HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures for the CBRSOOR/RA, CBSDUF/FA‘and CBSOOX/XA. Sections l and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 4 through 21 describe pans of the motorcycle, grouped according to location. if you are not familiar with this motorcycle, read Technical Feature in Section 1. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the motorcycle is in peak operating condition and emission levels are within the standards set by the US. Environmental Protection Agency, California Air Resources Board (CARB) and Transport Canada. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break»in period. Find the section you want on this page. then turn to the table 01 contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure, Refer to the troubleshooting in each section according to the malfunction or symptom in case of an engine trouble, refer to PGlVl-Fl section troubleshooting first. Your safety, and the safety of others. is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: i - Safety Labels 7 on the vehicle , - Safety Messages — preceded by a safety alert symbol {gand one ofthree signal words, DANGER, WARNlNG, or CAUTION. These signal words mean: mm; WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. AWARNING You CAN be KlLLED or SERIOUSLY HURT if you don’t follow instructions. ACAUTION You CAN be HURT if you don't follow instruclions, - instructions — how to service this vehicle correctly and safely. How To use THIS MANUAL SYMBOLS The symbols used throughout this manual show specific service procedures, lf supplementary information is required pertaining to these symbols, it would be explained specifically in the text Without the use ot the symbols. \ 2%” Replace the part(s) with new one(s) before assembly. ' Use the recommend engine oil, unless othen/i/i'se specified, Use molybdenum all solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi—purpose grease NLGl #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: - Molykote® BR72 plus manufactured by Dow Corning U.S.A. - Multi-purpose M72 manufactured by MitsubishLOil, Japan Use molybdenum disuifide paste (containing more than 40% molybdenum disuliide. NLGl #2 or equivalent). Example: - Molykote® G-n Paste manufactured by Dow Corning U.S.A. ' Honda Moly 50 (USA. only) - Rocol ASP manufactured by Rocol Limited, U.K, . Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. _‘ Apply locking agent. Use a medium strength locking agent unless otherwise specified, Apply sealant, Use DOT 4 brake fluid. Use the recommended brake fluld unless othennlise specified. Use fork or suspension fluid. CONTENTS I GENERAL INFORMATION I FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE ‘ PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVES CLTJTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH ‘TTéVRANKCASE/TRANSMISVSION CRANKSHAFT/PISTON/CYLINDERIBALANCERV V I ENGINE REMOVAL/INSTALLATION 7’ I FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION 7 HYDRAULIC BRAKE V ANTI-LOCK BRAKE SYSTEM (ABS; CBRsuoRAIcasodFA/XA) BATTERY/CHARGING SYSTEM 7 7 LIGHTS/METERS/SWITCHES WIRING DIAGRAMS INDEX ENGINE/ENGINE ELECTRICAL q CHASSIS FRAME ELECTRICAL N 1 IHIEHEIHEEEHEEEHHIHIIII MEMO 1. GENERAL INFORMATION SERV|CE RULES ........................................ ..1_2 MODEL IDENTIFICATION -------------------------- "1-3 SPEC|F|CAT|0NS ....................................... ..1_5 TORQUE VALUES .................................... ..1_14 LUBRICATION 8- SEAL POINTS ------------- -- CABLE & HARNESS ROUTING --------------- -- EMISSION CONTROL SYSTEMS ------------ -- TECHNICAL FEATURE ............................ I. 1-20 1 -24 1-80 1-83 1-1 GENERAL INFORMATION SERVICE RULES 1, Use Honda Genuine or Hondarrecommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. . Use the special tools designed for this product to avoid damage and incorrect assembly. , Use only metric tools when servicing the motorcycle. Metric bolts nuts and screws are not interchangeable With English fasteners. V Install new gaskets O-rings, cotter pins and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter Or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified, Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surlaces before reassembly, . After reassembly, check all parts for proper installation and operation . Route all electrical Wires as shown in the Cable and Harness Routing (page 1-24) . Do not bend Or twist control cables. Damaged control cables will not operate smoothly and may stick or bind, mN (DWNOE we ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts Or systems Abbrev. terl 7 F7u|lterm7 7 77 ’ ABS Anti-lock Brake System 7 iCKP sensor 7 7 Crankshafl Pflon sensor 7 7 W 7| 7 DLC 77 Data Link Canector 7* 7i 7 '7 D77? 7 7 Diagnostic Troublefide Wiri V 7 H 7 TEOM Engine Control Module ' 77 iECT sensor W i 7 # EEPROM ' ' T ' ’Eleciricaiiy Erasable Pro ammable Read Oniy’Mgm ’ EOP swnch 7 Engine Oil Pressure SWItch 77 77 'iEVAP W" H Evaporativ'eiE'mIssion V IKCV Idle Air Control Valve 7 7 ‘7 IAT sensor Intakejr Temperature sensoiii 7 7777 ‘ MAP sensor 77 Manifold Absolute Firessure sensor ViMCS 7 Motorcycle Communication system H 7 ML ' Malfunction Indicator Lamp ' 7 l 02 sensor Oxygen sensor PAIR Pulse Secondary Alr injection 7 PGM-Fl Programmed Fuel injection ' ' SCS7service connector Service Check Short service connector TP'sensor Throttle Position sensor VS sensor Vehicle Speed sensor DESTINATION CODE Throughout this manual, the toilowmg codes are used to identity individual types for each region, DESTINATION CODE T REGION 7 T 7 7 i A 49-State i i 7 7 7 AC 77 50-State7irnieets California emissions standards) CM Canada GENERAL INFORMATION MODEL IDENTIFICATION CBRSOUR/RA CBSOOF/FA CBSOOX/XA (ABS model shown) This manual covers followmg models: CBRSOOR (Conventional Brake) CBRSOORA (ABS) CBSODF (Conventional Brake) CB5OOFA (ABS) CBSOOX (Conveniional Brake) CBSOOXA (ABS) Be sure Io refer to the procedure for the appropriate model SERIAL NUMBERS/LABELS The Vehicle Identllicalionfiutnber (V,| N.) [1] is stamped on 7‘ The engine sgnal number [1] is stamped on (he upper right the right side 01 the sleerlng head, side of the crankcase. _ x \ ‘ ‘ CBR500RA shown' . . r \ 1-3 GENERAL INFORMATION fThe (Meme body idénlifiéahon numbe? [7] Is stamped on the lower right svde of the throme body CBR’500R/RA; The SafeTy’ eenitiéauon LaTJel [1] is attached ' ’ on ‘he ngm from side 01 the frame. CBSOOX/XA The Sa1e|y Cerllfleafion Labe‘ the left lower side uf Ihe name pipe. caéofi'F/FA: The safety Cemfrcahon Labe? [1] is ana'c'ried on Ihe lefl swde of the smenng headv The Emission Control InVorrnation Label [1] Iefl side of the swmgarm. iThe co‘or label [1] \s anaehed on m; rea} fender B unde? the seat When ordering ne‘er—coded parls, always specrfy Ihe desxgnaled co‘or code CBRSOOR/RA Shawn \ ‘ GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS CBRSOORIRA L'igi'i 7 JEM # iii 7 ’7 I SpgiFiCArlon 7 ’ig‘l DIMENSIONS '7 Overall length I 2975 mm (91.7 in) I ‘ 7Overall width i 740 mm (29.1 in) I l Overall height 7 1,145 mm (45.1 In) l I Wheelbase I 1,410 mm (555 in) l I Seat height ‘ 785 mm (30 9 in) rFoctpeg height 312 mm (12.3 in) 140 mm (55 in) ‘ Ground clearance Curb I CBRSODR I A, CM types 192 kg (423 lbs) weight I ' AC type 193 l Charging system W l Trlple phase output alternator W ; Regulator/rectifier I FEfEhorled/triple phase full wave 7 l l regtificatlon l 7 Lightan system W 77 WW" gattery 7 7 ( CBSDOF/FA ,7 ITEM ’ WEIFICATKT 7 7 DIMENSIONS ‘ Overall length 7 2, 5m’@ 7m) ' 7 7 Overall width 7 7807mm (30.7 In)’ ’ 1 Overall he)ghl ' 7 77' ‘ 1.706707er (41 7 in) 7 41 Wheelbase ’ 7 1.410 mm (55 5 in) 77‘ 7 if 7 777875 mril (30 )7 7’ ) 7Wpeg helght ' 312 mm (12 3 in) 7—1 Ground clearance 155 mm (6.1 in) V 7‘ 7Curb ' ‘ CB500F A lype "7 190 kg (419 lbs) j weigm Ac type 191 kg (421 lbs) CB5DUFA I A,'CM1ypes 7102 kg (423 lbs) ‘ l AC type 193 kg (4251bs) l 7 Maximum welghl capaclty 168 kg (370 lbs FRAME V VFTarrle type 7 Dlamond Front suspensmn Telescoplc fork ‘ " Front axle travel 7 108 mm (4 3 In) ‘ Rear suspension ’77 1 Swingarm Rear axle travel 119 mm (4.7 in) ‘ _7 Front tire SlZe 120/7OZR17M/C (58W) 7 ‘ Rear tire SlZe 160/602R17M/C (69W) . Front tire brand D222F (DUNLOP), ‘ ROADTEC 28 lNTERACT E (METZELER) Reartlre brand 7 7 7 76222 (DUNLOP). 77 7 W / # l ROADTEC ZBINTERACT(METZELER) Front brake V V V V Ml Hydraullgslngle dlsc Rear brake V 7 V ( ‘rLyglraultc slngle dlsc V N V 7 ( > Caster angle/7 V ( 25:30' 3 Traillength *7 l 102 mm (4.0 In) 7 rFuel tank capacity 7 15.7 Illers (4.15 us gaL 9.151mp gel)’ 7’ GENERAL INFORMATION ' 7 ITEM ' 7 7 ' :7? SPECIFICATIW 7ENGINE Cylinder arrangement ' ' 7 1 2 cylinders in-line, inclined 20“ irem vertical 7 Bore and stroke 67.0 x§©8 mm (2.64 x 2.63 in) i flfiplaoement 471 cm3 (28.7 cu—in) i i A7 Compression ratio 77 10 7: 1 I ‘ l Valve train Chain driven DOHC With rocker an; Intake valve I opens al1 min _ closes att mm Exhaust valve opens at 1 mm 0.047in)iirt i —5°BTDc 0.04 in) lift 35” ABDC 0.04iri)|lfl i 33° 3130c 1 closes ‘ at 1 mm 0.04 in) lift I — 13" ATDC i Lubrication system 'Foroed pressure and wet sump 7; Oil pump type Trochuid Cooling system Liquid cooled Air filtration V V I Viscous paper element 7 Engine dry weight ( 52 7 kg (116.2 lbs) 7 i Firing order I ‘ I; 2 V 7 V l Cylinder number ' Left: 1, Right: 2 ( FUEL DELIVERY 1 Type i PGM-FI (Programmed Fuel Injecti'en) SYSTEIi/L i Throttle bore 7 l 34 mm (1.3 in) 1 DRIVE TRAIN 7 Clutch system 7 ( Multi-plate wet " 7 Clutch operation system igi ‘ Cablfleratlng 7 V firansmission 77 V * Constant mesh, 6 speeds i V ‘ ' Primary reduction 2.029 (69/34) i iiFinal reduction 77 7 2.733 (41/15) 7 7 Gear ratio 1s? 3285 (46/14) 7 i l Pind i i 2.105 (40/19) _ W7 ‘ 1 3rd i 1.600 (32/20) i i 41F ( 1.300 (26%) 5th ‘ 1 150 (23/20) ‘ l )7 61h 1.0fi (24/23) 77 ’ I Gearshift pattern '7 Lefl foot operated return system I . i1-N7273»4-5.s i ( ELECTRICAL i Ignition system 1 Full transistorized ignition ( ‘ ‘ Starting system I Electric starter motor l I Charging system Triple phase output alternator Regulator/rectifier i FET shorted/triple phase full wave i i V rectification ( Lighting system Battery CBSOOXIXA ‘ ITEM ‘ SPECIFICATION “ DIMENSIONS Overall length _ 2.095 mm (82.5 in) ‘ AOverall width 7 V 7 830 mm (32 7 in) i Overall height 771,260 mm (49.6 in) ( Wheelbase r V 7 77 1,420 mm (55.9 in) 7 7 iSeat height i 810 mm (31,91ri) . ‘ 1 Footpeg height - i imimT‘IZE in) I V I if Grpurid clearance i 170 mrrTIéJ in) 7 V ( F Curb casoox ’Jtyge V 192 kg (g lbs) 77 i weight ‘ VAC type 193 kg (425 lbs) cesooxxx A, CMtlpes I 7 194 kg (420 lbfl * ( A AC type EH9 (430 lbs) Maximum weigmapaclty #171 kg (377 lbs) GENERAL INFORMATION l W ITEM ” 7 w W SPEClFICATloT "' 7 i ‘ FRAME Frame type Diamond 1 Front suspension 7 fl) Telescopic tork V ‘ Front axle travel 777 i 125 mm (1)9 in) ‘ Rear suspension ‘ Swingarm 7 Rearagrie travel ' 7115 mm (4.6 In) 7 Front tir'e size ’ 7' ' ’ 7 120/7OZR17M/C (58W) Rear tire size 160/602R17M/C (69W) ' Front tire brand ' " SCORPION TRAIL E (PlRELLl) ’ Rear tire brand ' SCOWTN TRAiL (PIRELLI) ‘ Front brake ‘ l Hydraulic single disc ’ l ’ Rear brake ‘ ' Hydraulic single disc 7 i i Caster angle fl 7 V 26" 30' W, i i Trail length 7" ‘ i 108 mm (4.3 in) 1 Fuel tank capacity ' 7 ""173 liters (A 57 us gai,‘ 3.81 Imp gal) l l ENGINE Cylinder arrangement W W 7777 7 2 cylinders in—line. inclined 1Q” from Vertical Bore and struke W 7.0 x 56 5 mm (264 x 2.63 in) Displacement 7471 :2 QB] cu-in) ‘ i Compressmn ratio 7 V I ' 1 V a V C with rocker arm 7 in (0 04 in) plo s at 1 mm (0.04%))“ 35 AVBDC Exhaust valve opens at 1 mm (0.04 in) lift 7 ‘ 33° BBDC 7 " closes at 1 mm (0 04 in) lift ° ATDC ‘ Lubrication system 7 r 7 ed pressure and-wet sump ) ' Oil pump type 77' 77 ' Trochpid V '7 7 casing; system L ’ quuld cooled V ‘ Air filtration ' Viscous paper element Engine dry weight 7 ' ' 527 kg (116 gigs) ' F7iri'n'g7order ' 71—2 7 Cylinder riTrr'fiber Left: 1 Rjgiit: z W 7 FUELDELIVERY 1 Type‘ ’ PGM-Fiftpragramrned Fuel Injection) SYSTEM ‘ Throttle bore ’ 1 "51mm (1 3 in) W V ' 7 DRIVE TRAIN Claret] system Multi-plate, wet ' i 1 Clutch operation system cable operating I Transmission 7 7'7 licbr’istant mesh, 6 speeds 777 Primary reduction 7 7 '7 2 029 (59/34) 1 WFlnaI reduction 2733 (41/15) ; ‘ Gear ratio 1st 1 3285 (46/14) ) 2nd ‘ 2105 (40/19) 7 ‘ :3qu Mi 1 600 (32/20) V 7 ‘ 4th ‘ 11300 (26/20) 7 ‘ ) 5th 7 7 1.150 (23/20) 7 1 6th 1 1.043 (24/23) I Gearshift pattern 7 77) Lefl fact operated retilrn system I r 1-N-2-3-4-5»6 l ELECTRICAL r Ignitidn system ‘ Fu Jsistorized ignitipri 7 r 1 Starting system 7 ' LEiectric starter motor i Charging system 1 Triple phase output alternator i Regulator/rectifier FET shorted/triple phase full wave rectification i V r 7 Lighting system H 7 V Battery 777* V V PGM-FI SYSTEM SPECIFICATIONS —' '—TI"EM7 "7 V 77' '7 7 7 ismisfi 7 h I iEnglne idle speed 1200 1100 rpm A l E ECT senor resistance (40“C/104°F) iAT sensor res nce7(20°C/68°F) ' Fuel imector'@ststefifid‘C/SS”F) Oz sensor heater reststance (20°C/68"F) IACV resistance (25“‘(3/7771?) 1-8 GENERAL INFORMATION IGNITION SYSTEM SPECIFICATIONS 7 EM I ' ' SPECIFICATION ' Spark plug * ' "’ CPRBEA-B (NGK) ’ ’ §parx plungép" ' 7 T 77 0.00 — 0.90 mm (0.031 — 0.035 In) I I’gnIIIon Coil peak voltage *7 ' 7 100 v minimum ’ CKP sensor peak voltage 7 0.7 V minlmum I Ignition timing ("F“ mark) :7 ' 6° BTDC at Idle speed77 ELECTRIC STARTER SPECIFICATION 7 Unit, mm (In) I ITEM 7 I '" STANDARD I ' SERVICE LIMIT Starler motor brush length ‘ 7 I 12.0 713.0(0747 e 0.51) '65 (0.26) FUEL SYSTEM SPECIFICATIONS ' ITEM ' ’ SPECIFICATIONS Throttle body A, CM types ' GQBJA‘ ‘ T )dentiIlcaIlon number AC Iype I GOBJB I Throttle grip IreeplaL ' 7 2 e 6 mm (0.1 » 0.2Tn) * Fuel pressure at )dle 7 '7' V V 343 kPa (3.5 kgf/Cfn .50 psi) Fuel pimp flow (a1 12 V) ’ I We cm3 (10 8 0&2, 11.2 Imp oz) mrnimurFMo seconds PAIR Control solenoid valve reslstanoe (ZR/68W) I i 24 r 28 Q 7 V I EVAP purge Control solenoid valve resislanée (20°C/68“F) _ 30 e 34 0 :7 COOLING SYSTEM SPECIFICATIONS 7" ITEM ' v SPECIFICATIONS 72mm capacity ' Radiator and eggs? 7 I ' 1 4 litemé’us qt, 1.2 Imp qt) ’ Reserve tank (Upper level) 0.12 IIIer (0.13 Us ol, 0.11 Imp qt) Radiator cap reWpressure 7' 108 7137 kPa (1.1 e 1.4 kgf/Cm , 15 — 20 per) ' Thermostat I Begln Io opeT' 77 80 — 84°C (176 —103?FT’ 'T‘ . Fully open " I 95°C (203°F) I I Valve lift 8 mm (0.3 In) minimum Recommended anliIreeze 7 Pro Honda HP Coolant or an equlvalent high quality ethylene I glycol antifreeze Conlaining Silicate-Tree corrosion inhibitors L7SIandard coolant wncenlratlon 7 ' I 7 1:1 mlxt7I7Ire wiIh dlstllled water7 7' i LUBRICATION SYSTEM SPECIFICATIONS Uml: mm (In) I ITEM ‘ ' I ' STANDARD SERVICE LIMIT Engine oll Capacity AI draining 2.5 Illers (2.6 US qt. 2.2 Imp 0|) 7 ‘» I Al oil Vlller Change 77 2.7 llters_(2.9 US ql. 2.4 Imp qI) I 777 l I At disassemny 3.2 liters (3.4 us o1, 2.8 Imp qt) I 7 Recommended englne oil I Pro Honda GNA Astioke 0il (U SA. 8. I I I Canada) or equivalent molorcycle oil I I API servlce classification: so or higher I I ‘ (except oils labeled as energy ‘ I I I Conservan on the clrcular AP) service ' label) JASO T903 standard: MA I Viscoslly: SAE 10w730 7777 7 I Oil pressure at EOF’ swnch 93 KPa (0.9 kgI/Crn‘, 13 ps)) 7 7 I at 1&90 rpm/BOT (176‘F) _ J I on pump rotor Tip clearance 0.15 (0.005) ‘ 0.20 (0.008) Body clearance 7 71.15 7 0.21 (0.006 A 0.000) 0.35 (0011) i Side Clearance 0.02 A 0.007(0001 e 0.004) ' 0.12 (0005) GENERAL INFORMATION CYLINDER HEADNALVES SPECIFICATIONS , Unit 60110 1 SERVICE LlMl‘r7 11372 kPa (14.0 kgj/cm‘771719 psl) 77 7 77 7 7 7 "WW", 7Cy1inder compresswn 3174750 (01717 l Valve clearance IN 1 0.16 1 0.03 (0 007620. 01) 7 i 77 777 EX 0.271003 (0 011 10.001) 7 7 Rocker arm, JIULLD. 1 IN/EX 10.000 710015103937 7 0394377 101010396) rickner arm Shah 0.0. l lN/EX 9.972 7 9 987 (0 3926 7 0 3932) 9175 (0,384) ' 7 5 a Arm»Io-shafl 7 7 clearance 1N/EX 0,013 7 0043100005 7 0.0017) 0.10 (0.004) 1 Camshaft "“ Cam 1obe helght IN 30.3955 7 30.635511.19667 71.20612) ' 30.376 (1.1959) " 1 Ex 30.1424 7'30 382411 186717119616) 30.122 11.1859) 611 clearance 0,020 7 0062100008 7 0,0024) 0.1010004) 7 7 Runout 1 i *7 ' 0.04 (0.002) Valve, valve 1 Valve stem 0.0 1 71N 4 475 7 4490101762 7 0.1766) 4.465 (0.1759) 1 gu1de 1 EX 1 4 465 7 4.460 (0.1756 7 0.1764) 1 4455101754) 1 1 Valve guide 1 0. 1N/EX 1 450074512 (01772701776) 77 "4.54 (0.179) 1 s1em7lo7gulde 1N '1 0005:0042 (0.0002 7 0 0017) 77 0.0710003) clearance 7 7 tax 7 7 100157M (00006707070720) 77 70.06 (0,003) 1 Valve 911166 height 1 1N/EX 14.1 7 14,30 (0 555 .563) 1 7 7 1 Valve seagwidlh ' 1N/EX 970 71. 010,035 7 0.043) 1510.06) ‘1 "Van/Ewing lree lenglh 17111161011190 'Outer1lN/EX) 7 265811.125) 1 38 78 11 527) 1 ‘7 filind’er head warpa’ge 77 " ' 1 7 0.10 (0.004) CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm (In) E’ lTEfi STANDARD SERVICE LIMIT" Wgulch'l'e'ver freep1ay 10'7 20 (0,4 7 0.8) 7 7 7 ' Clutch Spring free 1eng1h ' 432 (1.70) 42011.6 ) 1 ‘ Disc thlckness 2.30 7 2.50 (0 091 7 0,098) 7 2.2710069) .‘FTIaIe warpage 7 if, r 0 30 (0.012) Clutch outer guide 1 1.0. 22,000 7 22.021 (0.86617 0.6670) 22.031 (0.8574) 1 0.0. 27.937490001710187 1.1024) 27977711015) Mamshan 0.0,atclu1ch outer 0310's " 21967 7 21 98010 8648 - 0.8654) 219510.864) ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) T 7S7ERVICE LIMIT 1 51685120346) 1 7 ’leM 7 ” Staner driven gear boss 0 Slaner c1u|ch mule! | D. 7 7 STANDARD 51.705 7 51.716127 66.362 7 68.392 (2. CRAN KCASE/TRANSIVIISSION SPECIFICATIONS ’7 66 402 (W Unit. mm (m) 7 i 7 ITEM 7 ’ 7 7 J7 77 77 7 7 7§ENDARD 7 IERVICE LIMIT 1 Transm1ss1on Gear 1.0. 28 000 7 28.021 (1.1024 1032) 280411.104) 24.007 7 2402610945 ) 24 04 (0.9461 7 77 1 31.000 — 31.025 (fiz’c'l‘s 71 722715) ’ 31.04 (1222) Bushing 0.0. ' ’ Wei—27.960 (17100771 1* 7 1 3097073099511, 9 3) 1 8) I 1 30 950730.975 (T212757 1.2195)’i ’309311216) 1 Gear-Io-bushlhg 1 0.020 7 0 062 (0.0008 7 0,0024) 1 0.10 (0.064) c1earance 0.005 7 0.05510 0002 7 0,0022) 1 0.07 (0.003) Bushmg 1.0. ' 1 '7 25.000 7 25.021 10.9643 7 0.9651) ' ' 25 0410.966) 26 000728.021 (11024711032) 26 0411.104) Ma'lnshafl 0.0. 1 a1 M5 bushing 24.967 7 24.980 (0 9630 7 0.9835) 2749610963) 7 1 alcz bushmg 27 96772796011 1011771717016) 27 9511.100) * ’ Bushing-lo-shaft ‘ ’Ms, (:2 ’ ' 0.020 7 0.054 (0 0008 7 0.0021) 007 (0.003) ”1 clearance snm Iork1 Shift fork sh7 ’ 11.957 7 11358117311707 7 0.4712) 1 11.95 (0 470) ” fork shaft SLR! fork 1.0. 12010 (0.4724 7 0 47 '1‘)’ 1 120310474) 1751110 fork claw 1h1ckness ’ W023 7 07236)" ' 1-10 GENERAL INFORMATION CRANKSHAFT/PlSTON/CYLINDERIBALANCER SPECIFICATIONS Unit mm (in) "7 ITEM * STANDARD 1 SERVICE LIMIT I Wrankshan Connec'ung rod big efisiae clearane?’ 0.05 7 0.20 (0.002 7 0.0% I 0.25 (0.010) CrankpirTbearing oil clearance *' 0.037 0.032 (0.0012 — 07.0020) I 0.06 (0.002) 7 ' 'Main Iournal beenngfialearance 0.0717 7 .035 (0.0007 7 0.0014) 7 0.05 (0 002) I Runom ' I 7 7 0.05 (0 002) ( CyIInder 1.0. ' 67.000 7 67.015 (2 6376 7 2.6364) 67.10 (2,642)’ I I gut-enround * I 7 ' " 0.10 (0 004) 7' I *Taper _ 0.10 (0,004) I 7 Warpage 7 I 7 I 0.10 (0.004) I Piston, 7 Pislon 0.0. al 7 mm (0.3 in)1rorn bottom 66.970 7 66.990 (2 6366 7 2.5374) 1 66.905 (2.6340) plslon pin. F'Islon pln hole I D, 16.002 716.OOB(0.6300 7 0.6302) 16.02 (0,631) ‘ pismn ring 7 Piston pln 0.0 7 15.994 716.000(0.6297 70.6299) I 15.96 (0.629) 7 :I I PisIon-m-pisian pIn clearance i 0.002 7 0.014 (0.0001 7 0.0006) 1 0.04 (0,002) I I Pision ring end' I Top 1 0.10 7 0.20 (0.004 7 0.006) I 0.4 (0 02) I gap Second 0.21770,31(0.00670,012) 07.5 (0.02) I Oil (side rail) 0.20 7 0.70 (0.006 7 0,026) 1.0 (0.04) I Plston ring-Io-ring Top 0.030 7 0060 (0.0012 7 0.0024) 0.10 (0.004) I 7 l groove clearings I Secgnd 7’ 0.015 7 0.050 (0.0006 7 0.0020) 0.1g(0.003) ' deItIo-plsfllplearance 1010 045 (0 0004 7 0 001B) )7 79fiectmg7ro70-Iovp15mn @learanoe 77 7 Connecting rod small end ID. 16.030 44( 6311 T7) 0.0377 0.05 (0W7 0.002) FRONT WHEEL/SUSPENSIONISTEERING SPECIFICATIONS i 7 7* Unit: mm (In) f 7 ITEM 7 STANDARL ‘ I SERVICE LIWT‘ ' I Minimum lire inread de'pIn ’ 7 - I 1.5 (0.06) Cold tire IiUp I0 90 kg (200 lbs) load I 250 We (2 SEWQI/cm‘, 376' psi) ' ' 7 ' I pressurei7 Ii), Io maximum welghIcapacily ‘ 250 kPa (2.50 kgI/cm‘. 36 E) 7 7 ' I Axle runou! A 70.2 (0.01) 7 I ‘ Wheel nm Radi’al i" "50(006) I I mnout ’Axial 7 2.0 (0.06) 1 Wheel baIance welghl I 60 g (2.1 02) I I 1 max Fork . ' Spring free I_<:BR500R/RA ‘ 405.3 (15.96) 397 (15.6) I I length 17 CBSOOF/FA 381.3 (15.01) 374 (14.7) 1 I7 CBSOOX/XA 366.6 (15.23) 379 (14.9) fl I iTube runouI 0.20 (0.000) 7I 1 Recommended fork 7fluld Pro Honda Suspensmn Fluid 8578 (10W) 7 1 Fluid level I ' CBRSOOR/RA/ I 130 (5.1) I " 7 7 7CBSOOF/FA I i 77 77 c76500x/XA7 ‘ 1760 (6,3) 77 77 + 7' fl. I Fluid capacity CBRSOOR/RA I 503 t 2.5 cm3 (17,0 1 0.08 us oz, I 7 ' ‘ I i 17.7 1 0,097Imp 02) I I kca500FW=A r 460 1 2.5 cm3 (16.2 1 0.08 us oz, ' I if I I I I 716920.09 Imp 02) i ’ I I 66500>KI>12 11.2. 9) 1-16 CRANKCASEITRANSMISSION GENERAL INFORMATION T i in . l THREAD TORQUE ’ 7 "7m , 7°77: DIA. (mm) l 7Ntm (kgf-m, [bl-ft) l REMARES ) Balancer/rlght mainshaft bearing setting ‘ 4 , 6 ‘ 12 (1.2, 9) Apply locking agent to the r )7p7laie bolt7 7 777 , 7 threadi 1 Left malnshaft bearing outer race setting ‘ 1 6 l 12 (1.2, 9) Apply locking agent to the l ‘ plate bolt 1 7 r 1 threads, 1 ) Shift drum bearing setting washer-bolt l 2 l 6 12 (1 2,9) l G‘pplydlocking agent to the i i rea S, 7 l Crankcase main journal bolt l 6 ) 8 l 15 (1.5, 11) + 120” ‘ See page 13-7 ) l ) Replace with a new one. 7Crankcase 10 mm bolt 1 1 10 l 39 (4 o, 29) ) Crankcase 8 rnrn bolt > 3 8 l 24 (2 4, 18) l7Crankcase 6 mm bolt 7 10 6 12 (1.2, 9) CRANKSHAFTIPISTONICYLlNDERIBALANCER i ’ ‘ , THREAD TORQUE ) * "EM QTY DlA. (mm) ) N'm (kgf-m, Ibf-ft) REMARKS ‘ Connectan rod bearing cap nut ) A ‘ 8 1 33,3 (3 4, 25) ‘ Apglyerig'tne oill'lo the threads 7 7 7 71777 7 777 an seating su ac7e. 7 7 Balancer/right mainshafl bearing setting 4 l 6 12 (1.2, 8) 1 Apply locking agent to the l plate EL ) 77 ‘7 thread§7 77 7 ENGINE REMOVAL/lNSTALLATlON F‘ Wi’ if 1 THREAD '1” TORQUE )7 "EM 7 1 QTY DiA. (mm) l N-ILI (kgf-m, lbm) REMARKS Frontengine hanger bolt 1 2 to 45 4.6. 33 1 See pa e 1558 7 7 7 7 9 7 Upper engine hanger bolt 2 1D 60 (6.1 44) See page 15-8 7 Rear englne hanger nut 2 10 55 (5 6, 41) , Seepage15-8 7 Drive sprocket b7oli l 7 1 10 54 (5,5, 40) 7 l 7 t 1 Right crankcase cover bolt 1 7V 1 76 12 (1 2. 9) l 7 L Rider tootpeg bracket bolt 2 77 8 l 37 (3.8, 27) LEOP swuch terminal screw l 1 4 r 2 0 (0.2;57 l FRONT WHEELlSUSPENSIONISTEERING F ' l ' THREAD 1 TORQUE l ‘7 "EM 7 ) cm! DIA. (mm) l_ N-m (kgi-m, lbf~ft) ) REMARKS l Handlebar pinch bolt (CBRSOOR/RA) 2 8 l 27 (2.8. 20) l Handlebar holder bolt 4 B l 27 (2.8, 20) l gcasooF/FA/X/XA) i 3 , l Handlebar swnch housing screw ‘ 4 l 5 l 2.5 (0.3, 1,8) l Throttle cable Ajolnt nut ‘ 1 ‘ 10 l 1.5 (0,2, 1.1) r l (at switch housing) ) l F Throttle cable B joint nut 1 12 1 5 (0.2 1.1) l l } (at switch housing) 1 ‘ 7 7 1‘ Front master cylinder holder Dolt7 t 2 l 7 6 12 (172, 9) 7 l” Front brake disc bolt l‘ 6 ‘ a l 42 (4.3. 31) ‘ ALOC bolt: replace wtth a new . 7 7 l 7 7 9"9- , 7 Front axle 7 1 l 16 7 54 ) 7 T Front axle pinch bolt 7 l 1 7,777 a 7 22 (22, 16) l 777 J 7 l Fork socket belt ‘ 2 l 8 ‘12 20 (2.0 15) l Apply locking agent to the l 777 l_ ‘ threads. l 7 Fork caL7 7 l 2 777 37 l 22 (2.2, 16) 7 7 i Hop Dridge pinch bolt 2 7 8 ‘ 22 (2.2. 16) l 7 7) 7 Bottom bridgefliflbolt 2 10 32 (3,3, 24) 7 l 1 Front brake caliper mounting bolt , 2 l a 30 3,1. 22) ALOC ooit; replace with a new 7 l ‘ ‘ l l one. 1 Steering bearing adjustment nut ‘ 1 l 26 23 (2,3 17) ‘ See page 16-30 1 1 Apply engine oil to the l l 7 l_ threads. r7S7teering bearing adlustment lock nut 1 l 26 — t See page 16-30 7 Steering stem nut 1 i 24 l 103 (10.5, 76) l 1-17 GENERAL INFORMATION REAR WHEEL/SUSPENSION r ‘ l THREAD ’ rdRQUE 7 ITEM Q'TY DIA (mm) N1" ‘kgrm' M") REMARKS Rear brake dlsc bolt 1 4 fl 5 ‘ ' 42143131) ‘ ALOC bolTreJaoe with a nevT i one. Driven sprocket nut ’* 5 1"" 12 108 (11 '0, 80) l Ucnut '7 i " Rear axle nut ’ ’ "‘ 1 l 16 ’ ' 8819.0,65) uTut’ snack absorber mounting nut 2 l 10 ' T ' 314145.32) u-nut ' ’ ~Shock linkage nul ) 3 1b 44 (4,51 32) U-nut 'fl ’7 Drive chain slider tapping screw 3 '2 5 i 5.910 6, 4.4) _ ’ ) Swmgarm pivot nut 1 ll 14' ' as (9 o, 65) Apply engine OII to the threads 1 l ‘ _and seating surtace. Uenut HYDRAULIC BRAKE . THREAD TORQUE ; 1 "EM 7 I 0 TV ’ DIA. (mm) N-m (591m, let) _ REMARKS T l Brake hose oil bolt l 4 1o ' l 34 (3.5, 25) V V ’1 Brake Caliper bleed valve 1 2 ' 8 5.410 s, 4,0) l ' V ' Brake caliper pad pln 2 1 ‘ ’0 17 (1,7, 13) l 7 From master cylinder reservoir cap 2 "7’ 4 1 5(02,1.1) screw 7 i l W v 777 7 ¥ Front brake lever pivotth 1 ' e l 1.0(0101) ‘ Trent brake lever pivot nut' " ‘7’ 1 ' 7' '6 ' l 5 9 (o 6‘ 4 4) V fiérm’lult’dfi sicrewiiir 1 ‘ 7’ (if . ) 7 ' 7mm master cylinder holder bolt "1 2 .7 "6 V V Trent brake caliper pin ' 1 " 8 22 (2,2, 16) ‘ Ahoply locking agar} to the ) t reads. Front Eralre caliper mounting bolt ' ' 2 ’F' 0 (3,1. 22')’ 'TLOC bolt; replace with a new i Vane i 1 Wear brake reservoir cap flew il' 2 4 ' 5102, 1.1) r l ' Ear master cylinder bush rod loint nut V ‘ 1 g "177 (1 7, 13) ' '7 Ramaster cylinder nose joint screw 1 V 7774’ 1 5 (0 2. 11) Apply locking agent to the threads. ‘ "HRear master cylinder mounting bolt 7 2 6 2 (1.2. Q) l Rear brake caliper pin bolt 1 12 27 (2,8) 20) I Wear brake caliper bolt ’ ' “ 1 ' "12 l 22 (2.2, 16) 1 ALOC bolt: replace With a new 7 i one Rider roolpeg bracket bolt ’ 4 ‘ ' a ‘ 37 (3.8, 27) ‘ ANTI-LOCK BRAKE SYSTEM (ABS; CBRSDORA/CBSOOFA/XA) * ' ‘ l THREAD ' TORQUE l ' *1 tTEM Q'TY l DIA' (mm’ Mm (kgfml mm ‘ REMARKS 1 Brake pipe jomt nut 4 ' V 10 l 14 (1.4, 10) l Apply brake fluid to the 7 1 threads. "irate nose oil Bolt 'i 2 10 i 34 (£15, 25) i ' ¥Rldertootpeg bracket b6|t f r 72 a 1 "3713 8, 27) 1-18 LIG HTS/M ETERSISWITC HES GENERAL INFORMATION ' i . THREAD i TORQUE i ' 11* 7 ITEM 7 QTY 7 DIANE) 7 ‘ NT" “(9'17 mm l REMARKS 1 ’Headiigm mounting bolt (CBRgJOR/RA) 1 3 l 7 6 7 8 5 (0.9, 6.3) l, 7 ( Headlight mountlng bolt (CBSOOWAT l 277‘ is 7 8,5 (0.9, 6.3) 17 l Headlight mounting screw (CBSOOF/FA)7 , 2 i 6 777 _ 4,5 (0 5, 3.3) 7 7 77 ‘ Front turn signal/position light mounting 1 "2 l 6 7 10 (1.0, 7) , ‘ ‘ nut (CBRSODR/RA/CBSOOX/XA) 7 l l 7 7‘ ) Rear turn signal ilght mounting nut 2 ( 6 7 l 10 (1 0,7) l ( Brake/taillrght mounting screw 1 2 , 4 W 0.9 (0,1, 0.7) 1 Combination meter mounting screw 3 ‘ 5 V 1.0 (0.1. 0.7) ( ‘ i Wire clamp tapping screw 7 V 1 4 0,9 (0.1, 0.7) i l (at rear fender A) 1 l l EOP switch 7 ‘ 1 ‘ PT1/8 12 (1.2, 9) Apply Iquld sealant to the i 1 threads. , EOF7’ swrtch terminal screw ( 1 4 l 2 0 (0.2, 1.5) l ignition switch mounting bolt ‘ 2 ‘ B 1 24 (2,4, 18) One—way bolt; replace with a ,7 , new one. 7 7 ( Neutral swrich 1 ‘ 7 10 , 12 (1,2, 9) 7 '( 1 Neutral switch terrn7inal nut 17 7177 4 l 1.0 (0,1, 0.7) 7 777 OTHERS ' 7 i THREAB l TORQUE ’ fl 7 [EM 7 l 0'7: l DIA. (mm) 1 7N-m (kgf—m, [bi-ft) ‘ 7 REMARKS , Rider footpeg bank sensor cap bolt 1 2 ‘ B 7 12 (1 2, 9) 7 7 7 7 Gearshift spindle return spring pin 1 E i 23 (2.3, 17) Apply locking agent to the l r 7, 7 ‘ 77 threads. t Crankcase 10 "m socket sealing bolt 77i 77 10 l 7 18 (1,8, 13) ( 1 1 Engine sub-wire harness connector stay 1 5 i 1.0 (0.1, 0.7) , ‘ ‘, tapping screw (at air cleaner housing) 1 1 Air cleaner hois’ing intake duct lappin? l 2 ‘ i ( ‘ screw 7 17 Clutch lever pivot bolt ‘ 1 6 ‘ 1.0 (0.1, 0,7) 1 7 l Clutch lever pivot nut 7 ( 1 6 ‘ 5,9 (0.6, 4.4) ( 1 Turn signal light stud stay screw 1 4 l 67 l 2.5 (0.3, 1.8) , Tail reflex reflector nut l 1 1 5 1.5 (0.2, 1.1) ( U nut i Lateral reflex reflector nut 7 4 7 6 1 5 (0.2.1 1) l U nut 1-19 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL j LOCAfiON REMARKS ”‘ Sealant (TB1207B V l EOP switch threads See page 214? manufactured by ThreeBond l AlternatormP wire grommet sealing surface iifi ‘ or an equivalent) crankcase mating surface i see page i3—e Crankcase mating areas (left side) ‘7 See page 12-4 l ‘ Crankcase matingrareas (right side) See page 11-6 Vi ‘ Sealant (T85211 l Cylinder head semi-circular edges See page 10-8 ‘ i manufactured by ThreeBond, i l ‘ KEAST manufactured by ‘ Shin»Etsu Silicone or an r i equivalent) Engine Oil Engine Oil filter cartridg’e’threads V 7 (Without molybdenum Fuel ihiector seal ring N 7 additives) Cam chain 7 ‘ Camshaft holder bolt threads and seating surface ‘ Rocker arm shaft plug bolt threads l jalve stem seal fitting area Cylinder head bolt threads and seating surface 77 777 7 7 Piston sliding surface and ring grooves Piston pin hole innér surface Piston ring entire surface :Gearshift spindle shaft outer surface 7 7C|utch disc and plate entire surface 7 i 7 Clutch center lock nut threads and seating surface Primary drive gear bolt threads and seating surface Starter onerwayrclutch contacting surface 7F7lywhee| bolt threads and seating surface Connecting rod bearing cap nut threads and seating ‘ surface 7 Each gear teeth and rotating surface ‘ I Each bearing rotating area 7 77 7 Each O-ring "7 7’ Excépt sensor unit, IACV and ‘ water passage O-rings Other rotating’and sliding areas Crankshaft hole cap threads Each oil seal lips Multi-purpose grease 7 l ‘ Molybdenum oil solution (a [ Valve stem end and sliding surface 777 777 7 7 7 3 mixture of engine oil and Camshaft iournals‘ lobes and thrust surfaces ‘ . .x r res—w“ molybdenumdisulfidegrease : Rocker arm shaft outer surface 7 in a ratio of 1:1) Rocker arm sliding areas argthrust surfaces Clutch outer guide entire siJrfa A 7 Starter ' 7 “Transmission gear bushing entire surface (M5, OZ) 7 7 i ‘—‘i Transmission gear spline bushing outeTsurface (M6, W i 03, L4) , i Transmission gear shifter groove (ms/4, Ca, cc) Transmission needle bearing rotating area (C1) Shift forlr77guide area and guide pin Shift fork sTaft outer surface i Balancer driven sub-gear and washer sliding surfaces 7 Primary drive gear and subygear sliding surfaces i *Crankshaft mist surfaces 7 i rCrankshaft main journal bearing sliairfi surface 77 i Crankpi‘n bearing sliding surface 1 Connecting rod small end inner surface 7777 l 7 ‘ Piston pin outer surface 7 l V Heat-resistant locking agent i Shift drum center socket boll Coating width: 65 mm (0.26 in) ‘l (TBiaao manufactured by from tip ‘ ThreeBond or equivalent) 1 -20 GENERAL INFORMATION MATERIAL " ( 7 LOCATION 7 ( r REMARKS V ‘ Medium strength locking PAIR check valve cover bolt threads ‘ Coating width: 6.5 mm (0.26 in) agent (TB1322N 7 except 2 r1m(0,1 in) lrorn tip manufactured by ThreeBond. ( Oil pump driven sprocket Washer-bolt threads i Coating Width: 6.5 mm (0.26 in) LOCTITE 648 manufactured L 7 except 2 rrim (0 1 in) from tip i by LOCT'TE 0i equValem) i Carri chain tenSioner pivot bolt threads i Coating Width: 6.5 mm (0.26 in) l 7 l except 2 mm (0.1 in) from tip ‘ Gearshift spindle setting plate bolt threads Coating width: 6.5 mm (D 26in) ; l ( except 2 mm (0.1 in) from tip i Gearshift spindle oil seal setting plate bolt threads ( Coating Width: 6,5 mm (026 in) ‘ except 2 mm (0.1 in) from tip Shift drum stopper arm bolt threads Coating Width: 65 mm (0.26 in) . except 2 mm (0.1 in) from tip A Alternator stator bolt threads ‘ Coating Width: 6.5 mm (0.26 in) l i ( exceptZ mm (0.1 in) from tip ‘ CKF' sensor bolt threads ( Coating width: 6.5 mm (0.26 in) i i expeptz mm (0.1 in)‘lrcim tip 4“ iStarter clutch socket bolt threads ( Coating width' 6.5 mm (0.26 in) - ( from tip Water hose joint stud bolt threads (crankcase side) ‘ Coating width, 6.5 mm (0.26 infi i r ( exoept 2 min (0.1 in) tram tip (r Balanoer/right mainshaft bearing setting plate bolt ‘ Coating Width: 6.5 mm (026 in) ‘ threads k 4‘ except2 mm (0.1 initromtip i Left rrTainshaft bearing outer raoe setting plate bolt ‘ Coating width: 6.5 mm (0.26 in) ‘ threads ‘ except 2 mm (0.1 in) lrom tip ( Shift drum bearing setting bolt threads CoatinQWIdlh:6?rnm (0.26 in) i 1 except 2 mm (0.1 in) from tip i Gearshift spindle return spring pin threads W ( 7 i ‘ Engine oil filter boss threads ( Coating Width: 6.5 mm (fie in) i «cutoff 1-21 GENERAL INFORMATION FRAME a MATERIAL if j 7 LOCATION 7 ‘ REMARKS Urea based mum-purpose ( Steering bearing race sliding surface fl 7 l 3 ~ 5 g(0.1~ 0.2 oz) pTar each l extreme pressure grease bearing NLGl #2 (EXCELITE 5P2 Steering bearing dust seal lips manufactured by KYODO YUSHI (30., LTD” STAMINA ‘ EPZ manufactured by Shell ( l or equivalent) Mum-purpose grease Sidestand pivot sliding area Seat catch sliding area rThrwoflle grip cable groove and roll-up area i '7 Clutch lever Divot sliding area l Front wheel dust seal tips 7 7 if # * Rear wheel dust seal lips V l . Rear wheel hub O-rlng V V N ? Rear shock absorber needle bearing7otating area H V V l Final driven flange dust seal lips 7 7 Rear shock absorber dust seal lips Shock tlnk needle bearing rotating area ‘ Shock link dust seal lip’s’i h Swingfin needle bearing rotating area Swingarm ball bearing rotating area W ‘ Swingarm dust seal lips 7 W i l» Brake pEal pivot sliding area (grease groove) Gearshift pedal pivot sliding area (grease grooVe) Gearshift pedal tievrod pail joint ’ l Footpeg pivot sliding area "4) Steering peering adjustment nut threads 7 l r r 7‘ Tngine oil, Swingarm pivot nut thréads and seating surface _ iSiIiconeflgrease ‘ Front brake lever pivot sliding area 0 10 g (0.004 oz) Front brake leverrtovmaster piston contacting area 0.10 g (0.004 oz) Rear master cylinder push rod»to-master piston 0.10 g (0.004 02) contacting area 7' l Rear master cylinder boot push rod fitting area 0.10 g (0 004 oz) Front brake caliper pin sliding area 7” '_ 0.4 g (001 oi) Front brake caliper Bracket pin sliding area 77 0.4 g (001 oz) rRear brake caliper pin bolt sliding area 0 4 g (0 01 02) i Rear brake caliper sleevesliding area 7 0.4 g (0.01 oz) (inside of boot) Brake caliper dust seal 7 ‘ Brake caliper pad pin stopper ring 7 iDOT4 brake fluid > Brake master piston and cups 7 7 7 _ V Rear master cylinder hose Joint Orring r N i l Brake caliper fion seal 77 7 i fBrake caliper piston outer surface I ‘FBrake pipe Joint nutflads (cafiEOORA/c’ssoomxm V Tfiiubricanr ' 1 Clutch caple inside 7 V 7 Vi ‘ Seat opener cable instde i Pro Honda Suspensmn Fluid fork all seal lips V 7 i ss-a (10W) F Fork dust seal lips ' fl 1 (7 V V Fork cap Orrifl ” 7 if i 7 l Honda Bond A or Honda Left handlebargrip inner surface ‘ Ha‘nd Grip Cement (U SA. Brake pad retainer Qing surface 7 V V m 7 fl “A w on y . Pro Honda HP Chain Lube or i Drive chain entire surface, an equivalent High strength locking agent Final driven sprocket stud boltThTeads (driven flange side) (LOCTITE 638 manufactured by LOCTlTE, TB1305N manufactured by ThreeBond ‘ or equivalent) 1-22 GENERAL |NFORMAT|ON L MATERIAT V r 77 ' LOCATION ” REMRKS 7 Medium strength locking Fork spastic“ threads agent (TB1322N hRfieEr master pylmder hosepinlgfiew thregds 7 f 1 i V r r mamfacmre‘j by ThVeEBondv Front brake cahper pm threads 7 i r 7 ‘ LOCTITE 648 manufactured ‘ Coolin fan nut threads L 7b)! LOCICI'E or equjvalent) g V 1 -23 GENERAL INFORMATION CABLE & HARNESS ROUTING CBRSOORIRA HEADLIGHT 4P(B|ack) COMBINATION METER CONNECTOR 16P(Gray) CONNECTOR RIGHT TURN SIGNAL/ POSITION LIGHT 3P (LIghI blue) CONNECTOR ‘\ LEFT TURN SIGNAL/ POSITION LIGHT 3? (Orange) CONNECTOR OPTION 2P (EIack) CONNECTOR FRONT SUB-WIRE HARNESS InsIde OI mIdOIe cowl HEADLIGHT 4P (Black) POSITION LIGHT CONNECTOR . x / / TURN SIGNAL/POSITION ULB S K » B CO ET Rear sIde of headIlghI, I L‘GHT WIRE 1 -24 GENERAL INFORMATION CBRSOORIRA CBRSOOR: THROTTLE CABLES CLUTCH CABLE CLUTCH SWITCH ParaIIeI wIIh master cylinder upper surface FRONT BRAKE LIGHT SWITCH LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE 93%; ' . ,, a: RIGHT HANDLEBAR SWITCH WIRE y IGNITION SWITCH CBRSODR 1-25 GENERAL INFORMATION CBRSOOR/RA CBRSOURA THROTTLE CABLES CLUTCH CABLE CLUTCH SWITCH Parana‘ with mas‘er cyhnder upper surface FRONT BRAKE LIGHT SWITCH LEFT HANDLEBAR FRONT BRAKE HOSE SW‘TCH WIRE \GNITION SWITCH W‘ RE \ afi—w—sfi 7». ' 1 RisHT HANDLEBAR 'GN’TION SW‘TCH SWITCH W‘RE CBRSOORA FRONT BRAKE HOSE FRONT WHEEL SPEED SENSOR W‘RE v‘ \ _ \ / ,5 ,‘ FRONT WHEEL SPEED SENSOR 1-26 GENERAL INFORMATION CBRSDOR/RA RELAY BOX EOP SWITCH WIRE EOE SWITCH -_ ‘- I E "I I o SENSOR WIRE FRONT WHEEL SPEED K \ ,r a _ I' 2 SENSOR 2P IBIue) ~ CONNECTOR (CBRSDORA) o: SENSOR 4F (Black) CONNECTOR EOR SWITCH IP (WhIte) 0’ SENSOR CONNECTOR RIGHT HANDLEBAR SWITCH , 10F (Gray) CONNECTOR HEAT GUARD RUBBER FRONT WHEEL SPEED SENSOR WIRE (CBRSOORA) 1 -27 GENERAL INFORMATION CBRSOORIRA A, CM types: IGNITION SWITCH 2P (Blown) CONNECTOR FRONT SUB»W|RE HARNESS 4P (Black) CONNECTOR FRONT SUB»W|RE HARNESS 12R (B‘ack) CONNECTOR LEFT HANDLEBAR SWITCH ' , r 7 14p (Green) CONNECTOR J FAN MOTOR 2P (B‘ack) CONNECTOR FUEL TANK BREATHER HOSE V I. 97 ' . CRANKCASEBREATHERTUBE FAN MOTOR W‘RE HORN CONNECTORS FUELTANK FUEL TANK BREATHER DRAIN HOSE HOSE 1 -28 GENERAL INFORMATION CBRSODRIRA AC “'99: EVAP PURGE CONTROL IGNITION SWITCH EVAP SOLENOID VALVE—m. THROTTLE BODY HOSE 2P‘(Brown) CONNECTOR CANISTER r FRONT SUB-WIRE HARNESS / 4P (Black) CONNECTOR LEFT HANDLEEAR SW‘TCH , 14F (Green) CONNECTOR EVAP CANISTER FRONT SUBWIRE DRAIN HOSE EVAP CANISTER-IOVEVAP FAN MOTOR 2P (Black) HARNESS 12p (Black) PURGE CONTROL CONNECTOR CONNECTOR SOLENOID VALVE HOSE CRANKCASE BREATHER TUBE FAN MOTOR j' " I I RADIATOR RESERVE TANK OVERFLOW HOSE EVAP CANISTER DRAIN HOSE HORN CONNECTORS FUEL TANK EVAP CANISTER DRAIN HOSE DRAIN HOSE 1 -29 GENERAL INFORMATION CBRSOOR/RA FUEL PUMP 3P (BIack) CONNECTOR SIDESTAND SWITCH 2P (Green) CONNECTOR CKP SENSOR 2P (Red) CONNECTORHV REGULATOR/RECTIFIER 3P (Black) CONNECTOR FUEL TANK BREATHER HOSE (A. CM types) ALTERNATOR ‘ ' 3P (Gray) SENSOR UNIT CONNECTOR 5P (BIack) CONNECTOR _ i 4 REGULATOR/ . FRAMEGROUND RECTIFIER ‘ POINT NEUTRALl SWITCH SIDESTAND SWITCH WIRE DRIVE SPROCKET COVER ALTERNATOR/ WATER PUMP-TO-CYLINDER CKP SENSOR WIRE BLOCK HOSE BYPASS HOSE SIDESTAND SWITCH 1-30 GENERAL INFORMATION CBRSDORIRA REAR BRAKE LIGHT SWITCH WIRE REAR WHEEL SPEED SENSOR WIRE (CBRSOORA) REAR WHEEL SPEED SENSOR 2P (Gray) CONNECTOR (CBRSDORA) S'PHON HOSE REAR BRAKE LIGHT SWITCH 2? (Black) CONNECTOR MAIN FUSE CLUTCH CABLE FUEL TANK DRAIN HOSE ALTERNATOR/ SIPHDN HOSE CKP SENSOR WIRE I I SIDESTAND SWITCH WIRE RAD IATO R RADIATOR SSEEREIIEVIIANK RESERVE TANK UNDER HOSE OVERFLOW EVAP CANISTER COWL FUEL TANK HOSE DRAIN HOSE BREATHER HOSE FUEL TANK FUEL TANK DRAIN HOSE DRAIN HOSE 1-31 GENERAL INFORMATION CBRSODR/RA A, CM cypes: FUEL TANK BREATHER HOSE (Paint dot; facing from sxde) FUEL PUMP 3P (Black) CONNECTOR FUEL TANK DRAIN HOSE FUEL FEED HOSE 1 -32 GENERAL INFORMATION CBRSDORIRA AC type: FUELTANK-lo-EVAP CAN‘STER HOSE \ \ FUEL PUMP 3P (Black) (Pam! dot; (acmg from side) CONNECTOR FUEL TANK DRNN HOSE FUEL FEED HOSE PATR CONTROL FUEL TANK~to-EVAF SOLENO'D VALVE CANTSTER HOSE EVAP FURGE CONTROL SOLENOLD VALVErmr THROTTLE BODY HOSE EVAP CANISTER-lo- EVAP PURGE CONTROL SOLENOID VALVE HOSE EVAP CANISTER 1 -33 GENERAL INFORMATION CBRSOORIRA PAIR CONTROL SOLENOWD VALVE 2P (mack) CONNECTOR EVAP PURGE CONTROL SOLENO‘D VALVE-(o- THROTTLE BODY HOSE (A0 type) SECONDARY AIR SUPPLY HOSE FUEL PUMP 3P (Black) FUEL FEED HOSE CONNECTOR 1 -34 GENERAL INFORMATION CBRSDORIRA SECONDARY AIR SUPPLY HOSE SPARK PLUG WIRES EVAP PURGE CONTROL SOLENOID VALVEVID» THRO‘ITLE BODY HOSE (A0 type) SECONDARY AIR SUPPLV HOSE N0. 1 FUEL INJECTOR / 2P (Gray) CONNECTOR I No, 2 IGNITION COIL (Yellow/blue) IACV 4P (BIack) CONNECTOR No, 2 FUEL INJECTOR 4 . > 2P (Gray) CONNECTOR THROTTLE CABLES CRANKCASE BREATHER HOSE 1-35 GENERAL INFORMATION CBRSOORIRA Behind steering head pipe (viewed lrom rear side): EVAP PURGE CONTROL TURN S‘GNAL/HAZARD RELAV SOLENOID VALVE 2P (Black) 4}: (WW) CONNECTOR CONNECTOR (AC type) \ éANK ANGLE SENSOR \ 2 (Black) CONNECTOR EVAP PURGE CONTROL SOLENO‘D VALVE (AC type) BANK ANGLE SENSOR From heat guard rubber semng points: FLAFS (Pull down Lhrough slils) HEAT GUARD RUBBER ’ 1 /‘ 1-36 GENERAL INFORMATION CBRSOORIRA ENGINE SUBVWIRE HARNESS 6P (BIack) CONNECTOR CRANKCASE BREATHER TUBE ECT SENSOR 2P (BIack) ‘ CONNECTOR ENGINE SUB- WIRE HARNESS ‘ VS SENSOR 3P (BIackJ CONNECTOR VS SENSOR "7“ 30“ BRAKE PIPE A (caRsooRA; me master I clenderrlo-ABS moduIanr) BRAKE PIPE B (CBR5DORA, ABS Inside <— modulator»to-front brake caliper) 1-37 GENERAL INFORMATION CBRSDORIRA Rear heal guard rubber setting pomls' BRAKE PIPES (CBRSODRA) HEAT GUARD RUBBER FUEL TANK DRA‘N HOSE SIPHON HOSE HOSE GUIDE RUBBER HOLE Route through slits) BA‘I'FERY 2T STARTER MOTOR CABLE REAR FENDER a mag? REAR FENDER 3 (Route through 5m) HEAT GUARD RUBBER (Do not msen rubber In between gfigffié rear cowl and seat rail pipe) 1-38 GENERAL INFORMATION CBR500RIRA REAR BRAKE LIGHT CBRSOOR: REAR MASTER CYLINDER SW'TCH W'RE RESERVOIR HOSE REAR BRAKE L‘GHT SWITCH BRAKE HOSE 1 -39 GENERAL INFORMATION CBRSOORIRA BRAKE PIPE B (To front brake caliper) CBRSOORA: BRAKE P‘PE A (From lronl master cyllnder) ABS MODULATOR 1BP (Black) BRAKE HOSES CONNECTOR ABS MODULATOR REAR WHEEL SPEED SENSOR WIRE REAR BRAKE LIGHT CBRSOORA: SWITCH W‘RE REAR WHEEL SPEED SENSOR 1-40 GENERAL INFORMATION CBRSOORIRA (CBRSOORA only) OPTION 2P CONNECTOR DLC (CBRSOORA shown) FUSE BOXZ \ BATTERY FUSE BOX 1 CONNECTORS (From upper swde): cup 'R\GHT TURN SWGNAL LIGHT 2P (Lighl blue) - LEFT TURN S‘GNAL LIGHT 2P (Orange) ' LICENSE LIGHT 2P (While) ' BRAKE/TAILLIGHT 3? (White) 1-41 GENERAL INFORMATION CBSOOF/FA COMBINATION METER 16F (Gray) CONNECTOR OPTION 2P (BIack) CONNECTOR RIGHT TURN SIGNAL/POSITION LIGHT 3P (ngm blue) CONNECTOR ‘ x \ A? L,, r . POSITION LIGHT 2P (BIack) CONNECTOR HEADLIGHT 3p (BIack) FRONT SUBWRE CONNECTOR HARNESS 1-42 GENERAL INFORMATION CESOOFIFA CBSOOF: RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE j LIGHT SWITCH THROTTLE I CABLES II / SWITCH WIRE I IGNITION SWITCH WIRE IGNITION SWITCH FRONT BRAKE HOSE 1-43 GENERAL INFORMATION CBSOOFIFA CESDOFA: RIGHT HANDLEBAR SWITCH WIRE \ ‘ ~ CLUTCH SWITCH , a /‘ \ ,A\ I \x \\ CLUTCHCABLE ‘I I I \ I FRONT BRAKE I LIGHT SWITCH ‘ \ _ LEFT HANDLEBAR THROTTLE g‘I " a u‘ I I SWITCH WIRE CABLES _ ‘ I I / IGNITION SWITCH WIRE Li I if IL (I 3 ‘ , FRONT BRAKE HOSE IGNITION SWITCH 1 -44 GENERAL INFORMATION CBSODFIFA CE5OOF: CBSDOFA: FRONT BRAKE HOSE FRONT WHEEL. SPEED SENSOR WIRE (0.4m) / ma; 1-45 GENERAL INFORMATION CBSUOFIFA R BOX SIPHON HOSE ELAY EDP SWITCH WIRE EOP SWITCH '_ I I ' " OzSENSOR WIRE FRONT WHEEL SPEED \\ SENSOR 2P (BIue) ~ CONNECTOR (CBSOOFA) X Oz SENSORAP (BIack) CONNECTOR 02 SENSOR EOP SWITCH 1P(Wmle) CONNECTOR RIGHT HANDLEBAR SWITCH , 10R (Gray) CONNECTOR HEAT GUARD RUBBER FRONT WHEEL SPEED SENSOR WIRE (CBSODFA) 1-46 GENERAL INFORMATION CBSOOFIFA . FRONT SUB-WIRE HARNESS A' CM wpes' 12F (Black) CONNECTOR IGNITION SWTTCH 2P (Brown) CONNECTOR FRONT SUB-W‘RE HARNESS 4P (Black) CONNECTOR LEFT HANDLEBAR SWITCH 14F (Green) CONNECTOR FAN MOTOR 2P (mack) CONNECTOR FUEL TANK BREATHER HOSE CRANKCASE BREATHER TUBE FAN MOTOR WIRE Fronl / i ‘ T“ RADIATOR v RESERVETANK ‘ OVERFLOW “ HOSE HORN CONNECTORS FUELTANK FléiJLNTfigK BREATHER D SE HOSE 1-47 GENERAL INFORMATION CBSDOFIFA AC ‘VFE‘ FRONT SUBVWIRE HARNESS EVAP PURGE CONTROL TZP (Black) CONNECTOR EVAP SOLENOID VALVE»on CANISTER THROTTLE BODY HOSE FRONT SUB-WIRE HARNESS 4P (BIack) CONNECTOR LEFT HANDLEBAR SWITCH 14F (Green) CONNECTOR [GNmON SW‘TCH :gfi'zfévggOR EVAP CANISTER FAN MOTOR 2P (EIack) DRAIN HOSE EXQEEQNgiEEE‘LOEEV/‘p CONNECTOR SOLENOID VALVE HOSE CRANKCASE BREATHER TUBE FAN MOTOR WIRE EVAP CANISTER L DRAIN HOSE RADIATOR RESERVE TANK [5- OVERFLOW HOSE '\ EVAP CANISTER DRAIN HOSE HORN CONNECTORS FUEL TANK EVAP CANISTER DRAW HOSE DRAIN HOSE 1-48 GENERAL INFORMATION CBSOOF/FA FUEL PUMP 3P (Black) CONNECTOR SIDESTAND SWITCH 2? (Green) CONNECTOR CKP SENSORZP (Red) CONNECTOR“ REGULATOR/RECTIFIER 3P (BIack) CONNECTOR —> Inside FUEL TANK BREATHER HOSE (A, CM types) ALTERNATOR 3P (Gray) SENSOR UNIT CONNECTOR 5P (Black) CONNECTOR 7“ r , r , GULATOR/ ‘ FRAMEGROUND RECTIFIER I POINT NEUTRAL. SWITCH SIDESTAND SWITCH WIRE DRIVE SPROCKET COVER ALTERNATOR/ WATER PUMP-TO-CYLINDER CKF SENSOR WIRE BLOCK HOSE BVPASS HOSE Inside 4— SIDESTAND SWITCH 1-49 GENERAL INFORMATION CBsOOF/FA REAR BRAKE LIGHT SWITCH WIRE REAR WHEEL SPEED SENSOR WIRE (CBSOOFA) REAR WHEEL SPEED SENSOR 2P (Gray) CONNECTOR (CBSOOFA) S‘PHON HOSE REAR BRAKE LIGHT SWITCH 2P (BIack) CONNECTOR ' CLUTCH AK Ki CABLE M STARTER ‘ ‘ RELAv I I _ SWITCH I I ’ » ' , TEwfi FUEL TANK DRAIN HOSE / EWNJ ALTERNATOR/ \ SIPHON CKP SENSOR WIRE / ‘III ’ I I SIDESTAND WITCHWIRE \ S )JM - I SIFHON HOSE RADIATOR OVERFLOW Hose FUEL TANK OVERFLOW EVAF’CANISTER COWL HOSE DRAIN HOSE BREATHER HOSE FUEL TANK FUEL TANK DRAIN HOSE DRAIN HOSE 1 -50 GENERAL INFORMATION CBSOOFIFA A, CM types: FUEL TANK EREATHER HOSE (Pain! dot: facmg from Slde) FUEL PUMP 3P (Black) CONNECTOR FUEL TANK DRAW HOSE FUEL PUMP UNIT FUEL FEED HOSE 1-51 GENERAL INFORMATION CBSOOFIFA AC type: FUELTANK-lo-EVAF’ (Paintdotfaclnglrontsxde) ‘ y I ’ i -_ ‘ - FUEL PUMP 3P (Black) ' ‘ CONNECTOR FUEL TANK DRAIN HOSE FUEL FEED HOSE PA‘R CONTROL FUEL TANK-to-EVAP SOLENOID VALVE CANISTER HOSE EVAP PURGE CONTROL ' SOLENOID VALVE-I07 THROTTLE BODY HOSE EVAP CANISTER-tn- EVAP PURSE CONTROL SOLENOID VALVE HOSE EVAP CANISTER 1 -52 GENERAL INFORMATION CBSDOF/FA PATR CONTROL SOLENOID VALVE 2P (Black) CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE’IO- THROTTLE BODY HOSE (Ac type) SECONDARY AIR SUPPLY HOSE FUEL FEED HOSE FUEL PUMP 3F (Black) CONNECTOR 1 1-53 GENERAL INFORMATION CBSOOFIFA SECONDARY AIR SUPPLY HOSE SPARK PLUG WIRES EVAF' PURGE CONTROL SOLENOID VALVE-Io- THROTTLE BODY HOSE (AC type) Na 1 IGNITION COIL (BIue/yellow) SECONDARY AIR SUPPLY HOSE r TURN SIGNAL/ W HAZARD RELAY No 1 FUEL INJECTOR 2R (Gray) CONNECTOR No 2 IGNITION M COIL ‘ (Yellow/blue) C r 9 I , I No 2 FUEL INJECTOR I " v I CLUTCH CABLE 2P Ieray) CONNECTOR r ' ' THROTTLE CABLES CRANKCASE BREATHER HOSE 1 -54 ix GENERAL INFORMATION CBSDOFIFA ENGINE SUB-WIRE HARNESS 5P (Black) CONNECTOR CRANKCASE BREATHER TUBE CLEANER HOUSING ECT SENSOR 2P (BIack) CONNECTOR ENGINE SUB- WIRE HARNESS ENGINE GROUND POINT VS SENSOR 3P (BIack) CONNECTOR BRAKE PIPE A (CBSOOFA; From master cyImder-to-ABS modulator) 45V BRAKE PIPE B (CBSDOFA; ABS |n5Ide «— ‘\_ maduIator—Io-lrom brake cahper) 1 -56 GENERAL INFORMATION CBSOOFIFA Rear heat guard rubber setting polnts‘ BRAKE P‘PES (CBRsooRA) FUEL TANK HEAT GUARD RUBBER DRAIN HOSE S‘PHON HOSE HOSE GUTDE RUBBER HOLE WIRES (Rome through slits) BATTERY RUBBER STARTER MOTOR CABLE REAR FENDER B MQENNEVSE REAR FENDER 5 (Rome through 5m HEAT GUARD RUBBER (Do nok Insen rubber m between 335;: rear cowl and seat rail pipe) 1-57 GENERAL INFORMATION CBSOOFIFA REAR BRAKE LIGHT REAR MASTER CYLINDER SW‘TCH W'RE RESERVOIR HOSE CB500F: LIGHT SWITCH BRAKE HOSE 1-58 GENERAL INFORMATION CBSDOFIFA BRAKE FIFE a (To from brake callper) CBSDDFA: BRAKE PWPE A (From from mas‘er cylmder) ABS MODULATOR 18F (Black) / BRAKE HOSES CONNECTOR ABS MODULATOR REAR WHEEL SPEED SENSOR W‘RE REAR BRAKE L‘GHT CBSOOFA. SWITCH WIRE REAR WHEEL SPEED SENSOR 1 -59 w GENERAL INFORMATION CBSODFIFA OPTION ZP CONNECTOR (CBSDOFA only) DLC SEAT OPENER CABLE FUSE BOX 1 CBSDOFA shown) ( FUSE BOX 2 BATTERY )» CLIP CONNECTORS (From upper Slde RIGHT TURN SIGNAL LIGHT 2P - LEFT TURN SIGNAL LIGHT 2P (Orange) ' LICENSE LIGHT 2P (White) LIght blue) ( 'BRAKE/TAILLIGHT 3P (While) SEAT OPENER CABLE 1-60 GENERAL INFORMATION CBSOOXIXA COMBINATION METER 1GP (Gray) CONNECTOR POSITION LIGHT 2P (Black) CONNECTOR kw CONNECTORS v RIGHT TURN SIGNAL/ POSITION LIGHT 3P (LIghI que) CONNECTOR K OPTION 3P (EIack) CONNECTOR \ \ \ ‘ \ LEFT TURN SIGNAL! POSITION LIGHT 3P (Orange) CONNECTOR HEADLIGHT FRONT SUBVWIRE HARNESS HEADLIGHT 3P (Black) CONNECTOR 1-61 GENERAL INFORMATION CBSOOXIXA CBSOOX FRONT BRAKE I LIGHT SWITCH RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLES FRONT BRAKE I I HOSE IGNITION SWITCH CLUTCT‘I SWITCH CLUTCH CABLE IGNITION SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE 1 -62 GENERAL INFORMATION CBSOOXIXA CBSOOXA‘ CLUTCH SWITCH FRONT BRAKE LIGHT SWITCH CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE THROTTLE CABLES I I ' . > ‘ fi "' " ‘ LEFT HANDLEEAR I ‘ ’ ‘ VI SWITCH WIRE v I ‘ . J FRONTBRAKE ’ W 12. ,, "7 , HOSE ‘ " ‘ I I I I IGNITION SWITCH 1-63 GENERAL INFORMATION CBSOOX/XA CBSUOX. CBSOUXA FRONT BRAKE HOSE L FRONT WHEEL SPEED SENSOR WIRE FRONT WHEEL SPEED SENSOR 1 -64 GENERAL INFORMATION CBsooxIXA EDP SWITCH WIRE EOP SWITCH FRONT WHEEL SPEED ‘\ SENSOR 2P (BIue) CONNECTOR (CBSOOXA) 02 SENSOR 4P (Black) CONNECTOR EOP SWITCH 1P (WhIIe) 02 SENSOR CONNECTOR RIGHT HANDLEBAR SWITCH TOP (Gray) CONNECTOR 1-65 GENERAL INFORMATION CBSDOXIXA A, w types: IGNITION SWITCH 2? (Brown) CONNECTOR \\ FRONT SUBVWIRE HARNESS AP (BIack) CONNECTOR LEFT HANDLEBAR SWITCH MP (Green) CONNECTOR FAN MOTOR 2F (BIack) CONNECTOR FUEL TANK BREATHER HOSE CRANKCASE BREATHER TUBE \ FAN MOTOR / (A tag» \, WIRE RADIATOR I, RESERVE TANK I OVERFLOW ‘HOSE HORN CONNECTORS FUEL TANK FUEL TANK BREATHER DRAIN HOSE HOSE 1-66 GENERAL INFORMATION CBsonXIXA Ac type: EVAP PURGE CONTROL FRONT SUB-WIRE EVAP SOLENOID VALVE»to- HARNESS IZP (Black) CANISTER THROTTLE BODY HOSE CONNECTOR FRONT SUBVWIRE HARNESS 4P (Black) CONNECTOR \_ \ T VAC/r» 2P (Brown) LEFT HANDLEBAR SWITCH CONNECTOR MP (Green) CONNECTOR EVAP CANISTER DRAIN HOSE EVAPCANISTERrIo-EVAP FAN MOTOR 2P (mack) PURGE CONTROL CONNECTOR SOLENOID VALVE HOSE CRANKCASE BREATHER TUBE FAN MOTOR ' WIRE RADIATOR RESERVE TANK ‘ OVERFLOW HOSE EVAP CANISTER DRAIN HOSE HORN CONNECTORS FUEL TANK EVAP CANISTER DRAIN HOSE DRAIN HOSE 1 -67 GENERAL INFORMATION CBSDOXIXA FUEL PUMP 3P (Black) CONNECTOR SIDESTAND SWITCH 2P (Green) CONNECTOR CKP SENSOR 2P (Red) REGULATOR/RECTIFIER 3P (Black) CONNECTOR —> InsIde FUEL TANK BREATHER HOSE (A, CM Iypes) ALTERNATOR ’ 3P (Gray) SENSOR UNIT 5,, (mack) fl 7 J CONNECTOR CONNECTOR I REGULATOR/ FRAMEGROUND RECTIFIER ‘ POINT SIDESTAND SWITCH WIRE . . ' / DRIVE SPROCKET COVER / ALTERNATOR/ WATER PUMPVTOVCYLINDER CKp SENSOR WIRE BLOCK HOSE BYPASS HOSE [SWITCH WIRE SIDESTAND SWITCH 1 -68 GENERAL INFORMATION CBSDDX/XA REAR BRAKE LIGHT SWITCH WIRE REAR WHEEL SPEED SENSOR WIRE (CBSOOXA) REAR WHEEL SPEED SENSOR 2P (Gray) CONNECTOR (CBSODXA) S'PHON HOSE REAR BRAKE LIGHT SWITCH 2P (Black) CONNECTOR MAIN FUSE CLUTCH CABLE STARTER - FUEL TANK RELAY DRAIN HOSE SWITCH \_ ALTERNATOR/ CKP SENSOR WIRE .r I I II \ ‘ SIDESTAND _ HI SWITCH WIRE RADIATOR RADIATOR CRJE/EEFEXSWANK RESERVE TANK UNDER HOSE FUEL TANK OVERFLOW EVAP CANISTER COWL HOSE DRAIN HOSE BREATHER HOSE FUEL TANK FUEL TANK DRAIN HOSE DRAIN HOSE 1 -69 GENERAL INFORMATION CESOOXIXA A, CM types: FUEL TANK BREATHER HOSE (Palm dot: «acmg front swde) FUEL PUMP 3P (Black) CONNECTOR \ \ FUEL PUMP UNIT / , W / \\ FUEL FEED HOSE 1-70 GENERAL INFORMATION CBSODXIXA AC type: FUELTANK-lo-EVAP CANISTER HOSE (Paint dot facan front Slde) FUEL PUMP 3P (B‘ack) CONNECTOR FUEL FEED HOSE PAIR CONTROL FUEL TANK—(mEVAP SOLENO‘D VALVE CANISTER HOSE EVAP PURSE CONTROL SOLENO‘D VALVE-lo- THROTTLE BODY HOSE EVAP CANISTEFHOV EVAP PURSE CONTROL SOLENO‘D VALVE HOSE EVAP CANISTER 1-71 GENERAL INFORMATION CBSOOXIXA PAIR CONTROL SOLENOID VALVE 2P (Black) CONNECTOR EVAP PURGE CONTROL \7 SOLENOID VALVE-(O- / THROTTLE BODY HOSE ' (AC type) SECONDARVAIR SUPPLY HOSE FUEL PUMP 3P (Black) FUEL FEED HOSE CONNECTOR 1-72 GENERAL INFORMATION CBSOOX/XA SECONDARY AIR SUPPLY HOSE SPARK PLUG WIRES EVAP PURGE CONTROL SOLENOID VALVE-t0- THROTTLE BODY HOSE (AC Iype) No 1 IGNITION COIL SECONDARY AIR SUPPLV HOSE No.1 FUEL INJECTOR 2F (Gray) CONNECTOR { Na. 2 IGNITION COIL (Yellow/blue) IACV 4P (Black) CONNECTOR ND 2 FUEL INJECTOR 2P (Gray) CONNECTOR THROTTLE CRANKCASE CABLES BREATHER HOSE 1-73 GENERAL INFORMATION CBSOOXIXA Behind steering head pxpe (wewed from rear sxde): EVAP PURSE CONTROL SOLENOID VALVE 2P (Black) CONNECTOR (AC type) TURN STONAL/HAZARD RELAY 4P (Wmte) CONNECTOR EANK ANGLE SENSOR _ 2P (Black) CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE (AC type) BANK ANGLE SENSOR From heat guard rubber semng pomts: FLAPS (PuH down through slits) TABS HEAT GUARD RUBBER 1 -74 GENERAL INFORMATION cssooxmx ENGINE SUBEWIRE HARNESS 6P (Black) CONNECTOR CRANKCASE BREATHER TUBE CLBXNER I HOUSING ‘ ECT SENSOR 2P (Black) CONNECTOR ENGINE SUB» WIRE HARNESS ENGINE GROUND POINT vs SENSOR 3P (Black) CONNECTOR RY (—) CABLE BRAKE PIPE A (CBSOOXA; Front master clender-to-ABS moduIanr) \_ BRAKE PIPE B (CBSODXA‘ ABS Ins‘de ‘— , ' " ' \ modulanr-Io-Iront brake cahper) 1-75 GENERALINFORMANON CBSODXIXA Rear heal guard rubber semng poms: BRAKE P‘PES (CBRSOORA) FUEL TANK DRAIN HOSE HEAT GUARD RUBBER S‘PHON HOSE BATTERY (E) CABLE HEAT GUARD RUBBER (1 5 fl (Viewed from rear swde) I STARTER MOTOR CABLE REAR FENDER E MAIN W‘RE REAR FENDER B (Rome through slit) HARNESS HEAT GUARD RUBBER (Do not insert rubber m befiween rear cow‘ and seat raH pipe) BATTERY m CABLE 1-76 GENERAL INFORMATION CBSDDXIXA REAR BRAKE L‘GHT casuux, REAR MASTER CYLINDER SW‘TCH W‘RE RESERVOIR HOSE 1-77 GENERAL INFORMATION CBSDOXIXA BRAKE PIPE B (To from brake caliper) CBSOOXA: BRAKE PIPE A (From from masker cyhnder) ABS MODULATOR 18F (Black) /’ BRAKE HOSES CONNECTOR ABS MODULATOR REARWHEELSPEED SENSOR WIRE REAR BRAKE LIGHT CBSODXA: SWITCH WIRE \\ \\ REAR MASTER CYLINDER RESERVOIR HOSE REAR BRAKE LIGHT SWITCH REAR WHEEL SPEED SENSOR 1-78 GENERAL INFORMATION CBSODXIXA (CBSOOXA only) OFTLON 2P CONNECTOR DLC (CBSODXA shown) FUSE BOX 2 BATTE RY SEAT OPENER CABLE FUSE BOX 1 CONNECTORS (From upper side): cup - RIGHT TURN S\GNAL LIGHT 2P (Lighl blue) - LEFT TURN SKSNAL LIGHT 2P (Orange) A LICENSE LIGHT 2P (While) . BRAKE/TAILUGHT 3P (White) SEAT OPENER CABLE 1 -79 GENERAL INFORMATION EMISSION CONTROL SYSTEMS EXHAUST EMISSION REQUIREMENT The U.S. Environmental Protection Agency (EPA). Calilornia Air Resources Board (CARE) and Transport Canada require manuIacturers to certify that their motorcycles comply With applicable exhaust emissions standards during their uselul life, when operated and maintained according to the instructions provided, NOISE EMISSION REQUIREMENT The EPA also requires that motorcycle built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3730 miles) after the time at sale to the ultimate purchaser, when operated and maintained according to the instructions provided. WARRANTY COMPLIANCE Compliance with the terms oi the Distributors Limited 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 (CO). oxides of nitrogen (NOx) and hydrocarbons (H0), The control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions they react to form photochemical smog when subyect to sunlight, Carbon monoxide does not react in the same way, but it is IOXIC. Uncontrolled fuel evaporation also releases hydrocarbons to the atmosphere. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides oi nitrogen and hydrocarbons, CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere, Blow»by gas is returned to the combustion chamber through the crankcase breather hose [1] air cleaner housing [2] and throttle body [3], [2] \ I <:i Fresh Air 4—— Blow-by Gas 1-80 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed ot a pulse secondary air supply system, 3-way catalytic converter and PGM»FI system, SECONDARY AIR SUPPLY SYSTEM The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port [1]. Fresh air is drawn into the exhaust port by the Iunction of the PAIR control solenoid valve [2]. This charge oI fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor, The PAlR check valve [3] prevents reverse alrflow through the system, The PAIR control solenoid valve is controlled by the PGM- Fl unit. and the fresh air passage is opened/closed according to running condition (ECT/IAT/TP/MAP sensor and engine revolution). No adlustments to the secondary air supply system should be made. although periodic inspection ot the components is recommended. [2] [3] \K <: Fresh Air \l <— Exhaust Gas 3-WAY CATALYTIC CONVERTER This motorcycle is equipped With a 3-way catalytic converter. The 3»way catalytic converter is in the exhaust system. Through chemical reactions. they convert HC, CO and NOx in the engine's exhaust to carbon dioxide (COz), nitrogen (N2), and water vapor. 1-81 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (AC type) This model complies with California Air Resources Board (CARS) evaporative emission requirements. Fuel vapor from the fuel tank [1] Is routed into the EVAP canister [2] where it is absorbed and stored while the engine is stopped When the engine is running and the EVAP purge control solenoid valve [3] is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body [4] T1] ¢— Fresh Air 4— Fuel Vapor NOISE EMISSION CONTROL SYSTEM TAMPERiNG WITH THE NOlSE CONTROL SYSTEM IS PROHIBlTED: US. Federal law prohibits, or Canadian provincial law may prohibit the Iollowing acts or the causing there ot: (t) The removal or rendering inoperative by any person. other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any vehicle tor the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use, (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW, 1 Removal oi. or puncturing of the muftler, baffles. header pipes or any other component which conducts exhaust gases. 2 Removal oi, or puncturing ofany part oi the intake system 3. Lack of proper maintenance, 4. Removing or disabling any emissions compliance component, or replacing any compliance component with a non-compliant component, 1-82 GENERAL INFORMATION TECHNICAL FEATURE ECM-tO-COMBINATION METER TWO-WAY SERIAL COMMUNICATION This motorcycle is equipped with a ECM-to-commnation meter twovway serial communication system. The ECM sends the iollowing Information to the combination meter. 7 High coolant temperature indicator signal 7 Engine oil pressure Indicator signal 4 Engine speed Signal 7 MIL signal 7 Fuel pulse signal (for fuel mileage meter) The combination meter sends the vehicle speed signal inIormation to the ECM These signals are communicated between the ECM and combination meter via one Wire This Wire is called the serial communication (TXD/RXD) line. COMBINATION METER SERIAL COMMUNICATION LINE ’ ECT SENSOR — vs SENSOR 9,7 To COMBINATION MErER- _,_ 7 High coolant temperature indicator signai F 7 Engine oil pressure indlcator signai 7 Engine speed signal 7 MIL signal v 7 Fuel pulse signal C . . EOP SENSOR E M To ECM, 7 vs sensor signal l V.— r be FKPSENSOR COMBINATION METER INDICATION WHEN THE SERIAL COMMUNICATION LINE IS ABNORMAL II there is any problem In the serial communication line the combination A Ac‘ h f ’7 7 meter will show all of the following ‘ - Wes 5 Own- ‘ 7 MIL [1] and engine oil pressure indicator [2] stay on [2] [ll [5] r tachometer [3] does not operate (though the engine is running) I r Odometer, tripmeter or fuel mileage meter [4] indicates "7" (while the engine is running) 7 high coolant temperature Indicator [5] does not come on (except for the i initial operation) I I Serial communication line troubleshooting (page 21-11) ll there Is any problem in the serial communication, the ECM stores the ‘ DTC 86-1 (page 4-6) ‘ L (All indicators and segments displayed) 1-83 MEMO 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION --------------------------- --2-2 TROUBLESHOOTING ................................. ..2_2 BODY PANEL LOCATIONS! REMOVAL CHART ...................................... ..2_3 SEAT ............................................................ ..2_6 SIDE COVER“ ---2-7 M|DDLE COWL ........................................... ..2_3 BULB MAINTENANCE LID (CB5oox/XA) ............................................. ..2_1o REARVIEW MIRROR -------------------- -- .2_11 METER PANEL (CBR500RIRA/CBSOOX/XA)"- ----------- "2-11 FRONT COWL ........................................... ..2_13 WINDSCREEN (CBRSOUR/RAICBSOOX/XA) ----------------- "2-16 GRAB RA|L ............................. .. REAR COWL ............................................. “245 REAR FENDER COVER ........................... "2,20 REAR FENDER A ..................................... “no REAR FENDER B ..................................... "2.21 FRONT FENDER ....................................... ..2_22 UNDER COWL .......................................... "242 DRIVE SPROCKET COVER...............,.......2.24 DRIVE CHAIN COVER .............................. ..2_24 ABS MODULATOR COVER (CBRSOORAICBSOOFAIXA) ---------------------- --2-25 FUEL TANK UNDER TRAY ---------------------- --2.25 SIDESTAND 2-26 FOOTPEG BRACKET ............................... ..2_27 MUFFLER .................................................. "2.28 EXHAUST PIPE ---2.29 SEAT RAIL ................................................ “no 2-1 FRAMBBODYPANEL$EXHAUSTSYSTEM SERVICE INFORMATION GENERAL This section covers removal and installation of the body panels and exhaust system When disassembling, mark and store the mounting fasteners to ensure that they are reinstalled in their original locations. When installing the covers make sure the mating areas are aligned properly before tightening the fasteners. Always replace the gaskets with new ones after removing the exhaust system. When installing the exhaust system loosely Install all of the fasteners. Always tighten the exhaust pipe joint nuts first, then tighten the mounting bolt ~ Always inspect the exhaust system for leaks after installation TROUBLESHOOTING Excessive exhaust noise - Broken exhaust system - Exhaust gas leak Poor performance - Deformed exhaust system - Exhaust gas leak - Clogged muffler FRAM EIBODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS/REMOVAL CHART CBRSOORIRA (8) (15) (1) Rear Seal (page 2-6) (8) Windscreen (page 2716) (15) Under Cowl (page 2-22) (2) Front Seal (page 2-6) (9) Grab Rai) (page 2-17) (16) Drive Sprocket Cover (page 2724) (3) Side Cover (page 2-7) (10) Rear Cowl (page 248) (17) Drive Chain Cover (page 2724) (4) Middle Cowl (page 2—8) (11) Rear Fender Cover (page 2720) (18)‘ ABS Modulator Cover (page 225) (5) Rearvrew error (page 2-11) (12) Rear FenderA (page 2-20) (19) Fuel Tank Under Tray (page 2725) (6) Meler Panel (page 2-11) (13) Rear Fender B (page 2-21) (7) Fronl Cowl (page 2-13) (14) Front Fender (page 2722) ‘ CBRSDORA on)y - This chart shows removal order ol frame covers by means of arrow ) (2)FronlSeat H (1)Rear8eat )——|7 (9)GrabRail _) ) (3) Srde Cover (10) Rear cdwl 1 [‘(1 1) Rear Fender Cover I i ‘fi r f (4) M1dd)e Cowl )Ieli (15) Under Cowl J (12) Rear Fender A 1 (6) Meter Pane) H (5) Rearvlew Mrrror ) f ()3) Rear Fender B ) ) (7) Front Cowl (a) Windscreen J FRAME/BODY PANELS/EXHAUST SYSTEM CBSOOF/FA (11) 1) Rear Seat (page 2-5) 2) Front Seal (page 2-6) 3) 3m Cover (page 2-7) 4) Middle Cowl (page 29) 5) From Cowl (page 243) 5) ( ( ( ( ( ( Grab Rail (page 2-17) (13) Rear Cowl (page 2-17) Rear Fender Cover (page 2-20) Rear Fender A (page 2-20) ) Rear Fender B (page 221) )Rearvuew Mirror (page 2»11) (7 (8 (9 (1 (1 (1 ) Front Fender (page 222) J ) ) 0 1 2 ~ This chart shows removal order of frame covers by means of arrow | (2) From ISeat (‘1‘ (1) Rear Seal l (13) Under Cowl (page 2-23) (14) Drive Sprockel Cover (page 2-24) (15) Drrve Chain Cover (page 2-24) (16)' ABS Modulator Cover (page 2725) (17) Fuel Tank Under Tray (page 2-25) ‘ CBSOUFA only E (3) Slde Cover I ( (6) Gran Ran J l (8) Rear Fender Cover ( ( (4) Mrdd'le Cowl ( L r (7) Rear Cowl H v (9) Rear Fender A (5) Front Cowl (10) Rear Fender B 2-4 FRAM E/BODY PANELS/EXHAUST SYSTEM CBSOOX/XA (2) (18)' (17) (15) 1) Seal (page 276) 2) Srde Cover (page 2-7) 3) Middle Cowl (page 2-9) ( ( Grab Rall (page 2-17) 5) Under Cowl (page 2—23) ( ( ( ( (4) Bulb Maintenance Lid (page 240) ( ( ( ( ( ( ( ) (1 ) Rear Cowl (page 249) (16) Dnve Sprocket Cover (page 2-24) 0) Rear Fender Cover (page 2-20) (17) Dnve Chain Cover (page 2724) 1) Rear FenderA (page 2-20) (18)“ ABS Modulator Cover (page 2725) 5) Meler Panel (page 2-12) 2) Rear Fender B (page 2-21) (19) Fuel Tank Under Tray (page 2-25) 6) Wlndscreen (page 2-16) 3 7) From Cowl (page 244) A )Rean/Iew Mirror (page 2-11) B 9 .1 1 1 1 1 ) Front Fender (page 222) ' casouxA only - Thls charl shows removal order of frame covers by means of arrow. (1)5eal l (2)8IdeCover ‘ l (8)6(abRall I f(10)RearFenderCover ‘ r l [ (3)Mlddle0pwl J I (9)RearCowl H (11)RearFenderA l l l F (5)MelerPanel H (4)BuleaintenanceLid ‘ ( (12)RearFenderB l (7) Front Cowl 2-5 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION CBRSDORIRA/CBSDOF/FA: REAR SEAT Unhook the seat with the ignition key Remove the rear seat [1] by pulling it rearward. Install the rear seat by inserting the prongs [2] under the frame Push down the rear of the seat securely tn luck it CBRSODR/RA/CBSODF/FA: FRONT SEAT Remove the rear seat (page 276), Remove the two socket bolts [‘l] and collars [2], Remove the front seat [3] by pulling it rearward. Install the front seat by inserting the prong [4] into the seat retainer. install the socket bolts With the collars and tighten them. CBSDOX/XA Unhook the seat with the ignition key. Slide the seat [1] rearward and remove it. Install the seat while aligning the groove [2] with the l stopperon the fuel tank, and insert the prongs [3] under the frame Push down the rear of the seat securely to lock it, FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER REMOVAL/INSTALLATION CBR5OORIRNCB5OOFIFA Remove the tram seat (page 2-6). lER'SIW/ni' Remove the lollowtng: l J V W ‘ _ mm 0le (pin head) [1] ‘ _ socket bolt [2] ‘ Release the two grommets from the bosses [3] of the rear cowl. and the two tabs [4] from the lootpeg bracket ‘ and rear cowl ‘ Release the three bosses [5] from the grommets and ‘ remove the side cover [6]. ‘ \ lnstallatlon Is In the reverse order ol removal. NOTE - Before installan the fasteners, be sure to set the two tabs into place properly. CB500XIXA Remove the seal (page 2-6). Remove the followmg — 5 x 8 mm setting socket bolt [1] l A 6 x 22 mm socket boll [2] Release the six bosses [3] off of the grommets from the rear side, and the lower tab [4] from the iootpeg bracket to remove the stde cover [5]. NOTE - Insert the bosses in the sequence lrorn the front . side. belng careful not to dlSlOdge the grommets. and press the hook and loop faslenlng area [6] ol the cover to attach It onto the fuel tank securely. l Installation l5 in the reverse order of removal. ‘ 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM MIDDLE COWL REMOVAL/INSTALLATION CBRSOORIRA Remove the side cover (page 2-7). Remove the following: 7 two trim clips (pin head) [1] 7 socket bolt (6 x10 mm) and washer [2] 7 three setting socket bolts (two 5 x10 mm) [3] (6 x to mm) [4] Release the snap fit clip [5] by pulling it straight out of the under cowl. Release the hook and loop fastening [6]. Release the meter panel [7] and middle cowl [8] from the bolt hole stud [9] on the fuel tank Press the meter panel inward and release the SlX Side tabs [10] while spreading the middle cowl slightly, Do not hang the Release the three front tabs [1 ‘l] by turning the rear side of the middle cowl downward, then disconnect the turn cowlbythe (um signal/position light 3P connector [12}, S'gnaI/pasmnhgm lnstallation is in the reverse order of removal. NOTE: - When engaging the three front tabs. insert the bolt fixing stay [13] behind the meter panel and the trim clip fixing stay [14] into the front cowl. ' When attaching the snap fit clip, align the two lower tabs [15] with the slots in the under cowl. FRAME/BODY PANELS/EXHAUST SYSTEM Left mner panel. CBSODFIFA Remove the side cover (page 2-7). Remove the lollowmg setting socket bolts: 7 three 6 x 10 mm (black) [1] 7 6 x 10 mm (Silver) [2] 7 6 x 14 mm (black) [3] Release the hook and loop fastening [4}, and remove the middle cowl [5]. Installation is In the reverse order of removal. CBSOOXIXA Remove the side cover (page 2-7). Remove the lollowing: — trim clip (pin head) [1] ‘ 7 socket bolt (6 x 10 mm) and washer [2] 1 Release the middle cowl [3] and inner panel [4] from the ‘ boll hole slud [5] on the fuel tank. ‘ Pull the Inner panel inward while pushing il down and remove it lrom the tabs [6] of the middle cowl and meter panel. Remove the band clip {7] to remove the Inner panel. ‘ l7] (Lefl inner panel) l l l Removal ‘ ex 1 lhstallatlon Lock FRAME/BODY PANELS/EXHAUST SYSTEM Remove the following 7 trlrn Clip (Phllllps head) [1] 7 6 x 10 mm settlng socket bolt (sllver) [2] 7 two 6 x 10 rnm setting socket bolts (black) [3] Release the hook and loop fastenan [4] Release the five tabs [5] by sliding the mlddle cowl [6] forward and remove it. lnstallatron IS in the reverse order at removal NOTE - Set the front end of the Inner shroud [7] on the middle cowl onto the lnSldE ofthe front cowl Remova lnstallatmn l3] BULB MAINTENANCE LID (CB500XIXA) REMOVAL/INSTALLATION Remove the two lrtm cups (pin head) [1], [ Release the four tabs [2] and remove the bulb maintenance lld [3]. Installatlon is in the reverse order 0' removal. NOTE l - Set the two lower tabs [4] tnto the grooves in the 3 meter panel properly [1] [3] Removal lnstallatlon Lock 2-10 FRAM E/BODY PANELS/EXHAUST SYSTEM REARVIEW MIRROR REMOVAL/INSTALLATION CBRSOOR/RA Remove the two socket bolls [1] and rearview mlrror [2], r i' Installation Is tn the reverse order of removal. NOTE. - Install wtth the relerence mark [3] facmg the rear Slde. [3] TORQUE: Rearview mirror mounting socket bolt: 5.2 N-m (0.5 kgt-m, 3.5 lbf-ft) l2] CBSDOFIFA/XIXA Sllde the boot [1] off from the look nut [2]. V ’ Loosen the lock nut (left—hand threads) and remove the l rearvlew mirror [3] Remove the mlrror adaptor [A] ‘ Installation Is ltl the reverse order of removal. METER PANEL (CBR500R/RA/CB500X/X) REMOVAL/INSTALLATION CBRSODRIRA Remove the middle cowls (page 2-8). A. CM types shown' lf you plan to remove the tront cowl and wlndsoreen. you must remove the rearvtew mirrors (page 241). Remove the band Cllp [1] from the meter panel ‘ [1] Disconnect the front sub—Wire harness A? (Black) and l 12F (Black) connectors [2] Cover the front fender Wlth shop towels. Loosen the lower mountlng nut [3] of the oowl stay. ‘ Remove the upper mountan nut [4] and bolt [5], then rest the front cowl assembly [6] against the lender Positlon the lront oowl assembly so the meter panel ends [7] are not Interfered with the handlebars. FRAME/BODY PANELS/EXHAUST SYSTEM Remove the following. 7 two setting socket bolts (5 x 10 mm) [1] 7 two washers [2] 7 two rubber washers [3] Raise the front side of the meter panel [A] and release the tabs [5], Disconnect the 169 (Gray) connector [6] to remove the meter panel. Installation is in the reverse order of removal. NOTE ‘ When connecting the 16F (Gray) connector, install the connector boot into the groove in the combination meter properly. Align the three bosses [7] ol the combination meter With the grommets and engage the labs, ~ install the cowl stay mounting bolt from the right side, CBSOOXIXA Remove the lollowmg: 7 middle cowls (page 279) — bulb maintenance lid (page 2710) — two 5 x 10 mm socket bolts (lower side) [i] — two 6 x 10 mm socket bolts (upper side) [2] Release the tour tabs [3] on both sides of the front cowl by spreading it. Release the three bosses [4] from the grommets. Disconnect the 16P (Gray) connector [5] to remove the meter panel [6], ‘ installation is in the reverse order of removal. NOTE - When connecting the 1GP (Gray) connector. install the connector boot into the groove in the combination meter properly. - Set the upper edge of the meter panel into the guides [7] and then engage the three tabs with the groove in the meter panel. 2-12 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT COWL REMOVAL/INSTALLATION CBR500R/RA Remove the meter panel (page 2-11) 7" Support the front cowl assembly [1] securely and l [1] remove the oowl stay lower mounting nut [2] and bolt l [3], then remove It For dlsassembly/assembly‘ reler t0 Wlndscreen (page 2-16). ‘ lnstallation IS in the reverse order of removal. ‘ NOTE ‘ - Install the cowl stay mounting bolt from the rlght ‘ side, CBSDOFIFA Remove the left middle cowl (page 2-9). l7" Disconnect the front subrwwe harness 4P (Black) and l 12? (Black) connectors [1], Remove the followtng: — band Cllp [2] — two socket bolts (6 x 10 mm) [3] 7 front cowl assembly [4] 7 two mountan grommets [5] For disassemblylassembly (page 2-14). Installation ls in the reverse order of removal. 2-13 FRAME/BODY PANELS/EXHAUST SYSTEM Be careful no! to scratch the from cow.’ surface by the now! Stay CBSOOXIXA Remove the meter panel (page 2-12). Disconnect the followmg connectors‘ — headllght 3P (Black) [1] — turn signal/position light 3P (Orange) [2] — turn signal/position light 3P (Light blue) [3] Remove the posltlon light 2P (Black) connector [4} irom ‘ the stay and disconnect it. Support the front cowl assembly [5] securely Remove the followmg fasteners and remove the front cowl assembly. 3 7 four socket setting bolts (outside; 6 x 10 mm) [6] — two bolts and washers (inner side) [7] v two screws and washers (upper side) [8] For disassembly/assembly, Swrtches seclion r headlight (page 21-6) 7 turn signal/position light (page 2178) refer to Lights/Meters/ installation I: in the reverse orderof removal TORQUE: Headlight mounting bolt: 8.5 N-m (0.9 kgf-m, 6.3 mt“) Headlight mounting screw: 45 Nm (0.5 kgr-m, 3.3 mm) DISASSEMBLY/ASSEMBLY (CB500FIFA) METER COVER Remove the front cowl assembly (page 2-13) Remove the six trim clips (pin head) [11' Release the followmg tabs in lhe sequence as follows i and remove the meter panel [2} — two lowerlabs [3] — two side tabs [4] — (we uppertabs [5] Installation is in the reverse order of removal ‘ 2-14 FRAME/BODY PANELS/EXHAUST SYSTEM METER VISOR Remove the meter cover (page 2714) Remove the two tapping screws [1]. Slide the meter vlsor [2] lorward lo release the (our tabs 1 [3] and remove ll ‘ Installatlon is In the reverse order ol removal. REAR HEADLIGHT COVER Remove lhe meter cover (page 2-14). Remove the tapping screw [1] ‘ Release lhe rear headllghl cover [2] from each lour srde ‘ tabs [3] and lour lower tabs [4]. and remove it Installation lS In the reverse order oi removal NOTE - lnserl lhe guide areas (holes) [51 m between the l [5] x from cowl and lront headllght cover, and align them with the guide bosses FRONT COWL Remove the followmg‘ ‘ — lum Signal/position llghts (page 2177) — meler vusor (page 245) ‘ — rear headlighl cover (page 2—15) Remove the two lapping screws [1] Release the upper ends of the headlighl housing off of the screw hole studs and remove lhe headllght assembly [2], 3 Installation is In the reverse order of removal ( [2] NOTE - Alrgn the two labs with the grooves lI'l the front cowl properlyv 2-1 5 FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN (CBRSOORIRA/CBSOOXIXA) REMOVAL/INSTALLATION CBR5OUR/RA Remove the front cowl assembly (page 2-13), Remove the followtng. — two setting screws [1] — setting socket boll (5 x 10 mm) [2] - two washerrbolts [3] Release the two tabs [4] on both sides of the front cowl [5] Release the front cowl off 01 the bolt hole sluds [6] and remove it. Remove the two collars [7] Remove the lollowrng — two setting socket bolts (5 x 10 mm) [8] — two washers [9] v two rubber washers [10] e windscreen inner cover [1‘l] e windscreehHZ] Installation is In the reverse order of removal. NOTE - Install the Windscreen onto the inner cover. aligning the tab with the slot, and the windscreen/inner cover assembly onto the tront cowl. aligning the slots with lhe labs. When installing the front cowl, align the lollowrng tabs With the grooves properly, 7 two front cowl inner tabs [1 3] 7 two headlight housth lower tabs [14] CBSDOXIXA Remove the lollowing: — two rubber caps (rear side) [1] — four socket bolls [2] 7 four plastic washers (small) [3] e windscreen [4] » tour setting nuts [5] (by sliding them down) — tour plastic washers (large) [6] installation is in the reverse order of removal. “‘9” [10] [9] [3] 2-16 GRAB RAIL REMOVAL] INSTALLATION CBRSOORIRAICBSOOFIFA Remove the rear see! (page 2-6). Remove the following: — lrim clip (Philllps head) [1] — Iwo bolts [2] — grab rail [31 Installahon is in the reverse order ol removal CBSODXIXA Remove the seal (page 2-6). Remove lhe following, 7 trlm clip (Phillips head) [1] 7 socket Doll [2] and cable guard plate [3] 7 two bolts [4] 7 grab rail [5] lnslallallon IS In the reverse order of removal. NOTE: - Make sure the seal opener cable [6] rs positioned under the cable guard plate, FRAME/BODY PANELS/EXHAU ST SYSTEM Removal ‘ m l l [3] ‘m 7 %D 0‘ [41 l Removal lnslallation ., [1] [2] R ‘ 2-17 FRAM E/BODY PANELS/EXHAUST SYSTEM REAR COWL REMOVAL/INSTALLATION CBRSODRIRA/FIFA Remove the Slde cover (page Z7) Remove the two settlng socket balls (6 x 10 mm) [1] Slide the rear center cowl [2] rearward lo release the tabs [3] carefully and remove ll, Remove the followmg, 7 mm clip (Phillips head) [1] — twn sethng socket bolts (6 x 10 mm) [2] Be carelulnano Ralse Ihe bottom of lhe cowl slighlly and release the scratch the rear flve labs [3], lheh remove lhe rear cowl [4} from Ihe rear cawlonmegrab lender fall Left rear cowl. Release the seat opener cable [5] OH of the cable holder [6] and dlsconnect it from (he lock arm [7] to remove the rear cowl Installalion is In the reverse order of removal. Left rear COWI’ [4] [3] Removal lnstallatloh 2-18 FRAME/BODY PANELS/EXHAUST SYSTEM Left lea! cowl. CBSOOXIXA Remove the grab rall (page 247). Remove the two sethng socket bolts (6 x 10 mm) [1]. Slide the rear center cowl [2] rearward to release the labs [3] carefully and remove it Remove the followmg: — trim clip (Phllllps head) [1] — semer sockel bolt (5 x 8 mm) [2] Ralse the bottom of the cowl sllghtly and release the four tabs [3], then remove the rear cowl [4] from the rear fender Release the seal opener cable [5] off oi the cable holder [6] and disconnect ll from the lock arm [7] to remove the rear cowl. lnstallatlon IS in the reverse order of removal. Lefl rear cuwl, l2] 2-19 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER COVER REMOVAL/INSTALLATION release it from the rear fender A. Pull the rear lender cover ream/3rd and release the ilve tabs [3] to remove it from the rearferlder BY Installation is in the reverse order of removal REAR FENDER A REMOVAL/INSTALLATION Remove the followmg. — rear cowls (page 2715) — rear lender cover (page 2720) Disconnect the following connectors [11 in the connector boot: 7 turn slgnal light 2P (nght blue) 7 turn signal light 2P (Orange) 7 license light 2P (White) 7 brake/taillight 3P (White) Remove the wrre band [2] Remove the three nuts [3]‘ collars [4] and bolts [5L and the number plate bracket [6}. Remove the three setting bolts [7]. Release the front ends off of lhe bolt hole guides [8] and the boss [9] lrom the grommet to remove the rear fender A [101 Installation is in the reverse order of removal NOTE - Insert the two setting tabs [11] into the slots and set the two gulde tabs [12] onto the inner wall at the rear fender B properly. [10] 2-20 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER B REMOVAL/INSTALLATION Remove the [ollowmg: 7 barlery (page 20-5) 7 rear fender A (page 2-20) 7 mol kit strap [1] (from the hook of (he lrame) 7 cable chp [2] 7 battery rubber sheet [3] (horn the strap h01ders) 7 connector boot [4] 7 option 2P Connector [5] 7 [use boxes [6] 7 three semng bolts [7] Re]ease the fender arms [8] and remove the mam w1re harness [9] out oflhe fender B [10], Remove me iollowmg' 7 Ich hand clips (right side; battery cab]es) [11] 7 band clip(|ef1 swde; main wrre harness) [12] Re1ease the prongs [13] and setting guxdes [14] from Ihe frame by pulhng |he rear fender B rearward and remove the (chewing: 7 band c]ip(fronls1de; mam wwre harness) [15] 7 banen/ (—) cable (from Ihe guide [16]) Slide the rear fender B downward and remove 11 out of the frame. InslaHahon is In Ihe reverse order 01 removalv NOTE ‘ Posihon Ihe heal guard rubber [17] over the from end 01 Ihe rear fender B (page 1-24) [10} [14] 2-21 FRAM EIBODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the lollowtng: two 6 x 22 mm socket bolts [1] two 6 x 30 mm socket bolts [2] two 5 x 28 mm bolts [3] two reflex reflectors [4] brake hose clamp [5] two collars [6] and grommets [7} front lender [8} — lender bracket [9] Installation ts tn the reverse order cfremoval ttttttt CBRSDORA shown. UNDER COWL REMOVAL/INSTALLATION CBRSOOR/RA Remove the mtddle cowls (page 2—8), Release the hoses [1] from the under cowl [2], Remove the five setting socket bolts (6 x 10 mm) [3] and under wwl Installation l5 tn the reverse order 01 removal, ‘ 2-22 FRAME/BODY PANELS/EXHAU ST SYSTEM CBSOOF/FA Retease the hoses [1] from the under cowl [2] Remove the three setting socket bolts (6 x 10 mm) [3] and under cowlv Installation Is in the reverse order 0! removal, CBSDOXIXA Release the hoses [1] (ram the under cow‘ [2] Remove the five semng socket bolts (6 x 10 mm) [3] and under cowl. \nstaHahon is In the reverse order of removaL 2-23 FRAME/BODY PANELS/EXHAUST SYSTEM DRIVE SPROCKET COVER REMOVAL/INSTALLATION Remove the left rider footpeg bracket (page 2-27), Remove the followrng: — pinch oolt[i] — gearshift arm [2] — band clip (lower side) [3] - two bolts [4] - band clip (from side) [5] - drive sprocket cover [6] — drive chain guide [7] Installation is in the reverse order of removal, NOTE - Temporarily hang lhe chain guide on the water pump lug and drive chain, and then install lhe drive sprocket cover with the upper bolt to sel the chain guide and sprocket cover properly, - Route lhe sidestend switch wire [8] into the guide [9] in the sprockel cover - Align lhe slil in the gearshift arm With the punch mark on the spindle. TORQUE: Drive sprocket cover bolt: 12 Nm (1.2 kgr-m, 9 lbl-ft) DRIVE CHAIN COVER REMOVAL/INSTALLATION Remove the left rider footpeg brackel (page 2-27), Remove the two setting socket bolts (6 x 10 mm) [1], Slide the drive chain cover [2] forward and remove it from the stay [3] Installation is in lne reverse order of removal. 2-24 FRAM E/BODY PANELS/EXHAUST SYSTEM ABS MODULATOR COVER (CBRSOORAICBSOOFA/XA) REMOVAL/INSTALLATION Remove the left passenger loolpeg bracket (page 2» 27). Remove the two semng sockel balls (6 x 10 mm) [1]V Release the lab [2] and remove the ABS modulator 1 wver[3} Installalion is in the reverse order of removal FUEL TANK UNDER TRAY REMOVAL/INSTALLATION Remove lhe following 7 ECM (page 4736) r (urn signal/hazard relay (page 2123) Disconnecl the front subrwire harness 4P (Black) [1] and 12F (Black) [2] connectors and remove them from lhe slay CBRSOOR/RA, Ar CM lypes shown. Q - Release the ignlllon coil wires from the wrre guides [1} I and dlsconnect the connectors [2]. Remove the following and release (he PAlR conlrol solenoid valve [1] from Ihe slay [2]. — nut[3] 7 bolt [4] r collarlS] FRAME/BODY PANELS/EXHAUST SYSTEM Remove the setting bolt [1] Pass the turn signal/hazard relay 4P (White) connector ] [2] through the tray, Release the clutch and throttle cables off of the cable guide [3] Release the right setting guides [4] from the lrame to raise it and remove the Ihree band clips [5] from the tray Release the left setting guides [6] from the frame and clearthem out of the main wire harness [7] Disconnect the spark plug caps [8] and remove the luel tank under tray [9] Installation is in the reverse order of removal NOTE - Route the left spark plug Wire [10] over the secondary air supply hose [11] and connect the spark plug caps with their ends facmg to the front side - Fit the tray cutout [12] on the main wire harnesses. - When setting the tray. insert the PAIR control solenoid valve [13] and turn signal/hazard relay 4P (White) connector into each opening properly. TORQUE: PAIR control solenoid valve nut: 3.5 N-m (0.9 kgr-m, 6.3 Ibf-ft) SIDESTAND REMOVAL/INSTALLATION Remove the sidestand swnch from the sidesland pivot (page 2‘l-2‘l) Relracl the sidestand and remove the following — spring [1] — pivot nut [2] and bolt [3] — sidestand [4] installation is in the reverse order of removal. NOTE - Apply grease to the pivot area, - When tightening the pivot nuL hold the pivot bolt securely. O The spring is installed in the direction as shown. TORQUE: Pivot bolt: 10 N-m (1.0 kgf‘m, 7 lbf-ft) Pivot nut: 30 Nm (3.1 kgf-m, 22 Ithl 2-26 FRAME/BODY PANELS/EXHAUST SYSTEM FOOTPEG BRACKET REMOVAL/INSTALLATION NOTE - For right rrder fompeg bracket removaVinslaHalron, refer to following: 7 brake pedal (page 1845) 7 rear master cylinder (page 18710) LEFT RIDER FOOTPEG BRACKET Remove The iefl srde cover (page 2-7). Remove the two bolts [1] and foolpeg bracket [2] Installation is in me reverse order of removal TORQUE: Rider foolpeg bracket boll: 37 N-m (3.3 kgf—m, 27 Ibm) PASSENGER FOOTPEG BRACKET Rrglrl blacker orrr’y‘ Remove Ihe muffler (page 2-28) Remove the two buns [1] and lootpeg bracket [2] Installatron rs m the reverse order of remova‘, TORQUE: Passenger footpeg bracket bolt: 37 N-m (3.3 kgf-m, 27 mm) 2-27 FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER REMOVAL/INSTALLATION Loosen the muffler band bolt [1]. Remove the followtng: 7 nut [2] 7 bolt and washer [3) 7 muffler[4] 7 collar[5] 7 gasket [6] Be sure that the muffler band tab is allgned with the muffler groove in position. Install a new gasket and the collar. lnstall the muffler wlth the washer, bolt and nut, and ‘ loosely tlghten it. Tighten the muffler band bolt first, then tlghten the mountan nut to the speclfied torque. TORQUE: Muffler band ball: 22 N-m (2.2 kgf-m, 16 lbl-ft) Mufller mounting nut: 22 N-m (2.2 kgl-m. 161bf-ft) DISASSEMBLY/ASSEMBLY Dlsassemble and assemble the muffler cumponents as followmg lllustration, SOCKET BOLTS 10 Nm (1.0 kgf'm, 7 lbt-ft) TAlL CAP MUFFLER COVER Allen [61 S9} MUFFLER SETTING RUBBERS (lnstall with the rlbs racmg out) V J 1 \ SOCKET BOLT ‘lO N-m (1.0 xgrm 7 lblft) 2-28 FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE REMOVAL/INSTALLATION CBRSOOR/RA/ Remove the under cowl (page 2-22) CBSOOWA' CBSOUF/FA/X/XA Remove the right middle cowl (page 2-9) Remove the three socket bolts [1]. and the exhaust pipe cover [2]. Remove the three collars [3]. Disconnect the 02 sensor 4? (Black) connector and remove the 0; sensor Wire out of the frame (page 4-40), Remove the following: 7 muffler (page 2-28) 7 lourjointnuts[1] 7 mounting bottIZ] — exhaustpipe[3] — collar[4] ~ gaskets [5] Be sure to verify the length from the stud bolt head to the cylinder head surface (page 2729), Install new gaskets and the collar, Install the exhaust pipe With the mounting bolt and Joint nuts by setting the exhaust pipe flanges onto the stud bolts, and screw all the fasteners in fully, Tighten the joint nuts first to the specified torque. then tighten the mounting bolt. TORQUE: Exhaust pipe joint nut: 18 NM (1.8 kgf>m,13lbf-ft) install the removed parts in the reverse order of removal TORQUE: Exhaust pipe cover bolt: 12 N‘m (1.2 kgf-m, 9 lbf-ft) STUD BOLT REPLACEMENT Remove the exhaust pipe (page 2-29). Thread two nuts onto the stud bolt and tighten them together, and use a wrench on the inner nut to turn the stud bolt out, Install a new stud bolt With the short threads facing the cylinder head. Tighten the stud bolt to the specified torque, TORQUE:9.0 N‘m (0.9 kgl-m, 6.6 Ibf-fi) After installation, check that the length from the boil head to the cylinder head surface is within specification. Install the exhaust pipe (page 2-29). 2‘l 5 *22.5 mm ‘ (0.85 r 0.89 in) 2-29 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT RAIL CBRSOORA/ CB500FA/XA REMOVAL/INSTALLATION Remove the lollowmg. 7 fuel tank (page 7-9) 7 passenger footpeg brackets (page 2727) 7 rear tender B (page 221) 7 starter relay switch (page 679) r regulator/rectifier (page 2077) r ABS modulator cover (CBRSOORA/CBSOOFA/XA) (page 2—25) Loosen the air cleaner housing retaining bolt [1], and remove the four bolts [2] and fuel tank bracket [3]. Remove the following from the seat rail [4]. — heat guard rubbers [5] (from the fuel tank bracket and starter relay swnch stays) — Wire olip[6] — band clip [7] — 2P (Gray) connector [8] r 2P (Black) connector [9] r the bandsl10] 7 reservoir mounting bolt [11] (keep the reservoir upright to prevent airtrom entering the hydraulic system) 7 Wire clip[12] 7 band clip [13] 7 2R (Green) connector [14] e 2P (Red) connector [15] Support the bottom of the ABS modulator [16] With suitable wooden blocks and remove the two modulator mounting bolts [17]. Release the ABS modulator from boss [18] by sliding it to the left slightly. Remove the followmg fasteners and remove the seat rail. 7 two 10 x 45 mm bolts (lower) [19] a two nuts [20] and 10 x 35 mm bolts (upper) [21] installation is in the reverse order 01 removal. TORQUE: Seat rail mounting bolt: 60 Nm (6.1 kgf-m,44lbf-1t) [1] [3] [20] [21] [21] 2-30 3. MAINTENANCE SERVICE INFORMATION """"""""""""""""""" "3-2 EVAPORATIVE EMISSION CONTROL SYSTEM (Ac Type) ................................... ..3_13 MAINTENANCE SCHEDULE" "3-3 DRIVE CHAIN FUEL LINE ................................................... ..3_4 BRAKE FLUID .......................................... ..3_17 THROTTLE OPERATION ............................ ..3.4 BRAKE pAD WEAR AIR CLEANER ................ v. BRAKE SYSTEM ------- -- CRANKCASE BREATHER BRAKE LIGHT SWITCH ........................... .. 3.19 SPARK pLUG .............................................. ..3_6 HEADLIGHT AIM ...................................... ..3_20 VALVE CLEARANCE-'- CLUTCH SYSTEM ------------ -- 3.20 ENGINE OIL .............................................. ..3_1o SIDESTAND .............................................. ..3_21 ENGINE OIL FILTER ................................. ..3_11 SUSPENSION ........................................... ..3_21 ENGINE IDLE SPEED ..................... .7 342 NUTS, BOLTS, FASTENERS---- 3.22 RADIATOR cooLANT ............................. ..3_12 WHEELS/TIRES ........................................ ..3_22 COOLING SYSTEM ................................... ..3_13 STEERING HEAD BEARINGS ----------------- "3-22 SECONDARY AIR SUPPLY SYSTEM- 3-1 MAINTENANCE SERVICE INFORMATION GENERAL - Place (he motorcycle on a level surface before starting any work TOOLS Oimliér Wrench 7 7 V ‘ Dnvé ch§n tool set 07HAAVPJ70101 07HMH-MR10103 i i , ‘ ‘ , i C \ ‘ ‘ ‘ or 07AMA-MFJA100 (U S.Av on‘y) ‘ or 07HMH’MR1010C (U S A. only) 3-2 MAINTENANCE MAINTENANCE SCHEDULE Perform the Prerride inspectien in the Owners Manual at each scheduled maintenance period. l' Inspect and Clean. Adjust, Lubricate or Replace if necessary. C, Clean. R: Replace, A: Adjust L, LubrIcate. The following Items require some mechanical knowledge. Certain items (particularly those marked ' and “) may require more technical information and tools. Consult a dealer. I ' FREQUENCY WHICHEVER‘ ODOMETER READlNG (NOTE 1) " REFE I COMEsmWa 4 I 8 ‘12I16IzoI24 TO ITEMS FlRSTIx 1.00b krn I 10 I 6.4 1§8I19.2‘25,6I32,0I384 PAGEJ I' FUELLINE ’ ' ' I I I I I l 3-4 I- THROTTLEOPERATION 7 77 7 7 l7 ' ’I I ‘ 34'? m AIR CLEANER 77 NOTE2 7 , R R f 3-5 I IE7ICRANKCASE BREATHER I NOTES I g I c I c I c c c 73-6 I i; " SPARK PLU7G I ‘ I , I R I 3-6 DTVALVEELEARANCE 7 I I | I l I I I I‘ 3-7 ‘ “EJW I I INITIAL=1,000 km (600 mi)or I 4i I I I ‘ 1month: R, I E, ENG'NE 0” I REGULAR=Every12,800 km 3’“) ‘ 2‘ I7 77 777 77777 7I7 Ia,ooomiIor12 monthszR 7 97 7ENG|NEO|L FILTER I7 77 I 7I R 7RT R 7 R g * ENGINEIDLE SPEED ’ I I ‘ 7 77I7 I 7 I I ‘ I' 3|:RADIATD’RC700LANT 77 7' NOTE’s I "7 7| V I I I R IN ' COOLING 5Y75TEM ’ 7' ' ' 7 I71 I I I'I "SWW‘RY AlR SUPPLY SYSTEM "i 7'I *’ ’ I7 77 I I I'TV’EVAPOR’ATIVE EMISSION’CONTRQLSYSIEMT N0TE’4 7 I I 77 ’ I 77" I; IDRIVE CHM 77 77 ‘7 77 E7very 800 km (500 mi) I, L 7 IE7IBRAKE F7LUlD 7‘77 NOT7E5 7 77 I7 I I717I771 R I I7I7 7R77 IEI BRAKEPADWEAR 7 7 7f 7I7l I I I I I I I II E: 7.BRAKESYSTEM 7 7 7 77 I I 7 _77|7 I I I I7 I3 BRAKE LIGHTSWITCH 7 777 7 I I 7 I g HEADLIGHTAIM 7777 _ 7 77I , I I I zI7CLUTCHSYST7EM I I I I 7i ‘ I , I I i Ig SIDESTAND 77 7 ‘ I I I I I I I I9 ‘7,SUSPENS|ON 7 I I 77‘ I I I I I7 IEF‘NUTSfiOLTSI FASTENERS 7I 77I 7 I 7I77I I I 1 I I I I I I I I I l§TEERING H7E7AD BEARINGS ‘ Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. " In the interest of safety, we recommend these items be serviced only by a dealer. NOTES: At higher odometer readings, repeat at the frequency interval established here . Service more frequently when riding In unusually wet or dusty areas , Service more frequently when riding In mm or at full throttle . AC type Replace every 2 years, or at Indicated odometer interval, whichever comes first. Replacement requIres mechanical skill. 915mm; 3-3 MAINTENANCE FUEL LINE CERSODR/RA, Move the meter panel ends aside to ai/Oid interference THROTTLE OPERATION with the tank FUEL TANK LIFTING/LOWERING Remove the middle cowls (page 275) A, CM types i l [4] Remove the two bolts [1] and collars [2] Disconnect the fuel pump 3P (Black) connector [3] Lift the front of the fuel tank slightly and disconnect the foliowtng: ‘ e A, CM types. fuel tank breather hose [4] (al the hose iomt/ AC type fuel IankrtorEVAP canister hose [5] — fuel tank drain hose [6] (at the hose joint) Support the Iuel tank by placing a suitable support block between the air cleaner housing (flat surface area) and tank installation is in the reverse order of removal NOTE - Be sure to route the fuel feed hose [7] into the guide [8] in the air cleaner housing. - Check that the fuel tank breather hose (A, CM types) and fuel tank drain hose are not bent or pinched TORQUE: l A t - Fuel tank mounting bolt:10 N-mt1t0 kgf-m, 7 ihr-rti C we INSPECTION Lift the fuel tank and suppon it (page 374), Check the fuel feed hose for deterioration, damage or leakage Also, check the hose fittings for damage or looseness Replace the fuel feed hose if necessary Check for any deterioration or damage to the throttle " cable Check lhe throttle grip for smooth operation, Check that the throttle opens and automatically closes in all steering positions ‘ lfthe throttle grip does not return properly, lubricate and ‘ overhaul the throttle grip housmg (page 16-10), If the throttle grip still does not return properly, replace the throttle cables With the engine idling, turn the handlebar all the way to the right and left to ensure that the idle speed does not change It idle speed increases, check the throttle grip freeplay and throttle cable routing Measure the throttle grip freeplay at the throttle grip flange FREEPLAY: 2 — 6 mm (0.1 - 0.2 in) MAINTENANCE Throttle grtp freeplay can be adjusted at either end of the throttle cable Minor adjustment is made with the upper adjuster of the throttle grip side. "[31 Slide the boot [1] to remove it from the adiuster [2]. Loosen the lock nut [3] and turn the adjuster as required. Tighten the lock nut to the specified torque while \ holding the adjuster TORQUE: 3.8 N-m (0.4 kgf-m. 2.8 let) Install the boot over the adjuster properly ‘ ‘ r“) t .3, Major adjustment Is made With the lower adjuster on the throttle body. Lift the fuel tank and support it (page 341) ‘ Loosen the lock nut [1] and turn the adiuster [2] as i required. Tighten the lock nut to the specified torque while ‘ holding the adjuster i TORQUE: 3.0 N-m (0.3 mm, 2.2 lbt-ft) ‘ After adjustment recheck the throttle operation i Install the fuel tank (page 3-4). AIR CLEANER NOTE ~ The viscous paper element type air cleaner cannot be cleaned because the element contains a dust . adhesive. ~ it the motorcycle is used in unusually wet or dusty areas. more frequent inspections are required Remove the battery (page 20-5). Remove the lollowtng: 7 tapping screw [1] r wirejunctton [2] tour tapping screws [3] 7 air cleaner lid/element assembly [41 ~ tourwashervscrews [i] — air cleaner element [2] Replace the air cleaner element in accordance with the maintenance schedule (page 373) or any time it is excessively dirty or damaged Clean the inside of the air cleaner lid and housing, Make sure the rubber seal [3] in the lid is in position and i in good condition. installation is in the reverse order at removal. ‘ TORQUE: ‘ Air cleaner element washerscrew: ‘ 1,5 N-m (0.2 kgr-m, 1.1 Ibtrft) Air cleaner lid tapping screw: 1‘1N-m(fl.1kgf—m.0.8lbf~ft) 3-5 MAINTENANCE CRANKCASE BREATHER NOTE' ' Servtce more frequently when ridden tn rain, at full _ throttle. or after the motorcycle is washed or ‘ ' overturned. Sen/tee ll the deposit level can be seen tn the transparent tube Remove the crankcase breather lube plug [1] and dratn the deposits tnto a suitable containen then retnstall the plug securely Ltlt the fuel tank and support tt (page 3-4), Check the crankcase breather hose [1] for cracks. ‘ detertoratton, damage or loose connecttons Replace the breather hose ll necessary Install the fuel tank (page 3-4). SPARK PLUG Remove the luel lank under tray (page 2725) Clean around the Remove the spark plug [1}. spark plug base Check the insulator for cracks or damage, and the Wllh compressed atr heme remwmgflw electrodes for wear, toultng or dtscoloratton. Replace lu if n plug and be sure me p g ecessary that no dBDIlS ts SPECIFIED SPARK PLUG: CPR8EA-9 (NGK) allowed to entertnto V the combustion Clean the spark plug electrodes wtth a wtre brush or Mamba, spectal plug cleaner, Check the gap between the center and Side electrodes thh a wire-type leeler gauge. SPARK PLUG GAP: 0.80 — 0.90 mm (0.031 — 0.035 in) If necessary, adjust the gap by bendlng the slde ' electrode carelully Install and hand tighten the spark plug tc the cylinder head then ttghlen the spark plug to the specttted torque TORQUE: 16 N-m (1.5 kgt-m.12tbr-ft) lnstall the tuel tank under tray (page 2-25) MAINTENANCE VALVE CLEARANCE INSPECTION NOTE O Inspect and adiust the valve clearance while the engine is cold (below 35”C/95°F). Remove the following: — cylinder head cover (page 106) — crankshaft hole cap and Orring Rotate the crankshaft clockwtse slowly and align the "T" mark [1] with the index notch [2] in the crankcase cover, Make sure the timing marks ("IN" and "EX“) on the sprockets are Ilush With the cylinder head surface, and punch marks [1] are facing up If the marks are not in this position. turn the crankshaft clockWIse one full turn (360”) and reallgn the "T" mark with the index notch Record each valve Check the exhaust valve clearances of the No, 1 (left) clearance for and No, 2 (right) cylinders by inserting a Ieeler gauge reference in shim [1] between the rocker arm and shim. selection i/ act/Hyman; ,5 VALVE C LEARAN C E: required, EX: 0.27 t 0.03 mm (0.011 t 0.001 in) r. Turn the crankshaft clockWIse 1/2 of a turn (180‘) from the previous position, and align the timing marks (punch marks) [1] on the cam sprockets WlIh the cylinder head surface (the Camshafts are turned 90“). Check the intake valve clearances of the N0. 1 and No. ‘ 2 cylinders, VALVE CLEARANCE: IN: 0.16 1 0.03 mm (0.006 2 0.001 in) MAINTENANCE ADJUSTMENT NOTE - The valve clearance adjustment is perlormed by removing the rocker arm shafl Belore removing each rocker arm shaft, make sure the cam shaft is in the proper position to allow removal of the rocker arms (page 3-7). Remove the plug bolt [1] and washer [2] Remove the rocker arm shaft [3] using a 6 mm bolt while holding the rocker arms, Slide the rocker arms [‘l] outward and remove the shims [2] NOTE‘ - Do not allow the shims to fall into the crankcase or spark plug holes. ‘ Mark all shims to ensure correct reassembly in their ‘ original locations . The shims can be easily removed with tweezers or a magnet. Measure the shim [1] thickness and record it. NOTE - Sixty-nine different thickness shims are available in increments of 0.025 mm (from 1.200 mm to 2.900 mm). Calculate the new shim thickness using the equation below. A=(BrC)+D A New shim thickness B. Recorded valve clearance C Specified valve clearance D Old shim thickness NOTE - Make sure of the correct shim thickness by measuring the shim by micrometer. ~ Relace the valve seat it carbon deposit results in a i calculated dimenSion 0' over 2 900 mm, 185 mm 1.825 mm 1 875 mm MAINTENANCE Apply molybdenum oil solution to the stem ends ‘ Install the newly selected shims [1] into the valve spring ‘ retainers Apply molybdenum oil solution to the rocker arm sliding areas and thrust surfaces. and rocker arm shaft outer surface. t Set the rocker arms [2] into place. i I I and rocker arms while holding the rocker arm claws as Insert the rocker arm shaft [3] through the cylinder head ‘y shown, : Apply engine oil to the threads of plug bolt [1] and install r it with a new sealing washer [2] aligning the blade with the groove Exhaust side shoWn Tighten the plug bolt to the specified torque. TORQUE: 15 N-m (1.5 kgf-m, 11 lbf-ftl Rotate the Camshafts by rotating the crankshaft clockwise several times Recheck the valve clearance. Coat a new O-ring With engine oil and install it into the groove in the crankshaft hole cap. Apply grease to the threads of the crankshaft hole cap and install it. Tighten the crankshaft hole cap to the specified torque, TORQUE: 18 N-m (1.8 kgf-m,13lbf-ft) Install the cylinder head cover (page 1076). MAINTENANCE ENGINE OIL OIL LEVEL CHECK Start the engine and let it idle for 3 - 5 minutes. Stop the engine and wait 2 — 3 minutes Support the motorcycle in an upright position on a level surlace Check the oil level through the inspection window. It the level is below the lower level line [1], remove the oil filler cap [2] and fill the crankcase With the recommended engine oil up to the upper level line [3] RECOMMENDED ENGINE OIL: Pro Honda 6N4 4-slr0ke oil (U.S.A. 8. Canada) or equivalent motorcycle oil API service classification: SG or higher (except oils labeled as energy conserving on the circular API service label) JASO T903 standard: MA Viscosity: SAE 10W-30 Check that the Orring [4] on the filler cap is in good condition, replace it if necessary. Apply engine ml to the O»ring, install the filler cap. OIL CHANGE Warm up the engine, Stop the engine and remove the oil filler cap [1]. Remove the oil drain bolt [2] and sealing washer [3] to drain the engine oil, After draining the oil completely, install the drain bolt with a new sealing washer Tighten the drain bolt to the specrfied torque TORQUE: so Nrm (3.1 kgi-m, 22 let) Fill the crankcase with the recommended engine oil (page 3710). ENGINE OIL CAPACITY: 2.5 liters (2.6 US qt, 2.2 Imp qt) at draining 2.7 liters (2.9 US qt, 2.4 Imp qt) at oil filter change 3.2 liters (3.4 US qt, 2.3 Imp qt) at disassemny Check the oil level (page 340), Make sure there are no oil leaks 3-10 MAINTENANCE ENGINE OIL FILTER Drain the engine oil (page 3-10) Remove the on inter canndge [1] usan the Special tooI TOOL: [2] Oil filter wrench 07HAA-PJ7D10‘I or 07AMA-MFJA100 (U.S.A. only) Check that the oil finer boss protrusxon from me crankcase is specified length as shown SPECIFIED LENGTH: 15.5 -16.5 mm (0.61 — 0.65 in) NOTE - If the ml filter bass is removed, appIy lockmg agent to the oil filter boss threads and insIaII II (page 1720) TORQUE: 18 Nm (1.8 kgf-m,13lbf-ft) I I I r I 155716 5mm ‘ I (O 617 0.65 In] ED Apply engine mI Io Ihe threads and Orring of a new OII f i flIter cartridge [1] I ,7a [I] InslalI the OH filter cartridge and tIghten II to Ihe specwfied torque. I TOOL: ’ < I Oil filter wrench 07HAA-PJ70101 or r 07AMA-MFJA100 I I s \ (U.S.A. only) I . r TORQUE: 26 N-m (2.7 kgf~m.19 lbf-ft) I I FIII the crankcase with the recommended engine oiI // (page 3710). 3-11 MAINTENANCE ENGINE IDLE SPEED NOTE - inspect the idle speed after all other engine maintenance items have been pertormed and are within specifications. - Belore checking the idle speed, inspect the followmg items: — no MIL blinking r spark plug condition (page 376) 7 air cleaner element condition (page 3-5) » throttle operation and throttle grip freeplay (page 3-4) - The engine must be warm for accurate idle speed inspection, - This system eliminates the need tor manual idle speed adlustmentv Start the engine, warm it up to normal operation temperature and let it idle, Check the idle speed IDLE SPEED: 1,200 i: 100 rpm If the idle speed is out oi the specification‘ check the following: — Intake air leak or engine top-end problem (page 10-4) — lACV operation (page 7-17) RADIATOR COOLANT Check the coolant level oi the reserve tank with the engine running at normal operating temperature The level should be between the "UPPER" [1] and l "LOWER" [2] level lines With the motorcycle in an upright position on a level surface It the level is low, fill as tollows Remove the left side cover (page 277) Remove the reserve tank cap [1] and till the tank to the ‘ "UPPER" level line With a t 1 mixture at distilled water , and antifreeze RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors Check to see if there are any coolant leaks when the coolant level decreases very rapidly. It the reserve tank becomes completely empty, there is a possibility of air getting into the cooling system Be sure to remove any air from the cooling system (page 875). Install the reseNe tank cap Install the left side cover (page 2-7). 3-12 MAINTENANCE COOLING SYSTEM Check the radiator air passages for clogging or damage. ‘ Straighten bent tins with a small flat blade screwdriver i and remove insects. mud or other obstructions wrth compressed air or low water pressure Replace the radiator it the air flow is restricted over more than 20% of the radiating surface ‘ Remove the middle cowls (page 2-8) Check for any Coolant leakage from the water hoses and nose joints Check the water hoses for cracks or deterioration and replace them if necessary. Check that all hose clamps are tight. Install the middle cowls (page 2-8), SECONDARY AIR SUPPLY SYSTEM Remove the fuel tank under tray (page 2-25). Check the air supply hoses [1] between the air cleaner housing, PAIR control solenoid valve [2] and cylinder head cover for deterioration. damage or loose connections. Also check that the hoses are not kinked or pinched. If the air supply hose show any signs of heat damage, inspect the PAIR check valves (page 7-20), For secondary air supply system inspection (page 7- 18). EVAPORATIVE EMISSION CONTROL SYSTEM (AC type) Remove the fuel tank under tray (page 2-25). Check the EVAF canister [1] for cracks or damage Check the hoses between the fuel tank [2]. EVAP canister, EVAF' purge control solenoid valve [3] and throttle body [4] for deterioration, damage or loose connections. Also, check that the hoses are not kinked or pinched. ReIer to the Cable 8. Harness Routing for hose connections and routing (page 1-24) 3-13 MAINTENANCE DRIVE CHAIN Never Inspect and adjust the drive min we the engine l5 Iimnmg. DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF. Place the motorcycle on its sidesland and shift the I transmission into neutral. ‘ Check the slack in the drive chain lower run midway between the sprockets. DRIVE CHAIN SLACK: 35 —45 mm (14 — 18 in) Feta; th;x:u€x:nr,:§m§\ 1 Excessive chain slack, 60 mm (24 in) or more may (I a l éz damage the [fame {m Om???» " 35—45mm(14—78in) ADJ USTMENT Loosen the rear axle nut [T] and adjuster lock nuts [2] Turn the adjusting nuts [3] an equal number of a turn until the carrecl drive chain slack is obtained A scale is Included on the adjusters. Be sure the reading on the scale is same tor both Sldes. Tighten the axle nut to the specified torque TORQUE: 88 N~m (9.0 ngm, 65 lbf-fl) Tighten each lock nut while holding the adjusting nut to the specified torque TORQUE: 21 N-m (2.1 kgf-m,15lbf-It) Recheck the drive chain slack and free wheel rotation Check the drive chain wear Indicator label attached on the left swmgarm. If the index line [4] on left setting plate reaches the red zone [5] of the wear indicator label, replace the drive chain with a new one (page 3716) 3-14 MAINTENANCE CLEANING AND LUBRICATION Clean the drive chain [1] With a chain cleaner designed specifically for O-ring chains or a neutral detergent. Use a soft brush iithe drive chain is dirly Do not use a steam cleaner, high pressure cleaner. wire brush, volatile solvent such as gasoline and benzene, abrasive cleaner or a chain cleaner NOT designed specifically (or O-ririg chains to clean the drive chain. Inspect the drive chain for possible damage or wear. Replace any orlve chain that has damaged rollers, loose lining links or otherwise appears unserviceable. Be sure the drive chain has dried completely before ‘ lubricating, Lubricale the drive chain WIII’I Pro Honda HP Chain Lube or an equivalent [21 Do not use a chain lubricant NOT designed specifically for use with O-ring chalns to lubncale the drive chain. Wlpe off the excess oil or drive chain lubricant. SPROCKET INSPECTION Remove the drive sprocket cover (page 2—24) Inspect the drive and driven sprocket teeth lor wear or damage replace il necessary Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition or new replacement chain Will wear rapidly, Check the attaching bolt and nuts on the drive and driven sprockets. If any are loose, torque them to the specified toque TORQUE: [1] Drive sprocket bolt: 54 Nm (5.5 kgr-m, 40 Inf-rt) [2] Driven sprocket nut: 108 N-m (11.0 kgfrm, 80 lbf-ft) Install the drive sprocket cover (page 2-24) 3-15 MAINTENANCE Never reuse the old drive chain, master link. master link plate and O-rings REPLACEMENT This motorcycle uses a drive chain With a staked master link ‘ Fully slacken the drive chain (page 3-14). . Remuve the drive chain using the special tool. TOOL: Drive chain tool set 07HMH-MR101D3 or 07HMH-MR101OC (U.S.A. only) ‘ NOTE . When using the special tool. manulacturer‘s instruction. follow the Remove the excess drive chain links tram a new drive 7 chain With the drive chain tool set. SPECIFIED LINKS: 112 LINKS REPLACEMENT CHAIN: DID520V0 Insert a new master link [1] with new Orrings [2] from the inside ot the drive chain, and install a new plate [3] and O-rings with the identification mark lacing out Assemble the master link. 0»nngs and plate TOOL: Drive chain tool set 07HMH-MR10103 or 07HMH—MR101OC (USA. only) Make sure that the master link pins [1] are installed properly Measure the master link pin length projected from the plate, STANDARD LENGTH: Approx. 1.3 mm (Dt05 in) I Stake the master link pins With the drive chain tool set. l Make sure the pins are staked properly by measuring ‘ the diameter 01 the staked area. i DIAMETER 0F STAKED AREA: 5.40 — 5.60 mm (0.213 — 0.220 in) After staking. check the staked area of the master link for cracks If there is any cracking, replace the master link, O-rings } and plate 3-16 MAINTENANCE BRAKE FLUID Spilled fluid cah damage painted‘ plastic or rubber pans. Place a rag over these parts Whenever the system is serviced NOTE - Do not mix different types of fluid, as they are not compatible With each other. - Do not allow foreign material lo enter the system when filling the reservoir, - When the fluid level is low, check the brake pads for wear (page 348). A low fluid level may be due to wear of the brake pads ll the brake pads are worn arid caliper pistons are pushed oul, this accounls for a low fluid level. ll the brake pads are not worn and fluid level is low. check the enlire system for leaks (page 3719) FRONT BRAKE Turn the handlebar so lhe reservoir is level and check the from brake fluid level through the sighl glass If the level is near the "LWR" level line [1]. fill lhe brake fIUid as lollows CBRSOOR/RA shown Remove the fullcwing 7 two screws [1] r resewoir cap [2] r set plate [3] r diaphragm [4] Fill the reservoir Wilh DOT 4 brake fluid from a sealed container to the upper level line (casling ledge) [51 Install lhe diaphragm, sel plate and reservoir cover, and tighten the screws to lhe specified torque. TORQUE: 1.5 MW (0.2 kgf-m.1.1 lbf-ft) 3-17 MAINTENANCE REAR BRAKE Support the motorcycle upright position on a level surface and check the rear brake fluid level it the level is near the "LOWER" level line [1]‘ flll the brake llurd as follows Take care to not Remove the following allow Hurdle Spill from maresem — reservoir mountan balm] — two screws [2] e reservowcaplsi — set plate [4] — diaphragm [5] Temporarily install the reservoir onto the stay with the mounting bolt through the locating pin hole [6] and secure it using a 6 mm nut [7] so the reservoir is level. Fill the reservoir with DOT 4 brake fluid from a sealed containerto the upper level line [8] Carefully remove the reservoir from the stay by removing the 6 mm nut and mounting bolt install the dlaphragm‘ set plate. reservolr cap and tighten the screws lo the specified torque. TORQUE: 1.5 N-m (0.2 kgf-m,1t1 lbf‘ftl Install the reservoir, aligning the localan pin [9] with the hole in the stay and tighten the mounting bolt, BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pads for wear Always replace the Replace the brake pads ll either pad is worn to the wear brake pads as a set limit groove [1]. to assure even disc mesa”? For brake pad removal/Installation (page 1877) 3-18 REAR BRAKE PADS Check the brake pads for wear. Always replace the Replace the brake pads it either pad is worn to the wear brake pads as a set limit groove [1], to assule even disc For brake pad removal/installation (page 18-7). pressure BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal. and check that no ' air has entered the system. If the lever or pedal feels soft or spongy when operated, bleed the alrfrom the system (page 1875) lnspect the brake hoses [1], pipes and fittings for deterioration, cracks. damage and signs of leakage Tighten any loose fittings, Replace hosesi pipes and fittings as reqmred. BRAKE LIGHT SWITCH NOTE. - The brake light swuch on the front brake master cylinder cannot be adiusted It the front brake light switch actuatlon and brake engagement are not synchronized, either replace the switch unit or the malfunctioning parts oi the system. Check that the brake light comes on Just prior to the brake actually belng engaged. If the light fails to come on, adjust the swnch so that the light comes on at the proper time Hold the switch body [1] and turn the adluster [2], Do not turn the switch body. MAINTENANCE LA 44 3-19 MAINTENANCE HEADLIGHT AIM Dual headlight mode/1 Single head/ighi model NOTE - Adjust the headlight aim as specified by local laws and regulations. Support the motorcycle in an upright position on a level surface Adjust vertically by turning the vertical adjusting screw (lower side) [’1]. A clockwise rotation moves the beam down. Adjust horizontally by turning the horizontal adjusting screw (upper side) [2]. Left headlight (High beam): A clockwise rotation moves the beam toward the lefl. Right headlight (Low beam) moves the beam toward the right A clockWise rotation A clockwise rotation moves the beam toward the right. CLUTCH SYSTEM The adjuster ma y be damaged ii i! is positioned too far out, leaving minimS/ thread engagement Inspect the clutch cable for kinks or damage. and lubricate the cable if necessary, Measure the clutch lever ireeplay at the end ot the clutch lever. FREEPLAY: 10 — 20 mm (0.4 — 0.3 int Minor adjustment is made With the upper adjuster at the clutch lever. Loosen the lock nut [l] and turn the adjuster [2] as required Tighten the lock nut while holding the adjuster. It the adjuster is threaded out near its limit and the correct treeplay cannot be obtained, turn the adjuster all the way in and back out one turn, then perform the adjustment at major adjuster as follows. Dual headlight model‘ l lOrZOmm 3-20 MAINTENANCE Major adjustment is made With the lower adjusting nut [1] at the clutch lifter arm. Loosen the lock nut [2] and turn the adlusting not as requtred. Tighten the lock not while holding the adiusting nut If the proper treeplay cannot be obtained, or the clutch slips during test-ride, disassemble and inspect the clutch (page 111). SIDESTAND Support the motorcycle using a safety stand or hoist. Check the sldesland spring for damage or loss of tension. Check the sidestand for movement and lubricate the sidestand pivot if necessary. For sidestand removal/Installation (page 246). Check the sidestand ignition cut-off system 1. Sit astride the motorcycle and retract the sidestand, 2 Start the engine With the transmission in neutral, then shift the transmission into gearwhile squeezing the clutch lever 3, Fully lower the sidestand. 4. The engine should stop as the sidestand is lowered. If there is a problem with the system, check the sidestand switch (page 21-21). SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brake and compressing them several times Check the entire fork assembly for signs oi leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all fasteners. For fork sen/ice (page 1619). REAR SUSPENSION INSPECTION Check the action of the shock absorber by compressing them several times. Check the entire shock absorber assembly for leaks. damage or loose fasteners Replace damaged components which cannot be repaired. Tighten all fasteners For shock absorber service (page 17-10) Support the motorcycle using a hoist or equivalent and raise the rear wheel on the ground, Check for worn swingarm bearings by grabbing the swingarm ends and attempting to move it side to side. Replace the bearings if any looseness to noted For swingarm service (page 17713). 3-21 MAINTENANCE REAR SUSPENSION ADJUSTMENT SPRING PRE-LOAD ADJUSTER Spring pre-load can be adjusted by turning the adjuster TOOL: Pin spanner O7AMA-MFLA100 (U.S.A. onlyl STANDARD POSITION: 3rd position from minimum (aligning index mark [1] with lower mounting bolt head [2]) ADJUSTABLE RANGE: 9 positions Turn the adyuster in the direction A to decrease the pre- load Turn the adjuster in the direction B to increase the pre» load. NUTS, BOLTS, FASTENERS Check that all chassis nuts. screws and bolts are tightened to their correct torque values (page 144). Check that all cotter pins, safely clips. hose clamps and cable stays are in place and properly secured WHEELS/TIRES Support the motorcycle using a hoist or equivalent and raise the front wheel off the ground Hold the front fork leg and move the front wheel Sideways With force to see if the wheel bearings are worn For front wheel service (page iii-16) Support the motorcycle using a hoist or equivalent and raise the front wheel off the ground. Hold the sWingarm and move the rear wheel sideways with force to see lI the wheel and driven flange bearings are worn For rearwheel service [page 17-6). Check the tire pressure with a tire pressure gauge when the tires are cold. — Fronttire(pageir1l) e Reartire(pege1»12) Check the tires for cuts. embedded nails. or other damage. Check the front and rear wheels for trueness Measure the tread depth at the center of the tires, Replace the tires when the tread depth reaches the service limits, 7 Front [Ire (page 141) 7 Rear tire (page i-i2) STEERING HEAD BEARINGS Support the motorcycle using a hoist or equivalent and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. Make sure the control cables do not interfere With the handlebar rotation Check for steering stem bearings by grabbing the fork legs and attempting to move the front fork forward to backward. lithe handlebar moves unevenly, binds, or has vertical movement. inspect the steering bearings (page 1626) 3-22 4. PGM-Fl SYSTEM SERVICE INFORMATION MIL CIRCUIT TROUBLESHOOTING ---------4-3s SYSTEM LOCATION..............................,......4_3 ECM ............... .. ...4.36 SYSTEM DIAGRAM .................................... ..4_4 SENSOR UNIT .......................................... ..4_38 PGM-FI TROUBLESHOOTING ECT SENSOR """""""""""""""""""""""" "4-39 INFORMATION ............................................ ..4_5 VS SENSOR---- "-4-40 PGM-FI SYMPTOM TROUBLESHOOTING ------------------------- "4-3 oz SENSOR ............................................... "440 DTC INDEX """""""""""""""""""""""""""" "4-9 BANK ANGLE SENSOR ........................... ..4_41 DTC TROUBLESHOOTING ---------------------- --4-1o MAIN RELAY - 4-42 4-1 PGM-Fl SYSTEM SERVICE INFORMATION GENERAL - This section covers electrical system service ot the PGM»Fl system. For other service and fuel supply system, see Fuel System section (page 7-2) - The PGMyFl system is equipped With the selldiaghostlc system, When performing the troubleshooting, read "PGM-Fl Troubleshooting Information“ carefully (page 475)‘ and inspect and troubleshoot according to the DTC. - A faulty PGM-Fl system is often related to poorly connected or corroded connectors Check those connections before proceeding - Use a digital tester for PGM-Fl system inspection - The MAP, IAT and TP sensors are integrated in one sensor unit that is located on the left side of the two cylinders throttle body The MAP and IAT sensors are measured at the left (No. 1) cylinder of the throttle body and the ECM calculates the value in the right (No. 2) cylinder on the basis ot the left cylinder measurement. - The followmg color codes used are indicated through out this section Lg = Light Green R = Red V I Yellow 0 = Orange V = Violet LI.) 7 nght Blue F’ = Plnk W = Whlte TOOLS 7 SCS service confictor W 7 Test probe (2 required) 7 77 ‘7759nsor socmurrench, f2 mm if 070PZVZY30100 O7ZAJ-RDJA1‘lO 07LAA-PT50101 or equivalent commercially available in U S A. PGM-Fl SYSTEM SYSTEM LOCATION CBRSODRA shown No, 2 FUEL No. 1 FUEL INJECTOR ECM INJEC R To BANK ANGLE SENSOR \\ N 7\ SENSOR UN‘T: \ 7 \x E“ 7 MAP SENSOR 5 L\ f — IAT SENSOR — TP SENSOR RELAY BOX (MAW RELAY) ECT SENSOR VS SENSOR CKP SENSOR Oz SENSOR PGM-Fl SYSTEM SYSTEM DIAGRAM russ Enx - \GNWON 5mm w mews STOP Smrm ENG smv 1/ w MAW Raw ms; eon Fmsm ma paw EAWERV msa Box ‘ L was" RN ;7 5 m :aMawmuN w H0 m 1 w W LLUCKJVUHN u m FAN “5A, a v, © (544 54.2) BANK mst smsnn (0,) [11.1) \ssmsnp €333? mm u rxamxu 1 SENSOR wu WW 3 n .1, 172, my 9507. (Ems-2y ‘ 'Psznsow (9-1 9-2) ‘ nsENsnw © (74 7721 :cr SENSOR FUELV‘UMP Rmv vs m m w FAN: m © (33-2) ECM rs Bu Emu m m FAN cowwm may © (mug © (134ng m MOTOR r‘ «m quLwJEcmR No 2 run mrFCTOR gov swm— o, SPARK Pu w V» CC) V214 2371) 0: smsw mum colLs am PM»: come. sow ’Nom VA IF A; Wile 5w r‘uRsE wmm ‘ 25 smsmm we ‘ 21 sz scs 2x 55mm stEsrAVD SWWCH w mum D‘DDE : swncn @L I 5‘ Black F Pnk 38g 7 mm » ‘ B“ R R“ 7 . - ‘ é‘ ,, V ‘ am am v mom whence‘emq ms ‘ 225.252 xazynuanz’n" 6 Green W WM 61 GB) v Vewaw (Gt: Shon‘ermma‘s’nr ECM 339 (mam) CONNECTOR (ECM smex L9 Ughiween readmg OT: 0 ‘Orange PGM-Fl SYSTEM PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting If the MIL was on, but then went out, the original problem may be intermittent Opens and Shorts "Opens" and "Shorts" are common electrical terms. An open is a break in a Wire or at a connection. A short is an accidental connection of a Wire to ground or to another wire. In simple electronics, this usually means something Will not work at all With ECM this can mean something may work, but not the way it‘s supposed to if the MIL has come on Refer to DTC READOUT (page 476). If the MIL did not stay on lithe MIL did not stay on. but there IS a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 4-8). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The PGM-Fl system is equipped with the self-diagnostic system, When any abnormality occurs in the system, the ECM turns on the MlL and stores a DTC in its erasable memory. FAIL-SAFE FUNCTION The PGMVFI system is provided With a fail-safe function to secure a minimum running capability even when there is trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by pre»programed Value in the simulated program map, When any abnormality is detected in the injector. the failrsate function stops the engine to protect it from damage. DTC - The DTC is composed of a main code and a sub mole and it is displayed as a hyphenated number when retrieved from the ECM with the MOS. The digits in front of the hyphen are the main code, they indicate the component of function failure. The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure. For example, in the case of the TP sensor: A DTC 08-1 : (TP sensor voltage) — (lower than the specified value) A DTC 08-2 : (TP sensor voltage) - (higher than the specified value) ~ The MAP, ECT, TP and IAT sensor diagnosis will be made according to the voltage output of the affected sensor, if a failure occurs. the ECM determines the Function Failure, compares the sensor voltage output to the standard value, and then outputs the corresponding DTC to the MOS. For example: 7 If the output voltage line on the MAP sensor Is opened, the ECM detects the output voltage is about 5 V then the DTC 1-2 (MAP sensor cll‘CUlt high voltage) Will be displayed. 7 It the input voltage line on the TP sensor is opened, the ECM detects the output voltage is 0 V, then the DTC 84 (TP sensor circuit low voltage) will be displayed. MIL BLINK PATTERN ' II the MOS is not available, DTC can be read from the ECM memory by the lVIlL blink pattern ' The number of MIL blinks is the equivalent to the main code of the DTC (the sub code cannot be displayed by the MIL). - The MIL will blink the current DTC. in case the ECM detects the problem at present. when the ignition swrtch is turned ON with the engine stop switch "0" or idling with the sidestand down. The MlL will stay ON when the engine speed is over 1,900 rpm or with the sidestand up. ~ The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for IS seconds, the short blinking lasts (or 0.3 seconds, One long blink is the equivalent often short blinks, For example, when two long blinks are followed by nine short blinks, the DTC is 29 (two long blinks = 20 blinks, plus nine short blinks). - When the ECM stores more than one DTC, the MlL will indicate them by blinking in the order from the lowest number to highest number. MIL CHECK When the ignition switch is turned ON with the engine stop swrtch "(7", the MIL will stay on for a few seconds. then go off. If the MIL does not come on or stays on, inspect the MlL circuit (page 4-36). PGM-Fl SYSTEM CURRENT DTC/STORED DTC The DTC is indicated in two ways according to the failure status. 0 In case the ECM detects the problem at present, the MIL Will start blinking as its DTC, It is possible to read out the MIL blink pattern as the current DTC. ~ In case the ECM does not detect any problem at present but has a problem stored in its memory. the MIL will not blink It it is necessary to retrieve the past problem, read out the stored DTC by following the DTC Readout procedure (page 4-6), MCS INFORMATION - The MCS can read out the DTC, stored data. current data and other ECM condition. How to connect the MOS Remove the followmg' A CBRSOORi‘RA/CBSOOF/FA: front seat (page 245) e CBéOOX/XA: seat (page 276) Turn the ignltlon SWItch OFF ‘ ‘ ABS model shown: Remove the DLC [l] from the dummy connector [2]. Connect the MOS to the DLC Turn the ignition swrtch ON With the engine stop switch "0" and check the DTC and stored data 1 NOTE - Stored data indicates the engine conditions when the first malfunction was detected. DTC READOUT Current DTC Turn the ignition switch ON with the engine stop switch "(7" and check the MIL Start the engine and check the MIL, If the engine Will not start, turn the starter motor Ior more than 10 seconds and check that the MIL blinks. ltlhe MIL blinks connect the M05 to the DLC (page 4-6). Read the DTC stored data and follow the DTC index (page 479), - Ifthe MIL does not blink, the system is normal at present. If you Wish to read the stored DTC. connect the MOS to the DLC, ' II the MOS is not available, note how many times the MIL blinks and follow the DTC index (page 479) If you Wish to read the stored DTC, perform the tollowmg Reading stored DTC with the MIL Remove the following li'iiiiiir 'fi’j l e CBRSDOR/RA/CBSDDF/FA front seat (page 276) — CBSOOX/XA seat (page 2-6) ‘ [1] Turn the Ignition SWItch OFF Remove the DLC [1] from the dummy connector [2} and short the DLC terminals using the special tool. TOOL: [3] SCS service connector 070PZ-ZY30100 CONNECTION: Brown — Green Turn the ignition switch ON with the engine stop switch "(3", read the MIL ‘ M / \ ’”‘ / blinks and reter to the DTC index (page 4-9). \\ 4 ° If the ECM has stored DTC in its memory, the MIL will illuminate 03 seconds and go off. then start blinking as its DTC when you turn the ignition switch ON. - lithe ECM has no stored DTC, the MIL Will illuminate and stay on when you turn the ignition switch 0N 4-6 PGM-Fl SYSTEM ERASING STORED DTC NOTE - The stored DTC can not be erased by simpiy disconnecting the battery negative cabie Erase the DTC With the MOS while the engine is stopped. How to erase the DTC without MCS 1 Connect the 508 service connector to the DLC (page 4-6) [ 2. Turn the ignition sWItch ON with the engine stop swflch "(1“ 3 Disconnect the SCS sen/ice connector [1] from the DLC [2] i Connect the SOS servrce connector to the DLC again whiie the MIL ( stays ON Within 5 seconds (reset receiVing pattern). 4 The stored DTC is erased if the MIL goes off and starts blinking (successful pattern). - The DLC must be iumped while the MIL iights. It not, the MIL wili go off and stay on (unsuccessful pattern) In that case turn the ignition SWitch OFF and try again. I - Note that the sell»diagnostic memory cannot be erased if the ignition i sWItch is turned OFF beiore the MIL starts blinking. CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR - Aiways clean around and keep any foreign material away from the ECM 7 ' 7 ' ' ' F "i 33F (Black) connector beiore disconnecting it. - A faulty PGMVFI system is often related to poorly connected or corroded terminals Check those connections belore proceeding. ~ In testing at ECM 33F (Black) connector (including IACV 4P connector) terminal (wrre harness side), always use the test probe. insert the test probe into the connector terrninai. then attach the digital muitimeter probe to the test probe TOOL: [1] Test probe 07ZAJ-RDJA110 4-7 PGM-Fl SYSTEM PGM-Fl SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or MIL blinking. refer to the DTC index (page 4-9) and begin the appropriate troubleshooting procedure. If there are no DTC stored in the ECM memory do the diagnostic procedure for the symptom. in sequence listed below, until you find cause. iymptom 7 Diagnosisirocedu’r’ei” 7 Also chem W Engine cranks but won’t start 7 (No DTC and MIL blinking) 77 Engine cranks butwon'twstart W ) (No fuel pump operation sound when turning the ignition ON) Engine stalfifhiard to start", rough idling 1. Crank the engine for more than ten seconds and check the MIL (page4-6) and execute the troubleshooting according to the DTC, 2. Inspect the ignition system (page 545) 3. Inspect the fuel supply system (page 7-6), 4. Check the spark plug condition (page 3- ), 5. Check the cylinder compression (page 10— 5) 1. EcM power/ground circuits malfunction (page 4-37). 2. Inspect the fuel pump system (page 7» 2. Check the IACV (page 74 7). 10) 3. Inspect the fuel supply system (page 776) ' 1? Check the idle speecl'miage'éei'ir’” " . No fuel to fuel injector ( » Clogged fuel filter i — Pinched or clogged fuel tank breather hose (A, CM types) or ( fuel tank-torEVAP canister hose (AC type) — Pinched or clogged fuel feed hose — Faulty fuel pump — Faulty fuel pump circuits intake air leak Contammated/deteriorated fuel l Faulty fuel injector ‘ IACV stuck 7- Open'clrcuit in the power input and/or ground line of the ECM Short circuit in sensor unit line Faulty main relay and related c)rcult Restricted fuel feed hose Contamlnoted/deteriorated fuel . intake air leak Restricted fuel tank breather hose (A. CM types) orfuel tankrto»EVAF’ canister hose (AC type) Faulty ignltion system Afterburn when engine braking is used (page 7718). 2 rinspect the ignition system (page 5-3) "1. Inspect the secondary air supply system Backfiring or misfirlng during acceleration "if V Poor performance (driveability) and poor fuel economy Idle speed is below specifications orfast idle too low (No DTC and MIL blinking) Idle speed is above specifications or last idle too hlgh (No DTC and MIL blinking) MiLfiy’s on or MIL never comes on at all iiCheck Inspect the ignition system (page 5-3) Inspect the fuel suppvsystem (page 7-6) 1 Check the idle speed (page 3-12). 2, Check the IACV (page 7-17). ole speed (page’VS- 2. Check the throttle operation and reeplay (page 34). 3 Check the WW (page 747) Inspect the MlL C(r'cuii (page 4-36), ~ Air cleaner element contaminated - Pinched or clogged fuel feed hose . - Faulty pressure regulator (fuel pump) - Faulty fuel injector ~ Faulty ignition system - Faulty fuel supply system Faulty ignition system Faulty ignition system ‘ Intake air leak i Engine top-end problem Air cleaner coldition l 4-8 PGM-Fl SYSTEM DTC INDEX NOTE ~ lf the M08 is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the DTC. 7 7 7 7 , 7 7 7 7 7 7 7 , l DTC ‘ Function Failure ‘ Symptom/Fail-safe function I Riff, ‘ i7 _ , r 7 171 i MAP sensor Circuit low voltage (less than 0 029 V) - Engine operates normally 440 ‘ l - MAP sensor or its circuit malfunction l - Pre-program value 60 Wt} (450 mmHg) ‘ ; ‘ MAP sensor circuit high voltage (more than 3809 V) - Engine operates normally ‘ 172 ‘ - Loose or poor contact of the sensor unit connector - Pro-program value: 60 kPa (450 mmHg) 4711 ‘ - MAP sensor or its circuit mallunction 7 7, 7 7_1 r ECT sensor circuit low voltage (less than 0.049 V) ' Hard start at a low temperature 4713 ' ECT sensor or its circuit malfunction ‘ ' Pre-program value: 11g”C (230“F) ( ‘ ‘ ECT sensor circuit high voltage (more than 4946 V) l - Hard start at a low temperature ‘ ; 72 i - Loose or poor contact of the ECT sensor connector - Pie-program value‘ 110°C (230“F) 4714 l o ECT sensor or its circuit malfunction 7 l TP sensor circuit low voltage (less than 0.122 V) O Poor engine acceleration l E 8-1 - Loose or poor Contact of the sensor unit connector , O Preyprogram value: 0” 446 , 7 ~ TP sensor or its circuit malfunction 7 7 7 872 l TP sensor circuit high voltage (more than 4,965 V) ‘ - Poor engine acceleration ‘ 471i ~ [Pfiisfl or7its circuit malfunction 7 777 - Ererprogram value: 0“ 7 77 971 j lAT sensor circuit low voltage (less than 0.049 V) l - Engine operates normally 4719 17 7 j - lAT sensor or its circuimalfunction 7 7 '7 Preeprogram value: 35°C (95"F)7 l V i lAT sensor circuit high voltage (more than 4 946 V) - Engine operates normally 7 l 92 - Loose or poor contact of the sensor unit connector ‘ - Prerprogram value' 35"C (95"F) 4-20 J - lAT gensor or its circuit malfunction 77 7 ‘7 7777 7 777 7 777 V 1 VS sensor malfunction ‘ - Engine operates normally , 1171 r - Loose or poor contact of the VS sensor connector ( 422 l - VS sensor or its Circuit malfunction 7 7 L i i No 1 (left) fuel injector malfunction '7 r - Engine does not start ‘ V ‘ ‘ 12-1 ‘ - Loose or poor contact of the fuel injector connector r - Fuel injector, fuel pump and ignition coil $24 l l l - Fuel injector or its circuit malfunction shut down ‘ i No. 2 (right) fuel injector malfunction - Engine does not start l 13-1 l ~ Loose or poor contact of the fuel Injector connector ‘ - Fuel injector, fuel pump and Ignition coil l 4724 l 7 - Fuel injector or its circuit7malfu£tion l shut down ‘ ‘ ‘ ‘ 02 sensor malfunction V ‘ - Engine operates normally ‘ ‘ 21-1 « Loose or poor contact of the 02 sensor connector 4726 i ‘ ~ 0: sensor or its circuit malfunction ‘ j l ' 02 sensor heater malfunction - Engine operates normally ‘ 23-1 ‘ - Loose or poor contact of the 02 sensor connector ; 428 ‘ j ‘ - 02 sensor or its circuit malfunction 7 ‘ ‘ IACV malfunction i - Engine stalls, hard to start, rough idling ‘ i 29-1 - Loose or poor contact of the lACV connector ‘ 430 l 7 7 - IACV or its circuit malfunction l 7 j 3372, ECM EEPROM malfunction - Engine operates normally 4_32 ‘ - Does not h70|d the self-diagnosis data 7 Bank angle sensor circuit low voltage (less than 5020 V) l ' Engine operates normally ) ‘ ‘ 544 - Loose or poor contact of the bank angle sensor 1 ~ Engine stop function does not operate 4732 connector l j l 7 - Bank angle sensor or its circuit malfunction 7 ; 5L2 Bank angle sensor circuit high voltage (more than 4,986 V) - Engine operates normally 473; , 77 - Bank anglgsensor or its circuit malfunction ‘ ' Engine stop qution does not operate J '7 Serial communication malfinction ( - Engine operates normally ‘ ‘ 864 ‘ - Loose or poor contact of the related connector 4734 ‘ - Faulty combination meter or its circuit malfunction , j i l i ~ Faulty ECM 7 j 7 777 7 7 7 ( ‘ The MlL does not blink (DTC can be readout/erased only by MCS) PGM-Fl SYSTEM DTC TROUBLESHOOTING DTC 1 (MAP SENSOR) ECM 5 V SENSOR UNIT f (MAP SENSOR) J 5 V fl, Probable cause ‘ Open circuit In Yellow/red or Green/yellow WIre between the sensor um and ECM - Open or short clrcutt in Vlotet/red Wire between the sensor umt and ECM - Fautty sensar unit (MAP sensor) - Faulty ECM DTC 1-1 (MAP SENSOR LOW VOLTAGE) 1. MAP sensor system inspection Check the MAP sensor with the MOS Is about 0 Vindicated? YES — GO TO STEP 2 NO e Intermittent fatture 2. Sensor Unit Input Voltage Inspection Turn the ignmon switch OFF. Dtsconnect the sensor uml 5P (Black) connector [1] Turn the Igmtion switch ON win the engine slop swttch "0" Measure the voltage between the Wire harness side sensor umt 5P (Black) connector lermmals CONNECTION: Yellow/red (+) » Green/yellow (~) STANDARD: 4.75 - 5.25 V Is the voltage within standard value? YES — GO TO STEP 4, N0 — GO TO STEP 3, (Terrmnat Stde of the wwre harness) 4-10 PGM-FI SYSTEM 3. Sensor Unit Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 4-35). Check for continuity between the Wire harness side sensor unit 5F (Black) connector [1] and ECM 33F (Black) connector [2] terminals. TOOL: Test probe 07ZAJ-RDJA110 ‘ CONNECTION: Yellow/red — Yellow/red YES — Replace the ECM with a known good one, Is there continuity? ‘ and recheck, ‘ N0 — Open circuit in Yellow/red wrre MAP Sensor Signal Line Short Circuit Inspection Turn the ignition swrtch OFF F Disconnect the ECM 33F (Black) connector (page ‘ 44.6). Check for continuity between sensor unit 5P (Black) connector [1] terminal and ground. l CONNECTION: Violet/red — Ground i Is there continuity? YES NO — Short circuit in Violet/red Wire — GO TO STEP 5 . MAP Sensor Inspection Replace the sensor unit With a known good one (page 4738) Connect the ECM 33F (Black) Connector. Erase the DTC (page 477). Check the MAP sensor wrth the MOS, IS DTC 1-1 indicated? YES — Replace the ECM with a known good one, and recheck. N0 — Faulty original sensor unit (MAP sensor) DTC 1-2 (MAP SENSOR HIGH VOLTAGE) - Before starting the inspection. check for loose or poor contact on the sensor unit 5F (Black) and ECM 33F (Black) connectors and recheck the DTC, 1. MAP sensor system inspection Check the MAP sensor with the MOS Is about 5 vindicated? YES — GO TO STEP 2. N0 — Inlermiltent failure l (Terminal Slde of the wire harness) 4-11 PGM-Fl SYSTEM 2. Sensor Unit Input Voltage Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P (Biack) connector [1] Turn the ignition SWitch ON with the engine stop sWItch "C" Measure the voltage between the wire harness side i sensor unit 5P (Biack) connector terminals. CONNECTION: Yellow/red (t) — Green/yellow (—i STANDARD: 4,75 — 5.25 V Is the voltage within standard value? YES — GO TO STEP 3 N0 — Open circuit in Green/yellow wire 3. MAP Sensor System Inspection with Jumper Wire Turn the ignition switch OFF i Connect the Wire harness side sensor unit 5P (Black) connector [1] terminals with a Jumper wire [2] CONNECTION: Violet/red — Green/yellow Check the MAP sensor With the MOS ls about 0 Vindicated? ‘ ,_ YES 7 Faulty sensor unit (MAP sensor) / NO —GO TO STEP4 m i (Terminal Side oi the wire harness) ‘ 4. MAP Sensor Signal Line Open Circuit Inspection Turn the ignition swnch OFF. Disconnect the ECM 33p (Black) connector (page W 436) Check tor continuity between the Wire harness Side i sensor unit 5P (Biack) connector [1] and ECM 33F (Black) connector [2] terminais, TOOL: Test probe OTZAJ-RDJA110 CONNECTION: Violet/red — Violet/red Is there continuity? i YES v Repiace the ECM With a known good one. and recheck L N0 — Open Circuit in Vioiet/red wire 4-12 PGM-Fl SYSTEM DTC 7 (ECT SENSOR) ECM 5V ECT SENSOR { BUR + WW Bi/G + G/Y «fl * Probable cause - Open or short Circuit In BiacK/red or Pink/white wire between the ECT sensor and ECM - Open circuit in Black/green or Green/yeiiow Wire between the ECT sensor and ECM - Fauity ECT sensor - Fauin ECM DTC 7-1 (ECT SENSOR LOW VOLTAGE) 1. ECT Sensor System Inspection Check the ECT sensor With the MOS, Is about 0 V indicated? YES — GO TO STEP 2 NO — Intermittent iaiiure 2. ECT Sensor System Inspection with Connector Disconnected Turn the ignition swnch OFF‘ , Disconnect the ECT sensor 2P (Biack) connector ggieck the ECT sensor with the MCS Is about 0 V indicated? YES — GO TO STEP 3 NO — Faulty ECT sensor 4-13 PGM-FI SYSTEM 3. ECT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. ' W ’ if " Disconnect the ECM 33F (Black) connector (page i 4736) Check for continuity between the wire harness side ECT sensor 2P (Black) connector [1] terminal and ‘ Lia-‘3 ground BIVRLT CONNECTION: Black/red _ Ground ’ . /F\ Is there continuity? ‘4 YES — Snort circuit in Black/red or Pink/white wire ‘ \J ‘ i NO — Replace the ECM With a known good one. '7 l and recheckv (Terminal side of the wire harness) DTC 7-2 (ECT SENSOR HIGH VOLTAGEl - Before starting the inspection, check for loose or poor Contact on the ECT sensor 2P (Black). engine sub-Wire harness 5P (Black) and ECM 33F (Black) connectors, and recheck the DTC, 1. E01 Sensor System Inspection Check the ECT sensor With the MOS Is about 5 vindicated? YES — GO TO STEP 2 NO — intermittent failure 2. ECT Sensor System inspection with Jumper Wire Turn the ignition SWItcn OFFV _» Disconnect the ECT sensor 2P (Black) connector [1] Connect the wire harness side ECT sensor 2P (Black) connector terminals With aiurnper wire [2]. CONNECTION: Black/red — Black/green Check the ECT sensor With the MOS. Is about 0 vindicated? YES — GO TO STEP 4 NO — GO TO STEP 3. W ‘t, Bl/G EUR 1 \ [2] (Terminal side of the Wire harness) 4-14 3. ECT Sensor Line Open Circuit Inspection PGM-FI SYSTEM Turn the ignition switch OFF Disconnect the ECM 33F (Black) connector (page i [21“ 4-36) f i Check for continuity between the wire harness side ‘ \Qf ECT sensor 2P (Black) connector [‘1] and ECM 33F G/Y #» s _ (Black) ccnnector[2]termina|s BUG r ‘ _ ,fi r s.) i i r i i i Blacklgreen — Green/yellow l l Test probe O7ZAJ RDJA110 ‘ BUR ‘ 1 7 L L 12‘ ‘ CONNECTION: P’W ‘ Black/red — Fink/white l m Is there continuity? (Terminal side of the Wire harness) YES — Replace the ECM with a known good one, 7 ii*—' '777 ‘ and recheck. NO — - Open circuit in Black/red or Pink/while wire - Open circuit in Black/green or Green/ yellow wire 4‘ ECT Sensor Resistance Inspection Turn the ignition switch OFF i' #' Remove the ECT sensor (page 4-39) [1] Measure the resistance between the 2P connector terminals of the ECT sensor [1]. ‘ STANDARD: 1.0 — 1.3 k!) MOT/104$) Is the resistance within standard value? ‘ YES — Replace the ECM with a known good one, and recheck. i NO — Faulty ECT sensor Lee \ l 9 l DTC 8 (TP SENSOR) ECM SENSOR UNIT (TP SENSOR) of Ti Y/R \e R/Y v G/Y Probable cause - Open circuit In Yellow/red or Green/yellow Wire between the sensor unit and ECM . Open or short circuit in Red/yellow wtre between the sensor unit and ECM Short circuit between Yellow/red and Red/yellow Faulty sensor unit (TP sensor) Faulty ECM 4-15 PGM-Fl SYSTEM 3. Sensor Unit Input Line Open circuit Inspection DTC 8-1 (TP SENSOR LOW VOLTAGE) - Beiore starting the inspection check for loose or poor contact on the sensor unit 5P (Black) and ECM 33F (Black) connectors, and recheck the DTC 1. TP Sensor System Inspection Check the TP sensor with the MOS with the throttle ruiiy closed. Is about 0 Vindicated? YES — GO TO STEP 2 NO — intermittent failure 2. Sensor Unit Input Voltage Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector [1] Turn the ignition switch ON With the engine stop sWitch "0" Measure the voltage between the Wire harness side sensor unit 5P (Black) connector terminals CONNECTION: Yellow/red (+) — Green/yellow (—) STANDARD: 4.75 — 5.25 V Is the voltage within standard value? YES - GO TO STEP 4 N0 — GO TO STEP 3 Turn the ignition switch OFF Disconnect the ECM 33F (Black) connector (page 4-38) Check tor continuity between the Wire harness side sensor unit 5P (Black) connector [1] and ECM 33F (Black) connector [2] terminals. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Yellow/red — Vellawlred Is there continuity? ‘ YES — Replace the ECM with a known good one, and recheck. NO — Open circuit in Yellow/red wire 4-16 (Terminal Side oi the Wire harness) PGM-Fl SYSTEM 4. TP Sensor Signal Line Open Circuit Inspection Turn the Ignition switch OFF l’ Disconnect the ECM 33F (Black) connector (page ‘ [ ] 4-36). Check for continuity between the wire harness side I sensor unit 5P (Black) connector [1] and ECM 33F (Black) connector [2] terminals. l TOOL: Test probe 07ZAJ-RDJA11D l CONNECTION: Red/yellow — Red/yellow ‘ Is there continuity? ‘ YES — GO TO STEP 5 ‘ T ‘ d f h mina s t e h NO — Open circuit In Red/yellow Wire L V ( er > e 0 Wire amass) 5. TP Sensor Signal Line Short Circuit Inspection Check for continuity between the Wire harness side 1 sensor unit 5P (Black) connector [1] terminal and l 1 ground, ‘ ‘ CONNECTION: Red/yellow — Ground Is there continuity? YES —- Short circuit in Red/yellow wire ‘ NO — GO TO STEP 6 ‘ (Terminal side oi the Wire harness) 6. TP Sensor Inspection Replace the sensor unit with a known good one (page 4-38). Connect the ECM 33p (Black) connector. Erase the DTC (page 4-7). Check the TP sensor With the MOS. Is DTC 8-1 indicated? YES — Replace the ECM with a known good one, and recheck. NO — Faulty original sensor unit (TP sensor) DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Check the TF sensor with the MOS. Is about 5 V indicated? YES — GO TO STEP 3. NO — GO TO STEP 2. 2. TP Sensor System Inspection with throttle operated Check that the TP sensor voltage increases continuously when moving the throttle from lully closed posnion to fully opened position using the data list menu of the MOS Is the voltage increase continuously? YES — Intermittent failure N0 — Faulty sensor unit (TP sensor) 4-17 PGM-Fl SYSTEM 3. Sensar Unit Input Voltage Inspection Turn the igniiion switch OFF Disconnect the sensor unit 5P (Biack) connector [1] Turn the ignition swrich ON With me engine stop _ swrlch "0" Measure the voilage between the wrre harness Side sensor unit 5P (Black) connector terminals, CONNECTION: Yellow/red (+) — Green/yellow (—) STANDARD: 4.75 — 5.25 V Is the voltage within standard value? YES — GO TO STEP 4. NO — Open CirCUIl in Green/yellow wire (Terminai slde or Ihe wire harness) 4. TP Sensor Line Short Circuit Inspection Turn the ignition switch OFF DiSCOHneCI the ECM 33P (Black) connecior (page 4736). Check for continuity between the Wire harness side sensor unit 5P (Black) connector [1] terminais CONNECTION: Vellowlred — Red/yellow Is there continuity? YES — Short circuit between Yellow/red and Red/ yellow wires NO — GO TO STEP 5' 5. 1PSensorlnspection Replace the sensor unit wrih a known good one (page 4735). Connect the ECM 33F (Biack) connector. Erase the DTC (page 47) Check the TP sensor With the MOS ls DTC 8-2 indicated? YES — Replace the ECM with a known good one, and recheck. ND — Fauity original sensor unit (TP sensor) 4-18 PGM-Fl SYSTEM DTC 9 (IAT SENSOR) ECM 5 V SENSOR UNIT + (iAT SENSOR) (: s _l_> Probabie cause - Open or short circuit in Gray/blue wrre between the sensor unit and ECM ~ Open curcuii in Green/yeilow wure beiween lhe sensor unli and ECM ¢ Fauin sensor unit (iAT sensor) - Fauin ECM DTC 9-1 (|AT SENSOR LOW VOLTAGE) 1. IAT Sensor System Inspection Check the IAT sensor with the MCS. Is about 0 V indicated? YES — GO TO STEP 2 NO — Intermitteni iaiiure 2. IAT Sensor System Inspection with Connecmr Disconnected Turn the ignition swmch OFF. Disconnect the sensor unii 5P (Black) connector [1] Check (he IAT sensor Wiih the MCS Is about 0 Vindicared? YES — GO TO STEP 3, NO — Fauin sensor unit (IAT sensor) 4-1 9 PGM-Fl SYSTEM 3‘ IAT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. ' Disconnect the ECM 33F (Black) connector (page 4736). Check for continuity between the Wire harness side sensor unit 5P (Black) connector [1] terminal and ground. CONNECTION: Gray/blue — Ground Is there continuity? ‘ YES — Short circuit in Gray/blue wire N0 — Repiace the ECM with 3 Known good one and recheck. (Terminai Side oi the wire harness) L , 7 , fii, DTC 9-2 (IAT SENSOR HIGH VOLTAGE) - Before starting the inspection, check ior ioose or poor Contact on the sensor unit 5P (Black) and ECM 33F (Black) connectors, and recheck the DTC. 1. IAT Sensor System Inspection Check the [AT sensor With the MOS Is about 5 V indicated? YES — GO TO STEP 2 N0 — intermittent faiiure 2. IAT Sensor System Inspection with Jumper Wire Turn the ignition swrtch OFF Disconnect the sensor unit 5P (Biack) connector [1]. Connect the wire harness side sensor unit 5P 1 (Black) connector termihais with a jumper wrre [2]. CONNECTION: Gray/blue — Green/yellow Check the KAT sensor With the MOS ls about 0 vindicated? YES — Fauiiy sensor unit (IAT sensor) NO — GO TO STEP 3 Gri’BU 7A G/Y ‘ E ii] (Termlnai Side of the ere harness) 4-20 PGM-Fl SYSTEM 3. IAT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector (page 4-36), Check for continuity between the wire harness side sensor unit 5P (Black) connector [1] and ECM 33P (Black) oonnector [2] terminals. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: ‘ Gray/blue — Gray/blue Green/yellow - Greenlyellow IS Mere continuity? (Terminai side of the wire harness) YES — GO TO STEP 4 'i' '—_ N0 ~ - Open circuit in Gray/biue Wire - Open circuit in Green/yellow wire 4. IAT Sensor Resistance Inspection Connect the sensor unit 5P (Black) connector F ’ ' 7' ’ Measure the resistance between the wire harness side ECM 33F (Black) connector [1} terminals. TOOL: Test probe o7ZAJ-RDJA110 ‘ CONNECTION: Gray/blue — Greenlyellow STANDARD: 1 —4 m (20°Cl68°F) Is the resistance within standard value? ‘ YES — Replace the ECM with a known good one, i and recheck. N0 — Faulty sensor unit (IAT sensor) (Tem‘ma‘ Side 0' me MEETS“) 4-21 PGM-Fl SYSTEM DTC 11 (VS SENSOR) - Belore starting the inspection‘ check for loose or poor contact on the VS sensor 3P (Black), engine subrwwe harness 6P (Black) and combination meter tGP (Gray) connectors, and recheck the DTC. From (use box H vs SENSOR ' Probable cause ~ Open circuit in Pink/blue wire between the fuse box and VS sensor - Open circuit in Green/red or Green wire between the VS sensor and ground - Open or short circuit in Pink/green wtre between the VS sensor and combination meter Faulty VS sensor Faulty combination meter DTC11-1 (VS SENSOR) 1. Recheck DTC Erase the DTC (page 4-7). Test-ride the motorcycle above 3500 rpm. Stop the engine, Check the VS sensorwtth the MOS ls DTC 11-1 indicated? YES - GO TO STEP 2 N0 — Intermittent laiiure 2. VS Sensor Input Voltage Inspection Turn the ignition switch OFF i" Disconnect the VS sensor 3P (Black) connector (page 4430), _ Connect the tollowing connectors by temporarily installing the throttle body/air cleaner housing assembly, 7 IACV 4P (Black) 7 No, 1 and No 2 fuel injector 2P (Gray) 7 sensor unit 5P (Black) i Turn the ignition swttch ON with the engine stop switch Measure the voltage between the Wire harness side VS sensor 3P (Black) connector [1] terminals. CONNECTION: Pink/blue (+) » Green/red (—) Is there battery voltage? YES — GO TO STEP 3. N0 — - Open circuit in Pink/blue wire - Open circuit In Green/red or Green Wire COMBiNATION METER [l] P/Bu i G/R 9 (Terminal side at the Wire harness) 4-22 PGM-Fl SYSTEM 3. VS Sensor Signal Line Short Circuit Inspection Turn the Ignition swrtch OFF. Check for continuity between the wire harness side ‘ VS sensor 3P (Black) connector [1] ierrninal and ground CONNECTION: Pink/green — Ground l Is there continuity? YES — Short CiFCUlI in Pink/green wire N0 — GO TO STEP 4, ‘ l L (Terminal side or the wire harness) 4‘ VS Sensor Signal Line Open Circuit Inspection Disconnect lhe combination meter 16F (Gray) i connector as the combination meter power/ground line lnspeclion (page 2140) ‘ Check for continuity between the Wire harness side ; [2] ‘ VS sensor 3P (Black) connector [1] and oomblnalion [1] F07 :2 / meter 16P (Gray) conneclur [2] terminals TOOL: PIG Test probe n7ZAJ-RDJA11u we (“fl #4 ‘ CONNECTION: Pink/green — Fink/green Is there continuity? YES — GO TO STEP 5. NO - Open clrcuil in Pink/green WIre V (Termmal side oi me WIre harness) 5. VS Sensor Inspection Replace the VS sensor Win] a known good one (page 4-40), Connect the combination meter 16P (Gray) conneclor. Erase Ine DTC (page 4-7). Test-ride the motorcycle above 3,600 rpm. Stop lhe engine. Check the DTC with the MOS Is DTC 11-1 indicated? YES —Replace the combination meter With a known good one. and recheck, NO — Faulty original VS sensor 4-23 PGM-Fl SYSTEM DTC 12 (No. 1 [left] FUEL INJECTOR)! DTC 13 (No. 2 [right] FUEL INJECTOR) - Before startlng the inspection, check for loose or poor Contact on the fuel lnjector 2P (Gray) and ECM 33F (Black) connectors and recheck the DTC. ECM From main relay FUEL INJECTOR T BINV *J r L L No. 1: EUR J No 2' R/Bl Probable cause . Open Cll’CLIII in Black/white ere between the main relay and fuel lnjector ' Open or short circuit ln Black/red (No. 1) or Red/ black (No 2) w1re between the fuel injector and ECM - Faulty tuel Injector - Faulty ECM DTC 12-1 (No. 1 [left] FUEL INJECTOR)! DTC 13-1 (Not 2 [right] FUEL INJECTOR) 1. Recheck DTC Erase the DTC (page 4-7). Start the englne and check the tuel injector wlth the MOS Is the DTC 12-1 at 13-1 indicated? YES — GO TO STEP 2 N0 — lntermltlentfallure 4-24 PGM-FI SYSTEM 2. Fuel Injector Input Voltage Inspection Turn the ignition switch OFF, Lift the fuel tank and support it (page 3—4). Disconnect the fuel Injector 2P (Gray) connector [1]t Turn the ignition switch ON with the engine stop switch “()"V ‘ Measure the voltage between the Wire harness side injector 2P (Gray) connector terminal and ground. ‘ CONNECTION: Black/white (4r) — Ground (—) 1 [1] (No, 2) Is there battery voltage? § YES — GO To STEP 3, >' I NO - Open circuit in Black/white wire m (No' 1) “ L) ‘ 1 [1] I L L p , Bl/W “ e I V 3. Fuel Injector Resistance Inspection Turn the ignition swnch OFF. Measure the resistance between the 2P connector terminals of the fuel Injector [1]. STANDARD: 11 — 13 Q (NT/68°F) Is the resistance within standard value? YES — GO TO STEP 4. N0 — Faulty fuel injector 4. Fuel Injector Signal Line Open circuit Inspection Disconnect the ECM 33F (Black) connector (page fi' 4-36) ‘ m Check tor continuity between the wire harness side ‘ Vuel injector 2P (Gray) connector [1] and ECM 33F (Black) connector [2] terminals. ‘ , TOOL: No I «I ’ Test probe OTZAJ-RDJA110 ‘ km 7’ ‘ CONNECTION: I N 2 - LU L sf fi‘ Not 1: Black/red - Blacklred I 0' t: e R/BI No. 2: Red/black _ Red/black ‘ @ Is there continuity? U ‘ YES — GO TO STEP 5. ‘ (Terminal side olthe wire harness) N0 — - Open circuit in Black/red wire . Open circuit In Red/black wure 4-25 PGM-Fl SYSTEM 5. Fuel injector Signal Line Short Circuit Inspection Check for continuity between the wire harness 5m feweru—e WWW 2P (Grail) Connector [1] terminal and : grounds ‘ [1] CONNECTION: ‘ No. :Blacklred - Ground ‘ 1101 EUR No. ext/black — Ground No. 2' R/Bl Is there continuity? ‘ g?) YES ~ - Short circun in Black/red wire i / - Short circuit In Red/black wire ‘ NO — Replace the ECM with a known good one, and recheck ’ (Terminal side at the Wire harness) % 7wi , DTC 21 (02 SENSOR) - Betore starting the inspection check tor loose or poor contact on the 02 sensor 4P (Black) and ECM 33F (Black) connectors and recheck the DTC From main relay ECM 02 SENSOR i i L ‘ r > 7 Bl i W/G [ —> *- Gr fl SN 1 Probable cause ~ Open or short circuit in White/green wire between the ECM and 02 sensor ~ Open circuit in Green/yellow Wire between the 02 sensor and ECM Faulty 02 sensor Faulty ECM DTC 21-1 (02 Sensor) 1. Recheck DTc Erase the DTC (page 4-7). Start the engine and warm it up until the coolant temperature is we (176“F). Stop the engine. Check the O7 sensor With the MCS. Is the DTC 21-1 indicated? YES — GO TO STEP 2. NO - Intermittent failure 4-26 PGM-Fl SYSTEM 2t 02 Sensor Line Open Circuit Inspection Turn the ignition switch OFF. #" Disconnect the 02 sensor 4P (Black) connector (page 4-40). Disconnect the ECM 33F (Black) connector (page 1 4-36). Check tor continuity between the wire harness side O2 Sensor 4P (Black) connector [1] and ECM 33F G ”i (Black) connector [2] terminals. i ‘ TOOL: i W/G 7*; _‘V , , l Test probe 07ZAJ-RDJA110 l / W/G i CONNECTION: ‘ Q ‘ White/green — White/green “1 ‘ Greenlyetlow — Green/yellow (Terminal side at the wire harness) ,— Is there continuity? YES — GO TO STEP 3’ N0 — Open circuit in White/green or Green/ yellow wire 3. 01 Sensor Output Line Short Circuit Inspection Check the continuity between the wire harness side if 7" ’ ’ Oz sensor 4P (Black) connector [i] terminal and ground, CONNECTION: White/green — Ground ‘ Is there continuity? l YES — Short circuit in White/green Wire N0 —- GO TO STEP 4 i i T ‘ L (Terminatiotfltntfle harness) 1 4. 02 Sensor Inspection Replace the 07 sensor with a known good one (page 4-40) Connect the ECM 33p (Black) connector, Erase the DTC (page 4-7). Start the engine and warm it up until the coolant temperature is 80"!) (176*). Stop the engine, Check the ()2 sensor with the MOS is the DTC 21-1 indicated? YES — Replace the ECM With a known good one, and recheck. NO — Faulty original 02 sensor 4-27 PGM-Fl SYSTEM DTC 23 (Oz SENSOR HEATER) - Before starting the inspection, check for loose or poor Contact on the 02 sensor 4P (Black) and ECM 33F (Black) connectors, and recheck the DTCV From main relay Y BlNV Oz SENSOR Probable cause - Open circuit in Black/while wire between the main relay and 02 sensor - Open or short circuit in White wire between the 0: sensor and ECM Faulty O2 sensor Faulty ECM DTC 23-1 (02 SENSOR HEATER) 1. Recheck DTC Erase the DTC (page 4-7). Start the engine and check the 02 sensor heater with the MCS Is DTC 23-1 indicated? YES — GO TO STEP 2' NO — Intermittent failure 2. 02 Sensor Heater Resistance Inspection Turn the ignition swtlch OFF, Dlsconnecl lhe 02 sensor 4P (Black) conneclor (page 4740) Measure the resistance between the sensor side 02 sensor 4P (Black) connector [1] terminals. CONNECTION: White - White STANDARD: 10 — 40 D (ZO°C/68°F) Is the resistance within standard value? YES — GO TO STEP 3 NO — Faulty Oz sensor ECM (Termlnal side of the sensor wrre) 4-28 3. O2 Sensor Heater Input Voltage Inspection Turn the ignition switch ON with the engine stop swucn “0". Measure the Voltage between the wire harness side 02 sensor 4P (Black) connector [1] and ground. CONNECTION: Black/white (+) — Ground (—) Is there battery voltage? YES — GO TO STEP 4, N0 — Open circuit in Black/white Wire 4. 02 Sensor Heater Line Open Circuit Inspection Disconnect the ECM 33F (Black) connector (page 4736), Check the continuity between the Wire harness side 02 sensor 4P (Black) connector [‘I] and ECM 33F (Black) connector [2] terminals, TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: White — White Is there continuity? YES — GO TO STEP 5 N0 — Open circuit in White wire 5, 0: Sensor Heater Line Short Circuit Inspection Check the continuity between the wire harness side 02 sensor 4P (Black) connector [1] terminal and ground, CONNECTION: White — ground Is there continuity? YES NO — Short circuit in White Wire — Replace the ECM with a known good one. and recheck, r4, ti n11 l PGM-FI SYSTEM [1] EINV 6) (Terminal side of the wire harness) lifl W l l l l l l_ , i W (Terminal side at the wire harness) (Terminal side of the wire harness) 4-29 PGM-Fl SYSTEM DTC 29 (IACV) - Before starian the inspection, check for loose or poor contact on the IACV 4P (Biack) and ECM 33F (Biack) connectors, and recheck the DTC. ECM IACV T we T V/W ‘ r Gr/R W P/Bi r L Probable Cause - Open or short circuit in Vellow/green, Vioiei/wmte, Gray/red or Pink/black wire between the IACV and ECM - Faulty IACV - Faulty ECM DTC 29-1 (IACV) 1. Recheck DTC Erase the DTC (page 4-7), Check the iACV with the MCS. Is the DTC 29-1 indicated? YES — GO TO STEP 2' N0 — Intermittent faiiure 2. IACV Resistance Inspection Turn the Ignition switch OFF. Lift the fuel tank and support it (page 3-4), Disconnect the IACV 4P (Biack) connector [1] Measure the resistance between the 4P connector terminals oi the IACV [2], TOOL: i Test probe 07ZAJ-RDJA110 i CONNECTION: A— D B — C STANDARD: 110 — 150 n(25°c171"r) Is the resistance within standard value? YES — GO TO STEP 3 NO — Fauity IACV ‘ 4-30 PGM-Fl SYSTEM 3. IACV Internal Short Circuit Inspection Check for continuity between the 4P connector terminals of the iACV [1] T ' iiiiiiim i TOOL: A Test probe 07ZAJ-RDJA110 ‘ KS; CONNECTION: A — B i [1] A i B ‘ c — D ‘ / W i w ,r Is there continuity? \ V // YES — Fauity IACV C D No — GO TO STEP4 i i i ‘ i lACV Line Open Circuit Inspection Disconnect the ECM 33F (Black) connector (page 4735), Check tar continuity between the wire harness side ECM 33p (Black) connector [1] and IACVAP (Biack) connector [2] terminais. TOOL: Test probe (2 required) 07ZAJ-RDJA110 CONNECTION: Yellowlgreen — Yellow/green Violet/white — Violet/white Gray/red — Gray/red Pink/black — Fink/black Is there continuity? ‘ Q\ YES — GO TO STEP 5. [1] WW _ . . i V No 85:: Valium In VEHOW/green or mlev ‘ (Terminai side ofthe Wire harness) ~ Open circuit in Gray/red or Pink/black ‘ W wire . IACV Line Short circuit Inspection Check for continuity between the Wire harness side F Yellow/green — Ground Violethhite — Ground Gray/red — Ground Pink/black — Ground iAcv 4P (Black) connector [1] terminals and [11 i ground \ 1 TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: ‘ i i959? Is there continuity? ‘ 8/ i % (Terminai Side of the Wire harness) ‘ YES — - Short circuit in Yellow/green or Vioiet/ L white Wire ’ ' "if 7 ~ Short circuit in Gray/red or Pink/black wire NO — Repiaoe the ECM with a known good one, and recheckv 4-31 PGM-Fl SYSTEM DTC 33-2 (ECM EEPROM) 1. Recheck DTC Erase me DTC (page 477). Check the ECM EEPROM wilh the MCS. Is the DTC 33-2 indicated? YES — Replace the ECM wilh a known good one, and recheck. N0 —|nlermiltenllailure DTC 54 (BANK ANGLE SENSOR) From mam relay El/W g r BANK ANGLE SENSOR Probable cause Open circull in Black/white wire berween [he mam relay and bank angle sensor Open or shon clrcull in Black/blue wire between Ihe bank angle sensor and ECM Faulty bank angle sensor Faulty ECM DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE) Before stamng the Inspection, check for loose or poor contacl on lhe bank angle sensor 2P (Black) and ECM 33P (Black) connectors. and recheck the DTC . Bank Angle Sensor Syslem Inspection Erase the DTC (page 4-7) Check the bank angle sensor with the MOS. Is about 0 Vindicated? YES — GO TO STEP 2. N0 — lnterrniltenllailure ECM 4-32 . Bank Angle Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect Ine bank angle sensor 2P (Black) connector (page 4-41), Check for continuity between the wire harness side bank angle sensor 2P (Black) conneclor [1] terminal and ground. CONNECTION: Black/blue — Ground Is there continuity? YES NO — Short circuit ll'l Ihe Black/blue wire — GO TO STEP 3. . Bank Angle Sensor Signal Line Open Circult Inspection Check for continuin between the wire harness side 7 bank angle sensor 2P (Black) connector [11 and ECM 33F (Black) connector [2] terminals, TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Black/blue — Black/blue Is there continuity? YES — GO TO STEP 4. N0 — Open circuit in the Black/blue wire . Bank Angle Sensor Input Voltage Inspection Temporarily install the ECM to the wrre harness by connecting the 33F (Black) connector. Turn the ignition switch ON With the engine stop swrtch “0". Measure Ihe voltage between the Wire harness side bank angle sensor 2P (Black) connector [1] terminal and ground CONNECTION: Black/white (+)— Ground (Al Is there battery voltage? YES — GO TO STEP 5 N0 — Open circuit in Black/white Wire . Bank Angle Sensor Inspection Check the bank angle sensor (page 4-42). Is the bank angle sensor normal? YES — Replace the ECM with a known good one‘ and recheck NO — Faully bank angle sensor PGM-Fl SYSTEM (Terminal side of the wire harness) [l] \ (Terminal side of the Wire harness) 4-33 PGM-FI SYSTEM DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE) 1. Bank Angle Sensor System Inspection Erase the DTC (page 477) Check the bank angle sensor With the MOS Is about 5 V indicated? YES — GO TO STEP 2. NO — Intermittent failure 1 Bank Angle Sensor Inspection Replace the bank angle sensor With a known good one (page 4-41) Erase the DTC (page 4-7). Check the bank angle sensor With the M05 IS DTC 54-2 indicated? YES — Replace the ECM with a known good one‘ and recheck. N0 — Faulty original bank angle sensor DTC 86 (SERIAL COMMUNICATION MALFUNCTION) NOTE - Refer to Technical Feature for configuration of the serial communication (page 1-83) - Before starting the inspection check the following connectors for loose or poor contact and the fuse for blown A front sub-wire harness 12P (Black) and AP (Black) » ECM 33F (Black) » combination meter 16F (Gray) — CLOCKfl’URN fuse (7.5 A) DTC 86-1 (SERIAL COMMUNICATION) 1. Recheck DTC Erase the DTC (page 47) Check the serial communication With the MOS, Is DTC 56-1 indicated? YES - GO TO STEP 2 NO — Intermittent failure 2. ECM Serial Communication Output Voltage Inspection Turn the ignition swrtch OFF Remove the left middle cowl (page 2-8). Disconnect the front sub-Wire harness 12F (Black) connector [1] Short the DLC terminals using the SOS service connector (page 4-6). Open the throttle grip fully‘ hold II and turn the ignition switch ON with the engine stop switch "0" Wait for more than 10 seconds and release the throttle grip NOTE ~ The ECM enters the communication diagnostic output mode The open circuit in the ECM can be checked in this mode. CBRSOOR/RA; A, CM types shown / 4-34 PGM-Fl SYSTEM Measure the voltage between the wire harness side 12F (Black) connector [1] terminal and ground. CONNECTION: Red/blue (+) — Ground (—) Does the voltage repeat cycling between I) V to B Var more at intervals ofs seconds? YES — GO TO STEP 3, NO — Replace the ECM With a known good one, and recheck 1 Combination Meter Serial Communication Output Voltage Inspection Turn the ignition swnch OFF. Remove the 808 service connector Connect the Iront sub-Wire harness 12F (Black) connector. Disconnect the ECM 33F (Black) connector (page 4-36). Push and hold combination meter buttons SEL [1] . and SET [2], and turn the ignition swnch ON with the engine stop swnch "0" Wait for more than 10 seconds and release the buttons, NOTE: - The combination meter enters the communication diagnostic output mode, The open circuit in the combination meter can be checked in this mode, Measure the voltage between the Wire harness side ECM 33F (Black) connector [1] terminal and ground. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Red/blue (+) — Ground (—) Does the voltage repeal cycling between a V to 8 V or more at intervals of5 seconds? YES — GO TO STEP 4 NO —Replace the combination meter With a known good one. and recheck. 4, Combination Meter Back-up Voltage inspection Turn the ignition switch OFF. Disconnect the combination meter 1GP (Gray) connector (page 21711) Measure the voitage between the combination meter 1GP (Gray) connector [1] terminal and ground. CONNECTION: Red/white (H — Ground (-) Is there battery voltage? YES ~ intermittent failure NO — Open circuit in Red/white Wire between the fuse box 1 and combination meter [1] ‘ \r. i (Terminal side of the wire harness L, ,ii , hi. 7 if _ ‘ i i i i i ‘ (Terminal Side Of the wire harness) ‘ i; ,7# PGM-FI SYSTEM MIL CIRCUIT TROUBLESHOOTING Check that the MIL [1] comes on lor 2 seconds and goes Oh when the ignition switch is turned ON with the engine stop sWItch "0", NOTE - it the MIL and digital display do not function at all, reter Io combination meter initial operation check (page 21710) mire engine stop If the MIL stays on and the other indications function swrron isi'n the normally, check the combination meter indication when MIL wrll stay on the serial communication line is abnormal (page 1-83). even when the system IS normal it the indication is not according to above condition, check as follows. Turn Ihe ignition switch OFF Disconnect the ECM 33F (Black) connector (page 4- 36). Check for continuity between the Wire harness side ‘ ECM 33F (Black) connector [1] terminal and ground TOOL: Test probe 072AJ-RDJA110 CONNECTION: Brown — Ground "there is continuity, check for short circuit in the Brown wire between the DLC and ECM, II there is no continuity, replace the ECM with a known good one, and recheck. ECM REMOVAL/ INSTALLATION Lift the luel tank and support it (page 3-4) Turn the ignition swrlch OFF. Release the Junction wire from Ihe wire guide [1], Disconnect the ECM 33F (Black) connector [21. Remove the ECM assembly from the stays and the wire Junctions [3] irorn the rubber holder. Remove the ECM [A] from the rubber holder, Installation is in the reverse order of removal. 4-36 PGM-Fl SYSTEM POWER/GROUND LINE INSPECTION Disconnect the ECM 33F (Black) connector (page 4- 36), POWER INPUT LINE Measure the voltage between the wire harness side ECM 33F (Black) connector [1] terminal and ground TOOL: Test probe D7ZAJ-RDJA11O CONNECTION: Black/white (4,) — Ground (—) There should be battery voltage with the ignition swrtch turned ON and engine stop switch If there is no voltage. check the following — Black/while wire between the ECM and main relay Ior open circuit ‘ — rnain relay and its circuit (page 4-42) GROUND LINE Check tor continuity between the wire harness side T ECM 33F (Black) connector [1] terminals and ground: TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Green/blue - Ground Green — Ground There should be continuity at all times. It there is no continuity, check for open circuit In the i Green/blue or Green wire. SENSOR UNIT LINE Disconnect the sensor unit 5P (Black) connector [1] Check lor continuity between the wire harness side sensor unit 5P (Black) connector terminal and ground: CONNECTION: Yellow/red — Ground ‘ There should be no continuity. If there is continuity, check {or short circuit in the Yellow/red wire. (Terminal side oithe wtre harness) (Terminal side or the wtre harness) 4-37 PGM-Fl SYSTEM SENSOR UNIT REMOVAL/INSTALLATION Remove the throttle body/air cleaner housing assembly [1] (5 X17 mm) (page 7711) Remove the (allowing 7 torx screws [1] 7 sensor unit [2] e Orring A [3] 7 setting plate [4] e O-ring B [5] Installation is in the reverse order of removal NOTE i - Replace the O-rings with new ones and install them ‘ properly as shown (do not apply oil) If the O-rings are not installed properly, the idle air Will leak and engine idle speed Will be unstable 1 - Align the clip ol the TP sensor and shaft end of the throttle valve The light pressure is sutlicient to assemble the i sensor unit and throttle body in their correct position, ®§ It you cannot assemble them easily, the clip may be ~a misaligned Do not attempt to force them together [5] and make sure that the clip is aligned TORQUE: Sensor unit torx screw: 3.4 NM (0.3 kgt-m, 2.5 mm) Perform the TP sensor reset procedure (page 4-38). TP SENSOR RESET PROCEDURE ‘ Make sure that the DTC is not stored In ECM I1 the DTC is stored in ECM, TP sensor reset mode won't start by lollowmg the procedure below 1 Remove the following ABS mode‘ sman ' ‘ » CBRBOOR/RA/CBSOOF/FA: front seat (page 2—6) — CBSOOX/XA: seat (page 2-6) 2, Turn the ignition switch OFF. 3' Remove the DLC [i] lrom the dummy connector [21 and short the DLC terminals usmg the special tool TOOL: [3] 5C5 service connector 070PZ-ZY30100 4-38 PGM-Fl SYSTEM 4. Disconnect the ECT sensor 2P (Black) connector - l1]- Snort the Wire harness side ECT sensor 2P (Black) connector terminals with a iumperwne [2] m i i 5, Turn the ignition sWItch ON With the engine stop SWitch “(7'2 then disconnect the Jumper Wire from the ECT sensor 2P (Black) connector within 10 seconds while the MIL is blinking (reset receiving pattern) 6. Check it the MIL blinks After disconnection of the jumper Wire, the MIL should start blinking, (successtul pattern) It the jumper wire Is connected for more than 10 seconds, the MIL Will stay on (unsuccessful pattern), 7, i if , 7 7 Turn the Ignition swflch OFF and try again Irom the step 4 \TWJ-fl— @ O 3 seconds i 1 j L ; (J within 10 seconds it 0.3 seconds L 0V1 . L ‘ seconds t; i (we w: 1 e» MiL ON 7 Vi 7777 r - 1 2 seconds MIL OFF 7 r RESET RECEIVING PATTERN SUCCESSFUL pATTERN 7. Turn the ignition SWItch OFF. Remove the special tool and install the DLC into the dummy connector. 8, Install the removed parts In the reverse order at removal. 8. Check the engine idle speed (page 342) ECT SENSOR REMOVAL/INSTALLATION Drain the coolant (page 86) Disconnect the ECT sensor 2P (Black) connector [1] Remove the ECT sensor [2] and Orring [3] Installation is In the reverse order of removal NOTE ~ Replace the O-ring with a new one (do not apply oil) TORQUE: ECT sensor: 12 N-m (1.2 kgI-m, 9 Ibf~ft) Fill the and bleed the cooling system (page 875) 4-39 PGM-Fl SYSTEM VS SENSOR REMOVAL/INSTALLATION Remove the throttle body/air cleaner housing assembly (page 7-11) Disconnect the VS sensor 3P (Black) connector [1] i771? Remove the following: — bolt [2] — VS sensor [3] (pull the water hose aside) — O»ring [4] installation is in the reverse order of removet NOTE - Replace the O-ring With a new and coat it with ‘ engine oli. - Install the O—ring into the groove in the VS sensor, TORQUE: VS sensor bolt: 12 N-m (1.2 kgf-m, 9 lbf‘ft) 02 SENSOR REMOVAL/INSTALLATION - Do not get grease. oil or other materials in the 0; sensor air hole, - The 02 sensor may be damaged if dropped Replace it With a new one. If dropped. NOTE - Do not sen/ice the 02 sensorwhile it is hoL ' Do not use an impact wrench while removing or installing the 02 sensor‘ or it may be damaged Remove the lollowmg e CBRSOOR/RA/CBSOOX/XA under cowl (page 2722) e casoOF/FA/XiXA right middle cowl (page 275) CBEUOF/FNXAA' Release the Wire clip [1], CESUUF/FA Remove the two bolts [2] and the sensor protector [3] 4-40 CB500F/FA BANK ANGLE SENSOR PGM-Fl SYSTEM Disconnect the 02 sensor 4P (Black) connector [1] r Remove the wire band [2] (securing the 02 sensor and oil pressure switch wires) and the band clip [3] from the stay on the crankcase, Release the wire clip [4] l Release the 02 sensor Wire [5] from the Wire guide [6] ‘ and remove ll out ol the frame ‘ [4] (CBSDOF/FA) r/Vw \ Remove the O2 sensor [1] using the special lool. TOOL: [2] Sensor socket wrench‘ 07LAA-PT50101 or 22 mm equivalent commercially available in U.5.At installation l5 in the reverse order of removal. TORQUE: 02 sensor: 44 N-m (4‘5 kgfm, 32 lbl-ft) REMOVAL/INSTALLATION Remove the luel tank under tray [page 2725) Disconnect the bank angle sensor 2P (Black) connector [1] Remove the rollowmg 7 two nuts [2] A bank angle sensor [3] — two bolts [4] and washers [5] A two collars [6] lnslallation Is in the reverse order of removal NOTE - lnstall the bank angle sensor With the "UP" mark facing up TORQUE: Bank angle sensor nut: 85 N-m (0.9 kgrm, 6.3 Ibf-ft) 4-41 PGM-FI SYSTEM INSPECTION Remove the bank angie sensor without disconnecting ‘ 7 its connector (page 4-41), SVSTEM INSPECTION WITH MCS ‘ Temporarily install the ECM lo the Wire harness by connecting the 33F (Black) connector Connect the mcs to the DLC (page 4-6) Check the output voltage at each position of the sensor ‘ With the MOS STANDARD: Horizontal Position: 7.0 — 5.8 V Approx 50°: 0.40 — 0.34 v FUNCTION CHECK Temporarily install the ioilowmg components to Ihe wire harness by connecting each connector (page 575) » ECM — ignition coils Place the bank angle sensor [1] horizontal. Start the engine Inciine the bank angle sensor approximately 60“ to the left or right. The bank angle sensor is normal it the engine stops after a Iew seconds, MAIN RELAY CIRCUIT INSPECTION For relay inspection (page 21-25). Remove the main relay (page 2124). RELAY COIL POWER INPUT LINE Measure the voltage between the main relay terminal of the relay box [1] and ground. l CONNECTION: C (1*) —- Ground (—) ‘ There should he battery voltage when the ignition 1 switch is turned ON with the engine stop switch “C”. It there is no voltage, check the following. i — Black Wire between the relay box and engine slop ‘ SWItch for open circuit 7 engine stop switch (page 2148) — White/yellow wire between the engine stop switch and fuse box 1 Ior open circuit ; 7 ENG STOP (7,5 A) fuse Incilned Position. © 3’3 / ‘ 4\ Horizontal ;\ Position: i ‘r\ \9 , AW ’ \ L/ [1] (9 ‘/ Approx. 60° 4-42 PGM-Fl SYSTEM RELAY SWITCH POWER INPUT LINE Measure the voltage between the main relay termlnal of 7 the relay box [1] and ground CONNECTION: a (+) — Ground (—) ‘ There should be battery voltage at all llmeS. If there [S no voltage, check the following e Black/blue wire between the main relay and fuse box ‘ 2 for open circull ‘ 7 Fl (15 A) {use ‘ GROUND LINE Check for continuity between the main relay terminal of the relay box [1] and ground, ; CONNECTION: D — Ground There should be contmully at all times. If there is no contlnuity‘ check for open circuit in lhe ‘ Green Wire. l 4-43 MEMO 5. IGNITION SYSTEM SERVICE INFORMATION -------------------------- “5-2 TROUBLESHOOTING ................................. ..5_3 SYSTEM LOCATION ................................... ..5_4 SYSTEM DIAGRAM .................................... ..5_4 IGNITION SYSTEM INSPECTION -------------- --5.5 |GN|T|ON TIMING ....................................... "5,1 IGNITION COIL ........................................... ..5_8 5-1 IGNITION SYSTEM SERVICE INFORMATION GENERAL - The ECM maybe damaged it dropped Also if the connector is disconnected when current is flowing. the excessive voltage may damage the module. Always turn off the ignition sWitch before servicing. - Use spark plug of the correct heat range. Using a spark plug With an incorrect heat range can damage the engine ‘ Some electrical components may be damaged lf terrnlnals or connectors are connected or disconnected while the ignition swttch Is turned ON and current is present. . A faulty Ignltlon system ls often related to poorly connected or corroded connections. Check these connectlons before proceeding. - Make sure the battery is adequately charged Using the starter motor with a weak battery results ln a slower engine cranking speed as well as no spark at the spark plug. - The ignlIlDl’l timing cannot be adjusted slnce the ECM is factory preset. - When servlclng the ignitan system. always tollow the steps in the troubleshootan table (page 5-3). For Iollowlng components information, refer to each sectlon. e ignition switch (page 21717) engine stop swttch (page 2(18) » rnain relay (page 442) ~ bank angle sensor (page 4-41) — sldestand swttch (page 2121) — neutral SWItch (page 21-20) — neutral diode (page 6-9) TOOLS IgnltEnMate peak voltage tester Peak voltage adaptor 7 Test probe (2 requlred) W" MTPO7»0286 (U.S.A, only) 07HGJ-0020100 07ZAJ-RDJA710 (not available In U.S A.) wlth l commercially available dlgltal ‘ multimeter (impedance 10 MQ/DCV t minlmum) ‘ 5-2 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. 7 Faulty spark plug 7 Loose spark plug cap or spark plug wire connection 7 Water got into the spark plug cap (Leaking the ignition coil secondary current) is spark. the original Ignltlan coii is faulty. "O" (The engine is not cranked by the starter motor), No spark at spark plug If there is no spark at cylinder. temporarily exchange the ignition coil With a known good one and periorm the spark test If there "Initial voltage" or the ignition primary coil is the battery voltage With the ignition switch turned ON and engine stop sWitch turned i Unusual condition Wabablrecausie (Check in numeri72al order) Ignition coil primary voltage I No initial voltage with the ignition swuch turned ON and engine stop sWItch turned "0" (Other electrical components are normal) 1 An open circuit in the Black/white wire between the main 2 relay and ignition coil, Faulty main relay or its related circuits, 3. Loose or poor connection of the primary terminal, or an open circuit in the primary coil. 4. Faulty ECM (in case when the initial voltage is normal With the ECM connector disconnected). 2 — 4 V while cranking the engine. I I W s s, ,, lnitialvoltageisnormalbutitdropsby i I I 1.7Incorrect peak voltage adaptor connections (System is normal it measured voltage is over the specifications With reverse connections). 2. Battery is undercharged (Voltage drops largely when the 3, N0) 50.32 engine is started). connection. No voltage between the Black/blue (+) Wire and body ground (—) at the ECM connector or loosen ECM , An open circuit or loose connection in the Green or Green/ blue wire 01 the ECM. An open circuit or loose connection in the Blue/yellow or Yellow/blue wire between the ignition coil and ECM, Faulty sidestand much or neutral switch. Loose or poor connection or an open circuit in No, 6 related Wires. 7 Sidestand swrtch line: Green/white and Green 7 Neutral swrtch lirie Green/red and Light green Faulty CKP sensor (Measure peak voltage). Faulty ECM (in case when above No 1 through 8 are normal). Initial voltage is normal but there is noW‘ ) peak voltage while cranking the i engine. i I lnitigvoitage is normal but peak voltage is lower than the standard value. 1 2 3. 4. Faulty ECM (in case when above No. 1 through 3 are . Faulty peak voltage adaptor. Faulty CKF’ sensor. normal). . Incorrect peafvoltage adaptor connections. 1. The multimeter impedance is too lomelow IO MQ/DCV. 2. Cranking speed is too slow (Battery is undercharged). 3. The sampling timing ofthe testerand measured pulse were not synchronized (System is normal if measured voltage is over the standard voltage at least once). 4. Faulty ECM (in case when above No, 1 through 3 are normal). 7 i Initialehmaktloltages are normal 1. Faulty spark plug or leaking ignitiorfiil secondary current i W , i but no spark lumps ‘ 2. Faulty ignition coil. 7 CKP sensor Peak voltage is lower than standard 1, The multimeter impedance is too low; below 10 MQ/UCT 7 i value 2. Cranking speed is too low (Battery is undercharged). 3. The sampling timing ofthe testerand measured pulse were F‘No peak voltage not synchronized (System is normal if measured voltage is over the standard voltage at least once). are normal). Faulty peak voltage adaptor. Faulty CKP sensor. Faulty CKP sensor (in case when above No. 1 through 3 IGNITION SYSTEM SYSTEM LOCATION CBRSOORA shownv ECM ‘ A IGNITION SWITCH No 1 IGNITION N 2 COIL o T BATTERY IGNITION k COIL ENGINE STOP SWITCH FUSE 30x1 7 ENG STOP FUSE (7,5 A) A NEUTRAL DIODE MAINFUSE / BANK ANGLE K, SENSOR \,\\\\ I II ‘ RELAY BOX 1II I (MAIN RELAY] III SPARK PLUGS CKP SENSOR FUSE BOX 2 A FI FUSE (15 A) I I SIDESTAND SWITCH NEUTRAL SWITCH SYSTEM DIAGRAM R M BI/Bu Li I *w- II + 0—E ‘ MAIN IGNITION I ,, A,“ fir” .77 I” FUSE SWITCH Bl/Bu 3W V/Bu GNV G/R v G/Eu i BI R T g C: (3“) R/BI ”' I ’ BATTERY I z r fIaI—c\oiw/Y Bl/W T I W ENGINESTOP ENG SToF FUSE I SWITCH (7 5 A) BANK ANGLE' ““w SENSOR ~—-—-— BI —w—I «fl G BINV 7—0 J: NEUTRAL ‘ DIODE MAIN RELAV Bl. Black Bu: Blue G Green Lg ngmgreen R Red W: WhIte Y. YeIIow Lg ' NEUTRAL WE“ C/a SWITCH I G SIDESTAND IGNITION {A SWITCH No.2 COM-S , SPARK 4_ PLUGS 5-4 IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE. - lfthere is no spark at the plug, check all connections for loose or poor Contact before measuring the peak voltage. - Use a commercially available digital multimeter Wilh an impedance ol1o MQIDCV minimum, - The display value differs depending upon the internal impedance of the multimeter - If the peak voltage tester (U SA only) is used, follow the manufacturer‘s instructions Use the peak voltage tester or connect the peak voltage adaptor [1] to the digital multimeter [2]. TOOL: lgnitionMate peak voltage tester MTP07-0286 (U.S.A. only) or Peak voltage adaptor 07HGJ—0020100 with commercially available (not available in digital multimeter (impedance USA.) 10 MQIDCV minimum) IGNITION COIL PRIMARY PEAK VOLTAGE NOTE - Check all system connections betore performing this inspection Loose connectors can cause incorrect readings. - Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head Remove lhe ignillon coils (page 5-8), Temporarily install the following components to the wire harness by connecting each connector 7 ECM [1]: 33p (Black) [2] — ignIIiOn coils [3] 5-5 IGNITION SYSTEM AVDid touching the spark plug arid tester probes to prevent electric Shock Connect a known good spark plug [‘l] to the spark plug cap and ground It to the cylinder head as done in a spark test With the connectors connected connect the peak voltage tester or adaptor [2] probes to the tgnition coil primary terminal [3] and ground. CONNECTION: No.1 (left) ignition coil: Blue/yellow (+i — Ground (—) No. 2 (Right) igni on coil: Yellow/blue 1+) — Ground (~) Turn the ignition switch ON with the engine stop sWitch Check the initial voltage at this time, The battery Voltage should be measured ii the initial voltage cannot be measured, iollow the ‘ checks described in the troubleshooting table (page 5- 3), shift the transmission into neutral Crank the engine With the starter motor and read ‘ ignition coil primary peak voltage. PEAK VOLTAGE: 100 V minimum NOTE O Although measured values are different Ior each ignition coil, they are normal as long as voltage is higher than the specified value H the peak voltage is lower than the standard value, follow the checks described in the troubleshooting table (page 573) Install the removed parts in the reverse order at removal CKP SENSOR PEAK VOLTAGE NOTE - Check the cylinder compression and Check that the spark plugs are installed correctly in the cylinder head. Disconnect the ECM 33F (Black) connector (page 4- 36) Connect the peak voltage tester or adaptor [1] probes to the ECM 33F (Black) connector [2] terminals of the wire harness side using the test probes (page m7), TOOL: Test probe (2 required) 07ZAJ-RDJA110 CONNECTION: Yellow (+) — Green/blue (—) Shift the transmission into neutral Turn the ignition switch ON With the engine stop swttch Crank the engine With the starter motor and measure the CKP sensor peak voltage. PEAK VOLTAGE: 0.7 V minimum If the peak voltage measured at the ECM 33F (Black) connector Is abnormal measure the peak voltage at the CKP sensor connector. Green/blue i [2] (Terminal side at the wire harness) 5-6 IGNITION SYSTEM Turn the ignition SWitch OFF. Retease the Wire clip [1] and disconnect the CKP sensor 2P (Red) connector [2] Connect the peak voltage tester or adaptor probes to the 2P (Red) connector terminals of the CKP sensor side CONNECTION: Yellow (+) — White/yellow (—) In the same manner as at the ECM 33F (Black) connector. measure the peak voltage and compare it to the voltage measured at the ECM 33F (Black) connector. NOTE - if the peak voltage measured at the ECM is abnormal and the one measured at the CKP sensor is normal. the Wire harness has an open or short circuit or loose connection - If the peak voltage of the CKP sensor side is lower than standard value‘ follow the checks described in the troubleshooting table (page 53) For CKP sensor replacement (page 124). install the removed parts in the reverse order of removal, IGNITION TIMING NOTE. - The ignition timing cannot be adjusted since the ECM is factory preset. - The fuel tank under tray removal/installation is required to connect the timing light [1] to the spark plug wire (page 2-25). Start the engine. warm it up to normal operating temperature and stop it Stop the engine and remove the crankshaft hole cap Read the Remove the fuel tank under tray from the frame without instructionsfo/ disconnecting the spark plug caps and connect the timing light liming light. Ofle’allo" Temporarily install the fuel tank under tray Lower the fuel tank until the fuel pump 3P (Black) connector can be connected and support it. Temporarily connect the fuel pump 3P (Black) connector, Start the engine and let lI idle, IDLE SPEED: 1,201] 1100 rpm The ignition timing is correct if the "F" mark [2] on the primary drive gear aligns With the index notch [3] in the right crankcase cover. Coat a new Orring With engine oil and install it into the groove in the crankshaft hole cap Apply grease to the threads of the crankshaft hole cap and install it Tighten the crankshafl hole cap to the specmed torque, TORQUE:18 N-m(1t8 kgf-m,13|bftfli Remove the timing light in the reverse order of connection, Install the fuel tank under tray properly (page 2725). IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove ihe fuei tank under tray (page 2725) “mm 7’ Remove the nuls [1] and bolts [2]. Remove me No 1 (ieft) Igi'IIIIOI’I coil [31Iirsl and then the No 2 (right) ignition coil [4] by slipping the spark plug ’ caps Ihrough Ihe semicircular cutout [5] insiaiiation is in the reverse order of removal NOTE' ' Do not Interchange Ihe igniiion coils 7 No. 1 (iert) ignition coil: long Wire 7 No.2 (right) ignition coil: short Wire 5-8 6. ELECTRIC STARTER SERVICE INFORMATION TROUBLESHO0T|N6..........................‘........ SYSTEM LOCATION ................................... .. SYSTEM D|AGRAM 6-2 6-3 6-4 6-4 STARTER MoTOR ..................................... .. 6.5 STARTER RELAY swrrcH ....................... .. 6,8 NEUTRAL DIODE ....................................... .. 6_9 6-1 ELECTRIC STARTER SERVICE INFORMATION GENERAL If the current IS kept flowrng through the staner motor turn /I while the engine is no! cranking ovel‘ [he staner motor may be damaged. The s‘arler molor can be serviced wxlh Ihe engme msmlled In (he frame. A‘ways turn the \gmlion switch OFF before servicing the staner motor, The motor cou‘d sudden‘y start, causing serious Injury. A weak baflery may be unab‘e to turn Ihe sxarler motor quickly enough‘ or supply adequate \gnmcn current When SeNICmg the staner syslem, always follow the steps in [he troubleshoolmg flow chart (page 6-3) For followmg components miorrnauon, referto nghts/Melers/Swwlches sectwon — igninon swvlch (page 2147) — engme slop swnch (page 21-18) — starter switch (page 21-18) ~ dutch swutch (page 21-19) 7 s>desland swilcn (page 21-21) 7 neutral switch (page 2120) ELECTRIC STARTER TROUBLESHOOTING NOTE. 0 Make sure the battery is fully charged and in good condition - Check for a blown main iuse (30 A) and subyfuse (ENG STOP: 7,5 A). (Check for a short circuit in the related Wires if the fuse is blown again) - The starter motor should operate With the following conditions a transmission in neutral or clutch lever squeezed with sidestand retracted r Ignition swrtch turned ON With engine stop SWitch turned "0" — starter sWitch pushed Starter motor does not turn 1. Starter Relay Switch Operation Inspection Check the operation of the starter relay switch as above starting conditions (page 543) Does the starter relay switch click? YES — GO TO STEP 2. NO - GO TO STEP 3 2. Starter Motor Inspection Apply battery voltage directly to the starter motor and check the operation. (A large amount oi current flows, so do not use a thin wire) Does the starter motor turn? YES — ' Poorly contacted starter motor Cable - Faulty starter relay switch (page 6'9) N0 — Faulty starter motor (page 6-5) 3. Relay Coil Power Input Line Inspection Check the power input line of the starter relay switch (page 6-8). Is the input line normal? YES v GO TO STEP 4. N0 — Faulty ignition switch (page 21-17) Faulty engine stop switch (page 21-18) Faulty starter swrtch (page 21-18) Loose or poor contact of the related connector terminal Open circuit In Wire harness 4. Relay Coil Ground Line Inspection Check the ground line of the starter relay switch (page 6-8), Is the gmund line normal? YES — GO TO STEP 5 N0 — - Faulty neutral SWItCh (page 21720) - Faulty neutral diode (page 679) - Faulty sidestand switch (page 21-21) ~ Faulty clutch switch (page 21719) ~ Loose or poor contact of the related connector terminal Open circuit in Wire harness 5. Starter Relay Switch Inspection Check the starter relay sWItch (page 63) Is the starter relay switch normal? YES — Loose or poor contact of the starter relay swtch connector terminal N0 — Faulty starter relay sWitch Starter motor turns slowly - Low battery voltage - Poorly connected battery cables - Poorly connected starter motor cable - Faulty starter motor Starter motor turns, but engine does not turn - Faulty starter clutch or starter gear train (page 1277) - Faulty ignition system (page 5-3) ELECTRIC STARTER SYSTEM LOCATION CBR500RA shown: CLUTCH SWITCH IGNITION SWITCH ENGINE STOP SWITCH BATTERY STARTER SWITCH FUSE BOX1 v ENG STOP FUSE (7,5 A) * NEUTRAL DIODE STARTER STARTER RELAY SWITCHI MAIN FUSE (30 A) SIDESTAND NEUTRAL SW'TCH SWITCH f. R BI ‘ B‘ STARTER RELAY I STARTER R SWITCH I MOTOR if” " T ® C/ I I I M ‘ -——-—\3_/0——- I WT K / _[ MAIN FUSE BATTERY I (so A) I , A G/R Y/R R/Bu R T IGNITION L SWITCH R/B‘ g + G/R *7 NEUTRAL -——c\o-—~i 3140 \o‘ W/Y 4am—— SI. BBlfck DIODE GR STARTER ENGINE STOP ENG STOP FUSE “‘ “9 I I SWITCH SWITCH 75A G. Green I Siva)??? I I Lg: Ligm green R: Red 7 E BI/R w\m SI/v + GNV «a» Ga Y' YelIow ' CLUTCH SIDESTAND I W WhIte SWITCH SWITCH 6-4 ELECTRIC STARTER STARTER MOTOR REMOVAL Disconnect the negattve (r) cabte from the battery urn If, (page 20-5), (page 7-1 1). Remove the two mounting bolts [1] and negative (7) ‘ cabte [2], ‘ Remove the starter motor [3] from the crankcase Release the termmat cap [1] Remove the termxnal nut [2] and disconnect the starter motor cable [3] to remove the starter motor [4], Remove the 04mg [1]. Instatlatlon tS In the reverse order of removat NOTE ' Reptace the 0er with a new one and coat It with ‘ engme or]. ‘ ELECTRIC STARTER DISASSEMBLYIASSEMBLY Disassembie and assembie the staner motor as iollowmg illustration The CDI/ may be damaged If the magnet pulls the armature against the motor case. ARMATU RE TERMINAL NUT iONmiiD Kgfmfllbift) SEAL RING 9? MOTOR CASE SEAL RING Q“? FRONT COVER WASHER INSULATOR TERMiNAL TERM‘NAL STOPPER W— BOLT ,» % - REAR COVER @\ NEGATiVE BRUSH BRUSH HOLDER K SCREW BRUSH SPR‘NGS CASE BOLTS NOTE' ' instaii the armature [1] into the motor case from the case groove [2] Side so the commutator bars facing to the rear side, - When instailing the rear cover [3], align the tab with the groove (the index III’IES [4] are aligned) - When instaihng the front cover [5L take care to prevent damaging the Oil seai lip With the armature shaft Ailgh the Index lines [6] on the front cover and motor case. ELECTRIC STARTER Do not use emery or sand paper on the commutator. INSPECTION FRONT COVER Check the oil seal [1] in the front cover tor deterioration. wear or damage Turn the inner race of bearing [2] With your finger The bearings shouid Iurn smoothly and quietly Also check lhat the outer race fits lightly in the front cover. REAR COVER Check the bushing [1] in the rear cover for wear or damage. I2] Inspect the brushes for damage and measure the brush length SERVICE LIMIT: 6.5 mm (0.26 in) Check for continuity on the rear cover as follows v between the positive brush [2] and cable terminal; ‘ there should be continuity — between the cable terminal and rear cover: there should be no continuity 7 between negative brush [3] and rear cover; there should be continuity. ARMATURE Clean the metallic debris ofl the commutator bars [1] Check the commutator bars for discoloration. Check for CDI'IIlI’IUIIy on the armature as follows: 7 between pair 01 commutator bars; there should be continuity. 7 between each commutator bar and the armature shaft [2]; there should be no continuity 6-7 ELECTRIC STARTER STARTER RELAY SWITCH OPERATION INSPECTION Remove the right side cover (page 277) Shift the transmission Into neutrai or squeeze the ciutch iever With the stdestand retracted. Turn the ignition swuch ON With the engine stop swnch turned “0“ Push the starter szch The coil is normai ii the starter reiay switch [1] clicks. It you don't hear the starter relay swuch “CLICK’X inspect the reiay COII circuits, RELAY COIL CIRCUIT INSPECTION POWER INPUT LINE Release the connector boot from the starter reiay sWItch 4P (Red) Connector [1] Turn the ignition sWItch ON With the engine stop SWItch turned “0". Measure the voltage between the 4P (Red) connector terminal and ground CONNECTION: Yellow/red (+) — Ground (—) There shouid be battery voitege when the starter switch is pushed GROUND LINE Turn the Ignition swmch OFF. Disconnect the starter relay swiIch 4P (Red) connector [1] Check tor continuity between the 4P (Red) connector terminai and ground CONNECTION: Greenlred » Ground There shouid be continuity when the transmission is in neutrai or when the ciutch lever Is squeezed with the sidestand retracted (In neutrai‘ there is a siight resistance due to the diode) ELECTRIC STARTER RELAY INSPECTION Remove the starter relay swrtch (page 5-9) Connect a 12 \/ battery to the starter relay swrtch as shown l There should be contlnuity between the cable terminals when the battery :5 connected‘ and no continuity when r the battery is disoohnected REMOVAL/INSTALLATION Remove the right slde cover (page 2—7) Disconnect the negative (7) cable from the battery ' [page 20-5). Dlsconnect the starter relay switch 4P (Red) connector ' [ll Release the terminal cover [2] and remove the socket bolts [3] to dlsconnecl the Cables Remove the starter relay swttch [4] lrorn the stays lnstallation IS In the reverse order of removal NEUTRAL DIODE INSPECTION Remove the tollowmg. » CBRSOOR/RA/CBSODF/FA front seat (page 276) » CBSOOX/XA: seat (page 26) Remove the [use box cover [1] from the fuse box 1 (left) by releasing the two tabs [2] Remove the neutral drode [3} Check for contlnulty between the dlode terminals, l" When there l5 continuity. a small reslstance value wrll ‘ regrsterv If there IS cantinmty In drrectlon shown by the arrow the ‘ B diode :5 normal MEMO 7. FUEL SYSTEM SERV|CE |NF0RMAT|0N ........................... ..7_2 COMPONENT LOCATION“ --7.4 FUEL LINE INSPECTION ---------------------------- "7-6 FUEL TANK ................................................. ..7_9 FUEL PUMP UNIT ------ -- 7.10 THROTTLE BODY/ A|R CLEANER HousmG ......................... ..7_11 FUEL INJECTOR ...................................... ..7_15 IACV - SECONDARY A|R SUPPLY SYSTEM -------7-18 EVAP PURGE CONTROL SOLENOID VALVE (Ac type)v.,............. _._7_21 EVAP CANISTER (Ac type) ..................... ..7_22 FUEL PUMP RELAY ................................. ..7_23 7-1 FUEL SYSTEM SERVICE INFORMATION GENERAL Bending or twisting the control cable Will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. Before disconnecting the fuel teed hose, relieve fuel pressure from the system (page 776). Do not snap the throttle valve lrorn tull open to full close after the throttle cable has been removed. It may cause incorrect idle operation. Seal the intake port with a plece of tape or a clean cloth to keep dirt and debris trom entering the engine after the throttle body has been removed. Do not damage the throttle body. It may cause incorrect throttle valve operation, Prevent din and debris from entering the throttle bore and air passages after the throttle body has been removed Clean them using a compressed air if necessary. Do not loosen or tighten the white painted nut and screw of the throttle body. Loosening or tightening them can cause throttle valve and idle control lailure. Do not apply commercially available carburetor cleaners to the inside of the throttle bore. The parts of the throttle body not shown in this manual should not be disassembled, For fuel injector and IACV servicing. the throttle body removal/installation is required. For fuel level sensor inspection (page 21-17), The tollowtng color codes are used throughout this section. Bl : Black G : Green Lg = Light Green R = Red Y : Yellow Br : Brown Gr 2 Gray 0 = Orange V = Violet Bu 1 Blue Lb : Light Blue P = Plnk W I White TOOLS . 9 mm/9 mm Fuel pressure gauge ‘ Pressure gauge manlfoF 7 i Hose attachrn 0740670040004 U7ZAJ-SSAU‘l 11 1 D7ZAJ-85A0120 ‘ // l // i l \ A/ / fig or 0740670040006 (U.S.A, only) (not available in U.S.A.) (not available in u.s.A.) or 0740670040003 (U.S.A. only) ‘ i ihtose attachment, 8 mm/Q mrn i Kttachmenlj‘oiint, B rum/97mm Pressure manifold hose-7777 7' V 07AMJ-HW3A100 (USA only) O7ZAJ-S7C0100 ‘ 07ZAJ-S700200 . (not available in U SA.) (not available in U SA.) FUEL SYSTEM ‘7'Adapto}, lema‘e "C" O7AAJ-SSMA500 (U SA, only) 7 Adaptor, maé "CTV W 07AAJ-SSMA300 (u s A. only) 9 f \ FUEL SYSTEM COMPONENT LOCATION A, CM types CBRSOORA shown 10 N m (1.0 kg m, 7 Inf-ft) ’ " 10Nvm(0,1xgim,u.7IbI-m 7-4 FUEL SYSTEM AC type CBRSOORA shown: " 12 Nm (1,2 kgf-m) *4 \ 3.0Nvm(0.3 kgf-m) 10 N-m(o,1kgv»m) 7-5 FUEL SYSTEM FUEL LINE INSPECTION FUEL PRESSURE RELIEVING NOTE ~ Before disconnecting fuel feed hose, relieve pressure from the system as follows Turn the ignition swuoh OFF. A CM (ypes shown . Remove the left side cover (page 2-7). Disconnect the fuel pump 3P (Black) connector [1] . Start the engine, and let it idle until the engine stalls. 0|me; Turn the ignition swrloh OFF QUICK CONNECT FITTING REMOVAL NOTE ' Clean around the quick connect fitting before disconnecting the fuel feed hose and be sure that no dirt is allowed to enter into the fuel system - Do not bend Or IWlSl the fuel feed hose Relieve the fuel pressure (page 776) 2, Disconnect the negative (—) cable from the battery (page 2075) 3 Lifl the fuel tank and support it (page 3-4). [2] 4 Place a shop towel over the quick Connect fitting. ‘ Fu'el tank sée shown Pull and release the lornt rubber [1] from the retainer. 5' Hold the connector with one hand and squeeze the retainer tabs [2] with the other hand to release the ‘ IDCkll’Ig pawls [3], then pull the connector off the fuel ‘ pipe. ‘ NOTE ~ Be careful not to damage the fuel feed hose. l connector and fuel pipe Do not use tools, ‘ ~ Prevent the remaining fuel in the fuel feed hose from flowing out‘ usmg a shop towel ‘ if the Connector does not move alternately pull and push the connector until it comes off easily. I2] 6 Remove the retainer and Joint rubber Irom the fuel pipe 7 To prevent damage and keep foreign matter out, 7 cover the connector and fuel pipe wrth plastic bags [1] QUICK CONNECT FITTING INSTALLATION NOTE: - Always replace the retainer and joint rubber of the quick connect fitting when the fuel teed hose is disconnected. Use the same type of retainerand ioint rubber as the removed ones. Do not bent or twist the fuel teed hose. 1, Insert a new retainer [1] into the connector [2] by aligning the locking pawls With the holes. 2. Install a newioinl rubber [1] onto the fuel pipe. Install the connector onto the fuel pipe straight and align the retainer groove with the joint rubber tabs as shown Then press the connector until both locking pawls [2] click NOTE - If it is hard to connect, put a small amount at engine oil on the pipe end, 3. Make sure that the quick connect fitting is connected securely and the locking pawls [1] are locked firmly by pulling the connector. Make sure the joint rubber boss [2] is placed between the reiaineriabs [3] as shown 4, Temporarily lower the tuel tank (page 3-4) 5. Connect the battery negative (7) cable (page 2075). 6. Normalize the fuel pressure (page 7-8). [—.. FUEL SYSTEM Align Fuel tank side shown: FUEL SYSTEM FUEL PRESSURE NORMALIZATION 1, Be sure the fuel pump 3P (Black) connector [1] is connected 2 Turn the ignition switch ON with the engine stop 1 ‘ sWitch "0“ NOTE - Do not start the engine. The fuel pump wrll run for about 2 seconds and fuel pressure will rise, Turn the ignition swnch OFF. 3 Repeat step 2 two or three times, and check that there IS no leakage 4. install the fuel tank properly (page 3-4) FUEL PRESSURE TEST NOTE - Check the fuel tank breather hose on the frame (A, CM types) or fuel tank-to-EVAP canister hose (AC type) for pinches or clogs when the fuel tank IS lifted, Disconnect the quick connect fitting from the fuel tank (page 776) Attach the special tools between the fuel feed hose and fuel pipe of the fuel pump Except U.S.A. TOOLS: [1] Fuel pressure gauge 07406-0040004 [2] Pressure gauge manifold 07ZAJ-S5AO111 [3] Hose attachment, 9 mm/B mm 07ZAJ-55At1120 [4] Hose attachment, 8 mml9 mm D7ZAJ-S7CO1OD [5] Attachment joint, 8 mml9 mm 07ZAJ-S7COZOD U.S.A. TOOLS: Fuel pressure gauge 07406-00400060r 07406-0040005 07AMJ-HW3A1OO D7AAJ-56MA300 D7AAJ -SSMA500 Pressure manifold hose Adaptor, male "C" Adaptor, female "6" Lower the fuet tank until the fuel pump 3P (Black) connector [6] can be connected and support it Temporarily connect the fuel pump 3P (Black) connector, fuel tank breather hose and battery negative (») cable Start the engine and let it idle Read the fuel pressure STANDARD: 343 kPa (3.5 kgflcmi, 50 psi) If the fuel pressure is higher than specified pressure, replace the fuel pump unit If the fuel pressure is lower than specified pressure, inspect the tollowmg 7 fuel iine for leakage — fuel tank breather hose (tank side) for pinches or clogs (A, CM types) e fuel filter for ctogs 7 fuel pump (page 740) After inspection relieve the fuel pressure (page 7-5) Disconnect the negattve (7) cable from the battery (page 206), Remove the special tools. Connect the quick connect fitting (page 7-7) CM types shown 7-8 FUEL SYSTEM FUEL FLOW INSPECTION NOTE ' Check the fuel tank breather hose on the frame (A CM types) or fuel tank-to-EVAP canister hose (AC type) for pinches or clogs when the fuel tank is lifted, Disconnect the quick connect fitting from the throttle body (page 7-6). Wipe offspilied out Place the end of the fuel feed hose [1] into an approved gasoline gasoline container, Lower the fuel tank until the fuel pump 3P (Blackl [2] connector can be connected and support it, Temporarily connect the fuel pump 3P (Black) connector and battery negative (7) cable Turn the ignition swnch ON with engine stop sWItch "0“. The fuel pump operates for 2 seconds Repeat 5 times to meet the total measuring time, NOTE' - Return fuel to the fuel tank when the first fuel is flowed. Measure the amount of fuel flow Amount of fuel flow: 319 cm3 (10.8 US oz,11.2lmp oz) minimum] 10 seconds at 12 V |f fuel flow is less than specified volume inspect the fOHDWlngI — fuel feed hose for clogs ~ fuel tank breather hose (tank side) for pinches or clogs (Ar CM types) — fuel filter for clogs — fuel pump (page 7710) Connect the quick connect fitting (page 7-7). FUEL TANK REMOVAL/INSTALLATION Disconnect the quick connect fitting from the fuel tank (page 7-6) Lower the fuel tank, being careful not to pinch the Wire and hoses. Remove the nut [1] and bolt [2], and the fuel tank [3]. Installation is in the reverse order of removal NOTE - The mounting bolt is installed from the left side TORQUE: Fuel tank mounting nut: 12 MM (1.2 kgf-m, 9 lbf-ft) Connect the quick connect fitting (page 7»7) 7-9 FUEL SYSTEM FUEL PUMP UNIT INSPECTION Turn the ignition SWltCh ON with the engine stop swnch "C" and confirm that the fuel pump operates for ( CM ‘ypes Show" 2 seconds. , It the fuel pump does not operate inspect as follows: Turn the ignition SWitch OFFV Remove the left Slde cover (page 2-7), Disconnect the fuel pump 3P (Black) connector [1] Turn the ignition swuch ON With the engine stop sWitch [*7 i0" Measure the voltage between the terminals oi the wire side fuel pump 3P (Black) connector [1], CONNECTION: BIOWn (+) — Green 1—) There should be battery Voltage for 2 seconds, If there is battery voltage, replace the fuel pump unit, It there is no voltage inspect the tollowmg i 7 Green Wire between the fuel pump and ground for 3 open circuit 7 Brown Wire between the relay box and fuel pump for (Terminai Slde Dime Wire harness) open circuit , V — v fuel pump relay and its circuits (page 7723) r ECM (page 4-37) REMOVAL/INSTALLATION Remove the fuel tank (page 7-9) Clean around the fuel pump Loosen the six mounting nuts [1] in a crisscross pattern in several steps and remove them ' Be carefu/not to Remove the fuel pump unit [2] and the rubber seal [3] deform the float arm of the fuel level sensor 7-10 FUEL SYSTEM Installation is in the reverse order of removal. NOTE ' Replace the rubber seal [1] with a new one ‘ Clean the rubber seal seating areas oflhe fuel tank and fuel pump base plate‘ and be sure thal no foreign malenals are allowed. ‘ - Place the rubber seal With the boss [2] facing toward the fuel pipe [3] and pull the three retaining pins [4] ‘ in the holes securely to seat it on the base plate, ‘ [11 o Tighten Ihe six mounting nuts to the specified torque in the sequence as shown. TORQUE: Fuel pump mounting nut: 12 Nrm (1.2 kgf—m, 9 Ibf-fl) THROTTLE BODY/AIR CLEANER HOUSING REMOVAL/INSTALLATION NOTE - Always clean around the fuel system parts with compressed air before removing to prevent dirt and debris from entering the air passages In the throttle body. [A CM types shown’ Remove the fuel tank (page 79). l Disconnect the following — sensor unit 5P (Black) connector [1] — fuel injector 2P (Gray) connectors [1] e IACV 4P (Black) connector [2] FUEL SYSTEM 7 crankcase breather hose [1] r secondary air supply hose [2] , 7 AC type: EVAF’ canister-lo-thronle body hose [3] (from [he 3-way10inl) — throme cables [1] (remove from Ihe sabre holder and drsconnect from me lhrome drum) Remove the fol‘owmg. r tappmg screw [1] 7 wire Junction [2] r 6 mm bolt [3] (loosen) » [our 8 mm bows [4] r fue‘tank brackel[5] Loosen the two insulator band screws (cylinder head srde] [1]. 7-12 Do nolapplytorce Sllde the throttle body/air cleaner housing assembly (Lathe sensorunir rearward and release the Insulators [1] off of the and lli/eClUrS cylinder head Raise the lronl of the assembly and remove the engine sub-Wire harness 6P (Black) connector [2] from the stay on the air cleaner houstng, Remove the throttle body/air cleaner housing assembly out of the frame Installation is in the reverse order of removal. NOTE - When setting the assembly into the frame, position the crankcase breather tube [3] under the water hose and be sure it IS not Kinked or deformed - Tighten the Insulator band screw so the distance [4] ‘ between the band ends Is 10 11 0 mm (0 4 1 0.04 in) ~ When connecting the Injector 2P (Gray) connectors [5], align the groove with the lab 0! the injectorjolnt. TORQUE: Wire junction stay tapping screw: 1.0 N-m (0.1 kgfmY 0.7lb1-ft) Throttle cable joint bolt (at throttle body): 3.0 N-rn (0:4 mm, 2.2 let) Adjust the throttle grip (reeplay (page 374) sensor reset procedure (page 4735) 7-13 FUEL SYSTEM DISASSEMBLY/ASSEMBLY NOTE - The throttle body is factory prerset Do not drsassemble rn a way other man shown rn (hrs manual. - Do not snap the throttle valve from full open to lull close afler lhe throttle cable has been removed. It may cause rncorrecl rdle cperalion Do nol damage lhe lhmme body Il may cause rncorrect lhrcmle valve operation Do not loosen or lighten the whrle painted nut [1] and air screws [2] Loosening or lrghlenlng them can cause lhrollle body malfunction. Remove (he lollowmg: — lhrome body Insulalors [1] (loosen the band screws) — er lapping screws [2] — rear air cleaner housing [3] — three screws [4] 7 err funnel [5) 7 from err cleaner housing [6] — throtlle body [71 — rubber seals [8] For arr cleaner lrd and element [9] removal/Inslallallon (page 3-5) [7} [8] m5 7-14 FUEL SYSTEM Remove the following ‘ ~ sensor unit (page 438) 7 IACV (page 7-17) ~ fuel injectors (page 7-15) 7 AC type: EVAP canister-to-throttle body hoses [1] 7 three screws [2] — IACV body [3] e rubber seal [4] ~ two screw [5] A throttle cable holder [6] Clean the air passages in the throttle body and lACV body with compressed air. NOTE: - Cleaning with the a piece at wire will damage the throttle body, Assembly is in the reverse order of removal. NOTE - Replace the rubber seals with new ones. - install each insulator band over the insulator With the screw head [1] facing to the right and align the left band hole [2] with the locating boss. ‘ Install each insulator with the "UP" mark [3] facing toward the throttle body and align the groove [4] with thelug - Tighten the insulator band screw so the distance [5] between the band ends is 10 11.0 mm (0.4 1 0 04 in). TORQUE: Throttle cable holder screw: 3.4 N-m (0.3 mm, 2.5 lbf-ft) IACV body screw: 3.4 N-m (0.3 kgr-m, 2.5 ibr-ft) Air cleaner housing assembly tapping screw: 1.1 N-m (0.1 kgr-m, 0.8 mm) FUEL INJECTOR REMOVALIlNSTALLATION Remove the throttle body lrom the air cleaner housing A CM‘ es Sm;fl,’ [31 (page 7-14) ‘ yp ' Remove the tollowmg: ‘ 7 four bolts [1] 7 fuel pipe [2] and iuel injectors [3] (as an assembly) FUEL SYSTEM fl _ fuel inleclors [1] r — — seal rlngs[2] r O-rlngs [3] [31 9? 91 75L _m r Injeclorlomts [1] 7 fuel plpe[2] r Orrings [3] Check each part for wear or damage and replace n il necessary Installahon is ln the reverse order of removal NOTE - Replace the Orrings and seal rings with new ones and coat them wilh engine oil. - When Installing Ihe fuel injector, be careful not to damage the Orrihg and seal rlng - Allgn the Injector connectors [1] wilh the fuel joint tabs [2] to position (hem uprighl TORQUE: Fuel injectorjoint bolt: 5.1 N-m (0.5 kgf—m, 3.8 lbf-ft) 7-16 FUEL SYSTEM IACV INSPECTION - The IACV is installed on the throttle body and is 7 7 7 ‘ operated by the step motor. When the ignition switch l is turned ON, the IACV operates (or a lew seconds. Lift the fuel tank and support it (page 3—4) Turn the ignition SWItch ON with the engine stop SWitoh and check the IACV ii] If the operating (beep) sound is not heard with no MlL i blinking. periorrn the followmg inspection i Remove the IACV (page 7-17). Check the lACV slide valve [1] and lACV air passage in ‘ the throttle body for carbon deposits. Check the O-ring [2] on the IACV tor deterioration or damage. , Temporarily install the following components to the Wire harness by connecting each connector — throttle body, fuel injector 2P (Gray) and sensor unit 5P (Black) 7 IACV; 4P (Black) [3] Turn the ignition switch ON With the engine stop swuch "0" while holding the slide valve lightly. The slide valve should move back and forth Turn the ignition sWitch OFF Disconnect the connectors to remove the throttle body and IACV from the wire harness, Install the IACV (page 7-17), REMOVAL/INSTALLATION Remove the throttle body from the air cleaner housing (page 7714) Remove the tollowmg: 7 two screws[1] 7 setting plate [2] 7 lACV [3} e Orring [4] 7-17 FUEL SYSTEM Installation is in the reverse order of removal NOTE 0 Replace the Oerrng [1] With a new one (do not apply OII) - Turn the slide valve [2] clockwrse until It is seated lightly and install by aligning the long slot With the pm on the throttle body « Align the cutout in the setting plate [3] With the lug at the IACV body. TORQUE: lACV setting plate torx screw: 2.1 N-m (0.2 kgr-m,1.5lbr-n) SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature Stop the engine. Lift the fuel tank and support it (page 34), Remove the hose Clip [1] and disconnect the air supply hose [2] from the air cleaner housing Check that the hose jolt’tl (secondary air intake port) [3] oi the air cleaner housing is clean and tree of carbon deposits Check the PAIR check valve It the port is carbon fouled I ' (page 7-20) Lower the tuel tank until the fuel pump 3P (Black) connectorcan be connected and support rt Temporarily connect the fuel pump 3P (Black) connector Start the engine and open the throttle slightly to be ‘ certain that air Is sucked in through the disconnected air supply hose If the air is not drawn in, check the air supply hoses [1] r tor clogs and PAlR control solenord valve [2] (page 7- I 19) 7-18 FUEL SYSTEM PAIR CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the fuel tank under tray (page 2-25). Dlsconnect the 2P (Black) connector [1] Disconnect the air supply hoses [2] to remove the PAlR control solenoid valve [3} Installallon is in the reverse order of removal. PAIR CONTROL SOLENOID VALVE INSPECTION Remove the PAIR control solenoid valve (page 7-19) Check the air flow through the solenoid valve Air should flow Irorn lnpul hose mung (A) to output hose ‘ fittlng (8) Connect a 12 V battery to the 2P connector [11 terminals of Ihe PAIR control solenoid valve, Air should not flow when lne battery Is connected. Measure the resislance between Ihe 2P connector [1] terminals of the PAIR control solenoid valve. STANDARD: 24 ~ 28 Q {lam/68°F) If the resistance is oul of the specificatlon. replace the PAIR control solenoid valve 7-19 FUEL SYSTEM PAIR CHECK VALVE REMOVAL] INSTALLATION Remove the Me] tank under tray (page 2725). Disconnecl Ihe arr supply hose [1] from the cylinder head cover Remove the srphon hose [1] from the cramp [2] ’ Rerease (he nghl srde flap [3] and remove the heat ‘ guard rubber [4] out of the way [2] Remove the two bolls [1] and check verve cover [2] 7-20 FUEL SYSTEM Remove the PAIR check valves [1] and baffle plates [2] Installatron is In the reverse order of removal. NOTE - Apply locking agenl to the threads ofthe PAIR check valve cover bolt (page 1—20) TORQUE: PAIR check Valve cover bolt: 12 N-m (1‘2 kgf—m,91bf-ft) PAIR CHECK VALVE INSPECTION Remove the PAIR check valves (page 7-20) Check the reed [1] of the PAIR check valve for damage I or fatigue. Replace If necessary Replace the PAIR check valve if the rubber seat [2] is cracked, delenorated or damaged] or if Ihere IS clearance between Ihe reed and seal. EVAP PURGE CONTROL SOLENOID VALVE (AC type) REMOVAL/INSTALLATION Remove the fuel tank under tray (page 2725) Disconneol the Iollowing — 2P (Black) connector [1] — EVAP purge control solenoid valverto-throtlle body hose [2] I ‘ — EVAP canister-to-EVAP purge control solenoid _' valve hose [3] Remove the followlng. 7 two cap nuts [4] and washers [5] (outslde) 7 two bolts [6] and EVAP purge control solenoid valve ’ [7] 7 two collars [8] (Instde) Installation is in the reverse order of removal. 7-21 FUEL SYSTEM INSPECTION Remove the EVAP purge control solenoid valve (page i ’ I21), ‘ Check the air flow through the solenoid valve. Air should not flow from input hose lilting (A) to output ‘ hose fitting (B) i Connect a 12 V battery to the EVAP purge control solenoid valve 2P connector [1] terminals Air should flow when the batten/ is connected Measure the resistance between the 2P connector [1] terminals oi the EVAP purge control solenoid valve STANDARD: 30 » 34 Q (WT/68°F) lithe resistance l5 out spemtioation, replace the EVAP purge control solenoid valve EVAP CANISTER (AC type) REMOVAL/INSTALLATION Remove the left middle cowl (page 25) Disconnect the EVAP canister drain hose [1]. Remove the mounting bolt [2] and collar [3], and the EVAP canister [4] from the stay, Disconnect the lollowing and remove the EVAP canister: 7 fuel tankrtorEVAP canister hose [5] r EVAP oanister-lo-EVAP purge control solenoid e valve hose [6] Installation Is "1 the reverse order of removal. 7-22 FUEL SYSTEM FUEL PUMP RELAY CIRCUIT INSPECTION For relay inspection (page 21725). Remove the fuel pump relay (page 2124), RELAY SWITCH/COIL POWER INPUT LINE Measure the voltage between each Iuel pump relay terminal of the relay box [1] and ground. Al I CONNECTION: a (+)—Ground (—) m a (BINV) I 0 1+) — Ground (—) 17‘ ‘ l There should be battery voltage when the ignition , , ED switch is turned ON with the engine slop switch "(7" ‘ a) EU iv If there is no voltage check the following: (v 9 7 Black/white Wire(s) in the relay box between the g 2 main and fuel pump relays t D (BINV) e main relay and its circuit (page 442) I SIGNAL LINE Check for continuity between the fuel pump relay terminal of the relay box [1] and ground CONNECTION: C — Ground , There should be no continuity With the ignition switch ‘ OFF, If there is continuity, check for short circuit in the Brown/ I D D black wire between the relay box and ECM, Q t \0 There should be continuity (or a few seconds when the igniilon swrlch is turned ON with the engine stop switch ‘ T If there is no continuity, check for open circuit in the Brown/black wrre between the relay box and ECM 7-23 MEMO 8. COOLING SYSTEM SERVICE INFORMATION TROUBLESHOOTING ................................. ..8_2 SYSTEM FLOW PATTERN ------------------------- "8-3 SYSTEM TESTING- COOLANT REPLACEMENT ....................... ..8_5 THERMOSTAT ............................................ ..8_6 RADIATOR/COOLING FAN ------------------------ --s.7 n RADIATOR RESERVE TANK --------------------- --a.9 WATER pUMp .......................................... ..8_1o WATER HOSE JOINT ------------------------------- “8-11 8-1 COOLING SYSTEM SERVICE INFORMATION GENERAL AWARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out. seriously scalding you I Always let the engine and radiator cool down before removing the radiator cap ‘ Usmg coo/ant With si/icate corrosion inhibitors may cause premature wear of water pump sea/s or blockage of radiator passages Using tap water may cause engine damage Add coolant to cooling system at the reserve tankv Do not remove the radiator cap except to refill or drain the system All cooling system services can be done With the engine in the irame. Avoid spilling coolant on painted surfaces After servicing the system. check tor leaks with a cooling system tester For high coolant temperature indicator/ECT sensor inspection (page 21-14) For fan control relay inspection (page 2125) TROUBLESHOOTING Engine temperature too high - Faulty high coolant temperature indicator or ECT sensor (page 21714) - Thermostat stuck closed - Faulty radiator cap ' lnsuflioient coolant ' Passage blocked in radiator, hoses or water iacket - Air in system - Faulty cooling fan motor - Faulty tan control relay (page 21-25) ~ Faulty water pump Engine temperature too low - Faulty high coolant temperature indicator or ECT sensor (page 21714) - Thermostat stuck open - Faulty fan control relay Coolant leak - Faulty water pump mechanical seal - Deteriorated Oerings - Faulty radiator cap - Damaged or deteriorated cylinder head gasket - Loose hose connection or clamp - Damaged or deteriorated hose - Damaged radiator COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR CAP UPPER RADIATOR HOSE RADIATOR SIPHON HOSE WATER PUMP-Tor CYLINDER BLOCK HOSE THERMOSTAT RADIATOR LOWER RADIATOR HOSE RESERVE TANK WATER PUMP OVERFLOW HOSE BYPASS HOSE COOLING SYSTEM SYSTEM TESTING RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the right middle cowl (page 2-8). 1 Remove the radiator cap [1]. Wet the sealing surfaces of the cap [1], then Install the cap onto the tester [2]. Pressurize the radiator cap using the tester. Replace the radiator cap it it does not hold pressure‘ or II relief pressure is too high or too low The cap must hold the specified pressure for at least 6 seconds, RADIATOR CAP RELIEF PRESSURE: 108 — 137 kPa (1.1 — 1.4 kgflcm’, 16— 20 psi) Connect the tester to the radiatorl Pressurize the radiator‘ engine and hoses using the m tester. and check tor leaks. L Excessive pressure can damage the cooling system components Do not exceed 137 kPa (1.4 kgi/cm“, 20 psi) Repair or replace components if the system will not hold the specified pressure tor at least 5 seconds, COOLING SYSTEM COOLANT REPLACEMENT REPLACEMENT/AIR BLEEDING NOTE - When filling the system or reserve tank with coolant. or checking the coolant level, place the motorcycle “1 an upright position on a flat, level surface. Remove the left middle cowl (page 278). Remove the water pump drain bolt [1] and sealing washer [2] Remove the radiator cap [3] and drain the coolant. Remove the cylinder drain bolt [4], sealing washer [5] and drain the coolant from the cylinder, Reinstall the dram bolts With new sealing washers Tighten the drain bolts to the specified torque. TORQUE: Water pump drain bolt: 13 N-m (1.3 kgi-m,1o|brm Cylinder drain bolt: 12 NM (1.2 kgf-m, 9 lbf-ft) Disconnect the Siphon hose [1] irom the radiator, Release the siphon hose lrom the clamps [2] Remove the siphon hose out ol the frame to the lower Side and drain the coolant irom the reserve tank, Empty the coolant and rinse the lnSlde of the reserve tank with water. Install the siphon hose into the clamps and connect It to the radiator 8-5 COOLING SYSTEM Fill the system with the recommended coolant through the tiller opening up to filler neck [1] RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-tree corrosion inhibitors STANDARD COOLANT CONCENTRATION: 1:1 mixture with distilled water Bleed air from the system as follow: 1 Shin the transmission into neutral Start the engine and let it idle tor 2 r 3 minutes ; 2. Snap the throttle 3 r 4 times to bleed air from the L¥7_ system. 3. Stop the engine and add coolant up to the tiller neck it necessary, 4. install the radiator cap [2]. Fill the reserve tank With the recommended coolant (page 3'12) install the lth middle cowl (page 2—8) THERMOSTAT REMOVAL/INSTALLATION Drain the coolant (page 8-5), Remove the bolts [1] and thermostat cover [2] Remove the thermostat [1] from the cylinder head Installation lS in the reverse order of removal. TORQUE: Thermostat cover bolt: 12 Nm (1.2 kgt-m, 9 lot-ft) NOTE - Install the thermostat with the all‘ bleed hole [2] tacing up, aligning the body ribs With the grooves of 5* the cylinder head, Fill and bleed the cooling system (page 875) 8-6 Wear insulated gloves and adequate eye protection Keep flammable materials away from the electnc heating element Do not let the thermostat or rhermumeter [1] touch the pan, or you will get false reading RADIATOR/COOLING FAN COOLING SYSTEM Check the seal ring [2] for damage and replace if ‘ necessary, INSPECTIO N Visually inspect the thermostat [1] for damage. Replace the thermostat if the valve stays open at room temperature. Heat the water With an electric heating element to 1 operating temperature for 5 minutes. Suspend the thermostat [2] in heated water to check its operation. THERMOSTAT BEGIN TO OPEN: 80 — 84°C (176 —183°F) VALVE LIFT: 8 mm (0.3 in) minimum at 95”C (203“F) Replace the thermostat it It responds at temperatures other than those specified. REMOVAL/INSTALLATION Drain the coolant (page 8-5) Disconnect the tan motor 2P (Black) connector [1] and i remove it from the stay. Remove the wire band clip [2] [rpm the fan motor shroud. COOLING SYSTEM Release the hose Clip [1] and disconnect upper radrator hose [2] Drsconhecl the suphoh hose [3]. Release the hose clip [4] and drsccnhecl lower radiator hose [5]. Remove the upper mountlng bolt [1] and collar [21' Release the heat guard rubber [3] from the filler heck‘ I hooks and stay 4 Be care/u/ no! lo Release the radrator lower grommets [1] from the frame ‘ damage the bosses by moving the radialor lo lhe left to remove the radraro/ frns radiator [2]. Installatron rs rh the reverse order of removal Full and bleed the coolth syslem (page 875). 8-8 COOLING SYSTEM DISASSEMBLYIASSEMBLY Disassemble and assemoie the radiator as foliowmg iliuslrahon RADIATOR RADiATOR CAP COOLING FAN NUT 11Nm(01kgi*m,08lbrfi) COOLING FAN W n ’ FAN MOTOR FAN MOTOR SCREW 2.8 N m (0,3 kgi m, 21 um) FAN MOTOR SHROUD BOLT a 5 N m (0.9 kgl-m, 6.3 inf-fl) RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the foiiowing — left side cover (page 2-7) — swingarm (page 17-13) Remove the overflow hose [1] Vrom the under cowi Remove the socket bolt [21‘ then reiease the two bosses [3] of the reserve tank [4] from Ihe frame Disconnect the siphon hose [5] and dram the coolant to remove the radiator reserve tank. Disconnect the overflow hose [6] and reiease H from the guides [71' Installation is in the reverse order or removai. Fiil the reserve tank with the recommended cooiant (page 3—12). COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check the bieed hole [1] of the water pump tor Signs of ‘ coolant ieakage ‘ ' A smaii amount oi cooiant weeping from the bleed hoie is normai. ~ Make sure that there are no continuous coolant ieakage irom the bleed hole while operating the engine Replace the Water pump as an assemny it necessary REMOVAL/INSTALLATION NOTE ~ Piece 3 ciean oii pan under the engine because engine oil Wiii flow out when removing the water ‘ pump body Add the recommended engine oil to the specified Ievei after Installation (page 3-10), Drain the coolant (page 875) Remove the drive sprocket cover (page 2724) Support the moiorcycie in an upright position on a levei sunace Reiease the hose clips [1] and disconnect the foilowmg from the water pump: a lower radiator hose [2] e bypass hose [3] 7 water pump-torcyiinder block hose [4] Remove the foiiowing' 7 cover boIt [1] 7 three mounting bolts [2] 7 water pump cover [3] Remove the cover Orrlflg [1] from the water pump body Remove the water pump body [2] from the crankcase, 8-10 COOLING SYSTEM Remove the water pump body O-ring [1} Installation is in the reverse order at removal. TORQUE: Water pump mounting bolt: 12 Nm (1.2 kgt-m. 9 lbf-ft) Water pump cover bolt: 13 N-m (1.3 kgr-m,10ibt-rt) NOTE - Do not disassemble the water pump body - Replace the Oerings With new ones. - Apply engine oil to the water pump body O-nng - Do not apply engine oil to the cover Ovring. ‘ - Align the water pump shaft groove with the oil pump ‘ shaft end by turning the water pump impeller Check the on level (page 340). Fill and bleed the cooling system (page 8-5). WATER HOSE JOINT REMOVAL/INSTALLATION Drain the coolant (page 8-5), Remove the throttle body/air cleaner housing assembly (page 7-1 1 ), Release the hose clip [1} and disconnect the water pumprlo»oylinder block hose [2]. Remove the nuts [3L water hose joint [4] and Orring [5]. Installation is in the reverse order of removal. NOTE - Replace the O-ring with a new one Fill and bleed the cooling system (page 8-5) STUD BOLT REPLACEMENT Remove the water hose lent (page 8-11) Thread two nuts onto the stud and tighten them together. and use a wrench on them to turn the stud bolt out. ‘ Apply locking agent to new stud bolt threads (page 17 ‘ 20). Install the stud bolts into the cylinder block as shown After installing the stud bolts, check that the length from the bolt head to the Cylinder block surface is wrthin ‘ specification. SPECIFIED LENGTH: 15.0 — 15.0 mm (0.59 — 0.63 in) 15 o 716 0 mm (0.59 — o 63 In) Install the water hose Joint (page 8-11) i, 8-11 MEMO 9. LUBRICATION SYSTEM SERV|CE |NF0RMAT|0N ........................... .. TROUBLE LUBRICATION SYSTEM DIAGRAM OIL PRESSURE INSPECTION ------------------- -- 9-2 9-3 9-4 9-5 OIL PUMP ................................................... ..9_5 PRESSURE REL|EF VALVE 0|L STRAINER ........................................... "9.8 u 9-1 LUBRICATION SYSTEM SERVICE INFORMATION GENERAL Used engine oil may cause skin cancer it repeatedly left in Contact With the skin for prolonged periods Although this is unlikely unless you nandle used Oil on a daily basis it is sllll advisable to (norcughly wash your hands with soap and water as soon as possible after handling Used Oil The oil pump can be serviced with the engine installed in the frame. The service procedures in this section must be performed with the engine oil drained. When removing and installing the Oil pump, use care not to allow dust or dirt to enter the engine. lfany portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. After the oil pump has been Installed check that there are no oil leaks and that oil pressure is correct For engine orl pressure indicator/EOP SWitch inspection (page 21715) For piston oil Jet service (page 1446) TOOLS Oil pressure gauge set V ifOll pressure gauge attachment 07506—300000] 074060030000 or equivalent commercially available in i or equivalent commercially available in u sA. l u s A 9-2 TROUBLE SHOOTING Oil level too low - Oil consumption Exlernai oil leak Worn piston rings (page 14714) improperly installed piston rings (page 144 5) Worn cylinders (page 14-14) Worn stem seais (page 1047) Worn valve guide (page 1047) Low oil pressure - Oii levei low - Clogged oilslrainer - lntemai oii leak - Incorrect oil being used No oil pressure - Oil ievel loo low - Oii pressure reiief valve stuck open - Broken oil pump drive chain - Broken oii pump drive or driven sprocket - Damaged oil pump - Internal Oll leak High oil pressure - oil pressure relief vaive stuck closed ‘ Clogged oii iiiler, gaiiery or metering orifice . Incorrect oil being used Oil contamination - Oil or inter not changed often enough - Worn pislon rings oil emulsification - Blown cylinder head gasket - Leaky cooianl passage - Entry olwater LUBRICATION SYSTEM LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM EXHAUST CAM SHAFT INTAKE CAM SHAFT PISTON P‘STON OILJET PISTON OIL JET CRANKSHAFT . ’7 EOP SWITCH 01L ORlFICE ‘ ‘ O‘L OR‘HCE MA‘NSHAFT COUNTERSHAFT REL‘EF VALVE OIL PUMP \ ‘ ‘ O‘L STRAJNER 0‘ L FILTER CARTR‘DGE 9-4 LUBRICATION SYSTEM OIL PRESSURE INSPECTION NOTE - If the engine oil pressure indicator remains on while the engine is running check the indicator system before checking the oil pressure (page 21715) Remove the EOP switch (page 2146) lnstall the oil pressure gauge attachment [1] to the swttch base. Connect the oil pressure gauge [2] to the OH pressure gauge attachment. TOOLS: Oil pressure gauge set 07506-3000001 or equivalent commercially available in U.S.A. Oil pressure gauge attachment 0740643030000 or equivalent commercially available in U.S.A. Check the oil level and add the recommended oil it necessary (page 3-10). Warm the engine to normal operating temperature (approximately BO“C/176”F) and increase the engine speed to 1,200 rpm and read the Oil pressure. STANDARD: 93 kPa (0.9 kgflcm‘, 13 psi) at1,200 rpml 30°C (176°F) Stop the engine and remove the tools. lnstall the EOF’ switch (page 21-16). OIL PUMP REMOVAL/INSTALLATION Remove the clutch (page 1177) Remove the bolts [1] and [I'll pump [2] 9-5 LUBRICATION SYSTEM Installation IS In the reverse order of removal NOTE ~ Align the Oil pump shaft end WIth the water pump shalt groove DISASSEMBLYIASSEMBLY Dlsassemble and assemble the OII pump as Iollowmg illustration OIL PUMP BODY DRIVE PIN OIL PUMP PLATE OUTER ROTOR a INNER ROTOR a OIL PUMP SHAFT a OIL PUMP ASSEMBLY BOLT INSPECTION - For oll pump drive sprocket, dnven sprocket and dnve chain Inspection (page 11-10), Inspect the followtng parts (or damage abnormal wear, deformation or burnlng. — oil pump shaft 7 drive pin 7 Inner rotor 7 outer rotor r DII pump body Measure the all pump clearances according to LUBRICATION SYSTEM SPECIFICATIONS (page 17 9). If any oi the measurement IS out of the servtce limit‘ replace the OII pump as an assembly 9-6 LUBRICATION SYSTEM PRESSURE RELIEF VALVE REMOVAL/INSTALLATION Remove the oil pump (page 9-5). Remove the oil pressure relief valve [1] and Oering [21 Apply engine oil to a new O»ring. Install the O-ring to the oil pressure relief valve groove Install the oil pressure reliet valve into the crankcase Install the oil pump (page 9—5). lNSPECTlON Check the operation of the pressure relief valve by pushing on the piston [1]. Disassemble the pressure relief valve by removing the snap ring [2]. Remove the washer [1], spring [2] and piston [3] Check the piston for wear, sticking or damage. Check the spring tor fatigue or damage. Assemble the pressure relief valve in the reverse urder of disassembly. NOTE - Install the snap ring [4] with the chamtered edge lacing the thrust load side. - Make sure the snap ring is seated ‘in the groove l r [3] [2] l1] LUBRICATION SYSTEM OIL STRAINER REMOVAL Draln the englne Ol] (page 3-10). Remove the exhaust pipe (page 2729) AC type Remove the EVAP Canister drain hose cllp [1] trorn the stay, Loosen the bolts [1] in a cnsscross pattern In 2 or 3 steps. and remove the bolts on! pan [2] and gasket [3]. Remove the all stralner [1] and seal ring [2]. Clean the all stralner screen [3] and check for damage INSTALLATION Be Care/u/not to Clean any gasket material from the mating surtaces of damage the mallrlg the oil pan smaces Apply englne all to a new seal ring [1] and install lt onto the all strainer [2]. Install the all strainer mm the crankcase whlle allgnlng the all stralner boss wrth the crankcase groove 9-8 LUBRICATION SYSTEM Install a new gasket [1] onto the Oil pan [2] Install the Oll pan and bolts [3] to the crankcase, Tighten the belts in a crtsscross pattern m 2 or 3 steps. Acrypev Install the EVAP canister dram hose clvp [1] mm the slay Install the exhaust pipe (page 2729) Fill the engine with the recommended engine all and check that there are no Oll leaks (page 3710). MEMO 10. CYLINDER HEADNALVES SERV|CE |NF0RMAT|ON ......................... ..10_2 TROUBLESHOOTING ............................... ..1D_4 COMPONENT LOCATION ------------------------ --10-5 CYLINDER COMPRESSION TEST ----------- “10-6 CYLINDER HEAD COVER ------------------------ “10-6 CAMSHAFT. ....................................... ..10_9 ROCKER ARM ........................................ "1044 CYL|NDER HEAD ................................... “1046 CAM CHAIN TENSIONER LIFTER --------- "10-23 CAM CHAIN/TIMING SPROCKET ---------- "10-24 10-1 CYLINDER HEADNALVES SERVICE INFORMATION GENERAL - This section covers service of the cylinder head, valves, rocker arms and camshafls, - The rocker arms, Camshafts and cam chain tensioner lifter services can be done With the engine installed in the frame. The cylinder head and valve servme requires engine removal. - When disassembling. mark and store the disassembled parts to ensure that they are reinstalled In their original locations. Clean all disassembled parts With cleaning solvent and dry them by blowing them off with compressed air before Inspection - Camshafts and rocker arrns lubricating oil is fed through oil passages in the cylinder head and camshaft holder. Clean the oil passages before assembling them - Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. TOOLS iéompression gauge attachment VTenSioner holder B V ‘ Valve spring compressor i 07RMJ-MY50700 ‘ 070MG70010100 07757—001000!) or equivalent commercially available in or 07AMG-OO1A100 (U.S.A. only) } i, l U SA. or 07AMG-MFJA100 (U.S.A. only) iValve spring compressor attachmerf’ i ngefiide driver, 4.5 mm Valve guide adjustinEdriver O7959-KM30101 07HMD-ML00101 0774343020000 ‘ (not available in U SA.) Valve guide‘reamer, 4,5 mm Cutter holder, 4.5 mm " Seal cutter, 27.5 mm (IN. 45”) ’ 07HMH—ML001 01 0778170010600 0775070010200 or D7HMH-ML00105 (U SA. only) i or equivalent commercially available in or equivalent commercially available in ‘ i U SA U SA, 10-2 CYLINDER HEADNALVES l Sealcune'r,24mm(E>{,45“) ‘ Flalculler, 28mm (IN, 32“) '7 Flatsfitler24mmlgx,32‘) " ; 07780-0010600 07780-0012100 l 07780-0012500 ‘ \l /' A x l ‘ orequlvalenlcommerclally available In orequivalenlcommercially avallable ln ‘ orequivalemcommerclally available in ‘ U.S.A. u s.A. U sAA. ‘ ‘ Interior cutter‘ 26 nim (IN, 80°) Interior Cullen 22 mm (EX, 60") '7" ‘ 07780-0014500 0778043014202 l orequvvalenlcommerciallyavailablein ‘ orequivalenlcommerciallyavallableIn L USA, l USA. 10-3 CYLINDER HEADNALVES TROUBLESHOOTING ' Engine top-end problems usually affect engine periormance. These problem can be diagnosed by a compression test or by tracing engine noises to the topeend With a sounding rod stethoscope. - If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, cneck tor a seized piston ring (page 14-14), Compression too low, hard starting or poor per'ormance at low speed - Valves: — Incorrect valve clearance adjustment — Burned or bent valve — Incorrect valve timing — Broken valve spring — Uneven valve seating - Cylinder head: 7 Leaking or damaged cylinder head gasket v Warped or cracked cylinder head — Loose spark plug - Worn cylinder, piston or piston rings (page 14-14) Compression too high, overheating or knocking - Excessive carbon build-up on piston crown or on combustion chamber Excessive smoke ' Cylinder head: — Worn valve stem or valve guide - Damaged stern seal Worn cylinder. piston or piston rings (page 14-14) Excessive noise - Cylinder nead' » Incorrect valve clearance adjustment — Sticking valve or broken valve spring — Damaged or worn camshaft — Worn rockerarm and/or shaft 7 Worn rocker arm and valve stem end — Loose or worn cam chain — Worn or damaged cam chain — Worn or damaged cam chain tensioner — Worn cam sprocket teeth - Worn cylinder, piston or piston rings (page 14—14) Rough idle - Low cylinder compression 10-4 CYLINDER HEADNALVES COMPONENT LOCATION 10 N-m (1,0 kgl-m, 7 mm) 47 N-m (4.3 kgrm, 35 mm) 12 N-m (1.2 kgf-m‘ 9 lbffl) 10-5 CYLINDER HEADNALVES CYLINDER COMPRESSION TEST Warm the engine to normal operating temperature Stop the engine and remove the all spark plug caps and spark plugs (page 3-6) Temporarily install the ECM to the Wire harness by connecting the 33p (Black) connector Install a compression gauge [1] With the attachment into the spark plug hole. TOOL: [2] Compression gauge D7RMJ-MY50100 or attachment equivalent commercially available in U.S.A. Turn the ignition sWitch ON With the engine stop sWItch “,1” Shift the transmission Into neutral Open the throttle all the way and crank the engine With the starter motor until the gauge reading stops rising. The maximum reading is usually reached Within 4 r 7 seconds Compression pressure: 1.372 kPa (14.0 kgflcm’, 119 psi) at 450 rpm Low compression can be caused by: » Blown cylinder head gasket — Improper valve clearance adjustment — Valve leakage — Worn piston rings or cylinder High compression can be caused by: 7 Carbon deposits In combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL/INSTALLATION NOTE - The cylinder head cover can be sewiced With the engine installed in the frame Remove the fuel tank under tray (page 225). Disconnect the following: 7 PAIR control solenOId valve 2P (Black) connector [1] , 7 PAIR air supply hose [2] from the cylinder head cover — crankcase breather hose [3] from the cylinder head cover 7 AC type‘ EVAF' purge control solenoid valve-tor throttle body hose [4] at the hose idint [5] 10-6 CYLINDER HEADNALVES Remove the bolt [1] and clutch cable holder [2], then disconnect the clutch cable [3] from the clutch lifter arm [4] Remove the clutch cable out of the frame Loosen the throttle cable A adjuster lock nut [1] and adjuster [21 then dlsoohnect the throttle cable A13] from the throttle drum and cable holder. Loosen the throttle cable 5 adluster [4] then disconnect h the throttle cable B [5] from the throttle drum and cable holder, Remove the throttle cables out of the frame Drsoonneot the Upper radiator mounting bolt (page 878) CBRSDORA/CBSOOFA/XA Remove the boil [6] and disconnect the brake line Joint [7] from its bracket Remove the brake pipes [8] lrom the two clips [9] and remove the clips from the frame AC type. Remove the canister mounting bolt [1] and collar [2], and move the EVAP canlster [3] out of the way Remove the bolt [4] and connector stay [5]. AC type’ Remove the EVAP purge control solenoid valve from the frame (page 7721). Release the siphon hose [1] from the clamp [2]V Remove the heat guard rubber [3] from all locations except the siphon hose and move it to the right Slde of the frame. i CYLINDER HEADNALVES Place tape on me cylinder head cover to protect it upon removal Remove the cylinder head cover bolts [1] and mounting rubbers [2] Remove the cylinder head cover [3] from the cylinder head NOTE - Do not forcibly remove the dowel pins from the cylinder head cover, Remove the cylinder head cover packing [1] from the cylinder head cover Installation is in the reverse order of removal TORQUE: Cylinder head cover bolt: 10 N‘m (1.0 kgf-m, 7 lbf-fi) Right crankcase cover bolt: 12 N-m (1.2 kgl-m,91bf-ft) NOTE Replace the cylinder head cover packing With new packing Install lhe cylinder head cover packing into the groove in the cylinder head cover - Make sure the cylinder head cover packing caps [2] ‘ are installed In position. Apply sealant to the cylinder head semicircular edges as shown (8 places) (page 1720). while aligning the cylinder head cover packing with the grooves in the cylinder head semicircular areas Check the mounting rubbers [3] are in good condition, replace them it necessary facing up ~ Align the clutch cable holder hole with the right crankcase cover boss Adjust the following: 7 throttle grip freeplay (page 3—4) a clutch lever freeplay (page 3-20) ‘ ill/[2] Install the cylinder head cover onto the cylinder head Install the mounting rubbers With their "UP" mark [4] 10-8 CAMSHAFT Be careful not [0 let the cam sham gmde Dolls tall mtg the crankcase Be Careful not to let the camshaft holder bolts [all mm the crankcase Attach a place 0/ Wire (0 the Cam cham to prevent ll from tat/mg mm the crankcase REMOVAL NOTE - The camshth can be serviced With the engtne Instaned tn the frame Remove the cylinder head cover (page 10-6) Make sure the No 1 piston Is at TDC (Top Dead Center) on the compressxon stroke (page 3-7). Remove the sealtng bolt [1] and sealing washer [2] Turn the cam chain tenstoner ltfter shaft fulty in (clockWtse) and secure it ustng the specual tool TOOL: [3] Tensioner holder 3 070MG-0010100 or 07AMG-DD1A100 {USA only) or 07AMG-MFJA1OD (U.S.A. only) Remove the bolts [1] and cam sham guide B [2]. From outs/de to inside, loosen the bolls In a cnsscross t 1 pattern in several steps or the camshaft holder might \ l 1 break Loosen the camshaft holder bolts [1] gradually tn 3 ‘ cnsscross pattern m 2 or 3 steps, and remove them Remove the camshafi holders [2] wtth the dowel pins from the cyltnder NOTE ' Do not torctbly remove the dowel pins from the camshaft holders Remove the Camshafts [1] by removing the cam chatn ‘ [2] from the cam sprockets CYLINDER HEADNALVES CYLINDER HEADNALVES Ltfl the rocker arms [1] Remove the shtrns [2] NOTE - Do not attow the shims to tatt IMO the crankcase, ' Mark alI shtms to ensure correct reassembly In their cngmat Iocattons. - The shims can be easily removed with a tweezers or a magnet. INSPECTION Inspect the foIluwtng parts for damage abnormal wear, detorrnatlon, burnrng or dogs In oiI passages. a cam sprockets/Camshafts r camshaft hotders/dowet pins 7 cam chain gmde a Measure each part accordth to CYLINDER HEAD/ VALVES SPECIFICATIONS (page 140) Replace any part It it is out of servuce hmtt. CAMSHAFT RUNOUT Support both SldES DI the camshaft (at Journats) wtth Vrbtocks and check the camshafl run out WIIh a dial gauge SERVICE LIMIT: 0.04 mm (0.002 in) CAMSHAFT OIL CLEARANCE the any oil from the journats of the camshaft, cyltnder head and camshaft hotders Instalt the Camshafts onto the cyhnder head - AIign the punch mark [1] on the intake cam sprocket [2] wtth the cyttnder head top surface as shown ‘ Align the outsxde Index lune ("EX" [3] mark) on the ‘ exhaust carn sprocket [4] WIII’I the cyhnder head top I surface as shown 10-10 CYLINDER HEADNALVES Lay a strip of plastigauge [‘l] lengthwrse on top of each j camshaft journal avoiding the oil hole, ‘ NOTE' - Do not rotate the camshaft during inspection i, if —i ngi Be sure the dowel Install each camshaft holder With the arrow [1] iacing pins in the camshaft the intake side in the correct locations as shown. i:$::1:’;i: — homer/«i2: i head — camshaft holder B [3] ("lN" mark: intake side holder) 7 camshaft holder C [A] ("EX" mark: exhaust side holder) l r camshaft holder D [5] ‘ Apply engine oil to the camshaft holder bolt threads and ‘ seating surface ‘ Install the camshaft holder bolts' 7 6 x 39.5 mm bolts [1] r 6 x 32 mm bolts [2} FBI/me to tighten the camshaft holder in a CI‘ISSCIUSS pattern may cause the camshaft holder to break. From inside to outside tighten the camshaft holder bolts gradually until the camshaft holders seats on the cylinder head Tighten the camshaft holder belts in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE112 N-m (1.2 kgfim, 9 lbf-ft) Remove the camshaft holders and measure the width of each plastigauge The Widest thickness determines the oil clearance SERVICE LIMIT: 0.10 mm (0004 in) When the service limits are exceeded, replace the camshaft and recheck the out clearance. Replace the cylinder head and camshaft holders as a set if the clearance still exceeds the service limit 1041 CYLINDER HEADNALVES INSTALLATION Be careful no! lo Rmate lhe crankshaft clockwise. and a‘igfl the "T" mark /am the cam Chem [1] cm the pnmary drwe gear wnh the Index notch [2] on mm the rrmmg me nght crankcase cover sprocket on me crankshafl when rural/mg [he Craflkshaf! Be carelu/noxto/er \ns‘aH (he shims [1] In their original \ocatxons on the [he sh/ms fall mlo va‘ve relamer "’9 5’5"“5‘355 Lower the rocker arms [2] Each camshaft has an rdenhhcailon mark. - “IN” mark [1}: inlake camshafi - "EX" mark [2] exhaust camshaft 10-12 Be Sure the dowe/ pins in the camshaft holder align with the Iioles In the cylinder head All arrows on the Camshaft holders should face toward lhe intake Side. CYLINDER HEADNALVES Apply molybdenum oil solution to the camshaft [l] i’ i lobes, journal and thrust surfaces Apply engine oil to the cam chain [2] whole surface Install the camshafls onto the cylinder head while installing cam chain onto the cam sprockets Position the punch marks [3] on the cam sprockets facing up‘ and align the outside index line ("IN" [4] and EX" [5] marks) with the cylinder head top surface as shown l 11] install each camshaft holder with the arrow [1] lacing the intake side in the correct locations as shown 7 camshaft holderA[2] r camshaft holder B [3] ("lN" mark: intake side holder) 7 camshafl holder C [4] ("EX" mark' exhaust side holder) 7 camshaft holderD[5] Apply engine oil to the camshaft holder bolt threads and seating surface Install the camshaft holder bolts: » 6 x 395 mm bolts [1] r 6 x 32 mm bolts [2] Failure to tighten the camshaft holder in a crisscross pattern may cause the camshaft holder to break. Frorn Inside to outside tighten the camshaft holder bolls gradually until the camshaft holders seats on the cylinder head. Tighten the camshaft holder bolts in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE: 12 N-m (1,2 kgl-m. 9 Ibf-ft) 10-13 CYLINDER HEADNALVES InslaH the Cam Chain gurde B [1] wrth the "EX" mark [2] facrng the exhaust side Be carefulnorm/el Install and trghlen the Cam Chain gurde botts [3] me cam chem gurde securety bolts fal/ mm the crankcase Remove the tehsroner stopper [1] (ram Ihe cam chain tehsroner Mfter, Turn the crankshafl ctockwxse several times‘ and atign the "T" mark on the pnmary drive gear wrlh the index notch on the rrght crankcase Cover (page 10-12) Recheck the vatve trrnihg Inspect the valve ctearahce (page 3-7) \nstatl the sealrhg bolt [2] WIth a new seahng Washer [31 and tighten it securety InslaH the cyhnder head cover (page 10-6). ROCKER ARM REMOVAL/INSTALLATION NOTE - The rocker arm can be servrced With the ehgme F? mstalled m the frame, ‘ - The intake and exhaust rocker arm services are the ‘ same procedures. Remove the Camshafts (page 1079), Remove the plug butt [1] and sealrng washer [2] 10-14 CYLINDER HEADNALVES Remove the rocker arm shaft [1] using a 6 mm bolt [2] while holding the rocker arm [3]. Remove the rocker arms Apply molybdenum DII solution to the rocker arm sllding areast thrust surface and rocker arm shaft outer surface. install the rocker arms and rocker arm shaft. NOTE, ~ The rocker arms are identified by the stamped ‘ marks: ‘ » "I" mark [41 intake rocker arm 7 “E” mark [5]: exhaust rocker arm Apply engine oil to the threads of plug bolt [1] and Install i It with a new seallng washer [2], aligning the blade with the groove, Tighten the plug bolt to the specified torque. TORQUEHS NM (1.5 kgI-m, 11 IbI-ft) Install the Camshafts (page 1012). INSPECTION Inspect the following parts for damage, abnormal wear‘ deformation, burning or clogs in oil passages — rocker arms 7 rocker arm shafts Measure each part and clearance according to CYLINDER HEAD/VALVES SPECIFICATlONS (page 1-10) Replace any part if it is out of service limit 10-15 CYLINDER HEADNALVES CYLINDER HEAD REMOVAL Remove the forlowing: 7 engrne(page15~4) r rocker arms (page 10-14) — thermostat (page 8-6) Drsoonnect the ECT sensor 2P (Black) connector [1] Retease the hose clrp [2] and disconnect the bypass hose [3] Remove the 6 mm bolts [1] Suck out the grim Loosen the 9 mm washer»bolts [2] m a cnsscross the 9 mm washer- pattern In 2 or 3 steps‘ then remove them 5°” “Wes "We Remove the cylinder head [3], Iemovmg the bolts NOTE - Attach a prece of wrre to the cam chain to prevent it from faHing rnto the crankcase - Do not tap the cyhnoer head [00 hard and do not damage the matrer surface wrth a screwdriver Remove the dowet prns [1] and gasket [2] Remove the cam chain guide A [1] 10-16 CYLINDER HEADNALVES Remove the partition pin [1] Check the partition pin for deterioration or damage. DISASSEM BLY Remove the following: 7 spark plugs (page 3-6) 7 ECT sensor (page 4459) To prevent/ass or Remove the valve Spring cutters [1] using the special tension, do no! tools. compress the valve . sprrngs more than TOOLS- I necessawm [2] Valve spring compressor 07757-001000!) ,emovs ms. 50,195 [3] Valve spring compressor 07959vKM30101 attachment Mark allpar—is Remove the valve spring compressor and remove the during disassemb/y followmg: so they can be placed back In [heir original locations. » valve spring retainers [1] 4 Outer valve springs [2] 7 inner valve springs [3] - valves [4] 7 valve stem seals [5] r valve spring seats [6] Avoiddamegmgme Remove the carbon deposits from the combustion ‘ cylindermalmg chamber [7] and clean off the cylinder head gasket l 6 7 l surface and valve surface. H [5] ' ‘ searsurfaces [41 ' ‘ [3] [2] i [1] INSPECTION inspect the lollowmg parts for damage‘ abnormal wear‘ deformation. burning or clogs In oil passages a cylinder head 7 inner/outer valve springs » valves 7 valve guides r cam chain guide A Measure each part and clearance according to CYLINDER HEAD/VALVES SPEClFlCATIONS (page 1710), Replace any per! il it is out of service limit, - Ream the valve guide using the valve guide reamer to remove any carbon build up before measuring the guide (page 1018) ~ Refer to valve seat inspection [page 10-19). 10-17 CYLINDER HEADNALVES VALVE GUIDE REPLACEMENT Disassemble the cylinder head (page 10—17). Chill new valve guides in a freezer for about 1 hour. NOTE, - Be sure to wear heavy gloves to avoid burns when handling the heated cylinder head - Using a torch to heat the cylinder head may cause ‘ warpage. Heal the cylinder head to 130 — 140°C (266 7 284“F) With a hot plate or oven, Do not heat the cylinder head beyond 150“C (302”F). Use temperature indicator sticks‘ available from welding supply stores, to be sure the cylinder head is heated to the proper temperature. Support the cylinder head and drive the valve guides [1] L 7 7* out of the cylinder head from the combustion chamber side TOOL: [2] Valve guide driver, 45 mm U7HMD-MLOD1D1 Take out new valve guides [1] from the ireezer. While the cylinder head is still heated, drive new valve guides from the camshaft side until the exposed height is specified value. TOOL: [2] Valve guide adjusting driver 07743-0020000 (not available in u.s.A.) SPECIFIED HEIGHT: lNIEX:14.10 —14.3lJ mm (0.555 — 0.563 in) U.5.A. only installation: Mark the depth 01 the valve guide using a marker Use the valve guide driver to correct the depth. Let the cylinder head cool to room temperature Ream new Valve guides after installation. NOTE' ' Take care not to tilt or lean the reamer [‘i] in the ‘ guide while reaming ‘ - Use cutting oil on the reamer during this operation. ‘ the cylinder head and always rotate the reameri clockMse. TOOL: i Valve guide reamer. 4.5 mm D7HMH-ML00101 or i 07HMH-ML00103 (u.s.A. only) ‘ Clean the cylinder head thoroughly to remove any L metal particles after reaming and relace the valve seat (page 10-20), Insert the reamer from the combustion chamber side of i 10-18 The valves cannot be ground. It the valve lace IS burned. badly wom or If I! contacts the sea! uneven/y, replace the valve VALVE SEAT lNSPECTION/REFACING INSPECTION Disassemble the cylinder head (page 10-17). T Clean the intake and exhaust valves thoroughly to remove carbon deposits, Apply a light coat of Prussian Blue to the valve seats ‘ Tap the valve against the valve seat several times using ‘ a hand-lapping tool [1], wlthout rotating the valve to make a clear pattern. Remove the valve and inspect the valve seat face. The valve seat Contact should be within the specified ‘ width and even all around the circumference ‘ STANDARD: 0.90 — 1.10 mm (0‘035 — 0.043 in) SERVICE LIMIT: 1.5 mm (0.06 in) If the valve seat Width is not within specification, reface the valve seat (page 10-20), Inspect the valve seat Iace (or: o Damaged face: 7 Replace the valve and retace the valve seat ‘ Uneven seat width: » Bent or collapsed valve stem, Replace the valve and reface the valve seat - Contact area (too low or too high): — Relate the valve seat CYLINDER HEADNALVES 10-19 CYLINDER HEADNALVES REFACING Reface the valve seat using the tollowing tools. TOOLS: Cutter holder, 4.5 mm Seat cutter, 27.5 mm (IN, 45") Seat cutter. 24 mm (EX, 45") Flat cutter, 28 mm (IN, 32°) 07780-0012100 Flat cutter, 24 mm (EX, 32°) 07730-001250!) lnterior cutter. 26 mm (IN, 60”) 0778041014500 Interior cutter, 22 mm (EX, 60”) 07780-0014202 or equivalent commercially available in U.S.A. 07781-0010600 07780-0010200 07780-0010600 VALVE SEAT WIDTH: 0‘90 — 1.10 mm (0.035 — 0.043 in) NOTE M ‘ . Follow the refacer manufacturer’s operating “a seam/lam l instructions . . ' Be careful not to grind the seat more than I a necessary. i 432 1, Use a 45" seat cutter, remove any roughness or irregularities tram the seat, 2 Use a 32“ flat cutter, remove the top 1/4 of the ‘ Oldseatwmhl existing valve seat material, ‘ 3. Use a 50” interior Cutter. remove the bottom 1/4 of . the existing valve seat material. 4 Using a 45“ seat cutter, cut the seat to the proper width. ” 60° Make sure that all pitting and irregularities are 1*: l removed. / k ’7\ l 5. After cutting the seat. apply lapping compound to the valve lace. and lap the valve using light pressure NOTE « Excessive tapping pressure may detorm or damage the seat. 0 Change the angle of lapping tool [1] frequently to prevent uneven seat wear - Do not ailow lapping compound to enter the guides. After lapping. wash any residual compound off the cylinder head and valve and recheck the seat Contact Assemble the cylinder head (page 10-21) 10-20 CYLINDER HEADNALVES ASSEMBLY SHIM OUTER VALVE SPRING a,“ VALVE COTTERS ‘ VALVE SPRING RETAINER INNER VALVE SPRING " x ' § 93 3 E VALVE STEM SEAL VALVE SPRING SEAT VALVE GUIDE EXHAUST VALVE a a INTAKE VALVE Clean the cylinder head assembly With solvent and blow through all oil passages With compressed air, Apply engine oil to the fitting area of new valve stem E g seals [1]. ‘ Combustion chamber side Install the valve spring seats [2] and valve stem seals, Apply molybdenum oil solution to each valve stem end and sliding surface Insert the valves [3] into the valve guides while turning them slowly to avoid damage to the valve stem seals Install the inner valve spring [4] and outer valve spring [5] with the tightly wound coils should Vacmg the combustion chamber. Install the valve spring retainers [6] Grease the cutters Install the valve cotters [1] using the special tool. to ease installation To prevent loss of TOOLS: (ensign, do no! [2] Valve spring compressor 07757-0010000 compress the valve [3] Valve spring compressor 07959-KM30101 spring more than attachment necessary CYLINDER HEADNALVES Supportthe cylinder Place a suitable tool [1] onto the valve stem [2] head above the wD'k bench surface to prevent va/ue damage Install the lollowmg: Tap the tool gently to seat the valve cutters [3] llrmly usan a hammer v ECT Sensot (page 4739) 7 Spark plugs (page 376) INSTALLATION Do not allow dust Clean any gasket matenal from the cyllnder mating and am to enter the surfaces mankcase The lug as lnstall the pamtlon pin [1] Into the recess ol the No, 2 poslnonenm e/ther cyllnder lntake slde With the tapered slde facing dowh‘ the nght orlefi. allgnlng lts lug Wlth the cyllnder waterlacket Install the cam chain guide A [1] while aligning its pins ‘ wrth the grooves m the cylinder and us end Wlm the l ]\ groove In the crankcase Install the dowel pins [1] and a new gasket [2]. 10-22 CYLINDER HEAD/VALVES Route the cam chain through the cylinder head and i 3 install the cylinder head [1] onto the cylinder i l ] Clean the cylinder head 9 mm washervbolts in solvent, and dry them thoroughly. Apply engine oil to the 9 mm washer-bolt threads and seating surfaces. Install and tlghteh the 9 mm washerrhclt [2] in a crisscross pattern in 2 or 3 steps to the specified torque. l l TORQUE147 N-m (4.8 kgl-m. 35 lbi-ft) Install and tighten the 5 mm bolts [3] securely Install the following, — thermostat (page 8-6) » rocker arms (page 1044) , engine (page 15-8) CAM CHAIN TENSIONER LIFTER REMOVAL/INSTALLATION NOTE - The cam chain tensioner lifter can be serviced With the engine installed in the frame. Remove the sealing bolt [1] and sealing Washer [21' Turn the cam chain tensioner lifter shaft fully in —' (clockwtse) and secure it using the specral tool TOOL: [3] Tensioner holder B D70MG-0010100 or 07AMG-DO1A1OD (USA, only) or D7AMG-MFJA100 (USA. only) [4] and sealing washers {5]. Remove the cam chain tenSioner lifter [l] and gasket ' [2]» Installation ls in the reverse order of removal. NOTE - Replace the gasket and sealing washers With new i ones, 10-23 CYLINDER HEADNALVES INSPECTION Check Ihe cam chain Iensioner lifter {1] operation r The cam chain tensmner lifler shaft shouid riot go into the cam chain tensioner lifter body when it is pushed — When it is turned clockwrse with a Iensmner stopper or a screwdriver [2]‘ the cam chain tensioner iifter shaft should be puiied into the cam chain Iensioner lifter body, The cam chain tensiorier lifter shaft shouid spring oul of the cam chain tensioner iifler body as soon as Ihe stopper tool is released CAM CHAIN/TIMING SPROCKET REMOVAL Remove the foiiowmg‘ r Cyiinder head (page 1046) 7 primary drive gear (page 11714) 7 ciulch outer (page 11-7) Remove the bolt [1]. cam chain tensioner [2] and collar [3] Remove the cam chain [1] and liming sprocket [2] from Ihe crankshaft INSPECTION Inspecl Ihe Ioilowmg pans for scratch, damage, abnormai wear and deformation. Repiace if necessary 7 cam chain — cam chain tensioner ~ Iiming sprocket 10-24 CYLIN DER HEADNALVES INSTALLATION VnstaH (he nmmg sprocket [1] by ahgmng (he wme groove thh the wtde 100m ofthe crankshaft, Apply engine Oil to ihe cam chain [1] who]e surface and Install n to the filming sprocket App]y a lockmg agem ‘0 the cam chem tensioner pwot r be“ threads (page 1720). The co/Iaus InslaH the coHar [1], cam chem (ensiuner [2] and Don [S] Insfal/ed /n [he Tighten the cam chain tensioner pwot be]! 10 the direction as Shawn specmed torque TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) mstaH me vouowmg 7 dutch outer (page 1141) r pnmary drive gear [page 11715) 7 cyhnder head (page 1022) 10-25 MEMO 11. CLUTCH/GEARSHIFT LINKAGE SERWCEINFORMANONuumnmumnmnm1L2 TROUBLESHOOTIN5.........................‘..,....11_3 COMPONENT LOCATION ------------------------ --11-4 RIGHT CRANKCASE COVER ------------------ --11-5 CLUTCH .................................................... .‘11_7 PRIMARY DRIVE GEAR ......................... ..11_14 GEARSH|FT UNKAGE ........................... ..11_17 11-1 CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL - TI’lIS seclion covers service ol the clutch and gearshlft Ilnkage. All service can be done With the engine installed In the frame. ' Engine Oil viscosity and level have an effect on clutch disengagement. When the clutch does not dlsengage ur the motorcycle creeps wIlh clutch disengaged. Inspect the engine oil level before servican the clutch system. TOO L5 7 Clulcnrcenter hoEer Driver 77 V V ‘ Attachment, 32 x 35 mm i 07JMB-MN503OZ 0774941010000 077450010100 or omeayommoa (plate) and I I 07HGB-0010208 (collar) (U S A, only) I I with e x 40 mm bolts 1 I 7mm. 28 mm’ Vfieiar'hader, 2 5 I ' ' 07746-0041100 077240010100 I or 07724-001A1oo (U.S.A. only) 11-2 TROUBLESHOOTING Clutch lever is too hard to pull in - Damaged. kinked or dirly clutch cable ' Improperly routed clutch cable - Damaged clutch lifter mechanism - Faulty clutch lifter bearing ' Clutch lifter piece installed improperly Clutch slips when accelerating - Clutch litter sticking - Worn clutch discs ~ Weak clutch springs - No clutch lever treeplay - Engine oil mixed with molybdenum or graphite additive Clutch will not disengage or motorcycle creeps with clutch disengaged ‘ Excessive clutch lever freeplay (page 3—20) . Clutch plate warped ' Engine oil level too high, improper engine Oil viscosity or additive used - Loose clutch center lock nut - Damaged clutch lifter mechanism - Clutch lifter rod Installed improperly - Worn clutch outer slot and clutch center grooves - improper clutch operation Hard to shift Incorrect clutch cable adjustment Improper clutch operation Improper engine oil viscosity Damaged or bent shift lorks (page 13710) Bent shift fork shalt (page 13-10) Bent shift fork claw (page 13-10) Loose shift drum center bolt Damaged shirt drurn center Damaged shift drum guide grooves (page 13-10) Damaged or bent gearshift spindle Transmission jumps out of gear - Worn shift drum stopper arm - Weak or broken shift drum stopper arm return spring - Loose Shlfl drum center bolt - Damaged shift drum center ' Bent shift fork shaft (page 13-10) - Damaged or bent shift forks (page 13-10) ~ Worn gear engagement dogs or slots (page 13-10) Gearshift pedal will not return - Weak or broken gearshift spindle return spring - Damaged or bent gearshift spindle CLUTCH/GEARSHIFT LINKAGE 11-3 CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 23 N m (2 3 kg! m. 17 \bf'fl) 12 NM (12 kgf m, 9 ID! ft) 12 N m (1,2 kgf m‘ 9 \bH‘t) 103Nvm(10.5kng‘ 1 76 lbw 12 N-m (1.2 kgl-m, 9 mm 12 N m a 2 mm, 9 lbw) CBRSOOR/RA/ CBSODX/XA CESOOX/XA 11-4 CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVALHNSTALLAHON CBR500R/RN Remove the under cowl (page 2722). CE500X’XA' Dram me engme 0H (page 3710) Remove the bott [1] and clulch cable holder [2], then dxsconned the dutch cable [3] from me ctulch Ixfler arm [4] CBfiOOXMA Remove the Wire dip [1] from the under cowl stay [2] Remove the bolts [3] and under cow‘ slay Loosen the right crankcase cover butts [1] m a crisscross pattern in 2 or 3 steps. Remove the following 7 botts — under cowl stay (CBRSOOR/RA/CBSOOX/XA) [2] » tht crankcase cover [3] 11-5 CLUTCH/GEARSHIFT LINKAGE Remove the dowel plns [1] and gasket [2], Be carefu/not to Clean any gasket materrai from the mating surfaces 0! damage Ihe mating the crankcase and cover surfaces installation is in the reverse order ot removal TORQUE: Right crankcase cover bolt: 12 Nm (1,2 kgf-m. 9 le‘t) NOTE - Apply liquid sealant to the mating areas of crankcase as shown (page #20). - Replace the right crankcase cover gasket With a new one Airgn the ciutch cable holder hole with the right ’ crankcase cover boss Adjust the clutch ieverlreeplay (page 3720) Fit! the engine With the recommended engine oil and ‘ check that there are no OH leaks (page 3-10) 10 ’ 15 mm ‘ (0,47 06m) imrtsmm (0470mm DISASSEMBLYIASSEMBLY Remove the clutch Iri‘lev rod A [1] whiie turning the clutch Ilfler arm [2]. Remove the clutch lifter arm and return spring [3] from the right crankcase cover, ’ Remove the or} seal [1] from the right crankcase cover Assembly is in the reverse order of drsassembly. NOTE - Appiy grease to a new orl seai lips ‘ Instaii the oil seai to the specified depth as shown - Align the return spring hook WIth right crankcase cover Align the return sprung end with ciutch lrfler arm groove. Appiy engine oii to the clutch Ilfler arm and lifter rod ‘ A sliding surface ‘ 05—10mm (o 02— o 04 in)' 11-6 CLUTCH/GEARSHIFT LINKAGE INSPECTION Inspect the followrng parts for scratch. damage, abnormal wear and deformation Replace if necessary » clutch lifter arm bushlng — clutch llfler arm 7 return sprlng 7 Clutch lifter rod A CLUTCH REMOVAL Remove the right crankcase cover (page 116) If the clutch outer gulde wrll be removed, loosen the Oll pump driven sprocket washer»bolt [‘l] Wllh the clutch Installed. Remove the clutch lifter rod B [1]. Loosen the clutch llfler plale bolls [2] In a crlsscross pattern In 2 or 3 steps‘ and remove the bolts. lifter plate [3] and clutch springs [4] Remove the llfter plate bearmg [5] from me lifler plate Be careful not lo Unstake Ihe clutch center lock nul [l]. damage me mews/15F! threads 11-7 CLUTCH/GEARSHIFT LINKAGE Hofd me clutch pressure plate with the specie] (Gel and [oosen the dutch center lock nut [1], Use mm 5 x 417 mm TOOL: DO/I‘S [3] [2] Clutch Center holder O7JMB-MN50302 or 07HGB-00101OB (plate) and 07HGB-OD1OZDB (collar) (U.S.A. only) Remove and dlscard the [ock nut. Remove the lock washer [1] and washer [2] Remove the dutch cemer assembly [1] Remove the Vollowmg: ~ clutch Center [1] — spring sea] [2] r judder spring [3] clutch dlsc B [4] dutch plate E [5] 5.x clutch mscs A [6] [we clutch mate A [7] 7 pressure plale [8] [11] 11-8 CLUTCH/GEARSHIFT LINKAGE Remove the thrust washer [1]. Ahgn the primary drwe (smssors) gear Ieeth by msemng a screwdriver ink) the gear slot [1] and prymg me gears‘ and mskall a 6 x 14 mm ban [2] mm me primary dnve gear ho‘es. Remove the dutch outer [1] Remove the followmg: washer-bolt [‘1] on pump dnven sprocket [2] oil pump drive Chem [3] on pump drvve sprocke‘ [A] 11-9 CLUTCH/GEARSHIFT LINKAGE Remove the cluIch outer gurde [‘I] INSPECTION Inspect Ihe IolIowing parts for scratch. damage, abnormal wear and deformation, Replace N necessary * cluIch llfler rod B r cIulch Iifler bearrng r clutchnflerpIate r cIuIch springs r cluIch cemer — sphng seal — ruddersprmg — cIuIch dtscs/plates r cluIch outer/primary dnven gear/needIe bearing — clutch outer guide — oII pump drive/driven sprockets — on pump drive chain — mamshafl Measure each pan according lo CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (page 1710) Replace any part II it Is out of service IIITIIL NOTE: ' Replace me clutch sphngs as a set. ~ RepIace the clutch dtscs and plates as a ser. CLUTCH OUTER NEEDLE BEARING REPLACEMENT Press the needIe bearing [1] out of the cIuIch outer usmg Ihe speciaI toolsv TOOLS: I [2] Driver 07749-0010000 I [2, 010 7 090 mm ‘ [3] Attachmem, 32 X 35 mm 07746-0010100 ‘ (0 004 7 O 035 in) I [4] Pilot, 23 mm 0774641041100 I [3] Press In (he needle Press a new needIe bearing Into (he dutch ouIer so thal 1 bearing wllhrhe the depth from Ihe clutch outer IS 010 e 0.90 mm I marked srde /acing (0.004 » 0.035 In). usmg the same specraI IooIs Up .L / 11-10 CLUTCH/GEARSHIFT LINKAGE INSTALLATION 7% OIL PUMP DRIVE SPROCKET E CLUTCH OUTER GUIDE DRIVE CHAIN f ‘Jml 15 N m(15 kgI-m‘ 11 Ibf-fl) CLUTCH OUTER THRUST WASHER PRESSURE PLATE JUDDER SPRING SPRING SEAT /r i a CLUTCH PLATE B' CLUTCH CENTER WASHER LOCK WASHER 128Nm(131kgI'm194Ibifl) 9? E CLUTCH SPRING a LIFTER BEARING 99°61” L ? LIFTER ROD B 12 Nm (1,2 kgf-m, 9 1mm ‘, The CIutch plate a and A are CLUTCH LIFTER PLATE Idenwled by their surface treatment, Apply molybdenum oil sqution to the cluIch outer guIde [1] ennre surface and InsIall it to the mainshafl 11-11 CLUTCH/GEARSHIFT LINKAGE When installing me Clutch Dufefl turn the all pump driven sprocket Apply engine oil to the oil pump drive/driven sprocket teeth and drive chain Install the Oil pump drive sprocket [1] and drive chain [2] with the drive sprocket "MGZ" mark [3] lacing out Install the Oil pump driven sprocket [4] wlth lIS "OUT" mark [5] facing out by aligning the [lat surfaces. Apply a locking agent to the Oil pump driven sprocket washerrpolt threads [page 1-20) install the Oil pump driven sprocket washerrbolt [6]. NOTE - Tighten the driven sprocket bolt to the specified torque after installing the clutch Apply engine oil to the clutch outer needle bearing, primary drive gear and driven gear teeth Install the clutch outer [1] while aligning the bosses of the ml pump drive sprocket With the holes at the clutch outer NOTE ~ Make sure the Side surfaces [2] of the primary drive and driven gears are flush, Remove the 6 x M mm bolt [3] from the primary drive gear NOTE - Do not forget to remove the 6 x 14 mm bolt after installing the clutch outer Install the thrust washer [1] 11-12 CLUTCH/GEARSHIFT LINKAGE Apply englne on to the enttre surface of clutch discs and ’ plates. Install the spring seat [1] and judder spring [2] onto the clutch center [31 as shown install the clutch 1115!: B [4] and clutch plate 8 [5] onto the clutch center ' Clutch disc B larger LD, . Clutch plate B surface treatment difference from clutch plate A Install the clutch discs A [6] and plates A [7] alternately, starlan With the clutch disc install the pressure plate [8] onto clutch center while aligning "0" mark of clutch center and pressure plate. Install the clutch center assembly [1] into the clutch outer by aligntng the clutch disc tabs with the grooves of the clutch outer one by one, and the splines of the clutch center and mainshafl. Install the washer [1] Install the lock washer [2] With its "OUTSIDE" mark [3] lacing out. Apply engine oil to a new clutch center lock nut threads and seating surface. lnstall the clutch center lock nut [1] onto the rnainshaft. Hold the pressure plate With the special tool and tighten the lock nut to the specified torque. Use W/fh 5 x 40 mm TOOL: 90/“ [3] [2] Clutch center holder D7JMB-MN50302 or 07HGB-OD1010B (plate) and 07HGB-001OZOB (collar) (USA. only) TORQUE: 128 N-m (111 kgfrm,941bf-ft) 11-13 CLUTCH/GEARSHIFT LINKAGE Se carefulnotla Stake the clutch center lock nut [1] into the mainshafl damage the groove mainsriafl threads Apply engine oil to the litter plate bearing rotating area Install the lifter plate bearing [1] into the Iifler plate [2] Install the clutch Springs [a], litter plate and clutch lifter plate bolts [4]. Tighten the clutch lifter plate bolts in a crisscross pattern in 2 or 3 steps to the specilied torque. TORQUE:1Z N-m (1.2 kgf‘m. 9 lbi-ft) Apply engine Oll to the clutch lifter rod B sliding surface Install the clutch lifter rod B [5]. Tighten the oii pump driven sprocket washerrbolt the specified torque TORQUE: 15 N~m (1.5 kgf-m. 11 lbf-ft) lnstall the right crankcase cover (page 116) PRIMARY DRIVE GEAR REMOVAL Remove the right crankcase cover (page 11-5) Align the primary drive (SClSSOrS) gear teeth by inserting a screwdriver into the gear slot [1] and prying the gears and install a 6 x 14 mm bolt [2] into the primary drive gear holes, 11-14 CLUTCH/GEARSHIFT LINKAGE Hold the primary drive gear [7] usmg a special tool as shown. and remove the primary drive gear bolt [2] and washer [3] TOOL: [4] Gear holder, 25 07724-0010100 or 07724-001A1OD (USA only) Remove the gear holder and primary drive gear Remove the 6 x 14 mm bolt [1] and primary drive sub- i 1 gear [2] [ 1 Remove the springs [3] from the primary drive gear i grooves INSPECTION Inspect the foliowrng parts for scratch‘ damage, abnormal wear and deformation Replace it necessary 7 primary drive gear 7 primary drive sub-gear 7 springs INSTALLATION Apply molybdenum oil solution to the primary drive gear and sub-gear sliding suriaces. Install the springs [1] into the primary drive gear [2] . grooves Install the primary drive sub»gear [3] onto the primary drive gear so that the tabs are positioned against the spring ends and the index line of “B” mark aligns With the Wide tooth as shown 11-15 CLUTCH/GEARSHIFT LINKAGE Loosety mstaH a 6 x 14 mm hon [1] to prevgm WT, V ‘ dtsengaging the gears, [ ] ‘ \nstall the prtmary drive gear [1] on the crankshaft by fi' atignmg rts wrde groove wtth the wtde moth of the ‘ crankshafl Align the pnmary dnve (scrssors) gear teeth by msertrng a screwdriver Into the gear stot [1] and prying the gears, then engage the subygear wrth the primary dnven gear. 11-16 CLUTCH/GEARSHIFT LINKAGE *' m ;. Apply engine oil to the primary drive gear bolt threads 5* ' and seating surface 1 [3] Install the washer [1] and primary drive gear bolt [2]. Hold the primary drive gear usrng a speclal tool as shown, and tighten the primary drive gear bolt to the ' specified torque, TOOL: [3] Gear holder, 2.5 07724-0010100 or 07724-001A100 (U.S.A. only) TORQUE: 103 Mm (10.5 kgf-m, 76 Ibflft) Remove the gear holder Remove the 6 x 14 mm bolt [4] from the primary drive gear, NOTE 0 Do not forget to remove the 6 x 14 mm bolt after installing the primary drive gear. Install the right crankcase cover (page 11-5). GEARSHIFT LINKAGE REMOVAL Remove the iollowrng. — clutch (page 11-7) — gearshift arm (page 1121) Clean off any dirt from the gearshift spindle serration Remove the bolt [1] and settlng plate [2] Pull the gearshift spindle assembly [1] and thrust washer [2] out of the crankcase. 11-17 CLUTCH/GEARSHIFT LINKAGE Remove the shift drum center socket bolt [1] Remove the shift drum center [1] while holding the stopper arm [2] using a screwdriver as shown Remove the followrng' r dowel pin [3] 7 shift drum stopper arm pivot bolt [4] 7 shift drum stopper arm 7 washer [5] 7 return Spring [5] Remove the bolt [1]‘ gearshift spindle DlI seal selling plate [21‘ oil seal [3] and needle bearing [4] INSPECTION Inspect the followmg parts lor damage. abnormal wear and deformation, Replace if necessary. 7 shift drum Center 7 shift drum stopper arm 7 shift drum stopper arm return spring » gearshift spindle needle bearing 11-18 CLUTCH/GEARSHIFT LINKAGE GEARSHlFT SPINDLE Check the return spring [1] and spindle arm spring [2] 11"7 for tatigue or damage replace them if necessary. 1 Check the gearshift spindle [3] for wear or bend Check the spindle arm [4] for wear damage or‘ deformation, ‘ Replace the gearshift spindle as an assembly ill necessary. INSTALLATION Apply engine oil to the gearshift spindle needle bearing [1]] then install it into the crankcase Apply grease to a new oil seal [2] tips, then install it into the crankcase until It is flush With the crankcase surface Apply locking agent to the gearshift spindle oll seal setting plate bolt threads (page 1720) Install the gearshift spindle oil seal setting plate [3] in the direction as shown and tighten the bolt [4] to the specified torque, TORQUE:12 N-m (1,2 kgf-m, 9 lbf-ft) Apply locking agent to the shltt drum stopper arm bolt threads (page 1720) Install the return spring [1] washer [2] and stopper arm [3] while hooking the return spring at the stopper arm groove Install and tighten the stopper arm butt [4] to the specified torque. TORQUE: 12 N-m (1‘2 kgf-m, 9 lbtrft) Check the stopper arm for proper operation install the dowel pin [1] into the hole ofthe shift drum Hold the stopper arm [2] using a screwdriver as shown install the shift drum center [3] while aligning its slot With the dowel pin 11-19 CLUTCH/GEARSHIFT LINKAGE Apply lackrng agent to the shlft drum center socket bolt threads (page 1-20), lnslall and tlghten the shlfl drurn center socket bolt [‘l] to the specrfied torque. TORQUE223 N-m (2.3 kgf-m, 17 Ibf-ft] Apply englne ml to the gearshlft splndle shaft outer surface Install the thrust washer [1] and gearshrft splndle assembly [2] Into the crankcase while allgmng the return spnng ends WIth the spnng pm Apply locklng agent In the settlng plate bolt threads (page 1720). Install the setting plate [11 bolt [2} and tlghten It to the ‘ specified torque. TORQUE: 12 N-m (1.2 kgf~m, 9 lbf-ft) Install the lollowlng' ~ gearshift arm (page 1121) — clutch (page 1741) 11-20 CLUTCH/GEARSHIFT LINKAGE GEARSHIFT PEDAL REMOVAL] INSTALLATION Remove the pinch bolt [1] and gearshift arm [2] from the gearshift spindle Remove the pivot socket bolt [3] and gearshift pedal [4] Remove the dust seals [5] Check the dust seals and lierrod ball ioint dust cover [6] for deterioration or damage, replace them if necessary Installation is in the reverse order of removal TORQUE: Gearshift pedal pivot socket bolt: 27 N‘m (2.8 kgf-m, 20 lbl-ft) NOTE ' Apply grease to the dust seal lips - install the dust seals With the seal no side facing out ' Apply grease to the gearshift pedal pivot sliding area , (grease groove) ofthe pivot bolt - Apply grease to the gearshift pedal “640d bail joint - Align the slit of the gearshift arm with the punch mark on the spindle When adjusting the gearshift pedal heighl‘ perform by i loosmg the lock nuts [1] and it must be noted as foiiuwsv (i / ‘(G i NOTE 61* I? | 3 l i "s i ~ The gearshift arm Side lock nut has left hand i 5 5 mm (0-26 ‘m ‘ threads. ‘ i [8 5 mm (0 33 in) max] Adjust the tiered length so that the dlslance between ‘ W i i Ihe bail iOInt ends is standard length as shown i ‘ ‘ After adjustment tighten the gearshift pedal adiusler ‘ 2‘9 mm | lock nuts securely i <8 6 W ‘ NOTE ‘ i - Tighten the lock nuts With the position of each ball 1 ‘ joint in parallel to the gearshift arm and gearshift ‘ m ‘GOmmw 24"") E 1 pedal as shown. ‘ ' Be sure the thread length from the lock nut is less i \ [8 0 mm (0 31 m) max'] i than the specified value. i e gearshifl arrn side 8.5 mm (0 33 In) l r gearshift pedal Side: 8.0 mm (0 Si in) 11-21 MEMO 12. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION ------------------------- n TROUBLESHOOTING ............................... .. COMPONENT LOCAnON ........................ .. LEFT CRANKCASE COVER -------------------- -- 12-2 12-2 1 2-2 12-3 STATOR/CKP SENSOR ........................... ..12_4 FLYWHEEL ............................................... ..12_5 STARTER CLUTCH .................................. ..12_7 12-1 ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL - This section covers sen/Ice ofthe alternalur stator and flywheel AH service can be done With the engine insialled in Ihe Vrame. - For ailernamr charging coii inspeckion (page 20—7), - For CKP sensor inspection (page 5-6). - For slaner motor sewice (page 6-5) TOOLS ’Fiywheeihold? ’7 W vRomrmer 077250040001 ‘ 077330020001 i H\ i 1 5 \ \ \ ‘ \\ i i \ 1 1 / i if //’ i \e or 07933-3950000 (U SA only) A; i,, 7 7 TROUBLESHOOTING Starter motor turns, but engine does not turn - Fauny staner clutch - Damaged Slaner reduction gear/shaft - Damaged or fauin starler motor pinion gear - Damaged starter driven gear 12 N m (1.2 kgim, 9 mm) 12-2 ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL/INSTALLATION NOTE, - Ptace a clean oit pan under the engine because ‘ engine oil wrtt flow out when removing the left crankcase cover Add the recommended engrne oil to the specrfied lever after rnstattatton (page 3-10) Support the motorcycle in an upright posrtron on a tevet surface. Remove the toltowmg 7 under cowl (page 2722) r drtve sprocket cover (page 224) r regulator/rectmer (page 2077) Retease the CKP sensor wrre [t] trom the chp [2] Drsconnect the CKP sensor 2P (Red) connector [3] Remove the stator/CKP sensor wire harness band clrps (Brown [4], Black [5]) from the frame Remove the stator/CKP sensor wire harness [1] out of ; the frame Loosen the Left crankcase cover botts [t] m a crisscross pattern In 2 or 3 steps Remove the lottowmg. 7 botts 7 under now Stay (CBsOOX/XA) [2] r \eft crankcase cover [3] NOTE ‘ The tett crankcase cover (stator) ts magneticatly t attracted to the flywheet, be caretut during removat and Instattatron. ‘ 12-3 ALTERNATOR/STARTER CLUTCH Remove the dowel pins [1] and gasket [2] Be carefulnot to Clean any gasket material from the matlng surfaces of damage the mahng the crankcase and cover swam: Installatlon l5 in the reverse order of removal. TORQUE: Left crankcase cover bolt: 12 N‘m (1‘2 kgf-m, 9 Ibf‘l‘t) NOTE ~ Apply llquvd sealant to the mating areas 01 crankcase as shown (page 1—20) ~ Replace the left crankcase cover gasket with a new one. Check the oil level (page 3-10) Make sure there are no Oll leaks. (0.4 e0 5 m)‘ STATOR/CKP SENSOR REMOVAL/INSTALLATION Remove the left crankcase cover (page 1273) Remove and lnstall the stalor/CKP sensor as lollowrng lllustratvon - Apply locklng agent to the stator and CKP sensor bolt threads (page 1-20) - Apply sealant to the alternator/CKP sensorwve grommet seallng surface (page 1—20) Installahon Is In the reverse order of removal. ALTERNATOR STATOR BOLT cm CKP SENSOR BOLT 10Nm(10kgrm,7mm) 12Nm(12kglm‘9lbl-tt) STATOR LEFT CRANKCASE COVER 12-4 ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL Remove the left crankcase Cover (page 1273) Remove the starter reductron gear shaft [1] and starter reduction gear [2]. Hold the flywheel {1] using the specral tool and loosen " the flywheel bolt [2] NOTE - Set the holdmg block {3] oi the flywheel holder [4] avolding the flywheel reluctorsv TOOL: Flywheel halder 07725-0040001 Remove the flywheel bolt and washer [5]. Remove the flywheel [1] usan the specral tool. TOOL: [2] Rotar puller 07733-0020001 or 07933-3950000 (U.S.A. only) Be care/u! no! to Remove the woodruff key [1]. damage me key groove and crankshaft ALTERNATOR/STARTER CLUTCH INSPECTION lnspect the lollowmg parts for scratch. damage, abnormal wear and defarrnatlon. Replace If necessary. 7 starter reductlon gear shah 7 starter reductan gear v woodruff key — needle bearlng INSTALLATION Be careful not to Install lhe woodrufl key [1] damage the key groove and crankshaft Apply engine all to the needle bearan [2] rotallng area Clean any Dll from the crankshaft tapered area and flywheel thoroughly, Install the flywheel [1] whlle allgnlng the woodrul‘l Key on the crankshaft Wlth llywheel keyway Apply englne all to the flywheel bolt threads and seatlng ' surface lnstall the washer [1] and flywheel bolt [2] Hold the flywheel [3] usan the speclal tool and tlghten the flywheel boll to the specified lurque NOTE avoldlng the llywheel reluctors. TOOL: Flywheel holder 07725-0040001 TORQUE: 133 Mm (14.1 kgi-m,102lbf‘ft) 12-6 ALTERNATOR/STARTER CLUTCH Apply molybdenum on solutlon to the starter reductlon gear shaft outer surlace. Install the starter reduction gear [1] and shaft [21' Install the left crankcase cover (page 1273) STARTER CLUTCH ONE-WAY CLUTCH OPERATION INSPECTION Remove the llywheel (page 1275). [1] ' Check the operatlon of the onerway clutch by turning the starter drlven gear [1] l a / Make sure that the starter driven gear turns . e, V counterclockwise smoothly and does not turn Clockwlse REMOVAL Remuve the flywheel (page 1275), l Remove lhe starter driven gear [1] while lurmng the starter driven gear counterclockwise A ‘ Hold the flywheel [1] using the speclal tool and remove fi ' f the starter clutch socket bolt [2]. ‘ l l l 1 NOTE o Set the holding block [3] of the flywheel holder [4] } avoidan the flywheel reluctors TOOL: 1 Flywheel holder 07725—0040001 [2] ALTERNATORISTARTER CLUTCH Remove the starter clutch assembly, Remove the starter one-way cluIch [1] from the staner clutch ourer [2]. INSPECTION Inspect the (allowing parts for scralcn‘ damage, abnormal wear and deVorrnatlon. Replace If necessary. 7 slaner dnven gear e slaner clutch ouler e slaner one-way clutch Measure each pan according to ALTERNATOR/ STARTER CLUTCH SPECIFICATIONS (page 1-10). Replace any part if H is out of service IlmlI. INSTALLATION STARTER DRIVEN GEAR STARTER CLUTCH OUTER a ONEVWAY CLUTCH FLYWHEEL 29 N-m (3.0 kgf-m, 21 1mm am 12-8 Apply engine oil to the starter ohe»way clutch contacting surface. Install the starter onevway clutch [1] into the starter clutch outer [2], install the starter clutch assembly onto the flywheel [3]. Hold the flywheel [1] using the special tool. NOTE - Set the holding block [2] of the flywheel holder [3] avoiding the flywheel reluctors. TOOL: Flywheel holder 07725-0040001 Apply locking agent to the starter clutch socket bolt threads (page 1720) lnstall and tighten the starter clutch socket bolt [4] to the specified torque. TORQUEIZS N-m (3.0 kgf‘m, 21 |th) lnstall the starter driven gear [1] mto the starter clutch outer while turning the starter driven gear counterclockwrse, Check the one»way clutch operation (page 12-7). lnstall the flywheel (page 126), ALTERNATOR/STARTER CLUTCH fifiifli 12-9 MEMO 13. CRANKCASE/TRANSMISSION SERVICE [NFQRMATION................,..........13_2 CRANKCASE ............................................ ..13_5 TROUBLESHOOTING ............................... ..13_3 TRANSMISSION ....................................... "13.8 COMPONENT LOCATION ........................ ..13_4 13-1 CRANKCASE/TRANSMISSION SERVICE INFORMATION GENERAL - The crankcase must be separated to service the (allowing — transmission — crankshaft (page 14-4) — balancer (page 14-17) — piston/connecting rod/cylinder (page 14-13) - The tollewrng components must be removed before separating the crankcase » engine (page 15-4) — gearshifl linkage (page 1147) — flywheel (page 1275) 7 cylinder head (page 1016) r cam chain tensioner lifter (page 1023) r cam chain/timing sprocket (page 1024) 7 oil strainer (page 978) — pressure relief valve (page 977) — engine oil filter (page 3710) v water pump (page 8710) 7 water hose joint (page 8711) r EOP swmch (page 21716) 7 VS sensor (page 4-40) 7 neutral swttch (page 21-20) Be carehil not to damage the crankcase mating surfaces when servicing. Clean the oil passages beiore assembling the crankcase halves. Prior to assembling the crankcase halves‘ apply sealant to their mating surfaces. Wipe off excess sealant thoroughly. The crankpin and main iournal bearing inserts are select (it and are identified by color codes Select replacement bearings from the code lables. After selecting new bearings recheck the OII clearance with a plastigauge. Incorrect oil clearance can cause major engine damage. TOOLS Driver ’ W ( Attachment 32 x 35 mm ' 07949-3710001 07746-0010100 13-2 TROUBLESHOOTING Hard to shift . improper clutch operatien . improperenglne oii viscosuty - Bent shift York - Bent shift lurk shaft - Bent shift [ark slaw ~ Damaged shift drum guide groove - Bent gearshift spindle (page 1149) Transmissinn jumps out of ear Worn gear dogs Worn gear shifler groove Bent shifl fork shaft Broken shift drum slopper arm (page 1148) Broken Shifl drum stopper arm return spring (page i148) Worn or bent shift iorks Broken gearshift spindie return spring (page 1149) Excessive engine noise . Worn or damaged Iransmission gear - Worn or damaged transmission bearings CRANKCASE/TRANSMISSION 1 3-3 CRANKCASE/TRANSMISSION COMPONENT LOCATION 12 NM (1.2 xgm 9 mm) 15 N m (1.5 kgf-m‘ 11 |bffl)+120° 24 N-m (2.4 kg m‘ 18mm) 39 Nm (4,0 kgi-m‘ 29 mm) 24 Nm (2 4 kgfm‘ 15 mm) W © 2 12 N m (1 Z kgfm, 9 Ibi-fl) 4 a \“ \‘x 12 Nm (1,2 kgf'm‘ 9 mm 12 N>m(1.2kg('m‘ 9 mm) 12 N m (1 2 kgl-m, 9 Half!) 12 N-m (1.2 kgf-m,91bff() 13-4 CRANKCASE/TRANSMISSION CRANKCASE Donofprylrre Separare [he rower crankcase [2] from the upper crankcase halves crankcase, WW7 a Screwdnver SEPARATION Refer to Servrce \nformalion for remover of necessary pans before Separatan the crankcase (page 1372). Remove the crankcase 6 mm oaks [1] and sealing washer[2] Place Ihe engrne upside down [4] Loosen the crankcase 10 mm be" [1]. 8 x 75 mm borts [2]‘ 8 x 55 mm boh [3] and 6 mm bolts [4] rn a cnsscross ‘ paflern rn 2 or 3 steps, and remove an the bulls and ‘ sealing Washer [51, 1 r r 1 [Ms] r ‘ [2} ‘ r {3] m7 W —'7 Loosen Ihe crankcase main pumar bolt [1] rm 3 cnsscwss pattern In 2 or 3 sreps‘ and remove them Remove the dower pms [1] and oil onflces [2] CRANKCASEITRANSMISSION ASSEMBLY Clean the upper and lower crankcase mating surfaces thoroughly, belng carelul not to damage them Check the crankcase oil passages {or clogs, and clean them If necessary Apply llquid sealant lo the crankcase mating surface as l shuwn(page1-20) ‘ NOTE ‘ - Do not apply Ilqmd sealant more than necessary ‘ - Do not apply Ilquld sealant to the crankcase rnaln ‘ Journal bolts area and the oil passage area. J [2] Clean the all orlfices in solvent thoroughly Check the all onllces for clogs, and replace them if necessary. Insta/lrhe ollolri/ces Install the all onfices [1] into the upper crankcase [2]. wl'Ih rls large I D srde tam/lg the upper crankcase Install the dowel puns [1] mm the upper crankcase [2] 'm Apply molybdenum orl solutlon to the maln Journal beanng [1] sliding surlaces on the lower crankcase l Upper crankcase slde 13-6 Install the lower crankcase [1] onto the upper crankcase lnstall new crankcase rnain journal bolts [2] NOTE - Tighten the crankcase rnain journal bolts using the Plastic Region Tightening Method ' Do not reuse the crankcase main journal bolts. because the correct axial tension Will not be obtained - The crankcase main journal bolts are prercoated with an oil additive for axial tension stability Do not remove the oil additive from the new crankcase main journal bolt surfaces. ‘ m Make sure the upper and lower crankcase are seated securely Tighten the crankcase main journal belts in numerical order as shown in a crisscross pattern in Z or 3 steps to the specified torque Further tighten the crankcase rnain journal bolts 120°. TORQUE: 15 MM (1.5 kgf-m, 11 lbf-ft)+120° Install a new sealing washer [‘l] and crankcase bolts Tighten the crankcase bolts in a crisscross pattern in 2 or 3 steps to the specified torque NOTE - The sealing washer location is indicated on the lower crankcase by the "A" mark TORQUE: Crankcase1o mm bolt [2]: 39 NM (4.0 kgf‘m, 29 lbf~ftj Crankcase 8 x 75 mm bolt [3]: 24 N-m (2.4 kgt'm, 18 lbf-ft) Crankcase 8 x 55 mm bolt [4]: 24 N-m (2.4 kgt‘m,1albf-ft) Crankcase 6 mm bolt [5] 12 N-m (1.2 mm, 9 mm) Place the engine With the lower side down. Install a new sealing washer [1] and crankcase 5 mm j bolts [2]. j l NOTE: - The sealing washer location is indicated on the upper crankcase by the “,m“ mark [ll/[2] '0? 7‘ Tighten the crankcase 6 mrn bolts to the specified torque ‘ TORQUE: 12 NM (1.2 kgt‘m, 9 lbf-ft) lnstall the rernoved parts in the reverse order ot‘ removal (page1372) u , g ,7 ,, 7 4 13-7 CRANKCASE/TRANSMISSION TRANSMISSION REMOVAL/DISASSEMBLY Separate the crankcase halves (page 13-5), Ahgn Me Index \ine [1] on1he balancer dnve gear With the upper crankcase lop sudace of me from sude Remove the coumershafl assemmy [1] and dowe‘ pm T [2]» Remove the shwfl drum beanng semng washerrbolts [1] Remnve me shm fork shafl [1] and shvfl «mks [2] 13-8 Remove Ihe shin drum [1]/bearmg [2] assembly Remove me shift drum bearing from me shift drum. Remove the bolls [‘1] and ba‘ancer/thl mainshafl bearing sening p‘ate [2] Sllde me malnshaft assembly off the upper crankcase and remove the right mamshafl bearing [1], Remove ‘he mainshaft assemb‘y [1] 13-9 CRANKCASE/TRANSMISSION Disassemble the mainshafl assembly [1] and ' ' 1 countershafl assembly [2]. ’7 [ 1 NOTE ‘ 3 ~ Keep track of the disassembled parts (gears ‘ ‘ bushings, washers and snap rings) by sliding them onto a tool or a piece of Wire. ~ Do not expand lhe snap ring more ihan necessary for removal To remove a snap ring, expand the snap ring and pull il off using lhe gear behind it. INSPECTION Inspect the following parts for scratch‘ damage abnormal wear and delormaiionv Replace il necessary 7 iransmission gears r lransmission bushings r iransmissmn bearings r shifldrum/bearing r shiflfcrks — shiflforkshafl Measure each pari and calculate lhe clearance according to CRANKCASE/TRANSM‘SSION SPECIFICATIONS (page 1-10). Replace any parl if it is out of service limii, LEFT MAINSHAFT BEARING OUTER RACE REPLACEMENT Remove the lollowing: . balancer (page 1447) r pislon (page 14-13) Remove the ball [1] and bearing outer race selling plaie [2]. Remove me left mainshafl bearing outer race [3] from the upper crankcase using a suitable tool Drive in a new lefl mainshafl bearing outer race [1] squarely into the upper crankcase until it Is fully sealed using the special tools. TOOLS [2] Driver 079494710001 [Mmmmmmnnxfimm onwemmw 13-10 CRANKCASE/TRANSMISSION Apply lockmg agent to the bearing outer race seltlng plate bolt threads (page 1-20). Install the bearing outer race setting plate {1]. bolt [2] and tlghten the bolt to the spectfled torque TORQUE: 12 N-m (1.2 kgl'm, 9 lbf-ft) Install the removed parts in the reverse order of removal ASSEMBLY Clean all parts in solvent, and dry them thoroughly Apply engme ml to the gear teeth, rotatan surface and CORRECT lNcoRRECT bearing. ‘ Apply molybdenum oll solutlon to the gear spllne l bushing outer surlace (M8, C3, CA), gear bushing enllre surlace (M5‘ 02), needle bearing rotating area (C1land gear shtfler grooves (MS/4‘ 05‘ C6). Assemble the mainshafl and countershaft. NOTE, l - Coat each gear with clean engtne all and check for smooth movement. - Allgn the lock washer tabs with the spllne washer grooves. - Always install the thrust washers and snap rlngs with the chamiered (rolled) edge faclng away lrom the thrust load - Install the snap rings [1] so that the end gap allgns wtth the groove of the splines. - Make sure that the snap rings are tully seated in the shaft groove after installlng them 13-11 CRANKCASEITRANSMISSION MAINSHAFT MA'NSHAFT/W GEAR (MT) E ~ Gear Ieelh, rotating suflace and bearing M5 GEAR BUSHING a Gear spline bushxng outer surface‘ gear bushing enhre surface and gear shifter grooves M5 GEAR (20T) M3/4 GEAR (ZOIZOT) M6 GEAR SPLINE BUSH‘NG M6 GEAR (237') O M2 GEAR (19m SNAP R‘NG SNAP R‘NG NEEDLE BEARING SPLINE WASHER SPUNE WASHER LOCK WASHER THRUST WASHER COUNTERSHAFT Gear teeth‘ rolalmg sudace and bearings E . Gear splme bushing ouler surlace, gear CS GEAR (ZST) bushing entire surface, needle bearan mating area (C1) and gear shifter grooves SNAP RING SPLINE WASHER c3 GEAR SPLINE BUSHING ca GEAR (32T) LOCK WASHER SPLINE WASHER I 04 GEAR SPLINE BUSHING y 0 c4 GEAR (26T) 5% gym; SPLINE WASHER $50“ CG GEAR (241') 4 ’ I j ' NEEDLE BEARING THRUST WASHER NEEDLE BEAR‘NG 02 GEAR BUSHING 02 GEAR (41m COUNTERSHAFT BEARING SETTING RING OIL SEAL 9? ,fi. CRAN KCAS E/TRANSMISSION INSTALLATION Atth the index Irne [1] on the batanoer dnve gear wrth e4 the upper crankcase top surface at the front side ' Instalt the rnalnshaft assembly [1] into the upper crankcase, Appty engrne ow] to the right mainshaft beanng lnsta/Ithe Dee/mg lnstaH the nght malnshafl bearlng [1] into the upper mm the crankcase crankcase wrm the marked side facing om Appty locking agent to the batancer/right matnshafl bearing setting plate botts threads (page 1720), Install the batancer/nght mainshaft beanng setting ptate [1] and setting ptate bolts [2]. Trghten the setting plate bolts to the spemfied torque TORQUE: 12 N-m (1.2 kgfm, 9 Ibf-ft) 13-13 CRANKCAS E/TRANSMISSION Appiy engine ml to the shifl drum bearing and shift drum Journai outer surface Install the bearing insiaii ihe shirt drurn bearing [1] onto the shirt drum [2] onto the shirt drum wlth the marked Sldé‘ lacing out Instali the shift drum/bearing assembiy into the upper crankcase The shift forks have the foiiowmg identification marks ~ "L" mark [1]. ieft shifi fork mark [2] center shifl fork "R" mark [31* right shift fork Apply molybdenum oii soiution to the shift fork guide area and guide pin Appiy moiybdenum on soiution to the shift iork shaft outer surface. insiaii the Shifi rorks [1] into the shift drum guide grooves and shifter groove (center shifl fork) with the identification marks facing toward the right side of Ihe engine, then insert the fork shaft [2] Apply iocking agent to the shift drum bearing setting washer-bolt threads (page 120). InstaH and tighten the shift drum bearing setling washer-Dons [i] to the specified torque, TORQUE: 12 N-m (1.2 kgf'mi 9 Ibf‘ft) 13-14 CRANKCASE/TRANSMISSION '"S‘all "‘9 dOWEI pm [1] onto the upper crankcase hole lnslall Ihe countershafl assembly [2] by aligning the bearing setting rlng and oil seal flange with the upper crankcase grooves and needle bearing cap hole Wllh the dowel pin. NOTE - Make sure the Index lmes [3] on the bearing cap rs alrgned with the upper crankcase top surface. Alrgn Assemble the crankcase halves [page 1376). 13-15 MEMO 14. CRANKSHAFT/PlSTON/CYLINDERIBALANCER SERVICE INFORMATION ----------------------- "14-2 CRANKPIN BEARING ---------------------------- --14-10 TROUBLESHOOTING .............................. ..14_2 plSTON/CYLINDER ................................ ..14_13 COMPONENT LOCATION pISTON OIL JET ..................................... ..14.16 CRANKSHAFT .......................................... ..14_4 BALANCER ............................................. "14.17 MAIN JOURNAL BEARING------------------------14-7 14-1 CRANKSHAFTIPISTON/CYLINDERIBALANCER SERVICE INFORMATION GENERAL - The crankcase must be separated to service the crankshaft, balancer‘ Cylll’ldel‘ piston/connecting rod and piston oil jet Refer to procedures for crankcase separation (page 13-5) Mark and store the connecting rods. bearing caps and bearing inserts to be sure ot their correct locations for reassembly. The crankpin and main Journal bearing inserts are select fit and are identified by color codes Select replacement bearings from the code tables. After selecting new bearings recheck the oil clearance with a plastigauge. Incorrect oil clearance can cause major engine damage TOOLS Driver ‘ " ' Attachment, 42 x 47 mm Pilot, 20 Em " ’ "i 07949-3710001 l 07745-0010300 0774670040500 TROUBLESHOOTING Cylinder compression is too low, hard to starting or poor performance allow speed ‘ Leaking cylinder head gasket ' Worni stuck or broken piston ring - Worn or damaged cylinder and piston Cylinder compression too high. overheating or knocking - Excessive carbon built-tip on piston head or combustion chamber Excessive smoke ~ Worn cylinder. piston or piston ring ~ Improper installation of piston rings ~ Scored or scratched piston or cylinderwall Abnormal noise - Worn piston pin or piston pin hole - Worn connecting rod small end - Worn cylinder. piston or piston rings - Worn main journal beanngs - Worn crankpin bearings Engine vibration ~ Excessive crankshaft runout 1 4-2 CRANKSHAFT/PlSTON/CYLINDERIBALANCER COMPONENT LOCATION 33 a Nvm (3.4 kgv-m, 25 mm) 12 N-m (1.2 kgf m, 9 IDH‘I) 14-3 CRANKSHAFTIPISTONICYLINDERIBALANCER CRANKSHAFT SIDE CLEARANCE INSPECTION Separate the crankcase halves [page 136). Measure the connectIng rod sIde clearance, SERVICE LIMIT: 0.25 mm (0010 in) II the clearance exceeds the service IIrnIt replace the connectlng rod (page 14713) Recheck and II stIIl out of III’I'III‘ replace the crankshaft (page 1474) REMOVAL Do nut Interchange the beanng Insens, They must be Installed In the/r onglrra/ locatIons or the correct beanng orl clearance may not be obta/hed, resulting In ethhe damage Separate the crankcase halves (page 13-5) Mark the bearIng caps and beanngs as you remove them to IndIcate the correct cyIInder tor reassembly Be care/ulnnlto Remove the crankpln bearan cap nuts [1] and bearIng damage Ihe Caps [2] crankarI‘ mam Iourna/ and beahhg Inserts ~ Tap the Slde of the cap lightly II the beanng cap rs hard to remove Remove the crankshaft [3] Before removal posit/'an all the pistons at mo (Top ‘ Dead Center) to prevent damagmg the Gran/(pm WIth the connectan rod. Remove the main journal beanngs [1] from both crankcase halves. Remove the crankpin beanngs [2] from the connectth rods and bearIrIg caps. Do not Interchange the beanng Inserts They must be Installed In the/r orIgIrral locations or the correct bearrng orl clearance may not be obtaIned. resultIng In ehglne damage 1 4-4 CRANKSHAFT/PISTON/CYLINDER/BALANCER INSPECTION Support the crankshaft on both end journals, Set a dial gauge on the center mam Journal of the crankshaft avolding the oil groove and hole, Relate the crankshaft two revolutions (720°) and read the runout SERVICE LIMIT: 0.05 mm (0.002 in) Check the balancer drive gear [1] teeth for abnormal wear or damage. INSTALLATION Install the main journal beanngs [1] and crankpln bearings [2] in the origmal locations, 7 main Journal bearing (page 14-10) 7 crankpin bearthg (page 14-13) Do not Interchange the bee/mg Inserts, They must be installed In their angina! locations or the correct bearing oil clearance may not be obtarned, result/ng rn engine damage. Apply molybdenum oil solution to the mam Journal . bearing sliding surlaces on the upper crankcase and crankpln bearlng sliding surfaces on the connectan rods, Align both the piston Skll" ends With the cylmder edges. Apply molybdenum oll solutan to the thrust surfaces ol the crankshaft as shown Allgn the balancer shaft end groove With the projechon of the upper crankcase CRANKSHAFT/PlSTON/CYLINDER/BALANCER Be calefu/ no! to damage me c/enkpm, mam journal and bearing msens He‘d me crankshafl [1] over the crankcase secure‘y ' wnh mark [2] on the balancer drwe geav iacmg Ihe from side of me engme, and set its crankpins onto the conneclmg rods Install Ihe crankshafl onko the upper crankcase while ahgnmg me balancer drvven gear mdex hne [3] between the balancer dnve gear mdex hues [4] as shown Set me connecmg rods [1] onlo Ihe crankpins. compressed aw 14-6 CRANKSHAFT/PISTON/CYLINDER/BALANCER Apply molybdenum all solution to the crankpin bearing sliding surfaces on the crankpin bearing caps Install the crankpin bearing caps [1] by aligning the l D. code number on the connecting rod and bearing cap NOTICE Be sure to install each part in its original position, as noted during removal Apply engine oil to the crankpin bearing cap nut threads and seating surfaces. Install and tighten the crankpin bearing cap nuts [1] in 2 or 3 steps alternately lo the specified torque, TORQUE: 33.3 N-m (3.4 kgl'm, 25 let) Assemble the crankcase halves (page 13-6). MAIN JOURNAL BEARING Do not interchange the bearing inserts They must be installed in their original locations or the correct bearing oil clearance may not be obtained. resulting in engine damage BEARING INSPECTION Remove the crankshaft (page 14-4) [2] Check the main journal bearing inserts [1] for unusual wear or peeling. Check the bearing tabs [2] for damage, It the main Journal bearing damaged select a replacement bearing (page 148). 14-7 CRANKSHAFT/PlSTON/CYLINDERIBALANCER Do not rotate the crankshaft during rnspectlun OIL CLEARANCE INSPECTION Remove the crankshaft (page 14—4) , [1,], Clean off any oll from the bearan lnserts and mam Journals Install the crankshaft onto the upper crankcase (page 14-5) Put a strip of plasligauge [‘l] lengthwlse on each mam Journal avoldlng the oil hole Install the dowel pll’lS [1] onto lhe upper crankcase [2] lnstall the lower crankcase crankcase, [1] onto the upper} Clean the crankcase rnarn Journal bolls (reuse) in solvent. and dry them thoroughly Apply englne Oll to the crankcase rnaln Journal bolt threads and sealing surfaces lnstall the crankcase mam Journal bolts [2] Make sure the upper and lower crankcase are seated securely Tighten the crankcase mam journal bolts rn numerical order as shown m a crisscross pattern Il’l 2 or 3 steps to lhe specified torque. Furthertighlen the crankcase main journal bolts 120° TORQUEI15 N-m (1.5 kgf—m, 11 lblrft)+120“ Remove the crankcase maln Journal bolt and lower crankcase, Measure the compressed plastlgauge at its wldesl polnt on each rnaln Journal to determme the all clearance. SERVICE LIMIT: 0.05 mm (0.002 in) lf the all clearance exceeds the sen/Ice llmll. select a replacement beanng (page 1479) ‘ 14-8 CRANKSHAFT/PISTON/CYLINDER/BALANCER BEARING SELECTION Letters (A, Bar C) Record the crankcase bearing support ID. Code letters on the en side or [1} frum Iefl srde of the upper crankcase as shown ‘ upper crankcase are beanng sup/Jar? LD Codes from /eft 1o ngnr. Numbersm 20r3) If you are repIacIng (he crankshaft, record (he ‘—i 77 77 on Me Crank wergnr corresponding main journal 0 D code numbers [1] from are men journal the crank weigh! on cadesfmm/eft ’0 "gm If you are reusmg the crankshafi, measure Ihe crankpm 0 D. wrth a mrcromeIer 1 I I Cross-relerence (he mam journaI and bearrng support codes Io determine the repIecement beanng coIor code [1] MAIN JOURNAL BEARING THICKNESS: : Black: Thickesl B: Brown: C: Green: D I E > : Yellow: :Pink: Thinnest MAIN JOURNAL BEARING SELECTION TABLE: ’ 'i’ ’7' BEARING VSVUPPORT I’D. CODE ' i B I 37 0001 37 005 fin 37,006 7 37,012 mm 37'01’2 7 37 018 mrrT‘ (145677 1 4569 in) (14569714572m) (1 2 1.45741n) 34 660 234,006 mm ‘ E 1 D c I R (1 3386 71 33881n)I (Pink) 7 ( (YeIIow) (Green) ‘ 2 33 994 7 34 000 mm D 1 c 8 (1.3383 7 1 3386 m) I (Yellow) I (Green) (Brown) 1 ‘ I 33 988 7 33.994 mm C B A L F ((13351 —1.33831n)I (Green) ( (grown) r "(Blacm NOTICE After se/ect/ng new beanngs, recheck the clearance wrm a plastrgaugev Incorrecr clearance can cause severe engine damage 1 4-9 CRANKSHAFT/PISTON/CYLINDER/BALANCER BEARING INSTALLATION Clean Ihe bearing ouler surfaces and crankcase bearing supporls lnslall the main journal bearing inserts [1] onlo the crankcase bearing supports, aligning each lab with each groove CRANKPIN BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the surreal bearing 0/] clearance may not be obtained. resulting in engine damage BEARING INSPECTION Remove the cranksnall (page 14-4) [2] Check the crankpin bearing inserts [1] for unusual wear or peeling. Check me bearing labs [2] lur damage if (he crankpin bearlng damaged, select a replacement ‘ » bearing (page 14-12) I \ OIL CLEARANCE INSPECTION Remove me cranksnafl (page 144) Clean the mating surface of the connecIing rod and l crankpin bearing cap wxm solvenI and blow Ihem with compressed air. 14-10 CRANKSHAFTIPISTON/CYLINDERIBALANCER Clean oft any all from the bearing inserts and crankpins. Install the crankshaft onto the upper crankcase (page 145) Set the connecting rods onto the crankplns. Do notmlateme Put a strip of plastlgauge [t] lengthwise on each crankshaft dull/lg crankpln avoiding the oil hole inspection Install the crankpm bearing caps [1] by aligning the l D code number on the connecting red and bearing cap Be sure to InsiaH each part in its original pee/hon. as noted during removal. Apply engine oil to the crankpin bearing Cap nut threads and seating surfaces lnstall and tighten the crankpin bearing cap nuts [7] In 2 or 3 steps alternately to the specuhed torque TORQUE:33.3 Nvm (3A kgf-m, 25 Ital-ft) Remove the bearing caps Measure the compressed plastigauge at Its Widest polnt * on the crankpin to determine the Oil clearance ‘ SERVICE LIMIT: 0.06 mm (0.002 in) If the oil clearance exceeds the service lImit, select the correct replacement bearings (page 14-12). 14-11 CRANKSHAFT/PISTON/CYLINDERIBALANCER Numbers (1‘ 2 or a; on the connecrmg rods are the connecting rod r 0 codes Leners (A, a or C) on the crank wergm are me crankpln o 0 codes from lefl to right. BEARING SELECTION Record the connecting rod l.D, code number [1] or measure me I D wnh me crankpin bearing cap Installed Wlthoul beanng inserts: ll you are replacing the crankshaft, record the ' correspondan crankpln OD. code letter [1] If you are reusmg the crankshaft. measure the crankpln O D with a mlcromeler Crossrrelerence the connecting rod and crankpin codes to determlne the replacement bearan color code [1]. CRANKPIN BEARING THICKNESS: A: Blue: Thickest B: Black: C: Brown: D 1 E : Green: 1 Yellow: Thinnest CRANKFIN BEARING SELECTION TABLE: 1 391000 — $9 006 r'rTm' CONNEpTING'FEo'Dfi' cool: 7 W l 2 I39’006739.o12mm 39.012739.018mrn‘ (1 53547 1 5357 in) (15357—153591n) _(15359—1.5361 in) 7 (Brown) W ICRANKPINOD 'A 3 .994736 000mm1 E D 0 ‘CODE 7 (£4171 ~1.4173 in) ‘ (Yellow) (Grimi ‘ Bl35988—35994mm D C B M14168 — 1.4171 in) (Green) I (Brown) (Black) c135,982— 5.988 mm c 1 B A I(1,4166r1.4168 in)I (Brown) I 7(Black) (Blue) After seleclrng new beanngs, recheck the cleamnce with a plastlgaugev Incorrect clearance can cause severe engrne damage 14-12 CRAN KSHAFT/PlSTON/CYLINDERIBALANCER BEARING INSTALLATION Clean the bearing outer surfaces, crankpin bearing cap - and connecting rod Install the crankpin bearing inserts [1] onto the bearing cap and connecting rod‘ aligning each tab with each groove [1] ‘ PISTON/CYLINDER PISTON/CONNECTING ROD REMOVAL - Belore piston removal, place a clean shop towel around the connecting rod to plevent damaging the cylinder sleeve - Do not try to remove the piston/connecting rod assembly from bottom of the cylinder, the assembly Will get stuck In the gap between the cylinder liner and the upper crankcase. . Do not Interchange the hearing inserts They must he installed in their original locations or the correct hearing all clearance may not be obtained resulting In engine damage Remove the following. — countershaft (page 13-8) — crankshafl (page 14.4) Remove the piston/connecting rod assembly [1] from the top oithe cylinder. PISTON REMOVAL Remove the piston pin clips [1] with pliers Push the piston pin [2] out of the piston [3] and connecting rod [4], and remove the piston ‘ CRANKSHAFT/PISTONICYLINDER/BALANCER PISTON RING REMOVAL Spread each piston ring ends and remove them by lifting up at a point opposite the gap NOTE ~ Do not damage the piston ring by spreading the 1 ends too far. ' Be careful not to damage the piston when removrng the piston ring. Clean carbon deposits from the piston ring grooves With ’7 a ring that will be discarded NOTE ' Never use a ere brush‘ It will scratch the groove. INSPECTION Inspect the Iollowing parts Ior scratch. damage. abnormal wear, deformation. burning or clogs In Oil passages. » cylinder » piston » piston rings 7 piston pin 7 connecting rod small end Measure each part and calculate the clearance according to CRANKSHAFT/PISTON/CYLINDER/ BALANCER SPECIFICATIONS (page ‘I-i 1). Replace any part If it is out of service limit. 14-14 CRANKSHAFT/PISTONICYLINDER/BALANCER PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the ’ piston rings. - Apply engine oil to the piston ring entire surlace and . piston ri‘ng grooves - Avold piston and piston installation. ring damage during up. — “RE” mark: top ring [1] — "RNE" mark: second ring [2] then install the side rails [5]. stagger the piston ring end gaps 120” apart Irom each DIher Stagger the side rail end gaps as shown. After installation, the rings should rotate freely in the ring groove. PISTON INSTALLATION Install the crankpin bearings in the original locations (page 113-13). Apply engine oil to the piston pin hole Inner surface. Apply molybdenum DII solution to the connecting rod small end inner surface. Assemble the piston [1] and connecting rod [2] with the crankpln bearing tab [3] facing to the piston "IN" mark [4]. Apply molybdenum all solution to the piston pin outer surface. Install the piston pin [1] and secure it using new piston pin clips [2]. NOTE - Make sure that the piston pin clips are seated > securely. - Do not align the piston pin clip end gap with the piston cutout. Install the piston rings with the marked side Iaclng ‘ To install the oil ring [3]. install the spacer [4] Iirst. [l] ‘7E 20 mm (o e in) or more 14-15 CRAN KSHAFT/PISTON/CYLINDER/BALANCER lristal/ the piston/ Connecting rod assembly mm the piston “W” mark [3] tact/lg the intake Side, Make sure the piston ring compressor tool Sits flush on the top surface ofthe Cylinder Apply engine oil to the cylinder walls and piston sliding surface Install the piston/connecting rod assembly [1] into the cylinder usmg a commercially available piston ring compressor tool [2] When reusmg the connecting rods installed in their original locations, they must be - While installing the piston be careful not ta damage the top surface of the Cy/tnder, especiaHy around the cylinder bore - Be careful not to damage the cylinder s/eeve and crank/3m With the connecting rod Use the handle of a plastic hammer or equivalent tool to tap the piston into the cylinder. Install the followth — crankshaft (page 14-5) 7 countershaft (page 13713) PISTON OIL JET Be calefu/ riot in damage the outer hole REMOVAL/INSTALLATION Remove the piston/connecting rod assembly (page We 13) Remove the Oil jets [1] to the main journal Side while pushing the Oil let tip from the cylinder side Remove the 04mg [2] from the all let Clean the oil Jets In solvent thoroughly, Check the Oil lets tor clogs and replace them it necessary Blow through the oil passage on the upper crankcase and oil jet With compressed air Coat a new O-ring with engine oil and install it into the ‘ groove in the oil Jet. Install the oil Jets into the upper crankcase until it is fully seated while aligning the lug and groove in the . crankcase Install the removed parts is in the reverse order at removal No 1 cylinder side: " 14-16 CRANKSHAFTIPISTON/CYLINDERIBALANCER BALANCER REMOVAL Remove the plslon/connecllng rod assembly (page My 13). Remove the bolts [1] and balancer/rlgh! malnsnaft bearing selling plate [2]. Position the balancer snafl Wllh the left balancer welght ‘ [1] faclng up. Slide lne balancer shaft off the upper crankcase and remove (he ngnl balancer shafl bearing [2]. Remove the balancer shaft [1] INSPECTION lnspecl the following parts {or scratch. damage abnormal wear and deformallon. Replace If necessary 7 balancer driven gear — balancer driven subygear — sprlngs r balancershaft r balancer shaft beanngs 14-17 CRANKSHAFTIPISTONICYLINDER/BALANCER LEFT BALANCER SHAFT BEARING REPLACEMENT Drrve out the \efl barancer shaft bearing [1] ram the upper crankcase. Dru/em square/y Drrve In a new \efl balanoer shafl bearing [1] inle Ihe wrm the marked upper crankcase until it rs quy seated using the specia‘ ‘ 5rde facrng up tools, ‘ TOOLS: [2] Driver 07949—3710001 [3] Attachment, 42 x 47 mm 07746-001030!) [4] Pilot. 20 mm 07746-004050!) INSTALLATION Appr engine on lo the refl balancer shaft bearing [11' Instalr Ihe balancer shaft [2] mm the upper crankcase i whrle the left balancer werght [3] is facrng up Apply engine orl :0 me ngm balancer shaft bearan InslaH wrm the rnstaH lhe rrghl balancer shafl beanng [1] into the upper marked srde racmg crankcase our 14-18 CRANKSHAFTIPISTON/CYLINDERIBALANCER Apply locking agenl lo the balancer/rlghl malnshafl '- ‘ , A, .. v bearing selllng plate bolls lhreads (page 1720). m lnslall the balancer/rlghl mamshafl bearlng selling plale [1] and setllng plate bolts [2} Tlghlen the sellmg plale balls to llwe speclfied torque TORQUE112 N*m (1.2 kgf—m, 9 lbf-fl) Install (he piston/connecting rod assembly (page 14- 15). 14-19 MEMO 15. ENGINE REMOVAL/INSTALLATION SERWCE INFORMATION ......................... ..15_2 ENGmE REMOVAL ............... .. .....15_4 COMPONENT LOCATION ENGINE INSTALLATION ------- -- 15-1 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL - A hoist or equivalent is required to support the motorcycle when remoVing and installing the engine, - A floor jack or other adjustable support is required to support and maneuver the engine. Do not use the 01/ filter as a lacking poi/7L ~ When removing/installing the engine. tape the frame around the engine beforehand for frame protection When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence, If you mistake the torque or sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the correct sequence. - The following components can be serviced With the engine installed in the frame. 7 Starter motor (page 6-5) 7 Throttle body/air cleaner housing assembly (page 7-11) — Water pump (page 8-10) — Oil pump (page 95) — Oil strainer (page 9-8) — Camshaft (page 10—9) v Rocker arm (page 10-14) 7 Cam chain tensioner lifter (page 10-23) 7 Clutch (page 1177) 7 Primary drive gear (page 11-14) — Gearshift linkage (page 11717) — Stator/CKP sensor (page 1274) — Flywheel (page 126) — Starter clutch (page 724) - The followmg components require engine removal for service, — Cylinder head/valves (page 10-16) 7 Transmission (page (3-8) 7 Crankshaft (page 14-4) v Piston/cylinder (page 14-13) 7 Balancer (page 1417) 15-2 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 55 Nm (5.6 kgf'm. 41 lbffl) 60 N-m (5,1 kgim 44 lbl-fl) 60N>m(6,1kgl'm. 44 lblfl) 37 N-m (3 a kgm 27 mm) \, fl '\ 1/ \ k ‘ ’ \ / ». ‘ mm 45 Nm (4 6 kgl-m, 33 Inch) ' _‘ ’ ' a , { , r " ' V \ 12 N-m (1.2 kgrm, 9 lbw) 54 N m (5,5 kgV'm, 40 mm) 2.0 N rn (0‘2 kgf-m 1,5 mm) \ AC type omy 15-3 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Dram the engine on (page 3-10). Dram the cement (page 875) Ftu s‘acken the drrve cham (page 3714) Remove me rouowrng, 7 drive sprocket cover (page 2724) — exhaust prpe (page 2—29) 7 Mar tank under tray (page 2725) — starter motor (page 6-5) A regurator/reourrer (page 2077) e CBSOOF/FA under cowl (page 2723) Release the CKP sensor Wire [1] from the clrp [2] Disconneu me CKP sensor 2P (Red) connector [3} Remove the stator/CKP sensor wire harness band chps (Brown [41‘ Brack [5]) rrom me rrame Remove Ihe stator/CKP sensor wrre harness [1] out of ' the frame AC type Remove me EVAP canister drain hose clrp [1] from the stay Remove me boH [11 and dutch cable holder [2} then drscenned Ihe c‘umh cab‘e [3] from (he dutch lrfier arm [4] 1 5-4 ENGINE REMOVAL/INSTALLATION .\ V - 1 we» 1,, my Retease the rubber cap [1] from the EOP swtlch [2] Remove the terminal screw [3] and disconnect the switch wure [4]. Remove the bolt [1] and wife harness stay [2]. Disconnect the engine subrwu’e harness 6P (Black) ' connector [1]. [I . Release the hose dip [2] and disconnect upper radiator hose [3] from the thermostat cover Disconnect the FAIR atr supply hose [4] from the cylinder head cover Release the hosa 0in [1] and disconnect the lcwer radiatot hose [2] from the water pump. 15-5 ENGINE REMOVAL/INSTALLATION Support the rootpeg brackct 50 n does not hang from the brake hose DD nut twist the brake hose Do not use the or! filter as a jackmg pal/ll. Remuve the drive sprocket bolt [1], washer [2] and drive sprocket [3], Remove the bolts [1] and rlght rrder footpeg bracket [2]. Rtghl Side , Support the motorcycle securely with a host ur equlvalent Place a floor lack or other adjustable support under the englne NOTE - The Jack height must be continually adjusled to relleve stress lor ease of bolt removal Remove the from englne hanger bolts [1] and collars ‘ [2] Remove the upper engine hanger bolts [1] and collars [2] 15-6 Thread we 10 x 145 mm rear engme hanger nous mm me left and ngm upper engme hanger (70/! holes and use them as hand/BS In 6155151 m no/dmg me eng/ne During eng/ne removal, mm {he engme securely and be careful/70210 damage the frame and engine Remove the rear \ower engme hanger nut [1]. washer [2] and bolt [3] Remove me rear upper engme hanger nut [4] washer [5] and ban [6] NOTE ' Rawsmg the rear oflhe momrcycle so the rear whee‘ \s 150 mm (6 in) offthe ground can assist in engme remova‘, Careitu lower the Jack or adjustab‘e supporl‘ then remove We engme from the frame. ENGINE REMOVAL/INSTALLATION [4 [WI/[2N [3] 15-7 ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION NOTE - Do not use the oil filteras a lacking point, - The Jack height must be continually adjusted to relieve stress for ease bolt installation. - Carefully align the mounting points With the jack to prevent damage to engine, Vrame, radiator hoses, wires and cables. During engine Raise the rear of the motorcycle so the rearwheei is 150 mm (5 in) 0" the ground. installation, hold the engine secure/y and be careful not to damage the Place the engine under the frame on a jack or other adjustable support. heme and engine Thread the 10 x146 mm rearengine hanger bolts into the left and right upper engine hanger bolt holes and use them as handles Align the front engine hanger bolt holes with the frame mounts and loosely install the bolts and collars. Remove the 10 x 146 mm bolts Raise the engine while rotating it up in the rear to install the other hanger bolts and collars. Install the rear engine hanger nuts with the washers Tighten the bolts and nuts to the specified torque in the specified sequence as shown 7 55 N m (5,6 kgl-m, 41 mm) E 10x65 mm BOLT 60 N m (61 kglrn, 44 lbfft) 55 N m (5.6 kg? rn, 41 lbl’lt) E10 x 75 mm BOLT an N m (e 1 kgim, 44 mm) / F‘iomo mm BOLT s, 1% "are 45 N-m i4 6 kgf'm, 33 Ibftt) 10 x145 rnm BOLTS E10 x40 mm BOLT 35 mm COLLAR 45 N m (4,5 kgf m, 33 lot-ft) 8 mm COLLAR 8 mm COLLAR 15-8 ENGINE REMOVAL/INSTALLATION Install the removed parts m the reverse order of remova‘ TORQUE: Rigm riderfootpeg bracket boll: 37 N-m (3.3 kgf'm, 27 lbl-ft) Drive sprocket bolt: 54 N-m (5.5 kgt-m, 40 mm) EOP switch terminal screw: 2.0 N'm (0.2 kgfrm,1.5|bf-fl) Right crankcase cover bolt: 12 N-m (1.2 kgf-m, 9 Ihm) NOTE‘ . (natall the drive sprockm [1] wxlh us "OUT" mark [2] i‘ facmg oul - Align the clutch cable ho‘der hole wwth the right crankcase cover boss Adlusl the loHowmg: 7 (meme gnp freeplay (page 3-4) 7 clutch lever freep‘ay (page 320) r dhve chain slack (page 3-14) FIH (he engme wnh the recommended engme 01‘ (page r 340) Fm and head the coolmg system (page 875) Check me exhausk system and cooling sysmm for leaks 15-9 MEMO 16. FRONT WHEEL/SUSPENSION/STEERING SERVICE |NF0RMAT|ON ......................... .. TROUBLESHOOTING..n............................ COMPONENT LOCAT|0N HANDLEBAR (CBRSOOR/RA) ------------------ -- 16-2 16-4 16-5 16-7 HANDLEBAR (CBSOOF/FAlX/XA) ---------- --16-11 FRONT WHEEL ...................................... "16.15 ....................................................... ................................... 16-1 FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL A hoist or equivaleni is requrred to suppon the motorcycle when servicing ihe front wheeli Iork and steering stem. A contaminated brake disc or pad reduces stopping power. Discard coniaminaied pads and clean a contaminated diSc with a high quaiin brake degreasing agent, Do noi operare ihe brake lever after removing Ihe front wheei Use only Iires marked "TUBELESS" and Iubeless vaIVes on rim marked " FOR TUBELESS". Afler the from wheel installalioni check the brake operation by applying the brake lever, CBRSDORA/CBSOOFA/XA, Aiter the from wheei instaiieiien, perform the air gap inspection (page 19-22) For brake system service (page 1873), TOOLS 7 Bearing remover head, 17 mm Bearing removeréha’fliifi Imlrjriver ’— V ' 'W i 077460050500 077460050100 I 07749-0010000 , I i ’ I I 1 I i I I i I i I i , ‘ ‘ : \_/ i \ / ~ / BACK-UP > / Rim 1 FORK SLIDER / GUIDE i ; , / 1 , FORK r N / BUSHING 7 PISTON / i i 1 ‘ i Q REBOUND FORK SPRING a? 1 SPRING v F*** SEALING a? WASHER Q FORK TUBE BUSHING v 20 N m (2.0 kgI-m,15ibi-f!) 16-23 FRONT WHEEL/SUSPENSIONISTEERING Be carom/none Install a new tork tube bushing [1] if it has been damage the coating removed on the bushing Do not spread open the N OTE bushing more than - Remove the burrs from the bushing mating surface, ‘ necessary being caretul not to peel ott the Coating. install the following 7 rebound spring [2] (onto the tork piston) e fork piston [3] (into the lork tube) 7 oil lock piece [4] [onto the tork piston) Install the fork tube [5] into the fork slider Hold the fork slider in a vise with soft ]aws or shop towels Apply locking agent to the threads of the fork socket bolt [‘l] irthe tori< piston Install the socket bolt with a new sealing washer [2] and films With the tighten it to the specified torque sncketboit. I _ _ _ temporarily mm, TORQUE. 20 N m (2.0 kgt m, 15 thin) the fork spring, spring collar and rm can He carelui not (a scratch the fork tube Place the guide bushing [1] over the lork tube and rest it on the sliderv Put the back-up ring [2] and an old bushing or equivalent tool on the guide bushing Drive the bushing into place] using the special tools. TOOLS: [3] Fork seal driver 07947-KA50100 [4] Fork seal driver attachment, 07947—KF00100 41 mm Wrap vthyi tape around the tork tube top end to avold ; damaging the Oil seal lip, ; Apply fork flutd to the lips of a new oil seal [5] and install 1 it With the marking lacing up ‘ Drive the oil seal until the stopper ring groove [6] is visible using the same tools. Install the stopper ring [1] into the groove in the fork ‘W’ slider Apply tork fluid to the lips of a new dust seal [2] and install IL 16-24 FRONT WHEELlSUSPENSlON/STEERING Pour the specified amount of recommended fork fluid into the fork tube. RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-8 (10W) FORK FLUlD CAPACITY: CBRSODR/RA: 503 1' 2.5 cm’ (17.0 1 0.08 US 01, 17.7 I 0.09 Imp oz) CESODF/FA: 480 2 2.5 cm“ (16.2 1 0.08 US 02, 16.9 2 0.09 Imp oz) CBSOOXIXA: 453 2 2.5 cm“ (15.3 1 0.08 US oz, 15.9 2 0.09 Imp oz) E Siowiy pump the lork lube several times to remove any trapped air from the lower portion ofihe fork tube. Compress the fork tube iully and measure the fluid ievel from the top end of the fork tube. [1] FLUID LEVEL: CBRSOURIRAICBSOOFIFA: 130 mm (5.1 in) CBSOOXIXA: 160 mm (6.3 in) PuH the fork pipe up and instail the fork spring [1] With ' the iightiy wound coll side facing down Install the spring Guitar [2] with the stepped side facing down. Coat a new O-ring [1] with fork fluid and install It Into the groove in the fork cap [2]. Tighten the fork cap instaii the fork cap into the lurk tube, after insraI/mg the {ark tube mm the lurk bridges ‘ m\ 16-25 FRONT WHEEL/SUSPENSIONISTEERING STEERING STEM CER500R/RA Keep the reservoir upngm to prevent an from entenng (he hydraullc system CB500F/FA CB5DflX/XA REMOVAL Remove lhe followmg: — middle cawls (page 2-8). — AC lype.‘ EVAP canlster (page 7»22) — brake hose [1] (from the clamp [2]) — band clips [3] — slopperrlngs [4] — handlebar pinch bolls [5] (loosen) — handlebars [e] — cables [7] (from the cable guldes) Remove the following, — mlddle cowls (page 2-9) — front cowl (page 2-13) 7 AC type. EVAF’ canisler (page 7-22) 7 handlebar (page 16-1 1) 7 band clip [1] r lhronle cables [2] (from the cable gmde) — two bolts [3] — band clip stay [4] and front cowl stay [5] Remove the folluwing' 7 middle cowls (page 2-9) A AC type: EVAP canister (page 7-22) — handlebar (page 16711) — band clip [1} 7 cables [2] (from lhe cable guides) 16-26 FRONT WHEEL/SUSPENSION/STEERING Remove me three band clip [1] FB'RS'OO'R/R; A C’Mi‘ypes shown ‘ ‘ ‘ ‘ Remove the ignition switch 2P (Brown) connemor [2] ‘ from me stay and disconnect wt ‘ if; _ , ' ‘ «\ \ ,7 ‘ CBRSODRA/CBSOOFA/XA: Remove me bolt (6 X 10 mm) [1] and hose JomUcFamp say [2], Remove the bolt (6 x 12 mm) [3] and clamp [4]. Remove the stem cap [1], CBR5ooR/RA: \ ‘ Lassen the sheeran 5mm not [2] Remove the fork legs (page 16-19). Remove Ihe followmg: — CBSOOF/FA/X/XA. top bridge pmch bolt [3] and clamp[4] ‘ — stem nut - washer [5] -— top bridge [6] 1 6-27 FRONT WHEEL/SUSPENSIONISTEERING Strargnten the rock wasner tabs [1]. Remove the took nut [2] and took washer. Loosen the steenng beanng adjustment nut [1] usmg the specral toot. TOOL: [2] Steering stem socket 07916-3710101 Whrte holding the steermg stem, remove the adjustment nut and upper dust seal [3] Remove the fotlowmg, » steenng stem [1] — upper inner race [2] 7 upper steerrng beanng [3] — tower steermg beanng [4] BEARING REPLACEMENT A/ways replace the Remove the upper outer race using the speclat tools bearing and races as a set. TOOLS: Ball race remover set 07953-MJ10000 — [1] remover attachment 07953-MJ10100 — [2] remover shaft 07953-MJ10200 or 07953-MJ1000B (USA, only) For the remover attachmenlt use side A 16-28 FRONT WHEEL/SUSPENSION/STEERING Remove lhe lower outer race using the special tools, TOOLS: [1] Bearing remover 07946-3710500 Driver 079494710001 Attachment, 32 x 35 mm 01746-0010100 install the stern nut [11 onto the steering stem [2] to prevent the threads from being damaged when removing the lower Inner race [3] Remove the lower inner race With a chisel or equivalent tool‘ being carelul not to damage the stem. Remove lhe lower dust seal [4] lnslall a new lower dusl seal onto lhe sleering stem [1] Press a new lower inner race [2] using the special tool TOOL: [3] Steering stem driver D7946-MBOUOOD Drive In a new upper outer race [1] into the steering head pipe using the special tool TOOLS: [2] Driver 07749-0010000 [3] Attachment. 42 x 47 mm mus-0010300 Drive in a new lower ouler race TOOLS: Driver 0774941010000 Attachment, 52 x 55 mm 07746-001040!) 1 6-29 FRONT WHEE ED: LOWER STEERING BEARING @fi LOWER \NNER RACE \ @@ LOWER DUST SEAL STEERING STEM L/SUSPENSION/STEERING INSTALLATION CBRSOORA shown: LOCK NUT £0? LOCKWASHER “7% ADJUSTMENT NUT § § '3’ F65. \ ‘fl go? 'fi‘ UPPER DUST SEAL LOWER OUTER RACE UPPER \NNER RACE § \ 9L UPPER STEERTNG BEARING \ 63" e TE NO - Use urea based multI-purpose extreme pressure grease NLGT #2 (EXCELTTE EP2 manufactured by ‘ KYODO YUSHI CO LTD.‘ STAMINA EP2 T manulactured by She” or equivalenl) (or the bearmg ‘ race shdmg surface and dust seaVS ‘ Apply grease to (he Tip onhe lower dust sea‘ [1], App‘y 3 — 5 9(0170 2 oz) (per each bearing) of grease to the bearing race sliding suflaces. T ' App‘y grease to the hp oia new upper dust seal [21' App‘y engme oil to the threads or the adjustment nm [3] InsTall the followmg' lower sleenng bearmg [4] upper steering bearing [5] upper vnner race [6] sTeenng stem [7] upper dust sea‘ adjustment rTuT 16-30 FRONT WHEEL/SUSPENSION/STEERING i. Tighten the adjustmeni nu1[1]lothe specified torque , £ 7 using the special tooi. TOOL: [2] Steering stem socket 07915-37101!” TORQUE: 23 N»m (2.3 kgi-m, 17 Inf-ft) 2 Turn the steering stern left and righl‘ iock-to-iock at least five limes to seat the bearings. 3. Retighten the adjustment nut to the same torque install a new look washer [i], aligning its bent tabs With the grooves in the adjustment nut install the lock nut [2} and finger tighten it all the way, Do noiovertlghlen Further tighten the lock nut, within 90“ to align its the iock nut, m/S wM/ grooves with the tabs of the lock washer flatten the lock Bend the lock washer tabs [3] up into the grooves in the washer lock nut, 16-31 FRONT WHEEL/SUSPENSION/STEERING Do not lighten the top bridge pinch balls Clean the threads at the stern With a degreasing agent iCER5DdR/fiA. ‘ . install the top bridge [11‘ washer [2] and steering stem i nut [3] Temperarily install the fork legs into the bottom and top i bridges by tightening the bottom bridge pinch bolts. Tighten the stern nut to the specified torque, TORQUE: 103 Mm (10.5 kgf‘m, 76 Ith) Make sure the steering stern moves smoothlyi without 1 play or binding r * " Install the slerii cap [4] CBSOOF/FA/X/XA: Install the top bridge pinch bolt [5] W‘“ "‘9 damp [61' CBSOOFIFAi’X/XA: install the fork legs properly (page 1620). Install the clamp [1] onto the bottom bridge and lighten the bolt (6 x 12 mm) [2] CERSOORNCBSDOFA/XA: Install the hose Joint/clamp stay [3], aligning the locating pin With the hole and tighten the bolt (6 x 10 mm) [4] Connect the ignition switch 2P (Brown) and install it ontu the stay install the band clip [2], “meat” [1] V CBRSOORIRAi Al CM types shown 16-32 FRONT WHEEL/SUSPENSIONISTEERING CBR500R/RA CESDOF/FA CBSOOX/XA. Route the throttle cables [1] and the clutch cable [2] IMO each cable guide. Install each handlebar over the fork tube, aligning the bass with the groove in the top bridge. Be sure the handlebar holder IS lully seated on the top ‘ bridge. Push the handlebar forward to touch the boss against the inside of the groove, then tighten the pinch bolts [3] to the specified torque, TORQUE: Z7 N-m (2.8 kgf'm. 20 Ibf-I‘t) Install the stopper nng [4] into the groove In each lurk ‘ tube. Install the two band clips [5] and the brake hose [6] into the clamp [7]. [ Install the fotlowvng 7 AC type: EVAP canister (page 7722) 7 middle cowls (page 2-8) . Install the front cowl stay [1] and band clip stay [2]] and tighten the two bolts [3]. r Route the throttle cables [4] into the cable guide. Install the band clip [5]. Install the followtng: — handlebar (page 16-13) — AC type‘ EVAP canister (page 7-22) — Iront cowl (page 2713) — middle cowls (page 2-9) Route the throttle cables [1] and the clutch cable [2] into each cable guide. Install the band Clip [3] Install the following, 7 handlebar (page 16-13) 7 AC type: EVAP canister (page 742) i 7 middle cowls (page 2—9) ‘ fii, ‘ CBR5OORA shown: [4] 16-33 FRONT WHEEL/SUSPENSIONISTEERING STEERING BEARING PRE-LOAD Support the motorcycle securely using a hoist or *' equivalent and raise the front wheel oft the ground Position the steering stern straight ahead Hook a spring scale to the fork tube between the fork top and bottom bridges. Make sure there is no cabie, wire harness or hose interierence. Puli the spring scale keeping it at a right angle to the steering stern Read the scate at the point where the steering stem just starts to move. STANDARD: 9.8 — 14.7 N (1.0 — 1.5 kgl, 2.2 — 3.3 lbf) if the readings do not fall within the iimits, readjust the steering bearing adjustment nut (page 16-31). 16-34 17. REAR WHEEL/SUSPENSION SERVICE INFORMATION ......................... ..17_2 REAR WHEEL ........................................... ..17_6 TROUBLESHOOTING-----------------------------v-v-17-4 SHOCK ABSORBER/LINKAGE ------------- »- 17-10 COMPONENT LOCA'HON.........m..............17_5 SWINGARM ........................................... ..17_13 17-1 REAR WHEEL/SUSPENSION SERVICE INFORMATION GENERAL A hoist or equivalent is required to support the motorcycle when servicing the rear wheel and suspension. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc With a high quality brake degreasing agent Do not operate the brake pedal after removing the rear wheel Use only tires marked "TUBELESS" and tubeless valves on rum marked “FOR TUBELESS". After the rear wheel installation, check the brake operation by applying the brake pedal. CBRSOORA/CBSOOFA/XA: After the rear wheel Installation, perlorm the air gap inspection (page 19-22), Use only genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. For brake system servrce (page 18-3). TOOLS Bearing remover headf17 mm Bearing remover shaft 7 Driver 7 if 077460050500 07746-0050100 0774970010000 i ,, ,, , i , ,77i" W, Driver 1 Attachment. 22 x 24 mm Attachment. 24 x 26 mm 0794944710001 0774670010800 0774670010700 Attachment. 28 x 30 mrrni 7' Attachment, 32 x 35 mm 7 iAttachment, 42 x 47 mm W 0794571870100 0774570010100 07746-0010300 17-2 REAR WHEEL/SUSPENSION Attachmeit, 52 x 55 m? 7 ' ‘ mm, 15 mm" 7 Pilot, 17 mm” ‘ ‘ 077450010400 ‘ 077400040300 077400040400 ‘ t 1 //H 7\-. ‘ kt Not, 20 mmi ‘ P001. 25 mm , 4‘ Bearmg remover head, 15 mm ‘ 07746-0040500 0774841040600 1 079367KC10200 1 or 079367KC10500 (U.S.A. only) i" Enng refler shaft, 15 mm "7 Remover wengfiifir V "i Remtfier attachment, 24 mm ‘ ‘ 079367KC10100 07741-0010201 ‘ 07LMC-KV30200 ‘ ‘ w w / r’ t (2/ ‘ ‘ or 07936’KC10500 (USA only) ‘ or 0793673710200 (USA. only) ‘ or 07936671 020A( .S.A. only) \ Bearan remover attachment TrDriver shaft i V \ ‘ 07GMD-KT70200 ‘ 07945-MJ00100 17-3 REAR WHEEL/SUSPENSION TROUBLESHOOTING Steers to one side or does not track straight - Drive chain adjuslers nol adjusted equally - Bent axle - Damaged frame ~ Worn swrngarm pivot components Rear wheel wobbles Benl rim Faulty tire Worn or damaged wheel bearings Worn or damaged driven flange bearing Axle riot tightened properly Faully swingarm pivot bearings Suspension fasleners noi tightened properly Unbalanced tire and wheel Wheel hard to turn - Faulty wheel bearings - Bent axle - Faulty driven flange bearing - Drive chain too tight (page 344) ' Brake drag (page 18-2) Soft suspension ‘ Low tire pressure ‘ Incorrect suspension adjustment ~ Weak shock absorber spring - Oil leakage from damper unit 51m suspension ~ Hign tire pressure incorrect suspension adjustment Bent shock absorber damper rod Damaged suspension or swungarm pivot bearings improperly tightened sWingarm pivot Rear suspension noise - Loose suspension fasteners - Worn or damaged suspension pivot bearings - Faulty shock absorber 17-4 REAR WHEEL/SUSPENSION COMPONENT LOCATION CERSOORA shown: 44 N-m (4 5 kgf'm, 32 \bf-fl) 88 N’m (90 kg! m, 65 {bl-fl) _ 44 N-m (4 5 kg! m, 32 Ibi-fl) @/ 4 44 N-m (4‘5 kgf‘m, ‘ I \ 32 mm) as N’m (9.0 kg: m, 65 Inf-fl) ‘ 44 N'm (4 5 kg! m, 32 lbf-fi) (3%,, / ’/ 1,, , I ‘ 17-5 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL/INSTALLATION CBREOORA/ Remove the following CB5DUF‘VXA' two bolts [1] r wtre stay [2] 7 rear wheel speed sensor [3} Loosen the axle Hut [1], ralse the rear wheel off the ground Loosen the chem adjusters by tummg the lock nuts [2] g and adjusting nuts [3] so the wheel can be moved forward all the way. Push the rear wheel forward and dead the dnve chem [4] from the drlven sprocket Suppoh the cal/per Remove the followmg so It does not hang from the make hose Do not rwrs! the brake hose — axle nut _ settlng plate [5] — axle and settlng plate [6] — rearwheel 7 rear brake CallpeV [7] (from the swihgarm boss [8]} ~ chem adjusters [9] NOTE - Do not operate the brake pedal after removlng the wheel. Remove the following. e left Side collar (flange) [1] — rlght slde collar [2] 17-6 REAR WHEEL/SUSPENSION Installation is m the reverse order of removal NOTE - When lnstalllng the wheeL take care not to let the caliper come off the swxngarrn boss and not to damage the brake pads - The axle ls mstalled from the lth slde - CBRSOORA/CBSOOFA/XA: Betore Installing the rear wheel speed sensor [1], wlpe the sensor tlp and mounting area to remove any lorelgn material Adjust the drive chain slack (page 3714). CBRSOORA/ Check the air gap between the wheel speed sensor and CEEUOFA/XA pulser ring (page 1922) INSPECTION Turn the lnner race of each bearing with yourfmger‘ The bearings should turn smoothly and quletly Also check that the beanng outer race fits tightly In the hub. Replace the bearings it they do not turn smoothly, quletly‘ or ll they fit loosely In the hub Inspect the tollowmg parts for damage‘ abnormal wear. deformatlon or bend — rearaxle — spoke » wheel rim A driven sprocket (page 3-15) 7 damper rubbers (page 1778) Measure each part accordlng to REAR WHEEL/ SUSPENSION SPECIFICATlONS (page 1712). Replace any part it It l3 out of servrce limit, 17-7 REAR WHEEL/SUSPENSION DISASSEMBLYIASSEMBLY Dlsassemble and assemble the rear wheel as followmg illustratlon - For wheel balance servrce (page 1648) - Install each dust seal with the flat slde facrng out so that it IS flush with the hub and drlven flange end surfaces - Install the brake disc wtth the rotatan mark (arrow) lacing out. - lnslall the driven sprocket wrth the stepped surface facing out. DlSC BOLTS ax? ‘fl 42Nm(43kgtm‘ BRAKE DISC 31 mm) / PULSER RlNG (CBRSODRA/CBsOOFA/XA only) - DRIVEN FLANGE COLLAR Q“ WT / / r l DRlVEN FLANGE // z l f / 7% ,// avg» BEARING [6304UU) ~’ @‘l SEAL 4°? ,@ DRIVEN SPROCKET DUST SEAL §fl § \_ w; SPROCKET NUTS 9L BEARlNG(6303UU) : \ 108 N-rn (11 0kglm DlSTANCE COLLAR Vs _ 80 mm; 9? BEARING (6303UU) DAMPER RUBBERS O-RlNG @rfin BEARING REPLACEMENT WHEEL BEARING lnslall the bearing remover head [1] Into the bearing, ‘ [1 From the opposite side ofthe wheel‘ Install the bearing & remover shaft [2] and owe the bearing out of the wheel ‘ » hub TOOLS: Bearing remover head. 17 mm 07746-0050500 Bearing remover shaft 0774641050100 Remove the dlstance collar and dnve out the other beanng 17-8 REAR WHEEL/SUSPENSION Drive in a new right side bearing (brake disc Slde) squarely with the marked side facing up until it is fuin seated Instali the distance collar, Drive in a new left side bearing squarely with the ‘ marked Side Vacing up until it is fully seated ‘ TOOLS: [1] Driver 07749-0010000 [2] Attachment, 42 x 47 mm 07746-0010300 [3] Pilot, 17 mm 07746-004040!) DRIVEN FLANGE BEARING Drive out the driven flange collar [1] and the bearing [2], ‘ [1] ’ Place a new bearing [1] With the marked side facing down. Install the driven flange coiiar [2] into the bearing unlii it is fully seated TOOLS: [3] Driver 07749-001000!) [4] Attachment, 28 x 30 mm 079464 870100 [5] Pilot. 17 mm 077460040400 Drive in the driven iiange bearing/collar squarely With [2] the coiiarside racing down untii it IS fuily seated. TOOLS: i [6] Driver 07749-0010000 i [7] Attachment, 52 x 55 mm 07746-0010400 i: [8] Pilot, 20 mm 07746—004050!) 1 7-9 REAR WHEEL/SUSPENSION SHOCK ABSORBER/LINKAGE REMOVAL/INSTALLATION SHOCK LINKAGE Support the motorcycle using a hOlSt or equivalent and raise the rear wheel oft the ground Support the swmgarm and remove the following » three nuts [1] 7 three bolts [2] — shock arm plates [3] — under cowl bolt [4] r nut [5] 7 socket bolt [6] e shock link [7] ll; CBRSODR/RA shown: Installation is in the reverse order ol removal, NOTE - Install the shock link with the dust seals [1] facing the nght Slde ' Install each shock arm plate so the stamp [2] is lacing the left side and Its arrow laces forward, - lnstall all the bolts from the left side TORQUE: Shock linkage nut: 44 N-m (4.5 kgf-m, 32 Ibf-ft) Shock absorber mounting nut: 44 N-m (4.5 kgl-m, 32 lbf‘fl) SHOCK ABSORBER Remove the followtng — side covers (page 27) — regulator/rectifier (page 2077) - starter relay swttch [1] (page 679) CBRSOORA/CB500FA/XA: Disconnect the wheel speed sensor 2P (Gray) connector [2] and remove It lrom the I stay. Disconnect the brake light switch 2P (Black) connector [3] Release the heat guard rubber [4] from the relay swnch stays and remove the connectors out of the sheet through its Sllt 17-10 Remove lhe shock arm plales (page 1740) Remove the nut [1] and washer [2]. Remove lhe bolt [3] while supporting lhe shock absorber [4] securely, Remove the shock absorber our of the frame Installation is in the reverse order of removal NOTE - The mounting Doll is installed from the left srde, TORQUE: Shock absorber mounting nu‘: 44 N-m (4.5 mm, 32 lbf-fl) DlSASSEMBLY/ASSEMBLY Remove me pivot collars [11 and dust seals [2]. Apply grease is relating areas oltrre needle bearings Apply grease to the ilpS of new dusl seals. Install each dusl seal with lhe flat side facrng out so that ii is flush wnh lhe end surface Install lhe pivot collars. REAR WHEEL/SUSPENSION a»? 17-11 REAR WHEEL/SUSPENSION 17-12 INSPECTION Inspect the Iollowing parts of the shock linkage for damage, abnormal wear, deformation or crack v shock arm plates * Shocklink r plvotcollars r needle bearlngs inspect the followmg parts of the shock absorber for damage, abnormal wear. oil leakage or bend r damperunit r pivot bushing r needle bearing BEARING REPLACEMENT NOTE - For linkage bearing in the swungarm (page 17-16) SHOCK LINK Mark the shock link [i] side surface of the bearing flush ‘ side before removing to identify the bearing installation ‘ directron. Press the needle bearings out of the shock link using the special tools TOOLS: [2] Driver [3] Attachment, 22 x 24 mm [4] Pilot, 17 mm 07949-3710001 07745-0010800 07746-0040400 Apply grease to the dust seals lips and rotating areas of new needle bearlngs Place the shock link onto a hydraulic press WlII‘l the marking side [1] (which is marked in above step) lacing up. Press in each bearing [2] With the dust seal [3] (in the bearing) facmg up until the hydraulic press stops so that it is flush With the link surlace, using the special tools. TOOLS: [4] Driver [5] Attachment, 23 x 30 mm [6] Pilot, 17 mm 07749-001000!) 07946-1870100 07746-0040400 SHOCK ABSORBER Press the needle bearing out oi the shock absorber ' using the special tools TOOLS: [1] Driver [2] Attachment, 22 x 24 mm [3] Pilot, 17 mm 07949-3710001 07746—0010800 07746-0040400 Apply grease to rotating areas oia new needle bearing. Carefully press in the bearing [4] With the marked side facing up untll the depth from the pivot end surface is 5 O r 5 5 mm (0.20 7 022 in), using the same tools [i] i m 50—55mm \ji \Qkix‘ai REAR WHEEL/SUSPENSION SWI N GARM REMOVAL/INSTALLATION Remove the foilowing: 7 di’IVe chain cover (page 2-24) 7 rear wheel (page 17-6) » shock link plates (page 17-10) Remove Ihe two bohs [1] and clamps [2] Remove the pivol Hut [1] and the boil [2] Suppm (he caliper Move Ihe brake hose‘ speed sensor wvre and drive so U‘ does nor hang chain out of me way and remove lhe swingarm [3] from from me brake the frame "055 D” "or [Wm Installarion is in the reverse order of removai [he brake MOSS NOTE ~ The inOl bolt Is Inslaiied from the lefl side ~ Apply engine oil is Ihe rhreads and sealing sur'ace of the pivot nut. TORQUE: Swingarm pivot nut: 83 N-m (9.0 kgf-m, 65 mm) 17-13 REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY Disassemble and assemble the swingarm as following illustration. ~ Install each dust seal With the flat side facing out so that it is flush With the pivot end surface SNAP RlNG @ .fii BALL EEARlNGS (5202) DUST SEAL ya "a" RIGHT PIVOT COLLAR DlSTANCE COLLAR M Sui rfii NEEDLE BEARlNG Q /", V / / go? ,Jfiaq DUST SEAL LEFT PIVOT COLLAR \ \v, @ DRlVE CHAIN SLlDER NEEDLE BEARING ., E 9 DUST SEAL L”; ,@ SETTING PLATES 6:, LINKAGE PIVOT COLLAR TAPPlNG SCREWS 5.9 N'm (0.6 kg rri. 4 4 lbf-fl) INSPECTION Check the drive chain slider for wear or damage, The drive chain slider must be replaced il it is worn to the wear limit lndicalors [1]. Inspect the following parts for damage‘ abnormal wear, deformation, 7 swmgarm » pivot collars [1] — bearings ‘ 17-14 REAR WHEEL/SUSPENSION BEARING REPLACEMENT SWINGARM PIVOT BEARING Remove lhe snap ring [1]. Remove the ball bearings [1] uslng the special lools TOOLS: [2] Bearing remover head. 07936-KC10200 15 mm [3] Bearing remover shaft, 07536-KC10100 or 15 mm Bearing remover, 15 mm 07936-KC10500 (U.S.A. only) [4] Remover weight 07741-0010201 or 07936-3710200 (U.S.Ar only) or 07936-371020A (U.S.A. only) Remove the distance collar Press the needle bearing [1] oul of Ihe swingarm using 1' 7 V the special lools [3] TOOLS: or [41/[51/[51 [z] Remover attachment, 24 mm 07LMC-KV30200 4U 3A 0W) [3] Driver shaft 07946-MJ00100 USA. TOOLS: I [2] Bearing remover attachment 07GMD-KT70200 ‘ [4] Driver 07949-3710001 [5] Attachment, 24 x 25 mm 07746-0010700 [6] Pilot, 17 mm n714s-oo4o4oo l Apply grease to lhe rotating area of a new needle f bearing [1]. Caretully press the bearing in the left pivot With the ] marked Slde lacing up until the depth from the pivot end surlace is 50 r 60 mm (0 20 r 0.24 in), uslng the Speclal lools TOOLS: [2] Driver 07749-0010000 [3] Attachment. 32 x 35 mm 0774643010100 [4] Pilot, 25 mm 07746-0040600 REAR WHEEL/SUSPENSION Be Certain the snap ring is firmly seated in the groove Do not reuse it which could easily spin in the gmove install the distance collar [1] with the flange [2] lacung the needle bearing (left) side. i Apply grease to the rotating area 0! new ball bearings [1] Press the ball hearings in the right pivot with the marked Slde facing up until they are fully seated using the special tuols TOOLS: [2] Driver [3] Attachment, 32 x 35 mm {4] Pilot, 15 mm 07749-0010000 0774641010100 0774641040300 Install the snap ring [5] Into the groove with the chamlered edge lacing in. SHOCK LINKAGE BEARING Press the needle bearing Out of the swingarm using the special tools, 55760mm 0.22 » 0.24 TOOLS: ( m) [1] Driver [2] Attachment, 22 x 24 mm [3] Pilot. 17 mm 07949-3710001 07746-001080!) 07746-0040400 l y " z , Apply grease to the rotating area of a new needle bearan [4] ’2 / 4 /, Carefully press in the bearing With the marked slde lacing up until the depth from the pivot end surface is 5 5 r 6.0 mm (0.22 — 0.24 l”) using the same tools 17-16 18. HYDRAULIC BRAKE SERVICE lNFORMATION-- ~18-2 TROUBLESHOOTING ............................... ..13_2 COMPONENT LOCATION ------------------------ --1s.3 BRAKE FLUID REPLACEMENT] NR BLEEOmG ......................................... "18,5 BRAKE PAD/DISC .................................... ..13_7 FRONT MASTER CYLINDER ------------------- --18-8 REAR MASTER CYLINDER ------------------- --1a.1o FRONT BRAKE CALIPER ---------------------- --13-12 ........................ .. ....................................... “18,15 18-1 HYDRAULIC BRAKE SERVICE INFORMATION GENERAL Frequent Inhalation oi brake pad dust, regardless of material composition, could be hazardous to your health - Avoid breathing dust particles - Never use an air hose or brush to clean brake assemblies Use an OSHA-approved vacuum cleaner. Spitting brake fluid will severely damage instrument /enses and painted surface It is also harmful to some rubber parts, Be careful whenever you remove the reservoir cover: make sure the front reservoir is honzonla/ first. - This section covers service of the conventional brake components oi the brake system For Anti-lock Brake System (ABS; CBRSOORNCBSOOFA/XA) service (page 19-2), - The CBR500RA/CB500FA/XA models are equipped with the ABS however the brake lluid replacement procedure is performed in the same manner as in the ordinary air bleeding procedure Note that replacement and bleeding air tram the brake fluid in the ABS modulator is not necessary, as it is sealed in the modulator O A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc With a high quality brake degreasing agent. - Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid. they may not be compatible Never allow contaminates (dirt, water, etc )to get into an open reservoir. Once the hydraulic system has been opened, or it the brake feels spongy, the system must be bled. Always check brake operation before riding the motorcycle, CBR5OORA/CBSDOFA/XA. When the wheel speed sensor is removed, be sure to check the air gap between the wheel speed sensor and pulser ring after installing it (page 19-22). TROUBLESHOOTING Brake lever/pedal soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pad/disc Worn caliper pision seal Worn master piston cups Worn brake pad/disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged lluid passage Warped/deiormed brake disc Sticking/worn caliper piston Sticking/worn master piston Bent brake lever/pedal Brake lever/pedal hard - Clogged/restricted fluid passage . Sticking/worn caliper piston - Caliper not sliding properly - Worn caliper piston seal - Sticking/worn master piston ' Bent brake lever/pedal Brake drags - Contaminated brake pad/disc - Misaligned wheel ' Badly worn brake pad/disc - Warped/deiormed brake disc - Caliper not sliding properly ~ Clogged/restricted fluid passage - Sticking caliper piston 18-2 HYDRAULIC BRAKE COMPONENT LOCATION FRONT: CBRSDORA shown: 12 N'm(12 kgl-m. 9 Ibf'fi) 34 N-m (3.5 kgim. 25 mm) 34 N-m (3 5 kgl-m, 25 Ibf-h) 17 N m (1.7 kgl-m. 13 mm) CBRSODRA/CBSOOFA/XA my 30 N m (3,1 kgivm, 22 mm) 18-3 HYDRAULIC BRAKE REAR: CBR5OORA shown 37 N m (3 s kgf-m, 27 let) 12 N m (1.2 kgf-m‘ 9 lbfi ft) 34 N-m (3,5 kgf‘m. 25 \bf-ft) 17 N m (1.7 kgfvm, 13 mm) (2,2 kglm.16lbifl) 18-4 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING Forfmnlbrake Turn the handlebar so the reservoir is level cBRsooeiéA shown. Remove the lottowlng 7 two screws [1] v resen/oircap [2] r set plate [3] 7 diaphragm [4] Forreal brake Remove the mounting bolt [1] and reservoir [2] from the stay Take care In imi Remove the lollowing allow fluid to spiii — two screws 3 ham the reservoir [ ] reservoir cap [4] — set plate [5] r diaphragm [6] Temporarily install the reservoir onto the stay With the mounting bolt through the locating pin hole [7] and secure it using a 6 mm nut [8] so the reservmr is level Connect a bleed hose [1] to the caliper bleed valve [2] Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out ol the bleed valve. Close the bleed valve BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir to the upper level line [1] With DOT A brake fluid item a sealed container Connect a commercially available brake bleeder to the bleed valve, Operate the brake bleeder and loosen the bleed valve Checkme fluid/evel If an automatic refill system is not used‘ add fluid when often while bleedlng the fluid level in the reservoir is low. in pleverit air from bet/7g pumped mm the system Perform the bleeding procedure until the system is completely flushed/bled. Close the bleed valve and operate the brake lever or pedal ti it still feels spongy‘ bleed the system again HYDRAULIC BRAKE If the brake bleeder is not available, use the following procedure. Connect a bleed hose to the bleed valve. Pump up the system pressure with the brake lever/ pedal until the lever/pedal reSistance is lelt. Do not release the l Squeeze the brake lever or depress the brake pedal brake leverorpedal all the way. and loosen the bleed valve t/4 of a turn. will the bleed valve Wait several seconds and then close it. has been closed. 2 Release the brake lever/pedal slowly and wait several seconds afler it reaches the end of Its travel. 3. Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose. After bleeding the system completely, tighten the bleed valve to the specified torque TORQUE: 5.4 N‘m (0.6 kgr-m, 4.0 mm Fill the reservoir to the upper level line With DOT 4 brake fluid Forfrohrbrake' Install the diaphragm, set plate. reservoir cap and tighten the screws to the specified torque. TORQUE: 1.5 N-m (0.2 kgf—m, 1.1 mm) Forrearblake' Carefully remove the reservoir [1] from the stay by removing the 5 mm nut [2] and mounting bolt [3]. Take care to not Install the diaphragm [4], set plate [5], reservoir cap [6] allow fluld to spill and tighten the screws [7] to the specitred torque "0m "’9 New” TORQUE: 1.5 N-m (0.2 kgfvm, 1.1 mm) Install the reservoir, aligning the locating pin with the hole in the stay and tighten the mounting bolt. 18-6 HYDRAULIC BRAKE BRAKE PAD/DISC BRAKE PAD REMOVAL] INSTALLATION NOTE Check the fluid - if you replace the brake pads with new ones. push levelinlhe the caliper pistons all the way in by pushing the reservoir as this caliper body inward to allow installation of new brake operation causes pads beinre removmg the pads. the fluid level to Always replace the brake pads in pairs to ensure rise even disc pressure, FRONT Do no! operate the Remove the pad pin [1] by pushing the pads against the brake leverafter pad spring, then the brake pads [2] out of the caliper removing the pads CBRSOORA shown Make sure the pad spring [1] is installed in position f (page 1843) Be sure the stopper ring [2] on the pad pin is in good condition and replace it with a new one ii necessary Coat the stopper ring with silicone grease Install the pads [3] so that their ends are set in the retainer [4] properly install the pad pin [5] by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper body Tighten the pad pin to the speCified torque, TORQUE: 17 N‘m {1‘7 kgf-m,13lbf-ft) Operate the brake lever to seat the caliper pistons against the pads. REAR Loosen the pad pin [1] and remove the caliper bolt [2]. Do noiaperaze the Pivot the caliper body up, and remove the pad pin and brake pedal after brake pads [3] removing the pads. HYDRAULIC BRAKE Make sure the pad spring [1] ts Installed in posltton (page 1844) Be sure the stopper ring [2] on the pad pin lS ll’l good condltlon, and replace lt Wlth a new one lf necessary Coat the stopper nng Wllh sillcone grease Install the pads [3] so that their ends are rest on the pad retainer [4] properly Lower the caliper body and loosely lnstall a new caliper bolt [5]. lnstall the pad pm [6] by pushan the pads against the pad spring to allgn the pad pll’l holes tn the pads and caliper body Tlghten the caliper bolt to the specllled torque TORQUE: 22 N-m (2.2 kgf-m, 1S lbf-ft) Tighten the pad pin to the specified torque, TORQUE: 17 N-m (1.7 kgf'm,13|bl~ft) Operate the brake pedal to seat the caliper plSlDl’I agatnst the pads BRAKE DISC INSPECTION Visually Inspect the brake dlSC for damage or cracks, Measure the brake dISC according to HYDRAULIC BRAKE SPECIFlCATIONS (page 142) and replace ll necessary FRONT MASTER CYLINDER When mmovmg me 0/! bolt, cover the end or the brake hose to prevent contamination REMOVAL/INSTALLATION Drain the brake lluid Vrom the front brake hydraulic system (page 1375) CBRSOOR/RA show Remove the followmg’ r nght reawtew mirror (CBSOOF/FA/X/XA) (page Z-‘l l) — brake llght switch connectors [1] r all bolt [2] r seallng washers [3] r brake hose [4] 18-8 HYDRAULIC BRAKE » two bolts [’l] — master cylinder holder [2] — master cylinder [3] Installation is in the reverse order of removal. NOTE - Replace the sealing washers with new ones - Install the master cylinder holder With the "UP" mark [4] facmg up ‘ Align the edge of the master cylinder with the punch mark on the handlebar. and tighten the upper bolt first then tighten the lower bolt - Be sure to set the eyelet JOIHI into the groove when connecting the brake hose TORQUE: Front master cylinder holder bolt: 12 NM (1.2 kgf-m, 9 lbf-ft) Oil bolt: 34 NM (3.5 kgf-m, 25 int) Fill and bleed the front brake hydraulic system (page 18-5). DISASSEMBLY/ASSEMBLY Disassemble and assemble the front master cylinder as following illustration. - Do not allow the piston cup lips to turn inside out - Install the snap ring With the chamfered edge facing the thrust load side and be certain it is firmly seated in the groove. Do not reuse the snap ring which could easily spin in the groove - Align the sWitch boss With the master cylinder hole properly - When tightening the pivot nut, hold the pivot bolt securely. a SECONDARY PISTON CUP PRIMARY PISTON CUP (Grooves) PIVOT BOLT 1 o N m (o 1 kgf~m. 0 7 Inf-ft) m 010 g (0004 Oz) MASTER CYLINDER e MASTER PISTON SPRING ‘\ BRAKE LIGHT SWITCH BRAKE LEVER (fit PlvoT NUT BRAKE LIGHT SWITCH SCREW 0 ‘lO 9 (0.004 02) 5.9 N rn (0.6 kgf m. l 2 N M01 kgl my 0'9 lbf'ft) 4 4 Ibf ft) 18-9 HYDRAULIC BRAKE INSPECTION Check the following parts Ior scoring‘ scratches deterioration or damage — mastercyllnder — masterpistpn — piston cups 7 spring — boot Measure the parts according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-12) and replace it necessary REAR MASTER CYLINDER REMOVAL/INSTALLATION Dram the brake fluid Irom the rear brake hydraulic system (page 1&5) Remove the following: 7 nght side cover (page 2-7) 7 rear brake reservoir (page 1876) When Iemovmg the Disconnect the brake hose [1] by removing the Oil boil or! bolt, cover the [2] and sealing washers [3] end Dime brake hose ta preven! Comammalian. Support the right rider footpeg bracket [5] securely and remove the bracket bolts [6], Loosen the master cylinder mounting bolts [4] Remove the followtng. 7 cutterpin [1] 7 joinlpln[2] 7 mounting bolts [3] — maslercytinder[4] Installation IS in the reverse order of removal, NOTE ~ Replace the sealing washers and cutter pin With new ' ones - Be sure to rest the eyelet stopper pin against the stopper when tightening the Oil bolt TORQUE: Rider footpeg bracket bolt: 37 N-m (3‘8 kgf‘m, 27 Ibl-ft) Rear master cylinder mounting bolt: 12 N-m (1.2 kgf-m, 9 Ihf-ft) Oil bolt: 34 N-m (3,5 kgf~m, 25 Ibf-ft) Fill and bleed the rear brake hydraulic system (page 18- 5) 18-10 HYDRAULIC BRAKE DISASSEMBLYIASSEMBLY Disassemble and assemble the rear master cylinder as lollowmg illustration - Adiusl the push rod length between the center of the lower mounting bolt hole and center ol the joint pin hole when Installing the push rod Joint. ' Do not allow the piston cup lips to turn inside out. - install the snap ring with the chamlered edge facing the thrust load side and be certain it is lirmly sealed in the groove. Do not reuse the snap ring which could easily Spli’l In the groove. SNAP RING PUSHROD JOINT m , 010 g (0.004 02) gm o-RING '39 a JOINT SCREW V l 5 N-m (0,2 kgfvm, 1 l lot-fl) MASTER CYLlNDER l l SPRING 0 10 g (0 004 oz / . BOOT ) _ / / PRlMARY PISTON I / CUP (Grooves) / 3 / RESERVO'R HOSE JO'NT SECONDARV PISTON CUP % a MASTER PlSTON PUSH ROD When the push rod has been disassembled. adiust the *"7 push rod length so that the distance from the center cl ’7 the master cylinder lower mounting bolt hole to the ‘ center ol the Joint pin hole IS standard length as shown. If the length is adiusted to the longer position, make sure that the lower end of the push rad thread [’l] is Visible inside the joint. After adjustment, tighten the Joint nut [2] to the specified torque. TORQUE: Rear master cylinder push rod joint nut: 17 N-rn 11.7 kgi-m, 13 lbf-ft) I (62665; 52.30er . e m 18-11 HYDRAULIC BRAKE INSPECTION Check the tottowmg parts for scoring, scratches detericratton or damage r mastercyhnder 7 master ptstofl 7 piston Cups — spnng — boot Measure the parts according to HYDRAULIC BRAKE SPECIFICATlONS (page 1712) and replace If necessary. FRONT BRAKE CALIPER REMOVAL/INSTALLATION Dram the brake fluid from the front brake hydrauhc system (page 1875) CBRSDORA/ Remove the foHowmg. “MFA” r boltmand vm‘e ctampm 7 two bolts [3] and front wheet speed sensor [A] When removing the e brake pads [1] (page 1&7) ar/bu/t‘ (roverthe » on butt [2] end ofbrake hose » sealmg washers [3] m prevent — brake hose [4] contam/naz/on ~ mounting butts [5] — brake cehper [6] lnstaHatton ts tn the reverse order of removat NOTE ‘ Replace the brake caliper mountth bolts and ‘ seating washer: with new ones i 0 Be sure to rest the eyetet stepper pm against the caltper body when lightening the oil butt. ~ CBRSOORA/CBSOOFA/XA. Before instalting the wheet speed sensor‘ wupe the sensor Up and mounhng area to remove any foreign matenat TORQUE: Front brake caliper mounting bolt: 30 N-m (3.1 kglvm, 22 lbf‘ft) Oil bolt: 34 N-m (3.5 kgf—m. 25 lbl-fl) 18-12 HYDRAULIC BRAKE am CALIFER PIN BLEED VALVE s 4 N-m (o e Kgim 4 o ibrm —»§ 695’} ($1 STOPPER RiNG BRAKE PAD PIN 17 N rn (1,7 Kgf mi i3 ibi'fl) DISASS EMBLYIASSEMBLY Disassembie and assembie the (rent brake caliper as foilowmg iiiustratiori For brake pad removal/installation (page 1877). - Mark the pistons to ensure that they are rainsialled in their original iocations, - When removing the caiiper pistons with compressed air, place a shop towel over the pistons to prevent damaging the pistons and caliper body. Do not use high pressure or bring the nozzie too close to the fluid inlet. - lnstail the pistons with the opening toward the pads. W 04 9 (0,01 02) CALIPER PiN BOOT a? ~‘fl DUST SEAL 22 N rrl (2 2 kgl-m‘ 16 ibl-fl) CALIPER BRACKET AV/ \’ K PAD RETAINER" 3, mowiomoz) s 9? PISTON SEAL PAD SPRING BRACKET PiN BRAKE PADS COT ‘Appiy Honda Bond A or Honda Hand Grip Cement (U SA. oniy) io the retainer seating surface INSPECTION Check the foiiowing parts for scoring. scratches deterioration or damage. 7 calipercylinders r caliper pistons Measure the parts according to HYDRAULIC BRAKE SPECiFiCATIONS (page 1712) arid replace if necessary 18-13 HYDRAULIC BRAKE REAR BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the rear brake hydraulic 5 system (page 1875) When Iemuvrng [he — oil bolt [1] Dilbuir covering — sealing washers [2] end ofbrake hose yo — brake hose [3] prevent — brake pads (page 18-7) contamination — brake caliper [4] — caliper pin boot [5] installation l5 in the reverse order ol removal NOTE - Replace the and sealing washers with new ones, - It the pad retainer [6] was remuved, apply Honda Bond A or Honda Hand Grip Cement (U.S.A, only) to the retainer seating surface - Apply 0 4 9 (0.0102) oi silicone grease to the sliding area at the caliper pm bolt - Be sure to rest the eyelet stopper pin against the caliper body when tightening the oil bolt TORQUE: Oil bolt: 34 N-m13,5 kgf-m, 25 lbf-ft) Fill and bleed the rear brake hydraulic system (page 18- DISASSEMBLYIASSEMBLY Disassemble and assemble the rear brake caliper as following illustration. - When removing the caliper piston wrth compressed air, place a shop towel over the piston to prevent damaging the piston and caliper body Do not use high pressure or bring the nuzzle too close la the fluid inlet ~ Install the piston with the opening toward the pads é“? m w, E DUST SEAL \fl PISTON SEAL 54Nm(06kglm 40lblft) {y/ CALIPER PIN BOLT 27 N m (2,8 kglvm, 20 mm) BLEED VALVE - ' / {*2 _ 7 ‘ STOPPER RlNG m afiw/ it 2; \ BRAKE PAD PtN 17 N m (1.7 kgr-m. 13 let) CALlPER SLEEVE SLEEVE BOOT E 0.4 g (cm oz) BRAKE PADS PAD SPRING HYDRAULIC BRAKE INSPECTION Check the following parts for scoring. scratches, deterioration or damage 7 oailpercylinder 7 callperpiston Measure the parts according to HYDRAULiC BRAKE SPECIFICATIONS (page 1712) and repiace If necessary. BRAKE PEDAL REMOVAL/INSTALLATION Remove the right slde cover (page 277) Support the right rider footpeg bracket [1] secureiy and remove the bracket boils [2] Remove the toiiowihg 7 swttch springm » return sprlng [2] 7 cotter pm [3] 7 Joint pin [4] 7 snap ring [5] 7 washer [61 7 brake pedai [7] instaiiation is in the reverse order of remove! NOTE ' Appty grease to the pedai pivot sliding area (grease groove) - Instaii the snap ring with the chamfered edge facing ‘ the thrust ioad side and be certain it is firmiy seated I; in the groove. Do not reuse the snap ring which could easily spin in the groove. - Repiace the cotter pin with a new one - instali the each spring in the direction as shown TORQUE: Rider foatpeg bracket bolt: 37 N-m (3.8 kgf-m, 27 lbf-I't) 18-15 MEMO 19. ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RA/CBSOOFAIXA) SERVICE INFORMATION ------------------------- ~19-2 SYSTEM LOCATION ................................. ..19_3 SYSTEM DIAGRAM .................................. "194 ABS TROUBLESHOOTING INFORMATION .......................................... ..19_5 DTC INDEX ................................................ "19.9 ABS INDICATOR CIRCUIT TROUBLESHOOTING ............................ ..1g_11 ABS TROUBLESHOOTING- "19-13 WHEEL SPEED SENSOR ...................... ..19_22 ABS MODULATOR ................................. ..19_24 19-1 ANTI-LOCK BRAKE SYSTEM (ABS; CBRSOORAICBSOOFAIXA) SERVICE INFORMATION GENERAL - The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing. the excessive voltage may damage the control unit. Always turn off the ignition switch belore servicing. Spilling brake fluid WIll severely damage plastic parts and painted surfaces. it is also harmful to some rubber parts. This section covers service ol the Anti-lock Brake System (ABS) For other service (conventional brake) of the brake system. see Hydraulic Brake section (page 18—2). The ABS control unit is integrated in the modulator. Do not disassemble the ABS modulator. Replace the ABS modulator as an assembly when it is laulty. The ABS control unit performs ore-start sell-diagnosis to check whether the ABS functions normally until the vehicle speed reaches 10 km/h (6 mph), After prestart sell-diagnose. the ABS control unit monitors the ABS functions and vehicle running condition constantly until the ignition sWitch is turned OFF (ordinary sell-diagnosis) When the ABS control unit detects a problem. it stops the ABS function and sWItches back to the conventional brake operation, and the ABS indicator blinks or stays on, Take care during the test-ride. Read "ABS Troubleshooting Information" carefully, inspect and troubleshoot the ABS system according to the troubleshooting flow chart. Observe each step of the procedures one by one Write down the DTC and probable faulty part before starting diagnosis and troubleshooting, Use a fully charged battery. Do not diagnose with a chargerconnected to the battery. After troubleshooting. erase the DTC and perform the prerstart self-diagnosis to be sure that the ABS indicator is operating normally (page 195). Troubles not resulting from a laulty ABS (e.g, brake disc squeak, unevenly worn brake pad) cannot be recognized by the ABS diagnosis system. When the wheel speed sensor and/or pulser ring is replaced. be sure to check the air gap (page 1922). The lollowing color codes are used throughout this section Bl = Black G = Green Lg : Light Green R : Red Y = Yellow Br = Brown Gr = Gray 0 7 Orange V = Violet Bu : Blue Lb = Light Blue P = Pink W = White TOOLS SOS service connector Test probe (2 required) 070PZVZY30100 O7ZAJVRDJA1‘lO 19-2 ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RA/CB500FAIXA) SYSTEM LOCATION CBRSOORA shown. FRONT WHEEL SPEED SENSOR 19-3 ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RAICB§00FAIXA) SYSTEM DIAGRAM MNN FJSE Box‘ FUSE CLO KYURN gm, \,., m N R m R w R/Eh FRONT BRAKE I | shTsww'cH mum mm magam m musmny uwswm now: 5A; To max 5V P‘Bu -—J 5 cm GEL» ERAKE I new m ‘ “We” Aasmonmmw '63) (9-1) '— AESMAW m h I 6 (my I R’E' N R'E —. 7 K3 I a r r I ? <6 t 6 2) _\ ABS -[ l+ we u._ om, __®WD‘WOR — “3 M r®1 PUMP MmoR coMewmoN METER : ‘ W" : (rs-w R N WW —1 a MRoB I574) schqu VALVE (3:: 3' I - - » - - - - - - - - » - - - (M I a“~—_-a wwa l WE s4zE .‘ (My <44 472) O : |——w_ FROM PULSER we RE” WHEEL ‘24) SL7LG SENSOR O REAR PULSER mm: (@Mzra) sw mack av Brawn Bu time 6 Green a Ovange a Punk R Red x v (@y n: m Short leuwr ah m readwvg D'C LU? mm v While ABSMODULMORHEP(E‘ack:CONNECYUNJMODULATOR SIDE) y mm, 19-4 ANTI-LOCK BRAKE SYSTEM (ABS; CBRSOORAICBSOOFAIXA) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY or ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the associated part can be detected by reading the DTC. When the motorcycle is running. pulse signals generated at the front and rear wheel speed sensors are sent to the ABS control unit When the vehicle speed reaches approXimater 6 km/h (4 mph), the ABS control unit operates the pump motor to check it. When the vehicle speed reaches 10 km/h (6 mph). the ABS control unit turns off the ABS indicator ifthe system is normal and the pre-start self-diagnosis is completed it any problem is detected, the ABS indicator blinks or comes on and stays on to notify the rider of the problem, The self-diagnosis is also made while the motorcycle is running, and the ABS indicator blinks when a problem is detected. When the ABS indicator blinks. the cause of the problem can be identified by reading the DTC (page 1976). if the ABS indicator does not come on when the Ignition swttch is turned ON‘ or the ABS indicator stays on after the ore—start self» diagnosis is completed although the ABS system is normal. the ABS indicator circuit may be faulty. Follow the troubleshooting (page 19-11) Pro-start selfrdiagnosis when the system is normal IGNITION ON SWITCH OFF __I Running ----------------------------- - - ENGINE 510p Start VEHlCLE 0 6 km/h (4 mph) or above SPEED PUMP 0N MOTOR OFF ' ON - Rania/arm OFF __I I__ Pre-start settdiagnosis is completed at ‘10 km/h (6 mph) PRE-START SELF-DIAGNOSIS PROCEDURE (Daily check) 1 Turn the ignition switch ON with the engine stop switch “0" . Make sure the ABS indicator comes on. Start the engine. . Ride the motorcycle and increase the vehicle speed to approximately 10 km/h (6 mph), The ABS is normal it the ABS indicator goes off. cream 19-5 ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RA/C8500FA/XA) MCS INFORMATION - The MCS can read out and erase the DTC How to connect the MOS Remove the (allowing » CBRSDORA/CBSOOFA, front seat (page 2-6) — CBSOOXA seat (page 2-6) Turn the ignition switch OFF Remove the DLC [1] lrom the dummy connector [2], Connect the MOS to the DLC Turn the ignition swttch ON With the engine stop switch "(2" and check the DTC DTC READOUT NOTE - The DTC is not erased by turning the ignition switch OFF while the DTC is being output, Note that turning the Ignition switch ON again does not indicate the DTC. To show the DTC again, repeat the DTC readout procedures from the beginning. Be sure to record the indicated DTC(s). After diagnostic troubleshooting erase the DTC and perform the prerstart SeIIrdlagHOSIS procedure to be sure that there is no problem in the ABS (page 1975). - Do not apply the brake during DTC readout. Connect the MCS to the DLC (page 19-6) Read the DTC and follow the DTC index (page 19-9). - II the M08 is not available, perform the iollowmg Reading DTC with the ABS indicator Remove the following: 7 CBRSOORA/CBSOOFA. front seat (page 26) — CBSOOXA seat(page 276) Turn the ignition smtch OFF Remove the DLC [‘l] from the dummy connector [2] and short the DLC i terminals using the speCial tool TOOL: [3] SCS service connector 07DPZ-ZY30100 CONNECTION: Brown — Green Turn the ignition switch ON With the engine stop sWitch to “0" The ABS indicator should come on 2 seconds (start signal) (then goes off 36 seconds) and starts DTC indication. The DTC is indicated by the number 0! the times of the ABS indicator blinking If the DTC is not stored, the ABS indicator stays on. 19-6 ANTI-LOCK BRAKE SYSTEM (ABS; CBRSODRAICBSOOFAIXA) DTC INDICATION PATTERN NOTE ‘ The ABS indicator Indicates the DTC by blinking a specified number of times. The Indicator has two types of blinking. a long blink and short blink The long blink lasts for l 3 seconds, the short blink lasts for 0.3 seconds. For example. when one long blink is followed by two short blinks. the DTC is 1»Z (one long blink = 1 blink, plus two short blinks = 2 blinks) ' When the ABS control unit stores some DTCs the ABS indicator shows the DTCs in the order from the lowest number to highest number. For example. when the ABS indicator Indicates DTC 172, then Indicates DTC 273. two failures have occurred. IGNlTION ON ' SWITCH OFF J 11.3 sec. ‘l.3 1 3 569 sec Pattern repealed 2 sea 4H— 03 sec, _pv' « ‘ : . ‘ i . 5 ABS 0” INDICATOR OFF _ DTC start —> 4—- 4—u —>—4—v 5‘9"?" 0.4 sec 3 6 sec 0 5 sec, c._‘,__‘/ \___fl__.._x Lowest number DTC Highest number DTC (Example. 1-2) (Example 23) When the DTC ls not stored, 2 sec. 3 6 sec. ‘——>‘<——-’> ABS 0“ ’ " lNDlCATOR OFF _[ ERASING STORED DTC NOTE - The stored DTC can not be erased by simply disconnecting the battery negative cable. Erase the DTC With the MOS while the engine is stopped How to erase the DTC without M65 1. Connect the SOS sewice connector [1] to the DLC (page 19-6) *7 2 While squeezing the brake lever, turn the ignition switch ON with the engine stop switch to "O" The ABS indicator should come on for 2 seconds and go off " 3 Release the brake lever immediately after the ABS indicator goes off. The ABS indicator should come on. 4. Squeeze the brake lever immediately after the ABS indicator comes on. The ABS indicator should go off. l 5. Release the brake lever immediately after the ABS indicator goes 0" l When the DTC is erased. the ABS indicator blinks 2 times and stays on. if the ABS indicator does not blink 2 times. the selfrdiagnostic memory has not been erased so try again. 6. Turn the Ignition switch OFF and remove the 305 service connector irom the DLC. Install the following: — CBRSOORA/CBSOOFA: front seat (page 2—5) — CBSOOXA: seat (page 2—6) 19-7 ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RAICBSOOFAIXA) CIRCUIT INSPECTION INSPECTION AT ABS MODULATOR CONNECTOR Remove the ABS modulator cover (page 2725). Turn the lgnrtion swrtch OFF Dlsconnectlng procedure: Turn the lock lever [1] to this sude while pressing the lock tab [2] to release rt. Be sure the lock lever ls turned all the way and dlsconnect the ABS modulator 18F (Black) connector [3]. Connecting procedure Be sure to seat the lock lever agarnst the Wire side ol the connector fully Connect the ABS modulator 18F (Black) connector by pressan It stralght at the area as shown (arrow) untll the lock tab cllcks Make sure the connector Is locked securely ' Always clean around and keep any foreign matenal away from the connector before dlsconnectlng it A faulty ABS is often related to poorly connected or corroded connectlons Check those oonnectlons before proceeding ln testan at ABS modulator 18F (Black) connector termlnals (wrre harness slde: except No 9 and No. 18 terminals), always use the test probe [1]. lnsert the test probe into the connector termlnal, then connect the digltal multlmeler probe to the test probe, TOOL: Test probe 07ZAJ-RDJA110 TERMlNAL LAYOUT ‘ 19-8 ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RA/CB500FAIXA) DTC INDEX NOTE’ - The ABS indicator might blink in the followmg cases. Correct the faulty part. 7 Incorrect tire pressure 7 Tires not recommended for the motorcycle were installed (incorrect tire size) 7 Deformation of the wheel or me. ~ The ABS indicator might blink while riding under the following conditions. This is temporary failure Be sure to erase the DTC (page l9-7). Then, testrride the motorcycle above 30 km/h (19 mph) and check the DTC (page 19-6) Ask the rider for the riding conditions in detail when the motorcycle is brought In for inspection. 7 The motorcycle has continuously run bumpy roads. - The lront wheel leaves the ground for a long time when riding (wheelie) — Only either the front or rear wheel rotates » The ABS operates continuously, e The ABS control unit has been disrupted by an extremely powerful radio wave (electromagnetic interference) L DTC Function failure fietefheogi: Symptom/Fail-safe function Riser ‘ l 7 ABS indicator malfunction 77 7 ‘ 7 ‘ - ABS indicator never comes77‘ 19717 ( - ABS modulator voltage input line 7777 7 ON at all 7 7 7 7 l ( r _ - Indicator related wires ; - ABS indicator stays ON at l ( 1 . Combination meter ‘ l at 19 1 1 1 - ABS modulator ' l ~ IABS MAlN fuse (7.5 A) 777 i 77 77 7 l 7 ‘ Front wheel speed sensor circuit malfunction i ( - Stops ABS operation 1-1 (open circuit) l o 0 19-13 r O Wheel speed sensor or related eres 7 77 77 7 7 7 Front wheel 5 eed sensor malfunction 7i ‘ - Stops ABS operation l l p l 172 ( - Wheel speed sensor, pulser ring or related 1 O ‘ wires ( 7 77 - Electromagletiflerfirencei 77_ 7 7 7 77 7 77 7 77 74 '7 (_3 T Rear wheel speed sensor circuit malfunction O l O - Stops ABS operation 7 i ~ Wheel speed sensor or related Wires7 7l ‘ 7 (7 i 7 7 ‘ Rear wheel speed sensor malfunction ( l l - Stops ABS operation 1 ( 174 . wig-3: speed sensor, pulser ring or related ‘ O ‘ 1945 ‘ l7 ‘ - Electromagnetic interference7 7 ‘ 7 l 1 Front or rear wheel speed sensor circuit ( ‘ - Stops ABS operation ‘ 1.5 malfunction (short Circuit) l o i 0 19717 i i ‘ - Wheel speed7§ensor or related wires 7 ( 777777 7 77 7‘ 77 Front pulser ring ‘ - Stops ABS operation ‘ 7 ‘ ‘ 2-1 ‘ - Pulser ring or related wires7 r 7 O 7 ‘ 19 13 7 l Rear pulser ring l l - Stops ABS operation _ ‘ l 273 7‘ - Pulser ring or relat7ed wires 7 77 7 7 7 (7 19 15 ‘ 1 3-1 Solenoid valve malfunction (ABS modulator) ( 7 ( - Stops ABS operation ‘ ‘ # r ‘ ‘ ‘ l i O 0 19-19 ‘ i l l r l Front wheel Ioch 7 7'7 l O 77St3ps ABS operation 7 7 - Riding condition 7 7 i I y 194 3 ‘ Front wheel lock (Wheelie) ‘ O 7 7 y - Riding condition 77 7‘77 ‘ 7 77 77 7 473 Rear wheel lock ( O r - Stops ABS operation t 19715 i l - Ridan condition 7 ( l 7 7 l i i Pump motor lock l l . Stops ABS operation ‘ l 571 - Pump motor (ABS modulator) or related i o ( O ( 19719 ( Wires ( ( (7 i - ABS M. fuse (30 A) i ( ‘ Power supply relay malfunction ( - Stops ABS operation l - Power supply relay (ABS modulator) or ‘ ( 7 l ‘ 5'4 related wires t o ‘ O ( l 19 19 l l l . A7Bs M. fuse (30 A) 7 7 7 77 7 7 ANTI-LOCK BRAKE SYSTEM (ABS; CBRSOORAICBSOOFAIXA) DTC Function failure i Refer i ‘ ‘ B i “If v ‘ Power circuil under voltage i 671 - Input voltage (100 low) 0 ‘ ~ ABS MAiN fuse (7‘5 A) ‘ 7 19-20 6A2 ‘ Power Circul! over Voliage " O - Stops ABS cperaiion ~ inpui voltage ((00 high) 777 i 74 TireT-rnaifunction ' O - Stops ABS operation ‘ 194.] ~ ngize 7 ' ' ABS control unit 7' - Stops ABS operalion i i 8—1 ' ABS control unit malfunction (ABS 0 19721 i modulator) i (A) Prevslan sew-diagnosis (page 195) (B) Ordinary selfldiagnosis: diagnoses while the motorcycle is running (after pre—slari self-diagnoss) 19-10 1. ABS INDICATOR STAYS 0N (Indicator does not go off when the motorcycle is running) 1. ANTI-LOCK BRAKE SYSTEM (ABS; CBRSOORAICBSOOFAIXA) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) NOTE - Before starting this Inspection, check the initial operation of the combination meter (page 2140) Indicator Operation Inspection Turn the ignition switch OFF. Disconnect the ABS modulator connector (page 19-8). Turn the ignition switch ON with the engine stop Switch "0". Check the ABS indicator. Does the ABS indicator come on? YES — Faulty ABS modulator N0 — GO TO STEP 2. mp (Black) , Indicator Signal Line Short Circuit Inspection Turn the Ignition switch OFF. Check for continuity between the wire harness side ABS modulator 15F (Black) connector [1] terminal and ground, ‘ TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: 13 — Ground i Is there continuity? YES NO — Short circuit in the Orange/blue wire — Faulty combination meter Service Check Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator connector (page 19-8). Check for continuity between the wire harness side ABS modulator 13F (Black) connector [1} terminal and ground, TOOL: Test probe iBP OTZAJ-RDJA110 i CONNECTION: 14 — Ground Is there continuity? YES NO — Short circuit In the Brown Wire - GO TO STEP 2 ‘ [1] (Black) “1 (Terminal side oi the Wire harness) Terminal side of the wire harness g‘i a, ) 19-11 ANTI-LOCK BRAKE SYSTEM (ABS; CBRSDORAICBSOOFAIXA) 2. . Fuse Inspection Indicator Signal Line Open Circuit Inspection Short the Wire harness side ABS modulator 18F 1 (Black) connector [1] termlnal to the ground with a l 3 )umper wire {2]. TOOL: Test probe O7ZAJ-RDJA110 CONNECTION: 13 — Ground Turn the Ignition swrlch ON With the engine slap swrtcn “C” Check the ABS lndlcator. Does it go off? — GO TO STEP YES 3 (Terminal Side or the wire harness) J N0 — ' Open clrcult in the Orange/blue wire 7 N7 , - Faulty COmblnallDl’l meter (ll the Orange/blue wtre l5 OK) . Modulator Ground Line Open Circuit Inspection Turn the ignition switch OFF. Check for continuity between the Wire harness side ABS modulator ‘lBP (Black) connector [1] terminal and ground CONNECTION: 9 — Ground Is there cantinuity? YES — GO TO STEP 4 N0 — Open CerLllt in the Green/yellow wrre Remove the iollowmg — CBRSOORA/CESOOFA: front seat (page 276) ~ CBSOOXA seat (page 276) Remove the fuse box cover [1] from the Iuse box 2 (right) by releasing the two tabs [2], Check the ABS MAIN ruse (7.5 A) for blown Is the fuse blown? YES — GO TO STEP 5 NO — GO TO STEP 6. 19-12 ANTI-LOCK BRAKE SYSTEM (ABS; CBRSODRAICBSOOFA/XA) 5‘ Power Input Line Short Circuit Inspection With the ABS MAlN fuse (7 5 A) removed, check for continuity between the Wire harness side ABS i modulator iBP (Black) connector [i] and ground TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: 7 — Ground Is there continuity? YES NO — Short circuit in Red/black wire — intermittent failure Replace the ABS MAIN fuse (7,5 A) with a new one. and recheck. Power Input Line Open Circuit Inspection install the ABS MAIN tuse (7.5 A). Turn the ignition switch ON with the engine stop swrtch “0". Measure the voltage between the wire harness Side ABS modulator 18F (Black) connector [i] terminal and ground. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: 7 (+) - Ground (—) Is there battery voltage? YES — Faulty ABS modulator N0 — Open circuit in Red/black Wire ABS TROUBLESHOOTING NOTE Perform Inspection With the ignition swrtch OFF, unless otherwise specified. - All connector diagrams in the troubleshooting are viewed from the terminal side, - Use a tully charged battery. Do not diagnose with a charger connected to the battery. When the ABS modulator assembly is detected to be taulty, recheck the Wire harness and connector connections closely betore replacing it. ~ After diagnostic troubleshooting, erase the DTC (page 197) and test-ride the motorcycle to check that the ABS indicator operates normally during pre- start self-diagnosis (page 1975) DTC 1-1, 1-2, 2-1, 4-1 or 4-2 (Front Wheel Speed Sensor Circuit/Front Wheel Speed Sensor/Front Pulser Ring/Front Wheel Lock) NOTE ~ The ABS indicator might blink under unusual riding or conditions (page 139) This Is temporarytailure. Erase the DTC (page 1977) then test-ride the motorcycle above 30 km/h (19 mph) check that the ABS indicator operates normally (page 19-5). ~ It the DTC 4-1 Is indicated‘ check the front brake for drag [Hr '—‘ of A. [ii i (Terminal side of the Wire harness) 19-13 ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RAICBSOOFA/XA) 1. Speed Sensor Air Gap Inspection Measure the air gap between the speed sensor and pulser ring (page 19-22) is the air gap correct? YES — GO TO STEP 2 NO —Check each part for deformation and looseness and Correct accordingly. Recheck the air gap . Speed Sensor Condition Inspection inspect the area around the front wheel speed sensor Check that there is iron or other magnetic deposits between the pulser ring [1] and wheel speed sensor [2], and the pulser ring slots tor obstructions Check the installation condition of the pulser ring or wheel speed sensor for looseness. Check the pulser ring and sensor tip for deformation or damage (e g” chipped pulser ring teeth). Are the sensor and pulser ring in good‘ condition? YES — GO TO STEP 5 NO » Remove any deposits. Install properly or replace faulty part. . Front Wheel Speed Sensor Line Short Circuit Inspection (at sensor side) Turn the ignition swuch OFF. Disconnect the front wheel speed sensor 2P (Blue) connector (page 1922) Check for continuity between each terminal ol the sensor side front wheel speed sensor 2P (Blue) ‘ connector [1] and ground CONNECTION: White — Ground Blue — Ground Is there continuity? i VES — Faulty front wheel speed sensor NO — GO TO STEP 4 (Terminal side or the front wheel speed sensor) . Front Wheel Speed Sensor Line Short Circuit Inspection D'smmem the ABS modulator 1gp (mack) 77”i"*77 connector (page 1943) i [1] W Check for continuity between each terminal ot the ‘ wire harness side front wheel speed sensor 2P ‘ (Blue) connector [1] and ground CONNECTION: Blue/yellow — Ground ‘ White/yellow — Ground i Is there continuity? YES — ' Short Circuit iri the Blue/yeiiow Wire - Short Cll’CUiI in the White/yellow wire NO — GO TO STEP 5. I (Terminal Side of the Wire harness) 19-14 ANTI-LOCK BRAKE SYSTEM (ABS; CBRSOORAICBSOOFA/XA) 5. Front Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side ABS modulator 1BP (Black) connector [1] terminals with a jumper wire [2}- CONNECTION: a — 17 l Check for continuity between the Wire harness side front wheel speed sensor 2? (Blue) connector [3] terminals. ‘ CONNECTION: Blue/yellow ~ White/yellow Is there continuity? ‘ YES — GO TO STEP 6. ( NO — Open circuit in the Blue/yellow or White/ r yellow wire Failure Reproduction with a New Speed Sensor Replace the front wheel speed sensor with a new one (page 19-22). Connect the ABS modulator 18F (Black) and front wheel speed sensor 2P (Blue) connectors. Erase the DTC (page 19-7), Test-ride the motorcycle above 30 krn/h (19 mph). RecheCK the DTC (page 1975). Is the DTC 1-1, 1-2, 2-1, 4-1 or4-2 indicated? YES NO - Faulty ABS modulator — Faulty original wheel speed sensor DTC 1-3, 1-4, 2-3, or 4-3 (Rear Wheel Speed Sensor Circuit/Rear Wheel Speed Sensor/Rear Pulser Ring/Rear Wheel Lock) NOTE The ABS indicator might blink under unusual riding or conditions (page 19-9) This is temporary lailure Erase the DTC (page 18-7) then test-ride the motorcycle above 30 km/h (19 mph) check that the ABS indicator operates normally (page 186) It the DTC 4-3 is indicated, check the front brake for drag. . Speed Sensor Air Gap Inspection Measure the air gap between the speed sensor and pulser ring (page 19-22). Is the air gap correct? YES — GO TO STEP 2' NO —Check each part for deformation and looseness and correct accordingly, Recheok the air gap. [2] \ [3] (Terminal side or the ere harness) 19-15 ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RAICB500FAIXA) 2. Speed Sensor Condition inspection inspect the area around the rear wheel speed sensor: Check that there is iron or other magnetic deposits between the pulser ring [1] and wheel speed sensor [2], and the pulser ring slots for obstructions. Check the installation condition of the pulser ring or wheel speed sensor (or iooseness Check the pulser ring and sensor tip for delormaliori or damage (e g , chipped pulser ring teeth). Are the sensor and pulser ring in good condition? VES — GO TO STEP 5 NO — Remove any deposits. install properly or replace faulty part 3. Rear Wheel Speed Sensor Line Short Circuit Inspection (at sensor side) Turn the Ignition swnch OFF, Remove the right Side cover (page 2-7) Disconnect the rear wheel speed sensor 2P (Gray) connector [1} Check tor continuity between each terminal at the ‘ sensor side rear wheel speed sensor 2P (Gray) ‘ m connector [1] and ground ‘ CONNECTION: Blue — Ground White — Ground Is there continuity? ‘ YES — Faulty rear wheel speed sensor NO » GO TO STEP 4. ‘ (Terminal Side oi the rear wheel speed sensor) 4. Rear Wheel Speed Sensor Line Short Circuit inspection Disconnect the ABS modulator taF’ (Black): 1 "4 7 i ' 7 connector (pageiQyE), [ 1 Check tor continuity between each terminal at the wire harness side rear wheel speed sensor 2P (Gray) connector [1] and ground CONNECTION: White — Ground ‘ Blue — Ground Is there continuity? YES » - Short circuit in the White wrre - Short Circuit in the Blue Wire NO — GO TO STEP 5. ‘ (Terminal Slde oi the wire harness) 19-16