18.

IGNITION SYSTEM MXU 500

18
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18
IGNITION SYSTEM
__________________________________________________________________________________

IGNITION SYSTEM LAYOUT------------------------------------------- 18-1

IGNITION CIRCUIT ------------------------------------------------------- 18-2
SERVICE INFORMATION------------------------------------------------ 18-3
TROUBLESHOOTING----------------------------------------------------- 18-4
IGNITION COIL INSPECTION ------------------------------------------ 18-5
IGNITION CONTROL MODULE ---------------------------------------- 18-6

18-0
18. IGNITION SYSTEM MXU 500

IGNITION SYSTEM LAYOUT

18-1
18. IGNITION SYSTEM MXU 500

IGNITION CIRCUIT

(ON ROAD)

(OFF ROAD)

18-2
18. IGNITION SYSTEM MXU 500

SERVICE INFORMATION
GENERAL INSTRUCTIONS
● Some electrical components may be damaged if terminals or connectors are connected or
disconnected while the ignition switch is “ON” and current is present.
● When servicing the ignition system, always follow the steps in the troubleshooting on page 18-3.
● The ignition timing cannot be adjusted since the ignition control module is factory preset.
● The ignition control module may be damaged if dropped. Also, if the connector is disconnected
when current is flowing, the excessive voltage may damage the ignition control module. Always
turn off the ignition switch before servicing.
● A faulty ignition system is often related to poor connections. Check those connections before
proceeding.
● Make sure the battery is adequately charged. Using the starter motor with a weak battery results in
a slower engine cranking speed as well as no spark at the spark plug.
● Use a spark plug of the correct heat range. Using spark plug with an incorrect heat range can
damage the engine.
● See section 17 for ignition pulse generator removal/installation.
● See section 20 for following components:
ä Ignition switch
ä Engine stop switch

SPECIFICATIONS
Item Standard
Spark plug NGK-CR7E
Spark plug gap 0.7 mm (0.028 in)
Ignition system Full transistor digital ignition
Ignition timing 5°/1500 rpm

18-3
18. IGNITION SYSTEM MXU 500

TROUBLESHOOTING
LOW PEAK VOLTAGE
● Cranking speed is too low (battery is undercharged).
● Poorly connected connectors or an open circuit in the ignition system.
● Faulty ignition-coil.
● Faulty ignition control module.

NO PEAK VOLTAGE
● Short circuit in engine stop switch or ignition switch wire.
● Faulty engine stop switch or ignition switch.
● Loose or poorly connected ignition control module connectors.
● Open circuit or poor connection in ground wire of the ignition control module.
● Faulty ignition pulse generator.
● Faulty ignition control module.

PEAK VOLTAGE IS NORMAL, BUT NO SPARK JUMPS AT THE PLUG

● Faulty spark plug or leaking ignition coil secondary current.
● Faulty ignition coil.

18-4
18. IGNITION SYSTEM MXU 500

IGNITION COIL INSPECTION

IGNITION COIL PRIMARY PEAK
VOLTAGE

Check cylinder compression and check that the

spark plugs is installed correctly in the cylinder.
Disconnect the spark plug cap from the spark
plug.

Spark Plug Cap

Spark Plug
Connect known good spark plug to the spark
plug cap and ground the spark plugs to the
cylinder as done in the spark test.

Spark Plug Cap

Turn the ignition switch to “ON” and engine

stop switch ON.
Turn the engine stop switch in RUN (OFF
ROAD).
Connect the multi-meter (+) probe to the
Brown/Blue wire and the multi-meter (-) to the
body ground.
Check for initial voltage at this time.
The battery voltage should be measured.
If the initial voltage cannot be measured, check
the power supply circuit.

Ignition Coil

18-5
18. IGNITION SYSTEM MXU 500

IGNITION PULSE GENERATOR

INSPECTION

Disconnect the ignition pulse generator

connector.
Measure the ignition pulse generator resistance
between the Green/White wire and Blue/Yellow
wire.

Standard: 489±20% Ω (20ºC/68ºF)

Ignition Pulse Generator Connector

IGNITION COIL
REMOVAL/INSTALLATION

Disconnect the spark plug cap from the spark

plug (page 18-4).

Disconnect the ignition coil primary connectors.

Remove the two bolts and the ignition coil.

Installation is in the reverse order of removal.

Ignition Coil

IGNITION CONTROL MODULE Ignition Control Module

REMOVAL/INSTALLATION
Remove the seat (refer to the “FRAME
COVERS” section in the chapter 2).

Disconnect the ignition control module

connectors and remove the ignition control
module.

18-6
18. IGNITION SYSTEM MXU 500

RESISTANCE INSPECTION
＊ Due to the semiconductor in circuit, it
is necessary to use a specified tester for
Measure the resistance between the terminals. accurate testing. Use of an improper
tester in an improper range may give
false readings.

L/Y
G/GR

B/W

G
G/W B/Y

Unit: Ω
(+)
(-) B/W G/GR L/Y G/W B/Y G

B/W

G/GR 6.7 M 6.7 M 6.7 M

L/Y 0.785 K Continue

G/W 0.778 K 0.785 k

B/Y

G Continue 0.785 K

18-7
19. STARTER SYSTEM MXU 500

19
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STARTER SYSTEM
__________________________________________________________________________________
19
STARTING SYSTEM LAYOUT ----------------------------------------- 19- 1
STARTING CIRCUIT ------------------------------------------------------ 19- 2
SERVICE INFORMATION------------------------------------------------ 19- 3
TROUBLESHOOTING----------------------------------------------------- 19- 3
STARTER MOTOR --------------------------------------------------------- 19- 6
STARTER RELAY SWITCH/STARTER MAG ----------------------- 19- 7
RECOIL STARTER REMOVAL/INSPECTION/
INSTALLATION ------------------------------------------------------------ 19- 9
RECOIL STARTER HANDLE REPLACE ------------------------------ 19-11
RECOIL STARTER DISASSEMBLY/INSPECTION/
ASSEMBLY------------------------------------------------------------------ 19-12
STARTER PULLEY REMOVAL/INSPECTION/
INSTALLATION ------------------------------------------------------------ 19-18
STARTER CLUTCH REMOVAL/INSPECTION/
INSTALLATION ------------------------------------------------------------ 19-20

19-0
19. STARTER SYSTEM MXU 500

STARTING SYSTEM LAYOUT

19-1
19. STARTER SYSTEM MXU 500

STARTING CIRCUIT

(ON ROAD)

(OFF ROAD)

19-2
19. STARTER SYSTEM MXU 500

SERVICE INFORMATION
GENERAL
• Always turn the ignition switch to “OFF” before servicing the starter motor. The motor could
suddenly start, causing serious injury.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting flow chart
(page 19-2).
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate
ignition current.
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking
over, the starter motor may be damaged.
• See section 20 for following components:
ä Ignition switch
ä Starter switch
ä Brake light switch

SPECIAL TOOL
Flywheel puller A120E00060

TORQUE
Starter pulley nut 5.5 kgf-m (55 N-m, 40 lbf-ft)

TROUBLESHOOTING

• Check for the following before troubleshooting:

─ Blown main fuse (30A) and sub fuse (15 A)
─ Loose battery and starter motor cable
─ Discharged battery
• The starter motor can turn with the following conditions:
─ Ignition switch ON
─ Engine stop switch in RUN (OFF ROAD)
─ Rear brake lever fully squeezed
─ Starter switch pushed

Starter motor will not turn

Check for loose or poorly Abnormal •Poorly connected battery terminals.
connected battery terminals
and opened or shorted battery •Open or short circuit in battery.
cable.
Normal

(Go to following page)

19-3
19. STARTER SYSTEM MXU 500

(From previous page)

Check for loose or poorly Abnormal •Poorly connected terminal

connected starter MAG
terminals.

Normal

Check for loose or poorly Abnormal •Poorly connected starter motor cable.
connected or broken starter •Open circuit in starter motor cable.
motor cable.

Normal

With the ignition switch Clicks Connect the starter motor terminal
turned to “ON”, push the directly to the battery positive
starter switch and check for a terminal (Because a large amount of
click sound from the starter current flows, do not use a thin wire).
MAG.
Starter motor
No clicks Starter motor turns does not turn

•Faulty starter motor.

•Loose or disconnected starter motor cable.

•Faulty starter MAG.

Check the starter relay coil Abnormal •Faulty brake light switch.
ground line (page 19-6) •Loose or poor contact of connector.
•Open or short circuit in wire harness.
Normal

(Go to following page)

19-4
19. STARTER SYSTEM MXU 500

(From previous page)

Check the starter MAG No voltage •Faulty engine stop switch (OFF ROAD).
voltage (page 19-7). •Faulty starter switch.
•Loose or poor contact of connector.
Battery voltage registers •Open circuit in wire harness.

Check the starter relay for a Abnormal •Faulty starter MAG.

click sound from the starter
relay. (page 19-6).

Normal

•Loose or poor starter relay connector contact.

19-5
19. STARTER SYSTEM MXU 500

Starter Motor Cable

STARTER MOTOR

INSPECTION

Disconnect the starter motor cable from the

starter MAG.
Turn the ignition switch to “ON”.
Connect the starter motor cable directly to the
battery positive terminal.
If the starter motor does not turn, the starter
motor is faulty.

Rubber Cap
REMOVAL

Remove the carburetor (refer to the

“CARBURETOR REMOVAL/CHOKE
INSPECTION/INSTALLATION” section
in the chapter 5).

Turn the ignition switch turned to “OFF”

Remove the two mounting bolts and starter

motor.

Release the rubber cap and remove the

terminal nut to disconnect the starter motor Bolts Nut
cable from the starter motor.

O-ring
INSTALLATION

Coat a new O-ring with engine oil and install

it into the starter motor groove.

Connect the starter motor cable to motor

terminal with the terminal nut and tighten it.

Install the starter motor into the crankcase.

Install the two mounting bolts and tighten them

securely.

19-6
19. STARTER SYSTEM MXU 500

Starter MAG
STARTER RELAY
SWITCH/STARTER MAG
INSPECTION

Turn the ignition switch to “ON”.

Squeeze the brake lever or pedal fully.

The coil is normal if the starter relay switch
clicks.

Squeeze and hold the brake lever or pedal

fully then push the starter switch.
The coil is normal if the starter MAG switch Starter Relay
clicks.

If you do not hear the switch click. Inspect

the relay switch and starter MAG using the
procedure below. Starter Relay
GROUND LINE INSPECTION

Disconnect the starter relay switch connector.

Check for continuity between the Green wire
terminal and ground.

There should be continuity.

VOLTAGE INSPECTION

Connect the starter MAG connector.

Turn the ignition switch ON.

Measure the starter MAG Yellow/Red wire

terminal and ground.

If the battery voltage appears only when the

rear brake lever is squeezed fully (or the gear
change switch in neutral) and starter switch is
pushed, the circuit is normal.

Starter MAG

19-7
19. STARTER SYSTEM MXU 500

Starter MAG
CONTINUTY INSPECTION

Disconnect the starter MAG switch connector

and cables.
Connect a fully charged 12 V battery positive
wire to the relay switch Yellow/Red wire
terminal and negative wire to the
Yellow/Green wire terminal.

There should be continuity between the cable

terminals while the battery is connected, and
no continuity when the battery is
disconnected.

19-8
19. STARTER SYSTEM MXU 500

Recoil Starter
RECOIL STARTER
REMOVAL/INSPECTION/
INSTALLATION

＊ The recoil starter can not start the

engine when the battery is removal.

REMOVAL

Remove the six bolts, then remove the recoil

starter assembly.

Remove the two dowel pins.

Dowel Pins

INSTALLATION

Install the dowel pins.

Dowel Pins

19-9
19. STARTER SYSTEM MXU 500

Recoil Starter
Install the recoil starter assembly.
Install and tighten the six bolts diagonally.

19-10
19. STARTER SYSTEM MXU 500

RECOIL STARTER HANDLE

REPLACE

Remove the recoil starter assembly (refer to

the “RECOIL STARTER
REMOVAL/INSPECTION/
INSTALLATION” section in this chapter).

Remove the cap on the handle.

Cap

Knot
Replace the handle.

＊ Before untying the knot above the

starter handle, make a knot in the rope
so that the rope is not pulled into the
housing.

Knot Collar Handle

19-11
19. STARTER SYSTEM MXU 500

RECOIL STARTER
DISASSEMBLY/INSPECTION/
ASSEMBLY

DISASSEMBLY

Remove the recoil starter assembly (refer to

the “RECOIL STARTER
REMOVAL/INSPECTION/
INSTALLATION” section in this chapter).

Remove the handle (refer to the “RECOIL

STARTER HANDLE REPLACE” section
in this chapter). Knot

Untying the knot, then turn the reel clockwise Rope

with the rope slowly.

Reel

Bolt/Washer/Plate/Spring

Remove the bolt and then remove the washer,

friction plate and pawl spring.

19-12
19. STARTER SYSTEM MXU 500

Coil Spring
Remove the reel, then remove the coil spring.
＊ Wear hand and eye protection when
removing the reel, since the spring may
quickly unwind and cause and injury.

Reel

INSPECTION

Pull the rope and check that the ratchet is

pushed out.

Pawl Spring Drive Pawls

Inspect the rope, reel and drive pawl for wear

or damage.

Inspect the pawl spring for fatigue.

Reel Rope

19-13
19. STARTER SYSTEM MXU 500

Coil Spring
Inspect the coil spring for fatigue.

Hook

ASSEMBLY

Apply molybdenum disulfide grease to the

coil spring, then install the coil spring.
＊ ● Wear hand and eye protection when
installing the spring, since the spring
may quickly unwind and cause and
injury.
● Mesh the spring hook with the
housing slit, then wind the housing to
make the diameter of the spring
smaller and the spring will be into the Coil Spring
housing.

Reel
Pass the rope through the reel and make a
knot above the reel.

Knot Rope

19-14
19. STARTER SYSTEM MXU 500

Coil Spring
Install the reel.
＊ ● Wear hand and eye protection when
installing the reel, since the spring
may quickly unwind and cause and
injury.
● Engage the part of the reel with coil
spring end.

Reel

Housing Collar Knot

Hook the rope onto the hook part of the reel,

then pass the rope through the recoil starter
housing, handle and collar.
Make a knot above the collar.

Handle

Hook the rope onto the hook part of the reel,

turn the reel counterclockwise three or four
times with the rope.
＊ Wear hand and eye protection when
assembling the recoil starter, since the
spring may quickly unwind and cause
and injury.

19-15
19. STARTER SYSTEM MXU 500

Unhook the rope, then turn the reel clockwise

with the rope slowly.

Apply Grease Apply Grease

Apply molybdenum disulfide grease to the

washer and friction plate.

Spring

Bolt/Washer/Plate/Spring

Install the pawl spring, friction plate/washer.

Install and tighten the new bolt securely.

19-16
19. STARTER SYSTEM MXU 500

Pull the rope and check that the ratchet is

pushed out.

19-17
19. STARTER SYSTEM MXU 500

STARTER PULLEY
REMOVAL/INSPECTION/
INSTALLATION

REMOVAL

Remove the recoil starter assembly (refer to

the “RECOIL STARTER
REMOVAL/INSPECTION/
INSTALLATION” section in this chapter).

Remove the starter pulley nut by using a

suitable bar.
Nut/Washer

INSPECTION

Inspect the starter pulley for cracks or pitting.

Inspect the O-ring for wear or damage.

O-ring

Oil Stop Ring

Inspect the oil stop ring for crack or damage.

19-18
19. STARTER SYSTEM MXU 500

INSTALLATION

Install the starter pulley and washer.

Install and tighten the nut to the specified
torque by using suitable bar.

Torque: 5.5 kgf-m (55 N-m, 40 lbf-ft)

Nut/Washer

19-19
19. STARTER SYSTEM MXU 500

Flywheel Puller
STARTER CLUTCH
REMOVAL/INSPECTION/
INSTALLATION

REMVOAL

Remove the right crankcase cover (refer to

the “ALTERNATOR STATOR
REMOVAL/INSPECTION/
INSTALLATION” section in the chapter
17).

Remove the flywheel/driven gear by using

the special tool. Flywheel/Driven Gear

Special tool:
Flywheel puller A120E00060
Woodruff Key
Remove the woodruff key.

Reduction Gear
Remove the reduction gear.

19-20
19. STARTER SYSTEM MXU 500

INSPECTION

Check the operation of the sprag clutch by

turning the driven gear.
You should be able to turn the driven gear
clockwise smoothly, but the gear should not
turn counterclockwise.

Remove the starter driven gear by turning the

driven gear.

Check the starter driven gear teeth for wear or

damage.

Measure the starter driven gear boss O.D..

Service limit: 57.7 mm (2.272 in)

Measure the starter driven gear bushing I.D..

Service limit: 27.1 mm (1.084 in)

Reduction Gear

Check the starter reduction gear teeth and

shaft for wear or damage.

19-21
19. STARTER SYSTEM MXU 500

Reduction Gear
INSTALLATION

Apply oil to the starter reduction gear.

Install the starter reduction gear to the right
crankcase.

Woodruff Key
Install the woodruff key in the crankshaft key
groove.

Apply molybdenum oil solution to the starter

driven gear bushing.
Install the starter driven gear by turning the
driven gear clockwise.

19-22
19. STARTER SYSTEM MXU 500

Reduction Gear Driven Gear

Clean any oil from the tappered portion of the
flywheel I.D.

Install the flywheel/driven gear onto the

crankshaft, aligning the key way with
woodruff key.

Flywheel

19-23
20. LIGHTS/SWITCHES MXU 500

20
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LIGHTS/SWITHCES
__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 20- 1

BULBS REMOVAL--------------------------------------------------------- 20- 2
20
HORN (ON ROAD) --------------------------------------------------------- 20- 4
IGNITION SWITCH -------------------------------------------------------- 20- 5
HANDLEBAR SWITCH --------------------------------------------------- 20- 5
GEAR INDICATOR SWITCH -------------------------------------------- 20- 8
SPEED SENSOR ------------------------------------------------------------ 20- 9
2WD/4WD SELECTING SYSTEM -------------------------------------- 20-10
FUEL UNIT ------------------------------------------------------------------ 20-13

20-0
20. LIGHTS/SWITCHES MXU 500

SERVICE INFORMATION
● A continuity test can be made with the switches installed on the vehicle.
● All plastic connectors have locking tabs that must be released before disconnecting, and
must be aligned when reconnecting.
● To isolate an electrical failure, check the continuity of the electrical path through the part. A
continuity check can usually be made without removing the pat from the vehicle. Simply
disconnect the connectors and connect a continuity tester to the terminals or connections.

20-1
20. LIGHTS/SWITCHES MXU 500

Headlight Connector
BULBS REMOVAL

HEADLIGHT

Disconnect the headlight wire connector.

Remove the rubber boot from the headlight
case.

Rubber Boot

Lock Clip

Relax the lock clip to remove the bulb and

replace with a new one.

Install the bulb, aligning the bulb socket

groove with the bulb tab and set the lock
clip.
Connect headlight wire connector.
Install the rubber boot.

Install the front fender in the reverse order

of removal.

Bulb

POSITION LIGHT

Remove the bulb socket by pulling it out.

Remove the bulb.

Install the bulb in the reverse order of

removal

Bulb Socket Bulb

20-2
20. LIGHTS/SWITCHES MXU 500

TAIL/BRAKE LIGHT Bulb Socket Bulb

Remove the bulb socket by turning it

counterclockwise.
Remove the bulb.

Install the bulb in the reverse order of

removal.

Rubber Boot
TURN SIGNAL LIGHT (ON ROAD)

FRONT

Remove the rubber boot from the turn signal

light case.
Remove the bulb socket by turning it
counterclockwise.

Bulb Socket

Bulb

Remove the bulb.

Install the bulb in the reverse order of

removal.

20-3
20. LIGHTS/SWITCHES MXU 500

Bulb
REAR

Remove the bulb socket by turning it

counterclockwise.
Remove the bulb.

Install the bulb in the reverse order of

removal.

Bulb Socket

LICENCE LIGHT BULB (ON ROAD)

Remove the two screws and licence light

cover.
Remove the bulb.

Install the bulb in the reverse order of

removal

HORN (ON ROAD)

REMOVAL

Disconnect the horn wire leads.

Remove the bolt and remove horn.

INSTALLATION
Bolt
The installation sequence is the reverse of
removal.
Horn Wire Leads Horn

20-4
20. LIGHTS/SWITCHES MXU 500

IGNITION SWITCH

INSPECTION

Disconnect the ignition switch connectors.

(Refer to the “FRAME COVER” section in
the chapter 2.)

Check for continuity between the switch

side connector terminals in each switch
position.
Continuity should exist between the color
coded wires as right:

REPLACEMENT

Release the switch wire from the wire clips

on the steering shaft holder frame pipe.

Remove the meter cover (refer to the

“FRAME COVER” section in the chapter
2).
Remove the ignition switch from the cover
while pushing in the two stoppers.

Install a new ignition switch by aligning the

locating tab with the groove in the cover.

Install the removed parts in the reverse

order of removal.

HANDLEBAR SWITCH

INSPECTION

Remove front center cover (refer to the

“FRAME COVER” section in the chapter
2).
Disconnect the connectors.

Check for continuity between the switch

side connector terminals in each switch
position.
Continuity should exist between the color
coded wires as next page:

20-5
20. LIGHTS/SWITCHES MXU 500

Hazard Switch
(ON ROAD)

Winker Switch Horn Switch

Light Switch

Start Switch

2WD/4WD Select Button

20-6
20. LIGHTS/SWITCHES MXU 500

Dimmer Switch
(OFF ROAD)

Start Switch

Passing Switch Engine Stop Switch

2WD/4WD Select Button

20-7
20. LIGHTS/SWITCHES MXU 500

GEAR INDICATOR LIGHT

SWITCHES

INSPECTION

Disconnect the gear indicator light switch

wire connector.

Check for continuity between the switch

side connector terminal and engine ground.

Gear Indicator Light Switch

REPLACEMENT

Disconnect the gear indicator light switch

connector.

Remove the bolt, then remove the gear

indicator light switch and washer.

Gear Indicator Light Switch Connector

O-ring Washer
Install the washer and a new switch with a
new O-ring (apply engine oil to O-ring).

＊ Make sure that the lever on the gear

indicator light switch correctly engages
with the locating slot on the shift shaft.

Shift the drive select lever to check if the

gear indicator light is correct.

20-8
20. LIGHTS/SWITCHES MXU 500

SPEED SENSOR

Disconnect the connector.

Remove the bolt then remove the speed
sensor.

If the speedometer, odometer or trip meter

does not function properly. Inspect the
connection of speed sensor connector.
If the connection is all right, replace the
speedometer with a new one.
If the speedometer, odometer or trip meter
still does not function properly, replace the
speed sensor. Speed Sensor

20-9
20. LIGHTS/SWITCHES MXU 500

2WD/4WD SELECTING SYSTEM

The 2WD/4WD selecting system consists of

the following components:
● 2WD/4WD selecting button
● 2WD switch
● 4WD switch
● 2WD/4WD change ECU
● 2WD/4WD motor
● Battery

TROUBLSHOOTING

Does not shift to 2WD/4WD (2WD/4WD

motor will not run.)

Turn on the ignition switch. Listen for a

click from the 2WD/4WD change ECU Check the 2WD/4WD motor.
Clicks (See page 20-11)
when the 2WD/4WD selecting button is
pushed.

Runs Does not run

No click

Faulty 2WD/4WD motor

● Faulty 2WD/4WD change ECU

● Improper 2WD/4WD motor connector
connection

Check the 2WD/4WD selecting button.

(See page 20-11) Incorrect Faulty 2WD/4WD selecting button

Correct

Check the 2WD/4WD change ECU.

Incorrect Faulty 2WD/4WD change ECU
(See page 12)

Correct

(Cont’d)

20-10
20. LIGHTS/SWITCHES MXU 500

Check the 2WD switch or 4WD switch. Faulty 2WD/ switch or 4WD
(See page 12) Incorrect switch

Correct

Open circuit in wire harness

The 2WD/4WD motor runs, but does not

shift to 2WD/4WD. Check the front drive
sliding dog (refer to the “FRONT DRIVE
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the chapter 13).

INSPECTION

2WD/4WD motor

Remove the 2WD/4WD motor (refer to the

“FRONT DRIVE
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the chapter 13).

Connect the 12 V battery to the 2WD/4WD

motor lead wires as shown. If the motor
does not run , replace the motor assembly
with a new one.

Install the 2WD/4WD motor and tighten the

bolts to the specified torque (refer to the
“FRONT DRIVE
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the chapter 13).

2WD/4WD selecting button

2WD/4WD Select Button

20-11
20. LIGHTS/SWITCHES MXU 500

2WD/4WD change ECU

Make sure the 2WD/4WD selecting button

is correct (see page 20-11).
Disconnect the 2WD/4WD motor
connector.

Turn on the ignition switch.

Listen for a click from the 2WD/4WD
change ECU when the 2WD/4WD selecting
button is pushed.

2WD/4WD Change ECU

4WD Switch Connector (White)

2WD switch and 4WD switch

Remove the 2WD/4WD motor (refer to the

“FRONT DRIVE
DISASSEMBLY/INSPECTION/
ASSEMBLY” section in the chapter 13).

Disconnect the switch connectors.

2WD Switch Connector (Black)

4WD Switch Connector

Remove the 2WD switch and 4WD switch.

Inspect the switches.

2WD Switch Connector

20-12
20. LIGHTS/SWITCHES MXU 500

Apply three bond: 1215 to the 2WD/4WD

switches and tighten them to the specified
torque.

Torque: 2.2 kgf-m (22 N-m, 16 lbf-ft)

FUEL UNIT

REMOVAL

Remove the fuel tank cover (refer to the

“FRAME COVERS” section in the chapter
2).

Remove the fuel unit connectors.

Remove the four bolts, then remove the fuel
unit from fuel tank.
Fuel Unit Connectors
INSPECTION

Measure the resistance between the

Yellow/White and Blue/White terminals of
the fuel unit connector.

Standard (at 20°C/68°F):

Float at full position 1100 ± 33 Ω
Float at empty position 100 ± 3 Ω

INSTALLATION

Fuel unit installation is in the reverse order

of removal.
＊ Align the tab on the fuel unit with the
mark on the fuel tank.

20-13
21. WIRING DIAGRAMS MXU 500

21

21

21-0
21. WIRING DIAGRAMS MXU 500

21-1