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Basic troubleshooting instructions
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WARNING
Т Perform the troubleshooting [A] → [B] → [C] → [D] in order. The malfunction will not be diagnosed correctly if the troubleshooting is performed in the wrong order or if the steps are omitted.
Т Make sure that the battery has been sufficiently charged before troubleshooting.
У ABS malfunction check using the ABS warning light
У Detailed ABS malfunction check
The results of the self-diagnosis by the ECU (ABS) are displayed using the multifunction display or a pocket tester.
У Determining the cause and location of the malfunction
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
У ABS maintenance
Execute the final check after disassembly and reassembly.
4 - 99
ANTI-LOCK BRAKE SYSTEM (XP500A) CHAS
EAS00886
Basic troubleshooting process
| Does not come on. | [A] | Comes on for 2 seconds, then goes off. | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Check the ABS warning | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| light. | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Flashing | Remains on. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| [B-1] | [B-3] | [B-2] | [B-5] | [B-4] | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Warning light does | Warning light | Warning light | Present | Past | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| not come on. | keeps flashing. | remains on. | malfunction | malfunction | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| YES | NO | YES | NO | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| NOTE: Display the | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| malfunction code | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| number and record it. | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| [C-1] | [C-2] | [C-3] | [C-5] | [C-4] | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Only ABS warn- | All indicator | Warning light | Diagnose by | ABS warning light | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| ing light does | lights do not | flashes continu- | malfunction | flashes every | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| not come on. | come on. | ously. | codes. | 0.5 second. | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Check the | Check the | Check the | Check the | Check the wire | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| connectors | brake switch | ECU (ABS) | harnesses (ABS | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| fuse. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| and couplers. | circuit. | connector. | system’s circuit). | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Check the | For details, use the diag- | Normal | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| test coupler | nostic codes listed from | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| adaptor. | [C-5-1] to [C-5-13]. | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Check the wire harnesses | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| [D-1] | (ABS system’s circuit). | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| ECU (ABS) | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| [D-3, D-4] | [D-2] | [D-5] | [D-1] | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Sensor | Fail-safe relay | Hydraulic unit | ECU (ABS) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Not | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Check the | OK | Hydraulic unit test | ||||||||||||||||||||||||||||||||||||||||||||||
| hose routing. | [D-6-3-1] [D-6-3-2] | |||||||||||||||||||||||||||||||||||||||||||||||
| OK | ||||||||||||||||||||||||||||||||||||||||||||||||
| Have all problems been corrected? | ||||||||||||||||||||||||||||||||||||||||||||||||||
| NO | OK | Delete | ||||||||||||||||||||||||||||||||||||||||||||||||
| Return to [A] | [D-6-4] Delete the mal- | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Finished | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| function code record. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| Cannot delete | OK | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||
| [D-6-6] Delete function test | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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NOTE:
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Do not delete the malfunction codes during troubleshooting. Delete the malfunction codes only after service has been completed.
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure to per-form a final check before delivering the vehicle to the customer. (Refer to “[D-6] Final check”.)
4 - 100
| → [B-5] → Connect the coupler securely until a “click” sound is heard. |
| ANTI-LOCK BRAKE SYSTEM (XP500A) | CHAS | |
| EAS00887 | ||
| ABS troubleshooting | ||
| • [A] ABS malfunction check using the ABS warning light | ||
| Set the main switch to “ON”. (Do not start the engine.) | ||
| 1) | Warning light does not come on. | → [B-1] |
| 2) | Warning light remains on. | → [B-2] |
| 3) | Warning light flashes. | → [B-3] |
| 4) | Warning light comes on for 2 seconds, then goes off. | → [B-4] |
Х [B] Detailed ABS malfunction check
Х [B-1] Warning light does not come on
Do other indicators operate normally?
| 1) | Yes. | → [C-1] |
| 2) | No. | → [C-2] |
• [B-2] ABS warning light remains on
Check the ECU (ABS) and is located on the right side of the vehicle near the top of the front fork. Is the coupler connected securely?
1) Yes.
2) No.
• [B-3] Warning light flashes
NOTE:
Check the battery voltage before proceeding.
Check the test coupler located in the front cowling. Is the T/C terminal grounded?
1) Yes. → Disconnect the grounding lead from the T/C terminal and install the protective cap onto the test coupler.
NOTE:
When the test coupler adaptor is connected to test coupler, the T/C terminal is grounded.
2) No. → [C-3]
Function of the test coupler terminals
П The ABS self-diagnostic function of the ECU (ABS) is operated when the T/C terminal is grounded.
П The malfunction codes stored in the memory of the ECU (ABS) are recalled and output (rise and fall of voltage) at the T/F terminal.
П The ABS warning light terminal is used to check the ABS warning light circuit.
П To ground the T/C terminal, connect the test coupler adaptor to the test coupler.
| T/C (sky blue) | Grounding (black) | |
| T/F (light green) | ABS warning light (white/red) | Test coupler adaptor |
| Test coupler |
4 - 101
ANTI-LOCK BRAKE SYSTEM (XP500A) CHAS
• [B-4] ABS malfunction check using the ABS self-diagnosis (past malfunction)
To access the test coupler 1. Remove the protective cap and connect the test coupler adaptor 2 to the test coupler. The T/C terminal (sky blue) is now grounded.
1) Indicate the malfunction code (Example: malfunction code 11)
Multifunction display
2) ABS warning light flashes every 0.5 second for more than 6 seconds. → [C-4, C-5] If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in the memory of the ECU (ABS). If a malfunction code is displayed on the multi-function display, the ABS warning light flashes. Make sure that the customer understands the possi-ble conditions when the ABS warning light comes on.
CAUTION:
Р When checking for ABS malfunctions, the odometer and bottom tripmeter are not dis-played.
Р When checking for fuel injection system malfunctions or adjusting the exhaust gas vol-ume, the ABS malfunction codes are not displayed.
4 - 102
ANTI-LOCK BRAKE SYSTEM (XP500A) CHAS
• [B-5] ABS malfunction check using the ABS self-diagnosis (present malfunction)
NOTE:
Before proceeding, read [B-3], “Function of the test coupler terminals”.
To access the test coupler. Remove the protective cap and connect the test coupler adaptor to the test coupler. The T/C terminal (sky blue) is now grounded. (Figure И)
| И | К |
| (black) | ||
| (white | ||
| /red) | ||
| (light green) | ||
| Й | ||
| 1 Test coupler | ||
| (light green) | ||
| 2 Lock plate | ||
| 3 Protective cap | ||
| (white/red) | 4 Grounding | |
| 5 T/C terminal | ||
| 6 T/F terminal | ||
| 7 Light terminal | ||
| 8 Test coupler adaptor |
Because malfunction codes for present malfunctions are not displayed on the meter assembly, check the malfunction code as follows.
Set the pocket tester range to DC 20 V. Connect the pocket tester negative probe to the T/F termi-nal (light green) of the test coupler adaptor and the pocket tester positive probe to the positive bat-tery terminal. (Figure Й)
Determine the malfunction code according to the movement of the pocket tester needle. (Figure К) A tester reading with the digits of 10 and digits of 1 pattern is shown below.
| Example: malfunction code 12 | Example: malfunction code 21 | |||||||
| 12 V | ||||||||
| +1 + 1 | + | + | ||||||
| 0 V | 0.50.5 0.5 | 0.5 | ||||||
| Time | 1.5 | 1.5 | 1.5 | |||||
| (second) |
4 - 103
ANTI-LOCK BRAKE SYSTEM (XP500A) CHAS
17 [C] Determining the cause and location of the malfunction
18 [C-1] Only the ABS warning light does not come on when the main switch is set to “ON”
NOTE:
Check following the steps in sequence.
1. Visual check
22 Check the ABS fuse.
Determine the cause of the blown fuse and repair. Replace with a new fuse. (Refer to “CHECK-ING THE FUSES” in chapter 3.)
23 Check the wire harness (ABS system circuit) couplers.
Check that the wire harness (ABS system circuit) couplers are securely connected.
24 Check the connection of the wire harness (ABS system circuit) to the ECU (ABS).
Check that the wire harness (ABS system circuit) is securely connected to the ECU (ABS). 2. Confirmation using the test coupler adaptor
P Connect the test coupler adaptor to the test coupler. (Refer to “[B-5] ABS malfunction check using the ABS self-diagnosis (present malfunction)”.)
Q Ground the warning light terminal (white/red) of the test coupler adaptor or connect the warning light terminal to the negative battery terminal.
AA If the ABS warning light comes on, the wire harness (ABS system circuit) may be disconnected.
BB If the ABS warning light does not come on, the ABS warning light lead may be disconnected or the contact of the ABS warning light may be defective.
13. Remove the ECU (ABS) coupler and check the ECU (ABS) coupler and test coupler adaptor ends of the white/red lead for continuity.
If there is continuity, the ECU (ABS) is defective. → Replace the ECU (ABS). (Refer to “[D-1] Maintenance of the ECU (ABS)”.)
If there is no continuity, the warning light circuit in the wire harness (ABS system circuit) is defec-tive. Disconnection or short → Correct. (Refer to “CIRCUIT DIAGRAM”.)
• [C-2] ABS warning light and all other indicators do not come on
NOTE:
Check following the steps in sequence.
1. Check the power supply system.
1) Check that the battery is connected correctly.
2) Check the battery voltage. (Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.)
3) Check if the main fuse is blown. If the main fuse is blown, determine the cause and repair. Replace with a new fuse. (Refer to “CHECKING THE FUSES” in chapter 3.)
2. Check the connections.
1 Check that the main fuse coupler is securely connected.
1 Check that the wire harness (ABS system circuit) is securely connected.
1 Check that the main switch coupler is securely connected.
1 Check that the meter assembly coupler is securely connected.
When these checks are finished, return to [A] and check the ABS again.
4 - 104
ANTI-LOCK BRAKE SYSTEM (XP500A) CHAS
• [C-3] ABS warning light flashes
With the engine off, check the front and rear brake switches.
Check if the brake light comes on when the front or rear brake is applied. 1) The light does not come on for only one brake.
→ The corresponding brake switch connector is disconnected. (Refer to “CIRCUIT DIAGRAM”.) → The corresponding brake switch is defective.
2) The light does not come on for either brake.
→ The wire harness (ABS system circuit) may be disconnected or the fuse may be blown. Check the fuse and make sure the wire harness (ABS system circuit) (brown lead) is connected to the power source end of the brake switch. (Refer to “CIRCUIT DIAGRAM”.)
3) The brake light comes on.
→ The wire harness (ABS system circuit) couplers may be disconnected.
• Adjust the rear brake switch to the specified setting.
• [C-4] ABS warning light flashes every 0.5 second
If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in the memory of the ECU (ABS). If a malfunction code is displayed on the multi-function display, the ABS warning light flashes. Make sure that the customer understands the possi-ble conditions when the ABS warning light comes on.
1. Warning light flashes
The following are probable causes to explain why the ABS warning light flashed while riding and then stopped flashing or stopped flashing when the main switch was set to “OFF”, then to “ON”.
15 The rear wheel was rotated with the vehicle on the centerstand. → The system is normal.
16 The rear wheel raced. → The system is normal.
17 The vehicle was ridden on the rear wheel with the front wheel elevated. → The system is normal.
18 The vehicle was ridden on extremely uneven roads continuously. → The system is normal.
19 The brake switch is defective or improperly adjusted. → Replace or adjust.
8) Voltage drop
For the ABS to operate correctly, the voltage should be always higher than the specified voltage. If the voltage drops to lower than 10 V, the ABS warning light comes on and the ABS does not operate. When the voltage recovers to higher than 10 V, the ABS operates. However, the mag-neto, battery and rectifier/regulator must be checked. Follow the regular procedures for service of the power supply system.
9) ABS is stopped by the ECU (ABS)
The ECU (ABS) may stop the ABS operation if it is exposed to extremely strong electromagnetic waves or static electricity.
When the ECU (ABS) is no longer exposed to the electromagnetic waves, static electricity, and the ABS warning light is not flashing, there is no effect on the operation of the ABS. Explain to the customer that the ABS will operate normally.
4 - 105
ANTI-LOCK BRAKE SYSTEM (XP500A) CHAS
• [C-5] Diagnosis by the malfunction code
Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “[B-4] ABS malfunction check using the ABS self-diagnosis (past malfunction)” and “[B-5] ABS malfunction check using the ABS self-diagnosis (present malfunction)”.) The malfunction codes are explained in the following table.
NOTE:
Record all of the malfunction codes displayed and check the check points.
| Malfunction | Problem | Check point | Reference | ||||||
| code | |||||||||
| Front wheel sensor signal is not received prop- | • Installation of the front wheel sensor | [C-5-1] Mal- | |||||||
| erly. | • Front wheel sensor lead and coupler | function code | |||||||
| • Wire harness (ABS system’s circuit) | |||||||||
| *1 | • Front wheel sensor rotor | (page 4-108) | |||||||
| Rear wheel sensor signal is not received prop- | • Installation of the rear wheel sensor | [C-5-2] Mal- | |||||||
| erly. | • Rear wheel sensor lead and coupler | function code | |||||||
| • Wire harness (ABS system’s circuit) | |||||||||
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