1999-2002_

sanv‘cgmuuu

1999-2002

 

I. UI:I\II:I1I-\L IIVrUnIVIH I IUI\I

 

GENERAL SAFETY 1-1
SERVICE RULES 1-2
MODEL IDENTIFICATION 1-3
SPECIFICATIONS 174
TORQUE VALUES 1-13
1-18

1 TOOLS

LUBRICATION & SEAL POINTS 1-20
CABLE & HARNESS ROUTING 1-24
EMISSION CONTROL SYSTEMS 1750
EMISSION CONTROL INFORMATION

LABELS 1-54

 

 

GENERAL SAFETY

CARBON MONOXIDE

If the engine milsI be running to do some work, make
sure me area us well ventilated. Never run the engine in an
enclosed area.

m____

The exhaust contains poisonous carbon monoxide gas
that can cause lass a! consciousness and may lead to
death.

 

min mp, engine in an open area or With an exhaust
evacuation svslcm in an enclosed area.

GASOLINE

Work In a well ventilated area. chp cigarettes. flames or
sparks away from (Its work area or where gasuline is
stored.

AWARNING

Gasoline is extremely flammable end is explasive under
Email. sonditl'arla. KEEP our 0F REACH OF CHILDREN.

 

HOT COMPONENTS

M

Engine and exhaust system pans become very hot and
remain not lar some time after the angina Is run. Wear
insulsud glovus Ur wuit until the engine and exhaust
systsm have sealed balam handling thesE parts.

 

USED ENGINE OIL

MIME—fl

Used engine all may cause skin cancer if reputvdly lift in
cantact with in. 5“" {or prolonged periods. Although this
is unlikely unless you handle used all an a daily basis, it is
still advisable to thoroughly wash your hands with soap
and water as Man as possible after handling used oil. KEEP
OUT OF REACH OF CHILDREN.

 

BRAKE DUST

NEVEI use an air hose or dry hrllsh In clean Ihe hmke
assemblies Use an OSHArappravad vacuum cleaner or al-
ternate method approved bv OSHA, designed to minimize
the hazardcaused by airborne asbestos fibers

BRAKE FLUID

CAUTION:

Sal/ling fluid on painted, plastic or rubber parts will
damage them. Place a clean shop towel over these parts
whenever the system is serviced KEEP OUT OF REACH OF
CHILDREN

 

 

GENERAL INFORMATION

COOLANT

Under some candlhnns, the ethylene glycol in engine
coolant is combustible and its flame is not vtsrble, ll the
ethylene glycol does ignite, you will not see any flame, but
you can be bullied.

M

- Avoid spilling engine coolant or! the exhaust system or
engine parts. They may be hot enough to cause the
coolant to Ignite and burn without a visible flame.

- Coolant (ethylene glycol} can cause some skin irritation
and is poisonous if swallowed. KEEP OUT OF REACH OF
CHILDREN.

I Do not ran-rave the radiator esp when the engine is hat.
The coo/am is under pressure and could scald you.

. Keep hands and clothing nwlry Irom the cooling Ian, as it
start: automatically.

 

CAUTION’

 

Using coolant with silicate inhibitors may cause premature
water nl water pump seals or blockage of radiaiar
passages. Using tap water may cause engine dumnge.

 

SERVICE RULES

BMTERV HVDROGEN GAS 8r ELECTROLYTE

m—__

I The battery gives of! explosive guses,‘ king Sparks,

flames and cigarettes away, Provide adequate ventilation

when charging.

The battery contains sulfuric acid (electrolyte). Contact

with skin or eyes may cause severe burns, Wear protec-

tive clothing and a lace shield.

, ll electrolyte gets on your skin, flush with water.

7 If electrolyte gut: in your eyes, flush with water {or at
least 15 minutes and call a physician irmnedr‘ately,

Electrolyte is poisonous.

*lf swallowed, drink large quantities a! water or milk
and follow with milk of magnosia or Vegetable oil and
call a ph ysicinn. KEEP OUT OF REACH OF CHlL DREN,

 

1 Use genuine HONDA or HONDA-recommended parts ant! lubricants ur llneil equivalents. Pans that don’t meet HONDA's
deslgn spmlmalmns may nnllse damage to the motorcycle

2, Use the special tools designed for this product to avord damage and incorrect assembly.

3. U>e uIIIy metric lools when servicing the motorcycle. Metric bolts, rims and screws are not interchangeable with English
fasteners

4. Install new gaskets, O~rlngs, cnflnr pins, and lock plates when renssernhlirlg.

ELWth'l tightening bolts or l’lutG, begin with the larger diameter or inner bolt met, Then tighten to the specified torque
diagonally lll incremental steps unless a particular sequence is specified.

5 Clean parts ln cleanlng solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After reassembly, check all pans lor proper lnstnllannn and operation.

8 Route all electrical wires as snow on pagesl 24througnl 37. Cable and Harness Routing.

 

1-2

 

HOW TO USE THIS MANUAL

Tris sew :5 nTa1.aI:es:'ibesthe semen prnnadnrflt
:D' the CBTI'I 'IIJUXX,

=0 lcw he Mainlanai‘ce Scheddie (Secliu ‘ 3', www-
‘WEi'iD‘étICHS to 915W? Ihat The vehicie is m wak
nperamg cnndvtinn and the e-n 351m evels a'e
IA . 'hc stardards Oct bv the US, Environmental
aviator: Aqencv and Caifurr’id AiI ResquLus
Boaid

    
 

Deri‘ormirg no firs: achedulec maimenance is ve'y
women. it comprsates fur Hie miJai Wear IIiaI
occuis :‘urrwg he break-in pe'IOd

Schoris i and 3 apply to the whole motorcycie.
Seci'IuI'. 2 i‘uslraleh pruLedule: IUI ‘EIIIUVdII
nszaliax on ov‘ rnmmnsnu ch?! may he anIIirs-‘ri m
pefiorm serv‘ce dcscnbcd In the foliowmg scctions.
Sections 4 through 19 describe parts of the
‘IululLyuIe, giuuprd dL‘LU’L'IHg lu TUCaIICi.

=ind the semen you wam on VHS page. then Turn To
:1: Table ofconIenm on The first page of the section.

Most secfions have an aswmh y M Sys'am
Hustrahon. se'vice inVormalIOn and Iroublcshuming
5O'Ihe section.

The ”1.,“quny ways: 9w: dEZaIIed piocedures

‘f You are not fam her with this moto'cyciu. road
Tscnnicai Feature In section 21.

i’ vuu duu'I k-iuw HE :uuxce ol the tIoubIe, go to
snum 7? TroJOIeshnmIng

CONTENTS

 

GENERAL INFORMATION

 

4.414“ E ..

FRAME/BODV PANELS/EXHAUST
2mm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAINTENANCE a
LUBRICATION SYSTEM n
FUEL SVSTEM
Z (Programmed Fuel Injection)
E COOLING SVSTEM m
E ENGINE REMOVAL/INSTALLATION
n: ———-_-_
g CYLINDER HEAD/VALVES I:
z 7,
E CLUTCH/GEARSHIFT LINKAGE n
z
(29 ALTERNATOR/STARTER CLUTCH m
I“
CRANKCASE[PISTON/CYLINDER ]
CRANKSHAFT/TRANSMISSION/ m
BALANCER , 7
FRONT WHEEL/SUSPENSION] m
g: STEERING
m ..__
'g REAR WHEEL/SUSPENSION III
I
9 HVDRAULIC BRAKE E
BATTERY/CHARGING SYSTEM m
‘ 3’ IGNITION SYSTEM Ia
U :3
E ELECTRIC STARTER I”
o E,
w ,
L—J, LlGHTS/METERS/SWITCHES I E!

 

 

WIRING DIAGRAM

 

 

 

INDEX

TECHNICAL FEATURES

IL...

TROU BLESHOOTING

 

Dam ofissuc: Dcccmbcr.1998

 

GENERAL INFORMATION

 

MODEL IDENTIFICATION

    
    

<2) The engine serial number is slamped on the rum
we ullhe uppe‘ cranktase

14b The lIHoIIIe body identlficatmr‘. number, IS
swamped on me make Slde ofme throulc body as
shown.

  
    

 

FRAME SERIAL NUMBER

 

m The mm; serial nmfibe. is stamped on he rvghY
:vde of me steering head

VrllltLI: IDENTIFICATION NUMBER {VIN}

     

 

The Vehicle Idemification Number MM 25 locatr
ad on right side of the frame near the steenng
head on the smw (:amflcmlon Label.

<3

COLOR LABEL

(5' The color label is alldched as shown When
Uldeving coIor—cuded park, always specva (he
desngnared color code

 

1-3

GENERAL INFORMATION

 

 

SPECIFICATIONS
* GENERAL 7
ITEM SPECIFICATIONS
DIMENSIONS ‘ Overall length 2,160 mm iii?) 0 in)
i Overallwidrh 720 mmi28.3inl
Overall height '59; l 1,170 mm ”6.1 in)
Aher '99. ‘ 1,200 mm 147.2 in)
' Wheelbase ‘99: l Luis mm Ian 5 in)
1 After '99: ; 1490 mm l58.7 in)
‘ Seat height 310 mml31.9in)

Footpeg height

Ground clearance

Div weighi 49 stain/Ca nada type
California type

Curb weight As atale/(Znnadn type
California type

Maximum weight capacity

I
l
i
l

372 mm (us in)
130 mm (5.1 m)
223 kg (492 lbs)
224 kq (454 lbs)
253 kg (555 lbs)
2:» kg l550 lhsl

 

 

 

 

Engine dry weight

 

49 state/Calilonnia type 1711 kg l354 lbsl
Canada type 178 kg 1393 lbsl ‘
FRAME i Frame type Diamond
Front suspension Telescopic fork
From wheel Navel 109mm (4.3inl
Roar suspension Swingarm
Rear wheel travel 120 mm H] in)
Rear damper Nitrogen gas filled damper
Front llre rum 120/70 ZR17 (58W) [Radial
Heartlm size Inn/’55 7R17 (73W) [Radial
‘ Tire brand
Bridgeslone l Front: BTS7F RADIAL G (Rear: BT57R RADIAL G
l Dunlap i
Michelin i I mm. MACADAM 90X S lRear: MACADAM 90X 5
Front brake Hydraulic double disc brake with 3 piston calipers
Rear brake Hydraulic single disc brake WM! 3 pismn calipers
Caster angle 25“
Trail length r 99 mm (3.9 in)
Fuel tank capacixy ‘ 24.0 B (6.34 US gal , 5.28 Imp gal)
ENGINE Bore and stroke i 79.0 X 58.0 mm (3.11 X 2.28 inl
Displacement ‘ 1,137 cm“ (59.4 L'u-ill)
Compreeeion ratio 11.0:1
Valve Irain Chain drive and DOHC
Intake valve opens fi—ai ‘l lnrn 17° BTDC
closes (0.04 in) lifl r 40" ABDC
‘ Exhaust valve opens j 40" BBDC
closes 10° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid/double rotor
' Cooling svsiem Liquid caoled
Air filtratiun Paper filter
Crankshaft type Unit type

83 0 kg (1R3 0 lbs)
Four cylinder, inline 30° inclined from vemeal

 

Cylinder arrangemenr

 

1-4

 

GENERAL INFORMATION

 

 

,— GENERAL (Cont'd)
ITEM

SPECIFICATIONS

 

I CAHBURETION ‘ Type
Throulevbora

PG MrFl (Programmed FueI minivan)
42 mm (1‘7 in)

 

 

 

I DRIVE TRAIN Clutch system MuIIi-plale, Wei

Clutch npemmn system Hydraulic operated type

Transmission Constant mesh, firsoeed
Primary reduction 1.571 (83/56)
Final reduction 2.647 (45/17)
Gear nmn Ist 2.769 (36/13)
2nd I 2.000 (32/16)
3 3rd I 1.579 (30/19)
I 4th ‘ 1.333(28/21)
I 5th 1 167 (III/2‘)
r em 1042(25/24)

‘ Gearshiflpartern Lah Ioor operated return system 1vN» 4 5—6
ELECTRICAL I Ignition system Compuler-connolled digItal transistor Med wilh electric

Smning system
Charging svstem
Regulator/rectifier
Lxghtmg svs'am

 

advancn

Electric starter molar

Triple phase output alternakor

SCR sImned/lviple phase, full wave recrificaliun
Emmy

 

 

 

1-5

 

GENERAL INFORMATION

 

— LUBRICATION SYSTEM "
ITEM

Unit: mm (in)

STANDARD SERVICE LIMIT

 

Engine Oil capacity
Ar disasgembly

L Ardraininr

3.3 a (mus qt , 3.3 Impiqt) 7’ ‘

are u {A 9 us ql, 4.0 Imp qt}

 

At all fiiter change

are E [4.1 US gt . 3‘4 Imp qt)

 

Recommended engine oil

Oil pressure at all pressure switch

 

HONDA 6N4 4vslroke OH or equivalent
motor oil 1
API service classrficetion SF or $6
Visoosiy: SAE row-4o

490 kPa (5.0 kglfinn2 , 71 psi)“
5400 rpm/(Bo “(3/176 °n

 

 

 

 

 

 

   

 

 

‘BzGump rotor Feed pump Tm clearance 0,15 (DVDOGImaxr 0.20 (0.003)
_, Body clearance 0.167021 (000670.008) _ 035(0‘014) I
Side ciaaranca D.OI‘O.09(DIOOZ-O.004IV 012(0.005) I

Cooler Tip clearance 0.15 (D.006)max. 0.20 (0008)

- pump Bndy nlenrnnce ‘ HIS—0‘21 [0,0067 OD8I 0.35ID.01A)

Side clearance 0.04~0.09 (0110270.!)0“ 0.12 (0.005)

 

 

— FUEL SYSTEM (Progglmmod Fuel Injection)

 

 

 

SPECIFICATIONS
“Throme body 49 gargpanaua 1226 GO 40 D "7
igerrrificarimx number Caiilornia type GD 40 a _
Srnner valve vacuum dlflarence 20 mm Hg
Base throttle valve for synchronization No.3

 

. ldla speed
Throttle grip free play

» V_‘I,100_50rpm
7 fimmI'l/‘IS 1/‘InI

 

 

 

Intake arrternperamre sensor resistance (at 20 °C,’68 °FI 1—4 k 0
Engine cooianr temperature sensor resistance iat 20 'C.’68 'F‘r 2.3 — 2 Q _
Fuel injeclur raxislanue (al 20 “C/SS 'FI 13.0—14I4 k {2

 

FAIR solenoid valvr, ret stance (at 20 °C/Gfl cF)
7 Qt} Quisg generator goak voflagfltfiifiC/GB °F)

 

20 24 S!
0.7 V minimum

 

Ignition pulse generator psak voltage (at 20 “(3/68 °F)
iMfliiald absoiule pigssgejtidle
I'uni . a! Idle

   

‘ After ’99:

 

Fuel pump flowiat 12 V)

HV minimum
200—250 mm H9
294 kr’n (3‘0 kgf/cmk, 43 psi)
343 kPa [3.5 kgf/cm’ . 50 psi)

”' Minimum :20 cm’ (1.4 us 01 7‘7 Imp In) rur 10 seconds

 

 

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

  

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

'— COOLING SYSTEM " ‘
ITEM SPECIFICATIONS
Coolant capacity _R_adlaror and engine 3.2 D (0.85 US gal , 0.70 Imp gall
Reserve lenk , 1.1lH0 US gnl,n2llmE gall
Radia‘or cap relief pressure 108* 137 kPa (1.1 4 kgflcm‘ v16*201150
thermostat r Begins to open 80-84 'Cu76—133°F)
Fully oeen 7 95 “C (203 "F)
Valve lifi , H mm (0.3 In) minimum
Recommended antifreeve quh quality erhylcnc glycol antifreeze containing corrosion
proraction inhioimrs
Standard coolant concentraxlon 50% mixtur
7 CYLINDER HEAD/VALVES 1 U""' m’“ “"‘
ITEM STANDARD > SERVICE LIMIT
Cylinder compression 1,275 kPn (13.0 kuf/cm‘ . 185 psi) ‘
at 350 rpm
Cyllndcr head warpage l " 0.10 (0.004)
Valve, l Valve clearance _ IN .‘ 0.16 ' 0.0301006 1- 001)
valve guide l W EX 0.22 i 0.0310009 1l 1
Valve stern CD. IN 1975-4390 (01959-01965) 4.965 (0.1955)
l EX 1980—4375 (01953—01959) 4.950 (0.19‘9)
‘ 3 Valve guide LD. ‘ IN 5000 5.012 (01955—01973) K 5.0“) 10,1984)
l ‘ EX woo—5.012 (01969-01973) 5040101084)
1 Sum Io guide clearance W l 001070.037 (00004-00015)
EX ems—(1.052 (Doom—0.0020) v 7‘ _
1 Valve guide projenion IN i 16.3 16.510.64—055)
l ahnve cylinder head EX 16.3—16.5 (0.64—0.65)
‘ Volvo scarwidm lN/EX 0.90-1.I010.035#0.043) W l
Valve spring I Inner lN/EXi W 37.4 {1.47) _ l . ‘
Ilee length I Outer __ IN/FX 40.6 {1.5m 33 5 (1.52)
Valve Ilfler I Valve lifter OD, lN/EX 25375—25993 (1.0228i1.0233) 253711.022I
' Valve Iiher bore |.D. |N[EX 26.010i20.026(1.0240‘10146) 26.04 (1.025l
Camshaft ‘ Cam label‘sighl I IN 38.42—38.50 (1.513 1.516) 381211.501]
l fiEX 38.38—38.461‘1511—1514) 380811.499)
‘ Runoul — 0.05 (0.002) 1
‘ Oil clearance (102070.074(000084.003?) , 7 0 1010.004) 7 j

 

 

 

 

 

1-7

GENERAL INFORMATION

 

Unitzrmrn (in)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

'— CLUTCHIGEARSHIFT LINKAGE
ITEM STANDARD SERVICE LIMIT
Recommended plum. fluid DOT 4 brake mun
Clutch mastercylinder Cylinder ID. 3 12700712743 (050007022017) 12770 l0.502l fl
Pistun 0.0. l 11657-1168410.4983~0.4994) 12.6571149m fl
Clulcll springlraa length . 57,4(226) 55.2 (2.21) _
Clutch disc thickness A1 3 ' m mus 015317 . §.5lo.14) ,
,. A2 3.7273.38(0.146—0.153) : 3.5 (0.14»
‘ Clutcmatcwarpage 10.30 ((1.012)
Clulch outergulde LD. ‘ 28000—28021(MON—1.1032) l 23 031 (1.1036)
, 0.0. 37,975 34.991t1.377o .3776) _1
Malnshuh o L) at clutch outer guide 2733047993 (1.1016— 1021) 27.970 (1.10121
snlmork. Fork 4;) .. mono—12.021 (0.472.170.4733) r 12.03lu.474l
lurk snarl Claw lhlnknnss 5,93 —s.oo (0233—9136) 5.910 zal
7 FulksllaflOD. 11.957i11.96fi[0.l7n7 04712), '_ 11.95lo.47ol
— ALTERNATOR/STARTER CLUTCH . U""' m'" "“’
rrEM STANDARD l SERVICE LIMIT

 

 

Sinner driven gear mm; 0.0.

51.699“51.718(10354—720361) 51664 (7.70345)

 

 

 

 

 

 

 

 

 

 

 

 

 

CRANKCASE/PISTON/CYLINDER —— - ”""' "‘m “"’
ITEM STANDARD SERVICE LIMIT
Cylinder LD. 79900—79015(11102—11108) 79,100.11“
Out of round 7 —— 0.10 (0.004)
Taper fl — 0.10 (0.004L
l ‘Warflage __ 0,05(D.on7)
Piston. Piston mark direct-on . "lN" mark lauiuq loward the intake side ——
piston rings . Piston OD. 73 970 78.990 (11050-31098) 7 73.90 {3.106)
Piston 0D. lrleasursmsm point 15 mm {0.6 inlfrnm bottom 01 skin “ ;
Piston pln hare ID, 19.002*19.003(01481—074831 79.03 [0.7191 .

 

 

Piston pin 0.

18394—19000 D.7l78*0.7480) ,

18.934101474L‘

 

 

 

 

Piston-(o-g on gin clearance ‘ 0.007 0 01119250001 -—0.0006)
Piston ling—lu-rirlg Top ‘ 0030-0065 (00012-00026) 0 08 (0 003) 7
gmovn clearance Second ‘ 0.015*0.045 (00006-00018) 0.0601002)
' Piston ring end gap T012 7 ’ 0.20f0.35 (0.008*0.014 0.5 (002)
Second 0.40 55(1) 01§ 7.11022) 0.7 (0,031
Oil (side rail) 0.2— 0.8 (0.01 —0.03) 1 0 (0 M)

 

 

Cylinder to piston clearance

001070.045 (00004-00018)

 

Curlrlecling rod small and ID.

Connecting lod-lwpislun pin clearance
Crankpln ml nlearancer

 

 

19 030*1$.051(0.7A92*D.7500 19.061l0.7504l

0.030 n,nfi7(0.0012 0,0922)
0.030— 0.052 (moon—0.00201

0.052 40 0024)

 

 

 

 

GENERAL INFORMATION

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7 CRANKSHAFTITRANSMISSION/BALANCER 7 U“ mm W
ITEM ‘ STANDARD ) SERVICE LIMIT
Clankshafi Side clearance ) 0.05—0.20 40002-0008) 0.30 ((1,012)
Runoul _ ) . .. 0.3001012)
Mainjoumal ui( clearanca 0.017>0.035 (0.00077 0 0014) ‘ 0.045 (0.0018)
‘ Transmissian Gear |.[) M5, 6 31000—31025 (1.2205i142215) 31.0A (1 222) 7
C1 . 26000-26021(10236-10244) 26.04(1.025)
) C2, 3, 4 33 000 33.04 (1.301)
Bushing DD. 1 M5, 6 30.950 30.975 [1.2185i1.2195) 30.93 (1.218)
1 C2 7 31955—32380 (1.2974i14298‘) 32 93 (1.230)
C3, 4 32.950~32.975(1.2972-1.2982) 32,53 (1.296)
Bushing |.D. M5 27.905 78,006 (1,1018— 1.1026) 28.02 (1.103)
' C2 29385-30006(1.1805'10813) 30.02(1.132)
Gear-tmhushing ‘ M5, 6 0020—0062 (00008—00024) 0.10 (0.004)
clearance ? C2 . 0 020—0070 (00008—00028) 0.11 (0.004)
C3, l 0025* (1075010010 0.0030) 0.11(0.004)
Mainshafi OD. M5_V 27.967i27380(1.1011~1.101S) 77.957 (1.1007)
, Clulch oulevguide 27,930’47393(1.1016i1.1021) 27.9IU(1.1012)
Countershafl O.D. C2 "29367-29380 HANS—1.1803) 27.957 (1.1007)
Bushing-XO-Shah M5 ‘ 000570.039 (0.0007 0 0015) 0.08 (0.003)
L clearance C2 ‘ 0.005i0.039 (00002—00015) 0.08 (0 003) 1

 

 

 

1-9

GENERAL INFORMATION

FRONT WHEEL/SUSI'IEEEIIVSION/STEERING

Unit: mm lin)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD ‘ SERVICE LIMIT
Minimum lire tread depth 7 1.5 (0.06)
Cold tire pressure Up re 90 kg (200 lb) load 290 kPa (2 90 kgf/cm‘ . 42 psi) 47
Up Io maximum weight capacity 290 kPa (2.90 kgi/cmz , 41 psi) *i
Axla runuul 0.20 (0.008)
Wheel rim runout l Radial 7 2.0 (0.03)
Axial 2.0 (0.05l
Fork Spring Iree lengkh 232.9 (9.17) 228.7019!“
Spring direrxion With the tapered and facing down
Plpe runom * " 0.2010005)
Recommandad fork fluid Pro Hnndn Suspension Fluid SS—E
Fluid level 142 (5,6) , "*
Fluid capacity 483 t 2.5 cm" (16.3 0.08 US 01, #
l 17.1 .L 0.09 Imp nzl
Slecrlng head bearing pro—load 10 15N11.0-1.5 lgql) — a
Unix: mm (in

 

-' REAR WHEEL/SUSPENSION
ITEM

Minimum lire head depth

STAN DARD

 

 

l SERVICELIMIT
. 2.0 (0.05)

 

 

Cold tire pressure ‘ Up to 90 kg (200 lb) load

190 kPu (2.90 kgf/i:m2 , 42 psi]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

l U9 to maximum weight uagacigy 290 kPgi (2.90 kgflcrnx , 42 psil -—
Axle runout . r 0.20 (0.005) _
Wheel rim runout l'lnrllnl > 7.0 [0.08)
l Axial ' 2.010.08)
Drive chain 1 Size/link l DID IDSO7VS-1‘IOLE ’
‘ ‘ HK K50LFOZ1 HOLE ,, — __
_ . 1 Slack 25*35 (1.0714) 50 (2.0!
Shock absorber i Spring installed length 109.1 {8.23) if

 

 

 

 

1-10

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

       

 

 

 

"rHYDRAUUCBRAKE 77* “m‘mm““
ITEM STANDARD SERVICE LIMIT
Front . Sgeciv'ied brake Iluid . DOTA
Brake disc thigknerssfi 7 5.0(010) 4.001.115)
Brake disc runout 0.3010012)

1 Master cylinderLD. 12700-12743 (05000-05017) 12.76 (0.502)

1 Master EISIOH O.D. 12.557 -12.684 (0.495} , 0.4994) 12.55 (0 A98)
Sgcondary mastej cyflrjder ID. 14 000*10043 (05512705525) 14.055 (0.5533)
Secondary master piston 0.0. 13357713384(0.5495*0.5506) 13.945 (0.5490)
Caliper cyllnder ) Righ! Uppir 27000—27050 (1.0630 0650) 27.060 (1.0650)
LD. . . Middle 22 650' 22.700 (0.5917 0.8937) 22.710 (0 8941)

1 Lowe! 25.000—25150(1.0000‘13020) ZSJGOIIDDZA)

Left ) UDDC' 25.400—25.450 (1.0000—10020) 25.400(1.0024)

‘ MiddIs 22.650121700 (08817-03937) 7 22.710(0.89A1)
4 Lower 22.650 22 700(011517' 3937) 22.710(D.8941)

‘ calmer nusmn nghl ) Upper 26315—26368II.0597—I.0617) 268100.059“

0D. 1 Middle 22585—22618(05392—03905) 22.580 (0.8882)
£11m“ 25318—25368 (0.9968 0.9957) 75.310 (0.9965)
Lefl Upper 25 310*25368 (0.99684 9987) 25.310 (0.9965)
Middle 22.585'22518 (0.8892i0.8905) 21560033882)
Lows! 22585-11818 (03893—08905) 22.550 (0.3332)
Rear SgeciIiud brake fluid DOT 4
nge pedal height 6512.6)

) Brake dxsc thickness 6.0 (0.20) 4.00116)
Brake disc runoul 7 . — 0.30 M2)

J I cylinder LD. 17 460 17.5031 [0.6875 " 5091) 17515106896)

1 Master plsmn 0.0. 17.417 -17.444 (0.6857 7 5863) 17.405 (0.6852)
Caliper cylinder |.D. From 22.650i22.700 (0.8917i0.3937) 22.710 (0.8911)

Camel 25100—25450 (1.0000; 1 0020) 75 [En (1.0074)
fiear 72.650 - 22.700 (0.8917 - 8937) 22.710 (0.8941)
Caliper piston O D. Front 1 22585-21618 (0.8892 — 8905) 22.560fl8852)
Center ‘ 25318-25368 (0.9988- 9987) x 25.310 (0.9965)
Real 22,585j22018 (0.8899 0, . 05) ) 22.560 (0.515112)

 

 

— BATTERY/CHARGING SYSTEM
ITEM

 

 

 

 

 

 

 

 

Charging cm) resistance (70 "was 4)

SPECIFICATIONS
Battery Capaclly 12V-10AH
Current leakage 0.2 mA max. .
Voltage FuHx charged 13.0713 2 V
(20 “6/68 ”F) Needs charging Below . v
Chargmg curmm Normal 09 NS— 10 )1
Quick 4.0 No.5 h
Alternator Cagacily

 

 

 

1-11

GENERAL INFORMATION

 

,7 IGNITION SYSTEM
ITEM

SPECIFICATIONS

 

 

Spark plug “

'99:

CRQEHVX — 9 (NGK)

 

 

7 Spark plug_ga79 I

 

7 IMRQA' HINGK)
0.30—0.90 mm (0.031 A0035 in

     

 

Ignition coil peak vollaga

100V minimum

 

Ignition pulse generator peak voltage

0.7 V minimum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I rgmtmn timing I"r" mark) '99: 12" BTDC at mile
L After '99: 3' BTDC at idle
~ ELECTRIC STARTER ~ W ”“1139“
ITEM STANDARD ‘ SERVICE LIMIT
Starter molur brush Ierlqlh I 110— 13.0 (047—051) I 45 (0.18)
— LIGHTS/METERSISWITCHES
ITEM SPECIFICA‘HONS
Burn; Headlight HigI-Lbeam 12v 55w ’—
7 Lowbeam 12V-55W __7A
Brake/[ail light '99: I 12Vi21/5W 31 2
7mm '99; 7 _ _ 12v—32/3CP x 2
tmntmrn signal/running light 12v 32/3CP x 2
Hoarrurn signal light __ 12V—32cP x 2
I_L_igs_nss light 12V~ ACP
l Instrument Iight 397: 7 7 777 12 v—1.7w X a
After'SQ: 12 v—u’w X 2 __
Turn signal indicator '59: 12V—3W X 2
After '59: LED _ 7
High beam indicator '99: 12V-3W
After ’59: LED
Neurral indicator '99: 12V43W
7 After '99: LED
on pressure indicator '99; 12V 1W _ t____ , A.
After '99: LED
PGMAFI warning indicator ’99: 12V—3W
AIler ’99. LED
Fuse Main fuse 7 30A I
I PGM Fllusc 30A __ 7 ;
r Subfuse 20A x 2, 10A x 5 i
Tachomiegpeak voltage 7 7 10.5 V nimum
Thermo sensor resistance I all w(; ‘75 ~ 56.5 k g! ‘
I 120’C 14.9-17r3kfl
Fuel level Sellsul resistance Full 4' 10 C
7 7 I Empty 81791 52 77‘
Fan motor Stan to close (0N) __ 98— 1112 VG (208—216 “Fr
switch Stop to open 93-97 ”C [199—207 “Fl I

 

 

1-12

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

TORQUEVALUES
TORQUE TORQUE
FASTENER TYPE N-m (km-"I. [bl-ft) FASTENER TYPE ‘ N-m "WM“ Ibf-fl)
r
5 mm hex bolt and nut 5 (0.5 , 3.5. 5 mm screw 1 “01.23)
6mm hex bolt and nut 10(1 0,7) 5mm screw 9(0.9,6.5)
8 mm hex bolt and nut 22(22. 16) 6 mm flange bolt (8 mm head) ‘ 9 (0.9 , 6,5)
10 mm hex boltand nut 34(35‘25) 6mm flange bolt (10 mrn head) 12(1.2.9)
12 mm hex bolt and nut 5A (5.5 . 40) and nut
1 8 mm flange bolt and nut ‘ 25 (7,7 , 7m
1 10 mm flange bolt and nut ‘ 39013.29)
0 Torque specltlcatlons listed below are for important fasteners.
- Others should be tightened to standard torque values listed above.
NOTrs~ 1 Apply sealant to the threads.
2. Apply a locking agent to the threads.
3. Apply grease to the threads,
1., Stake.
5 Apply ml In the Ihmnds and flange slums.
5. Apply clean engine oil to the 0 ring.
7. U-nut.
E. ALOC bolt: replace with a new one.
0. CT bolt,
— ENGINE .
i , THREAD TORQUE
”EM ) a TV DIA. (mml N~m (kgf‘m, lbf-ft) REMARKS
MAINTENANCE
Spark plug 4 1n 17(1.7,e)
Timing hole can ; 1 45 18113, 13) NOTES
LUBRICATION SYSTEM: 1
Oildl'ain bolt { 1 l 14 Z9(3.0,22)
Oil fllter boss 1 i 20 )8 (1 Fl ,13) NOTl' 7
Oil pump assembly flange bolt 1 6 13(‘L3,9) NOTES
Oilpumu driven sprockatbolt l 1 e 15(1.5,11) NOTEZ
Oilstrainer nut i 1 e 12(1,2,9) NOTE7
0)) return pipe bracket bolt ‘ 1 6 12 l 2 , 5) NOTE 9
Oilfiltercartr'ldge 1 20 10(1.0,7) NOTES
Oil pressure switch 1 PT 1/3 12 (1.2 , 9) NOTE 1
Oil pressure swnlch wire terminal screw 1 A 2 (0.2 , 'l 4)
Oiloioe mounting bolt 2 6 12i1.2,9) NOTEZ
FUEL SYSTEM (Programmed Fuel Inlenlon):
ECT (Engine Coolant Telllperalurevvlerlnu sensor 1 I 12 10 (1.0 , 7) NOTE 1
Knock Sensor 1 l 12 31 i3 2 , 73)
Throttle body insulator band screw 8 5 See 09921715
Throttle cable bracket mounting bolt 2 5 3 (0.35 , 2.5)
Fuel pipe mounting nut 2 s 10 (1 o , 7) NOTE 7
Yellow palnt 1
Fuel pips setting bolt 2 8 22 (2.2, 16) Yellow paint
Pressure regulator lock nut 1 18 27 (2.8 , 20) Velluw painl
Starter valve synchronlrntlnn plate screw 4 3 1 (0.09 , rl 7)
Startervalve lock nut 4 10 2(D,18,1.3i
Wax unit mounting screw ; 2 6 5 (0.5 , 3.6) White paint
Wax ”an llnk bracket screw ‘ "1 3 1(0 09 , 0 7)
Vacuum Joint plug socket bolt fur synchronization 4 5 3 (0.3 , 2.2]
COOLING SYSTEM: ‘ '
Water pump cover bolt i 3 i 6 13 (1.3 , 9) NOTE 9

 

 

 

 

 

 

 

1-13

GENERAL INFORMATION

 

— ENGINE [Cont'd)

 

 

 

THREAD TORQUE
”EM 07" DIA. (mini 1 Min (kgrm, 1111.111 REMARKS
ENGINE MOUNTING:
Drive sprocket cover bolt 2 6 l 12 (1,2 , 91
Drive spruckel uuver damper mounting bolt 2 6 12 (1,2 , 9l NOTE 2, 9
Wireclampflange bolt 1 6 1 12 (1.2, 9l NOTE 2,9
Dnve sprocket specml bolt 1 10 “(5.544101
CVLINDER HEAD/VALVES: (
Cylinder head uuverbult 6 6 : 10(1,0,7l
Breather plate flange bolt 3 6 ‘ 12 (1.2 , Sl NOTE 2, 9
Camshaft holderflanue bolt 10 6 3 12 (1.2 , 91 Null. 5
Cylinder head sealing bolt 1 18 ‘ 32 (3.3 , 211 NOTE 2
Cylinder head SH boll 2 6 1 10 (1,0, 7l
(Iylmdar hand mmmnng halt/washer 1o 10 1 as (7.0, 511 NOTE 5
Cam sprocket bolt 4 1 l 20 (2.0, 141 NOTE 2
Cam chaintsnsionsr cap nut 1 6 j 12 (1219)
Cam chain tensionsr lifter mourning bull 2 6 l 10 (1,0 , 7l
Cam chum guldzAmountIng holt 1 s l 17(1.7.91
Cyllnder head stud bolt (exhaust pipe stud boltl S 8 1 See page 115
PAH? reed valvu cover flange bait II 6 - 10(1.0,7l
Cam pulse gensrator cover SH bolt 3 e i 12 (1.2 , 91
CLUTCH/GEARSHIFI' LINKAGE: i )
Clutch center lock nut 1 25 i 127 (13.0 , 9‘) NOTE 4. 5
Clutch splillg boll/washer 5 s l 12 (1.2.91
Clutch slave cylinder bleeder screw 1 E 1 9 (0 9 , 6.5)
Clutch slave cvlindcr mounting bolt 3 6 l 10 (1,0 , /1
Right crankcase cover SH bolt 11 6 l 12 (1.2 , 91
Right crankcase cover center bolt 1 6 12 (11 , 91
$111" drum center snnket bolt 1 8 1 73 (2.31 17) NOTE 2
Shift drum stopper pivot bolt 1 6 ‘ 12(1.2,9l
Gain-hill return spring pin 1 8 1 23 (2.3 . 17)
ALTERNATOR/STARTER CLUTCH: l 1
Alternator cover SH bolt 10 6 l 17 (1.7 , 9|
Alternator wire clamp socket bolt 1 6 9103.65)
Flywheel flange bolt 1 10 l 103 (10.5 , 76) NOTE 5
51am mmlntlng socket bolt 4 e . 12 (1.2, 91 1
Stator onerway clutch socket bolt 6 6 ) 16 (1.5, 12) NU‘IL 2
CRANKCASE/PISTON/CYLINDER: ‘
Crankcase bolt,10mm 1 1o ‘1 39(101291
9 mm (mam lournal bolt) 10 9 l 37 (3,8 4 27) ‘ NOTE 5
8mm 10 a 25(25118] 1
7mm 7 7 1 18(1.s,131 ‘
6 mm 6 B 1 12 (1.2 , 9)
Connectmg rod nul 8 E i 41 (4.2 , 30) ‘ NOTE 5
Lower crankcase flange bolt 1 1D ‘ 29 (3.0 , 22) ‘
Lower crankcase sealing bolt, 20 mm 1 20 l 29 (3.0 , 22) ‘ NOTE 2
3 mm 1 a j 22 (2.2 , 151 1 NOTE 2
CRANKSHAFT/THANSMISSION/BALANGER: ‘ 1
Mainshaft bearing set plate flange bolt 2 6 j 12 (1.2 , 91 ‘ NOTE 2
Shift drum set plate flange boll 2 6 1 12 (1.2 , 91 l NOTE 2
Balancertlmlng hole cap 1 30 ; 7 (0,7 , 5 11 1 NOTE 3
Balancer shaft noldertlangc bolt (fronUrearl 2 8 1 27 (2‘3 , 20) ‘
Balancet shall pinch bolt 3 6 ‘ 12 (1.2 , 9) E
Enlnncnrldle shaft holder flange bolt 1 B 1 2703,20) i
1 Balanccridle shaft bolt 1 s 12(1.2,91 ‘ NDIEZ

 

 

 

 

 

1-14

GENERAL INFORMATION

 

 

— ENGINE (Cont'd)

 

 

 

 

THREAD ‘ TORQUE
”EM u'rv DIA‘ (mm) ‘ N-m (kgl-m, mm) REMARKS
I

IGNITION SYSTEM: I ‘

Ignition puIse generatorcover SH mm 8 6 I 12 41.2 , 9) NOTE I

See page 1-20

Ignition puIse generator rotor special boIt ‘I 10 59 IS 0 , 63) NOTF 5
LIGHT/METERSISWITCHES:

NeutraI switch I I 10 12 41,2 , 9: I
Throma body Insulator clamp: Exhaust pipu stud bulk:

 

. 12 t 1 mm Iub : 0.04 m)

     

I ‘ \g/

 

 

/

/

/ / 33.5—39.0 mm 11,52— 1,54 in)

 

 

 

 

1-15

GENERAL INFORMATION

 

— FRAME

 

 

THREAD

TORQUE

 

 

 

 

 

 

ITEM OW DlA. (mm) l N-m (kgf-m. [bl-ft) 1 REMARKS
. , , . w .
l FRAME BODY PANELS/EXHAUST SYSTEM:
l Side srand pivot bolt 1 10 10 (1 O , 7)
Side stand pivot lock nut 1 ‘ 1o 2913.0,22)
Minn mm mnuntmg bolt ‘ 1 1 10 5415.5. 40) NOTE 8
Main footpeg holder socket bolt 4 3 26 (2.7 , 20) 1
Passenger foolpeg holder bull 4 E 25 (2.7 , 20) ,
Bank sensor 7 8 22 (2.2 v16} ‘
Exhaust pipe JDInt nut a 7 2012.0. M)
Muffler band bolt 11 8 17 (1.7 , 12) ‘
Muiller bracket bull 2 l E 1 26 (2.7 . 20)
Sea! rail mourning bolt { A 10 l u (4.5 , 331
FUEL SVSTEM (Programmed Fuel Injection]: ’
Fuelrube sealing nut (rhmnle body side) 1 12 22 (2.2 , 16)
Fuel lube bailiu bull (fuel tank side) 1 1 12 2717.7 ,16)
Servicecheck bolt 1 1 S 1511.5,11)
Fuelpump mouminq nur ' 6 6 1211.2.91
.
i
1
Fuel fiilcrcap bolt 3 ‘ 4 210.2, 1.4)
ENGINE MOUNTING.
Side stand bracket bolt 7 1D 54 [5.5 , WI
Engine hanger nut(rear/upperl 1 12 64 (6.5 4 47)
Engine hanger nut (rear/lower) 1 12 64 (6.5, 47)
Engine hanger bull 3 “ID ’ 4014.1, 30)
i'nglne hangeradjustlng bolt 7 22 ‘1 11 (1.1 .8)
Engine hanger adjusting bolr lock rim 2 22 i 54 (5,5 . 40)
CLUTCH/GEARSHIFI' LINKAGE:
Clutch maslel cylinder holder ball 2 e l 17 (1 7 , 91
(:Iumn master cylindarnnp screw 2 4 1 110.15, 1.11 . ‘
Clutch lever pivot bolt 1 ‘ 6 i 1 (0.1, 0.7) .
Clinch lever pivot nut 1 ‘ 6 i 6 (0,6 , 4.3) 1
Clutch lever adjuster 1 5 , A (0 4 , 2.9) 1 1
Clutch swrmh screw 1 . 4 i 1 10,12 . 0.9)
Gearshift pcdalbolr i 6 1 10110.71 1
FRONT WHEEL/SUSPENSION/STEERING: ‘ .
Handlebar pinch bolt 2 ‘ 8 25(17 , 20) 1
Handlebarwelgm mounting screw 2 6 10 (1.0 . 71 NOTE 3
Sreering stem nur 1 ‘ 24 103 (10,5 . 76) ‘~ See page 13-34
Tup lliread A 1 25 25 (7 I3,181 1
Top thread 11 1 1 ‘ 25 — I
Fork 10p bridge pinch bolt 1 2 . 8 2312.11.17) j
Fork b01107“ bridge pinch bolt ‘ 2 i 10 49150.36) 1
Flam axle ball 1 1 14 ‘ 5916.11.43) 1
Front axle hnlner hnil‘ 4 S 1 22 (2.2 , 161
From brake disc mounling boil 12 6 20 (2.0 , 141 NOTE 8
Fork cap 2 37 23(23, 171
Fork socket bolt 7 8 20(21) , 1M NOTE 2
Fork damperlock nut 2 10 20(20, 141

 

 

 

1-16

 

GENERAL INFORMATION

 

 

FRAME (Cont’d) ‘
l THREAD TORQUE
”EM 1 my DIA. 1mm) ‘ Mm 11191-1“, 11314:) REMARKS

REAR WHEEL/SUSPENSION: i ‘ i ;

Hear axle nu! 1 13 93195.69) 1 NOTE 7

Rear brake disc mounting boll A a 1 42143.31) 1 NOTE 8

Driven sprocke‘ nut 5 12 1 108111 0 , RD) NOTE 7

Rear shock absorber mounting Hul 2 10 4214.3 , 31) NOTE 7

Shock link nu. «ramp. 31119.) 1 ; 10 ‘ 5916.0, 43) NOTE 7

Shock link nut (shock arm plate sudel 1 1 10 1 42 14.3 , 31) NOTE 7

Shock arm plate nut (swingarm side) 1 ‘ 10 ‘ 42 14.3 , 31) NOTE 7

Swingarm pivol adjusisng bull 1 30 ' 1511.51111 ‘ See page 11-19

Swlngnrm pivm Inck nut 1 1 so 6416.51 471 1

Swingarm pivot nut 1 1 1a 93195191 1 110157

Driva chain EildEf Doll 2 ‘ 6 1 910.9, 6,5) NUTFR
HVDRAULIC BRAKE: 1 1

Front brake master cyllnder hnlrIi-J bolt 2 6 ‘ 12 (1.2 , 9)

From brake mastorcylindcr capscrew Z A ' 110.15,1.1)

Brake lever uivul bolt 1 1 s ; 1101.11.71

Brake lever pivot nut 1 e f 610,3, 4.3)

Brake lever adluster 1 5 A10 4, 2.9) ‘

From brake switch screw 1 4 1 10.12 , 0.9)

Right from brake caliper mounting bolt 2 8 3113.2 . 23) NOTE 8

Left from brake caliper pivot bolt 1 8 3113.2 , 23) NOTE 8

Left iront brake caliper boll lsennnd masterjnint) 1 B 7517.6 ,15) NOTE 8

Caliper body E bolt 5 8 3213.3 , 24) NOTE H

From brake caliper slide pin 1main) 3 12 2312.3 .17) NOTE 2

From brake caliper slide pin 1sub) 3 8 13113 , 9) NOTE 2

Pad pin :1 l 10 1811.8,13)

Brake caliper blender 6 8 6105.43)

Second master cylinder mounting boll 2 E 31 13.2 1 23) NOTE 8

Second master cylinder push rod nut 1 3 18118.13)

Second master cylinder connector 2 6 1011.0 , 7)

Rear manor cylinder mounting bolt 2 6 1211.2.9)

Rear masrer cylinder reservoir mounting bolt 1 ; 6 1211.2,9)

Rear master cylinder push rod nui 1 i a 1811.3,13)

Rear master cylinder hose 101m screw 1 4 1 10.1b,1.1) NOTE 2

Brake hose oil bolt , 12 10 3413.5 , 25)

Brake pipe iuini I B 10 1711.7 ,12) NOTE 5

Brake pipe 2/3 way joint 2 a 1711 7 , 9)

Brake hose clamp bolt 2 6 12112.51)

Delay valve mounting ban 2 6 1211.2,9)

PCV lPrupurliunal Cunlrul Valve) mounting bull. 2 6 1211.2 , 9)

Right (ronr hrake hnse clamp bolt 1 s 1211 2 A 9)
lGNlTION SVSTEM:

ignition coil mounting nut 4 6 1611.6 , 12)

ignilion coil mounting nut . 2 s 1011 0,7)
LlGHTSIMETERS/SWITCHES:

Ignirion Switch mounrlng bolt 2 8 25125.15)

Side srand switch mounting ban 1 6 1011.0 , 7)

 

 

 

 

1-17

 

 

GENERAL INFORMATION

TOOLS

NOTES: 1 l’qulvnlerrlcommerclallyavailableln U.S.A.

2. Not available in U.S.A.
3.Altarrlal'lve tool.

4. Newly provided rnnl,
5. Newly desrgned tool.

 

TOOL NUMBER

 

 

 

 

 

 

‘ DESCRIPTION REMARKS REF. SEC.
‘ on pressure gauge sat 075003000000 NOTE 1 4
Oil pressure gauge anachmanl 075104220100 NOTE 1 4
Clutch centel lrulder 077240050002 9
Flywheel ho|der , 07725 0040000 NOTE 1 10
Flywheel puller I 0773370020001 NOTE 3: 10
; 01933-3950000
Remover weight 1 07/41-0010201 1‘
Ananhment. 3/ X 40 mm 1 07746-0010200 ; 0, 14
Anachmem. 42 r 47 mm 07740-001030!) { 9. 1a
Anachnleul,52 x 55 mm 07746-0010400 14
Attachment, 62 x 60 mm 077460010500 14
Attachment. 24 x 26 mm 077460010700 , 14
Driver, 40 mm ID. 077450030100 12
Auadunenl, 30 mm ID 077450030300 12
Prlm, 17 mm 07746 0040400 14
Film, 20 mm 07746-00l0500 r 13, 14
Pllut, 25 mm 077400040600 1 1'1
Film, 35 mm 07 7415-0040800 1 9
Pilot, 28 mm 07746-0041100 ‘ 1‘
Bearing remover shaft 07746-0050100 l r 13, 14
Bearing rerrrover lread, 20 mm 077400050600 ‘ 13,14
nr1vr=r 071490010000 1 9413.14
Valve spring compressor 07757-0010000 9
Valve seat cutter NOTE 1 8
Seal cmer, 29 mm (45° EX) 0770070010300 ;
Seat cutter, 33 mm (45“ IN) 077800010800 1
Flat cun01.30 mm 132° EX) 07780-0012200 !
Flal Cutler, 33 mm 132° IN) 077800012900 r'
lmerlor cutter, 30 mm 150-7 FX) 07700-0014000 {
lmerior cutter, 34 mm 180‘ IN! 07780 0014700 : NOTE 5
Cunev ho1der, 5 mm 07781-0010400
Plvu1 adjuslillg wlellL‘h 07508-4690003 14
Snap rlng plrers 07914-5A50001 NOTE 2: 079140230001 9,15
Slccring stem socket 07816 3710101 l 13
Bearing remover handle 073303710100 ‘ 14
Bealing remover set 079303710600 14
Valve grrrne drlver, 5 mm 1 0/942rMA60000 3
Nccdm bearing remover 07946-KA50000 13
Ball race remover sat 07946-KM90001 NOTE 3: l 13
7 Driver attachment, A 07946~KM90100 Carr be used wirrr rhe rollow‘rrrg ‘
7 Drive! attachment, B 07946 KM90200 l combination:
- Driver shaft assembly D7946-KM90300 07VMF-MAT0100
7 Bearing remover, A 07946—KM90401 07Vlvll-MAT0200
nearlng remover, H U7SISrKMHObUU 07VMF7K230200
- Assembly base 07946rKM90600 l 07VMF-MAT0300
l 07VMF—M470400 ‘
: u7947KA50100
07965-MA60000
, o7946-ME90200
Steering slerrr driver 07946-M300000 13
Driver shaft 07940MJ00100 1‘

 

 

 

1-18

 

DESCRWTION

TOOL NUMBER

GENERAL INFORMATION

 

Oil sea‘ driver
SlldCl‘ weight

Valve spring compressor attachment
DVIVEY shaft

Valve guide reamet

Pin driver

OH filter wrannh

Peak voltage adaptor

Needle hanrlng remover, 28 mm
Tappct holc protector
Drive chain luul set
Need‘e bearing remnvar
Compresston gauge attachment
Lock nut wrench
Test pin box

LVECU test harnpss

 

079477KA40200
07947-KA50100

079597KM30101
o7964-MBDOZOO
0793A-MASODU1
(JIGMD KTSO‘ 00
07HAA-PJ70100
07HGJ-OO201DU

07HMC-MR70\00
07HMG-MR70007
07HMH-MR10103
07LMC7KV30100
07RMJ7MV501OD
07VMA-MATD100
O7WGZ-0010100
07WMZ-MBGO1DO

REMARKS REF. sec.
NOTE 3 13
D7NMD-KZBU1OA (U.$.A. only)

NOTE 3: 13
07NMDVKZ3010A1U s A. only)
8
12
079847MA6000C (U.S.Av only} 3
NOTE 2 14
3
NOTE 2: 1 5,17,19
Peak voltage taster
(USA only)
NOTE 7 \ 14
NOTE 2 ‘ a
D7HMH-MR10109 {USA only) ‘ 3
14
a
()7va MAT01OA (USA. omy) 1
NOTE 3 5
NOTE 3 i 5

 

 

1-19

GENERAL INFORMATION

 

LUBRICATION 8t SEAL POINTS
7 ENGINE

 

LOCATION

Crankcase ma'ung surface

I

104415 mm
[0 ‘40 6 In)

v\

V’fl

MATERIAL

quuld sealant (Three
Bond 12073 or equiv
alemt I

\\

r
A}

(\\
J

REMARKS
4,_._.-— .

 

 

r?

 

fir; «u

 

10415 mm
10.4‘ 0.6 in)
/

 

 

 

‘ Ignmnn puIse generatov cover bull threads marked 3
”A”,

 

on pressure swnch lhreads

Do not appIy seaIam to [he thread
head 3* Amy“ 10.1702 in).

 

Thermo unit Ihrafids

\\ my}

 

 

wwfi
(/V I

3%

\

1‘ Coming width: 6.5 :- 1 mm
1

 

 

 

 

1-20

GENERAL INFORMATION

, ENGINE (Cont'd) " 7 " 7 7
l Locxnom MATERIAL REMARKS

l cylindei head semi-circular cumin Sealant

 

 

(:nrnshm lobes/Journals Molybdenum disul i

‘ Valve liftcroutcr sliding surface fide oil is mixture of 1
Valve slam (valve guide sliding surface) 1/2 engine oil and 1/2
Piston pin sliding sul‘lace molybdenum dlsul-
Mnln jnllfnnl hearing :urlace tide qrcasc

Connecting rod bearing surface

Crankshaft iuurlrals

M314, C5, C0 shifter gear (shift fork grooves)
Clutch outer/primary driven gear sliding surface
Clutch outer guide sliding surface

Staner reducliun gear uulel sullace

Primary drive gear and suh gear sliding sllr'nne

APPLY AREA
l— r= //

l’ APPLY AREA
W|¥ I

 

Piston ring sliding area Engine oil
Main journal 9 mm bolt threads and seatlng surface
(after removing anti-rust oil addilive)

Cylinder head special bolt (after removlng anrrrusr
orl addltlve)

Oil srrainer packing

Oil filter cartridge llueads and O-l ing ‘
Flywheel bolt threads and seating surface '
Starter onerway clutch sliding surface
Connecting rod nut Ihreads

Clutch joint piece sliding surrace i
Clumh lifter md surface

Clutch center lock nut threads
Clutch disc surface

Eaah germ . trh and rmanng surface
Each bearing

Each O-ring

Other rotating area and sliding surface ,

 

 

 

 

 

 

 

1-21

GENERAL INFORMATION

ENGINE (Cont'd)

 

LOCATION

 

\ Craukshafthotecapthreads
natnncer damper ruhherflmng area
Balanccr timing hole cap threads
Oil seal lips
Cylinder head sealing bolt threads
Cylinder head caver breather Joint threads
Batancer idle shaft set plate bolt threads
Drive sprucketuover damper rubber Lrult threads
Lower crankcase sealing holtthreads
Starter one-way ctutch outer bolt threads
Oil pump driven sprocket bott threads
Oi! pass pipe bolt threads
on film boss vhreads
Drivc sprocket cover wire clamp bolt threads
Shift drum set plate bolt threads
Shift drum center bolt threads
Marnshafl bearing set plate bolt threads
Cam sprocket butt threads
Cylinder head cover breather plate bolt threads

Mum-purpose grease

Locking agent

 

 

 

1 -22

GENERAL INFORMATION

 

— FRAME
LOCATION

MATERIAL

REMARKS

 

Stccring head bearing sliding surface
Steerinq head dust seal lips
Swingarm pivot bearing
Swrngarm prvut dust seal hps
Front wheel dustssal lips
Rear wheel dust seal lips
Rear wheel side collar inner surface
Shock absorber needle bearing
Shock absorber dust seal lips
Shock link needle bearing
Shock link dust seal lips
Footpea sliding area
Passenger tootpag sliding area
Left iron: brake caliper pivot bearing sliding surrace
left lmni hrake caliper pivot mi seal sliding surface
Left fork nccdlc bearing sliding surface
Left lurk dust sea dii uriace
Rearhrakepedelpivotsli ngarea
Throttle pipe sliding area
_ Seat catch hook

   

 

 

Multipurpose grease

 

Side stand pivul suliaue
VMain stand pivot stirrace

Molybdenum disulfide
grp «e

 

Shock ageorber spring adjuster cam surface

Molybdenum paste

 

Steering stem top thread
Throttle cable casing inner
Brake pipe jnlnl‘ threads

Engine oil

 

Brake master cylinder cups
Brake caliper piston seals

DOT 4 brake fluid

 

Brake caliper dust seals

Front brake lever pivot and piston tips

Second masrer cylinder boot inside and push rod tips
Real aslrsr cylinder buul inside and push l‘UlJ lips
Brake caliper slide pin surface

 

Silicone grease

I
l

 

Brake caliper slide pin threads

Rear master cylinder hose ioint screw threads
For k socket bolt threads

Driven sprocket srnrl bolt threads

Locking scent

 

Handle grip rubbcr insidc

Fork cap Orring
Fork oil sealflps

 

 

Honda Bond A or
Honda Hand Grip
Cement (USA only)

 

Pro Honda Suspension
Fluid SS-S

 

 

 

 

1-23

GENERAL INFORMATION

 

CABLE & HARNESS ROUTING
'ss: R>GHT HANDLEBAR SWIIQHgR (RED) CQNNEQOR
\GNITION SWITCH M" (NAIUHAL) C()NNtCT()H
LEFT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR
COMBINATION METER 10F COMBINATION METER 1UP
(BLUED CONNECTOR (GRAY) CONNECTOR

 
  
  
 
   

LEFI'TURN SIGNAL
CONNECTOR

RIGHTTURN S‘GNAL
CONNECTOR

 

/
x0’
x” 1
z // z \
/ 5/ z \ \
N /\ - \ \\

MAIN HARNESS 20F
(BLUE) CONNECTOR

 

\

MAIN WIRE HARNESS

\
HEADLIGHTSOCKET HORN WIRE

 

1-24

GENERAL INFORMATION

  
   

AFI'ER ‘99:
RIGHT HANDLEBAR SWITCH 9P RED CONNECTOR
IGNITION SWITCH 4P CONNECTOR
/
COMBINATION METER we? /
BLACK CONNECTOR /
LEFT TURN SIGNAL
2P CONNECTOR
RIGHT TURN SIGNAL
CONNECTOR

\

 

MAIN HARNESS 20F
BLUE CONNECTOR

/ MAIN WIRE HARNESS

POSITION LIGHT 2P CONNECTOR HORN WIRE

 

1 -25

GENERAL INFORMATION

'99:
THROTTLE CABLES

PAIR CONTROL‘SOLENOID VALVE /

.I/ CRANKCASE B'REATHER HOSE

    
 
  
     

NO. 2/3 IGNITION COIL

N04 114 IGNITION
COIL

‘ ,
I“ ‘I
I L /THnorrLE
‘ SENSOR
I

I I
x /I / OIL PREssunr
/” SWITCH

\\ KNOCK SENSOR

ECT SENSOR /

“‘ IGNITION PULSE
GENERATOR WIRE

 

CAM PU LSE GENERATOR
WIRE

ALTERNATOR WIRE’ , I? \

I ENGINE SUB-HARNESS
STARTER MOTOR CABLE /
, (I VEHICLE SPEED SENSOR

I
STARTER MOTOR GROUND CABLE

 

1-26

GENERAL INFORMATION

 

AFTER '99:
THROTTLE CABLES

PAIR CONTROL SOLENOID VALVE

CRANKCASE EREATHEH HUSL

  
 
 
 
 
  

Nu. Z’SIGNITION COIL

.
IAT SENSOR -\ if
,

SUB-HARNESS MP
CONNECTOR \\

No.1/‘IC-NIIIUN
/CU|L

xTHRO‘I'TLE
//I/ SENSOR

      
   

      
 
   
 

 

‘ -
—\:~_
\

\U

      

I

"I I“

7.1) I
‘ ‘ T Mi: . WW/
\Mg’» z} ”5/ ,
“LP/ I‘: g! I » //*’
x E ‘ ,wg‘fxv L\\ ,' j

/- OIL PRESSURE
SWITCH

 

  

   
   

/ \ ~
MAP SENSOR ,/’ I /,/\\ I V I’
2 / ’ a I ‘1— U
I 2/ E l' I” }\\
/L r \n , I 9A \\ KNOCKSENSOR

ECT SENSOR /’

“\\ 4 '\
:1 ' ‘ I I

$11: A _ CAM PULSE GENERATOR
STARTER MOTOR CABLE/i, Q Q (\ O \ WIRE

,/ 01 SENSORWIHE

 

 

ALTERNATOR WIRE

STAHIEH MUIUH GROUND CABLE , I/ . ENGINE SUB-HARNESS

/
VEHICLE SPEED SENSOR

 

1 -27

GENERAL INFORMATION

 

’99:

| F! I HANDLEBAR SWITCH WIRE

CLUTCH \ IUSt

MAIN WIRE\<RNESS
/// v

 

  

LOWFR RADlAI DH HOSE

 

1-28

GENERAL INFORMATION

 

After '99:

CLUTCH HOSE

MAIN WIRE HAHNI’SS

LEFI' HANDLEBAR SWITCH WIRE

   

COMBINATION METER 16P
BLACK CONNECTOR\

  

LUWEH HAUIAI 0H HOSE

    

FRONT BHQKE HOSE

 

1-29

GENERAL INFORMATION

 

‘99:

THROTI’LE CABLES

 

RIGHT HANDLEBAR SWITCH WIRE

()ll CUULEH HUSI:

AIR ELEED HOSE\

 

1-30

GENERAL INFORMATION

AFTER '99:
THR07LE CABLES
RIGHT HANDLEEAR SWITCH WIRE /(/

OIL COOLER HOSE

///
//

AIR ELEED HOSE\

  

' «‘7-7‘ I
I r—
7

/
/ /
/
/
SIPHUN Host/ ,

  

UPPER RADIATOR
HOSE

 

1-31

GENERAL INFORMATION

 

No. 2/3 IGNITION COIL

I

PAIR CON I HDL SOLENOID

VALVE 7F‘ NATURAL
CONNECTOR

SI ARTEFI MOTOR CABLE

FAN MOTOR SWITCH WIRE

  

        

RADIATOR OVERFLOW HOSE

FUEL TANK AIR VENT HOSE

SIDE STAND SWITCH WIRE

ALTERNATOR WIRE

 

1-32

GENERAL INFORMATION

AFTER ’99:
No. 2/3 IGNIIIUN COIL
MAIN WIRE HARNESS /
PAIR CONTROL SOLENOID I’ CLUTCH HOSE

VALVE 2P CON NECTOR
\

     

L STARTER MOTOR CABLE

FAN MOTOR 2P CONNECTOR

FUEL TANK AIR VENT HOSE \ RADIATOR OVEHFLOW HOSE

    

SIDE lSTAND SWITCH WIRE

ALTERNATOR WIRE

 

1 -33

GENERAL INFORMATION

 

’99:

No 1/1 IGNITION COIL
\

\ AIR BLEED HOSE

    
 

STARTER MOTOR GROUND CABLE \
\
\

  
 

I
REAR BRAKE HOSE
OIL COOLER HOSE

I

I I
ERAKF I IGHT SWITCH WIRE I I SIPHON HOSE

 

/ UPPER RADIATOR HOSE

I
IGNITION PULSE GENERATOR WIRE

 

1-34

GENERAL INFORMATION

AFl'ER '99:

No, 1/4 IGNITION COIL
\

\ AIR BLEED HOSE

   
 
 

STARTER MOTOR GROUND CABLE

\ OIL COOLER HOSE

 

BRAKE LIGHT SWIICH WIRE / / SIPHON HOSE
9 N ' / ’
:éiLEIFggrgI/ngga / UPPER RADIATOR HOSE

IGNITION PULSE GENERATOR WIRE

 

1-35

GENERAL INFORMATION

'99:

MAP SENSOR
\

[ATSENSOR ‘\

OIL PRESSURE SWITCH
/

 

WAX UNIT /
VEH‘CLE SPEED SENSOR

ECT SENSOR \
KNOCK SENSOR

 

1 -36

GENERAL INFORMATION

 

AFTER ‘99:

MAP SENSOR

IAT SENSOR \

  
 

UIL PRESSURF SWITCH
/

VEHICLE SPEED SENSOR

ECT SkNSOH

KNOCK SENSOR

 

1-37

GENERAL INFORMATION

 

'99;

PAIR FRESH A|R HOSE
I

  
  
  
 

FUEL P>PE

FUEL TANK I
OVERFLOW HOSE
\

 

,
FUEL LEVEL/RESERVE \ \
SENSOR me / x‘ \ THROTTLE SENSOR
/ \\
/ ' \ L
J \\ FUEL RETURN HOSE

FUEL TANK \\
AIR VENT HOSE

WAX UNIT WATER ,HOSES

 

1-38

GENERAL INFORMATION

 

AFTER '95:
PAM FRESH AIR HOSE
/
FUEL PIPE /
FUEL TANK

OVERFLpW HOSE

\
\

  

 

 

 

 

I
FUEL LEVEL SENSOR WIRE

THROTTLE SENSOR

FUEL RETURN HOSE

FUEL TANK
AIR VENT HOSE

WAX UNIT WATER HOSES

 

1 -39

GENERAL INFORMA'HON

 

'99:

ENGINE STOP SENSOR
1

/ TURN SIGNAL RELAY ECM

FUSE BOX

      

/
STARTER RELAY SWITCH I \ MAIN WIRE HARNESS

HEADLIGHT RELAV \\
\
REGULATORIRECTIFIER

 

1-40

GENERAL INFORMATION

AFTER '99:

ENGINE STOPSENSOR

/ TURN SIGNAL RELAY ECM

     
 
 
  

FUSE BOX

ENGINE STOP RELAY

COOLING FAN RELAY
\

FUEL CUT-OFF RELAY \ \
\ MAIN WIRE HARNESS

STARTER RELAY SWITCH \
HEADLIGHT RELAY

MAIN HARNESS MP CONNECTOR
MAIN HARNESS 3P CONNECTOR
MAIN HARNESS 1P CONNECTOR

 

GENERAL INFORMATION

'99:

MAIN WIRE HARNESS
I

BARO SENSOR I PROPORTIONAL CONTROL VALVE

/

HHESEHVUIH HOSE * BRAKE LIGHT SWITCH WIRE

 

 

1 -42

GENERAL INFORMATION

 

AFTER '99:

REAR SUBVHARNESS
I

REGULATOR/RECTIFIER I PROPORTIONAL CONTROL VALVI:

RESERVOIR HOSE

 

BRAKE LIGHI SWITCH WIRE

 

1-43

GENERAL INFORMATION

’99:

REAR BRAKE RESERVO‘R

FROPORTIONAL CONTROL VALVE

  

RYAN UHAKF CALH’ER /

HEAR MASTER CVLI NDER

 

1-44

GENERAL INFORMATION

AFTER '59:

REAR BRA<E RESERVOIR

  
 
    

PROFORTIONAL CONTROL VALVF

REAR BRAKE CALIPER

l
REAR MASTER CYLINDER

 

1-45

GENERAL INFORMATION

 

'99:

FRONT MASTER CYL‘ NDL H

     
  
  
 
   
  

five,

$11? \LEFT 70m BRAKE CALIPER
‘ "ii: . ’
JED-'4‘ ». \

   
 

DELAV VALVE

RIGHT FRONT BRAKE CAMPER

SECONDARY MASTER CYLINDER

 

1-46

GENERAL INFORMATION

 

AFI'ER ’59;

FRONT MASTER CYLINDER

    
 

SECONDARY MASTER CYLINDER

LEFT FRONT BRAKE CALIPER

RIGHT FRONT BRAKE CALIPER

 

1 -47

GENERAL INFORMATION

 

CALIFORNIA TYPE:

PAIR CONTROL SOLENOID VALVE
\

    
  

I" ,’ ll CRANKCASE BREATHER HOSE
I /

c- /'

 

 

 

EVAF‘ CANISTER-TO-FUEL
TANK HOSE

/
/ / THROTTLE BODY-TOSOLENOID
EVAP CANISTER / VALVE HOSE

EVAP PURSE CONTROL SOLENOID VALVE

 

1-48

GENERAL INFORMATION

FUEL TANK-TO-EVAF CANISTER HOSE

 

\ EVAP PURSE CONTROL SOLENOID VALVE

r \
DRAIN HOSE EVAP CANISTER

 

1 -49

GENERAL INFORMATION

EMISSION CONTROL SYSTEMS

The. U S Envrronmental Protection Agency and California Air Resources Board (CARE) require manrrtacturers to certrry that
their motorcycles comply with applicable exhaust emissions standards during therr useful life, when operated and mainr
tained according to the instructions provided, and that mnvnrcyclas burlt after January I, 1983 comply with applicable noise
emission standards tor one year or 6,000 km (3,130 miles) aftcr the time of sale to the ultimate purchaser, when operated
and marntarned according to the instructions provided Compliance with the terms of the Distributor‘s l rmrtert Warranty for
Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in eflect,

SOURCE OF EMISSIONS

The combustion process produces carbon monoxide and hydrocarbons, Control n1 hydrocarbons rs very Important because,
under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not
ream in the same way, but it Is toxrc.

Honda Motor Co., Ltd. utilizes lean rnJectlon settings as well as other svsterrrs, to reduce carbon monoxide and hydrocarbons

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equlppcd With a closed crankcase system to prevent discharging ciankcase emissions into the atmosphere
Blow-by gas is returned to the uorrrbustiun charrrtrer through the air cleaner and tnrnttle body.

AlR CLEANER HOUSING

‘ Ii THRp'lTLE BODY
r /’
[A‘\

/ <_:| FRESH AIR

// _ BLOW-BY GAS

 

 

1-50

GENERAL INFORMATION

 

EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIFI SUPPLY SYSTEM)

The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should he made
except idle speed adjustment with the throttle stop screw Ihe exhaust emission control system is separate from the
nrankcnsa emission control system.

The exhaust emission control system consists ol a secondary air supply system which introduces irlvared air into the exhaust
gases in the exhausl port Fresh air is drawn min "to exhaust port by the function of the PAIR (Pulsc Secondary Air Injectionl
mmml valvet .

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 vnpnr

Ihe marl valve prevents reverse arr flow through the svstem. The PAIR control valve is operated bv the solenoid valve, The
solenoid valve Is controlled by the PGM~FI unit, and the lresh air passage is opened/closed according the running condition
(EC‘I’JIATfTPfMAP sensor and engine revolution),

No annistments to the secondary air supply system should be made. although periodic inspection of the components is
recommended,

AIR CLFANFR HOUSING

      
    

PAIR CONTROL VALVE
r

THRO‘I'I'I F BODY

EXHAUST PORT

 

1-51

GENERAL INFORMATION

EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY)

This mbdei complies wnh CBIifOrnlB Air Resources Board [CARBI evaporative emission requirements.

Fuel vapor Vrom (hr: Iuei xank is rouxcd into the cvaporativc emission (EVAF) canister where it is absorbed and stored while
(he engine is stopped. When the engine is running and \he svapora‘ivs emission iEVAP) purge cunlvul solenoid valve is open.
Iuel vapor in the EVAP canister is drawn into Ihe engine through the throttle body

FUELTANK

  
 

 

EVAF PURGE CONTROL
SOLENOID VALVE

w1~

  
 

 

 

 

 

 

 

 

 

4:
_ /

 

 

   

EVAP CANISTER

7.“. —W

 

 

 

 

 

 

 

 

 

 

 

 

<2: FRESH AIR
_ mu VAPUR

THROTTLE BODY

 

1 -52

GENERAL INFORMATION

 

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. federal iaw prohibits or Canadian prownimai law may
prohibi! (he Voliowing acre or me causing thereof: (1) The removal or rendering inoperative by any person, other man for
puipuses uI maiiiienance, iepail 0i replacement. OI any device or element of design incolpwated inlu any vell'icie for me
purpose oI noise controi prior to its sale or deiivery to lhe ultimate customer nr while n is in use; in the use of any vehicie
after such device or element of demgn has been removed or rendered inopermivc by any person.

AMONG THOSE ACTS PRESUMED TO CONS'HTUTE TAMPERING ARE THE ACTS IJSTED BELOW:

1, Removal oi, or puncturing onhe muffler, baffles, header pipes nr any nrher cnmpnneni which condiim Exhaust gases

2. Removal of. or puncturing of any pan of the Intake system.

3. Lack a! proper maintenance.

4. Repiauing any moving pails of [he veIIicIe, ui pails of Ihe exhausl or Intake system, wi‘h pans other than those specified
by the manufacturer

 

1-53

GENERAL INFORMATION

 

EMISSION CONTROL INFORMATION

LABELS

An kmlssmn Control lnformahnn Label :3 located
on the left side of the main frame as shown.
II qives base tuna-up speciIiuations‘

VACUUM HOSE ROUTING DIAGRAM
LABEL (CALIFORNIA TVPE ONLY)

Tho Vacuum Hose Routing Diagram Label is on the
all cleaner housing cover as shown.

The fuel tank must be opened to vead i2. Refev to
page 3-51m fuel mnk opening

VACUUM HOSE RIPUTlNG LABEL

/

     

EMICSIUN CDNIROL INFORMATION LABEL

 

 

4 VACUUM HOSE ROUTING DIAGRAM

ENGINi ”Hum;
EVAPORATIVE FAMILY-i ,,

CALIFORNIA VEHICLE

FBONT D
VEHICLE

7: run -

m:

 

 

 

F

g}—

u u 5mm n

     
     

   
  

 

 

 

1-54

 

 

MEMO

 

FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS

WINDSCREEN

   
   
  
  
    

UPPER COWL
\

\\

REAR FENDER

FRONT FENDER

SEAT COWL

WIND GUARD

 

2. FRAME/ BODY PANELS/ EXHAUST SYSTEM

 

I BODY PANEL LOCATIONS
1 SERVICE INFORMATION
I TROUBLESHOOTING
I SEAT
1 SEATCOWL
I LOWER COWL

UPPER COWL COVER/INNER PANEL

SERVICE INFORMATION
GENERAL

AWAHNING

' Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.

2-D UPPER COWL
2-1 WIND GUARD/RAM DUCT

2-1 FRONT FENDER
2-2 REAR FENDER
2-2 SEAT RAIL

2-3 MUFFLER/EXHAUST PIPE
2-5

2-8 1
2-14

n

' Serious burns may result if the exhaust sysfem is not allowed to can! belnm campanenfs are remu ved a! serviced.

 

I Wnrk in a well Vermlated area. Smoking or allowing flames ox soaiks in the walk area at where gasoline is slured can

cause a fire orexpiosion,

. This section covers removal and Installation of the body panels and cxhausl system.

I Always yeplacs [he uxlmusl pipe gaskets after removing the exhaust pips from the engine,

'W'tsn l'fitallmg 'he exhaust <ysIPl‘1 loosely install all of the exhaust pipe fasteners Always tighten the exhaust pipe
clamps first, then tighten the mounting fasteners. It you tighten the mounting fasteners first. the exhaust pipe may Hot

Seat properly.

0 Always inspect the exhauslsyslsln Iul leaks taller illsldllaliuli.

TORQUE VALUES

Main fOOlpeg holder socket boll
Passenger lnotneg holder hniv
Bank sensor

Exhaust pipe ioinl nut

Muffler band bolt

Muffler bracket halt

Seat rail mounting bolt

TROUBLESHOOTING

Excessive exhaus1 nolse
o Bruksn exhaust system
. Exhaust gas leak

Poul purfurmanofi
o Deiormed exhaust system
' Exhaust gas leak
I Clogged muffler

26 N-m [2.7 kglml , 2O lbl-I1)
713 N-m (? 7 kgf-m , 7n IhI-I’I‘I
22 N-m (2.2 kgf~m,16lblft)
20 N m (2.0 kgf‘m. 14 lbl-ft)
17 Nan (1.7 kQIAHI,12IL)l-fl)
26 NAm (2.7 kngm , 20 lbl-fl!
44 N m {4.5 kgf m , 33 ION!)

 

2-1

FRAME/BODY PANELS/EXHAUST SYSTEM

SEAT

 

 

REMOVAL
Unlock the 50m using 1‘19 :gnivon key.

Remove the seat rearward

 

 

 

IGNITION KEY

 

INSTALLATION

Ahgn m sea? hoéks wnh the 1ramc brackets and
Install the scat.
Push the rear and of the seal and lock IL

 

SEAT COWL BOLT CAP
REMOVAL

Ruluove the sea: Isee above).

Remove the rear grip mounting boIt caps.

 

Remove the two socket hnIts REAR GRIP
Remove me ssmng Dolls. cnIlavs. and reargrip. /’

    

gism‘r/Cgum

 

FRAME/BODY PANELS/EXHAUST SYSTEM

 

Remnvn m: Qntlowlng'
*Spccial bolts
Saninq bonsxcollars/spacers

Helga». the tabs from the frame grommets,
rcmcvc xhc sea‘ cowl backward.

 

INSTALLATION

huslallaliuu is in [he reverse order of removal‘

SEAT COWL Ix.

 

 

LOWER COWL TRIM CUPS ~\\
REMOVAL

NOTE

The rigm and \efi lower bowls can be removed
individuaHyv

 

Remuve the (our trim cl‘ps and [W0 specia‘ bolts
between the right and left \Uwel Cowl and inner half
cowl.

 

SPECIAL BOLTS

 

 

 

FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the two trim clips between the right and
left lower bowlsl ‘
Remove the (rim clip [mm the leaf end ol 'he Ieh
lower cowl.

Remove the special bolts.
Release \he buss from the inner hall cnwll than
separate and remnve the right and left lower cowls.

 

RIGHT LOWER EUWI. LEFT LOWER COWL

 

 

Remove the two (rim clips and illnel Ilall'cowl

 

 

INNER HALF COWL

 

 

2-4

FRAME/BODY PANELS/EXHAUST SYSTEM
INSTALLATION

Insrallarr‘on is In rho reverse order of remnval,

RIGHT LOWER CUWI

  

INNER HALF COWL

UPPER COWL COVER/INNER PANEL
REMOVAL

Remove the upper nnwl cover rrirn Ellps.

Remove the windscreen upper end spenml bolts! ‘
cap nuts.

 

 

 

FRAME/BODY PANELS/EXHAUST SYSTEM

Remove me special bolts and upper cowl covers UPPER (iOWL COVER
,3 ‘

,f . ‘

     

 

Remove the \Uwer cow‘ (page 2-3;,

Ramove the inner pane} xrim clips.

ReVease ‘hc inncr panel from me fuel tank and
frame bosses.

Remove the inner panel.

 

 

2-6

FRAME/BODY PANELS/EXHAUST SYSTEM
INSTALLATION

LLI Y UPPER COWL COVER

LEFT INNER PANEL

  

\
RlGHT INNER PANEL RIGHT UFPEH (30W! (TOVFR

mm“ m», mner paner

NOTE

Ahgn me mner panel with me name bu» and
iowcr edge 0' the fuel tank, then Install the boss
iHlu the fuel lznk grommen

InstaH the Irim clips‘

 

 

FRAME/BODY PANELS] EXHAUST SYSTEM

UPPER COWL

Install the hmh upper cowl cavar‘

NOTE:

Align me upper cowl covers with me mexer panel

bosses,

Iemporarilv inslall th special balm.

Install the upper ends of the windscreen special
bolts/nuts.

Install ma lrim clips.

I lgman the cap nuts while holding the special bolts.
Tighten the special bolts.

REMOVAL

Remove the following:
Alnner panel (pageirsl

— Upner cowl cover (page 2-5l

Remove the rnamew mirrar pivot noon

.4\ /

UPPER COWL COVER

 

 

 

 

 

 

 

 

2-8

FRAME/BODY PANELSIEXHAUST SYSTEM

 

.m xv
Loosen the rearview mirror <05th bans. SOClgE BQLTsi/W s

Remove the windscreen mounlmg bolts. ,, »
Slightlv pulllng up the upper cowl, remove the “4*
windsueen by lifting out une side 0! the windv ' '
snmen and sliding it outta the side‘

leNDSCREEN.

Remove the collars and special nuts from the wind-
screen,

Disconnecl the from turn signal connectors.

 

Remove [he iulluwing.
' Sockel bolts
‘Rearview mlvror

— Mirror plate

7 R ubbei cushion

 

 

FRAME/BODY PANELS/EXHAUST SVSTEM

de‘ease the wire harncas ‘rom me wxre clamp

Remove we Wm dip: between the upper mw‘ and
vam duct

Ilewpase m». unper cowl from the 'carvicw mirror
bracket and pul :"c upper cowl forward.

 

Disconnect the headl'ghr sockets, men remuve me
upuer cuwl.

Rcmovc ma new: and head‘ighx unit (page 19-73.

 

 

2-10

FRAME/BODY PANELS/EXHAUST SYSTEM

INSTALLATION

WINDSCREEN

   

REARVIEW MlfiROR
\

/
UPPER COWL

Install the head‘igm um: tpags 19-7).

Insmn 1hr, mhher sems onto the marmw mlrror
bracket,

Connect the headlight sockets

Insml! the upper cow‘ aligning the bosses on the
headlwght unn With the rubber grommets nn the
upper cowl stay‘

NOTE‘

Align Ihe raarview mirror hole on the upper cow‘
with the bosses on the upper cowl stay,

 

 

FRAME/BODY PANELS/EXHAUST SYSTEM

Clamp the mam wire harness to me wxre clamp.

Install the two trim clips‘

 

Rome the turn signal wires.
Set the rubber cushxon and mirror plate onto the
rearvmw mirror pivot.

NOT E.

Insmll the rubber cushion and mirror plate with
their "‘— FR" marks lacmg forward.

lnslall we washers and socket bolts, hm no not
tighten them yet.

 

 

2-12

FRAME/BODV PANELS] EXHAUST SYSTEM

 

 

Connect the front turn srgnal connemnrs, TURN SIGNAL CONNECTOR
Sel the turn signal connectors Into the upper cowl.

 

Install the collar and special nut onto the wind-
screen.
Install the windscreen into the upper cowl.

Install and lighten the fourspocial bolts as shown.

 

 

 

 

 

 

 

Tighten the rearview mirror socket bolts securely.

Install the rubber boat into the mirror plate proper
Iv

 

 

FRAME/BODY PANELS/EXHAUST SYSTEM

WIND GUARD/RAM DUCT ' TRIM cups
REMOVAL

 

Remove the uppfir mwl (page 2-3).

Remove the Khraa lrim clips and wind guard

Remove the ram duct from the air cleaner housing‘

 

 

 

INSTALLATION

Installation :5 In my, raverse order 0' removak

   

WIND GUARD

RAM DUC I

 

2-14

FRAME/BODY PANELS/EXHAUST SYSTEM

 

 

 

FRONT FENDER ‘smcmgon FRONT FEND:R
REMOVAL \ . . , ’

Remnve the speciai baits and socket bolls.

Puli the (rent fcndei iarward and remove it.

instai‘ation is in (he 'fivmsa nrder of removal.

 

REAR FENDER
REMOVAL

Remove the‘oilnw-ng‘
ASeat cow ipagc 2 2|
, Fue~ iank mounting bolts luaqe 3-6)
*Bdllery (page was)
Tum Signai reiay
Aheadiigmrcicy
Engine stop relay
~ Slallel veiay switch

Disconncci me Sub‘hafl’lass 14F, SP and ‘iP
conneciors. (Aile- '95 Jn‘y)

Unhook the rcxaimng (ab and remove mg luse box.
Unhook the retaininq Lab and remove (he main fuse
Case,

Disconneci the rear brake iigm switch 2P while
connector.
Disconnenr the engine stop sensor 3P groan
connectori

 

FRAME/BODY PANELS/EXHAUST SVSTEM

MR5: SENSGR ®NNET®R

ii ow. Jsrnnnect the BARS sewur uu'meutor.

 

 

Drsnnnnam rho <pai \nrk cab e

SEAT LOCK CABLE

    

DibLJUHHBC‘1he[aflr‘brake‘lghtcon'WCCKOYS and (car
run srgna Dcrn‘efluwr

 

Remjvo mo rctanrng band and ECM Lngr"I-‘.
Currlrur Mudwar, men disconnect [re mum
m—mectors.

 

Remove the son and ray brake reservoir.

maesenvarn

 

2-16

FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the rear lender mounting Dons, nuts and

BOL] swms
canars. r

Rc‘cosc the main wire harness from the rear fender
harness guides.

Lrh the rear and ofme he‘ tank.
F‘uH up (hp (mm and ofthe rearfendcr and release

the rear fender from rho rear shock absorber uppel
bracket colt ar‘d radiator reaelve \ank

CAUTION

 

Be careful not to damage.- rhe harness guide a! the
rear lender.

 

Release the rear fender from the seat rfll‘, men
remnvP It backward.

 

HEAR FEN DER

 

2-17

FRAME/BODY PANELS/EXHAUST SYSTEM

INSTALLATION
FUSE BOX

’99

    
   
 
 

HRAKF RESHIVOIR

REAR FENDER

BATI’ERV
STARTER RELAY SWITCH

“W '99 TURN SIGNAL RELAY FUSE BOX
I

   
     

/ RELAYS
MAIN I'Ilbil (:ASI:

14F AND HP CONNECIOHS
M,
WUQ

/ BRAKE RESERVOIR
/

HEAR FENDER '

 

2-18

FRAME/BODY PANELS/EXHAUST SYSTEM

Install the rear lender mm the seat rail, while
a igning the (row: groove at me vaaHender wrm the
CIU>S bat

NOTE'

While instaHing the rear render, route [19 wire
harness properly (page 1-2.“.

lr‘srall me from and of the rear lender onto the rear
shock absoxbel uppet bracket bo‘l and radiator
reserve tank.

CAUTION:

as careful nut to damage the harness guide a! the
rear lander.

“mm: m mam wrrn mama“ nm 'ha harness guide
o‘mc rcarfmdcr.

lr‘sta Hne rear fender mounung collar, be I and nut. \ SOUS/NU IS
»
l ,

 

Tigmuu lire mu: wlr'lr-s hu‘diug llm Luella.

   

 

 

FRAME/BODY PANELS/EXHAUST SYSTEM

 

ins:aH the removed parts m ths mverss nrdsr n'
mmnvm

NOTE:

Home the w‘res properly (page 1 24).

Connect the sub-harnes<1AP, RI‘ and 'H' nnnnectnrs
[After “an onWI.

SEAT RAIL
REMOVAL

Remove the rear fender Ipagc 2 15".
Remove [he led! Luake hose clamp bolt,
Rpmnve Yhn [‘(IV [l’mnnmonal Control VBIVEV

mounting bolts.

Remove the ligm passenger footpeg holder momm-
Ing holvs.

Remove the bo‘ts and regu<amrfrectilien

Remnve thP my passenger Innvneg homer
mounting bo‘ts.

Remuve (he seal vdil muuuling Luolts nms and seat
ril‘l

 

 

2-20

FRAME/BODY PANELS/EXHAUST SVSTEM

INSTALLATION
REGLKILATOR/RECTWIER

SEA\T FAIL \
\

   
  
 

 

44 N-m l4 5 ng-r‘ , 33 Win
/\

PASSENGER FOOTPEG

IMIHH the 55-31 Fall and lghmn m mnunnng hnlvs ‘
to the specified Iorquc.

TORQUE :45 Man (4.5 kgl-m , 33 lbf-ft)

mm” the \ch passenger fooxpcg ho‘dcr onto me
seat rail, tightan ms mourning backs to the specified
torqus,

TORQUE :26 N m t2.7 kgf m , 20 lbf m

install me regulamr/recrmer, hghmn the bolts,

 

 

FRAME/BODY PANELS/EXHAUST SYSTEM

~n3tall me fight passenger footpcg hclaet onro (he
seax ra‘\,1igh:an [he '“antinq ban; to the spec “ed
tuvque‘

TORQUE: 26 N ”1‘21 kg! m ‘20 lbf m

\nsmn am. ‘iglnen me PCV (Propomnnm (Innfml
Valvs) mmmhr‘g nous,

mm and tighter the rear make hose clamp bolt.

man “We re'flovad parts m m: rfivflrse mm m
rimmvak

MUFFLER/EXHAUST PIPE
REMOVAL

Dn na’ undo: the exhaust swam while iris hot.

 

 

Remove 1he \nww mwl (page 2-3:

Loosen we exhale pipar‘muffler CldHlp bulb

Remove the {C‘Hnwmg‘
Exhaust ovpe mounting nut

7 Foomcg holder mounting bong and fuutpeg

*Mumev ulumlthlg uulLWuL'L‘ollar

, Muffler

—Muffler gasket

 

  

R MOUNTING HULK

/

  
  
 

Hemovelhefo‘lawmg: dlL COOLER ‘JPF‘E
‘Uppflcow‘cover/innerpanehpage 2-5', ,
iwmu guild lpage 2.1m

 

Remove the oil cocler upper mauvzing bohs and
mam wire ha"vess guide.

 

‘ 1
HARNESS GUIDE

 

 

2-22

FRAME/BODY PANELS/EXHAUST SYSTEM

Disconnect the fan motor suhrhamess 2P natural
connector.

Rsmove the rad?awr JppEI v owning bun.

Remove the radiator (rom the upper and lower

brackeks by moving it to the la“, therr ruuve the
radlamnmr more: mrwam as an assammy,

 

Remove the exhaust pipe joim nuts‘

Remove the following:

~Exhaus\ pipe mounting bolt/can nut
*Washer

7Com"

— Exhaust pipe

*Exhaust pipe yaskels

 

 

FRAME/BODY PANELS/EXHAUST SYSTEM

INSTALLATION

      
 

/
RIGHT MUN l [H

17 Nvm 1“] kgm, x2 Ibf-m ”
Install the new exhaust pwpe gasket onto the ex
haunt ports of the cylinder head.

NOTE
Nwavs replace the exhaust pipe gaskets with new

ones.

lnsmll the exhaust D‘pc. temporarily instaH me ex»
haust pipe joint nuts and mounting bull.

NOTE.

 

Install the mounting coHars, washer, bolt and nan
properly

 

First ughten the exhaust pip; Jam! nuts m the spam
fled torque,

TORQUE .20 N-m (2.0 kgf-m , 1A Hal-ft)

26 N~m {2.7 kg! m . 20 1mm

 

2—24

FRAME/BODY PANELS/EXHAUST SYSTEM

 

Tighten me exhaust nip: moml‘ng box/nut.

meta“ the radia:or,’ovl coober assemmv allgning me
vadiatu' glumlnels with me uupev and luwel
hrarkPYs

mm” and l-gMeu Hm nadiaxu- mum-ling boll
ConnPnt mp Mn momr suhharness 7|? namml mn-
necton

IMMH mp mm \we harnms gmde on?!) ihe Iefl
mounting boss as shown.

 

HARNESS GU‘Ut

 

2-25

FRAME/BODY PANELS/EXHAUST SYSTEM

lhsralb and fighter: lhe ui‘ cooler upuer mmmhng O\L COOLER m?" H MDUKTNG BOLT ‘

bulls.

 

Installxhclohow‘mg:
*Wind guard (gage 2-14]
’ Uppe' cow‘ CnVRr/Inne' panel (page 2 7)

1
1

\nstall the nPw gackm mm m». muffler.

lhsxaH therrumers.
Tsmpuravi‘y iHMaH llle mumm mouming bolunut

\nsmH the mam foomeg holdcrs and ughtcn the
mounting bolts.

TDROUE '76 N-rn (7 7 kgf-rn , 2|) IhfiTl

Tithen the muffler bracket cap nul Lu the apeufied
tov que

TORQUE :26 N m (2.7 kg! m , 201mm

Tighten the rmIFfler monntmg hnlh’nm to ma sneak
had torque.

TORQUE .26 \lrm .‘2_7 kgf-m , 20 mm

Tighten lhc muffler damp bolts alrerhaxetv, (hen
tighxen m the specified torque.

TORQUE I '17 Wm :77 kg m , 12 befi)

mud” Lin-1 «WM Luwl lpage 2-4),

 

2-26

3. MAIN I I:I\IANUE

 

SERVICE INFORMATION 3-1 DRIVE CHAIN 3-22

I MAINTENANCE SCHEDULE 3-3 BRAKE FLUID 3-26
‘ FUEL LINE 3-5 BRAKE PAD WEAR 3-27
THROTTLE OPERATION 375 BRAKE SYSTEM 3—27
‘ AIR CLEANER 3-5 BRAKE LIGHT SWITCH 3-29 B
I SPARK PLUG 3-8 HEADLIGHT AIM 3-29
i VALVE CLEARANCE 3-12 CLUTCH SYSTEM 3-30
! ENGINE OIL/OIL FILTER 3-17 CLUTCH FLUID 330
I ENGINE IDLE SPEED 3-20 SIDE STAND 3-31
I RADIATOR CODLANT 3-20 SUSPENSION 3-31
I COOLING SYSTEM 320 NUTS, BOLTS, FASTENERS 3-32
SECONDARY AIR SUPPLY SYSTEM 3—21 WHEELS/TIRES 3-33
; EIYISATEJAFIIIIICRIIEFEOMRIINISAKTNIEEogNTgL 3-22 STEERING HEAD BEARINGS 3-33

 

 

SERVICE INFORMATION
GENERAL

be

- Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or
allowing flames or sparks in the work area or where the gasoline ls stand can valid 2 firs or nxplosian.

- When tho sngl'mv must be running to do somv work, make sure the area is well-ventilated. Never Iun the engine in an
enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to
death. Run the engine in an open area or with an exhaust evacuation system In an enclosed area,

 

. Plarerhe mmnrcvcle, nn 3 level ground before smmng any work.

SPECIFICATIONS

Uml‘ mm [\nI

M
L ITEM SPECIFICATIONS I

‘ 2*6(1l16*1l4|
'99 ‘ CRaEHvx 9(NGK)

‘ 7 ‘7 WV ‘ Afte[’99: I IMRBAifiHlNGK) , w
Spark plum qap _. , ,_ . 0.80-0.9010‘03170.035>
Valve cIearance IN ' 0,16 L 003 (uoqej 0 um

I EX 0.22 : 011310.009 1 0.001)

 

 

 

 

 

MAINTE NANCE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM i SPECIFICATIONS
l
Engine oil capacity At draining 7 T 3 B E M1) U5 gt,13|mggtl _
, At oil filter change l 3.9 R in US qr , 3.4 Imp qtl
Recommended engine ml HONDA GNA 4-itroke oil or equivalent molt-r Oil
| API servic: classification SF nr 36
A ylscosity' SAE low-Au
Engine idle §pegd i 1.700 : 50mm
Drive chain slack l 25‘35mmI1.0—1,£in)
Recommended brake fluid l DOT}
Tire size Front , 1 120/70 ZH'l7 [hSWl (Radial
_ Rear ‘ 130/55 ZR17 (73W) [Radial . fl
Tim hmnd Bridgestone From l BT57F RADIAL G
Rear , .‘ BT57R RADIAL G
Dunlap ‘ Front DZOSFJ
. Rear D2056 fl
Michelin Front MACADAM 99X 3
7 ’ Rear MACADAM 90x 5

Tire air pressure Up to 90 kg (200 lb) Front 250 Wt: (290 Ital/cm“ , 42 psi)

load l Flear 290 kPa (2.90 kgf/cm2 42 psi) V

Up to maximum Front 290 kPa (2.90 kgf/cm‘ . 42 psi)

weiqm capacity 7 ; Rear 290 WI: (7.90 kgI/cm‘ , 42 psi)
Minimum (ire tread depth ‘ 1mm 15 mm l0.06 inl

Wear l 2.0 mm 10.08 in) .

 

 

TORQUE VALUES

Timing hole cap

Spark plug

Cylinder head hover halt

Oil drain bolt

Oil filter cartridge

Rear axle nut

Drive sprocket specia| bolt

Driven sprocket nut

Rear mastel cylinder push rod nut

TOOLS

Oil Iilter wrench
Drive chnln tnnl set

18 Min (13 mm , 13 lblvft)
l2 N-m (1‘7, kgm , 9 mm)

10 N-m (1.0 kgfm 4 7 Ith)

29 N-m (3.0 kgf-m , 22 Inf-fl)
10 Nan (L0 kgf-m, 7 Infill

93 N-m (3.5 kgilrn , 69 mm)
54 Nm (5.5 mm , 4o lam)
103 Mm (11.0 kgI-m , so Min
18 N-m (1.3 kgf-m,13lhl-fi)

Apply grease to the threads.

Urnur.

07HAA—PJ70I00
OlHMHrMFl‘lOlU3 or07HMH MRIOWBIU.S,A.onlv)

Apply clean engine oil to the O ring.

 

3-2

MAINTENANCE

 

MAINTENANCE SCHEDULE

Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.

I: Inspect and Clean] Adlusc, Luhncnie m Replace if necessary. C. Clean. FI. Replace A: Adjust L: Lubviuale.

The Iollowing lleme require some mcchamcal knowledge. Certain Items lpnfllcularly Ihnse marked ' and "I may requiIe
more Ieuimiual information and tools. Consul! their authorized HONDA dealer.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FREQUENCY NOTE ODOMETER READING INDTE II REFER
\\ x 1 00mm 0.6 4 a 12 16 20 24. TOPAGE
“Ms 7, \:\ ‘1 x1WkaI1-OIGJ Ize 19125.6 32.0 aw
w * FUEL LINE . I I 7 I I I | 73-5
s I * ITHROTTLE OPERATION I g ‘ I I I I l 3-5
‘ g “ It AIR CLEANER NOTE2 1 I I R I R I as
.3 Ir ISI’ARK PLUG W I l I. I . R _ I R I R 3—8
I“: . av VALVE CLEARANCE . . ; I 342
S I ENGINEOIL I R I I R R R 3-17 I
g i ENGlNEOlL FILTER _ I R I l R R R 3-17 ‘
2 at IENGINEIDLI: SPEED 7 I l I l I I I I I I I 3-20
3 ‘ RADIATOR COOLANT NOTE 3 ' 1 l l l R 3-70
u_7_”* COOLING SVSTEM I I I I I . I 320
5 * SECONDARVAIR SUPPLYSYSTEM an“ A I I . I I 3.21
‘ * EVAPORATIVE EMISSION CON'i ROI svsmI/I mm 4 I 3-22
m DRIVE CHAIN 3-22
5 BRAKE FLUID NOTE 3 , 3-25
: BRAKI’ PADS WEAR __ . =‘ 3-27
B; A BRAKE SVSTEM _ I 3-27 ..
z * BRAKE LIGHTSWITCH : 3729 A
.1 * HEADLIGHTAIM I 3-29
“2‘ (:LU I(:II SYSTEM _____ . 330
9 I CLUTCH FLUID NOTEa 3-30
3 SIDE STAND 3 31
g ’i‘ SUSPENSION 3-31
31* NU'IS,HOLIS.IASIENERH 3732
o a: * WHEELS/TIRES 3733
2 It * STEERING HEAD BEARINGS 3-33

 

 

 

 

 

 

 

 

 

 

 

 

 

* Should be serviced by an auvhnnred HONDA dealer, unless the nwner has proper tools and service date and is
mechanically qualified.
* A: III IlIe interest ul safety, we recommend these 'nems be serviced only by an authorized HONDA dealer,
NOTES: 1. AI higher odometer reading. repeat DI the frequency interval es‘abliehed here
2. Service more frequently ii Ihe motorcycle ls ridden in unusually we! or dusw areas.
3 Replace every 2 years, In al the indicated odumeier inIerval, whichever comes firsI. Replacement requires
mechamcal SklII.

 

MAINTENANCE

 

AFTER '95:

Perform the Plevride inspection in the Owner’s Manual at each scheduled maintenance period.

I; Inspect and Clean AdjuSi, I uhncate or Replace if necessary, C: Clean. R, Replace. A. Adjust. l : Lubricate.

The tnllnwmg Items require some mechanical knowledge. Certain iterns (particularly those marked ‘ and "I may require
more technical information and tools. Consult their authorized HONDA dealer.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

\ \ \ \ FREQUENCY WH'CHM“ ODOMETER READING (NOTE 1)
\ \ \ COMES REFER
ITEMS \\\\ f5“ :9 x 1 000 mi 0.6‘ 4 a 12 . 16 20 34. TOPAGE
7 -\ _ NOTE ‘5 1 000 Km_,1»0l6-4 1234321255310 35M
‘ a: I Flll'L LINE l x l I l l 375
w . =r THROTTLE OPERATION | I I . I ‘. 35
E, * AIR CLEANER NOTE? I . | R l Fl l 3-67‘
’2 l I: SPARK PlUG EVERv Is,ooo mi [75,600kmll 3-3
8 WHY 32,000 mi (51,200 km) R
L; =1: 'VALVE CLEARANCE_ ‘ ‘ I l l 3-12
m ‘ENGINE OIL I R R R ‘ . R 347
; lENGINI OILFILTEH 1 R H R R 317
o * ENGINEIDLE SPEED i l I I . I I I 3.20
g RADIATOR COOLANTA NO I i: 3 I ’ I R 3-20
5 J _CO0LING SYSTFM I I l I 3-20
I.” a: ‘StCONDARY AIR SUPPLY SYSTEM I l T I 3 21
g * I EVAPORATIVE EMISSION CONTROL svSTEM NOTE 4 l I‘[ l I 3-22
.,, VDRIVE CHAIN EVERvsoom Iaoo Iun) I. L . 3722
E. . BRAKF rI UID NOTE 3 't I R I ' 'H 3-25
I: I BRAKE PADS WEAR 7 I I I I I 3 27
S BRAKE SYSTEM _ I I I I « I 3'27
5 =« BRAKE LIGHT SWITCH I I I 3.29 ..
m * IIrADLIGHIAIM I . I ‘ I 3-29
; CLUTCH SYSTEM I I 1 2 3 so
9 CLUTCH FLUID . NOTrrI I I l ‘ R I R I 3-30
g SIDE STAN_D _ I I I - I 331
5 I * SUSPENSION > I I I 3-31
3 * NUTS. BOLTS, FASTENERS 7 I I I I 332
o M WHEEL ITIRES , I I I 3-33
2 1r m STEERINI; III AD BtAHlNGS I I I I 73-33
3! Should be serviced bv your HONDA dealer, unless the owner has proper tools and service data and is mechanically

qualified. Rater to the Official HONDA shop manual.
as * In the Interest nl safety, we recommend these items be serviced only by your HONDA dealer

NOTES: ‘l. Al higher udumelel reading, repeat at the frequency Interval established here,
2 Service more lrequemly when rIdIng In unusually wet or dum areas,
3. Replace every 2 years. or at the indicated odometer interval, whichever Comes first. Replacement requires

mechanical skill.
4. California lype only,

 

3-4

MAINTENANCE

FUEL LINE

.‘Mt the Ia'iI’ Support the rear end nttnetuel tank lpage 5755i.
slowly. acmg
CSIQMHOI In Check the fuel lines for deteriorallun, damage or
the leakage. Replace the fuel Iine if necessary
in. nose
lnstall the fuel rank in me reverse order of removal.

 

ate/excel

THROTTLE OPERATION

Check for smooth throttle grip full opening and
automatic full closing in all sleelillg positions
Check the throttle cables and replam‘. them lI they
are. up rimmed. klnked or damaged.

Lubricate the throttle cables, if throttle ouelaliull is
not SNIQUHL

 

Measure the free play at the mronle grip llanqe.

FREE PLAY, 2*6mml1/1G 1/4an

'lhvonle grlp free play can be adjusted at ellner end
oftnethrottle cable.

Minn! adjustment are made With the upper adjuster.
Adlusr rho Iran play by loosening lhe lock nut and
rurninq the adjuster.

Maiur adjusllllerlls are made willl the lower
adjuster

Remove the alrcleaner housing (page 5-65).

Adjust the free play by loasenlng the lock nut and
turning the adjuster.

After adjustment. tighten the lock nut seculely
Rachael: the thmnle npmnnn,

Replace any damaged pans. it necessary.

 

 

MAINTENANCE

AIR CLEANER

Disconnect the fusl levellresews wnsm ’ll‘ hlarx
CON’IGCIOL

“Pmcvethefueltaflkleal wum‘mg bulb,

Release me :nner nanel bosses lrnm 1*» We tank.

Pul am the fuel tank from blackcl rubbcvs from the
frame

'4‘ .'
UBE S'

F'F'iON BRACKET}

 

 

MAINTENANCE

Remove :"e luex rank mounting collar anc
temyJO'a'lly l"s(a|l1l|e [Lelldrlkwountinq bo'rs.

 

thsranx Suppott llle hunt and ul‘ llle fuel tank using a sulta-
s/ava 0::ng hlp. suppnna< <hnwn
ca'a’ul 'VDHO
m/el enema me
lee/hose

Dl<rnnnfint 2'19 IAT Ilmak’e Air TemsNaLer) senmr
connector.

Remove the smews and all clear-e1 lluu>llly LUVEIV

 

Remove and uiscard me air cleaner clemo'n in
accordance with the maintenance schedule Ipage
3'3, 4‘-

Alsc replace me arr cleaner element anwlme '1 l5
excessively dlny or damaged.

Install the removed pans m the reverse urde' of
removal,

 

 

MAINTENANCE

 

SPARK PLUG
REMOVAL

CAUTION:

Be carelul not to damage the ail cooler and
radiator fins.

 

Remove the lollowmg:

7 Lower cowl [page 2-3!

-Upuev uuwl uuveUmner pane‘ (page 7-5»
Wind guard mags z-m

Remove the owl cooler upper mwming buns and
main whehalness guide

Disconncm the fan motor subvharness 2P natural
connectur.
Removp (hfi radmmr IIppev mnunhng ban.

Remove me radiator from IhC upper and lower
brackets by moving it (o the left, than move (he
vadialur/ui‘ coulel forwald as an assemb‘v

Remove the air guide lrom m 0H cuoIEr/radialur
bracket and cyiindel head cnver

 

 

Always use the
spawn: spam
plugs {M "1/5
Fromm fr'E

MAINTENANCE

DISLUImeLl (he spd'K pIJg caps.

NOTE

Clean a ourvd the spark plug bases wlth
comp‘ ssed alr hefnra removing, and as. sure. nn
debrls ‘5 allowed m cntcr m: combustion chamber.

Remove the spark plug “sung me. supplied spark
DIUg wrench or an equivalent.

Imam nr mplana a< described m the maintenance
schedulc.

 

INSPECTION ('99:)

 

Chew the followmg and mnlane II He.
{recommended spark plug pages Il

- Irmulalul Iul danmge

- rlprlmnss for wear

. Burning condmo", discoloration

ll the eledlode is Lorna-winded wilIl nuuuuluIalud
Objems or dry, clean the elemmde nsmg ma :perk
plug cleaner.

 

INSULATOR
CAUTION

- This motarcycle’s spark plug is equipped with —
platinum type electrodes. Do not us- a wire
brush to clean the electrodes

- The plug cleaner should be used with alr
pressure of less than 6 kgI/cm’ (85 psi] and far
less than 20 seconds

 

Replace the pIug II We L'ellle' electrode is ruunded
as shown In me lluslrahnn r

 

SPECIFIED SPARK PLUG: IMRQA- 9H (NGKl

 

 

MAINTENANCE

 

Alla/3V5 USE "IE
Jpn-lie: 3pm
plugs on ma:
male/cycle.

Chetk the gap belween the center and side
electmdes with a wire. type Ieeler gauge

CAUTION:

To prevent damaging the platinum coating 0/ the
center electrodes, me e Mire type feel” gauge tn
check the spark plug gap.

Make sure the 1.0 mm (0.04 in) diameter plug
gauge 'does not insert between the gap.

If the gauge can be inserted into the gap. replace
the plug with a new one.

CAUTION.

Do not adlust the spark plug gap. ll' thfl gap is out
of specification, replace the spark plug with a new
one.

INSPECTION (After '99:)

Check the following and replace if necessary
«recommended spark plug: page 3713

- Insulator for damage

' Electrodes for wear

I Burning condition, discoloration

it the elnmrndes are contaminated wnh
accumulated objects or din, mplacc the spark plug.
CAUTION:

Thia motorcycle'a spark plug ia equipped with an

iridium center electrode. Replace the spark plug it
the BIDC‘tI‘DdOS an contaminatad.

Replace the plug ii the cemer electrode is rounded
as shuwn in [lie i||u>llaliun.

SPECIFIED SPARK PLUG: IMRQA .. 9H (NGKI

Check Ihe gap between [lie center and side
rndes with a Wire rype feeler gauge

 

CAUTION:

To prevent damaging the iridium center electrode,
use a wire type leeler gauge ta check the spark
plug 93P-

Make sure the 1.0 mm lD.DIl in) diameter plug
gauge does not insert between the gap.

ll the gauge can be inserted mm the gap, replace
the plug with a new one.

CAUTION

Do not adl'ust the spark plug gap. If the gap is out
Dispecificatinn, replace the spark plug with a new
one.

  

 

 

WIRE TVAPE FEELER GAUGE
I

OX

e;

ELECTRODE

 

 

 

 

 

INSULATOR

 

 

 

HUUNDED ELECTRODE

A

g:

 

 

 

 

   

 

 

 

WIRE TYPE FEELER GAUGE
O / ><
/
//
A I A |

 

 

 

 

 

 

 

 

3-10

MAINTENANCE

 

Relllslall (he spark plug in [he cylinder head and
hngar-vighlen, then torque lo specification.

SPARK PLUG WRENCH

TORQUE: 12 N-m (1.2 min , 9 lbml

If uslng a new plug, Install a‘lnllnws:

Infilall and linger tighten the new spark plug, then
lighten it aboul ‘l/Z mm after (he seallng washer
nontacts the seat or the plug hole.

Install me spark plug maps

lustall me air guide by aligning its bosses with the
oil cooleu’ladialul blackels.

Install the radlalor/oil cooler assembly aligning me
radiator grommels With the upper and lower
brackets.

 

 

MAINTENANCE

 

Install and tighter ths raduamr .lpper mounllng bolt.
Connect the (an molar sub harncas 2P namral
connector.

Install the mam wire harness guide onto the [an oll
cooler mouminq boss as shown.

|n>la|l and tighten lhe oi‘ coolev upper mmmmg
bolls

Install [ha following.
*Wing guard (page 2-1A)

Upper cowl cover/Inner panel lpagc 2 7l
-Low0r COWI (page 24)

VALVE CLEARANCE
INSPECTION

NUTE'

 

ll’lsped and adjust the valve rlearanne whlle the
engme Is cold lbelow 35 c0’95 ”F).

 

Remnvemp nyllnder head nnvar (page 571:].

Remove the cam chaln \ensluner liner seallllg boll
and seal'mg washe'

 

4/

x/,
(w,

 
  
  
   
  

}\,H r
//

       

ZZZ”
gay/z
Gnu/5’
WM
‘67 6

Z?)

.\
"2)
z
¢

2

5
”2 4;,
,7
, 25¢

   

#17,

2’ ,
’4

 

’L‘AM CHAlN TENSIONER LIFTER

 

 

l SEALI’NG WASHER

 

 

 

3-12

MAINTENANCE

Tum the Ldi'v Li'airt Iensioner lifter shah ‘u‘iy and
secwe it using the methallics lerrsioner stopper
iaol (90908 6‘.

Remove the timing hole map and Ortiflq.

Turn me crankshnn rinnkwiw :n the "T” mark on
the ignition pulse generator rotor aiigns With the
index mark on the ignition pulse generator rotor
mover

The timing marks ("iN" and "EX": on the cam
sprockets must be “th with the cviinder head
surface and inning mitward as shown,

if the timing marks on the cam sprocket face inward,
turn the crankshéfl clockwise one fuil iurit (350°)
and realign the timing marks WIN’I the fiylvndfi‘r head
surface so they are facing outward.

 

 

MAINTENANCE

‘ hé

 

Mun
manna; ‘7: each
van/C for
'af—Grsncs my‘m
w :nnn m
amusmew: as
rammed

Assam mc

: earsfiss Fur 23m
va/VP w
'e’erence w 5mm
53‘ ‘ r‘ H
leJUflH‘E' r a
reqwred

  

 

\nsen (“e fee cr gauge betweer‘ [he va‘ve Mar av'd
mo cam \cbe' ‘No, 3 \NTAKE VALVES N0. 1 ’NTAKE VALVES
crux m: vame c‘earancfi mrme No 1 rd No 3 K \
tyl nde' INake valves using a fcclo' gauge‘

  

VALVE CLEARANCE:
IN: 0 ‘6 003mm10005:0.001lr‘]

Tum [he uravvksludf1tlockw}se112mm (1Rn“3:n1he
indpx hm: on me. \gnlhun pu‘se generator rmor
faces up as shown.

Check he valve clearance for the No. 2 and No.1
minder exhausx valvss using a feeler gauge.

VALVE CLEARANCE:
EX: 0.22 t 003 mm (0.009 i 0001 im

 

No. AFaniJm VALVES
rm 2 EXHAUST VALVES

Turn me crankshan clutkwima 1,‘2 [mm (180”) so the
"T" mark on the xgnimm pu‘se generazm rotor
aligns With the index mark on the ignition pulse
generamr rotor cover.

 

 

3-14

MAINTENANCE

 

Hmm’ We Check the va‘vc clearance for the No 2 and Na, 4
c‘esrance ‘w eacr minder mtake valves usmg feeler gauge. \10. 4 INTAKE VALVES
m VCYG' \
'élr'E‘IE‘GCEI’ENM
SE/EL‘I‘D' /’ VALVE CLEARANCE:
ad/«SI'TET? '5 IN: 0.16 f 0‘03 mm (0.006 ,- 1001 mV

requsrcc.

No 7 \MAKE VALVES 1

 

Tum The crankshaft clockwise 1/2 mm (180") so the
Index fine on xhe ignnion pulse gellevalul lulu!
faces up as shown

anc'a m9 Chenk the Valve c earance For the No 1 5rd No 3

cfgarancs 70/ each cylinder cxhaus‘ valves Jam; 5 feeler gauge.
HAM/é (u

reference In 5N!" VALVE CLEARANCE.
sclccr‘ofi r: EX: 0 77 - n 03 mm m 009 — n 001w
at/uslmsn.‘ rs
wqdrm:

 

ADJUSTMENT

Remove the camshaft [page 8771‘
Remove me valvc who»: and shims.

NOTE

oThe shlms may stick (0 the inside of me We‘ve
hflers. Do not allow (he shims to faH inlu [he
crankcase.

- Mark ali va‘ve Him: and shimn to cnsuvc corrccx
reassembw in me‘u u'igina‘ lucalions.

‘The valve Hh‘er ran he easi‘y removed wFth a
va‘ve lapp'mg loo! or magnet.‘ ,

I The shims can be easi'v removed with Iweezers
m magnex

 

MAINTENANCE

Clean the valve Shim contact area in the valve lifter
wtth compressed air.

Measure the shim thickness and record ll.

NOTE

 

Sixty five different shim thicknesses ale
available [rum 1,200 mm to 2.800 mm in interval:
of 0 025 mm,

 

Calculate the new shim vhinknass uslng the
equnnnn beluw.
A= lB - Cl ' D

A: New shim thickness

B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness

NOTE

 

OValily the correct shim thickness hy measuring
the shim wrih a micrometer.

' Refacc the valve seat If carbon deposits result in
a calculated dimension uluvel 1800 mm,

Install the newly selected shim on the valve
retainer.

Apply molybdenum disulfide oil to the valve lifters.
Install the valve litters mm the valve lifter bores.

NOTE:

Install the shims and valve llhcrs in their original
locations. '

 

Install the camshaft (page 8 23).

Ruwle [lie camshafts by rotating the nrankshaft
clockwls verai times.
Rechcck the valve clearance‘

 

VALV’E LIFTER

 

 

(I
I X”: [I

180 mm 1325 mm 1.85 mm 1.875 mm

 

 

STUPPER TOOL

 

 

3-16

 

MAINTENANCE

 

Remove t‘Ie carr chain Iensioner stopper Iooll

     

CAM CHAIN TENSIONER LlFTEP
/ /
lnslall the new scallng washer and cam chain "
tensions! lifter sealing bolt.

Tlghzen the bolt seculely‘

Install [he removed parts m the reverse order nI
IeIIluvaL

 

ENGINE OIL/OIL FILTER
OIL LEVEL INSPECTION

Sum the angina and le‘ It idle for 2-3 minutes.
Turn off the engine and support the motorcycle ll’l
an uprigm position on level ground.

Remove (he oil level rlianlck and wipe it clean
Reinstall the oil lcch dipstick. but do noI screw It In.

 

Remove (he all level dlpstlck and check Ina ml level.

If the level is below lIlE luwet mark on the dipstick.
fill the crankcase wrrh the recommended oil

UPPER LEVEL MARK

LOWER LEVEL MARK

Remove the uil filler can

 

 

MAINTENANCE

Adc :he reuummendeu engm ml m mo upper \evel
man

 

SAE 20w 4n 90w

 

RECOMMENDED ENGINE OIL
HONDA GNA A-stroke mi nr Pmnvalenl motor 0H
AF‘i <arv classmcstmn: SF or 56

 

NOTE

 

Other viscosities shown in (he chavl may be used
when the avelage iemperaune In your ndmg area
is withm ma mmnated range.

 

Reinstall the fil‘ei cap and dipstick

ENGINE OIL & FILTER CHANGE
m;

If the engine must be running In do some work,
mzka sure the area is well-ventilated Never run
the engine in an enclosed are. The exhaust
contains poisonous carbon monoxide gas that may
cause loss a! consciousness and may lead to death.

Warm up \hc onglne.

NOTE
Change the engine oil with me sng'ne deul and
me mummyuie um Ievc‘ gvonnd to asmm nnrnplete
draining

Remuve rue lower cowl (page 773»

Stop ‘hc engine and remove the oi‘ fiber Lap and
drain bolt.
Dvdm llie oi‘ complete‘y

CAUTION:

Used engine nil may muse skin cancer if
repeatedly left in contact with the skin In:
prolonged per/ads, Although this is unlikely unless
you handlfl used oil on a daily basis, if is still
advisable to thoroughly wash your hands with
soap and water as soon as possible after handling
used all.

 

Remove and discard the oil filler u
the speciai tooli

 

LHdge using

TOOL:
Oil filter wrench D7HAA-PJ70100

 

3-18

MAINTENANCE

Check (hm Inc sca‘ir‘g washer on me man salt 15 n
good condition. and 'Eplace if necessary.
\nsxall and xighten the dram hnltv

TORQUE: 29 "l m {3.0 kgf m , 2215”!)

App‘y oil It; Lhe l‘ew UH ’iltev Ordng

msval the new on Mar and tighten h [0 the
cpccihedlorque.

TOOL
Oil lil‘er wrench 07HN\VPJ70100

TOROUE' 10 Nm (1 0 kgf-m, 7 \n5-ftl

 

Pin the crankcase wnh me reuomme'lded angina uil.

OIL CAPACITY:
3,8 E MD us (“3 3 \mp qr!
4.1 us q; 3 4 \mp qt)

 

lnstall the owl filler cap.

Stalthe engine and let it Id‘efur 2 to 3 m‘nutes,
smnme engme and recheck the on ‘evel
Make sure more are no 0“ eaksn

 

 

MAINTENANCE

 

ENGINE IDLE SPEED

mama—m

When the engine must be running to da some
work, make sure the area is well vonn‘latpd. Never
run (ha Dngi'nu in an enclosed area. The exhaust
conlains poisonous carbon monoxide gas tha! may
cause loss a! consciousness and lead to death. Run
the engine in an open area or wmt an exhaust
evacuation sysnrn in an Enclosld was,

NOTE‘

. inspen and adj-us! Vine .me <peeri aher a|= other
engine maintenance items have been DC'formcd
and are within specifications.

'The engine must be waim to: accurate idle speed
inspemmn and adjustmem

Warm up the engine for about 10 minutes
Turn the mmme slop screw as requlred to ObIalr‘
the specified idie speed.

IDLE SPEED: 1,100 — ’30 rpm

RADIATOR COOLANT

Check the Conia'fl levei n' The reserve Iank with the
engine running at normai operating temperature
The levei shuulu be belween the "UPPER" anu
"LOWER" ievai lines

if necessary, add the recommended cooiant

RECOMMENDED ANTIFREEZE'
High puaiilv ethyiene glypoi antifreeze pertaining
corrosion protection inhibitors.

itemnw- mp seat (page 7,7]

Remove [no reserve tank fiiier cap and fill to the
”UPPER” ievel line with a 1 1 mixture uf disfiiiec
waterand em freeze

Reinstallth: ‘ilicrcap.

COOLING SYSTEM

Remove the iower cowl (page 273i.

Check the radiator Air pafisagee for nlogs nr
damage.

Straiqhten pent fins, and remove insects, mud or
other obstructions with compressed air or low
WflIeY nressu’e

Replace the radiator if the airflow is 'cctricted over
more than 20 :0 DI the radiating surface.

 

M .
V.
THFIGITT E STGJP SGREW

    

UPI-'LH LEvEL LINE ‘
t e {e i
X I

I i \

 

3-20

MAINTENANCE

 

Check thathe sealing washc' on in: rain boil is in
good condition, and replace i" necessary.
iiislal. and iigmen :he drain bok

TORQUE: 29 N m {3 O kgfrm . 22 lbf 5!)

Appiv oil to the new oi ‘Iiisr O-P‘nu.

li'is‘aii the Pew nil inter and nghien it in the
speniiiedtorque,

TOOL:
Oil filflr wrennh 07HAA-VJ7D'IUU

TORQUE: 10 N m 41.0 kgf m, 7 Wk}

Fiii the crankcase wiih m9 recommended engine oii.

OIL CAPACITY.
am (an i15;qi,33|mpqn
3.9 a (4 i US qx', 3‘4 Imp ml

Instr-1i the oi) ‘iiier cap.
Stanthe engine and .9i i( idie ior 2 IO 3 rninmes,

Slup [he eilgi'le and Iecheck (he on levei,
Make s..re iha’e are nn ml lF-aKS'

 

 

MAINTENANCE

 

ENGINE IDLE SPEED

M—

When the engine musl be running lu du some
work, make sure the area is well-venfiIafed Never
run the engine in an enclosed area. The exhaust
canrains palsonou: carbon monoxide gas that may
cause loss of consciousness and lead to death Run
the engine in an open area or Wm. M. exhaust
evacuation system in an enclosed area,

NOTF

Olnspsct and admin the {die speed after all other
er‘gine maintenance items have been pe'Iormed
and are wlmm spemfmatmns.

' The engine must be warm for accurate idle speed
inspection and adjustment.

Warm up the engine for about i0 minutes,
Turn IIie imuuie stup screw as required [0 ubtaii-
the spemfled idle speed

IDLE SPEED: 1,100 i 50 rpm

RADIATOR COOLANT

Check the coolant level otths reserve tank with the
engine 1 mining at normal operating tempel ature,
IhP. IeVaI should he between the “UI’I‘EI-I" and
”LOWER"icvc|l1ncs.

If necessary, add the recommended cooiant

RECOMMENDED ANTIFREEZE:
Hiqh quality ethylene glycul antifreeze cuntaiuiug
can asion protection inhibitors

Remove rho seat 19390 272i.

Remove the reserve tank filier cap and {Hi to the
“UPPER" level llne with a Iii mlqure of dls‘uiled
water and a"tifreeze.

Reirislali lire IiIler cap.

COOLING SYSTEM

Remove the lower cowl (page 2.3),

Check the radiator air passages for ciog: or
damage. ‘

Straighten hem tins, and remove msssm, mud or
other oastructmns wtth compressed air or iow
water pressure.

Rep‘aue the IdLIIaIUI iI LI'e air Iluw i5 restricted Dve
more than 20 “n hi the rad a'ing surface

 

LOWER LEVEL

1in

    

 

 

3-20

Inspect the radiator hoses lor cracks or deteriorat-
inn, and replace, it necessary.
Check the tightness of al'
fasteners.

hose clamps and

SECONDARY AIR SUPPLY SYSTEM

NOTE:

'This model is equipped With a built-in secondary
air supply system. The pulse secondary air
supply system is located en the cylinder head
COVEI.

0 lhe secondary air supply system introduces
filtered air into exhaust gases in the exhaust port.
The secondary air is drawn iiilu the exhaust port
whenever there is a negative pressure pulse in
the exhaust system This charged secondary air
promotes burning oithe unburned exhaust gases
and changes a curlsidewble amount at hydrocar-
bons and carbon mnnnxrne into relatively
harmless carbon dioxide and water.

 

Check the FAIR ir‘ulse Secondary Air Injection)
hoses borwcen rho PAIR control solenoid valve and
cylinder head cover lur duleriuraliuli, damage or
loose connections, Make sure the hoses are not
necked.

NOTE:

Ii the hoses show any signs of heat damage.
inspect the PAIR check valve in the PAlFl read valve
cover {or damage

Check the air suction hose between lhe air cleaner
housing and PAIR control solenoid valve lnr
deterioratinn, damage or loose connections

Make sure the hoses are not klnked, pinched or
cracked.

 

MAINTENANCE

 

 

 

 

 

 

 

/
EXHAUST FORT

 

 

PAIR CONTROL VALVE All? SUCTION HOSE

 

 

 

 

MAINTENANCE

EVAPORATIVE EMISSION CONTROL
SYSTEM (CALIFORNIA TYPE ONLY)

Clueuk the hose: beIween me iueI Ianx, EVAP
nanlster, FVAP purge mmmI solenmd valve and
thronle body for deterloratlon, damage or mass
connecnons.

 

Check me IVAP canister fo— cracks or other dam-
age.

Reier to the Vacuum Host: Ruulirg DIngdHI LaueI 1
(page 1-52) and Cnhla I; IIarnns< nmmng (mop / pURGE CONTROL
EVAP CANISTER SOLENOID VALVE

I 24) for hose connccfions

DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION

MEL—A

New: inspect and adjust [hi dn'w chain whily tho
engine is running

Turn the Ignhon swwch to "OFF”, Mace III:
motorcycle an as mne SIAM! and wn IhP
Irans'wiss'on inw neutral.

Check Live sack in the drive chair lower run
rmdway between the splockets

 

CHAIN SLACK: 25’ 35 mm 11.071 Aim)

CAUTION

Excsfliva chain slack, 50 mm 12.0 in! or more, may
damage the frame.

LubrIcaIe Ihe drIve chain with I 80 90 gcar 0i or
Pro Honda chain lube desig'ved apeciiIL-a‘ly I’Jl’ use
WIth OrrIng chmns WII-w of! any axcess M or chain
lubricant.

ADJUSTMENT

Loosen (he 'ear axle nut.

Tum bmh adiusting boils urm’l the current drive
Chiifl sIack Is UbldIIIeLJ.

Make sure me Ir‘dex marks on hath adjustevs are
aIigned WIm the ram and of the swmgarm.

TIgIIlen \he 'Ear axIe NH [0 (FE specifier: Iorque.

TORQUE: 03 \I-"I 0.5 kgIv'I , EFI (Ir-h)

 

 

3-22

Rcchcck the dnve chain slack and Ires wheel
roiation.

Lubricate the drive chain with 380-90 gear oil or
Pro Honda cnam Iuhs designed speciiicaliy for use
wirh O ring chains. Wipe off any excess ml or chain
lubricam.

Check Ihe drive chain wear indicalur label attached
on the Ieh‘ drive chain adjuster

lfrhe red zone of the indicator label reaches mg and
uflhe swinqarm, replace the drive chain wirh a now
one (page 3-24)

CLEANING AND LUBRICATION

(lean "19 chain with non-flammabie cu high flash
pcinr salvent and was it drv,

Be sure the chain has dried completely before
lublicazing,

Inspad ma drive chain lnr possible damage Dr
wcar.

Replace any chain [hat has damaged rollers, loose
fitting links, or otherwise appeals unseiviueable.
Installing n new chnin on harlly wnrn sprnckets will
cause the new chain to wear quickly,

lnspeci and replace sprocket as necessary.

Lubricale the drive chalrl with 380*90 gear oil or
Pro Honda chain iube designed specificaliy for use
With OArIng chains, Wlne on any excess oil or chain
lubricani.

SPROCKET INSPECTION

Inspect the drive and driven sprockei teelh for wear
or damage, replace ”necessary,

Never use a navy dl’lve nhmn nn wnrn sprncms
Borh chain and sprockets must be in good candi
lion, or the new replacement chain wili wear
rapidly

MAINTENANCE

NON-FLAMMABLE OH HIGH FLASH
POINT SOLVENT

\

CLEAN ‘\\

LUBHIUAIE

280*SOGEAROILOR «\2r
PRO HONDA CHAIN LUBE

 

 

  

 

 

 

 

 

 

 

MAINTENANCE

Chenk me attaching bolts and nuts on the drive and
driven sprockem,
If any are \ouse. lmque them

TORQUE:
Drive sprocke‘ bolt:
54 N-m (5‘5 kgf—m , 40 lbflfil
Driven sprackei nut:
108 N-m (11.0 kgf m , 80 [b' it}

REPLACEMENT

Thu: mnfnrrycln usns a dnve chain wnh a staked
master lvnk.

Loosen me drive chain (page 3722).

A>srmb|e the special tool as shmwn

TOOL:

Drivo chain tool at 07HMH-Mfi701030!
07) 1M! l-MIHO'IOH
(U.$.A. on yr

NOTE

 

When usmg mo spccxal wol‘ loHow the manufac-
turer’s instrucxion

 

Imam The mmpm pm pads n‘me maste' link from
the oumzdc at the chain. and remove mo Imk wuh
the drive chain (001 set.

TOOL:
Drlve chaln tool sel' 07HMH-MR10103 or
07HMH-MR1DWOB

ru SA my]

Remove the drive Chain.

 

  

 

/
UWVF CHAIN IUOL 5H

 

 

 

MASTER LlNK

  

 

 

3-24

MAINTENANCE

 

Hemove the excess drive chain links "cm the new
drive chain with [he drive chain tool set.

NOTE

 

Include the masrer link when you count the drive
chain links.

STANDARD LINKS: 110 links
REPLACEMENT CHAIN:

DID' DIUSDZVS-‘IZDZB

RK: RKSDLFOZ‘l 120LJVFZ

CAUTION:

Never reuse the old ch-ive drain, master link,
muster link plate and CHinas.

 

Assemble the new master |in|<, D-ring: and chew.

CAUTION:

insert the master link irom the inside a! the drive
chain, and insull the plate with the Identification
mark facing the outside.

Assemble and sel the drive chain tool sex.

TOOL:
Drive chain‘ool set OTHMH MR10103 or
07HMH-MR1D1OB

(USA only)

Make sure (he maexcr link pins are installed
properly.
Measure me master link pin length prujened from
the plain.

STANDARD LENGTH:
DID: 115*1‘55 mm “104" , 0,061inI
BK: 120— 1.40 mm (0047—0355 in)

Stake the maelvr link pins.

Make sure the pine ale staked properly by
measuring the diameier of Khe sxaked area using a
slide caIlpel.

DIAMETER OF THE STAKED AREA:
DID: 550* 5.80 mm (0.217 '0128 in)
RK: 5‘55 585 mm (D 219 0.230 In)

 

110 LiNKS ‘

 

 

O-RINGS l'lAlt

 

 

MASTER LINK PINS

 

 

 

 

MAINTENANCE

 

BRAKE FLUID

Aficr sIakmg, check the staked area or Me waster
‘ink‘crcvacks.

.l [haw I: anv waning, 'epIace me masrer link‘ ‘
U-rlngs and plalP GOOD NO GOOD

 

CAUTION:

A an" chain with a clip-typo master link must not
be used,

 

CRACKED

CAUTION

- Do not mlx dmerent types of fluld, as they are
no! compaliL-Ie with each olller.

' Do nnf allow Inmign matarial to enter the
system when filling the reservoir.

- Avoid spilling fluid on painted, plastic or rubber
pans Place .v shop towel over these parts
whenever the system is :ervr'cedv

 

NOTF

‘Nhsn (Ha quid IeveI Is Iow, Check [r19 brake pads
For weal (see bclowI. A Iuw [laid leve‘ may ue due
m wear at Ihe hrflkP midi II the hrakF pads are
worn. the caliper pisron is pushed our, and mis
accounts For a Iow reservoir IaveI. II the Drake Dads
are mm worn and We fluid level Is low, check the
erme system for Innks [see next mags)

FRONT BRAKE

Turn the hand‘ebar to [he Ieh so we reee'voir is
Ievel and cheLk the hunt brake ”ou reservoir Ievel
through lhe slghrglass ' .
II the Icch is near re :ower IeveI Ime, check me mLVEL UJ~

brake pad wear 1599 next page}. V

REAR BRAKE

 

PIdL‘e um IIIulurLycle on a leve surlace and support
It unngm pnsmnr

Check the rear brake fluid rsserva'lr level,

II \IIE leveI is near \"9 vower leveI line, check the
brake pad \NEaI 4552 naxt page)

 

3-26

BRAKE PAD WEAR

FRONT BRAKE PADS

Check the brake pad for weal.

Reniace the brake pads If either pad is worn to the
bottom of the wear limit groove.

Refer tn page1F-10 for brake pad repiacemenz.

REAR BRAKE PADS
Check the brake pad (or weak
Replace the brake pads if either pad is worn to the

bottom of the wear limit groove;

Refer iu page i5—11 ior brake pad replacement,

BRAKE SYSTEM

INSPECTION

This model is equipped with a Linked Braking
Sysmm. Check the from and rear brake upelaliun
as follows:

Place the motorcycle on its center stand and shift
the transmission inlo neutral.

Push the Inn irnnr brake finilpfl! upward by hand.
Make sure the rear wheel docs not turn while me
left from brake caliper is pushed.

 

 

 

 

MAINTENANCE

 

 

 

 

REAR WHEEL

 

3-27

MAINTENANCE

fly

QPAKI |‘LL)A_

Supnon II‘E motorcvme m ra‘se (he ’run. leecI ufl
the around.

CAUTION

 

Do not Nae Ihy ailfiltel as ajack point

Appwme rear brake pedal,
Make sure the bent whee‘ (Inf-w nm mm thIe the
mar brake peda‘ IS apmed

 

Immy anpry the brake Iavsr n' medal and mack
mama airhas cmcrcdrho SVGYCm

If m lavar Dr pada‘ Iaals sofi or sponqv when
operated bIeed the ah ham We system

Inspect the brake rose and fittings for dcwrioration,
cracks and signs 0' Ieakage

Trgmén any moss ‘ nmgs

Reolace hoses and fimngs as required.

ReIev u) page 155 {m brake bleeding prucedu'e3.

BRAKE LEVER ADJUSTMENT

The :Iw'stance between {ha top DIN-e make yeve» and
the gnp car‘ be adjusted by turn ng the adjuster.

DIRECTION A. Bvsku levev [urlhev awAy hum [he

0W1
DIRECTION B: Brake \evcr doaerta m»: grip

CAUTION.

Align the arrow on the brake lover With the index
mark on the adiusnrn

 

 

3—28

MAINTENANCE

 

BRAKE PEDAL HEIGHT ADJUSTMENT

Lnasen the lack nm and turn the. push md iil'i'll my.
correct pedal height is obtained.

BRAKE LIGHT SWITCH

NUIE.

The Font biake light swim: dues nut reunite ddgusI-
mam

Adjust the brake iight switch so the brake light
co'fles on Just prior to the brnkr. actually being
engaged.

ii (lie liglil In”: Lu come on, adiusl the switch so the
iight ramps rm atthe proper time

Hold the switch body and turn the adjuster, Do not
turn the switch body‘

HEADLIGHT AIM

An m w Hut—i if
amsred fiead/igir
may DWI? (1'?
coming cuver: or
w may fair In liy’r,’
me mad ’0' a safe
distance

Ari/451 me
neaaiighi beam as
SDEDI’AEG DV lDL‘L”

’aWS aIV’J

reguiahms

Piau: lIIe ~'IUlUiLyLia mi 4 level surface.

Adjust the headlight beam vemcailv by turning the
verticai beam adjusting screws.
Acluckwise tutelruli move: the bum" up.

Horizontaily beam adiustment are made using the
horizontal beam adjusting >L‘rew:

A clockwise 'mahnn moves the heam inwmd me
right side oithc ridcr‘

HEADLIGHT BEAM ADJ LISTER
\
\

 

‘

KE PEDAL

 

 

 

HORIZONTAL BtAM ADJUSIEH

 

 

 

 

3-29

MAINTENANCE

 

CLUTCH SYSTEM

CLUTCH LEVER ADJUSTMENT

The distance between the top of the clutch lever
and the grip can be adjusted by turning the adluster.

DIRECTION A: Clutch lever Iurther away from the
sun
DIRECTION 3: Clutch Icvcr closer (0 the grip

CAUTION:

Align the arrow on the clutch lever with the indnx
mark on thy adjuster.

CLUTCH FLUID

CAUTION'

 

- Do not rnlx diffs"!!! typos of fluid, as [In-y are
not compatible with each other.

- Do not allow farel'an malarial to enter the
system when filling the nurvoir.

- Avoid spilling fluid on painted, plistl‘l; or rubber
pans. Plus: a shop tnwel am these part:
whgnevsr the system is serviced.

 

NOTE

Whan the fluid level is low, check the unlit: >y>Iem
f0l leaksr

Turn the handlebar lu lIIE light so [he Ieselvoir is
level and check the clutch Hum rPSFJVOIr level
through me sight glass.

Firmly apply the clutch lever and check ll'lnt no air
has entered the system.

If the lever feels soft or spongy when uperaled,
bleed the air from the system

inspect the clutch nose and fittings lot deterioratiun,
cracks and signs of leakage.

fighlen any loose linings

Replace hoses and fittings as required

ReIel to page 9-4 ior hydraulic dutch hleprimg
procedures.

 

 

 

LOWER I FVI’I IINE

 

 

 

 

 

\
CLUTCH HOSE

 

3-30

MAINTENANCE

SIDE STAND

Suppnmhe motorcycie on a ievcl surface.

Check me side smu swing for damage a» ioss m

tension

Check the sde siand assembly fov smoox“

movement and lubricate Ihe siue stand pivut II

necessaxy.

Check the: side stand Igni'lon cut-off system:

-Si( asm’dc mo moIOiCyCIe and raise me side
stand.

—Start the engine with the transmission In neutral,
than shift the transmisswon mm gear. with me
clutch lever squeezed

*Muve the side sLaHd full duwn.

The pngms shmnn smp as the Slde stand IS
lowered

H time ‘5 a DvobIen'i With the system, check thP we
smnd swrrn [seal on 19).

SUSPENSION
M,

Laose, warn or damaged suspension parts Impnir
motorcycle stabiliiy and annual Repair nr replace
any damaged components balom riding. Riding a
motorcycle will: faulty suspension increases your
risk of an accldent and possible infury,

FRONT SUSPENSION INSPECTION

Check me acfion of the forks by operating the (rum
brakes and Eulnpvessing me Iront suspenswofl
severni "mas

Check the entire assombiv for signs of leaks,
damage or luuse Iasleners.

Repiace damaged components wnmh nannm he
repalred.

Tigmen ail nuts and boils.

Hater In sentlnn TI Inr Inrk service.

REAR SUSPENSION INSPECTION

Support (he mciorcycie on its center stand and
raise ille veal wheel uIHhe gluuud.

Ho|d (he swingarm and move me roar wncci
sideways with 50122 to see H the wheel bearings are
worn

 

 

MAINTENANCE

 

Checkfov worn ewiugarm Dealings by webbing [he
rear swmgarm and avemptrng to move the
Swingormsidcxosidc,

Rep‘acethe bearings ifany \ooseness is noxeu‘.

Check the actwon of the shock absorber by cow»
pressmg wt seven-fl llmes.

Check me entire shock absorber aaacmbly fo- sxgns
of Ieaks, damage or loose Iasleners.

Replace damaged components which cannot be
renewed.

Tighten an nuts and bolts.

Refer to secnnn141nr shnrk Bhsnthr «#va

REAR SUSPENSION ADJUSTMENT

REBOUND DAMPING ADJUSTERS

CAUTION,

0 Always start on full hard when adjusting the
damping.

- Do nar turn tha adjuster straws morn than the
given positions or (he adjusters may be
damaged.

 

{he rebound dampmg her he adjusted by turning
the adjuster.

DIRECTION H: Inueasus [he dan'pIHg fume
DIRECTION S‘ Uenrenses the damping Inrne

Turn ma rebound adiusrar clockwise until u stops,
then mm the adjusts-I coumelclockwise.

REBOUND ADJUSTER STANDARD POSITION:
One turn out "0m 1qu hard

NUTS, BOLTS, FASTENERS

(:herk rrw all nha<si§ nuts and hnIrs are trghtened
to mc'r corrccnorquc valuos \nagc1 13!,

Check ma: a‘l safew clvps, hose c‘amps and cable
stays are in :JIate and properly secured

 

 

3-32

MAINTENANCE

 

WHEELS/TIRES
NC'E

Trre pressure shou d be checked When (he tires are
card

RECOMMENDED TIRE PRESSURE AND TIRE SIZE:

—fi
r rmwr REAR I
Tm zsorzsowzr

 

 

Ti'e pressure 290 I .
kPa (kgI/cm’, pairrr

   

 

Tire 5172 120 ‘70 ZR17 130/55 ZR17
r IbMWr 173W1
Tire Bridqssrone‘ BT57F 375m ;
jiano ‘ RAQJA_LG RADIALGi
flaky) : mog- J 0205 G
Mmhclin ‘ MACADAM MACADAM ‘
_ 7 7 90x5 soxsw _J

Check the fires Ior nun, emhflddfld naiIs, or orher
damage.

Check [Ire Irunl and rear wnaals (or trusness {refer
Zfi sacnon ‘13 and 14)

Measure the tread dcprn at the ccnrcr of rho mes
RepIaL: we li'es when the mast: depth reaches the
rmlnwmg Imus

MINIMUM TREAD DEPTH:

FRONT: 1.5 mm r006 Em
REAR‘ 7 [1 mm (0 08 mt

STEERING HEAD BEARINGS

NOTE

 

Chpck that the canilo cables (10 nu: IHLerIere with
handlebar rotanon.

 

Suppm the mnmrnycle <srure|y and raise the front
whee! affirm ground

Check lIrul rhe nand‘ebar moves (veew from aide to
srde , ,

I? the handlebar mnves unevenly, binds, or has
vertical movement, insaccr rm: srccrmg head
bearings (Sthun 13».

 

 

LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

<_4_.._ 1—4—-

 

 

 

/ FRONT
BALANCEH

   
 
  

OIL COOLER /

 

 

 

 

// BALANCER IDLE
GEAR

H

 

 

 

 

 

 

RF REAR BALANCER

 

 

 

 

 

 

 

OIL FILTER CARTRIDGE RELIEF VALVE OIL PUMP

 

4-0

4. LUDHIDA I IUI\I DVD I EIVI

LUBRICATION SVSTEM DIAGRAM 4>0 OIL STARAINEH/PRESSURE RELIEF

VALVE 4.4
SERVICE INFORMATION 4-1

OIL PUMP 4-8
TROUBLESHOOTING 4-2 .

OIL COOLER 4-13 i
OIL PRESSURE INSPECTION 4-3 ‘

 

SERVICE INFORMATION u

GENERAL

D Whnn thn Origin. must be running (a do some wark, make sure the am: is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to
death. Run the engine in an open area ar with an exhaust evacuation syn-m in an cnclosnd am.

- Used englne all may cause skin cancer i! rnpnatadly [aft in coma“ with the skin for prolonged periods. Although this is
unlikely unless yau handle used oil on a daily basis, it is still advisable to thamuahly wash your hands with soap and
water us soon .15 possible after handling used ail. KEEP DU T OF REACH OF CHILDREN.

 

 

OTIIe UII pump can be serviced withthe engine installed In the frame,

. lhe sewing procedures In this section must be ocrformcd with the engine oii drained.

- When removing and InSIBIIing the oil pump, use cars not to alIow dust or divl to enter the engine,

. H any portiuu or the UH pump is wum beyond the specified service “mm, replnnn the on pump as an assembly.
0 Aherthe OiI pump has heen Installed, check that there are no oil ieaks and that oii pressure I: correct,

SPECIFICATIONS

Unit: mm (in!
ITEM STANDARD SERVICE LIMIT

igtellflDUSthEIln—tpqfi

4sna.9usm,4,olmpqtl V —
___, W .. Atou. filterchangc 3.9 11 14.1 US 03.3.4 imp qt» -., 7
Recommended cngmo or! HONDA GNA 4-:lvuke uil an equivalent ‘ 77
motor oil

AFI service classification SF or SG i
Viscosity: SAE 1ow740 ‘

 

Engine oii capacity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Oil pressure at oii pressure switch 490 km: (5.0 kgt/cm1 , 71 psi)at
,, I am!) rEmfIHn ”(2/175 {t

OII pump mmr reed pump ‘7 [in clearance 0.15 IUDQSLmaXt 7 ., (0.008)
Body ciearance 0.15-0.2i (000641008) 0.35 (0.014) W

_ Side clearance 0.04*0.09 (0,002’0 004) ‘ , 12 (0.005}

CooIer pump i Tipciearance 01am OUSImax. fl 0.20 (moss

Body clearance D 0.21 (ODDS-0.008) 0.35i0.014i

i Side ciearance 0.04—0.09 (0.002’000‘1) 0.12 (0.005I

 

 

 

4—1

LUBRICATION SYSTEM

TORQUE VALUES

Oil drain boll

Oll filter boss

Oll pump assembly flange boll

Ull pump driven spmnkat hnlt

Oil strainer nut

Oil return Dina bracket bolt

Oil filtel canrldge

Dll pressure swrmh

Oil pressure switch wirc termlnal screw
Oil Dine maunrinq bolt

T00 LS

Oil pressure gauge
Oil pressure gauge attachment
Oll filter wrench

TROUBLESHOOTING

Engine oil level too low
- Oil consumption
I Exll'sl Hal oil leak

o Worn piston ring or incnrrect plslol'l ring installation

~Worn valve guide crscal

Low or no oil pressure
0 Clogged Oll nrlrlce
- Incorrect oil being used

No oil pressure

- Oll level too low

I Oil pump drive sprocket broken
. Oil pump damaged (pump shall)
I Internal oil leak

29 Nm (3.0 kgf-m , 22 inf-fl]
18 N m (1.8 kgfm , 13 lblfi)
13 N-nl [1.3 kgl-m,91bf-ft)
15 Nm ll 5kgf-m, 11 lbffl)
‘12 N«m (1.2 kgf-m , 9 Ibf‘ftl
12 Nrm ler kglm , 9 In? R)
10 N-lrl (lo kgl-rrl, 7 lnl-ll.)
‘l? N-m (1‘2 kgfrm , 9 lbflfl)
2 N4“ l0.2 kgl-m , 1.4 lbf‘fll
12 Nm (1.2 kgl-m ,91bff1)

0750645000000
075104220100
U7HAA-l’J701nfl

Apply a locking agentto the threads.
CT bolt.

Apply a locking agent to the threads
U-nuL

CT bolt,

Apply clean engine oil to llle O-rirlgr
Apply sealant to lhe threads.

Apply a locking agent to the threadsr

Equivalent commercially available in USA.
Equivalent commercially available in USA.

Low oil pressure
- Clogged oil strainer screen
- on pump wurn or daruuguu

0 Internal oil leak

- Incorrecloil being used
I Low oil level

High oil preuure
~ Plugged oil filter, gallery, or motoring orifice
0 Incorrect all being used

 

LUBRICATION SVSTEM

OIL PRESSURE INSPECTION

NOTF

ll the oil pressure indicator light ’sma ns on a few
seconds, check the indicator system before chock
mg the nll pressure

check the oil level (page 3-17).

Warm up the engine to normal npera'lng rpmppra-
tura lapproximately 80 cC/176 ‘Fl.

Stop the engine and disconnect the oil pressure
swltch ers. mnnnrtmr lrnm the switch

 

Remove the all pressure switch and connect an oil
plessule gauge allu alldu‘unelll lo the switch hole.

TOOLS:

Oil prassura gauge ‘ 07506 3000000
lEuulValel‘l
rnmmprrially
avallable in U.S.A.l

Oil prossure gauge 075104220100

attachment (Equivalent

commercially
available ln U.S.A.l

Sta" tbs finglne and Increase tre rpm to 5,430 rpm
and readtne oil pressure

 

OIL PRESSURE: , Do not apply sealant m ‘he lrrsnn I
AROkPaankgilcm’,71p<llat5£00rnm head3r4mm (0,1,0: m 1
lso°Cll7s=l=l ;

Stop the engine and IEHIUVE the luul>.
Apply sealant tn the threads nl the all prnssllre
switch.

 

Instalianctlghtenlttnl'la spemnen: 'qllF
TORQUE: 12 N~rrl (1.2 ng-m , 9 lbf-fi)

CAUTION:

Yo prevent crankcase damage, do not DvEIiiglltEn
the switch.

Connect rhp oil pressure switch connector, tighten
the terminal screw to the specified torque.

TORQUE 2 N~m {0.2 kngll ,1.4|th}

 

 

LUBRICATION SYSTEM

OIL STRAINER/PRESSURE RELIEF VALVE om
REMOVAL

Drain me engine oii (page 3-18),
Remove Live exhdnl pipe image 242»

Remove lhc oi pan flange bo‘xs.
Disconnsci me oii mum pipe [IU'W the ‘uwei
crankcase and remove the Oil pan

 

    

   
  

Remove ihe bolt and oii nemm pipe mac-(Gt

RA KE
Hpmnve the mi remm pipe and o-nngs. B C T

 

OiL RETURN FIFE

Remove mo prossu’e rciisfvaivs awd Orr ng. RELiEF VA V ’

Remove the oil strainer and oil one set plate Wu:
and aims

 

 

LUBRICATION SYSTEM

Remove the oil strainer and gasket.

Clean the oil snainer screen

Remove the Dolls, oil wpe A, B and Orrings

INSPECT|0N

Check me operation of the pressure refief v¢|ve by ‘
pushing un Um plslon. '
Disassemble the. rAIIP.‘ valve hy removmg tho snap
rmg.

IllspuL‘L u".- p1$mnf0| wear, sticking nr damage
Inspert the spnng lnr weakness ov damage.

Assemble me renal valve in me levevse ordel oi
disassembly

INSTALLATION

Apply on \u me new o-n'ngs and mstall them nnm
the m1 pipe A and B.
Lnsxau the oil pipe A and B into the crankcase.

 

 

LUBRICATION SYSTEM

Apply a locking agcm to [he ‘EhC all nine moummg
boll threads.

Install and tighten the oil pipe maunlmg bolts 10 the
spemfled mrmle

TORQUE: 12 Nm l‘l,2 Kai-m , 9 leIl

Apply oil [0 the new gasket and insxali u onto the oil
slvdillel.

Install the nil stramn ln'n ma crankca<e wmla

alignlng Its grooves With [he has: and stud bolt in
the oil pump body.

lnslall We uil straiV'ev set plale align-Hg ll> Lul-Uuls
wvthfre ml plpes

Tlgmen the nuno the specified Iorque.

TORQUE. 12 Nan (1.2 kgl m , 9 lel}

Apply oil to the new O-Iing and mm“ it onto the
relief valve.

lnstall me relief valve "nm the crankcase,

 

 

4-6

LUBRICATION SYSTEM

 

hnstaH the new 0 rings OHIO ma 0:! rew'n pine and

_ _ _ ()‘LHEIURN PIPE
mSIaH ll Into me on pan.

 

 

Insxan the sex were and tighten the [)qu [U m
specified lulque.

TORQUE: 12 N m (1.2 kgf-m ,9 lb'vfl)

 

Clean the uII pan mating sulface thoroughly.
Apply Three Bond 17073 m m mun/men! to the
mating sudacc.

CAUTION.

Do not apply sealant man: than necessary/4

Apn|y m: to me new 0an and msfall n nnm me on
return Dipc‘

Insxall the oil pan while aligning me 0H return pipe
with the hole 1n the lower crankcasa

OIL RETURN PIPE,

 

 

LUBRICATION SYSTEM

 

Ten‘poran v ugmerr the AWL: buns first, then lights?
the a r halts m a crlssrm<< [1:11am m 2 3 steps

Instabl me exhaust pipe (page 2-24)‘
Fr I (he Llankcase wrur rechmenGei o'rl {page 3-
19}

NOTE

Aflpr rnQ'aHa'rn chem mm (here S'E *0 DII tacks.

 

OIL PUMP
REMOVAL

RPmnVer-‘fnlmw ng'
* C‘utch assemb‘v (page 9713}
*OH strainer and oil prpes (page 445}

d'ivcrdnvor‘ sprocket, crutch outer rude ar'd dr'we
cha‘n as an anenmw.

icmovc (he :hrzc flange bolts and oil pump asserrrv
ow.

 

DISASSEMBLY

NOTE

If any pmmon of me an pump ‘5 warn aeyonc the
specified servrce \imil, replace the oil Dump 25 an , ,
assemb‘v,

Straighten and remove the comer sin,
Remove the varve 5“,, :pvivrg and‘pressure relief
valvp

 

Checktw {”855er re.iel valve {0' wea' 0' damage

 

LUBRICATION SYSTEM

 

Remove me oil pump assembly boil. ASSEMBLY BOLT
/

 

Remove ma oil pump cover and dowel pins, COOLER PUMP SIDE-

Remove the water pump outer rotor and inner DOWEL ““5
VOCDIX

Remove the drive pim

(JUILH HUIUH

      

// a
INNE'R ROTOR
OIL PUMP' COVER DRIVE PIN

Remove (he oil pump spacer and dowe‘ puns FEED PUMP 5““:

Remove the lhrUSt washer. drive pln, feed pump DOWEL PINS

Outer rotor and mner romr from the oil pump body

 

DRIVE PIN /
WASHER OI! F‘UMF‘SF‘ACFR

INSPECTION

Temporarily install the oil pump shaft
InstaH the outer and Inner rotars mm the OII pump
body,

Meaulre the up mearanne fnr the feed and center
Dump.

SERVICE LIMITS,
Feed pump: 0.20 mm (U.UUB In)
Cooler pump: 0.20 mm 410.005 in)

 

 

LUBRICATION SYSTEM

Measure Ihc pump body cIearance for (he feed and
cDoIer Dump

SERVICE LIMITS:
Feed pump: 035 mm {0.014 In)
Cooler Dump. 0.35IIIIII (0.0141n)

Measure ma side clearance for the feed and cooler
pump using a stIaight edge and feelsr gauge

SERVICE LIMITS:
Food pump: 0.12 ‘nm (moo-5 im
Conlel pump 0 12 mm <0 00:- In»

 

ASSEMBLY
COOLER PpMP OUTER ROTOR
I COOLER P/UMP INNER ROTOR DOyEL PINS
I

OIL PW" BODY / / FEED PUMPINNER ROTOR
,
,

    
     

 

FEED PUMP
OUTER ROTOR

OIL PUMP SHAFT

/

, I ‘\
OIL PUMP COVER DOWEL PWS O'L PUMP SPACER

 

4-10

LUBRICATION SYSTEM

 

Install the lead pump outer and inner rotors into the FEED PUMI; SIDE:
oil pump body , . 3
Install the orl pump shaft through the oil pump

‘ ’Do’wsLPINs, , ,
bodyandinnerrotor. ‘ ' '

  
   
  

Install the drive pin into the hole In the pump shaft
and nlrgn the prn With the groove in the inner rotor
as shown.

Install the thrust waslrerr

Install the dowel pins and oil pump spacert

 

lnstall the drive pin into the hole in the pump shat? COOIER PUMP'SIDE: ' ' , I:

 

Install the cooler pump outer and inner rotor into , ‘
the all pump covert ”at:

-, our: ambit

     
 
 

 

Install the dowel runs.
Install the oil pump cover assembly onto the oil
pump bodvt

INNER noroa
on, PUMP

     

VER _, DRIVE PINK

Install and tighten the assembly bolt to the specir
erdIorque.

TORQUE: 13 Nun (1,3 kgl-m , 9 let)

Check the oil pump operation by turning the pump
shaft.
ll necessary, reassemble the oil pump.

Install the Oll pressure relief valve with its small
O.D. side facing the spring
Install the spring and sp

   

 

'“slanNG‘SEAT ” REILIEIEVALVE

 

4-11

LUBRICATION SYSTEM

 

Ho‘dthe spring sea and instaH a new coner :Jin ,, A
Benc the cotter pm semnew as mnmamd w m». ‘- \ .fiQQO-neafim
~ , N ‘V y .

iuus‘ration. _ /

      

INSTALLATION

shah grnnvfi

InstaH and ngmen the three flange mm securely.

Apply oi‘ to the clutch outer gmdc, oil pu'flp drive
sprocke‘, driven sprocke‘ and drive chazn

lnsrs’r MC arlpump InstaH the clutch outer guide, dnve/dnven sprockex
uwren sprocket and drive chain as an assembly.
Nylhl‘: OUT" ,

mark ram;
curwam‘.

 

4-12

LUBRICATION SYSTEM

 

pry a locking agent to the oil pump uriven
sprockal bolt Uneads.

Install and tighten the driven sprockcl bolvwasher
tn ms. specified torque,

TORQUE: 15 N-rn (1.5 kgf-m , ‘1! Inf-ft)

install the foliowing:

, OH strainer/oil pipe and oil pan [page 4-5)
—C|ulch assembiv (page 51-18)

After inmallallon, fili xha crankcase wixh leccll’n-

mended oil and check ma: there is no nii inks,
Check the oil ("fissure [page #3).

OIL COOLER
REMOVAL

0mm the engine oii may? 3-18)
riemnve me inwercowi and wind guard (Section 2).

Remove the oil uuulei has: joint mmmvmg bolts
and cooler hosss

Remove the mounting bolts, main Wire harness
guideand oiicooier.

Remove me uil pipe guide mounting bait,

 

 

LUBRICATION SYSTEM

 

Remuve the SH bulls and 0H cooler pipes and

O-rmgs
INSPECTION

Check the ow cooler nu nn<<age tor dogging or
damage.

Slvaighm» bent (in: wnh a small, Ila‘ made screw
driver and remove lvlaecls, mud or other

obsnucuons WIth campm.‘ an an

Check fur any oil \eakaqs from the oil cooler and
hnv

 

INSTALLATION

   

OIL COOLER

 

4-14

LUBRICATION SYSTEM

Apply clue" engine oil 10 the new Omngs, and
install them nnm the all cooler pipes
Install the oil cooler pipco mm the lowercrankcase.

lnslall and lighten the SH bolts

Inttall me ml plne gmde lo the cylinder block, and
lighten the bolll

lnstell the all cooler onto lhc bracketsl
lnamll me main wire harness guide umo the lell uil
cuoler mounting bus; as >|vuwn.

CAUTION:

DD nut crass thread a: overtighren the oil caaler
lower mnunrlng bolts.

 

 

 

LUBRICATION SYSTEM

 

Ayply clean engine UN to the new 04mg; and
irstall them onto the on cooler hose jUH"! flange

I‘man [he uil hose iuinls lo Hm ui‘ uuule: and
tigmen the bolts securely

Fill the crankcase with recommended engine oii
[page 3-16!, and Llleuk [ul UH Iuaks.

 

 

4-16

 

MEMO

 

FUEL SYSTEM [Programmed Fuel lnjectioin)

 

 

77 N>m1ZV2 kgf~m ,16lbf~ffi

 

5.FU[:L 8Y5 I thl (Programmed ruel IHIBCIIOHJ

 

 

 

 

 

SERVICE INFORMATION 5-1 STARTER VALVE
SYNCHRONIZATION 5-83
TROUBLESHOOTING 5-3
FAST IDLE WAX UNIT 5-85
SYSTEM LOCATION ('99) 5-4
BAROIMAP SENSOR 5-87
SVSTEM DIAGRAM ('99) 5-5
IAT SENSOR 5-38
SVSTEM LOCATION (After ’99) 5-6
ECT SENSOR 5-88
SVSTEM DIAGRAM (After '99) 5-7
CAM PULSE GENERATOR 5-83
PGM-Fl (PROGRAMMED FUEL
INJECTION) SVSTEM 5-8 TP SENSOR 5-90
PGM-Fl SELF-DIAGNOSIS MALFUNC- BANK ANGLE SENSOR 5-91
TION INDICATOR FAILURE CODES 5-12
ENGINE STOP RELAY 5-93
FUEL LINE INSPECTION 5—55
KNOCK SENSOR 5-93
FUEL PUMP 5.53
ECM (ENGINE CONTROL MODULE) 5-93
FUEL CUT-OFF RELAY 5-60
PAIR CONTROL SOLENOID VALVE 5-94
FUEL TANK 5-61
EVAP PURGE CONTROL SOLENOID
AIR CLEANER HOUSING 5-65 VALVE (CALIFORNIA TYPE ONLY) 5-95
THROTTLE BODY 5-88 0, SENSOR
(AFTER ’99 CALIFORNIA TVPE ONLVI 5-98
INJECTOR 5-76
I STARTER VALVE 5-79
SERVICE INFORMATION
GENERAL
mm

 

' Gasuline Is extrema/y flammable and is explosive under certain canditians, KEEP OUTOF REACH OF CHILDREN,

- Be sure ta relieve the fuel pressure while the engine is off.

I Bending or twisting the control cables will lmpalr smoozn operation and could cause the cables to stick or bind,

resulting in loss of vehicle cantml.

 

'Work in a well vemllmed area. Smoking or allowinq flames or spalks in the work area or where gasoline is “mad can

cause a fire or explosion.

 

FUEL SYSTEM (Programmed Fuel Injection)

 

CAUTION‘

 

 

O Do not apply commercially available carburetor cleaners to the de of the throttle bore, which is coated with
molybdenum.

- Do not snap the throttle valve from full open to lull close otter the throttle cable has been removed. It may cause
incorrect idle operation.

' Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris Irom entering the intake ports aller
the throttle body has been removed.

I Do not damage the throttla body. It may cause Incorrect throttle and idle valve synchronization.

0 Prevent dirt and debris l'rorn entering tha throttle horn, fuel hose and return hose, cloan thorn using comprossod alr.

' The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.

- Do not loosen or tighten the white painted bolts and screws of the throttle body lexcept wax unit mounting screwslt
Loosening or tightaning them can cause throttle and Idle valve synchronization lallure,

'Tighten the yellow painted bolls and screw of the throttle body to the specified tnrqulr Yellow paimod parts ol the
throttle body not shown in this manual should not be disassembled.

- Do not push the luel pump base under the fuel tank when the fuel tank is stored.

0 Always replace the O-ring when the fuel pump is removed.

 

NUIE.

 

- The ploglalnnled luel injection system is equipped with the Sell-Diagnostic System described on page 5-8. lithe warning
Indicator hlinks, follow the Sell-DiagnostIc Procedures to lemedy the plubleIIL

~ When checklnp the PGM-FI, always follow the steps In the troubleshooting tlnw chart lpage 5-12).

IThe PGM-FI system is provided wlth fallrsafc lunction to secure a minimum running capability cvcn when there Is any
lIouble in the system. When any abnormality is detected by the self-diagnosis function, running capability Is secured by
making use nt the ntin-IerIcal values of a situation preset in advance in the simulated program map. It must be
romcmbcrcd. however, that when any abnormallty ls detected In tour Injectors and/or the ignition and earn pulse
generator, the rail safe function stops the engine from tho mandpolnt of protecting it.

 

- rm row I system lnnatinn, see page 5-4, G.

-A faulty PGM Fl system is often related to poorly connected or corroded connectors. Check those connections heinre
proceeding.

- For fuel level sensuI illspecliuII, see section 19.

- The vehIcle speed sensnr «and; digital pulse signal to the ECM (PGMAFI unit] and computation, For vehicle speed sensor
inspection, soc section 19.

- Wllen disassembling The programmed fuel Injection parts. note the location of the O-rlngs. Replace them with new one;
upon reassembly.

- Belore disconnecting the lllel tIlhe, release the ltlel pressure by loosening the servIce check bolt atthe fuel tank.

' Always replace the scaling washers when the fuel tube banlo bolt is removed or loosened,

- Use a dIgilal tester for PGM—FI system inspection.

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

    

 

 

SPECIFICATIONS
IYEM 1 SPECIFICATIONS

Throttle body . 49 state/Canada type I GO Au D

identification number California type I ‘ __ V G0 40 B . 7_

Starter Iran/e yet-up... diliererlce . " 20 mm Hg

Base throttle vailvg for synchronization 7 .. No.3

Idlc speed 1, 100 1 SCI rpm

Throttle grlpfree play . 2— 6mml1’16-1J4Inl _4

Intake airtemper aimellsur resisldnce In 20‘Cr‘68“Fl ‘ 14 k2

Engine maiant Demure sensor resistance (at 20°CJI32=FI 273 , 23: it Q 7 W . ,7

Fuel i 7 tor resistance (at ZO‘CJGS‘FIV 13.07141. ks: I

PAIR s lenoid valve resistance (at 20’C/63°Fl _ _ 20- 24 Q I
”airlpulse generator peak voltage (at zoo/earl . 0.7 v .nlrrImun. 7
. Ignhlpn pulse generator peak VQLlf-lgn lat micrewrr I 0.7 v minimum

Manilold absolute pressure at idle > .. 7 ___» > . 7V 7 200 250 mn_1 Hg—

Fuel pressure at idle ’99; , 294 kPa I3. 0 kuflcm‘ 3}; 7 >

After :99 343 ltF'a 13 5 kgf/ij SD ps
Fuel pump flow lot 12 VI MlnImum 220 cm3 (I. 4 US 02, [.1 Imp oz) lor ‘IU seconds

 

 

5-2

TORQUE VALUES

ECT [E rlginc Coolarn Temperarurell’llleimu sensor
Knock sensor

Tliiunle body insulator hand screw

Thrnnlp. cable. bracket mounting screw

Fuel pipe mourning nut

Fuel pipe selling (mi!

Pressure relief valve lock nut

Sranervalve synchronization plate screw

Starter valve lock nut

Wax unil llluuming screw

Wax unit Ilnlr hrackP «crew

Vacuum lnmt plug socket bolt for synchronization
Fucl tube sealing nut (rnmnle body side)

Fuel lube balljo bolt (fuel (ank Sldel

Service thank hnll

Fuel pump mounting nut

Fuel filler cap boll

Cam pulse generatorcnvn SH mm

TOOLS

Puak voltage tester llLSA mlyl or
Punk vnliage adaplor

ECU test harness
lest plrl box

TROUBLESHOOTING

Engine won't to stun

- Intake air leak

I Fuel volulaminatedi’deterlorated

. Plnched nr nlngged fuel lube

- Faulrv fuel pump

- Clogged fuel filter

- Clugguo‘ fuel injector mm

- Sllnklng fuel lnjector needle

- Faulw (qu pump operating system

Engine stall, hard to start. rough idling

o lrllake arr leak

- Fucl comaminaled/‘deteriuralad

I Plnchad or Clogged fuel tube

. idle speed misadliismn

0 Starter valve synchronization misadl'uslsd

FUEL SYSTEM (Programmed Fuel Injection)

IO N-ml1l] kgf-m , 7lb1-fl)
31 N-m (3.2 kgf-m , 23 lell
See page 1-15

3 Nil“ (0.35 kgf-m 15mm»
10 MM (1 O kgf-m , 7 lDf-fil
22 N-m (2.2 kg( m , 16 Ithl
27 N m (2.8 kgl-lll , 20 (bf-h)
1 N-m (0.09 kgf-m , 0 7 lhl-fll
2 N-m (0 1H kgf-m , 1.3 (bl-I‘ll
5 N m (0.5 kg! m , 3.6 (bf-h)
l N m (0.09 kgf—m , 0.7 "3“!)
3 N-m (0.3 kgf-rn . 2 2 lhl-hl
7? Nim (2,2 kgflm ,16Ibf-fl)
22 N m (2.2 kgf-rn ,16Ibl-fl)
15 Mini (1.5 kgldl‘ ,11lbflft)
12 N-m(12 kgflm , 5 lhf-ftl
2 Nvm (0.2 kaf‘m ,1Jlbfhl
12 N m (1.2 kgV-rn , 9 Ile)

07HGJ-0020100 with

Urnul, Yellow palm
Velluw painl
Yellow palm

Wlllle paint

See page 5 51 forligmening sequence

Commerninlly available digital mullimeter (impedance 10 MQ/DCV

minimum)
07WMZ-MBGO‘IOO
O7WGZ—00101DO

Backfiring or misliring during acceleration
- Ignmon syslcm malfunction

Poor parlormance (driveahilityl and pour (uel economy
I Pinched or clogged fuel tube
- Fuulw pressure regulator

 

5—3

FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM LOCATION ('99)

 

TP SENSOR
CAM PULSE GENEHAIOR PRESSURE REGULATOR

   
  
 
 
   
 
 
  

FUEL PUMP
I
( IGNITION PULSE GENERATOR

FUEL CUT-OFF RELAY
ENGINE STOP RELAY
BANK ANULI: SENSOR

I'IARO SENSOR

 

 

KNOCK SENSOR VEHICLE SPEED SENSOR
FULL NAME ABBREVIATIONS
Manifold absolute pressure sensor Magserrsur
Barirlerrm pressure sensor BAnn sensor

 

 

Thromc poailion sensor
Imake air temperature sensor

Engine coolarrgremgerature sensor ‘ 7 , ,, ,
Engine control module . I ECM

 

 

 

 

 

 

5-4

FUEL SVSTEM (Programmed Fuel lniectinnl

 

SYSTEM DIAGRAM ('99)

/

(lfll ml
lll,

 

 

(1) l Englne slop relay (lel Cam pulse generalOI
l (2) ‘ Main fuse B (30AI (19) PAIR check valve
‘ (3] ‘ Engine stop swilch (20) [C1 sensor
(Al Sub-luse (10Al (21) Knock sensov
(5) l lgnltlnn swllnh (22) Ignilion pulse generator
‘ 46) 1 Main fuse A (30A) (23) Waler temperature meter
l (7) 1 Bank angle sensor (24) Fuel mil-arr relay
(8) l Sub-fuse l10Al IZSl Fuel pump
{9) Banerv (26) Vehicle speed sensor
(lol 3 Pressure regulator (27) Neutral swltnh
('l'll l IAT sensol (28) Clulcl’l switch
(17> l Spark plug (29) Side stand swhch
113) ‘ PAIR solenoid valve (30) Malfunction indicator
114) l T? sansor (31) Sen/mp. check conneclor
l15) ‘ BARO sensor i , (32) Tachomcler
116) 1 MAP sensor (33) Purge control solenoid valve (Calilnmla type only) i
117) ’ Injector (3M EVAP-canister

 

 

 

 

 

5-5

FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM LOCATION (After '99)

 

PAIR SOLENOID VALVE

TP SENSOR

\
CAM PULSE GENERATOR \ PRESSURE REGULATOR
I

     

ENGINE STOP RELAV
BANK ANGLL SLNSUH

    

INJECIUH

ECT SENSOR /

I
I

KNOCK SENSOR I U; SENSOR FUEL CUT OFF RELAY

VEHICLE SPEED SENSOR

 

 

 

 

FULL NAME ‘ ABBREVIATIONS
Manifold absulgte Qressure sensor I 7 MAP sensor #
Throme posmon senior 1’? sensor
_l[\take air temperature sensory IAT SEIrsur
Engine coulanl Lernperatul 9 sensor rCT sensor
anme nonrrnl module , ECM

 

 

 

5-6

SYSTEM DIAGRAM (After ’99)

FUEL SYSTEM (Programmed Fuel lniecfionl

 

ol

(9)

l W .
\r -,

((—7 m 3
M; _ ta

r'

 

 

 

 

 

(1) ) Engine smp relay (13) ' PAIR check valve

(1) ‘ Main fuse B (30A) (19) Knock sensor

[3) [ngma slop switch (20) ECT sensor

(4) Sub fuse (10A) (11) Ignmnn pulse generator

(5) Ignition swilcll (22) 0: Sensor (Calirornia xype only) 1
(6) Main fuse A (30A) (23) Waler lenrperature meter

(7) Bank angle sensor (24) Fuel cut-off relay

[8) ‘ Sub-(use ()OA) (25) Fuel pump ‘
(9) Battery (26) ‘ Vehlcls speed Sensor

(1n) Pressure regulator (27) ‘ Neutral swltch

ll 1) IAT sensor (28) ‘ Clumh swrtch

(12) Spark plug (29] Side stand swilch

(13) PAIR snlnnold valve (30) : Malfuncliuni dicator

(14) E TF sensor (31) Service the k nonnemor

(15) v MAP sensor > (32) Tachomcrcr

(16) Injector (33) Purge comrol solwruid valve (California type nn)y)
(1 I) Cam pulflgenararor (34) EVAE‘_canisger (California type only)

 

 

 

 

5-7

FUEL SYSTEM (Programmed Fuel Injection)

 

PGM-FI (PROGRAMMED FUEL
INJECTION) SYSTEM

SELF-DIAGNOSTIC PROCEDURES

Place llie riiulurcycle UH its side stand.
Start the engine and let it idle

If the malfunction indicator does not light or blinkl
[he sysieiii has no memory at problem dalar

If the malfunction indicator blinks, note how many
times the malfunction indicator blinks. and
determine the cause of the problem (page 5712
lliiuugii 5-54).

N01 E.

The malfunction indicator will start Liliiikiiig only
with the SIG! stand down and with the engine off
lcnginc stop switch on) or engine revs are below
5,000 rpm. In any other conditions, the malfunction
indicator will illuminate and slay on.

it you wish to mad the FGM FI memory Ior trouble
data, perform the following:

Turn the ignition swrtch in "0| F"

Remove the seal [page 272),

Short the PGMJI system service check connector
terminal: using a jumperwire.

 

'99:

MAIFUNCTION INDICATOR

 

 

 

AFTER '99

MALFUNCTION INDICATOR

 

 

 

 

 

JUMPER WIRE

 

fig”

 

SERVICE CHECK CONNECTOR

 

  

 

 

SC 51179 "19 InglllE
slop switch is in
the mposrlian.

Be sure mo Engine
:lUIJ switch min
the on position

FUEL SYSTEM (Programmed Fuel Injection)

Turn the igriiliun switch to “ON”.

If the ECM has no self diagnosis memory data, the
malfunction indicator will illuminate and stay lit,
when you turn the ignition switch to "ON".

It the ECM has self diagnosis memory data, the

malfunction indicator will start blinking when you
turn the ignition switch to "ON”.

NOTE:

 

Even if the FGM-FI has memory data, the malfunc-
tion indicator only illuminates (does not blink)
under engine running conditions (side stand up and
revs above 5,000 rpm)

 

 

Note how many times the malfunction indicator
blinks, and determine the cause of the problem
(page 512 through 55‘),

SELF-DIAGNOSIS RESET PROCE-
DURE

1.Turn the ignition swrtch to "OFF",

Isnnrt the service chock connector of the PGM—FI
system using a jumper wire.

3.7urn the ignition switch to "ON".

4. Remove the jumper wire from the service check
connector.

5,Thc maifunctiun indicalor will illuminate for
about 5 seconds.
While the indicator is lit, short the service check
connector again with the jumper wire.
The self-diagnosis memory data rs erased If the
maHunction indicator turns off and starts blinking.

NOTE

 

oThe service check nonnector must be jumped
while the indicator is lit, tf not, the malfunction
indicator will not start blinking.

. Note that the’selt diagnosis memory data cannot
be erased it you turn off the ignition switch
before the malfunction indicator starl: blinking.

 

if the. malfunction indicator blinks 20 times, the
data has not been erased.

 

 

MALFU NCTION INDICATOR

 

 

SERVICE CHECK CONNLCI OR
JUMPER writ

   
       
 

1.1. \1/ ,

 

 

 

 

FUEL SYSTEM [Programmed Fuel Injeclionl

 

PEAK VOLTAGE INSPECTION PROCE-
DURE

NOTE

-Use ms p'ocedure (or me ignition lesc
generaml and Lélil uulm: gellerdlor mspecrion.
nChenk all syvpm mnnprnons belore lnspeclIoIl.
if m: avslem IS disconnected, Incorrect pfifik

vullaqs miqhtba measured,

ICheck cyliwde: Lumplessio‘v and check that al
spa'k plug: m nvallpd correctly

0 Use the recommended dlgl‘al mnltlmetav or rnm-
merciallv available digilal multimeter With an
impeaanw oI 10 M .Zr’DCV IllIllIlllhlll

oThe display vamp (mum dppend ng upon me
internal i'fipccancc oi the mullimeler.

ODIscumveCl :r-e luel pump connecto' belore
necking the peak voltage

Suppu'l me rear and ol the fuel iank [sage 5551.
Disconnect the fuel pump 2|) hmwn rmnprvnr

Cm- ‘ELI we peak voltage adaptor to (he digital
mmmmpr

TOOLS:
Peak voltage lesler (U.S.A. only) or
Peak voltage adaptor n7ilmrnn7n1on

with commercially available digital multimeter
Iimpsdanci 10 M . DCV minlmum)

m__

Avoid touching ths tam: pmbss to prevent
electric shock.

TEST HARNESS CONNECTION

Remove the scat (Dag: 2 2)

Discnnnpn the ECM 22F black and 22p light gvay
connectors iromthe umL

 

 

l 22PmACK .D'\l
\

 

AGE AIDAPTOR

 
 

NF .IDH

22F LI(EI II (WA

 

 

\
V C(JNNI'CTOT‘I

 

5-10

FUEL SYSTEM (Programmed Fuel Injection)

 

Connacl lire lest harness to lhe (as! pin boxr

TOOLS:
ECU test hlmess 07WMZ-MBGO‘IOO ‘
Test pin box 07WGZ 0010100

Connect lhc ECU (es! harness between the main
wire harness and lhe ECM

NOTE

 

Match the connecmr colars hmween the main wire
harness and test harness.

 

ECU TEST HARNESS

TESY PIN BOX

  

 

TEST PIN BOX TERMINAL LAYOUT

The ECM conneulul terminals are numbered as
sIIuwII in the IIIUstMImn.

The test pin box No. 1 Iu Nor 22 terminals are for
ma ECM ZIP black connector A1 to A22 rerminalsr
Tlretesr pin box usesthe No.31to No 52 terminals \
inr me ECM 22F Iighl gray connuclor BI to n72
terminals.

Example:
ECM terminals: A4 (H-AS i»)
Tesl pin box terminals: ND. M i ) No.8l-I

Terminal conversion chart

___.__.—4—
r

_.—— rfi
VIEW FROM WIRE HARNESS SIDE:

 

A122? BLACK CONNECTOR
B: 22F LIGHT GRAV CONNECTOR

 

 

 

i_r 22? black No. Test pinflnx Nn.
A1 ; 1
A2 2
V I
, A22 22

22P iighr gray No. Test pin box No
8‘ i 31

82 I 32 I

I I
an r 52

 

TERMINALS FOR ZZP BLACK CONNECTOR

  

TERMINALS FOR 22F LIGHT GRAV

CONNI’CTOR

 

 

 

5-11

FUEL SYSTEM (Programmed Fuel Injection)

 

PGM-Fl SELF-DIAGNOSIS MALFUNCTION INDICATOR FAILURE CODES

- The PGMVFI malfunction indicator denotes the failure codes (the number at blinks irnm n to 20), When the indicator lights
lor 1.3 seconds it is equivalent to 10 blinks. For example, a 13 second illumination and two blinks (0.5 second >1 2i at the
indicator equals 12 blinks. Follow code 12 on page 5—30.

- When more than one failure occurs, the malfunction indicator slruws the blinks in the order of lowest number to highest
number. For examplc, if the indicator blinks once, then two times, two failures have occurred. Follow codes 1 and 2 On
page 542,

 

 

Number of PGMVFI
malfunction
lndinator blinks

41:?

Stavs lit

 

Causes

I Open or short circuit at the input power IlnF.

ol the ECM

- Faulty engine slop relay

' Faulty engine stop switch

- Faulty ignition switch

- Faulty bank angle sensor

. Faulty ECM

' Blown mam fuse El (30 A)

I Blown cnginc stop fuse (10 Al

' Blown luel pump fuse (30 A)

- Open circuit in engine slup swilcll ground
wire

0 Engine stop switch in off position

Symptoms
[lull-sale contents}

- tnglne does not sum

 

Rater to
page

 

 

0

Nn blinks

if}

Stays lit

3- Blown malfunction indicatol uulu

" Open Cll'Cull‘ in mnltunnnnn indicator ground

‘ wire

0 Open or short circuit in mallunction indicator
wrr-e

" Faulty ECM

‘0 Slrult circuil in the malfunction indicator
wrre

' Short circuit in sen/Ice check cnnnentnr wrre

Faulty ECM

 

l' Engine operates normally

- Engine operates normally

 

ii}

Rllnks

. Lnnsn or pom contacts on MAP sensm
connector

0 Open or short circuit in MAP sensor wire

~ Faulty MAP sensur

 

2
l
7 l

{3

I'llmks

{,1

Blinks

 

{>2

Blinks

- Loose or poor connection of the MAP sensor
vacuum hose
- Faulty MAP sensot

- Loose or poor contact on ECT sensor
I Open or sllutl circuit in ECT sansorwlre

‘ laulty [CT sensor

 

- Loose or poor contact on TP sensor
connector

- Open or short circuit in Tl" sensor wlre

' Faulty TP sensor

- Engine operates normally

I Engine operates normally

 

' Hard start at a low temperature
lsimulate using numerical values;
80 ”Cr’176 "Fl

- Poor engine response when
operating the throttle uulcklv
(simulate using numerical values,
Throttle opens 0V]

5718

 

 

Q.

Blinks

 

' loose or poor Contact on IAT sensor
" Open or short Circuit in mi se sor wrre
l- Faultv IAT sensor

 

 

0 Engine operates normally
(simulate using numerical values.
20 ”C/Ssr'Fl

 

 

 

 

5-12

FUEL SYSTEM (Programmed Fuel lniection)

 

Number of PGM-FI

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Blinks ' Faully knock sensor

 

 

 

 

malluliction CEUEBE "a liyrfnpmrrr ) Refer ‘0
indicator blinks ‘ i ' a e m” 0"“ ‘ ”a“
I Loose nr pnor Contact on BARO sensor I Engine operates normally at a low
‘ connector ‘ altltude
10 ' Open or short ci 'i in BARE) sensor wlre ‘- Engine idles roughly Hl a high altitude 5.25
l I Faully BARO sensor (simulate using numerlnnl
l Blinks l 760 mm Hg/‘l,013 hPal
‘ - Loose or poor contact on vehicle speed 0 Engine operates normally
sensor connector
11 {3. " Open or short circuit in vehicle speed ierlsul l 5.23
connector
Blinks ' Faultv vehicle speed sensor i
l
0 Loose or poor contact on No, 1 iniactut )- Engine does not start
onn tor i
12 a ‘ e co . , . _ _ . 1 5-30
0 Open or slluri moon I" No, 1 Injector WIre l
Blinks - Faulty Nov 1 Injector ' ‘
‘0 Loose or poor contact on No. 2 injector 0 Engine does not start “
. .i I. uuullecto-
‘3 l' Open or short circuit in No. 2 inlector wire l 5'33
Blinks ‘0 Faulty No. 2 injector
0 Loose or poor contact on No, 3 inicctor I Engine does not start l
14 l Q. annnector
‘0 Open or short circuit in No. 3 injector wire 5'35
‘ Blinks I Faulty Not 3 injector
0 Loose or poor contact on No. A inisctor - Engine rlnes not start
15 «a. connector 9
- Open or slion circuit in Nn. A injectorwire 5'3
Blinks - Faulty No. A injector
. Loose or poor contact on cam pulse 0 Engine does not start l
{ 1. generator
1“ - Open or short circuit in com pulse generator 5’42
nlinlts - Faulty cam pulse generator
[ - Luuse or poor contact an ignition pulse - Engine does not start
19 l {} generator connector
l ‘0 Open or short circuit in ignition pulse generator 5’“
‘ Blinks ‘- Faulty ignition pulse generator
l' . ‘ ,_
‘ G - laultv E‘EPROM in ECM . Engine operates normally
20 ' - Does not hold the selfldiagnosis . 5 45
Blinks data l ‘
0 Faul Or SENSOR 0 En ine o erntes normal] .
21 {I} w 9 n v : 5743
4% f l
23 i Q - Faulty or SENSOR heater . Engine operates normally 1 550
l Blinks ' , l
in Loose or poor cnninms on knock sensor - Engine operates normally
25 {:2 l connector . .
1- Open or short circuit in knock sensor wire ‘ 55‘

 

 

 

FUEL SYSTEM [Programmad Fuel Injection)

PGM-Fl MALFUNCTION INDICATOR 1 BLINK (MAP SENSOR)

 

Turn the ignition switch to "OFF”,

1

 

Disconnect the MAP sensor 3P cunnector.
Check for loose or poor contact on the MAP
oonsorconnector.

 

 

Connect the MAP sensor connector.

i’iace the motorcycle on its side stand.

Start the engine and check the maltunctmn
indicator bilnks.

 

’iblink

 

 

Turn the ignition switch to ”OFF”.

 

 

 

Disconnect the MAP sensor 3? connector.

Turn the ignition switch to ”ON”.

Measure the voltagn m the wire harness Side
we

connector,

  
 

Connectio 'Yellowxred l+ i 7 Ground ( )
Stand-rd: 4.75 — 5.25 V

 

Correct

 

 

Measure the voltage between thc connector ‘
terminals oi the wire harness side.

 

Connect n:Yeilow,’redHi mean/mange! )
Standard: 4.75 ‘ 5.25 V i

; Correct

 

 

Dues nul blink
—*.

Out of range

Out of range

 

I Loose or poor contact on the MAP sensor conncc
lOi.

- Open or short circuit in Vollow/rcd wircl
- Loose or poor contact on the ECM connectors.

0 Open or short circuit in Green/orange wire.
0 Loose or poor Contact on the ECM connectors,

 

5-14

i

 

Mpasure the volkagc between the ielminais of
the wire harness side.

 

Light green/yellow (4- ) > Greanr’nrnnge (—)
Slandard: A 75 5 25 V

Correct

Out of range

 

Turn the ignition swltch to "OFF' .
Connect the MAP sensor 3P conngulun.
(Th i \

 

 

 

 

Discunuect the ECM connectors.
Connect the lest harness l0 ECM connectors.
Turn mo ignifion switch m "ON'K

 

 

 

 

Measure the Vollage a! the test pin box [Armlnals

{page 5-11). ”0126 “the

    

 

Connaction: Na 37 H— I‘No. 22 i ‘)
sxandard: 2.7 “3‘1 V 1760 mm Hgl'l.013 kPa)

r
M— - Faulty MAP sensor,

 

 

FUEL SYSTEM (Programmed Fuel Injection)

I Open or shon circun in Light ween/yellow wire.
0 Loose or poor comact on the FEM connectors.

Correct , ' ,
0 Replace me ECM wnh a new one, and inspec: it

 

5-15

FUEL SYSTEM (Programmed Fuel Injection]

PGM-Fl MALFUNCTION INDICATOR 2 BLINKS (MAP SENSOR)

? Turn the ignition swiichm "OFF’C

Disconnect the hose from the MAP sensoi. M - Check |he hose insiaiiaiiun.
Connect the vacuum gauge between the ohrnmn
body and the MAP sensor using a 3 way jolnr.
i Stan [he engine and measure the manifold
i absolute pressure at idle speed

 

 

 

 

Correct

 

 

D‘iswunecl the vacuum gauge and connecr ms
rinse in the MAP sensor.

i'fi‘vr

 

 

Normal

 

 

Disconnect the ECM connentnrs.
Connect the test harness to rho ECM connccrorr

 

 

 

 

5-16

, {

 

Turn the ignition switch m "ON'K

Measure [he vokage a! the lesl pin box terminals
(page 5-11).

No.22 9 No.37 G3

 

 

\
nun-anaX-a .-
nnaoaaan
condone:
oonoooonooanw
snnnoeauooauu
nanooaoauooao
.uouaoonoouoo
annoaoooosooo

:nnnounnnooflflfl

lunnnaun-aonuu

 

 

 

Connection: Nu. 37 (-l-No 22 (—)
Sundard: 2.7 3.1V1760 mm Ha/1.013 kFa)

Out of range

 

 

l Conan

Start the englna‘
Measure m: vohage at the (es! pin box terminals
lpage 5.11).

No.22 e No.37 63

 
   
      

 

 

 

 

 

\
‘oouuuo$\uflwuu
‘uuuuubuuvflbnfl
unmannunsrrea 1
annuaonoonaaa
aonunoooouooo
nonuaoeoooooo
annunnaaowoon
nannaeeonacne
nanannnaanana
Mannnnonnnannu J

Connectlon: No. 37 (—)*No‘ 22 (7,
Standard: 2.7 V maximum

 

 

FUEL SYSTEM (Programmed Fuel Injection)

. Faulty MAP sensor.

w ~ Faulty MAP sensor.

0 Replace the [CM with a new one. and inspucl it
agmm

 

5-17

FUEL SYSTEM (Programmed Fuel Injection)

 

PGM-Fl MALFUNCTION INDICATOR 7 BLINKS (ECT SENSOR)

 

Turn the ignition Switbh to “OH",

 

 

 

Disconnect the ECT sensor 3P connemnr,
Check for loose or poor contact on the ECT sen-
sorconnectw,

 

 

 

Connect the BET sensor connemor,
Place the motorcycle on its side stand.
Turn the iguiliuu switch It) "ON",

/

   

\ )6
Check thal the malfunction indicator blinks.

 

7 blinks

 

 

 

Turn the ignition switch to “OFF".

Discommcl the ECT sensor connector‘

Measure the resislance at the ECT sensor [ermi-
rials.

 

 

Cannenio : Pink (‘i’Green/urauge (~)
‘ lscnsor side terminalsl
Standard: 2.2 - 2.7 k5) (20 °C/65 °F)

 

1 Normal

 

095: nm blink

Abnormal

 

- Loose or poor contacts un the ECT sensor connec-
my.

> . Faulty ECT sensor.

 

5-18

FUEL SYSTEM (Programmed Fuel Injection)

_____i_ 77

Turn the ignition swncn to “ON". 0‘“ °' ""9” - Open or shun ci-cuii in Pink and Pink/while Wire.
Measure the voiiagc between the ECT sansor 0 Loose or pnnrcnninns onthe ECM connector.

i connector terminal of the wire halness side and
Ground.

 

  
  

 

 

Connection: Pink (H-Ground (-i
Standard: 475- 5.25 V

 

Corrcm

 

 

Out 0! ran a . . . .
Measure the voltage at the ECT sensor cnnnanmr —g—~ 0 Open or short CII‘CUII In Green/orange: wna.

of the wine hnrn Aide, I Loose w your contacts on the ECM connecmr.

 

 

 

1 Connection: Pink (+i—Green/orangs (7)
‘ StandavdMJs—SJSV

 

 

— c 1 .
L____$__, . Replace [he 2cm wnh a new one, and inspefl i‘

again.

 

5-19

FUEL SYSTEM (Programmed Fuel Injection)

PGM-Fl MALFUNCTION INDICATOR 8 BLINKS lTP SENSOR)

 

Turn the ignition switch to "OFF”.

 

 

 

Disconnect the TP sensor 3P connector.
Check for louse m puuryonlacl on We TP sensor
connector.

 

 

Connect the T? sensor connector.

Place the motorcycle on its side stand.

Start the engine and check the maliunclion indica-
i tor hlmks.

 

 

8 blinks

 

Turn the ignition switch to "OFF".

 

 

 

Disconnect the TP sensor 3? connector.

Ttnn (he igniliun switch lo "0N".

Measure the voltage between the wire harness
side connector terminal and ground.

  

Connectio .Vcliow/rcd ('isGroundtfl
Standard: 4.75 - 5.25 V

 

Out of range

 

 

Correnl

 

-Loose or poor contacts on the TP sensor
EOHI‘IBCIDI'.

- Open or short circuit in the Yellow/red wire.
- Luuse ur puur culilacl on the ECM connector.

 

5-20

FUEL SYSTEM (Programmed Fuel Injection)

 

i

 

Measure the voltage at (he TP sensor (arminals
of \he wire harness side.

 

 

 

ConnectionzVeliow/redi 1 ) Green/nrangéfl F
Standard: 4.75- 5.25 V

o t of ran 2 , , , ,
——”—9—— - Open or short circuit .n Green/orange ma

0 | nose or poor Contact on the ECM nnnnecmrs,

 

Co- rec‘

 

 

Tum the ignition switch to ”OFF".
Disconnect ma ECM 22F connamors‘

\
\\\

     

\

 

 

 

 

 

Check for continuity belween the TP sensor
conneclul (ulninal of "I! wile lmrnass side 4an
gmund.

 

Connection: Red/yellow (+ )iGmund (7)
Smudard: No continuity

Conlinuilv

- Short circuii in Red/yellow wire.

 

 

No continuity

 

5-21

FUEL SYSTEM (Programmed Fuel Injection)

l

Connect the test harness to the ECM connectors,

 

 

 

 

 

 

Check for continuity between the test pin box
terminal and the T? sensor connector tel minal.

 

Connection: Red/yeIIOW* No. 39
Standard: Cm ILiuuilv

l Cont W

Connect the TP sensor 3F connector

 

 

 

 

Turn the ignition switch to “ON".
Measure the voltage at the test pin box terminals.
No.22 e No.39 $

 

 

Connection: Not 39 [AliNot 22 (_)
Standard: ‘0‘4 , 0.6 V (throttle iullv closed)

 

 

‘ A1 — 4.8 V (lluultle lul ly open)

 

 

No continuity

Normal

- Open or short circuit in Red/yellow wire.

- Replace the ECM with a new one, and inspect it
again

. Faulty T-P sensor‘

 

5-22

FUEL SYSTEM (Programmed Fuel Injectionl

 

A voltage marked‘ raters 10 the value when the voltage reading at the Tl‘ sensor 3P connector (page 5 21) shows 5 V.
When Ihe 'eading shows other than 5 V, derive a voltage range at me (as: harness as follows:

Example:
In the case of a vullage of 4.75 V al lhe TF‘ sensor 3P connector-

0 4 H 1,7b/b‘U » 0.33 V
0.6 h 4.75/5. =0.57V

 

Thus, the valm range rs “0‘38 7 0.57 v" for throttle fully closed.
Repeat lhls calculaxion using 1.2 and 4.8 10 get (he rasulllng range for the throttle fully open

 

5-23

FUEL SYSTEM (Programmed Fuel Injection)

PGM-Fl MALFUNCTION INDICATOR 9 BLINKS (IAT SENSOR)

 

Turn the ignition switch to "OFF".

 

i

 

Disconnect the lAT sensor 2P connector.
Check for loose or poor Contact on the IAT sensur
connector.

 

 

 

 

Connect the IAT sensor 7P cnnnectnr.

Place the motorcycle on its side Grand‘
Turn the ignition switch to "ON".

Check that the mail‘uuclian indicator blinkst

 

 

V 9 blinks

Docs not blink

 

Turn the ignition switch to "err".

 

 

 

Disconnect the IAT sensor 2P connector.
Measure the resistance at the IAT sensor
iat 20'30 ”CI'GB—SG “FD.

 

 

 

 

 

Normal

to "ON”,

 

 

 

 

uLoose or poor contacts on the IAT sensor
connectort

J‘bfllfi» . Faulty IAT sensor.

 

5-24

FUEL SYSTEM (Programmed Fuel Injection)

V ,
Ouluhane V V. ‘
Measure the voltage herwean the (erminals of ~—9—» . Open or short circuit In Gray/hum wire.
1 mp, wlve harness sxde. o Loosa or poor contac: on the ECM connectors.

 

Connection-
Gravlbluc (HiGround (7)
Standard: 4.75“5‘25 V

 

l Correct

 

. utofran e _ , , .
Measure the voltage between the terminals mi c7——g—>OOpen orshon mrcumn Gruen/urangewne.

the wire harness side. 0 Loose or your Contact an the ECM connectors,

  

 

Connoclion:
Gray/hum H- )—Greenlorangc (—1
Standard: 4‘75— 5.25 V

 

 

Correct .
—-—-——* I Replace the ECM wlth a new one, and Inspam I!

again

 

5-25

FUEL SYSTEM (Programmed Fuel Injection)

PGM-Fl MALFUNCTION INDICATOR 10 BLINKS (BAFlO SENSOR: '99 ONLY)

 

Turn the ignition switch to "OFF'C
Dixonnect the BARO sensor 3? cunnsctorr
Check rm loose or pnor contact on the BARO

sensor connector.

 

 

 

 

 

 

 

Connect the BARO sensor connectort
Place the mulurcycls on n: side stand.
Ium the ignnion switch to "ON",

Check that the malfunction mdmntnr hlinks

 

 

‘IO blinks

Turn Ihc Ignition swrtch to ”OFF".

 

 

Disconnect the BARO sensor 3? connector.
Tum [he ignition switch to "ON".

Measure the voltage at Ihe me harness sTds
EONI’ISC‘OI. I
r
I

  

Connectin :Vellnwlredf ) Graund(’I
Standard: 4.75 - 525 V

 

I can...“

Measure the voltage between the connector
IerminaIs of the wire harness side

 

 

 
    

, I _~ I

t A;

 

 

Connection: Yellow,’ren( I I (imam/nrangeI , )
Sunder 4 75 > 525 V

Co rrec‘t

 

Docs nm blink

 

* - l nose or poor contacts on the BARO sensor con-
ncclor.

0““ “We » . Open or short circuit in Vellow/red wirev

- Loose or poor contact an the ECM connectors.

Out of ran e . . . . .
, g 7+ 0 Open or short mum .n Green/orange wlrev

. Loose or poor contact on the ECM cnnnecmrs.

 

5-26

FUEL SYSTEM (Programmed Fuel lnjectioni

 

I

 

Measure ihe voltage between the terminals of
the wire harness Slde.

 

Connection:
Lighl green/black (+) Green/orange [—1
Standard: ‘15 525V

 

Correct

 

 

 

Turn me ignition swirch to “OFF".
Conncc! the EARO sensor 3? cunneclon

 

Disconnect the ECM connecters.
Connect the test harness to ECM connector;

 

 

 

Tum the ignition switch In "ON".
Measure the voltage ar the rest pin box lerminsis

i 5711 .
“9° ’ No.226 Noaae

 

 

Cannedio ‘ Nor 38 (‘H‘NQ 22 (—i
Slandard 2.7 —3.1 V (760 mm Hg/‘I,013 kPa) ,

 

4%

Correcl

Cum—L.‘ '3" e . Open msmn Clrcult in Light green/biackwire,

0 Loose or poor comact on the ECM conneuiuvs.

- Fauliy BARO sensor

I Replace the ECM With a new me, and inspect ii
again,

 

5-27

FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MALFUNCTION INDICATOR 11 BLINKS (VEHICLE SPEED SENSOR]

Turn the rgnmnn switch to "OFF".

 

 

 

 

Disconnect the vehicle speed sensor 3P
connecmr.

Check for loose or poor conracl on rhe vehicle
speed sensor conneclur

 

 

 

Connecl [he vehicle speed sensor 3P connector.
Stan rhe engine.

With the side stand up and keep the engine rev
more than 5,000 rpm aboul 20 second: or more
Check that the malfunction indicator blinks.

 

 

\
" thmks

 

} Turn the ignrliun swilch to "OFF".

 

 

 

Disconnect lhe veliiLlu speed sensor 3P
connector

Turn the ignirion swilch m "ON".

Measure (he voltage a! the wire harness side
cnnnecinr

 

Connection: Black/brown ( ‘ )
Standard: 12 V

Ground (7)

 

 

 

Correcl

Does not blink

Out of range

  
 
  

- L‘nnse nr pom contacts on the vehicle speed sen-
SOV OOnflEC‘OF,

‘—-—- - Open or shun cirnull in Black/brown wire

 

5-28

FUEL SYSTEM (Programmed Fuel Injection)

 

 

Outuhan e . . .
Measure the voltage between the connector my ———g—— - Open or short Cll’cult m Graph/black wlre

mlnals of the wire harness side‘

 

Connection: Black/brown (—l-Graan/b‘ack (—)
Standard: 12 V

 

Correct

 

Check «or uunlinuity of the Pink/green wim ML

between vehmle spud sensor connector and
HM connector.

. Open or short circuir in Pink/green wire.

 

 

Standard: Continuity

 

 

 

C l' ‘l
|—————-————’°" '"u' y - Reprace the ECM with a new one, and inspect it

again.

 

5-29

FUEL SYSTEM (Programmed Fuel Inject

ion)

 

PGM-FI WARNING INDICATOR 12 BLINKS (No.1 INJECTOR]

Turn the IgnIthl’l switch to “OFF“,

 

Drsconneclthe No. 1 injeclul 2P connectorr
Check for loos: nr pnnr contact on the Nur 1
injector 2F connector.

   

4‘

    
   

    

'/

/

J
A
\7’

 

 

, “

 

 

Connecr the No, 1 injector 2P connector,
Place ‘he molumycls units side standr
Turn vha Igninon switch to ”ON".

Check that the malfuncnon Indicator Minks

//4—
A’Wgy/M

\

  

 

I 12 blinks

Tum |h9 ugnirion switch w “OFF”.
Disconnecl me Nor 1 iniactor 2P connector and
measure the resistance of the Nu. 1 inieclon

 

Connmi n:
Blackfwhile (~L IiPink/yellow I—I
Standard: 13 0 14 A k S} (20 “fl/ES ”F)

 

Normal

 

#0095 not b"’.‘,“

Abnormal
’4

 

+ oLoose or poor cumacls on the No. 1 injector
connecmr

. Faulty No.1injaclur.

 

5-30

FUEL SYSTEM [Programmed Fuel Iniection)

 

‘ 7 Con inui ‘ .
‘ Check {or uulllinmty between me. Mn 1 Injecmr Annuity Nut 1 "nectar,

and ground.

 

   

Connect'on:
Blacldwhilet ) Grmmd (VI
Standard: No continuity

 

No cormnuny

 

Turn the ignition switch to "ON".
Measure the voltage between the No 1 injector
cunuectax oi the wire harness skin and ground.

 

Out at run a. . V . ,
———g> - Opan or short clrcun m Black/white wurc.

 

 

Connection:
Black/white (+ hGround (7)
Standard: Battery vohage

 

Correct

 

 

Turn the ignztian switch m "0H”.
(tnnneclthe Not 1 injector connector.

  

W

Disconnect the ECM connectors,
Connect the (es! harness and test pin box to the
wire harness connectors. “

 

 

 

 

5-31

FUEL SYSTEM (Programmed Fuel Injection)

 

t

 

Measure the resistance at the resr pm box rerr
mmals

 
  

   

N032 N013

' t

‘o ‘ \»o
aouuwuauaoovn
uuueuvoocooo:
oouoo onaooo r
oooeagrttrfrr”
ooaoooanaooo-
oneoneooaooou
sonoeoanoeooo
Oflaoannnannnn
nouoououuuuuu
nouaouoooooooac

 
 

 

Connection: Na. 13 No.32
Standard: 9* 15 Q (20 “3/68 “F)

 

l Normal

 

Check for continuity between rhe tast'rnn hnx
terminal and ground,

No.13

 
 
 

 

 
 

:

    

     

‘annuuuuunnoo
aooauuocoaeo
iuuoaouoeoaoni
‘uouoeaoefiaoat
aeeoonoouaenu
‘aoeao ounces:
oeuoo-oeoaoau ;
assessoeoaoaa I
conesnonnaeno ;
wonaaanuuuuau

’

 

Connection: No. 13* Ground
Standard. No continuity

 

 

Out of range

Congmuxry

‘Open crrcuit In Black/white and/m Fink/yellow
wire.

- Short circuit in Pink/yellow wire‘

m - Heplnnn the [CM mm a new nne, and mspect it

again,

 

5-32

FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MALFUNCHON INDICATOR 13 BLINKS (NO. 2 INJECTOR]

 

Turn the ignltlan switch to "OFF".

 

 

 

Disconnect the No.2 injector 2P connector.
Check lor loose or pour Contact on the No. 2
injector 7P nonnamor,

 

 

 

_ ‘ ‘ ’fi
Cannect the No. 2 Injector 2P connector.
Place the motorcycle on its side stand.
Turn the ignition switch to ”ON”,

Check lhnt the mallunctian indicator blinks.

 

 

i t
. “rink;

Turn the ignition switch to “OF ,
Disconnect the No. 2 injector 2P connector and
irieasure the resistance of the No. 2 injectorv

 

 

 

‘ Connealon:

Does not blink

 

Black/white (H'Pink/blue (‘l
Slandant 13.0 14 A k 9 l?!) "C168 ”F)

 

Normal

 

- Loose or poor contacts on the Not 2 injector con-
lleC‘Ol‘

A I . ,
bnorma - Faulty No. 2 injector.

 

5-33

FUEL SYSTEM (Programmed FueI Iniection)

I—i_____

Check for cnmtntttfy between the Mn. 7 injectnr
and ground.

 

 

Connection:
Black/white ('1 ’Gmund (it
Standard: No continuity

 

No continuity

 

 

Turn the ignition switch to "ON".
Measure the vuitage between the Nu. 2 injectur
nnnnamnr ni the wirs harness side and ground.

 

Connection:
Stack/white i+)’Gr0uttd (7)
Standard: Battery vo'tage

 

 

Correct

 

 

Him the rgnitinn swttch to “OFF".
Connect the No. 2 injector connector.

 

“ Disconnect the ECM connectors,
‘ Connect the test trainees and test pin box to the
Wtre harness nnnnemnrs

 

 

Continuity

Out of range

0 Faulty No. 2 injector

- Open or short clrcuit In Black/white wirc.

 

5-34

FUEL SYSTEM (Programmed Fuel Iniection)

 

 

Measure \he resistance al me Kesx pin box ter-
minals

No.2 No.32

J

anoooo can \

o

T‘

nnoooo can

?

nmoooooaac
nonoooeaa
nae-006::
nooooooau
nnannnaaaa
unouon
Dooooo
nan-mo ca
”no-u an
nan-on an
"as"; ea

c

 

 

Connection: No. 2 7 No, 32
Standard: 9* 15 Q (20 “(3/68 'F)

 

Normal

 

 

1 Check (or confinuity between the last pin bux
mrm‘mal and ground.

N52

 

 

Connection: Na. 2 — Ground
Standard: No continuiw

 

O f f .
" n ""9" IOpencircu'xtin Black/white and/m Pink/blue

wure.

C t' ‘
0" "WW . Shullciruuil in Finkt'bluu wire‘

N° “mummy > Human ma th wwh a new nne, and mspem it

again.

 

5-35

FUEL SYSTEM (Programmed Fuel Iniection)

 

PGM—Fl MALFUNCTION INDICATOR 14 BLINKS (NO. 3 INJECTOR)

   

Turn (he an on switch to "OFF

 

Disconnccl the No. 3 injcclor 2P connecmr.
Check ior loose or poor contain on me No. 3
injec‘or 2F :onnec‘ov.

 

 

Connecnhe No. 3 injector 2P L’ulllleclul.
Place the motorcycle on as side svand.
Turn the ignition switch to "ON”.

Check that [ha maiiunction indicator blinks.

 

 

l 14 blinks

Turn the :gmion switch to ”OFF".
Discanncct me No. a Inpemnr 7P tnnnemor and
measure Ihc resistance of ma No. 3 injector.

 

 

Connection ‘
Black/white ( A)‘PInK/green ‘7)
Stindud: 130— 14.4 “Z (20 °Ci'68 'FI

 

Normai

 

Does not blink

uLuuse u: puuv uunlacls on the Nui 3 injwlur
connector.

Ah 1 .
"mm . Faulty Nui3ivueclu1.

 

5-36

FUEL SYSTEM (Programmed Fuel Injection)

 

i

 

Check for continuity between the No. 3 injector
and ground.

 

 

 

 

Connection:
Black/White (' )* Ground (‘)
Standard; No continuity

 

No continuity

 

 

Turn the ignition switch to “ON"
Measure the voltage between the No. 3 Injector
connector 01 the wire harness side and ground.

 

Connection:
Black/white I H Grmmdt I
Standard: Battery voltage

 

Correct

 

 

 

Turn the ignition switch to ”OFF".
Connect the Nu. 3 injector cunnectur.

 

 

 

 

Uisnnnm‘ct the ECM connectors,
Connect the test harness and test pm hnx In the

 

 

Continuity

Out of range

- Faulty Not 3 injector,

I Open or short circuit in Stack/white wile,

 

5-37

FUEL SYSTEM (Programmed Fuel Inimion)

 

 

Omohmge

 

Measure me resis‘ance at me test pin box (err —— -0pen circuit in Blackiwhite and/or Pinldgreen
minals. wire
No.32 No.12
3’
L , \ u
mnnnngnonnafifi
uvuoouaonnunn
apnea acute
e e a e e ”—33—: a a a u
anaoocooooeoo
eoaoeoeeaeeoo ‘
engeaaeaoaeoo L
aeeeeaeoaacao
‘noennanancaao ;
ueuoauueuouou1_

 

 

‘ Connection Na. 12—No. 32 ‘
‘ Standardz9 "IS U (2U LUSH “F? ‘

NDIHIH‘

Conrnun . ,‘ ‘ .
1 Check for continuity bewveen the ‘est pin box I V IShon circumn Pmk’gruenwuu.

1 terminal and ground.
Non

J

Equinooooo
uoaanoaauu
noncnoownu
oaugnoonoo
aoaanmncoo
cooanooo-n
uoaevoooon
aooanooooo
numflnauuua
ewwaocooea
cooanaooe
ooooouooo
omoaonoaw
|

 

No continuity

 

.Replace the ECM with a new one, and inspec‘ it
Hgfiln.

 

5-38

FUEL SYSTEM (Programmed Fuel Injection)

PGM-FI MALFUNCTION INDICATOR 15 BLINKS (NO. 4 INJECTOR)

I Turn the ignition: switch to “OFF".

Disconnect the No. 4 injector 2P connector.
Check for loose. or pnnr cnntact on the No. 4
injector 2P connector.

 
  

, M17

 

 

Cunneul the Nu. 4 iniactorlP connector.
Place the motorcycle on its side stand.
Turn the ignition switch to “ON".

Check that the mailunctlon indicator blinks.

 

lbbnnk:

Turn the ignition switch to "OFF".
Disconnect the: No 4 lfljflnlnr 2P connector and
measure the resistance 0! the No. 4 Injector.

 

 

 

Connection:
Black/white 1 ~ i‘ Fink/black i-I

Does not blink

 

Standard. 110*144 k ‘2 (20 ”CJGS ”Fi

Normal

 

I Loose or poor contacts on the No. 4 injector mn-
NECKOL

Ab al
norm - Faulty No. A injector.

 

5-39

FUEL SVSTEM (Programmed Fuel lnjemion)

 

_—i—

Check tor continuity between the Not 4 injector
and ground.

 

Z Connocljon:
Black/white (+)—Ground(—)
Standard: No continulty

 

; Nu L'unlinuity
Turn the Ignition switch to ”ON".

Measure the voltage between the No. 4 inlector
couneclur of the wire harness side and ground.

 

 

 

Connection:
Black/white (+b—Ground [,,
Standard: Battery voltage

 

Correct

 

 

Turn the ignition switch to ”OFF",
Connect the Na 4 injector connector.

 

 

 

 

Disconnect "In [CM nonnnmnrs,
Connect the test harness and last pin box to the
wire harness connectors.

9,43%

    

 

 

 

 

Continuity

JIM.

, . Faulty No, A Injector.

' Open or short circuit in Black/white wire.

 

5-40

i,

Measure the vasinance a! the (as! pin box my
minals.
N01 ’1032

 

 

neooocen
anaconann \
nuannacnnn
ooaooaoone

c

 

Connomion:Nu,1—Nui32
Standard: 9-15 ‘2 (20 °Cf68 ”FD

 

Normal

 

 

Check for continuity herwnan the Vast pm box
terminal and ground.

No.1

 

 

Connecflon: No, 1* Ground
Stmdud: Nu uulllinuilv

 

FUEL SYSTEM (Programmed Fuel Injection)

0'" ”l ”"9” - Open Circuit in Biauwwnile and/m Pink/mack wiie,
CW'M'" . Short circuit in Pink/black wire.
No Continuity

. Reoiace the ECM with a new one, and inspect it
again.

 

5-41

FUEL SYSTEM (Programmed Fuel Injection)

PGM-Fl MALFUNCTION INDICATOR 18 BLINKS (CAM PULSE GENERATOR)

 

Tum the ignilion switch to "OFF‘Z

 

 

 

Discunneul the can: pulse generator 2P connec-
mr.

Check for loose or poor contact nn the. cam pulse
generator 2P connector.

 

 

 

Connect the cam pulse generator 2P connector,
Place the motorcycle on its side stand.

Turn the ignition switch to "ON" and check that
the malfunolion Indicator blinks.

 

1B blinks

 

 

Turn the ignition switch to "OFF" and the Hnglnfi
srop switch off.

Disconnect the cam pulse generator 2?
connenmr.

 

   
    

check the contrnuity between the cam pulse
generator connector terminal and grnnnn.

 

Cnnneminn‘ White/veIIDW*Ground
GraVA Ground
Standard: No continuity

 

  
 

No continuity

   

Does not blink

Continuity

 

nLoose or poor contact: an the ham pulse
ucncratorZPconnocror.

. Faulty can: pulse gellelatul.

 

5-42

FUEL SYSTEM (Programmed Fuel Injection)

 

, l

 

Turn the Ignition switch to ”ON".

Crank the engine with (he slarler lllulul, and
measure the cam pulse generator peak voltage at
tha cam pulse generator 2P connector.

 

Connection: White/yellow (+ )— Grav 1-!
Sllndlrd: 0.7 V minimum (20 “(3/68 ‘F)

 

Normal

 

 

Disconnect the cam pulse generator 7F
rnnnemor

Disconnect the ECM connectors.

Connect the test harness to ECM connectors.

 

Crank the engine with the starter motor, and
measure the cam pulse generntnr peak voltage a!

the teat pin bax terminals.
no.“ in No.4: 9

  
   
   

 

Connection: No. 42 H-l—No. 41 (—1
Standard: 0.7 V minimum (20 "(2/68 'Fi

 

 

Normal

 

 

Check for continuity between the test pin box ter-
minal and ground.
no.“

 

 

Connection: Not lZ—Ground
l Sund-rd:NoconIinuitv

 

 

um nl range

Continuity

No continuity

f
M— - Faulty cam pulse generator.

u - ()pen circuit In White/yellow and/or Grav wire.

I Short circuit in White/yellow wire.

I Replace the ECM with a new one, and inspect it
again,

 

5-43

FUEL SYSTEM (Programmed Fuel Injection)

 

PGM—FI MALFUNCTION INDICATOR 19 BLINKS (IGNITION PULSE GENERATOR)

 

Turn the ignition switch to “OFF".

i

 

Disconnect [he igniliun pulse generator 2?
connector.

Check for loose 01 poor contact on the cam pulse
generator 2P connector.

  

 

 

 

Connect the ignition pulse generator 2P
conriactur.

Place the motorcycle on its 'de stand,

Tum the lgnltlon swnch to "ON” and check that
the malfunction indicator blinks.

 

 

 

19 blinks

 

 

Turn the ignition switch to “OFF" and the engine
slop swiluii u".

Dismnnecl the Ignition pulse generator 1P cone
nector,

 

 

 

 

Turn the IgnlIinn switch in "OFF“.
Check for continuity between the ignition pulse

 

Connection: White/yollow- Ground
Yellow—Ground
Standard: No continuity

 

 

 

No continuity

Continuity

 

- Loose or poor contacts on the ignition pulse gen-
erator ZP connector.

. Faulty ignition pulse generator

 

5-44

_.__i—

Clank the Engine with the staner motor, and
measure the ignition pulse generator peak volt-
age at the ignirion pulse generator 2P connector.

 

Standar to] V minimum (20 °C/68 'F)

 

, ' Nnrmnl
Disconnect the nluon pulse generator 2P cun-

HECTOR
Disconnect the ECM connectors,
Connect the test harness to ECM connectors

  

Crank the engine with rho starter motor. and
measure the ignition pulse generator peak vullv
age at the lesl pin box terminals

M126 Pin—525

 

Connection: No. 52 (+ i* No. 421*)
Slandird: (17 V minimum (70 “(I/GR “Fi

 

Normal

 

 

Check for Continultv between me last nun box
terminal and ground. "0‘52

 

Connection: No. 52 — Ground
Standard. No continuity

 

 

 

 

FUEL SYSTEM (Programmed Fuel Injection)

Out i ' e . ,.
u ”"9 - Faulty Ignitan pulse generator

0 l f i A .
4.23191. . Open circuit m Whlte/yellnw wire.
0 (man circuit in Yellow wirel

Continul . . . .
W 'Shoncircullm Vellow Wire.

Nn nonhn ii
' ‘V - Rnplnne the ECM With a new one, and inspccr it

again

 

5-45

FUEL SYSTEM (Programmed Fuel Injection)

 

PGM-Fl MALFUNCTION INDICATOR 2|) BLINKS (EZ-PROM)

 

i
‘ Turn the i nirion swilulr lu "OFF
{*9

l ,, ,,7_

Disconnect lhe ECM connectors.
Check for lnnse nr pnpr Contact of the ECM

connectors.

 

 

 

 

 

 

20 blinks

 

Connccr the ECM connectors.

Shun the service check connector wirh a jumper
wire (page 5-8)‘

Turn the ignition :wrtch la "UN" and check rhnl
the malfunction indicator blinks.

 

 

; Does nm blink 20 times

 

conneuuv wage 543x

 

 

 

 

Dons not hllnk
?0 times

 

rhe malfunction indicator blinks.

 

 

 

7n hlinks

 

 

Blinks ‘
Remove me jumper wire from the service chock ‘——-‘

Reset the scltdiaunosis momorv data
(page 5%

Turn the ignition switch to “ON” and check llial
the mammalian Indlnalnr blinks.

 

20 blinks
V

0 Replace the ECM.

—-—-——‘- - No problem.

 

5-46

FUEL SYSTEM (Programmed Fuel Injection)

‘ , ,
» TJm the ignmnn swim in "own
l.

— ‘ Does not blink

, l 20 times

Short the servme check connector With a jumper r—-—~" . No problem.
wire (page 5 B]. ‘
Turn the ignition switch lu “ON" and check (hat

Llw mallunclion indicator blinks ‘

20 blinks

 

Does no: blink

Reset Ihe self-diagnosis mfimnry mm. [page 58L w» - No problem.

lurn the Ignmon swutch w "ON" and check that
me malfunction indicator blinks.

 

 

 

2° “mks - Replace the ECM

 

5-47

FUEL SYSTEM (Programmed Fuel Injection)

 

PGM-Fl WARNING INDICATOR 21 BLINK (Oz SENSOR: AFTER '99 CALIFORNIA TYPE ONLY)

Turn the ignition swnch rn “()rr”

 

V

Disconnect the 02 sensor connector
Check Ior loose 0r pour contact on the 02 sensor
cunneclor.

    

 

 

 

 

Disconnecuhe ECM connecmrs. .
Connect the lesl harness lo ECM connecmri,

 

 

 

 

 

No continuik , , . . .
-—V- - Open circuit In 0: sensor White/orange wrre.

 

Check the continuity between the lust pin box

terminal and Oz sensor cnnnecmr terminalv
No.35

 

Connectlon: Whireiorangev No. 35
Standard: Culllinuily

 

‘ Continuity

I
V . Coulilluily , , . .
Check lhe cunimully between the 02 sensor —-———.-Shonclrcultin OzsensorGreen/orange wure.

i conneclnrl mlnnlnndgrnund

 

     

Connection: (3 reeni’ora ngei Ground
Srandard: No continuity ‘ 1

Nn mnnnuny

 

 

5-48

 

Connect (he 0: sensor connector,

Tum the lgniiion switch to "ON" and warm up
lhn Engine up to coolant temperalurc is 80'C1176
“Fl.

 

 

spesd from idle to 5,000 rpm.

 

Operaie mo thronlc grip and snap the engine

 

 

 

_____—

Check the Vullage beiween the test pin box
terminals

No.11! % m: as E

  

  

Cunnzclion: No,l6— No.35
Standard:
With tho lhronle lully open:
0 G V minimum
With the mnmle quickly closed:
0.4 V maximum

FUEL SYSTEM (Programmed Fuel Injection)

Out of range

 

0 Faulty 0. sensor.

 

 

Normal

————-——’-Check the fuel supply system, if the sysmm is

nnrrnm, replace the ECM and inspect again.

 

5-49

FUEL SYSTEM (Programmed Fuel Injection)

 

PGM-Fl WARNING INDICATOR 23 BLINKS [D2 SENSOR HEATER: AFTER '99 CALIFORNIA TVPE ONLY)

Turn the ignition swirch ro ”OFF".

 

 

 

Disconnacr the 0: sensor connecmn
Check ion loose or your cunldcl on the 0: sensor
nonnaclnr

 

 

 

 

 

Connect the 02 sensor connecmr.

Piece the motorcycle on its side stand.

Stan the engine and check that the malfunction
Indlnalor hlinks

23 blinks

 

Turn the Ignmm‘. swivnh m "HIT”

 

> 7 ,/
v , ,, \. I ‘
Connmion: WhllE —Whlre
Standard‘ 10*40 D,

 

 

Disconnect the 02 sansnr 4P cnnnenmv
Measure rho resistance at the sensor side connec-
luv While ierminalsi

  

Normal

 

 

Does nut bhnk
;+.Louse or poor contains an Ihe DA sensor

connecmr,

“LOW—”9L, o Faulty 02 sensor,

 

5-50

FUEL SYSTEM (Programmed Fuel Injection)

 

l

 

Check lnr continuity each White terminal and
ground.

 

Connenlon: White — Ground
LStlndxrd: No continuity

 

No continuity

 

 

Tum the ignition switch to "ON”V
Measure the voltage at the 02 sensor wire ner-
ness side connector terminals.

  

Connection: HIn:k/white1+)- Black/green (—l
Standard: Battery voltage

 

 

l

 

Continuity

Normal

I Faulty 0: sensor.

 

 

 

Turn the Ignition switch to ”0F .
Disconnect the ECM 22F connector.

 

 

 

Turn the ignirirm swl on to "ON‘C
Measure the voltage at the 0: sensor wire
harness slds connector terminalst

 

Connection: Black/white l-l- Black/green (-)
Standard: Battery voltage ‘

 

Battery voltage Nu voltage

.Open circuit In 02 senr
sor Blacklgreen wlres,

ORepIacc the ECM and
inspect again.

 

5-51

FUEL SYSTEM (Programmed Fuel Injection)

 

ness Slde connector terminal and ground

    

 

Connection: Black/white 1—) ‘Glound 7—)
Standard: Battery voflage

 

Measure the voltage a! the 02 sensor wive har-

 

V Battery vohage

Turn me vgnitlon :wflch to "OHv’i

 

#

 

Connncl the 02 sensor 4P connectors,

,/,‘

 

 

 

 

Disconnect the ECM L‘ulllleulors.

win: harness connectors.

 

 

Canned the ma harness and tes‘ pin box to the

 

 

No voltage

-0pen circuit in Black/white wira between the 02
sensor and engine stup Ielay.

 

5-52

 

Measure the voltage anha lest pin box terminals,

No.17 6 No.2!) ‘6.

 

Conn-mien: No,17 (- ) - N010 (—)
Standard: Battery voltage

 

FUEL SYSTEM (Programmed Fuel Injection)

No voltage

Battery volxage

- Open want In Blankigrpen wlrs between the
ECM connector and Oz sensor AP cunneclors.

- Replace the ECM and lnspem again.

 

5-53

FUEL SYSTEM (Programmed Fuel Injection]

PGM-Fl MALFUNCTION INDICATOR 25 BLINKS (KNOCK SENSOR)

 

Turn the ignition switch to “OFF”,

 

Disconnect the knock sensor connector.
Check for loose or poor Contact on the knock

sensor connectort
,' r

 

 

Cuniiecl llie luiuuk sensul connector,
Place the motorcycle on its side stand.
Start the engine and hold the engine rev: above
2,500 rpm lor 10 seconds or more.

Check llial tile malluncliun iiidiualur biiiiks.

 

25 blinks

1 Does not blink

 

to ”OFF”.

Tum the ignition switch

 

 

 

Distannect the knock sensor connector.
Disconnect the ECM 22F light gray nnnnentnr.
Turn the ignition switch to ”ON”.

Clierk for continuity Blue wire terminals between
the knock sensor and ECM connector.

Standard: Continuity

 

   

Nn continuity

 

Replace the knock sensor With a new nne [page
593). '

Short the service check connector (page 5-8ii
sun thn engine and check that the malfunction
indicator blinks.

 

 

Does not blink
, ”m 7.4»

 

‘ 2b blinks .

>

    
 
 
    

- Loose or pour coiilauls on the knock sensui con-
nector.

- Open or short cirnuit in Blue wire.
I Loose or poor Contact on the ECM connectors.

o Replaced knock sensor is tauityt

I Repince the ECM with a new one. and inspect it
again. i

 

5-54

FUEL SYSTEM (Programmed Fuel Injection)

FUEL LINE INSPECTION
FUEL PRESSURE INSPECTION

m—

I Gasoline is extremely flammable and is
explosive under certain conditions.

0 Be sure to relieve fuel pressure while the engine
is of].

- II the engine must be running to do some work,
make sure the area is well-ventilated. Never run
the engine in an enclosed area. The exhaust con-
tains poisonous carbon monoxide gas that may
cause loss 0/ consciousness and may lead (0
death.

CAUTION

- Before dlsconneatlng fuel tubes, release the ins!
pressure by loosening the service check bolt at
the fuel tank

I Always replace the sealing washer when the
service chock bolt is removed or loosened.

Remove the seat lpage 2 2l.

 

”manner! lhe hannry negallve table from the
batcrvicrmlval.

Remove me iuel mm lllounzing bolls.

Release mo inner panel bosses lrorr m: lucl :ank
lpage 3-6l,

Lilithszanx mee rearendo‘theiueltankand suppcrmusmg
guwly Llellly ma equipped mole lrear axle wrench and
care’um1l.‘n extenslvnl a: slluw'l.
ova—mm: Jhc
'UEIKOSE

 

Dlscomcci the pressure regulator vacuum hose
and plug the vacuum hose.

 

 

FUEL SYSTEM (Programmed Fuel Injection)

 

Cover (he serwce check bolt Wlth a shop mwel. SHOP TOWEL SERVICE CHECK BOLT

» -M [H

Slowly luuwll llle >ulvice Llleck bu“ and 0.4m (he
remalnlng illral llslng an apprnved gavfllnp
conlalner.

 

Remove the scrwcc check bull and attach the fuel
pressure gauge.

TOOL’
Fuel pressure gauge 07405 0040002

Connectlr‘e battery negative cable
Slam“: engine.
HPar‘. the llwl prewlre m ldle spam

IDLE SPEED: 1,100 t 50 rpm
STANDARD: 294 kPa 13.0 kgtflnu2 , 43 ps7

Ii the fuel pressure is hlgher man speclfled, inspccl
the following:
*P'lndled o: (logged fuel .elum hose
Preullre regulator
—Fucl pump lpagc‘i 58h

 

If the fuel DIESSU'E is lowel than spemfied, Inspect
the fnllnwmg'
-Fuc| llnc leaking
* Clogged fue1 filter
F‘rgssure mgulamr
7 Fuel pump lpage 575m

Aflel lllspettiun, install the and tlghlen we service
nheck bolt llsmg lhe haw senllng washer,

CAUTION:

Always replace the sealing washer when the serv-
ice check ball is removed or loosened.

TORQUE: 15 N m (1,5 Kgf-m .11 \bfm

 

5-56

FUEL SYSTEM (Programmed Fuel Injection)

 

Cunnecnhe pressure regulawr vacuum iiuse.

Install the removed pans in the reverse order of
rcmovair

FUEL FLOW INSPECTION
mum—.___

Gasoline is extremely flammable and is explasive
under certain condition.

Remove rhe sent nnwi (page 7-31
Suppon rhc rear end of the lucl tank (page 5 55).

Disconnect the fuel cutoff relay connector,
Jump the Brown and Black/white Wll'e terminals of
the wire harness side using a jumper wire.

NOTE

IWIIEYI Llie luel relum hose is uiacurmecled, gnu;—
iine WIH Splil am from the has» Place the time in
an approved gasoline container and drain the
gasoline.

- ‘Nipe offspilled gasoline.

Disconnect (he fuai ramrn hose ax the MI Iank and
plug the fuel tank inletinint

Turn the ignirion swixch to “ON" for 10 seconds‘
Manure line amuunl ui luel liuw.

Amount oliuelllow:
Minimum 220 cm° [7.4 US 02 , 7.7 Imp ozilor 10
seconds

 

AFTER ’99

 

  
    

APPHUVH) (iASDLINt (ION | AINEH

FUEL cuter; RELAV
/

 

chNECTOH

 

‘\,’\

 

 

 

5-57

FUEL SYSTEM (Programmed Fuel Injection)

if the fuel flow 5 less than specified. l‘SpeCl lhe

loliowmgz

, Pinched m clogged fuel hose ant: tuel return
hnsP

iClogged fuel filter

7 Pressure regulator

“Fuel pump (page 5-58)

After inspection, connect the fuel return hose.
Start the engine and cneck fov leaks

 

FUEL PUMP
INSPECTION

1mm the ignition switch to "ON" and confirm that
ill: luel cums; operate: [or a few seconds.

it me nipl pimp an»: no! npsra'P, mmpm a<
follows:

Suppnr: the neav e \d oitlwe Llel tank lpage 5'55i

  

Disconnect the (uni pump 2P brown connector from
the fuel pumpc

Tum the lgntltm SWltEh to ' ON ' and measure the n

voltage between the terminals.
Culmactiun. Eruwii 4 +)* Gwen ,‘7‘
Thcrc should be battery voltage for a few seconds.

(that? is battery voltage, tep'ace (lie lue' pump
ltmere IS no mnery voltage, inspect the anlnvw'lg‘

*Main fual30A

' Sub ft 5910A, 20A

*Englne stop swutch {sage will)

' Fclel cutroff relay -page 5760-

*Enyille slup relay (page 5-92)
Hank angle wmor lpage 5’91!
55M (gags 5,93) 2P BROWN CONNECTOR

 

 

5-58

FUEL SYSTEM (Programmed Fuel lniection)
REMOVAL

M,

. Gnsnll'ne l; extremely flammable and IS
explosive under certain conditions.

I Be sure to relieve fuel prnssure while the engine
is u”.

CAUTION

 

D Belara disconnecting the fuel hose, release the
fuel pressure by loosening rho snrvice check ball
at the (us! tank,

- Always replace the sealing washer when the fuel
tube banjo ball ls remaved or loosened.

Remove the lucl tank (cage 5761).
Remove the luel pump mmlnling nuts

Remove the fuel pump assembly and packing.

FUEL FILTER REPLACEMENT

Disconnectxhc lucl hoses from tho luc‘ filzcr.
Remove the screws and fusl filler.

InstaH the hlel “Her m the reverse order of removal,

NOTE,

Nolethe dlrecnon oithe fuel filter,

 

FUEL FlLTER SCREW

INSTALLATION

Place a new packing umo me luel lank.

NOTE

Always rep‘ace packing with a new one

Install the he‘ pump being LalElel not to damage
the mel pumnwxre , .

 

 

FUEL SYSTEM (Programmed Fuel Injection)

 

\nsta‘l and Mghan the fuel puwp me‘li' g Huts m
the segue—ca shown

TONGUE. 12 N-m 41,2 kg! m , 9 mm

FUEL CUT-OFF RELAY
INSPECTION

HPmnvaP war [page 2-2',

'emove (he lue‘ who" IEIdV.

Connect (ho ohmwcter to the fuel cum“ 'e\ay conr
neuLur [Emma‘s

CONNECTION: E \ack/whrle 7 Brown

Cannect the 12-v bailevy 10 mg quuwI‘vg [ue‘ L'ul-
off -e>aycnmecmrmmmm

CONNECTION: Brown/black - B‘ack white

There shoum he cnntlmmy On‘v wren the 19M
banerv 5 connectod.

V [here is no cominuity when me 124/ banerv ‘5
:nnnmm mplarechsmel (ut-cffle‘ay

FUEL PUMP

AFTER '99:

FUEL CUT-OFF RELAY
\

 

 

 

 

 

 

 

5-60

FUEL SYSTEM (Programmed Fuel Injection)

FUEL TANK
REMOVAL

Disconnect me fue‘ levehreserve sensor 3P slack
connector.

Supponme rear end oflhe fuel tank (page 5 55).
Re‘ease the [uel ulessuv: {page 555).

Disconnect the fuel pump 2F brown Convector.

Dmcomnect the me! m k on veHl hu>e and uvelfluw
hose,

Disconnect l—e ‘uel hnse sealing mt Ana Seallng
washers.

Tempurdrilv nsta|.(he12 ' 30 mm bolupitch ‘ 751‘
and walmg washers m the fuel to): ba Iju, IIIEH
xigmc" mc seahng mt.

 

 

FUEL SYSTEM (Programmed Fuel Injection)

 

Dwsrcmner‘ [hp “19‘ rpnrn hnfie a! the throws. hndv

Pull the fue‘ tank backward and rc‘casc Inc lront
brackelfromzhe frame.

Place the fue‘ tank JDS‘dS down.

CAUTION

 

Be careful not to damsg- the fuel tank,

Disconnect the incl mum hose from the fuel pump.
Remove the fuel mass banu: huh and swing vm>|1-
ers, (hen Iemove the fuel hose from the [UPI pump

Rcicrto pagc19 27 for fuel level sensor remova‘.
Refer (0 Dane 5-58 lor [ue‘ pump remuvel.

 

 

5-62

FUEL SYSTEM (Programmed Fuel Injection)

INSTALLATION FUEL/TANK
/

    

22 N m (2.2 kél-m ,16IbI-ft) 15 Nlm (1.5 kgl-m , 11 le‘ll

Connect me fue‘ hose to the fuel pump with new
:euling Wa>|lelSA

NOTE

Alzgn the me: hose eyelet joint with the stopper on
the fuel pump.

Install and tighten the fuel hose banjo bolt to YHP
specufled torque.

TORQUE: 22 N-m (2.2 kgl.ln,16lbI-Ill

 

Connect ['10 fuel rclurn hose tome fuel pump.

Install the fuel tank hum blacks: into the flame

CAUTION:

Be careful not to damage the throttle cables

Suppon me lea! end oflhe fuel wk (page 5-55l.

 

 

FUEL SYSTEM (Programmed Fuel lniection)

 

Con—col the fuel pump 2P brown cmnector.

Ccnrcct rh: ‘ucl rank air vcnl hose and ovc'f‘ow
hosarohe fuel rank.

Connecrtha fuel return hose ro lhe rhronle body‘

Comm lhe inel hose hanlo to the mom: hndy
Wlth new seallng washers,

Whiie pushing the fuel hose banjo flapper ro \he
lluullle budy,'lv>1dll .mu lighlel me :ealing 'ul Lu
we ([‘réfiltf‘fl torque

TORQUE: 22 N m <22 kg!m,16lb1h)

Remove the support tools from the rear end of lhe
fuelta"|{

lnsrall me lnncr cover 3095 into the fuel tank
grurrnylels.

 

 

5-64

FUEL SYSTEM (Programmed Fuel Injection)

install the fuel tank mountng coiiars and bolts,
than tighten the mounting baits

   

FUEi. TANK

  

Connect the Luci \eve weserve sensor 3P black cow
USCKOL

AIR CLEANER HOUSING

REMOVAL
Remove the mr niPanPr nlemnnt (page 34",.
Loosen the ignition coii brackat mounting Quit, nit-m

mmuve mg igniiion coil assembly from tbs air
wane.- hmismg m hmh sine.

Disconnect the PAIR air suction mm imm the air
cieanerhmsing.

 

 

FUEL SYSTEM (Programmed Fuel Injection)

 

Remove the av funnel/air Clea-1e! housiv 9 HquHl-
mg screws, then remove the surfunnels

Release the air nmanar hn,1<mg from tht- ram ducts

Discannecx ma crankcase Dreamer hose 1ro~ me
ail cIeavteI housing,

Remove the air cleaner housing,

INSTALLATION

Check thaI lhv‘: myoul: budv O»n‘ug I: in guuu
condmnn, replare n necessary.

Connect the crankcase Dreamer hose to the air
dearer Ivuuaiug.

Insm‘I mp aw rlPaner housing mm the tHrottlz
body whim aIigning its air make opemngs wuh the
ram ducts.

 

 

5-66

FUEL SYSTEM (Programmed Fuel Injection]

 

)vlsldH the air deanev lluusillg unto the thulHe
hndy.

\nstal‘ the arr lunne‘s In (heir proper locatmns
referring their idanrrficarion marks,

msmn and nghmnrhe alrhmnnl/Mr Manner hnusmg
mounting Screws.

Conrccr mc PAIR fresh air hose to the air c‘cancr
housirqv

 

\ ,,

FA‘R FRESH NR HOSE 1

mm“ the igymiun coil bracket assemb‘y lu :he
housing, tigmen he bracker bo‘t secure‘y cm both
ssdes.

hula“ \he diV ulaanev a‘emum (page 3-7).

/

/
EDI BR-GKET

 

 

FUEL SYSTEM (Programmed Fuel Iniection)

THROTTLE BODY

n». W than me
[Name val-1e l'om
’L’i 00$"? 10 ful.’
L/use aller [he
mrml‘P €71th has
bCC/‘l: V50. It
H‘SV CEL‘SS
‘llttilrtl rule

   

"L‘P'a’lcn

(Ta'l‘flwa we
Dr‘ly

@—

- Gasoline is extremely flammable and is
"plush/a undlr curtain conditions,

- Be sure to relieve luel pressure while the engine
is alt.

CAUTION

'Bondlng ar twisting the control cabins will

impair smooth operation and could cause the
cables to stick or bind, rzsulting in has: all vehicle
control.
' Boron disconnecting the fuel "use, rslaan tho
luel pressure by loosening the service check bolt.
- Always replace the sealing washer when the
service chuck bolt is removed or Inoscnccl.

REMOVAL ('99)

Remove the lollow'lng:
Fuel tank lpage 5451}
—Alr cleaner housing {page 5455)

Remove the Ullullle slup screw [mm the guide.
Remove the throttle cable guide bracxct chnt‘mg
bolts.

Disconnect the thlatt‘e cab 9 9m]; harm the throttle
drum

Disconnect the EVAP purqa control solenoid Valve

hose from the throttle body vacuum tube Erway
iomt.

Discnnnect the No 1/3 lgnitlcm coi‘ primary wires

Disconnect the TP sensor connector.

 

TP SENSOR CONNECTOR

 

PRIMARY WHtS

  

 

5-68

FUEL SYSTEM (Programmed Fuel Injection)

 

Disconnect (we MAP sensor connects: and [ue‘ MAP SENSORC
injecluv cunnecmrs, '

@firgcn -

Disuu'lhecl the walel hoses h om the fast ‘dle wax
unit.

Innsen tho: anlne we msulamr hand screws

Remove [he lhrome budv ‘vom ma cvllnder head.

Do no: snap the Remove the ‘nsulalors from the mrome body.
HUGH/E Van's ’Ium
mu npen m 'm‘l CAUTION
crascavmrmn —
Wows can/s has Seal the cylindey head intake ports with rape or a
”an WWW/ed IV clean cloth to keep dirt and dsbn's [rum suturing
may cause the intake ports aflar the throttle body has been

incorrec' was removed,
upy'alluu

 

 

FUEL SYSTEM (Programmed Fuel Injection]

 

Do not snap the
throttle valve ham
lull open to lull
CIDSO ZYlOI MD

MI 0111? cable has
been removed, I!
may cause
incorrect Idle
Upsralran

REMOVAL (AFTER '99)

Remove the lollowing:
—Fuel tank (page 5-61)
A” cleaner housing (page 5-65)

Remove the throttle stop screw lrom the guide
Remove the throttle cable guide bracket mounting
halts

Disconnect the throttle cable ends from the throttle
drum.

Disconnect the No. 1/4 ignition primary wires.
Disconnect the 1?"an hndy 1M" nonnemnr.

Disconnect the water hoses from the fast idle wax
unit.

Loosen the engine side Insulator band screwst
Remove the throttle body [rum the cylinder hem

Disconnect the connectors from the each sensor
and iniaotor, then remove the throttle body sub-
harness from the throttle bodyr

 

 

up CONNE'CTOR

t
THROTrLe BODY at;
THROTILk CABLtb \ £9?

 

 

 

 

5-70

 

 

FUEL SYSTEM [Programmed Fuel Injection)
CAUTION

- Do mat damag: the throttle body. it may cause incorrecf throttle and idle valve synchranlzatlon,
- The throttle body is factory flmset Do not disassemble in a way other than shown in this munull.

0 Do not loosen or tighten the white painted bolts and wow: 0! [hr throttle body {except the wax unit mounting scrowsl‘
Loosening or tlgllum‘ng thnm can causl thwule and idle valve synchronization failuret

 

    
 

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOP VIEW:
wum’ PAINltD ES WHITE PAINTED
\ fi 1/
. e -
a _
VELLOW PAINTED
10 N411 (1.0 kgf-rn , 7 Ibfrft)
REAR VIEW:
YELLOW PAINTED YELLOW PAINTED
22 N-m (12 kgI-m , 16 IbI-II) 77 N-m IZH kgf‘m , 20 IDI‘fII
’\ /
WHI I E PAINTED
5 N m (0.5 kgtm , 3.6 mm
THROTTLE DRUM VIEW:

RIGHT SIDE VIEW:
3 N-m (0.35 kgf-m , 2.5 IDI-fl)

   

WHITE PAINTED

WHITE PAINTED

5-71

FUEL SYSTEM (Programmed Fuel lniecfion)

 

THROWLE LINK VIEW: WAX UNIT AND STARTER VALVE LINK VIEW-

WHITE PAINTED WHITE PAINTED
\

   

1Nrrn (0.09 kgf m , 0.7 lb! ft)

 

THROTTLE BODY VACUUM HOSE ROUTING ('99)

49 stale/Canada type:

 

 

5-72

FUEL SYSTEM (Programmed Fuel lniection)

Calilornia type:

 

i

To EVAP PURGE CONTROL
SOLENOID VALVE

THROTTLE BODY VACUUM HOSE ROUTING (AFTER '99)

 

 

5-73

FUEL SYSTEM (Programmed Fuel lniec‘tion)

INSTALLATION ('99)

Check the insu‘alur Dam; a-wgie

ADD‘V on lo the insu‘ator inside surfaces fur ease of
rhrome bodv inslallaliulL

InsmH the thronle body onto the cylinder head.

Tighten the hmulalul band so the Insulator hand
distance Is ‘2 —‘ 'lmn' {0.5 L 0.04 inI,

Connect the water hnses 10 me fast Ime wax unit,
ughren me clamp screw securely‘

    

INSULATORS
/‘V‘\
/ I m

/ \
’ \‘\

 

1mm

 

\NAX UN‘T

 

 

5-74

Cuii'wm Jyp!
only

FUEL SYSTEM (Programmed Fuel Injection)

Route the t'lanle body sub-harness referrlng the AAA? SENSOR eéfifié‘TfiR’ "‘3
wnwg diagram (page 1-24).

ConV‘CEI the luei injectors and MAP sensor
COHI’IGC‘OYS.

   

     

 

(Innnantthe lFithmttl position] sensor connector TP SENSOR CONfiEtTOR pRiMAHy WIRES
and No. i,’3 ignition coi primary Wires, t \ _

Connect the EVAP purqe contrui soienuid vaive
hose to the thiottie body vacuum hose 5-way Jam:

 

Instail the throttle cable guide bracket to the th mme
body, then tighten the baits to the specified torque.

TORQUE' 3 New (0.35 kgi-m , 2.5 lL-Hli
Instaii the throttle stop screw into the guide.

lnstail [he remnved pans in the reverse nrder M
rcmovai.

 

 

FUEL SYSTEM (Programmed Fuel lniection)

 

INJECTOR

INSTALLATION (AFTER '99)

Install the throttle body sub-harness trnm the
throttle body.

Connect the connectors to the each sensor and
injector.

Install the throttie body to the cylinder head,

Tighten the insulator band so that the insulator
band dls'anne is l7 *' 'lrnrn (0.5 + U 04 inI

Connect the water hoses from the fast idle wax unit.

Connect the throttle hndv1M’ mnneclm

Connect the Not/4 ignition primary wires.

Connect the throttle cable and: from the throttle
drum.

install and tighten the. throttle cable guide bracket
mounting bolts.

install the throttle slop screw from the guide

install the removed pans in the reverse order of
removal.

INSPECTION
m—

. If the engine must be running tn do some work,
make sure the area is wellventilamd. Never run
the engine in an enclosed a" .

.The exhaust contains poisonous carbon monox-
ide gas that may cause loss of consciousness
and may lead to death.

Start the engine and let it idle.
Confirm proper injector operating sounds with a
sounding rud ur stethoscope. »

If the Injector does not operalc, replace the injector.

   
  

14F C\ONNECTOR

r
THROTI'LE eonv \ ,,
i \ ($1

\
THROTTLE CABLES \ ‘
Ill \\ \ /
. ,
\ a .‘

   

WATER HOSES

/

THROTTLE 5T6P scaaw

 

 

 

 

 

 

 

 

SOUNDING HOD
/

 

    

iNJECTOR‘

 

 

5-76

FUEL SYSTEM (Programmed Fuel Injection)

  

REMOVAL MA} SENSOR
/

  

Remove the throme body {page 5-68)

Drsconnic: the MAP sensor vacuum hosc‘
Remove the <nrewand MAP aslIsuv.

Remove the nuis am: fuel was assembly.

”Pmnve the mjemons ‘vum llu: Lhruule budv.

 

Rcvovc :ne sea! rmg, O-rmg and cushion ving,

SEAL RING

 

 

5-77

FUEL SYSTEM (Programmed Fuel Injection)

INSTALLATION

Apply on to the new O-nng.
'Acplhe saaf Initall the new seal ring, cushion ring and O-Iing

mg, cusnron mug
and mm; wrm CAUTION; '8?

New One: 45 a S?! G
a; careful not to damage m O-n‘ng when install- SEN: R'N

ing it. ‘ \

 

 

 

 

 

InstaH the qul Injectors mm the throttle body.

CAUTION

 

Ba careful not to damage the us! ring when
installing the injector into the "wattle body.

r____.——A

Install mp ‘Iml mpe assembly over the fuel wnjecmrs.

CAUTION:

 

Be careful not to damage the Owlngs.

 

 

InstalI and ngmen the fuel pipe mounting nul :u the NUTS
soecxfied Torque.

TORQUE: 1o N-m (1.0 kg m , 7 Inf 9:)

 

FUEL PIPE Assi MBLV

 

5-78

FUEL SYSTEM (Programmed Fuel Injection)

\nslall the MAP sensor aligning 3‘s boss with the hole V
in the fuel wipe, '
Tighten [he mnnnnng srmw secumw

Connem Kha MAP sensor vacuum hose.

mean my. thmma hndy (page 5.74),

STARTER VALVE

DISASSEMBLY

Turn each starter valve adpmmg screw m, counnng
the number of turns until It scam lighny.
Record lhs number of turns.

 

 

No. 3/4 starter valve:
Removu the starter valve arm screws and manor
valve arm‘

No. 1/2 starter va|vez
Remove the screws and wax unit body muunling
screws.

 

 

5-79

FUEL SYSTEM (Programmed Fuel Injection)

Remove the starter valve aum scuews and sla'lel
valve arms,

Loasen the lock nuts and remove the Starlet valve
assembly.

(Jenn me smrrev vulva bypass usmg compressed
air,

CAUTION.

Do not apply commercially available carburetor
dram": ta the lnsldl II, the thrmla bare, whlch I5
coated with molybdenum

Remove the wax unzl link bracket screwv

 

 

5-80

FUEL SYSTEM (Programmed Fuel Injection)

 

Remove the staner valve shaft, khree collms and
return spring.

 

ASSEMBLY
1o Nan (1.0 kgf-ln,7 mm) MAP SENSOR
/’ STARTER VALVE
FUEL PIPE ' 95 2N-m10.18kgf’m41.3|nf-m
INJECTOR ‘

   
    
    

1 N-m 10.09 kgf-m , 0.7 mm.

5 Nlm 19.5 kgl-m . 3.6 mm)
\‘9"

1N-m (v.09 kgv-m, 0.7 {mm

Instan the three cnllars, return spring wax unit shaft
brackcx and s‘aner valve shah.

 

 

FUEL SYSTEM (Programmed Fuel lniecfion)

InsraM the slaner valve assembiy into the valve
hole.

Tigman the naner valve luck Hut lo the specified
torque

TORQUE: 2 N-m (0‘18 kgf-m .1.3|bf-fl)

Install and tighten the wax unit link hrarkel screw
to the specified torque.

TORQUE: 1 N-m (0‘09 kgfrm , 0.7 IM-FU

No. all starlar valve:
Hook the return spring and with [he Noni/4 Slaner
Valve arm‘

Inmall and ‘ighten me sxaner valve arm mounting
screws 10 (he specifiéd torque.

TORQUE: 1 N-m (0 09 kgf.m, 0 7 ”'3va]

 

 

5-82

FUEL SYSTEM (Programmed Fuel lniection)

 

ND. 1/2 stuns! valve:
Inflall the starter valve anns lu the slarler valve.
Tlg men the screws in the mpmhed torque

TORQUE: 1 NM (0.09 kgf m , 0.7 M fil

Instal! the wax unil aasembly unlu [he throttle body,
tlghten the screws m the specified rorque

TORQUE: 5 Nvm (0.5 kgf‘m , 3.6[h1m

Turn the starter valve snrew until u spars Ilghlly,
then back ir out as nclcd during removal

Install the thronle body (page 5—7A)V

STARTER VALVE SYNCHRONIZATION
MEL——

- II "In engine must bu running to do somu work,
make sure ‘ha area is wellvventilated. Never run
the engine in an enclosed area.

- Thu Ixhauit comins polsonoua carbon monox-
ide gas that cause loss 0' constiuusnass and
may lead to dash,

 

 

 

 

 

NOTE:

- Synchronize me starter valve with the engine at
the normal operating temperature and wilh me
lransmission' in neural.

0 Use a tachomm‘er wilh graduations 0f 50 rpm on
smaller that will accurately Indlcere bl) rpm
change.

Support the rear end of the fuel tank (pagé 5755).

 

 

Hemnvn mp. vacuum joint screws,

 

 

 

FUEL SYSTEM (Programmed Fuel Injection)

Connect the vacuum gauge adaptors to the vacuum
wins, the” culmec! the hose: to the vacuum gauge.

Connect (he Iachomexer.

 

 

 

K \‘
ADAPTORS
DiscunneuL [he PAIR air sucunn hoses from the —,;LUG NR SUCTION HOSE
reed valve mvsrs and pmgthe cover. \ \\ W.
x _ K): V,

‘7/

 

  

 

Stamhe engwne and adlusnhe Idle speed.

IDLE SPEED: 1,100 : 50 rpm

The No 3 Stan‘e/ Adpm each zntake vacuum pressure wwh the No. 3
valvccanaoroe cylvndcr‘
SU"US'EIIAIIS!“1E'
base Stan‘vr va’uP

 

5-84

FUEL SYSTEM (Programmed Fuel Injection)

Remove the p‘ugs and connect ""9 PAIR air suction PLUG AIR SUCTION HOSE
hoses to the raed valve covers. \ \
‘ H \

    

Adjust the idle speed If me \dle speed dufiers frnrn
the specified spend.

IDLE SPEED: 1.100 v 50 rpm

 

Remove (he vacuum gauge and adaptors.
mm” and tighten the intake pon vacuum joint
screws

VACUUM JOINT SCREWS

 

 

 

FAST IDLE WAX UNIT WAX ELEMENT covEH
\

DISASSEMBLY
CAUTION:

 

Do nnr loosen or remove the wax unit shah lack
run and adjusting nut.

 

Remove fhe starter valve shaft and wax unit
assembly lpagc 5 79). '

npmove the three wax element cover mounting
screws m a cnss~crnss naflern m 7 3 Maps

 

 

5-85

FUEL SYSTEM (Programmed Fuel lnjectionI

 

  

Remove the wax element‘ sprmg sent and compreSv WAX ELEMENT SPRING
sion spring \ ,’
\ l
\ (l
l
l
I l .r ’
I
/
/
SPRING Sl'Al
INSPECTION wa Fl rMLNl

Visually inspacl the wax element fov damage and
relum spring for fatigue or damage“

ASSEMBLY

Install new o-nngs onto the wax elemem grooves.
Install a now 0 ring mm the groove of the wax ale-
mam COVER

lnsvall the wax element, spring scar and comprcsr \
sion spring, a

\

 

\

 

l»
a $3
v ()-H|NLiS SPRING SEAT CJ-RINGI
Insiall lhe wax element cave! and mounting <rrews. WAX ELEMENT COVER
Ilghl‘en the screws In a CrISS'CrOSS pancm ‘ln MD or \

three GIBBS.

 

 

5-86

FUEL SYSTEM (Programmed Fuel Injection)

 

BARO/MAP SENSORS
OUTPUT VOLTAGE INSPECTION

(tonnam the test harness to the ECM (page 5001‘.

Measure the voltage at the test pin box ter'n‘nak

   
   

Wage 5-11).
CONNECTION:
BARO sensor: Nu. 38 (' ‘, “ND 2 b
MAP sensor an T No 211 ‘
STANDARD: 27,31 V 2 1

2.0
The BARO e! 0 MAP sensor Dutput vnl'age {nhnvm
\$ n‘Paerer‘. “Mar the standard atmosphere
Harm-1,030hP3). 1.5 T
The BARO and MAP sensuv Uulpu! vohage is
afiecred by the distance ahnve sea level because
the. nutput voltage Is changed by atmosphere

 

 

Check me see |eve\ measurement am: be we The: 1-0 ‘
[he wedsured voltage faHs within the memmd ‘
value
05
o 500 1000 1500 2000 :'n

(1,6503 ‘13!!!” Wilbur team-Ween

 

BARO SENSOR REMOVAL/

INSTALLATION ('99 ONLY) “A7,? ”WW

    

Remove the sear cowl (page 2-2L

strnnnnnr me BAHU sensor connector
Remove the screw anu BARO sensor from rhe
bracket.

Msrallmmn \S m the reverse orucroi rcmova‘.

MAP SENSOR REMOVAL/INSTALLA—
TION

Support the hunt em; 0’ 1h: fuel Iel'wk (page 343)

Draconrect mo MAP scrsor cownector,
Remove the screw and MAP aurleur from the
thmttle bony,

1nsla‘lanon is Tn rhe reverse order of removal.
NOTE

Ang\ me MAP smear boss wnh re hole ‘0! the fuel
pipe,

 

 

FUEL SYSTEM (Programmed Fuel Injection)

IAT SENSOR
REMOVAL/INSTALLATION

 

Suspon me from ens Mme ‘ual (ank (paqe $6).

D szonnpn' the \A1 sen<nrcnnnecmh
Remove the screws and IAT sensor from me air
cleaner "ousing

\nstaHahnn H m Ma reverse nmer n‘ remnva‘.

ECT SENSOR
REMOVAL/INSTALLATION

NOTE.

Hsplane me ECT sensov wmle me engmo ‘5 cold.

Drain the coolart from (he syswm lpagfi fi-Si
Suppoftthe from end oi me fus‘ zank ‘pug: 3 5».

Discunuecl [he ECT :gnaur LUIV‘Vé‘ClO‘ (mm the
sensor
Remove me ECT sensor and coming washer.

 
   

InslaH [he new sealing wa>her and ECT sense:

sea/mg y T‘gmen me rm sensnnmne sheathed mrque‘

n 3!!“ a new one.

YOROUE: 10 N m 11.0 kgf-m , 7 "If ft)

rm the nnnhng wstem wnh recommended coolam
Ipage 576}.

CAM PULSE GENERATOR
REMOVAL/INSTALLATION

Sllnnnr? The 1mm and n‘ the meal tank (page 376’.

D<scorvnect me cam pulse generalu' 2° Natural
Connects"

 

 

5-88

FUEL SVSTEM (Programmed Fuel Injection)

 

Remove ms bolts and cam pulse generalur uuver
«55:411ny (rum the cyllnder head

Remove the qasken
Remuve the socke‘ bolts and cam pulse generamr
{mm the nnvnr

Apply ssalanl to the cam pulse genevulol wile
grommet

Install the cam pulse generator onto the cam DUlsc
generator cover and righten the we socket bolrs.

Install the new gasket oma the cam pulse generamr
mver

lnsmll rhc cam pulse generator cover assembly
onto me cylinder head aligning the duwal pills with
the holes In the cylinder head.

Install the new sealing washers and hnlts, then
tighten the bolls m the specified torque.

TORQUE: 12 Nan (1.2 kghn , 9 Iblrfl)

 

 

FUEL SYSTEM (Programmed Fuel Injection)

Route the cam pulse generator wire properly,
connem me 2P natural connector.

Install the removed parts in the reverse order of
removal.

TP SENSOR

INSPECTION

Remove the seat (page 2-2).

Discunnecl ms ECM 12F black and 22F lighl gray
connectors.

Check the connector for loose or corroded
Terminals,

Connect Ihu ECU lesl harness and lest pin box
between the [CM and main wire harnesc.

TOOLS:
ECU test harness D7WMZVMBGO1DO
T25? pin box U7WGZ-001 0100

I. INPUT VOLTAGE INSPECTION

Turn the ignition switch to "ON" and measure and
rnnord the Input voltnga m the last pin box
terminals using a digital multimeter,

CONNECTION: No, 31 (*IiNo. 22 (7)
Standard: 15— 5.5 V

II [he measuremem is uul uI apuciI—Iualiun, chuck
the Iollowung:

— Loose connection of the ECM multiconnector
—Open circuit in wire harness

2. OUTPUT VOLTAGE INSPECTION WITH
THROTTLE FIJLLV OPEN

[urn the Ignmnn swnch to ”UN" and measura and

record the output volragn a! the mat pin box

terminals.

CONNECTION: No. 35 (-H- No, 22 (-)
MEASURING CONDITION: A! throttle fully open

 

2F NATURAL CONNECTOR

    
  
     
 

  

/
rug

in l;

,1

 

 

  

TEST PIN BOX

No.31 EB No.22 9

ll

onauooc
eoannnucam
oaannoocoa
ooaqoooaoa
oaaannapoa
ooaanna

aoaanna oa
0009000 no
oaaoooo nu
oncbnnn on
«manna. on
cannooo on

I

ooonoao

   

 

 

anvvonfiv
cocoacoo
clash-co
Oosaitte
oocaouoa
aueoaooa
ovooonoa
aaoonuno
aunanuau
augaauou

:-

 

 

 

5-90

 

FUEL SYSTEM (Programmed Fuel Injection)

 

3. OUTPUT VOLTAGE INSPECTION WITH
THROTTLE FULLV CLOSED

Turn the Ignlnfln swttch to “ON" and measure and

record the output voltage with the tluutzle lullv

closed,

CONNECTION: No. 39 ['I’NO. 22 (i)
MEASURING CONDITION: Al lhrullle IulIy closed

A. CALCULATE RESULT COMPARISON
Compare the measurement to the result of the
following calculation.

with the throttle fully open:
Maasured input voltage -’ 0.324 = Va

The sensor is norma it the measurement cutout
voltage measured tn step 2 is within 10%01Vo.

With the tIIlUllIe IuIIy LIuSed
Measured inpmvohnge 2' 0,1:Vc

The sensor is nO'MaI if the throttle uluacd output
voltage Illea>uleu in >th 3 is W‘Ithlfl ‘Inih or Vc

Using an analog motor. check that the needle DI the
voltmeter swrnqs siowly when the throttle :5
opened gtadJalIy

CONTINUITV INSPECTION

Disconnect the ECM 22F light qrav culllreulur and
the TF sensor 3P uunnulur

Check for cnnr‘nltlty between the ECM and TF
sensor.

ll there is no continuity, check the men or short
crrmlit Il’l wtre harness,

BANK ANGLE SENSOR

Do not drsmnnecl
mo new angle
SQFSDI CCHHECful

m i n] mmrhnn

INSPECTION

Sllnpnn‘thfi 'nmnrcche on its center stand.
anovc the seat (page 22L

Turn the igmtln’t wll‘t‘h In “ON” and measure the
voltage between the following terminals of the
bank angIe sensor connector wrth Uta tonnector
cunnetled

_ TERMINAL" SENDARD
‘ l e , l Battery voltagL
5 grpant I GrePnI 1 071V

 

 

 

 

:M
at)

onnmmn,

I

    

Manama
aammunnm
onnmmnnnoo
thnnnoun'
«MM/am.“
nmunoonfna
I

 

nonmmz-n

S

3F CONN ECTOR ,

 

 

FUEL SYSTEM (Programmed Fuel lniection)

 

Turn the igmlicn swnch :c "OFF”
Remove ("9 screws am: banx sng‘e sewsor

Ccnnect the bank anale sensor 3P green cun'vecxor
and 'Jlace the bank angle senscr horxloMal as
shown, annmrnthe .gnwmn swnch 19 "m1".

 

The bav‘k Hmfle se'wsu' is nurma‘ n [he ‘cnu'me slop ‘
new 5‘ cks anc powe: suppw ‘5 c osed

    

\
lwcl‘nc mo bank angle sensor approximately 60 i
deqrees w the 2’1 0' fight WW! I?! ingTliuu switch ‘ \ I»

 

 

tur-‘edto"ON"
He bank angle sensor ‘5 normm n the engme smp
rcbv cmks and newer supply we open

NORMAL (approxxmaxilvigf W ,
POSITION NM

 

   

NOTE

 

If you re uhls test. first lurr the :gmlion switch k
to ”OFF' , llle!‘ mm the ngmiqu :wiLle lo "ON' :

 

REMOVAL/INSTALLATION

Rpmnvpmp vanorrnm wnagP 741‘.

Disconnazt the aanx anqla sensor 3P gveen (onnac-
‘0!

Hpmnve m: iwn :nmws, runs and hank Ange
GCnGDI'.

lnslallafiu" i: ‘m We reverse Drum 111' 'emuvd.

NOH:

 

Install the bank angle sense: wkh Ms "LAP” *
lacmgun, -

 

 

5-92

FUEL SVSTEM (Programmed Fuel Injection)

ENGINE STOP RELAY Exam/mam
INSPECTION

vgmnw “w. angme stun reIay.

 

Cunnen (he ohmmetnr m the engme slop rcIav
mnnacmrrermnaIs.

 

 

 

 

 

 

 

CONNECTION: Black/W‘IIIE - Red/w'fl'p r— ’ ‘
‘ I
Liannem [we ‘IZ-V bancrv to me ioIlowinq anqme C; ‘ :
crop reIay connector xermInaIs. i d I-
.1 ‘ ‘
CONNECTION' Had/orangeiBlack ‘ ‘

There Should be continuity uIIIy when the 12V \
battery i, LOHHE‘Cléd. ‘
Ii them I: no cnnrmmty when the 12 v banery IE
connected, replace the engine stop raiav.

 

KNOCK SENSOR
REMOVAL/INSTALLATION

nusmnnecr rhe knock sensor connector.
Remove the knock Sensor.

InstaHatIon IS In the erPrsA n'ner oi removal,

TORQUE: 31 N m {3.2 kgf m , 23 IbHU

ECM (ENGINE CONTROL MODULE)
SVSTEM INSPECTION

Disconrcct PE ECM 22? track and 22? Iighl gmv
connecIurs

Connect the lost harness oerween (he Irain wire
harness and ECM Ipaqe 510.
Cu men I~eIesI pin bzx Ipage 540)

TOOLS:
ECU ‘85! harness 37WMZ- MEG 0100
Test pin box ."I7VE’KEZ-DU1U'IUU

 

 

FUEL SYSTEM (Programmed Fuel Injection)

Check the following items at the test nin box (ermlr

 

 

 

     

 

 

 

 

 

 

m l
No.32 {B No.11 Q
TERMINAL l STANDARD ‘ i
, 7 l
j‘1;th 3028:), gm Hui l BagerxvvaI-tlage _ “a a I a B a 6 o u a a e.
u mun on u

No.11ill Ground( l Cnntin SKEW
Nn.21(+)*Ground Continuity , 23323223383
No.22i+)*Ground(Al Continuity :ggggggggsggg
» aeaoonecoeese
V aeaeoaeeeeeae
It the Items are on! of spnmfina'mn, nhenk lm the .a e e a 9 a e a a e a a a

followmg:
*Open or short circuit in wire harness
- Loose on pool contacts connector

PAIR SOLENOID VALVE
REMOVAL/INSTALLATION

Remove the following:
- Lower cowl [page 2-3l
, Air cleaner houslng cover Ipage 3-6}

Disconnect the PAIR solenoid valve 2F nalmal
connector

Discunnucl [he PAIR air >uuliul| |Iu>e> and remove
the FAIR solenoid valve

Installation is in the reverse orderof removal,

INSPECTION
Remove the PAIR solcnaia valvc‘
Check that the air should not flow 1A) in In), nnly

when the 12V battery is connected to the PAlR
solenowd vaiveterminalat

 

 

 

 

 

 

 

5-94

 
  
 

 

FUEL SYSTEM (Programmed Fuel Injection)

 

Check the resistance berwaen Ihe levminals or the. ' PNR SOLENOIDVALVE
PAIR solenoid valve. /
/
STANDARD: 211724 3 OUT/68°F) i’
I
I! the FesisKance is our ol specifrcahnn. replace rho /
PAIR solenoid valve. LT“
. ; i
‘irfk j
>:_/'-

 

 

 

EVAP PURGE CONTROL SOLENOID EVAF PURGE CONTROL
VALVE (CALIFORNIA TYPE ONLY) SOLENOID VALVE

REMOVAL

Supuorl [he rear and ol the fuel tank (page 555).

Disconnect the EVAP purgn curuiol solenoid valve
2? connector.

Disconnect the air hnse: from the EVA? purge
conrrnl solenoid valve.

Remove the bolts and EVAF purge control solenold
valve braclul assembly

Installation is in the reverse order of removal
INSPECTION

Remove the EVA? purge control Solrnoid valve,
Check that rhe air shmilrl nm flow from IA) l0 (BI.

only when the lZ-V bancry is connected Iu the
EVAP purge comrol solenoid valve \alminals.

 

Check the resistance between the terminals of the

rVAP purge conlral eolenoid valve. . E%€E£gfg$AE32TROL

    

STANDARD: 30* 34 $1 (70 ”IT/'68 "H

II the resistance is out of specification, replace the
EVAP purge cunlvol solenoid valve.

 

 

 

 

 

FUEL SYSTEM (Programmed Fuel Injection)

 

02 SENSOR
(AFI'ER '99 CALIFORNIA TYPE ONLY)

REMOVAL

ML___

Do not suvr‘u thy Oz unsor while thl it is hm,

CAUTION:

' Handle with care the O: sansor,
‘ 00 not an grease, oil or other materials in the
0: sensor alr holes.

 

Remove the lower cowl (page 2-3).
Suppon me from end of me fuel tank (page 3 6).

Disnnnnecr the 07 sensor AP connector.
Remove the 02 sensor unix,

CAUTION

- Ba carolul no! to damage the sensor wire.
- Do not use an impacr wrnnclr Io rnmavn or
install the a 1 mr

     

Install the Dr sensor unit.
Trghren the mm In mp specified torque.

TORQUE: 25 N-m (2.5 kgfim , 18 Ibl fl)

Route the sensor wires porperly, then connect “la
0: sensor IF cunnector.

Insta‘l the lower uuwl (page 2-4),

07 SENSOR CONNECT/OR J _ .
fl // / A\‘”»” “A x
, fl 7‘

   
 

 

I
’37 w

31
(p L

l)

 

 

02 SENSOR

 

02 SENSOR CONNECTOR

 

 

 

 

5-96

 

MEMO

 

COOLING SYSTEM
SYSTEM FLOW PATTERN

FIRST IDLE WQX UNIT

  
  

   
    
    
  
  
   

 

:Z
\
\
/
z

/,
/

/
AIR BLEED HQSE

\\ / \(2‘ -

    

WATER PUMP

[OWER RADIATOR HOSE

 

6-0

b. UUULINU DVD I I:IVI

 

 

SYSTEM FLOW PATTERN 6~0 THERMOSTAT 6-5
SERVICE INFORMATION 6-1 RADIATOR 6-8
TROUBLESHOOTING 6—2 WATER PUMP 6-13
SVSTEM TESTING 6-3 RADIATOR RESERVE TANK 6-16
COOLANT REPLACEMENT 6-4

 

SERVICE INFORMATION

GENERAL a

AWARNI MG

' Wail until the engine is cool belore slaw/y removing the radiator cap, Removing fhe can while the engine is hot and the
coolant is under pressure may cause serious scalding,
I Radiator coolant is toxic. Keen haway from eyes, mouth. skin and clothes.
— if any coolant got: in your ayes, n‘nn them with water and consult a physician immedialely.
— "any coolant is swallowed, induce vomiting, gnrgle .mn consult n physician immediately.
—ll any coolant gets on your skin or clvthes, rinse thoroughly with plenty of water.
I KEEP OUT OF REACH OF CHILDREN.

 

CAUTION'

 

Using coolant with siliuatv corrosion inhibitors may cause premature wear a! water pump seals or blockage olradialor
passages.
Using tap water may cause engine damage.

 

- Add mnlnnt at 'he reserve Innk Do not remove the radiatnr cap except to refill or drain the system.
. All cooling system services can be done with the engine in the Irame,

I Avoid spilling coolant on painted surfaces.

0 After sewicing the system, check for leaks with a cooling system tester.

I IIEIEY to sertlnn 19 for fan motor swnch and coolant temperature sensor Inspection.

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
i SPECIFICATIONS
"Cou'lA'nilgpLil-ny 7 WM. 3.2 a (0.85 us gal , o 70 Imp gall
Reserve tank 1.181025 U§ 99L, 0,24 Injg gall‘¥r . .
_@i§t_griegpglief pregame . ...... “~77 108—137 KPalH—M kglicm‘. 16—20 pail
Thermostat Begins to open SOjjé ”C136" 183 “H W“ . ,,
Fully open . 95 'C {203 “Fl i
Valve Im 8 mm ll] 3 mmlnlmllflj“
Recommended anlilrecze High quality ethylene glycol antifreeze containing corroslon
-. .-,.,..,, protection inhibitors 1
Standald coolant concentration - Eo’imixture with soft water '
TORQUE VALUES
Water pump cover bolt l 13 N-m (1.3 kgi-m ,9 Ibl to CT bolt.
ECT {Engine Coolant Temperatureiithermo sensor 10 N m (1.0 kgl rn , 7 Ibl-ft) ADDlv sealant to the threads.
Fan molar nu! 2 N-m 10.25 kgim , 1 a lbw Applya locking agent to the threads.
Han mmpr SwlIfih 1H N-ml1H kglrm,13|bfvft) Apply sealant to the threads.

 

6-1

COOLING SYSTEM

TROUBLESHOOTING

Engine lemperalure too hlgh Coolant leak
- Fauliv radiator cap

- l aulry water pump mechanical seal
- lnsufficlent coolant

I Dctcriorawd Orrings

. Passages blocked in radiatur, hoses or water lackcl ‘ Damaged or delerioralud gasket
0 Air in sysxem

- Faulty water pump

- Thermostat stuck closed .

- Faulty temperature gauge or coolant xcmpcramrc sensor
' Faulty cooling fan motor

- Faulty [an ivlului swilull

- Loose hose connection or clamp
. Damaged nr uetenorared hose
- Faulry radiator cap

Engine temperature loo low

~ Faulry temperature gauge or ECT,‘marmo sensor
- Thermoslal stuck open
- Faulty Cooling (an mnmr swwnh

 

6-2

COOLING SYSTEM

SYSTEM TESTING ’ . RADIAI'IOH CAP
M

The engine must [76 ml balara Iamm/ing the
radiator up, or severe scalding may result.

 

COOLANT (HYDROMETER TEST)
Remove the lower nnwl1pnga 2-3)

Remove the radiator cap.

T651 1hs coolam gramy usinq a hvdrumeter (see
below 101 “Coolant gravity Chan").

For maximum rnrrn<1nn prmeclmn, a 1: 1 solutlon
of ethylene glycol and 013111100 waler is
racommended (page 6-4).

Louk 101 cumaminalion and replace the Coolant 11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

necessary
COOLANT GRAVITV CHART
Coolannemperamre‘c FF) 1 1 1 1
' 4-———\ 0 5 10 15120125 30 35j40 45 50
Coolam ratio 7. H (321 (4111501 1159) (68) . .77) 186) (95> (100 (113) 1122)
5 1.009 1.009 1.008 1008 1007 1.006 1005 1.003 1.001 0999 0.997
10 . 101311.0171.017101611015110141013(10111100911007ll005
15 10201027111251.02511.024‘1.0221.0201.01B1.0161.0141012
20 7 1.036I1.035 1.034 1033L03111029: 1027 1. 0251102311. 021 1019
25 _ 1,045.1.044 1.043 1.002‘10‘0 103B ‘l 0.15 1 (1'16 1 03111. 028 1. 025
30 7 51.0531105711051 1.017 104611045110“ 1.041 1m03811035110321
:15 1.063 1.062 1.060 1.058 1.056 1.0511 1.052 1.049 1.0116 1043 1040
40 |107211..o7011068 1.066 10611106211059 1056;105st
7» 45 1.0801.0781.o761074‘10721059 1066 1 063 106011067 1054‘
1" 50 110861084 103210110 1.077 1071 1071 1.10680651062‘1059
55 1.095 1.093 1.091 1.088 1.085 1.082 1079 1.075 1.073 1.070 1.067
60 |1,1ool1.osa 1.09511.09211.089!1.ose1106311.056 1077107411071

 

 

 

COOLING SYSTEM

 

Before installing
WE Cap in me
iesmr we: me
sealing surfaces.

RADIATOR CAP/SYSTEM PRESSURE
INSPECTION

Remove the radiator cap (see previous page).

Pressure msv the radIBIDT cap.

Replace the radiator can if it does not hold pressuie,
or if relie' pressure is mu high 0! too low

Iv. muleIuld specified pressure inr at least 6 sec-
onds.

RADIATOR CAP RELIEF PRESSURE:
108—137 kFal1.1—1.4 kgf/cm', 'IS 20 pS|i

Piessuie the radiator, engine and hoses, and check
for IPaks

CAUTION:

Excessive pressure can damage the cooling
eystem components. Do not expand 137 “’2
(1.4 kgf/nm’, 20 psi).

Repair or replace components if the system will not
hold specified piashure Ian at least 5 seconds.

COOLANT REPLACEMENT

PREPARATION
W_____

. Radiator coolant ls toxic. Keep it uw-y from ayes,
mouth, skin and clothes,
7 If any coolant get: in your eyes. rinse them
with water and consult: doctor Immediately.
—Il any coolant is swallowod, induce vomiting,
g-IgIe and consult a physician immediately.
7 If any coolant gets on your skin or clothes,
rinse thoroughly with plenty of water.
I KEEP OUT OF REACH OF CHILDREN.

CAUTION:

Using coolant with silicate inhibitors may cause
premature wear a! water pump seals or blockage
of radlamr passages. Using tap witer may Cause
engine damage.

 

RADIATO

GA

1..

P‘TE m

 

 

COOLING SVSTEM

 

NOTE
ANTlFREEZE
- lhn aflenluvenas: nl rnnlam denmaspe wlth ’he SOLUTION
accumulmlon o“ rusl or if more 5 a change nu ma
mlx‘lng Dropom‘on during usage. Therefore, for w
best .Jevfuununce change we Luuldm ~51,me LETHVLENE

   

as specified m the rr‘ammwanca smamue GLYCOL 8A5: ‘
'Mlx anly distilled. low mineral wa_cr wnh (he SOLUTIONl LOW MINERAL l

amil'esze. agglgmw ‘
RECOMMENDED ANTIFREEZE: 1
High quality ethylene glycol antil’eeze conlaunlnq
corrosion proleclion Inhibitors COOL/WT ‘
RECOMMENDED MIXTURE:

1: l lDlslllled walel and dlllll’leeiel

 

NADIAIUH (ZAP

    

REPLACEMENT/AIR BLEEDING

The Engine must be cool before servicing the coal-
Ing synem, or “vars scalding any result

NOTF

When filling the system or reserve lank wuh a cool-
am (checking coolam level), place the molovcycle in
a vemnal pnsmnn on a rim, level surface

Remove the ladiator cap

Remove the drain bolr on the Wale! pump cover
and drain lhe svslern coolant.

Hemove the cylmder dram bolt and dram the cool
am from the cylinder,

Hemstall the dram bnlt with the new seallng washer

 

 

COOLING SVSTEM

 

Remuve [he fullewiug
*Seat (Fig? 7-7)
Lower cow‘ (page Z 3)

D sconnec: We Mpholl hose hum we radiator

‘Jraln the reserve Iank coolant.
Emmv the coolant and ’mse the iHsTde or [he
resulve tank with waver

Hamstal the radwatorsbho" hose

Fill [he :ysten‘ with the recowmnnnan comm:
1hmugh the mm npenmg up In finer neck.

Remove :I-e radiatnr rssprw tank nap and nu the
rese've ter‘k to the upper level Ime.

Bleed air hum [he Wm.“ a: wow.
Shift vhe transmmunn mm neutral sum the
engme and «91 it wd‘e for 2 . 3 minutes.

. Snap the (meme 3*A times [C bleed 2.r from me
ay>lem.
Step mp. engme and add rnnlar‘l up to the nvnper
level ii necessary. Rcinsmll xhc radwamr cap,

.Check the level of coo‘ant in ms reserve ‘ank 87d
nu to (he upper levd if n ‘5 'ow.

N

u

p

 

THERMOSTAT
REMOVAL

Dram the coolant (page 975).
Supponme from end oixhe Vuel tank {paqe 3-61‘.

Remove [he lower Luwr [page 233.

Remove the nous and khermosim hcueiwg cover.

 

 

6-6

COOLING SYSTEM

 

no no! IaI ma
{/Irrnvi‘SVaI' or
Ihermnmzler
men mc can or
um WW gar IaIse
.eadng

Hemnve me thermostat from the housing.

INSPECTION
m ,

0 Wear insulated gloves and adequate eye prarec-
tian.

- Imp flammabla mar-rials away from the elec-
Iric hating element.

 

VisuaHy insueu'. [he lllev nmslal for damage
Check for damage m m ml rmg.

Heat the water with an electric healing elemem lo
uperdliug lenlpevaluve iov 5 mznmes.

Suspend mp vhprmnwm In hemad water to check
It: oparauon.

 

Rep‘mce the Ulelll‘u:lal ‘II Ihe valve stays open a:
room tefiperamre, nr If II respnnds m temperatures A\
omer than “1056 Specified ’

   

 

I v?—
THERMOSTAT BEGINS To OPEN: ‘ \’
8f] 84 3!: I|7FI 18.1 “H THERMOMETER
' 7K
VALVE LIFT: / (MIN: \
8mm IO.3iII) minimum 3:85 a(21185 °F) \/ \\

INSTALLATION

InsIaH the thermostat imo the housing wIth Its aIr
bleed hole [acmg up and allgning Its ribs with the
grooves ‘In Ihe housmg,

 

 

 

 

COOLING SYSTEM

lnslall the (heunosta! housing cove: 0110 the 'qu5-
mg,

Install and lighten me housing cover bolls

PM (ha sys‘lcm with recommended coolant and
bleedthealrlpaues-El.

RADIATOR
REMOVAL
Drain the molam (pagP 674!

Remove the following:

7 Lower cuwl (pay: 2-3:
er‘d gllarfl lpage 744i

l

l

Remove We all Cooler mounting Dolls and harness ‘

guide.

Remove the ml nnnler :mm the nrnnkels and ranmv

(or, men mow: the oil coolcr'orwam.

 

      

Dlsnnnnent the slphon mm and air bleed lube from - -‘ Emu-{q ‘
(he radiawr, m‘

Dlswnnecx lhe upper radiator hose.

 

COOLING SYSTEM

var

‘w _ “ \
WTLJFXAE CONNECTOR
1

‘2?

      
 

Discomeci the (av motor sub-harness 29 naru'al
canneclor.

  
 

Disconnect me lowev radialur huse‘

Hemovpms ramamr mnunnng hnlt

Shae me rametor to me left, then mouse the upper
and lower gyommem from the bracke‘ bosses.
Ramove the ”dim. aa>umbly

CAUTION:

Ba EarEfuIllul to damage the radiator mm,

 

 

/ 1' V,’ Ja- \K_\
LOWER GROM’MET HADIATOFI

 
 

D'SASSEMBLY Gaourgo EYELET CLjMP BQLTS

\

     

Discur‘ned the (an mnmr swumh nonnecmr and
release the cord from me clamoe «’99 mm.
Remove ms ‘hree bolxs, ground eyelel and Ian
mmol/Cnuling fan assemb‘y

     

 

6-9

COOLING SYSTEM

Remove We 'vul and cooling fan egoUNQ FAR

 

   

Remove (he cuHar from thP hm mnmr shah,
Remove the flange nuts and fan motor from me
brackcn

FLANGE NUTS

     

FAN MOTOR

For fan motor swmh infnrmmmn, rgiev m page
19-23.

/
COLL/\R

ASSEMBLY

'99:
2 N m (0 25 kgf-m ,1 8 lbf-fli‘

 

 

/ ,
RADIATO? / f

 

' FAN MD | UH
COOLING FAN COLLAR

 

6-10

COOLING SYSTEM

After'99'
2 N m10.25 kg! m , 1.8 [bf ft) 18 N‘m {1 B/kgfl'w, 13 \bf-h)
\ /

  
  
    
   

, BRACKET
/

RADIATOR

\

/

COOL|NG FAN FAN MOTOR
COLLAR

lnsraH the Van mntnr nnm me Van motor bracket anc FAN MOTOR
mghtsn Ihc nuxs
Install the CoHar unto the fan mmur shall.

Install the coolmg fan onm the fan molor shaft by
aligning the Hal surfaces

 

 

COOLING SYSTEM

Apply a IOLKSIIH agem m m rnnlmg Ian nut threads.
InslaH 5nd nghren he nu: lo the spccllnec quual

TORQUE :2 l\-m [0.25 kglrm , 'I 8 Hit)

 

 
   

Install thp ‘an mnmrmnollng lan assembly onto the GROUND EVELET CLAMF BOLTS
radiator ,
Home the fan motor swilul‘ culd and glo.:nd ey?‘PY

plupellv

ln<mll and flgmen the bolts.

Connect the (an mum >WlILI7 covd to the fan momr
switch and :larp v. as ahnwn (‘99 m-Iy).

INSTALLATION

CAUTION.

Be careful not to damage the radian" core‘

lnslnll the mmnmr assembly, allgfllr‘g ils grommets
with the bosses on the upper and lower brackels.

Install and tighten me radiator moaning bun

 

 

6-12

COOLING SVSTEM

 

. , . . . ., , . ex: \
Connect the (a! motor subltdrlless 2P Ildlu al Wm“ CONNEGIOR
connector .

Connect the lower tadrator hose.

 

Connect the upper radiator hose.
Connect the siphon hose and air bleed hose to the
radiator.

Install the ml cooler onm the radtator and oil cooler
brackets, install and tighten the mounting bolts.

NOTE

Inatall the main wire harness guide onto the left all
cooler bracket.

Fill the system Wlth the recommended coolant
{page 6-5).

Install the lollowtng:

'Lowet cowl (page 2-4)
rWrnd guild lpage 2-1“

WATER P U M P
MECHANICAL SEAL INSPECTION

 

lnspect the inspection hole for signs at coolant
leakage.

If there IS leakage, the mecha‘ntal seal is defectrve,
replace the water puma as an assembly.

 

 

COOLING SYSTEM

 

REMOVAL
Damn the coolant {page 674).

Dwacolmecl the \ower radmluv Muse and byudss
hose {mm the may pump rover,

Remove the four flange bows and wa‘er pump
covet

Remove {he Orrirlg hum llle Wale! pump budy.
Wemnvn mp water nur‘m hndy‘mm m» nrankra<a

Disconned the wee. meprloVwa‘er Jam: hose
i'om me water mmp hnfiv

 

 

6-14

COOLING SYSTEM
INSTALLATION

    
  

WATER PUMP BODY
\

VJATER PU MP COVE\R

73 N-n1113 kgflrfl , 9 le‘tI

Connect me wawr pump-[o-Water joint hose [0 [he
Mm pump and Ughlell me Llalnp surw.

Apply engine on m a new O-ving and irmaH u onto
the stmped pomon o! the water pump

Install the water pump into the crankcase while
alignifig the water pump shaft groove wmh the oil
pump rash and,

 

 

COOLING SYSTEM

A! gm the "'Dunt'mg bah hm“ 'n ma. wfiier rump
anr: snkcasa and ma<e sure no water pump 5
securely inmalleo.

 

Ingrall ; mew 0mm; mm up g-nnw, n m». wa-er
pump body.

Inna“ the water pump cover and [lghtel’l lhc four
flange oaks :0 me spcmficd mrque.

TORQUE '13 N m (1.3 kgi-m,9lb1-m

Connect the ‘owe' radiator hose and bvnass Kube,
than uqmsn m:- lelrlu mews.

RADIATOR RESERVE TANK
REMOVAL

Remove rho foHowing:
*Rearfsndsr {page 2-15!
v—sm la” (page 272m

Remove the brake pipe from me guide on me frame.

Rcmcveme shock absorber {sage 14-9).

Release the monk from we angme mounllng Cohan
then 'emovc the reserve tank backward.
Disconnect the siphon hose and drai'x [he uuulam
flu-w The reserve tank'

 

 

6-16

COOLING SYSTEM

 

INSTALLATION
Connect the siphon huse to the radiator and instaH
the radiator reserve tank ahgmng vrs hook with the

angrne mounting coHar.

Irma“ (he removed pans in the reverse order of
:emuvalv

NOTE.

 

A! rear fender msmminn, align the cur-out nf the
rear fender wrth the reserve rank filler neck boss.

 

SlPIjON HOSE RESERVE TANK

  

 

 

6-17

ENGINE REMOVAL/INSTALLATION

54 N-m (5.5 kgf-m , AD \bf-ft) 54 N-m15.5 kgtm , An Ihhm

/
z

39 Nm (4.0 kgf-n1,29 my” 6 H Nm (1 1 kgf‘m , 8 Inf-m
\ /

         

/
an N-m(A1kgf-m.
30mm

5A N-m (5.5 kgfim , 40 lbf ft)

   

[/54 N-m (tub kgV-m , 40 Ibf f1)

12Nm(1.2kgfm,9lbfm

12 Nrm (I 7 kgf-m , 9 H1141!

 

7. ENGINI: HtMUVAL/INSIALLAIIUN

 

SERVICE INFORMATION 7-1 ENGINE INSTALLATION 7-6
ENGINE REMOVAL 7-2

 

 

SERVICE INFORMATION
GENERAL

I During engine remaval and installation, support the motorcycle on iis center fland
0 Support the engine usmg a Jack or other ad’ustahle suppon to ease of engine hanger bolls removal.

CAUTION:

Du no? use the rail filter as a inking point.

 

 

- The (allowing compnnen's can he sen/med with the engine insiaiied in me. mime
~Alternator [Section 10)
*CIutch (Seclion 9)
7 Cylinder head/valves (Secliuii 8)
Front halancer (Section 17)
—Gcarsnifl linkage (Section 9)
*OI) cooler (Section 4)
, Oil pump (Seuliuli 4)
5th ’nrkslshm dmm (Harman 9)
nWamr pump (Suction 6)

- The following components require engine lemoval for service
Crankshaft/transmissmn (Section 17)
7 Pistoni'cylindcr (Scclion 11)
* Rear balancar (Saclion 12)

 

  

 

 

 

 

 

SPECIFICATIONS
ITEM ‘ SPECIFICATIONS
,Enginegri'weighl 7 Th ’ TAT 53.0 . T ’T
Coolant capacity Radialor and engine 3.2 A (0.85 US 95! ,_O.70 Imp qal)
Engine uil capacity Al disassembly 4.6 £34 9 us ql, 4 o Imp qt)
TORQUE VALUES
S<de slund hrankm hnlt 54 Mr" 15 ‘5 kgfvm , l0 lhI-fl)
Engine hanger bolr 40 N-rn (4.) kgI-m , 30 lb! Ill
Engine hangar nul (Rear/upper) 64 N‘rn (6.5 kg! m i 47 |bf>fll
(Rear/lower) SA N-Ill (6.5 kgI-ill , 47 lblifl)
Engine hanger adjllsllng mm 11 N-ml1,l kgf-m,8lbI-lt)
Engine hanger adjusting bolt lock mil 5‘ N-m (5.5 kglvm , 40 lel)
Drive spruckel cover damper mounting bolt 12 N-rn (1.2 kgl»m , 9 lbI-ft) Appl»l a locking dgEllI (u the threads.
CT bolt.
Wire clamp flange Doll 12 N-m 11,2 kgfrm , S Ibl-fl) Apply a locking agcnl lo the threads.
CT boll.
Drive sprockel special boll 54 N-m (5,5 kgf-m , 401nm)
TOOLS '
Lock mil wrench 07VMA-MATO‘IOD ul 07VMA—MAT010A/U SA, on(y)

 

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL

Suapo’l (he motorcycle securely on its Dewar stand.

Remove mp. Inllnwlng'
ALower cowl lpagc 2 3l
*Fusl rank (page 5761)

*7 Throttle body (page 568)

Disconnect the (ollowlng connectors:

*lgmion lese generator 2P red conneclor

‘ Cam pulse genelalol 2F blue connector
Speed sensor 3P natural connector

*Siac sta'ld swlrch 2P green connacror

- Engine subrhamess 6P nalmal cunneuur

Ulsconnect the alternator 3P whlte conncmor.
Release the allernalor ere from the frame.

Discornect the spark plug caps

Disconnect the PAIR alr hn<95 '(nm the "NH med
valve cover,
Rsmovs the PAR solanoid valvs.’hosas assembly.

Discumlecl me air bleed mm. and uppel radialol
hnse lmm me mermmlal hnusmg cover

Remove the hours and waler joint from llre cylinder
Islam

Remove the bolt and starter motor ground cablc.
Remove (he nul and starter molar cable.

 

CDNNHIIUHS

 

 

7-2

ENGINE REMOVAL/INSTALLATION

 

Disconnca me \ower radxator hose from me water
Dump COVBV.

Remove mamnnwmg-
7Mufflcr,’cxhausl pipe wage 2722)
- Oil pipes {page 4713)

, Radiatm (page 67;

7 Dutch slave cyhndar {page 940'

Remove the ban and gearsnm paaav,

Remove me bows and lowercovw brackets from the
92) pan
Hemnve fhe how and rad-am \anr bracket,

 

Remove the S4 bolls‘ dee 5:”
guwdemme.

e! ‘uvur om.’

Loosen t'vc ma“ 3on nut and make (he urlve cham
slack fully.

Shift he transmission ‘mo 6“. gem dud app‘y rear
brake.

Remove me bolt, washer and drive sprocket.

 

 

ENGINE REMOVAL/INSTALLATION

Remove the sticky hnlts and side stand b'ackci
assembly.

Remove the mar/upper and reenllower cnginc han
gar nuts

Inmen me rfinrl'upper engine hanger adjusting bolt
lock nux while holding the adjusting boll using ”it:

special tool.

TOOL:

Lock HUI wrench 07VMA-MAT01OO ur
07VMA-MATD10A
(u 5A nnlyl

mm the adjusting bok wim the engine hanger bolt
counterclockwse to release the adjuslillg bolt from
mg engine.

 

 

7-4

ENGINE REMOVAL/INSTALLATION

Loosen the rear iowcr cnginc hanger adiusting bolt
iuck nut whiie holding the adiusting boil using me
special tool,

 

TOOL:
Luck nu! wrench 07VMA-MAT0100 or
07VMA»MAT01OA
(u SA, nnly)
Turn the adjuenng bolt with the engine hanger bolt 55 EEILT ‘

uuunlemloukwise to release ma adiusting boll from
the engine.

 

Suppurl the engvne usinq a iack or other adiustabie
supporno ease of engine hangev bolls lemovai.

Remove the right CnginD hanger boil, washer and
distance collar.
Remove the left engine hanger boiis

 

Remove the lEar/uppu engine hanger DOM. dis-
tance nnliars and spacet.

 

 

ENGINE REMOVAL/INSTALLATION

Remove the rear/lower engine hanger boll. then
remove the Engine nun. the (lame.

ENGINE INSTALLATION

NOTF

 

- Now the diracxlon of the hanger bullsl
. Use a flaol jack or other adjustable <Ilnpnn to
carefully maneuvarthe engine Into placc‘

 

 

 

hula” Ule engine hanger adjus‘ing bolls so that me l
adjusting hnlvs dnes nnl nrmemed Inslde surface of
the frame.

lmlall HIE angina into the frame

Install the rear/iower el’lglne hanger hnlr

/

REAR/LQWER HANGER BOUT

 

 

ENGINE REMOVAL/INSTALLATION

Install the rear unpcr engme hanger With me.
distance collars,

4mm” the distance collar] washer and right cngme Ell-WP yggm
hange. boll. “

Install the left engine hanger bolts.

CAUTION,

Install the right and left Iron! engine hunger bolt:
in thnir proper [unions Improper Installation will
damage the cylinder hunt

Tighten the rear/lower engine hanger adjusting bolt
to the specified torque‘

TORQUE :11 N-m (1.1 kgl»m,8|bfhl

 

Tighten the rearJuppeA engine hanger adjusllllg
Doll [0 the specified (mane.

TORQUE .11 N-m(1,1kgf-m,81bf»fl)

 

 

ENGINE REMOVAL/INSTALLATION

Hold ‘he vean’luwer eng'me hanger adjuslmg bo‘l
and tighten the adlushng bo‘t lock nm (a [he speck
had mmue usmg mc succial mol.

TOOL:

Lock nu! wrench U'NMArMATO'lOO Dr
07VMA7MAT01OA
(U.S.A. on‘y)

TORQUE :54 Nm (5 b kgf‘m , 40 Ibf (1)

Hold the rear/upper engine hanger adjusmng bolt
and nghmn me adlustmg boll lock nul [0 the speci-
fied torque using the special xool.

TOOL:

Lock nut wrench 07VMA MATDIOO or
07VMA-MATOIOA
(U S A only)

TORQUE :54 NM (5.5 kgf‘rn , 40 \bf-m

nuls to the specified wrung

TORQUE164 N-m (G 5 kgf-rn , 47 mm»

llgmen from/fight and from/left cng'me hanger
bolts :0 the specified mrqua.

TORQUE :40 Nm [5 'I kgi-m , 3U lbf-ft}

 

 

ENGlNE REMOVAL/INSTALLATION

 

Rome the side szand switch wire properly Ipagc
1-24).

Install the side stand bracket and tighten the socket
hnlls m lha Specified torque

TORQUE :54 N-m (5,5 kgf—m , 40 lbfii)

Insmll the drlvc sprocket with its ”530” mark lacing
outward.

luslall the wasilel and lighten the bolt to the
speclfiedtnrque,

TORQUE :54 Nm (5.5 kgl-m , 40 inf-h)

Install me dowel pins and drive chain guide plaxe.

 

Install the drive sprockel cover and tigmsn the SH WWW

bolts.

  

 

ENGINE REMOVAL/INSTALLATION

metal the lower cowl brackets ante the oil pan fiADrAV-WRW I, .x
bosses, tignten the bolts securelyl ‘ ‘ .

Install the radiator inwer bracket onto the cvllndcr
hlock, tlgnten the bolt securely.

lnstall the clutch slave cylinder (page 9712).

lnstall the gearshift pedal altgntng us slrt wrth the
punch mark onthe gearsnlft splndlcl
Tighten the bolt securely.

Install the ranlamr tnnge. 5-12! and connect the
lower radiator hose and tighten the clamp screw,

Imlall [he llluHIel,’ex|1aust plpe lpage 2-24l
tznmem the ml nlpes (page MA).

Route the starter mutu— Ldble and gluulld cables.
Tlghten tne starter motor cable nut and grnltnd
cable bolt,

Illslel‘ me water julrlt tu the cvlilldel bluLk and
tughtenthe bolts

Connect the elr bleed hose and upper raciator hose
to the thermostat housing cover.

I":|a|l llle PAlR sulenuiu valvel‘huses assembly into
thetrnme

Connect the FAIR alr noses to the PAIR reed valve
covers,

Install the spark plug caps.

 

 

7-10

Route the attc'nator wire into the frame. connect
the altern- 0' GP wtme cunneutuv

Connect the followinq connector:

~ tgnition pulse genemtur 2P red connector
Spend sensor 3|“ whtte Cnnnectnr

, Sidc stand switch 3P green connector

> Enqina sub-harness 3P mack Cu'vlteclov

Install the followtng:
*Throttlc hodv {page 574}
*Fus‘ tank tpage 5'63)

, Lcuwg’ cowl {page 274',

Adjust the drive chain slack (page 3-22),

Puur recumv'wuded engine oil up to (he pvopet‘
1»va (pagP 371R)

F H the cooling system wim recommended Coolant
and Need the atr {page 6-“.

 

 

ENGINE REMOVAL/INSTALLATION

 

7-11

CYLINDER HEAD/VALVES

 

10 N-m (1‘0 kgfm , 7 lbi-ft)

\\ 12 Nrm [1.2 kgf-m,u mm
\

   

\ GB NAm (7,0 kgf-m.
‘ \ 51 leU
V

A
10 N-m (1.0 kgf-m . 7 Ibf ft)

\
12 N>m('12 kgfvm , 9 lbf-fl]

 

8—0

8. CYLINDER HEAD/VALVES

 

i SERVICE INFORMATION 8’1
TROUBLESHOOTING 8-3
CYLINDER COMPRESSION TEST s4
CYLINDER HEAD COVER REMOVAL 3-5
CYLINDER HEAD COVER
DISASSEMBLY 3-6

3 CAMSHAFI’ REMOVAL 8-7
CYLINDER HEAD REMOVAL 8-11
CYLINDER HEAD DISASSEMBLY 3—13

  
  

CYLINDER HEAD INSPECTION 8-14

SERVICE INFORMATION
GENERAL

VALVE GUIDE REPLACEMENT
VALVE SEAT INSPECTION/REFACING
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD INSTALLATION
CAMSHAFI' INSTALLATION
CYLINDER HEAD COVER ASSEMBLY

CYLINDER HEAD COVER
INSTALLATION

CAM CHAIN TENSIONER LIFTER

D Tm< servon covers service of We cylinder head, valve> and camshall.
. Tnc camshafl servmes can he dnns wwh the eng he Installed in the frame. The :ylmder head sevwce :Equiued EHgina

vemovat

8-16
8-17
8-20
8-21
8-23
8-27

8-27
8-30

 

- \N'IcH dISdSSEIIIIJIIIIg, mark and sxora the disassembled pans to ensure (hauhey are remstaued in mcir original locations.
'Iilean an dv<a<sembled parts with clean ng SuIVE‘HI and dry [ham by Mowing ihem qu will» wmprassed air before

mssectlon.

- Camshah lubricanng oi‘ is fed mrough on passages in the CYIlndeY head. Clean the 0H passages befiore nsgemhlmg the

cylinder head.

' I'IA rareful not K0 damage the mating suyfaLe> when removing IIIE cyflnder head uquv Alld cyIinder head‘

 

8-1

CYLINDER HEAD/VALVES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
.. Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression ‘ 1,275 kPa (13.0 kgmm2 , 185 psi)
_,, ‘ at3§0 rpm
. Cylinder head warpage 7* 0.10 (0.0041
Valve. valve Valve clearance IN 707.16 + 11 0:1 (0.006 t 0.001) —
guide 1 77 EX 0.22 1 0.03 (0.009 1 0.001) .. i
Valve «am 0.0. IN 5.975A4390 [0.1959-0.1965) 4955101955)
. Ex 11360-4375101953 (119591 4350101949)
Valve guidelD. ; IN 5000 5.012 (0.1569* .1973) 504010.19“)
‘_ I EX 5000* 5.012 (0.1969- .1973) 5.040 (0 [$541
, Stem-to-guide clearance 1 IN 0.010—0.037(0.0004— .0015) ——
l EX . 0.025— 0.052 (11.00107000201
Valve guide prujeLliDn IN 15.] ~ 16.11 (0.64'005) __
above cylinder head EX 163* 16.5 (0.64—0.85) ‘
Valve seatwidth IN/EX 030—110(0035—0043) 1 1.5(0.061
Valve spring Inner lN/EX 37.4 (1.47) 1 35.4 1.39!
free Inn in Outer 1 IN/EX 40.6 (1.60) ‘ 38.61152)
Valve litter Valve lifter (LL). INJEX 25.978i25393 (110228- 1.0233) . 2537110221
._ Valve lifter bore |.D. INJEXH 281010—26.026(1.0249 1 [17551 E 26.0411025!
Camshofi 1 Cam lobe heiqht IN 33 A? 311.5011513—1516] T 38.121115011 '
‘ LX 33.3av3a.aa(1.511—1.514) 1 33.011114991 |
Runm # 1 0.051000?)
1 Oil clearance 0.020~0.074 (0.0008 0.0079! l 0.10 (0.004) I
TORQUE VALUES

Cylinder head cover bolt
Erealliel plale flange bolt
Camshah hnlrler flange bolt
Cylinder head scaling bolt
Cylinder head mounting bolt

Cylinder head SH bolt

Cam sprocket bolt

Cam c1141" Iellsiuiiel cap nut

Cam Ehain tensioner Iim=r mnunnng halt
Cam chain Iensioner lihersealing bolt
Cam chain guideA mounting bolt
Cylinder head :lud bolt

F‘All'I reed valve cover tlnnge bait
Vacuum joint plug socket bolt

Cam pulse generator Cover 5H bolt

 

10 N-m (1.0 kgf-m , 7 Ihi-l’t)
12Nvmi1.2kgflm,9|bf1fii
12N»rn (1.2 kgf‘m , 9 Ibf-tt)
32 N-m (3.3 k
69 N-m (7.0 kg 411,51 Iht‘ft)

I , 24 lIuI‘ft)

Apply a locking agent to [he Ilireads CT bolt
Apply uil lo Ihe threads.

Apply a locking agent to the threads.

Apply molybdenum uisuliide oil to the threads.

(after removing anti-rust uil additivel.

10N m(1.o kg1m,7 lbf-ft)

20 Nrm12.0 kgl-m , 1A lbfrh}
12Nvm (1.7 kgi-m,9 1mm

1uN-m(1,o kgirn,7|thl

12 Nvm(1.2 kgfrn.9IbfAftl

12 Min (1.2 kghn, 9113110

See page 145

10 N-m (1.0 kgf»m,7 1mm

3 N m (0.3 kgf-m , 2.2 lbI-l‘tl
12 N-ni (1 2kgf-m,9 Ibm»

Apply a Incking agent to the threads.

 

CVLINDER HEAD/VALVES

TOOLS
Compression gauge attachment 07RMJ<MV50100 Equivalent DulllllIElElally available in USA
Valve spilng compressor 07757-0010000
Valve spring comnressnr attachment D7959-KM30101
Tappct holc protector 07HMGVMR70002
Valve guide driver, 5 mm 07942»MA80000
Valve guide reamei 07984-MA60001 or 07984»MA6000E (USA, only)
Valve sent miners . *these are commercially available in USA.
Scat cutter, 33 mm (45° lN) 0778070010800
Seat cutter, 29 mm (45" EX) 07780-0010300
Flat cutter, 33 mm (32‘ ml 07780-001290!)
llnt cutter, 30 mm (32“ EX) 01780-0012200
lntcrior cuncr, 34 mm (60' IN) 07780-0014700 Newly designed tool
lnlerior Cutter, 30 iii!" (60‘ EXl 07780-0014000
Cutter holder. 5 mm 077El-OO1OA00

TROUBLESHOOTING

0 Engine top>end problems usually affect engine performance these problem can be diagnosed by a compression test or by
tracing engine noises to the torrent! With a sounding rod stethoscope.

- lithe performance is poor at low speeds, check for white smoke in the crankcase breather tube. if the tube is siiiuky, check
lur a seimi pislun ring lSection 11),

Compression too low, hard starting in poor performance Exeesslve noise
at low speed 0 Cylinder head:
- Valves: Incorrect valve adjustment
Innnrrnnt valve adjustment —Stickina valve or broken valve spring
7 Burned or bent valve *Demaged or worn camshaft
* Incorrect valve timing * Loose or worn cam chain
‘ Broker valve Sphfig Wnrn or damaged cam chain
- Uneven valve seating —Wem or damaged cam chain tonsionor
. Cylinder head: *WOrn cam sprocket teeth
7 Leakinq or damaged head gasket ~ WOl n cylinder, piston or piston rings (Section 11)
*Werped or cracked cylinder head
' Worn cylinder, piston or piston rings [Section 1“ Rough idle

- Low cylinder compression
Compression too high, everliuating or knocking
. Exresswe carbon btiildvtip on pismn nrown nr nn
cembustlon chamber

Exu‘ssive smoke
- Cylinder head'
—Worn valve stem or valvc guldc
*Damaged stern seal
0Wumcyliiidei, piston or piston rings (Sectlon 1 1)

 

CYLINDER HEAD/VALVES

CYLINDER COMPRESSION TEST
m—

If 2h. angina musf be running on do 50m; wark,
make sure that the area is wellrvcnn'latcd. Never
run the engine In an enclassd area. The oxhaus!
contains poisonuus carbon monoxide gas that may
came loss of conscinllsnass and may lend to death.
Run the engine in an open area or with an exhaust
evacuation system In an enclosed area.

 

Warm up the engme In normal ODCmting (amperer
ture.

Slup [he 2' 9 me am} ve move the aII spark pIug can<
arm mark plllg< (pagp 3-8:

Suppcnthe rear and ohhc fuel tank {page 5 55),

Dmunneul the furl pump 2P brown connenor

InstaIl a compression gauge imo the spark pIug
hole.

TDOL'

Compression gauge anachmcnt 07RMJ-MV50100
(Equwa er‘l
m—nmmmauy
avai‘ablc in us A.)

 

 

Open the I'lrulle all A a way ahd tank the engme
wuh the stmer r‘omr Hn' I the gangs 'Fndmg stops
Hsmg

The maximum reading is usually {Eachsd wilhm
4’7 second:

NOTE

 

To dVUid dmlmgmg In: battew, co not onerate
the staner maimfor Mme than aaven seconds,

 

 

Conlpruss .. pruaaure‘
‘I 775 NW; I'I'I n kgf‘5m’ , IRS :15!) at 350 rpm

Low Compression can ba caused by.
, 3.0m. cyIinE' Hand gasket

lmpmpe‘valve nd‘ustMent

'alva Ieakogc

Worn pwston nng or uvI'mder

High compressxo‘ can r» m :sF-d hy-
L‘arbon deposits r combustion cwambcr or on
owszon head

  

 

8-4

CYLINDER HEAD/VALVES

 

CYLINDER HEAD COVER REMOVAL

Remove the a'lr cleaner housing (page 5-65L
Remove the spark plug caps (page 3-m

Disconnect the PAIR control solenoid valve 2?
nalural conneclurr

Disconnect the crankcase breather nose.

DISLOI'Illé-ct the PAR contlol solenoid valve air
fillrvlnn hnsex, chem mmnve lha PAIR control sale-
rloid valve assembly,

 

Remove me lhronle cable guide bracket mourning
bull:
Dlsmnnem rhe lnrnnle nahlp e-ds lrnm ‘ha vhrntfle
drum

Rumuve [he SH bull.- and PAlR reed valve Covers
from the cylinder head

 

 

CYLINDER HEAD/VALVES

Remove the Lyhndel head cove! huh: and washers

Remove the cyl'mder head cover lorward

CYLINDER HEAD COVER
DISASSEMBLY

Remove me cyfinder head cover packmg

Remove bone and breather scparaxor and gasket

 

 

8-6

CYLINDER HEAD/VALVES

 

Check me PAIR check vane for wear or damaqe,
replace 1r necessary

CAMSHAFT REMOVAL

Removc Ihc cyHndcr head cover (page 8 5),

Avoid damaging the cam pulse generator while
removlng Ihe Camshafts, remove the bolt:' sealing
washers and cam pu|5e generator [mm the cy‘inder
Meadr

Remove the timing hole cap and 0mg.

Turn me crankshaft c‘ockwise. align me ”T” mark
an (h: ignition pulse generalur ruLur wi me index
mark on the rgnman prnse generator rotor cover
Make sure the No. 1 piston is at TDC (Too Dead
Center) on ‘ha compression stroke.

 

 

 

CYLINDER HEAD/VALVES

 

Remove the cam chem tensione' lrfter sealrng ban
and scaring washer.

Turn :ha tensroner lrfier shah fully rrr “crockwrsev
and secure It using the sropper tool.

This \uol Lall easily be made [rum a [him (1 Hun
mrcknessr pier) mé stPel

 

 

MATERIAL THICKNESS: 1.0 mm

If you [Wm 00 repmne the camshah and/or mam
sprockor, loosen rho cam sprockcr bolts as foHow:

NOTE
It is nor necessary ‘0 remove rho cam sprocket

hum lhe camshaft except when 'Ep‘acir‘g the cam-
shaft andror cam sprocket

*Remuve [he can: sprocket huh lrurn intake and
exhaust Camshahs

NOTE

Be careful not to drnp the cam spmrker mm mm
rho crankcase.

*TJrn the crankshfifl one full mm 1350“, remove
me other cam sarockcr ball from the camshaft;

 

  

CAM CHAIN TENSIOVER L‘FTER
/

SEALING WASHER

‘1
r
r

 

 

i»; ‘

SIOPPER TOOL

 

Remove the bolts and cam chain guide 8.
*Rcmove :he cam sprocker from (he L'dl‘llhIleIZ.

Loosen and remove the camshaft holder bolrs. then
remove the camshaft holders and camshahs.

CAUTION

 

From outside to Inside, Iooun lha balls in a criss-
cmis pzflnrn in several steps 07 the camshlff
holder might break

 

NOTE

 

 

- Suspend the cam chain with a piece of wire to
prevenuha chain from falling lulurlre crankcase
- II is uuL necessary to remove the dowel puns irom

Ihe ramahsm holders.

Remove the valve lihers and shims

NUIE:

- Be caIeIuI not to damage the valve, llflflr have

t Shim may SUCK lathe Inside cflhc valve lifter. Do
not allowrhr: shims [0 (all into the crankcase.

. Mark all valve lifters and :hims Io ensure correct
reassembly in their original locations,

- lhe valve lifter can be easily removed with a
valvc lapping tool or magnet,

- The shims can be 23::Iy removed with a tweezers
or magnet

 

INSPECTION

CAMSHAFI' HOLDER

Inspsc! the bearing surface oi the camslrall holder
lo. scaling, searches, or evidence 01 msrmimem
Irmricanon,

inspect 1hr: oil orifices of the holders for clogging.

CYLINDER HEAD/VALVES

.t‘i‘z B/O‘LTsffiv

/

 

CAMFSHAFT HOLDERS

\‘,

a“;

        

 

8-9

CYLINDER HEAD/VALVES

CAMSHAFT RUNDUT
Support both ends of the camshaft wuth V-blocks
and check the camshah runoul with a dial gauge‘

SERVICE LIMIT' 0 05 mm (0 002 in)

CAM LOBE HEIGHT

Using a micrometer, measure each cam lobe
heighL

SERVICE LIMITS:
IN: 33‘12 mm H.501 in)
EX: 38118er (14993")

CAMSMAFT OIL CLEARANCE

Wipe any oil (mm the journals 0! me camshaft. cw-
inder head and camshall Ixulders.

Lay n strip of nlnsngauge lengthwise on mp of each
camshafljournal.

Install the camshafl holders and lighten me bolxs in
a crisscross pattern in 2" 3 stews.

NUTEV

 

Do not rutaIe (he camshaft when using pldsllgauge.

TORQUE: 12 N-ml1,2 kngm , 9 “DH“

 

 

8-10

CYLINDER HEAD/VALVES

 

Remove the camshaft holders arm measure the
widlhulea pastgasge.
The winest thickness determines the oi cleara’ce

 

SERVICE LIMIT: 0,10 mm (0 004 lm

Wth ma servuce Ilmlts a'e exceeded, replace the
camshaft and recheck the out clearance.

Replace the cvllnder head and camshaft holders as
a sel if llre Lleeldliue sl‘lll exceeds the se'vrue llunl

CAM CHAIN GUIDE B
lnspect Ihe cam chain slipoel suliace of the cam
cnsln gulde for wear nr damage.

CYLINDER HEAD REMOVAL

Remove the engrne from the frame (page my
Remuve us muslmrl lpage sen

Remove the cyllndcr draln bolt and sealing washerr
Dram coolant from cylinder head and cyl'nde'
uluek,

Check the scaling washer is in good condition, re-

place 'I necessary.
Reir‘sla” the seallng washer and drawn hnlt

Dlsrmrnectthe Hilfithermn sensor connector,
Dlsconncct the bypass hose from the thermostat
houslrg.

Remove the bolts and thermostat houslhg.

”(V

.2 l ‘
T "MW

 

 

8-11

CYLINDER HEAD/VALVES

Remove the cam chain tensioncr mourn ng cap mm '52“; N‘UEEEWAIIWG‘ \ , FrENsIONER
and sealmg washer‘ W' SHE - ’ ,

  
    

Remuvelhe calllulldhilensuonel. ! - r

Remove the xwo 6 mm flange DOIIG.
Luuwr We 9 mm Remove the ten 10 mm oaks and washers.
spmar .‘mhs m a
C"ssola£5 cartcm Hemnve mp nyhndav fiend
m 27 3 slaps

 

Remove the dowel pins and cylinder head ga5kct DOWEL PINS

/// \\

Remove the anifion pulse ueneramr rotor cover
and igmtion pulse generatm rem: (page 17-7)

Remove the mm cam cham guide and coHar.

aemmm (he cam chmn and turning sprocket from
the crankshah‘

 

 

8-12

CYLINDER HEAD/VALVES

 

CYLINDER HEAD DISASSEMBLV . L ‘ r'AngT HOLE EOTECTOH

Remove ma spark pmgs from the cylinder head

Install the Iappe! hoIe prmecluv iulo Ihe valve lifter
bole.

TOOL:
Tapper hole protoclor 07HMG-MR7OODZ

An equ'walanx tool can easily be made Irom a plas-
liu 35 mm film container as shown,

5mm-' 7" *5 mm

 

 

Remove the valve spring mum Inmg "19 special

tools as shnwn. VALVE SPRIN

   
     
  
    

TOOLS:

Valve spring compressar u7757-omoouu

Valve spring compressor unuchmem
07959-KM3010‘I

CAUTION.

 

Ta prevent loss a! tension, do not campus; the
"Ivy springs man than necessary to remavs the
canals

 

Al [ACHMENT

Remove me InHowIng:
Spring rename!
— Outer and inner valve springs

 

'VHIVe
Stem seal SPRING STATS
— Inncr and outer valve spring seals
INNER SPRING
NOTE-
RETAthH

Mark an pans during disassembly so they can be
placed back in lheIr uriginal Ioca‘ions.

  

ouT‘ER SPRING

 

VALVE
STE M S EAL

 

TOPVIEW
/'——\\ W >
i 4T m
, I‘31um. I j)
15 mm J I >
\; («J ‘
25 mm ID

(thn mmpmmm

 

8-13

CYLINDER HEAD/VALVES

CYLINDER HEAD INSPECTION

CYLINDER HEAD

Remove carbon deposivs Irom the combusnnn
chambevs,

Check me: Spark plug hole and valve areas Ior
cracks,

NOTE

 

Avoid damaging the gaskex swans.

 

Check the cvlinder head for warpagc wnh a straight
edge and mm gauge.

SERVICE LIMIT: 0 10 mm 10.U04 m1

CAM CHAIN TENSIONERICAM CHAIN
GUIDE

Inspam the cam chain mnsioncr and gmde far ex-
cesswe weal ur damage, replace ifnecessary.

VALVE SPRING

Measure the 1:00 \ength of the Inner and mrer
valve springs

SERVICE LIMITS:
Inner: 35.4mmI1'39inI
Oukev; 35.6 mm {152 mi

Replace me sanngs n they are shorter (IMF the
sen/ice hmim.

 

CAM CHAIN TENSIONER

 

CAM CHAIN GUIDE

 

 

 

8-14

CYLINDER HEAD/VALVES

VALVE LIFI' ER

Inspect each valve lifter for scratches or abnormal
wear,
Measure the earth valva lifter K) D

SERVICE LIMIT: 25.97 mm 11,022 in)

VALVE LIFTER BORE

lnspacl each valve tiller bun: luv scratches on abnor-
mal wear.
Measure the each valve Ilfler bore LD,

SERVICE LIMIT: 2604 mm (1.025 'm)

VALVE/VALVE GUIDE

Inspacl each valve Io! bendlng, burning or ahnnr-
mal stem wear

Check valve movement in the guide. measure and
record each valve srem O.D.

SERVICE LIMITS:
IN: 4.965 mm10.1955inl
EX: 5.950 mm (0.1949 in)

 

Ream the guides to remove any carbon deposits
before checking clearances.

Insert the reamer from the cnmhusImn chamber
Side of me head and always rotate the reamer
clockwise.

TOOL- Km"
Valve guide reamcr D79847MA60001 or
07984-MA60006

M s A, only)

 

 

8-15

CYLINDER HEAD/VALVES

Measure and record each valve guldel n
SERVICE LIMIT: lNIEX: 5 040 mm 10‘1934 ini

Subtract each valve stem 0 D. lrorn xhe corrpepond-
mg guide l.D. to omam the stem-tu-guide clearance.

STANDARDS:
IN: 0 010 (I 037 mm (D 000‘ D 0015 In)
EX: 0025*0052 mm (0.0010*0.0020 In)

II [he sleIIIrlu-guide uleaiauce is out of slandald,
determine iI a new guide erh standard dimeneinns
would bring the clearance wnhln tolerance. If so,
replace any guides as necessary and ream (0 fit.

If (he SIe-nvwrgmde clearance 'Is our oI slandald
wrm Ihe. new grime , replane me. valves and gmdes.

 

 

NOTE

Heince the valve sent-I whenever the valve guide-r
are replaced (page 8 17),

   

VALVE GUIDE REPLACEMENT

Cl‘Ii‘l the IeplaLemeIIl valve guides in the Iraezer
semrnn m a reingeramrfor about an home

Hcannc cylinder head to 100— 150 vC (Hz—300 VF)
with a hm plate or oven,

mm____

Ta avoid bums, wear heavy gloves when handling
the heated cylinder head.

VALVE GUIDE DRIVER

   

CAUTION:

Do not use a torch to heat the cylinder head; if may
cause warping.

 

Support the cylinder head and drive mu Ihe valve
guides from combustion chamber side of Ihc cylln
der head. '

TOOL:
Valve guide driver, 5 mm 07942rMA600000

 

8-16

CYLINDER HEAD/VALVES

  

Drive m the guide to the specified deplli hum Llie

lop ohm: cylinder head. VALVE GlngE DRIVER

  
    

SPECIFIED DEPTH.
INIEX:16.3' 16 5 mm (0 64*0 65 in!

TOOL:
Valve guide driver, 5 mm 079427MA600000

Le! me cylinder head cool to room tempernlurp,

Ream me new valva guide after installation.
lnsert the reamei fiom (lie combustion chambsr

side ofthe head and nlsn always mm: the reamer VALVE GUIDE REAMER.f

clackwisa.

TOOL:

Valve guid: reumer 079M»MA60001 or
07984 MASODOC
(USA. only)

NOTE

 

Use cuning oil on the reamcr during this operation.

 

Clean the cylinder head thoroughly tn remove any
malal paniclss.
Reface the valve sud (see next pagel,

VALVE SEAT INSPECTION/REFACING _ ‘ HANDLAPPWG TOOL
/

Clean the inlake and exhaust valves lhoroughlv to
remove narhnn deposits

Apply a light coaxing of Prussian Blue In the valve
seals.

Lap the valves and :eaLs using a rubber hose or
other hand»lanplng tool.

Remove and inspect the valves.

 

CAUTION ». J . ' . i w I W33?
— a

The valves cannot be ground. If a valve lace is
burnad or badly warn or If It contacts the sear
unevenly, rsplaes the valve.

Inspacl [he widlII ol each valve seat.

STANDARD: [190* 'I .10 mm (0.035 [1.043 In}
SERVICE LIMIT: 1.5 mm (006 in)

If the seal is mo wma, too narrow or has low spois,
me seat mus! be ground.

 

 

8-17

CYLINDER HEAD/VALVES

 

renew m:
rsracmq

Ina! ulaulwer 's
aneranng
Insirucnuns.

R: Ce w: my:
mm a 4549ng
cutter whensver a
valve- yuvue r>

 

VALVE SEAT REFACING

Va‘ve scat curlers/grinders or equivalent valve seat
retacing equipmenl are recommended to correct
wum va|ve seats

Use a 45~degrnn cutter to remove any roughness or
Irregumrlfies from the seal,

Use a 32»degrcc cuncr to remove rhe rop 1J4 of [Ira
cximing valve seat material.

Use a Gordegree cunsrto remove the bullum 1/4 of
the old seat.

Remove the tuner and Inspect the area you have
re'aced.

 

 

 

 

 

 

 

 

 

 

 

 

 

    
 
 

 

45“
\
A
y ‘\
‘\50°
4 " \32" \
41
ROUGHNESS

 

 

\JLD SEAT WIDTH

‘\

 

OLD SEAT WIDTH

f
60"
{

 

 

 

 

8-18

The qugliurl ol the
valve seat In
relation lo the
valve lane ls vary
.mpol law In: guod
sealing,

Do nal allow

Iappmg compound
m enter the guides,

lnslall 3 454199369 finish cuner and cux mo seat to
the proper wldth

Make sure that all pmmg and irregularities are
removedl

Refinish if necessary.

Apply a thin coating of Prussian Blue to the valve
seat.

Press me valve lhrough the valve guide and mum
the seal to make a clear panern.

[7 the contad area Is (on high on the valve, the seat
must be lowered using a 32 degrees flat cunerl

If the Contact area IS mo low on the valve, the seal
must be raised using a 60~degree inner cutter.

Refinish the son! to specilicnlmns. usmg a ‘5-
degree finish cutter.

After cutting the seal, apply lapping compound to
(he valve face, and lap the valve using light pm:-
sure, ,
After lapping, wash all residual compound off the
cylinder head and valve

CYLINDER HEAD/VALVES

 

 

 

 

 

 
    

OLD SEAL

 

l
l CONTACT TOO LOW

 

 

 

 

   
 

HAND-LAPPING TOOL

 

CVLINDER HEAD/VALVES

CYLINDER HEAD ASSEMBLY

VAlVl llHER*\ \>/‘
\‘K I

SHIM “c; I
COTTERS— I 7':

 

 

SPRlNG HETAINER”

 
  
     

INNLR VALVE SPRING"

OUTER VALVES F‘RING— é

SltMSEAL‘ N13

/

INNER SPRING SEAT '/ Q

(JUIER SPRING SEAT / f»
l ,
//‘/{,

/ ,

 

VALVF GUIDL

EXHAUST VALVE’/

\ INTAKE VALVE

Clean the nyllnder head assembly Wilh solvent and
blowthrough all oil passages with uumplessed airl

lnstall the Inner and omer valve sprlng scars. ‘
Install the new stem seals. SPRING 5pm 5

Lubricaxe the valve slams with molybdenum msulA
fide all and insert the valve mm me valve guide. INNER SPRING

To avo‘ld damage to ma stern seal, tum (he valve HETAINER

slowly when llwuug. \ VALVE

\ .\ STEM SEAL

OUTER SPRING

     

Install me tappcx hole pvoxeclol into the valve liner
bore.

TOOL‘
Taupe! hole prolmor 07HMGvMR70002

 

 

8-20

CYLINDER HEAD/VALVES

 

JusLel' Ihe va‘ve spr=ngs WIKI’I the llghIIy wmlnd
cm‘: Iacing the combustion chamber.
:nstal the valve. spring retainer.

 

2:15;:foth valve comers using me Speclfll mm M VALVE SPRING COMPRESSOR

To prevent loss 0! tensmn. do Hul uumpress the
valve sprxng more than necessary.

TOOL:
Valve spring compressor 077570010000

Valve sprlng compressor attachment
D7959 KM3010'I

ATTACHMENT

Tap the valve stems genIIy WIIh two pIBSYIC
hammers as shown (u >ual [he coners fwrmw.

CAUTION:

 

 

Support the cylindor hud above the work bench
surface to ppm/am possible valve damage.

 

CYLINDER HEAD INSTALLATION

lnslall the timing sprocket by aligning the wide
teelh between (he crankshaft and splocke!

 

IN 'SPROCKET“,

 

8-21

CYLINDER HEAD/VALVES

       
 

Install the cam chain.
install the cam chain gulde and tighten the bolt
washer

CAM CHAIN GUIDF

Install the lqniliull pulse generator rotor and igni
tion pulse generamr mmr cover lpogc Wye}.

Install 'tlw dowel pln‘ and a new cylinder head
gasket as shown.

DDWtL PINS
A
9/ \\

lnifall the cylinder head.

if using [he new bolt, remove nntkrust additive
(tom the bolt

Apply molybdenum disulfide oil to the lllledds and
scaling sur‘aca of [he l0 mm bolts,’washers and
install llleiil.

install the two 5 mm flange bolts.

Tighten the 10 mm bolts in a cr'lasuuss pattern in
273 Stags to We specified torque

TORQUE: EU N-m ITO kgfm.51lbl’h)

Tighten [he 6 mm flange bolt: to the socciiiod
torque

TORQUE: IO Mm (140 kglvln , 7 inf-m

lrstall the cam chain tcnsioner into the Cvlllldel
head.

Install the new sealing washer and ngmen the cap
nuL

 

 

8-22

CYLINDER HEAD/VALVES

\Hs‘a‘l We new O-m g mu me aroove of [he the"
masrat hnnsm; grnnve

InsxaH (he Ircrmostat housmg anm [he cyhnnw
head and rigmsn (he Dons securery.

Connect the bypass hn<e m ms thermosm ho.smg
Connect the ECTrmcrmo sensor connector.

ln<laH the engine into the flame (page 7-5}.

CAMSHAFT INSTALLATION

Apply mo‘ybdanm disumde on m the ou:or sur
iace ohhe eachvalveliheh

\nslall mo ohwms and va‘ve Ilfiers mm me valve
filler bores.

 

I' the ca~1 sprockm a'c removed, mstaH Me cam
:muckela unzo me carrshafts.

 

NO. 1 CVLNDAEH CAM LOBES

NUIL

 

mum” the iulske cam sprocket with [he nming
mark (IN! Varing outward and me Nuv " Ldl'V lube:
(using up and outas shown‘

- InsxaH the exhaust cam wrecker with (he fimmg
mark (EX) fading uuLwdrd and the No. 1 :am
rohes facmg up and out as shown,

 

    
  

/ EXHAUS [ CAN SPWObKET
\NTAKE CAM SPROCKET

    

Clean a'ld dpp‘y a \ock‘ng agentm we cam smock
ev hnlr'h'eads
\nstml Ira cam sp'ocket bans.

 

 

8-23

CYLINDER HEAD/VALVES

A: the exhamt cam sprocket installation. align the
cam pulse generator rotov line with the cam sorock-
e! "EX" mark.

Turn the mankshufi clockwtse and align the "T"
mark on the ignition pulse generator rotor with the
index mark an the ignition pulse generator rotor
covet.

Apply molybdenum disulfidc oil to the camsha‘:
lournals o‘the cylinder hsad and camshaft ‘iu‘dfl,

Install the cam chain over the cam sprockets and
men install the intake and exilauslcdlllshaks

NOTE

 

- Install the each carnsltalt [U the co-rec: location
with the identification marks
"lN"- Intake camshaft
"EX“: Exhaust camshaft

- Make sure that Ule lillling marks on the ram
sprockets are facmg mmnlald am flush With me
cyllnaer head uppe' suriacc as shown.

 

 

 

8-24

CYLINDER HEAD/VALVES

Inslall the camshaft hulners n"1n the camshafis.

NOTE

 

Install {he cach camshaft hnlner to the cancel
locatiuns wirh the identification marks.

"lN": lnrake canlsllall holder

"EX": Exhnusr camshaft holder

 

Temporarily lnSlCl“ [he eighteen holder hnlts until
the cam holders lighrlv conracx rho cylindcr head
surface

CAUTION:

Tightening the camsllalt Imldar bolts on only
onesr‘de might cause a camshaft holder to break.

 

lighten all camshafl holder bulls in the numerical
Order casted on the. camshaft holder.

TORQUE: 12 Nrrr\11.2 kqf m , 9 lb! ft)

Install [he cam chain guide B, and tighten the bolts

in case the cam sprockets were removed, \ighrcn
the cam sprocket bolts to the specified lurque.

TORQUE: 20 N m (2.0 kg! m ,14lbf-fll

Turn the crankshaft clockwise one full turn 1360")
and tighten the other cam sprocket bolts

 

 

CYLINDER HEAD/VALVES

 

Riemuve [he stopper mnl rmm the cam chem renr STOP’ER TOOL
sloner hher ’

   
 

\Mrnu a new sealing washer and righren the sealing
bun.

Recneck the valve nmmg.

Insrall rhe nsw gasker arm; the cum pub: gerer aror
cover.

Inerall the ham pulse generator cover aligning its
dowel pins wirnmc hole in me cylinder head,

 

 

GASKET CAM PULSE GENERATOR COVER 4

 

InstaH [he HEW sealing washers and bans, then
nghren we hmts m the specified torque.

TORQUE: 12 N.m (1.2 kgI‘l1l,9lb"fl)

 

 

8-26

CYLINDER HEAD/VALVES
CYLINDER HEAD COVER ASSEMBLY

lnsIaII the new gasket and crankcase brealher
separator to the cylinder head cover,

BREATHER SEPARATOR

 

Apply a lockan agent to the crankcase breather , -. ,.
sepalalur mounting bolx mreads. BREATHE“ 593““ 0" J—Im x 0L. 5‘
Tighten the bolts to the specified torque. ‘ -.

W

 

TORQUE: 12 N~m (1.2 kmm . 9 lbI-fl)

 
 
     

Illslall the PAIR check valves imo the cylinder head
cover.

 

CYLINDER HEAD COVER INSTALLATION

Inslall the cylinder head packing into the groove of
the cylinder head cover.

PACKING

 

 

8-27

CYLINDER HEAD/VALVES
Apply sealam m mo cy‘inder head semi-Gimme" !

cumuxs as shown.

{nstall trc air Joints and O-rings.

 

Install the cylinder head cuvsr uhlu me cylinder
head.

 

Inslall I? e waslvel s w'mh their “UP" mam hung up.

 

 

 

 

8-28

CYLINDER HEAD/VALVES

 

lnstaH and hgme" me cyiinder head cover specwal
buns lo [he specified lulque.
NOTE

'ighleu lhu “A” mavked side bolts first.

 

TORQUE: 10 NM (‘LD ka-m , 7 Inf-fl)

Inslali the PAIR reed va‘ve covey: and tighten the
SH boltsm ms.- speciiwd torque

TORQUE: 10 N m {1 0 kg‘rm , 7 WM!)

(:nnnerv me vhmme names mm the wronle drum
\nsmH and ngmm mc thromc cable guide bracket
moummg bohs to (he specif‘sd torque,

TORQUE: 3 NM in .15 kgflm , 2b Inf-fl)

 

vnsraH m: PAIR ac‘cnoid VOIVC assemb‘y and con
“sax [ha air suclwon hoses :0 the PAIR reed valve
Cox/Ex

‘ _
flame-ASE
BREATH-HER Fl

Connecuhe crankcase breather hose.

 

 

CYLINDER HEAD/VALVES

 

Connect the PAIR control solenoid valve 2P natural
connectar.

Install the spark plug cap< (page 3-11)
Ins‘all the an cleaner housmg [page 5 66).

CAM CHAIN TENSIONER LIFTER

REMOVAL
Remove the lower cowl lpaga 2-3].

Remove the cam rhnln 'ansinnar senllng Doll and
seallng washer,

Turn the Lenaiuuel shall lully ill (clockwisel and
secure it using the stopper mnl m nmvnm damagr
mg the cam them

See page 8-8 for detail of the tool.

Remove me bulls. sealing washem and cam mm
lensmner llher.
Remave the gasket,

 

SEALlNG WASHER ' >

 

 

STOPPER TO/Ul

 

 

GASKET

/.
y/r ~_

      
 

 

 

I" ‘_ v {V

l ltNSIONER LlI-TER

 

8-30

CYLINDER HEAD/VALVES

 

INSTALLATION

lnsmll me new gasket onto the cam chain lensiunev
llhcr.

NOTE

Now the direction of the gasket.

Install the cam chain lensionar lifxer lnm me cylin-
der block.

Install the new sealing washers and hnltsl than
lighten ma bolts to the specified lorquc.

TORQUE: 1O N«rn (1.0 kgf‘rn , 7 lbf-ftl

Remove the stopper lool.

Install a new seallng washar and hymen the sealing
bolt securely.

Install the Inwarcnwl (page 2-4),

 

 

l

  

 

TENSIONER LIFTER L

STOPPER TOOL

 

 

  

 

“I SEALING WASHtH

 

 

8-31

CLUTCH/GEARSHIFT LINKAGE

\~23 Nrm (2.3 kng,
17 mm

 

   

_,%@\

‘ ’ K x
12 N-m(1‘2 kgr.m.9mr.n) ‘ 1zN-m(1.2kgf-m,9\b1m

 

9-0

3. ULU l UHIUEAHDI'III'I LII\II\I-\L1l:

 

SERVICE INFORMATION

 

 

9-1 RIG HT CRANKCASE COVER
REMOVAL 9.12
TROUBLESHOOTING 9—3
CLUTCH 9-13
CLUTCH FLUID REPLACEMENT!
AIR BLEEDING 9-4 GEARSHIFT LINKAGE 9.21
CLUTCH MASTER CVLINDER s-s RIGHT CRANKCASE COVER
INSTALLATION 9-27
CLUTCH SLAVE CVLINnER 9-10
SERVICE INFORMATION
GENERAL

oThis section covers servme at the clutch, gearshift linkage, shill drum and shift lorks All servme can be done with the

Engine Installed in the frame.

0 Spillod brake fluid will severely damage instrument lenses and painted surfaces. II is also harmlul lu :ullle lubbel parts

Be carelul whenever you remove the reservmr can: make sure the tram reservun is horizontal first

0 Never allow mntammates ldln. water, etc.) to get into an Open Ieselvoir.

- Once the hydraullc system has been opened, or ll the clutch lever leels aponuv, the system must be bled.

OAIwavs use flash DOT 4 make lluid from :I sealed contamer when servicing the system. DU not mix different types .11

lluid they may not be companhle

'Transmisslnr- n-l VIscosin and level have an sheet on clululI disengagement When the clutch does not disengage or the
motorcyc’c creeps with clutch disenydged, inspect the transmlsslon oil level before servicing the Clutch sySle-Ill.

 

 

 

 

 

 

 

 

  

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
_ Unit: mm linl
ITEM ‘ STANDARD SERVICE LIMIT
» Reconvnended‘glllrrh Him DOTA brakenuid . i
C'IIYCI'I mastercvllndcr I CyllnderlD. 12.700 17,743 (05000-05017) l I216 10.502}
1 Piston O D 11651-11684 (0.4983’0199“. 12 65 l0.AQBl
iglutch s Tr'lug Ila: length a , 7 57.41226) 7 _
Clutch L‘IISC thickness , Al 3.7 3.85 lo 140 015le ,
__ . A2 372 3HR10.146—0.153l 3.5 (0.14)
Clutgh slate Warpaqe o 30 wow
Clutch Oulel guide VLU. 28.000*23.021H.1024i1,1032) 28.031 (1.1036)—
7 _ 0.D. l 34.975534 991 (13770 3.37 Isl , 34.965 (1.3766)
_ MaznshgfloDal Clutch Outer guide 27 980 27.993I’IJOI5—1JUZI) 273700.10”)
Shift tork, fork l FUIk ID 12.000— 12.021 (0.4724 0.4733) , 12 03 (0 47m .. _
shell ‘ I Claw thickness l 5.93'600 (0233/0 236) 5.5! (D, )

 

 

Fork shah OD.

I 11.957i11t9768 (l1 47U7EUA/12l

 

11.95 (0.37m

 

9-1

CLUTCH/GEAHSHIFT LINKAGE

 

TORQUE VALUES

Clutch master cylinder holder bolt
Clinch master cvlirldel cap mew
C|utch lever prvnt hnlt

Clutch lever pivot nut

Clutch lever adjuster

Clutch swnth screw

Clutch center lock nut

Clutch spl lng bulL’washsr

Clutch slave cylinder bleedel screw
Clutch slave cylinder mourning hnlt
Right crankcase cover SH bolt
Right crankcase cover center bolt
Shift drum center snake! bolt

Shit-t drum stopper plvot bolt
Gearshift lelurn spring pin
Gearshm drum hearing set plate Hangs bolt
Gnarshlh pedal bolt

Oil pump driven sprocket bolt

TOOLS

Snap Il'ttg pliers

[.‘llmzh center holder
Driver

Attachment. 37 ,v. 40 mm
Attachment, 42 x 47 mm
Prlot, 35 mm

12 Nrm (1,7 lrgtm , 9 Ibfrftl
1N m(0t15 kgf—m 41.1lbf-ft)
1 N-m(0.1kgfrm.0.7|b1vf{l
6 N-m (0.6 kgl-m , 4.3 lbirlll
a N~m (0.4 kglrm,7.91h1~fl)
1 N m (0.12 kgf-m , 0.5 lbfrftl
127 Mm l13,0 kqfrm , 94 let) Apply oil to the threads.
Stake the nut.
12 N-m 11.2 kgf-m , 9 th'tl
9 N m (0.9 kgf m . 6.5lb1vfll
10 N-m 11.0 kgf—m , 7|b1fl)
12 Mr. l1.2 tgrm , 9 mm)
12 NAm11.2 kgf-m , 9 lbf-ft)
23 N~m12.3 kgl m . 17 Inf 1!) Apply a locking agent to the threads
12 N-m (1.2 kgf-m , 9 lblrlll
23 N-m 12,3 kgtm ,I7Ib1-fl)
12 N»m (1.2 kgf m . 9 mm) Applva locklng agannnthe threads.
10 N4rrl (1.0 kgf-m . 7 Inf-h)
15 N-m 11.5 kgim, 11 lLrl-ltl Apply a locking agent to the threads.

07914-9A50001 Dr 07914-3230001

07724 0050002 Equlvelent commercially nvnilnbie in U.S.A,
07749-0010000

077450010200

0/]46-0010300

07746 0040800

 

TROUBLESHOOTING

Clutch lover soft or spongv
- Air in hydraulic system

0 l owtlmn lavel

' Hydraullc system leaking

Clutch lever too hard to pull in

- Sticking mastar nylindar piston

v Sticking slave cylinder piston

I Clogged hydraulic svstam

- Damaged clulch lifter mechanism

- Faulty clutch lifter hearing

I Clutch litter piece installed improperly

Clutch slips when accelerating

. Hydraulic system sticking

I Worn clutch disc

I Weak clutch springs

ITrallslrlission oil mixed with molybdenum or graphite
additive

Clutch wIll not dlsongago or motorcyclo crups with
clutch disangagcd

I Air in hydralllln system

' Low fluid level

I Hydraulic system leaking or clogged

. Clulcll plate warped

I Loose clutch lock nln

' Oll level too high

I Improper oil viscosity

0 Damaged Clutch lillel tlleLllarllSlll

- Clutch lifter piece lnstalled improperly

CLUTCH/GEARSHIFT LINKAGE

Hard to shift

I Improper clutch operation

I Improper oil viscosity

I Bent sllilt lurk

I Bent shift lurk shaft

I Bent fork claw

I Damaged shiftdrum cam groove
I Loose stopper plate bull

- Damaged stopper plate and pin
I Damaged gearshift spindle

Transmission jumps out ol gear

- Worn s drum stopper rlrm

I Weak or broken 3th arm return spring
I Loose stopper plate bolt

I Eenl shift lurk shall

- Damaged shift drum cam gronle.

I Damaged or bent shift forks

I Worn gear engagement dogs or slots

 

Gearshift pedal will not return
I Weak or broken gearshift spindle return spring
I Bent gearsnlfl spindle

 

9-3

CLUTCH/GEARSHIFT LINKAGE

CLUTCH FLUID REPLACEMENT/AIR
BLEEDING

CAUTION,

. Do not allow foreign material to enter the sysV
tern when fillinq the resarvair.

- Avoid spilling fluid on painted, plastic, 0’ rubber
parts Pleee e reg over these pen: whenever the
system is serviced,

CLUTCH FLUID DRAINING

Suopon the motorcycle on us cenlar stand.

Tul’l the IldlldIeIJdl Lu the nigh; um‘il nhe vesewoii is
paraHe’ in me grnlmd. nemm mum/mg me reser-
voircap

Remuve Illa suews, reselvuir cup, 521 plele and
d‘aph'agm

Connem a bleed hose [0 the clmch sieve cvlinder
bleed valve.

Loosen the bleed valve and pump (he male hII-‘PHV
er

Slon pumping the bloody who". no move fluid
flows out ohhe bleed valve.

CLUTCH FLUID FILLING/AIR
BLEEDING

Fil‘ ms resa'voir with DOT A brake ‘luid from a
seaied cunleineia

CAUTION'

Du nu! mix dim-mu types DI Iluid. They ira not
compatible

Cu'vnec. a uuinineruieHy avgilebIe brake bIeeLJer Lu
the b eed valve

Pumpthe brake header and loosen me bleed valve,
adding fluid when me fluid leve‘ ‘in me master
cylinder reservoi’ is Iuw.

 

NUVE

0Check the fluid Ievel ohen wnHe bIeedi'ng 1’15
brakes to prevent air from neing pumped imo 1‘13
svstem

'WI'EH using a brake bleeding luul, IuIIuw me
mamfiacmrersoperetmgivstmchons

 

9-4

CLUTCH/GEARSHIFT LINKAGE

 

l" al' < anmmg Reuse! the above slap pmmnye: wt l an aubbles
he bleezsr lrc'r do not appear n ma plast : hose

wdl‘nstl’se:

eaus. 551‘ C 056 the bleed valve.

We?“ n fl” Ope-are the cthcll levb‘ and rl‘ack clmm oneratlon.
:sllm 'acE ll ll snll leg 3 spongv, bleed the system again.

  

ll ‘0 make bleede- is no! available, use h: inllnwlng
D ocedurp-

Conqect a transparent blood hose to the bleed
va ve and placa me ouler end ul llle |IU>e n a
uu'lldlllel

Looser‘ mp, hlped valvs 1,4 mm and mep the
clutch lever unnl the fluld flaws am from the b sed
valve.

Pump [he make level sevelal (”1135, thn <nllsP7e
(he brakF- Invm al' m: way and loosen the bleed
valve ‘ll4 tum. VVZIl! several seconcs and close
me bleed valve.

NO'E

 

DL‘ no! release the clutch lever ull,i| lll: blend valve
la: DEEH Lluaed

2 Release me clutch lever slowv ulllil the bleed
valve has been uluaed.

3 Repeat we steps 1 7 mm: ‘here are no air
h.lbhles m the bleed hose.

After bleeding all cumuleluly and tlghten ll-e aleed
valves to :l'le specif ed torque

TORQUE: 6 N m (0.6 ‘(gl m , v1 3 lbf-h)

Fill the reservol’ lo the cdslillg ‘edge wllll DOT A
brake {lulu ‘lom a salad container

lrstall the dlaphragm, 55‘ plate and voscrvol‘r can.
Tlghxen me rese’voir cap screws to \he speci’ied
lulque.

TORQUE: 1N-rv (0.15 kgf m, H lbfftl

Check the clutch operallon lpaga 373m

 

 

CLUTCH/GEARSHIFI' LINKAGE

CLUTCH MASTER CYLINDER A 1‘
REMOVAL
Drain the clutch hydraulic system (page 974}.
D‘scnnnerx the clmch switch wire connectors

Remove the clutch hose ail bolt, Sefillng washers
and clutch hose eyelel.

CAUTION:

 

Avald spilling fluid on painted, plastic, ar rubber
parts. Plan a rag oval than parts whonaI/II the EVELET SWITCH CONNCTORS
system is serviced,

 

 

MASTER CYLINDER

Remove Nu.- hulls [mm the master cylinder holder
and remove the master cylinder assembly.

  

 

 

\\ ‘
HOLDER

 

DISASSEMBLY PIVOT B/OLT/NUT

Remnve the pivm bolt/nut and clutch level assemv
blv.

Remuve lhe screw and clulch switch.

SCREW CLUTCH SWITCH BRAKE LEVER

Remove the bow and push rod.

 

PUSH ROD

 

9-6

CLUTCH/GEARSHIFT LINKAGE

Remove the snag mg f'om re mame' cvlinday SNAP RIM;
body usmq me spasm (00‘ as shown /

  
  

TCDL'
Snap ring pliers 07914960001 or
0791473230001

SNAP RING PLIERS

Remove the masIer pismn and spring.

Clean the iiswde of the cyhnder and rP<Hrvmr with

make fluid.
SPRING
\
$6”
C: /
MASTER PISTON
INSPECTION

mark the lawn" ham, nnmnry cup and secondary
cupforfaliguc ordamagc.

Check me masts! cylinder and piston kn abnulmdl
scvamhes,

Measurema master cylmder LL),

SERVICE LIMIT: 12.76 mm (o 502 in)

 

Measuve ,he Hwy Wham. pm". 0.0

SERVICE LIMIT: 1165 mm (0498 IN

 

9-7

CLUTCH/GEARSHIFI' LINKAGE

DIAPHRAGM\\

/ é '
MASTER CVLINDER I‘V/K

RESERVOIR CAP
\

SET PLATE
\

ASSEMBLY

   
   
    

‘I \I-I'I (0‘12kgi‘xu , 0.9 |bHU

 

     
   

, BOOT
’ I
/ SNAP RING ’
\ / / 7/)
SPRING
5/ / g as? Q:
/ I ' I -
5/ / ‘ ‘ PUSHROD

MASTER PISTON

\ \ 1N-mI0‘Ikgf-m,n.7lht-m

\ .
' \\ CLUTCH SWITCH CLUTCH LEVER
a I?-
G
6 N-m IO 6 kgf-m , 4.3 mm}

CAUTIDN‘
Kong thv piston, cups, spring, snap ring and baa:
‘- A— 7 , , , SPRING

Coal all pans wIlh cIean brake fluid before assem-
bly.

Din the piston In brake fIIIId

Install the sprI’ng onwme master cylinder.

lnslall (he piston assembly into the mastercylinder.

PISTON curs V \

 

C;

CAUTION‘

, MASTER PISTON

when installing the cups, do not allow the lips to
tum inside out.

SNAI’ RING

    

IIIsLaII the snap rI’nq usIng the special [00L

CAUTIUN'

Be certain the snup ring is firmly seat-d in the
groove.

TOOL . ,

Snap ring pliers 07914»5A50001 nr
07914 SZSODOI

SNAP RING PLIERS

 

9-8

CLUTCH/GEARSHIFI' LINKAGE

 

Apply silicone grease to the boot lnsidc and tip of
Ihe DUSh rad.
Inslall the push rod and boot

  
  

PLISH BOD

BOOT

Applv silicone grease lo the up of the push rod,
then install the clutch lever assemblvr

 

\
CLUTCH LEVER
Install and tighten the pivot bolt to the specified PIVUI HULK/NU]
torque. /

TORQUE: 1 N»mln 1 kgrrm , D 7 th’f)

Hold the pivux bolt and tighten the piv0t nut to the
specified torque.

TDRQUE: 6 N m (0.6 kgrrm , t3 Ibf-i!)

   

Install the clutch swrlclt and lighten [he mew tu me ' ' 347%,“

s ecllled tor re L
P m ,/ 1/ \\

TORQUE: 1 N-m 10.12 kgf-m , 0.9 le’tl SCREW CLUTCH SWITCH BRAKE LEVER

Place the master cylinder assembly on the handler

Daf' _ _ HOLDER MASTER CVUNDER
Alrgn the end ofthe master WIIndB' With the punch / ‘ , /
/ e

   
 

mark on the handlebar,
/

       

lnstall the master cylinder holder with the “UP"
mark hung up.
Trgmen the upper hall first, then the lower bolt

TORQUE: 12 N m I11 kgfm,9lb1fi)

 

 

 

CLUTCH/GEARSHIFT LINKAGE

 

Install the clutch huse eyelet wilh [he ull bull and
new sealing washe's

Whlle pushing the clutch hose agalnst the stopper
and tlghton the oil boll to me speclfied torque.

TORQUE: 3A N-m (3 5 kgflm. 25lbf-f1)
Connccuhc clutch switch wlve connecmrsv

Flll xhé reservoir to the upper level and bleed we
hynmulm system lnnge 9-4..

 

CLUTCH SLAVE CYLINDER
REMOVAL

Dvain Lila clutch llydlaullu system (page 974)

Remove ma brake hose oil bolt, scaling washers
and brake hose eyelet

CAUTION

Avoid spilling fluid on painted, plastic, or rubbu
parts Plan! a ray over these parts whenevel the
system is serviced.

Hemov: the bull: and Llulc‘v slave cyllna‘e. assemr
nly,

Remove the gasket and dowel pins.

 

DISASSEMBLY

Remove the slave cylinder piston and spring

l" the plslon IS hard :0 remove, vemove {he follow
mg:

Place: a mup tuwel over [he pislul: lo Lushlon the
plum when n l: expklled, and memnn ma cylinder
w'm the piston downv

Apply small suulns of air pressure (a the ‘lu d inlet
to rsmovethe p'lslnns

NEW—w

Do not uss high pressure air 0! bring the nnnle 4;.\
too close (a the inlet.

 

’/ \
SLAVE CYLINDER PISTON

 

9-10

INSPECTION

Check the pismn spring for weakness or damagei
Inspeci Ihe oil and piston seals fov damage or
naterlnrnilnn

Replace [I‘IC oil seal and pismn scal if necessary.
Clean the seal grooves with clean brake fluid.

Check the slave cyIlanav in: scoring m nther dam-
age.

Check the slave cylinder piston for scratches,
scoring or other damage.

ASSEMBLY

we PISTON SEAL
v

 

10 N-m(10 kgf-m , 71bI-ft}

Install the new piston seal wiih iIs groove side
facing to the slave cylinder.

Install the new ml seal much its groove side facing to
the slave cylinder pifilon‘

Inslall the swing into the bass omie nislun.
Limrmminn the p‘ismn and piston seal with brake
fluid.

lnsiall the spring and piston into the slave cylinder.

CLUTCH/GEARSHIFI' LINKAGE

 

PISTON

   

34 N m (3.5 kg! m ,25 Ibf-hl

SLAVE CYLINDER

OIL SEAL

   

SPRING

PISTON SEAL PISTON

 

9-11

CLUTCH/GEARSHIFT LINKAGE

INSTALLATION

InelaH me dowe‘ pins and newgasket.

Apply si‘icuue gveaw lu We tip 0" (he :usn 'od ti:
|nstaH the slavp cylinder nrm ‘he rim/e sprankel
cover.

Iv'stal‘ aNd twghtpn MP. SH nmk In Me snemfled
torque.

TORQUE: 1O N>m§10 kgf-m . 7 lbi-M

has“ the c‘utch hose cycle! with the o‘l Don and
new sealing washers.

While puwng I": clulch hose against the stopper
and txghmn 1m rm hnlnn ‘hP spamhed 'nrque,

TORQUE: 34 Nvm [3.5 kgfrm , 25 IDHU

r H m msprmn m w, upper level and b‘eed the
hydrauhc system lpagc 9 4r.

RIGHT CRANKCASE COVER REMOVAL

Drain :ha anqms oil wage 3-18D.

Wemnv? ma ngm crankcase cover SH bolts are
'igh! crankcase cover,

Her-ova the gasket.

 

 

9-12

CLUTCH/GEARSHIFT LINKAGE

 

CLUTCH
REMOVAL

Remove the clutch spring bolls, sorinqs and pres-
sure plate.

Remove the clutch lxfiev piece and lifler rod.

Remove the IuIJuwzng.
, Seven dutch dwscs
-Six clumh p‘ates

Unstake the clumh cemer \ock nut

 

 

CLUTCH/GEARSHIFI' LINKAGE

Hold the clutch Center With the cmmh cemer holder,
then remave the lock nut.

TOOL:

Clutch cemev holder 0/ 124-0050002
(Equivalent commerr
uidlly avai‘able in U.S.A.)

Discard the lock nut.

Remove the lock washer. thrust washer and ciutch
CBYKSY.

Remove the washer.

Remove the ignition pulse generator voter cover
lpage 17—8)

Align the primarv drive 9ch and sub gear (com
with a sc'ewdrivar as shown.
Pull out the clutch o'uten

 

 

9—14

CLUTCH/GEARSHIFT LINKAGE

 

Remove the all purvm drwen sprocket bolL’wasth
Remove me oil pump drIva/dr‘wan sprocket and
drive chain a: 9” anemblv

Remove the cIulch outer guwdc.

INSPECTION

Clutch lifter bearing

Iurn the Inner race of the lifter bearing with you
linger.

The bearinq should mm smuulhlv and heely w‘nh-
out excessive play

Ii necessary replace the bearing,

 

Clutch spring
Measure the clmch spring fires length

SERVICE LIMIT: 56.2 mm (2.21 in)

Clutch center

Check the gmoves of (he cIuIch center for damage
of wear caused byme Clutch mates.

HspIace il necessary.

 

 

9-15

CLUTCH/GEARSHIFT LINKAGE

Clutch dis-z
HenIane the clutch drscs if they Show aigvls ul
scoring or discoloration

Measuve the Us: thickness oIeach uisc

SERVICE LIMIT: 3 5 mm (D 14 In)

CluIch plan
Chetk each disc plate for wa'DaQe on a mum
pIa‘e usmg a feelm gang?

SERVICE LIMIT: 0.30 mm (0.012 in)

Clutch outer/clutch oum guide

(Iherk me <Ints of the dutch outer for damage or
wear caused by the clutch dISCS.

Replace if necessary‘

 

Measwe the OD. and LD, u‘lhe damn outer guide.

SERVICE LIMITS:
0.3.: 34.965 mm {13766 in."
|.D.: 28 03‘! mm 11 1036 in)

 

 

9-16

CLUTCH/GEARSHIFT LINKAGE

 

Mamshafl
Measure :he mainshah OD. at clutch outer guide
ehding surface.

SERVICE LIMIT: 2/ 970 mm (1.1012 In!

 

Clmch liner rod UFTER ROD
Check the clmch liner rod {or wear and rrusnsss‘

 

CLUTCH OUTER NEEDLE BEARING DRIVER
REPLACEMENT /

Press the needle bearing our of rho clutch nuror
using the specia‘ tools,

 

TOOLS:

Driver 07749 0010000

Anachmant, 37 > 40 mm 07746-0010200

Pilot, 35 llllll 0774670050800

Press a new needle bearing 1nLulhe dutch uuler >U DRIVER

that the casing of the needle bearing 15 flush with
the clutch outer surface as shown

NOTE. .

Press rhc needle bearing into the clmch omcr with
Ihe marked side facing up.

TOOLS: . '
Drivur 077490010000
Attachment, [2% 47 mm 0774643010300

Pilot, 35 mm Ul/ASVUUWSOU

 

 

CLUTCH/GEARSHIFT LINKAGE

INSTALLATION

   
  
  
 
   
 
 
  
  

OUTER GUIDE
/
/ DRIVE SPROCKET
/
I DRIVEN SPROCKET

NEEDLE BEARING

I CLUTCH OUTER
// WASHER

«CLUTCH CENTER

LIFTER ROD
. x \
CLUTCH DISCS (BROWN /// I \§§§§ // LI7ER BEARING

WASHER /' I \\\ 1’, LIFTER PLATE

l()(2K WASHER /’
/

LOCK NUT
127 N-m {13 D kgf—m , 94 lbfvfl)

./ /,’7\" SPRING

A};

 

LIFTER PIECE 17 N~mI1 2kgi.m.9lbf.m

Illslall the clum: uuLe‘ guide, oII pump drive/driven
:pronke: and firm. cham as an nssemhw.

NOTE:

IMMII the all pump driven sprockex With Its "OUT”
mark facing our.

Apply a locking agent to thP threads or the 0H pump
driven sprocket bolt

TIgmen the driven sprockeI huh I!) the specified
Iuvqug.

TORQUE: 15 N m (1.5 kgf m , 11 Ibfhr

 

 

9-18

CLUTCH/GEARSHIFI' LINKAGE

Alvgn the primary drive gear subrgear teem Wlll’l a
sulewdllver as :lIleI.

Install the clutch auter.

Install the washer onto the clutch outer.

Install the clutch center.

Install the thrust washer.
Install [he lock wasllev wilh its "OUTSIDE" mark

tamng mm

lnslall the new look nutt

Huld the clutch center with the clulch center holder,
then tighten the lock nul to the specified torque

TOOL:

Clutch center holder 07724-005000!
([qurvalpnt commer-
cially available in USA)

TORQUE: 127 N‘m (1370 kgfm,91lbf-fll

 

 

CLUTCH/GEARSHIFI' LINKAGE

Stake lnnk nm mm the mainshaft groove with a
punch.

(20m ma clutch discs and plates with cicon engine
Oil.

Stack the :iutch dISCS and plates almmntelv‘

NOTE

Install the di nlnred "Blue” on both ends.

   

 

NOTE

 

Install the outer clutch disc colored "nine" In the
shaiinw sin? nu ma clutch autev,

 

 

Install the clutch iifler rod into the mainsnaft.

NOTE

Note the installation direction of the :iutch line. nod.

 

 

. i

SLAVE CYLINDER SiDE LIFTER PIECE SIDE

 

9-20

CLUTCH/GEARSHIFI' LINKAGE

Apply grease to the (lp ml the like! rod and Install
clutch Ilher piece into the maunshaft.

Install the lifter bearing into the pressure plalc‘
Install the pressure plate.

 

lns‘lall the clutch spnngs and spring bolts,

Tighten lhe balls in a uisscuuss pallevll in 273
mans 1n the spammed mrqup.

TORQUE: 12 N-m (1.2 kg' m , 9 lerl

Install the nghtcmnknase cover (nag!- 9-77).

GEARSHIFT LINKAGE
GEARSHIFT LINKAGE REMOVAL
Remove the following.
~Rigm crankcase novel lpnga 9-17)

-C|u(ch assemblv (page 9 13)

Remove the bolt and gearshifl pedal.

 

 

9-21

CLUTCH/GEARSHIFT LINKAGE

 

Pm me gearsni‘t spindle assembw and (trust ‘IGEARSHIFT
washeroumnne mnkcase, ' "

 

Remove me Iollowing:
— Stopper arm bolt
Stopper arm

*Remrn spring

, Washer

- DoweI pins

~ Sockel boIt

- Gearshift cam

 

GEARSHIFI' LINKAGE INSPECTION

Check the gearshifl spindle Ior wear, damage or
benuing
Check [ha return sn'lng for iangne or damagn.

 

J \
RETURN SPRING GEARSHIFT SPINDLE

SHIFT DRUM/SHIFT FORK REMOVAL

Rewuve We IuHuw'Hly:
Gennhm Imkage (page 9-21)
*Oiw can {page 4 4:

Remove m: baits and shm drum bear'mg set mam

 

 

9-22

CLUTCH/GEARSHIFT LINKAGE

 

Remove me shi‘: fork shafi and shin forks,

Remove me shifi drum nearing and shift mum,

 

SHIFT DRUM/SHIFT FORK
INSPECTION

Check 1hr: :IIIII fork and Iurk shall {or weav 0|
damage

Measure the ID. Oflhs shifi fork.

 

SERVICE LIMIT: 1? [)3 mm (0.474 m)
Measure the s‘lifi Fork claw thickness. 1

SERVICE LIMIY: bl) mm (023 In) t

Measure the OD. afrhc ehifliovk shaft

SERVICE LIMIT, 1195 mm 10 A70 in!

 

 

9-23

CLUTCH/GEARSHIFI' LINKAGE

Inspect the shnh drum grooves {or wear or damage.

Turn the inner race of the shifl drum bcarmg with
Vour finger.

The bearing shuuld Rum smuuWy and freely mm
mm excessive play.

H necessary rcplacc mo bearing'

 

 

SHIFT DRUM/SHIFI' FORK
INSTALLATION

\nstall Ihe Shlfl drum and Shlfl drum hfiarmg‘

NOTE:

' lhe shlfi fnrkfi have \nnannr‘ markk
"R"ior right
‘C"iorca'1tsr
"Ufm \eT':

 

 

9-24

CLUTCH/GEARSHIFI' LINKAGE

 

Apply molyodcnum disulfidc o’l to shifter fork
groove of the shift nears,
Installtheshiftforksonthettansmissiou

    

msHIETF RKfi“.TLl | Eillll . row
\

NOTE,

olnstall the left shift fork with its identification
mark facmg ta left.

- Install the center and right Shift fork shaft with
their identification mark factnq to right,

Install the shift fork shaft.

Inalall the bearing sat plates with their “OUT"
marks raclng out

Apply a locklng agent to firm threads at the 59: plate
Dolls.

Install and tighten the sat plate bolts ID the speci-
fied toruue.

TORQUE: 12 N m l1.2 kgi m,9 lbffll

install the gearsnirt linkage (see following :lepsl.

GEARSHIFT LINKAGE INSTALLATION

Install the follawmg:
— Washer

, Return spring

7 Stopper arm

Tighten the stopper arm bolt to the specified torquct

TORQUE: l2 N-m (1.2 kgf-m , 9 th-ft}

 

 

CLUTCH/GEARSHIFI' LINKAGE

 

Instaii the dowci pin onto the shin drum
4"?” the NW! Instali (he gearshift cam while holding ihe stopper
w. w Me sin/r arm usiiig a suewdiivei as )IIOWIL
mum zemer mm
mania: "move
an we gearsm‘i
cam

Apply a iocking agent to the gaarshih cam sockei
bolt threads.

Inrniie

TORQUE: 23 Ni“ (2.3 kgf-iii , 17 inU

insiall the thrust washer and gedrahin >pil‘ldle
dssembiv emu [he Ciankcase while ahgnmg me
spring ends wmh me minim .stopper [JUL

 

insraii ma gearshift pedal aligning ils slit with me
punch mark on the gearshih spindle

insiail and tighten the pinch boir re The specified
torque.

TORDUE: in N-m i110 Kgrm , 7 lbf-fii

 

 

9-26

CLUTCH/GEARSHIFT LINKAGE

RIGHT CRANKCASE COVER INSTALLATION

Apmy a sealant to the mming suflaccs ai :hc c'ank
case as shown.

   

‘15mm

10
. (0.4
1‘

r

 

15 mm
(0140.6 in)

   

 

1O

 

 

‘nstaH a nPw gasket nnln thp rigN nrankrnm nnvev

Insmn ms tht crankcase cover.
‘ns‘al‘ and Iightsn the fight crankcase cover SH
balls to he specified (ovque

TORQUE: 12 N m mg kg! m , S Int-m

Poul the recommended engme 0H \oage 3719»

 

9-27

ALTERNATOR/STARTER CLUTCH

      
  
 

12 N-m [1.2 kgf‘m,

s lbf-ft)~\\
R 4%,,
% o

103 N m {105 kgf-m , 76 lbf-ft)

16 N‘m (1.6 kgl-m ,121bf-fl)

12 N-m 11,2 1(qu , 9 mm

 

10-0

10. ALTERNA I UHIS I AH I I:H ULU I UH

 

 

 

SERVICE INFORMATION 10-1 FLVWHEEL REMOVAL
TROUBLESHOOTING 10-1 STARTER CLUTCH

ALTERNATOR COVER REMOVAL 10-2 FLYWHEEL INSTALLATION

STATOFI 10-2 ALTERNATOR COVER INSTALLATION

 

SERVICE INFORMATION

GENERAL

10-3 1

- This wchon COVEl s sewice of the altel Halon flywheel and staner nlmnh All snmm can he done mm the anglm‘. mvallen

In Vhe frame

- Refer to scclion 16 for akcrnator stmov inspection.

SPECIFICATIONS

1 ITEM

l' fia‘rier drivquear boss on

TORQUE VALUES

Allernator cover SH bolt

Flywheel flange non

Sldlul llluuming socket ban
Alwrnavnrwlle hnldar socket boll
Starter one way clumh sockcx boll

TOOLS

Flywheel holder
Romr puller

TROUBLESHOOTING

Engine dues nut turn
- Faulty stanerclutch
. Damaged idle gear/shaft

IZN mIl,2 kgfm,9lbffil
103 Mm (10.5 kgflm , 76 IbI-ll)
12 Nvm (’l 2 kgf-m , 9 lbI-ffl

9 N-m (0,1) kgf‘rn , 5.5 lbI-m
l6 N mll,6kgf-m,121bffl)

077250040000
07733-0020001

Unit: mm (in)

STANDARD ssnvms LIMIT
‘ 51699 51.11ai2.035A—2.0é€17

Apply uil lo the [In eads,

Apply a locking agent to the Ihreads.

51.6841210éigl

 

Equivalent commercially available in USA.

or 0793373950000

 

10-1

ALTERNATOR/STARTER CLUTCH

ALTERNATOR COVER REMOVAL

Remnve thianwmg'
*Lowar new} loage 273‘
*Seaupage 272’

Sea: .UWI (page Z-ZD

 

Dvsconnect We alrerramr 3P w'fim connccxcr.

Remove the dlzerr‘amr :uve' SH mm and «Kenny
torcove!

CAUTION:

The alternator cave! {59111an is magnztically
attached to the flywheel, be careful during removal.

NOTE

The engine oil wll run om when the almmalor
cover is removed‘ Set a dean ml pan ulldel Lhe
engi 4 and add the recommended (ml to PhP
finenmnd evm Hflar msraflmmn

Remove the gasm and dowel p n

STATOR
REMOVAL

Remove the auerr‘eto' wre grovme‘ "om (he otter
nator cover '

Remuve we suckal bull and :LsLUl wive Infidel,
Remove the sock?! hnlN and mm

 

. . in» :3. '
, \
STATOR W‘RE HOLDER

 

10-2

ALTERNATOR/STARTER CLUTCH

INSTALLATION

9 N m (0,9 kqf-m ,6.51bl~llj-

   

12Nm(1.2kgfm,9lbi-hl

SIAIOH

Inmallthe smut inlu the allemalor cover.
Annly sealant to the wire grommet, then install the
wire grommet inlo the alternaxor groove secuvely.

lnslall and liglllull Llle socket bolts to the spemmd
torque

TORQUE: 12 N»rn (1.2 kgf~m , 9 Ibf-k)

Install the wire holder and hghmn the socket bolt to
the specified torqucl

TORQUE: 9 N41} (09 kgf-m , 0,5 lbfvfl)

 

WIRE HOLDER

FLYWHEEL REMOVAL

Remove the allcmawr cover (page 1072.

Remove the staner Idle gear sham and Idle gear.

 

 

ALTERNATOR/STARTER CLUTCH

 

Hale the llvwheel us ng (he flvwheel ho‘dar, lher
'emuve l'le llywlluel but:

TOOL:

Flywheel holder 5772570040000
(Equivalent LOllllllelr
r ally avallahle I" U 5 AJ

Remove the washer.

 

Remove the flywheel using the spac‘al mol.

TOOL
Rotor puller 07733 0020001 or
0793343950000

 

Remove the woodrufl kav.

 

C'lSCk (he slaner idle gear and shaft lur wear 0'
damage

 

GE‘An IDLE GEAR SHAFT

 

10-4

ALTERNATOR/STARTER CLUTCH

 

STARTER CLUTCH
INSPECTION

Check cm. npsralinn nl the nnE-way clutch by
lurning the driven pearl

You should be able to turn lhe driven gear counlerr
uluckwise SlllUUlh‘y, DUI ”I! geal should llul lulll
nlnckwisa

DISASSEMBLY

llemnvn the stanar HYIVPI’I gear by turning i1 cnlln-
tcrclockwwc‘

Hold the flywheel wim a flywheel holder, and
remove the 51mm clutch mmmlmg mrx bolts

TOOL:

Flywheel holder 0772549040000
(Equlvalent commer-
ciallv available in USA)

Remove the slaner one-way clutch assemhly

Check the starter driven gear for abnormal wear of
damage.

Measure the starter driven gear boss (H).

SERVICE LIMIT: 51.684 mm (2.0348 in)

 

Check the one~way clutch [or wear or damage and y _ ONE-WAV CLUTCH
replace if necessary. ‘ 'L ’

 

 

1 0-5

ALTERNATOR/STARTER CLUTCH

 

ASSEMBLY

  
  
 

FLYWHEEL

DRIVEN GEAR

ONE-WAY CLUTCH

 

\
16 N-m (1,6 kgf m ,12lbf-fli

Install Ihe ane-way Chlmh mm the nhnnh outer w>lh

App‘y oil to the stat—tat onerway clutchA .7E ONE-WAY CLUTCH
\\
the flange side facing in,

  

tnstall me starter onerwav rlmch assembly nm‘n lhe
flywheel.

 

10-6

ALTERNATOR/STARTER CLUTCH

 

Apply a locking agent to the sinner clutch only Tnnx [mus
mountmg bolt threads. ‘

  

Hold me flywheel wllh a flywheel holder, and \
tighten Ihe slanev clulL'lI mounting lovx bolls.

TOOL:

Flywheel holder 07725—004 0000

lEquivalenl ccmmew
mally nvmlnhla m us A)

TORQUE: 16 Nm [1.6 kgf m , 12 lbfrm

Install me starter driven gear mm the one-way
clutch.

Recheck the one-way clutch operation

You should be able to turn me driven geav counter
clockwise smoothly, but the gear should nox [urn
clockwisel

FLYWHEEL INSTALLATION

Clean any oil from the c'ankshafl taper
lnslall the woodruff key on the cvankshahl

lnstall the flywheel aligning the key way in the fly-
wheel with lhe woodl u" key on the crankshaft

Apply oil (0 me flywheel boll Ihreads and seatvng
surface.
lnstall the washer and flywheel bolt.

 

 

ALTERNATOR/STARTER CLUTCH

He‘d me flywheel usmg :ne flywheel hnldm, mm
ngmen the bot: to the spemfied torque.

TOOL:

Flywheel holder 077 25-00Annnn
‘EQUIVEIEI’K commcr
ciaHy available in USA.)

TORQUE: 103 Nm [10 5 kgf-m , 75 lbtm

Apply 0“ m the starter kfle gear and gear shaft, and
msmnthem,

   

ALTERNATOR COVER INSTALLATION F

Apply ssalam to the maling surldce ur the uauk»
case as shown,

Install the dowel pln and new gasket.

 

 

1 0-8

ALTERNATOR/STARTER CLUTCH

nsxaH the alternator so vev,

CAUTION

The alternator cover {stator} is magnetically
attached to the flywheel, be careful during insrafla-
tian.

Install and tighten the SH halts m the specified
(crane.

TORQUE, 12 N-m V1.2 kghu , 9 [IN-M

Curlr‘e.L We anew-am 3P while L’umteutuv,

\nstaH n-efoHowmg:

*Seatcowl (page 23.
Seat Ipag: 24)
lnwwrnw‘ pagp 774)

 

 

10-9

CRANKCASE[PISTON/CYLINDER

39 N-m [1.0 kg! m A 29 lbfh)

37 N-m (3 R kgf-m , 21mm (
12 N-m (1.2 kg! m19 \bf-fl)

    

18 Nm (1.8 kgl-m, 13 |bl‘~m

25 N m. (2.5 kghn,13|bl>ft)

 

11-0

1 1 . UHANKUASEIFI5 I UI\IIUY LINUI:I1

 

 

SERVICE INFORMATION 11-1 PISTON/CONNECTING ROD 11.4
TROUNjSHOOflNG 102 CRANKCASECOMNNAHON 1142
CRANKCASESEPARAHON 103

SERVICE INFORMATION

GENERAL

. this senmn mums ”animus. separation rnr service of the crankshaft and piston.
o The following parts must be removed before separating the crankcase.
*AIIS'HSIOI‘I'IIVWI’IOSI (Section 10.‘
Clulcnlgealsllifl linkage lsecuun 9)
[Ivlmnfir hand lfiemlnn H)
7 Engine (Section 6)
7 Oil pumpiSectiond)
. Mark and store the disassembled pans to ensure that they are installed in lhelr nnglnnl locatlons
- Mark and store the bearing Inserla to be sure of their correct locations {or reassembly. II the inserts are improperly
installed, they will block the oil hole, causing insufficient lubrication and eventual engine seizure.
- Tlle uulllleclillg lod bearing illsells me select [it and ale idenl'lfied by color codes. Select replacement bearings from the
mde tables Aher insvnlling new hearings, recheck thm with plastlgnuge to verify clearance, Apply molybdenum
disulfloc oil lo the crank pin during assembly.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD I SERVICE LIMIT
Cylinder lD ”"— 79 000779 015(3 1109 31mm 79.10l1114)
Out 0! round ‘ 4— 0.1001004)
7 71gper # 7 7 7 0.10 (0.004)
Warpage 1 — 0 05 (0.002)
Plstol’l, piston Piston markdlrectlon _ "|N'7'_Q1arkIacmglnwnrr‘l'he intake Side ——
rings Piston OD, [8370—78390 (11090—31098) 78.90 (3.106)
Piston O.D. measurement poinr 15 mm (0.6 in) from bottom olskin 7 fl
Pislun [ in bore I.D. 19.002-19;0078lq7481707083) 1903(0 7A9) 7
7 7Pis7ton pln70 D 7 7 77 18 994 19 non in 7478 70.7450) 18.054 (0.14/4)
Pistonntonlston pln clearance 0002—00“l0.0001—0.0006l —
I Piston ring-to-ring Top ‘ 0030*0065 (00012700029, 0.08 (0.003)
I 7gggyg7¢7l7egranee Second 777777‘ 0.015*0.045(0 000570001770 0.00 (00071
4 Fusion ring . :1 gap Tan 0 20 0.35 lama—0.014) ~__.75 . 2)
Second 0.40-0.55 (0016-43022) 0.7 (0.03)
Oil (side rail) o.2~0.s (00170.03) 777 7 1 0 lo 04)
l Cylindemaplston clearance 0 010* 0 045 (0 0004 (l 0018) 7'7_»__7
5 Connectlng rod small and LD 19 030*19.051IU.7492- 0.7500} 19.061 {0. 504)
79707ng§ctjgridrtorpiston pin clearance 0030' 0.07577 (0.0012 — 0.0022) 7
Crankpirl oil Clearance 003070.052 (00012400020) l 0062 (70092747377

 

 

 

 

11-1

CRANKCASE/PISTON/CYLINDER

TORQUE VALUES
Crankcase bolt, 1n mm 39 N-m (“I kgf‘m , 29 lbf-l't)
9 mm 37 N m (18 kgf m , 27 Ibivl'tl Apply oil mine \hreads,
8 mm 25 N-m12.5 kgi-m , 18 Ibl-lll
7mm 18N-m(i.8kgf~m,13|bi-hl
5mm 12N:m(1.2kgf-m,£)lbf-h)
Connecting rod nui 4i N m (4,2 kgf m , 3U lblrhl Apply oil (a the iliieads.
Lower crankcase flange pair 29 N-m (3.0 kgl-m , 22 IDHU Apply a locking agent in ms. threads
Luwer uankwse sealing bolt, 20 mm 29 Nm (3 D kgi-m , 77 mm Applya lacking aqentlo the threads,

8 mm 22 ern (2.2 kgf-rn.16lbf-m Applya locking agenito ma threads.

TROUBLESHOOTING

Cylinder compression is too low, or engine is hard to man
0 Blown cylinder head gasket

I Worn, Stuck or broken pismn rinq

- Wum 0! damaged cylinder or pision

- Bern valve, or bent and deteriormed valve seat

Cvlindlr companion is we high, or engine overheah or

knocks

- Carbon deDOSlIeS on the cylinder head and/or piston
crown

Piston sounds

- Worn cylinder, piston andlor plsion ring
- Worn pision pin hole and piston pin

. Worn cunneutlng iud small end

Excessive smoke
- Worn, stuck or broken piston ling
o Worn valve stern sea!

Excessive noise

. Worn connecting 10d big end bearing
. Bern connecting rod

- Warn crankshaft muin journal bearing
0 Worn transmission bearing

Engine vibration
- Excessive crankshafi runout

 

11-2

CRANKCASE/PISTONICVLINDER

CRANKCASE SEPARATION

NOTE

Ramrm Ssrwce Information [page 11-1} for remov-
a! of necessary parts before seaaratmg me crank~
case.

RCmovC the scaling plug and 0 ring.

 

  

Remove the upper crankcase 8 mm bolts/sealmg Smrr‘ BOLTS
washers. A x

8 mm BOLTSI‘

SEALING W'ASHE , L
Remove ' 9 lower cra‘kcase 5 mm bolts (sixb. 7 mm BOLTS

 

7 mm bull >eveu) am; 10 mm bun. \
lnnsen we ran lower crankcase 9 mm hn‘ls m a
crisscross pattern in 2 -3 51905, then remove me
bolts and sealing washers.

 

Separam me lawn nrankcase trnm the unper «A >
crankcaac,

 

Remove (We dowel pin: and oil urihces.

 

 

CRANKCASE [PISTON/CYLINDER

PISTON/CONNECTING ROD
PISTON/CONNECTING ROD REMOVAL

 

CAUTION

Do not Interchange the bearing Inserts. They must
be installed in (heir original lacllivlls or the canect
bearing ail clearance may not be obtained,
resulting in engine damage.

NOTE

Mark 3” Darts durinq ramoval so may can be
Iep‘aceu in the}! original localions
Remove the runs and connacxing rod bearing cap.

Remove the plston/connectmg rod assemb‘v irom
th mp othc cylinder.

 

PISTON REMOVAL

   

ON [’IN
Remove the pislon pin clip with pliers,

Press the plsmn pm am 01 the DISH)“ and remove
rho pisron from rho connecting rod.

PISTON DISASSEMBLY

Removefhe piston nngs,

NOTE‘

Do not damagethp plsmn rmgs durxng remove}.

 

 

11-4

CRANKCASEIPISTON/CVLINDER

 

Remove any carbon deposlts from the piston nng
grooves, using an old piston ring as shown.

PISTON INSPCETION

Temporarily install the piston rings to their proper
position with the mark facing up.

Measure the piston ring-to-rlng’ groove clearance
with the rings uushed into the grooves.

SERVICE LIMITS:
Yon: 0.08 mm (0.003 In)
Second: 0.06 mm (0.002 in)

Inspect the piston (or wear or damage.

 

insert the pieron ring squarely into the bottom of '~
the cylinder anti measure the ring and gap.

  

NOTE-

Push the ring: into the cylinder with the [up of the
piston to be sure they are squarely in the cylinder,

SERVICE LIMITS:
Top: 0.5 mm (0.02 in)
Second: 0.7 mm (0.03 in]
0" (side r I). 1.0 mm (0.04 in)

 

Measure the diameter of the piston at 15 mm
(06 in) from the bottom and 90 degrees to the
piston pin hole.

SERVICE lJMIT: 78.90 mm (3.!06 in)

 

 

CRANKCASE/PISTONICYLINDER

Measure (he piston pin bore

SERVICE LIMIT: 19.03 mm (0.759 in)

MPHSIIVR "190,0. th2 pistan pin.
SERVICE LIMIT: 18.954 mm (0.7474 in)
(immune the rusmn-to-pistcn pin clearance.

STANDARD: 0.002 A0014 mm (0.0001 A 0.0006 in!

CYLINDER INSPECTION

Inspem the top of the cylinder fm warpage

SERVICE LIMIT: 0.05 mm I0.002 in)

inspect the cylinder bore for wear or damage.
Measure the cylinder LD. in X and Y axi5 al Linea
ieveis,

Take the maxvmum reaalng to determine the chn
derwear.

SERVICE LIMIT: 79 10 mm (1114\n)

Caicuiata [he Dislon-Ichcvlinder clearance.

Take a mahmum reading to determine the clear-
HHCR.

Refer (a page 11 5 '0! measurement ofrhe pislon
0.0,

STANDARDIUH'IOiUJMS mm l0.0004~0.0018 in)

 

 

11-6

Calculale me lapel and uul ul lound anhuee levels
m x and v axis Take lhn maximum reaming m
dete'mmethem.

SERVICE LIMITS:
Taper. 010 mm ln mm m]
cm of round: 0.10 mm l0.004 in)

The cylinder must be labored and an overslIP
plslon lmpd ilvhe servme lxmns are exceeded.

The following oversize plsluns are avaulable.
0.50 mm 10.020 in)

The piston to cylinder clearance forms oversize DlS-
lor‘ musl be: 0 015*0050 mm (0.0006’ 0.0020 in]

CONNECTING ROD INSPECTION

Measure the connecting rnd small and l u.

SERVICE LIMIT: 19.061 mm (07504 Fri)

Temporarily Install the connculng rod to the
crankshaft

luslall the bearing lnselts and bearlng cap, and
nghmnvhe hnll:

Measure the connecting rod side clearance.

SERVICE UMIT: U 30 mm l0.012 Inl

CRANKPIN BEARING INSPECTION

Wlpe all ml lrnm the hearing lnserls and nmnkplns.
Put a piece of plasrigaugc on each crankpin.

NOTE

- Do not putme plasllgauge overme oil hole in the

mukpiu.
- no nnl mule mp. rrankfihan dunng \nspechon,

 

 

 

CRANKCASE/PlSTON/CYLINDER

MlnI}Lt

501mm 4—»
x ,

 

 

 

 

CRANKCASE/PlSTON/CVLINDER

Inslail no bemmg cans and connecting rods on a
cu'recx crankpins and iighte': [he cap YU.5 no III:
specifiedmrque

‘ BEARING CAD

    

TORQUE: 4} N m {4.2 kgi m , 30 lb! (1‘

Remove the connecting rod caps and measure the
uullvpvessed piasligauge on each crankph

SERVICE LIMIT: 0.062 mm (0.0024 In)

if the connecting rod bearing clearancp w haynnn
tolerance, select: replacement bearing.

CRANKPIN BEARING SELECTION
Rncordma connecting rod i D, code number v1 or 2i

or measure we ID. with u.» healing Lap installed
withuul bearing insens

'i you are raplaclng the cronkshah, record the
carrcspond ng crankpin OD. code number (A or B},

NOTE

 

Numbers iA or B) on'me crankweigm are the cudes
For the cvankpin OD s staning from the left

if you are reusing (he Crankshaft, Hiedsuve [he
EFEI1(piH OD withthemicmmeter -

 

 

11-8

CRANKCASE/PISTON/CYLINDER

Crossvreference the Crankpm and red codes to

, I ' 'IDENTIFICAYION COLLAR
determine the replacement bearing colan ,

BEARING THICKNESS:
A (Brown): Thick

B (Graen): I

.C (Vallow): l'hm

 

CRANKPIN BEARING SELECTION TABLE:

 

 

 

 

 

 

 

Unix: mm (in)
\*\\ ‘ CONNECTWG ROD|.D‘ CODE
\ \ \ 1 1 7
\
\\\\ 1 43.DOD~43‘OUS 41008—43316
\\ ‘ (1,6929i1.6932‘ (1.6932i13935L
‘ ‘ A 39.995'50003 ‘ C E
‘ (IHANKI’IN (Ml . 115746 1.5759) } (Vellnw) 1 (Graenl
\ CORD LETI’ER ; E 1 39.987 -39.995 ‘ B ‘ A
‘ \ (1.674371576) (GveeflL i (Brcwm

 

InstaH the bearing insens into Ihe connecting rod
and bsdriug cap‘

NOIE:

Align the oil hula bzthen [he cunnecling rod and
hearing, and also ahgn ma hearing tabs with the
groove in [he conncming rod and bearing cap‘

 

EEA’RINGS

 

11-9

ORANKCASEIPISTONICVLINDER

 

PISTON ASSEMBLY ‘

‘ SECOND RING TOPRING
Clean me piswn ring grooves thoroughly and in \
sraIl the piston rings.

NOTE

 

- Apply oil lo um pision rings.

'Avnid piston and piston ring damage during in-
staHation.

- Instali the piston rings wirh ihe marking (R)
facing up.

0 Dn nni mix ma top and second rings: the :09 ring
is narrower than the second ring in width.

 

 

Space the piston ring and gaps 180 degrees apart.
Do not align me gaps in the oil r'ings Isida raiIsL

    
 

SPACER
Afler installation, the ring« shniilrI rovatn freely In

the ring grooves.

 

PISTON INSTALLATION

mm” the Assemble ihe piston and connecting rod,
Coll/10613779 705
mm Hg ail hale
svae lacing me
‘ IN mm on me
nvswn crown

Apply moiybdenum disulfide oil to the pisluii pin
outer surface
panorairgnme lnsIaH the pisicn pin. and secure it using a new
uisiun Um clips piston pin clips,
end gap mm mo
piston out out

 

 

 

 

11-10

GRANKCASE/PlSTON/CVLINDER

Apply all tome cy‘inder sleeves and piston rmgs.

lmam ‘flb‘plsmfl’ Install [he plslowuunnecliug rud dasemuly illlu We
connscmgma cyllnder using a commermally avallable plsmn 'lng
Sisemblv mm me compressor lool.
p‘slw IN 'mam
farlng in me CAUTION:
'nlaxeslde ' W' *7
- While installing the piston, being careful not to
dun-mg: rim top :uriaca o! the cylinder, “puial-
ly around the cylinder bore.
0 Be careful "of fn damage ”I: cylinder sleeve and
crankpin with the connecting rod bah threads.

 

/
PISTON RING COMPRESSOR

 

Milk: sure 7mg Use the handle of a plasllc hammer to tap the
commassor :an' piston lnlO me cylinder.
5‘15 ushwwnmp
su’lace 0' me
cymmer

Apply mulvbdeuum disuliide uil [U the cvankpin
hearlng snriane:

lnslall me bearing cap.

lnsure that the marks on the caps are aligned wlxh
me marks on [he connecling nods

Apply oil lo the connccring rod nuI :hrcads and
seating surfaces.

Install the connefitmg md nm and tighten the nuts
gradually and alternately/l

TORQUE A1 Nnm (4 2 kgf-m , 30 lbf-ft)

 

 

GRANKCASE/PISTONICVLINDER

CRANKCASE COMBINATION

Apply a llght, hm rhnrnugh, commg or llquld
sealant to lhc crankcase maring surface except [0
me main bearing journal boll (lower crankcase bull,
9 mm) area and lhe oil passage area as shown.

lrlslall the llllee duwel pins‘
Inslall nil orllirM hy aligning Ihmr cut-out wuh the
groove m the uppercrankcasc.

lnsrall IhP lnwm crankcase onto the upper
crankcaso'

Clean ma crankcase 9 mm bolls lhuruuglrly wllh
solvem and blow them dry

Apply clean engine ml torhe 9 mm bolt threads and
sealing surface and insrall (hem,

Loosely Install all the lower crankcase bolts
Make sure the upper and lower crankcase are
sealed securely.

From the Inside lo nmsidel tighten ma lower

crankcase 9 mm bolts in a crisscross pancrn in 2 — 3
S‘SDS.

NOTF

 

7 mm BOLTS

 

9 mm BOLTS l

 

 

 

 

 

 

 

 

Tlghlen the 9 rum bulls in numerical order as
shown in the lllustrallon

 

TORQUE: 37 N‘m (SIB kgf-rn , Z7 lbf-l‘tl

Tlghrcn the 10 mm bolt, and [hen me 6 mm bolts
and 7 mm bolts.

TORQUE: 10 mm bolt: 35 N~m (4.0 kgf-m . Z‘J Inf-W
7 mm bolt: 18 N rn (1,8 kgl m , 13 Math)
6mm bolt: 12 N-rrl (L2 kgl-m , 9 lbf-l‘tl

 

 

 

 

 

6mm BULIS

1o m‘m BOLTS

 

 

 

11-12

GRANKCASE/PISTON/CVLINDER

 

lnstaH the “may crankcase 8 mm boils and seal'mg
washers.

NOTE

The sealing washer Iacanons are Indmated on the
uppev crankcase using the "A" mark,

Tighten the 8 mm bolts to the specified torque.

TORQUE. 25 N-m [2 5 kgI-m , 16 lel)

lns|all [he new O-r'mg and sea‘ing plug,

 

8 mm BOLTS

 

 

 

11-13

CRANKSHAW/TRANSMISSION/BALANCER

   
      

27 N.-m (2,8 kgivm , 20 mm)

\

\ 12 N>m111 kgl-m,9lbi-ft)

\

\

\

\

27 N m {2.8 kglrm , 20 lbI-fl)

// \ 12 Nm (1.2kgfm,9lbffll

27 N m (2.3 kgf m , 20 m m ‘
\
\ 12 N-m e1 2 kgf-m ,9 Inf-m

\
12 N m (1.2 kgfrm , 9 Ibl-m

 

12-0

12. CHANK5HAFT/TRANSMISSION/BALANCER

SERVICE INFORMATION 12-1 TRANSMISSION 12-9

 

 

TROUBLESHOOTING 12.2 BALANCER 12-14
CRANKSHAFT 12-3

SERVICE INFORMATION

GENERAL

0 The clankcase must be separated [0 service the crankshaft. transmission and balancer. Ruler to section 1110f crankcase
separanoniassembly.

- Be carclul not to damage the crankshaft main journal and journal bearing while removing or Installing the crankshaft.

- Mark and store the disassembled parts In en<ure that they are installed in their original locations.

. Mark and store the bearing inserts to ensure manna parts are m Iheircorrecl locations during reassembly. Ii me inserts
are imprnnerly installed, they will blucklhe oil hole, causing insufficient lubrication and Hvenlual engine seizure.

- The main journal bearing Insens are a select m and are idenllfied by color codes. sclccr replacement bearings irom the
code rables. Afier installing new bearings, Inch . .k them with a plasliyauge lu verily clearance. Apply molybdenum
disulfide oil to the main journal during assembly.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
Unit: mm (in)
ITEM 1 STANDARD SERVICE LIMIT
Crankshah Side clearance I 00570101000270.0081 0.3010012)
ifiunout ,. ,,, ‘ — a 0.3010012)
Main joullml ui'l clearance 0.017 03510.0007 I) 0014) l 0 0115100018)
Transmisslan Gaar LI) M16 ‘ 31.000‘31025 (12205—12215) 31 0411.777.)
1 (21 > 2 00 26.02111 26.0‘l1.0251
I ,, I C2. 3, 4 33.000 33. 25 (1. 33.04 [1.301)
Bushing 0D. 1 M5. 6 1 30.950‘30375112135- , 30 9311.218) 7
‘ 1 C2 12355731930 (12974—12984) ‘ 3233 (1.255)
lk C3. 4 _ 22.950'32375(1.2972m1.2982) 32.93 (1.2961 ~.
i Bushing . . _ M5 22.54575 28.00611 101871 1026) 103)
‘_ , C2 29385—30006(1.1805—1.1H13) . W132)
Gearrurhushmg 1. M5. 6 0.020-D.062 (0.0008'00024) 0.10 (0.004)
clearance CZ 0 020*0070(0.0003*0.0028) g 0.11 (0 I 1
C3. 4 ‘ U.025‘0.075 [0 0010 0 0030) , 0.11 (0.904)
I Mainshafl OD M5 Z7.967*Z7.980(1.1011-]J916) 27357011007)
'___7 V Clutch outer guide Z7.980*27.993(1.1016'1.1021) 273700.101?)
_Countershafl OD, C2 79 967 39.98011 1798*1.1803I 27.957 (1.1007)
Bushing-urshafl J45 _ ODDS—0.035) 10.0002*0.0015) 70 03 (0 003)
clearanne C2 1 0.005—0.039 00002—00015) 0.0310003)

 

 

12-1

CRANKSHAFTITRANSMlSSION/BALANCER

TORQUE VALUES
Connecting rod nut

Mainshaft bearing sew plate bolt

l'lnlnncer (lmlng hole cap

Balancer shaft holdsr flange boll HtonUrear)
Balance! shall plnch bolt

Balancer Idle shaft holder bolt

Balancer idle shaft bolt

TOOLS

Driver, 40 mm ID.
Anachmsnl, 30 mm
Driver shah

Dtlver

Attachment, 32 X‘ 35 mm
Pilot, 15 mm

TROUBLESHOOTING

Excessive noise

- Worn connecting rod big and bearing
' Bent connectlng rod

0 Worn crankshall main journal bearing
. Warn transmissinn haarmg

~ Worn balance! bearing

. Incorrect balancar backlash adjustment

Hard tn shift

' Improper clutch operation

- Incorrect transmission uil weight
r luu‘mect clutch adjustment

- Bent shlfl fork

- BCI’K fork shah

I Earn fork claw

- Damaged shift drum nnm groove
- Bent shift spindle

41N,mr:.2kgr-m,3olbim

12 N-m (L2 kgl-m ,9 lefi
7 N-m (0 7 kgfwn , 571 lbf~ftl
27 N-m [2.8 kgf-m , 20 Ibf-m
12 N m (1,2 kglAm , 9 Ibllll)
Z7 N-m (2.8 kgf-m , 20 Inf-h)
12 N-m (1V7 kgf-m , E) le-hl

07746-003010!)
07746 0030300
07964vMEOO200
077490010000
07745-001010!)
077460040300

Apply uil lo the threads and seating sur
face
Apply a locking agent to the threads.

Apply a locking agenuo the threads

Transmission jumps om or gas!
- Worn gear dog: and slots

' Bent fork shaft

' Broken shin drum sluppet
' Wuru oi bent shiffiorks
- Brokr-‘n snifi linkage return spring

Englne vlbratlon

I Excessive crankshaft runout
- lnnnrrec' balancer timing

 

12-2

CRANKSHAFT/TRANSMISSION/BALANCER

CRANKSHAFT BEARING CAPS
REMOVAL

 

Separaxe the crankcase halvcslpage11~3).

Remove 1he cnnnecung rod heaving cap nuns and
bearing caps‘

CAUTION:

Before removal, pasitinn all the pistans at TDC
(Top Dnd Center] In prevent damaging the
crankpin with thy cannu‘ting rod bolt threads.

 

Remove ma cvankshah.

Hemnva vhe mam joumal braving: [rum bokh [he
crankcascs.

 

PRIMARY DRIVE SUB-GEAR REMOVAL *SW HM WWW SPR‘NG

Remove the special snap ring. washer and frmnon
sprmg.

 

 

 

12-3

CRANKSHAFI'ITRANSMISSIONIBALANCER

- Yau must use the new special snap ring. UEiIIg a

cut-outs as shown.

Remove the primary drive sub-gear and springs

PRIMARY DRIVE SUB-GEAR INSTAL- r
LATION

Install the primary drive sub-gear onto the primary
di‘rve gear, aligning the holes between the gear.

 

 

Apply molybdenum disulliuu oil in [he area shown
in lhe illustration

install 1hr, fnntron spnng, washer and new Speciai
snap ring.

CAUTION:

map ring othw than spa-flied or musing the
snap ring can cause severe engine damage.

- Install the new special snap ring with its large
tab facing to the right and the cham-lmd side
facing in.

. Make sure the new special snap ring end gap is
aligned with the right angle a! the crankshaft

 

 

 

 

., SNAP RING WPJde-VVle/ARGh IAB
w
m a “LA

V
52

 

CUTVOUTS

 

 

 

 

 

 

12-4

CRANKSHAFT/TRANSMISSION/BALANCER

 

lllslall the sprinqs into me prima’y drive gear as
shown

    

 

SPRING
l

 

STARTER CLUTCH NEEDLE BEARING
REPLACEMENT

Remuve lhe needle bearing wim a commercially
available universal bearing puller.

CAUTION:

Ta proud the crankshaft m-in jnumal Iran! the
bearing puller claws, cover the main inurnal
praporly; warn maln [ournal bearings are usable as
pratpctars,

 

 
 
 
 

w0RN MAIN ‘
JOURNAL l
BEARINGS

 

Press a new needle heaving nnm me crankshafl
using a hydraulic press and special tool.

TOOL:
Driver shaft D796A‘MBODZOO

  
 

DRIVER SHAFT

 

 

II the special tool is not available, prepare a
suilable collar, washer and 8 mm flange bull
(example; flywheel boltl for the bearing installation, ,
Assemble the above items, and screw the bolt
gradually, man install the new needle bearing.

 

WASHER \ ,. FLANGE BOLT

E

'7 ‘Tl
l

‘\‘ COLLAR
ll
'H

l \3’

i!
NttDLE BFARING

 

 

12-5

CRANKSHAFT/TRANSMISSION/BALANCER

 

INSPECTION

CRANKSHAFT RUNOUT

Hold the crankshaft Llulh end,

Sel a dial indicator on ma. center main Journal 0'
the crankshaft.

Home the crankshaft rwo revululious and lead
runoul al the cenlel journal.

 

SERVICE LIMIT: 030 mm (0.012 ml

MAIN JOURNAL BEA-RING _ _ MAIN JOURNAL BEARINGS
lnspccr me main Jaurnal baanng Inserts to:

damage or separaliun.

Wipe rho oil from the bearing inserts and iourmls.
Reinstall the upper crankcase’s main journal
bearing insens, then carefully lower lhe crankshaft
In place.

Put a piece of plasl‘lgauge on each journals.

NOTE

 

- Do nor pm me plastigaugs over the oil hula in me
main bearing journal ofthe crankshaft
- Do not rotate the crankshaft during lnspectlun.

 

 

Assemble me crankcase halves,
lelltefl the 9 mm bolts to the speCIIlen torque,

TORQUE: 37 NJ“ (3.8 kgfrm . 27 lbf‘h)

   

 

12-6

CRANKSHAFI'ITRANSMISSION/BALANCEFI

Remove (he 9 ‘WW boIls and luwer (:rarlIU.‘aSE.'r
Measure the nnmprss‘ed plastlgauge on each
journal.

SERVICE LIMIT: 0355 mm IDDO‘IS inI

If mam bearmg cIcarance l3 beyond tolerance,
select a replacamanr bearing‘

 

MAIN JOURNAL BEARING SELECTION

Record the crankcase I.D. leflcrs from the pad on
the left side (J the upper crankcase as shown.

NOT '

 

 

The leners (A, B or CI on Ilre upper urdukuase Me
the codes for N19. I'I'IHII’I jnurnal IDS from lefi '0
right.

Record me corresponmng mnln Journal 01;. cnde
numbers from the crank wcrght,

NOTE

The numbers (14 2 or 3) on the crank weighi are me
codes for [he main juumal O.D.s [rum Is“ to rIghI.

Cross reverence the case and journal codes (a
delermine llle replduerrlenl bearing cqur cudes.

  

VAIN JOURNAL O.D. CODE

BEARING THICKNESS: IDENTIFICATION COLOR
A (Bluck): Thick
a (Brown):

C (Greenl: I
D (VBIIUW):
E IPinkI: Thin

CAUTION:

 

After selecting new hearings, recheck the
clearance with a plastigauge» Incurred clurance
can cause severe engine damage.

 

 

12-7

CRANKSHAFI'ITRANSM|SSIONIBALANCER

MAIN JOURNAL BEARING SELECTION TABLE

 

llnn: mm (ml

 

     

 

 

 

 

 

 

 

xi \ x A ,
43 000 A1006 . 06—41012 43.01 43 18
,, \V (175929, L693“ (1.693] "1.6934! (1 8934 ‘l 6936]
1 40000740006 l E D c
» 115745715750) ‘ (P:nkl (Yellow) lGree_r\}
CHAN KSHAFT 2 39 994 — AG 000 D C B
CD CODE (1 574571.5/48l‘ (Yellowl (Gleen‘l [Hrqwnl
3 39.9884 39,994 C H A
(15743—15745) [Grer ‘ {Brown} lBlackl
INSTALLATION MAIN JOURNAL BEARINGS
Install the main journal bearlngs into me upper and
lower crankcase.
NOTF

 

The bearing labs :huuld be aligned wnh me.
grcnves in the case

 

Apply molybdenum disulfide oil so (ha nnner and
lower main Jnllrnfll hearings.

Install the nrankshafl‘

CAUTION:

Before installation, pasition all the pistons at TDC
I Tap Dead Center) to provant damqing the
Erznkpin with Rh: tunnecling mrl threads.

lnstall ma connocxing rod bearing caps.

Apply oil to we cannemng 10d nut threads and
sealing su'facas,

lnslall and tightén the nurs gradually anu
anemmaly

TORQUE. M N‘m (4.2 kgl-m , 30 low

Assemble the unpe' and lower crankcase lpage 11-
l2).

 

 

 

12-8

CRANKSHAFI'ITRANSMISSION/BALANCER

TRANSMISSION
REMOVAL/DISASSEMBLY

Separate me mankcase halves (page 11-3)

Remove the bolts and mainshah bearing sex ptate.

Remove the mamshafi and counmrshafl assemb‘y,

Remove the oi‘ seaL

Remove the dowel puns.

Disassemble \lle mainshah and caumershafl.

Check the gear dons, dog holes and [Hath (or abnor-
mal Wed! uv lack of lublicafion,
Measure lhe‘ 7) of ”or gear.

SERVICE LIMITS:
M5,ME 31D£mm41172xm
C'l: 26.04 mm (1.025im

C2. C3, (54133015 mm (1.301 in}

 

 

12—9

CRANKSHAFT/TRANSMISSIONIBALANCER

Measure the ID. and 07D, 01 each gear bushing.

SERVICE LIMITS:
0.0.: M5, MS: 3033 mm (1.218 in)
C2: 32.93 mm (1.296 in)
C3, Cl: 32.93 mm 11.296 in)
I D: M5' 28 DZ mml1,1DI!In)
CZ: 30.02 mm11.132in)

Check the shin lurk gruuve 01 [he sll'wIler gear for
excessive wear or damage.

(imam: me mamnan damper for wear or damage DAMPER

CAUTION:

Da nut try to remove the mainshnfl dampen I! it is
damaged, replace the mainshah‘ assembly.

Measure the 0D. 01 (he mainshafr and counter

shaft.

SERVICE LIMITS:
M5: 27.957 mm (1.1007 in)
Clutch om" guidlz 27.970111mI1.1D12in)
C?“ 27357 mm (1 1007 In]

 

 

12-10

CRANKSHAFI'ITRANSMISSION/BALANCER

BEARING REPLACEMENT

NOTE

 

Do not try |U vemuve the countarshafr bearing from
the shah. If the bearing is worn or damaged,
replace the countershaft as an assembly,

 

Turn the omar ram nf each bearing with your finger.
The boarlngs should (urn smoothly and quimly,
Also check that me bearing inner race firs (Ightly on
the shaft,

Remove and mannm vhe mainshaft bearing, if the
race does not turn smoorhly, aunerly. or fits loosely
on tho.- mairlshaft.

Replace the countershahl collar, and bearing a: an
assembly, if the race doe: nnt rum smnothly,
quisrly, or ms Iocsely on the countarshahr

Press out the mainshaft from the bearing ”5mg a
hydraulic press.

Install a new mainshafr bearing onra [he mainshafl
by pressing the mainshah bearing inner race using
me special tool.

TOOLS: .
Driver, H) mm I’DV 077-1643030100
Attachment. 30 mm 0/ [460030300

 

 

 

ATTACHMENT

 

MAINSHAFT

 

   
 

BtARING

 

CRANKSHAFT/TRANSMISSIONIBALANCER

ASSEMBLY
M2 GEAR nan

M6 GEAR (24Ti

MSH GEAR 119/211')

    

M5 GEAR (ZAT)

MAINSHAFT/NH GEAR (1ST)

COUNIERSHAFT
CZ GEAR (32Ti

@€£(§Q% 9%}

C3 GEAR (SOT)

 

CA GEAR (ZBT)
Cb GEAR IZST)
C1 GEAR (361"

 

 

 

 

 

 

 

12-12

GRANKSHAFT/TRANSMISSIONIBALANCER

Assemble the transmission gear and shafts.
Coat each gear with clean engine oil and check (or
smooth movemenn

Apply molybdenum disulfide oil [0 me shih fork
gmoves in the MEI/4, c5 and cs gear.

 

INSTALLATION

Install the dowel pins on the upper cvankcase holes.

Install the mnmshan and cnunvershafl by aligning
the countershafi bowing so! ring with (he groove
on the crankcase, and aligning ms bearing can
holes with the dowel pins

Also align me coumomhafl bearing moppcr pin
wiih the gvuuve in [he crankcasei

 

 

CRANKSHAFT/TRANSMISSIONIBALANCER

Apply a lomng Rain! In ma mmnsnafl bearing so!
plate bmlthreads‘

lnslall me mainshah bsarlnq sel pldle erh its
‘OUT SIDE" malk lacing out and t'lghlsn vhe halls
to the spec-hen mrr‘np,

TORQUE: 12 NW! (1.2 kgf-m , 9 ”JV-ll)

Assemble the crankcase (page ‘l 1-12).

BALANCER

THE balance! snsfl
WIN only cum: uul
lmfi‘ fine
pamumr posmon
imam I: urml v:
cums, uul taSl/y
do no! force :1 cu!

FRONT BALANCER REMOVAL
Remove the all pan lpagc 4 Al.

Remove (he flont balancer shaft holder hall,
I nnsen «ha punch bolland remove the holder.

Rotate the from balancer shall and place [he punch
mm u“ [he shah facing down.

Pull the lrom balancer shah out and vamuve the
balancsr weighUgear assembly.

REAR BALANCER REMOVAL

Separate the crankcase and remove the crankshaft
and transmission lSecliun 11).

Remove the balancer'ualc gear shafl holder 'uoln
Loosen me pinch bolt and remove ‘he holder.

 

‘ \
HOLDER PIKCH BOLT ‘

 

 

    

PINCH BOLT

x:

 

I l0LL§tH I

 

 

12-14

The balancil III/E
year shall wl‘ll
only come out
[mm mm
parliL‘u/al pasnim
Flrnafe fl until il
some: oul easily:
:10 ml lame ll our.

file “lancer snail
will only came ml!
llum one
particular mslliorl
Home ll Unlll ll
comes Du! easlly;
(10 not VOICE '1 DUI,

CRANKSHAFT/TRANSMlSSlON/BALANCEH

Remove the balancer Idle gear shaft stoppel bolt/
washer.

Rotate the balance! idle gear shaft and place ma
punch mark on me shah lacing down.

Pull cm the balancer ldlfi gem shaft and remove the
distance collar and ldlc gear.

Rerlwve the rear balancsr shaft holder bolL
loosen the pinch bolt and remove [he holder.

Hmave the rear balancer gear shall and place [he
punch mark on the shaft facmg downl

Pull the balancer shalt out and remove the balance!
weight/gear a. : emhlv.

 

l

 

 

‘ /( PUNCH MARK

. db

     
 

 

 

BALANCER wélGHTl
GEAR ASSEMBLV

 

BALANCER SHAFT

 

 

 

12-15

CRANKSHAFTITRANSMISSIDNIBALANCER

DISASSEMBLV WASHER A BALANCER WEIGHTJGEAFI

Remove (no side washer A, B and needIe bsav'mgs
from (he balancer weight.

 

NEEDLE BEARINGS WASHER B

Hemnvr. the baIancer gear and damper rubber: DAMPER RUBBERS
from the balancer weigm.

INSPECTION

NOTE

 

Replace Ihe balancer weight, shaft and needle
bearing: a: an assembly

Check me needle bearing sliding sulfaces of the
balance! weight Ior wear, damage m excessive
scramhes.

Check the needle bearing sliding sudaces of the
balancer shaft for wear, damagn or excessive
scrnlches.

 

   
 

BALANCER BEARING SELECTION BAI ANCH‘I WEIGHT
/

NOT E'

The balancer weIght, shaft and needle bearings are
select (med Iselecuoh table: see next page).

 

The baIancer shaft has a Ll), code number or color.

  
 

The balancer weight has (W0 I.D‘ code nmkiugs as _\

 

shown. I *
The markings are Idanmied each ID. of (he ‘ WEIGHT SIDE I.D. GEAR SIDE | D
balancu weigh! as shown. ‘ CODE MARKING CODE MARKING

 

12-16

CRANKSHAFT/TRANSMISSION[BALANCER

weight codes determine Illa raplacaman! bearing \
color.

Reler m the selection table below rm hearing
selection.

Cruss-rsfiaranca rhe balanccr shaft and balancer \_ ‘ , NEEDLE BEARINGS- ,

    
   

Check the naat‘lle hearing for smooth operation.

BALANCER BEARING SELECTION TABLE'
Unit, mm (in)

\\\alu\csasmrn 1 hr Blue 2 or Blackl 3 or Red
BALANCEF\\O\D m” l ~72» moon 7.9m ”355 nun-mm
wElGM‘lLuCODE ‘\ l u lmvaifl‘fll (07M~D.IO!5) m.7osl~a.7zss

 

 

 

 

 

 

 

 

 

26 996-27 000 l C B A
l1.062l3— USSOI‘ White Blue Red
B 25.991' 6.995 l D C B
l19§25—1.0513)5 Green While Blue
c 26.587 76 991 I E D C DISTANCE COLLAR IDLE GEAR SHAFT
l’l.0625>1,0626) Yellow Green White //

Check the balancer idle gear for wear or damage.
Check the hnlnncér idle gear shaft for wear,
damage or excessive scralches.

   

rum the Inner race of each bearing with youl fingen.
The bearings should turn smoothly and qumllv.
Also check that the bearing outer race {its rightly in
the gear‘ _
Remove and discard the bearing, if the race does .
not turn smoothly, quietly, or {its loosely m the
gean

, SNAP HING

m-JV

 
  
 
  

Remove the snap rrng
Drive me bearings oul oflhe idle gear.

 

Press the new idle gear bearing mm the Idle gear

. ‘ DRIVER
um; (he speclal tools.

TOOLS:

Driver 077490010000
Attachment, 32 X 35 mm 07746-0010100
Pilot 15 mm 077460040300

Install the snap ring into the gear groove scourely‘

   

 

12-17

CRANKSHAFT/TRANSMISSIONIBALANCER

 

ASSEMBLY

WASHERA DAMPER RUEBERS

I
l

    
  
   
  

BALANCEH GEAR

BALANCER WI‘IGH'I

Apply clean engine oil to the damper mhhers.
Install the damn" rubbers into the groove of me
balancer gear.

Insxall the balancer gsar unlo llle balancer weight
while aligning the grooves.

NOTE,

The reav balancer gear has ldenllllnalmn gronve on
the gear mam.

 

Install the needle bearings mm the balanccr weight.
Ins‘all the side washer A and B.

NEF DI t BEARINGS

WASHER B

GROOVES BALANCER WEIGHT

“"ng \ 59m
BALANcm GEAR?“ DAMPER RUBBE V
All: v my“

WASHER A BALANCER WEIGHT/GEAR

 

NEEDLE BEARlNGS

WASHER B

 

12-18

CRANKSHAFI'ITRANSMISSION/BALANCER

 

REAR BALANCER INSTALLATION

NOTE'

Always adjust the backlash after the balancer
installation

Remove the rear balancer hole cap.

Install a new O-ring into the groove of the roar
balancer shaft,
Apply small amount oi oil to the O-ring

Set the rear balancar assembly into the upper
crankcase, then install the rear balarlcer shaft with
Ital punch mark facing down.

NOTE:

lhe hnlanner shaft will only installed one panicular
position. Rotate it until it installed easily; do not
force it in,

install the rear balancer shaft holder and tighten
the holder bull to the specified torque.

TORQUE: 27 NH! (23 kgf—m , 20 int-m

Install the crankshaft (page lira).

Turn the crankshaft clockwise and make sure the
No. 1 piston at TDC lTou Deed Center).

NOTE

Make sure the index lines on the primary drive sutr
gear are aligned with the mating surface of the
crankcase

LDER BOLT

 

 

 

 

‘ HOLDER

 

 

 

INDEX LINES

 

 

 

CRANKSHAFTITRANSMlSSION/BALANCER

 

Tum the. rear balancer and align the index mark on
the balanccr gear tooth with the web on the upper
crankcase as seen through the timing hole

Set the halancer Idle gear onto [he rear balancer
gear and crankshaft drive geart

NOTE:

Make 5an the No. 1 piston at TDC. and the rear
balancar index line and L nkcase web are aligned

 

Install a new O-nng Into the groove ofthe halancsr
Idle gear shaft.
Applv small amount of oil to the Orring.

Install the disharmn collar, then install the balancer
Idle gear shaft with its punch mark facing down.

NOTE:

 

The balancer idle gcar shaft will only installed one
particular position. Rotate it unlil it installed easily;
do Itul lame it in.

 

Apply a Innklng agent to the stopper bolt threads.
Install and tighten the balancer idle gear shalt
stopper bolt/washer to the specified torque,

TORQUE: 17 N~m (1.2 kgf—m , 9 WM!)

Install the halnncer Idle gear shah holder and
tighten the holder bolt to the specified torque.

TORQUE: 27 Nvm (7,8kgt-m , 20 [bi-ft)

Assemble the crankcase (page ‘I 1-12).

 

 

 

 

|DLE GEAR

 

 

 

 

 

 

 

12-20

CRANKSHAFTITRANSMISSION/BALANCER

 

Set the front balancer assembly onto the crankshaft
drive gear while aligning it Index groove with the
boss on the lower crankcase

N01 E.
Make surethe No. 1 piston atTDC.

Install a new O-ring Into the groove of the from
balancer shalt.
Apply small amount of oil to the. D-rlng.

Install the from balancer shaft with Its punch mark
facing down.

NOTE:

 

The lronl balance: shalt will only installed one
particular position Rotate it until u Installed casulv;
do not force It in.

Install the "om balancer shah holder and tighten
the holder bull [0 [he specified touquet

TORQUE: 27 Nm [2.8 kglAm . 20 Ithl

 

 

 

 

 

BALANCER WEIGHTI’
GEAR ASSEMBLY

 

 

  

.HOLDER

  

 

I p \

FINCH BOLT

 

 

 

12-21

CRANKSHAFT/TRANSMISSION/BALANCER

 

Apply grease to the threads 01 rear balancer timing
hole cap.

Check the O-ring is in good condition, install the
.ear balancertiming hole cap,

Tighten the cap to the Speclrlcd torque.

TORQUE: 7 N-m (0,7 kgl’dn , 5‘1 IbI-h)

BACKLASH ADJUSTMENT

NOTE:

AdJIIK' the backlash while the engine is cold (below
35 ”C155 'Fi and the engine stopped.

 

Remove the balancer shaft holder pinch bolts and
the idle qcar shaft holder pinch bolt.

Turn the rear halnncer idle gear shalt counterclock‘
wise until the resistance is felt, then back it oft one
graduation using the punch mark as a measure.

CAUTION

Excasslv- force can cause a balance: glar, bearing
and shaft damage Do not turn the shaft more than
necessary.

 

Turn the rear balancer shaft counterclockwise until
the resistance is felt, then back it 0" one graduation
using the punch mark a: a measure.

    
    

 

‘o-HINE TINIING HOLE CAP

 

HOLDER BOLT

PINCII BOLT HOLDER

REAR BALANCER IDLE GEAR SHAFT:

 

   

UNTIL
RESISTANCE
IS FELT

ONE
GRADUATION

 

l IS FELY

REAR BALANCER SHAFI'

y

 

UNTIL
RESISTANCE

 

 

 

ONE
GRADUATION

 

 

12-22

CHANKSHAFT/TRANSMISSIONIBALANCER

Remove the front balancar shah holder pinch bolt.
Turn the front balance: shaft clockwise until the
resistance is felt, than hack it off one graduation
using the punch mark as a measure.

Warm up the engine and let it idle.

If the balance! gear noises excessive, editist the
balanccr backlash as follows:

1,Turn the real balance-1 idle gear shall uloukwisu
until the gears begin to make a “whining" noise.
Then, turn the gear shaft counterclockWIse until
the gear "whine" noise disappears.

lighten the gear shah pinch bolt to the specified
torque.

TORQUE: i2 N-m (1,2 kgl-m . 9 lbi‘ll)

n

.Turn the rear balancer shaft counterclockwise
until the gears begin to make a “whining“ noise.
[hem turn the gear shaft clockwise until the gear
"whine” noise disappears.

Tighten the gear shaft pinch bolt to the specified
torque.

TORQUE: 12 Nim (1.2 kgf-m , 9 lbf—ft)

3.Turn the front halancsr shaft clockwise until the
gears begin to make a “whining" noise. Then,
turn the gear smart counterclockwise until the
gear “whine" noise disappears.

Tighten the gear shalt pinch bull [U the specified
torque.

TORQUE: 12 Nan (1.2 kglim . 5 Ibf-ftl

After all gear backlash adjustments are done, snap
the throttle and make sure the gear noises is no
excessive

lithe gear "whine" noise is excessive, the backlash
islousmall.

It the gear “rattling" noise is excessive, the
backlash is excessive.

 

FRONT BALANCER SHAFT;
Ii ’2‘
L
RESISTANCE
FELT
i A

 

ONE
GRADUAIIUN

 

HEAR BALANCER IDLE GEAR SHAFT.

 

PINCH BOLT .

 

 

REAR BALANCER SHAFT; 7

PINCH BOLT

  

 

 

 

PINCH BOLT

 

 

12-23

FRONT WHEEL/SUSPENSIONISTEERING

26 N m (2.7 kgfvm , 20 IN“)

103 N-m (105 kg! m , 76 lbfrfi)

  
   
 
  

12 NA!" (12 kM-m . 9 mm)

\

\
\\

\1%
31 N»m (3,2 kgv-m, \jx
231mm

\

     
 
  
     

49 N-m (5,0 kqf-m , 36 lbf f!)

‘11 N-m11,2 kgf>m , 9 lhfil)

31 N-m (3 7 kgf-m , 23lb14fl)

 

22 N»m (2.2 kghn , 16 lbf-fl)

31 N m (3.2 kgf—m , 23 lel)

 

13-0

I3. I'I'IUNI WHEtL/bUbI’thblUN/D l I:I:I1II\IL'I

 

 

i SERVICE INFORMATION 13-1 FRONTWHEEL 13-9
I TROUBLESHOOTING 13-2 FORK 13-16
HANDLEBARS 13-3 STEERING STEM 13-27

 

 

SERVICE INFORMATION
GENERAL

AWARNING

0 A contaminated brake disc or pad reduces stopping powsr. Discard contaminltad pads and clean a contaminated disc
with a high quality brain dngroasing agent.
- After the Iron: wheel installation, check the brnke operation by appiying the brake lever and pedal.

 

I When servicing the front wheel, lurk ur steering stem, support the motorcycle Using a safety stand or hmst,
o Reiei 10 section 15 Ior brake system ininrmnvinn,
- Use only (Ire: marked "TUBELESS" and rubclcss valves 0n rim marked ”TUBELESS TIRE APPLICABLE”.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

    

—-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
‘Mrjmurn lirelread deglli , . 1191006)
Cold tire pressure i lip in 90 kg (200 in] [and 290 kPa i230 kgI/cm‘ , 42 psi)
__ W i Upro maximum weight capacity ‘ 290 kPa (2,90 kqf/cm2 42 psi)
A lo runom
Wnsel rim runuul i Radial — . i
, ‘_ Axial —- 2,0 (0,03)
Fork ‘__§pring free length 232.9 (9.17) 228.2 (§.95l ,
i Sprint: direction WilIl the tapmed end facing dquL
Pipe Iunoul , OBl
llannmmenflefiflrk fluid Fro Honda Suspension Fluid 55-8 1
Fluid level 142 (5.6l ‘ ,
Fluid canacitv 483 ; 25 cm1 [163 0.08 US 07, i i
i, 17.1— n.09imp ozl ,, 7 I
Stearing head hearing pra-Innd ‘ 10—15Ni1.0-1.5kgf| i v
TORQUE VALUES
Handlebar pinch bolt 26 Nm (2.7 kgf-m , 20 ibithi
Handlebar waiqm mounting screw 10 N‘I“ (1.0 kgf-m , 7 Ibf-hi ALOC hnli,
Stealing stem nut 103 N-m (1r) 5 kinm , 76 Inf-ft!“ See page 13 31.
Steering stem bearing adjusting nuiA 25 N~m (2.5 kgi m , 18 ibthl *-
Srecring stem bearing adjusting nur E 7
Fork top bridge pinCII bull 23 N-m (23 kng , 17 turn)
Fork bottom bridge pinch hnlt 49 N«m (5 u kgi-m , 36 lbf-ft)
Front axle boll A 59 N rn (60 kgfrm , 43 lbI-Iti
Front axle holder hair 22 N-m (2.2 kghn, 16 lbf-ftl
Froni biake disc mounting bolt 20 N-m (7 r1 kgt-m, 14 lhf-ftl ALOC bolt.
lork can 23 N-m (2,3 kgfrm. 17 lbi‘frl
Fork socket look 20 MM (20 kgf-m,14lbI-m Apply a locking agent to the threads
Fork damper luck nul 20 N-rn (2 0 kgf-xn, 14 |bf~ft1

 

13-1

FRONT WHEEL/SUSPENSIONISTEERING

 

TOOLS
Sieering slam socket (179166710101
Bali race remover set 079467KM90001 or 07VMF MATOiOD
- Driver allachmem, A 07946vKM90100 07VMF»MAT0200
Driver attachment, 5 07945-KM90200 07VMF-K230200
7 Driver shaft assembly G7955-KM90300 07VMF-MATnfmn
*Bearlng remover,/\ 07946 KM90401 07VMF MAT0400
- Bearing rurnuver, B 07946—KM90500 07947~KA50100
Assembly base ‘ 07946-KM90600 07965-MA60000
D7946-ME90200
Steering slam driver 07916 MBOODOO
Oil seal driver 07947-KA40200 — or 07NMD-K23010A (U.S‘Ai only)
Sliderweight 079A7-KA50100—‘
Driver urns-0010000
Attachment, 42 x‘ A7 rnm 077460010300
Pilol. 20 mm 077460060500
Bearing removershah 077460050100
Scaring remover head. 20 mm 077460050600
TROUBLESHOOTING
Hard steering Wheel turns hard
- Faulty or damaged steering head bearings I Faulty wheel bearing
I Insufiicienl tire pressure I Faulty speedometer gear
I Steering head hearing adjustment nul too tight I Benl from axle

I Bra ke d rag
Slam in one side or do“ not track “night

- u nevenly adjusted .igm and Ien lork legs Son suspension

' Bani fork I Insufficient fluid in fork
I Bent axle IWeakfork springs

I Wheel installed incorrectly I Tire pressure [00 low

- Faulty steering head bearings

I Bent frame Hard suspension

. Worn wheel bearing I Incorrect fluid woighr
I Wurri swingarm pivor componems . Bent fork tubes

0 Clogged lurk fluid passage
Front wheel wobbling

. Beni rim From suspension noisy
I Wurli irunl wheel bearings - Insufficient fluid in fork
0 Faulty tire I Loose lork lasteners

I Unbalanced lire and whael

 

13-2

FRONT WHEEL/SUSPENSION] STEERING

HANDLEBARS
RIGHT HANDLEBAR REMOVAL

Remove ihe screw and \he handlebar grip end.

 

Disconnect (he 1mm brake switch wires connectors

from the switch.
Remove the masmr cylinder holder bolls. holder

and mafler cylinder assembly.

Remove the right handiehnr swuvnhnhrcnle housing
scram.

 

Disconnect the Ihrmle came ends from rho mvonle
nine and remove me housing
Remove the throttle pipe (rum the righl handlebar,

 

 

THRO‘I'lLE PIPE

 

 

 

13-3

FRONT WHEEL/SUSPENSION/STEERING

 

Remove the stop ring f'om xhe fork pipe. W _ . ‘RIGHT HANDEEEAR

Loosen the rigm hand‘cbar punch bolt and remove
the handlebar.

 

LEFT HANDLEBAR REMOVAL

Disconnect the clutch switch wirc connccxors from
(he swilch,

Remove the clutch master cylinder holder bolls.
honer and clutch masmr nylxnder assembly

 

 

 

Remove [hr- screws and \ER handlebar switch hous-
ing.

fiemnve the srrew and handlebar gnp end.
Remove rho hand‘e gnu from the handlebar,

Remove the housing spacer from the handlebar

 

 

 

13-4

FRONT WHEELlSUSPENSION/STEERING

 

Hemove the stop ring ham thehjrk pipe

Loosen "‘0 Ion handlcaar pinch boh and remove
We hafidlebar.

LEFT HANDLEBAR INSTALLATION

Instal: the Ieh handlebar onm me fork BIDS whwle
aligning h: buss with m: groove of the [up bridge
MnkP surP the handlebar <5 semen on w mp
briuge‘

Ilgf‘lfin me left handlebar nmch hnu m the spam
ficdwruuc,

TORQUE: 26 N-m (2 7 kgf-m , 2K) lbfvfl)

HANDLEBAFI WEIGHT REPLACEMENT

Remove me grierom the handlebar.

SuaighIen the weight wlaiuer tab by [he surew-
driver or punch.

Apply/HD7755"! Temporari‘v instah the grip and and screw, xhcn
sp’a} Ih'fiugnthfi vemuve We havidlebar weight by turning (I‘e grip
ramackmg name and

ms runner 10'
easy :emava’

     
  

RUBBER \
‘ CUSHION / *-:\

‘ INNER WEIGHT /
,

‘ RETAINER HOLE

 

13-5

FRONT WHEEL/SUSPENSION] STEERING

Allow the aulraaivr
In dry for an hour
Dela/c usmg.

Remove the grip and Irum the handlebal weight.
Discard the retainer ring.

Install the new retainer onto the handlebar weight.
Install the grip and onto ll|e handlebar weight align-
ing its bass with the slot in the handlebar weight
Install a new mounting screw.

Insert the handlebar weight assembly into the hon-
dlebar.

Turn the handlebar weight and hook the retainer
tub with the hole in the handlebar.

Install [he left handlebar swntch <pnner mm the Ian
handlebar.

Apply Honda Bond A or Honda Hand Grip Cement
IU.S.A. only) to the inside of the grip and to the
clean surfaces of the hilt handlebar and throttle
grip.

Wait 3—5 minutes and install the grip,
Rotate the grip Ior even application of the adhesive,

 

INNER WEIGHT

 

4‘? RETAINER RING

 

 

 

RETAINER TAB RETAINER RING

 

 

 

 

 

 

13-6

FRONT WHEEL/SUSPENSION/STEERING

 

    

lWSlSl/ my space! lnstall the left handlebar swltch allgnmg m locating SWITCH-”GUS”;
mm mp hann'ahar pin with the hole in the handlebar. ‘ ~‘ :
swllch g'ocve.

Tighten the forward screw first, men the rear screw SWlTCH HOUSING

lllaldll [he clutch master cylinder assembly by
aligning the end ol [he maaier cylinder wilh the
punch mark on lhn hahdlehar

install the clutch master cylinder noldev With the
"UP" malk lacing up.

lighten the upper bolt filsl, than the 'UWEI bull.

TORQUE: 12 N m l1,2 kg! m,9 lbfftl

Canned the clutch switch wiles.

RIGHT HANDLEBAR INSTALLATION

Install the right handlebar nneo the fork pipe while
eligl'irlg its boss with the groove of the top bridge.
Make sure the handlebal is sealed on the top
bridge. '

 

 

13-7

FRONT WHEEL/SUSPENSION]STEERING

Tlghlen the righl handlebar pmch hnlt m the
specified torquev

TORQUE: 26 N m (2.7 kqf-r'l 1 20 min)

Install a stop ring mm the. groove of the fork tube.

Anulv grease lo the sliding sum», of the throttle
plpe
lnstall the throttle pipe on me right handlebar.

Apply grease to me thnflle name ends and sliding
survace.

Connect the throttle cables m the lluullle pipe
lnslall the rlghl handlenar swnch'mrcnlc housing

by aligning its locating p‘m wwh :he hole in the
handlebar.

Tigmen the forward screw first, then the rear screw.

 

 

13-8

 

 

 

 

FRONT WHEEL/SUSPENSIONISTEERING

Install the master cylinder by aligning the end of
the master cylinder with the punch mark on the
handlebar.

Install the master cylinder holder with the "UP”
mark facing up.

Tighten the upper bolt first, the lower bolt.

TORQUE: 17 N‘m (1 2 kgi-m I 9 lbfAft)

Connect the brake switch wirest

Install the grip and and tighten the new mounting
screw lo the specified torque.

TORQUE: 1U N‘m l'LO kgf~m , 7 lhi-Hl

FRONT WHEEL
REMOVAL

[AWARNING

A contaminated brake dist: or pad reduces
trapping power. Discard cantaminned pads and
clean a contaminant! disc with a high quality
brake dagmsing agent.

 

Support the motorcycle securely using a safety
stand era hOle.
Remove the bolts and front fendert

Remove the mounting bulls and right brake caliper.

CAUTION:

 

Suppofl the may. caliper with a piece of wire so
that it does not hang from the brake hose. Do rm!
twist the brake hose.

 

NOTE:

 

Do nnt operate the brake lever or pedal alter the
brake caliper is removed.

MASTER CYLlNDER
\" PUNCH MARK

:41

q \,

* <33:

 

 

 

FRONT FENDER

/

   

__/

    

 

   

Sl’l (IlAI HUI T

RIGHTBRAKE CALIPER BOLTS

,,\,,
K\

   
 
 
  
   

 

 

 

FRONT WHEEL/SUSPENSIONISTEERING

   
   
   

Remove me secondary master cylinder mounting
bolts. reilauor, leh brake caliuer pivul bull and side
the assembly oul of Ihe way

SECONDARY
MASTER
CYLINDER

CAUTION'

 

Supparl the bran caliper and secondary master

cylinder win: a piecg a! wire so that it does run \
hang from the brake hose. on not twin 2h: brako ‘ \‘
hate. I x
W /
l J ,’
NOTE. \ ‘ ‘
PIVOT BOLT llF1 BRAKE CALIPER

 

 

Du nol operale the brake lever m pedal after the
brake caliper is removed.

_._.—._._——-—

Loosen the right axle pinch hnlv:
Remnve the. Axle bolt,

 

Loosen the left axle oinch bolts.
Remove the axle and lhe from wheel

 

Remove the side collars.

 

 

13-10

FRONT WHEEL/SUSPENSION/STEERING

INSPECTION
Axle
Set the axle in V-bluck and measure the runclut.

Actual rttnnttt IS 'IJ'? the total indicator reading

SERVICE LIMIT: 020 mm (0.008 in]

 

Wheel bearing
Turn the inner race of Each bearing wtth your finger.
The bearings should turn smoorhly and quietly.
Also check that the healing oulel lace lit: tightly in
the hub.

nau’uem hear- Remove and dis ant the bearings ll they do not
mg: in DJITG mm smnmhly, quietly, or ll they fit loosely in the
hub.

Install the new buillltgs inlu tlru hub using the
spec-m lnnls (page 13713)

 

WHEEL BEARING

 

 

Wheel rim runout

Check the rim runout by placing the wheel in a
turning standr

Spin the wheel hy harm, and read the rtlnnut tusrng
a dial indicaror.

Actual runout is 1/2 the (Dial indicator reading.

SERVICE LIMITS:
Radial: 2.0 mm (0.03m)
AxiiI: 2,0 mm (0.08 in)

 

Wheel balance

CAUTION.

Wheel balance directly affzcls the stability,
handling and aye! all safety a! the motorcycle.
Always check balance when the fire has been
remand from the rim.

 

NOTE.

 

For optimum balance, the tire balance mark (a paint
dul on rha side wall) must be located next to the
valve stem Remuulll the tire ii necessavv,

 

 

FRONT WHEELISUSPENSION/STEERING

NOTE

Note the rotar-ng direcllon marks on rha wheel and
“'9‘

Remove the dust seals from the wheel.

Mount the wheel, tire and brake also: assembly in
an inspection stand.

Sp'ln the wheel, allow lt \c slop, and mark rhe
lowest lheavrest) pom! of the wheel WM 0 chalk.
Do this two or rhree limes lo verlfy the haavlesr
area.

If the wheel ls halannen, n wl.l not smp cansrstently
In the same posillon.

Tu balance llm wheel, llrsiall wheel weights on the
highw Sldfi m m, rlm, mp, SldF. npposfln me chalk ‘ y-

 

marks. Addjusl enough woighr sorhc whccl wlll no
longer stop in the same posirloh when ll is spun. 1 INSPECTION ST
Du 'lul add mule than 50 grams to the wheel. —" '

DISASSEMBLY

Remove the bolts and brake discs
Hemove the dust seals.

 

lnslallrhe bear‘lng remover head into The bearing.
From rhe opposite side, insrall the bearing remover
shafl and drive the bearlng out 01 the wheel hub.
Remove the dimance collar and drive our rhe orher

bearing.
TOOLS:

Bearing remover head. 20 mm ems-0050500
Bearing remover shaft 077450050100

 

 

13—12

FRONT WHEEL/SUSPENSION/STEERING

 

ASSEMBLY

\ RIGHT WHEEL BEARING
RIL‘HT BRAKE DISC (GZOGUU)

  
 
   

,6“ / ,5 , an 7 ” 5’7 ‘

RIGHT DUST SEAL

  

/

/
/ DFSTANCE COI | An
/

CAUTION.

Never install the old bearings. Once the bearlngs
has bun remand, [ha bearing must b: rsplurvd
with new ones.

Dvive in a new thl healing squavely.
IMMII the disranne nnHar, than rim/r m the Ian hur-
ing using me spoma‘ tool.

TOOLS

Driver 07745-0010000
Anachmem. Q X 47 mm 07746 0010300
Film, 20 mm 07746-0040500

M“—

Do not get greasy on thy blah: discs or snapping
power will be reduced

lnstaH the brake dust; on (he whee‘ hub
lnstaH and txghten me new maunnng bolts m the
specifiedtorque,

TORQUE: 20 N-m (2 0 kgf-m ,1Albfl‘1)

Apply grease to me dusx sea! lips, then install mam
into the wheel hub,

/
/

.,
.%m 1 1 Dust stAL

LEFT \NHEEL BEARING
(SZOAUU)

LtH BHAKL LHSC

 

@20 !\-m 12 o kgI-m , 14 mm)

 

 

 

FRONT WHEEL/SUSPENS|ONI STEERING

INSTALLATION

Install the side Collars.

Install the front wheel between the lurk legs while
allgning the left brake disL‘ between the leh nrake
caliper pads,

Apply thin layer of grease to the front axle surface.
Install the lrom axle [rum Llle left side.

Hold the axle and tighien the axle bolt to the spam!-
ied Luique

TORQUE: 59 N-m (6.0 kgflm ,431bf-ft)

fighten the right axle plnnh nnlts to the specified
torque.

TORQUE: 22 N-m (2.2 kgl-m , 1G lbf-ftl

Install the lell brake caliper and secnndary master
cylinder and reflector.

Install and tighten the new secondary master
cylinder mounting bulls to the specified torque

TORQUE: 31 N-m (3,2 kgfrm , 23 Inf-m

Install and tighten the new left brake caliper pivot
bolt to the Spvamflad torque.

TORQUE: 31 N-m 13.2 kgf—m ,23 IU-n)

p

 

 

 

13—14

FRONT WHEEL/SUSPENSIONISTEERING

 

 

Install the right brake caliper and tighten the new

mnunting bolts to the specified torque, R'GHT BRAKE CAUPER a

, ‘ \ ~—
Tonous: 31Nvm(3.2 Kgfm 4 231mm A» ,y// BOLTS

Install (hp ftnnt lender (page 245).

 

With the front brake applied, pump [he lurk up and
down several "mes to seal the axle and check
brake operation.

M

Check the brake operation by applying the brake
Iemandp-dal.

 

Tighlen lhe lnh nxh- plnnh bolts lo the specified
‘OVCIUB.

TORQUE: 22 N-rn 42,2 kgf-m,16lbf-fl)

Check the clearance between the brake disc and
Caliper bracket on each side after installation.
The clearance should be at least 0.7 mm 10.03 in).

 

 

 

FRONT WHEEL/SUSPENSION/STEERING

FORK

 

REMOVAL

Rellluvexhefruntwfieel(page13-9r

CAUTION:

Keep the brake and zlmah muster cylinders uprigm.

 

For the lull folk leg Ismoval, remnve the brake
hose rlamn hnn,

 

 

lnsnmnecessary l'nr vne ngm fork leg removal. remove the brake

 

       

, , l
:ommovc me o-r’ plpC 3 way jolnt mou'Iting bolt, men [he delay DELQY VAL\lREEFLECT0R 3,.wa [RIS'T
501:5 and or! plug valve mounl'mg banks and lelleclm. \\ /, ‘ ll PORT
n m rm: nmy \ ‘ \
valve ,

 

 

 

Remove the handlebar Stop vinq‘
Loosen the handlghar phwch bolls

When the fork lcg will be disassembled, loosen the
fork cap, but dc not remove i1 yet.

Loosen the [up bridge pHIC‘W bolt

 

 

13-16

FRONT WHEELlSUSPENSION/STEERING

 

Loosen the [wk bullum pinch ball and remove the
fork tube from the fork lop bridge, handlahar and
steering 5mm.

 

 

 

DISASSEMBLV

CAUTION:

Be mum! nut to scratch the fork tube or damage
the dust seal.

 

Remove the fork protector from the fork slider by
lifting at me three prv points.

 

Remove the fork cap from the fork pipe, FORK CAP

Huh! Lhe damper lud luck nuk with a 14 mm
spanner, then loosen and remnvethe tnrk can from
the damper 10d.

Remove the spl ing collar

 

 

FRONT WHEEL/SUSPENSION/STEERING

Remove rho spring joint plate and fork spring.

Pour our the fork fluid by pumping the fork pipe up
and down several times.

Hold the inrk sfider in n we wnh soft jaws or a
shop rowel.
Remove the fork socket hair with a hex Wrench.

NOTF

 

If the fork dampsr (urns together wilh (he >uckef
hon, temporarily instalf the fork spring, spring
couar and fork cap.

 

Remove rho fork damper assembly and oil lock
piece from lhe fork pipe.

FORK DfitMPER

JOINT PLATE

SPRING

 

 

i
OIL LOCK PIECE

 

13-18

FRONT WHEEL/SUSPENSION/STEERING

     

Remove the dust seal DUST SEAL

Remove the oll seal stopper rlng.

CAUTION:

Do not scratch the fork tube sl' 'ng surface.

 

/ . ,

STOPPIER RING

Pull the lurk lube out unfil you feel rasislancs from
me slider bushing, Then move it in and out, tapping
me bushlng llghtly until ma lork plpe separates
from the fork sllder.

The :Iidel bushing will be (urged out by the fork
nlpe hushlng

 

Remove mp. ml seal, back-up rlng and slider
bushing 1mm the fork pipe.

DILSEAL SLIDER BUSHING

  

NOTE

Do no! remove the lork plpc bushing unless it is
necessary lo leplace il wilh a new one.

BACk-UP RING FORK PIPE BUSHING

 

13-19

FRONT WHEELISUSPENSION/STEERING

INSPECTION

Fork spring
MeasuIe Ihe I01 k spring Iree length,

SERVICE LIMIT: 228.2 mm (8.98 in)

Fork plpnlslldsrldamper
Check the funk pIpe and folk slide! 10: score marks,
scraIches, or excessive or ahnnrmll wanr.

Replace any components which are worn or dam»
aged.

Folk dampw
Check the fnrk damper Inr damage.
Check the vebound spr'IrIg for VaIiguc or damage.

Replace the Imk damper assembly, if any camper
new are damaged.

Plane the fork pipe In V-hlock and measure the
runoux.
Amualrunoutis1/21helutalindicaluu wading.

SERVICE LIMIT: 0.20 mm (0.008 In!

  
     

l .
WORK SLIDER T“
Ej‘
\aI
J . . -.
‘-’ I onx PIPE
REBOUND SPRING

 

FORK DAMPER

DIAL GAUGE
/

 

 

 

13-20

FRONT WHEEL/SUSPENSIONISTEERING

Fork lube bushing

Visually 'lnspecl the slide! and 'DI k tube bushings.
Replace the bushings It mere. .s excesswe scaring BUSHING
or scratching, or if rhc lcflon is worn so that me
copper surface appears on more than 3/4 of lhe
emite surface

Check the back up ring: replace it if mere ls any 5 a 7/7’

BACKVUP RING

dislonlon at the points shown‘ \

CHECK POINTS
COPPER SURFACES

 

BRAKE CALIPER PIVOT BEARINGS REPLACEMENT
Remove the dust seals and mm cnllar.

 

PIVOT COLLAR

Press our the pivm heanngs uslng ma spenml mm. p ,7 DRIVER SHAFT ‘
TOOL:
Driver shah 079467KA50000

Apply grease to the plvol bearings.
Press the needle bearing imo the lurk slider using
the same tool

NOTE:

Install the beefing so that the heal-mg cage I! 3.5
mm (0 14 inl from the pivot surface.

 

Apply grease to the new dust seal lips.
lnslall the dusl seals and ulvot Collar.

    

PIVOT COLLAR

 

13-21

FRONT WHEEL/SUSPENSIONISTEERING

ASSEMBLY DUST SEAL
STOPPER RING

a on. SEAL
17 1mm

BACK-UP RING
[UHK DAMPER Sl IDrH BUSHINL‘\
/ / g

/
LOCK NUT
20 NM (2.0 kgl-m,
14 Ibffl)
SPRING COLLAR

SPRING JOIN] PLA1E

 
 
  

FORKCAP
23 N-m (2 3 kgf.m ,

 
   
   
 
 
 
 
  

FORK PROTECTOR

 

FORK SUDER

l OHK SPMNG
R FORK PIPE
20 N-m (2,0 kgv-rn, O'L LOCK F'ECE ‘FORK PIPE BUSHING
14'hf-fl)
Before assembly, wash a” parts wim a high [lash . ‘ ..
poim Dr nan-flammable solvem and wlpethern dry. a9 0“ SEAL 5‘ 'Dt" BUEH'N"

v

lnsxafl a new fork pipe bushing If the bushing has
been remuved.
mm! Ms W sea! Instabl the shder bushing, backup ring and a new
witnnsmsrked ongeaL

aide (mug up. 3 .
Apply lurk fluidmllm uil :ual lips. , /
Install the fork mpe mm the fnrk slider. / \ “

BACK UP RING FORK PIPE BUSHING

  
    

Drive the oil seal in using the special tools sumn WEIGHT

TOOL:
Slider weight 07947-KA501DO
Dil seal drivar D79477KA40200 or
» D7NMD7K230‘IOA
1U.S.A, only)

on SkAL DRIVER

 

 

13-22

FRONT WHEEL/SUSPENSION/STEERING

 

   

InstaH the stopper ring into the fork shder groove

STOPPER RING
secure‘y. I

install the dust seal. DUST SEAL

mm lhu uil \uck piece mm, the end or the fork
damper
mm the (ark damper assembly Into the fork pipe.

He‘d the folk slidzy in a v?“ wilh gull jaws u! a
shop towa‘

App‘v .3 making agent to me fork socket balk
threads.

Instarl the socket bolt wnh a new sealing washer,
(hen (rghten me bolt to the specified torque

NOTEV

IV the fork damper turns logether wrth the seeker
boli. ‘emporarilv install the fork spring, spring
col‘ar and fork bolt.

TORQUE: 20 Nnm I2,0 kgf-m,14lbf-ft)

 

 

13-23

FRONT WHEEL/5USPENSION/STEERING

Pour the Specified amount of recommended Iork
fluid into the fork pipe.

RECOMMENDED FORK FLUID:
Pro Honda Suspension Fluid $578
FORK FLUID CAPACITY:
483 .L 2.5 cm“ (16.3 1 0 08 US 01,
171: um Imp oz)

Pump the damper rod several limes.

Measure me all level [mm the top of the fork pipe
while compressing the pipe all the way («her
stroking the 6an nlpe slnwly mare than 5 times and
the damper vod more than 10 times.

NOTE,

 

Be sure the oil level is the same in the boxh iorks.

 

FORK OIL LEVEL: 142 mm (5.6 in)

Pun me damper rod up and insxan \he fork spring
wivh the tapered and facing down.

Install the spring 1mm plate.

Screw [he damper rod and um mm, by hand

 

 

 

  
 

142 mrms‘s‘m)

 

 

 

SPRING

JDINI PLATE

END NUT
\

 

 

FRONT WHEEL/SUSPENSIONISTEERING

 

mm” the sprmg co‘lar,

lnsraH new Orrings onro the fork cap.
App‘y furk fluid lo me new O-rinqs.

Hold the damper rod and screw the fork cap nmn

(he damper rod unril it scars on rho damper rod
locknut.

Hold the fork cap and tighten the lack mu m the
specified torque.

TORQUE: 7n N-m 12 D kgfm, H Ibi‘ft)

Screw the fork cap into me Iork pipe.

Install the fork protector onto the fOIk ledEI align-
ing the protector boss wrlh lhe groove In the Inrk
slider,

 

 

FRONT WHEEL/SUSPENSIONISTEERING

 

INSTALLATION

Instail me fork legs into the sleevmg slenL fmk top
bridge and handiebax.

F'Dsltlon the ion and of the fork pipe 39 mm 11.5 1n)
imm the upper surface oi me (on bridge as shown.

/ \
TOP BR‘DGE FORK PIPE

Tighten ihc bottom bridge pinch bolt to ma specir
fiedtorque.

TORQUE: 43 N‘m [5.0 kgf m , 35 lbl-f‘d

Tigmgn ma mp bridge pamn Duh m the specified
mique

TORQUE: 23 N m (2‘3 kg! m , i7 ibfrh)

 

Tighten the fork cap m lhe specuiied torque (if it
was removed).

TORQUE: 23 N>m12 3 kgf-m , ‘17 ‘bi-ffl

Tighten the handiebar pinch be“ w the specified
torque.

TORQUE: 26 N-m (2‘7 kgf m , 20 Hit VI:

install the handiebar slop ring mtg the groovy. of
thpfnrk pipe

 

 

13-26

FRONT WHEEL/SUSPENSIGN/STEERING

 

Install the delay valve and leflecwl mm the fight . DELAY VALVE REFLECTOR
furk leg and hgmen the mauntlng bolts to the '

specified to‘uue.

 

TORQUE: 12 N~m l1 2 kgf-m , 9 \bf-ffl

 

Install the 3-wnyjmn1 anmlgmanme mnuming hall
to the specified torque.

TOROUE: 12 N-m (I 2 kgl-m,81bflh)

 

 

lnsIaII and lighxen the brake hose clamp boll to the
specified lulquu.

TORQUE: 12 N-m (1.2 kgf—m , U Inf-fl]

|nslalllhe[rulxlwllaellpage13-14).

STEERING STEM
REMOVAL

Remove the frgm wheel (page13-9).

Remove the bolts and from brake hose/horn mount
ing bracket.

 

 

FRONT WHEEL/SUSPENSION/STEERING

Remove me steering slam nut can STEM NUT CAP
,

 

Loosen (he steering stem nuL
Remove the foHowing

, Fork‘egswage 13-1b)
iHandiebar (page 13-37

Remow? tho stem nm and who. can bridge,

 

 

Sflaighlsn the labs or [He 1m washer

Remove the lock nut and lock washer.

Remove the steering ste». hearing amusnng nut
usmg the special (00‘,

Tool;
Steerlng slam socket U7U1&3/70’IU1

 

 

13-28

Arwcys rcpmc mc
aaarmqs and
‘aies as a 59!

Hole me mslaflar
(Ion dr'actron or
w. 5:3emwy' base

FRONT WHEELlSUSPENSION/STEERING

Remnvs mp ronnwzng
*Dusr scar

, Upper bearing i"ner race
’Upper bearmg

, Staermg stem

*Luwcr bearing

BEARING REPLACEMENT

Except USA:
Haplnce m, rare; ”mg the Ball Race Remover Set
as described mmc foHowmg procedure

TOOLS:
—Ball race remover set D7946-KM90001
—Driver attachment. A (1] 07946 KMQOWOO

—Drivnr attachment, B (2) O7946-KM90200
Driver shaft assembly {3) D7546»KM90300

    

—Bearing remover, A (4] O/Ud6»KMHU4U1
—Bearlng removev,E15) 07946-KM90500 , r.
Assembly base! (6) 07546-KM90600 (1r (2} (M15)

DHVVEH AV IACHMENI NUI A
\ /,

InstaH the ball race remover into the head pipe as
shown

      
 

AHgn bearing 'cmovcr A with the groove in tho
slewing head.
Lughuyngmen nm E with a wrench

Holding (he driver shah with a wrench, rurn nut /\
graduaHy lu leluuve [he uppw uuler me:

UPPER
‘ OUTER ’
RACE
v
1 BEARING
r HEMOVEH A

 

 

/ .
DRYVEH ATTACHMENT DRIVER SHAFT \
_——_1

 

13-29

FRONT WHEEL/SUSPENSIONISTEERING

13-30

 

Install ball race remover B as shown and Iemove
rhe lower ourer race using \he same procedure as
{or the upper outer race

Align the bearing remover wilh (he groove in zhe
sleering head.

lnsrall a new upper outer race and the ball rncc
remover as shown.

Hold me driver shah wirh a Wrench and [um nut A
gradually umil the groove in driver nmmhmenl A
aligns with the upper and of the steering head. This
will allow you :0 lnsrall (he upper outer recs.

DRIVER ATTACHMENT

BEARING
REMOVER B

DRIVER ATTACHMI'NT

    
   

DRIVER SHAFI'

ASSEMBLY
BASE

NUTA

 

DRIVER ATTACHMENT

,/
ASSEMBLY
BASE

 

  

 

 

DRIVER SHAFT

 

DRIVER
ATTACHMEN I

FRONT WHEEL/SUSPENSION/STEERING

Install a new lower outer race and ball race re-
mover as shown.

Holding the driver shaft w'lth a wrench, turn nut A
gradually until the groove in driver attachment 5
aligns thh the upper end olthe sleeriltg head. This
will allow you to install the lower nmer race

   
   

DRIVER
ATTACHMENT

DRIVER
A'I'I’ACHMENT DRIVER SHAFT

 

 

U.S.A.onlv:
Replacu the steering head bearing outer races Ul’l’LR NUT m
using the special tools listed below.

  
  
   

MAIN BEARING

TOOLS' DRIVER ATTACHMENT
Main be. ng drivur attachment 07945-M590200
Fork seal drivar Weighfi 079£7~KA50100
Oil :eul driver MEGS-MASHDDU EORRIESE/‘VMEKGHT \
Insllller shaft 07VMF K2302“) \\
Installer attachment A 07VMF-MAT0100 UPPER BEARING \
Installer machmenl B 07VMF-MAT0200
Remover anachmem A UIVMFVMATUSDU OUTER RACE \
Rumovsr imchmsm B 07VMF-MAT0400 .

K REMOVER

Install the speclal tonls mm the steermg head plpe A‘I'I'ACHMENTA -\ ‘
as shown.

Align remover attachment A with the groove in the
steering head. 0 ’
While haldlng the installer shaft with the wrench, INSTALLER SHAFI' [T
turn the upper nut gradually to remove the upper
bearing outer race.

LOWER NUT ’/

INSTALLER
ATTACHMENT B /

 

 

 

 

 

13-31

FRONT WHEEL/SUSPENSION] STEERING

 

B: calel’ulrlol to Install the special luuls imo the steenng head pipe
won me altar-"A as shown. INSTALLER " ’
menI Inlalne Align remover attachment B with the groove in the ‘ Al IACHMENTA \
frame steering head. ,

Whils holding lhe iIIslaIleI shaft with the wrench,

turn the lower nut gradually to remove the lower INSTALLER SHAFT \\ >l

hearlng outer (EOE. \

 
 

UPPER NUI \\

\

REIVIovER \

A'I'I'ACHMENT B \

   
  
 
   
 

 

LOWER nummv’
OUTER RACF

OIL SEAL DRIVER

FORK SEAL /
DRIVER WEIGHT 1’

 

//

/
MAIN BEARING 1’
DRIVER A‘I'I'ACHMENT

 

LOWER NUT

 

 

Install a new upper bearing outer race and the
special tools as shown, UPPER NUT
While holding the installer shaft with the wrench, ‘ INSTALLER
mm the lowzr nut gradually until the groove in ‘ ATTACHMENTA\\\
inuallcr attachment A aligns wIIh the upper end of ‘
the steering head. This will alluw you to install the

upper bearing outer race UPPER BEAHING ,,/

OUTER RACE

  
  
  

ms I ALLER SHAFT ”

INSTALLER ‘
ATTACHMENT B \\ I

OIL SEAI DRIVER ”

FORK SEAL /
DRIVER WEIGHT /

MAIN BEARING "/
DRIVER ATTACHMENT

 

 

LDWFR NUI

 

 

 

 

13-32

FRONT WHEEL/SUSPENSION/STEERING

 

Inemll a new lower bearing outer race and special
louls as shown.

While holding the installer shaft with the wrench,
turn the upper nul gradually unrll ihe groove in
insialler anachrnenr B aligns wirh rha lower and of
llle sleerillg head. This will allow you to install (be
lower hearing nmer race

Temporarily insrall ihe steering stem nut onto the
stem lo prevent me threads from Delng damaged
when removing the lower bearing inner race from
[he slenl.

Remove the lower bearing inner race wirh a chisel
or equivalent tool, being careful not to damage me
$19!".

Remnve the dust seal.

Apply grease to new dust seal lips and install ii
over the steering stem

Inslall a new lower bearing inner race using a
snamal tool and a hydraulic press,

TOOL:

Steering stem driver U79A6—MBDOOOO

 

UPPER NUT
\

\

\

MAIN BEARING
DRIVER ATTACHMENT

FORK SFAL
DRIVER WEIGHT \\

INSTALLER
ATI'ACHME NT A \ \

/
INSTALLER $HAFT -/’

LOWER BEARING\
OUTER RACE

INSI ALLEH
AT1 AIIIIMLNI B

LOWER NUT ’/

  
 

  

’3

 

 

 

 

LOWEH INNER RACE

 

 

 

FRONT WHEEL/SUSPENSION] STEERING

INSTALLATION STEM NUT
103 N-m 110 EKQf-m ,76 IN m

\\ STEM NUT CAP
/

 

  

\\~ LOCK WASHER

‘3 \\
Q \ TOP THREAD
\~ UPPER DUST SEAL
‘3,

\ ‘UPPERINNEH RACE

\ UPPER BEARING

\

\
UPPER OUTER RACE

r

   

\\\
l 0W1 H OUTER RACE

   

T \ LOWER EEARTNG

I ' r7
L ‘ :EEARINGS
STEER‘NG STEM \ OWER INNER RACE

\ E 135212232“
LOWER DUST SEAL '

ADD‘V grease to upper and Tower bezr'mgs and
bearing races.

 

Insth the aner beanng onto the slccring mom.
men the steering stem imo the steering head pipe.

Install upper bearing, Inner race and dust seal.

Apply oil to the bearing adlusrmem nul lhvuads.
Irma” and |igl1len the stem bearing adlnsling who
the inmal mrque.

TOOL:
Steering stem socket D791573ITU'IUT

TORQUE: 25 NAm12.5 kghn , 151M“)

 

 

13-34

FRONT WHEEL/SUSPENSION/STEERING

Move :ne steetittg stem tight and left, tockrtortock,
‘tve ttmestn manna beartngs.

Make sure that the steenng stem mnvns smnnthly,
without play or binding; then loosen the bearth
adtusttng nut

Hangman ms hearing ad}\_ls!i"g nut to the specnted
torque.

TORQUE 25 N-n (2.5 kgf‘tn , 18 lbl-(U

Recheck that the steamy stern moves smnotnly
without ptav or bind a.

   

tnetatt the new took washer onto the steertng stern

Align the tabs 0! the luck washer with the gruuves
in the adjustment hm and hand [WEI opposite labs

Ishorter) down tntu the adjustment nut groove. =3 @l ”UK WASHER

 

lnstalt and finger t‘tqhtenthe \ock nut.

Itntd the took nut and futthev tighten the lock nut
wttnin 1/4 turn (90“) enough m altgn its grooves
with the lock washer tabs‘

Bend tne lock'wnsher tahs up into the luck nut
groove

 

 

FRONT WHEEL/5USPENSION/STEERING

Install the top bridoet

|nsta|itheinlinwrngz
iHandlebar (page i3 5)
*Fork legs (929191346)

install the steering stem nut
Tighten the steertng stem nut to the specified
torque.

TORQUE: 103 N-m (10.5 kgf m . 76 ihf fl)

Install the steering stem nut rap

 

 

|nstali the front brake DiDe joint and tighten the
mounting bolts.

Install the mm wheel {page 13-14»

STEERING HEAD BEARING PRE-LOAD
Removethe upper cowl [page 2-8)

Jackrup the motorcvcie to raise the from whaei off
the gruund.

POSIDOI’! the steering stem to the straight ahead
Position.

Houk a swing scaie to the fork plpe and measure
the steering head bearlng prerload.

Make sure that mere Is no cable or wire harness
interference.

the tare-load shnuid he wrtmn 10715 N (1.0«
1.5 kgi). t ;

If the reading: do nul MI within the limits, lower
the from when! m the gmum ant-t ndlust the
steering bearing adjusting nut.

 

 

 

13-36

 

MEMO

 

REAR WHEEL/SUSPENSION

 

15 Nm (1 5kgf-m ,‘I1Ihf-fl)
.

64 N m (65 kglrm , 47 mm)

    
  

42 Nrm (4.3 kgfvlu,31lbv'-m

42 N-m (4.3 kgf‘m , 31 lhf-m

 

1 4-0

4. I'II:AI'I WHttL/SUSI’tNSIUN

 

SERVICE INFORMATION 14-1 SHOCK ABSORBER 14-9
i TROUBLESHOOTING 14,2 SUSPENSION LINKAGE 14-11
i REAR WHEEL 14-3 SWINGAFIM 14,12
l

 

 

SERVICE INFORMATION
GENERAL

AWARNING

- A cantaminatod bra/to disc or pad "dunes stopping powu. Discard contlmlnllod pads and clean a contaminated disc
with a high quality brake degrensing agent.

0 After the rear wheel installation, check the brake operation by llppliflg the brake lever and pedal.

. The thock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber.

I Before disposal of (he shock ' bsorblr, rnlauo rho nitrogen ipago ”JUL

0 When servicing the rear wheel, support the motorcycle using a satetv stand or hoist.

- Relertc section 15 for brake system inlormaliun.

' Use onlyures market! "1 UBELESS" and tuheless valves nn rim marked "Tlll'Irl I'SS TINT APPI ICABLE”.
- Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point.

 

 

 

 

 

 

 

 

SPECIFICATIONS
Unit: mm (in)
i ITEM STANDARD ‘ SERVICE LIMIT
. Mrnlwtyrpjfl'raaddenth " _____ .. 4 2.0m osr
Cold tire pressure Upm so kg lzoolgjgaa 290 kPa 1.2.90 kgf/crn lpsi) —.
Unto maximum weight capacity 290 kPa (2,90 Ital/cmz , 42 psi) , * V“
. Axle runout . . ; . 7 . l 0.20 looosr _
Wheel rimrunout Hadial 7 .. W ?.fll0.08I

 

 

 

Axial " ' —— zogosrmfi

   

 

 

 

 

 

Dine Size/link Moro __DIDEOZVS-HOLE
FlK HKsoLFozmnoLE
» Slack 25—35(1.D—1.4) _59(2_U)»
Shock absorbs pring pre»|oad length 2091 (8.23) ~r~ —

 

TORQUE VALUES

Rear axle nut 93 N-m (9.5 kgI-m , 69 Ibilil) U-nut.
Rear brake dlSC mounting bolt 12 N-rn (4.3 kgIAm , 31 Ihl-tt) Al (1C hnlt
Driven sprocket nut 108 N rn (11.0 kgl m , so In! ft) U nut,
Sltuuk absorber upper mounting nut 42 N:m (4.3 kgf‘m , 31 |th) U-nut.
Shock llnlt nut (frame stdel 59 Nam 16.0 Ith-m , 43 |th) U-nut.
Shock link nut (shock arm plate Side) 42 N-m 0.3 kgl-m , 31 Iht-tt) U-nut,
shock arm plate nut (swingarrn side) 42 N m 14.3 kgl-m , 31 Iol ft) U nut.
Swingarm pivot adjusting bank 15 N-m (1.5 kgI-tr|,1'l|bI-It)vSee page 1449.
Swmgarm pivot lock nut ' 54 N-m (5 5 kgt-m , A7 Inf-ft)

Swingarm pivot nut 93 NM (9.5 kgf m , 69 Ibl-tt) # Urnut.
Drive chain slidgr bolt 9 N-m10r9 kqf-m , 6.5 lbf-ft)

Drive sprocket special bolt 54 Nut (5 5 Itgf-m , do Int-m

Brake hose guide bolt 12 N>ml1.2 kgf-malhirm

 

14-1

REAR WHEEL/SUSPENSION

TOOLS

Pivoi adiusiing wrench
Bearrng remover sec

7 Remover handle
-Removar 5E!

— Remover weight

r'in drlver

Necdirz hearing remover, 28 mm
Needle bearing remover
Driver shaft

Driver

Attachment, 37 r 40 mm
Auaulunenl, A2 X 47 mm
Anachment, 57 X 55 mm
Attachmenr,24 x 26 mm
Pliol. 17 mm

Piiul, 20 mm

F‘iim, ?H mm

Bearing rcmover shaft
Bearing remover head, 20min

TROUBLESHOOTING

Sofl suspension
- Weak shock absorber spring

- Incorrect suspension adj usrmcm

. Oil leakage from damper uniI
- Tire plessule too low

Hard suspension

079084590003

0793573710001

079363710100

079303710600

07141-001020! or 07936 3710200
07GMDVKT301OO NotavailableinUSA
07HMC-MH70100 Not available in U 50A,
07l MC-KVJO'ICIH

0I9467MJ00100

077490010000

07746-001020!)

0774647010300

07746 0010400

07746-0010700

0774670040é00

07746-00‘0500

07746 0041100

07746-0050100

07746-0050000

Steers to one side or does not track straight
0 Eenr rear axle
- Axle aligrlmenvchain adjusrmnni not equal on borh sides

Rear wheel wobbling
- Bent rim
- Worn rear wheel hearings

- Damaged shock absorber lllUqung bearing I Farmyrrre

o Benr damper rod

- Damaged swingarm pivot bearings

' Bent swingarm pivot

0 Incorrect suspuusiull adjusimem

0 Tire pressure inn high

I Unbalanced (ire and wheel
- Tire pressure loo iuw
. Faulty swingarm pivm hanrings

 

1 4-2

REAR WHEEL/SUSPENSION
REAR WHEEL ‘

REMOVAL )N
Suppon the motorcycle on its center stand ‘ V

Remave the axle mm and wasner.

F‘Imh thp rear Wham inrward
Dcrai‘ me drive chain from the driven sprocket.

Remove the ax‘e {mm the \eh side and remove rhc
mar Wham,

ficmovcxhc sudc collars.

INSPECTION
Axle
Place :he ax|e in Vrblocks and measure the vunout.

Actual Iulroulls 1/21het0tal indicator read'rng

SERVICE LIMIT: 0.20 mm “1.008 in!

 

 

REAR WHEEL/SUSPENSION

 

Replace the wheel
bearings in p411:

Wheel beating

Turn the mner race of each bearing with your finger.
Bearings should turn smoothly and quietly Also
check that the bearing outer race fits tightly in the
hub.

Remove and discard the bearings it the races do
not tum smoothly and quietly, nr it they fit loosely
in the hub.

Wheel rim runout

Check the rim runout by placing the wheel in a
turning slam].

Spin the wheel slnwly and read the runout using a
dial indicaton

Actual runout is 1/2 the total indicator leading

SERVICE LIMIT: Radial: 2.0 mm (0.08 in)
Axlal: 2.0 mm (0118 in)

Drlvun sprocket

Check the condition nt the ilnal driven sprocket
teeth.

Replace the sprocket if warn of damaged.

NOTE:

- It the final driven sprocket requires reulacamenl,
inspect the drive chain and drive splocket

0 Never install a new drive Chaln nn 3 worn
sprnnket or a worn chain on new Sprockets. Both
chain and sprocket must be in good condition or
the replacement chain or aplucket' will wear
rapidly

 

 

Wheel balanca
See page 13-12 for wheel halance.

DISASSEMBLV

Remove the bolts and brake disc.
Remove the right dust seal.

 

 

REPLACE

 

 

 

 

14-4

REAR WHEEL/SUSPENSION

Remove the driven flange assembly from the left
wheel hubi

NOTE
If you will be disassembling (he drlven flange,

loosen the driven spiockei nuts beluie :enmving
the drlven flange fmm the wheel huh

Remove me wheel damper rubbers.
Removethe Orli'1g.

Driven flange bearing removal
Loosen the driven sprockei mils

Reiiiuve 'ilie driven Henge (rum the wheel hub, lhsn
remove IhP driven sprockei rims and sprocket,

Remove the duel seal.

 

Remove me driven flange culla'.

Di‘ive Oulthe uiiveii flange bearing.

 

 

REAR WHEEL/SUSPENSION

 

Wheel bearing romoval

Install the bearing Iemover head into the bearing
From the apposite sme Install the bearing remover
shaft and dr'wc me bearing out onne wheel hub,
Remove Khe dlslance collar and drive out lhe ulluev

 

bearing,

TOOLS:

Billing “mover head, 20 mm 077460050600
Bearing remover shah 077000050100
ASSEMBLY

42 N-m (4,3 kgf-m , 31lbfft)
“ /

    

DRlVEN FLANGE BEARING
l6305UU'y

RIGHT WHEEL BEARING

/
‘ /
V /
\GSIMULJ) / L", d/{j\ / nmvrmwnomu
/ \ a
LEFTWHEELBEARING ‘
16304UU)

/
DAMPER RUBBERS /

/
DRIVEN FLAN GF

,
flan DUST SEAL

   

Wheel bearing installation
CAUTION:
Never install thg old bearings. 17an the bearings

has been removed, the hearing must be replaced
with nJW anus.

Dnve in a new rrghl bearing squarely.
Install the distance collar. then drive in me left side

bearing.
TOOLS: l 7.

Driver 077490010000
Attachment, 52 ‘A/ 55 mm 07746-0010400
Film, 2|] mm 07746-004050!)

 

 

14-6

REAR WHEEL/SUSPENSION

Driven Hang: bearing installation
Drive rhe new driven flange bearing mm the driven

flange using the special Iuols, :75,
TOOLS:

Driver 07749 0010000
Attachment 52 " 58 mm 077450010500

Film, 25 mm 07746-0040500

lnstall the driven flange collar.

Install the wheel damper rubbers mm film wheel
huh

Apply oil (0 the new 0er and Install rt mm the
groove of me wnaaw hub.

Install (he driven ‘Iange assemmy mm the left
wheel hub.

ll [he dr'rven sprocket was removed, install we
driven sprockel and tighten the nulsv

TDROUE: 108 N-m (110 kg! m 1 80 lbf m

Apply grease to the dust seal hm, then rnstall .t mm
the driven flange,

 

 

REAR WHEEL/SUSPENSION

Install the brake disc with its rotating diieclion
mark facing out.

install and tighten the new hnlis m the specified
torque

TORQUE: 42 N-vvl14.3 kgi-m ‘ 31 int)

INSTALLATION
Appiy grease to the sudc collar inside and grooves,

lnslali the side collars.

Instali the rear brake nailnm bracket onto the guide
n! the swmgarm.

Fiace the rear wheel inlo thc Swingarm.
Install the drive chain over the driven sprocket
lnalall the axle fiom the left Side

 

 

1 4-8

REAR WHEEL/SUSPENSION

 

I'Is‘all the washsv and luusely [HSIEI‘ me axle nun
Adjust m: d'ivc cham shack mags 3-22)
Tighten the axle nul xu the specified :o'que‘

TORQUE: 93 N m (5 5 kgf m , bi: lbf-fl)

SHOCK ABSORBER
REMOVAL

P‘ace me momrryms m- w< rpmpr stand

Hewuve flue followina:
maupage 2-2)
*Fucl tank (sage 551)

Renuw [he alwcx dbsurbef ‘uwer mounting bolu‘
NH

Remove the upper mounung b0 mm and shock abr
:uvber.

INSPECTION

Visually inspect the damper umHnr damage

Checkfol the,

*Damper rad tnr bend or damage
—Damper unit for dcformatlon aroil leaxs
- Bump rubberfor wear or damage

Inspeci aH khe other parts for wear or damage
If necessary, replace (he shocbg absorber {.5 an as
sembly.

 

 

REAR WHEEL/SUSPENSION

SHOCK ABSORBER D|SPOSAL PROCEDURE
Center puncntne dampcrto markthe drr‘lan puim.

Wraptne damper unit inside a plastm hag

Support the damper m a vise as shown.

inmugn the open and oi the bag, irseri a dim
motor with a sharp 2.1 mm (5'64"1/5 ‘ni driil in:

mm___.__

t Do not use a dull drill bit winch could came a
build up of excessive heat and pressure inside
the damper, landing to explosion and SOVDI‘E
personal injury.

- The shock absorber culiiat'ns nitrogpn 9.. and
oil undat high pressure. Do not drill any farmer
dawn the damper case than the measurement
given above. or you mny drill into the oil
chamber; oil escaping under high presaure may
cause serious personal injury.

- Always wear eye protection to avoid getting
moral shavings in your eyes when the gas
pressure is released. Th: plutr'c bag is anIy
intended to shield you from the escaping gas.

 

Hoid the bag around the d:1|l motor and nneny run
the rim rrmmr Inslde the bag: this will inflate tne
bag with air from the motor and ham keep we buy
from qatting caught: my the bitwhen van start.

INSTALLATION

install the shock ahsnrher mm the frame with the
rebound damping adjustcrfacmg to the right.

hmmH \IIE upper mounting boltand nut

Set the rammnr reserve tank grommet, than t gr n
we upper mounting boltsr’nuts to the spa
torque.

 

TORQUE: 42 N-m 14,3 kgi-m , 31 lbi m

Install mu tighten the lower moummg hnlts/nuis to
the spacmnd torque.

TORQUE: AZ N‘m (4.3 kghn . 31 \bfrfl‘.
Instali the ioHowingz-

*Fuel tank (page 5-63)
’Szat [pi-g: 2-2)

 

14-10

 

 

REAR WHEEL/SUSPENSION

SUSPENSION LINKAGE
REMOVAL/DISASSEMBLY

Place Ihe motorcycle on Its comer Gland.

Remove Ihe following:

Shark Ahsnrher Inwer mnlmnng hnltlnm
:Shock link bolt/ml! (shock arm plane side)
AShOCK arm plats bolt/mm (swirlqarrn side)
- Shock alm plates
~ Shock llnk socket bolllmu [frame aldel
*Shock link

 

Remove the pivot collars and dust seals from the DUST SEALS
shock llllk.

INSPECTION

Check Ihe dusI seals and cullals (cl wear, damage
oriatlgue

Check the needle boarlngs for damage or loose IIL
IIlIle needle beallllgs BIE damaged. replace them , _ '

SHOCK UNK NEEDLE BEARING REPLACEMENT
Press the needle hearlng om thP. :hnnk llnk usmg
speclal tools and a hydraulic press.

 

TOOL:

Pin driver U7GMD7KTSU‘IUO
(Not available
In U.S.A.)

 

Pack a new needle bearing with mult'l purpose

     
  

grease.

Free, a new needle bearing inlo Ihe shock link so WV

lhanhe needll‘ hParlng surfnne IS lower 5.24 DRIVER

5,7 mm IUIZOADJZ in) Irom (he and at the shock

link surfacel \\ 5‘2 57 'n'rl
(0‘20 0.22m)

NOTE

 

Press the needle bearing into the shock link with
the marked side faclng out

 

 

 

TOOLS, . A
Driver 0774970010000

., ‘ >/
I ,. I“ , l
Attachment, 24 ,- 26mm 0774670010700 _ A' {a
Pilut. 17 mm 0774600110400 ‘TT'A ‘ MEN l'PI‘V'OATi

 

 

 

 

 

 

 

REAR WHEEL/SUSPENSION

 

Apply grease to the dust seal \ips, Iher‘ ins\a‘l Me ,
dustsealsand pivotcollars ,@ mm ShALS

  

‘ \
INSTALLATION ,fiA )3
Inslah the inlmwmg: PIVOT COLLARS

*Shock link

*Shock link socket DON/nut
Shock arm p‘ates with their "FH" ma'k larmg m s
The from E '

AShock am: plate bull/nut [slluLk link side}
Shock ahmrher \nwer mnunvmg hnlvmm

Tighten ma shock link nut (frame side) lo the
specified torque

TORQUE: 59 N m (6.0 kg! m , 43 Ibf m

Tlghven me <hock arm mate bolts and shock ab»
sorbnr lower mounmng nut to me specified Iorque.

TOROUE' 42 N4“ (4.3 kgf-m , 31 ibI-fl’
SWINGARM

REMOVAL

Remove the rear wheel (page 14-3).

HFmOVP the «mth ho"; and drvve {ha n case.

REHIUVE [he SH bulls and brake huse guides.

 

 

14-12

REAR WHEEL/SUSPENSION

 

Remove We shock absorber lower mounting bole
nut,

Remove me shock arm plate bolt/nut (swungarm
side)‘

 

Remove me swingarm pivot nut

Remove the swingarm pivot lock nux whi‘c holding
the pivot bolt.

TOOL:
Pivox ndiustinq wrench 0790874690003

Loosen the :willgdrw adjusling be“ by turning the
nwnt hnlt
Remove me Divot bolt and swmgavm.

 

 

REAR WHEEL/ SUSPENSION

 

DISASSEMBLY/INSPEC'HON

Remove the tollawmg:
7 Drive chain slider
—Driva chain adiusur:

Check the drive chum allder for wear or damage.

fitmluve the pivot collar 3 and dust seals from the
swingnrm pivnt.

Check the dust seals and collar for damage or
fatigue.

Hamove the plvat collar,

 

Turn the Inner race of right pivot bearings with
your fiugev.

The bearings should turn smoothly and quletly.
Also check that the bearing outer race fits tightly in
the hub,

Remove and dlscard the bearings it the races d0

not turn smoothly and quietlvl ar it they fit loosely K ‘ l X ,
in the pivul. ‘ _ i x )
. J ‘
BEARlNG

 

 

 

 

 

14-14

REAR WHEEL/SUSPENSION

 

Remove me pivoi collar and dus: seals from the

shock link pivot.

Check me dusx seals and collar ior damage or

fatigue.

Check (he needle bearing Var damage.

PIVOT BEARING REPLACEMENT

Remove me snap ring‘

Remove the right pivot bearings (radial ball bear-
ings) [mm the swingarm plvol uslng the special

tools.

TOOLS:

Bailing runovlf m
Nunavut hand.

-Removor m

-Slldlng welght

Press me la" pivot bearing [needle bearing) out 0'
(he swingarm pivot using the special \ools.

TOOLS:
Noodle bur'mg gemov'r

Drinr shift

07930-3710001
079364710100
079353710600
077410010201 0r
07938-371020!)

DRIVLH
SHAFT

 
    

07HMC-MR70100
(Not available

in U.S.Al)
07946-MJ00100

 

 

 

 

 

 

 

 

 

m

_NEEbLE BEARING REMOVER ,

 

14-15

REAR WHEEL/SUSPENSION

Press a new left pivm bearlng (needle bearing) into
me swingarm pivol so that the needle bearing
surl‘ace is lower 4.0 mm (0.16 in) from the end of
the swingarm pivot surface using the special tools,

NOTE:

Pm: lhs needle bearing into the swingarm with
the marked slde faclng out.

TOOLS:

Drlvor 077490010000
Attachmu‘t, 37 ‘K 40 mm D77w-0010200
Pilotzflmrn WINS-0041100

Press new right pivot bearings (radial ball bearing)
into the swingarm pivot one at a time uaing the
spemnltnols.

TOOLS:

Driver 077 43-0010000
Aflnchment. 37 x 40 mm 07750010200
Pllot, 20 mm 07746-00‘0500

Install the snap ring inln vha swmgnrm pivot groove
aecurelv‘

Inslall the pivot collar.

 

  

A 'TIAQHM NT/PILOT
1‘3,

4.07 5.0 mm
(0.16'010 in)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14-16

 

REAR WHEEL/SUSPENSION

SHOCK LINK PIVOT BEARING REPLACEMENT
Remove the needle bearing out of the shnnk link
usmg special tool.

TOOL:
Needle bearing rumovlr o7LMC-KV301DO

P1055 Inc nesule Pack a new naadla bearing with multI-purpnse

bearing Wolhe gran”,
shark VIM wuhuve Install a new needla hearing into Ihe slluck link so
markedslde that man needle bearing surface is lower 5.5—
!scmg out. an rnrn Ion—0.24 in) from me and of the shock

link surface.
TOOL:

 

 

 

 

Needle bearing rsmovor 07LMC KV301OU
ASSEMBLY
9 N-m (0.9 kgl~m , 5.5 mm
I
231T DUST RIGHT PIVOT BEARINGS ,’
(20 X 37 X 9) //
PIVOT COLLAR f I’
, .
@ fl (0"
SNAP RING

  
   

PIVOT COLLAR

.61 NFEDLE BEARING

/ LEFT DUST SEAL
DRIVE CHAIN SLIDER/

. \ I
LEFT PIVOT NEEDLE BEARING PM“ U“ W‘ 3

 

14-17

REAR WHEEL/SUSPENSION

Apply grease to the dust seal lips, then install the
dust seals and pivot collar into the shock link pivot.

Apply grease lo the dust seal lips, then install the
dust seals and pivot collar B into the swingarm
pivm.

install the drive chain slider aligning its tabs with
me hnles In the swingarm,

Apply a locking agent to the drive chain slider bolt
threads.
Install ”Ie collars and bolts, men lighten the bolts to
the specified torquet

TORQUE: 9 N-m 10:9 kgf-m , 5.5 mm

Install the drive chain adjumers.

 

 

14-18

REAR WHEEL/SUSPENSION

INSTALLATION

Instail me swungnrm amusnng hon
1: :ns 9’10 2' We Be sure mm the lip 01 the bolt docs no! protrude
8:111:51”!nger inward.
does nrotruda, v:
WW 7153 DO 00551
me lo ,rslar/ ma
wwwyal’r‘

Appw min coal of grease to (he swingarm pivox
ban surface,
Inmll ma swingnrm and mm hnlv.

Push ms pivot bolt's hex shank into me adiusling
bull's sockel head.
Scrawvhe aflwshng nm hymrnmgvhn pwm halt

Tighlsn [he swingarm pivot ad:usling boll with me
pwot bah.

YOROUE: 15 N-m (1,5 kgf m. 11 lbf ft)

lHSld” and lighten me swingdrm pivul adiusling
bolt lock nut fully by hand, then tighten the 10d: nut
to (he specmed mrque while holding the pivot not!
using me specia1 1001.

TOOL:
Pivot adjusting wrench 07903 4690003

TORQUE: Gd N-m (G 5 kgf-m,471bl-h)

 

 

REAR WHEEL/SUSPENSION

Tlgh:en the swingarm pivot nut m the specifies
Luvuue.

TORQUE: 93 N m (9.5 kgf rn , 69 IDNU

Install and tighten the shock arm plale bolL/nu:
(swingurm side) and shock absorbev lower
mounting bolt/nut to the specmed tnrqup

TORQUE: 42 N-m (4.3 kgf-m , 31 lbf f1)

 

Route the brake hose properly, tighten me brake 7
huge gulde bull: [0 [he :peclried Lorque

  

TORQUE: 12 N-m {1‘2 kqfvm . 9 lblrh)

Install me drive chain cover and tighten the bolts.

Install the rearwheel [page urn),

 

 

14-20

 

MEMO

 

HYDRAULIC BRAKE

FRONT: /4 12 N~m 11.2 kgfm,9 law!)

97

 
    

12 Mm {142 kgf‘m,
,, 9 vhf-h)
,

/
//
//

     
 
    

//
‘ 31Nm43.2kgfm,
2:“an

25 N-m (2.6 kng,
191bf‘fi)

\
34 N»m (35 kng , 25 let)

34N-ml35kgf-m,25lbf-ftl M\

1 5—0

\31N.m(12 kgfrm 4 23 1171-11)

 

5. HYDRAULIC BRAKE

 

 

; SERVICE INFORMATION
f TROUBLESHOOTING

BRAKE FLUID REPLACEMENT]
AIR BLEEDING

BRAKE PAD/DISC
FRONT MASTER CVLINDER

SECONDARV MASTER CYLINDER

REAR:

12 Nnm(12 kgf‘n' ‘ 9 \bHHé/l

15-2
15—4

15-5
15-12
15-16

15-20

  

REAR MASTER CVLINDER
PROPORTIONAL CONTROL VALVE
DELAY VALVE

FRONT BRAKE CALIPER

REAR BRAKE CALIPER

BRAKE PEDAL

15-23
15-28 ‘
15-28
15-29
15-35
15-39

34 Nrm (3 5 kgi-m , 25 IM-fl)

 

 

15-1

HYDRAULIC BRAKE

SERVICE INFORMATION
GENERAL

m .

- A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake dcgreaslng agar-it.
- Check tho bnka svfl‘sm by applying the brake lever and pedal after the air bleeding.

 

 

 

CAUTION

 

- This model equipped with a Linked Braking System. Be sure to lallaw the system air bleedan procadun {page 15-5) i!
you disconnrcl or service any part of the brake hydraulic system.
. Du not disassemble the secondary master cylinder push Iod or the comct brake performance will not he nbtained.

 

- Spilled brake lluid will severely damage instrument lenses and painted surfaces. It is also harmlul to some rubber parts.
Be :arelul whenever ynu remove the reservoir cop: make sure the front reservoir is horizontal first

- Never allow contaminates (dirt. water, etc.) to get into an open reservoir.

- Once the hydraulic system has been opened, or it the brake teels spongy. the system must be bled.

o Always use fresh DOT 4 brake fluid Irnm a sealed container when servicing the system. Do not mix diHerent types of fluid
they may not be compatible,

. Always check brake operation before riding the motorcycle.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
. , Unit: mm (in)
ITEM STANDARD ‘ SERVICE LIMIT
Fiont Specified brake mm DOT 4 . ,7
Brake disc thickness 5.0 (0.20i 4.0 (016)
Brake disc runout .. fl ‘ > — 0.3001012)
Masler uylilldel ID. > 12700—12143 [0.5000405017) 121603.502)

l Master piston 0.0. ,_ 12.657 “12.634 (0.4953704994) ; 12.650149!” _
Secondary mastercyllndcrID. 14.000714.0:13105512—05529) ‘ I4.Ubb(0.5§33)
Secondary maswr piston 0.0. 13 957 713 984 (05495—05506) 13.9450154901
Caliper cyIIlIdtsl LD. . Right ‘ Upper 77.000-2/.050(1.0630-1.0650) 7 27.060 (1.065“

; Middle 22650722100(0.8917i0.8937l 7 1 22.710 (09941)
I Lower 25.400m25.450(1.0000*1 0020) 25.460 (1.0024) __
r Left Upper . 25 400*25450 (1.0000 1.0020) 25460110024)
‘ Middle 21650-22100(03917-03937) ‘ 22.710 (0.3941)
7 _ Lower r722550—21700(03917—03937) 7 22 710(0 3941)

‘ Caliper piston O.D. ‘ Right Upper l 26.916’26368 (1.0597* 1.0617) 910! 0594)

. ‘ Middle 1 22 sarizz 6m innaszwfltium . 60 (0.8882)

‘ Lower 75318425368 (03968-03987) 25.310 (0.9965)

Left gUEger 25318-25365 “15968-03987) 25 310013565)

. Middle 22585-2161810.8892*0.8905) 22.560 (0.8882l

Lower 22555721 618 (0 3892 W 0.0905) l 22.560 (0.8382)

 

 

15—2

HYDRAULIC BRAKE

 

 

 

 

 

 

 

 

 

Master Lylinder |.D.

 

7 Unit: mm (in
ITEM STANDARD ssrmce LIMIT
Rear Specified brake fluid nor 4 ' ' ..
Jake pedal height 5512.9 a
Brake dlsc thickn is 5.0 (0.20) 4.0 (0.16)
‘ Brake runout 0.30 (0.012)

 

17.480i17503 [0.5874 06891) 17.515 (0.65961

 

1 Master piston on.

17.417'17.444(0.5557’013868) 17 405105852)

 

 

 

i CalrpercvllnderlD : Front 22.650—12.700(03917—08937) 22.71010.8941)

1 1 Center 25.400 25A50(l.oooo—i.oozol_ 25.460i1.0024)

17 Rear 22650722700(0.891I*0.8937) 227101039“) ‘
Caliperpiston 0.0. : Front 22535721518mam—0.3905) 2255010555»

 

(

 

 

25.7318- 25.388 (03988—03987)
22.. . 22 618 (03892—03905)

25.310 (0.9965)
22.560 (0.8382)

 

 

 

 

 

 

TORQUE VALUES

Front brake master cylinder lloldar bolt

Front brake master cylinder cap screw

Brake Icvcr pivot bo(t

Brake lever pivot nut

Brake lever adiustet

Front brake swirnh screw

Right front brake caliper mounting bolt

Left front brake callpar pivot bolt

Left front brake caliper boll (secondary master joint)
Cahper body a halt

Front brake caliper slide pin (mam)

Front brake caliper slide pin (sub)

Pad pin

Brake caliper hleerlnr

Secondary master cylinder mounting bolt
Secondary master cylinder push rod nut
Secondary master cylinder Corlrlaclur

Rear master cylinder mounting bolt

Rear master cylinder reservorr mounting bolt
Rear master cylinder push rod nut

Hear master cylinder hose joint screw

Brake hose oil bolt

Brake pipe joint

Brake pipe 213 way ioint

Brake hose guide bolt

Delay valve mounting bolt

FCV (Proportional Control Valve) mounting bolt
Flight brake lluse ciemp bolt

 

12 NM (1.2 kgl-m . 9 lbl-ftl

1N-rl1 (0.15 kgflm 11.1Ib1-fil

1 N-m(0.1kgf-m , 0.7 Ibf-ftl

6 N-m [0,6 kgflm , 4.3lht-m

4 N-m (0.4 kgf—m . 2.9 le‘ti

1N-rn (0.12 kgf-m , 0.9 lel)

31 N-m (3.2 kgf-m , 23 lbf-fti ALOC bolt.

31 N‘m (3.2 kgfem , 23 lefl AI 0C bait.

25 N‘m (2.6 kgf-m .19lbf-ftl ALOC bolt.

32 Nrrn (3.3 kgf>m , 24 (bf-ft! ALOC bolt.

23 N-m (2.3 kgfvm , l7 |b(.ftl Apply a locking agent to the threads.
13 N-m (1.3 kgf-m . 9 Inf-ft) Apply a locking agent to the threads,
18 N-m (1.8 kgfvm ,13lbf‘ftl

5 N-rrl (0.8 kgf-rrl , 4.3 (bf-(t)

31 Mn! (3.2 kgflm , 23 Ibflft) ALOC bolt.

13 N~m (1.8 kqfem ,13lbf‘ft)

1o N-m (1.0 kgllm .7 lbfltl

12 N~lu (1.2 kgl-ru , 9 (bf-[ll

1? N~m (1.2 kgf-m , 9 lbfvfl)

18 NT" (1.8 kgf-m ,13Ib1-ftl

1 N-m (0.15 kglm , 1.1 le't) Apply a locking agent to the threads.
34 N-m (3.5 kg'd“ , 25 Ile)

17 N-m (1.7 kg'l-m , 17 (bf-ft) Apply oil to thethreads

12 N»m (1.2 kgirm ,9 lbf-fti

12 N‘m (1.2 kgf‘m ,9 lbf-ft)

12 Nem (1.2 kgf-m , 9 lbf-ft)

12 N~m (1.2 kgf-m , H Inf-ft)

12 Nm (1.2 kgfrm . 9 lbf-ftl

 

15-3

HYDRAULIC BRAKE

TOOL

Snap ring pliers

TROUBLESHOOTING

Brake lever/pedal son or spongy

0 Air in hydraulic system ,

I Leaking hydraulic system

I Contaminated brake pad/disc

I Wor n caliper piston seal

- an master cylinder piston cups
- Worn brake pad/disc

I Contaminated caliper

- Caliper not slidlng properly

I an Drake liuid level

I Clogged fluid passage

I Warped/delormed brake dwn

I Sticking/worn caliper piston

I Shaking/worn master cylinder piston
I Contaminated master cylinder

I Benl brake lever/pedal

Above items are normal but the brake system still has ponr
performance, check for "use dive during braking lithe nose
divs exuessive, check 'nr secondary master cylinder
hydrallllc system,

Brake lever/pedal hard

I Clogged/restricted brake system

I S'lnklng/wnrn caliper piston

I Caliper not sliding properly

- Clogqedi’restncled fluid passage

. Worn caliper plflnl’l seal

I Sticking/worn master cylinder piston
I Bent brake lever/pedal

07914751350001 or 079‘ 4-323000‘

Brake drags

. Contaminated brake pad/disc

I Misalignod wheel

I Clogged/Iestricted hmka hose joint

I Warped/deformed brake disc

I Caliper notaliding properly

I Improper sacundaly master cylinder installed length
I Ciuggedli estricted brake hydraulic system

. Sticking/worn celipcr piston

I Clogged master cylinder pull

Rear wheel looks when only the brake lovar is applied]

Front wheel locks when only lhl brake pedal is applied lln

the case that all items an normal in "Poor lever/pedal

brake performance")

Iirnpiuper secondary master cylinder push rod installed
length

I Faulty proportional control valve iPCVl

 

15-4

HYDRAULIC BRAKE

 

BRAKE FLUID REPLACEMENT]
AIR BLEEDING

m.—

A cantaminirfed brake disc or pad reduces
stopping power. Discard cantamineted pads and
clean a contaminated disc with a high quality
brake degreusr'ng lgem.

CAUYION'

- Do not alluw Ioraign material to enter th-
system when filling the reservoir

- Avoid spiumg flurd an painted, plasti; ar rubber
parts. Place a rag aver these parts whenever the
system is serviced.

 

NUFE

‘ The \ever brake Hue ail bleeding pruLedure rs
pennrmpn m we same manner as m the, nrmnal
air bleeding procedure.

I Once the hydraulic system has been opened, or if
the brake reels spongy, the system must be bled.
- When tmng a rnmmermuy evmmme brake
b‘ccder. lollow the manu‘acwrer‘s operating

irstrumions.

BRAKE FLUID DRAINING

Lever brake line

Support the motorcycle on its center stand.

Turn the handlebar to the left until the reservo'r is
parallel m the ground, heinre removmg the
rescrvpir cape

Remove the stews, reservoir cap, set grace and
draphregm

Conner! a commercral‘y avarlable brake hleeder to BRAKE BLEEDER OUTER BLEED VALVE
the front brake Cahper outer mead vawe.

Luuser me UleeJ valve and pump we brake
nleede'

Stop pumpmg‘ the bleeder when no more fluid
HOWSOUI Ufths bleadvaivs‘

 

 

15-5

HVDRAULIC BRAKE

 

PENN“ “"° 7 _ BRAKE auzrnm CENTER BLEEDVALVE i
Connect a commercmlly available brake bleeder lo v / l

me from brake caliper cenxsr bleed valve‘

 

Loosen the bleed valve and pump the brake bleed
er,

Stop pumping ma bleedar when no more fluid
flows am of the bleed valve,

Connect a commarclnlly avallable brake blecdcr [0
me rear brake caliper outer bleed valve‘

Lousen the bleed valve and pump the hrake hlaad-
er.

Stop pumping the blender when no more fluid
flows am of the bleed valve.

      

 

\ )J\

OUTER BLEED VALVE ‘

 

Conner: a mmmarcially available brake blccder to CENTER BLEED VALVE
me war brake caliper cemer blead valve.

Loosen me bleed valve and pump the brake bleedA
er.

Smp pumping the bleeder when no more fluid
flows uui of the bleed valve.

 

 

 

 

15-6

BRAKE FLUID FILLING/NR BLEEDING

Lever brake line

HYDRAULIC BRAKE

  

FRONT MASTFR CYl lNDFfl

 

 

Fill the reservoir with DOT 4 brake fluid from a
sealed container.

CAUTION‘

I Use only D014 brake fluid frum a sealed cantil‘n-
er.

- 00 not mix different types nf fluid. They are not
compatible,

Operate the brake lever several tlmes to blood all
from the masts! cylinder.

Connect a commercially avallabls brake bleeder lo
the outer bleed valve.

Pump the hrfikfi hlerr‘ler and loosen the bleed valve,
adding fluid when the fluid level in the master
cylinder reservuir is low‘

NOIE.

~Check the fluid level often while bleeding the
brakes to prevent air from hemg pumped mm the
system. , .

-Whar‘. using a brake bleeding tool, follow the
manufacturer's opelallng instructions

 

 

 

SHAKE BLEEDER
v

OUTER BLEED VALVE

   

 

 

 

 

 

HVDRAULIC BRAKE

l‘ W '5 cnlcr-ng Repeat the above step procedures until air bubbles l7 OUTER BLEED VALVE
ms meda- "am do not appear n the plastic hose. ‘
dluund [/78 bleed / / /

van/E threads seal Close the blast. valve
the mom: mm Operate the brake lever and check brake oneratlon.
Is'lon race If it stlll feels spongy, bleed the lever system aqain.

 

    

Ila brake bleeder ls nm Avullahle, tlsethe followlng
prosecure:

Connect a transpa'ent bleed hose to the bleed
valve and place the uutex end of the hose in a
container

Loosen the bleed valve W turn and pump the
brake lever until the brake fluid flows out lrom the
uleed valvet

.Pumpthc orakc lcvorscvcral times. then squeeze

the brake lever all the way and loosen the bleed
valve.- 114 lulu Wait several seconds and rtlnte
the bleed valve

NOTE

Dn rm! rele :e the Wake l., er until the bleed valve

has been closed

 

 

2.Helease the brake lever slowly until the bleed
valve has been closed,

3.Reuaat the steps 172 ulllll lllele ale no a'lr
bubbles l"\ the bleed hose

After bleeding alr completely and tlghten the bleed
valves to the specified torque.

TORQUE: 6 N-m (U.b kgf-m , 4.3 lbfrfil

Flll the reserve” to the casting ledge with DOT A ,.
Duke lluiu lruul a eealed wutalner MERVD'H CA3 r F
\ .‘

lnilfill the. dmnhragm, set p‘ate and reservotrcapt
SET PLATE\
\

DIApHRAGM

 

 

15-8

HYDRAULIC BRAKE

nghzcn X‘C 'cscrvoi' cap screws m :he specr‘lcd
IOVQJS‘

1ORQUE' WR-m If) 15 kg' rr 11Ihf-fi)

Cweu me Vrom brake ousrauor (page 3727).

Pedal brake line

NOTE

t Eeiore DSJ’fOleng ms :e'wce, prepare the brake
'luid 500 um' I163 US u1,141h’p UL) Ul H'uve
hnna mum: hrakp hm: w \nng

- F‘uld flng and nmcd air from m: 1mm pcda‘
fire in the seuLanca asfollow:

1 Mm hquLapr mm mm mm
7 .m mm rahner mnm- his-m wflvfi
3 Roarca‘lpcrccmcralccd valve

1 Rsarcanparousrblasdvawe

Rerova :ha Saal ch‘ Ipaqa 2-2).
Hernove the reservov cap, set plate and d aphragm,

Fi‘l U'e resewur wiln DOT d [rake l‘uid.

PJr‘p the bvake peda while ‘Hlimg the brake Nu d
andfeedm.mm1othe masver rylwnde'.

 

 

HYDRAULIC BRAKE

Rear master cylindw In from bralw caliper lines;

REAR MASTER CV1 INDtH

   
  
  
    

HEAR BRAKE
CALIPER

Whan usmga 1 Connect a commerciafly available hraka hleennr
brakc chcdcr. m the right from brake caliper center bleed valvc‘ ‘ ,
narrow/vs Pump the brake bleeder and loosen me bleed fi‘l/
vnanufaf'me": valve. ‘ ‘
opemrmg Operate the brake bleeder and lead Me brake /
mszrucr'ons fluid Unlll fluid flow out from the blecdcr valvc‘
Close the bleeder valve‘

     
 

Zfeed the brake Hum m the lefi from brake cahpav

_ BRAKE BLEEDER CFNTUl BLLtU VALVE
center bleeder valve at. same procedure In step l, - /

 

 

 

15-10

HYDRAULIC BRAKE

 

Secondary master cylinder to rear brake caliper
line:

3.Feed me brake fluid at \he rear brake caliper
outer bleedervalve as same procedme in sIEp1

4, Repeat mep 177 Unlil the pedal resistance is hell.

Hear master cylinder to rear brake caliper line:

 

 

 

OUTER BLEEDVALVE

 

 

REAR MASTER CYLINDER

 

 

 

 

 

 

 

 

 

 

S'Feed Ihe brake fluid at me rear brake caliper
center bleeder valvs as same procedure in step 1.

chi blced the air from the system without using a
brake bleeder tool.

 

   

 

REAR BRAKE
CALIPER

 

 

CENTER BLEED VAII.VE

 

 

 

 

HVDRAULIC BRAKE

Connect the trarspa'ent s‘eeder lube .u llue weer:
\‘a‘ve aw place :12 cuter and 0‘ *hp h m a
FOFIEI’VPr

 

Pump {he bra<e oedal 540 Limes, L'vell Ideas-:—
lhe pada‘.

Inmen me. Need verve, then pushwg dawn the
brake mam cH no way.

NOTE

Do not rclcasc the brake medal wrile onening we
mead valve.

CIOSC Vic bleed va‘ve.

2 Pe‘ease :he brake dea‘ <1nw‘y arm Mn severm
seconds efler :1 reaches Ihs rd of it .ravcv.

3 Pcpcal above Step ‘ and 2 uan bubb as cease [0
appear in he Hum ax the and of (he Heed hose
and pedal mevsianrp .< m

 

NOTE

-Afier m huhnln mass m appear m the mid.
rspeat aw olccd‘mg procedure aboutZ-S times.

I Carstully bland (he av from (he [63! blah! Co‘ipe‘
mm bleedew valve mm sarnndary masm'
my Inderdnflcy’rmrreer b'ake camper W10}.

 

Tighten we each bleed vbwe n 1h¢= Qpnr nan mane
TOROUE: e rx n‘ \O.6kgfm , 4.31:.th

Fill the Ieservmr upm me “UF‘F‘rn” [9va
SPECIFIED BRAKE FLUID: DOT a craks ma

lrstal‘ the map—vagm v? p‘ave and rash-vow cap.

BRAKE PAD/DISC

 

FRONT BRAKE PAD REPLACEMENT
m___

After brake pad rEpIzremi-nl, check the brake
npernfinn hy applying the brake Ie ver and pedal.

 

P.sh the Ca‘ioe' pistons al the way 1'! (u alluw
I: Mallet cm of New Luaxe pads

NOTE

 

Check the hike Fmd Mve‘ in h? hrnk? mai‘er
cvhrder reserve r as ms opemtwon 50.1566 (he love}
m V se

 

15-12

 

HYDRAULIC BRAKE

Remava the pad pin plug and looser me pad pin.

Remove the pad pin and brake pads.

Clean the inswde ol the caliper especwally around the
calmer pzsmns

Make sure me brake pad spring is in mace.

Install the new blake pads

Push the brake pads againsx the pad spring‘ lhcn
instalt the pad pin.

 

Tighten the pad pm m the specmed torque.

TORQUE: 18 N-m 11,8 kgfim ,131bf-m

 

 

15—13

HYDRAULIC BRAKE

Am dy: leulaue Me
brake pans m

paws w a55urc
even msc pressure,

tnslall andzighrcn me pad pin plug,

REAR BRAKE PAD REPLACEMENT
D

After brakn pad rnpl-camlnt. check the brake
operan‘an by applying the brake lever .nd pedal,

 

Push \he ca‘ipm pistons all the way in by pushing
the cahper body inward to allow msmllanon of new
brake pads,

NOTE

Check the brake fluid level in the brake master
cylinder reservoir as this onerariun causes mg lava
uni“,

Remova mo Dad Din um; and mm. We pad p'm

Remove the pad pm and hrnke pads.

 

15-14

 

 

HYDRAULIC BRAKE

Clean the irswde oithe caliber aspecIaHy around (he
taliper pistons

Make sure the brake pad spring is in claim
InsialI the new brake pads and Dad pm.

 

Tighten (In: pad pin lo file specified luruueI

TORQUE: 18 Nm 11.8 kgf-m,13\bf«ft)

mm“ anm-gmpn zhp pad pm plug

BRAKE DISC INSPECTION

VisuaIly inspecl the brake disc for damage 07
CISCkSV

Measure me make d'sc thickness with a micromer
ter,

SERVICE LIMITS:
FRONT: 4.0 mm l0.16 in)
REAR: 4.0 mm 1016 in)

Replace the brake disc ifhe smallest measurement
15 less than the service IImIL

 

 

HYDRAULIC BRAKE

Measure the brake disc Wdlpage with a dial innum-
luv.

SERVICE LIMIT: 0.30 mm {0.012 in)

Check \Iw whee bearings cm axnesswe piay, if the
warpaga exceeds the same: limit.

Repiacc the brake disc if the wheei bearings die
normal,

 

FRONT MASTER CYLINDER SEALING WASIIE HS O/IL BOLT
REMOVAL /.

    
     

DlaIIi [he levei biake hydraulic sys'em (pags ra-b‘»,

Disconnect the brake light switch wira connecluls
Remove the brake hose u'il boll, sealing washprs
and brake hose eyelet.

 

CAUTION:

Avoid spilling fluid on painted, plum, ar rubber
pans. Place a rag over these parts whenever the ‘
system Is servimd.

Remove \hc bolts from the master cvlindsr homer
and remove the master cylindel d>>Ellib|y

DISASSEMBLY

 

Rev‘iove the pivot bait/nm and brake lever assem- i
bly

/

. / \
BRAKE | FVFR PNOT NUT

 

15-16

HYDRAULIC BRAKE

 

Remove the sc'ew and brake light switch. SCREW BRAKE LIGHT SWITCH
/

Remove the hnnt

Remove the snap ring Irom the master cylinder
hndy usth the special tool as shown.

Toou
Snap ring pliL-rs 079i 4-SA50001 or
0791444230001

Remove the master piston and spring.

Clean Ihn Infi-de 0' ma cylinder and reserycur with
brake fluid.

 

INSPECTION

Check the piston boat. primary cup and secondary
cupio, fatigue w damage.

Check tha master cylinder and piston for abnormal
scratches.

Measure the master cylinder LD,

SERVICE LIMIT: 12.76 mm (0,507 In)

 

 

Mcasurc the master cylinder piston 0.0.

SERVICE LIMIT. 12.85 mm (0.498 in)

 

 

15-17

HYDRAULIC BRAKE

ASSEMBLY RESERVOIR COVER

     
  
  

1N>m (0.1 kgf-m , 07 ID? III E
\
\

MASTER\ PISTON \\ "

PUSH ROD

,/ SET PLATE

[/7 DIAPHRAGM
Cami)

BOOT

SNAP RING

\

\
MASTER CYLINDER

/ \\
/ 6 N m (0,6 kgf m , 4,3 lbfil) BRAKE LIGHT SWITCH
l

BRAKE LEVER I N-m In 12 MN“ , 0.9 lbf It)

CAUTION:

Keep the piston, cups, spring, :nap ring and boot
a: a set,- do not substitute individual parts.

 

Coat all pans wlm nInlln brake fluid before assum
bly‘

DID [he piston in brake fluid.

Illslall the spring (o lhe pistonA

 

Install the plsmn assembly mm me master cylinder, /
CAUTION:

—"——'* ' _ {:3
WI-um installing (ha cups, da not allow the lips to SPRING MASTER PISTON

turn inside aux.

_ ‘ SNAP mm;
Install the snap rlng usmg the spcclal (coll = , l

EIIUTION:

Be certain the stub ring is firmly seated in my
groove.

TOOL:
Snap ring plicrs 07914-3450001 or ,
079140230001

 

SNAP wa’n

 

15—18

HYDRAULIC BRAKE

Apply silicone grease lo the inside of the boot and
master piston up

Install the boot.

PUSH ROI.)

  
 
    

Inslall the brake light switch and tighten the screw

. SCREW BRAKE LIGHT SWITCH
(u the specrfied torque.

TORQUE: 1 Man (0.12 kgf-m , 0,9 IbI-fl)

Apply SIIIEOne grease to the conlac‘ surface of the
master piston, then instal‘ the brake lever assembly.

 

Insxall and lighten the plvot Don to the specified
luvuue.

mvou um!
I

TORQUE: 1 N-rn (0‘1 kgt-m,0‘7lb1-f0

Hold the pivofbolt and fighten the pivot nm to lhe
specmed torque.

TORQUE: 6 N‘m (0,6 kgl-m , 4.3 Ibl-fl)

\ PIVOT NUT

 

15-19

HVDRAULIC BRAKE

Plan: the lnastel cylinder assemnly m me. randleV
bar

Allgn the and o‘tl‘c maste' cylinder mm the yum;h
ma'k on (19 handlebar.

lmfiall The master cyll'lder holdcr with the "UP"
mark loclng up
Tlg‘ltel'l the uuuel bull :‘lm, lhen lhe lowel bolt

TORQUE: 12 Nrm l1 2 kgf‘m . 9 lb'fil

 

ln<fall the make. hose eyelet thh the all bolt and
newscallng washers

Pug" ma syelal iolm ‘ugdll‘M Llle sloppy, then
llglllell the all bait to (he sperlllpd vmqlla

,ALINC WASHERS

   
  
  
 

OI} BOLT
/

TORQUE: 34 l\ m 13.5 kgf m , 25 lb? f1)
Connect the brake light swilrh vaP connectors.

Fill the reservoir to the uapsr level and bleed Llle
brake syslem (page 15-7l‘
/ ‘ \
SWIYCH CONNECTORS EYELFTJONT

 

SECONDARY MASTER CYLINDER
REMOVAL
Dram ms pedal brake hydraulic Syslem (pags 15v5ll

Remove the lefl lronl brakp calmerjnlrl mall

Remove the brake hose Oll bull, sealle Washers,
Ijlakz hose eyelet

CAUTION

Avmd spllling fluid on painted, plasma. or rubber
pans. Place a rag ave! these pans whenever the
system is serviced.

Hcmove (he 50:0ncary maeler cyllncer mau'l‘ll’lq
bulls and velleclul

 

 

‘()N DAHV
MASH"?
CVI H\ Um

 

15-20

HVDRAULIC BRAKE

 

Remove m5 o'w‘ bait, sea in; wawexs and second- ra'L BOLT
v
\

ary master uyluuw.

Remove me boot.

Re’nrwp the snap rmg from the master cylinder
bocy using the special too! as shown

TOOL:

Snap nng pliers 079 1451\50001 or
0791£~3230001

Removemp push rnd, 'naster piston and spnng.

Clean the mside of me cylmde' with brake mm

M—

Do not disassemb/n thy sacundary master cylinder
push rud or the correct hmke performance is nu!
ohfmned.

 

INSPECTION

Check the piston bum, pnmarv Cup and secondary
cupfoyfztique 0rddmdge.

Check the master (‘vlmdPr and p ston (or annorma‘
«rashes

Nlcasurnmc mastercylindar LD.

SERVICE LIMIT' 14 0‘35 mm [U‘b533 ‘nI

Measurp 'hP. master cyhnder pisxon 0.0.

SERVICE LIMIT: 13.945 mm 10.5490 in)

 

 

  

CONDARV MAST} H mm

 

 

15-21

HYDRAULIC BRAKE

 

ASSEMBLV
SECONDARY MASTER CYLINDER

PUSH ROD ASSEMBLY ,

   
 

" SPRlNG

/
SNAP RING

\\IJHIMAHV CUP

 

MASTE R PISTO N

 

 

 

CAUTION

—-—-——-—-—— PRIMARY CUP

Keep the pisrnn, cups, spring, snarl ring and boat , l- M ASTER PISTON

as a set; do nat substitute individual pans. ‘ V ‘

Coal all pails wixh clean brake fluid befare assem-

my,

Dipxhc piston in brake fluid. (

Install the spring toms piston. ‘// J ‘

Install me pISIOH assembly SPRING _ {flair};

Apply swhnnne grease In the piston annual mean DI l\ ‘I‘

the push rod, , W
l

CAUTION. PUSH ROD ASSEMBLV

 

When installing the cups, do not allow the lips to
rum insidv out.

lnslall the push rod Intolhe masxe cylinder.

lnslall the snap ring using the special (ODI.

 

  

SNAP RING
\

 

CAUTION

Bo curtain the snap ring is firmly “and in the
groove.

TOOL:

Snip ring plievs 07914-SA50001 ov

07914-3730001

 

Inslall me boot,

 

15—22

HVDRAULIC BRAKE

 

Install the brake hose. evalel wlth the on Don and 5-4 Foo DARY MASTE CVUNEER
new sealing wasficrs. ,1 ‘ v % _ _ an"
Tlgmen the oil Mus n: :he spec‘fied lovque. / 1'

TOWOUE' 34 N-m f3 5 kgf-m , 25 Ibffll

Place the secondary master cylinder and reflecior
onto the fork leg. men lighten me new moumiug
bulls,

TORDUE: 31 N m (3.2 kg! m , 231bf-fi)

Install the brake hose with the nil hnh and new
sanhng washers.

Push the cycle: joint against the smpper, men
lighten the oil bult Lu the spenilied (ovque

TORQUE: 34 NM (35 kgim,25[b1»m

Install and :igmen me new Iev’l (an nuke call-oer
joint bah to the specified torque

TORQUE: 25 NM (26 kgfvm,191blfl>

Bleed (he air hum peaalbrakplmnmage15-7),

 

REAR MASTER CYLINDER
REMOVAL

 

Uraxn the pedal brake hydraulic system (page 15 51.

Remove the brake hose on non, seAlilIg wdallers
and brake hose eyeleumme

CAUTION:

Avoid spilling lluid on painted, plastic. or rubber
parts. Place a rag over these pans whenever the
symm is survicod,

Loosen the rear mastercylindey mounting bolts

 

 

HVDRAULIC BRAKE

Rcmov: mo exhaust prpc monming nur, main
tootoeq mounrmg bolts and rra‘m foorpeq,

Remove and discard the brake pedal jo‘mr cotter pin.
Remove the 5mm mu

Remove the screw and reservoir hose mint f'u'n
(he master cylinde:

Romuvc rhc mounting bchs and master cyhr‘dor
(rum mam fouweg‘

DISASSEMBLY
Remove the hon

Remove the snap ring from the master cylinder
body uswng the specia‘ (001 as shown.

TOOL.
Snap ring pliers 07914-5A500m m
0/91473230001

Removethe push rod, master pialun a"d spring.

 

Clean (“a ir‘swcc oft'm cyrindcr with brake fluid‘

 

15-24

HYDRAULIC BRAKE

 

INSPECTION

Check the pismn boot, primary cup and secondary
cup (or fatigue or damage.

Check the master cylinder and prstnn fnv ahnmmnl
scratches,

Measure the master cylinder I.D‘

SERVICE LIMIT: 17.5I5 mm Inst-196m)

 

Measure the master cyhnder pmon O.D.

SERVICE LIMIT: 1113051"!!! (0.8852IIII

 

ASSEMBLY

   

MASTER CYLINDER

DIAPHRAGM CO\VER
\

\

   

SET PLATE \\

DIAPHRAGM \\

// SPRING

/r’ l///
PUSH ROD
,‘ \ /,
[a g,
' SNAP RING \
/ \\ ‘ \\- MASTER PISTON

 

 

15-25

HYDRAULIC BRAKE

CAUTION: SPRING
I

Keep the piston, cups, spring, snap ring and boat

as a set: do nat substitute individual parts MASTER PISTON

 

Coat ail pan: w'th clean brake fluid before assem
biy.

Dipthe piston in brake fluid

Irmall Ihe spring to the piston

Install the prcmn assembly

Apply silicone grease to the piston contact area of
the push rod.

   

, PFIIMAHV CHI‘
CAUTION'

 

Wlun installing the cups, do no! allow the lips to
turn inside out.

SNAP RiNG

 

instai! the push rod into the master cylinder
inmnvhu. snap vmg ”3mg the specml tool.

CAUTIO

 

Be certain the snap ring is firmly seated in the
groove.

TOOL:
Snap rIng pllers 07914-5A50001 or
0791473230001

instail the boot.

if the push lad is disassembied adjust the push rod
iength a: shnwn.

After adjustment, tighten the lack nut to the speci-
fied torque.

 

 

TORQUE: 1H “Ln“. (1 H kg‘flm , 13 {bf-m

 

 

 

INSTALLATION

Piace the master cylinder onto the main footpeg
and temporarily tighten the mounting bolts and nut

Apply brake Fluid lu-a new-O-rmg and install it unto
me reservoir hose Joint

irstali the reservoir hose joint into the master
cylinder.

 

15-26

HYDRAULIC BRAKE

 

Applv a lockinq aqenz lo the reservoir hose iolm
screw threads
Install and 'lgh'en the screw to the Speleled torque.

TORQUE: 1N-m l0.15kgl»m, 1.1 Ibl-fl)

Connecl the brake pedal :0 \he push lot) lower join!
lnmll the JOIN pln and mm.» :1 Wm H m'w mm"
pirl.

Insmll The mnln lnorpeg hnlde: and ngman mp
mounnng bolls lo the spcclficd lorqlJc.

TOROUE' 26 N-m (2 7 kgllm , 20 lbflfl)
Install and tighten the exhaust pipe mounting nur.

Tlghten the rear master cylinder mounung bolts to
the specified torque.

YOROUE. 12 ern (1.2 kgf‘m , 9 lbI-IL)

Install mo brake hose eyelet loinls wrth the Oll bolt
and new sealing washers.

Push the eyelel jui'\l> .49; :L llm Sloppel, llusu
ngmen the ml hnll m M? snenilled rnrqllP.

TORQUE: 35 NM l3 5 kg! m , 25 lbf‘fi}

Fill the reservoir to me upoer level and bleed the
peda‘ brake line lpage ‘5»7l.

‘ ' ' MJQINTS

 

 

HYDRAULIC BRAKE

PROPORTIONAL CONTROL VALVE
REMOVAL/INSTALLATION

Remove [he seal cowl loage 2-21

Remove the all bolt, sealing washers and brake
hose evelet lrom me PCV (Propomonal Couuul
Valvu'l.

Loosen tl'w nil mpe nmnnd remove the ml plpe,

Remove the two mourning bolls and FCV.

 

Installatlon is In this rpverv‘. nmer of remove.

DELAY VALVE awn JOINT BOLT ' FVFlFl1[)lklfi
REMOVAL

Remuve the 0” bolts, sealing washws and make
hosn Pyplflm 1mm ma delay valve.

Remove ma brake 3-way iuim muumlng bull.

Remove the hrakP r'r‘F ,nmv nut.

 

l'lerrmve me lwo mounnng bolts, reflecto' and F"
dclav valve. ‘

 

BOLTS DELAV \JAl VL

 

15-28

HYDRAULIC BRAKE

 

INSTALLATION

lr‘slall the delay valve onto the rich! v'ork slide wl‘llla
Ir‘stalling the brake pipe inlo the delay valve

l'tslall me re‘ledn' and ’lghlen (he nfllfiy valve
mounting bolts lo the spcclficd torque.

TORQUE: 12 Km (1 2 kgf-m . 9 lbml

Tlghlen the brake pipe 10ml nut to the spccvficd
torque.

TORQUE: 17 N-m (\ 7 kgf-m ,17lhI-M

Inslall (ha 3 way jolfll and llgmen the bolt Io me
specified torque,

TORQUE: 12 Nun (l 2 kgf-m , 9 lbfiffi

Install the brake hose with the oil bull and new
sealing washers.

F‘usl‘l lhe eyelet loml against the stopper, than
IlgNenlhe oll bolnome specrflcd torque.

TORQUE: 34 Nvm (3.5 kgI-lll , 25 Hal-Ill

Fill (he reservow to the upper lcvcl and Blood mu
pedal brake lms (page 15-8),

FRONT BRAKE CALIPER ,
LEFT CALIPER REMOVAL OIL BOLTS/ g0} SEALING WASHERS

CAUTION:

Avoid spilling fluid on painted. plastic, or rubber
parts. Place a my over these parts whenever the
system is sew/cod.

Dra‘ln the level and pedal brake line hydraulic
sys‘em(page15-5l.

Remove the all bolts, seallng washers and brake
hose eveletloims. - -
Remove llle secondary master Lvlluuel lollll DUI!
and rallper plvot bolt, then remove the callner,’
bracket as an assembly.

 

 

HYDRAULIC BRAKE

RIGHT CALIPER REMOVAL

OIL BOLTS BOLTS

Remove We uil bolts seaHng washers and mm.
hose eyelet jnmts,

Remove the caliper bracket mounting bolxs and
men remove the caliper/bracket assembw.

DISASSEMBLY
Remove the brake padslpage15-12I.

Remove the caliper brackat "cm W ualiper budy‘

 

Remove the brake pad spring ham the caliper body.
Remove the brake pad rrtamev 0mm the caliper
bracket

PAD SPRING PAD RETAINER

   

Remove the bolts and caliper body B. BOLTS CAMPER Bnny n

 

 

15-30

HYDRAULIC BRAKE

 

Place the piece of waod sheet under the caliper
Dielons.
Mark ’hep‘s’ar‘s AppIV small suuills ul ail plessule la the fluid inlei
to ensure correct to remove the pistons.
reassembly.

m“—

Do not use high pressure air or bring the nozzle
too close to the inlet.

Push the dust seals and piexon seals in and lift them PISTON SI Al DUST SrAl
DUI.

CAUTION:

as cmlul nut to damage a.» piston sliding surface.

Clean me seal grooves with clean brake fluid.

INSPECTION

Check the caliper cylinder for scoring or Other
damage.
Maazule um uallpe. cylinder LD.

SERVICE UMITS:
nghu Upper: 27.060 mm 11,0654 in)
Middle: 22.710 mml039A1inI
Lower: 25.450 mm (1002‘ in)
Left: Upper: 25.450 mm [1.0024 in)
Middlo: 22.710 mm {0.8941 in)
Lower: 22,710 mm (0 8941inl

Check the caliper pistons far scratches, scoring or
mher damage.

 

Measure the caliper piston 0.D.

SERVICE LIMITS:
Right: Upper: 26.910 mm 1.1.0594 in)
Middle: 22.560 mm (0 8882 in)
Lawer: 25.310 mm [0.9955 In)
Leh: Upper. 25.310 mm (0.9965 in)
Middll: 22.560 mm (0.8882 in) x
Lower: 22,560 mm (0 8882 in) u"

 

 

15-31

HYDRAULIC BRAKE

 

ASSEMBLY CAMPER BRACKU ‘
PAD RETAINER if PAD SPRING 32 N>m 13.3 kgf‘m ‘ 24 lb ‘m

“‘9“ m CALIPER PIN BOOT \\

13N-mt1.3kgim,9lbffl)\ m
\
\

J‘s/Ii BRACKET PIN 3001' \ \\

\ \
\«

  
 
 
    
  
       

23 Nan {2.3 kgl-ul,17|bf>f\l

\\~ CALIPEH sum 5

\\\ é
\ CALIFERF‘STONS

 

\

\
BRAKE PADS

I a \ \
, \
/ CAMPER BODY @ PISTON HALE \v ,5531 DUST SEALS

WE N-m (1 B kgf-n1‘13lbf-fl)

Left

fl CALIPER PIN BOOT g,“ DUST SEALS

CALIPER BRACKET PAD SPRING
_\ [I

\ /
/ a»?

 
 
 
  
 

PAD RETAINER \7’/ PISTON SEALS

   
 
 
  

Z3 N-m12 3 kgf-m , ‘17 Half!)
/

s Nan (0.5 kghn,
4 3 mm

13 N-m m3 kgf-m, /
9mm /

1'

/ /

m cmmm F‘IN ROOT //

l
32 him (33 kgf-m,
2d \bf-fl)

CALIPER EODY
/.

   

I

V 18N-m(1,8k9fm.13|b1m
BRAKE PADS

 

15-32

M510” MC cash
p-‘slon seal Hus!
Sea’ and calipei

pislon In lhel‘r
proper locations

Nora mo
installation
dlrsclmn at the
pad spring,

Coat the new piston saals wilh clean brake fluid
Coat me new dust seals wim 5llicone grease.

lnstall the pistons and dust seals illlu the groove of
the callper body.

Coal lhe cal‘lper pistons with clean brake fluid and
install them into the calipel cylindel willl [heir
opening ands toward the pad,

lnslall the caliper body B and (lumen the new bolts
(0 lha specified torque,

TORQUE: 32 N-m (3.3 kgflrn , 24 Ibfrft)

Install me brake pad retainer onto the caliper
bracket.
lnmll ma pad spring into the callper body.

Apply silicone grease lo ll]: buul inside lllerl inslall
them.
Assomblc (he caliper and bracket.

       
 

PAD SPRING

 

CAMPER BRACKET

     

    

a PISTON SEAL

HYDRAULIC BRAKE

éPlSTOK
I

CALIPER BODY B

FAD RETAINER
/

CAI IF‘FH BODY
/

/

 

15-33

HYDRAULIC BRAKE

RIGHT CALIPER INSTALLAT|0N

mstaH the right brake caHper/orackex assembly we:
the Drake disc,
mm}! and widen Ihe new nahper mmmmg bans.

TORQUE: 31 N m I32 kqi-m , 23 lel!

Ir‘slaH we nrakn rvnw. nye‘els m the caliper body
thh lwn new scahng washers and oil bolt.

Push mp. hrake hose eyelet m the snapper on [he
cahpcr, [hen tigman me oil mu [0 the spemfied
lovqus,

TORQUE: 34 N-m13.5 kgf m , 25 mi f0

LEFI’ CALIPER INSTALLATION

InstaH the left brake calmer/hanks! assembly over
the brake dlSC‘

InuaH me new caliper pivm ban and Secondary
magLev cyfiudeu Juivll bolL

Txgh‘en the mu m the spacmed mrque.

TORQUE:
Pivul boll: 3‘ Nrm (3 2 kgf-m , 23 lbf-‘t:
Joint half' 75 N-m (Z 6 kgi-m ,19IDV-T'!‘

mszau me brake hose eva‘ezs lo we leipal body
Wm. two new seafihg washers and ml bnlr

Push me arake hose Eve‘s! m the sLuppgx an the
calipew, then tgmen the m halt to the spanned
torque

YOROUE; 3A N-m {3' 5 kgfnm , 25 luff!)
InsxaH the brake pads (page 15 12).

FHI and bleed me ‘ever and pedal I'm brake
hydraulic system (D292 15.5)

[0k BbUS

 

 

15—34

HYDRAULIC BRAKE

REAR BRAKE CALIPER ‘ . ‘ 'ouauu,

 

REMOVAL

Drain the pedal Vine brake hydraullc svsiem {page
155).

Loosen the oil bolls, the" remove ‘ha rear whee!
(page 14-3)

Remove the oil bolts. sealing washers and brake
huse eyeletjoims.

CAUTION:

 

Avnid spilling fluid on painted, plastic, or rubbor
parts. Place a ran over these parts whenever the
:yslem Is serviced.

 

DISASSEMBLV
Remove [he may brake pads (paqa 1544).

Remove the caliper bracket fvom the. calmer body

 

CALIPER BRAUKt I

Remove the brake pad spring from the ca‘iper bodv. PAD 5mm“; PAD LRETAINER
Remove the brake pad retainer hum lhe caliper ‘ ,
bracket

    

Hemovethe tanks and caliper budy B.

 

HVDRAULIC BRAKE

 

Mark rm: plsluns
ID 9NSUVF nnrrecl
reasssmoly.

Place the place of wood sheet under lhe caliper
pislons.

Apply small squilts cl air pressure an the. Ilmd lnlek
Io remove the plsmns.

M

Do not use high pressure air or bring xhe nozzle
too close to the Inlet

 

 

Push me dust seals and pislon seals in and lifi them
DUI.

  

DUSI SEAL

CAUTION:

Ba nun/u! not to damage the piston sliding surface.

 

Clean the seal grooves with clean brake fluid

INSPECTION

Check the caliper cylinder for scoring or other
damage.
Muasule me caliper cylinder I n

SERVICE LIMITS:
From: 22.710 mrn (0.8941 lnl
Center 25 460 mm (”I mm in)
Rear: 22.710 mm [0.89“ in)

 

Check the nallper plsmns for scramhes, scoring or
other damage.

Measure the caliper pislon O r),

SERVICE LIMITS:
From: 22.560mm(0.8882in)
Center. 25.310 mm (0 9965 In]
Rear: 22.560 mm (0.3382 lnI

 

 

15-36

HYDRAULIC BRAKE

 

           
 
    
 

ASSEMBLY
(filCALIPER PIN BOOT CALIPER
BRACKET
32 N-m «3.3 kgf-m, PAD RETAINER ,r
PAD SPRING 24 mm
\ 13 Nim H 3 kgfim,
BRAKE PADS 9 mm x \

6 N-m (0.6 kgf-m,
4 31b!!!)

    

CALIPER 23 Ni!“ (2.3 kglm,
mm, 1., mm) @2554 DUST SEALS
\xfil BRACKET PIN BOOT
13 Nm (1.5 kgf-m ,13|D(‘h|
final the new piston seals with clean blake fluid. L
T ,
Com me new dusl seals With silicone gveuae‘ a P's 0“ SEALY _ - P'STON

Inslall (he pisluns and mm :eals imu [he gruuve of
me caliper hndy

lnsra/Hhe each Coal the caliper pismns will! clean brake fluid and
mslan sul, dust install lhem inlD llle caliper cyliudu wilh lllell
coal and calm: npening ands toward the pad,
piston In their
nrnpfir lnmlinns

  
 
   

{$51 Dué‘r SEAL: ‘

BOLTS
92

lnstall the caliper bndv B and tighten the. new halls
lo the sneciiied torque,

     

TONGUE 3? ern (33 kgflm , 25 [bf-f0

 

HYDRAULIC BRAKE

 

lnstall the bake pad retalner mm rhe rahpar FADSPRING PAD RETAIKER
bracket. \ /

ways We msraua- lnazall me pac wring lnro the caliper bodv‘
.‘rfn L1H tom 0/

me pad sun 1g

     

Apply ulmnna grease to me. boot mslde then Install CALIFER BRACKET
(horn, ,
Assemble me :allper and bracket

    

lnslall the rear brake pads (page 'lé-Hl.

CALIPER BODY

INSTALLATION

Temporarily install me brake hose eyPlP's tn the
calmer body With new sealing washers and oil bolls.

Ins‘lall llIe caliper/bracket dsnembly unlo the

swingarm allgnmg the hrackm grnnve wrm the
swmgarm buss‘

Install the rear wheel lpage 14-8).

Push the brake hose eyelets to khe slopper on the
caliper, men \‘lgmen me oil bolls to the suecihed
luvque.

TORQUE: an Nm 1:1 5 kgf m . 25 M m

Flll alwd bleed the pedal brake line l‘ydlaulll: system
{page 15-5).

 

 

15—38

HYDRAULIC BRAKE

BRAKE PEDAL
REMOVAL

Luuwr llre reav nlasler cyhnder mountmg bolts

 

Remove the exhaust pipe mmmnng nut, mam r
mmpeg moummg Dons and mum lootpcg.

  

Hemnve 31d drscard rho brake poda‘ joim Cutler pin.
Remove the joim pin.

Remove me balls and master tyllnder assembw.

Unhcok (he switch spring and remove We brake
light switch {rum lhe step holder,
Unhook the brake perm return spring.

Remove me snau ring, washer and brake peda‘
from (he footpeg,

 

 

n I ullnvI—Iv guru“.

       
 
  
    

INSTALLATION
MASTEQ CVLWDER
» a I //
BRAKE LIGHTSWITCH 7\\‘(i' '/
SNAPRiNG \z '\\‘/\;I'/
I ' w

\
\

U WASHER

w

MAlN FOOTF‘EG
\

. _‘ ‘ ’ f
< ‘ i 1‘
_ / %
/ \
r \nHAKE PEDAL
w N‘m (1,2 kgfimfl mm ' \\\\
\ 34 N‘rn [3.5 kg*-m,25\b1>ft}
SWITCH SF'mNG

Assembie the brake pedal, foomeg and washer, RIGHT FOOTPEG

  
  

\NASHER

Secure the brake pedal mm a snap ring

Hack the brake pedal remrn spring.
\nstall me brake fight swilch and hook the switch

spring.

 

15-40

HYDRAULIC BRAKE

InstaH thn mavnrcvhnder and mourmng nous,

Irma” the brake peda‘ iomt anu‘ :ELule i1 wnh a
new LUHev pm

\n<VaY‘ the ngm footpeg assembly sum the frame,
\nstal and tighten me right main qulpeg holder
socks: boks to me specified (ovque

TORQUE: Z6 N~m (2.7 Kgi-m , 20 \b' R)

InstaH and zrgmell ll'c‘ exhaust pipe mnurmng nut.

Txgmcr v0 roar maste' cylinder muuxmng baits m
(we specifiedtorque.

TORQUE: 12 R-m 11.2 kg? r" 4 9 \bf fl)

 

 

15-41

BATTERY/CHARGING SYSTEM

SYSTEM DIAGRAM ,.
A", W

99“ MAIN FUSE

   
   
    

BATTERY

ALTERNATOR

AIler '99.

ALTERNATOR

 

16-0

’Ib. ISAI ltHY/UHAHUINU 5Y5 I tWI

 

 

"I
SYSTEM DIAGRAM 15-0 CHARGING SYSTEM INSPECTION 16-8

SERVICE INFORMATION 16-2 ALTERNATOR CHARGING COIL 16-10
TROUBLESHOOTING 16-4 REGULATOR/RECTIFIER 16-10
BATTERY 16-6

 

 

'9 9—0/7: 5
MAIN Fuss

30A

G
<——I
wmcenn
1 Jill
7—7 vvv
Gml m
I

l ”1"

 

 

 

 

 

lAr‘rERv

 

 

 

 

 

 

 

 

 

T

 

 

 

_n—I

 

 

 

h!—

 

REGULATOR!
RECTIFIER

 

 

 

 

ALYERNAYOR

I RED
. WHITE
. BLACK

Esrw<

 

 

16-1

YELLOW
. GFIEEN

BATTERV/CHARGING SYSTEM

SERVICE INFORMATION
GENERAL

' The battery give: of! explosive gases; lreep sparks, flames and cigarettes awayt Provide adequate ventilation when
charging,

t The battery contains sulfuric acid lelectrolytal. Contact with skin or eyes may cause severe burns. Wear protectlva
clothing and a lace shield.
— If Ulnflwlyte gets on your skin, flush with water.
— ll electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.

- Electrolyte is poisonous.
A I! swallowed, drlnlt large quantities of water or mill: and follow with milk of magnesia or vegetable oil and call a

physician. KEEP OUT OF REA CH OF CHILDREN.

- Always turn all the ignition switch before disconnecting any electrical component.

CAUTION'

Same oloctricul components may be damaged it terminals or connectors are connected or disconnected while the
ignition switch is turned to “UN" and current is present.

 

- For extended storage, remove the hanery, give no lull charge, and store it in a cool, dryspace. For maximum service life,
charge the stored battery every 2 weeks.
- For a battery remaining in a stored motorcycle, disconnect the negative battery cable lrnm the battery terminuit

NOTE

The maintenance free battery must be replaced when it leaLIIeS the end of its service lite

 

CAUTION:

 

The battery caps should not he removed. Attempting to remove the sealing caps from the cells may din-ago tho bifloly.

 

'Tlte battery can be damaged il overcharged or undercharged, or it left to discharge for a long period. These same
conditions mnmhme tn stmnening the "lite span" oi the battery. Even under normal use, the performance of [he balleiy
deteriorates after 2-3 years,

'Banerv vciIags may recover after battery charging, but under heavy load, battery vnltage wili drop quickly and
eventually die out, For this reason, the charging system is often suspected as the problem. Battery overcharge often
results trnm problems m the battery itself, which may appear to be an overcharging symptom. ll one or the battery celis
is shorted and bancry voltage does not increase, the regulator/rectifier supplies excess voltage to the battery, Under
these conditions, the electrolyte level goes down quickly,

O Before troubleshooting the charging system, check tor proper use and maintenance at the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight on for long pariods oi time Without riding the
motorcycle.

 

16-2

BATTERY/CHARGING SYSTEM

- The battery will sell-dischalge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to

prevent sulfatlnn from nccurrlng.
0 Filllng a new battery with clcctrolvte will produce some voltage, but ln order to achleva lts maxlmllm periorrnance. always

charge the battery, Also, the battery lite is lengthened when it ls initially charged.
- When checking the charging system, always lulluw llle steps in the troubleshooting flow chart lpage 1673).

Battery charging

This model comes with a maintenancerfrae lMFl battery. Remember the following about MF batteries,
, Use only the electrolyte that comes with the battery.

7mg all at the alaatmlyta,

A Seal the battery properly.

- Never (man the seals again.

CAUTION

For battury charging, do nut expand tln charging current and tlm inuifild an the battery. U:- a! axcaulva current or
charging tima may damaga the battery.

BATTERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery testing. The

recommended battery tester puts a “load" on the battery so that the actual battery condition of the load can be measured,

Reconlmendod battery tester BM-ZleAH ul BM-ZlO m BA‘I'I'ERY MATE or equivalent

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
ITEM SPECIFICATIONS
1 Battery“ T Capacity llVi loAH
wguirrent laakaqa 03 mA max.
Voltage (20 “0/68 ”Fl Fully charged _ 11m ’lgfl___ ‘
Needs charm Bclow12.3 V
Charglng current Normal 0.9 N5710 h
l Quick , W 40 No.5 n »_
Alternator ”‘8qu , 7 r "_ 0.46 kW/SDOD rpm «
‘ ‘ Charging coil resistance lZD ‘C/SB °Fl 0.1—l,0 £2

 

 

16-3

BATTERY/CHARGING SYSTEM

TROUBLESHOOTING

BATTERV IS DAMAGED 0R WEAK

 

Remove the battery {page 154;)
Check the battery condition using the recom-
mended battery tester.

RECOMMENDED BATTERV TESTER:
BM-2'IO-AH or EM 210 or BATTERY MATE or
equivalent

 

 

Correct

J____

Install the battery (page ‘16 6).
Check the battery current leakage [Leak test;
page1&9).

 

 

 

— Incorrect —- - Faulty battery.

and recheck the battery current leakage.

_+fi_

Incorrect

- shorted wire harness.
I Faulty ignition switch.

0 Faulty regulaton’rectlfier.

Cnrrect
Correct
Chuck the alternator charging coil (page 16-10). Fr lncorrert -> - l-rrulty charging coil.

STANDARD: 0.1 -1.0 $2 (20 '068 °F)

#_'___

Cmreet

 

 

Measure and record the battery voltage tt<tng .r
dlgllfll multimeter (page 166).

Stanthe engine.

Measure the charging voltage lpage 16-8i.
Compare the measurement to result at the tnllnw-
ing calculation.

 

STANDARD:
Measured hartery voltage < Masured charglng

 

voltage (4 15.5V

Incorrect

,A (:nrrect —'- - Faulty battery.

. ,' ,
-—Incorrect Drsconrrect the regulatorrrectrfier connector

 

16-4

BATTERY/CHARGING SYSTEM

 

Inmrmm
(thank the voltage and resistance a‘ the regulator/ — lncorrem —' - Open circu‘u in vslaxad wxre.
rectifier connecmr (page 16-10} - Loose or poor comacts of related terminaL
———-’—~—v‘ . shorted wire harness.
Correct

,‘——-—— - Faulty vegulaluu: clifier.

 

16-5

BATTERY/CHARGING SYSTEM

BATTERY
REMOVAL/INSTALLATION

Always cw 1m- Hevnove me seat page 2-2).
:m :mH‘w
oLL . Ramm'e the hanerv ~o der band.
venom: me Disconneci [he negan‘ve cable and men we pusi, we
wa'wy caole, and 'emuvg :l e uafiely

 

 

lns‘aII the batte'y m me rcvcrsc ordcr of removal
with me proper wiring as shown

 

NOTE

 

Connect [ha oosix'we lemvindI (m and men the
Hegdfivk gable

Afier Installmq the Daley, run! We (e‘mina‘s with
Jean glease
stmn we removec pans.

VOLTAGE INSPECTION

Measue me battery vongc using a digltal mum~
meler.

VOLTAGE:
Fully charged: 13.0 IBVZV
Under charged. Baku-112.3 V

IDOL:
Digital multimeter Cammsrc aHv awai‘aule

BATTERY TESTING
,

Always clear the work area of flammable materials
such as gasoline, brake fluid, electrolyte, Dr Eh)”: I
tDwEIs when operating the tester, the heat
gpnerared by the tester may cause a fire.

 

 

TESTE a BATTERV

 

Remove t‘e bfit‘firy 'lseP ahnvfi)

 

 

 

Securely come

   

be xesxer‘s pzsmve ('1 gable ‘
I
I

rm menww lenegalive ‘7 cable 3
TOOL: ,
amamasm ammo—AH w smzm BLACK

[U S A nnIv] I

 

16-6

NOTE.

 

rnr accurate test results, be sure the testcr's cables
and clamps are In good working condition and that
a secure connection can be maria at the battery.

 

Set the temperature swrtch to ”HIGH" or "LOW"
depending on the ambrent temperature.

NOTE
3

FM the first check, DO NOT charge the battery
before testing: test rt in an “as is" condition.

 

Push in appropriate test button for 3 seconds and
read the condition at the battery on the meter.

Tester damage can result from overheating when:

-The test button in pushed in for more than 3
seconds.

*Ths tester is used without being allowed to coal
for at least i miilulu when testing more than onc
battery.

*More than ten consecutive tests are performed
without allowing at least a 30 minute cool-down
nerlod

The result of a test on the meter scale is relative to
the amp. lruur rating of the battery. ANY BATTERY
READING IN THE GREEN ZONE IS 0K. Batteries

should only be charged it they register in the
YELLOW orREDzone.

BATTERY CHARGING

Remove the battery (page 1676!.

NOTE'

 

- Clean the battery terminals and position the
battery as tar away from the charger as the leads
will permit.

- Du not place batteries below the charger—gases
from the battery may corrode and damage the
charger. > x

' Do not place batteries on top of the charger Be
sure the air vents are not blocked.

BATTERY/CHARGING SYSTEM

 

 

tsvc (Sn‘F) or higher
LOW:
15‘C (60"F) or lower

 

 

TEST BUTTONS
l

 

 

 

 

RED

(

3r

2)

YELLOW
( 1) GREEN
l+1, +2, ‘3)

%

 

 

 

 

16-7

BATTERY/CHARGING SYSTEM

TOOL'
Christie battery charger MCiOlZ;21U.S.A.unlyi

‘l.Turrl the "POVt/ER“ switch on “nl’l’”,

2.5m the "BATTERY AMP. HRt SELECTOR
SWITCH” tor the size oi the battery Ueing
charged.

3tSet the “TIMER“ to the position indicated by the
Honda Battery Taster; RED 3, REDVZ or YELLOW
'I
It you are charging a new battery, set the switch
to the “NEW BA'I'I'” position

4. Attach the clamps the battery terminals red to
positive, block to negative,

Connect the battery cables only when the
"Powr R" switch is turned to ”OFF".

5.Turn the “POWER" switch tn “UN”,
NOTE

”—4——

Tnc charger will autulllalicallv swncn to the
"Trickle" made after the set charging time has
elapsed
__ e
6.When the timer reaches the “Trickle" positian,
the charging cycle is complete Turn the
“PnWLll” swltch to “OFF" and disconnect the
clamps.
7,Ler the battery cool for at least 10 minutes or
until gassing subsides after charging.
H.Hetest the battery using the Honda ballarv tester
and recharge if necessary using the above steps,

CHARGING SYSTEM INSPECTION

NOTE'

 

-Wlierr inspecting the merging system, check the
system components and lines step-by-step
according to the troublsshuuling on page 16-4.

'Measuring circuits with a large capacity that
exceeds the capacity of the tester may cause
damage to the tester. Belora starting each test,
set the tester at the highest capacity range first,
their gradually lower thr- capacity ranges until
you have the correct ranger

‘ When measuring small capacity Circuits, keep the
ignition switch u“. If the switch rs suddenly
turned on during a test, the tester fuse may blowt

 

CHARGING VOLTAGE INSPECTION

mfl
When the engine must be running to do some
work, make sure the area is well-ventilated. Never
run the engine in an enclosed area, The exhaust
contains poisonous carbon monoxide gas that may
cause lass a! consciousness and lead fa death. Run

the engine in an open area ar with an exhaust
evacuation system in an enclosed area.

 

Oluo3

 

NEW l'iAiT
\

\

\

YELLOW”

 

 

 

BATl’ERV AMP HR,
SELECTOR SWITCH

Fr 5w 9.0

3.0 to 5,0 515 In 16,0

16.5 to 30

 

Set the appropriate amp hour rating.

 

TIMER
Trickle
o
7:
RED
2

——1

 

1 6—8

 

 

BATTERY/CHARGING SYSTEM

 

Be sure (he
cattery [Sin good
COHEHlOfl DCIOI‘D
psrlorming this
last

Warm up the engine to normal Operating temperar
lure.

Stop the engine, and connect the multimeter as
shown.

CAUTION.

I To prevent I shall. make absolutely certain
which an thl positivn and nu 1 terminals or
cable.

' Do not dimnnec! the battery or any “his in the
charging system withaut first switching at! the
ignition switch. Failure to Iallaw this pruautiorr
can damage the tester or electrical components.

 

Restart the engine.

With the hadlight on hi beam, measure the volt-
age on the multimeter when the engine runs at
5,000 rpm.

Standard: Measured battery voltage {page 156) <
Measured charging voltage (see abuvei < 15.5 V at
5,000 rpm

CURRENT LEAKAGE INSPECTION

Turn the ignition awrtch off and disconnect the
negative battery cable lram the battery.

Connect the ammeter (+) probe to the ground
cable andthe ammeterl lprohatothe hattery( l
terminal.

With the ignition switch oil, check lor current
leakage.

NOTE:

 

0 When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current ilow higher than the
range selected may blow out the fuse in the
lesler.

- While measuring current, do not turn the Ignition
on. A sudden surge of current may blow out the
fuse in the tester.

SPECIFIED CURRENT LEAKAGE: 0.2 mA max.

If Currant leakage exceeds \‘hn specified value, a
shorted circuit is likely.

Locate the short by disconnecting connections one
by one and measuring the cur rent,

 

BA‘i'l’ERY

 

 

 

 

AMMETER \

 

 

NEGATIVE (— ) CABLE

 

 

1 6-9

BATTERY/CHARGING SYSTEM

ALTERNATOR CHARGING COIL

NOTE

 

 

it is nor necessary to remove the: >IBIOl coil to
ueliullllllllalest.

INSPECTION

Remove the mlmwi lr‘mge 2-2:.

D sconnect the regularor'rectilier 3° WIIile connec-
tor,

Cneck the recistance between all ll‘lee Velluw termi-
naist

STANDARD: 0.i ~ LU ‘1 (at 20 ‘068 :Fi

Check iul LulllllI.IIy between aii thrm’ Vellnw mrml-
nais and grmlrm
Trere should be no continuity,

II leading: are ‘3: beyond the slandarn, or n (my
wirP has rnrnmnry to ground, replace the alterna»

to' Staten
Re‘ev [0 section 10 for statue remind.

REGULATOR/RECTIFIER
SVSTEM INSPECTION

Remove :ha Seal Cuwi Ipdge 2-2}.

Disnnnnecl the regulator/rectifier connectors, and
cnock ir‘cr ioosc Contact or corroded terminals,

i" the regulated voltage reading (see pane 15-9i is
out of ma specification, Hie-dame the voltage ne-
tween cornector terminais (Wire harness sydel as

   

 

 

 

 

 

lnllnws-
i it ,, ‘ Temmlal Specific
‘ Dart rled/wnlte Banerv voltage
charging ‘ i land snould register
, line uruulld’ ,

CI‘ia'gll’lg Veilnw arn

cell line ‘_ Yellow

Grourd i ne Green and Cunliuuily

Jound 7 shmridexist

 

if ali ccmooncnts of the charging system are
normal and :nsre are no loose cunnections at the
legulatnr'rectilier connerlnrs, repiace the
’EQIIIHIL‘F rectifier unit.

 

 

16-10

BATTERY/CHARGING SYSTEM

REMOVAL/INSTALLATION

Tmnrnsmtw rnmnsmrs
:cmovc :hc rcgulamnrccfihcv urm mou‘t‘ng non:
am 'egulatofiectiflen

mm ~hs mgmamrrflrflher mm m thg reverse
ardcr 01 vcmova,

 

 

16-11

IGNITION SYSTEM
SYSTEM DIAGRAM

ENGIINE STOP SWITCH

IGNITION SWITCH

x2“; / lGN/ITION COIL

  
  
  
  
  
  
 
  

 

THRO‘I'I‘LE SENSOR
IGNII IUN PULSE GENERATOR

BATTERY
FUSE BOX/DIODF

SPARK PLUGS

NEUTRAL SWITCH

 

\_\ - ' I
\ \ ;

. \\\ //’
SIDE STAND SWITCH MAII\.l FUSE

7'- 7-:qu
mam: star
aruv

 

 

 

 

SIDE STAND EMTCN 3m El
”P am GM' W we am In," mm

5 ‘1‘ ——-—> Engine mp men
”w" ”3 “mm” mm FUSEIA)JI1A

 

 

i fix

—I::I—~——
VIN \ MAIN FUSE (D) 30‘

M—
RN
cunou sWIrcH w I, w smson
man:
3:11va 7
nIr v
wlv
2P [RED]

‘GNIESE BIJV VIBII WN v
a my
I

l 14 man an: no M vii
5 am MI mm m v
NEImaAL , l I | I l I I l 1
“MC" IGHIIIJN PUIjE GENERIDW
I I E C M

 

 

 

 

 

 

 

 

 

 

 

 

SPAR PLUG a .. ,, nEn , BLACK
5 ,, GREEN . BLUE
' , PINK

, BROWN

   

Ignill'on mm

, um" GREEN

 

17—0

7. IGNITION SYbTEM

 

I SYSTEM DIAGRAM 17-0 IGNITION COIL 17-6

‘ SERVICE INFORMATION 17-1 IGNITION PULSE GENERATOR 17-7
TROUBLESHOOTING 17-3 IGNITION TIMING 17-10
IGNITION SVSTEM INSPECTION 17-4

 

 

SERVICE INFORMATION
GENERAL

AWAHNII

When the engine must be running to do some work, make sure the area is well-ventilated Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to
death. Run the engine in an open area or with an exhaust evacuation syfiem in un enclosed area.

 

CAUTION

 

Some electrical calvvponents may be damaged i! terminals or connectors m nonnecfed or disconnected while the
ignition switch is turned to “ON"and current is present.

 

. When servtcing the ignition system, always follow the steps In the troubleshooting sequence on page 11-3.

- This motorcycle’s ignition Control Module IlCMl is built into the Engine Control Module (ECM).

- The ignition timing does not normally need to be adjusted since the ECM is factory preset.

OTIIe ECM may Lie darrraged il chopped. Also ii the connector is disconnected when current is flowing, the excessive
voltage may damagerhe mnmlIe Always mrrr nfilhe ignition swrmh before servicing.

I A faulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure the
battery is adequatelv charged. Using the starter motor with a weak battery results in a slower engine cranking weed A:
well a: lit) spark al the spark plug.

- Use a spark plug of the correct hnnt range Using a spark plug With an Incorrect head range can damage the engine.

~ Refer to section 5 for Throttle Position (TFI sensor and ECM inepoct'lon.

 

 

 

 

 

 

     

 

SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug _‘ '99: 7 . W . . cnsrllvx 9 (Ntikf "w‘
_ ”W ‘77, 7 Afier '99: lMReA—QH INGK)
Spark plug gap 0,80-090 mm 100314.035 in)
Ignition collgeak voltaqe l 100 v minimum
Ignition pulse generator peak voltage l . . 0,7 v minimum
Ignitlnn timing I“F” markl ’95: ., 12° BTDC at Le _
After ’99: 5° BTDC at Idle

 

 

 

 

17-1

IGNITION SYSTEM

TORQUE VALUES

Timing hole cap

Spark plug

Igniliun pulse generator rotor special Doll
Igniiiun pulse gellevaluv cuvai SH bolt

TOOLS

Peak voltage leslev {USA‘ uulyl m
Peak voltage adapter

1}! Nvm 11.3 kgf‘m,13|bf-fll Apply grease to Ihexhreadsv

12 Nvm (1.2 kgf-m ,9 lbfhl

59 N-m (6.0 kgI-m , 43 lbI-fl) Apply oil to the threads.

12 Nm (1 2 kgtm ‘ 9 lbf-m Apply sealant m thethreads 12 placesl,

D7HGJ»DOZUIUU With
Commercially available digital multimexer
(imuadancs 10 M51 l'DCV minimum)

 

17-2

IGNITION SYSTEM

 

TROUBLESHOOTING

. inspect the lolluwiiig before diagnosrng the system.
— Faulty spark plug
loose spark plug cap or spark plug wire connection
.. Water got into the spark plug cap (leaking the ignitinn nnil secondary voltage)
I it there is no spark al either cylinder, temporarily exchange the ignition coil with the other good one and perform the spark
test. If there is spark, the exchanged ignition coil is faulty.
- ”Initial voltage" of the ignition primary coil is the battery voltage with the ignition switch 0N and engine stop switch at
RUN (The engine is not cranked by the starter motorl

No spark at all plugs

 

Unusual condition | Probable cause [Check in numerical order)

 

 

Ignition mil No initial voltage with ignition and ' 1. Faulty engine sinp switch.

primary engine stop switches ON. ‘ 7. An open circuit in Black/White wires between the

voltage (Other electrical components I ignition coil and engine slop switch.

are normal) l 3. Faulty ECM (in case when the InlIllI voltage is normal

l _while disconnecting ECM connector).

Initial voltage is normal, but it drops " 1 incorrect peak voltage adaptor connections.

down to 2- A V while crankingthe 2. Undercharged battery.

engine 3. No vullage between Ihr Blank/White 1+) and Body
ground ( int the ECM multi connector or loosen ECM

. connection.

' 4.An open circuit or loose connection in Green wrre.

5.An open circuit or loose connection in Yellow/Blue and
‘ Blue/Yellow wires between the ignition coils and ECM.
6. Short circuit in ignition primary coil.
7. Faulty side stand switcher neutral switch.
8.1:" open circuit or lnoss connection in No, 7 related
. circuit wrres.
- Side stand switch line: Green/While wire.
- Neutral swiiclr liiie: LightGreen and
Light Green/Red wire
9. Faulty ignition pulse generator (measure the peak
voltage).
10. Faulty ECM (in case when above No.1 9 are normal].
Initial voltage is normal, but no peak 1. Faulty peak voltage adaptor connections.
voltage while cranking the engine. 2. Faulty peak voltage adaptor.
. ; 3. Faulty ECM (in case when above No.1,2 are normal).
Initial voltage is normal, but peak 1.The multimeter impedance \5 Inn Inw: below )0 Mar
voltage is lower than mandard value. 1 DCV.
' 7. (Irsnking speed istoo low (battery under-charged).
l 3.Thc sampling timing of the tester and measured pulse
l were not synchronised (system is normal if measured
l voltage is overthe standard voltage at least once).
. 7 a lsrillyECMfin cascwhen above No. 173 aierioimall
‘ Initial and peak voltage are normal, but i. Faulty spark plug or leaking ignition coil secondary

 

 

does not spark current ampere.
2. Faulty ignition cnil.
Ignition Peakvoltageisluwer than standard ‘I.‘lhe multimeter impedance is too low, below 10 M11
pulse value DCV.
generatnt 2. Cranking speed is too low (battery under charged).

3 The sampling timing of the tester and measured pulse
were not synchronised (system is normal it measured
l voltage is ovet the standard voltage at least once).
_ 4. Faulty ECM (in case when above No. l- 3 are riormall.
No peak voltage. , ., 1 l'allIIy peak voltage adaptor.
2. Faulty ignition pulse generator J

 

 

 

 

 

 

 

17-3

IGNITION SYSTEM
IGNITION SYSTEM INSPECTION

NOTE:

 

 

DIGITAL MU LTIMETER

  

 

. If there is no :dek at any plug. check all Connec-
tmns fnr lnnsF or poor contact before nIeaSUIEng
each peak voltage.

- Use recommended digital multimeter or summer
cially available digital multimeter with an
Impedance m In Migrncv minlmllm

o The display value dIf‘lers dependmg upon th:
internal impedance ofme multimeter

- ll using Peak voltage tester 1U,S.A, uulw, lulluw /
the manufacturnr'x instructions. "LAK VUUAGL ADAPTOR

 

 

 

(innnect the peak voltage adaptor to the digital
muItImeter. or use the Imrin diagnostic tester

TOOLS:
Peak voltage tester (U.S,At only) or
Peak voltage adaptor 07IIGJ-0070100

with commercially available digital multimeter
(irupadanco 10 ME IDCV minimum)

£32110“ COIL PRIMARY PEAK VOLT-

GOOD KNO/WN SPARK PLUG
O

//

AWARNING

Avoid touching the spark plugs and tester probes
to prnvflnt Electric shock,

 

NOTE.

 

ICheck all system connectiuns below inspection,
If the system Is dlscnnnected, incorrect peak
voltage might be measured.

oCheck cylinder compression and check that the
spark plugs are Installed Lurreclly.

 

Shift the transmission into neutral and disconnect
the all spark plug caps From the spaIk plugs
Connect a known good spark plugs tn the spark
plug caps and ground the spark plugs to the
nlender as done In a spark lesl.

 

17—4

With the Ignl'lfin coil primary wirc connscred,
cnnnecl the peak voltage adapter or lmrie tester to
the ignition coil.

CONNECTION:

Nor 1I4 coil:
Yellow/blue terminal 1+) — Body groundl )

No. 2/8 coil:
Blue/yellnwterminal (-wl 7 Body ground (7)

Turn the ignition swilclr “0N" and engine stop
swilch to “RUN"

Check for initial voltage in this time.

The battery voltage should be measured.

If [he initial voltage cannot be measured, check the
power supply circuit train! to the troubleshooting,
page 17—3»

Crank [he engine with the start" motor and read
ignition coll primary peak voltage.

PEAK VOLTAGE: 100 V minimum

It the peak voltage is abnormal, check for an open
circuit or poor connection in Yellow/Blue and
Blue/Yellow wiresr

If not defects arr Inllnd rn the harness, rclcr to the
troubleshooting char! on page 17-3.

IGNITION PULSE GENERATOR PEAK
VOLTAGE

M,

Avoid touching rne spark plug: and mm probes r

to prevent electric shock.

 

NOTE.

 

- Check all system connection belurs inspection. ll
ms system i: disconnected, incorrect peak
voltage mlght he measured.

ocheck cylinder compression and check that the
spark plugs are installed correctly.

Remove the scar (page 2-2).

Disconnect the 22F light gray connector lrorn Inn
ECM.

 

 

 

IGNITION SYSTEM

     

    

PRIMARY TERMINALS lGNlTION COIL
\

 

/

PEAK VOLTAGE ADAPT/OR

 

77F LIGHT GRAY CONNECTOR

 

 

17-5

IGNITION SYSTEM

Connect the peak voltage adaptor or lmne tester
probes to the connector termlnalo ot tne Wire
harness side.

TOOLS:

Peak voltage tester (U.S.A. only) or

Peak voltage adaptor 07HGJv0020100
with commeminllv available digital multimeter
(impedance 10 M :1 IDCV minimum]

CONNECTION:
Vellnwtermlnalt l White/yellowl-i

Crank the engine with the starter motor and read

the peak voltage.

PEAK VOLTAGE: 0.7 V minimum

It the peak voltage l‘le'neuied at ECM multi-
connector IS ahnnrmnl, measure the peak voltage
at the ignition pulse generator connector.

slmpnn the front end of the Fuel tank (page 375).

Disconnect the ignition pulse generator 2? red
colmectol and Lumlecl the tester probes to the
terminal (Vallnw and White/yellowi

In the some manner as at the ECM nnnnPflnr,
measure the peak voltage and compare it to the
voltage n'leasul ed al the ECM connector,

'lf the peak voltage measured at the [(IM l5
abnormal and the one measured at the ignition
pulse geneiatoi is llurlllal, the wire harness has
an open oirnlllt nr Innse tonnectlon

Ill both peak voltages measure are abnormal,
check each item in the troubleshooting chart. if
all items are normal. the ignition pulse generator
is faulty,

See page 777 Ior ignition pulse generator re-
easement.

IGNITION COIL

REMOVAL/INSTALLATION

Remove the air cleaner housing (page 5-65].
Dl>cultllect the nrimary wires from the ignition
mm 5

Disconnect the spark plug caps from the plugs,

then remove the ignition coll assembly.

lnstnllatmn is ln the levelse oldet Ul lellluval.

 

 

PEAK VOLTAGE ADAPTOR
/

2P REID CONNECTOR

:, -' , MAX?" 2

   

 

 

PEAKV‘OLTAGE AUAI’IIJH

 

 

17-6

IGNITION SYSTEM

IGNITION PULSE GENERATOR
REMOVAL

Removeth :owerme InagP 7-3)
Suppomhe from end oIme fueI tank Ipagc 3 5).

D'scumlecl me ignILqu lese generator 2? red
connecmr.
Release the M1 from me wvc cIa'no.

Hemove the SH bolts and IgnIIIOH pu 5c generaio'
rotor cover.

 

Rerove the gasket and dowaI pms.

 

Remove the wire grommet from the cover, C§®MMET BOLTS
Remove the nuns and Ignmnn pulse gene'ator. \ /\

   
 

 

 

r/

V, /
IGVITION F’ULSt GENEHATOR

 

17-7

IGNITION SYSTEM

 

  

Shlh (he transmlssion mm em gear and apply rear
brake,
Remove me Ignmnn pulse generator rotor boll.

Baron

   

We; ewes

  
 

NOTE:

If the englne ls out of the frame, remove lhc
alternator cover (page 1072) and hold the flywheel
with the flywheel hulder l07725-0040000l, then
remuve the bull.

INSTALLATION

Install the anIllOH pulse generator rotor by aligning
the wide groove wirh (he w‘lde math of the crank-
shall.

Apply oil to (he .gnmon pulse generamr mmr hnll
threads, men lnstall me washer and roxor poll.

Shih the Iransmmslnn mm srh gear and apply rear
brake.

Tigmen the ignilion pulse gerleralur mun bolt to
the specified torque

NOTE

If the engme lS out of frame, remove the alternator
cover [page 1072) and hold me flywheel with (he
Ilvwheel holder (077250040000), than lighten llre
boll . .7

TORQUE: 59 N.m [6,0 kghn , 43 lbLl’U

 

 

17-8

IGNITION SYSTEM

 

lnmll me ignition pulse generator inro me cover.
Apply sealant (O the wire grommet, lhen inslall it
into the groove ol the cover.

lnslall and tighten the ignition pulse generator bolls.

 

Apply liquid sealant [O the mating surface ol the
crankcase as shown.

 

 

 

lnslall me duweI pill> and a new gasketl

Apply sealant to the threads nl the two balls
indicated by "A.” mark on the cover.

Insrall me ignilion pulse generator rotor cover and
tighten lhe SH bull [0 1h: specified torque

TORQUE: 12 Mm 412 kg! rn . 9 IDHII

 

 

IGNITION SYSTEM

 

Rouze the igmzion pu 5e genelalof wile ulupwly,
mnnsrnha 7P rad mmsnm
Clams the wure wvth Me band.

InsIall :he removed pa'is in me vevexse Ovdw uf
removal

IGMNONHMWG
IEENM3______________“_

. If 1h; Angina must be running to do some wnrk,
mak: sum the area is well ventilamd. Navel run
the nnginfl in an Enclosed ifli.

. The exhaust contains poisonous carbon monox-
ide gas that may cause loss 0! consciousness
and may lead to death.

Remove the lower cowl tpaga 273),

R922”)? VVaHhupl‘v: gym.

msrruci‘or‘s rm snnnw any n: and remnvp mp nmmg hnls can.
mmcwm
ups‘ahw Comm ms [Iminq tht [0 ms N0. 1 spark plug

m I e

Stamhs enqine anu Iet it idle.
IDLE SPEED: 1,100 : :30 rpm

The ignmm tim'ng is LUHELI {Hue "F" mavk aHgfis
wnn :he :ndex mark on the Igmtmn pulse generator
I'OIOI' cover.

Increase the engine speed by mmmg +2 throttle
510:: screw awd make are the “F" ma'k begins to
mcve coumevcmckwise when the engine speed 3‘
aupmmmew 1,500 mm.

 

   

‘\.

 

 

17-10

IGNIT|ON SYSTEM

Chm the 07.; g is m good cond'wticn‘ rep‘ace ‘r
necpfisaw

App‘y oil :0 me 0 "ng and install me li'mng how
can

 

Tighlan mp. Hmmg hnln nanm ma spmhed torque.

TORQUE: 18 NW! V1.5 kufm , 13 IBM!)

 

 

17-11

ELECTRIC STARTER
SYSTEM DIAGRAM

IGNITION SWITCH

CLUTCH SWITCH /

STARTER SWITCH

  
  
 

BATTEFIV
I
/ FUSE BOX/DIODE

   
  
 
 
 

STARTER MOTOR

 

 

 

 

 

 

NEUTRAL SWITCH
} .
SIDE STAND SWITCH STARTER RELAY SWITCHI’MAIN FUSE
IGNITION swrrcn sums: RELAY
Bfl" SWl'lCl-I
9
STARTER
MOTOR
FUSE
10A
Bllfir
0—7 Vin
NEUTRAL sum-ER swrrcH CLUTCH squcu
Imcnon mun:
' gm G/Fl

 

NEUTRAL
. SWITCH

III—\g—I

   

 

Lg.

18-0

18. ELECTRIC STARTER

18-0 STARTER MOTOR

 

SYSTEM DIAGRAM

 

13-4
SERVICE INFORMATION 13-1 STARTER RELAV SWITCH 13-10 :
I TROUBLESHOOTING 18-2 DIODE 18-11 ‘
SERVICE INFORMATION
GENERAL

- The :mnpr mnmr can he remnvfid with 1hr pngmp in vhp Irame
- Forth: starter drive and driven gear rcmovaI/insmllatian, Gcc sec-Jon ‘IO.

 

 

 

SPECIFICATION
Uml' mm “m
ITEM I STANDARD SERVICE LIMIT
Starter "motor brush Iength ‘ 12 OVVADJO 47 o 51p ”— 45 (n 13:»

 

18—1

ELECTRIC STARTER

 

TROUBLESHOOTING

Stlflll motor dons not turn

I Check for a blown main or sub fuses belore servicing.
0 Make sure the battery is fully charged and in good condition

 

Check the starter relay switch operation.
You should hear the relay "CLICK” when the
starter switch button is depressedt

 

W"CLICK”hcard

 

 

"CLlCK"not heard

 

 

Disconnect the starter relay switch connector,

and check the relay Cnll gmunn wlre lines as be»

low for continuity:

1.6rean/Red terminal-clutch switch diodavnau-
tral switch line {with the transmission in neu-
Mal and clutch lever released).

2.Green/Red terminallclutch switch-side stand
swittll line tin any gear except neutral, and
with the clutch lever pulled in and the Side
stand up.

 

-—Abnolma| —*

 

 

Normal

 

 

Connect the starter relay switch connectort

With the ignition swltch ON and the mortar
switch pushed, measure the starter relay voltage
at the starter swnnh nnnnentor lbetween Yellow/
Red 1+! and ground 1- l.

— No voltage —»

 

 

Battery voltage registered

 

 

Check the starter relay switch operation.

Abnormal

— Normal —-

 

 
 
    
 

Apply battery voltage to the starter motor
directly and check the operation.

 

Abnormal

Normal

l

n Poully connected
starter mntnr cable

0 Faulty starter rclay
switch lpage 18-10).

0 Faulty starter motel
(page 'lH-A).

- Faulty neutral switch (page 19-32)
I Faulty neutral diode.

- Faulty clutch switch,

- Faulty clutch/side stand diode.

- Faulty side stand swilnh.

- Loose or poor contact connector.
0 Open circuit in wire harness.

- Faulty lgnition switch.

- Faulty starter switch.

- BIUWII out main or sub—fuse

. I nose or poor nnnlact nt connector.
- Open circuit in win: harness.

I Loose or poor contact starter relav switch connec-
lur.

;—-——-—-> - Faulty starter relay switcht

 

18-2

ELECTRIC STARTER

Thu sraner mulur [urns when the transmission is in neutral. hm dnas not lurn With me transmission in any position cxccpr

neu‘ral, with the Side stand up and [ha clutch lever pulled In.

 

Normai

 

Check the side stand swircn.

l

Normal

L—

 

 

 

smm molar rums engine slowly

- l ow battery vnl'nge

- Poorly connected battery rermlnal cable
- Poorly connected slarler molur cable

v Faulty starter motor

- Poorly connected battery ground cable

Starter motor turns, but angina does not turn
- Staner mnmr is running backwards
—Case assembled improperly
—Termina|s connected improperly
. Faully slarlel Clutch
0 Damaged nr minty starter dvlve gear

Startor lolav switch "Clicks", but engine does nul |urn over
- Crankshafl does not turn due to engine problems

Check me clulch swilch operation. 7 Normal a - Faulty clutch switch.

Normal —* - Faully clutch switch

+ - Open circull in wire harness.
. Loose or poor comm connector,

 

18-3

ELECTRIC STARTER

 

STARTER MOTOR

REMOVAL

WEE——

With the ignitinn switch OFF, remove the negative
cable at the battery bafare servicing the matter
muror.

Suapcnthc from end ofthc fuel Kank (page 3-b).
Dram [he coolant (paqe 6%).

 

Remove the two SH halts and wamr 1mm.

Helluve [he Hul and me slaner motor cable 1mm ismnrrn momn

 
 
  
  
   

the smnpr mntnr CARI F

CAUTION:

Be careful not to damage the water has.

 

npmnw the stanex mmm mourtiflg bull: and
groundwre.

Pu“ 1h: >l¢rlel mulor uul onhs crankcase

 

STARTER

     

MOT’OR ’
DISASSEMBLY

NOTE

Record me locanon and number at shim:

 

Hemnw the "flowing,
W chnc' mmo' case bolts

"1. \
k§\\\\
CASE BOLTS
, Rear gover assemb‘v SEAL RING REAR COVER
*Seal mg \ ’
*SNms ‘ I

   

 

18-4

ELECTRIC STARTER

REMOVE "‘9 f°”°W'"9? StAL RING AHMATURE FRONT covm

—Fronl cover assembly ‘ I

7 Seal ring

iLock washer

-|nsulated washer

—Shims ,
Armature ‘

  

INSULATED WASHER LOCKWASHER

INSPECTION

Check for commuiw between the cable terminal
and the brush wire (the indiqo colored wire or the
insulated brush holder).

I here should he continuity.

Check far mnunmry helween the motor case and
the cable terminal.
There shauld be My continuiw.

 

Inspect the brushes lor damage and measure the
brush length.

SERVICE LIMIT: 4.5 mm «0.13 in)

 

 

18-5

ELECTRIC STARTER

Check the bushing m the rear cover 9m wear or
damage.

 

Check the from cover oil seal for fatigue or other OlL SEAL
damage.
Check the needle bearing for damage.

NEEDLE BEARING

Inspect the commutaior bars for discoloration.
Bars disuululsd in pairs indicate grounded
armature coils, in WhICh case the starter motor
mus! be replaced

NOTE

Do not use emery 0v sand paper on the commute-
lur.

Check (or (:Dlllinuily between individual commuta-
tor bars; mere shmild he continuity

 

 

18-6

ELECTRIC STARTER

Also, check for continuity bolween individua‘ comr
rnukator bars and (he armature shaft; them should
be no cominuity.

 

 

Remove the following:

_N I-NUT
w‘“ n r e)“— -WASHER
_ ‘5 e 7* ‘/~INSULATORS
Insulators -0 RINC
—0~ring A a / ' "

 
    
  
  
  
 
   
 
 
   
  

—Brush holder assembly
*Brush/tarmmnl BRUSH HOLDER

g? ASSEMBLY

 

 

 

ASSEMBLY
ARMATUHE

 

SHIMS
INSULA1ED WASHtH

OIL SEAL
FRONT COVER

SEAL RING

\, L‘ HEAR COVER
6
BRUSH HOLDER
BRUSH

' SEAL RING

 

MOTOR CASE

 

18-7

ELECTRIC STARTER

Set the brushes an the brush holder.
Align m; lemma! Install the brush holder onto the motor case.
holder plate boss
mm the graave at
me mamr case

Install the Inmall the followlng:
lIlSu/EIUFSDIOpEl ’y —O—ring
as noted du'mg — Insulators

 

@‘_ WAS! IFR

 

 

l. — 7
remove int/fisher (g }‘_ INSULATORS
I ut @
— O-RING
Install the armature in the motor case, SEAL RING ARMATURE FRONT covga

Install mo 5mm: Install the Shims on the armature shaft.
prapélly as noted
dulmg remnva/ Install the insulated Washer and lock washer on [he
armature shaft

Install the seal ring onto the motor case.

   

INSULATED WASHER LOCKWASHER

Install the seal ring on the motor case
Install the sm‘ms Install the shims on the armature shaft. SEAL RING ALIGN
p-upyly a: mum!
during removal AssembIe the molar case and rear L'uver, aligning /
the brush hnlder hm with the groove m the mar
cover.

     

SHIMS REAR CO‘VER

 

1 8-8

ELECTRIC STARTER

 

lnstall the from cover lo ma motor case.
Make sure [he index lines are aligned.

Install and lighten the case bulls muralv.

INSTALLATION

Apply clean englno all [0 the new Oflng.
Insnll a naw O-ring onto the 51mm motor boss.

Install the starter mmor Imo the crankcase.

Rome the staner motor cable and ground cable.
Install the stirrer motor cables. then xiulllen the
mounting bolts and terminal "at securely.

CAUTION:
a. am": not to damage the mm hose.

 

 

 

 

  

 

 

GROUND CABLE

 

 

18-9

ELECTRIC STARTER

 

Check me Mr rio m O-rnq ls in guod common,
leulace W n2. ssaw

Inslall [he waterlo m to 9‘6 cylinder block.

Inslall and tighten [he SH bull»

Fl” mo system wlm the recommended coolant
(pageardl.

STARTER RELAY SWITCH
OPERATION INSPECTION

Hemove the sea: cowl lpage 272»

Sn fl‘lhetransm‘sslon Hm "eulral.

TL r‘ the ign‘tian sw‘tch In "ON" and depre<s the
slane' swmh button

Tre coll KS normal flhe star‘ler 'elay swnch clicks.

Inha mum 'CI ICK" I: ml heart lntnecrt‘w re ay
swuch mm; the proccdurc below,

GROUND LINE INSPECTION
Dvsmmect ih? 'elay connerlor

Check ‘0' con: nulw between 're Green red wwre
and ground '

l6 there lS mnnrmry wher “9 tmrsmussmn S n
neural Ol w"cl’l (h: clutch 'lG d‘scngagcd rd the
side gland switch .5 up, me qroum c mull ls nurmal
m wmral the? s a sllght resistance due to the
decal

 

 

18-10

ELECTRIC STARTER

 

DIODE

VOLTAGE INSPECTION

Cormectthe sraltel relay switch Connector.
smh me I'ansmlssmn mIn nnmrnl

Measure 1'16 voltaqe batwaer' the Yellow/rad wire
1'! and grounc at the Slaner relay switch connec-
tor.

There would as battery voltage only when the
sldlle' :WllLIl uuuon is dep'essed wit'l the ignition
swttch 15 ON

CONTINUITY INSPECTION
Disconnectrhe starter relay cnnnem‘mand cahlas

Connect an ulmllnelev lo the starlet relay switch
largetermmals

Connect a fully chargeo 12-V battery to the starter
relay sw‘tcn connector terminals lVellow,’red and
Gleamueur.

(:herk vnr mmmmvy between the :Mnnr relay
SwlIchtO'manals.

The? should be Continuilv whl'le 11V battery l's
cannected ‘0 MP, SMr’HV VF, fly swttch connector

terminals and should be no continulw when the
bdllery is discunnectad,

REMOVAL
Ramcye the seat lpage 2-2).

Open the fuse box and remnve Vhe drone.

INSPECTION

Checkfm :onli‘mity With an UlllHlIlEIEI

Normal dlrectlon: Continuity
Reverse directidn. Nu continuity

INSTALLATION

lnstal the diode tn ilw lave-1:6 order ul IEIIIUVd‘.

 

 

 

 

 

 

 

LlGHTS/METERS/SWITCHES

SYSTEM LOCATION FRONT BRAKE LIGHT SWITCH

I99: IGNITION SWITCH I/L‘W/
,4

/.

  
 
 
  
 
  
 
 
 
 
 

RIGHT HANDLEBAR SWITCH

/FUF| LEVEL SENSOR

/O|L PHFSSUHE SWITCH

HEADLIGHT RELAV

LEFT HANDLEBAR SWITCH
RADIATOR FAN MD I OR SWITCH
EC’T/THERMO SFNSUR

I

I
NEUTRAL SWITCH \Y}

SIDF SIAND SWITCH \
SPEED SENSOR REAR BRAKI’ | IGHT SWITCH

  
 
 
 
  
   
 
 
  

After ‘99:
FRONT BRAKE LIGHT SWITCH
IGNITION SWITCH
//RIGHT I-IANDLEBAFI SWITCH
//
(2|.U I CH SWITCH ’ , .; 5 /. FUEL LEVEL SENSOR
. I ; /’

/ OIL PRESSURE SWITCH
/ HEADI IGHI RELAY

$,.TURN SIGNAL RELAY
( I

ECT/"I'HERMO SENSOR -
NEUTRAL SWITCH

SIDE STANDSWITCH I:
II
V‘rx

. \
SPEED SENSOR REAR BRAKE LIGHT SWITCH

 

19-0

15. LIUI'I I DIIVII: I :HDIDVVI I bl‘IIZD

 

 

 

 

I
E SYSTEM LOCATION 19~0 COOLING FAN MOTOR SWITCH ('99:) 19-23 _‘
SERVICE INFORMATION 19-1 COOLING FAN MOTOR INSPECTION 1
(AFTER ‘99:) 19-24
TROUBLESHOOTING 19-3
OIL PRESSURE SWITCH 19-26
HEADLIGHT 19-6
FUEL LEVEL SENSOR/RESERVE
TURN SIGNAL 19-7 SENSOR 19-27
LICENSE LIGHT 19-10 IGNITION SWITCH 19-30 I
TAIL/BRAKE LIGHT 19-10 HANDLEBAR SWITCHES 19-31
COMBINATION METER ('99I 19-11 BRAKE LIGHT SWITCH 19-32
COMBINATION METER (Aher '99) 19-13 CLUTCH SWITCH 19-32
SPEEDOMETER/VEHICLE SPEED NEUTRAL SWITCH 19-32
SENSOR 19-15
SIDE STAND SWITCH 19-33
TACHOMETER 19-18
HORN 19-34
COOLANT TEMPERATURE GAUGE]
SENSOR ('99) 19-19 TURN SIGNAL RELAY 19-34
COOLANT TEMPERATURE SENSOR
(AFTER '99:) 19-22
SERVICE INFORMATION
GENERAL

AWARIIING

. A halogen headlight bulb becomes my hot while the headlight is on, and remains hat In! a whils after i! is turned all.
Be sure fa let it cool before servicilm,

' Use an electric heating element to hut tlm water/cools," mixture far the in tumor switch inspectian, Keep all
fizmmabln materials away [rum the electric heating element. Wear proleclive clothing, insulated glavas and syn
prutection

 

- Nulelhe Iulluwlllg when replacing the halogen headhghl bulb.
-- Wear clean gloves WhlIe replacmg the bum Do not put fingerprints on the headlight bulb, a: “lay may creme hm spots
an the bulb and cause ism faII.
, if you touch (he bulb with your bare hands, cIean it with a cloth moistened wnh alcohol to prcvcm its early failure.
7 Ba :me to install the dust cover after replacmg the bum
. Cherk the battery condition belore performing any inspection that requires proper ballery vohage,
' A cominuiry (on! can be made wnh the switches InstalIed un [Ila motorcycle
0 The following culul Ludes are used Ihroughout this sectlon
Bu=BIue (-1 :(ireen ' Lg—ngm Green R=Rcd
BI .. Black Gr Gray 0-Orange W=Whhe
Br-Brown LbsLight Blue P—Pink VzVailow

 

 

19-1

LlGHTS/METERS/SWITCHES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM SPECIFICATIONS
Bulbs I Headllght lligh beam 7 12v 755w
1 l Low bcarn 12 V755w
‘ Brake/tail light l '99: 12V-21/5W x _2
l Ahel '99; 12v—32/3cp x 2 , ,
Front tum slgnnl/runnlng Ilghf 12V*32/3CP X 2
Rearturn signal light 12V—32CP X 2
License light
Instrument light ‘99:
After '99:
Turn signallndicator ' '99:
I After '99:
High beam indicator ‘99: , , , 7 ,, "7777
After '99.
Neutral indicator ’99:
,_ __ __ AIler '99:
UII pressure. lndinatnr '99: 12V *EW
After '99: LED
PGM-FI warning indicator '99: 12V~3W
AftEI '99: LED WV ,, , 7W
Fuse Mam fuse 30A
FGMaFl Iusc 30A !
’Sub [use 20A x 2,10A x s “A 7
Tnchnmeverfleak voltage _w , _ ,,, ,, v _ 10.5lenimllm
Thermo sensor resistance 80 ‘C 47.5-56.8 k :z
_ 120K: 14.9—17.3th
Fuel level sensor lesistance Full L—10 $2
Fmpty 81~ 51 5;
Fan motor Startto close (ON) 98—102 “C (208—216 “Fl
switch Stop to open 93797 “C 11997207 "Fl
TORQUE VALUES

SIrIP. stand mounting bolt

Side stand lock nuI

Side stand switch mounting bolt
Side stand bracket bolt

Ignition swlfnh mounting bolt
Coolant temperature sensor
NeulraI switch

OlI pressure switch

OlI pressure swnch lnrmlnal screw

10 N-rn (1,0 kgf~m , 7 ”3”!)
29 Ntm [3.0 kgf—m , 22 Ibl-fl)
10 Ni!“ (1.0 kgfm . 7 lbf‘ft)
54 N-rn (5.5 kgf~m , 40 lbf-ft)
25 Nlm (2.5 kgf~m,18lbftfl)
10 N-m [1.0 kgf-m , I lbf-ftl
12 NT“ [‘12 kgf:m , 9 lbf‘fl)
12 Nil“ [1.1 kgIlm , 9 lbI-Ill
7 N.m (II ? kgm’n ,1,4|bf.fl)

ALOC bolt.
ALOC bull.

Apply sealant to the threads.

Apply sealant to the threads.

 

19-2

LIGHTS/ METERS] SWITCHES

 

TROUBLESHOOTING
SPEED SENSOR/SPEEDOMETER

The odometer/trip mater operates normally, but the speedometer does not operate

- Faulty speedometer

Th2 speedometer operates normally but the odometer/trip meter does not operate

- Faulty odomctcmrip meter

The speedometer operation is abnormal
. Check tor the roilewmg before dlagnoslng.
7 Blown main or sub fuses
— Loose ur corroded terminals ol the connectors-
Discharged battery

 

Check rrn loose a. pool Contact ol the speed
sensnr 31’ natural connectors

With the ignition switch turned to "ON" and
measure the voltage at the speed sensor

 

—Abnormel—— 0 Loose or poor Contact of related terminals.
' Open circuit in Black/brown or Green/black Wires
between the battery and speed consort

 

 

connector

Normal

 

Check for loose or poor contact of the combina~

tlurl meter illulti~coillleclms

With the Ignition swn‘ch turned to “ON" and

measure the voltage at the bottom of tho
speedometertarminals.

 

 

Normal

With the ignition switch turned to “OFF”, check
for continuity of the Fink/green wrre between the
terminals ol the speed sensor and speedometer,

 

—Abnolma|" 0 Loose or poor mutant 0! rulaluu terminals.
. Open Circuit in “lack/brown or Green/black Wll’es
between the battery and speedometer.

——-Abnormal—~-Open circuit or loose connscrion in Pink/green
wire.

 

 

Nurrrral

Support the motorcycle using a hoist or other
supponto ilse the Iear wheel off the ground.

Measure the output voltage (sensor signal) at the
speedometer with the ignition switch turned to
"ON” whlls slowlv turning the rear wheel by

 

—-AonormaI—~ . Faulty speed sensor.
- Loose speed sensor mounting hnlts,

 

 

you: hand.

Normal

l———> - Faulty speed sensor.

 

19-3

LIG HTS/METERS/SWITCHES

THERMO SENSOR/DIGITAL COOLANT GAUGE

NOTE

 

- The coolant temperature gauge is to be displavad only in a range from 35”C to 132$ (95* to 270“F)
- When checking the digital coolant temperature gauge, always follow the steps in the troubleshooting chart below.

 

 

 

 

 

 

Coolant temperature ’ Displayed
Bclow 34°C (93'F) - —"C
35-121"CV(95—250°F) V 35*;21'1: —
Above1227132‘C4252—270°Fl ‘ 122—132“C 7‘“
‘ Displayed figllre‘x blink and red line appears on the display.

 

 

Tum the lgnltlon swltch to "ON", but the digital coolant temporatuve gauge does not indicate
0 Replace ltle sub [use when lhe Ileullal indicator and side stand indicator dnes not operate

The digital coolant temperature gauge displayed "122 — 132°C” with figures blinking when the engine is cold

 

  
  
 

Disconnect the ECTlthermo sensor connector MNormaI—’ Rapiacethu ECT/theirno sensor.
withtha ignition switch turned lu”0FF", Start the engine and check the digital coolant
Tuln the ignition switch to "ON", check the temperature gauge operation.

 

digital coolant temperature gauge operation.
STANDARD: " '°C

 

Nnrmnl Abnormal
.
Abnormal 1‘
° Faulty ECT/thermo - l milty dlgl'fll coolant
sensor. KOMDOVEIUYG gauge,

Turn the ignition cwitch to “OFF" and disconnect —Continuity<> - Faulty wire harness.
the cambination meter 16? black conneclur.
Check for continuity at the combination meter 16
P black connector wire harness slde with the ECT/
thermo sensor connector is disconnected.
CONNECTION: Green/DwaiGruund

STANDARD: No cnntlntilty

___I__i

Nn continuity . 77*

 

 

I Faulty digital coolant temperature gauge.
0 Faulty combination meter circuil.

 

19-4

LIGHTS/METERS/SWITCHES

 

The digital coolant temperature gauge displayed "7 7-ch when the ang‘ne Is warming up

 

Dlscnnnert ma HIT/tharmn sensor cnnnecmr i Normal A‘Faultv ECTKIhcrmo sensor
wnh the Ignmon switch (umcd x0 “OFF".
Ground lhe Green/bum connectov using a Jumper
wve,
Turn the Ignmnn switch to “ON”, check the
\ digital coolant :cmpcralurc gauge operation.
1 STANDARD: 132%: with fiquras blinking

 

 

Abuuvmal

 

Check fuv cunliuuily between the ECT/thermo -No continuity > ' rnulry wire humus
senfinr nnnnemnr and the combmrmon meter 15?
black connector wire harncss mdc.

STANDARD: Continuity

 

 

 

(:nnnnuity W ,, W ' Faulty digital coo|anl tompcralurc gauge.

' Faulty combinatian mater circuit.

 

19-5

LlGHTS/METERS/SWITCHES

 

HEADLIGHT

BULB REPLACEMENT

m__—

A halogen headligln bulb becomes very hot while
flu headlight is an, and remains hat In! I while
after it is turned a”. He 5m! to let it cool down
before servicing.

Hemnve the upper mwl mvevs (page 2-5)

Remove the headligm bulb Conn-actors.
Remove the dust cover.

Unhook the bulb retainer and remave the headlight
bulb/suckel.

CAUYION:

Avoid lauclling halogen headlight bulbs. Finger-
print: an cigar: hm spars that cause a bulb tn
break.

It you much the bulb wnh your have hands, clean it
whh a cloth moimened whh denatured alcohol lo
prevent early bulb failure.

Remove the headlight bulb lrom the socket.

lnslall a new hlllh into the socket.

Install the headlight bulb/socket aligning lts tabs
wnh me groove In the headhght unn.

 

 

 

 

 

RFTAINlTl

 

 

 

 

 

 

 

BULB/SOCKET

 

19-6

LIGHTS/METERS/SWITCHES

 

\nstah the d .<x mvm nngy flgalnst (he headlight
mm the ”TOP" mark facing up.

Cum lecl the headlight sockets

REMOVAL/INSTALLATION
Remove the uppel c0w‘ (Page 28)
Remove tho Vour bone and headligm um.

lnsxarlation is in the reverse ordPr n0 mmnvm,

 

TURN SIGNAL
BULB REPLACEMENT

Front
Remove the rfiarvlfiw mirror hoot.

Remove the bows and mwrmr.

 

Tum the bJ‘b socket rnllnfernlonkwme and remove
It.

 

/
BULB SOCKET

 

19-7

LIGHTS/METE PIS/SWITCHES

 

Wh \: ausr‘i‘g irmu'n the bum commrclsckwmc lo m“ n ROCKIT
'erroue ‘and replace war a new one.

fists 4 he iron! turn sugna m me reve-se was: 0‘
'SW‘OVEI

Rear ('99:)
Re navethe smewand mm igfia‘ ‘ens

Wh \P mmhmg m4 turn the bulh Cour‘ffirc‘orkwme m
'emove \t and reolace WII” a new owe

:ywx [he may 1w gym m (Iv: lax/21>! urde' ur
'Pmnval

 

 

19-8

LIGHTS/METERSISWITCHES

 

Ram‘s the rum
Slgflal were
properly
magp 1-74;

Rear [After ’99.!

Remove mp scrfiw mm mng lens and rubber

Whlle pushing H, mm (he bulb counterclockwise LU 'UFK SIGNAL .EAS
'ell‘uve l: and Yep ace w th 3 new one

 
    

lsljh ax ns'fial' c He ri
n In crc r ur lg mm vme eome o RUBBER-\
removal. ‘ \

REMOVAL/INSTALLATION

For Iron! turn slgnal um ernval, rPYer ~n rear vlew
mlrror removal (page 2 8|.

For reartu'n signal removal, remove the seal {page
2-2).

Disconnect the turn slgnal connectorsr

Remove the nut and sen‘mg plate
Release the tum Signal Wire and remove the (urn
slgral uniL

Insla‘l the turn srgwal mm m lhp reverse mder or
removal. '

 

19-9

LlGHTS/METERS/SWITCHES

LICENSE LIGHT LICEASE LIGHT ‘
BULB REPLACEMENT y\ 1

 

 

Remove \hc \iccnsc Mg“! bracKet bells and we
Hcense Ugh: assemow.

Remove me screws, lscense hght cover and mm.

Whi‘e puswing in, turn the bum Cuunlwu oukwiw to
remuve u and veplace with .2 mm one

InstaH mc [urn signal igm lens in the reverse o'de'
oframoval.

 

TAIL/BRAKE LIGHT
BULB REPLACEMENT

Remove the seat (page 7,7)

Turn the tailvbrake \ighl socket coumsrclockwise,
than vernuvu [he lulb >ULk€l§

VVhlle nusmng m. turn me bums counlorc ockwisc
10 remove it and replace wim new ones.

\nsYaIl the bll‘h makevs I“ the reverse ordev Oi
'emcvaL

 

 

19-10

LlGHTS/METERS/SWITCHES

 

REMOVAL/INSTALLATION
Harm's the seat (page 2 2r.

Disconneu me ran/make “gm snnkms
Remove the bolts and Ind/brake Irgh: .znir.

Insrallafion is in the reverse uvdel of remova

COMBINATION METER ('99:) - . , , . H VSQCKET
BULB REPLACEMENT ‘

Remove {hp wlnr1<creen (page 2 8',

Pull Ms indicator \arrp suckel oul of the nnmhma-
Liuu HIE-(w

Remnva «he hu‘b from the sucker and realace iL
wrth : new ans.

 

REMOVAL
Remuve the uppe' cow‘ [page Y-BL

Drsconnccr the combination malel mulh-
COHHECIOTS.

  

melev assen‘b‘y ‘

Remove the rhree muum‘mg nuts and comhmahm COMBWAT‘OA METER ‘
- /

 

 

LIGHTS/ METERS] SWITCHES

DISASSEMBLV

Remove the screws and {rum cover.

Remove the meter mounflng screws.
Remove the harness hole plug.

Remove the speedomelel, lachumeler, luel level
gauge/coolant temperature meter and clock unit.

 

FRONT COVER

 

 

 

 

SCREWS

 

' FUEI LEVH GAUGE/

 

CLOCKUNIT SPEEDOMETEH TACHOMETER

 

 

 

COOLANT TEMPERATURE METER

 

19-12

LIGHTS] METERS] SWITCHES

     
   
 

ASSEMBLY
SPEEDOMETER
FUEL LEVEL GAUGE/
COOLANT TEMPERATURE

CLOCKUNIT \

\
COMBINATION METER HOUSING

TACHOMETER

FRONT COVER

Assemble the combmnnon meter in the reverse
order 0! removal.

INSTALLATION

Install the combInarion meter in the reverse order
cl removal,

NOTE-

 

Fouls lhe cumbinafion mm wire prnnerlv (page
1-24).

 

COMBINATION METER (AFTER ’99:)
REMOVAL

Remove the upper cowl (page 2-8).

Disconnect ma combinmion meter 1GP black
connecror.

 

 

 

LIGHTS] METERS/ SWITCHES

Remove the three mounting nuIs and combination
meter assembly.

DISASSEMBLYIASSEMBLV

Assemble the combination meter in the reverse
order of removal.

 

COMBINATION METER ASSEMBLV

 

COMBINATION METER HOUSING

DlGITAL FUEL METER]
DlGlTAL COOLANT TEMPERATURE GAUGE

TACH’OMETER

mom COVER

INSTALLATION

Install [he combinaIiDn meter in me reverse order
nf removal.

NOTE-

Roule rhe nnmhmalion meter wire properly (page
172“.

 
 
  
 

DIGITAL SPEEDOMETER

 

 

COMBINATION METER ASSEMBLY

 

 

 

19-14

 

LIGHTS/METERS/SWITCHES

SPEEDOMETER/VEHICLE SPEED SENSOR SPEED SENSOR EPWHITE CONNECTOR
VOLTAGE INSPECTION ('99) ‘ ‘ " ‘

Support the front end of the fuel tank lpage 376).

 

Disconnect lIIe speed sensor 3P white connector
and check Inr lnnse nr pnor contact of the
connector.

 

 

With the ignltion swltch turned to "ON" and
measure the voltage at the 3P whlte connector or
the wire harness side.

Connecdon: Black/brown (—l - Green/black (—)
Standard: Battery voltage

If there is no voltage, replace and repair the wire
harness

 

 

Remove lhe upper cowl (page 23).

Check lor loose or poor connection or the combina-
tion meter mulriconnectors.

With the igninnn swrtch turned to "ON" and
measure the voltage at the bottom ol the
combination meter lerminal.

 

Connection: Black/brown (+1 - Green/black (—I
Standard: Eaneryvoltage

If there is no voltage, replace and repair the wire

harness.

OUTPUT SIGNAL INSPECTION (’99)

Remove the upper cowl (page Z-ar.

With the ignition switch turned to "OFF”, check ior
continuity of the Pink/green wire belween the
speed sensor connector and combination meter
terminal,

There should be continuity.

If there IS no continuity, replace and repair the wire
harness.

 

 

 

 

19-15

LIGHTS/METERS/SWITCHES

 

Support the motorcycle on its center stand

Connect the speed sensor 3? white connector.
Measure the voltage at the combination meter ler-
minals with the ignition switch is turned to "ON"
WhliE slowly turning the rear wheel by hand.

CONNECTION: Pink (-H — Green/black?)
STANDARD: Repeat 0 to 5 V

If the measurement 15 out oi specification, inspect
the open circuit irt wire harness,

VOLTAGE INSPECTION (AFTER '99)
Support the front and of the fuel tank (page 3-6).

Disconnect the speed sensor 3P natural connector
and check for loose or poor contact of [I19
EOHHSCIOL

With the ignition switch is turned to "ON" and
measure the voitaga at the 3P natural connector of
the wire harness sidet

Connection: Black/brown 1+ i—Green/black (-,
Standard: Battery voltage

If there is no voltage, replace and repair the wire
harness.

Remove the upper cowl inane 2-8).

Check for loose or poor connection of the
combination meter 16F black connector.

With the ignition switch ts turned to "UN" and
measure the voltage at the bottom of tho
curnbi aliun meter terminals‘

Connectio .Blaok/brown (H‘Green/black (ii
Standard: Battery voltage

Ir there is no vnltage. replace and repair the wtm
harnchi

 

19-16

 

 

 

 

 

 

 

 

 

 

 

 

LIGHTS/METERS/SWITCHES

 

 

(AFTER '99) .‘

OUTPUT SIGNAL INSPECTION 16;. 3 ACK Cormgcma

Reilluve We uppev cowl (page Z-Bi

Wim the ignition swiich turned xo ”OFF". check for
CO'WHmJi'EV oi me Pink’qreen wire between :ile
speed sensor Connector and commnatmn maier
mrmlnai

There should cominuiw.

If there is no continuity, replace or rcaai’ the wire

harness.

SJppon Inc motorcycic on its center standr

 

C um the speed Sensor 3? namrai connector
Measure the voimge at the combination memr
(crminais with the ignition swiich is turned to UV"
w‘iiie slcwly turning me rear whee! by hand

 

Connectio 'Pmk xvi , Greenr’blacki l
Siandard: Repeai 0 m 5 V

n 'hre mpamirpmpm w n .1 n1 spermaminn, inspect
the open 0 row: in wire harness.

REMOVAL/INSTALLATION
Supponthe from end ofihe fuel tank {page 3 5|.
Disuum'eLl Hie :peed :e'isov 3P white cornecmr

Release the speed sensor wire f'om the clamp.
Remove the bows and speed sensor.

 

Ch k rat in; 0an is m gnnd cnndlr on, replace ~ ‘ ' 7 SPEED SENS
if necessary. ‘ _
instaii me 5399:: sensor {mo the upper crankcase, ' . .

 

 

19-17

LlGHTS/METEHS/SWITCHES

 

ns‘a l an: (lgl‘tan me mounting hnlrs sPrllr‘e v
Ruute fie senso' wire and ciamn ll

 

lznnnm m». spePrl sansnr 3v whi‘a cavneczor. . SP=ED 5550‘; 3p leTE CONNFCTOH
l

l /

     

TACHOMETER LlILHiAL ’v'IULiIMETER l
INSPECTION ('99) ' ‘

Remove the upper cowi lpage ml.

   

l: Pnk lnr 0059 n' pnnr rnnvam verm nals ni Tne
combination mctcr.

Calmecl the peak voitage adapmr m m? whom.»
my jacklyellowlermmai and grour‘d.

 

 

TOOLS:
Peak voltage tester (u s A only) nr
Peak vollage adamor 07HGJ 0020i00

with commercially available dlglxai mukimatsr
(impedance 10 M f. IDCV minimuml

CONNECTION: Vcl owig'ccr‘ l—l 3rd Ground 1' I

Stan the Engine and measure t’le larhofie'er mmr
voltage. '

 

PEAKVOLTAGE 10.5Vmiwimulll

lire value is normai, 'epiacc lhc lachcmct ,
If the measured Value is baiDW 10.5 V, replace (he
ECM

   

PEAK V0! 'AGF ADA‘TUI?

 

19-18

LIGHTS] METERS] SWITCHES

 

 

H the value is 0 V, perform the following:
Remove the seat (page 2-2) and disconnect the
ECM multiconncctor.

Check for continuity between the tachometer termi-
nal and the ECM multi-eonnectov Yellow/green
terminals.

If there is no continuity, check the wire harness for
an open circuit.

ll there is continuity, replace the tachometer uniL

For tachometer replacement, see 19-11: combina
tion meter disassembly and assembly

 

INSPECTION (AFTER '99)

Remove the upper cowl (page 2-8lt

Check for loose of poor contact terminals 01 the
combination meter.

Connect the peak voltage adaptor to the
combination mctcr 16F black connector.

 

 

TOOL:

Imrie diagnostic tester [model 625) or

Peak voltage adaptor o7HGJ-oozu1oo '/4 "W,"
with commercillly available digital multimeter PEAK VOLTAGE ADAPTOR

 

(impedance 10 M £2 IDCV minimum)

 

Connection: Vellow/graen (+ )7 Ground (—l 16? BLACK CONNECTOR

Start the engine and measure the tachometer input
voltage.

Peak voltage:1D.5 v mlnlmum

 

It the value is normal, replace the tachometer.
It the measured value is below 105 V, replace the
ECM

  

 

r l

PEAK VOLTAG E A‘DAPTD R

 

lf the value is 0 V, policy in the following: 7
Remove the seat (page 2-2) and disconnect the 1GP BLACK CONNECTOR ‘
ECM multirconnector.

Clleck luv continuity between the tachometer
terminal and the ECM mumconnector Yellow/
greenterminals:

If there is nn cnntifltlify, shank the wtre harness for
an open circuit.

ii there is continuity, replace the tachometer unit,
For tachometer replacement, see 19-13; combina-
tion meter disassemolv and assembly.

 

 

 

 

 

LIGHTS/METERSISWITCHES

 

COOLANT TEMPERATURE GAUGE/
SENSOR (’99:)

INSPECTION
Supoo1the fvomcnd ofmc fuel tank magc 3 6:.

D‘scol‘nect the ECT/thermo sense: wire COU‘BEIOI
from Ihe sensor.

Grnund mp. ‘hermn <en<nr mnnecmr Gre?‘/b|ue
:ermlnm with a [umpcr wvc.

Tum the ignition switch to ”ON" and Lheck the
coolant temperature gauge

Disconnecx the memo sensor wire conncclor from
the wound innnedialely if the gauge needle moves
mm! m H

CAUTION:

lrnmadv'afely dismnnm the sensor wire connector
from the grnund when the Mud/e maves to H [hall
to prawn! damage to the gauge.

I! the nccdlo movcs, chuck who (hcrmo ser‘sor unit
taee beIuwI.

I1 me need‘e does not move, chsnk mr vnlvage
between [he sensor wire connocror and ground,

n ma vnlmge I: measu'ed, we coolam [empelature
gaugc unil isfoulw‘

”them is no vmtage, check lor voltage between 1'19
BlacK/brown and Gleeny’MuE win: IETIIIIIIdI5.

H We ws no vouagc between the IelenaIS,
L'quA'vl temperature gauge unit is faulw‘
u vnnagp ‘5 present, checkthe w‘ue heme».

 

 

COOLANT TEMPERATOR METER

 

19-20

Alwaye repeats ["9
«am; washer
WI!!! a Few 0'10

THERMO SENSOR UNIT INSPECTION
mm!

-Wear Insulated glaves and adequate eye
protection.

'Keep flammable materials away from (ha
electric heating element,

 

Dram the enchant [page 6 3‘,

Disconnect the wives connector (mm the enchant
Iempeu ature sfinsnr and remove the sensor.

Suspend the ECT-‘tharrho serum in a pan or coolant
«1:1 l'lixluw] an electric hsnhng eIemem and
meawre the reslstance through the eensor as the
coolant hcats up.

NOTE

"(——

-Soak the thermo sensor in uuo|am up to its
threads with at )east 40 mm (16 In! from the
bonam o! the pan to the bottom oithc sensor,

'Keep the temperature constant for 3 minutes
belore testing. A sudden change of temperature
wiil Iesult in Incorrert rendmgs. Do not let the
thermometer or ECTIIhcrmo sensor touch the
pan.

 

 

i emgeramre so 5c 153

I Izofc Izas'H
.. I714.971_7.3k_

Resistance 47.5i56.

  

 

Hep'Iace the smear It I! Is out of specification by
more than 10 “/5 at anytemperatura Iisted.

Install and tighten the thermn sensor.
TORQUE: 23 N m (2.3 ng-m ,17let)
Connect the ECTkhermn sensor connector.

Fill the system and bleed the air (page 641.},

 

 

LIGHTS/METERS/SWITCHES

 

 

 

19-21

LIGHTS/METERSISWITCHES

 

COOLANT TEMPERATURE SENSOR
(AFI'ER '99:)

Army: ‘epface me.
soon»; washer
witha flew one.

INSPECTION

NOTE

Follow the troubleshooting Chan on page 19-4 for
digital coolant temperature gnuge/sensnr system
inspection.

 

Support the front and of the fuel tank [page 3-6!

Disconnect the ECT,’l|Iequ sensor wire connector
whom-wan“ nlemrlc heatlng element and

W—

‘Wenr insulated gloves and adequate eye
protection.

OKs-p flammable malarial: away from the
electric heating element.

Drain the coolant (page 6v3l.
Remove the ECT/thcrmo sensor.

Suspend the ECT/ther ma sensor in a pan or cooiant
l1:1 mixture) an electric heating element and
measure the resistance through the sensor as tho
cuuianl heals upr

NOTE:

OSoak the thelmo sulrsur in L'uulalll up Lu ils
threads won at least an mm (1.6 in) rrnm the
bottom at the pan to the bottom of the sensor.

’Keep the temperature constant for 3 minutes
before testing, A sudden change oi the
temperature will result in Incorrect readings, Do
not la! the thermometer or ECT/thcrmo sensor
touch the pan.

Unlt: k 52

 

ECT/THERMO SENSOR CONNECTOR

 

 

 

 

Teflgatyre 3 summer) 1zojcl248"F)
Resi ance 2.1‘15 0.62 0.76

 

Replace the sensor if il is out of specification by
morn than 1!] ‘3“ at any mmperaltlre listed

Inslall and tighten the ECT/thermo sensor.
TORQUE: 23 N-m17fi kgf-m , 17 th’f)
Connect the ECT,’thermo sensor connector.

Fill the system and bleed the air {page 64L

 

 

CONNECTOR

 

 

19-22

 

LIGHTS] METERS] SWITCHES

COOLING FAN MOTOR SWITCH ('99:) 7 _éqNN5c1-oa
INSPECTION ” .

 

    

Remove the following:
iSeat (page 2-2)
— Lower cowl (page Z»4l

Check for a blown fuse before Inspection.

Fan motor do“ not nap

Turn the ignition switch to “OFF”, disconnect the
connectnr from the fan motor sztch and turn the
IgnItion switch to “ON“ agaln.

 

If the fan motor does not stop, check for a shorted
mm between the fan motor and switch.
It the fan motor stops. replace the tan mulor switch.

 

Fan motor Eloes not start
Before testing, warm up the cnglne to operating
temperature.

Disconnect the connector from the fan motor
switch and around the ccnnccror to the body with a
jumper wire.

TuIn the ignition switch to "ON" and check the Inn
motor.

It the motor starts, check the connection at the fan
motor switch terminal
It it I: OK, replace the fan mozor switch.

It the motor does not start, check tor voltage ne-
tween the tan mntnr swutnh connector and ground.
It battery VOIIDDO is measured, replace tan motor.

It there is no battery voltage, check (or poor connec-
tion of the connector or broken wlre harness.

 

REMOVAL/INSTALLATION @ '

i!
Disconnect the fan motor switch connector and
remove the switch.

Install a new Orring onto the tan motor switch,
lnstall and tighten the fan motor switch.

TORQUE: ‘lfi N-m [7.8 kgf-m ,13lDf-ft)

Install the removed parls ‘III the reverseorder of
removal. / ‘ \
l l

FAN MOTOR SWITCH

19-23

 

 

 

 

LIGHTS/METERS/SWITCHES

 

COOLINGgfiAN MOTOR INSPECTION

(AFTER'9

Chenk tnr hlnwn Inst! before Inspection.

COOLING FAN RELAY INSPECTION

Unit inspection
Remove the seat (page 2-2).

Disconnect the cooling fan motor relay W
connector and remove the cooling tan motor relay,

Connect the ohmmeter to the cooling fan motor
relay connectorterminals.

Connection: Blank Green

Connect the 12-V battery to the cooling fan rlluiur
relay connector terminals.

Connection: Blochhlte — Green/blue

There should be continuity only when the 174/
battery is connected.

It there is no continuity when the 12-V battery is
L‘ulmeclsd, luplace the cooling fan motor relay

Voltage Inspection
Remove the seat (page 2-2)

Disconnect the cooling fan motor relay IIP
cullneclur.

Connect the voltmeter to the cooling fan motor
relay 4? connector Black/white terminal and
9mm.
Turn the ignmnn switch to "ON" and measure the
voltage.

Standard' Battery voltage

If there is no voltage, replace or repair the wire
harness.

Ground inspection

With the ignition switch turned to "OFF”, check for
continuity ol the Green Wire between the cooling
fan motor relay ‘P connector and hody ground.

There should be continuity.

If there Is no continulty, replace or repair the wire
harness.

COOLING FAN RELAY

 

4F CONNECTOR

 

 

COOLING IAN leLAV BATTERY

 

 

COOLING FAN RELAY

 

 

CONNECTOR

 

 

 

COOLING FAN RELAV

    

 

AP CDNNFCT()R

 

19-24

 

LIGHTS] METERS] SWITCHES

 

Continuity inspection
Disconnect the ECM rrlulli-uonnector,

With the ignition switch turned to "OFF", check for
continuity of the Green/blue wire between the
cooling fan motor relay AP connector and ECM
multl»connectorterminnls

There should be continuity.

If there is no continuity, replace or reoair the wire
harness.

Remove the lowel cowl {page 24).

Disconnect the cooling Ian motor 2P natural
COHHSCIO',

With the Ignition switch turned to-“OFF”, chock tor
continuity of the Black wire between the cooling Ian
motor relav dP cUlIllh‘L‘lUl and cooling fan motor 2P
natural connector terminals.

There should be continuity.

If there is nn continulfy, replace or repair the wire
harness,

COOLING FAN MOTOR SYSTEM
INSPECTION

Check the cooling fan relay unit hefnre inspection
(page 19-24].

Fan motor does nol stop

Turn the ignition swrmn tn "UH”, disconnect the
cooling fan relay 4? connector and turn the ignition
switch to "ON" again,

It the Ian motor does not stop. check for a shorted
wirc between the Ian motor and cooling fan relay.
Ir the (an Inulut slups, irlspecl the cooling fan reiay
continuity inspection lsae above).

if the cooling fan relay is normal, replace the ECM.

Fan motor does not start
Before testing, warm up the engine to operating
temperature.

Disconnect the'cooling tan relay AP connector and
short the cooling fan rclay 4P connector using a
jumper wire,

Connemion: Blank Graen

Turn the ignition switch to “ON" and check the fan
motor.

 

    

MULTl-CONNECTOR
\

 

 

CdDLING FAN REl AY

—‘
IGN|T|UN SWli CH 1

 

 

 

JUMPER WIRE

 

 

 

AP CONNECTOR

 

 

19-25

LIGHTS] METERS] SWITCHES

 

If the fan motor start, Inspect the cooiing tan relay
uunluluityipage19A24).
If the cnniing fan reiay is nnran replace the ECM.

It the tan motor does not start, inspect the coming
tan.

 

COOLING FAN INSPECTION 2P CONNECTOR
Remove the lower cowl (page 2 4).

Disconnect the cooling fan motor 2P natural
connector,

 

Mansure the voltage at the cooiing tun mote! 2P
natural connector wire harness side with the
ignition switch turned to “ON".

Connection: Buick/blue ( + )— Blackt—i
Standard: Battery voltage

If there is battery voltage, replace the cooling fan
(95921924).

I! there is no voltage, replace or repair the wire
hBIIIESS.

 

OIL PRESSURE SWITCH
INSPECTION

if the oil pressure Warning indicator stays on while
the engine is running, check the engine oil levei
before inspection.

Make >Ule that the oil preesuie warning indicator
comes on with the ignition switch turned to "()N"

 

 

:7) zoo: in ‘

 

 

19—26

LlGHTS/METERS/SWITCHES

 

inhe indicator does not come on‘ -n5pectasiollow1
Remove (he iower cowi :paus 2-4:

emnVF 1i"? d|l<f ETA/fir
move lhc screw and oil pressure switch re'minaii

F

Short the oii arsssure Swilch Wire Lermilldi to
giuund usmg a jumper wi-e

[he nll pre<si|rfi warning indicator should come on
when the ignition switch is turned [0 ”ON".

Ii (he iith does I‘u: comes uu, uiienk line sulrfuse
1mm and wires in a Ions: m—nmnn nr an nper
mmmr

51am [he engine and Nick! :uie ihe iight goes out
N the iight does nn gn om, C'wrk the ml oressure
(page 473).

If (he oil pressure is 'iormal, repiace the uri pray
3m: swilch ipage 473i

FUEL LEVEL SENSOR/RESERVE SENSOR
REMOVAL
Ran-owe tflp‘uei tank magi: 5-61)

Release me fuei ievei senso'r’rassrve sensor Wilt
iium the damp.

Remove the nuts and fuel Icvci sonsor’reserve
sensorunirfromrhefusixank,

CAUTION

Be careful not in damage the fluai in".

 

 

LlGHTS/METERSISWITCHES

 

FUEL SENSOR INSPECTION ('99)

Connect the Dhmmetet lo the fuel sensor Grav,’
hlnck and Green/black nnnnectnr,

Inspect the resistance of the float at the too and
bottom positions.

 

\ '\”"TWFULL' " [Ml‘TV

 

 

 

 

ResistanchZO C168°FII 4710 Q 81*91 £2

 

 

FUEL METER INSPECTION ('99)

(Innnem the 'IIHI sensnr connector tn the Wire
harness and move the float from empty to lull to
check the IueI mater indication.

If the fuel meter does not indicate properly, check
for an open or short circuit in the wire harness.

II the wire harness is good, replace the lual mater
With a newone (page 19-1‘Ii.

FUEL RESERVE SENSOR INSPECTION I'99I

Connect the fuel reserve sensor 3P black connector.
Turn lIte ignition switch is to ”ON” and make sure
the. met reserve indicator comes on,

If the fuel reserve indicator does not indicate prop-
er Iy, check [or the I'uiluwing.

Disconnect the fuel reserve sensor 3F black
connector.

Short the wire harness side connector Brownbeack
and Green/black terminals with a jumper wire.

Turn the IQI’IIhnn switch to "ON" and make sure the
fuel reserve indicatorcomes on.

It the. indicator comes on, replace the fueI unit.

If the indicator still does not come on, thank for an
open or short circuit in the wire harness.

If the wire harness is OK, replace the luaI meter
unit Ipage 19.11)

FLOAT

 

FUEL METER

 

 

 

JU M\PER WIRE

 

 

I'IJFI I'II'SI'I'IVI' INDICATOI‘I

 

 

19-28

 

LIGHTS/METERS/SWITCHES

 

FUEL LEVEL SENSOR INSPECTION
IAFI'ER '99)

Renov; me chI level sensor ‘page 19-27],

Ccnnpct zI-e ohmmptsr In the Inel IeveI sersor 2”
black connector IG'avyblack ar‘a Greewblack
mm‘inaIs],

I'lspecI we rentav-Le of the flcal at m: mp and
bottom nnsi‘nn:

Uni|: E‘. (RTE/68°F)

FLOAT POS‘TI ON

IIpsIsfance

    

DIGITAL FUEL METER INSPECTION

CDn'Iec: me fuel IevsI sensor 2F black cumleulu' lo
the wire hams»
T. m tho: Ignmnn mum to "UN" and move the boat
‘rcm (he empty [0 M to checx the dxg‘laI "uel
melsr InGiCalIOI’I.

W m» mgmal mm mater noes not rmcatc properly.
chock Ior an open or sham mrcuil in wxm harness

If me inE harness I: good, lepIaL: (he digi‘aI MEI
metev with a new one (pagp 19-15;

 

 

INSTALLATION

Chagk [he 0mg is in good Condmnn
Infi'aII the WM IInII mm the iuai tank.

CAUTION:

Be careful/nor to damage the float arm.

 

 

lnszaH 3rd lighten me hula :ELU’EIV,
CIam: tI-e wire tothe damn

InsIaIl the fuel tank {Dane 5-53I.

 

 

LIGHTS/METERS/SWITCHES

 

IGNITION SWITCH

INSPECTION
Remove the upper cowl [page 243’.

Disconnect the ignition switch wire 3P white
nnnnnmnrs

Check Ior continuity between the wire terminals of
the ignition switch connector in each switch
pnsitinn.

Continuuty should exist between the co|or coded
wires as lollows:

IGNITION SWITCH

' FAN ‘ lG BAT1 KEV .
ON c—tfi—ii" i KEVDN i ‘

 

 

 

 

 

 

 

OFF 3 _,. KEYOEL' i
LOCK KEY ()I‘I’
LOCK PIN
coma BuIO arm r: A

REMOVAL] INSTALLATION

Disconnect the ignition switch wire 3P white
COI’II’IBCKDL

Hemave the wlre Clampr
Remove the bolts and ignition switch

instaii the ignition switch in the reverse order of
removai.

 

3? WHITE CONNECTOR ,i‘
I/ // ‘~L

    

 

 

 

 

 

 

 

/ IGNITION
’ SWITCH

 

 

 

 

19-30

LIGHTS/METERSISWITCHES

HANDLEBAR SWITCHES 5 ENGINE STOP SWITCH
\L I

Disconnect the |Iand|enav sw‘IIL-h cunneclurs.

 

 

Chock for continuity between the wire terminals of
(he handlebar switch connenor.

Continuity should exist beMeen lhe COIOI coded
wlre (Ermlnnls as fnllows:

 

 

 

ENGINE STOPVSWITCH
\\ IG I BATz
on: ‘

STAHTE R SWITC H

 

 

 

 

 

RUN
COLOR Bl W/BI

 

 

 

 

 

 

 

STARTER swncn
\L ST I IG BAT: HL
FREE Q——Q
PUSH 0—;

coma vm Bl BI/‘Br Bu/W

 

 

 

 

 

 

 

 

 

 

 

 

 

D'MME“ sw'Tc” — ”A" i DIMMER SWITCH
\\ HL Lo HI I I
Lu
INI , ,
Hi ‘7 V L,

 

 

 

COLOR Bu/WI W Bu

 

 

     

 

 

 

 

 

HORN swrrcn
\\ Ho 1 BAT3 / I
I \\‘
FREE I TURN SIGNAL SWITCH HORN SWITCH
PUSH O ’ ‘

 

COLOR Lg ;Bl/‘E|r

 

 

 

 

 

 

 

 

 

 

 

 

TURN SIGNAL SWITCH 7 7 7
\\ W R L BATS I PH PL
R :fi—o c~~——*o
N > ’7 I o I O a
L ‘ o o
COLOR‘ 9R SB 0 Brw Lga/W O/W

 

 

19-31

LIG HTS/METERS/SWITCH ES

BRAKE LIGHT SWITCH BRAKE new SMyI’CH

\

FRONT

thcunnect the ‘mnt brake light sw'tch connectors
and check forcom'wr‘uiw between metermirals.

'hsre shnuld he rnmmulfy wnh the brake lever
apphed. and men: should be no cunmmw w‘nh ma
bra<e Iaver reIeasad.

REAR

Removo up way mags 74"
Remove the relays and fuse box Irom the rear
tender. (pace 245}

Dwrnn'mm me rear orake ugh: swvtc~ connector
and checkfor conrinuiry between he le'mina‘s.

Twere should be conlmmty with tho hmka pads‘

apphad, and there shouId we no commuity wiw me
brake pedaI re eased.

CLUTCH SWITCH

Dwsconnchr‘c clutch switch cornccmrs‘

TIvele should we contipuky with the cIuvnh waver
an1 ed, and were shnuId be no conunmy w th the
much IC‘J ' is messed.

 

NEUTRAL SWITCH

Rer'uve U'e Iuwar L'uwI may: 2-4.

Dzscornact the neural sztch conncmor from me
sw‘wcn. '

S’H'f‘, tha transmIssior Into neutraI and [bark fnr
con: nuny name? he nghl green w re ‘e'mnaI
3nd gvounc‘

fhere shou d be conwuity wi‘m 1"elrdHMHISSIDHIS
ir- weutfaI and no continuity when m» tranzmr“ an
15 mm gear.

 

 

19-32

LIGHTS/METERS/SWITCHES

 

SIDE STAND SWITCH
INSPECTION

Suppn: the trnn‘ am of the final tank {page 3-5:

Disconnect the side stand switch 3? green conner
tor

Check tor continuity between the wire tc'ménais 01
the side stand switch connscmv.

Continuity should exist o'tly w'ten tne side stand is
up,

REMOVAL

Disconnect the mo stand switch 3? green conncc
“3f.

Remove the bolt H'td SInF stand swttnh,

|NSTALLAT|ON

install the side stand switch by aiiqning the switch
pin with the side stand hole and the switch groove
with the return spring hoidtng pm.

 

3P GREEN CON "‘TOR

 

 

 

 

 

 

LlGHTS/METERS/SWITCHES

Secure me swde stsnc switch mm a new bolt

TORQUE m N m H {I kgf m , 7115f?)

,
mm/'

Cu‘mul the 3H: alum] >wizdv 3? 99911 LOWDECIDI'

 

HORN

Discom—ect the ere CunneLIurs [mm the vaH

Connect me 127\’ battery to (he horn (crmIna
directIy.

The hum ': nunrmI iI it :uuH‘Js Wren [he 127V
b . rymmnnpmdarmuekp hornvarmmals

 

TURN SIGNAL RELAY
INSPECTION

Check me followir‘g:
Banerv Condmcn
, Burned out an”: or nan-specIfied wafiagF
*Eurned fuse
—Ignmon SWIICh and turn signal swnch luncnon
'Luuw uqm eLlo':

If we above Items are aIl normalv 0!)ch inc (o‘jow
ing:

D'swnnect the Iu‘n signaI cannectn’s From th;
reIay

 

 

19-34

1,Shurl (he black and gray lerminals of lhe turn
s-gnal relay connector wilh a jumper wire. Slan
the englne and check that the turn signal lighl
comes on when the swnch ls turned on

v
ngm came; nn ngm does he! come on

V

- Broken wire harness.

2. Check for continuity between the green [ermlnal
ul lhe relav connacmr and ground,

Continulty No conllnulty

. Hroken grnund wire
1
9 Faulty lum signal relay.
0 Pnnr mnneclion of the connector.

LlGHTS/METEHS/SWITCHES

 

19-35

 

MEMO

 

”ODKK

20. WIRING DIAGRAMS

'99

 
   

{2‘}? in x1

Kg:

     
 
 
 
   
  

 

DDJDZrMATrLOflfl om

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

mm
LWFETM .
{“7537

W:
W

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

mm:

 

 

 

 

 

 

 

 

iéfléflj mm»

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

rm ‘6 an _ ‘e m *srwr. am pm
'5' ar; ‘ erE 3.0
7' 'au] 7/?) {usu (fly, 7"
ecu»: aw \ m mm m aw ma, am

 

      

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

00302- MAT -AODU
-LUflD

20-1

WIRING DIAGRAMS

After ’99:

“mm

mm “mm; me:

Fun muck

m4

mm: »

mm mm mm WM Ham
v

uvmcu( :.:u
\ w L s: L

a,

(“News

{LB

(295M

 

dvssw

 

wpr w

‘TVJZ/szk/ -

Lm mam mm mm mm

 

20-2

Lm mm mm chunn

, «m was: "mum:
mm mm mm wmcnan

 

     

 

   

 

 

mu m; smsun m

   

 

nogpz-Mnuznu 0va

 

 

 

 

 

49»;

av

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“75

W ’ Pvfibiconmm ‘
v mam um
M»; 1

”— B m mm mm
J

 

r zxmmv nu Wm WM “wk

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M m a.

mmjm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

v! 3(wa

 

 

 

 

 

 

 

 

 

 

 

5" ’ Kw wv av mm

as" _‘. um 3w» mu

 

 

 

 

 

 

» MM 5‘

 

W man we»

 

'H—‘EEJCUWW

mam w W W» mod

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

mu m mmums

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

”vamcpxz i
w ,

 

F33, I. )

 

 

 

 

 

 

r

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

m um swm

 

 

 

 

 

 

 

 

 

 

 

 

 

   
 

 

 

 

 

 

 

 

 

 

 

 

21;

a W{D»cw

 

 

 

 

 

 

 

I w,

 

 

 

       

 

 

 

 

 

 

BMW M;
if my am

AZDA Mumn

cm WIN stW m sampwmw]
‘ nun swim-5AM mm :wwn
E m rm my

run my

 

 

 

 

 

 

 

 

 

 

 

wa

sumik my 94‘ch

  
 
 

 

 

     

 

 

 

mm mm mm

 

mmnuu mu: mum

 

 

 

Em ‘NEWRAL-nuu MPdAma-Skin-’OSIVnm-MEYEPUCNYVVMU

 

 

 

 

 

 

mm mm mmm 5.1mm

 

 

s: m 3mm ML - :m‘ m

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wLGR a. a 2 a

 

 

 

éflrafljm

mm mm

.m w mm mm um

flaw)

Q:

J
m mmm Rim 4 an“ BRAKE wow wow

 

 

 

 

 

 

 

 

 

 

   

» w New mu

m sum 3, mm
v mm a nnANn:

m an: n ma 5va
3 mm H mm mm
a an; n w

w wwz a, m

DD3IJZ- MAT -A2Dfl
-l200

21. I tUHNIUAL I'I:AI UHtS

 

AUTOMATIC FIRST IDLE SYSTEM

 

21-1 KNOCK SENSOR

21-2

 

 

AUTOMATIC FIRST IDLE SYSTEM

This motorcycle’s first idle syslcm is fully aulomatic system controlled by the wax unIt.
Wax unit case 'Is connected In the engine cooling system by Mo waler hoses.

rIIIsI IDLE w"A'x‘3b§NI

53

When me engine coolanx Iemneraturo is low. the
wax uml shaft is pulled inlu lile wax body by the
force onhe return xprIng In Ihe wax unit

Ilhis limo, slancr valves in the I‘Irome body are
Itu open, and tha bypass air is drawn into the
(hrnme bars
The engine speed Is up hy Increasmg the hypass aIr
volume.

The angina is Iumlillg and the coolam temperature
IS up, "19 wax elempm in the unit is inflated and
pushing the wax urIIl shah gradually

The starter valves ale gradually closed, and the
bypass airflow .5 veguldled.

The englne speed is gradually down and then
keeps the Idle specd‘

 

 

 

 

 

 

 

 

 

 

21-1

TECHNICAL FEATURES

KNOCKSENSOR

in use the iuel gage i: msumuem 0- \he octave rate is iow '
ahnnrma! burning is nnrisr m me cnmhusnnn charher and came
scvcrc engine damugci

’he knack se~sor i5 insxalled behind the No‘ 3 cylincer onto the
:yiinder biock and i5 Drowned (he eng ne from :he abHO'n'ia
mining knocks

   

The knock sensov I5 pick up me engine knocks my me buil'fln vibralion plam, and converted into vuflage signal by the piezu
eieufic e‘eliielrt, Hier‘ mil \u the ECM

The ECM is separate the received signai mm the nose voixagc and abno'mai burning knock volxage,

Ifthe abnorma bu'nirg voltage is excessively measured Iran the programmed standard value, lhe ECM is Velald llie iguixiun
immig,

N we ahm‘rmal humlr‘g vnliage m ieu lhan fimnnard‘ me. ! (NI is granuaiiy advance the ignition timing untii the :xandard
vaiuc.

Send engine cancilion [O ECM
iEngiiie mu, Liuuule upeumg, Luuiam lump" :1: )

ECM

 

 

 

 

 

HiC

 

‘ CPU

 

 

  
   
   

 

ENGNEI: > {Av - (m —> iEi

 

 

 

l’il /(}l {LUXHK}
FHMFNT

/

 

 

 

 

 

i - [Dr

KNOCK
SENSOR

 

 

 

 

 

 

 

 

 

 

 

 

 

Sending Wing signai tc e'vgine

A
:5
C
Z)
E:

ViBRAT:ON PLATE
Heguinle me muui VUHAgE 99”.” wave
Noise mirage ruck-up mmim
Knock voilagc nick up c1rcui:

v Sensor fail safe DIRK-up nimu!

1, Derecnh: knock
2, Caicuiate properignmonriming

a 32mm 1“: ’a i Mi:

 

21-2

44. I HUUDLEDHUU I INLi

 

 

ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH
HARD TO START 22-1 SPEED 22-4
ENGINE LACKS POWER 22-2 POOR HANDLING 22-4
POOR PERFORMANCE AT LOW

‘ AND IDLE SPEED 22-3

 

ENGINE DOES NOT START OR IS HARD TO START

Posslble cause

 

1 Check for npermmn nnhe hml pllmp’ Ahnnrmal u . l'aulfy fuel pump (Sectlon 5|
Normal
2. Inspect the fuel flow Abnormal - Faulty orcssurc regulator ISccxlon 5)
Normal
3‘ luspecl llle fuel injeulur ——‘~Abnormal—‘—‘—.‘——’I See seCliUlI 5
Normal
A l’nr'nm‘ a sparkusv Weak or no spark , > - Faulry spark plug
l - Fouled spark plug
Gaod spark - Faulty ECM

s Blokell on shorted spalk plug me
. Faulty lgnmnn swnch

- Faulty ignh‘lon pulsc gcnc’alor

- Faulty englne smp sw'ltch

- Loose or alsconneeled lgnilion sys-

lfim WH‘BS
5.Tesl cvl'lnder compression— Low compression—> - Valve sluuk upen
. Worn cyllnder and @5an “mg
Compression normal - Damaged cylinder head gasket

- Seized valve
- lnlpruper vAlvc lilll'lug

 

6,5mmng lollowmg normal procedure Englne stanza but slop:—-‘ - lmproper starter valve operatlon

0 lnlake pipe leaking

Engine does not start 'll‘lplopel ignltion lilwlrlg lFaulty
lgnmnn mu m Ignmnn pulse generas

mr‘l
l . Fuel contaminarad

 

V
7.Remove and Inspeclspark plug'iwmplug oslaflervalveclosed E
‘ Thronle valve open
- Clugged aiv cleaner

 

22-1

TROUBLESHOOTING

 

ENGINE LACKS POWER

‘l.Raisc wheel oflthe ground and spin
blr hand

Wheel spins freely
l

r
2 Checktire pressure

Pressure normal

3.Accelerote rapldlv from low to sec
ond

Lnglne speed reducer! when clutch
is released
4. Accelerate lightly

Engine speed increase

5. Check lgnition timing
Correct

6 Test cylinder compression

l

Normal

I, r-spect fuel flow

Possible cause

 

Wheels do not spin ireelv —* - Brake dragging
- Worn or damaged wheel bearing

- Pressure low , ,,,,,,4,. Faultytlre valve

0 Functurod t‘lre

 

Engine speed doesn’t —> I Clutch slipping
change accordingly when U WUIII clutch discs/plates
clutch is released - Warped clutch drsnsr‘nlates
0 Weak clutch spring
0 Additive in engine oil

Engine speed does not in- —~
crease

- Air cleaner dirty

a Restricted fuel flow

. Clogged muffler

- Punched fuel tank breather
Incorrect —————’ I Faulty ECM

- Faulty ignition pulse generator

Incorrect —’

o Valve stuck open
- Worn cylinder and piston rings
- Leaking head gasket
Ilrnpropel valve timing

 

Normal

8.

nspact the fuel injector

Normal

9 Remove spark olugs

Not fouled or discolored

10. Check oi: level and condition

Correct

 

llnsmove cylinder head cover and
inspect lubrication

Valve train lubricated properly

Abnormal . Faulty pressure regulator (Section 5)

Abnormal —-‘-—’

- See section 5

Fouled or discolored 4» - Faulty spark plug

incorrect ——-—~

- Oil level too high
I Oil level ‘00 lDW
o Contaminated all

 

Valve train not lubricated—v - Clogged oil passage
properly . Clogged all control orlllte

 

22-2

TROUBLESHOOTING

 

Possible can"

72‘ Check lor anins overheating—— 0vcrheating—> - Coolant level low
. Fan motor networking (laultyfan molar
Not uverheatmg switch)

- Thermostat stuck close

- Excessive carbnn hullrl-up In combus»
tion chamber

I Use of poor uuaiitv fuai

- Wrong type of fuel

- Clutch slipping

13. Accelerate or run at high speed ' Engine knocks—v I Wm H pislun and cylinder
- Wrong type 01 luel
. Excessive carbon build-up in cnmhus»
tnglne does not knock (inn chamber

- Ignition timing l0 advanced ilaultv ECM)
' Lean fuel mixture

POOR PERFORMANCE AT LOW AND IDLE SPEED

Poselble cause

 

 

1. Check ignition timing Incorrect o Improper ignition timing

(.‘nrrent

 

2 Check the starter valve synchroniza- |ncorrect———~ I Soc section 5

 

tlc‘m
Correct
3. Inspect the fuel flow——— Ahnnrmal >777 > . Faulty pressure regulalor (Sectiun 5‘»
Normal
V
A Inspect the fuel injector Abnovmal —-—- ' See section 5
Normal
V
5. Check for leaks In the intake pipei Leaking—“v 0 Loose insulator clamp
i . Damaged insuialol
Nul leak
6. Perlonn spark chl ——— Weak or intermittent > o Faulty spark plug
spark - Faulty carbon or wet fouled spark plug
- Faulty ECM
. Faulty ignition coil
o Brnken or shnned spark plug wire
- Faulty engine stop switch
0 Faultv ignition pulse generator
Good spark . .. - Faulty ignition switch
0 Loosé or disconnected ignition <ystem
wiles

 

22-3

TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED

 

Possible cause

 

 

 

 

1 Check lgnilion liming— Incorrect - Faulty ECM
Correct

2 lnspacrmelllel flow Abnormal . Faulty pressure regulator (Section 5)
Normal

3. Inspecnholuel injector #Abnormal ———-—> - See sacrions
Normal

4. Check valve liming Incorrect - Camshaft not installed properly
Correct

5 Check valve sprlng Weak - Faultv valve spring
Nol weak

POOR HANDLING

Possible cause

 

1. I1 steering is heavy - Steering stem adjusting nunoulight
- Damaged steering head hearings

2 le’ Either wheel ls wmebling—ivr - - Fxcesswe wheel hearlng play
' Bent rim
- Improper installed wheel hub
. Swillgaun pivul bearing excessively
wnm
- Hem frame

3 ”(he lllululchle pulled 10 Due side W I Faully shock absorber
- rrnnr and ranrwheel not aligned
I Bnmlork
. Eenlswingarm
OBent axle

 

22-4

AIII CLEANER

AIR CLEANER HOUSING
ALTERNATOR/CHARGING COIL
ALTERNATOR COVER INSTALLATION
ALTERNATOR COVER REMOVAL
AUTOMATIC FIRST IDLE SYSTEM

BANK ANGLE SENSOR

BAROIMAP SENSOR

BALLANCER

BATTERY

BODY PANEL l DCAIIONS

ERAKL FLUID

BRAKE FLUID REPLACEMENT/AIR BLEEDING
BRAKE LIGHT SWITCH

BRAKE LIGHT SWITCH

BHAKE PAD WEAR

BRAKE PAD/DISC

BRAKE PEDAL

BRAKE SYS IEM

CABLE & HARNESS ROUTING
CAMSHAFTINSTALLATION
CAMSHAFT REMOVAL

CAM PULSE GENERATOR

CAM CHAIN TENSIONER

CHARGING SYSTEM INSPECTION
CLUTCH

CLUTCH FLUID

CLUTCH FLUID REPLACEMENT/AIR BLEI’DING
CLUTCH MASTER CYI INDLH

CLUTCH SLAVE CYLINDER

CLUTCH SYSTEM

CLUTCH SWITCH

COOLANT REPI ACI: MENT

COOLANT TEMPERATURE GAUGE/SENSOR (’99:)
COOLANT TEMPERATURE SENSOR (AFTER '9 I
COOLING FAN MOTOR INSPICIION (AFTER ’99:)
COOLING FAN MOTOR SWITCH [’99zI
COOLING SYSTEM

COMBINATION METER I'99:I
COMBINATION METER [AI‘ I ER '99:)
CRANKIIASE COMBINATION
CRANKCASE SEPARATION
CRANKSHAFT

CYLINDER COMPRESSION TEST
CYLINDER HEAD ASSEMBLY

CYLINDER HEAD COVER ASSEMBLY
CYLINDER HEAD COVER DISASSEMBLY
CVLINDTI‘I HEAD COVER INSTALLATION
CYLINDER HEAD COVER REMOVAL
CYLINDER HEAD DISASSEMBLY
CYLINDER HEAD INSPHZIION
CYLINDER HEAD INSTALLATION
CYLINDER HEAD REMOVAL

DELAY VALVE

DIODE

DRIVE CHAIN

ECT SENSOR

ECM (ENGINE CONTROL MODULE}
EMISSION CONTROL INFORMATION LABELS
EMISSION CONTROL SYSTEMS
ENGINE IDLE SPEED

ENGINE INSTALLATION

3-5
565
16-10
IO<8
10-2
21 '|
5-91
5-87
12-14

8-20
3-27

8-27
8-5
5713
8714
8-21
3-11
15 28
18-11
3-22
5-83
5 93

‘1-54

1-50
320
776

‘0. II\IIJI:I\

ENGINE OIL/OIL FILTER

ENGINE REMOVAL

ENGINE STDI‘ RELAY

EVAP PURGE CONTROL SOLENOID VALVE
(CALIFORNIA TYPE ONLY)
EVAPORATIVE EMISSION CONTROL SYSTEM
ICALIFORNIATYPE ONLY)

FAST IDLE WAX UNIT

FLYWHEEL INSTALLATION

FLYWHEEL REMOVAL

FORK

FRONT BRAKE CALIPER

FRONT FENDER

FRONT MASTER CYLINDER

FRONT WHEEL

FUEL CUTVOFF RELAY

FUEL LEVEL SENSOR/REST RVI: SENSOR
FUEL LINE

FUEL LINE INSPECTION

FUEL PUMP

FUEL TANK

GEARSHIFT LINKAGE

GENERAL SAFETY

HANDLEEAR SWITCHES

HANDLEBARS

HEADI IGIII

HEADLIGHT AIM

HORN

IAT SENSOR

IGNIIION COIL

IGNITION PULSE GENERATOR

IGNITION SYSTEM INSPECTION
IGNITION SWITCH

IGNITION TIMING

INJECTOR

KNOCK SENSOR

KNOCK SENSOR

LICENSE LIGHT

LOWER COWL

LUBRICATION SYSTEM DIAGRAM
LUBRICATION & SEAL POINTS
MAINTENANCE SCHEDULE

MODEL IDENTIFICA'ITON
MUFFLER/EXHAUST PIPE

NEUTRAL SWITCH

NUTS, BOLTS, FASTENERS

Ox SENSOR (AFTER '99 CALIFORNIA TYPE ONLYI
OIL COOI [R

OIL PRESSURE SWITCH

OIL PRESSURE INSPECTION

OIL PUMP

OIL STRAINER/PRESSURE RELIEF VALVE
PAIR CONTROL SOLENOID VALVE
PGM-FI (Fruglammed Fuel InjeCIIOI'II SYSTEM
PGM-Fl SELF-DIAGNOSIS MALFUNCTION
INDICATOR FAILURE CODES
PISTON/CONNECTING ROD
FROPORTIONAL CONT ROL VALVE

RADIATOR

HADIATOR COOLANT
RADIATOR RESERVE TANK
REAR BRAKE CALII’ER

3’17
772
5-93

595

3-22
5-85
1077
1073
13-16
15-29
2-15
15-16
133
5-60
19-27

5-55
5 58
5-81
921

19-31
134!
19-6
3-29
19-311

 

INDEX

 

REAR FENDER

REAR MASTER CYLINDER

REAR WHEEL

RI’GULATORIRECTIFIER

RIGHT CRANKCASE COVER INSTALLATION

RIGHT CRANKCASE COVER REMOVAL

SEAT

SEAT CDWI

SEAT RAIL

SERVICE RULES

SECONDARY AIR SUPPLY SYSTEM

SECONDARY MASTTR CVI INDER

SERVICE INFORMATION
(ALTERNATOR/STARTER CLUTCH)
(BATTERYI'CHARGING SYSTEM)
ICLU ICH/GEAHSHITT I INKAGF)
(COOLING SYSTEM)
(CRAN)(CASE/PISTON/CYLINDER)
ICRANKSHAFT/TRANSMISSION)
ICYLINDER HEAD/VALVES)
(ELECTRIC STARTER)
(ENGINE REMOVAUINSTALLATION)
IFRAMEJ‘BODY PANELS/EXHAUST SYSTEM)
(FRONT WHEEUSUSPENSIUN,’S I LERING)
IFUEL SYSTEM)
(HYDRAULIC BRAKE)
(IGNITION SYSTEM)
ILlGHTS!METERS/SWITCHES)
ILUERICATION SYSTEM)
IMAINTENANCE)
IHEAH WHI: I; [JSUSI’I’ NERON

SHOCK ABSORBER

SIDE STAND

SIDE STAND SWITCH

SPARK PLUG

SPECIFICATIONS

SPEEDOMETER/VEHICLE SPEED SENSOR

STARTER CLUTCH

STARTER MOTOR

STARTER RELAY SWITCH

STARTER VALVE

STARTER VALVE SYNCHRONIZATION

STATOR

STEERING HEAD BEARINGS

STEERING STEM

SUSPENSION

SUSPENSION LINKAGE

SWINGARM

SYSTEM DIAGRAM
(BA) WHY/CHANGING SYSTEM)
[ELECTRIC STARTER)
(FUEL SYSTEM,’99)
(FLJEI SVSTFM:Aher '99)
(IGNITION SYSTEM)

SYSTEM LOCATION
IFUEL SYSTEM)
{FUEL SYSTT M'Afmr '99)
ILIGHTS'METERS/SWITCHES)

SYSTEM FLOW PATTERN

SYSTEM TESTING

TACHOMETER

TAIL/BRAKE LIGHT

2-15
15-23
16-3
16-10
9-27
9 12
2-2
2-2
2-20

3-2 1
1 5-20

10 1
16-2
9-1
6-1
11-1
12-1

18-1
7-1

13-1
5 I
15-2
17-1
19-1

3-)
14-1
14-9
3-31
19-33
3-8

19-15
10-5
19-4
18 10
5-79
5—83
10-2
3 33
13-27
3-31
1l-11
14-12

5.4

19-0
6 o

53‘
19-18
15-10

THERMOSTAT

THROTTLE BODY

THROTTLE OPERATION

TORQUE VALUES

TDD) S

T? SENSOR

TRANSMISSION

TROUBLESHOOTING
(ALTERNAI DHJS TART ER CLUTCH)
(BATTERY/CHARGING SYSTEM)
(CLUTCH/GEARSHIFT LINKAGE)
(COOLING SYSTEM)
(CHANKCASEJPISTON/CYLINDER)
ICRANKSHAFTFFRANSMISSION)
(CYLINDER HEADNALVES)
IELECTRIC STARTER)
(ENGINE DOES NOT START OR IS HARD TO
START)
(ENGINE LACKS POWER)
(FRAME/BODY PANELS/EXHAUST SYSTEM)
[FRONT WHEEL/SUSPENSIONI’STEERINGI
(FUEL SYSTEM)
(HYDRAULIC BRAKE)
[IGNITION SYSTEM)
ILIGHTS/METERS/SWITCHES)
ILUBRICATION SYSTEM)
[POOR HANDLING)
{POOH PERFORMANCE AT HIGHT SPEED)
{POOR PERFORMANCE AT LOW AND IDLE
SPEED)
[REAR WHEEL/SUSPENSION)

TURN SIGNAL

TURN SIGNAL RELAY

UPPER COWL

UPPER COWL COVER/INNFR PANFI

VALVE CLEARANCE

VALVE GUIDE REPLACEMENT

VALVE SEAT INSPECTION/REFACING

WATER F‘UM)"

WHEE LSITIRES

WIND GUARD/RAM DUCT

WIRING DIAGRAM

5-5

5-68
3-5

1-13
1-18
5-90
12-9

10-1
16-4
9-3

11-2
12 2
8-3
18-2

22-1
22-2

13-2
5-3

15-4
17-3
19 3

22-4
22-4

22-3
14-2
19-!
19-34
2-3
7-5
3-12
8-16
8-17
6-13
3 33
2-14
20-1

 

23-2