HOW TO USE THIS MANUAL A Few Words About Safety Service Information The service and repair information contained in this manual is intended ior use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal saiety and the safe operation of the vehicle. It you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer‘s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. AWARNING Improper service or repairs can create an unsafe condition that can cause your customer orothers to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. For Your Safety Because this manual is intended for the proiessional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts—wear gloves). If you have not received shop safety training or do not ieel confident about your knowledge oi saie servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Some oi the most important general service safety precautions are given below. However, we cannot warn you oi every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful oi the following: ~ Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to periorm the tasks safely and completely. ~ Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dri|l, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. ~ Use other protective wear when necessary, ior example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. ~ Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do othenNise. This will help eliminate several potential hazards: ~ Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine ~ Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. ~ Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. ~ Use only a nonilammable solvent, not gasoline, to clean parts. ~ Never drain or store gasoline in an open container. ~ Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. 0-1 HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures tor the CRF250L. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures Ior removal/installation ol components that may be required to perlorm service described in the Iollowing sections. Section 4 through 20 describe parts ol the motorcycle, grouped according to location. Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition. Perlorming the Iirst scheduled maintenance is very important. It compensates tor the initial wear that occurs during the break-in period. Find the section you want on this page, then turn to the table oi contents on the Iirst page ol the section. Most sections start with an assembly or system illustration, service inlormation and troubleshooting tor the section. The subsequent pages give detailed procedure. Reler to the troubleshooting in each section according to the maliunction or symptom. In case oI an engine trouble, reler to PGM-Fl section troubleshooting lirst. Your salety, and the salety ol others, is very important. To help you make inlormed decisions we have provided salety messages and other inlormation throughout this manual. OI course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will lind important salety inlormation in a variety ol lorms including: - Salety Labels — on the vehicle - Salety Messages — preceded by a salety alert symbol : and one ol three signal words, DANGER, WARNING, or CAUTION. These signal words mean: “DANGER You WILL be KILLED or SERIOUSLY HURT it you don’t lollow instructions. m You CAN be KILLED or SERIOUSLY HURT it you don't lollow instructions. ACAUTION You CAN be HURT it you don’t lollow instructions. - Instructions — how to service this vehicle correctly and salely. As you read this manual, you will lind inlormation that is preceded by a m symbol. The purpose oI this message is to help prevent damage to your vehicle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. © Honda Motor (20., le. SERVICE PUBLICATION OFFICE Date ol Issue: June, 2012 HOW TO USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specilic service procedures. ll supplementary inlormation is required pertaining to these symbols, it would be explained specilically in the text Without the use ol the symbols. Replace the part(s) with new one(s) betore assembly. Use the recommend engine oil, unless otherwise specified. Use molybdenum ml solution (mixture oi the engine oil and molybdenum grease in a ratio at 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disultide grease (containing more than 3% molybdenum disuliide, NLGI #2 or equivalent). Example: O Molykote® ER-2 plus manutactured by Dow Corning U.S.A. O Multi-burbose M-2 manutactured by Mitsubishi Oil, Japan Use molybdenum disullide paste (containing more than 40% molybdenum disuliide, NLGI #2 or equivalent). Example: O Molykote® G-n Paste manulactured by Dow Corning U.S.A. O Honda Moly 60 (U.S.A. only) O Rocol ASP manulactured by Rocol Limited, UK. O Rocol Paste manutactured by Sumico Lubricant, Japan Use silicone grease. Apply locking agent. Use a medium strength locking agent unless otherwise specitied. Apply sealant. Use DOT 3 or DOT 4 brake lluid. Use the recommended brake tluid unless otherwise specitied. Use tork or suspension tluid. CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PG M-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER SYSTEM FUEL SYSTEM LUBRICATION SYSTEM COOLING SYSTEM CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRAN KCASE/CRANKSHAFT/TRANSMISSION/BALANCER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION q BRAKE SYSTEM BATTERY/CHARGING SYSTEM LIGHTS/METERS/SWITCHES WIRING DIAGRAM 21 INDEX MEMO 1. GENERAL INFORMATION SERVICE RULES-m- ----1-2 LUBRICATION 81 SEAL POINTS MODEL IDENTIFICATION CABLE & HARNESS ROUTING ......... SPECIFICATIONS ......................................... 1.4 EMISSION CONTROL SYSTEMS ..............1.27 TORQUE VALUES 1g GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed Ior this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable With English Iasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt lirst. Then tighten to the speciiied torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surIaces beIore reassembly. 7. After reassembly, check all parts ior proper installation and operation. 8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-17). 9. Do not bend or twist control cables. Damaged control cables Will not operate smoothly and may stick or bind. ABBREVIATION Throughout this manual, the lollowing abbreviations are used to identin the respective parts or systems. Abbrev. term Full term CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memory IACV Idle Air Control Valve IAT sensor Intake Air Temperature sensor MAP sensor ManiIoId Absolute Pressure sensor MIL Maliunction Indicator Lamp PAIR Pulse Secondary Air Injection PGM-Fl Programmed Fuel Iniection SCS connector Service Check Short connector TP sensor Throttle Position sensor VS sensor Vehicle Speed sensor DESTINATION CODE Throughout this manual, the lollowing codes are used to identify individual types Ior each region. DESTINATION CODE REGION E U.K. F France ED European direct sales U Australia, New Zealand MODEL IDENTIFICATION GENERAL INFORMATION SERIAL NUMBERS/LABELS The Vehicle Identification Number (V.|.N.) [1] is stamped on the right side 01 the steering head. [1] The throttle body identilication number [1] is stamped on the lower left side of the throttle body. [1] The engine serial number [1] is stamped on the lower lelt side of the crankcase. The Registered Number Plate (except U type) /Compliance plate (U type) [1] is stamped on the left lront side of the steering head. The color label [1] is attached on the frame behind rear brake master cylinder reservoir. When ordering color—coded parts, always specily the designated color code. 1-3 GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,195 mm (36.4 in) Overall width 815 mm (32.1 in) Overall height 1,195 mm (47.0 in) Wheelbase 1,445 mm (56.9 in) Seat height 875 mm (34.4 in) Footpeg height 365 mm (14.4 in) Ground clearance 255 mm (10.0 in) Curb weight 143 kg (315 lbs) Maximum weight capacity 159 kg (351 lbs) FRAME Frame type Twin tube Front suspension Telescopic tbrk Front axle travel 222 mm (8.7 in) Rear suspension Swingarm Rear axle travel 240 mm (9.4 in) Tire size Front 3.00-21 51F Rear 120/80-1BM/C 62F Tire brand Front GP-21 F Z (IRC) Rear GP-22R (IRC) Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 27° 35‘ Trail length 113 mm (4.4 in) Fuel tank capacity 7.7 liter (2.03 US gal, 1.69 Imp gal) ENGINE Cylinder arrangement Single cylinder inclined 20° lrom vertical Bore and stroke 76.0 x 55.0 mm (2.99 x 2.17 in) Displacement 249.6 cm (15.23 cu-in) Compression ratio 10.7:1 Valve train Chain driven DOHC with rocker arm Intake valve opens at 1.0 mm (0.04 in) liit 20" BTDC closes at 1 .0 mm (0.04 in) liit 35° ABDC Exhaust vaIve opens at 1.0 mm (0.04 in) liit 40° BBDC closes at 1 .0 mm (0.04 in) liit 0° TDC Lubrication system Forced pressure and wet sump Oil pump type Trochbid Cooling system Liquid cooled Air filtration Viscous paper iiIter Engine dry weight 34.5 kg (76.1 lbs) FUEL DELIVERY Type PGM-FI SYSTEM Throttle bore 36 mm (1.4 in) DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Cable operating Transmission Constant mesh, 6 speeds Primary reduction 2.807 (73/26 Final reduction 2.357 (40/14 Gear ratio 1st 3.333 (40/12 2nd 2.117 (36/17 3rd 4th 1.304 (30/23 5th 1.115 (29/26 6th ) I ) ) 1.571 (33/21) ) ) ) 0.962 (26/27 Gearshilt pattern Left lobt operated return system 1-N-2-3-4-5-6 ELECTRICAL Ignition system Computer-controlled digital transistorized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase tulI-wave rectilicatibn Lighting system Battery PGM-Fl SYSTEM SPECIFICATIONS GENERAL INFORMATION ITEM SPECIFICATIONS Fuel in)ector resistance (20°C/68°F) 11—130 IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATION Spark plug SIMRBAQ (NGK) Spark plug gap 0.80 7 0.90 mm (0.031 — 0.035 in) Ignition coil peak voltage 100 V minimum CKP sensor peak voltage 0.7 V minimum Ignition timing ("F" mark) 10° BTDC at idle ELECTRIC STARTER SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 11.8 — 12.3 (0.46 — 0.43) 6.5 (0.26) FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number (3032A Engine idle speed 1,450 i 100 min‘ (rpm) Throttle grip ireeplay 2 — 6 mm (0.08 — 0.24 in) Fuel pressure at idle 343 kPa (3.5 kgt/cm , 50 psi) Fuel pump llow (at 12 V) 83 cm (2.81 US oz, 2.92 Imp oz) minimum/10 seconds PAIR control solenoid valve resistance (20°C/68°F) 20 — 24 0 LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 1.4 liters (1.5 US qt, 1.2 lmp qt) — At oil lilter change 1.5 liters (1.6 US qt, 1.3 lmp qt) — At disassembly 1.8 liters (1.9 US qt, 1.6 Imp qt) — Recommended engine oil Honda "II-stroke motorcycle oil" or an equivalent API classification: SG or higher (except oils labeled as energy conserving on the — circular APl service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.003) Body clearance 0.15 — 0.22 (0.006 — 0.009) 0.35 (0.014) Side clearance 0.02 — 0.09 (0.001 — 0.004) 0.10 (0.004) GENERAL INFORMATION COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1.02 liters (1.08 US qt, 0.90 Imp qt) At draining 0.74 liter (0.78 US qt, 0.65 imp qt) Reserve tan k 0.16 liter (0.17 US qt, 0.14 imp qt) Radiator cap reliel pressure 932 — 122.6 kPa (0.95 — 1.25 kgl/cm , 13.5 —17.8 psi) Thermostat Begin to open 81 — 84"C (178 —133°F) Fully open 95°C (203°F) Valve lift 4.5 mm (0.18 in) minimum Recommended coolant High quality ethylene glycol antilreeze containing silicate-tree corrosion inhibitors Standard coolant concentration 1 :1 (mixture With distilled water) CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 490 min‘ (rpm) 1294 kPa (13.2 kgt/cm , 188 psi) — Valve clearance IN 0.16 1 0.03 (0.006 t 0.001) — EX 0.27 t 0.03 (0.011 t 0.001) — Valve, valve Valve stem O.D. IN 4.475 — 4.490 (0.1762 — 0.1768) 4.46 (0.176) guide EX 4.435 — 4.430 (0.1753 — 0.1764) 4.45 (0.175) Valve guide |.D. IN/EX 4.500 — 4.512 (0.1772 — 0.1776) 4.540 (0.1797) Stem-to-guide IN 0.010 — 0.037 (0.0004 — 0.0015) 0.07 (0.003) clearance EX 0.020 — 0.047 (0.0008 — 0.0019) 0.08 (0.003) Valve guide height lN/EX 13.8 — 14.0 (0.54 — 0.55) — Valve seat Width IN/EX 0.90 — 1.10 (0.035 — 0.043) 1.50 (0.059) Valve spring Free length Inner 34.58 (1.361) 32.85 (1.293) Outer 40.37 (1.539) 33.35 (1.510) Rocker arm, Arm I.D. IN/EX 10.000 — 10.015 (0.3937 — 0.3943) 10.10 (0.398) TOCKSV arm ShaIt O.D. IN/EX 9.972 — 9.987 (0.3926 — 0.3932) 9.91 (0.390) Sha" ““05”" IN/EX 0 013 — 0 043 (0 0005 — 0 0017) 0 10 (0 004) clearance ' ' ' ' ' ' Camshalt Cam lobe height IN 30.931 — 31.171 (1.2179 — 1.2272) 30.911 (1.2170) EX 30.839—31.079(1.2141—1.2236) 30.319(1.2133) Camshaft )ournal O.D. 19.959 — 19.930 (0.7858 — 0.7866) — Oil clearance 0.020 — 0.062 (0.0008 — 0.0024) 0.10 (0.004) Cylinder Camshaft )ournal area |.D. 20.000 — 20.021 (0.7874 — 0.7882) — head Warpage — 0.05 (0.002) CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder |.D. 76.000 — 76.010 (2.9921 — 2.9925) 73.04 (2.994) Out-ol-round — 0.010 (0.0004) Taper — 0.010 (0.0004) Warpage — 0.05 (0.002) Piston, iston Piston O.D. at 11 mm 0.4 in trom pin, p‘sfim bottom 1 I 75.960 — 75.990 (2.9905 — 2.9913) 75.39 (2.939) ring Piston pin hole |.D. 17.002 — 17.008 (0.6694 — 0.6696) 17.030 (0.6705) Piston pin O.D. 16.994 — 17.000 (0.6691 — 0.6693) 16.980 (0.6685) Piston-to-piston pin clearance 0.002 — 0.014 (0.0001 — 0.0006) 0.02 (0.001) Piston ring end Top 0.28 — 0.33 (0.011 — 0.015) 0.40 (0.016) gap Second 0.40 — 0.55 (0.016 — 0.022) 0.70 (0.023) Oil (side rail) 0.20 — 0.70 (0.009 — 0.023) 1.10 (0.043) Piston ring-to-ring Top 0.040 — 0.080 (0.0016 — 0.0031) 0.10 (0.004) groove clearance Second 0.015 — 0.050 (0.0006 — 0.0020) 0.09 (0.004) Cylinder-to-piston clearance 0.020 — 0.050 (0.0008 — 0.0020) 0.09 (0.004) Connecting rod small end |.D. 17.016 — 17.034 (0.6699 — 0.6706) 17.06 (0.672) Connecting rod-td-piston pin clearance 0.016 — 0.040 (0.0006 — 0.0016) 0.10 (0.004) 1-6 GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever treeplay 10 — 20 (0.4 — 0.8) — Clutch Spring tree length 41.5 (1.63) 37.5 (1.48) Disc thickness Disc A/B 2.30 — 2.50 (0.091 — 0.098) 2.27 (0.089) Plate warpage Plate A/E — 0.30 (0.012) Clutch outer guide |.D. 20.000 — 20.021 (0.7874 — 0.7882) 20.04 (0.789) Mainshalt O.D. at clutch outer guide 19.967— 19.980 (0.7861 — 0.7866) 19.947 (0.7853) ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear LD. 34.000 — 34.013 (1.3386 — 1.3391) 34.033 (1.3399) O.D. 51.705— 51.718 (20356—20361) 51.685 (2.0348) CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshail Runout — 0.03 (0.001) Connecting rod big end radial clearance 0.004 — 0.016 (0.0002 — 0.0006) 0.05 (0.002) Connecting rod big end side clearance 0.05 — 0.50 (0.002 — 0.020) 0.85 (0.033) Main )ournal oil clearance 0.018 — 0.045 (0.0007 — 0.0018) 0.075 (0.0030) Main )ournal O.D. 33.985 — 34.000 (1.3380 — 1.3386 33.975 (1.3376) Main )ournal bearing support |.D. 38.000 — 38.018 (1.4961 — 1.4968 38.038 (1.4975) ) Transmission Gear |.D. M5, M6 23.000 — 23.021 (0.9055 — 0.9063) 23.07 (0.908) 01 23.020 — 23.041 (0.9063 — 0.9071) 23. 09 (0. 909) 02 25.000 — 25.021 (0.9843 — 0.9851) 25. 04 (0. 986) 08, C4 28.000 — 28.021 (1.1024 — 1.1032) 28.04 (1.104) Bushing O.D. M5, M6 22.959 — 22.980 (0.9039 — 0.9047) 22.91 (0. 902) 01 22.984 — 23.005 (0.9049 — 0.9057) 22. 47 (0. 885) 02 24.959 — 24.980 (0.9828 — 0.9835) 24. 90 (0. 980) 03,04 27959—27980 (1.1007—1.1016) 27. 95(1. 100) Gear-lo-bushin M5, M6, C2, clearance 9 03, 04 0.020 — 0.082 (0.0008 — 0.0024) 0.10 (0.004) 01 0015—0057 (0.0008—0.0022) 0.10 (0.004) Bushing |.D. M5, 01 20.000 — 20.021 (0.7874 — 0.7882) 20.05 (0. 789) 02 22.000 — 22.021 (0.8661 — 0.8670) 22.07 (0. 869) 03 25.000 — 25.021 (0.9843 — 0.9851) 25.04 (0. 986) MainshaIt/ at M5 bushing 19.959 — 19.980 (0.7858 — 0.7866) 19.91 (0. 784) countershatt CD. at c1 bushing 19.959 — 19.980 (0.7858 — 0.7866) 19.91 (0.784) at c2 bushing 21.959 — 21.980 (0.8645 — 0.8654) 21.91 (0. 863) at ca bushing 24.959 — 24.980 (0.9826 — 0.9835) 24.90 (0. 980) Bushin -to-shaIt clearangce M5, 01, 02, 03 0.020 — 0.082 (0.0008 — 0.0024) 0.10 (0.004) Shiil Iork, ShiIt iork shaIt O.D. 11.957 — 11.988 (0.4707 — 0.4712) 11.95 (0.470) shift lork ShiIt iork |.D. 12.000 — 12.018 (0.4724 — 0.4731) 12.05 (0.474) shat) Shilt iork claw thickness 4.93 — 5.00 (0.194 — 0.197) 4.82 (0.190) Shift drum Shill drum O.D. Left side 18.968 — 18.984 (0.5498 — 0.5508) 13.94 (0.549) '53“ mum 19””3' Lell side 14.000 — 14.027 (0.5512 — 0.5522) 14.06 (0.554) Shift drum-to-shiil drum )ournal LeIl side 0.016 — 0.061 (0.0008 — 0.0024) 0.08 (0.008) clearance GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire thread depth — 3.0 (0.12) Cold tire pressure Driver only 150 kPa (1.50 kgt/cm , 22 psi) — Driver and passenger 150 kPa (1.50 kgt/cm , 22 psi) — Axle runout — 0.2 (0.01) Wheel rim runout Radial — 2.0 (0.08) Axial — 2.0 (0.00) Wheel hub-to-rlm distance 23.45 t 1.0 (0.92 1 0.04) — Fork Spring tree length (Right side only) 575.0 (22.64) — Pipe runout — 0.20 (0.008) Recommended Iork Iluld Honda ULTRA CUSHION OIL 10W or _ equivalent Fluid level Right 122 (4.8) — Left 38 (1.5) Fluid capacity Right 65B 1 2.5 cm _ (22.3 t 0.08 US oz, 23.2 t 0.09 Imp oz) Lett 683 i 2.5 cm (23.1 t 0.08 US oz, 24.0 t 0.09 Imp oz) Steering head bearing pre-load 10.6 — 21.2 N — (1.00 7 2.10 kgl, 2.33 7 4.77 lbl) REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire thread depth — 3.0 (0.12) Cold tire pressure Driver only 150 kPa (1.50 kgt/cm , 22 psi) — Driver and passenger 150 kPa (1.50 kgt/cm , 22 psi) — Axle runout — 0.2 (0.01) Wheel rim runout Radial — 2.0 (0.08) Axial — 2.0 (0.03) Wheel hub-to-rlm distance 26.9 1 1.0 (1.06 i 0.04) — Drive chain Size/link DID520VF-106LE — Slack 25—35(10—14) — BRAKE SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specltied brake iluid DOT 3 or DOT 4 — Brake pad wear indicator — To groove Brake disc thickness 3.3—3.7 (0.13—0.15) 3.0 (0.12) Brake disc warpage 0.3 (0.01) Master cylinder l.D. 12.700 — 12.743 0.5000 — 0.5017 12.755 (0.5022) Master piston O.D. 12.657 — 12.684 0.4983 — 0.4994 12.045 (0.4970) Caliper cylinder |.D. 27.000 — 27.050 27.060 (1.0054) Caliper piston O.D. 26.935 — 26.968 1.0604 — 1.0617 ) ) 1.0030 — 1.0050) ) 20.30 (1.0507) Rear Specltied brake iluid DOT 3 or DOT 4 Brake pad wear indicator — To groove Brake disc thickness 4.3—4.7 (0.17—0.19) 4.0 (0.16) Brake disc warpage 0.3 (0.01) Master cylinder l.D. 12.700 —12.743 0.5000 — 0.5017 12.755 (0.5022) Master piston O.D. 12.657 — 12.684 0.4983 — 0.4994 12.045 (0.4970) Caliper cylinder |.D. 27.060 (1.0054) Caliper piston O.D. ) ) 27.000 — 27.050 1.0030 — 1.0050) 20.935 — 26.968 1.0604 — 1.0017) 20.30 (1.0507) Brake pedal height 04 — 05 (2.52 — 2.50) GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type YTX7L-BS Capacity 12 V - 6 Ah (10 HR) Current leakage 0.34 mA max. Voltage Fully charged 13.0 — 13.2 V (20 0’68 F) gagging Below 12.3 v Charging current Normal 0.6 A/5 — 10 h Quick 3 N1 h Alternator Capacity 0.34 kW/5,000 mIn' (rpm) Charging coII resistance (20°C/6B°F) 0.1 — 1.0 {'2 LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATION Bulbs Headlight 12 V - 60/55 W Position light 12 V - 5 W Brake/laillighl 12 V - 21/5 W Front turn signal light 12 V - 21 W x 2 Rear turn signal light 12 V - 21 W x 2 Instrument light LED Turn sIgnal indicator LED High beam indicator LED Neutral indicator LED MIL LED Fuse Main luse 30 A Subiuse 10Ax5,5Ax1 TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TVPE N_m (kgm’ lbw) FASTENER TYPE N_m (kglm! M") 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6) (Include SH flange bolt) 6 mm llange boll (8 mm head, large 8 mm bolt and nut 22 (2.2, 16) llange) and nut 12 (1.2, 9) 10 mm bolt and nut 34 (3.5, 25) 8 mm llange boll and nut 27 (2.8, 20) 12 mm bolt and nut 54 (5.5, 40) 10 mm lIange bolt and nut 39 (4.0, 29) GENERAL INFORMATION ENGINE & FRAME TORQUE VALUES ~ Torque specifications listed below are for important fasteners. ~ Others should be tightened to standard torque values listed above. FRAME/BODY PANELS/EXHAUST SYSTEM . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Hook bolt 4 8 21 (2.1, 15) Left side cover assembly screw 2 4 0.9 (0.1, 0.7) Right fuel tank shroud assembly screw 4 4 0.9 (0.1, 0.7) Leltfuel tank shroud assembly screw 2 4 0.9 (0.1, 0.7) Headlight cowl mounting bolt 4 6 8.5 (0.9, 6.3) Rear side rellector mounting nut (U type 2 6 1.5 (0.2, 1.1) U-nut only) Rear reflector mounting nut 1 5 1.5 (0.2, 1.1) U-nut Brake/taillight mounting screw 3 6 4.5 (0.5, 3.3) Exhaust pipe protector socket bolt 2 6 12 (1.2, 9) Muffler protector cover screw 5 4 1.5 (0.2, 1.1) Muffler front mounting bolt 1 8 32 (3.3, 24) Muffler band bolt 1 8 22.5 (2.3, 17) Exhaust pipe joint nut 2 8 18 (1.8, 13) Exhaust pipe stud bolt 2 8 — See page 2-11 Air cleaner connecting hose band screw 1 4 1.5 (0.2, 1.1) Sub-frame upper mounting nut 2 8 27 (2.8, 20) Sub-frame lower mounting bolt 2 8 27 (2.8, 20) Rear master cylinder reservoir mounting 1 6 10 (1.0, 7) bolt Sidestand pivot bolt 1 10 10 (1.0, 7) See page 2-14 Sidestand pivot lock nut 1 10 30 (3.1, 22) U-nut, See page 2-14 MAINTENANCE ITEM Q‘TV THREAD TORQUE REMARKS DIA. (mm) N-m (kgf—m, lbf—fl) Throttle cable A adjuster lock nut (throttle body side) 1 6 3.0 (0.3, 2.2) Air cleaner cover screw 4 5 1.2 (0.1, 0.9) Spark plug 1 10 16(1.6, 12) Crankshaft hole cap 1 30 8.0 (0.8, 5.9) Apply engine oil to the threads. Timing hole cap 1 14 6.0 (0.6, 4.4) Apply engine oil to the threads. Engine oil drain bolt 1 12 24 (2.4, 18) Drive chain ad)uster lock nut 2 8 27 (2.8, 20) UBS nut Rear axle nut 1 16 88 (9.0, 65) U-nut Drive sprocket fixing plate bolt 2 6 10 (1.0, 7) Driven sprocket nut 6 10 50 (5.1, 37) U-nut Rear master cylinder reservoir mounting 1 6 10 (1.0, 7) bolt Master cylinder reservoir cover screw 4 4 1.5 (0.2, 1.1) Rear master cylinder push rod lock nut 1 8 17.2 (1.8, 13) Front spoke 36 BC 3.2 3.7 (0.4, 2.7) Rear spoke 32 BC 3.2 3.7 (0.4, 2.7) PGM-FI SYSTEM . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Sensor unit torx screw 3 5 3.4 (0.3, 2.5) ECT sensor 1 12 25 (2.5, 18) 02 sensor 1 12 25 (2.5, 18) Bank angle sensor mounting nut 2 6 9.0 (0.9, 6.6) 1-10 GENERAL INFORMATION IGNITION SYSTEM , THREAD TOROUE ”EM 0 TV DIA. (mm) N-m (kgI-m, Ibf-fl) REMARKS Timing hole cap 1 14 6.0 (0.6, 4.4) Apply engine oil to the threads. ELECTRIC STARTER . THREAD TOROUE ”EM 0 TV DIA. (mm) N-m (kgI-m, Ibf-fl) REMARKS Negative brush screw 1 5 3.7 (0.4, 2.7) Starter motor assembly bolt 2 5 4.9 (0.5, 3.6) FUEL SVSTEM . THREAD TOROUE ITEM a TV DIA. (mm) N-m (kgI-m, Ibf-fl) REMARKS Fuel pump mounting nut 6 6 12 (1.2, 9) For tightening sequence (page 7-9). Air cleaner housing mounting bolt 3 6 7.0 (0.7, 5.2) Insulator band screw 2 5 4.2 (0.4, 3.1) See page 7-13 Air cleaner connecting hose band screw 1 4 1.5 (0.2, 1.1) Throttle cable stay screw 2 5 3.4 (0.3, 2.5) Clamp stay screw 1 5 3.4 (0.3, 2.5) Throttle cable A )oint nut (grip side) 1 10 1.5 (0.2, 1.1) Throttle cable B )oint nut (grip side) 1 12 1.5 (0.2, 1.1) Throttle cable B nut (throttle body side) 1 6 3.0 (0.3, 2.2) ln)ector)oint mounting bolt 2 5 5.1 (0.5, 3.8) lACV setting plate torx screw 2 4 2.1 (0.2, 1.5) PAlR check valve cover bolt 2 5 5.2 (0.5, 3.8) COOLING SYSTEM , THREAD TOROUE ”EM 0 TV DIA. (mm) N-m (kgI-m, Ibf-fl) REMARKS Water hose band screw 4 — — See page 9-7 Fan motor shroud mounting bolt 3 6 8.5 (0.9, 6.3) Fan motor screw 3 4 2.7 (0.3, 2.0) Cooling lan nut 1 3 1.0 (0.1, 0.7) Apply locking agent to the threads. Water pump impeller 1 7 10 (1.0, 7) CVLINDER HEAD/VALVES , THREAD TOROUE ”EM 0 TV DIA. (mm) N-m (kgI-m, Ibf-fl) REMARKS Cylinder head cover bolt 2 6 10 (1 .0, 7) Camshaft holder mounting bolt 8 6 12 (1.2, 9) Applyengineoil to thethreads and seating surlace. Cylinder head mounting nut 4 10 45 (4.6, 33) Apply engineoil to thethreads and seating surlace. Cam chain tensioner litter plug 1 6 4.2 (0.4, 3.1) CYLINDER/PISTON , THREAD TOROUE ”EM 0 TV DIA. (mm) N-m (kgI-m, Ibf-fl) REMARKS Cylinder stud bolt 4 10 — See page 11-4 Cam chain tensioner litter plug 1 6 4.2 (0.4, 3.1) 1-11 GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Clutch center lock nut 1 16 108 (11.0, 80) Lock nut; replace Wllh a new one and stake. Apply engine oil to the threads and seating surlace. Clutch lilter plate bolt 5 6 12 (1.2, 9) Shift drum stopper plate bolt 1 6 10 (1 .0, 7) Apply locking agent to the threads. Shift drum stopper arm bolt 1 6 10 (1 .0, 7) Apply locking agent to the threads. Gearshilt spindle return spring pin 1 8 30 (3.1, 22) Apply locking agent to the threads. Primary drive gear lock nut 1 16 108 (11.0, 80) Apply engine oil to thethreads and seating surlace. ALTERNATOR/STARTER CLUTCH . THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Stator mounting socket bolt 3 6 10 (1 .0, 7) CKP sensor mounting socket bolt 2 6 10 (1 .0, 7) Apply locking agent to the threads. Coating width: 6.5 t 1.0 mm (0.26 1 0.04 in) irom tip Flywheel bolt 1 12 128 (13.1, 94) Apply engine oil tothe threads and seating surlace. Starter clutch socket bolt 6 8 30 (3.1, 22) Apply locking agent to the threads. CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Balancer shait nut 1 14 44 (4.5, 32) Apply engine oil to the threads and seating surlace. Cam chain tensioner pivot bolt 1 6 10 (1.0, 7) Apply locking agent to the threads. Coating width: 6.5 :1.0 mm (0.26 1 0.04 in) irom tip ENGINE REMOVAL/INSTALLATION , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Rear engine mounting nut 2 10 45 (4.6, 33) Front engine mounting nut 2 10 55 (5.6, 41) Engine hanger plate bolt 2 8 27 (2.8, 20) Drive sprocket lixing plate bolt 2 6 10 (1 .0, 7) 1-12 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgi-m, Ibf-fl) REMARKS Front axle bolt 1 14 73.5 (7.5, 54) Front axle pinch bolt 2 8 20 (2.0, 15) Front brake disc bolt 6 6 20 (2.0, 15) ALOC bolt; replace With a new one. Front spoke 36 BC 3.2 3.7 (0.4, 2.7) Top bridge pinch bolt 4 8 32 (3.3, 24) Bottom bridge pinch bolt 4 8 32 (3.3, 24) Front brake hose guide bolt 2 6 10 (1.0, 7) Front brake hose clamp bolt 2 6 10 (1 .0, 7) Fork protector socket bolt 6 6 7.0 (0.7, 5.2) ALOC bolt; replace With a new one. Front brake caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt; replace With a new one. Fork center bolt 1 8 20 (2.0, 15) Apply looking agent to the threads. Fork rod lock nut (Right side) 1 10 20 (2.0, 15) Fork inner damper rod lock nut (Left side) 1 10 20 (2.0, 15) Fork cap 2 50 35 (3.6, 26) Handlebar switch housing screw 4 5 2 5 (0.3, 1.8) Front master cylinder holder bolt 2 6 9 8 (1 .0, 7.2) Steering stem ad)usting nut 1 26 — Apply engine oil to the threads. See page 16-24 Steering stem nut 1 24 103 (10.5, 76) See page 16-24 Clutch lever pivot bolt 1 6 1.0 (0.1, 0.7) Apply grease to the sliding surlace. Clutch lever pivot nut 1 6 5.9 (0.6, 4.4) REAR WHEEL/SUSPENSION . THREAD TORQUE ”EM a TV DIA. (mm) N-m (kgi-m, Ibf-fl) REMARKS Rear axle nut 1 16 88 (9.0, 65) U-nut Driven sprocket nut 6 10 50 (5.1 , 37) U-nut Rear brake disc bolt 4 8 42 (4.3, 31) ALOC bolt; replace with a new one. Rear spoke 32 BC 3.2 3.7 (0.4, 2.7) Shock absorber upper mounting nut 1 10 54 (5.5, 40) U-nut Shock absorber lower mounting nut 1 10 44 (4.5, 32) U-nut Shock link nut 2 10 44 (4.5, 32) U-nut Shock arm-to-swingarm nut 1 12 74 (7.5, 55) U-nut Apply engine oil to the threads. Swingarm pivot nut 1 14 38 (9.0, 65) U-nut Rear brake hose guide mounting screw 2 5 1.2 (0.1, 0.9) Chain slider mounting screw 4 5 4.2 (0 .1) ALOC screw; replace with a new one. Chain case stay mounting screw 1 6 4 2 (0.4, 3 1) ALOC screw; replace with a new one. Chain guide mounting bolt 2 6 10 (1 .0, 7) ALOC bolt; replace with a new one. Chain slider guide mounting nut 2 6 2 5 (0.3, 1 8) U-nut 1-13 GENERAL INFORMATION BRAKE SYSTEM . THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Brake caliper bleed valve 2 8 5.4 (0.6, 4.0) Master cylinder reservoir cover screw 4 4 1.5 (0.2, 1.1) Rear master cylinder reservoir mounting 1 6 10 (1 .0, 7) bolt Front brake pad pin 1 10 17.2 (1.8, 13) Rear brake pad pin 1 10 17.2(1.8, 13) Brake hose oil boll 4 10 '34 (3.5, 25) Front master cylinder holder bolt 2 6 9 8 (1.0, 7 2) Front brake light switch screw 1 4 1.2 (0.1, 0.9) Rear master cylinder mounting bolt 2 6 14 (1.4, 10) ALOC boll; replace with a new one. Rear master cylinder push rod lock nut 1 8 17.2(1.8,1‘3) Brake lever pivot boll 1 6 1.0 (0.1, 0.7) Apply 0.1 g (0.004 oz) 01 silicone grease to the sliding surtace. Brake lever pivot nut 1 6 5.9 (0.6, 4.4) Front brake caliper mounting bolt 2 8 '30 (3.1, 22) ALOC boll; replace with a new one. Front brake caliper bracket pin 1 8 17.2(1.8, 13) Rear brake reservoir stay mounting 1 6 1.5 (0.2, 1.1) screw BATTERY/CHARGING SYSTEM , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Battery holder plaie bolt 2 6 7.0 (0.7, 5.2) LIGHTS/METERS/SWITCHES . THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf—m, lbf—fl) REMARKS Headlight unit mounting screw 4 5 1.2 (0.1, 0.9) Turn signal unii mounting nut 4 10 1 (2.1,15) Brake/taillight mounting screw 3 6 4.5 (0.5, 3 3) Hook bolt 4 8 21 (2.1, 15) Speedometer mounting screw 3 5 1.0 (0.1, 0.7) ignition switch mounting bolt 2 8 24 (2.4, 18) One-way bolt; replace with a new one. Neutral switch 1 10 12 (1.2, 9) Sidesiand switch mounting boll 1 6 10 (1 .0, 7) ALOC bolt; replace with a new one. 1-14 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant (Three bond 1207B,1215 or equivalent) Left crankcase mating surface See page 14-18 Alternator/CKP sensor wire grommet sealing surface Liquid sealant (Three bond 52110,1207B,1215,SS KE45 or equivalent) Cylinder head semi-circular cut-out Engine oil Oil pump rotor entire surface Oil pump shaft outer surface Water pump shaft outer surface Carn chain whole surface Cylinder inner surface Piston pin hole inner surface, ring groove and sliding surlace Piston ring entire surface Clutch disc entire surface Gearshift spindle shaft outer surface Starter one-way clutch sprag Starter driven gear sliding surface Each oil seal lips Each bearing rotating area Each gear teeth Each O-ring M u|ti-pu rpose grease Each oil seal lips (clutch lifter arm, gearshift spindle, countershaft, water pump) Molybdenum oil solution (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease) Valve stern sliding surlace Camshaft lobes and journal Rocker arm shalt outer surface Rocker arm inner surface, roller surface and slipper surlace Piston pin outer surface Clutch outer guide whole surlace Clutch lifter arm sliding surface Starter reduction gear inner surface Starter reduction gear shaft outer surface Crankshaft main journal bearing sliding surface Connecting rod big end sliding surface Connecting rod small end inner surface Left crankshaft needle bearing rotating surface Balancer driven gear and sub gear sliding surface Shilt fork inner surface and guide pin Shilt fork shaft outer surface Shilt drum journal outer surface and grooves M5, Cl, CE, OS gear bushing entire surface M6, C4 gear bushing outer surface Locking agent Mainshaft bearing setting plate bolt threads Coating width: 6.5 11.0 mm (0.26 10.04 in) fromtip 1-15 GENERALINFORMAHON FRAME MATERIAL LOCATION REMARKS Urea based multi-purpose grease with extreme pressure agent (example: Kyodo Yushi, EXCELITE EP2 or equivalent) Steering head bearing inner race and outer race rolling surlace 3—sg(0.1i—0.1soz) Steering head bearing dust seal lips Multi-purpose grease Sidestand pivot sliding surlace Axle outer surtace Throttle pipe llange cable groove Shock linkage needle bearing rotating area Shock linkage collar wnole suriace Swingarm pivot needle bearing rotating area Swingarm pivot collar whole surtace Swingarm pivot bolt outer surtace Swingarm cap lips Gap between the swingarm caps, pivot collar and bearings Brake pedal pivot sliding area Main step pivot pin sliding area Pillion step pivot pin sliding surlace Each dust seal lips Each O-ring Silicone grease Brake pad pin stopper ring surtace Brake caliper bracket pin boots 0.4 g (0.01 oz) minimum Brake caliper dust seal whole suriace Brake lever contacting area with master piston 0.1 g (0.004 oz) Rear mastercylinder push rod contacting area with master cylinder piston and boot 0.1 g (0.004 oz) Master cylinder boot 0.1 g (0.004 oz) DOT 3 or DOT 4 brake lluid Brake master piston sliding area and piston cups Rear master cylinder hose joint O-ring Brake caliper piston sliding area and piston seal Fork lluid Fork cap O-ring Fork oil seal lips Fork dust seal lips Fork guide bushing and slider bushing surtace Honda Bond A or equivalent Leit handlebar and throttle pipe outer surtace (grip rubber contacting area) Air cleaner connecting hose mating surtace with air cleaner housing Swingarm rubber cap mating surtace with swingarm 1-16 GENERAL INFORMATION CABLE 8: HARNESS ROUTING FRONT BRAKE HOSE CLUTCH CABLE THROTTLE CABLES LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR WIRE BANDS SWITCH WIRE HANDLEBAR Front < HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE THROTTLE AHgn the lower end 0! outer rubber with Ihe lower end a! hose c‘amp. 1-17 GENERAL INFORMATION Viewed Irom the Hunt side: RIGHT HANDLEBAR 0/ SWITCH WIRE ,Q“\ IGNITION ‘ SWITCH WIRE SPEEDOMETER SPEEDOMETER 16F WIRE CLAMP CONNECTOR BOOT IGNITION SWITCH 3P (BROWN) CONNECTOR LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR 14F (GRAY) CONNECTOR SWITCH 9P (BLACK) CONNECTOR FRONT BRAKE HOSE k: C; _ . I 3 '. - r _ . . . :1 \ THROTTLE CABLES [II I “I: : 7 Rigm FUEL TANK BREATHER HOSE SUB-FRAME 1-22 GENERAL INFORMATION PAIR AIR SUCTION HOSE PAIRAIRSUPPLV HOSE Viewed "cm the veav side: PAIR CONTROL SOLENOID VALVE RADIATOR SIPHON HOSE FAN MOTOR 2P (BLACK) CONNECTOR I 02 SENSOR 1P (BLACK) CONNECTOR SPARK PLUG WIRE WATER HOSE BAND a. 1 WATER HOSE BAND 90": 30" Fvom ¢ ' Q Front . ' ‘ 20”: 30" ECT SENSOR 3P CONNECTOR DLC PAIR AIR SUCTION HOSE PAIRAIR SUPPLY HOSE FUEL PUMP 3P (BLACK) CONNECTOR SENSOR UNIT 5P CONNECTOR 1 -23 GENERAL INFORMATION CONNECTORS: — ALTERNATOR 3P — REAR BRAKE LIGHT SWITCH 3P (BLACK) FUEL TANK — SIDESTAND SWITCH 3P (GREEN) BREATHER HOSE — CKP SENSOR/NEUTRAL SWITCH 3P (BLACK) VS SENSOR 3P (BLUE) CONNECTOR ET EN RP NNETR CS SO 3 CO 90 WIRECLAMP V'Iewed from the upper side: BATTERY NEGATIVE (-) CABLE STARTER MOTOR CABLE ‘ SIDESTAND SWITCH WIRE ALTERNATOR WIRE BATTERV NEGATIVE (-) CABLE BATTERY CASE DRAIN HOSE SIDESTAND SWITCH WIRE Viewed Irom the lower side: NEUTRAL SWITCH DRIVE SPROCKET COVER BATTERY CASE NEUTRAL SWITCH DRAIN HOSE U W'RE SIDESTAND SWITCH WIRE LEFT CRANKCASE COVER RESERVE TANK OVERFLOW HOSE FUEL TANK BREATHER HOSE 1-24 GENERAL INFORMATION Viewed fvom the from side: SUB'FRAME STARTER MOTOR CABLE FUEL PUMP RELAY MAIN WIRE HARNESS FAN CONTROL RELAY STARTER RELAY SWITCH 4P (RED) CONNECTOR 7"_ BATTERY NEGATIVE BATTERY POSITIVE (-) CABLE 9,) CABLE REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE 1 -25 GENERAL INFORMATION MAIN WIRE HARNESS BRAKE/TAILLIGHT 6P (BLACK) CONNECTOR RIGHT REAR TURN SIGNAL 2P (LIGHT BLUE) LEFT REAR TURN SIGNAL CONNECTOR 2P (ORANGE) CONNECTOR 1-26 GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide (CO), oxides ol nitrogen (NOx) and hydrocarbons (HC). Control ol oxides ol nitrogen and hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems (page 1—28) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner housing and throttle body. AIR CLEANER HOUSING THROTTLE BODY v CRANKCASE l \5 BREATHER HOSE <,:l FRESH AIR _ BLOWEY GAS 1 -27 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed ol a pulse secondary air supply system, three—way catalytic converter and PGM- Fl system. SECONDARY AIR SUPPLV SYSTEM The pulse seconda air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the unction o the PAIR control valve. This charge ol fresh air promotes burning of the unburned exhaust gases and changes a considerable amount ol hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevents reverse air Ilow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid valve is controlled by the PGM-Fl unit, and the fresh air passage is opened/closed according to running condition (ECT/ IAT/TP/MAP sensor and engine revolution). No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended. PAIR CONTROL SOLENOID VALVE AIR CLEANER HOUSING PAIR CHECK VALVE THROTTLE BODY EXHAUST PORT <:l FRESH AIR . EXHAUST GAS THREE-WAY CATALYTIC CONVERTER This motorcycle is equipped With a three—way catalytic converter. The three-way catalytic converter is in the exhaust system. Through chemical reactions, it converts HG, CO and NOx in the engine's exhaust to carbon dioxide (COz), nitrogen (N2), and water vapor. No adjustment to these systems should be made although periodic inspection ol the components is recommended. 1-28 GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERlNG WITH THE NOlSE CONTROL SYSTEM lS PROHIBITED: Local law may prohibit the iollowmg acts or the causing there oi: (1) The removal or rendering inoperative by any person, other than Ior purposes oI maintenance, repair or replacement, oi any device or element oI design incorporated into any vehicle Ior the purpose oi noise control prior to its sale or delivery to the ultimate customer or while it is in use; (2) the use oI the vehicle aIter such device or element oI design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTlTUTE TAMPERlNG ARE THE ACTS LISTED BELOW: 1. 2 3. 4 Removal oi, or puncturing oI the muiiler, baIIles, header pipes or any other component which conducts exhaust gases. . Removal oi, or puncturing oi any part oi the intake system. Lack oI proper maintenance. . Replacing any moving parts oI the vehicle, or parts oI the exhaust or intake system, with parts other than those speciiied by the manuiacturer. 1 -29 MEMO 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMAT|0N TROUBLESHOOTING----------------------------------- SEAT ............................................... SIDE COVER .................................. RESERVE TANK COVER FUEL TANK SHROUD -- SKID PLATE HEADLIGHT COWL FRONT FENDER- FRAME GUARD DRIVE SPROCKET COVER DRIVE CHAIN COVER (U TYPE ONLY) .............................. TOOLBOX ...................................... REARFENDERHMHmumumumumnmnmum REARUPPERFENDEnunmumumumumnu TMLCOVEWUGHTUNnummmmmmmm” REARLOWERFENDER"mumumnmnmum EXHAUST PIPE/MUFFLER SUB.FRAME"umumnmnmumumumumnm .............. 2.5 .............. 2.7 2-1 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL ~ This section covers removal and installation oi the body panels, sub-lrame and exhaust system. ~ Always replace the gaskets when removing the exhaust system. ~ Always inspect the exhaust system tor leaks atter installation. TROUBLESHOOTING Excessive exhaust noise ~ Broken exhaust system ~ Exhaust gas leak Poor perlormance ~ Delormed exhaust system ~ Exhaustgas leak ~ Clogged mulller SEAT FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION Remove the hook bolts [1] and collars [2]. Remove the seat [3] by pulling it rearward and releasing the hooks. Installation is in the reverse order ol removal. TORQUE: Hook bolt: 21 Nm (2.1 kgf‘m,15lbf‘ll) SIDE COVER Hignr side: Left side: REMOVAL/INSTALLATION Remove the socket bolt [1] and collar [2]. Remove the socket bolt [1]. Release the boss [3] lrom the lrame grommet, then remove the side cover [4] by pulling it reanNard. Installation is in the reverse order ol removal. - Align the cover grooves with the tabs of the luel tank shroud. DISASSEMBLY/ASSEMBLY (LEFI' SIDE ONLY) Remove the screws [1] and separate the side lower cover [2] from the left side cover [3] by releasing its slots [4] and holes [5] from the hooks and bosses ol the side cover. Assembly l5 in the reverse order 01 disassembly. TORQUE: Left side cover assembly screw: 0.9 N‘m (0.1 kgf‘m, 0.7 let) [1]/[2] 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM RESERVE TANK COVER REMOVAL/INSTALLATION Remove the trim clips [1], socket bolt [2] and reserve tank cover [3]. Installation is in the reverse order ol removal. ' Align the cover boss [4] with the hole [5] ol the stay. FUEL TANK SHROUD Right side only: Right side: Le" side: REMOVAL/INSTALLATION Remove the reserve tank cover (page 2—4). Remove the side cover (page 2—3). Remove the socket bolt A [1], socket bolts B [2] and fuel tank shroud [3]. Installation is in the reverse order ol removal. DISASSEMBLY/ASSEMBLY Remove the four screws [1] and separate the grille [2] and front shroud [3] from the rear shroud [4] by releasing its tabs [5] and boss [6] lrom the slots and hole ol the rear shroud. Remove the two screws [1] and separate the lront shroud [3] from the rear shroud [4] by releasing its tabs [5] and boss [6] lrom the slots and hole of the rear shroud. Assembly is in the reverse order ol disassembly. TORQUE: Fuel tank shroud assembly screw: 0.9 NM (0.1 kgf—m, 0.7 lbf—ll) l3] [2] (Right side only) [1] (Right srde only) [5] ' \ [a] [1] [e] 2-4 FRAME/BODY PANELS/EXHAUST SYSTEM SKI D PLATE REMOVAL/INSTALLATION Remove the two bolts [1] and skid plate [2]. Installation is in the reverse order ol removal. - Align the rear side of the skid plate With the lrame slot [3]. 3 l l [2] HEADLIGHT COWL REMOVAL/INSTALLATION Remove the lour bolt/washers [1] and headlight cowl [2]- Disoonneot the headlight 3P (Black) connector [3] and position light 2P (Black) connector [4]. Installation is in the reverse order ol removal. TORQUE: Headlight cowl mounting bolt: 8.5 N‘m (0.9 kgf‘m, 6.3 let) FRONT FENDER REMOVAL/INSTALLATION Remove the lour bolUwashers [1], front lender [2] and collars [3] Installation is in the reverse order ol removal. 2-5 FRAME/BODY PANELS/EXHAUST SYSTEM FRAME GUARD REMOVAL/INSTALLATION Remove the socket bolts [1] and frame guard [2]. Installation is in the reverse order ol removal. DRIVE SPROCKET COVER REMOVAL/INSTALLATION Remove the bolts [1] and drive sprocket cover [2]. Installation is in the reverse order ol removal. DRIVE CHAIN COVER (U TYPE ONLY) REMOVAL/INSTALLATION Remove the socket bolts [1] and drive chain cover [2]. Installation is in the reverse order ol removal. 2-6 FRAME/BODY PANELS/EXHAUST SYSTEM TOOL BOX REMOVAL/INSTALLATION Remove the lollowing: — Seat (page 2-3) — Left srde cover (page 2-3) Remove the two mountmg bo‘ts [1] and tool box [2]. Installatron is m the reverse order at remova‘. DISASSEMBLY/ASSEMBLY Disassemble and assemble the tool box as lollowing \Ilustration. TOOL BOX TOOL BOX COVER SPECIAL WASHER LOCK SPRING K- LOCK UNIT REAR FEN DER REMOVAL/INSTALLATION Remove the bo‘ts [1] and rear tender [2]. N Installatron is m the reverse order at remova‘. ’ I , J, [2] C I [1] 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY (u TYPE ONLY) Remove the nuts [1], bolts [2], collars [3], license holder plate [4] and license plate stay [5]. Remove the stopper rubber [6]. Remove the nuts [7] and rear side retlectors [8]. Assembly IS in the reverse order oI disassembly. TORQUE: Rear side retlector mounting nut: 1.5 N-m (0.2 kgt-m,1.1 lbt-tt) REAR UPPER FENDER REMOVAL/INSTALLATION Remove the seat (page 2-3). Remove the hook bolts [1] and collars [2]. Slightly spread the side covers [3] and release the bosses [4] and tabs [5]. Remove the rear upper tender [6]. Installation is in the reverse order ot removal. TORQUE: Hook bolt: 21 N-m (2.1 kgt-m,15lbt-I‘t) TAIL COVER/LIGHT UNIT REMOVAL/INSTALLATION Remove the tollowing: — Rear upper tender (page 2—8) — Rear tender (page 2-7) Disconnect the brake/taillight 6P (Black) connector [1]. Remove the bolts A [2], bolts B [3] and tail cover/light unit [4]. Installation is in the reverse order ot removal. [2] [5] [7] [6] ma] 2-8 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the lollowing: — Rear lender (page 2-7) — Rear lurn swgnal units (page 20-4) Disassemble and assemble the tail cover/Iighl unit as lollowing IIIuslralion. BRAKE/TAILLIGHT REFLECTOR MOUNTING SCREWS MOUNTING NUT SOCKET BOLTS 1.5 N-m (0.2 Kgl-m, 1.1 lbf-ft) 4.5 N-m (0.5 kgf-m, \ 3.3 lbl-ll) _ \\$ gr? ‘ RIGHT TAIL COVER &) C rd REAR REFLECTOR < ’ J P r \\ g) , r it x. i 7/ . ‘ ~ , > , , ‘ COLLARS “(W w BRAKE/TAILLIGHT UNIT REAR TURN SIGNAL UNIT STAY SCREW REAR LOWER FENDER REMOVAL/INSTALLATION Remove the lollowing: — Seal (page 2-3) — Side covers (page 2-3) — Tail cover/light uml (page 2—8) Release the wire bands [1]. LEFT TAIL COVER FRAME/BODY PANELS/EXHAUST SYSTEM Remove the rear lower fender mounting bolt [1]. till Remove the bolts [1], helmet holder [2] and rear lower 7 lender [3]. NOTE Use a drill or an equivalent tool when removing the helmet holder mounting bolts. Installation is in the reverse order ol removal. ' Replace the helmet holder mounting bolts with new ones. [2] :39 v 2-10 FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER REMOVAL/INSTALLATION Remove the lollowing: — Seat (page 2-3) — Right side cover (page 2—3) Remove the exhaust pipe/muffler as following illustration. Installation is in the reverse order oi removal. BOLT MUFFLER FRONT MOUNTING BOLT DAMPER RUBBER 32 N-m (3.3 kgim, 24 lbf-ft) / SOCKET BOLTS I 'J MUFFLER PROTECTOR MUFFLER g / BAND BOLT (b 22.5 N-m (2.3 kgf-m,17|bf-ft) GASKET 9 g‘\ JOINT NUTS SOCKET BOLTS 1a N-m (1.5 kgf-m, 12 Nm (1.2 kgf-m, 9 lot-ft) 1a Inf-n) EXHAUST PIPE EXHAUST PIPE PROTECTOR g GASKET STUD BOLT REPLACEMENT Remove the exhaust pipe (page 2-11). Thread two nuts onto the stud bolt and tighten them together, and use a wrench on them to turn the stud bolt out. Install and tighten new stud bolts to the specified \/\ torque. TORQUE: 9.0 MM (0.9 kgl‘m, 6.6 Ibl-ft) After installation, check that the length irom the bolt head to the cylinder head suriace is within specification. 22.0 t 0.5 mm (0.87 z 0.02 in) FRAME/BODY PANELS/EXHAUST SYSTEM SU B-FRAME REMOVAL/INSTALLATION Remove the lollowing: — Seat (page 2-3) — Side covers (page 2-3) — Muffler (page 2-11) — Fuel tank (page 7—8) — Battery (page 19-4) Remove the bolt [1] and resen/oir [2]. Disconnect the PAIR air suction hose [3] and crankcase breather hose [4] from the air cleaner housing. Remove the wire bands [1]. Remove the iollowing irom the air cleaner housing. Starter relay switch [2] Fuse box [3] Relay box [4] ere clips [5] Open the harness band [1] and release the wires. Disconnect the battery case drain hose [2]. Release the wire bands [1]. Disconnect the brake/taillight 6P (Black) connector [2]. 2-12 FRAME/BODY PANELS/EXHAUST SYSTEM Loosen the air cleaner connecting hose band screw [1]. Remove the sub—frame lower mounting bolts [1]. Remove the sub—frame upper mounting nuts [1] and bolts [2]. Pull the sub-lrame assembly ream/arc. then disconnect the air cleaner connecting hose from the throttle body. Remove the sub—frame. Install the sub-lrame in position, connect the air cleaner connecting hose to the throttle body. Tighten the band screw to the specified torque. TORQUE: 1.5 N-m (0.2 kgf—m, 1.1 lbl-ft) Loosely install all the mounting lasteners. Tighten the upper mounting nut llrst, then the lower bolts to the specified torque. TORQUE: Sub-frame upper mounting nut: 27 N-m (2.8 kgl-m, 20 lbt-ft) Sub-flame lower mounting bolt: 27 N-m (2.8 kgl-m, 20 lbt-ft) Install the removed parts in the reverse order ol removal. TORQUE: Rear master cylinder reservoir mounting bolt: 10 N-m (1.0 kgl-m, 7 lbl-lt) 2-13 FRAME/BODY PANELS/EXHAUST SYSTEM SI DESTAN D REMOVAL/INSTALLATION Remove the sidestand sWitch (page 20-14). Remove the return spring [1] and sub spring [2]. Remove the pivot lock nut [3], pivot bolt [4] and sidestand [5]. Apply grease to the sidestand pivot bolt sliding surlace. Install the sidestand and pivot bolt, then tighten it to the specified torque. TORQUE210 NM (1.0 kgf—m, 7 IbI-I‘t) Turn the pivot bolt counterclockwise about 45° — 90°. Install the pivot lock nut and tighten it to the specified torque while holding the pivot bolt. TORQUE: 30 NM (3.1 kgf—m, 22 Ibf—Il) Install the return spring and sub spring as shown. Install the sidestand switch (page 20-14). l2] [1] 2-14 3. MAINTENANCE SERVICE INFORMATION-----------------------------3-2 DRIVE CHAIN 312 MAINTENANCE SCHEDULE------------------------3-2 DRIVE CHAIN SLIDER 314 FUEL LINE33 BRAKE FLUID ............................................ 3.15 THRO‘n’LE OPERATION------------------------------3-3 BRAKE PADS WEAR316 AIR CLEANER34 BRAKE SYSTEM 317 BRAKE LIGHT SWITCH CRANKCASE BREATHER -- SPARK PLUG35 HEADLIGHT AIM 3.13 VALVE CLEARANCE------------------------------------3-6 CLUTCH SYSTEM 3.13 ENGINE OIL- SIDESTAND- ENGINE OIL FILTER-----------------------------------3-10 SUSPENSION ............................................. 3.1g ENGINE IDLE SPEED310 NUTS, BOLTS, FASTENERS---------------------3-19 WHEELS/TlRES-- RADIATOR COOLANT- COOLING SYSTEM311 STEERING HEAD BEARINGS 320 SECONDARY AIR SUPPLY SVSTEM--------3-11 3-1 MAINTENANCE SERVICE INFORMATION GENERAL ~ Place the motorcycle on level suriace beiore starting any work. ~ Gasoline is extremely Ilammaple and is explosive under certain conditions. ~ Work in a well Ventilated area. Smoking or allowmg flames or sparks in the work area or where the gasoline is stored can cause a tire or explosion. ~ The exhaust contains poisonous carbon monoxide gas that may cause loss oi consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. MAINTENANCE SCHEDULE Periorm the Pre-ride inspection in the Owner‘s Manual at each scheduled maintenance period. I: Inspect and Clean, Adiust, Lubricate or Replace it necessary. C: Clean. R: Replace. A: Adiust. L: Lubricate. The Iollowmg items require some mechanical knowledge. Certain items (particularly those marked ‘ and ") may require more technical iniormation and tools. Consult a dealer. NOTE FREQUENCY (NOTE ‘) ANNUAL REGULAR REFER To X 1,000 km 1 12 2" 36 48 CHECK REPLACE PAGE iTEMS x 1,000 mi 0.6 3 1e 24 32 ' FUEL LINE i i i i i 3-3 ' THROTTLE OPERATION i i i i i 3-3 ' AIR CLEANER NOTE 2 R R 34 CRANKCASE BREATHER NOTE 3 C C C C C 3-4 ' SPARK PLUG i R 35 ' VALVE CLEARANCE i i i 3-6 ENGINE OIL R R R R R R 39 ENGINE OIL FILTER R R R R R R 3-10 ' ENGINE iDLE SPEED i i i I i i 310 RADIATOR COOLANT NOTE 5 i i I i i 3 YEARS 3-11 ' COOLiNG SYSTEM i i I I i 3-11 ' SECONDARY AiR SUPPLY SYSTEM i i I I i 3-11 DRiVE CHAIN NOTE4 EVE Y1, 00 km (30 ml) 3-12 i, L DRiVE CHAIN SLIDER NOTE 4 i i I I 314 BRAKE FLUID NOTE 5 i i I I i 2 YEARS 3-15 BRAKE PADS WEAR i i I i i 313 BRAKE SYSTEM i i i I i i 317 BRAKE LiGHT SWlTCH i i I i i 317 HEADLIGHT AiM i I i i i 3-18 CLUTCH SYSTEM I I i I I I 13-18 SIDESTAND i I i i i 319 ' SUSPENSION i i I i I 319 ' NUTS, BOLTS, FASTENERS NOTE 4 I i i I i I 319 ,. WHEELS/TIRES NOTE 4 I EV:RY ,000 km I 3-20 (4,000 mi) I *' STEERING HEAD BEARlNGS I I i i i I i i I 320 ‘ Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualiiied. " In the interest oi saiety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test your motorcycle aiter each periodic maintenance is carried out. NOTES: . At higher odometer readings, repeat at the Irequency interval established here. . Sen/ice more trequently when riding in unusually wet or dusty areas. . Service more trequently when riding in rain or at tull throttle. . Service more trequently when riding OFF-ROAD. . Replacement requires mechanical skill. (spam—n MAINTENANCE FUEL LINE INSPECTION Remove the right fuel tank shroud (page 2-4). Check the quick connect litting [1] lor looseness. Check the fuel teed hose [2] for deterioration, damage or leakage. Check the quick connect fitting lor dirt, and clean it necessary. Replace the luel pump packing lI necessaiy (page 7-9). THROTTLE OPERATION Check for any deterioration or damage to the throttle cable. Check the throttle grip lor smooth operation. Check that the throttle opens and automatically closes in all steering positions. It the throttle grip does not return properly, overhaul and lubricate the throttle grip housing. It the throttle grip still do not return properly, replace the throttle cable. With the engine idling, turn the handlebar all the way to the right and left to ensure that the idle speed does not change. ll idle speed increases, check the throttle grip lreeplay and throttle cable connection. Measure the throttle grip Ireeplay at the throttle grip llange. FFIEEPLAY: 2 — 6 mm (0.08 — 0.24 in) Throttle grip Ireeplay can be adjusted at either end of the throttle cable. Minor adjustment is made with the upper adjuster [1] at throttle housing. Loosen the lock nut [2] and turn the adjuster. Tighten the lock nut securely while holding the adjuster. Recheck the throttle operation. MAINTENANCE Major adjustment is made With the lower adjuster [1] at the throttle body. Loosen the lock nut [2] and turn the adjuster. Tighten the lock nut to the specified torque while holding the adjuster. TORQUE:3.0 N-m (0.3 kgf‘m, 2.2 lbl-ft) Recheck the throttle operation. AIR CLEANER REMOVAL/INSTALLATION NOTE - The viscous paper element cannot be cleaned because the element contains a dust adhesive. - If the motorcycle is used in unusually wet or dusty areas, more frequent inspections are required. Remove the right side cover (page 2-3). Remove the screws [1] and air cleaner cover [2]. Remove the air cleaner element [3] by releasing its grooves from the housing. Inspect the air cleaner element in accordance With the maintenance schedule (page 3-2) or any time it is excessively dirt or damaged. Install the air cleaner element in the reverse order of removal. NOTE - Alter installing air cleaner element, make sure the air cleaner element grooves are secure. - Check that the condition ol the packings, replace them if necessary. TORQUE: Air cleaner cover screw: 1.2 N-m (0.1 kgrm, 0.9 let) CRANKCASE BREATHER Service more Check the crankcase breather hose [1] lor deterioration, frequently when damage or loose connection. Make sure that the hoses ridden m rain, arm/I are not kinked, pinched or cracked. throttle, or alter the motorcycle is washed or overturned. ' A Replace the crankcase breather hose if necessary. MAINTENANCE Service ll the Check the air cleaner housing drain plug [1]. deposits level can be seen In the all cleaner rruuslrig drain plug. Reinstall the drain plug securely. II necessary. remove the drain plug Irom the air cleaner and drain the deposits into a suitable container. SPARK PLUG REMOVAL/INSTALLATION Disconnect the spark plug cap [1]. Clean araunrltrie Remove the spark plug [1] using a spark plug wrench spar/(plug base [2]. Mm campressed 5" Inspect or replace the spark plug as described in the belcre remaving trie . _ sperkplug,enl1be maintenance schedule (page 3 2). sure [hallia debris Install and hand tighten the spark plug to the cylinder ls allowed in enter head, then tighten the spark plug to the specified torque into the cambusllon using a spark plug wrench. Charm" Tonouene NM (1.3 kngm, 12 let) Connect the spark plug cap securely. INSPECTION Check the Iollowing and replace II necessary (recommended spark plug: page 3—6). NOTE - Insulator [1] for damage - Center electrode [2] and side electrode [3] for wear - Burning condition, coloration [2] [3] This matarcycle's II the electrodes are contaminated with accumulated sparkplug is objects or dirt, replace the spark plug. equipped with an iridium center electrode. Replace the spark plug ll the electrodes are contaminated. MAINTENANCE Always use specllled spark plugs on this motorcycle. To prevent damaging the l'ridl'um center electrode, use a wire type IeeIeI gauge to check the spam plug gap. Do not adjust the spark plug gap. ll the gap I5 DUI ul specification, replace with a new one. Replace the plug il the center electrode [1] is rounded as shown in the illustration. SPECIFIED SPARK PLUG: NGK: SIMR8A9 Check the spark plug gap between the center and side electrodes WlIh a Wire type leeler gauge [1]. Make sure that the CD 1.0 mm (0.039 in) plug gauge does not insert between the gap. II the gauge can be inserted into the gap, replace the plug WlIh a new one. VALVE CLEARANCE INSPECTION NOTE - Inspect and adjust the valve clearance while the engine is cold (below 35°C/95"F). - Alter the valve clearance inspection, check the engine idle speed (page 3-10). - Inspection and adjustment can be done with the engine installed in the frame. Remove the cylinder head cover (page 10-4). Remove the timing hole cap [1] and crankshaft hole cap [2]- TOOL: Timing cap wrench 07709-0010001 Rotate the crankshaft counterclockwise and align the "T" mark [1] on the llywheel with the index notch [2] on the left crankcase cover. [1] MNNTENANCE Make sure that the outside index lines ("IN" [1] and "EX" [2] marks) on the cam sprockets are llush with the cylinder head top surface and lacing outward as shown. ll the "IN" and "EX" marks are facing inward, turn the crankshatt counterclockwise one tull turn (360° ) and realign the "T" mark with the index notch. Check the valve clearance by inserting a feeler gauge [1] between the rocker arm and shim. VALVE CLEARANCE: IN: 0.16 t 0.03 mm (0.006 t 0.001 in) EX: 0.27 t 0.03 mm (0.011 t 0.001 in) ADJUSTMENT NOTE - The valve clearances can be adjusted without removing the camshafts. - The intake and exhaust valve clearance service procedures are the same. Remove the bolt. sealing washer and rocker arm shaft (page 10-11). Slide the rocker arm [1] and remove the shims [2]. NOTE - Do not allow the shims to tail into the crankcase. - Mark all shims to ensure correct reassembly in their original locations. - The shims can be easily removed with a tweezers or magnet. MAINTENANCE Slxlyrni'ne dilferen! thickness shims are available lrorn the thinnest 1.200 mm Ihlckliess shim {a the Ihlckes! 2. 900 mm thickness shim in increments of lIislall 0.025 mm. me shims in their original locations Measure the shim [1] thickness and record it. Calculate the new shim thickness using the equation below. A=(B—C)+D A' New shim thickness ecorded valve clearance C: Specified valve clearance D: Old shim thickness NOTE - Make sure 01 the correct shim thickness by measuring the shim by micrometer. - Inspect the valve seat if the calculated dimension is over 2.900 mm. 1.80 mm 1.825 mm 1.85 mm Install the newly selected shim [1] on the valve spring retainer. Install the rocker arm shalt while aligning the hole of the rocker arm [2] and cylinder head (page 10-11). Rotate the camshaIts by turning the crankshaft counterclockwise several times. Recheck the valve clearance. Install the cylinder head cover (page 10-5). Apply engine oil to new O-rings [1] and install them to each hole cap. Apply engine oil to timing hole cap [2] and crankshaIt hole cap [3] threads. Install and tighten the timing hole cap and crankshaft hole cap to the specified torque. TOOL: Timing cap wrench 07709-0010001 TORQUE: Timing hole cap: 6.0 MM (0.6 kgl-m, 4.4 lbl-I‘t) Crankshall hole cap: 8.0 NM (0.8 kgl-m, 5.9 leI) 1.875 mm MAINTENANCE ENGINE OIL OIL LEVEL INSPECTION Hold the motorcycle in an upright position. Start the engine and let it idle for 3 — 5 minutes. Stop the engine and wait 2 — 3 minutes. Check the oil level through the inspection window. II the level is below the lower level line [1], remove the ( oil Iiller cap [2] and Iill the crankcase with the . recommended oil up to the upper level line [3]. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle il" or an equivalent API classitication: $6 or higher (except oils labeled as energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA Check that the O-ring [4] is in good condition, replace it it necessary. Apply engine oil to the O-ring. Install the oil Iiller cap. ENGINE OIL CHANGE Warm up the engine. Stop the engine and remove the oil Iiller cap [1]. Place an oil pan under the engine to catch the engine oil, then remove the engine oil drain bolt [ll/sealing i a [2] washer [2]. \ v Drain the engine oil completely. Install a new sealing washer onto the drain bolt. Install and tighten the drain bolt to the specilied torque. / TORQUE:24 N-m (2.4 kgf‘m, 18 let) ’/ Fill the engine with the recommended engine oil (page 3-9). ENGINE OIL CAPACITY: 1.4 liters (1.5 US qt, 1.2 Imp qt) at draining [1] 1.5 liters (1.6 US qt, 1.3 Imp qt) at oil filter change 1.8 liters (1.9 US qt, 1.6 Imp qt) at disassembly Install the oil Iiller cap. Check the oil level (page 3-9). Make sure there are no oil leaks. MAINTENANCE ENGINE OIL FILTER REPLACEMENT Drain the engine 0“ (page 3-9). Remove the Iollowing: — Bolts[1] — OiIIilter cover [2] — Gasket[3] — Spring [4] ‘7 [214k Remove the oil Iilter [1]. 1 [‘fi Install a new oil Iilter with the “OUT—SIDE" mark [2] Iacing out. NOTE Installing the oil Iilter backwards Will result in severe r engine damage. Install the oil Iilter spring [3] into the oil filter cover [4]. Install a new gasket [5] and oil Iilter cover. Install the cover bolts and tighten them. Fill the engine with the recommended engine 0“ (page 5" 3-9). I Make sure there are no oil leaks. ENGINE IDLE SPEED NOTE - Inspect the idle speed after all other engine maintenance items have been perlormed and are Within specilications. - Before checking the idle speed, inspect the following items. — No MIL blinking — Spark plug condition (page 3—5) — Secondary air supply system condition (page 3- 1 1) — Crankcase breather system condition (page 3-4) — Air cleaner element condition (page 3-4) - The engine must be warm for accurate idle speed inspection. - This system eliminates the need for manual idle speed adjustment compared to preVious designs. Start the engine and let it idle. Check the idle speed. IDLE SPEED: 1,450 1100 min" (rpm) II the idle speed is out ol the specilication, check the Iollowing: — Intake air leak or engine top-end problem (page 10- 2) — Throttle operation and freeplay (page 3-3) — IACV operation (page 7-16) 3-10 RADIATOR COOLANT COOLING Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" [1] and "LOWER" [2] level lines with the motorcycle in an upright position. ll the level is low, remove the reserve tank cap [3] and lill the tank to the "UPPER" level line With a 1:1 mixture of distilled water and antilreeze. RECOMMENDED ANTIFREEZE: H' h quality ethylene glycol antilreeze containing ale-tree corrosion inhibitors Check to see it there are any coolant leaks when the coolant level decreases very rapidly. ll the reserve tank becomes completely empty, there is a possibility ol air getting into the cooling system. Be sure to remove any air from the cooling system (page 9-5). SYSTEM Check the radiator air passages tor clogging or damage. Straighten bent tins, and remove insects, mud or other obstructions With compressed air or loW water pressure. Replace the radiator it the air llow is restricted over more than 20% of the radiating surlace. Inspect the water hoses for cracks or deterioration, and replace them it necessary. Check the tightness ol all water hose band screws (page 9-7). SECONDARY AIR SUPPLY SYSTEM NOTE ' This model is equipped With a built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover [1]. ' The secondary air supply system introduces tiltered air into exhaust gases in the exhaust port [2]. The secondary air is drawn into the exhaust poit Whenever there is negative pressure pulse in the exhaust system. This charged secondary air promotes burning ol the unburned exhaust gases and changes a considerable amount oi hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and Water. MAINTENANCE [1] [2] [1] [2] 3-11 MAINTENANCE Remove the right iuel tank shroud (page 2-4). ilthe hoses shew Check the PAlR air supply hose [1] between the PAIR anysi'gns u/heat control solenoid valve [2] and cylinder head cover lor damage, inspect deterioration, damage or loose connections. Make sure the PAIR check that the hoses are not cracked. valve in me cylinder head cover la! damage (page 7. 18). Check the air suction hose [3] between the air cleaner and PAIR control solenoid valve tor deterioration, damage or loose connections. Make sure that the hoses are not kinked, pinched or cracked. DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Never inspect and Turn the ignition switch OFF, support the motorcycle on ad/usi the drive its sidestand and shift the transmission into neutral. Chain While the , , , Check the slack in the drive chain lower run midway engine is run/ling. between the sprockets. DFIIVE CHAIN SLACK: 25 — 35 mm (1.0 — 1.4 in) Excessive chain slack, 50 mm {2.0 in) or more, may damage the frame. ADJUSTMENT Loosen the rear axle nut [1]. Loosen the lock nuts [2] and turn the adjusters [3] until the correct drive chain slack is obtained. .x,x;11.r5} A “a, . ft » ‘ WW”? I: " 3-12 Make sure the same index lines [1] on both adjusting plates [2] are aligned with punch mark [3] in the swingarm. Tighten the axle nut to the specilied torque. TORQUESB N-m (9.0 kgf—m, 65 lbf—lt) Hold the drive chain adjusters [4] and tighten the lock nuts [5] to the specilied torque. TORQUE:27 N-m (2.3 kgf—m, 20 lbf—lt) Recheck the drive chain slack and lree wheel rotation. Check the drive chain wear indicator label attached on the left swmgarm. ll the drive chain adjuster cut-out [1] reaches red zone [2] at the indicator label, replace the drive chain with a new one. CLEANING AND LUBRICATION Clean the drive chain [1] with a chain cleaner designed specifically for O-ring chains or a neutral detergent. Use a soft brush ii the drive chain is dirty. Do not use a steam cleaner, high pressure cleaner, wire brush, volatile solvent such as gasoline and benzene, abrasive cleaner or a chain cleaner NOT designed spectiically for O—ring chains to clean the drive chain. Inspect the drive chain for possible damage or wear. Replace any drive chain that has damaged rollers, loose litting links, or otherwise appears unserviceable. Be sure the drive chain has dried completely before lubricating. Lubricate the drive chain with drive chain lubricant [2] designed specifically for use with O—ring chains, #80 — 90 gear oil or equivalent. Do not use a chain lubricant NOT designed specifically for use with O-ring chains to lubricate the drive chain. Wipe olf the excess oil or drive chain lubricant. MAINTENANCE [1]/[3] 3-13 MAINTENANCE SPROCKET INSPECTION Remove the drive sprocket cover (page 2—6). Inspect the drive and driven sprocket teeth for wear or damage, replace it necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or new replacement chain wrll wear rapidly. Check the attaching bolts and nuts on the drive and driven sprockets. ll any are loose, tighten them to the specilied torque. TORQUE: Drive sprocket Iixing plate boll [1]: 10 Nm (1.0 kgI-m, 7 lbI-ft) Driven sprocket "HI [2]: so NM (5.1 kgI-m, 31mm) Install the drive sprocket cover (page 2-6). DRIVE CHAIN SLIDER U type only: Remove the drive chain cover (page 2—6). Remove the drive sprocket cover (page 2—6). Check the drive chain slider [1] lor wear or damage. The drive chain slider must be replaced il it l5 worn to the wear limit indicator [2] or wear limit line [3]. For drive chain slider replacement (page 17-10). 3-14 MAINTENANCE BRAKE FLUID Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system Is serviced. NOTE ' Do not mix different types of fluid, as they are not compatible with each other. ' Do not allow foreign material to enter the system when filling the reservoir. When the fluid level is low, check the brake pads for wear (page 3-16). - A low fluid level may be due to wear of the brake pads. If the brake pads are worn and caliper pistons are pushed out, this accounts for a low fluid level. If the brake pads are not worn and fluid level is low, check the entire system for leaks (page 3-17). FRONT BRAKE Turn the handlebar to the left so that the reservoir is level and check the front brake fluid level through the sight glass. If the level is near the "LOWER" level line [1], lill the recommended brake fluid. Remove the lollowing: Screws [2] — Reservoir cover [3] Set plate [4] Diaphragm [5] Add DOT 3 or DOT 4 brake fluid from a sealed container to the casting ledge [1]. Install the diaphragm, set plate and reservoir cover. Install and tighten the cover screws to the specified torque. TORQUE:1.5 N-m (0.2 kgl-m, 1.1 lbf-ft) 3-15 MAINTENANCE REAR BRAKE Support the motorcycle on a level surface, and check the rear brake fluid level. Check the brake fluid level. II the level is near the "LOWER" level line [1], fill the recommended brake fluid. Remove the bolt [2] and reservoir [3]. Remove the cover screws [4], reservoir cover [5], set plate [6] and diaphragm [7]. Add DOT 3 or DOT 4 brake fluid from a sealed container to the "UPPER" level line [8]. Install the diaphragm, set plate and reservoir cover. Install and tighten the cover screws to the specified torque. TOROUE:1.5 NM (0.2 kgf—m, 1.1 lbf-ft) [51/[61/[7] Install the reservoir and tighten the bolt to the specified torque while pushing the reservoir against the stopper [9]- TORQUE: 10 N-m (1.0 kgt-m, 7 lbt-ft) BRAKE PADS WEAR FRONT BRAKE PADS Check the front brake pads for wear. Always replace the Replace the front brake pads if either pad is worn to the brake pads as a set wear limit groove [1]. '0 assure eve" disc For front brake pad replacement (page 18-5). \ pressure. ; REAR BRAKE PADS Check the rear brake pads for wear. Always replace the Replace the rear brake pads if either pad is worn to the brake pads as a set wear limit groove [1]. to assure even disc ”955W; For rear brake pad replacement (page 18—6). 3-16 BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feels soft or spongy when operated. bleed the air from the system. For brake air bleeding (page 18—4). Inspect the brake hose [1] and fittings for deterioration, cracks and signs of leakage. Tighten any loose littings. Replace hoses and fittings as required. BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut [1] and turn the push rod [2] until the correct pedal height is obtained. For standard push rod length (page 18-9). After adjustment, tighten the push rod lock nut to the specified torque. TORQUE: 17.2 N‘m (1.8 kgI-m,13lbfAft) BRAKE LIGHT SWITCH The front brake light Adjust the brake light switch [1] so that the brake light switchdoesnu! comes on just prior to the brake actually being quulle adjustment. engaged. If the light fails to come on, adjust the switch so that the light comes on at the proper time. NOTE Hold the switch body and turn the adjuster [2]. Do not turn the switch body. MAINTENANCE [1] [2] 3-17 MAINTENANCE HEADLIGHT AIM Adjust the headlight aim as specified by iecai laws and regulations. Support the motorcycle in an upright position. Adjust the headlight aim horizontally by turning the horizontal beam adjuster [1]. Adjust the headlight aim vertically by turning the vertical beam adjuster [2]. CLUTCH SYSTEM The adjuster may be damaged ii it is positioned too [a] uni, Ieavlrig minimal thread engagement. Measure the clutch lever lreeplay at the end of the clutch lever. FFIEEPLAY:10 — 20 mm (0.4 — 0.3 in) 10 — 20 mm (0.4 — 0.3 in) Minor adjustment is made with the minor adjuster [1] at the clutch lever. Loosen the lock nut [2] and turn the adjuster. Tighten the lock nut while holding the adjuster. Recheck the clutch lever lreeplay. ll the adjuster is threaded out near its limit and the correct freeplay cannot be obtained. turn the adjuster all the way in and back out one turn, then perlorm the \ adjustment at major adjuster as lollows. Major adjustment is made with the major adjuster [1] on ' the clutch cable. [1] . Loosen the lock nut [2] and turn the adjuster to adjust the lreeplay. ’ Tighten the lock nut while holding the adjuster. ll proper lreeplay cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (page 12-9). 3-18 MAINTENANCE SIDESTAND INSPECTION Support the motorcycle using a salety stand or hoist. Check the sidestand spring [1] Ior damage or loss oi tension. Check the sidestand [2] tor movement and lubricate the sidestand pivot iI necessary. Check the sidestand ignition cut-oII system: — Sit astride the motorcycle and retract the sidestand. — Startthe engine. — Shift the transmission in gear and lower the sidestand. — The engine should stop as the sidestand is lowered. II there is a problem with the system, check the sidestand sWitoh (page 20-13). SUSPENSION Loose, worn 0! damaged suspension pans impair motorcycle stability and control. Loose, worn 0! damaged suspension pans impair motorcycle stability and control. FRONT SUSPENSION INSPECTION Check the action ol the torks by operating the Iront brake and compressing the tront suspension several times. Check the entire assembly Ior signs oI leaks, damage or loose Iasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. For lork service (page 16-6). REAR SUSPENSION INSPECTION Check the action ol the rear shock absorber by compressing the rear end several times. Check the entire shock absorber assembly Ior leaks, damage or loose iasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. For shock absorber service (page 17-6). Support the motorcycle using a satety stand or hoist, raise the rear wheel oil the ground. Check tor worn swmgarm bearings by grabbing the swingarm ends and attempting to move it side to side. Replace the bearings iI any looseness to noted. For swingarm service (page 17-10). NUTS, BOLTS, FASTENERS Check that all chassis nuts, screws and bolts are tightened to their correct torque values (page 1-9). Check that all cotter pins, saiety clips, hose clamps and cable stays are in place and properly secured. 3-19 MAINTENANCE WHEELS/TIRES Support the motorcycle using a saiety stand or hoist, raise the Iront wheel oil the ground. Hold the iront lork leg and move the iront wheel sideways With lorce to see ii the wheel bearings are worn. For Iront wheel service (page 16-4). Support the motorcycle using a saiety stand or hoist, raise the rear wheel oil the ground. Hold the swingarm and move the rear wheel sideways with iorce to see it the wheel bearings are worn. For rear wheel service (page 17-4). Check the tire pressure with a tire pressure gauge when the tires are cold. — Front tire (page 1-8) — Rear tire (page 1-8) Check the tires Ior cuts, embedded nails, or other damage. Check the iront and rear wheels tor trueness. Measure the tread depth at the center oi the tires. Replace the tires when the tread depth reaches the service limits. — Front tire (page 1-8) — Rear tire (page 1-8) Inspect the wheel rims and spokes Ior damage. Tighten any loose spokes to the speciiied torque using the special tool. TOOL: Spoke wrench 5.8 x 6.1 mm 07701—002030!) TORQUE: 3.7 N-m (0.4 kgI-m, 2.7 lbf-l‘t) STEERING HEAD BEARINGS Support the motorcycle using a saiety stand or hoist, raise the Iront wheel oil the ground. Check that the handlebar moves Ireely trom side to side. Make sure the control cables do not interiere with the handlebar rotation. Check Ior steering stem bearings by grabbing the Iork legs and attempting to move the Iront lork lonNard to backward. lithe handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (page 16-21). 3-20 4. PGM-FI SYSTEM SERVICE INFORMAT|0N PGM-Fl SYSTEM LOCATION----------------------- PGM-Fl SYSTEM DIAGRAM------------------------- PGM-Fl TROUBLESHOOTING INFORMATION .............................................. PGM-FI SYMPTOM TROUBLESHOOTING----------------------------------- SENSOR UNIT POWER LINE INSPECTION ................................................. 4-2 4-3 4-6 4-7 4-3 DTc TROUBLESHOOTING------------------------4-10 MIL TROUBLESHOOTING 4.2g MIL CIRCUIT TROUBLESHOOTING ---------4-43 SENSOR UNIT 4.44 ECT SENSOR 4.45 02 SENSOR-- BANK ANGLE SENSOR 4-48 4-1 PG M-FI SYSTEM SERVICE INFORMATION GENERAL ~ A Iaulty PGM-Fl system is oIten related to poorly connected or corroded connectors. Check those connections beIore proceeding. ~ When disassembling the PGM-Fl system parts, note the location oi the O-rings. Replace them with new ones upon reassembly. ~ Use a digital tester Ior PGM-Fl system inspection. ~ The Iollowmg color codes are used throughout this section. Bu = Blue G = Green Lb = Light Blue 0 = Orange R = Red BI = Black Gr = Gray Lg = Light Green P = Pink w e White PGM-FI SYSTEM LOCATION IGNITION SWITCH ENGINE STOP SWITCH DLC BANK ANGLE SENSOR FUEL PUMP INJECTOR OzSENSOR SENSOR UNIT: vs SENSOR — MAP SENSOR — IAT SENSOR — TP SENSOR ECT SENSOR CKP SENSOR Y = Yellow Br = Brown PGM-FI SYSTEM PGM-FI SYSTEM DIAGRAM FAN ms ‘m: w am mmow 5mm- mswa 5qu swrm ma, fl mumsmam AJERNAYEIR a w a a me MEYER m, Fusimm a G : saws»; may swwm vvv uzemm mum: smnwswm . EKFSENSOR M swam: mama @® BATTERY ma PUMP Lwr mDDE "sum, 5mm- 5 o DuwN SmEs’AND SWWCH (11) HGH wouw’ vswsmuus wchmR vs smsou a 5‘ am -o- - - a w © (54) 5mm um (1) mm»: ymmsoa m 3 mm cm mm PM © <8) mm © <9) m SENSOF PAW EDNYROL sujNovaVE (7) , 5mm: a»: Erma»: scs ‘5 \Acvm 2‘ m © (21) \Acwa :2 mm: 20 mm ME 3‘ : T T B! Bmwn B‘ E‘ack V VeHaw @( ) Manumbev BU BM . 6 Gwen fizEngmedoasnots‘an R M whendeteding MIL w Wm :Shon terminals tor O 0“"99 Lg ngmgveen readmgw 6, GM EU." JJP IELACKI CONNECTOR y ‘EDN5debHHema‘eVemmva‘s P F‘nk PG M-FI SYSTEM PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermIttent Iailure" means a system may have had a tailure, but it checks OK now. II the MlL does not come on, check Ior poor contact or loose pins at all connectors related to the circuit that oi the troubleshooting. lithe MIL was on, but then went out, the original problem may be intermittent. Opens and Shorts "Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an achdental connection ot a wire to ground or to another wire. In simple electronIcs, thIs usually means something WIII not work at all. With ECMs this can somethIng mean something work, but not the way It's supposed to. If the MIL has come on ReIer to DTC READOUT (page 4-5). If the MIL did not stay on lithe MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 4-6). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The PGM-Fl system is equipped with the seII-diagnostIc system. When any abnormality occurs In the system, the ECM turns on the MIL and stores a DTC in Its erasable memory. FAIL-SAFE FUNCTION The PGM-Fl system is provided with a Iail-sate Iunction to secure a minImum runnIng capability even when there Is trouble in the system. When any abnormality is detected by the selt-dIagnosis IunctIon, runnIng capabiIIty is maintained by pre-programed value In the simulated program map. When any abnormality is detected in the injector, the tail-sate tunction stops the engine to protect it Irom damage. MIL Blink Pattern ~ DTC can be read Irom the ECM memory by the MIL blink pattern. ~ The MIL will blInk the current DTC, in case the ECM detects the problem at present, when the ignitIon switch ON and engIne stop sWItch " or idling. The MIL WIII stay ON when the engine speed is over 2,100 min‘ (rpm). ~ The MIL has two types oi blinks, a long blInk and short blInk. The long blInking lasts Ior 1.3 seconds, the short blInking lasts Ior 0.3 seconds. One long blink is the equivalent oi ten short blInks. For example, when two long blinks are Iollowed by tive short blinks, the MIL is 25 (two long blinks = 20 blinks, plus tive short blinks). ~ When the ECM stores more than one DTC, the MlL will indicate them by blinking in the order trom the lowest number to highest number. MIL Check When the ignitIon switch is turned ON and engIne stop switch "(3' the MIL WIll stay on Ior a Iew seconds, then go oh. II the ML does not come on, troubleshoot the MIL circuIt (page 4-43). CURRENT DTC/STORED DTC The DTC is IndIcated In two ways accordIng to the Iailure status. ~ In case the ECM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC when the sIdestand Is lowered. It is possible to readout the MIL blInk pattern as the current DTC. ~ In case the ECM does not detect any problem at present but has a problem stored In its memory, the MILWIII not light and blInk. II It is necessary to retrIeve the past problem, readout the stored DTC by Iollowing the DTC readout procedure (page 4-5). PGM-FI SYSTEM HDS POCKET TESTER INFORMATION ‘ The HDS pocket tester can readout the DTC, freeze data, current data and other ECM condition. How to connect the HDS pocket tester Turn the ignition switch OFF. [1] Remove the dummy connector [1] from the DLC [2]. Connect the HDS pocket tester to the DLC. Turn the ignition switch ON and engine stop switch "(1" check the DTC and freeze data. NOTE Freeze data indicates the engine conditions when the lirst mallunction was detected. ECM reset The HDS pocket tester can reset the ECM data including the DTC, freeze data and some learning memory. After the ECM reset, perlorm the TP sensor reset procedure (page 4-45). DTC READOUT Start the engine and check the MIL. NOTE. When the ignition switch is turned ON and engine stop switch "It", the MIL will stay on lor a lew seconds, then go off. It the MIL stays on or blinks, read the DTC, freeze data and follow the troubleshooting index (page 4-7). To read the DTC with the MIL blinking, refer to the following procedure. Reading DTC with the MIL Turn the ignition switch OFF. Remove the dummy connector lrom the DLC [1]. Short the DLC terminals using the special tool. TOOL: [2] 505 connector 070PZ-ZY30100 Turn the ignition switch ON and engine stop switch "(1", read, note the MIL blinks and refer to the DTC index (page 4-7). NOTE. It the ECM has any DTC in its memory, the Mleill start blinking. ERASING DTC 1. Turn the ignition switch OFF. 2. Remove the dummy connector lrom the DLC [1]. Short the DLC terminals using the special tool. TOOL: [2] $68 connector 070PZ-ZY30100 3. Turn the ignition sWitch ON and engine stop switch "".C 4. Remove the special tool lrom the DLC. 5. The MIL will light for approximately 5 seconds. While the MIL lights, short the DLC terminals again with the special tool. The self-diagnostic ’ memory is erased il the MIL goes olf and starts blinking. NOTE ~ The DLC must be jumped while the MIL lights. It not, the MIL will not ’ start blinking. ‘ Note that the sell-diagnostic memory cannot be erased il the ignition switch is turned OFF belore the MIL starts blinking. 4-5 PG M-FI SYSTEM CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR ~ Always clean around and keep any Ioreign material away irom the ECM 33P (Black) connector belore disconnecting it. _ A Iaulty PGM-Fl system is olten related to poorly connected or corroded \ terminals. Check those connections beIore proceeding. . ~ In testing at ECM 33F (Black) connector (Wire harness side) terminal, always use the test probe [1]. Insert the test probe into the connector terminal, then attach the digital multimeter probe to the test probe. TOOL: [1] Test probe 07ZAJ-RDJA110 [1] PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one oi these symptoms, check the MIL blinking, reier to the MIL code index (page 4-7) and begin the appropriate troubleshooting procedure. II there are MIL blinking stored in the ECM memory, do the diagnostic procedure tor the symptom, in sequence listed below, until you iind cause. Symptom Diagnosis procedure Also check for Engine cranks but won‘t start (No MIL blinking) . Inspect the IACV (page 7-16). mm; . Inspect the ignition system (page 5-4). . Inspect the Iuel supply system (page 7-4). No tuel to injector — Clogged Iuel Iilter — Pinched or clogged tuel Ieed hose — Faulty Iuel pump — Faulty Iuel pump circuits Intake air leak Contaminated/deteriorated Iuel Faulty injector Engine cranks but won‘t start (No iuel pump operation sound when the turning the ignition ON) I. ECM power/ground circuits mallunction (page 4-49). 2. Inspect the Iuel supply system (page 7-4). Open circuit in the power input and/or ground wire ol the ECM ' Blown main Iuse (30 A) Blown Fl, IGN Iuse (10 A) Engine stalls, hard to start, I. Inspect the engine idle speed (page 3-10). ' Restricted iuel Ieed hose rough idling 2. Inspect the IACV (page 7-16). ' Contaminated/deteriorated Iuel 3. Inspect the Iuel supply system (page 7-4). ' Intake air leak 4. Inspect the battery charging system (page ' Faulty MAP sensor 19-4). ' Restricted iuel tank breather hose 5. Inspect the ignition system (page 5-4). Alterburn when engine braking I. Inspect the PAIR system (page 7- 17). is used 2. Inspect the ignition system (page 5- -4J. Backliring or misiiring during acceleration nspect the ignition system (page 5- -4). Poor perIormance (driveabilityJ and poor iuel economy I. Inspect the Iuel supply system (page 7-4). 2. Inspect the air cleaner element (page 3-4). 3. Inspect the ignition system (page 5-4). Faulty pressure regulator (Iuel pump) Faulty injector Faulty MAP sensor Idle speed is below specilications or last idle too low (No MIL blinking) . Inspect the IACV (page 7-16). . Inspect the ignition system (page 5-4). . Inspect the engine idle speed (page 3-10). Idle speed is above specilications or iast idle too high (No MIL blinking) . Inspect the throttle operation and Ireeplay (page 3-3). . Inspect the IACV (page 7-16). Inspect the ignition system (page 5- 4-J. pm NALQNA . Inspect the engine idle speed (page 3-10). Intake air leak Engine top-end problem Air cleaner element condition MIL never comes ON at all nspect the MIL circuit (page 4- -43J. MIL stays ON (No DTC set) Inspect the DLC circuit (page 4- -43J. 2. Inspect the MIL circuit (page 4-43). 4-6 PGM-Fl SYSTEM DTC INDEX DTC Reler Refer (MIL Function Failure Symptom/Fail-sale lunction to to blinks) (DTC) (MIL) MAP sensor circuit low voltage (less than 0.195 V) O Engine operates normally 1-1 (1) O MAP sensor or its circuit mallunction O Pre-program value: 525 mmHg/ 4-10 700 hPa MAP sensor circuit high voltage (more than 3.848 V) O Engine operates normally 4-29 1-2 (1) O Loose or poor contact ol the sensor unit O Pre-program value: 525 mmHg/ 441 connector 700 hPa O MAP sensor or its circuit mallunction ECT sensor circuit low voltage (less than 0.078 V) O Hard start at a low temperature 7-1 (7) O ECT sensor or its circuit mallunction O Pre-program Value: 80°C/176"F 4-13 O Cooling lan turns on ECT sensor circuit high voltage (more than 4.922 V) O Hard start at a low temperature 4-30 7_2 (7) O Loose or poor contact ol the ECT sensor O Pre-program Value: 80°C/176"F 441 connector O Cooling lan turns on O ECT sensor or its circuit mallunction TP sensor circuit low voltage (less than 0.215 V) O Poor engine acceleration 8-1 (8) O Loose or poor contact ol the sensor unit O Pre-program Value: 0’ 445 connector 4_32 O TP sensor or its circuit mallunction 8-2 (8) TP sensor circuit high voltage (more than 4.922 V) O Poor engine acceleration 4-16 O TP sensor or its circuit mallunction O Pre-program Value: 0’ 94 (9) IAT sensor circuit low voltage (less than 0.078 V) O Engine operates normally 4-18 O lAT sensor or its circuit mallunction O Pre-program value: 35°C/95°F IAT sensor circuit high voltage (more than 4.922 V) O Engine operates normally 433 9_2 (9) O Loose or poor contact ol the sensor unit O Pre-program value: 35°C/95°F 4-18 connector O lAT sensor or its circuit mallunction VS sensor mallunction O Engine operates normally 11-1 O Loose or poor contact ol the VS sensor 4-18 4_35 (1) connector O VS sensor or its circuit mallunction 124 Injector circuit mallunction O Engine does not start (l 2) O Loose or poor contact ol the injector connector O Injector, luel pump and ignition 4-21 4-36 O lnjeotor or its circuit mallunction coil shut down 214 02 sensor mallunction O Engine operates normally (21) O Loose or poor contact ol the 02 sensorconnector 4-23 4-38 O 02 sensor or its circuit mallunction 294 lACV circuit mallunction O Engine stalls, hard to start, (29) O Loose or poor contact ol the lACV connector rough idling 4-24 4-39 O lACV or its circuit mallunction 33-2 (— ECM EEPROM mallunction O Engine operates normally 4-26 _ ) Bank angle sensor circuit low voltage (less than O Engine operates normally 544 0.35 V) O Bank angle sensor does not (54) O Bank angle sensor or its circuit mallunction operate. 4-27 (The engine keeps running when the Vehiclelalls.) 4 41 Bank angle sensor circuit high voltage (more than O Engine operates normally ' 542 4.5 V) O Bank angle sensor does not (54) O Loose or poor contact ol the bank angle sensor operate. 4-28 connector (The engine keeps running O Bank angle sensor or its circuit mallunction when the vehicle lalls.) PG M-FI SYSTEM SENSOR UNIT POWER LINE INSPECTION BEFORE DTC TROUBLESHOOTING NOTE ' When the DTC displays 1-1, 1-2, 8-1, 8-2, 9-1 and 9- 2, check the iollowing betore DTC troubleshooting. ' Betore starting the inspection, check tor loose or poor contact on the sensor unit 5P connector and ECM 33F (Black) connector. 5 V SENSOR UNIT ' Y/R G/W Probable cause ' Open circuit in Yellow/red Wire between the sensor unit and ECM ' Open circuit in Green/white Wire between the sensor unit and ECM ' Faulty ECM 1. Sensor Unit Power Input Voltage Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P connector [1] (page 7-11). the ignition switch ON and engine stop switch Measure the voltage at the wire harness side. Connection: Vellow/red (1-) — Green/white (—) Standard: 4.75 — 5.25 V If the Voltage within 4.75 — 5.25 V? YES — Turn the ignition switch OFF. Connect the sensor unit 5P connector and start the DTC troubleshooting (page 4-10). N0 — GO TO STEP 2. 2. Sensor Unit Input Voltage Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1] (page 4-50). Check tor continuity between the ECM 33F (Black) connector and sensor unit 5P connector [2] oi the wire side. Connection: Yellow/red — Yellow/red Green/white — Green/white TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a know good one and recheck. N0 — ~ Open circuitin Yellow/red wire ECM G/W [2] [1] PGM-FI SYSTEM ~ Open circuit in Green/white Wire BEFORE MIL TROUBLESHOOTING NOTE ' When the ML blinks i, 8 and 9 times, check the tollowing petore MlL troubleshooting. ' Betore starting the inspection, check tor loose or poor contact on the sensor unit 5P connector and ECM 33F (Black) connector. 5 V SENSOR UNIT ' V/R ECM G/W Probable cause ' Open circuit in Yellow/red Wire between the sensor unit and ECM ' Open circuit in Green/white Wire between the sensor unit and ECM ' Faulty ECM 1. Sensor Unit Power Input Voltage Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P connector [1] (page 4-44). Turn the ignition switch ON and engine stop switch Measure the voltage at the wire harness side. Connection: Vellow/red (1-) — Green/white (—) Standard: 4.75 — 5.25 V If the voltage within 4. 75 — 5.25 V? YES — Turn the ignition switch OFF. Connect the sensor unit 5P connector and start the MIL troubleshooting (page 4-29). N0 — GO TO STEP 2. 2. Sensor Unit Input Voltage Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1] (page 4-50). Check tor continuities between the ECM 33F (Black) connector and sensor unit 5P connector [2] ot the wire side. Connection: Yellow/red — Yellow/red Green/white — Green/white TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a know good one and recheck. N0 — ~ Open circuit in Yellow/red wire ~ Open circuit in Green/white Wire PG M-FI SYSTEM DTC TROUBLESHOOTING DTC 1 (MAP SENSOR) SENSOR UNIT 5 V (MAP SENSOR) J5 v Y/R Lg/Bl e/w 1 Probable cause O Open circuit in Yellow/red wwre between the sensor unit and ECM O Open or short circuit in nght green/black wire between the sensor unit and ECM O Open circuit in Green/white wwre between the sensor unit and ECM O Faulty sensor unit O Faulty ECM DTC1-1 (MAP SENSOR LOW VOLTAGE) 1. MAP sensor system inspection Turn the lgnlticn switch ON and englne stop switch Check the MAP sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. NO — Intermittent lailure 2. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 4-8). Is the sensor uni! power line normal? YES — GO TO STEP 3. NO — Replace or repair the abnormal circult. 3. MAP Sensor Output Voltage Inspection ECM Turn the ignition switch OFF. Connect the ECM ESP (Black) connector. Disconnect the sensor unlt 5P connector [1] (page 4-44). Turn the ignitlon switch ON and engine stop switch [1] Measure the voltage at the sensor unit 5P connector ol the wwre side. Connection: Light green/black (1-) — Green/white (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 5. NO — GO TO STEP 4. 4-1 0 PGM-FI SYSTEM 4. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector. Check tor continuity between the sensor unit 5P connector [1] terminal oI the Wire side and ground. Connection: Light green/black — Ground Is there continuity? YES — Short circuit in Light green/black wire N0 — GO TO STEP 5. 5. MAP Sensor Inspection Replace the sensor unit with a known good one (page 4-44). Erase the DTC's (page 4-5). Turn the ignition switch OFF. Connect the sensor unit 5P connector. Turn the ignition switch ON and engine stop switch Check the MAP sensor with the H08 pocket tester. Is DTC 1-1 indicated? YES — Replace the ECM With a known good one. and recheck. N0 — Faulty original sensor unit (MAP sensor) DTC1- 2 (MAP SENSOR HIGH VOLTAGE) 1. MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop switch Check the MAP sensor with the H08 pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — ~ Intermittent iailure ~ Loose or poor contact on the sensor unit 5P connector 2. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 4-8). Is the sensor unit power line normal? YES — GO TO STEP 3. N0 — Replace or repair the abnormal circuit. 4-11 PG M-FI SYSTEM 3. MAP Sensor System Inspection 2 Turn the ignition switch OFF. Disconnect the sensor unit 5P connector [1]. Connect the sensor unit 5P connector terminals at the Wire side with a jumper wire [2]. Connection: Light green/black — Green/white Turn the ignition switch ON and engine stop switch Check the MAP sensor with the H08 pocket tester. Is about 0 vindicated? YES — Faulty sensor unit (MAP sensor) N0 — GO TO STEP 4. 4. MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire. Disconnect the ECM 33F (Black) connector [1]. Check the continuity between the ECM 33F (Black) connector and sensor unit 5P connector [2] oi the wire side. Connection: Light green/black — Light green/black TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM With a known good one and recheck. N0 — Open circuit in Light green/black wire DTC 7 (ECT SENSOR) NOTE [1] G/W [2] Lg/Bl Betore starting the inspection, check tor loose or poor contact on the ECT sensor 3P connector and recheck the MIL blinking. ECT SENSOR L, Y/ Bu 5] fit 2‘ cm L‘ 5V T i i— Probable cause ' Open or short circuit in Yellow/blue wire between the ECT sensor and ECM ' Open circuit in Green/white wire between the ECT sensor and ECM ' Faulty ECT sensor ' Faulty ECM ECM 4-12 PGM-FI SYSTEM DTC 7-1 (ECT SENSOR LOW VOLTAGE) 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the ECT sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent iailure 2. ECT Sensor Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 3P connector. Turn the ignition switch ON and engine stop switch Check the ECT sensor with the H08 pocket tester. Is about 0 vindicated? YES — GO TO STEP 4. N0 — GO TO STEP 3. 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor [1] terminals. Standard: 2.3 — 2.6 kn (20°C/68’F) Is the resistance within 2.3 — 2.6 k!) (20°C/68"F)? YES — Replace the ECM with a known good one and recheck. N0 — Faulty ECT sensor 4. ECT Sensor Short Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the ECT sensor 3P connector [1] oi the wire side and ground. Connection: Vellow/blue — Ground Is there continuity? YES — Short circuit in Yellow/blue wire N0 — Replace the ECM with a known good one and recheck. [1] 4-13 PG M-FI SYSTEM DTC 7-2 (ECT SENSOR HIGH VOLTAGE) 1. ECT Sensor System Inspection T rn the ignition switch ON and engine stop switch Check the ECT sensor with the H08 pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — ~ Intermittentiailure - Loose or poor contact on the ECT sensor 3P connector 2. ECT Sensor Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 3P connector [1]. Connect the ECT sensor 3P connector terminais at the Wire side with a jumper wire [2]. 7‘ Connection: Yellow/blue — Green/white 3‘? - Turn the ignition switch ON and engine stop switch Y/Bu t 4 Check the ECT sensor with the H08 pocket tester. Is about 0 V indicated? YES — Inspect the ECT sensor (page 4-46). N0 — GO TO STEP 3. [2] 3. ECT Sensor Open Circuit Inspection Turn the ignition switch OFF. [2] Remove the jumper wire. Disconnect the ECM 33F (Black) connector [1]. Check the continuities between the ECM 33F (Biack) connector and ECT sensor 3P connector [2] oi the Wire side. Connection: Vellow/blue — Yellow/blue Green/white — Green/white TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM With a knoWn good one and recheck. N0 — ~ Open circuit in Yellow/blue Wire ~ Open circuit in Green/white Wire 4-14 PGM-FI SYSTEM DTC 8 (TP SENSOR) SENSOR UNIT (TP SENSOR) 5V Y/R J G/W Probable cause O Open circuit in Yellow/red wwre between the sensor unlt and ECM O Open or short circuit in Yellow wire between the sensor unit and ECM O Open circuit in Green/white wwre between the sensor unlt and ECM O Faulty sensor unit O Faulty ECM DTC 8-1 (TP SENSOR LOW VOLTAGE) 1. TP Sensor System Inspection the lgnltion switch ON and englne stop switch Check the TP sensor with the HDS pocket tester when the throttle tully closed. Is about 0 vindicated? YES — . lntermittentiallure . Loose or poor contact on the sensor unit 5P connector N0 — GO TO STEP 2. 2. Sensor Unit Power Line Inspection Check the sensor unit power Ilne inspection (page 4-8). Is the sensor unit power line normal? YES — GO TO STEP 3. N0 — Replace or repair the abnormal circuit. 3. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P connector [1]. Check ior continuity between the sensor unit 5P connector oi the wwre side and ground. Connection: Yellow — Ground Is there continuity? YES — Short circuit ln Yellow wire N0 — GO TO STEP 4. ECM 4-15 PG M-FI SYSTEM 4. TP Sensor Output Line Open Circuit Inspection Disconnect the ECM 33F (Black) connector [1]. Check lor continuity between the ECM 33F (Biack) connector and sensor unit 5P connector [2] oi the wire side. Connection: Yellow — Vellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in Yeilow Wire 5. TP Sensor Inspection Replace the sensor unit with a known good one (page 4-44). Connect the sensor unit SP and ECM 33F (Black) connectors. Erase the DTC's (page 4-5). Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester. Is DTC 8-1 indicated? YES — Replace the ECM With a known good one and recheck. N0 — Faulty original sensor unit (TP sensor) DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 3. N0 — GO TO STEP 2. 2. TP Sensor Inspection Check that the TP sensor voitage increases continuousiy when moving the throttle trom lully closed to iuily opened using the data list menu oi the HDS pocket tester. Is the voltage increase continuously? YES — Intermittent lailure N0 — Replace the TP sensor (sensor unit) with a known good one and recheck. 4-16 PGM-FI SYSTEM 3. TP Sensor Flesistance Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Measure the resistance at the ECM 33F (Biack) connector ol the Wire side. Connection: Yellow — Green/white Standard: 0.29 - 0.71 I! (20°C/68’F) Is the resistance within 0.29 — 0. 71 {2? YES — GO TO STEP 4. N0 — Faulty sensor unit (TP sensor) 4. TP Sensor Power Input Voltage Inspection Connect the ECM 33F (Black) connector. Disconnect the sensor unit 5P connector [1]. Turn the ignition switch ON and engine stop switch Measure the voltage at the sensor unit 5P connector ol the wire side. Connection: Vellow/red (1-) — Green/white (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — Replace the ECM with a known good one, and recheck. N0 — ~ Open circuitin Green/white Wire ~ Open circuit in Yellow/red wire DTC 9 (IAT SENSOR) SENSOR UNIT (IAT SENSOR) T 4—, ECM Probabie cause ' Open or short circuit in Gray/biue wire between the sensor unit and ECM ' Open circuit in Green/White Wire between the sensor unit and ECM ' Faulty sensor unit ' Faulty ECM 4-17 PG M-FI SYSTEM DTC 9-1 (IAT SENSOR LOW VOLTAGE) 1. IAT Sensor System Inspection T rn the ignition switch ON and engine stop switch Check the IAT sensor With the HDS pocket tester. Is about 0 vindicated? YES — GO TO STEP 2. N0 — Intermittent Iailure . IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P connector. Turn the ignition switch ON and engine stop switch Check the IAT sensor With the HDS pocket tester. Is about 0 vindicated? YES — GO TO STEP 3. N0 — Faulty sensor unit (lAT sensor) . IAT Sensor Voltage Input Line Short Circuit Inspection Check tor continuity between the sensor unit 5P 1 connector [1] oi the Wire side and ground. [ 1 Connection: Gray/blue — Ground Is there continuity? < > f YES — Short circuit In Gray/blue Wire Gr/BuI ' N0 — Replace the ECM with a known good one, Q and recheck. DTC 9-2 (IAT SENSOR HIGH VOLTAGE) 1. IAT Sensor System Inspection T rn the ignition switch ON and engine stop switch Check the IAT sensor With the HDS pocket tester. Is about 5 vindicated? YES — GO TO STEP 2. N0 — ~ Intermittent iailure ~ Loose or poor contact on the sensor unit 5P connector . Sensor UniI Power Line Inspection Check the sensor unit power line inspection (page 4-8). Is the sensor unit power line normal? YES — GO TO STEP 3. N0 — Replace or repair the abnormal circuit. 4-18 3. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P connector [1]. Connect the IAT sensor terminals at the wire side with a jumper wire [2]. Connection: Gray/blue — Green/white Turn the ignition switch ON and engine stop switch Check the IAT sensor With the HDS pocket tester. Is about 0 vindicated? YES NO 4. IAT Sensor Voltage Input Line Open Circuit Inspection — Faulty sensor unit (lAT sensor) — GO TO STEP 4. Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Check tor continuity between the ECM 33F (Black) connector and sensor unit 5P connector [2] oi the wire side. Connection: Gray/blue — Gray/blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one and recheck. N0 — Open circuit in Gray/blue wire DTC 11 (VS SENSOR) NOTE PGM-FI SYSTEM [2] Gr/Bu G/W [1] Gr/Bu [2] Betore starting the inspection, check tor loose or poor contact on the VS sensor 3P (Blue) connector and recheck the MlL blinking. To SPEEDOMETER va VS SENSOR G/Bl Bl/R é W/ R o Probable cause ' Open or short circuit in Pink or White/red wire between the VS sensor and ECM ' Faulty VS sensor ' Faulty ECM W/R ECM 4-19 PG M-FI SYSTEM DTC11-1 (VS SENSOR) 1. VS Sensor System Inspection Erase the DTC's (page 4-5). Test ride the motorcycle. Stop the engine. Turn the ignition switch ON and engine stop switch check the vs sensor with the HDS. Is DTC 11 — 1 indicated? YES — GO TO STEP 2. N0 — - Intermittent tailure - Loose or poor contact on the VS sensor 3P (Blue) connector . Speedometer Inspection inspect the speedometer (page 20-5). Is the speedometer normal? YES — GO TO STEP 3. N0 — Replace or repair the abnormal circuit. . VS Sensor Signal Line Inspection Turn the ignition switch OFF. [1] Disconnect the ECM 33F (Black) connector [1]. . . , , . 3 Turn the ignition sWItch ON and engine stop swnch \ . Measure the voltage at the ECM 33F (Black) connector oi the Wire side. Connection: White/red (+)—Ground (—) @ TOOL: W/R Test probe 07ZAJ-RDJA110 Slowly turn the rear wheel by hand. 7 There should be 0 V to 5 V pulse voltage. Is there 0 — 5 V pulse voltage? YES — Replace the ECM With a known good one and recheck. N0 — Open or short circuit in White/red wire. 4-20 PGM-FI SYSTEM DTC 12 (INJECTOR) NOTE BeIore starting the inspection, check tor loose or poor contact on the injector 2P (Gray) connector and recheck the MIL blinking. ECM From ENGINE STOP SWITCH / INJECTOR T Bl/Bu l" i ii Probable cause ' Open circuit in Black/blue wire between the engine stop switch and injector ' Open or short circuit in Pink/white wire between the injector and ECM ' Faulty injector ' Faulty ECM DTC 12-1 (INJECTOR) 1. Injector System Inspection Erase the DTC's (page 4-5). Turn the ignition switch ON and engine stop switch Start the engine and check the injector With the H08 pocket tester. Is the DTC 12-1 indicated? YES — GO TO STEP 2. N0 — ~ Intermittent tailure ~ Loose or poor contact on the injector 2P (Gray) connector 2. Injector Input Voltage Inspection Turn the ignition switch OFF. Disconnect the injector 2P (Gray) connector [1]. Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P (Gray) connector ot the Wire side and ground. Connection: Black/blue (1-) — Ground (—) Standard: Batteryvoltage Does the standard voltage exist? YES — GO TO STEP 3. N0 — Open or short circuit in Black/blue wire 4-21 PG M-FI SYSTEM 3. Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. [1] Check ior continuity between the iniector 2P (Gray) connector [1] ol Wire side and ground. * _ Connection: Pink/white— Ground = Is there continuity? WW I YES — Short circuit in Pink/White Wire /9\ N0 — GO TO STEP 4. \ 4. Injector Resistance Inspection Measure the resistance between the iniector 2P 1 (Gray) connector [1] terminals. [ 1 Standard: 11 — 13 o (20°C/68°F) \ , Is the resistance within 11 — 13.0 (20°C/68"F)? YES — GO TO STEP 5. ‘ N0 — Faulty iniector i 5. Injector Signal Line Open Circuit Inspection Disconnect the ECM 33F (Black) connector [1]. [2] [1] Check the continuity between the ECM 33F (Biack) connector and iniector 2P (Gray) connector [2] oi the Wire side. Connection: Pink/white — Pink/white TOOL: {flu—B I . Test probe 07ZAJ-RDJA110 PM] ‘—W Is there continuity? n ® YES — Replace the ECM With a known good one and recheck. N0 — Open circuit in Pink/White Wire 4-22 DTC 21 (02 SENSOR) NOTE PGM-FI SYSTEM Betore starting the inspection, check tor loose or poor contact on the 02 sensor 1P (Black) connector or 02 sensor cap and recheck tne MIL blinking. ECM 02 SENSOR [ Bl J‘} Bl/W :* , ii i Probable cause ' Open or short circuit in Black/white or Black wire between the 02 sensor and ECM ' Faulty 02 sensor ' Faulty ECM DTC 21-1 (02 Sensor) 1. 02 Sensor System Inspection Start the engine and warm up the engine up to coolant temperature is 80°C (176°F). Test-ride the motorcycle and check the 02 sensor with the HDS pocket tester. Is the DTC 21-1 indicated? YES — GO TO STEP 2. N0 — intermittent tailure 2. 02 Sensor Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 460i Disconnect the 02 sensor cap [1] (page 4-47). Check tor continuity between the 02 sensor cap terminal [2] and ground. Connection: 02 sensor cap terminal — Ground Is there continuity? YES — Short circuit in Black or Black/white wire N0 — GO TO STEP 3. 4-23 PG M-FI SYSTEM 3. 02 Sensor Open Circuit Inspection Check ior continuity between the ECM 33F (Black) connector [1] and 02 sensor cap terminal [2] at the [2] wire side. [i] \ 4 . Connection: . ‘# Oz sensor cap terminal — Black/white if TOOL: Test probe 07ZAJ-RDJA110 Q ‘ Is there continuity? Bl/W YES — GO TO STEP 4. N0 — Open circuit in Black or Black/white wire 4. 02 Sensor Inspection Replace the 02 sensor with a known good one (page 4-47). Connect the ECM 33F (Black) connector. Start the engine and warm up the engine up to coolant temperature is 80°C (176°C). Test-ride the motorcycle and recheck the 02 sensor with the HDS pocket tester. Is the DTC 21-1 indicated? YES — Replace the ECM With a known good one and recheck. N0 — Faulty original 02 sensor DTC 29 (IACV) NOTE Beiore starting the inspection, check ior loose or poor contact on the IACV 4P (Black) connector and recheck the MIL blinking. ECM IACV Bu/W Bu/Bl Br/W Br/Bl Probable cause ' Open or short circuit in wires (Blue/white, Blue/black, Brown/white, Brown/black) between the IACV and ECM ' Faulty IACV ' Faulty ECM 4-24 PGM-FI SYSTEM 1. Ftecheck DTC Erase the DTC's (page 4-5). Turn the ignition switch ON and engine stop switch Check the IACV with the HDS pocket tester. Is the DTC 29-1 indicated? YES — GO TO STEP 2. N0 — ~ Intermittent iailure ~ Loose or poor contact on the IACV 4P (Black) connector . IACV Short Circuit Inspection Disconnect the ECM 33F (Black) connector (page 4-50). Check tor continuity between the iACV 4P (Biack) connector [1] at the wire side and ground. Connection: Blue/white — Ground Brown/white — Ground Brown/black — Ground Blue/black — Ground Is there continuity? YES — ~ Short circuit in Blue/white or Brown/ white wire ~ Short circuit in Brown/black or Blue/ biackwwe N0 — GO TO STEP 3. . IACV Open Circuit Inspection Check tor continuity between the ECM 33F (Biack) connector [1] and iACV 4P (Black) connector [2] oi the Wire side. Connection: Brown/white — Brown/white Blue/white — Blue/white Brown/black — Brown/black Blue/black — Blue/black TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — ~ Open circuit in Blue/white or Brown/ white wire ~ Open circuit in Brown/black or Blue/ biackwwe [1] \ Bu/W S2 Br/W £47132 Br/Bi Bu/Bl [1] [2] 4-25 PG M-FI SYSTEM 4. IACV Resistance Inspection Turn the ignition switch OFF. Disconnect the lACV 4P (Black) connector [1] (page 7-15). Measure the resistance at the IACV side connector. Connection: A (Blue/black) — D (Blue/white) B (Brown/black) — C (Brown/white) Standard: 110 — 150 n (25°C/77‘F) Is the resistance within 110 — 150 0 (25 "C/77"F)? YES — Replace the ECM With a known good one and recheck. N0 — Faulty lACV [1] DTC 33-2 (EEPROM) 1. Recheck DTC Erase the DTC's (page 4-5). Turn the ignition switch ON and engine stop switch Recheck the ECM EEPROM. Is the DTC 33-2 indicated? YES — Replace the ECM With a known good one and recheck. N0 — Intermittent iaiIure DTC 54 (BANK ANGLE SENSOR) NOTE Beiore starting the inspection, check tor loose or poor contact on the bank angle sensor 2P connector and recheck the ML blinking. ECM From ENGINE STOP SWITCH Bl/Bu R/Bu J 4» : I i @ BANK ANGLE SENSOR Probable cause ' Open circuit in Black/blue wire between the engine stop switch and bank angle sensor ' Open or short circuit in Red/blue wire between the bank angle sensor and ECM ' Faulty bank angle sensor ' Faulty ECM 4-26 PGM-FI SYSTEM DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE) 1. Ftecheck DTC Erase the DTC's (page 4-5). Turn the ignition switch ON and engine stop switch Check the bank angie sensor With the H08 pocket tester. Is the DTC 54-1 indicated? YES — GO TO STEP 2. N0 — Intermittent lailure 2. Bank Angle Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the bank angle sensor 2P connector [1] (page 4-48). Turn the ignition switch ON and engine stop switch Measure the voitage between the bank angie sensor 2P connector oi the wire side and ground. Connection: Black/blue (1-) — Ground (—) Standard: Batteryvoltage Is there battery voltage? YES — GO TO STEP 3. N0 — Open circuit in Black/blue Wire 3. Bank Angle Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 4-50). Check tor continuity between the bank angle sensor 2P connector [1] ot the Wire side and ground. Connection: Red/blue — Ground Is there continuity? YES — Short circuit in Red/blue wire N0 — GO TO STEP 4. 4. Bank Angle Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the bank angle sensor 2P connector [1] and ECM 33F (Black) connector [2] ol the Wire side. Connection: Red/blue — Fted/blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 5. N0 — Open circuit in Red/blue wire [1] [2] R/Bu R/Bu 4-27 PG M-FI SYSTEM 5. Bank Angle Sensor Inspection Replace the bank angle sensor With a known good one (page 4-48). Connect the bank angle sensor 2P connector and ECM 33F (Black) connector. Erase the DTC's (page 4-5). Turn the ignition switch ON and engine stop switch Check the bank angie sensor With the HDS pocket tester. Is DTC 54-2 indicated? YES — Replace the ECM With a known good one and recheck. N0 — Faulty original the bank angle sensor. DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE) 1. Flecheck DTC Erase the DTC's (page 4-5). Turn the ignition switch ON and engine stop switch Check the bank angie sensor With the HDS pocket tester. Is the DTC 54-2 indicated? YES — GO TO STEP 2. N0 — Intermittent lailure . Bank Angle Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the bank angle sensor 2P connector [1] (page 4-48). Turn the ignition switch ON and engine stop switch Measure the voltage between the bank angie sensor 2P connector oi the wire side and ground. Connection: Black/blue (1-) — Ground (—) Standard: Batteryvoltage Is there battery voltage? YES — GO TO STEP 3. N0 — Open circuit in Black/blue wire . Bank Angle Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF. Check tor continuity between the bank angle sensor 2P connector [1] and ECM 33F (Black) connector [2] ol the Wire side. Connection: FIed/blue — FIed/blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Inspect the bank angle sensor (page 4- 48). N0 — Open circuit in Red/biue wire R/Bu 4-28 PGM-FI SYSTEM MIL TROUBLESHOOTING MIL1 BLINK (MAP SENSOR) ECM SENSOR UNIT 5 V (MAP SENSOR) I5 v Y/R Lg/Bl G/W 1 Probable cause O Open circuit in Yellow/red Wire between the sensor unit and ECM O Open or short circuit in Light green/black wire between the sensor unit and ECM O Open circuit in Green/white Wire between the sensor unit and ECM O Faulty sensor unit O Faulty ECM 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 4-8). Is the sensor uni! power line normal? YES — GO TO STEP 2. N0 — Replace or repair the abnormal circuit. 2. MAP Sensor Output Voltage Inspection Turn the ignition switch OFF. Connect the ECM 33F (Black) connector. Disconnect the sensor unit 5P connector [1] (page 4-44). Turn the ignition switch ON and engine stop switch [1] Measure the voltage at the sensor unit 5P connector at the wire side. Connection: Light green/black (1-) — Green/white (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — Faulty sensor unit (MAP sensor) N0 — GO TO STEP 3. 4-29 PG M-FI SYSTEM 3. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector. Check tor continuity between the sensor unit 5P connector [1] terminal oi the Wire side and ground. Connection: Light green/black — Ground Is there continuity? YES — Short circuit in Light green/black wire N0 — GO TO STEP 4. 4. MAP Sensor Output Line Open Circuit Inspection Check Ior continuity between the ECM 33F (Black) connector [1] and sensor unit 5P connector [2] oi the Wire side. Connection: Light green/black — Light green/black TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM With a knoWn good one and recheck. N0 — Open circuit in Light green/black wire MIL 7 BLINKS (ECT SENSOR) NOTE Beiore starting the inspection, check tor loose or poor contact on the ECT sensor 3P connector and recheck the MIL blinking. ECM ECT SENSOR 'Ll ‘ '- Y/ Bu 5] f "i a... ,i m < é Probable cause ' Open or short circuit in Yellow/blue wire between the ECT sensor and ECM ' Open circuit in Green/White wire between the ECT sensor and ECM ' Faulty ECT sensor ' Faulty ECM 4-30 ‘l. ECT Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 3P connector [1] (page 4-46). Turn the ignition switch ON and engine stop switch Measure the voitage at the ECT sensor 3P connector ol the Wire side and ground. Connection: Vellow/blue (+) — Ground (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 3. NO — GO TO STEP 2. . ECT Sensor Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 4-50). Check tor continuity between the ECT sensor 3P connector [1] oi the Wire side and ground. Connection: Vellow/blue — Ground Is there continuity? YES — Short circuit in YelioW/blue wire NO — GO TO STEP 4. . ECT Sensor Resistance Inspection Measure the resistance at the ECT sensor [1] terminals. Standard: 2.3 — 2.6 kn (20°C/68’F) Is the resistance within 2.3 — 2.6 k!) (20"0/68"F)? YES — GO TO STEP 4. NO — Faulty ECT sensor . ECT Sensor Open Circuit Inspection Check lor continuity between the ECM 33F (Biack) connector [1] and ECT sensor 3P connector [2] ol the Wire side. Connection: Vellow/blue — Yellow/blue Green/white — Green/white TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one, and recheck. NO — ~ Open circuit in Yellow/blue Wire ~ Open circuit in Green/white Wire PGM-FI SYSTEM PG M-FI SYSTEM MIL 8 BLINKS (TP SENSOR) ECM SENSOR UNIT (TP SENSOR) 5V Y/R J G/W 1 % Probable cause O Open circuit in Yellow/red Wire between the sensor unit and ECM O Open or short circuit in Yellow wire between the sensor unit and ECM O Open circuit in Green/white Wire between the sensor unit and ECM O Faulty sensor unit O Faulty ECM 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 4-8). Is the sensor uni! power line normal? YES — GO TO STEP 2. N0 — Replace or repair the abnormal circuit. 2. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector and sensor unit 5P connector [1] (page 4-44). Check tor continuity between the sensor unit 5P connector oi the Wire side and ground. Connection: Yellow — Ground Is there continuity? YES — Short circuit in Yellow Wire N0 — GO TO STEP 3. 4-32 3. TP Sensor Output Line Open Circuit Inspection Check tor continuity between the ECM 33F (Black) connector [1] and sensor unit 5P connector [2] oi the Wire side. Connection: Vellow — Vellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in Yellow wire 4. TP Sensor Resistance Inspection Connect the sensor unit 5P connector. Check that the resistance varies in accordance with the throttle operation at the ECM 33F (Black) connector oi the Wire side. Connection: Yellow — Green/white Fully closed-Fully open position: Resistance increases Fully open-Fully closed position: Resistance decreases Is the resistance normal? YES — Replace the ECM with a known good one, and recheck. N0 — Faulty sensor unit (TP sensor) MIL 9 BLINKS (IAT SENSOR) PGM-FI SYSTEM < G/W [1] ECM SENSOR UNIT (IAT SENSOR) ‘ '- Gr/Bu l u: < ~—W.—+ i l— Probable cause ' Open or short circuit in Gray/blue wire between the sensor unit and ECM ' Open circuit in Green/white Wire between the sensor unit and ECM ' Faulty sensor unit ' Faulty ECM 4-33 PG M-FI SYSTEM 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 4-8). Is the sensor unit power line normal? YES — GO TO STEP 2. NO — Replace or repair the abnormal circuit. . IAT Sensor Output Voltage Inspection Turn the ignition switch OFF. Connect the ECM 33F (Black) connector. Disconnect the sensor unit 5P connector [1] (page 4-44). Turn the ignition switch ON and engine stop switch Measure the voltage at the sensor Unit SP connector ol the Wire side. Connection: Gray/blue (+) — Green/white (—) Standard: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — GO TO STEP 5. N0 — GO TO STEP 3. . IAT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector. Check tor continuity between the sensor unit 5P connector [1] ol the Wire side and ground. Connection: Gray/blue — Ground Is there continuity? YES — Short circuit in Gray/blue wire N0 — GO TO STEP 4. . IAT Sensor Output Line Open Circuit Inspection Check lor continuity between the ECM 33F (Black) connector [1] and sensor unit 5P connector [2] oi the Wire side. Connection: Gray/blue — Gray/blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM With a knoWn good one and recheck. NO — Open circuit in Gray/blue Wire Gr/Bu ' S G/W rm [2] 4-34 5. IAT Sensor Resistance Inspection Turn the ignition switch OFF. Connect the sensor unit 5P connector. Disconnect the ECM 33F (Black) connector [1]. Measure the resistance at the ECM 33F (Black) connector oi the wwre side. Connection: Gray/blue — Green/white Standard: 1.13 — 1.88 kfl (20°C/68°F) Is the resistance within 1.13 — 1.88 k!) (217°C/ 68°F)? YES — Replace the ECM with a known good one, and recheck. N0 — Faulty sensor unit (lAT sensor) MIL 11 BLINKS (VS SENSOR) NOTE PGM-FI SYSTEM / [1] Belore starting the inspection, check ior loose or poor contact on the VS sensor 3P (Blue) connector and recheck the ML blinking. To SPEEDOMETER v v \7 VS SENSOR G/Bl 7 Bl :: Bl/R é W/R o Probable cause ' Open or short clrcuit 1n Pink or White/red wire between the VS sensor and ECM ' Faulty VS sensor ' Faulty ECM 1. Speedometer Inspection lnspect the speedometer (page 20-8). Is the speedometer normal? YES — GO TO STEP 2. N0 — Replace or repair the abnormal circuit. W/R ECM 4-35 PGM-FI SYSTEM 2. VS Sensor Signal Line Inspection Tum the ignition switch OFF. U] Disconnect the ECM 33F (Black) connector [1]. \ Tum the ignitlon switch ON and engine stop switch fl Measure the voltage at the ECM 33F (Black) connector ol the ere side. Connection: White/red (4-) — Ground (—) 6') TOOL: W“ 6 Test probe 07ZAJ-RDJA110 Slowly turn the rear wheel by hand. 7 There should be 0 V to 5 V pulse voltage. Is there I] — 5 V pulse voltage? YES — Replace the ECM thh a known good one and recheck. N0 — Open or short circuit in White/red wire. MIL 12 BLINKS (INJECTOR) NOTE Belore starting the inspection, check tor loose or poor contact on the jnjector 2P (Gray) connector and recheck the MIL bljnking. ECM From ENGINE STOP SWITCH / INJECTOR Bl/Bu Probable cause ' Open circujt in Black/blue wire between the engine stop switch and injector ' Open or short circuit in Pink/white wire between the injector and ECM ' Faulty injector ' Faulty ECM 4-36 PGM-FI SYSTEM 1 . Injector Input Voltage Inspection Turn the ignition switch OFF. Disconnect the injector 2P (Gray) connector [1] (page 7-14). Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P (Gray) connector oI the Wire side and ground. Connection: Black/blue (1-) — Ground (—) Standard: Batteryvoltage Does the standard voltage exist? YES — GO TO STEP 2. N0 — Open circuit in Black/blue Wire . Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector. Check tor continuity between the injector 2P (Gray) connector [1] oi the Wire side and ground. Connection: Pink/white — Ground Is there continuity? YES NO — Short circuit in Pink/White Wire — GO TO STEP 3. . Injector Resistance Inspection Measure the resistance between the injector side connector [1] terminals. Standard: 11 — 13 Q (20°C/68°F) Is the resistance within 11 — 13.0 (20°C/68"F)? YES — GO TO STEP 4. N0 — Faulty injector . Injector Signal Line Open Circuit Inspection Check Ior continuity between the ECM 33F (Black) connector [1] and injector 2P (Gray) connector [2] oi the Wire side. Connection: Pink/white — Pink/white TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one, and recheck. N0 — Open circuit in Pink/White Wire [1] [1] [2] [1] P/W 4-37 PG M-FI SYSTEM MIL 21 BLINKS (02 SENSOR) NOTE Betore starting the inspection, check tor loose or poor contact on the 02 sensor 1P (Black) connector or 02 sensor cap and recheck the MIL blinking. ECM 02 SENSOR [ Bl Probable cause ' Open or short circuit in Black/white or Black wire between the 02 sensor and ECM ' Faulty 02 sensor ' Faulty ECM 1. 02 Sensor System Inspection Start the engine and warm up the engine up to coolant temperature lS 80°C/176°F. Test-ride the motorcycle and recheck the MIL blinking. Does the MIL blink 21 times? YES — GO TO STEP 2. N0 — lntermittent tailure 2. 02 Sensor Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 4-50). Disconnect the 02 sensor cap [1] (page 4-47). Check tor continuity between the 02 sensor cap terminal [2] and ground. Connection: 02 sensor cap terminal — Ground Is there continuity? YES — Short circuit in Black or Black/white wire N0 — GO TO STEP 3. 4-38 3. 02 Sensor Open Circuit Inspection Check ior continuity between the ECM 33F (Black) connector [1] and 02 sensor cap terminal [2] oi the wire side. Connection: 02 sensor cap terminal — Black/ white TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in Black or Black/white wire 4. 02 Sensor Inspection Replace the 02 sensor with a known good one (page 4-47). Connect the ECM 33F (Black) connector. Start the engine and warm up the engine up to coolant temperature is 80°C/176°F. Test-ride the motorcycle and recheck the MIL blinking. Does the MIL blink 21 times? YES — Replace the ECM With a known good one. and recheck. N0 — Faulty original 02 sensor MIL 29 BLINKS (IACV) NOTE PGM-FI SYSTEM [2] iii \ j; Bl/W Beiore starting the inspection, check ior loose or poor contact on the IACV 4P (Black) connector and recheck the MIL blinking. IACV Bu/W Bu/Bl Br/W Br/Bl Probable cause O Open or short circuit in wires (Blue/white, Blue/black. Brown/white, Brown/black) between the IACV and ECM O Faulty IACV O Faulty ECM 4-39 PG M-FI SYSTEM 1 . IACV Resistance Inspection Turn the ignition switch OFF. Disconnect the iACV 4P (Black) connector [1] (page 7-15). Measure the resistance at the IACV side connector. Connection: A (Blue/black) — D (Blue/white) B (Brown/black) — C (Brown/white) Standard: 110 — 150 n (25°C/77‘F) Is the resistance within 110 — 150 t) (25 "C/77"F)? YES — GO TO STEP 2. N0 — Faulty iACV . IACV Short Circuit Inspection Disconnect the ECM 33F (Biack) connector (page 4-50). Check ior continuity between the iACV 4P (Biack) connector [1] oi the Wire side and ground. Connection: Blue/white — Ground Brown/white — Ground Brown/black — Ground Blue/black — Ground Is there continuity? YES — - Short circuit in Blue/white or Brown/ white wire - Short circuit in Brown/biack or Blue/ biackwwre N0 — GO TO STEP 3. . IACV Open Circuit Inspection Check ior continuity between the ECM 33F (Biack) connector [1] and iACV 4P (Black) connector [2] at the Wire side. Connection: Brown/white — Brown/white Blue/white — Blue/white Brown/black — Brown/black Blue/black — Blue/black TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one, and recheck. N0 — ~ Open circuit in Blue/white or Brown/ white wire ~ Open circuit in Brown/black or Blue/ biackwwre [1] Bu/Bl 4-40 MIL 54 BLINKS (BANK ANGLE SENSOR) NOTE PGM-FI SYSTEM Betore starting the inspection, check tor loose or poor contact on the bank angle sensor 2P connector and recheck the ML blinking. ECM From ENGINE STOP SWITCH Bl/Bu J R/Bu J 4» BANK ANGLE SENSOR Probable cause ' Open circuit in Black/blue wire between the engine stop switch and bank angle sensor ' Open or short circuit in Red/blue wire between the bank angle sensor and ECM ' Faulty bank angle sensor ' Faulty ECM 1. Bank Angle Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the bank angle sensor 2P connector [1] (page 4-48). Turn the ignition switch ON and engine stop switch Measure the voltage between the bank angle sensor 2P connector oi the wire side and ground. Connection: Black/blue (1-) — Ground (—) Standard: Batteryvoltage Is there battery voltage? YES — GO TO STEP 2. N0 — Open circuit in Black/blue Wire 4-41 PG M-FI SYSTEM 2. Bank Angle Sensor Signal Line Short Circuit Inspection Tum the ignition switch OFF. Disconnect the ECM 33F (Biack) connector (page 4-50). Check tor continuity between the bank angle sensor 2P connector [1] oi the wire side and ground. Connection: Red/blue — Ground Is there continuity? YES — Short circuit in Red/biue wire N0 — GO TO STEP 3. 3. Bank Angle Sensor Signal Line Open Circuit Inspection Tum the ignition switch OFF. [2] Check tor continuity between the bank angle sensor [1] 2P connector [1] and ECM 33F (Black) connector [2] ol the Wire side. Connection: Red/blue — Fled/blue i:i . w TOOL: I Test probe 07ZAJ-RDJA110 R/Bu —W Is there continuity? KS? YES — GO TO STEP 4. U N0 — Open circuit in Red/biue wire 4. Bank Angle Sensor Inspection Replace the bank angle sensor With a known good one (page 4-48). Connect the bank angle sensor 2P connector and ECM 33F (Black) connector. Erase the DTC's (page 4-5). Tum the ignition switch ON and engine stop switch c eck ii the MIL blinks. Does the MIL blink 54 times? YES — Replace the ECM With a knoWn good one. and recheck. N0 — Faulty original the bank angle sensor. 4-42 PGM-FI SYSTEM MIL CIRCUIT TROUBLESHOOTING NOTE Betore starting the inspection, check the speedometer power input line (page 20-6). With The Ignition Switch ON, The MIL Does Not Come On lithe engine can be started but the MIL does not come on when the ignition sWitch is turned ON and engine stop switch "c", check as tollows: Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 4- 50). Ground the Iollowing terminal oi the Wire harness side ECM 33F (Black) connector [1] with aiumper Wire [2]. CONNECTION: White/blue — Ground TOOL: Test probe O7ZAJ-FIDJA110 Turn the ignition switch ON and engine stop switch "C" the MIL should come on. — It the MIL comes on, replace the ECM with a known good one and recheck the MIL indication. — it the MIL does not come on, check Ior open circuit 7 in the White/blue wire between the speedometer and ECM 33F (Black) connector. It the wire is OK, replace the speedometer. With The Ignition Switch ON, The MIL Does Not Go on Within A Few Seconds (Engine starts) Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 4- 50 . Turn the ignition switch ON and engine stop sWitc — It the MIL comes on, check tor short circuit in the White/blue wire between the speedometer and ECM. It the White/blue wire is OK, replace the ECM with a known good one and recheck. — it the MILturns oII, check the Iollowing. Check the continuity between the ECM 33F (Black) connector [1] oi the wire side and ground. [1] CONNECTION: Blue — Ground STANDARD: No continuity TOOL: Test probe O7ZAJ-FIDJA110 II there is continuity, check tor short circuit in the Blue Q wire between the DLC and ECM. II there is no continuity, replace the ECM With a known good one and recheck. 7 4-43 PGM-Fl SYSTEM SENSOR UNIT REMOVAL/INSTALLATION Remove the left Iuel tank shroud (page 2—4). Disconnect the sensor unit 5P connector [1]. Remove the torx screws [2] and sensor unit [3] Irom the throttle body. Remove the O-ring [1]. Install a new O-ring to the throttle body properly. NOTE II the O-ring is not installed properly, the idle airwill leak and engine idle speed will be unstable. Install the sensor unit [2] to the throttle body by aligning the Iollowing: — CIlp of the TP sensor with the boss ol the throttle valve — IAT sensor ol the sensor unit with the hole ol the ( throttle body Install and tighten the sensor unit torx screws [1] to the specified torque. TORQUE: 3.4 MM (0.3 kgf—m, 2.5 lbI-Il) Connect the sensor unit 5P connector [2]. Install the left fuel tank shroud (page 2-4). Perlorm the TP sensor reset procedure (page 4-45). 4-44 PGM-FI SYSTEM TP SENSOR RESET PROCEDURE NOTE II the sensor unit is removed, reset the throttle valve lully closed position as tollowmg. 1. Erase the DTC (page 4-5). 2. Turn the ignition switch OFF. 3. Remove the dummy connector. 4. Short the DLC [1] using the special tool. TOOL: [2] $65 connector 070P2-ZY3D100 5. Disconnect the ECT sensor 3P connector [1]. Short the ECT sensor 3P connector terminals 01 the Wire harness side with a jumper wire [2]. Connection: Yellow/blue — Green/white 6. Turn the ignition switch ON and engine stop switch "5:", then MIL will start blinking. Disconnect the jumper wire while the MIL blinking (Within 10 seconds). 7. Alter disconnection of the jumper Wire, the MIL will start short blinking. Check it the MIL blinks. It the MIL begins short blink (0.3 seconds), the TP sensor is reset successlully. Within 10 sec. MILON MIL OFF RESET RECEIVING PATTERN SUCCESSFVLJL PATTERN If the MIL remains ON, the TP sensor is not reset, repeat the reset procedure lrom step 1. 8. Turn the ignition switch OFF. 9. Connect the ECT sensor 3P connector. 10.Install the dummy connector to the DLC. 4-45 PGM-Fl SYSTEM ECT SENSOR Remove the ECT sensor while the englne is cold. Wear lnsulazed gloves and adequate eye protection. Keep flammable maren'als away lmm the burner. REMOVAL/INSTALLATION Drain the coolant (page 9—5). Disconnect the ECT sensor 3P connector [1]. Remove the ECT sensor [2] and sealing washer [3]. Installation is in the reverse order ol removal. - Replace the sealing washer with a new one. TORQUE: ECT sensor: 25 MM (2.5 kgf—m, 18 IBM!) Fill the cooling system with recommended coolant (page 9-5). INSPECTION Remove the ECT sensor [1] (page 4-46). Heat the coolant With an electric heating element. Suspend the ECT sensor in heated coolant and check the continuity through the sensor as the coolant heats up. - Soak the ECT sensor in coolant up to its threads With at least 40 mm (1.6 in) from the bottom of the pan to the bottom of the sensor. - Keep temperature constant for 3 minutes before testing. A sudden change ol temperature will result in incorrect readings. Do not let the thermometer [2] or ECT sensor touch the pan. CONNECTION: A — B Temperature 20 °Cl68°F 80 °Cl176°F Resistance 2.3 — 2.6 k0 0.31 — 0.33 k0 Replace the ECT sensor if it l5 out of specilicatlons by more than 10%. Install the ECT sensor (page 4-46). A m [2] 4-46 PGM-FI SYSTEM 02 SENSOR - Do not gel grease, oil or other materials in the 02 sensor air hole. - The 02 sensor may be damaged it dropped Replace it with a new one, it dropped. REMOVAL/INSTALLATION NOTE - Handle the 02 sensor With care. - Do not sen/ice the 02 sensor while it is hot. - Do not use an impact wrench while removing or installing the 02 sensor, or it may be damaged. Remove the left fuel tank shroud (page 2-4). Disconnect the 02 sensor 1P (Black) connector [1]. Remove the wire band [2] from the lrame. Disconnect the 02 sensor cap [1]. Remove the 02 sensor [2]. Installation is in the reverse order ol removal. TORQUE: 02 sensor: 25 Nm (2.5 kgl-m,1BIbI-ft) - Take care not to tilt the 02 sensor cap when connecting the cap to the 02 sensor. - Do not turn the 02 sensor cap alter connecting it. 4-47 PG M-FI SYSTEM BANK ANGLE SENSOR REMOVAL/INSTALLATION Remove the reserve tank cover (page 2-4). Disconnect the bank angle sensor 2P connector [1]. Remove the bank angle sensor mounting nuts [2], bolts [3], bank angle sensor [4] and plate [5]. Remove the collars [6] and mounting rubbers [7] irom the bracket. Installation is in the reverse order ol removal. ' install the bank angle sensor with its "UP" mark [8] iacing up. TORQUE: Bank angle sensor mounting nul 9.0 N-m (0.9 kgl-m, 5.6 lbt-fl) SYSTEM INSPECTION Remove the bank angle sensor (page 4-48). Connect the bank angle sensor 2P connector. Place the bank angle sensor horizontal as shown. Start the engine. Incline the bank angle sensor 70 i 5° to the Ielt or right. The bank angle sensor is normal ii the engine stops. 4-48 PGM-FI SYSTEM ECM ECM POWER/GROUND LINE INSPECTION NOTE Betore starting the inspection, check tor loose or poor contact on the ECM 33F (Black) connector and recheck the MIL blinking. ENGINE DOES NOT STAFIT (MIL does not blink) 1. ECM Power Input Voltage Inspection Disconnect the ECM 33F (Biack) connector [1] (page 4-50). T the ignition switch ON and engine stop switch Measure the voltage at the ECM 33F (Black) connector oi the Wire side and ground. Connection: Black/blue (1-) — Ground (—) Standard: Batteryvoltage TOOL: Test probe 07ZAJ-RDJA110 Does the standard voltage exist? YES — GO TO STEP 2. N0 — ~ Open circuit in Biack/plue wire ~ Fauity ignition switch ~ Biown main Iuse (30 A) ~ Biown Fi, IGN iuse (10 A) ~ Fauity engine stop switch 2. Sensor Unit Power Line Inspection Turn the ignition switch OFF. Check Ior continuity between the ECM 33F (Biack) connector [1] oi the wire side and ground. Connection: Vellow/red — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Short circuit in Yeliow/red Wire N0 — GO TO STEP 3. 3. ECM Ground Line Inspection Turn the ignition switch OFF. Check Ior continuity between the ECM 33F (Biack) connector [1] oi the wire side and ground. Connection: Green/black — Ground Green — Ground Green — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one, and recheck. N0 — ~ Open circuitin Green/biack Wire ~ Open circuit in Green wires [1] 4-49 PGM-FI SYSTEM REMOVAL/ INSTALLATION Remove the reserve tank cover (page 2-4). Turn the ignitlon switch OFF. Disconnect the ECM 33F (Black) connector [1]. Remove the rubber holder [2] and ECM [3]. Remove the ECM lrom the rubber holder. Installation is in the reverse order ol removal. 4-50 5. IGNITION SYSTEM SERVICE INFORMATION-mu ----5-2 IGNITION SYSTEM INSPECTION TROUBLESHOOTING ------------ IGNITION TIMING . SYSTEM LOCATION-------------------------------------5-3 IGNITION COIL 55 SYSTEM DIAGRAM 53 IGNITION SYSTEM SERVICE INFORMATION GENERAL ~ When servicing the ignition system, always iollow the steps in the troubleshooting table (page 5-2). ~ A iaulty ignition system is olten related to poorly connected or corroded connections. Check those connections belore proceeding. TROUBLESHOOTING ~ Inspect the iollowing beiore diagnosing the system. — Faulty spark plug — Loose spark plug cap or spark plug wire connection — Water got into the spark plug cap (Leaking the ignition coil secondary voltage) "Initial voltage" oi the ignition primary coil is the battery voltage with the ignition switch turned ON and engine stop switch "A." (The engine is not cranked by the starter motor). Unusual condition Probable cause (Check in numerical order) Ignition coil No initial voltage with the ignition 1. Faulty ignition sWitch primary voltage switch turned ON and engine stop 2. An open circuit in Black/blue Wire between the ignition coil switch "C" (Other electrical and engine stop switch components are normal). 3. An open circuit in Black/green or Black/red wires between the engine stop switch and ignition switch 4. Loose or poor connection oi the primary terminal, or an open circuit in the primary coil 5. Faulty ECM (in case when the initial voltage is normal With the ECM connector disconnected). 6. Faulty engine stop switch Initial voltage is normal, but it drops by 1. Incorrect peak voltage adaptor connections (System is 2 — 4 V while cranking the engine. normal il measured voltage is over the specilications With reverse connections). 2. Battery is undercharged (Voltage drops largely when the engine is started). 3. No voltage between the Black/blue (+) Wire and body ground (—) at the ECM connector or poor connection oi the ECM connector 4. An open circuit or loose connection in Green or Green/ black wire at the ECM 5. An open circuit or loose connection in Green/red wire between the ignition coil and ECM 6. Faulty sidestand sWitch or neutral switch or related wires 7. Faulty CKP sensor (Measure peak voltage) 8. Faulty ECM (in case when above No. 1 through 7 are normal). Initial voltage is normal but there is no 1. Incorrect peak voltage adaptor connections peak voltage while cranking the 2. Faulty peak voltage adaptor engine. 3. Faulty CKP sensor 4. Faulty ECM (in case when above No. 1 through 3 are normal). Initial voltage is normal but peak 1. The multimeter impedance is too low; below 10 MQ/DCV. voltage is loWer than the standard 2. Cranking speed is too slow (Battery is undercharged). value. 3. The sampling timing oi the tester and measured pulse were not synchronized (System is normal il measured voltage is over the standard voltage at least once). 4. Faulty ECM (in case when above No. 1 through 3 are normal). Initial and peak voltages are normal 1. Faulty spark plug or leaking ignition coil secondary current but no spark jumps. 2. Faulty ignition coil CKP sensor Peak voltage is lower than standard 1. The multimeter impedance is too low; below 10 Mfl/DCV. value. 2. Cranking speed is too low. (Battery is undercharged.) 3. The sampling timing oi the tester and measured pulse were not synchronized (System is normal il measured voltage is over the standard voltage at least once). 4. Faulty CKP sensor (in case when above No.1 through 3 are normal). No peak voltage 1. Faulty peak voltage adapter 2. Faulty CKP sensor IGNITION SYSTEM SYSTEM LOCATION IGNITION SWITCH ENGINE STOP SWITCH CLUTCH SWITCH ECM BANK ANGLE SENSOFI BATTERY MAIN FUSE (30 A) Fl, IGN FUSE (10 A) IGNITION COIL ,1, SPARK PLUG \‘ : , I / CKP SENSOR SIDESTAND NEUTRAL SWITCH SW'TCH SYSTEM DIAGRAM IGNITION SWITCH SIDESTAND BI: Black SWITCH Bu: Blue R/W >0)- - G: Green l [E MAIN FUSE (30 A) Bl/R . Lg: LIght green 0: Orange _ e 9 Rzfied BATTERY F'I'GN FUSEIIOA) _| GM G W:White Eve g BANK 4 v: Yellow ENGINESTGR SENS-SR T Br: Brown SWITCH BI/Bu —._I IGNITION 00”- Bl/Bu G/R 9/3. NEUTRAL G/R R/Bu G/O G G DIODE 1 I I I I Lg/FI U ECM .0. _ NEUTRAL SPARK SENSOR SWITCH PLUG IGNITION SYSTEM IGNITION SYSTEM INSPECTION A vold touching the spark plug and tester probes to prevent electric shock. NOTE - If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. - Use a commercially available digital multimeter with an impedance of 10 Mfl/DCV minimum. The display value differs depending upon the internal impedance ol the multimeter. If using the lmrie diagnostic tester (model 625). follow the manufacturer‘s instructions. Connect the peak voltage adaptor [1] to the digital multimeter [2], or use the lmrie diagnostic tester. TOOL: lmrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially availabl 'giIal multimeter (impedance 10 Mn/DCV min um) IGNITION COIL PRIMARY PEAK VOLTAGE Shilt the transmission into neutral and disconnect the spark plug cap (page 3-5). Connect a known good spark plug [1] to the spark plug cap [2] and ground it to the cylinder head as done in a spark test. With the ignition coil primary Wire connected, connect the peak voltage adaptor or lmrie tester to the ignition coil primary terminal [1] and ground. TOOL: lmrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially available giIal multimeter (impedance 10 Mn/DCV mlnlmum) CONNECTION: Green/red (1-) — Ground (—) Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch "C". Crank the engine with the starter motor with the throttle grip fully opened and read ignition coil primary peak voltage. PEAK VOLTAGE: 100 V m mum ll the peak voltage is abnormal. follow the checks described in the troubleshooting table (page 5-2). IGNITION SYSTEM CKP SENSOR PEAK VOLTAGE Remove the resenle tank cover (page 2-4). Disconnect the ECM 33F (Black) connector [1]. Connect the peak voltage tester or adaptor probes to the ECM 33F (Black) connector [1] terminals ol the wire harness side. TOOLS: Imrie diagnostic tester (model 625) or Peak voltage adaptor [2] 07HGJ-0020100 with commercially available gital multimeter (impedance 10 Mn/DCV m um) Test probe 07ZAJ-FIDJA110 CONNECTION: Blue/yellow (+) — White/yellow (—) Shift the transmission into neutral. Turn the ignition switch ON and engine stop SWitch "“.C Crank the engine with the starter motor and measure the CKP sensor peak voltage. PEAK VOLTAGE: 0.7 V minimum II the peak voltage measured at the ECM 33F (Black) connector is abnormal, measure the peak voltage at the CKP sensor connector. Turn the ignition switch OFF. Remove the left side cover (page 2-3). Disconnect the CKP sensor/neutral switch 3P (Black) connector [1] and connect the tester probes to the connector terminals ol the CKP sensor side. CONNECTION: Blue/yellow (+) — White/yellow (—) In the same manner as at the ECM 33F (Black) connector, measure the peak voltage and compare it to the voltage measured at the ECM 33F (Black) connector. NOTE - If the peak voltage measured at the ECM is abnormal and the one measured at the CKP sensor is normal, the wire harness has an open or short circuit or loose connection. - If the peak voltage of the CKP sensor side is lower than standard value, Iollow the checks described in the troubleshooting table (page 5-2). For CKP sensor replacement (page 13-4). Install the removed parts in the reverse order ol removal. IGNITION SYSTEM IGNITION TIMING Warm up the engine. Stop the engine and remove the timing hole cap using the special tool. TOOL: Timing cap wrench 07709-0010001 Connect the timing light [1] to the spark plug wire. Start the engine and let it idle. IDLE SPEED: 1,450 1 100 min" (rpm) The ignition timing is correct il the "F" mark [2] on the llywheel aligns with the index notch [3] on the left crankcase cover. Apply engine oil to a new O-ring and install it to the timing hole cap. Apply engine oil to the timing hole cap threads. Install and tighten the timing hole cap to the specilied torque. TORQUE:6.0 NM (0.6 kgI-m, 4.4 lbl-ft) IGNITION COIL REMOVAL/INSTALLATION Disconnect the spark plug cap [1]. Disconnect the primary wire connectors [2] from the ignition coil. Release the spark plug wire [3] lrom the guides [4] on the Ian motor shroud. Remove the bolts [5], spacers [6] and ignition coil [7]. Installation is in the reverse order ol removal. [51/ [6] l4] I it). _/~\\m [2] 6. ELECTRIC STARTER SYSTEM SERVICE lNFORMATION------ ----6-2 STARTER MOTOR ----- TROUBLESHOOTING ------------ STARTER RELAY SWITCH ----- SYSTEM LOCATION-------------------------------------6-3 NEUTRAL DIODE ......................................... 5.9 SYSTEM DIAGRAM 63 ELECTRIC STARTER SYSTEM SERVICE INFORMATION GENERAL ~ When servicing the starter system, always iollow the steps In the troubleshooting Ilow chart (page 6-2). ~ A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. TROUBLESHOOTING Unusual condition Probable cause (Check in numerical order) Starter motor Starter motor does not turn om N¢9>PNA . Loose or poor contact on related connectors and terminals . Blown Iuse Weak battery . Faulty starter relay switch Faulty starter motor Faulty engIne stop switch Loose connection, open or short circuit in starter motor cable . Faulty starter switch Open circuit In starter relay sWItoh ground circuit 10. Open or short circuit In starter relay sWItoh power circuit 11. Loose contact or open circuit In related wires engine does not turn over Starter motor turns only when the 1. Loose or poor contact on related connectors and terminals transmission is in neutral (Starter 2. Faulty clutch switch motor does not turn when the 3. Faulty sidestand sWItoh transmission is in any gear with the 4. Loose contact or open circuit in related wires sidestand retracted and clutch lever pulled in) Starter motor turns only when the 1. Loose or poor contact on related connectors and terminals transmission is in any gear with the 2. Faulty neutral diode sidestand retracted and clutch lever 3. Faulty neutral sWItoh pulled in (Starter motor does not turn 4. Loose contact or open circuit in related wires when the transmission is in neutral With the sidestand lowered and clutch lever released) Starter motor turns slowly 1. Low battery voltage 2. Poorly connected battery terminal cable 3. Poorly connected starter motor cable 4. Faulty starter motor 5. Poorly connected battery ground cable Starter motor turns, but engine does 1. Starter motor is running backwards not turn — Case assembled improperly — Terminals connected Improperly 2. Faulty starter clutch 3. Damaged or iaulty starter Idle gear and/or reduction gear Starter relay switch "Clicks", but 1. Crankshait does not turn due to engIne problems ELECTRIC STARTER SYSTEM SYSTEM LOCATION ENGINE STOP SWITCH STARTER SWITCH IGNITION SWITCH CLUTCH SWITCH BATTERY MAIN FUSE (30 A) Fl. IGN FUSE (10 A) STARTER MOTOR NEUTRAL SWITCH STARTER RELAY SIDESTAND SWITCH SWITCH SYSTEM DIAGRAM MAIN FUSE WW M (30 A) Fl IGN e (.9 o IGNITION SWITCH FUSE (10A) BATTERY Y/R agggn STARTER 1 Bl/G RELAY STARTER SWITCH SWITCH ENGINE STOP SWITCH —— — G/R _ Bl/Bu —O NEUTRAL DIODE E:— (am (am 0/6 I CLUTCH _| SWITCH G/O Lg/R G O\C GM 0 Bl' Black I Lg/BI SIDESTAND " NEUTRAL SWITCH Bu. BIue SWITCH G: Green Lg: LighI green 1 R: Red To NEUTRAL : Y: YeIIow INDICATOR W: WhIIe 0: Orange 6-3 ELECTRIC STARTER SYSTEM STARTER MOTOR REMOVAL/INSTALLATION - Always turn the ignition switch "OFF" before servicing the starter motor. The motor could suddenly start, causing serious injury. Remove the cam chain tensioner Iilter (page 11-7). Remove the bolts [1] and clutch cable guide [2]. Disconnect the clutch cable [3] lrom the clutch lifter arm [4]- Release the rubber cap [1]. Remove the starter motor terminal nut [2] and starter motor cable [3]. Remove the stater motor mounting bolts [4] and ground terminal [5]. Remove the starter motor [6]. Remove the O-ring [1]. Installation is in the reverse order or removal. - Apply engine oil to a new O-ring. 6-4 ELECTRIC STARTER SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the starter motor as Iollowing illustratlon. The coil may be damaged i! the magnet pulls the armature against the motor case. ”SEAL RING MOTOR CASE v SEAL RING FRONT COVER 4.9 N-m (0.5 kgf n1 3. s Int-It) g I O-RING NEGATIVE BRUSH 3.-(.-7Nm04kglm o/ge ‘8 .. ~m V 2. 7 lbl f-t) @ @\’ ' INSULATOR TERMINAL STOPPER REAR COVER ’\ ‘ BRUSH HOLDER SPRING ARMATURE POSITIVE BRUSHES TERMINAL BOLT Upon assembly, align the lndex lines on the covers and motor case. @KNUT WASHER ELECTRIC STARTER SYSTEM Do not use emery or sand paper on the commutator. INSPECTION Check the oil seal [1] of the lront cover lor deterioration or damage. Check the bearing [2] and needle bearing [3] lor wear or damage. Replace the starter motor as an assembly it necessary. Clean the metallic debris ofl between commutator bars [1]- Check the commutator bars ot the armature tor discoloration, wear or damage. Replace the starter motor as an assembly it necessary. Check for continuity between pair ol commutator bars [1]- There should be continuity. Check lor continuity between each indivrdual commutator bar [1] and the armature shaft [2]. There should be no continuity. [3] CONTINUITY: NO CONTINUITY: [1] ELECTRIC STARTER SYSTEM Check lor continuity between the positive brushes [1] and cable terminal [2]. There should be continuity. CONTINUITY: l {21 ‘fiyl Check lor continuity between the positive brushes [1] NO CONTINUITY' and rear cover [2]. There should be no continuity. Check lor continuity between the positive and negative brushes [3]. There should be no continuity. Measure the brush length. SERVICE LIMIT: 6.5 mm (0.26 in) Check the bushing [1] of the rear cover for wear or damage. [1] Replace the starter motor as an assembly it necessary. ELECTRIC STARTER SYSTEM STARTER RELAY SWITCH INSPECTION Remove the left side cover (page 2—3). Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch "C". Push the starter sWitch. The coil is normal il the starter relay switch [1] clicks. ll you don't hear the starter relay switch “CLICK", inspect the starter relay switch using a procedure below. GROUND LINE Disconnect the starter relay switch 4P (Red) connector Check for continuity between the lollowmg terminal of the Wire harness side and ground when the starter switch is pushed. CONNECTION: Green/red — Ground ll there is continuity under lollowing conditions, the ground circuit is normal. — When the transmission is in neutral (In neutral, there is a slight resistance due to the diode.) — When the transmission is in gear With the clutch lever pulled in and sidestand retracted STARTER RELAV INPUT VOLTAGE Connect the starter relay sWitch 4P (Red) connector [1]. Turn the ignition switch ON and engine stop switch "C". Measure the voltage between the following terminal at the starter relay sWitch 4P (Red) connector and ground. CONNECTION: Yellow/red (1-) — Ground (—) STANDARD: Battery voltage ll the battery voltage appears only when the starter switch is pushed with the ignition switch ON and engine stop switch “C" the starter relay input voltage is normal. ELECTRIC STARTER SYSTEM OPERATION CHECK Remove the starter relay sWitch (page 6-9). Connect a fully charged 12 V battery to the starter relay switch as shown. There should be continuity between the cable terminals when the battery is connected, and no continuity when the battery is disconnected. 6 9 BATTERY REMOVAL/INSTALLATION Remove the left side cover (page 2-3). [4145] Disconnect the battery negative (-) terminal (page 19- 4). Disconnect the starter relay switch 4P (Red) connector [1]- Release the starter relay switch [2] from the air cleaner housing. Pull back the rubber cover [3]. Remove the bolts [4] and cables [5]. Remove the starter relay sWitch Irom the stays With the shock rubber. Remove the starter relay switch Irom the shock rubber. Installation is in the reverse order oI removal. NEUTRAL DIODE INSPECTION Remove the left side cover (page 2-3). Open the fuse box cover and remove the neutral diode Check for continuity between the neutral diode terminals. When there is continuity, a small resistance value Will register. E II there is continuity, in direction shown by the arrow, A the neutral diode is normal. A C B C MEMO 7. FUEL SYSTEM SERVICE INFORMATION-----------------------------7-2 FUEL pUMp RELAY710 TROUBLESHOOTING-----------------------------------7-2 AIR CLEANER HOUSING 71o COMPONENT LOCATION----------------------------7-3 THROTI'LE BODY 711 FUEL LINE |NSPECTION------------------------------7-4 |NJEcToR ................................................... 7.14 FUEL TANK ................................................... 7.3 IACV 715 FUEL PUMP UNIT-- SECONDARY AIR SUPPLY SYSTEM -- FUEL SYSTEM SERVICE INFORMATION GENERAL Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a tire or explosion. Do not snap the throttle valve trom iull open to iull close aiter the throttle cable has been removed. It may cause incorrect idle operation. Bending or Misting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss ot vehicle control. Do not damage the throttle body. It may cause incorrect throttle valve operation. Seal the intake ports with tape or a clean cloth to keep dirt and debris irom entering the engine alter the throttle body has been removed. Prevent dirt and debris irom entering the throttle bore and air passages after the throttle body has been removed. Clean them using a compressed air it necessary. Do not loosen or tighten the white painted nut and screw oi the throttle body. Loosening or tightening them can cause throttle valve and idle control tailure. For tuel level sensor inspection (page 20-15). Beiore disconnecting the tuel teed hose, relieve tuel pressure irom the system by disconnecting the quick connect titting trom the system (page 7-4). TROUBLESHOOTING Engine won't start Deteriorated tueI Bent or kinked iuel hose/luel tank breather hose Clogged tuel tilter Faulty tuel pump or its drive circuit Intake air leak Faulty injector Faulty IACV Faulty ignition system Faulty ECM Faulty bank angle sensor or its related circuit Faulty tuel pump relay or its related circuit Faulty engine stop sWitch or its related circuit Blown Fl, IGN iuse (10 A) Engine stall, hard to start, rough idling Deteriorated tueI Bent or kinked iuel hose/luel tank breather hose Faulty IACV Intake air leak Faulty ignition system Faulty MAP sensor Faulty charging system Backtiring or mistiring during acceleration Faulty ignition system Engine lacks power Bent or kinked iuel hose/luel tank breather hose Clogged tuel tilter Faulty tuel pump or its drive circuit Faulty injector Faulty ignition system Clogged air cleaner element FUEL SYSTEM COMPONENT LOCATION 7.0 N-m (0.7 Kgl-m, 5.2 Ibm) I 10 N-m (1.0 kgf-m, 7 lbf-fl) ) 27 N-m (2.3 Kgl-m, 20 mm) 7.0 N-m (0.7 kgf-m, 5-2 W) 3.0 N-m (0.3 kgf-m, 2.2 mm) 3.0 N-m (0.3 kgf-m, 2.2 lbf-fl) 27 N-m (2.3 kgf-m, 20 mm) FUEL SYSTEM FUEL LINE INSPECTION FUEL PRESSURE RELIEVING NOTE Before disconnecting fuel feed hose, relieve pressure from the system as follows. 1. . Disconnect the fuel pump 3P (Black) connector [1]. <1!pr Turn the ignition switch OFF. . Start the engine. and let it idle until the engine stalls. . Turn the ignition switch OFF. . Disconnect the battery negative (—) cable (page 19- OUICK CONNECT FITI'ING REMOVAL NOTE Do not bend or twist fuel feed hose. 1. 2. 3. Relieve the fuel pressure (page 7-4). Remove the three bolts [1] and lift up the fuel tank [2] from the frame. Check the fuel quick connect fitting [1] for dirt, and clean if necessary. Place a shop towel [2] over the quick connect fitting. FUEL SYSTEM 4. Full and release the joint rubber [1] trom the retainer. [2] 5. Hold the connector with one hand and squeeze the retainer tabs [2] with the other hand to release the locking paw|s [3]. Pull the connector oil and remove the retainer. NOTE ' Absorb the remaining iuel in the luel leed hose lrorn flowing out with a shop towel. ' Be carelul not to damage the hose or other parts. ' Do not use tools. ' it the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes olt easily. 6. To prevent damage and keep loreign matter out, cover the disconnected connector and pipe end with the plastic bags [1]. QUICK CONNECT FITTING INSTALLATION NOTE ' Always replace the retainer and ioint rubber oi the quick connect lilting when the tuel teed hose is disconnected. ' Replace the retainer and joint rubber with the same manutacturer‘s item that was removed. ' Do not bent or tWist luel teed hose. 1. Insert a new retainer [1] into the connector [2]. NOTE ' Align new retainer locking pawls with the connector [1] v grooves. Qt Align FUEL SYSTEM 2. Set a new joint rubber [1] to the joint [2] as shown. Press the quick connect fitting [3] onto the pipe until both retainer pawls lock with a "CLICK". NOTE - Align the quick connect fitting with the joint. - If it is hard to connect, put a small amount of engine oil on the joint end. 3. Make sure the connection is secure and that the pawls [1] are firmly locked into place; check visually and by pulling the connector. 4. Make sure the joint rubber [2] is positioned between the retainer [3] and joint flange [4] as shown. 5. Reposition the fuel tank [1] and tighten the three bolts [2]. FUEL PRESSURE NORMALIZATION 1. Connect the fuel pump 3P (Black) connector [1]. Connect the battery negative (—) cable (page 19-4). 2. TUE" the ignition switch ON and engine stop switch NOTE - Do not start the engine. The fuel pump will run for about 2 seconds, and fuel pressure Will rise. Repeat 2 or 3 times, and check that there is no leakage in the fuel supply system. Turn the ignition switch OFF. m a FUEL SYSTEM FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting (page 7—4). Attach the special tools as follows: TOOLS: [1] Fuel pressure gauge 07406-0040004 [2] Pressure gauge manifold OTZAJ-55A0111 [3] Hose attachment, 9 mm/Q mm 07ZAJ-55A0120 [4] Hose attachment, 3 mm/Q mm 07ZAJ-S7CO100 [5] Attachment joint, 3 mm/B mm 07ZAJ-S700200 Temporarily connect the battery negative (—) cable and fuel pump 3P (Black) connector. Start the engine and let it idle. Read the fuel pressure. STANDARD: 343 kPa (3.5 kgt/cm’, 50 psi) It the fuel pressure is higher than specified, replace the fuel pump assembly. It the fuel pressure is lower than specified, inspect the following: — Fuel line leaking — Pinched or clogged tuel teed hose or fuel tank breather hose — Fuel pump unit (page 7—8) — Cloggedfuelfilter After inspection, relieve the fuel pressure (page 7-4). Remove the fuel pressure gauge, attachment and manifold from the fuel pump. Connect the quick connect fitting (page 7-5). FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick connect fitting (page 7—4). Wipe airspiiied out Connect the special tool to the luel pump joint. gasoline. TOOL: [1] Hose attachment, 3 mm/Q mm 07ZAJ-S7CO100 Place the end of the hose into an approved gasoline container. Temporarily connect the battery negative (—) cable and fuel pump 3P (Black) connector. Turn the ignition switch ON and engine stop sWitch "C“. Measure the amount of fuel flow. K ’ NOTE ' The fuel pump operates for 2 seconds. Repeat 5 times to meet the total measuring time. ' Return fuel to the fuel tank when the first fuel is flowed. Amount of fuel flow: 83 cm" (2.81 US oz, 2.92 Imp oz) minimum! 10 seconds at 12 V It fuel flow is less than specified, inspect the folloWing: — Fuel pump unit (page 7—8) — Cloggedfuelfilter Connect the quick connect fitting (page 7-5). FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Relieve the fuel pressure and disconnect the quick connect fitting (page 7-4). Lift up the fuel tank [1] and release the fuel leed hose [2] from the hose clamps [3]. Disconnect the fuel tank breather hose [4] and remove > the fuel tank. ‘ Install the fuel tank in the reverse order of removal. Connect the quick connect fitting (page 7-5). FUEL PUMP UNIT SYSTEM INSPECTION Turn the ignition switch ON and engine stop switch “C“ and confirm that the fuel pump operates for 2 seconds. If the fuel pump does not operate, inspect as follows: Turn the ignition switch OFF. Disconnect the fuel pump 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch "C" Measure the voltage at the fuel pump 3P (Black) connector terminals of the wire side. CONNECTION: Brown/red (+) — Green (—) STANDARD: Battery voltage There should be standard voltage for a few seconds. If there is standard voltage, replace the fuel pump unit. If there is no standard voltage, inspect the following: — Main fuse (30 A) — Fl, IGN fuse (10 A) — Ignition switch (page 20—1 1) — Engine stop switch (page 20-11) — Fuel pump relay (page 7-10) — Open circuit in Brown/red or Green wire FUEL SYSTEM REMOVAL/INSTALLATION NOTE Do not disassemble the fuel pump. Remove the fuel tank (page 7-8). Clean around the fuel pump. Loosen the fuel pump mounting nuts [1] in a crisscross pattern in 2 or 3 steps and remove the nuts. Remove the fuel pump unit [2] from the fuel tank, being careful not to damage the fuel level sensor float arm. Remove the packing [1] from the fuel pump unit [2]. [2] Install a new packing onto the fuel pump unit. ' Always replace the packing with a new one. ' Be careful not to pinch the dirt and debris between the fuel pump unit and packing. Install the fuel pump [1] into the fuel tank. Install and tighten the fuel pump mounting nuts [2] to the specified torque in the sequence as shown. TORQUE: 12 NM (1.2 kgf—m, 9 Ibf—ft) Install the fuel tank (page 7-8). INSPECTION Check the fuel pump unit [1] for wear or damage, replace it if necessaw. [1] FUEL SYSTEM FUEL PUMP RELAY INSPECTION Remove the left side cover (page 2—3). Remove the dust cover [1] Remove the luel pump relay [2]. Connect a ohmmeter to the luel pump relay [1] terminals. Connect a 12 V battery to the luel pump relay terminals as shown. There should be continuity only when 12 V battery is connected. ll there is no continuity when the 12 V battery is connected, replace the fuel pump relay. AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the sub—frame (page 2-12). Remove the bolts [1] and air cleaner housing. Installation is in the reverse order ol removal. TORQUE: Air cleaner housing mounting bolt: 1.0 N-m (0.7 kgl-m, 5.2 Ibf-ll) ®3 (+33 7-10 FUEL SYSTEM THROTTLE BODY REMOVAL Remove the luel tank (page 7-8). Disconnect the sensor Unit SP connector [1]. Disconnect the IACV 4P (Black) connector [1] and injector 2P (Gray) connector [2]. Release the wire band [3] from the clamp stay. Loosen the throttle cable A adjuster lock nut [1] and adjuster [2] then disconnect the throttle cable A [3] lrorn the throttle drum and cable stay. Loosen the throttle cable B nut [4] then disconnect the throttle cable B [5] lrom the throttle drum and cable stay. Loosen the connecting hose band screw [1] and insulator band screws [2], then remove the throttle body assembly [3]. FUEL SYSTEM DISASSEMBLY/ASSEMBLY - Do not remove the sensor unit unless it Is replaced. The throttle body/sensor unit Is factory pre-set. Do not dIsassemble In a way other than shown In this manual. Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect Idle operation. Do not damage the throttle body. It may cause incorrect throttle valve operation. Do not loosen or tighten the white painted nut and screw [1] of the throttle body. Loosening or tightening It can cause throttle valve and idle control failure. Always clean around the throttle body before each sensor removal to prevent din and debrIs from entering the air passage. Remove the Iollowing — Sensorunit(page4-44) — lnjectortpage 7-14) — IACV(page7-15) Clean the air passage of the throttle body using compressed air. - Cleaning the air passages and sensor hole with a piece oI wire will damage the throttle body. Check the air passage for clogs. Disassemble and assemble the throttle body as following illustration. THROTTLE CABLE STAY 3.4 N-m (0.3 KgI-m, 2.5 Ibt-ft) INJECTOR 6 CUSHION RING v 3.4 N-m (0.3 mm, 2.5 lbt-tt) CLAMP STAV THROTTLE BODY INSULATOR J 5.1 N-m (0.5 kgI-m, 3.3 lbf-ft) : ' . I - _ . > g INJECTOR JOINT SENSOR UNIT 2 _ H ’\ 2.1 N-m (0.2 kgt-m, 1.5 lbl-ft) SETTING PLATE c >\'CV ‘ I“. THROTTLE BODV O»RING s! ) a? 3.4 N-m (0.3 kgI-m,2.51bI-It O'R'NG V 7-12 FUEL SYSTEM Install the throttle body insulator [1] to the throttle body by aligning the tab of the throttle body with the groove of the throttle body insulator. NOTE - Install the throttle body insulator with "KZZ" mark [2] facing the cylinder head. - Align the insulator band hole with the insulator boss. INSTALLATION Install the throttle body assembly [1] to the cylinder head by aligning the tab of the cylinder head with the , groove of the throttle body insulator. Tighten the insulator band screws [2] to the specified torque. TORQUE:4.2 N-m (0.4 kgl-m, 3.1 lbl-ft) After tightening the insulator band screws, check that the band ends are seated With each other. Tighten the air cleaner connecting hose band screw [3] to the specified torque. TORQUE:1.5 N-m (0.2 kgl-m, 1.1 lbl-ft) Connect the throttle cables [1] to the throttle drum and throttle cable stay. Tighten the throttle cable B nut [2] to the specified torque. TORQUE:3.0 N-m (0.3 kgl-m, 2.2 lbl-ft) Connect the IACV 4P (Black) connector [1] and injector 2P (Gray) connector [2]. Install the wire band [3] to the clamp stay. 7-13 FUEL SYSTEM Connect the sensor Unit SP connector [1]. Install the Iuel tank (page 7-8). Adjust the throttle grip Ireeplay (page 3-3). NOTE II the sensor unit is removed, Perlorm the TP sensor reset procedure (page 4-45). INJECTOR REMOVAL Remove the Iuel tank (page 7-8). Disconnect the injector 2P (Gray) connector [1]. Remove the bolts [2] and injector assembly [3] Irom the throttle body. Remove the injector joint [1], O—ring [2], cushion ring [3] and seal ring [4] from the injector [5]. Check the removed pans for wear or damage and replace them if necessary. [4] \ [1] INSTALLATION Apply engine oil to a new O-ring [1] and a new seal ring [2]. Install a new cushion ring [3] and seal ring to the injector [4], being carelul not to damage them. Install the O-rin to the in’ector. 9 J gal [21 a 7-14 FUEL SYSTEM Be care/u! not to damage the seal ring. IACV Install the injector [1] into the injector joint [2], being oarelul not to damage the O-ring. [1] NOTE Align the injector body with the injector joint tab [3] as A shown. I. [2] V [3] Install the injector assembly [1] to the throttle body. Install and tighten the injector joint mounting bolts [2] alternately to the specilied torque. TORQUE:5.1 N-m (0.5 kgl-m, 3.3 lbl-ft) Connect the injector 2P (Gray) connector [3] while aligning its groove with the tab of the injector joint. Install the Iuel tank (page 7-8). REMOVAL Remove the Iuel tank (page 7-8). Disconnect the IACV 4P (Black) connector [1]. Remove the IACV torx screws [2], set plate [3] and IACV [4]. Remove the O-ring [5] from the IACV. INSTALLATION Turn the slide valve [1] clockwise until lightly seated on 1 IACV. I I 7-15 FUEL SYSTEM Install a new O-ring [1] to the IACV [2]. Install the IACV by aligning its slide valve slot With the pin in the throttle body. Install the set plate [1] by aligning its slot with the IACV tab, then tighten the torx screws [2] to the specified torque. TORQUE: 2.1 N-m (0.2 kgf-m,1.5lbf-ll) Connect the IACV 4P (Black) connector [3]. Install the Iuel tank (page 7-8). INSPECTION NOTE The IACV is installed on the throttle body and is operated by the step motor. When the ignition sWitch is turned ON, the IACV operates Ior a few seconds. Check the step motor operating sound With the ignition switch turned ON and engine stop switch """ II the IACV does not sound with no MIL blinking, inspect as Iollows: Remove the IACV (page 7-15). It the idling is unstable. check the condition ol the O- ring. Temporarily connect the IACV 4P (Black) connector [1]. Turn the ignition sWitch ON and engine stop switch "C" while holding the slide valve [2] as shown. The slide valve should move back and forth. Install the IACV (page 7-15). 7-16 FUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to coolant temperature is 80°C (176°F). Stop the engine. Remove the PAIR check valve (page 7-18). Check that the reed valve [1] l5 clean and Iree of carbon deposits. lithe reed valve is carbon fouled, inspect the following: — Reed valve Ior deterioration or damage — Rubber seat [2] for crack, deterioration or damage — Reed valve stopper [3] Ior damage or deformation Replace the PAIR check valve iI necessary. Start the engine and open the throttle slightly to be certain that air is sucked in through the air supply hose. II the air is not drawn in, check the air supply hoses [1] Ior clogs. II the hoses are normal, inspect the PAIR control solenoid valve [2] (page 7-17). <2: FRESH AIR '— EXHAUST GAS PAIR CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the right fuel tank shroud (page 2-4). h- Disconnect the PAIR control solenoid valve 2P (Black) ' connector [1]. 7-17 FUEL SYSTEM Remove the bolts [1], collars [2] and PAIR control solenoid valve [3] lrom the stay. Disconnect the air supply hoses [4] from the PAIR [1]/[2] control solenoid valve. ‘ ’ Installation is in the reverse order oI removal. INSPECTION Remove the PAIR control solenoid valve (page 7-17). Check that air does not llow (A) to (B) when the 12 V battery is connected to the PAIR control solenoid valve terminals. Air should flow (A) to (B) when there is no voltage applied to the PAIR control solenoid valve terminals. Measure the resistance between the connector terminals. STANDARD: 20 — 24 I) (20°C/68°F) II it is out of standard, replace the PAIR control solenoid valve. PAIR CHECK VALVE REMOVAL/ INSTALLATION Remove the bolts [1] and PAIR check valve cover [2]. 7-18 FUEL SYSTEM Remove the PAIR check valve [1] and balfle plate [2] lrom the cylinder head cover. Installalwon is m the reverse order 0! removal. TORQUE: PAIR check valve cover boll: 5.2 NM (0.5 mm, 3.8 let) 7-19 MEMO 8. LUBRICATION SYSTEM SERVICE INFORMATION ----8-2 ENGINE OIL STRAINER SCREEN-m- 8-4 TROUBLESHOOTING ............ ....3.2 OIL pump . LUBRICATION SYSTEM DIAGRAM ------------s-3 PRESSURE RELIEF VALVE 87 LUBRICATION SYSTEM SERVICE INFORMATION GENERAL ACAUTION Used engine oil may cause skin cancer it repeatedly left in contact with the skin tor prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. The oil pump can be serviced With the engine installed in the trame. The service procedures in this section must be perlormed with the engine oil drained. When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. It any portion ot the oil pump is worn beyond the specitied service limits, replace the oil pump as an assembly. After the oil pump has been installed, check that there are no oil leaks. TROUBLESHOOTING Engine oil level too low, high oil consumption ~ Oil consumption ~ External oil leaks ~ Worn valve guide or stem seal ~ Worn piston rings ~ Improperly installed piston rings ~ Worn cylinder Engine oil contamination ~ Oil not changed often enough ~ Worn valve guide or stem seal ~ Worn piston rings ~ Improperly installed piston rings ~ Worn cylinder Oil emulsification ~ Faulty cylinder head gasket ~ Leaky coolant passage ~ Entry bl water ~ Faulty water pump mechanical seal LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT ROCKER ARM OIL FILTER CRANKSHAFT MAINSHAFT COUNTERSHAFT LUBRICATION SYSTEM ENGINE OIL STRAINER SCREEN REMOVAL/INSTALLATION Remove the right crankcase cover (page 12-4). Be careluinona Pull the oil strainer screen [1] out ol the crankcase. 5:323:2759? Wash the oil strainer screen thoroughly in ' nonllammable or high flash point solvent until all accumulated dirt has been removed. Blow dry it with compressed air to clean completely. ) Before installing the strainer, it should be examined closely lor damage, and make sure the sealing rubber - is in good condition. Install the oil strainer screen with the thin edge lacing in and flange side hang up as Show“ OIL STRAINEFI SCREEN DIRECTION: i Install the right crankcase cover (page 12—8). CRANKCASE OIL PUMP REMOVAL/DISASSEMBLY Remove the right crankcase cover (page 12-4). Remove the oil pump driven gear [1]. Remove the oil pump mounting bolts [1] and oil pump assembly bolt [2]. Remove the oil pump cover assembly [3]. LUBRICATION SYSTEM Remove the inner rotor assembly from the oil pump cover [1] while holding oil pump shaft [2]. [5] I2] [4] Remove the oil pump shaft and lock pin [3] Irom the inner rotor [4]. Remove the outer rotor [5] and washer [6]. Remove the oil pump body [1] by releasing it from the ‘6' V oam chain guide hook [2] and pressure relief valve [3]. \ Remove the dowel pins [4] and O-ring [5]. INSPECTION Inspect the Iollowing parts lor damage, abnormal wear, deformation or burning. — Oi| pump driven gear — Oil pump shaft — Lock pin — Inner rotor — Outer rotor — Oil pump body Measure the oil pump clearances according to LUBRICATION SYSTEM SPECIFICATIONS (page 1— 5). ll any 01 the measurement is out o! the service limit, replace the oil pump as an assembly. LUBRICATION SYSTEM ASSEMBLY OIL PUMP BODV O-RING g 7I OIL PUMP COVER Eh .‘\EL PINS a @ OIL PUMP DRIVEN GEAR \NER ROTOR I d LOCK PIN . OIL PUMP SHAFT . CUTE R ROTOR WASHER OIL PUMP ASSEMBLY BOLT /‘ OIL PUMP MOUNTING BOLTS INSTALLATION Install the dowel pins [1]. Apply engine oil to a new O-ring [2]. Install the O-ring to the oil pump assembly [3]. Install the oil pump assembly while aligning its slit with oam chain guide hook and its hole with the pressure reliel valve. Install and tighten the oil pump mounting bolts [1]. lithe oil pump was disassembled, tighten the Oil pump / assembly bolt [2]. LUBRICATION SYSTEM Apply engine oil to the oil pump driven gear [1] teeth. Install the oil pump driven gear while aligning the Ilats of the oil pump driven gear and oil pump shaft. Install the right crankcase cover (page 12—8). PRESSURE RELIEF VALVE REMOVAL/INSTALLATION Remove the oil pump (page 8-4). Remove the oil pressure relief valve [1] and O-rings [2]. Apply engine oil to new O—rings. Install the O-rings to the oil pressure relief valve grooves. Install the oil pressure reliel valve into the right crankcase with the piston side facing outside. Install the oil pump (page 8-6). PRESSURE RELIEF VALVE INSPECTION Check the operation ol the pressure reliel valve by pushing on the piston [1]. Disassemble the pressure relief valve by removing the snap ring [2]. Remove the washer [1], spring [2] and piston [3]. Check the piston for wear, sticking or damage. Check the spring for fatigue or damage. Assemble the pressure reliel valve in the reverse order oldisassembly. NOTE - Install the snap ring with the ohamfered edges lacing the thrust load side. - Make sure the snap ring is seated in the groove. [3] [2] I1 I MEMO 9. COOLING SYSTEM SERVICE INFORMATION 9.2 TROUBLESHOOTING-----------------------------------9-2 SYSTEM FLOW PATrERN---------------------------9—3 SYSTEM TEanGg4 COOLANT REPLACEMENT-------------------------9-5 THERMOSTAT RADIATOR/COOLING FAN WATER pUMp .................................. RADIATOR RESERVE TANK FAN CONTROL RELAY WATER plpE 9-6 ............ 9.3 9-1 COOLING SYSTEM SERVICE INFORMATION GENERAL AWARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down belore removing the radiator cap. Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. ~ Add cooling system at the reserve tank. Do not remove the radiator cap except to relill or drain the system. ~ All cooling system services can be done with the engine installed in the lrame. ~ Avoid spilling coolant on painted suriaces. ~ Alter servicing the system, check lor leaks With a cooling system tester. TROUBLESHOOTING Engine temperature too high ~ Faulty indicator or ECT sensor ~ Thermostat stuck closed ~ Faulty radiator cap ~ lnsulticient coolant ~ Passage blocked in radiator, hoses or water jacket ~ Air in system ~ Faulty cooling ian motor ~ Faulty Ian control relay ~ Faulty water pump Engine temperature too low ~ Thermostat stuck open ~ Faulty Ian control relay Coolant leak ~ Faulty water pump mechanical seal ~ Deteriorated O-ring ~ Faulty radiator cap ~ Damaged or deteriorated cylinder head gasket ~ Loose hose connection or clamp ~ Damaged or deteriorated hoses ~ Damaged radiator COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR WATER HOSE SIFHON HOSE RESERVE TANK THERMOSTAT WATER HOSE WATER PIPE WATER PUMP COOLING SYSTEM SYSTEM TESTING RADIATOR CAP/SYSTEM PRESSURE INSPECTION Loosen the cap screw [1] and remove the radiator cap [2]- Wet the sealing surlaces ol the radiator cap [1], then install the cap onto the tester [2]. Pressurize the cap using the tester. Replace the radiator cap il it does not hold pressure, or ii relief pressure is too high or too low. It must hold the specified pressure lor at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 93.2 —122.6 kPa (0.95 — 1.25 kgt/cm’, 13.5 —17.8 psi) Pressurize the radiator, engine and hoses using the tester, and check for leaks. Excessive pressure can damage the cooling system components. Do not exceed 122.6 kPa {1.25 ng/cmz, 17.8 psi). Repair or replace components it the system Will not hold the specilied pressure for at least 6 seconds. Remove the tester. Install the radiator cap and tighten the screw. l1] l2] COOLING SYSTEM COOLANTREPLACEMENT When ruling the system or reserve tank with a coo/an! (checking coo/an! level), support the motorcycle on a level surtace. REPLACEMENT/AIR BLEEDING Remove the radiator cap (page 9-4). Remove the drain bolt [1] and sealing washer [2] on the water pump cover and drain the coolant trom the system. Install and tighten the drain bolt with a new sealing washer. Fill the system With the recommended coolant through the tiller opening. RECOMMENDED ANTIFREEZE: silicate-tree corrosion in bitors STANDARD COOLANT CONCENTRATION: 1:1 (mixture with distilled water) Bleed air irom the system as follows: 1. Shift the transmission into neutral. Stan the engine and let it idle ior 2 — 3 minutes. 2. Snap the throttle 3 — 4 times to bleed air from the system. 3. Stop the engine and add the coolant. 4. Install the radiator cap and tighten the cap screw. Remove the reserve tank cap [1] and fill the reserve tank to the "UPPER" level line [2]. Install the resenIe tank cap. THERMOSTAT REMOVAL/INSTALLATION Drain the coolant (page 9—5). Remove the bolts [1] and thermostat cover [2]. COOLING SYSTEM Remove the thermostat [1] from the cylinder head. Installation is in the reverse order oI removal. NOTE - Install the thermostat with the bleed hole [2] tacing up. - When installing the thermostat, align the tab of the seal ring [3] with the groove ot the thermostat cover. Fill and bleed the cooling system (page 9-5). INSPECTION Visually inspect the thermostat [1] tor damage. Check the seal ring [2] for damage and replace if necessary. Wearinsulated Heat the water with an electric heating element to gloves and operating temperature lor 5 minutes. adequate eye Suspend the thermostat [1] in heated water to check its protection. Keep operation. flammable materials away THERMOSTAT BEGIN TO OPEN. from the electric 81 - 84°C (178 — 133$) heating element. on nor/er the VALVE “F“ mermasrarol 4.5 mm (0.18 in) minimum at 95”C (203°F) [helmameler touch Ihe pan, or you wlll get Ialse reading. Replace the thermostat ii the valve open at a temperatures other than those specified. RADIATOR/COOLING FAN REMOVAL/INSTALLATION Drain the coolant (page 9-5). Remove the left luel tank shroud (page 2-4). Release the spark plug wire [1] and radiator siphon hose [2] from the guides [3]. Disconnect the tan motor 2P (Black) connector [4]. COOLING SYSTEM Disconnect the siphon hose [1] lrom the radiator. Loosen the water hose band screws [2] and disconnect the upper and lower water hoses [3]. Remove the radiator guard [4] by releasing the bosses [5] Remove the radiator mounting bolts [6] and radiator [7]. Installation is in the reverse order ol removal. Tighten the hose band screw to the specilied range. Fill the system with the recommended coolant (page 9- 5). 0—1 mm (0—0.04 in) DISASSEMBLY/ASSEMBLY Disassemble and assemble the radiator as lollowing illustration. RADIATOR CAP SCREW COOLING FAN 5.5 N-m (0.9 kgf-m, 6.3 lbl-lt) RADIATOR CAP x RADIATOR \© FAN MOTOR g3) 2.7 N-m (0.3 mm, 2.0 let) FAN MOTOR SHROUD 5 1.0 N-m (0.1 kgf-m, 0.7 lbl-lt) COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check the bleed hole [1] of the water pump for signs of coolant leakage. Ii water leaks through the bleed hole, replace the mechanical seal (page 9-9). It oil leaks through the bleed hole, replace the oil seal (page 9—9). Make sure that there are no continuous coolant leakage Irom the bleed hole while operating the engine. NOTE A small amount of weeping from the bleed hole is normal. REMOVAL Drain the coolant (page 9-5). Remove the bolts [1], drain bolt [2], sealing washer [3], water pump cover [4] and O-ring [5]. Remove the right crankcase cover (page 12-4). Hold the water pump shaft and remove the impeller [1] and plain washer [2]. Remove the water pump shaft [1] from the right crankcase cover. COOLING SYSTEM Check the water pump shalt [1] tor wear or damage, [1] replace it it necessaw. BEARING/MECHANICAL SEAL/OIL SEAL REPLACEMENT g .6 OIL SEAL BEARING“ 3! MECHANICAL SEAL 9 Remove the water pump shaft bearings [1] using the special tools. TOOLS: [2] Remover weight 07741-0010201 [3] Bearing remover set, 12 mm 079364660101 COOLING SYSTEM Remove the mechanical seal [1] and oil seal [2] lrom the right crankcase cover. Apply grease to a new oil seal [1] lips. Install the oil seal to the right crankcase cover as shown. (o — 0.02 in) Driver'nanew Drive in new bearings [1] into the right crankcase cover . bearing square/y using the special tools as shown. with me mamng side facing up. TOOLS: [2] Driver 07749-0010000 [3] Attachment, 28 x 30 mm 07946-18701 00 [4] Pilot, 12 mm 07745-0040200 After installing the bearing, lubricate it with engine oil. Press a new mechanical seal [1] until it is fully seated to the right crankcase cover using the hydraulic press and special tool. TOOL: [2] Oil seal driver, 30 x 36 mm D7HMF-KR1D1D1 9-10 COOLING SYSTEM INSTALLATION Apply engine oil to the water pump shaft [1] outer surlace. Install the water pump shalt to the right crankcase cover. Install the plain washer [1] and impeller [2] to the water pump shalt. Hold the water pump shaft and tighten the water pump impeller [1] to the specified torque. TORQUE: 10 NM (1.0 kgl-m, 7 Ibf-fl) Install the right crankcase cover (page 12-8). Install a new O-ring [1] to the water pump cover [2]. Install the water pump cover. 9-11 COOLING SYSTEM Install and tighten the bolts [1], drain bolt [2] and a new sealing washer [3] securely. Fill the recommended coolant and bleed the air (page 9-5). RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the right fuel tank shroud (page 2-4). Place an approved container under the radiator resenle tank [1]. Disconnect the overflow hose [2] and siphon hose [3] lrom the reserve tank. Remove the bolts [4] and radiator reserve tank Installation is in the reverse order ol removal. Fill the resenle tank with coolant (page 9—5). FAN CONTROL RELAY INSPECTION Remove the left side cover (page 2—3). Remove the dust cover [1] Remove the lan control relay [2]. Connect a ohmmeter to the lan control relay [1] terminals. [1] Connect a 12 V battery to the lan control relay terminals as shown. D There should be continuity only when 12 V battery is 9 ii =_ connected. ll there is no continuity when the 12 V battery is __| connected, replace the fan control relay. (D 6-) 9-12 COOLING SYSTEM WATER PIPE REMOVAL/INSTALLATION Drain the coolant (page 9-5). Remove the bolts [1] and water pipe [2]. Remove the O—rings [1] from the water pipe [2]. Installation is in the reverse order ol removal. - Replace the O-ring with new ones. 2;” the system with the recommended coolant (page 9— 9-13 MEMO 10. CYLINDER HEADNALVES SERVICE lNFORMATION------ -----10-2 CYLINDER HEAD COVER ------- ---10-4 TROUBLESHOOTING ............ .....1o.2 CAMSHAFT ........................... ....1o.5 COMPONENT LOCATION--------------------------10-3 ROCKER ARM .......................................... 10.11 m CYLINDER COMPRESSION-----------------------10-4 CYLINDER HEAD ..................................... 10.13 10-1 CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL ~ This section covers service ol the cylinder head, valves, rocker arms and camshalt. ~ The camshaft and rocker arm service can be done with the engine installed in the lrame. The cylinder head service requires engine removal. ~ Be carelul not to damage the mating surlaces when removing the cylinder head cover and cylinder head. Do not tap the cylinder head cover and cylinder head too hard during removal. ~ When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. Clean all disassembled parts with cleaning solvent and dry them by blowing them oil with compressed air belore inspection. Camshaft and rocker arm lubricating oil is led through oil passage in the cylinder head (stud bolt hole) and camshalt holder. Clean the oil passage belore assembling them. TROUBLESHOOTING ~ Engine top-end problems usually allect engine perlormance. These problems can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. ~ ll the perlormance is poor at low speeds, check tor white smoke in the crankcase breather hose. It the hose is smoky, check for a seized piston rings. Compression too low, hard starting or poor performance al low speed ~ Valves: — lncorrect valve adjustment — Burned or bent valve — lncorrect valve timing — Weak valve spring — Uneven valve seating — Valve stuck open ~ Cylinder head: — Leaking or damaged cylinder head gasket — Warped or cracked cylinder head — Loose spark plug ~ Faulty cylinder, piston or piston rings (page 11-3). Compression too high, over-healing or knocking ~ Excessive carbon build-up on piston head or combustion chamber Excessive smoke ~ Worn valve stem or valve guide ~ Damaged stem seal ~ Faulty cylinder, piston or piston rings (page 11-3). Excessive noise ~ Incorrect valve adjustment ~ Sticking valve or broken valve spring ~ Worn or damaged camshaft ~ Worn rocker arm and/or shalt ~ Worn rocker arm and valve stem end ~ Worn cam sprocket teeth ~ Worn and loose cam chain ~ Worn or damaged cam chain tensioner ~ Faulty cylinder, piston or piston rings (page 11-3). Rough idle ~ Low cylinder compression ~ Faulty luel system 1 0-2 CYLINDER HEAD/VALVES COMPONENT LOCATION 4.2 N-m (0.4 kgf-m, 3.1 lel) 45 N-m (4.6 Kgl-m, 33 mm) 1o N-m (1.0 kgl-m, 7 113141) ) 12 N-m (1.2 kgl-m, 9mm 1 0-3 CYLINDER HEAD/VALVES CYLINDER COMPRESSION Warm the engine to normal operating temperature. Stop the engine. Remove the spark plug (page 3—5). Lnsltall the compression gauge [1] into the spark plug 0 e. Turn the ignition switch ON and engine stop switch "C" Shift the transmission into neutral. To avoid Open the throttle all the way and crank the engine with discharging the the starter motor until the gauge reading stops rising. battery, do no! STANDARD: r m r rt , mfifi; ”3:37;: 1,294 kPa at 490 min“ (rpm) (13.2 kgiicm‘, 183 psl) 7 5550”“- Low compression can be caused by: Blown cylinder head gasket Improper valve adjustment — Valve leakage — Worn piston ring or oylinder High compression can be caused by: — Carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL Remove the lollowing: — Spark plug cap (page 3—5) — PAIR check valve (page 7-18) — Fuel tank (page 7—8) — Ignition ooiI (page 5-6) Remove the three bolts [1] and ground terminal [2] lrom the radiator reserve tank stay. Remove the cylinder head cover bolts [1], rubber seals [2], cylinder head cover [3] and packing [4]. I1 l/[2] @. / [1] I1 l/[2] [31/[41 1 0-4 INSTALLATION CYLINDER HEAD/VALVES Apply sealant (Three bond 52110, 12073, 1215, SS KE45 or equivalent) to the cylinder head semi—circular cut-outs as shown. Install a new packing [1] into the cylinder head cover [2] groove. Install the cylinder head cover onto the cylinder head. Check the rubber seals [1] are in good condition, replace them if necessary. Install the rubber seals to the cylinder head cover with their "UP" marks [2] lacing up. Install and tighten the cylinder head cover bolts [1] to the specified torque. TORQUE: 10 MM (1.0 kngm, 1mm) [2] [1] s! [2] 1 0-5 CYLINDER HEAD/VALVES Set the radiator reserve tank stay and ground terminal [1] in position. Install and tighten the three bolts [2]. Install the lollowmg: [1]/[2] / — Ignition coil (page 5-6) — PAIR check valve (page 7-18) — Fuel tank (page 7—8) Spark plug cap (page 3—5) CAMSHAFT REMOVAL Remove the cylinder head cover (page 10—4). Make sure the piston l5 at TDC (Top Dead Center) on the compression stroke (page 3—6). Remove the cam chain tensioner lilter plug [1] and O— ring [2]. Turn the cam chain tensioner Illter shaft fully in (clocKWise) and secure it using a tensioner stopper [1] to prevent damaging the cam chain. TOOL: Tensioner stopper 07DMG-001D100 Be careful not to let Remove the bolts [1] and cam chain guide B [2]. the Cam chain [2] gulde bolts [all into the crankcase. 1 0-6 CYLINDER HEAD/VALVES Be harem] not to let Remove the bolts [1] and camshalt holders [2]. the mmsha/rnumer bolts fallinlu the NOTE _ _ . crankcasa From outside to Inside, loosen the bolts In a crisscross pattern in several steps or the camshalt holder might break. Attachapr‘ece of Remove the camshaIts [1] by removing the cam chain wire [0 the cam [2] lrom the cam sprockets. chain to prevent II from [filling inlu the crankcase. Lift the rocker arms [1]. Remove the shims [2]. NOTE - Do not allow the shims to tail into the crankcase. - Mark all shims to ensure correct reassembly in their original locations. - The shims can be easily removed with a tweezers or a magnet. INSPECTION Inspect the Iollowing parts Ior damage, abnormal wear, delormation, burning or clogs in oil passages. — Cam sprocket — Camshalt — Camshalt holder/dowel pin — Cam chain guide B Measure each part according to CYLINDER HEAD/ VALVES SPECIFICATIONS (page 1-6). Replace any part it it is out of sen/ice limit. 1 0-7 CYLINDER HEAD/VALVES Du not rotate the camshaft when using plastigauge. Be sure the dowel pins in the mmshaf! holder align the holes in me cylinder head. CAMSHAFT OIL CLEARANCE Wipe any oil from the journals of the camshaft, cylinder head and camshaft holders. Lay a strip of plastigauge [1] lengthwise on top of each camshaft journal. Install each camshaft holder to the correct locations with the identification marks [1]. — "R" mark: right camshaft holder — L mark: left camshaft holder — “IN" mark: intake side — “EX" mark: exhaust side Apply engine oil to the camshaft holder mounting bolt [1] threads and seating surface. Failure to tighten the camshaft holder in a crisscross pattern may cause a camshaft holder to break. Tighten aII camshaft holder mounting bolts to the specified torque. TORQUE: 12 N-m (1.2 kngm, 9 lbfAft) NOTE From inside to outside, tighten the bolts in a crisscross pattern in several steps. Remove the camshaft holders and measure the width of each plastigauge. The widest thickness determines the oil clearance. SERVICE LIMIT: 0.10 mm (0.004 in) When the sen/ice limit is exceeded, measure the camshaft journal OD. and camshaft journal area ID. of cylinder head and camshaft holders, then compare the measurement With the standard value (page 1-6). - Replace the cylinder head and camshaft holders as a set if the difference from the standard value is larger than that of the camshaft. - Replace the camshaft if the difference from the standard value is larger than that of the cylinder head and camshaft holders. 1 0-8 CYLINDER HEAD/VALVES INSTALLATION Be careluinotta Rotate the crankshalt counterclockwise, and align the jamlhe cam chain "T" mark [1] on the flywheel with the index notch [2] on and timing sprocke! the left crankcase cover. on [he crankshaft when rotating ma crankshaft. Be mreiu/nattolet Install the shims [1] in their original locations on the the shims [all into valve retainer. me crankcase' Lower the rocker arms [2]. Each camshaft has an identilication mark. - "IN" mark [1]: intake camshaft - "EX" mark [2]: exhaust camshaft Apply molybdenum oil solution to the camshalt [1] lobes and journal surfaces. Apply engine oil to the cam chain [2] whole surlace. Install the camshafts into the cylinder head while installing cam chain onto the cam sprockets. NOTE Install the camshaft with its lobes facing up. 1 0-9 CYLINDER HEAD/VALVES Align the outside index line ("IN" [1] and "EX" [2] marks) 1 [2] on the cam sprockets with the cylinder head top surface I 1 [3] as shown. - Check that the punch marks [3] of the cam sprockets is facing up as shown. Install the camshaft holders. Note the correct locations With the identification marks [1] as shown. mark: right camshaft holder mark: lelt camshaft holder — IN" mark: intake side — “EX" mark: exhaust side Apply engine oil to the camshaft holder mounting bolt [1] threads and seating surface. Install and tighten the camshaft holder mounting bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf‘m, 9 Ibf‘ft) NOTE From inside to outside, tighten the bolts in a crisscross pattern in several steps. Be mreful not to let Install the cam chain guide B [1] and bolts [2]. the cam chain gulde baits IaIi into the crankcase. Tighten the cam chain guide bolts securely. 10-10 CYLINDER HEAD/VALVES {11 " y , Remove the tensioner stopper [1] from the cam chain tensioner lifter. Apply engine oil to a new O-ring [1] and install it to the cam chain tensioner litter. Install and tighten the cam chain tensioner lifter plug [2] to the specified torque. TOROUE:4.2 N-m (0.4 kgl-m, 3.1 lbt-ft) Inspect the valve clearance (page 3—6). Install the cylinder head cover (page 10—5). ROCKER ARM NOTE - The rocker arm can be serviced with the engine installed in the frame. - The intake and exhaust rocker arm service procedures are the same. REMOVAL/INSTALLATION Remove the oamshafts (page 10—6). Remove the bolt [1] and sealing washer [2]. 10-11 CYLINDER HEAD/VALVES Remove the rocker arm shaft [1] using a 6 mm bolt [2] while holding the rocker arm [3]. Remove the rocker arm. Apply molybdenum OII solution to the rocker arm inner surface, roller surface, slipper surface and rocker arm shaft outer surface. Install the rocker arm and rocker arm shalt. NOTE - The rocker arms are identilied by the stamped marks: — “IN"' Intake rocker arm [4] — “EX": Exhaust rocker arm [5] Install a new sealing washer [1] and bolt [2]. Install the camshafts (page 10-9). INSPECTION Inspect the following parts Ior damage, abnormal wear, deformation, burning or clogs in oil passages. — Rocker arm — Rocker arm shaft Measure each part and clearance according to CYLINDER HEAD/VALVES SPECIFICATIONS (page 1—6). Replaoe any part if it is out of sen/ice limit. 10-12 CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Remove the IoIIowing: . [21/[3] — Engine (page 15-4) — Camshalt (page 10-6) Be mralu/ not to I91 Remove the cylinder head bolts [1], nuts [2], washers [he cylinder head [3] and cylinder head [4]. balts and nuts rail NOTE i'nla the crankcase. _ , , . - Attach a piece of Wire to the cam chain to prevent It from Ialling into the crankcase. - Do not tap the cylinder head too hard and do not damage the mating surIace With a screwdriver. Remove the Iollowing: — Dowelpins[1] — Gasket[2] — Cam chain guide A [3] DISASSEMBLY Remove the Iollowing: — Spark plug (page 3-5) — Oz sensor (page 4-47) . . r — Rocker arm (page 10-11) : ' ‘ a Ta prevent/ass ul Remove the valve spring cotters [1] using the special tensiun. du no! tools. campresslhe valve TOOLS: sprin%:;::::ag [2] Valve spring compressor 07757-0010000 remove me cartels. [3] Valve spring compressor attachment 07959-KM30101 Malkallpansdurmg Removethelollowing: F ‘ “assembly“ — Spring retainer ._ L’k they can be _ . installedi'nrhell _ ngfer/mnervalve Sprms originallcmllons. _ Stem seal — Spring seat INSPECTION Inspect the Iollowing parts Ior damage. abnormal wear, delormation, burning or clogs in oil passages. Cylinder head — Inner/outer valve springs — Valves — Valve guides — Cam chain guide A [2] Measure each part and clearance according to CYLINDER HEAD/VALVES SPECIFICATIONS (page 1-6). Replace any part iI it is out of sen/ice limit. 10-13 CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT NOTE Refinish the valve seats whenever the valve guides are replaced to prevent uneven seating. Chill new valve guides in a treezer section oi refrigerator for about an hour. Du noluse a torch Heat the cylinder head to 130 — 140°C (266 — 284°F) Io heatme cylinder with a hot plate or oven. Do not heat the cylinder head head;i!maycause beyond 150”C (302°F). Use temperature indicator warping. sticks, available lrom welding supply stores, to be sure the cylinder head is heated to the proper temperature. To avoid burns, wear insulated gloves when handling the heated cylinder head. Support the cylinder head and drive out the valve 1 guides lrom the combustion chamber side ol the [I cylinder head. TOOL: [1] Valve guide driver 07HMD-ML00101 . . While the cylinder head is still heated, take oil a new valve guides [1] lrom the lreezer. Adjust the valve guide driver to the valve guide height ‘ i1 and drive in the valve guide lrom the camshaft side. K TOOL: [2] Valve guide driver 0774343020000 SPECIFIED HEIGHT: 7 lN/EX:13.8 —14.0 mm (0.54 — 0.55 in) Let the cylinder head cool to room temperature. 7’: v [i] Ream a new valve guides. TOOL: [1] Valve guide reamer, 4.5 mm 07HMH-ML00101 NOTE ' Use cutting oil on the reamer during this operation. ' Take care not to tilt or lean the reamer in the guide while reaming. Otherwise, the valves may be installed slanted, causing oil leakage from the stem seal and improper valve seat Contact. This may prevent valve seat relacing ' Insert the reamertrom the combustion chamber side ol the head and always rotate the reamer clockwise. Clean the cylinder head thoroughly to remove any metal particles after reaming and relace the valve seat (page 10-15). 10-14 CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING INSPECTION Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coat ol Prussian Blue to the valve seats. Tap the valve against the valve seat several times using a hand-lapping tool [1], Without rotating the valve to make a clear pattern. Remove the valve and inspect the valve seat tace width. Inspect the valve seat lace lor: ' Damaged lace: — Replace the valve and retace the valve seat ' Uneven seat width: — Bent or collapsed valve stem; Replace the valve and retace the valve seat ' Contact area (too low or too high area): — Relace the valve seat REFACING Relace the valve seat using the lollowmg tools. TOOLS: Cutter holder, 4.5 mm 07781-0010600 Seat cutter, 27.5 mm (45° EX) 07780-0010200 Seat cutter, 33 mm (45° IN) 07780-0010800 Flat cutter, 27 mm (32" EX) 07780-0013300 Flat cutter, 30 mm (32" IN) 07780-0012200 Interior cutter, 30 mm (60° EX) 07780-0014000 Interior cutter, 37.5 mm (60° IN) 07780-0014100 VALVE SEAT WIDTH: 0.90 - 0.10 mm (0.035 - 0.043 in) NOTE ' Follow the relacer manutacturer‘s operating instructions. ' Be carelul not to grind the seat more than necessary. 1. Use a 45" seat cutter, remove any roughness or irregularities irom the seat. . Use a 32" llat cutter, remove the top 1/4 oi the existing valve seat material. Use a 60" interior cutter, remove the bottom 1/4 ot the existing valve seat material. . Using a 45° seat cutter, cut the seat to the proper Width. 5. Alter cutting the seat, apply lapping compound to the valve tace, and lap the valve using light pressure. NOTE ' Excessive lapping pressure may deiorm or damage the seat. ' Change the angle at lapping tool [1] lrequently to prevent uneven seat wear. ' Do not allow lapping compound to enter the guides. >FA’N After lapping, wash any residual compound oil the cylinder head and valve and recheck the seat contact. [1] fl \ : \\Oid seatwidth I. saw \Cid seal width -1 f 60” 1 10-15 CYLINDER HEAD/VALVES ASSEMBLY INNEFI SPRING SHIM \I 0/ COTTERS v STEMSEAL I 5/ , RETAINER OUTER SPRING i INTAKE VALVE EXHAUSTVALVE 3 Clean the cylinder head assembly with solvent and ‘ . '- - 1 2 blow through all oil passages With compressed air. [ l l 1 g Install the spring seats [1] and new valve stem seals [2]. Apply molybdenum 0“ solution to each valve stem sliding surIace. Tu avolddamage to Insert the intake and exhaust valves [3] into the valve the seal, rum the guides. valve slowly when inserting. F7i [3] Install the inner valve spring [1] and outer valve spring [2] with the tightly wound coils should facing the combustion chamber [3]. [1] a; [3] 10-16 CYLINDER HEAD/VALVES Grease the callers Install the spring retainer [1]. 4] in ease rn rallarl'an. . . s Compress the valve spring using the special tools and To prevent loss 17/ . Ensign. du "a! Install the valve cotters [2]. compress the valve TOOLS: SW"? mare than [3] Valve spring compressor 07757-0010000 "5595535“ [4] Valve spring compressor attachment 07959-KM30101 iii/[21 Support lne cylinder Tap the valve stems gently with two plastic hammer to head above the tirmly seat the cotters tirmly. work bench surface in prevent valve damage. — Spark plug (page 3-5) — Oe sensor (page 4-47) — Rocker arm (page 10-11) Install the lollowmg: INSTALLATION Do notallowdus! Clean any gasket material from the cylinder mating and dirt to enter the suriaces. crankcase' Install the lollowmg: — Dowelpins[1] — Newgasket[2] — Cam chain guide A [3] [1] Route the cam chain through the cylinder head and install the cylinder head [1] onto the cylinder. Apply engine oil to the new cylinder head mounting nut [2] threads and seating surface. Be mrelul not to let Install and tighten the new cylinder head mounting nuts rne cylinder head with new washers [3] in a crisscross pattern in two or bolls. washers and three steps to the specified torque. nuts fall lnlu me mum“ Tonouams NM (4.3 kgrm, 33 mm) Install and tighten the cylinder head bolts [4] securely. Install the lollowmg: — Camshalt (page 10-9) — Engine (page 15-7) 10-17 MEMO 11. CYLINDER/PISTON SERWCEINFORMAHONum- "m1n2 CVUNDEWPSTON ......... TROUBLESHOOTING ------------ -----11-2 CAM CHAIN TENSIONER COMPONENT LOCATION 11.2 11-1 CYLINDER/PISTON SERVICE INFORMATION GENERAL This section covers maintenance of the cylinder and piston. To service these parts, the engine must be removed from the frame. Take care not to damage the cylinder wall and piston. Be careful not to damage the mating surfaces when removing the cylinder. Do not tap the cylinder too hard during removal. Camshaft and rocker arm lubricating oil is fed through an oil passage in the cylinder. Clean the oil passage before installing cylinder. ~ Clean all disassembled pans with cleaning solvent before inspection, use compressed air to dry the parts. TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed ~ Leaking or damaged cylinder head gasket ~ Worn, stuck or broken piston rings ~ Worn or damaged cylinder and piston ~ Loose spark plug Compression too high, overheating or knocking ~ Excessive carbon built—up on piston or combustion chamber Excessive smoke ~ Faulty cylinder, piston and piston rings ~ Improper installation of piston rings ~ Scored or scratched piston or cylinder wall Abnormal noise (piston) ~ Worn piston pin or piston pin hole ~ Worn or damaged cylinder, piston or piston ring ~ Worn connecting rod small end COMPONENT LOCATION 4.2 N-m (0‘4 kgI-m, 3.1 lbf-ft) 11-2 CYLINDER/PISTON CYLINDER/PISTON CYLINDER REMOVAL Remove the iollowing: — Water pipe (page 9-13) — Cylinder head (page 10—13) Lift the cylinder [1] and remove it, being careiul not to damage the piston with the stud bolts. NOTE - Attach a piece of wire to the cam chain to prevent it from ialling into the crankcase. - Do not tap the cylinder too hard and do not damage the mating suriace with a screwdriver. Remove the dowel pins [1] and gasket [2]. PISTON REMOVAL Place a clean shop Remove the piston pin clips [1] with pliers. Iuwel over the crankcase Ia prevent the piston pin clips from falling inlu the crankcase. Push the piston pin [1] out oi the piston [2] and connecting rod, and remove the piston. 11-3 CYLINDER/PISTON Spread each piston ring [1] and remove it by lifting up a point opposite the gap. NOTE ' Do not damage the piston ring by spreading the ends too far. ' Be careful not to damage the piston when removing the piston ring. INSPECTION Inspect the following parts for scratch, damage, abnormal wear, deformation, burning or clogs in oil passages. — Cylinder — Piston — Piston rings — Piston pin — Connecting rod small end Measure each part and calculate the clearance according to CYLINDER/PISTON SPECIFICATIONS (page 1-6). Replace any part if it is out of service limit. STUD BOLT REPLACEMENT Thread two nuts onto the stud bolt [1] and tighten them together, and use a wrench on them to turn the stud bolt out. Install new stud bolts into the crankcase and tighten them to the specified torque. TOROUE:9.0 NM (0.9 kgf—m, 6.6 lbI-ft) After installing the stud bolts, check that the length from the bolt head to the crankcase surface is within specification. 142.0 : 1.0 mm (5.5 t 0.04 in) 11-4 Be carelui no! la damage the piston and rings. wnen cleaning the cylinder mating cunace, place a shop luwel over the cylinder opening m pre vent dust or dirt enter me crankcase. PISTON INSTALLATION Apply engine oil to the piston ring grooves. Apply engine oil to the piston ring entire surIace. Carefully install the piston rings into the piston ring grooves With the markings [1] facing up. NOTE - Do not oonIuse the top ring [2] and second ring [3]. - To install the oil ring [4], install the spacer [5] first, then install the side rails [6]. Stagger the piston ring end gaps 120° apart from each other. Stagger the side rail end gaps as shown. Apply engine oil to the piston pin hole inner surIace and sliding surIace. Clean any gasket material from the cylinder mating surIace [1] oi the crankcase. Apply molybdenum oil solution to the connecting rod small end inner surIaces. Apply molybdenum oil solution to the piston pin [1] outer surIaces. Install the piston [2] With its "IN" mark [3] Iacing intake side. Install the piston pin. CYLINDER/PISTON 20 mm (0.8 in) OR MORE 11-5 CYLINDER/PISTON Install new piston pin clips [1] into the grooves of the piston pin hole. NOTE - Always use new piston pin clips. Reinstalling used g piston pin clips may lead to serious engine damage. ' - Set the piston pin clip in the groove properly. - Do not align the clips end gap [2] with the piston cut- out [3]. I [21 CYLINDER INSTALLATION Install the dowel pins [1] and a new gasket [2]. Apply engine oil to the cylinder [1] inner surface and piston [2] sliding surlace. Be careluinona Route the cam chain [3] through the cylinder and install damage the piston the cylinder over the piston while compressing the rings and cylinder piston rings with your lingers. WEII‘ Install the lollowmg: — Cylinder head (page 10—17) — Water pipe (page 9-13) 11-6 CYLINDER/PISTON CAM CHAIN TENSIONER REMOVAL/INSTALLATION Remove the cam chain tensioner |iIter plug [1] and 0- 7 ring [2]. Turn the cam chain tensioner lifter shaft fully in (clocKWise) and secure it using the special tool. TOOL: [3] Tensioner stopper 07DMG-0010100 Remove the cam chain tensioner lifter mounting bolts [4]- Remove the cam chain tensioner |iIter [5] and gasket [6]- . [1]/[2] Install a new gasket [1] on the cam chain tensioner lifter [2] and install them to the cylinder. Install and tighten the cam chain tensioner lifter mounting bolts [1]. Remove the tensioner stopper [2] from the cam chain tensioner lifter. Apply engine oil to a new O-ring [3] and install it to the cam chain tensioner lifter. Install and tighten the cam chain tensioner lifter plug [4] to the specified torque. TORQUE:4.2 N-m (0.4 kgl-m, 3.1 lbI-ft) INSPECTION Check the cam chain tensioner lifter [1] operation: — The cam chain tensioner |iIter shaft should not go into the cam chain tensioner lifter body when it is pushed. — When it is turned clocKWise With a tensioner stopper or a screwdriver [2], the cam chain tensioner lifter shaft should be pulled into the cam chain tensioner lifter body. The cam chain tensioner lifter shaft should spring out of the cam chain tensioner lifter body as soon as the stopper tool is released. 11-7 MEMO 12. CLUTCH/GEARSHIFI' LINKAGE SERVICE INFORMATION -----12-2 CLUTCH ...12_9 TROUBLESHOOTING ------------ -----12-2 GEARSHIFT LINKAGE... 12.14 COMPONENT LOCATION--------------------------12-3 PRIMARY DRIVE GEAR ........................... 12.17 RIGHT CRANKCASE COVER 12-4 12-1 CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL ~ This section covers service oI the clutch and gearshift linkage. All services can be done with the engine installed in the frame. ~ Engine oil viscosity and level have an eIIect on clutch disengagement. Oil additives also effect clutch performance and are not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch lever pulled in, inspect the engine oil level beIore servicing the clutch system. TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the Ireeplay. Clutch lever too hard to pull in ~ Damaged, kinked or dirty clutch cable ~ Improperly routed clutch cable ~ Damaged clutch lifter mechanism ~ Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle creeps with clutch disengaged ~ Excessive clutch lever Ireeplay ~ Clutch plate warped ~ Engine oil level too high, improper oil viscosity or additive used ~ Loose clutch center lock nut Clutch slips ~ Clutch lifter sticking ~ Worn clutch discs ~ Weak clutch springs ~ No clutch lever Ireeplay ~ Engine oil level too low or oil additive used Hard to shitt ~ Misadjusted clutch cable ~ Damaged or bent shift Iork ~ Bent shift Iork shaIt ~ Incorrect engine oil viscosity ~ Bent or damaged gearshiIt spindle ~ Damaged shiIt drum stopper plate ~ Damaged shiIt drum guide grooves (page 14-11) Transmission jumps out at gear ~ Worn shift drum stopper arm ~ Worn or broken gearshift spindle return spring ~ Bent shift Iork shaIt ~ Worn or damaged shiIt drum stopper plate ~ Damaged shiItdrum guide grooves (page 14-11) ~ Worn gear dogs or dog holes (page 14-11) Gearshift pedal will not return ~ Weak or broken gearshift spindle return spring ~ Bent gearshiIt spindle 1 2-2 CLUTCH/GEARSHIFI' LINKAGE COMPONENT LOCATION _ , ‘ 1 1 u.\ ‘ ‘ " >1 , L f 1 " 1‘ 0 ‘ I 108 N-mfikgf-m, ao mun/'69 “1. ‘1 { 1 ‘ 10N-m(1.0k9|—m,7lb. $00 1 —W 90 \ M% ‘ 103 N-m (11.0 Kgl-m, so lbl-ft) 1o N-m (1.0 kgf-m, 7 lbl-n) 1 2-3 CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-9). Drain the coolant (page 9—5). Remove the tollowing: — Water pipe (page 9-13) — Frame guard (page 2—6) — Brake pedal (page 18-12) Remove the bolts [1] and clutch cable guide [2], then disconnect the clutch cable [3] from the clutch lilter arm [4]- Loosen the water hose band screw [1] and disconnect the water hose [2]. Remove the bolt [3] and rear brake light switch holder [4]- Loosen the right crankcase cover bolts [1] in a crisscross pattern in 2 or 3 steps and remove the bolts. Be care/u] not to let Remove the right crankcase cover [2] while turning the the relum sprmg fall clutch lifter arm [3] counterclockwise to disengage the inlo the crankcase. lifter arm spindle from the lifter piece. Remove the dowel pin A [1], dowel pin B [2] and gasket [3]. 1 2-4 CLUTCH/GEARSHIFI' LINKAGE Remove the collars [1] and O-rings [2]. l1 l/[2] DISASSEMBLY Remove the return spring [1] from the right crankcase cover. Remove the clutch lifter arm [1] lrom the right, crankcase cover. INSPECTION Inspect the following parts lor scratch, damage, abnormal wear and delormation. Replace if necessary. — Oil seal — Clutch litter arm needle bearing — Clutch lilter arm — Return spring — Crankshaft bearing 1 2-5 CLUTCH/GEARSHIFT LINKAGE BEARING REPLACEMENT CRANKSHAFI' BEARING Remove the crankshaft bearing [1] using the special tools. TOOLS: [2] Remover weight 07741-0010201 [3] Bearing remover set, 12 mm 079364660101 Drive in a new crankshaIt bearing [1] into the right crankcase cover with the marked side tacing up until it is fully seated using the special tools. TOOLS: [2] Driver 07749-0010000 " . [3] Attachment, 28 x 30 mm 079464870100 ’ [Bl/[4] [4] Pilot, 12 mm 07746-0040200 After installation, apply engine oil to the bearing. CLUTCH LIFI'ER ARM NEEDLE BEARING Remove the oil seal [1] from the right crankcase cover. Remove the clutch lifter arm needle bearings [2] using the special tools. TOOLS: [3] Bearing remover set, 12 mm 079364660101 [4] Remover weight 07741-0010201 1 2-6 CLUTCH/GEARSHIFI' LINKAGE Install the bearlng remover head [1] to the pllot collar [2] as shown. [1] TOOLS: [1] Bearing remover head, 10 mm 07746-0050200 [2] Pilot collar, 16 mm 07PAF-0010620 [2] the specilied depth, uslng the speclal tools as shown. 1 Il’] g7. 6.5—7.5 mm I TOOLS: 0.26 — 0.30 in) [2] Bearing remover head, 10 mm 0774643050200 K— [3] Pilot collar, 16 mm 07PAF-0010620 After installatlon, apply engine oil to the beanng. Install a new all seal [1] to the right crankcase cover as shown. 0.5— 1.0 mm (0.02—0.04 m) g [11 ASSEMBLY Apply grease to the clutch lilter arm oil seal Ilps [1]. v Apply molybdenum OII solution to the clutch lilter arm [2] ;i sliding surlace. 5 Install the clutch lilter arm to the right crankcase cover. [11 FE» r21 1 2-7 CLUTCH/GEARSHIFT LINKAGE Install the return spring [1] to the right crankcase cover by aligning the spring short end with the hole of the clutch lifter arm and long end with the groove 01 the right crankcase cover. INSTALLATION Be care/u! not Ia Clean any gasket material from the mating surlaces of ' damage Ihe mating the right crankcase and cover. surfaces. Apply engine oil to new O-rings [1]. Install the collars [2] and O-rings. Install the dowel pin A [1], dowel pin B [2] and a new gasket [3]. the return spring tall clutch litter arm [2] clockwise to engage the lifter arm inlu the crankcase. spindle groove with the litter piece Ilange. Install and tighten the bolts [3] in a crisscross pattern in 2 or 3 steps. r Be carefulnottolet Install the right crankcase cover [1] while turning the ’[2] . 1 2-8 CLUTCH/GEARSHIFI' LINKAGE CLUTCH Connect the water hose [1] and tighten the water hose band screw [2] (page 9-7). Install the rear brake light switch holder [3] and tighten the bolt [4]. Connect the clutch cable [1] to the clutch lifter arm [2]. Install the clutch cable guide [3] and bolts [4]. Tighten the bolts securely. Install the lollowmg: — Brake pedal (page 18-12) — Frame guard (page 2-6) — Water pipe (page 9-13) Adjust the clutch lever lreeplay (page 3-18). Fill the engine with the recommended engine oil (page 3-9). Fill the recommended coolant and bleed the air (page 9-5). REMOVAL Remove the right crankcase cover (page 12-4). [1]/[2] Loosen the clutch lilter plate bolts [1] in a crisscross pattern in 2 or 3 steps. Remove the clutch lilter plate bolts and clutch springs [2]- Remove the clutch lifter plate [3]. Remove the clutch discs [4] and plates [5]. [3] Remove the clutch lilter piece [1], [udder spring [2] and spring seat [3]. 1 2-9 CLUTCH/GEARSHIFT LINKAGE Unstake the clutch center lock nut [1]. Hold the clutch center 1 wtth the s ecial tool and - ‘ "r‘ ' ' l l p @1441 loosen the clutch center lock nut [2]. TOOL: [3] Clutch center holder 07724-0050002 Remove the clutch center lock nut and washer [4]. Remove the washer [1] and clutch outer [2]. Remove the needle bearing [1], clutch outer gulde [2] and washer [3] lrom the mainshaft. 12-10 CLUTCH/GEARSHIFI' LINKAGE INSPECTION Inspect the following pans lor scratch, damage, abnormal wear and delormatIon. Replace if necessary. — Clutch lifter bearing — Clutch springs — Clutch center — Clutch dIscs/plates — Clutch outer — Clutch outer guide/needle bearing — Mainshait Measure each part according to cLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (page 1-7). Replace any part il it is out of serVIce limIt. - Replace the clutch springs as a set. - Replace the clutch discs and plates as a set. CLUTCH LIFTER BEARING REPLACEMENT Drive out the old bearing Irom the Clutch lIfter plate [1]. [3] Drive in a new bearing [2] squarely WIth its marked side lacing up. TOOLS: [3] Driver 07749-0010000 [Al/I5] [4] Attachment, 28 x 30 mm 079464870100 [5] Pilot, 12 mm 07743-0040200 After installatIon, apply engine oil to the bearIng. INSTALLATION CLUTCH CLUTCH PLATE CLUTCH DISC DISC A B (WhIle paint) B (Larger LD.) CLUTCH PLATE A CLUTCH LIFTER PIECE s! '7. BEARING , SPRING SEAT I JUDDER SPRING CLUTCH LIFTER PLATE \ {b CLUTCH SPRING ‘3‘ WASHER NEEDLE BEARING ’ CLUTCH OUTER GUIDE ’6 ' ,o ’/ CLUTCH OUTER 12 N-m (1.2 mm, 9 lbf-ft) /'®®‘\ WASHER WASHER CLUTCH CENTER 6’ LOCK NUT v 108 Mm (11.0 Kgl-m, sow-rt) 12-11 CLUTCH/GEARSHIFT LINKAGE Install the washer [1] to the mainshaft. Apply molybdenum Oil solution to the clutch outer guide [2] whole surlace and install it to the mainshaft. Apply engine oil to the needle bearing [3] rotating area and install it to the clutch outer guide. Install the clutch outer [1] and washer [2]. Apply engine oil to a new clutch center lock nut [1] threads and seating surface. Install the clutch center [2], washer [3] and lock nut. Hold the clutch center [1] With the special tool and tighten the lock nut [2] to the specilied torque. TOOL: [3] Clutch center holder 07724-0050002 TORQUE: 108 Nm (11.0 kgf‘m, 80 lel) 12-12 CLUTCH/GEARSHIFI' LINKAGE Be carelul not [0 Stake the lock nut [1] into the mainshaft groove. damage the mainsharr threads. Install the clutch lifter piece [1]. Install the spring seat [2] and judder spring [3] in the direction as shown. Apply engine oil to the entire surface of clutch discs. Install the clutch disc B [4] and clutch plate B [5]. - Clutch disc B: larger I.D. - Clutch plate B: white paint on outer circumlerence Install the clutch discs A [6] and plates A [7] alternately, starting With the clutch disc. [5] (white paint) Install the clutch lifter plate [1]. Install the clutch springs [2] and bolts [3]. Tighten the clutch lifter plate bolts to the specified torque in a crisscross pattern in 2 or 3 steps. TORQUE: 12 MM (1.2 kgf‘m, 9 Ibf‘ft) Install the right crankcase cover (page 12—8). [2]/[3] 12-13 CLUTCH/GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL Remove the tollowing: — Dnve sprocket cover (page 2-6) — Clutch assembly (page 12-9) Remove the pinch bolt [1] and gearshilt pedal [2]. Clean off any dirt from the gearshitt Spindle serration. Pull out the gearshitt spindle assembly [1] and washer [2]1rom the crankcase. Remove the gearshift spindle oil seal [1]. Be careful not to let Remove the shift drum stopper plate bolt [1]. the removed pans fall inlu the crankcase. 12-14 CLUTCH/GEARSHIFI' LINKAGE Be careful not to let the removed pans fall intu the crankcase. Remove the lollcwing: Shift drum stopper plate [1] Dowel pins [2] Shift drum stopper arm bolt [3] Shift drum stopper arm [4] Washer [5] Return spring [6] v [SJ/[6] INSPECTION Check the return spring [1] and spindle arm spring [2] for fatigue or damage replace them if necessary. [2] I1] Check the gearshift spindle [3] for wear or bend. Check the spindle arm [4] for wear, damage or deformation. Replace the gearshift spindle as an assembly if necessary. Inspect the gearshift spindle needle bearing and replace if necessary. [4] [3] GEARSHIFI' SPINDLE NEEDLE BEARING REPLACEMENT Remove the gearshift spindle needle bearing [1] using the special tools. TOOLS: [2] Remover weight 07741-0010201 [3] Be ' g remover shaft, 15 mm D7936-KC10100 [4] Bearing remover head, 14 mm 07WMC-KFGO100 Drive in a new gearshilt spindle needle bearing [1] into the left crankcase with the marked side facing up until it is fully seated using the special tools. TOOLS: [2] Driver 07749-0010000 [3] Pilot, 20 mm 07743-0040500 After installation, apply engine oil to the bearing. CLUTCH/GEARSHIFT LINKAGE INSTALLATION Apply locking agent to the shift drum stopper arm bolt [1] threads. Install the return spring [2], washer [3] and stopper arm [4] while hooking the return spring at the stopper arm groove. Install and tighten the bolt to the specilied torque. TORQUE: 1D N-m (1.0 kgf‘m, 7 lbf‘ft) Check the stopper arm for proper operation. Move the stopper arm [1] out of the way using a screwdriver. Install the dowel pins [2] into the shift drum holes. Install the shift drum stopper plate [3] while aligning its pin holes [4] with the dowel pins. Apply locking agent to the shift drum stopper plate bolt [1] threads. Install and tighten the shift drum stopper plate bolt to the specified torque. ‘ TORQUE: 1D N-m (1.0 kgf‘m, 7 lbf‘ft) Apply grease to a new gearshift spindle oil seal lip [1]. Install the gearshift spindle oil seal to the specified depth as shown. 0.5 — 1.0 mm (o 0.04 in) l 12-16 CLUTCH/GEARSHIFI' LINKAGE Apply engine oil to the gearshift spindle shaft [1] outer surIace. Align Install the gearshift spindle assembly and washer [2] to the crankcase by aligning the return spring ends with the spring pin. Install the gearshift pedal [1] onto the gearshift spindle while aligning the punch marks. i- Install and tighten the pinch bolt [2] securely. Install the Iollowmg: — Clutch assembly (page 12-11) — Drive sprocket cover (page 2-6) PRIMARY DRIVE GEAR REMOVAL Remove the clutch assembly (page 12—9). Temporarily install the washer [1], clutch outer guide [2], needle bearing [3] and clutch outer [4]. Insert the gear holder [5] between the primary drive and driven gears. TOOL: Gear holder, M1.5 07724-0010200 Loosen the primary drive gear lock nut [6]. Remove the clutch outer, needle bearing. clutch outer guide and washer. Remove the lock nut and washer [7]. Remove the primary drive gear [1]. 12-17 CLUTCH/GEARSHIFT LINKAGE INSTALLATION Apply engine oil to the primary drive gear [1] teeth. Install the primary drive gear while aligning its punch mark With the crankshaft punch mark. Install the washer [1]. Apply engine oil to the primary drive gear lock nut [2] threads and seating surface, then install ll. Temporarily install the washer [1], clutch outer guide [2], needle bearing [3] and clutch outer [4]. Insert the gear holder [5] between the primary drive and driven gears. TOOL: Gear holder, M1.5 07724-0010200 Tighten the primary drive gear look nut [6] to the specified torque. TORQUE: 108 Mm (11.0 kgf‘m, 80 lel) Install the clutch assembly (page 12-11). 12-18 13. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION-mu -----13-2 TROUBLESHOOTING ------------ -----13-2 COMPONENT LOCATION 13.2 LEFT CRANKCASE COVER 13.3 STATOR/CKP SENSOR ------ ---13-4 FLYWHEEL ........................... ....13.5 STARTER CLUTCH .................................... 13.7 13-1 ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL ~ This section covers the removal and Installation at the Ilywheel, aIternator and starter dutch. These serwces can be done with the engme instaHed in the Irame. TROUBLESHOOTING Starter motor turns, but engine does not turn ~ FauIty starter clutch ~ Damaged reductrdn gear ~ Damaged starter drwen gear ~ Damaged or IauIty starter motor pimdn gear COMPONENT LOCATION 128N-m13.1kf-m,94lbf-ft i . / / \ ( g ) 9\: \ §E 1 3-2 ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-9). Remove the lollowing: — Left side cover (page 2-3) — Drive sprocket cover (page 2-6) — Gearshilt pedal (page 12-14) Disconnect the tollowing: — Alternator 3P connector [1] — CKP sensor/neutral switch 3P (Black) connector [2] Release the alternator wire [3] lrom the clamp [4]. Disconnect the neutral sWitch connector [1] and release the wire from the Ielt crankcase cover groove. The lelt crankcase Loosen the left crankcase cover bolts [2] in a crisscross cave!(5la!ur)l's pattern in 2 or 3 steps and remove the bolts and left magnetically crankcase cover [3]. alt/acted m the flywheel, be Cale/Ill during rema val. Remove the dowel pins [1] and gasket [2]. INSTALLATION Be carelul not [0 Clean any gasket material lrorn the mating surlaces of damage [he malmg the left crankcase and cover. “News Install the dowel pins [1] and a new gasket [2]. ALTERNATOR/STARTER CLUTCH The Ielt crankcase Install the lelt crankcase cover [1] and bolts [2]. cover (siarar) is magnetically amacredmttie Connect the neutral SWitch connector [3] and set the flywheel. be careful wire into the left crankcase cover groove. during Installation. Tighten the bolts in a crisscross pattern in 2 or 3 steps. Connect the lollowing: — Alternator 3P connector [1] [3] — CKP sensor/neutral switch 3P (Black) connector [2] Secure the alternator wire [3] With the clamp [4]. Install the loIIoWing: — Gearshilt pedal (page 12-17) — Drive sprocket cover (page 2-6) — Left side cover (page 2-3) Fill the engine with the recommended engine oil (page 3-9). STATOR/CKP SENSOR REMOVAL/INSTALLATION Remove and install the stator/CKP sensor as following illustration. - Apply locking agent to the CKP sensor mounting bolt threads as specilied (page 1-12). - Apply sealant to the alternator/CKP sensor wire grommet sealing surface (page 1-15). d 10 N-m (1.0 kgf-m, 7 lot-ll) 10 N.m (1.0 Kat-m. 7 mm) m STATOR/CKP SENSOR E W fi g _ 0 LEFT CRANKCASE COVER 1 3-4 ALTERNATOR/STARTER CLUTCH FLYWH EEL REMOVAL Remove the left crankcase cover (page 13-3). Remove the starter reduction gear [1] and shaft [2]. Hold the tlywheel with the special tool and remove the flywheel bolt [1] and washer [2]. TOOL: [3] Flywheel holder 07725-0040001 Remove the llywheel [1] using the special tool. TOOL: [2] Flywheel puller 07733-0020001 Remove the needle bearing [1]. Be care/u! not [0 Remove the woodrufl key [2]. damage me key groove and crankshaft. ALTERNATOR/STARTER CLUTCH INSPECTION Inspect the following parts for scratch, damage, abnormal wear and delormation. Replace if necessary. — Starter reduction gear shaft — Starter reduction gear — Woodrutl key — Needle bearing INSTALLATION Apply molybdenum oil solution to the needle bearing [1] rotating area. Install the needle bearing onto the crankshaft. Clean any oil from the crankshaft taper surface. Be care/u! none Install the woodruff key [2] onto the crankshaft. damage the key groa we and crankshalt. Install the Ilywheel while aligning the woodrufl key on \\ the crankshaft With Ilywheel keyway. Apply engine oil to the Ilywheel bolt [1] threads and seating surface. Install the washer [2] and bolt. Hold the flywheel With a special tool and tighten the bolt to the specified torque. TOOL: [3] Flywheel holder 07725-0040001 TORQUE: 128 Nm (13.1 kgf‘m, 94 leI) 1 3-6 ALTERNATOR/STARTER CLUTCH Apply molybdenum oil solution to the starter reduction gear shalt [1] outer surface and starter reduction gear [2] inner surlace. Install the shalt and starter reduction gear. Install the left crankcase cover (page 13-3). STARTER CLUTCH REMOVAL Remove the llywheel (page 13-5). Make sure that the starter driven gear [1] turns counterclockwise smoothly and does not turn cIockwtse. Remove the starter driven gear While turning it counterclockwise. Hold the flywheel with a special tool and remove the starter clutch socket bolt [1]. [2] TOOL: [2] Flywheel holder 07725-0040001 Remove the starter clutch outer and starter one—way clutch. INSPECTION Inspect the following parts lor scratch, damage, abnormal wear and delormation. Replace if necessary. — Starterdriven gear Measure each part according to ALTERNATOR/ STARTER CLUTCH SPECIFICATIONS (page 1—7). Replace any part it it is out of sen/ice limit. 1 3-7 ALTERNATOR/STARTER CLUTCH INSTALLATION STARTER DRIVEN GEAR STARTER CLUTCH OUTER 7. STARTER ONE-WAY CLUTCH FLYWHEEL 30 N-m (3.1 kgl-m, 22 lbl-ft) Apply engine oil to the starter one-way clutch [1] sprag. Install the starter one-way clutch to the starter clutch outer [2]. Install the starter clutch assembly to the flywheel [3] as shown. Apply looking agent to the starter clutch socket bolts [1] threads. Install the starter clutch socket bolts. Hold the flywheel with a special tool and tighten the socket bolts to the specified torque. TOOL: [2] Flywheel holder 07725-0040001 TORQUE:3D N-m (3.1 kgf‘m, 22 IN“) 1 3-8 ALTERNATOR/STARTER CLUTCH Apply engine oil to the starter driven gear [1] sliding surlace. Install the starter driven gear while turning it counterclockwise. Make sure that the starter driven gear turns counterclockwise smoothly and does not turn clockwise. Install the llywheel (page 13-6). 1 3-9 MEMO 14. CRANKCASE/CRANKSHAFI'lTRANSMISSION/BALANCER SERVICE INFORMATION ........................... 14.2 TROUBLESHOOTING ................................. 14.2 COMPONENT LOCATION .......................... 14.3 CRANKCASE SEPARATION ---------------------- 14-4 CRANKSHAFT ............................................ 14.5 MAIN JOURNAL BEARING ........................ 14.7 TRANSMISSION ....................................... 14.10 BALANCER ............................................... 14.14 CRANKCASE BEARING REPLACEMENT ....................................... 14.15 CRANKCASE ASSEMBLV-- --14-18 14-1 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SERVICE INFORMATION GENERAL ~ This section covers crankcase separation for service of the crankshalt, transmission and balancer. ~ The crankcase must be separated to service the crankshaft, balancer and transmission. To service these parts, the engine must be removed lrorn the frame. ~ The followmg components must be removed pelore separating the crankcase. — Camshalt (page 10-6) — Cylinder head (page 10-13) — Cylinder/piston (page 11-3) — Clutch (page 12-9) — Gearshilt linkage (page 12-14) — Oil pump (page 8-4) — Primary drive gear (page 12-17) — Flywheel (page 13-5) — Neutral switch (page 20-13) — Starter motor (page 6-4) — Engine (page 15-4) Be careful not to damage the crankcase mating surfaces when servicing. Clean the oil passages pelore assembling the crankcase halves. Prior to assembling the crankcase halves, apply sealant to their mating surlaces. Wipe off excess sealant thoroughly. tables. After selecting a new bearing, recheck the oil clearance. Incorrect oil clearance can cause major engine damage. TROUBLESHOOTING Excessive engine noise ~ Worn, seized or chipped transmission gear ~ Worn or damaged transmission bearing ~ Worn or damaged connecting rod big end bearing ~ Worn main journal bearing ~ Worn connecting rod small end ~ Worn balancer shalt bearing ~ Improper balancer timing Hard to shill ~ Bent shift lork ~ Bent shift lork shalt ~ Damaged shilt drum guide groove ~ Damaged shilt lork guide pin ~ Bent shift lork claw ~ Damaged gearshift spindle ~ Loose shilt drum stopper arm bolt Transmission jumps out ol gear ~ Worn gear dogs or dog holes ~ Damaged shiltdrum guide groove ~ Worn shift lork guide pin ~ Worn shift lork groove in gear ~ Worn shift fork shalt ~ Bent shift lork shalt ~ Weak or broken gearshift spindle return spring Engine vibration ~ Excessive crankshalt runout ~ Improper balancer timing The main journal bearing inserts are select lit and are identilied by color codes. Select replacement bearing lrom the code 1 4-2 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER COMPONENT LOCATION 1o N-m (1.0 Kgf-m, 7 lbl-h) 14-3 CRANKCASE/cRANKSHAFT/TRANSMISSION/BALANCER CRANKCASE SEPARATION Reler to Service Inlormation (page 14-2) lor removal of ' ‘ necessary parts belore disassembling the crankcase. Remove the tensioner pivot bolt [1], collar [2] and cam chain tensioner [3]. Remove the cam chain [4] and timing sprocket [5]. Check the cam chain tensioner [1] for excessive wear or damage, replace it ll necessaw. Install a 3 mm (0.12 in) OD. pin [1] into the hole [2] of the balancer driven gear assembly [3]. Insert the gear holder [1] between the balancer drive gear [2] and balancer driven gear assembly [3]. TOOL: Gear holder, M2.5 07724-0010100 Loosen the balancer shalt nut [4]. Remove the nut, washer [5], balancer driven gear assembly and balancer drive gear. NOTE For balancer driven gear disassembly (page 14-14). 1 4-4 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Remove the woodruff key [1] from the balancer shaft. Loosen the crankcase bolts [1] in a crisscross pattern in 2 or 3 steps, and remove the bolts. Place the crankcase assembly with the right crankcase down. Do notplyme Carefully separate the lelt crankcase [1] trom the right crankcase halves crankcase [2] while tapping them at several locations with a screwdriver. with a plastic hammer. Remove the dowel pins [1] and O-ring [2]. _‘ , \wgl 14-5 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER CRANKSHAFT REMOVAL Separate the crankcase halves (page 14-4). Remove the crankshalt [1] from the right crankcase. INSPECTION Inspect the following parts lor scratch, damage, abnormal wear and delormation. Replace if necessary. — Crankshaft — Connecting rod — Timing sprocket Measure each part according to CRANKCASE/ CRANKSHAFT/TRANSMISSION BALANCER SPECIFICATIONS (page 1-7). Replace any part il it is out of sen/ice limit. CRANKSHAFT RUNOUT Place the crankshalt on V-blocks. Set the dial indicator on the crankshalt. Rotate the crankshaft two revolutions (720°) and read the runout. SERVICE LIMIT: 0.03 mm (0.001 in) 29.0 mm 6.0 mm (1.14m) (024M) INSTALLATION Apply molybdenum oil solution to the connecting rod big end sliding surface. Apply molybdenum oil solution to the crankshalt main journal bearing sliding surlace. Install the crankshaft [1] into the right crankcase. Assemble the crankcase (page 14-18). 14-6 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER MAIN JOURNAL BEARING BEARING INSPECTION Remove the following: — Crankshaft (page14-G) — Transmission (page 14-10) — Balancer shaft (page 14-14) Clean off any oil from the bearings. Check the main journal bearings [1] lor unusual wear, damage or peeling and replace them il necessary. MAIN JOURNAL OIL CLEARANCE MEASUREMENT Measure and record the main journal bearing ID. at > P0|NT between the bearing groove and crankcase outside end of the bearing, and 90 degrees to the index mark [2]. Clean off any oil from the crankshaft journals. Measure and record the crankshaft main journal O.D. SERVICE LIMIT: 33.975 mm (1.3376 in) Calculate the oil clearance between the crankshaft main journal and main journal bearing. SERVICE LIMIT: 0.075 mm (0.0030 in) II the clearance exceeds the service limit, select the main journal bearing (page 14-7). BEARING SELECTION Remove the following: — Crankshaft (page14-G) — Transmission (page 14-10) — Balancer shaft (page 14-14) Set a special tool and hydraulic press on the outside of the crankcase. TOOLS: [1] Driver, 30 x 36 mm 07HMF-KR10101 [2] Base, 42 mm 07GAF-SD40200 Press the main journal bearings [1] toward the inside of the crankcase. [1] 14-7 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Measure and record the crankcase maln journal . bearing support ID. at 90 degrees to the index mark [1]. I SERVICE LIMIT: 38.036 mm (1.4975 in) Depending upon the results _ol the _above measurements there are lour possible scenarios lor main journal bearing selection: - Crankshaft and crankcase are replaced - Crankcase only is replaced - Crankshaft only is replaced - Main journal bearings only are replaced Carefully refer to the following instructions and tables Ior main journal bearing selection. Record the bearing support |.D. code [1] letter. NOTE Letters A, B or C on each crankcase ls the code lor the crankcase maln journal bearing support I.D. Cross-reference the crankshaft and crankcase codes to determine the replacement bearing color. MAIN JOURNAL O.D. BEARING SUPPORT |.D. CODE (Crankcase replaced) BEARING SUPPORT I.D. 33.985 — 34.000 mm (1.3330 — 1.3336 in) (Crankshaft replaced) 33.975 — 33.935 mm (1.3376 — 1.3330 in) 38.000 — 38.006 mm C (Brown) B (Black) (1.4965 — 1.4963 in) (0.0788 — 0.0789 in) A . 1.993 — 1.999 mm 1.999 — 2.002 mrn “-4961 ‘1'4963m’ (0.0736 — 0.0737 (n) (0.0737 — 0.0739111) B (Black) A (Blue) B ff-fgga‘_3f-2;§5T$ 1.999 — 2.002 mm 2.002 — 2.005 mm - - (0.0737 — 0.0739 (n) (0.0739 — 0.0739111) A (Blue) 0.5. G (Pink) 0 38-012 ‘ 38-018 '"m 2.002 — 2.005 mm 2.005 — 2.009 mm (0.0739 — 0.0791 (n) 38.018 — 38.024 mm (1.4968 — 1.4970 in) 0.5. G (Pink) 2.005 — 2.009 mm (0.0739 — 0.0791 (n) 0.3. F (Yellow) 2.009 — 2.011 mm (0.0791 — 0.0792 (n) 38.024 — 38.030 mm (1.4970 — 1.4972 in) 0.5. F (Yellow) 2009 — 2.011 mm (0.0791 — 0.0792 (n) 0.8. E (Green) 2.011— 2.014 mm (0.0792 — 0.07931n) 38.030 — 38.036 mm (1.4972 — 1.4975 in) 0.8. E (Green) 2.011—2.014 mm (0.0792 — 0.0799 (n) 0.3. D (Red) 2.014 — 2.020 mm (0.0792 — 0.0795111) 14-8 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER BEARING THICKNESS: 0.5. D (Fled): Thick 0.5. E (Green): I 0.5. F (Yellow): 0.5. G (Pink): Middle A (Blue): 3 (Black): I C (Brown): Thin BEARING INSTALLATION Apply engine oil to new bearing [1] surface. Set new bearings to the metal installer as shown. TOOL: Metal installer set 070MF-KVJD100 Tighten the bolts [2] alternately in several steps. Set the bearings [1] and special tools assembly on inside of the crankcase, litting the bearing edge in the crankcase main journal. Align the mating line of the bearings with the index mark [2] on the crankcase as shown. Set the crankcase and special tools on the hydraulic press. TOOLS: [1] Metal installer set [2] Base, 42 mm 070MF-KVJ0100 07GAF-SD40200 Make sure the metal installer mating line is aligned with the index mark on the crankcase. ' ‘i ‘ IDENTIFICATION COLOR [2] 14-9 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Press the bearings [1] until the metal installer llange [2] is fully seated. Make sure the bearing mating line is aligned with the \ ' index mark on the crankcase. ' Check the oil clearance (page 14-7). NOTE After selecting new bearings, recheck the oil clearance. Incorrect clearance can cause severe engine damage. Install the lollowing: — Crankshaft (page14-G) — Transmission (page 14-11) — Balancer shaft (page 14-1 4) TRANSMISSION REMOVAL/DISASSEMBLY Separate the crankcase halves (page 14-4). Pull the shift fork shaft [1] and remove it from the shift forks. Remove the shift forks [2] and shift drum [3]. “3] Remove the mainshaft assembly [1] and ccuntershaft 1 assembly [2] together. [ ] 14-10 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Disassemble the mainshatt assembly [1] and 1 countershatt assembly [2]. I 1 NOTE ' Keep track ol the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece ol wire. - Do not expand the snap ring more than necessary tor removal. To remove a snap ring, expand the snap ring and pull it oft using the gear behind it. [2] INSPECTION Inspect the following parts Ior scratch, damage, abnormal wear and delormation. Replace it necessary. — Transmission gears — Transmission bushings — Transmission bearings — Shittdrum/journal — Shittlorks — Shiftlorkshalt Measure each pan and calculate the clearance according to CRANKCASE/CRANKSHAFT/TRANS- MISSION/BALANCEFI SPECIFICATIONS (page 1-7). Replace any part il it is out of service limit. ASSEMBLY/INSTALLATION Clean all parts in solvent, and dry them thoroughly. Apply molybdenum oil solution to the gear bushing INCORRECT CORRECT entire surlace (M5, Cl, CZ, CG), gear bushing outer surlace (M6, CA) to ensure initial lubrication. Assemble all parts into their original positions. NOTE ' Install the washers and snap rings [1] With the chamlered edge lacing the thrust load side. Confirm the inner side oi snap rings and washer when you detect the chamfered side. ' Do not reuse worn snap ring which could easily spin in the groove. ' Check that the snap rings are seated in the grooves and align their end gaps with the grooves ol the spline. 14-11 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER MAINSHAFI' SPLINE WASHER SNAP RING M3/M4 GEAR (21/23T) SNAP RING SPLINE WASHER i M6 GEAR BUSHING ‘ Ms GEAR (2m WASHER M2 GEAR (171) THRUST WASHER COUNTERSHAFT THRUST WASHER c1 GEAR (401) C1 GEAR BUSHING i THRUST WASHER cs GEAR (291) SNAP RING v» SPLINE WASHER Jun 04 GEAR (son I 0 ~31 i C4 GEAR BUSHING ca GEAR (SST) cs GEAR BUSHING cs GEAR (st) THRUST WASHER COUNTERSHAFT 7‘ 02 GEAR BUSHING 02 GEAR (SGT) THRUST WASHER 14-12 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Check the gears for freedom of movement or rotation on each shaft. ‘7. :Each gear teeth [1] Apply engine oil to the transmission gear teeth. Engage the mainshaft assembly [1] and oountershaft .. assembly [2]. [2] Install the mainshaft assembly [1] and oountershaft assembly [2] together into the right crankcase. Make sure the three thrust washers are installed (mainshaft; left only/countershafi; both ends). Each shift fork has an identification marks [1], "R" is for the right shift fork, "L" is the left shift fork and "C" is for the center shift fork. Apply molybdenum oil solution to the shift fork inner surfaces and guide pins. Install the shift forks [1] into the shifter gear grooves with the identification marks facing up (left crankcase side). Apply molybdenum oil solution to the shift drum [2] journal outer surface and grooves, then install it while aligning the shift fork guide pins with the guide grooves. 14-13 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Apply molybdenum oil solutIon to the shift Iork shaft [1] 1 outer surface and Insert it through the shift forks into the ;i l 1 rIght crankcase. After installation, check for smooth transmission operation. ti Assemble the crankcase (page 14-18). BALANCER BALANCER SHAFI' REMOVAL/ INSTALLATION Separate the crankcase halves (page 14-4). . Remove the balancer shaIt [1] Irom the right crankcase. ”‘1‘ Install the balancer shaft Into the right crankcase. Assemble the crankcase (page 14-18). BALANCER DRIVEN GEAR DISASSEMBLY/ASSEMBLY Disassemble and assemble the balancer driven gear as Iollowmg illustration. SPRING WASHER WASHER BALANCER DRIVEN SUB GEAR WASHER BALANCER _ DRIVEN GEAR “'9" SNAP RING "OUT" MARK WASHER BALANCEFI DRIVEN GEAR SPRINGS BALANCER DRIVEN WASHER SUB GEAR SPRING WASHER SNAP RING \ 14-14 CRANKCASE/CFIANKSHAFT/TRANSMISSION/BALANCER INSPECTION Inspect the following parts lor scratch, damage, abnormal wear and delormation. Replace if necessary. — Balancerdrlven gear — Balancer driven sub gear — Springs — Balancershalt — Balancerdrivegear CRANKCASE BEARING REPLACEMENT BALANCER/TFIANSMISSION BEARING Remove the lollowing: — Crankshaft (page14—6) — Balancer shaft (page 14-14) — Transmission (page 14-10) RIGHT CRANKCASE SIDE Remove the bolts [1] and mainshaft bearing setting plate [2]. Drive out the malnsnaIt bearing [3], shift drum bearing [4] and balancer shaft bearing [5]. Remove the countershaft bearing [1] using the special tools. TOOLS: [2] Bearing remover set, 17 mm 07936-3710300 Remover handle 07936-37101 00 [3] Remover weight 07741-0010201 14-15 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Drive in new bearings into the right crankcase until they are lully seated using the special tools. TOOLS: [1] Mainshaft bearing (marked side facing up): [2] Driver 07749-0010000 [3] Attachment, 52 x 55 mm 07746-0010400 [4] Pilot, 20 mm 0746-0040500 [5] Countershaft bearing (sealed side lacing down): Driver 07749-0010000 Attachment, 37 x 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 [6] Shift drum bearing (marked side facing up): Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 After installation, apply engine oil to each bearing rotating area. Drive in a new balancer shaft bearing into the right crankcase until it is lully seated using the special tools. TOOLS: [1] Balancer shaft bearing (marked side lacing up): [2] Driver 07749-0010000 [3] Attachment, 42 x 47 mm 07746-0010300 [4] Pilot, 20 mm 07746-0040500 After installation, apply engine oil to the bearing rotating area. Apply locking agent to the mainshaft bearing setting plate bolt [1] threads (page 1—15). Install the setting plate [2] with its “OUTSIDE" mark [3] facing out. Install and tighten the bolts securely. LEFT CHANKCASE SIDE Remove the snap ring [1]. Remove the countershaft oil seal [2] from the left crankcase. [31/[41 14-16 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Drive out the countershalt bearing [1]. Remove the mainshalt needle bearing [1] using the special tools. TOOLS: [2] Bearing remover set, 17 mm 07936-3710300 Remover handle 07936-37101 00 [3] Remover weight 07741-0010201 Remove the balancer shaft bearing [1] using the special tools. TOOLS: [2] Bearing remover set, 20 mm 07936-3710600 [3] Remover handle 07935-3710100 [4] Remover weight 07741-0010201 Drive in new bearings into the left crankcase until they _ are lully seated using the special tools. TOOLS: [1] Mainshalt needle bearing: [2] Driver 07749-0010000 [3] Attachment, 28 x 30 mm 079454870100 [4] Pilot, 17 mm urns-0040400 [5] Countershatt bearing (marked side facing up): Driver 07749-0010000 Attachment, 52 x 55 mm 07745-0010400 Pilot, 22 mm 07745-0041000 [6] Balancer shaft bearing (marked side lacing up): Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 20 mm 07745-0040500 After installation, apply engine Oil to each bearing rotating area. 14-17 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Apply grease to a new countershaft oil seal [1] lips. Install the countershaft oil seal with its marked side facing up, until it is flush with the snap ring groove. Make sure the snap Install the snap ring [2]. ring is firmly seated in the groove. CRANKCASE ASSEMBLY Clean the oil passages of each crankcase using a compressed air. Check the oil passage lor clogs. Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them and check lor damage. Apply a light but through coating ol sealant (Three bond 1207B, 1215 or equivalent) to left crankcase mating surface except the oil passage area. Apply engine oil to a new O-ring [1]. Install the dowel pins [2] and O-ring. 14-18 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Do not/urce the Install the left crankcase [1] on the right crankcase [2], crankcase halves being careful not to damage the oil seal “[35. together. II there Is excessive [area required, something Is Wrong. Remove the Ielt crankcase and check to! mlsallgnedparts. Install the crankcase bolts [1]. Tighten the bolts in a crisscross pattern in 2 or 3 steps. Becarelulnotla Install the woodrufl key [1] into the balancer shaft damagelhe key groove. groove and halancer shalt. Align the balancer gear [1] and balancer sub gear [2] 3 2 holes and install a 3 mm (0.12 in) pin [3] Into the hole. I l l 1 14-19 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Install the balancer driven gear assembly while aligning ‘ the woodrufl key on the balancer shaft with balancer , , driven gear keyway. Apply engine oil to the balancer shalt nut [1] threads and seating surlace. Install the washer [2] and balancer shaft nut. Apply engine oil to the balancer drive gear [3] teeth and install it while aligning its wide groove With the punch mark on the crankshaft. NOTE Install the balancer drive gear with its "OUT" mark [4] lacing out. Align the punch marks oi the balancer drive gear and balancer driven gear. Insert the gear holder [1] between the balancer drive - gear [2] and balancer driven gear [3]. TOOL: [1] Gear holder, M2.5 07724-0010100 Tighten the balancer shaft nut [4] to the specified torque. TORQUE“ N-m (4.5 kgf‘m, 32 lb!!!) Remove a 3 mm (0.12 in) OD. pin [5] from the balancer driven gear assembly. 14-20 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Install the timing sprocket while aligning its Wide groove " - ‘ with the punch mark on the crankshaft. Apply engine oil to the cam chain [1] whole surIace. Install the cam chain through the crankcase. Install the cam chain over the timing sprocket [2]. Apply locking agent to the cam chain tensioner pivot bolt [3] threads (page 1-12). Install the cam chain tensioner [4], collar [5] and cam chain tensioner pivot bolt. _ Tighten the cam chain tensioner pivot bolt to the specified torque. TORQUE: 10 MM (1.0 kgt‘m, 7 lbt‘l‘t) Install the removed parts (page 14-2) in the reverse order oi removal. 14-21 MEMO 15. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 15.2 ENGINE REMOVAL 154 COMPONENT LOCATION 15.3 ENGINE INSTALLATION----------------------------15-7 15-1 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL ~ When removing/installing the engine, tape the lrame around the engine belorehand lor lrame protection. ~ When installing the engine, be sure to tighten the engine mounting lasteners to the specilied torque in the specitied sequence. Ii you make mistake in torque or sequence, loosen all mounting lasteners, then tighten them again to the specitied torque in the correct sequence. ~ The lollowmg components can be serviced with the engine installed in the lrame. — Oil pump (page 8-4) — Throttle body (page 7-11) — Camshalt (page 10-6) — Water pump (page 9-8) — Clutch (page 12-9) — Gearshilt linkage (page 12-14) — Stator/CKP sensor (page 13-4) — Flywheel (page 13-5) — Starter motor (page 6-4) ~ The lollowmg components require engine removal lor service. — Cylinder head/Valves (page 10-13) — Cylinder/piston (page 11-3) — Crankshaft (page 14-6) — Transmission (page 14-10) — Balancer (page 14-14) 1 5-2 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 27 N-m (2.3 (gm, ‘ 20 mm) ‘ ‘ 0° 3 ‘ 45 N-m (4.6 kgf-m, 33 Inf-n) ‘ :. ‘ ' ‘ 55 N-m (5.6 (gm, 41 lel) ( 5. - 45 N-m (4.6 Kgf-m, 33 lel) ‘ fig ' 55 N-m (5.6 Kgf-m, 41 mm) ( ‘a 3 ‘ ( ‘ § 1 5-3 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-9). Drain the coolant (page 9—5). Remove the lollowing: Frame guard (page 2-6) Skid plate (page 2-5) Throttle body (page 7-11) Exhaust pipe/mulller (page 2-11) Gearshilt pedal (page 12-14) Brake pedal (page 18-12) Disconnect the lollowing: — Spark plug cap [1] — PAIR air supply hose [2] Disconnect the 02 sensor cap [1] and ECT sensor 3P connector [2]. Disconnect the lollowing: — Alternator 3P connector [1] — CKP sensor/neutral switch 3P (Black) connector [2] Release the alternator wire [3] lrorn the clamp [4]. Open the harness band [1] and release the wires. Disconnect the VS sensor 3P (Blue) connector [2]. 1 5-4 ENGINE REMOVAL/INSTALLATION Remove the bolts [1] and clutch cable guide [2], then [4 disconnect the clutch cable [3] from the clutch litter arm I 1 [4]- Remove the starter motor mounting bolt [1] and ground terminal [2]. Release the rubber cap [3]. Remove the starter motor terminal nut [4] and starter motor cab|e terminal [5]. Disconnect the crankcase breather hose [6]. Release the VS sensor wire lrom the guide [7] Loosen the water hose band screws [1] and disconnect the water hoses [2]. Remove the bolt [1] and rear brake light switch holder [2]- 1 5-5 ENGINE REMOVAL/INSTALLATION The jack height must be continually adjusted ru relieve stress Iur ease ul bulr remuvsi. During engine removal, hold the engine securely and be care/iii not to damage me Irame and engine. Loosen the rear axle nut [1], look nuts [2] and drive ohain adjusters [3]. Push the rear wheel forward and make the drive chain slack fully. Remove the bolts [1], fixing plate [2] and drive sprocket [3]. Remove the rear engine hanger upper mounting nut [1] and bolt [2]. Remove the bolts [3] and engine hanger plate [4]. Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal. Remove the following: — Front upper engine mounting nut [1]/washer [2]/two collars [3]/bo|t [4] — Front lower engine mounting nut [5]/washer/oo||ar/ bolt [6] — Rear lower engine mounting nut [7]/bo|t [8] From the right side of the vehicle, slightly lift up the . engine and turn its lower rear side out of the frame, then remove the engine from the frame. [7mg [51/[21/[31/[6] 1 5-6 ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION During engine Place the engine inthe frame, then loosely install all the l inslallati'un. hulrlme bolts [1], collars [2], washers [3] and nuts. “gm secure” Tighten the rear lower engine mounting nut [4] to the and be careful nor . . m damage the specified torque. frame and engine. TORQUEMS N-m (4.6 kgf‘m, 33 lel) Tighten the front lower engine mounting nut [5] to the specified torque. Tonoua:55 NM (5.3 kngm, 41 rum) Tighten the front upper engine mounting nut [6] to the specified torque. Tonoua:55 NM (5.3 kngm, 41 rum) With the engine hanger plate [1] in position, tighten the engine hanger plate bolts [2] to the specilied torque. TORQUE:27 N-m (2.3 kgf‘m, 20 lel) Tighten the rear engine hanger upper mounting nut [3] to the specified torque. Tonouams NM (4.3 kngm, 33 rum) Install the drive chain [1] over the drive sprocket [2] with the “MT" mark [3] of the sprocket lacing out. Install the drive sprocket to the oountershaft. Install the Iixing plate [4]. Rotate the fixing plate and align the holes in the plate with the bolt holes in the sprocket. Install and tighten the drive sprocket Iixing plate bolts [5] to the specified torque. TORQUE: 10 MM (1.0 kngm, 1mm) 1 5-7 ENGINE REMOVAL/INSTALLATION Install the rear brake light switch holder [1] while ' aligning its tab with the frame hole. Install and tighten the bolt [2]. Connect the water hoses [1] and tighten the water hose band screws [2] (page 9-7). Connect the crankcase breather hose [1]. Route the VS sensor wire through the guide [2] Install and tighten the starter motor terminal nut [3] with starter motor cable terminal [4]. Install the rubber cap [5]. Install and tighten the starter motor mounting bolt [6] with ground terminal [7]. Connect the clutch cable [1] to the clutch lifter arm [2]. Install clutch cable guide [3] and tighten the bolts [4]. 1 5-8 ENGINE REMOVAL/INSTALLATION Close the harness band [1] and secure the wires. Connect the VS sensor 3P (Blue) connector [2]. Connect the lollowing: — Alternator 3P connector [1] — CKP sensor/neutral switch 3P (Black) connector [2] Secure the alternator wire [3] With the clamp [4]. Connect the 02 sensor cap [1]. - Take care no! to tilt the 02 sensor cap when connecting the cap to the 02 sensor. - Do no! turn [he 02 sensor cap after connecting it. Connect the ECT sensor 3P connector [2]. Connect the lollowing: — Spark plug cap [1] — PAIR air supply hose [2] Install the lollowmg: — Brake pedal (page 18-12) — Gearshilt pedal (page 12-17) — Exhaust pipe/mulller (page 2-11) — Throttle body (page 7-13) — Skid plate (page 2-5) — Frame guard (page 2-6) Inspect the following: — Drive chain slack (page 3-12) — Throttle grip lreeplay (page 3-3) — Clutch lever lreeplay (page 3-18) Fill the engine with the recommended engine 0“ (page 3-9). Fill the recommended coolant and bleed the air (page 9— 5). 1 5-9 MEMO 16. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION -----1e-2 FORK -------- ---1e-s TROUBLESHOOTING ------------ -----16-2 HANDLEBAR----- ----16-16 COMPONENT LOCATION--------------------------16-3 STEERING STEM ..................................... 15.21 FRONT WHEEL164 16-1 FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Raise the lront wheel oft the ground by supporting the lrame securely when servicing. For hydraulic brake system service (page 18-3). Alter the iront wheel installation, check the brake operation by applying the brake lever. TROUBLESHOOTING Hard steering ~ Steering bearing lork pipe too tight ~ Worn or damaged steering head bearings ~ Worn or damaged steering head bearing races ~ Damaged steering stem ~ lnsullicient tire pressure ~ Faulty lront tire Steers Io one side or does noI track straighl ~ Bent lork leg ~ Damaged or loose steering head bearings ~ Worn wheel bearings ~ Bent lront axle ~ Wheel installed incorrectly ~ Bent lrame ~ Worn swingarm pivot components (page 17-10) Front wheel wobbles ~ Bent rim ~ Worm or damaged wheel bearings ~ Faulty lront tire ~ Low tire pressure ~ Loose or broken spokes ~ Loose lront axle tasteners Wheel Iurns hard ~ Faulty wheel bearings ~ Bent axle ~ Brake drag (page 18-2) Sofl suspension ~ Weaklork springs ~ Low fluid level in iork ~ Wrong type ol iluid in lork ~ Low tire pressure StiI'I suspension ~ Bent lork pipes ~ Fork pipe binds ~ High iluid level in iork ~ Incorrect lluid weight (high viscosity) ~ Clogged lork lluid passage ~ High tire pressure Front suspension noise ~ Loose lork iasteners ~ Worn slider or iork pipe bushing ~ Low fluid level in iork 1 6-2 FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION [777‘ fi 103 Mm (10.5 Kgl-m, 7e lbf-ft) 1o N-m (1.0 kgf-m, 7 lel) 32 N-m (3.3 Kgl-m, 24 lbf-ft) 1o N-m (1.0 kgf-m, 7 lbf-ft) 32 N-m (3.3 Kgl-m, 24 lbl-ft) 20 N-m (2.0 kgl-m,15|bf-ft) 73.5 N-m (7.5 Kgl-m, 54 lbf-ft) 1o N-m (1.0 kgf-m, 7 mm) 30 N-m (3.1 kgf-m, 22 \bf-ft) 1 6-3 FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL REMOVAL/INSTALLATION Raise the lront wheel oil the ground by placing a work stand or box under the irame. Loosen the axle pinch bolts [1] on the right lork leg and remove the iront axle [2]. Remove lront wheel and side collars [3]. NOTE ' Do not operate the brake lever alter removing the wheel. To do so will cause diliiculty in fitting the brake disc between the brake pads. Apply thin coat ol grease to the axle outer suriace. Install the side collars to the both sides ol the wheel. Place the wheel between the fork legs while inserting the brake disc between the brake pads. Install the iront axle from the right side ol the vehicle, then tighten it to the specified torque. TORQUE: 73.5 N-m (7.5 kgl-m, 54 lbl-l‘t) With the iront brake applied, pump the iorks up and down several times to seat the axle and check the brake operation. Tighten the axle pinch bolts to the specilied torque. TORQUE: 20 N-m (2.0 kgf—m,15lbf—ll) INSPECTION Turn the inner race at each bearing With your iinger. The bearings should turn smoothly and quietly. Also check that the bearing outer race lits tightly in the hub. Replace the bearings it they do not turn smoothly, quietly, or it they tit loosely in the hub. Inspect the lollowing parts lor damage, abnormal wear, delormation, looseness or bend. — Frontaxle — Spoke — Wheel rim Measure each pan according to FRONT WHEEL/ SUSPENSION/STEERING SPECIFICATIONS (page 1- 8). Replace any part il it is out of service limit. 1 6-4 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY/ASSEMBLY Disassemble and assemble the front wheel as lollowing illustration. 0,—6.4 v RIGHT DUST SEAL 9 F64 LEFT WHEEL BEARING (6202U) RIGHT WHEEL BEARING ()6202U DISTANCE COLLAR BRAKE DISC BOLTS g 20 N-m (2.0 kgf-m,15|bl-ll) .4 LEFT DUST SEAL BRAKE DISC BEARING REPLACEMENT Install the remover head [1] into the bearing. From the opposite side ol the wheel, install the remover shaft [2] and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: [1] Bearing remover head, 15 mm 07746-0050400 [2] Bearing remover shall 07746-0050100 Pack new bearing cavities With grease. Drive in a new left side (brake disc side) bearing [1] squarely With the sealed side lacing up until it is fully seated. TOOLS: [2] Driver 07749-0010000 [3] Attachment, 32 x 35 mm 07746-0010100 [4] Pilot, 15 mm urns-0040300 Install the distance collar. Drive in a new right side bearing with the sealed side lacing up until its inner race is lully seated on the distance collar. 1 6-5 FRONT WHEEL/SUSPENSION/STEERING WHEEL CENTER ADJUSTMENT Adjust the hub position so that the distance lrom the left end surface [1] ol the hub center to the side ol rim [2] is [2] within the lollowing specification as shown. _ . WHEEL HUB-TO-RIM DISTANCE: ‘ 23.45 t 1.0 mm (0.92 t 0.04 in) l ‘ WHEEL RIM FlUNOUT: ‘ Radial: 2.0 mm (0.08 in) or less [1] Axial: 2.0 mm (0.08 in) or less Tighten the spokes in 2 or 3 progressive steps. TOOL: Spoke wrench, 5.8 x 6.1 mm 0770143020300 1 fl TORQUE: 3.7 N-m (0.4 kgf—m, 2.7 lbl-ft) FORK REMOVAL Remove the lront wheel (page 16-4). Lelt side oni .. ~< Remove the lollowing lrom the left lork leg: [3] Bolts [1] [1] Brake hose clamp [2] Brake caliper mounting bolts [3] Brake caliper [4] [2] [4] — Socketbolts [1] — Fork protectors [2] 1 6-6 Leif side: Left side: Remove the bolt [1] and brake hose guide [2]. Loosen the lork top bridge pinch bolts [3]. [1] ll you will disassemble the fork, loosen the lork cap [4], but do not remove it. Loosen the fork bottom pinoh bolts [1] while supporting the lork leg. Pull the lork leg down and remove it out ol the fork bridges. INSTALLATION Install the outer tube into the bottom and top bridges. Align the top of the outer tube with the upper surface of [5] the top bridge. Tighten the bottom bridge pinch bolts [1] to the specified torque. TORQUE: 32 Nm (3.3 kgf‘m, 24 let) Tighten the lork cap [2] to the specified torque if it was removed. TORQUE: 35 Nm (3.6 kgf‘m, 26 let) Tighten the top bridge pinch bolts [3] to the specified torque. TORQUE: 32 Nm (3.3 kgf‘m, 24 let) Install the brake hose guide [4] and tighten the bolt [5] to the specified torque. TORQUE: 10 Nm (1.0 kgrm, 7 lbl-ft) FRONT WHEEL/SUSPENSION/STEERING 1 6-7 FRONT WHEEL/SUSPENSION/STEERING Install the lork protectors [1]. Install and tighten the new socket bolts [2] to the specified torque. TORQUE: 7.0 NM (0.7 kgf‘m, 5.2 lbl-ft) Install the brake hose clamp [1] to the lelt lork leg and . . tighten the bolts [2] to the specilied torque. Left S'de only. , TORQUE: 10 Nm (1.0 kgf‘m, 7 lbl-ft) Install the brake caliper [3] with new mounting bolts [4] and tighten them to the specified torque. TORQUE: 30 NM (3.1 kgf‘m, 22 Ile) Install the front wheel (page 16-4). Inspect the wear rings [1] for wear or damage. Replace the wear ring, if it is 1.5 mm (0.06 in) or flat with the outer tube. DISASSEMBLY NOTE - Clean the fork assembly, the sliding surface of the fork pipe and bottom ol the slider around the center bolt before disassembling the Iork. Lelrsi'rle: 53$;le lork pipe in a Vise with solt Jaws or shop Leltside only: Loosen the fork center bolt [1], but do not remove it yet. 1 6-8 FRONT WHEEL/SUSPENSION/STEERING Righlside talk cap Completely loosen the fork cap bolt [1] and lower the ball I5 under spring outer tube [2]. [1] pressure: use care when loosening it. ‘L. Pour out the fork fluid by pumping the lork pipe up and down several times. - ”III: III!!!” Rightside: Push the fork cap [1] down and compress the fork spring, then remove the stopper ring [2] from the groove in the lork pipe. Right side only: Remove the lork rod assembly [3]. Rightside: Loosen the look nut [1] while holding the lork cap [2] . . . with a wrench, then remove the lork cap. nghl slde °"IV' [2] Remove the O-rlng [3] from the lork cap groove. Remove the spring seat [4] and rebound spring [5]. [3] [1 ] [4] [5] 1 6-9 FRONT WHEEL/SUSPENSION/STEERING Rignrside: Remove the lork spring [1]. Right side only: Lelrside: Loosen the lock nut [1] while holding the lork cap [2] with a wrench, then remove the lork cap. Le“ side only: 2 Remove the O-ring [3] from the lork cap groove. [ ] Left side: Remove the lollowing: — Fork center bolt [1] — Sealing washer [2] / _ y 251.: Le‘ft side only: 7'\. Left side only: Lelrside: — lnnerdamper[1] 16-10 FRONT WHEEL/SUSPENSION/STEERING Becarelulnmla — Dustseal[1] scratch the/ark — Stopper ring [2] We Sliding SW5” Check that the lork pipe [3] moves smoothly in the outer tube [4]. ll the movement is not smooth, check the lork pipe lor bend or bushing for wear or damage. ll they are normal, inspect the outer tube. Using quick successive motions, pull the fork pipe [1] out of the outer tube [2]. The guide bushing will be lorced out by the lork pipe bushing. Do not damage the Carefully remove the slider bushing [1] by plying the sliderbushi‘ng, slot With a screwdriver until the slider bushing can be especially the pulled off by hand. sliding surlace. Ta prevent loss 0/ tenslun. du nu! — Guide bushing [2] apenlhe slider — Back—up ring [3] bushing murelhan — Oil seal [4] necessary. — Stopper ring [5] — Dust seal [6] Remove the Iollowing: INSPECTION Inspect the Iollowing parts Ior damage, abnormal wear, bend, delormation, scoring and teflon coating wear — Forkpipes — Outertubes — Forkspring — Sliderbushings — Guide bushings — Back—up rings Measure each part according to FRONT WHEEL/ SUSPENSION/STEERING SPECIFICATIONS (page 1- 8). Replace any part il it is out of serVice limit. 16-11 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY Beiore assembly, wash all parts with a high Ilash point or non-Ilammable Solvent and wipe them all complelely. RIGHT SIDE FORK CAP LOCK NUT 35 N-m (3.6 kgf-m, 26 IbI-fl) 20 N-m (2.0 kgl-m,15|bf-ft) SPRING SEAT STOPPER RING REBOUND SPRING FORK PIPE a 3! o—RING \ OUTER TUBE GUIDE BUSHING a BACK-UP RING a OIL SEAL g a STOPPER RING FORK ROD a WEAR RING FORK SPRING DUST SEAL v a LEFT SIDE LOCK NUT FORK CAP 20 N-m (2.0 kgf-m, 15 lbf-ft) 35 N-m (3.5 kgf-m, 26 lbl-ll) *7 w \ v O-RING FORK PIPE SLIDER BUSHING a OUTER TUBE GUIDE BUSHING a 3 J BACK-UP RING , / OIL SEAL v STOPPER RING s11 ‘ I» DUST SEAL l‘ I“ I; I / g3 g SEALING WASHER / ~ \ m WEAR RING SEEK ”SITE? 333m n INNER DAMPER 'mI ‘ g 'm’ I ) 16-12 FRONT WHEEL/SUSPENSION/STEERING Wrap the end of the fork pipe With tape [1]. Coat new fork oil seal [2] and dust seal [3] lips with recommended fork oil. Install the dust seal and stopper ring [4] onto the fork pipe. Install the oil seal onto the fork pipe with its marked side facing the dust seal. Remove the tape from the end of the fork pipe. Install the back-up ring [1], guide bushing [2] and slider bushing [3]. NOTE - Be careful not to damage the slider bushing coating. Do not open the slider bushing more than necessary. Install the back-up ring with its flange side facing toward the guide bushing. - Remove the burrs from the bushing mating surface, being careful not to peel off the coating. [1] [2] Coat the guide bushing and slider bushing with recommended fork oil, and install the fork pipe [1] into the outer tube [2]. Drive in the oil seal [1] into the outer tube using the special tool. TOOL: [2] Fork seal driver, 43.2 mm 07VMD-MCF0100 16-13 FRONT WHEEL/SUSPENSION/STEERING Install the stopper ring [1] into the groove in the outer tube [2], being careful not to scratch the fork pipe [3]. Install the dust seal [4] into the outer tube. Lelr side: Install the inner damper [1] into the fork pipe. aside only: [1] Lelrside: Apply looking agent to the fork center bolt [1] threads and install it with a new sealing washer [2]. Left side only: a [2] Lelrside: Hold the left lork pipe in a VlSe with soft jaws or shop towels. Left side only: Tighten the fork center bolt [1] to the specified torque. TORQUE: 2D N‘m (2.0 kgf‘m, 15 Ile) 16-14 Right side: Right side: FRONT WHEEL/SUSPENSION/STEERING Pour the specified amount of recommended fork fluid into the fork pipe. RECOMMENDED FORK FLUID: Honda ULTRA CUSHION OIL (10W) or equivalent FORK FLUID CAPACITY: Right side: 658 1 2.5 cm“ (22.3 1 0.08 US oz, 23.2 1 0.09 Imp oz) Left side: 633 1 2.5 cm“ (23.1 1 0.08 US oz, 24.0 1 0.09 Imp oz) Slowly pump the fork pipe several times to remove the trapped air from the lower ponion of the fork pipe. Compress the fork pipe fully and leave it for 5 minutes to remove air bubbles from the fluid. Measure the oil level from the top of the fork pipe by supporting the fork leg vertically. FORK OIL LEVEL: Right 5‘ e: 122 mm (4.8 in) Left side: 38 mm (1.5 in) Install the fork spring [1] with the tapered side facing up. Flight side only' Loosen the lock nut [1] until it stops. Right side only: Install the rebound spring [2] to the fork rod. 5 I4] @ a Install the spring seat [3] in the shown direction. I I V Apply recommended fork oil to a new O-ring [4], and I1] - install it to the fork cap [5]. ‘ Install the fork cap to the fork rod and tighten it until it , r stops. Hold the fork cap with a wrench, then tighten the lock nut to the specified torque. / [1] TORQUE: 20 N-m (2.0 kgf—m,15lbf—II) [3] l2] 16-15 FRONT WHEEL/SUSPENSION/STEERING Rights/He: Push the fork cap [1] down and compress the fork spring, then install the stopper ring [2] into the groove in the lork pipe. Right side only: Lelrsirle: Loosen the lock nut [1] untII it stops. Left side only: Apply recommended lork oil to a new O-ring [2], and install it to the fork cap [3]. Install the fork cap to the inner damper and tighten it until it stops. Hold the lork cap with a wrench, then tighten the lock nut to the specified torque. TORQUE: 20 Nm (2.0 kgf‘m, 15 lel) Completely extend the outer tube [1]. Install and tighten the lork cap [2] into the outer tube. Tighten the fork cap to the specified torque after installing the fork leg into the steering stem (page 16-7). [1] HANDLEBAR REMOVAL Remove the lollowing: — Wire bands[1] — Rearview mirrors [2] 16-16 FRONT WHEEL/SUSPENSION/STEERING Bolts [1] Bracket holder [2] Clutch lever bracket [3] Clutch switch connectors [4] — Screws [1] — Left handlebar switch housing [2] — Left handlebar grip [1] Keep the reserve” Brake light swttch connectors [1] upright ta prevent — Bolts [2] errtmm entermg — Master cylinder holder [3] the hydraulic — Brake master cylinder [4] system. 16-17 FRONT WHEEL/SUSPENSION/STEERING — Sorews[1] — Right handlebar switch [2] — Sorews[1] — Throttle housing cover [2] — Bolts[1] — Handlebar upper holders [2] — Handlebar[3] Pull out the handlebar [1] from the throttle pipe [2]. [2] Remove the tollowing: — Throttle cables [3] — Throttle pipe — Throttle housing [4] [41 [a] 16-18 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Apply grease to the cable rolling area of the throttle pipe [1] Ilange. .‘4 Connect the throttle cables [2] to the throttle pipe. Insert the handlebar [3] into the throttle pipe. [1] Align thepunch Install the handlebar and upper holders [1] with the mark an the punch marks [2] lacing forward. handlebar wllhme Install the bolts [3], tighten the front bolts Iirst, then top edge of the tighten the rear bolts securely. lowerholder. Install the throttle housing cover [1] by aligning its boss with the hole of the handlebar. Install the screws [2], tighten the upper screw first, then tighten the lower screw. Check the throttle grip Ior smooth operation. Install the right handlebar switch cover [1] by aligning its boss With the hole of the handlebar. 16-19 FRONT WHEEL/SUSPENSION/STEERING Install and tighten the upper screw [1] first, then tighten the lower screw [2] to the specified torque. TORQUE: 2.5 NM (0.3 kgf‘m, 1.8 lbl-ft) If the left handlebar grip [1] was removed, apply Honda Bond A or equivalent to the inside surface of the grip and to the clean surface of the handlebar. Allow the adhein/e Wait 3 — 5 minutes and install the grip. Rotate the grip m dry for 1 haul for even application of the adhesive. ”Elma ”5mg Position the handlebar grip so that the projection [2] of the grip is aligned With the punch mark [3] ol the handlebar. Install the left handlebar sWitch cover [1] by aligning its boss With the hole of the handlebar. Install and tighten the upper screw [1] first, then tighten the lower screw [2] to the specified torque. [1] TORQUE: 2.5 NM (0.3 kgf‘m, 1.8 lbl-ft) 16-20 FRONT WHEEL/SUSPENSION/STEERING Align the edge u! Install the brake master cylinder [1] and holder [2] with the master cylinder the “UP" mark [3] facing up. wlth the punch Install the bolts [4] and tighten the upper bolt Ilrst, then mark an the tlghten the lower bolt to the specified torque. handlebar. TORQUE: 93 Nm (1.0 kgf.m,1.2|bl-tt) [1] Align Connect the brake light switch connectors [5]. Align the edge 0/ Install the clutch lever bracket [1] and holder [2]. the bracket with the Install the bolts [3] and tighten the upper bolt Ilrst, then punch mark an the tlghten the lower bolt. handlebar' Connect the clutch switch wire connectors [4] Secure the WIres with the wire bands [1]. Install each rearview mlrror [2] and tighten the lock nut. Check the throttle grip Ireeplay (page 3-3). STEERING STEM REMOVAL Remove the Iollowing: — Front lender (page 2—5) — Headlight cowl (page 2-5) — Handlebar (page 16-16) — Front wheel (page 16-4) Disconnect the ignition switch 3P (Brown) connector [1]. Release the lgnltion switch wire Irom the harness bands [2]. Remove the bolts [3] and meter stay [4]. 16-21 FRONT WHEEL/SUSPENSION/STEERING Remove the bolt [1] and brake hose guide [2]. Remove the steering stem cap [1]. Loosen the steering stem nut [2]. Remove the lork legs (page 16-6). Remove the stem nut, washer [3] and top bridge [4]. Loosen the steering stem adjusting nut [1] using the special tool. TOOL: [2] Stem socket wrench 07916-KA50100 While holding the steering stem, remove the adjusting nut. Remove the tollowing: — Upper dust seal [1] — Upper steering bearing [2] — Steering stem [3] Inspect the bearings and outer races lor wear or damage. ll necessary, replace them as a set (page 16—23). 16-22 Always replace the bearings and races as a set. FRONT WHEEL/SUSPENSION/STEERING BEARING REPLACEMENT Remove the upper and lower bearing outer races [1] using the special tools. TOOLS: [2] Ball race remover 079484630100 [3] Remover shaft 07953-KA50000 Install the stem nut [1] onto the stem to prevent the threads from being damaged when removing the lower bearing [2]. Remove the lower bearing and lower dust seal [3] with a chisel or equivalent tool, being carelul not to damage the stem. [1] Apply specilied grease (page 16-24) to a new lower dust seal [1] lip and install it over the steenng stem. Press a new lower bearing [2] using a special tool. TOOL: [3] [3] Driver, 28 mm 079464300101 3 v [2] Drive in new upper and lower bearing outer races [1] into the steering head pipe. [2] r 07749-0010000 [3] Driver attachment, 42 x 47 mm 0774643010300 [3] 16-23 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION 1o N-m (1.0 mm, 7 lbI-It) g '6' ADJUSTING NUT ‘7. STEM CAP UPPER DUST SEAL STEM NUT A 103 N-m (10.5 mm, 76 lbI-It) s! HOSE GUIDE % UPPER STEERING BEARING WASHER M UPPER OUTER RACE TOP BRIDGE £9.61 LOWER OUTER RACE KLOWER STEERING BEARING METER STAV LOWER DUST SEAL STEERING STEM 10 N- -m 1.0 kgI- rn 7 Ibf-ft) HOSE GUIDE Apply 3 - 5 g (0.11 - 0.18 oz) ol specified grease (Urea ”'1 based multi-purpose grease with extreme pressure a v agent (example: Kyodo Yushi, EXCELITE EP2 or equivalent) to each new bearing and till it up. Apply specified grease to a new upper dust seal [1] lip. Insert the steering stem [2] into the steering head pipe, and install the following while holding the stern. — upper steering bearing [3] — upperdustseal Apply engine oil to the steering stern adjusting nut [1] threads. Install and tighten the adjusting nut to the initial torque using the special tool. TOOL: [2] Stem socket wrench 07916-KA50100 TORQUE: 29.5 NM (3.0 kgl-m, 22 lbI-I‘t) 16-24 FRONT WHEEL/SUSPENSION/STEERING Turn the steering stem [1] right and Ielt, lock-to—Iook several times to seat the bearings. Completely loosen the adjusting nut [2]. Retighten the adjusting nut [1] to the specified torque using the special tool. TOOL: [2] Stem socket wrench 07916-KA50100 TORQUE: 6.5 N‘m (0.7 kgrm, 4.8 lbl-ft) Install the top bridge [1]. washer [2] and stem nut [3]. Temporarily install the outer tube into the bottom and top bridges. Tighten the stem nut to the specified torque. TORQUE: 103 Mm (10.5 kgl-m, 76 Ile) Make sure the steering stem moves smoothly Without /. play or binding. Install the steering stem cap [1]. 16-25 FRONT WHEEL/SUSPENSION/STEERING lnstall brake hose guide [1] and tighten the bolt [2] to the specified torque. TORQUE: 10 Nm (1.0 kgf‘m, 7 lbl-ft) Install the meter stay [1] and tighten the bolts [2]. Secure the ignition switch Wire with the harness bands [3]- Connect the ignition switch 3P (Brown) connector [4]. Install the lollowmg: — Front wheel (page 16-4) — Handlebar (page 16-19) — Headlight cowl (page 2-5) — Front lender (page 2—5) STEERING BEARING PRE-LOAD Raise the lront wheel ofl the ground by placing a work stand or box under the frame. Position the steering stern straight ahead. Hook a spring scale to the outer tube between the fork top and bottom bridges. Make sure there is no cable, Wire harness or hose interlerence. Pull the spring scale keeping it at a right angle to the steering stem. Read the scale at the point where the steering stem just starts to move. STEERING BEARING PRE-LOAD: 10.6 — 21.2 N (1.08 — 2.16 kgf, 2.33 — 4.77 lbf) lithe readings do not fall within the limits, readjust the steering bearing. 16-26 17. REAR WHEEL/SUSPENSION SERVICE lNFORMATION------ -----17-2 SHOCK ABSORBER ------- ---17-6 TROUBLESHOOTING ------------ -----17-2 SHOCK LINKAGE ------------ ----17-7 COMPONENT LOCATION--------------------------17-3 SWINGARM .............................................. 17.10 REAR WHEEL17-4 DRIVE CHAIN GUIDE ............................... 17.12 17-1 REAR WHEEL/SUSPENSION SERVICE INFORMATION GENERAL ~ Raise the rear wheel oil the ground by supporting the trame securely when servicing. A box or work stand is required to support the motorcycle. ~ The shock absorber contains nitrogen under high pressure. Do not allow tire or heat near the shock absorber. ~ Beiore disposal oi the shock absorber, release the nitrogen (page 17-7). ~ A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. ~ Use only Honda Genuine replacement bolts and nuts tor all suspension linkage and swingarm pivot mounting points; ordinary bolts lack adequate strength lor these applications. Also take note ol the installation direction oi these bolts since they must be installed correctly. ~ For hydraulic brake system service (page 18-3). ~ Alter the rear wheel installation, check the brake operation by applying the brake pedal. ~ For drive chain information (page 3-12). TROUBLESHOOTING Sofl suspension ~ Incorrect suspension adjustment ~ Weak shock absorber spring ~ Oil leakage irom damper unit ~ Low tire pressure Stifl suspension ~ Incorrect suspension adjustment ~ Bent shock absorber damper rod ~ Damaged suspension or swingarm pivot bearings ~ Bent swingarm pivot or irame ~ High tire pressure Steers to one side or does not track straight ~ Drive chain adjusters not adjusted equally ~ Bent axle ~ Bent trame ~ Worn swingarm pivot components Rear suspension noise ~ Loose suspension lasteners ~ Worn or damaged suspension pivot bearings ~ Faulty shock absorber Rear wheel wobbles Bent rim Worn or damaged rear wheel bearings Faulty rear tire Low tire pressure Loose or broken spokes Worn or damaged swingarm bearings Bent trame or swingarm Axle tastener not tightened properly Wheel turns hard ~ Faulty wheel bearings ~ Bent axle ~ Drive chain too tight (page 3-12) ~ Brake drag (page 18-2) 1 7-2 REAR WHEEL/SUSPENSION COMPONENT LOCATION 54 N-m (5.5 kgf-m, 40 (but) as N-m (9.0 kgl-m, 55 mm) 1.2 N-m (0.1 kgf-m, 0.9 1111-11) as N-m (9.0 kgf-m, 55 mm) 9 74 N-m (7.5 191% 55 lbf-fl) V3 10 N-m (1.0 kgf-m, 7 1111-11) 2.5 N-m (0.3 kgl-m, 1.3 mm) 1 7-3 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL/INSTALLATION Loosen the axle nut [1] Raise the rear wheel off the ground by placing a work / [I4 C ' stand or box under the frame Loosen the lock nuts [2] and turn in the drive chain adjusters [3] completely. Remove the axle nut and right drive chain adjuster plate [4]- Push the wheel forward and derail the drive chain [1] from the driven sprocket. Support the caliper Remove the following: soildoes norhang _ MHZ] from the brake - . — Left chain adjuster plate [3] hose. Du nu! fwls! _ R e a, wh e 9' the brake hose. _ Side C wars I 4] NOTE - Do not operate the brake pedal after remoVing the wheel. To do so will cause difficulty in fitting the brake disc between the brake pads. Remove the rear brake caliper bracket [1] from the guide rail [2] of the swingarm. Install the rear wheel in the reverse order or removal. - Apply thin coat of grease to the axle outer surface. Adjust the drive chain slack (page 3-12). INSPECTION Turn the inner race of each bearing With your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Replace the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub. Inspect the following parts for damage, abnormal wear, deformation, looseness or bend. — Rearaxle — Spoke — Wheel rim Measure each part according to REAR WHEEL/ SUSPENSION SPECIFICATIONS (page 1-8). Replace any part if it is out of sen/ice limit. 1 7-4 REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY Disassemble and assemble the rear wheel as lollowing illustration. Va 'fii BEAR'NG (6303”) BRAKE DISC sons 9 s’ ,6 DUST SEAL 42 N m (4.3 kgf m, 31 lbl ll) DRIVEN SPROCKET NUTS 50 N-m (5.1 kgi-m, 37 lbl-ft) \ /-A\ WASHERS 2. l b DRIVEN SPROCKET DISTANCE COLLAR DRIVEN SPROCKET BRAKE DISC DUST SEAL BEARING REPLACEMENT Install the remover head [1] into the bearing. From the opposite side of the wheel, install the bearing remover shalt [2] and drive the bearing out ol the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: [1] Bearing remover head, 17 mm 07746-0050500 ' [2] Bearing remover shall 07746-0050100 Pack new bearing cavities With grease. Drive in a new right side (brake disc side) bearing [1] squarely With the sealed side lacing up until it is fully seated. TOOLS: [2] Driver 07749-0010000 [3] Attachment, 42 x 47 mm 07746-0010300 [4] Pilot, 17 mm urns-0040400 Install the distance collar. Drive in a new left side bearing with the sealed side lacing up until its inner race is lully seated on the [ distance collar. ' ' REAR WHEEL/SUSPENSION SHOCK ABSORBER WHEEL CENTER ADJUSTMENT Adjust the hub position so that the distance lrom the right end surlace [1] of the hub center to the side ol rim [2] is Within the lollowing specification as shown. WHEEL HUB-TO-RIM DISTANCE: 26.9 t 1.0 mm (1.06 t 0.04 in) 2.0 mm (0.08 in) or less .0 mm (0.08 in) or less Tighten the spokes in 2 or 3 progressive steps. TOOL: Spoke wrench, 5.8 x 6.1 mm 07701-0020300 TORQUE: 3.7 N-m (0.4 kgt-m, 2.7 lbI-ft) REMOVAL/INSTALLATION Raise the rear wheel off the ground by placing a work stand or box under the frame. Remove the sub—frame (page 2-12). Remove the upper mounting nut [1] and bolt [2]. Remove the lower mounting nut [3], bolt [4] and shock absorber [5]. Installation is in the reverse order ol removal. TORQUE: Shock absorber upper mounting nut: 54 MM (5.5 kgf—m, 4o lbI-fl) Shock absorber lower mounting nut: 44 NM (4.5 kgf—m, 32 IbI-fl) . [31/[4] INSPECTION Inspect the lollowing parts lor damage, abnormal wear, deformation, oil leakage or bend. — Damper rod — Damper unit — Bushing II the shock absorber is replaced, reler to shock absorber disposal procedure (page 17-7). 1 7-6 REAR WHEEL/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper case to mark the drilling point as shown. Wrap the shock absorber [1] inside a plastic bag. Support the shock absorber upright in a Vise as shown. Through the open end of the bag, insert a hand drill with a sharp 3 mm drill bit. NOTE - Point the drill hole away from you to prevent debris getting in your eyes. Hold the bag around the hand drill and briefly run it inside the bag; this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start. Drill into the shock absorber at the center punch mark to purge the nitrogen gas. Once all the nitrogen gas has been purged from the shock absorber and it is no longer under pressure. the item can be disposed of. SHOCK LINKAGE REMOVAL/INSTALLATION Raise the rear wheel off the ground by placing a work stand or box under the frame and support the swingarm. Remove the rear brake pedal return spring [1]. Remove the lollowing: — Shook absorber lower mounting nuUboIt [1] — Shook link-to-shock arm nut/bolUwasher [2] — Shook arm-to-swingarm nut/bolt/washer [3] — Shook arm [4] — Shook Iink-to-lrame nut/bolt [5] — Shook link [6] Installation is in the reverse order of removal. - Apply engine oil to the shock arm-to-swingarm nut threads. - Before tightening the nuts to the specified torque, install all the nuts, bolts and washers. TORQUE: Shock link-to-frame nut: 44 Nm (4.5 kgrm, 32 mm) Shock arm-to-swingarm nut: 74 N‘m (7.5 kgf‘m, 55 lbf‘ll) Shock Ii k-to-shock arm nut: 44 Nm (4.5 kgrm, 32 mm) Shock absorber lower mounting nut: 44 Nm (4.5 kgrm, 32 mm) 1 7-7 REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY Disassemble and assemble the shock linkage as tollowing illustration. ' Install the swingarm side shock arm dust seals to the specitied depth. ' Install other dust seals until they are fully seated on the bearings. 0.8—1.2 0.03—0.05' .. mm}. In) fiNEEDLE BEARING 0 8—1. 2 mm (0. 03— O 05 In) DUST SEAL (20 X 26 X 20) " 93:“; (20 x 25 x 4 5) - a? 6 Eng" v gfi\0\g DUSTSEAL \ / (20x2ex45) \ / o r @052 a g '6' My COLLAR (SWING NEEDLE BEARING KO ARM SIDE) E (17 x 24 x 17) SHOCK LINK COLLAR W( 3! '61 SHOCK ARM DUST SEAL g E 004/ (17 x 24 x 5) DUST SEAL (17 x 24 x 5) DUST SEAL / (17 x 24 x 5) ( 31' fan/09y \/> NEEDLE BEARING (17 x 24 x 25) / '6' (@ COLLAR (SHOCK SHOCK LINK COLLAR (SHOCK LINK SIDE ABSORBER SIDE) '6' ) NEEDLE BEARING (17 X 24 X 25) INSPECTION Inspect the tollowing parts tor damage, abnormal wear, detormation or crack. — Collars — Shock arm — Needle bearings — Shock linK BEARING REPLACEMENT SHOCK ARM Press the shock absorber and shock link side needle bearings [1] out of the shock arm using the special tool. SHOCK ABSORBER/ SHOCK LINK SIDE TOOLS: Shock nk and shock absorber side: [2] Driver 079494710001 [3] Attachment, 22 x 24 mm 07745-0010300 [SI/[4] [4] Pilot 17 mm 07745-0040400 [5] Fork seal driver attachment, 07746-0010300 27.2 mm 1 7-8 REAR WHEEL/SUSPENSION Press in the bearing with the marked side facing up. Press in the bearing with the marked side facing up. Press the swingarm side needle bearings [1] out of the shock arm using the special tool. TOOLS: Swingarm side: [2] Driver 07949-3710001 [3] Attachment, 24 x 26 mm 07746-0010700 [4] Pilot, 20 mm 077400040500 [5] Fork seal driver attachment, 07746-0010300 27.2 mm Apply grease to the needle rollers of new bearings [1]. Carefully press each needle bearing in the pivot until the depth from the arm outer surface is 5.8 — 6.2 mm (0.23 —0.24 in). TOOLS: Shock Link and Shock Absorber side: [2] Driver 07749-0010000 [3] Attachment, 22 x 24 mm 07746-0010300 [4] Pilot, 17 mm 07746-0040400 [5] Fork seal driver attachment, 07746-0010300 27.2 mm Apply grease to the needle rollers of new bearings [1]. Carefully press each needle bearing in the pivot until the depth from the arm outer surface is 8.8 — 9.2 mm (0.35 — 0.36 in). TOOLS: Swingarm side: [2] Driver 07749-0010000 [3] Attachment, 24 x 26 mm 07746-0010700 [4] Pilot, 20 mm 07746-0040500 [5] Fork seal driver attachment, 07746-0010300 27.2 mm SHOCK LINK Remove the needle bearing [1] lrom the shock link using the special tools. TOOLS: [2] Bearing remover, 17 mm 07936-3710300 [3] Remover weight 07741-0010201 Remover handle 07936-3710100 SWINGARM SIDE - SHOCK ABSORBER/ SHOCK LINK SIDE [2] [31/ [4] [31/ [4] 5.8 — 6.2 mm (0.23 — 0.24 m) .6: 1 - SWINGARM SIDE [2] [31/ [4] Cl [1] 8.8 — 9.2 mm a (0.35 — 0.36 in) v ,6: J ' [11 ‘ I , \ )4 1 7-9 REAR WHEEL/SUSPENSION Apply grease to the needle rollers of new bearings. 5.8 _ e 2 mm Press/h the bearing Carefully press the needle bearing in the pivot until the (0.23 —0.24 in) wim the marked depth from the link outer surlace is 5.8 — 6.2 mm (0.23 — . side facing up. 0.24 in). i TOOLS: [21 [am ( [2] Driver 07749-0010000 [3] Attachment, 22 x 24 mm 07746-0010800 [4] Pilot, 17 mm ems-0040400 fr—II / [‘1 ._\ l“ , K l i 4.5 ‘ d [1] 5.8 — 6.2 mm Iv ,6... (0,23 — 0.24 in) SWINGARM REMOVAL/INSTALLATION Remove the lollowing: — Rear wheel (page 17-4) — Dnve chain guide (page 17—12) Remove the shock arm-to-swingarm nut [1], washer [2] and bolt [3]. Remove the screws [1] and brake hose guides [2]. Remove the bolts [1] and drive chain case [2]. 7 17-10 REAR WHEEL/SUSPENSION Remove the swingarm pivot nut [1]. Remove the swingarm pivot bolt [2], then remove the swingarm lrom the lrame. Remove the swingarm dust seal caps [1]. Installation is in the reverse order ol removal. - Apply thin coat of grease to the pivot bolt outer surface. - Apply grease to the dust seal cap lips and lill the gap between the caps, collar and needle bearings with grease. - Align the drive chain case slot with the swingarm hook. - Apply engine oil to the threads of shock arm-to- swingarm nut. TORQUE: Swingarm pivot nul: as NM (9.0 kgl-m, 65 lbl-ft) Shock arm-to-swingarm nut: 74 Nm (7.5 kgl-m, 55 lbl-ft) Rear brake hose guide mounting screw: 1.2 NM (0.1 kgl-m, 0.9 let) DISASSEMBLY/ASSEMBLY Disassemble and assemble the swrngarm as following illustration. - Apply Honda Bond A or equivalent to the swingarm rubber cap mating surface with swingarm. CHAIN CASE STAV SCREW g 4.2N-m 0.-4kgfm 31mm) SWINGARM RUBBER CAPS r-EICOLLAR NEEDLE BEARINGS 3" DUST'EI SEALS CHAIN SLIDER SCREWS SWINGARM I O a} 4.2 N-m (0.4 mm, 3.1 lbf-lt) 17-11 REAR WHEEL/SUSPENSION BEARING REPLACEMENT Remove the pivot bearings [1] and dust seals [2] using the special tool. TOOLS: [3] Bearing remover, 20 mm 07936-3710600 [4] Remover weight 07741-0010201 [2] Remover handle 07936-3710100 Apply grease to the needle rollers ol new bearings [1] and new dust seal [2] lips. Install the dust seals to the specified depth with the marked side lacing in. Press the needle bearings to the specilied depth with the marked side lacing up, using the special tools. [4] s! ,6. I31 [1] » t ‘ s . c [41451 > x '4 TOOLS: / [3] Driver 07949-3710001 , / [4] Attachment, 24 x 26 mm 07746-0010700 ’ [5] Pilot 20 mm 07746-0040500 ‘ [6] Fork seal driver attachment, 07747-0010400 20 mm Left side: 27-0_27>5 mm Right side: 3204425 mm (1.06 — 1.08 in) (1.26 — 1.28 in) [1] i 7.0 — 7.5 mm [2] l2] . . (0.23—0.30 in) 12.0—12.5 mm (0.47 — 0.49 ln) DRIVE CHAIN GUIDE REMOVAL/INSTALLATION Remove the two nuts [1], screws [2] and chain slider guide [3]. Remove the bolts [4] and drive chain guide [5]. Installation is in the reverse order ol removal. - Replace the chain guide mounting bolts with new ones. TORQUE: Chain guide mounting bolt: 10 NM (1.0 kgI-m, 7 lbl-lt) Chain slider guide mounting nut: 2.5 N-m (0.3 kgI-m,1.8lbf—It) 17-12 18. BRAKE SYSTEM SERVICE INFORMATION ........................... 13.2 TROUBLESHOOTING ................................. 13.2 COMPONENT LOCATION .......................... 13.3 BRAKE FLUID REPLACEMENT] AIR BLEEDING ........................ ---1s-4 BRAKE PAD/DISC ...................................... 13.5 FRONT MASTER CYLINDER---------------------18-7 REAR MASTER CYLINDER ....................... 13.3 FRONT BRAKE CALIPER ........................ 13.10 REAR BRAKE cAL|pER .......................... 13.11 BRAKE PEDAL ......................................... 13.12 18-1 BRAKE SYSTEM SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation ot brake pad dust, regardless ol material composition, could be hazardous to your health. ~ Avoid breathing dust particles. ~ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the master cylinder reservoir Is horizontal first. ~ A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. ~ Always use iresh DOT 3 or DOT 4 brake iluid trom a sealed container when servicing the system. Do not mix dillerent types ot lluid as they may not be compatible. ~ Never allow contaminants (dirt, water, etc.) to enter an open reservoir. ~ Once the hydraulic system has been opened, or ii the brake teels spongy, the system must be bled. ~ Always check brake operation betore riding the motorcycle. TROUBLESHOOTING Brake lever/pedal salt or spongy ~ Air in hydraulic system ~ Leaking hydraulic system ~ Contaminated brake pad/disc ~ Worn caliper piston seal ~ Worn master cylinder piston cups ~ Worn brake pad/disc ~ Contaminated caliper ~ Contaminated master cylinder ~ Caliper not sliding properly ~ Low brake tluid level ~ Clogged lluid passage ~ Warped/detormed brake disc ~ Sticking/worn caliper piston ~ Sticking/worn master cylinder piston ~ Bent brake lever/pedal Brake lever/pedal hard ~ Clogged/restricted brake system ~ Sticking/worn caliper piston ~ Sticking/worn master cylinder piston ~ Caliper not sliding properly ~ Warped/detormed brake disc ~ Bent brake lever/pedal Brake drags ~ Contaminated brake pad/disc ~ Misaligned wheel ~ Badly worn brake pad/disc ~ Warped/detormed brake disc ~ Caliper not sliding properly ~ Clogged/restricted lluid passage ~ Sticking caliper piston 1 8-2 BRAKE SYSTEM 1.5 N-m (0.2 Kgl-m, 1.1 Ibm) O COMPONENT LOCATION FRONT: i? 4‘: 30 N-m (3.1 kgl-m, 22 lbf-fl) 34 N-m (3.5 kgl-m, 25 lbf-ft) \>® 9.3 N-m (1.0 kgl-m, 7.2 lbf-ft) HEAR: 34 N-m (3.5 Kgl-m, 25 Ibm) 1 8-3 BRAKE SYSTEM BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING For flunlbrake: Turn the handlebar until the master cylinder resenioir l5 level before removing the resenioir cap. Remove the screws [1], reservoir cap [2], set plate [3]. and diaphragm [4]. Fur Iearbrake: Remove the bolt [1] and resenioir [2]. Remove the cover screws [3]. resenioir cover [4]. set plate [5] and diaphragm [6]. [2] [41/[51/[6] Connect a bleed hose [1] to the bleed valve [2]. Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out of the bleed valve. Tighten the bleed valve. TORQUE: 5.4 N-m (0.3 kgf—m, 4.0 lbf-ft) BRAKE FLUID FILLING/AIR BLEEDING Close the bleed valve. FRONT: Fill the reservoirto the upper level line [1] with DOT 3 or [1] DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve. Operate the brake bleeder and loosen the bleed valve. Check the fluid/eve! If an automatic refill system is not used. add fluid when alten while bleeding the fluid level in the reservoir is low. men’ake'ap’evem Perlorm the bleeding procedure until the system l5 air [mm belng pumped/hm the completely flushed/bled. system. Close the bleed valve and operate the brake lever or pedal. If it still feels spongy. bleed the system again. 18-4 BRAKE SYSTEM II a brake bleeder is not available, use the following procedure: Connect a bleed hose to the bleed valve. Pressurize the system with the brake lever or pedal until lever or pedal resistance is felt. Du norrelease the 1. Squeeze the brake lever or depress the brake pedal, lever orpedal until open the bleed valve 1/4 turn and then close it. the bleed valve has b 2. Release the brake lever or pedal slowly and wait een closed. several seconds after it reaches the end ol its travel. 3. Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose. After bleeding the system completely, tighten the bleed valve to the specified torque. TORQUE: 5.4 N‘m (0.3 kgf‘m, 4.0 lbl-ft) Fill the reservoir to the upper level line With DOT 3 or DOT 4 brake fluid. Install the diaphragm, set plate and reservoir cover and tighten the screws to the specilied torque. TORQUE: 1.5 NM (0.2 kgf‘m, 1.1 lbl-ft) Fullearbrake: Install the reservoir and bolt, then tighten it to the specified torque while pushing the reservoir against the stopper. TORQUE: 10 Nm (1.0 kgf‘m, 7 let) BRAKE PAD/DISC FRONT BRAKE PAD REMOVAL/ INSTALLATION Remove the pad pin [1]. Pull the pad pin out ol the caliper body while pushing in the pads against the pad spring. Remove the brake pads [1]. Install the brake pads into the caliper so their ends rest into the pad retainer on the bracket properly. 1 8-5 BRAKE SYSTEM Apply silicone grease to a new stopper ring [1] and install it into the pad pin [2] groove. Make sure the pad Install the pad pin by pushing in the pads against the spring is Installed pad spring to align the pad pin holes in the pads and correctly. caliper body. Always replace the . . . make pads in pairs Tighten the pad pin to the specilied torque. to ensure even disc TORQUE: 17.2 NM (1.8 kgl-m, 13 lbl-I‘t) pressure. . . Operate the brake lever to seat the caliper pistons against the pads. REAR BRAKE PAD REMOVAL/ INSTALLATION Remove the pad pin plug [1] and pad pin [2]. Remove the brake pads [3]. Apply silicone grease to a new stopper ring [1] and install it into the pad pin [2] groove. Install the brake pads [3] into the caliper. Make sure the pad Install the pad pin by pushing in the pads against the spring is Installed pad spring to align the pad pin holes in the pads and correctly. caliper body. Always replace the . . . make pads in pairs Tighten the pad pin to the specilied torque. to ensure even disc TORQUE: 17.2 NM (1.8 kgl-m, 13 Ibl-ft) pressure. Install the pad pin plug [4]. Operate the brake pedal to seat the caliper pistons against the pads. BRAKE DISC INSPECTION Visually inspect the brake disc tor damage or cracks. Measure the brake disc according to BRAKE SYSTEM SPECIFICATIONS (page 1—8) and replace if necessary. 1 8-6 BRAKE SYSTEM FRONT MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake "Uld from the front brake hydraulic system (page 18-4). Remove the lollowing: Whenremovr‘ngthe — Right rean/lew mirror [1] ailball,caverthe — Oll bolt [2] end of the hose to — Sealing washers [3] prevent — Brake hose [4] contamination. — Brake light swuch connectors [5] — Bolts [1] — Master cylinder holder [2] — Master cylinder [3] Installation is in the reverse order oi removal. Replace the sealing washers with new ones. Align the edge ol the master cylinder with the punch mark on the handlebar. Install the master cylinder and holder with its "UP" mark [4] lacing up. - Tighten the upper bolt llrst, then tighten the lower bolt. TORQUE: Front master cylinder holder boll: 9.3 MM (1 .o kgl-m, 7.2 lbl-l‘t) Oil bolt: 34 MM (3.5 kgf—m, 25 lbf—lt) Fill and bleed the hydraulic system (page 18—4). 1 8-7 BRAKE SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the lront brake master cylinder as following illustration. - Replace the master piston. spring. piston cups and snap ring as a set. - Do not allow the piston cup lips to turn inside out. - Be certain the snap ring is firmly seated in the groove. PIV TB LT . mgom fl 0 O Align 1.0 N-m (0.1 kgf-m, 0.7 lbI-II) MASTER EPAFIATOR PISTON SNAP RING \@ SPRING . STOPPER RING BRAKE LEVER MASTER CYLINDER PIVOT NUT SCREW BRAKE LIGHT SWITCH 5.9 N-m (0.6 mm, DUST COVER 44 M") 1.2 N-m (0.1 mm, 0.9 lbf-ft) INSPECTION Check the Iollowmg pans for scoring, scratches, deterioration or damage. — Masteroylinder — Masterpiston — Pistoncups — Spring — Boot Measure the parts according to BRAKE SYSTEM SPECIFICATIONS (page 1-8) and replace it necessary. REAR MASTER CYLINDER When removing the oil ball, cal/er the end of the rinse in prevenr contamination. REMOVAL/INSTALLATION Drain the brake Iluid from the rear brake hydraulic system (page 18-4). Release the resen/oir hose [1] Irom the clamp [2]. Remove the Iollowing: — Oil bolt [3] — Sealing washers[4] — Brake hose 1 8-8 BRAKE SYSTEM — Cotter pin [1] — Joint pin [2] — Master cylinder mounting bolts [3] — Snap ring [1] — Hose joint [2] — O-ring [3] — Rear master cylinder [4] Installation is in the reverse order ol removal. - Replace the O-ring. master cylinder mounting bolts, cotter pin and sealing washers With new ones. - Apply brake fluid to the joint O—ring. TORQUE: Rear master cylinder mounting bolt: 14 N-m (1.4 kngm,10lbl-lt) Oil bolt: 34 N-m (3.5 kngm, 25 mm) Fill and bleed the hydraulic system (page 18—4). DISASSEMBLY/ASSEMBLY Disassemble and assemble the rear brake master cylinder as following illustration. - Replace the master piston. spring. piston cups and snap ring as a set. - Do not allow the piston cup lips to turn inside out. - Be certain the snap ring is firmly seated in the groove. Standard push rod length: 64 - 65 mm (2.52 -2.56 in) MASTER CYLINDER 5E; MASTER PISTON . @ § "— SNAP RING SPRING @‘\ BOOT ’6' . PISTON CUPS ‘ l " PUSH ROD LOCK NUT 5 ’ 17.2 N-m (1.5 kgf-m,13lbf-ft) PUSH ROD ASSEMBLY BRAKE ROD JOINT 1 8-9 BRAKE SYSTEM INSPECTION Check the followmg parts for scoring, scratches, deterioration or damage. Master cylinder Master piston — Pistoncups — Spring Measure the parts according to BRAKE SYSTEM SPECIFICATIONS (page 1-8) and replace if necessary. FRONT BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the front brake hydraulic I, system (page 18-4). v [4] . . v When remavmgtrie Remove the Iollowmg: \ Bilbo/f, Cal/arms Oil b0" [1] gm Dime r2559: — Sealing washers [2] ( caniamIi'Inaii'an _ Brake hose I3] V 'I ‘ — Brake caliper mounting bolts [4] J — Brake caliper [5] ' Installation is in the reverse order of removal. ' Replace the brake caliper mounting bolts and sealingwasherswith newones. '. . V [5] TORQUE: [1] Brake caliper mounting bolt: 30 N-m (3.1 kgI-m, 22 IbI-ft) Oil bolt: 34 N-m (3.5 kgI-m, 25 IbI-ft) Fill and bleed the hydraulic system (page 18—4). DISASSEMBLY/ASSEMBLY Disassemble and assemble the front brake caliper as Iollowmg illustration. 6 BRACKET PIN BOOT V C‘ALIPER PISTONS CALIPER BRACKET DUST/IE” SEALS .v C’ BLEED VALVE 5.4 N-m (0.9 kgf-m, 4.0 lbI-It) PISTON SEALS fif/ % CALIPER BODY BRACKET PIN 17.2N rn (1. Bkgf-rn 13let) ’6' BRACKET PIN BOOT STOPPER RING 0" V /PAD PIN 17. 2 N m (1.3 KgI-m,13lbf-ft) BRAKE PADS PAD SPRINGW xii-is! 18-10 BRAKE SYSTEM INSPECTION Check the Iollowmg parts for scoring, scratches, deterioration or damage. — Caliper cylinders — Caliper pistons Measure the parts according to BRAKE SYSTEM SPECIFICATIONS (page 1—8) and replace if necessary. REAR BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake Iluid from the rear brake hydraulic system (page 18-4). When removing the Remove the oil bolt [1], sealing washers [2], and brake oii bait. caverme hose [3]. end of the hose to maven! Remove the rear wheel (page 17-4). contamination. Remove the rear brake caliper [1] Irom the slide rail [2] of swingarm. Installation is in the reverse order oi removal. - Replace the sealing washers with new ones. TORQUE: on bolt: 34 MM (3.5 kngm, 25 lbl-ft) Fill and bleed the hydraulic system (page 18—4). 18-11 BRAKE SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the rear brake caliper as lollowing Illustration. RETAINER x‘fil SgggKET PIN v0 ’16.] DUST SEAL I g PISTON SEAL BLEED VALVE W 54 N-m (0.6 kgwn, 4.0 lbf-ft) CALIPER BODY / PAD PIN 17.2 N-m (1.3 KgI-m, CALIPER BRACKET BRAKE PADS 13 lbf-ft) . CALIPEFI PISTON & . PAD SPRING BRACKET R PIN BOOT ,fil PAD PIN PLUG INSPECTION Check the Iollowmg parts for scorIng, scratches, deterioration or damage. — Caliper cylinder — Caliper piston Measure the parts accordIng to BRAKE SYSTEM SPECIFICATIONS (page 1-8) and replace it necessary. BRAKE PEDAL REMOVAL/INSTALLATION Remove the Iollowing: — Brake light sWItch return spring [1] — Brake pedal return spring [2] <1 ; ~O, l‘./{ [2] 18-12 BRAKE SYSTEM Cotter pm [1] Joint pin [2] Brake rod joint [3] Stopper pin [4] Washer [5] — Brake pedal [1] — Dustseals [2] Installatlon is ln the reverse order ol removal. - Replace the dust seals and cotter pin wwth new ones. - Install the dust seals in shown directlon. - Apply grease to the brake pedal pivot slidmg surface and dust seal Ilps. [1] v [1] 18-13 MEMO 19. BATTERY/CHARGING SYSTEM SERVICE INFORMATION -----19-2 BATTERY-m- ---19-4 TROUBLESHOOTING ------------ -----19-2 CHARGING SYSTEM INSPECTION ---------- 19-4 SYSTEM LOCATION-----------------------------------19-3 ALTERNATOR CHARGING COIL .............. 19.5 SYSTEM DIAGRAM .................................... 19.3 REGULATOR/RECTIFIER--------------------------19-6 19-1 BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL AWARNING ~ The battery gives olt explosive gases; keep sparks, ilames and cigarettes away. Provide adequate ventilation when charging. - The battery contains sulluric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a lace shield. — Il electrolyte gets on your skin, ilush With water. — Il electrolyte gets in your eyes, llush With water lor at least 15 minutes and call a physician immediately. ~ Electrolyte is poisonous. — Il swallowed, drink large quantities oi Water or milk and call your local Poison Control Center or a physician immediately. ’ Always turn OFF the ignition switch before disconnecting any electrical component. ’ Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. ~ For extended storage, remove the battery, give it a iull charge, and store it in a cool, dry space. For maximum service lite, charge the stored battery every 2 Weeks. For a battery remaining in a stored motorcycle, disconnect the negative battery cable irom the battery terminal. The maintenance tree battery must be replaced when it reaches the end ol its service lile. The battery can be damaged il overcharged or undercharged, or ii lelt to discharge tor a long period. These same conditions contribute to shortening the "lile span" oi the battery. Even under normal use, the periormance ol the battery deteriorates alter 2 — 3 years. Battery voltage may recover after battery charging, but under heavy load, battery voltage Will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results irom problems in the battery itsell, which may appear to be an overcharging symptom. it one ol the battery cells is shorted and battery voltage does not increase, the regulator/rectilier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes doWn quickly. ~ Beiore troubleshooting the charging system, check tor proper use and maintenance oi the battery. Check ii the battery is lrequently under heavy load, such as having the headlight and taillight ON lor long periods ol time without riding the motorcycle. ~ The battery will sell-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to prevent suliation irom occurring. ~ For alternator removal (page 13-4). BATI'ERY CHARGING ~ Turn power ON/OFF at the charger, not at the battery terminal. ~ For battery charging, do not exceed the charging current and time specilied on the battery. Using excessive current or extending the charging time may damage the battery. ~ Quick charging should only be done in an emergency; sloW charging is prelerred. BA'I'I'ERY TESTING Reler to the instruction ol the Operation Manual lor the recommended battery tester lor details about battery testing. The recommended battery tester puts a "load" on the battery so the actual battery condition can be measured. RECOMMENDED BATTERY TESTER: BM-210 or BATTERV MATE or equivalent TROUBLESHOOTING Unusual condition Probable cause (Check in numerical order) Battery Battery is damaged or weak . Faulty battery 2. Current leakage higher than specitied value — Faulty ignition switch — Shorted wire harness . Faulty alternator charging coil . Faulty regulator/rectilier . Open circuit or loose connection in the wire harness anew 1 9-2 BATTERY/CHARGING SYSTEM SYSTEM LOCATION REGULATOR/RECTIFIER BATTERY MAIN FUSE (30 A) ALTERNATOR SYSTEM DIAGRAM MAIN FUSE (30 A) f [.7 EB 6 BATTERY REGULATOR/RECTIFIER ALTERNATOR Y: Yellaw G: Green R: Red W: White 1 9-3 BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the left side cover (page 2-3). Turn the ignition switch OFF. Disconnect the negative (—) cable [1] tirst and then the positive (+) cable [2]. Remove the bolt [3], battery holder plate [4] and battery [5]- Cannect the Install the battery in the reverse order of removal. positive cable Ills! _ and the" the TORQUE' "egame cable. Battery holder plate bolt: 1.0 N-m (0.7 kgI-m, 5.2 lbt-It) NOTE ' Install the batter holder plate by aligning its hook With the slit oi the battery case. ' For digital clock setting procedure (page 20-7). VOLTAGE INSPECTION Measure the battery voltage using a commercially available digital multimeter. ' VOLTAGE (20°C/68’F): Fully charged: 13.0 — 13.2 V Under charged: Below 12.3 V II the battery voltage is below 12.3 V, charge the battery. BATTERY TESTING Reler to the instructions that are appropriate to the batten/ testing equipment available to you. TOOL: Battery tester BM-210 or BA'I'I'EFIV MATE or equivalent CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the left side cover (page 2-3). With the ignition switch turned OFF, disconnect the negative (—) cable [1]. ' Connect the ammeter (+) probe to the wire harness negative (—) cable and ammeter (—) probe to the battery negative (—) terminal [2]. With the ignition switch turned OFF, check Ior current leakage. NOTE - When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current Ilow higher than the range selected may blow the Iuse in the tester. ' While measuring current, do not tu he ignition switch ON and engine stop sWitch to "(7". A sudden surge oI current may blow the Iuse in the tester. SPECIFIED CURRENT LEAKAGE: 0.34 mA max. 1 9-4 BATTERY/CHARGING SYSTEM II current leakage exceeds the specified value, a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. CHARGING VOLTAGE INSPECTION Remove the left side cover (page 2—3). Be sure the battery is in good condition before pertorming this test. Warm up the engine to normal operating temperature. Connect the multimeter between the battery positive (+) terminal [1] and negative (—) terminal [2]. NOTE ' To prevent a short, make absolutely certain which are the positive (+) and negative (—) terminal or cable. ' Do not disconnect the battery or any cable in the charging system without Iirst turning the ignition switch OFF. Failure to tollow this precaution can damage the tester or electrical components. With the headlight high beam, measure the voltage on the multimeter when the engine runs at 5000 min‘ (rpm)- STANDARD: Measured BV < Measured CV < 15.5 V - BV = Battery Voltage - CV = charging Voltage ALTERNATOR CHARGING COIL INSPECTION Remove the left side cover (page 2—3). Disconnect the alternator 3P connector [1]. Measure the resistance between the Yellow wire terminals of the alternator side connector. STANDARD: 0.1 — 1.0 fl (20”0/68”F) Check for continuity between each Wire terminal ot the alternator/stator side connector and ground. There should be no continuity. Replace the alternator stator it the resistance is out of specification, or it any wire has continuity to ground. For stator replacement (page 13-4). 1 9-5 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER REMOVAL/INSTALLATION Remove the radiator reserve tank (page 9-12). Disconnect the regulator/rectifier 5P connector [1]. Remove the bolts [2] and regulator/rectifier [3] from the reserve tank stay. Install the regulator/rectifier in the reverse order of removal. SYSTEM INSPECTION Remove the nght fuel tank shroud (page 2-4). Turn the ignition switch OFF. Disconnect the regulator/rectifier 5P connector [1], and check it for loose contacts or corroded terminals. ll the charging voltage reading (page 19-5) is out ol the specification, check the lollowmg at the wire harness side connector [1]: Item Terminal Specification Battery charging Red/white (+) Battery voltage line and ground (—) should register Charging coil line Yellow and 0.1 — 1.0 0 at Yellow (20°C/68"F) Ground line Green and Continuity should ground exist ll all components of the charging system are normal and there are no loose connections at the regulator/ rectilier connector. replace the regulator/rectifier unit. 1 9-6 20. LIGHTS/METERS/SWITCHES SERVICE INFORMATION ........................... 20.2 SYSTEM LOCATION ................................... 20.2 HEADLIGHT ................................................ 20.3 POSITION LIGHT ........................................ 20.3 TURN SIGNAL LIGHT ................................. 20.4 BRAKE/TAILLIGHT --20-5 SPEEDOMETER .......................................... 20.5 VS SENSOR ................................................ 20.3 HIGH COOLANT TEMPERATURE INDICATOR ................................................. 20.9 IGNITION SWITCH .................................... 20.10 HANDLEBAR SWITCH ............................. 20.11 BRAKE LIGHT SWITCH ........................... 20.12 NEUTRAL SWITCH .................................. 20.12 SIDESTAND SWITCH ............................... 20.13 CLUTCH SWITCH--- ”.2044 FUEL GAUGE/FUEL LEVEL SENSOR .................................................... 20.14 HORN ........................................................ 20.15 TURN SIGNAL RELAY ............................. 20.15 20-1 LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL - Note the following when replacing the halogen headlight bulb. — Wear clean gloves while replacing the bulb. Do not put lingerprints on the headlightbulb, as they may create hot spots on the bulb and cause it to fail. — If you touch the bulb with your bare hands, clean It with a cloth moistened with alcohol to prevent its early lal‘lure. Be sure to install the dust cover after replacing the headlight bulb. A halogen headlight bulb becomes Very hot while the headlight is ON, and remains hot tor a while aiter it ls turned OFF. Be sure to let it cool down beiore servicing. Check the battery condition belore oeriorming any inspection that requires proper battery voltage. A continuity test can be made Wlth the switches installed on the motorcycle. The Iollowmg color codes are used throughout this section. Bu = Blue G e Green Lb = ngm Blue 0 = Orange R = Red Y = Yellow BI e Black Gr = Gray Lg = ngm Green P = Plnk w = Whlte SYSTEM LOCATION IGNITION SWITCH FRONT BRAKE LIGHT SWITCH SPEEDOMETER ENGINE STOP SWITCH DIMMER SWITCH STARTER SWITCH CLUTCH SWITCH FUEL LEVEL SENSOR HORN SWITCH TURN SIGNAL SWITCH TURN SIGNAL RELAY HORN NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH SIDESTAND SWITCH VS SENSOR 20-2 LIG HTS/METERS/SWITCHES HEADLIGHT BULB REMOVAL/INSTALLATION Remove the headlight cowl (page 2-5). Remove the dust cover [1]. Unhook the bulb retainer [2] and remove the headlight bulb [3]. Avoid touching halogen headlight bulb. Fingerprints can create hot spots that cause a bulb to break. Install the bulb while aligning its tabs with the slots of the headlight unit. Hook the bulb retainer into the headlight unit groove. Install the dust cover tightly against the headlight unit. Install the headlight cowl (page 2-5). HEADLIGHT UNIT REMOVAL/ INSTALLATION Remove the headlight cowl (page 2-5). Remove the screws [1] and headlight unit [2] Irom the headlight cowl. Installation is in the reverse order oI removal. TORQUE: Headlight unit mounting screw: 1.2 NM (0.1 kgrm, 0.9 mm) POSITION LIGHT BULB REMOVAL/INSTALLATION Remove the headlight cowl (page 2-5). Pull out the bulb socket [1] lrom the headlight case. Remove the bulb [2] from the socket. Installation is in the reverse order oI removal. [2] 20-3 LlGHTS/METERS/SWITCHES TURN SIGNAL LIGHT Lei! side only: BULB REMOVAL/INSTALLATION Remove the screw [1] and turn signal light lens [2] by releasing its tab [3]. [2] [3] While pushing in the bulb [4], turn it counterclockwise to remove it. Installation is in the reverse order ol removal. 9 Check that the packing is installed in position and is in good condition, replace it with a new one it necessary. FRONT TURN SIGNAL UNIT REMOVAL/INSTALLATION Remove the headlight cowl (page 2-5). Disconnect the lront turn signal 2P connector [1]. — Right side: Light blue — Leftside:0range Release the wire irom the wire band [2]. Release the wire irom the wire band [3]. Remove the nut [4] and lront turn signal unit [5]. Installation is in the reverse order ol removal. TORQUE: Turn signal unit mounting nut: V [3] (Left 21 N-m (2.1 kgl-m,15lbf—I’t) Side cnl NOTE Align the Ilats ol the turn signal unit and speedometer stay. REAR TURN SIGNAL UNIT REMOVAL/ INSTALLATION Remove the rear tender (page 2—7). Disconnect the rear turn signal 2P connector [1]. — Right side: Light blue — Left side: Orange Remove the nut [2] and rear turn signal unit [3]. Installation is in the reverse order ol removal. TORQUE: Turn signal unit mounting nut: 21 N-m (2.1 kgI-m,15lbt-I’t) NOTE Align the Ilats ol the turn signal unit and turn signal unit [3] stay. 20-4 LIG HTS/M ETERS/SWITCHES BRAKE/TAILLIGHT NOTE For brake/taillight removal/installation (page 2-8). BULB REMOVAL/INSTALLATION Remove the rear tender (page 2-7). Remove the brake/taillight mounting screws [1] and collars[2]. Remove the hook bolts [3] and collars [4]. Pull the tail cover/light unit [5] rearward while pulling up the rear upper tender [6]. [5] Turn the bulb socket [1] counterclockwrse and remove it. While pushing in the bulb [2], turn it counterclockwise to [ remove it. Installation is in the reverse order ol removal. TORQUE: Hook bolt: 21 N-m (2.1 kgf—m,15lbf—ll) Brake/taillight mounting screw: 4.5 N-m (0.5 kgf—m, 3.3 Ibf-lt) SPEEDOMETER REMOVAL/INSTALLATION Remove the headlight cowl (page 2-5). Release the wire bands [1] lrom the meter stay. Remove the screws [2], washers [3] and speedometer [4] by disconnecting the speedometer 16F connector [5]. Remove the mounting rubbers [6]. Installation is in the reverse order ol removal. TORQUE: Speedometer mounting screw: 1.0 N-m (0.1 kgf—m, 0.7 Ibf-lt) LIGHTS/METERS/SWITCHES SYSTEM INSPECTION NOTE Check for loose or poor contact terminals at the speedometer 16F connector. When the ignition switch is turned ON, check that the meter segments turn on. II the speedometer does not show the initial lunction, perlorm the power and ground line inspection of the speedometer (page 20-6). ll the speedometer shows the initial function but speedometer does not move when running, check the speedometerNS sensor system inspection (page 20-8). POWER/GROUND LINES INSPECTION Remove the speedometer (page 20-5). NOTE - Do not disconnect the speedometer 1GP connector [1] during inspection. - Alter inspection, reposition the dust cover [2] securely. Remove the dust cover. With the speedometer 1GP connector connected, check the lollowing at the wire harness side connector. POWER INPUT LINE Measure the voltage between the speedometer 16F connector [1] and ground. CONNECTION: Black (4-) — Ground (—) There should be battery voltage With the ignition switch turned ON. II there is no battery voltage, check the following: — Open circuit in the Black Wire — Open circuit in Black/red Wire between the Iuse box and ignition sWitch — BIoWn METER, TAIL Iuse (1D A) - v“ 20-6 LIGHTS/M ETERS/SWITCHES GROUND LINE Check lor continuity between the speedometer iSP connector [1] and ground. CONNECTION: Green — Ground There should be continuity at all times. ll there is no continuity, check lor an open circuit in the Green wire. BACK-UP VOLTAGE LINE Measure the voltage between the speedometer iGP connector [1] and ground. CONNECTION: Red (4-) — Ground (—) There should be battery voltage at all times. II there is no battery voltage, check the iollowing: — Open circuit in the Red wire — Blown ODO, CLOCK tuse (5 A) — Blown main tuse (30 A) — Open circuit in Red/white wire between the iuse box and starter relay switch SPEEDOMETER DIGITAL CLOCK SET PROCEDURE E TYPE: Turn the ignition switch ON and engine stop sWitch "(2". Push and hold both the A button [1] and B button [2] until the speed and mileage units [3] start blinking. Push the B button to select either "mph" 8. "mile", or "km/h" & "km" tor the speedometer, odometer and trip meter. Push the A button to coniirm the unit setting, and then the display moves to the clock setting. The hour digits [4] Will start blinking. Push the B button until the desired hour is displayed. NOTE Push and hold to advance the houriast. Push the A button, then the minute digits [5] start blinking. Push the B button until the desired minute is displayed. NOTE Push and hold to advance the minute last. Pusn both the A button and B button to complete the setting. NOTE The time can also be set by turning the ignition switch OFF. \filfififl [3] «w' , y 'l [4] [5] 20-7 LIGHTS/METERS/SWITCHES EXCEPT E TVPE: Turn the ignition switch ON and engine stop switch "C'. Push and hold both the A button [1] and B button [2] until the hour digits [3] start blinking. Push the B button until the desired hour is displayed. NOTE Push and hold to advance the houriast. Push the A button, then the minute digits [4] start blinking. Push the B button until the desired minute is displayed. NOTE Push and hold to advance the minute Iast. Push both the A button and B button to complete the setting. NOTE The time can also be set by turning the ignition switch OFF. VS SENSOR SYSTEM INSPECTION NOTE ' Beiore starting this inspection, check tor speedometer system inspection (page 20-5). ' Do not disconnect the speedometer 16F connector during inspection. ' After inspection, reposition the dust cover securely. Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch "F". With the speedometer 16P connector [1] connected, measure the voltage between the speedometer iGP connector terminals. CONNECTION: White/red (4») — Green/black (—) Slowly turn the rear wheel by hand. There should be 0 V to 5 V pulse voltage. II pulse voltage appears, replace the speedometer (page 20-5). II pulse voltage does not appear, check the Iollowing: — White/red wire tor open or short circuit — Green/black Wire Ior open circuit — It the Wires are OK, check the VS sensor (page 20- 9 . [1] 20-8 LIG HTS/METERS/SWITCHES VS SENSOR INSPECTION Remove the left side cover (page 2—3). Check lor loose or poor contact of the VS sensor 3P (Blue) connector [1]. Disconnect the VS sensor 3P (Blue) connector. Turn the ignition switch ON and engine stop sWitch "“.C Measure the voltage between the VS sensor 3P (Blue) connector terminals at the wire side. CONNECTION: Black/red (4-) — Green/black (—) STANDARD: Battery voltage ll battery voltage appears, replace the VS sensor. ll there is no voltage, check the lolloWing: — Black/red Wire lor open circuit — Green/black Wire lor open circuit — Speedometer (page 20-5) REMOVAL/INSTALLATION Remove the left side cover (page 2—3). Disconnect the VS sensor 3P (Blue) connector [1]. Remove the VS sensor wire from the guide [1]. Remove the bolt [2], VS sensor [3] and O-ring [4]. Installation is in the reverse order oi removal. - Replace the O—ring With a new one. - Apply engine oil to a new O-ring. 20-9 LIGHTS/METERS/SWITCHES HIGH COOLANT TEMPERATURE INDICATOR SYSTEM INSPECTION - Before starting the inspection, check lor loose or poor contact on the speedometer 16F connector, ECT sensor 3P connector and ECM 33F (Black) connector. Turn the ignition switch ON and engine stop switch "C" Check that the high coolant temperature indicator [1] comes ON. Ii the high coolant temperature indicator blinks, follow the PGM-Fl troubleshooting for ECT sensor (page 4- 30). lithe high coolant temperature indicator does not come ON at all or remains ON, inspect as follows. Remove the resenIe tank cover (page 2-4). Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Turn the ignition switch ON and engine stop switch "C" Check that the high coolant temperature indicator remains OFF. - If the indicator comes ON, check for short circuit in the Green/blue Wire between the speedometer and ECM. - If the wire is OK, replace the speedometer With a known good one and recheck. Turn the ignition switch OFF. Ground the loIIoWing terminal ol the wire harness side ECM 33F (Black) connector [1] with a jumper Wire [2]. CONNECTION: Green/blue — Ground TOOL: Test probe 07ZAJ-RDJA110 Turn the ignition switch ON and engine stop switch “a“ the high coolant temperature indicator should come on. - If the indicator does not come ON, check lor open circuit in the Green/blue Wire between the speedometer and ECM. - If the indicator comes on With the Green/blue wire grounded but does not come ON With the ECM 33F (Black) connector connected, replace the ECM with a known good one and recheck. 20-10 LIG HTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the headlight cowl (page 2-5). Disconnect the ignition switch 3P (Brown) connector [1]. Check for continuity between the switch side connector terminals in each switch position according to the chart (page 21 -2). REMOVAL/INSTALLATION Remove the top bridge (page 16-21). Remove the ignition switch mounting bolts [1] and ignition switch [2]. NOTE Use a drill or an equivalent tool when remoVing the ignition sWitch mounting bolts. Install the ignition switch onto the top bridge. Install and tighten new ignition switch mounting bolts to the specified torque. Tonouam NM (2.4 kngm, 18 let) Install the top bridge (page 16-24). HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH Remove the headlight cowl (page 2-5). Disconnect the right handlebar sWitch 9P (Black) connector [1]. Check for continuity between the switch side connector terminals in each switch position according to the chart (page 21 -2). l2] 20-11 LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCH Remove the headlight cowl (page 2-5). Disconnect the left handlebar switch 14P (Gray) connector [1]. Check for continuity between the switch side connector terminals in each switch position according to the chart (page 21 -2). BRAKE LIGHT SWITCH FRONT Disconnect the lront brake light sWitch connectors and check tor continuity between the switch terminals [1]. There should be continuity with the brake lever squeezed, and no continuity with the brake lever released. REAR Remove the left side cover (page 2—3). Disconnect the rear brake light switch 3P (Black) connector [1]. Check lor continuity between the switch side terminals. There should be continuity with the brake pedal [2] depressed, and no continuity when the brake pedal released. 20-12 LIG HTS/METERS/SWITCHES NEUTRAL SWITCH REMOVAL/INSTALLATION Drain the engine oil (page 3-9). Remove the gearshift pedal (page 12-14). Disconnect the neutral switch Wire connector [1]. Remove the neutral switch [2] and sealing washer [3]. ) Installation is in the reverse order oI removal. - Replace the sealing washer with a new one. TORQUE: Neutral switch: 12 MM (1.2 kgf‘m, 9 lel) Fill the engine with the recommended engine oil (page 3-9). INSPECTION Make sure that the neutral indicator come on With the ignition sWitch ON and transmission is in neutral. II the neutral indicator does not come on, inspect as Iollows: Remove the drive sprocket cover (page 2—6). Disconnect the neutral switch Wire connector. Check for continuity between the switch terminal and engine ground. There should be continuity With the transmission is in neutral, and no continuity When the transmission is into gear II the continuity inspection is normal. check lor open circuit in Light green/red wire between neutral switch , wire connector and neutral indicator. II the continuity inspection is abnormal, replace the neutral sWitch (page 20-13). SIDESTAND SWITCH INSPECTION Remove the left side cover (page 2—3). Disconnect the sidestand sWitch 3P (Green) connector Check the continuity between the tollowing terminals of the sWitch side connector. CONNECTION: Green/white — Green The switch is normal it there is continuity when the sidestand is retracted, and no continuity when the sidestand is lowered. 20-13 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the sub—frame (page 2-12). [Eiifconnect the sidestand sWitch 3P (Green) connector Release the wire from the clamps [2]. Remove the two bolts [1] and switch cover [2]. Remove the mounting bolt [1] and sidestand switch [2]. Installation is in the reverse order ol removal. ' Replace the sidestand switch mounting bolt with a new one. ' Align the switch groove With the spring pin of the frame. TORQUE: Sidestand switch mounting bolt: 10 N-m (1.0 kgl-m, 7 lbl-ft) CLUTCH SWITCH Disconnect the clutch switch wire connectors and check 1 lor continuity between the switch terminals [1]. [ 1 There should be continuity with the clutch lever squeezed and no continuity With the clutch lever released. 20-14 FUEL GAUGE/FUEL LEVEL SENSOR FUEL GAUGE INSPECTION II the fuel gauge [1] is indicated as shown, check for an open circuit in wire harness and the fuel level sensor. If the wire harness and fuel level sensor are good, replace the speedometer assembly (page 20-5). FUEL LEVEL SENSOR INSPECTION Remove the luel pump unit (page 7—9). Connect the ohmmeter to the lollowing terminals of fuel pump 3P connector. CONNECTION: Red/black — Black/white Inspect the resistance ol the lloat at the lull and empty LIG HTS/METERS/SWITCHES positions. Float position FULL EMPTY Resistance 9 — 11 Q 213 — 219 Q Replace the luel pump unit il fuel level sensor is out of specification. Install the luel pump unit (page 7-9). HORN INSPECTION Remove the reserve tank cover (page 2-4). Disconnect the connectors lrom the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals. FULL EMPTV 20-15 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the reserve tank cover (page 2-4). Disconnect the wire connectors [1] from the horn [2]. Remove the bolt [3] and horn. Installation is in the reverse order ol removal. TURN SIGNAL RELAY INSPECTION STANDARD INSPECTION Check the tolloWing: — Battery condition — Burned out bulb or non—specilied wattage — BloWn TURN, HORN, STOP tuse (10 A) — lgnition switch and turn signal sWitch function — Loose connector ll above items are normal, remove the reserve tank cover (page 2-4). INPUT VOLTAGE INSPECTION Disconnect the turn signal relay 3P (Black) connector [1] lrom the relay. Turn the ignition switch ON and check the voltage between the tolloWing terminals ol the Wire harness side connector. CONNECTION: Black/orange (1-) — Green (—) STANDARD: Batteryvoltage ll there is no battery voltage, inspect the lollowing: — Open circuit in Green Wire — Open circuit in Black/orange wire between the turn signal relay 3P (Black) connector and tuse box SIGNAL LINE INSPECTION Short the tollowing terminals oi the turn signal relay 3P (Black) connector With a jumper wire. CONNECTION: Black/orange — Gray Turn the ignition switch and turn signal switch ON. Check that the turn signal lights come ON. — lt the turn signal lights do not come ON, check tor open circuit in Gray wire. — lt the turn signal lights come ON, replace the turn signal relay with a known-good one and recheck. 20-16 LIG HTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the reserve tank cover (page 2-4). Disconnect the turn srgnal relay 3P (Black) connector [1] tram the turn signa‘ re‘ay [2]. Remove the turn signal relay from the frame. Installatron is \n the reverse order at remova‘. 20-17 MEMO 21. WIRING DIAGRAM WIRING DIAGRAM--------------------------------------21-2 21-1 WIRING DIAGRAM SPEEDDMETER PNR :oNrRoL HDRN II ”II” ”III .33 gggmg E75033 TURN sLsNRL RELAV RLGRr HANDLEBAR swch no MAW EusE mom aRrrERv 22$: Lb (firm: E_ RLGRT FRONT mRN chNAL new m 2‘ w apu @222E]:2_ LEFT ERoNr mRN chNALLLGRT V 2v 2‘ w HEADUGHI sz snsssw WIRING DIAGRAM _ Em: w @W WWW WWW LEFT REAR mRN sLsNAL UGHT sz 2m BRAKE‘TNLUGHT I 2v 2‘ ssw 2) m w as E RosmoN UGHT sz 5w J .JNEE D‘MMER TURN HORN swch SWNRLEWT'E: swch n :R El” 3% magma E1; 5me GN mRN RoRN STOP ENGLNE st swme mRN smNAstch 3: m ng R NEUTRAL SENSO swch DLMMER swch HORN swch Lo M w Re FREE PUSH coLoR an: L9 coLoR em w Eu El ‘GRDUND gRouND ERKME FRAME (33ROUND iSROUND ancchws SECUNJMAZKWG 21-2 MEMO AIR CLEANER AIR CLEANER HOUSING ALTERNATOR CHARGING COIL- BALANCER- 4.14 BANK ANGLE SENSO 4.48 BATTERY-m 19.4 BRAKE FLUID~ 3 15 BRAKE FLUID REPLACEMENT/AIR BLEEDING - BRAKE LIGHT SWITCH LIGHTS/METERS/SWITCHES --------- MAINTENANCE BRAKE PAD/DISC- BRAKE PADS WEAR BRAKE PEDAL .- BRAKE SYSTEM BRAKErTAILLIGHT CABLE & HARNESS ROUTING- CAM CHAIN TENSIONER CAMSHAFT CHARGING SYSTEM INSPECTION CLUTCH ------ CLUTCH SWITCH - CLUTCH SYSTEM- COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH BRAKE SYSTEM ------ CLUTCH/GEARSHIFT LINKAGE 1 CRANKCASE/CRANKSHAFT/TRANSMISSION/u BALANCER n CYLINDER HEAD/VALVES CYLINDER/PISTON ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING- FUEL SYSTEM ----- REAR WHEEL/SUSPENSION 17-3 COOLANT REPLACEMENT -5 COOLING SYSTEM ------ 3-11 CRANKCASE ASSEMBLY 4-18 CRANKCASE BEARING REPLACEMEN CRANKCASE BREATHER ~- -4 CRANKCASE SEPARATIO CRANKSHAFT 14-6 CYLINDER COMPRESSIO 10-4 CYLINDER HEAD ----- 0-13 CYLINDER HEAD COVER CYLINDER/PISTON DRIVE CHAIN DRIVE CHAIN GUIDE DRIVE CHAIN SLIDER~--- DRIVE SPROCKET COVER DTC INDEX ----- DTC TROUBLESHOOTING- ECM ..... ECT SENSOR~ EMISSION CONTROL SYSTEMS- ENGINE IDLE SPEED -- ENGINE INSTALLATION- ENGINE OIL---~ ENGINE OIL FILTER ENGINE OIL STRAINER SCREEN ENGINE REMOVA EXHAUST PIPE/MUFFLER- FAN CONTROL RELAY FLYWHEEL- FORK FRAME GUARD- FRONT BRAKE CALIPER FRONT FENDER-- FRONT MASTER CYLINDER- FRONT WHEEL--- - FUEL GAUGE/FUEL LEVEL SENSOR 20-15 FUEL LINE FUEL LINE INSPECTION FUEL PUMP RELAY FUEL PUMP UNIT FUEL TANK-- FUEL TANK SHROUD GEARSHIFT LINKAGE HANDLEBAR-m HANDLEBAR SWITCH HEADLIGHT -- HEADLIGHT AI HEADLIGHT COWL HIGH COOLANT TEMPERATURE INDICATOR - HORN ~ IACV IGNITION COIL IGNITION SWITC IGNITION SYSTEM INSPECTION IGNITION TIMING INJECTOR ----- LEFT CRANKCASE COVER- LUBRICATION & SEAL POINT LUBRICATION SYSTEM DIAGRAM MAIN JOURNAL BEARING-~~ MAINTENANCE SCHEDULE MIL CIRCUIT TROUBLESHOOTIN MIL TROUBLESHOOTING-m MODEL IDENTIFICATION NEUTRAL DIODE NEUTRAL SWITCH- NUTS, BOLTS, FASTENERS PGM-FI SYMPTOM TROUBLESHOOTING PGM-FI SYSTEM DIAGRAM- PGM-FI SYSTEM LOCATION PGM- FI TROUBLESHOOTING INFORMATION POSITION LIGHT- - PRESSURE RELIEF VALVE PRIMARY DRIVE GEAR RADIATOR COOLANT-~~ RADIATOR RESERVE TANK RADIATOR/COOLING FAN REAR BRAKE CALIPER REAR FENDER--- REAR LOWER FENDER REAR MASTER CYLINDER REAR UPPER FENDER- REAR WHEEL ----- REGULATOR/RECTIFIER RESERVE TANK COVER - RIGHT CRANKCASE COVER- ROCKER ARM - SEAT ...... SECONDARY AIR SUPPLY SYSTEM FUEL SYSTEM MAINTENANCE SENSOR UNIT~ SENSOR UNIT POWER LINE INSPECTION SERVICE INFORMATION ALTERNATOR/STARTER CLUTCH BATTERY/CHARGING SYSTEM BRAKE SYSTEM ------- CLUTCH/GEARSHIFI' LINKAGE COOLING SYSTEM ------ CRANKCASE/CRANKSHAFTNRANSMISSION/ BALANCER ------ INDEX CYLINDER HEAD/VALVES CYLINDER/PISTON ELECTRIC STARTER SYSTEM ENGINE REMOVAL/INSTALLATION FRAME/BODY PANELS/EXHAUST SYSTE FRONT WHEEL/SUSPENSION/STEERING FUEL SYSTEM ----- IGNITION SYSTEM - LIGHTS/METERS/SWITCHE LUBRICATION SYSTEM MAINTENANCE PGM-FI SYSTEM REAR WHEEL/SUSPENSION 17- SERVICE RULES-~ SHOCK ABSORBER- SHOCK LINKAG 17- SIDE COVER SIDESTAND FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE~--- SIDESTAND SWITCH SKID PLATE SPARK PLU SPECIFICATION SPEEDOMETER STARTER CLUTCH STARTER MOTOR STARTER RELAY SWITCH STATOR/CKP SENSOR ~- STEERING HEAD BEARINGS STEERING STEM SUB-FRAME SUSPENSION - SWINGARM SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM - ELECTRIC STARTER SYSTEM IGNITION SYSTEM ----- SYSTEM FLOW PA'I'I'ERN- SYSTEM LOCATION BATTERY/CHARGING SYSTEM ELECTRIC STARTER SYSTEM~ IGNITION SYSTEM LIGHTS/METERS/SWITCHES SYSTEM TESTING ----- TAIL COVER/LIGHT UNIT- THERMOSTAT - THROTTLE BODY THROTTLE OPERATION TOOL BOX~--- TOROUE VALUE TRANSMISSION- TROUBLESHOOTING ALTERNATOR/STARTER CLUTC BATTERY/CHARGING SYSTEM BRAKE SYSTEM CLUTCH/GEARSHIFT LINKAGE COOLING SYSTEM CRANKCASE/CRANKSHAFT/TRANSMISSION/ BALANCER ----- CYLINDER HEAD/VALVES- CYLINDER/PISTON ELECTRIC STARTER SYSTEM~ FRAME/BODY PANELS/EXHAUST SYSTEM- FRONT WHEEL/SUSPENSION/STEERING FUEL SYSTEM IGNITION SYSTEM LUBRICATION SYSTEM REAR WHEEL/SUSPENSION TURN SIGNAL LIGHT TURN SIGNAL RELAY VALVE CLEARANCE - VS SENSOR- WATER PIPE WATER PUM WHEELSFTIRES WIRING DIAGRA ‘9w99w9w Gnu“ 4? rbooommmmbrbmmmmmmmmw NNNNN ozoxub—‘uwmbmmum oummmeQ—‘gf. norluoonow N o @499; "v‘v.