ELECTRICAL SYSTEM 16-93

Switches and Sensors

Oxygen Sensor Installation (Equipped Models)

CAUTION

Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] to prevent oil contact. Oil contamination from hands can reduce sensor performance.

•Tighten:

Torque - Oxygen Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb)

•Run the oxygen sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Oxygen Sensor Inspection (Equipped Models)

•Refer to the Oxygen Sensor Inspection in the Fuel System (DFI) chapter.

Oxygen Sensor Heater Inspection (Equipped Models)

•Refer to the Oxygen Sensor Heater Inspection in the Fuel System (DFI) chapter.

Gear Position Switch Removal

•Remove:

Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter)

Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter)

•Disconnect the connector [A].

•Remove: Screws [A]

Holding Plate [B] Gear Position Switch

•Remove the pins [A] and springs from the shift drum.

16-94 ELECTRICAL SYSTEM

Switches and Sensors

Gear Position Switch Installation

•Securely place the springs [A] and pins [B] into the holes [C] of the shift drum.

•Apply grease to the new O-ring [D].

•Install the gear position switch [E] and holding plate [F].

•Apply a non-permanent locking agent to the threads of the gear position switch screws [G].

•Tighten:

Torque - Gear Position Switch Screws: 2.9 N·m (0.30 kgf·m, 26 in·lb)

•Run the lead [H] correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

•Install the removed parts (see appropriate chapters).

Gear Position Switch Inspection

NOTE

○Be sure the transmission and external shift mechanism are good condition.

•Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).

•Disconnect the connector [A].

ELECTRICAL SYSTEM 16-95

Switches and Sensors

•Set the hand tester [A] to the × 1 k Ω or × 100 Ω range and connect it to the terminals in the connector [B] and ground.

○When changing the gear position from lower gear to higher gear, raise the rear wheel off the ground with the stand and rotate the rear wheel by hand.

Internal Circuit [C]

[1]LG Lead

[2]G/R Lead

[3]BK Lead

Special Tool - Hand Tester: 57001-1394

	Gear Position Switch Resistance					(Unit: kΩ)
			Connections
	Gear	[1]-Ground	[2]-Ground			[3]-Ground
	Position
	Neutral	about 0	8.64		9.54	about 0
	1st	–	2.22		2.46	about 0
	2nd	–	1.42		1.58	about 0
	3rd	–	0.955		1.055	about 0
	4th	–	0.644		0.711	about 0
	5th	–	0.410		0.453	about 0
	6th	–	0.241		0.266	about 0

If the tester reading is not as specified, replace the gear position switch with a new one.