink/blue wire
• Open circuit in the Yellow/blue wire
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Pink/blue – Pink/blue
Pink/blue – Pink/blue
Yellow/blue – Yellow/blue
Yellow/blue – Yellow/blue
Y/Bu
P/Bu
Y/Bu
P/Bu
Y/Bu
P/Bu
P/Bu
Y/Bu
[1] [2]
[1]
[2]
26-153
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 32-1 (FAIL SAFE RELAY CIRCUIT
MALFUNCTION)
• Before starting the inspection, check for loose or
poor contact on the PCM 33P (Brown) connector,
and recheck the DTC.
1. Shift Control Motor Power Supply Voltage
Inspection
Check the shift control motor power supply voltage
with the MCS.
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Red/white wire
between the PCM 33P (Brown)
connector and fuse DCT M 30 A
• Blown fuse DCT M 30 A
2. DTC Recheck
Recheck the DTC with the MCS.
Is DTC 32-1 indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Intermittent failure
DTC 37-1 (P0562) (IGNITION HOLD
RELAY MALFUNCTION)
• Before starting the inspection, check for loose or
poor contact on the PCM 33P (Brown) connector,
and recheck the DTC.
1. PCM (DCT Drive Circuit) Sub Power Voltage
Inspection
Check the PCM sub power voltage with the MCS or
GST.
Is the battery voltage indicated?
YES – GO TO STEP 2.
NO – • Open circuit in the Red/white wire
between the PCM 33P (Brown)
connector and fuse box
• Blown sub fuse DCT MAIN 10 A
2. DTC Recheck
Recheck the DTC with the MCS or GST.
Is DTC 37-1 (P0562) indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Intermittent failure
26-154
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 41-1 (N-D SWITCH
MALFUNCTION)
1. N-D Switch Power Input Voltage Inspection
Disconnect the right handlebar switch 6P (Black)
connector (page 22-23).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the wire harness side
6P (Black) connector [1] and ground.
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – GO TO STEP 2.
2. N-D Switch Power Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
6P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Yellow/red wire
3. N-D Switch Inspection
Turn the ignition switch OFF.
Check for continuity at the switch side 6P (Black)
connector [1] in each switch position.
Is there continuity with the switch pushed and
no continuity with the switch released?
YES – GO TO STEP 4.
NO – Faulty N-D switch
Connection: Yellow/red (+) – Ground (–)
[1]
Y/R
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
[2]
[1]
Y/R
Y/R
Connection:
N switch:
Light green/yellow – Yellow/red
D switch:
Blue – Yellow/red
[1]
Y/R
Lg/Y
Bu
Y/R
[1]
26-155
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. N-D Switch Output Line Open Circuit Inspection
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
6P (Black) connector [1] and 33P (Brown) connector
[2].
Is there continuity?
YES – GO TO STEP 5.
NO – • Open circuit in the Light green/yellow
wire
• Open circuit in the Blue wire
5. N-D Switch Output Line Short Circuit Inspection
Check for continuity between the wire harness side
6P (Black) connector [1] and ground.
Is there continuity?
YES – • Short circuit in the Light green/yellow
wire
• Short circuit in the Blue wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 42-1 (P0826) (SHIFT SWITCH
MALFUNCTION)
1. Shift Switch Power Input Voltage Inspection
Disconnect the Left handlebar switch 12P (Black)
connector (page 22-23).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the wire harness side
12P (Black) connector [1] and ground.
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – GO TO STEP 2.
TOOL:
Test probe 07ZAJ-RDJA110
Connection:
Light green/yellow – Light green/yellow
Blue – Blue
[2]
[1]
Lg/Y Bu
Lg/Y
Bu
Connection: Light green/yellow – Ground
Blue – Ground
[1]
Lg/Y Bu
Connection: Yellow/red (+) – Ground (–)
[1]
Y/R
26-156
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Shift Switch Power Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
12P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Yellow/red wire
3. Shift Switch Inspection
Turn the ignition switch OFF.
Check for continuity at the switch side 12P (Black)
connector [1] in each switch position.
Is there continuity with the switch pushed and
no continuity with the switch released?
YES – GO TO STEP 4.
NO – Faulty shift switch
4. Shift Switch Input Line Open Circuit Inspection
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
12P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 5.
NO – • Open circuit in the Green/blue wire
• Open circuit in the Light green/red wire
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
[2]
[1]
Y/R
Y/R
Connection:
"+" switch: Green/blue – Yellow
"–" switch: Light green/red – Yellow
G/Bu
Y
Lg/R
Y
[1]
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Green/blue – Green/blue
Light green/red – Light green/red
[2]
[1]
Lg/R
G/Bu
G/Bu
26-157
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. Shift Switch Input Line Short Circuit Inspection
Check for continuity between the wire harness side
12P (Black) connector [1] and ground.
Is there continuity?
YES – • Short circuit in the Green/blue wire
• Short circuit in the Light green/red wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 44-1 (P0197) (EOT SENSOR LOW
VOLTAGE)
1. EOT Sensor System Inspection
Check the EOT sensor with the MCS or GST.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. EOT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the EOT sensor 2P (Black) connector
(page 13-81).
Turn the ignition switch ON.
Check the EOT sensor with the MCS or GST.
Is about 0 V indicated?
YES – GO TO STEP 3.
NO – Faulty EOT sensor
3. EOT Sensor Input Line Short Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check the continuity between the wire harness side
2P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Blue/green wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
Connection: Green/blue – Ground
Light green/red – Ground
[1]
Lg/R
G/Bu
Connection: Blue/green – Ground
[1]
Bu/G
26-158
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 44-2 (P0198) (EOT SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the EOT sensor 2P (Black) and
PCM 33P (Brown) connectors, and recheck the
DTC.
1. EOT Sensor System Inspection
Check the EOT sensor with the MCS or GST.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. EOT Sensor Inspection
Turn the ignition switch OFF.
Disconnect the EOT sensor 2P (Black) connector
(page 13-81).
Short the wire harness side 2P (Black) connector [1]
terminals with a jumper wire [2].
Turn the ignition switch ON.
Check the EOT sensor with the MCS or GST.
Is about 0 V indicated?
YES – Faulty EOT sensor
NO – GO TO STEP 3.
3. EOT Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
EOT sensor 2P (Black) connector [1] and PCM 33P
(Brown) connector [2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Blue/green wire
4. EOT Sensor Ground Line Open Circuit
Inspection
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
2P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Gray/black wire
Connection: Blue/green – Gray/black
[2]
[1]
Bu/G Gr/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue/green – Blue/green
Bu/G
[1]
Bu/G
[2]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black– Gray/black
Gr/Bl
Gr/Bl
[2][1]
26-159
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 47-1 (P1704) or 48-1 (P1706) (No.1
or No.2 CLUTCH EOP SENSOR LOW
VOLTAGE)
1. Clutch EOP Sensor System Inspection
Connect the MCS or GST and start the engine.
Check the clutch EOP sensor with the MCS or GST.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Clutch EOP Sensor Inspection
Stop the engine.
Disconnect the clutch EOP sensor 3P (No.1: Gray,
No.2: Black) connector (page 13-80).
Turn the ignition switch ON.
Check the clutch EOP sensor with the MCS or GST.
Is about 0 V indicated?
YES – GO TO STEP 3.
NO – Faulty clutch EOP sensor
3. Clutch EOP Sensor Input Voltage Inspection
Measure the voltage between the wire harness side
3P connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 5.
NO – GO TO STEP 4.
4. Clutch EOP Sensor Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
3P connector [1] and 33P (Gray) connector [2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Yellow/red wire
Connection: Yellow/red (+) – Gray/black (–)
Gr/Bl Y/R
[1]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
Y/R
[2][1]
Y/R
26-160
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. Clutch EOP Sensor Output Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
sensor 3P connector [1] and ground.
Is there continuity?
YES – • Short circuit in the Yellow/green wire
• Short circuit in the Black/green wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 47-2 (P1705) or 48-2 (P1707) (No.1
or No.2 CLUTCH EOP SENSOR HIGH
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the clutch EOP sensor 3P (No.1:
Gray, No.2: Black), and PCM 33P (Brown) and 33P
(Gray) connectors, and recheck the DTC.
1. Clutch EOP Sensor System Inspection
Check the clutch EOP sensor with the MCS or GST.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Clutch EOP Sensor Inspection
Turn the ignition switch OFF.
Disconnect the clutch EOP sensor 3P connector
(page 13-80).
Short the wire harness side 3P connector [1]
terminals with a jumper wire [2].
Turn the ignition switch ON.
Check the clutch EOP sensor with the MCS or GST.
Is about 0 V indicated?
YES – Faulty clutch EOP sensor
NO – GO TO STEP 3.
Connection:
No.1 clutch EOP sensor:
Yellow/green – Ground
No.2 clutch EOP sensor:
Black/green – Ground
[1]
No.1: Y/G
No.2: Bl/G
Connection:
No.1 clutch EOP sensor:
Yellow/green – Gray/black
No.2 clutch EOP sensor:
Black/green – Gray/black
[2]
[1]
Gr/Bl No.1: Y/G
No.2: Bl/G
26-161
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Clutch EOP Sensor Ground Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
clutch EOP sensor 3P connector [1] and PCM 33P
(Gray) connector [2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Gray/black wire
4. Clutch EOP Sensor Output Line Open Circuit
Inspection
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
No.1 clutch EOP sensor 3P connector [1] and No.2
clutch EOP sensor 3P connector [2], 33P (Brown)
connector [3].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – • Open circuit in the Yellow/green wire
• Open circuit in the Black/green wire
DTC 49-1, 49-2 (CLUTCH LINE LOW
OIL PRESSURE)
1. Clutch Line EOP Sensor System Inspection
Check the clutch line EOP sensor with the MCS.
Is Low voltage (about 0 V) or High voltage (about
5 V) indicated?
YES – • About 0 V (while engine running): See
DTC 9-1 (page 26-142).
• About 5 V: See DTC 9-2 (page 26-143).
NO – GO TO STEP 2.
2. Engine Oil Level Inspection
Check the engine oil level (page 3-11).
Is the engine oil level correct?
YES – GO TO STEP 3.
NO – Add the recommended oil to the upper
level.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
Gr/Bl
[2][1]
Gr/Bl
TOOL:
Test probe 07ZAJ-RDJA110
Connection:
No.1 clutch EOP sensor:
Yellow/green – Yellow/green
No.2 clutch EOP sensor:
Black/green – Black/green
Bl/G
Y/G
[2]
[1]
Bl/G
Y/G
[3]
26-162
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Clutch Line Oil Filter Condition Inspection
Check the clutch oil filter (page 3-13).
Is the oil filter in good condition?
YES – GO TO STEP 4.
NO – Replace the clutch oil filter.
4. Clutch Line EOP Sensor Inspection
Replace the clutch line EOP sensor with a known
good one (page 13-80).
Erase the DTC (page 25-60).
Test-ride the motorcycle above 2,000 min
-1
(rpm)
and stop the engine.
Check the DTC with the MCS.
Is DTC 49-1 or 49-2 indicated?
YES – GO TO STEP 5.
NO – Faulty original clutch line EOP sensor
5. PCM Inspection
Replace the PCM with a known good one (page 4-
39).
Test-ride the motorcycle above 2,000 min
-1
(rpm)
and stop the engine.
Check the DTC with the MCS.
Is DTC 49-1 or 49-2 indicated?
YES – • Oil pressure relief valve stuck open
• Damaged oil pump
• Internal oil leak in the clutch oil line
NO – Faulty original PCM
DTC 51-1 (P1702) (TR SENSOR LOW
VOLTAGE)
• Before starting the inspection, check for loose or
poor contact on the TR sensor 3P (Black), PCM 33P
(Blue) and 33P (Gray) connectors, and recheck the
DTC.
1. TR Sensor System Inspection
Check the TR sensor with the MCS or GST.
Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TR Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the TR sensor 3P (Black) connector
(page 13-79).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P
(Black) connector [1].
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 5.
NO – GO TO STEP 3.
Connection: Yellow/red (+) – Gray/black (–)
Gr/BlY/R
[1]
26-163
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. TR Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Yellow/red wire
4. TR Sensor Ground Line Open Circuit Inspection
Check for continuity between the wire harness side
33P (Gray) connector [1] and 3P (Black) connector
[2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Gray/black wire
5. TR Sensor Signal Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Blue) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Blue) connector
[2].
Is there continuity?
YES – GO TO STEP 6.
NO – Open circuit in the White wire
6. TR Sensor Output Line Short Circuit Inspection
Check for continuity between the wire harness side
3P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the White wire
NO – GO TO STEP 7.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow/red – Yellow/red
Y/R
[2][1]
Y/R
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
Gr/BlGr/Bl
[1] [2]
TOOL:
Test probe 07ZAJ-RDJA110
Connection: White – White
W
[1]
W
[2]
Connection: White – Ground
[1]
W
26-164
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
7. TR Sensor Inspection
Replace the TR sensor with a known good one
(page 13-79).
Connect the 3P (Black) connector, 33P (Gray)
connector and 33P (Blue) connector.
Check the TR sensor with the MCS or GST.
Is about 0 V indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original TR sensor
DTC 51-2 (P1703) (TR SENSOR HIGH
VOLTAGE)
1. TR Sensor System Inspection
Check the TR sensor with the MCS or GST.
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. TR Sensor Inspection
Replace the TR sensor with a known good one
(page 13-79).
Turn the ignition switch ON.
Check the TR sensor with the MCS or GST.
Is about 5 V indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original TR sensor
DTC 52-1 (NEUTRAL SWITCH STUCK
OFF)
• Before starting the inspection, check for loose or
poor contact on the neutral switch terminal and PCM
33P (Black) connector, and recheck the DTC.
1. DTC Recheck
Recheck the DTC with the MCS.
Is DTC 52-1 indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Neutral Switch Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Remove the neutral switch terminal (page 13-82).
Check for continuity between the wire harness side
33P (Brown) connector [1] and neutral switch
terminal [2].
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Light green wire
Connection: Light green – Light green
TOOL:
Test probe 07ZAJ-RDJA110
[2]
[1]
Lg
Lg
26-165
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Neutral Switch Inspection
Replace the neutral switch with a known good one
(page 13-82).
Connect the PCM 33P (Black) connector.
Turn the ignition switch ON.
Recheck the DTC with the MCS.
Is DTC 52-1 indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original neutral switch
DTC 52-2 (NEUTRAL SWITCH STUCK
ON)
1. Neutral Switch Line Short Circuit Inspection
Remove the neutral switch terminal (page 13-82).
Check for continuity between the neutral switch
terminal and ground.
Is there continuity?
YES – Short circuit in the Light green wire
NO – GO TO STEP 2.
2. Neutral Switch Inspection
Replace the neutral switch with a known good one
(page 13-82).
Install the neutral switch terminal (page 13-82).
Check the DTC with the MCS.
Is DTC 52-2 indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original neutral switch
DTC 53-1 (P0715) (INNER MAINSHAFT
SENSOR SPEED LOW)
• Before starting the inspection, check for loose or
poor contact on the inner mainshaft sensor 3P
(Black), PCM 33P (Brown) and 33P (Gray)
connectors, and recheck the DTC.
1. DTC Recheck
Erase the DTC (page 25-60).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 53-1 (P0715) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
Connection: Light green – Ground
26-166
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Inner Mainshaft Sensor Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the inner mainshaft sensor 3P (Black)
connector (page 13-78).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P
(Black) connector [1].
Is there about battery voltage?
YES – GO TO STEP 5.
NO – GO TO STEP 3.
3. Inner Mainshaft Sensor Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Brown) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Black/brown wire
4. Inner Mainshaft Sensor Ground Line Open
Circuit Inspection
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Gray/black wire
Connection: Black/brown(+) – Gray/black (–)
[1]
Gr/BlBl/Br
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Black/brown – Black/brown
Bl/Br
[2][1]
Bl/Br
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray/black – Gray/black
Gr/Bl
Gr/Bl
[2][1]
26-167
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
5. Inner Mainshaft Sensor Output Line Inspection
Measure the voltage between the wire harness side
3P (Black) connector [1] and ground.
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 8.
NO – GO TO STEP 6.
6. Inner Mainshaft Sensor Output Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Brown) connector
[2].
Is there continuity?
YES – GO TO STEP 7.
NO – Open circuit in the Pink wire
7. Inner Mainshaft Sensor Output Line Short
Circuit Inspection
Check for continuity between the wire harness side
3P (Black) connector [1] and ground.
Is there continuity?
YES – Short circuit in the Pink wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
8. Inner Mainshaft Sensor Inspection
Turn the ignition switch OFF.
Replace the inner mainshaft sensor with a known
good one (page 13-78).
Erase the DTC (page 25-60).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 53-1 (P0715) indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original inner mainshaft sensor
Connection: Pink (+) – Ground (–)
[1]
P
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Pink – Pink
P
P
[2][1]
Connection: Pink – Ground
[1]
P
26-168
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 54-1 (P2765) (OUTER MAINSHAFT
SENSOR SPEED LOW)
• Before starting the inspection, check for loose or
poor contact on the outer mainshaft sensor 3P
(Black), PCM 33P (Brown) and 33P (Gray)
connectors, and recheck the DTC.
1. DTC Recheck
Erase the DTC (page 25-60).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 54-1 (P2765) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Outer Mainshaft Sensor Input Voltage
Inspection
Turn the ignition switch OFF.
Disconnect the outer mainshaft sensor 3P (Black)
connector (page 13-78).
Temporarily install the removed electrical parts in
the reverse order of removal.
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P
(Black) connector [1].
Is there about battery voltage?
YES – GO TO STEP 5.
NO – GO TO STEP 3.
3. Outer Mainshaft Sensor Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Brown) connector
[2].
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the White wire
Connection: White (+) – Gray (–)
[1]
GrW
TOOL:
Test probe 07ZAJ-RDJA110
Connection: White – White
W
[2][1]
W
26-169
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Outer Mainshaft Sensor Ground Line Open
Circuit Inspection
Disconnect the PCM 33P (Gray) connector (page 4-
39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Gray) connector
[2]
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Gray or Gray/black wire
5. Outer Mainshaft Sensor Output Line Inspection
Measure the voltage between the wire harness side
3P (Black) connector [1] and ground.
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 8.
NO – GO TO STEP 6.
6. Outer Mainshaft Sensor Output Line Open
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
3P (Black) connector [1] and 33P (Brown) connector
[2].
Is there continuity?
YES – GO TO STEP 7.
NO – Open circuit in the Pink wire
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Gray – Gray/black
Gr/Bl
Gr
[2][1]
Connection: Pink (+) – Ground (–)
[1]
P
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Pink – Pink
P
P
[2][1]
26-170
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
7. Outer Mainshaft Sensor Output Line Short
Circuit Inspection
Check for continuity between the wire harness side
3P (Black) connector [1] and ground
Is there continuity?
YES – Short circuit in the Pink wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
8. Outer Mainshaft Sensor Condition Inspection
Turn the ignition switch OFF.
Replace the outer mainshaft sensor with a known
good one (page 13-78).
Erase the DTC (page 25-60).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 54-1 (P2765) indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Faulty original outer mainshaft sensor
DTC 55-1 (P0745)/55-2 (P0745)
(No.1 LINEAR SOLENOID VALVE)
• Before starting the inspection, check for loose or
poor contact on the linear solenoid valve 4P (Black)
and PCM 33P (Brown) connectors, and recheck the
DTC.
1. DTC Recheck
Recheck the DTC with the MCS or GST.
Is DTC 55-1 (P0745) or 55-2 (P0745) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. No.1 Linear Solenoid Valve Inspection
Turn the ignition switch OFF.
Disconnect the linear solenoid valve 4P (Black)
connector (page 13-60).
Measure the resistance at the linear solenoid valve
side 4P (Black) connector [1].
Is the resistance within 5.0 – 5.6 (20°C/68°F)?
YES – GO TO STEP 3.
NO – Faulty linear solenoid valve
Connection: Pink – Ground
[1]
P
Connection: Yellow – White/red
[1]
W/R
Y
26-171
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. No.1 Linear Solenoid Valve Line Open Circuit
Inspection
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
4P (Black) connector [1] and 33P (Brown) connector
[2].
Is the continuity normal?
YES – GO TO STEP 4.
NO – • Open circuit in the Yellow wire
• Open circuit in the White/red wire
4. No.1 Linear Solenoid Valve Line Short Circuit
Inspection
Check for continuity between the wire harness side
4P (Black) connector [1] and ground.
Is there continuity?
YES – • Short circuit in the Yellow wire
• Short circuit in the White/red wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 56-1 (P0775)/56-2 (P0775)
(No.2 LINEAR SOLENOID VALVE)
• Before starting the inspection, check for loose or
poor contact on the linear solenoid valve 4P (Black)
and PCM 33P (Brown) connectors, and recheck the
DTC.
1. DTC Recheck
Recheck the DTC with the MCS or GST.
Is DTC 56-1 (P0775) or 56-2 (P0775) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. No.2 Linear Solenoid Valve Inspection
Turn the ignition switch OFF.
Disconnect the linear solenoid valve 4P (Black)
connector (page 13-60).
Measure the resistance at the linear solenoid valve
side 4P (Black) connector [1].
Is the resistance within 5.0 – 5.6 (20°C/68°F)?
YES – GO TO STEP 3.
NO – Faulty linear solenoid valve
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Yellow – Yellow
White/red – White/red
W/R
Y
[2]
[1]
W/R
Y
Connection: Yellow – Ground
White/red – Ground
[1]
W/R
Y
Connection: Blue – Gray
[1]
Gr
Bu
26-172
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. No.2 Linear Solenoid Valve Input/ground Line
Open Circuit Inspection
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
4P (Black) connector [1] and 33P (Brown) connector
[2].
Is the continuity normal?
YES – GO TO STEP 4.
NO – • Open circuit in the Blue wire
• Open circuit in the Gray wire
4. No.2 Linear Solenoid Valve Input/ground Line
Short Circuit Inspection
Check for continuity between the wire harness side
4P (Black) connector [1] and ground.
Is there continuity?
YES – • Short circuit in the Blue wire
• Short circuit in the Gray wire
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 57-1 (GEARSHIFT MECHANISM
MALFUNCTION)
Refer to DTC 27-1 (page 26-151).
DTC 57-2 (GEAR POSITION
MALFUNCTION; JUMPS OUT OF
GEAR)
Refer to DTC 27-1 (page 26-151).
DTC 58-1 or DTC 59-1 (No.1 or No.2
CLUTCH DOES NOT DISENGAGE;
WHEN SHIFTING GEAR)
1. Clutch Condition Inspection
Remove the dual clutch assembly and inspect the
clutch for sticking (page 13-63).
Is the No.1 clutch stuck?
YES – Faulty clutch
NO – GO TO STEP 2.
TOOL:
Test probe 07ZAJ-RDJA110
Connection: Blue – Blue
Gray – Gray
Bu
Gr
[2]
[1]
Gr
Bu
Connection: Blue – Ground
Gray – Ground
[1]
Gr
Bu
26-173
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Clutch Oil Line Inspection
Check the clutch oil passages in the right crankcase
cover and mainshaft for clogging.
Is the oil passage clogged?
YES – Clean the oil passage.
NO – Replace the PCM with a known good one
and recheck (page 4-39).
DTC 61-1/61-2/61-3/61-4/62-1/62-2
(No.1 CLUTCH OIL PRESSURE
MALFUNCTION)
1. DTC Recheck
Recheck the DTC with the MCS or GST.
Is DTC 47-1 (P1704), 47-2 (P1705), 55-1 (P0745),
or 55-2 (P0745) indicated?
YES – • DTC 47-1 (P1704) is indicated (page
26-159).
• DTC 47-2 (P1705) is indicated (page
26-160).
• DTC 55-1 (P0745) is indicated (page
26-170).
• DTC 55-2 (P0745) is indicated (page
26-170).
NO – GO TO STEP 2.
2. No.1 Clutch EOP Sensor Inspection
Replace the No.1 clutch EOP sensor with a known
good one (page 13-80).
Erase the DTC (page 25-60).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 61-1, 61-2, 61-3, 61-4, 62-1 or 62-2
indicated?
YES – GO TO STEP 3.
NO – Faulty original No.1 clutch EOP sensor
3. PCM Inspection
Replace the PCM with a known good one (page 4-
39).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 61-1, 61-2, 61-3, 61-4, 62-1 or 62-2
indicated?
YES – • Faulty No.1 linear solenoid valve
• Clogged No.1 clutch oil line
• Internal oil leak in the No.1 clutch oil
line
NO – Faulty original PCM
26-174
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 63-1/63-2/63-3/63-4/64-1/64-2
(No.2 CLUTCH OIL PRESSURE
MALFUNCTION)
1. DTC Recheck
Recheck the DTC with the MCS or GST.
Is DTC 48-1 (P1706), 48-2 (P1707), 56-1 (P0775),
or 56-2 (P0775) indicated?
YES – • DTC 48-1 (P1706) is indicated (page
26-159).
• DTC 48-2 (P1707) is indicated (page
26-160).
• DTC 56-1 (P0775) is indicated (page
26-171).
• DTC 56-2 (P0775) is indicated (page
26-171).
NO – GO TO STEP 2.
2. No.2 Clutch EOP Sensor Inspection
Replace the No.2 clutch EOP sensor with a known
good one (page 13-80).
Erase the DTC (page 25-60).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 63-1, 63-2, 63-3, 63-4, 64-1 or 64-2
indicated?
YES – GO TO STEP 3.
NO – Faulty original No.2 clutch EOP sensor
3. PCM Inspection
Replace the PCM with a known good one (page 4-
39).
Test-ride the motorcycle and stop the engine.
Check the DTC with the MCS or GST.
Is DTC 63-1, 63-2, 63-3, 63-4, 64-1 or 64-2
indicated?
YES – • Faulty No.2 linear solenoid valve
• Clogged No.2 clutch oil line
• Internal oil leak in the No.2 clutch oil
line
NO – Faulty original PCM
DTC 65-1 (P170C) (FRONT AND REAR
WHEEL SPEED SIGNAL
MALFUNCTION)
• Before starting the inspection, check that the tire
sizes are correct, and the drive and driven sprockets
are the specified ones.
1. DTC Recheck
Erase the DTC (page 25-60).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 20 seconds.
Stop the engine.
Check the DTC with the MCS or GST.
Is DTC P0500 or P1500 indicated?
YES – • DTC P0500 is indicated (page 26-76).
• DTC P1500 is indicated (page 26-88).
NO – GO TO STEP 2.
26-175
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Front Wheel Speed Sensor Condition Inspection
Inspect the area around the front wheel speed
sensor.
Check that there is no iron or other magnetic
deposits between the pulser ring and wheel speed
sensor, and check the pulser ring slots for
obstructions.
Check installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.
Are the sensor and pulser ring in good
condition?
YES – GO TO STEP 3.
NO – Remove any deposits. Install properly or
replace faulty part.
3. VS Sensor Condition Inspection
Remove the VS sensor (page 4-42).
Check the VS sensor for damage or contaminated.
Is the VS sensor in good condition?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Replace the VS sensor with a known good
one and recheck.
DTC 68-1 (No.1 CLUTCH OPERATION
MALFUNCTION; CLUTCH SLIPS)
1. DTC Recheck
Erase the DTC (page 25-60).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 20 seconds.
Stop the engine.
Check the DTC with the MCS or GST.
Is DTC P0500 indicated?
YES – Refer to DTC P0500 troubleshooting (page
26-76).
NO – GO TO STEP 2.
2. Clutch Condition Inspection
Disassemble and check the No.1 clutch assembly
(page 13-63).
Is the No.1 clutch in good condition?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Replace the faulty part.
26-176
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 69-1 (No.2 CLUTCH OPERATION
MALFUNCTION; CLUTCH SLIPS)
1. DTC Recheck
Erase the DTC (page 25-60).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 20 seconds.
Stop the engine.
Check the DTC with the MCS or GST.
Is DTC P0500 indicated?
YES – Refer to DTC P0500 troubleshooting (page
26-76).
NO – GO TO STEP 2.
2. Clutch Condition Inspection
Disassemble and check the No.2 clutch assembly
(page 13-63).
Is the No.2 clutch in good condition?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Replace the faulty part.
DTC 71-1 (P1700)/72-1 (P1701) (INNER,
OUTER MAINSHAFT/COUNTERSHAFT
SPEED RATIO FAILURE)
1. DTC Recheck 1
Check the DTC with the MCS or GST.
Is DTC 53-1 (P0715), 54-1 (P2765), or 11-1
(P0500) indicated?
YES – • DTC 53-1 (P0715) is indicated (page
26-165).
• DTC 54-1 (P2765) is indicated (page
26-168).
• DTC P0500 is indicated (page 26-76).
NO – GO TO STEP 2.
2. DTC Recheck 2
Erase the DTC (page 25-60).
Test-ride the motorcycle above 20 km/h (12 mph)
for more than 20 seconds.
Stop the engine.
Check the DTC with the MCS or GST.
Is DTC 71-1 (P1700) or 72-1 (P1701) indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Intermittent failure
DTC 84-1 (P0606) (CPU IN THE PCM
MALFUNCTION)
1. DTC Recheck
Erase the DTC (page 25-60).
Check the DTC with the MCS or GST.
Is DTC 84-1 (P0606) indicated?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Intermittent failure
26-177
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
A/M SWITCH TROUBLESHOOTING
If the engine can be started but AT/MT mode cannot be
changed, perform this troubleshooting.
• Before starting the inspection, check for loose or
poor contact on the right handlebar switch and PCM
33P connectors, and recheck the A/M switch
operation.
• If the PCM is replaced, perform the Clutch Initialize
Learning Procedure (page 13-82).
1. A/M switch Power Input Voltage Inspection
Disconnect the right handlebar switch 8P (Black)
connector (page 22-23).
Turn the ignition switch ON with the engine stop
switch " ".
Measure the voltage between the wire harness side
6P (Black) connector [1] and ground.
Is there battery voltage?
YES – GO TO STEP 2.
NO – Open circuit in the Yellow/white wire
between the right handlebar switch
connector and fuse box (ENG STOP 10 A)
2. A/M switch Inspection
Turn the ignition switch OFF.
Check for continuity at the switch side right
handlebar switch 8P (Black) connector [1] in each
switch position.
Is there continuity with the switch pushed and
no continuity with the switch released?
YES – GO TO STEP 3.
NO – Faulty A/M switch
3. A/M switch Input Line Open Circuit Inspection
Disconnect the PCM 33P (Brown) connector (page
4-39).
Check for continuity between the wire harness side
right handlebar switch 8P (Black) connector [1] and
PCM 33P (Brown) connector [2].
Is there continuity?
YES – Replace the PCM with a known good one
and recheck (page 4-39).
NO – Open circuit in the Blue/black wire
Connection: Yellow/white (+) – Ground (–)
[1]
Y/W
Connection: Black/white – Blue/black
Bl/W
[1]
Bu/Bl
Connection: Blue/black – Blue/black
TOOL:
Test probe 07ZAJ-RDJA110
[2]
Bu/Bl
[1]
Bu/Bl
26-178
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
RIGHT CRANKCASE COVER
(CRF1000D2/DL2)
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
REMOVAL
Remove the bolts [1].
Remove the right skid plate bracket [2].
Remove the right crankcase cover [3].
INSTALLATION
Install the right crankcase cover [1].
Install the right skid plate bracket [2].
Install the bolts [3] and tighten them in a crisscross
pattern in 2 or 3 steps to the specified torque.
ENGINE REMOVAL
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
Support the motorcycle using a safety stand or hoist.
Remove the following:
– Muffler/exhaust pipe
– CRF1000A/D/AL/DL (page 2-16)
– CRF1000A2/D2/AL2/DL2 (page 26-58)
– Engine oil filter (page 3-12)
– Ignition coil tray (page 26-124)
– Radiator (page 8-6)
– Radiator reserve tank (page 8-10)
– Rear brake pedal (page 19-15)
– Battery box (page 21-5)
– Gearshift spindle cover (CRF1000A/A2/AL/AL2)
(page 12-17)
– Shift pedal (CRF1000A/A2/AL/AL2) (page 12-21)
– EOP switch (CRF1000A/A2/AL/AL2) (page 22-19)
– EOP sensor (CRF1000D/D2/DL/DL2) (page 22-20)
– Front side pipe stay (CRF1000A2/AL2/D2/DL2)
(page 26-47)
– Lower cross pipe bracket (CRF1000A2/AL2/D2/DL2)
(page 26-47)
Do not allow dust or
dirt to enter the oil
passages.
[1][2][3]
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[3][1] [2]
26-179
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000A/A2/AL/
AL2:
Disconnect the following:
– Rear brake switch 2P (Gray) connector [1]
– Sidestand switch 2P (Black) connector [2]
– Alternator assembly 6P (Black) connector [3]
– Gear position sensor 3P (Black) connector [4]
– Shift spindle switch terminal [5]
– Neutral switch terminal [6]
Release the O
2 sensor wire clip [7] from the connector
clip stay.
CRF1000D/D2/DL/
DL2:
Disconnect the following:
– Rear brake switch 2P (Gray) connector [1]
– Sidestand switch 2P (Black) connector [2]
– Alternator assembly 6P (Black) connector [3]
– Shift spindle angle sensor 3P (Blue) connector [4]
– Inner mainshaft sensor 3P (Black) connector [5]
– TR sensor 3P (Black) connector [6]
– Neutral switch terminal [7]
Release the O2 sensor wire clip [8] and shift spindle
angle sensor wire clip [9] from the connector clip stay.
Remove the following:
– Front middle bolt (10 x 100 mm) [1]
– Collar (left side, long) [2]
– Front middle nut (10 mm) [3]
– Collar (right side, short) [4]
– Front middle bolts [5]
– CRF1000A/AL/D/DL: 8 x 87 mm
– CRF1000A2/AL2/D2/DL2: 8 x 90 mm
– Front middle nuts (8 mm) [6]
– Lower cross pipe bracket (left side) (CRF1000A2/
AL2/D2/DL2) [7]
– Stay (left side) [8]
– Lower cross pipe bracket (right side) (CRF1000A2/
AL2/D2/DL2) [9]
– Stay (right side) [10]
[5]
[1]
CRF1000A shown:
[2]
[4]
[3]
[6] [7]
’16 model
CRF1000D
shown:
[1][2][3]
[5] [4]
[9]
[6]
[7]
[8]
[10]
[1]
[3]Left side:
Right side:
[6]
[5]
[8]
[4]
[2]
CRF1000A/AL/D/DL:
[10]
[1]
[3]
Left side:
Right side:
[6][5]
[8]
[4]CRF1000A2/AL2/D2/
DL2:
[7] [9]
26-180
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ENGINE INSTALLATION
• For procedures not described below, refer to the
Service Manual of 62MJP00 or 62MJP00Z.
CRF1000A/A2/AL/
AL2:
Install the O2 sensor wire clip [1] to the connector clip
stay.
Connect the following:
– Rear brake switch 2P (Gray) connector [2]
– Sidestand switch 2P (Black) connector [3]
– Alternator assembly 6P (Black) connector [4]
– Gear position sensor 3P (Black) connector [5]
– Shift spindle switch terminal [6]
– Neutral switch terminal [7]
CRF1000D/D2/DL/
DL2:
Install the O2 sensor wire clip [1] and shift spindle angle
sensor wire clip [2] to the connector clip stay.
Connect the following:
– Rear brake switch 2P (Gray) connector [3]
– Sidestand switch 2P (Black) connector [4]
– Alternator assembly 6P (Black) connector [5]
– Shift spindle angle sensor 3P (Blue) connector [6]
– Inner mainshaft sensor 3P (Black) connector [7]
– TR sensor 3P (Black) connector [8]
– Neutral switch terminal [9]
Install the alternator assembly wire onto the frame:
– CRF1000A/A2/AL/AL2 (page 11-4)
– CRF1000D/D2/DL/DL2 (page 11-5)
Install the following:
– Muffler/exhaust pipe
– CRF1000A/D/AL/DL (page 2-16)
– CRF1000A2/D2/AL2/DL2 (page 26-58)
– Engine oil filter (page 3-12)
– Ignition coil tray (page 26-124)
– Radiator (page 8-6)
– Radiator reserve tank (page 8-10)
– Rear brake pedal (page 19-15)
– Battery box (page 21-5)
– Shift pedal (CRF1000A/A2/AL/AL2) (page 12-21)
– Gearshift spindle cover (CRF1000A/A2/AL/AL2)
(page 12-17)
– EOP switch (CRF1000A/A2/AL/AL2) (page 22-19)
– EOP sensor (CRF1000D/D2/DL/DL2) (page 22-20)
– Front side pipe stay (CRF1000A2/AL2/D2/DL2)
(page 26-47)
– Lower cross pipe bracket (CRF1000A2/AL2/D2/DL2)
(page 26-47)
Adjust the drive chain slack (page 3-16).
TORQUE:
Shift spindle switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
Neutral switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
[6]
[2]
CRF1000A shown:
[3]
[5]
[4]
[7] [1]
TORQUE:
Neutral switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
’16 model
CRF1000D
shown:
[3][4][5]
[7] [6]
[2]
[8]
[9]
[1]
26-181
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
SWINGARM
DISASSEMBLY/ASSEMBLY
• Install the dust seals until it is flush with the
swingarm surface.
• Apply ThreeBond 1521 or an equivalent to the
swingarm cap mating surface.
PIVOT COLLAR A
CHAIN
SLIDER
SWINGARM
DRIVE CHAIN
ADJUSTING
BOLTS
DUST SEAL
PIVOT DISTANCE
LEFT COLLAR
DUST SEAL
SNAP
RING
BEARING
6003
WASHERS B
NEEDLE BEARING
NEEDLE BEARING
(24 x 31 x 28 mm)
REAR SWINGARM
CAPS (5 pcs)
LOCK NUTS
WASHER A
DRIVE CHAIN GUARD
WASHERS
27 N·m (2.8 kgf·m, 20 lbf·ft)
DUST SEAL
PIVOT DISTANCE
RIGHT COLLAR
DUST SEAL
COLLARS
Front
Left
DRIVE CHAIN GUARD BOLTS
10 N·m (1.0 kgf·m, 7 lbf·ft)
DRIVE CHAIN SLIDER SCREWS
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
CHAIN SLIDER RUBBER
26-182
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
FRONT BRAKE CALIPER
DISASSEMBLY/ASSEMBLY
• Be careful not to damage each piston.
• When removing the caliper pistons with compressed
air, place a shop towel over the piston to prevent
damaging the piston and caliper body. Do not use
high pressure or bring the nozzle too close to the
fluid inlet.
• Mark the pistons to ensure correct reassembly.
• Be careful not to damage the piston sliding surface.
• Install each caliper piston in their proper locations.
– Piston A: larger O.D.
– Piston B: smaller O.D.
• Do not disassemble the caliper bodies unless
necessary.
5.4 N·m (0.6 kgf·m,
4.0 lbf·ft)
PISTON SEAL A
DUST SEAL A
PAD SPRING
PISTON SEAL B
DUST SEAL B
BLEED VALVE
BRAKE PADS/
SHIMS
PISTON B
(smaller O.D.)
PISTONS A
(larger O.D.)
DUST SEAL A
PISTON SEAL A
DUST SEAL B
PISTON SEAL B
O-RING
FRONT BRAKE CALIPER
ASSEMBLY TORX BOLTS
27 N·m (2.8 kgf·m, 20 lbf·ft)
CALIPER BODIES
PISTON B
(smaller O.D.)
26-183
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ABS SYSTEM DIAGRAM
1
10 11 12 13 14 15 16 17 18
2345678 9
RVW S (-)
RVW B (+)
IND
BLS
FVW S (-)
FVW B (+)
IG
DIAG
GND
13
4
5
SCS 14
10
15
6
17
8
7
18 FSR +B
11 MODE SW
MODE IND 2
ESS 16
RPO 3
FPO 12
1 MOTOR GND
9MR +B
W
R/Bl
G
R/Bl
BlBl/Gr
R
R/G
R/Bl
CRF1000A/A2/AL/AL2: R
CRF1000D/D2/DL/DL2: R/Bl
Bl/R
G/Y
G
Bl Bl
Bl/G
R/G
R/Y
R/Y
W
G
Bu
Bu/Bl
Bu/Y
Bl/G
W
Bu
G/Bu
W
Gr/Bu
G
W/Bu
G/Y
W/G
Bl
CRF1000A/A2/AL/AL2: Bl
CRF1000D/D2/DL/DL2: G
CRF1000A/A2/AL/AL2: Bl/Y
CRF1000D/D2/DL/DL2: Bl/R
BATTERY
IGNITION
SWITCH
ABS FSR +
30 A
REAR ABS
SWITCH
ILLUMI STOP HORN
10A
ABS MAIN
10A
MAIN FUSE
30 A
FRONT BRAKE
LIGHT SWITCH
REAR BRAKE
LIGHT SWITCH
FRONT WHEEL
SPEED SENSOR
REAR WHEEL
SPEED SENSOR
FRONT PULSER RING REAR PULSER RING
DLC
ABS MODULATOR
SOLENOID VALVE
ABS
INDICATOR
COMBINATION METER
BRAKE/TAIL
LIGHT
ABS MODULATOR 18P (Black) CONNECTOR (MODULATOR SIDE)
REAR ABS
OFF
INDICATOR
Bl
Bu
G
Gr
R
W
Y
: Black
: Blue
: Green
: Gray
: Red
: White
: Yellow
PUMP MOTOR
TURN
SIGNAL
RELAY
ECM
ABS M
30 A
26-184
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ABS DTC INDEX
• The ABS indicator might blink in the following cases. Correct the
problem.
– Incorrect tire pressure.
– Tires not recommended for the motorcycle were installed (incorrect
tire size).
– Deformation of the wheel or tire.
• The ABS indicator might blink while riding under the following conditions.
This is a temporary failure. Be sure to erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph) and check the DTC
(page 20-6). Ask the rider for the riding conditions in detail when the
motorcycle is brought in for inspection.
– The motorcycle has a continuous run on bumpy roads.
– The front wheel leaves the ground for a long time when riding
(wheelie).
– Only either the front or rear wheel rotates.
– The ABS operates continuously.
– The ABS control unit has been disrupted by an extremely powerful
radio wave (electromagnetic interference).
DTC Function failure
Detection
Symptom/Fail-safe function
Refer
to
AB
–
ABS indicator malfunction
• ABS modulator voltage input line
• Indicator related wires
• Combination meter
• ABS modulator
• Sub fuse ABS_MAIN 10 A
• ABS indicator never comes
ON at all
20-10
• ABS indicator stays ON at
all
20-10
1-1
Front wheel speed sensor circuit malfunction
• Wheel speed sensor or related wires
• Stops ABS operation
26-186
1-2
Front wheel speed sensor malfunction
• Wheel speed sensor, pulser ring or related
wires
• Electromagnetic interference
• Stops ABS operation
26-186
1-3
Rear wheel speed sensor circuit malfunction
• Wheel speed sensor or related wires
• Stops ABS operation
26-188
1-4
Rear wheel speed sensor malfunction
• Wheel speed sensor, pulser ring or related
wires
• Electromagnetic interference
• Stops ABS operation
26-188
2-1
Front pulser ring
• Pulser ring or related wires
• Stops ABS operation
26-186
2-3
Rear pulser ring
• Pulser ring or related wires
• Stops ABS operation
26-188
3-1 Solenoid valve malfunction (ABS modulator) • Stops ABS operation
26-189
3-2
3-3
3-4
4-1
Front wheel lock
• Riding condition
• Stops ABS operation
26-186
4-2
Front wheel lock (Wheelie)
• Riding condition
4-3
Rear wheel lock
• Riding condition
• Stops ABS operation
26-188
5-1
Pump motor lock
• Pump motor (ABS modulator) or related wires
• Fuse ABS M 30 A
• Stops ABS operation
26-190
5-2
Motor stuck off
• Pump motor (ABS modulator) or related wires
• Sub fuse ABS M 30 A
• Stops ABS operation
26-190
5-3
Motor stuck on
• Pump motor (ABS modulator) or related wires
• Stops ABS operation
26-190
26-185
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
(A) Pre-start self-diagnosis (page 20-5)
(B) Ordinary self-diagnosis: diagnoses while the motorcycle is running (after
pre-start self-diagnosis)
5-4
Power supply relay malfunction
• Power supply relay (ABS modulator) or related
wires
• Fuse ABS M 30 A
• Stops ABS operation
26-191
6-1
Power circuit under voltage
• Input voltage (too low)
• Sub fuse ABS_MAIN 10 A
• Stops ABS operation
26-192
6-2
Power circuit over voltage
• Input voltage (too high)
• Stops ABS operation
7-1
Tire malfunction
• Tire size
• Stops ABS operation
26-193
8-1
ABS control unit malfunction
• ABS modulator
• Stops ABS operation
26-193
8-2
Rear ABS off indicator
• Rear ABS off indicator or related wire
• Rear ABS off mode function
does not work
26-193
DTC Function failure
Detection
Symptom/Fail-safe function
Refer
to
AB
26-186
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ABS DTC TROUBLESHOOTING
• Perform inspection with the ignition switch OFF,
unless otherwise specified.
• All connector diagrams in the troubleshooting are
viewed from the terminal side.
• When the ABS modulator assembly is detected to be
faulty, recheck the wire harness and connector
connections closely before replacing it.
• After diagnostic troubleshooting, erase the DTC
(page 20-6).
Then test-ride the motorcycle to check that the ABS
indicator operates normally during pre-start self-
diagnosis (page 20-5).
DTC 1-1/1-2/2-1/4-1/4-2 (Front Wheel
Speed Sensor Circuit/Front Wheel
Speed Sensor/Front Pulser Ring/Front
Wheel Lock)
• The ABS indicator might blink under unusual riding
conditions (page 26-184). This is temporary failure.
Erase the DTC (page 20-6).
Then test-ride the motorcycle above 10 km/h (6
mph) to check that the ABS indicator operates
normally (page 20-5).
• If DTC 4-1 is indicated, check the front brake for
drag.
1. Front Wheel Speed Sensor Clearance Gap
Inspection
Check the clearance gap between sensor bracket
and pulser ring (page 20-21).
Is the clearance gap correct?
YES – GO TO STEP 2.
NO – Check the related parts for deformation
and looseness, or damage and repair if
necessary. Recheck the clearance gap.
2. Front Wheel Speed Sensor Condition Inspection
Inspect the area around the front wheel speed
sensor:
Check for iron or other magnetic deposits between
the pulser ring and wheel speed sensor and check
the pulser ring slots for obstructions.
Check the installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.
Are the sensor and pulser ring in good
condition?
YES – GO TO STEP 3.
NO – Remove any deposits. Install properly or
replace faulty part.
26-187
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Front Wheel Speed Sensor Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the front wheel speed sensor 2P (Black)
connector (page 20-20).
Check for continuity between each terminal of the
sensor side 2P (Black) connector [1] and ground.
Is there continuity?
YES – Faulty front wheel speed sensor
NO – GO TO STEP 4.
4. Front Wheel Speed Sensor Line Short Circuit
Inspection
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Check for continuity between each terminal of the
wire harness side 2P (Black) connector [1] and
ground.
Is there continuity?
YES – • Short circuit in the Blue wire
• Short circuit in the White wire
NO – GO TO STEP 5.
5. Front Wheel Speed Sensor Line Open Circuit
Inspection
Short the wire harness side 18P (Black) connector
[1] terminals with a jumper wire [2].
Check for continuity between the wire harness side
2P (Black) connector [3] terminals.
Is there continuity?
YES – GO TO STEP 6.
NO – Open circuit in the Blue or White wire
6. Failure Reproduction with a Known Good Front
Wheel Speed Sensor
Replace the front wheel speed sensor with a known
good one (page 20-20).
Connect the 18P (Black) and front wheel speed
sensor 2P (Blue) connectors.
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 1-1, 1-2, 2-1, 4-1 or 4-2 indicated?
YES – Faulty ABS modulator
NO – Faulty original front wheel speed sensor
CONNECTION: White – Ground
Blue – Ground
[1]
WBu
CONNECTION: Blue – Ground
White – Ground
Bu W
[1]
CONNECTION: 8 – 17
CONNECTION: Blue – White
[3]
[2]
[1]
8
17
Bu W
26-188
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 1-3/1-4/2-3/4-3 (Rear Wheel Speed
Sensor Circuit/Rear Wheel Speed
Sensor/Rear Pulser Ring/Rear Wheel
Lock)
• The ABS indicator might blink under unusual riding
conditions (page 26-184). This is temporary failure.
Erase the DTC (page 20-6).
Then test-ride the motorcycle above 10 km/h (6
mph) to check that the ABS indicator operates
normally (page 20-6).
• If DTC 4-3 is indicated, check the rear brake for
drag.
1. Rear Wheel Speed Sensor Clearance Gap
Inspection
Check the clearance gap between sensor bracket
and pulser ring (page 20-23).
Is the clearance gap correct?
YES – GO TO STEP 2.
NO – Check the related parts for deformation
and looseness, or damage and repair if
necessary. Recheck the clearance gap.
2. Rear Wheel Speed Sensor Condition Inspection
Inspect the area around the rear wheel speed
sensor:
Check for iron or other magnetic deposits between
the pulser ring and wheel speed sensor and check
the pulser ring slots for obstructions.
Check the installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.
Are the sensor and pulser ring in good
condition?
YES – GO TO STEP 3.
NO – Remove any deposits. Install properly or
replace faulty part.
3. Rear Wheel Speed Sensor Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the rear wheel speed sensor 2P (Black)
connector (page 20-23).
Check for continuity between each terminal of the
sensor side 2P (Black) connector [1] and ground.
Is there continuity?
YES – Faulty rear wheel speed sensor
NO – GO TO STEP 4.
CONNECTION: Blue – Ground
White – Ground
WBu
[1]
26-189
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
4. Rear Wheel Speed Sensor Line Short Circuit
Inspection
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Check for continuity between each terminal of the
wire harness side 2P (Black) connector [1] and
ground.
Is there continuity?
YES – • Short circuit in the White wire
• Short circuit in the Blue wire
NO – GO TO STEP 5.
5. Rear Wheel Speed Sensor Line Open Circuit
Inspection
Short the wire harness side 18P (Black) connector
[1] terminals with a jumper wire [2].
Check for continuity between the wire harness side
2P (Black) connector [3] terminals.
Is there continuity?
YES – GO TO STEP 6.
NO – Open circuit in the White or Blue wire
6. Failure Reproduction with a Known Good Rear
Wheel Speed Sensor
Replace the rear wheel speed sensor with a known
good one (page 20-23).
Connect the 18P (Black) connector.
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 1-3, 1-4, 2-3, or 4-3 indicated?
YES – Faulty ABS modulator
NO – Faulty original rear wheel speed sensor
DTC 3-1/3-2/3-3/3-4 (Solenoid Valve)
1. Failure Reproduction
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 3-1, 3-2, 3-3 or 3-4 indicated?
YES – Faulty ABS modulator
NO – Solenoid valve is normal (intermittent
failure).
CONNECTION: White – Ground
Blue – Ground
WBu
[1]
CONNECTION: 6 – 15
CONNECTION: White – Blue
[3]
[2] [1]
6
15
WBu
26-190
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 5-1/5-2/5-3 (Pump Motor)
1. Fuse Inspection
Turn the ignition switch OFF.
Remove the starter relay switch cover (page 6-5)
and check for a blown sub fuse ABS M. 30 A [1].
Is the fuse blown?
YES – GO TO STEP 2.
NO – GO TO STEP 3.
2. Motor Power Input Line Short Circuit Inspection
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
With the sub fuse ABS M. 30 A removed, check for
continuity between the wire harness side 18P
(Black) connector [1] terminal and ground.
Is there continuity?
YES – Short circuit in the Red/yellow wire
between the starter relay switch and 18P
(Black) connector
NO – Intermittent failure. Replace the sub fuse
ABS M. 30 A with a new one and recheck.
3. Motor Power Related Line Open Circuit
Inspection
Install the sub fuse ABS M. 30 A.
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Measure the voltage between the wire harness side
18P (Black) connector [1] terminals.
Is there battery voltage?
YES – GO TO STEP 4.
NO – • Open circuit in the Black or Red/yellow
wire between the 18P (Black)
connector and battery
• Open circuit in the Green wire between
the 18P (Black) connector and ground
terminal
4. Failure Reproduction
Turn the ignition switch OFF.
Connect the 18P (Black) connector.
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 5-1, 5-2, or 5-3 indicated?
YES – Faulty ABS modulator
NO – Pump motor is normal (intermittent failure)
[1]
CONNECTION: 9 – Ground
[1]
9
CONNECTION: 9 (+) – 1 (–)
[1]
91
26-191
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 5-4 (Fail-safe Relay)
1. Fuse Inspection
Turn the ignition switch OFF.
Remove the battery box cover (page 6-5).
Remove the fuse case cover and check for a blown
sub fuse ABS FSR 30 A [1].
Is the fuse blown?
YES – GO TO STEP 2.
NO – GO TO STEP 3.
2. Solenoid Power Input Line Short Circuit
Inspection
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
With the sub fuse ABS FSR 30 A removed, check
for continuity between the wire harness side 18P
(Black) connector [1] terminal and ground.
Is there continuity?
YES – Short circuit in the Red/green or Red/
yellow wire between the 18P (Black)
connector and sub fuse ABS FSR 30 A
terminal
NO – Intermittent failure. Replace the sub fuse
ABS FSR 30 A with a new one and
recheck.
[1]
[1]
CRF1000A/A2/AL/AL2: CRF1000D/D2/DL/DL2:
CONNECTION: 18 – Ground
[1]
18
26-192
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Solenoid Power Input Line Open Circuit
Inspection
Install the sub fuse ABS FSR 30 A.
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Measure the voltage between the wire harness side
18P (Black) connector [1] terminal and ground.
Is there battery voltage?
YES – GO TO STEP 4.
NO – Open circuit in the Red/green, Red/yellow
or White wire between the 18P (Black)
connector and battery
4. Failure Reproduction
Turn the ignition switch OFF.
Connect the ABS modulator 18P (Black) connector.
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 5-4 indicated?
YES – Faulty ABS modulator
NO – Solenoid valve is normal (intermittent
failure).
DTC 6-1/6-2 (Power Circuit)
1. Battery Voltage Inspection
Inspect the battery voltage (page 26-200).
Is the battery voltage normal?
YES – GO TO STEP 2.
NO – Replace the battery (page 26-199).
2. Charging Voltage Inspection
Inspect the battery charging voltage (page 26-201).
Is the voltage above 15.5 V?
YES – Faulty regulator/rectifier
NO – GO TO STEP 3.
3. Failure Reproduction
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 6-1 or 6-2 indicated?
YES – Faulty ABS modulator
NO – Power circuit is normal (intermittent failure)
CONNECTION: 18 (+) – Ground (–)
[1]
18
26-193
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
DTC 7-1 (Tire Size)
• Check the following and correct the faulty part.
– Incorrect tire pressure
– Tires not recommended for the motorcycle were
installed (incorrect tire size)
– Deformation of the wheel or tire
1. Failure Reproduction
If the above items are normal, recheck the DTC as
follows:
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 7-1 indicated?
YES – Faulty ABS modulator
NO – Tire size is normal (intermittent failure)
DTC 8-1 (ABS Control Unit)
1. Failure Reproduction
Erase the DTC (page 20-6).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-6).
Is the DTC 8-1 indicated?
YES – Faulty ABS modulator
NO – ABS control unit (ABS modulator) is
normal (intermittent failure)
DTC 8-2 (Rear ABS Off Indicator)
1. Rear ABS Off Indicator Inspection 1
Turn the ignition switch OFF.
Disconnect the ABS modulator 18P (Black)
connector (page 20-7).
Turn the ignition switch ON and check the rear ABS
off indicator.
Is the rear ABS off indicator indicated?
YES – GO TO STEP 2.
NO – GO TO STEP 3.
2. Rear ABS Off Indicator Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the combination meter 32P (Gray)
connector (page 22-12).
Check tor continuity between the wire harness side
18P (Black) [1] connector and ground
Is there continuity?
YES – Short circuit in the White/green wire
NO – Replace the combination meter with a new
one and recheck (page 22-12).
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION: 2 – Ground
2
[1]
26-194
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
3. Rear ABS Off Indicator Inspection 2
Ground the wire harness side 18P (Black) connector
[1] with a jumper wire [2].
Check the rear ABS off indicator.
Is the rear ABS off indicator off mode indicated?
YES – GO TO STEP 5.
NO – GO TO STEP 4.
4. Rear ABS Off Indicator Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the combination meter 32P (Gray)
connector (page 22-12).
Check tor continuity between the wire harness side
18P (Black) [1] and 32P (Gray) [2] connectors.
Is there continuity?
YES – Replace the combination meter with a new
one and recheck (page 22-12).
NO – Open circuit in the White/green wire
5. Failure Reproduction
Erase the DTC (page 20-6).
Recheck the DTC (page 20-6).
Is the DTC 8-2 indicated?
YES – Faulty ABS modulator
NO – ABS control unit is normal (intermittent
failure)
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION: 2 – Ground
2
[1]
[2]
TOOL:
Test probe 07ZAJ-RDJA110
CONNECTION: 2 – White/Green
[2]
[1]
W/G
2
26-195
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ABS MODULATOR
Spilled fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
• When removing the oil bolt, cover the end of the
brake hose to prevent contamination.
• Be careful not to bend or damage the brake pipes
during assembly or removal.
REMOVAL/INSTALLATION
Remove the following:
– Fuel tank (page 26-128)
– ETC tray (page 26-49)
Release the following:
– Fuel pump relay [1]
– Headlight relay [2]
– Engine stop/FI relay [3]
Disconnect the rear wheel speed sensor 2P (Black)
connector [4].
[1]
[2]/[3]
[4]
[2]
26-196
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Disconnect the ABS modulator 18P (Black) connector
[1].
Remove the following:
– Oil bolts [2]
– Sealing washers [3]
– Rear brake hose A [4]
– Rear brake hose B [5]
– Brake pipe joint A [6]
– Brake pipe joint B [7]
Remove the bolts [8] and washers [9].
Remove the ABS modulator assembly [10] by releasing
its grommet from the rear fender boss [11].
Remove the following from the modulator tray [1]:
– Bolts [2]
– ABS modulator [3]
– Grommets [4]
Installation is in the reverse order of removal.
• Apply brake fluid to the joint nut threads.
• Replace the sealing washers with new ones.
[11]
[1]
[5]
[4]
[10]
[3]
[7]
[6]
[3]
[2]
[8]/[9]
[8]/[9]
TORQUE:
Brake hose oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)
Brake pipe joint:
14 N·m (1.4 kgf·m, 10 lbf·ft)
[3]
[4]
[4]
[1]
[4]
[2]
26-197
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
BATTERY/CHARGING SYSTEM SERVICE INFORMATION
GENERAL
• Do not jump-start the motorcycle. It may blow out the built-in fuse in the lithium ion battery.
• Always turn OFF the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 26-198).
• For alternator/stator servicing (page 11-2).
• The following color codes are used throughout this section.
• For extended storage, remove the battery and store it in a cool space.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for a long period. These same conditions
contribute to shortening the “life span” of the battery.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery at a suitable time to prevent
it from discharging.
BATTERY CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• These models are equipped with the Lithium Ion (Li-Ion) battery. To charge the battery, use only the specified battery charger
(C-1401B manufactured by ELIIY Power Co., Ltd.). Follow the manufacturer’s instructions.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instruction in the Operation Manual for the recommended battery tester for details about battery testing.
The recommended battery tester puts a “load” on the battery so that the actual battery condition can be measured.
• If electrolyte gets on your skin or clothes, flush with clean water such as tap water etc. immediately.
• If electrolyte gets on your eyes, flush with large quantities of water immediately and consult an eye doctor.
Be = Beige Bl = Black Br = Brown Bu = Blue G = Green Gr = Gray
Lb = Light blue Lg = Light green O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow
Battery charger: C-1401B manufactured by ELIIY Power Co., Ltd.
26-198
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
BATTERY/CHARGING SYSTEM TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery (page 26-199).
Check the battery condition using the recommended battery tester.
Is the battery good condition?
YES – GO TO STEP 2.
NO – Faulty battery
2. CURRENT LEAKAGE TEST
Install the battery (page 26-199).
Check the battery current leakage test (page 26-200).
Is the current leakage below 0.66 mA?
YES – GO TO STEP 4.
NO – GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR
Disconnect the regulator/rectifier 3P (Black) connector and recheck the battery current leakage.
Is the current leakage below 0.66 mA?
YES – Faulty regulator/rectifier
NO – • Shorted wire harness
• Faulty ignition switch
4. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil (page 21-9).
Is the alternator charging coil resistance within 0.1 – 1.0 (20°C/68°F)?
YES – GO TO STEP 5.
NO – Faulty charging coil
5. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter (page 26-200).
Start the engine.
Measure the charging voltage (page 26-201).
Compare the measurement to result of the following calculation.
Is the measured charging voltage within the standard voltage?
YES – Faulty battery
NO – GO TO STEP 6.
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier connector (page 21-8).
Are the results of checked voltage and resistance correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related wire
• Shorted wire harness
• Loose or poor contacts of related terminal
Battery charger:
C-1401B manufactured by ELIIY Power Co., Ltd.
STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage
• CV = Charging Voltage
26-199
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
STARTER MOTOR CANNOT BE TURNED
1. STARTER SYSTEM INSPECTION
Check that the starter motor can be turned.
Can the starter motor be turned?
YES – GO TO STEP 2.
NO – Check the starter system (page 6-2).
2. BATTERY CONDITION INSPECTION
Check the battery for cracked or deformed case, electrolyte leakage, nasty smell or heat generation.
Is the battery in above conditions?
YES – Follow the emergency manual.
NO – GO TO STEP 3.
3. BATTERY VOLTAGE INSPECTION
Leave the battery for 30 minutes and check the battery voltage.
Is the voltage below 6 V or above 14.6?
YES – Replace the battery (page 26-199).
NO – GO TO STEP 4.
4. CHARGING CONDITION INSPECTION
Charge the battery using the specified battery charger (C-1401B manufactured by ELIIY Power Co., Ltd.).
Is the battery charged?
YES – Battery is normal.
NO – Replace the battery (page 26-199).
BATTERY
REMOVAL/INSTALLATION
Remove the socket bolts [1] and tool box [5].
Always turn the
ignition switch OFF
before removing the
battery.
Remove the bolt [1] and disconnect the negative (-)
terminal [2] first.
Then remove the bolt [3] and disconnect the positive (+)
terminal [4].
Remove the trim clip [5].
Open the battery holder [6].
Remove the battery [7].
Install the battery in the reverse order of removal.
• Connect the positive (+) terminal first and then the
negative (-) terminal.
• For digital clock setting procedure (page 22-15).
[2]
[1]
[5]
[6]
[3]/[4]
[1]/[2]
[7]
26-200
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
VOLTAGE INSPECTION
Remove the tool box (page 26-199).
Measure the battery voltage using a commercially
available digital multimeter.
BATTERY TESTING
Remove the battery (page 26-199).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE TEST
Turn the ignition switch OFF.
Disconnect the negative (–) terminal (page 26-199).
Connect the ammeter (+) probe [1] to the negative (–)
cable [2] and the ammeter (–) probe [3] to the battery (–
) terminal [4].
With the ignition switch OFF, check for current leakage.
• When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blow the fuse in the tester.
• While measuring current, do not turn the ignition
switch ON. A sudden surge of current may blow the
fuse in the tester.
If current leakage exceeds the specified value, a
shorted circuit is the probable cause.
Locate the short by disconnecting connections one by
one and measuring the current.
VOLTAGE (20°C/68°F):
Fully charged: 13.5 – 14.0 V
Needs charging: Below 10.8 V
TOOL:
Battery charger C-1401B
manufactured by
ELIIY Power Co.,
Ltd.
SPECIFIED CURRENT LEAKAGE:
0.66 mA maximum
[4]
[2]
[3]
[1]
26-201
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CHARGING VOLTAGE INSPECTION
• Make sure the battery is in good condition before
performing this test.
Start the engine and warm it up to the operating
temperature; then stop the engine.
Remove the tool box (page 26-199).
Connect the multimeter between the positive terminal
[1] and negative terminal [2] of the battery.
• To prevent a short, make absolutely certain which
are the positive and negative terminals or cable.
• Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.
With the headlight on high beam, restart the engine.
Measure the voltage on the multimeter when the engine
runs at 5,000 min
-1
(rpm).
If the charging voltage reading is out of the
specification, inspect the regulator/rectifier (page 21-8).
TURN SIGNAL LIGHT/RELAY
AUTO TURN SIGNAL CANCEL
SYSTEM INSPECTION
Check the following:
– No ABS DTC indicated (page 20-6)
– Turn signal light (page 22-9)
– Left handlebar switch (page 22-23)
– Set switch line open circuit (page 26-201)
– ABS modulator output line open circuit (page 26-
202)
If any parts are OK, replace the turn signal light relay
with a known good one and recheck (page 22-9).
SET SWITCH LINE OPEN CIRCUIT
Disconnect the following:
– Turn signal light relay 18P connector (page 22-9)
– Left handlebar switch 10P connector (page 22-23)
Check for continuity between the turn signal light relay
18P connector [1] and Left handlebar switch 10P
connector [2] terminals.
There should be continuity.
If there is no continuity, check for open circuit in Light
green/white wire.
STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 26-200)
• CV = Charging Voltage
[1]
[2]
CONNECTION:
Light green/white – Light green/white
[2]
[1]
Lg/W
Lg/W
26-202
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ABS MODULATOR OUTPUT LINE OPEN CIRCUIT
Disconnect the following:
– Turn signal light relay 18P connector (page 22-9)
– ABS modulator 18P connector (page 20-7)
Check for continuity between the turn signal light relay
18P connector [1] and ABS modulator 18P connector
[2] terminals.
There should be continuity.
If there is no continuity, check for open circuit in Blue/
black or Blue/yellow wire.
ESS SYSTEM INSPECTION
(Except KO model)
• While the hazard system is operating, the ESS
system will not operate.
Check the following:
– No ABS DTC indicated (page 20-6)
– Turn signal light (page 22-9)
– Turn signal light relay (page 22-9)
– Brake light switch (page 22-24)
– Brake light switch line open circuit (page 26-203)
– Brake light switch line short circuit (page 26-203)
– ESS line open circuit (page 26-203)
– ESS line short circuit (page 26-203)
– Hazard flasher system (page 22-9)
• Even if any turn signal lights are abnormal, other
normal turn signal lights will work with the ESS
system.
• If the ESS system operates at all times, replace the
ABS modulator with a new one (page 26-195).
To forcibly activate the ESS system, perform the
procedure as follows:
1. Connect the SCS short connector to the DLC (page
25-25).
2. Turn the ignition switch ON.
3. Apply the front or rear brake and check the turn
signal lights operation.
The turn signal lights should be blinking with the
brake applied and turning OFF with the brake
released.
CONNECTION:
Blue/black – Blue/black
Blue/yellow – Blue/yellow
Bu/Bl
Bu/Y
[1][2]
Bu/Bl
Bu/Y
26-203
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
BRAKE LIGHT SWITCH LINE OPEN CIRCUIT
INSPECTION
Disconnect the following:
– Right handlebar switch 8P connector (page 22-23)
– Rear brake light switch 2P (Gray) connector (page
22-24)
– ABS modulator 18P connector (page 20-7)
Check for continuity between the right handlebar switch
8P [1], rear brake light switch 2P (Gray) [2] and ABS
modulator 18P [3] connector terminals at the harness
side.
There should be continuity.
If there is no continuity, check for open circuit in Green/
yellow or Blue/black wire.
BRAKE SWITCH LINE SHORT CIRCUIT
INSPECTION
Disconnect the ABS modulator 18P connector (page
20-7).
Check for continuity between the ABS modulator 18P
connector [1] terminal and ground.
There should be no continuity.
If there is continuity, check for short circuit in Green/
yellow wire.
ESS LINE OPEN CIRCUIT INSPECTION
Disconnect the following:
– Turn signal light relay 18P connector (page 22-9)
– ABS modulator 18P connector (page 22-9)
Check for continuity between the turn signal relay 18P
connector [1] and ABS modulator 18P connector [2]
terminals at the harness side.
There should be continuity.
If there is no continuity, check for open circuit in Black/
green wire.
CONNECTION:
Green/yellow – Green/yellow
Green/yellow – Green/yellow
[1]
G/Y
G/Y
[3]
[3]
G/Y
G/Y
[2]
CONNECTION: Green/yellow – Ground
[1]
G/Y
CONNECTION: Black/green – Black/green
[1]
Bl/G
Bl/G
[2]
26-204
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ESS LINE SHORT CIRCUIT INSPECTION
Disconnect the turn signal light relay 18P connector
(page 22-9).
Check for continuity between the turn signal relay 18P
connector [1] terminal and ground.
There should be no continuity.
If there is continuity, check for short circuit in Black/
green wire.
COMBINATION METER
POWER/GROUND LINE INSPECTION
Remove the front cover (page 26-44).
Remove the connector cover and disconnect the
combination meter 32P (Gray) connector (page 22-12).
Check the following at the wire harness side connector
terminals of the combination meter.
• If the power and ground lines are OK, replace the
combination meter (page 22-12).
POWER INPUT LINE
Measure the voltage at the wire harness side 32P
(Gray) connector [1] and ground.
There should be battery voltage with the ignition switch
turned ON.
If there is no voltage, check the following:
– Open circuit in the Black/red wire
– Blown sub fuse ILLUMI STOP 10 A
BACK-UP VOLTAGE LINE
Measure the voltage at the wire harness side 32P
(Gray) connector [1] and ground.
There should be battery voltage at all times.
If there is no voltage, check the following:
– Open circuit in the Red/white wire
– Blown sub fuse CLOCK TURN 10 A
CONNECTION: Black/green – Ground
[1]
Bl/G
CONNECTION: Black/red (+) – Ground (–)
STANDARD: Battery voltage
Bl/R
[1]
CONNECTION: Red/white (+) – Ground (–)
STANDARD: Battery voltage
[1]
R/W
26-205
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
GROUND LINE
Check for continuity at the wire harness side 32P (Gray)
connector [1] and ground.
There should be continuity.
If there is no continuity, check for open circuit in the
Green wire.
GEAR POSITION SENSOR
(CRF1000A/A2/AL/AL2)
REMOVAL/INSTALLATION
Remove the left rear cover (page 2-10).
Support the motorcycle using a safety stand or hoist,
raise the rear wheel off the ground.
Remove the rear shock absorber (page 18-8).
Release the gear position sensor 3P (Black) connector
[1] from the connector clip stay and disconnect it.
Remove the following:
– Bolt [1]
– Sensor cover [2]
– Gear position sensor [3]
– O-ring [4]
Installation is in the reverse order of removal.
• Always replace the O-ring with a new one.
• Apply engine oil to a new O-ring.
• Align the flat surfaces of the gear position sensor
and shift drum end.
• Route the wires properly (page 26-17).
CONNECTION: Green – Ground
[1]
G
[1]
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[1]
[2]
[3]
[4]
Align
[4]
26-206
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
NEUTRAL SWITCH
(CRF1000A/AL/A2/AL2)
REMOVAL/INSTALLATION
Release the rubber cap [1].
Remove the nut [2] and disconnect the neutral switch
terminal [3].
Remove the neutral switch [4] and sealing washer [5].
Installation is in the reverse order of removal.
• Apply engine oil to the neutral switch threads and
seating surface.
• Replace the sealing washer with a new one.
INSPECTION
Remove the neutral switch terminal nut and neutral
switch wire terminal (page 26-206).
Shift the transmission into neutral.
Check for continuity between the neutral switch terminal
and ground.
There should be continuity with the transmission in
neutral, and no continuity when the transmission is in
gear.
SHIFT SPINDLE SWITCH
(CRF1000A/AL/A2/AL2)
REMOVAL/INSTALLATION
Release the rubber cap [1].
Remove the nut [2] and disconnect the shift spindle
switch terminal [3].
Remove the shift spindle switch [4] and sealing washer
[5].
Installation is in the reverse order of removal.
• Apply engine oil to the shift spindle switch threads
and seating surface.
• Replace the sealing washer with a new one.
TORQUE:
Neutral switch:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Neutral switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
[2]
[1]
[3]
[5]
[4]
TORQUE:
Shift spindle switch:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Shift spindle switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
[2]
[1]
[5]
[4]
[3]
26-207
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
GRIP HEATER
(CRF1000A2/AL2/D2/DL2)
REMOVAL/INSTALLATION
GRIP HEATER CONTROLLER
Remove the left side cover (page 2-10).
Disconnect the grip heater controller 10P (Black)
connector [1].
Remove the grip heater controller [2].
Installation is in the reverse order of removal.
LEFT GRIP HEATER
Remove the following:
– Left middle cowl (page 26-42)
– Knuckle guard (page 2-5)
Release the wire band [1] and wire clip [2].
Release the wire band [1] and wire clips [2].
[2] [1]
[1]
[2]
[1]
[2]
[2]
26-208
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Disconnect the following:
– Left grip heater 2P (Black) connector [1]
– Left grip heater 4P (Black) connector [2]
Remove the left grip heater [1] from the handlebar.
[1][2]
[1]
26-209
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Installation is in the reverse order of removal.
• When replacing the left grip heater, install the left
grip heater to the following procedure:
Clean the outside surface of the left handlebar [1].
Apply Honda Bond A or equivalent adhesive to the
outside surface of the left handlebar as specified. Spray
isopropyl alcohol over the inside of the left grip heater
[2] and outside of the left handlebar.
Install the grip heater as indicated.
• Do not tap the grip end with a hammer and do not
twist the grip with force to insert the left grip heater
onto the handlebar, as it can damage the element.
• Avoid putting pressure on the switch part when
inserting the left grip heater. There is a possibility
that the switch part will break. Also, install so that
there is no gap with the left handlebar switch.
• If the grip gets stuck halfway during installation,
apply isopropyl alcohol to the gap between the grip
heater and handlebar. Do not try to remove the left
grip heater using force or tools as the grip heater
element can be damaged.
Install the heater with the lower edge of the heater
switch [3] is 4 mm (0.2 in) above the lower edge of the
dimmer switch [4].
• Push the left grip heater in tight against the left
handlebar switch.
• Allow the adhesive to dry for at least 1 hour before
touching or checking the heater operation.
• When checking the heater operation, do not set the
heater level higher than level 2.
• Make sure to turn off the heater switch after the
operation check.
• Do not set the heater level higher than level 2 for the
first week after installation.
[1]
100 mm (3.9 in)
Spray isopropyl alcohol.
4 mm
(0.2 in)
[2] [3] [4]
26-210
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
RIGHT GRIP HEATER
Remove the right handlebar switch/grip APS (page 26-
116).
Disconnect the right grip heater 2P (Black) connector
[2].
Release the harness clips [1] from the stays.
Remove the clamps [1].
Installation is in the reverse order of removal.
• When replacing the right grip heater, install the wire
band to the following procedure:
1. Remove the wire band [1].
[1]
[1]
[1]
[1]
[1]
26-211
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
2. Mark [2] the right handlebar switch/APS wire A [3]
and right handlebar switch/APS wire B [4] as shown.
3. Install a new wire band [5] by aligning the yellow
tape [6] of the right grip heater wire and the marking
of the right handlebar switch/APS wire.
FAILURE SYMPTOM CHECK
When any abnormality occurs, the heater level
indication [1] of the combination meter blinks "E1", "E2"
or "E3" and the heater switch indicator [2] on the left
grip heater blinks according to the meter indication (1
blink, 2 blinks, or 3 blinks) at the same time.
– E1: Low battery voltage
– Inspect the battery voltage (page 26-200)
– E2: Short circuit in the grip heater or related circuit
– Inspect the grip heater resistance (page 26-212)
– Inspect the grip heater power input line short
circuit (page 26-214)
– Inspect the grip heater controller power input line
short circuit (page 26-213)
– E3: Faulty grip heater switch or other failures
– Inspect the grip heater resistance (page 26-212)
– Inspect the grip heater switch (page 26-213)
– Inspect the grip heater controller power input line
short circuit (page 26-213)
– Inspect the grip heater circuit (page 26-214)
WIRE A: 200 ± 10 mm (7.9 ± 0.4 in)
WIRE B: 210 mm (8.3 in)
[3]
CRF1000D2/DL2:
[4]
Gray tape
CRF1000A2/AL2:
[3]
WIRE A: 200 ± 10 mm (7.9 ± 0.4 in)
WIRE B: 210 mm (8.3 in)
[2]
[2]
[4]
[6]
[5]
[2]
[1]
[2]
26-212
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
If the grip heaters do not work at all, check the following:
• Blown OP fuse (10 A)
• Inspect the grip heater controller power/ground line
(page 26-213)
• Inspect the grip heater switch (page 26-213)
• Inspect the grip heater switch power input line open
circuit (page 26-215)
• Inspect the grip heater switch ground line open
circuit (page 26-215)
Indicator on the left grip heater does not function, check
the following:
• Inspect the grip heater switch indicator line open
circuit (page 26-216)
• Inspect the grip heater switch indicator line short
circuit (page 26-216)
• Inspect the grip heater switch ground line open
circuit (page 26-215)
• Faulty left grip heater (page 26-207)
• Faulty grip heater controller (page 26-207)
Indicator on the combination meter does not function,
check the following:
• Inspect the combination meter indicator line open
circuit (page 26-216)
• Inspect the combination meter indicator line short
circuit (page 26-217)
• Inspect the combination meter power/ground line
(page 26-204)
• Faulty combination meter (page 26-204)
• Faulty grip heater controller (page 26-207)
INSPECTION
Grip Heater Resistance Inspection
Turn the ignition switch OFF.
Disconnect the following:
– Left grip heater 2P (Black) connector (page 26-207)
– Right grip heater 2P (Black) connector (page 26-
210)
Disconnect the left grip heater 2P (Black) connector [1]
and right grip heater 2P (Black) connector [2].
Measure the resistance between the grip heater
connector terminals at the grip heater side.
If the resistance is out of specification, replace the grip
heater.
CONNECTION:
Left: Black – Black
Right: Black – Black
STANDARD: 7.4 - 9.0
[1]/[2]
BlBl
26-213
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Grip Heater Switch Inspection
Turn the ignition switch OFF.
Disconnect the left grip heater 4P (Black) connector
(page 26-207).
Check for continuity between the left grip heater 4P
(Black) connector [1] terminals at the grip heater side.
There should be continuity only when the grip heater
switch is pushed.
There should be continuity.
If there is no continuity, the grip heater switch is faulty.
GRIP HEATER CONTROLLER POWER/
GROUND LINE INSPECTION
Grip Heater Controller Input Voltage Inspection
Turn the ignition switch OFF.
Disconnect the grip heater controller 10P (Black)
connector (page 26-207).
Turn the ignition switch ON.
Measure the voltage between the grip heater controller
10P (Black) connector [1] terminals at wire side.
There should be battery voltage.
If there is no voltage, check for open circuit in Red/
yellow and green wire.
Grip Heater Controller Power Input Line Short
Circuit Inspection
Turn the ignition switch OFF.
Disconnect the grip heater controller 10P (Black)
connector (page 26-207).
Check for continuity between the grip heater controller
10P (Black) connector [1] terminal at the wire side and
ground.
There should be no continuity.
If there is continuity, check for short circuit in Red/
yellow wire.
CONNECTION: Gray – Green
Gr
G
[1]
CONNECTION: Red/yellow (+) – green (–)
[1]
R/Y
G
CONNECTION: Red/yellow – ground
[1]
R/Y
26-214
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
GRIP HEATER CIRCUIT INSPECTION
Grip Heater Power Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the following:
– Grip heater controller 10P (Black) connector [1]
(page 26-207)
– Left grip heater 2P (Black) connector [2] (page 26-
207)
– Right grip heater 2P (Black) connector [3] (page 26-
210)
Check for continuity between the left/right grip heater
2P (Black) and grip heater controller 10P (Black)
connector terminals at the wire side.
There should be continuity.
If there is no continuity, check for open circuit in Yellow/
blue or Yellow/red wires.
Grip Heater Power Input Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the following:
– Left grip heater 2P (Black) connector (page 26-207)
– Right grip heater 2P (Black) connector (page 26-
210)
Check for continuity between the left [1]/right [2] grip
heater 2P (Black) connector terminal at the wire side
and ground.
There should be no continuity.
If there is continuity, check for short circuit in Yellow/
blue or Yellow/red wire.
Grip Heater Ground Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the following:
– Left grip heater 2P (Black) connector [1] (page 26-
207)
– Right grip heater 2P (Black) connector [2] (page 26-
210)
Check for continuity between the left [1]/right [2] grip
heater 2P (Black) connector terminal at the wire side
and ground.
There should be continuity.
If there is no continuity, check for open circuit in Green
wire.
CONNECTION:
Left: Yellow/blue – Yellow/blue
Right: Yellow/red – Yellow/red
[1]
Y/Bu
Y/R
Y/R
Y/Bu
[2]
[3]
CONNECTION:
Left: Yellow/blue – ground
Right: Yellow/red – ground
[1] [2]
Y/Bu Y/R
CONNECTION:
Left: Green – ground
Right: Green – ground
[1]
G G
[2]
26-215
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Grip Heater Switch Power Input Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the following:
– Grip heater controller 10P (Black) connector (page
26-207)
– Left grip heater 4P (Black) connector (page 26-207)
Check for continuity between the grip heater controller
10P (Black) [1] and left grip heater 4P (Black) [2]
connector terminals at the wire side.
There should be continuity.
If there is no continuity, check for open circuit in Gray
wire.
Grip Heater Switch Power Input Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the left grip heater 4P (Black) connector
(page 26-207).
Check for continuity between the left grip heater 4P
(Black) connector [1] terminal at the wire side and
ground.
There should be no continuity.
If there is continuity, check for short circuit in Gray wire.
Grip Heater Switch Ground Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the left grip heater 4P (Black) connector
(page 26-207).
Check for continuity between the left grip heater 4P
(Black) connector [1] terminal at the wire side and
ground.
There should be continuity.
If there is no continuity, check for open circuit in Green
wire.
CONNECTION: Gray – Gray
[1]
Gr
[2]
Gr
CONNECTION: Gray – ground
[1]
Gr
CONNECTION: Green – ground
[1]
G
26-216
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
INDICATOR CIRCUIT INSPECTION
Grip Heater Switch Indicator Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the following:
– Grip heater controller 10P (Black) connector (page
26-207)
– Left grip heater 4P (Black) connector (page 26-207)
Check for continuity between the grip heater controller
10P (Black) [1] and left grip heater 4P (Black) [2]
connector terminals at the wire side.
There should be continuity.
If there is no continuity, check for open circuit in Blue
wire.
Grip Heater Switch Indicator Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the left grip heater 4P (Black) connector
(page 26-207).
Check for continuity between the left grip heater 4P
(Black) connector [1] terminal at the wire side and
ground.
There should be no continuity.
If there is continuity, check for short circuit in Blue wire.
Combination Meter Indicator Line Open Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the following:
– Combination meter 32P (Gray) connector (page 22-
12)
– Grip heater controller 10P (Black) connector (page
26-207)
Check for continuity between the combination meter
32P (Gray) [1] and grip heater controller 10P (Black) [2]
connector terminals at the wire side.
There should be continuity.
If there is no continuity, check for open circuit in White
wire.
CONNECTION: Blue – Blue
[1]
[2]
Bu
Bu
CONNECTION: Blue – ground
[1]
Bu
CONNECTION: White – White
[1]
W
W
[2]
26-217
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Combination Meter Indicator Line Short Circuit
Inspection
Turn the ignition switch OFF.
Disconnect the combination meter 32P (Gray)
connector (page 22-12).
Check for continuity between the combination meter
32P (Gray) connector [1] terminal at the wire side and
ground.
There should be no continuity.
If there is continuity, check for short circuit in White
wire.
CONNECTION: White – ground
[1]
W
26-218
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
IMMOBILIZER SYSTEM (HISS) SYSTEM DIAGRAM
CRF1000A/A2/AL/AL2:
Bl: Black
Bu: Blue
G: Green
R: Red
O: Orange
P: Pink
R: Red
W: White
Y: Yellow
Br: Brown
Gr: Gray
IGNITION
SWITCH
IMMOBILIZER
RECEIVER
BATTERY
CLOCK TURN
10 A
MAIN FUSE
30 A
ECM
CKP
SENSOR
HISS INDICATOR
FI FUSE
15 A
R
Bl
FI
RELAY
W/Y
Bl/Gr
Br/Bl
R/W
Bu/OO/Bu
R/Bl
G/O
R/W
G
G
Bl
Y
G
P
Gr/Bl
Y/R
COMBINATION METER
R/Bu
Bl/R
W
RBl
R
26-219
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000D/D2/DL/DL2:
Bl: Black
Bu: Blue
G: Green
R: Red
O: Orange
P: Pink
R: Red
W: White
Y: Yellow
Br: Brown
Gr: Gray
IGNITION
SWITCH
IMMOBILIZER
RECEIVER
BATTERY
CLOCK TURN
10 A
MAIN FUSE
30 A
ECM
CKP
SENSOR
HISS INDICATOR
FI FUSE
15 A
R
Bl
FI
RELAY
W/Y
Bl/Gr
Br/Bl
R/W
Bu/OO/Bu
R/Bl
Gr
R/W
G
G
Bl
Y
G
P
Gr/Bl
Y/R
COMBINATION METER
R/Bu
Bl/R
W
RBl
R
G/O
26-220
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING
The HISS indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned ON
with the properly registered key and the HISS functions normally. If there is any problem or the properly
registered key is not used, the indicator will remains on.
HISS indicator does not come on when the ignition switch is turned ON
1. Combination Meter Initial Operation Inspection
Check the combination meter initial operation (page 22-12).
Is the initial operation displayed?
YES – GO TO STEP 2.
NO – Check the combination meter power and ground lines (page 26-204).
2. PGM-FI DTC Inspection
Check the MIL indicated.
Does the MIL indicated?
YES – Check the PGM-FI DTC (page 25-25).
NO – Check the ECM/PCM power/ground lines (page 26-115).
HISS indicator remains on with the ignition switch turned ON
1. Immobilizer Receiver Jamming Inspection
Check that there is any metal obstruction or the other vehicle‘s transponder key near the immobilizer
receiver and key.
Is there any metal obstruction or the other transponder key?
YES – Remove it and recheck.
NO – GO TO STEP 2.
2. First Transponder Key Inspection
Turn the ignition switch ON with the spare transponder key and check the HISS indicator.
The indicator should came on for 2 seconds then go off.
Is the indicator go off?
YES – Faulty first transponder key
NO – GO TO STEP 3.
3. Diagnostic Code Inspection
Perform the diagnostic code indication procedure (page 23-7).
Check that the HISS indicator comes on then it starts blinking.
Is the indicator brinks or stay lit?
Brinks– Read the diagnostic code (page 23-7).
Stay lit– GO TO STEP 4.
4. PGM-FI DTC Inspection
Check the MIL indicated.
Does the MIL indicated?
YES – Check the PGM-FI DTC (page 25-25).
NO – GO TO STEP 5.
5. CKP sensor Line Open Circuit Inspection
Check the CKP sensor lines (page 26-222).
Is there continuity?
YES – • Open circuit in the Yellow wire
• Open circuit in the White/yellow wire
NO – Faulty ECM/PCM
26-221
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
Diagnostic code is indicated (Code signals cannot send or receive)
1. Immobilizer Receiver Power Input Line Inspection
Check the immobilizer receiver power input line (page 26-222).
Is the input line normal?
YES – GO TO STEP 2.
NO – Open or short circuit in the Yellow/red wire
2. Immobilizer Receiver Ground Line Inspection
Check the immobilizer receiver ground line (page 26-223).
Is the ground line normal?
YES – GO TO STEP 3.
NO – • CRF1000A/A2/AL/AL2: Open circuit in the Gray/black wire
• CRF1000D/D2/DL/DL2: Open circuit in the Gray wire
3. Immobilizer Receiver Signal Line Inspection
Check the immobilizer receiver signal lines (page 26-223).
Are the signal lines normal?
YES – GO TO STEP 4.
NO – Open or short circuit in the Pink or Blue/orange wire
4. Immobilizer Receiver Inspection
Replace the immobilizer receiver with a know good one (page 23-10).
Perform the diagnostic code indication procedure (page 23-7).
Is the Diagnostic code indicated?
YES – Replace the PCM with a known good one and recheck.
NO – Faulty original immobilizer receiver
26-222
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
ECM (CRF1000A/A2/AL/AL2)/
PCM (CRF1000D/D2/DL/DL2) (HISS)
CKP SENSOR LINE INSPECTION
Disconnect the ECM/PCM 33P (Gray) connector (page
4-39).
Disconnect the alternator assembly 6P (Black)
connector (page 11-4).
Disconnect the alternator assembly 6P (Black)
connector (page 11-5).
Check for continuity between the 6P (Black) [1] and 33P
(Gray) [2] connectors.
There should be continuity.
IMMOBILIZER RECEIVER
POWER INPUT LINE INSPECTION
Turn the ignition switch ON and engine stop switch " ".
Measure the voltage between the immobilizer receiver
4P (Black) connector [1] and ground at the wire side.
There should be approx. 5 V.
CRF1000A/A2/AL/
AL2:
CRF1000D/D2/DL/
DL2:
CONNECTION: Yellow – Yellow
White/yellow – White/yellow
TOOL:
Test probe 07ZAJ-RDJA110
[2][1]
Y
W/Y
CRF1000A/A2/AL/AL2:
CRF1000D/D2/DL/DL2:
Y
W/Y
Y
W/Y
Y
W/Y
[2][1]
CONNECTION: Yellow/red (+) – Ground (–)
[1]
Y/R
26-223
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CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
GROUND LINE INSPECTION
Check for continuity between the immobilizer receiver
4P (Black) connector [1] and ground at the wire side.
There should be continuity at all times.
SIGNAL LINE INSPECTION
Turn the ignition switch ON and engine stop switch " ".
Measure the voltage between the immobilizer receiver
4P (Black) connector [1] and ground at the wire side.
There should be approx. 5 V.
Disconnect the ECM/PCM 33P (Gray) connector (page
4-39).
Check for continuity between the immobilizer receiver
4P (Black) [1] and 33P (Gray) [2] connectors at the wire
side.
There should be continuity.
Check for continuity between the PCM 33P (Gray)
connector [1] and ground at the wire side.
There should be no continuity.
CONNECTION:
CRF1000A/A2/AL/AL2:
Gr/Bl (+) – Ground (–)
CRF1000D/D2/DL/DL2:
Gr (+) – Ground (–)
[1]
CRF1000A/A2/AL/AL2: Gr/Bl
CRF1000D/D2/DL/DL2: Gr
CONNECTION: Pink (+) – Ground (–)
P
[1]
CONNECTION: Blue/orange – Blue/orange
TOOL:
Test probe 07ZAJ-RDJA110
Bu/O
Bu/O
[2]
[1]
CONNECTION: Blue/orange – Ground
TOOL:
Test probe 07ZAJ-RDJA110
Bu/O
[1]
MEMO
dummyheaddummyhead
26-225
dummytext
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
WIRING DIAGRAM (CRF1000A/A2/AL/AL2)
33P Bu 33P Bl
FAN
FLR
O2HT1
TBWRLY
IMOAU
PCP
PCS
TPS1
APS1
PB
IMOID
IMOV
ENG STOP
TW
EX-AI
TPS2
TAC HO
RVW
PCM
APS2
TA
A-1
A-2
A-3
A-5
A-6
A-7
A-4
A-8
A-9
A-10
A-12
A-13
A-14
A-11
A-15
A-16
A-17
A-19
A-20
A-21
A-18
A-22
A-23
A-24
A-26
A-27
A-28
A-25
A-30
A-31
A-32
A-33
A-29
C-1
C-2
C-3
C-5
C-6
C-7
C-4
C-8
C-9
C-10
C-12
C-13
C-14
C-11
C-15
C-16
C-17
C-19
C-20
C-21
C-18
C-22
C-23
C-24
C-26
C-27
C-28
C-25
C-30
C-31
C-32
C-33
C-29
D-1
D-2
D-3
D-5
D-6
D-7
D-4
D-8
D-9
D-10
D-12
D-13
D-14
D-11
D-15
D-16
D-17
D-19
D-20
D-21
D-18
D-22
D-23
D-24
D-26
D-27
D-28
D-25
D-30
D-31
D-32
D-33
K-LINE
M-TXD
INJ2
INJ1
CANL
BA
SG1
CANH
SG2
VCC1
VCC2
VSP
SCS
FVW
PG
PG
SG4
VCC3
VCC4
SG3
SSTAND
NEUTRAL
CLUTCH
SPINDLE
D-29
IG2
IG1
PG
PG
TBW+B
TBW+B
TMOM
TMOP
IG3
SSTRK
IGP
PG
O2-1
IGP
IG4
PG
PG
LG
DRUMANG
24P
W
12P
W
3P
Bl
2P
Bl
18P
GND
POS CHG
ANS BACK
IND L
FR L
RR L
RR R
ESS
IND R
R SW
SET SW
FR R
L SW
VSP FR
VSP RR
BATT
IGN
18P
Bl
RVWS
FPO
ESS
RVW B
IG
MR +B
FSR +B
GND
MOTOR GND
MODE SW
IND
SCS
DIAG
FVW B
FVW S
BLS
RPO
MODE IND
12P
Bl
12P
Bl
32P Gr
HIGH BEAM
FUEL RES
FR FOG
TURN L
TURN R
SP SIG
AIR TEMP
OIL-P
AIR TEMP(GND)
GND
SEL DWN SW
SEL UP SW
TC SW
MODE SW
ACC
BATT
NEUTRAL
GRIP HEATER
F-CAN(L)
F-CAN(H)
FUEL
ABS
ABS REAR OFF
BAT2
HO
PASS
BAT1
LO
HI
W
L
R
W
R
L
GND
GND
SEL UP
SEL DWN
SET
VCC
TC
8P
2P
Bl
4P
Bl
2P
Bl
GND
GND
HEATER L
LED
SW
4P
Bl
4P
Bl
2P
3P
Bl
MAIN 30A
ABS M 30A
2-1
1-1
1-2
2-2
6P
Bl
2P
Bl
2P
Bl
2P
Bl
TPS1
TPS2
VCC
SG
6P
Bl
2P
Bl
4P
3P
Gr
3P
Bl
6P
Bl
3P
Bl
8P
GND
HEATER R
GND
Vcc
RxDT
TxCT
IG BAT
BAT
BAT
ST
IG
IG
2P
Bl
2P
Bl
4P
Bl
2P
Br
2P
Bl
UP DOWN
2P Bl
2P
HI
LO
GND
POS
2P O
4P
2P Bl
2P Bl
2P Bl
MODE
GND
IN
OUT
2P Lb
2P Bl
6P
4P
2P Lb
3P Bl
2P W
2P O
IGN
SW
GND
METER
HEATER L
LED
HEATER R
10P
Bl
10P
Bl
4P
R
4P
Bl
2P
Bl
2P
3P
Bl
2P
Bl
2P
Bu
8P
Bl
VCC1
SG1
SG2
APS1
APS2
VCC2
3P
2P
R
2P Bl
(GRIP
HEATER)
(NO GRIP
HEATER)
2P
Bl
2P
Bl
DUMMY
LO
BAT1 LO HI
(N)
HI
PASS
FREE
VCC TC
PUSH
FREE
SET GND
PUSH
R
WR L
N
L
FREE
BAT2 HO
PUSH
OFF
WR L
ON
ON
BAT ON
OFF
LOCK
FREE
MODE GND
PUSH
UP
SEL
UP
GND
SEL
DOWN
N
DOWN
12P
Gr
10P
Gr
2P
Bu
33P Gr
2P
Gr
Gr/Bu
Br/Bl
W
Y
Bu/O
Y/W
Bu/Bl
Y/Bl
Lg/Bl
P
Bu/Y
Bl/W
Lg
Br/Bl
Y/Bu
Bu/Bl
Br/R
W/Y
Y
Bl/R
Bu/W
W
W
P/Bl
Bl
P/Bu
R/Bu
P
P
Br
Gr/Bu
Lg
Y/R
Gr/Bl
G
G
Y
G/W
Lg
G/Y
Y/W
Lg
Bu/Y
Bu/Bl
Bu/W
G
G
Bu
Bu/R
Bu/R
G
Br/G
Br/G
Br/Bl
Bl
Br/Bl
Bu/Y
G/Bu
Bl/Bu
G
G
W
Y/R
Y/R
Y/R
Y/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Y/R
Gr
W
W
W
G
G
G
G
G
G
G
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
G
G
G
Gr/Bu
Gr/Bu
Gr/Bu
Y/R
Lg/Bl
Gr/Bl
Lg
Gr/Bl
W
R/G
Bl/G
R/Y
G/Y
R/G
Bu
W
G
G
W/Bu
Gr/Bu
W
Bu
Bu/Y
R/Bl
W/G
Bu/Bl
G
O
O
Y
O
G
Lb/W
Lg/W
Bu/Y
Bu/Bl
Lb
Lb
Lb
R/W
O/W
Bl/R
Bl/G
R/W
Lg/Y
R/Bu
G/Bl
G
Bu/W
Bl/R
Bl/R
Bl
P
Bl/W
O
R/Bu
R/Bl
Bu/Bl
R/Y
W/Bl
Lb
Lb
G
W
O
R/Bl
W/G
Lg
W/Bu
Bu
Br/Bl
Br/Bl
Br/Bl
Br/Bl
Br/Bl
R/Bu
R/Bl
Bu/Bl
R/Y
Lb
Lb
G
W
O
O
R/W
Lg
R/Bu
G/Bl
G
Bu
Bl/R
Bl/R
Bl/RBl/R
Bl
P
R/Bl
W/G
Lg
W/Bu
Bu
R/W
G/Bl
Lg/Y
G
O
P
W
Bl
Bl/R
Bu/W
Bu/Bl
Bu/Bl
Lb
W/Bu
W/G
Bl/R
Bl/W
Bl/R
Lg
Bu
R/Bl
R/Bu
W/Bl
G
Bu/Bl
G/Bl
G
Lg
Bu
Bu/Bl
Bl/W
G/Bl
G
Lg/Y
Bu
G/W
G/Y
O/W
Lb/W
R/W
Lg/W
Y/Bu
Bl/R
Bu/R
Bl
Bl/Bu
Bl/Br
O/W
Lb/W
R/W
Lg/W
Y/Bu
Bl/R
Bu/R
Bl
Y/Bu
G
G
Y/Bu
Bu
Bu
Gr
Gr
G
G
Y/Bu
G
Bl/Br
Y/G
G
Y/W
Br/Bl
Bl
Y/R
R/Bu
R/Bl
G
Br/Bl
Br/Bl
Bl
G
Bl/W
Bu/R
Bu/R
G
Bu
Br/G
Y/W
G
R/Bu
G
Bl
G/R
W
R
R/Y
R/Bu
R/G
R/W
R/Y
W
R/Y
W
R/W
Bl/Gr
Bl
Bl/Gr
Bl
R/W
Bu/Y
R/W
Bu/W
R/W
Bu/Bl
R/W
Bu/R
R/W
Bu/Y
Bu/W
Bu/Bl
Bu/R
R/W
Br/Bl
Bu/Y
Bu/W
Bu/Bl
Bu/R
Br/Bl
Br/Bl
Y/Bu
G
Bu/Bl
Bl
Bl/W
Bu/R
Bu
Lg
Y
Bu/W
Bu/Bl
Br/Bl
P/Bu
Br/Bl
P/Bl
G
G
Bl
G
G
G
G
G/Bu
G/Bu
G
G
G
G
Br/Bl
Y/Bl
Y
Y
Y
R
G
Bl/R
P
G
Bl
W/Y
Y
Bl/R
P
G
Bl/R
W/Y
Y
W/Y
Y
Bl/R
P
G
Bl
W
Bl/R
Y/W
G/Y
G/Y
Y/W
Bl
W
Bl/G
Bl/Y
Bl
Bl
Y/R
G
Y/R
G
G/O
Y/R
P
O/Bu
Bl
Bl/W
GrBl
Y/R
P
Bu/O
G
Bu/Bl
W
Bu
W
Bu
R
R/Bl
R
R/Bl
G/W
G
G/W
G
R
R/Bu
R/W
R/Bu
R/Bl
Y/Bu
Bl/R
Y/W
Bu
W/Bl
G
Bl/R
Gr
Bl
G
Br
Bl
Bl/G
O
G
Bu/Bl
R/Y
G
R/Y
G
R/Y
G
R/Y
G
Bl/W
R/Bu
R
Bl
R/Bl
G
Bl
Bl/G
Lb
G
R/Bl
R/Y
R/Y
R/Bl
R/G
G
R/W
R/Y
G/Y
G
R/W
R/Y
Y
R/Bu
Br/Bl
Gr/Bu
Bu/Bl
G
Bl/R
G
Lb
G
Br
Bl/G
Bl
G/Y
G
Bl/R
G
O
Bl/G
Bl
W
Gr
Bu
G
Y/R
Y/Bu
R/Y
Bu
Y/Bu
W
G
R/Y
Gr
Y/R
W
Gr/Bu
Br/Bl
G/Bu
Bl/R
G/Y
Bl
Bl
Br/Bl
W
Bl
Gr
W
Bu
W
Bu
W
W
Bl
Gr
G
R/Bl
Y/R
R/Bl
Bl/W
Y/R
Bl/W
Y/R
R/Bu
G
R/Bu
G
Bl/W
Gr/Bl
Br/R
Y/R
W/Bl
Y/Bl
W/R
Bu/W
Gr
Br
Lg
P
W
Bu/Y
Y
Bl
Bl
Bl
Bl
W/Bl
Bl/W
R
R
Y/W
Y/W
Y/W
Y/W
Br/Bl
R/W
Gr/Bl
Bl/Bu
Y/R
Lg
Lg
G/R
G/Y
G/Y
G
W
Y/R
Gr/Bl
W
Y/R
Lg
Y/Bu
PCM
JUNCTION 1JUNCTION 2
MAP SENSOR
ABS
MODULATOR
COMBINATON
METER
TURN
SIGNAL
LIGHT
SWITCH
DIMMER
PASSING
SWITCH
HORN
SWITCH
METER
SELECT
SWITCH
MODE
SWITCH
TORQUE
CONTROL
SWITCH
CLUTCH
SWITCH
HAZARD
WINK
CANCEL
HEATER
L1
HEATER
L2
FI
RELAY
FUEL
PUMP
RELAY
ENGINE
STOP
RELAY
TBW
RELAY
HEADLIGHT
RELAY
BATTERY
YTZ14S
ABS FSR+
30A
FI 15A
STARTER
RELAY
SWITCH
STARTER
MOTOR
IGNITION COIL
PAIR
CONTROL
SOLENOID
VALVE
FAN
MOTOR
FUEL
INJECTOR 2
FUEL
INJECTOR 1
TBW UNIT
EVAP
PURGE
CONTROL
SOLENOID
VALV E
CKP SENSOR
EOP SWITCH
REGULATOR/
RECTIFIER
ALTERNATOR
VS SENSOR
STARTER
SWITCH
ENGINE
STOP
SWITCH
FRONT
BRAKE
LIGHT
SWITCH
HEATER
R
HEATER
R
DUMMY
IGNITION
SWITCH
IMMOBILIZER
RECEIVER
FAN
MOTOR
FRONT
WHEEL
SPEED
SENSOR
SIDESTAND
SWITCH
TBW
10A
ENG STOP
10A
ILLUMI STOP
HORN
10A
HEAD LIGHT
20A
FAN
20A
CLOCK TURN
10A
HEADLIGHT
DRIVER
LEFT FRONT
TURN SIGNAL
LIGHT
FRONT OPTION
SOCKET
DUMMY
DUMMY
RIGHT FRONT
TURN SIGNAL
LIGHT
BANK ANGLE
SENSOR
REAR ABS
SWITCH
ABS MAIN
10A
OP
10A
FAN CONTROL
RELAY
DUMMY
REAR OPTION
DUMMY
REAR OPTION
RIGHT REAR
TURN SIGNAL
LIGHT
LEFT REAR
TURN SIGNAL
LIGHT
LICENSE
LIGHT
12V 5W
BRAKE/
TAILLIGHT
GRIP HEATER
CONTROLLER
GRIP HEATER
CONTROLLER
DUMMY
DUMMY
REAR BRAKE
LIGHT SWITCH
REAR WHEEL
SPEED SENSOR
O
2
SENSOR
FUEL
LEVEL
SENSOR
RESERVE
SENSOR
SHIFT
SPINDLE
SWITCH
RESISTOR
FUEL
PUMP
UNIT
APS
HORN
OPEN AIR
TEMPERATURE
SENSOR
DIODE
NEUTRAL
SWITCH
HEATER
L
DUMMY
HEATER
SWITCH
DUMMY
ECT SENSOR
DIMMER SWITCH
TORQUE CONTROL
SWITCH
MODE SWITCH
TURN SIGNAL LIGHT
SWITCH HORN SWITCHHAZARD SWITCH
IGNITION SWITCHREAR ABS SWITCH
DUMMYDUMMY
CRF1000A2/AL2
CRF1000A/AL
IAT SENSOR
Except IN model
Except IN model
IN model
DLC
CRF1000A2/AL2
CRF1000A/AL
GEAR
POSITION
SENSOR
SHIFT
STROKE
SENSOR
DUMMY
DUMMY
METER SELECT SWITCH
CRF1000A2/AL2
CRF1000A/AL
CRF1000A/AL
CRF1000A2/AL2
CRF1000A2/AL2
CRF1000A/AL
FUSE BOX 2FUSE BOX 1
FUSE CASE
ED/KO/TH/FO/
MA models
TURN SIGNAL LIGHT RELAY
Except IN
model
Except IN/FO
model
Black
Yellow
Blue
Green
Red
White
Brown
Orange
Light Blue
Light Green
Pink
Gray
Bl
Y
Bu
G
R
W
Br
O
Lb
Lg
P
Gr
26-226
dummytext
CRF1000A/A2/AL/AL2/D/D2/DL/DL2-J ADDENDUM
WIRING DIAGRAM (CRF1000D/D2/DL/DL2)
32P Gr
2P Bl
HIGH BEAM
FUEL RES
FR FOG
PAR KING
TURN L
TURN R
SP SIG
AIR TEMP
AIR TEMP(GND)
GND
SEL DWN SW
SEL UP SW
TC SW
MODE SW
ACC
BATT
NEUTRAL
GRIP HEATER
F-CAN(L)
F-CAN(H)
FUEL
ABS
ABS REAR OFF
2P Bl
2P O
2P
4P
HI
LO
GND
POS
2P Bl
MODE
GND
MODE
GND
IN
OUT
2P Lb
4P Bl
8P
Bl
12P
Bl
VCC
D
VCC
MOD
VCC
N
GND
Vcc
RxDT
TxCT
IG BAT
8P
8P 8P
2P
Bl
2P
Bl
2P
Bl
2P
Bl
4P
Bl
4P
Bl
2P
Br
3P
Gr
3P
Bl
2P
Bu
33P Bu 33P Br 33P Bl 33P Gr
FAN
FLR
O2HT1
TBWRLY
IMOAU
PCP
POIL
PCS
TPS1
APS1
PB
IMOID
IMOV
ENG STOP
TW
EX-AI
TPS2
RVW
PCM
APS2
TA
GMODESW
A-1
A-2
A-3
A-5
A-6
A-7
A-4
A-8
A-9
A-10
A-12
A-13
A-14
A-11
A-15
A-16
A-17
A-19
A-20
A-21
A-18
A-22
A-23
A-24
A-26
A-27
A-28
A-25
A-30
A-31
A-32
A-33
A-29
B-1
B-2
B-3
B-5
B-6
B-7
B-4
B-8
B-9
B-10
B-12
B-13
B-14
B-11
B-15
B-16
B-17
B-19
B-20
B-21
B-18
B-22
B-23
B-24
B-26
B-27
B-28
B-25
B-30
B-31
B-32
B-33
B-29
C-1
C-2
C-3
C-5
C-6
C-7
C-4
C-8
C-9
C-10
C-12
C-13
C-14
C-11
C-15
C-16
C-17
C-19
C-20
C-21
C-18
C-22
C-23
C-24
C-26
C-27
C-28
C-25
C-30
C-31
C-32
C-33
C-29
D-1
D-2
D-3
D-5
D-6
D-7
D-4
D-8
D-9
D-10
D-12
D-13
D-14
D-11
D-15
D-16
D-17
D-19
D-20
D-21
D-18
D-22
D-23
D-24
D-26
D-27
D-28
D-25
D-30
D-31
D-32
D-33
K-LINE
INJ2
INJ1
CANL
BA
ST INH
SG1
CANH
SG2
VCC1
VCC2
VSP
SCS
FVW
PG
PG
SC4
VCC3
VCC4
SC3
SSTAND
D-29
IG2
IG1
PG
PG
TBW+B
TBW+B
TMOM
TMOP
IG3
IGP
PG
O2-1
IGP
IG4
PG
PG
LG
DRUMANG
SPOLANG
PVB
NM1P
SMOP
SMOP
STOP
VSENSE1
NEUTRAL
SFTDOWN
SMOM
LSOL2P
LSOL2M
LSOL1P
LSOL1M
PVB
SEL-D
SMOM
PC2
SFTPANG
PC1
SUB VB
NM2P
MODE SW
SFTUP
VSENSE2
SEL N
TO
PLINE
SUB VB
3P
Bl
2P
Bl
3P
Bl
3P
Bl
3P
Bu
2P
Bl
4P
Bl
2P
Bl
18P
GND
POS CHG
ANS BACK
IND L
FR L
RR L
RR R
ESS
IND R
R SW
SET SW
FR R
L SW
VSP FR
VSP RR
BATT
IGN
18P
Bl
RVWS
FPD
ESS
RVW B
IG
IGN
SW
GND
METER
HEATER L
LED
HEATER R
MR +B
FSR +B
GND
MOTOR GND
MODE SW
IND
SCS
DIAG
FVW B
FVW S
BLS
RPO
MODE IND
10P
Bl
10P
Bl
4P
R
2P Lb
3P Bl
2P W
2P O
6P
DUMMY
4P
DUMMY
3P
Bl
3P
Gr
3P
Bl
3P
Bl
3P
Bl
2P
Bl
UP DOWN
2P
Bl
24P
W
24P
W
3P
Bl
2P
Bl
4P
Bl
4P
2P
Bl
3P
Bl
2P
Bl
2-1
1-1
1-2
2-2
2P
Bl
2P
Bl
2P
Bl
4P
Bl
4P
Bl
2P
Bl
12P
10P
Gr
BAT2
TPS1
GND
GND
HEATER L
LED
SW
TPS2
VCC
SG
HO
SET
GND
PASS
BAT
LO
HI
W
R
L
2P
2P
GND
GND
SEL UP
SEL DWN
MODE
6P
6P
Bl
6P
Bl
2P
R
VCC
VCC
VCC
UP
TC
DOWN
VCC1
SG1
SG2
APS1
APS2
VCC2
FREE
MODE GND
PUSH
FREE
MODE GND
PUSH
OFF
BAT1 IG ST
(N)
RUN
ST
ON
BAT ON
OFF
LOCK
LO
BAT1 LO HI
(N)
HI
PASS
FREE
VCC TC
PUSH
FREE
SET GND
PUSH
R
WR L
N
L
FREE
BAT2 HO
PUSH
FREE
VCC UP
PUSH
FREE
VCC
DOWN
PUSH
FREE
VCC MOD
PUSH
OFF
WR L
ON
UP
UP GND
DOWN
N
DOWN
HEATER R
GND
UP
SEL
UP
GND
SEL
DOWN
N
DOWN
D-S
DN
FREE
N
VCC
12P
Gr
2P
Bu
3P
Gr
2P
Gr
R/W
R/Bu
W
Gr/Bl
Y/R
W
Bl
Y/R
W/Y
W/Y
Y
Y
W/Y
Y
Y
Y
Y
R
G
Bu/Bl
G/Bl
R/Bl
G
Bu/Bl
G/Bl
R/Bl
G
Bl
Bl/G
Lb
G
R/W
G/Bl
Lg/Y
G
O
P
W
Bl
Bl/R
Bu/W
Bu/Bl
Bu/Bl
G/Y
Lb
W/Bu
W/G
Bl/R
Bl/W
Lg
Bu
R/Bl
R/Bu
W/Bl
Bl
Bl
W/Bl
Bl/W
Bu
Y/Bu
G
Bl/R
Gr
Bl
G
Br
Bl
Bl/G
O
G
Bu/Bl
R/Y
G
R/Y
G
R/Y
G
R/Y
G
P
W
G/Bu
Bu/Bl
Gr/Bu
Br/Bl
W
Y
W
Bu/G
Bu/O
Y/W
R/G
R/W
Lg/Y
Bu/Bl
Y/Bl
Lg/Bl
P
Bu/Y
Bl/W
Lg
Br/Bl
Y/Bu
Bu/Bl
Bu/Bl
W/Y
Y
Br/R
Bl/R
Bu/W
W
W
P/Bl
Bl
P/Bu
R/Bu
P
P
Y/W
Br
Gr/Bu
Be
Y/R
Gr/Bl
G
G
Y
G/W
Lg
Bu/Y
Bu/Bl
Bu/W
G
G
Bu
Bu/R
Bu/R
G
Br/G
Br/G
Br/Bl
Bl
Bu
Br/Bl
Bu/Y
G/Bu
G
G
W
W
R/W
P/Bu
Bl/Br
P
Lg
Lg/R
Y/Bu
Gr
Y
R/W
W/R
G/Y
Bu
Y/G
Bl/G
Y/Bl
Y/Bu
R/W
P/Bu
Bu
Gr
Y
W/R
Gr/Bl
Y/G
Y/R
Gr/Bl
R/G
Y/R
Gr/Bl
Bl/G
Y/R
Br/R
Gr/Bl
Y/R
G
R/W
Lb/W
O/W
Bl/G
Bl/R
Y/W
Bl
W
R/W
Lb/W
O/W
G/Y
G/Y
Bl/R
Y/W
Bl
W
R/W
Lb/W
O/W
Bl/R
Bl/G
W
Bl
Bl
Bl
Y/R
G
G/O
Y/R
P
O/Bu
Bl
Bl/W
Gr
Y/R
P
Bu/O
G
Bu/Bl
W
Bu
W
Bu
R
R/Bl
R
R/Bl
Bu
Gr
Y
W/R
Y/R
Bu
Bl/W
Bu/Bl
Lg/Y
Y/R
Bu
Y/W
Bu/Bl
Lg/Y
Y/R
W/Bl
Y/Bl
W/R
Bu/W
Gr
Br
Be
P
W
Bu/Y
Y
G/Bu
G
Y/R
Lg/R
Bu/Bl
G/Bl
G
Lg
Bu
G/Bu
Y
Lg/R
Bu/Bl
Bl/W
G/Bl
G
Lg/Y
Bu
Bl/Br
Bl/Bu
O/W
Lb/W
R/W
Lg/W
Y/Bu
Bl/R
Bu/R
Bl
G/Y
G
O/W
Lb/W
R/W
Lg/W
Y/Bu
Bl/R
Bu/R
Bl
G
Y/Bu
G
Y/Bu
G
G
Y/Bu
Bu
Bu
Gr
Gr
G
G
Bl/Br
Y/G
G
Bl
Bl
Br/Bl
Y/Bu
G
Bu/Bl
R/W
Bu/Y
R/W
Bu/W
R/W
Bu/Bl
R/W
Bu/R
Y/R
Lg/Bl
Gr/Bl
Lg
Gr/Bl
R/W
Bu/Y
Bu/W
Bu/Bl
Bu/R
R/W
Br/Bl
Bu/Y
Bu/W
Bu/Bl
Bu/R
Br/Bl
Bu/R
Bu
Lg
Y
Bu/W
Bu/Bl
Br/Bl
P/Bu
Br/Bl
P/Bl
G
G
Bl
G
G
G
G
G/Bu
G/Bu
G
G
G
G/R
W
R
R/Y
R/Bu
R/W
R/G
R/W
R/Y
Bl/Gr
Bl
Bl
Bl/Gr
W
W
W
Gr/Bl
Y/Bl
Y/R
Br/Bl
Y/Bl
Y/R
Y/R
Y/R
Y/R
Bl
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Y/R
Y/R
Y/R
Y/R
Y/R
Y/R
Y/R
Y/R
Gr
Gr
G
G
G
G
G
G
G
G
G
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bl
Gr/Bu
Gr/Bu
Gr/Bu
Gr/Bl
Gr/Bl
W
Y/R
Y/Bu
P/Bu
G
W
Y/R
Bl
P
G
G/W
G
Bl
Bl/W
G/W
G
Y/W
Br/Bl
Bl
Y/R
R/Bu
R/Bl
G
G
Br/Bl
Br/Bl
Bl
Bl
G
Bl/W
G/R
Bl
Y/W
G
Bu/R
Bu/R
G
Bu
Br/G
Y/W
G
R/Bu
R
R/Bu
R/W
R/Bu
R/Bl
Y/Bu
Bl/R
Bl/R
Y/W
Y/W
R
R/W
R/W
R/Bl
R/Y
R/Y
R/Bl
R/G
G
R/W
R/Y
G/Y
G
R/W
R/Y
Y
R/Bu
Br/Bl
Gr/Bu
Bu/Bl
G
Bl/R
G/Y
G
Bl/R
G
O
Bl/G
Bl
G
Br
G
Lb
Bl/G
Bl
Gr/Bl
P
Bl/Br
G/Bl
P
Bl/W
G
R/Bl
Y/R
R/Bl
Bl/W
Y/R
Bl/W
Y/R
R/Bu
G
R/Bu
G
Lg
Lg
Gr
P
W
Bu
W
Bl
Gr/Bl
W
Y/R
Bu/G
Gr/Bl
Bl/R
G/Y
Bl
Bl
Br/Bl
W
Bl
Gr
W
Bu
W
Bu
R/W
W
Bl
Gr
W
Gr
Bu
G
Y/R
Y/Bu
R/Y
W
Gr/Bu
Br/Bl
G/Bu
Bu
Y/Bu
W
G
R/Y
Gr
Y/R
W
R/W
R/Bu
R/Y
W
W
Bl/W
W
R/G
Bl/G
R/Y
G/Y
R/G
Bu
W
G
G
W/Bu
Gr/Bu
W
Bu
Bu/Y
R/Bl
W/G
Bu/Bl
G
O
O
Y
O
G
Lb/W
Lg/W
Bu/Y
Bu/Bl
Lb
Lb
Lb
R/W
O/W
Bl/R
Bl/G
R/W
Lg/Y
R/Bu
G/Bl
G
Bu/Bl
Bu/W
Bl/R
Bl/R
Bl
P
R/W
Lb
R/Bu
R/Bl
Bu/Bl
R/Y
Y/Bu
O
Lb
G
W
O
Br/Bl
Lb
R/Bu
R/Bl
Bu/Bl
R/Y
Y/Bu
O
Lb
G
W
O
R/W
Lg
R/Bu
G/Bl
G
Bu/Bl
Bu
Bl/R
Bl/R
Bl
P
R/Bl
W/G
Lg
W/Bu
G/Y
Bu
R/Bl
W/G
Lg
W/Bu
G/Y
Bu
Y/R
Y/R
Bu
Bl/W
Bu/Bl
Lg/Y
RIGHT FRONT
TURN SIGNAL
LIGHT
G SWITCH
BANK ANGLE
SENSOR
REAR ABS
SWITCH
G SWITCH REAR ABS SWITCH
ENGINE STOP & STARTER
SWITCHIGNITION SWITCH
DIMMER SWITCH
SHIFT UP SWITCH SHIFT DOWN SWITCH
TORQUE CONTROL
SWITCH
MODE SWITCH
TURN SIGNAL LIGHT
SWITCH HORN SWITCH
COMBINATON
METER
OPEN AIR
TEMPERATURE
SENSOR
HEADLIGHT
DRIVER
LEFT FRONT
TURN SIGNAL
LIGHT
FRONT OPTION
WINK
CANCEL
METER
SELECT
SWITCH
MODE
SWITCH
TORQUE
CONTROL
SWITCH
SHIFT
DOWN
SWITCH
SHIFT
UP
SWITCH
TURN
SIGNAL
LIGHT
SWITCH
DIMMER
PASSING
SWITCH
HORN
SWITCH
PAR KING
SWITCH
HORN
HEATER
L1
HEATER
L2
HEATER
SWITCH
DUMMY
HEATER
L
DUMMY
MAP SENSOR
ECT SENSOR
IGNITION COIL
PAIR
CONTROL
SOLENOID
VALVE
FAN
MOTOR
FUEL
INJECTOR 2
FUEL
INJECTOR 1
TBW UNIT
ABS FSR+
30A
FI 15A
DCT M
30A
PEDAL
SHIFTER
EVAP
PURGE
CONTROL
SOLENOID
VALV E
BATTERY
YTZ14S
STARTER
MOTOR
JUNCTION 1JUNCTION 2
STARTER
RELAY
SWITCH
REGULATOR/
RECTIFIER
ALTERNATOR
VS SENSOR
TR SENSOR
SIDESTAND
SWITCH
SHIFT MOTOR
TBW
10A
ENG STOP
10A
ILLUMI STOP
HORN
10A
HEAD LIGHT
20A
FAN
20A
CLOCK TURN
10A
FI
RELAY
FUEL
PUMP
RELAY
ENGINE
STOP
RELAY
STARTER
RELAY
TBW
RELAY
HEADLIGHT
RELAY
EOP SENSOR
CKP SENSOR
FAN CONTROL
RELAY
REAR OPTION
REAR OPTION
ABS MAIN
10A
OP
10A
DCT MAIN
10A
RIGHT REAR
TURN SIGNAL
LIGHT
LEFT REAR
TURN SIGNAL
LIGHT
LICENSE
LIGHT
12V 5W
BRAKE/
TAILLIGHT
GRIP HEATER
CONTROLLER
GRIP HEATER
CONTROLLER
DUMMY
TURN SIGNAL LIGHT RELAY
ABS
MODULATOR
FUEL
LEVEL
SENSOR
RESERVE
SENSOR
FUEL
PUMP
UNIT
NEUTRAL
SWITCH
INNER
MAINSHAFT
SENSOR
OUTER
MAINSHAFT
SENSOR
SHIFT SPINDLE
ANGLE SENSOR
EOT
SENSOR
REAR BRAKE
LIGHT SWITCH
REAR WHEEL
SPEED SENSOR
O
2
SENSOR
PCM
IGNITION
SWITCH
IMMOBILIZER
RECEIVER
FAN
MOTOR
No.2
LINEAR
SOLENOID
VALV E
No.1
LINEAR
SOLENOID
VALV E
CLUTCH
LINE EOP
SENSOR
No.1
CLUTCH
EOP
SENSOR
No.2
CLUTCH
EOP
SENSOR
IAT
SENSOR
FRONT
WHEEL
SPEED
SENSOR
ENGINE
STOP
SWITCH
FRONT
BRAKE
LIGHT
SWITCH
HEATER
R
HEATER
R
DUMMY
HAZARD
STARTER
SWITCH
A/M
SWITCH
APS
MAIN 30A
A/M SWITCH HAZARD SWITCH
METER SELECT SWITCH
Black
Yellow
Blue
Green
Red
White
Brown
Orange
Light Blue
Light Green
Pink
Gray
Bl
Y
Bu
G
R
W
Br
O
Lb
Lg
P
Gr
SOCKET
DUMMY
DUMMY
DUMMY DUMMY
DUMMY
DUMMY
DUMMY
N-D SWITCH
CRF1000A/AL
CRF1000A2/AL2
N-D SWITCH
DLC
CRF1000A/AL
CRF1000A2/AL2
Except IN model
Except IN model
IN model
BeigeBe
METER SELECT SWITCH
CRF1000D/DL
CRF1000D2/DL2
CRF1000D/DL
CRF1000D2/DL2
CRF1000D2/DL2
CRF1000D/DL
FUSE BOX 3FUSE BOX 2
FUSE BOX 1
ABS M 30A
ED/KO/TH/FO/MA models
FUSE CASE
Except IN
model
Except GS/IN
model
Honda Motor Co., Ltd. 2017
Published by Honda Motor Co., Ltd.
Printed in Japan
Book number : 62MJP00Y
A.2017.11
