2001-2003 CBR600F4i HOW TO USE THIS MANUAL Thls servlce manual descrloes (he servrce plocaflures lor me CBRSGOFAL Follow me Malnlenanoe Schedule (Sacllon 3) recommenoauons lo ensure mar me uehlcle l5 lh peak operaung conolllon and the emission levels are mm the standards sex by me u.s. Env-ronmehlal Prolecuon Agency, Calllorrua Alr Resources Board and Transoon Cahaoa FErfovming lhe llrsr scheduled mamlehahce ls very rmponanl ll compen- sales for me lrll al wear lhal occurs durmg [he hreakan perrod. Secxlons l am: 3 apply lo rhe whole molchyc‘ea Seclion 2 llluslrales plocs~ oures Iol lemuva laHaKion ol componems lhar may he required lo per- lorm Selvlce oescrmeo II'I me lollowmg secllons. Secllons t mrough ls oescrlhe pal-ls ol lhe mumlcvcle, groupeo accoromg to locahon Flnd lhe seenon you wzm on rhls page, then turn lo me lahla ol conlenls on rhe firs! page al the seam. Mosl secuons slam WIUI an assembly or syslem lllusrrahon, Servlce Infmmas mm and rrouoleshaollng for lhe secuon. The subsequenl pages glve nelalleo procedures. ll you are nor Izmillarwflh (hrs muzorcyale, read lechrucal Fealure m Seclion zl ll you do not knuw (he source ol me (loublE, go to seollon 22 Tmubleshummgc chul salery. ano rhe ssIely ol orhers, Is very impunarll. To help you make mffllmed declswns we have provided salely messages and olher lrlior matloll lhlougl’lout lhls manuaL ol course, ll ls nol planical or pusslhle m waln you apoul all me hazards assoclareo wllh servlclng (hls yehlole. Van musl use your own good ludgemenlv You wrll find lmporlanr salely lnlormauon m a vanely ol lorms lneluolng. - Salaly Lahels , on me vehlclc - Salaly Messages — placedafl by a saIetv alerl symbol A and one of rhree slgnal woros, DANGER, WARNING. pr CAUTlON These signal words mean you WILL oe KILLED or ssmousw HURT ll A "ANGER you don‘tfnllow lhsxrucuons, You CAN be KlLLED or SERIOUSLY HURT ll AWAHN'NG you dun‘l IoHnw lnslrucllons. you CAN be HURT ll you dcn'l lollow A CAUTION lnsllummns. . lnsuuchons 7 how m sarvlce [his yemcle eorreclly and solely. CONTENTS GENERAL INFORMATION 2 I I FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE El ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM I: I FUEL SYSTEM (Pro rammed Fuel ln'ecticln) COOLING SYSTEM I : ENGINE REMOVAL/INSTALLATION I. CYLINDER HEAD/VALVES l:l CLUTCH/GEARSHIFI' LINKAGE E I ALTERNATOR/STARTER CLUTCH I I: I CRANKCASEITRANSMISSION I I I CRANKSHAFr/PISTON/CYLINDER CHASSIS FRONT WHEEL/SUSPENSION] STEERING REAR WHEEL/SUSPENSION II: I HYDRAULIC BRAKE IE. BATTERY/CHARGING SYSTEM I I 5' As you read me manual, you wrll find mlormaliou rhar ls preceded oy a ’m’Tcl symool. The purpose of Ms message Is [u help prevem damage to your veluele, orher properly. or me enVllonmenl ELECTRICAL IGNITION SYSTEM ELECTRIC STARTER LlGHTS/METERSISWITCHES 19 WIRING DIAGRAM E:l TROUBLESHOOTING :2! SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information Is required per- taining to these symbols, it would be explained specifically In the text without the use of the symbols. 95 Replace the partlsl with new onelsl before assembly. 3% Use recommended engine oil, unless otherwise specified. 2 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1l l ,fii i Use multi-purpose grease llithium based multipurpose grease NLGl #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or (m equlvaleml. Example: Molykote' BR-Z plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl #2 or equivalent). Example: Molykote” Gan Paste manufactured by Dow Corning U.S.A. Honda Moly 50 (USA. only) Rocol ASP manufactured by Rocol Limited, UK. Rocol Paste manufactured by Sumico Lubricant, Japan ,fil Use silicone grease. Om Apply a locking agent. Use a medium strength locking agent unless otherwise specified. 4GB]! Apply sealant. Use DDT 4 brake fluid Use the recommended brake fluid unless otherwise specified. film i-Wa fl Use fork or suspension fluid. 1. GENERAL INFORMATION SERVICE RULES 1-1 LUBRICATION & SEAL POINTS 1-19 j MODEL IDENTIFICATION 1-1 CABLE Br HARNESS ROUTING 1-23 m SPECIFICATIONS 1-3 EMISSION CONTROL SYSTEMS 1'38 TORQUE VALUES 1-12 EMISSION CONTROL INFORMATION ‘ TOOLS 147 LABELS IU.S.A. ONLY) 1-41 1 SERVICE RULES 1. 2. 3. 4. 5 Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Part5 that do not meet HONDA’s design specifications may cause damage to the motorcycle. Use the speuial tools designed Inr this product to avoid damage and incorrect assembly. Use only mP'rIC tools when scrvicing the mOlDICVCIet Melrit. bolts, nuts and screws are not interchangcable with English lastencrs, Install new gaskets, 0»rings, cotter pins, and lock plates when reassembling, When tightening bolts or nuts, begin with the larger diameter or inner bolt first Then tighten lo the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean perm in clennirlg solvent upon disassembly. Lubricatc any sliding surfaces balore reassembly 7. a. Home all electrical wires as shown on pages 1-23 through 1-37, Cable and Harness Routing, Alter reassembly, check all pans for proper Installation and operation. MODEL IDENTIFICATION 1-1 GENERAL INFORMATION FRAME SERIAL NUMBER (‘H T‘we ham..- aevi'dl number is summed on me righl side unhe steering head — ( mum SFRIAL NUMBER \ ’ ‘2) The engine serlai numbe' IS smmppd rm vhp right side of the upper crankcase. i3} The VuiviL‘ie IUEIIIIIILdliUII Number IVIN) is iucatsd 01 Ian SH‘IH 0V Ihe mam frame on the Eafew Certification Lasois. COLOR LABEL (5) The color iabel is anadied as Shaw“. When uvdermg calorrcoued pans, alwavs spemly the nESIQna'Pd calm £009. £11] Tha mronle body identification number is sxarwpcd on the imak: side vi the lhrullle body as shown. 1-2 GENERAL INFORMATION SPECIFICATIONS * GENERAL ITEM SPECIFICATIONS DlMENSIONS Overall length 2,0“ mm (30.4 in) Overall width EH5 mm (27.0 In) Overall helght 1.135 mm (44.7 1n) L Wheelbase 1.336 "1111 (54.6 in) Seal lleiglll 810 mm (31 in) Foolnen heigh' ‘ 350 mm (14.2 in) Ground clearance ‘ 135 mm 15.3 in) ‘ Dry waigm . 49 sates/Canada tyna . 168 kg (370 lbs) ‘ Callfornla type i 169 kg (373 lbs) Curb weight ‘ l 49 Slates/Canada l’yruI 196 kg (‘32 lbs) 1 Callfornla type 197 kg (434 lbs) Maxlmum weignr capacity 1 175 kg (386 lbs) FRAME Frame rype . Diamond ‘ Flulll suspension ‘ 1alesmplc rm ‘ Frnnr axle. lrnvel I 120 mm W] in) . Roar suspension 1 Swingalm ‘ Rear axle llavel ‘ 170 mm 14.7 ml Front llre sin. 1 120/70 ZR 17 (53WI Rear tire SIZB , 180/55 ZR 17 (73WI From Kira brand BTD1DFF (nridgesvnnal D207FJ (Dunlap) Pllol SPORT E (Michelin) Rear rlra brand BTD1DRF (Bridgestone) UZU7P (DunIOD) ‘ Pllor SPORT E (Michelin) From brake Hydraulic double disc Real brake Hydrnlllln slngln dlsc Caster Angle 24' Tvall length 96 mm (3.8 in) Fuel tank capacity 18.nli1eru 76 US gal, 3.96 lrnp gall ENGINE Cylinder arrangement 4 cylinders in-line, innllnnrl 311‘ 1mm vertical Bole and stroke Dlsnlacement Compression ratio Valve Iraln Intake valve ODEI’IS closes Exhaust valve opens closes ‘ Lubrication sysrem . Oil pump type Cooling system Alr flltratlon Engine dry weighl Firing order 511 mm 1 (0.04 in) lifl 67.0 X 42.5 mm [2.54 X1571") 599 cm3136.5 cu-inI 12.0 . I (Ihaln drlvcn. DOHC 22" BTDC 43' ABDC 38’ UBDC 7' ATDC Forced pressure and wel sump Trochnid quuld cooled Paper elemem 59 kg (130 lbs) 1 r 2 r 4 r 3 GENERAL INFORMATION - GENERAL (Cont'dl " ITEM SPECIFICATIONS CAREURETION l Type PGM-Fl lF‘rogrammed Fuel Injection) Throttle bore 38 mm 115 in) DRIVE TFlAIN Clutch system Multi plate, wet Clutth operatiun system Cable operating Transmrssron Constant mesh, 6-speeds Primary reduction 1.822 (IR/‘5) Final reduction 2.875 (46/16) Gear retro 1m 1833136112) 2nd 2.062 [33/15) 3rd L647 (28/17) l Am ‘ 1.421127/19) 5th ‘ 1272 (78.7% ‘ 6m ‘ 1.173 (2723' (janrshth pattern Lell [not operated return svnem, l , N 2 » 3 — 4 — b — 6 ELECTRICAL Igmtinn system Computer-controlled digltal uansistorizcd with electric advance 1 Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier ‘ SCR shorted/triple phascr full wave rectification Lighting system l Battery GENERAL INFORMATION Unit: mm (in) i— LUBRICAHON SYSTEM i , ‘ ITEM 1 STANDARD ‘ ssnwc: umrr Engine nII capacity Afier drai n9 3.0 liter [3 2 us qt, 2.6 Imp qtl —— After urai ng/filler change 3.3 liter (3 5 US at] 2.9 lmp qt) — # After disassemblv 3.7 liier (33 us (11,3 3 Imp qt) , , — ,7 Recommended engine oil ‘ Pio HONDA GNA or Ill’l Arstmke OlI i _. (USA, and Canada! or Honda 4-stroka i ‘ oil (Canada only), or equivalent motor oil i APl service classification SF nr 56 ‘ Viscosity: SAE 10W—AU i Oil pressure ai oil prassure switch 490 kPa (5.0 kgl/cm’, 71 psi) at — 6,000 rpm (BOT/176T) i Oil pump rotnr lip clearance , 0 15 (0006} 020 (0003) Body Lleaiance U 15 — 0.22 (0006 0.009! 77 035 10.014) ‘ Side clearance 0.02 — 0.07 (0.001 r 0.003! 010 {000“ ‘ — FUEL SYSTEM (Programmed Fuel Injection) l SPECIFICATIONS ITEM Throttle body identification except California type i Gnsioc "umber ciilirnrnia type Gosnn 7 Starter valve vacuum difference 20 mm Hg Base throttle valve fur synchronization No.1 Idle speed 1,300 x 100 rpm anonlc grip tree play 2 ."s "“11 (1:1 — m in) # Intake air temperature sensor resistance lair zu‘C/se‘Fl ‘ 1— 4 kn Engine coolantiemperatura sensor lesistance (m zones?) i is — 2,6 m Fuel injeuor rcsisianca (at zo’C/GB'F) 11.1112 3 n PAlR solenoid valve resistance (at ZO‘C/BS'FI zo — 24 n » . Cam pulse generator peak voltage (at ZO‘C/SS'F) 0‘7 V minimum Ignition pills: generator peak voltage (ai Zo‘C/sa'F) Manifold ahsniute pressure at ldle 0.7 V minimum 150 - 250 mm Hg Fuel pressure nr idle Fuel pump flow (at inV) l 343 kPa (3‘5 kgf/cmz, 50 psi) Minimum "18 cm’ (5‘4 US 01,6.6lmp utter 10 seconds GENERAL INFORMATION — COOLING SYSTEM SPECIFICATIONS Coolant capacity Radix-nut and engine Res ve tank 2.7 liter 12.9 US qt. 2.3 Imp on 0.31 litcr (0.33 US qt, 0.27 Imp an 137 kPa 11.1 — 1.4 kgf/cm1,15 — 20 pan 108 «1 80-34 131176—183 ’H 90 'C (19‘ 'H R dlUV cap relief pressure 7Thermustat 1 39910 [07 open 17Fully open 1 valve Ill) ‘1 77 H mm in :l in) mlriimum Recommended antifreeze 1 Pro Honda HP Coolant or an equivalent high quality ethylene ' glycol antlfrsezo conmining corwsion pmtection Inhibitor: | Standard coolant concentration 50% mixture with soft waler — CVLINDEH HEAD/VALVES Unit. mm (in) IYEM Cy) der compression STANDARD 1 1,226 kPa (12.5 kgf/cmi, 173 99.11 SERVICE LIMIT 111350 rpm Valve cleavance 77 IN ; 0.20 2 0.0310008 x 0.001) EX 0.23 2 00310011 2 0.001) 7 7 — Carn;haft ' Cam lone heigh! IN 3656 00171.439—1449) 36511.44) 77? 35.34 5.5811391—1401) 7 35.21139) —77 "111mm" 77 777 ‘ : 0.0510002) on clearance 77 0.030 — 0.07210001727— 0.0025) 77 01010004) Valve Iihnr Valve Ilfler 0.0. 7 7 7 25.978 - 25.9937 022 0233) 1 25.97 11.022) 1 ValvETfiF bore LD. 20.010 _ 261126110240 — 1.024s) 260411.025) Valve, Vine—stem 0.0. 7‘ m 1 3.975 — 3390101565 01571) j 3365101551) VB'VE 91““ 1 ‘ EX 7 ‘ 3.965 — 3.980(0.1561e 0.1507) 1955101557) 171/3110 guide |.D. lN/EX 4.000 4012101575 — 0.1500) 1 4.0410159) 1 Stems-guide clearanc: 7 IN 0.010 e 0037 10.0004 - 0.0015) 7 0075100030) 1 EX 0.020 - 0.047 [0.0000 — 0.0019) ‘ 0.085 10.0033) 1 Valve guide projection above 1N 16.1 ~16.41fl.53 » 0.65) — 1 Cylinde' head 5x 1 14.: — 14,01Esse 0.57) — 1 Valve scat width lN/EX 0.00 — 1.10 1000* — 0.043) 1.5 (0.061 Valve spring IN Omar 473711.00) 413611.628) 1' *6 1‘4"!!!" 1 Inner 30 411 43) 7 77 1 353711400) 1 ex 7— 736311.43) 7 355711.400) cvlinaev head warpage 77' 7 — 7 7 0.1010004) 1-6 GENERAL INFORMATION Clutch outer guide Plale warpage |.D. 0.D. Mainshall 0.D. aI clutch 0mm gmde 25.000 7 25.02} (0.9803 1 24.980 — 24.993 (0.9835 7 0.984.131 9851) 34.975 — 34.991 (1.3770 —1.3776) 7 3‘37 11 771 — CLUTCH/GEARSHIFT LINKAGE ”"i‘: mm W ITEM 4 STANDARD ‘ SERVICE LIMIT CluIch 1am free play ‘ 10 - 20 (3/8 — 13/101 I Vii 1:101:11 Spring free lenglh ' 44.7 11.761 43.4 (1.711 1 DISC thickn0ss 2.92 — 3.03 (0.115 - 0.121) 2.6 [0.10) I 012] 25.03 (0.9851 W31 — ALTERNATOR/STARTER CLUTCH ITEM Univ mm (in) STANDARD SERVICE LIMIT SIaIIeI driven gear hos: 0.D. 51.099 — 51.71012 0:154— 2.03511 515841103481 - CRANKCASE/TRANSMISSION Unit: mm Iin) ITEM STANDARD SERVICE IJMIT 5111114511, 10. 12.000— 12.021 1 4724-04732) 1 12.03 10.4741 ' ‘0'“ 5”" Claw 11111-2110.“ 7 3.93 — 00010233 .2301 V 1 5.9 10231 $11111 1m shah 0.0. 11.957 410031024707 — 0.47121 1195104701 Transmisfiiun Gear 1.13. M5. M6 23.000 - 23.021 11.1024 — 0321 20.0411 0417 1 c2. c3, (:4 31.000 — 1025112205 -1.22151 7 #73104 (1.2221 7 1 60m bushing 0.0. M5, M6 1 27.959 — 27.080 (1.1007 -1.1016) 77.94 11.1001 # 07 30.955 — 30900112107 _ 1.21971 3094112101 1 . ca, 04 30.950 - 30975112105 — 1.21951 3003 11.21111 fiber-10120011119 ‘7 M5, M6 0020 7 0.052 (0.0000 — 0.00241 N 07101000417 ‘ “WW? 1T? . 0.02m 007010.0008-000231 ' 0041 7 1 ca, 04 V . 0.025 - 0075100010 — 0.00301 ‘ 3041 7 Gear bushing 1.0. ’ M5 ' ‘ ‘ 74.911545006109037 — 0.95451 ’ 250161053491 I . c2 1 77.905—20.0us(1.101a 1.10251 230211110321 1 Main-shah 0.0. al M5 1 2.1.007 —24.Hau 10.9330 0.03351 24.96 (0.9031 Counmrshaft 0.0, at 02 27 007 — 27.900 11.1011 1.10151 2790111011 ’Bushing Io~shafl M5 0.005 , 00391000027 0.00151 006100021 . ”93'3"” C: To our — 003.910.0002 : 0.00151 ‘ 096100021 GENERAL INFORMATION — CRANKSHAFTIPISTONICVLINDER ——7 7 UN“ mm “m‘ rrEM STANDARD SERVICE LlMlT . Clallksllah ‘ Connecting rod side glegrance 9.10 0.25 (0—5” — 0.010) l [1.10 (n 017) ) Crankpin bearing oil clearance 0.028 0.052 «1.0011 — 0.0020) nm in 007) ‘ Main Journal bearing oil clearance ($020 0.038 [0.0008 — 0.0015) I 0.05 (0 002) Runoul V ‘ . V — V 0.05 (0.002) Fislon, pismn 1 Pinion 0.0. at 15 mm ' )1r0m bonom 66.965 — 56.905 12 6.10.1 — 7.0.172. ' 55.90 (2.530) I “"95 3 Pislon pin bore LD. 11.002 — 17 00010 6694 — 0 0090) 17.02 (0.070) i Piston pin>O.D.-_" ‘ V _ 1 15.994 7 17.000 (0 0091 - 0.6693) ,l 16.98 (0.305) Pislonrtonimon pin clearance ‘ 0.002 - 0.010 (c 0001 — 0.0003) 0.04 10.002) ‘ Piston ring and 900 Top 1 0.10 — n 70 i0 004 _ 0.008) 7 0.410.021 ‘ . Second 0.1R - 0 30 (0.007 ~ 0.012) 7' 0.51002) . oil (:lde ml) 0.7 - 0 7 (0701 — 0.03) 1.0 (0.04) - 1 Piston ring-to-rmu Top 1 0.020 — 0 050 (0.0008 — 0.0020) 00310.00) 1 9m“ 0'93""59 5mm? 7 0 0151 0.050 (0.0006 » 0.0020) H 0.03 0003) Cylinder ' 57.000 — 67.015 (2.6378 — 2.03543 . 67.1?16757AH _ > V ‘ 0.103.004) > . V — H 0.10 (0.004) w — 0.10 (0.004) 7 7‘ 0.015 — 0.050 (0.0000 — 0.0025) 0.10 (0.004) 17.015 — 17.034 (0.6699 0.0706) ‘ . 17.04 l0.s71) 0.016 —0.040 (0.0000 0,0016) ‘ 0.0501007) 1-8 GENERAL INFORMATION Unit: mm lin) FRONT WHEEL/SUSPENSIONISTEERING [ ITEM F Minimum lire head depth STANDARD SERVICE LIMIT 1.5 10.05) Cold lira pressule Up to 90 kg (200 lb) load 250 kPa (2.50 kgf/cm’. 36 psi) l Up Io maximum weight capacity 250 kPa (2.50 ng/cmz, 36 psi) Axle runoul 0.2 (0.01) —thel rim runout Radial H" j 2.0 (0.08) 7 Axial ’ , 7 7‘ 2,010.08) when! balance weigm — 509m 01) max. ' Fork ‘ Spring (we Iellglh 2R6 111.31 230.3 (11.03) FTubo runuul .__ ‘ 0.2610008) ‘ Recommended ruii lluid Pro Honda Suspension Fluid SS 8 i Fluid level Fluid capacity . Pro-load adjuster iniiial serving 116 (4.6] ‘62 z 2.5 cm‘ {15.6 - 0.08 US 02, 16.3 L 0.03 Imp all «h groove from top 1 1-3/4 turns out from lullyrurned in ' COmDI’BSSiDIi adjuster inilial setting 1-1/4 turns out from fully rurned In . Rebound adjuster initial amino 1 steering head bearing pro-load 1.0 - 1.5 kgf (2.2 » 3.3 lbfl — REAR WHEEL/SUSPENSION ““"1 mm W ITEM ‘ STANDARD SERVICE ullnrr Minimum tire iread dapih — 2.010 08) Cold tire pressure ‘ Up in 90 kg [200 lb) load I 290 kPa (2.90 kuf/cm’, 42 psi) - l — ‘ Up to maximum weigh: capanify ‘ 290 kPa (2,90 kgl/cm’, 42 psi) > —-— _ Axle runour '. 0.2 (0.01) Whncl rim runour Radial 2,016.08) ’ Axlal A, 2.0 lofosl Wheel hnlnnce weighi — 609 (2.1 01) max. Drive chain Size/link DID DIDSZEHVJOHLE J ._ ‘ iRK ‘ RKGaszannzHoaLE ‘ — # ASlack 25-35(1—1-3/Rl — Siriouk absorber Spring adjuster standard position Position 3 Rebound adjuster iniriai setting 1.1/2 turns out from fully inrned in Compression adjumer initial setting . 1-1/2 turns out from hilly turned in 1-9 GENERAL INFORMATION A HVDRAULIC BRAKE —+ . 011.1; '"m "m ITEM . STANDARD SERVICE lerr From" Specified brake fluid 1 Honda DOT 4 Brake HIIId —— Brake disc thickness ‘ 4.4 — 1.611117 — n 18) 3.5 (0.141 Brake dlsc runout 7 W“ A 1 — 0101013081 Masler cyllndrerr 1.0.” a 15 I170 — 15513100248 — 0.6265) 1 15,925 19270) Master pIsIon 0.0. 15827 - 15354105231 ~ 0.52421 153151002261 Callper cyllnder | D. A 33 90 — 34.01 11.337 ~ 1.339) ' 34.02 11.3391 1 ‘5" 32.030 — 32030112810 — 1.20301 32.09 (1.263) c.1111)... plsmn (111' A 33 1302 31035113303 — 1.33211 33.794 11.33051" 0 7 31.377 31316112550 — 1.25631 ‘ 313691125471 11.... ' Specifier! hrake 111.111 Honda 1301' 4 Brake Fluid — Brake pedal heigh Brake disc thlckne 75 13.0) 4.2 A 5.210.19 - 0.201 Brake 1115: 1011qu ' "_ W’ ' 1 14,000 — 14045105512 41.55291 WA 1 13.957 —1 .9114 10.5495 —0.55051 [Elmer cylinder LD. ‘ 38.18 — 332311.053 — 1.5051 4.0 10.151 0.30 (0.012) 14.055 10.55331 13.945 1054901 33.24 11.5061 ' Calipel pisl 1 O 1 28.098: 38.148114999 1.50191 BATTERY/CHARGING SYSTEM . 38.0911.500) ITEM l SPECIFICAHDNS 0mm Capacity 12-v — 8.6 Ah 352111 leakage 1 ‘ 2.0 mA max. .. 1 Village lib'C/GS’F) fl charged " ‘_ 13.0 13.2 v ' ”if 1 ‘ Neal‘s charging Below 12.3»V 1 1 Chavgillg 01.1.0111 Normal . 7 .7 y H 70.51/05 -10 11 7 ‘ 1 Quick 1 4.5 A105 h 1 41115111410: Capacity 7 ‘ 0.433 kW,’5,000 rpm ‘ Charging coil resistance lZO'C/68”F) A 0.1 :I ,0 Q — IGNITION SYSTEM 7 .. ITEM SPECIFICATIONS Spalkplug 111101.111.) NGK lMRsA-sH DENso " 7 111112711 ' ‘ E15109 gap E1110“ cull peak vonage 707 millul1timinq("F"mafk1 100 V mmm’ulm II pulse generawr peak voltage 0.7 v mInimIIm 13‘ BTDC a1 Idle 0.80 7 0.90 mm (0 031~ O 035 in) 1-10 , ELECTRIC STARTER ‘ ITEM ; , 1 Staner momr brush lengm I 1 I 12.0 —13.0(DI47 — 0.51) GENERAL INFORMATION Unil: lulu (in! STANDARD SERVICE LIMIT , ,, 6L5 (0.26) Front (um signal/running light Hearlurn signal Iigm — LIGHTS/METERSISWITCHES V ITEM 1 _ ‘ sggcuncmous Bulbs Headlight Hi I L 12V755W Lo ‘ L 12v — 55 w L if 'Evakenan Hgm L ‘ Elia/5w 2 L LL 12v732/3 (#123: 7W): 2 12v—32 CF (23 W) x 2 License light ‘ _ \ 12V ~ 4 CP (5 W) fistjumem light # I _ LED ‘ Turn signal Indicator L _ LED 7‘ ‘ ngh beam unmcator L L Eb ‘LLNmnval Indlcator 1 MALED on pressure Indicator 3 LED I PGM»FI waning indlcator ‘ [ED LL Low fuel indicator ‘ LED Fuse - Maifmse 77777 30 A LL PGMAFI fus: L L 20 A 1 Sub Ius; L L 10Axe L Tachummsr peak vullage LL 3 wfifib V minimum Li a motor 1 5mm close (0N) L L as — 102 ‘c 1208 - 216 'F) W swim“ ‘ Smp if: :Jpen L - 53 - 97 'c (199 —_207 ‘FI 1-11 GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TVPE NW MM", “M” FASTENER "’5 ~.m (kgflm, lbf-hl 5 mm hex bolt and Hut 5 [0.5, 3.6) 5 mm screw 6 mm hcx bolt and nut 10 (1.0. 7l 6 mm screw 8 mm hex bolt and nut 77 (7.7, 16] 6 mm flange bolt is mm head, 10 mm hex bolt and nux 34 (3,5, 251 small flange) 12 mm hex bolt and nut 5415.5.40l 6 mm flange bull 113 mm head, 12 (1.2, 9| large flange) 6 mm flange boll (10 mm headland nm 12 (12. Si 8 mm flange. hnlf and run ‘ 76 (7.7, 7D) 10 mm flange boil and nut 39 (4.0, 29) - Torque specificalions listed below are for specific fasteners. - Other hummer: shnuld he ligh'ened m mnriml torque values listed above NOTES: 1. Apply sealant la the threads. 7 Apply a locking agent to the threads 3, Stake. 4. Apply oil {0 (he mraads and flange surface. 5 U»nut 6, ALOC boll/screw: replace wnh a new one. 7, Apply grease to the threads. 8. Apply molybdenum disullide uil lo we llneads and sealing surface. S. (Jl boll. * ENGINE ‘ THREAD TORQUE ”EM “TV DIA. [mml N-m mgr-m. IbMtl REMARKS MAINTENANCE: ‘ Spark plug 4 } 10 12 (1.2, Bl Tlrning l'lole cap 1 A5 18(l.5,13l NOTE 7 Engine oil filter camidge 'l 20 26 [2. 20) NOTE 4 Engine oil drain bolt 1 12 29 [3. 22) LUBFHCATION SVSTEM: OII main gallery sealing bolt 2 20 29110.22) NOTE 2 Oil pump cover bolt 1 6 81011.53) NOW 9 Oil uuuler bull lfiller boss) 1 20 6416.5. d7l NOTE 4 FUEL SVSTEM (Programmed Fuel Iniectinn): ECT (Engine Coolant Temperaturemhermo sensor 1 17 23 (2.3. 17) Throme badv insulator band screw 3 5 See page 1714 Throttle cable bracket mounting bolt 2 5 3 (0.35, 2.5l Starter valve lock nut 4 1D ‘ 2 (0.13, 1.3l Sxaner valve synchronization plare screw 4 3 l 1 ((1.09, 071 Fat idle wax unil link plale screw 1 3 ‘l (0.09, 0.7l Fast 1de wax uni! mounting screw 2 6 . 5 (0.5, 3.8) ‘ Pleasure regulator mounxing bolt 2 S ‘ 10 H D, 7) Vacuum joint for synchronization 2 5 l 3 (0.3, 2.2) COOLING SVSTEM- ‘ Water pump cover flange bolt 2 E l 12 41 2. 9) NOTr 9 Thermostat cover flange Doll 2 6 l 12112.9) NOTE 9 ENGINE MOUNTING: l Drivc sprocket speclal bolt 1 10 l 54 (5 5, 4m 1-12 GENERAL INFORMATION ,— ENGINE (Cont'd) CV DER HEAD/VALVES Cylmder hand mounting bolt/washcr Camshaft holder flange bOl! Cylinder head sealing bull Cylinder head cover hnli Breather plate flange bolt PAIR reed valve covar SH boll Cam spluckel flange dowel bolt Cam pulse generator rotor flange (10ch bolt Cam chain lifter mounting socket bolt Cam chain IellSIOIIEl pivot socket bolt Cam chain guide bolt/washer Cylinder head stud boll (exhaust pipe slud bolt) CLUTCH/GEARSHIFT LINKAGE: Clulch center lock mil Clutch spring bolt’washcr Oil pump driven sprocket bun/washer Shiil drum center sucket hon Shift drum stopper arm ONO! bolt Gearshift spindle return spring pin Ignition pulse yelleiator wire guide hon/washer ALTERNATOR/STARTER CLUTCH: Alternator stator socket bolt Starter Clutch oulsr souket bolt Flywheel flange bolt Sinner ere clamp flange bolt GRANKCASEITRANSMISSION: Mainslmfl healing 52: plate hon l Gearshlft nmm bearing/fork shaft Sol bolt/washer Crankcasc bolt (main journal) Crankcase boll Clankcase bolt Crankcase bolt [upper side} CRANKSHAFI’IPISTON/CVUNDER: Cunnecling rod bearing can nut IGNITION SVSTEM: ignition pulse generator rcltur special bull ELECTRIC STARTER: Starter mntnr Terminal nut LlGHTS/METERS/SWITCHES: Oil pressure switch oil pressure swnnh wlre terminal boll/washer Neutral switch ‘ THREAD 1 10ROUE l my DIA. (mm) N-m (1191-111, IhI-h) REMARKS ‘ 1o 9 1714.11.35) ‘ NOTES 20 6 12 (1,2, 9) ‘ NOTE .1 1 1A 1811.8,13} 1 NOTE? 3 6 1011.0.7) ‘ i 3 6 12(1.2,9) , NOTE 2,9 l . .1 s 121125) NOTES 1 1 7 20 (2.0. 14) NOTE 2 ‘ 2 e 12 (1,2. 9) NOTE 2 2 6 1n (1 n, 7) 1 s ; 10110.7) NOTEZ ‘ 1 6 ‘ 12 (1.2. 9) s , 5 See page 1.14 l l 1 i 22 127 (13.0.94) ‘ NOTE 3, A , 5 . s 12 (1,2, 9) ‘ 1 . s , 15115.11) ‘NOTEZ ‘ 1 s i 23(2.3, 17) ‘ NOTE 2 1 a 12 (1,2, 9) l 1 3 22 (2.2, 16) l l 1 ‘ e 12 (1,2, 9) ‘ A 5 17 (1 2, 9] a a 16(1.6. 12) - NOTEz 1 10 103 (10.5. 78) 1 NOTE 4 1 a 12 (1 7,9) l NOTE» 3 s 12 (1.2, 9) NoTE2 1 2 ‘ e 12 (1.2, 9) NOTE 2 l 10 j n 2512.5,13) NOTE 8 , 1 1o 39 (4.0, 29) s 7 1 15 (1.13. 13) ‘ 5 a 1 75 (2.5, 111) , , s 7 ‘ 25 (2.6. 19) ‘ NOTE 1 1 111 l 50160.43] 1 l 6 ‘ 12 (1.2, 9) 1 1 PT1/8 12 (1.2. 9) NOTE 1 1 ‘ 4 . 2 (o 2, 1.1) l 1 10 12112.9) 1-13 GENERAL INFORMATION ‘ Insula‘ov clamp l‘hronle body side). ‘ Insulator clamp (cylinder head side]: ‘ ‘ 7 :1 mm (0.3; 0.04 Im A L] mm (02 1 0.0! W ‘ < >— FEE : /’ Q " Exhaust pipe stud boh: 1-14 GENERAL INFORMATION FRAME Windscreen setting scmw Mulfler hand flange bolt Fuel pump mounting nut COOLING SYSTEM: Cooling Ian mouniing nul Fan inolor mounllng nut ENGINE MOUNTING: Front engine hanger boll Comer engine hanger boil Rear engine hanger nut Front brake disc bull Frunl axle bolt ‘ Fork sonket halt Steering stern nut l THREAD TORQUE ITEM 0'" DIA. (mm) 111.". IkgI-m. [bf-ft) REMARKS FRAME aonv PANELS/EXHAUST SVSTEM: ‘1 * Upper cowl lo lower cowl screw 6 . 5 7 (o 15, 111 Inner hall cowlvlu—lowei cowl screw 6 i s 210.15. 1.11 s l 1 1 (0.05, 0.41 Sam I’Hll upper mounting flange bait/nut 2 ‘ 10 £9 15 D, 36) Seat rail lower mounting llange boll/nut 7 l 10 49 15.0, 36) l Exhausl pipe joini flange nut ‘ a 7 12 (1.2, 91 ‘ 2 8 23 12.3, 17) Passenger looipeg bracket flange bull a R 26121.20) FUEL SYSTEM (Programmed Fuel Injection) Fuel filler cap hnlt l 3 A 2 (0.18, 1.3) Service check bolt 1 1 G 1511 5, 11) Fuel hose banio boll (fuel Iank side) ‘ 1 12 2212.2, 151 Fuel hose sealing nui (inmme body smei 1 12 2212.2,16) l 5 s 17 11.2, 91 ‘ a l ‘l l i l i l 0; sensor (California type only) 1 12 2517.6, 191 l 1 5 310.27, 2.0) NOTE 2 ‘ 3 5 5 (0.5, 3 6) 2 10 39 (4.0, 29) w See page 7-10 2 10 39 [4.0, 29) a Cenier engine hanger adjusting bolt 1 1 1 20 310.3, 2.21 Center engine hanger luck nul ‘ 1 l 20 5A (5.5, 401 7 1 ‘ 10 39 (4.0, 29) A Real engine hanger adjusling hair 1 ‘ 22 310 3. 7.21 — l‘lnar engine hanger lock nut lriqht sidel l 1 l 22 5415.51.40) Shock link brackei ilul ‘ 2 1 1o 39 44,0, 291 7 FRONT WHEELISUSPENSION/STEERING: l l Handlebar Weight mounting screw 2 G 10 (1.0, 7) NOTE 6 12 5 20110, 141 NOTE 6 1 l 14 59 (6.0, 431 FrnrlI axle holder flange Doll 1 I 8 22 (2.2, 16) Front brake hose clamp flange ball (left front) ‘ 1 i 6 1211.2,9) Frulll brake nose 3—way1mntllnnge bolt (right from) 1 6 12 (1.2, 9l 2 10 311:1 5, 25) NOTE 2 ‘ Fork boil 1 2 39 2312.3, 171 , Fork (up bridge pinch socket hall 2 a 23 (2.3, 17) ‘ Fork hnnnm bridge pinch flange boll ‘ z 10 3915 o, 29) Slecring bearing adjusting nui ; 1 26 2512.5, 18) ml» See page 13-29 Steering healing adjusling nut lock mil 1 , 25 -‘l l 1 24 103110 5, 71;) 4 1 5 1011.11.71 ‘ From brake hose clamp bok (steering stem) 1-15 GENERAL INFORMATION r FRAME (Cont'd) Mfi’ ’ i i THREAD TORQUE "EM 1 “TV 1 MA lmm) m (kqf ",1“, m REMARKS , 1 V 7 _ | REAR WHEEL/SUSPENSION? 1 Rear brake disc bolt 4 25 £215,131) i NOTE 6 Fina) driven spvuckel Hut 6 ‘ )0 64 (6.5, 47) ‘ NOTE 5 Hem axle nm 1 ‘ 18 93 (9.5, 69) ‘ NOTE 5 Rear shock absorber mounting rm! 2 1 10 44 (4‘5, 33) 1 NOTE 5 Shuck link plate-lo»swinqarm nm 1 10 4414.5,33) i NOTE 5 Shock Iink-tcvshock link plale mu 1 10 4‘ (4.5, 33) NOTE 5 i Shock imk-io-bracket nut 1 10 44 (4.5, 33) ‘ NOTE 5 4‘ Drive chain slider flange bolt 2 6 91079, 65) NOTE 6 4 Swingarm pivot adjusiing bolt 2 30 7 (0.7, 5.1) ‘ See page 14 22 Swmgarm plvot adjustlng bolt iock nut 2 3O 64 (6‘5, 47) — Swingarm pivot nut 1 3 1a 9319 5, 69) 7 HYDRAULIC BRAKE: I ‘ Front mamr cyllndnr reservnir nap mew 2 1 4 2 40.2. 14) i From brake icvor pivot bolt 1 i n 1 «o 1, 0.7) -’ FIuIIL brake iever pivot nul 1 i 6 6401:3431 Hnnt h'HkF iight switch screw 1 1 4 1 401.07) Front master cyiindcr mounting bolt 1 7 6 121119) From. brake caiiper assembly lorx boit i 8 ‘ a 23 (2.3, 17) NOTF 7 ant hrakr caliper mounting flange bolt A S 30 (3.14 22) 1 NOTE 6 Rear master cviinder push rod joint nut i 1 i a 18(1.8,13) Rear master cyiindar mounting bolt 1 z i b 9 my, G5) Rear brake reservoir mounting boil/nut 1 6 1 1211.2, 9) Rear brake caiiper bolt 1 S 23 (2.3, 17) Rear brake caliper pin bolt 1 12 2712 3,20) Pad pin 5 10 ‘ 1811.8, 13) 1 Pad pin plug 1 10 1 310.3,22) 3 Brake hose oi) be): 5 10 3413525) Brake L‘dlipel bleeder valve 3 i 8 6 (0.6. 4.3) LIGHTS/METERS/SWITCHES: i 1 1 Sidc Stand Gwllch bolt 1 i 6 ‘ 10(110, 7) NOTE 6 Ignition switch mounting unit 2 a 25 [7.5, 1R) Fan mntnr switch 1 ‘ 16 18 l1.3, 13) NOTE 1 OTHERS: ‘ Side stand pivor bolt 1 10 i 10 (1 0, 7) Side stand pivot lock Hut 1 10 1 2913.0, 22) Slde stand bracket flange hnli 2 1O ‘ 4414 33) ‘ NOTE 5 Driver toorpcg brackcl socket bolt 4 8 i 26 (2.7, 20) 1-16 TOOLS NOTES ‘l, 2 Not available in USA. 3. Alternative tool. 4. Newly designed tool Equivalent commercrnlly available in U.S.A. GENERAL INFORMATION DESCRIPTION Fuel pressure gauge Url pressure gauge so! Oil pressure gauge ananhmem Universal bearing puller Clrrrch center holder Flywheel holder Rotor puller Remover weighr Attachment. 32 x 35 mm Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment. 52 x 55 mm Allauhment, 24 x 75 mm Attachment, 22 x 24 mm inner driver C Allaulrrrreul, 25 mm ID - Anacrrmentv 30 mm ID, Film, 17 mm Pilot, 20 mm Film, 25 mm Pilot, 35 mm Pilot, 28 mm Hearing remover shaft 30’ my remover head, 70 mm Dri or Valve snrrng compressor Valve aebl cutter Scat cutter, 245 mm (45' EX) Seat mmnr, 27.5 mm (45' lNl Flat Cutler, 24 mm (32‘ EX) Fla! outlet. 27 mm 132‘ IN) Interior curler, 72 mm (60' EX) Interior cutter, 28 mm 160' INl Cutler holder, 4.0 mm LuLIt nut wrench Snap ring pliers Sreerrng stem socket Bearing remover handle Bearing remover head Ananhment, 28 x 30 mm Ball race remover set , Driver attachment, A 81‘ ananhment, B - 0 er shall membrv , Bearrng remover, A — Bearrng remover, B - Assembly base Steering slam driver 1 Fork seal driver weight Fork seal driver attachment Driver TOOL NUMBER REMARKS REF. sac. 0740041040003 NO 1 E :1: 0/400—0040002 5 075003000000 NOTE1 r 4 07510 MJ10100 1 NOTEl ‘ 4 07031—0010000 r NDTEl r 12 07724—005000: l NOTE1 l 9 07725-0040000 l NOTE1 10 0773-0020001 NOTI' .1- 07933-3950000 ‘ 10 07741—0010201 NOTE 3: 14 07910 37102014 10.5.11. onlyr OWNS—0010100 0.14 07746—0010200 9, 14 07745-0010300 13,14 077400010400 14 07746 0010700 14 0774041010000 ; 14 07745—0030r00 r 11 07740 0030200 12 07740-0030300 11 0774154040400 9, 14 mus—0040500 r 13, 14 077400040000 1 14 07745—0040300 1 9 07746—0041100 l 14 077400050100 ‘ 13, 14 07746 0050600 13. 14 0774041010000 9. 13, 14 07757—0010000 r 0 NOTE 1 s 07700—0010100 ‘ 07730—0010200 ; 07/00—0012500 ‘ 0778043013300 l 07730—001420: l ‘ 07711041014500 1 07731—0010500 r l 079084690003 1 4 n79‘lb—SASDOU'I l 15 079164710101 NOTE 4- 075103710100 13 0793673710100 14 H7935—37106DU 14 07946—1370100 14 0794s KMSOOm NOTE 3: 13 0794041490100 Can be used With the following 07946—KM90200 Dunlbirraliun 1054 only): 0794EH Lmuid sealant" ' 1anee Bond 1207B 0! 1 equivalent» l r 1 1 r \ r - 15mm 10 10.4 — 0.6 in) ID! -0‘E in) 1 T 10415 m’fi j Right crankcase cover mat-ng surface Oil pressure swirch (hreads ‘ Do not apply scalanr to (he rhread ‘ head3—4 mm (OJ-0.2 in}, 4, < , 1-19 GENERAL INFORMATION _ ENGINE [Cont’dl — 7 LOCATION MATERIAL 'cvlindcr head scml clrcuiar cutout fl ‘ Main lmirnal bearing surface Piston pin Sliding surface Connecting rod hearing suriace Connecting rod small end inner surface Crankshaft thrust suriace Camshaft lobes/journals and thrust surface Valve stem lvalve guide sliding surface) Valve ilher outer slldlng stlflnce Water pump shalt 5plino and thrum washer sliding surface Clutch Oulel/plilllaly uiiven gear sllding sunaca Clutch aim-.7 guide sliding surface M3,’4, C5. C6 shifter gear (shift fork grooves) Starlet reduction gear shaft outer surface r'rirnary stihrgear friction spring sliding suliace APPLICATION AREA APPLICATlON AREA _ . fl Plsron ring sliding area on stiallrer packing Clmnh disc surlace Starter one way clutch sliding surface Connecting rod nut Ihrsads Flywheel bnlt threads and seating surface - Main journal 97mm bolt threads and seating suriace rafter removing anti-rust oil additive) Cylinder head special bolt laflel Iemovilly .nil-iuet oil additive) Clutch center lock nut threads Oil filter camidge threads and O-rillg Camshaft holder boll threads and seating stiflace Oil cooler center bolt threads ‘ Each gear teeth and lulalillg surface Each bearing Each O»ring ‘ Other rotating area and sliding suriace Sealant l i Muiybdenum disumde nil in mixture 0' U2 engine oil and 1/2 molybdenum dieulfide grease i Engine ml REMARKS 1-20 GENERAL INFORMATION , ENGINE (Cont'dl *7 LOCATION MATERIAL REMARKS l Timing hole can lltleadsr ‘ Multi purpoge grease b 7 if 7 Each oil seal lip: ‘ Upper crankcase scaling bolt threads ‘ Locking agent I '7 ._ I M Lower crankcase sealing bolt threads Cylindel head sealing hnlt threads Cylinder hand cover breather joint threads Cvltndcr head seallnq bolt threads Cam pulse gettetator rotor bnlt threads Starter one-way clutch outer bolt threads on pump driven sprocket bolt threads Shift drum bearing set plate bolt threads Mainshah bearing set plate bolt threads Cam sprocket bolt threads Cylinder head cover weather plate bolt threads Shilt drum center boll "trends r —r l Cam rham tensloner pivot bolt threads 1 Spindle plate tightening bolt threads Crating wtdth: lib ; 1 mm 1-21 GENERAL INFORMATION * FRAME LOCATION Seat catch hook sliding nma Front wheel dust seal lips Final driven flange-tweet wheel huh mating surface and O—rlng Rear wheel dust seal “95 Rear wheel side collar inner surface Thrnme grip pipe flange Clutch Icvcr pivot bolt sliding area Rear brake pedal pivot sliding area Gearshift pedal link tierlud ball juirlls Gearshift pedal pivot Rider rootpeg slid‘ng area Pillion lootpeg sli my area Side stand plvor Center stand pivot Steel ing head bearing sliding surface Steerlng head dust seal lips 1 Swingarm pivot bearings ‘ Swinyalrn pivul dust seal lips Shock arm and shock link needle bearings Shock arm and shock link dust seal lips Shack absorber needle bearings Lenin-x absorber dust seal lips ‘l'irronlc cable A'B outer inside Clutch cable outer insude Clutch cable Outer inside handlebar grip rubber min;— i MATERIAL REMARKS Multi-purpose grease Multi-purpose grease {Shall Alvania EPZ or equivalent) Cable lubricant Honda Band I\ or Honda Hand Grip Cement IU.S,A. only) Steering bearing adjustment nut threads Englne oil Front brake lever to master piston containing area Front brake lever pivot Rear master brake master pisluu-lu-push rod contacting area Brake caliper dust seals Hear brake caliper boot inside Rear brake caliper pm hnot inside Brake master piston and cups Brake caliper piston and piston seals Silicone grease 1301' A brake fluid ‘ Fork nap O~ring Fork dust seal and ml seal Ilps Rear brake reservoir hose joint screw threads rmnc brake caliper assembly bolt threads Roar brake caliper pm halt threads Fork fluid Inciting agent 1 -22 GENERAL INFORMATION CABLE & HARNESS ROUTING CLUTCH CABLE THRO‘I‘I’LE CABLES - war A L ,4, ' 9.; ' ”*6” / ‘t ,,r:;@(/ #0.; \\ 105E ‘ ‘ L T 'v I <, FRONT I’IRAKI’ a “L/ COMBINATION METER 9? (BLACK) CONNECIUH RIGHT HANDLEBAR SWITCH 9P (BLACK! CONNEC | OH COMBINATION METER 9P (NATURAL) CONNECTOR IGNITION SWITCH 4P LEFT HANDLEBAR SWITCH (NATURAL) CONNECTOR SP (BLACK) CONNECTOR ENGINE STOP RELAY HEADLIGHT RELAY TURN SIGNAL RELAY WHITE TAPE RIGHT TURN SIGNAL CONNECTORS LEFT TURN SIGNAL CONNECTORS HEADLIGHT SOCKETS FRONT 5U BVHARNESS ‘ZP IGRAVI CONNECTOR 1 -23 GENERAL INFORMATION LEFT HANDLEBAR CLUTCH CABLE SWITCH WIRE / —} ,‘—\ WIRE BANDS Amy—)9 \\ MAIN WIRE HARNESS HORN WLRE COMBINATION METER SUBr HARNESS FRONT SUB»H/\HNESS 12P1GRAY) CONNECTOR COMBINATION METER 9P tfiLACK) CONNECTOR COMBINATION METER 9P [NATURALI CONNECTOR 1-24 GENERAL INFORMATION THROTTLE CABLES CLU ICH CABLE HIGH] HANDLEBAH SWITCH WIRE WIRE BAND WIRE BAND WIRE BAND FRONT BRAKE HOSE 1 -25 GENERAL INFORMATION WIRE BAND THROTTLE CABLES RIGHT HANDLEEAR SWITCH WIRE BRAKE HOSE LEFI' HANDLEBAR SWITCH WIRE HORN WIRE IGNITION SWITCH WIRE WIIII BANDS CLUTCH CABLI: MAIN WIHE HARNESS 1-26 GENERAL INFORMATION IAT SENSOR MAP SENSOR FUEL INJECIUH K SUE HARNESS 9P (GRAY! CONNECTOR No 4 INJECTOR NDJ INJECTOR No.3 INJECTOR No.2 INJECTOR PRESSURE REGULATOR 1-27 GENERAL INFORMATION PAIR CONTROL SOLENOID VALVE CRANKCASE BREATHER HOSE THROTTLE CABLES PAIR AIR SUCTION HOSF , J PAIR AIFI SUCTION ' ' ’ HOSES WIRE BAND IGNITION COIL SUN-HARNESS FUEL INJECTOR SUB-HARNESS ‘IOP IGRAYI CONNFCTOR THROTTLE SEN- SOR 3P (GRAY) CONNECTOR N0.'I VACUUM HOSE No.4 VACUUM HOSE WHITE TAPE MAIN HARNESS CLAMP FUEL TANK AIR VENT HOSE GROUND POINT FUEL TANK OVERFLOW HOSE COOLANT OVERFLOW HOSE 1 -28 GENERAL INFORMATION SIPHON HOSE IGNITION COII SlIH-IIARNLSS 6P (BLACKI CONNECTOR AIR BLEED HOSE CAM PULSE GENERA TOR 2P (NATURALN SIDE STAND SWITCH 2I’ (UHEENIIENGINE SUB-HARNESS 12F ‘ :ETGSREX‘fIOR (GRAVI CONNECTORS CONNECTOR FAST IDLE WAX UNIT WATER HOSES IGNITION PULSE GENERATOR 1P (HEDI CONNECTOR STARTER MOTOR CABLE STARTER MOTOR GROUND CAEI F UPPER RADIATOR HOSE OVERFLOW HOSE VEHICLE SPEED SENSOR 3P (BLACK) CONNFCTOR 1-29 GENERAL INFORMATION ALTERNATOR 3? (NATURAL) REGULATOR/RECTIFIER 6P CONNECTOR (BLACK) CONNECTOR HEAR SUB HARNESS HP IGRAVI CONNECTOR SIDE STAND SWITCH WIRE THROTTLE BODY SUB-HAH- NESS 10F IGRAYI CONNECTOR MAP SENSOR 3P IGRAV) CONNECTOR IAT SENSOR 2P (GRAY) CONNECTOR CAM PULSE GENERATOR 2P (NATURALV SIDE STAND SWITCH 2P IGREENV ENGINE SUBVHARNESS 12F IGFIAVI CONNECTORS IGNITION COIL SUB»HAI'INFSS SP (BLACK) CONNECTOR F‘AIFI SOLLNOID VALVE 2P INATURALI CONNECTOR RADIATOR SUB-HARNESS 2P (BLACK) CONNECTOR CAM PULSE GENERATOR 1-30 GENERAL INFORMATION PAIR AIR SUCTION HOSE FUEL TANK AIR VENT HOSE NR BLEED HOSE FUEL TANK OVERFLOW HOSE SII’HON HOSE REAR BRAKE HOSE UFPFI'I RADIAIOH HOSE BRAKE LIGHT SWITCH WIRF CLUTCH WIRE IGNITION PULSE GENERATOR WIRE 1-31 GENERAL INFORMATION FUEL PUMPIRESERVE SENSOR WIHI: FUEL TANK OVERFLOW FUEL PUMP/RESERVE SENSOR 3F (BLACKI CONNECTOR FUEL TANK AIR VLN'I HOSI' FUEL HOSE FUEL Ht I UHN HOSF 1-32 GENERAL INFORMATION ECM 22F (BLACK) CONNECTOR / / // \v// ,2 k ECM 22F ILIGHT GRAV) CONNECTOR BATTERY MAIN WIRE HARNESS REGULATOR/RECTIFH’H FUSE BOX PGM Fl FUSE HOLDER » ’ 7 / / / x4 / / > SERVICE CHECK CONNECTOR STARTER RELAY SWITCH/ MAIN FUSE WIHE BAND SI IOCK ABSORBER RESERVOIR HOSE 1-33 GENERAL INFORMATION REAR SUBVHARNESS TURN SIGNAL‘LICENSE LIGHT CONNECTORS REAR SUB-HARNESS IAI’ (GRAY) CONNECTOR ALTERNAIOH 3F (WHITE? CONNECTOR REGULATOR/RECTIFIER 6F (BLACK) CONNECTOR BRAKE LIGHT SWITCH 2P IBLACK) CONNECTOR MAIN WIRF HARNESS WIRE BAND BATTERY NEGATIVE (-) TERMINAL WIRE BANDS BRAKE RESERVOIR HOSE HEAR BRAKE HOSE FIIFI CUTvOFF RELAY ENG‘NF STOP REIAY TAIL/BRAKE LIGHT CONNEC | OHS 1-34 GENERAL INFORMATION CALIFORNIA TYPE: 5-WAY JOINT h in/ S‘J—I , ‘ FL Q "3 FUEL TANK AIR VENT HOSE CANISTER DRAIN HOSE EVAP PURGE CONTROL EVAP CANISTEH SOLENOID VALVE 1-35 GENERAL INFORMATION EVAP PURGE CONTROL SOLENOID VAl Vl' CAN‘STER DRAIN HOSE EVAP CANISTER FUEL TANK AIR VENT HOSE 1-36 GENERAL INFORMATION R m w R R C N P E mm H 3“ m Hm WK M R RN W ER 5 TN ,10 mo R 1N C BVT c w 8 EN UAC AI 0 SN N MO SHE WE m TD an RN RmmN E.“ E H” A 0K APN TN 3 GK H Tc EAO MW 2 me E mm R1C I. O m. R E I UB KB W G( A1 D EP RF MW R6 52 em E R m 0) SENSOR 3F (NATUHAH L m A T m c M m R N F. 0 D C l_‘ E N M G E N Y R R 5m m S V EA R NE E n m AHA R E E U ME S ,1 R0 E R S BH S A 0 NE E H mo a H mm A E H AN H NN R pluo A SC \ E NT R RH Um IL FUEL CUT-OFF RELAV ENGINE STOP RELAY TAIL/BRAKE LIGHT CONNECTORS 1-37 WIRE BAND GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency. California Air Resources Board (CARBi and Transpun Canada require iiiaiiuiac» tutors to certify that their motorcycles comply with applicable exhaust emissions standards during their useiiil iiie, when oper- ated and maintained according to the instructions provided, and that motorcycles built after January 1. 1933 comply with applicable noise emission standards for one Vear or 3.730 miles (6.000 km) after the time oi sale to the ultimate purchaser. when operated and maintained according to the instructions provided. Compliance with the Ierms oi the Dislributor's Limited Warranty tor Honda Motorcycle Emission Control Systems is necessary in order to keep the emissmns system warranty in effect. SOURCE OF EMISSIONS The ooiiioosiiuii process produces Lalbon iiiuiiuxide, liyiiiocarlions arid oxides oi iiilrugen. Control oi hydrocarbons and oxides oi nitrogen is very important because, under (tannin mnriitinns. they react to form photochemical smog when suh- jcctcd to sunlight. Carbon monoxida does not react in the some way, but it is toxw. Honda Motor 60., Ltd. utilizes PGM~F|, two liireerway catalytic converters and a heated oxygen sensor to reduce carbon monoxide, hydrocarbons, and oxides oi nitrogen CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions mm the ntmnsphere. Blow-by gas is 19“"an to the combustion chamber through the air cleaner and throttle body. AIR CLEANER HOUSING THRO‘I'I'LE BODY <‘,= FRESH AIFI fix F _ BLOW-BY GAS 1-38 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR SUPPLY SYSTEM) The exhaust emission conltul system is composed oil a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase cmis smn control system. The exliausl emission control system consists nl pl secnndnry air supply system which Introduces filtered air Into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the Pulse Secondary Air Injection (PAIRT control valve. This charge of llesh aIl promotes burning ot the unburned exhaust gases and chnnges n consuiernhle amount of hydrocar- bons and carbon monoxide Into relatively harmless carbon dioxide and water vapor, The read valve prevents reverse air flow through the system, The PAIR SDIEfiOld control valve is mntrnllert hy the I’GM-H unit, and the iresh air passage is opened and closed according the running condition lECTJIAT/TPJMAP sensor and engine revolur hon). No adjustments to the secondary air supply system should be made, although periodic Inspection of the components is rec ommended. AIR CLEANER HOUSING PAlR CHECK VALVE H\THROT‘I’LE sopv / _ (H— 1 FRESH AIR LI “ EXHAUST GAS FAIR CONTROl VALVE EXHAUST PORT CaIIIomIa type: lhe Calilornia type is equipped with two thrcerwav warm up catalytic converters. a threerway catalytic converter. and a heated oxygen sensor. The three-way catalytic converters are in the exhaust system Through chemicei reactions, they cnnven‘ HC, C0, and N0): in the engine‘s exhaust to carbon dioxide (C02), dinitrogen (N2), and water vapors No adjustment to these systems should be made although periodic inspection of the components is recunuueuded. 1-39 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TVPE ONLY) This model complies wilh California Air Resources Buard evaporalive emissiurt requirerrrents, Fuel vnnm imm the hiel innk IS muted min the. evaporative emissinn IFVAPI canister where it is absorbed and stored while the engine is moppcd. When the engine is. running and the cvaporativc emission (EVAPI purge control solenoid valve l5 open, Iuei vapor In the EVAP canister is drawn into the engine through the throttle body FUEL TANK / 1’ \‘x a", l r ' "§\\ r i r “fix “a” L \L \\‘\\ J \ IHHUI ILI; uouv \ \‘\\ “N \ \ \ \x \ ‘ I'VAI" PUI’IGI' CONTROL SOLENOID VALVE 6—H FRESH AIR 4- FUEL VAPOR NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal, stale and legal law pruhrblts the Ioilowing acts or the causing thereof: 11} The removal or rendering inoperative by any person, nthnr than fnr purposes oi maintenance, repair or 'epiacemem, of any device or element of design incorporated into any new vehicle for the purpnse of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, i2l the use at the vehicle ailer suuh device or element of design has been removed or rendered Inoperatrve by any persnn, AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMP‘ERING ARE THE ACTS LISTED BELOW: 1. Removal at, or puncturing or the rnutrler, names, header pipes or any nther component which rondnnts exhaust gases. 2. Removal of. or puncturing at any part of the intake system. 3' Lack orpiupei rrldirllellallce. 4. Replacing any moving parts at the vehicle, or pans hr the exhaust or intake system, with parts other then those sperified by the manufacturer, 1-40 GENERAL INFORMATION EMISSION CONTROL INFORMATION WEEK LABELS (U.S.A. ONLY) An Emissmn Contrm Iniovmaxion Laba‘ is located on the storage Lompanment as shown. The plllinn sent must be removed to read It. It gvaS base xunerup specificaxions‘ VACUUM HOSE ROUTING DIAGRAM LABEL (CALIFORNIA TYPE ONLY) The Vacuum Hose Routing Diagram Label 15 on the air cleaner housing covav as shown. The fuel tank musl be npensd vn read it Ramm page 3-4 for fuei tank opening. ‘ VACUUM HOSE ROUTING DIAGRAM LABEL 1-41 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS WINDSCREEN UPPER COWL PILLION SEAT FRONT FENDER REAR FENDER REAR COWL LOWER COWL INNER HALF COWL NR DUCT COVER FRONT AIR DUCT COVER AIR DUCT 2. FRAME/ BODY PANELS/EXHAUST SYSTEM l BODV PANEL LOCATIONS 2-0 UPPER COWL 2-7 —‘ SERVICE INFORMATION Z-1 FRONT FENDER 2-12 TROUBLESHOOTING 2-1 REAR FENDER 2-13 ' SEAT 2-2 SEAT RAIL 2—16 B PILLION SEAT/REAR COWL 2-2 MUFFLER/EXHAUST PIPE 2-19 l LOWER COWL 2-4 SERVICE INFORMATION GENERAL Work In a well ventilated area, Smokinq or allowing flame: or sparks in the work area or where gasoline Is stored can cause a fire or explosion. Thls section covers removal and Installatlon of the body pant-.ls and exhaust system Serious burns may result it the exhaust system is not allowed to cool before components are removed or sen/Iced Always replace the exhaust pipe gaskets ahe- removing the exhaust pipe from the engine. When installing the exhaust system, lnnsaly Install all at the exhaust pipe tasteners, Always tighten the exllauhl dumps flrSI. than tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust DID? may nnt spar plouerlv. Always insrwnt the exhaust system for Ipaks aher installation. TORQUE VALUES Upper cowlrtoAlower cowl screw 2 N-m lu,15 kgt~m4 1.1 lhI-m Inner halt cowl-to-luwer cowl screw 2 N-m (0.15 kgf-m. 1.1 lbI-fti Vi/indauleen selling screw 1 Nut! (0.05 kgI-m. 0,4 lbf-h) SP!!! mil upper mounting hall/nut 49 N~m [5 0 kgI-nx 3G lbf'fll Scat rail lower mounting bolt/nut 49 N-m (5.0 kgf'm. 3b lbf-ft) Exhaust plpe iuint flange nut 12 N'm (1.2 kgI-rn,91bI-ftl Muffler band flange bolt 23 N-m (2 3 Irgf-m, 17 lbI-l'l) Passenger tootoeg flange bolt 26 N-m (2,7 kgi-m. 20 lht-h) TROUBLESHOOTING Ex n axhnust rials: ~ Broken exhaust system - Exhaustgas leak Poor pedormance ‘ Delotmed exhaust svslam ~ Exhaust gasleak - Clogged muffler 2-1 FRAME/BODV PANELS/EXHAUST SYSTEM SEAT SEAT REMOVAL , ‘ Remove the (we Seal mouminq bolts behind me ssaL -. 77 F Sula the Sam back and then remove It. Remove the mounting collars. COLLARS INSTALLATION sous so ca'cl‘mnm :: lnsxall the mounting collars into (he see: brackets as HOOK drop me mm" shuwvn "y We» Angn the seal hank with the hm tank mar hrnnkev and install the scat. Install and tighten the sea! mounting bolts securely, ' ”‘ COLLARS PILLION SEAT/REAR COWL I REMOVAL IéNITION KEV Remove the seat (see above). Unhnnk me pillmn sear Inck nsmg lhe lgnltinn key Pull up mo rear and of rho pillion seal and than remove Ihe seat. Remove the mar cowl sorting bolts. and washers WASHERS FRAME/BODY PANELS/EXHAUST SYSTEM Remove the M0 5 mm screws and four (rim clips. Carefully pull both sides of the rear now], then remove I1 from the seat fail. INSTALLATION SEAT TRIM CLIPS REAR COWL PILLlON SEAT REAR COWL 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM Instanation is in the reverse order of removal. TRIM CLIPS Wu 51m: m Tlghlen the rear cowl screws and setting bolt securely Maw/VG surfaces 1‘ MP cowl bot- :o'r' ale seam} ENG 2‘ C 750/ {army nmfier/y Dsfols rrg'filemng the raszeners LOWER COWL REMOVAL Remove the two trim clips from the bottom of the lower cowl. Remove the two trim chps and four screws from the inner half cowl. SCREWS SCREWS Remove the six lower cowl mounring screws. ‘ LOWER COWL SCREWS FRAME] BODY PANELS/EXHAUST SYSTEM Release the lower cowl bass from the air intake due! I BOSS/GROMMET cover grommet, then remove the lower cowl. , LOWER COWL I Remove the two lrim clips and inner half cowl / / INNER HALF COWL INSTALLATION RIGHT LOWER COWL 2 N‘m (0,15 kgf‘m, 1.1 lbf'fil , / J ,N ‘ ‘ ”VI” ‘ . ,. z I ‘ / ‘ x I $5“ I ~ I I I , ' ’2‘ V .7 w 2 N~m (0.15 kgi-m, 1.1 Ibf-fl) INNER HALF COWL LEFT LOWER COWL FRAME/BODY PANELS] EXHAUST SYSTEM Install fire inner hair L'owl inlu the upper cowl and ; WM Cl ”,5, J secure n wrrh mm mm clips , , / \NNER HALF COWL Sc! rhc lower cowl onto the frame and Insmll mp. ; lower cuwl boss into me air dual cover grommet. LOWEH COWL Install the six screws. SCREWS ‘l’rghmn the upper cowl ro lower cow‘ screws 9n the specified lurque. wsrrsrron TORQUE: 2 N-m (0.15 kgfim, 1.1 lbfAm LOWER COWL SCREW (4 mml lnstaH the Inner half cowl-m»lnwer mwl two trim clips TRIM CLIPS and four screws, ‘ Trghten the screws to the specified turquer TORQUE: 2 N-m (0.15 “WM. 1.1 leII SCREWS SCREWS 2-6 FRAME/BODY PANELS/EXHAUST SYSTEM lnsmll the two mm EIIDS mm the bottom of the lower cowll UPPER COWL 39 (NEW v m‘ m da-nsqs ms '305 REMOVAL Remove the lnwarcnwl and Inner halloawl (page 2-41. Remova (he air duel cove: mounting two screws. Carefully relaasa ma mr mmke duct cover boss and hook from the me! tankl Remove ma air ducl cuvel while leleasing the hook ham the upper cowl grnnve. Remove the socket DOIIS, plastic and rubber washers, then remuve the windscreen, SCREWS AIR DUCT COVER AIR DUCT COVER HOOK RUBBER/WASHER GROOVFS PLASTIC WASHER 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM Remove me rearview mirror mounting sockcx bo|ts and rearview mirrur. Se «Val/Maul (’4 Disconnect the from subrhamess connector. scram ms was] cow’ m: Mm Release me upper cowl off the rcarvicw mirror bolt Fender hole studs and remove Ihe upper cowl assembly, Unhook the resonator chamber smya from the res» onalurs. Remove the air dun from the air cleaner Intakn duct. Remuve [he lrim clip and resonator from the air duct. SOCKET BOLTS REARVIEW MIRROR SUB-HARNESS CONNECTOR AIH DUCT RESONAYOR CHAMBER TR|M CLIP Am DUCT 2-8 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the from 8" duct covers from the upper cowl. FRONT AIR DUCT COVER SCREWS Disconnem the mrn signal/lunning light connemorsl TURN SIGNAL UNIT Remove the nut and setting plate. man remove the front turn signal unin Reler to seclinn 15 for from sub-harness. headlighl/ turn signal relay and headlight uni! removal/ installation Rum to section 51m engine stop sensor and relay removal/installation. SETI'ING PLATE NUT INSTALLATION WINDSCREEN AIR DUCT COVER REARVIFW MIRROR AIR DUCT UPPER COWL FRONT AIR DUCT COVER 2-9 FRAME/BODV PANELS/EXHAUST SYSTEM Route the mm slgnal wire into lhe upper cuwl, inner middle cowl and scning plate. Install and lighten the nut securely. Connect the turn argnaI/runmng Ilghf Cnnneclorsv Install (ha from air duct covers into the upper cowl and tighten the screw securely. lnsmll me resonator oma the ail duul and secure it with a trim clip. Install the air duct into the alr cleaner Intake dlmv Honk the resnnmnr chamber stays to the chambers, WUHN SlGNAL UNIT SETI'ING PLATE NUT FRONT AIR DUCT COVER SCREWS 1 7 / AIR DUCT AIR DUCT 2-10 flnma vua harness and mates 3,, «saga ' Jr msza‘l the bum >thkel nm'rs mm {’79 lOWEV ends 5* ENE wmasclcnn m. FRAME/BODV PANELS/EXHAUST SYSTEM Install ma upper cowl onto the upper cowl stay while aligning the headlight unit bosses with the upper cowl stav grommets, Be sure to align the mr duct covers wnh the air ducts. Set the upper cowl onto the rearview mlnur bolt hole studst Connect the front sub-harness conneclm. Install the reamew mirror and tighten the socket bolts securely, BUISKEI BOLTS REARVIEW MIRROR Install the windscreen. then install the lubbel and liw plastic washers and socket bolts First tighten the lower four socket bolts, than tighten the upper two socket bolts to the specified lulque. INDsanEN SOCKFT BOD 5 TDHUUE: 1 N-m "1.05 kgftm, DJ lbf-ft) LONG 50th FRAME/BODY PANELS/EXHAUST SYSTEM Install the alr duc‘ cover aligning the dual boss with the groove in the upper cowl Be sure to align the pm and tab will the fuel tank gramme: and groove. 594 LaVe'u'HUI :u ammo we ran: Instafl and tlghten the screws securely. FRONT FENDER REMOVAL Remove the from fender mounting special smews. brake hose clamp bolts and reflectors, Remove the from tender forward INSTALLATION Install Ihe from vendor in the reverse order of removal. AIR DUCT COVER HOOK GHOOVES SCREWS AIR DUCT COVER FRONT FENDER CLAMP BOLT ; : SPECIAL SCREW 2-12 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL Remnve the following: , Roar cowl (page 2le — ECM (Page 5-85) - Battery (Dag! 16-5l Release the bones from [he may lender, then remove lhe battery tray cover. Unhoak the ramming tab and remove the PGM Fl fuse case and fuse box. Remove the stanar relay sw'rtch from the rear lender boss. Disconnect ma following cmmeclors. - Real lum signal cnnneclnrs - Lucense light connector , Tail/brake light connscmrs Unhook vhe seat lock cable "cm the cable stay, Remove the fuel cu1~off relay and engine slop relay from the rear Vender bosses‘ Release the mar Sub-harness from the rear fender wire guides, ‘ BATTERY IRAV COVER F‘GM-FI FUSE CASE FUSE 50X STix'm'LR HELAY SWITCH TAIL/I'BRAKE LlGHT CONNECTORS ' SEAT l DCK CABLE (7.. l 7' ‘ LlCENSE LIGHT CONNECTOR TURN SIGNAL CONNECTORS FUFl CUT-UFF RELAY ENGlNE STOP RELAY SUB-HARNESS 2-13 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the Mo rear lender mmmfing bolts and collars. Unhuuk [he rear lander fram the seal rail brace, [hon remnva the rear iender while moving il back. REAR FENDER SEAT RAIL BRACE INSTALLATION ENGINE SIUP RE! AV BA] fl‘flY FUEL CUT-OFF RELAV REAR FENDER FUSE BOX PGM-H FUSE HOLDE R STARTER RELAV SWITCH EATTFRY TRAY COVER 2-14 VVhlle nsraI/m. the fear lsfldfil 5m ere me me a» plougr’y «page l23‘ FRAME/BODY PANELS/EXHAUST SYSTEM |nsta|l the rear lender whlle aligning rts lower groove wrth the scat rail brace, Install the rearfander mounting cellars and Dolls, and tighten llle bolls securely Ruule the last sub—harness properly and install n into the rear tender wrre guides. Install the tucl cut-off relay and turn signal relay onto the rear lender bosses Connect the followlng connectors: — Rear turn signal connectors — License light connector 7 Tail/brake light connectors Connect the seat Inck tabla m the nahle stay Install the removed parts in the reverse order of removal, SUB-HARNESS ' l lAIL/BHAKE LIGHT CONNECTORS SEAT LOCK CABLE fithSE LIGHT CONNECTOR TURN SIGNAL CONNECTORS 2-15 FRAME/BODY PANELS/EXHAUST SVSTEM SEAT RAIL REMOVAL Remove the rear Vendar (page 2713L Loosen the rear shock absorber reservorr tank band and remove the reservoir tank from the sear rail. Remove me brake light swilch wire band. Remove the bolt/nut and rear brake reservoir tank from the sear rail. Remove In: regulator/rectifier (page 1645). Rellluve the muffler mourning boll/nuL Remove the hnfls and ngm nillmn inmpeg hrankev Remove the bulls and lefr pilliun foutpeg brackerv BO LT/N UT RESERVOIR TANK | BOLTS HOLT/NUT PILLION FOOTPEG BRACKET BOLTS PILLION FOOTPE‘G BRACKET 2-16 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the main wire harness band. COLLAR/WASHER BOLTS/FLANGE NUTS Remove the sear rail mounting halts/nuts, cnoIant reservoir tank mounting collar/washer and seal rail. | I ‘ BOLTS/CAP NUTS WIRE BAND ‘ INSTALLATION 26 N-m (2.7 «gr-m. 20 [hr-m SEAT RAIL RIGHT PILLION \ FOOTPEG BRACKET \ - ' REGULATOR/RECTIFIER 49 N-m 15.0 kgl-m, 36 Inf-m 26 N-m (2.7 kof-m. 20 Inf-h) BRAKE RESERVOIR LEH FILLION FOOTPEG BRACKET 49 N-m (5.0 kgf‘m, 36 |le) COOLANT RESERVOIR TANK Inslall lhe seal rail unlu the flame. BOLTS/FLANGE NUTSV Insta"me cap Sal lhe coolant reservoir rank, collar and washer to wul: am me Mr lhe right upper mount, then install the mouming bulls sear ran momr and nuts HoId the mounting bulls and Kighlen the nuts to the specified torque, TORQUE: 45 Man (5.0 kgl-m. 36 lbI-fl) Secure lhe main wrre harness With the Wire hand. BOLTSICAF NUTS WIRE BAND FRAME/BODV PANELS/EXHAUST SYSTEM |ns(all the left pillion footpeg bracket and Uglllun llle bolts to the specrfred torque, TORQUE: 26 N‘m (2.7 kgl-m, 20 IBM!) PILLION FDOTPEG BRACKET Instal‘ the lch uillion footpeg bracket and tighten the ——BOLTS bolrs to the specifiad torque. ' TORQUE: 26 Ncm 12.7 knl-m, 20 Ibf-m lnsrall the muffler mounting bolr,washer arlduul,ar1d tlghten the nut secure‘vr InslaI! [he Iegu‘dluu‘leulifier (page 16-8). BOLT/NUT P|LLION FOOTPEG BRACKET Route the rear brake reservoir hum: properly, inslall and tIghlen me bait/nut to thy: spammed rnrque TORQUE: 12 N-m (1.2 kgl-m, 9 lbl-fl) clamp the rear brake light swirch wxre With the wire band. BANb ‘ BOLT/NUT Install the rear shock absorber reservoir wwh in mm- , . . BAND pressron adjuster facing out. Women the hand screw securely, RESERVOIR TANK Insrall me removed pans in the reverse order of removal 2-18 FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER/EXHAUST PIPE 4P1NA1UHAL> CONNECTOR REMOVAL Remove the lower cow! and inner half cowl (page 2»AL C‘m‘r‘nmm M'Ie Disconnect (he 0: sensor 4? (Natural? connector. aw Remove me 0: sensor wire hum the flame. Loosen ma muffler baud buns Remove the muffler mounting bolrlnut and washer, then remove rho muffler. Remove the gasm. Remove me radiamr lower muunling bolt/nut, then move the radiator forward FRAME/BODY PANELS/EXHAUST SYSTEM Remove the exhausl pipe juim nuls. Remove the foHowmg: - Exhaust pipe mounting boln’nux — Washe! — Exhaust pipe — Exhaucx pipe gaskets Remove me nnllar and mounting rubbers from the cxhaual pipc brackcL INSTALLATION Excam Calflornla type: MUFFLER 23 N-m (7 3 kgfim, 17 ”of-fl) EXHAUST P‘PE ASSEMBLV 2-20 FRAME/BODY PANELS/EXHAUST SVSTEM California type: MUFFLER O: SENSOR 25 N'm (7 6 kgf-m, 19 thfl 23 NW" (2.3 kgf-m, 17 leI) Am,” .wldw Install the new exhaust plpe gasket: onto the exhausi m: cxnausmmc pons of the cylinder head. 9mm wl one: Install the mourning rubbers and collar in“) me exllausl pipe mounting bracket lr‘smllmc lnslall the exhausx pipe, temporarily install the h. Nd exhaust pipejoim nuts, mounting washer and mount- p'avsl mg bolt/nut. EXHAUST PIPE 2-21 FRAME/BODV PANELS/EXHAUST SVSTEM figmn the Exhaust mpe jninl nun m m; magma torque. TORQUE: 12 N-m (1V2 kgf-m. 5 Ibi-h) Tugmen me exhausi pipe mounung bolt/nut. Install the radiator lower moummg bolmm and tightv en the nur. Install the new gaskcI Onto the exhaust pipe as >huwn. lwsxall (ha mufl‘cv. V GASKET 2-22 FRAME] BODY PANELS/ EXHAUST SYSTEM Ten-uo-a-ilv insxall the muffler mourning bun/nut. Tlghxcn the band band bolxs xo me speclfled mrque. TORQUE: 23 N-m (7‘3 kghm, 17 lbivfl) I hghten the muffler mouming bolt/nu! securciy. Cahrorma Mae Rome me O: sensur wile ‘mLu the (lame WW Canned the 02 _ .nsnr AP (Nammlh connecmr‘ Install the inner half cowl and lower cowl (page 2-7) BOLTS MUFFLER BAND fiOLTf NUT/WASHER ‘ // @w 2-23 MEMO 3. MAINTENANCE SERVICE INFORMATION SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE THROTTLE OPERATION AIR CLEANER SPARK PLUG VALVE CLEARANCE ENGINE OIL/OIL FILTER ENGINE IDLE SPEED RADIATOR COOLANT COOLING SVSTEM SECONDARV AIR SUPPLY SYSTEM EVAPORATIVE EMISSION CONTROL SVSTEM (CALIFORNIA TVPE ONLVI 3-1 3-3 3-4 3-4 3-5 3-6 3-9 3-14 3717 3-17 3-17 3-18 3-19 DRIVE CHAIN BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION NUTS, BOLTS. FASTENERS WHEELS/TIRES STEERING HEAD BEARINGS 3-19 3-23 3-24 3-24 3-25 3-25 3-26 3-26 3-27 3—30 3-30 3-31 i ' GENERAL - Piece the motorcycle uu Ievel ground heIore awning any work. - ifthe angina "um be runnlng m do some work. make 3 Gasoline i> extremr-‘Iy Ilnmmablc and is exDIosive under cevlain CDVICIIVIOI'ISV - Wonk in a we“ Ve'IIIIaICd area. SmOkIng ur allowing ilamns or sparks in the work area or where the gasoline IS stored can muse a iirc or expiosion, aredv The exnausI contains poisonous covbnn monmfldn gas that may caus the engine In an Open aiea or With an exhaust evacuation svsxam in an enciosed area. ure [he area is well Venvllnmd. Never run the engine In an uiiLlased 9 I085 of cuvmuiuusness and may Iead to doom. Run 3-1 MAINTENANCE SPECIFICATIONS Thronie'grip free play Spark plug Spark plug fl Valve clealallce 1 IN ‘ Ex Recurrlmanded engine oil ?n§ine idle speed ITEM ‘ DEEO Engine uilcapaciw ‘ After draining SPEOIFICATIONS 2~6rnrniii161 mini 7 ' IMRSArQH .. 1011sz "V 0.80 0.90 mm (0051— 0.0351n) o 03 rnm (0.008 2 a 001m) .03 mm (0.011 . 0,001 in) 3.0 liter (3.2 us m. 7.5 imp qt) ‘ After draining/oil filrer 0hangc 3.3llier135 us m, 7.9 imp qil Pro Honda GNJ nr HPA 4-slroke oil (USA. and Canada), or Honda I eirokc OII iCanada only), or equlVHlHnV motor oil APl service classification SF or SG Viscnsiry: RAE 1DW—40 0 ~ 106er Drive chain slack Recommended brake fluid Clutgh lcvor Ircc ploy ‘ 0014 l 75 - 35 mm 11 7 1-3/3 in) ‘ . l in; 20 mm 13/8 —1:i/1einl Tire size Front 120/70 2R 17 (58W) l Rear 7 ' 180155 in 17 (73W) * 7“ Tlrc brand Brldgesmne V7 ‘ Front BT010I=F 7 A 7‘ <7 g ivfieai' BTU10RF W lnlnp i From ' D207FJ 7‘ M Rem 0207p ‘ v4 . Michelin- " rruni Pilot SPORT E ' ‘ '7 i ; Rear Piloi SPORT: 7 V I ‘— >Tlre Air pressure i Up lo 90 {975200 lb) i From i 250 kFa (2.50 kgf/cm’, as psi) - . 1 ‘ '0” ‘ Rear 290 m 12.90 kgflcrn’, ‘2 psi) ”11:10 maximum 7 From 7 250 kPa 12.50 kgf/‘izrrr’, :la psii . W9” ”Parity Rear 1 290 kPa 12.90 kgiinmr, 47 psi) A —M—iriirrluln ine "Lid depIh From 1 1.5 mm 10.06 in) V Rcair l 2,0 mm (Don ln) A; W TORQUE VALUES Timing hole cap Spark piug Cylinder head cover bull Engine oil drain hnli Engine oil filter cartridge Rear axle ilul Drive sprocket spemal bolt Final driven sprockci nui Rear masier cylinder push rod joint nur TOOLS (in Mar wrench Drive chain (ool set 18 N-m (1.3 kgf-m, i3 ibI-fll 12 Mom (1.2 kgf-ml 9 lbl-rli lo N-m (1.0 kgf-m, 7 lbf-h) 29 N-rrl (3.0 kgf-m, 22 lief-fl) 7G N-m (2 7 kgf-m, zo lbi-ril 93 him (9.: kgf'm, as lhhfil 54 N-m (5,5 kgI-m. 40 IBM!) 64 N-rr1(6 5 kgl-nr, r17 lbi-fl) 13 N-m (1 a kgi-m,13lhi—h) 07HAA7PJ70100 Apply grease to the threads Apply clean engine oil 10 rim 0 ring. U—n Lit U-nur. 07HMH-MR10103 or 07HMH~MR10103 (USA. onlyl 32 MAINTENANCE SCHEDULE Perform me Pre-ride inspecriun in thP Owner’s Manual ar each scheduled nIaiIIIenance period I: lnspecl and MAINTENANCE Clean, Adjust, Lubricarc or Replace if necessary. C Clean. R- Replace. A: Adjust. L: Lubricara. The follnwmg Items require some rneulIanIcal knowledge Cenarn items (particularly moss marked ‘ and “I may rnqulre more technical Informaliun and tools Consult the" authorized HONDA dealer. '*= FREQUENCY NOTE ODOMETER READING (NOT II . _, x1,ooqui 0. :L2 15 (I7 fiEFtH ITEMS ’ ' ’ X100 km'I w 6 I123 192 256 320 354 TO PAGE - FUFI LINE I ‘ l l I 3-4 m‘-' THROTTLE OPERATION W ‘ I I’m l _ 34 7 . E ' AIR CLEANER , NOTE 2 _ R R 3-5 I: I SPARK PI uu I I R I 3-6 ‘ é ‘ VALVE CLEARANCE ,. _ I I I I I as V 5 I ENGINE OIL _ R R ‘ ‘ R ‘ R 3-” E I— I ENGINE OIL FIITm 7 I R _, R n R 314 EI . ENGINE IDLE SPEED I I I I I I I I I I 3-17 g‘wDIATOR COOLANT ‘ NOTE4 I I I I ‘ I I I R 3.17 E , COOLING SYSTEM I I I I I I 3.17! , r I SECONDAHV AIR suPPLV SYSTEM I I ‘ I V , I I :I-Is TI EvAPORArIVE EMISSIQN CONTROI SVSltM ' NOTE3 I I I I 3-19 A DRIVE CHAIN I _ EVERY goo mi (800 km) I, L 3-19 g BRAKE FLUID , NOTI’ a I I R I I R 3-237 “5 ’ nnAKE PAD WEAR I I I I I ! _3-24 BI BRAKE SVSTEM . I I I I I 3-24 '5 . I BRAKE LIGl:lT swncn . I I I E I 3-25 I “I; * HEADUGHI AIM . , I I I I 325 _ g I CLUTCH SYSTEM I , l I I I , I I ' I 3-25 gI ‘ SIDE STAND . _‘ 7 ‘I Y I I I 3-26 5 . . SUSPENSION I I I l I I 3-27 I g I- I NUTS, BOLTS, FASTENERS ‘ I I I I I 3-30_ g "I WHEELS/TIRES , l _ I I 3-30 7 ,HI STEERING HEAD nLARINGs I I I I I I l 3-31 Should be serviced by an autnomed HONDA dealer. u callv qualified, nless the owner has proper tools and service data and is mecham- In the Interest 0! safety, we recommand these items he serviced only by an amhuriied HONDA dealert NOTES: . At higher odometer reading. reveal a! the frequency interval estnhllshad here. , Semce more frequently if the mulorcycle Is rldden In unusually wet or duslv areas. I 2 3. CaIifornia type cnIy. 4 . Replace every 2 years, or at indicared odometer interval, which cal ski“, ever comes first. Replacement requires mechanI— 3-3 MAINTENANCE FUEL LINE BOLTS/WASHEHS Remove the an dud mvsrs (page 2-7) Remove (he fuel (ank Iron: mouming boltel Opell and support me Iron! and of the fuel xanx usmg a sumahlp support lzGO-mml as slmwn. Jaw-1; mm m- 'ln‘,’ nose Check the fuel lines Ior deterlormmn, damage 0| leakv age. Replace the fuel line if necessarvl InS‘IO‘I the fuel tank m the (averse order of removal. THROTTLE OPERATION Cluck Iur smoum m'onle grip full opening and enter mane full rlosmg in all Steering pusiliuns. Chuck [he thronle cables and replace them if they are delenorated. kinked or damaged, Luhricate the thronIe cablas, il Lhrunls onetazlon is nol smooth. Measme the flue ulay at the throttle grip flange, FREE PLAV: 2 , 6 mm (1/15 *1/4in) Thrnme grip free play can be adjusted m Either Pnd nl the (hronlc cable. Minor adjustments are made wi‘h the upper adjuster Adyusl the free play by loosening the lock nut and turning the adjuster. Major adjustments are made with me lower adjuster. Remove ma air clcanar housing (page 5-60). Adjusl the [lee play by loosening the quk um and mrning the nrlyusver. Aher adjustment, tighten the lock nut securely. Racheck the "aroma uperaiion. Replace any damaged parts, if necessary AIR CLEANER Suppon the from end or fuel tank (page 3-41. Disconnecl {he IAT llntaks Air Tsmperaiuvs) ssnsor Conneclul. Remove mo screws and air cleaner hsusing cover. Remove and discard me air cleaner element in accor dance wilh lhe mainlanallce lledulu (page 3.3). Also replace the air cleaner element any turn: II is cxccsaively dinv or damage. Install lhe removed pans In The reverse Order of removal. MAINTENANCE LOCK NUT ADJUSTER ADJUST”! l DCK NlJT -. ——.r -' [AT SENSOR CONNECTOR HOUSING COVER MAINTENANCE 2? (BLACK) CONNLC [OR SPARK PLUG . - REMOVAL NOTICE Be careful not to damage my vadr‘aror fins Remcvc the lower com and inner half cow‘ (page 24). Disconnect the v'an mmar Suh-harna<< 7F inlankl nnn» nectar. Remove We Iddialov Iowél mounmng mm mm and wa" Make sure that the 91.0 mm (0.04 in! pluq uauqe does not go between the gap 0. w my» m: ”the gauge can be inserted inn; me gap, replace: the span» pm: as: '-‘ pmg wnh a new one, Reivlslal‘ lhe spdvk plug ill lhe cylinde! head and hand nghmn, than rnrque m spenihmtion TOHOUE: 12 N-m [1,1 kghm, 9 Ibl-m I! using [no new plug, unstall as foHows: Inslall and hand lighten the new spark plug, than lighten it about 1/2 (urn after the seaiing washer run» was the seat of the plug how. \nstal‘ the direct ignifion Cuils. Connect the connectors 10 the asancxated direct ignir non co". Install ma radlamr gromme‘ mm the Name hnss 3-8 MAINTENANCE InslaII me washer and radiator upper mounting boll. UPPER MOUNTING BOL [hen 1.qu2” the bull, Install and tighten the radiator lower mounting bolt/nut. LO‘YVER MOUNTING BOLTINUT ‘ Connect me fan molar sub»harnese 2P (Black) cunneclul. Install the mncr hal! cowl and lower cowl (page 2 51. VALVE CLEARANCE ‘ CAM CHAIN TENSIONER LIFTER Bum INSPECTION Remove the cylinder head cover lpage 87M Remave the cam cham Iensmner mm sealing hall and sealing washer. SEALING WASHER MAINTENANCE Tum the cam chain tensionel lift?! shah ful‘y and secure It usnng the mechamc's tens‘onar stopper mm (page 8 7r, Remove the timing ho‘c can and O ring Turn (h? crankshaft C‘ockwise and alvgn the " ark on the Ignmon pulse generator rotor wnh the IndF-‘X mark on the right crankcase cover‘ The timing mama ("IN" and "EX”D on me cam sprockr eh mum be flush with Ihe cylinder head surface and shnuld fare outward as shown If [he limlng marxs on me cam sprocker are 1acing inward turn the crankshaft dockwise one [ull mm (360‘) and realign he tummg marks With the rylmder head surface so they are lacing curward. STOPPER TOOL Tm: N (3.135727? 3-10 lusevt the feelex gauge between the valve Iihel and ma mm Inhe. Check me valve clearance 'orme N01 and No.3 cvlinr der imakg valves using a [valet gauge. Hero's Iv my»? ewe J k‘finf VALVE CLEARANCE: IN: 0.20 z 0.03 mm (0.008 3 0.001 in) away 1 y “any r TQM/ICC lum the crankshah c‘ockwisc1,’Z!urn(180‘)and align me Index line on the igninon pulse generalur wluv so u Is facing up as shown. R crd we 01‘s.?- znce ‘0' 9110' ”w rm 9-3 . arc; If saws Sahara"? 571115" me": u Wynn—u Check the valve Clearance [or me N02 and No.4 cylin- den exhaust vawes Mmg 313mm gauge. VALVE CLEARANCE: EX: 0'28 : 0 03 mm (0‘0“ 1 0.001 in) Turn the crankshaft clockwise 132 lurn (130’) and align the "T” mark on me ignition pulse generamr rowr wxlh lhe index mark on the right crankcase cover MAINTENANCE "0'3 "WAKE VALVES NOJ INTAKE VALVES \ INDI'X | INI' i i N02 EXHAUST VALVES MAINTENANCE no.4 INTAKE VALVES No.2 INTAKE VALVFS ‘ 96304110: :voor Check the valve clearance for the No.2 and No.4 uyliw an 'an?“ der Intake valves using feelel gauge wave '0' Vs'err ‘1" WM VALVE CLEARANCE: ”5:; IN: 0.20 s 0.03 mm (0.008 x 0.001 in) men: is . Turn the crankfihlh clnnkwlse1H2mrnl180’iand align the Index iinc on the ignition pulse generator rotor 50 that it is facing up as shown. 1» a 0363“ Check me va|ve ciearance lorlha No.1 and No.3 cvlin~ ? ‘0' sec? def exilausl valvz) using a feeiex gauge r . ., . _ 3‘3 VALVE CLEARANCE: L 55 “5 “"5" Ex: 0.28 x 0.03 mm (0.011 a 0.001 in) We ii: :weu ADJUSTMENT Remuw llle cmmhall (page 8-6) Remove the valve Iihevs and shims. ' The shims may Stick to The lnSldfi of the valve ilfler Do not allow me shims to fall into the crankcase. - Mark all vaive lifters and shims lo euwle uuuecl reassembly in their originai innatinns - The vaive lifter can be easily removed with a valve lapping tool or maqnet. - The shims cam b: easiiy removed With tweezers or a magnet. 3-12 MAINTENANCE Clean ‘he valve shim Contact area in the valve [IHPV VALVE LIFTER wnh compressed arr. elm-we alf‘c'cnf Measure the shim thickness and record in Sian' rhirknaufis a'e aval/aD/a from ‘ you mm to SHIM Calculate the new shim thickness usmg the equation . "0’1 7 below, t a t mh m marvels yo 025 A (B ' c) + D "W A: New shim thickness B: Recorded valve clearance c; Specified valve clearance U: (ml shlm thlckness - Make sure [he correcl shim is selected by measur ing it wim a micrometer, - Hefacc the valve seat I! carbon deposits result in a ‘ cleamncs over 1800 mm. ‘ ® (9 Q9 @ \H/ \,/ \ 1' V' 1.80 mm 1825 mm 185 mm 1.5175 mm I insrall‘ the slums Install the newly selected shim on the valve ratainen S TOFFER T00 and wile in» m Apply molybdenum disuifide oil to the valve liners, L "Ell Dllwalloca- Install the valve lifters into the valve lifter holes, iiO'iS Inslall the Lamshafl (page 3-13). Rotate the camshahs bv rotating the crankshaft clockA wise several limes. Hecheck the valve clearance Remove the cam chain lensiuner sluppev luol. 3-13 MAINTENANCE Install mp new seanng washer and cam chain ten» sioncr liner scaling bolt, figlulen the 170‘! sscuralv, Install the removed pans m the reverse nrder of removal. ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION Stan the englne and I” [Y idl! Icar 2 — 3 minmeS‘ Turn off the engine and suppon the motorcycle on n lava] surlaue. Check (hf: oil Icvm through me inspection wrnnow. If the level ‘5 below me lower Ime, remove‘x‘we oil IIIIEI can and fiII me crankcase wixh [he recommended on (a (he uppity levaI I‘me. Remove the oil filler cap, CAM CHAIN TI'NSIONER LIFTER 3-14 3mg «‘5Lu:die.\ :nown n rnar‘ my use: w 5 2mm m » 1w; arm * a w 4 "”5 'IUICEIEC rarge mange the wgme ; w‘./ the cacao Aarrr' am we mozcmcie (.W ewe‘ 9mm :0 55M.- 'nmp'fi'fi cramp; MAINTENANCE Add lhs recommended englne OII untII the OII IeVeI IS tome upper lcvci line. RECOMMENDED ENGINE DIL: ‘ Pro Honda 6N4 or HP. 4-slmke ail (USA and Canada), or Honda 4-stroko nil (Can-d3 onlvl. 0: equivalent motov oil API service classification: SF or $0 Viscosity: 1ow—4o I Hi fiwm 15w an Remqan mp. mm: cap. 0 1.. .u w I» luv F ENGINE OIL 81 FILTER CHANGE Warm up the engine. Remove we lower cowl (page 2-4) Stop the engine and remove the oil fiIIEI’ cap. Remove lhe dram bolt and drum mo oil complcwlv. OII DRAIN BUJ SEALING WASHER Remove and discard {he uil finer ca'tlidge using the special tool, TOOL: Oil filter wrench D7HAA—PJ7D1DD MAINTENANCE Check that lhe Sfiflllng washer on Oh? drain bolt is in good condinon and replace it necessary. Inaull cmu liglllen the drain Doll. TORQUE: 29 N-m [3,0 kgf-m. 22 [bl-fl! Apply Lledn engine oil to me new oil filler Orring. lnsrall the new oil filler and human It 2n me spmhed loluuu. TOOL: Oil final wrlnch 07HAA~PJ7UTDO TORQUE: 26 N-m (2.7 kghm, 2|] Ihf-fll Fill the clankww with the recommended engine oil, ,’"'—L" OIL CAPACITY: 3 0 liter (3.2 U$ qt, 2,6 Imp qt) after dra'n'ng 33 liter (3 5 us (11, 2'9 Imp q1) alter drammg/liltar change Install the oil filler cap Slarl the engine and let i! idle hr 2 (o 3 minutes. Stop the engine and lecheuk lhe oil level‘ Make sure there are no Ol‘ leaks, Install the lower cowl lpage 2-5), 3-16 MAINTENANCE ENGINE IDLE SPEED ' " THRO‘ITLE STOP SCREW - inspect and adlust the idle sneed after all other engine maintenance items have been pe'IutIlled and are within specification . The angina must be warm for accurate idle speed inspcction and adlustmentt Warm up the engine for about 10 minutes. him the throttle stop screw as required to obtain the speclfiad idle speed. IDLE SPEED: 1,300 x 100 rpm RADIATOR COOLANT Check lIIe uuulalll level in the resPrvP Hank with the engine running a' normal operating temperature. The level should be between (he "UPPER" and "LOWER" level lilies, It necessary. add the recommended coolant. RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalem high quail- ty ethylene glycol antilmaze containing corrosion pmhctiull inhibitors 1 LOWER LEVEL LINE ' Removc the reserve tank filler cap and fill to the "UPPER" level line with a 1/1 leI’llfP of dislllled water and antrireere IIer‘SIBlIIheIIIICI’CUDV .— RESERVE tANl< COOLING SYSTEM Remove the lower nnwl and lnner halt cowl (page 274', Check the radiawr air passage: Iul clogs or damage, Straighten any bent fins, and rémnve insects, mud or nlher obstructions With compressed air or low water preasure. Replaca lhe radiator if the air flow is restricted over more man 20% or the radiating surlacc‘ MAINTENANCE lnspecl lhe radiatnr hoses for cracks or deleviuralicn, and replace if necessary. Check lhe lighmsss of all hose clamps and iaslcners. SECONDARY AIR SUPPLY SYSTEM . This model is equipped with a mum secondary air supply syste’m Th: pulse secondary air supply sys lcm i5 located on the cylinder head cover, The secondary air supply system Inlvodlmes filmed air into exhausl gases in the exhaust port. The sec- cndary Air 15 drawn into the exhaust pull whenever there is negative pressure pulse In "in exhaust sysr i (em. This charged secondary air promotes burning oi ma unhurnnd exhausl gases and changes a con- siderable amount of hydrnnnrhnns and calbun munoxme II'IIO relatively harmless carbon ninxlne ‘ and water Remove the air cleaner housing (page h-EUL rmrmm Check the PAIH ipmse secondary an miecuurii hoses my 5; NM” between me PNR conrroi solenoid valve and cylinder Ja H =5 ”SPEC head cover [or deterioration, damage or loose conr i 9W: ~E neclions. Makr‘ sure the hoses are not cracked. p ass yaw; £3,2- r:' can age EXHAUST PORT Check the air suction hose between the air cleaner PAIR CONTROL VALVE-v A”? 5133‘! h’lusmg and PAIR control sulenuid valve for deterior ration, damage or loose connechnns MAke sure we hoses are not Kinkcd, pinched nr cracked 3-18 MAINTENANCE EVAPORATIVE EMISSION CONTROL EVAP PURGE CONTROL SOLENOiD VALVE i SYSTEM (CALIFORNIA TYPE ONLY) i ' DRIVE CHAIN fa‘a Check the hascs between the iuei tank, EVA? canister, EVAP purge controi solenoid vaive Iui deterioration damage 0i loose connenmm Check the EVAP canister for cracks or other damage ‘ Refer m the Vacuum Hose Routing Diagram Labci ipagci 41) and Cabie & Harness Rouxinq [page 1723i ‘ ior hose connections, i DRIVE CHAIN SLACK INSPECTION Turn me ignition switch to “OFF", plate Hie mummy- tie on ils aid: >Idiid and shifl (he iransmiwnn mm neutral Check [he siack in me drive chain iower run midway between [he sprocket» CHAIN SLACK: 25 v 35 mm (1 — 1-3/8 In) NOTICE___ Exceaav've [IIBi-N slatk, 5n mm i7n m) nr more, may damage me I/ame. Lubricale [he dvlv: chain with #80 — 9“ gear mi or Pm Honda (ham IIIhP. demgned specifically for use with 0 ring chainsi Wipe 0H any excess oii ur chain iubricanl. ADJUSTMENT AXLE mfi —_- ADJ USTING BOLT Luu>el1the rear axie nut mm mm adiusting boils until ma covrect drive chain siack is obtained. Make suite the index marks rm hnih adjusting plates are aligned With the end DI the swingarmi ‘figmen the rear axis nut in the specified luvquz TORQUE: 53 N-m [9.5 kgIvmi 59 lbI-h) J ‘ l l ADJUSI ING PLATE 3-19 MAINTENANCE flashed: the drive chain slack and free wheel rorarion. , Lubricate the drive CI’IHIn wlth #80 - 90 gear oil or Pro Honda chain lube designed specifically Ior USP. with O- ring chains. Wipe 0" any excess oil or chain lubri— cant. Check the drive chain wear indicator Inhel attached on the Ian drive chain adiuming plara. If the swingarm index mark reaches the rad zone on the indicator label, replace Ihe drivP chain with a new one (page 3-21). CLEANING AND LUBRICATION Clean the chain wrth non-flammable or high (lash puilll solvent and wipe it dry. Make sure the chain has dried completely before lubricating. Inspect the drive chain for possible damage or wear. Replace the chain H it has damaged rollers, loose fit- ling links, or olherwrse appears unselviceable. lnsralllng a new chain on badly worn sprnckets will cause the new chain to wear quickly. Inspect and replace the sprockets as necessary. RED ZONE NON-FLAMMABLE 0R HIGH FLASH POINT SOLVENT CLEAN WIFE AND DRY 1" a iii—4‘, INDICAI OR I AREL Lubricate the drive chain wilh #80 — 90 gear oil or Pro Honda chain lube designed snecmcnlly for use wilh 0- iing chains. Wipe off any excess oil or chain Irlhn» can! SPROCKETS INSPECTION Inspect the drive and driven sprocket teeth for wear ur damage, replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must he in good condition, or the new replacement chain will wear rapidly. LUBRICATE $4 \\ // «so — 90 GEAR OIL on PRO HONDA CHAIN LUBE 3-20 MAINTENANCE b'mcn mm; the mm: «m; I: [he Faw‘ac- 1w:' 5 «mama Check the attachmg bolts and nms on me drive and dliven sprockals. If any are IDose, Iorque them TORQUE: Drivu spun-kn bolt: 54 N-m (5,5 kgf-ml 60 Ibfvft) Driven sprodtet nut: 64 N-m (6.5 kgf~m, l7 lbicfl) REPLACEMENT This motorcvcle uses a drive chain with a staked mas- le: link, Loosen the drive chain (page 3 19). Assemble (he spacial ‘ool as shown. TOOL: Drive chain tool set o7HMH—MR10103 or 07HMH—MR101DA (U.S.A. onlv) Locate the uvimped pin ends of the master link from the outside of the chem, and remove me link with the drive chain tow set. TOOL‘ Drive chain tool set 07HMH-MR10103 or O7HMH-MRID10A [U.S.A. only) Remove me drive chain. DRIVE CHAIN TOOL SET —> 4'— MASTER LINK 3-21 MAINTENANCE Infludé me ' ' [5’ W man you com: The an we mm m,» men Inc was? w my ms as 5! the “w. chum mamsw.‘ my wclé‘ mm 1“: Iden'rf/carrofi mark ’amng wt Remove xhe excess drive chain links flom lhe new dnve cham wIth the dnve chum mnl ser STANDARD LINKS: 108 links REPLACEMENT CHAIN: DID: DIDSZSHV—1ZDZB RK: RKGBSZSHOZ1-120LJ—FZ NOTICE . Never muse the aid dnvn nhnin, masn‘r (Ink, masrer Imk plare and O~rings. Assemble the new master link, O-rIngs and plate. Asspmble and insrall the drive chain 1qu )EL TOOL: Dlive chain tool 591 07HMN-MR10103 or 07HMH—MR1OIOA (USA. onlyl Make sun: \hc masmr link pins are \nSYflIIed properly Maa:ure the master lmk pm lenqth projected from me mare, STANDARD LENGTH: MD 1 15 - 1.55 mm (0.0‘5 - 0.061 ill) RK: 1.2 » 1.4 mm (0.05 ~ 0.06 In] Stake the master link pins. PLATE MASTER LINK DRIVI’ CHAIN TOOL SET MASTER LIN K PINS 3-22 MAINTENANCE A drive me,” .wn a Clln'rl’cs master llrt mus? wt be used Make sure the pins are staked properly by measuring the diameter of the staked area using a slide caliper. DIAMETER OF THE STAKED AREA: DID: 5.50 * 530 mm (0.217 — 0.228 In) BK: 555 - 5.85 mm (0.219 - 0.230 in) Allel staking, check the staked area of (he masler link lnr cranks If there is any cracking, replace the master link] 0- rings and plule. BRAKE FLUID _NOTICE - no nnr mix rllflerenr types of flulrl, as they are nnr campan’blc with each orhon Do not allaw foreign material lu Eula! Hie syslem when filling the reservoir Avuld spilling fluid on painted, plastic or rubber pans. Place a rag over these pans whenever the system is serviced When the fluid level is low. check the brake pads for wear lsee next page). A low fluid level may be due to wear nl the brake pads. ll the brake pads are worn, the caliper piston is pushed our, and rhis accounts for a law reservoir level. II the brake pads are not worn and the fluid level .5 law, check me entire system for leaks {see next page). FRONT BRAKE Turn the handlebar so the reservoir is level and Check the front brake lluid reservoir level lime level Is nearlhe lower level llne, check brake pad wear (see next page). REAR BRAKE Place lhe mololeycle on a level surface and support ll m an uprlghr posmon Check the rear brake fluid reservoir level. II llle level is near the luwev level line, check brake pad wear (see next page] GOOD \JM \/ \/ v’} \‘tz \ / V \_/=—‘\\_ 4 SLIDE CALIPER ‘ NO GOOD "‘ fix 7 CRACKED ' LOWER LEVEL LINE LOWER LEVEL LINE 3-23 MAINTENANCE BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pad for weal. Replace the brake pads if either pad is worn I0 “18 bottom of me wear limit groove. ReIer m pay. 15-7 Ior brake pad replacemenl. REAR BRAKE PADS Check [he brake pad: {or wear. Replace the brake pads if either pad is wulll [0 [he bottom of mu wear limit groove. Refer to page15-8for brake pad leplacelllelll. BRAKE SYSTEM Align me vna'x an Mrs D aka l‘sw' mm me lwasx wfibe' an "le 41. m INSPECTION Firmly apply the bvak: lever in pedal, and check that no air has cnterad the system If the lever or pedal 1ch5 sch or spongy when operat- ed, Mead lIle air from [he svnsm. Inspcc! the brake hose and finings (or ddtarlnmnnnl Cracks and signs of leakage, Tighten any loose fittings, Replace noses and Ilmngs as required. Refer Io page 15-5 Iul brake bleeding procedures. BRAKE LEVER ADJUSTMENT in: distance hatween the top of the brake lens- and me grip can be adjusted by turning me adluster. WEAR INDICATOR 3-24 BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal he‘mht is oblained, BRAKE LIGHT SWITCH The . ILV'dIr Adjust the brake light switch so the brake light comes ham swncfl does on just pnor to the brake actually bemg engaged, us: secure adrusr If the ||ght fails to come on, ad}ust the switch so the " W hght comes on at the proper time. Hold the swutch body and turn the amumr Do not turn the switch body, HEADLIGHT AIM August the neaa— Place the motorcycle on a level surface, llgN hPflP“ as sparr‘rsa bvma/ Adjust the headllght beam vemcnuy hv mrmng the WWW {cw vertical beam adiuslet. "w A clockwise rutaliun muves um beam up and coun— tercIockwise rotatlnn moves the heam down, Adlust the headhght heam hnnmntnuy by turmng the horizontal beam adjuster A clockwise rutatiun moves IIIe beam toward the right srda of the nder. MAINTENANCE PUSH ROD BRAKE PEDAL LOCK NUT HORIZONTAL BEAM ADJUSTING SCREW 3-25 MAINTENANCE CLUTCH SYSTEM Measure me clutch lever free play al me end of (he clutch lever. FREE PLAY: I0 — 20 mm (318 — 13/16 In) Minor adyusrments are made uslng the upper adjuster ax the clutch lever. Loosen me luck um and lulu the adjuslev. NOTICE The adjusrcr may be damaged if i! is positioned zoo far out, /saw'ng minimal thread engagement. if the adjuster is (hreaded om near its limit and the correct Iree plav cannox be obtained. turn the adjus‘er all the way in and back out one rum, Tighten the lock nul and make a minor adjusrmnm as described as follow. Major adiaslmenl: are perIurmud at (he clulch arm. Loosen the Infik m" and turn the an'usling nut to adius! the free play. Hold lhe adiusting nut securely while tightening the lnnk mil if proper free play cannot be obtained, or the clutch slips during tesl ride. disassemble and impact [he clutch (see section 9). SIDE STAND Squon the motorcycle an a level surname, Check the Side stand spling ru. Ialigue or damage. Check the Side stand assemhly lnr movement and |ubricare me side srand pivot if necessary. LOCK NUT ADJUSTER LUCK NUT , ADJUSTlNG NUT 3-26 MAINTENANCE Check the side sland ignition cuI-o" syslem, - sir asvrma the motorcycle and "use the side standi Start the engine mm the transmission in neutral, than shih the ttansmission imu gear, with the clutch lever squeezed — Lower the sude stand fully. r The engine should stop as the side stand ls lowV exed. If there is a problem with the system, check the side slaud swilch lsecliun 19). SUSPENSION LOOSE WOW 0! Uslrlage‘d snug“ , am part; mas/r min/ml; SIREN" :y dud Lumm' FRONT SUSPENSION INSPECTION Check me acliun at the forks by operating the front brakas and nomprssslng the front suspension several times. Check (ha entire assmnbly lur signs ut luaks, damage or loose fasteners, Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Reler to section 13 {or fork service. FRONT SUSPENSION ADJUSTMENT SPRING PRE-LOAD ADJUSTER Spring pre-Ioad can he adjllsled hy turning the adjuster‘ TURN CLOCKWISE: Increase the spring pre-Iond TURN COUNTERCLOCKWISE: Decrease the spring pre—load PRELOAD ADJUSTER ADJUSTABLE RANGE: 6 - 21 mm (0.2 - 0.8 in! from "I! top 0' [hi folk hol‘ PRE-LOAD ADJUSTER STANDARD POSITION: m» groove from the lop ofthe Iovk bolt PRE-LOAD -_ ADJUSI EH MAINTENANCE IC Sci/VS! both :ldrs euuglly, saw me namena (arr dampflg ELI/ushers m We s‘m par :vm COMPRESSION AND REBOUND DAMPING ADJUSTERS NOTICE l Always start with the adjusters fully turned in when adjusting the damping Do nut turn the adjuster screws more than (he gII/En pasin'ons or me adiusmrs may be damaged. Make sure he rebound and compressiun adiuslurs are firmly/ocsledm s delenr, and not between posi- “ODS. The compm inn and rnhnund damping can be adjusted by turning the adiuslcrs, DIRECTION H: Increase the damping force DIRECTION S: Decrease the damping force Turn the compression adjuster clockwise until iL stops, then turn the admsxer counterclockwise COMPRESSION ADJUSTER STANDARD POSITION: 14“ turns out from Iully turned in REBOUND ADJUSTER Turn the rebound adjuster clockwise umil it stops, men Iurn Ihe adjuster counlemInnkwlsn. REBOUND ADJUSTER STANDARD POSITION: 1-3/1 turns out Irnm Iully turned in REAR SUSPENSION INSPECTION Support me momrcycle securely and muse the rear wheel off the ground Hold the swungarm and move me rear whul side- ways with force to see i! the wheel bearings are worn. 3-28 Chenk Inr wnm :wmgarm henrmgs hy grabbing the (car swingarm and attempting to move the awingarm side to side, Replace the hearing: -r any Inn<9nPSS xs noted Check the action of the shock absorber Dy compress~ inq it several limes. Check the entire shnnk nhsnrher nssemhry In! signs nI leaks, damagc er loose Iasrcncrs. Replace damauad component: which cannot be repaired Irghlen arr nuts and bans, RvIer (u secliun 1A Ior shock absorber service REAR SUSPENSION ADJUSTMENT COMPRESSION AND REBOUND DAMPING ADJUSTERS NOIICE I - Always start With the adr‘uslyrs fully turned in when adjusting the damping - Do nnt turn the ad/uster screws more than the grven positions or the adjusters may be damaged. The tomnressrnn and rehnrmd damnrng can he adjusted by rurrrrng rhc adiusrcrs. DIRECTION H: Increase the damping force DIRECTION S: Decrease the damping lore: Turn the compression adjuster clockwise umn it stops, then turn the adiuster countercrockwrse COMPRESSION ADJUSTER STANDARD POSITION: 1—1/2 turns out from fully turnad in MAINTENANCE REBOUND ADJUSTER MAINTENANCE my. the veboufld adjust? dockvuse unlil u mus, then turn me adlusler counterclockwxse REBOUND ADJUSTER STANDARD POSITION: 'Iv1/2 turns out from fully turned in RFROUND ADJUSTER NUTS, BOLTS, FASTENERS Check that all 0155515 runs and hnln a—p nghwnfid to their correct torquc vaIucs (page 1 12), Check [Lat aH :51!er dips, hose damp; and came flay: aw m nlarp arm prnppr‘y wrured WHEELS/TIRES ‘n'e pressIJre shauld be checked when :"e llrc: ave coId, RECOMMENDED TIRE PRESSURE AND TIRE SIZE: >RONT REAR 250 (2‘50, 36 290:? 90, ‘2} 11.2 pymme kPa (kgtmr, us‘] . - 12-0/7'62'fi’17 130x552n17 Tra ma issw WWI Bridgemone BTioWFF BTWDWF me "i brand Damon DZO‘IFJ DZUIP —r I , , VIIO' mm M‘Che'm 5mm E 1 SPORT F Chack (II: lima [w .‘ulg, embedded naIs, m 0019' carnage Deck me from add rear wheels (or trumcss (refer to sequuh 13AM! 14L Measure me mad cool: at me ccmer of the tires. ReDIace the tires when the tread daplh reaches the ‘cIIawmg IImits MINIMUM TREAD DEPTH: FRONT: 1 5 mm (D 06 in) REAR: 2.0 mm (0.08 in) 3-30 MAINTENANCE STEERING HEAD BEARINGS Check that the control cables do not infien‘ere wi‘h handIeber rotation. Supporl lIIe mquluycle securely and raise the [mm wheel on the gmund Check that the handlebar moves freely from Side to side. If Ihe handlebar moves unevenly, binds, or has veni- cal movementl Inspect the SIEeflng head befil’lngs (Secfion 13). 3-31 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFTS PISTON CRANKSHAFT \r‘ MAINSHAFT 0H HITFR CARTRIDGE J‘ COUNIEHSHAFT OIL COOLER ”y \\ O‘L PUMP u ' ‘1 q % ‘ RELIEF VALVE OIL STRAINER 4-0 4. LUBRICATION SYSTEM LUBRICATION SVSTEM DIAGRAM 4.0 OIL STRAINER/PRESSURE RELIEF SERVICE INFORMATION 4-1 VALVE 4.3 ‘ . TROUBLESHOOTING 4_2 OIL PUMP 4.5 l SERVICE INFORMATION a GENERAL Used engine orl may cause skin cancer if repeatedly lel‘l In contact WI‘JI llre skin lul prulurlued periuds. All‘mugh this is unlikely unless you handle used on an a dally basis, it is still adv sable m thnrnllghly wash van hands wth soap and walev as >00“ as posslbls after handlrng used ml. Tnc orl pump can be serviced with the engine installed m the name. he servrce procedures In (Ills Sectlon must he nerlnrmed With the engine oll dralned. When removmg and installlng the OII pump, use care not to allow dust or dirt to enter the enqine. ll any pomon ol the all pu'fip l5 worn beyond the specified sen/Ice limits, replace the oil pump as an assemhly After the oil pump has been installed, check that there are no nil leaks and that fill pressure ls Correct. SPECIFICATIONS . . 7 , Urut; mm 4m) IYEM STANDARD SERVICE LIMIT Engine; OlI cepecltv Aher draining .0 lrler :12 us qt. 2.0 lmp qtl — Alter draining/filter change ‘ a 3 Illflr (3 5 Us at, 2.9 lmp qtr l i Alter dudhaelulill‘fl 7 3.7 |lterl39llS qr, ."l .1 lmn ml 7 7, l Recommended engine oil Plo HONDA GNA or HF‘4 475mm- nll 7 l llJ.S.A. and Canadar or Honda 4 Stroke ‘ oil (Canada only). or equivalent motor 0i: ‘ API servlce classilltallon SF DI SG VlSEflQI'y‘ SAI lniW—au W ‘ Oil pressure at all pressure swllnh 400 kPa (5,0 ngrcml, 71 psi) at —- . . 7 6,000 rpm (sot/176w "l l Ol Omit: rotor 1 Tlp clearance , 0.15 (0 006) , I r Body clearance 0.15 » 0.22 llmus 7 0.009) 0.35 1001‘” l ‘ Side r Aarence 0.02 0.07 (0.001 0,003) 0.101000“ TORQUE VALUES OII ma‘u gallery sealing bolt 29 N-rn (3.0 kgl'lll, 22 lbI-ft) Apply a lanklng agenr m me threads. Oll pressure sw-tch 17 N-ml12 kghm, E] lbI-fil Apply sealant to the threadsi Oil anssure swrtch wrre terminal bolt’waehcr 2 N-m 10.2 kgI-m. l.4 lbi-ftl Oil pump cover bolt 8 N-m (0.8 kgl-lll, 5.8 lbI-hl CT bolt oil cooler bull (filtel boss) BA N-m (6 S kgl-m, 47 Ital-ft) Apply all to the threads and flange surface. Englnc Oll Iiltcl cartridge 26 N'm l2.7 kgI-m, 20 lbI-Il) Apply all to the threads and ‘Iange surface and Usrmg. Engine all draln ball 2!) Wm I10 kgl'm, 22 IDI‘IU Oll pump driven sprocket bolt'wasner 15 \l-m ll.5 kgf-m, “l lOI-l‘tl Apply a luuklllg agent to the threads 4-1 LUBRICATION SYSTEM TOOLS on pressure gauge set Oil pressure gauge attachment Oil filter wrench TROUBLESHOOTING oil level we low Oil consuinptiuii brtamnl nil lPak Worn piston rings Improperly installed piston rings Worn cylinders Worn stem seal: Worn valve guide Low oil pressure - Oil level low - mugged oil strainer - imilry nil pump - Internal oil leak - Incorrect oil being used No oil pressure - Oil level too low - Oil pressure relief valve stuck open ~ Broken oil pump drive chain - Broken oil pump drive or driven sprocket - Damaged oil pump 0 internal oil leak 0750&3000000 Equivalent commercially available in USA, 07510-MJ10100 Equivalent commercially available in U.S.A. 07HAA—PJ [0100 High oil pressure - Oil pressure relief valve stuck clnsed - Clogged oil filter. gallery or metering orifice - Incorlect oil being used oil contamination - Oil 0! filter not changed often enough - Wnrn piston rings Oil amulslllcatlon - Blown cylinder head gasksl - Leaky conlant passage - Entry of water 4-2 OIL PRESSURE INSPECTION l' we Dll pressure ‘wdrcelor llgm ren‘al'ls ul- a Ila-n sccanai, mecx mp mdmmr 5/:- zem belole Unwi- ng me on arcs Sula Check the oil level lpage 3-14). Warm up the engine lu nuvmal operating temperature (appvox‘lmmely BUG/176T I, Stop the engine and remove the oil main gallery sealr mg bah. Connect on oil pressure gauge and anachmenl tn vhe maln gallery. TOOLS: Oil pyessure gauge sn 07506-30me (equivalent commercially nvallablo In USIAJ Oil pressure gauge machm-m D7510—MJ‘ID‘IW (equivalent commarclally avallable in USAJ Starl IIle engine and Increase engine speed m 6,000 rpm and read the oil pressure‘ OIL PRESSURE: ‘90 kPa I5 0 kgflcm‘. 71 psi) at 6,000 mm] (BD'C/‘I75'FI Slup lhe engine and remove me tools. Apaly a locking aqenl lo the sealing plug threadsl Install and \ighten (hp saal-ng plug to (ho specified mrque, TORQUE: 25 N-m (3 0 kgf-m, 22 IM-m OIL STRAINERIPRESSURE RELIEF VALVE REMOVAL Drain me engine oil (page 3-15) Remove the Exhaust plpe Usage 2 ml Remove the all pan flange bolts and (HI pan LU BRICATION SYSTEM SEALING BOLT Oll PRLSSURE GAUGE SEALING PLUG LUBRICATION SYSTEM Remove the p'essura relref valve and Orrin; RELIEFVALVE , w npmnve m» ml strainer and packing Clean ma oi‘ strainer screen. 'NSPECTION RELIEF VALVE BODY / Check me oneravon or me pressu'fi mm valve Dy ‘- pusmng on the piston Disassembl: U‘e Ie‘lar va‘ve by removing me snap rmg. x SF‘FUNG Inspect (he pmlofl for wear, unsmoclh movomom or damage stpcc‘ the spnng for iflugue or Carnage PISTON Assemule me Izlref valve llr we reverse Order 0‘ (1‘57 assembly / \ (1 Apulv 0H lo the new packmq and insra I r! mm the on sframe‘ Install (he 0H stramcr Into Ihe crankcase whne ahgnv ing its boss with me groove in the crankcase. 4-4 LUBRICATION SVSTEM Apply ull to the new O—nng and mstall i: onto the relief valva Install mo rellel valve into the cvankLase. RELIEF VAE/ Clean vhp ml nan mating surface thoroughly FUR-",1 y Apply ancc Bond 1207!! or an equivalent to the mac- csslan: more an ing surface. rm" ,arw lnmall (he oil pan unlu the lower crankcasa. Install [he oil pan mnurmng bolls. Tlghten all nl the bolts in a Crlsscrcss oanarn in [Wu [0 three steps, lmlali the ethlsl plpe lpagc 2 ml Full me cyankcasc with the recommended oil (page 3- 'HI. Aher insmllauon. check that there are no oil leska. OIL PUMP REMOVAL Remove the cluxch and oil pump driven sprocket (page 9-4). Remove the mvee flange bull: and oil pump assem- blv. LUBRICATION SYSTEM DISASSEMBLV DOWEL PINS ASSEMBLY BOLT Remove "Ia dowel Dina. annve the oil pump assembly bulL and uil pump cover. OIL PUMP COVER Remove the thrusI washer, drive pin‘ oiI pump shah, outer rotor and inner rolor Irom the ml pump body 0 UTER ROTOR H. OIL PUMP ' SHAI-‘r 7). / DRIVE PIN WASHER INSPECTION 'uuy uwuv o~' Temporarily Inslall the oil pump shaft. rm arsurro c lns‘aIl rI-e quel und Inner romrs into The oil pump .-J.',rr‘ nPynrd m.» DOW- semcs .‘ImL rcprace me :u‘ ,m mo 3) c! asssmb'v Measure the rotor lip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) Mpasme me pump body defiance, SERVICE LIMIT: 0.35 mm [0.014 ml LUBRICATION SYSTEM Measure IlIe sude clealance using a straight edge and teeler gauge SERVICE LIMIT: 0.10 mm [0,004 in) ASSEMBLY OUTER ROTOR OIL PUMP BODY INNER ROTOR OIL PUMP SHAFT OIL PUMP COVER ,/ II // uuth PINS a N-m (0.3 kgI-m, 5’s lbf-ft) WASHER DRIVE PIN I, ”I :Iv “var Install the enter mm.- mm vhe ml pump body wlth Its INNER ROTOR , OUTER ROTOR 0W err I-‘S punch mark facing rho oil pump cover. DINA ”5"“ ‘50“? Insrall the inner ruler in“: the outer rulur wilh il: driv: ”I? ‘1" W71 pin groove facIng the oil pump cover ”My Install the oil pump shah through lhc 'Inncr rotor and oil pump budv‘ OIL PUMP SHAFT Install the drive pin into the hole In the pump shaft and align the pin with the groove in the inner rutur as shown, Install the thrust washer. DRIVE PIN WASHER LUBRICATION SYSTEM ”5‘3” "‘9 d9W9‘ 9” , nong PINS ASSEMBLY BOLT InstaH the otl pump cover and t-ghten the bolt to the specified torque. TORQUE: 8 N-m (0.8 kgi-m, 5.8 Ibf-h.) Check the oil pump operation by turning The pump shaft. Ii necessary reassemb‘e the oil pump INSTALLATION InstaH the oil pump onto the cvankcase wlnle aligning the pump shaft \ug wtth the water purrp shaft groove by turning the oi‘ Dump shaft, InstaH and figh‘en the three flange bolts socuro‘y. \nstHH the clmnh assemhlv (page 9-9» Aha! instdhaliun, fill the crankcase wwlh the recom- mended ml anrl check that there are no oil leaks Check the owl pressure Ipage 4731. OIL COOLER REMOVAL Drain the engine on and remove the oil filter canndge Wage 3-15). Dram the cnnlam frnm the eyetem (page 5-4} Loosen the hose bands and disconnect the oil cooler water hoses from the coder, 4-8 LUBRICATION SYSTEM Remove me oil cooler hon (filler buss), washei and oil comer, Remove the O-ring from the oil cooler. INSPECTION Check me all cooler for damage. INSTALLATION WATER HOSES OIL COOLER OIL comm BOLT 54 N-m (6.5 kgI-m, 47 mm) OIL FILTER CARTRIDGE 26 Nun {2,7 kgf-m, 70 ”1941) g —7a ORING IOCK WASHER _ . i . . ‘ Cgai a newo mug wnh engine ail and vnstali II mm me OIL COOLER oil comer groove. \ Inslall me oii cuulel aligning its guide groom: With the lug on the crankcase. LUBRICATION SYSTEM Apply oil to the oil cooler bolt threads and seaxing 5m W hen muau chock Insml‘ the lock washer and oil cooler hnlr, washer mm m LUHL‘dVe 569 ('0' mark? facrng tn: n1! *m/flr "O" MARKW ccoJer Dal: new “‘3” "’5“ “W TORQUE: 54 Nut! [65 kgl'm, l7 lbf-n) 7‘ teaser Make we M N fightcn me oul cooler bolt m the. specwied torque '- Cmmecl xhe oil comer water hoses and tighten the hose hands securely Insxall the oil finer camidgc and fill the crankcase wuh the recommended uil (page 3-14». Fin Ihe cooling sysmm and weed any ail (page s-u. 4-10 MEMO FUEL SYSTEM (Programmed Fuel Injection) 22 N-m (2‘2 kgI-rn, 75 Inf-fl) 5. FUEL SYSTEM (Programmed Fuel Injection) SERVICE INFORMATION TROUBLESHOOTING l SYSTEM LOCATION SYSTEM DIAGRAM PGM-FI (PROGRAMMED FUEL _ INJECTION) SYSTEM PGM-FI SELF—DIAGNOSIS MALFUNC- TION INDICATOR LAMP IMIL) FAILURE CODES FUEL LINE INSPECTION FUEL PUMP FUEL CUT-OFF RELAY FUEL TANK AIR CLEANER HOUSING THROTTLE BODY INJECTOR PRESSURE REGULATOR SERVICE INFORMATION GENERAL - 89 sure :0 reheve the Iucl pressure w'ltI'. rr-a engine u". 5-1 53 574 5-5 5—6 5-10 5-50 5-53 5-54 5-55 5-60 5-62 5-69 5-70 FAST IDLE WAX UNIT STARTER VALVE STARTER VALVE SYNCHRONIZATION MAP SENSOR IAT SENSOR ECT SENSOR CAM PULSE GENERATOR TP SENSOR BANK ANGLE SENSOR ENGINE STOP RELAY ECM (ENGINE CONTROL MODULE) PAIR SOLENOID VALVE PURGE CONTROL SOLENOID VALVE (CALIFORNIA TYPE ONLY) 02 SENSOR (CALIFORNIA TYPE ONLY) 5-71 5-73 5-77 5-79 5-80 580 5-81 5-32 5—83 5-85 5-85 586 5-87 5-88 - Bending or [Wlsr‘lng the L'unIru‘ Lalfles will imparr smnmh nnermlon and could cause the cables IO srick or bind, resulting In loss of vuhisle control. - Work In a wpll ventilated area, Smoking or a|)uwinq flames or spdvks in the work area m where gasoline is smrcd can cause a Iirc or cxploslon, FUEL SYSTEM (Programmed Fuel Injection) Do not apply commercially available carhuretnr cleaners to the inside oi the throttle bore, which Is coated with molyooc num. Do not snap the throttle valve from fully open to fully close after the throttle cable has been removed: it may cause incor- rect Idle operation. Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed. Do not apply excessive inrne to the fuel pipe on the throttle body while removing or installing the throttle body Do not damage the throttle body. It may cause incorrect throttle and idle valve synchronization. Prevent dirt and debris from entering the throttle bore. fucl hose and return hnse, (lean them using compressed air. The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual Do not looscn or tighten the white painted halts and screws of the throttle body. Loosening or tightening them can cause throttle and idle valva synchronization failure. Do not push the fuel pump base under the fuel tank when the fuel tank is stored. Always rcplooe the packing when the fuel pump is removed. The programmed fuel Injection cyctcm is equipped With the Seltniagnostic System described on page 5-6, lithe malfunc trnn indicator lamp lMILl blinks, follow the Self-Diagnostic Procedures to remedy the. problem. When checking the PGM-Fl, always follow the steps ill the troubleshooting flow chart (page 5—1Ul. The PGMFI system is providcd with fail-safe function in secure a mi mum running capability even when there is trouble in the system, When any abnormality is detected by the self-diagnosm function, running capability is secured by making use of the numerical values of a situation preset ill advance in the simulated program map. it must he remembered how ever, that when any abnormality is detected in tour injectors and/or the ignition and cam pulse generator, the fall safe func- tion stops the engine to avoid engine damage. For PGM-l’l system location, see page 54. A faulty PGM Fl system Is often related to poorly connected or corroded connectors. Check those COflhEmIOHS before pro- ceedilrg. l-nr fuel reserve sensor inspection, see section 19. The vehicle speed sensor sends digital pulse signals to the ECM lPGM-Fl unit] for computation. Fnr vehicle speed sensor inspection] see section 19. When disassembling the programmed fuel injection parts, note the location of the Oil-ings. Replace them with new ones upon reassembly. Before disconnecting the fuel hoses, release thP itlel pressure by loosening the fuel hose banjo bolt at the fuel tank. Always leplaue the sealing washers when the fuel hose banjo link is removed or Iousuned. Use a digital tester for FGM-Fl system inspection. SPECIFICATIONS .1 ITEM SPECIFICATIONS I ' Throttle body raenrrrrcrirrnrr ‘ Excel.) California {we 6090C "“ml’c' Cali orma type ' 7' manta .. ’7 . Starter valve vnnri:m differengu 7 20 mm fig" Base throttle valve for synchronization ' No? i i idle speed V ‘ V V . 1,301) x 100 rprrr V Throttle grip free Jay l 7 2:6 rnnr l1r’16 — 1/4 in) intake air tempelalule sensor resistance (at zo'Cles‘Fl ' '7 7 1 — 4 krz ' l Engine coolant Ernperarure sensor resistance (at ZO'CIBB‘Fl l ‘ 2.3 — 2.6 kt: Fuel injector resistance (at zo-crea‘Fl l h 11.1 — 12.3}; V _l>5l solenoid on; resistance (at zoo/sari ‘ 20 — 24 o cern‘pulse generator peak voltage lat 2 ‘C/sa‘rl lg on pulse generator peak voltage int 20 (2/68 Fl Manifold absolute pressure at idle "0.7 v minimum 0.7 V minimum ‘ 150 - 250 mm Hg 7 i Fuel pressure at idle v ' 343 kPa (3.5 kgflcm‘, 50 psi) 1 Fuel pump flow lat i2 yr 183 cm’ (6.4 us 02, 6.6 Imp OZl rnlnimumr‘io seconds 5-2 FUEL SYSTEM (Programmed Fuel Iniectinnl TORQUE VALUES- ECTnhermo sensnr Thmme body insulator band screw Throttle cable bracket mounting screw Starter valve synchromnmon plate scrcw Starter vaivp lock nut last idle wax unit link plate screw Fast idle wax unil mounting screw Pressure regulator mnunting bolt Vacuum Joint for synchronization Fucl filler cap bolt Service ulieck boll Fuel hose haniu bolt (fuel tank side) luel nose scaling nut llhrulllu body side) Fuel pump rnuunling nut 02 wusur lCalifnrnIa type onlyl TOOLS Fuel pressure gauge Peak voltage tester (USA only) or Peak voltage adaptor tCU test harness TROUBLESHOOTING Engine won't start ' intake air leak Fuel contaminmed/deteriorated Pinched or clogged fuel hasa Faulty fuel pump Clogged fuel filter Clogged fuel injector filter Sticking fuel injector needle Faulty fuel pump operating system Engine mu, hard to start, mug]! idling . Intake air leak - Fuel contammatad/deterioratcd - Pinnhed or clogged fuel hose - Idir: weed mlsadjuated - Staner valve synchronization misadlusted 23 N-m (2.3 kgl-m, 17 ibf-fti See page 1-14 3 N-m [0.35 kgf-m, 2,5 luv-m 1 N-m (0.09 kgl-m, 0.7 Inf-ft! 2 N-m (018 kgl-m, 1.3 mm. 1 N-m (0.09 kglom.u.71nwri 5 N-m (0.5 kgf‘m,3.6lb1‘-lll 1o N-m (1.0 kgf-m. 7 Ibf‘ftl 3 N-m if) 3 kgtvm, 2.2 WM“ 2 N-m (0.2 kgf-m, 1.4 llaf-ftl 15 N‘m (1.5 kgl-ni, l1lbf-hl 22 Nm (2.2 kgf-m, 16 lbl-ftl 22 N-m 12.2 kgl-m. 16 lbl-fl) 12 N'm (1,2 kgr-m, 9 Im-ni See page s—sA for tightening sequence. 25 N-m (2 G kgl-m,191n(~m 07150643040003 or 0740H050002 07HGJ 0020100 (not available in U.S.A.l with Commercially available digital multimeter limpcdance 10 MWDCV minlmuml OIYMZ 0010100 llwu quulied) Backflrlng or misfiring during acmleratian - Ignition system malfunclion Poor performanoo ldrivnbililyl and poor fuel economy . Pinched or clogged lunl hose - Faulty pressure regulator 5-3 FUEL SYSTEM (Programmed Fuel Injection) SYSTEM LOCATION California type shown: PAIR SOLENOID VALVE IGNITION SWITCH IAT SENSOR F . p UH ' ”M ENGINE STOP RELAY ECM IULL CUT-0H RELAY MAP SENSOR (2AM PULSE GENERATOR INJECTOR PHTSSURF I'IFGUI ATCFI IGNITION PULSE GENERATOR VEHICLE SPEED SENSOR 0; smsun [Cantnrma type nnly) PURGE CONTROL SOLENOID VALVE {CalIforma type only; FULL NAME ABBREVIATIONS Manifold absolute pressure sensor 7 ~77 MAP sensor Thmme posmon s V V_- TP senmr A” Intake mr tempe IAT sensnr —Eng|ne coolant lempnramre sefisor ECT sensor Engine cnnIrnl—n:ndule ECM 5-4 SYSTEM DIAGRAM Ill m \o—m FUEL SYSTEM (Programmed Fuel Injection) slsl Iii m (2» (3| m (5) (6) (7) (Bl ‘ (9) H10) (11» ‘(12) us); (H) (15) may (17% Engine slop relay PGMrrl (use (20Al Engine stop switch Sub-fuse (10A) ignition swflch Main (use A [SON Bank angle sensor Sub-fuse (10A) Banerv Pressure reguldlor EVAP canister (Cnlilnrma type only) IAT sensor Direct igniiion coil and spark plug PAIR solenoid valve Tl" sensor MAP sensor lnleclur (32) (33) Cam nulse generator PAIR check valve ECT sensnr Ignition pulse generamr 0: sensor (California type only! Water temperature 1 CD Fuel curroff relay ‘ EVAP purge control solenoid valve (Califomia type nnlyl ‘ Fuel pump Vehicle speed sensor Neurral swirch ‘ Clutch swirch ‘ 5m stand swimh 1 Maliunciion indicator lamp (MIL) Service check conneaor Tachometer FUEL SYSTEM (Programmed Fuel Injection) PGM-FI (PROGRAMMED FUEL MALFUNCTION INDICATOR LAMPlMl INJECTION) SYSTEM SELF-DIAGNOSTIC PROCEDURES Place the motorcycle (In its side stand. Start me engine and lcl it idle. Tm: mal'lmcilor‘ ll me maliunclion indicatou lamp lMIL) does not light WWI ’4 or blink, the system has nu memory of problem data. Will ll me malfunction indicator blinks, note how many ”MW? ”W W” limes the MIL blinks, and delsrmine the cause of the we mje . ‘ _ .-_ as” MD M‘ problem (page 510 lhrmlgh J 49). m: swamp m“ «er we sra: Info: is argwe rs/s 5'9 ae/ow 5,l/[)U FD’Tl ’7 5”} "hi' i‘ ‘.'\l L‘ '=, we WL mu mm ”are ENC HEY 0'1 5m: if you wish [0 read [he PGM Fl memory for lrnllble data, perlarm (he (allowing: Turn the ignition switch [0 "OFF". Remove the seal (page 22). Short [he PGM-FI system service check connector ter- mmals using a junipev wire. JUMPER WIRE t wen :4 rm: PGM F/ has Timmy data, the ML does not blink when m, gym i: wanna FUEL SYSTEM (Programmed Fuel Injection) Turn Ihe ignition switch to "ON" and the engine stop Switch to 'RUN" II the ECM has no sell diagnosis memory data, the ML will illuminate, when you turn the ignition swutch to "ON'i If the ECM has self diagnosis memnry main, the MIL will start hlinking when you turn the ignition switch to “ON". Note how many times the MIL blinks, and determine the cause of the problem (page 510 through 5-49). SELF-DIAGNOSIS RESET PROCEDURE LTurn the engine stop switch to "RUN" and the igniv tion switch lo "OFF”A 2. short the servme check connector 0! the PGM-FI system using a jumper wire. 3.Turn the ignition swilull to ”ON”, 4.Remove the Jumper wire lrom the service chock connector. 5. The MIL lights about 5 seconds. While the indicator lights, shnrl the service check cnnnnclor again with the jumper wire, Scll diagnosis memurv data is erased ii the MIL turns all and linen starts blinking. The service check connector must be jumped while the indicator lights. ll not, lhe MIL will nut start blinking, Note that the self diagnosis memory data cannot be erased if you turn 0" [he iguiliun switch before the ML starts blinking. If the MlL blinks 20 times, the data has not been erased. so try again FUEL SYSTEM (Programmed Fuel Injection) PEAK VOLTAGE INSPECTION PROCE~ DURE Use Ihls procedure furthe lgmtrnn pulsp generator and cam pulse generator Inspection. Check all system coulleuiulls before inspection. II the system ls dlscnnnaclnd, Incurred peak voltage m'lght be measured. Check cylinder colvlpression and Check that all spark plugs are lnstallfid correctly Use the recommended dlgllal mulllmater nr 3 mm. lnerciallv available digital multimeter with an impndance 0(10 MQ/DCV minimulll. II the Peak Voltage Tester IU 511 nnlyl ls llsed‘ lol- Iow the manufacturer's Instruction. The dlsplay value dlllm depending upan the inter- nal Impedance of the mllltlmsmr, Disconnect the fuel pump connector before check» ing the peak vullage. Open and supuorl: the from end of fuel tank (page :Ml Ulsmnnpnt the fuel pump/reserve selrsul 3P (Black) CDI’VIOETOIZ Cnnnecl the peak vultage adaplur lu [he digltal multi- meter, TOOLS: Peak voltage tester [USA only] or Peak voltage adaptor 07HGJAW20100 (not available in U.S.A.) with commerciallv available digital multimeter limpadano. 10 M12/DCV uml TEST HARNESS CONNECTION Remuv: llre rear cowl (page 2.21.. Remove the ECM holder band and remnve the ECM [mm the battery trav cover. Dlsconnect the ECM 22F (Black) and 22? (nghx gray) connectors. Connect the ECU tesl harnesses between the main ere harness and the ECM TOOL: ECU test harness 07VMZ—001D1lm (two required) ECU TEST HARNESS FUEL SVSTEM (Programmed Fuel Injection) TEST HARNESS TERMINAL LAYOUT The ECM connector rarminals are umvlbeved as shown in me illusu anon. The \est harness ‘ermlna‘s are the same layout as for ‘ FOR 22p {ELACKl CONNECTOR FOR 22? (LIGHT GHAVI CONNECTOR zhp [CM connector terminals as shown. "VIEW FROMWIRE HARNESS SIDE: ' 1 A: 22F {BLACK} CONNECTOR \ B: 22F (LIGHT GRAVI CONNECTOR ‘W— ‘ ngfifii‘éfi 21*” u m .1 1: mm: uuufiuj'lu‘lxyA FUEL SYSTEM (Programmed Fuel Injection) PGM-FI SELF-DIAGNOSIS MALFUNCTION INDICATOR LAMP (MIL) FAILURE CODES - The PGM-Fl MIL denotes the failure codes {the number of blinks from 0 to 33]. when the indicator lights for 1 3 seconds it is equivalent to 10 blinks For example, a 1.3 second lllUIIIlIIHllUll and two blinks (0.5 second X 2) of the indicator equals 12 blinkst Follow code 12 on page 5-26. - When more than one failure occurs, the MIL shows the blinks in the order of lowest number to highest number. For exam- ple, ii the indicator blinks once, then two times, two lailures have occurred. Follow codes 1 and 2 on page 5.12 Number ni FEM-Fl Causes Symptoms ‘ Refer to ‘ MIL blinks ' ‘ (Failrsale contents} page Opcn Clrcult attire power input wire oi the l - Engine does not slarl ECM l l Faulty bank angle sensor Open circuit "1 bank angle sensor related circuit Faulty engine slup relay Open mum in Pnglne stop relay related wires - Faulty enginc stop switch 5-85 0 O - Open L‘ircull in engine stop switch related wires No blinks - Faulty ignition SWitclt ' Faulty ECM Blown PGM-Fl fuse (20 A) Open circuit in engine stop switch ground Blown sub-fuse (10 Al lStartcr/ignition) O . Open or short circuit in MIL wire - anine operates normally - Faulty ECM 59 No blink: Short circuit in service check connector . Engine operates normally Q - Faulty ECM _ - short circuit in service check connector Wire ‘ l Stay Iii | y - Loose or poor Lulllacls on MAP sensor - Engine operates normally l 1 connector ‘ 5’12 ‘ - Open or short circuit in MAP sensor wtrn Blinks - Faulty MAP sensor Luuse or poor connection ottne MAP scnsor I - Engine operates normally vacuum hose l 5-1A Faulty MAP sensor Hard start at a low temperature Loose or poor cont at on FCT sensor {Ir Blinks v C? Blinks {1 ' Open or short circuit in EcT sensor Wire (simulate using numelicel 5-16 - Faulty ECT sensor ‘ values; sat/194T: - Luuse or poor contact on TF sensor ; - Poor engine response when I 8 connector l operating the throttle quickly 5 18 - Open or short circuit in TF sensor wire 1 lsimulate using numerical Blinks - Faulty TP sensor i values; Throttle opens 0') - Loose or poor Contact on IAT sonsor ~ Engine operates normally 3 ‘Q' - Open or short circuit in IAT sensor wire lsimulatc using numerical 5~22 Blinks - Faulty IAT sensor values;25‘Ci77‘F) i 5-10 FUEL SYSTEM [Programmed Fuel Injection) 1 Number of PGM-Fl l rrlallurluliou Causes [F .flgpvwnf t I l Refer to ‘ 1 lndtnatnr hltnks ‘" 5 e m“ e" s 1 p399 ‘ - Loose or poor contact on vehicle speed . Engine operates normally 1 ‘ sensor connector i it Q - Open or short cilcuit ln vehicle speed sensor ‘ 5.24 Blinks - Faulty vehicle speed sensor - Loose or poor contact on No.1 injector . Engine does not start ‘ ' connector 526 y ‘2 Q - Open or short circuit in Nn.1 Injemnrwirp. ‘ Blinks - Faultv No.1 inlectar ‘ ‘ l - Loose or poor contact on No.2 injector - Engine docs not start l ' connector l 5-29 ‘ ! 13 Q - Open or short circuit in No 2 injector wire r i Blinks - Faulty Na? miemor l ' - Loose or pnnr mntnm on No 3 injec‘nr - Englne does not start connector 1 5-32 H {:2 - Open or ihorl circuit in Nut; injector wire i l 3 "its . Faulty No.3 injector i r..- ,, , ,, , ,, i e . Loose or poor contact on No A injector - Engine does not start i CIA nonnnmor ‘ 5-35 15 . - Open or short circuit in No.4 inlemor wire Blinks . Faulty Nounjector r i - Loose or put)! contact on cam pulse - Engine does not start generator _ ‘3 a - Open or shon circuit in cam pulse generator 5 38 Blinks - Faulty cam pulse gensralur ' f - Loose or poor Contact on ignition pulse . Engine does not start ‘ generator connector ‘ 19 - Open or short circuit in ignition pulse l 5-40 Blinks generator l - Faully ignition pulse generator 1 r . - Faulty 02 sensor lealirernia type only) - Engine operates normally r 21 Q 5-42 ‘ Blinks Faulty 0: sensor heater (Califgnia type only) - Engine operates n‘unrmallv Blink: j l ‘ ~ Faulty E7-PROM in ECM ‘ - rngrne operates normally 33 , - Does not hold the sell- ‘ 5-43 Blinks 1 ‘ diagnosis data 1 5-11 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 1 BLINK (MAP SENSOR) Tum the ignition wulch to “OFF”. Disconnect the MAP sensor 3F connector. Check fur louse or poor contact on [he MAP senr snr nnnnerrmr . Does not blinks Lnnnem the MAP sensor connector. % . Loose or poor contact on the MAP sensor connec- ‘ Place the motorcyc‘e on its side stand. tnr. Start the engine and check that the MIL blinks. 1 hllnk Turn the :gnmon swltnh tn "OFF". . ' g ‘ Out change , ‘ _ ‘ Dtscumleul [he MAP sensor 3? connector: *b - Open or short curcmt In Yellow/Red wuet Imn the igmtion switch to “ON”. - Loose or poor contact on the ECM connectors. Measure the voltage at the Wire harness sidP ; cutmecton { Connection: Yellow/Red (+1 — Ground (—1 Stundird: 4.75 - 5.25 V I antage exists Out of range Measure the voltage between the conneclot Ler- ——> - Open or short circuit In Green/Orange with minals of the wire harness stde - Loose nr poor contact on the ECM uuunecturs. 1 Connectia Vallnwlfled (¢)-Green/Drange[-) ‘ ; Standard: 4.75 , 525 v Vonage exists 5—12 FUEL SYSTEM (Programmed Fuel Injection) ,, l l —“+ Om of range 1 Measure the voltage belweeu Ihe lermmals of —> - Open or shun circu‘n in Light green/Vellow wire 1 the wive harness side - Loose or poor comam on ma ECM connectors. Connectlun: ugm green/Vallow l.) - Green/Orange (-l Standard: ‘15 - 525 V ; Voltage exists Turn the ignil'lun switch (0 ”OFF" Connect (hp MAP sensor 3P connector. Disconnect the FCM mnnemors, (:nnnnct the test harness to ECM connectors. _ Out of range Measure the voltage at the lest harness lenm- . Faulty MAP sensor nals (page 5,9), l Connenionz 37 (o) - B1 (-l Standavd' 2.7 - 3.1 v [150 mm Hg/Lma kPa) Voltage emsts - Replace the ECM will! a new one, and inspect I1 again. 5-13 FUEL SVSTEM (Programmed Fuel Injection) PGM-Fl MIL 2 BLINKS (MAP SENSOR) mm the Ignlhon swmth to "OFF'X ell—“é“ Disconnect the vacuum hose [rum the MAP sen» ‘ ‘ snr Connect the vacuum gauge between me thromc bodv and the MAP senior using a 3-way joinn Start the engine and measure the manifold absolule pressure at we speed. Standard: 150 ~ 250 mm Hg i Dsscnnnect the vacuum gauge and connen the hose to me MAP sensor, ,_'{% Disconnec‘ me ECM connccxors‘ ConneuL the lesl hamess lo the ECM Connamorv Out of range - Check hose innallatian. 5-14 FUEL SYSTEM (Programmed Fuel Injection) ¢ ‘ Turn the \gmtian switch to "ON". ‘ Measure me vouage at the test harness xermir 1 nals (page 59!. manna 'x” r :‘Y‘W’Eif‘nm, ‘ «mums-"l! u-Z Einunmw Connecflon: B7 [+1 — B1 (—1 Stand-rd: 2‘7 — 1.1 V (780 mm Pig/1,013 It?!) ; Voltage exists Stan the engine, Measure [he VOHSQE at "16 [est harness term]- nals ipdge 5-9)‘ r1 7 ‘ gm n 7mm ‘ IFQOTIKI.CY)CH.§! uun'utwwlalnn vnnusuvvlwnnn Connection: 37 (+) — B1 l—) ‘ Standard: 2.7 V n mum Out of range ~ Faulty MAP sensor. Out of range - Fauky MAP :ensul. Vullags exists I:——> - Rep‘are the ECM with a new one, and mspect il again, 5-15 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 7 BLINKS (ECT SENSOR] Turn the ignition switch to "OFF". Disconnect the ECT sensor 3P nnnp mr Check for ioose 01 Door contacl on the ECT senr sor ccnnecmn No blinks Cmmecl the ECT SEIlSOi connector. __A_,_,,____ - loose or pnnr contact on tha kCI sensor connec- Platte ms, mn'nrcycie on it: :Ide stand, tor. Turn the ignition switch to “ON". I \ Check that the Mn. blinks. 7 hllnks , , ‘ Ab Turn the Ignition swnch to "OFF". r—me-p . Faulty ECT Sensm Disconnect the ECT sensor connector. Measure the resistance at the ECT sensor termi- nals , 75:? _‘ Connection. Pink1o)- Green/Orange (-) {sensor side Oerminnls) Slandard: 2‘3 7 2.6 kg (ZU'C/Sa'F] Normal 5-16 i Turn the ignition switch to “ON" Measure the voltage between the ECT sensor connector lcrminal oi the wire harness side and ground. Connaction: Pink/While (o) - Ground (-l Standard: L7" - 5.75 V ; Voltage exists Measure the voltage at the EC‘T sensor connec- tor at the win: harness side Cannmion: Pink/White l.) — Green/Orange (-l l Standard: 1.75 — 5.25 V FUEL SYSTEM (Programmed Fuel Injection! Out ol range ‘ , _ _ - Open or short arm!!! In Pmk and Fink/White wire. - Loose or poor contacts on the FCM nnnnemor, Out 0' range . _ - Open or short circuit In Green/Orange wrro. - Louse ut pom contacts on the ECM cnnnectnr. ‘ Voltage exists . , ~ Replace the l:CM With a new one, and Inspect ll again. 5-17 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 8 BLINKS (TP SENSOR) Turn the ignition switch to “OFF”, ,, , _ ‘ Disconnect the T? sensor 3? connecmr. ‘ Check in: loose Ul puui cuiilaui on [he TP sen- :or connecmr Docs not biink Connem the 7P sensor nonnnctor. _> ' Loose or poor contact on the TP sensor connector, Place the motorcycle on its side stand. Start llle engine and check that (he MIL blinks. ; 8 blinks Turn the ignition switch to "OFF". ' Out of range A Disconnect the TP sensor 3P conncclor. _> - Open or shull Eircuil in the VeHow/Red Wire. Turn the ignition Swiluh lo "0N", - Loose or poor contact on the ECM connectort Measure the voltage hmween the wire harness side connector Icrminal and ground. 2,, «I 1 Connection: Yellow/Red lo) ~ Ground l—i Standard. 4.75 - 5.25 V Voltage exusts 5-18 r ,__..—,, , ‘ Measure rho volrage at (he TP sensor terminals ofma wire harness side. i Connectlun: VollowlR-d [+1 - Green/Orange (-) Standard: [.75 - 5.25 V Turn the rgnirion swirch ro "OFF . Disconnecr {Ira ECM 22F connemnrs. Check for conunu-ry between the TP sensor con» nemnr terminal of rho wire harness side and ground. I Connection: Hod/Vollnw (o) - Ground (-l Srandard. No cantin rty No continuity FUEL SYSTEM (Programmed Fuel Injection) Out of range . . . - Open or short clrcult In Green/Orange wire. - Loose or poor conram on ma ECM cannscrors, Connnmry ' Short :ircuir in Rad/Yellow Wire 5-19 FUEL SYSTEM (Programmed Fuel Iniection) I Cominuily Connect kne test harness to the hCM mnnan- tors. Check iuv continuity belween the iest harnes: termmnl and the Ti" sensor connector terminal. i % quA-qulllllll Connection: fied/Veilow- 38 Standard: ' C, )OOV 3;.ng Canned (he TP sensor 3P connector. Turn the ignition swilch lu "ON”. Measure the voltage at The test harness termi- nals‘ il’ffli‘lfil'? 4’——T i i. n .. wxrn Connection: 38 lol- 51 (-l Sund-rd: :0. 4 0 s V (thrcme lully closed] V (“Ironic lullv open) Nn continuity Normal Om m rang - Open or shun circuii In Hed/Vellnw wurav ' Replace the ECM with a new one, and inspect it again - Faulty TP scnsun FUEL SYSTEM (Programmed Fuel Injection) A voltage marked ' refers [O the value when the voltage reading a\ the TP sensor 3P cunneclur (page 5-19) shows 5 V. When the reading shows olive! [ham 5 V. derive a voltage at :he ‘25! harness 35 fallnws: In the case of a voltage of 4.75 V at me TP sensor 3? nonnamor: 0.4 x 4.75/50 2 0.38 V 0.6xd75/Tnn=057v Thus. the solution is "0.38 — 0.57 V" with the throme hdly clnspd, Rep|ace 0.4 and 0 G with 4.? and A H respectlvely, In the above cqumions to determine the mrome mHy open ranae. 5-21 FUEL SYSTEM (Programmed Fuel lniection) PGM—FI MIL 9 BLINKS (IAT SENSOR) Turn the ignition swilch lo "OFF", Dusmnnm the \AI sansm 2P connector, Check [or loose or poor contact on the IAT acn sur cunneclur. Connect the IAT sensor 2? connector Piace me mororcvc‘e on its side stand. Turn the ignition switch to “ON”. Check that (he MIL blinks. 9 blinks I Turn the ignmon swucn m "UH". Disconnect the IAT sensor 2P connector. Measure the resistance a the IAT sensor (ar 20 30 'C/SS , 86 ‘FL Standard: 1 - 4 kn i ; Nnrmal Turn the Ignmon swrtch to “UN", Does not b‘ink Abnormal - Luuse or poor uunlacl on me IAT sensor uunnecwr, - Fau‘rv IAT sensor. 5-22 i Measure the voltage between the terminals of the wire harness side Connection: ‘ Guy/Blue (.1- Ground 1-» 1 Standard: us - 5.25 v Measuta the vuitage between the tevminais of the wire harness sidt Connedion: Guy/Blue to) — Green/Orange 1—) Standard: 4,75 — 5.25 V ; Voltage exists FUEL SYSTEM (Programmed Fuel Injection] Out 01 range . - Open or short circuit in GraviBlua wira, - Loose or poor Contact on the ECM connectors. Out of range V - Open or short mtcuil in Green/Orange WIre. ~ Loose at you: uultlact on the ECM connectors . Replace the ECM with a new one, and Inspect it again 5-23 FUEL SVSTEM (Programmed Fuel Injection) PGM-Fl MIL 11 BLINKS (VEHICLE SPEED SENSOR) ‘ Turn the Ignition switch to “OFF". I ‘ Disconnect the veh‘rule speed sensor 3? uunnec» mr Check (or louse or poor contact on the vchiclc :peed sensuv connector. Connect thn vehicle speed sensor 3P connector Start the cnginc‘ Ride the molnrcycle and keep the engine revs more than 5,000 rpm for 20 seconds or male, Pm the side stand down and check that the MIL blinks. { 11 blinks Turn the Ignmon swltnh tn ”HIT" Discounted the vehicle speed ssnsor 3P connec- tor. Turn the ignitton swnch to “ON". Measure the voltage at the wire harness side connector, Connection: Black lo) - Green (-) Standard: 12 V Voltage exisls Does not blink _ - Loose or poor contact on the vehicle speed sensor connector. Out of range ‘ , ‘ Open or shnrt CIrClll' In Black wn‘e of the engine sub-harness. - Open or short circuit in Black/Brown wire ol the main wire harness. 5-24 l Connect the speed scnsm 3P connecluv. Disconneul the ECM connectors, Canned the tes1 harness to me wire harness ' connecxors. Support the mulorcvcle sncurely and place the rear wheel on the graund, Shift the iransmissiun into 151 gearl Measuve me voltage at the ten harness termi- nals with the ignition swutch is turned ‘0 "DN’l while slowly mrmng the rear wheel by handl CONNECTION: Pink/Green (q) — Ground (—) STANDARD: Repeal 0 to 5V FUEL SYSTEM [Programmed Fuel Inieclion) Abnormal ~ Open or short circuit in Pink wirn oi the engine sub-harnessi - Open or short circuit in Fink/Green wire of the mm wire harness. Normal . Replace the ECM with a new one, and inspect it again. 5-25 FUEL SYSTEM (Programmed Fuel Infection) PGM—FI MIL 12 BLINKS (No.1 INJECTOR) Turn the ignirion swirch la “OFF“, Disconnect the N111 InJHC'nr 7P mnnector Check for loose or poor coma“ on the Nuj injector 2P cunnectun i .f F‘— Cannent the No1 injector 2P :cnnemor, Place the motorcycle on its side stand. Turn the ignition switch to ”ON". (Shank that rhe MIL blinks‘ Turn the ignition swnch m "(Jrr' Disconnect the No.1 injector 2P connector and measure the resistance of the No.1 injector, ‘ Connection: ‘ Black/whim lo) - Pink/Vellum! 1-) 1 Standard: 11.1 712.3 r: mat/sari Normai Does not blink Abnormal - Loose or poor contact on the anl injecinv mnner- rnr - Faulty No.1 injecxor, 5-26 FUEL SVSTEM [Programmed Fuel Injection) *7 r I__.‘ Check for continuity belween the No 1 injemnr ‘ and ground, Continuily - Faulty No.‘ injector. Connection: Black/White (H — Ground (—l Standard: No contlnuity No cominuiry . ‘ Out of range Tum (he Ignmnn swnch to "ON”. Measure me voltage between the No.1 iIIjeLlul conncmor or the wire harness side and ground - Open or short circmv in Blanklwhfle wire. Connecfion: Black/While (o) - Ground (-1 Standard: Battery voltage g I Vokag Turn the ignmun swilun l0 "OFF" Connect the No.1 Inn-mm connector. g i l I x 5-27 FUEL SYSTEM (Programmed Fuel Injection) ___i__ Dusconnem the ECM cnnnnmnrs, Connect me ms! harness to the wire harness conneclom Measure the rcsislance at the test harness ter- nlillals. Connection. AM (—I - 86 M ‘ Standard; 9 - 15 D (ZO'C/GS’F) Check for continuity between me last harness lenm’nal and ground. 1 Connection: A14 7 Ground ‘ Standard: No continuity Out a! re nge Continuiw - Open circuit in Black/White and/or Pink/Yellow wire. - Short circuit In Pink/Yellow wire. No cominuily . Rep|ace Hm ECM wilh a new one, and inspecl it again‘ 5-28 FUEL SYSTEM (Programmed Fuel Inlection) PGM-FI MIL 13 BLINKS (No.2 INJECTOR) Turn (he ignition switch lu “OFF". ‘ Dwsconnect the No.2 injector 2F connector. Check Var loose or poor Cunlacl on um No.2 injeuluv 2P conneclor Does not hlink . > Connect the No.2 Inleclor 2P connector‘ ———> - Loose 0' poor Contact on the No.2 Injector connec- ‘ P‘ace \he motorcycle on its side stand. tor. Turn the igniilon switch to "ON". Chzck that the MIL blinks, f1}, \ / L;~ lira/git 13 blinks Ahnnrrnnl , Turn the ignition switch to “OFF", r'—’ - Faullv No.2 inleclor, Ulscfll’ll’lefl Ihc No,2 mjeuor 2P connector and measure ”the resistance at me No,2 injector, Connlflinn: Black/White lo) - Pink/Blue [7) Standard: 11,1 ~ 12.3 0 (ZO'C/SB'F) 5-29 FUEL SYSTEM (Programmed Fuel Injection) t and ground Connection: Black/White M — Ground (—1 Standard: No cnmlnulty Check for continuitv between the No.2 injector No contmuttv Turn the Icnmon :wltch to "ON‘C Measure the voltage between the No.2 injector connectot at the wine Names - side and ground. Connection: Black/White to) - Ground (4 Standard: Battery voltage Vonage exists Turn the :gmtlon switch to "OFF" Cannon the No.2 injectur connector. Cnnttnm fv - Faulty No.2 injector. Outo! range , . . . . - Open an shout cnuult m BldckWhIle Wire. 5-30 FUEL SYSTEM (Programmed Fuel Injection) ____$_____ ? Disconnect the ECM connmms \ Connect the ten harness to the wire harness connectors. Out of range _ _ V ‘ - Open Clrcult m Black/White and/or Pink/Blue wxre. mlnals. ConnBcfic-n A3 (-I - BS (9) Standard: 9 — 15 {I (ZO‘C/BB'F) _ ; Nam. . . Comlnuily _ Check for cullllnully between the ‘95! harness - Snnn circun In Pink/Blue wnre, ‘ermmal and ground. “Hum...“m ”mun...“ Connmiun: A3 - Ground ‘ Standard Nn continuity 7 No cominuiw - Replace the ECM with a new one, and Inspect u again. 5-31 FUEL SYSTEM (Programmed Fusl Injection) PGM - Faulty N03 injector and ground. Connection: Black/White (+1 - Ground (-) Standard: No continuity ; No continuity Out at range Turn the ignition swnch to ”ON”. ——> ~ Open nr snort Circuit in Black/White wire. Measure the voltage batweun the No 3 injector connector oi the wile harness ' and ground. Connection: Black/Whln (6) - Ground (—) Standard: Battery voltage Voltage exists iurn the ignition switch to "OFF". Connect the No.3 Injector connentnr. {,1 5-33 FUEL SYSTEM (Programmed Fuel Injection) $ Discnnnect the ECM cnnnerjnrs. Connect the xesx harness to me wire harness connemors. ‘1 Moasurc the resistance at the my harness ter- minals. a 4 ‘ V ’33’c-“QW3 Ivy-"n Axm' 1 W: o v3; \ f 1 Connection: A2 4—) — as m \ Sxindard: 9 _ 15 :1 (2012/68?) Normal Check for connmmy between the test hamux: terminal and ground. Connection: A2 — Gmund Standard: No continuity Out of range Continuity No continu‘ny ' Open circuit in Black/White and/or Pink/Gram wxre - Shorl cwrcult m fink/Green wire “a - Replace the ECM With a new nne, and inspect it again 5-34 FUEL SYSTEM (Programmed Fuel Iniection) PGM-FI MIL 15 BLINKS (No.4 INJECTOR) Tum the ignition switch to “OFF” i ,, Disconnect the No.1 injector 2P connector, Check for loose ur puov Contact on the No.5 iniecror 2P connector Connect the No.4 injector 2P connector. Place the motorcycle on its side stand. Turn the ignition switch to “ON", Check that the MIL hllnkst E 15!) nk§ Disconnect the No.4 iniectur 2P connector and i Turn the tgnltlcn switch (0 "OFF”t i measure the re>istance of the N04 inieman Connection; Black/White l+) — Pink/Black [-1 Standard: 11.1 — 12.3 9 (ZO'C/OS'F) Does not bllnk Abnormai - Loose Ul pom contact an the Nail injmtnr nnnnec- lor. ——-—> ~ Faulty No 4 inlemnr. 5-35 FUEL SYSTEM (Programmed Fuel lnisctionl i Check lor continuity between the No.4 injector . and ground. Connection: Black/Whl‘e (+) — Ground (—l ‘ Standard: No continuhy E No cont uIiv Turn the ignition switch to “ON". Medsule the voltage between [he No.4 injector connector ni the wire harness side and ground. Connection: ‘ Black/White (+) - Ground H i Standard. Bannrv voltage ; Voitage ts Turn me ignition swmnh tn "OFF". Connect the No.4 inicctur connector. Connnux ty - Faulty No.4 injector. Out of range _ _ _ . _ - Open or shuvl uncull m Black/Wilma wne. 5~36 _._L ,7 f Disconnect the ECM connectors. Connect (he (asx harness lu Hue wire harness connectors. Measure the resistance at the test harncss tcr» minals. 4.x finnm in“ ‘ :09 m NJfllJ Gnu“; “41...", Connectlovn: A13 (-1 — as m Standard: 9 - 15 a Izo'C/ss'ri Normal Check for continuity between the iest harness ' terminal and ground. onnocfion. A13 — Ground tandard‘ No continuity - Replace the ECM with a new one, and inspem It again. FUEL SYSTEM (Programmed Fuel Injection) cm of range ‘ _ _ - Open circuit in BIaclownira and/or Pink/Black wire, Conlinuil V - Short circuit in Pink’Elack wire. 5-37 FUEL SYSTEM (Prugrammed Fuel Injection) PGM-Fl MIL 18 BLINKS (CAM PULSE GENERATOR) ‘ Turn the ignition swr ll 10 “OFF”. I r Disconnect the cam pulse generator 2? connec- tor. Check for loose or poor contact on the cam pulse generator 2? connector. Connect the cam pulse generator 2? connector. Place the motorcycle on It: side stand. Turn the :laner mntor ior more than 10 sennnds and then check that the MIL blinks. 1Rb|nks [urn the ignmnn switch to "OFF” and the engine stop switch to "OFF". Dimsunnact the cam pulse generator 2? conncc‘ mr. 1 Check the conhmnly between the cam pulse generator connector terminal and ground. Connection: White/Yellow , Ground Standard. No continuity No continultv Does nul blink - Lease or pnnr contact on the cam pulse genelalor 2P comleclot. Continuity - Faulty cam pulse generator. 5-38 FUEL SYSTEM (Programmed Fuel Injection) r . l Out at range ‘ Crank the engine wnh the starter motor and L———-—> ~ Faulty cam pulse generator 1 measure the cam pulse generator peak voltage ‘ l at the cam pulsc generator 2F connector. Connection: Gray 1+) — White/Yellow l—) Standard: 0.7 V mlnlmum (ZO'C/Bs‘F) * Normal Connect the mam pulse generator 2P connector, DlSConnCCl the ECM connectors. Connect the test harness [u ECM connectors. _ _ l Out ofrange _ Crank the stigma With the starter mnlnr and ———> - Open circuit In WhlteNellow and/or Gray WIre. measure the cam pulse generator peak voltage at the test harness terminals. Connecfinn: 322 I.) — Ground H Standard: ‘7 V mlnlmum (ZO'C/GB'F) - Replace the ECM with a new one, and inspect it again 5-39 FUEL SVSTEM [Programmed Fuel Injection) PGM-FI MIL 19 BLINKS (IGNITION PULSE GENERATOR) Turn the ignition switch to ”OFF", I Disconnect the ignition pulsp gpnsratnr 7F mn- nectar. Chuck fol lease at poor Contact on (he igniilon pulse generator 2P connector, Connect the ignition puisc gcnctalor 2? can HDCKOL Place the motorcycle on its side stand. Turn the starter moiov for more than 10 seconds and then check that the ML biinks. 19 hllnks Tllrn the ignilinn swimh tn “OFF" and the engine atop switch to “OFF”, Disconnect the ignition pulse generator 2P can— nectar Check the continuity betwaen the lgnmnn pulse generator COnnDClOr terminal and ground. Connection: White/Yellow ~ Ground Standard. No continuity I No continuity Does nol blink Abnormal alor 2F conrleclon ~ Faulty ignition pulse generatoL 5-40 Lnnsa 0r pnnr comm rm rhn igninnn pulse gener- FUEL SVSTEM (Programmed Fuel Injection) l Crank the engine with the starter motor and measure the ign' 'on pulse generator peak volt age at the ignition pulse generator 2P connec- tor. Connection: Vellow (o) - Yellow/White (-) Standard: 0.7 V min urn IZO'C/GB'FI E Normal (:nnnect the ignition pulse generator 2P con- . nccror. Disconnect the ECM connectors, Connect the test harness to ECM connectors. Crank the engine with the starter motor and measure the ignition pulse generalov peak volt- ‘ age at the test harness terminals. ammi nhvrr-rmmi W 7? m Ground (-) "um (20' [5817) Connection: B11 (0) Stand- V m Out oi range Out of range - Faulty Ignition pulse generator. - Open circuit In White/Yellow wrre. - Open circuit in Yellow wire. Normal > Replace the ECM with a new one, and inspect it again. 5-41 FUEL SYSTEM (Programmed Fuel lniectionl PGM-FI MIL Z1 BLINKS (Oz SENSOR/CALIFORNIA TYPE ONLY) r——¥* 1 1 Turn the ignnion swilcll [0 "OFF“, 1 : Disconnect mo 01 sensor connector. I Check lur loose or poor contac: on [he 02 sen snr cnnnectoh Disconnem (ha HIM connectors, Connect the test harness to ECM connectors. _ . _ No continuity , Check th continuity beiween the (est harness h» - Open circuit in 0: sensor OmngeANhiie wire. torminai and 0) sensor cnnnecmr terminal Connection: Orange/While - A5 Standard: Continuity Continully 5-42 FUEL SYSTEM (Programmed Fuel Injection) #L___ Vi, . Check the continuity between the 0, sensor 1 curingctor terminal and ground. Connunion‘ Orange/White - Ground 7 Standard: No continuity Nn nnntmuity Cuntiuuily Connect the 0: sensor connertnr Tum the ignitlnn swttch to ”ON" and warm up the engine until the coolant temperature is RO'C (1757) . Operate the tlituttle grip and Snap the engine weed from idle to 5,000 rpm. —F——_ Check the voltage between the test harnnu ter- mlnals. ”um. "m. H mm): .r...r.r.n.i..(..., Connection: B1 - B4 Stindard: With the throttle fully open: 0.6 V mlnimum With the throttle quickly closed: 0.: V maximum Oul ut valtge ~ Short circuit in 02 eensor Orange/White wiret - Faulty 0; sensor. T Nurmal ‘ . . Check the fuel supply system, ii the system is cor- rect, replace the ECM and inspect again. 5-43 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL Z3 BLINKS (02 SENSOR HEATER/CALIFORNIA TYPE ONLY) Turn the Ignltton swttch tn "on". Disconnect the 0: sensor connectors. Check for loose or poor contact on the 02 Seth sor connector. Connect the 0: sensor connector. Place the motovcycle on its side stand, Stanthe engine and nhenk that the MIL blinks. ; 23 blinks l Turn the ignition Switch to "OFF". Disconnect the 0; sensor AP rnnnector Maasure the resistance at the sensor side can nectar White terminals Connection: W no - Whlll Standlrd‘ ‘Ifl - 4.0 D Normal Does not blink - Loose or poor contact on the 0; sensor connector. Out of range - Faulty Oz sensor, 5-44 FUEL SYSTEM (Programmed Fuel Injection) Continuity Check for continuity between me White iermlr -—> - Faulty 0: sensor. i 1 nai and ground. Connection: White — Ground Standard: No continuity ; No continuity Normal Turn the igninnn switch to "ON". —>‘ Turn the ignition switch to “OFF". Measure Ihc voltage ar the 0: sensor wire har- Disconnecx me ECM 22F connector nass side conneulor lerlllindis. Connection: Black/Wlnln M - Black/Green (-I Slandnrd: Emery voltage Turn the ignition switch to ”ON". Measure the voltage at the 01 sensor wire harness side connector terminals “w. Connection: Black/W (o) — Black/Green (—1 Standard: Battery voltage Battery vnliage Nn voltage ~ Open cirmiii‘ m 0) Sam sur Black/Green wives. - Replace the ECM and inspect again 5-45 FUEL SYSTEM (Programmed Fuel Injection] ____+__ Measure the voltage at the 0. sensor wire ha» ness suds connector terminal and ground. \ ”‘1‘ Connection: Black/White ‘Ql - Ground l-) Snndard: Banerv voltage ; flattery voltage Turn rhp ignitxon switch to "OFF" r Connect me 0; sensor 1P connecmm, Disuuurved (he ECM connectors. Connect the rest harness to the wire harness connectors. No voltage - Open circuit in Black/Whiter wire belween the 02 sensor and the engme stop relay, 5-46 FUEL SYSTEM (Programmed Fuel Injection) No voltage Measure the vohage at the test harness termi- —-——> - Omen cucuil in Black/Green wire between (he ECM na‘s connector and 0: sensor 4? conncaor. . ‘ 1 Connection new-A5 (-1 ‘ Standard: Battery vohaae Battery vomage , _ - Replace the ECM and Inspect again. 5-47 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 33 BLINKS (EZ-PROM) ‘ Tum the gn on switch to “OFF Disconneci me ECM connectors. Check lui louse uI poov camaci althe ECM con» nermrs Connect the ECM connectors. Sheri the service check connector with a junipui wire (page sci, Turn the ignition swltch lo “ON" and check lhal the ML blinks. Excapt 33 blinks Remove thnjllmperwire mm m. snrvine check connector (page 5 e) to ON and checklhar Turn the ignition swilcn the MIL blinks. 33 blinks 33 blinks Blinks Does not blink 33 lines Reset the sell-diagnosls memory data (page 5-7). Tum ilie igiiiiiun swilcli in "ON" and check ihal the MIL blinks - Replace the ECM ' No problem. $33k) Iks 5-48 rid ‘ Tum me ignition switch to "OFF". V ; Short the servxce check connemur with a jumper Wire (page 5-6). 1 Turn ‘he Ignmnn swvmh to "ON" and check the! 1 me MIL blinks. 33 blinks ‘ Reset (he selfldiagnosi‘ mamnry data (0695 5 7). Turn me ignmon swrlch 10 "ON" and check that His MIL Minks Does not b‘ink 33 was ———> Does nol b‘ink 33 times '-——> FUEL SYSTEM (Programmed Fuel Injection) - Na prnhlam - No promem‘ ‘— 33 blinks - Replace the ECM. 5-49 FUEL SYSTEM [Programmed Fuel Injection) FUEL LINE INSPECTION FUEL PRESSURE INSPECTION NOTICE . [79!an dl'scannecll'ng the fuel Muses, release the fuel pressure by loasemng the «wire check bulr at me fuel lank. - Alway: replace the sealing washers when me scr we check mm 1: rpmnved or loo5ened Remove ma sea! {Dane 272). Remove the ECM holder band and rpmnvs the ECM {mm the banerv cover. Unhookme battery caver retainers, then open the bal- IGrV COVQI’. DISCON’ICC' ms hamary negarwe cabIe flow the bar lery terminal. Support me from end of fuel tank (page 34). Dvsnnnnent the pressu'e leguIaluv vacuum hose and plug the vacuum hose. ”01’s yr "oss- Covev ms service checx mm with a rag or shop towcll SIowa loosen the service check bolt and dram the vema'uung {ueI into an approved gasolme conmincr. BAND NEGATIVE TERMINAL ‘ I BATTE RV PRESSUHI'. HI GUI ATOR VACUU M HOSE A 5-50 FUEL SVSTEM (Programmed Fuel Injection) Remove m». semce chock Doll and attach the fuel pressurc gauge TOOL: Fuel pressure gauge Duos—0040003 or 07‘06—00‘0002 Connecl the ballerv llegalwe cable Slarl [he :ug‘me Read rhn. me‘ Dressurc at idle speed. IDLE SPEED‘ 1,300 : 100 rpm STANDARD' 343 kPa (3.5 kgllcmz, 50 psl) If we fus uruswu i, higher 'han snemhed, Inspect llle {oliowmg‘ ~ l’lnched or clogged fuel retu'r hose Pressure regululuv - Fuel pump lpagP 5-53: lhhc fuel pressure ls Iuwu: lllan speclhed, mm»: Me lolluwlug: , Fuel lms leaklng 7 Clogged fue‘ filter — Pressure legulatol , Fuel plm’m ‘nage 54:10 After lnspacuuu, mum the luel pmsura gauge and reimlall and tnghven the gamma chock boll using the new senlmg washer. TORQUE. 15 N-m (1.5 kgl-m, 11 Ib'Afl) Connect (he pressure regulalal vacuum HOSP ln:lall me removed parts in the reverse order of removal. / \ACUUM HOSE ‘ 5-51 FUEL SYSTEM (Programmed Fuel Injection) FUEL FLOW INSPECTION [UH CUT-OFF RELAY Remove the rear cowl (page 2-2). l Support the from ena n1 mel tank (page 3-“ Discuunecl IIIE fuel L'ulrofl relay conneclor. Jump me Brown and Blackerte wire lermlnals nl the wire harness slde using a lumper wire. ‘ When the fuel return nose I: disconnected, gasoline may spill out lrom the hose. Place 5 approved I gasolme Lonlaille: ulldel [he hose and drain the gasoline. Wipe off any spilled out gasoline. CONNECTOR JUMPER WI‘-ll: Dlsconnect the luel Ielulll lluse dl [he fuel tank and ; FUEL RETURN HOSE plug the luel tank Inlet 1mm Tum (he lgnillun swilch to ~ON" lor 10 seconds. Meafilm‘. thP amount of fuel flow Amount of fuel flow: Minimum 188 cm’ (6“ US 01, 6.6 Imp 01) for In seconds ax 12 V II Ul! luel lluw i; Iezs than specified, inspect the lol- lnwmg‘ Pinched or clogged fuel hose and luel return hose l - Clogged fuel filter - Pressure regulate! , , Fuel pump mage 5-53) FUEL HE l UHN HOSE AILEl luspecliun, uunnect the fuel return hose. man the engine and check 1m leak. 5-52 FUEL SYSTEM (Programmed Fuel lniection) FUEL PUMP INSPECTION Turn the ignition switch to "ON” and confirm that the fuel pump ope-rules luv a lew secunus. If the hlfil pump fines not nperale, mspect as lnllows Support the front end of fuel tank (page 34). Disconnect the fuel pump 3? (Black) connector. Tum the Igllllion switch to "ON" and measure the vnlmge between the termmals. Connection: Brown I.) — Green (-1 There should be battery voltage for a few seconds. If there is battery voltage, replace me luel pump. If there IS no battery voltage. inspect the following: — Main fuse 30A 7 Sub fuse 10A — Engine stop swutch (page 19 19) Fuel cut-off relay (page 5-54l » Engine slop telay (Page 534) — Bank angle sensor (page b~53l ECM lpagc 5 85! REMOVAL l NOfiITE: ' Before discurmecllug Ille luel hose, release the fuel pressure ny Innsenmg the sen/me check ball at the fuel tank. - Always replace the sealing wuellers when Mrs eel» wee check bolt is remnl/Nl or loosened Remove the fuel tank (page 5-55l, Remove the fuel pump mountlng nuts. NUTS Remove the fuel pump assembly and packing. FUl’L PUMP ASskMBLV FUEL SYSTEM (Programmed Fuel Injection) FUEL FILTER REPLACEMENT Disconnect the \‘uel hoses {tom the fuel filter Remove the screws and final filler lnslall \he luel lillev in we reverse order of removal, c: [’39 'ue“ finer FUEL HOSES FUEL FILTER INSTALLATION FUEL PUMP As MBLV s @3569 Place a new packing onto the fuel tank. ‘L E Inuall the fuel pump being careful not w damage the fuel pump wrre‘ Install and tighten the we pump mummng nuts in the sequence shown, I _FUEL PUMP TORQUE 12 NH" [1.2 kgl-m, 9 [bl-ft) FUEL CUT RELAY INSPECTION Remove m rear cowl Ipage 2-2». Disconnect me me! cutrofl relay 4? conneclor. remove Ihe fuel :ul-Ull relay. 5-54 FUEL TANK me we: raw v” ,r 0cm x All «5' n: arm swans ‘Lel lBN FUEL SYSTEM (Programmed Fuel Injection) Com-eel the Ullmmeter lo the fuel cut-ofl relay conr hector termmnls. FUEI (Hf-UH RELAY BATTERY CONNECTION: ink/White - Brown Conan the 12 V bancry to the following luel uul-ull relay connector terminals. CONNECTION: Brown/Black - Black/Whit. There should 1».- conllnuity only when the 12-v battery l5 connects»! ll there l5 no cominulw when the 12V ballely i: new nested. replace the luel cutoff relay REMOVAL Remove the air duct cover lpage 7-7). Remove rhc fuel tank from mounting bulls and washers, Suppurl the ham end oliuel rank and support l! usmg r' ' ' Sl ”TANK SUPPORT (250 mm) a suitable support [250 mm]. ' ' ‘ ‘ Release me luel plessure lpage 575m Disconnect me iucl pump/lesewe sensor 3F lBlackl connector, h. .4 SP lsLACKfico'N‘NEQ'OR D 5-55 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the fuel tank an venx hose and overflow nose m \ AIR VENT HOSE k OVERFLUW HOSE Hold the fuel pipe nut and lemuve llle fuel hose sealv mg nut and seallng washers, 'hen dlsnnnnar' ths- fuel hose. NOTIC - Do not Apply excessive mm: m the fuel pipe - Always hold zhc flml DlDC nut Whl/e remnvmg the fuel lune sealing nut, Temporarily install a 12 x 30 mm non lpltch 1.75; and sedllnq washsrs m the fuel nose banjo, than tighten m» sealing nu! SEALING NUT Disconnect the fuel return hose anhe pressure regu» , FUEL RETURN HOSE lalul. ‘ TNO‘fiCE Du not apply excessn/e mm m rne luel plpe, Cluw lhe fuel lank. Remove (he fuel tank rear mounting bolts, sea: black- 9! and fuel lank‘ FUEL TANK 5-56 22 NW?! ‘12 kgf-m, 16Ih1-fl) 15 N-m (1.5 kgl-m, 11 WW“) Angr‘ we my nose eyelar,wm WEI: m: stooaor an r l; mm! mm: FUEL SYSTEM (Programmed Fuel Injection) Place lhe luel tank upside down. FUEL RETURN H SEV 'w. BANJO BOLT fie mmlul nol m damage me fucl lank. Disconnecl llle fuel relurn hose from the fuel pump Remove the th hnse hanjn Doll and sealing washers, then remove the fuel hose from the fuel pump. Helm lo page 5-53 for mu pump mmml INSTALLATION FUEL TANK AIR VENT HOSE OVERFLOW HOSE 22 NM 12.2 kgl-m, 15 lbf'ft) Connect the fuel hose to the fuel pump Wilh new sealr FUEL RFTuméE " BANJO BOLT ing washers. , _ ALIGN ‘ Insmll and tighten the fuel hose banjo ball to the spec ificd torque. YOROUE: H N-m (2‘2 kgf-m. 16 Ibf~fll Connect the (ue| letuln hose to the fuel pump A : , “:3: ’ SEALING FUEL HOSE , WASHERS; , “ ‘ 5-57 FUEL SVSTEM (Programmed Fuel Injection) Install the that tank onto the frame \nstau the seat bracket and fuel tank rear mmmtmg butts. Suppon the front end o‘ the fuel tank wtth a sultab‘e suupwt (2504mm. Conner! the fuel return hese to UK: ple::ure regulator. NOTTCE Do no: app/v excessive force to the fuel pipe. Connect the fuel hase DEMO to the throttle nndy with new :edling washers. Whrte pushing the lust hose banju stopper to the throttle body, tnstaH and ttghten the :eahng nut to the soscified torque. NOTICE: T — Do not anpty excessive force to the fue.’ prpe. - Always ha/d th ruc/ pipe nut why/e Ughlemng me fuel “use >sa/r'ng nut. TORQUE: 22 N-m (2.2 kg1-m. 16 Ihfvfll BOLIS FUEL RETURN HOSE SEALING NUT 5-58 FUEL SVSTEM (Programmed Fuel Injection) Connect me fuel tank air venl lluse and uvelfluw ho>e lU llle fuel tank pa .. _ AlR VEN?HOSE — OVERFLOW HOSE Connen the lnpl pllmpl‘reserve sensor 3? (Blackl con nemor. Remove the suppon and close lhe luel ldnk. lnstall the fuel tank fmm mounting bolts and washers, BOLTS/WASHERS then tighten the from and rear fuel tank mounting l Dolls. 1 5-59 FUEL SYSTEM (Programmed Fuel Injection) AIR CLEANER HOUSING WSEN’S REMOVAL Hemnve the air cleaner elemnm {pngn 3-5) Discuuneul the MAP :ensuv uuuneuiuv and vacuum hme. Disconnect the PAIR control valve mr sucvinn hose and intake vacuum hoses from the air cleaner hous- ing. EVACUUM HgPQSA Disculmect the Uldllkcase breather hose from the air Manner hnuslng. Remove me arr mum/an nlenner houslng mounting screws, men remove me air funnels. Remove the Mr ananer hmmng. ‘ AIR FUNNELS 1 5-60 FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION Insrall the air cleaner liuusing onlo Ihe tirionle body Install the air funnels ll'l 'hfilr proper locations Install and lighten the air lunnel/air cleaner housing mourning screws. Connect the crankcase breather nose to the air clean~ er housmg. Cunnui the PAIR comroi valve air sncnnn nnxe and make vacuum noses lo rhe air cleaner housing. Connem the MAP sensor connemor and vacuum nose. Install the air cleaner piemem (page 3-51 VAcuuM HOSE scinrsws _ FUEL SYSTEM (Programmed Fuel injection) THROTTLE BODY REMOVAL - Beforc disconnccnng the fuel hose, release the fuel pressure by \oosenlng the service check boll, - Always replace the sealing washer when ‘he service check boll IS removed or luosened Drain ‘he coolam from the cooling syslem (page 5-4), Remove the fol‘owing: — Fuel tank (page 555) — Air nlanner housing (Fags 5-60! Remove (he mrome came bracket mounting bolrs. ‘ swan‘w Disconnect the (hrottle cable ends from the thlollle W: /n NE ":1" drum. Remove the throttle stop Sclew knob hum the damp, my u. u n I 0‘; an; rm Disconnect rhe thrcnle body subvhame» 1GP [Grayl COWHECYOL u/z v.39 Discunnccr rhc lhrome bodvrtorEvAP purge comm! my» solenoid valve hose. AIR HOSE 5-62 FUEL SYSTEM (Programmed Fuel lniecfion) Loascn mc cngmc swdc insu|mor band screws usmg 3 mm: (we uhiilxps screwdrwav through me frame hole, Remove the Inrottle body fmrr the cyhnder head NOTICE ‘ Do not Hold the [UM pipe an the vauw body while removing ma rhmme hndy Luusen Hue huw baud mew: and diwunnecl [he last we wax mm wamr hoses 6mm ms. wax uni! Seal lhc cyiindcr hand inlakc pens with tape or a dean clmh m keep dirt and dsbns from entering me intake ports after the thronle body has been removed Dmcnnnemmp w sansnr connector and master conr ncclors, then remove the (Nome body sub-harness‘ Remove the insulators from me throttle body. fHR'czTrLE'fiD?“ \ 1 WAKEH Hosag SUB-HARNESS INJECTOR CONNECTORS TP SENSOR CONNECTOR INSULATORS 5-63 FUEL SYSTEM (Programmed Fuel Injection) NOTICE . - Do not damage ma mmma body, this may cause incurracr throttle and idle valve synchram‘zaliun. ' The "Home body is factory [are-set, do not disassemble it in a way uther than shown in this manual . an no! loosen or tighten the whrre painted bolts and screws of the mmn‘le body. Laasenmg ar tightening them can cause throttle and idle valve synchronization failura‘ TOP VIEW: WHITE PAINTED 1o N-m(1‘U kgf~m, 7 Ibf‘m REAR VIEW: 70 N-m [1‘0 kgl-m, 7 Ibl-m 'I N-m [0,05 kgl'm. 0.7 Ihf-h) 5 N'm {0.5 kgl-m, 3.6 lbf‘m 5-64 FUEL SYSTEM (Programmed Fuel Iniection) THROTTLE DRUM VIEW: RIGHT SIDE VIEW: 3 N-m {0.35 kgf‘m, 775 IhI-fl) WHITE PAINTED WHITF PAINTED THROTTLE LINK VIEW: STARTER VALVE LINK VIEW: WHITE PAINTED WHITE PAINTED 1 N-m (0.09 kgf-m, 0.7 lbf‘ft) 5-65 FUEL SYSTEM (Programmed Fuel Injection) THROTTLE BODY VACUUM HOSE ROUTING Except Calilotnia type: Calllomla type: INSTALLATION Check the insulator band angle install the insulators onto the throttle body. INSULATOHS Tighten the throttle body side inaulatot band so that the insuialut barid distance is 7 :1mm10.3 : 0.04 in). ‘ i 7 ‘1 mm 71703 1 um ini Apply oii to the insulator inside surfaces 101 case of throttle body instaliation. a: E r \ / i 5-66 FUEL SVSTEM (Programmed Fuel Injection) Roma me thruule body >ubAhamess properly and Cunnect the imacmr :nnnecmrs and TF' sensor Corr nectar. SUBVHARNESS INJECTOR CONVECTORS Conrwrf the (as! mine wax unit waxcr hoses \o the unit. than nghrcn the hose bands secure‘y. Infltall the thronls body unto 1h: cylindel head _N0V'|1(£ Du not hold the fuel pipe on the throw/o body while mare/1mg the throttle body. Tighten the cylmder head Slde msula‘or band so that me Insulator band disiance is 4 z1mmt0‘2 = 0.04 in)» ‘ 23:21.7)?4 W ‘ <4 ‘ ' FUEL SYSTEM (Programmed Fuel Iniecfion) Route (he iniaclor Subrharness referring lhe cable and hamess taming (page 1-23). Connect the throttle body sub harness 10F iGrav! conneclor. 35mm {we Connemme mmme body-tu-EVAP purge comm sole- w ‘v noid valve hose. Route the throws smp conlrul cable pruper‘y, 'msxall me central knob to the. clamp on the bypass hose Connect the mmnm nahie ends tn the 'hrnfile drum, \ ‘ Install the "Home cab“: guide bracke‘ (0 me thronlc [x body, then xighten the bolts to the specified turquel TORQUE: 3 Mm (035 kgf~m. 2.5 lel) InstaH the removed parts in the reverse ordzr of removal. 5—68 FUEL SYSTEM (Programmed Fuel Injection) INJECTOR INJECTOR SOUNDING HOD INSPECTION S‘an me engine and \at it idle. Confiur pvupel injectuv operaliun MIN 3 suunding mu m «amnmnpe ”(he iniector does not operate proparw, rsp‘ace i1. REMOVAL Remove the thronlc bodv (page 5 62). Remove the boNs and fuel pipe assemb‘y Remove the injecmrs horn the Fuel pipe, ’ FUEL INJECTOR Remove the seal ring, 0 ring and Cushion ring. a -' a CUSHION RING v INSTALLAT|ON O-RING $0 Auplv oil w the new O-ring, a r‘vydsfemésea rnscan the new see‘ ring, mmhxon ring and D-r'mg, { qu cusnm rmc, bemg careful not to damage the Orring‘ ans $7"ng WI?“ mywure: a: E SE! FUEL SYSTEM (Programmed Fuel lniecfion) lnhlall the Iuel injeuuxs into the fuel pipe, being care- rm nm to damage me (J-nng and cushion nng. FUEL INJECYOH \nstall the fuel pip: assembly onto 1hr: rhronlc body, FUEL INJECTORS belng carelu! nul 10 damage the seal rings, \nsraH and tighten the MCI pipe Inuqung nulls. \nstall the thromc body (page 5 56a PRESSURE REGULATOR REMOVAL/INSTALLATION NQTICE 1 Du not apply Excessive fun-e to We fuel piper How the fuel Dipc securaw, remove We pressure reg~ maror mounring bolts, men remove the pressure regr ulator VACUUMVhogE 5-70 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the vammm hnsa from the pressure regu- mm. O’RING PRESSURE REGULATOR Install a new O-ring unto the preE the outpul voltage is changed by atmosphere. //7 [Maul (3.10m H.950] 15mm u r ; :5 . Check the sea level measurement and be sure that the i measured Voltage falls within the specifiad value. I r | Ln ‘ i l as l l l l o 500 Loon 1,5on 2.000 :m l l I l MAP SENSOR REMOVAL/INSTALLA- TION Support the horn end of lusl lank (page 3-A). Disconnect the MAP sensor connector. Disconnect the Vauuulll Iruss (mm the MAP sensor. VACUUM HOSE FUEL SYSTEM (Programmed Fuel lniectiun) Remove lhe div cleaner housing (page 5-60’ MAP SENSOR Remove the screw and MAP sonnor [mm the air cleaner housing. installation IS m the reverse order of removal IAT SENSOR CONNECTOR IAT SENSOR REMOVAL/INSTALLATION Support Ihe from end of fuel tank (page 34». Diacuvllleci the iAT sensor connecron Remove the screws and MT sensor lrom the alr clean- er housing cover. instailalicn is in the vevevse ondev ol remuvai. ECT SENSOR REMOVAL/INSTALLATION Drain ms coolam from the svstem (page 6-5). Remove the throttle body (page 562) Disconnecr the ECT sensor connecto! from the sensor Remcve the ECT sensor and sealing washei. 5-80 FUEL SYSTEM (Programmed Fuel Injection) I -... , ,4 _ § SEALlNG WASHER ECT SgNSOR \ | w , m r ‘ \ Aunav: ’60339 a hislall (he flew sealing washer and ECT sensor am was-n" Trgmen the ECT sensor to the specified torque. , : den mm: TDROUE‘ 23 N-m (2,3 kgl-m, 17 lbl-hl Connect the ECT sensor connccror. FiH [he cooling system wwth the recommended nnnlam ”1.92. E>5L CAM PULSE GENERATOR REMOVAL/INSTALLATION Remove the air cleaner housinq {paqs 5—60b. DiSLunnect [he cam pnlsfi generator 2P INamraH con- nemnr, Ps-mnve lhe belt and cam pulse generator from [he cyhndcr head. lnslall the new 0 Nng onlo the cam pulse generator. ‘\ O’HING Install me cam pulse generalul illlu the cyhnder head, ‘ '— ‘ i 7 Install and (ngmcn the mounting bolt securely, FUEL SYSTEM (Programmed Fuel Injection) Route the cam puke generator wtre properly. connect the 2P (Natural) connectort Install the removed parts in the reverse order n1 removal. 2? (NATURAL) CONNECTOR TP SENSOR INSPECTION ECU TEST HARNESS Remuve llie lea! cowl (page 22). Disconnect the ECM 22F (Black) and 22? (Light gray! COHnBClOI’St Check the connector Ior loose or corroded terminals Connect the ECU teat harness between the ECM and main wire harness. TOOL: ECU test harness 07VMZ—0010100 (Mu vaquirad) 1, INPUT VOLTAGE INSPECTION Turn the ignition swltch to “ON" and measure and VEL‘UIU the input voltage at the test harness lemtiiiak using a dlglIHI multimeter. CONNECTION: BE (9) - 31 (-1 Standard: 45 - 5.5 V If the nleaaulellleul is uul ul >pecificaliun, check llle ““ ““ " ‘”'“""“r ‘1““"’ “Emu—1“ lnllnwmg: Loose connection of the ECM multi connector - Open circuit in wire harness 2. OUTPUT VOLTAGE INSPECTION WITH THROTTLE FULLY OPEN Tum the ignition switch to “ON" and measure and iEEOid the output voltage at the lgsl harness lermi» nals CONNECTION: BB (4) - B1 (-I MEASURING CONDITION: At throttle fully open 5-82 FUEL SYSTEM (Programmed Fuel Injection) 3 OUTPUT VOLTAGE INSPECTION WITH THROTTLE FULLY CLOSED Turn the ignition switch to "ON" and measure and record the Dquu! voltage with the thrnttle tnlly closed. CONNECTION: BE [4) - B1 (-1 MEASURING CONDITION: At throttle fully closed 4. CALCULATE RESULT COMPARISON Compare the measurement to the result at the [allow ing calculation With the throttle tullv open: Measured input voltage x 0.514: Va The sensor is nnrmnl ltthe measurement output volt Inge measured in step 2 is within 10% of V0, with Ihe throttle tullv closed: Measured input voltage I 0.1 . Vs The sensor is normal N the throttle closed output volt- age measured in step 3 I: Wlthln 10% a! Vc. Using an analog meter, check that the needle at the voltmeter swings slowly when the throttle Is opened gradually. CONTINUITY INSPECTION _, Support the front end at fuel tank (page 3 4i, 3P CONNECTOR Disconnect the ECM 22F (Lighl gray! connector and [he TP sensor 3? connector, Check for continuity between the ECM and TF sensor. It there is no continuity, check for an open or shnrt nrr- cuil In the wire harness ZZP (LIGHT (SR/XVII CONNECTOR BANK ANGLE SENSOR INSPECTION aAN’K ANGLE SENSOR CONNECTOR Support the muturcycle level surface Remove the windscreen (page 2'7). Turn the ignition switch lu ”0N" and measure the volt- l age between the following terminals of the bank angle sensor connector with the connector connected. TFRMINAL l STANDARD White/Black l.) — Green l—l ‘ Battery voltage Red/White (.l - Green (—1 o , 1 v FUEL SYSTEM (Programmed Fuel Injection) Dc nor measures: we bank angle sensor l‘w‘nm‘mr :u'lng AWSDQCI'D’V lnsrall :nc 0.1 wk angle sensor w-'rl .‘a 'LlD" l'l Turn the ign'ltiun switch to “OFF", Rellluve the screws and bank angle sensnrv Place the bank angle sensor horizontal as shown, and turn the rgnmon switch to "ON". The bank angle sensor is nurmal it the engine slop relay clicks and nnwer supply l5 clam: Incllna the bank angle sensor approxlrnalalv 60 degrees to the left or right with the ignition switch turned to ”ON". The bank angle sensor is normal l! the snglne stop relay clicks and puwel supply is open. If you repeat this test, first turn the ignition switch to "OFF',thenlurn1he ignilion switch to “ON", REMOVAL] INSTALLATION Disconnect the hank angle sensor 3P (Green) connec— tor. Remove the two scrsws, nuts and bank angle sensor. Installation is in the reverse order 01 rcmavalt ‘fig l-rten the mounting screws securely SCREWS BANK ANGLE SE NSOR so" BANK ANGLE POSITION“ NORMAL POSITION q 60' lappmxummlyl ISCREWS BANK ANGLE SENSOR CONNECTOR 5-84 FUEL SYSTEM (Programmed Fuel Injection) ENGINE STOP RELAY ENGINE STOP RELAY INSPECTION I ‘ Disconnect the engine stop relay 4? connector, remove the engine stop relay, Connect the ohmmctcr to the engine stop relay cun- nector terminals. ENGINE STOP nrtAv am-rgny CONNECTION: Red/White — BIack/Whlte Connect the iz-V ballely to the fnllnwmg engine stop relay uunnector terminals. CONNECTION: Rid/whim - Black There shnuld he continuity only when the 12-V battery Is connected. If there is no continuity when the 12v battery is can lteuled, replace thp. engine stop relay. ECM (ENGINE CONTROL MODULE) REMOVAL/INSTALLATION Remove the rear cowl Ipnge 272), Remove the ECM huldev band and remove the ECM from the battery tray cover. Diuconnect the ECM 22F (Black) and 22? ILight may) cnnnectols. POWER/GROUND LINE INSPECTION Connect the test harness between the main wive Ilar- ness and ECM (page 5-8). TOOL: ECU test harness 01VMZ—001o1nfl [two required) GROUND UNE Check lur continuity between the ECM test harness connedor A9 terminal and ground. between the A20 terminal and ground, and between the Biz terminal and ground. TIIEIE should he continuity at an times. If there is no continuity, check for an open Lircuit in the Gteen/Pink wire and Green wire FUEL SYSTEM (Programmed Fuel Injection) POWER INPUT LINE Turn the ignition Gwllch to “ON" with the engine stop Switch in the "RUN" pusiliun. Measure the voltage between the. HIM lest hmness connector 85 termmal M and ground. There should he battery voltage ll [hate is no voltage, check for an open clrcuit m the nlankANhue wlre between the ECM and bank angle scnsorlrclay. IV the wtre ls OK, Llleck [he bank angle sensumelay {page 5-83) PAIR SOLENOID VALVE REMOVAL/INSTALLATION Remuve the air :leanel housing (sage mo: Dieconncct the PAIR solenoid Valve 2P (Black) con~ weclur. DisLumIeLl llve PAIR all >ULUUll huaesv Remove We hnlt and I’Alil solenmd VHlvR lnslallation is in the reverse order of removal INSPECTION Remove the PAIR aolennm valve CT‘SCK that the air should not flow vA'; to lBl, only when the 12-V battery is connected to the PAIR sole- mn: valve termlnals. 5-86 FUEL SYSTEM [Programmed Fuel Injection) Check the resustancc between the terminals of the FAIR solenoid valve. STANDARD: 20 - 2‘ t) (20 "(i/SST] lf the resistance is out or specification. replace the. PAIR suienuid valve. FAIR SOLENOiD VALVE l EVAP PURGE CONTROL VALVE (CALI- lzpcomm j 7 FORNIA TYPE ONLY) REMOVAL Remove the bolt and EVAP nenmeri‘EVAP purge con- trol valve bracket assembly. Disconnect the EVAP purge control valve 2P conncc '0'. BOLTS Disconnect the air hoses from the LVAP purge control valve. Remove the bolts and EVAP purge cunllol Selena-d valve. Ittsldllafion us In the reverse order a! removal. INSPECTION Remove the EVAP purge control valve, Check that air should not flow 1A) to (m, nnly when the 12V battery is connected to the EVAP purge con- trol valve terminals. FUEL SYSTEM (Programmed Fuel Injection) Check the resistance between the terminals 01 (he EVAP purge conirol vaivei STANDARD: 30 - 3t (2 (20 'CISE'FI If the rcsimance is out of specification, replace [he EVAP purge CUIillDI vaive. EVAP PURGE CONTROL V LVE 02 SENSOR (CALIFORNIA TYPE ONLY) APINATUFIALD CONNECTOR REMOVAL [ , NOTICE - Handle the 0/ sensor with care. - Do not get grease. oil or other materials in the 01 sensor air hoie‘ LID no? 55 'V‘CL‘ II is ‘IDI Remove the sea! Image 2-2). Disconnect the 0: sensor AP iNaIurali uunnuciur. Remove the OA sensor w-re from the frame. Remove the 0; sensor unit. ”NOTICE . Be canefni no! to damagP (he sensor wire, - Do not use an impact wrench while removing or installing the 02 ssnsur. instali the 0: sensor umI. Tlgmen the unit ‘0 the Specified quue, TORQUE: 25 N-m (2.6 kgf'm, 19 Ibl-HI 5-88 FUEL SYSTEM (Programmed Fuel Injection) Route the 02 sensor wue into the irame. — ' " ' ' \ Connect lhe 0: sensur 4P [Natural] nnnnacmr‘ 4P (NATURAL CONNECTOR ., # _. , , 5—89 SYSTEM FLOW PATTERN COOLING SYSTEM TH E R M OSTAT WATER PUMP IR BLEED HOSE UPPER RADIATOR HOSE A SIPHON HOSE LOWER RADIATOR H RADIATOR UIL COOLER WAI I:H HOSI: 6-0 6. COOLING SYSTEM ‘ SVSTEM FLOW PATTERN 6»0 THERMOSTAT 6-6 SERVICE INFORMATION 6-1 RADIATOR 6-8 TROUBLESHOOTING 6-2 WATER PUMP 6-13 SYSTEM TESTING 6-3 RADIATOR RESERVE TANK 6-15 COOLANT REPLACEMENT 6-4 SERVICE INFORMATION GENERAL —fl Wat x mm the angmc 5 cool be‘o'e sluva 'emoving mp radlavnr cap, Removing :lue Lap WWI? {hp engine IS th and me cooIam IS undev pwsN-e may ramp W'wmn scammg, I , I A CAUTION Radiamv coulant is (man. Keep w awav Irom eves. mouth‘ akin and damp: ‘ - H any (:30 am gets in vol“ eye>,v1nsetho—n wnh water and consuII a pI‘vsICIdu imllledialer - If any one am m >waHowef‘, Induce vomuing, gargIe and consult .1 p' ys‘tian Immpmmam - II any Lucian! got: 0" your skin or clothes, rinse lIvu'ougth wnh planty 0‘ water. N TICEV I my coo/am win: S: ta Inhibrmrs may muse p’emarurc wear of water yum]. seafls o~ h'm‘AagP orradmror passages. ’4'ng zap VI'HIe" may tangy“ Pngme damage. - Arm mn‘ant m xhc re ” vs :ark. Do nm ‘emnvF the racua‘o' cap exceotto reIi I U! dwa'm the aywwr ~ AI‘ cool ng sysism :ev ces :an m: none wuh mo angina in (he now. - Avmd y Mung coolant on palmcc surfaces. - Ahev spmrmg the system check {on leaks with a \‘nnllng systemwswr. ‘ Helertc sec: on '9 hr Ian momr swnch and ccolowt Iemperaturs semuv mspecl‘nn 6-1 COOLING SYSTEM SPECIFICATIONS ITEM Coolant capacity ‘ Reserve tank Radiator cap reliei pressure 1 Radiator and engine SPECIFICATIONS 2.7 litor12.9 US qt, 2.4 Imp qt) 3 US at, 0 27 Imp qti 16 20 ml) Thermostat Fully open Valve lift ‘ Begin to open 80— M 90 'C 119‘ Ti 8 mm (0.3 in] minlmum l Recommended antifreeze Standard coolant cnnnnntrntinn Fro Honda HP Cnnlnnt or an Equivalent high quality nthylenn glycol antifreeze containing corrosion protection inhibitors 50% mixture with soft water TORQUE VALUES Water Dump cover flange bolt Thermostat cover flange bolt ECT/thermo sensor Cooling tan mounting nut Fan motoi mounting nut Fan mOIDr swnch TROUBLESHOOTING Engin: temperature too high Faulty temperature gauge or ECT/thermo sensor Thermostat stuck closed Faulty radiator cap insufficient coolant Passages blocked in radiator, hoses or water jacket Air in system Faulty cooling fan motor Faulty tan motor switch Faulty mm pump Engine temperature too low - Faulty temperature genus or ECThherrno sensor - Thermostat stuck open - Faulty cooling fan motor SWllch IZ N-m (1‘2 kgt‘m. 9 lbf'R) 12 N-m '11 kgf‘lll, 9 Ibr-ll) 23 N-m (2.3 kgt-m,17|hf~fll 3 N-m (0.27 kgI-m, 2.0 lbt-ft) 5 N‘III (0,5 kgI-m, 3.6 Ibf‘m 1R N-m (1 8 kgt‘m,13lbf-l‘l) CT bolt. CT boiti Apply a locking agent to the threads. Apply sealant to the thread» Coolant leak . iaiilry wan-r pump mechanical seal - Detorioratcd 0 rings - Faulty radiator cap - Damaged or deteriorated cylinder head gasket ~ Loose hose connection or clamp . Damaged or deteriorated hose SYSTEM TESTING COOLANT [HYDROMETER TEST) Remnve (he ngm air intake duct (page 2»71. Remove 1I1e1adiator cap COOLING SVSTEM RADIATOR CAP 1 Test the mnlunt gravity using a hydrcmaler (see De|ow for "COOLANT GRAVITV CHART") For maximum covrosion proteminn, 1: 1:1 solution 01 elhylene g|ycnl arm dxsnlied water is recommended (page (Hi. Look for contaminauun and replace Ihe nnnlant if nec» essary. COOLANT GRAVITV CHART ‘ . Coolant lnmneratuve 'C(’FI 1 1 1 1 1 -—1 . 015. 10115 20 25 30 35140145150 0001an11a1iu°4 1321 1 1411 (501 159) 1081 (771 (051 (95) 111041 11131 11221 7 5 .1009 1.0091I.ODS 100011.007 100611.005 1.0031001109991033 1 10 ?1.018 1.017 1.017 10131101511014 1.013 101110090007 1.005 ‘ 15 11020110271025 1.02511024110221020 1018 1010 1.0141012 # 720 10301.0351.03410331031‘1.020?1.027 102510231021 1019 H 25 1. 045 1.0441043104211040 1030 10301034 1.031 1028 1.025 1 30 1.053 10521105111. 04711046 104511. 043 1.041 1.035 1035 1032 35 1063110021000?1.0511110501.05410521049104610431040 40 11072 107010601000 1.0641.0611.05910561053 1.050 ‘E 45 . 11.000 1.070 1.076 1014 1072 100911 1000 105311.060 1.057 1.054 5“. 1.030 1.084 1002 108011.077 1.07411. 0711 105311.055 1.002 1.059 551.10951.09311.0911108810851.0821.079107611.1073110701.057 50 ‘1.100 1.090 1.0951.092100911000110031.0801077 1.074 1.071 6-3 COOLING SYSTEM 5mm InsraW'g new ‘4 l":- CCNCK W0? "‘5 (fiallrg (mam RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator can [see prevrous pagel. Pressure lest [he rddialuv cap. Replace the radiamr min .1 It does nm hnld pressum, or if relief pressure is :00 high or we low. Ir musr hold the specified pressure for at Isas! 6 sec- onds. RADIATOR CAP RELIEF PRESSURE: 108 - 137 kPaI11- 1V4 kg'lcm’, 16 —20 psi) Pressurize [he radiator, engine and hoses. and check fur leaks. NOTICE Excessivc pressure can damag: IhC cooling system com- ponanls, Do not exceed 137 10°27 (14 kgf/cm‘", 20 psi). Repair or replace components if the system will not hold me specified pressure Ior at least 6 seconds, COOLANT REPLACEMENT mo: f ng o mam or .a raw ,wr mean ’CI'FCI f‘ (Joint DEC? {’5 ”’0 W06 ‘7‘ 5 VSF al‘ wsuw a: a ., .avs: sumac: PREPARATION - The effecxlveness of coolam decreases with me actunrulaliull ur rusl or ii [here is a changs in the mixing nl'npomnn during usage, Therefore. for near performance change the caoiam regularly as specified in the maimsnance schedule. Mix only distllled, low mineral waler wilh ”IE anli- freeze. RECOMMENDED AN’TIFREEZE. Pro Honda HP Coolant or an equivalent high quali- ty ethylene glycol antifreeze containing corrasian pmienian inhibitnrs RECOMMENDED MIXTURE: 1:| [distill-rd wits! and an‘iivaeze) REPLACEMENT/AIR BLEEDING Remove the radiator Lap. I hXDI/EofiEAE TESTER ' WV RADlATOR CAP I HADIATOH CAP IESIEH (ANTIFREEZE SOLUTION IETHYLENI: GLYCOL BASE LOW MINERAL SOLUTIONI OR DISTILLED WATTI'I COOLANT RADIATOR 537i” 6-4 COOLING SVSTEM Remove the lower cowl (page z-Al, Remove the dram bnli an the water pump cover and drain the coolant. Remuve the cylinder drain bolt and drain the coolant from the cylinder. Reinstall the drain bolt with the new (sallng washer Tighten the water pump drain bolt to the specified torque. TORQUE 12 MM (12 kghm, 9 lbl-fll Remove the tight ail duct ipagp 7-71 Disconnect the siphon hose item the radiator. Drain the reserve tank coolant. l‘mrity the coolant and rinse the inside ol the reserve tank with water. Reinstall the radiator siphon hose. Fill the system with the recommended Cuulatll through the llller moaning up [U the tiller netk Remove the radiator reserve tank cap and fill the reserve lanlt in the upper level line. Blood air from the system as lollow .shilt thetransmiseinn mm neutral. Start the engine and let it idle for 2 3 minutes. Snap the throttle three to fun. times to bleed air from the system. Stnpthe engine and add coolant to the proper level if necessary. Reinstall the radiatur cap. .Check the level of coolant in thfi reserve rank and fill to the upper level it it is low. 9'7 m COOLING SYSTEM THERMOSTAT THERMOSTAT REMOVAL Drain me uuulam tpage 675‘. Remove ms mmnle hndv wage 5-52I. Remove the bolts and llIerInuslal Housing uuvel. Remove [he memwslal [rum we huuaillg. INSPECTION Wear msmmed glows and adenume eye prmemmn. Keep flammable material: away from me Clcclric healing e‘ement. szual y inspect the Ihcrmosm for damage. Check for damage 0' the seal rmq. Hear me water wnh en e‘ecmc heal‘ng emmem m ooeramng xemperature (or 5 minmes Suspend lhe lhermufial 'm hedlud waLer lo ut'euk \ls npprannn M "01M 1'9 Repiace the marmostat if the vah/a stays oper ax yum lelllpuva' ye, ul ‘( u responds al lempelcluvu: other than th ,se specmed. THERMOSTAT BEGIN TO OPEN: 8!) — 8‘ 'C (175 — 133 'F) VALVE LIFI': 5 mm (0. in) minimum a: 95 ”C (203 ’FJ 9’. :1 § E; SEAL H‘NG THEHMDSTAT COOLING SYSTEM THERMOSTAT HOUSING REMOVAL BOLT'S ECT SENSOR’CONNECTOR Dmmnnect the ECT sensor connector. Disconnect the last idle wax uml Water hose and bypass Iluse llom xhe (hermnsIav hnusmg Removc the bDIIs and marmoslal huusmg hum me cylinder head. . J "\_;’ r V ' THERMIOS'TAI HOUSING“ THERMOSTAT HOUSING INSTALLATION Inatall a new O-ring mm the ngOVe of (hp vhsrmnsm body. Install lhe Ihermostal housing Dnlo [he cylinder head. Install and hghmn the (hormonal housing mourning BOLT'S mm hulls. ' ' ConllECI the fast idle wax unll water Mae and bypass hocp Connect the ECT sensor uunnecmr RMIOSJA‘I‘ HOUSINiG u THERMOSTAT INSTALLATION install the (nermosm inlu Ule housing with IIS air bleed hula lacing rearward _ AIR BLEED HOEE COOLING SYSTEM InstaH the :hermostat housmg cover onto the hous- mg. Instan and tighten the housmg cover DORE to the spec~ ified torque. TORQUE: 12 N-m [1,2 km-m. 5] Ibl-ffl Fill me system with (he recommended cuo‘am and Need any arr (page G-SI, RADIATOR REMOVAL Remove We \owe' cow! and mne' half cowl mags 2-41‘. Dram me comam lpage 6-4). Disconnect the siphon hose and air breed hose from the Iadiatou‘ stconnect the upper radiator hose, Disconnect xhe radzator sub-harness 2? \Black} con hector Disconnect the Iawer radiator how and on cooker water hose Hemnve the mmaw \anr mounting boumu; am.‘ wasnen u OIL COOLER I :VAJEH HOSE COOLING SYSTEM ‘é OHM/ASHER Removc the radiator unper mUunLiHH ooh and washer Slide the radium (a he right, than rerease the upper Wm H LRQMMET g'ummet {mm the frame boss. | Remove the radiator assamb‘vt DISASSEMBLY D'suzmnect (ha tan motor switch connector. EYELET Rcmove the three bults‘ ground eya‘et and coo‘ing tan mulur assemNy V ’ ' FAN MOTOR CONNECTOR AbSEMELY Remove [he nut and Loafing, [3'1 COOLING SYSTEM Remove the flange nuts and fan momr from the fan FAN MOTOR mmnr shruuu. Fur ran mum uwi‘cll Informalion‘ Iefer m page 1945 FLANGE NUTS ASSEMBLY A ‘5)? 3 NWT) (0.21 kgf'm, 2.0 |bi~fl¥ RADlATOR 1 f5; 1“» COOL‘NG =AN I 5 NM m s kgm, 3.6 \bf-m 18 N-m 4L3 kgf‘m, 13 lbf'm Install me fian moxor onto the fan motor shroud and — fighten the flange nuts (0 the specified torque. FAN MOTOR TORQUE: 5 N-m (0‘5 kgl-m, 3.6 lefl FLANGE NUTS 6-10 ; care” war :5 Jamage my mu, lo' 00’? COOLING SYSTEM lnsmll me coolmg fan onto the fan motor shah by aligning me fla: surlacasl COOLlNG FAN Apply a locking agent (0 the cooling law llul llueads. lnslall and (ighlen the nut to the smeth mrqns TORQUE: 3 Mm (027 kgl-m, 2.0 lbl-l‘l) Install the cooling fan mnmr assembly omo the manner. Rome The ground eyelet properly. Install and lighlen the bolts, GROUND EYELET Install mc radiator sub-harness conneclur Lu [he ran motor brackel. Connect the fan mnmr switch conneclor. FAN MOTOR CONNECTOR ' ASSEMBLY INSTALLATION UPPER GEOMMET lnsrall the radiator assembly, aligning irs grommet with me frame buss. RADIATQR 6-11 COOLING SYSTEM mstau xhe washer and upper mounting bolt, than uqhxen me bolL BOLT/WASHER {A , h1s\a|l We Iadialuv iuwev u uunling Duh/nut, (ithen me mu sacurmy Co'mcc! xhc fan mow' submerness ZI’ Wank) mn- Hector. Carmen the Iowan xad‘atur lune anu uvl cooler water hose. I! OIL cobLER ' WAJEH HUSF Cuuueu Lhe uppey radxawr hose. Comm me swphon hose and an blew nose (a me radimor. 4 n m 5 securely inmucd. WATER PUMP BODY on; COOLER WATER Hosm 6-14 COOLING SYSTEM Inslall a new O-r'mg imu We groove in the water pump body. lnslall 1he waker pump cover, two SH bolts and MO flange bolts. Tlghtcn the flange bolls lu lhe specified torque TORQUE: 12 N~m 11.2 kqf'm. 9 le-ftl fighlan lhe lwu SH bolts Lonngct the lower radlamr huh! and bypass hose, BYPASS HOSE (hen ughten lln: damp screws _ . ”I . ,, Flll the system with the recommended uuolanl (page 6 5], lnslall [he lower cowl [page 2751‘ RADIATOR RESERVE TANK REMOVAL Remove the sea! rail (page 2-16). Remove the radmmr reserve (ank from me engine hanger collar. COOLING SYSTEM DRSconnem [he siphon hose and drain the coolant from the reserve mnk, then remove the reserve tank Disconnect the Overflow hose (rem the reserve Kank. RESERVE TANK DVERFLOW HOSE SII;H[)N HOST INSTALLATION RESERVE TANK OVERFLOW HOSE SIPHON HOSE HANGER COLLAR Connect lhc swphon hose and ovartlnw hm? to the ”mews link RESERVE TANK (M’LRILC)W HOSV S‘P’HON HOSE 6-16 COOLING SYSTEM Install we reserve tank onto me engine hanger collar. Install the seal rail [page 23173 lnswll the flange collar and washer as shown. Tlghten (h? spat ml mnuml'vg nuts [page 2-1 I), COLLAR WASHER NUT I 6-17 ENGINE REMOVAL/INSTALLATION 39 N'm (4.0 k ('m, 29 lbf-ft) A4 N'm (4.5 kgf'm. 33 lbi4'l 54 N-m (5.5 kgf-m, do Ibl-fl) 44 N-m (4.5 kgf'm, 33 Ihf'ffl 7-0 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7-2 ENGINE INSTALLATION 7-10 SHOCK LINK LOWER BRACKET SHOCK LINK LOWER BRACKET REMOVAL 773 INSTALLATION 7-16 I ENGINE REMOVAL 7-5 39 NH“ (4.0 kglml, 29 IbI-h) 54 N-m 15.5 kgf-m. 4o [bf-m 39 N-m (4.0 kgf-nu, 29 mm) 12 N-m (1.2 kgf-m, 9 IbI-m 3 WM (0.3 kgI-m, 2.2 lbI-h) 39 N-m 14.0 kgI-m, 29 IbI-Il) 7-1 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL . A Ituisl or equlvalent is required to support the motorcycle when removing and installing the engine. - A tlnnr Jack nr other ijltStBbIe support l5 required to support and maneuver the engine. 7 NOTICE; \ Do not use the oil filter as a jacking poinL » Crankshaft piston/cylinder (Sectiuu 12) — Transmission (Sec on 11) mt them again to the specified torque in the cnrrect sequence, SERVICE DATA f ITEM SPECIFICATIONS When tislng the lock nut wrench forthc adjusting bolt lock nut, use a 20 inch long deflecting beam tvpc torque wrench. The lock nut wrench increases the torque wrench's leverage, to the torque wrench reading will be less than the torque actually applied In the lock nut The specification given is the newer? torque applied to the lock nut, not the reading on the torque wrench, Do not nvamghten the lock nut. The specification later in the text gives both actual and Indicated torque values. The lollcwing components require angina removal tor service. When lnStfliIlnD the engine, be sure to tlghtcn the engine mounting fasteners to the specified torque in the specified sequence. ltyou do not tighten to the pruuur torque or to in the ptupei :equettue, luusen all mounting lastenexs, then tight- ; Engine dry weight 59 kg Hangs) Engine oil capacity l After disassembly 3.7 liter (3 9 US qt, 3.3 Imp qtt ll CquaIIlL‘apaLilv l'né'ciia'tm and engine 2.7 liter (2.9 US qt, 2.‘ Imp qt} TORQUE VALUES Front engine hanger ball Center engine hanger bull Center engine hanger adjusting bolt [right side) Center engine hanger lock nut (right side) Hear engine hangar nut Rum engine hanger adjusting bolt lright side) Hear engine hanger lock nut trtght side) Shock link bracket nut Shack link-tu-brackel rtul Drive sprmket spacial hnlt Starter motor terminal nut Side stand bracket bolt TOOL LULk nut \Nl ench 39 N-m t4.0 kgf-m, 29 lbt-ttl 39 N-m mo tgr-nt, 29 Ibtoltl it N-rn 10.3 kgt-m, 2.2 lht-tt) 54 N-m (5.5 kgf-m. AU le-I'tl 39 N-m 44.0 kgI'm, 29 lbI-Itl 3 Mom (0.3 kgf-m, 2 2 [bf-ft) 54 N-m (5.5 kgi-m, 40 Ibi-ttl 39 N-m MO kgf'mv 29 "3'40 44 Nvm (4.5 kgi-m. 33 IL-I-ftt 54 N-m (5 5 kgt-m, 40 Int-m ‘lZ N-m (1.2 kgf-mv 9 lbI-fti 4A N-rn (4.5 kgI-m, 33 lbI'Itl ALOC buIL. 07VMA—MEBOI00 or D7VMA—MBBUIOI 7-2 ENGINE REMOVAL/INSTALLATION SHOCK LINK LOWER BRACKET REMOVAL Remove the fol‘owing: — Mufflev/exhausl pipe lpage 2-19) — Throttle bndv (page 5-62] Disconnsct the side sland switch 2? Green) connector. 2P [GREEN] CONNECTOR Remove the genrshinnrm pinch bolt, then remove the GEARSHIFT ARM [1an gearshift arm lrcm me gearshift spindle. ' Remove thn shocvk Imk lower bracket/side :ldlld black- BUTT/NUT 130” at moummg bull/nut. Hemove the bow and side stand bracket assembly. Remove the two bo‘ts, drwe snmcke! mower and gume ptace ENGINE REMOVAL/INSTALLATION Car/rm :we Remuve [he bolt and EVAP namsmr bracket assembly omv from tho shock llnk bracket Disconnect me EVAP purge control snlnnnm valve 2P (Black) connenmr Drsconnect the EVAP canister hoses and EVA? uurge r comrol solenoid valve hoses. (IANISIEH HOSES Remove the shock link lower muuming 5mm —_ ham/nut BRACKET BOLT/N UT Remove the shock link lower bracket mounting SHOCK LINK BOLT/NHT. \ bolL’nut, ‘hen remove» the right and left |ower brackets H Remove the dnwel nlns‘ DOWEL PINS ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL ‘_ ' ”fiflfiurlcfim Remove me following: Fuel tank (page 5455! 7 Luwer bracket (page 7-3) DISCOnnCEl (he PAIR air suullun hoses from me mad valve covers. Disconnecl vha rgmtmn coll connemors, then remove the direct Ignition coils. DlRECT IgglegélLs \ Remove the wile band and release me brake light 7P mlN'K) CONNECTOR wire from the seat rail. Dlsconncct the brake liqm swiluh 2P (Blackl connector l | , l Dismnnem the lower radiator huse [mm the water pump cover. LOWER RADlATOR Hosr Disconnect the oil cooler water hase from (he oil ‘ ‘OIL COOLER w'ArEH'Ho‘sE l cooler r j ENGINE REMOVAL/INSTALLATION Disconnect the air nleed hose and upper 'adlator hose ‘Kl'RB—LEEb‘HOSE 'mofi HOSE- from the thermostat housing covert . - t . , Remove me radmmr .page 6-8]. Remuve me burl and radiator lower bracket. npmnvp rha ‘nmu and lnwpr mw! hrarken from the owl pan. 7.0th BRACKET 23% haw , ’ ‘ ' ‘ V 5 fi .- : ‘ . -. _ ‘ REMOVE the hens and thermostat housmg from the cyHnder headt Remove the starter motor mounting bow and starter mater ground cable Fomove the terrmnal nut and starter motor cahle 7-6 Disconnect the engine sub4|avlless 12F (Gray) and cam pulse generator 7P (Nammn connectors, DisconnPrJ vhe )mmnnmr 3P (Whlm connector. Remove the sockex bows, sealing washer: and cam chain LEVISiUlIEI “flew from the cylinder hPfld Remove the bolts and clutch cable gmde Then r1157 connect the clukch came from (he clutch Iincr lever. ENGINE REMOVAL/INSTALLATION 12¢ 1GRA'v'u CBNNECTOR ' 7. ‘ c , , TENS‘ONER LIFTER SOCKET BOLTé '7 GASKET SEALING WASHERS CLUTCH CABLE CABLE GUIDE LIFTER LEVER BOLT ENGINE REMOVAL/INSTALLATION Remove the dvive spruckel, washer and lhe drwe sprocket wnh the drive cham +mm «hp nnunlershah Remuve me swingarm pivul nut and bah, Ihsn loosen the adjusting bolts 1page 15-14), Supuort the engine using a Jack or another adlusmhle suppon to ease engine hanger bolt removal. ‘_ REAR HANGER NUT CENTkH HANGtH BOLI/ / :i .' Hemove rm. ngm sum. n9 ms. center hangsr bolt Remove the rigm side of the roar hanger nut. Luusen [he cenler engine hanger adiusting new look run wng m» spew-n lnnl TOOL: Lack nut wtench D7VMA-MBBO100 av D7VMA—MBBO1D1 loosen rm rear Moms hanger adjusting bun lock nut using me spccm rool‘ TOOL: Lock run wrench 07VMA—MBEUIDI) or 07VMA7MBBOID1 7-8 ENGINE REMOVAL/INSTALLATION Remove me lell Side loe center hanger boll. , CENTER HANG”. BOW Push ma right side of the rear hangev boli until the ediusting non can be louselled. Loosen the rear hanger adjusting bolx. Loosen the center hanger adjusting hon. 7 CFNTLRfiiGER ADJU‘Si’ING BOLT ’ , ‘ \ M7 Remove {he front engine hanger bolt and dislance coliar on both sides ENGINE REMOVAL/INSTALLATION Remove the rear englne hanger huh and dlstanue L'Ul- lar, then remove the engme {mm the irame ENGINE INSTALLATION Nme (he dlrccnon of 1hr: hanger bolts, When nghlening the lock nul Wilh the lOCK nut wrennh, rPIer tn lorque wrench reading 'qu'n alluu on page 7 2 "SERVICE lNFOFIMATION”, The lack height must be comlnualIy adiu‘slcd to relieve stress from the maunliny Fasteners. Home me wire and cables properly maga 1773) NOTICE“ Be mm m [lg/Hell all engine mounting fasteners to rhe spamhpd .‘nrqI/A in the specified segueuue described followmg page, If you make 3 WISMA’P rum lug (be tlghlsnlnq torque or sequence, loosen all mnummg fasrensl-s then rig/um: ll ayaln to the specified torque m the snecmen Seal/PUFF lnstal‘ the engine hallgev adjusling bolts fully ln ‘rom the inside (71 the flame Carefully lnswll the engine Into the heme. Install the left slda of ms CEl’Itel hanger bull. .- - ~ .4: HEAR IIANGI'R “CIT ADJ USTl NG BOLT 7-10 ENGINE REMOVAL/INSTALLATION |ns‘all the front hanger distance collar and hanger bolt on bath sudes. F” , ‘ > M 5 x: “ DLSTANCE COLL/\H . .. ‘r-fi: lnsta|l the rear engine hangar distance collars and temporarily insxall ms rear engine hanger boli (rum [he lefl side. REAR HANGER-36L?" Tighten the left side center hanger boll n.- [he speci» fiecl tovque, TORQUE: 39 N-m {4.0 kgi-m,29lb1-fl) Tvgmen the la" svde frnnt engine hanger bolt to the specified torque. TOHQUE' 35 Nvm (tn kgI-m, 29 IbI-H) figman the right side (rum engine hanger bull to the specified torque TORQUE: 3S N-m (Ml kgf-m, 29 lbf-h) 7-11 ENGINE REMOVAL/INSTALLATION Tighten the right side center llanyEI adjusting bolt to the specified torque TORQUE: 3 N-m (0.3 kgl-m, 2.2 Ihf-h) lum me fldjushng bolt out 180 and chock that more is; no clearance between the adjusting bolt and the engine, lighten the right Slde rear hanger adjuslmg boltto me cpemlied torque. TORQUE: 3 N-m [0‘3 kgf-m, 2.2 “71-11) Tum llle adjumng bull uul 130‘ and check um mm l5 no clearance between me nr‘llllslmg mm and ms distance collar. human and lighten um .iqu slde uelllev hanger adjust- mg hnll lnnk Nit m me specified mrqne, WhllP holdmg the adjusxing boll. TOOL Lock nul wrench 07VMA~MEBUIOD or 07VMA—M330101 TORQUE: Actual: 5! N-m (5,5 kgl-m, 40 Ibl-ft) Indicawd: 49 MM (5.0 kgl-m, 39 lbl-ft) Install and hghmn the right side mar hanger amnslmg DUI! lock nu! m the specified lorquc, while holding the adjualing bull. TOOL: Lock nut wrench 07VMA-MBBOIOD ov D7VMA-MBBMD1 TORQUE: Actual' 5‘ Mm: (575 kgl-m, AD lbf-lt) Indicated: 49 Nem (5.0 kgl-m, 35 Ihldfl / ,‘ CENTER ADJUS‘FING BOLT .' W ;, 7-12 ENGINE REMOVAL/INSTALLATION Install and tighten the nght side center hanger bolt to REAR‘l-TALNGEH NUT m T d\ . V a spear le urque (I'LNIER HANGER QOLT/ ' / TORQUE: 39 N-m [4.0 kgf'm, 29 Ibl-fl) Fully install the rear engins hanger halt. lnctall and (lgh‘el’l the rear engine hanger nut to the specified torque. TORQUE 39 N-m 14.0 kgfrm. 29 lbl-ft) lnstall the swingarm between thP Engine and tmme, install nnrl tighten the pivot components (pagc 14722). Install the driVe sprocket with the drive chaln onto the Lountershah with the "M l 4F" mark facing out. Install the washer and bolt. tighten the bolt to the specified torque. TORQUE: 54 N~m (5.5 kqf-m. W [bf-k] connect the clutch cable to the clutch liftsr lever. CLUTCH CABLE CABLE GUIDE Install lhe clutch cable glllde to thc rlght crankcase cover and tlgnten the mounting bolts eecurely. . . than LEVER BOLT Install the cam chaln temiuuer liner onto the cylinder * TENSION,“ LIFTER SOCKET BOLTR head. * install ma seallng washers and bolts. tighten the bolts ‘ to the specified torque. TORQUE: 1D N-m [1.0 kgf-m, 7 IM-fl) Q; a? ‘fl GASKET v SEALINGWASHERS 7-13 ENGINE REMOVAL/INSTALLATION Route the alternator wire property, connect the filter 4 namr 3P {Whilel LuflfleC‘OL 3F IWHITE) CONNHHOH Cannemthp Pngine sub-harness 12F (Gray) connector and cam pulse generatur 2P {Nnturah connector, Connect the starter motor ground cable and InstaH and nghten the Matter motor mounting bolt. Connect the staner motor cable to [he motor teminal. tighten the terminat nut to the snemmd torque TORQUE: 12 MM (172 kgl-m, 9 lbf-k) \nstatl a new 0-:‘mg into the thermostat housmg groave‘ Install the thermostat houstng to the nylvnder hzid. 7-14 ENGINE REMOVAL/INSTALLATION Iusxall and t-ghmn the thermostal housing mounfing bolts. \nslall llle thermosm and thermostat housing cover {page 6-D THERMOSTAT HOUSING InsIsH the lower cowi brackets unlo the oil pan, ugh!- on me bong. Inuan the radimor lower bracket [U the cylinder h‘nnk, nghtcn the bolxs Secmely. lnflall [ha radialor as5emhly {page 6 H), Connect the air bleed hose and uppe: radiator hose '0 Inc Ihermosxat housing cover and nghten (he hose band sclew ' .— ()L COOLER WATER HOSE l Carmen the oil cooler waxer hose lu \he oil cooler, ngmen (he hose band smw securely ENGINE REMOVAL/INSTALLATION Connect the lower radiator hose to the water pump Cove! and lighten llle hose band selew seLuuely. LOWE R RADIATOR HOSE connector. Cnnnpct the rear brake llght swnch 2P lBlack) 2P lELACKl CONNECTOR Clamp the brake lighl switch wire with the wire band. ' Install the direct ignition coils into the spark plug . v fim—SUCTIW holes and Lunllecl the iyuilluu L'uil Connectors. 9 . Connect the PAIH mr sumnn hnses m the reed valve covers, Install the mel tank (page 55H Add the recommended engine oil to the proper level lpage 3»14l Fill the coolmq system With the rennmmended coolant and bleed any air lpage 6 M. SHOCK LINK LOWER BRACKET INSTALLATION Install the four dowul pin: lulu the shock link bracket bolt hole: In the engme. DOWEL PINS l h 7-16 ENGINE REMOVAL/INSTALLATION Install lhc rlgm and left shock link luwel brackets onto the engine. Inslall lhe shock Imk lower brackel bolt and nul. Install the shock link lower mounting socket bull and mu. ”alumna sym— Connecl me EVAP camslPr hnse and EVAP purgc con ml» lrol solennm valve hoses. Connecl lhc EVAP purge conlrul solenuiu valve 2P (Black) chneclur. Install the EVA? canister brackel assembly lu [he shook link bracket and tighten the bok securely‘ lnstall the drive chain guide plate and drive sprocket cover, tighter (he nous securelvl BRACKET BOLT/NUT SHOCK LINK BOLT/NUT ,7 i (IANIS I ER HOSES ENGINE REMOVALI|NSTALLATION Install the side stand bracket and then install the side stand blackellsllock link lower blacket mounting bolt from the Ian stde Install the nut EDI WNUT Install the side stand bracket mmmting hnlt SIDE STAND BRACKFT Tighten the shock link lower bracket nuts to the spec- BRACKET BOLT/NUT ihed torque, TORQUE: 39 N-Iu (1.0 kgl-nly 23 lbl-fll Tighten the shock link to lower bracket nut to the specified torque. TORQUE: 44 N-m (4.5 kuf-m, 33 IthI SHOCK LINK BOLT/NUT BRACKET BOLT/NUT Tighten the side stand bracket bolt to the specified tovqua. BOIT TORQUE: M N-m (4‘5 kuI-m. 33 lbf-nl SlDE STAND BRACKET Install the gaarshifl arm to the gearshill 5pllldle, allgn- ing the arm slit wrth the punch mark on the splndle. Install and tighten the pinch bolt. GEAHSHIFT ARM BOLT 7-18 Home the SldE stand wrre properly, connect the Slde srand switch 2P (Greeni connector. waste“ the rnunwmg- - Throttle body (page 5 66) A Mufflenexhausl DIDG 111296 2720} \nsteH the removed parts In the reverse order of removaL ENGINE REMOVAL/INSTALLATION 2P (GREEN) CON NECTOH 7-19 CYLINDER HEAD/VALVES 10 N-m (1.0 kgf-m 7 leI) é; Wm \ 12 N-m (1‘2 kgfim, I ) 9 lbf-ll) \\ f \1 20 Mn (24) kgf-m, w . 14 [bf-h) W ‘ ; fl \1. @3155)” A399 ‘3‘“ f / ‘ Q 41 N-m(4.8 kgf-rn, 35 lbf-hl 12 N-m (1.2 kgf'm, 9 IbI-m 1n N‘m 41 D kgiom, 7 \DV-fl] 59 N-m (6.0 kgi-m, l3 lbl‘fl) 12 N'ln 11.2 kgf-m, 9 le!) 8-0 8. CYLINDER HEAD/VALVES SERVICE INFORMATION TROUBLESHOOTING CYLINDER COMPRESSION TEST CYLINDER HEAD COVER REMOVAL I CYLINDER HEAD COVER DISASSEMBLY CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL I ‘ CVLINDER HEAD DISASSEMBLY I CYLINDER HEAD INSPECTION I , SERVICE INFORMATION GENERAL 34 373 3—4 8-4 8-5 8-6 8-11 8-12 8-13 VALVE GUIDE REPLACEMENT VALVE SEAT INSPECTION] REFACING CYLINDER HEAD ASSEMBLY CYLINDER HEAD INSTALLATION CAMSHAFI' INSTALLATION CVLINDER HEAD COVER ASSEMBLY CYLINDER HEAD COVER INSTALLATION CAM CHAIN TENSIONER LIFTER ~ I ma secxion covers servIce 0( [he Lylinder head, valvas and camshaft. - The camshafl :evvlce caI'I be dnna wflh the engine installed in the frame. TIIE‘ cylinder head wrvlce requlres CngInc lellIuvaI 8-16 8-17 8-19 8-21 8-23 8-27 8-28 3-29 - When d-sasscminng, mark and slum (he disassembled pans to ensure lhauhcy are reInsIaIIed in [fish urigirlal locafiohs - Clean all disassembIed pans wnh rlennIng Solvent and dry them by blow'Ing xhem uII vwlh compressed Mr hmore inspec lion. - Camshah IIIbrIcstIng oil Es ‘ed through uiI passages in the cyIinfler head. Clean Ihc oiI passages before assemblmg The chIndcr head. - Be careful IIul (a damage the mahng surfaces when removing the cylinder head cover and nyIInder head, CYLINDER HEAD/VALVES SPECIFICATIONS Unit. mm (in) ITEM STANDARD same: umn 7minleiléulilplesslull 1,225 kPa 112.5 kgt/cm=, 175 psi) P 7 a1 350 rpm 1 Valve clenrnnnn 7 IN 0.20 1 0.03 10,005 2 0.0011 7 7 — EX 0.25 2 0.0310011 = 0.0011 — Camshaft Cam 105137551911: 1M 3555 — 355011.429 71.4491 ' 315311.744) 7 EX 353471355311391—14011 7 '7 1 35911.29) Runoul 7 77 — 777 1 51 0021 011 ulealallce 7i 7 0.030 — 007210.001: .0 251 1 0.10 10.0041 Valve li(lel 1&0”.- 11110109. 777 7 25.975 — 25.993 11.0225 — 1.02331 25.97 11.0221 1 Valve liner bure 10. 25.010 — 25025110240 — 1.02451 2504110251 71/7007 77 77 7 Vail/e slelll 0.0. IN 3.975 - 33970101555 — 0.15711 77 7 19551015511 “M OW“ EX 7 5.955 — 3350101551 7 0.15571 39551015571 Valve guids 1.1:. '7 77 lN/EX 4.000 — 40121707575 0.15901 4.0410 1501 7' Slam-to7-7guids 51755017507 7 IN 1 0.010 7.0.0377 10.0004 0.00151 7 0.07571000301 7 5x 0.0720 0.047 10.0009 - 0.0019) 0005 1000331 Valve guide projection above 7 IN 15.1 15.41053 - 0.551 — 0111.100. "'-‘"“ 1 EX . 14.34 14.5 10.55-11.51) —- 1 7Valvc 51:51 width lN/EX ' 0.00—1.1010035 - 0.0431 1510.001 l 7101171755511“; 1 IN Outer ; 4 211.551 _ 4130110251 "96 ”"5““ 71mm 95.411431 35571070717 7 7 36.3 11.431 7777 25.57 11.400) Cyllnderhhlead warpnge 7 77 7 — 7 I 0.10 (0.004) TORQUE VALUES Cylilldel head mounting bolu‘washsr Camshan holder flange bolt Cylinder head sealing Doll Cylinder head cover boll Breather plate flange boll PAIR 1:21] valve L'uvev SH bull (tam snrncket flange dowel bolt Cam pulse gcncramr rotor flange dowel bolt Cam chain lifter mounting socket boll Cam chaln tensmner pivot socket bolt Cam chain guide bolt’washer Cylinder hsad stud bolt (exhaust pipe stud boll) lgnition pulse generatol r0101 special bull 47 N-rn (4.8 kgf-m. 35101-01 17 N-m (1 7 kgf—m, 9 lbf‘fll 18 N-m (1.8 kgi'm, 13101-0) 10 N'ITI (1.0 kgf-m, 7 lbl-I‘Il 12 N-m (1.2 kgl~m, 9 lell 12 N-m (1.2 kgI-m, 9 lbI-fIl 20 N-m (2.0 kgI'm, ‘lA lbI-ill 12 N-m 11.2 kgl-m, 9 lbml 10 N-m (1.0 kgl-m, 7 lbi‘fll 10 N-m (1.0 kgi-m, 7 lbf'hl 12 N-m (1 7 kghm, 9 lbf-hl See page 1 14 59 N-m (6.0 kgf-m, 43 lbf-hl Apply molybdenum dllLIIIldF. ml 10 the 1hreads and seating surface. Apply oil to [he “Heads. Apply a locklng agent In the threads. Apply a locking agent In Ihs lhvaads. CT hnll CT bolx. Applv a locking agent lo the Ihreads. Apply a lacking agem to the tlneads. Apply a locking agent [0 the xhreads. TOOLS Compression gauge attachment 07RMJ7MY50100 CYLINDER HEAD/ VALVES Equivalent commercially available in U.S.A. Valve spring compressor 07757—0010000 Valve spring compressur anachmenl 07959—KM30101 Taupe! hole protector 07HMG MR70002 Valve guide driver 07JMD—KY20100 Valve guide reamer, 4.008 mm Valve seal cutters 07MMH—KV901DD Equivalent commercially available in U.S.A. Seat cutlery 775 mm (45‘ IN) 077804010200 Seal tuner, 24.5 mm (45' EX) 07780—0010100 Flai curler. 27 mm (32' IN) 07780-0013300 Flat cutter, 2‘ mm (32' EX) 0773070012500 interior cutter, 26 mm l60' lNl 07730—0014500 lnrerlor euner, 22 mm (60‘ EX) 07780-001470? Cullel holder, 4 0 mm TROUBLESHOOTING 07731-0010500 ~ Engine (Durand pvublems usually affect engine performance. These problem can be diagnosed by a compression lesr or by Uacing engine nnl. - lime performance ls lor a seized eislcn ring iSecliun 12) Compression too low, hard starting or poor periorrnancu a low speed - Valves; — Incnrrnnl valve adjustment — Burned or bcnl valve — incorrect valve liming 7 Broken valve snrlng — Uneven valvc scaling Cylinder head: — Leaking or damaged head gasket — Warped nr cracked cylinder head Worn cylinder, piston or pislon ling: (auction 12) Culupression too high, overheating or knocking ~ Lxcesslve carbon buildup on pisron crown ur ull wmbus- lien chamber Exces ive smoke ' Cylinder head: - Worn valve stem or valve gillde - Damaged stem seal ‘ Worn cylinder, melon or piston rings lauclion 12) In the tep»end wilh a sounding rod or stethoscope, poor ar low speeds, check lor while smuke in lhe crankcase breather hose if the nose is srnokv. check Excessive noise - Cylinder head: Incorrect valve adiuslmem — Sticking valve or bloken valve spring — Damaged or worn camshaft — Lease or worn cam chain — Worn or damaged L‘aul chain , Worn or damaged nnm chain lensioner — Worn cam sprocket reeth - Worn cylinder, piston or pislull rings (section 12) Rough idle - Low cylinder compression CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Warm up the engine to normal operating [ampera- turc. Stop the anqine and remove all the direct ignltlcn coil/spark plug caps and spalk plug: lpage 36), Support the from and m ml tank lpage a-Al Disuullllecl the fuel pumpr‘resarve sensor 3P IElacKi connector Illslall a compression gauge mm the spark plug hole. TOOL: Compression gauge attachment 07RMJ-MV50'IDD (equivalent com- mevcially avail- able in USA] 0an the throttle all the way and crank the engine with [he Gtaflcr motor until the gauge reading stnps lisillg. The maximum reading is usually ledulled within 4 - 7 seconds. sierra» n an t ‘ Compression plessure: "W " ”' 13;? 1,225 kPn 112,5 kgI/cm’, 179 psi) at 350 rpm Low culllpressiun can be caused by: — Blown cylinder head gaskeI — Improper valvc adjustment — Valve leakaqe — errn piston ring or cvlindel High compression can be causal-l hy‘ — Carbon deposits in combustion chamner or on pis- ton head CYLINDER HEAD COVER REMOVAL Remove the followmg — anonle body (page 562i — Spark plug cap/lglliliull coils (page 3-6) \r— . CRANKCASE EHEATIIFR HOSE - Remove the crankcase brcalher hose. Disconnecl lIle PAIR air suciion hoses from the PAIR reed Valve nnvsrs, 8-4 CYLINDER HEAD/VALVES Remove the cyhnder head cover bolts and washers. BOLTSWAS-H'Efig ,? ' Remove the cylinder head cover rearwarm CYLINDER HEAD COVER DISASSEMBLY Remove (he cylinder head cover panklng. PACKING Remove Dams and breathe! separawr and gaskex REED VALV'E cox/ER é CYLINDER HEAD/VALVES Check the PAIR check valve for wean OI damage, rculacc If necessary. Remove the pen plane: from the cylinder head cover CAMSHAFT REMOVAL Remove the cy‘indrl head cover (page 8-4’, .‘m; udmag‘fig Remove the bolt and cam gulse generator 0mm the ‘75 ca"- ov c :yl'mde: head. Remove the wrung hole cap and ()Armg - 8-6 : remwe m: rm tram :Ire an cxcem v. an min-mg me cams/watt and i “am summer 5D care‘u’ not 10 amp a cam Sprocket LILY/is , o the traflk‘case CYLINDER HEAD/VALVES Turn the nranksheft clockwise. align the “T” mark on ‘*\ / the Ignition pulse generator rotorwrth the index mark an the right crankcase cover, Make sure the NM piskln IS at TDC (Top Dead Center) on the compression stroke. INDFX MARK , “r“ MARK‘ Remove the cam chain iensioner iiiter sealing bolt m BOLT and sealing washer , ‘ Turn the lensioner lifter shaft fully m (clockwise) and secure It using the stopper Iooi. This tooi can easily be made from a thin I1 mm thick- ness! piece ui sluel 15 mm 19mm 3mm 15 mm MATERIAL THICKNESS: 1,0 mm Ii you plan in repiace the camshaft and/cream sprock- * CALI; SPROCKET BOLTS el, loosen the cam sprocket bulls a: fulluw " t‘ 3‘ fi¥w\ — Remove the cam sprocket bolts from the intake and exhaust camshaftst CYLINDER HEAD/VALVES 7 Turn the crankshaft one full turn (360'). remove the other cam sprocket bans from the camshafls. — Remove the mm: and cam chain guide Br — Hemnve the. tram snrncm mm the camshaft. .t '9 ' CAM cr—wwfisumee iRm th blt d | enernm t, in ' “"'—_'-- " ‘ e “a 9 ° 5 a" W“ p“ ’e 9 ' "’ m ,3! CAM PULSE GENERATOR ROTOR Loosen and remove the camshaft holder bobre. then remove the camshaft holder and camshaft. www- #9 we , ‘ram w; 'ne NOTICE 1 my"; From ourside w Inside, loosen rm:- bolt: in a crisscross pattern m several step: or the camshaft holder might break, Do not forcibly remove the dowel pins from Ihe namehafi holder Remove the VBIVF lihers and shims - Be careful no! to damage Ihe valve lifter bore. The shim may stick to the msrde ol the valve llflers Do not allow the slums to fall mm the crankcase. Mark all valve liners and shims lo ensure correct reassembly in [hair uligrnal localions Thp valve lihm can he easnly removed with a valve lapping tool or magnet. The shims can be easily vemuveu wIIll a lweemls w magnet. INSPECTION CAMSHAFI' Check the cam and Iournal surlaces ul [he udmshall luv scaling, scratches or evidence of insufficient luhri- umnn. Check the all holes In the camshafx lov clogsl Support hnlh and: of the camshnfl with V-blocks and check the camshaft runoul wlm a dlal gauge. SERVICE LIMIT: 0.05 mm (0.002 in) Uzing a mlcuomeler. measure each cam lobe height SERVICE LIMITS: IN: 36.5 mm (1.“ ill) EX: 35.3 mm (1.35 in) GAMSHAFT HOLDER Inspect me bearing surface of we camshah holder lur :CUIillgl snatches, or evidence of insufficvem lubricar nnn, Inspecl the all orifices of the holders for clogs. CYLINDER HEAD/VALVES CAMSHAFT HOLDE Fl 8-9 CYLINDER HEAD/VALVES CAM CHAIN GUIDE B Inspect the cam chain Sllpper surface at the cam chain guide for wear or damage. CAMSHAFI OIL CLEARANCE Remove the cylinder head and valves (page 8-11} V‘lee any nil rrnm the Journals m the camshaft, cylm- der head and camshaft holders. Lav a srrlp ol plasllgauge lengthwise on lop ol each camshaft journal Install the camshaft holder onto the camshaft: Apply engine oil m lhe threads and seating surfaces of the camshaft holder bolts. Install the twenty holder bolts with the eight sealing washers, In case me valves in cylinder head: The camshall holder have [he number ”1 Wm 20". Temporarily tighten the fnllr bolts or the center area graduallv in the sequence 5 ,5 8 , 7 until the dowel Dlns on the camshaft holder inserts into the pin holes in the cylinder head properly lThe clearance belween the holder and head ls 1~5 mm) hem righren rhe all holder bulls in numerical order C35! on [he LdlllSlldIl Ilulder l‘l lhru. ZOl in several slaps, rhen hgnlen rhem m the __—_=‘; vice timits. >-—-===i I 6,—4.1 CAM CHAIN TENSIONER/CAM CHAIN [3AM CHAIN TENSlONER GUIDE I. Inspecl we cam chain IeIIsIuIII-sr and cam chain guide far excessvve wear or damage, replace if neressarv CAM CHAIN GUIDE 8-14 CVLINDER HEAD/VALVES VALVE/VALVE GUIDE Check that the valve moves smnolhly in me guide. Inspect each valve for bends, bums nrahnnrmal stem wear. Check vaIve muvemeul in Hue gurde, measure and record each valve mm (In SERVICE LIMITS: IN: 3.955 mm (0.1561 in) EX: 3.955 mm (0.1557 in) Ream the guides to remove any carbon deposits before checking clearances. Insert "In renmer Imm the combustion chamber side of the head and always rotaxc the resmer cIockwrse. TOOL: Valve uuide reamer. 0.008 mm 07MMH-MV901DD Measure and record each valve guide |.D. SERVICE LIMIT: lN/EX: 4.04 mm (0.159 in) Summer earn vaIve stem 0.0. mm the carrespond- ing guide ID. to obrain rho stem to guide clearance. SERVICE LIMITS: IN: 0.075 mm (0.0030 in) EX: 0.085 mm (0.0033 In) If the s‘emrmrgulde clearance I: am of sInndard, derermine if a nsw guide wim standard dimensions would bling the clearance w'IIhin Ioler'nnue. II 50, 5'5 “I” ”5"“ 35:99 repIace any gumes as net ary and ream tn fit 5‘7‘ II the eremrmguiae cIearance is our of srandard with the new Quirks, replace lhe valves and gu‘Idesr 8-15 CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement valve guide: in a lleezer for about all IlUul. Heat the cylinder head to 100 150C I212 7 ZOO'F‘, With a hot plate or oven. NOTICE l Do not use a torch rn heat the cylinder head: rt may cause warpage. Suppull the cylinder head and drive nut the valve guides tmm combustlon chamber side of the cylinder head. TOOL: Valve guide driver D7JMD—KVZO100 Drive in the guide to the specified depth from the top at the cvllnder hcodl SPECIFIED DEPTH: IN: 16.1 -16.4 mm [0.63 - 0.65 in] EX: 14.3 —14.6 mm (0.56- 0.57 in] TOOL: Valve guide driver 07JMD-KV20100 Let the cylinder head nnnl tn mom temperature. I. my cm Ream ms new valve quide dIlerlll3IdIId110ll. VALVE culDE REAMER ‘1’ :54 rear 21w”; Insert the I'eaMer from the combustion chamber side \ "M ”la-“7“" of the head and also always rotate mt: rcamur clock wisei TDOt Valve guide Warner, 4008 mm 07MMH—MV90100 Clean the cylinder head thmnugnly to remove any metal particles. Reface the valve ssat (see the following piuuedulel. VALVE SEAT INSPECTION/REFACING Clean the intake and exhaust valves thnrnllghly to remove any carbon deposits. Apply a light coat of Prussian Blue to the valve seals. Tap [he valves and seats using a rimher lime or anniher hand-lapplng toolt 8—16 7’75 -'fllle: canrm c: c'cmc 1*: mm vase ‘5 burner] w LaU’y worr m n n can- :a:l we see! ufirzvsmy. rep: ins valve, zflllnw ‘he 'elac mg mumm- 3" 1‘ Del?! '19 MS! 52015 Remnve the valve and inspecl the valve seat face. The valve seat Contact should he wrtmn the specified widm and even all aruund the circumference. STANDARD: 0.90 -1,10 mm (07035 - 0‘0“ in) SERVICE LIM": 1.5 mm [0.06 in) ll vhe sear mdrh is not wilhin specification, reface mc valve seal (page EJBL Inspecl the valve seat face (or: - Uneven seal Wldtn: — Heplacc the valve and nelace the valve seat. - Damaged lace; - Replace the valve and rcface the valve seal. ~ Contact arca ltoo low or luu high) Reface me valve seat, VALVE SEAT REFACING Valve seal cullevslgrinders nr fiqulVfllel’ll valve sea! relacing equipment are recommended to current worn valve scam. CYLINDER HEAD/VALVES l / / I SEA! WIDTH \ DAMAGED lACE UNEVEN SEAT WIDTH / 3 \\ 7 // TOO LDW TOO HIGH \ 60' 32‘ L 1 Y 8-17 CYLINDER HEAD/VALVES : degree 7 «mar wner ever < w vs was /: If [he COWIBCI area i5 (00 high On the valve, [he sent ‘V x IGH must be lowered usmg a 32‘ flat culler. CONTACT TOO H \ OLD SEAT E WIDTH H the cumacx area is [00 low on the valve, mp. «at \\ \ mus! be «mad using a so‘ interior cuner. \ D ‘ , Q I \ 32 CONTACT TOO LOW 01 n SEAT F — ‘\-\‘ \ WIDTH \ \ Use a ‘5-degma runer to remove any vuughness or irregularities from the seat. TOOLS: Seat cutter. 27.5 mm (IN) D77B0—0010200 Seal Guitar, 215 mm (EX) 0778041010100 Cutter holder] LO mm 07781-0010500 or equivalent common cially available Usu a 32-degroe cutter to remove the top 1/4 n7 the naming vah/e seat malarial. TOOLS: Flat tuner, 27 mm (IN) 0778047013300 Flat cufier, 74 mm (EX) 07780—0012500 Cutie! holder, 4.0 mm 07781-0010500 or ‘ equivalent commer- cially avallable Use a [ED-degree cutter [0 remove the bottom 1/4 of ' the ow seat. TOOLS: Interlor Cunar, 26 mm IIN] 0778043014500 Interior cutter, 22 mm (EX) 077804014202 Cutter holder, 4.0 mm 0773140010500 or equi lunt cornmer cially available 8-18 CYLINDER HEAD/VALVES Using a 45‘ seal cuner. cm the seal lo the proper width. Make sule that all pitting and irrcgularllies are remnVFd, \ 1.0 mm {004 in) \ Refinish il necessary Ahoy cutting llie seal, apply lapping compound to me valve lace, and lap the valve using lighl pressuve. ___NOTICE - Excessive lapping piessure may deform or damage [Ila sear, - Change ma angle of me lapping toul frequently to prevent uneven seal weai. ' Do nul allow any lapping compound to enter the guides. After lapping, wash all residual comuound of! me cylinder I‘Pfld and valve, CYLINDER HEAD ASSEMBLY : a O A ‘ >9; VALVI: LlFTEFl——->\ , (3:; \ ( f SHlM /'g COTI‘ERS /- SPRING RI'TAINER ' EXHAUST VALVE SPRING INTAKE VALVE SPRlNG [INNERI lNTAKE VALVE SPRlNG {OUTER} V STEM SEAL SPRING SEAT VALVE GUIDE / i EXHAUST VALVE \y INTAKr VALVE 8-19 CYLINDER HEAD/VALVES Blow out all ml nassaga< in the cylinder head with compresncd air '— _‘ . v- PPET HOLE PROTECTOR .’ lnsrall the tappet hole protector into lhe valve liner bore. TOOL: Tappat hole pmmmr n7HMG-MR70002 install the valve spring seals. Install the new alum seals. Lubricate the valve slcms wnh molybdenum oil soiu- sPnING SEAT lion. Insert the valve into the valve guide while lulvlillg il slowly lo avoid damage lo the stem seal RETAINER ‘ EXHAUSI VAiv: SPRING install the valve spring with the tightly Wuund coil; facing (he combustion chamber. install me valve spring retainer. 3 (g i i i l Cigg, (\r" 2’ l ‘ :<_:('-‘>‘, 2 I {c 22 lg é— a] C _.> {K i ;_,___: LL“ ' :.__,"‘ =1 E Goa—r :hc Install the valve coners usrng the special moi as mum» w shown, NOTIC§_ To prevent lass of mnqinn, rm nnr compress the va/VE spring more than necessary. TDOLS' Valve spring compressor 07757—0010000 Valvs spring compressor anachmem 07359—KM30101 8-20 ShSDC‘n m cm; . box: UH W'm/ 1cm" " ' ww p um damage CYLINDER HEAD INSTALLATION CYLINDER HEAD/VALVES Tap the valve stems gently wnh :wo pmstic hammers 9 as shown m sea! the cutter: hrm‘y Inslal‘ and wghxen the spark plugs‘ TORQUE: 12 N-m l1 2 kgl-m, 5 IhI-fl) Inslall the timing sprocket by aligning the wide teem bemenn vha crankshak and sprocket. Install mo cam chain‘ Inskall the cam cham guide and nnmwasner. CAM CHAN GUIDE ‘26 WASHER 8-21 CVLINDER HEAD/VALVES App|y a \nckmg agent to the cam chain tetxsxulle' WASHER (2AM CHAIN TENSION—R. socket bolt threads. Install the washar, cam sham tensioner and socket bok fightan the cam chain guide and cam chain tensvoner socket bolts 10 the apauified \uruue. TORQUE: Cam chain unsinnor socket bolt: 10 N-m (1,0 ham“, 7 Ibl-fl) Cam chain guide :ocket bolt: 11 NW" (1.2 kgi-m, 9 Ibl-fl) Install the ignition purse genernmr mtnr and rlght crankcase cover (page 17-7). |nsth the dan pins and a new cylinder head gasket 35 shown. Install the cy‘indcr head onto the cvlmder block Amy 'unlybdenum disutfide 0H auluLiun to [he threada and scaling surface of the 9mm hniwwash- en. and inslall them. Install the two 67mm flange halts Tighten the 9-n~m bulls in a crisscross panern in two to three steps to the specified torque TORQUE; 47 Mom 14.5 kgf-m, 35 “31-01) ‘fightcn the 6 mm flange bolts. 8-22 CYLINDER HEAD/VALVES Install the cam chain tensluuer lifter nnm the cvllndcr head with a new gasket TENSIUNER LIFTER SOCKET BOLTS Install new sealing washers and Ughlen the mnuntmg bolts to the specified torque TORQUE: 1D N-m (1.0 Ital-m, 7 |bf-fl) Remove the lullowing’ A Thevmostm housing lpnge 677) — (Inmshah (see below) CAMSHAFI' INSTALLATION Apply molybdenum oil snlutlnn to the outer suflace 01 each Valve lihnr l‘va’l m 5""‘5 Inmall [he shims and valve litters Into the valve lifter in: valve- l Met: ll bores‘ :Harr Cllglra/ 3553- mm: ll N18 cam sprockets are removed, ”Niall the Cam sprockets onto the camshahs. - lnslall the intake cam Sprockel wxlh the tlmmg mark lIN) lacing uutwmd and the No.1 Cam lobes facing up and uut as shown. - Install the exhaust carn sprocket with the timtng mark (EX) facing Culwald and the Nn,‘l cum lobes lacing up am] out as shown. tXHAUST CAM SPROCKEY l l TAKE CAM SPROCKET l Clean the cam sprocket hnlt and apolv a locking agent to the threads. lnstall the cam sprocket bult> 8-23 CYLINDER HEAD/VALVES Clean and apply a locking agent to the cam cam Dulse generalur rotor lhleads. met: the cam Install the cam pulse. generator war and mountlng elazw bolts. ’alor v m me ha ‘ mmshafz any: law y up an: In: rain“ “on?“ «mark ten mg own as molm Turn the crankshaft clockwise and allgn the “T" mark on the lgnmon pulse generator rotm with the Index mark on the right crankcase covert Apply molybdenum ail solution to the camshaft Jour~ llals at [he uyllllder head and camshaft holder. Install the cam chain over the cam sprockets and then Install the Intake and exhaust camshafts - lusts“ each camshaft to the correct locations. Note the Identificatinn marks "IN": Intake camshaft "EX": Exhaust Camshaft Make sure the timlng marks on the cam sprockets are facing outward and flush With the cylmder head upper surface as shown. ”OUT" MARK INDEX MARK TIMING MARKS EIHAUST CAMSHAFT 8—24 MIKE are we irnwp‘ wt in we all?” Drape l’rr W's: in w: cylinder was Coat new n-nngs wrth oil and install them mm the grooves in the camshaft holder. Install the camshaft holder ontn the namshahs Apply engine oil to the threads and seating surlaces ol the camshaft holder bolts. Install the 70 hnldnr bolts wlth Eight new washers as shown, Finger tighten the bulls. The Lamshaft holder have the numbers “1 through 70mm nn theme Gradually tighten the v5, #5,:13, and #7 bulls (in um order) 'l/"lu1/‘Z cl 3 turn at a time m draw the holder down evenly nrml the clearance between the cylinder head and thc holder is Z - 3 mm all the way around. ll llle holder tilts toward me #1 cylinder dullng lhls nmcess, readjust bolts #6, #5, #8, and #7 as necessary to keep the holder level. When the holder is parallel With the cvllnder head, rnsume tightening the bolts in the sequence specified above‘ Once the clearance Is Wlll’llrl 2 , 3 mm, begin tighten ing all the bolts in the proper numerical order ml, #2, $13,.”1‘20I 1/4 turn al a lime unlil the liuldel is lully seated against the cylinder head TORQUE: 12 MM (LZ Ingf-m. 9 lbl-hl install cam chain guide B and tighten the bolte, CYLINDER HEAD/VALVES CAMSHAFT HOLDER 8-25 CYLINDER HEAD/VALVES In case the cam sprockets were removed. tighten the cam sprocket bolts to the specified torque. TORQUE: 20 N-Iu (2.0 kgl-m, 14 leO Turn the crankshaft clockwise one full turn $603 and tighten the ullrer cam sprocket bulls. in case the cam pulse generator rotor bolts were removed, lighten the lulu! bull: to the specified torque TORQUE: 12 N-m [1.2 kgf-m, 9 Ibi-h) rlemnve the stopper tool from the cam L'llain lension- er liftcr‘ Install a new sealing washer and tighten the sealing bull, Recheck the valve timing. l l t-l‘x .- GENERATOR 1 CAM CHAlN TENSIONEH LIFTER BOLT l , l 8-26 CYLINDER HEAD/VALVES Apply all m the new Orring and install it Onto the cam pulse generator Install the cam pulse generator in“) me cylinder head. Install and lighten the P‘Ounhng boll securely. CYLINDER HEAD COVER ASSEMBLY Install the PAIR check valve port ulale: inlu (he cylinr der haad Cover. - u A. lnstall the PAIR check valves Into the cylmdcv head FAIR (mum VmESW Coven ‘ fl ”‘2 CYLINDER HEAD/VALVES Inlldll O D, al Clinch outer guide I 24.990 — 24,993 [0.9835 0.95‘0) 219610.983) TORQUE VALUES (:lulch center lock nut 127 Mm (13.0 kgf-ni, 94 lbI-ft) Applv oil In the threads. Stake the nut. ClutclI >piing bolri’washer 12 N-m \1,7 kgI-m, U |bf~fil Oil pump driven sprocket bolt 15 N-rn (1.5 kgf-m, ll lbf-ftl Apply a lockIng agent to the threads. Shifi drum cemsr sOLkeI bolt 23 N-m (2.3 kgth, 17 lbf-fil Apply a locking ageni Io ma threads. ShIh drum slopper arm pivot con 12 N-m l1 2 kgiAm, 9 mm) Gearshift >ule plale. Remnve the nhnn?‘ hfter piece from lh: liner bearing. Remove the "olwowmg: — Eight clutch discs — Seven dutch plates 7 Spring scat — Frimiun spring L i: 6 54 ~ , . J. I \ SPRING BOLTSJSEBlN .5; CLUTCH DISCS,’PLATES SPRING SEAT j 9-4 CLUTCH/GEARSHIFT LINKAGE Ullslake xhe clutch center lnnk nun ENS-TAKE Hold the clutch center with the clutch center holder. “m .7 men remove me lock nul. CLUTCH CglJIEH § TOOL: clutch cemer holder 07724-005000! (equivalent nommerv oially available in USA) Discard the lock nut. Remove llle luck washer and clutch center Remnve the washerl CLUTCH/GEARSHIFT LINKAGE Remove mo rhronlc body :page 5-52” Luusen the cam chain rensioner lpagc 8 25h. Se cs'em retro Align the gear teeth at th ’«c c .9—1 REMOVAL/DISASSEMBLY ,_ e 7'. \ Separate me cranknase halves {page 11-3» Remove the mainslun and cuunlershall assemblies. 11-6 Remove the dowel pins and munmrshan hParlng set rlng. Disasselllbl: [he mainshaft and countelshah Clean all nlsnssemhled pans m solvent thoroughly. Check me mainshah and coulllersllall needle bearr ings for abnormal wear or damagp Check the gear shlfter groove for abnormal wear or damage. Check the gear dogs, dug hula; and Leelll Iur abnor- mal wear or latk of lubrication Muasurc the ID. of each gear. SERVICE LIMITS: M5. M6: 28.04 mm {1.10 C2, C3, Cl: 31.04 mm (1.222 In) Measure the 0.0. of each gear bushing. SERVICE LIMITS: M5, M6: 27.94 mm (1,100 in) C2: 30,94 mm (1.218 In) C3, C4: 30.93 mm (1.218 In) Calculate (he gcar lo bushing clearance. M5, MS: 0.10 mm (0.001inl [22: 0.10 mm (0.004 inl C3. C4: 0.11 mm (0.004 in) Measure the 0.0. of each gear bushing. M5; 25.016 mm [0.9849 inl (27' 28 021 mm [1.1032 in) Check the mainsllaIl and cuulllersllall IUl dbllurlllal wear or damage CRANKCASE/TRANSMISSION DOWEL PINS \ . : “u 11-7 CRANKCASE/TRANSMISSION Measure lhe mainshafl O.D. at the M5 9831. SERVIfi LIMIT: 24.96 mm (0.953 in) Measure the cauntershah 0.0 a! the C2 gear. SERVICE LIMIT: 27.96 mm (1.101 In) Calculate the gear bushmgvlu-shah clanrnnne SERVICE LIMITS; MS: 0.06 mm (0.002 in] C2: 0.06 mm [0.002 In) Turn mo outer race of each bearmg wnh your finger. The baarinqs should mrn smoothly and quietly. Also check that the bearing inner tau: ms lightly on the shaft. Remove and discard me mainshah bearing if (he race does not lun- smoolllly. quietly, or m; loosely on ma mainshaft, Replace the countershafi. collar, and bearing as an assembly ir lhs race does not turn smoothly. qulelly, nr ms Innsely on the countershafl. MAINSHAFT BEARING REPLACEMENT Pros: om Ihc mainshah from the bearan usmg a hydraulic press. lnstall a new mamshafl hparing onto the mainshalt by pressing the mainahaft bearing inner race using the special tuuls. TOOLS: Inner drivur C 07746—003010!) Attachment, 25 mm I D, 07746-0030200 BEARING ? ‘ MAINSHAFT l I i I {f3 DRIVER, ‘0 mm | D ATTACHMENT BEARING ‘ 11-8 CRANKCASE/TRANSMISSION ASSEMBLY MAINSHAFT/M1 GEAR (1211 I 9: M6 GEAR 123T) x ’> (:3 I a V M2 GEAR 116T! C1 GEAR (341’! O®$§FE 05 GEAR 128'!) 29% r, \ ‘ 7>\ c3 GEAR (28T! 0@@\ C2 GEAR (SIT) I CG GEAR (27H COUNTERSHAFT 11-9 CRANKCASE/TRANSMISSION Assemble the transmission gear and shat-ts. Coat each gear with clean engine owl and check for smooth mavement Align the OII holes in the M6 bushing and mainshaft, and the C3‘ CA spline bushings and countershafl‘ Align the lock washer tabs with the spline washer gmoves Always inatall the thrust washer and snap rmg With the chamfared (rolledi edge facing away from the thrust load install the snap rmg so that its and gap aligns with the groove in the splines. Make sure the map ring is fully ssated in the shaft woman. after installing it 11-10 CRANKCASE/TRANSMISSION INSTALLATION Apply mo‘ybdcnum oil SOIUUOH to the smn fork grooves in the MGM, C5 and C6 Hear. Inna“ the dowel pms 'm the uppel crankcase holes Install the countersunk beflrlng set nng mm me ”ppm crankcase groove. Insmu Ihe mamshafl and cauntershafr bv angnmg me countershafl bearmg groove with me 59! ring on the crankcase, and my" the bearing Lap Mule: with the dowel pms AHgn me countershah bearmq swpDer pin wim the glam/e in me crankcase STOPPI R F‘W 11-11 CRANKCASE/TRANSMISSION CRANKCASE ASSEMBLY Install (ha swingarm pivot collars into the lower crankcase Apply a llght, hm thnmugh, nnatmg ol quuld sealam to the crankcase mating surface, Do not apply sealant tome main Dealing journal bolt llowar crankcase bolt, 3 mm) arm! and w oil passage area as shown. Install the three dowel pim. Inslall on Drl'ICBS aI-gnmg 1helr nutrnuts with the groove in the upper crankcase. COLLARS ,, l DOWEL Ems 11-12 r ’15 serum; wash er lucalvo‘ls a‘e vndrzared or. [he unner crankcase Usmg me "A” new Install rhe lower crankcase omo the upper crankcase Clean llre new crankcase B—rrrrrr bolls llruruuglrlv wilh solvent and hlnw fhem dry Apply oil to the 8 mm bolr threads and scaring surr lace, and install mam. Install the 10-mm bolt, six 7-mm bolts and two 6-mm bolls. Make sure llle upper and lower crankcase-s are sealed securely, From me inside to outside, tighten the lower crankcase B»mm bolts {main journal bolts) in a criss- cross pattern in M0 or three steps. TORQUE: 25 NH" [26 kgl-nr, IS lbl-hl Trthcn the 10 mm boll [0 the specified torque, and then llghran 7-mm bolts and B-nun bulls. TOROUE:10-mm bolt: 39 N-rrr (to kvf-m, 29 “77-“! 7-mm boll: 18 MI!“ (1.! kgl-m, 13 Ibf-fl) Install the uppercrankcase five 87mm bolts and seven 6 mm boks with new sealing washers. Trghren rhe H-mm hnns In a crisscross panern In two or three srcps. TORQUE: 25 N-m (2.5 kgl-m. 1B Ihf‘fl] Trghten (he 6-mm bolts in a crisscross panern in two pr three steps securely. CRANKCASE/TRANSMISSION 7 mm BOLTS 8 mm BOLTS 10 mm BOLTS 6 mm BOLT/ " SEALING WASHER 6 mm BONE 8 mm BOLTS 9? Fl mm BOLTSI' SEALING WASHERS 11-13 CRANKCASE/TRANSMISSION Appiy a iocking agent ro the set piate bolt threads. insraii (he mainshafi bearing sex plare with its ”OUT SIDE” mark facing Instali and tigmen the bolts to the spanned torque! TORQUE: 12 Norn ILZ kgl-m, S lel) hisLaH a new O-ring irllu the groove in the water hose 1mm grnnvp instail m: water hose 10m to me CYllnder hlnnk Instail and righren the watel huse juim bulb securely. lnstail [he uii pressure switch (page 1916i. Install the speed sen-w. (page 1942‘. A ..,..---r‘ ‘ LSPEED SE: SOR OIL PRESSURE SWITCH lnsrall the engine suhrhnrness and mnnecr the [DIV lowing connectors: ~ Speed semur 3F1Black) connector , Oil pressure swrmh mnnecmr — Nourral switch connector 7"” orL‘fiéssufifiv'i/ncu cor'GNEcTori : ~ , " , » Install the removed pans in the ravens order of rcmovai. Jr (W ACK) CONNECTOR v~/ " 11-14 MEMO CRANKSHAFI'IPISTON/CVLINDER 25 N-m (2.6 kgV-m, 19 ”3"!) 12-0 12. CRANKSHAFT/PISTON/CYLINDER I SERVICE INFORMATION 12-1 TROUBLESHOOTING 12,2 3 CRANKSHAFT 12.3 SERVICE INFORMATION GENERAL separation and assammy. reassembly. MAIN JOURNAL BEARING CRANKPIN BEARING PISTON/CYLINDER 12-6 12-8 12-11 The crankcase must be separated 10 same: the crankshaft and piston/connecting 10d. Refer to section 11 101 crankcase Mark and store the connecting Iods, healing caps, uistun: and bearing inserts to be sun: Of their correct locattons dunng The crankpin and ma‘m journal bearing inserts are select fit and are Idenmied hy nolor codes. Select Ieplacenuem beak ings rom the Lude tables. AIIer selecting new bearings, recheck the on clearance WIth plastigauge. Incorrect ml dear- nnne can cause may“ enginP damage. SPECIFICATIONS . . UnIt: PM I ITEM v STANDARD sgnwce LIMIT 1 CraIIksIIaIt Connacfing rod side clearance 0.10 — 0.2510004 0.010) 0.3010 012) Crankpin bearing Oil clearance 0,020 - 0052100011 7 0.00207 0.06 10 007) Main Iouma) bearing oil 519.5% 0.020 7 0.038100008 - 011015) 0 0510 002) R0n0m77 7 7 — 7 0 0510 002) m Piston, piston Piston 0.0. at 15 mm (0.6 in; from 00an 66.965 , 66.980 (2.5354 — 2 5377) 7 7 7 009012.034) ' 7 I ""95 Piston pin bore ID. 7 17.002 ~ 17.001) 10 6694 570090) 17 027107670) Piston pin 0.0. I 15.994 - 17000100601 — 0.0093) 16 5510.009)77 Piston torp' 11 pin clearance 0.04 (0.002) PIston rIng eng7gap Top 0.41002) 5 and 770.10—030100707 0510.02) I.__ . __ ‘ . 711115019, ml) 0.2 —077 1017171 -003) 77 1.01004) .I Piston ring-to-ring Tap 0 020 - 0.050 (0.0003 — 0.0020) 0.03 (0.003) I 9W”e C'emnce Second 7770 015 — 0.050 (0.0005 — 0.0020) 000170.003) Cylmder ID 7 7 '; 67.000 _ 67.70715 12.15370 - 2.6384.) 7 757.101.2042) Out-uf—round—77777 7 I 7 — 777 0.10 10.004) 7 73—132} 77 77 7 1 — 0.10 710E211) 7Warpaée I 7 _ 7 7 0.1010004) . 111510).qu 00 0.015 #70050 (0.0006 0.070227) 0.10 40.004) 7 Comm-10.9 rod small 0.0710. 17.010 - 17.034105599 0.0700) 7 110110571) ConnectIIIg Iud-Iu-pislult pm 0100170.“ 0016 , 00401000070 0.0015) 7 7 70.06 (0.002) . 12-1 CRANKSHAFT/PISTON/ CYLINDER TORQUE VALUES Connecting rod bearing can nut Crankcase bolt [main journall 25 N-m (2.6 kgf'm, 19 [hf-m 25 N-m (2.6 kgl-m, 19 [bf-fl) Apply ml tn the threads and seating surface. Apply oil to the threads and seating surface. TOOLS Inner driver C 07746—003010!) Allaulnnelll, 30 mm ID. O774€>0030300 Universal bEafIHg puller 07631—0010000 Equivalent commercially available in U.S.A. TROUBLESHOOTING Cylinder compression is loo low, hard to star! or poor per- lnrmanue at low speed - Leaking cylinder head gasket - Wum, suck in broken pislun ring - Wnrn m damagm cylinder and pmon Cylinder compression Kan high, ovum-us or knocks - Carbon deposits on the cylinder head andi‘nr nisvnn cmwn Excessive smokn - Worn Cylinder, piston or piston ring - lmprnper insraumon of piston rlngs - Scored or scraiched pimon or cylinder wall Abnormal noise ' Worn DIS‘DH pin or piston pin hole v Worn connecting rod small and - Worn cylinder, pisxon on piston rings - Warn mam journal bearings - Worn crankpin bearings Engine vibration - Excessive crankshaft runou! 12-2 CRANKSHAFT/PlSTON/CYLINDER CRANKSHAFI FEELER GAUGE Separate (he crankcase halves (page ‘H 3). SIDE CLEARANCE INSPECTION Measure [he connecting rod side clearance. SERVICE LIMIT: n.3n mm (o 012 in) I! [he clearance exceeds the service llmir, renlace (he tonnPCting rod RcCthk and If Still out of 1mm, reulsca the crankshafl REMOVAL Mark the bearing caus and bearings as you remove them m lndicale lhe torrect cylinder Icr reassembly, Remove the connecting rod bearing cap ml: and bear'll'lg caps. lap me slde of the can llgmly It the haarlng can i: hard lo remove. llnmnvs Vhe mankshafl INSPECTION IInld rhn nrankshrm nnrh and Set a dial gauge an the cantor main Journal a! rho crankshafil Rotate We crankshaft two revolutions and read (he YUHOLK. SERVICE UMIT. D 05 In!" {0002 in) Check rhs primary drive gear and subAgear team for SNAP RING FRICTION SPRING abno‘mal weal or damage PHIMARV DRIVE SUB-GEAR REMOVAL Hemave the specral snap rlng and frmllnn Lse worn "lam many available ln ,rauma' Manny: U.S.A,I ‘0’ nr~srm»< p57? \A‘v 12-4 ORANKSHAFI'IPISTONICYLINDER Pm: w» m Pless a new needle bearlng onto the crankshaft uslng n‘a/ksc we ’a=- a hydraulic press and special tools until its edge is . "79 ”‘7 flush with the groove in the crankshaft. v NthDLh HtAH'Nb Make sule that the height from the crankshaft end is 27.6— 77,9 mm ll 09— 1‘10 ml. E; l TOOLS: O E ‘ l Inna driver c Mus-mambo -— ‘ Attachmenk, 30 mm ID. 077450030300 I ‘ —“ "D ‘— 1 77 6 - 273 mm l Il.0971.10inl j INSTALLATION 3.1 (701921be Apply molybdenum oll solution to the main journal lvulnguwllwl hearlng slidlng surfaces on the upper crankcase and mm" mo We the ulallkpill beallng sliding sun‘aces on the canned- narmg rm mg "ms Apply molvbdmlum oil solution to the thrust surfaces of the nrankshnh as shown. Lower all of the pistons to top dead center to avoid damaging the crankpin with the connect‘lng rod bolts. Carefully install the crankshaft unto the upper crankcaset Set the connecting rods onto the crankpins, CRANKSHAFT/PlSTON/CVLINDER Apply molybdenum nil solution to the crankpm bear- BEARING CAP lug sliding surfaces on (he bearlnq caps. . KW , Install Qhe bearing caps by al'lgning the ID. code on me connecting rod and bearing map. Be sure each pan is installed in ixs original position, as noted during removaI Apply oil to the bearing cap llul lllreads and ssatinq surfaces and Install the can nuls, Tighten the nut in two or three steps and torque them. TORQUE: 25 N-m (7,6 kgi-m, 19 Ihlrfl) Assemble the crankcase halves (page 11-12). MAIN JOURNAL BEARING 7 NOTICE Do not mmmhange the beanng lnsens They mun be Installed m their wlginal locations ar Ihe carrarrr heap iny uil clearallce may nut be obtained, resulting m fiNglnP damage Remove the crankshaft (page 1273L BEARING INSPECTION Illgpecl His main iournal bearing inserts on the upper and lower :rankcase for unusual wear ur peeling. Check lhc bearing tabs for damage, OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and mm journals Install the crankshaft nnm the upper crankcase. Put a strip of plastigaugc lengthwrse on each mam journal and avoid the oil hole. 12-6 CRANKSHAFr/PISTONICVLINDER Inslall [he dowel pins and oil orifice; Carelully Install the lower crankcase on the upper crankcase. Apply engine oil (mm the main journal B—mm boll threads and seating surmr s and Install them. Tighten the 8 mm bolts in a crlsscross pattern in MD or three steps. TORQUE: 25 "-1" (2.6 kql-m, 19 lhf'fl) Hemnve the B—mm bolts and lower crankcase. Measure the compressed plastiqauge at its widest point ml each main joulnal to determine the oil clear- ance SERVICE LIMITS: 0.05 mm [0.002 in) If mam bearing clearance exceeds the service Iimk, select the correct replacemenl bearingst A we. BEARING SELECTION CH (he rel: Side 5’ 1419:" Udl‘kfiiS? are the soda: for w, Maw/lg sou» ;D'l I D a [sum IN! {D "35f Record the crankcase bearing support LD. code letters from the lull side of the upper crankcase as shown thrower: 1: 7a! Record the cnrrespnnmng main lnurnal on code 3/ on We crank numbers from the crank weight. yVe/gh.’ EVE IN: rod!" M ”j Cross reference the main journal and bearlng sunpnn‘ ‘ W" 10““ codes to determine mo replacement Marina 60'“ I; U 5 from ’5’? [6‘ ”gm code. 12-7 CHANKSHAFT/PISTON/CYLINDER MAIN JOURNAL BEARING SELECTION TABLE: Unit. mm (in) BtARING SUPPORTID. CODE A a cifi 33 09—0 - 33.000 53.006 — 33.012 ' 33.012 ~ 33.018 _ {1.2992 1.2954) ‘ (1.2994 —- 1 2997) ”.7997 — 1.2999) V — . 30,000 , 30.006 E ‘ D c ‘ 11.1811 — 1,1813) (Pink! ‘ (Yellow) (Green) MAIN JOURNAL 2 . 29.99.240.000 D ‘ c ' a 0.0. CODE ‘ 11 may 1811] (VelIOwI [Graam IErownI . 955 — 29 994 c a A {1.1806 —1.18I)UI (Ur-inn) (Brown) (Black) BEARING THICKNESS: A lBlackI Thick B [Brown]: C (Green). I D (Vellow): E (Flnk) Thin NOTICE—. Avmr scheming new hearings, recheck the deg/anus with a plasr/‘gaugc. Incorrect clearanm can cause severe angina damaga. BEARING INSTALLATION Clean the bearing outer surfaces and crankcase hear- Tug supports. Insvall the main journal bearing inserts unm the crankcase bearing suppnns, nlvgnlng each (ab wiIh aach groove. CRANKPIN BEARING NOTICE Do not imerL-hange the bearinq inserts, They must be Instill/Ed m rhelr nriginal Iacations a: [he L'IJHEL'I bear- ;‘ng of/ clearance may not be omamm, resuhmg In engine damage. Remove the crankshaft (page 124}. BEARING INSPECTION Check me bearing inserts for unusual wear or peelmg. Check the heaving labs for damage. IDENTIFICATION COLOR 12-8 CRANKSHAFI'lPISTON/CVLINDER OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and nmnkpin. Carefully Install me crankshah mm the upper crankc ‘e. 521 the cannemng rods onto the crankpln. Pm a strip of plasrigauge lengmwise on the crankpln and avoid the all hule‘ Carcfullv install me bearing caps bv allgning the LD, nude. Apply engine ml to ma connectlng rad bearing mp nut threads and scaling surfaces and install them. ‘l'lthen the cap lluls m lwu ol lluee sleps. TORQUE: 211 NM! (2.6 kgf-m. Is IM-ftl Remove the nuts and beallng cap Measure me compressed piasugnune SI Its widesl point on (he crankpin (0 determine the oil clearance. SERVICE LIMIT: 0 06 mm (0.002 in) ll me oil clearance exceeds llle SEIVICEIIIIIIL>EIEL1”I! collect replacement hearlngs BEARING SELECTION Record the connecmg vod LDI code number (‘I or 2l or measure the 1.04 with me bearing cap insralled wlihoul bearing inserts, PLASTlGAUGE CONNECTING ROD | D CODE 12-9 CRANKSHAFT/PISTON/CYLINDER Lefié‘f IA cm F” If yuu are IepIacmg (he clankshaft, record We cune- on me c'arw :pnndmg nrankpin I) D nnne number (A m B) I1'§.g‘7t 5r HE WU” ’0 " * Ii you are reusing me cranksha“, measure the . WW ’3 ‘7 5 crankpin 0 n with a micrometer. mm 191' ya «ya: Cross-rsference the crankpm and rod canes to dawn rnIne the replacement bearIng color. CRANKSHAW O D. CODE CRANKPIN BEARING SELECTION TABLE: Unit: mm (m, ' ’~ ._ , CONNECTING ROD LD. CODE V T \ 34000—341308 1 34,008 SLOTS ‘ ' , 385 3389) I (1.3389 392} A I 1,492 — 31.500 5 CHANK (”IN I 740% IYellowI (Green) ()D. CDDF 3 31.492 B A 1.2398) IGveen) (Brown? BEARING THICKNESS: A (Brown); Thick IDENTIFICATION COLLAR 3 (Green)‘ C [Vellowbz Thin L NOTKT Afier seleczing new bearings, recheck the clearance with a wast/gauge, /ncarract clearance can cause severe engine damage. BEARING INSTALLATION Clean the bearing outer sun‘aces beam-g Cap and connectmg rodI InsIall ma crankpin bearing insens onto me bearing cap and commenting 10d, angning each lab wilh each groove. BEARINGS 12-10 CRANKSHAFT/PISTON[CYLINDER PISTON/CYLINDER NUTS 1”:anPISTON/CONNECTING ROD REMOVAL ‘ .2: you Iemve "-9" i3 Mime Remove the nuts and connecling rod bearing cup. .Ne . mu ammo (or raxwmn/y Remove the pistonlconnecling rod assambly from the [up of the cylinder. in: w’ we ‘rw in: we was: crankcase PIS | ()N/(JON NECTING HOT) ASSEMBLY PISTON REMOVAL PISTON PIN CLIP Remove [he piston pin clip with pliers, Push the plsinn pm from me piston and connecting rod, and remove the piston. PISTON DISASSEMBLY Spread each DiGwn ring and vcmovc it bv Iifling up an a point opposixe Ihe gap, CRANKSHAFTIPISTON/CYLINDER tier carom Remove any carhnn deposits from the piston ring dJmm's ‘nm ms groovest 'n'rg groc v25 wry an ola 535m" mg Irma, “(a 3 ms brush, 4r wn‘ scratch the y‘wve PISTON INSPECTION Temporarily install the piston rungs to thaw proper poslliun with the mark lacing up. Measure the piston ring-to-nng groove clearance with the rings pushed into the grooves. SERVICE LIMITS: Tap/second: 0‘08 mm (0.003 in) Insm the plSIDn rlng squarely iulu the bottom of the cylinder and measure the rlng and gap. SERVICE LIMITS: Top: I! 4 mm (0.02 in) Second: 0.5 mm (0.02 in) oil I rail): 1.0 mm (0.04 In] Measure the piston pm bore. SERVICE LIMIT: 17112 mm (0570 InI 12-12 CRANKSHAFTI PISTON] CYLINDER Measure the 0D. 0! the pismn pin. SERVICE LIMIT: i638 mm (0.669 in] Calculate me piswnrtcrpisron pin clearance, SERVICE LIMIT: 0.05 mm (0.002 in] CONNECTING ROD INSPECTION Measure me connecting rod small and Lo, SERVICE LIMIT: 17.0‘ mm (0.671 in) Measiire me diameter oi the DISIOn at 15 mm (0.6 in) from tho bonom and 90 degrees to the piston pin hole. SERVICE LIMIT: 66.90 mm (163‘ in) CYLINDER INSPECTION Inspect the cylinder bars for wear or damage. Megsuve the cylinder ID in the X and Y axes at three IEVEIS. Take me maximum reading to determine the cylinder wear. SERVICE LIMIT: 67.10 mm (2.642 In! Calculate the piston-tnmylmder clearance. Take a maxrmum reading to dclclminc rho clearance. ReIer IO page 11-5 for measurement of the piston O.D. SERVICE LIMIT: 0.10 mm “1.004 in! CRANKSHAFI’IPISTON/CYLINDER Calculate the taper and outrofrround at three levels in the X and Y axes, Take the maximum reading to determine them SERVICE LlMl'l'S: aner: 010 mm (0,004 in) Out of round: 0‘10 mm 10.004 in) The cylinder musl be labored and an uversize piston titted if the servlnn Ilml's are exceeded The [ulluwing oversize piston is available: 0.25 mm [0.010 in) The piston to cylinder clearance for the oversize pis ton must be: 0.015 ‘0 050 mm (0.0006 —00020 in). inspect the top of the cylinder for warpage. SERVICE LIMIT: 110 mm (0.00‘ inl PISTON ASSEMBLY Carehrlly Install me piston rings mm the piston ring SECOND R‘NG TOP RING grooves with their marks lacing up. i Apply oil to the piston rings Avoid piston and piston ring damage during metal, lation. Install the pislulr rings with the marks facing up. Do nm mIX the Inn and sncnnd rings; the mp ring is narrower than the second ring in width. Slaggerlhe plston ring and gaps 120‘ apart from each other. Sragqer the side rail and gave as shown, 12-14 CRANKSHAFI'IPISTON/CVLINDER PISTON INSTALLATION “le MARK mt HULt Apply moIvhdenum OII solution to the connecting rod small end inncr surtaces and piston pin outer sur- faces. install the piston pin into the piston and connecting rod PISTON (IONNtCTING ROD Install new piston pin uiips ale into the grooves of the , PISTON FlN CLIP piston pin hole. 7a @ - Make sure that the piston pin clips seated secuiely. . Do nul align the piston pin clip and gun With the pis- ton cumm. Apply engine oil in the nylmdev wall. piston and pic Inn rings. Install the piston/connecting rnd assembly Into the cylinder nstng a commercially available piston ring commcssor tool. NOTICE: . While installing the piston, being careful not to damage the tap surface ofthe cylinder, especially around the cylinder bum. . Be L'Eleful not to damage the cylinder sleeve and ‘ nmnknin with the connecting rod bolt threads. PISTON RING COMPHF‘SUR Use the handle of a plastic hammer to tap the piston into the cylinder. 12-15 CRANKSHAFT/PISTON/CYLINDER Apply molvbdenum all solution lo we Cldllkplll beav- ing surfaces Install the bearlng cap. Make sure the marks on the caps are allqnad with me mark: on fine C(mnecling rods Apply oil xo (he connocllng rod nul threads and sear lng surfaces. P‘stnll the mnnemmg rad nuts and tlgmen me nuts g'aduallv and altcmatcly. then (lghrcn them [a (he spawned lurque. TORQUE: 25 MM [2.6 kgf-m, 19 IM-ftl 12-16 MEMO FRONT WHEEL/SUSPENSION/STEERING 103 N-m 1105 k V-m, 761hf‘ft) 23 Nm (2.3 kgl‘m. 17 let) 12 N>m (1,2 kgV-m, 9 Ibf'ffl L39 N-m 44.0 kgi-m. 29 Inc-m 59 N-m [so kgf-R 215% 43 Ibf-fl) ‘ \ M 30 N~m (31 kgf—m. 72 lhl-fl) 72 N~m (2,2 kghm, 151mm) 13-0 13. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 13-1 TROUBLESHOOTING 13-2 HANDLEBARS 13-3 SERVICE INFORMATION GENERAL with a high qllailfy mm degreusmg agent, Ralar [0 section 15 (or brake syslenl IVIIUlllldlIOII. FRONT WHEEL FORK STEERING STEM After front wheel installation. check the brake operation by applying the brake leven 13-9 13-1 When servicing the front wheel, fork ol staarinq stem, support the motorcycle using a salatv stand or hoist. A uuntanlinateu blake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc Use Only lites marked ”TIJHFI FRS" and vllheless valves 0n rlm marked “IUBI’LFSS TII'II' AI‘PI ICAUI F" 4 SPECIFICATIONS . > ______ ._ Unit: mm (in) n'EM ; STANDARD $ERVICE LIMIT Mililiiium til ead depth ‘ — 1 5 (one)? 7 Cold lire ple>;ul& Up to 90 kg (200 lb) load ‘ 750 ml (9 5n kgh‘cm’, an psi) — 'Up to maximum weight cAianllQ 250 kPa (7 50 tat/me 30 psi) — ‘ Axle runout ' V w '7 7 m — o 2 (0.011 i’v'vhsel rim runoul Radial ' V i H 7 —; " 7' 7 2 o totes) l Axial ' _ 1' ’“fi 7‘ ‘:' ' V" ‘ ‘4’ "do one {Vi/hue balance walght A —— 509 (2‘1 DlI-r:1ax_ W" W V Signing free lsngtn ‘ 238 (113) 250 371103) i ‘ — _ 010(0008) A Tube runou! Recommended fork lluid FlUld lovci Fluld capacity Pro-load adiuster initial selling Renound adiustal initial selling Complessinn adiuster initial setting iStaerlng head Eaaring pre~load7 Fm Honda Suspension Fluid 35-8 116 (mm 462 1 2,5 cm use a 0.03 USWoz, 16 3 z 009 imp 01) All] gloove Irom lop 1-3/4 Iulll) oul Ilum Iuii llald 147/4 Iurlls uul hum lull Il'dld 13-1 FRONT WHEEL/SUSPENSIONISTEERING TORQUE VALUES Handlebar weight mounting screw Front brake than half Front axle bolt Frulll axle holder flange bolt ant brake. hose clamp flange bolt (left fork) Front brake hose Srway joint boll (right fork) Fork socket bull Fork hnlf Fork too bridge pinch sockm bblr Fork bottom bridge pinch flange bull Steering bearing adjustment nut Steering bearing adiusrment nut lock nut Steering stem nut from brake hose clamp bolt lsteenng stem! From mamer cylinder mounting bolt Frunt brake caliper nluulllillg bolt TOOLS Bearing remover shaft Bearing remover head, 20 mm Driver Attachment, 42 x 47 mm Print, 20 mm Fork seal driver weight Fork seal drivel allecllmenl lifeerlng stem sucker Ball race remover set - Driver allacllment, A , Driver Attachment, B Driver shaft assembly — Bearing remover, A , Hearing remover, B , Assembly base Steering stern driver TROUBLESHOOTING Hard steering - Steering heed bearing adjustment llul. luu tiglll - Worn or damaged steering head bearlngs - Bent steering stern - Insufficient rire pressure Steers to one side or does not truck straight - Damaged or loose sreenng head bearings Bent lurks Eenf axle Wheel installed incorrectly Bent frame Front wheel wobbles ~ Bent rim - Worn or damaged front wheel bearings - Faulty tire ~ Unbalanced frnnf flre and wheel Worn or damaged wheel bearings Worn or damaged swrngarm pivol bearings 10 N'm [1.0 kgf‘m, 7 lbf'fll 20 N-m (2.0 kgf-m, M [hf-ft) 59 N-m (6.0 kgf-m, 43 lbf-ft) 22 NW“ [2.2 kgf-m, 'lB Ibf'ft] 12 N‘m (1.2 kgf'rn. 9 lhf‘fl) 12 N-ln (1.2 kgl-m. 9 Ibfrll) 3A N-m (35 kgf-m, 75 IhI-h) 23 N-m (2.3 kgf-m. ’l7 |bf~ft) 23 N-m (2.1 kqf‘m, 17 lbf-fl) 39 N-m (4.0 kgf-m, 25 lbf-ft) 25 N-m (2.5 kgf‘m. 18 lbf-ft) 103 N-m (10 5 kgl-m, 76 Ihf~ffl 10 N-m (1.0 kgf-m, 7 lbf'fll 12 NH“ (1.2 kgl‘ml 9 lbfrfll 30 N-m l3.l kgf-m, 22 Inf-ft) 07746—0050100 077464050600 07745—0010000 0774643010300 07746 0040500 O7947-KA50100 07947—KA40200 07916—3710101 079‘6—KM50001 075A6—KM901OD 075d6—KM90200 07946 KM90300 07946—KM90401 07946—KM90500 0794RKM90600 o7946—M 500000 l ALOC screw; replace with a new one. ALOC bolt; replace with a new one. Apply a locking agent fo the threads. Apply oil to the threads and seating surface. See page 13-29. ALOC bolt; replace with a new one. Front heel turns hard - Faulty from wheel bearing ' Bent front axle ' Front brake drag Soft suspension ~ Insufflmentfluld ln fork - Incorrect fork fluid welght - Weak lurk springs - lnsufflctenf hra prassure Hard suspension - Bent fork tubes A Too much fluid in fork ' incorrect fork fluid weight . Clogged fork fluid passage Front suspension noise - Insufficient fluid in fork - Loose fork fasteners 13-2 FRONT WHEEL/SUSPENSIONISTEERING HANDLEBARS W HANDLEBAR REMOVAL Hold the hand|ebar weigh! and remove the mounting screw and me weight. scnew Disconnect rne from brake switch wire connectors MA—STER CV—UNDE—R ‘ ' HOLDER from me swnch. Nee: rne were Remove the master cylinder holder borts, holder and , Wasfc' y‘nac' muster Cyllndcl’ assembly. , ’avar‘v Wu"? 3W rm ems/NJ ('19 Warm” C ‘ son's ‘ Remove Ihe righl handmbdr swilch/lluoule housing SWITCH HOUSING screws , V, nlsconnflfi' the dutch swnnh wrre connectors from the switch. Remove the clutch lever brackel holder bolls, holder and clutch lever bracket assembly LEVER BRACKET 13-3 FRONT WHEEL/SUSPENSION[STEERING Remuve lhe swam and leh handlgbal mum hnusmg, Hemnve mp. screw and hnnmehar grip and Rcmnvc the handle grip from the handlebar. Remove the handlebar stopper ring. Luusew Um I.dud\ebo: p‘mw bull and vemuw [he haw mnhav frnm the mm mm Remove the '1qu haudleba- :wiich |Iou>ing and lhrul- He pwpe +mm ma ngm handlebar SV\’\TCH HOUSING SCREWS SVVIICH HOUSVNG HANDLLBAR V STOPPEH RING IHHU: ILE PWE ‘ \ \ v’ 4::j ‘ 13-4 FRONT WHEEL/SUSPENSION/STEERING Discannm (he lhvonle cable ends from the thronlc pipe and remove the housing, INSTALLATION Connect the thrnnle cable ends (0 the (meme pipaI Apply grease m Ihu sliding surface of the mrcmle pipe. Install mp. throttle pipe into the light handlebar. InslaIl each handlebar onto the fork mbc, aligning its hnss With me groove in the Iork [DD bridge. __—————. RIGHT HANDLEBAH .; THRO LE PIPE ‘ r/A y] CABLE ENDS THRO‘I'I'LE PIPE CABLE ENDS “ THROTI’LE PIPE 13-5 FRONT WHEELISUSPENSIONISTEERING :smolar Trglnen the handlebar plnch bolts securely. Install xhc stopper nng mm the Inrk mhe groove HANDLEBAR WEIGHT REPLACEMENT Remove rhc gnp from the handlebar SlraIghlen ms weight relalner lab with a Screwdrlvef nr punch Tcrnporenly ll'lstall the grip Pnd and sc'ew, then remove the handlebarwcight by turnlng the gnp and Remove lhe grlp end from the handlebar welgnt. DIscam‘ III! leldiner. Install the new chainer onto the handlebar weight Install lhe qup and onto me handlebar wclghl aIlgnr mg ns bass with the :Iul in [he handlebar weight. InsIaII a new mmlrmng smw Ill:erl the handlebar weigh: assemblv into the handlebar Turn the handlebar welght and hank the rermner tat- wllh lIIe hole in Ihe handlebar. HANDLEBAR PINCH BOLI “ STOPPER RING RETAINER TAB RUBBER CUSHION INNER WEIGHT : RETAINER HOLE INNER WEIGHT HANDLEBAR WEIGHT § 9 RETAINER RING RETAINER TAB FIETAINII'I I'IING RETAINER RING INNER WEIGHT HANDLEBAR WEIGHT RETAINER RING I I I I I 13-6 FRONT WHEEL/SUSPENSION/STEERING Apply Honda Bond A or Honda Hand Gllp Cemenl (USA onlyl to the inside nl the grip and m the clean surfaces of the left handlebar and throttle grip, Wail 3 — 5 minutes and inslall the grip. {ilk-M :l a win» Flmalp vhp grip for even applicatmn of the adheswe. sue to on W ‘ :oJr 9640'? a; no Install the left handlebar swrlch housing allgnlng n: locating pm with the hole in me handlebar‘ Tighten the forward screwiirsr,1hen the rear screw. SCREWS” lrlslall [he :Iulch lever bracket assembly by aligning HOLDER LEVER BRACKET the and n1 lhe hrankel With the punch mark on (he handlchan lnslall lhe clutch IEVEI blanket holder with the “UP" mark facing up. Tlghrcn lhc upper bolr first, men the lower bolt Connect the clutch cs ull llle wheel hub. 0" we mars mscs Install and tugmcn the new mnllnhng balls to the 000'“? WM" speclfied torque. n ‘I my slum: TORQUE: 20 N~m (2 D kgivm, 1A Ihfvfl) Apply grease to the dust seal lips. then install them Into The wheel hub 13-12 FRONT WHEELISUSPENSION/STEERING INSTALLATION Install the ssde collars. lnstall the hunt wheel between the fork leg< Apply a [hm layer of grease to [ha from axle surlace. Install the (ram axle llum the left side. Hold [hp axle and lighten the axle bolno me specified (orque. TORQUE, 59 N-m [5.0 kgf-rn, 43 lbl-ftl Tlgnxcn [he rlght axle pimh bulls m the spemfled torque. TOHOUE: 22 N-m (2.2 km-m, 16 Ibl-ft) Install bmh brake calipers and Lighten the new magm- ing bull: to the specified torque TORQUE: 30 N-rn (3.1 kgi-m 22 Ibl-fl) FRONT WHEEL/SUSPENSIONISTEERING With the from brake appfied, Dump the fork up and down several ‘imes to seat the axle and check brake npernhnn by applying the brake lever. 719mm mp left axle pinch hnhs m We specified [DTQUQ TORQUE: 22 N-m (2.2 kgf-m,16|hf-h) Check the clearance between the brake disc and caliper black! on each side allel iu>lallalium The Inarance shnulrl he at least 0 7 mm 10 03 In) FORK FHONT FENDER REMOVAL \J * Remove the "on! whee! (page 13 9) Remnve the special screws, brake hose clamp boltsl reflectors and (mm fender. , 1 9 ‘ 1 SPECIAL sanw REFLECTOR . L__—_____.# 13-14 FRONT WHEEL/SUSPENSION/STEERING Remove lire handlebar swrrch wrre band. Remove the handlebar stopper rinqr Loosen the handlebar pirrulr bull and top bridge prnnh bull. When the fork leg will be disassembled, loosen the fork can. but do nor remove it yel. Remnve rhs. handlebar assembly and secure it. Luuwn the fork bottom plnnh bolts and remove the lnrk vrrhe lmm the fork lop bridge and meerrng slam. DISASSEMBLY Remove the lork proraclor by prying ‘rx carefully using a CCYEWGV’VGL FORK PHUIECTOR] 13-15 FRONT WHEEL/SUSPENSION/STEERING Remove the fork ball from rhe fork rube. FORK BOLT Push down Ihe joint plare and install the 14mm spam FORK BOLT her mm the rebound adjuster. L‘ruuu.‘ WM Hold the rebound adjuslur. [hen louse" and remove merebwnc the [ark bait from the rebound adjuster. damfl‘ng an/us'er [{U‘r'r the dar'rpel m. or fork damp my PM?!“ wu‘r‘ be change. SPRING JOINT PLATE Remove the following: ' “tfiJ‘RK SPRING — Spring join! plate ~. \ — Spring LOIIEI » Sprung sear Fm“ Spring JOINT PLATE 9 SPR|NG SEAT SPRING COLLAR Four our the fork fluid by Dumping the vork rube sev- er 31 times, Four our the fork fluid from the fork damper by pumpr ing the damper rod several rimes, \ ["7 mumrmr:réununuu rmrmrmnmnmuuu mmmmmnunnm é 2 flurmmmurulluu‘l 4 13-16 FRONT WHEEL/SUSPENSION/STEERING How the axle Mulder in a WU! wixh so“ jaws m a shop towpl Remove mo fork damper socke! bow and scaling washer. 50"”‘0 ,Fqg llamnvn the Qm‘k damper assembly 7mm "19 fork tube. FORK DAMPER Remove the dust sea}. DUST SEAL Remove :he an seal smpper ringA 13—17 FRONT WHEELISUSPENSION/STEERING Pull the fork lube out unlil you feel resislance hum lhe Sllde' bushing‘ lhen move It In and out, tapping the bushing Iigmlv until the fork lube separakes from (he lurk slider‘ The slider hushing will he forced nm by «hp lnrk tube bushing. Remove the all look piece from the fork Sllder. BACK~UP RING Remove the stopper ring, oil seal, back-up ling and guide bushmg from the fork tube m not remove Calefully remove the sliding bush 9 by prying (he slit ms 5"le busn- wlth a screwdriver until the hushlng ran be pulled off my urless .: ‘5 by ham; mm“ m rea’ace rt mm a raw one OlL SEAL SL lNSPECTION Furk spring Measvre the lurk spring free lengm. SERVICE LIMl‘l’: 280.3 mm (11.03 inl (MM/m FORK TUBE BUSHING OlL LOCK PlECE IDER BUSHING IllWWllll'll Fork tuba/slider/damper ~ ORK S l R Check the fork tube and fork slider for score marks, FOHK P'PE r L DE scvaluluus, or excessive or abnormal wear. Repla . any componenls which are worn 01 um. aged, '< Check the fork damper for damage. Check me all lock valve for wear or damage Replace (he lurk damper assemblyl if any component lfl damaged FORK DAMPER 13-18 FRONT WHEEL/SUSPENSIONISTEERING Place the (ark lube in V»bIocks and measure (he runuul, Actual mnnm IS 1/2 the Intel Indlcatoy readmg. SERVICE LIMIT: 0.20 mm (0,008 in) Fork lube bushing VIsuallv Inspect the sllder and fork tube bushings. Replace the bushings if there is excessive scoring or scraIching, 01 if Ihe zeflon is worn so that the copper surface appaars on more than 3/4 of the enhre sur- 'acc. Check the backup ring; replace II II when Is any ms- (onion at the points shown. ASSEMBLY DUST SEAL FORK TUBE STOPPER RING \f‘gf I 3‘ V I a OIL SEAL HACK UP HIN(§ SLIDER BUSHING FORK PROTECTOR FORK SLIDEH I}; A? Nflflfigfl v 34 N-m (3.5 kgl-m, 25 [bf-R) OIL LOCK PIECE DIAL GAUGE I FORK TUBE BUSHING ‘ BACK-UP RING [:DZEZU CHECK POINTS COPPER SURFACES FORK DAMPER FORK BOLT 22 N~m12.2 kgf'm 15 Ibf'h) ° ‘ g g ‘ 6/ C353..— SPRING SEAT )1?) STOPPER K, [\SPRING COLLAR Q. 5%? $1 SPRING SEAT g @1 1 I ; FORK SPRING 13-19 FRONT WHEEL/SUSPENSION/STEERING Before assembly, wash all parts With a hlgh flash or nonrflammable solvent and wipe them dry. Dr: Hmong-i ms Install the new sliding hushlng haang careiul not to bustlrlly ' 'mw damage me coming of the bushing ii ix has been BACK-UP RING FORK TUBE BUSHING marl ncccssarr removed , a V A Remove the burrs from the bushing mating surface, , / being careful nm [0 peel off the coating. .‘nsrallme ml 55211 Install the guide bushlngl back-up ring and new nil Mn .1: rllylkeu seal onm the fork slider. :lu: l‘acvng an N! OIL SEAL SLIDEH BUSHING Coal a new O-ring with fork fluid and install lt into the groove in the all lock piece. a? a O-RING Install the all look place Into the Iork tube. v Apply rpm fluid lu ule uil seal lips. Install Iha ’nrk sllrinr mm [ha Invk "In!" s OlL LOCK PIECE Drive the ail seal ‘lrl using the special mols. TOOL: Fork seal drivar weiglil 07947-“50100 Fark seal driver nnachment D7947—KA402M Inslall me siopner nng Into the fork slider grouve securely. 13-20 FRONT WHEEL/5USPENSION/STEERING Install [Me (Just seal DUST SEAL lnstnll the fork damper assembly into the fork lube. FORK nAMr‘rR Apply . qukmg agent ‘0 the fork socket bait threads Insxall the make! hnl1 With a new sealing washer, ‘2? 95* SEALING WASHER SOCKET BOLT Hold the axle holder In a was wnh soft laws or a shop towel. l- M; 50w campy Tighten the lurk suckel bull lu [he specified lolque. W W I? TORQUE134 N-m (3.5 kgf-m. 25 mm S'Vnorarvy :H (F: f9": , w (my 595? CD/S' 5'10 Y3”? DOV! FRONT WHEEL/SUSPENSIONISTEERING Pour the specified amounr of (he recommended fork fluid into the fork tube RECOMMENDED FORK FLUID: Pro Hondl Suspension Fluid SS—B FORK FLUID CAPACITY: 452 : 2.5 enr‘ (15.6 : 0.08 US 02,163 x 0.09 Imp uz) F‘Ilmplhe damper rod several times until the fork fluid flows out of the oil hole in the rebound nnmnmg adiuslar. SIDwa pump the fork \ube several limes lo remove the trapped arr, Compress Ihe lurk lube sluwly. wake Eur: me or.‘ Measure the oil level from rhe top of (he fork tube. We! ,e m {amp W W! 370?“ ‘5’” FORK OIL LEVEL: 116 mm 14.6 in) Pull the damper rod up and install the fork spring with ( ‘F‘O‘RK SPRING lhe lapered and facing up. __ Remove the roIIowmg: - Spring sea! ~ Spring collar , Sprung 1mm plma SPRING SEAT lnsrau a new o-r‘mg onto the fork burr. AnI-IIV rm fluid onto the new O-ring Screw the fork bolt inro me rebound adjuster unliI ix seats. Hold the rebound adjuster wrth a 17~mm spanner and tighten the fork bolt. F0 SPRING COLLAR RK BOLT 13-22 FRONT WHEEL/SUSPENSION/STEERING Screw the fork boll mm the fork tube. FORK BOLT Inslau the [ark woleutun INSTALLATION lnetall me folk leg through the bonom bridge and mp - hrldge so that the helghl from the top brldge upper audacc [0 mo fork tube end is 33 mm (1.3 in). ‘ Tighten thP fork mp hmr‘lge nmnh ho" to the spammd torque. TORQUE: 23 N-m (2 3 kgI-m, 17 Ihf-fl) \ \ 1 x \ TOP BRIDGE Tighten the bottom bridge pinch bolts ‘0 me specified torque. TORQUE: 39 N-m [4.0 kgl-m, 25 let) FRONT WHEELlSUSPENSION/STEERING fights” the {ark bull w the speuiried luvque 3’ il was HANDLEBAR DlNcH BOLT remnved ' ‘ TORQUE: 23 NM! [2,3 kgf-m, 17 Ibf-ft) lnsmfl the handlebar. Make surame handlebar boss is posixioned in me fork mp blidge glouve Tighten the handmhar pmch hnn secumly [1‘ \ TOP BRIDGE PINCH BOLT Secure the hand‘ebsr switch wlre wnh the mm, mm Secuve me halld‘webal switch and hum wire wim ma Wire hands mage 1‘23. Inslall [he from wheel (page 13-13). ‘ 0 WIN; HANDS; STEERING STEM WIRE CLAMP WIRE BAND REMOVAL Remove me followmg: — From wheel (page 13 Q) — Uppey L'uwl (page 2-7r ~ Handlebars [page 13-3- xgnmon switch AP (White! toulleuul. \ \ Release the wire band and clamp, then disconnccnhe ‘ 4P1WHITE) CONNECTOR 1 1 _. . HAK HUSL CLAMP HOLT Remove the bmt and front brake hose damp, Disconnec‘ the horn connector, Remove the ban and horn unil. HUHN UNII 13-24 FRONT WHEEL/SUSPENSION/STEERING Remove the sIeeriv-g stem nm cap. Remove the stern nm and the top bridge. Remove the Ian: legs (page 13-15)‘ Straightsn the tab: of the lock washen Remove. the :teering bearing adjustment nux lock nut and lock washer. Remove the steering 5mm hearing amustmnnl nut using the specim (col. TOOL. Steering stem sooke‘ 0781$371D1D1 STEM NUT CAP ADJUSTING NUT FRONT WHEEL/SUSPENSIONISTEERING “WWW "'8 ‘°”°W'“9: ‘ INNER RACE/UPPER BEARING DUST SEAL — nusr seal 7 Upper bearing inner race 7 Upper bearing — Steering slem — Lawerbenrmg STEEFUNG STEM LOWER BEARING BEARING REPLACEMENT eray: ‘en’fir‘z- Replace the races using the ball race remover set as 3"? ESE/WES 5"” described in the fullawmg procedure mac: 2: a 5132 TOOLS: Bull race remover set 07945—KM90001 — Driver anachmem. A (1) o79t5—KM90100 - Drivur attachment, B (1) 07946—KM90200 - Driver shaft assembly (3) 079WKM90300 — Bearing remover, A (4) wens-KMemm - Bearing rlmovof, B (5) 019‘5—KM90500 );-_4 (1) (2) 14) (5) — Assembly base (5) 07956-KM90800 " chsmsms n’a- Install me ball race remover into the head pipe 03 ”,7 Liver, 1 0? shown. UHIVEH A'I'I’ACHMENT NUl A 1%: abar'uuly 999° Align bearing remover A win: the groove in the steep Farris”. m z B 'th 1 ASSLMHLY lg ryng an nu w: a wrenc), 3 BASE ‘ 14/ \ While holding the driver shaft wixh a wrench, rurn nut A gradually lo lenluv: lhe upper bearing uular race. UPPER OUTER RACE BEARING \ REMOVER A KW \ roll , ,1 / DRIVER ATTACHMENT DRIVER SHAFT 13-26 FRONT WHEEL/SUSPENSION/STEERING Nut:- my ll>13/la’ Insrall the ball race remover into the steering head nan :h-ecrton a! plpe as shcwn. the ESSWNV Align bearing remover B with ma groove in the slearr “m ing head. nghtly \‘lghlen nm E. While holding the driver shaft. mm nut A gradually to remove the lower bearlng uuler race. DRIVER A‘I'I'ACHMENT DRIVER SHAFT BEARING HEMOVER B LOWER OUTER RACF NUTB DRIVER ATTACHMENT ASSEMBLY BASE NUTA lnslall a new upper outer race and the ball lacu m remover fl: shown. While holding the driver shah with a wrench. xurn nur A gradually until the gruuve in driver attachment A aligns wrth the upper end or the sleermg head This will allow you to install the upper bearing outer racer ‘ ASSEMBLY : EASE NUTA FRONT WHEELISUSPENSION/STEERING lnstall a new lower outer race and hall mm remnvar as shown. While holding the driver shaft with a wrench, (urn nut A gradually until the groove in driver attachment B aligns wrth the lower end of the steering head. ThlS will allow yen to install the lower bearing outer race. u. .only: Replace the steering head bearing outer race: using the special tools listed below. ASSEMBLV BASE DHIVtH ATl'ACHMENT DRIVER ATTACIle NT DRIVER SIIAI'T TOOLS: Main bearing driver attachment 07945ME90200 Fork seal dvlver walg m 07947-KA50100 Oil seal driver 079$!»MA60000 Installer shaft D7VMILK230200 Installer attachment A 07VMF—MAT0100 Instillnr anichmum B 07VMF—MAT0200 Remover attachment A D7VMF—MAT0300 Remover attachment B 07VMF—MAT0400 Install the special tools into the steering head prpe as Shawn Align remover anachmsnr A with the groove in ms sleerlng Ilgad. Whrle hnldmg the Installer shaft With the wrench, turn the upper nul gradually to remove the upper bearing outer race. llFPFR NU] MAIN BEARING DRIVER ATTACHMENT FORK SEAL DRIVER WElG HT UPPER BEARING OUTER RACE REMOVER ATTACHMENT A INSTALLER AWACHMENT B 13-28 FRONT WHEEL/SUSPENSIONISTEERING Install the special luuls iillo Ilie steering head pipe as shown Align remover attachment B with the groove in the steering head. While holding the installer shah with the wrench, turn the lower nut gradually to remove the lower bearing ourer race, InsIaII a new upper bearing outer race and Ihe special tools as shown. While holding the inslaller snail wllh me wrench, turn the lower nul gradually until [he groove in insraller allacllment A aligns with the upper end of the sleev- ing hand. lhix will allow you to installing upper hear- ing outer race. —.—‘ INSTALLER ATTACHMENT A INSTALLER SHAH REMOVER ATTACIIMI'NT B LOWER BEARING 0U l EH HAUL OIL SEAL DRIVER FORK SEAL DRIVER WEIGHT MAIN BEARING DRIVER ATTACHMENT LOWER N UT UPPER NUT INSTALLER A‘I'I’ACH M E NT A UPPER BEARING OUTER RACE INSTALLER SHAFT INSTALLER ATTACHMENT B OIL SEAL DRIVER FUNK SEAL DRIVER WEIGHT MAIN BEARING DRIVER ATTACHMENT LOWER NUT 13-29 FRONT WHEEL/SUSPENSIONISTEERING lnsmll a new lower hearing miler mm and me apecial lools as shown. UPF‘l’Fl NUT While holding the inslaller shaft with the wrench. turn the upper nut gradually until the groove In insialler attachment B aligns with the lower end of the steering hsadl This will allow you to ingrall ihe lower bearing “DAéiirESEA/rrg‘giMENT outer race. 1 FORK SEAL DRIVER WElGHl INSTALLER ATTACHMENT A INSTALLER SHAFT Q) LOWUI BFARING OUTER RACE l INSTALLER r ATTACHMENTS r r LOWER NUT Temporarily install ihe steering stem nui onto the slam in prevent the thread: from being damaged when removing me lower bearing inner race from the stem. DUST SEAL Remove rho lower bearing inner race wixh a chisel or equivalent tool, being careful not lo damage the stem. Remove the dust seal LUWE H INNE R RACE Apply grease to a new dual seal lips and insiall n over é-TEERlNG STEM DRIVER the steering stem. Install a new lower bearing lnnel race using the spe- crai mm and a hydraulic press. TOOL' Stenring s‘em drivar WISHES-M30000!) LOWER INNER RAC 13-30 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION , , LOCK NUT : BEARINGS L—fim :EEARING RACES M LOCK WASHER : DUST segLs é\\:?/TOP THREAD ‘s V UPPER DUST SEAL k (7, STEERING SIEM 4/," K UPPER INNER RACE 7 / lfll <‘ ‘ l , 21>? /’ UPPER BEARING / UPPER OUTER RACE LOWER OUTER RACE g“SQLOWER BEARING \ LOWER INNER RACE LOWER DUST SEAL Applv grease to the upper and lower hnnrlngs and ‘ INNER RACE/UPPER BEARING DUST SEAL bearlng races. E Install Ihe lnwnr hearing nnlo the steering s‘eml Insert Ihc mooring slam into the steering head pipe. Install upper bearing, inner race and dusl sual. STEERING STEM LOWER BEARING Apply oil to the bearing adjustment nut threads. STEERING STEM SOCKET Install and Ilghlen lhe slum bearing adiusting "UK In \\ \ (he Inmal lurqua. \\ TOOL: Steering sum sockat 079153710101 TORQUE: 25 N-m [2.5 kgf-m, 18 lbI-hl ADJUSTING NUT 13-31 FRONT WHEEL/SUSPENSION/STEERING Move the steering 5mm to the ngm and left. lock to lock, five times to sea the bearings. Make sure (he sxeeriug stem moves smoothly, thh- uul play Or binding; than loosen the bearing adjusting nut fictightcn the bearmg adiuslinq nut to (he specmed ‘OVQUG, TORQUE: 25 N-m [2.5 kgl-m, 18 Ibf-h) Recheck mm the smenng smm moves smoothly wwh out play or blnding. InstaII the new lock wash” nnln mu stearmg stem. Nign the ‘abs of the lock washer wixh me groove: in me adjuflmem nut and bend the two oppnsn» tahs (shonen down mm the adjustment nut uroovc‘ \nsml and finger hgh‘en the lock nut. Ho‘d the lock nm and funherlighten [he lock nul with- m 1:4 mm {90% enough to align IlS gram/es With the Lock washer tabs. Bend [he iuck washertabs up into the lock nut groove @ LOCK NUT & J ADJUSTKNG NUT LOCK NU] [OCK \NASHkH TAB 13-32 FRONT WHEEL/SUSPENSIONISTEERING Insiau the fork regs (page 13-73) Instail the loo brrdqs and srearing Slam nut. Tighten the steering stem nut to the specified torque TORQUE: 103 Nvm [10.5 kgf-m. 76 IM-M Install rm: steering Stem nut cap. Instal! me from brake hu:e Ll'amp. tighten the bolt lo the specified iorque TORQUE: 10 N-m (1.0 kghm, 7 lhf-h) lnsrali the horn umv nssembiv and lighten the mount mg bolt. Connect the ham wire Lin-nectar; Connect the ignition swrrch 4P iWhneI connector and secure the wires with me wrre band and c‘amp (uage 1-23}, Install the toliowing: » Front whee‘ (page 13-13) — Handlebarmage 13:.) 7 Upper cowl (page 2 9) AP ‘WHiTEi CONNECTOR 13-33 FRONT WHEEL/SUSPENSION/STEEHING STEERING HEAD BEARING PRE-LOAD Suppan the momrcyclc so me from wheel is off the ground. Position the steering stem straight ahead. Make sure M's Hook a spring scale to me fork lube and umasuve the ‘- w Lab’s m WW sKeering head [mam-g pre-load . 'néss mafia/- 5“ The on: load should be within 1.0 — 1,5 kgf (2.2 7 33mm If [he readings do uul (all within the limits, lower the from wheel to the ground and adjust the steering bearing adlusnng nut. 13-34 MEMO REAR WHEEL/SUSPENSION 7 N-m (0,7 kgl-m, 5.1 lbl-ft) 44 N-m (4.5 kgf-m, 33 le-ft) 64 Nom [5 5 kgf'm, 47 "1741) 7 N'm {0.7 kgf-m, 5.1 [bf-fl! 93 N'm (9.5 kgf‘m, 69 Ibf'fl) SA N-m (6.5 kgfi-m, 47 Mom 14 N-m (4.5 kaf-m, 33 |b1~ffl u N-m (4.5 kgf-m. :3 var-m 93 N-m (9.5 kgI-m, 69 lbi-fl) AA N-m {L5 kgf-m. 33 Inf-fl) 1 4-0 14. REAR WHEEL/SUSPENSION SERVICE INFORMATION 14-1 SHOCK ABSORBER 14-9 TROUBLESHOOTING 14-2 SUSPENSION LINKAGE 14-12 I REAR WHEEL 14-3 SWINGARM 14-14 SERVICE INFORMATION GENERAL ~ /\ contaminated brake disc or pad raducss stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degieasing agent. - After the rear wheel InstaIIrmnn, check brake operallnn by appIylng the brake portal The shock absorber contains nitrogen under high pressure. Do nor allow the or heat near the shock absorber. Before disposal ol the shock absorber, release the nitrogen wage 14,13). When servicing the rear wheel and suspension, support the motorcycle using a safety stand or hoist Use only tires marked “TUElELESS” and lubclcss valves on rims marked “TUBELESS TIRE APPLICABLE". Use genuine Honda replacement bolts and nuts for all suspension pivot and mountinq point. When using the luck nut wrench for the adjusting bolt lock nut, use a 20 inches long deflecting beam type torque wrench The lock nut wrench increases the torque wrench‘s leverage. so the torque wrench reading Will be less than the torque actually applied to the lock nut. The specification later in the text gives both actual and indicated. When installing the swinganii, be sure to lighten the swingarm pivot fasteners to the specified torque in the specified sequence If you make a mistake during the tightening torque or sequence, loosen all pivot testeners, then tighten them again to the specified torque in the correct sequence. Refer to section 15 for brake system inturniatiuii. SPECIFICATIONS _ . Unit: mm iin) I ITEM . srANDAnD SERVICE LIMIT 7 Minimum tire tread depth L ‘30 in om ITold tire pressure i Up to 90 kg (200 Ibl luau" W I H V250 kFa (2.90 kgticmZ, 42 psi) 4 7 m I Up to maximum WEigItl udp;LIl; ' i 290 We list) kgticmz 42 psii ,4. _* ,7, , . , _ , _ 7 Axis runout AA , 2 i0.01l 'i/Vheel rim runout I Radial 7 W 7 a too I iA-Xiiitl fl — 2.0 . .03» ' ‘ i belanceiyveight # 4 W 7 , —— i 69912.1ozimax' i Drive Lhaln Size/link DID DID525HV—108LE ‘ i RK RKGéggRBZI—tosLE Slack V 25 - ash—1.3m 7 , — i shnrk ahsnrber Spring adjuster standard position Position 3 — Rebound adjuster initiel setting 1 Ii‘Z turns out from full hard ‘ — Compression adiuster initial setting 171/2 turns out from full hard # 14-1 REAR WHEEL/SUSPENSION TORQUE VALUES Rear brake disc bolt Final driven sprocket nut Real axie nut Hear shock absorber mountlng nut Shock link plalerlo-swirlgarm nul Slluck Illrk-lo-shock link p1ate nut Shock link-m-bracket nut Drive chain slider flange bolt Swmgarm pivut adlustilrg ball Swrngarm pivm ndllxstlng bolt lock nut Swlngarm pivot nut TOOLS Bearing remover shaft Bearing remover heed, 20 mm Urlver Driver head Allaulllllanl, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachlllent, 52 x 55 ill!“ Anachmnnt, 75 x ?6 mm Attachment, 22 x 24 mm Pilot, 17 mm Film, 20 mm Pllot, 26 mm Pilot, 28 mm Attachment, 28 x 30 mm Lock nut wrench Bearing remover handle Bearing remover head Hemover weight Driver Atlachmelll, 34 mm Anachmpnl. 37 mm Bearing rcmovcr set TROUBLESHOOTING 5m suspension - Weak shock absorber wring - Incorrect suspension adjuslrnent ~ Oil leakage from damoer unit - Insufficrenttlre pressure Hard suspension A Incorrect suspensmn adjustment - Damaged rear suspension pivor bearings . Bentdalllper ruu - Inmrrecr swingarm prvol rnsleners lrgnlemng A Tire pressure (00 high 42 N-m (4.3 kgl-m, 31 Her-m 64 N-m (5,5 kghm, 47 Ibf~ft) 93 N-rn (5.5 kgl-m, 59 inf-m M N-rrr 14.5 kqf-m, 33 Ibf-ll) 44 N-rn 14 5 kgf-m, 33 Mrs) u N-m (4.5 kgf~m, 33 lbf-ftl 44 N-m (4A5 kgl-m, 33 Inf-m 9 N-nl (0.9 kgf-m, 6.5 lbivhl 7 N‘m (0‘7 kgl-m, 5.1 leu 64 N~m16.5l< 14-4 REAR WHEEL/SUSPENSION Remnvn me dnven flange asGembw from (he lefi DHNEN FLANGE I wnecl hub. Remove ma wheel rubbm \Jn'upws Re "owe the O-nng Dnven flange bearing removaI LOOSOn the driven sprockeK nuts, Remnvfi- m9 dnvew Mange from the when‘ hub‘ men remove the dr ven sprockex nuts and sp'ockel. Remcve (he chm WI 4 ’ ,F 3) " . \JL an? , / “ “i ”35%: 7 ¥ . r t 4“ NUTS WM” SPROCKET Drive \he awe” flange cu‘ldv uul [mm the driven DRIVER Flamge bearing TOOLS: Driver 077‘9—0010000 Attachment, 24 x 26 mm 07715770010700 Pilot, :0 mm 07745—0vo500 7 DR‘NER HEAD 14-5 REAR WHEEL/SUSPENSION Dave the drlvcn flange bearing om using the special “3015‘ DRIV:R TOOLS: Drlver 0774947010000 Attachment, 37 x 40 llllll 0774641010200 PiIni, 25 mm 07746—0040600 Whanl bearing lumoval Install (hp hPanng rnmnver head mm mu. hnarmg From me opposllc side instoH the bearing remover shaft and drive the bearing out DI the whee‘ hub. Remove tI‘e dIstance colIar and driv? OUT (hil Mhpr bearing. TOOLS: Bearing remover head, 20 mm mus-0000500 Scaring remover shaft 07745—0050100 \ ’ ’/ .REMOVEH HEAD REMOVER S‘HAFT ASSEMBLY DRIVEN FLANGE BEARING 42 N-m (4,3 kgI-m,31 IbI-ftr (27 X 52 X 2378I DRIVE N FLANGE COLLAR RIGHT DUST SEAL @ LEFT DUST SEAL 51 N‘rl" (S 5 kghm, 47 Ibfihx BRAKE DISC DRIVEN SPROCKET HUBBEH DAMPERS RIGHT WHEEL \ BEARING [GZOAUUI I \ ‘ I I , b I ' ff DISTANCE COLLAR LEFT WHEEL BEARING (6204UU) a U-HING DRIVEN FLANGE 14-6 REAR WHEEL/SUSPENSION Wheel bDaring instillation! DRIVER Drive m a new right bearing squarelv‘ TOOLS Driver 0774940010000 ‘ W Attachment, 42 x 47 mm 07746-0010300 Film, 20 mm 07746-0040500 lnsrall me d>stancc col.ar Dun/e ln (he left we heanng usmg the same tools. Pr?“ the dnven flange collar In (he now drlven flange bearing unul it is fully seared. TOOLS: Driver 07749-001000!) Anachment, 28 X 30 mm 07748—1 B70100 Pilot, 20 mm 077A6—00‘0500 Driven flange bearlng installation Drive the new driven flange hearing mm the driven flange usan we speclal tools. TOOLS: Driver 07749» 0010000 Attachment, 52 x 55 mm 0774641010400 Pilot 20 mm 0774641040500 EVACHMENTJPILDT Install the whesl mhher dampers mm the wheel nub, Apply ml to me now 0 rlng and install ’1 mm rhe groove of the wheel hub‘ , RUBBER DAMPERS I HEAR WHEEL/SUSPENSION lllS‘all me driven flange assembly into l'le lell wheel hub If the dnven sprocket was removed, lrls‘lall the drlvcn sprocket and (lqmerl ms nuls TORQUE: 64 N-m [5.5 kgf-m, 47 Ibefll Auply glease 10 the dusl seal lips, men lllslall il llllu mp. drlvan flange lnstall the b'ake ms: with the mark facing out. lnsrall and llgmen me new bolls lo the smaller! torque. TORQUE: 42 N~m (4.3 kgf~m, 31 Ibf'ft) INSTALLATION Apply grease lo [he side collar lns‘da arld grooves‘ lnslall lhe Slde collars. lnszall the ray make calmer hrnrkel mm the glllde of me swlnqarm. 14-8 ’ REAR WHEEL/SUSPENSION place the rear whee‘ into the swingarm Hislal‘ the drums Chfim oval the driver sprocket. 031$ Ins'al! the rear axle from {he left siue. \nstaH Mr— washe' and ach nu: Adiusl [he dvive w ah slarh (nage BJ‘JL ngmen the axle mu [0 me specified twque TORQUE' 33 N-m [9.5 kgf-m, 59 lblvm SHOCK ABSORBER REMOVAL Remove the seat 19090 2 2‘. Supaon the mu‘xuxvcle using a hms‘ or an eqmva‘cnt‘ Loosen {he skock absorber 'Eservuu ba'IJ screw and rerove [he resenul fvorr he sea! ram R$=mrwe me shock absorber lower P‘Oufllvnq bOWnul. _ LOWER MOUNTING BOLTWUT 1 4-9 REAR WHEEL/SUSPENSION Hamnvp the shock ahsorher upper moummg bom‘nul and me shock absorber. INSPECTION Check the damper unn, reservmr hose and reservmr (or leakaas or omer damage. Check the Llppel Jolnl bushing for wee. cl udllldge. Replace the shock absorber assembly ll nficPssary Remove lhe luwel juilll plvul uollav. Check the handle heanng, nlvn' nnllar and dust seals (or wear or damage. NEEDLE BEARING REPLACEMENT Remove lhe pm: collar and dusl seals, Pass the needle henrlng mll‘ of N19 fihnnk ahQnrher lower moum using me special tools, TOOLS: Driver DGB4$371DUO1 or 07946-MJ00100 Attachment 22 x 25 mm 0774H010800 Film, ‘7 mm Dl7£i¥00l0l00 SHUCK ABSORBER umvm MOUNTING BOLT/NUT DAMPER PIVOT COLLAR DRXVER ATTACHMERT’HLOT 14-10 5re:t in? ”990‘? bea'mg mm m uwe‘ mom wrrh me marks: slde :5:an our Press a new needle hanrlng Into the lower moum so the needle besrlng surface is 7.8 - all mrrll0.31— 0.32 ml lower from (he and or the |uwer mount using me same luuls. Auply grease to the new dust seal lips and install them into the lower mount lnstall the pawn collar. SHOCK ABSORBER DISPOSAL PROCEDURE Camel punch the reservoir rank end 10 mark the dnlllng pnlnl. Wrap the dalanI unit l'nside a plasllr. mg. Suppon the reservolr tank m a VlGL‘. as shown Through me open end of the bag, insert a drill mulol with a Sharp 2 — 3 llllll (5/54 —1.‘8ln l drill hll, WOIICE Dn no! use a dull drill bir which could cause a bulld~ up of excessive heat and pressure inside the ddlllpEl, leading to explosrnn and severe personal Inlllfy The shock absorber contains nitrogen gas and oil under high pressu/ev Du not drill any ranller dawn the damper n 55 than the measurement given above, or you may drill into rhs oil chamber; oil escaping under lllgn plessure may cause serious personal mjury Always wear eye protection to avoid gaming metal shaving in your eye when the gas pressure is released The plastlc bag '5 only lmnaeu la shield you fmm the escaping gas. Hold me bag around me drill nlulul and blielly run lhs drill lllUlOl inside the bag; thls will mrlam the mag with air from the motor and help keep me bag from getting caught in me hit when your start. REAR WHEEL/SUSPENSION 7‘8 — 8.2 mm (031* 0.32 inl l V A a DUST SEALS 049‘ ”\ \, a uvv’ PIVOT COLLAR 14-11 REAR WHEEL/SUSPENSION SUSPENSION LINKAGE INSTALLATION SHOCK ABdeiBE Install the shock absorber mm the frame WIN" the reserve rank outlet facing to the left, lnstall the upper and lower mounting bull/um. fighten the upper mnunnng mu m the saecified [OFQUA YOHQUE' M N-m (A 5 kgf-m, 33 lhl-h} Tlghien lhe Iuww Hluullling nuL ID the specified torque. TORQUE: 44 Nrm [4.5 kgfwn, 33 IM~hI Install the reservolr Into the reservoir hand fightan the band screw securely. Install the removed pans m w: reverse order or removal. REMOVAL Suppon the motorcycle usmg a hniv or equivalent Remuve [he rulluwirrg; » Shock ahsnrber lower mounting bolt/nut Shock llnk platermrswmgam‘ bolt/nut - Shock llnk platertcrshocx link boln’nut — Shock link plates 14-12 I: I'm‘ fl‘L-U "‘ik mm: as removes mane". ms 1vava m SCCu'C‘V m ‘IU'S‘ W v“ ] HuaVQH‘ am: Jansen w SPSCL’ “m DVJCKC! «As 1; 3.» m; 0195(3165 bay/5e" Mr: SHL‘LK lmk ar'w Dramats megs 74/ C iF‘C (705619 ue, rhe shock H’W Wm! mg m «mm 4m; 7H — Shnck hnk-tovbrackct bolt/um Shock link INSPECTION Check that the suspension ‘inkage compnnenm mr damage, lepVace any damaged componems. SHOCK LINK BEARING REPLACEMENT Remove the pivot «mm and dust seals. Pless (he needlr. nearing out of the shock link using the special tools. TOOLS Driver 04949—3110001 or 07945-MJ00100 Attachment, R x 24 mm 0774841010800 Pilot, 17 mm 07746-004040!) Press a new needie buallng into the shock link so the neelfle bearing surface ‘5 5.2 — hfl mm (0.20 022 im |nwer lrom me and of [he shook link using the same tools. REAR WHEEL/SUSPENSION SHOCK LINK DUST SEALS DRIVER A‘I'I'ACH M E NT/Pl LOT 5.2 - 5.7 mm 1020 - 0,22 in) 14-13 REAR WHEEL/SUSPENSION ADD‘V QI'COSE [D the new BUSY seal ‘Ifls and mntali mm mm the shock link 0 instaH the pivoz Canal. INSTALLATION ‘V'MBH [he shock iink inlo [he iink brackets, iani the shock iink socket bull hum [he iefi side. insult me nut. instali the shock imk plates with the arrow facing [He left and from side. InstaH the shock li'nk plate bolt from the right Sldc‘ InstaH Ihe nut. ‘fighien the link bracket nuts ii ihey were ioosened (page 7-17; figmen ihe suspension hnkago nuts (0 the spemfled mrque TORQUE: M N-m [4.5 kgf-m. 33 |bI~fN , x‘ “)7 . HWIWES..~ SWINGARM REMOVAL Remove the rear wheAl mags :43) Remove [he two screws and drive c'iam case. SEREWS 14-14 REAR WHEEL/SUSPENSION Remove the bolts and brake hose guides‘ BRAKE HOSE GUIDES ' ‘71 Remove (he shuLK link pla‘eriorswingarm bolb’nut SHOCK LINK PLATE-TO- !“ SWINGARM BOLTS/NUT “ ._._._. nemnve The swmgarm pivot nut and washer. PIVOT NUTM’ASHEH Remuve 1h: sw'mgarrn pivot hnlr Loosen the ‘2“ pwol ndjuslmg bDII lack mu: using the special moi TOOL: Lock nut wrench 079034590003 REAR WHEEL/SUSPENSION Loosen the right pivcl adiusting bow \ock nu: using mp special tool TOOL: Luck nu! wrench 079084890003 Innsen the right plvnt adjuslmg bolt Loosen the loft pivot adjusting bDIL then remove the :w'mgarm. DISASSEMBLYIINSPECTIO“l umvt CHAIN SI InFR ‘ nans; Remove me three SH bolts and drive chain ster, ‘ Check me drive chem shaer for wear or damage, 14-16 Remove the pivul collar and dusl seals hum lhe lefl swingarm pivot, Check [he dust seals and collar: for damage or laligue. Remuve [he pivol distance collar and dust seals from the swingarm right pwm, Check the dust Seals and collars {or damage or fatigue. Turn [ha inner race ul [he righl pivot bearings with your linger The Mflflngs should turn smooxhly and quickly. Also check that the bearing outer race fils tightly in lhe swingarm pivot. Hemnv: and dlscard the bearings if the races do no‘ turn smoothly and quisllv, or il they lil loosely in (he swingarm plvOL PlVOT BEARING REPLACEMENT Remove the snap ring. REAR WHEEL/SUSPENSION BEARING REAR WHEEL/SUSPENSION Remove xhe right uivux radia! ball bearing using the BE‘ARBJG‘REMOVER special tools \ \ TOOLS: Be g vemavev hindle 0793b37$0100 Bearing mmover hand 07936-37106!» Remover weight 07741—0010201 Press the right pivot needle bearing om using the DRIVFR SHAFT specwal tools and a hydrauhc press TOOLS: Driver 079l9—3710001 Attachment, 3‘ mm 07ZMD-MBW0100 0f DriVDr shah 07946-MJ00100 Attachment, 3‘ mm 07ZMD—MBW01DO \ ATTACHMENT Pack a new neudle bearing with grease. DRNER Pra‘s me needle bearing into the right swingarm pivox unm it seem using the Speclal mm: and a hydraulic press. TOOLS: Driver 07749-001000!) Anachmnnt, 37 mm 07ZMD—M BWOZOO Pilot, 28 mm 07746-0041 100 ATTACHMENT and a hydraulic press Press in [he vad'wal baH bearing using the specia‘ zoo|s DRIVER é; ' TOOLS: Driver 0774941010000 Attachment, 32 x 35 mm 0774641010100 Pilot, 20 mm 0774641040500 or Driver 0774541010000 Anlchmanx, 37 mm 07ZM|¥MBW0200 Pilot, 2|) mm 07746—004050!) ATTACHMENT/PILOT 14-18 lvmall the snap ling into the gloove secuvely. Remove me left plvm needle hearing from the swingarm pivot using the special tools. TOOLS: Driver 079494710001 Anachmem, 37 mm 07lMD—MBWOZDO or Driver shaft 079‘5-MJDO100 Amehmem, 37 mm 071MD—MBW0200 or Driver shift 07546-MJ00100 Needle bearing remover 07HMO—MR70100 Press a new Ieh pivot nccdlc bearing into the swingalm pivot so the needle bearing iurlace is 5.0 — 6.0 llllll (0‘20 — 0.25 in) lower from the end Of the swingarm plvnl surface using the special tools and a hydraulic press. TOOLS: Driver 07749-0010000 Attachment. 37 x 40 mm 07746-00!on Pilot, 28 mm 07746-0M1100 0f Driver 0774941010000 Attachment, 37 mm 07ZMD-MBW0200 Pilot, 23 mm 07116-004110!) Shock Ilnk plate bearing rapllcement Remove me pivot collar and dus‘ seals from the shock link plme pivnl of the swungarrn. REAR WHEEL/SUSPENSION DRlVER ATTACH MENT " SNAP RING DRIVER svn - so mm 10.20 0.2! m) :21: PIVOT CO LLAR 14-19 REAR WHEEL/SUSPENSION Draw [he needle bearing out of (he swingarm usmg the special tonl TOOL: Searing Vemover set ITILMG-KVSO'IDO Apply grease to the needle rollers of the new bearing. Install the needle bearing Into the pivot until the depth (rum [he swingdml uulel surface is 5.5 — 6.0 mn1(0.22 — 0.7: inl, using the same taol. Apply grease ‘0 [he dust seal lips, then install the due! seals and pivot Collin iulu um swinganu NEEDLE BEARING REMOVEH 1 I! 'l b.b—S,Umm l i (0.22 — 0.24 in) ‘ H r—l — PIVOT OLLAR 1 4-20 REAR WHEEL/SUSPENSION ASSEMBLY RIGHT PIVOT BEARING (20 x 37 x 9) a DUST SEALS RIGHT I-‘lVUT (2: x 37 x 4) NEEDLE BEARING PIVOT DISTANCE SNAP RING PIVOT COLLAR fl DUST SEAL (2Bx3Ax Al DUST SEAL LEFT PIVOT NEEDLE (26 x 37 x 5D BEARING DRIVE CHAIN SLIDER 3 N‘m (n 9 k '-m, 6.5 Ihi‘m Eu a WWII] COLLAR NLLDLL HEARING Apply grease m me dust seal le5, Ihen Inslall the dual seals into the rigm swingarm pivot. Fill the grease up between the inner dusI seal and needle heaving. InsmII me nIvm dIsIance collar. 6 DUST SEALS G‘SIaf‘CS I: 3' has 5/ we» ' 3. Jr Apply grease to me dust seal lips. then install the dust seals and pivot collar into me Iefl swingarrn pivoI, 14-21 REAR WHEEL/SUSPENSION my «gnaw; l‘la aw i L! w m ‘OCK nut vWPF n Mm ‘rl toraue wrench MATJON” lnstall the dl'lVe chain slider aligning the slit with the boss on the swingarm. ltlSld“ tllt: di ive chain slider bosses 'lnto the hole in the swungarm Install and tighten the new drive chain slider mount— ing bolts to the specified torque TORQUE: 9 N-m (0.9 kgfim, 6.5 IM-fl) INSTALLATION Be sure to tighten the swlngarm pivot fastenels to (II: speclfied tolaue in the specified sequence. It anl do not tighten the lastsners to the correct torque or in the proper sequence, loosen all pivot lasteners, than tighten them again to the spec-tied torque in the cor- rect SEQUENCE. 1 Install the left and rlght adjusting bolts sat lhey du not project out of the flame inner surface. 2,0bzain a spare pivot bolt (PIN 521017MBW7000) or use a 20 mm (08 inl 0.Dt shaft, Set the swlngarm into the frame and the shock link plates and temporarily Insert the pivot bolt from the left side to support the swingarm. DHIVt CHAIN SLIDFH ”* T K: ADJUSTING BOLT 14-22 ELTIQMOI’I the right pivnl adjusting bOII m the initial iorqual TORQUE: 12 N-m [1.2 kgl-m, 9 IMO“) Loosen Ihe right pix/oi adjusting bolt, and retighten it in the specified torque. TORQUE: 7 N-m (0‘7 Iigfim. 5.1 lbf-fl) >. .lniiall lha righl pivul luck nut. Hold the right pivot Adjusting bolt, then tighten the lock nui io thc specified torque using the special tool. TOOL: Lock nin wrench 01908-468000: TORQUE: Actual: 64 N-m (6.5 km'm, 47 lbl-fll lndlcamd: 58 Min (53 kgl-m, 43 lM-Ill 5 Insert ihe other pIVOI’ bolt irom the right side, grad- ually pushing the lcfl side plvoi boll out from the Ieft side. Effigmen the left pivo! adiusfing bolt (0 me initial [DIODE TORQUE: 12 MI“ l1.2 kgf-ln. 9 leII Loosen the Iefi pivot amusiing hall and rmighmn II to the specified Karena. TORQUE: 7 N-m (0‘7 Ital-In, 5.1 lhf-ft) REAR WHEEL/SUSPENSION RIGHT ADJUSTING BOLT l PIVOT sour xiv/,1?“ 4 /;w / -’ REAR WHEEL/SUSPENSION 7‘ install the lek lock nut, Hold (he left pivo! afljusnng mm, than ngman the lock nut to the 59chth torque using me specia‘ tool. LOCK NUT WRENCH TOOL: Lack nm wrench 07908—4690003 TORQUE: Actual: 64 N-m {6‘5 kgf-m, 47 Ibl-h) Indicand: 58 N-m (5‘9 kgl-m, 43 Ibi-ft) H Push 1he pivot half until If ‘5 Sealed. Install the pivot nut with the washer and Iigmen me pivot mu: [0 the specified lolqua. TORQUE193 N-m (9,5 kgl-m, 69 IM-h) Install (he shock an plate-w-swingarm bolt/mu, men (iglllun [he nul lu Hve weaned lulque. TORQUE: « N~m 14.5 kgl-m, 33 lel) b I ‘ ‘Q SHOCK UNK PLATE T0 V’ éw'wa Roma me brake hose pvopevly, than inslaH the rad! 'IEWCKET \' \ brake cahper/brackm mm the boss of the swingfirm . 14-24 REAR WHEEL/SUSPENSION IV‘SIaH the bake hose guide and nghten the bolts \nan ma Hrlve chem case aligning the hole With me boss ofmc swingarm. ‘ngmn (he Urwe L‘Hain Lane screws securely, Inslall the rear wheel LDagC 1478:. & sgzsws 14-25 HYDRAULIC BRAKE FRONT: 1 N-m (0‘1 kgf‘m, 0.7 IM'flr 3.5 N-m (3,5 kgf-m, 25 Inf-h) 12 N-nl (1‘2 kgl-m, 9 [bl-fl) 34 N'm (3‘5 kgf‘m, 25 [bf-fl) TE N-m 11.8 kgI~m, 13 lhl-h) 30 N-m (3.1 kgf-rn, 22 ‘bf-m 15-0 15. HYDRAULIC BRAKE SERVICE INFORMATION 15-2 FRONT MASTER CYLINDER 1540 £ TROUBLESHOOTING 15-3 REAR MASTER CYLINDER 15-15 BRAKE FLUID REPLACEMENT] FRONT BRAKE CALIPER 15-19 “R “55”“; ‘5" REAR BRAKE CALIPER 15-23 BRAKE PAD/DISC 15-7 BRAKE PEDAL 1526 REAR: 9 N~m 10.9 kgf‘m, 6.5 |bf~ft> 3A N-m (3 5 kgf-m, 25 lbf-ft) 26 N-m (2.7 kgf-m, 20 Ian 34 N-m (3.5 kgf-rn,25lb1-fi) 18 NEW! (18 kgf-m,13|bf-m 23 N-m12.3 kgi-m, 13 Ibf‘fl) 15-1 HYDRAULIC BRAKE SERVICE INFORMATION GENERAL CAUTION . Flequent inhalahnn nr hrake pad dust, regardless 0! material composiiiori could be Ildzaldous to voul health - Avmd breathing dusi panicles. I - Never use an air liuse ui brush to clean brake auemhlies, Use and OSHA~approvcd vacuum cleaner, - A rnnmmmated brake dISC or pad reduces stoppinq power. DISL'dllI cuiilaminaled pads and clean a contaminared ms: with a high eualily brake diqrsasing ageiil. Check llle bxake system by applying the brake lever or pedal after the air bleeding. Spilleri hmke fluud will severely damage instrumem lenses and painied surlaces. l1 I: alsu hainn’ul to some rubber p515 Us carclul whenever you remove me reservuir cap; make 9012 the irom reservoir is hnrimmnl hm Nsver allow CuliIdlllilldleS ldin, water, ere ) tn gar me Im open reservoir. Once the hydraulic sysrem ha: been opened, or if the brake feels spongy, xha SYEIEI'I" must be bled. Always use Ircsh DOT 4 brake fluid from a sealed uulilaiiiel when saivic'ing the system Do not mix difiarflm 'ypes oi fluld they may not be compatible. A‘ways check brake ripen-non before riding the molOrCVCIC. SPECIFICATIONS __. . Umr mm [in- ITEM STANDARD SERVlCE LIMIT ‘ . rmm ‘ Specliied brake fluid DOT4 77 — ‘ Brake OISE micknes; 7 7 4 4 — 4,510.17 — 0.1737) 3.5 (0.7174) 7l‘lrake r1130 rimout77 77 7 — 7 0.2010 008) — Maéna} cylinder LU. 77 15.8707 15.913 (0 6248 — 0.6265) 77 7 15.925 (0.6270) Masreflwan (1.1). 77 15.827 15.85L10.6231 70.572743 15.78175 (0.6226) 7baiipemyunde} i 11, A '7 33.06 7 34.01 (1.337 1.339777 777 34.02 (1.333) 711 32.030 , 32,030 i1.2610 71.2630) 7 7 . 32.09 (1.263) Caliper pieten 0 D, A 7 7 33.802 , 315135113305 713321) 33,794 (1.3737051 ‘ B 77 7 7 31377 > 319107 550—12553) 7 ‘ 869 (1.2547‘1 Rear Speuhed brake IIUrd 7 7 Brake W131 1.017910 7 7 7 Brake disc mickries; 7 7 4 37— 5 2 io 19 — 0,20) —77 7 7 Brake disc runout 777 A 7' 77 777 .— n 30 (11.0121 7 Masler cylinder i.D. 7 777 10000—14043 (0 5512 41757572917 y ‘ ,, 1110550155m Master pisron 0.0. 13,957 —13.98A(0.5495 -0.55061 13 945 (0 5 9n) Caliper77cylinucr i3. 7 38.18 — 33.23 (1.053 -1.505) 7 1 33.2471 506) Caliparpision 0.0. 7 . 35.098—378.‘|48(1.4999— 5019) 3 330911500) 77- 15-2 TORQUE VALUES rrnnt masiar cylinder reservoir cap screw Brake Icvcr pivot bolt Brake lever pivol riut Front brake light switch screw Front master cylinder mounting boll Front brake calipar assembly torx bolt Flam blake Caliper mouming flange bolt Rm master Cy dar 1mm nut Rear master cy acr mounting bolt Rear brake reservuir llluulllillg bull/Hui Rear brake caliper brankni hnl' Rear brake caliper pin bolt Pad pln Pad pin plug Brake hose DII bolt Brake caliper bleeder valve TOOL Snap rinq pliers TROUBLESHOOTING Brake lever/pedal soft or spongy Air in liydlauliu system leaking hydrnllllc system Contaminated brake pad/disc Worn caliper piston seal Worn master cylinder pislnn cups Wnrn brake pad/disc Contaminaled caliper Rear caliper lIUl sliding properly Low hrnke iliiid level Clogged fluid passage Warped/deformed brake dis: StickingMorn callper pismn Sticking'worn master cylinder omen Contaminated mas‘er cylinder Bent brake lever/pedal Brake lever/pedal hard - mugged/restricted brake system - Blinkinglwnrn caliper pislcn Rear caliper not sliding properly Cluggedfresuiclrd lluid passage Worn caliper pismn seal Sticking/worn master cylinder piston Bent brake lever/pedal 2 N~m [0.2 kgl'm, ‘l A "1741) i N-m (0.1 kgl-m. 0.7 lbl‘l‘!) 6 N-irl (0.6 kgl-iri, 4.3 lbl‘fi) l N-m (01 kgf-m, 0.7 lbf'm 12 N-m (1,2 kgf'm, 9 Inf-ft) 23 NW“ (2.3 kgl-m, 17 Ibl'fl) 30 Nm‘ (3.1 kgl-m, 22 let) 18 N-m (1.8 kgi-m, 13 lbfvft) 9 N‘l'l'l (0,9 kgf-m. 6.5 lbf‘fll 12 N~nl (1,2 kgl'lli, 9 Ibl-ll) 23 N-m (2 3 kgi-m,17lhi'fll 27 N'm (2.8 kgl'm. 20 lbl-fll 18 N-rn (1.8 kgl-rn, 13 lbl'l‘l) 3 N-m (0.3 kgf-m, 7.7 Ibi-fll 34 N-m (3.5 kal-m, 25 Inf-m 6 N-rn (0.6 kgl-m, 4.3 lbf-fll NEH—SASDDM Brake dllgs HYDRAULIC BRAKE Apply a locking agent to the threads. ALOC bull. Apply a locking agent to the threads. Contaminated brake pad/disc Misaligned wheel CIDggad/restricted brake hose iolnt Warped/deformed brake disc Rear caliper not sliding properly Clogged/restricted brake hydraulic system Sliuking/wurii caliper pislorl Clngged master cylinder pnn 15-3 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING NOTICE - Do not allow forelgn mazorlal to cnrer the system when filling the reservoir. - Avoid spilling fluid on painted, plastic, or rubber parts Place a rag over these parts whenever the system is serviced. BRAKE FLUID DRAINING For me from brake, turn the handlebar unlil me reser- voir is parallel to the ground, before removing the reservoir cap. Remove (he screws and reservoir can. Hemnve the drophrngm plate and diaphragm. For the rear brake, remove the rear brake reservoir mourning bull/nut. Remove rhc reservoir cap. Remove the dlaplrragm pldle and diaphragm. SCREWS RESERVOIR CAP BOLT/N UT x5 1 ‘4 DlAPHFlAGM 15-4 Connect a bleed hose to the caliper bleed valve. Luusell the bleed valve and pump the brake lever or pedal. Stop pumping the lever or pedal when fluid stop flow- ing out ol the bleed valve. BRAKE FLUID FILLING Fill the reservnlr wnh DOT 4 brake fluid from a sealed container. ‘ NOTICE ‘ . Use only DOT A brake fluid from a sealed mnmner. - Do nnr mlx different types of fluid. rhcy are not comparib/e. Connect a commemlnlly available brake bleeder to the bleed valve. Pump the brake blesder and luuaull the bleed valve, addlng 'luid when the fluid level in lhn master cylin- der reservoir is low. . Check the fluid level often while bleeding the brakes to prevenl am from being pumped Into the system. ' When using a brake bleedlng tool. follow the manA ulaclurer's operating instructions. Repeal the previous step procedures untll air bubbles do not appear in the plastic lluse. If air is entering the blocacr from around the bleed valve threads, seal the threads with teflun tape. ll a brake bleeder is not available, fill the master cylinder and operate the brake lever or pedal to fill the svstem. Close the. bleed valve. Next. perform the brake bleeding procedure. HYDRAULIC BRAKE l‘il FED VALVE BLEED HOSE BLEED VALVE BLEEli HOSE HYDRAULIC BRAKE DD not rclcacc m. ml» r». v pedal mm .‘Ea bleed tame has Ué'éfi clnset’ BRAKE BLEEDING Connect a clear bleed nose to the bleed valve. Pump lhe lever ur pedal until there are no ail bubbles in m. fluid flowing om oi the master cylinder, and lover or panel resistance is felt. 1.8queeze the brake lever or push the brake pedal, open the bleed valve 1/2 of a turn and then close the valve. 2.Helease the brake lever 07 pedal until the bleed valve has boon closed. nepm steps 1 and 2 until bubbles cease to appear in the fluid coming out of the bleed valve. Tighten the bleed valve. TORQUE: 6 Min [0,6 kqf-rn, £3 lbl-ftl Fill the fluid reservoir to the upper level, Reinstall the diaphragm and diaphragm plate. Install the reservoir cap, and tighten the screws to the specified torque. TORQUE: 2 NM (0.2 Itqf-m, 1.4 Ibl'fll Install the Ieservoir Cap securely, then install the reservoir onto the sear rail and tighten the mounting bolt/nut to the specified torque. TORQUE: 12 Nvm (1,2 kgl-rn, 9 [bl-fl] BLEED VALVE BLEED HOSE 15-6 HYDRAULIC BRAKE BRAKE PAD/DISC PAD PINS Aw 3 FED/536 FRONT BRAKE PAD REPLACEMENT _ at: “an n 34‘ 5 ’9 6 Lousen the pad pms “‘r’ d“ ”E“ Hemove the bolts and brake caliper. awe Push the carpal pIsmns ml the way m m anw mstal- iannn n‘ new brake pads. Remnve the pad pins‘ pad spring and brake pads. _ BRAKE pADs ' \ Clean me inside of the calipel capeCIaHv aluund (he caliper p'stons, 15-7 HVDRAULIC BRAKE lnstall the new brake pads lnstall the pad sprlng wvm lts arrow mark facing up as shown. Push the pad sprmg, than lnsrall the: pad pm 55 care-u’nol :c lnszall me brake caliper to me fork icg so that the dlsc may; we pans, ls positioned bulweau lhe pads. Install and tighten (he new brake calmer mh‘unhng bulls. TORQUE: 30 N~m (3.1 kgl-m, 22 [bl-m Tlghten the pad pins, TORQUE: 18 N-m (1.8 kgf-m,13|bf'fl) s Enrica REAR BRAKE PAD REPLACEMENT peas m .‘ma. ms- war V1\ Check me brake lluid lewl in the brake rr‘aster cyl'ln- der reservoir asvhm inrmlon causes me level [U .m. Push m: Lalipel ulsluns all the way in by pushing me caliper hndy lnwam (0 allow imallatiuu or new brake Dads. Removc lrle pad pm plug. 15-8 Loosen the pad pin. PAD PIN Remove the caliper bracket bolt Pivol me Lalipev uu "Pmnvn vhp pad mm and brake mm Make we the brake pad sprlng Is In place‘ Install me new b'ake pads Lower the cahper whHe pmhmg the pads agamsr vhe pad sonng so the pad ends arc posmoncd onm the retainer on ma caliper bracket. Inunn the, pad pm, Install and tighten th cahper bracket bot. TORQUE: 23 N-m (2.3 kgl-m, 17 Ibi-fl) Tighter the pad pin TORQUE: 18 N-m (1.8 kg!Am,13lb1~h) HYDRAULIC BRAKE 15-9 HYDRAULIC BRAKE Install and tighten the pad pm plug, TORQUE. 3 N‘m (0.3 kgI-m, 2.2 lbI-fl) BRAKE DISC INSPECTION VisuaHv inspect the brake disc for damage or cracks. Measure the herP dzsr Ymrkness with a micvomelw, SERVICE LIMITS: FRONT’ 3.5 mm [0 14 in) REAR: 4.0 mm [0.16 in) Raplane the brake dis: if the smalleu vneawrevvven: is loss than [he servrce Hmn. Measure the hmke dlsr. warpage wuh a oiaI IIIdILdIUI SERVICE LIMITS: FHDNT‘ 0,70 mm 10.008 'n) REAR: 0.30 mm "1.012 In) Check the wheel beauings Im excesswe plav, H the warpage exceeds me sen/me Ilmit. Replace the brake disc If the wheel beermgs are nnrr mal FRONT MASTER CYLINDER SEALING WASHERS OIL 50L REMOVAL 'J'am m: from hydraulic system lpaye 15-11). . D‘scuvmect the brake light ewwch wire conncc‘ors, Remove the brake hos: uIl buIl, sealing washers and brake hose eyeIet MUM we I SWITCH CON NECTORS HYDRAULIC BRAKE Remove Ma bolts 6mm (hp "miter Cylmder holder and "MASTER CYLINDER HOLDER remove the master CYIIHGCV assembly. BOL S DISASSEMBLY mam Hemnva mp. pwnt now/mm and brake Icvcr asscmmv. BRAKE LEVER \‘IVUI NU‘ Remove {he screw and brake fight switch SCREW BRAKE L‘GHT SWITCH fiemnve the boot. BOOT 15-11 HYDRAU LIC BRAKE Remove the snap rung from the master cylmder hndy SNAP RING SNAP RING mmg using the speciaI tool as shown‘ TOOL: Snap ring pliers 0791475A50000 \, Remove the mastev pIsloH and spring MASTER PISTON MASTER CVLINDER clean the Inswdc of [he cyllnder and Veservmr with b: ake Hun]. PISTON CUPS SPRING INSPECTION Check me pxston boot, nrlmary cup and secondary cup forfatigue or damage. Check the master cyIder and piston Ior abnormal fl scratches‘ Measure the master cylinder LD‘ SERVICE LIMIT: 15 925 mm (0.6270 inl Manure the master chinder pwswn O.D. SERVICE LIMIT: 15.815 mm [0.6226 in) \~ 15-12 HYDRAULIC BRAKE ASSEMBLY 2 N‘m [0.2 kgi-m, 1‘4 Im-m RESERVOIR CAP D|APHHAGM § 9 ’W, MASTER CYLINDER MASTER P‘STON SNAP RING 1 N-III (0.1 kgf-In, 0.7 lell 6 N‘m {0.6 kgf-rn, 4.3 lbf-m 1 N-m (0.1 kgl-m, 0.7 WM!) BRAKE LIGHT SWITCH (set; we 03mm (inav all nuns wxm mean brake. fluid ha'nre assembly. A» 4‘ my, Mm, ma a'u mm as a 5st, 0 my: 541:5!“ my 'AumrULa’ Dan: M :4 ”bluffwg Dip the pismn in brake fluid, ”m can an F0: Insmtl the sprung Into the piston ‘ 5"” "'9 ”55 3‘7 Instafl the piston assembly inxo the masier cylinder. , :u: ‘ MASTER PISTON MASTER CYLINDER 1 ml? um R G g Emsmwcups SPRING 5g mm m Install me snap ring. snap "r7315 fr'mw seamd 'n rhfi TOOL: 9501/5 5n“, rlng pllers 0791+SA50000 SNAP RING SNAP RING PLIERS 15-13 HYDRAULIC BRAKE lnstall (he DUOL lnstall me brake Ilgm swltch and (lgmen the screw m SCREW me specified torque. BRAKE LIGHT SWITCH TORQUE: ‘I N-m [0,1 kM-m, 0.7 IM-fll Apply :l‘iuurle grease to We cunlacl surlaces of (he hrfil’P Imm- and mum [In lnsmll the brake lever assembly, ngmpn the plvm hnll lo :he specified (Olque. TORQUE 1 N-m (fl 1 kgfvm, O 7 IM-fi) Hold the pivol bell and llqhten me plvcl nm (0 :we sthified torque TORQUE: 6 N-m (0‘6 kgV-m, 4.3 lbl-fl) BRAKE LEVER PlVOT NUT 15-14 Place the master cylinder assembly on the handlebar. Align the and Oi the master cylinder with the punch mark on the handlebar Install the master cylinder holder with the “UP" mark lacing up. Tighten in; upper holi hrsi, than me lower mm m ins specified torque, TORQUE 12 N-m (1.2 kgf-m, 9 lM-ftl Install the brake hose eyelet Willi llie uil bull and new sealing washer; Push the eyelet lomt against the stopper, then tighten the oil bolt to the specified torque TORQUE: 34 N-m (3.5 kql-m. 25 lbf-ftl Counsel the brake light switcli wile connectors. Fill the reservoir to the upper level and bleed the brake system (page 15~4l. REAR MASTER CYLINDER fit/oi: Swill": he 0' as men p‘aéil. Hi .iiue Laws “are a '5: over these parts REMOVAL Drain the rear hydraulic system (page 15-i). Remnve "1E brake light swncn Wire clamp, Disconnect the brake light switch 2P lBlackl connao tor, Remove the rear master cylinder reservoir mounting bolt/nut. Remove the brake hose oil bolt. sealing washers and brake liu>e, Loosen the rear master cylinder mounting bolts, Remove ilie rider loutpeg biacket socket bolts and driver fnntpeg hrnnket assembly. HYDRAULIC BRAKE MASTER CVLINDER HOLbER “UP" MARK BOLTS E? SEALING WASHtHS 01L sou l v _ , SWITCH CONNECTORS BOLT/NUT RESERVOlR t SEALING 4 WASHERS V FUD ll’HS BHACKEI , HYDRAULIC BRAKE Remove and discard the. brake pedal joint cotter pin. Remove the joint pin. Remove the master cyUnder mourning bolts, step guard and master cylinder. DISASSEMBLV Remove me screw and reservoir hose 10m! from me maflev cvlirrdw. Remove the hem. Rmnuve the snap ring from the master cylinder body usmg me spec-5‘ moi as shown. TOOL: Snap ring pliers 0791 #6150000 Remove the push rod, master prston, prrmary cup and spring Clean me inaidc o! the cv‘inder wrth make Hmd BOOT SPRING .37; MASTER PISTON SCREW SNAP RING SNAP RING PLIERS PHIMAHY CUP S/tLDNDAHY CUP Q‘K, § PUSH ROD ASSEMBLY 15-16 HYDRAULIC BRAKE INSPECTION Check the pislun buul, primary cup and secondary cup for Inllgun or damage Check me master CYIlnder and pman for abnormal sclalclles‘ Measure the master cylinder LD, SERVICE LIMIT: 14.065 mm [0.5533 in) Measure the mastercyllnder piston 0.0 SERVICE LIMIT: 13.945 mm (0.5490 In] ASSEMBLY RESERVOIR JOINT RESERVOIR CAP g OrHINU @/ MASTER CYLINDER DIAPHRAGM PL ATE E SPRING\ PRIMARY CUP a MASTER PISTON i a 6 @ SECONDARY _ V CUP /1€:’j’ SNAP RING (a BOOT LOWER JOINT v DIAPHRAGM 1a N-m (1.8 kgbm, 13 lbI-fll Keep me prsron Coat all parts wnh clean brake fluid hefnre assembly CuCS sp'vng snap SPRING d PRIMARY cup llvugrdLmUIege a 8 59:: {16 "C! subsu SECONDARY CUP Me Mammal ,L: 1, WW, rrsrallmg Dlp mg pismn m brake Hum, 4‘. ,1 “9 cum (in am Install (he spring onto me primary cup. IllslaII [he sprinngrirnary cup and masxer pislon 8‘ , , I‘m/1 [Hilda 0L4! assemhly ’ Apply slliconc grease to the plsmn contact area onhe push rad. MASTER PlSTON PUSH ROD ASSEMBLY 15-17 HYDRAULIC BRAKE Ba ca’ta'n my amp Wig ‘5 WWW Séarsa‘ if m» Worm: Insrali me push rod into me master cylinder Insiall the wrap mug, TOOL: Snap ring plills 0791LSA50000 Install the boot Apply brake limrl vn a new U-rlng and Install n nmn rhc rcscrvoir joint. Install the reservoir iuini inlu me masler cylinder. Auplv a locking agent In the reservoir joint screw threads Install and tighten the screw securely. If the push rod is disassembIed. adjust the push rod length as shown After adiustmenr, righren the lock nut to the specified torque, TORQUE: 18 MM [1,8 kgI-m, l3 IMAM fi BOOT SNAP RING SNAP RING F‘l II'RS RESERVOIR JOINT RESERVOIR JOINT LOCK NUT LOWER JOINT \lfl 100 mm (33 im 15-18 FRONT BRAKE CALIPER woo 5a in»; 4m n’ mm”, DVES'lL‘ or NUDE! :cr»: utccearag m1? {HE/5t (41".: ‘t'y ’lE’leVé‘f [“9 : me 5g HYDRAULIC BRAKE INSTALLATION Place the mastel :ylindet ulllu the main footpeg bracket, install the step guard and master cvlindel mounting belts. CnnnPct the bake pedal to the push rod Iowel iuint. Install the 10m! pin and secure it With a new mm" pm. Install the rldcr footpog bracket onto the frame, tight- en the socket bolts to the specified torque. TORQUE: 26 MM [2.7 kql-m, 20 |b1~m Tighten the Illusler Lylillder mounting bulls [U the specified 'mqll! TORQUE: 9 N-m [0.3 kgf-m, 55 lbl-fl) Install the brake hose thh the ct! bolt and new seal- ing washers. Pull the eyelet joint against the stoppEl, tlmt tighten 0hr. nll halt to the snemnm tomuz. FOOTPEG BRACKET _ — TORQUE: 3A N-m (3.5 kglnm, 25 lbl-ftl “GIT/NUT Install and tlghten the brake reservoir mounting bolt/nut to the specified torque. TORQUE: 12 N-m (1.2 kal'm, 5| Ibfthl Connect \he brake light >wilch 2P (Blackl culllleclur. Secure the brake light swnrh wtre With a erF niamp Fill the rasarvoir to the upper level and bleed the brake system (page 15-4) t‘z; BRAKE UGHT SWITCH CONNECTOR ééitlm REMOVAL Drain the front brake hydraulic system (page 15-4l. Remove the oil bolt, scaling washers and brake hnse eyelet icint. Remove the caliper mounting bolts, calipei and the ‘ brake pads (page 1576). l BRAKE CALIPEH 15-19 HYDRAULIC BRAKE DISASSEMBLY Inslall uunugalvd cardbuard or a sheet of soft wood between the pistons. La my :43: mgn Apply small squins at air pressure to the fluid inlet to nnzww am remove the pistons, on“; the nozzle 'DC 51052 YD t"C mgr Remove the four caliper assembly bolts and separate nu.- caliper Nah/2L ASSEMBLY BOLTS fiemnve (hp {ollnwmg- JON“ scars - Caliper pismn A — Cah'per piston a CALIPE H PISTONS JOINT SFAI 5n : ’3‘13’70315 Push (no dust seals and piston sea‘s m and Ixft them out, PISTON SEAL Clean the seal grooves thh c‘ean brake fluid. DUST SEAL 15-20 HYDRAULIC BRAKE INSPECTION check the caIipcr cylinder Ior scoring or other damage. Measure the canper cylinder LD. SERVICE LIMITS: A: 34.02 mm 11.335il1) B: 32.09 mm (L263 in) Check the caliper pistons fol scratches. sccuing or omnr damage. Measure the caliper pislull OIDV SERVICE LIMITS: A: 33.794 mm (13305 ill) 5‘ 31 869 mm (1.2547 in) \ ASSEMBLY CALIFER PISTON E 5 N-m (0 S kgI-rrl, 4.3 Ibf‘R) SI? CALIF’ER PISTON A @m DUST SEAL PISTON SEAL 23 N-m (2.3 kgI'm,17IbI'Ill JOINI SEAL HYDRAUUC BRAKE Coal me new piston seals with clean brake fluid. Coal me new duel seals wirh silicone grease, Install the [vslnn and dust seals mm me gmnves in the caliper body. Coal the caliper plstons wurh clean brake fluid anrl lnStall them Into the caliper cylindcr Wlth their opcn ends toward me Dad. install the new lulm seal inlu the fluid passage on caline' Assemble me Caliper halves. Apply a locking agent [0 the caliper assembly bolt threads lnsrall and lighten rhe calmer assembly halts to the specified roruuc. TORQUE' 23 N-m (2.3 kgl-m, 17 Ihl-fl) INSTALLATION install me brake pads and caliper saw me fork leg (page 15-5.. Insrall and tighten the new caliper mounrlng bolts to the >peuilled torque. TORQUE: 30 N-m (3.1 kgl-m. 22 lbl-ftl Install the brake hose eyelet 10 lhe caliper body willl two new sealing washers and Oil boll. CALIPER a PISTON V m DUSTSEAL L‘ALII’LH PIS 'l ()NS JOlNT SEAL ~4 BOLTS ' ERAKECALIPER 15-22 REAR BRAKE CALIPER ,Imra sat/ma Illm or {willed c t HALL)!” 5x750 a '99 HYDRAULIC BRAKE Push the brake hose eyelet to the stopper on the l caliper. then tighten the oil bolt to the specified EYELET JOINT STOPPER lurque. - TORQUE: 34 NW“ (3.5 kgl~m. 25 IM-fl) Fill and bleed the front brake hydraullc :ys‘em (page 'IErA]. REMOVAL Drain the rear hrake hydrnuhc system (page 15m Remove the oil bolt, sealing washers and brake lluse eyelet joint. Remove the caliper bracket bolt and the brake pads (page 153). Pivot the caliper up and remnve ll DISASSEMBLY (ZULLAH BOOT Remove the pad wring. collar and boot lrom the wipe. body. PAD SPRING 15-23 HYDRAULIC BRAKE Du ”u Ugy r iyli oresrws aw 0! may me moms, w uvae it, me ,n I: :6 carem/ net to many? if DiSISH sham .= mm Place a shop iowel over the vision. Posiiioll the calipei body willl lIle pislurl down and apply small squms at Air pressure in the fluid inlet to remove the piston. Push my. must seal and nistnn seal in and lift them our. PlSTDN SEAL Clean the seal grooves wim clean brake fluid. DUST SEAL INSPECTION Check me caliper cyiindcr Ior scoring or other damagz. Measure ihc caliper cylinder LUV SERVICE LIMIT: 332‘ llllll (1.506 in) Chsck the Caiipel pisions Iur :cralches, scoring or other damage. Measure the caliper pisiuii an. SERVICE LIMIT: 38,09 mm [1500 in) 15—24 HYDRAULIC BRAKE ASSEMBLY 5 N.m (0,6 Irgf-m, 15,3 lbl-fil v a PISTON SEAL CALIPER PISTON DUST SEAL PAD SPRING 27 N‘m I23 kgf-m, ZO Inf-hi Cual ll}: new piston seal with clean brake fluid . . D T SEAL Coat (he nnw dust seal wrlh silicone grouse. 0* & US lnsrall the piston seal and dust seal into the groove of the caliper body Coat [he caliper pislun with than Luck: fluid and install it into the Caliper cylinder wrm IYS open end /// toward the pad. 9: E g M PISTON SEAL CALIPEH PISTON Install rhc pad spring into the caliper body. BOOT If the Caliper and bracket pin buuls are hard or Malari- Grated, replace them With nPw nnsw i \ Apply silicone grease to the inside cl the bracket pin ' COLLAR boot Install the breaker pin boot and collar Into the caliper. PAD SPRING 15-25 HVDRAULIC BRAKE BRAKE PEDAL Install the pad retainer mm the bracket, - ‘ BRAKE CALIPER INSTALLATION Appbv sxllcone grease to the cahpn.’ pin and mstaH the ca‘iper onto the bracket \nstan the brake pads ([1391: 15-8) |nBRACKET BOLT SIUHI’tH REMOVAL Remove the main footpcg bracket mounting bots and bratkel aasembly from the \ower brackett Remove and discard the brake pedal ,nmt mner pm CUTTER PIN SNAP RING Remove the ioint pm. BRAK, PEDAL Unhook the return spnng and remnve the hraxe fight switch from the step homer. Unhook the brake pedal velum springt Remove the snag ring, thrust washer, and wave washv er Remove the brake pedal From the pivot 15-26 HYDRAULIC BRAKE INSTALLATION 9 N-m (0.9 kgf—m, 6 5 mm» SNAP MNG WAVE WASHER THRUST WASHER 20 N-m (7‘7 kghm, BRAKE PEDAL 20 "DH“ RIDER FOOTPEG BRACKET Appiy grease to (he si-dung surface of the brake pedal and mnmegi 'fii Instail the brake pedai, wave wahhrl and Khrus! washv er in the pedal pivot ‘ ’ WAVE WASHER {-3 9 ’3‘ . ' THRUST -’ z , ' WASH}! / BRAKE PEDAL Secure the pcdai pivox with a snap ring. i COTTER PIN SNAP RiNG " BRAKE F‘FDAL Hook the brake ppdal return sprlngi |nstall me brake Iigm switch and hook the switch spring. Connect the brake pedal to fhp push rod iower jomL Install the Join! pin and secure it with a new sonar pin. , 1 ' ‘r: , ~ . SWITCH §£R|NG 15-27 HVDRAULIC BRAKE M‘stall Me right nder foams: brackex assembly onm m» tramp \nsm‘l and tngmcn the ngm nderfomoeg bracket snnk- " e1 bolts to the specified torque. ’ ‘ TORQUE: 26 N-m l2.7 kgf-m, 20 lbi-M] 15-28 MEMO BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM BATTERY MAIN FUSE REGULATOR/RECTIFIER ALTERNATOR e 6F 0/0 a ‘ wuNFus: ' ‘ aArrERv ”A : ‘ a i § G 5 {a I GPBlnck v v v I n I I G R J | aseummnmscnnan ALTERNATOR 16—0 16. BATTERY/ CHARGING SYSTEM SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING BATTERV SERVICE INFORMATION G ENERAL 16-0 16-1 16-3 16-5 CHARGING SYSTEM INSPECTION 16—7 ALTERNATOR CHARGING COIL REG ULATOR/RECTIFIER A WARNING 16—8 16—9 The battery gives ofl explosive gases; Keep apalka, flames and Ligarettes away. Provide adequate ventilation when charging. The ha'rpry nnmmns snlturic acid lelectrolvtel. Contact With skin or eyes may causc severe burns. Wcar protective clothing and a fact: shield. — ll electrolyte gets on your skill, flush with water » ll eleLiIuIyte gels in your eyes flush wtth waver tor a: least 15 mmutes and call u physrctan Immediately. flertrnlyte rs nmsnnnus. » if swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a pllyaici‘dll } mmed'ately. Always turn or! 'he ignmnn swrtch before disconnecting any electrical component. Some electrical components may be damaged if terminals or connectors are connected ur dieuunneeted while the lg'llr :ion switch is turned to “ON" and current is present For extended storage, remove the battery, give it a hill charge, and store it in a cool, dry space, For maximum scrvicc tile charge the stored battery every two wccks. For a battery remaining in a stored motorcycle disconnect the negative battery cable from the battery terminal The maihtanance Iree battery must be replaced when it reaches (Pm and DI its Servine llle The battery can be damaged nl nvPrrhnrget‘l or lrndercharged, or of left to discharge Ior long period Those some can- mtinns rnntnhure to shortening the “life span" of the battery. Even under normal use, the performance of the battery detcriorctcs after 2—3 years. Battery voltage may recover alter batIery charging, but under heavy load, battery voltage wlll drnn ally die out For this reason, me nhargmg system l5 drten suspected as the problem. Battery overcharge often results r—nrr nrnhlpms m the battery itself, which may appearto be an overcharging symptom. If one ofths battery Cells is :IIUYI- ed and battery vultage does not increase, the regulalUr/reclilier :upleea exueaa vullage to the battery Under these conr Cltlons, the alsctro‘yte lEVEI Que: down quickly quleIV and evenluV Before troubleshooting the Charging :ysrem, check for proper use and maintenance of the battery. Check if the battery .< trenuen‘ly under heavy load, such as naying V18 headlight and taillight on for long periods of time withdut riding the moto'cycle. 16—1 BATTERY/CHARGING SVSTEM . Ihe battery wm self-discharge when the motorcycle is not in use For thrs reason, charge the battery every 2 weeks to pre— vent sulfation from occurring, - When checking lIIe charging system, always follow the steps in the troubleshooting flow chav1(page 16-3). - For hanery nhargrng, no not exceed the ehergtng current and trme specified on the nettery Use of excesmve current or chargmg turn: may damage the battery. BATTERV TESTING Refer to the rnstructron of the Operation Manual for the recommended battery testert The recommended battery tester puts a flood" on the battery so that the aema‘ battery eonditlon of the load can be measured. Recommended battery tester BM210-AH IU.S.A. only]. BM-ZIO or BATTERY MATE or equivalent SPECIFICATIONS ITEM SPECIFICATIONS ‘ Battery Capacity ”7 12v 5,6 Ah fitment leakage 7" I 2.0 mA max‘ we; (ZO’C/EB'F) FuIly charged 13.u—_13.2 v Needs charging '77 7 Below 12.3 V Charging currem Normal 0 9 N5 -10 h Quick # 4.5 AIKS h Alternator Capacity W" 0.433 kW/5.065 rpm ' "Eh ginfifiresistanceIEE/‘fir V 0,1 — 1.0 n 1 6-2 TROUBLESHOOTING BATTERV IS DAMAGED 0R WEAK Remove the banerv (page 16-5lr Check the battery condition using the recom- mended battaryveqer RECOMMENDED BATTERY TESTER: BM-2‘lO or BATTERY MATE or equivalent Correct install the battery (page 16-5), Check the battery current leakage (leak test; page 15-7t Correct ____L___% l Chenk the alternator charging coil lpage terat STANDARD: 0,1 - LO .0 (2012/68?) Correul r___.__Y__7 Measure and recnrd the batterv voltage using a dlgitalmultimcwrtpage1675l. Start the Engine. Measure the charglng vnltage [page 1673). Compare the measurement to result of the fol- lowing calculation. Measured battery voltage < Measured charg- ing voltage < 15.5 v l 1 STANDARD: lncorrect BATTERV/CHARGING SYSTEM Incorrect 7,,7A~A—> - Faulty battery. 7 '0,9‘1!".e£‘_ W, Dlsconnect the regulaton‘rsctllier connector and recheck the battery current leakage. l Correct Incorrect r V l - shorted wire harness. - Faulty ignition switch. w- . Faultylegulatou’lectlfiet: Incnrranr . > - Faulty charqlng corl. ”we” ,> - Faulty battery, 16-3 BATTERY/CHARGING SYSTEM —_L.._— Check the vaItage and resustance a: the rcgula '"W'm‘ . Open aim,“ m related Mm [or/rectifier connector mass 169). - Loose 0v pom cumam of velaied levminalv - Shoned wire harness‘ Correc: —__¥ A Mdga - Fatu regulmon‘reclifier. 16-4 BATTERY Always run me gm «rcr rs ’5' tie/ore rerrow'ia the nermw Cur-no“ rm: now me zem‘ma' first and men we nea- ar‘ve Law: REMOVAL/INSTALLATION Remove the ECM (page S-BSI Open the battery case cover by releasing the two lonkv Ing clips. Disconnect the negative cable and men the positive cable, and remove the battery. Install thc battery in the reverse order of removal with the proper wiring as shown. After installing the battery, coat the terminals with clean grease. VOLTAGE INSPECTION Measure the battery voltage using a di tal multime- tar. VOLTAGE: Fully charged: 13,!) - 131V Under charged: Below 113V TOOL: Dlgllll mummm Commercially available BATTERY TESTING Always clear the work area 0! flammable materrals such as gasoline, brake lluid, electrolyte, or cloth row- els when operating the tester. The heat generated by (he rester may cause a we. Remove the battery (see above), Securely connect the testers positive (ll cable first, then connect the negative l—l cable. TOOL: Battery tester BM-ZIO—AH (USA, only), BM210 or BATTERV MATE nr equivalent BATTERY/CHARGING SYSTEM CASE COVER POSITIVE TERMINAI BATTERY BATTERY/CHARGING SYSTEM Fm amvam easy resulrs be sure the taste": cables and damp: mg m aooa work/n9 mrvdlllnr nn‘} may a sen/re con/lace Inn (27'. ac made a.» rre barrely #0! me IVS! ‘k, 00 NOT charge 5 DBHCW Dela/a mung lESl l! J!) an ‘35 '3' CDI'dJ!lal’l Sel llle lemperalure swilch 10 ”HIGH" or "LOW" dapenrllng on the. nmhlem lemperamre Push In the appropriate lest button for 3 seconds and read the condition of the battery on the meter. To avoid damaging the lesler. only lest ballerles wirh an nmparagn rating or less than 30 Ah Tester damage can rcsull from overheating when: » The last button is pushed in for more than 3 sec- onds. A The tes1er ls used Wlthout belng allowed m nnnl for at least 1 minute when resting more than one bar lery. - Morn than 10 CnnsanllYlVe Iests are performed with our allowing a: lens! a 30 minure cool-down panels. The result afa (as! on the mere: scale is lelalive lo the amp. hour rntlng om; battery. ANV BATFERYREAD» lNG IN THE GREEN ZONE lS 0K. Eaneries should only be charged ll they reglsler in me vELLow or RED Inna BATI'ERY CHARGING Remove the banery (page 16-5], Clean the bauery Ierllllllals and position lhs battery as m away lmm mp. nharger as the leads will permit. Du not place baneries below the chargerflases tram the hafiery may corrode and damage the charger. Do not nlace barreries on top of the charger. Be sure the air vans are not blocked. HIGH: 15 VC (60 'F) or higher LOW: 15 ’C 50 'F) or lower TEST BUTTONS E©©00066 VELLOW 1-1) RED 1—3, —2) O GREEN (~1, *2, +3) 1 6-6 BA'ITERY/CHARGING SYSTEM T00 —’ ' Christie battery charger MC1012/Z (USA. only) BA‘I'I'ERV AMP HR. SELECTOR SWITCH 1. Turn the Power Switch to the on position 2. Set the battery Amp. Hr. Selector Switch Ior the size 5'5 ‘° 1° 01 the battery being charged. 15 In 5-0 9.5 to 16,0 3. Sel lhe T‘llllel to the positiun indicated by the Honda Battery Tester; RFD—3, RED-2, or YELLOW 1 if you are charging a new battery, set the switch to the NEW BATT position. LAtlach the clamps to the battery termtnals: RED to Positive, BLACK to Negative. 0m 0:. 1651.030 Set the appropriate amp. hnllr rating. Collilecl the battery cables only when the Power Switch is OFI’ 5. Turn the Power SWItch to the ON pus' 'olt. Tneci‘ta‘gel » ll 6. When the timer reaches the 'Trickle" position, the TIMER showman nharglng cycle is complete. Turn the Power Switch Trickle ’ “9 OFF and disconnect the clamps. NEW BATT ”‘3“ 7. Let the battery uuul tut at least in minutes or until "Muff ”15:: gassing subsides utter charging. htu ‘ “ ' Emma H. Reset the battery usmg the Honda Battery Teeter and recharge if necessary using the above slepst + YELLOW CHARGING SYSTEM INSPECTION ‘ AMMETEH CURRENT LEAKAGE INSPECTION " ' Turn the igllitiun switch ott and disconnect the nega- tive battery cable tmm the battery. Connect the ammctcr [ll probe to the ground cable and the ammater 1—) probe lo the battery (—i terminal. With the ignition switch on, check for current leakage, - When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester. While measuring current, do nol tutti the igrtiliull on A sudden surge or current may blow out the (use in the tester, SPECIFIED CURREN‘I LEAKAGE: 2.0 mA max. It current leakage exceeds the specified value, a short- ed circuit is likely. anate the short by disconnecting cannectlons one by one and measuring the current. 16-7 BATTERY/CHARGING SYSTEM 50 no: arsconnscr Ma canary cr anv raw u: me (narg. rno sysrsm mm our msr swrrmmg off me ryvnllor- 5mm Farm". 1 How we precauner cm damagc tn: ‘nsrw 0' ole—r'w?’ comments CHARGING VOLTAGE INSPECTION Be sure the battery is in good condilion befole per- forming this last Warm up the engine [0 normal operatinq temperature. Stop the engine and connect the multimeter as shown. - Tu prevent a shall, make absolutely certain which are mp, pnsnivs and negalive terminals nr cable Restart the engine. With the headlight turned to the high beam position. measure the voltage on the mummeter when the engine runs at 5,000 rpm. Standard: Measurnd battery voltage (page 16-5) < Measured charging voltage lsee abovel < 155 V at 5,000 rpm ALTERNATOR CHARGING COIL /! -5 n5! macs 'y m remu. m,» srarz. can :a make mm ’M' INSPECTION Remuve the left lower cowl (page 2-4). Disconnect the alternator 3P (White) connemnr. Check the resistance between all three Yellow termlr nale. STANDARD: 0.1 ~10 n [at 20‘0/68‘Fl Chenk lor continuity between all three Yellow tenni- nals and Ground. There shculd be no COMIHUITV. If readtngs are far beyond the standard, or If any wire has continuity to ground, replace the alternator stator. Reler lu eccliun 10 luv slalur removal, BATTERY "5F (WHITE) CONNECTOR 16-8 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER fil’ lELACK) CONNECTOR SYSTEM INSPECTION Remove the rear cowl (page 2-2). Disconnect the regulatorlrectilier connectors. and check it for loose contact or corroded terminals. 3? (WHITE) CEDNNECTOH It the regulated voltage readlng (see page 16-6) is oul 6? (BLACK) CONNECTOR of the specification, measure the voltage between connector terminals lwrre harness srdel as follows: llem l Terminal Specuhcatlon Eanerv l Red/White 14») r nutter-y voltage charging l and should register lrne ground (—) Charglng coil l Yellow and 0.1 - 1.0 (1 line 1 Yellow (at 20"C/58'F) Ground lirre Green and (Inntrnultv ground should exist tf all components or the changing system are normal and there are no loose nnnnentrons at the regulator/rec tifier mnneclors, replace the regulator/rectifier unit. REMOVAL/INSTALLATION Disconnect the alternator 3P (Whltel connector. Disconnect the alternator 8? (Black) connector Remove the ragulatutr‘lectifier unit mounting bolts, . regulatnr/remrlrer and plate. Install the regulator/rectifier unit in the reverse order of removal IGNITION SVSTEM SYSTEM DIAGRAM I'NGINI' STOP SWITCH IGNITION SWITCH 'IHHOTILE SENSUI'I BATTERY MAIN FUSE FUSE BOX ENGINE STOP RELAY DIRECT IGNITION COIL CAM PULSE GENERATOR SPARK l‘l UGS IGNITION PULSE GENERATOR NEUTRAL SWITCH SIDI: S IAND SWITCH Tat-mu I "46:47st I m lust-mm 1 um I. Wt m "M an E an; "mums.— ‘JF, '- “5 ‘fihhpnhuim v", ”(non-u «WW I I... . ‘ 4 I-N—————4—-I—u\u—.I—o_mwa M m\ mruscm U ansm mm ‘- Iv/w 1 . W m. T m I “in, LL ‘ 4 ~ AerI I a m. MIMI r. M.“ — unmuu mm emu-m: ’ ‘ u u n mm m cm. I; a... m w. v u... u cum 17-0 17. IGNITION SYSTEM l ‘ SYSTEM DIAGRAM 17-0 IGNITION SYSTEM INSPECTION 17-4 SERVICE INFORMATION 17-1 IGNITION PULSE GENERATOR 17-6 TROUBLESHOOTING 17-3 IGNITION TIMING 17-8 SERVICE INFORMATION GENERAL Some electrical components may be damaged ii terminals or connectors are connected or disconnected while the inn» tion switch IS turned to “ON" and current is present When servicing the ignition system, always follow the steps in the troubleshooting sequence on page i7-3. This mntnmycle’s ignition Control Module tchl is built into the Engine Control Module (RM. The ignition timing does not normally need to be adjusted since the ECM is factory preset The ECM may be damaged it dropped. Aisn it the connector I: diaconnected when current 15 flowmg. the excessive volt- age may damage the module. Always turn otithc ignition switch before servicing. A faulty ignition system is often related to poor connections, Clreckthose connections before proceeding, Make sum the battery is adequately charged. Using the starter motnr With a weak battery results in a slower engine cranking speed as well as no spark at the spark plug Use spark plug of the correct hcat range. Using spark plug with an incorrect heat range can damage the engine The direct ignition coil that the ignition coil and spark plug cap are tntegrated, is adopted in this motorcycle. Refer to section 5 lot Throttle Positron lTF‘) sansnr, cam pulse generator and ECM inspection. SPECIFICATIONS ‘ ITEM SPECIFICATIONS Sparkblug (lrldlitm) I NGK - lMRSA-QH DENSO wimp ' ' ’ Spunk piugggi; T I 70.80 - 0.90 mm (0.031 —0.035 in) __ 1 Ignition coil peéfioitage "7 ‘ ' ‘iOO v minimum ' ilgnition pulse gettelalot peak voltage 0.7 V minimum Ignition timing (”F" mark) I 13' BTDC a! in} 17-1 IGNITION SYSTEM TORQUE VALUES Tlm‘ng hols mp 18 N-rn 4.1.8 kgfvm, 13 lbl-(lI Apply grease to (he mreads. Spark plug 12 N-m [1,2 kghm, 9 lhi-m lgninun nulsa generate! rotor special bOIl 59 N-m (6.0 kgf‘m, £3 Inf-It] TOOLS Peak vollage testev (USA. on‘y) or Peak vukage ndapmr O7HGJ-0020100 (Nul available in U,S.A.I with cammercmtly avaAhIe dwgita‘ multimetev (impedame 10 Mflr‘DCV mini- mum) 17-2 TROUBLESHOOTING Inspect the following hetnre diagnosing the system. - Faulty spark plug Loose spark plug cap or spark plug wire connection IGNITION SYSTEM - Water got into the direct ignition mrl (leaking the ignition coil secondary voltage) If there is no spark at either cylinder. temporarily exchange the direct ignition coil with the a known-good one and periorm the spark test. If there is spark. the exchanged direct ignition coil is faulty. ”Initial voltaqe" ol the ignition primary coil is the battery voltage With the ignition switch turned to “ON" and the engine slop switch turned on (the engine I: not cranked by the starter motor). No spark at all plug: Unusual ccndltlon Probable cause (Check In numerical order) Ignillnn cnrl No initial voltage with Ignition and 1. Faulty engine stop switch primary engine stop switches turned on iother 2. All open ‘ '1 ill Black/White wire between the rlirerrt ' voltage electrical components are normal), Ignition coil and engine stop switch. 3. Loose or poor connect of the direct Ignition coil primary wire term-rial, or an open circuit in primary coil [check at the ECM connenor). A. Faulty ECM (in case when the initial voltage is normal while disconnecting ECM connector) Initial voltage is normal. but it drops 1. incorrect peak voltage adaptor connections. down to 2 e A v while (ranking the 1 2. Undercharged cattery. engine, 3, No voltage between the Black/White Hi and body grnnnrl ‘i-) at the ECM mum-connector or loosen ECM connection. 4. An open circuit or loose connection in Green wire. 5. An open circuit or loose connection in Blue/Black, Vellow/Whitc, Red/Blue and Reel/Yellow wires between ' the direct ignition coil: and ECM. l 6. Short circuit in ignition primary r. 7. Faulty side stand switch or neutral switch. a. An open clrcult or loose connection in No.7 related cir- cuit wires. . Side stand switrh line: GreenNVhile wire 1 . Neutral switch lln Light Green wire ‘ 9. Faulty ignition pulse generator (measure the peak volt- ago). i ID. Faulty ECM (in case when above No. 1- 9 are nurmaI). Initial voltage is normal, but no peak i l. Faulty peak voltage adaptor connections. voltage while cranking the engine. 2, faulty peak voltage adapter. 3. Faulty ECM (in c when above No.1. 2 are normal). initial voltage is normal, but peak volt— 1 The multimeter mpedance is too Io . below 10 age is lower than standard value. Mn/DCV. 2. Crankirlg speed is too low (battery underchargedi. 3, The sampling tlmlng ot the tester and measured pulse were not synchronised (system is normal it measured . voltage is over the standard voltage at least once). i 4. Faully ECM (in case when above No 1 3 are normal). initial and peak voltage are normal. but i 1. Faulty spark plug or leaking gnrtian c I secondary cure ‘ does not snark . rent ampere. 2. Faulty ignition coil (5). ignition pulse Peak voltage is lower than standard 1 ‘l. The multimeter impedance is too low: helnw 'lD generator i value. MILIDCV. i Z. Crankrng speed is loo low (battery undercharged). i l 3 The sampling timing of the tester and measured pulse i ‘ were not synchronised lsystam ls normal it measured . voltage is over the standard voltage at least once), i 4. Faulty ECM (in case when above No.1- 3 are normal) No peak voltage. 1. Faulty peak voltage adaptor. i 2. Faulty ignition pulse generator. 17-3 IGNITION SYS‘IEM IGNITION SYSTEM INSPECTION If there Is no spark at any plug, check all connec- tions for louse or poor contact before measuring each peak voltage Use the recommended digital multimeter nr mm- mercially available digital multimeter with an impedance of ’ID MQJDCV minimum, The display value. timers depending upon the Intel- nal impedance of thc multimeter. lithe peak voltage tester iU.S.A. only) is used, iolr low the manufacturer’s instruction. Connect the peak voltage taster or peak voltage adap- tor tn the digital multimeter. TOOLS: Peak voltage tester IU.S.At onlvi or Peak voitlae adaptor 07HGJ—0020100 Inot available in USA) with commercially available digital multimeter iimpedance 10 MQ/DCV minimum) IGNITION COIL PRIMARY PEAK VOLT- AGE Check all system connections before inspection. If the syeteni is disconnecred, incorreCt peak voltage might be measured, Chock cylinder compressinn and check that the spark plugs are installed corrective Disconnect the dilem‘ ignition coils from the spark plugs (page in Connect the direct ignition coil 2P connectors to the direct ignition coil. Shiii the transmission into ncutraIt Connect known-good spark plugs to the direct igni tion can: and ground the spark plugs to the cylinder head as done in the spark tcst. DIGITAL MULTIMETER PEAK VOLTAGE ADAPTOR KNOWN-GOOD SPARK PLUG 17-4 mu «m pl _ and lsslar moves {0 Die Vent 210’“ 5 “ram with the ignninn cml sub-harness 9P (Elam connec- tor connected, connect the peak voltage adapter or peak voltage Iester to [he 9P (Black) culmeutur prima- ry wire terminal and ground CONNECTION: No.1 coil: Blue/Black terminal (o) - Body ground (-1 No.2 coil: Vollnw/White torminal (o) — Body ground I—) No.3 coil: Red/Bluo terminal (a) — Body ground (-I No.4 coll: Red/Vallow tarminal to) - Body ground (-1 Turn the ignition switch to “ON” and the engine stop switch on. Check for inltlal voltage at this time. The batterv voltage should be measured. If the initial voltage cannot be measured, check the power supply circuit (refer to the trotlhleshontlng, page 17-3). Crank the engine with Ilte starter motor and read the ignition coil prlmrlry paak voltage. PEAK VOLTAGE: 100 V minimum II the peak voltage is abnormal. chock Ior an open circult or poor connection in the Blue/Black, Vellow/Wltilu, Red/Blue and Red/Yellow wires if no defects are tmlnd In the harness. refer to the troubleshooting chart on page 17-3. IGNITION PULSE GENERATOR PEAK VOLTAGE Check all system connections beIore lnspectlorl. II the system ls disconnected. Incorrect paak voltage might be measured. Check cylinder cumptassiun and check that the spark plugs are installed nnrractly Remove the followi q: — Seat (page 2-2) A anar cowl [page Zrdl Dlsconnecl the 22F (Light gray) connector from the ECM 9P (BLACK) CONNECT OR / IGNITION SVSTEM PEAK VOLTAGE ADAPTOR 22F (LIGHT GRAY) CONNECTOR 17-5 IGNITION SYSTEM Avoid touching the ([v-rk plug< WW {3519’ DIODES f0 DWSVGF‘I 9/9637‘6 Sv‘wz‘l IGNITION Connect the peak voltage tester or peak voltage adap~ tor probes to the connector terminal of the wire harn Hess side and gluulld. TOOLS: Peak voltage taster lU.S.A‘ only) at Peak Voltage adaptor D7HGJ—00201DD (not available in U.s.A.l with commotciaIlv availabl digital multimeter [impedance 10 MQIDCV min um) CONNECTION: Yellow terminal (6) - Ground 1-) Crank the cnginc with the starter motor and read the peak voltage, PEAK VOLTAGE: 0.7 V minimum It the peak voltage measured at ECM mulli-cunneclo. is annnnnnt measure the peak voltage at the ignitinn pulse genetator connector. Dlsnnnnnct the ignition pulse generatnr ?F’ (Red) con- ncclor and connect the roster probes to the terminal lVellow and White/Yellow). in the same manner as at the ECM connector, mean sure the [leak voltage and compare it to the voltage measured at the ECM connector. ‘ II the peak voltage measured at the I:(‘ s ahnnr- mal and the one measured at the ignition pulse generator is normal, the wire harness has an open cirnlllt or loose connectlon II both peak voltages are abnormal, check each item in the troubleshooting chart. If all items are normal, the ignition pulse generator is faulty. See following step: for ignition pulse generator replanement. PULSE GENERATOR REMOVAL Remove the low?! cowl lpage Z-dl. Disconnect the ignition pulse generator 2P (Red) con neclm. PEAK VOLTAGE ADAPTOR ZZP lLlGHT GRAY) CONNECTOR 7P lREDl CONNECTOR PEAK VOLTAGE ADAPTOR 17-6 IGNITION SYSTEM Remove the right crankcase cover (page 9-3). Remove the wire grommet from the cover. Remove the bolts and ignition pulse generator. Mme vs Shirt the transmission into 61h gear and apply the rear 5 '“é'nc brake. "* rm“ Remove the ignition pulse generator tutor bull. mags mm rm“, win we WW) so My? 'Mvnml nalde' iPi’N 07725—oodoooor mew remove rho r t-m- INSTALLATION Install the ignitinn pulse generator rotor by aligning the Wide groove with the wide teeth oftha :rankshali. Apply oil to the ignition pulse generator rotor bolt threads, then install the washer and rotor bolt. :r the mom ,5 Shift the transmission into 61h gem and apply the rear our of trams, brakg 'QW‘VB "‘9 its? Tighten the ignition pulse generator rotor bolt to the warm saw (We 5 ecitied tor us. ‘l‘L’r‘i inr.‘ MGM in: D a ‘lvwlieel Vim the ri/wnecl nolacr i’D/N 077254040000}. tnen Irg’ii‘e'l rm: bo‘t ' hrlGNlTlON PULSE Ee'iieriitg ROTOR .- M., ’ ‘ ' TORQUE: 59 N-m [60 Utah", 43 “>74" IGNITION SVSTEM Install the ugn‘mnn puIse generator into the cover, Apply sealant to the Wire grommet,then1nstall II mm the groove ohhe cover, Ins‘all and tighten the IgllilIOII pulse gevrelaluv bulls. \ '1 IGNITION PULSE GENERATOR mean me right crankcase cover (page 9-17). ‘ V 2? IREDI CONNECTOR Home the. Ignlflflh pulse genetator wire propeuly, um» necx mo 2P (Rod! connector. I In See salmon 19 Ior Iollowxng components: » IgnltIOn switch — Eliglfle stop swnrh — Sinner swuch , Neutral switch — Side stand >wilnh — Clmrh swnnh SPECIFICATION F ITEM Starter motor brush Innglh STANDARD 12 fl , 13.0 (n 47 — 0.51) 6.5 (0.26) I! the current is kapl flowing through the staner motor In mm ir thIH the engine Is not cranking ovcr, the starter mom: Unil: ml (in) SERVICE LIMIT TORQUE VALUE Starter mDIUr terminal mu: 12 N-m 41.2 kgI-m,9lb1-m 18-1 ELECTRIC STARTER TROUBLESHOOTING Starter motor dais not turn - Check for hlnwn main or 5th fuses before servicingv - Make sure the battery is fully charged and in good condition Check the starter relay switch operation. Cl-ck harm You should hear the relay click when the starter swltch button i depressed. Click not heard 7 Abnormal Disconnect the starter ralav switch connector. and check the relay coil ground wire lines for continuity as stated below: ‘i. Green/Red terminal-clutch switch diode ncu tral switch line (with the transmission in neu- tral and clutch lever relensertl, 2t Green/Rad terminal/clutch switch side stand switch line (in any gear except neutral, and with the clutch lever pulled in and the side stand up). Normal Connect the starter relay swrtoh connector. With the ignition switch turned to “ON" and the starter switch pushed. measure the starter reiny voltage at the starter swttch connector (between Velluw/Red l+l and ground l-l. Battery voltage registered ___L Check the Starter relay swrtch operation Normal , Abnormal b l Nu vu tags Apply battery voltage to the starter motor direct- Iy and check the operation. Normal l V Poorly connected starter lltulur cable. Faulty starter relay switch (page 18-10), Abnormal . Faulty starter motor lpage 15-4). lnulry neutral switch (page 19/10) Faulty neutral diode Faulty clutch switch Faulty clutch/side stand diode Faulty side mnrt switch Loose or poor Contact connector Open circuit in wire harness Faulty ignition switch. Faulty starter switch. Blown our main or subvfuse. Loose or poor contact at connector Open circuit in wire harness. Loose or poor contact starter relay switch con- nectar. Faulty starter relay switch 18-2 ELECTRIC STARTER The starter motor turns when the transmission is in neutral. but does not turn with the transmission in any position except neutral, with the side stand up and the clutch level pulled in, Check the clutch switch aperstmn. Novmal Normal i J ,7 Check thc sidc stand switch. Normal Normal Start" motor turns engine slowly - Low battery voltage - Poorly connected battery lenninal cable - Poorly connected starter rrlnlnr nahle - Inulty starter motor - Poor connected battery ground cable Startar motor turns, but engine does not turn Starter motor is running backwards -Case assembled impwpeuy ATerminals connected .mnmpuly Faulty starter clutch Damaged or faulty starter drive gear Starter relay switch Tilda", but engine does not turn over - Crankshaft does not turn due to angina problems Faulty clutch switch, Faulty clutch swutcht Open ciicuit in wire harness. Loose m pnnr nnmnm cnnnactor. 18—3 ELECTRIC STARTER STARTER MOTOR HUS? REMOVAL Suppun :he v': om end of fuel tank lpagn 3-41 Drain the moment [page 6-45. Remove me mrome body (paqe 5-60), Remove we lheunosxm housing (page 6‘7) Wmh the \gnition switch turned {0 “OFF", remove the neqa‘ive cable at in: battery Define sew/icing (he staner motorv Remove the um and the starter motor cabve imm {ha “H"Pr mntnv. Remove the 5mm muluv mouming DBMS and ground came. Pu“ [he s‘anar moior um of the crankuaw. DISASSEMBLY ”Pmnve ma rnhnwmg: Starter motor case bolts'O-rings — Front cover . Seal 'ing 7 Lock washer 7 hemmed washer » Shimm} BIOLTS EC‘T SENSOR CONNECTOR V \ N (La\ THERMOSTAT HOUSING) CASE BOLTS FRONT COVER lNSULATED WAS! [EH ' hEAL RLNU SHWHS‘r LOCK WASHER 18-4 ELECTRIC STARTER Remove the foHowing: , Hear cover assembly SEAL RING REAR COVER — Seal ling — Shims Armature . Q <' I ‘ ARMATURE SHIM INSPECTION BUSHING Check the bushing in the rear cover for Wear or dam- age, Check the nil seal and needla bearing in (he from OIL SFAI NLtDLE HEARING hover 1m deterxoraiion, wear or damage. Do me: use emery Check me commutator bars of (he armature for dis- ARMATURE mm L)! gem: coloration. DEDEf 071 We commutsta' COMMUTATOR EARS 18-5 ELECTRIC STARTER Check fnr continuity between the palrs Uf commutator bars. fi There should be continuiw. ‘ Check (or continuirv between each commutator bar and (he axmatuve shaft. lhere shnuld he nn nnnvimlity. Check my continuity between the insulated brush and cable terminal (the mdigo colored wure nrrhe Insulap ed brush holder). There should be continuity Check for cominulty between me cable terminal and [he rear cover. There shou‘d be nu continuikyv 18-6 ELECTRIC STARTER Remove the following: , Nut — Washer - Insulamrs Drying , Brush hoider assembly — Brush/terminal Inspem the brushes for damage and measure the brush lenglhv SERVICE UMIT: 6.5 mm (0.261“) ASSEMBLY REAR COVER BRUSH O-RlNG BRUSH HOLDER WSULATORS WASHER \3 NUT Mm INSULATED WASHER LOCK WASHER FRONT COVFR BRUSH HOLDER INSULATORS NUT > C; O-RING WASHER ARMATURE SEAL RING MOTOR CASE 18-7 ELECTRIC STARTER Install the brushes into the nrnsh holder, Install the cable terminal and brush holder into the rear cover, aligning the holder (at: with the rear cover groove lnstall the lollowlng: — New O-ling - lnsulmed washzrs 7 Washer — Nut ALIUN Install the armature in the meter easel When installing the allllalme illlu the lllutur case, hnlrI mp. nrmahlra vighnyvn prevent m magnet from Pulling the armature against the case. f *4 The coll may be damaged l‘f the magnet pulls my armature against the case. ARMATURE MOTOR CASE Install the same numbel of shims in (he tame IUL‘dliulI “ ”INC as noted during disassemhly. g ”LN ‘ REAR COVER Install a new seal ring onto the motor case. Apply a thin coal of glass! to the armature shaft and. Install the rear cover, wh‘llc pushlnq in the brushes into the brush holder and alignan the brush holder l‘ tah with the motor case groove _ , ARMATURE SHIM l‘l‘sfal’ me snms Install the shims and insulated washer mm the army» yaw/m ,md Ms shaft. “33 SEAL RING FRONT COVER 44 "'9' , MW“ Install a new seal ling unlo 1h: mulut Lase. V Apply grease to the OII seal hp and nnedla hnanng In the from cover‘ Install the lock washer onto the front cover. Install the front cover. SHIMlS) LOCK WASHER 18-8 ELECTRIC STARTER lnstall ncw Qrmgs onto the mulul case bolls O-RlNGS Install and uglueu rhe case bolts sacrurely. @ MOTOR CASE BOLTS INSTALLATION ( a? 0 mg Coar a new Orring wuh oil and install it mmme starter V mum] groove. Install the manor moror lnro the crankcase. Ruure the starter mmnr cable and ground cable. 6: Ldlelu‘ m r- lnslnll the ground cable and mounting bolts, and 17mm I've were“ rlghrcn the Dolls securely. *D-‘e lnsrall [he :laner motor cabl», 'hen llghlen (he terml nal nm to the spemfied torque. TORQUE: 12 N-m (1.2 kglvm, S Ibf-I't] lnsvall the rubber cap securely. lnstall a new O-rlng into (he thermostat hnnsmg groove, lnsrall the thermuslal huu:lng to the cylinder head THERMOSTAIHUUSlNG 1 8-9 ELECTRIC STARTER STARTER Install and tighten the mounting bolts, Insta“ the following. 7 Thermostat housinghhermnstat (page 6-5) 7 Thronie body ipage 5 Gal. till the. system with the recommended coolant (page 674). RELAY SWITCH OPERATION INSPECTION Remove the seat (page 7-7) Sliiit llie traiisiriission into neutralt turn the ignition switch to “ON" and engine slop switch on, Push the starter switch button The soil is normal it the staitei ieIay switch clicks. if vau do not hear the switch click, inspect the relay switch using the piuusuure neiuw. GROUND LINE INSPECTION Disconnect the stanei ielay switch AP cunnectur. Check ior continuity between the Green/Red wire igiuuiid line) and ground. If there is continuity when the transmission is in new trial or when the clutch is disengaged and the side stand switch is retracted, the ground uiicuit is normal (in neutral, there is a slight resistnnn. dire tn the diode). STARTER RELAV VOLTAGE INSPECTION Connect the starter relay swmch AP chnnentnr shift the transmission into neutral. Measure the voltage bemeen the Yellow/Red wire ter- minal (H and ground (7). It the battery voltage appears only when the starter switch is pushed with the ignition switch turned tn ”ON" and the engine stop switch on, it is normalt 4\ ,r' “ w» l (A THERMOSTAT HOUSING) r.— STARTER RELAY SWITCH i RELAV SWiTCH CONNECTOR I STARTER RELAY SWITCH 18-10 DIODE CONTINUITY INSPECTION Disconnect the starter relay connector and cables. Connect an ohmmeter to the large starter relay switch terminals. Connect a IulIy charged 12-V battery tn the stnrmr relay switch cnnnectnr terminals (Yellow/Red and Green/Rad). Check tor continuity between the starter relay switch terminals. There should be continuity while 12-V battery is con- nected to the starter relay switch connector terminals and should be no continuity when the battery to dis- connected. REMOVAL Remove the seat lpage 2»2). Open the luse box and remove the diode. INSPECTION Check lor continuity between the diode terminals. When there is continuity, a small resistance value will register, If there Is continuity, in one direction, the diode is normal. INSTALLATION Install the mode in the reverse order at removal. DIODE ELECTRIC STARTER 18-11 LlGHTS/METERSISWITCHES SYSTEM LOCATION FRONT BRAKE LIGHT SWITCH IGNITION SWITCH LEFI HANDLEBAH SWITCH TURN SIGNAL W'l AV m HT HAN H III’ADLIGHT G DLEBAR swrrc RELAY OIL PRESSURE SWITCH ECT/THERMO SENSOR REAR BRAKE LIGHT SWITCH CLUTCH SWITCH HORN RADIATOR FAN MOTOR SWITCH NEUTRAL SW] I CH SIDE STAND SWITCH 19-0 20. WIRING DIAGRAM 003OZ-MBW-A100 OOSOZ-MBW-L100 20-1 19. LIGHTS/METERS/SWITCHES SYSTEM LOCATION 19—0 COOLING FAN MOTOR SWITCH 19—15 I SERVICE INFORMATION 19—1 OIL PRESSURE SWITCH 19-16 I TROUBLESHOOTING 19.3 FUEL RESERVE SENSOR 19.17 HEADLIGHT 19.4 IGNITION SWITCH 19-18 TURN SIGNAL 19-6 HANDLESAR SWITCHES 19.19 1 TAIL/BRAKE LIGHT 19.7 BRAKE LIGHT SWITCH 19.20 l LICENSE LIGHT 13-7 CLUTCH SWITCH 19.20 I COMBINATION METER 19.3 NEUTRAL SWITCH 19—20 “ SPEEDOMETER/VEHICLE SPEED SIDE STAND SWITCH 19.21 i I SENSOR 19—11 HORN 19.22 TACHOMETER 19‘” TURN SIGNAL RELAY 19-23 ‘ COOLANT TEMPERATURE GAUGE! SENSOR 19-14 SERVICE INFORMATION GENERAL 3 ,NOTICE A halogen hsad/I'ght bulb becomes very hm whlle the headlight is on, and remams hat {or .1 wlula after it is turner! r791 Be- sun: [U leI I'I cool dawn nefore Servicing. - Us: an electric haaling element to heat the mnlnnt forthe fan molar GWIICh inepecnon. Kaap flammable Iualellals away from the eleLllic heating element. Wear prolccfivc Clothing, InsuIalad qluve; and eye plotacfion NOle (he InlIanng when replacing the halogen headlinIL bulb v Wear clean gloves while raplacing ”I! bulb Do nnl pm vmgar prints on me headllghl bulbv as they may Create hot spots on The bulb and Lause il to fall — If you much the hIIIh wIm your barn hands. clean 'II with a dull. IIIuISleIled with alcohnl In prevent IIS early failure, , Be Sure lo Install The dust cover after replacing the bulb ‘ Check the banerv CondilIuII before perfnrmlng any Inspection Thar requires proper banery voltage. A cuuliuuin test can he made wxlh the switches installed on ma moluruyrlg The lnllnwmg color (:0ch are used throughuul l'l‘: Seclim Bu = Blue G ,— Green Lg = ngm Green H _ Hed Bl — Black Gr = Gray 0 = Orange W : Wh‘Ie Br = I‘Imwn Lb 7. Lignr Blue P = Plnk v = YeIIcw m 19-1 LlGHTS/METERS/ SWITCHES SPECIFICAHONS ‘ SPECIFICATIONS Bulbs 3 Headlight H. 1 12V — 55 w — ‘ l n 12v — 55 w Brakem llght 12v- zwa z W‘— rmmmm signal/running light 12v- 323 cflza/s W) x 2 '7 Heat lur ‘gnal Iigm W 7 mass 9 x wzvr 4 CF 5W] iV 1. Instrument light ‘ _ ~ A 7 “st _ Tum signal indicator LED High be u Indicator ‘ _ .,_ LED Tum. indicamr ' 7 LED , Bil pressure indicator “7 ‘LED PGM-Fl warninq lndicélo; __ r _ LED Low moi indléatér V“ LE1.) Fuse ' Main fuse _ ‘ 1 30 A ‘PGM-Fl fuse ‘ 20 A ‘ Sub fuse _ 1n A x G A Tachometer peak vollagc 1015 V minimum Fan motor Start to close lONl "W 98 — 102 'C (208 ~ 216 ‘F) sw'm" ‘ Stop to open 93 — 97 'c (199 — 207 ’F) TORQUE VALUES Cuulanl lmnperakure/ECT sensor Svdn sland switch boll Ignmon switch mounting bolt Fan motor switch on pressure switch Oil measure sthch wme terminal hnIVwasher Neutral switch 23 NW! (2.3 kgf-m, 17 lbf'fl) 10 NW! (1.0 kgl'm, 7 lbl-fl) 25 N-m (2.5 kgbm, 181bf'fl) 18 N-m (1.8 kgf-m, 13 Ibf-fl) 12 N-m (1.2 kgl-m, 9 lbfim 2 N-m (0 2 kghm, 1.4 lel) 12 N-m (1.2 kgf~m, S Ihl-m ALOC bolt: replace with a new one, Apply sealant to the threads Apply scalam to the threads‘ 19-2 TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER LIGHTS/METERS/SWITCHES The odometer/trip meter operate normally, but the spudometer does not operate ~ inulty speedometer The speedometer operate normally, but the odometer/trip meter does not operate - Faulty odnmemmnp meter Tho spudomotu opcrate is abnormal - Check for the following hnlnm diagnosing. - Blown main or sub fuses , Loose or corroded terminals U! the uoriiiectuis - Discharged battery Check lor loose or pool contact of the spend sensor 3P lNatllrall connacmr. With the ignition switch turned to ”ON" and mu- sure the voltaqe at the speed sensor connector. Normal Y Check tnr Innsa or poor contact of thc combina- tion mcicr rnulti connectors, With the ignition swilLli turned to "ON" and measure the voltage at the bottom oi the speedometertcrminals. Normal With the lgnltinn switch turned to ”OFF". check for continuity of tho Pink/Green wire between the terminals of the speed sensor and speedometer ‘ ,!—__ Support the motorcycle using a huist or other support lo rise the rear wheel off the ground Measure the mnput voltage (sensor signal) at the speedometer with the ignition switch is turned to “ON" while slowly turning the rear wheel by your hand Normal Abnormal Abnormal Ahnnrrnnl Abnormal Loose or poor contact of related terminals. Open circuit in Black/Brown or 6";anle wires between the battarv and spssd Benson Loose or puor uuiilaul ul related terminals. Open nirclm in l'llnck/Hrnwn or Green/Black erc$ between the battery and speedometer. Open circuit or louse L‘QIIIIEL‘lOn in Pink/Green wire Faulty speed sensor Loose speed sensor mourning bolts. > - Faulty speed sensor 19-3 LIGHTS/METERSISWITCHES HEADLIGHT ‘ , DUSTCOVER BULB REPLACEMENT , 1 / ' Remove the air duct cover {page 23). Release llle iesullaml chamber from the hawk arm. Disconnect the headlight bulb connectors. Remove the dust cover. l ‘ \ BULB CONNECTOR Avoid Youc‘ilw Unhnnk the bulb rammer and remove the headlight RETAINER (lie lid/aye!” l.E4M- bulb!sockcl. ,, , lgmbum. Fm_ puny: Mr rmm ha: spur; l‘ld! Cal/3D 9 Salt: is hmek H you touch We hulh w'nh vnllr hare hunds, nlenn It With clolh moistened wllh denatured alcohol [0 mar Van! early bulb failure, BULBi’SOCKET Remove the headlight bulb from the socket. BULB SUCKEI Install a new bulb inlo the socket Install the new headlight bulb/socket aligning its tabs with U’IE groove in me neadllgm unit B ULBl'SOCKET 19-4 LlGHTS/METERS/SWITCHES r V . . V Hook \he bu b relalller unto me headhgm umr gruove. RETAINER B ULB/‘SOCKET Install the mm nnvm tightly agnms‘ the headlight uni‘ . ARROW MARK DUST COVER wrm \(s arrow mark focung up. ‘ 4 _ Connect the headllghY rnnnnntnrs Hook the resonator chamber to the hook ioim. hula” the air dud cover lpagn 242). REMOVAL/INSTALLATION Remove the upper cowl (page 2-7». Disconnect the rum signal/running light connecrors. Remove the four screws and headlighl unil. Install the head‘ight unir in [he rcvcmc order or removal. LIGHTS/METERS/SWITCHES TURN SIGNAL Hum Jr! r,_,, r Fwy may; MW BULB REPLACEMENT Remove llre screw and turn signal lens While pushing in the bulb. mm ir counterclockwise, remove n and mplace with a flaw one. Install the [urn signal lens in the reverse urder of removal. REMOVAL] INSTALLATION rnr lrnnt turn signal nnir removal, see upper cowl removal (page 279). For rear turn signal removal, remove the sear/rear cowl (page 2-2l Disconnecl the turn signal connector, Remove me rurn signal mourning nur. Release the turn signal wile and remuve xlra lurrr sig~ nal unlt. lnslall llre lurn signal unil In the reverse Order of removal TURN SIGNAL LENS SCREW BULB SETTING PLATE 19-6 LlGHTS/METERS/SWITCHES TAIL/BRAKE LIGHT V 7' ELIE SOCKETS BULB REPLACEMENT / Remove the pillion sea: lpagc 272lr Discuunecl Ihe tail/brake light connectors Turn mp hlilh socket coumerclockwisc, then remove the bulb socket. Whiln pushing in the bulb, turn them counterclockv wise, remove mam and replace with new unes. install the tail/brake light sockets in the reverse order of removal. REMOVAL/INSTALLATION Remove the rear cowl (page 2-9). Remove the Mn nurs, wire clamps and tail/brake light unit. Installation is m the reverse order aI removal, NUTS WIRE CLAMP LICENSE LIGHT BULB REPLACEMENT , LICENSE LIGHT I Remove the license light bracket bulls and (he license light assembly l ‘ sons 1 9-7 LlGHTS/METERS/SWITCHES Remove the screws, Incense ngm Cover and \Pns ‘ COVER BULB Wlliie pushiug in the bulb, turn a: Cuuvuewlockwess, ernVP u and rep‘ace wuth a new one Install the license light assembrv in the reverse order cf remova‘, COMBINATION METER REMOVAL Rpmnve the upper com {page Z7) Disconnect (he combination mater 9P 1Namral‘ and 9? (Buck) Conneclws, Remove the comanalion me‘ev mountmg screw> and combznanon meter‘ DISASSEMBLY Remove the screws and comblnafion meter harness connector lid. SCREWS 19-8 LIGHTS/METERSISWITCHES Duscnnnem the combination mcmr subrharness conr necmrs, Remove lha scvaws and combination memr rear '—‘ ' SCREWS cuvel. ! ‘ Remove the comhmannn meter pnnt board assembly PRINT BOARD irnm the from cover. ASSEMBLY i \ 1 InstaH lhc print board assembly into the [rum cuver ‘ :nsml‘ me rear cover and tighten the scraws secure‘y. ‘ ' SCREWS‘ REAR COVER 19-9 LlGHTS/METERS/SWITCHES Connem the combinaxlon meter subrharness to [he plinl board. Install the humans canneuor lid while installing the grommet mm the grooves of the rear cover and her- nass lid‘ SCREWS INSTALLATION SCREWS COMBlNATION METER Insla“ the combinatlon mctcr onto the bracket align» ing [he bosses wilh the grommets on the bracket. Insmll and lighten the mounnng screws. Connect the combination meler 9P (Nalurall and 9P lBlackI conneclors. 9P lNATllRALl CONNECTOR l l Install me uppel cuwl {page 2-9». ‘ l l l l " H'v. ‘ 9l 'El ACK: CONNECTOR 19-10 LIGHTS/METERS] SWITCHES POWER/GROUND LINE INSPECTION Disconnect the nnmhinmmn meter multi-connector. Check the following at the wire harness side connecr tor terminals of the Combinatiun mule-r. Power input line i Measure the voltage between the Black/Brown wire terminal (e) and Ground (-l. ‘ There should he. battery voltage With the ignition switch turned to ”ON". If there is no voltage, check for an open circuit in Black/Brown wire. Back-up voltage lino Measuie the voltage between the Red/Green wwe ter- minal (1-) and Ground 1-). There should be battery voltage at all times. If there is nu voltage, check tor an open circuit in Red,’Green wire Sensor ground line Check for continuity between the Green/Black wire terminal (-l and Ground I l. There should be battery voltage al all times. ii there is no voltage, cheek tor an npen circult in Green/Black Wire. SPEEDOMETERIVEHICLE SPEED SENSOR SYSTEM INSPECTION 9P (NATURAU CONNECTOR Check that the tachometer and coolant temperature meter function properly. - ll they do not function, perform the power and ground line inspection of the combination meter (see abovel. - ll they function, shift the transmission into neutral. disconnect the combination meter combination _ meter 9P (Natural) and 9P (Blackl Culllleclovs and . turn [he igiiiliuri switch to "ON". Measure the voltage between the Pink/Green ll) MSFNECTOR and Green/Black H wire terminals of the wire har- ness side conneclur. Slowly turn the rear wheel hy hand. There should be 0 to 5 V pulse voltage. I ll no pulse voltage appears, replace the combinatmn meter print circuit board. It pulse voltage does not appear, check luv an open or short circuit in Pink/Green wire. it the Pink/Green wire is OK, check for tho speed sensor (page l9-12l, 19-11 LIGHTS/METERS/SWITCHES SPEED SENSOR INSPECTION Remove the throttle body (page 562: Dlsconncct the speed sensor 3P lBlack) connector and check for loose or poor uunlacl of the uunnectun Also check for lonse or poor contact nl the. engrns sub-harness 12P lGrayl connector, Connect the engine sub harness 12P (Grayl connector and speed sensor 3P lBlack) connector. Turn the ignition swttch Is to ‘ON" and mcasum the voltage at the 3P (Black) connector with the connector connected Connection: Black (+1 — Green 1-) Standard: Battery voltage if there is no voltage. check for on open circuit in the Black and Green wires and loose Contact of the wire harness ronneatnrs Support the motorcycle securely and place the rear wheel an the ground Shift the transmission into neutral. Measure the voltage at the sensor connector termi- nals with the ignitlon switch is turned to "ON” whlle slowly turning the rear wheel try hand. CONNECTION: Pink to) — Green (—l STANDARD: Repeat 0 to 5V ll the measurement ls out or spenttrnation, replace the speed scncor REMOVAL/INSTALLATION Remove the throttle hnny {page stm Dlsuunlleul the speed sensor 3P (Black) connector from the engrne sub-harness. Remove the bolts and speed sensor. r , I 3? (BLACKl/CONNECTOR t, SlgEED SENSOR ) r- .m 19-12 LlGHTS/METERS/SWITCHES tjnpcx that the O’Ylng is in good condition. replace if HOCCGSBVY, lnstall the speed sensor imo the upper cranknam Install and tighten U19 mounting bult: securely nnuta the sensor wrre. Connect the speed sensor 3? {Blackl mnnectnr TACHOMETER SYSTEM INSPECTION Turn the lgniliuri wvilui to ”ON" and nhenk that the tachometer needle move to full scale and then returns tn zero, it the needle does not snnw initial functlon. check for combination meter power input line mags 19-11}. Dischnecl the combination meter Fll‘ (Nniltralr and SP (Black) connectors (page 19 11). Connect the peak voltage adaptur to the laLilulIIeLel Ye|low,’Green (‘r leimiivai and Green 1—. TOOLS: Peak voltage leslar (USA. only] or Peak vullage adaptor mum—0020100 lnot availab|e in USA) with commercially avallable digital multimeter limpadance 10 MQ/DCV minimum) CONNECTION: Vellolereen h) and Green (-i Start the Pflglne and measure me tachometer input peak voltage. PEAK VOLTAGE. 10 ‘5 V minimum Ilzne value is normal, reulaue the taclrumeler. II the measured value lS hplnw in 5 V, replace the ‘ HIM PEAK VOLTAGE ADAPTOR 19-13 LlGHTS/METERS/SWITCHES if the vaiue IS 0 V. check for continuity between the combination meter 9? (Eiacki connectors terminal and the ECM mulli-connecto: VeHUW/G'EEH lenninals. if there :5 no continuity, check the wire harness and combination meter subrharness for an open circuit. 1! mere is cunlivluiiv. replace the uulllbivldiiun meter printed mmm hoard mags 1942i. COOLANT TEMPERATURE GAUGE/SENSOR THERMO SENSOR UNIT INSPECTION Dram the commit (page My. Discanllecl the wire uullneclor from the ECTnhsrmo sensor and remnvn "’18 SPHSEII. Suspend the ECT/thermo sensor in a pan of coolant ”*1 mixture) on an electric healing element and mea- sure the resistance through the sensor as the coolant heats up. Soak the ECi/thermn sensnr in mniant up to its rhraads with at Ioasr 40 mm We ini from the bottom altne pan lu [he bullum 0! the sensor. Keep the temperature constant for 3 minutes bEIule naming. Asuddcn change of temperature will resnit in incurred readings. Do not let [he thermomcrcr or ECT,‘thermo sensor (ouch [he pan. Reciace the sensor if it is out of specification by more than 10% at any leinpwslure listed. ,____——. Temperature BO'C 468T! 120C {248°Fy Resistance 2.1 — 2.6 In?) 0 65 - 0.73 k!) HIT/THFI'IMD SENSOR i i THERMO SENSOR TERMINAL 19-14 LlGHTS/METERS/SWITCHES M 231006 instali and tighten the ECT/lhermo sensor to the spec- ’"L7 ”3"" Ified torquet er W‘m a new ”"5 TORQUE123 N-m [2,3 kgf-m, 17 “$41) Connect the ECTnheimo sensor connector Frli the system and bieed the air {page 6-4) COOLING FAN MOTOR SWITCH INSPECTION Remove the toliowing: 7 Seat (page 2-2) - Lower cuwl ipage u) Check tor a biown iuse bevore inspection. Fin motor does not stop Turn the ignition swttch to “OFF", disconnect the cun- ncchr from the fan motor switch and turn the ignmnn switch lu "0N” again It the tan motor does not stop, Chuk tor a shorted VAN MU'OH SWITCH CONNECTOR wrrs between the ‘an motor and swrtch. if the fan mmm stops, replace the fan motor switch. Fan motor does not start Beiore testing, warm up the engine to operating tom parature. Disconnect the connector trom the fan motor switch and ground the connector to the body with a iurnper wire, Tum the ignition switch to ”()N" and check the fan motor, If the motor starts, check the connection at the tan motor swrtch terminal. if it is OK, replace the fan motor switch, LlGHTS/METERS/SWITCHES If (he moror does not sran. check for volrage between \IIE Ian Illulul swilcll cunneclur and gluulld. Il haflnry voltage is mansllmd, ranlacfi, the. ear. mmnr ll there is no battery vollagc. check lor poor conncc (Ion of (he connecmr or a damaged wrre harness REMOVAL/ INSTALLATION Disconnecl the Ian motel switch cumreclur and remove the :wrfch Install a new 0»riny ulllu ilru Lm uruwr switch. Apply sealant In the van mnrnr swilch threads. Install and tighten mo fan molar swilch. TORQUE: 18 Nem (1.8 kgl-m, 13 Ile) Install the removed pans in the reverse order of removal v OVRING CONNECTOR OIL PRESSURE SWITCH Wfipfiessuas WAEKuNG INDICATOR INSPECTION ii the all pressure warning indicator slay: ur. while lhe engine 15 running, check the HHgInH ml level before inspection. Make sure me ml pressure warnlng indicator come on with me Ignition switch rurnca (0 "ON". If the indicatov does not cums on, 'inspecl as follow: Remove the throttle body [page 5767) Remove the dust cover. Remove me straw and nil pressure switch lerminal. TERMINAL SCREW 19-16 short the all pressure switch wire terminal wrth the ground using a jumper Wire The oil pressure warning indicator comes on with the ignition switch turned to “ON", ll the light does not came on, check the sub fuse (10A) and Wiles far a loose connection or an cpan circuit Start the engine and make sure the light goes out. if the light does not go nut, check the oil pressure (page 4-3). if the oil pressure is norrnal‘ replace the nil pressure switch (see below). REMOVAL/INSTALLATION Remove the boot, terminal screw and wire terminal (see previnus page). Hemcve tho oii pressure switch item the crankcase, Apply sealant to the oil pressure switch threads as snnwn. lnsteil the oil pressure switch onto the crankceae, tighten it to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 5 lhl-lt) Connect the oil pressure switch terminal [0 the switch and tighten the screw to the specified lurque TOROUE: 2 N-nt (0,2 kgl-m, 1.4 IM-ftl Install the dust cover. FUEL RESERVE SENSOR INSPECTION Turn the ign on switch to “ON" and make sure the (uel reserv dicatui comes on If the fuel reserve indicator does nut indicate proper- ly, check for the lulluwrng, Disconnect the fuci rceerve sensor 3P (Blackl connec- KDI'. Short the wire harnet Slde connector Brown/Black and Green/Black terminals with a jumper wire. LIGHTS/ METERS] SWITCHES Dc: not apply sealant to the thread head 3 5 mm (0.1— 0.2 irtl. H7 LlGHTS/METERS/SWITCHES IGNITION Turn the ignition switch Io “ON” and make sure [he fuel reserve indicator comes on WIN] the side stand retracted, II the indimnr Comes nn, replace the fuel pump assemblyl ll IIIE indicator still does not come on, check for an open or short circuit in wire harness. SWITCH INSPECTION Remove the upper cowl «page 2-7). DiMonncct the ignition switch wirc 4P (Natural) con» naaors. Check for cuminuiiv between the wire terminals of the ignman swnch connector in each switch posiiion. Continuity should exist between the color coded wires as Iollows: IGNI‘HON SWITCH '\‘\\\\i KEY ON 1 KEY ON OFF 3 KEY OFF ‘ l i KEY OFF LOCK ‘ LOCK PIN COLOR Bu/O R/BI a i REMOVAL/INSTALLATION Remove the top bridge (page 13-24). Remove the bolts and ignition switch, Install the ignmnn switnh in the reverse order oI removal. Tighten the igniliun swnch mounting boltto me spec- IIIPJ‘I torque TORQUE: 25 MM (2.5 kgf-m, 18 lbf- h) n AP (NATURAL) CONNECTOR IGNITION SWITCH IGNITION SWITHI 19-18 HANDLEBAR SWITCHES Discnnnem the handlebar switch connemors. Check for continuity between the wire terminals M the handlebar swimh connector. Cnntlnwty should cxisx between the color coded wire terminals as ioIluws; STARTER SWITCH ST I IS BAT: HL FREE I o—o PUSH o—I—o ICULUK we I BI SIIR Bu/w TURN SIGNAL SWITCH LIGHTS/METERS/SWITOHES ENGINE STOP SWITCH STARTER SWITCH \.\_‘ w I R I Ii. I was PR PL a o——~q ‘ o , 70 N I V 0 o I 0 . L I o—I~——o (}I 0 ICOLOHI GR I sh I o ; Er/W SB/WI o/w DIMMER SWITCH _1 HL I Lu _ Hi Lo I 1N» o—-fi TT—L —o" ENGINE STOP swmm ‘x IG ‘ BAT ! OH? I RUN O_‘—O 'cm on an wxm HORN SWITCH ‘ ~ He I BATE- FREE PUSHI o I u 4—?— ‘COLORI Lg I 9|:an DI MMEH SWITCH TURN SIGNAL SWITCH HORN SWITCH 19-19 LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect the tram brake light swttcn connectors and check for continuity between the te’minals, Thprp shmllrl he cnrmnlllry wtth the NHL? IFVPI' applied, and there should be no continuity WiII‘I the brake lever released. REAR flemmie thP seat ipage 7A7i Disconnect the rear brake light switch connector and check ior continuity between the terminals. There should be continuity with the brake pedal applied, and there should be no culllilluily with the brake pedal released. CLUTCH SWITCH Disconnect the clutch switch connectors. There should he continuity With the clutch lever applied, and there should be no continuity With the cluILIi level released. NEUTRAL SWITCH Disconnert the neutral switch connector how the swnch. Shift the transmission into neutral and check ior cone tinuity between the Light gieen wire terminal and ground. There should be continuity with the transmissmn in neutral, and no continuity when the transmission is in gear NEUTRAL SWi I L'H CUNNLCIOH 19-20 SIDE STAND SWITCH INSPECTION Supper! me from and of fuel tank (page 3-4), Disconnect tho: :Ide stand switch 2P (Green) conncc tor. Check for continuiw between me wire lsrminals u( the side stand swiluh cullllec‘Kor Corwflnui‘y should must only when me sldc stand Is my. REMOVAL Disconnect the side stand swikch 2? (Green) nnnnantnr. Remnve the hon and side stand switch. INSTALLATION InstaH the sma stand swntch 5y aligning the switch pin with the side mend hole and the switch groove with the relurn spring homing pin‘ LIGHTS] METERS] SWITCHES SIDE STAND SWITCH HOLT SIDE STAND SWITCH 19-21 LIGHTS/METERS/SWITCHES Secure the side stand switch Wilh a new ball. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-R) Connect the side >land switch 2P (Green) conneulou HORN Disconnect the wue connector: from the home Connect the 12V balletv [0 [he hum lerminal direcuv. [he hmn Is nnrmal it It sounds when the 17V battery is connected across the horn terminals. 19-22 LIGHTS/ METERS/ SWITCHES TURN SIGNAL RELAY l TURN SIGNAL RELAY INSPECTION Remove the upper cowl (page 29» Check the lullowing. ~ Battery nnnnmon — Burned our bulb or non-specified wanage 7 Burnsd fuse — Iglil‘ian switch and turn signal switch function - LDOSE conneclors Inhe abuve items are all normal, check the following: Disconnect the turn signal connectors from the YEIE‘Ii Shon ma black and gray terminals of the turn signal relay connector with a jumper wire. Start (he engine and check inc [um signal light by turning the switch on. ‘ V Light comes on Light does nnv come on - Broken wire harness. ~ Faulry mm signal relay. ~ Poor connection of me conneclon 19-23 MEMO 21. TECHNICAL FEATURE FUEL RESERVE TRIP INDICATOR ThIS motorcycle is equipped WIII’I a Iue' :esidual quantity intimamr mm indicate a residuai fucl quantity according (c: the mileage incrementally. The IueI Iewrve trip indlCHIUr IS controlled by a fuel reserve sensor (Lhermislei). ECM IengIne revolulinn), vehicle speed sensor SUIF. stand switch and ignition swnch. SYSTEM DIAGRAM RESERVE SENSOR M .,// \ U @f ‘C‘/ SPEED SENSOR SIDE STAND SWITCH IGNITION PULSE GENERATOR 21-1 TECHNICAL FEATURE Function First the fuel reserve sensor detects a low fuel condition, the Combina- tion meter reserve Indicator and four segments of the fuel reserve trip indicators all light up Fin. 1). As the mileage increases, the segments begin blinking from the top down (Fig. 2 - 4i, until all the segments are blinking iFig. 5L When refueling, the fuel reserve Indicator IS reset when the following conditions are met: ' Mom than 90 seconds have elapsed allei [Iii-.- ignition switch is turned in "ON" - The engine is. running, - The side stand is raised If the ignition switch is turned to "OFF” during the 90 seconds, the fuel reserve indicator will not reset until the next 90 seconds after the igni- tion switch is turned to "ON", More than 90 seconds have elapsed afterthe Ignition switch is turned to “ON” and the engine is running, but the side stand is lowed, [he indica- tor will still blink until the Side stand Is raised. The ielueliug amount is less than 3.5 liter (0.92 US gal, 0.77 Imp galiv the illel reserve indlnntnr fines not reset Ii llie lusl tusurvs trip indicator does not operate properly, check each plan Individually I! there are no problems. replace the combination meter as an assembly. Fig. @i A ii iii if Fig. 1: n5. 5: 21-2 22. ENGINE DOES NOT START OR IS TROUBLESHOOTING POOR PERFORMANCE AT HIGH HARD TO START 22-1 SPEED 22-4 ENGINE LACKS POWER 22-2 POOR HANDLING 22-4 ‘ ‘ POOR PERFORMANCE AT LOW I AND IDLE SPEED 2273 7 , J ENGINE DOES NOT START OR IS HARD TO START Posslble cause 1 Abnormal —- > - lmmv luel pump ISeclion 5) u . Starting Iolluwiug normal procedure . Remove and inspect spark plug Check lor operation of the iue pump hulmai . IHSDELI (he Iuel flow 7—1‘ Normal Inspect rm: (uel inieclor NulmaI . Perform a spark ms! -————-— Good spark l V r Tesl cylinder compression ———/l r compression nurrnal Engine does nor man I Abnormal ————> Abnormal ———7 > wank or no spark a l nw compression ——> Engine srarts hm ———> stops Wet plug i» Faully pressure regrrlmor (Section 5i See secrion 5 Faulty spark plug Vnulnd spark DIug Faulty ECM Broken ul shoned spark plug wrrc Faulry rgnmon swnch Faulry ignirion pulse genelanr Faulrv engine >Iop swrrnn Luose or dncnnnecled ignition sysvem wires Valve Muck open Worn cylinder and piston rinq Damaged cylinder head gasket Seized Valve Improper valve (lmIl’lQ improper starter valve operation make pipe leaking Improper Ignition riming (laulry ignirion coil or ignition pulse an- sranrI Fuel contaminated Starter Valve closed Throtfle valve npen Clogged air cleaner 22-1 TROUBLESHOOTING ENGINE LACKS POWER 11, Raise wheei of! me ground and spin by hfnd Wheel spins rreely l V Check tire pressui 2 Pressure normal Accelerate rapidly lrom low to second EngInP speed reduced when clulcll is released Accelerate lightly Engine speed iliuledse Possible cause Wheel dues not spin—> rreely Pressure low , anine speed doe not change accord- ingly when clutch is released _. Engine speed does “p not Incrnase Check i nitiuii liming ——— Incorrcct a ‘3 Correct l V Test cylinder compression Nnrmal V lnspect luel lluw Normal Inspect the fuel lnleclnr Normal V Remuye spark plugs th toulcd or discolored t Check oil level and Cnndlllon Correct Remove cylinder head cover and inspect lubrication Veive train lubricated properly i V Incurred hfi Abnormal — + Abnormal ——> Fouled or dlsfinlofed ——> Incorrect —__> Valve train rim liihri- + cared properly Brake dragging Wcrri or damaged wheel bearing Faulty tire valve Punctured tire Clutch slipping Worn clutch digs/plates Warped nliitah discs/plates Weak clutch spring Additive in engine oil Air cleaner dirty Restricted fuel llow Clngged mumei Pinched fuel tank breather Faulty ECM Faulty ignition pulse generatol Valve stuck open Worn cylinder and piston rings Leaking hudd gasket improper valve timing Faulty pressure regulator (Section 5l See section 5 Faulty spark plug Oll level too high Oil level we low Contaminated uil Clugged oil passage Clogged nil control eririee 22-2 V 11. Check to. engine overheating Not overheating V 12. Accelerate Ul iuii at high spnerl V Engine dues nut kliuck Overheating ”4» Engine knocks ——> TROUBLESHOOTING Possible cause Coolant level low Fan iriuloi not working lfaulty fan motnr switnhi Thermostat stuck close Excessive carbon build-up in com- bustion chamber Use of poor quality fuci Wrong tvoa oi fuel Clutch slipping Worn piston and cvlinder Wrong type or fuel Lxcasswe carbon build-up in corn bustion chamber Ignition timing to advanced (faulty FCM) Lcan iuol mixture POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1‘ Check ignition liming Co rrcct 2, Check the stancr valve synchronilatiun Correct 3. inspect lhe luel flow Normal 4. lnspectrho fuel injector Normal 5. Check for leaks in the intake pipe Not ieak 6. Perform spark last i | Good snark Incorrect ———~—> inmnem ——> Abnormal ———> Ahnnrmni —'—> Leaking ———> , Weak or intermittent 4+ spark Improper ignition timing Sec section 5 Faulty pressure I’Rgllln'nr (Section bi See section 5 Luose insulator clamp Damaged insulator Faultv spark plug Faultv carbon or wet fouled spark plug unity ECM Faulty ignition coil Faulty engine stop switch Faulty ignition pulse generator Faulty ignition switch Loose or disconnected ignition sys- tem wires 22-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Check ignition timing Correct 2. Inspect the fuel flow l Normal r 3. Inspcm the fuel injector l r Nnrmal 4. Check valvetlming l Correct Inco rrecl Ahnnrmal p Abnormal —> Incurred —> 5‘ Check valve spring Nm weak POOR HANDLING Weak p - Faulty ECM . Fauhy pressure regulator (Section 5} - See section 5 - Camshaft Hul ilnlalleu ulupevly - Faulty valve saving Possihle cause 1. Steer‘rng is heavy 2. Wheel wobble: 3 Molorcycle pull: lu Une side Slaering slam adiusting nut ‘00 right Damaged sleering head bearings Excessive wheel bearing play Bent rim lmnrnper Inetalled wheel hub Swingarm pivol bearing excessively wurn Bent frame Faulw shock absorber From and IEEI wheel not aligned Bern fork Bern swrngarm Benl axle 22-4 AIR CLEANER AIR CLEANER HOUSING ALTERNATOR CHARGING COIL ALTERNATOR COVER INSTALLATION ALTERNATOR COVER REMOVAL BANK ANGLE SENSOR BATTERY BODY PANEL LOCATIONS BRAKE FLUID BRAKE FLUID REPLACEMENTIAIR BLEEDING BRAKE LIGHT SWITCH ERAKF l IGIII’ SWIICH BRAKE PAD WEAR BRAKE PAD/DISC BRAKE PEDAL BRAKE SYSTEM CABLE & HARNESS ROUTING CAM CHAIN TENSIONER LIFTER CAM PULSE GENERATOR CAMSHAFT INSTALLATION CAMSHAFT REMOVAL CHARGING SYSTFM INSI‘ECIION CLUTCH CLUTCH SWITCH CLUTCH SYSTEM C(JMHINATION METER COOLANT REPLACEMENT COOLANT TEMPERATURE GAUGE/SENSOR COOLING FAN MUIOH SWITCH COOLING SYSTEM CRANKCASE ASSEMBLY CRANKCASE SEPARATION CRANKPIN BEARING CRANKSHAFT CYLINDER COMPRESSION TEST CYLINDER HEAD ASSEMBLY CYLINDER HEAD COVER ASSEMBLY CYLINDER HEAD COVER DISASSEMBLY CVLINOFR HEAD COVER INSTALLATION CYLINDER HEAD COVER REMOVAL CYLINDER HEAD DISASSEMBLV CVLINDFR HEAD INSPECIION CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL DIODE DHIVE CHAIN ECM IENGINE CONTROL MODULE) ECT SENSOR [MISSION CONTROL INFORMATION LABEL (USA. ONLY) EMISSION CONTROL SYSTEMS ENGINE DOES NOT START OR IS HARD TO START ENGINE IDLE SPEED ENGINE INSTALLATION ENGINE LACKS POWER ENGINE OIL/OIL FILTER ENGINE REMOVAL ENGINE STOP RELAY EVAPORATIVE EMISSION CONTORL SYSTEM (CALIFORNIA TYPE ONLY) FAST IDLE WAX UNIT 19-1‘ 19-15 3-” 1142 11-3 125 12-3 8 15 8-27 8-5 8728 8-12 8713 $21 8v11 18-11 3 19 5-85 5-80 1-41 1-38 2271 3-17 7-10 2272 3-14 7-5 5-85 3-19 571 23. INDEX FLYWHEEL INSTALLATION FLYWHEEL REMOVAL FORK FRONT BRAKE CAI IPFI'I FRONT FENDER FRONT MASTER CYLINDER FRONT WHEEL FUEL CLI T RELAY FUEL LINE FUEL LINE INSPECTION FUEL PUMP FUEL RESERVE SENSOR FUEL RESERVE TRIP INDICATOR FUEL TANK GEAHSHIFI LINKAGE HANDLEBAR SWITCHES HANDLEBARS HFADLIGH T HEADLIGHT AIM HORN IAT SENSOR IGNITION PULSE GENERATOR IGNITION SWITCH IGNITION SYSTEM INSPECTION IGNIIION TIMING INJECTOR LICENSE LIGHT LOWER COWL LUBRICATION 81 SEAL POINTS LUBRICATION SYSTEM DIAGRAM MAIN JOURNAL BEARING MAINTENANCE SCHEDULE MAP SENSOR MODEL IDENTIFICATION MUFFLER/EXHAUST PIPE NEUTRAL SWITCH NUTS, BOLTS, FASTENERS OI SENSOR (CALIFORNIA TYPE ONLY) OIL COOLER OIL PRESSURE INSPECTION OIL PRESSURE SWITCH OIL PUMP OIL STRAINERIPRESSURE RELIEF VALVE PAIR SOLENOID VALVE PGM-Fl IPROGRAMMED FUEL INJECTION) SYSTEM PGM-FI SELF-DIAGNOSIS MALFUNCTION INDICATOR LAMP [MIL] FAILURE CODES PILLION SEAT/REAR COWL PISTON/CYLINDER POOH HANDLING POOR PERFORMANCE AT HIGH SPEED POOR PERFORMANCE AT LOW AND IDLE SPEED PURGE CONTROL SOLENOID VALVE (CALIFORNIA TYPE ONLY) PRESSURE REGULATOR RADIATOR RADIATOR COOLANT RADIATOR RESERVE TANK REAR BRAKE CALIPER REAR FENDER )0-7 1073 13‘14 15-19 2 12 15-10 13-9 5-511 3,4 5—50 5—53 19 ‘17 Z‘I-I 5-55 9-12 19-19 13-3 IS-A 5710 12-11 INDEX HEAR MASTER CYI INDER REAR WHEEL REGULATOR/RECTIFIER RIGHT CRANKCASE COVER INSTALLATION RIGHT CRANKCASE COVER REMOVAL SEAT SEAT RAIL SECONDARY AIR SUPPLV SVSTEM SERVICE INFORMATION (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEARSHIFI LINKAGE) (COOLING SVSTEM) (CRANKCASE/TRANSMISSION) ICHANKSHAFT/FISTON/CVIJNDERI (CYLINDER HEADNALVES) (ELECTRIC STARTER) IENGINI’ REMOVAL/INSTALLATION) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEL’SUSPENSION/STEERING) (FUEL SYSTEM) (HYDRAULIC BRAKE) (IGNITION SYSTEM) (LIGHTS/METERS/SWITCHES) ILUBRICAIIUN SYSTI'M) (MAINTENANCE) (REAR WHEEL/SUSPENSION) SFRVICF. RULES SHIPI' FORK/SHIFT DRUM SHOCK ABSORBER SHOCK LINK LOWEFI BRACKET INSTALLATION SHOCK LINK LOWER BRACKET REMOVAL SIDE STAND SIDE STAND SWITCH SPARK PLUG SPECIFICATIONS SPEEDOMETERNEHICLE SPEED SENSOR STARTER CLUTCH STARTER MOTOR STARTER RELAY SWITCH STARTER VALVE STARTER VALVE SYNCHRONIZATIUN STATOR STEERING HEAD BEARINGS STEERING STEM SUSPENSION SUSPENSION LINKAGE SWINGAHM SYSTEM DIAGRAM (BATTERYJCHARGING SYSTEM) (ELEC TRIC STARTER) (FUEL SYSTEM) (IGNITION SYSTEM) SYSIEM FLOW PATTERN SYSTEM LOCATION (FUEL SYSTEM) (LIGHTS/METERS/SWITCHFS) SYSTEM TESTING TACHOMETER TAII [URAKF [IS] IT THERMOSTAT 15-15 'IA-3 16-9 9-15 9-3 2-2 2-16 3-13 10 1 18-1 9-1 11-1 12-1 5-1 18 1 2-1 13-1 5—1 15-2 17-1 19-1 4-1 3-1 14 1 1-1 11-4 14-9 7-16 7-3 3-25 19-21 3-8 1-3 19-11 10-5 18-4 18 10 5-73 5—77 1072 3-31 13-24 3-27 14-12 14-14 1670 18-0 1 770 6-0 5-4 19-0 5-3 19 I3 19-7 6-6 THROTTLE BODY T) IRDTTLE OPERATION TOOLS TORQUE VALUES TP SENSOR TRANSMISSION TROUBLESHOOTING (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEAHSHIFT LINKAGE) (COOLING SYSTEM) (CRANKCASE/TRANSMISSION) (CHANKSHAI'T/‘PlSTON/‘CVI INDI'I'I) (CYLINDER HEAD/VALVES) (ELECTRIC STARTER) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEL/SUSPENSION/STEERING) IFUEL SYSTEM) (HYDRAULIC BRAKE) IIGNI TION SVSIEM) ILIGHTS/METERS/SWITCHES) ILUBRICATION SYSTEM) IRFAR WHFEUSUSPENSION) TURN SIGNAL TURN SIGNAL RELAY UPPER COWL VALVE CLEARANCE VALVE GUIDE REPLACEMENT VALVE SEAT INSPECTION/REFACING WATER PUMP WHEELS/TIRES WIRING DIAGRAM 23-2