1. GENERAL INFORMATION SERVICE RULES 1-1 LUBRICATION at SEAL POINTS 1-19 MODEL IDENTIFICATION 1-1 CABLE & HARNESS ROUTING 1-23 m SPECIFICATIONS 1-3 EMISSION CONTROL SYSTEMS 1-40 TORQUE VALUES 1-12 EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLY) 1-43 TOOLS 1-17 SERVICE RULES 1VUSe genuine HONDA Or HONDA-recommended pans and lubricants Or their equivalents. Paris that don’t meet HONDA’S deSIgn specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English Iastenersv 4. Install new gaskets, O-rings, Cotter pins, and lock plates when reassembling. 51 When lightening bolls or nuts, begin with the larger diameter or inner bolt first. Then tighten to the Specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts In cleaning solvent upon disassembly. Lubricate any sliding surfaces beIore reassembly. [After reassembly, check all parts for proper installatlon and operation. 8 Route all electrical wires as Show on pages 1-23 through 1-39, Cable and Harness ROutIng MODEL IDENTIFICATION 1-1 GENERAL INFORMATION ill The frame serial number is stamped on the right Side oi the steering head. , n ”LI/Xi _\ t /'/ VEHICLE IDENTIFICATION NUMBER (VIN) (3) The Vehicle Identification Number lVIN) I5 located on left side of the main frame on the Saietv Certification Labal. ENGINE SERIeL NUMBER V r ' 53. (2) The engine serial number is stamped on the righ side of the upper crankcase. I THROTTLE BODY lDENTIFlCATION NUMBER COLOR LABEL W The color label is attached as shown. When ordering colorrcoded parts, always specify the designated color code. (4i The throttle body identification number is stamped on the intake side of the throttle body as shown, GENERAL lNFORMATlON SPECIFICATIONS * GENERAL ITEM SFECIFTCATIONS DIMENSIONS 1 Overall length 2,065 mm (81.3 inl . Overallwidth 680 mml26.8in) Overall height 1,125 mm (44.3inl Wheelbase 1,395 mm (54.9inl Seat height 820 mm (32.3 in) Footpeg height 384 mm 115.1 in) Ground clearance 130 mm 15,1 inl Dry weight 49 states, Canada type California type Curb weight 49 states, Canada type California type Maximum weight capacity A9 states, Canada type California type 172 kg (379 lbsl 174 kg 1384 lbsl 197 kg 1434 lbs) 199 kg (439 lbs) 160 kg (353 lbs) 164 kg (362 lbs) Displacement Compression ratio Valve train Intake valve at 1 mm (0.04 in) lifl opens closes Exhaust valve opens Closes—4 Lubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine dry weight Cylinder arrangement Firing Order FRAME Frame type Diamond Front suspension Inverted telescopic fork l Front wheel travel 110 mm (4.3 in) Rear suspension Swingarm Rear wheel travel 135 mm (5.3inl . Flear damper Nitrogen gas filled damper l Fronttire size 1ZO/7OZR17l58Wl/Radial Heartire size 190/50 ZR17 (73W) /Radial Tire brand Bridgestone Front: BTDlUF /Rear: BT010R Michelin Front: Pilot SPORT E /Rear: Pilot SPORT E Front brake Hydraulic double disc brake with 4 pot caliper Rear brake Hydraulic single disc brake with l pot caliper Caster angle 23°45' Trail length 97 mm (3.8 in) Fuel tank capacity 18.0 2 (4.76 US gal , 3.96 Imp gall ENGINE Bore and stroke 74.0 X 54.0 mm 1291 X 2.13 inl 929 cm“ l56.7 cu-in) 11.3 : 1 Chain drive and DOHC 25° BTDC 35° ABDC 40° EBDC 20u ATDC Forced pressure and wet sump Trochoid Liquid cooled Paper filter Unit type 62.1kgl136i9lbsl Four cylinder, inline 30° inclined from vertical 1-2-4-3 1-3 GENERAL INFORMATION "CAEEOREWOW Twin/E TRAIN "éLE’C’T’RTC/ii' # GENERAL (Cont'dl ITEM Type HiThrgltle bore .. Clulch system Clutch operalion system Transmisslon Primary reduction Final reduction Gear ratio 151 2nd 3rd 4m 5m 6m Gearshifi panelg Ignlllon system Sxa rung system Charging system Regulator/rectifier Lighting system SPECIFICATIONS PGlVlrFl (Programmed Fuel Injection) AD mm‘(1.§inl Mullirplate, wel Cable operared type Constam mesh, 6’speed 1521 (73/481 2.687 (43/16) 2.692 135/13) 1.933 (29/15) 1.600 (32/20) 1.400 (28/20) 1.285 l27/21) 1.190 (25/21) . _Lef! fool operated return syilem, 17 N 7273117575 l . r i Computerrcomrolled digital transislonzed with electronic advance Electrlc starter motor Triple phase output alternator SCR shorted/triple phase, full wave rectification Bauer — LU BRICATION SYSTEM ITEM ' I-Tdralfig tdisassembly Atroiilfilter cha nge O ' Engine oil capaeriv Recommended englne oil GENERAL INFORMATION Unit: mm (In) STANDARD SERVICE LIMIT 4 3.5 07173.7 us qt7,773.1 Imp an 7 l _ 40217427543 qr,737,5lmp qt) 7 ‘ , 7 3.7 E (3.9 US qt, 3.3 Imp qt) Pro Honda GN4 or HF'4 Arstroke oil l (U,S,A 8t Canada) or Honda 4rstroke oll (Canada onlyl, or equivalent motor oil API service classification SF or 56 l O 7 7 77 Viscosity: SAE lowe 40 r 77 Oil pressure at all pressure switch 490 kPa 15.0 kgf/cmz , 71 psi) ,7 777 7 7 7 7 7 7 7 at 5,400 rpm l80”C/175°F) 7 7 Oil pump rotor l Tlp clearance l 0,2077l0.008l 777 l Bod clearance 0.15 0220006711009) 0,35to.014l Side clearance 00270.07 (000170003 010 (0.00M l O — FUEL SYSTEM (Programmed Fuel Injection) ITEM SPECIFICATIONS Throttle body identification 77A79 5tate7$77C1njgflyB§7Ii7 7777 7 7 77 (3060(3777 number_ 777 7 7 l California type GQeoB . 7 Starter v79 vacuum dlfference 20 mm Hg 7 77 77 Base throttle valve for s nchronization No.1 we speed, , Throttle grip rree Plfl77 1,200 i 100 rpm 772*6rnmtl/15—1/4jn) 7 Intake alr temoerature sensor resistance lat 20°C/685Fl 1* 4 k {1 77Englne coolantgemperature sensorreslstancelat20°C/68°Fl 2.3»26 ksl 7 7F7uel injector resistange lat 29°C/68°Fl 7 11.1—1237:7277 7 777 . PAl7Fl solenoid valve resistance lat 20°C/68°Fl 77 20 ~24 ksl 7 7nge control solenoid valve resistance la120°C/68°F) 30734 kc: 77 7 793m Pulse generator peak voltage la120°C/68°F) ’07 v minimum l( n7'l7tlon pulge generator peak voltage (at 20°C/68°FI 0.7 V minimum 7 Manllol7d7absolute pressure at idle 1507250 mm H97 7 Fuel pressure at idle ’ 343 kP7a (3,5 kgf/crn2 , 50 psii Fuel pump flow lat 12 VI 188 cm316.4 us 01,6.6lmp ozl minimum/10 seeorrds 1-5 GENERAL INFORMATION — COOLING SYSTEM SPECIFICA‘HONS Tommi capaclty 10271970 and 9.0.3; "'3 2 213.1116 qI 2 8 Imp qII ITEM 1 i 1 jfierve. tan}... 042170.4U8qt, 041mpqt1 70 (711310777 Cap relief p7res750r7e 108'71737 1<7 011: 00011 7 ‘ 1N . . 101762 01768) 4465101758) 7 EX ‘ 4 465* 4 48010.1758*0.1764) 4.4551017541 1 Valve gmdel D IN ‘ 4.500 4.51210.1772* 0.17761 1 EX 4500* 4.51210.1772* 0.17761 1 Stem to guide C1earance IN 7 0. 0170 0.7037 10. 0004* 0. 00151 7 ‘ E25 0. 020* 0. 047 10. 0008 0. 00191 Va1ve guide pIoIecIion 171N777 14.371413 10.56 0.571 1 abov7e7ylihder head 1 Ex 127471271049 70.501 7 77 7 77 7 i Va|7ve seatwidth 1 lN/EX 0.9071,1010.035~o.0431 1.510.06) Valve spring 77 7 IN/EX 34. §9 11. 3701 34.111.341 771r§§7197n791h Outer 77777 lN/EX 37. 97 11. 4951 7 37.2114571777777 Valve llflel' valv7e7lin7eLOD. lN/EX 25. 978 25.9931102284- 1.0233) 25.977 11.0221 7 77 77 Valve lI IeI bore717p.7 7 lN/EX 26.010—26026110240 71072746177777 2 041170251 Camshafl Cam lobe height I N 36.48 *35.7Z11,4367*7 446) 3645114351 1 EX 36.50 11.4371 Rynow 777 7 77 77: 7 0.05 10.002777 777 Oil clearance 1 0.020*0.05210.0008*0,00241 0.1010004) GENERAL INFORMATION 7 CLUTCH/GEARSngAT LINKAGE IT Uml: mm 1ir1) STANDARD SERVICE LIMIT . £70190 19177971711790 7 _ 10401313431161 7: 7 W ,gmchfigrmg 092100910 3, . , . 3,, .41081199. , . ..47.-4,<1.§7.1 , 7 010m 0150 thrckness Green color 2.9273081011570121) 2.6101077 Purple color 2.92T3.0810.115T0,121) 2.610.10) 7 9101011 platmarpage 7 7 030100121 Ciutch Outer guide 25000725021 10.984370. 250310.985) . 7 7 7 7 7 77773407544391 1137707137761 3719717137777 7 7 51130 CD. at clutch outer guide 7 24.9807 24393109835 70.984017 249610.983) Shiflfork, 1 Fork LD, 12.000T1Z.0’|810.4724T0.47311 12.0;10.{Z4) fork shaft 1 i Clayy7tgickness 5.93-76.0010.23370.2351 7 7717 75.910. 71 ‘ Fork shaft OD. 11.957"11.96810.4707 '047121 ‘ 113510.470) . i ALTERNATOR/STARTER CLUTCH Um“ m'“ “”’ ITEM STANDARD SERVICE LIMIT Starter driven gear boss O.D. 516997511181103547103611 516841203481 7 CRANKCASE/PlSTON/CYLINDER ”’"L mm “"’ ITEM STANDARD SERVICE LIMIT . 70011111151 ' 1 1,0 7 7400577740201201367201121 7415120191 77 1 001 of roung7 7 0.1010000 ; ,ger _. . . .1 9.010.904), i 77 7 7 7 Warpage 77 7: ,_ 0.05100021 PisIon, Etgnmark direction "IN“ mark facing toward the intake side T pislon rings 90 0.0. 7 7773779765; 73.985 97017207231281 73.9012. 097177777 . ‘77Piston O.D, measurement point 13 mm 10.5 in1 from bottom of skirt ‘ if 1 gggn p1n bore 1.13. 17.002T17.00810.6694 , 066961 1703105701 1' Flslon ph} O.D. _ 16.994 T17.000(0.6691T 0.66931 1 16.9810.6691 ‘7 '7s7ton-to-piston pin clearance 0.002T0.01410.0001T0.00061 7 ' Piston ringviornng 1 r0077 0.030 10005 10.0012- 77 7 79.0810 070.1 777 groove clearance 1 Second 0015700451000 006100021 . PiSlOn r1ng end gap . Top . . , 0.510021 17 §E£ond 0.40 5510015700221 0710.031 7 1‘ __ 1 011 15100031117 0270710017 0031 0.910.041 Episton c17e_gr7a_nce 7 021170.055 100003 70.0022) -~ ~ 7 ng rod sman end 10. 17016717034 10.66991 0.67061 17071100711 iggnnpginggpdrlorpigton pin clearance 7 . 0010700401000007000101 77* Crankpin oil ciearance 1 0.030’0052 10.0012T0.00201 0621000241 0 O O O 1 -7 GENERAL INFORMATION Unit: mm (int CRANKSHAFT/TRANSM!SSION ITEM STANDARD 1 SERVICE LIMIT Crankshah _Side C(earance 0.05 < 0.20 (0.002’0008) 0.30 (0.0121 7 Runout .. "i . 7 T . I130 (0&2), Main journal oil No.1anqNo.5 0.017i0.035(0.0007i0.0014! 0.045(00018! , , ( clearangg No. 210 NO, 4 0.027i0.045(0.0011"0.0018D 0.055 (0.0022! Transmission 1 Gear |.D. MS, MS 31.000731702511220?1.2215) 310411.222) 7 ‘ C1 26.000i26.021(1.0236i1.0244) 25.04 (1025’ . 7 71 (32,3 4 33.0 33.025(1.299271.3002) 33.04(1.301jwfi Bushmg OD. MEJVIGA 30.950i30fi75(1.218571.2195) 3093(1218’ C3 7_ 32.950’32375 (1.2972E1 2982), 32.93 (1.2961 1 CA 3235073729775 (1.29727 1.29821 1 3293112961 7777777 Bushing LD. L, M5 27.985’28006(1.1018’14026) ‘ 28.02(1.103D 777W” 1 C2 29.985730.006(1.1805* 418131 300211.182) fGear-m-bushing M5, M6 o.og§70.g75 (000107000301 ,7 0.11 (0.0041 Lplearance C3 0.025 0.075 (000107000301 0.11 (0.0041 Mainshaft 00, M5 _ 27.96]: 198011.1011f130161 21957111007) Clutch outer guide 24.980 , 24.893019835’ 0.98“” 24.96 (0.933) ‘7goumershafl 0D, . 027 29867729380 (1.1798711803) 29§5(1.180) 7 Bushingrmrshafl M5 0005—0039(0000270001571 ,, . 0.0810903) clearance ( CZ 0.005'0039(0.0002’00015) ' 0.08 (0.003) 1-8 GENERAL INFORMATION Unit: mm linl 7 FRONT WHEEL/SUSPEJIVSION/STEERING lTE STANDARD SERVlCE LIMIT ire rread depth 77 .5( Cold tire pressure 7709979707kg (2007l7bl (oa7d7 ‘ 777 7 Upto maximum weigntjapacit ( 7 7A7xie rgn07ut77 77 7 0 2010008) Wheel rrm runout 77Radr7ql7 7 7 7 7 72.0(03777 7 7777 77 7 77 Axial 7 7 7 77 2.0(003) 7 7 Fork Spring free length 2305 (9.07l777 225.97l8.89) Sprrngmrection With rhe tapered end facingyp ' 75813383 gaspensminmiii ' in? WW a, mlrrehgeagrkrhnd Fluid leve7l77 90 (3.5) Fluid capacrty 488 t 2.5 cm‘ (16.5 + 0.07% US oz, I 17.2 i 0 |r7npo T’iémm (0.7 (in ir?m 1036mm hon 7' 7 Tension aglys7ter initial setting 7 Compression adjuster mlllal setting ring pre~|oad steering head 1turn from full hard l 1-1/27t7ulr7tsirornfullhard 10’15 N 11,0’15 kg” 7 REAR WHEEL/SUSPENSION U"”' "‘m ""’ ITEM ‘ STANDARD SERVICE LIMIT Minlmqrr] lire thread depth 7 , 2.0 (0.08) Cold tlre pressure 7 Up7to 90 kg (200 lb) Ioad77 290 kPa (2.909 m2 , 42 psil 7 v 77 77 Up to maximum Weight capacity 290 kPa (2.90 kgf/cm1 , 42 psil v 7447):“) runoul i 7 0.20 (0,003; Wheel rim runout 77R7e7erai 77 7 7 r 7_ 7 Axial 77 7,, Drive chain Size/link DID DID. 50VA8 Cl 7__ i RK , RKGBSOHEQZS l 7 77 777 Slack ( 49750 (1,572.0) : 50 (2.07l77 Shock absorber Spring adjuster standard pos7irion 4th groove 7 Tension adjuster initial setting l 2 turns from full hard Compression adjuster initial setting 1 Hum from full hard 1-9 GENERAL INFORMATION Unit: mm (inI * HYDRAULIC BRAKE 1 1 ITEM STANDARD 1 SERVICE LIMIT ’ From Ti Specified brake fliid‘ "W Honda DOT 4 BrakE Fluid 77* LBiralgeigIEIihiglgnress 4.510.181 3.510.141 Brake disc runout" . 03010.0121 Mastercylmder 1.01” iMaster pistgn 191051075221 13006101483)” 19050719093 1075004175171. 1 19013719034 10711377074931 1 Caliper cylinder 1.0. Upper 3395077340101133707133901 3402113391 7 "Lower 50*3018011 211 29111931 Caliper piston 0.0. Upper . _ . 02*33335 , . 211 .,,. 79411.33 7 Lower > 30.082~30.1151118437118561 30.074 11.13401 Rear igggjfied brgkefluld DOTA 7 Brake pedal he'lght _ 7513.01 1 Brake disc thickness 5.010.201 . Eraje dis; runout 030100121 Masters linder |.D. 15.870‘1531310.6248‘032651 A15 9251062701 Master piston O.D. Caliperc |inderl.D. < 15.827 *15.85410.6231' 0.62421 38.180m38.23011.5031"1.50511 .. 53151002261 382411.506) Caliper piston 00. 38.098’38J48 11,4999’150191 38.09011.4996) * BATTERY/CHARGING SYSTEM ITEM SPECIFICATIONS I Capamty 12VVS,6 Ah 1 CA! rrent leakage 1 VoltagelZO”C/68°F) FlilIi/chargedi Needs charging Charging current iNormal Quick 0.421 kW/SDOO rpm Alternator 1 Capacit _ I Charging :oil resistance 120°C/68°F1 0.1- 1.0 51 * IGNITION SYSTEM ITEM SPECIFICATIONS Spark plug 7 "' _ |UH27D 113511501 .,. 1 Optional IUH24D1DENSOI Spark plug gap 080*030 mm 10.031 *0.035 in) Igrfl' [176011 peak voltage 100V minimum lgnmon pulse generator peak voltage 0.7 V minimum Ignition timing 1"F" markl 15° BTDC atidle GENERAL INFORMATION U I: i ELECTRIC STARTER I ”‘ mm ""’ ITEM l STANDARD SERVICE LIMIT . isEaTIe’r'rfiéiJfis’Ifienqm I 12043.0 10.4770 51) ‘ 4.5mm) — LlGHTS/METERS/SWITCHES 1 ITEM I SPECIFICATIONS ' Bulbs } Headlight l Hi ”7 12v-55w \ 2 7 . I 7 1 Lo 12V755V7l/ 7 7 Brake/(ail light 7 12v721/5w Fronttum slgnal/runnlng light 12Vr32/3cp123/8Wl / 2 77B7ea7r71ums7ignalllght7‘7 7 7 7 7 127v7-271yv7x 2 7777 7 LIcerIce lIgl’Il Izv-sw 77 lnslrumenlllght LED Tqrnysignal indicator 77 LED x 2 77 7 . 7H7ig_h beam indicator 7 LED 7 Neutral indicatgg LED 7777 I OllpressureindIcator 7 LED Malfunction indicator lamp LED 7 7 Fuel rgsgrveindicator _ 7 777 LED 7777 7 77 Fuse Mamfuse 30A PGMrFIfuse 20A 7 7 0 7 §ybluse 20A V I, 10A \ 5 Tachomelergeak voltage 10.5v mlnimum ThermosensonesIsIance 80°C 777 2.172.5k22 77 77 7 7 77120°C 0135sz k2: Fan moIor sumo close IONI axe—102°C (208*215 °Fl SWIIch I Stop to open 93'97 ”01199*207 ”Fl 0 O O I O O 1-11 GENERAL INFORMATION TORQUE VALUES l l TORQUE TORQUE FASTENER TYPE 1 Mm “(gm mm) FASTENER TYPE Nm (Wm, lbw 5 mm hex bolt and nut 5 10.5 , 3.6) l 5 mm screw l 410.4,291 6mm hex boltand nut l 10(1.0,7l 6mm screw 9l0.9,6.5l 8mm hex boltand nut 22l2.2,16l 5mmflange boltlB mm head) i 9l0,9,6.5l 10 mm hex boltand ntll 34l3.5,25) 6mmflange boltl10 mrn head) i 12(1.2,9) l and nut ; 12 mm hex bolt and nut r 54 (5.5 , 40) 8 mm flange bolt and nut l 26 l2.7 , 20) y . 10 mm flange bolt and nut 39 l4.0 , 29) u Torque specifications listed below are for important fasteners. - Others should be tlghtened to standard torque values listed above. NOTES 1. Apply sealant to the threads. 2. Apply a locklng agent to the threads. 3, Apply grease to the threads. 4. Stake. 5. Apply Oll to the threads and flange surface. 6. Apply clean engine oil to the Orring, 7. Urnul 8. ALOC bolt: replace with a new one. 9. CT bolt 10. Apply molybdenum disullide oil to the threads and seating serface (after removing antirrust oil additive) — ENGINE . THREAD . TORQUE 'TEM orv DIA. (mm) ‘ N-m (kgI-m, Ibl-ft) REMARKS MAINTENANCE: Spark plug 4 10 l 12l1.2,9) Timing holecap ‘ 1 45 , 18l1.8,13l NOTE3 LUBRICATION SYSTEM: Olldrain bolt 1 12 29l3.0,22l ‘ Oll cooler mounting bolt 1 20 74175.54) 1 Oll pump assembly Ilange bolt 1 6 8 (0.8 , 5.8) NOTE 9 Otl pump driven sprocket bolt 1 6 15ll.5, 11) NOTE 2 OII filter cartrldge 1 y 20 26 l2.7 , 20) NOTE 6 Oil pressure switch 1 1 PT 1/8 1211.2 , 9) NOTE 1 Oil pressure switch er9 Lermlnal screw 1 A 2 (0.2, 1.4) FUEL SVSTEM (Programmed Fuel injection): ECTlEngine Coolant Temperalure)/thermosensor 1 12 . 23 (2,3, 17) Throttle body insulator band screw 8 l 5 See page 1714 Throttle cable bracket mounting bolt 1 2 l 5 3 l0.35 , 25) Fuel pipe mullntlng bolt ‘ 3 5 10 (10,71 Pressure regulator mounting bolt 2 5 10 (1.0 , 7) Starter valve synchronization plate screw 4 3 1 l0,09 , 0.7) Fast idle wax unit link plate screw 1 3 110,09 , 0.7) Fast idle wax unit mounting screw 2 6 5 l0.5 , 3.6) Starter valvelock nut 4 10 210.18.13) Vacuum joint plug bolt for synchronization 4 5 3 (03,22) COOLING SVSTEM: ‘ 1 Water pump Cover flange bolt . 2 6 12 (1,2 , 9) NOTE 9 Thermostat cover flange bolt 2 6 12 l1.2 , 9) NOTE 9 ENGINE MOUNTING: ‘ Drive Sprocket special bolt 1 l 10 54 (5.5 , 40) 1-12 GENERAL INFORMATION 7 ENGlNE (Cont'd) 1 ‘ , THREAD ‘ TORQUE . . "EM 0" DIA.1mml 1 N~m1kgfvm,lbf~ft1 r REMARKS CVLINDER HEAD/VALVES: Cylinder head cover bolt 4 6 1011.0,71 ‘ PAIR reed valve cover flange bolt 4 6 1211.2,91 NOTE2 Breather plate flange bolt 3 6 1211.2,91 NOTE 2 Camshaft holder flange bolt 1 10 6 1211.2,91 NOTE 5 . CVlll’lclEr head sealing bolt l 1 18 2712.8, 20) NOTE 2 Cyllrlcler head mountlrlg bolt l 2 8 ‘ 2412.4,17) . NOTE 5 Cyllnder head mounting socket bolt/washer 'IO 9 ‘ 5115.2 , 38) ‘ NOTE 10 Cam sprocket bolt 4 7 2012.0,141 NOTE 2 Cam pulse generator rotor dowel bolt 2 . 5 12 (1.2 , 9) ; NOTE 2 Cam Chatn tensioner pivot socket bolt 1 l 6 1011.0,71 i NOTE2 Cam chain guide mounting socket bolt 1 6 ‘ 12112.91 NOTEZ 0 Cylinder head stud bolt 1exhaust pipe stud boltl 3 s ‘ See page 114 CLUTCH/GEARSHIFT LINKAGE: Clutch Center lock nut 1 ‘ 22 1271130 , 94) NOTE 4, 5 Clutch spring bolUWasl’ler 5 6 1211.2,91 Shift drum Center socket bolt 1 1 3 23 12.3 , 171 NOTE 2 Shift drum stopper arm pivot bolt 1 6 1211.2,91 Gearsmrt return spring pin 1 8 2312.3,171 . Shlft drum bearing/Shift fork retaining bolt/Washer 2 6 1211.2 , 91 NOTE 2 ALTERNATOR/STARTER CLUTCH: Alternator wire clamp socket bolt 1 5 12 (1.2 , 91 NOTE 9 Flywheel flange bolt 1 l 10 103 (10.5 , 761 NOTE 5 Stator mounting socket bolt ‘ 4 l 6 12 (1.2 , 91 Starter onerway clutch socket bolt 5 5 1611.6,12) NOTE 2 . CRANKCASE/PISTON/CVLINDER: ‘ Mainshaft bearing Set plate bolt 2 6 1211.2 , 91 NOTE 2 Crankcase bolt, 10 mm '1 10 3914.0 , 291 9 mm 1malrl journal boltl l 10 9 35 (3.6 , 261 . NOTE 5 8mm 12 8 2412.4,171 Connectlng rod nut 8 8 3513.6 , 261 NOTE 5 Upper crankcase sealing bolt 1 8 2212.2,161 NOTE 2 . Lower crankcase sealing bolt, 20 mm 1 20 30 13,1 , 221 NOTE 2 10mm 1 1o 1 1211.2,91 f NOTEZ O O . 0 1-13 GENERAL INFORMATION A ENGINE (Cont’d) ‘ , ‘ THREAD TORQUE ”EM TV ‘ DIA. (mm) N~m (kgfvm, mm) ‘ REMARKS . IGNITION SYSTEM: ‘ Ignmon puIse generator rotor mountvng bolt 1 ‘ 10 59 (6.0 , 43I 1 NOTE 5 ELECTRIC STARTER: I I ‘ Stanermolorlermmalnm 1 I 5 1211,29) I LlGHTS/METERS/SWITCHES: 1 ‘ 1 NeutraI swilch 1 I 10 I 12 (1.2 , 9) I . InsuIamr clamp (Throttle body side): Insulator clamp (Cylinder head side): 7 : 1 mmIos t 0.04 inI 12 1'1""‘1‘0'5 t 0'04”” . A> <7 0 Exhaust pipe stud bolt: . O O O O O 1-14 GENERAL INFORMATION — FRAME . THREAD TORQUE ”EM 0 TV ‘ DIA. (mm) N~m (kgim, ibm) REMARKS FRAME BODY PANELS/EXHAUST SYSTEM: ‘ Upper cowl stay mounting bolt 2 a 26 (2.7 , 20) Middle Cowl pan screw 14 5 1 (0.15,1.1l Lower cowl pan screw 2 5 1 (0.15 ,1.1l Innerpanelpan screw 2 5 1(O,15,1,1l Inner middle cowl pan screw 2 5 110.15, 1.1l Rear cowl truss Screw 2 5 1(0.15,1,1I Pillion seat bracket mounting bolt/nut 2 6 12 (1.2 , 9i Pillion Saat mounting nut 2 6 10 (1.05 , 8i NOTE 7 Seat rail mounting bolt, 8 mm 4 3 39 (4.0 , 29) 10 mm 2 10 39(4.0,29l Pillion footpeg mounting socket bolt 4 8 39 (4.0 , 29) Exhaust pipejointtlange nut B 7 12 (1.2,9) FUEL SYSTEM (Programmed Fuel Iniectionl: Fuel filler cap bolt 3 A 2(0.2,1.4l Fuel tube banjo bolt (fuel tank side) 1 12 22 (2.2 y 161 Fuel tube sealing nut (throttle body side) 1 12 22 (2.2 ,16] Fuel pump mounting nut 6 l 6 12(1.2,91 (see tightening sequence below) : l l l l l Exhaust valve mounting bolt (frontl ‘ 4 6 14 (1.4, 10) (rear) 1 4 s 14 (1,4, 10! Exhaust valve cover mounting bolt . 4 s 12 (1.2.9) Exhaust valve pulley nut l 1 | 7 12(1.2,9) Exhaust valve pulley cover mounting bolt (lower) 1 1 6 12 (1.2 ,9) Ozsensor ‘ 1 12 25 (2.6, 191 COOLING SYSTEM: l Cooling fan nut ‘ 1 5 3 (0.27 , 2.0) Fan motor nut l 3 6 5 (0.5 , 3.6) ENGINE MOUNTING: l Main footpeg bracket mounting socket bolt 1 4 a as (4.0 , 291 Main footpeg mounting bolt i 2 10 44 (4.5 , 33) NOTE 8 Bank sensor 1 2 8 1211.2,9) ‘ Lower bracket mounting nut i 1 10 42 (4.3 , 311 . See page7-11 ‘ l ‘ NOTE 7 Lower bracket mounting pinch bolt ‘ 1 l 8 26 (2.7 , 201 g ( Engine hangernut (front) 1 2 l 10 39 (4,0,29) —‘L See page 776 Engine hanger nut (middle) 1 1 12 54 (5.5 , 40) e—1 ‘ Engine hanger nut (rear) ; 1 12 54 (5.5 , 401 f Rear engine hanger pinch bolt ( 1 8 26 (2.7 , 20) 7* Side stand bracket bolt 1 2 10 44 (4.5 , 33l l NOTE 8 Side stand pivot bolt 1 10 10110.7) i Side stand pivot lock nut i 1 10 29 (3.0 , 22) l NOTE 7 CLUTCH/GEARSHIFT LINKAGE: l Gearshift pedal link pinch bolt 1 6 10(1.0,7l ‘ GENERAL INFORMATION i FRAME (Cont'di THREAD TORQUE ”EM 0“ DIA.1mrn) N»m1kgl-m,lbf-fl) REMARKS FRONT WHEEL/SUSPENSION/STEERING: ‘ Handlebar pinch bolt 2 8 2612.7,20) ‘ Handlebar weight mounting screw 2 6 10 (1,0 , 7) ‘ NOTE 8 Steering stem nut 1 24 103 110.5 , 761 , :f See page 13-31 Top threadA 1 26 2913.0,221 l ToplhreadB 1 26 #w 4 ‘ Fork top bridge plnch bolt 2 8 1 2212.2 ,161 Fork bottom bridge p1nch bolt 4 8 1 2612.7 .201 ‘ Front axle bolt 1 18 ‘ 78 (8.0 , 581 Front axle holder pinch ball 4 8 2212.2,161 Front brake disc rnountlng bolt 12 6 2012.0 ,141 NOTE 8 Fork bolt 2 42 22 (2.2 ,151 Fork center bolt 2 10 34 13,5 , 251 REAR WHEEL/SUSPENSION: l Rearaxle nut 1 22 113111.5,831 1 NOTE7 Rear brake disc mounting bolt 4 3 4214.3,311' ’ NOTES Driven sprocket nut 5 10 6416.5, 471 NOTE 7 Rear shock absorber upper mounting nut 1 1D 44 14.5 , 331 NOTE 7 Shock arm plate nut 3 10 4414.5 , 331 1 NOTE 7 Shocklink nut1frame side1 1 10 4414.5,331 ‘ NOTE7 Swingarm plvot nul 1 24 1181120 , 871 NOTE 7 Swingarm pivot pinch bolt 2 8 2512.7 , 20) Drive chain slider bolt 3 6 9(O.9,6.51 NOTES HVDRAULIC BRAKE: 1 Front brake master cylinder Cup mounting nut 1 6 1 610.6 , 4.31 NOTE 7 Brake lever pivot bo1t 1 6 ‘ 1011.0,7) Brake lever pivot nut 1 5 610.6 , 4.31 1 Front brake switch screw 1 4 1 (0.12 , 0.91 ‘ Front brake caliper mountlng bolt 4 8 3013.1, 221 NOTE 8 Caliper body assembly tOrX bolt 8 8 2312.3,171 NOTE8 Padpln 3 10 1311.8,131 Pad pin plug 1 10 210.25,1.81 Brake caliper bleeder 3 8 610,5 , 431 Rear brake hose clamp screw 4 5 410.4,231 NOTE 8 Rear mastercylinder push rod nut 1 8 1811.8,131 Rear master cylinder hose joint screw 1 4 110,15,1.1) NOTE 2 Rear brake Caliper pin bolt1ma1n1 1 12 2712.8,201 NOTE 2 Rear brake caliper pin bolt 1sub1 1 3 2212.2 ,161 NOTE 2 Brake hose oil bolt 5 10 3413.5 , 251 LIGHTS/METERS/SWITCHES: ign1tion swrtch mounting onerway boit 2 8 2612.7 , 20) Side stand switch mounting bolt 1 6 1011.0,71 Fan motor swllch 1 16 i 1811.8,13) NOTE1 1-16 GENERAL INFORMATION TOOLS NOTES: 1,Equlvalent commerciallv available in USA, . 2,Not available in USA. 3,Alternative [00L 4,Newly provided (001, 5,New1y designed tool. . DESCRIPTION TOOL NUMBER REMARKS REFi SEC. Fuel pressure gauge 0740570040002 "’5 ' Oll pressure gauge set ‘ 07506-3000000 4 Oll pressure gauge attachment 1 U7510-MA70000 1 4 Clutch center holder 07724-0050002 ‘ 9 Flvwheel holder 07725-0040000 NOTE 1 1 10 Flvwheel puller 077330020001 ‘ 10 . Attachment, 42 x 47 mm 07746-0010300 , 9, 13, 14 Attachment, 52 x 55 mm 1 077460010400 14 Attachment, 24 I 26 mm . 0774670010700 14 Attachment, 22 / 24 mm , 07746701310800 14 Attachment, 40 ,1 42 mm 0774670010900 NOTE 5 14 Driver, 40 mm 1.0, 0774670030100 1 12 . Attachment, 30 mm ID. 077450030300 1 12 Pilot, 17 mm 077450040400 14 Pilot, 25 mm 077450040600 1 13, 14 Pilot, 35 mm 1 077460040300 1 9 Bearing remover shall 1 077450050100 1 13,14 Bearing remover head, 25 mm 07746-0050800 1 13, 14 Driver 077490010000 1 13, 14 9 Valve spring compressor 077570010000 1 8 Valve seat cutter NOTE 1 8 Seat cutter, 245 mm 145° EX1 07780-0010100 1 Seat cutter, 29 mm 145° IN) 077500010300 1 Flat cutter, 25 mm 132° EXl 077800012000 Flat cutter, 33 mm 132° lNl 0778070012900 . Interior cutter, 26 mm (60° EX1 0773070014500 1 Interior cutter, 30 mm (60“ IN) 0773070014000 1 Cutter hoitler, 4.5 mm 0778170010600 1 Snap ring pliers 0791473A50001 NOTE 3: 0791473230001 1 15 Steering stem socket 1 07911573710101 NOTE 3: 0791673710100 1 13 Ball race remover set 079467KM90001 NOTE 3: 1 13 ,, Driver attachment, A 079467KM90100 Can be used with the 1 O , Driver attachment, B 07946»KM90200 following combination 7 Driver shaft assembw 07946-KM90300 ‘ 1U.S,A onlv1: — Bearing remover, A 1 07946-KM90401 07VMF-MAT0100 1 7 Bearing remover, B , 079467KM90500 07VMF-MAT0200 1 *Assemblv base 079467KM90500 07VMF-KZ30200 ‘ 07VMF-MAT0300 O 07VMF~MAT0400 07947-KA50100 1 07965~MA60000 1 07946-ME90200 Steering stem unver 1 079467M800000 13 Driver shaft 1 07945-MJ00100 14 Driver attachment handle 079403710001 14 . Va1ve spring compressor attachment 07959-KM30101 8 Oil filter wrench 07HAA-PJ70100 1 3 Peak voltage adaptor 1 U7HGJ-0020100 NOTE 3: 5, 17, 19 1 Peak voltage tester 1 1U.s.A.onlyl 1 O 1-17 GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Tappet hole protector O7HMG-MR70002 NOTE 2 a Vaive guide drlver r D7HMD-MLOO1D1 5 Valve guide driver, 4,508 mm ‘ D7HMH~ML00101 NOTE 3: 8 07HMH7ML0010A 1U.S.A only) Drive chain [001 set 07HMH-MR1D103 NOTE 3 07HMH7MR1D1OB ; 1U.S,A. onlyi Needle bearing remover i D7LMC~KV3D100 14 Driver pilot, 32 ‘ 50 mm 07MAD¢PR90200 14 Compressmn gauge anachmenl 07RMJ4MV50100 8 Fork damper holder 07YMBVMCF0101 13 01! seal driver 07VMDVMCFO1OD NOTE 3: 13 07KMD7KZ30100 Wiih 07NMD7KZ30101 (except U.S.A.) 07NMD7K23010A (U,S.A‘ only) Driver attachment, 25 x 38.5 mm 07YMD-MCJO‘IDO NOTE '5 14 InsIaHer shaft guide 07VMF7MCJ0100 NOTES 5 Inslailer shall 07YMF~MCJ0200 NOTE 5 5 Inslailel shaft, 14 ‘ 30 mm 07YMF-MCJ03OD NOTE 5 5 Remover, 14 1 15 mm j 07YMF-MCJ0400 NOTE 5 5 ECU test harness 1 U7YMZ-0010100 NOTE A 5 GENERAL INFORMATION LUBRICATION 8: SEAL POINTS * ENGINE . LOCATION MATERIAL REMARKS caakcase' mating surlég ' ' ’Liquid‘s‘ealamm’ "" ’ ’ ' (Three Bond 12078 or equivalenn O 2: 5% Eva Eco mo m‘o \— ‘ r- eg; ‘2; EE r-A ’ En a: 3? mo \ g T; 29 29 . ‘ ‘ O . . 1 Oil pressure swnch threads . Do not apply sealantlo the thread ‘ head 3’4 mm10‘1*0.2in). —>—<7 o i E 1-19 GENERAL INFORMATION — ENGINE (Cont’dl ’cvlrnde'r' n’éa’n’gérnfin’cwar cut-out Main journal bearing surface Piston pin sliding surface Connecting rod bearing surface Connecting rod small end inner surface Crankshaft thrust surface Camshaft lobes/Journals and thrust surface Valve Stem lvalve guide sliding surface) Valve lifter outer sliding surface Clutch outer/primary driven gear sliding surface Clutch outer guide sliding surface MEX/4, C5, C6, shifter gear (shift fork grooves) Starter reduction gear shaft outer surface Primary sub-gear friction spring sliding surface APPLICATION AREA APPLICATION AREA (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide greasel LOCATION MATERIAL ‘ REMARKS Sealant .., V V VIVlolybdenun: disulfide oil Piston ring sliding area Oil slralner packing Clutch dlsc surface Starter one-way clutch sliding surface Connecting rod nutthreads Flywheel bolt threads and seating surface Main lournal 9 mm bolt threads and seating surface (after removing anti-rust oil additivel Cylinder head special bolt (after removing antirrust oil additivel Clutch center lock nut threads Oil filter cartridge threads and O-ring Camshaft holder bolt threads and seating surface Oil cooler center bolt threads Each gear teeth and rotating surface Each bearing Each O-ring Other rotating area and sliding surface Engineoll 1-20 GENERAL lNFORMATlON ENGINE (Cont’d) i LOCATION MATERIAL REMARKS Timing riole cap threads ‘ Multi-purpose grease i , Oil seal lips .7 ‘ Upper crankcase sealing bolt threads Lower crankcase sealing boltthreads ‘ Cam chain guide A mounting bolt threads ‘ LoEking Qe’rh Cam pulse generator rotor bolt threads Cylinder head sealing belt threads l Cylinder head cover breather ioint threads ‘ Starter onerwav Clutch outer bolt threads ; l Coating width: 6.5 1 1 mm Oil pump driven sprocket bolt threads Shift drum bearing set plate bolt threads Mainshaft bearing set plate bolt threads Cam sprocket bolt threads Cylinder head cover breather plate boltthreads Shift drum center bolt threads Cam chain tensioner pivot bolt threads Cam chain guide pivot bolt threads Gearshift return spring pin i t LL 7 i LAJ ‘ 1-21 GENERAL INFORMATION — FRAME LOCATION MATERIAL REMARKS Front wheel dust seal lips Rear wheel dust seal lips Footpeg Sllding area Pillion footpeg sliding area Flear brake pedal pivot sliding area Gearshift pedal plvot sliding area Clutch lever pivot bolt sliding area Throttle pipe sliding area Pilliorl seat pivot sliding area Pillion seatcatch hook Pillion seat spring sliding area Pillion seat snnpg cross plate Contact area Multi-purpose grease Steering head bearing sliding surface Steering head dust seal llps Swingarm pivot bearing Swingarm pivot dust seal lips Shock absorber needle bearing VShoch absorber dlfil seal lips Side stand pivot surface Throttle pipe cable sliding surface Multi»purpose grease (Shell Alvania EPZ or equivalent) Molybdenum disulfide grease VSMk abso ber spring adjustercam surface Molybdenum paste Radiator la voter switch threads Liquid sealant l Steering- st topthread Throttle cable casing inner Brake pipe joint threads Engine oil Throttle cable A, B casing inner Clutch cable Casing inner Variable intake valve cable inner Variable exhaust valve cable A, B casing inner Cable lubricant Brake master cylinder cups WBrfake callperpiston seals DOT A brake fluid Brake caliper dust seals Front brake lever pivot and piston tips Rear master cylinder boot inside and push rod tips Rear brake caliper slide pln surface Silicon grease Hear brake caliper slide pin threads Rear master cylinder hose joint screw threads Driven sprocket stud bolt threads Locking agent 7 flanglegriprubberinside Honda Bond A Fork cap Orrlng Fork oil seal lips Fork fluid 1-22 GENERAL INFORMATION CABLE 81 HARNESS ROUTING TURN SIGNAL RELAY HEADLIGHT RELAV FRONT BRAKE HOSE THROTTLE CABLES CLUTCH CABLE COMBINATION METER MULTIVCONNECTOR ‘ HORN WIRE \ MAIN WIRE HARNESS / WHITE TAPE RIGHT TURN SIGNAL ' CONNECTORS I LEFT TURN SIGNAL CON N ECTORS LEFT HAN DLEBAR SWITCH I2P INATURALI CONNECTOR HEADLIGHT SOCKETS IGNITION SWITCH 4P RIGHT HANDLEBAR INATURAL) CONNECTOR SWITCH 6P IRED) CONNECTOR 1-23 GENERAL INFORMATION THROTTLE CABLES ’, .— CLUTCH CABLE l V I LEFT HANDLEBAR K© SWITCH WIRE WHITE TAPE 5* RIGHT TURN SIGNALWIRE HORN WIRE HEADLIGHT SOCKETS ‘o\\‘\ Xi P FAN MOTOR WIRE / \-/ LEFT TURN SIGNAL WIRE ‘— INSIDE 1-24 GENERAL INFORMATION THROTTLE CABLES METER SUBVHAR NESS RIGHT HANDLEBAR SWITCH WIRE ’1' E » CLUTCH CABLE w IIIIIK» / é' E S 0 H E K A R B T N O R F 1-25 GENERAL INFORMATION LEFT HAN DLEBAR SWITCH WIRE {a / \g/X/ m “/3qu ,, ¥ \\ x \ I \/ aw“ ' pew (n 'y E «I \oé‘d 'I A ,C / IGNITION SWITCH WIRE .F» . wr\ \ @‘Wrrg \ \ r Na b FRONT SU BVHAR NESS \ 1. 20p CONNECTOR l ‘- SIPHON TUBE OIL COOLER WATER HOSES 1-26 GENERAL INFORMATION THROTTLE CABLES PAIR CONTROL SOLENOID VALVE PAIR CONTROL SOLENOID VALVE 2F INATURALI CONNECTOR CAM PULSE GENERATOR 2P (NATURAL) CONNECTOR IGNITION COIL SUBVHARNESS BLUE TAPE QPIBLACK) CONNECTOR CRANKCASE BREATHER TUBE FUELINJECTOR SUB-HARNESS THROWLE SENSOR IGNITION PULSE GENERATOR WIRE VARIABLE INTAKE VALVE CONTROL CABLE OIL PRESSURE SWITCH CONTROL CABLES ENGINE SUBVHARNESS ALTERNATOR WIRE STARTER MOTOR CABLE VEHICLE SPEED SENSOR STARTER MOTOR GROUND CABLE 1-27 GENERAL INFORMATION O OIL COOLER WATER HOSE SIPHO N TU BE . LOWER RADIATOR HOSE I O / §| AIR BLEEDTUBE I O O 0 O FAST IDLE WAX u NIT TU BES BYPASS HOSE . THERMOSTAT HOUSING-TO- WATER PUMP HOSE O O 1-28 GENERAL INFORMATION VARIABLE INTAKE VALVE CONTROL CABLE MAIN WIRE HARNESS . FUELTANKAIRVENTTUEE FAN MOTOR SWITCH WIRE FUEL TANK OVERFLOW TUBE ALTERNATOR WIRE SIDE STAND SWITCH WIRE EGCV (EXHAUST GAS CONTROL VALVE! 1-29 GENERAL INFORMATION IGNITION COIL SUB-HARNESS PAIR SOLENOID VALVE WIRE FUEL TANK OVERFLOW TUBE AIR BLEED TUBE FUEL TANK AIR VENT TUBE SIPHON TUBE UPPER RADIATOR HOSE REAR BRAKE HOSE CLUTCH WIRE BRAKE LIGHT SWITCH WIRE IGNITION PULSE GENERATOR WIRE 1-30 GENERAL INFORMATION . IAT SENSOR . No.3 INJECTOR NO.4INJECTOR No.2 INJECTOR No.1 INJECTOR \ MAP SENSOR . / ' IGNITION PULSE /‘ a \ GENERATOR 2P . Aq‘rfifi" IREDI CONNECTOR - ‘33» " Erfififfi' "'241'1‘“. ‘Imblflq z’: “F' . “Mr . / , / ”NEE ENGINE SUB-HARNESS 2PIBLUEI CONNECTOR PRESSURE REGULATOR ECT SENSOR . FUELINJECTOR suarHARNEss 9P IGRAVI CONNECTOR . 0 . 1-31 GENERAL INFORMATION FUEL RETURN TUBE FUEL TANK BREATHER TUBE FUELTANK OVERFLOW TUBE FUEL PUMP/RESERVE SENSOR WIRE THROTTLE SENSOR FUEL TUBE FUEL PUMP/RESERVE SENSOR 3P(BLACK) CONNECTOR 1-32 GENERAL INFORMATION BRAKE LIGHT SWITCH ZP R T R (NATU ALI CONNEC 0 MAIN WIRE HARNESS BATTERY NEGATIVE 1*) CABLE SERVICE CHECK CONNECTOR ECM 22F (LIGHT GRAY) PGM-Fl FUSE HOLDER CONNECTOR FUEL CUT RELAY FUSE BOX BANK ANGLE SENSOR ENGINE STOP RELAY ALTER NATOR 3P (WHITEI CONN ECTOR REGULATOR/RECTIFIER 4P INATURALI CON NECTOR ECM ZZP (BLACK) CONNECTOR STARTER RELAY SWITCH BATTERY POSITIVE (+I CABLE 1-33 GENERAL INFORMATION REAR BRAKE LIGHT SWITCH . 2P INATURALI CON NECTOR MAIN WIRE HARNESS SERVICE CHECK CONNECTOR RESERVOIR HOSE . . REAR BRAKE HOSE BRAKE LIGHT SWITCH WIRE 1-34 GENERAL INFORMATION CALIFORNIA TYPE: THROTTLE CABLES PAIR CONTROL SOLENOID VALVE PAIR CONTROL SOLENOID VALVE 2P INATU RALI CONNECTOR CAM PULSE GENERATOR 2P \ INATURAL) CONNECTOR IGNITION COIL SUBVHARNESS BLUE TAPE SPIBLACKI CONNECTOR CRAN KCASE BREATHER TU BE FUEL INJECTOR SUBVHARNESS THROTTLE SENSOR IGNITION PULSE GENERATOR WIRE OIL PRESSURE SWITCH /I{ r ENGINE suBrHARNEss v/ VARIABLE INTAKE VALVE I Q . CONTROLCABLE \@ 4 000 @5429: T. / EGCV @ \ ¢: (EXHAUST GAS CONTROL VALVEI CONTROL CABLES ALTERNATOR WIRE {1 EVA? CANISTER ( VEHICLE SPEED SENSOR STARTER MOTOR CABLE J 02 SENSOR 4P (NATURAL) CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE STARTER MOTOR GROUND CABLE 1-35 GENERAL INFORMATION IGNITION COIL SUB-HARNESS PAIR SOLENOID VALVE WIRE FUEL TANK OVERFLOW TUBE AIR BLEED TUBE FUEL TANK AIR VENT TUBE SIPHON TUBE REAR BRAKE HOSE UPPER RADIATOR HOSE O: SENSOR WIRE BRAKE LIGHT SWITCH WIRE CLUTCH WIRE IGNITION PULSE GENERATOR WIRE 1-36 GENERAL INFORMATION FUEL RETURN TUBE FUEL TANK BREATHER TUBE FUEL PUMP/RESERVE FUEL TANK OVERFLOW TUBE SENSOR W‘RE THROTTLE SENSOR FUEL TUBE Y EVAP PURGE CONTROL SOLENOID VALVE EVAP CANISTER FUEL PUMP/RESERVE SENSOR 3F {BLACK) CONNECTOR 1-37 GENERAL INFORMATION BRAKE LIGHT SWITCH 2P INATURALI CONNECTOR MAIN WIRE HARNESS BATTERV NEGATIVE (*I CABLE SERVICE CHECK CONNECTOR ECM ZZP ILIGHTGRAVI P , IF H L CONNECTOR GMF USE O DER FUEL CUT RELAY FUSE BOX BANK ANGLE SENSOR ‘ u '1‘!!! \\, my ENGINE STOP RELAY ALTERNATOR 3P (WHITE) CONNECTOR REGULATOR/RECTIFIER AP (NATURAL) CONNECTOR ECM 22F IBLACKI CONNECTOR STARTER RELAv SWITCH BATTERY POSITIVE I+I CABLE 1-38 GENERAL INFORMATION REAR BRAKE LIGHT SWITCH RA MAIN WIRE HARNESS 2P INATU L) CONNECTOR . SERVICE CHECK CONNECTOR RESERVOIR HOSE . REAR BRAKE HOSE BRAKE LIGHT SWITCH WIRE 02 SENSOR WIRE 1-39 GENERAL INFORMATION EMlSSlON CONTROL SYSTEMS The US Environmental Protection Agency, California Air Resources Board lCARB) and Transport Canada require . manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply With applicable noise emission standards for one year or 6,000 km 13,730 milesl after the time of sale to the ultimate purchaser, when Operated and maintained according to the instructions provided, Compliance with the terms of the Distributor’s Limited Warranty for Honda Motorcycles Emission Control System is necessary in order to keep the emissions system warranty in effect. 0 SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons, Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic Honda Motor (30., Ltd, utilizes lean injection settings as well as other systems, to reduce carbon monoxide and hydrocarbons. . CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped With a closed crankcase system to prevent discharging crankcase emissions into the atmosphere, Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body. 0 AIR CLEANER HOUSlNG . THROTTLE BODY O O C < '_J FRESH AIR I h BLOWVBV GAS I 1-40 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) The exhaust emission control system is composed of 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 emisston control system. The exhaust emission control system consists ofa secondary 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 PAIR (Pulse Secondary Air Injection) control valve. . This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevents reverse air flow through the system, The PAIR control valve is operated by the solenOId valve. The solenoid valve is controlled by the FGMVFI unit, and the fresh air passage is opened/closed according the running condition IECT/IAT/TP/MAP sensor and engine revolutioni. . No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended. AIR CLEANER HOUSING 0 PAIR CONTROL VALVE O THROTTLE BODY . . PAIR CHECK VALVE O EXHAUST PORT U . . California type: The calilornia type also equipped two three-way warm-up catalytic converters, a three-way catalytic converter, and a heated oxygen sensor, The threerway catalytic converters are in the exhaust system. Through chemical reactions, they convert HC, CO, and NOx in the engine’s exhaust to carbon dioxide (C01), dinitrogen (Nil, and water vapor. . No adjustment to these systems should be made although periodic inspection 01 the components is recommended. 1-41 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with California Air Resources Board evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission lEVAPl canister where it is absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission lEVAPl purge control solenord valve is open, luel vapor in the EVAP canister is drawn into the engine through the throttle body. FUEL TANK EVAP PU RGE CONTROL VALVE <:i FRESH AIR 4— FUEL VAPOR NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the lollowing acts or the causing thereof: Ill The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; l2) the use of the vehicle alter such device or element of desrgn has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED T0 CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal oi, or puncturing of the muffler, baffles, header pipes or any other component which Conducts exhaust gases. 2. Removal of, or puncturing of any part of the intake system. 3, Lack ol proper maintenance. 4, Replacing any moving parts of the vehicle, or parts at the exhaust or intake system, with parts other than those specified by the manufacturer. 1 -42 GENERAL INFORMATION EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL LABELS (U. S. A. ONLY) I . An Emlssmn Control Information Label is located on the storage compartment as shown The seat must be removed to read iL II glves base tune-up specifications. 0 . VACUUM HOSE ROUTING DIAGRAM LABEL (CALIFORNIA TYPE ONLY) (#K——\\ The Vacuum Hose Routing Dlagram Label is on Ihe mfiuthwnm alr cleaner housing caver as shown, “WWW PAW: The fuel tank musl be opened Io read it. Refer to culronuu VEHICLE mgngugn . page 3-4 forfuel tank openlng. @ M FORWARD ‘ 7 / ENG Hgg Emmy . YAVE PREssynE REGULAIE W M THHOI'ILEVECDY VACUUM HOSE ROUTING DIAGRAM LABEL O . O O . 1-43 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS REAR FENDER PILLION SEAT REAR COWL S EAT LOWER COWL MkDDLE COWL \NNERPANEL , \ / T x 0' * / n “"2171 \ \\ \ s ' "- ’ J INNER MIDDLE COWL HEAT GUARD WLNDSCREEN UPPER COWL FRONT FENDER 2-0 2. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS SERVICE INFORMATION TROUBLESHOOTING SEAT PILLION SEAT/REAR COWL MIDDLE/LOWER COWL 2-0 2-1 2-1 2-2 2-2 2-5 UPPER COWL FRONT FENDER REAR FENDER SEAT RAIL MUFFLER/EXHAUST PIPE 2-9 2-14 2-14 2-17 2-19 SERVICE INFORMATION GENERAL 0 Thls secllon covers removal and lnstallatlon of the body panels and exhaust system OAIways replace the exhaust plpe gaskets alter removing the exhaust p‘lpe from the englne. - When ll’lSIaIIll’lg the exhaust system, loosely install all of the exhaust plpe fasteners. Always tlghten the exhaust clamps fnst, then tlghten the mountrng fasteners. If you tlghten the mounting fasteners first, the exhaust pipe may not seat properly. - Always Inspect the exhaust system for leaks after installation, TORQUE VALUES Upper cowl stay moumlng bolt Mltldle COWI pan screw Lower cowl pan screw lnnor panel pan screw Inner nntltlle cowl pan screw Rearcowl truss screw Pllllon seat bracket mountlng boltrunr Plllloll seat mountrng hut Seat rall mountmg bolt, 8 mm Seat rall mounllng bolt, lo mm Pllllon step mountlng socket bolt Exhaust plpe lount flange nut Exhaust valve cover mountlng bolt Exhaust valve pulley cover mountlng bolt TROUBLESHOOTING Excessive exhaust noise . Broken exhaust system . Exhaust gas leak Poor performance - Deformed exhaust system 'Exhdllsl gas leak ocmugutl muffler 26 N-m (2.7 kgfvm , 20 lbfvfll 1N m (0,15 kgfvm,1.1|bfvfl) 1 Nxm (0.15 kgl»ln,1t1lbf-ftl 1N‘m (0 15 kgf-m,1t1lbl»fll 1N4“ (0,15 kgfvm,11|bfvm 1N m (0.15 kgf m, 1.1 lbf III 12 N-m(12 kgf m , 9 IleI 10 N‘m (1.05 kglm , 8 lbltft) Urnul 39 NW! (4.0 kgf‘m,29|b1»ft) 39 NT" (4.0 kgi‘m, 29lh1-ft) 39 N‘m (4.0 kgf‘m , 29 leII 12 N‘m (1.2 kgi‘m , 9 IN“) 12 N‘l’n (1,2 kgfm , 9 ”3”!) 12 N‘m (1,2 kgf m , 9 Ibfvftl FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Remove the two seat mounting socket bolts behind the seat. Slide the seat back and then offv Remove the mounting coIIars. INSTALLATION Install the mountlng collars into the seat brackets as shown Align the seat hook with the fuel tank rear bracket and Install the seat. InstalI and tighten the socket boils securely. PILLION SEAT/REAR COWL REMOVAL Remove the seat Isee abovet. Open the piIIion seat using the ignition key. Remove the rear cowl setting bolls, collars and spacers. SEAT BOLT HOOK COLLAR BOLT PILLION SEAT IGNITION KEV SETTING BOLT COLLAR FRAME/BODY PANELS/EXHAUST SYSTEM O O O O O O 0 Male ma: these . (mm clrps are s/rgnuy arr/elem man [hose removed In Ihe prewous step, 0 0 Remove the piIIion seat bracket mountlng bolts/ nuts, then remove the pilIion seat/brackel as an assembly Disconnecr the rear brake/tail light connecrors‘ Remove the two rrim cles underrhe rear cowl. Remove the two trim clips and two retaining screws. Carefully spread the bottom of both sides of the rearcowl, then remove it from the seat raiI. RETURN SPRII\IG/—\\ PILLION SEAT ASSEMBLV BOLT/NUT TRIM CLIP TRIM CLIP 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION PILLION SEAT ASSEM BLY O 1 N>m10,15 kgfvm ,1.1|bl>m HEAR COWL . C C C Gem/y spread me Install the rear cow! over the side rail being careful TRIM CLIP SCREW sldeslolu over not to damage the wire harness. ? / the regu/amr/ reclu‘ler. Install the two (rim dips . Instal! and tighten the mounting screws m the speci- fied torque. TORQUE: 1 N-m10.15 kgf-m ,1.1 Ibf-M O REAR COWL InstaH (he {ower trim clips‘ . C TR|M CUP FRAME/BODY PANELS/EXHAUST SYSTEM Route the Wire harness and clamp lt as shown. Connect the rear brake/tail llght connectors. Install the pilllon seat/bracket assembly onto the seat rail. Check the return spring hook position, then install the bracket mounting bolts/nuts. Hold the bolt and tighten the nut to the specified torque. TORQUE: 12 N-m (1.2 kgfrm , 9 lbf‘fll Install the spacers, setting collars and setting bolts, then tlghten the bolts securely. MIDDLE/LOWER COWL REMOVAL Remove the trim clips from the inner middle cowl, BRAKE/TAIL LIGHT CONNECTORS RETURN SPRING PILLION SEAT ASSEMBLY BOLT/NUT SPACER SETTING BOLT COLLAR 2-5 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the six screws and special bolt. Release the middle cowl bass from the inner panel grommet, then remove the middle cowl. Remove the four Speclal bolts. Remove the lower cowl assembly from the right side. Remove the two screws, Special bolt and inner lower cowl, Remove the two trim clips and separate the right and left lower cawls. SPEClAL BOLT GROMMET MIDDLE COWL SPECIAL BOLTS LOWER COWL LEFT LOWER COWL RIG HT LOWER COWL lNNER LOWER COWL 2-6 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION MIDDLE COWL : g LOWER COWL fissemble the inner lower cowl, right and left lower LEFT LOWER COWL w . Install the two trim cllps and Special bolt. Install and tighten the inner lowercowl screw to the specified torque. TORQUE: 1N-m (0.15 kgf~m , 1V1 lbf-ftl RIGHT LOWER COWL INNER LOWER COWL lnsla/I bollom Install the lower cowl onto the lrarne from the right INNER MIDDLE COWL ends of the mner slde. mrddle cowl mm the Inner lower cuwl grooves INNER LOWER COWL FRAME/BODY PANELS/EXHAUST SYSTEM Install and tighlen the speclal bolts. 0 0 SPECIAL BOLTS Install the middle cowl while aligning its boss with GROMMET . the inner panel grommel. O 0 Install the specual bolland screws. 3 Tighten the screws to the specified torque. ” r TORQUE: 1Nrm 10.15 kgf-m , 1.1 lbf‘fll . Tighten the special bolt. 0 SPEClAL BOLT SCREWS Secure the inner lower cowl and middle cowl using TRIM CLIPS fourtrim clips. M ‘ r \ . FRAME/BODY PANELS/EXHAUST SYSTEM UPPER COWL SCREW , / ~ REMOVAL C Remove the mlddle cowl lpage 275). Remove the two trim clips from the inner panelr Remove the screw and then remove the inner panel lrom the upper cowl. C INNER PANEL . Remove the screw and heat guard on both side, 0 0 Remove the rearview mirror mountlng socket bolts REAR VIEW MIRROR and rearview mirror. 0 0 SOCKET BOLTS . Remove the screws, washers and windscreen. WINDSCREEN SCREWS 0 O 2-9 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the upper cowl mounting bolt and Washer. Pull the upper cowl forward. Dlsconnect the headllght sockets and turn signal connectors, then remove the upper cowl. Remove the screws and air guard. Remove the nut and settlng plate, then remove the frontturn signal unit. SCREWS SETTING PLATE NUT TURN SIGNAL UNIT 2-10 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the m'm CIIpS and then remove Ihe inner INNER MIDDLE COWL middle cowl from the upper cowl. NOTE Refer to page 19-5 (or headlight unit removal. TIM CLIPS INSTALLATION WINDSCR AIR GUARD REAR VIEW MIRROR INNER PANEL UPPER COWL HEAT GUARD INNER MIDDLE COWL Install the Inner middle cowl mm the upper cowl and secure it wuh trim clips. INNER MIDDLE COWL TIM CLIPS 2-11 O FRAME/BODY PANELS/EXHAUST SYSTEM Route the turn signal wire into the upper cowl, in- \ SETTING PLATE NUT ner middle cowl and setting plates lnstallandtightenthe nut securelv. Route the turn signal wire into the Inner middle . groove as shown. 0 \ TURN SIGNAL UNIT Installthe air guard andtightentwo screws. AIR GUARD . C 0 Place the upper cowl onto the upper cowl stay, connect the headlight connectors, position light connector and turn signal Connectors. 0 O Houtethenarness Install the upper cowl onto the upper cowl stay . and wiresproper/y while aligning the headlight unit bosses with the (page 1-23) upper cowl stay grommets. l [7‘ l1 7 ‘ . l BOSSES O 2-12 — FRAME/BODY PANELS/EXHAUST SYSTEM Install the washer and upper cowl mounting bolt. Tighten the upper cowl mounting bolt securely, Install the windscreen and washers, then secure it with screws. Install the rearview mirror and tighten the socket bolts. Install the heat guard onto the inner middle cowl aligning its tab with the hole in the inner middle cowl. Install a nd tighten the screw to the specified torque. TORQUE: 1 Nrm (0.15 kgf-rn , 1.1 Ibfrhl WIN DSCREEN \\_/\ WASHERS 2-13 FRAME/BODY PANELS/EXHAUST SYSTEM lnstall the inner panel onto the upper cowl and SCREW inner middle cowl. Secure the inner panel and lnner middle cowl with two trim clips, install and tighten the inner panel mounting screw to the specified torque. TORQUE: 1 N-m (0315 kgfvm , 1.1 “3”!) INNER PANEL FRONT FENDER REFLECTOR CLAMPNUT FRONTFENDER REMOVAL _}\ / ‘ Remove the brake hose clamp mounting nuts, Remove the front fender mounting special bolts and reflectors Remove the front fender forward. INSTALLATION Installation is In the reverse order 0! removal. REAR FENDER REMOVAL Remove the following: *Rear cowl (page 272l ’Battery (page 1675l Disconnect the tum signal connectors and license light connector. FRAME/BODY PANELS/EXHAUST SYSTEM Unhook the retaining tab and remove the fuse box. Remove the starter relay Switch from the rear fender. Disconnect the rear brake light switch 2P (Naturall connector. Disconnect the ECM lEngine Control Modulel multlr connectors, them remove the ECM (page S-BSL Disconnect the alternator 3P (Naturall connector and regulator/rectifier AP (Natural) connector. Remove the fuel out relay from the rear fender. Release the regulator/rectifier wire and main wire harness from the seat rail and rear lender. Remove the two rear fender mounting bolts and Collars. STARTER RELAY 2P lNATURALl CONNECTOR ALTE RNATOR FUEL CUT RELAY CONNECTORS ’ FRAME/BODY PANELS/EXHAUST SYSTEM Unhook The rear lender from the seat rail brace, then remove the rear fender backward. REAR FENDER: - ”I: ‘ -‘ O 0 INSTALLATION 0 C BATTERY FUSE BOX REAR FENDER O . FUEL TANK REAR BRACKET O STARTER RELAY SWITCH Why/elnsIa/lmg Install the rear fender by aligning its Tower groove . me rear lender‘ with the seal rail brace‘ rouze Me Wrre har- ness proper/y (page 1-23) 0 C 2-16 FRAME/BODY PANELS/EXHAUST SYSTEM Connect the license light connector and turn signal TURN SIGNAL CONNECTORS Connectors. , . Roulelhe WrrES Install the removed parts in the reverse order of properly (page removalv 1723) ’ SEAT RAIL REMOVAL BRACKET Remove the rear fender lpage 2-14)‘ Remove the rear brake reservoir mounting bolt . lpage 1574). Remove the muffler mounting bolt/nut Remove the socket bolts and right pillion footpeg bracket. , x , . MUFFLER MOUNT NGQE’QEW Remove the socket bolts and left pillion footpeg SOCKET BOLTS REGULATOR/RECTIFIER bracket . Remove the bolts and regulator/rectifier. 0 Remove the seat rail mounting 8 mm bolts, 10 mm 8 mm BOLTS . bolts/nuts and seat railv / - ,, O O 2-17 FRAME/BODY PANELS/EXHAUST SVSTEM INSTALLATION 39 N-m (4.0 kgf‘m , 29 ibfrft) 39 N-m (4.0 kgf-m, 291nm) SEAT RAIL REGULATOR/RECTIFIER 39 N-m (4-0 kgfvm , 29 WW PILLiON FOOTFEG BRACKET 39 N-m (4.0 kgf-m , 29 lbf-fti lnstaii the seat raii and tighten the mounting bolts and nuts to the specmed torquev 8 mm, BOLTS TORQUE: 8 mm bolt: 39 Nm (4.0 kgf‘m , 29 lbf-fti 10 mm bolt/nut: 39 N-m (4‘0 kgf-m , 29 lbf-m lnstail the regulator/rectifier, tighten the bolts. SOCKET BOLTS REGULATOR/RECTIFIER lnstail the left pillion footpeg bracket and tighten the socket bolts to the specuiied torque. TORQUE: 39 N»m (4V0 kgf‘m , 29 Ibf-ft) e ,\ PtLLION FOOTPEG BRACKET FRAME/BODY PANELS/EXHAUST SYSTEM lnstall the left pilllon footpeg bracket and tighten P‘LLION FOOTPEG the socket bolts tothe specified torque BRACKET ‘ TORQUE: 39 N-m (4.0 kgf-m , 29 lbf-fll Install the muffler mounttng bolt, washer and nut, tighten the nut securelyv Install the removed parts in the reverse order of removal. MUFFLER/EXHAUST PIPE REMOVAL Do not service the exhaust system whtle Ills hot. Remove the mlddle/lower cowl (page In Remove the exhaust pipe-to-muffler mounttng bolts. Remove the muffler mountmg bolt/nut and washer, then remove the mulfler. Remove the gasket Canto/ma type Dlsconnect the 0; sensor 4P1Naturallconnector, UNIV Remove the 0: sensor wlre from the frame 2-19 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the 0‘ sensorwne clamp, CLAMP RIGHT STEP GUARD Remove the right step guard mounting bolls‘ \ \x O 0 Release the 0; sensor wire from the right step 0 guard 02 SENSOR WlRE filGHT STEP GUARD O 0 Remove the two bolts and EGCV (Exhaust Gas Control Valve) pulley coverv O O PULLEY COVER Disconnecl me EGCV control cables from the pulley. CONTROL CABLES . O PULLEY FRAME/BODY PANELS/EXHAUST SYSTEM Remove the radlator lower mounting bolt/nut, then move the radiaxor forward. O 0 C Remove the exhaustpipejoim nuts. 0 ‘x \ \\\\>\2\ 4 \‘ VFW»; , ’ J { WWW / 0 Remove the following: *Exhaust pipe mounting boanut *Washer *Collar . *Exhaust Pipe *Exhaust pipe gaskets See page 5100 for exhaus‘ valve removal/disas- sembly. . EXHAUST PIPE U I i 2-21 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Except California type: . MUFFLER EXHAUST PIPE ASSEMBLY California type: MUFFLER EXHAUST PIPE ASSEMBLY 2-22 FRAME/BODY PANELS/EXHAUST SYSTEM Install the exhaust pipe mounting bushing and collar into the lower bracket hole. O .‘ Alwaysrep/acelhe Install the new exhaust pipe gaskets onto the Exhaust/we exhaust ports ofthe cylinder head. gaskets With new ones 0 O Instant/1e washer Install the exhaust pipe, temporarily install the boil and mi! exhaust pipe joint nuts and mounting bolenut. propel/y, First tighten the exhaust pipe joint nuts to the . specified torque. TORQUE: 12 N-m (1.2 kgf»m , 9 Ibf-fll O lighten the exhaust pipe mounting bolt/nut. O . EXHAUST PIPE FRAME/BODY PANELS/EXHAUST SYSTEM Connect the EGCV control cables to the exhaust valve pulley. Adjust the control cables (page 5-95). CONTROL CABLES Install the EGCV pulley cover and tighten the bolts to the specified torque. TORQUE: Upper mounting bolt: 12 N-m H‘Z kgf‘m , 9 lbf-ftl Lower mounting bolt: 12 N-m 11.2 kgf-m , 9 lbf-fll Install the radiator lower mountlng bolt/nut and ' tighten the nut. Call/arms lype Clamp the 0} sensor wlre to the right step guard‘ only FRAME/BODY PANELS/EXHAUST SYSTEM Install the rigth step guard and rear master cylinder, CLAMP RIGHT STEP GUARD thentighten the mounting boltsi \\ Clamp the 0; sensor wrre with the rear brake reseroir hose usmg the hose clamp. \/ BOLTS Route the 0; sensor wire into the frame‘ Connect the 02 sensor 4F (Natural) cannectorv install the new gasket onto the exhaust pipe as shown. Install the muffler, Temporarily install the muffler mounting bolt/nut. Tighten the mulfler/exhaust pipe mounting bolts securely, Tighten the muffler mounting bolt/nut securely. Install the middle/lower cowl (page 277), 3. MAINTENANCE SERVICE INFORMATION 3-1 DRIVE CHAIN 3-20 MAINTENANCE SCHEDULE 3-3 BRAKE FLUID 3-25 FUEL LINE 3-4 BRAKE PAD WEAR 3<25 THROTTLE OPERATION 3-5 BRAKE SYSTEM 3 MOUNTING BOLT . install a fuel tank mounting bolt _ ) O 0 Open and support the front end of fuel tank using a sultable support as shown. ’3 0 Check the fuel lines for deterioration, damage or leakaget Replace the fuel line if necessary. 0 Install the fuel tank m the reverse order of removal‘ 0 C THROTTLE OPERATION Check for smooth throttie grip full opening and automatic full closing in ali steering positions, Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is not smooth. Measure the free play at the throttle grip flange. FREE PLAY: 2’5 mm l1/16’ 1/4 in) Throttle grip free play can be adjusted at either end ofrhethrottle cable, Minor adjustments are made with the upper adjusterv Adjust the free play by ioosening the lock nut and turning the adjusteri Major adjustments are made With the lower adjuslr er, Remove the air cleaner housing (page 5766). Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely, Recheck the throttle operation, Replace any damaged parts, it necessary AIR CLEANER Open and support the front end of luel tank (page 3-4). Disconnect the IAT (Intake Air Temperaturei sensor connector lpage 578“. Remove the screws and air cleaner housing covert MAINTE NANCE LOCK NUT ADJUSTER O MAINTENANCE Remove and ‘dtscard the arr cleaner eiement m . , . - ELEMENT accordance With the maintenance schedule (page 33” Also replace the arr cleaner element any time it is . EXCESSIVBIV dirty or damage. instail the removed parts in the reverse order of removall O SPAR K PLU G . REMOVAL Be careful not to damage the radiator fins. . Remove the middle cowl {page 275), SPECIAL BOLT SCREWS 0 Disconnect the fan motor Subrharness 2P (Black) 2P (BLACK) CONNECTOR connector. 0 C Remove the radiator lower mounting bolt/null . O MAINTENANCE Remove the radiator upper mounting bolt and washer. Remove the radiator grommet from the frame boss by moving it to the right, then move the radiator forward. Clean around the spark plug bases mm compressed arr be/Ure removing and be sure Ihal no debris IS allowed to enter The Cumin/siren chamber Disconnect the direct ignition coil connectors. Remove the direct ignition coils term [he spark piug. Remove the spark plug using a equipped spark plug wrench or an equivalent. Inspect or replace as described in the maintenance schedule UPPER MOUNTING BOLT'WASHER pIRéCflGNITION COILS MAINTENANCE Tnls molorcycle s spark plug equlpped Wllh llldlum center eleclrooe Replace me spark plug rl the electrodes rs contamlnaled Always use specllled spark plugs on Mrs motorcycle To prevenl damaglng lne lrldlum center EIGEWOUQ, Us? a wlre lype lee/er gauge to check the spark plug gap Do not ad/ust the spark plug gap l/ the gap IS on! o/ spec/flcallon. replace Wlfh a new one INSPECTION Check the followlng and replace if necessary (rear ommended spark plug: page 371) ' Insulatorfor damage 0 Electrodes for wear 0 Burning condition, coloration If the electrode is contaminated wlth accumulated objects or dirt, replace the spark plug. Replace the plug if the center electrode is rounded as shown in the illustration SPECIFIED SPARK PLUG: |UHZ7D (DENSO) Check the gap between the center and side electrodes wlth a wire type leeler gauge Make sure that the $10 mm (0.04 ml plug gauge does not insert between the gap. If the gauge can be Inserted lnto the gap, replace the plug with a new ones Reinstall the spark plug in the cyllnder head and hand tlghten, then torque to speCIlication. TORQUE: 12 N-m (1t2 kgf-m ,9 lbfeft) If using the new plug, install as follows: Install and hand tighten the new spark plug, then tighten it about 1/2 turn after the sealing washer contacts the seat ofthe plug holes ELECTRODE INSULATOR —>—— _ ROUNDED ELECTRODE WIRE TVPE FEELER GAUGE MAINTENANCE install the direct ignition coils. install the blue Connect the direct ignition coil connectors. Iaped Wire connector {0 the N0 2 direct ignition corl Install the radiator grommet onto the frame boss. Install the washer and radiator upper mounting bolt, then tighten the bolt, instaii and tighten the radiator lower mounting bolt] nut. MAINTENANCE Connect the fan moKor subharness 2P IBIack) connector. Install the middIe cowl Ipage 277)‘ VALVE CLEARANCE Inspecv and adjust Ihe valve clearance why/e [he engme /5 cold (below 35 cm 95 ’F). INSPECTION Remove the cylinder head cover (page 375), Remove the cam chain tenstoner lifter sealing bolt and sealing washer‘ Turn the cam chain lensioner lifter shaft fuIly and secure it using the mechanic's lensloner stopper tool (page 878I. 2P (BLACKI CONNECTOR MIDDLE COWL SPECIAL BOLT SCREWS CAIVI CHAIN TENSIONER LIFTER BOLT STOPPER TOOL 3-10 MAiNTE NANCE Remove the timing hole cap and O-ringr O O . Turn the crankshaft clockwise, align the "T” mark on the Ignition pulse generator rotor with the index mark on the right crankcase cover. 0 O The timing marks I"|N" and “EX"l on the Cam sprockets must be flush with the cylinder head surface and facing outward as shown, I If the timing marks on the cam sprockets are lacing inward, turn the crankshaft clockwise one full turn l360°l and realign the timing marks with the cylinr der head surface so they are facing outward. I . Insert the leeler gauge between the valve lilter and the cam lobet N03 lNTAKE VALVES Record me Check the valve clearance for the No.1 and No.3 cylr No.1 INTAKE VALVES Clearance Ior each inder intake valves using a leeler gauge. valve for reference in shim VALVE CLEARANCE: selection” IN: 0.16 i 003 mm (0.005 L 0.001 in) . adjustment is required O 3-11 MAINTENANCE Turn the crankshaft ciockwise 1/2 (urn H80”). align the index line on the ignition puise generator rotor 50 that it is facing up as shown. Record the Check the valve crearance for the No.2 and No.4 cyl- ciearance /or each inder exhaust valves using a feeler gauge. valve for re/erence m shim VALVE CLEARANCE: selection if EX: 0.27 : 0.03 mm {0.011 A» 0.001 in) ad/usrmem l5 reqtured Turn the crankshaft ciockwtse 1/2 turn (180“), align the "T" mark on the ignition pulse generator rotor With the index mark on the right crankcase cover. Record the Check the valve clearance (or the N02 and No.4 cyl- clearance /ar each inder intake valves usmg feeler gauge. valve m: reference in shim VALVE CLEARANCE: seleclionlf IN: 0.16 i: 0.03 mm 10,006 i 0.001 ini adjustmeflr is requued INDEX LINE No.2 EXHAUST VALVES No.4 EXHAUST VALVES INDEX MARK 3-12 MAINTENANCE O O 0 Record the clearance for each valve for reverence H7 shrm seleclron If ad/uslmenl ls recurred, O O O I E O I Turh the crankshaft cloclfvvrse 1/2 turn (180“), allgn lNDEX LINE the mdex llne on the lgnltlon pulse generator rotor so that rt is lacing up as shown Check the valve clearance for the No.1 and N03 cylr inder exhaust valves using a feeler gauge, VALVE CLEARANCE: EX: 0.27 I 0 03 mm (0.011 I 0.001In) N03 EXHAUST VALVES No.1 EXHAUST VALVES ADJUSTMENT Remove the camshaft lpage 8-7). Remove the valve llflers and shims‘ 0 Shim may stick to the Inside oflhe valve lifter. Do not allow the ShlmS to fall into the crankcase 0 Mark all valve lifters and shlms to ensure correct reassembly In their original locations. 'The valve lifter can be easily removed with a valve lapping tool or magnet. ' The shims can be easlly removed with a tweezers or magnet. Clean the valve shlrn contact area In the valve lrlter VALVE LlFTER wrth compressed air. _ 3-13 MAJNTENANCE slxlv-rlve Measure the shlm thlckness and record it, dl/Iefeflt l‘h/Cknessshlms Calculate the new shlm thickness using the SHIM areavallable hem equanon below. . me lhlnnesI A f (B aCer 1 200 mm Ihlcklless shlm la A: New shlm thickness the thlckesz 2 800 B: Recorded valve clearance mm lhlckness slum C: Speclfied valve clearance m lnlerva/s 0! D: Old shim thickness . U 025 mm 0 Make sure of the correct shlm thlckness by meas» uring the shim by micrometer. - Reface the valve seat lf carbon deposit result in a calculated cllmenslon of over 2800 mm. 0 O 1.80mm 1825mm 1.85mm 1.875 mm 0 lnslallIhe slllms Install the newly selected shlm on the valve relaln' STOPPER TOOL and Valvellll‘els ln er. meuongmal Apply molybdenum disullide oil to the valve lifters. locarlons Install the valve lifters into the valve lifter holesr . Install the camshaft (page 8-24), Rotate the camshafts bv rotat‘lng the crankshaft clockwise several times. Recheck the valve clearance. C Remove the cam chalntensioner stoppertoolv 7 \ 11 Install the new sealing washer and cam cham tenr CAM CHAIN TENSlONER LIFTER BOLT . sloner lifter sealing bolt. __ \ Tighten the bolt securely. Install the removed parts in [he reverse order of removalt I C 3-14 MAlNTE NANCE ENGINE OlL/Oll. FlLTER OlL LEVEL INSPECTION Start the engine and let II idle for 2 , 3 minutes‘ Turn of! the engine and support the motorcycle level surface, Check the oil level through the inspection window If the level is below the lower line, remove the oil filler cap and fill the crankcase with recommended all up to the upper level line. Remove the oil filler cap, Fill the recommended engine oil up to the upper level line. Other vrscos/ues RECOMMENDED ENGINE OIL: shown in the Char! Pro Honda GN4 or HP‘ 4rslroke Oil (USA & may be used when Canadal, or Honda 4rstroke oil lCanada onlyl, ‘ (heaverage or equivalent motor oil Iemperalure m API service classification: SF or SG your riding area rs Viscosity: lDWrAD SKE zaw-su sAE zaw-w snE wuwrw Wllhln (he 0 2a 4n so an ma 'F lnd/CaIEd range. Reinstall the liller cap and dipstick. l_1—_l_.l—l 2H m a m 20 an m c MAINTENANCE ENGINE 0!]. & FILTER CHANGE Change me engme Warm up the engine. oI/W/Ih me engme . warm and the Stop the englne and remove the oil filler cap motorcycle on level glound to assure complete dlalnmg, 0 Remove the drain bolt and draln the oil completely, 0 O 0 Remove ”‘9 midd'e/‘Owe’ COW' (Page 2'5" OIL FILTER CARTRIDGE OIL FILTER WRENCH Remove and dlscard the oil filter cartrldge using the speclal tool. . TOOL: Oil filter wrench o7HAA-PJ70100 0 Check that the sealmg washer on the drain bolt Is in 7‘ good conditlon, and replace if necessary, . Install and tlghten the drain bolt. TORQUE: 29 N-m (3,0 kgf-m , 22 lbf-m 0 w? OIL DRAIN BOLT/ ~4 SEALING WASHER 0 3-16 — MAINTENANCE Apply Oil to the new oil filter O»ring. Install the new oil tiller and tighten it to the speck fled torque. TOOL: Oil filter wrench 07HAA7PJ70100 TORQUE: 26 Nm (2.7 kgf-m , 20 lbf-ftI Fill the crankcase With recommended engine oil. OIL CAPACITY: 3.5 B (3.7 US at , 3.1lrnp ml at draining 3.7 t (3.9 US qt , 3.3 Imp qt) at oil filter change Install the oilfiller cap. Start the engine and let it idle for 2 to 3 minutes. Stop the engine and recheck the Oil level. Make sure there are no oil leaks. Install the middle/lower cowl (page 277). OIL FILTER CARTRIDGE \ g a O’RING OIL FILTER CARTRIDGE OIL FILTER WRENCH / \_‘d4, 3-17 MAINTENANCE ENGINE IDLE SPEED ' Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications, - The engine must be warm for accurate idle speed Inspection and adjustment. Warm up the engine for about ten minutes. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,200 i 100 rpm RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the “UPPERH and "LOWER“ level lines, If necessary. add recommended coolant. RECOMMENDED ANTlFREEZE: High quality ethylene glycol antifreeze containing corrosion protection inhibitors. Remove the middle cowl lpage 275i, Remove the reserve tank filler cap and fill to the ”UPPER" level line with 50/50 mixture of distilled water and antifreeze. Reinstall the fillercap. COOLING SYSTEM Remove the middle/lower cowl (page 25). Check the radiator air passages for clogging or damage, Straighten bend iins, and remove insects, mud or other obstructions with compressed air or low wa- ter pressure. Replace the radiator ii the air flow IS restricted over more than 20% of the radiating surface. THROTTLE STOP SCREW UPPER LEVEL LINE 3-18 MAINTENANCE Inspect the radiator hoses for cracks or deterioration, and replace ii necessaryr Check the tightness of all hose clamps and fastenr ers. SECONDARY AIR SUPPLY SYSTEM If the hoses show any Signs 0/ heel damage, lnspec! (he PA/Fi check valve H1 lhe PAIR reed valve cover lor damage 'TI’IIS model is equipped built»in secondary air supply system The pulse secondary air supply system is located on the cylinder head cover. - The secondary air supply system introduces Vila tered air into exhaust gases in the exhaust port The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system This charged secondary air promotes burning ofthe unburned exhaust gases and changes a considerable amount of hydrocar- bons and carbon monoxide into relatively harmless carbon dioxide and waterv Remove the air cleaner housing (page 5-58l. Check the PAIR (pulse secondary air injectionl tubes between the PAIR control solenoid Valve and cylinder head cover for deterioration, damage or loose connections. Make sure that the hoses are not cracked. Check the air suction hose between the air cleaner housing and PAIH control solenoid valve for deterioration, damage oi loose connections. Make sure that the hoses are not klnked, pinched 0r cracked, RADIATOR HOSE PAIR REED VALVE EXHAUST PORT CVLINDER HEAD COVER PAIR CONTROL VALVE AIR SUCTION HOSE MAINTENANCE EVAPORATIVE EMISSION CONTROL EVAPCANlSTER SYSTEM (CALIFORNIA TYPE ONLY) A Check the tubes between the fuel tank, EVAP canister, EVAP purge control solenoid valve for deterioration, damage or loose connections Check the EVAP canlster Ior cracks or other damage. Refer to the Vacuum Hose RotItIng Diagram Label lpage LABI and Cable 8t Harness Routing (page 1723l for tube connections. DRIVE CHAlN Never mm, and DRIVE CHAIN SLACK INSPECTION ad/ust {he drlve charm whrlelhe Turn the ignition switch OFF, place the motorcycle errgmels runnmg on its side stand and shirt the transmission Into neutral, Check the slack In the drive chain lower run midway between the sprockets. CHAIN SLACKMO’SO mm (1,6T2t0 Inl Excessive chain s/ack, 50 mm (2.0 in) 0r more, may damage the frame. LubrIcate the drive chaIn with 280790 gear oil or drIve chain lubricant designed specifically for use with O-ring chains. Wipe off the excess oil or chain lubrIcant. . ADJUSTMENT _r s ' from NL‘J?‘ Loosen the rear axle nut. Loosen drive chaIn adjust bolt lock nuts and turn both adjusting bolts until the correct drive chain slack is obtained. Make sure the index marks on the both adjustlng plate are aligned with the swingarm index mark. Tighten the rear axle nut to the specified torque. TORQUE: 113 Nm l11.5 kgfvm , 83 Ibf-ltl Tighten both drIve chain adjusting bolt lock nuts. 4 .AXLg NUT’ 3-20 MAINTENANCE Recheck [he drlve chain slack and free wheel rotation, Lubricate the drive Chain wlth 380*90 gear oil or Pro Honda chain lube designed specifically for use with Orring chains. Wipe off the excess oil or chain lubricant. Check the drive chain wear Indicator label attached on the left swingarm. If the drive chain adjusting plate Index mark reaches red zone of the indicator label, replace the drive chain With a new one (page 3A22I. CLEANING AND LUBRICATION Clean the chain with nonrflammable or high flash pointsolventand wipe itdry. Be sure the chain has dried completely before lubricating. Inspect the drive chain for possible damage or wear, Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace the sprocket as necessary. Lubricate the drive chain with :80 '90 gear oil or Pro Honda chain lube designed specifically Ior use With Orring chains. Wipe off the excess oil or chain lubricant. SPROCKET INSPECTION Inspect the drive and driven sprocket teeth Ior wear or damage, replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condi- tion, or the new replacement chain will wear rapidly. INDICATOR LABEL RED ZONE NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT WIPE AND DRY 7" LUBRICATE i 3. 80*90 GEAR OIL OR PRO HONDA CHAIN LUBE NORMAL 3-21 MAINTENANCE When using the spec/a1 Iaol. /cllow Ihé manu/acrurer's INSNLJCIVOH Check the attaching bolts and nuts on the drive and driven sprockets If any are loose, torque them. TORQUE: Drive sprocket bolt: 54 N‘m15,5 kgr-m , 40 Ibf~ftI Driven sprocket nut: 64 N~m 16,5 kgf-rn , 47 IbfrftI REPLACEMENT This motorcycle uses a drive chain with a staked master link. Loosen the drive chain (page not Assembie the special tool as shown. TOOL: Drive chain (00! set O7HMH-MH10103 or 07HMH~MR1010A (U.S.A. only) Locate the crumped pin ends 0! the master link from the outsrde of the chain, and remove the link with the dere Cham tool set. TOOL: Drive chain tool set 07HMH7MR10103 or 07HMHVMR101DA (USA, onlvi Remove the drive ChaH’l. DRIVE SPROCKET DRIVE CHAIN TOOL SET MASTER LINK DRIVE CHAIN TOOL SET 3-22 lnclude me masler Imk when you Counl me dr/Ve chain [mks Remove the excess drive chain links from the new drive chain with the drive Chain tool set. STANDARD LINKS:1DS links REPLACEMENT CHAIN: DlD:D|D SOVAS C1 RK: RK GBSOHFOZS Route the drive chain Into the swingarm as shown. Never reuse the oil drive chain, master link, master link plate and Orrings. Insert [he masler link from me msrde 0/ me drive Chain, and msra/i the plate WlIh me ldenli/icallon mark Iacmg Ihe oulslde Assemble the new master link, O-rings and plate. Assemble and set the drive chain tool set TOOL: Drive chain tool set D7HMH-MR10103 or D7HMH-MR1010A (U,S.A. onlyl MAiNTE NANCE 108 LINKS O-HINGS PLATE MASTER LINK DRIVE CHAIN TOOL SET 3-23 '4 MAINTENANCE Make sure that the master link plns are installed MASTER LINK PINS properly‘ Measure the master link pm length projected from . the plate, 7'7' STANDARD LENGTH: DID:1.15 155 mm (0045 ’0.061ll’ll RK: 12,14 mm (0,05’0361n) Stake the master link puns. . Make sure that the pins are staked properly by SLIDE CALIPER . measuring the diameter of the staked area usmg a sllde caliper. DIAMETER OF THE STAKED AREA: DI ' 50*5‘80 mm (0,217 *0228 In) BK: 545 "5,85mm10215io230inl . . Adm/e char/7 wrlh After staking, check the staked area of the master a C/lprlype master link for cracke lmk muslnolbe lf there IS any cracklng, replace the master link, 0- used rings and plate. Goon NO GOOD 0 u m C CRACKED O O O 3-24 MAlNTENANCE BRAKE FLUID . 0 Do not mix different types of fluid, as they are not compatible With each other. v Do not allow foreign material to enter the system when filling the reservoir. 0 Avoid spilling fluid on painted, plastic or rubber . parts. Place a rag over these parts whenever the system is serwceii V‘lhen the fluid level is low, Check the brake pads for wear lsee belowl. A low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper piston is pushed out, and this 0 accounts for a low reserVOIr level. If the brake pads are not worn and the fluid level ls low, check entire system for leaks (see next page). FRONT BRAKE . Turn the handlebar so that the reservoir lS level and check the front brake fluid reservoir level. ll the level is near the lower level line, check the brake pad wear (see belowl. REAR BRAKE 0 Place the motorcycle on a level surlace, and supr LOWER LEVELQNE port it upright position. Check the rear brake fluid reservoir level. lithe level is near the lower level line, check the WEAR INDICATOR brake pad wear (see belowl. . BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom orwear llmit groove. Refer to page 1577 for brake pad replacement. REAR BRAKE PADS Check the brake pad for wear. Replace the brake pads it either pad is worn to the l bottom of wear limit groove. l Refer to page 1578 for brake pad replacement. l #l H ~_._.. ll WEAR lNDICATOFt 3-25 MAINTENANCE BRAKE SYSTEM BRAKE HOSE INSPECTlON ‘ 'i .‘ Firmly apply the brake lever or pedal, and check that no air has enlered the system. If the lever or pedal feels soft or spongy when Open atecl, bleed the air from the system. Inspect the brake hose and littings for deterioration, . cracks, and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required, Refer to page 1575 for brake bleeding procedures. BRAKE LEVER ADJUSTMENT ADJUSTER . Align Ihe The distance between the top of the brake lever and allowance on me the grip can be adjusted by turning the adjuster. Drake lever wnn the llidE'X number on [he ad/Usler . I BRAKE PEDAL HEIGHT ADJUSTMENT PUSH ROD' Loosen the lock nut and turn the push rod until the correct pedal height is obtained. . C The honlbrake Adjust the brake light swltch so that the brake light . llgnlswncn does comes on just prior to the brake actually being no! require engaged, ad/ustmenl If the light fails to come on, adjust the switch so thatthe light comes On at the proper time. Hold the switch body and turn the adjuster. Do not , W.— turn the switch body . “ " C I 3-26 HEADLIGHT AlM Adjusl me headlight beam as spear/led by local laws and regulallons CLUTCH SYSTEM Place the motorcycle on a level surface. Adjust the headlight beam vertically by turning the vertical beam adjusters A clockwise rotation moves the beam up and counterclockwise rotation moves the beam clown. Adjust the headlight beam horizontally by turning the horizontal beam adjuster, A clockwise rotation moves the beam toward the right Slde of the riderv Measure the clutch lever free play at the end of the Clutch lever. FREE PLAV: 10720 mm (3/3713/15 in) Minor adjustments are made using the upper adv juster at the clutch lever. Loosen the lock nut and turn the adjuster. The adjuster may be damaged if it is positioned too far out, leavmg minimal thread engagement, ll the adjuster tS threaded out near its limit and the correct free play cannot be obtained, turn the adjust- er all the way in and back out one turn Tighten the lock nut and make a major adjustment as described as follow. MAINTENANCE ADJUSTER LOCK NUT 3-27 MAINTENANCE Major adjustments are performed at the clutch arm. Loosen the lock nut and turn the adjusting nut to adjust free play Hold the adjustlng nut securely while tightening the lock nut. If proper free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch lsee section 9). SIDE STAND Support the motorcycle on a level surface. Check the side stand spring for damage or loss of tension Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary. Check the Side stand Ignition cutrofi system: *Stt astrltle the motorcycle and raise the side standi Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squeezed. , Move the side stand full down. *The engine should stop as the side stand is lowered if there is a problem With the system, check the side stand switch (section 19). SUSPENSION Loose, worn or damaged suspens/on parls lmpalf motorcycle SlabI/rIy and Conlml FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension sever- al times. Check the entire assembly for signs of leaks, dam- age or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts. Reler to section 13 for fork service. SIDE STAND SIDE STAND SWITCH 3-28 To ad/usl both sides equa/Iy, 55! the fig/7f and lei! damping ad/uslers (O the same position FRONT SUSPENSION ADJUSTMENT SPRING PRE-LOAD ADJUSTER Spring pre~Ioad can be adjusted by turning the adjuster. DIRECTION A: Increase the spring pre~load DIRECTION B: Decrease the spring prerload PRE-LOAD ADJUSTER ADJUSTABLE RANGE: 10 *25 mm (04* 1.0 in) from top of fork boIl PRE-LOAD ADJUSTER STANDARD POSITION: T8 mm 10.7 In) from top Of fork boll COMPRESSION AND REBOUND DAMPING ADJUSTERS sA/ways start on full hard when ad/‘ustlng the damping - Do not turn the adjuster screws more than the given positions or the adjusters may be damaged. 0 Be sure that the rebound and compression adjusters are firmly located In a detent, and not between posrtions, The compression and rebound damping can be adjusted by lurnIng the adjusters. DIRECTION H: Increases the damping force DIRECTION S: Decreases the damping Iorce Turn the compression adjuster clockwise until It stops, then turn the adjuster counterclockwise, COMPRESSION ADJUSTER STANDARD POSITION: 171/2 turns from MI hard MAINTENANCE PREVLOAD ADJUSTER MAINTENANCE Turn the rebound adjuster clockwlse unnl it stops, then turn the adjustercounterclockwise, REBOUND ADJUSTER STANDARD POSITION: . 1 turn from full hard 0 REAR SUSPENSION INSPECTION . Support the motorcycle securely and raise the rear wheel offthe ground. Hold the swmgarm and move the rear wheel sideways to see it the wheel bearings are worn. . 0 Check for worn swmgarm bearings by grabbing the rear swingarm and attempting to move the swlngarm side to side, Replace the bearings if any are looseness is noted. . 0 Check the action of the shock absorber by . compressing It several tlmes. Check the entlre shock absorber assembly for slgns of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired, Tighten all nuts and bolts. 0 Refer to section 14 for shock absorber service. 0 3-30 MAlNTENANCE REAR SUSPENSION ADJUSTMENT COMPRESSION AND REBOUND DAMPING . ADJUSTERS IAlWays start on full hard when adjusting the dampmg. . - Du not turn the adjuster screws more than the given posttions or the adjusters may be damaged. The compression and rebound damplng can be adjusted by turning the adjusters. DIRECTION H: lncreases the damping Iowa 0 DIRECTlON 5: Dec. eases the dampmg Iorce Turn the compressjon adjuster clockwise until it stops, then turn the adjuster counterclockwise COMPRESSION ADJUSTER STANDARD POSITION: . 1turn from full hard 0 Turn the rebound adjuster clockwise until it stops, then turn the adjuster counterclockwise. REBOUND ADJUSTER STANDARD POSITION: O 2 turns from full hard 0 . NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values {page 1-13}. Check that all safetv clips, hose clamps and cable stays are in place and properly secured, O O 3-31 MAINTENANCE WHEELS/TIRES The pressure should be checked when the tires are COLD RECOMMENDED TIRE PRESSURE AND TIRE SIZE: - . I FRONT REAR figrgssure 23012.5073W2’96725,’427 jfla Ikgf/Crri, psi) _‘ __ Tire size 120/7OZR17 190/5OZR17 7.," 7 7 158va (73wi T” B id I ne BTOIOF BT010R bland i: 965 O . . Pilot Pilot M‘Che'm SPORTE SPORTE Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels for trueness (refer to section 13 and 14L Measure the tread depth at the center of the tiresv Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH: FRONT: 1.5 mm 10.06 mi REAR: 2.0 mm 10.08 inl STEERING HEAD BEARINGS Check that the control cables do not interfere with handlebar rotation. Support the motorcycle securely and raise the front wheel 0“ the ground. Check that the handlebar moves freely from side to slde. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (Section 13L 3-32 4. LUBRICATION SYSTEM LUBRICATION SYSTEM DlAGRAM 4-0 SkLS/ERAINERIPRESSURE RELIEF 4—3 SERVICE INFORMATION 4-1 OIL PUMP 4-5 TROUBLESHOOTING 4-2 OIL COOLER 4-9 OIL PRESSURE INSPECTION 4-3 SERVICE INFORMATION - GENERAL ACAUTION Used engine oil may cause skin cancer if repeatedly left in Contact With the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. ‘ The Oil pump can be serwced with the engine installed in the frames ° The serVIce procedures In this section must be perlormed with the engine oil drained ° When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine ‘ If any portion OI the Oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. ‘ After the Oil pump has been installed, check that there are no Oil leaks and that oil pressure is Correct. SPECIFICATIONS Unit: mm (in) ITEM ‘ STANDARD i SERVICE LIMIT if Atdraining 7 film my 4,0214,2U5qt,3;5|flpqtl l ,i,,,, , i_At9i ilterchange 3.7 a (3.9 us qt,3.3 imp qt) , Recommended engine oil Pro Honda GNA or HPA Arstroke oil iU.S,Ar ‘ & Canada), or Honda 4»stroke Oli (Canada only), or equivalent motor oil l API service classification SF or 86 i W, ,7" 7m, ViscosiLES/AE 10W-40 V7 7 ‘ on pressure atoil pressure switch l 490 kPa 15.0 kgr/cm2,71 psii at l E7, , i,,,i, Am rgmLizg)°p/175°Fi 777i 7 7777 ‘ Tip clearance .15 10.006imax. 0.20 (0.008l i Lgody clegflL ; r15*0.2210.006*0.009i 0'35 «101“ i Side clearance i 002—007 10001 “0.003) l 0,10 (000“ 'EhEiTie'WcaEéEiiT‘ Tbiflurfifib'tc? 4-1 LUBRlCATlON SYSTEM TORQUE VALUES OII drain bolt Oll cooler mounting bolt Oil pump assembly flange bolt Oil pump driven sprocket bolt Oil filtercanridge Lower crankcase sealing bolt 29 N‘m (3.0 kgf-m , 22 lbf-fl) 74 N‘l’n l7.5 kgf-m , 54 lbf-fil a N»m love kgf-m , 5.8 lbf-l‘tl 15 Nm l1.5 kglrm ,11lbf-fll 26 Nm l2.7 kgi~rn , 20 lbfhl 30 N‘ml3.1kgf~m,22lbf‘fll Apply a locking agent to the threads CT bolt Apply a locking agent to the threads Apply clean engine oil to the Orring Apply a locking agent to the threads TOOLS Oil pressure gauge Oil pressure gauge attachment Oil filter wrench 075068000000 O7510-MA70000 O7HAA-PJ701OO Equivalent commercially available in U. St A. TROUBLESHOOTING Engine oil level toolow OOrI consumption ‘ External oil leak - Worn piston ring or incorrect plslon ring installation 0 Worn valve guide or seal Low oil pressure 0 Clogged oil strainer screen 0 Oil pump worn or damaged 0 Internal oll leak I Incorrect all being used 0 LOW oil level Low or no oil pressure 0 Clogged Dll orilice . Incorrect oil being used High oil pressure 0 Plugged orl filter, gallery, or metering orifice 0 Incorrect oil being used No oil pressure I OII level too lDW 0 Oil pump drive sprocket broken 0 Oil pump damaged lpump shaft) 0 Internal oil leak Oil contamination - From coolant mixing with oil *Faultv water pump mechanical seal s Faulty cylinder head gasket ~Water leak In crankcase *Faulty oil cooler LUBRICATION SYSTEM OIL PRESSURE INSPECTION ll Ihe or! pressure . lndlL‘alor ngm remarns on a law seconds, check me mdlcator syslern belore checking me on . pressure Check the all level (page 3715l, Warm up the englne to normal operating tempera- ture lapproximately 80"C/176°Fl. Stop the engine and remove the crankcase seallng bolt. Connect an Oil pressure gauge and attachment to the crankcase. TOOLS: Oil pressure gauge 0750573000000 lEquivalent commercially available In USA.) on pressure gauge attachment D7510-MA70000 Start the engine and Increase the rpm to 5,400 rpm and read the oil pressure. OIL PRESSURE: 490 kPa (5.0 kgl/Cl’nZ , 71 psllat 5,400 rpm/ (80°C/175"Fl Stop the englne and remove the tools. Apply a locking agent to the sealing plug threads. Install and tighten the sealing plug to the specified torque. TORQUE: 30 Nm (3.1 kgfvm , 22 lbl‘ft) . OIL STRAINER/PRESSURE RELIEF VALVE REMOVAL Drain the engine oil [page 3-16). Remove the exhaust pipe lpage 2-13). Remove the oil pan flange bolts and all pan. SEALlNG PLUG O LUBRICATlON SYSTEM Remove the pressure relief valve and Orring. RELIEF VALVE ‘ _ O 0 Remove the oil strainerand gasket IL 5W 0 Clean the oil strainer screen. 0 O INSPECTION Check the operation of the pressure relief valve by P‘STON pushing on the piston. . Disassemble the relief valve by removing the snap ring. WASHER Inspect the piston for wear, sticking or damage. % Inspect the spring for weakness or damage. Assemble the rehei valve in the reverse order or RELIEF VALVE BODY @ O disassembly. SPRING SNAP RING Apply oil to the new gasket and install it onto the Oil . Strainer, Install the oil strainer into the crankcase while aligning Its boss with the groove of the crankcase O O 44 LU BRICATION SYSTEM Apply Oll to the new Orrlng and install it onto the RELIEF VALVE 7 ’W \ relielvalve. * O WNG 5?? 9 install the relief valve unto the crankcase. O O O Cleanthe on pan mating Surfacethoroughlv. 00 n0! apply Apply Three Bond 12073 or an equivalent to the sealant more than mating surface. necessary 0 0 Install the oil pan onto the lower crankcase, Install the oil pan mounting bolts. Temporarily tighten the two bolts lirst, then tighten . the all bolts in a crisscross pattern in 2*3 steps. install the exhaust pipe (page 2720l. Fill the crankcase with recommended oil lDage 3715i After installation, check that there are no oil leaks. O BOLTS . OIL PUMP ‘ _ ‘ jfioufih Gl‘JVlDEo REMOVAL " g 3 Remove the following: *CIutoh assembly (page 94) *OiI strainer and pressure relief valve lpage 44H 0 Remove the bolt/washer, then remove the oil pump drive/driven sprocket, clutch outer guide and drive Chain as an assembly 0 4-5 LUBRICATION SYSTEM Remove the three flange boIts and DH pump assem- My. 0 O DISASSEMBLY DOWEL PINS ASSEMBLY BOLT . Remove the dowel pins. Remove the ml pump assembly bolt and OH pump cover. 0 OIL PUMP COVER 0 Remove the thrust washer, drive pin, oi! pump IN” \ER ROTOR OUTER ROTOR shaft, outer rotor and ‘mner rotor from the oiI pump at» ‘ “r body. 0 fl OIL PUMP SHAFT O DRIVE PIN WASHER fi INSPECTION . Temporarily instalI the oil pump shaft‘ Install the outer and Inner rotors into the oil pump body. Measure the tlp clearance‘ , O SERVICE LIMIT: 020 mm 10.008 ”II C LUBRICATION SYSTEM Measure the pump body c‘earancev SERVICE LIMIT: 035 mm (0.014 W . O . Measure the side clearance using a slraight edge and leeler gauge, SERVICE LIMIT: 0.I0 mm (0004 in) O . ASSEMBLY DOWEL PINS . INNER ROTOR . DRIVE PIN ‘ OILPUMPSHAFT O 0”— PUMP BODV OIL PUMP COVER OUTER ROTOR . WASHER 8 N»m10,8kgi.m, 5.8 lbfAfl) C 4-7 LUBRICATION SYSTEM Install the Outer role! will Its pt/nC/I mark Aacmg me ml pump cal/er Install the cuter and Inner rotors Into the or] pump INNER ROTOR OUTER ROTOR body, L “v Install the oil pump shaft through the Inner rotor and oil pump body‘ Install the drlve pln InlO the hole In the pump shaft and align the pin with the groove in the inner rotor as Shown. Install the thrust washer. "ma” the We‘ W‘s' V DOWEL PINS ASSEMBLY BOLT Install the orl pump cover and tlghten the assembly bolt to the specified torque, TORQUE: B N»m 10.8 kg?!“ , 5.8 lbf-ftl Check the 0i! pump operatron by turning the pump shaft. If necessary, reassemble the oil pump. ‘ 5%» OIL PUMP COVER iNSTALLATION Install the all pump Into the crankcase while alignr lng the pump shaft lug with the water pump shaft groove. Install and tighten the three flange bolt securely. LUBRICATION SYSTEM Install the on pump urn/en smock er wrthlts our" mark ramng outward Apply oil to the clutch outer guide, oil pump drive sprocket, driven sprocket and drive chain. Install the clutch outer guide, drive/driven sprocket and drive chain as an assembly‘ Apply a locking agent to the oil pump driven sprockr et bolt threads, Install and tighten the driven sprocket bolt/washer to the specifiedtorque. TORQUE: 15 Nvm 11.5 kgf»m,11|bf-ftI Install the following: *0” strainer/oil pipe and oil pan lpage 475i *CIutch assembly [page 9A9l After installation, fill the crankcase with recomr mended oil and check that there is no oil leaks‘ Check the oil pressure lpage 4-3)V OIL COOLER REMOVAL Drain the engine oil and remove the oil filter cartridgelpage3-16l. Drain the coolant from the system lpage 674i. Remove the radiator reserve tank (page 647i. Loosen the hose bands and disconnect the oil cooler water hoses from the cooler. Remove the oil cooler mounting bolt, lock washer and Oil cooler, Remove the Orring‘ INSPECTION Check the oil cooler for damage. RGUIDB OIL COOLER LUBRICATION SYSTEM INSTALLATION WATER HOSES OlL COOLER OlL COOLER BOLT 74 NW! [7.5 kgl~m , 54 lbflfll OIL FILTER CARTRIDGE 25 Nvm l2.7 kgfvm , 20 lbfrlll .‘ eweom LOCK WASHER Coal a new Owing with engine OII and install it into OIL COOLER lhe oil cooler groove. Install the oil cooler by allgnlng Its guide groove ‘ with the rib on the crankcase. g CARING ALIGN Apply oil to the oil cooler mounting bolt threads MOUNTING BOLT ”0,, MARK and seallng surface. “75‘8” We look Install the lock washer and oil cooler boll. washer erh 713 Concave Slde ("0 ‘mark) /acmg the or! Cooler WASHER 4-10 Be sure lhe cooler Tughlen the oil cooler mountlng bolt (0 the speclfied ba/ICo/lars/ldes lorque, lnslde H79 OH O COO/er, TORQUE: 74 N-m (7.5 kgfvm,541bf-ft) O 0 Connect the on cooler water hoses, tighten the hose band securely, Install the oil Vllter cartridge and fill the crankcase with recommended oil (page 345). Fill the cooling system and bleed air lpage 6-4). 0 O O O O O O LU BRICATION SYSTEM MOUNTING BOLT 4-11 FUEL SYSTEM (Programmed Fuel Injection) 22 N-m (2‘2 kgf-m,16lbfvft) 3 N-m10.35 kgf-m , 2‘5 lbf-m 5-0 51 FUEL SYSTEM {Programmed FueI Injection) SERVICE INFORJ‘AATION 5-1 MAP SENSOR 5-83 TROUBLESI—I DOTIFI‘G 5-3 IAT SENSOR 5-84 SYSTEM LOCATION 5-4 ECT SENSOR 5-85 SYSTEM DIAGRAM 5-6 CAM PULSE GENERATOR 5-85 PGM-FI (PROGRAMMED FUEL TP SENSOR 5-86 INJECTION) SYSTEM 5-8 BANK ANGLE SENSOR 5-88 PGM-FI SELF-DIAGNOSIS MALFUNC-TION INDICATOR ENGINE STOP RELAY 5-89 LAMP (MIL) FAILURE CODES 5~12 ECM (ENGINE CONTROL MODULE) 5-89 FUEL LINE INSPECTION 5-56 PAIR SOLENOID VALVE 5'91 FUEL PUMP 5-59 PURGE CONTROL SOLENOID VALVE FUEL CUT RELAY 5-60 (CALIFORNIA TYPE ONLY) 5-92 FUEL TANK 5-61 02 SENSOR (CALIFORNIA TYPE ONLY) 5-92 AIR CLEANER HOUSING 5-66 EGCV AND AIR INTAKE VALVE INSPECTION 5-94 THROTTLE BODY 5-68 EGCV AND AIR INTAKE VALVE INJECTOR 5-73 SERVO MOTOR 5-97 PRESSURE REGULATOR 5-75 EGCV 5-100 FAST IDLE WAX UNIT 5-75 VARIABLE AIR INTAKE VALVE 5-107 STARTER VALVE 5-78 STARTER VALVE SYNCHRONIZATION 5-81 SERVICE INFORMATION GENERAL ‘ Be sure to relteve the fuel pressure while the engine is OFF. ‘ Bending or IWISIII’Ig the control cables wiII Impair smooth operation and cDuld cause the cables to suck or bind, resuIting in I055 of vehicIe controI. FUEL SYSTEM (Programmed Fuel Injection) o Do not apply commercially available carburetor cleaners to the ll’lSlde of the throttle bore, which is coated with molybdenum. I Do not snap the throttle valve from full open to full close alter the throttle cable has been removed. it may cause incorrect idle operation. I 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. I Do not apply excessive force to the fuel pipe on the throttle body while removing or installing the throttle body. I Do not damage the throttle body. It may cause incorrect throttle and idle Valve synchronization. I Prevent dirt and debris from Entering the throttle bore, fuel tube and return tube, clean them using compressed air. I The throttle body is factory Dre-set. Do not disassemble in a way other than shown In this manual. I Do not loosen or tighten the White painted bolts and screws of the throttle body. Loosening or tlghtening them can cause throttle and Idle valve synchronization failure. . Do not push the fuel pump base under the fuel tank when the fuel tank is stored. . Always replace the packing when the itiel pump is removed. IThe programmed fuel injection system is equipped With the SelfrDiagnostIc System described on page 58. lf the malfunction indicator lamp blinks, follow the Self-Diagnostic Procedures to remedy the problem. I When checking the PGlVIrFI, always follow the steps In the troubleshooting flow chart lpage 5712). IThe PGMVFI system is provided with failrsafe function to secure a minimum running capability even when there is any trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making use of the numerical values of a situation preset in advance in the simulated program map. It must be remembered, however, that when any abnormality is detected in four injectors and/or the ignition and cam pulse generator, the fail safe function stops the engine from the standpoint of protecting it. I For PGM-Fl system location, see page 5-4. I A faulty PGIVI-Fl system is often related to poorly connected or corroded connectors. Check those connectlons before proceeding. I For fuel reserve sensor inspection, see section 19. I The vehicle speed sensor sends digital pulse signal to the ECM lPGM-Fl unitl and computation. For vehicle speed sensor inspection, see section 19. I When disassembling the programmed fuel injection parts, note the location of the O-rings. Replace them with new ones upon reassembly 0 Before disconnecting the fuel tube, release the fuel pressure by loosening the fuel tube banjo bolt at the fuel tank. I Always replace the sealing washers when the fuel tube banjo bolt is removed or loosened. I Used a digital tester for PGlVlrFl system inspection. I EGCV is the abbreviation for Exhaust Gas Control Valve. SPECIFICATIONS ITEM 1 SPECIFICATIONS Throttle body identification 49 states, Canada type (3060C _ number W. 7 W Californiatype cocoa fistagervalve vacuum difference V . 1 20 mm Hg 7 fl 7 Ease throttle valve for synchronization ' No.1 ldleispeed fij 1,200 i 100 rpm thptlle gripfree play 276 mmli/1571/41nl 77 Intake airtemperature sensor resistance (at 20"C/68°Fl 1* A k 52 Engine coolant temperature sensor reelstance (at 20°C/68°Fl M 2.3 a 2.6 k 52 Fuel injector resistance la}lO°C/68°Fl 11.17123 52 m M PAIR solenoid valve resistance lat 20”C/68"Fl 20 a 24 k E} m____ Jgrge control solenoid valve resistance lat 20°C/68"Fl l 30 a 35 k7; Cam pulse generator peak voltage lat 20°C/68°Fl 0.7 V minimum , “m Ignition pulse generator peak voltage lat 20°C/68°Fl _‘ 0.7 V minimum Manifold absolutipressure at idle . 150*250 mm Hg ,7 Fuel pressure at idle_v 7 343 kFa (3.5 kgf/cm1,50 psil w Fuel pumpflowlat 12 V) , 188 cm“(6.4 US 02,6.6lmp oz) minimum/lOseconds 5-2 FUEL SYSTEM (Programmed Fuel Injection) TORQUE VALUES ECT (Engine Coolant Temperatureilthermosensor Throttle body insulator band screw Throttle cable bracket mounting screw Fuel pipe mounting bolt Pressure regulator mounting bolt Starter valve synchronization plate screw Fast idle wax unit link plate screw Fast idle wax unit mounting screw Starter valve lock nut Vacuum joint plug socket bolt for synchronization Fuel filler cap bolt Fuel tube banjo bolt (fuel tank sldel Fuel tube Sealing nut (throttle body side) Fuel pump mounting nut Oi sensor Exhaust valve mounting bolt (front) (rear) Exhaust valve cover mounting bolt Exhaust valve pulley nut Exhaust valve pulley Cover mounting bolt ilowerl TOOLS Peak voltage tester iU.S,A. onlyl or Peak voltage adaptor ECU test harness Installer shait guide installer shaft installer shaft,14 ' 30 mm Remover, 14 ( 16 mm TROUBLESHOOTING Engine won’t to start ‘ intake air leak 0 Fuel contaminated/deteriorated - Pinched or clogged fuel tube 0 Faulty fuel pump 0 Clogged fuel filter ° Clogged fuel injector filter 0 Sticking fuel injector needle I Faulty fuel pump operating system Engine stall, hard to start, rough idling ' Intake air leak ' Fuel Contammated/deteriorated ' Pinched or clogged fuel tube ° Idle speed mleadjusred 0 Starter valve synchronization misadjusted 23 N-m (2.3 kgfvm,17lblrft) See page 1-14 3 N-rn (0.35 kgfam , 2.5 lbf‘lt) 10 N»m (1.0 kgf-m , 7 lbl~ftl 1D N-m (1.0 kgfam , 7 lbfrftl 1 Mm (009 kgf~m , 0.7 lbfvftl 1 Mm (009 kgf~m , 0.7 lbfritl 5 Nam (05 kgfam , 3.6 lbf~fti 2 N-rn (0.18 kgfrm,1,3lbfvfrl 3 N-m (0.3 kgi~m , 2.2 lbf-fti 2 N-m (0.2 kgiorl’l ,1.4lbfvftl 22 Nam (22 kgf-m,16|bf-fl) 22 N.m (2.2 kgf-m ,16lbf-ft) 12 N»m (1,2 kgf-m , 9 |bf~fti See page 5760 for tightening sequence 25 N-m (2.5 kgf-m ,19Ibf‘frl 14 N-m (1.4 kgf~m ,10lbf~ftl 14 N-m (1.4 kgf~m,10lbiafll 12 N-m (1.2 kgfrrn , 9 lbf-ftl 12 N-m (1.2 kgfrm , 9 lbf-ftl 12 N-m (1V2 kgf-m , 9 lbf-fll 07HGJ70020100 with Commercially available digital multimeter (impedance 10 Mil/DCV minimum) 07VMZ-00i 0100 (two required) D7YMF7MCJ0100 D7VMF7MCJ0200 07YMF-MCJ0300 07YMF-MCJ0400 Backfiring or misfiring during acceleration - Ignition system malfunction Poor performance (driveahility) and poor fuel economy ‘ Pinched or clogged fuel tube 0 Faulty pressure regulator 5-3 FUEL SYSTEM (Programmed FueI Injection) SYSTEM LOCATION Except California type: TP SENSOR PAIR SOLENOID VALVE IAT SENSOR MAP SENSOR FUELPUMP ENGINE STOP RELAY BANK ANGLE SENSOR FUEL CUT RELAV INJECTOR CAM PULSE GENERATOR PRESSURE REGULATOR EGCV AND AIR INTAKE VALVE SERVO MOTOR ECT SENSOR VEHICLE SPEED SENSOR IGNITION PULSE GENERATOR FULL NAME ABBREVIATIONS Manifold absolute pressure sensor MAP sensor 77 Throttle positron sensor TP sensor Intake alrtemperalure sensor I _IAT sensor Engine coolangt‘eflperature sgnspr I ‘E‘QT sensor Engine controI module ‘ ECM FUEL SYSTEM (Programmed FueI Injection) California type: TP SENSOR PAIR SOLENOID VALVE IAT SENSOR MAP SENSOR FUEL PUMP ENGINE STOP RELAV / BANK ANGLE SENSOR FUEL CUT RELAY INJECTOR CAM PULSE GENERATOR PRESSURE REGULATOR EGCV AND AIR INTAKE VALVE SERVO MOTOR ECT SENSOR Oz SENSOR VEHICLE SPEED SENSOR IGNITION PULSE GENERATOR FULL NAME ABBREVIATIONS ManifoId absolute pressure sensor MAP sensor Throttle po_sit|on sensor TP sensor , Imake an: temperature sensor IAT sensor Engine coolannemperature sensor WEQT sensor Engine control module ‘ ECM 5-5 O FUEL SYSTEM (Programmed Fuel lnjection1 Except California type: 0 O O O O O O 111 Engine stop relay 117) ‘ Injector 121 ‘ Main fuse 5120A1 118) ‘ Cam pulse generator 131 1 Engine stop switch (191 PAIR check valve 141 Subrfuse 110A) 1201 ‘ ECT sensor 151 ignition switch 1211 Ignition pulse generator . 161 3 Main fuse A 130A1 1221 Coolant temperature LCD 17) 1 Bank angle sensor [231 Fuelcut relay 181 1 Subrfuse 110A) (241 Fuel pump 151 ‘ Battery 1251 Vehicle speed sensor 1101 Pressure regulator 1261 I Neutral switch 1111 lAT sensor 1271 Clutch switch . 1121 Direm ignltion coil/spark plug [281 ‘ Side stand switch (131 PAlR solenoid valve 129) ‘ Malfunction indicator lamp (141 ‘ TP sensor 1301 1 Service check connector 1151 1 EGCV and an intake valve servo motor 1311 1 Tachometer (151 l MAP sensor FUEL SYSTEM (Programmed Fuel Injection) California type: 11) Engine stop relay 118) 1 Cam pulse generator 12) ‘ Main fuse B120A) (19) 1 PAIR check valve 13) l Englne stop switch (20) 1 ECT sensor 14) ‘ Sub-fuse 110A) 121) ‘ Ignition pulse generator (5) ‘ Ignition switch 122) Coolanttemperature LCD (61 ‘ Main fuse A 130A) 123) Fuel cut relay 171 Bank angle sensor 124) Fuel pump 18) ‘ Sub-fuse 110A) 1251 1 Vehicle speed sensor 19) ‘ Battery 1261 “ Neutral switch 110) 1 Pressure regulator 1271 1 Clutch switch 111) ; IAT sensor 128) Side stand switch 1121 1 Direct ignition coll/spark plug 129) Malfunction Indicatorlamp 113) ‘ PAIR solenoid valve 130) 1 Sen/ice check connector (14) TP sensor 131) ‘ Tachometer 115) ‘ EGCV and air intake valve servo motor 1321 1 EVAP purge conlrol solenoid valve 116) 1 MAP sensor 1331 Oz sensor 117) |n1ect0r 134) EVAP canister 5-7 FUEL SYSTEM (Programmed Fuel Injection) PGM—Fl (PROGRAMMED FUEL INJECTION) SYSTEM SELF-DIAGNOSTIC PROCEDURES Place the motorcycle on lts side standt Start the engine and let it idle. Themallunatlan lf the mallunctlon lndlCalOr lamp (MlLl does not lndlcalor laffip light or blink, the system has no memory of (MIL) will alert problem data bllnklngon/y Wllh II the malfunction indlcator blinks, note how many the sldesIaNd times the malfunction lndlcator lamp lMlLl blinks, down and will Ihe and determine the cause of the problem (page 5-12 engine on (engine through 559. stop sztcn in RUN) or engine revs are below 5 000 rpm ln any other Cofldlfloflsi me malfunction indicator lamp (MIL) WIII ll/L/mmale and slay 0/7 If you wish to read the PGMrFI memory for trouble data, perform the following: Turn the lgmtlon switch OFF. Remove the seat lpage 2-2l. Short the FGMVFI system service check connector terminals using alumpelwire. MALFUNCTION INDICATOR LAMP lMlL) IGNITION SWITCH SERVICE CHECK CONNECTOR JUMPER WIRE O FUEL SYSTEM (Programmed Fuel injection) Even if (he PGMr FI has memoly data, the MIL does no! blink when the engine /5 running Turn the ignition switch 0N and engine stop switch RUN. If the ECM has no self diagnosis memory data, the MIL will illuminate when you turn the ignition swttch ON. If the ECM has self diagnosis memory data, the ML will start blinklng when you turn the ignition switch ON. Note how many times the MIL blinks, and determine the cause of the problem (page 5712 through 5-55l. SELF-DIAGNOSIS RESET PROCEDURE 1.Turn the engine stop switch to RUN and ignition switch OFF. 2. Short the service check connector ol the PGMVFI system using a jumper wire. 3.Turn the ignition switch ON. 4. Remove the jumper wrre from the service check connector. 5. The MIL lights about 5 seconds. While the indicator lights, short the service check connector again with the jumper wire. Self diagnosis memory data is erased, ii the MIL turn off and start blinking. 0The service check connector must he jumped while the indicator lights. if not, the MIL will not start blinking. 0 Note that the self diagnosis memory data cannot be erased if you turn off the ignition switch be— fore the MIL starts blinking. if the MIL blinks 20 times, the data has not been erased. so try again. lGNlTlON SWITCH MALFUNCTION INDICATOR LAMP (MIL) SERVICE CHECK CONNECTOR JUMPER WIRE MALFUNCTION INDICATOR LAMP lMILl 5-9 FUEL SYSTEM (Programmed Fuel Injection) PEAK VOLTAGE INSPECTION PROCEDURE . Use this procedure for the ignltion pulse generar O tor and cam pulse generator inspection. ' Check all system connections before inspection. If the svstem is disconnected, incorrect peak volt- age might be measured. ‘ Check cylinder compression and check that the all spark plugs are installed correctly, . ‘ Use recommended digital multimeter or commerr ciallv available digital multimeter with an Impedance of 10 M il/DCV minimum. - The clisplav value dilfers depending upon the internal impedance oi the multimeter. ' Disconnect the fuel pump connector before checkr ingthe peak voltage. 0 Open and support the front end of fuel tank lpage 3-4). Disconnect the fuel pump 3P (Blacki connector. AVON: 'WC’WW the Connect the peak Voltage adaptor to the digltal ‘ testerp/obeslo multimeter. prevent electric shock TOOLS: Peak voltage tester (USA. only) or Peak voltage adaptor 07HGJ-0020100 , with commercially available digital multimeter PEAK VOLTAGE ADAPTOR a (impedance 10 M 11 /DCV minimum) 1 i TEST HARNESS CONNECTION ' Remove the seat (page 2-2), Remove the fuel tank mounting bolts and then re- move the luel tank rear bracket (page 5789). Remove the ECM cover. G I 5-10 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM ZZP lBlackl and 22P lLight 22P(LlGHT GRAV)CONNECTOR gray) connectors lrorn the unit. \ 22PlBLACKl CONNECTOR Cennect the ECU test harnesses between the main ECU TEST HARNESS ECM wrre harness and the ECM. TOOL: ECU test harness 07YMZVMCF0000 (two requiredl TEST HARNESS TERMINAL LAYOUT VIEW FROM WIRE HARNESS SIDE: The ECM connector terminals are numbered as shown in the illustration. A22 312 A: 22PlBLACKl CONNECTOR B: 22F (LIGHT GRAY! CONNECTOR The test harness terminals are same layout as lor FOR ZZPlBLACKl CONNECTOR the ECM connector terminals as shown. FOR 22F lLIGHT GRAY) CONNECTOR o Slept ls'sbmcoe —j s o'e‘o‘n Need“ I ‘ 5-11 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI SELF-DIAGNOSIS MALFUNCTION INDICATOR LAMP (MIL) FAILURE CODES ' The PGM-Fl MIL denotes the failure codes lthe number of blinks from 0 to 35). When the indicator lights for 1.3 seconds it is equivalent to ten blinks, For example, a 13 second Illumination and two blinks (0.5 second / 2) of the indicator equals 12 blinks. Follow code 12 on page 5-28l 'When more than one failure occurs, the MIL shows the blinks in the order of lowest number to highest number. For example, if the indicator blinks once, then two times, two failures have occurred, Follow codes 1 and 2 on page 5714). NumberofPGMrFl ‘ Symptoms Refer to MIL causes (Fail-safe contentsl page 0 Open circuit at the power input wire of the 0 Engine does not start i ECM r l- Faulty bank angle sensor ‘ l - Open circuit in bank angle sensor related circuit " Faulty engine stop relay 0 lOOpen circuit in engine stop relay related 1 wires 5-90 0 Faulty engine stop switch } Open circuit in engine stop switch related l No blinks ‘ wires 0 i' Faulty ignition switch ' Faulty ECM ‘ ,' Blown PGMrFI fuse l20 Al r l' Open circuit in engine stop switch ground l- Blown subrfuse l10 Al lStarter/ignitionl O 1' Open or short circuit in Mleire ' Engine operates normally ' Faulty ECM - ‘ 5-11 i. No blinks l' Short circuit in service check connector 'Englne operates normally {j} l wire lo Stays m Faulty ECM 1 ° Loose or poor contacts on MAP sensor con- 0 Engine operates normally fl 1 Q l nector 5-14 , ' Open or short circuit in MAP sensor wire B'Inks . Faulty MAP sensor 0 Loose or poor connection of the MAP sen- .. Engine operates normally ‘ 2 fl" sor vacuum tube 5-16 Blinks ,0 Faulty MAP sensor " Loose or poor contact on ECT sensor 0 Hard start at a low temperature 7 i} ,' Open or short circultin ECTsensor wire lSimulate using numerical values; 5-18 Blinks U ‘- Faulty ECTsensor , 90°C/194°Fl ‘ Loose or poor contact on TP sensor connec- 0 Poor engine response when operate a 1;} tor ing the throttle quickly 5'20 ‘ ,‘Open or short circuitin TF‘ sensorwire [Simulate using numerical values; 3"“k5 l- Faulty TP sensor Throttle opens Tl i' Loose or poor contact on IAT sensor 0 Engine operates normally 9 ‘Open or short circuitinlATsensor wire (Simulate using numerical values; 524 Blinks ' Faulty IAT sensor 25“C/77°Fl FUEL SYSTEM (Programmed Fuel Injection) Number of PGMVFI 1 Symptoms Refer to . MIL blinks ‘ ca‘fies (Failrsafe contents) l page i l- Loose or poor contact on vehicle speed 0 Engine operates normally ‘ . ‘ sensor connector ‘ 11 Q j. Open or short circuit in vehicle speed sens i 5-26 l sor connector l . W l Blinks s‘ Faulty vehicle speed sensor 7\_ 7", ,7, fl 7 l j- Loose or poor contact on No. 1 injector cone * Engine does not start 12 {j i nector 5728 l ' Open or short circuit In No.1 injector wire l Blinks Faulty No. 1 injector - Loose or poor contact on No.2 injector cone ' Engine does not start 0 13 {1} j nector > > , . . _ 5-31 it Open or short Circuit in No. 2 injectorWire ‘ Blinks . Faulty No, 27injector # W > ‘ W __7 l l. Loose or poorcontact on No. 3 injector con- ° Engine does not start 14 Q r neetor . V _ , _ 5734 Open or short circuit in No, 3 injector Wire auntsw aulty No. 3 injector ‘ . Loose or poor contact on No. 4 injector cone ' Engine does not start 15 {j j hector . _ > > . ‘ 5-37 l. Open or short circuit in No. 4 injector Wire Blinks 0 Faulty No, A} injector - Loose or poor contact on cam pulse gener- ator 0 Engine does not start 13 Q . Open or short circuit in cam pulse genera~ 540 . i tor Blinks l0 Faulty cam pulse generator _V r0 Loose or poor contact on ignition pulse 'Engine does notstart r generator connector 19 l 3- Open or short circuit in ignition pulse gene 5‘42 erator . - Faulty ignition pulse generator r l0 Faulty 0; sensor - Engine operates normally 21 l l 5744 e l ‘0 Faulty Oz sensor heater - Engine operates normally i 23 l l j 546 ‘ Faulty EIVPROM in ECM ° Engine operates normally 4‘ 33 ‘ ' Does not hold the selfrdiagnosis 5-50 7 l Blinks fl , data ‘ ‘- Faulty EGCV and air intake valve servo - Engine operates normally 34 , motor potentlo meter voltage ‘ g 5752 Blinks . fl ‘0 Faulty EGCV and air intake valve servo ' Engine operates normally L 35 l motor 554 l Blinks D I 5-13 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 1 BLINK (MAP SENSOR) Turn the ignition swltch OFF. Make sure the engine stop switch is in RUN. Disconnect the MAP sensor 3P connector. Check for loose or poor Contact on the MAP senr soy connector. Connect the MAP sensor connector. Place the motorcycle on its side stand. Start the engine and check that the MIL blinks. 1 blink Turn the ignition switch OFF. Disconnect the MAP sensor 3P connector. Turn the ignition switch ON. Measure the voltage at the wire harness side con- nector. Connection: Yellow/Red i +i’GrDund ‘7) Standard: 4.75 7525 V Voltage exists Measure the voltage between the connector terr minals of the wire harness side. i 2* Connection: Yellow/Red H—l—Green/Orange (7, Standard: 475 7 5.25 V i Voltage exists N0 blinks Out of range Out of range ' Loose or poor Contact on the MAP sensor connec- tor 0 Open or short circuit in Yellow/Red wire - Loose or poor contact on the ECM connectors ‘ Open or short circuit in Green/Orange wire - Loose or poor contact on the ECM connectors 5-14 l Measure the voltage between the terminals of the wire harness side. Connection: Light green/Yellow l 1' l *Green/Orange 1-) Standard: 4.75” 5.25 V Voltage exists Turn the ignition switch OFF. Disconnect the ECM connectors. Connect the test harness to ECM connectors. Turn the ignition switch ON. Measure the voltage at the test harness terminals lpage 5-9). 4 CAOOAL! SMSAE (SAG — case's 91761601 Connection187 l+l~B1 ‘7’ Standard: 2.7 -3.1 V 1760 mm Hg/1,013 kPal FUEL SYSTEM (Programmed Fuel Injection) Out of range Out of range Voltage exists ' Open or short circuit in Light green/Yellow wire 0 Loose or poor Contact on the ECM connectors - Faulty MAP sensor ' Replace the ECM with a new one, and inspect it again 5-15 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 2 BLINKS (MAP SENSOR) Turn the Ignition switch OFFt Disconnect the vacuum tube from the MAP sensor, Connect the vacuum gauge between the throttle body and the MAP sensor using a 37Wayjointv Start the engine and measure the manllold absolute pressure at idle speed. /, Standard: 150 250 mm Hg Disconnect the vacuum gauge and connect the tube to the MAP sensorv Disconnect the ECM connectors. Connect the test harness to the ECM connector. Out of range - Check the tube Installation l Turn the ignition switch ON. Measure the voltage at the test harness terminals (page 579”. Connectio B7l+l ’31 1*) Standard: 27 ’31Vl750 mm Hg/l,0'|3 kPa) Voltage exists Startthe englne. Measure the voltage at the test pin box terminals lpage ‘579l. e C : EB Connection: B7 H—liB'l (*l Standard: 2.7 V maximum FUEL SYSTEM (Programmed Fuel Injection) Out of range Outof range Voltage exists . Faulty MAP sensor I Faulty MAP sensor 0 Replace the ECM with a new one, and Inspect it again 5-17 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 7 BLlNKS (ECT SENSOR) Turn the ignition switch OFF. Disconnect the ECT sensor 3F connector. Check for loose or poor Contact on the ECT sen- sor connector. Connect the ECT sensor connector. Place the motorcycle on its side stand. Turn the ignition switch 0N. Check that the MIL blinks. 7 blinks Turn the ignition switch OFF. Disconnect the ECT sensor connector. Measure the resistance at the ECT sensor termi- rials. Connection: Pink/White (+i’Green/0range ‘7) (sensor side terminals) Standard: 2.3 - 2.6 k {A i20°C/68°F) Normal No blinks Abnormal . Loose or poor Contact on the ECT sensor connecV (or C Faulty ECT sensor 5-18 FUEL SYSTEM {Programmed Fuel Injection) l , Out of ran e . . . V . Turn the ignition swrtch ONr ;—g> . Open or short circult m Pink and PInk/Whlte wrre Measure the voltage between the ECT sensor 0 Loose or poor contacts on the ECM connector connector terminal of the wire harness side and ground. 0 Connection: Pink/White 1+)iGround 1*) . Standard: 4.75 7 525 v Voltage exists Out of range t . . t Measure the voltage at the ECT sensor connector ——> 0 Open or short circuit In Green/Orange wire of the wire harness side. ' Loose or poor contacts on the ECM connector 0 0 Connection: Pink/White (+l’Green/Orange (7) Standard: 475 — 525 V V It e e s , L———-—OL—> 0 Replace the ECM with a new one, and inspect it . again 0 O I . 5-19 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MlL 8 BLINKS (TP SENSOR) Turn the ignition switch OFF. Disconnect the TP sensor 3P connector Check (or loose or poor Contact on the TP sensor connector. Connect the TP sensor connector. Place the motorcycle on its side stand. Start the engine and check that the MIL blinks. 8 blinks Turn the ignition swnch OFF. Disconnect the TP sensor 3P connector. Turn the ignition switch ON. Measure the voltage between the wire harness Sldl? connector terminal and ground. Connection: Yellow/Red l 'liGround iii Standard: 4.75 *525 v Voltage exists N0 blinks Out of range - Loose or poor contact on the TP sensor connecV tor 0 Open or short circuit in the Yellow/Red wire G Loose or poor contact on the ECM connector 5-20 FUEL SYSTEM (Programmed Fuel injection) 1 , Out 0! ran 5 . 0 Measure the voltage at the TF‘ sensor termrnals A ' Open orshon circuit rn Green/Orange wrre ofthe wire harness side, ' Loose or poor Contact on the ECM connectors 0 Connection: Yellow/Red l + l , Green/Orange 1*) Standard: 4‘75 7 525 V . Voltage exists Turn the lgnltion switch OFF. Disconnect the ECM 22Pconnectors. . O _ . Continuity . , . Check for continuity between the TP sensor ——— - Short ClI‘Cull In Red/Yellow wxre connector terminal of the wire harness side and ground. O 0 Connection: Red/Vellow 1+) , Ground til Standard: No continuity No contlnuity O I D 5-21 FUEL SYSTEM (Programmed Fuel injection) l Connect the test he mess to the ECM connectors. Check for continuity between the test harness terminal and the TP sensor connectorterminali Connection: Red/Val low 7 38 Standard: Continuity Continuity Connect the TP sensor 3P connector. Turn the Ignition switch ON. Connection: 881+|* El 1* l Standard: “0‘4 *06 V (throttle fully closed) ’ 4.2 7 4.8 V (throttle fully open) Measure the voltage at the test harness terminals. No continuity Normal Out of range I Open or short circuit in Red/Yellow wire - Replace the ECM with a new one, and inspect it again‘ - Faulty TP sensor 5-22 FUEL SYSTEM (Programmed Fuel Injection) A voltage marked ' refers to the value when the voltage read'mg at the TF sensor B? Connector lpage 5-19) shows 5 V. When the reading shows other than 5 V, derive a voltage at the test harness as follows: . In the case of a voltage of 4.75 v at the TP sensor 3P connector: 04 / 4.75/50 = 0.38 V 0.6 / 4.75/50 = 0.57 V Thus, the solution is "0.38~0.57 V' with the throttle fully closed. . Replace 0.4 and 0.5 with 4.2 and 4.8, respectively, in the above equations to determine the throttle fully open range. 5-23 FUEL SYSTEM (Programmed Fuel Injection) PGM—Fl MIL 9 BLlNKS (lAT SENSOR) Turnthe n onsw hOF Disconnect the IAT sensor 2P connectori Check lor loose or poor contact on the IAT sensor connector. Connect the IAT sensor 2P connector. Place the motorcycle on its side stand. Turn the Ignition switch ON. Check that the MIL blinks. 9 blinks Turn the ignition switch OFF. Disconnect the [AT sensor 2P connectort Measure the resistance at (he IAT sensor (at 20* 30°C/68*SS°F). Standard: 1 VVAkEZ Normal Turn the ignition swrtch 0N. No blinks Abnormal I Loose or poor Contact on the IAT sensor connecr tor . Faulty IAT sensor 5-24 FUEL SYSTEM (Programmed Fuel Injection) l Out of ran 9 . Measure the voltage between the terminals of ___—g_ 0 Open or short circuit in Gray/Blue WIre the wire harness side‘ - Loose or poor Contact on the ECM connectors 0 Connection: Gray/Blue HkGround til 0 Standard: 4 757 525 v Voltage exists . Out of range . . . . Measure the voltage between the terminals of 0 Open or short CerUII in Green/Orange WIre the Wire harness side. / 0 Loose or poor Contact on the ECM connectors O O _ , Connection: Gray/Blue ( +l—Green/Orange (*l Standard: 475 7515 V Volta e exists . . V g . Replace the ECM WIth a new one, and Inspect n . again. 0 C O I 5-25 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 11 BLINKS (VEHICLE SPEED SENSOR) Turn the ignition switch OFF, Disconnect the vehicle speed sensor 3P connec- torv Check for loose or poor contact on the vehicle speed sensor connectorv Connect the vehicle speed sensor 3P connector. Start the engine. With the side stand UP and keep the engine rev more than 5,000 rpm about 20 seconds or more. Put the side stand down, and check that the MIL blinks, 1'l blinks Turn the ignition switch OFF. Disconnect the vehicle speed sensor 3P connecV tor. Turn the ignition swttch ON. Measure the voltage at the wire harness side connector, Connection: Black/Brown (+l‘Green/Black 1*) Standard: 12 V Voltage exists No blinks Out of range tLoose or poor Contact on the vehicle speed Sensor connector. - Open or short circuit in Black/Brown wire 5-26 FUEL SYSTEM (Programmed Fuel Injection) l Connect the speed sensor 3P connector. Disconnect the ECM connectors. Connect the test harness to the wire harness connectors. Support the motorcycle securely and place the rear wheel off the ground, Shift the transmission into neutral. Measure the voltage at the test harness terminals with the ignition switch is ON while slowly turning the rear wheel by hand. CONNECTION: 317 l?) " Ground lil STANDARD: Repeat 0 to 5V Abnormal Normal - Open or short circuit in Pink/Green wire ' Replace the ECM with a new one, and inspect it again. 5-27 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MlL 12 BLINKS (NO. 1 INJECTOR) Turn the lgl’llllOl’l switch OFF. 1 Disconnect the No, l injector 2P connector. Check for loose or poor contact on the No. 1 InjeCIOf 2P connector. Connect the No. 1 injector 2P connector. Place the motorcycle on its side stand. Turn the ignition switch ON‘ Check that the NHL blinks. ‘12 blinks Turn the ignition switch OFF. Disconnect the No. 1 injector 2P connector and measure the resistance olthe No.1 injector. Connection: Black/White l +liPink/Yellow l ,) Standard: 11.1i12.3 £2 1205C/68°Fl Normal No blinks Abnormal 'Loose or poor contact on the No. 1 injector connector - Faully No. 1 injector 5-28 FUEL SYSTEM (Programmed Fuel Injection) i . Continu't . Check for contlnuily between the No. 1 Injector —IV‘>. Faulty No. 1 injector and ground. 0 Connection: Black/White ( HiGround i ._) Standard: No continuity O No continuity . .. . Out of range , . . , Turn the ignition swltch 0N. — . Open or short Clrcull In Black/White wrre Measure the voltage between the No. 1 injector connector of the wire harness side and ground. 0 Connection: Black/White(+i’Gr0und 1,) . Standard: Battery voltage Voltage exists Turn the ignition swrtch OFF. Connect the No. 1 injector connector. 0 0 Disconnect the ECM connectors. . Connect the test harness to the wire harness conr nectors. “e O D 5-29 FUEL SYSTEM (Programmed Fuel Injection) 1 Out f e . . Measure the reswstance at the test harness 4fl>OOpen crrcuh m Black/Whine and/0r Pink/Yellow . termmals. wire ”(3‘ <9 0 — [ xe‘awgrsom‘ae Connectio ‘A141‘DiBGfi-W Standard: 9~ 15 £2 (ZOE/68°F} 0 Normal Contin '( , , . . Check for continuity berween the rest harness _my—>oshortcircultm PInk/YeHowwue terminal and ground. I O Connecfion: A14 *Ground Standard: No continuity No continuit V . Replace the ECM with a new one, and inspect it . again . O . . 5-30 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 13 BLINKS (N0. 2 INJECTORl Turn the ignition switch OFF. Disconnect the No. 2 injector 2Pconnector. Check for loose or poor Contact on the No. 2 injector 2P connector. Connect the No. 2 injector 2P connector. Place the motorcycle on its side stand. Turn the ignition switch ON. Check that the MlL blinks, No blinks 0 Loose or poor contact on the No. 2 injector cone nectar ‘ 13 blinks Turn the ignition switch OFF. Disconnect the No. 2 injector 2P connector and measure the resistance of the No. 2 injector. Connection: Black/White l+l4Pinlelue (A) Standard: 11.!7123 52 l20°C/68°F) Ab | ”0"“ OFaulty No. 2 injector Normal 5-31 FUEL SYSTEM (Programmed Fuel Injection) l Check for continuity between the No. 2 injector and ground, Connection: Black/White 1‘} 'Ground (7’ Standard: No CODUHUIIV No continuity Turn the ignition switch ON‘ Measure the voltage between the No. 2 injector connector of the wire harness sid no ground. Connection: Stack/White (+)"Ground t it Standard: Battery vottage Voltage exists Turn the Ignition switch OFF. Connect the No, 2 injector connector: Disconnect the ECM connectors. Connect the test harness to the wire harness conr nECIOrSV /% / I / ////,J / Continuity Out of range ° Faulty Not 2 intector ° Open or short circuit in Black/White wire 5-32 FUEL SYSTEM (Programmed Fuel Injection) l . V . Outof range , . . . Measure lhe resistance at the test harness lermlr 0 Open circun In Black/Whlte and /or Punk/Blue na‘s Wire (—3 \Q (9 0 Connection: A3 1*)*36 1+} . 5(andard:9 H15 :2 none/saw) Normal Cont‘nuit Check for continuity between the test harness #‘L—b IShoncircuitin Punk/Blue wure terminal and ground O ©>~ I Connection: A3 7 Ground Standard: No cantinuity . No continuil ——~—-——————v> I Replace the ECM with a new one, and inspect it again D I I ' 5-33 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 14 BLINKS (NO. 3 INJECTOR) Turn the ignition switch OFF. Discon necr the No. 3 injector 2F connector. Check for loose or poor contact on the No. 3 injector 2P connector. Connect the No. 3 Injector 2P connector. Place the motorcycle on its side stand. Turn the ignition switch 0N. Check that the MIL blinks. 14 blinks Turn the ignition switch OFF. Disconnect the No. 3 injector 2P connector and measure the resistance oi the No. 3 injector. Connection: BlackNVhite l +lAPinHGreen (*1 Standard: 11.1 7 12.3 52 (20°C/68°Fl Normal No blinks Abnormal 0 Loose or poor contact on the No. 3 injector con- nector - Faulty No. 3 injector 5-34 FUEL SYSTEM (Programmed Fuel Injection) l . Comm 't Check for contlnuity between the No. 3 injector ——u'L> ' Faulty No. 3 Injector. and ground. 0 Connection: Black/White( )iGround (7, Standard: No continuity O . . No COnllnullv . ,. . Outof range . . . . . Turn the Ignmon swttch ON. *> - Open or short circuit In B‘ack/thte Wire Measure the voltage between the No. 3 injector connector of the wire harness side and ground. 0 . Connection: mack/White (H’Ground (A) Standard: Battery voltage Voltage exists Turn the ignition switch OFF. Connect the No. 3 Injector connector. I D Disconnect the ECM connectors. . Connect the test harness to the wire harness connectors. I I 5-35 FUEL SYSTEM (Programmed Fuel Injection) 1 Measure Ihe resistance at the test harness termir nals‘ e @ (43 W Connection: A2i *i , 861') Standard29715 i; (NT/68°F} Normai Check for continuity between the test harness (erminai and ground Q Connection: AZ 7 Ground Standard: No confinultv om of range Continuity No continuity ‘Open circun in Black/White and/or Pink/Green wire - Short circuit in Pink/Green wure O Replace the ECM With a new one, and inspect it again 5-36 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 15 BLINKS (NO. 4 INJECTOR) . Turn the \gnmon switch OFFA ; r r Disconnecl the Nov 4 rnjeclor 2P connector Check for loose or poor Contact on the No. 4 Q 1njector2P connector 0 . No bunks , Connectthe No. 4m1ector 2P connector. ———> 0 Loose or poor contact on the No. 4 «mentor conr . Place the motorcycle on is side stand. neCIOr Turn the {gnmon swltch ON. Check that the MIL blinksr O O 15 blinks . V . Abnorma‘ ‘ ‘ Turn the Ignmon swrlch OFF, M’ t Faulty No. 4 Inlector Disconnect the No. 4 Injector 2P Connector and measure the resisrance of the No‘ 4 Nation 0 D Connection: Black/White (+D’Pink/Black 1*) Standard: 111*123 £2 (20°C/58‘FD Normal I I 5-37 FUEL SYSTEM iProgrammed Fuel Injection) i Check for continuity between the No. 4 injector and ground. Connection: Black/White (+i *Ground ( ,) Standard: No continuity No continuity Turn the ignition swnch ON. Measure the voltage between the No. 4 injector connector of the Wire harness side and ground. Connection: Black/White («alAGi’ound (-i Standard: Battery voltage Voltage exists Turn the ignition switch OFFV Connect the No. 4 injector connector. Disconnect the ECM connectors, Connect the test harness to the wire harness con— nectorst Continuity Out of range - Faulty Not 4 injector 0 Open or short circuit in Black/White wire FUEL SYSTEM (Programmed Fuel Injection) 0 tot ran a . . . . Measure the resistance at the test harness —u—g—>00pen circuit In Stack/White and/or Pmk/Btack terminalsV wure Q 69 ,f. 9 Connection: A131*)*BS(+D . Standard, , 15 SE 120°C/68°FD Normal Continuit , . . V V Check (or continuity between the test harness -v—>OShonCtrcu1tIn Punk/Black WIre terminal and ground Connection: A13 7 Ground Standard: No continuity No cont'n ’t V V . . v—‘—————I-u>' Replace the ECM With a new one, and xnspect It again 5-39 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 18 BLINKS (CAM PULSE GENERATOR) Turn the ignition switch OFF. Disconnect the cam pulse generator 2P connecr tDr, Check for loose or poor contact on the cam pulse generator 2P connector. Connect the cam pulse generator 2Pconnector. Place the motorcycle on its side stand. Turn the ignition SWIlCh ON and check that the MIL blinks. 18 blinks Turn the ignition switch OFF and the engine stop switch OFF. Disconnect the cam pulse generator 2P connecV tor Turn the ignition switch OFF, Check the continuity between the cam pulse gene erator connector terminal and ground. Connection: Grayi Ground WhiteiGround Standard: No continuity N0 continuity N0 blinks Continuity 0 Loose or poor Contact on the cam pulse generar tor 2P connector. ' Faulty cam pulse generator 5-40 l Crank the engine With the starter motor, and measure the cam pulse generator peak voltage at the cam pulse generator 2P connector, Connection: Gray 1+ leWhIte [7) Standard: 0.7 V minimum (20°C/68°F) Normal Connect the cam pulse generator 2P connector. Disconnect the ECM connectors. Connect the test harness to ECM connectors, T Crank the engine with the starter motor, and measure the cam pulse generator peak voltage at the test harness terminals, Connection: 322 Hl—Ground 1 ‘l Standard: 0‘7 V minimum 120°C/68°Fl FUEL SYSTEM (Programmed Fuel Injection) Out of range Out or range Normal 0 Faulty cam pulse generator 0 Open circuit in White/Yellow and/or Gray wire - Replace the ECM with a new one, and inspect it again 5-41 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 19 BLINKS (lGNiTlON PULSE GENERATOR) Turn the ignition switch OFF. ’ . I Disconnect the ignition pulse generator 2? cone nector. Check for loose or poor Contact on the ignition . pulse generator 2P connectcrt O r , ‘, No blinks . .t Connect the Ignition pulse generator 2P connec- —> 0 Loose or poorcontact on the Ignition pulse generr tort ator 2P connector . Place the motorcycle on its side stand. Turn the ignition switch ON and check that the MIL blinks. 19 blinks Turn the ignition switch OFF and the engine stop . switch OFFt Disconnect the ignition pulse generator 2P con- nector, O O . . . . Continuity , , . Check the continuity between the Ignition pulse —>° Faulty Ignition pulse generator generator side connector terminal and ground 0 i O [1 f 0 Connection: Yellow-Ground White/YeIIUW*Ground Standard: No continuity i No continuity O 5-42 fl FUEL SYSTEM (Programmed Fuel Injection) l . . Out of ran a , , , O Crank the engine with the starter motor, and ——9—>- Faulty .gnmon pulse generator measure the ignition pulse generator peak volt age at the ignition pulse generator 2P connector. 0 Connection: Vellow 1+ l—White/Vellclw [#l 0 Standard: 0.7 v minimum (NT/68°F) Normal Connect the ignition pulse generator 2P conneo (Or. . Disconnect the ECM connectorsr Connectthe test harness to ECM connectors. . _ Out of ran 9 , . Crank the engine WIth the Starter motor, and —g—>-0pen circuitinWhIte/Yellowwne measure the Ignition pulse generator peak volt- ‘Open circuitin Yellow wire . age at the test harness terminals. . Connectionzfin i+liGroundlml Standard: 0‘7 V minimum 120°C/68"F) . 0 Normal ———'——‘> OReplace the ECM with a new one, and inspect it again . 5-43 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 21 BLINKS (02 SENSOR/CALIFORNIA TYPE ONLY) Turn the ignition switch OFF. Disconnect the 0, sensor connector. Check for ioose or poor Contact on the 0: sensor connector. Disconnect the ECM connectors. Connect the test harness to ECM connectors. Check the continuity between the test harness terminal and 0; sensor connector terminal. <2 Connection: Orange/White , A5 Standard: Continuity Continuity Check the continuity between the 02 sensor connector terminal and ground. Connection: Orange/whiteiGround Standard: No continuity i No continuity No continuity Continuity 0 Open circuit in 0: sensor Orange/White wire 0 Short circuit in 0: sensor Orange/White wire 5-44 _ FUEL SYSTEM (Programmed Fuel Injection) Fr? . Connect the 0} sensor connector‘ Turn the ignition sw1tch ON and warm up the engine up to coolant temperature is 80°C1176‘7F). O O Operate the throttle grip and snap the engine speed from idle to 5,000 rpm, 0 Out of ran e Check the voltage between the test harness !___g_> - Faulty Olsensor terminals. 0 Connection: 81* B4 Standard: With the throttle fully open: 0 , V 0‘5 V minimum With the throttle quickly closed: 0.4 V maximum Normal V —————f——>tcheck the fuel supply system, if the system is . correct, replace the ECM and inspect again. 0 O O 5-45 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MlL 23 BLINKS (02 SENSOR HEATER/CALIFORNIA TYPE ONLY) Turn the ignition switch OFF, Disconnect the 0‘ sensor connectors. Check for loose or poor Contact on the 0; sensor ConneCIOrt Connect the 0; sensor connector, Shonthe service check connector (page 5-8). Start the engine and checkthat the MIL blinks‘ 23 blinks Turn the ignition switch OFF. Out of range Disconnect the 0: sensor 4P connector. Measure the resistance at the sensor side connectorWhiteterminais. 0 Faulty Or sensor Connection: Whlle ' Standard: 10 v 40 L3 Normal 5-46 FUEL SYSTEM (Programmed Fuel Injection) l . Continuit Check for Continuity White terminal and ground, __L_, - Faulty 0: sensor 0 . Connection: White 7 Ground Standard: No continuity No continuity , , V Normal . V ‘ ‘ Turn the ignition sthch ON. Turn the Ignition swnch OFF, Measure the voltage at the 0: sensor wire harr Disconnect the ECM 22F connector. . ness side connector terminals. 0 Connection: Black/White 1+) *Black/Green (*l Standard: Battery voltage . Turn the ignition switch ON. Measure the voltage at the 01 sensor wire harv ness side connector terminals. 0 Connection: Black/White l+l*Black/Green ‘7, . Standard: Battery voltage Battery voltage N0 Voltage 0 0 Open circuit ln 0: sen- sor Black/Green wires 0 Replace the ECM and . inspectagain 5-47 FUEL SYSTEM (Programmed Fuel Injection) i Measure the voltage at me 0‘ sensor wire harr ness side connector terminal and ground Connection: Biack/Whlte (+iiGround t 7, Standard: Battery voltage Battery voitage Turn the ignition switch OFF. Connect the 0: sensor 4P connectors. Disconnect the ECM Connectors. Connect the test harness to the wire harness connectors. No voitage ' Open circuit In Black/White wire between the 0: sensor and engine stop reiay 5-48 FUEL SYSTEM (Programmed Fuel Injection) i . Measure the voltage at the test harness terminals Novella e . g o0pen ctrcult m stack/Green ere between the ECM connector and 0; sensor 4P connector Cnnnection:BB(+)*A51—) Standard: Battery voltage B n one L—AV—E‘ . Reptace the ECM and inspect again 5-49 FUEL SYSTEM (Programmed Fuel Injection) PGM~FI MIL 33 BLlNKS (EZ-PROMI Turn the ignition switch OFF, Disconnect the ECM connectors. Check for loose or poor contact oi the ECM cone nectors. Connect the ECM connectors. Short the service check connector with a jumper wire (page 5»8I. Turn the ignition switch ON and check that the MIL blinks. 33 blinks Except 33 bl inks Remove the jumper wire from the service check connector {page 5-9). 59). MIL blinks. Reset the sell-diagnosis memory data (page Turn the ignition switch ON and check that the Other than 33 blinks Turn the ignition switch ON and check that the MIL blinks. Except 33 blinks 33 blinks 0 No problem (no blinks) 33 blinks ' Replace the ECM 5-50 Turnlhe ignition switch OFF. Short lhe service Check wire (page 5-8l, connector With a jumper Turn the ignition swilch ON and check that the MIL blinks‘ 33 blinks Reset Ihe self-diagnosrs memory data lpage 5-9lv Turn the ignition swirch ON and check (hat the MIL blinks. FUEL SYSTEM {Programmed Fuel Injection) Except 33 blinks Except 33 blinks 33 blinks 0 No problem (no blinks) 0 No problem (no blinks) - Replace the ECM FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MIL 34 BLINKS (EGCV AND AIR INTAKE VALVE SERVO MOTOR POTENTIOMETER VOLTAGE) Turn the ignition swrtch OFF. DlSCOnnecl the servo motor GP connector. Check for loose or poor Contact on the servo motor 6P connector Connect the servo motor 6P connector. Place the motorcycle on its slde stand. Turn the ignition swltch ON and check that the MIL blmks. 34 blinks Turn the ignmon switch OFF and the engine stop switch OFF, Disconnect the servo motor 6P connector. Measure the reslstance at the servo motor 6P Connectorterminals. Connection: Yellow/Red l +) *Gteen/Orange ( ,) Standard: 5 ktl (20°C/68‘lF) Normal NO blinks Abnormal 0 Loose or poor Contact on the servo motor 5P con- hector, - Faulty servo motor 5-52 FUEL SYSTEM (Programmed Fuel Injection) l . Abnormal . Measure the resrstance at the servo motor 6P con- ———> C Fau‘tv servo motor nectar termina‘s‘ . Connection: Lrght green/Pink { , fi’Green/Orange 1*) . Standard: 0 7 5 k Q (20°C/GBDF) Normal Drsconnect the ECM connectors, Connect the test harness to the wire harness con- . nectorst O . Na continuity V V V Check for continuity between the test harness ter- .___. . Open crrcurt In related wlre minal and servo motor 6? connector termina‘s of . the wrre harness side. 0 Connection: A1 *Red A12 7 Blue . B1 *Green/Orange BSiVellow/Red B16 'nght green/Pink Standard: Contintnty Cont . . t 0 Repmce the ECM With a new one, and Inspect ll . again, 0 5-53 FUEL SYSTEM (Programmed Fuel Injection) PGM-Fl MlL 35 BLINKS (EGCV AND AIR INTAKE VALVE SERVO MOTOR) Turn the ignition sthch OFF. Disconnect the servo motor 6P connector. Check for loose or poor contact on the servo motor 6P connector. Connect the servo motor 6P connector. Place the motorcycle on its side stand. Turn the ignition switch ON and check that the MIL blinks. 35 blinks Turn the ignition swltch OFF and the engine stop switch OFF. Disconnect the servo motor 6P connector. Disconnect the control cables from the servo motor. Turn the ignition switch 0N and check that the MIL blinks. 35 blinks No blinks No blinks 0 Loose or poor contact on the servo motor 6P conr nector ' Check the intake, exhaust valve and cables. 5-54 l Remove the servo motor (page 578%. Connect the 12 V battery to the servo motor connector terminais and check the servo motor function. Connection: Red i+l* Blue iii Normal Disconnect the ECM connectors. Connect the test harness to the wrre harness con- nectors. Check for continuity between the test harness terminal and servo motor 5? connector terminals of the wire harness side. ‘\\\\ Connection: A1 v Red A12 7 Blue Standard: Continuity FUEL SYSTEM (Programmed Fuel Injection) Abnormal No continuity Continuity - Faulty servo motor 0 Open circuit in related wire 0 Replace the ECM with a new one, and inspect it again. 5-55 FUEL SYSTEM (Programmed Fuel Injection) FUEL LINE INSPECTION FUEL PRESSURE INSPECTION - Before disconnecting fuel tubes, release the fuel pressure by loosening the fuel tube ban/o bolt at the fuel tank. I Always replace the sealing washers when the fuel tube banjo bolt is removed or loosened. Remove the seat (page 22). Disconnect the battery negative cable from the banerytermmal. Open and support the front end of luel tank Ipage 5761). Disconnect the pressure regulator Vacuum tube and plug the vacuum tube. Cover the fuel tube banjo bolt with a rag or shop towel. Slowly loosen the fuel tube banjo bolt and catch the remaining fuel using a approved gasoline container. NEGATIVE TERMINAL BATTERY BANJO BOLT 5-56 FUEL SYSTEM (Programmed Fuel Injection) Always replace the sealing washers when me luel lube ban/0 boll is removed or loosened, Remove the fuel tube banjo bolt and attach the fuel pressure gauge With the following Honda Genuine parts. Banjo bolt, 12 mm Parts N0, SOOOBVPPA-EOZ Sealing washer, 12 mm Pans No, 904284306003 Sealing washer, 6 mm Parts ND. 90430-PDGVOD3 TOOL: Fuel pressure gauge 07406-0040002 Connect the battery negative cable. Start the engine. Read the fuel pressure at idle speed. IDLE SPEED: 1,200 i 100 rpm STANDARD: 343 kPa (3‘5 kgf/Cm2 , 50 psi) If the fuel pressure is higher than specified, inspect thefollowing: *Plnched or clogged fuel return tube *Pressure regulator *Fuel pump (page 5759” If the fuel pressure is lower than specified, inspect the following: ~Fue| line leaking *Clogged fuelfilter *Pressure regulator 7 Fuel pump (page 5755M After Inspection, remove the fuel tube banjo bolt and reinstall and tighten the original fuel tube banjo bolt using the new sealing washers. TORQUE: 22 N-m (2.2 kgf-m , 16 |bf~ftl Connect the pressure regulator vacuum tube Install the removed parts in the reverse order of removal. BANJO BOLT Z/ / SEALING WASHERS FUEL PRESSURE GAUGE FUEL SYSTEM (Programmed Fuel Injection) FUEL FLOW INSPECTION FUEL CUT RELAY Remove the seat lpage 272i. Open and support the front end of fuel tank (page 0 34L Remove the ECM cover and disconnect the fuel cut relay connector. 0 Jump the Brown and Black/White ere terminals of O the wire harness side using a jumper ere. O When the fuel return tube is disconnected, gasoline will spill out from the tube. Place an approved gasoline container underneath the tube and drainthe gasoline, . ‘ Wipe off spilled out gasoline. 0 Disconnect the fuel return tube at the pressure regulator, plug the pressure regulator inlet joint. Turn the ignition switch ON for 10 seconds. . Measure the amount of fuel flow. Amount offuel flow: 188 cm“ 16.4 US 02 , 6.6 Imp ozl minimum/10 seconds If the fuel flow is less than specified, inspect the following: . *Pinched or clogged fuel tube and fuel return tube iClogged fuel filter ~ Pressure regulator 'Fuel pump lpage 5-59) Alter inspectlon, connect the fuel return tube. Start the engine and check for leaks. . C C 5-58 FUEL SYSTEM (Programmed Fuel Injection) FUEL PUMP INSPECTION Turn the ignition switch ON and confirm that the fuel pump operates for a few seconds. If the fuel pump does not operate, inspect as follows: Open and support the front end of fuel tank (page 3.4). Disconnect the fuel pump 3P (Black) connector. Turn the ignition switch ON and measure the volt- age between the terminals. Connection: Brown( Green ( ,) There should be battery voltage for a few seconds, If there is battery voltage, replace the fuel pump, llthere is no battery voltage, inspect the following: *Main fuel 30A nSub fuse 10A, 20A *Engine stop switch (page 1948) *Fuel cut relay (page 560) *Engine stop relay (page 5-89l 7 Bank angle sensor (page 5-88” 7 ECM (page 5789l REMOVAL 0 Before disconnecting the fuel tube, release the fuel pressure by loosening the fuel tube banjo 5‘ bolt at the fuel tank. . 'Always replace the sealing washers when the fuel tube ban/o bolt is removed or loosened. Remove the fuel tank (page 5761). Remove the fuel pump mounting nuts. Remove the fuel pump assembly and packing. FUEL SYSTEM (Programmed Fuel Injection) Note the direction 0/ [he fuel filler Always replace pack/n9 mm a new one. FUEL FILTER REPLACEMENT Dlscon nect the fuel tubes from the fuel filter, Remove the screws and fuel filter. Install the fuel filter in the reverse order of removalr INSTALLATION Place a new packing onto the fuel tank. lnstall the fuel pump being careful not to damage the fuel pump wire. Install and tighten the fuel pump mounting nuts in the sequence shown. TORQUE: 12 N-m (1.2 kgl~rn , 9 Ithl FUEL CUT RELAY INSPECTION Remove the fuel tank rear bracket and ECM cover (page 58% Disconnect the fuel cut relay 4P connector, remove the fuel cut relay. FUEL FILTER 5-60 FUEL SYSTEM (Programmed Fuel Injection) Con nectvthe ohmmeter to the fuel cut relay connec~ FUEL CUT RELAV BATE Ry tor terminals‘ CONNECTION: Black/White , Brown Connect the 12 V battery to the following fuel cut relay connectorterminalst CONNECTION: Brown/Black , Black/VVhlIe There should be continuity only when the 12 V battery is connected. If there is no continuity when the 12 V battery is connected, replace the fuel cut relay. FUEL TANK REMOVAL Remove the fuel tank front mountlng bolts and Washers. Remove the fuel tank rear mountlng bolt and collar. \ » ‘ BOLT/COLLAR Temporarily Install the fuel tank rear mounting bolt, ' ’ * MOUNTING BOLT FUEL SYSTEM (Programmed Fuel Injection) Lift and support the lront of the fuel tank and support it using a suitable support (310 mm). Release the fuel pressure (page 5-56), Disconnect the fuel pum p/reserve sensor 3P (Black) connector, Disconnect the fuel tank air vent tube and overflow tubel Hold the fuel pipe nut and remove the fuel tube sealing nut and sealing washers, then disconnect the fuel tubel Do not apply excessive force to the fuel pipe. 0 Always hold the fuel pipe nut while removing the fuel tube sealing nut. Temporarily install a 12 X 30 mm bolt (pitch 1.25) and sealing washers to the fuel tube banjo, then tighten the sealing nut. SUITABLE SUPPORT (310 mm) SEALING NUT 5-62 Be careful no! to damage the Mel (alt/r, FUEL SYSTEM (Programmed Fuel Injection) Disconnect the fuel return tube at the pressure regulator. Do not apply excessive lame to the fuel pipe. FUEL RETURN TUBE Remove the fuel tank rear mounting bolt and them remove the fuel tank from the frame. Place the fuel tank upside down. BANJO BOLT Disconnect the fuel return tube from the fuel pump. Remove the fuel tube banjo bolt and sealing washers, then remove the fuel tube from the fuel pump. Refer to page 5-59 for fuel pump removal. FUEL TUBE INSTALLATION FUELTANK 22 N-m (2.2 kgf-m ,16lbf-f!) 22 Nm (2.2 kgfvm ,16lbf-fll 5-63 FUEL SVSTEM (Programmed Fuel injection) Align me lLlel lube eyelet mm: mm!) me sin/mar on we luo’ pump Connect the fuel tube to the fuel pump with new Seallng washers Install and Ilghlen the fuel tube banjo bolt [0 (he specified torque TORQUE: 22 N>n712.2 kgf»m,16|bfvfll Connect the fuel relum lube to the fuel pump Install the fuel tank onto the frame, temporarllv install the fuel tank (ear mountlng bolt and support the from end of fuel tank uslng a sullable support (310 mm) Conneu the fuel tank all vent tube and overflow lube [U the fuel lallkv Connect the fuel regulator. Do nol apply excesswe lorce lo lhe fuel pipe. return tube to the plessure BANJO BOLT K FUEL RETURN TUBE FUEL TUBE SUITABLE SUPPORT (310 mm} 5-64 FUEL SYSTEM (Programmed Fuel injection) Connect the fuel tube bamo to the throttle body Wllh new sealing Washers Whlle pushing the fuel tube banio stopper to the throttle bodv, lnstall and tighten the sealing nut to the speclfled torque. NOT! CE 0 Do not apply excessive force to the fuel pipe ° Always hold the fuel prpe nut While tightening the fuel tube sea/mg nut. TORQUE: 22 N-rn l2.2 kgfm, ‘15 letl Connect the fuel pump/reserve sensor 3P lBlackl connector. Remove the supporting tool and close the fuel tank. Install the fuel tank mounting collar and bolt, Install the fuel tank front mounting bolts and washers, then tighten the front and rear fuel tank mounting bolts FUELTUBE SEALING NUT l , BOLT/COLLAR 5-65 FUEL SYSTEM (Programmed Fuel Injection) AIR CLEANER HOUSING REMOVAL Remove the air cleaner element {page 3-5l. Remove the EGCV and air intake valve servo motor mounting bolt, Remove the servo motor assembly from the bracket and disconnect the intake valve control cablefrom the servo motor pulley, Disconnect the MAP sensor connector and vacuum tube. Remove the air tunnel/air cleaner housing mount- ing screws, then remove the airfunnelst Disconnect the crankcase breather tube and PAIR control valve air sucllon tube from the air cleaner housing. Remove the air cleaner housing. See page 5-107 for intake air control valve dtsassembly/assembly. SERVO MOTOR hm in AIR CLEANER HOU AIR SUCTION TUBE . 5-66 FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION Route the variable intake air control valve wire properly, then install the air cleaner housing onto the throttle body Connect the crankcase breather tube and PAIR control valve air suction tube to the air cleaner housing. Install the air tunnels in their proper locations Install and tighten the airfunneI/air cleaner housing mounting screws Connect the MAP sensor connector and vacuum tube‘ Connect the variable air intake control cable to the servo motor pulleyv Install the servo motor onto the bracket, then tighten the bolt securely. Install the aircleaner element [page 375). VS avoamofofi P’w «4" /, E 5-67 FUEL SYSTEM (Programmed Fuel Injection) THROTTLE BODY REMOVAL 0 NOTICE 0 Before disconnecting the fuel tube, release the fuel pressure by loosening the fuel tube banjo bolt U Always replace the sealing Washers when the . fuel tube banjo bolt ls removed or loosened. Dra‘ln the coolant from the coolmg system (page 6-4). Remove the following. . *Fuel tank lpage 5761l *Atr cleaner housing (page 5756l Remove the throttle cable gulde bracket mounting bolts Do no! snap the D‘lsconnect the throttle cable ends from the throttle Q throttlevalvelrcm drum. lull open to lull closeallerlhe Remove the throttle stop screw knob from the throttle cab/shes bracket, beenremoved lI may cause Incorrecl Idle . Opalallon Loosen the hose band screws and dlsconnect the fast idle wax unit water hoses lrom the Wax unlt, O O Dlsconnect the TP sensor connector and fuel . Inlector connectors. If you Wl” not be disassembling the throttle bodv, disconnect the throttle body Sub-harness multi- connectort O INJECTOR CONNECTORS . 5-68 FUEL SYSTEM (Programmed Fuel Injection) Loosen the engine side Insulator band screws. THROTTLE BODV . Remove the throme body lrorn the cylinder head. Do not hold the fuel pipe on the throttle body while removing the throttle body. . ’ Do not snap the Remove the insulators from the throttle body. throttle valve rmm iull open to run NOTICE close alter the throttle cable has Seal the cylinder head intake ports with tape or a been removed it clean cloth to keep dirt and debris from entering . may caUse the intake ports after the throttle body has been incorrecrid/e removed. operation . ’ Do not damage the throttle body, it may cause incorrect throttle and idle valve synchronization, ' The throttle body is factory prersett 00 not disassemble In a Way other than shown in this manual, . ' Do not loosen or tighten the White painted bolts and screws of the throttle body. Loosening 0r tightening them can cause throttle and idle valve synchronization failure. TOP VIEW: 10 Nrm (1.0 kgf-m , 7 |th) 5-69 FUEL SYSTEM (Programmed Fuel Injection) REAR VIEW: 10 N»m I‘LU kgf‘m , 7 lbf-m 1 N-m 10.09 kgfvm ,0.7 IthI ©|> PEI .@ 5 N‘m10.5 kgf-rn , 3‘6 Ibf-ftI THROTTLE DRUM VIEW: RIGHT SIDE VIEW: 3 Mm (035 kgfvm , 2.5 lel) e_fi 7 0 0D 83 WHITE PAINTED WHITE PAINTED THROTTLE LINK VIEW: STARTER VALVE LINK VIEW: WHITE PAINTED WHITE PAINTED 1N>m {0‘09 kgf‘m , 0,7 Ibf-fl) 5-70 FUEL SYSTEM (Programmed Fuel injection) THROTTLE BODY VACUUM TUBE ROUTING Except California type: California type: INSTALLATION Check the insulator band angle. Apply oil to the insulator inside surfaces lor ease of throttle body installation. Install the throttle body onto the cylinder head. NOTICE Do not hold the fuel pipe on the throttle body while installing the throttle body. INSU LATOR BAND SCREWS 5-71 FUEL SYSTEM (Programmed Fuel Injection) Tighten the insulator band so that the insulator band distance is 12 i 1 mm 10.5 l 004 mi l ‘lz 1 1 mm I (0 5 : 004 in) . 0 Route the injector subrharness referring the wiring TP SENSOR CONNECTOR I diagram (page 1-23). _ Connect the fuel injector connectors and TP sensor connector. 0 0 Connect the last idle wax unit water hoses to the unit, then tighten the tube bands securelyt O 0 install the throttle cable gulde bracket to the throttle ' , BRACEE’I’Q . body, then tighten the bolts to the specified torque. ' “in . TORQUE: 3 N-m (0‘35 kgf-m , 2V5 lbf-m Install the removed parts in the reverse order or removalr O . 572 FUEL SYSTEM (Programmed Fuel Injection) INJECTOR INSPECTION Starttheengineandletrtidle. Confirm the injector operatlng sounds With a sounding rod or stethoscope. lf the Injector does not operates, replace the inlector. REMOVAL Remove the throttle body (page 5v68L Remove the bolts and fuel pipe assembly. Remove the injectors from the fuel pipe. Remove the seal ring, Orring and CLIShIOn ring. SOUNDING ROD perv 30 LTS b FUEL INJECTOR SEAL RING FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION \ .2337 SEAL RlNG Apply all to the new O'Hngt V Hep/ace the seal Install the new seal rlng, cushion mg and Orrlng. O “”9 Cuihlon Hng being careful not to damage the Orrlng. and o-rlng Wlm new ones as 5 Se! 0 Install the fuel injectors into the fuel pipe, being . careful not to damage the O-nng and cushion ring. I b FUELlNJECTOH . Install the fuel pipe assembly onto the throttle body, FUEL INJECTORS being carelul not to damage the seal rings. O O lnstall and tighten the fuel pipe mounting bolts to the specified torque. ‘. TORQUE: 10 N-m (1.0 kgl~m , 7 lbf-fll Install the throttle body (page 5771). O FUEL PIPE ASSEMBLKY . 574 FUEL SYSTEM (Programmed Fuel Injection) PRESSURE REGULATOR PRESSURE REGULATOR BOLTS REMOVAL/INSTALLATION Do not apply excessive force to the fuel pipe. Disconnect the vacuum tube from the pressure regulator, Hold the fuel pipe securely, remove the pressure regulator mounting bolts, then remove the pres- sure regulators Install a new Orring into the pressure regulator body. Install the pressure regulator onto the fuel pipe Hold the fuel pipe securely, tighten the pressure PRESSURE REGULATOR BOLTS regulator mounting bolts to the specified torque. TORQUE: 10 N-m (1.0 kgf‘m , 7 lbf-ftl Connect the vacuum tube to the pressure regulator. FAST IDLE WAX UNIT 00 m, [men or DISASSEMBLY remove Ihe wax um! shalt lock nu! Remove the wax unit mounting screws. and adjuslmg nu! FUEL SYSTEM (Programmed Fuel Injection) Release the wax unit shah loint piece from the wax unrt link arm, then remove the wax unit assembly. Remove the three wax element cover mourning screws m a cuss-cross pattern in 2 *3 steps. Remove the wax element, spring seat and compres- sion spring. INSPECTION Visually inspect the wax element for damage and return Sprmg for fatigue or damage. WA '2 g; ELEMENT COVER WAX ELEMENT SPRING SEAT s. ““1, v WAX UNIT , ‘33” in SCREWS SPRING / V WAX ELEMENT 5-76 FUEL SYSTEM (Programmed Fuel Injection) ASSEMBLV .. WAX ELEMENT SPRING lnstall new O-rlngs onto the wax element grooves. Install a new O-ring into the groove of the wax element cover. Install the wax element, spring seat and compres- sion spring. 7' I377 \ £0; O~RING ~fl O-RINGS % SPRlNG SEAT Install the wax element cover and mounting screws. Tighten the screws in a crischross pattern In 273 steps. SCREWS Install the wax unit shaft jomt piece to the wax unit link arml \\ > I} ‘ k? ”XLINKARM‘ Install and tighten the wax unit mounting screws to , WAX UNIT the specified torque. ‘ TORQUE: 5 N m (05 kgf‘m , 3.6 lbf-fl) FUEL SYSTEM (Programmed Fuel Iniecfionl STARTER VALVE STARTER VALVE DISASSEMBLY Remove the fuel pipe and inleclors (page 5*73l. Turn each starter valve adjusting screw in, counting number of turns until it seats lightly. Record the number of turns. No. 3/4 starter valve: Remove the starter valve arm screws and staner valve arm. No. 1/2 starter valve: N . 1 2 STAHTE ALVE: Remove the last idle wax unit {page 5-75» ° I R V Remove the staner valve arm screws and starter valve arms. Remove the screw and fast idle wax unitlmk arm. Loosen the lock nut and remove Ihe starter valve assemblv. STARTER VALVE ARM , 5-78 FUEL SYSTEM (Programmed Fuel Injection) Do HUIBDP/y Clean the starter va‘ve bypass using compressed Gamma/wally airv avar/ab/e carburetor cleaners lo the rnstde 0/ the theme bore which Is coated wnn molybdenum Remove t-he starter valve shaft, Ihree coHars and COLLARS thrust sprlngr START‘ER VALIVE SHAFT ”P‘THRUS {ism ASSEMBLY PRESSURE REGULATOR 10 Nm (10 kgf-m . 7 Ibf‘fn 10 Nm (1.0 kgf-m , 7 lbw) FUEL PiPE STARTER VALVE INJECTOR 5 N-m10.5 kgf-m , 3‘6 \bf-fl) 5-79 FUEL SYSTEM (Programmed Fuel injection) lnstall the three collars, thrust spring and starter valve shaft. COLLARS Install the starter valve assembly into the valve hole, Tighten the starter valve lock nut to the speclfled -' EOCK'NDl%\WST’Xl§lEH torque. ‘5. J A \ , fa.- a TORQUE: 2 N-m (0.18 kgf»m,13lbfvftl No. 3/4 starter valve: . 4STARTER VALV Compress the thrust spring and install the No. 3/4 N° 3/ E starter valve arm onto the starter valves. 7"” , Install and tighten the starter valve arm mDunting screws to the specified torques TORQUE: 1 N~rn 10.09 kgf‘m , 0.7 [bf-it) 5-80 FUEL SYSTEM (Programmed Fuel Injection) “‘1 ”2 “am" “3'“: No. 1/2 STARTER VALVE: STARTER VALVE lnstall the No. 1/2 starter valve arm to the starter ARM valves. lnstall and tlghten the starter valve arm mounting screws to the specified torque. TORQUE: 1 Mm ((109 kgfvm , O.7|b1»ftl Install the fast idle wax unlt link arm and tighten the screw to the specified torq uev TORQUE: 1 Nvm l0.09 kgf‘m , 0.7 lbf~ft) install the fast idle wax unit lpage 5-77). Turn the starter valve screw until it seats lightly. then back it out as noted during removal, Install the throttle body lpage 5771). STARTER VALVE SYNCHRONIZATION - Synchronize the starter valve with the engine at the normal operating temperature and with the transmissron in neutral. 0 Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change. Open and support the front end of fuel tank (page 3-4l. Remove the vacuum joint screws Connect the vacuum gauge adapters to the vacuum joints, then connect the tubes to the vacuum gauget Connectthe tachometer. ADAPTORS 5-81 FUEL SYSTEM {Programmed Fuel Injection) Disconnect the PAIR air suction hoses from Ihe reed valve covers and plug the cover‘ Stan the engine and adjust the idle speed. IDLE SPEED: 1,200 : 100 rpm The Na 1slarler Adjust each intake vacuum pressure with the No. 1 valve Cannorbe cylinder, ad/usred, n IS the base Starla! valve Remove the plugs and connect the PAIR air suction hoses to the reed valve covers. THROTTLE STOP SCREW No. 4 SCREW No.3 SCREW /, PAIR REED VALVE COVER 5-82 FUEL SYSTEM (Programmed Fuel Injection) Adjust the idle speed if the idle speed differs from the speculied speed. . IDLE SPEED: 1,200 i 100 rpm 0 . Remove the vacuum gauge and adaptors. Install and tighten the intake port vacuum joint screws to the specified torque. TORQUE: 3 N-m (0.3 kgf-m , 2.2 lbI-ft) O . VACUUM JOINT SCREWS OUTPUT VOLTAGE INSPECTION . (V) ‘ ‘ Connect the test harness to the ECM (page 5*8l. Measure the voltage at the test harness terminals (page 5-5”. CONNECTION: B7 (+)*BI (’I 0 STANDARD: 2.7 73.1 v The MAP sensor output voltage (abovel is meas- ured under the standard atmosphere (1 atm =1.030 y hF‘al. The MAP sensor output voltage is affected by the ‘ . distance above sea level, because the output 1 voltage is changed by atmosphere. 1 5 ‘ ‘ Check the sea level measurement and be sure that ‘ i the measured voltage falls within the specified ‘ ‘ value. i 1.0 ‘ 0 . ‘ i 0.5 ‘ i . i ‘ 0 500 1000 1500 2000 : m . 11, 650! (3,300) 14,9511” 16,600} (feet) 5-83 FUEL SYSTEM (Programmed Fuel Injection) MAP SENSOR REMOVAL/INSTALLA- TION Open and support the front end oHueI tank (page 0 3,4” Disconnect the MAP Sensor Connector, 0 Disconnecnhe vacuum tube, 0 ' _ MAP Remove the screw and MAP sensor from the air SENSOR cleaner housing. Installatlon lS in the reverse order of removal. O O REMOVAL/INSTALLATION Open and support the front and of fuel tank (page . 34). Disconnect the lAT sensor connector. 0 Remove the screws and lAT sensor lrom the air cleaner housmg cover. 0 Installation ls in the reverse order of removal. 0 O 5-84 FUEL SYSTEM (Programmed Fuel injection) ECT SENSOR Replace the ECT sensor Whl/S the engme Is cold Always replace a sea/mg washer with a new one, CAM PULSE GENERATOR we ‘ r CONNECTOR REMOVAL/INSTALLATION ieeT-semsofiy . / Drain the coolant from the system (page 675). Open and support the front end of fuel tank lpage 374)t Disconnect the ECT sensor connector from the sensor. Remove the ECT sensor and sealing washer. Install the new sealing washer and ECT sensor. Tighten the ECT sensor to the speclfled torquev WW ,‘ "“‘f V ‘ SEALING WASHER ECTSENSOR ago? ,. / E TORQUE: 23 N-m (2V3 kgf-m , 17 lbfift) Connect the ECT sensor connector. Ftll the cooling system with recommended coolant lpage 6-5)l REMOVAL/INSTALLATION Remove the air cleaner housing (page 5-66l. Dlsconnect the cam pulse generator 2P lNatural) connectort Remove the bolt and cam pulse generator from the cylinder head. 5-85 FUEL SYSTEM (Programmed Fuel Injection) Install the new O-ring onto the cam pulse generator, Install the cam pulse generator into the cylinder head, . install and tighten the mounting bolt securely. 0 Route the cam pulse generator wire properly, COn' . nect the 2P iNatural) connectorl Install the removed parts in the reverse order of removal, 0 0 TP SENSOR ECU TEST HARNESS ECM INSPECTION 5 Remove the ECM cover (page 5-89). Disconnect the ECM 22F (Black) and 22? (Light gravl connectors Check the connector ior loose or corroded termi- nelsv Connect the ECU test harness between the ECM . and main wire harness. TOOLS: ECU test harness 07VMZ~0010100 itwo required! 1. INPUT VOLTAGE INSPECTION . Turn the ignition switch 0N and measure and record the input voltage at the test harness termi- nals using a digital multimeter. CONNECTION : BSiH’Bi i 0 Standard: 45*55 V If the measurement is out of specification, check the following: A Loose connection of the ECM multi-connector AOpen circuit in wire harness . 5-86 FUEL SYSTEM [Programmed Fuel Injection) 2. OUTPUT VOLTAGE INSPECTION WITH THROT- TLE FULLV OPEN Turn the Ignition switch ON and measure and re cord the output voltage at the test harness termlr nalsi CONNECTION : BS (+ I * B1 lml MEASURING CONDITION: At throttle fully open 3, OUTPUT VOLTAGE INSPECTION WITH THROT- TLE FULLY CLOSED Turn the ignition switch ON and measure and tar cord the output voltage with the throttle fully closed. CONNECTION : BS (+ I * BI l *) MEASURING CONDITION: At throttle lullv closed 4. CALCULATE RESULT COMPARISON Compare the measurement to the result of the (ole lowing calculation, With the throttle fully open: Measured input voltage >< 0.824 = V0 The sensor Is normal it the measurement output voltage measured in step 2 ls withln 10% of V0. With the throttle fully closed: Measured input voltage X 0.1 =Vc The sensor is normal if the throttle closed output voltage measured in step 3 is withrn10% of Vc. Uslng an analog meter, check that the needle ol the voltmeter swings slowly when the throttle is openedgradually, CONTINUITY INSPECTION Open and support the front end of fuel tank lpage 374)t Disconnect the ECM 22P lLIght gravl connector and the TP sensor 3P connector, Check for COUtinuity between the ECM and TP sensor. If there is no contlnuitv, check the open or short circuit in wire harness. 3P CONNECTOR l 22F lLlGHT GRAY) CONNECTOR 5-87 FUEL SYSTEM (Programmed Fuel Injection) BANK ANGLE SENSOR Do not d/sconnecl the bank angle 59/750! conneclor during inspection INSPECTION Support the motorcycle level surface. Open and support the front end of fuel tank (page 3-4i. Turn the ignition swltch ON and measure the volt- age between the following terminals of the bank angie sensor connector with the connector connec- ted. > TERMINAL 2 STANDARD '7 Green ( 7) 1 Battery voltage— Red/Whitelw' *Green ("I i 0 _ 1 V BANK ANGLE SENSOR CONNECTOR Turn the ignition switch OFF. Remove the screws and bank angle sensorv Connect the bank angle sensor 3P (Green) connecV tor and place the bank angle sensor horizontal as shown, and ignltlon switch DNA The bank angle sensor is normal it the engine stop relay clicks and power supply us closedt Incline the bank angle sensor approximately 60 degrees to the left or nght with the Ignition switch ON. The bank angle sensor is normal it the engine stop relay clicks and power supply is open. If you repeat this test, first turn the ignition switch OFF, then turn the ignition switch ON. REMOVAL/INSTALLATION Disconnect the bank angle sensor 3P (Green) con— nector. Remove the two screws, nuts and bank angle senr sor. SCREWS 60° BANK ANGLE POSITION NORMAL POSITION iapproximatervl BANKANGLE SENSOR SCREWS CONNECTOR 5-88 FUEL SYSTEM (Programmed Fuel Injection) lnslall me bank Installation is In the reverse order of removal. angle sensor WlI/l lls UP mark Tighten the mounting screws securely, laCIIIg up ENGINE STOP RELAY INSPECTION Disconnect the engine stop relay 4P connector, removethe engIne stop relay. Connect the ohmmeter to the engine stop relay con- nector terminalsv CONNECTION: Red/Whlte - BIack/Wmte Connect the 12V battery to the following engine stop relay connector terminals. CONNECTION: Red/OrangeiBlack There Should be continuity only when the 12V battery is connected. If there is no continuity when the 12V battery is connected, replace the engine stop relayl ECM (ENGINE CONTROL MODULE) SYSTEM INSPECTION Remove the luel tank mounting bolts (page S-Bll. Remove the bolts and fuel tank rear bracket. ENGINE STOP RELAY ENGINE STOP RELAY BATTERY 5-89 l FUEL SYSTEM (Programmed Fuel Injection) Remove the ECM cover. Disconnect the ECM 22F (Blackl and 22F (Light grayl connectors. POWER IGROUND LINE INSPECTION Connect the test harness between the main wire harness and ECM (page 577l. Connect the test harness lpage 5-7l. TOOL: ECU test harness 07YMZ-0010100 (two required) GROUND LINE Check for continuity between the ECM test harness connector A9 terminal and ground, between the A20 terminal and ground, between the B1 terminal and ground. and between the B12 terminal and ground. There should be continuity at all times. if there is no continuity, check for open circuit in Green/Pink wrre and Green wire. POWER INPUT LINE Turn the ignition swnch ON wire the engine stop switch in RUN position. Measure the voltage between the ECM test harness connector BS terminal l+l and ground. There should be battery voltage. if there is no voltage. check for open circuit in Black /White wire between the ECM and bank angle sensor/relay. If the wire is OK, check for the bank angle sensor/ relay (page 5-88). ECM COVER 22PlBLACKl CONNECTOR ECM 5-90 FUEL SYSTEM (Programmed Fuel Injection) PAIR SOLENOID VALVE 2P (NATURALI CONNECTOR REMOVAL/INSTALLATION k [I Remove the aircleaner housing (page 5766). Disconnect the PAIR solenoid valve 2P (Natural! connector. Disconnect the PAIR air suction hoses. PAIR CONTROL Remove the bait and FAIR solenoid valve. SOLENOID VALVE Instailation is in the reverse order of removal. AIR SUCTION HOSES INSPECTION Remove the PAIR solenoid valve. (BI (BI Check that the air should not flow (A) to 18!, only when [he 12 V battery Is connected to the PAIR (A) solenoid valve terminals. Check the resistance between the terminals of the PAIR SOLENOID VALVE PAIR soienoid valve. STANDARD: 20 7 24 k D. (ZO°C/68"FI if the resistance is out ol specification, replace the PAIR solenoid valve. FUEL SYSTEM (Programmed Fuel Injection) EVAP PURGE CONTROL VALVE (CALIFORNIA TYPE ONLY) 30” 2PCONNECT0R REMOVAL Open and support the front end of fuel tank lpage 34). Disconnect the EVAP purge control valve 2P Connector. Disconnect the air tubes from the EVAP purge control valve. Remove the bolt and EVAP purge control valve bracket assembly, Installation is in the reverse Order Of removal. INSPECTION Remove the EVAP purge control valve. Check that the air should not flow (Al to (Bl, Onlv when the 12 V battery is connected to the EVAP purge control valve terminals. Check the resistance between the terminals of the EVAP purge control valve. STANDARD: 30 W 34 Hz l20 “0/68”Fl II the resistance is out Of specification, replace the EVAP purge control valve. 02 SENSOR (CALIFORNIA TYPE ONLY) REMOVAL DO not service the 0; sensor while it is hot. - Handle the 0: sensor with care. 0 Do not get grease, oil or other materials in the 0: sensor air hole. Open and support the front end of fuel tank lpage 37“. Disconnect the 0; sensor 4P (Naturall connector, Remove the 0: sensor wire from the frame. 5-92 FUEL SYSTEM (Programmed Fuel Injection) Remove the O~sensor wire clamp, Remove the right step guard mounting bolts, Release the 0; sensor wire from the right step guard. Remove the 0: sensor unit. 0 Be careful not to damage the sensor Wire 0 Do not use an impact wrench while1 removing or installing the 0; sensor. Install the 0: sensor unit. Tighten the unit to the specufied torquev TORQUE: 25 N-m (2‘6 kgf-m,19lbf‘ltl Oz SENSOR WIRE RIGHT STEP GUARD 07 SENSOR UNIT 5-93 FUEL SYSTEM (Programmed Fuel Injection) Clamp the 0, sensor wire to the right step guard. Install the right step guard and rear master cylinder, then tighten the mounIing boltsr Clamp the 0: sensor wire with the rear brake reservoir hose using the hose clamp. Route the 01 sensor wire into the frame. Connect the 0) sensor 4P lNaturaI) connector. EGCV AND AIR INTAKE VALVE INSPECTION Belore operating inspection, check that the PGM-Fl warning indicator does not indicate EGCV failures Remove the middle/lower cowl (page 25). Remove the air cleaner element lpage 375). Remove the bolts and EGCV pulley covert CLAMP RIGHT STEP GUARD PULLEV COVER 5-94 .4 FUEL SYSTEM (Programmed Fuel Injection) Turn the Ignition switch ON and check for EGCV cable guide pulley position. Make sure that the pulley index line is positioned 90“ (facing forward) as shown. Start the engine, warm up the engine to operating temperature. Gradually increase the engine rev upv Make sure that the EGCV cable pulley is moved to 0° (pulley index line facing upi at about 3,000 rpm as Shown. Check that the EGCV cable pulley is moved to 180" ipulley index line facing downl atabout8,000 rpm. Also check that the intake flap valve is opened at the same time. If the intake and EGCV position is incorrect, adjust the cables isee following steps]. If the intake and EGCV operation is incorrect, check for each related parts. CABLE ADJUSTMENT SERVlCE CHECK CONNECTOR JUMPER WIRE Remove the seat (page 272). Turn the ignition switch ON and engine stop switch in RUNt Short the service check connector with a jumper wire. FUEL SYSTEM (Programmed Fuel Injection) EGCV CONTROL CABLE ADJUSTMENT Make sure that the EGCV cable gulde pulley index line is aligned WIth the EGCV cover Index line. If the index lines do not aligned, adjust the EGCV control cables. Fully loosen the No, l adjusting cable (spring equipped cablel lock nut and adjusting nut. Adjust the EGCV positlon by loosening the No. 1 adjusting cable lock nut and turning the adjusting nut. Move the cable several times and recheck the index line. Hold the No. 1 Cable adjusting nut, then tighten the lock nut securely. Turn the No.2 cable lock nut and adjust the cable so that there is no free play. Tighten the No.2 cable lock nut securely. Remove the Jumper WIre from the service check connector. INDEX LINES ADJUSTING NUT No. 1 CABLE LOCK NUT ADJUSTING NUT No.1 CABLE LOCK NUT LOCK NUT No.2 CABLE ADJUSTING NUT FUEL SYSTEM (Programmed Fuel Injection) INTAKE VALVE CONTROL CABLE ADJUSTMENT Turn the ignition switch ON and short the service check connector with a Jumper wire (page 5‘95l. Remove the air cleaner element (page 375). Make sure the index llnes between the intake valve shaft pulley and air guide are aligned. lltne index lines are not aligned, adjust as follows INDEX LINE Loosen the intake valve cable adjuster lock nut. INTAKE VALVE CABLE ADJUSTER Turn the intake valve cable adjuster, align the intake valve cable gulde pulley index line with the index line on the valve shaft. At this point, turn back the cable adjuster 1/2 turn. Tlghten the lock nut securely, Remove the jumper wire from the service check connector, EGCV AND AIR INTAKE VALVE SERVO MOTOR REMOVAL Open and support the front end of fuel tank (page 3-4). Disconnect the servo motor 6P (Natural) connector, Remove the servo motor mounting bolt and pull SERVO MOTOR BOLT out the servo motor lrom the bracket. 5-97 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the Intake air valve and EGCV control cables from the servo motor pulley, then remove the servo motor. 0 O INSPECTION 0 Connect the 12 V battery to the servo motor 6P (Natural) connector terminals and check that the motor operation Connection: Red l+laBlue l’l . If the servo motor does not turn, replace the servo motor With a new one C Measure the resrstance between the servo motor 6P lNaturall connector terminals. Connection: Yellow/Red *Green/Ovange . Standard: 5 k L2 Connection: Light green/Pink 7 Green/Orange Standard: 0 7 5 k 52 ll the resistance is out of range, replace the servo moron 0 INSTALLATION 6? (NATURAL) CONNECTOR . Connect the servo motor 6P (Natural) connector. \ O O 5-98 // you using me NEW servo mum/i ll [5 not necessary to do this procedure: FUEL SYSTEM (Programmed Fuel Injection) Short the service Check connector (page 5795M Turn the ignition switch ON. The servo motorturns, then stops. Secure the servo motor pulley at this position using a 3 mm socket bolt as shown. Socket bolt, 3 X 28 mm: Part number: 31420-MCJ-640 Connect the EGCV control cables to each position, then connect the intake valve control cable Adjust the intake and exhaust valve control cables (page 5-95). Remove the 3 mm socket bolt lrom the servo motor pulleyt Install the servo motor onto the bracket. Install and tighten the servo motor mounting bolt. Connect the servo motor 6P1Natura|)connector. 3 mm SOCKET BOLT PU LLEV SERVO MOTOR FUEL SYSTEM (Programmed Fuel Injection) I/ you using the Short the service check connector lpage 5-95). new servo motor, 3 mm SOCKET BOLT :1 is not necessary Turn the ignition switch ON. . to do this The servo motor turns, then stops. g PU LLEV Procedures Secure the servo motor pulley at this position using a 3 mm socket bolt as shown. Socket bolt, 3 X 28 mm: Part number: 314207MCJ7640 O . Connect the EGCV control cables to each position, then connect the intake valve control cable. Adjust the intake and exhaust valve control cables lpage 5795). . Remove the 3 mm socket bolt from the servo motor pulley. 0 Install the servo motor onto the bracket. SERVO MOTOR BOLT Install and tighten the servo motor mounting bolt. / O . Connect the sen/o motor 6P (Naturall connector. FUEL SYSTEM (Programmed Fuel Injection) EGCV OPERATING INSPECTION Disconnect the EGCV control cables (page 248x Turn the EGCV pulley from 0 to 180° and Check the smooth operation. If operation is not smooth, check for carbon deposuts in the EGCV and valve body (page 5790), Check the EGCV Dre-load using a torque wrench. PRE-LOAD: 34 N m 13.5 Kgf~m, 25 lbf-ftl maximum ll prerload is excessive, disassemble and inspect the EGCV REMOVAL Remove the exhaust pipe assembly (page 2-18l. Remove the bolts, front exhaust pipe and gasket. Remove the bolts, rear exhaust pipe and gasket. FRONT EXHAUST PIPE 5-100 FUEL SYSTEM (Programmed Fuel Injection) DISASSEMBLY Turn the EGCV cable guide pulley counterclockwtse. and seat llS tab wwth the stopper on the valve coverr Loosen and remove the nut, then remeve the valve Cable guide pulley. - Be careful not to damage the thrust Washer B. I Do not use any cleaning solution to clean the thrust Washer B. - Do not apply any lubncant to the thrust washer 8, Remove the following: *Spring retainer *Thrust washer B *Thrust washerA rThrust spring Check the thrust washer B for wear or damage, Replace the thrust washer B if it is wear or damage, Remove the EGCV cover mounting bolts, cable stay, EGCV cover and metal gasket, Remove the EGCV from the valve body. Remove carbon deposits from the EGCV and valve body. - Do not use any cleaning solution to clean the EGCVbushlngs, ' Do natapply any lubrrcentto the EGCV bushings. Check that the EGCV for wear or damage. Check that the EGCV body for wear or damage. NUT SPRING THRUSTWASHER B ./ 1%“? W SPRING RETAlNER J THRUST WASHERA VALVE COVER CABLE STAY BOLTS EXHAUST VALVE FUEL SYSTEM (Programmed Fuel Injection) Press the EGCV bushing unm us and below 0 37 0.5 mm {0 01* 0.02 m) from the valve body surface as shown EGCV SHAFT BUSHING REPLACEMENT Remove the valve body side EGCV bushing and cap using the following tools. TOOL: Remover, 14 X 16 mm 07VMF7MCJ0400 Install the EGCV cap into the EGCV body until it seats using the special tools. TOOLS: Installer shaft guide 07VMF-MCJ0100 Installer shaft 07VMFAMCJ0200 Press the EGCV bushmg in using the special tool, TOOLS: Installer shaft guide O7VMF7MCJ0100 Installer shaft 07VMF7MCJ0200 Press the valve cover sude EGCV bushing out using the following tool. TOOL: Remover, 14 X 16 mm 07YMF-MCJO4DO REMOVER CAP BUSHING 0.3 7 0.5 mm 10.01 — 0.02 In) 1 REMOVER BUSHING 5-102 FUEL SYSTEM (Programmed Fuel Injection) Press [he EGCV Press the EGCV bushing in using the speciaI tool‘ bushmg mm as end pro/ecled 0 3 TOOL: 0 5 mm (D 01* Installer shaft, 14 X 30 mm O7YMF7MCJ0300 0 02 In) Ham the valve cover surface as Shown INSTALLER SHAFT 0.3 7 0.5 mm (0.01 , 002 in) ASSEMBLY VALVE COVER CABLE GUIDE BUSHING > %\/ METAL GASKET 12 N-m11.2 kgf-m,9 Ibf-m @ 12 N-m (1.2 kgf‘m,9 Ibm) ‘ 19236?) ”'2 kgf‘m' @ : PULLEY COVER THRUST WASHER A THRUSTWASHER B / SPRING RETAINER EXHAUST VALVE BODY FULLEY BUSHING Q EXHAUST VALVE 12 N-m11.2 kgfrm , 9 Inf-ft) InsIall the EGCV into the EGCV body. FUEL SYSTEM (Programmed Fuel Injection) Install Ihe EGCV CUVel Wllh Its Index line faclng dawn lnsIall (he mrusl washer B Wllh llS chamlered Slde racing to the spring retainer Make sure that Ihe thrust spring l5 seated on the exhaust valve cover buss Install the metal gasket and EGCV covert InstaII the EGCV cable stay and tighten the four EGCV cover mounting bolts to the specified torque. TORQUE: 12 N~m 11.2 kgf‘m , 9 Ibf‘ft) ' Be careful not to damage the thrust Washer B. ' Do not use any cleaning solution to clean the thrust washer B. ' Do not apply any lubricant to the thrust washer B. Install the thrust washer B and A onto the spring retainer. Install the thrust spring onto the EGCV cover. Install the spring retainer assembly onto the thrust spring. METAL GASKET VALVE COVER INDEX MARK VALVE COVER CABLE STAY THRUST WASHER B THRUST WASHER A SPRING RETAINER VALVE COVER BOSS A THRUST SPRING 5-104 FUEL SYSTEM (Programmed Fuel Injection) Install the valve cable guide pulley by aligning its cut-out with the valve shafltab as shown. Install the valve cable guide pulley flange nut. Turn the valve cable guide pulley clockwise, seat the pulley tab with the stopper on the valve cover, Tighten the nut to the spemfied torque. TORQUE: 12 Nvm (1.2 kgf‘m , 9 lbf‘ft) Check the EGCV pre-load uSlng a torque wrench. PRE-LOAD: 34 N-m (3.5 kgf‘m, 25 lbiAftl maximum If prerload l5 excessive, reassemble the EGCV. EGCV INSTALLATION Install the metal gasket and rear exhaust pipe onto the EGCV body. GROOVE PULLEV NUT PU LLEV VALVE BODV REAR EXHAUST PIPE METAL GASKET 5-105 FUEL SYSTEM (Programmed Fuel Injection) Tighten (he EGCV mounting bolt to the specified torque, TORQUE: 14 Nm (1.4 kgf-m,10|bf-ft) InstaH the metal gasket and front exhaust pipe onto the EGCV body, Tighten the EGCV mounting bolt to the specified torque. TORQUE: 14 Nim (1.4 kgf-m , 10 lbf-fll Install the exhaust PIPE assembly (page 2720L Connect the EGCV control cables and adjust the control cables lpage 5—95L Remove the EGCV cover front upper bolt. Install EGCV cable guide pulley cover and tighten the bolts to the specufied torque. TORQUE: 12 N-m (1.2 kgfrm , 9 lbfAft) REAR EXHAUST PIPE FRONT EXHAUST Pl PE VALVE BODY METAL GASKET FRONT EXHAUST PlPE PULLEV COVER \ 5-106 FUEL SYSTEM (Programmed Fuel Injection) VARIABLE AIR INTAKE VALVE CONTROL CABLE VALVE FLAP DISASSEMBLY / /’ ' . O / , Remove the air cleaner housing {page 5766L Open the intake valve flap by hand, disconnect the intake Valve Cable and from the drum. 0 DRUM . Unhook the return spring ends lrom the hooks. O 0 If necessary, loosen the control cable nut and remove the control cable from the air cleaner housing. 0 I . Remove the intake valve shaft holder mounting AIR GUIDE A 'AIR G—UID_E B— screws and holder, Remove the air guide A and B mounting screws. Remove the intake valve flap/shaft assembly, air guide A and B. D . FLAP/SHAFT ASSEMBLV SCREWS 5-107 FUEL SYSTEM (Programmed Fuel Injection) ASSEMBLY AIR GUlDE B FLAP/VALVE SHAFT ASSEMBLY . AIR GUIDEA RETURN SPRING O O RETURN SPRING . AlR GUIDE CABLE DRUM 0 Install the intake valve drum onto the shaft aligning FLAP/SHAFTASSEMBLY AIR GUIDE its groove with the intake valve shaft boss. Install the return spring on both sides‘ Install the air guide with its "UPPER” mark lacmg . up. Install the intake valve flap/shaft assembly onto the air cleaner housing. 0 RETURN SPRINGS Install the air guide A and B, then tighten the AIR GUIDE A AlR GUIDE B mounting screws \ 0 Install the lntake Valve shaft holder plate with its “UPPER” mark facing up. Install and tighten the mounting screws. 0 \ ‘ FLAP/SHAFT ASSEMBLY SCREWS . 5-108 FUEL SYSTEM (Programmed Fuel Injection) Open the intake valve flap by hand, connect the intake valve control cable end to the drum. Turn the return spring end counterclockwise turn and then install it onto the hook as shown Face the control cable lo the Ian, men tightening [he lDCK nlll Tighten the cable lock nut securely if It is removed. lnstall the air cleaner housing lpage 5-57). Adjust the variable air intake valve control cable lpage 5-95ll CONTROL CABLE RETURN SPRING CONTROL CABLE ' 6 COOLING SYSTEM l SYSTEM 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 6-16 . COOLANT REPLACEMENT 6-4 GENERAL 0 ’ ' ' AWARNING Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. O Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. . ' If any coolant gets in your eyes, rinse them With water and consult a doctor immediately. - II any coolant is swallowed, induce vomiting, gargle and consult a physmian immediately, - If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. . Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. . Add cooling system at the reserve tank. Do not remove the radiator cap except to refill or drain the system. . All cooling system services can be done with the engine in the frame. - Avoid spilling coolant on painted surfaces. ' After servicing the system, check for leaks with a cooling system tester. . - Referto section 19 for fan motor switch and coolant temperature sensor inspection. 0 O O COOLING SYSTEM SPECIFICATIONS ITEM 1 V‘jgdlal’a and englne Reserve tank city 7, Eagflrrawzifirw15§ge SPECIFICATIONS . Fla-A US at , 2.8Jmpql) ’ 0.4 I]. (0.4 US qt , 0.4 lmp qt) 1087137 kPa11.171.A kgf/cmz, 16 *20 psi) l 1 Fully Opel .. , ..,. .i.i.Via“/§Mt.m.i Recommended antlfreeze Thermostat Begm EQPPefl. 7. 8075 , 83.5 °C1177 *182 “F) g 95 °C 1203 °F) > 8 mm 10.3 inlfllnlmulh High'qfla ty ethylene glyco1 antifreeze containlng corrosio'o' protection inhibltgrsi 'Eénd’a’rElEo’olam mincentratiorr" 50 % mixture with soft water TORQUE VALUES Water pump cover SH bolt ECT1Engine Coolant Temperaturel/thermo sensor (3001an {an nut Fan motor HUI Fan motor switch TROUBLESHOOTING Engine temperature [00 high I Faulty radiator Cap I lnsuftlcient coolant 0 Passages blocked in radiator, hoses or water jacket 0 Air in system . Faulty water pump - Thermostat stuck closed - Faulty temperature gauge or coolant temperature sensor . Faulty cooling fan motor U Faulty 1am motor switch Engine temperature too low 0 Faulty temperature gauge or ECT/thermo sensor 0 Thermostat stuck open - Faulty cooling fan motor switch ‘IZ Nim 11.2 kgfvm,9lbf-ft1 23 Nim 12.3 kgf~m,17|bf1‘t) 3 Nvm 10.27 kgfvm , 2.0 lbf-flI 5 Nrm 10.5 kgfim , 3.61th) 18 N‘m 11,8 kgI-m, 13|b11t1 CT bolt Apply Sealant to the threads Apply a lockan agent to the threads Apply sealant to the threads Coolant teak 0 Faulty water pump mechamcal seal 0 Deteriorated O-rings I Damaged or deteriorated gasket ' Loose hose Connection or Clamp - Damaged or deterlorated hose 0 Faulty radiator cap COOLING SYSTEM SYSTEM TESTiNG 1140141011041: . COOLANT lHYDROMETER TEST) Remove the rlghl heat guard lpage ZrSl. Remove the radiator cap. 0 . Test the Coolant gravity using a hydrometer (see below for ”Coolant grawty cha rt”l. For maximum corrosion protection, a 50 50% solution of ethylene glycol and distilled water is recommended lpage 6-4). Look for contamination and replace the coolant if . necessary. 0 COOLANT GRAVITV CHART Coolant temperature °C (“Fl l l ‘ ‘ l 0 5 1015 20 25130 35140 45l50 . Coolant ratio % x 1321 1 1411 1501 l 1591 ‘ l68l 1771 (301 1951 1104) (11311122; 5 V 1009 1.009 1.008'1.000:1,007 100011.005 10031100110999 0g 10 1.0181.017l1.017 1.010l1.0151.014l1.0131.011:1.009l1.007'l1. 05 15 1.0281.DZ7 102010251024 1.022 1.020 101011.010 101411.012 20 1.030 1.035 1.034 1.033l1.031 1.029 1.027 1.025l1023 1.021l1.019 ,. 25 1.045 1.044 1.0431042 1.040 103811.036 1.034 1.031 1.028 1.025 30 l1.053 1.052 1.0fl1.047l1.046 1.045l1.043 1.041l1.038i1.035 1.032 g 35 _ l1.003 1.002 1.000 105811.055 1.054.1052 1.049 1,040 1.043 1.040 40 l1.072 1.070 1.008 1.000 1.064 106211.059 1.056 1.053 1.0503047 45 ‘1.080 1070 1.0701074 1.072 100011.060 1,003 1.000 1,057 1.054 50 1.080 1.084 1.082 1.080 1.077 1.074l1.o71 1.000l1.065l1.062 1.059 55 1.0951093 1.091 1.088 1.085 1.082 1.079 1.076 107311.070 1.007 00 l1.100l1.098 1.095l1.092 1.039 1.030 1.003 1.080l1.077l1.074 1.071 O O O 6-3 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Before inslallmg Remove the radiator cap lsee previous pagel. me cap in Ihe (ester. wet Ihe Pressure test the radiator cap. sealing surfaces Replace the radiator cap if it does not hold pressure, or illhe reliel pressure is too high ortoo low. it must hold the specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108" 137 kPa (1.1 ~14 kgf/sz ,16i20 psi) Pressure the radiator, engine and hoses, and check for leaks. Excessive pressure can damage the cooling system components. Do not exceed 137 kPa {1.4 kgi/cm’, 20 psi). Repair or replace components if the system will not hold specified pressure for at least 6 seconds. COOLANT REPLACEMENT PREPARATION 'The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mlxing proportion during usage. Therefore, for best performance change the coolant regularly as specified in the maintenance schedule. 'MIX only distilled, low mineral water with the antlfreeze. RECOMMENDED ANTIFREEZE: High quality ethylene glycol antifreeze containing corrosion protection inhibitors RECOMMENDED MIXTURE: 50 7 50 lDistilled water and antifreeze) When ill/ms lhe REPLACEMENT/AIR BLEEDING syslern or reserve tank With a Coolant Remove the radiator cap. (checkmg caolanl level), place lhe motorcycle in a Velllcal posilion on a flat, level surface RADlATOR CAP TESTER RADIATOR CAP ANTIFFIEEZE SOLUTION I W lETHVLENE GLVCOL BASE LOW MINERAL SOLUTION) OR DISTILLED WATER COOLANT RADIATOR CAP Remove the middle/lower cowl (page 2-5l. Remove the drain bolt on the water pump cover and drain the system coolant. Remove the cylinder drain bolt and drain the coolant from the cylinder. Reinstall the drain bolt with the new sealing washer. Open and support the front end of fuel tank (page 3-4). Disconnect the siphon tube from the radiator. Drain the reserve tank coolant. Empty the coolant and rinse the inside of the reserve tank with water. Reinstall the radiator siphon tube. Fill the svstem with the recommended coolant through the filler opening up to filler neck. Remove the radiator reserve tank cap and fill the reserve tank to the upper level line. Bleed air from the system as follow: 1.Shift the transmission Into neutral. Start the engine and let it idle for 2 -3 minutes. 2. Snap the throttle 374 times to bleed air from the system. 3. Stop the engine and add coolant up to the proper level if necessary. Reinstall the radiator cap. 4, Check the level of coolant in the reserve tank and fill to the upper level if it is low. COOLlNG SYSTEM COOLING SYSTEM THERMOSTAT THERMOSTAT REMOVAL Dram the coolant lpage 675). Remove the throttle body (page 5-68lv Remove the bolts and thermostat housing coverr v» Remove the thermostat from the housing. INSPECTION THERMOSTAT SEAL RING Wear Insulated gloves and adequate eye protection, Keep flammable materials away from the electric heating element Visually inspect the thermostat for damage, Check for damage of the seal ring. Do not let me Heat the water with an electric heating element to thermoslal or operating temperature (or 5 minutes. mermomeler Suspend the thermostat in heated water to check touch the Dan. or its Operatlon. you will get /alse reading Replace the thermostat If the valve stays open at room temperature, or if It responds at temperatures other than those specified. THERMOSTAT BEGIN TO OPEN: 805*835 ”C 1177 *182 “Fl VALVE LIFT: 8 mm 10.3 ml minimum at 95°C (203°Fl THER MOSTAT 6-6 COO UNG SYSTEM THERMOSTAT HOUSING REMOVAL Disconnect the ECT sensor connector. Disconnect the last idle wax unit water hose and bypass hose from the thermostat housing‘ Remove the bolts and thermostat housing from the cylinder headt THERMOSTAT HOUSING INSTALLATION Install a new {)7er into the groove of the thermostat bodyt Install the thermostat housing onto the cylinder head. Install and tighten the thermostat housing mount- ing boltsv Connect the fast idle wax unit water hose and bypass hose. Connect the ECT sensor connector. THERMOSTAT INSTALLATION Install the thermostat into the housing with its air bleed hole facing rearward. COOLING SYSTEM Install the thermostat housing cover onto the housing. Install and tighten the housing Cover b0l15. E "lgl-lERMOSTAT HQ 0 Fill the system with recommended coolant and bleed the air (page 65L 0 RADIATOR . REMOVAL Remove the following: " Middle/lower cowl {page 2»5l *Heat guard (page 2-9l . Drain the coolant lpage 6*4l. Disconnect the siphon tube and air bleed tube from the radiator: Disconnect the upper radiator hose. 0 Disconnect the fan motor switch connector from the swltch, release the wire from the inner middle cowl. O 0 Disconnect the radiator sub—harness 2P (Black) 2P (BLACK) . connector. CONNECTOR Disconnect the lower radiator hose and oil cooler water hose 0 COOLING SYSTEM Remove the radiator lower mounting bolt/nut. Remove the radiator upper mounting bolt and washer, Slide the radiator to the right, then release the upper grommet from the frame boss, Be careful not In Remove the radiator assembly. damage the radialor core DISASSEMBLV Release the fan motor subrharness connector from the fan motor bracket Remove the three bolts, ground eyelet and cooling lan/motor assembly. COOLING FAN/MOTOR ASSEMBLV 6-9 COOLING SYSTEM Removemenumoormgranand drsranceconar. NUT COOLING FAN O 0 Remove the flange nuts and fan motor from the fan FLANGE NUTS FAN MOTOR 0 motor bracke!‘ For fan motor switch mformauon, refer to page 19-14 0 O ASSEMBLY 3 N-m (0‘27 kgV-m , 2,0 mm 18 Nm 11.8 kgf-m , 13 mm @ COOL'NG FAN . 5 Nvm10.5 kgf~m, . O O RADIATOR FAN MOTOR BRACKET 0 6-10 COOLING SYSTEM Install the fan motor onto the fan motor bracket and FLANGE NUTS " FAN MOTOR tlghtel’l the Irange nuts to the specified torque, TORQUE: 5 Nrm (0.5 kgf‘m , 3.6 Ibf-fiI Install the dISLaI’ICe collar onto the tan motor shaft. COOLING FAN Install the cooling fan onto the fan motor shaft by aligning the Ilatsurfaces. Apply a locking agent to the cooling fan nut threads. Install and tighten the nut to the specified torque. TORQUE: 3 N-rn 10,27 kgf‘m , 2.0 lbf‘ftl Install the cooling fan/motor assembly onto the GROUND EYELET CONNECTOR BOLTS radiator. Route the ground eyelet properly. Install and tighten the bolts. Install the radiator sub-harness connector to the fan motor bracket, COOLING FAN/MOTOR ASSEM BLV 6-11 COOLING SYSTEM genre/Mom INSTALLATION UPPER momma damage me /, VadlalOfCO/E lnstall the radiator assembly, aligning its grommet with the frame bossl . O RADIATOR Install the washer and upper mounting bolt, then BOLT/WASHER . lighten the bolt. 0 0 Install the radiator lower mounting bolt/nut, tighten the nut securely. O 0 Connect the fan motor sub-harness 2P (Blackl 2PlBLACK) connector. CONNECTOR . Connect the lower radiator hose and Oll collar water hose. 0 O 6-12 COOLING SYSTEM Connect the upper radiator hose: SIPHON TUBE / Connect the siphon tube and air bleed tube to the // radiator. UPPER RADIATOR HOSE AIR BLEED TUBE Route the fan motor switch wire properly, connect the connector to the switch. Fill the system with recommended coolant (page 65). Install the iollowing: *Heat guard (page 2-15! 'Middle/lower cowl (page 277) WATER PUMP MECHANICAL SEAL INSPECTION Inspect the inspection hole (or signs of coolant leakage if there is leakage, the mechanical seal is defective and replace the water pump as an assembly, »‘ i I cilantro, _ REMOVAL Draln the coolant (page 6A4l. Disconnect the lower radiator hose, bypass hose and oil cooler Water hose from the water pump coverl LOWER RADIATOR HOSE COOLING SYSTEM Remove xhe (W0 SH bolts, [W0 flange bolts and Water pump cover. Remove the OAring from the water pump body Remove the water pump body from the crankcase. Disconnect the waxer pump-to-water joint hose from the water pump body. WATER PUMP COVER WATER PUMP BODV COOLING SYSTEM INSTALLATION 12 N-m {1‘2 kgfvrn , 9 lbf-fil Connect the water pump-terwater joint hose to the water pump and tighten the clamp screw. Apply englne oil to a new Orring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while aligning the water pump shaft groove with the oil pump shaftend. COOLING SYSTEM Align the mountlng bolt holes In the water pump WATER PUMP BODV and crankcase and make sure the water pump is U _ ‘ securely installed. _ l . lnstall a new O-ring Into the groove in the water pump body. 0 Install the water pump cover, two SH bolts and two WATER PUMP COVER . flange bolts. Tighten the flange bolts to the specified torque. TORQUE: 12 N~m11.2 kgf‘m , 9 lbf-ltl Tighten the two SH bolts, . 0 Connect the lower radiator hose, bypass hose and OIL COOLER WATER HOSE BYPASS HOSE Oil cooler water hose, then tighten the clamp . screws. Fill the system with recommended coolant (page . 6-5). 0 ‘ - v} ‘. LOWER RADIATOR HOSE RADIATOR RESERVE TANK RESERVE TANK . REMOVAL " Remove the middle/lower cowl lpage 2-5l. Disconnect the siphon tube and drain coolant from \v, the reserve tank. \ r. Remove the radiator reserve tank lower mounting \y bolt. ‘ SIPHON TUBE . 6 6-1 COOLING SYSTEM Remove the reserve tank upper mounting bolt and OVERFLOW TUBE reserve tank. Disconnect the overflow tube. ‘ RESERVE TANK INSTALLATION UPPER BRACKET are W @W RESERVE TAN K SIPHON TUBE Route the overflow tube properly (page 1723). Install and tighten the reserve tank upper mounting bolt. COOLING SYSTEM InslaH and lighten the \ower mounting bolt Connect the siphon Iube to Ihe reserve tank. Insrall the removed parts in Ihe reverse order of remova‘. RESERVE TANK 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7-1 ENGINE INSTALLATION 7-5 LOWER BRACKET REMOVAL 7-2 LOWER BRACKET INSTALLATION 7-11 ENGINE REMOVAL 7-3 SERVICE INFORMATION GENERAL - During engine removal and (nstallatIon, support the motorcycle using a hoist or equivalent. - Support the engine using a Jack or other adjustable support to ease of engine hanger bolts removal. - Do not use the 0/, filter as a jacking point. O The following components can be serviced with the engine installed in the lrame, TAlternatDr (Section 1m Camshaft (Section 8) *Ciutch (Section 9) *Gearshifl linkage (Section 9i 7 Oil coolerlSectIon 4i 7 Oil pump (Section 4) * Shift forks/shift drum (Section 9) *Water pump (Section 6i ' The fOIIOWIng components require engine removal for service. *Crankshalt/transmission (Section 12) 7Clender head/valves (SectIon 8i 7 Plston/cylinder (Section 11l SERVICE DATA ITEM SPECIFICATIONS "Engine dry weight 62.1 kg (1359 lbsl "goolant capacit I Radiator and engine 32 ll (3.4 US qt , 2.8 Imp qtl Engine Oil capaclty l At disassembly 4.0 B (4.2 US qt , 3.5 Imp qt) TORQUE VALUES Main step bracket mountIng socket bolt 39 Nm (4.0 kgf-m , 29 IbI-rt) Main step mounting bolt 44 N-m (4.5 kgf-m , 33 lbf-Itl ALOC boll Bank sensor 12 N-m (1.2 kgf-m , 9 Ith) Lower bracket mounting nut, 10 mm 42 N~m (4.3 kgf-m,31lbf-ftl 7 U-nut, see page 7-11 Lower bracket mounting pInch bolt 26 N~m (2.7 kgf-m , 20 lbl~ftl *'4 Engine hanger nut lfrontl 39 N-m (4.0 kgf-m ,29 let) E 7 See page 776 Engine hanger nut (middle) 54 N-m (5.5 kgf-m , 40 lbf-ftl Engine hanger nut lrearl 54 N-rn (5.5 kgf-m , 4O lbf-ltl Rear engine hanger pinch bolt 26 N-rn (2.7 kgf-m , 20 lbf-fll Side stand bracket bolt 44 N»rr\ (4.5 kgf-m , 33 lbf-fll ALOC bolt Drive sprocket special bolt 54 N-m (5.5 kgf~rn , 40 Ibf-ft) ENGINE REMOVAL/INSTALLATION LOWER BRACKET REMOVAL Open and support the front end of fue‘ tank {page 3-4L Remove the foHowing: Muffler/exhaust pipe (page 2-19D 7 Rearfender (page 2-14) *Suspenslon linkage (page 1479) 7 Rear shock absorber (page 14711} *Swmgarm (page 14-14} Disconnect the sude stand 2P (Green) connector Remove the bolls and side stand bracket assemb‘y. Remove the lower bracket front socket bolt and nut. Loosen the rear socket bo‘t pinch bolt. SIDE STAND BRACKET REAR SOCKET BOLT PINCH BOLT as ENGINE REMOVAL/INSTALLATION Remove the lower bracket rear socket bolt and nut .7 ,, ,. m‘ V ‘ _/ i _ then remove the lower bracket from the engme. EAR SOCKET BOL‘ NUT .‘h . ENGINE REMOVAL PAIR CONTROL THROTTLEBODV SOLENOID VALVE Remove the following: L 1 *Fuel tank Ipage 5431) ‘ ’ *EGCV and air Intake valve servo motor (page 5-97I -- Throttle body lpage 5758l , Lower bracket (page 7-2) 7 PAIR control solenoid valve assembly (page 8-5) "Ignithfl coil/spark plug subrharness Ipage 8-5l IGNITION COIL SUB-HARNESS Dlsconnect the fol lowing connectors: ., ZPIRED) CONNECTOR , Ignition pulse generator 2F IRedl connector 7 Speed sensor 3P INaturall connector - Engine sub-harness 2P IBIueI connector Disconnect the alternator 3P (Whitel connector. 3P (WHITE) CONNECTOR 7-3 ENGlNE REMOVAL/INSTALLATION Disconnect the alr bleed tube and upper radlator hose lrom the thermostat housing cover. Remove the thermostat housing cover and . thermostat (page BVGL ‘ O mammal/Arrest H®SE Disconnect the ECT sensor Connectorv . Remove the bolts and thermostat housing from the cylinder head. 9 9 Remove the starter motor mountlng bolt and starter motor ground cable. Remove the terminal nut and starter motor cable. 0 0 Remove the bolts and clutch cable guide then W" . ' 'GLUTCHCABLE _ CAB E | disconnect the clutch cable from the clutch lifter 5“ ‘ L GU DE . lever. ENGINE REMOVAL/lNSTALLATlON ESTOVE the radiator lower mounting bracket bolt] WATER HOSE LOWgR BRACKET Disconnect the siphon tube from the radiator reserve tank. Remove the bolts, radiator reserve tank and radiator lower mounting bracket. Disconnect the Oil coolerrloVradialor Water hose from the Oil cooler, SIPHON TUBE RESERVE TANK Disconnect the lower radiator hose from the water pump cover, Support the engine using a jack or other adjustable support to ease ofengine hanger bolts removal Remove left side ofthe front [10 mm) and middle 112 mm) engine hanger bolts. Remove the right side of the front (10 mm) and middle 112 mml engine hanger bolts and distance collars‘ ENGINE REMOVAL/INSTALLATION Loosen the rear engine hanger pinch bolt. V EAR HANGER BOLT O 0 Remove the rear engine hanger socket bolt and nut, . then remove the engine from the Frame. 0 O - Note the direction of the hanger bolts. ' Use a floor jack or other adjustable support [0 . carefully maneuver the engine into place. . Be careful not to Install the engine into the frame. REAR HANGER BOLT/“UT . damage the cam , K" \ chamtensioner lnstall the rear engine hanger socket bolt and nut. Ilflel . O 7-6 ENGINE REMOVAL/INSTALLATION Install the rlght Slde ol the from No mml and fl’yi ‘~ ‘1??? middle (12 mml engine hanger bolts With the film" HANGER BOLT mmmmNGfl SQ” distance collars. . t u - Installtheleltslde ofthelronIHOmmland middle '10mm HANGER BOLT 12mm HANGER BOLT l12mmlengine hanger bolts. " install the right and left front engine hanger bolts in their pmper locations. Improper installation will damage the cylinder heart. Hold the rear engine hanger socket bolt, then tighten the nuuo the specified torque. TORQUE: 54 N-rn (5.5 kgf‘m , 40 Ibf-it) Tighten the rear engine hanger pinch bolt to the specified torque‘ TORQUE: 26 N-m 12.7 kgf-m , 20 ”JUN ENGINE REMOVAL/lNSTALLATION Tighten the left side of the front 110 mml and ~10mm HANGER: BOLT 12 mm HANGER BOLT‘ middle (12 mm) engine hanger bolt to the specified 1‘ torque, W ‘ . '. ‘ C TORQUE: Front [10 mm): 39 Nm (4.0 kgi-m , 29 lbf-ft) Middle (12 mm): 54 Nvm15.5 kgfrn , 40 |bt~ft) C Tighten the right sude of the front 110 mm) and 1 m‘n‘fi-IANGER BOLT 10mm HANG RVB®LT . middle (12 mml engine hanger bolt to the specified ‘ / . torque. TORQUE: Front [10 mm): 39 N-m (4‘0 kgf-m , 29 |bf~fll Middle (12 mm): 54 N-rn (5.5 kgf-m , 40 |bf~ftl . 0 Connect the lower radiator hose to the water pump cover and lighten the hose band screw. 0 C LOWER HADIATlQR HOSE 5 ’ Connect the oil cooler-terradiator water hose to the WATER HOSE LOWER BRACKET oil cooler, tighten the hose band securely. ' Install the radiator reserve tank and mounting bolts, tighten the bolts Connect the siphon tube to the reserve tank. install the radiator lower mounting bolt/nut, tighten the nut securely. I SIPHON TUBE RESERVE TANK ENGINE REMOVAL/INSTALLATION Connect the clutch cable end to the clutch lifter _ \‘ACL lever‘ f Install the clutch cable guide to the right crankcase ‘ cover and tighten the mounting bolts securely, UTCH CABLE CABLE GUIDE Connect the starter motor ground cable and install and tighten the starter motor mounting bolt. Connect the starter motor cable to the motor terminal, tighten the terminal nut. Install a new O-ring into the thermostat housing groove. Install the thermostat housing to the cylinder head. Install and tighten the thermostat housing mount: ing bolts. Connect the ECT sensor connector. ENGINE REMOVAL/lNSTALLATiON Install the thermostat and thermostat housing cover{page6r7l, Connect the air bleed tube and upper radiator hose 0 to the thermostat housmg cover and ttghten the hose band screw 0 Route the alternator wire, connect the alternator 3P 0 (White) connector. 0 \_ \\_ 3P{WH|TE{ CONNECTOR . Connect the following connector: 2P {RED) CONNECTOR Algnltlon pulse generator 2P {Fledl connector I, -Speed sensor 3P {Naturall connector *Englne sub~harness 2PtBluelconnector . O 3P{NATURAL{CONNECTOR ”ma” ¥he'°”°w'"9¢ PAIR CONTROL THROTTLE BODV . ilgnltlon coll/spark plug subrharness {page 8731) SOLENQ|D VALVE *FAIR control solenoid valve assembly {page 831D , Lower bracket {page 7-11) *Throltle body {page 5-71) *EGCV and air lntake valve servo motor {page 5-95l “Fuel tank {page 5A63l . Pour recommended engrne oil up to the proper level (page 3-15{. Fill the cooling system wlth recommended coolant and bleed the air {page 6-4l. O 7-10 ENGINE REMOVAL/lNSTALLATlON LOWER BRACKET INSTALLATION SWINGARM PlVOT NUT 113 N-m (12 kgfvm , 87 lbf-fll ‘ \ PlNCH BOLT \. \\ \ 26 Nlm (2.7 kgfrm , 20 Half!) \ / 6M? PINCH BOLT 25 Nm (2.7 kgf-m, 20mm 26 N-m 12.7 kgf»m , 20 leIl 10 mm SOCKET BOLT/NUT 10 mm SOCKET BOLT/NUT PINCH BOLT 26 Nlm (2.7 kgf-m , 20 |bf~ftl Install the lower bracket onto the engine. Temporarily install the from and rear 10 mm bolts and nuts. Temporarlly llghlen the 10 mm nuts. Install the swungarm lpage 14723). Hold the swingarm pivot bolt, then lighten the pivot nut to the specified torque. TORQUE: 118 Nm 112.0 kgl-m , 87 lbf-hl ENGiNE REMOVAL/INSTALLATION Tighten the front 10 mm socket bolt and nut to the specified torque. TORQUE: 42 N-m 14,3 kglm , 3T Ibf-iti Hold the rear 10 mm socket bolt, tighten the nut to the specified torque. TORQUE: 42 Nm [4V3 kgiArn , 31 lbf-m Tighten the 10 mm socket pinch bolt to the specified torque. TORQUE: 26 N~m12.7 kgfim , 20 lbf-Ft) Instail the side stand bracket assembly, tighten the new bolts to the specified torque. TORQUE: 44 N-rn14.5 kgf-rn , 33 ibf-fl) 10 mm SOCKET BOLT/NUT 10 mm SOCKET BOLT/NUT ~\' 9% SOCKET BOLTS SIDE STAND BRACKET 7-12 ENGINE REMOVAL/INSTALLATION Route the side stand wire properly, conned the side stand swuch 2F [Greem connector, . InstaH the foHowing: 7 Rear shock absorber (page 1443’ *Suspension linkage (page 1441) *Rearfendertpage 2-16! , Muffler/exhaust pipe (page Z-ZOD \, 2P1GREEN} CONNECTOR 7-13 ° 8. CYLINDER HEAD/VALVES SERVICE INFORMATION 8-1 VALVE GUIDE REPLACEMENT 8-17 I . TROUBLESHOOTING 8-3 VALVE SEAT INSPECTION/REFACING 8-18 CYLINDER COMPRESSION TEST 8-4 CYLINDER HEAD ASSEMBLY 8-20 CYLINDER HEAD COVER REMOVAL 8»5 CYLINDER HEAD INSTALLATION 8-22 . CYLINDER HEAD COVER CAMSHAFT INSTALLATION 8-24 DISASSEMBLY 8-6 CYLINDER HEAD COVER ASSEMBLY 8-29 CAMSHAFT REMOVAL 8-7 CYLINDER HEAD COVER CYLINDER HEAD REMOVAL 8-12 INSTALLATION 8-30 . CYLINDER HEAD DISASSEMBLY 3-13 CAM CHAIN TENSIONER LIFTER 3-32 } CYLINDER HEAD INSPECTION 8-14 m E . SERVICE INFORMATION GENERAL ' This section covers Service of the cylinder head, valves and camshaft - The camshaft sen/ices can be done With the engine installed in the frame. The cylinder head serVice required engine removal . I When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations, 'Clean all disassembled parts Witli cleaning solvent and dry them by blowmg them off with compressed air before inspection - Camshaft lubricating Oil is led through oil passages in the cvlinder head. Clean the oil passages belore assembling cylinder head - Be careful not to damage the mating suifaces when removing the cylinder head cover and cylinder lieadt O I I I I CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm Iinl ITEM STANDARD SERVICE LIMIT Cylinder compression 1,226 We 112.5 kgf/cmz, 178 psil if at 350 rpm I iCylinder head w 7* l Valve, clearance I [N W (1.16 : 0.0310006 f: 0.001) valve guide if 7, l EX 0.27 : 0.0310011 : 0.0011 l I Valve stem on. 41177777455 74.49010.l7§27011_7§87)vw ‘ 7 7 V l .. Ex 44657448010175 0.1754) . 55 (017541 I Valve guide LD. IN 4500*4512 10.1772 *0.17751 I 4.540 (0.17871 I ... 77 .,. ... EX 4.5004.5121947717017751 l 4540401787) I Stemrto-guide clearance IN 0010 4.037100004700015) 7‘ 7: IN ,7 777 EX 0.020‘D.D471000087000191 l i. 7. I Valve gulde projection IN 443* L416 10,515‘0571 ,, 7” I A above cylinder head EX 12.4*12.710,49 '0501 7 ”7 .. . Valvewseiatiwjdtiji lN/EX 0.907110 10.035~0.o43L 1.5 (0.061 _. Valve sprlng ilrnrrlgrrii "mm, IN/EX 348011.370) 34.1 11.34) .. free length Outer lN/EX 373711.495) 7 37211.45) _ Valve lifter . 13359 lifter Q9. W .., IN/EX 25.978-~25.993 (Lg 1.9233) 25.97 (1.0221, _ Valve liller bore ID. IN/EX 26.010“‘26.02611.0240*‘l.0246) 26.04 (1.0251 Camshaft Cam lobe height IN 35_ 48:36.72 11.436*1.4461 36451111351 .7. _ EX 35.08i36.3211_.420 1.43m 3650114371 Runolll g, _ , 005100021 Oil Clearance 0.020 4.1052 ID.0008*0.0024I 0.10100041 TORQUE VALUES Cylinder head cover blot PAIR reed valve Cover flange bolt Breather plate flange bolt Camshaft holder flange bolt Cylinder head sealing bolt Cylinder head mounting socket boll/washer Cyllnder head mounting bolt, 8 mm Cam sprocket bolt Cam pulse generator rotor dowel bolt Cam chaln tensloner plvot socket bolt Cam chain guide mounting socket bolt Cylinder head stud bolt lexhaust pipe stud boltl Vacuum joint plug for synchronization 10 Nm (1.0 kgf~m , 7 |bf~fll 12 N~m 11.2 kgi‘m , 9 lbf~ftl 12 N~m 11,2 kgf‘m , 9 lbi~ftl 12 N~m 11.2 kngm , 9 lbfh) 27 Mm 128 kgf‘m , 20 lbf-fti 51 N-m 15,2 kgi-m , 38 lbf-ftl 24 Mm 124 kgf-m,17lbf-ftl 20 NAm12,0 kgi-m,14lbf-ftl 12 N-m 11,2 kgtm , 9 lbtm 10 Nm 11,0 kgtm , 7 Ith) 12 N-m 11,2 kgtm , 9 lbf-ft) See page 1.14 3 N-m (0.3 kgf-m , 2.2 lbf-l‘t) Apply a locking agent to the threads Apply oil to the threads Apply a locking agent to the threads Apply molybdenum disulfide oil to the threads and seating surface (after removing anti-rust oil additiVEI Apply oil to the threads Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads CYLINDER HEAD/VALVES TOOLS Compression gauge attachment Valve spring Compressor Valve spring compressor attachment Tappet hole protector Valve guide driver Valve guide reamer, 4,508 mm Valve seat cutters Seat cutter, 24.5 mm (45" INl Seat cutter, 29 mm (45" EX) Flatcutter, 25 mm (32° IN) Flat cutter, 33 mm (32° EXi Interior cutter, 26 mm 150” W) Interior cutter, 30 mm 160” EX) Cutter holder, 45 mm 07757-0010000 07959-KM30101 0778070010100 0778070010300 0778070012000 07780-0012900 07780-0014500 07780-0014000 07781-0010600 TROUBLESHOOTING 07RMJ-MY50100 07HMG-MR70002 07HMD-MLDO‘01 07HMH7ML00101 Equivalent commercially available in U.S.A. Not available in USA 07HMH-ML0010A1U.S.A. onlyl *these are commercially available in USA - Engine toprend problems usually affect engine performance, These problem can be diagnosed by a compression test or by tracing engine noises to the topvend with a sounding rod stethoscope. 0 If the performance is poor at low speeds, check for white smoke in the crankcase breathertube. If the tube is smoky, check for a seized piston ring (Section 11). Compression too low, hard starting or poor performance at low speed 0 Valves: , incorrect valve adjustment ~ Burned or bent valve Incorrect valve timing , Broken valve spring 7 Uneven valve seating . Cylinder head: , Leaking or damaged head gasket *Warped or cracked cylinder head I Worn cylinder, piston or piston rings lsection ill Compression too high, overheating or knocking OExcessive carbon buildrup on piston crown or on combustion chamber Excessive smoke 0 Cylinder head: "Worn valve stem or valve guide * Damaged stem seal - Worn cylinder, piston or piston rings (section lll Excessive noise - Cylinder head: * Incorrect valve adjustment ' Sticking valve or broken valve spring mDamaged or worn camshaft 7 Loose or worn carn chain *Worn or damaged cam chain ~Worn or damaged cam chain tensioner *Worn cam sprocket teeth 0 Worn cylinder, piston or piston rings lsection 11l Rough idle 0 Low cylinder compression CYLINDER HEAD/VALVES CYLINDER COMPRESSiON TEST Warm up the engine to normal operating tempera— zurev Stop the engine and remove the all direct ignition coil/spark plug caps and spark plugs lpage 3-6). Open and support the front end offuel tank (page 3-4lv Disconnect the fuel pump/reserve sensor 3P (Blackl connectors Install a compression gauge ll’llO the spark plug hole‘ TOOL: Compression gauge attachment 07RMJ7MY501DO lEquivalent commercially avallable In USA.) Open the throttle all the way ancl crank the engine with the starter motor untll the gauge reading stops rising, Toavoid The maxlmum reading is usually reached within dlschargmg me 4 777 seconds, ballery, do nol Operate "‘9 Slalfer Compression pressure: molar for more 1,225 kPa (125 lm11.2 kgl-m , 9 lbl-ftl Install me ignllion pulse generator rotor and right . crankcase cover lpage 17-Sl. . Install the dowel pins and a new cylinder head DOWEL PINS gasket as shown. D ' #03 GAS? 8-23 CYLINDER HEAD/VALVES Install the cylinder head. 9 mm BOLTS If using the new bolt, remove anti-rust additive from the bolt. . Apply molybdenum dlsulfide oil to the threads and seatlng surface of the 9 mm bolts/washers and my stall them. Apply oil to the 8 mm llange bolt threads and seating surface, Install the two 8 mm flange bolts. . Tlghlen the 9 mm bolts tn 2: cnsscross pattern in 2 3 steps to the speclfied torque. TORQUE: 51 N-m (5.2 kgt‘m , 38 lbf‘ft) Tighten the 8 mm flange bolts to the specified 0 torque. TORQUE: 24 Nm (2.4 kgf-m , l7 lbf‘ftl C C Install the Cam Chain tensioner lifter onto the cylin- der head wlth new gasket, Install and tighten the mounting bolts. Install the engine intothe frame (page 7-6l. . O C S STALLATION . Apply mDIVbdenum disulfide oil to the outer sur- face of the each valve lifter. Install the shims and valve lifters into the valve lifter bores. I C 8-24 CYLINDER HEAD/VALVES If the cam sprockets are removed, install the cam NO 1 CYLINDER CAM LOBES sprockets onto the camshahs. ‘ 'Inslall the intake cam sprocket with the timing mark (IN) facing outward and the No.1 cam lobes facing up and out as shown. - Install the exhaust cam Sprocket with the timing mark lEXl facing outward and the Noll cam lobes facing up and out as shown. EXHAUST CAM SPROCKET INTAKE CAM SPHOCKET Clean and apply a locking agent to the cam sprook» et bolt threads. install the cam sprocket bolts. Clean and apply a locking agent to the cam pulse generator rotor threadsr lnsrall lhe cam Install the cam pulse generator rotor and mounting pulse generalar bolts. rolor Will: the Na 1 camshaft/01725 Iacmg up and mlor ‘ 0UT"mark facing down as shown ’ OI ’ \ ”our” MARK Turn the crankshaft clockwise and align the "T” INDEX MARE mark on the ignition pulse generator rotor with the index mark on the rightcrankcase cover. CYLINDER HEAD/VALVES Install the sealing washers onto Ihe Cams/Ian holder B and Cs center row bolls as shown Apply molybdenum disulfide oil to the camshaft journals of the cylinclerhead and camshaftholder, Install the cam chain over the cam sprockets and then install the intake and exhaust camshalts. 0 Install the each camshaft to the correct locations With the identification marks. ”lN”: Intake camshaft "EX”: Exhaust camshaft oMake sure that the timing marks on the cam sprockets are facing outward and flush with the cylinder head upper surface as shown. Install the each camshaft holder onto the Camshafts. lnstall the each camshaft holder to the correct loca- tions with the identification marks. “A”: Right camshaft holder ”E": Center camshaft holder “C": Left Camshaft holder Temporarily install the twelve holder bolts and seal- ing washers. "i t USiTfiEAMSHAFT 3,» CAMSHAFT HOLDER B CAMSHAFT HOLDER C 8-26 CYLlNDER HEAD/VALVES First, gradually tighten the four bolts (No.57N0J‘5 BOLTS N07, No.8) in the numerical order casted on the / camshaft holders. Gradually tlghten the other camshaft holder bolts untll the Camshaft holders lightly Contact the cylinder head surface. Tightening the camshaft holder bolts on only one- side might cause a camshaft holder to break. Tlghten all camshaft holder bolts in the numerical order casted on the Camshaft holderst TORQUE: 12 NW (1.2 kgf-m , 9 letl lnstall the cam chatn guide B, and tighten the bolts. ln case the cam sprockets were removed, tighten the cam sprocket bolts to the specified torque, TORQUE: 20 Nm (2.0 kgl‘rn , 14 Ibf-ftl Turn the crankshaft clockwise one full turn l360°l and tighten the other cam sprocket bolts. In case the cam pulse generator rotor bolts were removed, apply locking agent to the rotor bolt threads. Install and tighten the rotor bolts to the specified torque. TORQUE: 12 N-m 11.2 kgf-rn , 9 lbf~ftl CYLINDER HEAD/VALVES Remove the stopper tool from the cam chain ten- STOPPKR TOOL sioner hfter, L I I Install a new seaimg washer and tighten the sealing CAM CHAIN TENSIONER LIFTER BOLT I boll. \\" \ Recheck the Valve timing. I - e 2% i ‘ SEALING WASHER I Apply on to the new 0 ring, and instail it omo the 9 ,\ “ ‘mING cam pulse generator has. 1 Instail the cam pulse generator into the cylinder head. ' I instaii and iighlen the mounting bolt securely, . I I 8-28 CYLINDER HEAD/VALVES CYLINDER HEAD COVER ASSEMBLY BREATHER SEPARATOR Install the new gasket and crankcase breather separ ratortothe cylinder head cover. 1‘1 ‘ w ls-v—lf‘a .' é ”*Ef'fi‘ifilé’ea Apply a locking agent to the crankcase breather L separator mounting bolt threads am BO TS BREATHER SEPARATOR Install and tlghten the bolts to the specllied torque. TORQUE: 12 N-m (1,2 kghn , 9 IbfvftI Install the PAIR check valve port plates Into the cylinder head cover. Install the PAIR check valves into the cylinder head PAIR CHECK VALVES cover‘ ,- we, 8-29 CYLINDER HEAD/VALVES CYLINDER HEAD COVER JNSTALLATION Install the cy‘inder head packing Into the groove of the cylmder head cover. Apply sealant to (he Cander head semi-circular cutouxs as shown‘ lnstal! the cylinder head cover omo the cylinder head. InstaH the washers with their "UP" mark facing up. PACKING “UP” MARK 8-30 CYLINDER HEAD/VALVES lnstall and tighten the Cyllnder head Cover special bolts to the SDeleiEd torque, TORQUE: l0 ern (l.0 kgtAm , 7 lbf-ttl install the PAIR reed valve covers and tighten the SH bolts to the specified torque. TORQUE: 12 an’l 11.2 kgf~rn , 9 lbfvftl Connect the throttle cables from the throttle drum. Install and tighten the throttle cable guide bracket mounting bolts to the specified torque, TORQUE: 3 N-m l0.35 kgfm , 2.5 lbf-fll Install the direct ignltlon coils and spark plug sub- harness. Connect the cam pulse generator 2P lNaturall con- nectar. lnstall the PAIR solenoid valve assembly and can heat the air suctlon hoses to the PAIR reed valve cover. Install and tighten the FAIR solenoid valve mounting bolt. Connect the PAIR Solenoid valve 2P (Naturall con- nector. ,rA x ’4" Connect the crankcase breather tube. CRANKCASE BREATHER TUBE 8-31 C‘IUNDER HEAD/VALVES Connect the radlator sub-harness 2P (Blackl connec- (Or. install the heat guard rubber onto the cylinder head covert Install the air cleaner housing (page S-SSL CAM CHAIN TENSIONER LIFTER REMOVAL Open and support the front end 0! fuel tank lpage 374). Remove the cam chain tensioner sealing bolt and sealing washer. Turn the tensloner shaft fully ln lclockwlsel and 597 cure It using the stopper tool to prevent damaging the cam chain‘ See page 878 for detail of the tool. ZPlBLACKl CONNECTOR CAM CHAIN TEN S‘ONER LlFTER BOLT \ STOPPER TOOL 8-32 CYLlNDER HEAD/VALVES Remove the bolts and cam cham tensioner llfter. Remove the gasket, INSTALLATION Install the new gasket onto the cam chain tensioner lifter. Install the cam chain lensloner lifter into the cylin~ der head, Install and tighten the mountlng bolts. Remove the stopper tool, GASKET / TENSIONER LIFTER BOLTS 0 \ 2’? GASKET TENSIONER LIFTER STOPPER TOOL l 8-33 CYLINDER HEAD/VALVES InstaH a new sealing washer and tighten the sealmg CAM CHAINTENS‘ONER LIFTER BOLT bolt securety, \ \ 8-34 9. CLU’TCH/GEARSHIFT LINKAGE SERVICE INFORMATION 9-1 CLUTCH 9-4 I TROUBLESHOOTING 9-2 GEARSHIFT LINKAGE 9-12 RIGHT CRANKCASE COVER REMOVAL 9-3 RIGHT CRANKCASE COVER INSTALLATION 9-17 SERVICE INFORMATION GENERAL 0 This section covers service Of the clutch, gearshift linkage, shift drum and shift forksv AII service can be done with the engine InstaIled in the Iranie. 0 Transmission OII Viscosity and level have an effect on Clutch disengagement, When the cIutCh does not disengage or the motorcycle creeps With clutch disengaged, Inspect the transmission oil level before servicing the clutch system. SPECIFICATIONS Unit: mm Iinl I ITEM t STANDARD ‘ SERVICE LIMIT H "ER 77* ,Qflefi'flh 7 7 7 777 c thickness LGLeerchiior 77 7 77’ 7, 77 777‘? 7 Purple color ,VPIUEheLaJe gag: 7 7, 7 7,7 Clutch outer guide 170. goon 725.021 1098437 0.9875: i 7 7 "7 AI '34. V if 7Ma7iu5hj 0 7 Efimfiriuide 777 7 7 , smrt fork, fork Fork Up ,7 r 12.03 (uni 7 shaft I, 77* LrClawthickness I 33 40017054737137.2739 77 imam 7 Fork shaft 0 Dr 41 11'957'*11.95810,4707* 0‘4712) 11.95 (0.470) TORQUE VALUES Clutch centet lock nut 127 N~m (110 kgfvm , 94 lbf~ttI Apply OII to the threads Stake the nut Clutch Spring bolt/washer I2 N-m (1.2 kgfrm , 9 leU Shift drum center socket bolt 23 N~m (2.3 kgf‘m,17|bf‘ftl Apply a IOCkInQ agent to the threads Shift drum stopper arm pivot bolt 12 N~m I1.2 kgf‘m , 9 Ibf‘ftl Gearshift return spring pin 23 Mm 123 kgtm,17lbf~f1l Gearshift drum bearing/shift fork retaining bolt/Washer 12 N-m Il.2 kgfrm , 9 IbfrftI Apply a locking agent to the threads Gearshilt pedal link pinch bolt 10 Nm I1.0 kgf~m , 7 Ith) OII pump driven sprocket bolt 15 N~m (1.5 kgllm , 11 Ibf-ft) Apply a locking agent to the threads 9-1 CLUTCH/GEARSHIFT LINKAGE TOOLS Clutch center holder 07724-0050002 Driver 07749-0010000 Attachment, 42 ' 47 mm 077450010300 Pilot, 35 mm 0774570040800 TROUBLESHOOTlNG Clutch lever too hard to pull in O Damaged clutch lifter mechanism ' Faulty clutch lifter bearing O Clutch lifter piece installed improperly Clutch slips when accelerating O Worn clutch disc O Weak clutch springs ' Transmissuon oul mixed wuth molybdenum or graphite ad- ditive Clutch will not disengage or motorcycle creeps with clutch disengaged 0 Clutch plate wa rped O Loose clutch lock nut O Oli level too high O Improper oil vtscosxty O Damaged clutch litter mechanism O Clutch lifter piece installed improperlv Hard to shift ‘ Improperclutch operation O lmproperoil vtscosvty O Eentshlft fork 0 Bentshift fork shaft ' Bent tork claw O Damaged shlft drum cam groove O Loose stopper plate bolt O Damaged stopper plate and pin O Damaged gearshift spindle Equivalent commercially available In USA. Transmission jumps out of gear ‘ Worn shift drum Stopper arm ‘ Weak or broken shift arm return spring ‘ Loose stopper plate bolt ' Bent shift fork shaft O Damaged shift drum cam groove O Damaged Or bent shift forks O Worn gear engagement dogs or slots Gearshift pedal will not return 0 Weak or broken gearshift spindle return spring ’ Bent gearshift spindle 9-2 CLUTCH/GEARSHlFT LlNKAGE RlGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-16), Remove the middle/lower c0w( (page 2-5). Open and support the front end of fuel tank (page 3V4)‘ Disconnect the ignition pulse generator 2P (Red) connector. Remove the bolts and clutch Cable gulde, then d'lSr connect the clutch cable end from the clutch lifter [even The liner arm Remove the right crankcase cover SH bolts. spindle lS engaged Remove the right crankcase cover while turning the WI! Ihe clutch clutch lifter arm counterclockwise to disengage the li/Ierpiece inside litter arm spindle from the lifter piece. (he righl crankcase cover Remove the two dowel pins. Clean any sealant off From the right crankcase cover mating surfaces CLUTCH/GEARSHlFT LINKAGE CLUTCH LIFTER LEVER Remove the clutch lifter lever, return spring and . washer from the right crankcase cover, Check the lifter lever spindle for wear or damage. Check the return sprlng for fangue or damage. 0 Check the lifter lever oil seal and needle bearings . for wear or damage Install the clutch lifter lever with the Washer and spring ln the reverse order of removal. C C REMOVAL , C Remove the right crankcase cover (page 973l. Remove the clutch spring bolts, springs and pres- sure plate. Remove the clutch lifter piece from the lifter hear? ing. . Remove the following: . 7 Nine clutch discs *Eight clutch plates — Judder spring — Judder spring seat I CLUTCH/GEARSHlFT LJT‘JKA GE Unstake the clmch center lock nutv Hold the Clutch center With the clulch center holder, then remove the lock nut. TOOL: Clutch center holder 0772470050002 lEquivalent commerr cially available in USA) Dlscard the lock nut. Remove the lock washer, thrust washer and clutch center, Remove the washer, CLUTCH/GEARSHIFT LINKAGE Align the primary drive gear and sub-gear teeth CLUTV’ClZlOv ‘ UTE. with a screwdriver as shown. "V‘ Pull out the clutch outer, Remove the oil pump driven sprocket boluwasher. Remove the oil pump drive/driven sprocket and drive chain as an assembly. Remove the Clutch outer guide, INSPECTION Clutch lifter bearing Turn the inner race of the lifter bearing with your finger. The bearing should turn smoothly and freely with out excessive play, If necessary replace the bearing. Clutch spring Measure the clutch spring free length SERVlCE LIMIT: 47.4 mm [1.87 in) CLUTCH/GEARSHlFT LINKAGE Clutch center Check me grooves of the clutch Center for damage or wear caused by the clutch plates. Replace if necessary. C|utch lifter piece Check the clutch lifter piece for damage or abnors mal wear, Clutch disc Replace lhe clutch discs If they show signs of scoring or discoloratlonr Measure the dlsc lhickness of each dlsc. SERVICE LIMIT: 2,5 mm 10.10 inl Clutch plate Check each disc plale for warpage on a surface plate using a feeler gauge. SERVICE LIMIT: 030 mm 10.012 inl CLUTCH/SEARS HWFTLI‘ ”(AGE Cimch :ymar/Slutch cmer guide Check the slots of We dutch outer for damage 0" wear caused by [he dutch cixscs. Repiace if necessaly. O 0 Measure the 0.0. and LD. of Ihe Clutch outer guide. 0 szevacs ust: 0.0.; 34.97 mm H 377 m) 1.0.: 25.03mmwssam7 I O Mainshafi Measure the mainshaft OD. at dutch outer guide snding surface. SERVICE LIMIT: 24.95 mm (0.983 m ‘ I CLUTCH OUTER NEEDLE BEARWG DRIVER REPLACEMENT 0 Press Ihe needle bearmg out of the clutch outer using the specm tools. TOOLS: Driver 0774970010000 . Attachment, 42 >< 47 mm 0774670010300 Pilot, 35 mm 0774670040800 0 9—8 CLUTCH/GEARSHFT LINKAGE Press Ihe needle Press a new needle beanng into the clutch outer so bearmgmrome (hat the casmg of the needle bearing IS flush with clumh ouIeI WWI me dutch outer surIace as shown‘ Ihe marked srde facmg up. TOOLS: Driver 077 4970010000 Anachmem, 42 X 47 mm 0771670010300 Pilot, 35 mm 0774570040300 INSTALLATION JUDDER SPRING 15N-m115kgl-m11lbfm CLUTCH OUTER WASHER CLUTCH CENTER DRIVEN SPROCKET CLUTCH DISCS (PURPLEI THRUST WASHER CLUTCH DISC (GREENI‘ \ LOCK NUT J/7 127 N~m (13.0 kgf»m, 94 [NM LIFTER BEARING 12 N47! (12 kgf-m , 9 INT” SPRING LIFTER PLATE Install me or/pump Install the clutch outer guide, oil pump drive/driven drrven sprocket sprocket and drive chain as an assembly. wrm Ils "OUT” mark Iacmg out. O CLUTCH/GEARSHlFT LINKAGE Apply a locking agent to the threads of the Oll pump driven sprocket bolt, Tlghlen the driven sprocket bolt to the speclfied torque, O TORQUE: 15 N-m (1.5 kgf-m,11lbf.ftl 0 Be surelhe clutch Allgn the prlmary drive gear and subrgear teeth . outer W5 seems/y with a screwclnver as shown onto me posmon- mg labs o/ Ihe all Install the clutch outer, pump drive spmr cekl Halale me or! pump awe cham . whlle msIa/lmg {he clulch ouler to properly seat I! I Install the washer onto the clutch outer, C I lnslalllhe clutch center. . Install the thrust washer. Install the lock washer with Its "OUTSIDE" mark facing out. I I 9-10 CLUTCH/GEARSHIFT LSNKAGE lnstall the new lock nut. Z" "- W’Efim Hold the clutch center Wlth the Clutch center holder, 3’ . then ttghten the lock nutto the spectfied torque. TOOL: Clutch center holder 07724-0050002 tEqulvalent commerr cially avallable in USA) O TORQUE: 127 Nm tl3.0 kgflm , 94 lbf-fl) O Stake lock nut into the mamshaft groove with a punch. lnstall the Judder sprung seat and judder spring Coat the large lD clutch dISC wlth clean engine OII and Install lt, C 0 Coal the clutch discs and plates with clean engine oil. . lngtall the 51199” cu/ured Stack the clutch discs and plates alternately. dlSC an me Oulslde 0/ the Clutch assembly 0 Install the green colored outer clutch disc in the u u . shallow slot on the clutch outerv GREEN COLORED DlSC CLUTCH/GEARSHll-‘l' LINKAGE Install the llfter bearing mm the pressure plate. Install the clutch lifter piece into the lifter bearing lnstall the pressure plate. lnstall the Clutch springs and spring boltsr Tighten the bolts in a crisscross pattern in 2,3 steps then tighten them to the speclfled torque. TORQUE: 12 Nvm 11 2 kgf‘m , 9 letl Install the rightcrankcase cover (page 9717). GEARSHlFT LINKAGE GEARSHlFT LINKAGE REMOVAL Remove the lollowmg: ~ Flight crankcase cover lpage 9-3l rClutch assembly (page 9-4l Remove the bolt and gearshift pedal link. Pull the gearshift spindle assembly and thrust wash- er out ofthe crankcase. CLUTCH/GEARSHIFT UNKAGE Remove mefo‘lowmg, *m cper arm soc *Stopaer arm Return spnrg WWasher *DDWeI pins - Socket bolt ' Gearshift cam GEARSHEFT UNKAGE lNSPECTlDN Check the gearshift spindle for wear, damage or bending. Check the return spring for fatigue or damage. RETURN SPRING GEARSHIFT SPINDLE SHIFT DRUM/SHiFT FORK REMOVAL Remove the foHowing: . #Gearshm linkage through socke: bolt/gearshift cam remova‘ {page 9712) —Oil pan (page 4-3b Remove the bo‘ts and shift drum bearing set p‘ales. Remove (he shtft fork shaft and shift forks‘ CLUTCH/GEARSHIFT LINKAGE _ w . “kw—r. "W“ SHIFT DRUM Remove me Shlft drum bearing and shifl drum. SHIFT DRUM/SHIFT FORK INSPECTION Check Ihe shift fork and fork shaft for wear or damage Measure the LO oIthe shift fork. SERVICE LIMIT: 12.03 mm (0.474 inI Measure the shxft fork clawlhickness. SERVICE LIMIT: 5.9 mm (0.23 in) Measure the OD, oflhe shift fork shall, SERVICE LIMIT: 11.95 mm (0.470 inI Inspect the shwfl drum grooves for wear or damage‘ 9-14 CLUTCH/GEARSHIFT LINKAGE Turn the outer race of the shift drum bearing wnh yourfingerv The bearing should turn smoothly and freely without excessive play If necessary replace the bearing. The shiftvforks have location marks. IDENTIFICATION MARKS "Fl" for right " ’forcenter l’L" for left Apply molybdenum disulfide oil to shifter fork groove ofthe shift gears. Install the shift forks on the transmission. Install the shift fork shafts with their Identification mark facing to right. 1RIGHT SHIFT FORK / g5 A; SHIFT DRUM/SHIFT FORK INSTALLATION Install the shift drum and shift drum bearihg‘ W - ”SHIFT DRUM \ CLUTCH/GEARSHIFT LINKAGE Install the shll‘t fork shaft. O I Apply a locking agent to the threads of the set plate I bolts. lnstall and set plates and bolts, tighten the bolts to the specified torquev TORQUE: 12 N4“ (12 kgf-m , 9 lbt-ftl Install the gearshift linkage 1592 following stepsl, . I GEARSHIFT LINKAGE INSTALLATION install the lollowing: *Washer *Return spring ' , Stopper arm 7 Socket bolt Tighten the stopper arm socket bolt to the specified tarque, I TORQUE: 12 N‘m (1.2 kgf‘m , 9 [him Install the dowel pin Onto the shift drum. Allgnlhedowe/ Install the gearshift Cam while holding the stopper I pm on the shift arm using a screwdriver as shown. drum Center With the Wide groove On Me gearshm cam I I 9-15 CLUTCH/GEARSHIFT LINKAGE Apply a locking agent to the gearshllt cam socket bolt tlll‘eadsi Install and tighten the socket bolt to the specified torque TORQUE: 23 NA!" (2.3 kgf-m, l7 lbf-fll install the thrust washer and gearshift spindle assembly into the crankcase while aligning the spring ends Wlth the crankcase stepper pin, Install the gearshill pedal llnk by aligning IlS Slll Wlth the punch mark on the gearshift spindle. Install and tlghten the pinch bolt to the specified torque TORQUE: 10 N~m (LO kglm , 7 lbfift) Install the clutch assembly lpage 9-8)V RIGHT CRANKCASE COVER INSTALLATION Apply a sealant to the mating surfaces of the crank- case as shown. 10415 mm 10 4 ‘0 5 in) 10415 mm l0 4 D 5lnl 9-17 CLUTCH/GEARSHIFT LlNKAGE Apply sealant [O the mating surface of the nghl crankcase coverl 0 0 Install the [W0 dowel pins. 0 C 0 Install the right crankcase cover whlle mrning the lifter arm clockwise to engage the lifter arm groove wxlh the lifter piece flange, 0 0 Install and lemporarily tlghlen the right crankcase RIGHT CRANKGASE @QVER . cover SH bolls. A" ' l C O CLUTCH/GEARSHIFT UNKAGE Connect the clutch cable and to the clutch \ifter lever, then Install the ciutch cabte bracket with the two botts. C O . Tighten the right crankcase cover crisscross pattern in 2 , 3 steps. 0 0 Connect the tgmtion pulse generator 2P (Red) cow nector‘ . Pour the recommended engine oil (page 345p. . 2P (RED) CONNECTOR I D I 9-19 TXEATDRISTJQRTER QLUTCH SERVTCE l?~lFORl‘/lATlON 10-1 FLYWHEEL REMOVAL 10-3 TROUBLESHOOTING ‘10»1 STARTER CLUTCH 10-5 ALTERNATOR COVER REMOVAL 10-2 FLYWHEEL INSTALLATION 10-7 STATOR 10-2 ALTERNATOR COVER INSTALLATTON 10:8 SERVICE INFORMATTON GENERAL ' Tnls Sectlsn :DVeIs service of the allernatol, flywheel and starter clutch. All servlce can be done wllh the engme installed In the frame. - Refer to Secllon 16 for alasmalor Stator Inspection SPEClFlCATlONS Unit: mm lln) ITEM l STANDARD 1 SERVICE LIMIT s'I’aYier driven geal boss of? l 510699i511718120354 - 2035“ l 51684120310? TORQUE VALUES Allematorwlre clamp bolt 12 N-m (1,2 kgf»m,9 Ibf-fl) CT boll Flywheel flange bolt 103 N-m (10.5 kglm , 7e lbml Apply Oll Io the threads Stalor mounting Socket bolt 12 Mm 112 kgf-m , 9 Ibf‘m Starter oneway Clutch socket bolt 16 N~m1116 kgf-m,12lbl»ft) Apply a lockan agenno the Ihreacls TOOLS Flywheel holder 077250040000 Equivalent commercially ayallablein U.S.AI Rotor puller 07733-0020001 or 079333950000 Engine does not turn . Faulty starter Clutch ' Damaged idle gear/shaft 10-1 ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL The a/Iemalor COL/8f (51310015 magnenea/Iy ale lac/75d m the Hywneel. be care/L11 durmg removal STATOR Remove the fuel tank rear bracket and ECM cover (page 5789) Remove lhe middle/lower cowl (page 25). DISCOnHeCt the alternator 3P (Whltel connectorv Remove the allemalor cover SH bolts and alterna- tor cover. The englne Oll wlll run out when the alternator cover is removed. Sex 3 clean oil pan under the engine and add [he recommended 0I| to [he speclr fled level after lnslallationv Remove the gasket and dowel pin. REMOVAL Remove the allernalor wxre grommet from the alter nator cover. Remove lhe socket bolt and stator ere clamp. Remove the socket bolts and stator, 3? WHITE) CONNECTOR 10-2 ALTERNATOR/STARTER CLUTCH INSTALLATION WIRE CLAMP 12 N‘m (1.2 kgf-m , 9 inl) ml “:2 12 N-m (1.2 kgf-m,9 ibt‘ttl ALTERNATOR COVER STATOR Install the stator into the alternator coverv Apply sealant to the wire grommet, then Install the wire grommet into the alternator groove securelyr Install and tighten the stator mounting socket bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 lbf-fli Install the wire clamp and tighten the bolt to the specified torque. TORQUE: 12 N~m (1.2 kgf‘m , 9 lbf-ft) FLYWHEEL REMOVAL Remove the alternator cover (page 1072). Remove the starter idle gear shaft and idle gear. C ALTERNATOR/STARTER CLUTCH Hold the flywheel using the flywheel holder, then remove the llvwheel boll, TOOL: O Flywheel holder 0772570040000 lEquivalem commerr clally available in U.S.A'l Remove Ihe Washer, C Remove the flywheel using the special tool. “We 0 TOOL: Rotor puller 0773370020001 or 0793373950000 0 0 Remove the woodruff key. 0 0 Check the starter Idle gear and shaft for wear or lDLE GEAR IDLE GEAR SHAFT damage. _ . O O 10-4 ALTERNATOR/STARTER CLUTCH STARTER CLUTCH INSPECTION Check the operatlon of the onerway clutch by turn- ing the driven gear. You should be able to turn the driven gear counten clockwise smaothly, but the gear should not turn cloclese DISASSEMBLY Remove \he starter driven gear by turning it counr lerClOCkWiSe. Hold the flywheel with a flywheel holder, and re- move the starter clutch mounting torx bolts. TOOL: Flywheel halder 0772570040000 Remove the starter onerway clutch assembly. Check the starter dnven gear for abnormal wear or damage Measure the starter driven gear boss OD. SERVlCE LIMIT: 51.684 mm 12.0348 inl Check the one-way clutch for wear or damage and ONEVWAY CLUTCH replace li necessary. 10-5 ALTERNATOR/STARTER CLUTCH ASSEMBLY CLUTCH OUTER FLYWHEEL DRIVEN GEAR 16 Nvm (1.6 kgfmn ,12lbf‘m App‘v Oll to me staner onerway clmch. ONE-WAV CLUTCH Install the onerway Clulch into the clutch outer With :E the flange side facing out. CLUTCH OUTER Mstall the starter one-way clutch assembly onto (he ONE-WAY CLUTCH ASSEMBLY flywheel. :1 FLYWHEEL 10—6 ALTERNATOR/STARTER CLUTCH Apply a locking agent to the starter clutch outer n mounting bolt threads. J—lm TORX BOLTS Hold the flywheel with a flywheel holder, and tlgl’llel’l the starter clutch mounting torx bolts, TOOL: Flywheel holder 0772570040000 lEquivalent commer- cially available in USA.) TORQUE: 16 Nm (1.5 kgfrm ,12lbf‘ftl FLYWHEEL HOLDER 5 lnstall the starter drlven gear into the onerway clutch. Recheck the one-way clutch operation. You should be able to turn the driven gear counter- clockwrse smoothly, but the gear should not turn clockwise. FLYWHEEL INSTALLATION Clean any oll from the crankshaft taper. Install the wootlruff key on the crankshaft. Install the flywheel aligning the key way in the FLYWHEEL flywheel with the woodruff key on the crankshaft. Apply Ull to the flywheel bolt threads and seatlng surface. Install the Washer and flywheel bolt. WASHER BOLT 10-7 ALTERNATOR/STARTER CLUTCH Hold the flywheel uslng the flywheel holder, then ‘FLVWHEEL HOLDER tighten the bolt to the speclfied torque. TOOL: Flywheel holder 0772570040000 (Equivalent Commerr clallv available in U.S.A.l TORQUE: 103 NJ?! (10.5 kgl-m , 76 lbf~ftl Applv molybdenum dlsulfide oil to the starter Idle gearshaft. Applv oiltothe staneridle gear, Inslall the starter idle gear and shaft onto the crankcase. ALTERNATOR COVER INSTALLATION Apply sealant to the mating surface of the crank- case as shown. 10415mm 104 ‘061nl 104415 mm (0,440.6 In) install the dowel pin and new gasket. 10-8 ALTERNATOR/STARTER CLUTCH Thea/wrhamr msxaH thea‘ternatorcoven cover (stalarfls magnelrca/ly human and tighten the SH bolts to me specified allached I0 me torque. flywheel be care/u! dunng mr TORQUE: 12 N-m (1.2 kgf m , 91mm slal/aI/on ALTERNATOR COVER ' Ml Connecx (he auernator 3P (White) connecmr, InstaH the mxddle/‘ower cow! (page 277). msmll the ECM cover and fuel tank rear bracket [page 5-89}, 10-9 11. CRANKCASE/PISTON/CYLINDER i SERVICE INFORMATION 11-1 PISTON/CONNECTING ROD 11-4 . TROUBLESHOOTING 11-2 CRANKCASE COMBINATION 11-12 CRANKCASE SEPARATION 11-3 0 SERVICE INFORMATION GENERAL - This section covers crankcase separation for service of the crankshaft and piston. 0 The followmg parts must be removed before separating the crankcase. *Alternator/flywheel (section 10) . 'Clutch/gearshift linkage (Section 9i c3 GEAR 132w \ '- * ‘ 00%;? C4 GEAR (233T? C5 GEAR (27T) C1 GEAR 135“ 12-12 CRANKSHAFTITRANSNHSSION Assemble the transmission gear and shafts. Coat each gear wuth clean engine oil and check for smooth movement. Apply molybdenum disulfide oil to the shift lork grooves in the M3/4, C5 and C6 gear. INSTALLATION Install the dowel pins in the upper crankcase holes. Install the countershaft bearing set ring into the up per crankcase groove. Install the mainshaft and countershait by aligning MAINS‘A the countershaft bearing groove with the set ring on the crankcase, and aligning the bearing cap holes with the dowel pins. Also align the countershaft bearing stopper pin with the groove in the crankcase. Assemble the crankcase lpage 11712). STOPPER PIN 12-13 13. FRONT WHEEL/SUSPENSION/STEERING I SERVICE INFORMATION 13-1 FRONT WHEEL 13-9 TROUBLESHOOTING 13.2 FORK 13-15 I HANDLEBARS 13-3 STEERING STEM 13-25 SERVICE INFORMATION GENERAL 0 When servICIng the front wheel, fork or steering stern, support the motorcycle using a safety stand or hoist. 0 A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. o Ahel the front wheel Installation, check the brake operatlon by applying the brake lever. U Refer to section 15 for brake system information, U Use oniv tIres marked 'ITUBELESS’I and lubeiess valves on rim marked 'ITUBELESS TIRE APPLICABLE”. SPECIFICATIONS Unit: mm iinI ITEM ‘ STANDARD I SERVICE LIMIT TI/Iihimum tire tread depth II ' I 1.510 oEI’ Coidtire pressure Ir UptoSOkngOplbIloag TfififikPaQflkgflgm Bipflr , Axle runout Wheel rIm runotlt I 'FEIIE ' i Ax1_al 7., , Fork . Spring has length 230 5 (9.07) l Sgring dlrecllon With the tapered end Iacmg up ¥ Tube runout ¥ mmended fork‘ fluidw Pro Honda Suspension FIUId SS 8 _ Fluld level I 9013 BI II , * i Fluid capaclty I 488 + 2.5 cm 116.:5 0.08 US 02, ‘ _ ‘ ,ii,i, 172+009lmpoy7 I i Pre- load adjuster initial settIng .4 18 m [0 mi irom top 0! fork bolt , IV Tension aggster Initial setting I lturn from lull hard i Compressron adlusieriniliai setting I 1-1/2 turns from full hard Steering head bearing pre load I 10*15Nil.0*‘l.5 kng . 13-1 FRONT WHEEL/SUSPENSION/STEERING TORQUE VALUES Handlebar pinch bolt Handlebar Weight mounting screw Steerlng stern nut Top thread A Top thread B Fork top bridge pinch bolt Fork bottom bridge pinch bolt Front axle bolt Front axle holder pinch bolt From brake disc mounting bolt Fork bolt Fork socket bolt TOOLS Steering stem socket Ball race remover set *Driver attachment, A 7 Driver attachment, B *Drrver shaft assembly *Bearing remover, A , Bearing remover, B *Assembly base Steering stem driver Fork damper holder Oil seal driver Driver Attachment, 42 / 47 mm Pilot, 25 mm Bearing remover shaft Bearing remover head, 25 mm 25 N-m (2,7 kgl-rn , 20 lbf-ftl 10 N~m (1,0 kgf-m , 7 lbf-ft) ALOC bolt 103 N-ml10.5 kgf-m ,76 lbf-ftl See page 13-29 29 Nrrn (3.0 kgfm , 22 lbf-ltl i 22 N~rn12.2 kgf~m,16lbf-ftl 26 Nrm12.7 kgfrm , 20 lbf‘ftl 78 N~m18.0 kgfrm , 58 lbf-ftl 22 Nm IZ,Z kgl~m,16|bf-ftl 20 N»rn12,0 kgl»m,14|bf-ftl ALOC bolt 22 NH! 122 kgf-m,15|bf-ltl 3A N»rn (3,5 kgf-m , 25 Ibf-ftl Apply a locking agent to the threads 0791673710101 or 079163710100lU.S.A.0nlv) O79467KM90001 orD7VMF-MAT0100 079457KM90100 D7VMF~MAT0200 079467KM90200 D7VMF7K230200 07946-KM90300 O7VMF7MAT0300 07946-KM90401 07VMF~MAT0400 07946-KM90500 07947-KA50100 07946-KM90600 07965-MA50000 07945-ME90200 O7946-MBOOOOO O7YMB-MCF0101 07YMD-MCF0100 or 07KMD-KZ30100 with O7NMD-K230101 (except U.S.Atl 07NMD—KZ3010AIUrSrA.onlyl 0774970010000 07746-0010300 07746-0040500 07746-0050100 077460050800 TROUBLESHOOTING Hard steering Wheel turns hard 0 Faulty or damaged steering head bearings 0 Faulty wheel bearing - lnSuflelenl tire pressure 0 Bent front axle . Steering head bearing adjustment nut too tight . Brake drag Steers to one side or does not track straight 5th suspension ' Unevenly adjusted right and left fork legs ' Insufficient fluid in fork ' Bent fork ‘ Weak fork springs ' Bent axle “Wheel installed incorrectly . Faulty steering head bearings 0 Bent frame - Worn wheel bearing 0 Worn swingarm pivot components Front wheel wobbling 0 Bent rim O Worn front wheel bearings - Faulty me 0 Unbalanced tire and wheel ' Tire pressure too low Hard suspension 0 Incorrect fluid weight 0 Bent fork tubes ' Clogged fork fluid passage Front suspension noisy 0 Insufficient fluid in fork 0 Loose fork fasteners 13-2 — FRONT WHEEL/SUSPENSION/STEEBlNG HANDLEBARS _ 7 ' V ‘ GRIPEND REMOVAL ‘ ’ Remove the screw and the handlebar grip end. Dlsconnecl the from brake swrtcn eres connectors from the swilch, Remove the master cylinder holder bolts, holder and master cvllnder assembly, Remove the right handlebar switch/rhroule housing screws. WITCH HOUSING SCREWS Remove the right handlebar swnch housing and SWITCH HOUSING THROTTLE PIPE throttle pipe from the righlhandlebar. _, » 13-3 FRONT WHEEL/SUSPENSlON/STEERlNG DlSCOflneCl the throttle cable ends from the throttle plpe and remove the housing. CABLE ENDS “Mm THROTTLE PIPE Disconnect the clutch swnch ere connectors from LEVER BRACKET the swutch, Remove the clutch lever bracket holder bolts. holder and Clutch lever bracket assembly. BOLTS HOLDER Remeve the screws and left handlebar switch SWITCH HOUSING housmg. Remove the screw and handlebar grip end. Remove the handle grip from the handlebar. GRIP END GRIP 13-4 FRONT WHEEL/SUSPENSION/STEERING Loosen the top bridge pinch bolts and handlebar pinch bolt. Remove the steering stem nut and remove the top bridge, Remove the handlebars from the fork tubes. INSTALLATION lnstall the handlebar stopper ring onto the fork tube groove lnstall the handlebars onto the fork tube. Install the top bridge while aligning its grooves withthe handlebarstopperpm, Tighten the steering stem nul. TORQUE: 103 N~m (1&5 kgl‘m , 76 Ibl-ftl Tighten the top bridge pinch bolts to the specified torque. TORQUE: 22 N‘m l2.2 kgf-rn , 15 Ibfvft) Seat the handlebar pivot upper surface with the top bridge lower surface, then tlghten the handlebar pinch bolt to the specified torque TORQUE: Z6 N-m 12,7 kgf m , 20 lbf-ftl TOP BRlDGE TOP BRIDGE PlNCH BOLT TOP BRIDGE GROOVE HANDLEBAR STOPPE Fl PIN STEM NUT TOP BRIDGE PINCH BOLT HANDLEBAR HAN DLEBAR PINCH BOLT 13-5 L FRONT WHEEL/SUSPENSION/STEERING App/y lubricant spray Ihrough (he lab locking hole to Ihe rubber ror easy removal Allow the adhesrve to dry lur an hour belare uSIng HANDLEBAR WEIGHT REPLACEMENT Remove the grip from the handlebar. Straighten the weight retainer tab by the screw- driver or punch. Temporarily install the grip end and screw, then remove the handlebar welght by turning the grip end, Remove the grip end from the handlebar weight. Discard the retainer. Install the new retainer onto the handlebarweight. Install the grip end onto the handlebar weight aligning its boss with the slot in the handlebar weight. Install a new mounting screw. Insert the handlebar weight assembly into the handlebar. Turn the handlebar weight and hook the retainer tab with the hole in the handlebar. Apply Honda Band A or Honda Hand Grip Cement (U.S.A. onlyl to the inside of the grip and to the clean surfaces of the left handlebar and throttle grip. Wait 3 "5 minutes and install the grip. Rotate the grip for even application oithe adhesive. RUBBER CUSHION INNER WEIGHT RETAINER HOLE RETAINER RING INNER WEIGHT £9 RETAINER RING HANDLEBAR WEIGHT RETAINER TAB RETAINER RING GRIP [7 GRIP 13-6 FRONT WHEEL/SUSPENSlON/STEERlNG Install the left handlebar switch aligning its locating HOLE SWlTCl—l HOUSING pin with the hole in the handlebarv . \ . { O O Tighten the lorward screw first, then the rear screw, 0 . SCREWS Install the clutch lever bracket assembly by aligning LEVER BRACKET the end of the bracket with the punch mark on the handlebar. . Install the clutch lever bracket holder with the "UP” mark facing up Tighten the upper bolt first, then the lower bolt. TORQUE: 12 N-m (1.2 kgfirn , 9 lbf-fll Connect the clutch switch wires. U . Connect the throttle cable ends to the throttle pipe. i THROTTLE PIPE . 13-7 FRONT WHEEL/SUSPENSION/STEERJNG Apply grease to the sliding surface of the throttle RIGHT HANDLEBAR THROTTLE PIPE prpe, Install the throttle pipe mm the right handlebar. O O lnstall the right handlebar switch/throttle housing SWITCH HOUSlNG THROTTLE PIPE . by aligning lls locating pin with the hole in (he _ ... handlebar. ' O O Tighten the forward screw first, then the rear screwt . 0 Install the masler cylinder by allgning the end of the master cylinder with the punch mark on the O handlebar. lnslall the masler cylinder holder wilh the ”UP” mark lacing up. Tighten the upper bolt first, the lower bolt. TORQUE: 12 NvmlltZ kgf‘m ,91bl-ft) . Connect the brake switch wires. 0 13-8 FRONT WHEEL/SUSPENSION/STEERING Install the grip end and tighten the new mounting screw to the specified torque. GRIP END TORQUE: 10 Nm (1.0 kgf-m , 7 lbf-ftl FRONT WHEEL REFLECTOR CLAMPNUT FRONTFENDER REMOVAL ‘2‘ Support the motorcycle securely using a safety stand or a hoist, Remove the brake hose clamp nuts, special bolts, reflector and front fender. Danol uperaleme Remove the mounting bolts and both brake Drake/evelalle/ calipers. Ihe brake caliper is removed Support the brake caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the brake hose. Loosen the right axle pinch bolts. Remove the axle bolt. ’NC V50“;it 13-9 FRONT WHEEL/SUSPENSION/STEERING Replace the bearings H7 pairs Loosen the left axle pinch bolts, Remove the axle and the frontwheel. Remove the side collars. INSPECTION Axle Set the axle in V-block and measure the runouL Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 020 mm 10.008 in) Wheel bearing Turn the inner race ofeaoh bearing with yourfinger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if they do not turn smoothly, quietly, or if they fit loosely In the hub Install the new bearings into the hub using the special tools (page 13712lt WHEEL BEARING FRONT WHEEL/SUSPENSION/STEERING For optimum balance, Ihe We balance mark (a pain! dot on Ihe side wall) must be [063196 HEX! [0 me valve stem Hemount the life ll necessary Wheel rim runout Check the rim runout by placing the wheel in a turning stand. Spin the wheel by hand, and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading, SERVICE LIMITS: Radial: 2.0 mm l0.08 inl Axial: 2.0 mm l0.08 inl Wheel balance Wheel balance directly affects the stability, handling and over all safety of the motorcycle. Always check the balance when the line has been removed from the rim. Note the rotating direction marks on the wheel and tire. Remove the dust seals from the wheel. Mount the wheel, tire and brake discs assembly in an inspection stand. Spin the wheel, allow it to stop, and mark the lowest (heaviestl point of the wheel with a chalk. Do this two or three times to verify the heaviest area. lithe wheel is balanced, it will not stop consistently in the same DOSllion. To balance the wheel, install wheel weights on the highest side of the rim, the side opposite the chalk marks, Add just enough weight so the wheel will no longer stop in the same position when it is spun, Do not add more than 60 grams to the wheel, INSPECTION STAND\/ . 13-11 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY f*, V , Remove the bolts and brake discs, Remove the dust seaIs, . O InstaIl me bearIng remover head into rhe bearing, 1 From the opposiKe side, inslaIl the bearmg remover shaft and drive the bearing out of the wheeI hub, Remove the (Instance collar and drive out the omer bearIng. TOOLS: . Bearing remover head, 25 mm 07746-0050800 Bearing remover shaft 07746-0050100 . ASSEMBLY RIGHT BRAKE DISC 0 RIGHT WHEEL BEARING IEODEI LEFT WHEEL BEARING IBOOSI @ ’ LEFT BRAKE DISC RIGHT DUST SEAL . DISTANCE COLLAR . '&1 LEFT DUST SEAL \ $590 N~m (2.0 kgf-m,14Ibf‘m . 13-12 FRONT WHEEL/SUSPENSlON/STEERING Never Install ”18 Drive In a new right bearing squarely. ‘ DRIVER old bearmgs Once Install the distance collar, then drive in the left ‘ me bearmgs has bearing uslng the special tool. been removed Ihe bearlng mus! be TOOLS: replaced wrth new Driver 07749-0010000 ones Attachment, 42 X 47 mm 07746-0010300 Pilot, 25 mm 0774670040600 Do not get grease Install the brake discs on the wheel hub‘ Onlhe brake dlscs Install and tlghten the new mounting bolts to the 0’ stoppmg DDWE’ specified torque. wm be reduced TORQUE: 20 N-rn (2,0 kgf‘rn , M Hall!) Apply grease to the dust seal lips, then install them into the wheel huh. INSTALLATION Install the side collars. Install the front wheel between the fork legs, Apply thln layer of grease to the front axle surface Install the front axle from the leftside. FRONT WHEEL/SUSPENSION/STEERING Hold the axle and tlghten the axle bolt to the specified torque. TORQUE: 78 Nm i8 0 kgf‘m , 58 [bi-ft) . Tighten the right axle pinch bolts to the specufied torque. TORQUE: 22 N-m i2 2 kgf-m , 16 lbf~ftl O Install the both brake caliper and tighten the new O mounting bolts to the specified torque. TORQUE: 30 Nm (3.1 kgf‘m , 22 Ibi-fll Install the (rent fender (page 2715). C C With the front brake applied, pump the fork up and down several times to seat the axle and check brake operation. Check the brake operation by applying the brake . lever. O Tighten the left axle pinch bolts to the specified 7 torque. O TORQUE: 22 N-m (2.2 kgf‘m ,18Ibf-ftl O O 13-14 FRONT WHEEL/SUSPENSION/STEERING Check the clearance between the brake disc and callper bracket on each side after lnstallatlon. . The clearance should be at least 0.7 mm (0.03 ml. ° FORK Keep the brake REMOVAL master cylmdels upngm. Remove the front wheel (page 134». . Loosen the handlebar pinch bolt and top bridge pinch bolt. When the fork leg Will be disassembled, loosen the fork cap, but do not remove it yet, O Loosen the fork bottom pinch bolts and remove the fork tube from the lork top bridge and steering stem, 0 D . Be care/u! no! to DISASSEMBLV scratch the lurk STOP RING lube or damage Remove the handlebar stop ring. - the dust seal, Remove the stop ring. I . *erDliEB/XR STOP RING 13-15 FRONT WHEEL/SUSPENSIONISTEERING Turn the prerload adjuster counterclockwise, then remove the prerload adjuster and adjusting plate. PRE'LOAD ADJUSTER O t ; . \ . O ADJUSTING PLATE Remove the fork bolt from the fork tube. . Push the fork slider slowly down the York slider, and gently seat the dust seal onto the axle holder, C 0 Push down the spring seat and install the 17 mm FORK BOLT spanner into the groove ofthe rebound adjusters Hold the rebound adjuster, then loosen and remove . the fork bolt from the rebound adjuster, C Remove thefollowmg: .. . *Sprmg jolnl plate *Sprlng seat stopper *Sprlng collar *Fork spring 0 t (‘ SPRING COLLAR . 13-16 FRONT WHEEL/SUSPENSION/STEERING Pour out the fork fluid by pumping the fork tube several times, . , Four out the fork fluid from the fork damper by pumpmgthe damper rod severaltimes‘ I” H H! H H . IlIlH‘. H [H ”luuimm‘!amnuuul . Hold me axle holder m a vice wrth soft laws or a shopfowelr He‘d the fork damper wifh the fork damper holder, then remove the fork Socket boll. TOOL: . Fork damper halder D7VMBVMCFU1O1 0 Remove the fork damper assembly and centering p‘ate from the fork tube. 0 D CENTERING PLATE FORK DAMPER . Remove the dust sealr DUST SEAL I j/ I 13-17 FRONT WHEEL/SUSPENSION/STEERING Fork tube/slider/damper Check the fork tube and fork slider lor score marks, scratches, or excessive or abnormal wear. Replace any components which are worn or damaged. Check the fork damper for damage. Check the oil lock valve for wear or damage. Replace the fork damper assembly, if any compo nent are damaged. Place the fork tube in Vrblock and measure the runouL Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm 10.008 in) Fork tube bushing Visually inspect the slider and fork tube bushings. Replace the bushings if there is excessive scoring or scratchlng, or if the teflon IS worn so that the copper surlace appears on more than 3/4 of the entire surface. Check the backup ring; replace it if there is any distortion at the points shown. FORK SLIDEH FORK DAMPER OIL LOCK VALVE DIAL GAUGE FORK TUBE BUSHING BACKVUP RING CHECK POlNTS COPPER SURFACES 13-19 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY FORK TUBE BUSHING SLIDER BUSHING\\§fl BACKUP WWW / PRE LOAD ADJUSTER Q5 @ OIL SEAL”—"® STOPFER RING/g, ®;W/ADJUSTING PLATE . DUST SEAL /§® (g FORK BOLT ~— ../.,.22Nm(22kgfm, § 16 lbf m Q SPRING JOINT PLATE . FORK TUBE SEAT STOPPER SPRING COLLAR . , 4 / 45: V l——/@ FORK SPRING E 4 / FORK SLIDER FORK DAMPER I239 CENTERING PLATE . \f 34 N~m (3.5 kgffn , 25 lbfrftl Before assembly, wash all parts with a high flash or SLIDER BUSHING DUST SEAL nonrflammable solvent and wipe them dry. @’ OIL SEAL Install the mlsea/ Install the dust seal, stopper rung, new oil seal, " . Wm Its marked backup rlng, and slider bushing. WM ' slde Iacmg up Install a new fork tube bushing. Apply fork fluid to the oil seal lips. R / Install the forktube into the fork Sllder. . FORK TUBE BUSHING BACK-UP RING STOPPER RING Drlve the oil seal In usmg the special tools. .. . TOOL: Oilseal driver D7YMDVMCFOIUO or D7KMD7KZ30100 Wlll'l D7NMDr KZBD10‘I lexcept U.S.A.) 07NMD- KZ3OIDA 0 (USA, onlyl O 13-20 FRONT WHEEL/SUSPENSION/STEERING lnstaH the stopper rmg into the fork shder groove securety‘ STOPPER RtNG Install the dust sezlv DUST SEAL Install the centerlng plate onto the end of the fork dampen Install the fork damper assembly into the fork tubev CENTERING PLATE FORK DAMPER Apply a locking agent to the fork socket bott threadst InstaH the socket bolt with a new sealing washer. SEALING WASHER SOCKET BOLT 13-21 FRONT WHEEL/SUSPENSION/STEERING Hold the axle holder in a vise with soft jaws or a shop towel. a“ Hold the fork damper With the fork damper holder, ‘\ . then tighten the fork socket bolt to the specified '. torque. TOOL: Fork damper holder 07YMB-MCF0101 TORQUE: 34 N-m (3.5 kgf-m , 25 lbf-ftl 0 Pour the specified amount of recommended fork . fluld into the fork tube. RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-8 FORK FLUID CAPACITY: 488 2 2.5 Cm3 (16.5 i 0.08 US 02, 17.2 i 0.09 . Imp ozl I Bleed the air as follows: 1.Purnp the damper rod slowly 8* 10 times. 2.Extend the fork, cover the top of the fork slider with your hand and compress the fork slowly, . 3. Pump the fork slider slowly 8A 10 times. C Slowly push down the fork slider, and gently set . the dust seal onto the axle holder and leave it for 5 minutes. 85 sure the or! After the oil level stabillzes, measure the oil level . 90 mm Iavelrsmesame from top ollork slider. 13.5 in) in the both /orks FORK OIL LEVEL: 90 mm (3.5 inl . O 13-22 FRONT WHEEL/SUSPENSlONISTEERING Pull the damper rod up and install the lork spring with the tapered end facing up. Remove the following: *Spring collar 7 Spring seat stopper - Spring joint plate Install new O-ring onto the fork bolt. Apply fork lluid to the new O-ring, Screw the fork bolt to the rebound adjuster until it seats. Hold the rebound adjuster with a 17 mm spanner and tighten the fork bolt to the specified torque. TORQUE: 34 NJ“ (3.5 kgf-m , 25 lbfvfil Screw the fork bolt into the fork tube. Install the adjusting plate into the fork bolt aligning its pins with the holes in the fork bolt. Apply fork fluid to the pre-Ioad adjuster O-ring. Screw the pre-load adjuster onto the rebound adjuster. fl O-RING \ —\ ‘FOR SPRING“ SEAT STOPPER ”M W??? M‘fiQINT PLATE SPRING COLLAR FORK BOLT SPRING SEAT ADJUSTING PLATEV .‘~m . 7,“ r PRE-LOAD ADJ USTER FRONT WHEEL/SUSPENSION/STEERING Install the stop ring into the groove 0! the rebound adlusm / STOP RING Install the handlebar stop rmg. O 0 INSTALLATION . Install the fork leg through the bottom bridge, handlebar and top bridget Posttlon the top end of the fork tube flush with the upper surface of the top bridge as shown C . Tighten the bottom bridge pinch bolts to the specified torque. TORQUE: 26 N-m (2‘7 kgflm , 20 Ibf-ltl . C If the lork bolt was loosened, tighten it to the specified torquev TORQUE: 22 Nm (2.2 kgf~m,16lbftftl . Tlghten the top bridge pinch bolt to the specified torque. TORQUE: 22 Nm (2.2 kgf-m , 16 |bf>ltl Tighten the handlebar pinch bolt to the specified . torquet TORQUE: 26 N-m (2.7 kgf‘m , 20 lbf-ftl Install the front wheel (page 13-13). . 13-24 FRONT WHEEL/SUSPENSlON/STEERlNG STEERING STEM REMOVAL Remove the following: ‘- Front wheel lpage 1379l 7' Upper cowl (page 2711) Remove the bolt and horn unit. Remove the following: ~Handlebarlpage13r3) —Fork legs (page 13-15l Remove the stem nut and the top brldge. Straighten the tabs of the lock washer. LOCK NUT Remove the lock nut and lack washer, w "“1 A E . v» A ~. 4» I: r 4 . . LOCK WASHER TAB Remove the steering stern bearing adjusting nut STEERING STEM SOCKET using the special tool. TOOL: Steering stern socket 07916-3710101 or 0791673710100 lU,S,A. Dnlyl $ADJUSTING NUT 13-25 FRONT WHEEL/SUSPENSION/STEERING Always replace the bearings and races as a 59!. NDle the mslallalron direction of the assembly base Remove the following: 7 Dust seal *Upper bearing inner race 7 Upper bearing *Steerlng Stem 7 Lower bearing BEARING REPLACEMENT Except U.S.A.: Replace the races using the Ball Race Remover Set as described in the following procedure TOOLS: Ball race remover set O7946-KM90001 ‘Driver attachment, A (1) 079467KM90100 —Driver attachment, 3 (2) 079467KM90200 ‘Driver shalt assembly (3) 079457KM90300 —Bearing remover, A (4) 079467KM90401 ‘Bearing remover, B [5) 079467KM90500 *‘Assembly base (6) 07945~KM90600 Install the ball race remover into the head pipe as Shown, Align bearing remover A with the groove in the steering head. Lightly tighten nut Bwlth a wrench. Holding the driver shaft with a wrench, turn nut A gradually to remove the upper outer race. NUTB (a) (GI DRIVER ATTACHMENT BEARING REMOVERA DRIVER ATTACHMENT ASSEMBLV NUTB DRIVER SHAFT 13-26 FRONT WHEEL/SUSPENSION/STEERING InstaII ball race remover B as shown and remove the lower outer race using the same procedure as for the upper outer racev Align the bearing remover with the groove in the steering head. Install a new upper outer race and the ball race remover as shown. Hold the driver shaft with a wrench and turn nut A gradually until the groove in driver attachment A aligns with the upper end of the steering head. This will allow you to install the upper outer race. DRIVER ATTACHMENT DRIVER SHFT BEARING REMOVER B , ASSEMBLY A BASE DRIVER ATTACHMENT NUTA DRIVER ATTACHMENT DRIVER SHAFT ASSEMBLY BASE DRIVER ATTACHMENT 13-27 FRONT WHEEL/SUSPENSION/STEERlNG Install a new lower outer race and ball race remover as shOWn. Holding the driver shaft with a wrench, turn nut A ”UTA gradually until the groove in drlver attachment B O aligns with the upper end of the steering head. This ASSEMBLV will allow you to install the lower outer racer BASE ‘ l O DRIVER ATTACHMENT ~\' 2°; . LOWER OUTER RACE r ‘ a DRIVER ATTACHMENT DRIVER SHAFT . USA. only: Replace the steering head bearing outer races UPPER NUT ' h ' | t | i | . usingt e Specla 00 5 listed be ow MAIN BEARlNG fl R ATTACHMENT *7 TOOLS: DR'VE ‘ Main bearing driver attachment 07946-ME90200 Fork seal driver weight O7947-KA50100 FORK SEAL on seal driver 07965~MA50000 DRIVER WEIGHT Installer shaft 07VMF~KZ30200 Installer attachment A 07VMF7MAT0100 ' Installer attachment B 07VMF-MAT0200 UPPER BEARlNG Remover attachment A 07VMF-MAT0300 OUTER RACE Remover attachment B 07VMF7MAT0400 1 Install the special tools into the steering head pipe l as shown‘ REMOVER ‘ Align remover attachment A with the groove in the ATTACHMENTA . steering head. l While holding the installer shaft with the wrench, ‘ turn the upper nut gradually to remove the upper ‘ bearing outer race. LOWER NUT ‘ ‘1 / J . INSTALLER SHAFT ‘ 1r lNSTALLER T A'l'lACHMENT B C 13-28 FRONT WHEEL/SUSPENSION/STEERING Becare/ulnol to Install the special tools into the steering head pipe INSTALLER drool/79 as shown. ATTACHMENTA alrachmenls mm Align remover attachment B with the groove in the — O the/rams steering head. While holding the installer shaft with the wrench, turn the lower nut gradually to remove the lower INSTALLER SHAFT bearing outer race. \ O UPPER NUT REMOVER I ATTACHMENTS l . LOWER BEARING L OUTER RACE OIL SEAL DRIVER FORK SEAL 0 DRIVER WEIGHT MAIN BEARING DRIVER ATTACHMENT W l_ LOWER NUT 0 Install a new upper bearing outer race and the UPPER NUT special tools as shown, While holding the installer shaft with the wrench, r. turn the lower nut gradually until the groove in wTSTTAACII—IIIE/IFENTA . installer attachment A aligns with the upper end of . the steering head. This will allow you to install the I ‘ UPPER BEARING upper bearing outer race. OUTER RACE INSTALLER SHAFT 4’ O INSTALLER ATTACHMENT B ‘ I I . OIL SEAL DRIVER/ I FORK SEAL DRIVER WEIGHT 0 MAIN BEARING DRIVER ATTACHMENT _’ LOWER NUT O 13-29 FRONT WHEEL/SUSPENSlON/STEERWG Install a new lower bearing outer race and the UPPER NUT special tools as shown While holding the installer shaft with the wrench, turn the upper nut gradually until the groove in “DAFfiiiVEgi/w/ANEHMENT :— . installer attachment B aligns with the lower end oi the steering head. This will allow you to install the lower bearing outer race. FORK SEAL DRIVER WEIGHT 0 INSTALLER ATTACHMENTA ‘ C INSTALLER SHAFT/ LOWER BEARIN ' OUTER RACE . INSTALLER ATTACHMENT B _i LOWER NUT . Temporarily install the steering stern nut onto the DUST SEAL stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem. . Remove the lower bearing inner race with a chisel or equivalent tool, being carelul not to damage the stern. Remove the dust seal. . LOWER INNER RACE Apply grease [0 new dust seal lips and install it STEERING STEM . overthe steering stem. DRIVER Install a new lower bearing inner race using a special tool and a hydraulic press. TOOL: Steering stem driver O7946-MBOODOO O FRONT WHEEL/SUSPENSION/STEERING LOCK NUT .@ i BEARINGS MLOCK WASHER 1 BEARING RACES :DUST SEALS Wrap THREAD S‘>:Minimum tire trea_d depth ' ., 20 (0.08) Cold tire pressure i Up to 90 kg 1200 lb) Ioad_ 290 kPa 12.90 kgf/em7 ,7le psi) ’ 7“ ‘ i Up to maximum weight capacity 290 kPa (2.90 kgf/cm2 , 42 psi) *7 igxle runogt 7 . A 0.20 (0.003) Wheel rim runout Radial #“' 2.0 (0.08) W” . Axial ‘—i . A? (0.03) Drive chain Size/link i DID D.l.D.50\/A8 C17 7 #- L_ ‘ FlK RKGESOHFOZEi m i Slack 40m50(1,6*2,0) 50 (2.0) Shock absorber Dpring adjuster standard position 4th groove _ Tension adjuster initial setting 2 turns from full hard _-_7 Compression adjuster initial setting lturn from lull hard i 7’7 14-1 WHEEL/SUSPENSION QUE VALUES Rear axle nut Fear brake disc mounting bolt Driven sprocket nut Shock absorber upper mounting nut Shock arm plate nut Shock link nutlframe sidel Swingarm plvot nut Swingarm pivot pincn bolt Drive chain slider bolt Mam tootpeg bracket socket bolt Drive sprocket special bolt TOOLS Driver Attachment, 42 ‘ 47 mm Attachment, 52 ‘ 55 mm Attachment, 24 A 26 mm Attachment, 22 x 24 mm Attachment, 40 42 mm Pilot, 17 mm PllOl, 25 mm Bearing remover shaft Bearing remover head, 25 mm Driver shaft Driver attachment handle Needle bearing remover Driver pilot, 32 50 mm Driver attachment, 25 ‘ 385 mm 113N-mt11.5 kgt‘m,83lbl»ttl U-nut 42 Nrm (4.3 kgtern , 31 Ith) ALOC bolt 64 Nvm16.5 kgf~m , 47 letl U-nut 44 N-m (4.5 kgf~m , 33 |bf>ftl U-nut 44 N-m (4.5 kgtrm , 33 lbftttl U-nut 44 N-m (4.5 kgfvm , 33 lbf‘ftl U-nut 118 N-m 112.0 kgfvm , s7 lbf-ftl U-nut 25 N m (21 kgf-m , 20 lbf‘ttl 9 N-m 10.9 kgf‘m , 6.5 lbf‘ttl 39 N~m (4.0 kgf-m , 29 mm 54 N~m15.5 kgtrn , 40 ibrrtl 0774970010000 0774670010300 0774670010400 07746-0010700 077430010800 0794870010900 0774570040400 07746-0040600 077 46-0050100 077460050800 07946-MJ00100 079493710001 07 LMC-KV3D100 07 MADVPRSOZOO D7YMD7MCJ01OO TROUBLESHOOTING Soft suspension 0 Weak shock absorber spring - Incorrect suspension adjustment I Oil leakage from damper unit 0 Tire pressure too low Hard suspension - Damaged shock absorber mounting bearing 0 Bent damper rod . Damaged suspenston llnkage bearlngs o Damaged swmgarrn pivot bearings . Bent swingarm pivot - Incorrect suspension adlustment I Tire pressure too high Steers to one side or does not track straight 0 Bent rear axle o Axle alignment/chain adlustment not equal on both sides Rear wheel wobbling o Bent rim - Worn rear wheel bearings - Faulty tire o Unbalanced tire and Wheel 0 Tire pressure too low . Faulty swingarm pivot bearlngs 14-2 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Suppon the motorcycle usmg a safety stand or heist, raise the rear wheel off the ground, Remove the axle nut and drive chain adjusting plate Push the rear wheel lorwardv Derail the drive chain from the driven sprocket. Remove the axle and drive chain adlusting plate from the left side and remove the rear wheell r, _ m") ,5, ADdlinglNG PLAVTE Remove the side collars, INSPECTION Axle Place the axle in V-blocks and measure the runoul. Actual runout is 1/2 the total indlcator reading. SERVICE LIMIT: 0.20 mm 10.008 inl REAR WHEEL/SUSPENSION Wheel bearing Turn the inner race of each bearing With your linger. Bearings should ttlrn smoothly and quietly. Also . check that the bearing outer race fits tightly in the hub. Hep/acelhe wheel Remove and discard the bearings it the races do bearingslnpairs not turn smoothly and quietly, or if they fit loosely in the hub. O WHEEL BEARING Wheel rim runout . Check the rim runout by placing the wheel in a turning stand. Spin the wheel slowly and read the runout using a dial indicator, Actual runout is 1/2 the total indicator reading. 0 SERVICE LIMITS: Radial: 21) mm (0.03 ml Axial: 2.0 mm [0.08 inl 0 Driven sprocket Check the condition of the final driven sprocket teeth. Replace the sprocket if worn or damaged. @000 REPLACE . - If the final driven sprocket requires replacement, 0 X inspect the drive chain and drive sprocket. 0 Never install a new drive chain on a worn sprocket or a worn chain on new sprockets. Both chain and sprocket must be in good condition or the replacement chain or sprocket will wear . rapidly. Wheel balance . See page 13711f0r wheel balance. DISASSEMBLY Remove the bolts and brake disc. Removethe right dustseal. . s . " , . . - r " DUST SEAL . . 14-4 REAR WHEEL/SUSPENSION llyou wr/lbe Remove the driven flange assembly from the left drsassemb/e Ihe wheel hub. drrven Mange. . loosen me drlvsn sprocket nuts before removmg me driven flange Irom the Wheel hub O I Remove the wheel damper rubbers Remove the Orring. O 0 Driven flange bearing removal Loosen the driven sprocket nuts. . Remove the driven flange from the wheel hub, then remove the driven sprocket nuts and sprocket, Remove the dust seal. I . Remove the drlven flange collar. , ' DRIVER Drive out the driven flange bearing. I ATKHMFTNT/PILOT D . ‘ >4 _ _ 14-5 REAR WHEEL/SUSPENSION WheeI bearing removal InstalI the bearing remover head Into the beanng. From the opposIte sIde install the bearing remover shaft and drive the bearing out of the wheeI hub. Remove the dIstance collar and drive out the other bearing. TOOLS: Bearing remover head, 25 mm 0774570050800 Bearing remover shah 0774670050100 ASSEMBLY 42 N-rn (4.3 kgf-m,31|bf-m fl RIGHT DUST SEAL DISTANCE COLLAR O’RING % BRAKE DISC DRIVEN FLANGE COLLAR DRIVEN FLANGE BEARING RIGHT WHEEL IZ7Z<52X23.8I BEARING 16205) DRIVEN SPROCKET DAMPER RUBBERS LEFT WHEEL BEARING IGOOSI DRIVEN FLANGE 'fit LEFT DUST SEAL 64 N-m (6.5 kgf-m , 47 lbf-III Never msra/I the Wheel bearing installation old bearings once = - DRIVER the bearings has Drive in a new rIght bearing squarely, bi been removed the ” ‘ Dealing muslbe TOOLS: WPIBCEU WW7 ”6W Driver 0774970010000 ones Attachment, 52 7 55 mm 0774670010400 Pilot, 25 mm 077460040500 ATTr GHMENTV/PILEJT g 14-6 REAR WHEEL/SUSPENSMu l Install the distance collar. DISTANCE COLL; ' Drive in the left side bearing. TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 07746-0010300 Pilot, 25 mm 07746-0040500 ATTACHMENT/PILOT Install the driven llange collar into the new driven flange bearing. DFllVEN FLANGE COLLAR DRIVEN FLANGE BEARING Driven flange bearing installation Drive the new driven flange bearing into the driven flange using the special tools. DRIVER TOOLS: Driver 0794970010000 Attachment, 52 X 55 mm 0774641010400 mm...” ., 3% Pilot, 25 mm 07746-0040500 & ATTA-Cz MENT/PILOT 14-7 REAR WHEEL/SUSPENSION Install the wheel damper rubbers into the wheel > ' ' ' DAMPER RUBB 7R ‘ hub. . . _ V . 7 ‘ “MES Apply oil to the new O-ring and install it into the groove of the wheel hubs . O lnslall the driven flange assembly into the lelt . wheel hubs lf the driven sprocket was removed, Install the driven sprocket and tighten the nuts‘ TORQUE: 64 N-m 15.5 kgf-m , 47 lbfvfll Apply grease to the dust seal lips, then install it into . the driven flange. 0 Install the brake disc with its rotating direction 7* DI‘SE mark facing out. 9 B®LTS Install and tighten the new bolts to the Specified ' torquet O TORQUE: 42 N-m (4.3 kgf:m , 31 lbfrftl C ' . ° - J DUST‘SEALhFlOTATINGIDIHEGTlON MARK INSTALLATION 0 Apply grease to the side collar inside and grooves Install the side collars. O O 14-8 REAR WHEEL/SUSPENSION Install the rear brake caliper bracket onto the guide ofthe swingarm. O O O Placethe rearwheel into the swingarm. Install the drive chain over the driven sprocket. Install the drive chain adjusting plate and axle from the left side. 0 0 Install the drive chain adjusting plate and axle nut, Adjust the drive chaln slack ipage 3-2oi. . Tighten the axle nut to the specified torque. TORQUE: 113 N-m (11.5 kgf-m , 83 |bf~ft) O O REMOVAL Support the motorcycle using a hoist or equivalent. Remove the muffler and exhaust pipe ipage 2718). . Remove the exhaust pipe mounting collar and mounting rubber. . COLLAR/MOUNTING RUBBER 1 4-9 REAR WHEEL/SUSPENSION Remove the followmg: 7 Link plate bolts/nuts ' Link plates *Shock arm bolt/nut , Shock arm INSPECTION Check that the suspension linkage companents for damage, replace anydamaged components SHOCK ARM SHOCK ARM BEARING REPLACEMENT Remove the pivot collar and dust seals. DUST SEALS Press out the needle bearing out of the shock arm uslng the speclal tools, DRIVER TOOLS: Driver attachment handle 0494973710001 Attachment, 22 X 24 mm 0774670010800 Pilot, 17 mm 0774670040400 ATTACHMENT/PILOT Fresslhe need/e Press a new needle bearing into the shock arm so baa/mglnlolhé that the needle beanng surface is lower 5,275.7 52,5] mm (020,022 In) shock arm Wlthlhe mm 10.20A0.22 in) from the end of the shock arm marked Slde using the same tools, $ Iacmg our 14-10 REAR WHEEL/SUSPENSlON Apply grease to the new dust seal lips, install them into the shock arm. Install the pivot collar. 0 O 0 a 0 INSTALLATION Install the shock arm Into the lower bracket, install the mountmg bolUnut. Hold the Socket bolt and tighten the nut to the specified torque. . TORQUE: 44 N-m (4.5 kgl‘m , 33 lbf‘fl) lnstall the link plates with its "FFlmr mark facing forward. Install the link plate bolts/nuts, then tighten the nuts to the speculied torque. . SHOCK ARM TORQUE: 44 N-m (4.5 kgf‘m , 33 Ihf‘fll Install the exhaust pipe mounting rubber and collar. Install the exhaust pipe and muffler lpage 2-20l, O C COLLAR/MOUNTING RUBBER . SHOCK ABSORBER " m“ “ ‘ ‘ ‘-« LOWER MOUNTING‘BOL‘T/NUT . r . V REMOVAL , ~ -~ .. ., Place the motorcycle using a hoist or equivalent. Remove the rear brake light switch and switch stay (page 15-27l, . Remove the shock absorber lower mounting bow nut. Remove the link plate bolts/nuts and link plates. LINK PLATE BOLTS/NUT O 14-11 REAR WHEEL/SUSPENSlON Press (he need/e bearing mm me lower mm mm the marked srue lacing our mountlng nut. Loosen and remove the shock absorber upper J UPPER MGHNTIN ELM UT Lower the Shock absorber, then remove ' ‘ r INSPECTION DAMPER Vlsuallv lnspect the shock absorber for damage, Check for the: , Damper rod for bend or damage *Damper unit for deformatlon or oil leaks *Bump rubber for wear or damage Inspectallthe other partslorwearor damage. If necessary, replace the shock absorber as an assembly. NEEDLE BEARING REPLACEMENT agfs'rsemiggA ”g: V . w a: Remove the pivot collar and dust seals. \ , Press out the needle bearing out of the shock l‘; absorber lower mount using the special tools. TOOLS: Driver attachment handle 049496710001 Attachment, 22 X 24 mm 0774570010800 Pilot, 17 mm 0774570040400 PIVOT COLLAR Press a new needle bearing into the lower mount so that the needle bearing surface IS lower 8.0 mm {0.31 ml from the end of the lower mount using the same tools. 8.0 mm (0.31 ml n 14-12 Do not remove the valve core until pressure l5 releaced Apply grease to the new dust seal lips, install them into the lower mount. Install the pivot collar. SHOCK ABSORBER DISPOSAL PROCEDURE Remove the damper reservoir capv Release the nitrogen from the reservoir by depressing the valve core. NOTICE 0 Point the valve away from you to prevent debris getting in your eyes 0 Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock absorber reservoir. INSTALLATION Install the shock absorber into the lrame from the bottom, and install the upper mounting bolt/nut. Tighten the nut to the specified torque, TORQUE: 44 N-m (4.5 kgfrm , 33 lbf-I‘tl REAR WHEEL/SUSPENSION PIVOT COLLAR DUST SEALS RESERVOIR CAP REAR WHEEL/SUSPENSION Install the link plates, link plate bolts/nuts and shock absorber lower mounting bolt/nut. Tighten the nuts to the specified torque TORQUE: 44 N‘m14.5 kgf-m , 33 Ibfrfll Install the removed parts in the reverse order of removal. SWINGARM REMOVAL Remove the rear wheel (page 14-3lv Remove the [W0 SH bolts and drive sprocket cover and spacer. Remove the drive sprocket bolt, washer and dere sprocket Remove the screws and brake hose guides. DRIVE SPROCKET _ ‘ l ‘ l / ‘ l 14-14 Ca/rlomra type only‘ Remove the shock absorber lower mounting bolt/ nut Remove the lmk platertorswingarm bolt/nut. Remove the right main footpeg bracket socket bolts and main footpeg bracket. Retease the 0; sensor wire from the wire guide behind the right step guardv Remove the bolt and gearshift link arm from the gearshillspindle Remove the tefr main footpeg bracket socket bolts and main footpeg bracket Loosen the swingarm pivot pinch bolts, REAR WHEEL/SUSPENSWN N”, «'3‘ LINK PLATEVT §vWNdARM BOLT/NUT REAR WHEEL/SUSPENSION Hold the prvot bolt using a 24 mm socket wrench, [hen loosen and remove the swmgarm pIVOl nut using the same (00!, O 0 Remove the pivot bolt and then remove the . swmgarm from the lower bracket and engine‘ 0 I DISASSEMBLY/INSPECTION TRIM CLIP DRIVE CHAIN CASE A Remove the SH bolt, trim Clip and drive chain case ’ A- o O SQ» VVSVH BOLT «5 Remove the SH bohs and drive Chain case B. DHIVE CHAIN CASE 3 . O O 14-16 Remove the three SH bolts and drive chain slider. Check the drive chain sliderfor wear or damage. Remove the pivot collar and dust seals from the swingarm left pivot. Check the dust seals and collar for damage or fatigue. Remove the side collar and dust seals from the swingarm right pivot. Check the dust seals and side collar for damage or fatigue. Turn the inner race of right pivot bearings with yourfinger, The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the pivot. REAR WHEEL/SUSPENSION DRIVE CHAlN SLIDER BEARING 14-17 Remove the three SH bolts and drive chain slider. Check the derE chain slider for wear or damage. Remove the pivot collar and dust seals from the swingarm left pivot. Check the dust seals and collar for damage or fatigue. Remove the side collar and dust seals from the swinga rm right pivot, Check the dust seals and side collar for damage or fatigue. Turn the inner race of right pivot bearings with your finger, The bearings should turn smoothly and quietly. Also check that the bearing outer race lits tightly in the hub. Remove and discard the bearlngs if the races do not turn smoothly and quietly, or if they fit loosely in the pivot. REAR WHEEL/SUSPENSION DRIVE CHAIN SLIDER BOLTS BEARING 14-17 REAR WHEEL/SUSPENSION PIVOT BEARXNG REPLACEMENT Remove the snap nngv Remove the right pivot bearings {radial ball bearings) and distance collar from the swingarm pivot usmg the speclal tools and hydraulic press. TOOLS: Driver shah 07946-MJ00100 Driver attachment, 25 X 38.5 mm D7YMD-MCJO1DO Press the inner beating into the swingarm right pivot untll it seats llSll’Ig the special tools and hydraulic press. TOOLS: Driver 07749-0010000 Attachment, 40 X 42 mm 077460010900 Pilot, 25 mm 077460040600 Install the dlstance collar. SNAP RING ATTACHMENT DRIVER ATTACHMENT/PILOT / DISTANCE COLLAR 14-18 REAR WHEEL/SUSPENSION Pless the needle bearing into the swingalm Wim the marked slde lac/rig out Install the outer bearing using the special tools‘ TOOLS: Driver 077 1353-0010000 Attachment, 40 X 42 mm 077 4670010900 Pilot125 mm 0774670040600 Install the snap ring into the groove securely. Remove the left pivot needle bearing from the swungarm pivot using the special tools‘ TOOLS: Driver 0774970010000 Attachment, A“) X 42 mm 077460010900 Driver Film, 32 X 50 mm 07MADVPR90200 Press a new lelt pivot needle bearing into (he swingarm pivot so that the needle bearing surface is lower 8* 9 mm l0.3*0.4 in) from the and of the swungarm pivot surface using the special tools. TOOLS: Driver 0774943010000 Attachment, 40 X 42 mm 07746-00i0900 Driver Pilot, 32 X 50 mm 07MAD-PR90200 DRIVER ATTACHMENT/PILOT SNAP RING DRlVER A'l'l'ACHMENT/PILOT / ' 8*9mm «0370mm ex REAR WHEEL/SUSPENSlON Remove the pIVOl collar and dust seals from the DUST SEALS llnk plate DIVOL O D / x 33 PIVOT COLLAR Remove the shock link pivot needle bearing using . _ NEEDLE BEARING REMOVER the speClal tool. TOOL: Needle bearing remover 07LMC7KV30100 ‘. 0 Install the shock link pivot needle bearing into the swingarm so that the needle bearing surface is lower 5.5*B,D mm (022*024 inl from the end of the swingarm pivot surface using the same (00L . TOOL: Needle bearing remover 07LMCVKV30100 0 Apply grease to the dust seal lips, then install the ‘8” . dust seals and pivot collar into the swingarm. v. PIVOT COLLAR O 14-20 REAR WHEEL/SUSPENSION ASSEMBLY DRIVE CHAIN CASE B DRIVE CHAIN CASE A a SNAP RING % H DUST SEALS RIGHT PIVOT BEARINGS (6905! I ,@ DUST SEAL SIDE COLLAR f PIVOT COLLAR .4631 DUST SEAL @ LEFT PIVOT NEEDLE BEARINGS (3214mm DUST SEAL % DRIVE CHAIN SLIDER Apply grease to the dust seal lips, then Install the dusl seals and side collar into me right swingarm pivot. Apply grease to the dust seal lips, (hen Install the PIVOTCOLLAR dust seals and pivot collar into lhe Iefi swingarm EDUST SEALS pivot. 14-21 REAR WHEEL/SUSPENSlON InstaH the drive chain slider ahgnlng its tabs with the boss on the swingarm as shown. O O Appry a locking agent to the drive chain slider boll DRIVE CHA‘N SLIDER BOLTS I threads, : ‘QEEI InstaH the collars and bolts, than tighten the bolts to the specified Iorque‘ TORQUE: 9 N~m (0.9 kgf-m , 6,5 lbf-m ’. 'F O InstaH the drive Chain case B and tighten the SH DRIVE CHAIN CASE B bolt secure‘v. !. . inslall the driye chain case A and secure it With a TRIM CLIP DRIVE CHAIN CASE A . SH bolland mm cup. 0 SH BOLT _ x 0 14-22 REAR WHEEL/SUSPENSION lNSTALLATlON WOT 305913973 Apply thin coat of grease to the swingarm pivot .7 _ boll surface. install the swmgarm between the lower bracket and engine, then install the pivot bolt from the left side. Install the swrngarm pivot nut. Hold the pivot bolt using a 24 mm hex wrench, tighten the swingarm pivot nut to the specified torque usingthe same tool. TORQUE: 118 Nvm112.0 kgf~m , 87 “3”!) Tighten the swingarm pivot pinch bolts to the specified torque. TORQUE: 26 N-rn (2.7 kgf‘m , 20 lbf‘ltl Install the left main footpeg bracket onto the lower bracket and tighten the socket bolts to the specified torque. TORQUE: 39 N-m (4.0 kgf~m , 29 lbfvftl Install the gearshllt pedal link to the gearshift spindle while aligning its slit with the punch mark on the spindle. Tighten the gearshift pedal link pinch bolt to the specified torque. TORQUE: 10 N'm 11.0 kgfvm , 7 lbf‘hl REAR WHEEL/SUSPENSION Call/(WM (V139 Clamp the 0) sensor wire to the wire guide behind O SENSOR WIRE BOLTS only the right step guard. ’ Install the right mam footpeg bracket onto the 0 lower bracket and tighten the socket bolts to the specified torquev TORQUE: 39 Nrm14.0 kgl»m , 29 lbl-fll 0 Install the link plate-to-swingarm bolt/nut, then I tighten the nut to the specified torque. TORQUE: 44 N-m l4v5 kgf‘m , 33 lbf-ftl O C Install the brake hose guides and tighten the screws to the specified torque. TORQUE: 4 N-m (0‘4 kgf‘m , 2.9 lbf-ftl . C Install the drive sprocket with its "ML7" mark facing out. . Install the washer and special bolt, then tighten the bolt to the specified torque TORQUE: 54 NT“ (5.5 kgf‘m , 40 lbf-ftl I "ML7" MARK WASHER . 14-24 REAR WHEEL/SUSPENSION Install the spacer and drive sprocket cover, tighten SPACER DR‘VE SPROCKET COVER the SH bGIISV ». . Install the rearwheelrpage14~8L Instalr the removed parts in the reverse order of remova‘, 14-25 15. HYDRAULIC BRAKE SERVICE INFORMATION 15-2 FRONT MASTER CYLINDER 15-10 TROUBLESHOOTING 15-3 REAR MASTER CYLINDER 15-16 BRAKE FLUID REPLACEMENT] FRONT BRAKE CALIPER 1520 AIR BLEEDING 15-4 REAR BRAKE CALIPER 15-24 BRAKE PAD/DISC 15-7 BRAKE PEDAL 15-27 REAR: California type shown: 34 N~m (3‘5 kgf-m , 25 Ibf-fi) 39 N-m (4.0 kgf‘m , 29 Ibf-flI 34 N»m13.5 kgf-m , 25 let) 18 N.m(1.8kgf-m,13lbf$ \ m» 2 Nrm 10.25 kgfvm , 1.8 Ibf-m 22 N-m (2.2 kgf‘m , IE Ibf‘flb 15-1 HYDRAULIC BRAKE SERVICE INFORMATION GENERAL ~ "" A CAUTION ‘ Frequent inhalatlon of brake pad dust, regardless of material composition could be hazardous to your health. 0 Avoid breathing dust particles. - Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner, 0 A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc With a hlgh quality brake degreasing agent - Check the brake system by applying the brake lever or pedal afterthe air bleeding. 0 Spllled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts, Be careful whenever you remove the reservoir cap: make sure the front reservoir is horizontal first. . Never allow contaminates (dirt, water, etel to get into an open reservoir. - Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. I Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid they may not be compatlble. t Always check brake operation before riding the motorcycle. SPECIFICATIONS Unit: mm linl ITEM STANDARD SERVICE LIMIT Front pecified brake fluid Honda DOT 4 Brake Fluid . , *- i Brake discthickness VfiélOJBl m , 3519.14) 7, Brake disc runout 7 7 0.3010012) “k Masterc linderlD. 19.050‘49093 (0,7500m0.7517) 1g105i0.7522i liMasteirrpiston 0.0. 19013719034107487707494) 19,006 l0.]483l Caliper cylinder ID. 1 Upper i 33.9607'34310 (1.3370*1.3390l ‘ 34.02 (1.339I l 7" 7 ., rn‘igvygrA‘AM 30.250730.2807fl:1909*1.192“ W. 30.29 (1.93» Caliper piston OD. i Upper 353802 ~33.835 i1.3308*1.3321i ‘ 3%,794113305I 7 7 777 Lower 3D.DSZ*30.115(1.1843:1.1856i ‘ 30.07411,1340l Rear rispeciried brake fluid D915 .,...,. i A 1, 7 l Brake pedal height 75 (30) fi' . Brake disc thickness __5.D(0.20i 4,010.16) i Brake disc runout ———‘ 03010012] Master Cylinder ID. 15.870m15913 (0.6248*0.6265i 15.925 (0.6270i Master piston 0.0. l iS.8_Z]~i5,85410.523170.6242i 15.315 (0.6226l a Caiipercylinder i.D. ‘ 38.130’38230 (1.5031 * 1.5051) 332411.506) Caliper piston OD, ‘ 38.098 *38.148H.4999'1.5019i 38.090(1.4996l 15-2 HYDRAULIC BRAKE TORQUE VALUES Front brake master cylinder cup mounting nut Brake lever pivot bolt Brake lever pivot nut Front brake switch screw Front brake caliper mounting bolt Caliper body assembly torx bolt Fad pin Pad pin plug Brake caliperbleeder Rear brake hose clamp screw Rear master cylinder push rod nut Hear master cylinder hose joint screw Rear brake caliper slide pin lmainl Hear brake caliper slide pin (sub) Brake hose oil bolt TOOL Snap ring pliers TROUBLESHOOTING Brake lever/pedal soft or spongy - Air in hydraulic system - Leaking hydraulic system 0 Contaminated brake pad/disc 0 Worn caliper piston Seal - Worn master cylinder piston cups I Worn brake pad/disc 0 Contaminated caliper 0 Caliper not Sliding properly (rear) 0 LOW brake fluid level - Clogged fluid passage ° Warped/deformed brake disc ' Sticking/Worn caliper piston 0 Sticking/worn master cylinder piston o Contaminated master cylinder O Bent brake lever/pedal Brake lever/pedal hard 0 Clogged/restricted brake system 0 Sticking/worn caliper piston - Caliper not sliding properly irear) O Clogged/restricted fluid passage ' Worn caliper piston seal 0 Sticking/worn master cylinder piston 0 Bent brake lever/pedal 6 Nrrn (0V6 kgfrn , 4‘3 lbf‘ltl Urnut ‘ID Nm l1.0 kgfm , 7 lbf-itl 6 N-m (0.6 kgf-rn , 43 ”Jim 1N-m 10.12 kgfvm , 0.9 lbf-ltl 30 N-ml3.1 kgf-m,22|bf-itl ALOC bolt 23 N:rn (2.3 kgf:m , l7 lbf-l‘tl ALOC bolt 18 N-m (1.8 kgf‘m,13lbf~ftl 2 N~m (0.25 kgf-m,1v8|bl>ft) 6 N~m (0.5 kgfrm , 4.3 mini 4 N~m (0.4 kgfrn , 2‘9 le‘tl ALOC bolt 18 N~m (1.8 kgflm ,13Ibl-fl) 1 Nrm (0.15 kgl-rn,1.1lbf-fll Apply a locking agent to the threads 27 N-m 12.8 kgf-m , ZO lbfvftl Apply a locking agent to the threads 22 N-m (2.2 kgf-m ,16lbf-ftl Apply a locking agent to the threads 34 N-m (3.5 kgfrm , 25 lbf-ftl 0791475A50001 or 079143230001 Brake drags 0 Contaminated brake pad/disc . Misaligned wheel - Clogged/restricted brake hose joint - Warped/deformed brake disc 0 Caliper not sliding properly (rear) ' Clogged/restricted brake hydraulic system 0 Sticking/worn caliper piston 0 Clogged master cylinder port 15-3 0 HYDRAULIC BRAKE EiRFfiBKEEEI-SflthGREPi-ACEM ENT/ SCREWS 0 - Do not allow foreign material to enter the system ' when filling the reservolrv 0 Avoid spilling fluid on painted, plastic, or rubber parts Place a rag over these parts whenever the system rs serviced. . BRAKE FLUID DRAINlNG DIAPHRAGM PLATE ' For the from brake, Iurn the handlebar unlil the res ervolr Is parallel to the ground, before removing the reservorr cap. Remove the screws and reservoir cap I Remove the diaphragm plale and diaphragm‘ C For the rear brake, remove the rear brake reservoir mounting bolt Remove the reservoir cap. . C _‘ ‘ BOLT Remove the diaphragm plate and diaphragm DIAPHRAGM PLATE . O rDl’APflBAGM . 15-4 HYDRAULIC BRAKE Connect a bleed hose to the caliper bleed valve. Loosen the bleed valve and pump the brake lever or pedal. Stop pumping the lever or pedal when no more fluid flows out of the bleed valve. BRAKE FLUlD FILLING Fill the reservoir with DOT 4 brake fluid from a sealed container. 0 Use only DOT 4 brake fluid from a sealed contain- er. 0 Do not mix different types of fluid, There are not compatible. Connect a commercially available brake bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve, adding fluid when the lluid level in the master cylinr der reservoir islow. oCheck the fluid level often while bleeding the brakes to prevent air from being pumped into the system. nWhen using a brake bleeding tool, follow the manufacturer’s operating instructions. Repeat the previous steps until air bubbles do not appear in the plastic hose. 0 If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape, a If a brake bleeder is not available, fill the master cylinder and operate the brake lever or pedal to flu the system. Close the bleed valve. Next, perform the BLEEDING procedure. BLEED VALVE BLEED HOSE } Q HYDRAULIC BRAKE BRAKE BLEEDiNG BLEED VALVE BLEED HOSE Connect a clear bleed hose to the bleed valve. I . Pump up the system pressure with the lever or ped- al until there are no air bubbles in the Vluld llowing out of the master cylinder and lever or pedal resIsV tance is felt. Do no! release the 1.8queeze the brake lever or push the brake pedal, brake/eve/or open the bleed valve 1/2 turn and then close the . pedal unlll the valve. bleed valve has been closed 2.Release the brake lever or pedal until the bleed valve has been closed. Repeat steps 1 and 2 until bubbles cease to appear . in the lluid coming out of the bleed valve. Tighten the bleed valve. TORQUE: 6 N-m (0.6 kgf-rn , 4.3 lbf‘fll Fill the fluid reservoirto the upper level. . Reinstall the diaphragm and diaphragm plate. ‘ On the front brake, install the reservoir cap, and SCREWS tighten the screws. 0 0 On the rear brake, install the reservoir cap securely, . then install the reservoir onto the frame and tighten the mounting bolt. 0 O 15-6 HYDRAULIC BRAKE BRAKE PAD/DISC BOLTS PAD PINS Alwaysreplace lhs FRONT BRAKE PAD REPLACEMENT I * brake pads m pans to assure Loosen the pad pins. even dlSC pressure Remove the bolts and brake caliper. Check me brake Push the caliper PIStOnS all the way into allow my Huld level m me stallatlon 01 new brake pads. brake master cylln~ der reservatr as this ope/anon causes the level to use Remove the pad pins, pad spring and brake pads‘ Clean the inside of the caliper especially around the caliper pistons. HYDRAULIC BRAKE Be care/ill not re damage we pads Always replace the brake pads m parrs I0 assure even disc pressL/Ie. Install the new brake pads. Install the pad spring with Its arrow mark facmg up as shown, Push the pad spring, then install the pad pinr Install the brake caliper to the fork leg so the disc is positioned between the pads. Install and tighten the new brake caliper mounting bolts. TORQUE: 30 N-m (3.1 kgf~m , 22 lbf-fll Tighten the pad pins. TORQUE: 18 Nm (1.8 kgf‘m,13lbfrftl REAR BRAKE PAD REPLACEMENT Check the brake fluid level In the brake master cylin- der reservoir as this operation causes the level to rise. Push the caliper pistons all the way in by pushing the caliper body inward to allow installation of new brake pads. Remove the pad pin plugr as? BOLTS N! , ,’ 1 5-8 HYDRAUUC BRAKE Loosenthe pad pin. Remove the caliper bracket bolt. 0 O O Pivotthe camper up. Remove the pad pin and brake pads. . 0 Make sure the brake pad spring is in place. Install the new brake pads. . Lower the ca‘iper while pushing the pads against the pad spring so that the pad ends are posrtioned onto the retainer on the caliper bracket. InstaH the pad pin. . . InstaH and trghten the caliper bracket bolt, TORQUE: 22 N-m12.2 kgf-m ,16IbHU Tightenthe pad pint TORQUE: 18 N~m (1,8 kgf m , 13 lbfrft) O . 15-9 I HYDRAULIC BRAKE install and tighten the pad pin plugv TORQUE: 2 N-m (0.25 kgfh’i , 1.8 lbt‘ltl . C BRAKE DISC INSPECTlON ' Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness with a microme- ter, I SERVICE LIMITS: FRONT: 3.5 mm 10'14inl REAR: 4.0 mm 10.16 in) Replace the brake disc if the smallest measurement is lessthanthe service limit. 1 Measure the brake disc warpage with a dial indica- tor, SERVICE LIMIT: 0.30 mm (0.012 ini ‘ Check the wheel bearings for excessive play, if the warpage exceeds the service limit. Replace the brake disc If the wheel bearings are nor mal. C REMOVAL . Drain the front hydraulic system lpage 15-4lv AVON SDI/“I79 f/LIId Disconnect the brake light switch wire connectors. onpamted‘ plastic, Remove the brake hose orl bolt, sealing washers mlubbEr/Jarts and brake hose eyelet. Place a rag over . these parts Whenever (he syslem is serviced C 15-10 HYDRAULIC BRAKE Remove the baits from the master Cylinder hoider and remove the master cylinder assembly. DISASSEMBLY Remove the dust Cover and snap ring, Remove the bolt and brake reservoir from the masV ter cylinder, Remove the O-ring Remove the pivot boIUnut and brake lever assemv blyv Remove the screw and brake light switch. IMA=STERf§VNDER SNAP RING DUSTI'iYEOVER xi, BOLT PIVOT BOLT \ PIVOT NUT SCREW BRAKE LEVER BRAKE LIGHT SWITCH 15-11 0 HYDRAULIC BRAKE Remove the boot. BOOT O I Remove the Snap ring from the master cylinder SNAP RING 0 body uslng the speclal tool as shown. TOOL: Snap ring pliers 07914rSA50000 or 0791473230001 Remove the master piston and spring. . Clean the inside of the cylinder and reservoir Wlth brake fluid. e SNAP RING PLIERS . INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal ' scratches. Measure the master cylinder LD. SERVICE LIMIT: 19.105 mm (0.7522 in) 0 Measure the master cyIlnder piston 0.D. . SERVICE LIMIT: 19.006 mm (0.7483 in) C O 15-12 HYDRAULIC BRAKE ASSEMBLY RESERVOIR RESERVOIR CAP ION‘mIIVO kgf-m,7 Ibf‘ft) /' DIAPHRAGM , % PLATE / ‘\ I % / \ / SPRING MASTER PISTON SNAP RING - \DIAPHRAGM BOOT BRAKE LIGHT SWITCH \ %%\ eN‘mlo.ekg,.m,4.3.bm 6Nm106kgfm 43lbfft) \2.Nm1025kgfm I8IbfflI Keep Iheplslon, Coat all parts with clean brake fluid before assemr cups, sprlng snap nyI my and boat as a sell do no! substitute IndIVIdua/parls MASTER CVLINDER MASTER PISTON When mstallmg Dip the pismn in brake fluid, the cups do not Install [he spring we the plslon. al/GW Iheltps Io Install the piston assembly into the master cyhnder. Iurn Inside 0U! SPRING PISTON CUPS Be cerlamthe Install the snap ring. SNAP RING Snap mg [5 Mme - sealed m the TOOL: groove Snap ring pliers 07914~SA50000 or 0791473230001 SNAP RING PLIERS HYDRAULIC BRAKE Install the boot‘ Install the brake light switch and tighten the screw to the speclfied torque‘ TORQUE: 'IN»m 10.12 kgf-m , 0.9 lbf-fil Apply silicone grease to the contact surfaces 0! the brake lever and piston tip. Install the brake lever assembly, tighten the pivot bolt to the speclfied torque. TORQUE: 10 Nm (1.0 kgfvm , 7 lbf-fil Hold the pivot bolt and tighten the vaot nut to the specified torque. TORQUE: 6 N-m 10.6 kgfnm , 4V3 lbf‘ftl BRAKE LIGHT SWITCH PIVOT BOLT BRAKE LEVER SCREW \ PIVOT NUT 15-14 HYDRAULIC BRAKE Apply brake fluid to the new reservoir lDint Orringr % OrRlNG RESERVOIR JOlNT Install the master cylinder reservoir joint into the SNAP RING DUST @EH master cylinder and secure the Joint with a snap ring. Installthe dust covert Install and tighten the reservoir mounting bolt. Place the master cylinder assembly on the handle- bar. Align the end of the master cylinder with the punch mark on the handlebar. install the master cylinder holder With the "UP" mark facing up. Tighten the upper bolt first, then the lower bolt, Install the brake hose eyelet with the oil bolt and new sealing washers. Push the eyelet jomt against the stopper, then tighten the oil bolt to the specified torque. TORQUE: 34 N-m l3l5 kgf-m , 25 lbf‘ft) Connect the brake light swrtch wire connectors Fill the reservoir to the upper level and bleed the brake system lpage 15m. 15-15 HYDRAULIC BRAKE REAR MASTER CYLINDER Avoid Spilllng Huld on painted, plasllc or rubber parts Place a lag ovel mesa parls whenever the system lS Serviced Call/omia Iype only REMOVAL Drain the rear hydraulic system (page 15*4l. Remove the rear master cylinder reservoir mountr mg boll. Remove the brake hose oil bolt, sealing washers and brake hose, Loosen the rear master CVIlndel‘ mounting bolts Remove the main footpeg bracket socket bolts and main iootpeg bracketassembly, Release the 0: sensor wire from the wire guide behind the light step guard. Remove and discard the brake pedal joint cotter pin. Remove the joint pin. Remove the master cylinder mounting bolts, step guard and master cvllnder‘ DISASSEMBLY Remove the screw and reservoir hose joint from the master cylinderv 02 SENSOR, WIRE ‘/ SEALING WASHERS FOOTPEG BRACKET COTTER PIN BOLTS RESERVOIR JOINT 15-16 HYDRAULIC BRAKE Removethe booti SNAP RING Remove the snap ring from the master cylinder body using the special tool as Shown, TOOL: Snap ring pliers O791473A50000 or 079147323000I SNAP RING PLIERS Remuve the push rod, master piston and spring. SPRING PRIMARV CUP Clean the inside 0! the cylinder With brake Iluid, SECONDARY CUP @ If We ,7 I MASTER PISTON PUSH ROD ASSEMBLY |NSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder |,D. SERVICE LIMIT: 15325 mm (0.6270 Inl Measure the master cylinder piston OD, SERVICE LIMIT: 15,815 mm (0.6226 in) 15-17 HYDRAULIC BRAKE ~\'% g PRIMARY CUP MASTER PISTON #‘é mm: was Keep the prslon, cups sp/mg‘ snap mg and hour as a 591‘ do nal subslrlule mdrvlclual parts. When mslallmg Ihe cups, do no! allow me l/ps m [urn rnsrde Du! Be cerlam the snap Nng ls f/rm/y sealed m the groove MASTER CYLINDER ASSEMBLY \ RESERVOIR JOINT em) if O’RING SPRING SNAP RING/g EBOOT / / LOWER JOINT Coat all parts with clean brake fluid before assemr blyv Dip the piston in brake fluid. Install the spring t0 the primary cup, Install the spnng/prlmary cup and master piston assembly. Apply slllcone grease to the piston Contact area of the push rod. Install the push rod into the master cylinder. Install the snap rlng. TOOL: Snap ring pliers 07914-SA50000 or 0791473230001 Install the boot. 1N-m 10,15 kgf-m,1,1lbf~ft) RESERVOIR CAP DIAPHRAGM PLATE DIAPHRAGM 18 Nm I13 kgI-rn, 13Ibf~ftl SPRING PRIMARV CUP § £9 MASTER PISTON \ 92' SECONDARY CUP PUSH ROD ASSEMBLY SNAP RING 15-18 HYDRAULIC BRAKE Apply brake fluid to a newVOrring and install it onto the reservoirjointv Install the reservoir joint into the master cylinder. Apply a locking agent to the reservoir joint screw thread, Install and tighten the screw to the specified torque. TORQUE: 1N-m (015 kgf:m , 1.1 lbf-ftl II the push rod lS disassembled, adjust the push rod length as shown. After adjustment, tighten the lock nut to the speci- fied torque. TORQUE: 18 Nm (1.8 kgf~rn , 13 letl INSTALLATION Place the master cylinder onto the main footpeg bracket, install the step guard and master cylinder mounting bolts‘ Connect the brake pedal to the push rod lower joint. Install the joint pin and secure it with a new cotter pin. RESERVOIR JOlNT RESERVOIR JOINT LOCK NUT LOWER JOINT 75 i 1 mm 130 1 004 in) HYDRAULIC BRAKE Call/0mm type only Clamp the or sensorwire to the Wire guide behind the right step guard. Install the main footpeg bracket onto the lower bracket, tighten the socket bolts to the specified torque. TORQUE: 39 N-m (4.0 kgf~m , 29 lbf-ltl Tighten the master cylinder mounting bolts, Install the brake hose with the oil bolt and new sealr lng washers. Push the eyelet joint against the stopper, then tightr en the oil bolt to the Specified torque. TORQUE: 34 N»rn (3.5 kgfvm , 25 letl install and tighten the brake reservoir mounting bolt. Fill the reservoir to the upper level and bleed the brake system (page 154“, FRONT BRAKE CALIPER Avold spll/Ing Hold on palnted. plesnc. or rubber parls Place a rag Over these parts whenever the syslem ls servrced Do not use hlgh pressure alr or bring the nozzle I00 Close to the lnlel REMOVAL Drain the front brake hydraulic system (page 154i. Remove the oil bolt, sealing washers and brake hose eyeletloint. Remove the caliper mounting bolts, caliper and the brake pads (page lS-6l. DISASSEMBLY Install corrugated cardboard or soft wood sheet between the pistons. Apply small squirts of air pressure to the fluid inlet to remove the pistons. MOUNTING BOLTS OIL BOLT SEALING WASHERS FOOTF'EG BRACKET BOLTS 15—20 HYDRAULIC BRAKE Remove the four caliper assembly bolts and sepa- rate the callper halves. ASSEMBLY BOLTS Mark zne prslons Removethe following: CALIPER PISTONS :0 ensure Buffet! 7 Join! seals reassembly 7 Caliper piston A "Caliper plslon B JOINT SEAL Be careful no! la Push the dust seals and piston seals in and Iill them damage Ihe piston out, S/ldmg sur/ace PISTON SEAL Clean the seal grooves with clean brake fluld. DUST SEAL INSPECTION Check the caliper cylinder for scoring or other damage Measure the caliper cylinder LD. SERVICE LIMITS: A: 34.02 mm 11.339 in) B: 30.29 mm (1.193 inl 15-21 HYDRAULIC BRAKE Check the caliper plstons for scratches, scorlng or other damage Measure the caliper piston 0J3, . SERVICE LIMITS: A: 33.794 mm l1,3305 in) B: 30.074 mm “.1340 in) c / ‘ ASSEMBLY . PAD SPRINGW 6 N-m (0'6 kgf-m , 4.3 lbffl) BRAKE PADS fl 1 c 18 Nm l1.8 kgf-m,13lbf-fl) 23 N~m (2.3 kglAm,17letl Coat the new piston seals with‘elean brake lluid. a3? PISTON SEAL CALIPER ‘ Coat the new dust seals WIth silicone grease. ~’ , “ pISTON I Install the piston and dust seal into the groove of the caliper body. Coat the caliper pistons with clean brake fluid and Install them into the caliper cylinder with their openA ing ends toward the pad. 15-22 HYDRAULIC BRAKE Install the new joint seal into the fluid passage on cahpen Assemble the caliper halves and install and tighten the new caliper assembly bolts to the specified torque. TORQUE: 23 N~m 12.3 kgf‘m, 17 lbflft) INSTALLATION Install the brake pads and caliper onto the fork leg 1page15-61. Install and tighten the new caliper mounting bolts to the specified torque. TORQUE: 3O N-m 13.1 kgf‘rn , 22 lbf-fll Install the brake hose eyelet to the caliper body with two new sealing washers and oil bolt. Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque, TORQUE: 34 N-m13.5 kgf‘m , 25 lbflftl Fill and bleed the front brake hydraulic system 1page15-4l. ~fl ASSEMBLY BOLTS OIL BOLT my SEALING WASHERS ~--! ,/ 1 1‘: j / BRAKE CALIPER STOPPER 15-23 HYDRAULIC BRAKE REAR BRAKE CALIPER ,fifis'aou . REMOVAL \ . Drain the rear brake hydraullc system (page 15-5). Avuld spllllngHuld Remove the oil bolt, sealing washers and brake unpammd.P/ESIIC hose eyelet joint. or Iubberparls i Place a rag over » ' ’ . Ihese parts ‘ , , ‘ “gig: whenevellhe ‘ . . ' _ ~39” system ls sen/load : O , x \ SEAL‘ING WASHERS ’ . Remove the callper bracket bolts and the brake BRAKE CAMPER . pads (page 15-8). Pivot the callper up and remove it, C O DISASSEMBLY COLLAR BOOT Remove the pad spring, collar and boot from the V caliperbodyr . . PAD SPRING Place a shop towel over the plstont . Do not use hlgh Fosltion the caliper body with the plston down and , , pressure an or apply small squirts of air pressure to the fluld inlet ‘ ’ brmg me nozzle to remove the piston. (00 close (0 the ”7/6! 15-24 HYDRAULIC BRAKE Be tarem/nol [0 Push Ihe dust seal and pxston seal In and lift them PISTON SEAL damage the piston out. sliding sur/ace Clean the seal grooves with clean brake fluid. DUST SEAL INSPECTION Check the caiiper Cylinder for scoring or other damage. Measure the caliper cyIinder |.D. SERVICE LIMIT: 3824 mm 11.506 in) Check the caliper pistons for scratches, scoring or other damage. Measure the caliper piston 0D. SERVICE LIMIT: 38,090 mm (14996171! ASSEMBLY \ PAD SPRING 99% PISTON SEAL \ 92' BRAKE PADS DUSTSEAL CALIPER PISTON BOOT COLLAR / 6 N~m {0.6 kglm , 4 3 Ith) / 27 Nm (2V8 kgf~m , 20 lbf-fl) 15-25 . HYDRAULIC BRAKE Coat the new plston seal with clean brake fluid. Coat the new dust seal with Sllicone grease. DUST SEAL . install the piston seal and dust seal into the groove of the caliper body. Coat the caliper piston with clean brake fluid and Install it into the caliper cylinder With its opening end toward the pad. PISTON SEAL % CALIPER PISTON lnstallthe pad springinto the caliper body. PAD SPRING BOOT . If the caliper and bracket pin boots are hard or deteriorated, replace them with new ones. Apply silicone grease to the inside ol the bracket / . pin bDot, Install the bracket pin boot and collar into the COLLAR . caliper. C Install the pad retainer into the bracket. INSTALLATION Apply silicone grease to the caliper pin and install the caliper onto the bracket. install the brake pads (page 15-8l. Install and tighten the caliper bracket bolt to the speciliedtorque, TORQUE: 22 N‘m (2.2 kgf~m ,16lbf~ft) Install the brake hose eyelet to the caliper body with two new sealing washers and oil bolt. Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque. TORQUE: 34 N-m (3.5 kgl~m , 25 Ibleft) Fill and bleed the rear brake hydraulic system (page i5-4l. ye? 15-26 HYDRAULIC BRAKE BRAKE PEDAL Ca/Ilorma type only» REMOVAL Release the 02 sensor WIre from the WIre guide behind the rIghrstep guard. Remove the main footpeg bracket mounting bolts and bracket assemblyfrom the lower bracket. Remove and dIscard the brake pedal joint cotter pin. Remove thechInt pin. Unhook the return sprIng and remove the brake lIght swuch from the step holderv Unhook the brake pedaI return spring. Remove the footpeg mounting bolt, footpeg, brake pedaI and wave washer. O; SENSOR WIRE RIGHT FOOTPEG BRACKET BOLTS BOLT COTTER PIN FOOTPEG BAR j :WIC: 7 RETURN SPRING BRAKE PEDAL INSTALLATION @COTTEFI PIN Except California type: JOINT PIN / 5 \ ( W77 \ \ ~p 44 N-m (4.5 kgf-m , 33 lbfrft) / \ I \ I . '9 . \Q . \ / / <3? a WAVE WASHER MAIN FOOTPEG IZ N-m 11.2 kgf~m ,9 Ibf-ft) BRAKE PEDAL SWITCH SPRING BRAKE LIGHT SWITCH 39 N-m (4.0 kgf-m , 29 lbIrft) 15-27 HYDRAULIC BRAKE WAVE WASHER MAIN FOOTPEG Except California type: JOINT PIN \ 5 £03 44 N-m (4‘5 kgf-m , 33 mm) 12 N-m (1.2 kngm,91bf-ftl BRAKE PEDAL Apply grease to the sliding surface of the brake pedal and footpeg. Assemble the brake pedal, footpeg and wave washer, Install a new lootpeg mounting bolt and tighten it to the specified torque. TORQUE: 44 Nvm14.5 kgf-m , 33 Ithl Hook the brake pedal return spring. Install the brake light switch and hook the switch spring. Connect the brake pedal to the push rod lower joint. Install the Jornt pin and secure It with a new cotter pm. 0,» SENSOR WIRE SWITCH SPRING BRAKE LIGHTSWITCH 39 Nm 14.0 kgffn , 29 lbf‘ft) BRAKE PEDAL 4;]; FOOTPEG WAVE WASHER v—fim \ \ lflBOLT @COTTER PIN FOOTPEG BAR ~a ~— _ I _ /\\\ SWITCH x SPRING RETURN SPRING BRAKE PEDAL 15-28 HYDRAULIC BRAKE Call/omlafyoe Clamp the Qt sensor wire to the wire guide behind O~SENSOR WIRE only the nght step guard, ‘ . Install the rlght maln lootpeg bracket assembly onto the lower bracket. Install and tlghten the right main foolpeg bracket socket bolts to the specified torque, TORQUE: 39 Nm (4‘0 kgfvm , 29 letl RIGHT FOOTPEG BRACKET 15-29 16. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM 16-0 CHARGING SYSTEM INSPECTION 15-6 SERVICE INFORMATION 16-1 ALTERNATOR CHARGING COIL 16-7 TROUBLESHOOTING 16-3 REGULATOR/RECTIFIER 16-7 BATTERY 16-5 SERVICE INFORMATION GENERAL AWARNING - The battery gives 0" explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging, 0 The battery contains sulluric acid (electrolyte), Contact with skin or eyes may cause severe burns. Wear protective Clothing and a face shield. -|f electrolyte gets on your skin, flush with water. —If electrolyte gets in your eyes, flush with waterfor at least 15 minutes and call a physician immediately, Electrolyte is poisonous. mli swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physiman immediately. 0 Always turn off the ignition switch before disconnecting any electrical component. ~Sorne electrical components may be damaged it terminals or connectors are connected or disconnected while the ignition switch is ON and current is present, 0 For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life, charge the stored battery every two weeks. 0 For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal. I The maintenance free battery must be replaced when it reaches the end of its seNice life. oThe battery can be damaged of overcharged or undercharged, or of left to discharge for long period. These same conditions contribute to shortening the “life span” ofthe battery. Even under normal use, the perlormance of the battery deteriorates after 2*3 years. 0 Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and m eventually die out. For this reason, the charging system is olten suspected as the problem, Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. 0 Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the motorcycle. 16-1 BATTERY/CHARGING SYSTEM - The battery will selfrdtscharge when the motorcycle is not In use. For lhIS reason, charge the battery every two weeks to prevent sulfation from occurring - When checking the charging system, always follow the steps in the troubleshooting flow charttpage16-3l. 0 For battery charging, do not exceed the charging current and time specufied on the battery. Use of excessive current or charglng tIme may damage the battery. BATTERV TESTING Refer to the lnstructlon oI the Operation Manual Ior the recommended battery testerv The recommended battery tester puts a "load“ on the battery so that the actual battery condition of the load can be measured. Recommended battery tester BMVZIO-AH, IBM-210 or BATI’ERY MATE Or eqtnvalent SPECIFICATIONS ITEM SPECIFICATIONS Battery .CapaCIty 12V78.6 Ah "W7 Current leakage , 0.2 mA max. Voltage HOT/68°F) Full Charged 13.0_* 132 V W Needs charging Below 123 V Charging Current fittermal 0‘9 A/Smtflh 7”,, Quick 40 N0. h Alternator Capacity 0.421 kW/5,000 rpm "W Charging coil reststancet20°C/58°Fl 0 1'11) 53 16-2 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK O Incorrect Remove the battery lpage 1675lt ———> 0 Faulty battery Check the banew condition using the recomr mended battery tester. . RECOMMENDED BATTERV TESTER: BM-ZlOrAl-‘l, BM-Z'IO or BATTERV MATE or equivalent Correct . Incorrect t . V Install the battery lpage 1575). Disconnect the regulator/rectlfier connector and Check the battery current leakage (Leak test: recheck the battery current leakage, page 164i, Correct Incorrect . Correct 0 shorted wire harness - Faulty ignition switch ——“> I Faulty regulator/rectifier O Incorrect . V Check the alternator charging cotl (page 16-7lv _> . Faulty charglng coll STANDARD: 01 *10 E2 OTC/68°F) 0 Correct . Corr t Measure and record the battery voltage using a —§-C—> UFaulty battery digital multimeter (page 16-5lv Startthe engine, Measure the charging voltage lpage 15*6l. Compare the measurement to result of the following calculation. 0 STANDARD: Measured battery voltage“iMalured charging voltage/15.5 v . Incorrect O 16-3 O BATTERY/CHARGING SYSTEM Incorrect . V Incorre I . . . V Check me vonage and resuslance at the reguwaror/ —~C—— - Open clrculk In related wrre recrifier canneclor (page 168), ' Loose or poor Contacts of related rerminal . Shoned wire harness . Correct ——-————> I Faulty regulator/rectifier I I I I I I I I 16-4 BATTERY/CHARGING SYSTEM BATTERY Always mm the Ignlllon swrlcn OFF be/ore removmg me Dallely. Connect Ihe pOSllH/e terminal first and men Ihe negative cable Turn powel ON/OFF a! we charger. no! a! ”is battery terminal REMOVAL/INSTALLATION Remove the seat (page 2-2l. Remove the battery holder band. Disconnect the negative cable and then the positive cable, and remove the battery. Install the battery in the reverse Order of removal with the properwiring as shown. After installing the battery, coat the terminals with clean grease. VOLTAGE INSPECTION Measure the battery voltage using a digital multimeter. VOLTAGE: Fully charged: 110‘ 13.2 V Under charged: Below 12.3 V TOOL: Digital multimeter Commercially available BATTERY CHARGING Remove the battery (see abovei. Connect the charger positive (+l cable to the battery positive 1+) terminal. Connect the charger negative (—l cable to the battery negative (7, terminal. ' Quick-charging should only be done in an emergency; slow charging is preferred. 0 For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery. BATTERY NEGATIVE TERMINAL HOLDER BAND POSITIVE TERMINAL BATTERY BATTERY CHARGER BATTERY 1 6-5 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION Do not disconnect the battery or any cable in 1/79 charging system erhOuI first swrtchmg or! the ignition swrtch Failure to tor/ow this precaution can damage the (ester or electrical components CURRENT LEAKAGE INSPECTION Turn the ignition switch off and disconnect the negative battery cable from the battery Connect the ammeter I+l probe to the ground cable and the ammeter I ,) probe to the battery I “l terminal, With the ignition switch off, check for current leakage. o 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. 0 While measuring current, do not turn the ignition on. A sudden surge of current may blow out the fuse in the tester. SPECIFIED CURRENT LEAKAGE: 0.2 mA max. If current leakage exceeds the specified value, a shorted CIrCuIt is likely. Locate the short by disconnecting connections one by one and measuring the current, CHARGING VOLTAGE INSPECTION Be sure the battery is in good condition before performing this test. Warm up the engine to normal operating tempera- ture. Stop the engine, and connect the multimeter as shown. -To prevent a short, make absolutely certain which are the positive and negative terminals or cable. Restartthe engine, With the headlight on Hi beam, measure the voltage on the multimeter when the engine runs at 5,000 rpm. Standard: Measured battery voltage (page 16-5) < Measured charging voltage (see above) < 15.5 V at 5,000 rpm NEGATIVE I *l CABLE BATTERV 16-6 ALTERNATOR CHARGING COIL Ills rial necessary I0 IBITIOVE [he stator call I0 make This rest INSPECTION Remove the fuel tank rear bracket and ECM cover (page 5781). Disconnect the alternator 3P lNaturall connector. Check the re5istance between all three Yellow terminalsv STANDARD: 0.1 m 10 £2 lat 20”C/58°Fl Check for continuity between all three Yellow terminals and Ground. There should be no continuity. If readings are far beyond the standard, or if any wire has continuity to ground, replace the alternar tor Stator. Refer to section 10 (or stator removal. REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the rear cowl (page 2-2]. Remove the fuel tank rear bracket and ECM cover lpage 5-89l Disconnect the regulator/rectifier connectors, and check it Ior loose contact or corroded terminalsl If the regulated voltage reading lsee page 1676l is out of the specification, measure the voltage between connector terminals lwire harness sidel as follows: BATTERY/CHARGING SYSTEM 3P lNATURALl CONNECTOR 4P lNATUFlALl CONNECTOR Item ‘ Terminal Specification Tiattery Red/White 1+) Battery voltage icharging line i and ground (,) should register Charging coul l Yellow and 0.1410 Ll line l Yellow lat 20“C/68“Fl V Green and Continuity Gr°”"d""e ground should exist 3PlNATURALl CONNECTOR .J BATTERY/CHARGING SYSTEM ll all components of the charging system are 3P(NATURAL) CONNECTOR normal and there are no loose connections at the regulator/rectifier connectors, replace the regular . tor/rectifier unit. REMOVAL/INSTALLATION Disconnect the alternator 3P lNaturall connector. Disconnect the alternator 4P1Naturallconnector. 0 Remove the regulator/rectifier unit mounting SH . bolts and regulator/rectifier, Install the regulator/rectifier unit in the reverse order of removal. 0 O O O O O O 1 6-8 17. IGNITION SYSTEM 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 if terminals or connectors are connected or disconnected while the Ignition swttch :5 ON and current is present. oWhen serVIcing the ignition system, always follow the steps in the troubleshooting sequence on page 17-3. oThis motorcycle’s lgnltion Control Module llCMl is built Into the Engine Control Module (ECM). oThe ignition tIming does not normally need to be adjusted since the ECM is lactory preset. .The ECM may be damaged If dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the module. Always turn off the ignitIon switch belore servicing. oA faulty Ignition system is often related to poor connections. Check those connections before proceeding. Make sure the battery is adequately charged. Using the starter motor with a weak battery results In a slower engine cranking speed as well as no spark atthe spark plug. 0 Use spark plug of the correct heat 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 integrated, is adopted in this motorcycle. 0 Refer to section 5 for Throttle Position lTP) sensor, cam pulse generator and ECM inspection. SPECIFICATIONS ITEM 1 SPECIFICATIONS "sparkbiug' l srand‘ard ' ‘ ' |UH27D(DENSOl ‘ anoptgnai g IUHZADlDENSOl ,Epao 9'29 gap , ilgniitiojflcoil peak voltage 7 iflgjjtion p se generator peak voltage , 0.7 V minimum > ignition timing (”F” mark) 15" BTDC at Idle 17-1 IGNITION SYSTEM TORQUE VALUES Timmg hole cap 18 N‘m 11.3 kgf-m,13|bf-fl) Apply grease to me threads . Spark plug 12 N‘m 11.2 kgf-m , 9 lbf-fll Igmtlon pulse generator rotor special boll 59 N-m 15.0 kgf-m , 43 lbf—fl) TOOLS Peak voltage (ester 1U.$.A, onlyl or Peak Voltage adaptor 07HGJ70020100 with . Commercially available digllal multimeter (impedance 10 M51 /DCV minmuml O O O O O O O O 17-2 IGNITION SYSTEM TROUBLESHOOTING 0 Inspect the followtng before diagnosing the system. W Faulty spark plug , Loose spark plug cap or spark plug wire connection "Water got into the direct ignition coil (leaking the ignition coil secondary voltage) ' If there is no spark at either cylinder, temporarily exchange the direct ignition coil with the other good one and perform the spark test. If there is spark, the exchanged direct ignition coil is faulty. "'Initial voltage" of the ignition primary coil is the battery voltage with the ignition switch 0N and engine stop switch at RUN (The engine is not cranked by the starter motor). No spark at all plugs » Unusual condition Probable cause (Check in numerical order) 77 lgnition can No initial voltage with ignition and (. Faulty engine stop switch. primary volt- engine stop switches ON. (Other eiectri- 2.An open circuit in Black/White wire between the direct age cal components are normal) ignition coil and engine stop switch, 5" Loose or poor connect of the direct ignition coil primary wire terminal, or an open circuit in primary coil (Check at the ECM connector). Faulty ECM (when the initial voltage is normal while disconnecting ECM connector) Incorrect peak voltage adaptor connections. Undercharged battery. No voltage between the Black/White l') and Body ground (a) at the ECM multirconnector or loosen ECM i connection. An open circuit or loose connection in Green wire. An open circuit or loose connection in Blue/Black, Yellow/White, Red/Blue and Red/Yellow wires between i the direct ignition coils and ECM. .Short circuit in ignition primary coil Faulty side stand switch or neutral switch. ,An open circuit or loose connection in No, 7 related circuit wires. 0 Side stand switch line: Green/White wire ' Neutral switch line: Light Green and Light Green/Red Wire Faulty ignition pulse generator (measure the peak voltage). 10. Faulty ECM (when above Not179 are normal). Initial voltage is normal, but no peak .Faulty peak voltage adaptor connections. voltage while cranking the engine 2. Faulty peak voltage adaptor. 3. Faulty ECM (when above No. 1, 2 are normal), Initial voltage is normal, but peak 1.The multimeterimpedance is too low; below 10 Mil/DCV voltage is lower than standard value. 2. Cra nking speed is too low (battery underacharged). 3.The sampling timing of the tester and measured pulse were not synchronized (system is normal if measured voltage is over the standard voltage at least once). , 4.Faulty ECM (when above No. 1a3 are normal). 7v Initial and peak voltage are normal, but 1. Faulty spark plug or leaking ignition coil secondary P initial voltage is normal, but it drops down to 274 V while cranking the engine, we l-"P 7107 an 5° does not spark, ‘ current ampere. m . _ .. 2. Faulty ignition coil (5). Ignition ‘ Peak voltage is lower than standard ) 1.The multimeter impedance is too low; below 10 Mil/DCV. pulse gener- value. 2. Cranking speed is too low (battery under charged). ator 3tThe sampling timing of the tester and measured pulse i i were not synchronized (system is normal it measured voltage is over the standard voltage at least once). i 4. Faulty ECM (when above No.1i3 are normal) No peak voltage. 1.Faulty peak voltage adaptor. ‘ 2. Faulty ignition pulse generator. 17-3 IGNITION SYSTEM IGNITION SYSTEM INSPECTION DIGITAL MULTIMETER . If there is no spark at any plug, check all connece tions for loose or poor contact before measuring each peak voltage, 0 Use recommended digital multimeter or commer- cially available digital multimeter With an impedance of 10 M ;1/DCV minimum. oThe display value differs depending upon the internal impedance of the multimeter. 0 If using peak voltage tester iU.S.A. onlyi, follow the manufacturer's instructions. Connect the peak voltage tester or peak voltage PEAK VOLTAGE ADAPTOR adaptor to the digital multimeter. TOOLS: 0 Peak Voltage tester (U.S.A. only) or Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter (impedance 10 Mil/DOV minimum) IGNITION COIL PRIMARY PEAK VOLTAGE -Check all system connections belore inspection. Ii the system is disconnected, incorrect peak voltage might be measured. oCheck cylinder compression and check that the spark plugs are installed correctly. Disconnect the direct ignition coils from the spark plug (page 376). Connect the direct ignition coil 2P connectors to the GOOD KNOWN dlrect ignition coil. SPARK PLUG Shili the transmission into neutral. Connect a known good spark plugs to the direct ignition coils and ground the spark plugs to the cylinder head as done in a spark test. . 17-4 IGNITION SYSTEM With the ignition coil subrharness 9P lBlackl 9? (BLACK) CONNECTOR connector connected, connect the peak voltage _ adaptor or lmrie tester to the 9P (Blackl connector 0 primary wiretermlnal and ground. CONNECTION: No.1 coil: Blue/Black terminal (+lmBody ground l ‘) N0. 2coil: . Yellow/White terminal lw—l *Body ground ‘7) No. 3 coil: Red/Blue terminal l+lmBody ground l ’l No. 4120“: Red/Yellow terminal l+)*Body ground l’l AVOid Iouchlng the Turn the ignition switch "ON” and engine stop . spalk plugs and switch to "RUN". Iesler probes Io Check for initial voltage at this time. prevent electric The battery voltage should be measured. shock If the initial voltage cannot be measured, check the power supply circuit lrefer to the troubleshooting. page 1773i . Crank the engine with the starter motor and read ignlllOl’l coil primary peak voltage. PEAK VOLTAGE: 100 V minimum If the peak voltage is abnormal, check for an open . circuit or poor connection in Vellow/Blue and Blue/ Yellow wires. ll no defects are found in the harness, refer to the troubleshooting chart on page 1773. EClVl IGNITION PULSE GENERATOR PEAK VOLTAGE O OCheck all system connections before inspection. if the system is disconnected, incorrect peak voltage might be measured, OCheck cylinder compression and check that the spark plugs are installed correctly. 5 Remove the fuel tank rear bracket and ECM cover (page 58“, 22P ILIGHT GRAVl CONNECTOR Disconnect the 22F (Light grayl connector from the ECM. I D D 17-5 IGNITION SYSTEM Avoid touching the spark plugs and Iesler probes to prevent elect/IE shock Connect the peak voltage tester or peak voltage adaptor probes to the connector terminal of the wire harness side and ground. TOOLS: Peak voltage tester (U.S.A. only) or Peak voltage adaptor 07HGJ~0020100 with commercially available tal multimeter (impedance 10 M :2 /DCV minimum) CONNECTION: Vellow terminal l+lAGround l 'l Crank the engine Wlth the starter motor and read the peak voltage. PEAK VOLTAGE: 0.7 V minimum If the peak voltage measured at ECM multin connector lS abnormal, measure the peak voltage at the ignition pulse generator connector. Open and support the front end of fuel tank (page 3-4). Disconnect the ignition pulse generator 2P (Red) connector and connect the tester probes to the terminal lVellow and White/Yellow). in the same manner as at the ECM connector, measure the peak voltage and compare it to the voltage measured at the ECM connector. -ir the peak voltage measured at the ECM is abnormal and the one measured at the ignition pulse generator is normal, the wire harness has an open circuit or loose connection. 'll both peak voltages measure are abnormal, check each item in the troubleshooting chart. If all items are normal, the ignition pulse generator is faulty. See following steps for ignition pulse generator replacement. IGNITION PULSE GENERATOR REMOVAL Open and support the lront end of fuel tank [page 34). Disconnect the ignition pulse generator 2P (Fledl connector. PEAK VOLTAGE ADAPTOR ZZP (LIGHT GRAY) CONNECTOR 2PlRED) CONNECTOR PEAK VOLTAGE ADAPTOR 2PlHEDl CONNECTOR 17-6 IGNITION SYSTEM Remove the right crankcase cover lpage 973l. Remove the wire grommet from the cover. Remove the bolts and ignition pulse generator. If the engine is our Shift the transmisslon into 6th gear and apply rear “IGWNIT‘IONx of the rrame, brake, remove the Remove the ignition pulse generator rotor bolt. alternator cover (page 10-2) and hold the llywheel wrm Ihe flywheel holder {07725 0040000l then remove the boil. INSTALLATION Install the ignition pulse generator rotor by aligning the wide groove with the wide teeth of the crank- shaft. Apply Oil to the ignition pulse generator rotor bolt threads, then install the washer and rotor bolt. IGNITION SYSTEM ll the englne ls oul Shift the transmission into 6th gear and applv real or name remove brake. the allernalor Tighten the lgnltion pulse generator rotor bolt to cover/page l0-2) the specilled torque C and hold the l/ywneel Wllh lhe TORQUE: 59 NM (6.0 kgf~m , 43 lbf-ft) llywheel holder (0772570040000), men l‘lghten the bell . Install the ignition pulse generator into the cover. I Apply sealant to the wire grommet, then install lt into the groove of the cover. Install and tighten the ignition pulse generator bolts. C 0 Install the right crankcase cover lpage 9-17). Route the ignition pulse generator wire properly, Connect the 2P IFIed) Connector. . Install the removed parts In the reverse order of removal. 0 IGNITION TIMING . Warm up the engine. Stop the englne and remove the timing hole cap. 0 O 17-8 IGNiTlON SYSTEM Headlne Connect the timing light to the No. 1 spark plug i lliSfIL/Ci‘lons NJ! Wifel timinglight operation TIMING LiGHT Start the engine and let it idle. _ INDEX‘M'ARK IDLE SPEED: 1,200 1 100 rpm The ignition timing is correct if the “F" mark aligns with the index mark on the ignition pulse generator rotorcover. Increase the engine speed by turning the throttle stop screw and make sure the “F” mark begins to move counterciockwise when the engine speed at approximately 1,500 rpm, Check the Orring is in good Condition, replace it necessary. Apply grease to the timing hole cap and install the O-ring and timing hole cap. Tighten the timing hole cap to the specified torque. TORQUE: 18 Nm l1.8 kgf-m,13lbfrfti ' 18. ELECTRIC STARTER SYSTEM DIAGRAM 18-0 STARTER MOTOR 18-4 . SERVICE INFORMATION 18-1 STARTER RELAY SWITCH 18-10 TROUBLESHOOTING 18-2 DIODE 18-11 0 SERVICE INFORMATION GENERAL - The sIarter motor can be removed with the engine in the frame. 0 For the starter drIve and dnven gear removal/installation, see section 10. ' SPECIFICATION Unit: mm mm ITEM ‘ STANDARD SERVICE LIMIT SlarterInotor brush length 1iV0/713I010A77051) I I 4.5I0.13) . O 5 I O O 0 18-1 ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 0 Check for a blown main or sub fuses before servicing. . Make sure the battery IS fully charged and in good condition. Check the starter relay switch operation. Vou should hear the relay "CLICK” when the starter swrtch button is depressed. "CLlCK”heard “CLlCK”not heard Disconnect the starter relay switch connector, and check the relay coil ground wire lines as below for continuity: LGreen/Red terminalrclutoh sWitch diode- neutral Switch line (with the transmission In neutral and clutch lever released)‘ 2.Green/Red terminal/clutch switchrside stand swrtch line lin any gear except neutral, and with the clutch lever pulled in and the side stand up. Connect the starter relay switch connector. With the ignition switch ON and the starter switch pushed, measure the starter relay voltage at the starter switch connector [between Yellow/ Red Hi and ground tilt Battery voltage registered Check the starter relay switch operation. Abnormal Abnormal No voltage Normal Apply battery voltage to the starter motor directly and check the operation. Normal Abnormal 0 Poorly connected starter motorcable - Faulty starter relay switch (page 18~10l . Faulty starter motor lpage1874l - Faulty neutral switch lpage 19-20l - Faulty neutral diode - Faulty clutch switch 0 Faulty clutch/side stand diode 0 Faulty side stand switch - Loose or poor Contact connector 0 Open circuit in wire harness 0 Faulty ignition swrtch - Faulty starter switch I Blown out main or sub-fuse - Loose or poor contact oi connector 0 Open circuit in wrre harness 0 Loose or poor contact starter relay switch connector ————————~—> - Faulty starter relay switch 18—2 ELECTRIC STARTER The starter motor turns when the transmissuon is in neutral, but does not turn with the transmiSSIon ll’l any position except neutral, with the Side Stand up and the clutch lever pulled in, O . Normal Check the clutch swttcn operation. —-—‘> I Faulty clutch SWllCh Normal . Normal , Check rhe Slde stand switch. — ~ Faultv clutch swllch Normal I ___—_._» Open Circuit in wire harness - Loose or poor contact connector Starter motor turns engine slowly . . Low battery voltage . Poorly connected battery terminal cable . Poorly connected starter motor cable a Faulty starter motor I Poor connected battery ground cable Starter motor turns, but engine does not turn . 0 Starter motor is running backwards *Case assembled Improperly , Terminals connected improperly O Faulty starter clutch o Damaged or faulty starter drive gear . Starter relay switch "Clicks”, but engine does not turn over c Crankshaft does not turn due to engine problems 18-3 ELECTRlC STARTER REMOVAL . Open and support the front end of fuel tank (page 3-4l. Drain the coolant lpage 57M. Remove the throttle body lpage 5-60). Remove the thermostat housing (page 6-7l. C With the ignitlon switch OFF, remove the negative ' cable at the batterv, Be care/ulnar 10 Remove the nut and the starter motor cable from damage the water the starter motorl hose Remove the starter motor mounting bolts and . ground cable Pull the starter motorout of the crankcase. C DISASSEMBLY Record the Remove the lollowing: local/0n and "Starter motor case bolts l number of shlms 0 CASE BOLTS R93’ 90"“ assemb'v SEAL RING REAR COVER 0 * Seal rung * Shims C C 18-4 ELECTRIC STARTER Remove‘he'o'bwmgi . LEAL RING ARMATURE FRONT COVER 7 Front cover assembly . — Seal ring * Lock washer . Insulated washer 7 Shims *Armature O INSULATEDWASHER LOCKWASHER O INSPECTION Check for continuity between the cable terminal and the brush wire (the indigo colored wire or the insulated brush holderl. There should be continuity. . 0 Check for continuity between the motor case and the cable terminal. There should be no continuity. 1. O . Inspect the brushes for damage and measure the brush length. SERVICE LIMIT: 4.5 mm (0.18 in) O O 18-5 ELECTRlC STARTER Check the bushlng of the rear cover for wear or BUSHING damage. I 0 Check Ihe from cover on seal for langue or other OIL SEAL NEEDLE BEARING I damage, Check the needle bearing for damage. 0 O Donotusa emery lnspeclthe commutator bars for discoloration. ARMATURE orsandpape/On Ears discolored in pairs lndicate grounded mecommulalor armature coils, m Wthh case the starter motor must be replaced‘ . 0 Check lor continultv between individual come mulalor bars;(here should be continuity. . C C 18-6 ELECTRIC STARTER Also, check for Continuity between individuat commutator bars and the armature shaft: there . shoutd be no continuity, . C » , Remove the followmg /NUT :wlagher O/WASHER "Insulators [INSULATORS *0er 7 Brush holder assembly . *Brush/{erminal BRUSH HOLDER ASSEMBLY I ASSEMBLY ARMATURE I INSULATED WASHER OIL SEAL FRONT COVER . SEAL RING REAR COVER BRUSH HOLDER . t BRUSH SEAL RING MOTOR CASE 18-7 ELECTRIC STARTER Set the brushes on the brush holderr Allgn [he Iermmal Install the brush holder onto the motor case huldel plate [7055 With the groove 0/ . the mom! case C lnslall the Install the following: . Insulators properly 7 04mg as noted durlng Insulators removal *Washe! , Nut 0 I Installlhe armatureinthe motorcase. is?“ RING ARMATURE FRONTCOVEH lristall the slums Install the shims on the armature shaft. properly as noted . durlng removal. Install the insulated washer and lock washer on the armature shaft. Install the seal ring onto the motor case I INSULATED WASHER LOCK WASHER lnstallthe seal ring onthe motor case. SEAL RING REAR COVER . Install the shims lnstall the shims on the armature shaft pruperly as noted durlng removal Assemble the motor case and rear cover, aligning the brush holder boss with the groove in the rear covet C SHIMS C 18-8 ELECTRlC STARTER lnstall the front covervto the motor case. lNDEX LlNES Make sure the Index IlneS are aligned. Install and tighten the case bolts securely, INSTALLATION Apply clean engine oil to the new O-ring. Install a new Orring onto the starter motor boss. Install the starter motor Into the crankcase. Route the starter motor cable and ground cable‘ “ 3n- RTER wok Be careruInov to Install the starter motor cables, then tighten the ‘ damage the water mounting bolts and terminal nut securely. nose ELECTRIC STARTER Install a new O-ring Into the thermostat housmg groove, Install the thermostat housing to the cylinder head. Install and lighten the mounting bolts. Install the following: "Thermostat housing/thermostat (page 677l, *Throttle body lpage 5763l. Fill the system with the recommended coolant (page 6-4). STARTER RELAY SWITCH OPERATION INSPECTION Remove the seat lpage 272). Shift the transmission into neutral. Turn the ignition switch ON and depress the starter switch button. The coil is normal it the starter relay switch clicks. II the switch ”CLICK” is not heard, inspect the relay switch using the procedure below. GROUND LINE INSPECTION Disconnect the relay connector. Check for continuity between the Green/Red wire and ground. If there is continuity when the transmission is in neutral or when the clutch is disengaged and the side stand switch is up, the ground circuit is normal iin neutral, there is a slight resistance due to the diodel, RELAV SWITCH CONNECTOR 18-10 ELECTRIC STARTER DIODE VOLTAGE INSPECTION Connect the starter relay switch connector. Shlftthetl’al’lsmlssion into neutral, Measure the voltage between the Yellow/Red wire 1") and ground at the starter relay Switch connector. There should be battery voltage only when the starter switch button is depressed with the ignition swltch is ON, CONTINUITY INSPECTION Disconnect the starter relay connector and cables Connect an ohmmeter to the starter relay switch large terminals, Connect a fully charged 12V battery to the starter relay swnch connector terminals lYellow/Red and Green/Refill. Check {or continuity between the starter relay switch terminals There should be continuity while 12V battew is connected to the starter relay switch connector terminals and should be no continuity when the battery IS disconnected. REMOVAL Remove the seat (page 2-2). Open the fuse box and remove the diode. INSPECTION Check for continuity with an ohmrneter. Normal direction: Continuity Reverse direction: N0 continuity INSTALLATION Install the diode in the reverse order of removal. FUSE BOX l Am C C B B DIODE A 18-11 19. LIGHTS/METERS/SWITCHES SYSTEM LOCATION 19-0 COOLING FAN MOTOR SWITCH 19-14 SERVICE INFORMATION 19-1 OIL PRESSURE SWITCH 19-15 TROUBLESHOOTING 19-3 FUEL RESERVE SENSOR 19~17 HEADLIGHT 19-4 IGNITION SWITCH 19-17 TURN SIGNAL 19-6 HANDLEBAR SWITCHES 19-18 TAIL/BRAKE LIGHT 19<7 BRAKE LIGHT SWITCH 19-19 LICENSE LIGHT 19-7 CLUTCH SWITCH 19-20 COMBINATION METER 19~8 NEUTRAL SWITCH 19—20 SPEEDOMETER/VEHICLE SPEED SIDE STAND SWITCH 19-20 SENSOR 19~10 HORN 19-22 TACHOMETER 19<12 TURN SIGNAL RELAV 19-22 COOLANT TEMPERATURE GAUGE/ SENSOR 19:13 SERVICE INFORMATION GENERAL A halogen headlight bulb becomes Very not while the headlight is ON, and remains hot fora while after it is turned OFF, Be sure to let it cool down before servicing, - Use an electric heating element to heat the water/coolant mixture {or the thermosensor inspection. Keep all flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection. 0 Note the following when replacing the halogen headlight bulb. *Wear clean gloves while repiacmg the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. vlf you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. *Be sure to install the dust cover after replacing the bulb. I Check the battery condition before performing any inspection that requires proper battery voltage, o A continuity test can be made thh the switches installed on the motorcycle. 0 The followmg color codes are used throughout this section. BuzBlue G=Green Lg=Light Green R=Red Bl:BIack Gr=G ray 0=Orange W=White Br:Brown Lb=Light Blue P=Pink VzVellow 19-1 LlGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Thins "m l'HeadIighfi l Hi / 12V755W77 2 1 Lo 12v-55w (”Brake/tail light 12V-Z‘i/5W X 2 Front turngignal/runntng light 12v-32/3 cp 123/33 Whiz, Rearturnsignal light W 12V~21W 4‘2 L‘i‘cenceligjjt W A, izyflv, i nlnstrumentlight LED Turn signal indicator #_ LED . 2 ., ”fl finign beam indicator . 7!»,W iLiEL .. Neutral indicator 7 LED H “we.“ on pressure indicator LED l Malfunctionindtcetorlamp LED 77 .i i Fuelre§erveindicator LED Fuse Main fuse . 7 30A .._... 7. .. r 20A WW Subfuse l 20A /~ 1,10A - 5 Vijgggme’terpeakvoltage . i mavtnint um Thermo sensor resistance r 80°C 2.1 , 2.5 k _, ___ -, NV ‘ 120°C 0.65%.).73 :3" Fan motor Start to closelONl m 98—102“Cl208*216°Fl .,,., switch l Stopto open 93797 5c (1997207 °F) TORQUE VALUES Ignition switch mounting one-way bolt Side stand switch mounting bolt Fan motor switch Coolant temperature/ECT sensor Oil pressure switch Oil pressure switch Wire terminal screw Neutral switch 26 N~m l2.7 kgf‘m , 20 Ibf-ftl 10 Nm l1.fl kgf-m ,7 Ibf-ft) 18 N-m 11.8 kgf‘m ,13lbf-hl 23 Nm (2.3 kgfern,17|bf-fll 12 N-m l1.2 kgf-m,9 lbf~ftl 2 N-m (0.2 kgf-m , 1.4 lbf-th 12 N-m li.2 kgf~m , 9 Ibi-ftl ALOC bolt Apply sealant to the threads Apply sealant to the threads 192 TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER LlGHTS/METERS/SWITCHES The odometer/trip meter operate normally, but the speedometer does not operate ' Faulty speedometer The speedometer operate normally, but the odometer/trip meter does not operate - Faulty odometer/trip meter The speedometer operate is abnormal 0 Check for the followmg before diagnosing, , Blown main or sub fuses , Loose or corroded terminals of the connectors ~ Discharged batter Check for loose or poor Contact of the speed sensor 3F (Natural) connector, With the ignition switch ON and measure the voltage at the speed sensor connector, Normal Check for loose or poor contact of the combina» tron meter multmonnectors With the ignition switch ON and measure the voltage at the bottom of the speedometer termi- nals. Normal With the Ignition switch OFF, check for continuity of the Pink/Green wire between the terminals of the speed sensor and speedometer, Normal Support the motorcycle using a hoist or other support to rise the rear wheel oflthe ground Measure the output voltage (Sensor signal) at the speedometer with the ignition switch is ON while slowly turning the rear wheel by your hand Normal Abnormal Abnormal Abnormal Abnormal 0 Loose or poor Contact of related terminals 0 Open Cerult In Black/Brown or Green/Black wires between the battery and speed sensor - Loose or poor contact of related terminals 0 Open circuit in Black/Brown or Green/Black wires between the battery and speedometer 'Open circuit or loose connection in Pink/Green wire 0 Faulty speed sensor 0 Loose speed sensor mounting bolts #—————-——> 0 Faulty speed sensor 19-3 LlGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT ‘ Disconnect (he headlight bulb connectors. Remove the dust cover. I Amid tour/7mg Unhook the bulb relainer and remove the headlight V I ha/ugen headlight bulb/socket. ’ bulb. Finger pllnls can create ho! If you touch the bulb wilh your bare hands, clean it spols ma! Cause a wilh cloth moislened with denatured alcohol to bulb to break prevenl early bulb failure I I Remove Ihe headlight bulb from the sucker. BULB SOCKET Install a new bulb into the Sockel. I I Inslall the new headlight bulb/socket by aligning its tabsWIIhthe grooveinlhe headlightunit. I I . 19-4 Conner! [he whne rape conneclol to [he cenler headllghl‘ bulb sucks! (/0 beam) Houk the bulb retainer lI’IIO the headlight unll groove. Install Ihe dust cover tightly againsl (he headlight unit with $15 arrow mark facing up‘ Can necl the headllght connectors. REMOVAL/INSTALLATION Remove the upper cowl (page 2*9l. Remove the four bolts and headlight unit, Install the headlight unit In the reverse order of re moval. LlGHTS/METERS/SWlTCHES mg a . .4uwmw"? R W ‘ RETAINE BOLTS HEADLlGHT UNIT 19-5 LIG HTS/METERS/SWlTCHES TURN SIGNAL Route me turn Signal wire proper- ly (page 1724;. BULB REPLACEMENT Remove the screw and turn slgnal lens. While pushing in, turn the bulb counterclockwise to remove 4t and replace with a new ones Install the turn slgnal lens in the reverse order of re movalr REMOVAL/INSTALLATION For frant turn signal unit removal, see upper cowl removal (page 2-9). For rearturn slgnal removal, remove thefollowing: 7 Seat/rear cowl (page 272l Disconnect the turn signal connector. Remove the turn signal mounting nut. Release the turn signal Wire and remove the turn signal unit. Install the turn signal unit in the reverse order of removal, TURN SlGNAL LENS TURN SIGNAL CONNECTORS SETTING PLATE 19-6 TAIL/BRAKE LlGHT Align me ram brake/19h! um! tabs mm the bracket holes BULB REPLACEMENT Disconnect the tail/brake light connectors. Turn the bulb socket countercloclese, then re- move the bulb socket, While pushing in, turn the bulbs counterclockwwe to remove them and replace with new ones‘ Install the laillbrake llght sockets in the reverse order of removal. REMOVAL/INSTALLATION Remove the rear cowl (page 2*9l. Remove the two screws and tail/brake light unit, Installation is in the reverse order of removal. LICENSE LIGHT BULB REPLACEMENT Remove the license light bracket bolts and the license light assembly. LlGHTS/METERS/SWITCHES SCREWS LICENSE LlGHT LlGHTS/METE RS/SWlTCHES Remove the screws, license llght cover and lens. Whlle pushing ln, turn the bulb counterclockwise to . remove ll and replace Wlll'l a new one. Install the license light assembly In the reverse order of removal 0 COMBINATION METER ' REMOVAL Remave the upper cowl (page 29). Disconnect the combination meter multlrconnector, . MULTIACONNECTOR . Remove the combinatlon meter mounting bolt. BOLT COMBlNATION METER Release the combination meter case bosses from , the bracket grommets, then remove the combina- tion meter. C I DISASSEMBLV . Remove the screws and combination meter rear cover. C SCREWS ‘ 19-8 Remove the COmblnallOl’l meter print baard assem- blv from the from cover. ASSEMBLY Install the pnnt board assembly into the front cover. Install the rear cover and tighten the screws securer ly, lNSTALLATlON Align [he Install the combination meter unto the bracket, CDmblnaflon meter case bosses mm Install and tighten the mounting bolt. the grommets on the meter bracket, Connect the combination meter multi-connector. Install the upper cowl [page 2711)t LlGHTS/METERS/SWITCHES PRlNT BOARD REAR COVER SCREWS BOLT COMBINATION METER FRONT COVER MULTIVCONNECTOR LlGHTS/METERS/SWITCHES SPEEDOMETER/VEHICLE SPEED SENSOR VOLTAGE INSPECTION Open and support the front end or fuel tank (page 3,4). Disconnect the speed sensor 3P (Natural) connector and check for loose or poor Contact of the connector. With the ignition swnch is ON and measure the voltage at the 3P (Natural) connector of the wire har- ness side, Connection: Black/Brown lYI-Green/Blacld ,) Standard: Battery voltage If there is no voltage, repair or replace the wire har- ness, Remove the upper cowl lpage 2-9). Check for loose or poor connection of the combina- tion meter multi-Donnector. With the ignition switch is ON and measure the volt- age at the multi-oonnector terminals Connection: Black/Brown (+l’Green/Black (7) Standard: Battervvoltage If there is no voltage, repair or replace the wire harr nessi OUTPUT SIGNAL INSPECTION With the ignition switch is OFF, check for continuity of the Pink/Green wire between the speed sensor connector and combination meter multirconnector. There should he continuityv If there is no continuity, repair or replace the wire harness, 3P (NATURAL) CONNECTOR 19-10 LlGHTS/METERS/SWITCHES Support the motorcycle securely and place the rear wheel off the ground Shift the transmission into gear, Connect the speed sensor 3P (Natural) connector. Measure the voltage at the combination meter ‘er, mlnals with the ignition switch is ON While slowly turning the rearwheel by hand, CONNECTION: Pink/Green lv‘) *Green/Black l 7 ) STANDARD: Repeat 0 to 5 V ll the measurement is out of specification, inspect the open circuit In wire harness. REMOVAL/INSTALLATION Open and support the front end ol fuel tank lpage 3-4), Disconnect the speed sensor 3P (Natural) connec- tor. Remove the bolts and speed sensorv Check the Orring is in good condition, replace If near essarv. Install the speed sensor into the upper crankcase. MULTI~CONNECTOR 3P lNATURAL) CON N ECTOR LlGHTS/METERS/SWITCHES Install and tighten the mounting bolts securely. O 0 Route the sensor wire. . Connect the speed sensor 3P lNaturall connector, 0 O INSPECTION C Remove the upper cowl lpage 2-9l. Check for loose or poor contact terminals of the combination meter multi-connector. Connect the peak voltage adaptor to the tachomer . Ker Black/Yellow terminal and ground. TOOLS: PEAK VOLTAGE ADAPTOR lmrie diagnostic tester (model 625) or Peak Voltage adaptor O7HGJ70020100 with commercially available digital multimeter . (impedance 10 Mil/DEV minimum) CONNECTION: Vellow/Green 1+) and Ground 1*) Start the engine and measure the tachometer input peak voltage. 0 PEAK VOLTAGE: 10.5 V minimum ll the value is normal, replace the tachometer. II the measured value is below 10.5 V, replace the ECM. C 19-12 LlGHTS/METERS/SWITCHES if the value is o v, pertorm the following: Remove the ECM cover ipage 5781) and disconnect the ECM mulri-connector. Check for continuity between the tachometer termi— nal and the ECM multlrconnector Vellow/Green ter- minals. If there Is no continuity, check the wire harness for an open circuit. If there ls continuity, replace the tachometer unit. For tachometer replacement, see 19-8; combination meter disassembly and assembly, COOLANT TEMPERATURE GAUGE/SENSOR INSPECTION Open and support the lront end of fuel tank (page 3-4), Disconnect the ECT/therrno sensor wire connector from the sensor. THERMO SENSOR UNIT INSPECTION Drain the coolant (page 673). Disconnect the wire connector from the ECT/ thermo sensorand remove the sensor. Suspend the ECM/thermo sensor in a pan 01 coolant 150*50 mixture) an electric heating ele ment and measure the resistance through the senr sor as the coolant heats up. ' Soak the ECT/thermo sensor in coolant up to Its threads with at least 40 mm (1.6 in) from the ECTfFHERMO SENSOR bottom of the pan to the bottom of the sensort 'Keep the temperature constant for 3 minutes before testing, A sudden change of temperature will result in incorrect readings, Do not let the thermometer or ECT/thermo sensor touch the pan. THERMO SENSOR TERMINAL 19-13 LlGHTS/METERS/SWITCHES .W R I“ new Temperature 80°C1680F) i 120”C (248°Fi ECT/TH/I; MO SENSOR , / ! Resistance i 2.1 ’26 kl! 0.65’073 ksl Replace the sensor if it is out of specification by more than 10 % at any temperature listed. A/ways replace the InstaH and tighten the ECT/thermo sensor to the sealing Washer specified torque. With a new one TORQUE: 23 N>m12.3 kgf-rn ,17lbfvfti Connect the ECT/therrno sensor connector. Fiil the system and bleed the air lpage 574i. COOLING FAN MOTOR SWITCH INSPECTION Remove the foiiowmg , Seat (page 272i - Middle/lower cowl {page 275) Check for a blown fuse before inspection. Fan motor does not stop Turn the ignition switch OFF, disconnect the con nector from the fan motor switch and turn the Ignltioh switch ON again. If the fan motor does not stop, check for a shorted CONNECTOR FAN MOTOR SWITCH wrre between the fan motor and switch. If the fan motor stops, replace the fan motor switch. Fan motor does not start Before testing, warm up the engine to operating temperature, Disconnect the connector from the fan motor swltch and ground the connector to the body with a jumper wire. Turn the ignition switch 0N and check the fan mo- tor. It the motor starts, check the connection at the fan motor switch terminal. It is OK, replace the fan motor swrtch. 19-14 LlGHTS/METERS/SWITCHES If the motor does not start, check for voltage be tween the fan motor Switch connector and ground, If battery voltage is measured, replace ian motor, . If there is no battery voltage, check for poor connec- tion ofthe connector or broken wrre harness. . REMOVAL/INSTALLATION ~\' E? OrRlNG Disconnect the fan motor switch connector and remove the switch. install a new O-ring onto the fan motor switch. . Apply sealant to the fan motor switch threads, Install and tighten the fan motor switch. *\ TORQUE: 18 N‘m (1‘8 kgfrm ,13lbf-fti i Install the removed parts in the reverse order of t removali ~ . CONNECTOR FAN MOTOR SWITCH OIL PRESSURE SWITCH INSPECTION . If the oil pressure warning indicator stays on while the engine running, check the engine oil level before inspections Make sure that the oil pressure warning indicator came on with the ignition Switch ON, C . lfthe indicator does not come on, inspect as iollow: Open and support the front end of fuel tank {page 3-4). Remove the dust cover. Remove the screw and Dli pressure swrtch terminal. 0 DUSTQOVER . ll 19-15 LlGHTS/METERS/SWlTCHES Short the on pressure switch wire terminal with the ground using a Jumper wrre. The oil pressure warning indicator comes on with the ignition switch in ON. I If the lrght does not comes on, check the sub-fuse (10 Aland Wires for a loose connection or an open CerUiL Start the engine and make sure that the light goes ouL . If the llght does not go out, check the oil pressure (page 4-3). If the oil pressure is normal, replace the all pres- sure swnch (see belowli REMOVAL/INSTALLATION I Remove the boot, terminal screw and wire terminal. Remove the oil pressure switch from the crankcase C C Apply sealant to the oil pressure switch threads as Show” Do not apply sealant toihe thread l ‘headaili mm 10.1701 lnl. —>—<— l l ' I t V , , I , Install the Oll pressure swrtch onto the crankcase, IL PRESSURE SWITCH . tighten it to the specified torque. .‘ TORQUE: 12 NJ“ (12 kgf-m , 9 ”JUN Connect the oil pressure switch terminal to the swltch and tlghten the screw to the specrfied torquev TORQUE: 2 N-m (0.2 With , 1.4 lbf‘fl) . lnstalt the dust cover. I 19-16 LlGHTS/METERS/SWITCHES FUEL RESERVE SENSOR JUMPER WIRE INSPECTION ‘ Turn the ignition switch in ON and make sure the luel reserve indicator comes ON. If the fuel reserve Indicator does not indicate DrOpA erlv, check forthe lollowmgt Disconnect the fuel reserve sensor 3P (Blackl con- nectarv Short the wire harness side connector Brown/Black and Green/Black terminals with a jumper wire. Turn the ignition switch is ON and make sure the fuel reserve indicator comes ONI II the indicator come ON, replace the fuel pump assembly. If the indicator still not come ON, check for open or short circuit in wire harness. IGNITION SWITCH , s, , ,: INSPECTION ' Remove the right inner panel (page 279) Disconnect the ignition switch Wire 4P (Natural) COW nectors. 4P INATURALI CONNECTOR Check for continuity between the Wire terminals of the ignition switch connector in each switch posir fio“: . . IGNITION SWITCH Continuity should exist between the color coded wires aslollows: IGNITION SWITCH FAN IG i BATI KEV 6N »; ': KEV ON orr 7 7 7 key OFF LOCK KEY OFF LOCK PIN ”COLOR Bu/O V R/Bl R . 7 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION ,, , Disconnect the ignition switch wire 4P (Natural) connector. . Remove the wire clamp, Remove the top bridge ipage 1375), C Remove the bolts and ignition swrtch. . Install the ignition switch in the reverse order ol \ removal. ' (Er . t l \ \ IGNITION SWITCH . HANDLEBAR SWITCHES ENGWE smpswncn Disconnect the handlebar switch connectors. Check for continuity between the Wll’e terminals of O the handlebar swrtch connector. Continuity should exist between the color coded wire terminals as follows: ENGINE STOP SWITCH . ‘ IG iBATz OFF 1 l kSTARtTIER SWITEH RUN ‘ COLOR: Bl iW/Bi O STARTER SWITCH \ J ST IG ‘BATa HL FREE l Cn—J: PUSH l 7a . COLOR Y/R Bi Bl/Br‘Bu/W O 19-18 LlGHTS/METERS/SWITCHES W DIIVIMER SWITCH TURN SIGNAL SWITCH HOFIN SWITCH HORN SWITCH TURN SIGNAL SWITCH W BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors and check for continuity between the terminals. There should be continuity with the brake lever applied, and there should be no continuity with the brake lever is released. BRAKE LIGHT SWITCH REAR BRAKE LIGHT SWITC’H CONNECTOR Remove the seat (page 2-2l. 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 continuity with the brake pedal is released. BRAKE PEDAL LIG HTS/METE RS/SWITCHES CLUTCH SWITCH Disconnect the clutch switch connectors. There should be continuity with the clutch lever applied, and there should be no continuity with the clutch lever is released, NEUTRAL SWITCH Dlsconnect the neutral Switch Connector from the switch, Shift the transmission into neutral and check for continuity between the Light green wire terminal and ground. There should be continuity with the transmission IS in neutral, and no continuity when the transmission isinto geart SIDE STAND SWITCH INSPECTION Open and support the front end oi fuel tank lpage 3—1”. Disconnect the side stand switch 3F (Greenl connec- (or. Check for continuity between the wire terminals of the side stand switch connectort Continuity should exist only when the side stand is UPV ZIP(GREEN) CONNECTOR 19-20 REMOVAL Disconnect the side stand switch 3? (Green) connec- (Or, Remove the bolt and side stand swttch, INSTALLATION Install the side stand switch by aiigning the switch pin with the side stand note and the switch groove With the return spring holding pin. Secure the Side stand swttch with a new bolt. TORQUE: 1D N»m11.0 kgf~m , 7 ibf‘ftl Connect the side stand switch 3P (Green) connectort LlGHTS/METERS/SWITCHES 3F tGREEN) CONNECTOR SIDE STAND SWITCH ALIGN 3PtGREENi CONNECTOR 19-21 LlGHTS/METERS/SWITCHES HORN Disconnect the Wire connectors from the horn. C Connect the 12 V battery to the horn terminal directs ly, The horn is normal if it sounds when the 12 V bats tery is connected across the horn terminals. I TURN SIGNAL RELAY I INSPECTION Remove the upper cowl (page 279i. Check the followtng: Battery condition . , Burned out bulb or nonespecified wattage , Burned fuse "Ignition switch and turn signal switch function 7 Loose Connectors If the above items are all normal, Check the lollOWV . ing: Disconnect the turn signal connectors from the relay, 1.Short the black and gray terminals of the turn signal relay connector with a jumper wire. Start the engine and check the turn signal light by turn- . ing the switch one i l Light comes on Light dose not come on I 0 Broken wtre harness 2.Check for continuity between the green terminal of the relay connector and ground. C Continuity No continuity ' Broken ground wire - Faulty turn signal relay. 0 Poor connection oi the connector. . O 19-22 21. TECHNICAL FEATURES H-VlX (Honda variable intake exhaust control system) HVVIX Is the new technology to provide high performance in all speed ranges. This system consists ofthe variable exhaust control valve, variable intake air control valve and a servo motor. The servo motor is controlled by the ECM. Both the variable intake and EGCV (Exhaust Gas Control Valvel are controlled by the same servo motor. EGCV CONTROL Generally, the 180° exhaust collector design is used for high speed setting and the 360° exhaust collector design is used for the low and medium speed settings. The EGCV has a 180° collector and 360° collector in the same exhaust system. In the low and middle speed ranges, the exhaust collector is in the 360” position, to produce more engine torque. In the high speed range, the exhaust collector is in the 180° position to maximize high engine power. INTAKE VALVE CONTROL The Intake valve IS controlled by the same servo motor used {or the EGCV to control intake air volume. In the low and middle speed ranges, the intake valve is closed and, in combination with the exhaust valve, produces more engine torque. In the high speed range, the intake valve is opened by the servo motor and maximizes engine power in combination Wllh the exhaust valve, 21-1 TECHNICAL FEATURES When the engine revolutions are below 3,000 rpm, the EGCV pulley is positioned at 90° (lacing forwardl by the control cables from servo motor. At this position, the No.1 exhaust pipe gas flows into the Not 2 exhaust pipe, and the N04 exhaust pipe gas flows Into the No.3 exhaust pipe by (he EGCV. No. 2 When the engine revolutions increase and pass 8,000 rpm, the EGCV cable pulley is moved to 180° (pulley index line facing down) by the control cables from servo motor. AI this position, the exhaust gases flow directly through the EGCV 1360’ collectorl. No. 2 When the engine revolution increase and pass 8,000 rpm, the EGCV cable pulley is moved to 180° lpulley index line facing down) by the control cables from servo motor. At this position, the No.1 and No.2 and the No.4 and N03 exhaust pipe gases are crossed by the EGCV (180” collectorlt 21-2 TECHNICAL FEATURES A the same Mme, xhe intake flap va‘ve :5 opened by the control cab‘e from servo motor‘ A! Iow and middle speed ranges: At high speed range: 21-3 22. TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HlGH HARD TO START 22<1 SPEED 22-4 ENGINE LACKS POWER 22-2 POOR HANDLING 22-4 POOR PERFORMANCE AT LOW AND IDLE SPEED 22-3 ENGINE DOES NOT START OR IS HARD TO START Possible cause 1.Check for operation of the fuel pump Abnormal 0 Faulty fuel pump (Section 5) Normal 2. inspect the fuel flow Abnormal . Faulty pressure regulator (section 5) Normal 3. Inspect the fuel injector # Abnormal v———> ' See section 5 Normal Week or no spark -——> I Faulty spark plug ' Fouled spark plug Good spark ‘ Faulty ECM 0 Broken or snorted spark plug wire - Faulty ignition switch - Faulty ignition pulse generator 0 Faulty engine stop switch 0 Loose or disconnected ignition system Wires 4,Perrorm a spark test 5. Test cylinder compression —— Low compression ——> - Valve stuck open 0 Worn cylinder and piston ring Compression normal - Damaged cylinder head gasket 0 Seized valve 0 Improper valve timing Engine starts but stops ——> - Improper starter valve operation - Intake pipe leaking 6. Starting followmg normal procedure Engine does not start 0 Improper ignition timing lFauIty ignition coil or ignition pulse genera- tor) 0 Fuel contaminated 7t Remove and inspect spark plug ——-— Wet plug . Throttle valve open . Clogged air cleaner 22-1 0 Sta rter valve closed a TROUBLESHOOTING ENGINE LACKS POWER Possible cause 1. Raise wheel oil the ground and spin by hand Wheel spins lreely 2,Check tire pressure Pressure normal 3. Accelerate rapidly lrom low to second Engine speed reduced when clutch 5 released 4,Acce|erate lightly Engine speed increase Wheels do not spin freely/a Pressure low *> Engine speed doesn’t —--> change accordingly when clutch is released Engine speed does not fl increase 5. Check ignition timing Correct 6. Test cylinder compression incorrect Incorrect fi—"—‘— ' Normal 7.|n‘specl fuel flow Abnormal Normal B,lnspectthe fuel Injector Abnormal ——> Normal 9. Remove spark plugs Not fouled or discolored 10.Check oil level and condition Correct “Remove cylinder head cover and 'nspect lubrication Valve train lubricated properly Fouled or discolored —> incorrect —-—-———> Valve train not lubricated 4’ properly 0 Brake dragging o Worn or damaged wheel bearing c Faulty tire valve ' 0 Punctured lire o Clutch slipping o Worn clutch discs/plates I Warped clutch discs/plates 0 Weak clutch spring 0 Additive in engine oil c Air cleaner dirty 0 Restricted fuel flow 0 Clogged mufller o Pinched fuel tank breather . Faulty ECM - Faulty ignition pulse generator . Valve stuck open 0 Worn cylinder and piston rings 0 Leaking head gasket - Improper valve timing - Faulty pressure regulator (Section 5) 0 See section 5 . Faulty spark plug - Oil level too high . on level too low 0 Contaminated oil 0 Clogged oil passage 0 Clogged oil control orifice 22-2 TROUBLESHOOTiNG Possible cause . 11.Check for engine overheating — Overheating ——> 0 Coolant level low 0 Fan motor not working lfaulty fan Not overheating motor swttchl 0 Thermostat stuck close 0 Excessive carbon build-up in combusr tion chamber 0 . Use or poor quality iuel 0 Wrong type oi iuel . Clutch slipping 12.Acce|erate or run at high speed i Engine knocks ———— . Worn piston and cylinder ' Wrong type of fuel . ' Excessive carbon build—up in combus- Engine does not knock tion chamber - Ignition timing to advanced (faulty ECMl — 0 Lean iuel mlxture . POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1,C|‘1eck ignition timing Incorrect - Improper Ignition timing . Correct 2. Check the starter valve synchronization # Incorrect ———-‘> 0 See section 5 Correct 0 3. inspect the fuel flow Abnormal - Faulty pressure regulator iSection 5) Normal . 4, Inspect the fuel injector ; Abnormal _> I See section 5 Normal 5‘ Check for leaks in the intake pipe — Leaking _'—> 0 Loose insulator clamp . - Damaged insulator Not leak 6. Perform spark test ———— Weak or intermittent 4—> o Faulty spark plug spark - Faulty carbon or wet fouled spark plug 0 Faulty ECM O . Faulty ignition coil - Broken or shorted spark plug wire Good spark I Faulty engine stop switch I Faulty ignition pulse generator - Faulty ignition switch 0 Loose 0r disconnected ignition system wires 0 22-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause reheck ignition timing Incorrect . Faulty ECM Correct 2‘ Inspect the fuel flow Abnormal o Faulty pressure regulator (Section 5i Normal ' 3‘ Inspect the fuel injector — Abnormal — 0 See section 5 Normal 4‘ Check valve liming Incorrect I Camshaft not installed properly Correct 5' Check valve spring Weak o Faulty valve spring Not weak POOR HANDLING Possible cause 1.1fsteering is heavy o Steering stem adjusting nut too tight 0 Damaged steering head bearings 2, If either wheel is wobbling ————— - Excessive wheel bearing play - Bent rim 0 Improper installed wheel hub ‘Swingarm pivot bearing excessively worn o Bentframe 3. If the motorcycle pulled to one side——v—v—v—> 0 Faulty shock absorber 0 Fronland rear wheel not aligned - Bent fork I Benlswingarm - Bentaxle 22-4