Notes:

SPEEDOMETER 1) Pulse count

DIAGNOSIS should be 49440.

2) The speedometer and speed sensor

do not share a power and
ground circuit.
Does the speedometer do an
initial sweep from 0 to 60 and
back when powered up?

No Is power available Yes

at the speedometer?

Is the pulse count

Inspect red power correct (see note 1)? Inspect green
wire from signal wire.
speedometer
to EHC. Yes No
Is there a short
No or an open in
Is there a short or
open in red wire? green wire?

Repair wires
Yes Inspect black wire as needed
for an open.
06006
Is there a Perform test on
good ground?
speed sensor,
Repair wires checking power
as needed No
at sensor.
Yes No
06006
Repair wires
as needed
Yes
06006
Check connector
at the EHC.
Yes Replace
Is there power at speed sensor
the connector?
06029

No
Does the
No
speedometer bounce?

Yes
Replace EHC

06012
Replace Call Tech
speedometer Support

06051
 VIBRATION

Are tires in good

Yes condition and at the No
proper pressures?

Set tire pressures

Are handlebar to specifications.
mounting bolts Replace tires
No properly Yes
as needed.
tightened?
Maintenance.

Tighten to Are the forward

specifications. control mounts
No tighten to Yes
specifications?
0911

Is drive
Tighten to No belt tight? Yes
specifications.

09045
09046 Adjust
drive belt. Are all engine
mount bolts
Maintenance. No tightened Yes
properly?

Tighten mount
bolts to
specifications.
Is the primary
09033 Yes chain in Yes
adjustment?

Check primary chain Remove outer

for alignment. primary cover.
Yes No Yes
Is primary chain Is sprocket shaft
aligned? nut loose? Adjust primary chain,
per BDM
Service Manual.

Check clutch
basket and main No 04001
shaft run out. Tighten to
Check washer behind specifications.
clutch basket for damage.
Replace if needed.
04013
Align chain per BDM
Service Manual.
Call
Tech Support. 03005
 STARTER BUTTON
(CONTINUITY TEST)

With the ignition key

in the OFF position,
connect the backbone
breakout box to the EHC.
No Fault Measure continuity between
pins B6 and B28 while Fault Found
Found
operating start button.
There should be a closed
circuit when pressed,
and open when released.
Inspect backbone and
hand control harness connectors,
as well as right hand
control PCB for failure.
Call Tech Repair as needed.
Support
06038

STARTER SOLENOID
POWER TEST

Connect power harness

breakout box to the EHC.
Closed circuit Measure continuity between Open circuit
green solenoid wire and pin A-1.

With the solenoid

wire disconnected
from the starter,
use power harness
breakout box to measure Battery
voltage from pin A-1 to A-4. voltage
There should be Inspect power harness
8 volts standing and and terminal on starter
12 volts when solenoid for damage.
starter is activated. Repair as Needed.

06004

EHC failure.
No battery Confirm failure with
voltage EHC tester.
Call Tech Support.

06040
 CHARGING SYSTEM

Charge battery to a minimum of 12.8 volts.

Load test the battery and replace if necessary.
Check battery cables and all connections.
Check for current drain or draw with power OFF.
Less than 1.4 mA carbureted, and 2.4 mA EFI.

TEST A

Start engine. Below 13.8

Measure voltage
across the battery
Above 14.8 terminals.

Is voltage below
13.8 volts or Stop engine.
above 14.8 volts? test circuit breaker.
Measure voltage at
No both CB terminals. Yes
Replace
voltage regulator. Is there a voltage
Retest. difference?
Check for voltage
regulator ground.
06018 Measure resistance
from VR case to
battery Push the reset button
Ref. No ground, and also to Yes on breaker.
Test A engine ground. Replace CB if it
cannot be reset.
Is resistance more
Remove stator than 0.5 Ohms ?
06052
plug, start engine
and measure
AC voltage Ref.
Yes across pins.
Test A
Is stator output 16 No Remove VR.
to 20 volts per Clean and inspect all
1000 RPMs? contact points.
Reinstall and retest.
Ref.
Replace With engine OFF Test A
measure resistance 06018
voltage regulator. across stator pins.
Retest.
Is resistance more No
06018 than 0.5 Ohms? With engine
Yes OFF, measure
resistance from
Ref. stator pin to
Test A engine ground.

Is continuity
present?
Replace No
stator/rotor. Yes
Retest.

06017
Reconnect the two-pin
Ref. Ref. stator plug and retest stator/rotor.
Test A Test A If low voltage condition still exists,
replace stator/rotor. Retest.

06017
 Note:
VOLTAGE REGULATOR
TEST 1) For diagnosis times
above 0.3 call Tech Support.

This test requires the VR to be

removed from the
charging system circuit.
Disconnect B+ from circuit
breaker and unplug stator/rotor.
Test may also be performed
With VR removed
from the motorcycle.

Using DMM, connect black probe

to ground and red probe to B+.
Measure resistance between
Yes B+ and ground. No

Is resistance less than 2megohm?

Replace
voltage regulator
Connect black probe to B+
and red probe to pin 1. Measure
06018 resistance between Pin 1 and B+.
Yes Repeat from Pin 2 to B+. No

Is resistance less than 1megohm?

Connect black probe to pin 1

and red probe to pin 2.
Measure resistance between
Yes pins in both directions. No

Is resistance less than 1megohm?

Replace
voltage regulator

06018 Connect black probe to ground

and red probe to pin 1.
Measure resistance between
pin 1 and ground.
Yes Repeat measurement for No
pin 2 to ground.

Is resistance less than 1megohm?

Reconnect voltage regulator.

Retest charging system using
CHARGING SYSTEM
flow chart.
 STARTING SYSTEM
(ENGINE WILL NOT CRANK)

Charge battery.
Check battery voltage.

Yes Does battery register No

at least 12.8 volts?
(Replace battery
TEST B if necessary) Inspect
Attempt to start charging system.
motorcycle. Refer to
CHARGING
Does solenoid
engage or attempt SYSTEM
No
to engage? flow chart.

Yes

Does headlight turn

No off when starter Yes
is activated?
Refer to
Test C

Disconnect green wire from

starter solenoid. Measure voltage
from solenoid wire to ground
Refer to when the starter is activated
STARTER (It is common to have around 8 volts on the Yes
BUTTON wire before the starter is activated).
flow chart.
Does the green wire
No have battery voltage?

Refer to
STARTER
SOLENOID
flow chart.
Disable ignition so
motorcycle will not start.
Measure DC voltage drop
across power cable from positive
battery terminal to starter
terminal while cranking.
TEST C
Disable ignition so
motorcycle will not start.
Measure DC voltage drop
No from starter housing to negative
battery terminal while cranking.
Is the voltage drop greater
than 1.0 volts?

Is the voltage drop greater

No than 1.0 volts? Yes Yes

Inspect battery cables

Verify there are no mechanical Inspect power cable
and connections.
faults in the engine or drive train. and connections.
Verify the starter ground/mounting
Inspect starter motor. Clean and repair
bolt is clean and tight.
Repair/replace as needed. as needed.
Clean and repair as needed.

15001 06004 06004

Ref. Ref.
Test B Test B
 Note:

ENGINE CRANKS 1) For diagnosis times

BUT WON’T START above 0.3 call Tech Support.
(2005 – 2008)

Is there an adequate
Yes supply of fresh fuel? No

Fill with fresh fuel.

Using a known good spark Does problem

tester and spark plug wire, still exist?
check for spark while
cranking. No

Is spark present?
Yes

Yes No

Stop.
Remove seat and right Continue at
Check for bad spark plug electrical cover to gain NO START,
access to the ignition module. ENGINE CRANKS –
wires, fouled spark plugs The red LED on the ignition SECTION G
or incorrect gap. module should flash while cranking. flow chart.
Is this happening?
06044

System Ok
No
07017
Yes

Stop. The blue and yellow LEDs

Continue at should flash alternately
NO START, while cranking the engine. Yes
ENGINE CRANKS –
SECTION A Is this happening?
flow chart.

No

Stop.
Continue at
NO START,
ENGINE CRANKS –
Replace SECTION E
ignition module. flow chart.

06041
 Note:
NO START,
Section 1) Refer to BDM Service Manual for
ENGINE CRANKS
A location of the LEDs for the ignition
(2005 – 2008)
fault circuit.

With key ON, observe the EHC.

When the Run switch is activated
the red LED at fault circuit #4
should illuminate (see note 1).

Is this your observation?

No

With key ON, observe the

ignition module. When
Yes Run button is pressed,
the red LED on the
ignition module should
momentarily light up.

Is this your observation?

Stop.
Continue at
NO START, Yes
ENGINE CRANKS –
SECTION B
flow chart. No

EHC fault circuit #4

LED is inoperative.
The ignition module is
receiving power. Replace EHC.
At this point the EHC
is not at fault.
06050

Stop.
Continue at
NO START,
ENGINE CRANKS –
SECTION C
flow chart.
 Note:
NO START,
Section 1) Use appropriate test connector with
ENGINE CRANKS
B leads from RK-03 Pigtail Kit located
(2005 – 2008)
in the Electrical Service Kit
#SK-4000-03.

Disconnect 3-place connector 8/9.

Set voltmeter to DC volts.
Place red test lead on red
ignition module power wire terminal
at connector 8 (see note 1).
No Place black lead to ground. Yes
With the key ON and Run switch
activated, voltmeter should
read battery voltage.

Is this your observation?

Disconnect EHC connector “A” (power harness). Disconnect EHC connector “A” (power harness).
Set voltmeter to read Ohms. Set voltmeter to read Ohms
Check for continuity between Check for continuity between EHC
EHC and connector terminal A19 and and connector terminal A23 and the black
red wire terminal in connector 8. wire terminal in connector 8.
Resistance should be less than 1 Ohm. Resistance should be less than 1 Ohm.

Is this your observation? Is this your observation?

Yes

No No Yes

Set voltmeter to read Ohms

Check for continuity between
Repair open in red ignition module Stop.
Repair open in
red ignition module power wire at connector Continue at
8 and ground. black ignition module
power wire. NO START, C
ground wire.
ENGINE CRANKS –
Is continuity present?
SECTION C
06006 06006 flow chart.
No Yes

Replace EHC Repair short to ground

in red ignition module
power wire.
06050

06006
 Note:
NO START,
Section 1) Use appropriate test connector with
ENGINE CRANKS
C leads from RK-03 Pigtail Kit located
(2005 – 2008)
in the Electrical Service Kit
#SK-4000-03.

Reconnect connector 8/9.

Reconnect EHC connector “A” (power).
Disconnect crank position
sensor connector at 27/28.
Set voltmeter to AC volts.
No Connect test leads to C.P.S. (see note 1). Yes
Voltmeter should read a minimum of
1 volt AC while cranking the engine.

Is this your observation?

Replace crank
Disconnect connector 27/28
position sensor. at the ignition module.
Set voltmeter to Ohms.
Check for continuity on brown wire
06058 between ignition module 28 and
crank position sensor connector 27.
Resistance should be less than 1 Ohm.

Is continuity present?

Yes

No

Check for continuity on brown wire

(see note 1) from ignition module
Yes connector 28 to ground.

Is continuity present?
Repair open in
brown wire.

Repair short to ground on brown wire 06006

between ignition module connector 28
and crank position sensor connector 27. No

06006

Stop.
Continue at
NO START,
ENGINE CRANKS -
SECTION D
flow chart.
 Note:
NO START,
Section 1) Use appropriate test connector with
ENGINE CRANKS
D leads from RK-03 Pigtail Kit located
(2005 – 2008)
in the Electrical Service Kit
#SK-4000-03.

Check for continuity on black wire

between ignition module connector
28 and crank position sensor
connector 27 (see note 1). No
Resistance should be less than 1 Ohm.

Is continuity present?

Repair open
in black wire.
Yes
06006

Check for continuity on

black wire from ignition
module connector 28
(see note 1) to ground.

Is continuity present?

Yes No

Repair short
Replace
to ground in
ignition module.
black wire.

06006 06041
 Note:
NO START,
Section 1) Use appropriate test connector with
ENGINE CRANKS
E leads from RK-03 Pigtail Kit located
(2005 – 2008)
in the Electrical Service Kit
#SK-4000-03.

Disconnect red power wire at ignition coil.

Set voltmeter to DC volts.
Place red test lead on red
ignition coil power wire (see note 1).
Place black lead to ground.
With key ON and Run switch activated,
Voltmeter should read battery voltage.

Is this your observation?

Yes No

Disconnect blue wire at ignition coil. Disconnect connector 25/26.

Disconnect connector 25/26. Set voltmeter to DC volts.
Set voltmeter to read Ohms. Connect red test lead to red ignition coil
Check for continuity on blue wire power wire at connector 25 (see note 1).
between connector 26 and wire Connect black test lead to ground.
terminal at ignition coil (see note 1). With key ON and Run switch activated,
Resistance should be less than 1 Ohm. voltmeter should read battery voltage.

Is continuity present? Does it?

Yes No

No
Yes

Set voltmeter to read Ohms. Replace

Connect red test lead to red
Repair open ignition coil power wire at ignition module.
Stop. in blue wire. connector 26 (see note 1).
Continue at Connect black test lead to ground. 06041
NO START, Meter should read Infinity or ”OL”.
06006
ENGINE CRANKS –
SECTION F Is this your observation?
flow chart.

Yes No

Repair open Repair short to

in red ignition ground in red ignition
coil power wire. coil power wire.

06006 06006
 Note:
NO START,
Section 1) Use appropriate test connector with
ENGINE CRANKS
F leads from RK-03 Pigtail Kit located
(2005 – 2008)
in the Electrical Service Kit
#SK-4000-03.

Disconnect yellow wire at ignition coil.

Set voltmeter to read Ohms.
Check for continuity on yellow wire
between connector 26 and
wire terminal at ignition coil (see note 1).
Resistance should be less than 1 Ohm.
Yes Is continuity present? No

Set voltmeter to read Ohms.

Measure resistance of the primary Repair open
ignition coil. Place one test lead to red in yellow wire.
coil terminal. Place the other lead to
the yellow coil terminal (front cylinder). 06006
Resistance should be 2-4 Ohms.

Is this your observation? Yes

Disconnect blue wire at ignition coil.

No Set voltmeter to read Ohms.
Measure resistance of the
Primary ignition coil. Place one
test lead to red coil terminal.
Place the other test lead to the
Replace blue coil terminal (rear cylinder).
ignition coil. Resistance should be 2-4 Ohms.
Yes
Is this your observation?
06024

Set voltmeter to read Ohms.

No Measure resistance of the
secondary ignition coil.
Place a test lead in each spark plug wire
terminal in the ignition coil.
Resistance should be 12-21K Ohms
(19,000-21,000 Ohms).
Replace
ignition coil. Is this your observation?

06024

Yes No

Replace Replace
ignition module. ignition coil.

06041 06024
 NO START,
Section
ENGINE CRANKS
G
(2005 – 2008)

Remove fuel line from fuel valve.

Attach a drain hose to fuel valve.
Using a suitable container,
check fuel valve for flow.

Is adequate fuel flow present?

No

Yes

Check for a restricted

fuel valve screen.
Yes No
Is screen restricted by debris?
Check condition
of spark plugs.

Are spark plugs OK? Clean fuel

valve screen
Yes
Check for
07010 defective fuel valve
No
Does fuel valve
function properly?

Replace Check for restricted Yes No

fuel line.
spark plugs.
Is fuel line OK?
06044 Fuel
No Yes valve OK.
Replace
fuel valve
07011
07010
Check for restricted
carburetor or
incorrect float level.
Replace
fuel line. Does problem still exist?

07011 Yes
No

Problem is mechanical.
System OK.
Perform compression test.

07015 01001
 Notes:

OIL LIGHT ON - 1) Always recheck oil pressure

NO OIL PRESSURE after any/all repairs.

2) Include an ignition module download

with all engine claims.

Yes
Check oil level in tank.
Verify oil pressure at
No tappet screen fitting
with known
accurate gauge. Remove wire
at oil sender,
Check oil feed Is pressure with key ON touch
lines and within specifications? No wire to ground.
connections. Yes
No Does the light
Are the illuminate?
lines tight? Yes

Replace
Check continuity at the oil pressure
sending unit and sending unit.
Tighten oil lines No the tach board.
and/or fittings.
Remove cam Is there continuity? 01044
cover and
09026 inspect oil Yes
pump drive gear
and keyway.

Is the keyway
sheared?
Repair open Replace
in wiring. tach board.
Yes
06006 06056

Remove cover from

oil pump and inspect
gears and housing
for debris. No
Is there debris present?
Remove oil pump and
inspect for any
No Yes debris that may have
No locked up pump. Yes

Is debris present?

Replace key
and pump gears
as necessary. Remove and Remove and Remove oil tank
replace oil pump. replace oil lines and pump.
Clean and flush lines. pump assembly. Clean as needed Inspect
01031
engine for debris.
01031 01031 Repair as needed.

09026
 Notes:

NOISE 1) Always recheck oil pressure

(CAM CHEST AREA) after any/all repairs.

2) Include an ignition module download

with all engine claims.

Remove lifter
blocks and check
cam endplay.
Refer to BDM
Yes Service Manual No
for specification.

Is endplay
within specification? Remove cam and
replace thrust
Remove cam and washer with proper
pinion gear, then check sized washer.
measurements. Compare
with BDM Service Manual
recommendations to 01030
No ensure gear lash is Yes
within specification.

Is pinion
within specification?
Inspect pinion
gear for cracks.
No Yes
Are cracks
Replace pinion evident?
gear with correct,
measured gear. Replace pinion
gear with correct,
measured gear.
01032 Inspect cam and
bushings for damage.
No Yes
Is there damage? 01032

Replace damaged
Inspect inner cam cam cover or
bearing and cam pinion bushings
Yes for damage. No
Is either damaged? 01028

Inspect pinion
bearing for damage
No
Is there damage?
Replace inner cam
bearing or cam.
Yes

01030
Call Tech
Support

Replace
pinion bearing

01032
 Notes:
NOISE
1) Include an ignition module download
(TOP END
with all engine claims.
ENGINE CYLINDER)

Remove cylinder
head and cylinder.
Inspect piston
for proper
No coating adhesion. Yes

Is coating
coming off?

Inspect piston and

cylinder for
noticeable damage. Replace piston and
Yes
cylinder as a set.
Is there noticeable
damage?
No 01014
01015

Verify piston
and cylinder Yes
No size match. Yes
Do they match?
Inspect cylinder for
indication that piston
Measure cylinder rocks in the cylinder.
and verify it is within Inspect for uneven
specified wear limits. wear marks Yes
throughout cylinder.
Is it within
specification? Are marks present?
Replace piston and
No No
cylinder as a set.

01014
01015
Check wristpins
for wear. Replace piston and
No Yes
Are the cylinder as a set.
wristpins loose?
01014
Check rod side 01015
play, scraper
clearance.
Yes No
Is clearance
within specification?

Refer to NOISE
(CAM CHEST Call Tech
AREA) Support
flow chart.
 Notes:
NOISE
(TOP END ENGINE - 1) Include an ignition module download
ROCKER BOX AREA) with all engine claims.

Verify oil pressure

(using the OIL LIGHT
ON – NO OIL PRESSURE
flow chart).

Verify pushrod
adjustment.
No Yes
Are the pushrods
adjusted correctly?

Readjust
pushrods Check pushrod tubes
for interference.
No Is there evidence of Yes
01003
rubbing inside
pushrod tubes?

True
Remove top pushrods
rocker box cover
and verify oil is
Yes present. No
01003
Is oil present?

Look for restriction

Verify proper in valve train system
rocker arm causing lack of oil.
end play.
Yes No
Is end play 01024
.001 to .015? 01023

Replace
Remove rocker arms rocker arms and
and check bushings recheck endplay.
for wear, per BDM
Yes Service Manual. No 01046
01047
Are bushings
within specification?

Refer to NOISE
(TOP END Replace
ENGINE – rocker arms
HEAD AREA)
Flow Chart. 01046
01047
 Notes:
NOISE
(TOP END ENGINE - 1) Include an ignition module download
HEAD AREA) with all engine claims.

After completing the

Rocker Box Noise
Flow Chart,
remove both
rocker boxes.

Do the valve
No springs have a solid Yes
retaining collar ?

Refer to NOISE
(TOP END
ENGINE
CYLINDER)
flow chart.

Remove heads.
Remove valve springs.
Inspect valve guides.
No Yes
Are the guides
within specification?

Replace cylinder Replace valve

heads with springs with current
factory reworks. S&S springs.

01008 01010
01009 01011
 CLUTCH SLIPPING

Verify clutch Is Adjust clutch per

Yes adjusted per BDM No
Service Manual. BDM Service Manual.

03001

Verify clutch
dome height on
2005 and 2006
models built prior to No
August 8, 2005.

Is height correct? Perform SB-1064.

Replace clutch spring.
2005-2006 models built
Yes prior to Aug 8, 2005.

SB-1064
Verify clutch basket
has correct
bearing carriers. Does clutch
Yes No still slip?
Does the clutch
basket have the
correct carrier?
Replace with updated
style clutch basket.
Replace clutch
disc and plates.
03005

Verify wear on clutch Maintenance

plates and discs.
Yes Is the clutch worn? No

Is stack height 1.93?

Verify ball and ramp are
in good condition.
No Is there any wear or Yes
damage on
ball and ramp?
Replace clutch
disc and plates.

Maintenance
Replace ball
Call Tech and ramp
Support.
03011
 Notes:

PRIMARY NOISE 1) On 2005 models built before July 8, 2005

(2006 – 2008) inspect primary adjustment shoe,
per SB-1059

2) Inspect carrier bearing basket

for cracks on all 2005 models.

Is the correct
No amount of primary Yes
fluid present?

Remove outer
Add the correct primary cover.
amount of fluid.
Yes Is primary No
chain tension
Maintenance adjusted correctly?

Adjust primary chain

Is torque on per SB-1086.
No engine sprocket Yes
nut correct? (2006 Models)

SB-1086

Is torque on clutch
No hub nut correct? Yes

Tighten engine sprocket

nut to recommended
torque specifications.

04013
Inspect primary
Tighten clutch hub chain alignment.
nut to recommended No Yes
torque specifications. Is primary chain
in alignment?

04013

Perform primary chain

alignment, per SB-1074. Call Tech
Shim as needed. Support.
(2005-2006 models built
before Feb 16 2006)

SB-1074
SB-1074 shim
 TRANSMISSION NOISE

Is the correct amount

Yes of fluid present? No

Add the correct

amount of fluid.

Is the noise a grind Maintenance

Yes or gear noise? No

Perform SB-1090
Countershaft Washer
Replacement.
(2005-2006 models built before
July 22, 2006) Is there a
squeal noise
Yes when disengaging No
SB-1090
the clutch?

Perform SB-1065A
Clutch Pushrod Replacement. Call Tech
(2005-2006 models built before Support.
March 23, 2006)

SB-1065A
 TRANSMISSION AND
PRIMARY LEAKS

Transmission
Primary Area Verify Leak Area

Inspect inner or Inspect

outer primary transmission
seal. Replace seals seals.
No Yes Yes No
as needed.
Is leaking Is leaking
evident?. evident?
04012

Inspect starter
Inspect
No Is starter Yes transmission
leaking primary vent tube.
fluid? Yes No
Is vent tube
leaking?
Replace starter

15008 Verify fluid level,

Inspect starter
hole in inner per BDM Inspect transmission
primary. Service Manual. top cover.
Yes No
Is it 2.125 inch Is cover leaking?
Maintenance Verify flatness.
diameter?
No

Inspect
countershaft
seal.
Call Tech
Replace No
Support. Does bike have
inner primary. a shifting issue? Yes

04014 Is seal leaking?

Perform SB-1051A Yes Verify Flatness.

Primary Leak Replace top cover if needed.
Troubleshooting. Verify dowel pins are
(early 2005 models) installed correctly.
Perform SB-1090
SB-1051A
Countershaft Washer Replacement. 02010
(2005-2006 models built
before July 22, 2006)

SB-1090
 Notes:
TRANSMISSION SHIFTING
1) Include an ignition module download
ISSUES
with all engine claims.
(2005 – 2008)

Verify clutch
adjustment, per
Adjust clutch and BDM Service
cable, per BDM No Manual. Yes
Service Manual.
Is clutch adjusted
correctly? No
03001

Inspect shifter arm

and heim joints.
Yes Replace shift rod
Do all components and joints
move freely?
as needed.

Inspect shifter pawl 02001

adjustment.
No Yes
Is adjustment
correct?
Verify SB-1090
Adjust shifter Countershaft Washer
pawl, per BDM Yes Replacement No
Service Manual. has been done.
(2005-2006 models)

02013
Remove transmission top
cover and inspect shift
drum and shift forks.
No Yes
Are there any signs of Perform SB-1090
damage or wear Countershaft Washer
on these parts? Replacement.
(2005-2006 models
built before Jul 22, 2006)
Inspect 1st gear
countershaft to 3rd and SB-1090
4th gears on main shaft Replace damaged
No for clearances. Yes
or worn parts
Are the gears rubbing? as needed.

02007

Remove clutch basket

Call Tech and inspect shim.
No Yes
Support. Has main shaft moved
or is shim damaged.

Replace shim
and related parts
as needed.

03005
 Note:
AIR RIDE SYSTEM 1) Allowable leak down is 10psi in a 24
LEAK DOWN TEST hour period, or 15psi over 200 miles.

Take air system to 100psi.

Starting at the air gauge, coat all
fittings with soap and water.
Yes Check for air bubbles No
at all connections. Inspect air shock
body. Coat with soap
Are there any leaks? and water.
Inspect check
ball area.

Is shock leaking?

Check for loose fittings No

on push type lines. Yes
Be sure the line is cut
straight and is fully Yes
seated onto the connector.

Are leaks evident? Replace

air shock.
Inspect air compressor’s
fittings. Check relief valve 09050
connections. Inspect air
Repair as No manifolds bolt’s.
needed.
Are leaks evident?
No
A16002

Yes

Call Tech Call Tech

Support. Support.

Repair as
needed.

A16002
 AIR RIDE
COMPRESSOR/RELIEF VALVE
INOPERATIVE

Remove seat.
Turn key to ON.
Press Start.
Observe The LEDS Refer to
Yes on the EHC. No
Test D
Is the air ride
mode LED On?

Press the Hi or Lo
button and observe
the EHC.
No Does the air compressor Yes
or air relief valve LED
illuminate when
pressing the buttons?
These LEDs indicate a fault.
Inspect blue wire (A2) from the
harness and the orange wire
from the compressor.
Inspect pins in the connector;
make sure they are fully seated
and are properly crimped.
Inspect the blue and black wires
(A18 and A32) from the relief valve
for loose connections and for a
short to ground.

TEST D Repair wire

as needed.
Cycle key.
Press Run to start motorcycle.
Cycle the Hi/Lo button. No
06006
Does the headlight go
from hi to low?

Replace PCB Boards.

Prior to replacement check
Yes all connections and wiring
from the EHC.

06008
06009
Call Tech
Support.
 Note:
MANIFOLD ABSOLUTE
PRESSURE (MAP) 1) Always clear historic DTCs
BAROMETRIC SENSOR ERROR before retesting.

Unplug the manifold absolute pressure

(MAP) sensor; with key ON, measure the
Voltage Voltage
voltage across connector terminals A
≤ 4.5V ≥ 5.5V
(ground, BK/W) and C (power, R/W).
This must be 5 volts.

Unplug the ECU module,

and verify continuity between There is a short to 12 volts.
MAP connector terminal C and Locate by checking continuity
Voltage between 12 volt power (terminals 13
terminal 14 of the
= 5V and 31 of the ECU module connector)
ECU module connector.
and the MAP connector (terminal C).
Repair as needed.

No
continuity Continuity Jiggle the wires while monitoring the
continuity between terminal A of the MAP
sensor connector and terminal 26 of the ECU
module connector. Repeat this process with
terminals B of the MAP sensor
Repair
Verify the continuity between Connector and terminal 25 of the
harness.
MAP connector terminal A ECU module connector;
and terminal 26 of the also repeat with terminal C of the MAP
06006
ECU module connector. sensor connector and terminal 14
of the ECU module connector. No
intermittent

No
Continuity Intermittent
continuity

With the ECU module and MAP sensor connected and

the key ON, attach a vacuum pump to the pressure
port of the MAP sensor and apply a vacuum.
Repair Replace Repair wiring
Monitor the signal voltage across MAP signal
harness. ECU. as needed.
wire (V/W) and the sensor return wire (BK/W) by
probing through the back side of the MAP connector.
06006 16015 06006
If the MAP sensor is functioning correctly,
the signal will lower as vacuum is applied.

No voltage
change Voltage
change

Relace Replace
MAP sensor ECU.

16006 16015
 Note:

INTAKE AIR TEMPERATURE 1) Always clear historic DTCs

(IAT) SENSOR ERROR before retesting.

Disconnect the IAT sensor.

Measure the resistance across the
two terminals of the sensor’s
Resistance Resistance
connector. At 68F°, the resistance
in range out of range
should be approx. 3750 ohms. At
86F°, the resistance should be
approx. 2400 ohms.

Replace
IAT.
With the sensor disconnected
16004
and key ON, measure the voltage
between the terminals of the Voltage
IAT sensor harness connector. < 4.7V
The voltage must be
approximately 5 volts.

Disconnect the ECU module

Voltage and check the resistance
= 5V between terminal A (GN) of Resistance
the IAT sensor connector < 2 Ohm
and terminal 7 of the
ECU module connector.

Replace
ECU.
Resistance Disconnect the ECU module
16015 > 2 Ohm and check the resistance
Resistance between terminal B (BK) of
> 2 Ohm the IAT sensor connector
and terminal 26 of the
ECU module connector.
Repair
shorted wire.

06006
Repair
shorted wire. Resistance
< 2 Ohm
06006

Replace
IAT.

16004
 Note:

FRONT/REAR INJECTOR 1) Always clear historic DTCs

OPEN OR SHORT CIRCUIT before retesting.

Disconnect the affected

injector connector.
Resistance Measure the resistance Resistance
in range across the injector sensor out of range
terminals. The resistance
should be 10 to 25 ohms.

Replace
Start with ignition ON and key OFF. Injector.
Monitor the voltage between the
terminals of the rear injector connector 16001
Voltage Voltage
while the key is turned ON.
< 12V = 12V
The voltage across the injector terminals
should be the same as battery voltage for
the first two seconds after key ON.

If the voltage remains at battery voltage

After the first two seconds, check the
For a front error, check continuity between resistance between terminal B (GN/GY)
pin B of the injector connector and ECU pin 21. of the injector connector and terminal 10
For a rear error, check continuity between pin B of the ECU module connector.
of the injector connector and ECU pin 19. The resistance should be
greater than 1M Ohm.

Continuity
OK Resistance Resistance
<1m Ohm OK
Open
circuit

Check continuity between

terminal A (Y/GN) of the Repair Replace
injector connector and harness. ECU.
Repair the EFI relay.
harness. 06006 16015

06006
Check the resistance between terminal
Open A (Y/GN) of the injector connector
Continuity Resistance
circuit and terminal 10 of the ECU module
OK OK
connector. The resistance should be
greater than 1M Ohm.

Repair
harness.
Repair Open
06006 harness. circuit

06006
 Note:

ENGINE TEMPERATURE 1) Always clear historic DTCs

SENSOR (ETS) ERROR before retesting.

Disconnect the engine temp sensor.

Measure the resistance across the two
terminals of the sensor’s connector. No
Resistance
At 68°F, the resistance should be Resistance
approx. 3500 ohms. At 86°F, the
resistance should be approx. 2200 ohms.

Check for short between Replace

terminal A and the metal Short ETS.
surface of the sensor.
16004

No Replace
short ETS.

16004

With the sensor

disconnected and key ON,
Disconnect the ECU and
measure the voltage
check the resistance between
between the terminals of Voltage Resistance
terminal B (BK) of the ETS
the engine temp sensor ≠ 5V > 2 Ohm
connector and terminal 26
harness connector.
of the ECU connector.
The voltage must be
approximately 5 volts.

Repair
Resistance short in wire
Voltage ≤ 2 Ohm
06006
= 5V

Check the resistance between

terminal A (Y) of the ETS Resistance
connector and terminal 6 > 2 Ohm
Replace of the ECU connector.
ECU.

16015 Repair
short in wire

06006
Resistance Replace
≤ 2 Ohm ECU.

16015
 Note:

HIGH DUTY CYCLES 1) Always clear historic DTCs

FRONT / REAR before retesting.

Add fuel to vehicle,

Is there fuel in clear historic DTCs,
Yes No
the vehicle? and monitor for any
further DTCs.

Perform fuel
pressure test.

Probable harness fault.

Measure voltage at
Measure voltage at
Pressure Pressure pin A of both injectors. Not
pin B of ignition coil.
low OK This must be 12V
This must be
approximately 12V.
approximately 12V.

Call Tech
Support

12V 12V

Not
12V

Replace Repair wire

ECU. between injector
and coil.
16015 Check continuity
06006 between ignition
coil pin B
and relay.
Continuity

Check continuity
No
between relay
Continuity
and battery.

No
Continuity
Continuity

Repair harness
between coil pin B
and relay.
Repair harness
06006
Check battery between relay
voltage and and battery.
charging system.
06006
 Note:

THROTTLE POSITION 1) Always clear historic DTCs

SENSOR (TPS) ERROR before retesting.

Unplug the TPS sensor and with

key ON, measure the voltage
Voltage Voltage
across connector terminals B
> 5V = 5V
(power, R/W) and A (ground, BK/W).
This must be 5 volts.

There is probably a short Voltage

to 12 volts. Locate by < 4.5V Jiggle the wires while monitoring
checking continuity the continuity between terminal A
between 12 volt power of the TPS connector and
(terminals 13 and 31 of terminal 26 of the ECU module
the ECU module Turn key OFF, unplug the connector. Repeat this process with
connector) and the TPS ECU module, and verify terminals B of the TPS connector
connector (terminal B); continuity between TPS and terminal 14 of the ECU module
repair as needed. connector terminal B and connector; and terminal C of the TPS
terminal 14 of the ECU connector and terminal 24 of the
module connector. ECU module connector.
Verify the continuity between This will determine if there is
06006
TPS connector terminal A an intermittent problem.
and terminal 26 of the
ECU module connector.
No
continuity
Continuity

Repair
Harness. Intermittent
No
06006
intermittent
Replace
ECU.
Repair
16015
Harness.

06006
With the ECU module and TPS sensor
connected and the key ON, monitor
the signal resistance across TPS signal
Resistance wire (terminal C, GY/V) and the sensor return
Resistance Replace
does not wire (terminal A, BK/W) by probing through
increases ECU.
increase the back side of the TPS connector.
If the TPS sensor is functioning correctly,
16015
the resistance will increase as the
throttle position is increased.

Replace
TPS.

16003
 Note:

1) Always clear historic DTCs

CHECK ENGINE before retesting.
LIGHT STATUS

Light Light
on off

Check DTC
list at
service interval.
Check current and
historic DTC list.
Yes No
Are there
DTCs present?

Go to
specific Using Pro Tune ll BDM
DTC select the Test Outputs
flowchart Light function to test the Light
flashes Check Engine light. stays on
The light should flash
for 5 seconds

Disconnect
annunciator/tach ring.
Check for short between
Jiggle the gray gray engine check Open
engine check wire wire and ground.
at the annunciator, Shorted
This should be an
the EHC and open circuit.
Yes No
the ECU.

Does light flash

during jiggle test?
Repair short
to ground.

Repair 06006 Disconnect ECU.

intermittent
harness. No Does the check Yes
Call Tech
Support. engine light
06006 stay on?

Replace
ECU. Call Tech
Support.
16015
 Note:

1) Always clear historic DTCs

STEPPER MOTOR ERROR
before retesting.

Disconnect the IAC and the EFI module. Verify continuity between
terminal A (BE/GN) of the IAC connector and terminal 35 of the ECU
module connector, terminal B (BN/R) of the IAC connector and
Continuity terminal 36 of the ECU module connector, terminal C (BK/PK) of the No
OK IAC connector and terminal 18 of the ECU module connector, continuity
and terminal D (BK/O) of the IAC connector and terminal 17 of
the ECU module connector. Jiggle the wires while verifying
continuity to test for an intermittent problem.

Repair
harness
as needed.
06006
Reconnect IAC And EFI module.
With air cleaner removed, turn Verify actual stepper
ignition ON and observe stepper count is the same as
motor position in throttle body the target with Replace
and monitor the Stepper Position Motion engine off. No stepper motor.
in Pro Tune II BDM. The Stepper Verify IAC within 20 Retest.
Position should go to 0 counts steps of the target
16002
(full out) and then park at 200 at Idle.
counts (full in).

Yes

No
No motion
motion With air cleaner removed, turn
ignition off and observe stepper
motor position in throttle body and
monitor the Stepper Position in Pro
Tune II BDM. The Stepper Position
should go to 0 counts (full out) and Possible ECU
then park at 200 counts (full in). failure.
Call Tech
Using the EFI Software Support.
Test Output of IAC
motor, listen for the
motor to activate.

Replace
stepper motor.
Retest.

16002
 FRONT OR REAR ADAPTIVE
MAXED OUT ERROR

Are any other

No current or historic Yes
DTCs set?

The .BOX file loaded in the VFI module does not

match the given engine configuration. Consult a Perform diagnostics
qualified BDM dealer for an appropriate .BOX file for other DTCs first.
which matches the engine configuration.

BATTERY VOLTAGE ERROR

Voltage Check battery Voltage

< 12.0 V voltage gauge > 12.0 V

Charge battery to
12.5 and recheck OK
for current DTC.

06035
 Note:

STUCK O2 SENSOR ERROR 1) Always clear historic DTCs

(FRONT OR REAR) before retesting.

Using Pro Tune II BDM, monitor the

O2 sensor volts (front & rear)
while the engine is idling.
Voltage
If the voltage is constant but in-range
drops
(0.0 to 1.0V) for 60 seconds,
disconnect the affected oxygen sensor.
Monitor the O2 sensor voltage.

Due to the allowable low voltage (0.00V),

a low voltage as an
open circuit is not detectable.
Voltage stays Use the “Stuck fault” when this occurs. Replace
in range O2 sensor.

16007
16008

Measure the resistance

between the oxygen sensor
Resistance
connector pin 3 and all other
in range
pins. The resistance should be
at least 400 kilohms.

Resistance Replace
< 400 kilohms ECU.

16015

Repair shorted
wires.

06006
 Note:

FRONT OR REAR 1) Always clear historic DTCs

O2 SENSOR ERROR before retesting.

Using Pro Tune ll BDM, monitor the rear O2

sensor volts while the engine is idling. If the
voltage exceeds 1.00V, either the O2 sensor is
faulty or there is a short on the O2 harness.
Turn off engine.

Inspect intake for leaks.

Inspect O2 sensors for
leaks at exhaust.

Disconnect the O2 sensor.

With the engine off and the ECU module
powered on, monitor the O2 sensor volts
No Yes
(front and rear).

Does voltage drop to 0.0V?

Replace
O2 sensor.

16007
16008

Check for continuity

between pin 1 at the O2
connector
No Yes
and ground.

Is continuity present?

Repair Replace
harness ECU

06006 16015
 Note:

FRONT / REAR DUTY 1) Always clear historic DTCs

CYCLES TOO HIGH before retesting.

Check for intake

Are both front and Refer to HIGH
leak on affected
rear duty cycle DUTY CYCLES
cylinder. No Yes
“Too High” FRONT/REAR
faults set? flow chart.
Any leaks?

Yes No

Test rear or front injector

Test rear or front injector using
using Pro Tune II BDM
Repair leak. Pro Tune II BDM test outputs,
test outputs.
Clear historic Yes while monitoring fuel pressure.
DTCs. Compare front and rear pressure
Is affected injector
drops while injectors are actuated.
16010 actuating properly?

Drop .2 or
No < 0.5 psi

Pressure
OK.
Replace
Continued on injector.
next page.
16001

Jiggle the wires at the affected injector

and at the ECU while monitoring
fuel pressure as above.

Was pressure intermittent?

Steady
pressure.
Intermittent

Clear historic DTCs Repair

and monitor for any Harness.
further occurrences.
06006
 Note:
FRONT / REAR DUTY
1) Always clear historic DTCs
CYCLES TOO HIGH
before retesting.
(continued)

Continued from
previous page.

Measure voltage at Pin A of affected

Not
12v injector after turning key ON. This must be
12v
approximately 12 volts for 2 seconds.

For a front error, check

continuity between pin B of the
injector connector and
Probable harness fault.
ECU pin 21.
Measure voltage at
For a rear error, check
12v pin B of ignition coil.
continuity between pin B of the
This must be
injector connector and
approximately 12 volts.
ECU pin 19.
There should be Repair wire
0 ohms resistance. between
injector and coil.
Not
0 Ohms 06006 12v

Not
0 Ohms Check continuity
Continuity
between ignition coil
Replace OK
pin B and relay.
ECU.

16015
Repair
harness
as needed. No
Check continuity between continuity
06006 relay and battery.

Continuity No
Repair harness
OK continuity
between coil pin B
and relay.
06006

Repair harness
Check battery between relay
voltage and and battery.
charging
system. 06006
 Note:

BAD SITES 1) Always clear historic DTCs

(FRONT OR REAR) before retesting.

Are any other Perform

No current or historic Yes diagnostics for
DTCs set? other DTCs first.

Was the vehicle

recently run No
out of fuel?

Is bike still
Yes No
stock?
Yes

oxygen sensor
Put gas in vehicle,
clear DTCs and reset
adaptive maps
using Pro Tune II BDM.
Maintenance
Check both
Sensor
(not OK) If any engine modifications were
connectors.
recently performed, particularly
cam, head, or exhaust changes,
this fault may indicate that
the ECU module cannot
adequately compensate for
Sensor those modifications.
OK

Perform an
Fail Pass
intake leak test.

Perform fuel
Repair Fail
pressure test.
intake leak.

01022 Pass

Identify and repair

source of fuel
pressure failure.
Continued on
next page. 16011
 Note:
BAD SITES
1) Always clear historic DTCs
(FRONT OR REAR)
before retesting.
(continued)

Continued from
previous page.

Using ProTune II BDM,

Positive Negative
read the rear/front
values values
cylinder adaptive maps.

Test affected injector using Pro Tune II

BDM test outputs, while monitoring fuel
pressure. Compare front and rear pressure
drops while injectors are actuated.
Perform a flow test on the affected fuel injector.
Ensure that fuel flow stops crisply when the
injector is closed. If fuel continues to dribble
out of the injector, replace the injector.

No
Pressure
pressure
drops equally
drop
Using the Test Outputs function in Pro Tune II BDM,
test the stepper motor.
Ensure that the pintle moves freely in the bore.
If it does not move freely, remove the stepper motor
Replace injector and clean both the pintle and the bore.
that has lower Replace the stepper motor if cleaning does not
or no pressure drop. return the stepper to proper operation.

16001

Other mechanical issues may be

restricting fuel flow into the engine.
Check items which affect intake valve
actuation, such as camshaft
timing or pushrod adjustment.