SERVéCPMANUAL HOW TO USE THIS MANUAL Thls semoe manual descrlbes lhe servme moceflmes lol me csmooonn-a FOIIW lhE Malnlenanoe Schedule (Semen 4) lecommendallons la ensure lnal me yahrcle ls ln peak dperanng cdndmun and me emrsslon leveIs ara wrmrn me slandards sel dry me u s Envlvonmemal Pralecuon Agsncy. Callldrnra An Rssuumss Board and Transnon Canada. Pennrmmg lne WEI scnedulad malnIenance Is very lmponanl II compensalas rarma lnhlaI wear \hal occurs durlng me breaknn pellad SecIlons l and 4 apply lo we wndla mumlcycle Sedion a .llusrralas procedures lor ramuyal/mslallallon ol componems lnal may be requued Io panorrn service desnllbed ln lne Iollowmg saclrans, Seclmn 5 lnrdugn 20 dsscrlba parls dl lna maloraycla grauped ammdlng ID IncaIIun Flnd lna sedlun yuu wanI un lhls page lnan mm la lna lanla nl sdnlenrs an me Ilrsl paga dl lna sectlun MusI sermons sIarl wlIh an assembly m sysIem lllusIlaIlon sevvlce lnIurmaIlon and naudleshaonng ldr lna sect-on Tna sudseguenr pages glve flelalIsd procedurs II you are ndr lammar wrvr mls mordrcycle. read Tacnnlcal Faaxuras m Secllonz II yau danl know lne source ul lna IruubIE ga la sacndn 22 TroubIeshouIlrlg Your salary and ma salaly al ulnars is very lmparxam Tu help you make rnlorrned dacrsruns we have nrovlded salaly messages and oIher lnIalmallon mmugnam lhls manual. 01 course, n ls nol pracllcal cl pusslbIe la warn you abou! all me hazards assocrarad wnn saryrarng Ihls yenrela You musl use your own good yudgemenl You will nnd lmponam salsly lnldrmaunn lrr a finely er larrns rnsludrng - salely LabEIs a on me ysnmla - Salaly Messages 7 preceded by a salely aIerI symbol [L and we arouse slgrlaI words DANGER, WARNING‘ DrCAUTION, These slgnal wards maan vou WILL be KILLED ar SERIOUSLY ADANGER HURT ll ydu uunl lelldw lnsIrucIlDrls vou CAN be KILLED or ssnlousu HURT .l you ddn'l IuIIow lnsIrucIlans You CAN be HURT w you ddnv lollow CAUTION lnsImClmrls ~ Inslrunrons - how Io semce lms vehche conecuy and salely AWARNING CONTENTS GENERAL INFORMATION TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM FUEL SYSTEM (Programmed Fuel Injection) COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEADNALVES CLUTCH/STARTER CLUTCH ALTERNATOR TRANSMISSION/GEARSHIFT LINKAGE CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER CHASSIS FRONT WHEEL/SUSPENSION] STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE As you read lnls manual. you WIII lrnu lnIumlaIlorl lnal IS araeadad by a ”one? symdal The puvuuse oI nus message ls Ia help prevsnl damage I0 your yenrcle othel properly, 0v me enwonmenr ELECTRICAL BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX _a_a_a...a_a_a ‘4 LDCI‘IOIU'I-b —| Dale of Issue: March, 2004 Contents SYMBOLS The symbols used throughout this manual show specillc service procedures, It supplementary inlormation ls required perlaining to these symbols. it would be explained specifically in the text without the use ol the symhols g Replace the part(s) with new one(s) belore assembly. ”7% iUs‘e-irecommended englne oil, unless otherwtse specified. gvri 7 7 U;olybdenum all solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1). fl Use multi»purpose grease (Lithium based mum—purpose grease NLGI «2 or equivalent). Use molybdenum disullide grease (containing more than 3% molybdenum dlsulllde. NLGI #2 or equivalent). xfil Example: Molykole‘m BR»2 plus manufactured by Dow Cornlng u,S.A. MUIII'DLII’POSE M-2 manulaclured by Mllsutlishi Oil. Japan Use molybdenum disultide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykole® G-n Paste manufactured by Dow Corning U.S.A. 2%! Honda Maly 60 (USA. only) FIOCOI ASP manulactured by Rocol Limited. UK. Flocol Paste manulaclured by Sumlco Lubricant, Japan fl Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant Use Fork or Suspension Fluid. a “ Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise spectlied. l Contents 1. GENERAL INFORMATION SERV|CE RULES ............................................ 1.2 MODELIDENT|F|CAT|0NU...‘,....,.....u..........‘ 1.2 GENERAL SPECIFICATIONS 1-4 LUBRICATION SYSTEM SPECIFICATIONS ........................................... 1-6 FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS .......................... 1.5 COOLING SYSTEM SPECIFICATIONS --------- 1-6 CYLINDER HEAD/VALVES SPECIFICATIONS ........................................... 1.7 CLUTCH/STARTER CLUTCH SPECIFICATIONS TRANSMISSION/G EARSHIFT LINKAG E SPECIFICATIONS ........................................... 1.3 CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER SPECIFICATIONS --------- 1-8 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ........................................... 1V9 REAR WHEEL/SUSPENSION SPECIFICATIONS ............................................ 1.9 HYDRAULIC BRAKE SPECIFICATIONS .......................................... 1.10 BATTERY/CHARGING SYSTEM SPECIFICATIONS ......................................... 1.10 IGNITION SYSTEM SPECIFICATIONS ELECTRIC STARTER SPECIFICATIONS ------ 1-10 LlGHTS/METERS/SWITCHES SPECIFICATIONS .......................................... 1." STANDARD TORQUE VALUES ------------------- 1~12 ENGINE 8t FRAME TORQUE VALUES LUBRICATION 8t SEAL POINTS ------------------ 1-20 CABLE 8: HARNESS ROUTING ------------------ 1-24 EMISSION CONTROL SYSTEMS ‘ EMISSION CONTROL INFORMATION LABEL (U.S.A. ONLY) .................................. 1.39 Contents Chapter 1 1-1 GENERAL INFORMATION SERVICE RULES . Use genuine Honda or Hondarrecommended pens and lubricants or their equivalents. Pans that don't meet Honda's design specifications may cause damage to the motorcycle. . Use the special tools designed for this product to avoid damage and incorrect assembly. . Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners, . Install new gaskets, O-rings, cotter pins, and luck plates when reassembling. . When tighlening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. . Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. . After reassembly, check all parts for proper installation and operation. . Route all electrical wires as shown in the Cable and Harness Routing (page 1724). um; wM—e mum MODEL IDENTIFICATION 1'2 Contents Chapter 1 GENERAL INFORMATION The frame serial number is stamped on the right side of the steering head. The engine seria‘ number is stamped on the rear side of the tower crankcase. The throttle body ident'wfication number is stamped on the intake side W of the throttle body as shown. The color labe‘ \5 attached on the rear fender B as shown When ordering calor»coded parts. alwavs speCIfy the designated color code. ’ {a Contents Chapter 1 GENERAL INFORMATION The Vehicle Identification Number lVlN] is located on the left side of the mainframe on the Safety Certification Labels. GENERAL SPECIFICATIONS VEHICLE lDENTlFlCATlON NUMBER lVlNl l l‘T‘E’M SPEQFIQATiDNs IiDIMENSlONS Overall length Overall width Overall height 2035 mm (80.131) 720 mm lzea inl 1,120 rnml44,1in) Front tire size Rear tire size Front tire brand Reartire brand Front brake Rear brake Caster angle Trail length Fuel tank capacuyv Bridgestone: Pi rel ii: Bridgestone: Pirel ll: Wheelbase 1,405 mm [55.3 in) Seat height 820 mm (32.3 ml Ground clearance 130 mm (5.1 in) i Dry weight A, CM type: 180 kg lam ibsl 1 AC type: 18‘l kg I399 lbs) Curb weight A, CM type: 210 kg (463 lbs) AC type: 211 kg (4651bs) Maximum weight A, ACtype' 155 kg lass lbs) capacity CM type: 170 kg 1375 lbs) FRAME Frame type Diamond Front suspension Telescopic fork Front axle travel 1‘l0 mm (4.3 ml Rear suspension Swingarm Rear axle travel 135 mml53inl guinea/1.75 us gal, 3.86 Imp gal) 120/70 ZR17 M/C (58W) 190/50 ZR17 M/C (73W) BT014F RADIAL G DIAELO CDRSA H BT0l4R RADIAL G DIAELO CORSA H Hydraulic double dISC Hydraulic single disc 23: 45' 102 mm (4.0 inl Contents Chapter 1 GENERAL INFORMATION ENGlNE ‘ Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake opens: valve closes. ‘ Exhaust opens: valve closes: Lubrication system Oil pump type Cooling system Air filtration l . . ‘ Engine dry weight F ng order k > ‘ ‘ . ,.._ FUEL DELIVERY Type ' ’ ’ SYSTEM Th nle bore . clutch system Clutch operation system Transmission anary reduction Final reduction Gear ratio ‘ DRIVE TRAIN ‘ Gearshift pattern at1rnml0.04in)lift atl mm [0.04m] lift at1 mrn (0.04m) lift atl mm (0.04m) Ii“ 15: 2nd 3rd 4th 5th 6th PGM-Fl lPTr‘zgramméd Fuel Inlectionl ’ 44.0 mm (1.73 in) 7 ‘ SPECIFICATIONS l 11 cylinders ineline, inclined 23° from vertical ‘ 75.0 x 56.5 mm (2.95 x 2.22 in) 998.4 cm3 (60.92 cu—inl 11.9: 1 Chain driven, DOHC 18° BTDC 46" ABDC 39° BBDC 11° ATDC Forced pressure and wet sump Trochoid Liquid cooled Paper element 65.8 kg [145.1 lbs) 1 . 2 - 4 - 3 Multi-plate, wet Hydraulic operating Conslanl mesh, Gespeeds 1.604 (77/48T) 2.562(15/411') 2.538 (BS/131’) 1.941 (33/17T) 1.578130/1QTI 1.380 (ZS/21'” 1.250 (25/20T) 1.160 (ZS/251') 17N72r3-47576 ELECTRICAL lgnition system Computer—controlled digital transistorized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Hegulatcr/rectlfier SCR shunted/triple phase, full wave rectifica» lion Lighting system Battery Contents Chapter 1 GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit‘ mm (in) ITEM Engine Oil capaeity Afier d ng Alt enenge . , , W, STANDARP. 3.0 liter (3 2 us qt, 2.6 lm 3.1 liter (3.3 us qt, 2.7 Imp qi) ‘ 751:5“ch LIMIT ,.,, y' Anerdlsasserfialy Recommended engine oil 3.8 liter (4.0 us at; 3.3 Imp qt) . Pro Honda GNA or HP4 (without molybr denurrl additives) Arstroke oi] (U.S.A. and Canada), or Honda Arstroke oil [Canada only], or an equivalent motor I oil API sen/ice classification. SG or Higher except oils labeled as energy conseer ing on the clrcularAPl service label JASO T 903 standard: MA Viscosity SAE 10w-40 on pressure at EOP (engine oil pressure) SWIlch 490 kFa (5,0 kgf/crrl’, 71 psi) at 5,000 rpm/(80“C/176“FI ‘ Oil pump l Tip clearance 0.15 (0.006) 0.20 (0.008) . l Body clearance . 0.15 — 0.2119006 — 0.008) 0.35 (0.014) l Slde clearance — 5310.002 —0.004) 0.17 (0.007) FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identifica- A, CM type GQADC tron number AC Iype GQADB" Starter valveyacuum dirrerence 20mm Hg TEa’s’e (FFomevalveT ' V ‘ N0. 1 :é 160 rim 1,2 274 mmll/Iseams in) intake air temperature sensor resistance (at 20°C/68“F) 1 , 4 k0 Engine coolant temperature sensor resistance 2.3 — 2.5 kg ' E ary i 10.5 S1759 ' ’ lat 20°C /68°F) Secondary in' PAIR control SOLE” CMP [Camshaft p5 68‘Fi alve reSIsiance la 'n) sensor peak val CKP (Crankshaft oosmonl sensor peak vollage (at 20°C/ 682Fl 07 V minimum Manifold absolute pressure at idle Fuel pressure al Idle lVSO , 250 mm Hg Fuel pump llow (at 12V) ,, .139.ch (6-395 02., COOLING SYSTEM SPECIFICATIONS ’ 3T3kTPa (3.5 kgr/cmiLso 51) 7 .. . > _‘_‘ LIE? oz) mlnlmum/‘lo seconds . ilTEM' ' SPECIFICATIONS icaolant capacity 3.15 liter (3.33 us qt, 2 77 imp qt) l 7 Radiator and Engine l Reserve tank 1 0.4 liter (0 42 us qt, 0.35 Imp qt) Radiator cap relief pressure 103 7137 kPa(1.141.4 kgf/CE2,15 - 20 psi) Thermostat Begin to open ‘ Fully epen l Valve lift so , 34 ac §:18§ ”Fl 9233.194 "FL 8 mm (D 3 in) minimum Recam'mata'e'd antifreeze High quality ethyleneglycol antifreeze containing corrosion protection inhibitors Standard coolant oSnE 1:1 mixtiure wirnaistilled water Contents Chapter 1 GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) . " ITEM STANDARD : SERVICE LIMIT ‘ Cylinder compression 1,098 We (11.2 kgi/cm2, 159 psi) at 350 1 A rpm Valve clearance 7 IN 0.16 i 0 03 (0.006 1 0.001) , w EX 0.30 e 0.03 (0.012 1 0.001) 1 , Camshaft Cam lobe height m 3702 — 37.10 (1,457 , 1.461) 37.00 (1.457) EX . 36.66 — 36.74 (1.443 —1.445) ( 36.64 (1.443) Runout . — 1 0.05 (0,002) ) Oil clearance 0.020 — 0.062 (0.0008 , 0.0024) 1 0.1010004) ( Valve lifter Valve litter 0.0. 25.973 — 25.993 (1.0223 - 1.0233) 25.97 (1.022) 1 Valve lifter bore )0 26.010 » 26.026 (1.0240 —1.0245) 26.04 (1.025) Valve, Valve stern 0.0. IN 3.975 — 3.990 (0.1565 — 0.1571) 1 3.965 (0.1561) valve guide EX 3.965 , 3.930 (0.1561 — 0.1567) ) 3.955 (0.1557) ) WalVe guide |.D. lN/EX 4.000 , 4.012 (0.1575 _ 0.1580) 1 4.04 (0.159) 1 SIem-to-guide clearance IN 0.010 — 0037100004 - 0.0015) 1 0075100030) ’E’x 0.020 — 0.047 (0.0008 _ 0.0019) ‘ 0.085 (0.0033) . Valve guide projection IN ) 16.1 — 16.4 (0.63 — 0,65) — ) . above cylinder head EX 15.5 — 15.5 (0.61 — 0.62) l — ‘ 1 Valve seat width IN ‘ 0.90 — 1.10 (0.035 — 0.043) ) 1.5 (0.06) . 1 Ex 0.90 —1.1010.035 — 0.043) ‘ .06) Valve spring IN ’ " 39.5 (1.56) ' 38.7 (1.52) free lens") EX 39.5 (1.56) 7 1 38.7Q52) __ Cylinder heaa'warpage’ ’7 ‘ '1 0.10 (0.004) CLUTCH/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ) ITEM ) STANDARD 7 SERVICE LIMIT ) SpeCIfied clutch fluid ' ' ) 00T4 brake fluid — m Tlutch master cylinder ) Master cylinder 1.0. ) 12.700 —12.743(0.5000 7 0.5017) 12.75510W2) '— WI’EsTer piston 0.0. 12.657 - 12.684 (0.4983 , 0.4994) 12.645 (0.4978) Clutch Spring (tee length 56312.24) 55.7 (2.19) Disc A thickness ' 3.72 — 3.8510146 — 0.153) )7 3.4 (0.13) 01sc 9 thickness 1 3.22 , 3.33 (0.127 — 0.133) 2.9 (0.11) Plate warpage - 0.90 (0.012) clutch outer guide A |.D. 27.993 , 28.003 (1.102t’11025) 28.0T2 (1.1028) (without )0 mark) 0.0 35.004 — 35.012 (1.3731 —1.3784) 34.994 (1.3777) Clutch outer gulde B 10. 27.993 — 28.003 (1.1021 — 1.1025) 29.012 (1.1028) (With )0 mark) 0.0. 34,936 — 35.004 (1.3773 — 1.3791) 34.936 (1.3774) Fri’mary driven gear 10. A 41.008-41.016(1.6145—1.6148) 41.026(1.6152) l B 41.000 — 41.0013 (1.6142 71.6145) 41.018 (16149) on pump drive sprocket 1 1.0. 28000—28021 (1.1024 — 1.1032) 23.030 (1.1035) ‘ guide 00. ' 7‘ ( 34.975 - 347991713770 — 1.3776) 1 34.365 (1.3766) Oil pump drive sprocket |.D. 35.025 — 35.145 (1.3739 71.3637) ' ) 35.155 (138417" Mainshafl 0.0. at clutch o’uter guide 27.980 4 27990711016 — 1.1020) . 27.96 (1.101) Mainshaft 0.0. at oil pump drive sprocket guide 27960 , 27.990 (1.1016 71.1020)? 2796 (1.101) Starter idle gear Gear )0 10.013 —10.035 (0.3942 — 0.3951) 10.05 (0.396) snatt 0.0. 9.991 —10.000(0.3933 — 0.3937) 9.93 (0.393) Starter driven gflboss 0.5. 45.057 — 451373117975 — 1.7901) 45.642 (1.7969) Contents Chapter 1 GENERAL INFORMATION TRANSMISSION/GEARSHIFI' LINKAGE SPECIFICATIONS 7 W Unit2mm1in) ITEM STANDARD ( SERVICE umrr snm fork I ID. 12000 — 12.010 (0.4724 7 0.4731) 1 120310474) 7,. W .. ( Claw thickness I 5.93 7 6.00 (0.233 — 0.236) . . 5.9 (0.23) Shih fork n 0.0. 11957 —11.963(0.4707 7 0.4712) 11.95 (0.470) Transmission Gear LD. M5, M6 31.000 — 31.025 (1.2205 — 1.2215) 31.04 (1.222) c1 28000—29021 (11024711032) 2004(1104) 02, c3, 04 33.000 — 33.025 (1.2992 71.3002) 33.04 (1.301) Gear busing 0.0. M5. M6 30.955 7 30.980 (1.2197 71.2197) 30.935 (1.2179) 02 . 4 — 1.2984) 32.935 (1.2967) (:3, c4 32.950 — 32975112972 71.2992) 32.930 (17.2993) ., Gear-mbushing M5, M6 0.020 7 0.070 (0.0009 — 0.0028) 0.10 (0.004) C(earance 02 0.020 — 0.070 (0.0003 7 0.0028) 0.10 (0.004) '03, CA 0.025 7 0.075 (0.0010 7 0.0030) 0.11 (0.004) Gear bushing )0 M5 27.985—28.006(1.1018—1.1026) 28.016(1.1030) 02 29 gs5—3o.006(1.101971.1026) 30.021 (1.1919) Mainshaft 0.0, at M5 00( 1011 27.957 (1.1007) ‘ Countershah 0.0. atCZ 900 (1 79 . 29.960 (1.1795) . Bushing to shaft M5 0005 — 0.039 (0.0002 — 0.0015) 0.06 (0.002) . clearance (:2 0.005 — 0.039 (0.0002 7 0.0015) . _0.96 (0.002) CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER SPECIFICATIONS Unit: mm (in) ITEM ' §TATV6ARD SERVICE LIMIT 7 Crankshsfl ) Connecting rad side clearance 0.05 _ 0.20 (0.002 7 0.009) 7 "0.25 (0.098) ) Crankpin bearing oil clearance 0.030 — 0.052 (0.0012 — 0 0020) 0.06 (0.002) LMaI'n Journal bearing oi) clearanceir 0.019 — 0.037 (0.0007 , 0.0015) 0.0501002) Runom _ 7 0.05 (0.002) Piston. plston Piston 0.0. at 4.0 (0.16) from bot- I 74.960 — 74.900 (2.9512 7 2.9520) 74995129496) rings torn Piston pin bore 1.0. 17.002 —17.009(0.6694 — 0.6696) 17.030 (0.6705) Piston pin 0.0. 16994 —110W(0R90 — 0.6693) 1699506695) Piston-to-piston pin clearance 0.002 — 0.014 (0.0001 — 0.0006) 0.04 (0.002) Piston ring and Top 022 — 0.32 (0.009 — 0.013) 0.52 (0.020) gap Second 0.48 7 0.63 (0.019 — 0.025) 7 0.82 (0032) Oil 0.2 — 0.7 (0.01 7 0.03) " 1.0 (0.04) (side rail) Piston ring-to-ring Top 0.050 — 0.085 (0.0020 7 0.0033) 0.125 (0.0049) groove clearance Second 0.015 — 0.050 (0.0006 7 0.0020) 0.075 (0.0030) . ’CVIinder I.D. 75.000 —75.015(2.95297 2.9533) 75.15 (2.959) 001 oi round _ . W 0.10 (0.004) Taper " 7 0.10 (0.004) ) Warpage .. 0.10 (0.004) CvlindEr-to-piston cIearance 0,020 — 0.055 (0.00 — 0.0022) 0.10 (0.004) Connecting rod small and )0 717.130 — 17042 (0.6705; 0.6709) . 17.049 (0.6712) . 7 Conngcgng rod-to-piston pin clearance 0.030 7 0.046 (0.0012 7 0.0019) 0.07 (0.003) . 1-8 Contents Chapter 1 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) l HEM STANDARD SERVICE LIMIT l l Minimum tire tread depth , 1,5 (0,06) _l Cold tire pres- Up to 90 kg (200 lbs) load 250 kPa (2.50 kgi/cm , 36 psi) — sure Up to maximum weight capacity 250 ltPa (2,50 kgi/cm , 36 psi) 2 ' ‘l ’Axle runouli _ 0.2 (0.008) Wheel rim ‘ Radial — 2.0 (0.08) runout Axial — 2.0 (0.08) l Wheel balance weight 1 — 60 g (2101) ‘ l 7 . max. Fork ’Spring free length 210.2 (0.59) ‘ l 213.0 (8.42) i ‘ Fork pipe runout r 0.20 (0.005) r Recommended fork fluid Pro Honda Suspensian Fluid, 55755 or equivalent Fluid level 90 (3.5) * Fluid capacity l 466 z 2.5 cm3 (15.3 2 0.03 US 01, 15.4 :r — 0.09 Imp oz) Prerload adjuster Initial sening 7 turns frqm minimum Rebound adjuster iniIial setting 2 turns out from full hard Compression adjuster initial setting 2 turns out from full hard SIeering head benring Dre-laid- 12 — 19 N (1.2 — 1.919?) REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM ‘ STANDARD i _ _ l SERVIEEUMIT Minimum (irelraad depth 7 “7* 7H - 7' v 2.0 (0.08) Cold tire 7 Up to 90 kg (200 lbsi‘load 290 kPa (2.90 kgf/crn .42 psi) , pressure , uifia‘maximum weight capacin 290 kPa (2.90 kgf/cm ,4: psi) - Axle runout _ 0.2 (0.01l l Wheel Radial * 2.0 (0.03) W W rlm ' Axial ’ — ‘ 2.0 (07683 7 runqu_ 7 Meal balance weig ht , 50 g (2.1 02) max. Drive Size/link DID ‘ DlD50VM2-114YB — ' chain i 7 l RK RK50GFOZ1-114LJFZ — Slack 25 — 35 (1 — 1-3/8) , r 375d Spring prerload adjuster standard pasi- absorber (ion Fashion 4 Rebound damping adjuster initial set 2 , ‘l/Z turns out from full hard Eggnpresslon damping adjuster initial l 9 clicks out from full hard — semng 7 .. h 1 1 '9 Contents C apter GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS 7 Unit; mm (in) I ITEM I STANDARD SERVICE LIMIT I From 77$pec7iiicd brake fluid DOT4 ' I _ Brake disc thickness 5.0 (0.20) 7 . I 4. $.16) Brake disc runout I , ' 0 i: Master cylinder (.0, I 17.460;1775073 (0.6874 , 0.6891) 1 . .68 6) Master piston 0.D. I 17321 —17.367 [0.6819 — 0.6837) 17309 (07.6815) I Caliper c‘y’I‘ifider ID. A 32080—32130(1.2630—1.2650) 7 32.140 (1.2654) I I B I 30290 730.330(1.19217 1.1941) 3 40 (11945) I I . Caliper piston 0.D. A I 31957 — 32000112535 71.2598) 31.957 (1.2531) ‘ B I 30167—30200 (11877—11890) I 30157 (1.1873) Rear SpECIfied brake fluid I DOT 4 — Brake pedal hggiL 7 I 75 (3.0) — Brake disk thIokness ‘ A I 5.00120) 4.0 (016) Brake disc runout — 0.3010012) Master cyIInder (.0. 15.870 —15.913(0.5248 , 0.6255) 15325105270) 15.627 — 15054106231 , 0.6242) 15815010226) I Master piston 0D. I CaliparcylinderlD. 35.150 — 38.230I1.503171.5051) 38.24 (1.506) I Caliper piston 00. 38.038 — 38.148 (1.4999 *1.501§)A 38.09 [1.500) BATTERY/CHARGING SYSTEM SPECIFICATIONS I ITEM SPECIFICATIBN'S’ Battery Capacity 7 12v — 8.6 Ah Current leakage v. 2.0 mA max. TVoItage FuIIv charged " 13.0—13.2 v move/68°F) Needs ’7 Beiow 124 V I charging I —5harging current Norrr71§7l 0.9 A75 — 10 h ‘ I Quick ' 4.5 MI h Afiérnator Capacity 0.344 kW/5,000 rpm Charging coiI resistance (ZINE/68°F) I 77 7 _ 0.1 , 1.0 Q IGNITION SYSTEM SPECIFICATIONS 7 7 ITEM SPECIFICATIONS I Spark plug (Iridium) NGK 7 iMnsogHEs . DENSO VUHZ7ES Spark plug gap 0.50 — 0.90 mm (0.031 , 0.035 in) ignition coil peak vol|age 7 Ignition pulse 9 atqr peak voltage IgnIIIO‘VTfifiEQ‘I‘ rnark) 100V minimum 0.7V minimum 8°12'BTD767at1dle ELECTRIC STARTER SPECIFICATIONS Unit: mm (in) ITEM Starter mutor brush length 7 I SERVICE LIMIT 6.5 (0.26) 7 77STANDARD I 12.0—13.0 (0.47—0.51) . 1-10 Contents Chapter 1 GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS 'fi'E'Iv'I ' 7 777 SPECIFICATIONS Bulbs ‘ Headlight, ‘ Hi 12v — 55 w Lo ‘ 12v — 55 w ’ Posmon light i 12v—5w Brake/tail iighl LED 77Front turn sig7n7aflming light 77 I 12V — 23/8 W x 2 (32/3 on) Rearturn signaiiigm 12v—23 Visz ’ 7 Instrument Ii LED Turnikanql ifidTatHr 7' LED High beam indicator LED Neutral indicator "' LED 7 Malfunction indicator lamp (MIL) LED Fuse Main fuse 7 an A 7 7 J PGM-Fl Iuse 20 A ’Subfuse 10Ax4,20Ax2 Tachometer peak voltage 10.5 v minimu’rfi' " ECT sensor resistance i 50 “C [175 “F) 7 2,1 7 2.6 kn 7 _ 7 ‘ 120 “C (248 "Fi 437.65 —0i73 kfl 7 Contents Chapter 1 1'11 GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE l FASTENER “PE N-m (kgf‘m, (bf-ft) FASTENER TYPE N-m (kgf—m, (bf-ft) 5 mm hex bolt and nut 4.9 (0.5, 3.6) 5 mm screw 3.9 (0.4, 2.9) l ‘ 6 mm hex bolt and nut 9.8 (1.0, 7) 6 mm screw 3.310995) 8 mm hex bolt and nut 22(2.2, 16) 6 mm llange opll 9.8 (1.0, 7) 10 mm hex bolt and nut 34 (3.5, 25) (8 mm head, small flange) 12 mm hex bolt and nut 54 [5.5, 40) 6 mm flange bolt 12 (1.2, 9| (8 mm head, large flange) 6 mm flange bolt 12 (1.2, 9) (10 mm head) and nut 11 mm flange bolt and nut 26 (2.7. 20) 10 mm flange bolt and nut 39 (4.0, 29) ENGINE & FRAME TORQUE VALUES - Torque specifications listed below are for important fasteners. - Others should be tightened to standard torque values listed above. NOTE 1. Apply sealantto the threads. 2. Apply a locking agent to the threads. 3. Stake. 4. Apply oil to the threads and flange surface. 5. U-nut. a. ALoc bolt/screw: replace with a new one. 7. Apply grease to the threads. 9. Apply molybdenum d'lsulllde oil to the threads and seating surface 9. CT bolt ENGINE MAINTENANCE: THREAD TORQUE fl . > > 7 ,7 7 ”FM I 07" DIA. (mm) N-m (kgf-m, Ibl-h) REMARKS Spark plug "" ' l 4 , ’ 1o 16l1.6,121 Timing hole cap 1 45 18l1.8,13) NOTE 7 Engine 01' filter canridge 1 ‘ 20 26 (2.7. 20) NOTE 4 l Engine oil drain bolt 1 l (2 29 (3.0, 22) LUBRICATION SYSTEM: THREAD TORQUE ”EM QTY 1 DlA. (mm) N-m (kgf-m, (bl-rt) REMARKS ‘ Oil pump assembly flange bolt 3 ( 6 12 (1,2, 9) NOTE 9 l Engine all drain base Deli 1 ‘ 6 12 (1.2, 9) NOTE 2 , Oil filler boss 7 1 l 20 See page 1~15 FUEL SYSTEM (Programmed Fuel lniecxion): . . THREAD TORQUE "EM ,7 7 a TV ‘ DlA. (mm) N311 (kgf‘m, lbw) REMARKS _ ECT (Engine CoolantTemperature)/tnermo sensor 1 ;' ' 12 23 (2.3, 17)" "E ‘ l Throttle body insulator band screw 9 ‘ 5 See page 1-15 ‘ Sewlce check bolt 1 s 12 (1.2, 9) Starter valve look nur 4 10 1,3(0.1B,1.3) Staner valve synchronization plate screw 4 3 0.9 (0.09, 0.7) Fuel pipe mounting bolt 3 s 9.8 (1 7) Fast idle wax unit llnk plate screw I 3 0.9 (0.09, 07) East idle wax unit mgflting screw 2 e 4.9 (0.5, 3.5) . A 7 , i 1 -12 Contents Chapter1 COOLING SYSTEM: GENERAL INFORMATION THREAD TORQUE ”EM 0'“ DIA. lrnm) Nrm lkgf‘m. Ith) REMARKS Water pump assembly flange bolt "2 6 l 12 (1.2, 5) NOTE 9 L Thermostat housing cover flange bolt 2 e . ‘_ 12 (1.2, 9), NOTE 9 ENGINE REMOVAL/INSTALLATION: , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf-m, lbI-It) REMARKS Drive sprocket special bolt 1 1o 54 (5.5, 40) CYLINDER HEAD/VALVES: THREAD TORQUE ”F: 0"” DIA. (rnrn) N-m (kg-m, lbf-fl) “EAR“ Cylinder head mounting bolt/washer 10 9 51 (5 2, 38) NOTE 8 Camshaft holder flange bolt 20 6 12112,!” Cylinder head sealing bolt 2 1E 27 (2.3, 20) NOTE 2 Cylinder head cover bolt 4 6 9.8 (1.0, 7) Breather plate flange bolt 3 s 12 (1.2, 9) NOTE 2 PAIR reed valve cover bolt 4 s 12 (1.2, 9) NOTE 2 Throttle insulator socket bolt 8 s 12 (1.2, 9) ‘ Cam sprocket flange bolt 4 7 20 (2.0, 14) NOTE 2 l CMP lcamshaft position) sensor rotor bolt 2 S 12 (1.2, 9) NOTE 2 ‘ Cam chain tensioner pivot bolt 1 s 9.8 (1.0, 7) NOTE 2 Cam chain guide torx bolt 1 e 12 (1.2, 9) NOTE 2 Exhaust pipe stud bolt 3 a See page 1715 CLUTCH/STARTER CLUTCH: THREAD TORqu ”EM 0"” DIA, (mm) N-m lkgf-m, lbf-ft) REMARKS Clutch center lock nut 1 25 127 (13,11, 94) NOTE 3, 4 Clutch spring bolTJwasher 5 5 12 (1,2, 9) Oil pump driven sprocket bolt 1 E 15(1.5, 11) NOTE 2 _ Starter clulch outer bolt 1 1o 83 (5.5, 61) NOTE 4 ALYERNATOR: THREAD TORQUE ”EM QTY DIA. (mm) N-m (harm. lam “MARE Stator wire clamp flange bolt 1 s . 1271.2, 9) ’ “NOTE 9 A Flywheel flange bolt 1 1o ‘ 103 (10.5, 76) NOTE 4 Stator mounting socket bolt 4 6 12 (1.2, 9) TRANSMISSION/GEARSHIFT LINKAGE: l ITEM O'TY THREAD l TORQUE REMARKS DlA. (nnrn) *Tr‘ansmission h’olatflaTEe bolt 5 s ‘ Bearing set plate lmlt 2 6 . NOTE 2 snilt drum center socket bolt 1 8 23 (2.3, 17) 1 NOTE 2 Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) Gearshift spindle return spring pin 1 a 23 (2.3, 17) Shift drurn boll/washer 1 a 12 (1.2, 9) NOTE 2 . Stfl drum stopper plate flange bolti 1 s 12 (1.2, 9) j NOTE 2 . Contents Chapter 1 1-13 GENERAL INFORMATION CRANKCASE/CRANKSHAFT/BALANCERIPISTON/CYLINDER: - THREAD ’ TORQUE” "EM 1 0"” DlA. (mm) Nsm (kgfirrr, lbf-ft) REMARKS Crankcase 7 mm bolt 12 ‘ 7 18(13, 1’5) 1 3 mm bolt 5 8 24(24, 17) ‘ 9 mm bolt (main journal bolt] 10 9 See page 13-21 NOTE 4 ‘ 1 Lower crankcase seallng bott 1 22 59 (6.0, 43) NOTE 2 Lower crankcase socket bolt 1 1o 12 (112, 9) NOTE 2 Lower crankcase sealing ban 1 20 29 (3.0, 22) NOTE 2 Lower crankcase socket bolt ‘ 1 8 23 (2.3, 17) NOTE 2 Connecting rod boll (new bolt) 8 8 See {1519213721 NOTE 4 Cannecting rod bolt {retighteninm E 8 Sggvpage 13-12 4 NOTE 4 ELECTRIC STARTER: "’7 W ""‘ ‘T'HRFA‘DW " TORQUE 1 ”EM 07" DIA. (mm) Nsm (Iggfrm, lbw) REMARKS Starter motor terminal nut 1 6 1 12 112,91 LIGHTS/METERSISWITCHES: ‘ ‘ THREAD TORfiUE 1 :77 , 77—"EM7 fl , 7 W 07" D!A;(mml N-m (kgfrm. lbl-h) REMARKS on pressure switch 1 PT1/B 1 121125) NOTE 1 on pressure switch wire terminal screw 1 4 1 2.01012, 1.4) 1 fleutral switch 1 1o ‘ 12711.2, 9) 1 7 . ,1 Contents Chapter 1 Oil filter buss: Insulator clamp (Throttle body side): Exhaust pipe stud hok: GENERAL INFORMATION T LL_ llllfll LE. 14.9:05mm (0.59+0.04in) 7 t1mm(113 1 0.0:: in) Contents Chapter 1 1-15 GENERAL INFORMATION FRAME FRAME/BODV PANELS/EXHAUST SYSTEM: , THREAD TORQUE ”EM QTY DIA. 1mm) N-m (kgfrm, [bf-ft) REMARKS Seat rail flange socket bolt/flange nut 2 10 ‘ 59 16.0, 43) Seat rail special bolt/flange nut 2 10 59 16.0, 43) Seat rail assembly flange bolt/nut 2 8 30 13.1, 22) Seat rail brace socket bolt 4 s 26 (2.7, 20) Passenger seat bracket special bolt 2 8 26 (2,7, 20) Passenger seat bracket socket bolt 2 8 26 (2.7. 20) Rlder seat bracket mounting bolt/nut 4 6 3.8 11.0, 7) Rider footpeg bracket socket bolt 4 8 37 (3.8, 27) , Bank sensor_ 2 5 11 11.1, a) , Passenger footpeg bracket socket bolt 4 3 2612.7, 20) , Exhaust pipeloinznut a 7 12 11.2, 9) Exhaust pipe mounting bolt 1 8 23123.17) Exhaust joint pipe clamp SH bolt 1 6 9.8 11.0, 7) Exhaust valve pulley nut 1 6 4.9 (0.5, 3.6) Exhaust valve retaining screw 2 4 1.51015, 11) Exhaust valve pulley housing flange SH bolt 2 6 ‘ 9.8 (1.0, 7) Exhaust pipe clarnp bolt 1 8 . 1511.3,131 Upper cowl stay flange bolt 2 s l 3213.3,24) ‘ Cowl stay mounting bolt 2 6 1 12 11.2, a) , Windscreen mounting screw 6 5 0510.05, 0.4) 1 Middle cowl pan screw 2 5 T 1.510.15, 1.1) Mlddle cowl special screw 2 6 ; 9.811.117) Under cowl pan screw 6 5 ‘ 1.51015, 1.1) Under cowl special screw 4 6 ‘ 9.3 11.0, 7) 1 Inner cowl special screw 1 6 , 9.3 11.0, 7) ‘ Front fender pan screw 6 6 12 (1.2, 9) ‘ Rearview mirror socket bolt 4 6 L7 7 67871977, 5.1) , MAINTENANCE: . THREAD TORuUE ITEM 0 TV DIA. (mm) 1 N-m [kgf-m, th't) ‘ EMEFES Throttle cable adjuster lock nut 2 6 5.4105540) ' 1 -16 Contents Chapter1 FUEL SVSTEM (Programmed Fuel Injection): GENERAL INFORMATION Contents Chapter 1 THREAD TORQUE "EM 0:” DIA. (mm) N-m (kgr-rn, Ibf-ftl REMARKS ) Fuel filler Cap socket bolt 3 ' 4 1.8(0.18, 1.3) ‘ Fuel teed hose banjo bolt (fuel tank sldel 1 12 22 (2.2, 16) Yellow paint Fuel hose sealing nut (throttle body side) 1 12 22 (2.2, 16) l Fuel pump flange nut 6 s 12 (1.2, 9) l l i 1 Fuel tank mounting bolt (front) 2 a 26 (2.7, 20) Fuel tank mounting bolt (rear) 2 s 9.8 (1.0, 7) Fuel rail joint hose bolt 2 S 9.8 (1.0, 7) Yellow palnt l Fuel rail joint hose sealing nut 1 12 22 (2.2, 16) Yellow paint Air cleaner housing/air funnel pan screw 6 5 4.410.115, 3.3l Top air cleaner housing mounting screw 5 5 1.2 (0.12, 0.9) Middle air cleaner housing mounting screw 8 5 1.2 (0.12, 0.9) IAT sensor mounting screw 2 5 1.2 (0.12, 0.9) A1 ntake ductjoint screw 2 5 2.5 (0.25, 1.8) Air intake duct cover screw 6 4 1.2 (0.12, 0.9) Secondary injector base mounting bolts 5 5 5.4 (0.55, 4.0) Bank angle sensor mounting screw 2 4 1.5(o.15, 1.1) COOLING SVSTEM: , THREAD TORQUE ITEM QTY DIA. (mm) Nam (kgf-m, Ibf-ft) REMARKS Cooling fan nut 1 5 2.9 (0.3, 2.2) NOTE 2 Fan motor nut 3 5 4.3 (0.5, 3.6) inrmoitor bracket mounting bolt 3 5 8.8 (0.9, 5.5) l l ENGINE REMOVAL/INSTALLATION: T' ’ , THREAD TORQUE ’1 "EM a TV I DIA. (mm) N-m lkgf~m, lbw) l EEMARKS ; Engine hanger adjusting bolt 2 20 15 (1.5, 11) ‘ Engine hanger adjusting bolt lock nut 2 20 54 (5.5, 40) Rear upper engine hanger nut 1 12 64 (6.5, 47) See page 8- Flear lower engine hanger nut 1 12 64 (6.5, 47) S Front engine hanger bolt 2 12 64 (6.5, 47) Middle engine hanger bolt 2 12 B4 (6 5, 47) l CLUTCH/STARTER CLUTCH: THREAD TORQUE ”EM 0'" DIA. (mm) Nam lkgf~m, 10m) T REMARKS Clutch master cylinder oil cup screw 1 4 1.5(0.15, 1.1) NOTE 2 Clutch lever pivot bolt 1 6 1.0 (0.1, 0.7) Clutch lever pivot nut 1 6 5.9 (0.6, 4.3) Clutch switch screw 1 4 1.0 (0.1, 0.7) Clutch hose oil bolt 2 10 34 (3.5, 25) Clutch master cylinder holder bolt 2 6 12 (1.2, 9) , Master cylinder bleed valve 1 a 5.9 (0.6, .3) 7 1 - 1 7 GENERAL INFORMATION TRANSMISSION/GEARSHIFI’ LINKAGE: I . THREAD l TORQUE "EM (:1 TV DIA. (rnrn) I Nrm (kgf‘m, IbI-I't) REMARKS Gearshift pedal pivot bolt 1 's I 22(22, 15) Gearshift pedal link pinch bolt ‘ 1 6 l 5.3 (1.0.7) Linkarm locknut 2 5 I 9.5114047) FRONT WHEEL/SUSPENSION/STEERING: 7" "' ' . T" TTREAD TORQUE ”EM “TY DIA. (mm) I N-m (kgI-m. let) REMARKS Handlebarweight mounting screw 2 6 l 9.8 (1.0, 7) NOTE 5 Handlebar pinch bolt ‘ 2 s I 26 (2 7, 20) Front axle bolt 1 1 18 78 (5.0, 58) Front axle holder pinch oolt I 4 a . 22 (2.2, 16) Front brake dl’sc bolt 12 a 20(2)),14) NOTE 5 Fork socket bolt 2 10 ‘ 34 (3.5, 25) Fork bolt 1 2 4e 34 (3.5, 25) Fork damperlock nut I 2 14 I 25(2.6,19) Fork compression adjuster plug oolt I 2 14 , 18 (1 s, 13) Fork tap bridge pinch boIt ‘ 2 s 23 (2.3, 17) Fork bottom bridge pinch bOIt 4 3 ‘ 23 (2.3, 17) Steering damper second arm nut I ‘I 6 I 12 (1.2, 3) NOTE 5 Steering damper second arm bolt ‘ ‘I 6 8.8 (0.5, 6.5) Steering damper mounting bolt 3 6 I 8.3 (0.9, 6.5) Steering stern adjusting nut I 1 2e ‘ 20 (2.0, 14) I 5 Steering stem adjusting lock not 1 25 e 1535399 Steering stern not I 1 24 103 (10.5,776I REAR WHEEL/SUSPENSION: THREAD TORQUE ITEM I 0“ DIA. (mrn) N-m (kgf‘m, lent) REMARKS Rear axle nut '1 “‘1 A" '22’ '7113(11 .33) NOTE 5 Rear brake dlsc bolt 4 a 42 (443, 31) NOTE 6 Flnal drlven sprocket nut 6 10 i 64 (5.5, 47) NOTE 5 Rear shock absorber upper moumlng nu! 1 10 44 (4.5, 33) i NOTE 5 Rear shock absorber lower mounting not 1 1o 44 (4.5, 33) NOTE 5 Shock link-tarframe pivot not 1 1o 44 (4.5, 33) NOTE 5 Shock armrto-shock link nut 1 1o 44 (4.5, 33) NOTE 5 Shockarm-to-swingarm nut 1 1o 44 (4.5, 33) NOTE 5 Drive chaln case flange bolt 3 ‘ 6 12 (1.2, SI Swingarm pivot adjusting bolt 1 36 15(15, 11) Swingarm pivot adjusting bolt lock nut 1 35 64 (5.5, 47) Swingarm pivot nut 1 22 113 (11.5, 83) AW? chain slider bolt 3 I 6 8.8 (0.9, 6.5) NOTE 2 1 -18 Contents Chapter 1 GENERAL INFORMATION Contents Chapter 1 HVDRAULIC BRAKE: ' , THREAD . TORQUE 'TEM _ #:TI DE. (rrlrn) ‘ N-m (kgf-m, lbm) y REMARKS Brake hose oil bolt 5 10 l 34 (3.5, 25) 1 Rear brake caliper pad pin 1 10 1 13113.13) ( Hear caliper bleed valve 1 B ‘ 5.53616, 4.3) \ Rear brake caliper slide pin boll ‘ 1 12 ‘ 27 (2.5, 20) Rear brake caliper mounting bolt 1 B 23 (2.3, 17) Rear brake hose clamp bolt 1 ‘ 5 3.3 (0.4, 2.9) Rear master cylinder push rod joint nut 1 E 18(1.8,13) 1 Rear brake reservoir hose joint screw 1 4 l 1.5 (0.15, 1.1) NOTE 2 Rear master cylinder reservoir cap screw 2 4 1.5 (0.15, 11) Rear master cylinder reservoir mounting bolt 1 6 12 (1.2, 9) Rear master cylinder mounting bolt 2 l 6 5.311117) Brake pedal pivot bolt 1 ‘ 8 18 (1.8, 13) From brake caliper mounting bolt 4 10 45 (4.6, 33) NOTE 6 Front brake caliper assembly bolt 3 ‘ e 23 (2.3, 17) NOTE 2 Front brake caliper pad pin 2 l 10 16 [1.6, 12) Front caliper bleed valve 2 , 8 7.8 (0.8. 5.8) Front brake hose clamp 1 l 6 8-5 (0.9, 6.5) Front brake hose 3»way joint bolt 1 6 9.8 (1.0, 7) Front brake hose clamp (left side) 1 , 6 9.3 (1.0, 7) Front master cylinder reservoir cap screw 2 4 1,5(015, 1.1) From master cylinder reservoir stay bolt 1 J 6 12 (1.2, 9) Front brake light switch screw 1 l a 1.0 (0.1, 0.7) Front master cylinder reservoir mounting nut 1 6 5.5 (015,43) NOTE 5 Front brake lever pivot bolt 1 6 1.0 (0.1, 0.7) From brake lever pivot nut 1 6 5.9 (0.6, 4.3) Front master cylinder bleed valve 1 l 8 5.9 (0.6, 4.3) From rrlasuflcylinder holder bglt _ 2 ei_ 1211.2,9) fl, LlGHTS/METERS/SWITCHES: THREAD TORQUE lTEM , o'Tv l “A (mm) «515,9 M L REMAEKS . Ignition switch mounting one-way bolt ’ 2 . a " 26 (2 7, 20) fl 1 1 Flight handlebar switch screw 2 4 a 910.09. 0.7) l Combination meter assembly screw 3 5 1.0 (0.1, 0.7) Side stand sw1tch special bolt 7 _ _ 1 5 7 9.8 (1.0, 71 NOTE 6 OTHERS: THREAD TORQUE . 7 ”EM (1“le DIA. (0mm) N m [kgf m, lb! ft) REMARKS Side stand socket bolt ‘ 54 (5 5,40) Side stand pivot bolt 10 l 9.8 (1.0, 7) Side stand pivot nut _ 1 J0 l 29 (3.0, 22) 1 -1 9 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE \ ' 'EOCATION y MATERIAL \ REMARKS "T ‘ Crankcase mating surface Liquid sea‘ant ‘ [Three Bond 12073 or I equiva‘ent) ‘ \ t \ \ ‘ i t t ‘ \ t \ _ E E ,_ \ :w o L a u, Q, : 7; 2°. 0 co 9:: ‘ 92 ‘ v o N. ‘ 92 a - 0 1 o A “3 D 0 ‘ _ 10415 mm (0.440.5m] ‘ 0\ 10415mm (04406 m] /F / r4 5% \w 10415an (“Anew on pan mating surface 3”}? l: w“ M 1'20 Contents Chapter 1 GENERAL INFORMATION LOCATIde MATERIAL ] REMARKS High! crankcase cover mating surface Oil pressure swiIch threads Do not apply sgaranl m the thread head3 A4 mm (on ~ 02 In) Liquid sealant [Three Bond 12075 or equivalem] Contents Chapter 1 1-21 GENERAL INFORMATION LOCATIO N MATERIAL ,, EEK/[AWE ”7 7' Main journal bearing surface Piston pin sliding surface Connecting rod bearing surface Connecting rod small end inner surface Crankshaft thrust surface Camshaft lobes/journals and thrust surface Valve stern (valve guide sliding surfacel Valve lifter outer sliding surface Water pump shaft thrust washer sliding surface Clutch outer/primary driven gear sliding surface Clutch outer guide sliding surface Oil pump drive sprocket and collar sliding surface M3/4, C5, C6 shifter gear (shift fork grooves) Starter reduction gear shaft sliding surface Starter idle gear shaft sliding surface Cylinder head special bolt (after removing anti-rust Oil additive) Molybdenum disulfide oil la mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease Do not apply mating sur» face ofthe camshaft holder ‘ Each oil seal llps Clutch joint piece sliding surface Clutch lifter rod outer area Piston and piston ring sliding area Oil strainer packing Clutch disc surface Starter onerway clutch sliding surface Flywheel bolt threads and seating surlace Clutch center lock nut threads and seating surface Oil filter cartridge threads and O»ring Camshaft holder bolt threads and seating surface Starter clutch outer bolt threads and seating surface Connecting rod bolt threads and seating surface Each gearteeth and rotating surface Each hearing Each Orring Other rotating area and sliding surface Engine oil Timing hole cap threads Balancer damper rubber fitting area g'bolitfiéa’ds 7 Lower crankcase 20 mm sealing bolt threads Lower crankcase 10 mm sealing bolt threads Lower crankcase 8 mm sealing bolt threads Cam chain guide A bolt threads CMP (Camshaft position) sensor rotor bolt threads Cylinder head sealing bolt threads Cylinder head cover breather joint threads Oil orifice bolt threads Oil pump driven spruaket bolt threads Shift drum bearing set plate bolt threads Oil filter boss stud thread Mainshart/countershart bearing set plate bolt threads Cam sprocket bolt threads Cylinder head cover breather plate bolt threads Shift drum center bolt threads Cam chain tensioner pivot bolt threads Spindle plate tightening bolt threads Shift drurn stopper plate bolt threads Oil pan drain base bolt threads Gearshift splndle cover bolt threads M ultl-purpose grease Looking agent Coating width: 6.5 :1 mm Coating width: 6.5 :1 mm Coating width: 6.5 :1 mm Coating width: 5.5 :1 mm Coating width: 6.5 :1 mm ' ' 6.5:1 mm 6.5 11 mm Coating width: 6.5 :1 mm Coating width: 6.5 :1 mm Coating width: 6.5 :1 mm Coating widt 6.5 11 mm Coating width: 6.5 :1 mm 1-22 Contents Chapter 1 FRAME GENERAL INFORMATION LOCATION Side stand pivot Rider footpeg sliding area Passenger peg sliding area Rear brake pedal pivot sliding area Throttle grip pipe sliding surface Passenger seat catch hook sliding area Gearshift pedal pivot sliding area From wheel dust seal lips Rear wheel dust seal lips Final driven flange Caring Rear shock absorber pivot dust seal lips MATERIAL l Multirpurpose grease ‘ REMARKS 7 7 Steering head bearing adjusting nut threads Upper and lower steering head bearing Steering head dust seal lips Swingarm pivot hearings Swingarm pivot dust seal lips Shock arm and shook link needle bearings Shock arm and shock link dust seal lips Gearshift pedal link tierrod ball joints Urea based multi-purpose grease with extreme pres sure (example: EXCE- LIGHT EPZ manufactured by KVODO YUSHI, Japan), Shell stamina EF2 or equivalent Multipurpose grease (Shell Alvania EFZ or equivalent) 0.1 - 0.3 g 3 - 5 g (eami Throttle cable A, B cable inside Cable lubricant ‘ Exhaust valve cable A, B cable inside Moly‘baenum oil Handlebar [:er rubber insid; Honda bond A, Pro Honda Handgrip Cement (U.S.A. only) or equivalent "iront braiemer pivotJadiuaer/pusn red sliding area Front brake push rod and piston contacting area Roar brake caliper boot inside Rear brake master piston-to—push rod contact area Brake caliper dust seals Clutch lever sliding area and piston contact area utch pivot bushing and piston contact area Silicone grease eke master piston and cups Brake caliper piston and piston seals DOT 4 brake fluid Fork cap O-ring Fork dust seal and oil seal lips Pro Honda Suspension Fluid 88-55 or eguivalent Rear brake reservoir hose joint screw threads Front master cylinder oil cup stay mounting bolt threads Front brake caliper assembly bolt threads Rear brake caliper pin bolt threads Clutch oil cup tightening screw threads Locking agent Contents Chapter 1 1-23 GENERAL INFORMATION CABLE & HARNESS ROUTING THROTTLE CABLES IGNITION SWITCH WIRE LEFI' HANDLEBAR SWITCH WIRE RIGHT HANDLEBAH SWITCH WIRE FRONT BRAKE HOSE HORN WIRE FRONT SUB-HARNESS 12P(GRAV) CONNECTOR COMBINATION METER POSITION LIGHT , .1 MULTl-CONNECTOR 2P (NATURAL) CONNECTOR ’ RIGHT TURN SIGNAL 3P (LIGHT BLUE) CONNECTOR BANK ANGLE SENSOR 3P (GREEN) CONNECTOR LEFT TURN SIGNAL 3P (ORANGE) CONNECTOR FRONT SUBVHARNESS 1 2P (GRAY) CONNECTOR HEADLIGHT SOCKET 1-24 Contents Chapter 1 GENERAL INFORMATION THROTTLE CABLES HORN WIRE FUSE BOX FRONT BRAKE HOSE Contents Chapter 1 1-25 GENERAL INFORMATION THROTI'LE CABLES FRONT BRAKE HOSE MAINWIRE HARNESS RADWATOH SIPHON HOSE 1-26 Contents Chapter 1 GENERAL INFORMATION IAT SENSOR 2P (GRAY) CONNECTOR MAIN WIRE HARNESS CMP (CAMSHAFT POSITION) SENSOR 2F (BLACK) CONNECTOR SECONDARY INJECTOR FUEL JOINT HOSE PRIMARY INJECTOR FUEL HOSE VS (VEHICLE SPEED! SENSOR 3? (NATURAL) CONNECTOR Contents Chapter 1 1 -27 IAT SENSOR 2P (GRAY) CONNECTOR No.4 No.3 No.2 No.1 No.2 ECT SENSOR 3P (GRAY) CONNECTOR I) V Chapter 1 Contents GENERAL INFORMATION No 1 IAC THERMAL VALVE Y RS mm NT 0C E mu. SW PRIMARY INJECTORS 1-28 GENERAL INFORMATION REGULATOR/RECTIFIER 2? (NATURAL) CONNECTOR SIDE STAND 2P (GREEN) CONNECTOR FUELTANK BREATHER HOSE CMP (CAMSHAFT POSmON) SENSOR ZP (BLACKI CONNECTOR SIDE STAND SWITCH WIRE Contents Chapter 1 1-29 GENERAL INFORMATION IGNITION COIL SUB-HARNESS MAIN WIRE HARNESS k.” ’2" . »§ -.‘ REAR BRAKE LIGHT SWITCH WIRE RADIATOR SIPHON HOSE ENGINE SUB-HARNESS CKP (CRANKSHAFT RADIATOR OVERFLOW mglETION) SENSOR HOSE 1'30 Contents Chapter 1 GENERAL INFORMATION HEAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR IGNITION COIL SUB-HARNESS CKP (CRANKSHAFT POSITION) SENSOR 2P (RED) CONNECTOR 6” (NATURAL) CONNECTOR ,/ \ REAR BRAKE LIGHT RADIATOR SIPHON HOSE SWITCH WIRE RADIATOR OVERFLOW HOSE Contents Chapter 1 1-31 GENERAL INFORMATION EGCV SERVOMOTOR 6P (NATURAL) CONNECTOR VEHICLE SPEED SENSOR 3P EGCV SERVOMOTOR (NATURAL) CONNECTOR EGCV CONTROL ' CABLES FUEL TANK BREATHER HOSE NEUTRAL SWITCH Contents Chapter 1 GENERAL INFORMATION MAIN WIRE HARNESS TURN SIGNAL/LICENSE STARTER RELAV wrrcH _SEAT LOCK CABLE LIGHT CONNECTORS S STARTEHMOTOR GROUND CABLE REAR BRAKE HOSE §m¥CE1RcV||<|§EUGHT Contents Chapter 1 1-33 GENERAL INFORMATION CALIFORNIA TYPE: FUEL mum; THROW“ 90'“ EYa‘tESBFDGvEAieé‘EE‘Orh/mm CANISTER HOSE 5-WAY JOINT CONNECTOR ( ) wags“ EVAP CANISTER SOLENO‘D VALVE 134 Contents Chapter 1 GENERAL INFORMATION EVAP PURGE To fuel tgnk T0 5-way joint SOLENOID VALVE CANISTER-TOGOLENOID DRAIN HOSE EVAP CANlSTER VALVE HOSE Contents Chapter 1 1'35 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The US. Environmental Protection Agency (EPA), Transport Canada and California Air Resources Boad (CARS) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided. The EPA also requires that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control System is necessary in order to keep the emission system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of hydrocarbons and oxides of nitrogen 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 lean injection settings as well as other systems, to reduce oxides of nitrogen, carbon monoxide 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 chambertnrough the air cleaner and throttle body. AIR CLEANER HOUSING THROTI'LE BODY FRESH AIR l:"> BLOWVBY GAS * 1'36 Contents Chapter 1 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed oi a secondary air supply system, a oxidation catalytic converter and a lean fuel injection setting, No adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crank case emission control system. SECONDARY AIR SUPPLY SYSTEM The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the FAIR (Pulse Secondary Air Injection] control valve, This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevents reverse air flow through the system. The PAlR control valve is operated by the solenoid valve. The solenoid valve is controlied by the PGM-Fi unit, and the fresh air passage is opened/closed according to running conditions (ECT/lAT/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. AlFi CLEANER HOUSING PAIR CHECK VALVE THROTTLE BODY EXHAUST FORT PAIR CONTROL VALVE FRESH AIR i:> EXHAUST GAS * OXIDATION CATALYTIC CONVERTER (CALIFORNIA TYPE ONLY) This motorcycie is equipped with a oxidation catalytic converter. The oxidation catalytic converter is in the exhaust system. Through chemicai reactions, it converts Hc, co, and NOx in the engine‘s exhaust to carbon dioxide (COzi, dinitrogen (N2), and water vapor. Nu adjustment to these systems should be made although periodic inspection or the components is recommended. Contents Chapter 1 1-37 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with CARB evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAF) canister where is it absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAF canister is drawn into the engine through the throttle body. FUEL TANK EVAP PURGE CONTROL SOLENOID VALVE THROTTLE BODY EVAP CANISTER NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: US. Federal Law prohibits or Canadian Provincial Law may prohibit the following acts or the causing there of: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, oi any device or element of design incorporated into any new vehicle iorthe purpose of noise control prior to its sale or delivery to the ultimate purchaser orwhile it is in use; (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any persons AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baflles,header pipes or any other component which conducts exhaust gases. 2. Removal of, or puncturing of any part of the intake system. 3. Lack of proper maintenance, 4. Replacing anv moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those speci» fied by the manufacturer. 1-38 Contents Chapter 1 EMISSION CONTROL INFORMATION LABEL (U.S.A. ONLY) An Emission Control Information Label is located on the storage compartment as shown. GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL Contents Chapter 1 1 -39 MEMO Contents Chapter 1 2. TECHNICAL FEATURES HESD (Honda Electronic Steering RADIAL-MOUNTED FRONT BRAKE Damper) ....................................................... 2.2 CALIPER ....................................................... 2.5 EGCV (Exhaust Gas Control Valve)-u-r--«----~2-6 Contents Chapter 2 2-1 TECHNICAL FEATURES HESD (Honda Electronic Steering Damper) This motorcycle is equipped with the Honda Electronic Steering Damper [HESDL The HESD system consists of the following components. — Steering damper assembly with linear solenoid - VS (vehicle speed) sensor — ECM v Malfunction indicator lamp (MIL) and HESD Indicator The steering damper assembly is installed on the main frame near the steering head pipe and the linkage arm is installed on the top fork bridge. The damping characteristics are automatically controlled by the ECM in response to vehicle speed and acceleration and offers optimum han» HESD DAMPING CHARACTERISTIC - a a a - - DAMPING s. -7 dling over a Wide range or l’ldlng conditions. CHARM; TERISTICS HESD employs a hydraulic rotary damper unit. The hydraulic oil is filled into the steering damper and is sealed permanently. The steering damper unit is not serviceable. Each component of HESD functions as follows. — Damper nil chamber/Vane The damper oil Chamber is divided in two by a moving vane connected internally to the linkage arm. The edge of the vane is covered with an oil seal so that the left and right chambers are sealed from each other. Therefore oil moves between the left and right sides of the chamber via check valve controlled hydraulic passages. — Check valve Four one-way check valves ensure that oil flows through the main valve in only one direction, whether the vane is moved left or right. e Accumulator Accumulator compensates for temperature-induced changes in oil volume. — Main valve/Linear solenoid The opening of the main valve is controlled by a linear solenoid that receives its control signals from the ECM. The damping characteristics are varied by the main valve/linear solenoid. m Reliel valve The relief Valve controls and sets a limit to the maximum damping force. ACCUMULATOR CHECK VALVES RELIEF VALVE MAIN VALVE/LINEAR SOLENOID 2-2 Contents Chapter 2 TECHNICAL FEATURES DAMPER OIL FLOW DIAGRAM WHEN THE STEERING MOVES TO LEFT: WHEN THE STEERING MOVES TO RIGHT: Contents Chapter 2 TECHNICAL FEATU RES CONTROL SYSTEM Receiving the signal from the VS sensor, the ECM calculates the vehicle speed and rate of acceleration. The ECM outputs the control current to the linear solenoid coii based upon the vehicle speed and acceleration. The linear solenoid depresses the main valve according to the control current which passes through the linear solenoid, and controls the damping char- acteristics of HESD. @ ° @ BATTERY ,. .. \ olL CHAMBER VANE ECM \ R A _ 22:3” {sews J W INDICATOR E CHECK ' CHECK VALVES '7 VALVES HELIEFVALVE % ACCUMULATOR - SYSTEM CONTROL ~ vs (VEHICLE SPEED) : SENSOR g {3% LINEAR SOLENOID/MAIN VALVE SENSOR - ------------ - STEERING DAMPER SELF-DIAG NOSTIC SYSTEM The HESD system is equipped with a self-diagnostic and faiirsafe system that is linked to the F'GM-FI system. When the ECM detects any tailure of the linear solenoid or vs sensor, it stops controlling the linear solenoid and informs the rider of system trouble by turning on the MIL and displeylng the HESD indicator. lithe malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures (page 6-9) to remedy the problem. The fail-safe system secures a minimum running capability when there is any trouble in the system. When any abnormality is detected by the self-diagnosis function, the ECM stops the HESD system control by shutting off the current supply to the linearsolenoid and the HESD wili operate under minimum damping characteristics. The HESD system is also equipped with the Function Test Mode so that a technician can compare the minimum with max- imum damping characteristics without riding. The HESD system is set to minimum damping at no vehicle speed under normal conditions, By using the Function Test Mode, the ECM operates the linear soierlcid with maximum current so the HESD system is temporarily set to maximum damping. Contents Chapter 2 TECHNICAL FEATURES RADIAL-MOUNTED FRONT BRAKE CALIPER The CBRlOOORR's new front brake system features a set of radial-mounted calipers. These calipers feature distinctive turret-like mounts that are perpendicular to the front axle, onto which the calipers bolt straight down. The caliper halves are held together by three lateral bolts for a more rigid design that provides both stronr ger grip and more even pressure distribution across the entire surface area of the pads for highly efficient braking with excellent feel at the lever. Along with these new radial-mounted front brake calipers, the new front brake system features a newly developed vertical piston layout master cylinder. This system minimizes lost motion and moves the lever pivot farther away from the end of the lever which offers high braking efficiency with excellent feel and controllability. Contents Chapter 2 2-5 TECHNICAL FEATURES EGCV (Exhaust Gas Control Valve) This motorcycle is equipped with the EGCV that provides high performance and driveabllily especially at low to middle speed range by varying the exhaust gas flow. This system consists ol the variable exhaust control valve located in the muffler and a servomomr located under the fuel tank. The variable exhaust control valve is operated by cables from the servomotor thai is controlled by ECM. Basically, rhe EGCV is positioned middle ax iowio middle speed range and opens fully at high speed range. EGCV OPENING ANGLE: I nition Gear osition . EGCV o enin an le gwitoh (Clinch s‘leitch OFF) “9"“ 59““ from ful'I’y classed 9 ON Neuiral » Approx. 50° ON Neurral idle Approx. 50° ‘ 0N Without neutral idle Approx. 00“ ' iON Without neutral 5,000 — 6,000 rpm Approx. 75° , 90“ ON Without neutral l over 6,000 rpm Approx. 90° NOTE Ii is necessary to inspecl the EGCV condition and cable adjuslmem in accordance with the maintenance schedule (page 4-4). EGCV SERVO MOTOR EGCV'PULLEY v *’ EGCV CONTROL CABLES 2-5 Contents Chapter 2 3. FRAME/ BODY PANELS/ EXHAUST SYSTEM BODY PANEL LOCATIONS ......................... 3.2 UPPER COWL .......................................... 3.12 SERVICE INFORMATION ............................. 3.3 TOP SHELTER .............................................. 3.13 TROUBLESHOO‘HNG .................................... 3.3 FRONT FENDER ............................................ 3.1g RIDER SEAT ................................................... 3,4 REAR FENDER .............................................. 3.13 PASSENGER SEAT ........................................ 3.4 SEAT RAIL .................................................... 3.27 REAR SEAT COWL ....................................... 3.5 EXHAUST PlPE/MUFFLER----AA-u~-------~--«-----3-30 UNDER COWLS/MIDDLE COWLS ------------- 3-7 3-1 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS FRONT SIDE COVER WINDSCREEN TOP SHELTER RIDER SEAT PASSENGER SEAT REAR SEAT COWL UPPER COWL FRONT FENDER REAR FEN DER A INNER LOWER COWL UNDER COWL MIDDLE COWL INNER MIDDLE COWL Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL I This section covers removal and installation of the body panels, exhaust system and seat rail. Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. Always replace the exhausl pipe gaskets with a new one afler removing the exhaust pipe from the engine, When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust pipe clamps first, then tighten the mounting fasteners, - Always inspect the exhaust system for leaks after installation. TORQUE VALUES Sea! rail flange soCket bolt/flange nut 59 N-rn (6,0 kgfrn, 43 lbf-fil Seat rail special boll/flange nut 59 N-m (6,0 kgfrrn, 43 lbf-ft) Seat rail assembly flange nut 30 N-m (3.1 kgf-m, 22 lbf-fi) Seat rail brace socket bolt 25 N-m (2.7 kgfim, 20 lhf-ft) Passenger seat bracket special bolt 26 N~m (2.7 kgfrm, 20 lbf-ft) Passenger seat bracket socket bolt 26 Nm (2.7 kgfvm,201bfftl Rider seat bracket mounting boltJnut 9.8 N‘m (1.0 kgf~m, 7 lbf-ft) Rider footpeg bracket socket bolt 37 N4“ (3.8 kgl~m, 27 lbi-fl) Bank sensor 11 N-ml1.1kgf-m,8lbf-ft) Passenger footpeg bracket socket bolt 26 Nrm (2.7 kgf-m, 20 lbf-ftl Exhaust pipe joint nut 12 N-m (1.2 kglrn, 9 WW” Exhaust pipe mounllng bolt 23 N-m (2.3 kgf‘m, 17 |bf~ftl Exhaust loint pipe clamp SH bolt 9.3 NM (1.0 kgf-rn, 7 lot-ft) Exhaust valve pulley nut 4.9 N‘m (0.5 kgf-m, 3.6 lbfrfll Exhaust valve retaining screw 15 N-m (0,15 kgf-m,1.1 lbf-h) Exhaust valve pulley housing flange SH 8.8 N-rrl (1.0 kgl-m, 7 lbf-ftl bolt Muffler pipe clamp bolt 18 N-m (1.8 kgl-m.13lb1vftl Upper cowl stay flange bolt 32 Nrm (3.3 kgf-m, 24 lbf~ftl Cowl stay mountlng bolt 12 Nam (1.2 kgl-m, 9 let] Windscreen mounting screw 05 N-m (0.05 kgf-m, 0.4 lbf-ft) Middle cowl pan screw ’ 1.5 N~rn (0.15 kgf-m, 1.1 lbfrft) Middle cowl special screw 9.8 N-m (1.0 kgf-m, 7 Ibf‘fll Upper cowl pan screw 1.5 N-m (0.15 kgf—m, 1.1 lhfm Upper Cowl special screw 9.8 N-m (1.0 kgf‘m, 7 lbf‘ftl Inner cowl spacial screw 9.8 me (1.0 kgf-m, 7 lbf‘ftl Front fender pan screw 12 N-m (1.2 kgfvm, 9 lbf-ft) Rearview mirror socket bolt 6.8 N~m (0.7 kgl-m, 5.1 lbf'fll TROUBLESHOOTING Excessive exhaust noise I Broken exhaust system - Exhaust gas leak Poor performance I Deformed exhaust system - Exhaust gas leak - Clogged muffler Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM RIDER SEAT REMOVAL/INSTALLATION Remove the two seat mounting pan screws and col» Iars‘ Remove the seat by pulling it backward. Install the seal hooks under the seat bracket on the seat rail. InstalI the collars and seat mounti‘ng pan screws, tighten the screws, PASSENGER SEAT REMOVAL/INSTALLATION Llnhook the passenger seat lock using the ignition key. Remove the passenger seat by pulling it forward. InstaIl the passenger seal In the reverse order of removal. PAN SCREWS RIDER SEAT FASSEN GEH SEAT IGNITION KEV Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM REAR SEAT COWL REMOVAL Remove the following: - Rider seat (page 3—4) SPECIAL SCREWS — Passenger seat (page 3-4) REAR SEAT COWL Remove the four spacial screws. Carefully pull out both sides of the rear seat cowl, then remove it upward. Disconnect the tail/brake light connector, TAIL/BRAKE LIGHT CONNECTOR DISASSEMBLV/ASSEMBLY Remove the screws and tall/brake light unit. TAIL/BRAKE LIGHT UNIT Remove the two screws, trim clip and air duct Install the air duct and tail/brake light unit in the reverse order of removal, AIR DUCT \Q Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION PASSENGER SEAT RIDER SEAT REAR SEAT COWL Make sure that me Connect the tail/brake light connector. manng surfaces of Install the rear seat cowl over the seal rail and rear SPECIAL SCREWS the caw/Darlom fender being careful not to damage the wire her are seated ama the ness. tearfenderpmp Align the tail/brake light bolt studs with the gram» erly before rrghmrr mets on the rearfender as shown. mg the bolts HEAR SEAT COWL Install and tighten the rear seat cowl mounting screws. Insta|l the removed parts in the reverse order of remnval. TAIUERAKE LIGHT CONNECTOR 3-6 Contents Chapter 3 FRAME] BODY PANELS] EXHAUST SYSTEM UNDER COWLS/MIDDLE COWLS REMOVAL Be careful/101w Remove the special screw and four trim clips from damage We tabs me hannm nnhe under cowls. andgmaves. Remove the six [rim clips from ‘he inner lower cowl and inner middle cowl. Remove the under cowl-to-middle cuwl pan screws. Remove the under cowl mounting special screws and then remove the under cowls and inner lower cowl. \ SPECIAL SCREWS UNDER COWL Contents Chapter 3 3-7 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the middle cuwl-tnvinner middle cowl trim i clips ‘ i TRIM CLIPS Remove the middle cuwl-lo»upper cowl pan screws. SPECML SCREWS ‘ V PAN scnsws Remove the middle cowlAto-inner middle cowl Spar cial screws and middle cowl mounting special screw. Remove the middle cowl While releasing the hooks on the uppev cowl. Disconnect the turn signal can nectar. TURN SIGNAL CONNECTOR 3-3 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the inner middle cowIs IN NEH MIDDLE COWL INSTALLATION RIGHT MIDDLE COWL LEFT MIDDLE COWL IN NER LOWER COWL LEFT UNDER COWL Contents Chapter 3 3'9 FRAME/BODY PANELS/EXHAUST SYSTEM Install the inner middle cowls. INNER MIDDLE COWL Connect the iurn signal connemon HOOKS lnsiall the middle cowl onto the upper cowl while aligning the slits in the middle cowl with the hooks on the upper cowl. Install and tighten the upper cowl-to-middle cowl pan screws to the specified torque, TORQUE: 1.5 Nimlnl15 kghn, 1.1 Ibf-ft) Install and zighien the middle cowl special screws in the specified torque. TORQUE: 9.8 N‘m [1.0 kgf-m. 7 Ibl-R) 3-10 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Install the lrim clips. TRIM CLIPS Install the rignl and left under cowls by aligning the bottom end. PAN SCREWS Install and tlghten the under cowl-to-middls cowl pan screws lo lhe specified torque, TORQUE: 1‘5 N~m (0.15 kgfrm,1c1 IM-R) Ins‘all and tighten the under cowl mounting special screw to the specllied torque. TORQUE: 9.8 N-m (1.0 kgf-m. 7 lbI-ftl SPECIAL scnews UNDER com Secure the bottom of the under cow|s using the four trim clips and pan screw. Tighlen xhe special screw to the specified torque. TORQUE: 9.8 N~m [1‘0 kgl-m, “l Ibf-ftl TRIM CLIPS Contents Chapter 3 3'11 FRAME/BODY PANELS/EXHAUST SYSTEM Secure the under cowI between the inner lower _ cow( and inner middle cowI using the six trim clips TRIM CLIPS UPPER COWL WINDSCREEN REMOVAL Remove the under cowls/middle cowls (page 3-7I. Remove the screws, ptasfic and rubber washers, then remove the windscreen. SCREW WINDSCREEN , PLASTIC WASHER ,1 RUBBER WASHER UPPER COWL REMOVAL Remove the rearvrew mirror mounting socket boIts and rearvtew mirrorsr VEARVIEW MIRROR I SOCKET BOLTS 3'12 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Disconnect the combination meter multi-connector, Release the upper cowr ofl the rearview mirror bolt hole studs and bosses of the upper cowl from the meter stay grommets, then remove the upper cowl assembly. Disconnect the from sub—harness mutti»connector. See page 205 for head‘ight unit removal/mstalla- lion, COMBINATION METER MULTl-CON NECTOR GROMMETS " SUBAHARNESS MULTHZONNECTOR Contents Chapter 3 3-13 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION 6‘8 N~m (0.7 kgf-m, 5.1 lbfvh) 0,5 N-m [0.05 kgf-m, 0.4 le-ft) WINDSCREEN REARVIEW MIRROR UPPER COWL Chapter 3 Contents 3-14 FRAME/BODY PANELS/EXHAUST SYSTEM Connect the from sub—harness connectors. combi- nation meter multi-connector, SUB-HARNESS MULTI»CONNECTOH install the upper cowi, aligning the bosses with the grommets on (he upper cawi stay. GROMMETSG , .5 Connect the combination meier multi-connector, COMBINATION METER MULT|»CON NECTDR Align the rearview mirror bolt hole studs of upper —‘ cowl with the rearview mirmr stay. REARVIEW MIRROR Ins‘all (he rearview mirror and tighten the socket bolts to the specified mrque. TORQUE: 5.8 N-m (0.7 kgf—m, 5.1 Ibf-ft) SOCKET BOLTS Contents Chapter 3 3—15 FRAME/BODY PANELS/EXHAUST SYSTEM TOP SHELTER Install the cowI setting nuts imo the windscreen holes. Inslall Ihe windscreen, then install the rubber and plastic washers and screws. Tighten lhe screws to the specified Iurque. TORQUE: 0.5 N-m (0.05 kgf-m, 0.4 "1”!) WINDSCREEN Install Ihe middle cowls/under cowls (page 3»7). REMOVAL/INSTALLATION Remove xhe rider seat (page 3-4). Remove the from side cover special screws‘ Remove [3th from side covers by releasing The tabs from the top shelter. FRONT SIDE COVER SCREW PLASTIC WASHER 3-16 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the special screws, mounting screws/wash- ers and top shelter: TOP SHELTER SPECWAL SCREWS MOU NTING COLLARS SCREWS Remove the screws and center cover from the mp ‘#* shelter, 1 TAB/GROOVE lnstaH the center cover, afign the tab of the center 3 cover Into the groove of the tap shelter, then tighten the screws. SCH EWS CENTER (:0sz : Contents Chapter 3 3'17 FRAME/BODY PANELS/EXHAUST SYSTEM Be smelt/l no: [0 let me Collars (5/! mm the frame, Install the top shelter onto the fuel tank, Align the fuel filler hole flange on the top shelter with the rubber an the fuel fill cap. Install and tighten the special screws and mounting screws/washers. Install the from side cover while aligning its tabs with the gram/es in the top shelter. Install and lighten the special screw on bnt‘h sides. Install the rider seat (page 3-4). SPECIAL REWS COLLARS SPECIAL SCREW FRONT SIDE COVER TOP SHELTER MOUNTING SCREWS 3-18 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the front brake hose 3-way joint Bolt and hose clamp nut. 37WAY JOINT BOLT Remove the pan screws, front fender. reflectors and grommets from the fork legs. Install the front fender in the reverse order of removal. TORQUE: From. fender pan screw: 12 N-m (1.2 kgf-m,91bf-fl) Front brake hose clamp nut: 9.5 M"! (1,0 kgf-rn, 7 IbM!) Front brake hose 3—way joint bun: 9,8 N‘m (1‘0 kgf-m. 7 Ilel FRONT FENDER 1 1 PAN SCREWS ‘ _ \ a \\ , / HOSE CLAMP NUT ‘ REAR FENDER 7 REAR FENDER A REMOVAL ,, Remove the rear cowi [page 3-5). Disconnect the turn signal and license light connec» BOLTS] tars. WASHERS Remove the rear fender A mounting bolts, washers and rear fender A assembiv. CONNECTORS REAR FENDER A Contents Chapter 3 3'19 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER A DISASSEMBLY Remove me nuts and Iicense light uniL Remove the run, retainer and rearturn signal unit LICENSE LIGHT UNIT TURN SIGNAL UNIT Remove the screw and Ief‘! rear fender bracket, har— ness guvde and Cover. I, , HARNESS GUIDE COVER REAR FENDER B REMOVAL H h n 17- . emove‘ 9 ”a a” (page 5) PAN SCREW/COLLAR REAR END COVER Remove the pan screws, muffler rear end cover and \\ coHar. PAN ECREWS 3'20 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Remuve the pan screws and passenger seat rear hook, PASSENGER SEAT REAR HOOK Remove the flange bolts and passenger seat hooks. Remove the passenger seat hook specrat bolts, then remove the passenger seat bracket. SPECIAL BOLTS Unhook the Seat lock cab‘e from the sea! Iack lever, then remove the passenger seal bracket. SEAT LOCK LEVER Disconnect the seat lock Cable from the Seal lock key cylinder, Remove the retamer and remove the seat lock key cvnnaer from the rear lender B, Contents Chapter 3 3'21 FRAME/BODY PANELS/EXHAUST SYSTEM Remove ‘he bol‘s and nu‘s,-‘hen remove the rider ~ BOLTS/NUTS sea‘ bracket from the saw ran. Release the wire harness Clamp and release the main wire harness and starter motor cables Remove the rear fender Brtoheax protector trim chps‘ Remove the rear fender E lmm ‘he sea‘ rail. 3-22 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the muffler and muffler heat protector (page 3-30). Remove the heat protector from the seat rall and frame. REAR FENDER B INSTALLATION 26 N»m l2,7 kgtm, 20 Ibf-ft) 26 N-m (2.7 kgf m, 20 1m to 5.8 N-m [1.0 kgf‘m, 7 lbfrft) f: I REAR FENDER B HEAT PROTECTOR \(é‘ , w Install the heat protector onto the seat rail and frame. Install the muffler and muffler heat protector (page 3-36). HEAT PRo‘TEcron’ Contents Chapter 3 3'23 FRAME/BODY PANELS/EXHAUST SYSTEM Instatl the rear fender B mm the seat rait. HEAR FENDER B Install the rear fender Brio—heat protector mm Cltps and secure them, Secure the main w'tre harness and starter motor cables with wire clamp. Instant me rider seal bracket onto the seat ran. Instan and tighten the r'tder seat bracket mounting bolts and nuts to the speCIfied torque. TORQUE: 9.8 N-m (1.0 kgf-m, 7 Ibf-I't) RIDER SEAT BRACKET 3-24 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM \nstall the seat \ock key cylmder Into the rear fender B and secure "t \Mth retainer. SEAT LOCK CABLE Connect the seat lock cable to the seat lock key cyl- ‘ inder and clamp it with cable clamp. Hack the seat lock cable to the seat Iock lever. Instal‘ the passenger seat bracket. Install the passenger seat bracket special bolts lnstaH the passenger seat hooks and flange ban, Tighten the passenger seat bracket specia‘ ban: and flange buns to the specmed torque, TORQUE: 26 N-m [2.7 kgfm, 20 lbf ft) InstaH me passenger seat rear hook and Ugmen the pen screw securely. Contents Chapter 3 3'25 FRAME/BODY PANELS/EXHAUST SYSTEM lnseu the Collar Install the muffler rear end cover and collar. between the muf» fl'er and Veer fandcrfi Install the battery (page was). PAN SCREW/COLLAR REAR END COVER Install and tighten the pan screws. REAR FENDER A ASSEMBLY When lnstalllng the grommets and collars, note the installation dlrection of the grommets and collars. Route the turn signal and tail light wire into the left harness guide. Install the cover and bracket and tighten the screw securely HARNESS GUIDE COVER Install the right cover onto (ht; rear fender A bracket, tlg hten the screw. Install the turn slgnal bracket onto the rear lender A bracket, then assemble the rear tender A. brackets and license light. LICENSE LIGHT UNIT Install and tlghten (he llcense llght mounting nuts. Install and tlghten the rearturn signal unit mounnng nuts. TURN SIGNAL UNIT 3-26 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER A INSTALLATION Install Ihe rear fender A assembly, washers and bolts, than tighten the bolts securelyv Connect the turn signaI and lrcense light connec- tors. BOLT/' I WASHERS Install the rear cow! (page 375), CONNECTORS HEAR FENDER A SEAT RAIL REMOVAL Remove thafullowing: [Wren REAR FENDER B e Muffler (page 3730) — Rear fender A and 8 (page 349) - Fuel tank (page 6736b Remove the bolt and rear brake reservoiv. / / RESERVOIR L— Hemeve me socket bolts and Ief‘t passenger footpeg bracket. Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the seat rail mounting speclal bolts and nuts, then remove the seal rail assembly. SEAT RAlL DISASSEMBLY/ASSEMBLY Remove the socket bolts and seal rail brace. Remove the seat rall assembly bolts/nuts, then sepr aralethe right and left seal rail BO LTS/NUTS Hemline Ihesear Assemble the seat rail by installlng the seat rail lal/HS an assembly assembly flange bolts/nuts. BOLTS/N UTS 3-23 Contents Chapter 3 FRAME/BODY PAN ELS/EXHAUST SYSTEM Install the seat rail brace and then install the socket bolts. SEAT RAIL BRACE INSTALLATION RIGHT SEAT RAtL 26 N-m (2.7 kgf-m, 2L) Hat-fl) , n‘ /’ H! / L}; 30N-rn (a. kgfm,22\bfft] 58 N-m (5.0 kgf—m, 43 lbf-m r /- / / . “7// "6/ KC“ LE FT SEAT RAIL 26 Nm (2.7 kgfm, 20 Ibf‘ft) 26 N-m (2.7 kgt-m, 20 lbf-m Install the seat rail to the frame. SEAT RNL Install the upper mountlng bolts/nuts and lower mounting bults/collars/nms. Tighten the bolts and nuts to the specified torquet TORQUE: Uppar mounting flange nut: 59 N-m [6.0 kgf-m, 43 [bf-ft) Lower mnunting flange nut: 59 N‘m (6.0 kgf-m, 43 WHO Tighten the four seat rai! brace socket bolts and seat rail assembly flange nuts to the specified torque. TORQUE: Seat rail brace socket bolt: 28 N‘m (2.7 kgf-rn, 20 lbI-fl) Seat rail assembly flange nut: 30 N‘m (3.1 kgt-m, 22 mm) Contents Chapter 3 3'29 FRAME/BODY PANELS/EXHAUST SYSTEM Install me left passenger rompeg bracket and tighten the socket bolts to the specified mrque. SOCKET BOLTS TORQUE: 26 Nrm (2.7 kgl-m, 20 lbf-ft) InsraH (he rear brake reservoir and (Ighren the bolt. |ns\a!| the foHowing: , Mufller1page3-30D » Rearfenderlpage 3718b — Fuelianktpage 6-36) EXHAUST PIPE/MUFFLER REMOVAL Remove the renewing- , Top shelter (page 3716) - Under cowls/middle cow‘s (page 377) — Rear seat cowl [page 35) — Rear fender A (page 349} Remove me radiator lower mounting burr. LOWER MOUNTING BOLT Avoid damaging me radiaxor fins, remove me ban and radiator lower bracket from the engine. 3-30 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the radiator reserve tank mounting bort and filler neck mourning bo‘l. Disconnect the fan motor 2P1Black) connector. Loosen the radiator upper mounting bolt. Move khe radiator to the right and release the radiar (or grommet from the bracket boss, then move the radiator dawnward A . 2 RADIATOR Contents Chapter 3 3'31 FRAME/BODV PANELS/EXHAUST SYSTEM Remove the muffler guard moummg pan screw, col- -—- \ar and screw. PAN SCREW' 0 e _MUFFLER GUARD Remove the muffler guard boss from the sear rail bracket grommet, men remove the muffler guard, I SCREW/COLLAR ‘ Remove the Socks! bolts and right passenger Vool- V peg bracket. v PASSENGER FOOTPEG BRACKET ‘ Remove the socket bolts and right foolpeg bracketr 332:3“: me pan screw and exhaust pipe heal E_w HEAT GUARD 3-32 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Loosen the muffler band flange bOIL Remove the exhaust ptpe Joint nuts. Remove the exhaust pre mounting bolt/washer, then remove the exhaust pipe. Remove the bolt and exhaust jomt pipe clamp. Remove the exhaust joint pipe, gaskel and flange. BOLTV’VVASHER 1 ‘ JOINT CLAMP Contents Chapter 3 3-33 FRAME/BODY PANELS/EXHAUST SYSTEM Remove lhe pan screws, muffler rear and cover and Eullar. PAN SCREW/COLLAR HEAR END COVER Remove the bolls and exhaust valve cover. - ‘ Bend the luck lab and remove the run from the pul- lav Remove the pulley from the shaft Loosen Ihe cable adjuster lock nul and remove the exhausl valve control Cables from the pulley A 4— LOCK NUTS FRO-N‘FR/IOUNTING BOLT/COLLAR Remove the muffler from mounting bolt and collar. 3-34 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the muffler rear mounting bolts. men remove the muffler assembly. REAR MOUNTlNG BOLTS MUFFLER Remove the muffler heal guard from mounting bolt and nuL Remove the muffler heat guard rear mounfing buns, then remove the muffler hem guard. HEAR MOUNT'NG BQLTS MUFFLER HEAT GUARD Contents Chapter 3 3-35 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION MUFFLER HEAT GUARD GASKET GASKET 37 N-m [3.8 kgl-m. 27 mm) "'1 12 Nm (1,2 kgf‘ml 9 Ith) EXHAUST PIPE HEAT GUARD EXHAUST PIPE 23 N-m12.3 kgf-m,17lbt-fl} 3'36 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM lnstall the muffler heat guard into the seat rail, then Install the muffler heat guard rear mounting bolts. REAR MOUNT'NG BQLTS Install the muffler heat guard front mounhflg bolt and nut, ' Tighten the nut securely. Install the muffler assembly and temporarily lnstall the muffler rear mounting bolts. MUFFLER Install the muffler from mounting collar and bolt. Tighten the mumerrrum mounting bolt securely. Tighten the muffler rear mounting bolts securelyl Contents Chapter 3 3-37 FRAME/BODY PANELS/EXHAUST SYSTEM Route the exhaust valve control cable properly, and hook the cable ends with the drive pulley. install the pulley onto the exhaust valve shaft and tighten the nut. Bend the lock tab pverthe nut. Adjust the exhaust valve control cables and tighten the lock nuts securely [page 4735). lnstall the exhaust valve cover and tighten the bolts. lnsml/ the caller Install the muffler rear end cover and collar. bciwuun Z/lc rrru/rlcr aim real ‘snvrtlé' 5 install and tighten the pan screws securely. FAN SCREWS install the exhaust pipe joint flange and new gasket onto the exhaust icint pipe. 3-38 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM lnslall the exhaust joint pipe clamp while aligning i its boss with the groove on the muffler pipe JOINT CLAMP Install and temporarily tighten the SH bolt. install new gaskets onto the exhaust ports at the cylinder head. install a new gasket onto the exhaust pipe. install the exhaust pipe assembly into the joint pipe and cylinder head install the exhaust plpe iuint nuts. Install the exhaust pipe mounting bolt/washer. Contents Chapter 3 3'39 FRAME/BODY PANELS/EXHAUST SYSTEM First ‘ighten Ihe exhaust pipe jclnt nuts to me speci- fled mrque. TORQUE: 12 N-m (1.2 kgf‘m, 9 lbf‘h] Tigmen the exhaust pipe mounting bcmwasher. TORQUE: 23 N!“ [2.3 kgl-m, 17 lbfvft) Tighten me exhausx pipe clamp SH bolx m Ihe spec» L'— ified torque. JOINT CLA\P G) TORQUE: 9.8 N‘m (1.0 kgf‘m, 7 IN“) Tighten the muffler band flange bol( to the specified torque. TORQUE: 1B N-m [1.8 kgf-m,13lbf-ft) 3-40 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM Install the exhaust pipe heat guard while aligning its !——W v tabs with the grooves on the exhaust plpe, HEAT UARD ' Install and tighten the exhaust pipe neat guard [—— mounting pan screwv #SCREW w ‘ Install the fight foutpeg bracket onto the frame and ‘— " tighten the socket bolts to the specified torque. FOOTPEG BRACKET TORQUE: 37 N-m (3.3 kgf~m, 27 IBM!) Install the right passenger footpeg bracket onto the seat rail, then tighten the socket bolts to the speci» fled torque. TORQUE: 25 N-m (2t7 kg'rm, 20 lM-fi) I PASSE NGER FOOTPEG BRACKET Contents Chapter 3 3-41 FRAME/BODY PANELS/EXHAUST SYSTEM Install me muffler guard while alrgnmg n boss with [he grommet onto xhe seat raTI. InstaH me pan screw, collar and screw, then xigmen a the screws securely. PAN SCREW InskaH the radiator omo the bracket while a‘igning the grommeland frame boss‘ mm and tighten the radiator upper mourning bolK. PPER MOUNTING BOLT £5? \ n ' 3-42 Contents Chapter 3 FRAME/BODY PANELS/EXHAUST SYSTEM \nslall the radiator luwer brackex m me engine and tighten the hon \nsmll and tigmen the radiator lower mounting bok, LOWER MOUNTING BOLT Canned the fan motor 2P (B‘acM connector. .2E’TmA—CMWVNECTOR Install and lighten the radiamr reserve tank moumr ing bolt and filler neck mounting mm InstaH the follnwmg- , Top shelter [page 3-16) , Under Cowls/middle cowls (page 34) — Rear fenderA {page 3727) , Rear seat cow‘ (page 375) RESERVE TAN K Contents Chapter 3 3'43 MEMO Contents Chapter 3 4. MAINTENANCE SERVICE INFORMATION 4.2 MAINTENANCE SCHEDULE ------------------------ 4—4 FUEL LINE 4.5 THROTTLE OPERATION-----------------~~~~-----~ 4.7 AIR CLEANER ............................................... 4.8 SPARK PLUG ~- VALVE CLEARANCE ................................... 4.15 ENGINE OIL/OIL FILTER ............................. 4.21 ENGINE IDLE SPEED ................................... 4.24 RADIATOR COOLANT ................................. 4.24 COOLING SYSTEM ..................................... 4.24 SECONDARY AIR SUPPLV SYSTEM ---------- 4-25 EVAPORATIVE EMISSION CONTROL BRAKE FLUID ............................................... 4.30 BRAKE PAD WEAR ...................................... 4.31 BRAKE SYSTEM BRAKE LIGHT SWITCH ................................ 4.33 HEADLIGHT AIM .......................................... 4.33 CLUTCH SYSTEM -- CLUTCH FLUID 4.34 EXHAUST GAS CONTROL VALVE CABLE ........................................................... 4.34 SIDE STAND ................................................. 4.35 SUSPENSION ............................................... 4.37 NUTS, BOLTS, FASTENERS ------------------------ 4-41 WHEELS/TIRES ............................................ 441 SYSTEM (CALIFORNIA TYPE ONLY) -- - 4-26 STEERING HEAD BEARINGS DRIVE CHAIN ............................................... 4.25 4-1 Contents Chapter 4 MAINTENANCE SERVICE INFORMATION GENERAL ' Place the motorcycle on a level ground belore starting any work. - The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or With an exhaust evacuation system in and enclosed area, SPECIFICATIONS l VITEM r spechlcmjpnlsW Throttle gripfree play 2—4mm (1/16—3/16in) Spark plug NGK IMRSC-QHES DENSO VUH27ES Spark plug gap 77 0.80 — 0.90 mm (0.031 — 0.035 in) Valve l N ' 7 0.16 : 0.03 mm (0.005 a 0.001 in) clearance . Ex 0.30 z 0.03 mm l0.012 : 0.001 in) R ' Engine all r After draining 3.0 liter (3.2 us qt, 2.6 lrnp qtl l capacity After oil filter change 3.1 liier (3.3 us qt, 2.7 imp qt) Recommended engine oil Pro Honda 5N4 or HP4 (without molybdenum additives] 4 stroke oil (USA. and Canada), or Honda 4rstroke oil (Canada onlvl, or an equivalent motor oil API service classification: SG or Higher except oils labeled as energy conserving on the circular API service label JASO T 903 standard: MA Viscosity: SAE ‘lUW—40 Engine idle speed 1,200 1100 rpm Drive chain slack 25—35 mm l1 — 1-3/5 inT' Recommended brake fluid DOT 4 Recommended clutch fluid DOT 4 Tire size Front 120/70 zn 17 MIC (saw 77 .7 ,7 i Rear 190/50 ZR 17 M/C (73w) Tire brand ’ Bridgesmne’ ' From BT014F RADIAL 6 Rear BT014R RADIAL G l Pirelli Front DIABLO CORSA H y . Rear W VDIABLO CORSA H Tire air l Up to 90 kg . Front 250 kPa (2.50 kgl/cmz, 36 psi) pressure (200 leI load l Rear 290 kPa (2.90 kgl/crn , 42 psi) ,7 ‘ Up to maximum Front 250 kPa (2.50 kgI/cm , 3605i) . weight capacity Rear 290 kPa (2.9 f/cmz, 42 psi) Minimum iire'rread depth i Front 1.5 mm [0.06 7 ,i ,,,.., .. l Rear 2.0 mm (0.03 in) TORQUE VALUES Fuel tank front mounting bolt Spark plug Timing hole cap Engine oil filter cartridge Engine oil dram bolt Cylinder head cover bolt 26 Nrm (2,7 kgf-m, 20 lbf-ft) 16 N-rn (1.6 kgf-m, 12 lbf it) 18 N-m (1.8 kgf-m, 13 |bf~ftl 26 N-m (2.7 kngm, 20 lbf‘fl) 23 NM (3.0 kgf—m, 22 [bf-ft) 3.8 N-m (1.0 kgf—m, 7 lbf-ft) Apply grease to the threads Apply clean engine oil to the O—ring Rear axle nut 113 Mm (11.5 kgfm, 83 Ibf-ft) Urnut Drive sprocket special bolt 54 N-m (5.5 kgf-m, 40 Ibf-ft) Final driven sprocket nut 64 N-rn (65 kgfrm, 47 |bf~fl) U-nut Rear master cylinder push rod joint nut 18 N-m [1.3 kgf‘m,13lbfift) Contents Chapter 4 MAINTENANCE TOOLS Oil filter wrench ; Drive chain 100] set Cam chain lensioner holder ‘ 07HAA-PJ70101 ‘ 07HMH-MR10103 07ZMG-MCAA400 w: “V4; @ @gfiwi or U7HMH‘MHYU10C(U.S.A. only) ‘ or 07NMG-MY90100 ‘ SCS service connector 070PZ»ZY30100 ‘ Contents Chapter 4 4'3 MAINTENANCE MAINTENANCE SCHEDULE Perform the Prerride inspection in the Owner‘s Manual at each scheduled maintenance period. I: Inspect and Clean, AGJUSI, Lubricate or Replace If necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The followmg Items require some mechanical knowledge. Certain items (particularly those marked * and “I may require more technical Information and tools. Consult their authorized Honda dealer. FREQUENCY : rn E m on METER READI >A REFER TO ’St1,000mi 0,6 4 B 2" PAGE F'N OfE' x100 km 10 64 128 9; FUEL LlNE "7" " l l 7 45" 7‘ s< THROTTLE OPERATlON AIR CLEANER . NCTE v v SPARK PLUG ' I EVERY 15,000 mi l25,600 Kml: lv EVERV 32,000 mi l51,200 km): R l e .VALVE CLEARANCE 4-ie lENGINEOIL ‘ENGINE OIL FfiER v ENGINE IDLE SPEED RADIATOR COOLANT NOTE 3 —-:u:: xl COOLINtTS‘IETEM SECONDARV AIR subPN’sVS'T Ii/i EMlSSION RELATED ITEMS t ____;u;u_ * EVAPORATIVE EMISSION CONTROL EM NOTE 4 UST GAS EONIROEyALVE CABLE EVEN/16,000 mi (25,600 km): I ID ECHAIN lBRAkE FLUID EVERY 500 mi (800 km): l, l. r l r IBRAKE FAD WEAR , * HEADLIGHT AIM' CLUTCH SYSTEMi , , W i SEE STAND SUSPENSION I NUTS]BOLTS,'EASTENEHS We WHEELS/TIRES 7 N STEERING HEADA EAnINGs NONAEMISSION RELATED ITEMS mechanically qualified. H l ,1. . l l | | If I | | ‘ ,ELAE Should be Serviced by an authorized Honda dealer, unless the owner has proper tools and service dale and iS H In the interest or Safety, we recommended these items be serviced only by an authorized Honda dealer. NOTES: 1. At higher odometer reading, repeat at the frequency Interval established here. 2. Service more frequency If the motorcycle is ridden in unusually wet or dusty areas. 3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requlres mechanlcal sklll. 4 . Caiirornia type only. Contents Chapter 4 MAINTENANCE FUEL LINE Remove the top shelter [page 3716}. FUEL TANK Remove the fuel tank from mourning bolxsv Disconnect the Vue‘ tank dram hose from me hose ‘7 jOTnI as shown. ‘ FUELTANK Lift the fuel ‘ank as shown. Support the fuel tank using a sunable suppon as shown. Contents Chapter 4 MAWTENANCE Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. Check the fuel rails and fuel hose jolms for damage or leakage. Replace them lf necessary Check the fuel pump mounting area for leakage, Replace the fuel pump packing if necessary. Check the primary/secondary lnjectors rot damage or leakage. Replace (hem lf necessary. Remove the suitable support, then lower the fuel tank. NOTE - Route the hoses, wlres and harness properly (page1»24). ' Be Careful not l0 damage the harness and hoses. After lnstalling the fuel tank, make Sure the drain, breather and fuel hoses are nol kinked or bound. Connect the drain hose to the joint pipe. Contents Chapter 4 MAINTENANCE Installandtlghtenlhe fueltankfrontmouming bolts . to the speclfied torque. FUEL TANK TORQUE: 26 Nvm [2.7 kglrm, 20 [bl-fl] Install the removed parts in the reverse order of removal. THROTTLE OPERATION Check for smooth throttle operallon at full openlng and automatlc tull closmg tn all steering posltions. Check the throttle cables and replace them rt they are deteriorated. klnked or damaged. Lubricate the throttle cables, If throttle operatlon l5 not smooth. Measure the free play at the throttle grlp flange. FREE PLAV: 2 - 4 mm (1/15 , 3/15 in) Throttle grip lree play can be adjusted at elther end ofthe throttle cable Minor adjustment l5 made with the upper adjuster. Adjust the tree play by loosening the lock nut and turning the adjuster. Malor adlustment ls made with the lower adjuster, Remove the air cleaner housing lpage 640i. Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighlen the luck nut securely. Recheck the throttle operation, Replace any damaged parts, it necessary. Contents Chapter 4 4-7 MAINTENANCE AIR CLEANER Remove the top shelter (page 3—16). D'rscormect the IAT sensor 2PtGray1connemor. Remove the screws and air cleaner housing cover Hepraee the air c‘eaner elements in accordance wrrh V the mamlenance schedule (page 4-4). Krista” the air cleaner elements while alrgnlng their bosses with the grooves in the air creamer housing. tnstall the removed parts in'the reverse order of removal. SPARK PLUG REMOVAL Be carer‘U/nor :0 Remove the under cowls/middle cow‘s (page 3-7). damage me- rad/am! "'75 Remove the radiator lower mounting bolt. LOWER MOUNTING BOLT Contents Chapter 4 MAINTENANCE Avoid damaging the Remove the bolt and radiator lower bracket from 73min)! fins the engine. Remove the coolant reserve tank mountlng bolt and filler neck mounting bolt. Disconnect the fan motor 2? (Black) connector Remove the radiator upper mounting bolt. Contents Chapter 4 MAINTENANCE Move the radiator to the right and release the radia- tor grommet from the bracket boss, then move the radiator downward, 5. i n O AHADI‘A Disconnect the CMP sensor 2P {Black} connector. Remove me two mm cups and arr Intake ngH. Disconnect the vacuum hose (mm the variable air intake diaphragm. Contents Chapter 4 4-10 MAINTENANCE Remove the air duct mounting bolts, Remove the intake air duct mounting screws Remove the intake air duct from the air cleaner housing. Clean around me Disconnect the direct ignition cell connectors spark plug bases with COWDA’ESSEL Remove the direct Ignition cells from the spark plugs. flu-Em: as ”5‘: wed (a e er 5 Combusrlun chamber REMOVE the Spark plug using the equipped spark ,7 , ~~V .7 plug wrench or an equivalent. V , §PARK PLUG WRENCH . ”W Inspector replace as described in the maintenance ‘ schedule (page 4.4L Contents Chapter 4 4'11 MAINTENANCE This motorch/e s spark plug lS equipped With iride iurn center elee heee Rea/ace the spark plug it the electrudes are 60777 laminated Alla/8V5 use SDECl' tied spa/K p/l/gs on [ms mam/CVL‘IQ To prevent damag- ing the indium Cell rer elecrrude, use a this type teeter gauge la cheer the snark plug gap, Do not art/us! the spark plug gap /l‘ {lie gay is Dul at’ WWW/Cation replace the plug wirh a new one INSPECTION Check the lolluwing and replace if necessary (rear ammended spark plug: page 472) - lnsulatorterdemage - Electrodesl‘orwear - Burning condition, coloration If the electrodes are contaminated wlth accumu- lated objects or dirt, replace the spark plug Replace the plug if the center electrode is; rounded as shown in the illustrallon, SPECIFIED SPARK PLUG: NGK: IMRBCSHES DENSO: VUH27ES Check the gap between the center and side elee trodes With a wire type teeler gauge. Make sure that the t 1 0 mm 1004 in) plug gauge does not insert between the gap If the gauge can be inserted into the gap, replace the plug with a new one. INSTALLATION install the spark plug in the cyllnder head and hand tighten, then torque to speeitieetien TORQUE: 16 N-m (1.6 kgf«m,1ZIbI-ft) lNSULATOR CENTER ELECTRODE SIDE ELECTRODE HOUNDED ELECTRODE I l l WIRE TYPE FEELER GAUGE >< fli— SPAFlK PLUG WRENCH KJ 4-12 Contents Chapter 4 MAINTENANCE Install the dlrect ignition coils. Connect each connector to each direct ignition coil. DIRECT IGNITION COILS CONNECTORS Remove the right from side cover (page SV’ISIV Install the intake air duct assembly, whlie ailgning Its tab with the Icwer air cleaner housing beset Make sure that the intake air duct is properly seated on the housing, install and tighten the intake air duct mounting screws. TORQUE: 2.5 N-m (0.25 kghu, 1.8 Ibf-fl) Install and tighten the air duct mounting bolts. Contents Chapter 4 4-13 MAINTENANCE Connect the vacuum hose to the variabte air intake diaphragm. InstaH the am mtake gnu and secure it with mm E cups. Install the radiator onto the bracket wrnte aligning me grommet and frame boss. \nslalt and tighten the radiator upper mounting bolt. 4'14 Contents Chapter 4 MAINTENANCE Insxau the radiator lower bracket to the engine and tighten the bolt. LOWER BRACKET InstaH and Ughten the redraror tower mounting bolt Connect the fan motor 2P {Black} connector Install and tighten the radiator reserve tank mount» ing bolt and finer neck mounting bolt. RESERVE TANK Contents Chapter 4 4-15 MAINTENANCE Connect the CMP sensor 2P IBIackI connector. Remove the under cowIs/middle oowis [page 34). VALVE CLEARANCE inspeci and adjust the valve ciearahoe whie the engine is raw (De/ow 35-17 95 “Fl INSPECTION Remove ihe cylinder head cover [page 976). Remove ihe cam chain iensioner Iifler sealing bolt and seaiing washer, Turn the tensioner lifter shaft fully in (cIockwiseI and secure it usmg the spawn tool to prevem dam» aging the cam Chaim TOOL: . Cam chain tensioner holder 07ZMG»MCAA4DD or D7NMG-MY90100 Remove the iiming hoie cap and Orring. SEALING BOLT CAM CHAIN TENSIONER HOLDER 4-16 Contents Chapter 4 Recard the clear ance for each valve {of reference in shim Selection if ad/ustmenr is required MAINTENANCE Turn the crankshaft clockwise, align the "T" mark on f- a? the crankshaft position sensor rotor with the index ' INDEX MARK § mark on the right crankcase cover. Fr i The timing marks (“IN" and ”EX“) on the cam sprockets must be flush with the Cylinder head sur- face and facing outward as shown. It the timing marks on the cam sprockets are facing ,« inward, turn the crankshaft clockwise one Iuli turn (360“) and realign the timing marks with the cylinv der head surface so they are facing ourward. Insert the feeier gauge between the valve lifter and cam lobe. Check the valve clearance forthe N411 and No.3 cvl- inder intake valves using a feeler gauge. VALVE CLEARANCE: IN: 0,16 1 0,03 mm (0006 t 0.001 in) Turn the crankshaft clockwise 1/2 turn (180°), align '_ the index line on the crankshaft DOSItiOn sensor ' rotor so that it is facing up as shown. Contents Chapter 4 4'17 MAINTENANCE Record the Clea.“ ance for each valve far reference m shim ss/ecmn yr adjustment rs required. Record me CIEEI' anm far sac/t valve for reference In smm se/emm rr ad/ust'nervt 15 required Check the Valve clearance for the No.2 and No.4 cylr inder exhaust Valves using a feeler gauge. VALVE CLEARANCE: EX: 0.30 t 0.03 mm [0.012 t 0.001 in) Turn the crankshaft clockwise 1/2 mm [180% align the "T" mark on the Crankshaft position sensor rotor with the index mark on the right crankcase cover Check the valve clearance for the No.2 and No.4 cyI» inder intake valves using feeler gauge. VALVE CLEARANCE: IN: 0.16 t 0.03 mm (0.006 1 0.001in) Tum the crankshaft clockwise 1/21urn(180°|. angn the index line on the crankshaft position sensor rotor so that it 25 facing up as shown. No.4 EXHAUST VALVES ‘ No.2 EXHAUST VALVES LINE 4-18 Contents Chapter 4 Record the clearr arte- lal each valve ‘or reference in shim select/07‘ i! 5d,..‘srr'76'7: v) «sawed l! IS NO! necessary In remove me cam smacks! mam me camshah BXCHflY when replacing the camshafl and/or cam sprocket MAINTENANCE Check the valve clearance lor the No.1 and N03 cylr — * i inder exhaust valves using a feeler gauge. No.1 EXHAUST VALVES l l VALVE CLEARANCE: No.3 EXHAUST VALVES EX. 0.30 i 0‘03 mm ((1012 i 0.001 in) ADJUSTMENT Remove the Camshafts (page 9-8), Remove the valve lifters and shims‘ ' Shim may Sllck lo the Inside of the valve lifter. L Do not allow the shims m (all into the crankcase I Mark all valve lifters and shims to ensure correct reassembly in their original locations. ' The valve lifter can be easily removed with a valve lapping tool or magnet. 0 The shims can be easily removed with a [wee- zers or magnal. Clean the valve shim Contact area in the valve lifter thh compressed air. VALVE LlFTER Measure lhe shim thickness and record it. Contents Chapter 4 4-19 MAINTENANCE Swill/Jill‘s different Calculate the new shim thickness usmg the equar thickness ShllYls are tlon below. avallabls from the A = lB — Cl + D Illlnnes: l 200 mm A: New shim thlckness thickness slim to B Recorded valve clearance the tlllckestz 9017 C. Specified valve clearance mm thlckness shlm D: Old shim thickness in lnzervals 0H7 025 mm Make sure of the Correct shim thickness by meae suring the shim by micrometer. Relate the valve seat if carbon deposlt result in a calculated dimension of over 2 900 mm 1.80 lTII'l’I 1.825 mm 135 mm 1.875 mm Install the alums lnstall the newly selected shlm on the valve spring and valve lifters m retainer. IhelrurlglnallUCar Apply molybdenum disulfide oil to the valve lifters. rlons lnslall the Valve lifters Into the valve litter holes. lnstall the camsharts (page 9-26]. Rotate the camshafls bv rotatlng the crankshaft '1 clockwise several times. " Recheck the valve clearance. Remove the cam chaln (enslaner holder tool. lnstall the new sealing washer and cam chain — tensioner lifter seallng bolt. Tighten the bolt securely, l J Al SEALING WASHER J. l. ‘ SEALING BOLT 4'20 Contents Chapter 4 MAINTENANCE Check that the 0 Apply grease to the timing hole cap threads. rlng is ln good con- Tighten the timing hole cap to the specified torque, dltlan, rep/ace ll‘ . necessary TORQUE 18 N-m (1,8 kghn, 13 [bftm Install the removed parts in the reverse order of removaL ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION Stan the engine and let it idle for 3 A 5 minutes. Stop the engine and wait 2 - 3 minutes. Hold the mutorcycle in an upright position. Check the clil |eve| through the inspection window. If the level is below the lower level line, remove the oil filler cap and fill the crankcase with the resume mended oil up to the upper level line as follows: Remove the oil filler cap. Contents Chapter 4 4-21 MAINTENANCE Fill the recommended engine oil up to the upper level liner Oiher wscasmes RECOMMENDED ENGINE OIL: shown in we than Pro Honda em or HP4 [wi hout molybdenum i "WV be USED W’E‘" additives) 4-stroke oil or equivalent motor oil "'9 average 79” API service classification: 86 at higher 59’3“” ’” Wu" JASO T 903 standard: MA mmgaroa IS Wimm \fiscosity; SAE 10W—40 me indicaied range, Reinstall the Oli filler cap. ENGINE OIL 81 FILTER CHANGE Change ihe Eng/fie Start the engine and let it. idle for 3 - 5 minutes. ol mm the warm Stop the engine and wait 2 — 3 minutes. aria (he rhoiuiwule Hold the motorcycle in an upright position mi .avei ground in a we complem- draiiiing Remove the oil filler cap. Remove the under cuwls (page 3-7). Remove the drain bolt and sealing washer, drain the oil Completely. Remove and discard the oil filter cartridge using the special tool. TOOL: oil filter wrench O7HAA—FJ70101 4'22 Contents Chapter 4 MAINTENANCE Check that the sealing washer on the drain bolt is in good condition, and replace it necessary. install and tighten the drain bolt. TORQUE: 28 N-m (SJ) kgf-m, 22 Ibf-ft) Apply clean engine oil to the oil filter cartridge threads and new Orring. install the new oil filter and tighten it to the specified torque. TOOL: Oil filter wrench D7HAAAPJ7D101 TORQUE: 26 N-m (2.7 kgf-m. 20 Ibl-ftl install the radiator reservoir tank and bolt. Fill the crankcase with recommended engine oil OlL CAPACITY: 3.0 liter (32 us qt, 2.5 lmp qt) after draining 3.1 liter (3.3 us qt, 2.7 imp qt) after oi I ter change Check that the Orring on the oil filler cap is in good condition. and replace it if necessary. Install the oil filler cap. Start the engine and let it idle for 3 , 5 minutes. H , Stop the engine and wait 2 e 3 minutes and recheck " the oil level. Make sure there are no oil leaks. Install the under CDWlS (page 3-7). Contents Chapter 4 4'23 MAINTENANCE ENGINE IDLE SPEED 0 Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specification. 0 The engine must be warm for accurate idle speed Inspection and adjustment. Warm the engine for about 10 minutes. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,200 i 100 rpm RADIATOR COOLANT Check the coolant level of the reserve tank with the ‘ engine running at normal operating temperature. The level should be between the "UPPER“ and ‘ "LOWER" level lines lf necessary, add recommended coolant. RECOMMENDED ANTIFREEZE: High quality ethylene glycol amitreeze contai corrosion protection inhibitors. Remove the under cowls/middle cowls (page 377) Remove the reserve tank filler cap and fill to the “UPPER" level line with 1:1 mixture cfdlstilled water and antifreeze. Reinstall the filler cap. Install the under cowIs/middle cowls (page 379) COOLING SYSTEM Remove the under cawls/middle cowls (page 377). Check the radiatoralr passages for clogging or damv age. Straighten bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the alr flow is restricted over more than 20% of the radiating surlace. UPPER LEVEL LINE 4-24 Contents Chapter 4 inspect the radiator hoses for cracks or deteriora- tion, and replace them if necessary. Check the tightness of all hose clamps and laslena ers. SECONDARY AIR SUPPLY SYSTEM if lne noses show any Sly/is of lleal damage inspect the PAW reed valves in The F-‘UH sneak valves Iar damage - This model IS equipped built-in secondary alr supply systems The pulse secondary air supply system is located on the cylinder head cover. - The secondary air supply system introduces rll- tered air into exhaust gases in the exhaust port. The secondary air ts drawn ima the exhaust pun whenever there is negative pressure pulse in the exhaust system. This charged secondary air pros motes burning of the unburned exhaust gases and cha nges a considerable amount 0' hydrocara hens and carbon monoxide into relatively harmv less carbon dioxide and water. Remove the air cleaner housing [page 574ml Check the PAIR (pulse secondary an injection) hoses between the FAlR control solenoid valve and cylina der head cover for deterioration, damage or loose connections Make sure that the hoses are not Cracked. Check the air suctlon hose between the air cleaner housing and PAlFl control solenoid valve for deterich ratlon, damage or loose connectzons. Make sure that the hoses are not kinked, plnched Dr cracked RADIATOR HOSES \ PAIR REED VALVE MAINTENANCE CYLINDER HEAD COVER Contents Chapter 4 MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) Check the hoses between the fuel tank, EVA? canis- ’—'—" Ier, EVAP purge control solenoid valve for deteriora tion, damage or loose connection. Check the EVAP canister for slacks or other damages Refer tn the Cable at Harness Routing (page 1-24) Ior hose ednnectiens. EVAF CANlSTER ‘ l l l l DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn the lgnitlon swltch OFF, place the motorcycle on its side stand and shift thetransmission into neu- tral, Check the slack in the drive ehain lower run midway between the sprockets. CHAIN SLACK: 25 — 35 mm (1 — 1-3/5 in) Excessive chain slack, 50 mm (20 in} or more, may damage the frame, Lubricate the drive ehain with #30 - so gear oil or chain lubricant designed specifically for use with o- ring chains, Wipe off the excess oil or chain lubrie Cant. ADJ USTMENT Loosen the rear axle nut. Turn both adjusting bolts until the correct drive chain slack is obtained. Make sure the index marks on both adjusting plates are aligned with the end of the swingarms Tighten the rear axle nut to the specified torque, TORQUE: 113 N-m (11.5 kgf—m, 83 lbf-ft) L ADJUSTING PLATE 4-26 Contents Chapter 4 MAINTENANCE Recheck the drive Chain slack and free wheel rela- tion. Lubricate the drive chaln with #80 — 90 gear oil or drive chain lubricant designed specifically for use with O-ring chains. Wipe off the excess oil or chain lubricant. Check the drive chain wear indicator label attached on the left drive chain adjusting plate. If the swingarm index mark reaches red zone of the indicator label, replace the drive chain WI"! 3 new one (page 4*28li CLEANING AND LUBRICATION Clean the chain with non-flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubri- eating. inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing a new chain on badly warn sprockets will cause the new chain to wear quickly. inspect and replace sprocket as necessary, Lubricate the drive chain with #80 , 90 gear oil or drive chain lubricant designed specifically for use with Daring chains Wipe off the excess oil or chain lubricant. SPROCKET INSPECTION Inspect the drive and driven sprocket teeth for wear or damage. replace if necessary. Never use a new drive chain on worn sprockets Bath chain and sprockets must be in good condi- tion, or the new replacement chain will wear rap- idly. rlNDiEATOR LABEL M w NON FLAMMABLE OR HIGH FLASH POINT SOLVENT \ “it. r' \ WIPE AND DRV RED ZONE LUBRICATE l #80 - 90 SEA OIL OR i DRIVE CHAIN LUBRICANT DAMAGE l NORMAL l Contents Chapter 4 4-27 MAINTENANCE i ii using we 75.‘ (chow Check the attaching bolts and nuts 0n the drive and driven sprockets If any are loose, torque them, TORQUE: Drive sprocket special bolt: 54 N‘m (5.5 kge-I’n, 40 lbf-fl) Fina! driven spracket nut: 54 N-m (5.5 kghn, 47 lbf-fl) REPLACEM ENT This moiorcycie uses a drive chain Willi a siaked masler link. ‘ Loosen the drive chain (page 4-26). Assemble We special tool as shown. TOOL: Drive chain tool set 07HMH-MR101D3 or 07HMH-MR101OC (U.S.A.only) Locate the crimped pin ends at the master link mm the outside oi the chain, and remove me link with the drive chain [00! set, TOOL: Drive chain ma! set D7HMH»MR1D103 or 07HMH-MR101OC (U.SlA,on|y} Remove ihe drive chain. 4-28 Contents Chapter 4 MAINTENANCE lnclude the master Remove the excess drive chain links from the new lmk when you drive chain With the drive chain tool set. count the drive Cm W5 STANDARD LINKS: 114 LINKS REPLACEMENT CHAIN DID: DID50VMZ-1ZDZB RK: RKSOGFOZ1-120LJFZ I Never reuse the old drive chaln. master link. master link plate and Orrings. (/7557? me masmr Assemble the new master link, O-rings and plate. lmk tram the msrde of the drrve charm, and Install the 0/618 with the ldthlIl‘Ca' mm mark fac/ng the nursrde Assemble and set the drive chain tool set. TOOL: Drive chain mnl set D7HMH-MR10103 or 07HMH-MR10’IOC (U.S.A.on|yl Make sure that the master link pins are installed properly. Measure the master link pin length projected from the plate, STANDARD LENGTH: DID: 1.15 — 1.55 mm (0.045 — 0.061 in] RK: 1.2 71.4 mm (0.05 — 0.06 in) Stake the master link pins. 114 LINKS OefilNGS MASTER LINK PINS Contents Chapter 4 4-29 MAINTENANCE Make sure that the pins are staked property by mear ‘ suring the diameter of the staked area using a slide SLIDE CALlPEH caliper. DIAMETER OF THE STAKED AREA: DID: 5.50 — 5.80 mm (0.217— 0.228 in) RK: 5.30 — 5.70 mm (0,209 — 0.224 in) Adm/c chamwrma After staking, check the staked area or the master cl/plwie master link link for cracks. niusrrmtbe used If there is any cracking, replace the master link. 0- rings and plate. (3000 NO GOOD KW CRACKED BRAKE FLUID Spilled fluid can damage painted, plasllc or rubber parts. Place a rag aver these parts whenever the system is serviced. ' Do not mix different types at flurd, as they are not compatible with each other, - Du 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 4441). A low fluid level may be due to wear of the brake pads. If the brake pads are worn. the caliper piston is pushed out, and this accounts for a low reservoir level. If the brake pads are not worn and the fluid level is low, check entire system for leaks (page 432). FRONT BRAKE Turn the handlebar so that the reservoir is level and check the from brake fluid level. If the level is near the lower level line, check the brake pad wear (page 4-31). LOWER LEVEL LINE 4'30 Contents Chapter 4 MAINTENANCE REAR BRAKE Place the motorcycle on a level surface, and support it an upright Daemon Check the rear brake fluid levet. If the level is near the tower level line, check the brake pad wear (page 431). LOWER LEVEL LINE‘ BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pads for wear. Reprace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to brake pad replacement (page 16-11). REAR BRAKE PADS Check the brake pads forwear. Replace the brake pads If either pad is worn to the bottom of wear llmil gmove. Rater to brake pad replacement {page 15.13). J; . ' WEAR LIMIT GROOVEj Lee—- Contents Chapter 4 4-31 MAINTENANCE BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system lf the lever or pedal feels soft or spongy when oper- ated, bleed the air from the system (page 1&8) lnspect the brake hose and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required Refer the procedure for brake bleeding (page 1577). BRAKE LEVER ADJUSTMENT Angn we allow The dlstance between the top of the brake lever and mark on the brake the grip can be adjusted by tumlng the adjuster. level with the Max number an the anL/SIEI BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod untll the correct pedal height lS ubtalnedu Make sure the push rod threads can be seen ‘T through the pedal joint hole. LOCK NUT After adjustment, ughten the lock nut to the speciv tied torque TORQUE: 18 N-m (1.8 kgi-m,13lbf‘ftl We HOLE PEDAL JOlNT 4'32 Contents Chapter 4 MAINTENANCE BRAKE LIGHT SWITCH The front brake lrg'it smzch does no: 'Equl'é' aa/uslr menr HEADLIGHT AIM Ad/usr the headligh: aim as screamed by local laws and regu- rations Leir Head/lghr Highr Headilght Adlust the brake light switch so that the brake light comes on just prior to the brake actually being engaged. If the light fails to come on, adjust the switch so that the light comes on at the propertime. Hold the switch body and turn the adjuster. Do not turn the switch body. Place the motorcycle on a level surface. Adjust the headlight aim vertically by turning the vertical beam adjusting screw. A clockwise rotation moves the beam up and (mum terciockwise rotation moves the beam down. Adjust the headlight aim horizontally by turning the horizontal beam adjusting screw. A clockwise rotation moves the beam toward the right and counterclockwise rotation moves the beam toward the left side of the rider. A clockwise rotation moveS the beam toward the 3‘ ieft and counterclockwise rotation moves the beam toward the right side of the rider, CLUTCH SYSTEM CLUTCH LEVER ADJUSTMENT The distance between the tip at the clutch lever and the grip can be adjusted by turning the adjuster. Contents Chapter 4 MAINTENANCE CLUTCH FLUID SDI/led fluid can damage painted, plastic or rubber parts, Place a rag war these parts whenever the system is serviced. - DD not mix different types of fluid, as they are not compatible with each other. o Do not allow foreign material to enter the system when filling the reservolr. When the fluid level Turn the handlebar to the right so that the reservoir l5 low, check entire IS level and check the clutch fluid level. ”5’5” ””5“?“ Firmly apply the clutch lever, and check that no air has entered the System, II the lever feels soft or spongy when operated, bleed the air from the system Inspect the clutch hose and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. Refer the procedure for clutch fluid bleeding (page 'lO-SI. EXHAUST GAS CONTROL VALVE CABLE OPERATING INSPECTION Remove the left middle cowl (page 3,” Turn the ignition switch to "ON". Shortthe Data Link Connector [DLC) terminals using the special tool, TOOL: 865 service connector 070PZ-ZV30100 ‘ _ , l DATA LlNKCONNECTDR 4'34 Contents Chapter 4 MAINTENANCE Make sure that the EGCV (Exhaust Gas Control Valve) cable guide pulley Index line is aligned with the EGCV housing index line as shown, If the pulley Index line ls not within the tolerance, adjust the EGCV control Cablest Turn the ignition switch OFF and remove the SCS service connector, BEARING INSPECTION Move the exhaust valve pulley with your hand, check the exhaust valve shaft for excessive plav. lr there is excessive play, replace the exhaust valve shaft bearings with new ones‘ CONTROL CABLES CABLE ADJUSTMENT 1t Fully loosen the spring equipped side cable lock nut and adjustan nut. 2. Short the Data Link Connector (DLC) terminals using the special tool (page 4-34). LOCK NUT 3. Loosen the adjusting cable lock nut and adjust- ing nuts 4. Adjust the pulley position by turning the adjust» ing nut. 5. Tighten the lock nut securely. ADJUSTING N UT Contents Chapter 4 4-35 MAINTENANCE 6. Move the cable several times and recheck the index line. 7. Seat the adjusting nut to the housing and tighten the lock nut securely. LOCK NUT 8. Remove the SCS service connector from the DLC, then relrlsiall IL Make sure that the EGCV (Exhaust Gas Control Valve) cable guide pulley index line is aligned with the EGCV housing index line. SIDE STAND Support the motorcycle an a level surface. Check the side stand spring For damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stand pivdt it near essarv. Check the side stand lgnltion Cubol'f system: 7 Sit astr'llzle the molorcycle and raise the side stand. 7 Startthe engine with the transmission in neutral, then shift the transmission into gear, with the eluteh lever squeezed. 7 Move the Side stand full down. 7 The engine should stop as the side stand is low- ered. If there l5 6 problem with the system, check the side stand switch lpage 20-22). SIDE STAND SWITCH 4'36 Contents Chapter 4 MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the action of me forks by Operating the from brakes and compressIng Ihe from suspension sev- eral IImes. Check the entire assembly for signs at leaks, dam- age or loose fasteners. Replace damaged componenrs which cannot be repaIred. TIgmen all nuts and bolts. Referto Iork service (page 1472“. Check for worn steering stem bearings bv grabbing the from fork Iegs and attempting to move the front fork from to back. RepIace me bearings if any IoOseness IS noted. FRONT SUSPENSION ADJUSTMENT SPRING PRE-LOAD ADJUSTER Spring preAlOad can be adjusted by Iurmng the 7’ adjuster. TURN CLOCKWISE: Increase the spring pre-Ioad TURN COUNTERCLDCKWISE: Decrease the spring prerload PRE-LOAD ADJUSTER ADJUSTABLE RANGE. 15 turns PRErLOAD ADJUSTER STANDARD POSITION: 7 turns in from minimum Contents Chapter 4 4-37 MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS Do not turn the adjusters more than the given posr'r tr'ons or the adjusters may be damaged. - AII damping adjustments are referenced from the fuII hard posmon. - Be sure that the rebound and compression adjusters are firmly located in a detent, and not between positions ustbcm The compression and rebound damplng can be g——— qreuy 5N adjusted by turning the adjusters. REBOUND ADJUSTER and Ieit , 9 saw DIRECTION H: Increase the damping force 7: the same p05» DIRECTION S: Decrease the damping force non :10 ”u m , age-L COMPRESSION ADJUSTER -— fi—u—u Turn the compression adjuster cIockwise until it stops (full hard posttiont, then turn the adjuster counterclockwise. COMPRESSION ADJUSTER STANDARD POSITION: 2 turns out from lull hard Turn the rebcund adjuster clockwuse until It stops (full hard position), then turn the adjuster counterc clockwise. REEDUND ADJUSTER STANDARD POSITION: 2 turns out from full hard 4'38 Contents Chapter 4 MAINTENANCE REAR SUSPENSION INSPECTION Support the motorcycle secureiy and raise the rear wheel off the ground. Hold the swingarm and move the rear wheei side ways with force to see if the axis bearings are worn Check for worn swingarm bearings by grabblng the rear end of the swingarm and attempting to move the swingarm side to side. Repiace the bearings if any are looseness is noted. Check the action of the shock absorber by com pressing it several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Reptace damaged components which cannot be repaired. Tighten ali nuts and boits. Refer to the shock absorber servicetpage15714). Contents Chapter 4 4-39 MAINTENANCE REAR SUSPENSION ADJUSTMENT COMPRESSION AND REBOUND DAMPING ADJUSTERS Do not mm the adjusters more than the given posit h'dns or the adjusters may be damaged. ~ An damping adjustments are referenced from (he mu hard position. The compression and Iebound damping can be adjusted by iurning the adjusters. COMPRESS'ON ADJUSTER DIRECTION H; Increase the damping force DIRECTION s: Decrease the damping force Turn the compression adjuster clockwise unriI it sIops (full hard position), Ihen turn the adjusler counterclockwise. COMPRESSION ADJUSTER STANDARD POSITION: 9 clicks out from full hard Turn the rebound adjuster clockwise unm it stops [full hard position), then mm the adjusier counter- clockwise. REEOUND ADJUSTER STANDARD POSITION: 2 — 1/2 turns out from full hard 'R ODN D AEDJUSTR 4-40 Contents Chapter 4 MAINTENANCE NUTS, BOLTS, FASTENERS Check that all Chassis nuts and bDItS are tlghtened to their correct torque values (page 1712). Check that all safety cllpe, hnse clamps and cable stays are ln place and properly secured. WHEELS/TIRES Tire pressure should be checked when the tires are COLD. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: > FRONT REAR T 7 — lre pressur’kpa (kgt/cmz D: l250 (2 50, 36) _l 29°F?'9°’4?L Tlre slze 120/7 ZR 17 190/50 ZR 17 M/C (58W) M/C (73W) l ‘ BTmaF BTUMR Tire Fr'dgemf RAElALfi RADIAL G ‘Plrem l DIABLO ; DIABLO bland ‘ ‘ CORSA H CORSA H Check the tlres tor cuts, embedded nails, er other r damage Check the front wheel lpage 14-16) and rear wheel [page 15-7) for trueness Measure the tread depth at the center of the tires. Replace the tlres when the tread depth reaches the following limltsv MINIMUM TREAD DEPTH: FRONT: 1.5 mm [0.06 in) REAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS Check that the control cables do not interfere w'lth handlebar rotation. Support the motorcycle securely and ralse the tram wheel ett the ground Check that the handlebar moves freely from slde to slde. 1f the handlebar moves unevenly, binds, or has ver~ tlcal movement, inspect the steering head bearings (page 14735l. Contents Chapter 4 4'41 MEMO Contents Chapter 4 5. LU BRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ------------- 5-2 SERVICE INFORMATION 5-3 TROUBLESHOOTING.t...t...........t.....u..t.....t.. 5,4 OIL PRESSURE INSPECTION ---------------------- 5-5 OIL STRAINERIPRESSURE RELIEF VALVE-545 OIL pump .................................... ................... 5.3 5-13 Contents Chapter 5 5-1 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFTS PISTON OIL JET CRANKSHAFT OIL COOLER EOP SWITCH MAINSHAFT COUNTERSHAFT OIL FILTER CARTRIDGE OIL PUMP OIL PRESSURE RELIEF VALVE OIL STRAINER 5-2 Contents Chapter 5 LU BRICATION SYSTEM SERVICE INFORMATION GENERAL ACA TIO Used engine oil may cause skin cancer if repeatedly left in Contact with the skin ior prolonged periods. Although this is unlikely unless you handle used oil on a daily baSls, It is still advisable to thoroughly wash your hands with soap and ‘ water as soon as possible after handling used oil. I The oil pump can be serviced with the engine installed in the frame. - The service procedures in this section must be performed with the engine oil drained. I When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. I If any portion of the oil pump is worn beyond the specified service limits, replaCe the Oil pump as an assembly. I After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct, SPECIFICATIONS fl . 7 7 Unit: mm (inf) l ‘7 i'T'Eii/l ' STANDARD SERVICE LIMIT ‘ Engine all capacity ‘ After draining 3 0 liter (3.2 US qt, 2.6 Imp qt) , l ‘ After oil filter change 3,1 liter (3.3 US qt, 2 7 lmp qti a . Afié disassfinbiy ' a a lite? (420 us qt, — Recommend d engine oil " ’ ”Pro Honda GNA or HP? — denurn additives) Astroke oil (U.S.A. and Canada}, or Honda 4rstroke oil (Canada onlyi, or an equivalent motor ‘ Oil API service classification: 36 or Higher except oils labeled as energy conserv- ing on the Circular API service label i ‘ JASO T 803 standard. MA Viscosity: SAE 10W~40 l Oil pressure‘at'EDF (engine oil pressurei switch . 4'90 kPa (5.0 kgf/cm ,71 psi) at " , ’ W 7, ., h 77 6,000 rpm/(80“C/I7G‘Fl i Oil pump ip clearance 7 7 0.15(0,006i 7 io.20¢(o.onai 1 Body clearance ’ 7' 0.15 $0.21 (0.006 7 0.00m o 35 (a 014i O. l Side clearance 0.04 , 0.03 (0.002 — 0.0% 0.17 (0,007) i TORQUE VALUES Engine oil filter cartridge 26 Nvm (2.7 kgf«m,201bf~fll Apply clean engine oil to the Orring Engine oil drain bolt 29 N~m (3.0 kgl~m, 22 [bf-ft) Engine ail drain base bolt 12 N-m (1.2 kgI-m, 9 Ibt rti Apply a locking agent lo the threads Oil pump assembly iiange bolt 7.8 N-m (0.8 kgf-rn, as ipt-tti CT bolt on filter boss See page 1.15 EOF (engine oil pressurel switch 12 N-m (l2 kgl-m, 9 ibi-ft) Apply sealant to the threads EOF‘ (engine oil pressure( switch wire 2.0 N»m (0,2 kgf~rn, 1.4 lbf-ftl terminal screw Oil pump driven sprocket bolt 15 N-rn (is kgf-m, l’l lbI-l‘tl Apply a locking agent to the threads Contents Chapter 5 LU BRICATION SYSTEM TOOLS i oil pressure gauge sei Oil pressure gauge anachrnem ‘ i 07506-300000! 07406-0030000 l \__\ 7/ or equivaleni commercially avail or equivaleni commercially avail able in U.S.A. (MT37A) able in U,S.Ac (AT77AH) TROUBLESHOOTING Oil level too low - on censumprien 0 External oil leak Worn piston rings Improperly installed plsron rings Worn cylinders Warn valve stem seals Worn valve guide Low oil pressure - Oil level low - Clogged oil strainer 0 Internal oil leak - lncerreci pil being used No oil pressure ' Oil level (00 low Oil pressure reliel valve sluck open Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pump Internal Dll leak High oil pressure - Oil pressure relief valve sluck closed - Clogged oil (iirer, oil cooler gallery or metering erilice - lncerrecl oil being used Oil contaminafion ' Oil or filler nm changed Dhen enough - Worn pislon rings Oil emulsificatian - Blown cylinder head gaskel - Leaky coolant passage - Entry ofwater Contents Chapter 5 LUBRICATION SYSTEM OIL PRESSURE INSPECTION // the or/ pressure Remove the under cowls (page 37). mdlcatol llg/ll remams on a few seconds, wreck me mdlcamr sysrem oelere cnecklng me all pressure Remove the screw and disconnect the EOP switch wlrev Remove the EOP switch whlle holding the Switch base. Install the oil pressure gauge attachment to the switch base. Connect the all pressure gauge to the all pressure gauge attachment, TOOLS: Oil pressure gauge 52! 0750641000001 or equivalent commercially avail- ahle in USA (MT37A) Oil pressure gauge attach- 07405-0030000 or men! equivalent commercially avail- able in U.$.A, (AT77AH) Check the all level (page 4721). Warm the engine to normal operating temperature lapproxlmatelv BOT/176$) and increase the englne speed m 6,000 rpm and read the oil pressure. OIL PRESSURE: 490 kPa (5‘0 kgl/em‘, 71 psi) at 6,000 rpm/ (sane/175w) Slop the engine and remove the tools, Al 5 | ttcth EOP 'lhm d n , up” ea 3" 9 SW' c '83 ”55 0w" Do not apply sealantm thethread head 3 4mm10170 'l EOP SWITCH ‘ Contents Chapter 5 LUBRICATION SYSTEM install and tighten the EOP switch to the specified [ . torque while holding the switch base. TOROUE:12 Nrm (1.2 kgf‘m, 9 Ibi-ft) Connect the EOP switch wire terminal to the switch and tighten the screw to the specified torque. 0”- PRESSURE SWITCH , - TORQUE: 2.0 N-m (0,2 kgf-m, 1.4 Inf-fl) Instali the dust cover. InstaH the under cow's (page 3-7). OIL STRAINER/PRESSURE RELIEF VALVE REMOVAL Drain the engine oil (page 4722). .. _ Remove the exhaust pipe (page 3730). , _ O‘L PAN 5 Remove the oil pan SH flange boits and oil pan. Remove the oil strainer and packing. OIL STRAINER Clean the oil strainer screen. ’ v // 5-6 Contents Chapter 5 LUBRICATION SYSTEM Remove the pressure relief valve and O-ring. INSPECTION Check the operation of the pressure reliel valve by pushing on the piston. . Disassemble the reliel valve by removing the snap PISTON ring. Inspeclthe piston for wear, unsmooth movement or damage. Inspect the spring for fatigue or damage. RELlEF WASHER Assemble the relief valve in the reverse order of dis~ VALVE BODY assembly. :4 SPRING SNAP RING/V INSTALLATION Apply nil to a new packing and install it onto the oil - strainer flange. Install the oil strainer into the oil pump while alignr ing the oil strainer bass with the groove of the oil pump. yvplL STRAINER valve. Install the relief valve Into the crankcase. Contents Chapter 5 LUBRICATION SYSTEM Do not apply mare 56015”! Ilia/7 necas‘v sarv OIL PUMP To gain access in the Oil Dump driven sptncket bolt, first remove the Oll pan. lithe oil pan drain base is removed, install the fol- J lowing: l BOLT OIL PAN DRAIN BASE — Install a new O-ring into the oil pan drain base groove. — Install the oil pan drain base onto the oil pan, and temporarily install and tighten the Oll drain bolt. — Apply a locking agent to the oil pan drain base mounting bolt threads. — Install and tighten the oil pan drain base mounts ing bolt to the specified torque. TORQUE: 12 Nm (1.2 kgl-m, 9 [bf-ft) Clean the oil pan mating surface thoroughly. Apply sealant lThree Bond 12078 or an equivalent) to the mating surface. Install the oil pan onto the lower crankcase install the oil pan SH flange bolts, Tighten the butts in a crisscross pattern in two or three steps Install the exhaust pipe [page 3-35). Fill the crankcase with the recommended oil lpage 4722). After installation, check that there are no oil leaksv REMOVAL Drain the engine oil (page 4722). Remove the clutchlpage1046l. Remove the bolt, washer and OII pump driven sprocket. BOLTNVASHER V Contents Chapter 5 LUBRICATION SYSTEM Remove the oil pan (page 56). OIL PUJPASSEMBLY Removathefolluwmg: 7 Oil pump mounting bolts 7 on pump assembly 7 Dowel pins 7 on pass caHar/Osring DISASSEMBLY Remove the on pump assembly bolts ASSEMBLY BOLTS Remove the on pump cover and dowel pins. OIL PUMP BODY OIL PUMP COVER DOWEL PINS Remove the thrust washer, drive pin, oil pump shah, outer rotor and inner rotor from the all pump body. C‘ean all disassembly parts thoroughly. OUTER ROTOR THRUST WASHER O‘LF‘UMP SHAFI’ INNER ROTOR DRIVE P‘N Contents Chapter 5 LUBRICATION SYSTEM INSPECTION Ifanypunlnn arme Temporarily lnsrall the outer and inner rotors into ' on pump :5 worn the oil pump body. T'P CLEARANCE beynnd (he servrce Temporarily install the drive pin and oil pump shah. ll'nll, rep/ace me or! pump as an assem- bly SERVICE LIMIT: 0.20 mm (0.008 in) Measure the rotor tip clearance. Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.014 in) Measure the side clearance using a straight edge and feeler gauge. SIDE CLEARANC SERVICE LIMIT: 0.17 mm (0.007 in) 5-10 Contents Chapter 5 LUBRICATION SYSTEM ASSEMBLY IN NEH ROTOR DRIVE FIN OUTER ROTOR OIL PUMP COVER OIL PUMP SHAFI' WASHER ,\ ' p a l g DOWEL PINS OIL PUMP BODY 12 N-m 11.2 kgf-m, 9 Ibf-ft) Dip all parts in clean engine oil. Install the outer rotor into the oil pump body. OUTER ROTOR Install the inner rotor into the outer rotor with its drive pin groove facing the oil pump cover. Install the oil pump shaft through the inner rotor and oil pump body. OUTER ROTOR Install the drive pin into the hole in the oil pump , ~ , ‘ shaft and align the drive pin with the groove in the ' -' THRUST WASHER inner rotor. Install the thrust washer. OIL PU MP SHAFT INNER ROTOR DRIVE PIN Contents Chapter 5 5'11 LUBRICATION SYSTEM Install the dowel plns lnta the all pump cover. OIL PUMP BODY OlL PUMP COVER Install the oil pump coverto the oil pump body. DOWEL PINS Install and tighten the oil pump assembly bolts to the specified torque. TORQUE: 12 Nvm (1.2 kgfrm, 9 lbf-ft) Check the oil pump operation by turning the pump shah, if necessary, reassemble the oil pump. INSTALLATION install the dowel pins, Apply oil to a new Orring and install it with the oil pass collar, install the oil pump assembly onto the crankcase while aligning the oil pump shaft lug with the water pump shaft groove by turning the oil pump shaft. 5'12 Contents Chapter 5 LUBRICATION SYSTEM Install and tighten the three flange bolts securely. OIL PUMP ASSEMBLY, \ Apply oil m the oil pump driven sprocket and drive chain Install the driven sprocket with its "our" mark fac- irig out. Apply a locking agent to the oil pump driven sprocket bolt threads. , Install and tighten the driven sprocket bolt/washer to the specified torque. TORQUE: 15 N-m (1‘5 kgf‘m, 11 Ibf-h) Install the 0H pan [page 577). ihsraii the right crankcase cover (page 10-34). After instailation, fiil the crankcase with the recom- mended oil (page 4-22) and check that there is no oil leaks. Check the oil pressure (page 5-5). OIL COOLER REMOVAL Drain the engine oii (page 4»22i. Drain the cooiant [mm the system (page 776), Remove the exhaust pipe [page 373m. Loosen the hose clamp screws and disconnect the oil cooler water hoses from the oil couler. Contents Chapter 5 5-13 LU BRICATION SYSTEM Remove the three bulls and oil cooler. Remove the O-ring from the oil cooler. INSPECTION Check the oil cooler for damagei INSTALLATION Coat a new OAring with engine oil and install it into the oil cooler groove. Install the oil cooler on the crankcase Install and tighten the three bolts. Connecl the oil cooler Waller hoses imo the oil cooler and (igmen The hose clamp screws securely. Install the exhaust pipe (page 336) Fill the crankcase with we recommended oil lpage 4722) and check manners is no oil leaksi Fill the cooling system and bleed any air (page 76). 5'14 Contents Chapter 5 6. FUEL SYSTEM (Programmed Fuel Injection) COMPONENT LOCATION SERVICE INFORMATION .............................. 5.3 TROUBLESHOOTING....um...“...,.................. 5.5 SYSTEM LOCATION-- SYSTEM DIAGRAM ....................................... 5.3 PGM-Fl SELF~D|AGNOSIS INFORMATION .............................................. 6-9 MIL CODE INDEX ........................................ 5.13 MIL TROUBLESHOOTING .......................... 5.15 FUEL LINE INSPECTION 5.31 FUEL PUMP UNIT ....................................... 5.33 FUEL CUT-OFF RELAY ----------- - 5-35 FUEL TANK .................................................. 5.35 AIR CLEANER HOUSING ---------------------------- 6-40 SECONDARY |NJECTOR-- -G~43 THROTTLE BODY ........................................ 5.47 PRIMARY INJECTORI.,,............,.................. 5.54 IDLE AIR CONTROL (IAC) THERMAL VALVE ......................................... 5.55 IDLE AIR CONTROL (IAC) VALVE --------------- 6-57 IAC VALVE SYNCHRONIZATION ---------------- 6~61 MAP SENSOR ............................................... 5.54 IAT SENSOR ................................................. 6-65 ECT SENSOR ................................................ 5.55 CMP SENSOR ............................................... 6-66 BANK ANGLE SENSOR ............................... 5.57 ENGINE STOP RELAY668 ENGINE CONTROL MODULE (ECM)«--~------6.69 PAIR CONTROL SOLENOID VALVE 6-71 EVAP PURGE CONTROL SOLENOID VALVE (CALIFORNIA 1'va ONLY) 572 INTAKE AIR DUCT ........................................ 5.73 EGCV (Exhaust Gas Control Valve)-------~-r-6-7G EGCV SERVOMOTOR .................................. 5.73 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) COMPONENT LOCATION 4A N-m (0‘45 kgfm, 3.3 [bf-f!) 5V4 Nvm (0.55 kgf~m, 4‘0 \bf-ftl N-m (0.12 kgf—m. A lbf-fl) N-m (0.12 kgf-m, 1.2 0.9 lbf-ft) 22 N-m (2.2 kgf»m,16lbf-fl) 26 N-m (2.7 kgfvm, 20 Ith) see N«m 11.0 kgf‘m, 7 mm) 5-2 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel lniection) SERVICE INFORMATION GENERAL Be sure to relieve the fuel pressure while the engine is OFF. - Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, result— ing in loss of vehicle control. - Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. - Do not apply commercially available carburetor cleaners to the inside of the throttle bore, which is coated With molyb- denum. I Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incor- rect idle operation. Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed. Do not apply excessive force to the fuel pipe on the throttle body while removing or installing the throttle body. Do not damage the throttle body. it may cause incorrect throttle and idle valve synchronization. Prevent dirt and debris from entering the throttle bore, fuel hose and return hose, clean them using compressed air. The throttle body is factory ore-set. Do not disassemble in a way other than shown in this manual. DO not push the fuel pump base under the fuel tank when the fuel tank is stored. Always replace the packing when the rue) pump is removed. The programmed luel injection (PGMsFI) system is equipped With a Selstiagnostic System, described page 6-51 ii the malfunction indicator lamp (MIL) blinks, follow the Selstiagnostic Procedures to remedy the problem. When checking the PGM-FI, always follow the steps in the troubleshooting flow chart [page 6715). The PGMrFI system is provided with fail—safe function to secure a minimum running capability when there is any trow ble in the system. When any abnormality ‘is detected by the self-diagnosis function, running capability is secured by using numerical values preset in advance in the program map. It must be remembered, however, that when any abnors mality is detected ‘in a injectors and/or the CKP (Crankshaft Position) sensor and CMP (Camshaft Position) sensor. the fail safe function stops the engine to protect it from damage. Refer to F'GMsFl system location (page 6s7]. A faulty PGM-Fl system is often related to poorly connected or corroded connectors, Check those connections before proceeding. Refer to procedures for fuel reserve sensor inspection [page 2047), The vehicle speed sensor sends a digital pulse signal to the ECM (PGM»F| unit) for computation. Refer to procedures for vehicle speed sensor inspection (page 20-12). When disassembling the programmed fuel injection parts, note the location or the Osririgs. Replace them with new ones upon reassembly. Before disconnecting the fuel hose, release the fuel pressure by loosening the fuel hose banjo bolt at the fuel tank. Always replace the sealing washers when the fuel hose banjo bolt is removed or loosened - Use a digital test meter for FGM-Fl system inspection. on SPECIFICATIONS , ’ i lTiM SPECIFICATTCSNS 7 i Throttle body iinfica- A, CM type GOAoc * tion number AC type GQAoB l idle air control lIAC) valve vacuum difference ' 20 mmHg ; Toss throttle valve for synchronization No. 1 ' Idle speed ’ W " ”“1200 :t loo rpm Throttle grip free play 2—4 mm ll/‘IS—S/IG in) Intake air temperature sensor resistance [at 20“CISB°F) 1 » 4 kfl l Engine coolant temperature sensor resistance 23 — 2.6 kn * (at mitt/63W) Fuel injection resistance Frimary' ' ctor lu.5~ 14.5 :1 lat 20“C l68“Fl 77 Secondary injector i 10.5 — 14.5 n . i » fruit control solenoid valve resistance (at 20"C/68”Fl l 20 — 24 o CMP)(Camshaft position) sensor peak voltage lat zo°c1 . 0.7 v minimum ssar CKP [Crankshaft position) sensor peak voltage (Et'zovty ‘ ofi’v'r’ninimum ‘ 68°F) Manifold absolute pressure’a’tid’le 150 ~ 250 mmHg Fuel pressure at idle 343 kPa (3.5 kgflcm’, 50 psi) Fuel pumpjlowlat 12V) 189 cm“ l6.4 US oz, 6.7 Imp oz) minimum/1O seconds Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) TORQUE VALUES ECT (Engine Coolant Temperature)/ thermo sensor Throttle body insulator band screw Service check bolt lAC valve lock nut lAC Valve synchronization plate screw Fuel pipe mounting bolt lAc thermal valve link plate screw lAC thermal valve mounting screw Fuel filler cap socket bolt Fuel feed hose banjo bolt (fuel tank side) Fuel hose sealing nut (throttle body side) Fuel pump flange nut Fuel tank mounting bolt (front) Fuel tank mounting bolt lrearl 23 N‘m (2.3 kgt-m, 17 lbf-fl) See page 1-15 12 NM (1.2 kgf-m, 9 lbf-ft] 1.8 N'm (0.18 kgt‘m,1.3lbf~ft) 0.9 N-m (0.09 kgf-rn, 0.7 lbt-ftl 9,3 N-m (1,0 kgf‘m, 7 Ibt~ftl 0.9 N-rn (0.09 kgf-m, 0.7 |bl~fll 4.9 N‘rn (0.5 kgtvm, 3.6 lbt-ft) 1.8 N»m (0.18 kgf»m.1.3|bl-fll 22 N‘m (2.2 kg!-m,16lbf~ft 22 N-m (2.2 kgf-m, 16 ital-ft) 12 N-m (1,2 kgf-m, 9 Inf-ft) 26 N«m (2.7 kgfrm, 20 lbf-ft) 9.8 N-m (1.0 kgl-m, 7 lot-ft) Yellow paint See page 1-17 lor tightening sequence Fuel rail joint hose SH boll 9.8 N-m (1.0 kgl-m. 7 lbf-ft) Yellow palm Fuel rail joint hose sealing nut 22 N-m (2.2 kgf-m,16|b(-ttl Yellow paint Air cleaner housing/air funnel pan screw 44 Nvm (0.45 kgV-m, 3.3 lbl-fl] Top air cleaner housing mounting screw 12 N-m (0.12 kgfrm, 0.9 let) Middle air cleaner housing mounting 1.2 N-m (0,12 kgf~m, 0.9 lDf-ft) screw IAT sensor mounting screw 1.2 N-m (0.12 kgf—m, 0.9 Ibf-ftl Air intake duct joint screw 2.5 N-m (0,25 kgf—m, 1.8 lbf—f‘t) Air intake duct (lap screw 1.2 N-m (0.12 kgf-m, 0.9 lbf-ftl Secondary injector base mounting bolt 5.4 Nrm (0.55 kgf-m, 4.0 Ibf-ft) Elank angle sensor mounting screw 1.5 N-m (0.15 kgf-m, 1.1 lbf‘ft) -4 6 Contents Chapter 6 TOOLS FUEL SYSTEM (Programmed Fuel Injection) Fuel pressure gauge 074060040003 or o7aaryoowooa or 07406-004000A (USA. only) SCS service connector 070F'ZVZY30100 Inspection adaptor ‘ omMJMLsomo Peak voltage adaptor 07HGJ-0020100 (not available in U.S.A.) with commercially available digital mullimeter [Impedance 10 MQ/DCV minimum) ‘ ECM lest harness, 32F 070M270010201 (two required) IgnitionMate peak voltage raster MTP07-0286 [U.SiAi only) Vacuum gauge set ovLMJromoooa ®®®®u UUU‘U ’ or D7LMJ-001000A Contents Chapter 6 6-5 FUEL SYSTEM (Programmed Fuel Injection) TROUBLESHOOTING Engine won't start 0 Intake air leak 0 Fuel contaminetted/deteriorated - Flnched or clogged luel hose 0 Faulty fuel pump unit . Clogged fuel filter/strainer - Clogged fuel injector filter - Stlcking fuel injector needle - Faulty fuel pump operating system Engine stalls, hard to start, rough idling - Intake airleak . Fuel cuntamlnated/deteriorated - Pinched or clogged fuel hose . idle speed misadjusted - IAC valve synchronization misadiusted Backfiring or misfiring during acceleration - ignition system maltunctlon Poor performance ldriye ability) and poor fuel economy - Pinched or clogged fuel hose - Faulty pressure regulator Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) SYSTEM LOCATION FAIR CONTROL SOLENOID VALVE IAT SENSOR IGNITION SWITCH ECM SECONDARY INJECTOR MAP SENSOR BANK ANGLE SENSOR FUEL PUMP ECT SENSOR FUEL CUT-OFF RELAV ENGINE STOP RELAY INTAKE AIR CONTROL SOLENOID VALVE CMP SENSOR TP SENSOR PRIMARY INJECTOR EGCV SERVOMOTOR CKP SENSOR VS SENSOR FULL NAME ABBREVIATIONS Manifold absolute pressure sensor MAP sensor Throttle position sensor TP sensor Intakar temperature sensor HAT sensor Engine coolant temperature sensor ‘ECT sensor Camsl’Eff position sensor CMP sensor Crankshaft position sensor CKP sensor Vehicle speed sensor VS sensor Engine control module ECM Contents Chapter 6 6'7 FUEL SYSTEM (Programmed Fuel Injection) SYSTEM DIAGRAM ml .355: (D (an 695‘s 4 may (1) Engine stop relay (20) EVAF purge control solenoid valve (2) PGM-Fl fuse (20A) (21) Fuel indicator [3) Engine stop switch (22) Fuel pump unit [4) Sub-fuse (10A) (23) Primary injector (5) Ignition switch (24) CMP (camshaft position) Sensor (6) Main (use A (30A) (25) Direct ignition coil/spark plug (7) Bank angle sensor (26) MAP sensor (8) DLC (data link connector) (27) PAIR check valve (9) Battery (28) ECT sensor (10) EVAP canister (29) CKF (crankshaft position) sensor (11) HESD (Honda Electronic Steering Damper) (30) EGCV servomotor [12) Fuel cutoff relav (31) Water temperature LCD [13) IAT sensor (32) Speedometer [14) Secondary injector (33) VS (Vehicle speed) sensor (15) Intake duct diaphragm (34) Neutral switch (16) Intake air control solenoid valve (35) Clutw switch [17) Vacuum chamber (36) Side stand switch (18) PAIR control solenoid valve (37) Malfunction indicator lamp (MIL) (19) TF sensor (38) Tachometer Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Iniection) PGM-Fl SELF-DIAGNOSIS INFORMATION The MIL wlll bllnk only with the side srano down and n’ltl‘ me ENQWE or’ lengtne slap swrrcr’i l5 RUM or engine revs are below 5, 000 pm. in any lather condition, the MIL wll illuminale and srav on SELF-DIAGNOSTIC PROCEDURE Place the motorcycle on its side stand. MALFUNCTION lNDICATOR LAMP lMlLl Start the engine and let it idle. NOTE: If the engine will not start, turn the starter motor for i more than 10 seconds and check that the MIL blinks. If the malfunction indicator lamp lMlLl does not light or blink, the system has no memory of prob lem data. If the malfunction indicator bllnks, note how many times the MIL blinks and determine the cause of the problem [page 6713). it you wish to read the PGM~F| memory for trouble data, perform the following: Turn the ignition swnch OFF. Remove the left middle cowl (page 37). Disconnect the Data Link Connector lDLC). Turn the ignition switch OFF. Remove the leh middle cowl (page 37), Shor‘lthe Data Link Connector (DLCI terminals using the special tool. TOOL: 505 service connector 070PZ-ZV30100 Connection: Brown , Green Turn the ignition switch ON and engine stop switch l '/ " O" l " DATA LINK CONNECTOR 6-9 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Even if the PGMVFI has memory data, the MIL does not blink when the engine IS running. lithe ECM has no self diagnosis memory data, the MIL will illuminate, when you turn the ignition switch 0N. If the ECM has self diagnosis memory data, the MIL will start blinking when you turn the ignition switch ON. Note how many times the MIL blinks, and determine the cause ofthe problem (page 5-13. SELF-DIAGNOSIS RES ET PROCEDURE Reset the seif»diagnosis memory data as follows: 1. Turn the engine stop switch “ 82" and ignition switch OFF. 2. Short the Data Link Connector IDLC) terminals using a special tool. TOOL: SCS service connector 07OPZVZV30100 Connection: Brown 7 Green 3. Turn the ignition switch ON 4. Remove the special tool from the Data Link Con- nector (DLCI. 5. The MIL lights about 5 seconds. While the indica» tor lights. short the Data Link Connector (DLCI again with the special tool. Self-diagnosis memory data is erased, if the MIL turns offend starts blinking. I The Data Link Connector (DLC) must be Jumped while the indicator is lit. If not, the MIL will not start blinking. Note that the self diagnosis memory data Cannot be erased if you turn off the ignition switch before the MIL starts blinking. If the MIL blinks 20 times. the data has not been erased. so try again. . MALFUNCTION INDlCATOR LAMP lMIL) PGMVFI INDICATOR scs SERVICE CONNECTOR ' \\\e_ , K ‘ \ , \_ rr Ax fr) DATA LINK CONNECTOR MALFUNCTION INDICATOR LAMP lMILIi PGM-Fl INDICATOR 6-10 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel ln]ection) PEAK VOLTAGE INSPECTION PROCEDURE - Use this procedure for the crankshaft position sensor and camshaft position sensor inspection. I Check all system Connections before inspection. If the system is disconnected, incorrect peak volt age might be measured I Check cylinder compression and check that all spark plugs are installed correctly - Use the recommended digital multimeter or commerCIally available digital multimeter wilh an Impedance of 10 MQ/DCV minimum - If the lgnitionMate peak voltage tester is used, iollcw the manufacturer's instruction. - The display value differs depending upon the internal impedance of the multimeter. - Disconnect the fuel pump connector before checking the peak voltage. Lift and supporl the tuel tank (page 4-5l. Disconnect the fuel pump Unit SP (Black) connector 3P (BLACK) CON NECTOR Connect the peak voltage adaptor to the digital mule ‘ “mam _ , DIGlTAL MULTIMETER ‘ TOOLS: i i lgnitionMate peak voltage tester M'rPln-ozss ‘ (USA. only) or l Peak voltage adaptor 07HGJ—0020100 ‘ (not available in U.S.A.i with commercially available digital multimeter (impedance 10 MQ/DCV minimum) PEAK VOLTAGE ADAPTOR " TEST HARNESS CONNECTION Remove the under cowls/mlddle cowls (page 3-7l. Disconnect the ECM 32F (Black) and 3ZP (Light grav] connectors from the ECM (page 6r69l. 32F (LIGHT GRAY) CONNECTOR Contents Chapter 6 6'11 FUEL SYSTEM (Programmed Fuel Injection) Connect the ECM test harnesses be‘ween The main wure harness and \he ECM. TOOLS: ECM test harness, 32F (”DMZ-0010201 (two required) TEST HARNESS TERMINAL LAYOUT The ECM connector terminals are numbered as Shown. The ECM (as: harness termina‘s are the same lavom as for the ECM connector terminals as shown. ECM TEST HARNESSES VIEW FROM WIRE HARNESS SIDE: A: 32F (BLACK! CONNECTOR B: 32P1L‘GHT GRAY) CONNECTOR FOR 32F {BLACK} CONNECTOR Qimm Mm ,, T wooeooooonococo asaoaooaooaooooa :Jm %- c ouoooaowo season on on 9563800380 Wu H ummmmsu mm Mum FOR 32? (LIGHT GRAY) CONNECTOR 6-12 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) MIL CODE INDEX ' The PGM~Fl MIL denotes the failure codes (the number of blinks from 0 to 49L When the indicator lights for 1.3 seconds, it is equivalent to ten blinks. For example, a 1.3 second illumination and two blinks (0.5 second x 2) of the indicator equals 12 blinks. Follow code 12 troubleshooting (page 6424). When more than one failure occurs, the MIL shows the blinks in the order of lowest number to highest number. For example if the indicator blinks once, then two times, two failures have occurred. Follow codes ‘l (page 6-15) and 2 (page 6-16) troubleshooting. MIL l Function Failure Causes Symptoms “‘3," No blinks ECM malfunction - Faulty ECM I Engine does not start ($69 No blinks ECM power/ - Open circuit at the power input - Engine does not start . 6-69 ground circuits Wire of the ECM ‘ malfunction I Faulty bank angle sensor I Open circuit in bank angle sen- ‘ sor related Circuit - Faulty engine stop relay ‘ - Open circuit in engine stop relay related wires - Faulty engine stop swrtch - Open circuit in engine stop 1 switch related wires - Faulty ignition switch I Blown PGM-Fl fuse (20 Al l I Blown sub-fuse (10 Al (Starter. l _ Bank angle sensor) W . No blinks ECM output line I ECM output voltage line (Yellow! - Engine does not start 7 l malfunction Red wire) short circuit No blinks MlL circuit mal- I Faulty ECM I Engine operates nor- 5-9 function I Open or short circuit in MIL wire mally ‘ Stays lit Data link Circuit I Short circuit in data link connec- I Engine operates nor- - malfunction tor mally I Faulty ECM l I Short circuit in data link conneo tor wire 1 Blink MAP sensor cire - Loose or poor contact on MAP - Engine operates nors 1 6:15 cuit malfunction sensor connector mally l - Open or short circuit in MAP sen» r sor wire l I Faulty MAP sensor l 2 Blinks MAP sensor pers I Loose or poor connection of the I Engine operates nur- 646 formance prob- MAP sensor vacuum hose mally lem ., I Faulty MAP sensor 7 Blinks ECT sensor cirs - Loose or poor contact on ECT - Hard start at a low tam- 6-17 cult malfunction sensor peratu re (Simulate using Open or short circuit in ECT sen» numerical values: 90 “CI ‘ sor wire 1511 3F) l 7 - Faulty ECT sensor 8 Blinks l TP sensor circuit I Loose or poor contact on TP sen- I F'oor engine perfor» 649 l malfunction sor connector mance response and Open or short circuit in TP sens when operating the sor wire throttle quickly (Simu- Faulty TP sensor late using numerical vals ; A muss; Throttle opens a“) l 9 Blinks lAT sensor circuit Loose or poor contact on lAT I Engine operates nor» 6-21 malfunction sensor mally (Simulate using l Open or short circuit in lAT sen~ numerical values; 25 “C/ sor wire 77 °F) I Faulty lAT sensor ‘ l1 Blinks VS (Vehicle - Loose or poor contact on V8 sen- l I Engine operates nor- 6-22 ‘ speed) sensor cir- sor connector l mally cult malfunction Openlor short circuit in VS sen- . HESD does not function sor wrre Faulty vs sensor Contents Chapter 6 6-13 FUEL SYSTEM (Programmed Fuel Injection) i MIL Function Failure Causes ‘ Symptoms ' “f2" ‘ 12 Blinks No.1 primary I Loose or poor contact on No.1 ‘ Engine does not start 6—24 injector circuit primary injector connector ‘ malfunction I Open or short circuit in No.1 pri- mary injector wire ., A i I Faulty No.1 primaryinjectori , , l 13 Blinks No.2 primary I Loose or poor contact on No.2 Engine does not start 6-25 injector Circuit primary injector connector malfunction I Open or short circuit in No.2 pri- mary injector wire _ V I Faulty No.2 primary injector 14 Blinks No.3 primary I Loose or poor contact on No.3 Engine does not start 6-25 i injector circuit primary injector connector malfunction I Open or short circuit in Nos pri- ‘ mary injector wire " V ojzuity No.3 primary injector j 15 Blinks No 4 primary I Loose or poor contact on No.4 Engine does not start 5.25 ‘ injector circuit primary injector connector malfunction I Open or short circuit in No.4 pri» mary injector wire I Faulty No.4 primary injector 16 Blinks 1 No.1 secondary . Loose or poor contact on No.1 Engine does not start 625 injector circuit secondary injector connector 1 i ‘ malfunction I Open or short circuit in No.1 sec. i ondary injector wire ‘ ‘ . Faulty No.1 secondary injector ‘ i 17 Blinks No.2 secondary I Loose or poor contact on No.2 Engine does not start 525 injector circuit secondary injector connector malfunction - Open or short circuit in No.2 secr i ‘ ondaryinjectorwire ‘ I Faulty No.2 secondary injector 18 Blinks CMP (Camshaft I Loose or poor contact on CMP Engine does not start 526 i position) sensor, sensor i no signal I Open orshort circuit in CMP sen- l i sor . if; __ , - Fauityeamshari position sensor "failinks CKP (Crankshaft - Loose or poor Contact on CKP ' Engine does not start 6-27 position) sensor, sensor ‘ no signal I Open or short circuit in CKP sen» ‘ ‘ sor I Faulty crankshaft position sensor i j 33 Blinks EEPHOM in ECM I Faulty ECM ‘. Engine operates nor- 6-28 . malfunction ‘ rnally 34 Blinks EGCV POT I Faulty EGCV servomotor POT i Engine operates nor- 6728 (potentiometer) ‘ mally malfunction v 7 ‘ » >77 35 Blinks l EGCV servomotor I EGCV servomotor lodt Engine operates nor— 6~30 ‘ malfunction mally 43 Blinks No.3 secondary - Loose or poor contact on N03 Engine does not start e25 ‘ injector circuit secondary injector connector i malfunction I Open or short circuit in No.3 set:- i ondary injector wire i I Faulty No.3 secondaryVinj_ector i 49 Blinks No.4 secondary I Loose or poor Contact on N04 Engine does not start 6-25 injector circuit secondary injector connector . malfunction I Open or short circuit in No.4 sec— 1 onoary injector wire ‘ ’ i I Faulty No.4 secondary injector _ i i 51 Blinks HESD linear sols.L I Loose or poor contact on HESD Engine operates norc 1477 noid malfunction solenoid connector - Open or short circuit in HESD solenoid wire I Faulty HESD solenoid mally ) HESD does not function Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) MIL TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) 0 Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) con- nector and recheck the MIL blinking. 1. MAP Sensor Output Voltage Inspection Turn the ignition switch OFF, Connect the ECM test harness to ECM connec- tors (page 6-11). _ Turn the ignition switch ON and engine stop m switch " O ‘ ooooocoooooooocg oaooooooooo «mag Measure the voltage at the test harness termi- ooooouooocoooooo- Ioouoooooo o coco "815- Connection: B12 (+) — 326 (A) Is the voltage within 27 — 3. 1V7 VES — - lntermittentfailure , v Luase or poor contact on the ECM connectors N0 — I About 5 V GO TO STEP 2. - About 0 V GO TO STEP 3. 2. MAP Sensor Output Line Inspection Turn the ignition switch OFF. Disconnect the MAP sensor 3? (Black) connecA 3” ‘BLAC'O CONNECTOR tor. d i <9 Turn the ignition switch ON and engine Stop switch H 0 “. Measure the valtage at the Wire harness side. Connenion: Blue/black (+1 — Gray/black (—i Is the voltage within 4.75 — 525V? VES — Faultv MAP sensor No — - Open circuit in Blue/black wire i - Open circuit in Gray/black wire a. MAP Sensor input Voltage inspection Measure the voltage at the wire harness side, Connection: Yellow/red (+) 7 Ground (—) Is the voltage within 4. 75 — 5.25 V? YES ~ GO TO STEP4‘ N0 — GO TO STEP 5, Contents Chapter 6 6'15 FUEL SYSTEM (Programmed Fuel Injection) 4. MAP Sensor Output Line Short circuit Inspec- tion f3“.:25.‘2;:z::::."r::::::rgazmfisesrggz Wi_—T side and ground. . Connection: Blue/black - ground Is there continuity? VES — Short circuit in Blue/black wire NO — Faulty MAP sensor 5. MAP Sensor Input Line Inspection Turn the ignition switch DFFu *7 Disconnect the ECM 32F connectors. Check for continuity at the Vellow/red wire between the MAP sensor antaiack) connector 5“ 3' “J“ ‘1 terminal and the ECM 32F (Light gray) connecV mummumm 5% ‘0‘“ umoooooowogq pmuamoaumuum Connection: B18 ~ Yellow/red 512 M7 Is there cantinuity7 VES — Replace the ECM with a known good one, and recheck. N0 — Open circuit in Yellow/red wire MIL 2 BLINKS (MAP SENSOR) - Before starting the inspection. check for loose or poor contact on the MAP sensor 3? (Biack) con- nectar and recheck the MIL blinking. 1. MAP Sensor Hose Inspection Turn the ignition switch OFF Check for connection and installation of the MAP sensor vacuum hose. Is the MAP sensor hose connection correct? YES — GO TO STEP 2. N0 — Correct the hose connection or installa» tion VACUUM HOSE 6-16 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel lniection) 2‘ MAP Sensor Output Voltage Inspection Connect the ECM test harness to ECM connec- tors (page 6-11). Turn the ignition switch 0N and engine stop W switah " Q ". Measure the voltage at the test harness termi- g) °°°°HM°° g rials. noonoooooooooeoo [Wm Connection: 312 (H 7518 (7) Is the voltage within 2.7 - 3.1 V? VES 7 GO TO STEP 3‘ No — Faulty MAP sensor 3. MAP Sensor Output Voltage Inspection At Idle Start the engine. Measure the voltage at the test harness tenni- nals. , ,. 'r .7” - ——-.r min—um Connecti n: 312 (Id—615 (—) mm Standard. 2] v maximum WW3 Is the voltage less than 27 V7 ”‘mm'wfl‘mm YES — Replace the ECM with a known good one, and recheck . N0 — Faulty MAP Sensor MIL 7 BLINKS (ECT SENSOR) I Before starting the inspection, check for loose or poor Contact on the ECT sensor 3P (Gray) can» nectar and recheck the MlL blinking 1. ECT Sensor Output Voltage Inspection Turn the ignition switch OFF. Connect ECM the test harness to ECM connec- tors (page 6-11). jg! - V W W Turn the ignition switch 0N and engine stop switch " n " Doeoooooaooooooa Measure the voltage at the ECM test harness ter» °°°°°°°°°°°°°°°° minals. Llumzi 24 :4; Connection: 327 H) -326 l-l Stand-n1: 2.7 — 3.1 V HUGE/68°F) Is the voltage within 2.7— 3.1 V7 VES - ' Intermittent failure . Lease or poor Contact an the ECM connectors No — GO TO STEP 2. Contents Chapter 6 5-17 FUEL SYSTEM (Programmed Fuel Injection) 2, ECT Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 3P [Gray] connector. Turn the ignition switch 0N and engine stop switch " Q Measure the voltage at the wire harness side of ECT sensor connector. Connection: Blue/yellow (+) — ground (—1 Is the voltage within 4. 75 — 5.25v7 v55 — Go TO STEP 3. No - Go To STEP 4. . ECT Sensor Resistance Inspection Turn the ignition switch OFF. Disconnect the ECT sensor 3P (Gray) connector. Measure the resistance at the ECT sensor termie nals. Connection: Blue/yellow (4») — Gray/black (—) (sensor side terminals) Standard: 2.3 A 2.5 k9 (20°C/68°F) Is the resistance within 2.3 — 2.6 kg Imus/58°F}? N0 — Faulty ECT sensor. VES — GO TO STEP 4. , ECT Sensor Open Circuit inspection Turn the ignition switch OFF. Check for continuity at the Pink and Green/ orange wires between the ECT sensor 3P (Gray) connector terminal and the ECM 32F (Light gray) connector terminal. Connection: 327 — Blue/yellow 326 e Gray/black Is there continuity? YES — GO TO STEP 5. N0 — 0 Open Circuit in Blue/yellow - Open circuit in Gray/black wire t EDT Sensor Output Line Short Circuit Inspection Check for continuity between the ECT sensor 3? (Gray) connector terminal of the wire harness side and ground. Connection: Blue/yellow — ground Is there continuity/7 VES — Short circuit in Blue/yellow wire N0 —- Replace the ECM with a known good one, and recheck 3P (GRAV) CONNECTOR 3P (GRAV) CONNECTOR 3P (GRAY) CONNECTOR 6-18 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) MIL 8 BLINKS (TP SENSOR) - Before starting the inspection, check for loose or poor contact on the TF sensor 3P [Black] connec- tor and recheck the MIL blinking. . TP Sensor Output Voltage Turn the ignition switch OFF. Connect the ECM test harness to ECM connec- tors (page 671'”. Turn the ignition switch ON and engine stop switch " O m Measure the TP sensor output voltage at the test harness terminals. Connection: 330 (+i — 326 H Standard: *0.4 — 0.6 V (throttle fully closed) “4.2 , 1E V [throttle fully opened) NOTE: - A voltage marked * refers to the value of the ECM output voltage (STEP 3) when the Volt . age reading shows 5 v. When the ECM output voltage reading shows other than 5 V, derive the TP sensor output voltage at the test harness as follows: In the case of the ECM output voltage is 4.75 V. 0.4 X 4.75/50 = 0.38 V 0.6 X 4.75/50 : 0.57 V Thus, the solution is ”0.38 , 0.57 V” with the throttle fully closed. Repiace 0.4 and 0.6 with 4.2 and 4.8 respec- tively, in the above equations to determine the throttle fully opened range. Is there standard voltage7 YES — ‘ lntermittentfailure - Loose or poor Contact on the ECM connectors NO — GO TO STEP 2. . TP Sensor Input Voltage Inspection Turn the Ignition switch OFF. Disconnect the TP sensor 3P (Black) connector. Turn the Ignition switch ON and engine stop switch “ O “. Measure the voltage at the wire harness side. Connection: Vellow/red H) - Gray/black (—) Is the voltage within 4.75 —5.25 V? YES » GO TO STEP 4. N0 7 GO TO STEP 3. t . I ll rm: oeoonooaoocooonn 2:": oceanoooooeaoooo inn-um 3P iBLACKi CONNECTOR Contents Chapter 6 6-19 FUEL SYSTEM (Programmed Fuel Iniection) 3t ECM Output Vahage Inspection Turn the ignition switch OFF. Connect the ECM test harness to ECM connec- tors (page 6-11). Turn the Ignition switch 0N and engine stop switch " Q Measure the voltage at the test harness termi- nals. Connection: B18 (+1 —826 H Is the voltage within 4. 75 — 525 V? YES — ' Open circuit in Yellow/red wire I Open circuit in Gray/black wire N0 , Replace the ECM with a known good one, and recheck. 4. TP Sensor Output Line Inspection Check for continuity between the TP sensor 3? (Black) connector terminal of the wire harness side and ECM 32F (Light gray] cunnector. Connection: Red/yellow 7 330 Is there cantinuity? YES - GO TO STEP 5‘ N0 - Open circuit in Red/yellow wire 5. TP Sensor Output Line Short Circuit inspection Turn the ignition switch OFF. Check fur continuity between the TP sensor 3P (Black) connector terminal of the wire harness side and ground. Connecliun: Red/yellow (+1 — gruund H Is there continuity? ves — snort circuit in Red/yellow wire NO — Faulty TP sensor accooaoaumoooea nonuwobcooouaooa ounce canuno 3mm 3? (BLACK) CONNECTOR 6-20 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) MIL 9 BLINKS (IAT SENSOR) 0 Before starting the inspection, check for loose or poor contact on the IAT sensor 2P (Gray) conneci tor and recheck the MIL blinking. 1. IAT Sensor Output Voltage Inspection Turn the ignition switch OFF. Connect the ECM test harness to ECM connec- tors (page 6711), , A . . . mm: m7! 7: ; Turn the lgnlllon sWItch ON and engine stop ‘ switch " r} ooooonaoonouooa no Measure the voltage at the test harness lermi- °°°°°°°f°° W ' nals. IT“V , . ,. , Connection: BB (4-) —BZS (—) Standard: 2.7 — 3.1 V (ETC/63“” Is the Voltage within 2.7- 3.1 V? YES » v Intermittentfaiiure - Loose or poor Contact on the ECM connectors N0 — GO TO STEP 2. 2. IAT Sensor Input Valtage Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Gray) connectort Turn the ignition switch ON and engine stop switch " O Measure the voltage at the wire harness side at iAT sensor connector, Connection: Gray/blue — Gray/black Is the voltage within 475 — 5.25V? YES — GO TO STEP 3. N0 — GO TO STEP 4‘ 3. IAT Sensor Resistance Inspection Turn the ignition switch OFF. Disconnect the iAT sensor 2P (Gray) connector Measure the resistance at the IAT sensor termi- nals (at 20 — 30’C/68 ~ 86°F). Standard: 1 — 4 kn (20 — awe/ea — sear) Is the resistance within 1 — 4 km NO — Faulty IAT sensort v55 — GO TO STEP4. ; IAT SENSOR Contents Chapter 6 6'21 FUEL SYSTEM (Programmed Fuel Injection) 4. IAT Sensor Open Circuit Inspection Turn the ignition swrtch OFF. Check tor continuity at the Gray/blue and Gray/ black wires between the IAT sensor 2P (Gray) connector terminal and the ECM 32F (Light gray) connector. Are there continuity? YES — GO TO STEP 5. N0 - - Open circuit in Gray/blue wire ' Open circuit in Gray/black wire 5. IAT Sensor Output Line Short Circuit Inspection Check for continuity between the IAT sensor 2P (Grayl connector termlnal of the wire harness side and ground. Connection: Gray/blue , ground Is there continuity? VES — Short circuit in Gray/blue wire NO — Replace the ECM with a known good one, and recheck. MIL 11 BLINKS (VS SENSOR) - Before starting the inspection. check for loose or poor Contact on the vs sensor connector and recheck the MlL blinking. 1. Vehicle Speed Sensor Pulse Inspection Turn the ignition switch OFF. Connect the ECM test harness to the ECM con- nectors (page 641). Support the motorcycle securely and place the rear wheel off the ground. Shift the transmission into gear. Measure the voltage at the test harness termi- nals with the ignition switch 0N and engine stop switch " O " while slowly turning the rear wheel by hand. Connection: 325 M — A4 t—l Standard: Repeat 0 to 5 V Is there standard voltage? VES — ' Intermittent failure 0 Loose or poor contact on the ECM connectors MD A GO TO STEP 2. ooooooooo coco: ooooocnoocoocooo oooouo mm 2P (GRAY) CONNECTOR mm an on 6-22 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) 2‘ Combination Meter Inspection Check for operation of speedometer. Baas the speedometer operate normally? YES — Open or short circuit in the Brown/white Wire N0 — GO TO STEP 3. 3. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3? (Natural) connecV ton Turn the ignitiun switch 0N and engine stop switch " O ". Measure the voltage at the wire harness side. Cannection: Pink (4-) — Green/black (-) Is there hattery voltage? VES — GO TO STEP 4. No — - Open circuitinthe Pink wire 0 Open circuit in the Green or Green/ 1 hiack wire ' 4. VS Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFFV Check for continuity between the test harness and the ground. . ’ww ’ ’ i . mm mm c°""9°"°“5 525 ’ 9'°“"d aoooeooooanoaouo unouoonuououonau .—::- :fl . . on no 000 Finance Is there wrmnmty? oooceooooeoooo one mu IVA-minim Miami m fit YES — Short circuit in the Pink wire NO — Inspect the VS sensor (page 20-11) Q Contents Chapter 6 5-23 FUEL SYSTEM (Programmed Fuel lniection) . I - 943%? BLINKS (No 1 PR MARY INJEC A32? (BLACK) CONNECTOR I MIL i INJEC- POWER SIGNAL SIGNAL POWER INPUT LINE 1 TOR INPUTLINE LINE ATECM 12 rgéjer Black/white ‘PInk/yellow A11 ”4.1.: m“ w A ‘ - \ooooa-cooaooouoo 13 [1:39, Blank/white rink/blue A12 _ 14 No.3 Black/white Red/white A13 m Lower \ . ‘ 15 No.4 ‘BIack/white Vellow/red A14 ‘ Lower ‘ _»A ;16 No.1 Black/white ‘Pink/velluw ‘AB 3' 32P(LIGHT GRAY) CONNECTOR I Upper i ‘17 No.2 Black/whlte Pink/blue ‘Aio Upper , I 143 No.3 Black/white Pink/green ‘A15 I Upper _ ‘ 149 No.4 Black/white Pink/black ‘A16 ‘ Upper ‘ 1. injector Circuit Resistance Inspection Turn the ignition switch OFF. Connect the ECM test harness to the ECM con» nectors (page 6-11). 7 Measure the resistance at the test harness termi- a a o rials. 0170 a Connection: rowan INPUT LINE — SIGNAL AT Is there continuity7 VES — GO TO STEP 4. NO , GO TO STEP 2. 2. iniector Resistance Inspection Disconnect the No.1 primary injector 2P connec- tor and measure the resistance of the No.1 pri- N01 PRIMARV INJECTOR 2P CONNECTOR mary injector 2F connector terminals. Is the resistance within 10.5 - 14.5 {2 (20’6/ 68?)? was e GO TO STEP 3. No — Faulty injector 5-24 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) a. Injector Input Voltage Inspection :flgfledgf‘m" sw‘m‘ 0“ and “9i" 5‘” No.1 PRIMARV INJECTOR 2P CONNECTOR Measure the voltage between the No. 1 primary injector conneclor of the ere harness side and ground. Connection: POWER INPUT LINE (+) - ground (—) Is there battery voltage? ves — Open circuit in SIGNAL LINE wire N0 — Open circuit in POWER INPUT LINE wire 4. Injector Sign-l Line Short Circuit Inspection Check for continui‘y beIwaan the test harness (terminals and ground. Connection: SIGNAL AT ECM — ground .7 .J y. . Juan- TI—r‘rgfi' rm...“ .. Is there continuity? no 0 nooocooooooaoono o W n —onoaoooanooaoooo YES — - ShoncircuwtintheSlGNALLlNEere - Faultyinjector NO - Replace the ECM with a known good one, and recheck me 471 n n m n a ”effigy tum n MIL 13 BLINKS (No.2 PRIMARY INJECTOR) (page 6724) MIL 14 BLINKS (No.3 PRIMARY INJECTOR) (page 6724) MIL 15 BLINKS (No.4 PRIMARY INJECTOR) (page 6-24) MIL 16 BLINKS (No.1 SECONDARY INJECTOR) (page 6-24) MIL 17 BLINKS (No.2 SECONDARY INJECTOR) (page 6-24) MIL 48 BLINKS (No.3 SECONDARY INJECTOR) (page 6-24) MIL 49 BLINKS (No.4 SECONDARY INJECTOR) (page 6-24) Contents Chapter 6 6'25 FUEL SYSTEM (Programmed Fuel Injection) MIL 18 BLINKS (CMP SENSOR) - Before starting ihe inspemiun, check for loose or poor comact on the CMP sensor connector and recheck the MIL blinking. 1. CMP Sensor Peak Vohage Inspection at ECM Turn the ignition switch OFFV Cnnneci me ECM test harness to the ECM con- neciors (page 6-11). Turn the ignition switch 0N and engine stop switch " O ", Crank the engine with the slaner motor, and measure {he CMP sensor peak voiiage ai ihe \esr harness terminals. Connection: B10 i+) — A31 [-i Is the voltage more rhah 0.7 v (20 ”6/58 ”F)? YES - - Imerminemfailure - Loose or poor Contact on the ECM connectors NO — GO TO STEP 2. 2. CMP Sensor Peak Voltage Inspectiun Turn ihe igniiiun switch OFF. Disconnect the (IMP sensor 2P (Black) connector. Turn the ignition switch ON and engine stop switch " O Crank the engine wiih the starter motor, and measure ihe CMP sensor peak Voltage at the CMP sensor 2P (Black connecior. Connection: Gray (+) — White/black (—i Is the voltage more than 0,7 v (20 90/68 ”F}? YES - Open or short circuit in [he White/black wire or Gray wire NO _ Fauiry CMP sensor mmm 3*: ram“ 6-26 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) MIL 19 BLINKS (CKP SENSOR) . Before starting the inspection, check for mass or poor Contact on the CKP sensor connector and recheck the MIL blinking. 1. CKP Sensor Peak Vohage Inspection at ECM Turn the ignition switch OFF. Connect the ECM test harness to the ECM con- nectors (page 6711i Turn the ignition switch ON and engine stop switch " n Crank the engine With the starter mmorv and measure the CKP sensor peak vortage at the test harness terminate. Connectian: B11 i+) —A31 H Is the voltage mare than 0.7 V {20 “6/68 “F)? YES 7 ' Intermittent fallure - Loose or poor contact on the ECM connectors NO ~ GO TO STEP 2. 2r CKP Sensor Peak Voltage Inspection Turn the ignition switch OFF. * w —’ j Disconnect the CKP sensur 2P (Red) connecmn 2P (RED) CONNECTO,“ Turn the ignition switch ON and engine stop switch ~ 0 '. Crank the engine with the starter motor, and measure the CKP sensor peak voltage at the CKP sensor 2P (Rad) connector. Connection: Vellow (+) - White/black (—) Is the voltage more than 0.7 VIZ!) “(3/58 ”F}? VES ~Open or shun circuit in the Yellow, White/blackwire NO — Fauity CKP sensor Contents Chapter 6 5-27 FUEL SYSTEM (Programmed Fuel lnjectionl MIL 33 BLINKS (EEPROM) 1. Recheck MIL Blinks 1 Reset the seltrdiagnosis memory data (page 6- i0). Turn the ignition switch ON and engine stop switch " Q Check that the MIL blinks. Dues the MIL hlink 33 times? YES ~ Replace the ECM with a known good one, and recheck. ND - GO TO STEP 2. 2. Recheck MIL Blinks 2 Turn the ignition switch OFF. Short the data link connector with the SCS ser- vice Connector I070PZ-ZV30100L Turn the ignition switch ON and engine stop switch " fl ", Check that the MIL blinks. Does the MIL blink 33 times? YES — GO TO STEP 3. N0 — intermittent failure . ' Tax :9 DATA LINK CONNECTOR 3. Recheck MIL Blinks 3 Reset the self-diagnosis memory data (page 6- 10). Turn the ignition switch 0N and engine stop switch " 0 Check that the MIL blinks Does the MIL blink 33 times? YES — Replace the ECM with a known good one, and recheck, N0 — Intermittent failure MIL 34 BLINKS (EGCV POT) . Beiore starting the inspection, check for loose or poor contact on the EGCV servomotor connector and recheck the MIL blinking. 1. EGCV POT Output Voltage Turn the ignition switch OFF. ‘ Connect the ECM test harness to ECM connecr tors (page 6711). Turn the ignition switch ON and engine stop mm in .. w . m switch " O oocuccoacocoocco aoaonooonoou- % Measure the EGCV POT output voltage at the aggngooo'zoooeaono oqovooo o'eooono testharness terminals. ztmimttu 1mm 1!,le Connection: 824 [+) _ 326 H Standard: 2.0 r 2.1 V mm to 2» t Is there standard Voltage? i V 5 YES — - Intermittentfailure 0 Loose or poor contact on the ECM connectors J N0 7 GO TO STEP 2. 6'28 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) 2. EGCV POT Input Voltage Inspection Turn the ignition switch OFFr Disconnect the EGCV servornotor 6P (Naturai) connectorv Tu rn the Ignition swrtch ON and engine stop switch ., Q Measure the voitage at the wire harness side. Connection: Vellow/red (1-) — Brown/black (—) Is the voltage within 4.75 - 5.25 V7 VES — GO TO STEP 4i NO - GO TO STEP 3. 3. ECM Output Voltage Inspection Turn the ignition switch OFF. Connect the EGCV servomotor 6? (Natural) con- nector. Turn the ignition switch ON and engine stop switch " O ". Measure the voltage at the test harness Ierrni» rials. Connection: 318 (+1 —826 H Is the voltage within 4. 75 — 5.25V7 VES — - Open circuit in Yellow/red wire - Open circuit in Green/orange wire N0 — Replace the ECM with a known good one, and recheck. 4. EGCV POT Output Line Inspection Check for continuity between the EGCV servo~ motor 6? (Natural) connector terminal of the wire harness side and ECM 3ZP1Lightgrav) conr nectar. Connection: Light green/black — 524 Is there continuity? ves — GO TO STEP 5. N0 — Open circuit in Light green/black wire 5 EGCV POT Output Line Short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the EGCV servo- motor 6P (Natural) connector terminal of the wire harness side and ground Connection: Light green/black (4») A ground H Is there continuity? YES , Short circuit in Light green/blackwire ND —- Faulty EGCV servomotor 6P [NATURAL] CONNECTOR 6P (NATU RAL) CONNECTOR - v i m ooooc hing—og‘gfigle on oao noon: ooaoaoooooo one ooaooooooooooooo “illumm :rr 4 4.5 r: Lam mum aoonooooonaoo on ooeooooo=oaofi§o mm Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) MIL 35 BLINKS (EGCV SERVOMOTOR LOCK) - Beiore starting the inspection, check for loose or poor Contact on the EGCV servomotor connector and recheck the MIL blinking. 1. EGCV Operating Inspection Disconnect the EGCV control cables from the exhaust valve pulley [page 6-76). Turn the ignition switch ON. Check the EGCV servomotclr pulley rotation when shorting the DLC with the 5C5 service cone nector (page 6-9). Does the EGCV servumnfar pulley operate car- rectly7 vzs - - Check the EGCV cables binding, sticking or lock. - Check the EGCV at muffler side. N0 — GO TO STEP 2, Z. EGCV Servomotor Inspection Turn the ignition switch to OFF Remove the EGCV servomotor (page 6-78). Connect the 12 v battery to the EGCV sen/ome- tor connector terminals and check the servomor tortunction. Connection: Red (+) ~ Blue [>) Does the EGCV servamatar opera (e nominlly? VES ~ GO TO STEP 3. NO , Faulty EGCV servomotor 3. ECM Output Line Inspection Connect the ECM test harness to ECM connec- tors (page 641). Check lor continuity between the EGCV sen/av TL , , . m , W“ 11mm], mtrSPNlurlcnntrtrm‘l lh o o ( a a) 0 er; 0 e mas o t e uoocaooooooccoc neoconeo'Z'anoeoooo wire harness side and ECM 32F (Black) connec— lllmremn nmi tor. Connection: Red (+) — A7 (—i Blue (+) — AB l-i Is there continuity? VES ~ I Open circuit in Red wire - Open circuit in Blue wire N0 — Replace the ECM with a known good une, and recheck. 5'30 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) FUEL LINE INSPECTION FUEL PRESSURE INSPECTION - Before disconnecting fuel hoses, release the fuel pressure by loos- ening the fuel feed hose banjo belt at the fuel tank. - Failure to release the fuel pressure could result in fuel spilling onto painted or plastic pans, which will be damaged, Always replace the sealing washers when the fuel feed hose banlo bolt 15 removed or loosened. Remove the seat (page 34). Disconnect the battery negative cable from the battery terminal Lift and support the fuel tank (page 45). Cover the service check bolt on the secondary injector fuel rail with a rag or shop towel, Slowly loosen the service check bolt and catch the remaining fuel using an approved gasoline container. Remove the service check bolt and sealing washer. Attach the tuel pressure gauge to the luel rail. TOOL: Fuel pressure gauge 07406—0040003 or 074054040003 or o74os—ooaoooA [U.S.A. only) Connect the battery negative cable. Stan the engine. Measure the fuel pressure at idle speed. IDLE SPEED: 1,200 :100 rpm STANDARD: 343 We (35 kgt/em’, 50 psi) If the fuel pressure is higher than specified, replace the fuel pump unit (page 6-34). If the fuel pressure is lower than specified, inspect the following: — Fuel ll'ne leaking — Fuel strainer (page 6-34) Contents Chapter 6 5-31 FUEL SYSTEM (Programmed Fuel Injection) Alwaysreprsce me After inspection, remove the pressure gauge and -. sralna Washer remstall and tighten the service check bolt using a , new sealing washer. MM; mm, TORQUE: 12 N-m (142 kghn, 9 Ibl-ft) 9”” Remove the suitable suppon and close the luel tank (page 45). Install the removed parts In the reverse order of removal. FUEL FLOW INSPECTION Remove the left middle cowl (page 3»7l Remove the relay box from the bracket. Release the retainers (brown) and remove the relay connector base, Remove the fuel cul-ofl relay from the cunnector. Jump the Brown and Elack/whlte wire termlnals ol the wire harness side using a jumper wire. fin , PI ("i—i , FUEL CUT-OFF 1 RELAY r CONNECTOR (EROWNl CONNECTOR (BROWNl JUNIPER WIRE 6-32 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Do nolapoly excesr Remove the fuel pipe joint mounting bolts, then dls- ,_ . i, ‘ srveforrc mme connect the fuel laint hose from the secondary - foe/rail maybe injector fuel rail. “may” - Place an approved gasoline container and drain the gasoline. - Wipe off spilled gasoline. Turn the ignition switch ON for 10 seconds. Measure the amount of fuel flow. l Amount of fuel flow: 185 cm’ (6.4 us oz, 6.7 Imp oz) minimum 110 seconds at 12 V If the fuel flow is less than specified, inspect the fnlr lowing: — Pinched or clogged fuel hose — Fuel pump unil (page 6-33) After inspection, install a new O-rlng into the groove of the fuel joint hose. 59 c5 ‘u/noi’m Install the fuel joint hose to the secondary injector is 04mg fuel rail, tighten the two bolt to the specified torque. While installing mo . fuel/ointhose m TORQUE. 9.5 NM (1.0 kgl‘m, 7 lhf‘ft) the fuel rail Start the engine and check for fuel leaks. FUEL PUMP UNIT INSPECTION Turn the ignition switch ON and confirm that the fuel pump operates for a few seconds. If the fuel pump does not operate, inspect as fol- lows: Lift and support the fuel tank lpage 4-5). . Disconnect the fuel pump unit 3P (Blackl connector, ‘1, Contents Chapter 6 FUEL SYSTEM [Programmed Fuel Injection) Be careful not to damage we Dump wire and fuel level gauge. Turn the ignition switch 0N and measure the Volt age between the terminals, Connection: Brown M — Green i—l There should be battery voltage for a few seconds if there is battery voltage a few seconds, replace the fuel pump unit. If there is no battery Voltage, inspect the following: 7 Main fuse 30A 7 Subfuse10A 7 Engine stop switch (page 20-19l — Fuel CutAoff relay (page 665) 7 Engine stop relay (page 8768l _ Bank angle sensor (page 567) — ECMlDage 6-70) REMOVAL I Before disconnecting fuel hoses, release the fuel pressure by loosening the fuel feed hose banjo bolt at the fuel tank. I Failure to release the fuel pressure could result in fuel spilling onto painted or plastic parts, which will be damaged, I Always replace the sealing washers when the fuel feed hose banlo bolt is removed or loose erred. Remove the fuel tank (page east Remove the fuel pump unit mounting nuts, clamp, fuel hose guide and breather hose guide. Remove the fuel pump unit and packing. INSPECTION Check the fuel pump unit for wear or damage, replace it if necessary Clean the fuel strainer screen with nonrflammable or high flash point solvent. 3? (BLACK) CONNECTOR UNIT BREATHER \ HOSEGUlDE Rt, / \ CLAMP BREATHER HOSE GUIDE FUEL PUMP UNIT PACKING FUEL STRAINEH SCREEN FUEL PUMP UNIT ASSEMBLY 6-34 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION Always replace me Place a new packlng onto the fuel pump unit. FUEL PUMP UNIT pack/Hg With a new one. Be seem not to Install the fuel pump unit into the fuel tank damage the pump me and fuel level gauge Install the hose guides and clamp and tighten the fuel pump unit mountl‘ng nuts in the Speclfied sequence as shown‘ TORQUE: 12 Min (12 kgl-m, 9 lbl-f‘tl Install lhe fuel tank (page 6738). FUEL CUT-OFF RELAY INSPECTION Remove the fuel Cutruff rela frum the rela box 7’ i [page 6-32]. V V l FUEL CUT-OFF RELAY BATI'ERY Connect the ohmmexer to the fuel cut-off relay con- nector terminals. Connection: A — B l l Connect the 12 V battery to the following fuel cutvoff relay connector terminals Connection: C (+) — D H There should he continuity only when the 12 v bath tery l5 connected, If there is no continuity when the 12 v battery is connected, replace the luel tutrofl relay. l Contents Chapter 6 5-35 FUEL SYSTEM (Programmed Fuel Injection) FUEL TANK REMOVAL Remove the top shelter (page 3-16L Remove the fuel tank from mounting bolts‘ Lifl the fuel tank as shown. Disconnect the fuel tank drain hose from the hose ’7 ' ' jolm as shown yTANK Support the fuel tank using a suilable support. SUITABLE SUPPORT l 5-35 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the luel pump unit 3P (Black) connector, Disconnect the fuel tank drain hose and breather hose. , BHEATHEfi-lOSE DRAIN HOSE \It I Cover the fuel hose banjo bolt with a rag or shop towel. Slowly loosen the banjo bolt and catch the remain ing fuel using 3 approved gasoline container. Remove the fuel hose banjo bolt and sealing wash- ers, then disconnect the fuel hose. - Before disconnecting fuel hoses, release the fuel pressure by loosening the fuel feed hose banjo bolt at the fuel tank. Failure to release the fuel pressure could result in fuel spilling onm painted or plastic parts, which will be damaged. 0 Always replace the sealing washers when the fuel feed hose banio bolt is removed or loos- erred. Remove the suitable suppon and Close the fuel tank. Remove the fuel tank pivot bolts, Collars and fuel tank. Refer to procedures for fuel pump unit removal (page 6—34). Contents Chapter 6 6'37 FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION FUELTANK BREATHER HOSE ' . ’/i 26 N-m12,7 kglvm, 20 lbf-ft DRAIN HOSE 22 NW! (22 kgf~m, ‘IG Ibf ft 9.8 N-m (1,0 kgf-rn, 7 Ibf-fi Install the fuel tank, collars and pivot bolts into the frame and (lghten the bolts securely , FUEL TANK : Open and support the fuel tank (page 4-5), A'ygn me me: nose InstaII the new sealing washers and tighten the fuel et'et’aI/Otnl win me hose banjo bolt to the specified torquet @ SEAUNG WASHERS swoper or» [he hat pump mounl‘ng my TORQUE: 72 N-m (ZtZ kgf-m, 16 Ibf-ft) 6-38 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Route me noses Connect the fuel tank drain hose and breather hose. ‘ BREATHER HOSE Waller/V lrlage 1' 24/. DRAIN HOSE Connecr the fuel pump unit 3? (Black) connecmr. Remove the sultable support and Close the fuel tank # i J on the frame NOTE' ‘ - Route me hoses, wires and harness properly ‘ lpage1-24l. Be careful nol to damage the harness and hosesl ‘ Do not rwisr the breaxher hose or proper fuel Supply would be ubslrucled. Check the red line on Khe breaxher hose, After installing the fuel (ank, make sure the drain, breather and fuel hoses are run kinked or bound. Contents Chapter 6 5-39 FUEL SYSTEM (Programmed Fuel Injection) Install and tighten the fuel tank front mounting bolls w me specified \orque. TORQUE: 25 N~m (2‘7 kgf-m, 20 Ibf-ft) Tlgmen the fuel tank rear mounting Dolls in me specified torque. TORQUE: 9,8 N-m (1.0 kgf—m, 7 lbf—h) Install the mp shelter lpage 3716), AIR CLEANER HOUSING REMOVAL Remove (he a‘lr cleaner elements lpage 4-Bl. Remove the screws and sub harness clamps. Remove lha flve bolts and secondary injector mourning breekel from me air cleaner houslng. Remove \he elgnl screws and upper alr cleaner houslng. UPPER AIR CLEANER HOUSING Remove me alrl‘unnel.’alr cleaner housing mounting screws, then remove the air funnels, 6‘40 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Remove the a1r cleaner housmg mounting screws. " Disconnect (he PAIR air suction hose from the air cleaner housinge Disconnect the crankcase breather hose from the air c‘eaney housing. Remove the air cleaner housing. Remove the oil separation chamber from the lower air cleaner huusing‘ OIL SEPARATION CHAMBER Contents Chapter 6 6'41 FUEL SYSTEM (Programmed Fuel Injection] INSTALLATION lnslall the oil separation chamber to the lower air cieaner housing OIL SEPARATION CHAMBER Connect xhe crankcase breather hose lo the air cleanerhousmg Connect the PAIR alr suction hose to the air cleaner housing. install the air cleaner housing onto the throttie body and airmtake duct. Install the lower air cleaner housing onto the air intake duel, tighten the mounring screws TORQUE: 1.2 Net“ (0.12 kgfim, 0.9 Ibf-fl) 6-42 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) InsTaH me an iunneIs in their proper locanons. InstaIl and tighten the air funnel/air cIeaner housing mounting screws. TORQUE: 4.4 M!“ (0.45 kgf-m, 3.2 lbl-fl) InstaIl the upper a‘r cleaner housmg and eight " SCREWS SCYSWS. Tighten lhe screws. TORQUE: 1.2 MM (0.12 kgf-m, 0.9lh1-fl) \-~ :_ // \ UPPER AIR CLEANER HOUSING \ InslaIl the secondary injector mounting bracket onto .1 the aircIeaner housing. “ Tighten the belts to the Specuned torque. TORQUE: 5.4 N-m (0.55 kgf~m, 4 IbMt) InslaIl The air cleaner element {page 478]. SECONDARY INJECTOR INSPECTION Start the engrne and let i: idle. Confirm the injecror operating sounds with a sound- . ing rod or stethoscope. NOT 5 The secondary injectors operate with foIlowIng cons dilions , Engine speed is over 5,500 rpm — Throttle opening Is over 20mm) ‘ SOUNDINGHOD / ,_ INJECTOR Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) REMOVAL Before disconnecting fuel hoses, release the fuel CLAMP SCREWS pressure by loosening the fuel feed hose banjo , bolt at the fuel tank. - Failure to release the fuel pressure could result in fuel spilling onto painted or plastic parts, which wlll be damaged. - Always replace the sealing washers when the fuel feed hose banlo bolt is removed or loos» ened. Remove the wire band. Remove the harness clamp screws Disconnect the secondary injector connectors, Lin and supponthe fuel tank (page 475). l ' INJECTOR CONNECTORS Donolapp/y Excesr Remove the tuel hose joint mounting bolts, then s'vefarce o/r'le disconnect the fuel joint hose from the secondary fuel ’dll may oe injector fuel rail damages Remove the three fuel rail mounting bolts. Remove the fuel rail/secondary injector assembly from the mounllng bracket. "\\ FUEL RAIL/SECONDIQRY-l NJECTOR ASSEMBLY 6'44 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Remove the mlectors from the fuel raxl. , , Z t o-RWG ‘r Remove the dust sealsr N CUSHION RING Remove the O—rlng and cushion ring. DUST SEAL O-HING a t! / CUSHION RING INSTALLATION Apply oiltoa new Owing‘ DUST SEAL Replace messas‘ Install the new cushion ring, and o-ring. being care- ’sng, cus’mn nng ful not to damage the O-rTng. ana 0-an w‘m " 3? O-RING l 7 , / a? CUSHION RING Install me fuel injectors into the iue‘ rail, being careV ful not to damage the Orring and cushion ring, Check the dust seal for wear or damage, reptace it if necessary. CUSHION RING Contents Chapter 6 5-45 FUEL SYSTEM (Programmed Fuel Injection) install the fuel rail/secondary injector assembly onto the mounting bracket, being careful not to damage the seal ring, Tighten the fuel rail mounting bolts to the specified torque. TORQUE: 9.8 N-m (1.0 kgf—m, 7Ibf-f1) Aner inspection, install a new O»ring into the groove oi the luellomt hose. 5n caretulnol to install the fuel joint hose to the secondary injector 1137mm: WE (firing fuel rail, tighten the two bolt to the speCliied torque. ”we “S‘s/””9 ms TORQUE: 9.8 Nrm (1.0 kgrm, 7 mm) ruel ,lol'li l- era ”6 mews/l Start the engine and check for leaks. Connect the secondary injector connectors. Install and tighten the harness clamp screws. Secure the wire harness to the fuel rail using a Wire band. Install the removed parts in the reverse order of removal. 6-45 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) THROTTLE BODY REMOVAL Before disconnecting fuel hoses, release the fuel pressure by loosening the service check ball at the secondary injector fuel rail. . Failure to release the fuel pressure could result in fuel spilling onto painted or plastic parts, which will be damaged. - Always replace the sealing washers when the service check bolt is removed or loosened. Drain the coolant from the cooling system (page 7-6). Remove the rollowing: 7 Under oowls/mioole cowls (page 3-7) _ Fuel tank (page 6436) — Air cleaner housing (page 5-40) Unfasren the wire bands and release the wire har- ness from the fuel rail. Remove the sealing nut, sealing washers and fuel joint hose from the primary injector fuel rail Disconnect the MAP sensor 3F (Black) connector. Disconnect the primary fuel injector connectors from the injectors. Disconnect the EVAF vacuum hose from the Val? uum junction iAC type only). VACUUM CHAMBER HOSE Disconnect the vacuum chamber hose from the throttle body. Disconnect the TP sensor 3P (Black) connector. Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Remove the fuel feed hose sealing nut whi!e hold» ing the fue‘ raiL SEALING .3 §EAL|NG NUT Loosen the hose clamp screws and disconnect the water hoses from the idle air Central (\AC) thermal valve. Loosen the \ock nuts and disconnect the throme cable ends from (he throttle drum. Remove the throttle step screw knob from the clamp on the bypass hose. THROTI’LEWSTQP s‘cgw KNOB 5-43 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Loosen the engine side insulator band screws using a lung phillips screwdriver. Do no: hold the fuel Remove the throttle body from the cylindervheadl fail on me :nrome body to iamave (he [H/Ulile body or u may be damaged 0 Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed. If debris is allowed to enter the ports the engine may be damaged. I Do not snap the throttle valve from fully open to fully closed after the throttle cable has been removed. It may cause incorrect idle operation I Do not damage the throttle body. It may cause incorrect throttle and idle valve synchronization. . The throttle body is factory pre-set. Do not disas— semble in a way Dther than shown in this man— ual‘ ' Do not loosen or tighten the painted white balls and screws of the thruttle bodyt Loasem'ng m tightening them can cause thrattle and idle valve synchronization failure TOP VIEW: PAINTED WHITE E HRO'I'l'LE 300W , ‘ t .g ; . Contents Chapter 6 6-49 FUEL SYSTEM (Programmed Fuel Injection) REAR VIEW: 0.9 N-m (0.09 kgf-m, 0‘7 Ibf-I‘t) 0.9 N-rn (0‘09 kgfm, 0.7 [bf-ft) H «.5 aw b}? 3 N-m (0.35 kgf-m, 2.5 [bf-ft) PAINTED WHITE PAINTED WHITE 0.9 N-m (0.09 kgf-m, 0.7 Ibf-fi) 6'50 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) THROTI’LE BODY VACUUM HOSE ROUTING EXCEPT CALIFORNIA TYPE: D " /\ I ,/~\ A\ fl \ / \ fl / 3 LL" can Ho 0 L0 0 7L He can \V/ ’ \v/ “\\, W \xi 0 \ v x a ° \ J CE w W A r U 3; CALIFORNIA TYPE: Contents Chapter 6 6-51 FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION Adjustthe insulator band angle as shown. Applv oil to the insulator inside surfaces for ease of throttle body installation. DU narhal’dlhe lus/ Install the throttle body into the insulators. fall on me m/ozrle may to Install me mull/e may, j’ififiLONG SCREWDRIVER /‘ Tighten the throttle body side insulatar band screw E so that the insulator band distance is 7 11 mm (0.3 i 7 :1 mm103 i 004 W 0.04 inl. Route the throttle stop screw knob properly, install it onto (he clamp. . THROTTLE STOP SEEW KNOB 6-52 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Route the throws Connect the throttle cable ends to the throttle drum, , ! cables propel/y lpage 7-24) Connect the water hoses to the IAC thermal valve and tighten the hose clamp screws. Install the fuel feed hose to the fuel ralI with new sealing washers, Install and tlghten the sealing nut to the specified torque while holdlng thetuel rail. TORQUE: 22 N~m (2.2 kgftm, 16 IM-ft) Connect the TF‘ sensor 3P (Blackl Connector. Contents Chapter 6 6-53 FUEL SYSTEM (Programmed Fuel Injection) Connect the primary fuel injector connectors to the injectors. VACUUM CHAMBER HOSE Connect the EVAP vacuum hose to the vacuum junction (AC type only), Connect the vacuum chamber hose to the throttle body. Connect the MAP sensor connector. Install the fueI joint hose to the primary injector fuel rail with new seallng washers. InstalI the sealing nut. ‘ a JOINT HOSE Tighten the seaIing nut to the specified torque while holding the fuel rail securer. TORQUE: 22 N-m (2.2 kgf-m, 161th) Secure the w'lre harneSS to the fuel raiI using Wire bands. lnstaII the removed parts in the reverse order of removal. Arter installation, adjust the throttle grip tree pIay Ipage 477). PRIMARY INJECTOR INSPECTION Start the engine and let it ldIe. Confirm the injector operating sounds wlth a sound ing rod or stethoscope, gCiJNDING ROE) 6'54 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) REMOVAL Remove the throme body (page 6-47Il FUEL HAIL BOLTS Hemuve the bolts and fuel rail/primary injector assembly. Remove the Injectors Irom the fuel rail. FUEL RAIL INJECTOR Remove the seal ring, O-rlng and cushion ring. e O-RING INSTALLATION 9 Apply oil to the new O-ring. Replace me SFal Install the new seal ring, cushion ring and O»ring, o Img, human [my being careful nm to damage the O»ring. and 04mg W707 G? new mes asaser SEAL RING § 93 CUSHION RING Install the fuel injectors into the Iuel rail, being care- )7 ful not to damage the Orring and cushion rings FUEL RA’L INJECTOR Contents Chapter 6 5-55 FUEL SYSTEM (Programmed Fuel Iniection) lnstall the Fuel rail/primary injector assembly onto the throttle body, bemg careful not to damage the FUEL 'NJECTORS seal r'lngs T'hl thfl'l t' blt " tolgqueer‘ e ue ral moun mg 0 smthe speclfled FUEL RAIL BOLTS TORQUE: 9.8 N-m [1t0 kgf-m, 7 let) Install the throttle body (page 552). IDLE AIR CONTROL (IAC) THERMAL VALVE REMOVAL/INSTALLATION Do not loose-n 0! Remove the throttle body (page 5-47l. O l'h J7 V ’9’” V9 9.” Remove thethermal valve mauntlng screws ma! valve Shaft lack nurana aC/[l/Sflng m. Release the thermal valve shaft joint piece frcm the thermal Valve I'lnk arm, then remove the thermal valve assembly. LINK ARM THERMAL VALVE 5-55 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel lniection) Install the thermal valve shaft joint piece to the ther» . mal vatve link arm. , OINT PIECE Tighten the therma‘ vatve mounting screws to the specified torque. TORQUE: 4.9 N-m (0.5 kgf-m, 3.6 Ibf-ft) .VV (3/7 ;" THERMAL VALVE IDLE AIR CONTROL (IAC) VALVE DISASSEMBLY Remove the thronte body (page 6-47) Remove the fuel rail and primary injectors (page $55), Turn each IAC valve adjusting screw in, recording , the number of turns until it seats lightly. ' No.1l2 IAC valve: Remove the IAC valve arm screws and IAC Valve arm. Remove the screw and IAC valve arm, Contents Chapter 6 FUEL SVSTEM (Programmed Fuel Injection) ”0.3/4 IAC valve: Remove the IAC valve avm screws and IAC valve arm. SCREWS Remove the IAC va‘ve shaft and three collars VALVE SHAFI' COLLARS Markms/AC va/vss Loosen the lock nut and remove the IAC valves, dunnq msassemblv 50 they can be praceu back m they! any! wa/ locarrons LOCK NUT Check the IN: valve for scratches, scoring or other damage, replace it If necessary. IAC VALVE 6-53 Contents chapter 5 FUEL SYSTEM (Programmed Fuel lniection) 00 not apply cums mean the IAC valve bypasses using compressed aTr. manna/[y away/able carburetor Elsaners m that/157112 cf me moms bore, wmm 75 6031941 With molybdenum, ASSEMBLY FUEL RA“- MAP SENSOR 9.8 N-m (1A0 kgf—m, 7 IbV-fl) INJECTOR 1.8 N-m (0.18 kgf‘rn, 1.3 [bf-fl) IAC VALVE IAC THERMAL VALVE 5 N~m (0.5 kgf-m, 3.6 Ibf-ft) 0.9 MW (0-09 kgi-m, 0.7 WM 0.9 N-rn (0,09 kgf-m, 0.7lb1-ft) Contents Chapter 6 5-59 FUEL SYSTEM (Programmed Fuel Injection) Install the IAC valves into the valve holes. r—Gfl' IAC VALVE 22$! Tighten the IAC valve lock nut to the specified torque. TORQUE: 1.8 N~m (0.18 kgf-m,1.3lbf‘fl) Instatl the three collars and IAC valve shaft. COLLARS No.1/Z lAC valve: Install the No.1/2 IAC valve arm to (he IAC valves. Install and tighten the \AC Valve arm mounting screws to the specified torque. TORQUE: 0.9 N-m [0.09 kgf~m, 0.7 lbt-ft) Install the thermal valve link arm and tighten the screw to the specified torque. TORQUE: 0.9 N-m [0.99 kgl‘m, 0.7 Ibf-f!) LINK ARM 5-50 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) ”0.3/4 IAC valve: Install the No.3/4 IAC Valve arm Onto the lAC valves. Install and tighten the IAC valve arm mounting screws to the specified torque, TORQUE: 0.9 Mm (009 kgf-rn, 0‘7 lbl-ft) Install the IAC thermal valve (page 6756). Turn the IAC valve screw until it seats lightly, then back it out as noted during removal Install the throttle body (page 6-52). IAC VALVE SYNCHRONIZATION I Synchronize the IAC valves with the engine at normal operating temperature and with the transmission in neutral. I Use a tachometer with graduations at 50 rpm or smaller that will accurately indlcate 50 rpm change. Lift and support the fuel tank (page 4-5), Dlsconnect the each vacuum hase from the 5-way joint. Contents Chapter 6 6'61 FUEL SYSTEM (Programmed FueI Injection) Connec‘ the vacuum hoses to the vacuum gauge. VACUUM GAUGE TOOL: Vacuum gauge set 07LMJ—OD10‘IOB or D7LMJ—001000A (USA. only) Connect a tachometer. Disconnect the PAIR air suction hoses from the reed valve covers, then plug the covers. Stan the engine and adjust the idle Speed wi‘h lhe throttle stop screw. IDLE SPEED: 1,200 i 100 rpm 7719No.1/ACva/ve Ma‘ch each intake vacuum pressure with the MM cannot 02 adjusled, IAC valve. 1! rs We base lAC valve IAC VALVE VACUUM DIFFERENCEZO mmHg 6-62 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Remove the p‘ugs and connect (he PAIR alr sucuon hoses to the reed valve covers. AIR SUCTION HOSE PLUG ‘ Adjust ma idle speed if the Idle speed differs 1mm the specified speed IDLE SPEED: 1,200 : 100 rpm Remove me vacuum gauge from the vacuum hoses, Connect the each vacuum hoses to the firwayjoint. Resaéme ECM failure code (page 6710). Contents Chapter 6 6-53 FUEL SYSTEM (Programmed Fuel Injection) MAP SENSOR OUTPUT VOLTAGE INSPECTION Connect the test harness to the ECM (page 6-1”. Measure the voltage at the test harness lerminals (page 6-12). Connection: B15 (+l - B17 (-l STANDARD: 2.7 — 3.1 V The MAP sensor output vottage (above) is mea sured under the standard atmosphere H atm : 1,013 hPa) The MAP sensor output vorcaga is affected by the distance above sea levet, because the output voltr age is changed by atmosphere. Check the Sea \eve‘ measurement and be sure that the measured voltage falls Within the specified value. REMOVAL/INSTALLATION Lift and support the fuet tank (page 4.5). Drsconnect the MAP sensor 3P (Black) connector. Disconnect the vacuum hose from the MAP sensor Remove the screw and MAP sensor from the prtr mary tnjectorfuel ray]. InstaHation is in the reverse order of removal. (vr t if. \ \m 2.7 \\26\ 2.5 \ I m 1.5 // 2.n 2" 1.5 1.0 0.5 a son Lam) 1,5nu 2,nno:m nasal mam 15,3an {5,50flltlul) 6-64 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) IAT SENSOR REMOVAL/INSTALLATION Lift and support the fuei tank (page 45), 2F (GRAY) CONNECTOR Disconnect the IAT sensor 2P (Gray) connector Remove the screws and lAT sensor from the air cleaner housing. Installation is in the reverse order of removal TORQUE: 1.2 N-I'I'I (0.12 kgf-m, 0.5 lbf-ft) ECT SENSOR Rep/ace the ECT REMOVAL/INSTALLATION 59"” Wm’e ”19 Drain the coolant from the system (page 776), engine if cold. Lift and support the fuel tank (page 45; Disconnect the 3P (Gray) connemor from the ECT SENSOR Remove the ECT sensor and sealing washer. Aiwaysreplacea Install a new sealing washer and ECT sensor. sealing washer with Tighten the ECT sensor to the specified torque. 5 ”W W TORQUE: 23 N-m (2.3 kgf-m, 17 ibt-tt) Connect the ECT sensor 3? (Gray) connector. Fill the cooling system with recommended coolant (page 76). _ 3 v, SEALING WASHER s: Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) CMP SENSOR REMOVAL/INSTALLATION Remove me under Cow‘s/middle cowls (page 377). Lift and supponmemer tank (page 4-5), Disconnect the CMP sensor 2F1B‘ack)connecx0r. Remove the bolt and CMP sensor from the cv‘indsr head. App‘v oil to a new O-ring and rnstall i! arm: the cam- shaft posnion sensor groove. InstaH the CMP sensor into the cylinder head. Tighten the mounting be“ securely. Connect the CMP sensor 2P1Elack) Connector. InstaH rhe removed parts in the reverse order of removal. 2P1BLACK) CONNECTOR 6-66 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) BANK ANGLE SENSOR INSPECTION Remove the headlight unit (page 20-5). Disconnect the bank angle sensor 3F (Greeni cone nectar and connect the special tool between the connectors. TOOL: Inspection adaptor 07GMJ-MLBO100 BANK ANG LE SENSOR l Reinstall the headlight unit and bank angle sensor onto the upper cowl (page 3712). Connect the front sub-harness multisconnectcr Turn the ignition switch ON and englne stop switch INSPECTION ADAPTOR Measure the voltage between the following term'l» nals Ol the test harness. Jmifiiflj 1,1 yWhite/blackhi—Greeni-l , iBattery voltage l l Red/white (+l— o- 1 v as no: dlsconnect Turn the ignition switch OFF. the bank angel sen- BANK ANGLE SENSOR sorconnmwdw Removethe upper cowl (page 342). mg mspectlon Remove tne flange nuts and bank angle sensors Reinstall the upper cowl and connect the from sub- harness multirconnector, Place the bank angle sensor horizontal as shown, and turn the ignition switch ON. The bank angle sensor is normal it the engine step relay clicks and power supply is closed. incline the bank angel sensor approximately 60 [min 'ht’h ‘ dotalgrees o e e orrlg Wlt the lgnltlon swnch NORMAL The bank angle sensor is normal if the engine stpp POS'T'ON relay cllcks and power supply is open. If you repeat this test, first turn the ignition switch OFF, then turn the ignition switch ON. © 60' (approximately) Contents Chapter 6 5-57 FUEL SYSTEM (Programmed Fuel Injection) REMOVAL/INSTALLATION Remove the bank angle sensor mounting um and , sensor from the headlight unit . BANK ANGLE SENSOR Remove me headllgm unit (page 2075). Disconnect the bank angle Sensor 3P (Green) cone nectar. lnslallrhe bank InstallaIion is In Ihe reverse order of removal. allglesensorwrrh I . .. “WP/flaw” 232:: me mounong screws to [he specvfled mg up TORQUE: 175 N-m [0.15 kgf-m, 1.1 IbI-ft) ENGINE STOP RELAY INSPECTION Remove the left mlddle cowl (page 377l Remove relay box from the brackeI. 6-68 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) T Fieiease ihe retainers (Blue) and remove the reiay connector base. Remove the engine stop relay from ‘he connecior. CONNECTOR (BLUE) C ecith h L tolhe en ine sto rela con- ngagr (ErnfiSaigjme E! g P y ENGINE STOP RELAY BATTERV Connection: A — B Conneci a 12 V battery in the toilowing engine slop reiay connector terminals. Connection: C (1») — D (—) There should be continuity only when 01512 V balr lery is connected. If ihere is no continuity when (he ‘12 V battery is cannecied, replace the engine smp reiay. ENGINE CONTROL MODULE (ECM) REMOVAL/INSTALLATION Remove the under cowls/middle cowls (page 3-7}. Disconneclthe ECM 32F (Biack) and 321> (Light grav) Connectors. Remove the hoider band and ECM. Inslaiiaiion is In the reverse order of removai. 32iI {LIGHT GRAY! CONNECTOR Contents Chapter 6 6-59 FUEL SYSTEM (Programmed Fuel Injection) ECM POWER/GROUND LINE INSPECTION ENGINE DOES NOT START (MIL DOES NOT BLINK) 1. ECM Power Input Voltage Inspection Disconnect the ECM 32F IBIack) and 32F (Light gray) connectors. Turn the Ignmon swnch ON and engine slop swilch " n Measure the voilage at the ECM 32F (Light gray) connectorterminai and ground Connection: 515 m 7 ground H 516 1+) 7 ground (7) Is there battery voltage? was 7 <30 TO STEP 2. No 7 GO TO STEP 3. 2. ECM Ground Line Inspection Turn the ignmon swiich OFF. i Check for continuity between the ECM 32F (Black) connecior terminais and ground, Connection: A4 (+) , ground H A18 (+) 7 ground (7) A19 (+1 7 ground (7) Are there continuities? YES - Replace the ECM with a know good one, and recheck. N0 7 ' Open circuit in the Green/pink IA‘IBI we I Open circuit in the Green /pInk (AA) wire 3 Engine Stop Relay Inspection 1 Turn the ignllion swiich OFF Remove the engine stnp relay from the reIay connector base. Turn the ignilion swiich ON and engine stop switch “ n Measure the Voltage at the engine stop reiay connectorterminals. Connemian: Black (+) — Red/blue (—) Is there battery voltage? VES — GO TO STEP 4, No — Inspect the bank angle sensor (page 57 67) usuacnuumuumoan I uumumuummnu noonnuonnomona' CONNECTOR (BLUE) mum—“minimum ; usuauncnuuuuanun i unauuacwusuauua 6-70 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) 4. Engine Stop Relay Inspection 2 Turn the ignition switch OFF. Jump rhe englne stop relay connector terminals CONNECTOR (BLUE) Connection: Red/white ~ Black/white Turn the Ignlilon switch ON. Measure (he vul‘age at the ECM connector tern mlnal and ground. Connection: 815 h) — ground (—) 315 (+) , ground l—l Is there battery voltage7 YES — Inspecl the engine stop relay [page 6- ssl No — Open circuit in power inpm line [Black/ JUMPER W'RE white ur Red/white) between the battery and the ECM PAIR CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the air cleaner houslng (page 6-40), WCONTROL 2? (BLACK) CONNECTOR Disconnect the PAIR control solenoid valve 2F SOLENOID VALVE . ' \ . ' - (Black) connecror. ; Disconnecl the PAIR air suction hoses and remove . the PAIR control solenoid valve. lnstallalion ls in the reverse order oi removal INSPECTION Remove (he FAIR control solenoid valve. Check that air flows (A) to (El when the 12 v battery IS connected to the PAIR control solenoid valve rer— (E) l mlnals. Arr should not flow (Al to (Bl when there lS no voltage applied to the PAIR valve terminals. Contents Chapter 6 5-71 FUEL SYSTEM (Programmed Fuel Injection) EVAP PURGE CONTROL SOLENOID VALVE (CALIFORNIA TYPE ONLY) Check the resistance between the terminals of the PAIR control solenoid valve. STANDARD: 20 — 24 [2 (2|) c(3/65 °F) If the resistance is out of specification, replace the PAlR control solenoid valve. REMOVAL/INSTALLATION Disconnect the EVAP canister-towel tank hose from the canister. Disconnect the EVAP canister-to-purge control sole- noid valve hose. Remove the mounting bolts and EVAP canlster from the bracket, Disconnect the purge control solenoid valve~to- throttle body hose from the solenoid valve. Remove the bolts and canister brackeflsolencid Valve as an assembly from the frame Remove the bolts and EVAP purge control solenoid valve from the bracket. installation is in the reverse order of removal. PAIR SOLENOID VALVE CANISTERATO-FUEL TANK HOSE EVAP CANISTEH BOLTS CONTROL 2P CONNECTOR EVAP PU RGE SOLENOlD VALVE HOSE m iluranle body EVAP CANlSTEFl EVAP PURGE CONTROL SOLENOID VALVE CANISTER BRACKET 6-72 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) INSPECTION Remove the EVA? purge control solenoid valve. Check that air should not llow (Al to (El, only when the 12 V battery is connected to the EVAP purge control solenold valve (ermlnal. (BI Check the resistance between the terminals of the 7* EVAP PURSE CONTROL EVAF' purge control solenmd valve. SOLENOID VALVE STANDARD: 30 — 34 H [20 ”6/63 “Fl If the resistance is out of specification, replace the EVAP purge control solenoid valve. ' INTAKE AIR DUCT INTAKE AIR DUCT CONTROL SOLENOID VALVE Removal/Installation Remove the left middle cowl (page 37). Disconnect the vacuum hoses and connector from the bypass control solenoid valve. Remove the bolt and bypass control solenoid valve. BYPASS CONTROL ‘_ VACUUM HO ES h SPLENOIDVALVE Contents Chapter 6 6-73 FUEL SYSTEM (Programmed Fuel Injection) Hallie (he vacuum hose-5 correctly Inspection Remove the bypass control solenoid valve. , SOLENOID Check that the air should flow (A) to (a). only when VALVE the 12 V battery is connected to the bypass control solenoid valve terminal. Check the resistance between the terminals of the i’ bypass control solenoid valve, STANDARD: 28 s 32 £2 (20 “C/68 :F) It the resistance is out of specification, replace the bypass control solenoid valve, VACUUM CHAMBER/ONE-WAY VALVE Removal/installation Remove the left middle cowl ipege 377). Disconnect the vacuum hoses and the vacuum ' chamber. Installation is in the reverse order of removal. inspection Check the Vacuum chamber for damage and fi—i scratches,replaceifnecessarys ‘ VACUUMCHAMBER ONE-WAYVALVE ‘ Check the one-way valve operation in the vacuum chamber as lollows: — Air should flow (A) to (B) — Air should not flow (5) to (A) if the operation is incorrect, replace the vacuum chamber/one-way valve assembly. 6-74 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) INTAKE AIR DUCT DIAPHRAGM/FLAP Remove the intake air duct from the air cleaner , housing (page 478i, AIR DUCT COVER Remove the screws and air duct cover. SCREWS Unhookthe diaphragm rod from the flap valve, then remove the flap valve. DIAPHRAGM ROD ‘ FLAP VALVE Remove me diaphragm Irom me intake air duct. ‘ Install lhe diaphragm into the intake air duct. Hook the diaphragm rod with the flap valve hole as shown. any? Place rhe fla valve onto me intake air duct. p FLAP VALVE Insrall the air duct cover and Lighten the screws to me specxlied torque. AIR DUCT COVER TORQUE: 1.2 Nrm (0,12 kyf-m, 0‘9 Ibf-ft) ‘ . ‘ /"// ' / Install the intake air duct to the air cleaner housing (page 4-8). SCREWS Contents Chapter 6 6-75 FUEL SYSTEM (Programmed Fuel Injection) EGCV (Exhaust Gas Control Valve) EGCV control cable adjustment (page 4-35), DISASSEMBLY Disconnect the control cables from the pulley. Bend up the tabs of the lock washer. Hold me pulley and loosen the pulley nut. Remove the lock washer, pulley, stopper arm, spring collar and return spring. Remove the bolts and pulley housing. Bend up the tabs of the lock washer. Remove the butterfly valve retell-ling screws, lock washer and butterfly valve BUTTERFLY VALVE SCREWS LOCK WASHER 6-76 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Remove the bearing cap, Push the exhaust valve shafi and remove the outer B ”G CAP bearing b VALVE SHAFT 1 Remove the inner bearing. OUTER BEARlNG w INNER BEARING ASSEMBLY Press the new inner bearing into the exhaust shaft j® BEARING CAP pivot, lnsteli the exhaust valve shaft, then press the new VALVE SHAFI’ outer bearing into the exhaust valve shah pivot. Install the new bearing cap securely. §@ OUTER BEARING // l \ \ use i ,3\/ {\r/fla: _ v INNER BEARING Note the drrecrran install the butterfly valve into the muffler pipe. alme bufisrfly valve Place the new lock washer mm the butterfly valve and then install and tighten the retaining screws to the specified torque. TORQUE: 1.5 N-m (0.15 kgf-m,1.1lbl-ft) Bend up the tabs of the lock washer and secure the screw head. BUTTERFLY VALVE SCREWS 9; LOCK WASHER l Install the pulley housing onto the muffler pipe, lighten install and lighten the housing bolts to the specified torque. TORQUE: 3.8 N-m (1.0 kgfrm, 7 lbi-ftl PULLEV HOUSING BOLTS Contents Chapter 6 5-77 FUEL SYSTEM (Programmed Fuel Injection) install the return spring onto the housing while aligning its end with the housing boss. install the spring collar. Install the stopper arm onto the valve shah. Install the pulley and then install the new look . washer while aligning its tabs with the pulley as Shown. Install and tighten the pulley nut to the specified torque. TORQUE: 4.5 N-m (0.5 kgf—m, 3.6 Ibf-ft) Bend up the tabs of the lock washer and secure the nut. Connect the control cables to the pulley. Adjust the control cable (page 435), EGCV SERVOMOTOR REMOVAL Lift and support the fuel tank (page 45). Disconnect the servomotor 6P (Natural) connector. Remove the bolt and middle cowl Stay/cable protec- tor. \‘RETURN SPRiNGQ SPRING COLLAR LOCK WASHER PU LLEY STOPPER ARM CONTROL CAB LES 6'78 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Remove the servomotor mounting bolt and pull out the servomokor from the bracket. Disconnect the EGCV control cab‘es frum the servo- motor puHey, then remove the servomomr. Remove the bolt and servomotor bracket. BRACKET INSPECTION Connect the 12 V battery to (he servomolor 6F (Natr ura‘) connector terminals and check that the motor operation. Connection: Red (-0-) - Blue (-) If the servomolor does not turn, replace Ihe sen/0v mntor with a new one. Contents Chapter 6 5'79 FUEL SYSTEM (Programmed Fuel Injection) ll VOLI use a NEW servummor, n rs not necessary to do "715 procedure Measure the resistance between the servomotor 6P (Natural) connector terminals. Connection: Yellow/red — Green/orange Standard: 5 kn Connection: Light green/pink — Green/orange Standard: 0 — 5 k!) If He resistance is out of range. replace the serVOv motor. INSTALLATION Connect xhe servomotor SF (Natural) conneclor Shon me DLC [page 5-9). Turn the Ignition switch to "ON“. The servomotov turns, then stops. Secure the servomolor pulley a! (his position using a 3 x 28 mm bolt as shown. Connect the EGCV control cables 10 each position. Remove the 3 mm socket bolt from the servornolor pulley. Adjust the EGCV comrol cables (page 4-35l. Install the servomomr onto the bracket. Install and tighten the servomotor mounting bolt. CONTROL CABLES 3 x 28 mm BOLT ll‘/ 6-80 Contents Chapter 6 FUEL SYSTEM (Programmed Fuel Injection) Install the middle cowl stay/came protector and _ ' tighten the bolt securelyt STAY/PROTECTOR Connect the servomotor 6P (Natural) connector, InstaH the removed parts in the reverse order of removal‘ * * L 5? (NATURAL) CONNECTOR Contents Chapter 6 6'81 MEMO Contents Chapter 6 7. COOLING SYSTEM SYSTEM FLOW PATTERN ........................... 7.2 SERVICE INFORMATION 7.3 TROUBLESHOOTING .................................... 7.4 SYSTEM TESTING ......................................... 7.5 COOLANT REPLACEMENT............-.,......A.,.A 7.5 THERMOSTAT ................................................ 7.8 RADIATOR .................................................... 7.10 WATER pump 717 Contents Chapter 7 RADIATOR RESERVE TANK ------------------------ 7-20 FAN CONTROL RELAY ................................. 7.21 7-1 COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR RESERVE TANK RADIATO R IAC THERMAL VALVE THERMOSTAT RADIATOR SIPHON HOSE UPPER RADIATOR HOSE OIL COOLER 7'2 Contents Chapter 7 COOLING SYSTEM SERVICE INFORMATION GENERAL AWARNING Removmg the radiator cap while the engine is not can allow the coolant to spray out, senausiy seaming you. ‘ Always let the engine and radiator cool down before removing the radiator cap ‘ Using cue/ant 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 reiili or drain the system. All cooling system services can be done with the engine instaiied in the frames Avoid spilling coolant on painted surfaces. After servicing the system, check for leaks with a cooiing system tester. Pieter to the ECT sensor inspectlon [page 2044). .o-oo SPECIFICATIONS ITEM 7 gcwnows 7 7 Coolant capacity Pfieglartorranie gi'ne” '7: fl :7 ail US qt, 2 Wimp gLifr ‘ Reserve tank i 35 Imp qt) Fiad'iator cap relief pressurei ' W" ‘ io'sfl'sm’a’il. .‘kg’t’iom”? :20 psi}' ’ Thermostat Beginto open 80784°C1176r183ifl Tilly open 7 i' so ”c (194 °FI * 7 i Valve Iift "” ' 3 mm (0.3 In) minimum i ’Recommended antifreeze '* '7 ' 7 ' ‘ High 'qti'a'llty ethylerE'glycol entfieze containing corrosfin ‘ 7 protection inhibitors 1:1 mixture with distilied water Ste-Indore colilalt concentratEm TORQUE VALUES Water pump assembly flange bolt 12 N-m l1.2 kgf-m, s Ibf—ft) CT bolt Thermostat housing cover flange bolt 13 N-m 11.3 kgf-rn, 10 mm) CT bolt ECT lEngine Coolant Temperatureli 23 N-m l2.3 kgtrm,17ibffli thermo sensor Cooiing ton nut 2 9 N-m (a 3 kgfim, 2V2 lbw Apply a locking agent to the threads Fan motor mit 4.9 N-m (0‘5 kgfrml 3.6 lbf-ft) Fan motor bracket mounting bolt 8.8 N»m (0V9 kgfrm, 5.5 [bf ttl Contents Chapter 7 COOLING SYSTEM TROUBLESHOOTING Engine temperature too high - Faulty temperature gauge or ECT sensor Thermostat stuck closed Faulty radiator cap Insufficient coolant Passage blocked in radlaxormoses or waterjacket Air in system Faulty cocllng fan motor Faulty fan control relay Faulty water pump Engine temperature too low ' Faulty temperature gauge or ECT sensor - Thermostat stuck open - Faulty coollng lan control relay Coolant leak I Faulty water pump mechanical seal Deterioraled O-rings Faulty radiator cap Damaged or deten‘oraled cylinder head gasket Loose hose someone" or clamp Damaged or detenorated hose 7-4 Contents Chapter 7 COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the right side under cowl/middle cowl (page 3—7). RADIATOR CAP Remove the radiatorcap. Test the coolant gravity using a hvdrometer (see be1cw for "Coolant gravity chart“). For maximum corrosion protection, a 1'1 solution of ' ethylene glycol and d1stilled water is recommended (page 773). Look for contamination and replace the coalant 1f necessary. COOLANT GRAVITY CHART Coolant temperature C ( in” 5 1o 1 15 20725 30 " 35 40’ 45* 50’ 77 7L2) (41) (5(7))7 7‘ (59) (68) (77) (86) (95) [104) (113) (122M 777 5 71.009' 1.000J1900 1.008 1.0fl710706 1.005 70037 1.001 0.000 70.907 1 ' 10 1.13 1.01711017 1010 1 15 1.0147 1:1 71.011 71007 1.00757 ’15 77 1.028 ‘ 1026 ‘ 1025 1.0241022 0 1018 ‘ .014 1012 .sE‘ 20 1.036 1.034 1,033 1.031 1.7020 1027 1.025 1021 1019 2.7 25 1.045 . 1.043 1.042 1.040 1.035 1.036 1.034_ 1020710257 E 307 7 1053771052 717.0571 17.046 1045 1.043 1.041 g 35 1053 1.062 1060 1.058 17.056 1054 1.052 1.040 B 40 1.072 ‘ 1,070 1.068 1,066 1.054 1 1062 1.050 1056 1050 8 45 1076 1.074 107211069 1.066 HE 1.057 1 f' 50 77. 7 1000 1. 7 . 4 1.071 1.068_ 1062 7 55 7 77 1.095 1001 1088 1005 1062 1.070 1.0767 1.070 1.067 ‘ 1 60 1.100 1.005 1002 71.0007 1.086 1.033 1.030 7 1074 7170717 Contents Chapter 7 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 7.5) BD'DlE installing the Pressure test the radiator cap. cap/ii the zesrer, Replace the radlator cap it it does not hold pressure, Werihe sealing sure or if relief pressure is too high or too low, (r1595 it must held specified pressure for at least 5 sec- onds. RADIATOR CAP RELIEF PRESSURE: 108 — 137 kPa (1.1 , 1.4 kgf/cmz. 1B 720 pSi) TOOLS (Cummercially available): Cooling System Pressure Pump STV26232 Cooling System Adapter OTCJ33984A Pressure Ihe radiator, engine arid hoses, arid check for leaks. Excessive pressure can damage the cooling system components, Do not exceed 137 kPa (1.4 kgf/cmg, 20 psi} Repair or replace components if the system will riot hold specified pressure for at least 6 seconds, COOLANT REPLACEMENT PREPARATION - The effectiveness of coolant decreases with the accumulation of rust or If there is a change in the mixing proponion during usage. Therefore, ier ANT‘FREEZE best performance change the coolant regularly SOLUTlON as specified in the maintenance schedule. - Mix only distilled waterwitl’i the antifreeze, RECOMMENDED ANTIFREEZE: High quality ethylene glycol antifreeze containing EECBLLEE‘ESE DIST'LLED corrosion protection inhibitors SOLUTION) WATER i RECOMMENDED MIXTURE: 1:1 lDistilIed water and antifreeze) COOLANT REPLACEMENT/AIR BLEEDING Wr‘el‘ wring i’ie Remove the under oowls/iniodle cowls [page 377i. — system or reserve RADlATOR CAP rank mm a coolant Jrl’iei'mrlg content is yell. place tlie .liloinrch/e m a yere n ipesimn on e lee'l surface Remove the radiator cap. Contents Chapter 7 COOLING SYSTEM Remove the drain bolt on the water pump cover and e drain the system Coolant. Reinstall the drain bolts with new sealing Washers. Tighten the water pump drain bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft] Disconnect the siphon hose from the radiator. Drain the reserve tank coolant. Empty the coolant and rinse the inside of the reserve tank with water. Connect the radiator siphon hose, Fill the system with the recommended coolant thruugh the tiller opening up to filler neck. Remove the radiator reserve tank cap and fill the reserve tank to the upper level line. Bleed air from the svstem as follows: 1. shift the transmission into neutral, Start the engine and let it idle for Z — 3 minutes. 2. Snap the throttle three to four times to bleed air from the system. 3. Stop the engine and add coolant up to the proper level If necessarv, Reinstall the radiator cap. 4. Check the level of coolant in the reserve tank and fill to the upper level if it Is low. install the radiator reserve tank cap. Install the under cowls/middle COWIS lpage 3-7), Contents Chapter 7 COOLING SYSTEM THERMOSTAT DI} flotlel [he Illefr nwstat or there mmrleter YUUCt‘l the pan, or you will get false ream/lg REMOVAL Drain the coolant (page 776l. Remove the throttle budy lpage 6—47), Remove the bolts and thermostat housmg cover. Remove the thermnstat from the housing. INSPECTION Wear insulated gloves and adequate eye protection. Keep flammable materials away from the electric heating element. SEAL RING Visually inspect the thermostat for damage Check for damage of the seal ring. Heat the water with an electric heating element to l uperatlng temperature for 5 minutes. ‘/ u THERMOSTAT BEGIN TO OPEN: _ _ I‘d sorswcmeelszcm * ,x‘ other than those specified. Suspend the thermostat in heated water to Check its operation. Replace the thermostat :r the valve stays open at 5/ room temperature, or it it responds at temperatures A“ r l _ ,/ VALVE LIFT: 8 mm (03 in) minimum at 35 CC (203 °F) THERMOSTAT TH? MOSTAT 6uélNG COVER THERMOSTAT THERMOMETER 7-8 Contents Chapter 7 COOLING SYSTEM THERMOSTAT HOUSING REMOVAL Disconnect the ECT sensor connector. If necessary, remove the ECT sensor from the therr mostat housing (page 20-14]. It necessary, disconnect the fast ldle wax unit water hose and bypass hose from the thermostat housing. Remove the bolts and thermostat housing from the cylinder head Remove the Orring from the housing. THERMOSTAT HOUSING INSTALLATION Install a new O»ring into the groove at the thermo- stat housing. Install the thermostat housing onto the cylinder head. Install and tighten the thermostat housing mounting bolts securely. Connect the fast idle wax unit water hose and bypass hose if it has been removed. Install the ECT sensor if it has been removed (page 20-14). Connect the ECT sensor connector. OSTAT HOUSING THERMOSTAT INSTALLATION Install the thermostat into the housing with its air bleed hole lacing rearward. Contents Chapter 7 7'9 COOLING SYSTEM instali the thermostat housing cover onto the hous- mg. install and tighten the housing cover boils to the specified torque. TORQUE: 13 N-m [1.3 kgf-m. 10 Ith) Fill the system With the recommended coolant and bleed any air ipage 776i. ‘ THEFMOSTAT HOUSING COVER RADIATOR REMOVAL Remove the under cuwis/middle cowls (page 377i, Drain the coolant [page 775). Loosen the hose clamp screw and disconnect the lower radlator hose. Remove the bolts and air guide/reserve tank iower bracket from the radiator. Remove the bolt and radiator overflow hose guide. Disconnect the siphon hose and filler neck Jalnt hose from the radiator. 7-10 Contents Chapter 7 COOLING SYSTEM Disconnecl me fan motor 2P (Black) connector. ~2P‘IBTCK1‘CONNECTOR ‘ ' \\ w Remove me radiator lower mounting bolt. Remove the radiaxor upper mourm'ng bolt and Washer. 55 carefu/nor 7:: Move xhe radiator assemb‘y lo the nght and release carnage me 'adraml the radiator upper grommet from the bracket boss. m then remove the radtator assembly. Contents Chapter 7 7-11 COOLING SYSTEM DISASSEMBLY Unnook the hooks from the radiamr bosses, men remove the radiator griH. RADIATOR GRILL HOOKS Remove the three bolts and cooling fan motor assembly hum the radiator. Remove me nut and coming fan‘ COOLING FAN Re‘ease the fan motor connector from the fan motor brackel. - CONNECTOR 7-12 Contents Chapter 7 COOLING SYSTEM Remove the nuts and fan motor from the fan motor bracket‘ FAN MOTOR BRACKET Refer to the fan control relay information (page 7-21). NUTS ASSEMBLY 2,9 N‘m10.3 kgh’n, 2.2 IbfAft) HADIATOH COOLING FAN 4.9 N-m (0,5 kgfrm, 3‘6 lbfvft) FAN MOTOR 7.8 N-m (0.8 kngm, 5.8 let) Install the fan motor onto the fan motor bracket and tighten the nuts to the specified torque. TORQUE: 4.9 N4“ (05 kgf—m, 3.6 Ile) FAN MOTOR BRACKET N UTS Contents Chapter 7 7'13 COOLING SYSTEM Instalt the fan motor connector onto the fan motor bracket boss. CONNECTOR Install the cooling fan onto the (an motor shaft by atigning the flat surfaces. COOLIN G FAN Appty a locking agent to the cooling tan nut threads. NUT : Instalt and tighten the nut to the specified torque TORQUE: 2.9 N-m (0.3 kgl-m, 2.2 Ital-ft] InstaH the fan motor assembly unto the radlator. InstaH and lighten the three bolts to the specified turque. TORQUE: 3.8 NM (0.9 kgf-m, 6.5 Ith) / FAN MOTOR ASSEMBLV 7-14 Contents Chapter 7 COOLING SYSTEM Inslaii the radiator grill onto me radiator, and install the hooks secureiy. ‘ V RADIATORGR‘LL HOOKS INSTALLATION Secarefur’noiro install the radiator assembly, aligning its upper damage the radiator grommet with the frame bracket boss. fins Instali the radiator upper mounting bolt and washer, tighten the bolt secureiy Instaii and tighten the radiator iower mounting bait. LOWER MOUNTING EOLT Contents Chapter 7 7'15 COOLING SYSTEM Connect the fan mmur 2P lBlackl connectors Connect the filler neck joint hose and tighten me hose clamp screw. Connect the siphon hose to lhe flller neck and secure ix wim cllp. Hume me mmamr Install the alr guide/reserve tank lower bracket onto ram/1055 and aver me radlamr, Lighten lhe bolts securely. (/nw/msemmme Install lhc radialor Overflow hose guide onto the hracker radiator, lighten the bull. Connem lhe lower radlator hose and [Igmen the hose clamp screw, Fill me system wlth me recommended coolant (page 7-5). Inslall the under cowls/middle cowls (page 377)_ 7-16 Contents Chapter 7 COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Remove the under cowls (page 377). Inspect the inspectlan hole for signs of coolant leak- age. If there 15 leakage, lhe mechanical seal is defective and replace the water pump as an assembly. REMOVAL Drain me molam (page 775). Discunneclthe lower radiator hose and bypass hose from the water pump cover. Remove the flange bolts, sealing washar‘ Remove the water pump cover assembly Remove the Owing from me water pump body. WATER PUMP BODY Contents Chapter 7 7'17 COOL|NG SYSTEM Remove the separator mate from the water pump cover. Remove the dowel pins and Orring from the water pump cover. DOWEL P‘NS OVFUNG SEPARATOR Dtsconnect the water joint hose from the water pump body Remove the water pump body from the crankcase INSTALLATION WATER PUMP COVER SEPARATOR WATER PUMP BODY '12 Nvm (‘LZ kgfvm, S Ibf-fl) 7-18 Contents Chapter 7 COOLING SYSTEM Apply sngine oil to a new Orrl'ng and install it onto m the stepped portion of the water pump body. Install the water pump body into the crankcase while aligning the water pump shah groove with the oil pump shaft end. Align the water pump shaft groove wlth the all ‘ pump shaft end by turning the water pump impelv lert Align the mounting bolt holes ln the water pump and crankcase and make sure the water pump is securely Installed. Connect the joint hose to the water pump body, tighten the clamp screw. lnstall a new O-rlng mm the groove in the water pump cover. Install the dowel pins. lnslall the separator onto the water pump cover, 9} O-RING SEPARATOR Contents Chapter 7 7-19 COOLING SYSTEM Install the new O»r|ng into the water pump body groove. Install the water pump cover assembly onto the , water pump body, Install a new sealing washer and flange bolts. Tighten the flange bolts to the specified torque. TORQUE: 12 N-m (1,2 kgf—m, 5 lbf-h) Connect the lower radiator hose and bypass hose, then tighten the clamp screws. Fill the system with the recommended coolant (page 776l install the under cowls (page 377]. RADIATOR RESERVE TANK REMOVAL Remove the right side under cowl/middle Cowl (page 37). Disconnect the siphon hose and drain the coolant from the reserve tank, Remove the bolt and radiator reserve tank. installation is in the reverse order of removal. .\. _ - § s RESERVE ANK 7'20 Contents Chapter 7 COOLING SYSTEM FAN CONTROL RELAY INSPECTION Remove the under cowls/middle cowls (page 377]. Remove the relay hex from the bracket. Release the retainers lbrownl and remove the relay [ cennecror base. FAN CONTROL l RELAY Remove ihe fan control relay lrom the connector base. \ / 'li' . CONNECTOR lBRISWNl Connect the ohmmeter to the tan control relay conr nectar tetmlnals. i BA'ITERV Connection: A , B i , ,, , , Ccnnect a 12 V battery lo the followmg engine stop relay connectorterminals I ' i—L ‘ A C Cunnectiun: C k) v D (—) There should be continuity only when the 12 V bat- l tery is connected. l lf there is no continuity when the 12 v banery l5 connected, replace the ten control relay. 7 AN 5/ D Contents Chapter 7 7-21 MEMO Contents Chapter 7 8. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ............................. 3.2 ENGINE REMOVAL84 SERVICE INFORMATION .............................. 8-3 ENGINE INSTALLATION-------------~-------------r---8—9 a 8-1 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION % * Log/{9L S4 N-m16.5 kgf-m, 47 lbf-ftl 54 ”"1 (5'5 “Si-"h 4° ”“1 15 Nm (1,5 kgf-m, 11 mm) 3-2 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL - A hoist or equivalent is required to support the motorcycle when removing and installing the engine. A floor [ask or other adjustable support is required to support and maneuver the engine. Do not use the oil filter and oil cooler as a jacking point. When using the lock nut wrench for the adjusting bolt lock nut, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the torque wrench‘s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The specification given is the actual torque applied to the lock nut. not the read- ing on the torque wrench. Do not overtighten the lock ML The specification later in the text gives both actual and indi- cated. - The following components can be serviced with the engine installed in the frame. — Alternator (page 1l-4l — Clutch [Page 10-16) - Camshaft (page 9-8) , Gearshift linkage (page 1211) 7 Oil cooler lpage 5713) s Oil pump (page 573) — Transmission/gearshift linkage lpage 12-11) — Water pump (page 7-17) - The following components requlre engine removal for service — Cylinder head (page 9-13) — Crankshaft (page 13-7) - Fistun/cylinderipage13715) - When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. II you mistake the torque or sequence, loosen all mounting fasteners, then tighten them again to the speci- fied torque in the correct sequence. SERVICE DATA P 7 i ITEM l igECIFICATTONL l Engine dry weight l 658 kg (145.1 lbs) l Engine oil capacity l After disassembly : 3.8 liter (4.03sq7t3a3 Imp qt] _, s, l Coolant capacily Radiator and engine l TORQUE VALUES Engine hanger adjusting bolt 15 Mm 115 kgf-rn,11 Ibfiftl Engine hangar adjusting bolt lock nut 54 N-m l5l5 kglrm, 40 lbf‘ftl Hear upper engine hanger nut 64 N-m leis kgfrm, 47 lbf‘h] Rear lower engine hanger nut 54 N-m is 5 kgf-m, 47 lei-rt) Front engine hanger bolt 64 N-m 1&5 kgfm, 47 letl Middle engine hanger bolt 54 N-m (6.5 kgtm, 47 lbl-ftl Drive sprocket special bolt 54 N-rn 15.5 kgi‘m. 40 lbf-ftl Starter motor terminal nut 9.3 Nam (1V0 kgf-m, 7 lbf-ft) TOOLS Lock nut wrench, 20 mm 07VMAAMBEDiUD Contents Chapter 8 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the toilowing: , Under cowls/middie cowi ipage 3-7) , Exhaust pipe {page 3730) » Fueltankipage 6736) » Radiator reserve tank (page 7-20) , Air cleaner housing (page 6740) — Thronie body (page 6-47) Disconnect the foHow'ing Connectors: 7 Vehicie speed sensor 3F1Naturai1connector ~ Engine subrharness 2P (Biack) connector Remove the terminal nut and disconnect the starter motor cable from the starter motor Remove the starter motor mounting bait and starter » motor ground cabie Disconnect the camshaft position sensor 2P (Biack) connector. Disconnect the alternator 3P iNamrai] connector and side stand switch 2P (Green) connector. 8-4 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION Discunnem the following connectors: 2P (HEDl CONNECTOR ‘ l 5P (NATURAL) CONNECTOR , Crankshaft position sensor 2? (Red) connector 7 Rear brake light switch 2? (Black) connector — Ignition coil sub-harness 5P (Natural) connector Remove the ignition coil sub»harness 5P (Natural) connector fmm the stay. Hemnve the rear brake light switch wire from the clamps on the right crankcase cover. Remove the pinch bolt and disconnect the gear Shift arm from the gearshift spindle. Remove the bolt, washer, wave washer and gear shift pedal assembly. GEARSHIFT PEDAL Contents Chapter 8 8'5 ENGINE REMOVAL/INSTALLATION Disconnect the PAIR control valve air hoses from the reed valve cover. Disconnect the crankcase breather hose from the cylinder head cover. BREATHER HOSE . , .;\ D'rsconnect the upper radiator hose lrorn the (her mostat housing cover. Disconnect Ihe ECT sensor 3P (Gray! connector. Loosen the hose damp screw and disconnect the r radiator hose from the water pump, Loosen the hose clamp screws and disconnect the water hoses from the oil comer. Remove the radiator assembty. Remove me two bolts, drive sprocket cover and guide plate wage 1277). Loosen the rear axle nut. Turn the drlve chain adjusting bolts make the drive chain slack fullv. Remove the drive sprocket special bolt, washer and drive sprocket. ( PAIR AIR HOSE ( r 8-6 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION Remove the ball and radiator lower stay from the all pan. LOWER STAY BOLT Support the engine using a jack or other adjustable support to ease of engine hanger balls removal. Remove the left from englne hanger bolt and mid» dle englne hanger bolt. Remove the right front engine hanger bolt and mid dle engine hanger bolt and dlstance collars. ' k» .4.“ . ‘ FRONT HANGER BOLT/COLLAR Remove the rear lower engine hanger nut whlle holding the hanger bolt. REAR LOWER HANGER NUT Contents Chapter 8 8’7 ENGINE REMOVAL/INSTALLATION Remove the rear engine hanger lock nut using the special tool. TOOL: Lock nut wrench, 20 mm O7VMA-MBBO1DO or D7VMA-MBBO101 Turn the engine hanger adjustlng bolt counterclock- T . wise fully by loosening the rear engine hanger bolt. Remove the rear upper englne hanger nut while holdlng the hanger bolt. Loosen the rear upper engine hanger adjusting bolt luck nut using the special tool. TOOL: Lock nut wrench, 20 mm 07VMA»MBBD1DO or 07VMA-MEBD1D1 LOCK NUT , LOCK NUT WRENCH , 8'8 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION Turn the engine hanger adjusting bolt counterclock» —-’ wise fully by loosening the rear engine hanger bolt ADJUST‘NG BOLT Support the engine using a jack or other adjustable support to ease engine hanger oolrs removal. Remove the iollowmg: 7 Rear lower engine hanger bolt — Rear upper engine hanger bolt and collars Carefully lower the adjustable support, then remove the engine rrorn the frame. ENGINE INSTALLATION REAR UPPER HANGER BOLT UPPER ADJUSTING BOLT (9 N DISTANCE cotLARs REAR UPPER HANGER NUT LOCK N UTS HEAR LOWER HANGER BOLT FRONT HANGER BOLT MIDDLE MlDDLE HANGER HANGER BOLT BOLT DISTANCE COLLARS LOWER ADJUSTING BOLT REAR LOWER HANGER NUT FRONT HANGER BOLT Note the direction of the hanger bolts/collars When tightening the lock nut with the lock nut wrench, refer to the torque wrench reading infore matian in "SERVICE INFORMATION" (page 573). - The jack height must be continually adjusted to relieve stress from the mounting fasteners. Route the wire and cables properly [page 144]. Be sure to tighten all engine mounting fasteners - to the specified torque in the specified sequence described on the falluwing page. If you mistake the tightening torque Dr sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the specified sequence. Contents Chapter 8 ENGINE REMOVAL/INSTALLATION Install lhe rear upper and rear lower englne hanger adjustlng bolts fully from the lnside of the frame. ADJUSTING BOLT _ {I Carefully Install the engme lmo lhe frame. ADJUSTING BOLT \ Do nmlnremhange Install the collars and rear upper engine hanger bolt m upuel and lower from the right side Hangar bulls The upper hanger balr l5 no! ho/low Align the flats of the rear upper hanger bolt head wllh lhe adlusling bolt bossl Install the rear lower engine hanger boll from the rlght side Align the flats of the rear lower hanger boll head with the adjushng bolt boss. w lronr hanger lnslall me distance collars, rlghtfrom englne hanger LlU/Ils hollow bolt and middle engine hanger bolt. 8-10 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION install the left from engine hanger bolt and middle , engine hanger bolt, MIDDLE l-lANGER BOLT Turn the upper and lower engine hanger adjusting bolt by turning the hanger bolt until the adjusting bolt is seated on the engine. Tighten the rear lower engine hanger adjusting bolt to the specified torque by turning the hanger bolt. TORQUE: 15 N-m (1.5 kgf-m, 11 [bf-ft) instali the rear lower engine hanger adjusting bolt iock nutv Hold the adjusting bolt by holding the hanger bolt and tighten the lock nut to the specified torque, TOOL: Lock nut wrench, 20 mm OWMA-MBBOIOD or D7VMA—MBEO101 TORQUE: Actual: 54 N-m (5.5 kgfam, 40 IbeR) Indicated: 49 N-I'I'I (5.0 kgf-m, 39 let) Tighten the rear upper engine hanger adjusting bolt to the specified torque by turning the hanger bolt. TORQUE: 15 N-m (1.5 kgl-m, 11 IN“) Contents Chapter 8 8-11 ENGINE REMOVAL/INSTALLATION Install the rear lower engine hanger adjusting bolt lock nutr Hold the adjusting halt by holdlng the hanger bolt and tighten the lock nut to the specified torque, TOOL: Lock nut wrench, 20 mm O7VMA-MBEO100 or 07VMA7MBBO101 TORQUE: Actual: 54 NH! (55 kgf-m, 40 Ibf-m Indicated: 45 N-m (5,0 kgf-m, 39 Ibf-fl) Tighten the rear lower engine hanger nut to the . specified torque whlle holding the hanger belt. TORQUE: 64 Nam (65 kgfm, 47 let) Tighten the rear upper engine hanger nut to the specified torque while holding the hanger bolt. TORQUE: 54 N-m (sis kgt-m, 47 lbf-ft) Install and tighten the left side from engine hanger bolt to the specified torque, TORQUE: 64 N-m (6.5 kgt-m, 47 lbf-ft] Install and lighten (he left side middle engine hanger bolt to the specified torque. TORQUE: 54 N-m (6.5 kgf-rn, 47 lbf-ft) 8-12 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION Install and tighten the right side from engine hanger — 7‘ , bolt to the specified torque, M’DDLE HANGER BOCLT’OLLAF,‘ TORQUE: 64 NM (6.5 kgf~m, 47 lbflt) Install and tighten the right side middle engine hanger bolt to the specified torque. TORQUE: 64 MM (5.5 kgfim, 47 lbf-lt] yes... ' .ié- FRONT‘ HANGER BOLT/COLLAR "I . DRIVE SPHOCKET Install the drive sprocket with the marks facing out. install the washer and special bull. tighten the spe- cial bolt to the specified torque, TORQUE: 54 Nm (5.5 kgfm, 40 Ihf-ft) install the drive sprocket cover and clutch slave cyls lnder(page12711) lnstall the gearshift pedal assembly onto the trame, then install the washer and pivot bolt. Tighten the pivot bolt to the specified torque. TORQUE: 26 N-m (2.7 kgf-m, 20 Ibf-fl) Install the gearshift pedal link to the gearshih spine die while aligning its slit With the punch mark on the gearshitt spindle. Install and tighten the pinch bolt to the specified torque. TORQUE: 9.8 MW! (1.0 kgf-m, 7 half!) ,/ . PUNCH MARK) . 5 Contents Chapter 8 8-13 ENGINE REMOVAL/INSTALLATION Install the radiator unto the frame. ’ OIL OOLER WATER HOSE Connect the radiator hose and tighten the clamp X / screw securelyv t Connect the all cooler hose and tighten the clamp screw securely, Connect the upper radiator hose to the thermostat huusing cover and tighten the clamp screw securely, Connect the ECT sensor 3P (Gray) connector. Connect the PAIR control valve air hoses to the reed valve cover. Connect the crankcase breather hose to the cyllnder BREATHEH HOSE head cover. Route the rear brake light switch wire properly and clamp it wlth wire clamps on the right crankcase cover 8-14 Contents Chapter 8 ENGINE REMOVAL/INSTALLATION Connect the following connectors: — Crankshaft position sensor 2P (Red) connector 4 Rear brake light switch 2F (Blackl connector — lgnitlon coil sub-harness 5F (Natural) connector Connect the alternator 3P (Naturall connector and side stand switch 2P lGreenl connector. s/// 3P (WHITE) CON NECTOR Connect the camshaft uosition sensor 2P (Blackl connector. Route the starter motor cable and ground cable properly. ConneCl the ground cable with the starter motor mounting bolt, tighten the mounting bolt Connect the starter motor cable to the staner motor terminal, tighten the terminal nut to the specified torque, TORQUE: 12 N-m (1.2 kgf‘m, 9 |bf~ftl Contents Chapter 8 3-15 ENGINE REMOVAL/INSTALLATION Connect the following connectors: — Vehicle speed sensor 3P (Natural) connector , Engine subrharness 2P (Blackl connector lnstall the following: , Throttle body (page 647) — Air cleaner housing (page 6-40) — Radiator reserve tank (page 7~20l — Radiator (page 7-10) — Fuel tank [page 6—36) — Exhaust pipe (page 3—30) A Under Bowls/middle COWI (page 3-7l Adjust the drive chair. slack (page 4»26l. Four recommended engine oil up to the proper level (page 422(- Fill the cooling system with the recommended coolr ant and bleed any alr (page 7-6). 8-16 Contents Chapter 8 9. CYLINDER HEAD/VALVES COMPONENT LOCATION ---------------------------- 9»2 CYLINDER HEAD INSPECTION ---------~--------9-16 SERVICE INFORMATION ----------------------------- 9.3 VALVE GUIDE REPLACEMENT ------------------- 9-18 TROUBLESHOOTING ------------------------------------ 9-5 VALVE SEAT INSPECTION/REFACING ------s-19 n CYLINDER COMPRESSION TEST ................ 9-6 CYLINDER HEAD ASSEMBLY 922 CYLINDER HEAD COVER REMOVAL ----------- 9-6 CYLINDER HEAD INSTALLATION~--~-~----~9-24 CYLINDER HEAD COVER DISASSEMBLV 9-7 CAMSHAFT INSTALLATION ----------------------- 9-26 CAMSHAFT REMOVAL--- 9-8 CYLINDER HEAD COVER ASSEMBLY--------9~31 CYLINDER HEAD REMOVAL ---------------------- 9-13 CYLINDER HEAD COVER INSTALLATION-- . 932 CYLINDER HEAD DISASSEMBLY --------------- 9-14 CAM CHAIN TENSIONER LIFTER ---------------- 9-34 Contents Chapter 9 CYLINDER HEAD/VALVES COMPONENT LOCATION 9.8 NW (10 kgV-m, 7 Ibf ft) . 12 Nvm (1.2 kgf-m, 9 lbfvfi) 12 Nvm 11.2 kgfrm, 9 lbf-fi\% 3.8 N‘m (1‘0 kgi-m, 7 ”3”!) , O \ \ % y/ %@\/@ 12 NW! (1.2 kgf~m, S lbf-ft) 9-2 Contents Chapter 9 CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL This section covers service of the cylinder head, valves and bamshaft. - The camshaft services can be done With the engine installed in the frame. The cylinder head seNlce requires engine - Wwefilvzli'sassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original [0087 Elli all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before . €:r%:?;?tnlubrlcating oil is fed through all passages in the cylinder head. Clean the oil passages before assembling cylv - Efiérliifim to damage the mating surfaces when removlng the cylinder head cover and cyllnder head. SPECIFICATIONS Unit: mm (in) l lTEM _ STANDAFED 775512ch LIMIT ) J Cylinder compression ’ " "7 *I 1,098 kPa (11.2 hill/52159 psi) — ‘ / ) at 350 rpm ) Valve clearance HN ) 0.15 i 0.03 (0.006 1: 0.0017 __‘__ ; i # EX 0.30 1 0.03 (0.012 1 0.001) — Camshalt ’ Cam lobe ght # ) IN 3702 — 3710 (1.457 ~1.461) 37.00 (1.457) ‘ ) EX ) 36.66 — 36.74 (1.443 ~1.446) 36.64 (1.443) Runout r _ 0.05 (0.002) i .., on clearance ) 0.020 - 0.062 (0.0003 - 0.0024) 0.10 (0.004) l—Valve‘lTrE\“Valve lifter 0.0. [ 25.978 7 25.993 (1.0228 —1.0233) 25.97 (1.022) Valve lifter bore (.0. 7 26.010 , 26.026 (1.0240 7 1.0246) , 26.04 (1.025) ‘ Valve, Valve stem 0.0. ‘) ’I'N 3.975 —3.990 (01565701571) ’ 3.965 (0.1561) i valve guide 7 ) EX ) 3.965 — 3.900(0156141567) 3.955 (0.1557) Valve guide (.0.‘ ) lN/EX 4.000 — 4.012 (0.1575 — 0.1500) 4.04 (0.159) ‘ Stemrto-guide clearance L VIN¥7 410170 — 0.037 (0.0004 — 0.0015) 0.075 (0.0030) EX . 0.085 (0.0033) ‘ Valve guide projection ' IN A i; above cylinder head EX ‘ Valve seat width IN ' 1‘090 e 1.10 (o .043) . L EX 0.90 e 1.10 (0.035 - 0.043) 1.5 (0.06) ) Valve spring IN 335 (1.56) 30.7 (1.52) I free length TX ‘ ’ ' 39.5 (1.56) r 33.7 (1.52) Tylinder head warpage ‘_ — 0.10 (0.004) TORQUE VALUES Cylinder head mounting bolt/washer 51 N-m (5.2 kgf-m, 38 lbf-ft) Apply molybdenum disulride oil to the threads and seating surface Camshaft holder flange bolt 12 N-rn (1.2 kg1~m, s lbftft) Apply oil to the threads Cylinder head sealing bolt 27 N-rn (2.0 kgf-m, 20 lbftft) cylinder head cover bolt 9.8 N-m (1.0 kgf-m, 7 Inf-ft) Breather plate flange bolt 12 N-m (1.2 kgf-m. 9 lot-(t) Apply a locking agent to the threads CT bolt PAIR reed valve cover bolt 12 N~m (1.2 kgftm, 9 Inf-ft) Apply a locklng agent to the threads Throttle oody insulator socket bolt 12 Nam (12 kgf-rn, s (bf-ft) Cam sprocket flange bolt 20 N-m (2.0 kgf-rn, 14 |bi~ft) Apply a locking agent to the threads Cam chain tensiuner pivot bolt 9.8 N-rn (1.0 kgltm, 7 )bfrft) Apply a locking agent to the threads Camshaft position sensor rotor bolt 12 Nm (1.2 kgf-m, 9 lbftft) Apply a locking agent to the threads Cam chain Iensioner lifter mounting 8.8 N-m (1.0 kgf-m, 7 )bf-ft) socket bolt Cam chain gulde torx bolt 12 N-rn [1.2 kgf-m, Bibi-f1) Exhaust pipe stud bolt See page 1715 Spark plug 16 N-m (1.6 kgf-m,12|bf-fl) Contents Chapter 9 9'3 CYLINDER HEAD/VALVES TOOLS Compression gauge attachment 07RMJ-MV501OD or equivalent commercially availr able in U.S.A. Velve spring compressor attachment 07359-KM30101 Cam chain tensioner holder i a7ZMGrMCAA400 l or 07NMG7MYBU100 Tappet hole protector O7HMG-MR70002 USA. only; Make your own tool (page 9-15) Valve spring compressor 0775770010000 Valve guide driver 07GMD»KT70‘|00 Valve guide driver 0774370020000 Not available in USA 07MMH7MV90100 /‘3’// Valve guide reemer, 4.00 mm o/ 07MMH»MVBD1OA lUiSA. only) Valve seal cutter, 29 mm (45" IN) 07780-001030!) or equivalenr commercially avall- able in U.S,A. Valve sear cutter, 27.5 mm (45° EX) 07781143010200 or equivalent commercially avail- able in U.S.A. Flat cutter, 30 mm (32” lNl 077800012200 O 3 or equivalent commercially avail» able in U.S.A. Flat Cutter, 27 mm (32" EX) 077800013300 or equivalent commercially avail- able ln U.S.A, 9-4 Contents Chapter 9 FM . . . we , e, . Interior cutter, 30 mm (60°INl i Cutter holder 0773070014000 c7JMHrszozoa or equivalent commereially avail- able in USA. able in U.S.A. TROUBLESHOOTING or equlvalent commercially avails CYLINDER HEAD/VALVES - Engine toprend problems usually affect engine performance. These problem can be diagnosed by a compression test or by tracing engine noises to the top»end with a sounding rad stethoscope. - lithe performance is poor at low speeds, check tor white smoke in the crankcase breather hose. If the hose is smoky, check for a seized piston ring (page 1346). Compression too low, hard starting or poor performance at low speed - Valves: ~ Incorrect valve adiustment - Burned or bent valve ~ Incorrect valve timing — Broken valve spring — Uneven valve seating Cylinder head: 7 Leaking or damaged head gasket — Warped or cracked cylinder head - Worn cylinder, piston or piston rings (page 1316) Compression too high, overheating or knocking - Excessive carbon buildrup on piston crown or on combustion chamber Excessive smoke - Cylinder head: — Worn Valve stem orvalve guide 7 Damaged stem seal - Worn cylinder, piston or piston rings (page 13-16) Excessive noise - Cylinder head: — Incorrect valve adjustment ~ Sticking valve or broken valve spring 7 Damaged orworn camshaft m Loose or worn cam chain — Worn or damaged cam chain 7 Worn or damaged cam chain tensioner A Worn cam sprocket teeth - Worn cylinder, piston or piston rings (page 13-15) Rough idle - Low cylinder compression Contents Chapter 9 CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Warm the engine to normal operaiing temperatures Slop ine engine and remove me all direcr igniiion coil/spark plug caps and spark plugs (page 43), Lirr and suppon the ruei tank ipege 45). Disconnect the fuel pump unir 3P lBiack) connector, Install a compression gauge into the spark plug ——l hole. COMPRESSION GAUGE 1 TOOL: Compression gauge O7RMJ-MV50100 or attachment equivalent commer- cially available in U.S.A. Open [he throttle all the way and crank the engine With the slarler motor unul the gauge reading stops rising. Tne maximum reading is usually reached within 4 — 7 seconds. Compression pressure: 1,093 We (11.2 kgf/cmz,159 psi) at 350 rpm Low compression can be caused by — Blown cylinder head gasket _ improper valve adjustment — Valve leakage , Worn pismn ring or cyllnder High compression can be caused by: 7 Carbon deposits in combuslion chamber or on pislon head CYLINDER HEAD COVER REMOVAL Remove Ihe throttle body (page 647). BEEATHER HOSE : Remove lhe crankcase breather hose, ., ’- Jl‘ Disconnect the PAIR alr hoses from the cylinder head and remove the PAIR control solenoid valve (page 641i. 9-6 Contents Chapter 9 CYLINDER HEAD/VALVES Discunnect the Igmtion con connectors and remove (he direa ignition coils. DIRECT IGNITION COILS Remove me cylmder head cover buns. CYLINDER HEAD COVER Remove the cvlmder head Cover from the cylinder head. CYLINDER HEAD COVER DISASSEMBLY Remove the cylinder head cover packing. PACKING Remove the bolts and PAIR check va‘ve cover. Contents Chapter 9 CYLINDER HEAD/VALVES Remove the PAIR check valves from the cylinder head cover. Check the FAlR check Valve for wear or damage, replace 'lf necessary, FAl R CHEK VALVES / Remove the port plates from the evllnder need cover. CAMSHAFT REMOVAL Remove the cvllnder need cover (page 975). Avoid dameglng the CMF (camshaft position] senr sor whlle removing the Camshafts, remove the bolt and (IMF sensorfrom the cylinder head, ZP(B ~— Remove the nmmg hole cap and o-nng, ’ HOLE CAP 9-8 Contents Chapter 9 CYLINDER HEAD/VALVES mom/ARK“ Turn the crankshaft clockwise, align the "T" mark on 4 Y the ignlhcn pulse generator rotor with the index mark on the right crankcase cover. i, The timing marks (“IN“ and "EX") on the cam sprockets must be flush with the cylinder head surs face and facing outward as shown. If the timing marks on the cam sprocket are facing inward, turn the crankshaft clockwise one qu turn (360“) and realign the timing marks with the cylin- der head surface so they are facing outward, Remove the cam chain (anstoner lifter sealing bolt and sealing washer. Turn the tensioner lifter shaft quy in (Clockwise) and secure it using the special tool to prevent darn- CAM CHAIN TENSIONER HOLDER aging the cam chains TOOL: /\ 2/? r ‘ \ \\\r1 n _\ s \ Cam chain tensioner holder o7ZMG-MCAA400 or O7NMG-MV90100 / r\ EASE? \ \fi "LU ‘ r / /Vfi/ Contents Chapter 9 CYLINDER HEAD/VALVES Remove the bolts and cam chem guide E. m nm necessary If you plan to replace the camshah and/0r cam 10 remove me cam sprocket, loosen (he cam sprocket bolls as follows: Smacks! v'mm the camshaft excepr when /eplac'ng the Camshafi and/or cam sprocket. Ba careful/worm 7 Remove the cam sprockei bolts from [he imake drop the cam and exhaust camshafis. smacker bolts and cam sprocket mo the crankcase - Turn the crankshaft clockwise one full turn (360°), remove the mher cam sprockex bolts from Ihe Camshafts. — Remove the cam sprockets from the Camshafts, 7 Remove the bolts and CMP sensor rotor from {he Exhaust camshaft. CMPSENSOR RQT'QR 9-10 Contents Chapter 9 Suspend me cam chain wriir a piece of Wire to preverii the chain flom fall» mg me me Cram Case CYLINDER HEAD/VALVES Loosen and remove the camshaft holder bolts/ washers, then remove the camshaft holders and 53.81%??le CAMSHAFT HOLDER E Camshafts. NOTE: From outside to inside, loosen the belts in a miss cross pattern in several steps or the camshaft holder might break. Do not forcibly remove the dowel pins from the Camshaft holders. Remove the valve litters and shims. Be careful not to damage the Valve lifter bore. Shim may Stick to the inside of the valve lifter Do not allow the shims to fall into the crankcase. I Mark all valve litters and shims to ensure correct reassembly in their original locations, 1 - The valve lifter can be easily removed with a . valve lapping tool or magnet. . The shims can be easily removed with a twee- zers or magnet. INSPECTION CAMSHAFI’ Check the cam and journal surfaces ol the camshaft for scoring, scratches or evidence of insufficrent lubrication. Check the oil holes in the camshaft for clogging. Suppon both Sides of the camshaft (at Journals) with V-blocks and check the camshaft run out with a dial gauge. SERVICE LIMIT: 0.05 mm (0.002 in) Using a micrometer, measure each cam lobe height. SERVICE LIMITS: IN: 3100 mm (1.457 in) EX: 36.54 mm (1.443 in) 9-11 Contents Chapter 9 CYLINDER HEAD/VALVES Du not rutate the camshaft when using plastlgauge Se SU/E the dowel pins .n the cam shall holder align the holes in the CV/r lflder neat: CAMSHAFT HOLDERS inspect the bearing surface at the each camshaft holder lot scoring, scratches, or evidence of insuffir CAMSHAFT HOLDER A Giant lubrication. Inspect the oil orifices of the holders for clogging. CAMSHAFI' OIL CLEARANCE Wipe any oil from the Journals of the camshaft, cy|~ lnder head and camshaft holders. Lay a strip of plastigauge lengthwise on top of each camshaft journal. «i lnstall the each camshaft holder to the correct loca- tlons with the identification marks. BOLTS/SEALING WASHER BOLTS - "Fl" mark: center camshaft holder lHolder A) — "l." mark: left camshaft holder (Holder B) Apply engine oil to the threads and seating surfaces of the camshaft holder bolts. Install the twenty holder bolts with the eight sealing washers. Finger tighten the bolts. First gradually tighten the four bolls (No.5 — No.6 - No.7 7 No.8) in the numerical order cast on the cam- shaft holders. Gradually tighten the other camshaft holder bolts until the camshaft holders llghtly contact the cylin- der head surface Failure to tighten the camshaft holder in a crisscross pattern might cause a camshaft holder to break. Tighten all camshaft holder bolts in the numerical order cast on the camshaft holders. TORQUE: 12 NM (1.2 kgl-m, B flat“) 9-12 Contents Chapter 9 CYLINDER HEAD/VALVES Remove the camshaft holders and measure the ' width of each plastigauge. The widest thickness determines the all clearance. SERVICE LIMIT: 0.10 mm (0.004 in) When the service limits are exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft holders as a set ifthe clearance still exceeds the service limit. CYLINDER HEAD REMOVAL Remove the engine from the Irame lpage 8’4). ‘7l—lERMOSTAT HOUSiNG \ Remove the Camshafts [page 973). , Remove the bolts, thermostat housmg and Caring. Till the engine and drain the coolant from the cylln~ der head and cylinder, Remove the bolts, sealing washers, cam chain tensioner lifter and gasket. Remove the two 5 mm bolts, Loosen the 9 mm Remove the ten 9 mm bolts/washers. cans in a mesa C(GSS Dane/n 1n mm D! mree 51555 Remove the cylinder head. 9-13 Contents Chapter 9 CYLINDER HEAD/VALVES Remove the gasket and dowel pins DOWEL PINS Remove the following: — Right crankcase cover (page 10-15) — Sraner clulch (page 1028) Remove the torx boll, washer, cam chain gulde and pivot collar. Remove the socket bolt. cam chain tensioner and washer. Remove the cam chain and timing sprocket from the crankshaft / , , s TlMING SPROCKET CYLINDER HEAD DISASSEMBLY Remove the cylinder head {page 943). Remove me bolls and xhrome body insulators from the cylinder head. 9-14 Contents Chapter 9 CYLINDER HEAD/VALVES Remove lhe spark plugs from me cylinder head. I TAPPET HOLE “(HECTOR Install the [applet hole proteclor into “19 valve lll’ler _ bore. TOOL: Tappel hole protector D7HMG-MR7DODZ ’7 (not available in u.s.A.l An equlvalennool can easily be made from a plastic 35 mm film container as shown. 25 mm ID. (when compressed) l To prevenl/oss cf Remove the valve spring cutters using the special VXLVE SPRlNG COMPRESEO-R ‘ lenstofl, donor tools as shown, ‘ l Cnmplsss me valve sy'lngs more than TOOLS: \ NECESSary 10 Valve spring cumpressov 07757-0010000 /emove- Me 6037er Valve spring compressor attachment 07559-KM30101 Mark aI/parrs dur- Remove the following: lng a’lsassembly so they can be placed back m men urlglnal locatlons , Spring retainer — Valve springs ~ Valve Stem seal 7 Valve sprlng seal STEM SEAL ’ RETAINER SPRING SEAT ' VALVE SPRING Contents Chapter 9 9'15 CYLINDER HEAD/VALVES CYLINDER HEAD INSPECTION CYLINDER HEAD Avmddamagmgme Remove carbon deposits from the Combustion gaskezsudace chambers. Check the spark plug hole and valve areas for cracks. ’ Check the cylinder head for warpage WI"! 3 straight edge and feeler gauge. SERVICE LIMIT: 0.10 mm [0.004 in) VALVE LIFTER BORE Inspect each valve lifter bore for scralches or abncr» mal wean Measure the each valve lifter bore |.D. SERVICE LIMIT: 26.04 mm (1.025 in) VALVE LIFI'ER Inspect each valve Iifler for scratches or abnormal wear. Measure the each valve lifter OD. SERVICE LIMIT: 25.97 mm (1.022 in) 9-16 Contents Chapter 9 CYLINDER HEAD/VALVES Herace me valve sears whenever me valve guides are replaced (page 9 20; VALVE SPRING Measure the free length of the valve springs. SERVICE LIMITS: IN: 33.7 mm (1.52 in) EX: 33.7 mm (1.52 in) Replace the springs if they are shorter than the ser» vice limits. VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Inspect each valve for bending, burning or abnorr mal Stem wear. Measure and record each valve stem OD. SERVICE LIMITS: IN: 3.965 mm [0.1561 in) EX. .355 mm I0.1557 In) Ream the guides to remove any carbon deposits before checking clearances. Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise. TOOL: Valve guide reamer, 4.00 mm VALVE GUIDE REAMER 1 Measure and record each valve guide |.D. SERVICE LIMIT: INIEX: 4.04 mm (0.159 in) Subtract each valve stem CD from the correspond» ing guide l.D. to obtain the sternrlnguide clearance. . SERVICE UMIT: . IN: 0.075 mm (0.0030 in) EX: 0.085 mm (0.0033 in) If the stemrtorguide clearance is out of standard. determine if a new guide with standard dimensions would bring the clearance Within tolerance. If so, replace any guides as necessary and ream to fit. if the stem-torguide clearance exceeds the service limit With the new guides, replace the valves and guides. Contents Chapter 9 9-17 CYLINDER HEAD/VALVES CAM CHAIN TENSIONER/CAM CHAIN GUIDE Inspect the cam chain tensioner and cam chain guide for excessive wear or damage, replace them if necessary, CAM CHAIN TENSlONER CAM CHAIN GUlDE Inspect the cam chain tensioner B for excessive wear or damage, replace it if necessary. CAM CHAIN TENSIONER B VALVE GUIDE REPLACEMENT Do nu: use a lurch to hear me cylinder head: it may cause warping Chili the replacement valve guides in the freezer «. section of a refrigerator for about an hour. Heat the cylinder head to 100 — 150°C (212 — 300°F] with a hot plate or oven. To avoid bums] wear heavy gloves when handling the heated cvlinder head. Support the cylinder head and drive out the valve guides from combustion chamber side of the cylin- der head. TOOL: Valve guide driver 07JMD-KY20100 (not available in USA) Drive in the guides to the specified depth from the top of the cylinder head. TOOL; Valve guide driver 0774343020000 (not available in USA.) 9-18 Contents Chapter 9 CYLINDER HEAD/VALVES SPECIFIED DEPTH: A—W IN: 16.1 — 16.4 mm (0.53 — 0.5501) EX: 15.5 , 15.8 mm (0.61 A 0.62 in) Let the cylinder head cool to room temperature. Usa' curring 0!] on Ream the new Valve guides after installation. mereameraunng Insen the reamer from the combustion chamber rms opslamn side at the head and also always rotate the reamer clackwise. TOOL: Valve guide reamer. 4.00 mm 07MMH~MV90100 VALVE GUIDE REAMER Clean the cylinder head thoroughly to remove any metal particles. Retace the valve seat (page 9-20). VALVE SEAT INSPECTION/REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light caating of Prussian Blue to the valve seats. Tap the valves and seals using a rubber hose or other handalapping tool. HANDALAPPING TOOL Remove the valve and inspect the valve sear face. The valve seat Contact should be Wlthin the speci- fied width and even all around the circumference. STANDARD: IN: 0.90 — 1.10 mm (0.035 — 0,043 in) EX: 0.90 — 1.10 mm (0.035 — 0.043 in) SERVICE LIMIT: IN: 1.5 mm (0.06 in) EX: 15 mm (0.06 in) If the seat width is not within spelelcation. raises the valve seat (page 9420), SEAT WIDTH Contents Chapter 9 9'19 CYLINDER HEAD/VALVES The valves mnnat be nguNd lfa valve face [5 burned OI had/y worn or ll '1 contacts we seat uneven/y, replace me valve. Fallow the re/amng manufacturer‘s aperamg lnsnuo trons Inspect the valve seat face for: - Uneven seat width: — Replace the valve and reface the valve seat. - Damaged face: 7 Replace the valve and reface the valve seat, - Contact area (too high or tea Iowl — Reface the valve seat. VALVE SEAT REFACING Valve seat cutters/grinders or equ‘lvalent valve seat refaclng equupment are recommended to correct worn valve seatsv II the Contact area is too high on the valve, the seat must be lowered using a 32*degree flat cutterv If the contact area is too low on the valve, the seat must be raised using a EEO-degree interior cutter. UNEVEN SEAT WIDTH DAMAGED FACE TOO LOW TOO HIGH \ 45° _ l \\ j E , l, ‘. CONTACT TOO HIGH OLD SEAT WIDTH a»)? CONTACT TOO LOW OLD SEAT WIDTH 9-20 Contents Chapter 9 Reface me seat will a 45degree cutie! whenever a valve guide is replaced. Use a 457degree cutter to remove any roughness or irregularities from the seat. TOOLS: Seat cutter, 23 mm (mi Seat cutter, 275. mm (EX) Cutter holder 0778043010300 D7780<001 0200 07JMH-KV20200 or equivalent commer- cially available in USA. Use a 32-degree cutter to remove the (on 1/4 oi the existing valve seat material. TOOLS: Flat cutter. 30 mm (IN) Flat cutter, 27 mm (EX) Cutter holder 0778070012200 0771300013300 D7JMH»KV20200 or equivalent commer- cially available in U.s.A. Use a 60vdegree cutter to remuVE the bottom 1/4 of the old seat. TOOLS: Interior cutter, 30 mm (IN) Interior cutter, 30 mm (EXl Cutter holder 0778070014000 07780—001500!) 07JMH-KVZDZOD or equivalent commer- cially available in U.s.A. Usmg a 45-degree seat cutter, cut the seat to the proper width. Make sure that all pitting and irregularities are removed Refinish if necessary. CYLINDER HEAD/VALVES HOUGHNESS OLD SEAT WIDTH Contents Chapter 9 9-21 CYLINDER HEAD/VALVES After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pres- SLIYE. HANDVLAPPl NG TOOL . Excessive lapping pressure may deform or damr age the seat. - Change the angle or lapping tool rrequently to prevent uneven seat wear. - Do not allow lapping compound to enter the guides. After lapping, wash all residual compound off the cylinder head and valve. CYLINDER HEAD ASSEMBLY SHIM 553‘— CO'I'FERS («its g SPFllNG RETAINER VALVE SPRING STEM SEAL SPRlNG SEAT VALVE GUIDE EXHAUST VALVE INTAKE VALVE Blow through all oil passages ‘ln the cylinder head with compressed air. Install the tappet hole protector 'into the valve lifter bore. TOOL: Tappet hole protector 07HMG»MR70002 or refer to page 945 for alternative tuol 9'22 Contents Chapter 9 The exhaust valve Sp/lngs have orange palm marks and the intake valve spllngs have gray palm marks Glease the callers m 5555 lnstal’arlofl Suppon the Cy/lnr GE! neadabove the work bench sun face to prevent p037 slhle valve damage install the valve spring seats. install the new stem seals. Lubricate the valve stems with molybdenum oil solution. Insert the valve into the valve guide while turning it '0‘ slowly tn avoid damage to the: stem seal, ~¢ STEM SEAL ’ i' SPRING’SEAT RETAINER ' VALVE SPRING install the valve springs with the tightly wound coils facing the combustion chamber. install the valve spring retainer. Install the valve cutters using the special tool as VmE SPRING c0MPRES‘SB‘R shown. , NOTE To prevent loss of tension, do not compress the r < valve spring more than necessary. TOOLS: Valve spring compressor 0775743010000 Valve spring campressor attachment n7959-KM30101 Tap the valve stems gently with two plastic ham- mers as shown to seat the cotters firmly, install and tighten the spark plugs. TORQUE: 15 MI" (1.6 kgfvm, 121bf-fl) 9-23 Contents Chapter 9 CYLINDER HEAD/VALVES Install a new Orrlng into the groove of the insulator. ' Installthe insulator onto the cylinder head. , . l ‘ , 'NSULATOR I Install and tighten the insulator mounting socket bolts to the specified torque. TORQUE: 12 N-rn (1.2 kgf-m, 9 lbt-ft) CYLINDER HEAD INSTALLATION install the timing sprocket by aligning the wide splines between the crankshaft and sprocket. Install the cam chain. 9'24 Contents Chapter 9 CYLINDER HEAD/VALVES Apply a locking agent to the cam chain guide torx bolt threads. PIVOT COLLAR install the pivot collar, cam chain guide, washer and tent boil. , WASHER TOHX BOLT CAM CHAIN GUIDE Apply a locking agent to the cam chem tensioner socket bolt threads SOCKET BOLT Install the washer, cam chain tensioner and socket boit. r—\ WASHER CAM CHAIN TENSIONER Tighten the cam chain guide torx boit to the speci~ ’ y fied torque. t Aigf ‘ ' UIDE TORQUE: 12 Mr?! (1.2 kgf~m, 9 Ibl'fl) Tighten the cam chain tensmner socket bait to the specified torque. TORQUE: 9,8 N-m (1.0 kgf-m, 7 Ibf-ft) Instali the starter ciutch [page 10-32) and right crankcase cover (page 10»3A). Instali the dowel pins and a new cylinder head gas- ket as shown. Contents Chapter 9 9'25 CYLINDER HEAD/VALVES Apply molybdenum disulfide oil solution to the threads and seating surface of the 9 mm bolts/wash- ers and install them, lnstall the two 6 mm flange bolts. Tighten the 9 mm bolts ln a crisscross pattern in two or three steps to the specified torque. TORQUE: 47 N-m (4.8 kgf-m, 35 let) Tighten the 6 mm flange bolts. install the cam chain tensioner lifter onto the cylinA der head with a new gasket. Install and tighten the socket bolts to the specified torque, TORQUE: 9.8 N-m (1.0 kgl-m, 7 lbf-ft) Install the engine into the frame lpage 88L a GASKET N @SEALINGWASHERS BOLTS l CAMSHAFT INSTALLATION Apply molybdenum oil solution to the outer surface ol‘ the each valve lifter. litslar’lZ/ie shims Install the shims on the retainers and Valve lifters 1 and valve lifts-Is n into the valve lifter bores " their Orlglllal locar trons Each camshaft has an identification mark “EX“ MARK - IN: lntake camshaft - EX: Exhaust camshaft “IN" MARK 9-25 Contents Chapter 9 CYLINDER HEAD/VALVES If the cam sprockets are removed, install the cam —W'\fifil Sprockets onto the camshaft; NOJ CYLINDER CAM LOBES I Install the intake cam sprocket with the tlml’ng I mark (IN) facing outward and the No.1 cam lobes facing up and out as shown. l Install the exhaust cam sprocket with the llmlng mark (EX) faclng outward and the No.1 earn lobes facing up and out as shown. % » n “(X/(l EXHAUS INTAKE CAM SPROCKET Clean and apply a locking agent to the cam sprocket bolt threads. Install the Cam sprockets and bolts. BOLTS/'k‘gm Exhallslcamshafi Clean and apply a lockan agent to the CMP sensor aniy' rotor bolt threads. lnsrall the CMP Install the CMP sensor rotor and bolts. SEflS‘O' mlol wllh me No 7 cyllnder cam lobes team; up and rotor 'aur' mark Iacmg out as S/lawm "OUT" MARK Turn the crankshaft clockwise and align the "T" ,‘ mark on the crankshaft position sensor rotor wlth ;, the index mark on the right crankcase cover. Contents Chapter 9 9-27 CYLINDER HEAD/VALVES Appiy moiybdenum oil solution to the camshaft journal of \he cyiinder head. Instaii the cam chain over the cam sprockets and then instali the intake and exhaust Camshafts - Install the each camshaft (O the correct locations with the identification marks. "IN": Intake camshaft "EX": Exhaust camshaft IDENTIFICATION MARKS . Make sure that the timing marks on the cam sprockets are facing outward and flush with the cylinder head upper surface as shown. Coal new Orrings with oil and install them into Ihe grooves in the camshaft holders. Appiy molybdenum oil solution to the camshafl journals of the camshaft holders. Be sure the dowel Install the each camshaft hoider onto the camshafts. p/fls m the cam shah hoide/ align proper/y wizn the holes on the Cylinder neadpmpsr/y 9? a O»RiNGS 9-28 Contents Chapter 9 CYLINDER HEAD/VALVES Note the correct locations with the ldentification marks as shown A No mark: right camshaft holder - "R" mark: center camshaft holder , "l.“ mark: left camshaft holder IDENTlFICATlON MARKS Apply engine oil to the threads and seating surfaces am. camshaft hm. hm aggggsfigALING CAMSHAFT HOLDER B Install the twenty holder bolts with new eight seal- ing washers as shown. Finger tighten the bolts. First gradually tighten the four bolts (No.5 , No.6 , 4"" T— No.7 — No.8) in the numerical order cast on the cam- shaft holders. Gradually tighten the other camshaft holder bolts until the camshaft holders lightly Contact the cylinr der head surface. Failure to tighten the camshaft holderin a crisscross pattern might cause a camshaft holder to break. Tighten all camshaft holder bolts in the numerical order Cast on the camshaft holders. TORQUE: 12 N-m (1‘2 kgI-m, 9 Ibf-fll In case the cam sprockets were removed, apply a locking agent to the cam sprocket bolt threads Tighten the cam sprocket bolts to the specified torque. TORQUE: 20 N-m (2.0 kgf—m, 14 Ibf-M Contents Chapter 9 9—29 CYLINDER HEAD/VALVES Turn the crankshaft clockwise one full turn {360°} and tighten the other cam sprocke‘ bons. In case the camshaft position sensor rotor was remnvedl mghten the camshaft position sensor rotor bolts w xhe specified mrque. TORQUE: 12 N-m (1.2 kgf-m, S lbl-h) Instan the cam chain guide B, and tighten the bolts. Remove the special tool from the Cam chain tensioner lifter. 9-30 Contents Chapter 9 CYLINDER HEAD/VALVES Install a new seallng washer and tighten the sealing fl bolL CAM CHAIN TENSIONER LIFTER Hecheck me valve timing. BOLT ORING 1. ’E \ . “5 N1 Apply all to a new OJSHQ, and Inslall It unto me CMP sensor. Install the CMP sensor into the cyllnder head Install and tlghten the mourning be“ securely. Connect ‘he CMP sensur2P18lack)connector Install me cylinder head cover (page 8732). CYLINDER HEAD COVER ASSEMBLY Inslall me PAIR check valve pen plates into the 0/17 Indcr head cover. Contents Chapter 9 9'31 CYLINDER HEAD/VALVES Install the PAIR check vaives into the cyiinder head cover. I FAIR CHECK VALVES . / :‘rlorzlx‘iangogléll??higae§;m [he FAIR check valve cover PAIH CHECK VALVE COVERS Install the PAIR check valve cover and iighien the bans in the specified torque. TORQUE: 12 N‘m (1.2 kgfim, 9 Ibf-ft] \nstaH ihe new cylinder head cover packing into the cylinder head covergrooves. “fir PACKING CYLINDER HEAD COVER INSTALLATION Apply sealanno the cylinder head semicircular cut- ig— ’7' outs as shown. 9-32 Contents Chapter 9 CYLINDER HEAD/VALVES Install the cylinder head cover onto the cylinder head~ "up" MARK Install the washers to the cylinder head cover with their “UP" mark facing up. ' Install and tighten the cylinder head cover bolts to the specified torque. CVLINDER HEAD COVER TORQUE: 9.5 Nvm (1.0 kgf~m, 7 lbi-fl) install the direct ignition calls and connect the lgni- tion coil connectors. Connect the PAIR air hose: onto the reed valve new ers, Connect the PAlR control solenoid valve 2P (Black) connector (page 6-71]. BREATHER HOSE Install the crankcase breather hose to the cylinder head covert Install the throttle body (page 6-47). Contents Chapter 9 9-33 CYLINDER HEAD/VALVES CAM CHAIN TENSIONER LIFTER REMOVAL Remove (he Cam Chain Iensiuner sealing bolt and sealing washen I CAM CHAIN TENSIONER LIFTER Turn the lensmner shaft 'ully in (clockwise) and secure it using The special tool In prevent damaging the Cam chain. TOOL: Cam chain tensioner holder D7ZMG-MCAA400 or D7NMG-MV901DO Remove the boIts, seaIing washers, cam chain ‘ _ lensionerlifler and gasket. I ‘ GASKET INSTALLATION Narememsla/lanon Install a new gaskex mm the cam chain xensioner mrecnon ofme lifter, 955*“ Install me cam chain tensioner lifter into the cylin- der head. kg SEALING WASHERS BOLTS TENSIONER LIFTER GASKET 9-34 Contents Chapter 9 CYLINDER HEAD/VALVES Instatl the sealing washers and bolts, tighten the socket bolts. TENS‘ONER LIFTER GASKET 92* SEALING WASHERS BOLTS Rem” the Spec'a' “m" CAM CHAIN TENSIONER HOLDER \ Install a new seating washer and tighten the sealing bolt securely. Install me mmnle body (page 6752). \ ‘ \y \‘ J BOLT ¥ ‘\:, \ gt a /\J _(/ ‘\\41 t @ SEALING WASHER Contents Chapter 9 9'35 MEMO Contents Chapter 9 10. CLUTCH/STARTER CLUTCH COMPONENT LOCATION -------------------------- 10-2 CLUTCH SLAVE CVLINDER --------------------- 10-13 SERVICE INFORMATION -------------------- 104 RIGHT CRANKCASE COVER REMOVAL “10-15 TROUBLESHOOTING .................................. 10.5 CLUTCH ....................................................... 10.15 m CLUTCH FLUID REPLACEMENT/ STARTER CLUTCH ------------------------------------- 10-23 AIR BLEEDING ............................................. 10.5 RIGHT CRANKCASE COVER CLUTCH MASTER CYLINDER --------------------- Io-s INSTALLATION ------------------------------------------- 10-34 10-1 Contents Chapter 10 CLUTCH/STARTER CLUTCH COMPONENT LOCATION 34 N-m (3.5 kngm, 25 IN“) 34 Nm (3 5 kgf-m, 25 [bf-h) 10'2 Contents Chapter 10 CLUTCH/STARTER CLUTCH 127 NM (130 kgf-m. 9 “If-ft) 4 12 N-m (1.2 kgf—m, F: 9 mm) -3 H \ Contents Chapter 10 10-3 CLUTCH/STARTER CLUTCH SERVICE INFORMATION GENERAL Spilled fluid will severely damage instrument lenses and painted surfaces, it is also harmful to some rubber parts. Be care» ful whenever you remove the reservoir cap; make sure the reservoir is horizontal first. - This section covers service of the clutch and starter clutch. All service can be done with the engine installed in the frame. 0 Transmission oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system. SPECIFICAflONS Unit: mm (in) "7' ITEM ‘ STANDARD SERVICE LIMIT i Specified clutch lluid DOT 4 brake (luid ‘ 2 Clutch master cylinder 1 Master cylinder LD. 12.700 — 12.743 (0.5000 — 0.5017) 12.755 (0.5022) Master piston 0.D. 12.657 -12.$84(0.4533 — 071994) . 12.645 (0.4973) Clutch 1 Spring free length 56.8 (2.24) "’ ’ 55.7 (219) Disc A thickness 3.72 — 3.89 (0.146 , 0.153) 7 7 3.4 (913) Disc 9 thickness . 3,22 — 3.39 (0.127 , 0.133) No.11) Plate warpage — 0.30 (0.012] filutch outer guide A I.D. .- s. 7 .. 27.993 — 29.063’iii‘62'1 — 1.1025) 29.012 (1.1029) (without ID mark) 0.0. 35004 — 5.012 (1.3731 —1.37s4) 34994113777) Clutch outer guide a 1.0. 27.993i29003 (1.1021 — 1.1025) 729.012 (1.1051)’: 1 (With ID mark) 00. 34.996 ~ 35.004 (1.3773 — 1.3731) 34.996 (1.3774) ' Prir‘na'ry driven gear |.D. ' A 41.008 — 41.015 (1.6145 — 149) 41025 (1.6152) B 41.000—41.008(1,614271.61454) 41.019( 149) Oil pump drive sprocket LD. 23000—23021(1.1024—11032) 23.030"( .1035): guide 0.0. 34.975 — 34.991 (1.3770 —1.3776) 34.965 (1.3766) oil pump drive sprocket LD. 35.025 _ 35.145 (1.3789 41.3837) 35.155 (1.3941) ’ Tshaft oTlfat'cIutph outer guide 27.950 — 27.990 (1 1015 , 1.1020) 74227.90 (1.101) Mainshait 0.0. at oil pump drive sprocket guide 27.950 — 27.990 (1.1015 — 1.1020) 27.95 (1,101) 7 Starter idle gear Gear LD. 10,019— 10.035 (03942703951) 1005(0 396) Shaft 0.0. 9.991 — 10.000 (0.3933 , 0.3937) 9.99 (0.393) Starter driven gear boss 0.0. " “ 45.6571 45.673 (1.7975 — 1.7981) 45.642 (1.7969) TORQUE VALUES Clutdw center look nut 127 Nm [13.0 kgf~m, 94 Ith) App|v oil to the thread Stake the nut Clutch spring bolt/washer 12 Nvm (1.2 kgf-m, 9 lbf-h) Oil pump driven sprocket bolt 15 N-m (1.5 kgi-m, 11 lbf-h) Apply Blocking agent to the threads Starter clutch outer bolt 83 N-m (8.5 kgf—m, 6t [bf-ft) Apply oil to the threads and flange suriace 10'4 Contents Chapter 10 CLUTCH/STARTER CLUTCH TOOLS ‘ Snap ring pliers Clutch centerholder Gear holder, M25 07914731150001 l 0772470050002 07724-0010100 or equivalent commercially availr able in USA. TROUBLESHOOTING Clutch lever soft or spongy - Alr ln hydraulic system - Low fluid level I Hydraulic system leaking Clutch lever too hard to pull in - Sticking master cylinder piston - Sticking slave cylinder - Clogged hydraulic system ° Damaged clutch lifter mechanism - Faulty clutch lifter bearing ' Clutch lifter piece installed improperly Clutch slips when accelerating - Hydraulic system sticking ' Worn clutch dlsc 0 Weak clutch springs ' Transmission oil mixed with molybdenum or graphite additive Clutch will not disengage or motorcycle creeps with clutch disengaged Air in hydraulic system Low fluid level Hydraulic system leaking or clogged Clutch plate warped Loose clutch lock nut on level too high Improper oil Vlscosity Damaged clutch lifter mechanism Clutch lifter piece installed improperly Hard to shift ' Improper clutch operation 0 Improper oil viscosity i ll or 07724-001A100 lU.S,A. only) Contents Chapter 10 10-5 CLUTCH/STARTER CLUTCH CLUTCH FLUID REPLACEMENT/AIR BLEEDING CLUTCH FLUID DRAINING Support the motorcycle on its side stand SOPPER PLATE , p RESERVOIR EXP Turn the handlebar to the rlght until the reservoir is parallel to the ground, before removing the resere vuir can Remove the screw and stopper plate. Remove the reservoiroap, set plate and diaphragm Connect a bleed hose to the bleed valve of the clutch slave cylinder. Loosen the bleed valve and pump the clutch lever until fluid stops flowing out or the bleed valve, CLUTCH FLUID FILLING/AIR BLEEDING Use unlyDOTAZ Fill the reservoir with DOT 4 Brake fluid from a ' brake fluldfmma sealed container. sealedcontainer Connect a commercially available brake bleeder to the bleed valve. Do not mix dl‘ferem Pump the brake bleeder and loosen the bleed valve. types orrluid rhev Add brake fluid when the fluid level in the reservoir are not Compatible is low. ' Check the fluid level ohen while bleeding the clutch to prevent alrfmm being pumped intothe . system ' When using a brake bleeding tool, follow the manufacturer's operating instruction. llama entering the Repeat the above procedures until new fluid flows bleedertrbm out ofthe bleed valve and air bubbles do not appear around the bleed in the plastic hose, valve threads, seal the threads wrrh zcflon tape Close the bleed Valve and operate the clutch lever. if it is still spongv, bleed the system again 10'6 Contents Chapter 10 CLUTCH/STARTER CLUTCH If a brake bleeder is not available, use the following procedure. Pump the clutch lever until lever reSIStance ls felt. Connect a bleed hose to the bleed valve and bleed the system as follows: 1. Squeeze the clutch lever, open the bleed valve 1/ 4 of a turn and then close it. Do not release the clutch lever until the bleed valve has been closed. 2. Release the clutch lever slowly and wait several seconds after it reaches the end of Its travel. Repeat steps 1 and 2 until air bubbles do not appear in the bleed hose. T‘lghten the bleed valve to the specified torque TORQUE: 9 N4“ (0.9 kgf-m, 6.5 lbf—l’t) Fill the reservoir to the upper level line with DOT 4 brake fluid from a sealed container. lnslall the diaphragm and set plate. \"1 UPPER LEVEL LlNE Install and tighten the reservmr cap. Install the stopper plate and tighten the screw. Check the clutch operation (page 4733]. Contents Chapter 10 10'7 CLUTCH/STARTER CLUTCH CLUTCH MASTER CYLINDER REMOVAL Sui/led fluid can damage painted, plastic, or rubber pans. Place a shop luwsl over these pans whenever the system is serviced. Drain me clumh hydraullc system (page 1076}. Disconnect the clutch switch wire connectors. Remove me clmch hose oil bolt, seallng washers and clulch hose syslel. Remove the bnlts from the master cylinder holder and remove the mas‘er cylinder assembly. DISASSEMBLY Remove the pivot boll/mu and clumh lever assemr bly. PIVOT BOLT PIVOT NLJT CLUTCH LEVER 10'8 Contents Chapter 10 CLUTCH/STARTER CLUTCH Remove the screw and clutch switch. SCREW CLUTCH SWITCH Remove the screw and 0H cup and Orrings from the master cylinder body. OIL CUP Remove the boot and push rod. PUSH ROD Remove the snap ring from the master cylinder body using the special tool as shown. TOOL: Snap ring pliers 0791LSA50001 Contents Chapter 10 10'9 CLUTCH/STARTER CLUTCH Remove The master piston assembly and spring. MASTER CYLINDER CIean the inside of (he cylinder and reservoir with brake fluid. PISTON CUPS SPRING 0 MASTER PISTON INSPECTION Check the piston boot, primary cup and secondary cup for farigue or damage. Check the master cylinder and piston for abnormal scraxches. Measure the master Cylinder LD. SERVICE LIMIT: 12.755 mm (0.502 in) Measure the master piston O D SERVICE LIMIT: 12.645 mm (0.4978 in) ASSEMBLY RESERVOIR CAP DIAPHRAGM PLATE 1.5 N m ‘l.'I IbI-fl Safe 0 RINGS<§O MASTER CYLINDER PUSH ROD fl BOOT 7 SNAP RING 0 MASTER PISTON 1‘0 N-m {0-1 kgf-m, 0-7 “3”“ 5.9 N-m (0.6 kgf-m, 4.3 IleI 10'” Contents Chapter 10 CLUTCH/STARTER CLUTCH When msrallmg the cups, do not allow Me Up: to turn mslds our 59 certam m9 Snap nng rs firm/v seated m we groove Elf-mt all parts wulh clean brake fluid before assem» MASTER CYLINDER Dip the pismn in brake fluid. (a Install the primary and secondary cups unlo me masler piston. Install (he spring and masrer pvston assembly Into the master cylinder. PISTON CUPS & SPRING O % MASTER PISTON Install the snap ring uslng the special tool. TOOL: Snap ring pliers 07914—SA50001 Apply clean brake fluid to the Orrlnga' _and install them oil cup and masler cylinder body grooves. lnstall me all pup onto the master cylinder body‘ Install and ngmen me an cup mourning screw :0 me speclfied torquer OIL CUP / Tl TORQUE: 1,5 N-m (0.15 kgf-rn,1.1 lbf‘ftl Contents Chapter 10 10-11 CLUTCH/STARTER CLUTCH Apply Silicone greaSe to the boat inside and tip of the push rod install the clutch switch and tighten the screw to the i , specified torque. TORQUE: 1 Nvm (0.1 kglrm, 0,7 Ibf‘ft) SCREW CLUTCH SWiTCH Applv silicone grease to the top of the push rod, then install the joint piece and clutch lever assem~ CLUTCH LEVER ASSEMBLY bly, JOINT PIECE m Apply silicone grease to the clutch lever pivot slid» mg smug ,fil PIVOT BOLT Instaii and tighten the pivot bolt to the specified torque. TORQUE: 1 N‘m [0.1 kgf-rn, 0.7 Ibi-ft) F» Hold the pivot bolt and tighten the pivot nut to the specified torque. TORQUE: 5.9 MI" (0.6 kgf-m, 4.3 Ibf-fl) PIVOT NUT CLUTCH LEVER ”'12 Contents Chapter 10 CLUTCH/STARTER CLUTCH INSTALLATION :iaarcethe master cylinder assembiy onto the handle- ‘_' ' HOLDER MASTEE CYLINDER Align the end of the master cylinder with the punch . ' / mark on the handlebar. lnstail the master cylinder holder WIII’] the "UP“ mark facing up. Tighten the upper bolt first, then the lower boil, TORQUE: 12 Mr“ [1.2 kgI-m. S IbI-ft) Instail the clutch hose eyelet the oil bait and new seaiing washers. While pushing the ciulch hose against the stopper and tighten the oii boit to the specified torque TORQUE: 34 N~m (3‘5 kgf-m, 25 Ibf-ftl Connect the clutch swilch connectors. Fili the reservoir to the upper level and bieed the hydraulic system (page 1076). CLUTCH SLAVE CYLINDER REMOVAL Drain the clutch hydraulic svstem [page1075). Avcia spiiiing Him Remove the clutch hose cil boit, sealing washers u—oemed, piasnc, and brake hose eyeiet, (7’ UDDW pans Piece 2 Sflou rcwei nve' M959 US’IS WhSnEi/C' the svsr rem ’5 serviced Remove the baits and clutch sieve cylinder assem- bly. Remove the gasket and dowel pins. Contents Chapter 10 ““3 CLUTCH/ STARTER CLUTCH Do not use high pressure arr or D/lllg the nozzle m close m we rnlel SLAVE CYLINDER DISASSEMBLY Remove the slave cylinder piston and spring. If the pismn is hard to remove, remove the IoIlown ing: Place a shop mwel over the piston to cushion the piston when it is expelled, and position the cylinder with the piston clown. Apply small squirts of air pressure to the fluid inlet to remove the piston. INSPECTION Check the piston spring for weakness or damage. Inspect the oil seai and 0»rings for damage or dete- rioration, replace if necessary. Clean the O-ring grooves WIih clean brake fluid Check (he slave cylinder for scoring or other dam- age. Check the slave cylinder piston for scrmchesy score ing or other damage. ASSEMBLY % PISTON SPRING SLAVE CYLIN DER SPRING PISTO N SLAVE CYLINDER PISTON OIL SEAL DIL SEAL OVRINGS 10-14 Contents Chapter 10 CLUTCH/STARTER CLUTCH Lubricate the piston wnh brake fluidv Applv silicpne grease to the new O»rings and install (hem lo lhe slave cylinder piston grooves. Install the spring into the boss uf the piston. Install the spring and piston into the slave cvllnder. SLAVE CYLINDER SPRlNG L PlSTON INSTALLATION lnslall the dowel pins and new gasket, Apply silicone grease to the lap of the push rod, lnslall the slave cylinder unto the lefi crankcase rear cover Install and lighlen the SH bolls. lnslall the clutch hose eyelet with the OII balk and new sealing washers. While pushing the clutch hose against the stopper, tighten the oil bolt to the specified torque. ' TORQUE: 34 N-m (3‘5 kgltm, 25 Ihf‘h) Flll the reservoir to the upper level and bleed the hydraulic system (page io-el. RIGHT CRANKCASE COVER REMOVAL Remove the under cowls/mlddle eowls lpege 3-7l Drain the engine oil (page 4722). Disconnecl the crankshafl position sensor 2P (Red) conneclor. Contents Chapter 10 1045 CLUTCH/STARTER CLUTCH Becarem/nnzm Remove the right crankcase cover bolts] wire — ampmemmsr/ c‘amps and ngmcrankcasecover. . RIGHTCRAN CASECOVER we v9 w65’7c/s mm . [he crankcase Remove the thrust washer and wave washer from the slafler idle gear. [70 nor nun llre Remove the dowel ans. clankshaiz counter- clockw/se after .rsmovmg me ngm C’anA’EBSE cover {0 prevem me erarzm rsducnun gear {rum damage Clean off any sealant from the right crankcase cover matrng surfaces. CLUTCH REMOVAL Remove me right crankcase cover (page 10-15). Prevent damaging the starter reduction gear shaft, remove the S‘aner idle gear and shafl from the crankcase, 10-16 Contents Chapter 10 CLUTCH/STARTER CLUTCH Remove the clurch spring bolts, springs in a en'ss- cross pattern in two to three steps, then remove the pressure plate. Remove the clutch Iiher piece and Iifier rod. Remove me following: Two clutch disc A Six c‘u‘ch disc B Seven clutch Mates anion spring Spring seat rrrlx Unstake rhe clutch center lock nut. Contents Chapter 10 10'” CLUTCH/STARTER CLUTCH Hold the clutch center with the special tool and remove the clutch center lock nut, TOOL: Clutch center halder 07724—0050002 or equivalent commer- cially available in U.S.A. Dlscard the lock nut, Remove the luck washer, thrust washer and clutch THRUST WASHER 3 center. \ Remove the thrust washer. Pull out the clutch outer gulde, then remove the needle beanng. ”'18 Contents Chapter 10 CLUTCH/STARTER CLUTCH Remove the clutch outer. CLUTCH OUTEtR I‘r Remove the oil pump driven sprocket boil/washer. DRWIVE CHAI Tuga'i‘accesszc Remove the oil pump drive/driven sprocket and me oi’pumu maven drive chain as an assembly. SDVOth'L first ierimyc me on pan ‘1‘ DRIVEN SPROCKET INSPECTION clutch lifter bearing 2:;rérme inner race of the iiher bearing with your LINER BEARING The bearing should mm smoothly and ireeiy with» out excessive piay. If necessary, replace the hearing. Clutch spring Rea/ace ihe Ci'ui‘cn Measure the clutch spring free iehgrh, springs as a sci SERVICE LIMIT: 557 mm (2.19 in) Contents Chapter 10 10'” CLUTCH/STARTER CLUTCH Clutch center Check me gruoves of the clutch cenler for damage or wear caused by the clutch plates, Replace it I! necessary. Clutch lifter piece Check the clutch lifter piece for damage or abnormal wear. Clutch lifter rod Check the clutch rod for vend or other damage Clutch disc Rap/ace the crunch Replace me cluxch discs if they show signs of scor~ d‘scs anagram-.15 as ing or disculoralion. a 59’ Measure the disc mickness of each disc. SERVICE LIMIT: A: 3.4 mm (0.13 in) B: 2.9 mm (011 in) 10-20 Contents Chapter 10 CLUTCH/STARTER CLUTCH Replace me clutch dlscs and plates as 5 Sal Clutch plate Check the plates for discoloration Check the plate warpage on a surface plate using a feeler gauge. SERVICE LIMIT: 0.30 mm (0.012 in) Friction spring/spring seat Check the friction spring and spring seat for defor- mation, warpage or damage; replace as necessary. - A damaged or warped spring seat will cause the friction spring to be pressed unevenly. - A damaged friction spring also causes the weak contact between the discs and plates or uneven disc/plate Contact. clutch outer/primary driven gear Check the slots of the clutch outer for damage or wear caused by the clutch discs. Check the primary driven gear for abnormal wear or damage. Measure the ID. of the primary driven gear. SERVICE LIMITS: A: 41.025 mm (1.5152 in) a: 41.013 mm (1.6149in) Replace the clutch outer assembly if necessary, When the clutch outer assembly is replaced, be sure to select the needle bearing according to the selec» tive fit table (page 10-22). Clutch outer guide/needle bearing Measure the 0.0 and ID. of the clutch outer guide. SERVICE UMITS: A (without ID mark): O.D.: 34.994 mm (1.3777 in) ID ’ 28.012 mm (1.1028 in) B (WIth ID mark): 0.0 34386 mm (1.3774 in) I. . 28.012 mm (1.1028 in) SPRING SEAT FRICTlON SPRING CLUTCH OUTER Contents Chapter 10 10-21 CLUTCH/STARTER CLUTCH Check the needle bearing for wear or damage. Replace the bearing if necessary. When the clutch outer guide and/or needle bearing is replaced, be sure to select the needle bearing according to the selective fit table (page 10-22). Oil pump drive sprocket/sprocket guide Measure the 0.0. and ID. of the on pump drive sprocket guide. SERVICE lIMITS: 0. 34.955 mm (1.3766 in) ID 28.030 mm (1.1035 in) Measure the ID. oi the oil pump drive sprocket. SERVICE LIMIT: 35.155 mm (1.3341 in] ‘— Mainshaft Measure the rnainshaft CD. at clutch Outer guide and oil pump drive sprocket guide sliding surfaces, SERVICE LIMITS: on pump drive sprocket guide position: 2736 mm (1.101 in) Clutch durer guide positinn:27.56mm (1.101 in) NEEDLE BEARING SELECTION The primary driven gear has LD. code ieuer as shown. 10'22 Contents Chapter 10 CLUTCH/STARTER CLUTCH The clutch outer guide has O.D. code letter as shown. O.D.CODE LETTER Cross-reference me primary driven gear and clutch outer guide codes to determine the replacement needle bearing. Refer to the selection table below lor bearing seler; lien. NEEDLE BEARING SELECTION TABLE: (.7 E i, E i ' CLUTCH OUTETGUlHE fiMA’R’Ki l . GUIDE A GUTJE s lwmiom ID mark) l (Wish ID markli l 35.004 — 35.012 mm " 34.995— 35.00A mm l i i (1.3781 —1.§1784 in) l (1.3778 — 1.3731 in) PRIMARY A 410037411116 mm DRIVEN GEAR [1.6145 *1.6148 in] I NEEDLE HEARING B NEEDLE BEARING A LD. MARK B 41.000 ~41.008 mm‘ ‘ ‘ i 1&6142716145ln) ‘ NEEDLE BEARING C ‘ NEEDLE BEARING B Contents Chapter 10 10—23 CLUTCH/STARTER CLUTCH INSTALLATION OIL PUMP DRIVE SFROCKET GUIDE DRIVEN SPROCKET DRIVE SPROCKET CLUTCH CENTER 15 N-m (1,5 kgf-m, 11 lbf-ft) CLUTCH OUTER 47 ‘ SPRING \ 127 N-m (13.0 kgfm, 94 lbf-ft) LIFTER ROD . LIFTER PIECE NEEDLE BEARING THRUST WASHER CLUTCH DISCS! CLUTCH PLATES DISC A LIFI'ER PLATE SPRING 12 N-m (1.2 kgf-rn, 9 lbI-ft) ”'24 Contents Chapter 10 CLUTCH/STARTER CLUTCH Install the oil pump drive sprocket guides Install me mlpumo Install the oil pump drive/driven sprocket and drive driven sprocket chain as an assembly. wlth rrs 'DUT'mark fan/rig 0m Apply a lockan agent to the threads of the Oil pump driven sprocket bolt. Install the oil pump driven sprocket bolt, washer and tighten the bolt to the specified torque. TORQUE: 15 Mm 115 kgfim. 11 Ibfrft) Apply molybdenum all solution to the clutch outer sliding surface, Make sure the Install the clutch outer while aligning the bosses on slaneneductmn the Oil pump drive sprocket with holes in the clutch geai is installed outer. before lnsla/llng me clutch. Apply molybdenum oil solution to the clutch outer guide sliding surface. r Inszallihe clurch Install the clutch outer guide and needle bearing autergulde wrrhrrs onto the mainshah (Flefer to the needle bearing — f r l grooves facing our selection: page 10-23). W Contents Chapter 10 10—25 CLUTCH/STARTER CLUTCH Install the thrust washer. Install the clutch center and thrust washer. Install the lock washer with its "OUT“ mark facing out. Apply oil to the threads and seating surface of a new clutch center lock nut, then inslall it onto the malnshafl. Hold the clutch center wilh the special tool and tighten the lock nut to the specified torque. TOOL: Clutch camel holder 077244050002 or equivalent commer- cially available in USA TORQUE: 127 N-m (13.0 kgf‘m, 94 Ihf-ft) BE Ca/El‘u/nof w SKEke the lock nut mm the mainshafi groove with a damage we punch. lvzalnsl’lal’l :hreads 1026 Contents Chapter 10 CLUTCH/STARTER CLUTCH lnslall the spring seat and friction spring onto the l i " ' .1 clutch center as shown. l . . , l Coat (he clulch discs and plates wlth clean engine CLUTCH PLATE E CLUTCH 0“ DISC A Surface treatmenr First install the clutch discA (larger Lo. disc) inmme CLUTCH 0'50 A afcluzch plats E l5 clutch outer, and then install (he clutch plale EV dlffersnffmm ma: Stack the six clutch discs (E) and plates (A) alterr ufp/atoA natelyv CLUTCH DISC 5 Install lhe clutch dlsc A (larger |.D. disc] and set the tabs of ll in the shallow slots of the clulch cuter. malnshafl. Contents Chapter 10 1027 CLUTCH/STARTER CLUTCH Mare sure the starter moror is installed before insra/i‘mg me srarrer idle gear and sna/r STARTER CLUTCH Install the pressure plate. lnsrali the clinch springs and spring bolts. Tighten the bolts to The specified torque in a criss- cross pattern in two to three steps. TORQUE: 12 N-m (1.2 kgfvm, 5 Ibf‘ft) lnsiall the sraner idle gear and shah. Install the right crankcase cover (page 1073:“. REMOVAL Remove the clutch (page 1016). Remove lhe starter reduction gear from the crank- case. Temporarily insrali the primary driven gear. Insert the gear holder between the primary drive and driven gear as shown TOOL: Gear holder. M25 07724-001010!) or 07724-00‘1A100 (U.S.A. only) Remove the starter clutch outer special bolr and ‘ washer. ‘ Remove me temporarily installed parts, Hemove ine sianer cluzch outer assembly. 0‘ , _ _.. a ' STARTER CLUTCH OUTER ASSEMBLY I 10-28 Contents Chapter 10 CLUTCH/ STARTER CLUTCH Remove the thrust washer. INSPECTION Check the operation of the onerway clutch by turn ing me driven gearr You shou‘d be able to turn the driven gear clockr wlse smomhlv, but the gear should not turn coun- rerclockwise. DISASSEMBLY Remove the starter driven gear by turning it coun- lerclockw'xse. Remove xhe needle bearing. Remove the snap ring and one-way clutch. Check the starter clumh ouker inner surface and one- way clutch [or abnormal wear or damage and replace them if necessary, STARTER CLUTCH OUTER ONE-WAY CLUTCH Contents Chapter 10 10-29 CLUTCH/STARTER CLUTCH Check the starter driven gear for abnormal wear or damage. Measure the starter driven gear boss OD. SERVICE LIMIT: 45.642 mm “1969 in) Check the starter reduction gear for wear or damage and replace it i| necessary STARTER REDUCTION GEAR Check the starter idle gear and shaft for wear or damage, replace them if necessary. SERVICE LIMITS: Shah O D ‘998 mm (0.333 in) Gear I. 10.05 mm (0395 in) ”'30 Contents Chapter 10 CLUTCH/STARTER CLUTCH ASSEMBLY STARTER DRIVEN GEAR SNAP HING STARTER CLUTCH OUTER NEEDLE BEARING a ONEWAV CLUTCH Apply on to the onerwav clutch Install the one-way clutch into the starter dutch outer with its identification mark (white paint) facing out. IDENTIFlCATION ONE-WAV CLUTCH MARK STARTER CLUTCH OUTER Install the snap ring into the starter dutch outer groove securely. SNAP RING ONE-WAY CLUTCH Contents Chapter 10 10-31 CLUTCH/STARTER CLUTCH lnstalt the starter driven gear into the starter Clutch outer Whlle turning the starter driven gear clocks wise STARTER DRIVEN GEAR tnstall the needle bearing NEEDLE BEARING Recheck the one-way clutch operation (page 10-25». INSTALLATION Install the thrust washer tnFo the crankshaft. 5 THRUST WASHER Instatl the starter clutch outer assembly into the crankshah white ahgning the Wlde teeth of the crankshaft and the starter clutch assemblve 1032 Contents Chapter 10 CLUTCH/STARTER CLUTCH Apply oil to the starter clutch outer special bolt threads and sealing surface Install the washer and starter clutch outer special bolt. Temporarily install the Following: — Oil pump drive gear guide - Oil pump drive gear - Clutch outer — Clutch outer guide — Clutch outer needle bearing Be Caren/Motto Attach the gear holder between the primary drive drug rhe gear gear and driven gear. miner into me TOOL: [JG “3” 555 Gear holder.M2.5 0772441010100 or o7724-ooiAiou lu,s.A. only) Tighten the starter clutch special bolt to the speci- ‘ fied torque. TORQUE: a: N-m (3.5 kghn. 51 let) Remove the temporarily installed parts. Apply molybdenum Dll soluliorl to the starter redue lion gear sliding surface. install the starter reduction gear into the crankcase, Install the clutch lpage10»24). STARTER REDUCTION GEAR Contents Chapter 10 10-33 CLUTCH/STARTER CLUTCH RIGHT CRANKCASE COVER INSTALLATION Apply sealant to the mating surface of me rlgm ' crankcase cover. Install the two dowel Dinsv Install the wave washer and thrust washer onto the starter ldle gear, Install the right crankcase cover whlle alignlng the starter 'ldle gear shaft and reduction gear shaft with the holes in me right crankcase cover, then allgn the dowel Dlns with the cover holes. Install the wire clamps and right crankcase cover bolls, Tlghlen the right crankcase cover bolts crlsscross pattern in two or three steps. ”'34 Contents Chapter 10 CLUTCH/STARTER CLUTCH Connect the crankshaft position sensor 2F (Red) connectorv Add the recommended engine oil (page 4-22). \ns‘all the middle cow‘s/under cowls (page 377). Contents Chapter 10 10-35 MEMO Contents Chapter 10 1 1. ALTERNATOR COMPONENT LOCATION ........................... 11.2 STATOR ........................................................ 11.4 SERVICE INFORMATION ........................... 11.3 FLYWHEEL ................................................... 11.5 ALTERNATOR COVER REMOVAL-v 11-4 ALTERNATOR COVER INSTALLATION ------ 11-7 Contents Chapter 11 "'1 ALTERNATOR COMPONENT LOCATION ‘ 12Nm(12kgfm 9 lbfvft) 12 Mr“ (1.2 kgf-ml 9 lbi-h) 103 N-m “0.5 kgf-m, 76 Ibf-ft) Chapter 11 Contents 11-2 ALTERNATOR SERVICE INFORMATION GENERAL I This section covers sen/Ice of the ailernamr stamr and flywheei, All service can be done with the engine installed in the flame. - Refer [a procedures for aliernalor stamr inspection (page 178). - Refer to procedures for slaner motor sewlcing (page 13-6). TORQUE VALUES Stator wlre clamp flange boll Flywheel flange bolt Stator mounting socket bolt 12 N-m (1‘2 kgf-m, 8 lbfft) 103 Mm (105 kgfrm, 76 lbfrftl Appiy oil lo the threads 12 N-m ll.2 kgf-m, 9 lbr-m TOOLS Flywheel holder ‘ Razor puller 070MB~MELClOO 077330020001 ‘ i ‘ Dr 07333-3950000 [U.S,A. only] Contents Chapter 11 11-3 ALTERNATOR ALTERNATORCOVERREMOVAL R tn :1 l / l - . emuve e un er cow 5 mldd e cowls (page 3 7] SP (WHITE) CONNECTOR Disconnect the alternator 3P (Whitel connector. . The alternator cover Remove the alternator cover SH bolts and alternator (stator) lS magnellr cover. Cally attracted to the flywheel, be ease-m durmg removal - Engme oil will run out when the altematar cover is removed. Set a clean all pan under the engine and add the recommended oil to the specified level after installation. Remove the dowel pl n5. Clean off any sealant from the rlght crankcase Cover matlng surfaces. STATOR REMOVAL Remove the bolt and stator wire clamp. Remove the alternator wire grommet from the alter SOCKET BOLTS BOLT nator COVEI’. Remove the socket bolts and stator. {‘4 . . GROMMET WIRE CLAMP STATO R 11-4 Contents Chapter 11 ALTERNATOR INSTALLATION WIRE CLAMP 12 N-m (1.2 kgf-m, 9 [bl-ft) ALTERNATOR COVER / \I t' >. STATOR \ ‘12 N‘m (1.2 kgf-m, 9 lbf'fil Install the stator into the alternator cover. SOCKET BOLTS Apply sealant to the wire grommet, then install the wire grommet into the alternator cover groove securely. Install and tighten the socket bolts to the specified torque. TORQUE: 12 N»m (1.2 kglvm. 9 lbl-hl install the wire clamp and tighten the flange bolt to the specified torque. TORQUE: 12 N"! (1.2 kghn, 9 [M40 GROMMET WIRE CLAMP STATOR FLYWH EEL REMOVAL Remove the alternator cover (page 11-4l. Hold the flywheel using the speclal tool. then remove the flywheel bolt. TOOL: Flywheel holder D7OMB-MELC1DO Remove the washer. Contents Chapter 11 ALTERNATOR Remove the flywheel using the speclal tool. TOOL: Rotor puller 07733-0020001 ur 07933-3950000 (USA. only) INSTALLATION Clean any oil from the crankshaft taper Install the flywheel. Apply oil to the flywheel bolt threads and seating surface Install the washer and flywheel bolt. Hold the flywheel using the special zool, then tighten the boluo the speclfied torque. TOOL: Flywheel holder 070MB-MELC1OO TORQUE: 103 N-m (10,5 kgf-m, 76 Ith] 1 _ 1 6 Contents Chapter 11 ALTERNATOR COVER INSTALLATION Apply a sealam to me mating surface oi the alterna- ‘ \ (or cover. InstaH the dowel pins. Th9 a/fiemara' cover Install the a‘ternator cover. Install and tighxen the SH bolls securely :nsra/‘anon Connect me alternator 3P Iwmet connecmr. InstaH the under cowls/mfddle cowls1page 3-7). '3 ALTERNATOR M‘A ( o //“\M\\// ‘ F) x" “w \ 1 3‘ > f, l L f \ Contents Chapter 11 11-7 MEMO Contents Chapter 11 12. TRANSMISSION/GEARSHIFT LINKAGE COMPONENT LOCATION ........................ 12.2 GEARSHIFT spINDLEW.,.‘..‘..‘.m,...u..‘.,...,.,12.7 SERVICE INFORMATION -------------------------- 12—4 TRANSMISSION ---------------------------------------- 12-11 TROUBLESHOOTING 12.5 Contents Chapter 12 12'1 TRANSMISSION/GEARSHIFT LINKAGE COMPONENT LOCATION 9.8 N-m (1,0 kgf-m, 7 \bf‘fl) 54 N m [5.5 kgf m, 40 [bf M 12'2 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE 29 N-m (3.0 kgf‘m, 22 Ibf-f‘) 12-3 Chapter 12 Contents TRANSMISSION/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL . fThis section covers the transmission and gearshift linkage sen/Ice. These service can be done engine installed in the rame. SPECIFICATIONS Unit: mm (in) 7 ITEM ' """ STANDARD SERVICE UMIT Shirt fork 1.13. " “12.000 712.019(0.4724 7 0.4731) 120310.474) Claw thickness 1 5.93 , 6.0010233 , 0.236) 5.9 (0.23) isflift fork shaft OD. 7 1 11.957 —11.968(0.4707 — 0.4712) 11.95 (0.47017 Transmission Gearl.D. M5, M6 1 31000—31025(12205—12215) 3104(1222) #131 . 29000—29021 (1.1024_ 1.1032) . 23.04 (1.104) g 62, 03. 04 33.000 — 33.025 (1.2992 — 1.3002) 33.04 (1301) Gear busing 0.0, M5, M6 30.955 — 30.990 (1.2187 — .2197) 30935 (1.21779) 1 1:2 '73235; 2590' (1.2974 2904) 32 935(— 967) l elicit, " 32950—32975 (1.2972— .2933) " ’ 32930112964) Gear-to-bushirlg M5, MB 0020 _ 0.070 [0.0008 - 0.0020) 0.1010004) , _, ‘ clearance 02 0.020 , 0.070 (0.0009 , 0.0029) 0.10 (0.0047 ' l cs, 04 . 0.025 — 0.075 (0.0010 — 0.0030) 0.11 (0.004) ‘ ‘ Gear bushing 10. 1 M5 W 77 .' '27‘9’9’5 — 29.005111012311026) 28.016 (1.1030) 7 7 77777 if i (:2 r 29 985730.006 [1.10187 . 30.02] (117919144 Mainshaft 0.0. l at M5 21967721980 (1.1011 , 1.1016) 27.957 (1.1007) Countershaft 0.0. i at (:2 29.967 2 29.930 (1.1799 —1.1803I 29.960 (1.1795) Bushing to shaft l M5 0005 — 0.039 (0.0002 — 0.0015) 0.06 (0.002) clearance . C: 0.005 — 0039100002 _ 0.0015) 011610.002] TORQUE VALUES Transmission holder flange bolt Bearing set plate bolt Shift drum center socket bolt Shift drur'rl stopper arm pivot bolt Gearshift spindle return spring pin Shift drum bolt/washer Shift drum stepper plate flange oolt Drive sprocket special bolt Gearshift pedal pivot bolt Gearshift pedal link pinch bolt Link arm lock nut 29 N«m (3.0 kgf-rrl, 22 Ibf‘ft) 12 N~m (1.2 kgf-m, 9 (bf-(I) 23 N~m [2.3 kgfvrn, 'l7 lbftfl) 12 N‘m (1.2 kgrm. 9 lbi-ft) 23 N-rn (2.3 kgfvm.17|bI-ft) 12 N-m (1.2 kgf-m, 9 lbtft) 12 N-m (1.2 kgf-rn, 9 lbf-(t) 54 Nam (5.5 kgfrm, 40 let) 25 N-m (2.7 kgf~m, 20 ibl'fl) 5.8 N-m (1.0 kgf-m, 7 lbf-fti 9.8 N-m (1.0 kgf-m, 7 (bi-hi Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads 12-4 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE TOOLS Bearing remuver handle 079366710100 Bearing remover set, 20 mm 079366710600 Remover weight 0774143010201 or 079367371020A (U.S.A. only) Driver 077490010000 Anachment, 42 x 47 mm 07746-0010300 Attachmem, 52 X 55 mm 07746-001040!) ‘//\ r ,9 a r Attachment, 62 x 68 mm \ 0774670010500 Attachment, 42 x 47 mm 077450010300 Film, 20 mm 0774570040500 Film, 25 mm 07746-004060!) Pilot] 28 mm 07746-0041100 Contents Chapter 12 12-5 TRANSMISSION/GEARSHIFT LINKAGE TROUBLESHOOTING Hard to shin - Improper clutch operation Incorrect engine oil weignr Bent shift fork Bent shift fork shaft Bent shift fork claw Damaged shin drum cam groove Bent gearshift spindle Transmission jumps am or gear Worn gear dogs Worn gear shifter groove Ben| shift fork shah Broken shift drum sropper arm Broken shift drum stopper arm spring Warn or bent shift forks Broken gearshift spindle return spring Excessive engine naise - Worn or damaged transmission gear - Worn or damaged xransmission bearings 126 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE GEARSHIFT SPINDLE REMOVAL Remove the pinch bolt and disconnect the gear snm ' arm 1mm lhe gear shift spind‘e. P‘NCH BTOL ' Jr GEASH'FT Mb ,, \ ‘ x37 $7. 5.5“ m ' , 1 E 4"» V V 1 Remove me clutch slave cylinder (page 1013). Remove lhe bohs and }efl crankcase rear covere Remove me gasket, gurde plate and dowel pins. INS Loosen the rear ax‘e nut. Turn (he dnva chain adjusting bolts make the drive chain s‘ackfullyr Remove me drive sprockel specia‘ boll, washer and drive sprocket. 12—7 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE Remove the baits and gearshift linkage cover. Remove the gasket and dowel pinst . 4 — GASKET Remove the gearshift spindle and washer: GEARSHIFT SPlNDLE _. INSPECTION Check the gearshift spindle for wear, damage or bends. Check the return spring for fatigue or damage, if the snap rings are removed, install them with their chamfered side facing the thrust washers. GEARSHiFF SPINDLE RETURN SPRING 128 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE Check the dust seal for wear or damage. Check the needle bearing for wear or damage, DUST SEAL EEDLE BeARlNGi INSTALLATION insiaii the gearshift spindle and washers. Install a dowel pins and new gasket GASKET Install the gearshift linkage cover being careful no! to damage the all seal lips. App/ya locking install and tig hlen the linkage cover bolts. agent to me (Heads of {he bu’r truncated Contents Chapter 12 12-9 TRANSMISSION/GEARSHIFT LINKAGE Install the drlve sprocket with lls mark facing out. WASHER Install \he washer and speclal boll, tl'ghten lhe spe- cial bolt to (he specified torque. TORQUE: 54 N-m [5.5 kgf-m, 4D Ibf-ft) lnsrall me dowel pins, gulde plate and newgasket. ii a? GAKET V ‘ ~v :v;,\\\~ \ a l gm.» DOWEL PlN Install the left crankcase rear cover and llgmen the ‘ E REAR CQVER mounting bolls. . Install the clumh slave cylinder {page 10-13), lnstall the gearshift arm to (he gearshift spindle, , whlle allgnlng ms slit with the punch mark omo the spindlev lnslall lhe gearshlfi arm to the gearshift spindle, llgmen the pinch bolt. TORQUE: 9V3 N-n’l (140 kgf'm, 7 Ibf‘fl) 12—10 Contents Chapter 12 TRANSMISSION/GEARSHIFF LINKAGE If the gearshifi pedal has been removed, install the washer. gearshift pedal and pivot bolt onto the frame. Tighten the pivot bolt to the specified torque TORQUE: 26 MI“ (2.7 kgf—m, 20 let) TRANSMISSION REMOVAL Remove the following; , Right crankcase cover (page 10715) — Clutch [page 10-16) , oil pump drive sprockeUchain/driven sprocket (page 10-19) , Drive sprocket (page 12»7) REDISCE ‘he mans. Remove the transmission bearing holder mounting missian bearing bolts, homer and crank case as a ser Be careru/norro mu Pull out the bearing holder/transmission assembly the or» arms mm from the crankcase, mo mnrcasa Remove the dowel puns and all orificet DISASSEMBLY Remove the shift fork shafts and shift forks. Contents Chapter 12 TRANSMISSION/GEARSHIFI' LINKAGE Remove the mainshafl and countershah assemb‘v. MAINSHAFT/COUNTERSHAFT Remove me socket boll, stopper arm, remrn spring and washer. Remove the gearshift cam bolt. Remove the gearshift cam and dowel pins, GEARSHIFT CAM FLANGE COLLAR Remove the flange cul \ar. 12- 12 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE Remuve the shift drum from the bearing holder. SHlFT DRUM Disassemble the mainshafl and countershaft assembly. COUNTERSHAFI MAINSHAFF INSPECTION Check the shift fork guide pin for abnormal wear or damage Measure the shift fork |.D. SERVICE LIMIT: 12.03 mm (0.474 in) Measure the shift fork claw thickness SERVICE LIMIT: 5.!) mm (0.23 in) Measure the shift fnrk shaft OD, SERVICE LIMIT: 1135 mm (0.470 in) Contents Chapter 12 12-13 TRANSMISSION/GEARSHIFT LINKAGE Turn the outer race of the shlft drum bearing wlIh your finger. The bearlng should turn smootth and freely with out excessl've play. If necessary replace the bearlng. Inspect the shm drurrl guide grooves for abnormal wear or damage. Check the gear dogs, dog holes and teeth for abnor- mal wear at leek or lubrlcation, Measure the lot of each gearv SERVICE LIMITS: M5, MB: 31.04 mm (1.222 In] C1: 28.04 mm (1.104 in) 02, CS. 54:3104 mm “301 in) Measure the OD. of each gear bushing SERVICE LIMITS: M5, M6: 30,935 mm (1.2179 in) C2: 32.935 mm (1.2967 in} C3, C4: 32.930 mm (1.2964 in} Measure the LB. or each gear bushing. SERVICE LIMITS: M5: 281116 mm (1.1030 in) CZ: 29.960 mm (1.1795 in) CaIcuIate the gearrmrbushing clearance. SERVICE LIMITS: M5, MS: 0.10 mm [0.004 in) CZ: 010 mm [0.004 in) C3, C4: 011 mm (0,004 in) 12'” Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE Check the gear shifter groove for abnormal wear or damage. Check the mainshafl and countershafl for abnormal wearer damage. Measure Ihe mainshafl OD, at the M5 gear. SERVICE LIMIT: 27.957 mm (1.1007 in) Measure the countershaft 0.0. at the C2 gear. SERVICE LIMIT: 29.950 mm (1.1795 in) Calculate the gear bushing-torshah clearance. SERVICE LIMITS: MS: 0.06 mm (0.002 in) c2: 0.06 mm (0.002 in) Turn the outer race uf each transmission bearlng with yourIinger, The bearing should rurn smoothly and freely with our excessive play. If necessary replace the bearlng, TRANSMISSION BEARING REPLACEMENT Replace me trans Remove the bolts and shift drum bearing set plates. mrsslon bearmg holds-rand crank- case as 3 Se! Remove ‘he bolts and mainshah bearing set plate Contents Chapter 12 1245 TRANSMISSION/GEARSHIFI' LINKAGE Remove the bolt and mu ntershaft bearing set plate. Remove the countershaft bearing using the special tools. TOOLS: Belting vemover handle 07936-3710100 Bearing mmovar set 079364710600 Remover weight 077410010201 or 07536-371020A (USA. only) Drive out the countershafl bearing and shift drum bearing. Bearing Locations MA‘NSHAFT BEARING SHIFT DRUM BEARING COUNTERSHAFT BEARING : ”'16 Contents Chapter 12 TRANSMISSION/GEARSHIFI' LINKAGE Drive each bearing into the bearing holder using the ‘ , t ' ‘ ““ " “v' special tools 3 ' ' DRIVER TOOLS: Mninshafi bearing: Driver 07749-0010000 Attachment, 62 x 68 mm o7745-omosoo Pilot, 23 mm 0774641041100 Countershaft bearing: Driver 0774941010000 Attachment, 52 X 55 mm 07746-0010400 Pilot, 2!) mm 077450040500 Shift drum bearing: Driver 07749-0010000 Attachment, 42 X 47 mm 0774641010300 Pilot, 25 mm 0774641040600 Apply a locking agent to the cnuntershaft bearing set plate bolt threads. Install the set plate and tighten the bolt to the speci fied torque. TORQUE: 12 Nrm (1.2 kgf-m, 9 lbl-ft) Apply a locking agent to the malnshatt bearing set plate bolt threads and shift drum bearing set plate bolt threads. Install the mainshaft bearing set plate with its "MEL OUTSIDE" mark facing out. Install and tighten the bearing set plate bolts to the . specified torque. TORQUE: 12 N-m (1.2 kgftm, 9 Ibf-fl) Om Contents Chapter 12 12'" TRANSMISSION/GEARSHIFT LINKAGE ASSEMBLY Mainshafl: M2 GEAR (171') M6 GEAR (25T) M4/3 GEAR IZ1/19T) M5 GEAR (ZOT) MAINSHAFT/M1 GEAR (1ST) Countershaft: C4 GEAR (ZST) C5 GEAR (251') C1 GEAR (321T) C2 GEAR (33T) C5 GEAR (ZST) C3 GEAR BUT) COUNTERSHAFT ”'18 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE Coat each gear with clean engine oil and check for smooth movemeni. OIL HOLES Assembie [he vansmission gear and shafls - Aiways instaH the thrust washer and snap ring with Ihe chamfered (roiled) edge facing away from the lhrus‘ load. lnstali me snap ring so mat its end gap aligns with the groove in the splines . I Make sure that ‘he snap ring Is quy seated in the W- shaft groove after insiaiiing iL Align the oil holes beiween Khe shah, gear and col- | OIL HOLES er. Contents Chapter 12 12-19 TRANSMISSION/GEARSHIFT LINKAGE Align the lock washer tabs with the spline washer grooves SPUNE WASHER Apply molybdenum ml solution to the shift fork grooves In the M3, 04 and c5 gear. 7E COUNTEHSHAFF ASSEMBLY MAINSHAFT ASSEMBLY ‘u a \ 7 '- / COLLAR BEARING HOLDER GEARSHIFT CAM STOPFER ARM ”'20 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE Install the shift drum into the bearing holder. SHIFT DRUM Install the flange collar with it flange facing in. Install the dowel pins onto the gearshll‘t cam. Install the gearshlfi cam onto the gearshlfl drum. GEARSHIFT CAM Apply a locking agent to the shift drum cam flange bolt threads. Tighten the bolt securely. ‘iGlEARS'HIiFl' CAM Contents Chapter 12 12-21 TRANSMISSION/GEARSHIFT LINKAGE Install the followmg: — Washer — Return spring — Stopper arm » Pivot bolt Tighten the stopper arm pivot bolt to the specified torque, TORQUE: 12 N-m (1‘2 kgf-m, 9 lbf-ft) SCKET BOLT Install the mainshaft and countershaft as an assem- v blvta the bearing holder. MAlNSHAFl/COUNTERSHAFT The shift forks have locatlon marks: — “RL” for right and left — “C" for center lDENTIFlCATION MARKS Install the shift lurks mm the shift drum guide groove with the identification marks lacing up. SH'” FORK SHAFTS ”'22 Contents Chapter 12 TRANSMISSION/GEARSHIFT LINKAGE INSTALLATION Install me oil oriiice with its small LD. side facing in Install the dowel pins. Turn the shift drum while turning the mainshan, position the transmission lnlo neutral install the bearing holder/transmission assembly mm the crankcase, BEARING HOLDER/TRAN ' mm—a—fi install and tighten (he bearing nulder moumlng bolls to the specified torquel TORQUE: 29 N!" (3.0 kgf—m, 22 Ibf-ft] Install the following: — Drive sprocket [page 12-9) , Clutch (page 10-16l — Right crankcase cover lpage 10734) Contents Chapter 12 12-23 MEMO Contents Chapter 12 13. CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER COMPONENT LOCATION‘---~----v-----u----v----13-2 SERVICE INFORMATION ........................ 13.3 TROUBLESHOOTING ................................ 134 CRANKCASE SEPARATION ----------------------- 13-5 CRANKSHAFT .......................................... 13.7 MAIN JOURNAL BEARING ......................... 13.9 CRANKPIN BEARING ................................ 13.12 PISTON/CYLINDER ................................... 13.15 CRANKCASE ASSEMBLY 13-21 BALANCER ............................................. 13.23 Contents Chapter 13 13-1 ORANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER COMPONENT LOCATION + 150° 20 N-m (2.0 kgf-m,14|bf-ft] 20 N-rn (2.0 Kgfm, 14 [bf-ft) + 90° N M 7 m ,W k A R m N 4 2 Chapter 13 Contents 24 N>m12 4 kgf‘m. 17 lbf~m 13-2 CRANKCASE/CRANKSHAFI'IBALANCERIPISTON/CYLINDER SERVICE INFORMATION GENERAL The crankcase must be separated to service the following: , Crankshah (page 13-7) 2 Piston/connecting rod/cylinder (page 1345) I The following components must be removed before separating the crankcase: - Engine (page 8-4) - Clutch (page 1016) 7 Cylinder head (page 5'13) — Flywheel (page 'l‘lv5l — Gearshirt linkage/transmission (page 12-11) — Oil pan (page 5-6), oil pump (page 5-8) and oil cooler (page 5-13) — Starter clutch (page 10-28) » Starter motor (page 19-6) — Water pump (page 7.17) Replace the crankcase and transmission bearing holder as an assembly. Be careful not to damage the crankcase mating surfaces when servicing. Prior to assembling the crankcase halves, applv sealant to their mating surfaces. Wipe off excess sealant thoroughly. The crankcase must be separated to seerce the crankshaft. cylinder and piston/connecting rod. Refer to procedures for crankcase separation (page 13-5) and assembly (page 13-21). - Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassems bly, - The crankpin and main journal bearing inserts are select it and are identified by color codes. Select rep1acement bear— ings from the code tables. After selecting new bearings) recheck the oil clearance with a plastigauge. Incorrect oil clear- ance can cause major engine damage. I Clean the oil jets in the upper crankcase with compressed air before installing the pistons SPECIFICATIONS Unir mm (in) F ITEM 7) STANDARD SERVICE LIMIT Crankshaft Connecting rod side clearance 7_ ( ‘ 0.05 50.20 (0.002 — 0.008) 0.25 (0.090) Crankpln bearing oil clearance ‘ 0.030: 052 (0.0012 — 0.0020) 0.06 (0.002) Main journal bearing oil clearance 1 0.019 _ 0.037 (0.0007 — 0.0015) 0 05 (0.002) :77 Runout ' e ' '1 0.05 (0.002) 1 Piston, piston Piston o D, at 4.0 (0.15) (torn bots 74.960 — 74930129512 , 2.9520) 74.095 (2.9486) rings tern (flaiston pin here I D. 17.002 — 17008 (0 6694 - 0.0696) '— 17030 (0.6705) 1 . Piston pin 0.0. 10.094 — 17.000 (0.6690 — 0.6693) 16.980 (0.6685) Piston ' 7" ' . W 014(00001 — 0.0006) 0.04 (0.002) 1 Piston rlng end 7 ' ’ 0.22 — 0. 2 (0.009 —0.013) 0.52 (0.020) gal: 0.43—0.63 (0010—0025) 0.02 (0.032) ' 0.2 e 0.7 (0.01 e 0.03) ' ' 'i ‘ 10 (0 04) W . (side rail) 7 ‘Pi'sten ringing-ring Top 0.050 — 0.005 (0.0020 - 0.0033) g > 0.125 (0.0049) " groovejlearance ’ Second 1 0.015 — 0.050 (0.0006 — 0.0020) 1 0.075 (0.0030) 7. Cylinder (.0 75000—75015(23528—29533) 75.15 (2.959) Out of round ’ _ 0.10 (0.004) Taperr ’ ' _ 0.10 (0.004) Warpage W . .7 — 7 0.10 (0.004) . Cylinderioyflon clearance 0.020 2 0.055 (00000“— 0.0022) 0.10 (0.004) Connecting rod small end LD. 17.030 717.042(0.s705 7 0.57051) 17.048 (0.6712) Connecting rodstospiston pin clearance ( 0.030 — 0.046 (0.0012 - 0.0018) _ 0.07 (0.003), . Contents Chapter 13 13'3 CRANKCASE/CRANKSHAFI'IBALANCER/PlSTON/CYLINDER TORQUE VALUES Crankcase 7 mm bolt 18 N-m (1.8 kgf-rn,13|bf~ft) 8 mm bolt 24 N-m (2A kgfrm,17|bf~ft) 9 mm boll (main Journal bolt} See page 1321 Apply oil to the threads and seating surface Lower crankcase sealing bolt 59 N-m (5.0 kgf-m, 43 [bf-ft) Apply a locking agent in the rhreads Lower crankcase socket bolt 12 N-m [1V2 kgl-m, e lbi-ft) Apply a locking agent to the threads Lower crankcase sealing bolt 29 N-m [3‘0 kgfm, 22 lbi-ft) Apply a locking agent to the threads Lower crankcase socket bolt 23 N-rrl [2.3 kgf~m, 17 lbf~ftl Apply a locking agent to the threads Connecting rod bolt lrlew boltl See page 13-8 Apply oil to the threads and seating surface Connecting rod halt (retightening) See page 1342 Apply oil to the threads and seating surface TROUBLESHOOTING Cylinder compression is too low, hard to starting or poor performance at low speed ~ Leaking cylinder head gasket - wdrn, stuck or broken piston ring - wdrn or damaged cylinder and pision Cylinder cnmpression the high, overheating or knocking - Excessive carbon built-up on piston head or combusrion chamber Excessive smoke - Worn cylinder, piston or pisrdn ring - Improper installation of piston rings - Scored or scratched piston or cylinder wall Abnormal noise - Worn piston pin or piston pin hole - Worn connecting rod small and . Worn cylinder, piston or piston rings - wdrn main Journal bearings ' Worn crankpln bearings Engine vibration I Excessive crankshaft runout ' Incorrect balancer timing 13'4 Contents Chapter 13 CRANKCASE/CRANKSHAFr/BALANCER/PISTON/CYLINDER CRANKCASE SEPARATION Refer to Service Information See page 13-3 for removal of necessary pans before separating the crankcase. OIL PRESSURE SWITCH ’ Remove the terminal screw and wrminal eyelet from the oil pressure switch‘ Disconnect the neu‘ral switch connector, then .— remove the engine sub-harness. “UTHAL SWITEH ! Remove the bolts, water hose joint and Orring. WATER HOSE J0” ./ Remove the bolts, uil inspemion window and Orring “Kai-T5" from the crankcase‘ ‘ OIL INSPECTION WINDOW K A =_.._k~ w—a Contents Chapter 13 1 3'5 CRAN KCAS E/CRANKSHAFT/BALANCER/PlSTON/CYLINDER Loosen the 7 mm bolts (5in and Sealing washer in two to three steps. 8 mm BOLTS Loosen the 8 mm bolts (five) ln two to three steps. Remove the 8 mm bolts, 7 mm bolts and sealing washer. Place the engine upside down. Lonsen the 8 mm bolt and 7 mm bolts (slx) in a crisscross pattern in two to three steps. Loosen the 9 mm bolts (maln journal bolts) in a criss-cross pattern in two to three steps, then remove the bolts 7 mm BOLTS 9 mm BOLTS Separate the lower crankcase from the upper crank» ease. 5mm BOLTS Remove the three dowel pins and two oll arlfices. Clean any sealant off from the crankcase mating surface. Remove the mainsheft bearing and clutch lifter rod FM oil seal from the upper crankcase. ,HINSHNEEAWG ‘ 13-6 Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER CRANKSHAFT SIDE CLEARANCE INSPECTION Separate the crankcase halves lpage 135). MeaEure the connecting rod side clearance. SERVICE LIMIT: 0.25 mm (0.093 in) If the clearance exceeds the service limit] replace the connecting rod. Recheck and if still out of limit, replace the crank shah. REMOVAL Before removal, position all the pistons at TDC (Top Dead Center) to prevent damaging the crankpin with the connecting rod. Mark the bearing caps and bearings as you remove them to indicate the correct cylinder for reassemblyv Remove the connecting rod bearing cap bolts and bearing caps. Tap the side oi the cap lightly if the bearing cap is hard to remove. Position all the pistons at TDC (Top Dead Center), then remuve the crankshaft. Remove the main journal bearings from both the crankcase halves. Contents Chapter 13 13'7 CRANKCASE/CRANKSHAFI'IBALANCER/PlSTON/CYLINDER INSPECTION Support the crankshaft on both and journals. Set a diai gauge on the center main journaI of the crankshaft. Rotate the crankshaft two revolutions and read the runoutt SERVICE LIMIT: 0‘05 mm (0.002 in) MEASURE POINT Check the primary drive gear teeth for abnormal wear or damage. INSTALLATION Apply molybdenum oil solution is the main Journal bearing sliding surfaces on the upper crankcase and the crankpln bearing SIIdIrlg suriaees on the cone nectlng rods. The Dearll‘rgiabs install the main journal bearings into the upper shop/abs airgnea crankcase. With the gloove: in the mankcase Apply molybdenum oil solution to the thrust sure faces of the crankshaft as shown. Pnsirion all the pistons at TDC (Tap Dead Center) 20 prevent damaging the crankpin with the connecting rod. Install the crankshaft onto the upper crankcase. Set the connecting rods onto the crankpins. Apply molybdenum oil sqution to the crankan bearing siiding surfaces on the connecting rod hear- ing caps. InstaIl the connecting rod bearing Caps, aligning the dowei pins with the hoies in the connecting rods. Be sure each pen is installed 'in its original position, as noted during removal. 13-8 Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER The connemlngmu AppIy oil m new cennectlng rod bearing cap bolt 7“ bolts cannalbe threads and seallng surfaces, and install lhe bolls. @ reused Once the umlllecllllg rad bolts have been ioosened ’EDlaL‘e them mm new ones Tlghten the bolts ln two or three steps ellernately, u then tighten the bolts to the specified torque. , TORQUE: 20 N-m (2.0 kgi-m.14lbf»hl Further tighten the connecting rod bearing Cap boIts 90 degrees. Assemble Xhe upper and lower crankcase (page 13- . 21). MAIN JOURNAL BEARING Do not interchange the bearing inserts. They must be installed in their original /ocan‘ans or the correct bearing Oil clearance may n0! be obtained, resulting in engine damage. Remove the crankshaft (page 1377). BEARING INSPECTION Inspect me main IDUI’HBI bearing means on the upper and lower crankcase halves for unusual wear or peeling, Check the bearing tabs fur damage. .375? MAIN JOURNAL BEARINGS Contents Chapter 13 13-9 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER OIL CLEARANCE INSPECTION Clean off any oil lrorn the bearing inserts and main juurnals. Install the crankshaft Onto the upper crankcase. Put a strip of plasrlgauge lengthwise on each main iournal avoiding the oil hole. PLASTIGAUGE ' Do not rotate the crankshaft during inspection. lnstall the lower crankcase onto the upper crank- case, then install the crankcase 9 mm bolls (main Journal bolts)‘ Tighten the 9 mm bolts in numerical order to the specified torque. TORQUE: 20 N-m (2.0 kgf-m, 14 Ibf-ft) Further tighten the 9 mm bolts 150 degrees Remove the crankcase 9 mm bolts (main journal bolls) and lower crankcase, measure the comr pressed ulastigauge at its widest point on each main journal to determine the oil clearance. SERVICE LIMIT: 0.05 mm “1002 in) II the oil clearance exceeds the service limit, select a replacement bearing. 1340 Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER LenerslA. 5mm BEARING SELECTION W ”WWW” Renard the crankcase bearmg support 1.0. code ls:- WWW/311K557? Iers from the pad on the left side of the upper crankr are We codes mv case ES Show...» rhe oeenwg 51477 par: l 0.5 *rom Ier’r to war. Mlmhe'sfl 20,31 Record the correspondmg mam journal 0.1:. code 0.11119 Dank welgnl numbers from me crank weigh‘. O D s «we e": w 'lgm‘ MAIN JOURNAL DD. CODE WWW Cross reference the mam journal and bearing sup port codes to determine the replacemem bearing color code. MAIN JOURNAL BEARING SELECTION TABLE: I 7 BEARING suppommpoue A B c 73 37.000 — 3700?; mm 37006 — Q7012 mm 37.012 —37.o10 mm (1.4567 71.4569 in) (1.4558 _1_4572 inI (1.4572 71.4574th 34 000 - 34.005 mm ‘ ‘MAINJOURNAL 0,0, CODE 1 11.337357133313191, “9" I . Pin}: .il .Yfilkfwi 33394734000 mm . f . 12 (1.3383— 1.3385 1m P‘fi . fllow iGreen ‘ I 33 SEE r 33,994 mm 1 1 (1.3381 713383111) 1 . Ye“°"" Glee" Brown I BEARING THICKNESS: IDENTIFICATION COLOR Brawn: Thickes: Green: Yellow: 1 Pink: Red: Thinnest After selecting new bearings, recheck the clearance . mm a plastigauge. Incorrect clearance can cause severe englne damage, Contents Chapter 13 13'1 1 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER BEARING INSTALLATION Clean the bearing outer surtaces and crankcase bearing supports Apply molybdenum DII solutlon to the maln Journal bearing sliding surfaces on the upper crankcase, Install the main journal bearing lnserts onto the crankcase beanng supports, alignlng each tabs with each grooves. MAIN JOURNAL EEAR‘INGS /‘ " CRANKPIN BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing ail clearance may not be obtained, resultlng in engine damage. Remove the crankshaft (page 137], BEARING INSPECTION Check the bearing inserts for unusual wear or peelr in . Check the beanng tabs for damage. OIL CLEARANCE INSPECTION Clean an any oil from the beanng lnserts and crank pms. Carefully instaII the crankshaft onto the upper crank- ease. Set the connecting rods onto the arankpins Put a strip at plastlgauge lenglhvwse on each crank- pin avoiding the oil hole. . Do not rotate the crankshaft durlng inspection, 13'” Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALA Carefully install the connecting rod bearing caps, V aligning the dowel pins with the holes in the con- necting rods. Liserhe removed Apply oil to the connecting rod bearing cap bolt cannecmg rod threads and seating surfaces and install the bolts. bmra' when chem Tighten the bolts in two or three steps alternately, mg the uric/esp then tighten the bolts tn the specified torque. me TORQUE: 14 N-m (1.4 kgf-m,10lbI-ft) Further tighten the connecting rod hearing cap bolts 'y ‘ 90 degrees. Remove the bearing caps and measure the com- pressed plastigauge at its widest point on the crank pin to determine the oil clearance. SERVICE LIMIT: 0.06 mm (0.002 in) II the oil clearance exceeds the service limit, select the correct replacement bearings. BEARING SELECTION Numbers (7 0r 2/ an Record the connecting rod l.D. code number (1 or 2) me connecrmgrods or measure the l.D. with the connecting rod bearing a'e me 50095 for cap installed without hearing inserts. ms corms-cm; mu lD letters lA ore) on If you are replacing the crankshaft, record the corre» we crankwergmare Spondlng crankpm 0.0. code letter lA or B). the codes ra— me- cranks/n O D s from ref! to rigr‘r If you are reusing the crankshaft, measure the crankpin 0.0. with a micrometer. Contents Chapter 13 13-13 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER Cross-rQIerence Ihe connecting rod and crankpin codes to demrmine xhe replacemem bearing color. CRANKPIN BEARING SELECTION TABLE: 39.500 — 39.506 mm (15551 4115554 in) T 2 CENNECTING ROD |.D.CODE 1 3 33.506 , 39.512‘ rnm'is'afsszésT~ 18 mm‘ (1.5554— 1.5556 in) (1.5556—115358inl 1 1 ICRANK PIN ”35.497 7 36,503 mm 1 O.D.CODE A I (1.4369 - 1,4371 in) YE”°"" Erie? Brown I 35.491 7 35.497 mm ‘3 (1.4357—1,43651n) G’ea" Bmw" ,, Lila“ ‘ c 367485 —36 491 mm Brown Black Blue (14364 v 14367 In) BEARING THICKNESS: Blue: Thickest Black: Brown: I Green: Yellow: Thinnest After selecting new bearings, recheck the clearance with a plastigauge. Incorrect clearance can cause severe engme damage, BEARING INSTALLATION Clean the bearing outer surfaces, connecfing rod bearfng cap and connecting rod. InstaII me crankpm bearlng Inserts onto 1115 hearing Cap and Connecfing r0d,aI1gning each lab 1mm each groove. IDENTIFICATION COLOR BEARINGS 13-14 Contents Chapter 13 ORANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER PISTON/CYLINDER Mam all pans as you 'er‘nave mm m lndlcafa the cm rec! CV/lnljer lar reassembly DD ”07 I f V [0 lemm/e me mm heating rod/plston assmvluly llon‘l [he opnom or me Cyllrl- del. Ills assembly Wl/l be locked so mat the all rlng expands m me gap vetween the L‘Wlnr tier liner and the upael crankcase PISTON/CONNECTING ROD REMOVAL - This motorcycle is equipped with aluminum cyla inder sleeves. Eefore piston removal, place a clean shop towel around the connecting rod to prevent damaging the cylinder sleeve. - Do not try to remove the piston/connecting rod assembly from bottom of the cyll'ndel‘,‘ the assembly Wl'll get stuck in the gap between the cylinder ll‘ner and the upper crankcase - Do not interchange the bearing inserts. They must be installed in thelr original locatl'uns or the correct hearing all clearance may not be obtained. resulting in engine damages Remove the bolts and connecting rod bearing caps Remove the piston/connecting rod assembly from , the top oflhe cylinder. PISTON REMOVAL Remove the piston pin clip w‘lth pliers Push me piston pin out at the pistun and connecting rod, and remove the plstont Contents Chapter 13 13-15 CRANKCASE/CRANKSHAFI'IBALANCER/PISTON/CYLINDER PISTON DISASSEMBLY Be carsfu/ not to Spread each piston ring and and remove them by damagE the piston lifting up at a point opposite the gap. rlng by spreading the Ends ma far Never usea W/fE Ciean carbon depusits from the piston ring grooves brush, U will scratch with a ring that W!” be discarded. m;- groove. PISTON INSPECTION inspect the piston rings (or movement by rotating the rings. The rings shouid be able to move in their grooves without catching. Push the ring until the outer surface of the piston I ring is neariy flush with the piston and measure the ring-to-ring groove clearance. SERVICE UMITS: Top: 0.125 mm (0.0043 in) Secund: 0.075 mm (0.0030 in) Push the rings into Insert the piston ring squarely into the top of the cylr the cylinder wrrh inder and measure the ring and gap. me top at the pis» 10/1 to be sure they SERVICE LIMITS: are squarely in me Top: 052 mm (0.020 in) Cylinder. Second: 0.82 mm (0.032 in) Oil (side rail): 1.0 mm (0.04 in) 13-16 Contents Chapter 13 CRANKCASE/CRANKSHAFI'IBALANCER/PISTON/CYLINDER Measure the piston pin bore. SERVICE LIMIT: 17.030 mm (0.6705 in) Measure the 0.0. at the piston gin. SERVICE LIMIT: 16,980 mm (0,6685 in) Calculate the pistonrtonlston pin clearance. SERVICE LIMIT: 0.04 mm mm in) Measure the diameter of the piston at 40 mm (0.16 in) from the bottom and 90 degrees to the piston pin hole‘ SERVICE LIMIT: 74395 mm (2.9486 in) CONNECTING ROD INSPECTION Measure the connecting rod small end LD. SERVICE LIMIT: 11048 mm (0.5712 in) Calculate the connecting rod-to-piston pin clear- ance. SERVICE LIMIT: 0.07 mm (0‘00! inI Contents Chapter 13 13-17 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER CYLINDER INSPECTION Inspect the cylinder bore for wear or damage. Measure the cylinder ID. in X and Y axis at three levels. » Take the maximum reading tn determine the cylin- der wear. SERVICE LIMIT: 75.15 mm (2,959 in) Calculate the piston-tocylinder clearance. Take a maximum reading to determlne the clear- ance. Refer to the procedures for measurement of the pis- ton 0.D. (page 13-17). SERVICE LIMIT: 0.10 mm (0.004 in) Calculate the taper and outfit-round at three levels in X and Y axis. Take the maximum reading to determine them. SERVICE LIMITS: Taper: 0.10 mm (0.004 in) Dut-af»round: 0.10 mm (0.004 in) MIDDLE The cylinder must be rebored and an oversize pis- \ , ton fitted ii the service limits are exceeded. \ _ , ’ Thu following oversize pistan is available: / ’ “‘ \ 0.25 mm [0.010 in) BOTTOM \ The piston to cylinder clearance forthe oversize pis- \ ‘ ‘ ” ’ tori must be: 0.015 — 0.050 mm (0.0006— 0.0D20 in). Inspect the top of the cylinder for warpage. SERVICE LIMIT: 0.10 mm (0.004 in) PISTON OIL JET REPLACEMENT Always replace me Remove the bolts and piston oil jets from the upper 07mg when me Oil crankcase. ”’5” mm" inspect the oil jets lor clogs, and replace it if neceSe sary. 13-18 Contents Chapter 13 ORANKCASE/CRANKSHAFI'IBALANCER/FISTON/CYLINDER Install the Dll jet collar onto the all let. OILJET OIL JET COLLAR The piston Oll jet has identification marks (A or B) on ‘ l-—- the body. , . 9L”? lnstall the oil jet A into the N02 and 3 cylinder, and the oil jet B Into the No.1 and 4 cylinder as shown. Apply a locking agent to the piston oil jet mounting bolt threads. Install and tighten the piston oil jet mounting bolts. PISTON ASSEMBLY Clean the piston ring grooves thoroughly and install the piston rings. - Apply oil to the piston rings. . Avoid piston and piston ring damage during SECOND R'NG installation install the piston rings with the marking (R: top ring. RN: second ring) facing up. I Do not mix the top and second rings; top ring is narrower than the second ring in width. I To install the oil ring, install the spacer first, then install the side rails. TOP RING Stagger the piston ring end gaps 120" apart from each other, Stagger the side rail end gaps as shown, Aher installation, the rings should rotate freely in the ring groove. SPACER SIDE RAILS Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER PISTON INSTALLATION Apply molybdenum oil solution to the connecting TAB rod small end Inner surfaces and piston pin outer surfaces PISTON Assemble the piston and connecting rod with the journal bearing tab racing to the piston "dot" mark. CONNECTING ROD "DOT" MARK ’7E PISTON PIN Install the piston pin and secure it using new piston pin clips. - Make sure that the piston pin clips are seated securely. ' Do not align the piston pin clip end gap with the piston cut-out. Coat the cylinder walls, pistons and piston rings with engine oil. Instant/10 piston/ install the piston/connecting rod assemblies into the amine-sting rod cylinders using a commercially available piston ring assembly mm me compressor tool. plSVo/‘l 'lN’ Milk 3‘5» mg m mm m TOOL (Commercially available): Piston ring compressor R6400 When reusing the connecting rods, they must be i installed in their original locations. ' While installing the pismn, be careful not re darnv age the zap surface of the cylinder, especially around the cy/l'nder bore, . Be careful not to damage the cylinder sleeve and crankpl'n with the connecting rod Make sure the piss Use the handle of a plastic hammer or equivalent ran ring cameras tool to tap the piston into the cylinder. 5m malslrs flush | - , OF ME lop SWECE nstall the crankshaft (page 13 El or me cylinder 13-20 Contents Chapter 13 CRANKCASE/CRANKSHAFr/BALANCER/PISTON/CYLINDER Apply molybdenum all solution to the crankpin bearing sliding surface on the bearing caps. BEARING. CAPE Install the connecting rod bearing caps, aligning the dowel plns with the holes in the connectl'ng rods. The canflecllng rod Apply oil to new connecting rod bearing cap boltFB“ bolts cannoi be threads and seating surfaces, and install the bolts. reused Once me connecting rod bulls have been loosened replace them Wll/l new ones Tighten the bolts in two or three steps alternately. TORQUE: 20 Nrm (2.0 kgf-rn, 14 lhf-fl) Further tighten the connecting rod bearing cap bolts 90 degrees Assemble the crankcase halves [page 1372”. CRANKCASE ASSEMBLY Replace me trans Apply a light, but thorough, caating of liquid sealant mission bearing to the crankcase mating surface. Do not apply seal- halrie/aridcrankr ant to the crankcase 8 mm bolt lmain journal boltl case as 5591 area and the oil passage area as shown. Contents Chapter 13 ”'21 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CVLINDER Inslall the mainshafl bearing while aligning it local- ing pin with me crankcase hole. MAINSHAFTBEARJNG '5 Install the clukch liner rod oil seal. Angn me (:ul-Uurs Install the oil urlfices in the upper crankcase, between me on (m- We and crankcase lnslall the three dowel pins. ”'22 Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALANCER/PlSTON/CYLINDER BALANCER TIMING ALIGNMENT/ LOWER CRANKCASE INSTALLATION 1. Avoid damaging the balancer drive and driven gear, turn Ihe balancer shah and place the punch mark facing down, to setthe balancer backlash at maximum. 2. Remove the sealing bolt and seallng washer from the lower crankcase. 3. Temporarily rnsrall the special boil or equivalenl into me sealing bolt hole, hold (he balancer weight securely, Make sure the special bolt xip inlo the balancer welgh! hole, Special bolt, 6 X 18 mm: BOOM-MMS-OOO 4, Place the crankshafr onto the upper crankcase so (her Ihe No.1 piston ar TDC (Top Dead Center), Slightly rum me crankshafl clockwise and align the crankshaft 5th spline center (from the wide splinel with the “A" mark an the upper crankcase as shown. Contents Chapter 13 ”'23 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER Tempararlly lnsrall the starter clutch assembly to check me TDC 5. Carefully place the lower crankcase onto the upper crankcase. NOTE. The crankshaft will slightly move counterclockwise when engaging the balancer gears. 6. Check that the upper and lower crankcase seats properly. Check that [he Crankshaft 51h Spline center aligns with the next "A" mark on the upper crankcase as shown. Make sure the No.1 piston at TDC (Tclp Dead Center). If the crankshaft is not in the proper posnion, reassemble the crankcase halves from the begin- ning. 7. Remove the temporarily installed special bolt from the balancer weight. install a new sealing washer and bolt, tighten the bolt securely. Install new crankcase 9 mm bolts (main journal bolts). Loosely install all the lower crankcase bolts. Make sure the upper and lower crankcase are seated securely. - Tighten the crankcase 9 mm bolts (main journal bolts) using the Plastic Region Tightening Method described on next procedure. - Do not reuse the crankcase 9 mm bolts (main journal bolts), because the correct axial tension will not be obtained. - The crankcase 5 mm bolts [main journal bolts) are pre-coated with an oil additive tor axial ten- sion stability. Do not remove the oil additive from the new 9 mm bolts (main journal bolts) surface. LOWER CRANKCASE 8 mm BOLTS 13-24 Contents Chapter 13 GRANKCASE/CRANKSHAFI'IBALANCER/PISTON/CYLINDER PLASTIC REGION TIGHTENING MEI'HOD: Tighten the crankcase 9 mm bolts (main journal bolts) in numerical order in the illustration in two to three steps to the specified torque. TORQUE: ZO N-m (2.0 kgf>m, 14 |bf>ft) Further tighten the crankcase 9 mm bolts (main W ' journal bolts) 150 degrees, Tighten the 8 mm bolt to the specified torque. TORQUE: 24 NA!" (24 kgf—m, 17 IN“) 7 mm BOLTS From the inside to outside, tighten the 7 mm bolts to the specified torque. TORQUE: 18 Net" (1.8 kgf~m,13lbf-ft) Place the engine with the lower side down. install the upper crankcase 8 mm bolts, sealing washer and 7 mm bolts. Contents Chapter 13 13-25 CRANKCASE/CRANKSHAFT/BALANCER/PlSTON/CYLINDER The sealing washer locations are indicated on the upper crankcase using the "A" mark. Tighten the 3 mm boil In a crlsscross pattern in 2 - 3 steps. TORQUE: 24 MRI (2.4 kg'rm, 17 Ith) Tighten the 7 mm bolt in a crisscross pattern in 2 -3 steps. TORQUE: 18 Nm (1.8 kgt-m, 13 lbf-ft) Set the initial balancer backlash adjustment (paga13-33). Apply oil to a new Orring and install it into the oil inspection window groove. @ Install the oil inspection window onto the lower v crankcase, game Install and tighten the bolts securely‘ r OIL INSPECTION WINDOW , 13-25 Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER Install a new Orring into the water hose joint W groove, ,7 Install the water hose joint to the crankcase, tighten the two balls securely. Route me Brlglne sub-harness properly, connect the E“ » neulral swllch connecmr NEUTRAL SWITCH Apply a sealant to the oil pressure switch threads as shown. Do rlm apply sealanlto the thread head 374mm10r1~02inl OIL PRESSURE SWITCH Contents Chapter 13 13-27 CRANKCASE/CRANKSHAFT/BALANCER/PlSTON/CYLINDER Tighten the oil pressure switch to the specified torque while holdlng the switch base. TORQUE: 12 N-m [1‘2 kgi-m, 5 Ihl-h) Install the terminal eyelet to the oil pressure switch lighten the terminal screw to the specified torque, TORQUE: 20 N-m (0.2 kgl-m, 1.4 Ibfvft) , / removal, BALANCER REMOVAL Separate the crankcase halves [page 1375). Loosen the balancer shaft pinch bolt. Remove the balancer shah hnlder bolt and balancer holder. PINCH BOLT Pull the balancer Shaft out and remove the balancer weight assembly from the lower crankcase. DISASSEMBLY Remove the Ovrlng from the balancer shaft. BALANCER SHAFT ovnle ”'28 Contents Chapter 13 ORANKCASE/CRANKSHAFI'IBALANCER/PlSTON/CYLINDER Remove the washers and needle bearlngs from the WASHER A balancer welghl assembly. WASHER B NEEDLE BEARINGS Remove me balancer gear assembly from me balr ancer weight. BALANCER GEAR u—m Essen/e the damper rubbers from the halancar BALANCEH GEAR DAMPER RUBBERS INSPECTION HapllacerfIEba/~ Check the needIe bearlng for wear or damage, NEEDLE BEARINGS ancer welgm, bah replace if necessary. ancershaft needle baa/mg as a sex Contents Chapter 13 ”'29 CRANKCASE/CRANKSHAFI'IBALANCER/PISTON/CYLINDER 3:55;? balancer wetght and gear for wear or BALANCER GEAR DAMPER RUBBERS Check the damuer rubbers for fatigue or damage, replace if necessary. BALANCER BEARING SELECTION my balance: The balancer weight has two ID. Code Ieners as mug/:1 and neeme shown. neanngsareseflec! The marking identify each ID, of the balancer rmea weight as shown. GEAR SIDE |.D. WEIGHT SIDE LD, Reference the baIancer weIght ID. code letters to GEAR determine the repIacement bearing color. SIDE ID ID, CODE Refer to the seletmon table beIow for bearing seIecV LETTERS tIon. WEIGHT / SIDE |.D. BALANCER BEARING SELECTION TABLE: BALANEEFIWEIGHT IDLCODE fi’" 8 ' [—C 1 27.000 7 27,004 mm 26.391 — 26.996 mm 25,987 , 26.991 mm (1.0630 ~1.0631 In) 11.0626 —1.osza in) I (1.0624 71.0627677inI7 Blue White I Green BALANCER 17.990 —17.596 mm flil,,,, , ,,_fl79§3- 0-7035 ”1! ,- ”'30 Contents Chapter 13 CRANKCASE/CRANKSHAFT/BALANCERIPISTON/CYLINDER DISASSEMBLY NEEDLE BEARING WASHER B BALANCER WEQGHT DAMPER RUBBERS BALANCER GEAR W/(Wjfl/ <6‘/ WASHERA * Wm/ 1 , . \_/ ~ J ,/'/ / N’ r/ x \ BALANCER SHAFT HOLDER Install the damper rubbers into the balancer gear. ALIGNING MARKS Assemble rhe ba‘ancer gear and weight while alignr ing the alrgning marks. BALANCER GEAR .. App‘y oil to xhe needle bearing, ins‘all them into the balancerwefght. WASHER A Instail the washer A and B. WASHER E 7% NEEDLE BEARINGS Contents Chapter 13 ”'31 CRANKCASE/CRANKSHAFT/BALANCER/PlSTON/CYLINDER Install a new O-llng to the balancer shaft. BALANCER SHAFT W9 O’RING ‘fl INSTALLATION Install the balancer weight into the lower crankcase. BALANCER WEIGHT ASSEMBLY Install the balancer shaft. Y ' Turn the balancer shaft and place the punch mark on me shaft facing down Install the balancer shaft holder. PlNCH BOLT Install the balancer holder bolt and balancer holder pinch bolt. Assemble the crankcase halves (page 13»2l l. ”'32 Contents Chapter 13 Ari/us: the backlash While me engine '5 cold (below 35 “6/ 95¢] and the engine vs not ILA/7' mng Excesswe name can cause balancer geal, bearing and shah damage Do nut mm the shah more men Feces sary CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER INITIAL BACKLASH ADJUSTMENT Install the engine into the frame (page 8-9), Loosen (he balancer shah holder pinch boll. Turn (he balancer shaft clockwise until resistance is felt, then back It off one graduanon using the slot as a measure. FINAL BACKLASH ADJUSTMENT Warm up the engine and let n idle. If ‘he balancer gear noises are excessive, adjust the balance! backlash as follows: Turn (he balancer gear shaft caunterclockwise until the gears begin to make a "whining" noise. Then turn the gear shah ciockwuse until the gear “whin— ing“ noise disappears. Tighten the balancer shah pinch boll. After all gear backlash adjustments are done, snap the Ihronle and make sure the gear noises are not excessive, If The gear "whine" noise is excessive, the backlash is [00 small. II the gear "rattling“ noise is excessive, the backlash is excessive. PINCH BOLT 1. 2. 3 UNTIL ONE ‘ RESISTANCE GRADUATION iS FELT BALANCER SHAFT PINCH BOLT Contents Chapter 13 13-33 MEMO Contents Chapter 13 14. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION-----------------‘--~-----14-2 HANDLEBARS .............................................. 14.9 sEchg INFORMATION .......................... 14.3 FRONT WHEEL ........................................... 14.15 TROUBLESHOOTING--------m--->-----m--------->-14~6 FORK ........................................................ 14.21 HESD (Honda Electronic Steering Damper) STEERING DAMPER ----------------------------------- 14-34 TROUBLESHOOTING .................................. 14.7 STEERING STEM ........................................ 14.35 14-1 Contents Chapter 14 FRONT WHEEL/SUSPENSIONISTEERING COMPONENT LOCATION 103 Mm (10.5 kgf-m, 76 [bf-fl) (2,3 kgf-m, 17 lbf-ft) 23 N-m 8.8 N‘m (0‘9 kgf~m, 6.5 Ibftfl) 26 N-m 12.7 kgfm, 2n uni-m 8. N-m (0.9 kgf-m, 6.5 \bf—ft] 9.3 N‘m (1.0 kgl-m, 7 mm) 73 N~m 18.0 kgf-m, 58 mm) 22 N m (2.2 kgf~m,16|bf-ft) 14'2 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL When servicing the front wheel, tort or steering stern, support the motorcycle securely using a twist or equivalent. I A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent After the front wheel Installation, check the brake operation by applying the brake lever. Use only tires marked "TUBELESS" and tubeless Valves on rim marked "TUBELESS TIRE APPLICABLE”. Refer to the brake system information lpage 1674). SPECIFICATIONS Unit: mm (in) ITEM i "v STANDARD SERVICE LIMIT Minimum tire tread depth ’ 7 ’ — 1.5 (0.06) Cold tire pres» l Up to 90 kg (200 lbs) load 250 kPa (2.50 kgf/cmz, 36 psi) I — i sure I' Up to maximum weight capacity ’ 250 kPa (2.50 kgf/cm’, 36 psi) l — ‘ Axle runout — 0.2 (0.008) Wheel rim l ‘ 7 — 7 2.0 (0.08) runout firm i ' ’" »’ ’ 2.010.055) Wheei'ba’iance weiprT' , so 9 (2.102) r _. 7, ‘ max. Fork Lispring tree length 218.2 less) 213.8 (8.42) Tube runout _ 0.20 10.005) Recommended rerk tiuid Pro Honda Suspension Fluid, 35-55 or — 7 7 7 equivalent I . Fluid level ' ' ’90 (3.5) 7 l7 — ‘ I Fluid capacity . 166:2,5cm’l15.8:0.08 us 01, 16.4: ‘ — I ‘ 0.09 Imp oz) i Prerlaad adiusteri tial setting ’ 7 turns from minimum # . — 7 Rebound adIUster initial setting 2 turns out from full hard ' , Compression adjuster initial I 2 turns out from tuii hard I e I, fwflgii ,. fl 7 fii” l Steering head bearing pre—load /'712719N(1.271.9k970 TORQUE VALUES Handlebar weight mounting screw Handlebar pinch bolt Front axle bolt Front axle holder pinch bolt Front brake disc bolt Fork socket bolt Fork bolt Fork damper lock nut Fork eampressidn adjuster plug bolt Fork top bridge pinch bolt Fork bottom bridge pinch bolt Steering damper second arm nut Steering dampersecond arrri bolt Steering damper mounting bolt Steering stern adjusting nut Steering stem adjusting lock nut Steering stern nut 9.5 N-m (1.0 kgf-m, 7 int-rt) 25 Nm (2.7 kgf rn, zo ibl ft) 78 N~rn l8.0 mm, 58 ibrrt) 22 N-m l2.2 mm, 16 iwt) 20 N-m (2.0 kgf-m,14lbf-it) 34 N-m (3.5 kgt-m, 25 ibi-fti 34 N-m (3.5 kgt-m, 25 int-ft) 25 N-m (2.6 kgfvrn,19lbfsft) 18 N-m (1.3 kgitm, 13 lbI-ft) 23 N-m 12.3 kgf-m,17let) 23 N-m (2.3 kgf-m,17lbf-ft) 12 N-m (1,2 kgf~m, 9 ibtit) 8.8 N-m (0.9 kgfim, 6.5 lei-it) 8.8 Nsm (0.9 kgf-m, 6.5 lot-ft) 20 N-m (2,0 kgf-m,14|bf-ft) 103 N-m (10.5 kgirm, 76 lbf~fti ALOC screw: replace with a new one ALOC bolt; replace with a new one Uanut See page 1¢42 Contents Chapter 14 14-3 FRONT WHEEL/SUSPENSION/STEERING TOOLS Attachment, 42 x 47 mm 0774670010300 Film, 25 mm 07745-0040600 €01 \/ Bearing remover head, 25 mm 07746-0050800 Driver 07749-0010000 Bearmg remover, A D7946-KM90401 Steering stem socke‘ 0791643710101 [1711 1 r' 5‘1 31¢) 0791673710100 [Us A,on1y) Assemb‘y base D79467KM90600 (J 1 1 Driver shah assembw 07946vKM90301 1 1 1 Steering srem driver O7946»M 300000 Driver attachment (upper) O7OMF7MCJO100 Driver attachment (lower) 070MF—MCJ0200 Bearing remover shaft 076600010100 14-4 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Bearing remover, E 07NMFVM‘I70110 Fork damper hulder 07YMBVMCF0101 or U7VMBrMCFA‘lOU (U.S.A. only) Fork seal driver O7YMD~MCF0100 or D7NMD-K2301OA (USA. only) Damper rod holder ‘ U7DMB-MEL0200 or O7OMBrMELCZUO Main bearing driver attachment O7946-ME90200 ‘ Fork seal driver weight 07947-KA50100 Oil seal driver 07965-MA60000 lnstallar shaft D7VM FVKZSOZOO Installer attachmentA 07VMF—MAT0100 (USA. only) lnsraller attachment 3 07VMFVMAT0200 (U.S.A, only) Remover attachment E 07AMF—MELA1OD(U.S,A. only) l Remover attachment F 07AMF-MELA2001U.S.A. only) Contents Chapter 14 14-5 FRONT WHEEL/SUSPENSIONISTEERING TROUBLESHOOTING NOTE If there is any problem with steering, remove the steering damper (page 1434) and inspect the steering condition. Check the HESD by uslng the Function Test (page 14-7l in case of no faulty parts with the steering, Hard steering I Faultv steering damper (HESD) . Steering stern adjusting nut too tight . Worn or damaged steering head bearings - Bent steering stern . Insufficient tire pressure Steers to one side or does not track straight Faulty steering damper (HESD) Unevenlv adlusted right and left forks Damaged or loose steering head bearings Bent fork legs Bent axle Wheel installed incorrectly Bent frame Worn or damaged wheel bearings Worn or damaged swingarm pivot bearings Front wheel wobbling I Benr rim I Worn or damaged front wheel bearings I Faulty tire I Unbalanced front tire and wheel Front wheel hard to turn - Faulty front wheel bearings I Bent front axle I From brake drag Soft suspension I Insufficient fluid in fork I Incorrect fork fluid weight - Weak fork springs - Insufficienttire pressure Stiff suspension - Bent fork legs I To much fluid in fork - Incorrect fork fluid weight I Clogged fork fluid passage Front suspension noise I Insufficient fluid in fork - Loose fork fasteners - Incorrect fork fluid weight 14-6 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING HESD (Honda Electronic Steering Damper) TROUBLESHOOTING IThe HESD (Honda Eiectronic Steering Damper) system is equipped with 3 Sell- Diagnostic System that is linked to the FGM Fl system If the malfunction indicator iamp [MIL] blinks (page 5- 9}, follow the Self-Diagnostic Procedures to remedy the problem (Refer to MIL troubieshooting; page 1478). The HESD system is aiso equipped with a Function Test Mode that makes it possible to check the HESD under maximum damping characteristics. If there is any abnormal condition in the HESD sysr tern without MIL blinking, follow the HESD function test and check the HESD function. ' The HESD system includes a failrsafe function to Secure a minimum running capability when there is any trouble in the system, When any abnormality is detected by the selfrdiagnosis function, the ECM stops the HESD system controi by shutting off the current supply to the linear solenoid and the HESD will operate under minimum damping characteristics accordingly. Refer to system diagram in the PGM-FI system (page 58) Refer to PGMVFI selfrdiagnosis information for self-diagnosis procedure and reset procedure in the PGM—Fl system (page 6-9). Refer to test harness connection (page 6~1 1) and terminal location (page 6-l2). Refer to MIL code information (page 1478) before starting troubleshooting. A fauitv HESD system is often related to pooriy connected or corroded connectors. Check those cons nections before proceeding. ... II the following symptoms occur to the HESD, check the MIL blinking and perform the troubleshooting in accordance with MIL biinks. - MIL biink 11 times (page 6722i - MIL biink 51 times (page 14-8) 0 MIL does not blink, although HESD does not work. — When the vehicle speed rises] the damping force does not increase - Aithough vehicle IS not running, the damping force is strong (hard steering]. HESD FUNCTION TEST NOTE - The HESD system is also equipped with a Function Test Mode so that a technician can compare the minimum with maximum damping characteristics without riding. The HESD system is set to mini- mum damping at no vehicle speed under normal conditions. By using the Function Test Mode, the ECM operates the linear solenoid with maximum current so the HESD system is temporarily set to maximum damping. ' It is not possibie to use the HESD Function Test Mode when any problems occur (MIL blinking), Before performing the HESD function lest, remove the HESD unit from the vehicle (page 1434) and check the following. — Steering stem prerload (page 14-44) — Wear or damage of steering head bearing (page 14-35) — HESD-to-steering Iinkage (page 14-34) HESD FUNCTION TEST PROCEDURE 0 Support the motorcycle securely using a hols or equivalent and raise the front wheel off the ground. ' Belore function the test, check the feel for mi imum damping characteristics by moving the Steering right and Ieft quickly severai times. Operate the steering quickly and at a uniform force during the test. Perform the HESD function test as follows: 1. Lower the side stand (side stand switch OFF). 2. Shift the transmission into any gear other than neutral. 3. Open the throttle grip fully. 4. Turn the ignition switch ON with keeping the state of 1 — 3 The HESD indicator starts blinking and the HESD system enters the Function Test Mode for i0 sec— onds. Make sure that the damping characteristics (force) changes, by means of comparing the minimum damping characteristics before Function Test with the maximum damping characteristics under the Function Test. If the HESD damping characteristics (force) in Function Test Mode does not change at all, replace the HESD unit with a new one (page14-34I. Contents Chapter 14 14'7 FRONT WH EEL/SUSPENSION/STEERING MIL TROUBLESHOOTING 3:2; Causes ‘ Symptoms Riff - Loose or poor Contact on speed sensor i ~ Engine operates normally i connector 0 HESD does not lunction l 11 . Open or short circuit in speed sensor — ECM does not control the i 6-22 wire linear solenoid ‘ - Faulty speed sensor — Minimum damping charr , acteristics i i - Loose or poor contact on linear sole- . Engine operates normally noid connector ~ HESD does not function ‘ 51 I Open or short circuit in linear solenoid - ECM does not control the ”>8 wrre linear solenoid - Faulty linear solenoid 4 Minimum damping char- l acteristics MIL 51 BLINKS (LINEAR SOLENOID) . Linear Solenoid Resistance Inspection recheck the MIL blinking. . Linear Solenoid Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM connectors and connect the ECM test harness to the ECM connectors at the wire harness side (page 6-11). Measure the resistance at the test harness termir nals, Connection: BZ — HI! I Before starting the inspection, check for loose or poor contact on the linear solenoid connector and Q Is the resistance within 5.0 - 5.0 {2 (20°C/6‘83F)? lv_u4_Lr,v,,,li u l luul lu t, I rrrm in .rgsjn v _ T5,: 3 oo ooooooooooooo l1 noonooeoooooie ’5 GO To 5 anooooogoouoonoo: if...» WW5 No — GO TO STEP 2 W wamammu’flu, Remove the steerlng damper [page 14-34) and disconnect the linear solenoid 2P connector. Measure the resistance at the linearsolenoid ter» minals. Is the resistance within 5,0 — 8,0 I} (20 “0/68 4F)? Yes — Open circuit in White/green or White/ blue wire i No — Faulty linear solenoid 2P CON NECTOR STEERING DAMPER f? 14-8 Co ntents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING 3. Linear Solenoid Short Circuit Inspection Check for continuity between the test harness and body ground. Connections: 32 (+) — body ground (—) E3 (4-) —body ground (—) Is there continuity? Ves — Short Clrcuit in White/green cr Wh'lte/ blue wire No — Replace the ECM with a known good one, and recheck HANDLEBARS Keep me :r‘urm mesler cylmder uerlgnr to prevent alr lrom emenng :ne hyd’Eu/lc sys- rem, REMOVAL Support the motorcycle securely uslng a hoist or equivalent and raise the front wheel of the ground Hold the handlebar welght and remove the moumr ing screw, then remove both handlebar wmghls/ waShers. Disconnect the clutch switch connectors from the switch. Remove the master cylinder holder bolts, holder and clutch master cylinder assembly. Remove the screws and left handlebar switchv 1 r z -MJ§7 - r mum w r rm w- Wynn ocooowcauuooone l: : 90905009 006 one MASTER CYJ‘LlN DER a oaeaceoaoeoe; E=_ l eoooaocnoeoooaog ’fl; l. x1l1,7l7.‘51;i‘z€7l:fl) ‘7 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Remove the left handlebar grlp and switch and cover. HANDLEBAR GRIP Dlsccnrlact the front brake llght swltch connectors from the switch Keenmenlake Remove the masler cylinder holder balls, holder mastercyllnuer and brake master cylinder assembly. uprlgm lo prevent an from emermg m: llvd'aullc svs HOLDER lam \ Remove the screws and rlgm handlebar switch. Remove the screws and throttle cable housing cover. SCREWS ”'10 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Remove the HESD unit (page 1464) ‘ STEM NUT . TOP BRIDGE Lucsen the [op bridge pinch bolts and handlebar .» / .\ pinch bolts. ‘ ' Remove the steering stem nut and top bridge. Remove the handlebars from the fork sliders. Remove the throttle cable housing/throttle pipe from the right handlebar. INSTALLATION Make sure that the handlebar stopper ring is installed in the fork slider groove properly. Apply grease to the slidlng surface of the throttle plpe. Install the throttle cable hOuSIng/throttle pipe to the right handlebar. Contents Chapter 14 14-11 FRONT WHEEL/SUSPENSION/STEERING App/y lubricant splay through the lab lockl'lig hole to the rubber for easy remava.’ Install the right and left handlebars onto the fork sliders. InstalI the top bridge while aligning its holes with the handlebar stopper pins, Install the steering stem nut and tighten it to the speclfied torque. TORQUE: 103 Mm (10.5 kgf—m, 76 Ihf-ft] Tighten the top hridge pinch boIts m the specified torque, TORQUE: 23 N-m (2.3 kgf-m,17|bf-ftl Seat the handlebar upper surface with the top bridge lower surface, then tighten the handlebar pinch bolts to the specified torque. TORQUE: 26 N-m (2,7 kgf-m, 20 lbf-fl) install the steering damper (page 1434i HANDLEBAR WEIGHT REPLACEMENT Straighten the weight retainer tab by the screwe driver or punch Temporarily install the handlebar weight and screw, then remove the inner weight by turning the handle barweight. Remove the handlebar weight from the inner weight. Discard the retainer ring. Install the new retainer ring onto the inner weight Install the handlebar weight omu (he lnner weight while aligning the bosses and grooves each other, Install and temporarily tighten the mounting screw, TOP BRIDGE HANDLEBAB TOP BRIDGE FINCH BOLT e; RETAINER HOLE HANDLEBAR WEIGHT RUBBER CUSHIONS HANDLEBAR WEIGHT 14-12 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Insert the handlebar weight assembly into the hanr dlebar. Turn the handlebar weight and hook the retainer ring tab with the hale in the handlebar. RETAINER RING RUBBER CUSHION Remove the mounting screw and handlebar weight. INNER WEIGHT RETAINER HOLE HANDLEBAR WEIGHT If you remove the right handlebar grip from the r ' throttle pipe, install it in accordance with following . procedure. Apply Pro Honda Handgrlp Cement or equivalent adhesive to the Inside of the handlebar grip and to the clean surfaces of the throttle pipe. Wait 3 r 5 minutes and install the grip. Allow me adhesn/e Rotate the grip for even application of the adhesive, to dry tor an ham and align the inner groove of the grip with the index before usmg line cfthronle pipe. Install the throttle cable housing cover to the thratr tie pipe flange, aligning its locating pin with the hole in the handlebar. install and tighten the housing cover screws securely. SCREWS Contents Chapter 14 14-13 FRONT WHEEL/SUSPENSION/STEERING Install the right handlebar switch, aligning its locat» - , ing pln with the hole in the handlebar. E R‘GHT HANDLES/m SW'TCH Tighten the screws to the specified torque, TORQUE: 0.9 Mm (009 kgf-m, 0.7 |th) Install the front brake master cvlinder and holder with the “UP“ mark facing up Align the end of the master cylinder with the punch mark on the handlebar, and tighten the upper bolt firstl then lower bolt, TORQUE: 12 N-m (1.1 kgf~m, S lbf‘ft) Connect the front brake light switch connectors. Check the throttle grip operation and free play lpage 4-7), Install the switch end cover to the left handlebar. Apply Pro Honda Handgrip Cement or equivalent to the inside surface of the handlebar grip and to the Clean surface of the handlebar. Wait 3 A 5 minutes and install the grip. Allnw ll‘e adt; ire Rotate the grip for even application of the adhesive. to dry foran hour before esmg HANDLEBAR GRIP 14'” Contents Chapter 14 FRONT WH EEL/SUSPENSION/STEERING Make sure that me Install the left handlebar switch, aligning its locating l , mm sthch enaplare is pin With the hole In the handlebar. V _7 SWITCH lwsrai’ed into the ‘ handlebar FWIICI'V gluove Tighten the forward screw first, then the rear screw. Install the clutch master cylinder and holder with the "UP“ mark facing up. Align the end of the master cylinder with the punch mark on the handlebar, and tighten the upper bolt first, then lower bolt. TORQUE: 12 N-m (1.2 kgf—m, 9 lbt-ft) Connect the clutch switch connectors. Install the washer and handlebar weight on both handlebars, aligning with each handlebar and hen dlebar walght cutout. Contents Chapter 14 ”'15 FRONT WHEEL/SUSPENSION/STEERING Tighten the new mounting screws to the specified torque. TORQUE: 9.8 N-m (1.0 kgf-m, 7 [bi-h) FRONT WHEEL REMOVAL Support the motorcycle securely using a hoist or equlvalent, and raise the front wheel off the ground. Remove the brake caliper mounting bolts and both brake calipers. Do notoperate ma Support the brake caliper with a piece of wire so . brake lever aHer the that it does not hang from the brake hose. Do not " brake calypsrls twist the brake hose. removed Loosen the right axle holder pinch bolts, Remove the axle bolt. Loosen the left axle holder pinch bolts. Remove the axle and front wheel. ”'16 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Reu‘ace ‘he lyeer l'lgs m pens Remove the I’lgh! and left slde collars. INSPECTION Axle Set the axle an Veblocks and measure the runoul. Actual runout is 1/2 the total indicalor readlng. {(9 SERVICE LIMIT: 0.2 mm (0.008 in) Wheel bearing Turn the Inner race of each bearlng wllh yourfinger. ‘ The bearings should turn smoothly and qulelly. Also check that the bearing uuter race ms tightly in the hub. Remove and discard the bearings if they do nouum smoolhly, quletly, or If they fix loosely m the hub. Replace Ihe wheel bearings, if necessary (page 147 ‘ lal. ‘ ‘ WHEEL BEARING Check the rim runoul by placing the wheel in a mm- l " lng sland. Spin the wheel by hand. and read the runoul usmg a l dial indicator. Actual runcut is 112 the total lndlcator reading. ‘ SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Am 2.0 mm [0.08 in) Wheel rim runout Contents Chapter 14 14-17 FRONT WHEEL/SUSPENSION/STEERING Far uphmum Lia.L Wheel balance ance m: we. DEF” . Wheel balance directly affects the stability, hen» all?” Wald" dling and over all safety of the motorcycle. 0'0”! 25’ E Always check balance when the tire has been “’5‘” "’“5’ be removed from the rim lnralea next In me valve stem am the me if necessary BALANCE MARK \ Note the rotating direction marks on the wheel and tlre. Remove the dust seals from the wheel. Mount the wheel, tire and brake discs assemblv ‘ln an inspection standt Spln the wheel, allow it to stop, and mark the lowest (heaviest) point of the wheel with a chalk. Do this two or three times to verify the heavlest area. it the wheel is balanced, it will not stop consistently in the same position. T0 balance the wheel, install the wheel weights on the highest side of the rim, the side opposite the chalk marks. Add Just enough weight so the wheel will no longer stop in the same position when it is spun. Do not add more than 60 grams to the wheel. NOTE‘ INSPECTION STAND This model is equipped wnh the new shape wheel weight made of erIC speller. Tl’llS wheel weight l5 incompatible with the conventional one in case of installation tn the wheel, DISASSEMBLY Remove the bolts and brake discs. Remove the dust seals. ”'13 Contents Chapter 14 20 Nrm (2.0 kgf-m,14 lbf h) a? if Never Install the old bear/n95 Once {he Dearmgs have been removed. we bear mgs must be FRONT WH EEL/SUSPENSION/STEERING Install the bearing remover head into the bearing. From Ihe opposite side, msran the bearrng remover shaft and drive the bearing our of the wheel hub. Remove the distance cellar and drrve out the other bearing. TOOLS: Bearing remover head, 25 mm 0774670050800 Bearing remover shah 07GGD-0010100 ASSEMBLY RIGHT BRAKE DISC § 32 RIGHT WHEEL BEARING .fir RlGHT DUST SEAL LEFTWHEEL BEARING $27 o—fil LEFT DUST SEAL LEFT BRAKE DlSC Drive in a new right wheel bearing squarely umil n * is fully seared using the special tools. lnslall lhe disxance collar, (hen drlve in new left k wheel bearing using the same tools. DRIVER replaced wrm new T9015: mes Dnver 077490010000 Attachment. 42 x 47 mm 07746-0010300 Pilot, 25 mm 07745—0040600 14-19 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Do mrgcvgrme Install me brake discs wllh the arrow mark facing a" we make dlscs the normal rulaling direction. u'slopplng power Install new disc bolts and tighten them in a criss- - WllIDe reduced cross patlern In two or three steps. TORQUE: 20 Nrm (2.0 kgl-m, 14 lbl-ftl Apply grease to new dust seal lips. Install lhe dust seals into the wheel hub. INSTALLATION lnslall lhe righl and lefi side collars. Install the front wheel belween lhe fork legs. Apply a thln layer of grease to the from axle su dace. Inslall the from axle from the left side. Install the axle boll. Hold the axle and lighten the axle boll to (he speciv , fled lovque. TORQUE: 78 Nlm (8.0 kgfim, 58 Ibf‘ft) Tighten me rlght axle holder plnch bolls lo me spec» ified torque. TORQUE: 22 MM (2.2 kgl-m, 16lb1>ftl ”'20 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Inslall the both brake calipers and lighten lhe new mou nllng bolls lo the specified torque. TORQUE: 45 N-m [4,6 kgfrm, 33 Ibm] Wllh the front brake applied, pump the forks up and down several me: (0 seal me axle and check brake opera‘icnl Tighten lhe left axle holder pinch bolls to (he specir fled lorque. TORQUE: 22 Nm (2V2 kgfrm, 16 mm) Recheck the front brake operation. FORK REMOVAL Remove the following: 7 From wheel (page 1446) , Front fender [page 3—19] Loosen the handlebar pinch boll and lork top brldge pinch bolt. When the fork leg will be dlsassembled, loosen the fork boll, but do not remove it yer. [H 14-21 Contents Chapter 14 FRONT WHEEL/SUSPENSIONISTEERING Keepmefronz While holding the fork leg, loosen the fork bonom Drake ands/um bridge pinch bolls and remove the fork slider from maslel cvlmae' the handlebar and fork brldgas. uprlgh.’ BOTFOM Pl NCH BOLTS DISASSEMBLY as careful no: ra Remove the handlebar stopper ring. , am the m Remove the slopper ring and Dre-load adjuster‘ 5llna' PRE-LOAD ADJUSTER STOPPER RING STOPFER HING Remove the Orring from the damper rod adjust easel Remove lhe fork ball from lha fork slider. Push the fork sllder slowly dawn, and gently seal the dust seal onto the axle holder ”'22 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Hold the damper rod adjust case, then loosen the leak nut. Rsmove the lock nut and fork bolt, Remove the following; A Jointcoliar — Spring coilar , Forkspring SPRING COLLAR u mugs)- Removs the O-rlng from the damper rod adjust O-RING CESE. Vdi . Pour out the fork fluid by pumping the fork tube sev- eral timesi Pour out the fork fluid from the fork damper by pumping the damper rod several times. Contents Chapter 14 14-23 FRONT WHEEL/SUSPENSION/STEERING Remove the compression adjuster from the axle holder. Hold the axle holder in a visa with soft jaws or a shop towel. Hold the fork damper with the fork damper holder, then remove the fork socket bolt and sealing washers TOOL: Fork damper holder 07YMB-MCF0101 or 07YMB-MCFA‘IGD (USA. only) Remove the fork damper assembly from me fork slider. FORK SLIDER Hemove the dustseal. \ DUST SEAL ”'24 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Do 00: scratch the Remove the oil seal stopper ring. fork lube s"dlng Mace, STOPPER RING Pull the fork tube out until you feel resistance from the slider bushlng, Then move it in and out, tapping the bushing lightly until the fork lube separates from the fork sliderv The Slider bushing will be forced out by the fork tube bushiflg, Remove the fork tube bushing, slider bushing, back- T up ring, oil seat stopper ring and dust seal from the FOEKJ’UVB‘E BUSHING ‘ BACK-UP RING fork tube. 7 . . . , OIL SEAL SLIDER BUSHING INSPECTION Fork spring Measure the fork spring free length. SERVICE LIMIT: 2133 mm (8.42 in] Contents Chapter 14 14-25 FRONT WHEEL/SUSPENSION/STEERING Fork tube/slider/damper Check the fork slider for damage or deformation. , ' ' Check the fork damper for band or damage . . FORK DAMPER Replace any components which are damaged. Check the oil lock valve lor wear or damage. Replace the fork damper assembly, if any compo- nents are damaged. Check the fork tube for score marks, scratches, or excessive or abnormal wear, Place the fork tube on V-blocks and measure the runout.fi Actual runout is 1/2 the total indicator reading‘ SERVICE LlMlT: 0.20 mm (0.008 in) FORK TUBE Fork mbe bushing Visually inspect the slider and fork tube bushings. Replace the bushings if there is excessive scoring or scratching, or it the teflon is worn so that the copper BUSHING surface appears on more than 3/4 of the entire sur- face BACKVUP RING Check the back-up ring; replace It ifthere is any disV tortion at the points shownt CHECK POINTS COPPER SURFACES “'26 Contents Chapter 14 FRONT WHEEL/5USPENSION/STEERING ASSEMBLY FORK TUBE BUSHING HANDLEBAR STOPPER RlNG STOPPE\R RlNG BACK up ”‘6 5"]? \ o- RINGS fl / PRELOAD /.@ @4/ADJUSTER g? OlL SEAL ( ‘ fl) STOPPER RING LOCK NUT 25 N-m (2.6 kgf-m,19lb1-ftl § FORK BOLT w SLlDER 34 N-m DUST SEAL BUSHING (3.5 kgf‘m, 25 let] ADJUSTING PLATE FORK TUBE/ STOPPER RING JOINT COLLAR SPRING COLLAR ‘ / FORK ‘ l \z \ SLIDER \ I f COMPRESSION ‘N’ FORK SPRING QM ADJUSTER 34 N~m (3.5 kgf-m, 25 lbf-ft) 13 N-m (1.8 kgf-m, 13 [er-m FORK DAMPER . Eefore assembly, wash all parts with a high flash >1» ‘ TAPE or nonrflammable sulvent and wipe them dry. 0 When installing the fork dust seal and oil seal. wrap the edge and groove of the fork tube with “ tape. Apply fork fluid to new dust seal and oil seal lips. BACKAUP RING lnstal/ me ctr/seal Install the dust seal, stopper rung and oil seal. mm yrs marked SLIDE“ BUSHlNG .fi ' syde em toward v I!“ the axle Mulder " FORK TU BE DUST SEAL Remove the burrs Install the back-up ring, slider bushing and fork tube lrom ms slicer bushing. bushmg matmg surr Install the fork tube into the fork slider, lace bemg careful n0! [0 neelm‘! me coanng. BUSHING OlL SEAL STOPPEH RING‘ Contents Chapter 14 ”'27 FRONT WHEEL/SUSPENSION/STEERING Drive the oil seal in using the special tooll TOOL: Fork seal driver. 43 mm 07YMD-MCF01DO or _ O7NMD-KZZO1DA (U.S.A. only) FORK SEAL DRIVER Do nozscravch the Install lhe stopper ring into the fork slider groove fork tube 50qu securelyv survacs STOPPER Rl NG lnstall the dust seal into the fork slider. fl DUST SEAL Install the fork damper assembly imo the fork slider. 'FQRK §LIDER ”'28 Contents Chapter 14 FRONT WHEEL/SUSPENSIONISTEERING Apply a locking agent to the fork socket bolt threads. Install the socket bolt with a new sealing washer. Hold the axle holder in a vise with soft jaws or a shop towel. Hold the fork damper with the fork damper holder, then tighten the fork socket bolt to the speclfied torque TOOL: Fork dampar holder O7VMB-MCFD101 nr 07VMB-MCFA100 (U.S.A. only) TORQUE: 34 N-m (3.5 kgl~m, 25 [bl-ft) Apply fork fluid to new O-ring and install it to the campressron adjuster. Install the com pressicn adjuster to the axle holder. TORQUE: 1B N-I'I'I (1.8 kgf-m, 13 lbf-ft) Pour the specified amount of recommended fork fluid into the fork leg, RECOMMENDED FORK FLUID: ‘ Pro Honda Suspension Flui , 55-55 or equivalent . FORK FLUID CAPACITY: ‘ 46612.5 an3 (15.8 1 0.08 US 02, 16.4:039 Imp oz) 14-29 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Bleed the air from the fork leg as fellows: FORK DAMPER P r g: 90 mm (3.5 in] 1. Extend the fork, cover the top of the lork slider with your hand and compress the lurk leg slowly. 2. Remove your hand and extend the fork slowly. Repeal above procedure 2 or 3 times. 3. Pump the rork damper rod slowly s ,10 times. tn: . ;, Slowly push the fork slider, and gently seat the dust seal onto the axle holder and leave it for 5 minutes. Be sure lhe villevei After the Oil level stabilizes, measure the oil level s the same m me from top of the fork slider. W" ““5 FORK on. LEVEL: so mm (3.5 in) L Apply fork fluid to new O—ring. Extend the fork damper and install the O-ring m the :3? fl O’R'NG damper rod adjust case groove. “ ‘. install the fork spring into the fork slider with the tapered end facing up. TAPEHED END FORK SPRING ”'30 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Arrach the handle to the damper rod holder aher Insrall- my the spring cellar and low: collar Extend the fork damper fully and Install the damper rod holder onlo (he damper rod adjusl case TOOL: Dnmpar 1nd holder D7OMB-MELDZOO or 07DMB-MELCZOD Install the spring collar and joint collar. Attach the handle to the damper rod holder, then ‘ lower the spring collar while pulling up lhe damper rad holder. Anach lhe 14 mm wrench to the damper rod adjust case as shown. Make sure lhat lhe damper rod adjust case is lirmlv fixed, (hen remove the damper rod holder, Apply fork fluid to new Orrings and install them to the fork boll. Turn the Dre-load adjusling plate clockwlsa until it seats llghllv. l SPRING COLLAR a O-RINGS PRE OAD ADJUSTING PLATE DAMPER ROD HOLDER r \/7/\/ ,‘ JOINT COLLAR l ill“ ,‘ Q \\ SPRING COLLAR DAMPER ROD HANDLE t HOLDER @XL ‘ /——«/ WRENCH FORK BOLT Contents Chapter 14 14-31 FRONT WHEEL/SUSPENSION/STEERING Install the fork bolt to the damper rod adjust case while aligning the grooves of the adjusting plate with the damper rod adjust case. FORK BOLT Instalt the lock nut to the damper rod adjust case. Hotd the damper rad adjust case and tighten the ‘ lock nut. Remove the 14 mm wrench from the damper rod adjust caser Hotd the damper rod adjust case, and then tighten the lock nut to the specified torque TORQUE: 25 Nm (2.6 kgfvm, 15 Iht-ft) Tighten the fork Install the fork bolt to the fork slider, balraher msra/nng \nstall new O-ring to the damper rod adjust case. the fork S/IdEr Into the fork br/dges EORK BO_LT ”'32 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Install the handlebar stopper rlngt Install the preload adjuster and stopper ring. PRE’LOAD ADJUSTER , STOPPER R'NG STOPPER RlNG INSTALLATION lnsrall the fork leg thrbugh the bottom bridge, han- dlebar and top bridge (page 14-44). Position the top end of the fork slider flush wlth the upper surface of the top bridge as shown. Tighten the bottom bridge pinch bolts to the speci- fied torque TORQUE: 23 Mn: (2.3 mm, 17 lbf-ft) It the fork bolt was loosened, tighten it to the specie fied torque. TORQUE: 34 Nrm [3.5 kgf-m, 25 lbf-h) Tighten the top bridge pinch bolt to the speclfied torque. TORQUE: 23 N-m (2.3 kgf-m. 17 [bf-ft) Tighten the handlebar pinch bolt to the specrfied torque. TORQUE: 25 M!!! (2.7 kgf-m, 20 Ibfrfl) Install the following: ~ Front wheel (page 14-20) - Front fender (page 3-19) Adjust the prerload and compression/rebound damping adjusters (page 4737). Contents Chapter 14 14-33 FRONT WHEEL/SUSPENSIONISTEERING STEERING DAMPER REMOVAL/INSTALLATION Remove the top shelter (page 3‘15). , . TOP COVER \‘\ W? Remove the butts and steering damper top cover ~ V 2/ Remove the bolts and steering linkage cover. Remove the second arm bolt/washers, three mount 9‘ SECOND ARM 'mg butts and steering damper unity BOLT/WASHERS Disconnect the 2P18|ack)cunnectorfmm the steep ing damper unn. » / A 2P [BLACKTCONNECTOR “'34 Contents Chapter 14 FRONT WHEEL/SUSPENSION/STEERING Connect the 2P (Black) connector. ‘5 BOL‘F/WASHER Insra“ a Washer Install the steering damper am the mp bridge, than i' between the sreer- install the washers and steering damper second mg dampersecond arm boll. am and rot: Dredge Install the sreering damper mpuming bans, and xighlen khe second arm bolt and mounting bows m the spemfied torque. SECOND ARM BOLTNVASHERS TORQUE: 8.8 M"! [0.9 kgf-m, 6V5 Ibl-fl) lnsta‘l me removed pans in the reverse order of remova‘. STEERING STEM REMOVAL Remove me foHowing: 7 From wheel (page (4716) , — FronHender(page 3-13) 7 Upper cowl (page 3712) 7 Top shener (page 3-16) — Steering damper (page 14-34) Remove the steering stem nut. Remove the fork legs (page 111721). Remove the bake and wind protector Remove the be“ and horn unit. Contents Chapter 14 14-35 FRONT WHEEL/SUSPENSION/STEERING Remove the bolt and front brake hose clamp. Straighten the tabs of the lock washer, Remove the lock nut and lock washer. Remove the steerlng stern adjusting nut using the specie! tool. TOOL: Steering stem socket 07916-37101!“ or 0751521710100 Remmve the following: ' INNER RACE — Dustseal — Upperbeannginnerrace UPPER BEAR‘NG — Upperbearing ' ~ Steering stern — Lower bearing A‘ ‘ . ‘ $ iflvER BEAM/1 ”'36 Contents Chapter 14 Always replace the beanngs and races as a 55! Nate Ine- mslallanon derecnon at me assemnly base, me small l a slug fac- mg m,- upper anaclwlent FRONT WHEEL/SUSPENSION/STEERING OUTER RACE REPLACEMENT Replace the races using lhe special tools as described ln khe following procedure, TOOLS: (Nut available in U.S.A.) (1) Driver anachment (upper) 07nMF-MCJD100 l (2) Driver anachmem (lower) 070MF---w-------~---»-----v---------------15-20 REAR WHEEL 15,7 Contents Chapter 15 151 REAR WHEEL/SUSPENSION COMPONENT LOCATION 15 N-m11.5 kgf-m,11|bfvfi} N-m (4.5 kgf-m, 33 \bf-h) 44 N-m (4.5 kgf-m, 33 Ibf-m 113 Mm (11.5 kgf-m, 83 lbf-ft) 44 N-m (4,5 kgf-m, 33 [bf-f0 15'2 Contents Chapter 15 REAR WH EEL/SUSPENSION SERVICE INFORMATION GENERAL I A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. After the rear wheel Installation, check the brake operation by applying the brake pedal. The shock absorber contains nitrogen under high pressure. Do not allow fire or heat nearthe shock absorber. Before disposal of the shock absorber, release the nitrogen (page 1546). When servicing the rearwheel and suspension. support the motorcycle using a safety stand or hoist. Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE“ Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point. When installing the swingarm, be sure to tighten the swingarm pivot fasteners to the specified torque in the specified sequence. If you mistake the tightening'torque or sequence, loosen all pivot fasteners, then tighten them again to the specified torque in the correct sequence. . When using the lock nut wrench for the swingarm pivot, use a 20-inch long deflecting beam type torque wrench. The lock nut wrench increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actu- ally applied to the lock nut. The specification given on this page is actual torque applied to the lock nut, not the reading on the torque wrench when used mm the lock nut wrench. The procedure later In the text gives the actual and indicated torque Refer to the brake system information (page 164). I000... SPECIFICATIONS Unit: mm (in) ITEM 'i W '7“ ' ‘F" ’f” *' §TANDARD i SERVICE LIMIT Minimum tire tread depth _ 2.0 (0.08) I Cold tire Up to 90 kg (200 lbs) load 290 kPa (2.90 kgflcm , :12 psi) l — pressure Up to maximum welght capEcW if 90‘ firflamifimfiz 'p’siT'r’fi — ‘ r Axle runout Wheel rim Radial fl' '7‘ #_ fi‘ runout l Axial l i Wheel balance weight i _ l "a, ,. 7 ‘iii RKSEOZIAI14UVFZ¥ . I, .- 25— en PositBn 4 7 2 briveohain ] Size/link l fiar 7 7 Shock Spring pre-Baad art] 7 absorber Rebound damping ad 5 turns tfiTom hard’fi I I Compression damping adiuster initial setting , 9 clicks out from full hard , TORQUE VALUES Rear axle nut 113 N-m (11.5 kgf-rrl, 83 lbfit) Usnut Rear brake disc bolt 42 N-m (4.3 kgf-m, 31 lbfvhl ALOC bolt; replace with a new one Final driven sprocket nut 64 N-m (6.5 kgi-rn, 47 IBM!) U-nut Rear shock absorber upper mounting nut 44 Nvm (4.5 kgf-m, 33 |bf>fti U~nut Rear shock absorber lower mounting nut 44 Nam (4.5 kgf-m, 33 let) U-nut Shock linkstvarame pivot nut 44 N-m (4.5 kgi-rn, 33 lbf ftl U~nut Shock arm-to-shock link nut 44 N-m (4.5 kgf-m, 33 lbftt) U-nut Shock Brrnstoszingarrn nut 44 N-m (4.5 kgi-ml 33 Ibf-fl) Urnut Drive chain case flange bolt 12 N4m (1.2 kgfm, 9 let) Swingarm pivot adjusting bolt 15 N~m (1.5 kgfvm,11 lbf-ft) Swingarrn pivot adjusting bolt lock nut 54 N-m (8.5 kgf-m, 47 |bf~ft) See page 1529 Swingarm pivot nut 113 Mm (11.5 kgf-m, 83 lief-ft) Drive chain slider bolt 8.8 N»m (0.9 kgf~m. 6.5 lbf-ft) Apply a locking agent to the threads Contents Chapter 15 15'3 REAR WHEEL/SUSPENSION TOOLS Remover “Eight ‘ 07741-0010201 0753637102011 (USA. only) or 07936737102001U.S.A.on¥v) Attachment, 32 x 35 mm 0774670010100 Attachment, 42 x 47 mm 0774670010300 Attachment, 52 X 55 mm 07745-0010400 Attachment. 24 x 26 mm 07746-0010700 Attachment, 22 X 24 mm 07746-0010800 (,j or 07745-0D1ABOO (USA, only) Attachment, 40 x 42 mm 07746-0010900 ‘ Pilot, 17 mm 077460040400 Pilot, 25 mm 077450040500 Pilot, 28 mm 07746-0041100 (C97 \\_/ Pilot, 19 mm 07746-0041400 Bearing remover head. 25 mm 07746-0050800 15-4 Contents Chapter 15 REAR WHEEL/SUSPENSION Driver 0774970010000 Remover handle 07336-3710100 Bearing remover, 17 mm 079333710300 Film, 32 mm Attachment, 28 X 30 mm 079464870100 Driver 070G D»0010100 or O7OGD-001A1001U5‘A. on‘y) Ball race remover ‘ 079484630100 \g; T Bearing remover shafx 07GGD-0010100 Driver 0794973710001 1 Bearing driver D7GMD-KTSO1OO ‘ 07MADVPR90200 Anachmenl, 42 mm \ 07QAD~POAO100 : Swmgarm lock nut Wrench, 1 5,8 x 47 mm 07YMA»MCFO1OO ‘ '0 only) or 07VMA-MCFA100 (U S Contents Chapter 15 15-5 REAR WHEEL/SUSPENSION [ Attachment, 34 mm 07ZMD7MEWU1OO or 07ZMD7MBWA100 (U SA. only) TROUBLESHOOTING Soft suspension - Weak shock absorber spring - Incorrectsuspenslon adjustment - Oil leakage lrom damper unit - lnsufficlenltire pressure Stiff suspension - Incorrect suspension adjustment ' Damaged rear suspension pivot bearings 0 Bentdamperrod - Benz swingarm pivot 0 Tire pressure 100 high Rear wheel wobbling ' Bent rim - Worn or damaged rear wheel bearings o Faulty reanlre I Unbalanced reartire and wheel - lnsufflcient rear tire pressure - Faulty swingarm pivot bearings Rear wheel hard to turn - Faulty rear wheel bearings 0 Ben! rear axle - Rear brake drag I Drive chain too tight Rear suspension noise - Faulty rear shock absorber - Loose rear suspension fasteners - Worn rear suspension pivm bearings Steers to one side or does not track straight - Bent rear axle ~ Axle alignment/chain adjustment not equal on both sides 15-6 Contents Chapter 15 REAR WHEEL/SUSPENSION REAR WHEEL Do 716700.. :e me brake pe alaner remeving me rear Wrinei REMOVAL Loosen the lock nuts and drive chain adjusting bolts. (page 4-25) Loosen the rear axle nut. Support the motorcycle using a safety stand or hoist and raise Ihe rear wheel off the ground. Remove the axle nut. washerand drive chain adjust- ing plate. Push the rear wheel rorward and derail the drive chain from the drlven sprocket. Remove the rear axle and drive chain adjusting plate tram the left side, then remove the rear wheel. ' ADJUSTING PLATE‘l Remove the Side collars, OLLARS INSPECTION Axle Place the axle on Veblocks and measure the rundut. Actual runDut ls 1/2 the total Indicator reading. SERVICE LIMIT: 0.2 mm (0‘01 in] Contents Chapter 15 REAR WHEEL/SUSPENSION Replace the wneel Dearlngs m 031': Wheel bearing Turn the inner race of each bearing wlth your finger. i Bearings should turn smooihly and quietly. Also check that the bearing ouler race fits lighrly in the hub or driven flange. Remove and dlscard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub or driven flange. Remove the wheel bearings, if necesaary (page 15- 10). WHEEL BEARlNG Wheel rim runout Check the rim runout by placing the wheel in a (ru- ‘ ing stand. ‘ Spin the wheel slowly and read rhe runout using a dial indicator. Actual runoul is 1/2 the total indicator reading. SERVICE LIMITS: Rad'al: 2.0 mm [0.08 in) Axial: 2.0 mm [0.08 in) Driven sprocket Check rhe condilidn or me final driven sprocket ' teeth. Replace lhe sprocket ilwcrn or damaged. l GOOD REPLACE I If the linal driven sprocket requires replacement, . inspect the drive chain and drive sprocket. . - Never install a new drive chain on a worn O X sprocket or a vvorn chain on new sprockets. Both chain and sprocket must be in good condition or f :gfilreplacemenl chain or sprocket wlll wear raps ‘ L;F\\:\ afiQT Wheel balance i Refer to the wheel balance servicing {page magi. DISASSEMBLY Remove the right dust seal. Remove the bolts and brake disc. 15-8 Contents Chapter 15 REAR WHEEL/SUSPENSION rimu wrr arsase Remove the left dust seal. 59mm we mm DRIVEN SPROCKET NUTS flange, 10055" the mmmkel‘ and [JD/15 before removrng me enven flange Han" me wheel a un Remove the driven flange assembly from the \efl wheel hub. DRIVEN FLANGE Remove the wheel rubber dampers and mm Driven flange bearing removal Remove me nms, washer, bolts and drrven sprocket from zhe driven flange. DR‘VEN SPROCKET BOLTSJNUTSNVASHERS Contents Chapter 15 15'9 REAR WHEEL/SUSPENSION Drive the driven flange collar out of the driven p _ _ DRlVER flange bearings using the speclal tools. TOOLS: Driver 07749-0010000 Filok, 28 mm 07745-004110!) PILOT Drive out the driven flange bearings uslng the - ' ‘ . cialtools. ' , DRlVER TOOLS: Driver 07749-0010000 Attachment, 4D x 42 mm 07746-0010900 Pilot. 28 mm 07746-0041100 Wheel bearing removal Install the bearing remover head Into the bearing From the opposlle side, install the bearing remover shaft and drive the bearing out of the wheel hub‘ Remove rhe distance collar and drive out the other bearing. TOOLS: Bearing remover head. 25 mm 07746-0050800 Bearing remover shaft 07GGD-0010100 REMOVER HEAD 15'” Contents Chapter 15 REAR WH EEL/SUSPENSION ASSEMBLY go? 42 N-m (4.3 kgf-m, 31 IthI § 30, RIGHT WHEEL BEARING A 7/ L ' r_\<\\T\ A ‘ ‘3 , \, < \\ DISTANCE COLLAR , ‘ , ‘w . fl\ j /KL: L / “ ‘ LEFT WHEEL BEARING BRAKE DISC . ‘ RUBBER DAMPERS DRIVEN FLANGE @ gag RIGHT DUST SEAL LEFT DUST SEAL § 93 DRIVEN FLANGE BEARINGS 64 NM (6 5 kgf»m. 47 Ibf-ftI DRIVEN FLANGE COLLAR Never Install the old Wheel bearing installation MEWS “meme - Installthe rightwheel bearing previously. . DRIVER bearmgs has been removed, the heap Drive in a new fight bearing squarely, until It is fuIIy t Ings muswe seated, ran/now vwh new TOOLS: ones Driver 0774941010000 Attachment, 52 x 55 mm 077464010400 Pilot. 25 mm 0774541040600 InstaII the distance coIIar Drive in a new left bearing squarer, TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-001030!) Pilot, 25 mm 0771150040600 Contents Chapter 15 REAR WHEEL/SUSPENSION lnslall "75? warmers Wll‘i" Meir msmr {area we lasing Driven ilange bearing installation Press the driven flange cellar ln the new driven Ji flange oearings unlil ll is fully sealed. DR'VEN FLANGE COLLAR TOOLS: \ Driver 077490010000 1 i i l i Aflachment, 32 x 35 mm 077450010100 Pilot, 25 mm 07746-004060?! DRIVEN l FLANGE l BEARINGS Drive ihe new driven flange bearings With me collar DRIVER imo lhe driven flange using lhe special tools TOOLS: Driver 0774970010000 Attachment, 52 x 55 mm 07746-0010400 Film, 25 mm 0774643040600 Install the wheel rubber dampers into the len wheel hub. Apply grease to new Orrlng and inslall it lo the groove ofthe wheel hub. Install the driven flange assembly into the left wheel hub ll lhe drlven sprockel was removed, Install lhe driven sprocket bolls, driven sprocketl washers and nuts Tighlen the rims Io rne specified rorqve. TORQUE: 54 N-m (6.5 kgf-m, 47 lhl-ft) Apply grease in new dust seal llpS, then install it lo the driven flange. DUST SEAL 15-12 Contents Chapter 15 REAR WHEEL/SUSPENSION £222: glutibrake disc with its rmaling direction mark BRAKE DISC ROTATING DIRECTiON MARK Tighten the new brake disc bolts to the specified (Orque. TORQUE: 42 N-m (4‘3 kglm, 31 Ibf~ft) Apply grease in new dus! seal lips, men install ii to the right wheel hub. INSTALLATION Install the side collars. Make sure manhe rear brake caliper breaker is peei- lioned in the guide ofthe swingarm. Be care'u/ nor ra Place the rear wheel in the swingarm. damage We brake Install the drive chain over me driven sprocket pads Apply a thin coat of grease to (he rear axle Instali me drive chain adjusl'lng plate and rear axle from the left side. Contents Chapter 15 1543 REAR WHEEL/SUSPENSION Install the adjusting plale, washer and axle nut. Adjust the drive chain slack (page A26). Tighten the axie nut to the specified torque, TORQUE: 113 N-m (11.5 mm, 33 Ibf-ft) L SHOCK ABSORBER REMOVAL Support (he motorcycle secureiv using a safety —'_"" stand or hoist and raise the rear wheel of? the V SHBCWKéNK ground. i, Remove the bolts/nuls and shock Ilnk. Remove the shock absorber lower mounting bolU nut. Remove the shock absorber upper mounting boh/ rim. Remove the shock absorber to downward through me swingarm. 15'” Contents Chapter 15 REAR WHEEL/SUSPENSION INSPECTION Visually inspect the shock ahsorper for damage. Check the following: DAMPER UNIT a Damper rod for bends or damage a Damper unit for deformation or oil leaks 7 Rubber bumper for weal or damage RUBBER BUMPER Inspect all the other parts for wear or damage. If necessary, replace the Shock absorber as an assembly. DAMPER ROD SPH ERICAL BEARING REPLACEMENT Remove the dust seals. Remove the stopper ring from the leh side pivot STOPPER RING Prepare the metal pipe tas a base holder; LD. 27 mm or other suitable collar) for the spherical baarlng EEAR'NESFL'XER? removal. mm Press the spherical bearlng put of the shock absorber pivot using the metal pipe and special moi. TOOLS: l SPHERVCAL Bearing driver o7GMD-KTao1ou BEARWG (Use only 17 mm collar) BASE HOLDER Press new spherical bearing into the shock absorber pivot trpm the left side until It is fully seated, usmg the special tool and hydraulic press, TOOLS: Bearing driver 07GMD-KT80100 (Use only 17 mm collar] SPHEHICAL BEARlNG Contents Chapter 15 1545 REAR WHEEL/SUSPENSION Install a new stopper ring into the groove of the shock absorber pivot securer ®§ STOPPER RING rrelenpivbroust Apply grease to the new dust seal lips and install seaia o. is/a'gsr them into the shock absorber pivot. than rig/it nivni dust seal a 0 A DUST SEALS SHOCK ABSORBER DISPOSAL PROCEDURE Dr: hm remove the Remove the shock absorber reservoir cap. valve cola l/l'iIl/ Put on safety gIasses, then reIease the nitrogen nlessu/e is from the reservoir by depressmg the valve core, released - Point the VaIve away rrern you to prevent debris getting in your eyes. i - Before disposal or the shock absorber, release the nitrogen by pressing the vaIve core. Then remove the valve horn the shock absorber reser- ‘ VOIY. ‘ VALVE CORE INSTALLATION Set the shock absorber to the upper mount with the rebound damping adjusterfacing iert. Install the upper mounting pelt and nut. InstaII the lower mounting bolt and nut. Tighten the upper and lower mounting nuts to the specified torque, TORQUE: 44 N-m (4.5 kgI-m, 33 Ibf-ft) 15'” Contents Chapter 15 REAR WHEEL/SUSPENSION lnslall the shock link In the frame and shoek arm, _ WK i v w w lnslall the shock link bolts and nuts. Tighten the nuts to the specified torque. TORQUE: 44 N-m (4.5 kgf—m, 33 Ibf-ft) SUSPENSION LINKAGE REMOVAL Support the motorcycle securely using a safety stand or hoist and raise the rear wheel off the ground. Remove the belts, nuts and shock link. Remove the following: »5 SHOCK ARM BOLT/NUT — Shock arm boll/nut (swingarm Side) ‘ISWINGARM SIDEl ~ Shock absorber lower mounting bolt/nm ’ “ - Shock arm Remove the pivot collar and dust seals from the shock link. Check the dust seals and pivot collar for wear, dam» age or fatigue. Check the needle bearings fur damage er loose in. Check the shock link for cracks or damage. lfthe needle bearings are damaged, repIace them. SHOCK LINK PIVOT COLLAR Contents Chapter 15 15'” REAR WHEEL/SUSPENSION Press the needle bearings in in this shock link with the marked side facing our Remove the following SlDE COLLAHS WASHERS r Thrust washers — Dust seals 7 Side collars — Pivot collars Check the dust seals, thrust washers arid collars lor wear, damage orlaligue. Checkthe needle bearings for damage or loose fit, Check the shock arm ror cracks or damage. lflhe needle bearings are damaged, replace khem. BEARING REPLACEMENT SHOCK LINK NEEDLE BEARING Remove the needle bearings from the shock lirik using the special tools TOOLS: Remover handle 07335~3710100 Bearing remover, 17 mm 07936—371030!) Remover weight 07741-00102!” or D7936-371020A, 07536-3710200 (U.S.A. only) BEARING REMOVER Pack the new needle bearings With multlrpurpose DRlVER grease lShell Alvania EPZ or equwalent). 4.8 , 5.2 mm Press the new needle bearings into the shock link (01970.20 inl pivm so me: the needle bearing surface is 4.9 — 5.2 mm [0.l3 so.20 in) below the end loe shock link surface, using the special tools and a hydraulic press. TOOLS: Driver 07749-0010000 Attachment, 24 x 25 mm 07746»001D700 Pilot, 17 mm 0774647040400 A'I'I'ACHMENT/PlLOT NEEDLE BEARING SHOCK ARM NEEDLE BEARING Press the needle bearings (shock link side, DRIVER swingarm sidel om or the shock arm using lhe spe- cial tools and a hydraulic press. TOOLS: Driver 0794941710001 Attachment, 22 x 24 mm o774s-omosoo or 07746-001A800 lU.S.A. only) Pilot, 17 mm 07746-0040400 15-18 Contents Chapter 15 Press the needle bearing (shock absorber side] out of the shock arm using the special tools and a hydraulic press. TOOLS: Driver 07549-37100!” Attachment. 24 x 26 mm 0774641010700 Pilot, 19 mm 077460041400 Pack the new needle bearings with multivpurpose grease (Shell Alvania EPZ orequlvalent). Press the new needle bearlngs into the pivot [shock link side and swingarrn side) so that the needle bearing surface is 4.8 - 5.2 mm (0.19 r 0.20 in) below the end of the shock arm surface, usan the Press the needle bearlngs mm the shock am-l wllh the marked Slde {55ng our. special mole and a hydraulic press. TOOLS: Driver 07749-0010000 Attachment. 24 K 26 mm 077480010700 Pilot, 17 mm 07746-0040400 Pack the new needle bearlrlg wlth multipurpose grease lShell Alvania EP2 or equivalent). Press the new needle bearlng into the shock absorber side plvot so that the needle bearing sur» face l5 5.35 — 5.65 mm [0.211 r 0.222 in] below the end orthe shock arm surface, using the special tools and a hydraulic press. TOOLS: Driver Attachment, 24 x 28 mm Pilot. 19 mm 07743-0010000 077460010700 077460041400 INSTALLATION Apply multi~purpose grease (Shell Alvania EP2 or equivalent) to the dust seal Ilps, collars and needle bearings. - Make sure the needle bearing rollers of the shock absorber side are In posmon before installing. , Number of needle rollers: 27 lnstall the pivot collars, side collars, dust seals and thrust washers to the shock arm. REAR WHEEL/SUSPENSION DRIVER ATl'ACHMENT/PILOT DRlVER 4.3 , 5.2 mm l0.19 , 0.20 inl l ' e? AWACHMENTIPILOT NEEDLE BEARING DRIVER 3 75.65 mm . 1 —0.222 in) l l NEEDLE BEARING SIDE COLLARS PIVOT COLLARS Contents Chapter 15 15-19 REAR WHEEL/SUSPENSION AppIy muIIi-purpose grease (ShelI AIvanIa EP2 or equivalent) to lhe dusI seal lips, pivor coIIar and needIe bearings. lnstail the pivot coliar and dust seais to the shock link. 'fii DUST SEALS SHOCK LINK Loosely instaII the foliowing. - Shack arm , Shock arm boII/nut [swvngarm Side) , Shock absorber lower mouming bolt/nut Tighten Ihe shock absorber lower mounting nut to the specified torque: TORQUE: 44 N-m (4:5 kgf-rn, 33 Ibi-fi) Instali the following: 7 Shock link — Shock arm bolt/nut Ishock link sideI — Shock link bolt/nut {frame SldeI Tighten the nuts re the specified (orque. TORQUE: Shock link-to-frarne pivot nut: 44 N‘m (4.5 kgf-m, 33 Ibf-ft) Shock armrtu-shock link nut: 44 Nvm (4.5 kgl-m, :3 lbf-I't) Shock arm-to-swingarm nut: 44 N-m (4-5 kgf-m, 33 lbf-ft) SHOCK LINK SHOCK ARM BOLT/NUT BOLT/NUT (SHOCK LINK SIDE) SWINGARM REMOVAL Remove me foIlow'ing: BRAKE HOSE GUIDE , Rearwheel (page i577) e Shock absorber (page 15-14I , Suspension Iinkage {page 1517) Remove (he boltand rear brake hose guide from the swmgarm. 15'” Contents Chapter 15 REAR WHEEL/SUSPENSION Remove the bolt and gearshift arm from the gear— " , shift spindle, ‘ ’ GEA HIFF ARM ) /: r5 not necessa/y Remove the clutch slave cylinder (page 10713). to draw the Clutch hydraulic sysrem m 0'69! to remove the swmgarm Remove the clutch lifter rod, Remove the bolts and drive sprocket cover. Remove the gasket. spacer and dowe‘ pm. Remove the bolt, washer and drive sprocket. Contents Chapter 15 15-21 REAR WHEEL/SUSPENSION Remove the swingarm pivot nut and washer, Hold the swingarm pivot shah and remove the swingarm pivot lock nut from the rlght pivot using the speciai tool. TOOL: Swingarm lock nut wrench, 5‘8 x 47 mm D7VMA—MCF0100 or 07VMA—MCFA100 (U.S.At on|y) Loosen the swingarm pivot adjusting boil with the pivot shaft. Be carefu/somal Remove the swingarm pivot shah and the swing (/76 mm! col/5r: do arm. not damage the main frame, SWINGARM PIVOT SHAFT 15-22 Contents Chapter 15 REAR WHEEL/SUSPENSION DISASSEMBLY/ INSPECTION Remove the heirs and rear inner fender. HEAR INNER FENDER Remove the two bolt and drive chain case A. Remove ihe boll, [rim clip and drive chain case B. Remove (he three bolxs, coilars and drive chain slider. Check the drive chain slider for wear ar damage. BOLTS/COLLARS Contents Chapter 15 1523 REAR WHEEL/SUSPENSION Remove the pivot collars and dust seals. Remove the distance collar from the swingarm left Slde plvot. . PIVOT COALLH DISTANCE COLLAR Check the dust seals for damage or fatigue. Check the pivot collar and distance collar for wear or damage. Turn the inner race of right side pivot ball bearing with your finger. The bearlng should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the swingarm pivot. Remove and discard the bearing it the races do not turn smoothly and quietly, or if they fit loosely in the swingarm plvot. BEARING PIVOT BEARING REPLACEMENT Remove the snap ring from the swingarm right side l pivot. SNAP RING Remove the left pivot bearing needle rollers before removing the rlght plvot bearings. Press the right pivot needle and ball bearings out of the swingarm pivot using the special tools and a hydraulic press. géklgthG TOOLS: Driver 07OGD-0010100 or 07OGD-OO1A100 [U.s.A. only) Attachment, 28 x 30 mm 079464870100 /,//{\/\ , { }7/ Pilot, 25 mm 07746-0040600 7,, , 57/ / / NEEDLE BEARING 15'24 Contents Chapter 15 REAR WHEEL/SUSPENSION Cnaeh the speCial tools into the left pivot needle ATTACHMENT earlng cage as shown. Press the left pivot needle bearing cage out of the swingarm pivot, using the special tools and a hydraulic press. TOOLS: Driver D7DGD-0010100 or 07DGD-001A1DO iu.s.A. only) Attachment, 34 mm 07ZMD-MBW0100 or O7ZMD-MBWA100 (U.s.A. only) Ball race remover 07S48-4530l00 Packthe new ball bearing cavities with grease (Shell Alvania EPZ or equivalent). Press the ball bearing into the swingarm right pivot until it is fully sealed, using the special tools and a . hydraulic press. TOO LS: Driver 07749-001000!) Attachment, 40 X 42 mm 07746~0010900 Pilot, 25 mm 0774641040600 ATTACHMENT/PILOT BALL BEARI G Pack the new needle bearing with grease (Shell Alvania EPZ or equivalent). ATTACHMENT DR‘VER Press the needle bearing into the swingarm right pivot until it is fully seated onto the ball bearing, using the special tools, removed right pivot collar REMOVED * COLLAR and a hydraulic press. TOO LS: Driver 07749-0010000 Attachment, 42 mm 070AD-POA0100 \" NEEDLE BEARING Install the snap ring into the right swingarm pivot graove securely. SNAP RING Contents Chapter 15 15-25 REAR WHEEL/SUSPENSION Pack We new needle bearing with grease (Shell AIVania EPZ or equivaleml. Press ms need/s bearing mm me swingaml will the marked SldB Iacmg 0U! Press the needIe bearing inxo We left swingarm pivot until the depth from the swingarm pivot sur» ' face is 7.0 ~ 8.0 mm [018 — 0.31 in), using the special tools and a hydraulic press. TOOLS: Driver 077490010000 Attachment, Ml x 42 mm 077450010900 Pilot. :2 mm D‘IMAD-PRSOZOO ASS EMBLY RIGHT PIVOT COLLAR ,fil DUST SEAL \\ SNAP RING ©6> a RIGHT PIVOT NEEDLE \, BEARING RIGHT PIVOT /§ BEARING DISTANCE COLLAR Asian LEFT PIVOT fl® NEEDLE BEARING Q. LEFT PIVOT COLLAR B 8 N-m (03 kgf»m, 6.5 [bf-ft) Install the distance collar from she lefl side pivotl Apply grease (Shell Alvania EP2 or equivalent) lo new dust seal lips. I . Install the dust seals and pivot collars into the I, swingarm pivot. :IfII/CT DRIVER 7,0 — 30 mm (028 — 031 mi ATTACHMENT/PILOT NEEDLE BEARING INNER FENDER DRIVE CHAIN SLIDER "E”, DUST SEALS 15-26 Contents Chapter 15 REAR WHEEL/SUSPENSION Install me drive chain slider allgning irs slit with the - boss on the swingarrn, DRIVE CHAN SLIDER Install the drive chain slider mounting ball (from). Insiall the cullars and new drive chain slider mount- ing bolts (rear). Tighten the bolts to the specified torque. TORQUE: 3.8 MI“ (0.9 kgfrm. 6,5 Ibf‘f‘) Install lhe drive chaln case B and tighten Khe bolt securely. Install the trim clip. Install the drive chain case A and lighten the bulls securely. Contents Chapter 15 1527 REAR WHEEL/SUSPENSION Install the rear inner fender and tighten the bolts securely, REAR INNER FENDER INSTALLATION Make sure that the adjusting bolt does not protrude inside of the frame pivot. Apply a thin coat of grease (Shell Alvania EP2 or equivalent) to the swingarm pivot shaft sliding sur- face. Install the swingarm to the frame. Install the swingarm pivot shah from the right Side. Tighten the adjusting bolt with the pivot shaft TORQUE: 15 Nm (1.5 kgf‘m, 11 Ith) 15-23 Contents Chapter 15 Fle'el (D torque wrench rsedrng intermarron on page 1573 ‘Serv‘ce mic" manon' TORQUE: 113 Mm (11.5 kgf—m. 83 Ibi-fl) instant the washer and swingarm pivot nut, and WIN tighten the nut to the specified torque. Hold the swingarrn pivot shaft, tighten the pivot adjusting boit lock nut to the specified torque. TOOL: Swingarm lock nut wrench. 5.8 x 47 mm 07VMA-MCFO1OD or 07VMA-MCFA1OO / e (U.S,Ae only) / TORQUE: Actual: 64 New! (6.5 kgf-m, 47 lbf—ft) Indicated: 58 Ntrn (5.9 kgf-m, 3 Ibf-fl) tnstan the drive sprocket with its marks tacing out, install the washer and sprocket bolt, then tighten the bolt to the specified torque. TORQUE: 54 N-m (5.5 kgf-m, 4D Ibf-ft) Install the dowel pins, spacer and new drive sprocket cover gasket, REAR WHEEL/SUSPENSION GARM PIVOT NUTNVASHER ‘ .- , Contents Chapter 15 15-29 REAR WHEEL/SUSPENSION lnstall the drive sprocket cover and tighten the bolts securely. lnslall the clutch lifter rod, , —v‘?‘ > . lnsiall (he gearshlh arm aligning its slit with the 9" “ ~ punch mark an the gearshift spindle. , GEASH'FTARM \, Tighten the gearshift arm pinch bolt securely » 5:” install the clutch slave cylinder (page 10-15lv ' * lrlsmll ills brake lnstall the rear brake hose guide and lighten the bolt hose guide securely. belween the inner - , Wmmandswmg lnstall the following. arm — Shock absorber (page 15—16l — Suspension linkage (page 15-19l — Rear wheellpage15v13) 15-30 Contents Chapter 15 16. HYDRAULIC BRAKE COMPONENT LOCATION-~-m--m---~~~------16-2 SERVICE INFORMATION ............................ 15.4 TROUBLESHOOTING .................................. 16-6 BRAKE FLUID REPLACEMENT/ AIR BLEEDING 16-7 BRAKE PAD/DISC16-11 FRONT MASTER CYLINDER ---------------------- 16-15 REAR MASTER CYLINDER ------------------------ 15—21 FRONT BRAKE CALIPERS -------------------------- 16-27 REAR BRAKE CALIPER ............................. 15.31 BRAKE PEDAL ............................................ 15.34 Contents Chapter 16 16-1 HYDRAULIC BRAKE COMPONENT LOCATION FRONT: 12 N-m (1.2 kgf~m, 9 Ith) 9.8 N-m (1.0 kgf-m, 7 mm) 34 Nm (3.5 kgf'm, 25 WHO 45 N-rn14.5 mm, 33 lbt-m Chapter 16 Contents 16-2 HYDRAULIC BRAKE REAR: 16-3 (1‘0 kgf-m, 7 ibf-ft) 9.8 N-rn 34 N-m (3.5 kgf-m, 25 lbI-fl) m M 9 Z m m. 4. w m l N. m 3 m 3 n6 ,1 mr f we mo. ma N.h ) NC a.“ M) w mm 7 mm m mm, w .3 Ma. 0. n kg U 8k e H3 m ..l a N n m N.Nm n 0 m3 C 2 HYDRAULIC BRAKE SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation c1 brake pad dust. regardless of material composition, could be hazardous to your health. 1 0 Avald breathing dust particles. . Never use an air hose or brush to clean brake assemblies. Use an OSHA approved vacuum cleaner. Spllled brake fluid will severely damage insrrumenr lenses and painred surfaces. Iris also harmful to some rubber parts. Cover these surfaces with a shop towel before servmlng the brake system. Be careful whenever you remove the reserl/Dl'r cap; make sure {he reservoirs are horizontal first - A contaminated brake disc or pad reduces stopping power. Discard contaminared pads and clean a contaminated disc with a high quality brake degreasing agent. Check the brake system by applying the brake lever or pedal after the air bleeding. Never allow contaminants ldirt, water, etc.) io get into an open reservoir. Once the hydraulic system has been opened, or ii the brake feeis spongy, the system musl be bled. Aiwavs use lresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix dinerent types of fluid; they may not be compatible. - Always check brake operation before riding rhe motorcycle, Master cylinderl. D. 17.515 10.6895) ' 17.309 [0.5515) SPECIFICATIONS Unit: mm (in) ITEM ‘ STANDARD SERVICE LIMIT .me. :Specliied brake Iiuid 7 , 7 — 777 V 1 40 (0.15) Brake disc runout i_ 0.3010 012i i i Mesler piston 0 D. i Brake disc thickness i CallpercyiinderlD A 1 32. 03 — ,7 ( 32,140 (12554)" 7 B #7 30. 230— 30 330 (1.1921 — 11941);"’77 _. 370317170 17171945)77 Caliper piston 0.0. A 31. 967— 32. 000 (12585 712598) ) 31.957l12581) B 30.167—30.20011.1877—1.1890) l 30,157i11373) Rear soecilied brake tluid TOT 4 ' ' 'BFa'ke pedal height 7 75 l3.0) - Brake disk thickness ’“ fi) (0.20) ‘ 4.00116) Brake disc runout ' a 0. 30 (0. 012) Mastergylinder ID. 15370 —15.S13(0.624B — 0.6265) 7i7 15 925 (0 6270) Master plslcn 0.0. 7 15.1327 7153541052317 0.6242) _ 15. 815 10. 627276): Caliper cylinderlD. ’ 38.180738.230(1.503171.5051) 3s. 24l1. 506) i Caliper piston 0:). 33.70798 7 33148114999 — 5019) 33.09l1.500) . 16'4 Contents Chapter 16 HYDRAULIC BRAKE TORQUE VALUES Brake hose oil bolt Rear brake caliper pad pin Rear caliper bleed valve Rear brake caliper slide pin tiplt Rear brake Caliper mounting bolt Rear brake hose clamp bolt Rear master cylinder push rod joint nut Rear brake reservoir hose joim screw Reer master cylinder reservoir cap screw Rear master cylincler reservoir mounting boll Rear master cvllrlder mounting bolt Brake pedal pivot bolt From brake caliper mounting bolt Front brake caliper assembly bolt Front brake caliper pad pin From caliper bleed valve From orake nose clarnp Front brake hose Sawfly joint bolt From brake hose Clamp (left sidel Front master cylinder reservoir cap screw Front master cylinder reservoir stay bolt From brake lighl Switch screw Front master cylinder reservoir mounting nut Frpnt brake lever pivot bolt Front brake lever pivot nut Front master cylinder bleed valve From master cylinder holder bolt TOOLS Snap ring pliers 07514»SA50001 34 N-m 13.5 kgf-m, 25 lbf-ft) 18 Ntm11.B kgf-m, 131bftftl 5.9 N-m (0.6 kgl-rn, 4.3 (bi-rt) 27 N-m (2.8 kgfvm, 20 Ibl-fl) 23 Nm 12.3 kgf-m,17|l:f~h) 3 9 N-m (o 4 kgfvm, 2.9 lbf-ltl 13 N-m 11.3 kgf-m,13lbf-ftl 1.5 N‘m 10.15 Kgf~m, 11 1mm 1.5 N-m 10.15 kgf-m, 1.1 lbf-fr) 12 N«m11.2 kgf~m, a lbf-frl 9.8 N-m (1.0 kgi-m, 7 lbf-fil 18 N~m (1.8 kgf~m,13lb1vfll 45 N-m (4.6 kgl-m, 33 lbf-fl] 23 N-m 12.3 kgr-m.17lbi-m ‘16 Nam 11.6 kgf«m,12lbf~ft) 7s N«m 10.3 kgr‘m, 5 3 lbf‘ft) 8.8 N-m (0.9 kgf-m,6.5lbf1hl 9.8 N-m (1.0 kgf-m, 7 (bi-ft) 9.3 N-rn (1.0 kgf-rn,7lbf-l'1) 1.5 N-m 10.15 kgf—m,1.1|bf-hl 12 N-m11.2 kgfim, 9 lbfvl‘rl 1.0 N‘m 10,1 kgf-m, 0.7 lbl-ttl 5.9 N m (0.6 kgf m, 4.3 lbfft) 1.0 N-m 10,1 k9f-m,0.7 lbf-ftl 5.9 N-m 10.5 kgi m, 4.3 Ibf-l‘tl 5.9 N-m 10.6 kgrm,4,3lor-rt1 12 N~m 11.2 kgf~m, 9 (but) Apply a locking agent to the threads ALOC bolt: replace with a new one Apply a locking agent to the threads Urnul Contents Chapter 16 16-5 HYDRAULIC BRAKE TROUBLESHOOTING Brake lever/pedal soft at spongy - Air in hydraulic system . Leaking hydraulic system ' Contaminated brake pad/disc . Worn caliper piston seal I Worn master cylinder piston cups . Worn brake pad/disc - Contaminated caliper I Caliper no! sliding properiv (rear) I Low brake fluid level - Clogged fluid passage ' Warped/deformed brake disc - Sticking/worn caliper piston - Sucking/worn master cylinder piston - Contaminated master cylinder ~ aent brake lever/pedal Brake lever/pedal hard - Clogged/restricted hydraulic system I Sticking/worn caliper piston I Caliper not sliding properly (rear) I Clogged/restricted fluid passage - Worn caliper piston seal - Sticking/worn master cylinder piston . Bent brake lever/pedal Brake drags Contaminated brake pad/disc Mlsalignsd wheel Clogged/restricted brake hose jelnl Warped/deformed brake disc Cailper not sliding properlv (rear) Clogged/restricted hydraulic system Sticking/worn caliper piston Clogged master cylinder pen Sticking master cylinder piston ocaeeeece 16'6 Contents Chapter 16 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ AIR BLEEDING Spilled fluid can damage painted, plastic, or rubber parts. Place- a shop towel aver these parts whenever the system is serviced. - Do not allcw foreign material to enter the system when filling the reservoirc BRAKE FLUID DRAINING FRONT: Beiore removing the reservoir cap, mm the handle- bar until the reservoir is parallel to the ground. SCREWS Remove the screws, reservoir cap, set plate arid dia- . . RESERVOIR CAP p phragm. Conneci the bleed huse to ihe masicr cylinder bleed valve. Loosen the master cylinder bleed valve, and pump ihe brake lever. Stop pumplng the brake lever until no more lluid flows out of the bleed valve Connect the bleed hose to the caliper bleed valve. Loosen the Caliper bleed valve, and pump the brake lever. Slop pumping the brake lever until no more fluid flows out of the bleed valve. Perform this operation for the other Slde brake ca|i~ per. Contents Chapter 16 16-7 HYDRAULIC BRAKE REAR: Remove the rear seat cowl (page 35!. SCREWS Remove the screws, reservoir cap, set plate and dia- phragm. Connect a bleed hose to the caliper bleed valve. Loosen me bleed valve and pump the brake pedal. Stop pumplng the brake pedal untl'l no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/AIR BLEEDING NOTE. I Use only DOT 4 brake fluid from a sealed con- tainer. - Do not mix different types oi flu'ld. They are not compatible. . Do not allow forelgn material to enterthe system when filling the reservoir. FRONT; Close the bleed valves. Fill the reservoir with DOT 4 brake fluid from a sealed container. ’uiPER LEVEL LlNE 16-8 Contents Chapter 16 iinol using an auto- i'iaii rail.“ 5 stem, add b» 2 {mid Wl‘E’i the N 'l level in the resell/Dir is law HYDRAULIC BRAKE 1. Connect a commercially available brake bleeder to the master Cylinder bleed valve. MASTER CYLINDER ExLEED VALVE Operate the brake bleeder and loosen the bleed valve I Check the fluid level often while bleeding the brakes to prevent eirtrom being pumped into the system. - If air is entering the bleeder from around the bleed valve threads. seal the threads with teflon tape. - When using a brake bleeding tool, iollow the manufacturer's operating instructions Repeat above procedure until air bubbles do not appear in the bleed hose. Close the master cylinder bleed valve. TORQUE: 5.9 N!“ [0.6 kgf-m, 4.3 [bf-fl) 2. Connect a brake bleeder to the caliper bleed valve. operate the brake bleeder and loosen the bleed valve. Repeat above procedure unnl air bubbles do not appear In the bleed hose. Close Ihe bleed valve and perform air bleeding for the other Side caliper bleed valve. Close the caliber bleed valves. TORQUE: 7.8 N-m (0.3 kgl~m, 5,8 lbf-ft) 3, Perform the bleeding procedure at the master cylinder bleed valve again until the system is eompletelyiiushed/bied. Operate the brake lever. If it still ieeis spongy, bleed the system again. Fill the front brake reservoir to the upper level with DOT 4 brake fluid from a sealed container. Install the diaphragm, set plate, reservoir cap and screws. Tighten the screws to the specified torque. TORQUE: 1.5 N-m (0.15 kgf~m,1.1lbl~fll DlAFHRAGM/ ET PLATE (/97, REAR: Fill the reservoir with DOT 4 brake iluid from a sealed container RESEHVOlR Contents Chapter 16 16-9 HYDRAULIC BRAKE rr nrr‘ tlSlng an auras mall: i'ei’lli‘ system, and brake Y'lllld wner‘ the ill/id level in “is IESEIVOK '5 low. DD not release the meke level ar edal Connect a commercially available brake bleeder to the bleed valve. Operate the brake bleeder and loosen the bleed valve, ' Check the fluid level often while bleeding the brakes ta prevent airtrom being pumped into the system, - lf air is entering the bleeder from around the bleed valve threads, seal the threads with tellon , tape. I When using a brake bleeding tool, follow the manufacturer‘s operating instructions. Repeat above procedure until air bubbles do not appear in the bleed hose. Close the bleed valve. TORQUE: 5.9 N-m (0.6 kgf-m, 4.3 Ibf-ft] Operate the brake pedal. If it still feels spongy, bleed the system again. Fill the rear brake reservoir to the upper level Wlth !- ——1 DOT A brake fluid from a sealed container D'APHRAGM/SET P SCREWS Install the diaphragm, set plate, reservoir cap and _ -. Screws. s Tighten the screws to the specified torque. , . s i' ' , € TORQUE: 1.5 N»m (0.15 kgf-m, 1.1 lbf-ftl Install the rear seat cowl (page 376). If the brake bleedar is not available, perform the tol- lowing procedures: Connect a clear bleed hose to the bleed valve. Pressurize the system with the brake lever or pedal until there are no air bubbles In the fluid flowing out of the reservoir small hole and lever or pedal resis tance is felt, 1. Squeeze the brake lever or push the brake pedal, open the bleed valve 1/2 turn and then close the Valve. t . 2. Release the brake lever or pedal slowly and wait , several seconds after it reaches the end of its \ travel. ' _ . l 3. Repeat steps 'I and 2 until bubbles cease to ‘ ‘ BFEED VALVE appear in the fluid coming out of the bleed valve, 4. Tighten the bleed valves. TORQUE: Front caliper bleed valve: 7.8 N-rn (0.8 kgfvm, 5.8 lbf-ft) Front master cylinder bleed valve: 5.9 N»m [0.6 kgl-m, 4.3 lbf~ftl Rear caliper bleed valve: 59 N-m [0.6 kgt-m, 4,3 Ibf-ft] 5. Fill the reservoir to the upper level line with DOT 4 brake lluid from a sealed container. Install the diaphragm, set plate and reservoir cap. 16-10 Contents Chapter 16 HYDRAULIC BRAKE BRAKE PAD/DISC Aiwayseniace live FRONT BRAKE PAD REPLACEMENT 5'5” Dads "N W5 Loosen the pad pins. wassweeve" dist Remove the caliper mounting bolte and brake cali» pressure pen Discard the brake caliper mounting bolts. BRAKE CALlPER 39 W PADPINS - Cliecklhsbrfike Push the caliper pistons all the way in to allow i‘lmaleve’in the installation of new brake pads, make Western/[w :15' zesermii as (his operallan causes me level in rise Remove the pad pins, brake pads and pad springi Clean the inside of the caliper especially around the caliper pistons. Contents Chapter 16 16-11 HYDRAULIC BRAKE Instail the pad sprlng with ns bent stde downward » PAD SPRING Install the new brake pads with the cut portion of the shims toward entrance side of the brake disc which rotates normal direction, Install the pad pins while pushing the brake pad up into the caiipar. Be tara‘ulnalzo install the brake caiiper to the fork ieg so that the damage the pads disc is positioned between the pads (page 16-30it Tighten the new btake caliper mounting bolts to the specified torquev TORQUE: 45 MI“ (4.6 kgf—m, 33 [bf-ft) Tighten the pad pins to the specified torque, TORQUE: 16 N-m (1.6 kgf‘m,12|bf-fli DISC ROTATING DIRECTION VCUT PORTION PAD Ems " . 16'” Contents Chapter 16 HYDRAULIC BRAKE REAR BRAKE PAD REPLACEMENT Check me Drake Push the caliper piston all the way in by pushing the r fluid/evelm the caliper body inward to allow installation of new make master Cylan brake pads tier resell/Dir as m: ope/arian causes me level in N55 Remove the pad pin Remove the caliper mounting bolt. Pivot the caliper up, and remove the brake pads. Clean the inSIde of the caliper especially around the caliper piston. Make sure the pad spring is in place. Contents Chapter 16 16-13 HYDRAULIC BRAKE Install the new brake pads. Lower the caliper while pushing the pads against the pad spring so that the pad ends are positioned onto the retainer on the caliper bracket. Install new O-ring to the pad pin groove. Install the pad pin. Tighten the caliper mounting bolt to the specified , torque. TORQUE: 23 Mai (2.3 kgt-m, 17 lbt-I‘tl Tighten the pad pin to the specified torque. TORQUE: 18 N»m (1,8 kgf~m,13lbftft) BRAKE DISC INSPECTION Visually inspect the brake discs for damage or cracks. Measure the brake disc thickness with a microme [BIC SERVICE LIMITS: FRONT: 4.0 mm (0.16m) REAR: 4.0 mm (0.15 in) Replace the brake disc if the smallest measurement ‘ is less than the service limitt Measure the brake disc warpage with a dial indica- tor. SERVICE LIMITS: FRONT: 0.30 mm (0.0012 in) REAR: 0.30 mm (0.0012 In Check the wheel bearings for excessive play [page 14717 and 1578], it the warpage exceeds the service limltt Replace the brake disc if the wheel bearings are nor- mal. 16'” Contents Chapter 16 HYDRAULIC BRAKE FRONT MASTER CYLINDER Spilled fluid can damage painted, plastic, or rubber parts. Place a shop towel over these pans whenever the system is serviced. REMOVAL Drain me lronl hydraulic system (page 1677). -— SEALING WASHERS ‘ CONNECTOR§V Disconnecr the brake light switch connectors. Avoru sor’svvg’ruld Remove me brake hose oil boll, sealing washers a: named. sJasrrc and brake hose eyelet joim. 0’ 'ubbe'oa'rs Remove xhe bolrs from the master cylinder holder and remove the master cylinder assembly. DISASSEMBLY Remove the dust cover and snap ring. r. TOOL: Snap ring pliers 07914-5Asooo1 Remove the bolt and brake reservoir from {he mas» [er cylinder. Remove the Orring from the reservoir joint. Contents Chapter 16 16'15 HYDRAULIC BRAKE Remove the pivot bolUnut and brake \ever assem~ BRAKE LEVER bly. f I PIVOTBOLT PIVOT NUT Remove the screw and brake light switch Be careful not to Remove the boot and push rod, damage the boot, PUSH ROD Remove the snap ring from the master cylinder body using the special too) as shown. SNAP RWG TOOL: Snap ring pliers 07914-SA50001 Remove the master anon, spring 3nd spring guide lrom the master cylinder body. >. SNAP RING FLIERS “5'15 Contents Chapter 16 HYDRAULIC BRAKE INSPECTION Clean Ihe inside of the cylinder and reservoir with clean brake fluid, SPRING GUIDE Check the piston boot, piston cups for damage or deterioration Check the master cviinder and piston Ior abnormai " scratches. ‘ MASTER PiSTON Check the spring for iatlgue or damage. \ MASTER CVLINDER «’0 SPRING PISTON CUPS Measure the master cylinder LD. SERVICE LIMIT: 17.515 mm (0.6396 in] Measure the master cylinder piston OD. SERVICE LIMIT: 11309 mm (0.6315 in) Contents Chapter 16 15-17 HYDRAULIC BRAKE ASSEMBLY 5.9 N-m10.6 kng, 4.3 IbI-i‘t] 10 N-mi01kgfvm,07lbf-ft) AF V‘ég RESEFIVCNR C 1.5 N-m (0.15 kgf-m, 1.1 ibf-ft) MASTER CYLINDER SPRING GUIDE SPHiNG . 7/ MASTER PISTON 5. a N m _ 7 5 t/ in. s kgf m 4.3 ibf-ft)\@ SET PLATE BRAKE LiGHT SWITCH DIAPHRAGM BRAKE LEVER - Keep the piston, cups, spring, snap ring and boot MASTER CYLINDER as a set; do not substitute individual parts. Coat the master piston and pistun cups With clean brake fluid. SPRING instaii the spring guide into the spring. Wher- iiisza/iing the lnstaii the spring guide/spring and master piston MASTER suns, do notaii‘cw into the master cylinder. PiSTON me iips to mm inside out fig) SPRiNG GUIDE 32 Certain the snap Instaii the snap ring with the special tool, SNAP RING ring [5 tirmiy seared H1 the gnome TOOL: Snap ring pIiers 07914-SA50001 SNAP RiNG PLIERS ”'18 Contents Chapter 16 HYDRAULIC BRAKE Apply siiicane grease to Contact surfaces of the push rod and master piston, Install the boot with the push rod. BOOT/PUSH ROD install the brake light switch and tighten the screw to the spemfied torque. TORQUE: 1.0 N-m (0.1 kgf-m, 0.7 le‘t) Apply silicone grease to push rod tip. install the brake lever by aligning the hole of brake lever with the push rod. Apply silicone grease to the brake lever pivot bolt sliding surface. Install the brake lever pivot bolt and nut. Tighten the pivot bolt to the specified torque. TORQUE: 1.0 N‘m [0.1 kgf-m, 0.7 IbH’t) BRAKE LEVER Hold the pivot bolt and tighten the pivot hut tn the specified torque. TORQUE: 5.3 N-m (0.6 kghn, 4.3lb1h) PIVOT NUT Contents Chapter 16 15-19 HYDRAULIC BRAKE lrlsra/l the master L‘Vllllder holder Wlt‘ll lls 'UP' mark fanlng us Apply brake fluid to new O-ring and install it to the reservoir hose joint. Install the master cylinder reservoir Joint into the ., master cylinder and secure the joint with the snap ring. TOOL: Snap ring pliers 07914-SA50001 Install the dust cover. Install the reservoir stay onto the master cyllnder and tighten the muunting bolt to the specified torque. TORQUE: 12 N-m [1.2 kgf-m, 9 IN“) BOLT Install the master cyllnder assembly, master cyllnn MASTER CYLINDER der holder and belts. Align the end of the master cylinder with the punch mark an the handlebar (page 14-14). Tighten the upper bolt first, then the lower bolt to the specified torque. TORQUE: 12 N‘m (1.2 kgf-m, 9 Ith) 1,\ 7 . 4.»; HOLDER Q ~ Install the brake hose eyelet with the Oil bolt and new seallng washers. Push the eyelet ioint against the stopper, then tighten the oil bolt to the speclfled torque. TORQUE: 34 N-m (3.5 kgl~m, 25 Ruth) Connect the brake light switch connectors. Fill brake 'Iu'ld and bleed air from the from brake hydraulic system lpage 16-8). 16-20 Contents Chapter 16 HYDRAULIC BRAKE REAR MASTER CYLINDER Spr'I/Ed fluid can damage painted, manic, or rubber parts, Place a shop towel over these pans whenever the system is serviced. REMOVAL Remcve the bolts and exhaust pwpe proleclor, Drain the rear hydraulic systemtpage1677). Remove me bolts and passenger peg bracke‘. Remove the bolt and rear master cylinder reservoir. RESERVOIR Contents Chapter 16 16—21 HYDRAU LIC BRAKE Avaidsprii/ngflma Remove the brake hose on bail, seaiing washers an oemze piasfrc, and brake hose eyelet joint. fir 'ubner {19/15 Wm , A ’ ‘ LSEALiNG WASHERS ' Loosen the rear master cviinder mounting bolts, Remove the bolts and right footpeg bracket, then remove the master cylinder mounting baits, step guard and rear master cylinder from the right foot- peg bracket. Remove and discard the brake pedal joint cotter pin. Remove the nut, washers, jomr bait and rear master cyiinder, (see COTTER PIN DISASSEMBLY Remove the screw and reservoir hDsE joint from the master cylinder. Remove the mm; from the reservoi RESERVOiR HOSE JOINT O’BiNG SCREW 15-22 Contents Chapter 16 HYDRAULIC BRAKE Be carefulnor ro Remove the boot from the master cylinder body. damage me has: Remove the snap ring using the special toolt BOPT , _ SNAP RING PLIERS TOOL: Snap ring pliers 07514-5Asaou1 Remove the push rod, master piston, primary cup and spring SNAP RING INSPECTION CIean the master piston, spring and inside of the chInder wlth clean brake fluid. Check the push rod boot, primary cup and secondr ary cup for damage or deterioration. Check the master cylinder and piston for abnormal SECONDARY CUP scratches. Check the spring forfatigue or damage. SPRING PRIMARY CUP ” BOOT MASTER PISTON PUSH ROD ASSEMBLY Measure the master Cylinder I‘D. SERVICE LIMIT: 15,925 mm (0,6270 in) Measure the master cylinder piston CID. SERVICE LIMIT: 15.815 mm [0‘6226 in) Contents Chapter 16 1623 HYDRAULIC BRAKE ASSEMBLY 1.5 N-m [0.15 kgf-m,1.1 Tbi-fl) MASTER CVLIN DER RESERVOIR CAP / PUSH ROD \75 SET PLATE H‘ . ,, RESERVOIR PEDAL JOINT MASTER PTSTON - Keep the plston, cups, sprlng, snap ring and boot R N as a set; do not substitute indlvldual parts. 5P ‘ G Coat the master piston and piston Cups with clean brake fluld, SECON DAHV CUP Install the primary cup to the spring. L’Vhenmstah‘lnqthe Install the spring/prlmary cup and master piston cups do note/low into the master cylinder. ”“5””? ”C" Apply siHcone grease to the piston contact area of PR|MARV cup @519 / ’“5 5 W“ the push rod, . a, Install the push rod assembly Into the master cyll‘n- ’ - der. last MASTER PISTON PUSH ROD ASSEMBLY InstaH the snap rlng usmg the speclal tool. BOOT SNAP RING PLIERS Be CelTal‘n the snap TOOL: "”995 WWW Ssaffi‘d Snap ring pliers 07914-SA50001 m the groove Apply slllcone grease to the push rod boot inside. Install the boot into the master cylinder. SNAP RING “5'24 Contents Chapter 16 HYDRAULIC BRAKE If the push rod joint is disassembled, adjust the push rod length so that the distance between the JO'NTNUT centers of the master cylinder lower mounting bolt note and joint pin hole is 75 mm 130 in). After adjustment, tighten the mint nut to the specified torques TORQUE: 18 N-m (1.5 kgf-m,13|bf-fl) 4—» 75mmt3.nint Apply brake fluid to new O»ring and install it onto the reservoirjoint. Install the reservcir joint to the master cvlinderr RESERVOIR INT ' 33:23:, locking agent to the reservoir Joint screw RESERVOIR HOSE JOINT Tighten the screw to the specified tcrquet TORQUE: 15 NW“ (0.15 kgftm, 1.1 Ihf-ft) INSTALLATION Connect the push rod lower Joint to the brake pedal and install the joint bolt and nut with washers. Tighten the nut and secure it with new cotter pin Contents Chapter 16 16-25 HYDRAULIC BRAKE Install the step guard and rear master cylinder to the ‘- right footpeg bracket, then tighten the master cylin» STEP GUARD der mounting bolts. Ruffle bracket/net Install the right iootpeg bracket and tighten the the hook of we bolts to the specified torque. ”95’9“” TORQUE: 37 Nm (3.8 kgftmi 27 “3”” Tighten the rear master cylinder mounting bolts to the specified torque. TORQUE: 9.3 N-m (1.0 kgf-m, 7 lbf-k) lnstal! the brake hose with the oil bolt and new seal- lng washers. Push the eyelet joint against the stopper, then tighten the oil bolt to the specified torque TORQUE: 34 N-m (3.5 kgf-m, 25 lbl-ft) J m ’A ‘9 SE LING WASHERS? lnstall the reservoir and tighten the bolt to the spec- lfied torque. TORQUE: 12 Nvm (1.2 kgf-m, 9 let) Install the passenger peg bracket and tighten the bolts to the specified torque. TORQUE: 25 N-m [2.7 kgl-m, 2|) lbf-hl ”'26 Contents Chapter 16 Install the exhaust pipe protector and tighten the bolts securely. Fill brake fluid and bleed alr the rear brake hydraullc system (page 16-8). FRONT BRAKE CALIPERS Amid 50 ng fluid Do not use high aressmp Ell! Ul [3/ng a close (0 3’1: n’cf. Spilled fluld can damage painted, plastic, or rubber parts. Place a shop towel aver these pans whenever the system is serviced. REMOVAL Drain the front brake hydraulic system lpage 16-7). BRAKE CALIPER Remove the brake hose oil boll] sealing washers N and brake hose eyelet joint, Remove the caliper mounting bulls and brake can- per. Remove the brake pads (page 16—11). DISASSEMBLY install a corrugaled cardboard or sofl wood sheet between the caliper pistons. Apply small squirts of alr pressure to the fluid lnlel to remove the pistons. HYDRAULIC BRAKE EXHAUST PIPE PROTECTOR Contents Chapter 16 16-27 HYDRAULIC BRAKE Remove Ihe three caliper assembly torx bans and separate the caliper halves, ASSEMBLV BOLTS Mark the psrons 10 Remove Ihe following: crszxe correct reas» . PISTON E «mow , Joml seal " ‘ Calvper pxslon A — Caliper piston B JOINT SEAL PISTON A Be carefulnor 10 Push the dus‘ seals and pIsIon seals In and IIfl them > PISTON SEAL damage the plslun out slldlng surface Clean the seal grooves wllh clean brake fluid, DUST SEAL INSPECTION ggeeck [he callper cylmder Ior scorlng or other damr CYLINDEH A CYLINDER B Measure the caliper clender |.DI SERVICE LIMITS: Cylinder A: 32.140 mm (1.2654 in) Cylinder B: 30340 mm (1.1945 in) 15-28 Contents Chapter 16 HYDRAULIC BRAKE Check the caliper pistons for scratches, scoring or other damage. Measure me caliper pismn 0.0. / SERVICE LIMITS: Piston A: 31.957 mm (1.2551 in) Pistun 3: 30.157 mm (1.1873 in) ASSEMBLY PAD SPRING 7.8N- U. k f- ,5.8|bf-fl CALIPER m‘ 8 Q m ) - » . PISTONS ' ~Et ‘ JOINTSEAL ’ l Ski/fin 1e N«m (1.5 kgf—m, 12 mm) PISTON SEAL DUST SEAL BRAKE PADS Coal new pislon seals. with clean brake fluid. Coat new dust seals with silicone grease. a9 P'STON SEAL Inslall the pislon and dust seals into the grooves oI ~’ vdi the caliper body. Cuat me caliper pistons with clean brake fluid and (fl install them into the caliper cylinder with Iheir open DUST SEAL ends Koward the pad. a PlSTON A PISTON B Contents Chapter 16 1629 HYDRAULIC BRAKE Install ”the new joint seal into the fluid passage on the caliper. JOlNT SEAL % ASSEMBLY BOLTS Assemble the caliper halves. Apply a locking agent to the caliper assembly torx bolt threads. install and tighten the caliper assembly torx bolts to the specified torque. TORQUE123 Mm (2.3 kgf—m, 17 Ibt-ftl INSTALLATION Install the brake pads (page ‘lSr‘l‘ll. Make sure that the Install the caliper to the caliper bracket. ‘ dowe’pl'ns am Tighten the new caliper mounting bolts to the speCI- ~ installed llllo the tied torque. calmer bracket , Draper/V TORQUE. 45 N-m (4.5 kglm, 33 lbf-ft) Install the brake hose eyeletjomt tn the caliper body with two new sealing washers and oil bolt. Push the brake hose eyelet joint to the stopper on the caliper, then (Igmen the Oil bolt to the specified torque. ’ TORQUE: 34 NW (35 kgI‘m, 25 [bf-ft) F‘lll brake fluid and bleed air from the tront brake hydraulic system (page 16-8]. ' 15-30 Contents Chapter 16 HYDRAULIC BRAKE REAR BRAKE CALIPER Amid swung film an palnlerl, maslla or rubber Darts Sail/ed fluid can damage painted, plastic, or rubber pans. Place a shop towel over these pans whenever the system Is serviced. REMOVAL Drain the rear brake hydraulic system [page 15ml , ’ 01L BOLT .-.. Remove the all bolt. sealing washers and brake hese eyelet jolnl. Remove the caliper mountlng bolt and the brake pads (page 15713). Pivm (he caliper up and remove ll iram lhe caliper brackel. DISASSEMBLY Remove lhe pad spring, collar and boot from the caliper bodyv BOOT COLLAR 16-31 Contents Chapter 16 HYDRAULIC BRAKE Place a shop towel over the piston Du not use high Positian the caliper body with the piston down and pressure alrorbrlng apply small squirts of air pressure to the fluid inlet me nozzle we close to remove the piston. YO mam/er Be careful not to Push me dust seal and plston seal In and Im them PISTON SEAL Damage the plston out. slldl'lg surface Clean the seal grooves with clean brake fluid DUST SEAL INSPECTION Check the caliper cylinder for scoring or other dam- age. Measure the caliper cylinder l.D. SERVICE LIMIT: 38.24 mm (1.505 in) Check the caliper piston for scratches, scoring or other damage. Measure the caliper piston 00 SERVICE LIMIT: 38.09 mm (1.500 in) 16-32 Contents Chapter 16 HYDRAULIC BRAKE ASSEMBLY REAR BRAKE CALIPEH ,fi §fl PISTON SEAL DUST SEAL CALlPER PISTON 3% s0? ,6» 18 Nm [1.8 kgfm,13lbftfl) \/ TOWARD THE film \W‘ BRAKE PAD CALM ”5m“ 27 Nm (2.8 kgi~m, 20 Inf-m @ é FlSTON SEAL Coal a new piston seal Willi clean brake fluid. Coat a new dust seal with silicone grease. Install the piston seal and dust seal into the groove oi the caliper body. COB! the calipev piston with Clean brake fluid and install it into the caliper cylinder wnh its open end toward the pad. if g/fil DUST SEAL fl % CALIPER PISTON install the pad spring into the caliper body. COLLAR Apply silicone grease to the inside of the boot and / install the boot and collar into the caliper. If the boot is hard or deteriorated, replace it wrth a \ new one. ‘ FAD SPRING ’ Contents Chapter 16 15-33 HYDRAULIC BRAKE INSTALLATION Make sure that the pad retainer ls installed on the . caliper bracket properly. BRAKE CAUPER Apply Silicone grease to the caliper pin and install the caliper onto the bracket. Install the rear brake pads and tighten the caliper mounting bolt and pad pln (page lselal. Install the brake hose eyelet joint to the caliper body , with new sealing washers and oil bolt. Push the brake hose eyelet joint to the stopper on the caliper, then tighten the all bolt to the specified torque. TORQUE: 34 N~m (3.5 kgf-m, 25 lbf-fl) Fill brake fluid and bleed air from the rear brake hydraulic system (page 16-8). BRAKE PEDAL REMOVAL Remove the right middle cowl (page 3_7)_ Disconnect the rear brake light SWltch 2P connector and release the light Switch wire from the clamps. Remove the exhaust pipe protector (page 1621). Remove the righl footpeg bracket socket bolts and bracket assembly from the frame. ”'34 Contents Chapter 16 HYDRAULIC BRAKE Remove and discard the brake pedal joint cotter pin. Remove the nut, washers and joint bolt, and discon- nect the push rod lower joint from the brake pedal. Unhonk the brake light swttch spring and brake pedal return spring from the brake pedal Remove the snap ring and thrust washer, then remove the brake pedal and wave washer. SNAP RING/WASHER \ INSTALLATION SWlTCH SPRlNG EHAKE LlGHT SWlTCH BRACKET WAVE WASHER THRUST WASHER BRAKE PEDAL Apply grease to the sliding surface of the brake pedal and pivot shaft. Install the wave washer, brake pedal, thrust washer and snap ring onto the brake pedal pivot. Connect the push rod lower Joint to the brake pedal and install the Jail“ bolt and nut with washers. Tighten the nut and secure it with new cotter pin. lnstall the brake pedal return spring and brake light switch spring. Contents Chapter 16 "5'35 HYDRAULIC BRAKE PufrhebrackeI/nax [nsLaH me right footpeg bracket to the frame and the hook arr/vs tighxen the bolts to the specTfied torque. neat guard. TORQUE: 37 Nvm (3.3 kgl-m, 27 Ihf-It) Route the rear brake light switch wwre propefly Connem the 2P {BlacH Connector and secure the brake Hgm switch wwre m me wire damp. Install the right middle cowl (page 378), z’ "4. 4‘ 4 A"? 16-35 Contents Chapter 16 17. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM .................................... 17,2 SERVICE INFORMATIONw--m---------»-----~-- 17-3 TROUBLESHOOTING .................................. 17.4 BATTERY 17,5 CHARGING SYSTEM INSPECTION ------------- 17-7 ALTERNATOR CHARGING COIL 178 REGULATOR/RECTIFIER ---------------------------- 17.3 Contents Chapter 17 17-1 BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM MAIN FUSE REGULATOR/RECTIFIER ALTERNATOR MAIN FUSE 30A) l— ,—o«§>—R—® e G 5 BATTERY 3P U v v v —J—‘— 2" v . G n . . REGULATOR/RECTIFIER ALTERNATOR T T R.,....RED V ...... YELLOW G..‘...GREEN 17'2 Contents Chapter 17 BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL AWA NIN - The battery gives off explosive gases; keep sparks, llames and cigarettes away, Provide adequate ventilation when l charging. ‘ - The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns, Wear protective clothing and a face shield. ‘ a II electrolyte gets on your skin, flush with water, a If electrolyte gets in your eyes, flush with water for at least 15 minutes and calla physician immediately. - Electrolyte is poisonous. ~ If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician immediately. Always turn off the ignition switch before disconnecting any electrlcal companent. I Some electrical campunents may be damaged if terminals or connectors are connected or disconnected while the ignir tmn swrrch is ON and current is present. . For extended storage, remove the battery, give it a full charge. and store it in a cool, dry space. For maximum service life, charge the stored battery every two weeks. 0 For a battery remaining in a stored motorcycle, disconnect the negative battery Cable from the battery terminal. 0 The maintenance free battery must be replaced when it reaches the end of its seerce life - The battery can be damaged il overcharged or undercharged, or it left to discharge tor a long period. These same con- ditions contribute to shortening the "life span" ol the battery. Even under normal use, the perlormance of the battery deteriorates alter 2 — 3 years. . Battery voltage may recover after pattery charging, but under heavy load, battery voltage Will drop quickly and eventu- ally die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itseit, which may appear to be an overcharging symptom. lr one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. I Before Iroubleshuoting the charging system, check tor proper use and maintenance of the battery. Check if the battery is frequently under heavy load. such as having the headlight and taillight ON lor long periods ol time without riding the motorcycle, . The battery will seltrdischarge when the motorcycle is not in use For this reason, charge the battery every two weeks to prevent sultation from occurring. When checking the charging system, always follow the steps in the troubleshooting ilow chart (page 1774). For battery charging, do not exceed the charging current and time specified on the battery. Use of excessive current or charging time may damage the battery. ' Refer to (page 114) for alternator removal and disassembly. BATTERV TESTING Refer to the instruction of the Operation Manual for the recommended battery tester. The recommended battery tester puts a “load“ on the battery so that the actual battery condition of the load can be measured. Recommended battery tester: BM-210 Dr BATTERV MATE or equivalent SPECIFICATIONS l ILEM ’ ’7‘ ’ 7 SPECIFICATIONS h A l Battery . Capacity . , 12 v a 3.5 Ah i Currentieakage T; 2.0 mA max. Voltage Fully charged 1 13.0 — 13.2 v lZOT/SEVF) Needs l Below 12.4 v ’ i . _ 7 . charging l Charging current Normali 7 0,5 Al5v l0 h . 7 Quick ’i ’ ' 45 N1 h Alternator 1 Capacity 77., W ’ . 0.344 le5,000 rpm 7 Charging?” resistance (EEC/68°F) 01 ~10 n Contents Chapter 17 17'3 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED 0R WEAK 1t BATTERV TEST Remove the battery (page 17-5]. Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM210 or BA'I'I'ERV MATE or equivalent Is the battery in 900:! condition? No — Faulty battery YES 7 GO TO STEP 2. 2. CURRENT LEAKAGE TEST Install the battery (page 17-5). Check the battery current leakage (Leakage test; See page 17-7), Is the current leakage below 2.0 mA? VES 7 GO TO STEP 4. NO , GO TO STEP 3. 3 CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTED Disconnect the regulalorlrectifier 2P Connector and recheck the battery cu rrent leakage. Is the current leakage belaw 2.0 mA? VES — Faulty regulalor/rectttier NO — I shorted wire harness I Faulty'ign'ition switch 4. ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging COII [page17-BL Is the alternatar charging cail resistance Within 0.1 — 1‘0 IJ {201/68 ’F)? No - Faulty charging coil YES , so TO STEP 5. 5. CHARGING VOLTAGE INSPECTION Measure and record the battery voltage using a digital multimeter (page 17-5). Start the engine and measure the charging voltage (page l7-7i. Compare the measurement to result of the following calculatlon. STANDARD: Measured battery Voltage < Measured charging voltage < 15.5 V Is the measured charging vultage within the standard voltage? VES — Faulty battery NO — GO TO STEP 6. 6. REGULATOR/RECTIFIER SVSTEM INSPECTION Check the voltage at the regulator/rectifier connector (page 17-8]. Are the results of checked Voltage correct? VES — Faulty regulator/rectifier N0 , - Open circuit in related wire - Loose or poor contacts 01 related terminal 0 shorted wire harness 17'4 Contents Chapter 17 BATTERY Always turn inc ignition swrrch orr eerore r Wing me aeneny 3 use , me: u. stand men :he negarlve some Eur ' ‘Cu "5' tesl ' be sore the Ter's Cath and dams are in good .‘.'C'Alrv(7 condivion a/‘:! 5 cue COT‘IECHO he maoe at the hit’i‘eiy BATTERY/CHARGI NG SYSTEM REMOVAL/INSTALLATION Remove the rider seat (page 37M, Remove the battery holder band. Disconnect the negative cable first, then the positive cable. Remove the battery from the battery tray. install the battery In the reverse order of removal. After installing the battery, coat lhe lerminals with clean grease. . [J 7* 9‘ 'I “/21“ ‘ VOLTAGE INSPECTION Measure the battery voltage using a commercially available digital multimeter, VOLTAGE: Fully charged: 13.0 —1:I.2 V Under charged: Below 12.3 V BATTERY TESTING Always clear the work area of flammable materials such as gasoline, brake Iluid, electrolyte] or cloth towels when operating the tester, the heat generr ated by the tester may cause a tire Remove the battery (page 1775). Securely connect the tester‘s positive l+l cable first, then connect the negative H cable TOOL: Battery tester BM-Z’IO-AH (U.S,A. only) or BM-Z‘IU TESTER Set the temperature switch to "HIGH" or "LOW" depending on the ambient temperature. HlGH ‘ IS’C (SO‘F) or higher LOW 15‘ C (80‘?) or luwer Contents Chapter 17 17-5 BATTERY/CHARGING SYSTEM Fol 1/18 ’lIS! check, DO NOT charge the barrevy belcre 15er ll‘g, ’65! it in an '65 5' condition Push in the appropriate test button for 3 seconds and read the condition of the battery on the meter. To avoid damaging the tester, only test batteries with an amperage rating or less than 20 Ah. Tester damage can result from overheating when: — The test button Is pushed m for more than 3 sec- ends. 7 The tester is used without belng allowed to cool for at least 1 minute when testing more than one battery. ~ More than 10 consecutive tests are performed without allowing at least a 30-minute coolrdcwn period. ' The result of a test on the meter scale is relative to the amp. hour rating at the battery. ANY BATTERY READING IN THE GREEN ZONE IS OK. Batteries should only be charged it they register in the YEL— LOW or RED zone. BATTERY CHARGING Remove the battery (page 17-5), 0 Clean the battery terminals and position the bat- tery as far away rrcrn the charger as the leads will permit. - Do not place batteries below the charger - gases from the battery may corrode and damage the charger. - Do not place batteries on top at the charger. Be sure the air vents are not blocked. TOOL: Christie battery charger MC1012/2 [U.S.A. only) 1. Turn the Power Switch tn the OFF posltion, 2. Set the BATTERY AMP HR. SELECTOR SWITCH her the size ofthe battery being charged. 3. Set the TlMEH to the position indicated by the Honda Battery Tester; RED-3, REM, clr YELLOWel. lt you are charging a new battery, set the switch to the NEW BATI' position. 4. Attach the clamps to the battery terminals: RED to Positive, BLACK to Negative. TEST BUTTONS YELLOW Hi GREEN (+1. +2, +3) BATTERY TESTER BATTERY AMP HR. SELECTOR SWITCH 5.5 to 5,0 3.5 to 5.0 95m 16.0 on, 0,3 16.5w 30 + Set the appropriate amp. hour rating. 17-6 Contents Chapter 17 BATTERY/CHARGING SYSTEM Connect the battery cables only when the Power i Switch is OFF. TlMER _ _ _ NEW BAT—i Trickle RED St Turn the Power Swltch to the ON posltlon. 6. When the timer reaches the “Trickle" posmon, \ the charging cycle is complete. Turn the Power Switch OFF and disconnect the clamps The charger will automatically switch to the "Trickle" mode after the set charging time has elapsed, —i— 7. Let the battery cool for at least 10 minutes or until gassing subsides after charging. Br Re-test the battery using the Honda Battery Tester and recharge if necessary using the above steps. . YELLOW CHARGING SYSTEM INSPECTION \ Do nordlsconnerl CURRENT LEAKAGE INSPECTION the barre/y orany cable in the charge my system Wlmaur Turn the ignition switch OFF and disconnect the bats i’ifsl switching pti tery negative cable from the battery. the ignirian switch Connect the ammeter (+l probe to the negative , NEGATIVE l»l ' TERMINAL Remove the driver seat (page 34). Faluiem (oliawthis cable and the ammeter (~l probe to the battery (e) precaution can terminal. damage the tester With the ignition switch OFF, check for current leak» Drelecirimlcumpo age. a . ”e ’5 - When measuring current using a tester, set it to a high range. and then bring the range down to an appropriate level. Current ilcw higher than the .t /‘ . . 9% , at, - range selected may blow out the fuse in the 93% , . . tester. > J i/ s i — . I While measuring current, do not turn the ignition it] PROBE NEGATIVE H CABLE swltch on. A sudden surge or current may blow out the fuse in the [Estert SPECIFIED CURRENT LEAKAGE: 2.0 mA max. It 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 Be sure the battery is in good condition before per forming this test. Warm up the engine to normal operating tempera- ture. t Stop the engine, and connect the multimeter between the positive and negative terminals of the battery. ‘ To prevent a short, make absolutely certain which are the positive and negative terminals or Cable Restart the engine. With the headlight on Hi beam, measure the voltage on the multimeter when the engine runs at 5,000 rpm, Standard: Measured BV < Measured CV < 15.5 V at 5,000 rpm av = Battery Voltage [page 1775) CV = Charging Voltage Contents Chapter 17 17-7 BATTERY/CHARGING SYSTEM ALTERNATOR CHARGING COIL ii is not necessary INSPECTION WWW ”765” Remove the left middle cowl (page 377). to.- coil to make this _ _ > ”.5, Remove the wire band and dlsconnem the alternar tor 3P (Natural) connector. Check the resistance between three Yellow termi- nals ot the alternator side connector. STANDARD: 0‘1 — 1.0 £7. [at 20”C/58°FI Check for continuity between each terminal and ground. There should be no continuity. If resistance is out of specification, or if any wire has continuity to ground. replace the alternator stator. Refer to page 1174 for stator removal. REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the left middle cowl (page 377). Remove the wire band and dlsconnect the regular tor/rectifier 2P (Natural) connector and alternator 3F (Naturall connector. Check the connectors for loose contacts or corroded terminals. lithe regulated Voltage reading (page 1777) is out of the specification, check the following at the ere harness Side connector. 17'8 Contents Chapter 17 BATTERY/CHARGING SYSTEM BATTERV LINE Measure the Voltage between the red wire terminal and green wire terminalt There should be battery voltage at all time. GROUND LINE Check the continuity between the green wire termir _ nal and ground. There shuuld be continuity at all time. lf all components of the charging system are normal and tnere are no loose connections at the regulator/ rectifier connecwrs, replace the regulatOr/reclifier unit (page 1779). REMOVAL/INSTALLATION Disconnect the alternator 3P (Natural) connector and regulator/rectifier 2? (Natural) connector (page 1778). Remove the regulator/rectifier mounting bolts Remove the regulator/rectifier unit and heat guard plate. Install the regulator/rectifier unit in the reverse order of removall Contents Chapter 17 17'9 MEMO Contents Chapter 17 18. IGNITION SYSTEM SYSTEM DIAGRAM ..................................... 13.2 IGNITION SYSTEM INSPECTION ................ 13.5 SERVICE INFORMATION-------------------»-~----- 18-3 CKP (CRANKSHAFT POSITION) SENSOR--18-7 TROUBLESHOOTING .................................. 18-4 IGNITION TIMING ........................................ 13.7 Contents Chapter 18 18'1 IGNITION SYSTEM SYSTEM DIAGRAM ENGINE STOP SWITCH DIRECT IGNITION COIL IGNITION SWITCH ECM BA‘I'I'ERY SPARK PLU G RELAY BOX (ENGINE STOP RELAY) SIDE STAND SWITCH NEUTRAL SWITCH ww ENGINE 510? I asuw u :10: Sum) swrrcu I snow: smp swrrcu UP GAME avw RIBII BI—o/o—WIBI mw GT Icumm sercN "'55 Down to sink mm m" Pan-Fl T ""W R ruse ELIJ'I’CH swncn (IDA) GIR an: —o\o—s/w R m mm pus: (an) up man: “Ni *va = ' aA-rrswv I m, w W W E | m ww an: man man luIEII 51w ll/w V WIEI v uzumu. I | l swrrcH I v I ‘ _ 3—1— —1— ; é , ECM “ I ' SP—ARK PCuss ' 18‘2 Contents Chapter 18 IGNITION SYSTEM SERVICE INFORMATION GENERAL O The ECM may be damaged ifdropped. Also if the connector is disconnected when current is flowing, the excessive volt age may damage the module. Always turn off the ignition switch before servicing. Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine. Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is ON and current is present. When sen/icing the ignition system, always follow the steps in the troubleshooting sequence (page 18-4). This motorcycle's Ignition Control Module IICM) is built into the Engine Control Module (ECM). The Ignition timing does not normally need to be adjusted since the ECM is factory preset. A faulty ignition system is often related to poor connections. Check these connections before proceeding. Make sure the battery Is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug. - This motorcycle features direct Ignition coils, where the ignition coil and spark plug cap are integrated. There are four direct ignition coils. - This motorcycle's spark plug is equipped with iridium type electrode, Do not use spark plugs other than specified. 0 Refer to the CMP (camshaft position) sensor Inspection (page 6-68) and ECM Inspection (page 6-69). SPECIFICATIONS ‘7' ITEM [ SPECIFICATIONS i Spark piug(|ridium) l NGK ‘ iMRsc-sHEs , FoeNso I VUH27ES Spark plug gap 0 30— 0.90 mm {0.031 — 0.035 in] (lg 'tion coil peak voltage 100 v minimum C (crankshaft position) sensor peak voltage . , 0.7 V minimum _> 7 Ignition timing (“F"mark) 77 8°12’ BTDC at idle 77 TORQUE VALUES Timing hole Cap 13 NM (1.8 kgf-m, 13 lbm) Apply grease to the threads TOOLS IgnitionMate peak voltage tester i Peak voltage adaptor i ECM test harness, 32F ‘ MTF07r0236 (USA. only) 07HGJ70020100 070MZ-0010201 (not available in U SA.) with commercially available digital multimeter [impedance 10 MmDCV i ‘ (two required) i 1 minimum) i Contents Chapter 18 18-3 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. — Faulty spark plug v Loose direct ignition coil and spark plug connection 7 Loose direct ignition coil connectors » Water got into the direct ignition coil lshorting the Ignition coil secondary voltagel . It there is no spark at any cylinder, temporarily exchange the direct ignition coil with the other good one and perform the Spark test. If there is spark, the exchanged direct ignition Coil is faulty. - “Initial voltage“ of the ignition primary coil is the battery voltage with the ignition switch turned ON and engine stop switch turned “ Q i [The engine is not cranked by the starter motor), No spark at all plugs i Unusual condition 7 " Probabliause (Check in numerical order) l i Ignition coil No initial voltage with the ignition l i. Faulty engine stop relay. primary volt- 0N and engine stop switch turned 2. An open circuit in Black/white wire between the direct age " 0 " (other electrical components i ignilion 00" and engine step relev- _ .. , aye normal, 3. Loose or poor connect at the direct ignition coil connec- i tors, or an open circun in primary coil (Check at the l ECM connectori, 4. Faulty ECM (in case when the initial voltage is normal while disconnecting ECM connectorsl Initial voltage is normal, but it j i, incorrect peak voltage adaptor connections. drops down to 2 —4 v while crank- i 2. Undercharged battery. mg the engine, i 3. No voltage between the Black/white (+l and body ground l—l at the ECM multi-connector or loosen ECM ‘ connection. 4. An open circuit or loose connection in Green wire. 5. An open Circuit or loose connection in Blue/black, Yel- ‘ low/white, Red/blue and Red/yellow wires between the i direct ignition coils and ECM l 1 6. Faulty side stand switch or neutral switch, 7. An open circuit or loose connection in No.6 related cir~ ‘ l i cuitwlres, i — Side stand swnch llrie: Green/white wire ‘ — Neutral switch line-Light green wire l 8. Faulty CKP sensor Measure the peak voltage). l 9. Faulty ECM (in case when above No.1— 8 are normal). Initial voltage is normal, but no i. Faulty peak voltage adaptor connections peak voltage while cranking the 2. Faulty peak voltage adaptor. engine. ‘ 3. Faulty ECM lin case when above No. 1 and Z are nor- ‘ mall. Initial voltage is normal, but peak 1. The multimeter impedance is too low; peiow lo Mn/ ‘ Voltage is lower than standard , DCV. valve, 2. Cranking speed is too low (Battery is underchargedl. 3, The sampling timing of the tester and measured pulse were not synchronized (System is normal it measured i voltage is over the specification at least once) ‘ 4. FauityECM (Ln case vyhen aboveNo 1—3 are normali. , i. Faulty spark plug or leaking ignition coil secondary Curr l rent ampere. , 777 . . 7W . 7 777"" . liz, Faulty direct ignition coil is). ., — CKP sense; Peakvoltage is lowerthan standard ‘l ‘l. The multimeter impedance is too low; below 10 MRI i lnitiaian'd peakvoitage are normal, but does not spark. Value. DCV. 2. Cranking speed is too low (Battery is undercharged). 3, The sampling timing of the tester and measured pulse i were not synchronized (System is normal if measured voltage is over the specification at least once). A, Faulty ECM (in case when above No. 1 —3 arenprmali. . Faulty peak voltage adaptor 2. Faulty CKF sensor. No ark vaiiagef ” 18'4 Contents Chapter 18 IGNITION SYSTEM IGNITION SYSTEM INSPECTION - If there is no spark at any plug, check all connec- tions tor loose or poor contact before measuring each peak voltage. ' Use recommended digital multimeter or come marcially available digital multimeter with an impedance of 10 MQ/DCV minimum. The display value differs depending upon the internal impedance ofthe multimeter. ‘ If the lmrie diagnostic tester [model 625) is used, follow the manufacturer‘s instruction. Connect the peak voltage tester or peak voltage ig‘.’ -1 adaptor to the digital multimeter, DIGITAL MULTIMETER TOOLS: .. ‘ lgnitionMate pealt voltage tester MTP07—0286 ' lu.s.A. only) or Peak voltage adaptor 07HGJ-0020100 (not available in / u.s.A.) with commercially available digital multimeter (impedance 10 MtzIDCV minimum] PEAK VOLTAGE ADAPTOR IGNITION COIL PRIMARY PEAK VOLTAGE - Check all system connections beiore inspection, If the system is disconnected, incorrect peak voll- age might be measured. - Check cylinder compressiun and check that the spark plugs are installed correctly Remove the direct ignition coils from the spark plugs(page478). Connect the direct ignition coil 2P connectors to the direct ignition coil. Connect known-good spark plugs to the direct ignie tlon coil and ground the spark plug to the cylinder head as done in a spark test. KNOWN-GOOD SPARK PLUG Connect the ECM test harness to the ECM connec- tors (page 5-17). A3 Connect the peak voltage tester or adaptor probes A1 A2 to the test harness terminals. / B16 CONNECTIONS: : rt Il‘l in em ii No.1 ignition coil: udlaoooopoacoaoa ooooooooooooooo 4 515 H) _ A17 1—) txoooooooz‘oooooeoo :oooooooa‘Zoeooeoo No.2 ignition coil: ’ BIGI+I-A1I-I No.3 ignition coil: B16(+l—AZ(—) ® NoA ignition coil: B16 (e) — A3 (7) Contents Chapter 18 18—5 IGNITION SYSTEM Avoid touching the spam plugs and tester grabs: to prevent electric Shock Turn the ignition switch ON and engine stop switch Check for initial voltage at this time Battery voltage should be present. If the initial voltage cannot be measured, check the power supply circult (refer to the troubleshooting, page 184i. Shift the transmission into neutral. Ctanltthe engine with the starter motor and read the ignition coil primary peak voltage. PEAK VOLTAGE: 100 V minimum If the peak voltage is abnormal, check ror an open crrcun or poor connection in Blue/black, Yellow/ White, Red/blue and Red/yellow wires. It not defects are found in the harness, refer to the troubleshooting chart (page ‘lB-Al. CKP (CRANKSHAFT POSITION) SENSOR PEAK VOLTAGE . Check all system connections berore inspection, it the system is disconnected, incorrect peak voltr age might be measured - Check cylinder compression am Check that the spark plugs are installed correctly. Remove the right middle cowl [page 3.7L Disconnect the ECM 32F (Light gray) connector from the ECM. Connect the peak voltage tester or adaptor probes to the connector terminal of the wire harness side and body ground Toots: lgnitionMate peak voltage tester MTPOHJZSS (u.s.A. only) or Peak voltage adaptor 07HGJ-0020100 (nut available in U.S.A.) with commercially available (impedance 1D MEI/DCV min CONNECTION: Yellow tem1ina|I+1— body ground (7) Crankthe engine With the starter motor and read the peakvoltage, PEAK VOLTAGE: 0.7 V minimum If the peak voltage measured at ECM connector is abnormal, measure the peak voltage at the CKP senr 50f connector. 18-6 Contents Chapter 18 IGNITION SYSTEM Remove the right middle cowl (page 3.7) Disconnect the CKP sensor 2? (Redl Connector and connect the tester probes to the terminal (Yellow and Yellow/white). In the same manner as at the ECM connector, mea sure the peak voltage and compare it to the voltage measured at the ECM connector. 2? (REDl CONNECTOR . It the peak voltage measured at the ECM is abnormal and the one measured at the CKP sen— sor is normal, check the 2P (Red) connector for loose connection and the wire harness for an open circuit or loose connection. ' If both peak voltage measured are abnormal, check each item in the troubleshooting Chan (page 184). If all items are normal, the CKP sen- sor is faulty. See following steps for CKP (crank- shaft position) sensor replacement. CKP (CRANKSHAFI' POSITION) SEN- SOR IGNITION TIMING REPLACEMENT Remove the right crankcase coverlpage10«‘lsl. , . , BOLT/WASHER "" Remove the wire grommet from the cover. ' {-9 Remove the bolts and CKP sensor. Apply sealant to the grommet seating surface. Install a new CKP sensor and the grommet into the cover groove properly. Tighten the mounting bolts securely. l , Home the CKP sensor wire into the groove of tha '. right crankcase cover. GROMMET Install the washer and bolt, then tighten the bolt securely, Install the right crankcase cover (page 1034). Remove the under cowls (page 3—7), Warm up the engine. Stop the engine and remove the timing hole cap. Contents Chapter 18 18-7 IGNITION SYSTEM Read meifiSf/UC' Remove the intake air duct (refer to the spark piug nansformriingi/gin removal; page 4%) and connect the timing iight to aparaxiunv the No.1 direct Ignition coii connector wire. Start the engine, let it idle and Check the ignition timing IDLE SPEED: 1,200 i100 rpm The ignition timing is correct if the “F" mark on the CKP sensor rotor aligns with the index mark on the right crankcase cover at idle. Increase the engine speed by turnlng the throttle stop screw and make sure the “F" mark begins to move cou nterciockwse. Apply mi to (he Orri ngv C/iECkIhaTthe 0- Apply grease to the timing hole cap threads and , ring/S in good Corr install the Orring and (Iming hole cap. diuon, iep/ace it i/ necessary TiMING HOLE CAP Tlgi'iIen the tlmlng hole cap to the spemfied torque. TIMING HOLE CP TORQUE: 18 Nvm [1.3 kgI-m, 13 Ibf-fl) ‘ , Remove the undercowls (page 377). 18'8 Contents Chapter 18 19. ELECTRIC STARTER SYSTEM DIAGRAM ..................................... 19.2 STARTER MOTOR ........................................ 19.5 SERVICE INFORMATION ---------------------------- 19.3 STARTER RELAY SWITCH ------------------------- 19-13 TROUBLESHOOTING ................................. 19.4 DIODE ........................................................ 19.14 Contents Chapter 19 19“ ELECTRIC STARTER SYSTEM DIAGRAM ENGINE STOP SWITCH IGNITION SWITCH STARTER SWITCH STARTER RELAY SWITCH/ CLUTCH SWITCH BATTERY MAIN FUSE FUSE BOX/DIODE STARTE R MOTOR SIDE STAND SWITCH NEUTRAL SWITCH STARTER RELAY SWITCH STARTER MAW (—9 @ MOTOR FUSE BATTERY I30AI CLUTCH T IGNITION i SWITCH SIR SWITCH FUSE ‘IDA GrBIWEIfl—G/R‘I 7RWR5I+R wn unG Dawn Gm CLUTCH —o\o— El/R SIDE STAND DIODE STARTER SWITCH SWITCH G La _I_ _ NEUTRAL T SWITCH 19'2 Contents Chapter 19 ELECTRIC STARTER SERVICE INFORMATION GENERAL If the current ls kept flowing through the starter motor to turn rt while the engme is net cranking over, the starter motor may be damaged. I Always turn the Ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious Inlul'y. The starter motor can be servlced with the engine in the frame. When checklng the starter system, always follow the steps in the troubleshooting flow chart (page 19—4). A weak battery may be unable to turn the starter motor qulckly enough, or supply adequate ignition current. Refer to the starter clutch servicing (page 1028). Refer to the followmg components informations. — ignition switch (page 20-18) — Starter switch lpage 2049) ~ Neutral switch (page 2021) — Side stand switch (page 2022) . Cluten switch (page 20-21) SPECIFICATIONS Unit: mm linl ’ "l’fEM * " 7' " §TANDARD SERVICE LIMT starter motorTeru'sh Engtb * ' ' " ' 'szl 1310 10.47 — 0251) ' i TORQUE VALUES Starter motor terminal nut 12 N-m11.2 kgr-rn, 9 lbfvl‘tl Contents Chapter 19 19—3 ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 1. Fuse Inspection Check for blown main iuse or sub (use. Is the (use blown? YES — Replace the ruse N0 7 GO TO STEP 2‘ . Battery lnspecliun Make sure the battery is fully charged and in good conditions Is the battery in good candifian? VES - GO TO STEP 3. NO — Replace the battery . Starter Relay Switch Operation Check the starter relay swrtch operation. You should hearrhe relay "CLICK" when the engine starter switch button is depressed. Is there 3 "CLICK"? YES ~ GO TO STEP 4. NO — GO TO STEP 5. . Starter Motor Inspection Apply battery voltage to the starter motor directly and check the operation. Does the starter motor turn? YES — - Poorly connected starter motor cable - Faulty starter relay swnch (page19—13] No — Faulty starter rneior (page 196) . Relay Coil Ground Wire Lines Inspecfion Disconnect the starter relay switch connector, and check the relay coil ground wire lines as below for continuity: ‘l. Green/Red termlnal — clutch diode — neutral switch line (with the transmission in neutral and clutch lever released). 2. Green/Red terminal - clutch switch — side stano switch line (in any gear except neutral, and with the clutch lever pulled in and the side stand up, Is there cantinm'ty? NO — Faulty neutral switch (page 2021) Faulty clutch diode (page 19-14) Faulty clutch switch (page 2021i Faulty side stand switch (page 2042) LOOSE or poor COHIBCI connector Open circuit in wire harness YES — GO TO STEP 6‘ . Starter Relay Voltage Inspection Connect the starter relay switch connector. With the ignition switch ON and the starter switch pushed] measure the voltage at the starter relay switch connector (between Yellow/Red (+1 and body ground [—)). is the starter relay switch operation correct? N0 — - Faulty ignition swuch (page 20-18] ~ Faulty starter switch (page 20719) - Loose or poor contact connector Open circult in wire harness YES — GO TO STEP 7. 19-4 Contents Chapter 19 ELECTRIC STARTER 7. Starter Relay Switch Continuity inspection Disconnect the starter relay switch 4? connector and cables. Connect a fully charged 12 v battery positive wire to the relay switch Yellow/red wire terminal and negative wire to the Green/red wire terminal. Check the continuity between the starter relay switch large terminals while the battery connected. Is there continuity? N0 — Faulty starter relay switch vss — Loose or poor contact of the starter relay switch 4P connector The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position except neutral, with the side stand up and the clutch lever pulled In. 1. Clutch Switch Inspection Check the clutch switch operation. Is the clutch switch operation narmal? N0 7 Faulty clutch switch VES — GO TO STEP 2. 2. Side Stand Switch Inspection Check the side stand switch operation. Is the side stand switch operation normal? N0 — Faulty side stand switch lpage 20-22) VES — ' Open circuit in wire harness - Loose or poor contact connector Starter motor turns engine slowly - Low battery voltage - Poorly connected battery terminal cables ' Poorly connected starter motor cable - Faulty starter motor - Poorly connecled battery ground cable Starter motor turns, but engine does not turn - Starter motor is running backwards » Starter motor assembled improperly - Terminals connected improperly - Faulty starter clutch I Damaged or faulty starter driven gear, idle gear and/or reduction gear Starter relay switch "Clicks", but engine does not turn over - Crankshaft does not turn due to engine problems Contents Chapter 19 19-5 ELECTRIC STARTER STARTER MOTOR REMOVAL . With the ignition switch OFF. remove the nega- |IVE cable at me battery before servicing the starter mOIOL Remove the EGCV servo motor (page e-78L Remove the rubber cap, terminal nut and staner . v mountable. Remove the two mounting bolts and ground cabia. Remove the staner motor from the crankcase. Remove the Orring from the starter motor 19-6 Contents Chapter 19 ELECTRIC STARTER DISASSEMBLY Remove the fouowing; CASE BOLTS/OVRINGS — Starter motor case bolts/0»rings Record the [0652an Front cover andnumberm' — Seal ring SEN-RING smms — Lockwasher —- InsulaIed washer — Shim(s] SHIMISI LOCK WASHER Record me locaflon 7 Rear cover assembly . WWWDQW, _ Seal ring SEAL RING REAR COVER ASSEMBLY shrms — ShimIs) ‘ , ~ Armature ARMATURE SHIMIS) INSPECTION Check the bushing in Ihe rear cover for wear or damage. BUSHING I Contents Chapter 19 19-7 ELECTRIC STARTER Check the oil seal and need‘e bearing in the front cover (or deterioration, wear or damagsv OIL SEAL NEEDLE BEARING Do not use emery Check the commutator bars of the armature for dis- rv Sam paper an coloration. me cammulamr ARMATURE Check for continuity between pairs of commutator bars. There should be continuwty. Check for continuity between each commutator bar and the armature shaft. There should be no continuity. 19'8 Contents Chapter 19 Check for continuity between the insulated brush and cable terminal. There should be continuity. Check for continuity between the cable terminal and the rear cover. There should be no continuity. Recs/d me Incanan Remove the following: andnumberoggsr: _ Nut ~ Washer — lnsulators A Orring — Brush holder assembly Remove the brush springs and brushes from the brush holder. ELECTRIC STARTER BRUSH HOLDER £0 INSULATORS BRUSH HOLDER BRUSHES WASHER NUT BRUSH SPRINGS Contents Chapter 19 19-9 ELECTRIC STARTER Inspect the brushes for damage and measure the brush xengm. SERVICE LIMIT: 6.5 mm (0.26 in) ASSEMBLY REAR COVER g O-HING INSULATORS BRUSH SPRING ARMATURE WASHER \‘® #0} SEAL RING MOTOR CASE / 99 Q SEAL RING /¥»/@@ SHIMS / ,. INSULATED WASHER ' ‘ LOCK WASHER FRONT COVER | t H h b h b hntfldaer.‘ e rus es and rush springs to the brush BRUSH HOLDER BRUSHES BRUSH SPRINGS 19'10 Contents Chapter 19 lnslall (he lnsu/amrs properly as noted _ dun/lg remuval lnsla/l {he Shims properly as noted during removal ELECTRIC STARTER Install the cable terminal and brush holder into the rear cover, aligning the holder tab with the rear cover groove Install the following: New O-ring lnsulators — Washer — Nut . WASHER BRUSH HOLDER / ”UT (”39/ INSULATORS Install the armature m the motor case. ARMATURE When installing the armature into the motor case, hold the armature tightly to keep the magnet of the case from pulling the armature against it. The coil may be damaged if the magnet pulls the armature against the case. MOTOR CASE Install a new seal ring unto the motor case. Install the shim(s) onto the armature shaft. Apply thin coat of grease to the armature shaft and Install the rear cover assembly, while pushing in the brushes into the brush holder and alignlng the brush holder tab with the motor case groove. ®§ SEAL RING REAR COVER ASSEMBLY ‘fl ARMATURE SHIM(S) Contents Chapter 19 19-11 ELECTRIC STARTER ”mar/ma smms Install the shlm(s) and lnSUlated washer onto the Draper/y as nored armature shaft. dwmg 'emvval Install a new seal ring onto the motor case Apply grease to the oil seal Up and needle bearing in the front covert Install the lock washer to the from cover with the lock washer tabs faclng to the front cover, and install them onto the armature shahv PEAL RING FRONT COVER SHIMlSl LOCK WASHER Make sure the index lines are aligned. Install the new Orrings onto the motor case bolts. Install and tighten the case bolts securely. INSTALLATION Coat a new Orring with oil and install it lnto the sta ner motor groove. Install the starter motor lnto the crankcase. Route the starter motor cable and ground Cable properly (page 1724). Install the ground cable and mounting bolts, and tighten the bolts securely. 19'” Contents Chapter 19 ELECTRIC STARTER Install the starter motor cable to the terminal, then tighten the terminal nut to the specified torque TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) Install the rubber Cap securely. Install the EGCV servo motor [page 6780). STARTER RELAY SWITCH OPERATION INSPECTION Remove the driver seat (page 3-4), Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch r. O Press the starter switch button The coil is normal ifthe starter relay swllch clicks. If you don‘t hearthe switch “click", inspect the relay switch using the procedure below. GROUND LINE INSPECTION Disconnect the starter relay switch 4? connector. Check for continuity between the Green/red wire lground line) and body ground. it there is continuity when the transmission is in neutral and clutch lever released or when the clutch lever pulled and the side stand up, the ground cir- cult is normal (In neutral, there is a slight resistance due to the diode). STARTER RELAY VOLTAGE INSPECTION Connect the starter relay switch 4P connector, Shift the transmission Into neutral, Measure the voltage between the Yellow/red w'ire terminal H) and ground 1—). If the battery voltage appears only when the starter switch is pushed with the ignition switch 0N and engine stop switch " 0 it is normal, 4P CONNECTOR Contents Chapter 19 19-13 ELECTRIC STARTER CONTINUITV INSPECTION Disconnect the Starter relay switch 4P connector and cables. Connect a fully charged l2 v battery posltive wrre re the relay swuch Yellow/red wire termlnal and nega- tlve w'lre to the Green/red wire terminal. There should be continuity between the large termi» nals while the battery is connected, and no continu- ity when the battery ls disconnected. STARTER RELAY SWITCH DIODE REMOVAL/ INSTALLATION Remove the left middle cowl (page 377) Open the luse box and remove the diode. Install the dlode in the reverse order of removal. INSPECTION Check for continuity between the diode terminals When there is Continuity, a small reSlstance value will register. l If there Is continuity, In one dlreclinn, the dlode Is normal. / * ”r ; 19'” Contents Chapter 19 20. LlGHTS/METERS/SWITCH ES SYSTEM LOCATION-- 20-2 SERVICE INFORMATIONA-----w--~--wu~-u-- 20—3 HEADLIGHT 20.5 POSITION LIGHT ..................................... 20.5 TURN SIGNAL ........................................... 20.7 TAIL/BRAKE LIGHT 20.3 LICENSE LIGHT .......................................... 20.9 COMBINAT|0N METER ............................ 20.10 SPEEDOMETER/VEHICLE SPEED SENSOR ..................................................... 20.11 TACHOMETER ........................................... 20.13 ECT SENSOR 20-14 EOP (ENGINE OIL PRESSURE) SWITCH»- FUEL RESERVE SENSOR ......................... IGNITION SWITCH ..................................... HANDLEBAR SWITCHES- BRAKE LIGHT SWchH ............................ CLUTCH SWITCH NEUTRAL SWITCH .................................. SIDE STAND SWITCH ............................... HORN ........................................................ TURN SIGNAL RELAY HEADLIGHT RELAY ................................... 20-15 20-17 20-18 20-21 20-21 20-22 20-24 20-24 20-25 Contents Chapter 20 20-1 LlGHTS/METERS/SWITCHES SYSTEM LOCATION RIGHT HANDLEBAR SWITCH IGNITION SWITCH HORN LEFT HAN DLE BAH SWITCH ECT SENSOR VEHICLE SPEED SENSOR IVSSI RELAY BOX (HEADLIGHT RELAYI EOPIENGINE OIL PRESSURE) SWITCH / SIDE STAND SWITCH NEUTRAL SW'TCH REAR BRAKE LIGHT SWITCH 20-2 Contents Chapter 20 LIGHTS/M ETERS/SWITCHES SERVICE INFORMATION GENERAL I A halogen headlight bulb becames very hot while the headlight is ON, and remains hot for a while after it is turned OFF Be sure to let It cool dawn befare servicing. Note the following when replacing the halogen headlight bulb. — Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. — lr'you touch the bulb with your bare hands, clean it with a cloth moistened with denatured alcohol to prevent its early failure — Be sure to install the dust cover after replacing the bulb Use an electric heating element to heat the water/coolant mixture for the ECT sensor inspection Keep flammable mate rials away from the electric heating element. Wear protective clothing, Insulated gloves and eve protection Check the battery condition before performing any inspection that requires proper battery voltage. A contInuIty test can be made with the switches installed on the motorcycle. The following color codes are used throughout this section, Bu =B|ue G : Green Lg=nght Green R=Red B|=Black G Gray O=Orarlge W:Wl’ute Br:Br0wn Lb=LIght Blue P:Plnk Y:Ye|low SPECIFICATIONS , ITEM SPECIFICATIONS Bulbs ' ’Headltgnt Hi 12v—55w Lo 12 v7 55 w Position light 12 vesw Taii/braEélight LED ' 7 7 12v723/ew13'2/3WX‘2 7 12 v a 23 W x 2 " LED 7 7 7TurFt signal indicator 7 7 LED ’7 7 7 High beam Indicator ‘ LED " Neutral lndl 77,, LED 1 ‘,,7,,M§flnfli9n,inflcat9Ll§leMlLl ,LED ,,,, W , i ,7‘ ‘ Fuse Main ruse ’ ’ " ’ ’ 30A PGMrFl fuse 20A Suptuse ,,, 10Ax4,2oAx2 Tachometer peak voltage 7777 i 771E57vfilfiimum7777 7 77 7 7 ECTsensor resistance . 80”Cl176“Fl l 77 7 7 21 v2.5 kn ‘ I V120rc (248"Fl 1 eyes — 0.73 k9 7, 7 L, ,,,I TORQUE VALUES EOP Engine Oil Pressure) switch EOP switch Wire terminal screw Neutral switch 12 N-m 11.2 mm, 9 thl 2 o N-m 102 kgfvm,1.4lbl-ftl 12 N-m 11.2 kgf—rn, 9 lbf-ftl Apply sealant to the threads Ignition switch mounting orie~wav bolt Right handlebar swnch screw Combination meter assembly screw Side stand switch special bolt 26 N-m 12.7 kgl-m, 20 |bl~ftl O 9 N-m (0.09 kgf-m, 0.7 inf-ft] 1.0 Nvm lot kgf-m, o 7 lbt-ttl 9 8 N-ml10 kgf-rrl, 7 lbfhftl ALOC bolt; replace with a new one Contents Chapter 20 20-3 LIGHTS/M ETERS/SWITCHES TOOLS Peak vottage adaptor ‘ lgnitionMate peak voltage tester ‘ Inspection adaptor 07HGJ70020’IOD 1 MTFO7»0285 (USA. only) ‘ 07GMJ»ML80100 (not available in U S A.) with commercially available digital ‘ multimeter (Impedance 10 MSZ/DCV V minimum) 20'4 Contents Chapter 20 LIGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT Disconnect {he headligh‘ bulb connector. Remove ‘he dust cover. Unhook ‘he bulb re‘amer and remove the headhgh! bulb/socket. BU L/SOCKET Remove xhe headlight bulb from the socket, BULB SOCKET \nsla” new bu‘b imo the socket. Avoid touching me halogen headlight bulb, F/‘nger pnnts can create hut spots may cause a bulb m , break. If you touch the bmb with your bare hands, clean it wnh a clam morsxened wnh denatured alcohol to 1 prevent early bulbfailurev ‘nsIaH me new neadngm bulb/sockel aligning i‘s tab with the groove 1n the headlight unit, and hook me bulb retainer properly Contents Chapter 20 20'5 LIGHTS/METERS/SWITCH ES Install me dust cover ugrulv agamsr the headlrgm ‘ . ARROW MARK unit with its arrow mark facing up. // Connect the heanght bulb connector‘ REMOVAL/INSTALLATION Remove the upper cowt (page 3712) Remove the nuts and bank angle sensor Remove the five screws/washers and headlight umt, SCREWS/WASHERS rtorlretf‘e we hen Instatl the headlight unit in the reverse order of removal POSITION LIGHT BULB REPLACEMENT Remove the windscreen (page 3-12). Remove me screws and posrnon ugh: lens. POSITION LIGHT LENS 20'6 Contents Chapter 20 LIGHTS/M ETERS/SWITCHES Remove the bulb from the socket, and replace it with new one. Install the removed parts in the reverse order of removal. TURN SIGNAL BULB REPLACEMENT Remove the screw, turn signal light lens and seal rubber. While pushing in, turn the bulb counterclockwise to remove it and replace with new one Install the seal rubber onto the turn signal light case. Install the lens bv aligning the lens tab with the turn Signal light case groove, and tighten the screw securely. Contents Chapter 20 20'7 LlGHTS/METERS/SWITCH ES HEMOVAL/INSTALLATlON Far from turn signal lighl removal, remove the mlde dle cowls (page 3-7l. TURN SIGNAL LIGHT Remove the nut, setting plate and the turn signal llght from the middle Cowl. Install the turn signal light in the reverse order of removal. For rear turn signal removal, see rear tender A dis» assembly (page 3~zol. TAIL/BRAKE LIGHT INSPECTION Turn the ignition switch ON, and check the taillight operation. Check that all LED in the tail/brake light unit light illumlnale with the front brake lever and/or rear brake pedal applied. TA|l_/BRAKE LIG HT UNIT If any LED does not turn on, replace the tail/brake light assembly. REMOVAL/INSTALLATION Remove the rear seat cowl (page 35). Remove the tall/brake light unit mounting screws. Pull out the labs from the grooves of rear seat cowl, then remove the tail/brake light unit. Install the tail/brake light unit onto the rear seat cowl while aligning the tabs with gmove oi the rear . seat cowl. Installation is in the reverse order of removal. 20-8 Contents Chapter 20 LlGHTS/METERS/SWITCHES LICENSE LIGHT BULB REPLACEMENT Remove the two nuts and wire clamp. / \l l l \ / \ CLAMP Remove me Mo screws and join: plale Remcve the two nuts and lens cover. Turn the license light bulb socket counterclockwise ,-' and remove it from the lens caver. ’ Remove the bulb from the socket, replace it wuh HEW OHEV VCLiAMP LlCENSE LIGHT l BRACKET Install the license llgm bulb socket and lens cover ln the reverse order of removal. ./ JOlNT PLATES LENS BASE SEAL RUBBER LENS COVER Contents Chapter 20 20-9 LlGHTS/METERS/SWITCHES COMBINATION METER REMOVAL/INSTALLATION Remove the upper cowl (page 3421‘ SCREWS/WASHERS Remove the three screws/washers and combmation meter from the bracket. mstall the combination meter in the reverse order of removalr DISASSEMBLY/ASSEMBLY Remove the screws. SCREWS lRemove the meter upper case, Circuit board and UPPER CASE CIRCUIT BOARD ower case. Assembte the meter upper case, circuit board and lower case, then tlghlen the screws to the specified torque. TORQUE: 1.0 N-m (0.1 kgl-m, 0.7 lbl-fl) LOWER CASE 20'” Contents Chapter 20 LIGHTS/M ETERS/SWITCHES POWER/GROUND LINES INSPECTION Check the following at the wire harness side can» :, nector terminals ofthe combination meter. Power input line Measure the voltage between the Brown/white wire terminal H) and body ground (—I. There should be battery voltage with the ignition switch ON. If there is no voltage. check the subsfuse 110 A] and an open circuit in Brown/white wire. Booleup voltage line Measure the voltage between the Red/green wire terminal HI and body ground (—1, There should be battery Voltage at all Ilmes. If there is no voltage, Check the subJuse (10 A] and an open circuit in Red/green wire. Ground line Measure the continuity between the Green wire terr minal (+1 and body ground l—l. There should be contmully at all limes. ll there is no continuity, check lor open circuit in Green wire. Sensor ground line Measure the continuity between the Green/black wire terminal M and body ground H. There should be continuity at all times. If there is no continuity, check for open circuit in Green/black wire. SPEEDOMETERIVEHICLE SPEED SENSOR SYSTEM INSPECTION Check that the tachometer and coolant temperature . meter function properly. ' If they do not function, perform the power and ground Ilne inspection of the combination meter (page 2041). - If they function, remove the dust cover and dis- connect the combination meter ZOP [Black] cone nector. Shift the transmission into neutral and turn the ignition switch ON. Measure the voltage between the Pink l+l and Green/black (—1 wire terminals of the wire har- ness side connector. Slowly turn the rear wheel by hand. There should be 0 to 5 v pulse voltage. — lf pulse voltage appears, replace the combinatlon meter printed olrcult board [page 2040]. r If pulse voltage does not appear. check for open or short circuit in the Flnk wire If the Pink wire is OK, check the vehicle speed sensor (page 2042i. MULTl-CONNECTOR // :1 GREEN/BLACK RED/GREEN (+1 ‘ BROWNANHITE [4-) Viewed irom _ terminal sine- Contents Chapter 20 20-11 LlGHTS/METERS/SWITCHES VEHICLE SPEED SENSOR (VSS) INSPECTION Lift and support the fuel tank lpage 45). Disconnect the VSS 3P (Natural) connector Measure the voltage between the Brown/white (H and Green/black (i) wlre terminals at the harness side 3P connector. CONNECTION: Brown/white (+) — Green/black (—l STANDARD: Batteryvoltage There should be battery voltage with the ignition switch ON. If there ls no voltage, check for open circuit 'in related wires. If there ls vultage, check the VSS as follows. Support the motorcycle securely us'lng a safety stand or heist, and raise the rear wheel off the ground Connect the inspection adaptor to the sensor 3P COHI’leCIDI’Si TOOL: Inspection adaptor 07GMJrMLBD1OO Measure the voltage between the Red CIID (H and White clip (7) CONNECTION: Red clip (+1 — White clip (—1 STANDARD: Repeat 0 to 5 V 5th the transmission intc neutral and turn the igni~ lion switch ON. Slowly turn the rear wheel by hand, There should be 0 to 5 V pulse voltages If the pulse voltage does not appear, replace the vss (Page 20712). REMOVAL/INSTALLATION Liftand support the fueltanklpage 4-5). Remove the VSS 3P (Natural) connector from the stay and disconnect the connector. Remove the bolt, stay and VSSV 3P (NATURALI CONNECTOR RED CLIP HI (PINK WIRE) INSPECTION WHITE CLIP I-I ADAPTOR (GREEN/BLACK WIREI 3P lNATURAL] CON NECTOR 20-12 Contents Chapter 20 LIG HTS/METERS/SWITCHES Check the condition of the Orring, replace it if neces- sary Install the VSS into the upper crankcase. Install the stay and tighten the bolt securely. Home the EGCV Connect the VSS 3P (Natural) connector and install servo motorcable it to the stay en: We! rank breather min), prep evly/page 1724). TACHOMETER SYSTEM INSPECTION - Check for loose or poor Contact terminals at the combination meter 20F lBlackl connector and front sub-harness 22F connector. Tum Iha ignition switch ON, check that the tachom- eter needle moves to full scal’e and then returns to zero, If the needle does not Show initial function, check the combination meter power input line (page 20-11) Contents Chapter 20 20-13 LIGHTS/METERS/SWITCHES Remove the windscreen (page 3712) and expose the comhlnation meter 20F (Blackl connectorr Connect the peak voltage tester or adaptor probes to the tachometer Yellow/green term'lnal and body ground. TOOLS: lgnitionMate peak Voltage tester MTMzss (USA. only) or 07HGJ-0020100 (not available in U.S.A.) with commercially available digital multimeter [impedance 10 Mtz/DCV minimum) Peak voltage adaptor CONNECTION: Yellow/green l+l 7 body ground (7) Stan the engine and measure the tachometer ‘lnput peak voltage PEAK VOLTAGE: 10.5 V minimum If the peak voltage IS normal, replace the comblnar tion rneter printed circuit board (page 2010], If the measured value is below 105 v, replace the ECM lpage area). If the value is 0 V, check tor continuity between the combination meter 20F (Black) connector and ECM 32F lnght gravl connector Yellow/green terminals. If there is no contlnultv, check the wire harness and front subaharness for an open circuit. If there is continuity, replace the ECM (page 6-68). ECT SENSOR REMOVAL/INSTALLATION Drain the coolant lpage 76), Disconnect the 3P connector and remove the ECT sensor from the thermostat housing, DUST COVER l 32? (LIGHT GRAV) i CONNECTOR Contents Chapter 20 LIGHTS/METERS/SWITCHES Aiwavs rep/ace me Install the ECT sensor with new sealing washer and sealmg Washer wil’i tighten it to the specified torque. a new one TORQUE: 23 N-m (2.3 kgf-m, 17 lbf-ftI Connect the ECT sensor 3P connector. Fill the svstem with recommended coolant and bleed the air (page 7-6l. INSPECTION Suspend the ECT sensor in a pan of coolant (50 — 50 mixturel on an electric heating element and mea» sure the resistance through the sensor as the cools ant 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 lo the bottom or the sensor. - Keep the temperature constant far 3 minutes belore testing. A sudden change of temperature will result in incorrect readings. Do not let the thermometer or ECT sensor touch the pan. Replace the sensor it it is out of specification by more than i0% at any temperature listed Temperature we lsa‘t )_ 120”C (2430f) Leslistanicreir 2.1"— 2.6 kg as -o.73 kn ECT SENSOR TERMlNAL EOP (ENGINE OIL PRESSURE) SWITCH INSPECTION if the oil pressure warning indicator stays on while , the engine is running, check the engine oil level I before this inspection (page 4-21). Make sure that the oil pressure warning indicator comes on with the ignition switch 0N. OIL PRESSURE WARNING INDICATOR Contents Chapter 20 2°45 LlGHTS/METERS/SWITCHES l! the indicator does not come on, inspect as fol- lows: TERMINAL SCREW/WlRE . DUST COVER I Remove the under cowls (page 3-7). Remove the dust cover. Remove the terminal screw and EDP switch wire. Shantha EOP switch wire to ground using a jumper wire. The oil pressure warning indicator should come on when the ignition sWItch Is ON. if the indicator does not come on, check the sub- ‘ fuse (10 A) and wires for a louse connection or an open circuit. Connect the wire to the EOP switch and start the engine, and make sure the indicator goes out. If the indicator does not go nut, check the oil pres- sure lpage 575). If the oil pressure is normal, replace the EOP Switch (page 20-16), Install the under cowls (page 37) REMOVAL/INSTALLATION Remove the under cowls (page 3»7l. Release the rear brake light switch wire from the clamp. Remove the dust cover, terminal screw and wire. Remove the EOP switch while holding switch hasa. Apply sealant to the EOP swncn threads as shown. Do not apply sealanttothe thread head 3 — 4 mm (0.1 — 0.2 in). ”'16 Contents Chapter 20 LIG HTS/METERS/SWITCH ES install the EOP switch unto the switch base, tighten g the EDP switch to the Specified torque while holding the switch base. TORQUE: ‘lZ N-m (1.2 kgf—m, 9 [bf-ft) Connect the EOP switch wire to the switch and tighten the screw to the specified torque. TORQUE: 2.0 N-m (0.2 kgf-m, 1.4 lbl-fl) Install the dust cover. Clamp the rear brake iighl switch Wire properly. Install the under cawls (page 379). FUEL RESERVE SENSOR FUEL RESERVE SENSOR INSPECTION Fuel reserve indicator dues not go of! Lift and suppon the fuel tank (page 4-5), : 3P ‘BLACH CONNECTOR Disconnect the fuel pump unit 3P (Black) connector. ' Turn the ignition switch ON and check the fuel 4 reserve indicator. if the indicator goes offi replace the fuel pump unit (page 6-34). if the indicator is still on, check for short circuit in Brown/black wire between the iuel pump unit can- nector and combination meter. Contents Chapter 20 LlGHTS/METERS/SWITCHES . black and Green terminals with a jumper wire. Fuel reserve indicator does not come on Before this inspection, perform the power and 7 ground line inspection of the combination meter JUMPiERivi/R'F [page 2041}, ‘ Disconnect the fuel pump unit 3P (Black) connector . and short the wire harness side connector Brown/ * _, _ Turn the ignition swrtch 0N and check the indicator. 7 , V ifthe indicator comes on, replace the fuei pump unit ‘ ,.— - (page 6734). , If the indicator does not come on, check tor open ‘ circuit in Brown/black wire between the iuei pump t unit connector and combination meter. if they are OK, replace the combination meter ‘ 3,; ‘BLACK, CONNECTOR ipage 20710L i—__.~_— IGNITION SWITCH INSPECTION Remove the air cleaner housing Ipage seam. Remove the tnrn Clips and connector covers. Disconnect the ignition switch wire 2P (ErownI can~ nectar, Check for continuity between the Wire terminals of r'vr the ignition switch connector in each switch posi~ V tion. Continuity should exist between the color coded wires as follow IG EAT1 KEY 0N 0—0 KEYON OFF KEY OFF KEY OFF LOCK LOCK PIN COLOR R/BI R _‘ 20-18 Contents Chapter 20 LIG HTS/M ETERS/SWITCHES REMOVAL/INSTALLATION Remove the air cleaner housing (page 6740) and connector covers [page 20718I. Disconnect the ignitlon swutch wire 2? lBrownl con— nectar. Remove the top bridge (page 14-11I, IGNITION SWITCH Remove the mountlng bolts and ignition switch. lnstall the ignition switch to the top bridge, Tlgnten the new ignmon switch mounting bolts to the specified torque, TORQUE: 26 N-m (2.7 kgf-rn, 20 [bf-ft) Install the removed parts in the reverse order of removal. 9? BOLTS HANDLEBAR SWITCHES Remove the air cleaner hauslng [page 6-40IV Disconnect the handlebar switch connectors. — Right handlebar switch: 8P (Naturall connector ~ Left handlebar switch: 12F IGray) connector Check for continuity between the wrre termmals of the handlebar switch connector. Continuity Should exist between the color coded wire terminals as follows, ENGINE STOP SWITCH: IG BAT OFF RUN O—O COLOR Bl W/Bl STARTER SWITCH: BAT ST H/L FREE 0 O PUSH GO COLOR Bl/R Y/R Bu/W Contents Chapter 20 20-19 LIGHTS/M ETERS/SWITCH ES TURN SIGNAL SWITCH‘ iam— \ he: , , . DIMMER SWITCH TLIRN SIGNAL SWITCH ‘ L/ W R I. P PR R N L COLOR Gr Lb O Br/WLb/W O/W DIMMER SWITCH: HL Lo Hi Lo (N) HI COLOR Bu HORN SWITCH: Ho BAT FREE PUSH GO COLOR B W/G BRAKE LIGHT SWITCH FRONT Disconnect the front brake llght switch connectors and check for continuity between the terminals. There should be continuity with the brake lever applled, and there should be no continulty when the brake lever is released REAR Remove the right mlddle cowl (page 3-7). Disconnect the rear brake light swltch 2? (Black) connector. 20'” Contents Chapter 20 LIGHTS/METERS/SWITCHES Check for continuity between the terminals. There should be continuity with the brake pedal applied, and there should be no continuity when the brake pedal is released. CLUTCH SWITCH Disconnect the clutch switch connectors. There should be continuity with the clutch lever applied, and there should be no continuity when the clutch lever is released. NEUTRAL SWITCH Remove the exhaust pipe (page 3-30). Disconnect the neutral switch connector from the switch. Shift the transmission into neutral and check for , continuity between the Light green wtre and bodv ground. There should be continuity with the transmission in ,V neutral, and no continuity when the transmission 15 In gear. ' Contents Chapter 20 LlGHTS/METERS/SWITCHES SIDE STAND SWITCH INSPECTION Remove the left under and middle cowis (page 3-7). 2P (GREEN) CONNECTOR Remove the wire band and puH out the 2P (Green) connectorfrorn the connector boot. Disconnect the side stand switch 2P (Green) connec- tor. Check for continuity between the Wire terminais of the side stand switch 2P [Green] connectori Continuity should exist oniy when the side stand is up. REMOVAL Remove the wire band and puli out the 2P (Green) connector from the connector boot (page 2022). Disconnect the side stand switch 2? (Green) connec- tor. Remove the belt and side stand switch. 20-22 Contents Chapter 20 LIGHTS/METERS/SWITCHES INSTALLATION Route the side stand switch wire properly I‘ ‘ ' —— (page1_z4)_ E. SlDE STAND SWITcrh Install the side stand switch by aligning the switch 1 ' l pin with the side stand hole and switch groove with the return spring holding pin Secure the side stand switch with a new bolt. TORQUE: 9.3 N-m (1.0 kgf-m, 7 lbf-ft) Connect the side stand switch ZF lGreenl connector. install the 2P (Green) connector into the connector boot with regulator/rectifier 2P connector. Bundle the connector boots in the wire band. Install the mlddle and under ccwls lpage 3-9). ‘W/fl Contents Chapter 20 20-23 LlGHTS/METERS/SWITCHES HORN Disconnect the wire connectors from the horn. Connect a 12 V battery to the horn terminal directly. The horn is normal if it sounds when the 12 V bat- tery is connected across the horn terminals. TURN SIGNAL RELAY INSPECTION 1. Related Circuit Inspection Check the lollowing , Burned bulb or nonesoecified wattage , Blown fuse 7 ignition switch (page 2018) and turn signal switch function (page 20-20) , Loose connector Check the above items. Are the above Items in good candition? NO — Replace or repair the failed penis) YES — GO TO STEP 2. 2. Turn Signal Circuit Inspection Remove the upper cowl (page 3-12], then remove the head light unit from the upper cowl (page 20-6). Disconnect the turn signal 2P (Black) connector and short the Gray and White/green terminals of the wire harness side connector with a jumper wrrei Connect the front subrharness 22F connectori Turn the ignition swrtch ON and check the turn signal light by turning the turn signal switch on. Does the light came on? VES ~ ~ Faultytum signal relay ° Loose or poor Contact of the conneo tor terminals NO — Open circuit in related wires ”'24 Contents Chapter 20 LIGHTS/M ETERS/SWITCHES, HEADLIGHT RELAY INSPECTION Remove the left middle cowl (page 3-7). Remove the relay box from the bracket. Remove the relay box lBIuel connector from (he i relay box, and then remove the headlight relay, HEADL‘GHT RELAV Connect an ohmmerer lo lhe following headlighl ’ 7' i 7' relayrermlnals. HEAD LIGHT RELAY BA ERY " CONNECTION: Black/red — Blue Connect a 12 V barrery to the following headlight ‘ relay lermlnals. CONNECTION: White , Green There should be continuity only when the 12 V bat» tery is connected. If there ls no cominuity when lhe 12 V battery is connecred, replace rhe headllgm relay, Contents Chapter 20 20'25 MEMO Contents Chapter 20 21. WIRING DIAGRAM A, AC, CM type 21.3 Contents Chapter 21 21-1 Contents WIRING DIAGRAM A, AC, CM type: FAIR SMEMHI VALVE IE} mm: AIR uum mam snLEan VALVE 7mm BRAKE HEW 9”“! L7 Sm; 5mm 75mm svw-sunmz 9mm > Ell")! INN : : RIGHV Mull?” SIGNAL um“ IZVWn/lm Pasmouuam , um ‘zvsw r wunsnax mnuemm ,_ LlCflISE LIW «zvssw {LE " W Bv/Jnfilfl'p—fijvmvsw NWUGNT [W Wkfligp I ,_ mmjm mm mm umr Firm Wm ‘ZVWMIWIW/(W‘ LEN marina» slam um gagsxfiwmm—m «mum NI aim mm swam NELAV cum 5mm! 1mm SWNAl-IIIIIHER-MOM 5mm ; g E F R sumac mnmum am: we sum \ rm I? mm m sump w sansoa HM mm mm mvt um um um usumL 5mm! EDP SVHTKIHV’ (c: pszm W m u we mauE u'c; :; mm sumaz RELAY 5mm EJ21314— E. REMAHR _ Emma: ALIERMAIUR mm wssw u —‘L::=13'.mm.m nfliflrCl/ZI vzvzan Lm’m W SWIM. um Fuss mx Azm (NEADUEHLSMRYER: 5m [mum - m « saw - ”mm- swzmzm - msmm . um): Hem- mumm Cm (TURN slum-mm" Hem ambmnm D m (WK we sansam Ezm (FM mum F m :mausvm OOSOZ—MEL-6700(A, CM type) -7700(AC type) Chapter—21 21-3 Contents Chapter 21 22. TROUBLESHOOTING ENGINE DOES NOT. START OR IS HARD POOR PERFORMANCE AT LOW AND TO START- .., .V. 22.2 IDLE SPEED ................................................... 22.5 ENGINE LACKS POWER 22-3 POOR PERFORMANCE AT HIGH SPEEDm-ZZ-S POOR HANDLING ...................................... 22.5 Contents Chapter 22 22'1 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 1. Spark Plug Inspection Remove and inspeci spark plug. Are the spark plugs in guild candi'tion? N0 7 - Incorrect spark piug heai rariga . lncorreci spark plug gap - Dlrly allaleaner YES — GO TO STEP 2. 2. Spark Test Pericrm spark test. Are there good sparks? NO — Loose or disconnected igniiion svslem Wire Fauity lgnnion cell Broken or shorted direct ignition coii connector wire Faulty ignition pulse generaior Faulty engine stop switch Faully engine comroi moduie (ECM) YES e GO TO STEP 3. 3. Fue| Pump Inspection Check for operatitm oflhe fuel pump and inspect irie fuel liow. is the iuel pump unit normal? N0 — Faulty fuel pump unit (page 533). YES — GO TO STEP 4. 4. Programmed Fuel Injection Syslem Inspection Check the fuel injection system, Is the fuel iniecrian system narrnal? No 7 Faulty fuel injeciion sysiem lpage 6754, 6743) VES 4 GO TO STEP 5. 5. Cylinder compression lnspecfion Test The cviinder Compressmn, is the compression specified? NO , Valve stuck open Worri cylinder and piston rings Damaged cylinder head gaskel Seized valves lmpropervalve liming YES 7 GO TO STEP 6. 5. Engine sun conuiiion Star! by rollowing normai procedure. Did the engine start but stops? YES — - Leaking intake manifold - Leaking intake pipes - Faultystartervaives - improper igniiion iiminp (Fauitv ECM or lgnltlofl pulse generator) ~ Coniemineied fuel 22'2 Contents Chapter 22 TROUBLESHOOTING ENGINE LACKS POWER 1. Drive Train Inspection Raise wheel oi-itne ground and spin by hand Did the wheel spin freely? NO - . Brake dragging - Worn or damaged wheel bearings YES — GO TO STEP 2. . Tire Pressure Inspection Check ihe tire pressure. is the tire pressure correct? No , - Faulty tire valve - Functurediire VES — GO TO STEP 3. . Cintch Inspection Accelerate rapidly, shift irom first to second. Did the engine speed change accordingly when clutch is released? N0 - - Ciurcn slipping - Worn clulch discs/plates - Warped oiutcn discs/plates - Weak clutch spring - Additive ll'l engine oil VES 7 GO TO STEP 4. , Engine Periorrnsnce Inspection Acceleraie lightly. Did the Engine speed increase? N0 - - Dinvaircleaner - Restricted fuel flow - Clogged mumer YES — GO TO STEP 5. Spark Plug Inspection Remove and inspect spark plugs. Are the spark plugs in gond condition? No — I Plugs rim serviced frequently enough - Incorreci spark plug heat range - Incorrect spark plug gap YES — GO TO STEP 6. Engine Oil inspection Check the oil level and condition. Is the engine oil in good conditiari? NO < ' Oil level too high - Oil level (00 low - Contaminated oil YES — GO TO STEP 7. Ignition Timing Inspection Check the ignition timing. is the ignition timing os specitied7 NO 7 I Fauliv engine Control module (ECM) - Faulty ignition pulse generator - Improper valve liming VES — GO TO STEP 8 Contents Chapter 22 22-3 TROUBLESHOOTING 3. Cylinder compression Inspection Test the cylinder compression, is the eampressian as specified? NO 7 Valve clearance tao small . - Valve stuck open - Worn cylinder and plsmn rings - Damaged cylinder head gasket - Improper valve timing VES — GO TO STEP 9. 9. Fuel Pump Inspection Inspect the fuel flow Is the fuel pump uni! normal? NO - Faulty fuel pump unitlpage 6-33). YES — GO TO STEP 10‘ 10. Programmed Fuel Iniection System Inspection Check the luel injection system. Is the fuel injection system "armal? N0 7 Faulty tuel injection system lpage 6754, 6743). YES — GO TO STEP 11, 1 . lubrication Inspection Remove cylinder head cover and inspect lubrication. is the valve train lubricated praperly7 N0 — ' Faulty oil pump - Faulty pressure regulator valve - Clogged oil strainer - Clogged oil passage was a so To STEP 12. 12. Over Heating Inspection Check lor engine over heating. is the engine ever heating? YES 7 ‘ Coolant level loo low Fan motor not working Thermostat stuck closed Excessive carbon buildup in combustion chamber Use of poor quality fuel Wrong type ol fuel Clutch slipping NO - GO TO STEP 13. 13. Engine Knocking Inspection Accelerale or run at high speed. is the engine knocking? YES - Worn piston and cylinder Wrong type of fuel Excessive carbon buildup in combustion chamber lgnllion turning we advance (Faulty ECM) Faulty ignition pulse generator Faulty cam pulse generator N0 — - Engine does not knock 22'4 Contents Chapter 22 POOR PERFORMANCE AT LOW AND IDLE SPEED 1. . Ignition Ti Spark Plug Inspection Remove and Inspect spark plugs. Are the spark plugs in gaod condition? No — ~ Plugs not serviced frequently enough - Incorrect spark plug heat range - Incorrect spark plug gap VES — GO TO STEP 2. 9 Inspection Check the Ignition timing. is the ignition timing as specified? no _ . Faulty engine control module [ECM) . Faulty ignition pulse generator - Faulty cam pulse generalor - Faulty vehicle speed sensor - Improper valve timing VES — GO TO STEP 3 , Fuel Pump Inspection Inspect the loci flows is the fuel pump unit normal? No - Faulty fuel pump unit ipage 5.33). vs 7 GO TO STEP 4. . Programmed Fuel injection System Inspection Check the fuel injection system is the fuel injection system normal? N0 A Faulty fuel injection system lpage 654, 6-43, VES — GO TO STEP 5. . Starter Valve Synchronization Inspection Check the starter valve synchronization. Is the starter valve synchronization as specified? N0 — Adjust the starter valve synchronization (page 6761). YES - GO TO STEP 6‘ . Intake Pipes Leaking lnspectiun Check for leaks at [he intake manifold pipes. Are there leaks? YES 7 - Loose insulator - Damaged insulator TROUBLESHOOTING Contents Chapter 22 22-5 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Ignition Timing inspectian Check rhe igntrion Iimlng. is the ignition timing as specified? No _ FaultyenginecomrolmodulelECM) Faulty ignition pulse generator Faulty cam pulse generator Faulty vehicle speed sensor Improper valve timing YES _ GO TO STEP 2. Fuel Pump inspection Inspect the fuel flow. Is the fuel pump unit operation narmal? NO , Faulty ruel pump unit (page 6733). YES — GO TO STEP 1 . Programmed Fuel Injection System lnspemion Check the fuel iniection system, is the fuel injectipn system normally? NO , Faulty fuel injection system (page 5754, 543i. YES 7 GO TO STEP 4. Valve Timing Inspection Check the valve timing, is the valve timing carrect? N0 — Camshafts nol installed properly YES — GO TO STEP 5, Valve Spring Inspection Check for the valve springs is the valve spring ['29 length as specified? No — Faulty valve springs YES — Not weak POOR HANDLING Steering is heavy Faulty steerlng damper lHESD) Steering stem adiustlng nut loo tight Damaged steering head bearings Insufficient tire pressure Either wheel is wobbling 0 Excessive wheel bear'lng play Bent rim Sw'lngarm pivot bearing excessively worn Bent frame The motorcycle puiis to one side e-eee- Fronl and rear wheel not aligned Faulty shock absorber Bent lurk Bent swingarm Bent axle Benz frame 22-6 Contents Chapter 22 23. INDEX AIR CLEANER AIR CLEANER HOUSING v ALTERNATOR CHARGING COIL} ALTERNATOR COVER INSTALLATION ALTERNATOR COVER REMOVAL BALANCER ......... BANK ANGLE SENSO BATTERY v BATTERY/CHARGING SYSTEM SPECIFICATIONS 1710 BODY PANEL LOCATIONS BRAKE FLUID- BRAKE FLUID REPLACEMENT/AIR BLEEDING- BRAKE LIGHT SWITCH LIGHTS/METERS/SWITCHESA MAINTENANCE BRAKE PAD WEAR BRAKE PAD/DISC- ERAKE PEDAL BRAKE SYSTEM CABLE & HARNESS ROUTING CAM CHAIN TENSIONER LIFTER CAMSHAFT INSTALLATION CAMSHAFT REMOVAL-m- CHARGING SYSTEM INSPECTION CKP (CRANKSHAFT POSITION) SENSOR CLUTCH CLUTCH FLUID CLUTCH FLUID DRAINING CLUTCH FLUID REPLACEMENT/AIR BLEEDING - CLUTCH MASTER CYLINDER- CLUTCH SLAVE CYLINDER- CLUTCH SWITCH CLUTCH SYSTEM CLUTCH/STARTER CLUTCH SPECIFICATIONS CMP SENSOR---- COMBINATION METER ----- COMPONENT LOCATION ALTERNATOR-I CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER-m CYLINDER HEAD/VALVES ENGINE REMOVAL/INSTALLATION FRONT WHEEUSUSPENSION/STEERING~ FUEL SYSTEM (Programmed FUeI Injection HYDRAULIC BRAKE u REAR WHEEL SUSPENSION TRANSMISSION/GEARSHIFT LINKAGE COOLANT REPLACEMENT COOLING SYSTEM ----- 4—24 COOLING SYSTEM SPECIFICATIONS- CRANKCASE ASSEMBLY-- CRANKCASE SEPARATION - CRANKCASE/CRANKSHAFF/BALANCER/ PISTON/CYLINDER SPECIFICATIONS » CRANKPIN BEARING-- *- CRANKSHAFT CYLINDER COMPRESSION TEST CYLINDER HEAD ASSEMBLY- CYLINDER HEAD COVER ASSEMBLY- ~20-2‘I -’Ir7 20-10 CYLINDER HEAD COVER DISASSEMBLY 9-7 CYLINDER HEAD COVEFI INSTALLATION - 9-32 CYLINDER HEAD COVER REMOVAL 976 CYLINDER HEAD DISASSEMBLY 944 CYLINDER HEAD INSPECTION , CYLINDER HEAD INSTALLATIO CVLINDER HEAD REMOVAL CYLINDER HEADNALVES SPECIFICATIONS- DIODE-n - 19714 DRIVE CHAIN 4726 ECT SENSOR 15-65 20-14 FUEL SYSTEM (Programmed Fuel Injecfion LIGHTS/METERS/SWITCHES---- EGCV (Exhaust Gas ControI ValveI FUEL SYSTEM (Programmed Fuel Injection TECHNICAL FEATURES EGCV SERVOMOTOR ELECTRIC STARTER SPECIFICATIONS EMISSION CONTROL INFORMATION LABEL (U,S.A. ONLYI'" EMISSION CONTROL SYSTEMS ENGINE & FRAME TORQUE VALUES- ENGINE CONTROL MODULE (ECM) ENGINE IDLE SPEED- ENGINE INSTALLATION ENGINE OIL/OIL FILTER ENGINE REMOVAL- ENGINE STOP RELAY EOP (ENGINE OIL PRESSUREI SWITCH EVAP PURGE CONTROL SOLENOID VALVE (CALIFORNIA TYPE ONLYI" EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) EXHAUST GAS CONTROL VALVE CABLE EXHAUST PIPE/MUFFLER FAN CONTROL RELAY -4»26 -4-34 -3-30 -772’| FLYWHEEL- ”IT’S FORK 14er FRONT BRAKE CALIPERS- 16-27 FRONT FENDER-~F-m -3-19 FRONT MASTER CYLINDER 18-15 FRONT WHEEL-- 14716 FRONT WHEEL/sUsPENSION/STEERING SPECIFICATIONS-- FUEL CUTVOFF RELAY- FUEL LINE- FUEL LINE INSPECTION FUEL PUMP UNIT-- FUEL RESERVE SENSOR FUEL SYSTEM (Programmed FueI anectIonI SPECIFICATIONS FUEL TANK GEARSHIFT SPINDLE- GENERAL SPECIFICATIONS HANDLEBAR SWITCHES HANDLEBARS HEADLIGHT-- HEADLIGHT AIM- HEADLIGHT RELAY HESD (Honda EIeCtronIC SleerIng Damper HESD (Honda EIectronIC SteerIng DamperI TROUBLESHOOTING- HORN .......... HYDRAULIC BRAKE SPECIFICATIONS IAC VALVE SYNCHRONIZATION -- IAT SENSOR ‘‘‘‘‘ IDLE AIR CONTROL (IAC) THERMAL VALVE IDLE AIR CONTROL (IAC) VALV IGNITION SWITCH --------- IGNITION SYSTEM INSPECTION IGNITION SYSTEM SPECIFICATIONS- IGNITION TIMING INTAKE AIR DUCT LICENSE LIGHTm » LIGHTS/METERS/SWITCHES SPECIFICATIONS- LUERICATIDN & SEAL POINTS LUBRICATION SYSTEM DIAGRAM - Contents INDEX LUBRICATION SYSTEM SPECIFICATIONS MAIN JOURNAL BEARING ----- MAINTENANCE SCHEDULE MAP SENSOR- MIL CODE INDEX MIL TROUBLESHOOTING MODEL IDENTIFICATION NEUTRAL SWITCH- NUTS, BOLTS, FASTENERS , OIL COOLER OIL PRESSURE INSPECTION v OIL PUMP| OIL STRAINER/PRESSURE RELIEF VALVE PAIR CONTROL SOLENOID VALVE- PASSENOER SEAT... PGMvFI SELF-DIAGNOSIS INFORMATION PISTON/CYLINDER- POSITION LIGHT PRIMARY INJECTOR ----- RADIAL MOUNTED FRONT BRAKE CALIPER RADIATOR- RADIATOR COOLANT RADIATOR RESERVE TANK REAR BRAKE CALIPE 16731 REAR FENDER REAR MASTER CYLINDER - REAR SEAT COWL- REAR WHEEL- - REAR WHEEUSUSPENSION SPECIFICATION REGULATOR/RECTIFIER RIDER SEAT-- RIGHT CRANKCASE COVER INSTALLATION 1034 RIGHT CRANKCASE COVER REMOVAL 1045 SEAT RAIL-- SECONDARY AIR SUPPLY SYSTEM SECONDARY INJECTOR SERVICE INFORMATION ALTERNATOR BATTERY/CHARGING SYSTEM CLUTCH/STARTER CLUTCH/GEARSHIFI' LINKAGE-u COOLING SYSTEM CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER CRANKCASErrRANSMISSION CYLINDER HEADNALVES ELECTRIC STARTER ENGINE REMOVAL/INSTALLATION - FRAME/BODV PANELS/EXHAUST SYSTEM FRONT WHEEL/SUSPENSION/STEERING FUEL SYSTEM (Programmed Fuel Iniemion)- HYDRAULIC ERAK IGNITION SVSTEM LIGHTS/METERS/SWITCHES LUSRICATION SYSTEM MAINTENANCE REAR WHEEL SUSPENSION SERVICE RULES -. SHOCK ABSORBER Is-IA SIDE STAND 4-36 SIDE STAND SWITCH 20-22 SPARK PLUG A78 SFEEDOMETEFINEHICLE SPEED SENSO STANDARD TORQUE VALUE STARTER CLUTcH ----- STARTER MOTOR STARTER RELAY SWITCH STATOR ----- STEERING DAMPER STEERING HEAD BEARINGS» STEERING STEM SUSPENSION" SUSPENSION LINKAGE SWINGARM ----- SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM ELECTRIC STARTER AAAAA FUEL SYSTEM (Programmed Fuel InjectIon) IGNITION SYSTEM -~ SYSTEM FLOW PATTERN SYSTEM LOCATION FUEL SYSTEM (Programmed FueI InjectIon) LlGHTS/METERS/SWITCHES SYSTEM TESTING- TACHOMETER - TAIL/BRAKE LIGHTr THERMOSTAT- THROTTLE BODY THROTTLE OPERATION TOP SHELTER TRANSMISSION TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS-- TROUBLESHOOTING BATTERY/CHARGING SYSTEM CLUTCH/GEARSHIFI’ LINKAGE COOLING SYSTEM -- CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER--- CRANKCASE/TRANSMISSION CYLINDER HEADNALVES- ELECTRIC STARTERM- ENGINE DOES NOT START OR IS HARD TO STARTW ENGINE LACKS POWER- FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEL/SUSPENSION/STEERING -- FUEL SYSTEM IProgrammed FUel Injection) HYDRAULIC BRAKE- IGNITION SYSTEM POOR HANDLING - POOR PERFORMANCE AT HIGH SPEE POOR PERFORMANCE AT LOW AND IDLE SPEED » REAR WHEEL SUSPENSION- TURN SIGNAL-- TURN SIGNAL RELAY UNDER COWLS/MIDDLE COWLS UPPER COWL--- VALVE CLEARANCE -- VALVE GUIDE REPLACEMEN VALVE SEAT INSPECTION/RE FACING WATER PUMP WHEELS/TIRES WIRING DIAGRAM A, AC, CM Iype . .NN L NMmmm&tIdNr9 comma mmk-mr‘nmuwm 23-2 Contents