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    Varadero 2004 Abs Addendum

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    Varadero 2004 Abs Addendum

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    159 views102 pages
    Manual

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    varadero_2004_abs_addendum

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    159 views102 pages

    Varadero 2004 Abs Addendum

    Uploaded by

    she rif
    Manual

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    © All Rights Reserved
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    TYPE CODE XL1000VA-4 ‘Throughout this manual, the following abbreviations are used to ident individual mode T CODE AREA TYPE: © | EUROPEAN DIRECT SALES. | olin Danmar Span, Belgium, Portugal, tly, Aus, Sweden, Norway, Finlend E | ox teotanad Germany, Ausra, Switzerland, Hollond, A Few Words About Safety Service Information “The sence end reparation contin in thi manual nlended for use by quale, profesional tactician. ‘Atemsting ere or ops wih the prope raning lel, and equipment cou cae gay to you or eer. Kou leo ‘aumage tho hile oceate an Ura conaton “This manual doscrbes he proper methods ad procedures for perforing sovc, maintonance, and pars. Some procedures rogue the we of special designd teas and dodcated equpment. Any person who intends to Use a Yelacemet par, arcs ‘Procedure oe a isnot econmended by Honda, ras etorine the oko We personal sly are slo operation the vehi, you edo replace apart, use genuine Honda parts withthe coect part number or an equvalent part. Wa strongly ecormend ‘at you dort uso replacorant parts ifr quay. Pom cuanto ne Le AWARNING Props and matters a eal oct ety and ‘hovalanty ofthe ele Any ae ov omegh hfe covery awe | IMBUPS erika or pas can cee an Cantos niu open, dogs ota wc eraytochew. | ee concn a cas fou itn ‘ote be sou hat oe For Your Safety Follow the procedures and precautions in this cain te nn tended rhe reas sn tact, we | hen soe mars ati do rot poe wring sa may abe op aby pres fog Hk pies gon yw need ip ig Pot RTT wel confident about your knowledge of sale servicing practice, we CNN feinenonde tou ft earl perm posetuse Gxt’ | rate to propa flow mamas and iavemana Drcnton canton yuts be at ht ‘Some of the most important general service safety precautions are given | % kite. Set nar cana a you ny conte haad at can | Flow he pocetes and pecans ie ‘ton in prating soca ard tpa poate, Gry yuan dacs | ranacarh Str oe you shoud pte ta Important Safety Precautions. . ‘Mako sure you have a lar understanding of al basic shop slay practices and hat you are wearing appropriate clothing and ‘sing salty upmost. When prtorming any serc ask be especialy caret ol he along: “+ Rea a the instructions belre you bgin, and make sue you hav the ols, tho replacement or repair pats, andthe sis reqaredtcparorm he take ese and compet + Protect your ees by using proper sally sas588, goggles or face shi any tne you hammer, il, gd, pry or wrk rcund proseuded aio bls, and springs cher stred-nergy comganani I eres any doubt pl on aye protection + Use oer protective wear when nacestay for xampe gles oF salty shoot. Hang hot or sharp pars can cause severe burs ore: Baore you gab someting al oaks ca Rut you, op and put on goes. + Prec youself and thers whenever you hve th val up inthe ait. Any time you ft the vio, ther wah a hoist o a jak, nate auratat tis uaye securely supported. Use ack tans Mako cur the engi is f bear you bain any servicing procedures, ures the instruction els yu to do cherie ‘This wl Pap ebmiatesovrl pote azar: ‘Buns rom hot parts or cola Let the engine and extaust system cool Bore working In thos areas. + Ine rom moving pas. the nsucton als yu to ran the engine, be sure your hands, agers and cating ro out ofthe way. Gasoline vapors and hyrogon gases rom batarios are explosive, To rduce the poss of re or exposlon, be careful when ‘woking around gasoline oratories + Use nt noelammale sort, not gasoline to clan pats + Never dan stor gasone in an open contains, + Koop all oboe, pars and flames away om the battor ad al uote parts INTRODUCTION ‘This addendum cortans he information for the XL1000V8- Fete toXL1O00V SHOP MANUAL (No G2METSO) for erie procedures and dat ot included inthis eddendum, ‘Your ety, and to eal of terse vary nparian Tohelp youneko isormed decane we have provided sally meseagos and other ifomatontreughout tis manual. OF cours, i nt practical or posible to warm you abou all the hazards assocaled ih senveng bi vee ‘You must us your own good jdgorant ‘You Wil fed irpotant salty oration ina varity of ome incu: + Safety Labels on the vile 1 Sant aeseages"™ preceded bya seoty aot symbol and one et tee signal words, DANGER, WARNING, or CAUTION, ‘Thos signal word moan "You WILL be KILLED or SERIOUSLY HURT if you don folow instructions. ERTIES You CAN be KILLED ox SERIOUSLY HURT you dn follow inarctns ‘You CAN be HURT # you don flow netructons. ‘Inerutons how to serve thi eis correct and sally ‘As you ead this manual, you wl fe irermation hats predod by a[NME] eyo. The purpose ol this message sto help prover damage your vehi, oer property, rhe envionment ‘ALL INFORMATION. ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLIGATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TE OF APPROVAL FOR PRINTING. nds Motor Co. Lis RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WHHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. TH MANUAL Is WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co. La. ‘SERVICE PUBLICATION OFFICE Date of fouo: Ware 2007 ‘Honda Motor Co. Lid 25. XL1000VA-4 ADDENDUM MODEL IDENTIFICATION: GENERAL SPECIFICATIONS. 25-4 ‘CYLINDER HEAD/VALVES COMPONENT LOCATION: LUBRICATION SYSTEM SPECIFICATIONS 25-6 FUEL SYSTEM (Programmed Fuel SPECIFICATIONS. jection) "25-6 COOLING SYSTEM SPECIFICATIONS. CYLINDER HEAD REMOVAL. CYLINDER HEAD INSTALLATION. (CYLINDER HEAD/VALVES SPECIFICATIONS. CLUTCH SPECIFICATIONS. 25-7 ALTERNATOR/STARTER CLUTCH- FRONT WHEEL. 25.35] FORK REAR WHEEL/SUSPENSION COMPONENT LOCATION. REAR WHEEL. 25.54) ‘SHOCK ABSORBER. 25-55 CCRANKCASE/TRANSMISSION ‘ANTL-LOCK BRAKE SYSTEM (ABS) SPECIFICATIONS. SYSTEM DIAGRAM. 25-58 CCRANKSHAFT/21STON/CYLINDER ‘ANTF-LOCK BRAKE SYSTEM (ABS) ‘SPECIFICATIONS. 258 |_| SERVICE INFORMATION. --25-59| FRONT WHEEL/SUSPENSION/STEERING ABS SELF-DIAGNOSIS INFORMATION:--25-60| ‘SPECIFICATIONS. 25-9 BEFORE TROUBLESHOOTING. 25-62 REAR WHEEL/SUSPENSION SPECIFICATIONS: -25-9 | ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING -- 25-64 HYDRAULIC BRAKE SPECIFICATIONS. 25-10 WHEEL SPEED SENSOR -25-86| BATTERY/CHARGING SYSTEM SPECIFICATIONS. 25-10 | [aas MODULATOR maa IGNITION SYSTEM SPECIFICATIONS 25-10 | [aBs CONTROL UNIT ELECTRIC STARTER SPECIFICATIONS- 25-11 | [ BaTTERY/GHARGING SYSTEM DIAGRAM. LGHTS/METERS/SWITCHES SPECIFICATIONS. v0 25-11 REGULATOR/RECTIFIER ENGINE & FRAME TORQUE VALUES 25-12 CABLE & HARNESS ROUTING. v= 25-18 [WIRING DIAGRAMS: ED, E, F, G (English, French, German}: WIRING DIAGRAMS: ED, E,F, G type. (ttalian, Spanish, Dutch)’ XL1000VA-4 ADDENDUM MODEL IDENTIFICATION XL1000VA-4 ADDENDUM “The trot body dentfoation number fs stamped on the front ede of the twotle Body es shown ‘The color label is atached as shown. Wen ordering color-coded ors slweye epacy the casigntod coror code. 25-3 XL1000VA-4 ADDENDUM, GENERAL SPECIFICATIONS — rest ‘SPECIFICATIONS [omens fngth 30000 i) wit ‘830mm (86) height 168 mm (677i) Winosibace {1590 mm (61.4 in) Seat eight 143 mm (3320) Footpag height 338 mm (133m) ‘Ground clearance 181 mm (21 il Dry weight 253 rg (558i) ‘cure worght 272g (600 bs) Maximum weight apechy 201 kg (ois os) FRAME Frame type ‘Biamona Front spension Toloscopic fork Front axla travel 155 rym (6.109) Rear suspension Swingarm Rear aso travel 145 rom (5:70 in) Front tre io ‘oworteNe 9H Rear tire see {SOIR 63H Front te brand ‘TWI0! RADIAL E (Bridgestone) ‘60x Nico) Fear tire brand TWI52 RADIAL (Bridgestone) ‘TEEXA Michoin)| Front brake Hydrol double dise Rear brake Hyareule single dee Cester ang zrao ‘ral ength omm (3) Fusttane capacity 250 Iie (6.60 US gal 560 imp ga [eNane ‘Cylinder arangement tov Bore and soko 98.0 X 65.0 mm (390 X2.60 In) Dieplacoment 996 em? (608 cuin) aa: Chain driven, BOM Intake valve opens at 1 mm{00¢in) i | 18° BTDC coves stTmm{0.08in} i | 30° ABDC Exhaust valve opens tT mm (0.04in) tit | 40° BBOC closes attmm (dein) | 5° ATOC Lubrication system Forced pressure and wet sump Cit pump ype ‘Tornoe Coating eystm Liquid cooled Aiefiteaion (ied pape aloment Engine dy weight 754g (166.2 fs) Firing oder Rear = 480 Front 770" Rear FUELDEIVERY [Type GNI (Programmed Fas injection) SYSTEM Throtle bore 42mm (17 in) [DRIVE TRAIN} Clutch sytor ‘Mateplato, wet Clutch operation system Ceble operating Transmission Constant mesh, speeds Primary reduction ‘ea2 aay Final radation 2930 47716) oar ratio 2571 are) ‘6 are) 11282 (3128), ‘00 30) 0969 8132) 0859 2028) et toot operat return system, TiNs2-3-4-8-6 25-4 XL1000VA-4 ADDENDUM TEM ‘SPECIFICATIONS. TELECTRICAT Stating system Charging systor Lighting system Computercontalied digits! tansetraed wrth electric sdvance Electric starter motor Tiple phase output stornstor EFTitipe pose, ull wave rectification Batary XL1000VA-4 ADDENDUM LUBRICATION SYSTEM SPECIFICATIONS Unit: mm Tew Engine ol [Ata raining ‘STANDARD SERVICE UNIT 34 er EUS at 3.0 Imoatl = tapecty ‘3otier BEUS qe 32impal = [a titer tS qe 38 Imp gt) | [Recommandedengine of Honda stroke olor equivalent motor = | ot [AP sorvceclassfeaton SE, SF oF SG Misco: SAE T0W.a0 | oWrpresa “BEB Pa [60 Kalen, BS pal-at =— $5,000 min® (prion 76-F ‘UII ‘Os (C006) TzTTO row 10.16 - 0271 (0.008 =O006T D5 (0014) ‘802-009 0.001 0008) — 210.005) FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS SPECIFICATIONS “Toi by Kenifieaion nuribar Starwave vacium dierence Base str value fr synchronieatoR (si z0-cis") Fel lnjecion eslstanca (at 20°CI65FL ECT (Engine soTant ternprature] soneorrsisianee ‘Bypateslanoid valve resistance (at 20° CSF] 2-320 AIR solenoid vale resistonc st 20°C8 7 20-2401 ‘CMP (Camshak postion! sensor peak voltage [at 20°C7 ‘OF Viminimar oor KP (Crarkahalt polio) sensor peak vatege at 2% O7 Vian ea Manifold absoiuo pressure at ala m=O AG Fusl posture at 32 B10 (32-37 Egor”, ABB pal, [rss um tow tt 1207 Zien (8.1 US oz, 85 Ip oe irene 10 seconde — "SPECIFCRTIONS | caotaneeapacey Radlator ad engine Zale (.0US g. 28 Img] Reserve tak ‘05 er (05 US a. 0.4 Imo a) Taint ep rT prea TOE=TI? WPA TL = 14 Ree, 16= 20a | Therinoset Bogie pen 75 82°C (167-1807) Fully onset - Oe (sna = Valve if ‘mm (0.3 in minim Recommended anraaee igh qual ativlano glycol anaeze containing cvrsion Drotetion nnibitore owt ture with sm water XL1000VA-4 ADDENDUM CYLINDER HEAD/VALVES SPECIFICATIONS Unit mm in Trew st sevice unit} nda COM PrIOT [SERPS hatter = Vat ca Ww 16 003 ODE OUT nee Feast sessteptesoon = ‘Cemshatt Carn Tobe eight [IN| “exis —| | ‘aesrcist—| Runoue = 0.06 (0.002) —] ‘Oil elesrancs (0020.08 Y-0008 = O.D0R 9.10(0.0041 ve Thar —|Vave tite OD: 33978-38005 13977-13389) 3397 (1397 ae a bore TB 3010 = 34.020 (L9H= 15390) TaN, Valve stem O.. w $075 ~5.000 (0.2352 = 02358) 965 (0.7306) valve guide Ex, 986 ~5.960(0.2948 0.2364), 5.965 0.7344) —| Valve guide 0. | iex | “6.000 = e012 02362 =0 29671 |e. 080 10.2370) eto guide dear [IN ‘2.010 =0.037 (0.0008 = 0.001), ‘00751000901 | fnce eX (0.000 0.047 (0.0008 - 0.0013) — 0.085 (0.00351 Valve gue projeaion above in| 140-142 1086-0.56) =| Serena ive seat wath [IN T= 13 w04—o0sy a7aa7r x 1515 (105 = 006) 1910.07) ‘ala spring foe on 43573, 229 169) [eylindar nad wero = 010 {0.0087 CLUTCH SPECIFICATIONS Unite ing Tre —— ‘STANDARD SERWIce Li) 70-70 88-136) = ‘Spring Wes Tang 761187) “ass —| Disetsknaes ‘372 3.88 (0.148 = O89) 35 (014) Plata warp = (o0raT | crore omer gaiae i "8.000 = 8.008 [i0Re = 17082) ———|~zaa1 (1.1038) [Oo (13770 13976), e965 (1376) Mainshati 0.0: a deh ove guide ‘21960 = 27995 (.i016~ L107 zia70 T1012) ALTERNATOR/STARTER CLUTCH Unit: ee ing TEN ‘STANDARD ‘SERVICE Liar | (Caanecarven garbor 00. SITS 51788 (2.2798 = 277] 57655 (2.2602) | XL1000VA-4 ADDENDUM. CRANKCASE/TRANSMISSION SPECIFICATIONS ni mn i re — STANDARD] sefvice Ln “Wanamianion | Gear 1D. 6M | “L000 = ONG (1.208 = -22TY———|~st.04 (1222) cr [2000 76.021 1.0736 Lo2tl 26:04 1.025) [rezrcarea [33.000 23.025 (12007-13002 33051130 ‘Gear basing OD [ME "20.955 = 30000 (1.2187 = 1.2197] [aoa 1218). [ris | 30,980 = 20.975 12185 = 12185), 3098 1218) (2, 3,04 [32956 - 0.900 (12974 1.2084) 32.85 (1.286) ta baehing [MS ‘0.020 - oer (0808 -0:0024) = doarance cc ‘8.020 0.061 (0.0008 0.0024 = __[-e2.03:ca—| 0020-00070 0008-00028) = / wear ouanng to |-ns 21985 = 7BOVS(10TS= 1020) FBORTOS @ (a.ne6= 30 006 (1805 irersT [soz rez ainenaOD— [at 21967 = 27900 (107 = L106 7196 (01 Courtershatt 0. | atcz 28.960 28975 (1791 = 11801) 289211. J Bushing-shatt — [Me ‘0.005 ~ 0139 0.0002 - 0.0015, = toaranee C2 -Bat0 0.056 (0.0004 -0.0022) = ‘ShiRTore | Fork. ——— 2000-12021 (0728 0.4735 00a forkshat | Caw mistnass 53 ~ 600 (0253-0758) 591028) [Shifter shat. ‘T1967 = 11988 (04707 047721 1195 (0.797 CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS Unit me er ‘STANDARD [SERVICE Una | crankaian [Connecting ra set ‘2W=OIOTHOO = O01. ‘ao (aor8 nour = 0.050 0021, | Main jour Bearing ol clonranes —|-.020 aaa ox0008 0:0015) ‘0.086 (400TeT a ‘96.005 ~ 08.05 (5 8685 - 3.85921 36.10 (3.8622) ‘Out ofround = — [a0 (0008 Teper = '90.1010.0041 ‘wrpage 0.0510 0021, Piston pista 6S = BTaRE (3 8ea= TBST | 97900 (3.85) ings [-akoar=pa oe sao: 2aDTTO SET [2.958 24.000 (0 9448-o.st49) [23.808 f-s0_| Piston topiston in clearance 1.002 - 0.014 (0.0007 = 0.0006) Boas (0.0018) Pastonving end Tos 0.25 040 (001-0016) 35 0022) oP ‘Second | va0=035 2018-0022) 7010028) ay | 07007010008 0127 9010038) fae eit | Paronrngtoiag |Top ‘355 =0,700 (0.002 = 00039 ‘is roo (groove cleerance’_| “Second | oss = 070 (o.001¢ 0.0028) 10.085 (000007, Cylinder isan dlearance ‘0.020 = 1.080 (0.0008 0.0024 10.200(0.00751 ‘Confetng rod smal nd 0: 7020-2404 (0.9457 - OSH [anictng rod piston pin ‘0.020 0047 10.8457 - 09468) 25-8 XL1000VA-4 ADDENDUM. FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS nit mm TEN ‘STANDARD ‘SERVICE LIMIT ria ie wed depth = 151006) ‘Cold re pes- | Dever only — Pa 50 gle, 36 pal = su Driver and passenger 250 Pa (280 ke, 36 pl) = Be noe = ‘cata ‘Wheel in| aa = 201008) runout al 201008) [Wiser beans weight = [eo iio] Fok esa 475773) = wav TU OOS! Honda ula cushion ai TOW oF aque: = Ione Fd Tevel [gh 08 tat (orate) = Fad eapaety—| Right 3 25 em OTE OB US oz, ST = 0.09 Imp or, tate Sil =2 ben WIS =O0SUS az WOE | — 8.09 Imp oa ea boaring preiond 10-15 gf (22-3 = REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm TEM! ‘STANDARD ‘SERVICE Lar] ‘inure ead dpi = 201008) Cold tre pros Driver oaly igen 36 pal = Sure river and pastenger (200k. 41 psi. Tern CACC Wheat rim Ra = 201008) —] uncut ‘Axial = 201008) | Wheat batanca weight = 9 (2:02) max. ‘ive sian Shalak [oo ease race = | [ak sasaozr race Shae 35-45 (F398 1374) ‘Shoak Prostoad adjuster sandard pasion | els from minimum posion absorber 25-9 XL1000VA-4 ADDENDUM. HYDRAULIC BRAKE SPECIFICATIONS we - soe sent tht am Saat re : oes ela seo saws = Seat [ter sine TOS = ‘cry ac nrtd-—| oom = Soto ‘Eten 2 ewan = vet ome seston = yrawrst pte = Sra = fax ore me = sda Sua fra Susieume : ‘saison tr iner ema Sipe oindo'8 — row —| Helos OO a BATTERY/CHARGING SYSTEM SPECIFICATIONS ‘SPECIFICATIONS | eaary 12V 17188 7 Ima mie Fly charged Ta0=132V Need Below 123 ‘Charging curent TAB=R, BSA05R, ‘Atemator — | Capaciy ase 000 min ep} ‘Charging col veinance DOTTY 03-050) IGNITION SYSTEM SPECIFICATIONS we ‘SPECIRCATIONS, Spark lug ard ‘Siandar TOREES INGKT Spark pl 180-090 mm 031 ~0:63STaF————} Ignition col peak varge {ODV minimum CA retaken sensor peak ato (07 Vin Ignite ~ = TO" BTOC ticle 2-10 ELECTRIC STARTER SPECIFICATIONS. XL1000VA-4 ADDENDUM Unie me i = ‘STANDARD, ‘SERVICE LMT ‘Ser ator Bae Tgth s20= 7301047051), 651020) LIGHTS/METERS/SWITCHES SPECIFICATIONS ‘SPECIFICATIONS. [sae Tw =cOWX? = TV =8EWX? | 1-5 ___ aS riswix2 TW WXS 1-5 Instrument IghE TED. “Turn signal indies LED- - High Beam inciestor —0, ‘Neutral nestor eo. ‘Oi pressure inaleatar r ——p PGWLFI malfunction indice Tenmobilzerindestor eb. Faas Mala fuse —2, Sub WAKA, 20AX_30AXT 108 V minimums Tachorntor pea vtage | Thetmosen= = ACBEC (7T6-F] ——————} sorrosstanco~AtY20°C (48 ram Fan motor Start close (ON) 802 C208 P16 teh fp © oper XL1000VA-4 ADDENDUM. ENGINE & FRAME TORQUE VALUES + Torque speifiation etd below are for important festners (thas erould be tightened to standara torque vss listed sbove. nore: 1. Apply sealant to the hoa. 2 Appi lctingagont he threads 3 Sta ‘ od end ange surtece 5 8 AGC beter replace wit 2 now ono 4: opt ease tthe toads 2 Appt teyodonum Sse othe treads and seating surface ENGINE [MAINTENANCE “THREAD | ——~ToROUE rem OTF | pialtmm) | tem tigtm.tny_| REMARKS Sparco z " wei) Ting ae cop 1 “ sei. — | Nore? Crantaat hote ap 1 2 sasm | Note? Engine ol itr cridga : Fy ser) — | NOTES Engine al din bot ja | eam | LUBRICATION “rineAD ToROUE or OY | oinstm) | tem tigtm.tay_|_ REMARKS ‘Oar eee 7 “ See page 2-18 iipumpaesombly bol 6 1303.9) | NOTES FUEL SYSTEM (Programmed Fuel jection r ‘inex | —ronaue 7 re OT | i tm)_|_nemtigtn. rte) | REMARKS ECT [Engin pao Trier sasor 1 2 Basi ‘ 5 101008.0.7 2 3 teas, 23) ‘Starer ve sypvoniation plat screw 2 4 | 2hte2n 15) Stam sav lock ot 2 ” 23i023 10 IMAP ego rock crew 3 5 it035,28) Map sonar crow i ‘ 2A loa 1} actu ose guide rw : a {aero Feel el zy bot ‘ 3 shtoss, 40) Fol ail mounting bolt ‘ 5 Salnss 40) Flat mouming bot —j2] 3 Satass, 80) 25-12 XL1000VA-4 ADDENDUM ERGNE MOORE - “ew Terex] —rorave = TY | DiA.tmm)_| Nm gt, tse) | REMARKS: “oes Ne pre aoe ADNAN TORQUE reManKs | | vem [Nem (gt, tof) ‘s Hae Ren TEE Sg ores Shion neo soa ok Bass | nore? com htertge bo Reva | homes ninarrecorerbon auton awn feng ‘enz3) | novezs Ee stidet an | Nore? Com soc bot woieore) | NTE Sneha dbl eho pp su bot) seit crew oy | eR] —rorove _ 07 | oct) | managtm tn) | PEMARKS pring Ba spe whee utc ot ut + | | pisos | nose Sitar veneer bot :| isi” | NoreZ inate ga bot Pl 8 Shee | eres GEARsHFT LAs = EK] 090 rea] mew TY | ik towm)_| Neen gn, ott) 6 Sue ssa a 7-48 See oTeZ Suns apna or ng rls | Beem | CRANKCASERANSMISSION ee - Tana] —rorave OTY | DIA. mm)_|_ Nem tage, tse) | REMARKS cranes ba a ara oe nS ote s anes fongebot ‘| « souaa eereeamtcraea’ ok >| 8 usin | ores eimai set pos Bein | Nore? CRanKSHAFTISTON/CTLNDER Tnx —rorave _ eM OY | pia (mm)_| Nem kgm, totte) | REMARKS | | eamraainaroaa eg Noree | Sie 71s Stoa2d | NOTE? | BATTERV/cHARGING SSE s Teneo —Torave ro ory | ota tm | matte) | PEMARHS aoa Ta 7 geal | WoTEe Strraneiny sc sot ot | 3 Sein | NOTE? peers s| 3 pea XL1000VA-4 ADDENDUM. ienmow system — THREAD “TORQUE rem OY | otAtmm)_|_ nm ttm. torey_| REMARKS ‘CRP [Gaalshat postion) sensor flange bal 3 mz 3) NOTED ELECTRIC STARTER ~ . THREAD. TORQUE eM OY | prv.tmm) | nm tgtm. tore) | REMARKS Saree or aaa nat r . Ott.) LUHTSmerERs/swircHES sag THREAD. TORQUE OT | pinto) | nmi REMARKS EOP TERS BraaSarT oT T Pri "2 Note EOP (Engine ll pressure itch trminalserow 1 4 2010214) Neural uit 1 1212.8) (i fer bose 6-170 (083-07 ny Exhaust pipe stud bolt: = 385408 mm (1.58004 in) 21520 mm 0.850.041) XL1000VA-4 ADDENDUM FRAME FRAN B00 PANELS/EXHAUST SYSTEM nea] —ronave em OT | out mm) | mem agen nen) | REMARKS Tae a = ve Mate on Upper co! stay ower mounting bot 3 0 wies33) Upper com! sty mounting mit heed pe) i ° Doan Echo peer a ; wae) | for exit ip band bol : a nen aor ard ba 2 ‘ seen) rust evsrem sine] —ronave _ rm Ov | oiatm | nantigio, ty | REMARES | ar tar eap bt ze ones Fuel hoe rj ok el pum sis) | 2 naa) penn 2 | & nas Fuel oct lover ere 2 : estoos.07) ‘tunel cow 4 : otasa: 90) rousg rw : i 28 loas. 18) I ep say) : ‘ was ‘CooL sysTEM rc 7 ToRGUE = ne on | |_wmtigtmanens | romans | coat Be OTT a +} teaz0 Fen note bce meuntng bot 2 “aioase) Fen motor mouning elt 3 As(os 26) | Fan motor ewer i nina | thermosensor 1 1010.7), NOTE 1 Enaine wounTia ‘ineaD | —ronave { nem Ty | om tmm | wont) | REMARKS era ge GS TAT T i weean | Engine nanger ange nt) 1 1 cienan Engine ange ngs bok (2) 2 io soz | Showtine tema mt 2) : atesan | Shoat ink bac nt rm) : i 7alns. 50 FRONT WHEEL/SUSPENSION/STEENING r— ‘nea —]—yoRaue [ re OT | out tmm | wantigtm, torn) | REMARKS ano WT TOURS BST 2 ¢ aati. | NOTES | Throttle housing screw. 2 5 410.42, 30) | Ghat ever pest i 8 antes. 0) Nandlbar upper ld bot a ® ‘lea 20) | Front asi bot : te Sioa) i] 8 Bes i} a} oe Beam — | noree Fereocet bot : 8 | Beem — | Nore Ferkeop 2 ® a Fork rper odlck mt (XL1000VA) i ® | Seen Stoning som at 1 2 123 908.99 Swing beeing eng ut 1 ae ‘ete aay String bearing ating muta ut 1 2 - Fork op tig ech bt ‘ : naa.) rk boom Spe pind bot ‘ & sila) BT XL1000VA-4 ADDENDUM, REAR WHEL/SUSPENOOH : sex] —rorave few TY | tA. fomm)_| Neem thgtim, Noe) ae tara a 7S Bee NOTES Fria spot : | a tein. for bra dc bot : : “auaan | Noree Sninoum svt ut | 8 siege | nores Since ier sew 2 : avasiao | Nore? Stok asrbr ver mountg mut i | ot ‘olson | NOTES Stork srrber aa mung nat 1 ° flesy | nores Stes ite taken |b seas) | noes Sst tr chou nt ple rut 1 ” lesan | ores See i ae ite missy | noes HYDRAULIC BRAKE sex] —rorave few TY | UA. fonm)_| Nem (ag-m, oe) REMARKS Fon nie Sine ea Sp ow 7 t Tere t Front mat ne hola bok i : wae | ont re over pot ot i : sbascan | Front tever po 1 : soca Front rt vr sjsor 1 5 Sboa a, Front rte it wt ow 1 i tie 08) Fg wet ke cpr mrtg bot 2 3 S22 | nore {ak hort bake cape’ prott i : Haze. | noree Lehre cape’ bok bcaindmasteroind | 1 : heza —| hore Caliper ody 8 ot 3 3 dese | heres Fromcelpe min sie pin 2 | 2 Beat Front celpr sub lds nn 3 : “ais. fran 3 | * eta Bra cspersleodvave : : soa 40) Scene materia push od rat : : serie) | Soin mat eyndar coma 1 ° betta. fear mor int moun bl 2 ° ‘ener Fatma’ finesse motng bol i : tia fear man hiner pod na 1 : eter) | foermater finer tocmecirhsejonscew | 1 ‘ weioasnn | Nove2 | brates oboe n | i 28) | fates ae P| of tra — | nowes Brae fn ray ot 2 : me Brak ee gue bk 3 ° sation Enty wave ota tt 3 ° wee Fev repeal tela) mauningsot | 2 : maa 8s ronave om TV | WA. fmm) _| Nm tag, Es) REMARKS oni ws pag na Ba z : serstr For walple ing moore 3 : satan ae a] & Sine oo ‘owmion system Trem wen ORO | REARS aig al aga pet —| LUcrT/METERS/SvATCNES sexo] —ronoue rem TY | WA. fom) _| Nim tgs, ett) =— ils ch BOE 7 . seo odsmowe ever | * aa (lion Sb onting Bo 2 : mier2 Bie CSS... XL1000VA- ADDENDUM OTHERS “THREAD | TORQUE Tat TY | tact | _Wantegten my) _| REMARKS de wand pvat bo T 0 3B (10,7) Side stand pivot mut 1 0 120,22) {Change pedal ble 1 e Footpeg bracket alt 2 2 39140, 20) Bank angle eens bolt 2 8 98(10,7) Bear tur signal wit nut 2 10 4910836) XL1000VA-4 ADDENDUM. CABLE & HARNESS ROUTING TURN SIGNAL RELAY HEADLIGHT RELAY (Hi) ENGINE STOP RELAY HEADUGHT RELAY (Lo CHOKE CABLE THROTTLE CABLES 3 FRONT ERAKE HOSE BANK ANGLE SENSOR 7 riGuTHaNoLenan ~ [ SwiTon WRE nmosiuzen RECEIVER WIRE DELAY VALVE HEADLIGHT CONNECTORS CLUTCH CABLE FUEL CUT-OFF RELAY LEFT HANDLEBAR ‘SWITCH WIRE Tenmon SWITCH WoRE HORN ~ POSTION uGHT Bm |. XL1000VA-4 ADDENDUM Q Ny 1ONT WHEEL SPEED SENSOR 2P (ORANGE) CONNECTOR 5-1: XL1000VA-4 ADDENDUM FRONT BRAKE HOSE FIGHTHANDLEBAR SWITCH WIRE immoaiuzen ‘wine BAND’ RECEIVER WIRE FAN MoTOR swaTcH 2 > (BLACK) CONNECTOR FAN MOTOR SwHTeR WIRE RIGHT FRONT BRAKE SUB HOSE FRONT WHEEL SPEED SENSOR WRE 5-20 XL1000VA-4 ADDENDUM. XL1000VA-4 ADDENDUM. LEFT FRONT BRAKE MAIN HOSE 5-22 XL1000VA-4 ADDENDUM FUELTANK OVERFLOW Hose FUEL TANK FUELTANKAIR BREATHER HOSE RAN HOSE REGULATOR TynoTTLe goby suB- RECTIFER WIRE HARNESS ab CONNECTOR REARIGNMONCONL 2° CONNECTOR auteanafor cor swricn Spark PLUG wire wire Sesenson wine (GTvee ONLY) neurRat switcH SIDE STAND SWITCH WIRE ‘STARTER MOTOR CABLE XL1000VA-4 ADDENDUM. FUELTANKAR RAIN HOSE. FUEL TANK [OVERFLOW HOSE BREATHER HOSE Pet PUMP wine waren PUMP. ‘OVERFLOW HOSE FEL TANK FUEL TANK. OVERFLOW HOSE BREATHER HOSE uel FEED HOSE RADIATOR OVERFLOW Hose XL1000VA-4 ADDENDUM, BP CONNECTOR RADIATOR SIPHON HOSE ‘CNP SENSOR 2° (BLACK) CONNECTOR CCRANKCASE BREATHER HOSE PAIR CHECK VALVE HOSE tuRorite sro Ror RADIATOR rear araxé swrrcn wine CONTROLKNOR (OVERFLOW Hose FUELHOSE ‘waren PuMP: FueL RESERVE * SENSOR WIRES 25-25 XL1000VA-4 ADDENDUM 25-26 XL1000VA-4 ADDENDUM ImMosiLzen RECEIVER AP CONNECTOR FRONT SPARK PLUG WIRE FRONT WHEEL SPEED SENSOR VACUUM HOSE. 2P [ORANGE] CONNECTOR XN FRONTIGNITION g Coit CONNECTOR ‘ re seusonae | TW {BLACKS CONNECTOR = ‘CMPSENSOR 2P (BLACK) 7; = CONNECTOR CCRANKCASE BREATHER = r HOSE FRONT) | THamecasies PAIR CHECK VALVE ‘CHOKE CABLE BP CONNECTOR laTsenson 2p hy. CCRANKCASE BREATHER (CONNECTOR I Hose (REAR) TuRoTmLeacoy SUBHARNESS t FUELTANKBREATHER Hose Mar seNson’ SPCONNECTOR FUELTANKOVERFLOW Hose SS ) PAIR CHECK VALVE HOSE MAIN wine HARNESS FUELTANK AIR Rain HOSE, 25-27 XL1000VA-4 ADDENDUM. EotNgeron REAR WHEEL SPEEDSENSOR ean ags unt 2P (GRAY) CONNECTOR EAR BRAKE SWITCH WIRE REAR BRAKE SUBHOSE REAR ERAKE RAR MASTER MAN HOSE (CYUNDER HOSE XL1000VA-4 ADDENDUM CONVERTER UNIT Fuse 80x BATTERY POSITIVE x} CABLE svaRTER RELAY Sve BATTERY NEGATWE. Crcaste REGULATOR! RECTINER WIRE BPCONNECTOR ALTERNATOR WIRE EAR BRAKE SUB HOSE EAR WHEEL SPEED ‘SENSOR Wine REAR BRAKE MAIN HOSE 25-29 XL1000VA-4 ADDENDUM. BRAKE HOSE/PIPE ROUTING FRONT MASTER CYLINDER PROPORTIONAL CONTROL VALVE SECONDARY MASTER CYLINDER REAR BRAKE CALIPER REAR MASTER CYLINDER AIGHT BRAKE CALIPER LEFT aRANE CAUPER XL1000VA-4 ADDENDUM CYLINDER HEAD/VALVES COMPONENT LOCATION 8.8Nm (1.0 kgf, 71) 53Nm(54kofm, 39 1661 XL1000VA-4 ADDENDUM. CYLINDER HEAD REMOVAL (oven 0m Font ne Remove the following = Throttle body (page 5-60) = Cora 8) = Cam chatn tenconer titer (page 8.32) ‘Remove the SH bolts and water joint rom the ey: Indor head. Looten the screw and remove the throttle body Ineulaton Remove the two 6 mm flange bol Remove thes 10 mm bots Remove the cylinder head. Remove the gasket, dowel pins and special collar Remove the flywheel page 105) Remove the Bolt nd front cam cheln guide and col Remove the bolt front cam chin tensioner and co Femove the ent com chain XL1000VA-4 ADDENDUM Taarcynaor Remove the primary dive goer (page 18) omove he bolt and rar cam cain guide femave the bot amove the front and rear cam ehsine and timing ‘sprocket rom the crenkshat ‘emave the rear cam chain, CYLINDER HEAD INSTALLATION Fewroindr tl the cam cheln onto the timing sprocket ‘tal ho eam chan gulde and bolt ‘tall ho eam chan fonsiona collar, tnsionor and tore “ighen the cam, chain, guide and cam chain sarsloner bata the specified torque TORQUE: ‘Cam chain tensioner bolt 123 Nem (23 kgm, 1716) Cam chain guide bot 23 Nem (23 gsm, 17 bt) Install th primary drive gear (page 8-1) Frentevinse Install tha cam chain onto an ‘Tighton tho, cam chain guido and cam chain ‘mnsioner bolts othe specifi torque ‘orave: ‘Cam chain tonsoner bot: "23 Nem (23 kgf, 71) ‘com chein guide bolt 25 Nm (23 hgtim, 17 ER ‘neal he Myo! (page 109) ‘neal a now gasket end dow pins ‘etal the speci colar with te Oring sida feing op. [CAM CHAIN GUIDE PT [CAM CHAIN GUIDE” XL1000VA-4 ADDENDUM. the eytinder heed anta the eyinde Block, ‘Apply oll to the threads and seating surfeca ofthe TORQUE: 53 (5.4 kfm, 391664) ‘Tighten the 6mm flange bots securly. Install @ new zing into the groove of the wa hose joint Install the wator joint to the cylinder head, then Install nd ighten the bok Instal the throttle body insulator with the ‘UP! mark. rms acing out and up so thet tho tab i postonod as || "UP! MARK. shown, XL1000VA-4 ADDENDUM FRONT WHEEL DISASSEMBLY FRONT PULSER RING REMOVAL emnove the front wee page 19-18), emove the bolts and front pulser ring from the gn wheal bub, Disessembe front wheel (page 18-18) FRONT PULSER FING XL1000VA-4 ADDENDUM. "ASSEMBLY 69m (07 kgfm, 5:1 foHt) ‘RIGHT DUST SEAL DISTANCE COLLAR Terr weet, BEARING (6208 UU) FRONT LEFT BRAKE DISC PULSERRING FIGHT aRAKE DISC sais ver ousr ea. FIGHT WHEEL BEARING (6204 UU) P aon mizorgtm 14010) FRONT PULSER RING INSTALLATION ‘Assemble tho tront whoo! page 1318). Install to front pulser rng onto the ight wheel hub, thon tighten the new bolts tothe spaced torque. TORQUE: 69 1 (07 kgm, 5.1 tt) Insta ho front whoo page 1320. XL1000VA-4 ADDENDUM FORK DISASSEMBLY Rorovo the fork (page 13-21, FIGHT FORK crf otto Remove the fork cap from the fork tbe, “somo too omove the spring collar and spring seat rom the = fork tube. Femove the frk spring rom the fork tube. our out the fork id by pumping the fork tube sev- bra nas ‘old he ork sder ina vice with so jams or sho emove the fork socket bolt and sealing washer XL1000VA- ADDENDUM. sles i rece sy reece wih Yan ae srg ‘ce Remove the dust 0 Remove the oil es stopper ing. eck that the fork tbe moves smoothly in the fork It Ts does not, check the fork tube for bending or ‘damage, and bushings fr wear or damage. ul he fork tube out until you fot resistance from {ser bushing’ then mave tin and out oppng the bushing ligmiy ‘ntl the Tork tube Separates {tom ta fork shor ‘The slider bushing wil be forced out by the fork {ube bushing XL1000VA-4 ADDENDUM FORK TUBE FORK SUDER < lL Lock Piece Femove ne ise backupring and ier bushing Ser NT ‘Back UP AING. not remove the Carfuly remove the frk tube bushing by prying ‘erase mshng_ the at witha srowdriver unl the bushing ean be ras tncessary pled off by hand. Teverce wi FORK TUBE'SUSHING LEFT FORK. ‘cfu otto Remove the fork cap fom the fork tube ‘om ot FORK CAP i | Fok Tose XL1000VA-4 ADDENDUM Hold the damper rod with @ 14 mam opan ‘ranch, then loosen the damper rod Tock mit and Famove ha forceap om the damper rod. 3 ZZ f FORK CAP Remove the spring seat and fork spring Pour outthe fork ula by purmping the fork tube sav- tral mos, Pour ut the fork fd fom the fork dampor by ‘pumping the damper od several times. Troan FORK SPRING ‘SPRING SEAT Hold he fork sider in a Vie with softjowe oF# shop towel ‘tio fepcon Ramave the fork socket bolt and sealing washer. pe ecto worn a Troan sorry sn te, FORK SOCKET BOLTISEALING WASHER Remove the fork damper assembly and oll lock pe from the fork tuba, FORK DAMPER FORK TUBE on. Lock piece en Remove te dust soa Remove the ol sel stopper rng. Sock thatthe fork tube moves smoothly inthe fork doesnot, check the fork tube for bending ‘he bushing lightiy until the fork tube seperatos ‘Tomine orcaider dar bushing will be foresd out bythe fork flamove th ol oa, bac-up rng and sider bushing ‘Tom the fork tbe XL1000VA-4 ADDENDUM XL1000VA- ADDENDUM. Tone ne Carty rove tm GA lp Fosng BY BRD ‘ctcobang thet wha etewarvr unt he husky oe vtec pido hod omar INSPECTION Fork spring "Measure the fork spring fre length [SERVICE LIM, 475.7 mm (18.73 in) ca Fork tube/tider ‘check the fork tube and fork sider for score marks, Scratches or oxcesive or abnormal weer Replace sn components which are worn or dam aged, Fork piston Right fork) {Check the for piston ing for woar or damage. {Check the rebound spring fr fatigue or damage. Replace the component i aceesay. Tork daraper (Lat for) {heck the fork damper for damage. Pace the fork tubs in Viblock and messure the Setal runout is 172 he total indestor reading, Replace the fork damper assembly, if any compo rent ee damaged, SERVICE LIMTE 0.20 mm (0.008) Fork tbe bushing Surface appears on more than 38 ofthe entre sur Chack the beccup ing: replace tthe tation atthe points shown, ny XL1000VA-4 ADDENDUM FORK DAMPER FORK TUBE BUSHING BACK-UP RING Heck Yomnrs: ‘COPPER SURFACES XL1000VA-4 ADDENDUM "ASSEMBLY RIGHT FORK FORK CAP 22Nmi22 BACK-UP RING geen 181) ouroerrece Pre fe / FORK SUDER. ‘SPRING COLLAR Phin sear 4 FORK PISTON RING PORK PISTON REBOUND SPRING FORK SPRING zonm(2oxgtm, vine — BP ork Tuse BUSHING Betoraassombly, wash al pats with a high fash or nom ammeble solvent and wipe them Sy aot js te. Intl the new frk taba bushing being earl no to ishing sme damage the coating of the bushing it has been ‘ronnocasry removed Remove the bur from the bushing mating surface, Soing earful nt to pas of the coating ® ronx Wee ausuns ‘Appl fork oil to the new ol ei. ‘ess neot sex Install the slider bushing, back-up ring and naw oll Peay SEAL suDER BUSHING BACK-UP AING 25-44 XL1000VA-4 ADDENDUM, ork be, Install the fek tae into the Tok dor. Drive the ol oa in using the special tools. Toots: Slider weight o7earxasor00 Oil eea ever 7947 KA40200 Insta the stopper ring Into the fork sider groove cual, Intall the dust al, XL1000VA-4 ADDENDUM. Tnsal ho rebound spring the fork piston Insta ho for pletion Into the fork tbe. ene [REBOUND SPRING Hold the ane holder in 8 vise with soft jaws or & reese Tone fork socket bo te seed oie er eee TORQUE 20 Ne 20g, 116 ree iota Pour the spectod amount of recommended fork fui into the forte RECOMMENDED FORK FLULD: Honda ultra cushion oll OW or equivalent FORK FLUID CAPACITY: Daur ZB em (162 0.08 US oF, 690.09 Pump tho fork tubo sovorl ties. XL1000VA-4 ADDENDUM ‘Bearesne odin’ estore the of level fom the tp of the fork be ‘Sthesome nto hla compressing the tube a the ey after sok non Ing the ork tube slow more than times: FORK OWL LEVEL: 103 mm (4.1 in) Pull he fork tube up and int the tapered end facing down, the fork spring with Install he spring seat and cola. Install ne O-ring onto the for cap. ‘Apply for Mud tha naw O-ring Toten a kes lntall the fork cap int the fork tb. ‘ter singe ‘ern ne ne ‘erase } —_ ‘TAPERED END ‘SPRING SEAT [|] SPRING COLLAR XL1000VA-4 ADDENDUM. LEFT FORK BP onsen ——_STOPPERRING —DUSTSEAL ag umm (2 04ghm, 7 rd To. Sencar 22Nmi22 gt 161 BACKUP RING OIL Lock RIECE She sear ror ruse SOS | Fork oaMER ron ruee / Fork sins 20m OKs, 14166) SSP FonK TUBE BUSHING REBOUND SPRING Betore assembly, wash al parts with 2 high flash or ‘om flammabie solvent and wipe them dry. to rotonn de Install te new fork tube bushing being earful no to iehng stmere damage the coating of te bushing iit has been ‘onnacnsay, romoved. Remove th burs from the bushing mating sutace, bing earful notte pool ff the coating Drone tse pusHiNs eres BACK-UP RING ‘Appl fork it the new ot 8 ip. stot eo ea! natal the alder bushing, backup ting and new ol Twehtemand Sel anta the fork tube. FORK TUBE SIDER BUSHING re XL1000VA-4 ADDENDUM Trea the fork tube tote fork sider ‘rive the ol seal in using the special tots. roots: Sider weight o7ee7-Kasor0o Oi seal crver (raarkaez00 SIDER BUSHING ‘nsal the stopper ring into the fork slider groove ‘eure. ‘retall he dust soa, XL1000VA-4 ADDENDUM. Insta tho ol lock place and for damper Into the fork abe Hol e axle holder in vse with soft jaws or shop towel and apply @ locking agent to the fork sockot { ‘yo expsten Tightan the fork socket bolt othe specified torque, wre Stolerbot TORQUE: 20 Nem (2.0 kgf, 18 tt) semeecoet Pour the spected amount of recommended fork ‘dina the fork tube RECOMMENDED FORK FLUID: onda ula cushion oll 10W or equivalent FORK FLUID CAPACITY. BH LPS em! 929. C00US 0, 100 6001p os) Pump the fork damper ro saver ti Slowly pump te fork ube several times em “FORK SOcKET BOLTISEALING WASHER 25-50 XL1000VA-4 ADDENDUM ‘Benretie ler) Mossure th ol level from the top of the fork tbe ‘Sthesane ne while compreasing the tube al the way afer rok a ons, ing the fork pipe slowly mare thn 8 ime FORK ON LEVEL: 114 mm (4 in) 114 mm(as in) Pull the fork tube up and install he fork spring with the pera end facing down. omy ‘TAPERED END Screw the damper od lock nut in fly by hand wire Lock NUT Pull up the fork darmpor rod using apace of wite ‘atl the spring seat SPRING SEAT instal naw Ong ont the fork cap, ppl fork ts othe new O-ring. moms FORK CAP Instal th fork cop tothe demper rod until it seat on the dempar rod lock nut. Fold the fork cap and tighton tho dampar lock aut to ‘he sectid torque. TORQUE: 20.Nen 20 Ryton, 14) Dbawren ROD Lock WUT 25-51 XL1000VA-4 ADDENDUM Tver ft apts he ork cap i he ot abe ‘eye ata te fork (age 1222 ‘ove FORK CAP 25-52 XL1000VA-4 ADDENDUM REAR WHEEL/SUSPENSION COMPONENT LOCATION 58. (G0 kgf, 491668) 83.Nem (9.5 kgm, 69 HF) TON (t.Okgtem, 7 oF 83 Nem (8.5 kat, 68) 5-53 XL1000VA-4 ADDENDUM. REAR WHEEL DISASSEMBLY REAR PULSER RING REMOVAL Remove he rear wheal page 14-0, Remove the bots and rear pulsar ing tom he right whos ab. Disassemble the ear wheel page 147. ASSEMBLY BP zy (43 tm 31 HH Ox REAR PULSER FING (as = 31 nd DISTANCE COLLAR bawPen nuBiEA coat DAIVENFLANGE FINAL ORIVEN sPROCKE' 208 Nn (11.0 kg, AO) 5-54 XL1000VA-4 ADDENDUM REAR PULSER RING INSTALLATION ‘Assemble the rer whee! (page 14-9), pulse ring onto the right wheel hub, 1 new bots tthe spectedtoraue, ‘TORQUE: 8.8 Nm (08 kgf, 6 Io) Inetal the rear whee! page 14-1), SHOCK ABSORBER Remove the side cover (page 2-2, Remove the fuol nk (page 85) Remove the rear ABS modulator (page 25-01), Becwetuleetto Ramove the serew, adjuster knob, locking ball lesetetckig a ring. asoine Remove the bolt end pf frame Disconnact the starter motor cable fom the starter lay sve (page 18-14). Aamova the adjustr hose from thei TADJUSTER HOSE. XL1000VA-4 ADDENDUM Remove the shock absorber lower mounting bol hot and shor nto shock ink plate bltnut FSrockUNKTOSHOCK LINK PLATE BOLTNUT Remove the upper mounting bolunut and shock sbrorber. INSTALLATION Install he shock sbsorbar Into the frame with the ‘juste hose oi facing to tho right Install tha upper mounting bolt and nut and tighten the upper mounting nut othe spaced torque. TORQUE: 59. (6.0 gm, 43 EA) Install the shock absorber lower mounting bolt and tighten the Tower mounting nut to Tho specified ‘Shock unrTO sock torque, Link PLATE BOLTINUT TORQUE: 44 Nim (45 hgfom, 3 it) TORQUE: 46 Nm (45 kgm, 33 FA) {LOWER MOUNTING BOLTINUT XL1000VA-4 ADDENDUM. Insta the adjuster hose to the clamp securely ‘Connect the starter motor cable to the starter relay sch (page 1814). Install he proto adjuster to the frame and tighten the bolt securely secret mata te ging ond fck bat imo te preoes [I AouusTER roe, LoCKNG PAL” Sra Loerie a auster body. ‘massing nel the pretoad adjuster knob while pushing the tok bal Geen and spply locking agent to the scrow ‘heads etal and tghten te srow securely. Ine he side cover (nage 2 Inetal the fel tank page 6-6) XL1000VA- ADDENDUM. ANTI-LOCK BRAKE SYSTEM (ABS) SYSTEM DIAGRAM REAR WHEEL GPEED SENSOR FRONT WHEEL SPEED SENSOR ut XL1000VA-4 ADDENDUM ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION GENERAL + This section covers servic ofthe Antck Brake Systom (ABS). For other sorvice ofthe conventional brake (page 25-00, + Vinen the ABS contol unit detects problem, It stops the ABS function and switches beck to the conventional bra {2peradon, and tie ABS indistor Dlnksorstaye'on Toke care during te teat de ‘roubles not reauting trom a faulty ABS (e.g. brake dsetquosk, unevenly worn brake pad) cannat be recognized by the 88 dlopnosis stom. + Read "ABS rlt-hagnosis information” and ‘afore Toubleshoating” carefully, inspect and troubleshoot the ABS oye {em according 1 the Diagnostic Troubleshooting Flow Chart Observe eechstap of the procedures one by one, Wats ‘down the problem code end probe felty pant before sterting ciegnosis end aubleshooting, + ‘Akar oubleaheoting, erase the falure code and perform the pre-str setclagnosi tobe sure thatthe ABS indeator i rf ot to daa the whee speed sensor and pulser ing whan removing and installing the whesl or sped sen ‘inen the wheel speed sensor andor pulsar ing ie replaced, check the claranca (ar gap) between bath components. ‘Tho ABS contd unt may ba damaged If dropped. Also i's connector is disconnested when current lowing, the xcoeaive voltage may damage tha EM. Aly mn itch before srvcing, ‘Bo not eigaseomble te ABS modulate. Replace tha modulate as on saserniy when is aly. Betorto ret lagram of ABS (page 25-08) ‘The flowing color codes are used throughout his section. Bo =Bive G=creen Lp=LightGrean R= Red l= Back Gre Gray O Orange, We Wits BraBrowm — Lb=Lightlue Pink Yvon TORQUE VALUES Front whee! pulsing mounting bolt Nm (O7kgim,S.1IbER) _ALOC bot replace with a new one Rear whee! pulsrring mounting bolt 8ENm{OGkgim, 6S lot} ALO bot replace witha naw one Brake hose ll lt 34 Nem (35 kat, 25 oF XL1000VA-4 ADDENDUM. ABS SELF-DIAGNOSIS INFORMATION SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM + The ABS prestatsttlagnsis syste dagnoses he lca yet a wl ‘hon ter is any abnormality, the problom and nosis scompleteds ne Ha prosiom tisgnons ‘led retieval procedure (page 25-64) tne operating stats of tho module- problematic part can be detected by outputing the flue code ed spend of 1D urn (8 mph) inleaing that he age rider of the problem. The sat suo ON enone une sen pL sere sr west . Scan ore I = PRE-START SELF-DIAGNOSIS PROCEDURE (Dally check) 1. Tur th gation switch 1 “ON 2 Make 4 Star the engine 4 fie ts malarcyde and ners he veil psed 0 approximately 10 kn 16 moh estat et agnoas com pista $e ABS fe normal the ABS Indlestor go ot 25-60 XL1000VA-4 ADDENDUM ‘SELF-DIAGNOSIS PROCEDURE (RETRIEVAL OF FAILURE CODE) * Alto etreval, ABS indcator indicates the sure code by blink ing aspect rumbarof tin ‘Tho fale code fe not erased by tuning the ignition switch to OFF white the flare code fe beng ouput. Note that turning the Ignition uiteh:o "ON again doesnot indeat the problem sod ‘Toshow the fale code again, repeat the problem code retrieval rocaduras om the beginning + Th ABS contal unt stores Up to Mo f {he fetes fale code frst and then the earl code altemataly. ‘Wien the two fue codes ae indiested, begin diagnostic trouble hooting, begining with tho code that was indeated frst + Braue to malas note of he retoval eure codes). 1 hae diagnnstintuhiachneting, men th fae ale dpa {orm tho prota saf-dlagnoste to be sure that thore smo probiam inthe ABS indistorlndcatorf operating normal. RETRIEVAL: 1. Remove the Na. and 3 contol motor use with the gniton switch turned to ‘OFF tobe sure that onch fu te not burned ot st armed outs perform the troubleshooting of proba No.1 fae) or “8 (No.3 fsa without nstaling te uve. 2, Turm the ignition switch to YON’. The ABS Indeator should come re codes end indicates Inciestor of within 3 seconds). 5, Thealure cade indested bythe aumber of times teri, Failure code indication pattern Flore code star signal 025 se (inks once) 20, Eater ine tore ‘Example: bins 3 umes coe “roblom code’) ‘When the fale cade nt stored: ‘XL1000VA-4 ADDENDUM. ‘SELF-DIAGNOSIS MEMORY RESET PROCEDURE (ERASURE OF FAILURE CODE) ‘TO ERASE THE FAILURE CODE: 1. Intall th remaining fuse (Not oF No) while 2. When cod erasure ie completo, the ABS ind te ftre code is being indcated the ABS indiator sinking arava fata it igtion paren ume to natal either fuse Install remaining fuse igumon ON Winning ITCH’ ort ——1L seconds ream! os) cnn ans ON INticaToOR ore ~—I aire code () BEFORE TROUBLESHOOTING ‘+ Allconnsctr diagrams i the troubleshooting ae vow from the trminal side { Feioinpecton wh the ignonawton trae to “OF' ules ater cid 2 Geely dnarge battery. Do not diagnose with» charge’ connected tothe batay 1 Wen the ABS contol unt is datoted fo be lout, recheck the wie harass end connector connections closely before ‘replacing i + Fler traubieshooting, erage the fallare code (page 2562) and porform the prestart sel-lagnosis to be eure thatthe ‘ABS indeato is operating normaly. «+ The ABE indietor might ine nthe following cates. “incorrect re pressure, tire rt recommended for the motoceyele wer installa Incorrect tre sz) Front rer wheel turning when ater sido whoa stope = Notas ple, = The ABS operate long time + Tne ABE inslestor might bnk while riding under the folveng eandltions. Erase the problem code and perform th tar eli ciagnosi, The ABS a nocmel the Indicator gous of. Ask herder forthe Fiding conditions in deta when the motores brug re motoreyete When lang, the ater daing later 430 seconds) withthe motoreyle paced onthe conor stand XL1000VA-4 ADDENDUM ‘ABS INDICATOR FAILURE CODE INDEX f aa rT “Modulator ~ | 3 elglil eles) | oi z i a) Elals]8a] a | ge) F i : Hel) | bla G i i Pale iG Py) lait Hi elggjeiiie | | | [zeiilz | 7 of fet Flelet fel lel tele 2 | Rane oe) fof fojo| | fol |ojo|ases «leer | [el fel fet ||| [ele ze s el [el fe olo [ 25-70 8 o| fo] fo| Jol jo ofo| fo] fo) [olzse 8 | | Reazconeot of fol jo} fo] fo} Jolo 0] [olo| ze. | glEewrseree 7 Sof fol fo ojo 778 3] g[Raraerer | fol fo ole | [200 a | Power circle T LL felelel |] 2582 aoa cme |o eelolo) | |) | lem XL1000VA-4 ADDENDUM. ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING PEgRERLSaDE2 AND 5 CRON TRERSPEA BNE ENTS Ly “The ABS indicator might blink under unusual ding {rcondlions Erase the problem code, perform the pro-startso-diagnosis and chock the ABS Indestor Fotore rocbloshooting. 1. Wheel Pulsr Air Gap nepection {Check tha toa around the front whee! speed Mossure the sr gap batwoen the speed sonsor ‘bd puter tng ‘Standard ale gap: 04 12 mm (0.02005 in) {5 thor correct air gap? INO Chock each port for deformation and Toosanees andeorrect secordingly Yes -coToster2 2. Whoo Pulser Magnetic Deposits inspection Check for iron or other magnetic. deposits Senweun the pulse rng and wheel spect son (Check for a loose pulser ring oF wheat speed ‘Chock the plea ring for deformation or damage {eg chipped teeth) and tho wheel spood tip tor damage, ‘Ae thre any deposits between gap? YES. — Remove any deposits end instal prop ‘yor replace any fly part no -coToster3, 2. The ABS Indleator Function inspection Retrieve the problom code and erase I. [With the fgnition switch tured to "ON" (do not el appreximataly 4 keh (25 mph) 1s tho indcator blinking? “The ABS contol unit has been ie. Tupted by. an extromely powertl rio wove. + Cheek the connector and wie har hots ofthe whe ‘thm for loose connection, No - GoTOSTEP4. 25-64 7 Wheel Speed Sensor Line Short Girl epee. ‘lon at ABS Control Unit Disconnect the ABS control unit 12° Black) con Meesure for continuity between the ABS control 12P (lack) connactar wire harnoss side nals and ground, ‘Connection: Black/pink- ground Greenforange = round Standerd: No continuity Is thore continuity? No = GoTo STEPS, 5. Wheel Speed Sensor Line Short Cireuit Ispee- ton st Sensor Connector Check for continuity betwoen the sensor side ter male ana ground. ‘Connection: Black/pink - ground CGreenforange = round {a thore continuity? NO = Short circuit in the wire harass between the ABS' contol unit and ‘wheel speed sensor. YES. ~ Faulty front whoo! speed sonsor. | Wire Harness Continuity Inepection Disconnect the front wheel speed sensor 2° {Oren ‘Short the termineis of the connector with 2 jumper wire (Check fr continuity between the ABS contel ‘nit 12 (loch) conector wire harnoss side ta ‘Connection: Black/pink -Green/orange ‘Standards Continuity Ie there continuity? Yes - GOTOSTEP?, NO - Open oF short circuit in wire between ‘ho ABS cont nit and rent whe XL1000VA-4 ADDENDUM. Go avr ao 25-65 XL1000VA-4 ADDENDUM. 25-66 7 Rechecking indicator Function Remove the front wheal speed sensor and ‘place with anew one, [Connect the ABS contol unit 12 (lack connee- ‘ho ABS insist. 1s theindeator blinking? ‘YES ~ Foulty ABS conta unit NO Foulty removed whoo! speed sensor. PROBLEM CODE 3 AND 9: REAR. WHEEL SPEED SENSOR SYSTEM AND ABS CONTROL UNIT Nore: Tha ABS Indicator might blink under unusual ding ‘or conditions. Erase the problem code perform the rest sgnosia and check the ABS ineator Eotore troubleshooting 1. Whee Pulser Alr Gap Inspetion Check the area around the rear wheel speed son Messe the airgap batween the speed sensor tnd pulser ing Standard a gap: 04 1.2mm (002-005 in) 1s there correc air gp? NO Check each patt for deformation and Taoeenaes and cortect accordingly. Yes - GoTOSTEP2. 2. Whee Pulser Magnetle Deposits Inspection Check for iron. or other _magr bemoan the pulsar ring and Check for a lose pulser ring or whos! speed ‘Chock the plea ing for deformation or damege '. chip tath end the wheel speed sensor Up for damage Ie there any dopoute betwoon gop? YES Remove any deposit ond install prop- ‘ty or replace any fatty part No. - GoTOSTEPs. 1 The ABS Indlestor Function Inspection Retiev the problem code and ora it With the ignition switeh turned to “ON” (do not ‘parte tho Ignition switch ator erasing the problem ‘code turn the rear wheel by hand Frehile speed; approximatay 4 kh (28 mph) ‘or aboval and heck the ABS nde links |e the indiestor blinking? YES. ~ + The ABS control unit has bean dis rupted. by an extremely powedUl slo wave heck the copnactor and wire har fase of ta whos! speed senane Sys. "or loose connection No - GoTo stEP4 Wheel Speed Sensor Line Short Circuit Inepes- ‘om at ABS Control Unit Disconnect the ABS contol unit 12P (Back) con- “Measure for comtoulty betweun the ABS contro Y2P (Sack) connector wire harness sie nal ond ground! ‘Connection: Black/orange- ground brown ground Standart: No-continuty 1 there continuity? Yes -GoTOSTEPs, No - GoTo sTEr¢ 5. Wheel Speed Sensor Line Short Circuit Inpec- tlon et Sencar Connector ‘Chock for continuity between the sensor side ‘minal and ground: Connection: Black/orange - round Bluerbrown ground Is there continuity? NO =-Short circuit in the wie harness eweon the ABS contol unt and ined speed sensor ‘YES. ~ Foulty rear wheel speed senso. XL1000VA-4 ADDENDUM v0 bupe 25-67 XL1000VA-4 ADDENDUM. Wire Harness Continuity Iepeston Dicconnect tho rear wheel speed sensor. 22 cee tcamer enon | Th : a lather continuity? NO = Open oF short circuit in ire between the ABS. conl unit ‘end reat wie! peed sensor 7 Recheckng lndleator Funetion Remove the rear wheel speed sensor ond replace with now one Connect the ABS contol unit 12 (Black) connec: Perform the prestartsadiagnosis and check ‘ABS indiestor 1e the indestor blinking? YES ~ Faulty ABS contr uni. NO. ~ Faulty ear whoo ps PROBLEM CODE 4: FRONT MODULA- ‘TOR CONTROL MOTOR SYSTEM 1. ABS Indiator Function Rechecking Before troubleshooting chock forthe following: Front ABS fuse 304 connection 1 Shortor open criti mire harness between the fuse box and ABS conta unit Revive the problem code and erase I. Perfo the prestartsefclagnose and check {ho ABS indestor 1s theindeator etl blinking? NO = « Fine foreign matter in modulator or {ho ABS control unit has been dee "pad ‘by 98 exveraly powetl + Check the connector and wire here hoes of te wheal speed sensor sys: Yes - Go TOSTeP2. 7 ABS Gontrol Unt Battery Votoge inspection Disconnect the ABS control unit SP (Black con ‘Measure the votage between the ABS control {it 8 (lack) connector wire hamess edo tor: Connection: Red - ground ‘Standards Battery voltage 1c hore battery voltage? NO - Open or short chcuit in wire harnase Between the fuse box and ABS contra Yes - coTostera 2 Modulator Motor Ground Circuit Inspection at [ABS Conta Unit ‘Check for continuity betwoon the ABS contol Sin (8c) sir harness sido connector to: Connection: Green/yellow- ground {there continuity? NO Open cireuitin Ge Yes - GoTOSTEPS, 4 Modulator Motor Short Circuit Inspection at ‘Modulator Connector Disconnect the front ABS modulator 2° connec: ‘Chock for continuity between the ABS modulator ‘Side 2° connector terminals and ground Connection: Brown/yllow - ground Yollowrgreen round le there continuity? YES ~ Short ckcult in wire harness between the ABS control unit and madustor. No = GoToSTEPS, XL1000VA-4 ADDENDUM. XL1000VA-4 ADDENDUM '& Wire Horners Open Grit mapection Between the Modulator and Control Unit Disconnect the ABS contol unit SP (Black) eon: Chock for continuity between the ABS modulator | WIG Boy Byteman sso connor ABS con ‘Connection: Brown/yallow -Brown/ yellow o Yellowrgreen - Yolo green {s there continuity? NO. - Open cecult In wire harness between | t YES - GOTOSTEPS. 16. Modulator Motor Inspection by Replacing Front td Rear Mod CConnact the ABS contol unt 9 (Bis) connec: fron and rer modulators and inter ‘adulator 3° (Gray) and 2° oar modulo. modulstor 3P (Gray) and 2° Petoum he re-start eal-dlagnosie and retrieve the prablam code, and record ‘sany problem code indicated? S5 blinks-Faulty front ABS modulator. 4 blloks-Fauty ABS contol unit PROBLEM CODE 5; REAR MODULA- TORCONTROL MOTOR SYSTEM 1. ABS idestr Faction Racecing fore woubeshonting check othe folowig: fer ABS fue 204 connection. + Seton cate etme benoon thon Sb and As cota fatiov te proba ode a ern Fels tyres seiagnose ‘nd check SURES indo nth inet ning? NO = * Fine forsign mater in modulator or {ho ABS ontrl unt has been at ‘pied by. an @xtemaly powerful ‘do wave, + Check the connector and wire har. ross of the wheal speed tensor sys. ves - GoTo steP2, 5-7 ABS Control Unit Battery Voltage nepestion Disconnect the ABS conto unit 8 (own) eon Measure the voltage between the ABS contol Unit P row) connector wire hermes sido tr ‘minal and ground, Connection: Back/bive - ground Standard: Battery voltage le there battry voltage? NO = Open or short chcut in wite harness SSenwoon the fuse box end ABS cantel ves - coTosters Modulator Motor Ground Ciruit nspction at [R88 Control Unit Check for continuity between the ABS contrat Unk BP Brown) wita harness side connector tr Iminas and ground, Connection: Green/ellow ground ls there continuity? NO = Open circuit in Gr YES -GOTOSTEPA Modulator Motor Short Cireuit Inspection at ‘Modulator Connector “ Disconnect the rear ABS modulator 2P connee- ‘Check for continuity between the ABS modulator ‘ide 2F connector terminals and ground, Connection: Brown/light green - ground ediblck- ground 1 there continuity? YES short cieuit in wire harness between fhe ABS contol unitand modulator No - GoTostéPs. XL1000VA-4 ADDENDUM eu ents Re XL1000VA-4 ADDENDUM 25-72 '. Wire Hamesa Open Cicult inspection Between {he Modulator and Control Unit Disconnect the ABS contol unit SP (Brown con Check or continuity between the ABS modulator Connection: Brown/ight green = Brownvlight Fe/blac-Red/back 1s thore continuity? {fevAaS convel unt nd modulator. Yes - GoTOSTEPS, 6. Modulator Motor Inspection by Replacing Front tnd Rear Modulators Connect the ABS control unit SP (Brown) con Remove te front and rear modulator and intr: ange them {Connect the ont modulator 3° (Gray) and 2° nnectore othe rear mods. Connect the rear modulator 3P (Gray) and 2° ‘connector othe font masulstor. Perfor the pre-tatsalf-dlagaesie,reviove the problem cade ond ecard it 1s any problem code indicated? 4 blinks-Foulty rar ABS modulator. S blinks Faulty ABS contol unit. )BLEM CODE 6: FRONT MODULA. TOR CRANK ANGLE SENSOR SYSTEM INSPECTION 1. ABS Indieator Checking “Tue the ignition switch to “ON and check tho ‘BS indiestor Inthe indicator blinking? no - GoTosTer2, Yes - GOTOSTEPS. 7 AS Indiestor Fnction Rechesking Retrieve the problam code and erase it. Perform the pre-startsadiagnosls and check {he ABS indicator. Is theindleator stil biking? NO « Fine frsign matter in modulator of the ABS contra unt hae boon ie fupted by an exvemely ves - GoTo sTEra 3. Crank Angle Sensor Input Voltage Inspection Disconnect the front ABS modulator 3P (ight ‘roy sonnet Mostar ha tage between he 3P ight ry) ignition swteh tured to “ON Connection: Orange/green +) -Pink/bive -) Standard: 45-550 lathe voltage within standard value? No - GoTostePs, YES - GOTOSTEP4 4 Crank Angle Sensor Short Circuit Inepecton at ‘288 Control Unit Connector Disconnect the ABS contol unit 12 (Blac) con Connect the front ABS modulator 3° (ight gry) CChack for continuity batween the ABS control Unit 12° tele) wire hormone side connector and ground, Connection: White/pink - ground ls there continuity? YES - GOTOSTERS, No - GoTosTEP6, XL1000VA-4 ADDENDUM. ols Pau we ST XL1000VA-4 ADDENDUM. Crank angle senor short Grout iapection at ‘modulator connector Disconnect the front ABS modulator 3 (Light ‘ray connector. CChack for continuity batween the front ABS | rior ‘Sg gay coer rund oaneton: Warn round I eth contiy? u YES. Short cicult in wire harness between the front ABS modulator snd the ABS No - GoTo stEP?, 6. Wire harness continuity Inspection Disconnect the front ABS modulator 3° (Light (ray) connector. Check or emtny between th ABS cont Soa Seed er 1 | Sidgh goes Connection: White/pik- Wite/pink teehee canta? NNO" Open ctr wie human twowean |W Seat shsacar any ess & Seer vas coroster, U q 7. Modulotor inspection by replacing the front and ‘earmodulators ‘Connect the ABS contol unit 5° (Black connec: Remove the front and rear moduletors and inte: change thom Connect the front modulator 3P (Gray) and 2P ‘connectors ta the ear modular. Connect the rear modulator 2° (Gray) and 2P ‘connectors tothe front modulator fata seltiegnosis,roviove the {Is any problem code indicated? 7Tbnke-Foulty front ABS modulator, inks-Feulty ABS contol unit ‘modulator Disconnect the ABS conta unit 12 (Black con: ‘Chock for continuity between the front ABS Plight grey wire harness side con tector terminal and ground sa thers continuity? YES. ~ Short ccult In wire harness between the trom ABS merator and the No -GoTosTers. 1 Wire harness continuity inspection Chock for continuity between tha front ABS la thers continuity? ‘YES. ~ Foulty ABS conto uni. NO ~ Open ciccuit in wire hamost between the front ABS modu control unt FOREMAN ANGLE SENSOR System INSPECTION. 1. ABS Indleator Checking ignition awitch to “ON and check the 288 indestor 1s the indeator stl baking? No -GoTosTEP2 Yes -GoTOSTEPS XL1000VA-4 ADDENDUM Wire harness short ceultInepestion for front Ut I os Pree 25-75 XL1000VA-4 ADDENDUM. 5: Tt 2, ABS indicator Function Reshecking Retrieve the problem code and arse i Perfor the pre-startsef-dlagnosls and check {he ABS ndeatr. Ie theindeator sil inking? NO * Fine foreign matter in modulator or the ARS contra unit has been rugs ‘by a0 externa power + Ghoek the connector and wie har nets the moe spe senor ay Yes - GoTOSTEP, ‘3, Crank Angle Sensor Input Voltage Inspection Disconnact the rear ABS modulator 3P (Light (9107) connector “Measure the voltage between th 3 (Light ray Ignition ewitch umd to “ON” Connection; Orange,blue +) -Pink/white Standort. 45°83 1s tho voltage within standard value? No - GoTosTers, Yes - GoTOSTERS 4. Crank Angle Sensor Short Circuit Inspection at ‘ABS Control Unit Connector Disconnect the ABS control unit 12° Black) con: ABS modulator 3° (Light gray) CChack for continuity between the ABS conto! ‘nit 12 taleh) wire names side conacetor anid ground Connection: Pink/areen- ground Ie there continuity? YES - GOTOSTEPS, No - GoTostere. Gronk Angle Sensor shor Girault hepection at Modulator Connector Disconnect the raar ABS modulator 3P (Light {ray connector. CChack fr continulty between the rear ABS mod ‘lator 3° (Light gray) connector and ground Connection: Pink/green - round Is there continulty? YES ~ short cieit in wire harness between Sharon ABS mods and te ABS (Wire Harness Continuity Inspection Disconnect tha rear ABS modulator 3P (Light ‘107 connector. Check for continuity between the ABS control “init 12P (Bick) connector and rar modulator 3 (Cant ray connector. ‘Connection: Pink/gren -Pink/gren (sthere continuity? NO = Open circuit in wire harness betwoen the resr ABS modulator and the ABS ves - GoTo sTEr?, 2. Modulator Inspection by Replacing tho Front ‘nd Rear Modulators ‘Connect the ABS contol unit P (Black onnee- Remove the front and change them Connect the rear modulator 3P (Gray) and 2° ‘connectors to the roar modulator Connect the front modulator 3P (Gray) and 2P ‘connectors to the from madultor. modulators and inter: Perform the prestart self clognosle and eetrlave ‘he problom code, and rocora lc any problem code indicate? {blinks Foulty rar ABS modulator. 7bolinks-outy ABS conto unit XL1000VA-4 ADDENDUM 25-77 XL1000VA-4 ADDENDUM. '& Wire Homose Short Creu Inepestion for Rear Modulator Disconnect the ABS conta unit 12 (Black) con Cchac for comsnuity betwen the rear ABS mod Slstor 3 (ugh gray ue tide connec: tor tarminal and ground, Connection: Orange/bi Pinkie le there continuity? YES ~ Short cieuit in wi contol unit No - GoTOSTEPs. 8, Wire Hamess Continuity Inspection Check fr continuity btw Connection: Orange/bue -Orange/biue Plak/ite: Pink/ white 1s thor continuity? obs ‘YES. ~ Foulty ABS contol unit NO Open circult in wir harass between Pw EROPLEM CODE to: ABS CONTROL INIT (FRONT RELAY CIRCUIT) 1. ABS ndleator Checking “The ABS indiator Binks oF come on on when 2, ABS |NOICATOR [RSS contol unt fe norm focus agin “Tur the Ignition switch t9"ON* and chock the {8S indestr. Inthe indicator stil Blinking? No - GoTo STEP Yes - GoTOSTEPS 7 ABS indleator Funetion Rechecking Retrieve the problem co Pecorm the prestart {he ABS incieato, {a theindeator stil blinking? NO = + Fine foreign matter in the, ABS conto unit h ness of the whee spend {om forages connection, Yes - GoTOSTEP3. 4 Rechecking the Problem Code Retiove the problem code and record the latest problem code, |e the problem code other than 10 blinks? YES - Diagnosis at tho latest problem code No. - GoTo STEPS. 4 Modultor inspection by Replacing the Front ‘tnd Rear Modulators ‘Connact the rant ABS control unit (Gray) and ‘Preannectors tothe rer ABS modulator, ‘Connect the rear modulator 3° (Gray) and 2° onnactors to the oar modulator. Pefocm the pre-tatslf-dlagnosie and retrieve the problom code, and record 1s any problem code indicate? blinks Foul front ABS modulator 10bitnks-Foulty ABS control unit. XL1000VA.4 ADDENDUM ~

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