é HONDA SHOP MANUAL CRF1000/A/D CRF1000/AIDG HOW TO USE THIS MANUAL A Few Words About Safety Service Information The servIce and repair Information contaIned in thIs manual is Intended for use by qualIfied, professional technIcIans. Attempting service or repaIrs without the proper traInIng, tools, and equipment could cause Inlury to you or others. It could also damage the motorcycle or create an unsafe conditIon. ThIs manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operatIon of the motorcycle. If you need to replace a part, use Honda Genuine parts with the correct part number or an equIvalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer‘s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of the motorcycle. Any error or oversIght thle servicing a motorcycle can result in faulty operation, damage to the motorcycle, or Inlury to others. AWARNING Improper service or repairs can create an unsafe condItIon that can cause your customer to be serIously hurt or killed. Follow the procedures and precautIons In thIs manual and other service materIals carefully. For Your Safety Because this manual is Intended for the professional servIce technIcIan, we do not provIde warnings about many basic shop safety practices (e.g., Hot parts—wear gloves). If you have not received shop safety traInIng or do not feel confident about your knowledge of safe servicing practIce, we recommended that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautIons are given below. However, we cannot warn you of every conceIVable hazard that can arIse In performing service or repaIr procedures. Only you can decIde whether or not you should perform a given task. AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or Killed. Follow the procedures and precautIons In thIs manual carefully. Important Safety Precautions Make sure you have a clear understandIng of all basic shop safety practIces and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: ~ Read all of the instructIons before you begin, and make sure you have the tools, the replacement or repair parts, and the skills requIred to perform the tasks safely and completely. ~ Protect your eyes by using proper safety glasses, goggles or face shields any tIme you hammer, drIll, grind, pry or work around pressurIzed aIr or liquids, and springs or other stored-energy components. If there Is any doubt, put on eye protection. ~ Use other protective wear when necessary, for example gloves or safety shoes. HandlIng hot or sharp parts can cause severe burns or cuts. Before you grab somethIng that looks like It can hurt you, stop and put on gloves. ~ Protect yourself and others whenever you have the motorcycle up in the air. Any time you lift the motorcycle, eIther with a hoIst or a Jack, make sure that It Is always securely supported. Use jack stands. Make sure the engIne Is off before you begIn any servIcIng procedures, unless the Instruction tells you to do otherWIse. ThIs Will help eliminate several potential hazards: ~ Carbon monoxide poisoning from engine exhaust. Be sure there Is adequate ventIlation whenever you run the engIne ~ Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. ~ Injury from moving parts. If the instructIon tells you to run the engine, be sure your hands, fingers and clothIng are out of the way. GasolIne vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a Me or explosion, be careful when working around gasolIne or batteries. ~ Use only a nonflammable solvent, not gasoline, to clean parts. ~ Never draIn or store gasolIne in an open container. ~ Keep all charettes, sparks and flames away from the battery and all fuel-related parts. 0-1 HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures for the CRF1 DOO/A/D-G. Sections 1,2 and 3 apply to the whole motorcycle. Section 2 Illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 4 through 24 describe parts of the motorcycle, grouped according to location. Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI section troubleshooting first. Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good Judgement. You will find important safety information in a variety of forms including: - Safety Labels — on the vehicle - Safety Messages— preceded by a safety alert symbol I and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: m You WILL be KILLED or SERIOUSLY HURT If you don’t follow instructions. N You CAN be KILLED or SERIOUSLY HURT if you don‘t follow Instructions. “CAUTION You CAN be HURT if you don’t follow instructions. - Instructions — how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a m symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. © Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: September, 2015 HOW TO USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. 0* Replace the part(s) with new one(s) before assembly. v 7% Use the recommend engine oil. unless othervvise specified. ’73 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). 6 Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NOGI #2 or equivalent). fl Example: ~ MolyKote® BR-2 plus manufactured by Dow Corning U.S.A. ~ Multi-purpose M-Z manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide. NOGI #2 or equivalent). Example: ~ MolyKote® G-n Paste manufactured by Dow Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) ~ Rocol ASP manufactured by Rocol Limited, U.K. ~ Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless othervvise specified. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fluid. xfii Jim Apply sealant. CONTENTS GENERAL INFORMATION FRAM E/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM _\ .n .n N g COOLING SYSTEM E LUBRICATION SYSTEM 5 CYLINDER HEADNALVEICAMSHAFT E ALTERNATOR/STARTER CLUTCH g CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) I” DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) CRANKCASEITRANSMISSIONIBALANCER CRANKSHAFTIPISTONICYLINDER ENGINE REMOVAL/INSTALLATION g FRONT WHEEL/SUSPENSIONISTEERING g REAR WHEEL/SUSPENSION I 0 HYDRAULIC BRAKE A ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000AID) “El g BATTERY/CHARGING SYSTEM E E LIGHTSIMETERS/SWITCHES LIJ IMMOBILIZER SYSTEM (HISS) WIRING DIAGRAM INDEX MEMO 1. GENERAL INFORMATION SERVICE RULES ................................. ..1.2 MODEL IDENTIFICATION --------------------- ~-1-3 SPECIFICATIONS~- ..1_5 TORQUE VALUES ............................. .. 1.12 LUBRICATION & SEAL POINTS ---------- -- 1-22 SPECIAL TOOL LIST ------------------------- -~ 1-24 CABLE & HARNESS ROUTING ----------- -- 1-26 EMISSION CONTROL SYSTEMS -- . 1.47 TECHNICAL FEATURES -------------------- ~- 1-50 1-1 GENERAL INFORMATION SERVICE RULES 1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts 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 fasteners. 4. Install new gaskets. O-rings. cotter pins. and lock plates when reassembling. 5. When tightening bolts or nuts. begin With the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly. check all parts for proper installation and operation. 8. Route all electrical Wires as show in the Cable and Harness Routing (page 1-26). 9. Do not bend or tWIst control cables. Damaged control cables Will not operate smoothly and may stick or bind. ABBREVIATION Throughout this manual. the following abbreviations are used to identify the respective parts or systems. Abbrev. term Full term ABS Anti-lock Brake System CKP sensor Crankshaft Position sensor DCT Dual Clutch Transmission DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memony EOP sensor Engine Oil Pressure sensor EOT sensor Engine Oil Temperature sensor EVAP Evaporative Emission HSTC Honda Selectable Torque Control IACV Idle Air Control Valve IAT sensor Intake Air Temperature sensor MAP sensor Manifold Absolute Pressure sensor MCS Motorcycle Communication System MIL Malfunction Indicator Lamp PAIR Pulse Secondary Air Injection PCM Powertrain Control Module PGM-Fl Programmed Fuel Injection SCS Service Check Signal TP sensor Throttle Position sensor TR sensor Transmission Range Sensor VS sensor Vehicle Speed sensor DESTINATION CODE Throughout this manual. the following codes are used to identify individual models for each region. DESTINATION CODE REGION ED. IIED. IIIED European direct sales RU. IIRU. IIIRU Russia U. IIU. IIIU Australia. New Zealand GENERAL INFORMATION MODEL IDENTIFICATION CRF1000/A: SERIAL NUMBERS/LABELS CRF1000D: The motorcycle Identification Number (V.|.N) [1] is stamped on the right side of the steering head. The engine serial number [1] is stamped on the lower back side of the crankcase. The throttle body identification number [1] is stamped on the upper front left side of the throttle body as shown. The color label [1] is attached on the up side of the ETC tray. When ordering color-coded parts, always specify the designated color code. The registered number plate (ED, RU models) [1] is attached on the right side of the rear frame. The compliance label (U model only) [1] is attached on the front side of the down tube. GENERAL INFORMATION TYPES TYPE DESTINATION Manual Dual Clutch Anti-lock HSTC CODE CODE Transmission Transmission Brake System CRF1000 ED, IIED, IIIED o — — — U 0 — - - CRF1000A ED, IIED, IIIED o — O O RU, IIRU, IIIRU o — O O U, IIU, IIIU o — O O CRF1000D ED, IIED, IIIED — o o o RU, IIRU, IIIRU — O O O U, IIU, IIIU — O O O GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2.335 mm (91.9 in) Overall width CRF1000 875 mm (34.4 In) CRF1000A/D 930 mm (36.6 In) Overall height 1.475 mm (58.1 in) Wheelbase 1.575 mm (62.0 in) Seat height 870 mm (34.3 In) Footpeg helght 351 mm (13.8 In) Ground clearance 250 mm (9.8 in) Curb welght CRF1000 228 kg (503 lbs) CRF1000A 232 kg (511 lbs) CRF1000D 242 kg (534 lbs) Maximum weIght capaclty 195 kg (430 Ibs) FRAME Frame type Semi double cradle Front suspenslon Telescopic fork Front axle travel 204 mm (8.0 in) Rear suspension SWIngarm Rear axle travel 220 mm (8.7 in) Front tIre size 90/90-21M/C 54H Rear tire size 150/70R18M/C 70H Front tIre brand D610F (DUNLOP) Rear tire brand D610 (DUNLOP) Front brake Hydraulic double disc Rear brake Hydraulic single dIsc Caster angle 27” 30‘ Tran length 113 mm (4.4 in) Fuel tank capacIty 18.8 liters (4.97 US gal. 4.14 Imp gal) ENGINE Cylinder arrangement 2 cylinders In»lIne, slant angle 22.5“ Bore and stroke 92.0 x 75.1 mm (3.62 x 2.96 In) DIsplacement 998 cm (60.9 cu-in) CompressIon ratio 10.0 : 1 Valve train ChaIn driven, OHC with valve IIIter and rockerarm Intake opens at1 mm (0.04 In) lift 5° BTDC valve closes at 1 mm (0.04 In) lift 40" ABDC Exhaust opens at1 mm (0.04 In) lift 40° BBDC valve closes at 1 mm (0.04 In) “It 5° ATDC LubrIcatIon system Forced pressure and dry sump OII pump type TrochoId Coollng system Liquid cooled Air filtratlon Viscous paper element EngIne dry weIght CRF1000/A 68.2 kg (150.4 lbs) CRF1000D 76.4 kg (163.4 lbs) Firing order 1 - 2 FUEL DELIVERY Type PGM-Fl SYSTEM Throttle bore 44 mm (1.73 In) DRIVE TRAIN Clutch system Multi-plate. wet (CRF1000/A) Clutch operation system Cable operatIng TransmissIon Constant mesh, 6-speeds PrImary reductlon 1.733 (78/45) Final reductlon 2.625 (42/16) Gear ratIo 1st 2.866 (43/15) 2nd 1.888 (34/13) 3rd 1.480 (37/25) 4th 1.230 (32/26) 5th 1.100 (33/30) 6th 0.968 (31/32) Gearshift pattern Left foot operated return system. 1-N-2-3-4-5-6 GENERAL INFORMATION ITEM SPECIFICATIONS DRIVE TRAIN Clutcn system 2 Multi-plate wet clutches (CRF1000D) Clutcn operation system Automatic Transmission Constant mesh. 6-speeds Primary reduction 1.883 (81/43) Final reduction 2.625 (42/16) Gear ratio 1st 2.562 (41/16) 2nd 1.761 (37/21) 3rd 1.375 (33/24) 4th 1.133 (34/30) 5th 0.972 (36/37) 6th 0.882 (30/34) Gearshiit pattern Automatic and electric shift (IeIt hand operated) return system. N-1-2-3-4-5-6 ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier FET shorted/triple phase full wave rectification Lighting system Battery PGM-Fl SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS IAT sensor resistance (at 40°C/104°F) 1.0 — 1.3 k0 Fuel injector resistance (at 20°C/68°F) 11 — 13 Q 02 sensor heater resistance (at 20°C/68°F) 6.7 — 10.5 0 IACV resistance (at 25°C/77°F) 99 — 121 0 IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Spark plug SILMARBA9S (NGK) Spark plug gap 0.3 — 0.9 mm (0.03 — 0.04 in) Ignition coil primary peak voltage 100Vminimum CKP sensor peak voltage 0.7V minimum Ignition timing ("F"mark) 10° BTDC at idle FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number GQASA Engine idle speed 1200 1100 min1 (rpm) Throttle grip freeplay 2 — 6 mm (0.08 — 0.24 in) Fuel pressure at idle 324 — 367 kPa (3.3 — 3.7 kgI/cm , 47 — 53 p51) Fuel pump flow (at 12 V) 319 cm (4.2 US oz. 4.4 Imp oz) minimum/10 seconds PAIR control solenoid valve resistance (at 20°C/68°F) 24—280 GENERAL INFORMATION COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and CRF1000/A 1.63 liters (1.72 US qt. 1.43 Imp qt) engine CRF1000D 1.65 liters (1.74 us qt. 1.45 Imp qt) Resen/e tan K 0.33 liter (0.35 us qt. 0.29 Imp qt) Radiator cap relief pressure 108 — 137 kPa (1.1 — 1.4 KgI/cm , 16 — 20 psi) Thermostat Begin to open 30 — 84°C (176 —183°F) Fully open 95“c (203°F) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze High quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors Standard coolant concentration 1:1 mixture with distilled water LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engineoil CRF1000/A After draining 3.9 liter (4.1 US qt. 3.4 Imp qt) — capac'w giggggre‘glengm 0" 4.1 liter (4.3 us qt, 3.6 imp qt) — After disassemny 4.9 liter (5.2 US qt. 4.3 Imp qt) — CRF1000D After draining 4.0 liter (4.2 US qt. 3.5 Imp qt) — After draining/engine oil filter/clutch oil filter 4.2 liter (4.4 US qt. 3.7 Imp qt) — change After disassemny 5.2 liter (5.5 US qt. 4.6 Imp qt) — Recommended engine oil Honda "4»stroKe motorcycle oil" or an equivalent motor OlI. API classification: SG or higher — JASO T903 standard: MA Viscosity: SAE 10W»30 Oil pressure (at OlI filter cartridge) 499 — 637 kPa (5.1 —6.5 kgf/cm . 72 — 92 psi) at 5000 min'1 (rpm)/ — (80°C/176°F) Oil pump rotor I Tip clearance 0.15 (0.006) 0.20 (0.008) CYLINDER HEADNALVEICAMSHAFT SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 500 rpm 1245 KPa (12.7 kgf/cm . 181 psi) — Valve clearance IN 0.16 :t 0.03 (0.006 :t 0.001) — EX 0.23 :I: 0.02 (0.009 t 0.001) _ (between roller and cam lobe) Valve. valve guide Valve stem OD. IN 5.475 — 5.490 (0.2352 — 0.2358) 5.465 (0.215) EX 5.465 — 5.480 (0.2152 — 0.2157) 5.465 (0.214) Valve guide I.D. IN/EX 5.500—5.512 (02165—02170) 5.542 (0.219) Valve guide projection IN 17.7 —1S.0 (0.70 — 0.71) — above cylinder head EX 17.8 — 16.1 (0.70 — 0.71) — Valve seat width IN 1.1 — 1.3 (0.04 — 0.05) 1.5 (0.06) EX 1.3 — 1.5 (0.05 — 0.06) 1.9 (0.07) Valve spring Free length 43.20 (1.701) 42.2 (1.97) Valve lifter Valve lifter OD. IN 28.978 — 28.993 (1.1409 — 1.1415) 28.97 (1.141) Valve lifter bore I.D. IN 29.010 — 29.026 (1.1421 —1.1428) 29.04 (1.143) Rocker arm Arm I.D. EX 12.000 — 12.018 (0.4724 — 0.4731) 12.05 (0.474) Shaft O.D. EX 11.977 — 11.990 (0.4715 — 0.4720) — Camshaft Carri lobe height IN 41.240 — 41.480 (1.6236 — 1.6331) 41.21 (1.622) EX 41.531 —41.771 (1.6351 —1.6445) 41.50(1.634) Oil clearance 0.020 — 0.062 (0.0008 — 0.0024) 0.10 (0.004) Cylinder head warpage — 0.10 (0.004) GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear boss 0D. 57.749 — 57.768 (2.2736 — 2.2743) — |.D. 44.000—44.016(1.7323—1.7329) — CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (CRF1000/A) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch lever freeplay 10 — 20 (0.4 — 0.8) — Clutch Spring free length 52.48 (2.066) 51.48 (2.02) Disc thickness 3.22—3.38 (0427—0133) 3.0 (0.12) Plate warpage — 0.20 (0.008) Primary driven gear I.D. 41958—41983 (1.6519— 1.6529) — Clutch outer guide OD. 34.975 — 34.991 (1.3770 — 1.3776) — |.D. 28.000—28.021(1.1024—1.1032) — Mainshaft O.D. at clutch outer guide 27.967 — 27.980 (1.1011 — 1.1016) — DUAL CLUTCH TRANSMISSION SPECIFICATIONS (CRF1000D) ITEM STANDARD SERVICE LIMIT Shift clutch Clutch clearance 0.9 — 1.1 (0.035 — 0.043) Disc thickness 1.88 — 2.00 (0.074 — 0.079) worn out lining Plate thickness 1.95 — 2.05 (0.077 — 0.081) discoloration EOT sensor resistance (20° /68°F) 2.5 — 2.8 k0 CRANKCASEITRANSMISSIONIBALANCER SPECIFICATIONS (CRF1000IA) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear l.D. M5, M6 31.000 — 31.025 (1.2205 — 1.2215) — C1 25.000 — 25.021 (1.3780 — 1.3789) — C2. C3, C4 33.000 — 33.025 (1.2992 — 1.3002) — Gear bushing M5 30.955 — 30.980 (1.2187 — 1.2197) — OD. M6 30.950— 30.975 (1.2185— 1.2195) — C1 24.959 — 24.980 (0.9826 — 0.9835) — C2 32.955 — 32.980 (1.2974 — 1.2984) — C3. C4 32.950 — 32.975 (1.2972 — 1.2682) — Gear bushing |.D. M5 27.985—28.006 (1.1018— 1.1026) — C1 21.985 — 22.006 (0.8655 — 0.8664) — C2 29.985— 30.006 (1.1805— 1.1813) — MainshartOD. at M5 27.967—27.980(1.1011—1.1016) — Countershaft at C1 21.987 — 22.000 (0.8656 — 0.8661) — OD. at C2 29.967 — 29.980 (1.1798 — 1.1803) — Shift fork, Fork |.D. 12.000 — 12.018 (0.4724 — 0.4731) — fork shalt Claw thickness 5.93 — 6.00 (0.233 — 0.236) 5.83 (0.230) ShiIt fork shaft O.D. 11.957 — 11.968 (0.4707 — 0.4712) GENERAL INFORMATION CRANKCASEITRANSMISSIONIBALANCER SPECIFICATIONS (CRF1000D) Unit: mm (In) ITEM STANDARD SERVICE LIMIT Transmission Gear |.D. M5 35.000 — 35.025 (1.3780 — 1.3789) — M6 43.000 — 43.025 (1.6929 — 1.6939) — C1 35.000 — 35.025 (1.3780 — 1.3789) — C2 25.000 — 25.021 (0.9843 — 0.9851) — C3, C4 33.000 — 33.025 (1.2992 — 1.3002) — Gear bushing OD. M5 34.950 — 34.975 (1.3760 — 1.3770) — M6 42.950—42.975 (1.6909— 1.6919) — C1 34.950 — 34.975 (1.3760 — 1.3770) — C2 24.959 — 24.980 (0.9826 — 0.9835) — C3, C4 32.950 — 32.975 (1.2972 — 1.2982) — Gear bushing l.D. M5 32.000 — 32.025 (1.2598 — 1.2608) — M6 40.007 — 40.028 (1.5751 — 1.5759) — C1 30.000 — 30.021 (1.1811 — 1.2067) — C2 21.985 — 22.006 (0.8655 — 0.8664) — Inner mainshaft OD. M5 31.957 — 31.970 (1.2581 — 1.2587) — Outer mainshaft OD. M6 39.975 — 39.991 (1.5738 — 1.5744) — Countershalt OD. C1 29.967 — 29.980 (1.1798 — 1.1803) — C2 21.987 — 22.000 (0.8656 — 0.8661) — Shiftfork l.D. 12.000— 12.018 (0.4724— 0.4731) — Claw thickness 5.93 — 6.00 (0.233 — 0.236) 5.83 (0.230) Shaft OD. 11.957 — 11.968 (0.4707 — 0.4712) — CRANKSHAFTIPISTONICYLINDER SPECIFICATIONS Unit: mm (In) ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod side clearance 0.10 — 0.20 (0.004 — 0.008) 0.35 (0.014) Runout — 0.05 (0.002) Main journal bearing Oil clearance 0.019 — 0.038 (0.0007 — 0.0015) 0.05 (0.002) Crankpin bearing Oil clearance 0.027 — 0.045 (0.0011 — 0.0018) 0.065 (0.0026) Cylinder l.D. 92.000 — 92.015 (3.6220 — 3.6226) 92.10 (3.626) P.'5‘°”' . P'Sm" 03' 3‘ 12 mm (0'5 'r‘) "0"“ 91.981 — 91.996 (3.6213 — 3.6218) 91.39 (3.618) pls»ton pin. bottom piston ring Piston pin hole l.D. 22.002 — 22.008 (0.8662 — 0.8665) 22.02 (0.867) Piston pin 0.0. 21.994 — 22.000 (0.3659 — 0.8661) 21.98 (0.865) Piston ring end gap Top 0.15 — 0.30 (0.006 — 0.012) 0.40 (0.016) Second 0.45 — 0.60 (0.018 — 0.024) 0.70 (0.028) Oil (Side rail) 0.20 — 0.70 (0.008 — 0.023) 0.90 (0.035) Piston ring»to-ring Top 0.030 — 0.060 (0.0012 — 0.0024) — groove clearance Second 0.030 — 0.060 (0.0012 — 0.0024) Connecting rod small end |.D. 22.030 — 22.044 (0.8673 — 0.8679) 22.054 (0.8683) GENERAL INFORMATION FRONT WHEELISUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cold tire Driver only 200 kPa (2.00 kgf/cm , 29 psi) — pressure Driver and passenger 200 kPa (2.00 kgf/cm , 29 psi) — Axle runout — 0 2 (0.01) wheel rim Radial — 1 0 (0.04) runout Axial — 1 0 (0.04) Wneel hub-to-rim distance 255 — 30.5 (1.12 — 1.20) Wneel balance weight 60 g (2.1 oz) max. Fork Spring free length 433.7 (17.07) 425.0 (16.73) Recommended fork Iluid Honda Ultra Cushion Oil 10W (SS-47) Fluid level 95.0 (3.74) Fluid capacity 721 1 2.5 cm (24.4 1 0.1 US oz. 25.4 1 0.1 Imp oz) Pre-load ad)uster CRF1000/A 5 turns from the full soft position standard position CRF1000D 8.5 turns from the full soft position Rebound adjuster standard position 2 1/4 turns from maximum position Compression adjuster standard position 8 clicks from maximum position Steering nead bearing pre-load 9.8 — 14.7 N (1.0 — 1.5 KgI, 2.2 — 3.3 lbI) REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cold tire pressure Driver only 250 kPa (2.50 kgf/cm , 36 psi) — Driver and passenger 280 kPa (2.80 kgf/cm , 41 psi) — Axle runout — 0 2 (0.01) wheel rim runout Radial — 1 0 (0.04) Axial — 1 0 (0.04) Wneel hub-to-rim distance 5.2 — 7.2 (0.205 — 0.283) — Wneel balance weight — 60 g (2.1 oz) max. Drive chain Slack 35 — 45 (1.4 — 1.8) — Size/link DID525HV3-124LE — Shock absorber Pre»load ad)uster standard 7 clicks from maximum position _ position (first click is “0" position) Rebound adjuster standard 11 clicks from maximum position _ setting Compression adjuster 14 clicks from maximum position — standard position HYDRAULIC BRAKE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 brake fluid — Brake disc thickness 4.5 1 0.1 (0.18 1 0.004) 3.5 (0.14) Brake disc warpage — 0.20 (0.008) Master cylinder |.D. 14.000 — 14.043 0.5512 — 0.5529) — Master piston OD. 13.957 — 13.984 (0.5495 — 0.5506) — Caliper cylinder Upper 30.230 — 30.280 (1.1902 — 1.1921) — |.D. Lower 27.000 — 27.050 (1.0630 — 1.0650) — Caliper piston Upper 30.148— 30.198 (1.1869— 1.1889) — OD. Lower 20918—20968 (1.0598— 1.0617) — Rear Specified brake fluid DOT 4 brake fluid — Master cylinder pusn rod length 83.0 — 85.0 (3.28 — 3.35) — Brake disc thickness 6.0 1 0.2 (0.24 1 0.008) 5.0 (0.20) Brake disc warpage — 0.30 (0.012) Master cylinder l.D. 12.700 — 12.743 (0.5000 — 0.5017) Master piston 0D. 12.657 — 12.684 (0.4983 — 0.4994) Caliper cylinder I.D. 38.18 — 38.23 (1.503 — 1.505) Caliper piston O.D. 38.098 — 38.148 (1.4999 — 1.5019) 1-10 GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type YTZ14S Capacity 12 v— 11.2 Ah (10 HR)/11.8 An (20 HR) Current leakage 0.66 mA max. Voltage Fully charged 13.0 —13.2 V (20°C/68°F) Needs charging Below 12.3 V Charging current Normal 1.1A/5 — 10 h Quick 5.5 A/n Alternator Capacity 0.49 kW/5.000 min1 (rpm) Charging coil resistance (20°C/68°F) 0.1 — 1.0 Q LIGHTS/METERSISWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight Hi LED Lo LED Brake/taillight LED Position light LED Front turn signal/position light (CRF1000) 12 V — 21/5 W x 2 Front turn signal light (CRF1000A/D) LED Rear turn signal light CRF1000 12 V — 21 W x 2 CRF1000A/D LED License light 12 V — 5 W Instrument light LED Turn signal indicator LED High beam indicator LED Neutral indicator LED Low oil pressure indicator LED Fuel reserve indicator LED MIL LED High coolant temperature indicator LED HISS indicator LED ABS indicator (CRF1000A/D) LED Rear ABS indicator (CRF1000A/D) LED Parking brake indicator (CRF1000D) LED Torque control indicator (CRF1000A/D) LED Torque control off indicator (CRF1000A/D) LED Fuse Main fuse 30 A Fl fuse 15 A ABS MAIN fuse (CRF1000A/D) 30 A DCT M fuse (CRF1000D) 30 A Subfuse CRF1000 ZOAX1,1OAX1,7.5AX5 CRF1000A 20AX1,10AX1,7.5AX6 CRF1000D 20AX1,10AX1,7.5AX7 ECT sensor resistance 40°C (104°F) 1.0 — 1.3 K0 100°C(212°F) 0.14—0.18“) Open air temperature sensor resistance 25°C (77°F) 4.9 — 5.1 KG Fuel level sensor resistance Full 6.4 — 10.4 0 Empty 2043—21030 1-11 GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE N-m (kgf-m. FASTENER TYPE N-m (kgf-m. let) let) 5 mm bolt and nut 5.2 (0.5. 3.8) 5 mm screw 4.2 (0.4. 3.1) 6 mm bolt (Include SH Ilange bolt) 10 (1.0. 7) 6 mm screw 9.0 (0.9. 6.6) and nut 6mmflange bolt (Include NSHF)and 2 (1.2. 9) 8 mm bolt and nut 22 (2.2. 16) nut 10 mm bolt and nut 34 (3.5. 25) 8 mm flange bolt and nut 27 (2.8. 20) 12 mm bolt and nut 54 (5.5. 40) 10 mm flange bolt and nut 39 (4.0. 29) ENGINE & FRAME TORQUE VALUES FRAME BODY PANELS/EXHAUST SYSTEM THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Windscreen mounting screw 4 5 0.42 (0.04. 0.3) Skid plate mounting bolt 3 8 26 (2.7. 19) Left rear cover mounting bolt 2 6 2 (1.2. 9) Brake nose oil bolt (CRF1000A/D) 2 10 34 (3.5. 25) Brake pipe Joint nut (CRF1000A/D) 2 10 14 (1.4. 10) Apply brake Iluid to the threads. Exhaust pipe cover C pan screw 3 6 9.0 (0.9. 6.6) Exhaust outer cover screw 1 6 9.0 (0.9. 6.6) Exhaust pipe joint nut 4 8 20 (2.0. 15) Exhaust pipe cover A pan screw 1 6 9.0 (0.9. 6.6) Exhaust pipe cover B band screw 1 — 3.5 (0.4. 2.6) Muffler band bolt 2 8 17 (1.7. 13) Muffler cover pan screw 2 6 9.0 (0.9. 6.6) Tail cap cover bolt 2 6 9.0 (0.9. 6.6) Exhaust pipe stud bolt 4 8 — See page 246 Sidestand pivot bolt 1 10 10 (1.0. 7) See page 219 Sidestand pivot nut 1 10 29 (3.0. 21) See page 219 U-nut 1-12 GENERAL INFORMATION MAINTENANCE THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Throttle cable adjuster lock nut 1 7 3.8 (0.4, 2.8) (throttle grip side) Throttle cable A lock nut 1 8 8.5 (0.9, 6.3) (throttle body side) Air cleaner element mounting screw 4 5 1.1 (0.1, 0.8) Tapping screw Air cleaner cover screw 8 5 .1 (0.1, 0.8) Tapping screw Spark plug 4 10 22 (2.2, 16) Valve adjusting screw lock nut 4 5 10 (1.0, 7) Apply engine oil to the threads and seating surface. Timing hole cap 1 14 6.0 (0.6, 4.4) Apply grease to the threads. Crankshaft hole cap 1 30 8.0 (0.8, 5.9) Apply grease to the threads. Engine oil drain bolt 2 12 30 (3.1, 22) Oil filter boss (crankcase side) 1 20 — Apply locking agent to the threads. See page 3-12 Engine oil filter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads. Clutch oil filter cover bolt 2 6 2 (1.2, 9) (CRF1000D) Rear axle nut 1 1B 100 (10.2, 74) U»nut Drive chain adjuster lock nut 2 8 27 (2.8, 20) UBS»nut Drive sprocket bolt 1 10 54 (5.5, 40) Driven sprocket nut 5 12 100 (10.2, 74) U»nut Parking brake adjuster lock nut 1 8 17.2 (1.8, 13) (CRF1000D) Front spoke 36 BC 3.5 3.7 (0.4, 2.7) Rear spoke 32 BC 3.5 3.7 (0.4, 2.7) PGM-FI SYSTEM THREAD TORQUE ITEM Q'TY DIA- (mm) N-m (kgf-m, REMARKS lbI-ft) ECT sensor 1 1O 2 (1.2, 9) IAT sensor mounting screw 2 5 1.1 (0.1, 0.8) Oz sensor 1 12 24.5 (2.5, 18) PAIR reed valve cover bolt 2 6 2 (1.2, 9) ELECTRIC STARTER THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Starter motor setting bolt 2 5 4.9 (0.5, 3.6) Starter cable terminal nut/washer 1 6 0 (1.0, 7) Negative brush mounting screw/ 1 5 3.7 (0.4, 2.7) washer 1-13 GENERAL INFORMATION FUEL SYSTEM THREAD TORQUE ITEM Q'TY DIA- (mm) N-m (kgf-m, REMARKS Ibf-ft) Fuel filler cap bolt 3 4 1.8 (0.2. 1.3) Fuel pump/reserve sensor terminal 2 4 1.0 (0.1. 0.7) screw Fuel pump mounting nut 5 6 12 (1.2. 9) See page 7»10 Fuel pump mounting cap nut 1 6 12 (1.2. 9) See page 7»10 Connecting hose band screw 2 4 1.5 (0.2. 1.1) See page 7»12 IACV holder screw 3 5 3.4 (0.3. 2.5) Throttle cable A/B lock nut 2 8 8.5 (0.9. 6.3) (throttle body side) Insulator band screw 2 — See page 7-15 (throttle body side) IACV setting plate screw 2 4 2.1 (0.2. 1.5) Fuel injector assembly mounting bolt 4 5 5.1 (0.5. 3.8) PAIR reed valve cover bolt 2 6 12 (1 2. 9) COOLING SYSTEM THREAD TORQUE ITEM Q'TY DIA- (mm) N-m (kgf-m, REMARKS Ibf-ft) Coolant drain bolt 1 6 13 (1.3. 10) Thermostat cover bolt 2 6 12 (1.2. 9) Fan motor shroud bolt 6 6 5 (0.9. 6.3) Cooling fan mounting nut 2 3 0 (0.1. 0.7) Apply locking agent to the threads. Fan motor mounting screw 6 4 .7 (0.3. 2.0) Water pump cover bolt 4 6 13 (1.3. 10) Apply locking agent to the threads. (’1) See page 1-20 LUBRICATION SYSTEM THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Engine oil filter cartridge 1 20 26 (2.7. 19) Apply engine oil to the threads. Sealing bolt (22 mm) 1 22 30 (3.1. 22) Apply locking agent to the threads. (’2) See page 1-21 Sealing bolt (24 mm) (CRF1000D) 1 24 30 (3.1. 22) Apply IOCKII’IQ agent to the threads. (’2) See page 1-21 Oil pump flange bolt 6 6 2 (1.2. 9) Oil pump mounting bolt 3 6 16 (1.6. 12) CYLINDER HEADNALVEICAMSHAFT THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Cylinder head cover bolt 3 6 O (1.0. 7) Rocker arm shaft bolt 2 6 12 (1.2. 9) Apply engine oil to thethreads and seating surface. Rocker arm shaft stopper bolt 1 14 18 (1.8. 13) Camshaft holder bolt 6 6 12 (1.2. 9) Apply engine oil to thethreads and seating surface. Carn sprocket bolt 2 7 20 (2.0. 15) Apply locking agent to the threads. (’2) See page 1-21 Cylinder head bolt 6 12 83 (8.5. 61) Apply molybdenum oil solution to the threads and seating surface. Apply engine oil solution to the washer. Insulator band screw (engine side) 2 — — See page 10-19 1-14 ALTERNATORISTARTER CLUTCH GENERAL INFORMATION THREAD TORQUE ITEM Q'TY DIA- (mm) N-m (kgf-m, REMARKS lbl-ft) Alternator cover bolt 12 6 2 (1.2, 9) Stator mounting bolt 5 6 2 (1.2, 9) Apply locking agent to the threads. (‘1) See page 1-20 CKP sensor mounting bolt 2 6 2 (1.2, 9) Apply locking agent to the threads. (‘1) See page 1-20 Flywheel mounting bolt 1 12 137 (14.0, 101) Apply engine oil to the threads and seating surface. Starter clutch torx bolt 6 8 9 (3.0, 21) Apply locking agent to the threads. (‘2) See page 1-21 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Right crankcase cover bolt 15 6 2 (1.2, 9) Engine right side rear cover bolt 6 0 (1.0, 7) Clutch center nut 1 25 128 (13.1, 94) Apply engine oil to the threads and seating surface. Clutch set plate bolt 3 6 2 (1.2, 9) Primary drive gear mounting bolt 1 10 103 (10.5, 76) Apply engine oil to the threads and seating surface. Cam chain tensioner pivot bolt 1 8 23 (2.3, 17) Apply locking agent to the threads. (‘1) See page 1-20 Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads. (‘1) See page 1-20 Shift drum center bolt 1 8 23 (2.3, 17) Apply locking agent to the threads. (‘1) See page 1-21 Gearshift spindle set plate bolt 1 6 2 (1.2, 9) Apply locking agent to the threads. (‘1) See page 1-20 Gearshift spindle cover bolt 2 6 2 (1.2, 9) 1-15 GENERAL INFORMATION DUAL CLUTCH TRANSMISSION (CRF1ODOD) THREAD TORQUE ITEM Q'TY DIA- (mm) N-m (kgf-m, REMARKS lbf-ft) Feed pipe guide plate bolt 2 5 5 (0.5. 3.7) Feed pipe cover bolt 3 6 2 (1.2. 9) Right crankcase cover bolt 15 6 12 (1.2. 9) Water pipe mounting bolt 2 6 2 (1.2. 9) Clutch EOP sensor Wire stay bolt 1 6 2 (1.2. 9) Clutch EOP sensor cover socket bolt 2 6 10 (1.0. 7) Shift spindle angle sensor mounting 1 6 12 (1.2. 9) bolt Engine right side rear cover bolt 2 6 0 (1.0. 7) Linear solenoid valve body cover 4 6 12 (1.2. 9) bolt Linear solenoid valve stopper plate 1 6 2 (1.2. 9) Apply locking agent to the threads. bolt (’1) See page 1-20 Linearsolenoid valve body mounting 4 6 12 (1.2. 9) bolt Primary drive gear mounting nut 1 22 118 (12.0. 87) Apply engine oil to the threads and (left-hand thread) seating surface. Reduction gear cover torx bolt 3 6 4 (1.4. 10) Shift control motor mounting torx bolt 3 6 14 (1.4. 10) Shift control motor cover bolt 2 6 2 (1.2. 9) Shift drum center bolt 1 8 31 (3.2. 23) Apply locking agent to the threads. (’2) See page 1-21 Drum shifterguide plate/drum shifter 2 6 2 (1.2. 9) Apply locking agent to the threads. assembly mounting bolt (’1) See page 1-20 TR sensor mounting bolt 1 6 2 (1.2. 9) No.1/No.2 clutch EOP sensor 2 10 20 (2.0. 15) Clutch line EOP sensor 1 10 20 (2.0. 15) EOT sensor 1 10 15 (1.5. 11) Apply engine oil to the threads and seating surface. Neutral switch 1 10 12 (1.2. 9) Neutral switch terminal nut 1 4 1.7 (0.2. 1.3) CRANKCASEITRANSMISSIONIBALANCER THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Front balancer right bearing set plate 3 6 2 (1.2. 9) Apply locking agent to the threads. bolt (’1)See page 1-20 Front balancer gear bolt 1 10 103 (10.5. 76) Apply engine oil to the threads and seating surface. Oil pump driven gear set plate bolt 1 6 2 (1.2. 9) Apply locking agent to the threads. (’1)See page 1-20 Rear balancer shaft holder bolt 3 8 29 (3.0. 21) Mainshaft bearing set plate bolt 3 6 2 (1.2. 9) Apply locking agent to the threads. (’1)See page 1-20 Shift drum bearing setting bolt 2 6 2 (1.2. 9) Apply locking agent to the threads. (’1)See page 1-20 Main journal bolt 6 10 43 (4.4. 32) Apply molybdenum oil solution to the threads and seating surface. Crankcase 6 x 40 mm bolt 1 6 2 (1.2. 9) Blue paint Crankcase 8 mm bolt 9 8 24 (2.4. 18) Crankcase 10 mm bolt 1 10 39 (4.0. 29) Cam chain tensioner bolt 1 8 23 (2.3. 17) Apply locking agent to the threads. (’1)See page 1-20 1-16 CRANKSHAFTIPISTON/CYLINDER GENERAL INFORMATION THREAD TORQUE ITEM Q TY DIA- (mm) REMARKS Crankpin bearing cap bolt (new) 4 9 22 (2.2, 16) + 120° Apply engine oil to the threads and seating surface. Replace with a new one. Main journal bolt 6 1O 43 (4.4, 32) Apply molybdenum oil solution to the threads and seating surface. Crankpin bearing cap bolt 4 9 2 (2.2, 16) + 90° Applyengine oil to the threads and (retightening) seating surface. ENGINE REMOVAL/INSTALLATION THREAD TORQUE ITEM Q TY DIA- (mm) REMARKS Right lower Irame bolt 4 10 44 (4.5, 32) SWingarm pivot nut 1 16 80 (8.2, 59) Applyengine oil to the threads and seating surface. U»nut Rear lower nut (10 mm) 1 10 44 (4.5, 32) Front lower nut (10 mm) 1 10 44 (4.5, 32) Front middle nut (8 mm) 2 8 32 (3.3, 24) Front middle nut (10 mm) 1 1O 44 (4.5, 32) Front upper bolt 3 8 32 (3.3, 24) Rear upper bolt (8 x 25 mm) 2 8 32 (3.3, 24) Rear upper nut (8 mm) 1 8 32 (3.3, 24) Drive sprocket bolt 1 10 54 (5.5, 40) EOT sensor (CRF1000D) 1 1o 15 (1.5, 11) Clutch EOP sensor wire stay bolt 1 6 2 (1.2, 9) (CRF1000D) Clutch EOPsensorcoversocket bolt 2 6 0 (1.0, 7) (CRF1000D) FRONT WHEELISUSPENSIONISTEERING THREAD TORQUE ITEM Q TY DIA- (mm) REMARKS Handlebar weight bolt 2 18 55 (5.6, 41) ALOC bolt: replace with new ones. Lower handlebar holder mounting 2 1O 39 (4.0, 29) U»nut nut Upper handlebar holder socket bolt 4 8 32 (3.3, 24) LeIt handlebar switch housing 2 5 2.5 (0.3, 1.8) screw/washer Right handlebar switch housing 2 5 2.5 (0.3, 1.8) screw/washer Front brake master cylinder holder 2 6 9.8 (1.0, 7.2) bolt Pulser ring bolt (CRF1000A/D) 3 5 7 (0.7, 5.2) ALOC bolt: replace with new ones. Front brake disc bolt 12 6 20 (2.0, 15) ALOC bolt: replace with new ones. Front axle holder pinch bolt 4 8 22 (2.2, 16) Front axle nut 1 16 60 (6.1, 44) Fork bolt 2 — 35 (3.6, 26) Fork damper lock nut 2 1O 20 (2.0, 15) Fork socket bolt 2 — 34 (3.5, 25) Fork bottom bridge pinch bolt 4 8 25 (2.5, 18) Fork top bridge pinch bolt 4 8 22 (2.2, 16) Front brake hose clamp mounting 1 6 0 (1.0, 7) bolt Steering stern adjusting nut 1 26 15 (1.5, 11) See page 17-26 Steering stern nut 1 24 100 (10.2, 74) See page 17-26 1-17 GENERAL INFORMATION REAR WHEEL/SUSPENSION screw THREAD TORQUE ITEM Q'TY DIA- (mm) REMARKS Rear brake disc bolt 6 8 42 (4.3, 31) ALOC bolt: replace with new ones. Driven sprocket nut 5 12 100 (10.2, 74) Apply engine oil to thethreads and seating surface. U-nut Pulser ring bolt (CRF1000A/D) 4 5 7 (0.7, 5.2) ALOC bolt: replace With new ones. Rear axle nut 1 18 100 (10.2, 74) U-nut Rear shock absorber upper 2 10 54 (5.5, 40) U»nut mounting nut Rearshockabsorberlowermounting 2 10 4 (4.5, 32) U»nut nut Lower cushion arm nut 1 1O 55 (5.6, 41) U»nut Upper cushion arm nut 1 12 74 (7.5, 55) U-nut Cushion connecting rod mounting 1 10 45 (4.6. 33) Apply engine oil to the threads and nut seating surface. U-nut Drive chain slider screw 3 5 4.2 (0.4, 3.1) ALOC screw: replace with new ones. Drive chain guard bolt 2 6 O (1.0, 7) ALOC bolt: replace with new ones. Swmgarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and seating surface. U-nut Parking cable guide bolt 1 6 O (1.0, 7) (CRF1000D) Rear brake hose clamp mounting 1 6 O (1.0, 7) bolt Rear brake hose guide mounting 3 5 1.2 (0.1, 0.9) ALOC screw: replace With new ones. 1-18 GENERAL INFORMATION HYDRAULIC BRAKE THREAD TORQUE ITEM Q'TY DIA- (mm) N-m (kgf-m, REMARKS lbI-ft) Brake caliper bleed valve 3 8 5.4 (0.6, 4.0) Front brake mastercylinderreservoir 2 4 1.5 (0.2, 1.1) cap screw Rear brake master cylinder reservoir 2 4 1.5 (0.2, 1.1) cap screw Rear brake master cylinder reserve 1 6 0 (1.0, 7) tank mounting bolt Front brake caliper mounting bolt 4 10 5 (4.6, 33) ALOC bolt: replace with a new one. Rear brake caliper mounting bolt 1 8 2 (2.2, 16) ALOC bolt: replace with a new one. Rear brake pad pin 1 10 7 (1.7, 13) Parking brake caliper mounting bolt 2 8 1 (3.2, 23) ALOC bolt: replace with a new (CRF10000) one. Parking brake caliper cover socket 2 6 9 (0.9, 6.6) bolt (CRF1000D) Parking brake pad pin (CRF1000D) 2 8 17.2 (1.8. 13) ALOC bolt: replace with a new one. Front brake master cylinder holder 2 6 9.8 (1.0, 7.2) bolt Brake hose oil bolt 5 10 34 (3.5, 25) Front brake light sWItch mounting 1 4 1.2 (0.1, 0.9) screw Front brake lever pivot bolt 1 6 1.0 (O 1, 0.7) Front brake lever pivot nut 1 6 5.9 (O 6, 4.4) Step bracket mounting bolt 4 10 35 (3 6, 26) Rear brake master cylinder 2 6 14 (1 4, 10) mounting bolt Rear brake master cylinder hose 1 4 1 5 (0.2, 1 1) Apply locking agent to the threads. Joint screw (‘1) See page 1-20 Rear brake master cylinder push rod 1 8 17.2 (1.8. 13) lock nut Parking brake lever pivot bolt 1 6 1.0 (0.1, 0.7) (CRF10000) Parking brake lever pivot nut 1 6 5.9 (0.6, 4.4) (CRF10000) Parking brake lock lever pivot bolt 1 6 6.9 (0.7, 5.1) (CRF10000) Parking brake stopper stay flange 1 6 11.9 (1.2, 9) bolt (CRF1000D) Parking brake stopper stay HEX bolt 1 4 2.3 (0.2, 1.7) (CRF10000) Parking brake switch mounting 1 4 1.2 (0.1, 0.9) Apply locking agent to the threads. screw (CRF1000D) Parking brake adjuster lock nut 1 8 17.2 (1.8. 13) (CRF10000) Parking brake caliper pin bolt 1 8 2 (2.2, 16) (CRF1000D) 1-19 GENERAL INFORMATION ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000AID) THREAD TORQUE ITEM Q TY DIA- (mm) N-m (kgf-m, REMARKS lbf-ft) Front brake hose clamp mounting 1 6 O (1.0, 7) bolt Rear brake hose clamp mounting 1 6 O (1.0, 7) bolt Rear brake hose guide mounting 3 5 1.2 (0.1, 0.9) ALOC screw: replace With new screw ones. Brake hose oil bolt 2 10 34 (3.5. 25) Brake pipe Joint nut 2 1O 14 (1.4, 10) Apply brake fluid to the threads. Front wheel speed sensor mounting 1 6 O (1.0, 7) ALOC bolt: replace with a new bolt one. Rear wheel speed sensor mounting 1 6 O (1.0, 7) ALOC bolt: replace with a new bolt one. LIGHTS/METERS/SWITCHES THREAD TORQUE ITEM QTY DIA- (mm) N-m (kgf-m, REMARKS lbf-ft) Turn signal light mounting nut 4 6 8.8 (0.9, 6.5) (CRF1000) License light cover screw 2 5 3.8 (0.4, 2.8) Combination meter mounting screw/ 4 5 1.0 (0.1, 0.7) Tapping screw washer EOP sWitch (CRF1000/A) 1 PT 1/8 2 (1.2, 9) Apply sealant to the threads. See page 22-20 EOP sWitch terminal bolt/washer 1 4 2 (0.2, 1.5) (CRF1000/A) EOP sensor (CRF1000D) 1 10 22 (2.2, 16) Ignition switch mounting bolt 2 8 26 (2.7, 19) Replace with a new one. Gear position switch mounting bolt 1 6 10 (1.0, 7) (CRF1000/A) Sidestand sWitch mounting bolt 1 6 10 (1.0, 7) Replace With a new one. OTHERS THREAD TORQUE ITEM QTY DIA- (mm) REMARKS Clutch lever pivot bolt (CRF1000/A) 1 6 1.0 (0.1. 0.7) Clutch lever pivot nut (CRF1000/A) 1 6 5.9 (0.6, 4.4) U-nut Pillion step bracket mounting bolt 4 8 34 (3.5. 25) Throttle cable A/B nut 2 10 1.5 (0.2, 1.1) (sWitch housing side) ’1: Apply locking agent to the threads as shown. 6.511.0rnrn 2.011.0mrn (0.26 1 0.04 in)», «(0 00 t 0.04 in) Apply this area Don The bolt shown is typical. ot apply this area. 1-20 GENERAL INFORMATION ‘2: Apply locking agem to ‘he threads as shown. 6.5 x 1.0 mm (o 26 x 0.04 in) Apply mis area. The be“ shown is lypica‘. 1-21 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Sealant (T512075 manufactured by ThreeBond or an equivalent) Crankcase mating surface See page 14-27 Alternator cover mating surface See page 1 1-6 CKP sensor Wire grommet See page 1 1-7 Right crankcase cover mating surface CRF1000/A: See page 12-6 CRF1000D: See page 13-55 Linear solenoid valve wire grommet See page 13-61 Sealant (T55211C manufactured by ThreeBond, KE45T manufactured by Shin-Etsu Silicone or an equivalent) Cylinder head cover packing See page 10-5 Molybdenum oil solution (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease) Rocker arm sliding area and thrust surface Rocker arm shaft outer surface Camshaft journals carn lobes, and thrust surface Valve stern sliding area and stem end Starter reduction gears shaft outer surfaces Clutch outer guide entire surface (CRF1000/A) Primary driven gear teeth and clutch outer sliding surface (CRF1000/A) Judder spring and judder spring seat entire surface (CRF1000/A) Primary drive gear sliding surface Primary driven gear teeth, friction springs, and boss sliding area (dual clutch assembly, CRF1000D) Front balancer driven gear sliding area and thrust surface Rear balancer driven gear, sub driven gear. friction spring. and washer sliding surface Rear balancer thrust spring sliding surface Rear balancer driven gear sliding area and thrust surface Oil pump driven gear shaft outer surface Each transmission bushing inner/outer surface Each transmission needle bearing inner/outer surface Each transmission spline bushing outer surface M3. M4, C5, C6 gear (shift fork grooves and spline area) Shift fork shaft outer surface Main Journal bearing sliding surface Crankshaft thrust surface Crankpin bearing sliding surface Connecting rod small end inner surface Piston pin outer surface Engine oil Valve adjusting screw threads Oil strainer seal ring entire surface Starter one-way clutch sliding surface Clutch discs entire surface Dual clutch assembly O-ring entire surface (CRF1000D) Piston pin hole inner surface Piston sliding surface Piston ring groove Piston ring entire surface Each bearing rolling area and contact surface Each gear teeth and rotating surface Each O-ring entire surface Other rotating area and sliding surface Lithium based multi-purpose grease NLGI #2 or equivalent Each oil seal lips Locking agent Carri chain guide plate bolt threads Coating Width: See page 1-20 UNIREX N3 manufactured by ExxonMobil or equivalent Shift reduction gear teeth and journal (CRF10000) 2 —4 g (0.07—0.14 02) 1-22 GENERAL INFORMATION FRAME MATERIAL LOCATION REMARKS Urea based multi-purpose extreme pressure grease NLGI #2 (EXCELITE EPZ manufactured by KYODO YUSHI CO., LTD. or equivalent) Steering head bearing rolling contact surface 3—5 g (0.1 —0.2 oz) Steering head dust seal lips Lithium based multi-purpose grease NLGI #2 or equivalent Seat catch hook sliding area Gearshift pedal pivot sliding area (grease groove) (CRF1000/A) Throttle cable end and throttle grip pipe flange groove Wheel dust seal lips Rear wheel hub O-ring (driven flange side) Rear brake middle arm pivot sliding surface Parking brake stopper stay teeth and lock lever pivot sliding surface (CRF1000D) Parking brake lever pivot sliding surface (CRF1000D) Clutch lever pivot sliding area (CRF1000/A) Molybdenumdisulfidegrease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent) Sidestand collar outer surface Sidestand pivot sliding surface Swmgarm pivot dust seal lips Swingarm pivot needle bearings Cushion arm dust seal lips Cushion arm needle bearings Cushion connecting rod needle bearings Cable lubricant Seat lock cable outer inside Honda Bond A or an equivalent Handlebar grip rubber inside ThreeBond 1521 or an equivalent Swingarm cap mating surface Rear brake pad retainer mating surface Silicone grease Front brake lever pivot bolts sliding surface 0.10 g (0.004 oz) minimum Front brake lever-to-master piston contacting area 0.10 g (0.004 oz) minimum Rear brake master cylinder push rod sliding surface 0.10 g (0.004 oz) minimum Rear brake master cylinder push rod boot fitting area 0.10 g (0.004 oz) minimum Rear brake pad pin stopper ring Brake caliper dust seals Rear brake caliper sleeve sliding surface 0.4 g (0.01 oz) minimum Rear brake caliper pin bolt sliding surface 0.4 g (0.01 oz) minimum Parking brake push rod rolling surface (CRF1000D) 0.4 g (0.01 oz) minimum Parking brake piston sliding surface (CRF1000D) 0.4 g (0.01 oz) minimum Parking brake shaft threads (CRF1000D) 0.4 g (0.01 oz) minimum Parking brake shaft boot lips (CRF1000D) 0.4 g (0.01 oz) minimum Parking brake pin bolt sliding surface (CRF1000D) 0.4 g (0.01 oz) minimum Parking brake caliper bracket pin sliding surface 0.4 g (0.01 oz) minimum (CRF1000D) DOT 4 brake fluid Brake master piston and cups Brake caliper piston Brake caliper piston seals Rear master cylinder reservoir hose Joint O-ring Fork fluid Fork cap O-ring Fork dust seal and oil seal lips Dive chain lubricant designed specifically for O-ring chains or SAE #80-90 gear oil Drive chain whole surface 1-23 GENERAL INFORMATION SPECIAL TOOL LIST TITLE TOOL No TOOL NAME MAINTENANCE 077080030400 Valve adjusting wrench 07HAA-PJ70101 Oil filter wrench 07HMH-MR10103 Drive chain tool set PGM-Fl SYSTEM 070PZ-ZY30100 SCS connector 07ZAJ-RDJA1 10 Test probe FRXMI 7 (Snap on) Sensor socket wrench IGNITION SYSTEM 07HGJ-0020100 Peak voltage adaptor 07ZAJ-RDJA1 10 Test probe FUEL SYSTEM 074060040004 Fuel pressure gauge 070MJ-K260i00 Pressure gauge attachment set 07ZAJ-SSA0130 Hose attachment, 6 mm/Q mm 07ZAJ-S7C0i00 Hose attachment, 8 mm/9 mm 07ZAJ-S7C0200 Attachment Joint. 8 mm/Q mm 07ZAJ-SSA0150 Attachment Joint. 6 mm/Q mm LUBRICATION SYSTEM 070MJ-0010101 Oil pressure gauge attachment 07HAA-PJ70101 Oil filter wrench 07506-3000001 Oil pressure gauge set 07406-0030000 Oil pressure gauge attachment CYLINDER HEAD/VALVE/CAMSHAFT 070MG-0010100 Tensioner holder B 07757-0010000 Valve spring compressor 07742-0010100 Valve guide driver 5.5 mm 07743-0020000 Valve guide driver 07984-2000001 Valve guide reamer. 5.5 mm 07781-0010101 Cutter holder. 5.5 mm 07780-0010500 Seat cutter. 40 mm (45° IN) 07780-0010400 Seat cutter. 35 mm (45° EX) 07780-0013000 Flat cutter. 42 mm (32° IN/EX) 07780-0014700 Interior cutter. 34 mm (60° IN/EX) ALTERNATOR/STARTER CLUTCH 077250040001 Flywheel holder 07733-0020001 Rotor puller CLUTCH/GEARSHIFT LINKAGE 07724-0050002 Clutch center holder PD. 4% >135 (CRF1000/A) 07916-9690000 Lock nut wrench 30 X 40 mm 07749-0010000 Driver 07746-0010100 Attachment. 32 X 35 mm 07746-0040400 Pilot. 17 mm 07QAD-POA0100 Attachment. 42 mm 07746-0010300 Attachment. 42 X 47 mm 07746-0040800 Pilot. 35 mm 07724-0010100 Gear holder. 2.5 DUAL CLUTCH Transmission (DCT) 07ZAJ-RDJA110 Test probe (CRF1000D) 07HGJ-0020l00 Peak voltage adaptor 07741-0010201 Remover weight 07JAC-PH80200 Bearing remover shaIt 07JAC-PH80100 Adiustable bearing puller. 20 — 40 mm 0793645710600 Bearing remover set. 20 mm 0793645710100 Remover handle 07749-0010000 Driver 07746-0010400 Attachment. 52 X 55 mm 07746-0040900 Pilot. 40 mm 07746-0040500 Pilot. 20 mm 07LAE-PX40000 Clutch compressor set 07724-0010100 Gear holder. 2.5 1-24 GENERAL INFORMATION TITLE TOOL No TOOL NAME CRANKCASE/TRANSMISSION/BALANCER 07724-0010100 Gear nolder, 2.5 07LAE-PX40000 Clutch compressor set 07936-ZV10100 Bearing remover shaft set, 25 mm 07741-0010201 Remover weight 07949-3710001 Driver, 15 x 280L 07746-0010400 Attachment. 52 x 55 mm 07746-0040600 Pilot. 25 mm 07746-0040200 Pilot. 12 mm 07PPD-YE10100 Seal driver. 14 x 22 mm FRONT WHEEL/SUSPENSION/STEERING 077460050600 Bearing remover head, 20 mm 07746-0050100 Bearing remover shaft 07749-0010000 Driver 07746-0010300 Attachment. 42 X 47 mm 07746-0040500 Pilot. 20 mm 070MF-MBZC110 Spring collar holder 070MF-MBZC130 Stopper plate 07KMD-K230100 Fork seal driver, 45.2 mm 070MF-MBZC120 Damper rod holder 07916-KA50100 Steering stem socket 07953-MJ10100 Remover attachment 07953-MJ10200 Remover handle 07946-3710500 Bearing remover 07946-Ml300000 Inner driver, 30 x 36 x 300 L 07746-0010400 Attachment. 52 x 55 mm REAR WHEEL/SUSPENSION 07749-0010000 Driver 07746-0010800 Attachment. 22 X 24 mm 07746-0040400 Pilot. 17 mm 07746-0050600 Bearing remover head, 20 mm 07GGD-0010100 Bearing remover shaft 07746-0010300 Attachment. 42 x 47 mm 07746-0040500 Pilot. 20 mm 07946-1870100 Attachment. 28 x 30 mm 07746-0010400 Attachment. 52 x 55 mm 07746-0041000 Pilot. 22 mm 07741-0010201 Remover weight 07936-3710100 Remover handle 07936-3710300 Bearing remover set. 17 mm 07936-3710600 Bearing remover set. 20 mm 07949-3710001 Driver handle 15 x ZSOL 07746-0010100 Attachment. 32 x 35 mm 07746-0040600 Pilot. 25 mm HYDRAULIC BRAKE 07914-SA50001 Snap ring pliers ANTI-LOCK BRAKE SYSTEM (ABS) 07ZAJ-RDJA110 Test probe (CRF1000A/D) BATTERY/CHARGING SYSTEM BM-210 Battery tester LlGHT/METERS/SWITCHES 07ZAJ-RDJA110 Test probe 07HGJ-0020100 Peak voltage adaptor IMMOBILIZER SYSTEM (HISS) 07XMZ-MBW0101 Inspection adaptor 070MZ-MEC0101 Test harness adaptor 07ZAJ-RDJA110 Test probe 1-25 GENERAL INFORMATION CABLE & HARNESS ROUTING THROTTLE CABLE B CRF1000IA: CLUTCH CABLE CRFIOOOD: PARKING BRAKE CABLE THROTTLE CABLE A CRF1000IA: CLUTCH CABLE CRF1000D: PARKING BRAKE CABLE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE B THROTTLE CABLE A RIGHT HANDLEBAR SWITCH WIRE 70 mm (28 in) SEE%S FRONT BRAKE HOSE A 1-26 GENERAL INFORMATION CRF1000D shown: COMBINATION METER 32F (Gray) CONNECTOR I I l CRF1000A: REAR ABS SWITCH I HEADLIGHT 2 2F' (Black) CONNECTOR [I 2P (BIaCk) CRF1000D: REAR ABS/G SWITCH , CONNECTOR HEADLIGHT 1 AP (Black) CONNECTOR I 2P CONNECTOR FRONT OPTION 4P CONNECTOR LEFT FRONT TURN SIGNAL LIGHT 2P (Orange) CONNECTOR OPEN AI R TEMPERATURE SENSOR 2F' (Black) MAIN FRONT SUB CONNECTOR WIRE HARNESS 2 HARNESS 12p (Gray) RIGHT FRONT TURN FRONT SUB HARNESS 3 CONNECTOR SIGNAL LIGHT 2P CONNECTOR (LIgm que) CRF1000/A: 12F (Black) FRONT SUB HARNESS 1 CONNECTOR CRF1000I3: 8F' (Black) 1ZP (BIack) CONNECTOR 1-27 GENERAL INFORMATION CRF1000D shown: IMMOBILIZER RIGHT RECEIVER WIRE HANDLEBAR LEFT SWITCH WIRE HANDLEBAR IMMOBILIZER SWITCH WIRE RECEIVER WIRE FRONT SUB HARNESS 1 12P (BIack) CONNECTOR FRONT SUB HARNESS 2 LEFT HANDLEBAR 12P (Gray) CONNECTOR SWITCH WIRE MAIN WIRE IGNITION SWITCH HARNESS WIRE FRONT BRAKE HOSE A HORN WIRE FRONT WHEEL SPEED SENSOR WIRE (CRF1000A/D) IGNITION SWITCH WIRE FRONT WHEEL SPEED SENSOR WIRE (CRF1000A/D) CRF1000: FRONT BRAKE HOSE A CRF1000AID: FRONT BRAKE HOSE D FRONT WHEEL SPEED SENSOR (CRF1000A/D) CRF1000: FRONT BRAKE HOSE B CRFIOOOA/D: FRONT BRAKE HOSE E 1-28 GENERAL INFORMATION CRF1000D shown: HORN WTRE MAIN WIRE HARNESS LEFT FAN MOTOR 2P (BTack) ‘GNITION CONNECTOR SWITCH WIRE OPTION 4P (Black) CONNECTOR (an heaIer swimh) IMMOBILIZER RECEIVER WIRE OF'T‘ON 2P (BTack) CONNECTOR LEFT (Lefl grip healer) HANDLEBAR SWITCH WTRE LEFT HANDLEBAR SWITCH CONNECTOR CRF100014P (Black) CRF1000A: 6P (Black) CRF1000D:12P(BTack) LEFT HANDLEBAR 5/ SWITCH CONNECTOR , / CRF1000: 12p (Gray) CRF1000A/D: 1GP (Gray) / ECT SENSOR 2P (Black) CONNECTOR MAIN WIRE HARNESS No.1 CYLTNDER SUB PLUG CAP MAIN WIRE HARNESS 1-29 GENERAL INFORMATION CRF1000IA (CRF1ODO shown) ALTERNATOR ASSEMBLY WIRE SIDESTAND SWITCH WIRE To VS sensor GEAR POSITION SWITCH WIRE FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE RADIATOR RESERVE TANK DRAIN HOSE SIDESTAND SWITCH ALTERNATOR WIRE ASSEMBLY WIRE FUEL TANK BREATHER HOSE SIDESTAND EOP SWITCH SWITCH WIRE RADIATOR ALTERNATOR DRAIN RESERVE ASSEMBLY WIRE HOSE TANK DRAIN HOSE 1-30 GENERAL INFORMATION cRF1ODDD: VS/OUTER MAINSHAFT SENSOR WIRE ALTERNATOR SIDESTAND ASSEMBLY WIRE SWITCH WIRE SHIFT CONTROL MOTOR 2P (BIack) CONNECTOR ALTERNATOR FUEL TANK ASSEMBLY WIRE DRAIN HOSE / SIDESTAND SWITCH WIRE FUEL TANK BREATHER HOSE RADIATOR RESERVE TANK DRAIN HOSE EOP SENSOR 3P (Black) CONNECTOR SIDESTAND SWITCH WIRE ALTERNATOR ASSEMBLY WIRE 1-31 GENERAL INFORMATION CRF1000D shown: FRONT BRAKE HOSE A RIGHT HANDLEBAR SWITCH W‘RE CRF1000/A: CLUTCH CABLE CRF1000D: F'ARK‘NG BRAKE CABLE THROTTLE CABLES FRONT BRAKE HOSE A FRONT BRAKE P‘PE A CRF1000: FRONT BRAKE HOSE A CRF1000A/D: FRONT BRAKE HOSE D FRONT BRAKE PIF'E C FRONT WHEEL SPEED SENSOR WIRE CRF1000: FRONT BRAKE HOSE B CRF1000A/D: FRONT BRAKE HOSE E 1-32 GENERAL INFORMATION an1ooo/A (CRF1000 shown) RIGHT HANDLEBAR SWITCH OPTION 2P (Black) CONNECTOR 8P (Gray) CONNECTOR (Righx grip healer) I I THROTTLE ,’ THROTTLE CABLE B CLUTCH CABLE RIGHT FAN MOTOR 2F' (Black) CONNECTOR SIF'HON HOSE AIR CLEANER HOUSING DRAIN HOSE N02 CYLINDER SUB PLUG CAP RADIATOR HOSE B RADIATOR LOWER HOSE Oz SENSOR 4P (Black) CONNECTOR 1-33 GENERAL INFORMATION CRF1000D: LINEAR SOLENOID VALVE 4P (Black) CONNECTOR OPTION 2P (Black) RIGHT HANDLEBAR CQNNECTOR SWITCH 6P (Black) (RIghI ngp healer) CONNECTOR LINEAR SOLENOID RIGHT HANDLEBAR VALVE WIRE SWITCH 8P (Gray) CONNECTOR stHoN HOSE SIPHON HOSE THROTTLE CABLES FRONT BRAKE PARKING PIPE A BRAKE CABLE RIGHT I=AN MOTOR 2P (BIack) CONNECTOR AIR CLEANER HOUSING DRAIN HOSE STARTER RELAY SWITCH No.2 CYLINDER SUB REARBRAKE PLUG CAP SWITCH RADIATOR HOSE B PARKING LINEAR SOLENOID BRAKE CABLE VALVE WIRE SHIFT SPINDLE ANGLE SENSOR LOWER RADIATOR HOSE No.1 CLUTCH EOP SENSOR MAIN WIRE HARNESS %/ N01 CLUTCH EOP SENSOR Oz SENSOR 4P (Black) WATER PIPE CONNECTOR U CLUTCH LINEAR EOT SENSOR LINE EOP MAIN WIRE E] SOLENOID 3P (Black) L, From SENSOR » From HARNESS I I‘D: VALVE WIRE CONNECTOR _v J Iil‘JEfl yfi RIM/Nx 10 mm ’ AIRCLEANER v/ 5? (Lomfi HOUSING LINEAR SOLENOID ~ maXImum DRA'N HOSE LINEAR SOLENOID VALVE WIRE VALVE WIRE MAIN WIRE HARNESS MAIN WIRE HARNESS 1-34 GENERAL INFORMATION CRF1000D shown: FRONT WHEEL SPEED SENSOR 2P (BIack) CONNECTOR IAT SENSOR RAD'ATOR 2P (Blue) MAIN WIRE PAIR CONTROL HOSE A CONNECTOR HARNESS SOLENOID VALVE 2P SIPHON (BIack) CONNECTOR HOSE RAD'ATOR AIR SUPPLY HOSE MAINWIRE HARNESS K " I ,4» ’ GLTsSEUCT‘O” BREATHER HOSE No.2 Y ID No.1 CYLINDER MAIN CYLINDER IGNITION COIL ‘Igl-NINHON COIL IGNITION SWITCH . _ . 2P (Brown) CONNECTOR No.2 CYLINDER SUB IGNITION COIL No.1 CYLINDER THROTTLE CABLE A SUB IGNITION COIL THROTTLE CABLE B IMMOBILIZER RECEIVER 4P (BIack) CONNECTOR IGNITION COIL WIRE 6F' (Black) CONNECTOR 1-35 GENERAL INFORMATION CRF1000: MAP SENSOR 3P (Black) CONNECTOR IACV 4P (Black) CONNECTOR CLUTCH CABLE \ FUEL TANK DRAIN HOSE MAIN WIRE HARNESS \ 7, FUEL TANK ’ E BREATHER HOSE SIPHON HOSE FUEL LEVEL SENSOR 2P (Black) CONNECTOR FUEL FEED HOSE FUEL TANK BREATHER HOSE C (OPEN AIR) 1-36 GENERAL INFORMATION CRF1000A/D: MAP SENSOR 3P (Black) CONNECTOR IACV 4P (Black) CONNECTOR / \ I I\ \ \I \ J\U/ MAIN WIRE HARNESS FUEL TANK DRAIN HOSE ‘ FUEL TANK BREATHER HOSE FUEL LEVEL SENSORZP (Black) :léESLEFEED CONNECTOR SIF'HON HOSE FRONT BRAKE PIPE A FRONT BRAKE PIPE C \ FUEL TANK BREATHER HOSE C (OPEN AIR) FRONT BRAKE HOSE C FRONT BRAKE HOSE B 1-37 GENERAL INFORMATION CRF1000: MAIN WIRE HARNESS SEAT LOCK CABLE FUEL PUMP 3P (Black) CONNECTOR TURN SIGNAL LIGHT RELAY REGULATOR/RECTIFIER 3P (Black) CONNECTOR FUEL PUMP 3P (Black) CONNECTOR MAIN WIRE HARNES HISS 2P (Red) CONNECTOR SEAT LOCK CABLE MAIN WIRE HARNESS FUSE BOX 2 I FUSE BOX 1 I I I— ETC TRAY CLIP ETC TRAY HISS 2P (Red) CONNECTOR 1-38 GENERAL INFORMATION CRF1ODOA/D: REAR WHEEL REAR SPEED SENSOR BRAKE WIRE HOSE B FRONT BRAKE HOSE C REAR FENDER FRONT BRAKE HOSE B FUEL PUMP UNTT REAR 3P (mack) BRAKE CONNECTOR HOSE A REAR WHEEL SPEED SENSOR 2P (Black) SEAT CONNECTOR LOCK CABLE REAR BRAKE HOSE B MQLNNVé/ISIRSE OPTION 3P (BIaCk) CONNECTOR (DCT Shifl pedal) FUSE BOX 3 (CRF1000D) MATN WTRE HARNESS FUSE BOX 2 r CLTP ETC TRAY FUSE BOX 1 ETC TRAY H|SS 2P (Red) CONNECTOR 1-39 GENERAL INFORMATION CRF1000: MAINWIRE HARNESS FUEL TANK \ DRAIN HOSE I FUEL TANK \ BREATHER HOSE C (OPEN AIR) ALTERNATOR ASSEMBLY WIRE / FUEL TANK BREATHER HOSE ALTERNATOR 3P (Gray) CONNECTOR BATTERY NEGATIVE (-) REAR BRAKE HOSE B CABLE BATTERY POSITIVE m CABLE CRF1000A/D: MAIN WIRE FRONT BRAKE REAR BRAKE REAR BRAKE REAR BRAKE HARNESS HOSE B HOSE A PIPE HOSE B FUEL TANK FRONT BRAKE DRAIN HOSE HOSE C FRONT BRAKE FUEL TANK PIPE B BREATHER HOSE C (OPEN AIR) 9 ; FUEL TANK BREATHER ALTERNATOR HOSE ASSEMBLY WIRE BATTERY ALTERNATOR 3P (Gray) CONNECTOR PARKING BRAKE NEGATIVE (-) CABLE (CRF1000D) BATTERY CABLE POSITIVE (+) CABLE REAR BRAKE HOSE B 1 -40 GENERAL INFORMATION CRF1ODOIA: JUNCTION 1 JUNCTION 2 MAIN WIRE HARNESS ALTERNATOR ASSEMBLY WIRE SIDESTAND SWITCH 2P (BIacK) ALTERNATOR CONNECTOR ASSEMBLY 6P (Black) CONNECTOR REAR BRAKE LIGHT SWITCH 2P (Gray) FUEL TANK CONNECTOR BREATHE HOSE REAR BRAKE LIGHT SWITCH SIF'HON HOSE FUEL TANK DRAIN HOSE Oz SENSOR WIRE GEAR POSITION SWITCH 8P (Black) CONNECTOR cRF1oooD: MAIN WIRE JUNCTION 1 JUNCTION 2 sIDESTAND HARNESS SWITCH 2P (BIack) CONNECTOR ALTERNATOR ASSEMBLY WIRE \ REAR BRAKE LIGHT SWITCH 2P (Gray) CONNECTOR PARKING BRAKE CABLE \ I I ALTERNATOR ASSEMBLY 6P I (Black) CONNECTOR ( NEUTRAL ~ A _ _ _ % I REAR BRAKE LIGHT SWITCH SIPHON HOSE SWITCH T SHIFT SPINDLE ANGLE SENSOR 3P (Blue) CONNECTOR FUEL TANK Oz SENSOR WIRE DRAIN HOSE / TR SENSOR 3P (BIacK) CONNECTOR INNER MAINSHAFT SENSOR 3P (BIack) CONNECTOR 1-41 GENERAL INFORMATION CRF1000D shown: 7 REAR TURN SIGNAL LIGHT WIRES 7 LICENSE LIGHT WIRE REAR OPTION 6P CONNECTOR FAN CONTROL RELAY MAIN WIRE HARNESS BRAKE/TAILLIGHT 3P (Black) CONNECTOR OPTION 10P (Black) CONNECTOR (G rIp heaIer Conxroller) LICENSE LIG WIRE RIGHT TURN SIGNAL LIGHT WIRE // LEFT REAR TURN \ SIGNAL LIGHT 2P / (Orange) CONNECTOR I R, LICENSE 2P (WIIIIe) \ CONNECTOR \ RIGHT REAR TURN STARTER \\ / SIGNAL LIGHT 2F' (Lighl RELAY HEADLIGHT MAIN WIRE blue) CONNECTOR (CRHOOOD) RELAY HARNESS FUEL PUMP FI RELAY RELAY RELAYS RELAY Insen The upper cover lab COVER Inlo Ihe lower Cover sIoI. 1 -42 GENERAL INFORMATION CRF1000: SIF'HON HOSE REAR BRAKE LIGHT SWITCH REAR BRAKE RES E RVE TAN K REAR BRAKE HOSE A REAR BRAKE HOSE A 1 -43 GENERAL INFORMATION CRF1000A/D: REAR BRAKE CRF1000D Shown: HOSE B REAR BRAKE PARKING SIPHON REAR REAR WHEEL SPEED HOSE A BRAKE CABLE HOSE BRAKE SENSOR WIRE (CRF1000D) LIGHT SWITCH REAR BRAKE HOSE B REAR BRAKE RESERVE TANK PARKING PARKING BRAKE CABLE BRAKE CABLE (CRF1000D) (CRF1000D) REAR BRAKE HOSE B Up a S?» - REAR WHEEL SPEED SENSOR WIRE Up REAR WHEEL SPEED SENSOR WIRE REARBRAKE HOSE B Up '9 L . REAR WHEEL REAR WHEEL (Q J R'gm SPEED SPEED SENSOR WIRE SENSOR WIRE REAR BRAKE HOSE B REAR WHEEL REAR BRAKE HOSE B SPEED REAR WHEEL PARKING SENSOR SPEED BRAKE CABLE SENSOR WIRE (CRF1000D) 1 -44 GENERAL INFORMATION CRF1000D shown: White paint RADIATOR UPPER HOSE thte paxnt Wmte paint Prevent the water hase band from interfering thh the radiator stay. RADIATOR ‘ HOSEB Rear CRF1000/A. Right 5!! "Es? RADIATOR LOWER HOSE 1-45 GENERAL INFORMATION CRF1000D shown: \nsen me hose unlil Ihe index mark. WATER BOTTOM HOSE thle pain: CRF1000/A: WATER BOTTOM HOSE RAD‘ATOR HOSE A Insen me hose unm Ihe punch mark. Insert Ihe hose umil the index mark, - \nserl the hose unm me punch mark. 1 -46 GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide (CO), oxides oI nitrogen (NOx) and hydrocarbons (HC). The control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Uncontrolled fuel evaporation also releases hydrocarbons to the atmosphere. Honda Motor Co., Ltd. utilizes various system to reduce carbon monoxide, hydrocarbons, and oxides of nitrogen. 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. AIR CLEANER HOUSING <)=| FRESH AiR BLOW»BY GAS 4- g _W J 1-47 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a secondary air injection system, a three-way catalytic converter and PGM-FI system. SECONDARY AIR SUPPLY SYSTEM The secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse Secondary Air Injection) control solenoid valve. This charge 01 Iresh air promotes burning of the unburned exhaust gases and changes a considerable amount 01 hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevents reverse air flow through the system. The PAIR oontrol solenoid valve is operated by the solenoid valve. The solenoid valve is controlled by the ECM/PCM. and the fresh air passage is opened/closed according the running condition (ECT/lAT/TP/MAP sensor and engine revolution). No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended. AIR CLEANER HOUSING PAIR CONTROL THROTTLE BODY PAIR REED VALVE EXHAU ST PORT Q: FRESH AIR {- EXHAUST GAS 7, Three-way catalytic converter This motorcycle is also equipped with three-way catalytic converter, and two heated oxygen sensors. The three-way catalytic converter is in the exhaust system. Through chemical reactions, they convert HC, CO, and NOx in the engine‘s exhaust to carbon dioxide (C02), dinitrogen (N2), and water vapor. No adjustment to these systems should be made although periodic inspection ot the components is recommended. 1 -48 GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local low may prohibits the following acts or the causing thereof: (1) 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 motorcycle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use: (2) the use of the motorcycle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2. Removal or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4. Replacing any moving parts of the motorcycle, or parts of the exhaust or intake system, with parts other then those specified by the manufacturer. NOISE EMISSION CONTROL SYSTEM (U model) TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local low may prohibits the following acts or the causing thereof: (1) 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 motorcycle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use: (2) the use of the motorcycle after such device or element of design has been removed or rendered inoperative by any person. 1 -49 GENERAL INFORMATION TECHNICAL FEATURES ABS WITH MODE-SELECTION MECHANISM (REAR ABS OFF MODE) (CRF1000AID) SYSTEM OVERVIEW The CRFiODOA/D (ABS type) is equipped with an ABS with selectable modes. In the ABS with mode»selection mechanism, the front ABS functions as a regular ABS, but the rear ABS can be cancelled; this mechanism gives greater freedom of off-road riding while ensuring the safety. To switch between the modes, press and hold the rear ABS switch for more than two seconds when the motorcycle is stopped, then the rear ABS OFF indicator blinks. Releasing the rear ABS switch while the indicator blinks turns the indicator to stay on and cancels the rear ABS. When in the rear ABS OFF mode, only when the rear ABS OFF indicator fails, the fail safe function is activated to actuate both front and rear ABSs. Neither the front nor rear ABS is actuated by other types Of failure: for those failures, the ABS indicator starts blinking to warn of the failure. To cancel the rear ABS OFF mode, press the rear ABS switch for more than two seconds. INDICATORS AND SWITCHES LOCATION REAR ABS OFF INDICATOR REAR ABS SWITCH SYSTEM DIAGRAMS (f m Motorcycle speed I {5/ R __ i I I Iant/reartire slipping rate Hydraulic brake pressure control ) Sensing rear wheel speed Sensing front / wheel speed The front ABS / is controlled. FRONT WHEEL SPEED SENSOR The rear ABS hydraulic brake pressure control IS canceled when the rear ABS OFF mode. FRONT BRAKE CALIPER ABS MODULATOR REAR BRAKE REAR WHEEL CALIPER SPEED SENSOR 1-50 GENERAL INFORMATION COMBINATION METER @) 335$? 3%} Switch signal 59?. /\ Rear wheel speed Fronl wheel speed ! —! ABS MODULATOR lndicalor ECU signal Ouipul lndicalor signal oulpul RearABS OFF ABS DIAGNOSIS Indicalor diagnosis SYSTEM % Real‘ABS OFF mode swnching judgemenl ' Syslem fail signal Rear ABS OFF mode ' swilching signal oulpul \l/ \V v v ABS CONTROL: » Sening map swnching » Rear lN-VALVE/OUT»VALVE switching REAR F RONT MASTER MASTER CYLlNDER CYLlNDER |N>VALVE ‘N_VALVE '7 ' 7 Ti ABS l MODULATOR FRONT WHEEL SPEED SENSOR REAR WHEEL SPEED SENSOR 1-51 GENERAL INFORMATION G RIDE (CRF1ODDD) SYSTEM OVERVIEW The CRF1 000D (DCT type) is equipped with the G ride designed for ofl-road riding. To switch to the G ride. press the G switch with the throttle fully closed when the motorcycle is stopped. The G indicator displays to confirm that the mode is successiully switched to the G ride. The G ride directly transfers the engine power to the road surIace by minimizing clutch slipping occurring during throttle operation. When used with the rear ABS OFF mode, it can offer truly enjoyable machine control, satisfying the broad range of users. INDICATORS AND SWITCHES LOCATION G SWITCH G INDICATOR 1-52 DUAL CLUTCH TRANSMISSION CONTROL CIRCUIT (G RIDE) LEFT HANDLEBAR SWITCHES GENERAL INFORMATION COMBINATION METER RIGHT HANDLEBAR G SWITCH SWITCHES L [21] — [22] PCM [1] I21 I vvvv ~ — I [3] : I [4] I PGM-Fl I [5] : CONTROL : I61 L ____ L J [7] ~ _ _ _ _ _ I Is] .' ‘. [g] | I ALTERNATOR [10] | DCT I : [11] : CONTROL : I— NO.1 LINEAR SOLENOID VALVE L ,' r No.2 LINEAR "" ‘— :_I‘ SOLENOID VALVE J m7 [12] *4 OIL PUMP [1] [2] [3] [4] [5] [6] [7] [3] [9] I1 0] I1 1 I AM SWITCH SIGNAL N-D SWITCH SIGNAL FRONT WHEEL SPEED SIGNAL REAR WHEEL SPEED SIGNAL SHIFT DOWN SIGNAL SHIFT UP SIGNAL THROTTLE POSITION SIGNAL No.1 CLUTCH OIL PRESSURE SIGNAL No.1 LINEAR SOLENOID OUTPUT No.2 CLUTCH OIL PRESSURE SIGNAL No.2 LINEAR SOLENOID OUTPUT [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] OIL TEMPERATURE SIGNAL CLUTCH LINE OIL PRESSURE SIGNAL SHIFT SPINDLE ANGLE SIGNAL OUTER MAINSHAFT REVOLUTION SIGNAL VS SIGNAL INNER MAINSHAFT REVOLUTION SIGNAL TR SIGNAL SHIFT CONTROL MOTOR OUTPUT CRANK PULSE SENSOR SIGNAL G SWITCH SIGNAL TXD OUTPUT 1-53 GENERAL INFORMATION S MODE (CRF1000D) SYSTEM OVERVIEW The CRF1000D(DCT type) is equipped with the 5 mode designed Ior sport riding. To switch to the 5 mode. press the N-D switch when the motorcycle is stopped for safety. The S indicator displays to confirm that the mode is successfully switched to the S mode. After set to the S mode, the mode can be selected from three levels by pressing and holding the D-5 side of the ND switch with the throttle fully closed. INDICATORS AND SWITCHES LOCATION S INDICATOR D INDICATOR N-D SWITCH A/M SWITCH INDICATOR PATTERNS BY OPERATING SWITCHES [1]: Press and hold the D-S side ot the N-D switch with the throttle fully closed. [2]: Press the D-8 side of the ND switch when the motorcycle is stopped. ‘ N.D SWITCH (press) ('1 [3]: Press the D-S side ot the ND switch when the motorcycle is stopped. d NM SWITCH (press) [4]: Press the N side of the ND switch when the motorcycle is stopped. \ N»D SWITCH (press and hold) [5]: Press the D-S side ot the ND switch when the motorcycle is stopped. [6]: Press the AIM switch when the motorcycle is stopped. [7]: Press the N side of the ND switch when the motorcycle is stopped. (‘1): The selected level is maintained even when the ignition switch is turned 0". or transmission is switched to out of S mode. 1-54 GENERAL INFORMATION D AND 5 MODE SHIFT TIMING Illa! Elli! Engine speed high Sports A Level 1 ENE Comfon Engine speed low 1-55 MEMO 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION ---------------------- ~- 2-2 TROUBLESHOOTING -- -2-2 BODY PANEL LOCATIONS ------------------- ~- 2-3 MAIN SEAT ........................................ .. 2.4 WINDSCREEN ------------------------------------ ~- 2-5 KNUCKLE GUARD (CRF1000A/D) -~ -2-5 MIDDLE COWL ----------------------------------- -- 2-6 FRONT SPOILER -------------------------------- ~- 2:] FRONT COVER ----------------------------------- -- 2-7 INNER PANEL COVER ------------------------- -- 2-8 INNER COVER- -2-8 FRONT FENDER --------------------------------- ~- 2-9 TANK FRONT COVER -------------------------- -- 2-9 TANK SIDE COVER ----------------------------- -~ 2-9 TANK REAR COVER- SKID PLATE (CRF1000AID) ---------------- -- 2-10 LEFT REAR COVER -------------------------- -- 2-10 PILLION SEAT ---------------------------------- -- 2-11 ETC TRAY- SIDE COVER ------------------------------------ -- 2-11 REAR CARRIER -------------------------------- ~- 2-12 REAR FENDER A ------------------------------ -- 2-12 REAR FENDER B ------------------------------ -- 2-13 MUFFLER/EXHAUST PIPE-- SIDESTAND ..................................... .. 2.19 2-1 FRAMHBODYPANELSEXHAUSTSYSTEM SERVICE INFORMATION GENERAL ~ This section covers removal and installation of the body panels, exhaust system and sidestand. ~ Always replace the exhaust pipe gaskets after removing the exhaust pipes from the engine. ~ When installing the exhaust system, loosely install all of the exhaust pipe lasteners. Always tighten the exhaust clamps lirst, then tighten the mounting fasteners. ll you tighten the mounting fasteners lirst, the exhaust pipe may not seat properly. ~ Always inspect the exhaust system for leaks after installation. TROUBLESHOOTING Excessive exhaust noise ~ Broken exhaust system ~ Exhaust gas leak Poor performance ~ Delormed exhaust system ~ Exhaustgasleak ~ Clogged mufller FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS [6] [5‘] [4] [3] [Z] [7] [a] [é] [1] From cover (page 2-7) [2] Windscreen (page 2-5) [3] Tank from cover (page 2-9) [4] Knuckle guard (CRF1000A/D) (page 2-5) [5] ETC tray (page 2-11) [6] Rear carrier (page 2-12) [7] Muffler/exhaust pipe (page 2-16) [8] Tank side cover (page 2-9) [9] Inner cover (page 2-8) [10] From spoiler (page 2-7) [11] Skid plale (CRF1000A/D) (page 2-10) BODY PANEL REMOVAL CHART [1 l [20] [21] [12] [13] [14] [15] [16] [17] [13] [19] This chart shows removal order of frame covers by means o1 arrow. [17] Main seal [11] [191 [1a] [171 [161 [151 [14] [121 [131 Left rear cover (page 2-10) Rear fender B (page 2-13) Side cover (page 2-11) Rear fender A (page 2-12) Pillion seal (page 2-11) Main seat (page 2-4) Tank rear cover (page 2-10) Inner panel cover (page 2-8) [20] Middle cowl (page 2-6) [21] From fender (page 2-9) ([8] Tank side cover (—»( [20] Middle cowl ( ([2] Windscreen ( ([16] leon sea (—>( [18] Tank rear cover ( ([10] From spoiler (—>( [1] From oover ( [14] Side cover [6] Rear carrier [15] Rear lender A [5] ETC (ray [19] lnner panel cover [9] Inner oover [3] Tank from cover [4] Knuckle guard pipe [7] Mufller/exhausl [13] Rear fender B [12] Lefl rear cover [11] Skld plale [21] From fender FRAME/BODY PANELS/EXHAUST SYSTEM MAIN SEAT MAIN SEAT REMOVAL/INSTALLATION Unlock the main seat [1] using the ignition key [2]. Remove the seat while pulling it forward and upward. Install the seat while aligning its hook [3] with the retainer on the rear carrier. Push the seat downward, and lock it. SEAT CATCH STAY REMOVAL] INSTALLATION Remove the tank rear cover (page 2-10). Remove the bolts [1] and pull up the seat catch stay [2]. Disconnect the seat lock cable [3] from the stay. Remove the bolt [4] and seat catch hook [5]. Installation is in the reverse order of removal. NOTE . Apply grease to the seat catch hook sliding area. . Align the seat catch hook boss with the stay hole. SEAT LOCK CYLINDER REMOVAL] INSTALLATION Remove the ETC tray (page 2-11). Disconnect the seat lock cable [1] from the seat lock cylinder [2] and stay [3]. Remove the lock spring [4], cylinder, and stay. Installation is in the reverse order of removal. NOTE . Align the lug [5] of the cylinder with the grooves [6] ot the rear Iender B, lock spring, and stay. FRAME/BODY PANELS/EXHAUST SYSTEM WIN DSCREEN REMOVAL/INSTALLATION Remove the socket bolts [1], plastic washers [2]. rubber washers [3], and windscreen [4]. Remove the well nuts [5] and cowl stay covers [6] if necessary. Installation is in the reverse order of removal. NOTE . When installing the cowl stay cover. set the stay cover boss [7] into the Iront cowl stay hole [8]. TORQUE:0.42 N'm (0.04 kgfrm, 0.3 lbl-ft) KNUCKLE GUARD (CRF1000A/D) REMOVAL/INSTALLATION Remove the handlebar weight bolt (page 17-6). Remove the socket bolt [1] and knuckle guard [2]. Installation is in the reverse order of removal. NOTE . Install the knuckle guard by aligning its boss [3] with the hole [4] ot the stay. 2-5 FRAM EIBODY PANELS/EXHAUST SYSTEM MIDDLE COWL [4] REMOVAL/INSTALLATION Remove the tank side cover (page 2-9). Remove the socket bolts [1] and trim clips [2]. Release the bosses [3]. Remove the middle cowl [4] by releasing the tabs [5]. Installation is in the reverse order of removal. [3] [5] DISASSEMBLYIASSEMBLY Remove the middle cowl (page 245). Remove the screws [1] and lront side cover [2] from the middle cowl [3]. Installation is in the reverse order of removal. [2] [1] 2-6 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SPOILER REMOVAL/INSTALLATION Remove the middle cowl (page 245). Remove the trim clips [1]. Remove the front spoiler [2] by releasing the tabs [3] from the front cover and inner cover. Installation is in the reverse order of removal. FRONT COVER REMOVAL/INSTALLATION Remove the front spoiler (page 24). Remove the windscreen (page 2-5). Remove the socket bolts [1] and trim clips [2]. Remove the front cover [3] while pulling it forward. Remove the left and right front inner oovers [4] from the front cover. Installation is in the reverse order of removal. NOTE . Right side only: Install the tab [5] of the inner panel cover into the groove [6] of the right front inner cover Install the lug [7] of the inner panel cover into the slit [8] of the front cover. . Align the grooves of the inner panel cover and front cover Align the groove [9] of the front cover with the lug of the headlight. FRAM EIBODY PANELS/EXHAUST SYSTEM INNER PANEL COVER REMOVAL/INSTALLATION Remove the iront cover (page 2-7). Disconnect the ioIlowing: Left side: — Front turn signal light 2P (Orange) connector Right side: — Front turn signal light 2P (Light blue) connector [1] — CRFiOOOA: rear ABS switch 2P (Black) connector [2] — CRF1000D: rear ABS/G switch 4P (Black) connector [2] Remove the socket bolt [3] and trim clips [4] and then remove the right inner panel cover [5]. Installation is in the reverse order of removal. NOTE . Install the tab [6] of the inner cover into the groove [7] oi the inner panel cover. INNER COVER REMOVAL/INSTALLATION Remove the inner panel cover (page 2-7). Release the tab [1] of the air cleaner duct irom the inner cover [2]. Remove the trim clip [3]. Remove the inner cover by releasing the tabs [4] oi the radiator shroud. Installation is in the reverse order of removal. Right side shown: [3] [2] FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the socket bolts [1] and collars [2]. Remove the tender cover [3]. CRF1000A/D: Release the front speed sensor wire [4] irom the fender clamp [5]. Remove the bolt [6] and brake hose clamp [7]. Remove the socket bolts [8] and collars [9]. Remove the front fender [1 0]. Installation is in the reverse order of removal. NOTE . Route the wire and hoses properly (page 1»26). [10] [9] [8] [2] [3] [1] TANK FRONT COVER REMOVAL/INSTALLATION Remove the socket bolts A [1] and B [2]. Remove the tank front cover [3]. Installation is in the reverse order of removal. TANK SIDE COVER REMOVAL/INSTALLATION Remove the main seat (page 2-4). Remove the socket bolts A [1] and B [2]. Remove the tank side cover [3]. Installation is in the reverse order of removal. FRAM EIBODY PANELS/EXHAUST SYSTEM TANK REAR COVER REMOVAL/INSTALLATION Remove the main seat (page 2-4). Remove the trim clips [1]. Remove the tank rear cover [2]. Installation is in the reverse order of removal. SKID PLATE (CRF1000A/D) REMOVAL/INSTALLATION Remove the bolts [1], washers [2], and collar [3]. Remove the skid plate [4]. Installation is in the reverse order of removal. NOTE . Align the right rear grommet [5] of the skid plate with the boss [6] o1 frame. TORQUE:26 N-m (2.7 kgfrm, 19 lbf-ft) LEFT REAR COVER REMOVAL/INSTALLATION CRF1000/A: Remove the gearshift arm (page 12-21). Release the sidestand wire clip [1] from the left rear cover [2]. Release the sidestand wire irom the left rear cover wire guide. Remove the bolts [3], left rear cover and drive chain guide plate [4]. Installation is in the reverse order of removal. NOTE . Align the hole of plate with the boss of the oover. . Route the wires properly (page 1-26). TORQUE: 12 N-m (1.2 kgf-m, 9 lbfrft) 2-10 FRAME/BODY PANELS/EXHAUST SYSTEM PILLION SEAT REMOVAL/INSTALLATION Remove the main seat (page 2-4). Remove the bolts [1] and collars [2]. Release the tab [3] and remove the pillion seat [4] by pulling forward. Installation is in the reverse order of removal. ETC TRAY REMOVAL/INSTALLATION Remove the seat catch stay (page 2-4). Release the iollowing: — Fuse box 1/2 [1] — Fuse box 3 [2] (CRFiOOOD) — Main wire harness clip [3] — HISS 2P (Red) connector [4] — Main wire harness clamps [5] Remove the trim clips [6] and ETC tray [7] Installation is in the reverse order of removal. NOTE . Route the wire harnesses properly (page 1-26). SIDE COVER REMOVAL/INSTALLATION Remove the pillion seat (page 2-11). Remove the ilange bolt [1] and collar [2]. Release the tabs [3] of side cover [4] irom the rear carrier. Remove the side cover by releasing the snap fit [5] and tabs [6]. Installation is in the reverse order of removal. FRAM EIBODY PANELS/EXHAUST SYSTEM DISASSEMBLYIASSEMBLY Remove the side cover (page 2-11). Remove the screws [1]. Remove the side inner cover [2] by releasing the tab [3]. Installation is in the reverse order of removal. REAR CARRIER REMOVAL/INSTALLATION Remove the side covers (page 2-11). Remove the socket bolts [1]. Remove the ilange bolts A [2]. Remove the ilange bolts B [3] and oollars [4]. Remove the ilange bolts C [5] and washers [6]. Remove the rear carrier [7]. Installation is in the reverse order of removal. REAR FEN D ER A REMOVAL/INSTALLATION Remove the rear carrier (page 2-12). Disconnect the iollowing connectors. — Right rear turn signal light 2P (Light blue) connector [1] — Left rear turn signal light 2P (Orange) connector [2] — License light SR (White) connector [3] Remove the socket bolts A [4], socket bolts B [5], and collars [6]. Remove the rear fender A [7] while pulling rearward by releasing its tabs [8] from the rear fender B. Installation is in the reverse order of removal. NOTE . Route the wires properly (page 1-26). 2-12 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER B REMOVAL/INSTALLATION CRF1000A/D: Drain the brake fluid from the hydraulic system (page 1945). Remove the following: — Regulator/rectifier (page 21-8) — Fuel tank (page 7-6) Remove the wire band [1]. Disconnect the turn signal light relay 18F (Black) connector [1]. CRF1000: Release the turn signal light relay [1]. 2-13 FRAM EIBODY PANELS/EXHAUST SYSTEM Disconnect the lollowing: — Grip heater control (Option) 10F (Black) connector [1] — Brake/taillight 3P (Black) connector [2] Release the lollowing: — Fan control relay [3] — Dummy oohnector/DLC [4] Remove the rear fender A (page 2-12) CRF1000A/D: Release the rear speed sensor wire clip [1]. CRF1000A/D: Remove the 0“ bolt [1], rear brake hose A [2], and sealing washers [3]. Sp: e m can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. NOTE . Always replace the sealing washers with new one. CRF1000A/D: Disconnect the rear brake hose B [1] from the ABS modulator by removing the oil bolt [2] and sealing washers [3]. Disconnect the lollowing: — ABS modulator 18F (Black) connector [4] — Rear speed sensor 2P (Black) connector [5] Release the rear brake hose B and speed sensor wire through the hole [6] ol rear lender B. Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. NOTE . Always replace the sealing washers with new one. 2-14 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the screw [1]. Remove the mud guard [2] downward by releasing its tab [3] from the slit [4] ofthe rear fender B. CRF1000A/D: Loosen the brake pipe joint nuts [5] and disconnect the brake pipes [6]. Remove the joint bolt [7]. Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the syslem is serviced. Remove the socket bolts [8]. Remove the rear fender B [9] by pulling it rearward. Remove the following from the rear fender B. — ABS modulator (page 20-24) (CRF1000A/D) — Brake/taillight (page 22-11) — Turn signal light relay (page 22-8) (CRF1000A/D) Installation is in the reverse order of removal. NOTE . Apply brake fluid to the joint nut threads. . Place the tender hooks onto the rear frame. . Route the wires, pipes and hoses properly (page 1- 26). TORQUE: Brake hose oil bolt: 34 N-m (3.5 kgf'm, 25 let] Brake p‘ ejoint nut: 14 N-m (1.4 kgf'm,10let] [6] [5] 2-15 FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER/EXHAUST PIPE MUFFLER REMOVAL/INSTALLATION MUFFLER MOUNTING BOLT RUBBER WASHER WASHER MUFFLER STAY MUFFLER ASSEMBLY OUTER COVER MUFFLER BAND BOLTS F'AN SCREWS 17 NM (1.7 kgfvm.13lbf-fl) COLLAR 9.0 N'm (0.9 kgf-m. 6.6 lbfvft) EXHAUST OUTER COVER SCREW 9.0 Nvm (0.9 kgf-m. 6.6 lbf-ft) EXHAUST OUTER COVER NOTE . Always replace the gasket with a new one. . When installing the muffler, loosely install the mounting bolt. and washer and tighten the muffler band bolts I I FrSt to the Specifed torque, and then tighten the mounting bolt securely. . Align the slots of the outer cover with the bosses oi the exhaust pipe cover C. 2-16 FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER DISASSEMBLYIASSEMBLY Remove the muffler (page 2-16). TAIL CAP COVER BOLT MUFFLER 9.0 NM (0.9 kgf-m, 5.5 lbfvfl) % COLLARS . / Va . ‘ T \ \ . side FUEL SYSTEM FUEL FLOW INSPECTION Disconnect the quick connect fitting from the fuel rail 7 (page 7-4). Clean up any spilled Place the end of the fuel feed hose [1] into an approved fuel. fuel container. Temporarily connect the battery negative (—) cable and fuel pump unit 3P (Black) connector. Turn the ignition switch ON and engine stop switc Measure the amount of fuel flow. NOTE . The fuel pump operates for 2 seconds. Repeat 5 times to meet the total measuring time. . Return fuel to the fuel tank when the measurement is oompleted. Amount of fuel flow: 319 cm3 (4.2 US oz, 4.4 Imp oz) minimum/10 seconds at 12 V If the fuel flow is less than specified, inspect the following: — Pinched or clogged fuel hose or fuel tank breather hose — Fuel pump unit (page 7-7) Connect the quick connect fitting (page 7-4). F U E L TAN K REMOVAL/INSTALLATION Relieve the fuel pressure and disoonnect the quick 10 connectfitting (page 7-4). [ ] Remove the fuel tank mounting bolt [1] and washer [2]. then remove the fuel tank [3] by releasing its grooves [4] from the mounting rubbers [5]. Disconnect the following: — Fuel tank breather hose [6] — Fuel tank drain hose [7] — Fuel level sensor 2P (Black) connector [8] Fuel pump unit 3P (Black) oonnector [9] [1] Remove the fuel filler cap [10] by removing the cap bolts, if necessary. Installation is in the reverse order of removal. FUELSYSTEM Installation is in the reverse order of removal. NOTE . A pressure release can be heard when opening the fuel cap. but this is not blockage of the passage. |f checking for clog in the passage of the fuel tank side is necessary. apply air pressure to the breather hose end with the fuel filler cap opened. . If the fuel filler cap was removed. replace the breather seal [1] with a new one. Route the hoses. wires and harness properly. Be careful not to damage the harness and hose. After installing the fuel tank. make sure the drain. air vent. overflow hose and fuel hoses are not kinked or bound. TORQUE: Fuel filler cap bolt: 1.3 N-m (0.2 kgf'm. 1.3 lbf‘ft) FUEL PUMP UNIT INSPECTION Turn the ignition switch ON and engine stop switch "C" and confirm that the fuel pump operates for a few seconds. If the fuel pump does not operate. inspect as follows: Turn the ignition switch OFF. Disconnect the fuel pump unit 3P (Black) connector (page 7-4). Turn the ignition switch ON. Measure the voltage at the wire harness side 3P (Black) connector [1]. CONNECTION: Yellow/red (1-) — Green (—) There should be battery voltage for a few seconds. If there is battery voltage for a few seconds. replace the fuel pump unit. If there is no battery voltage. inspect the following: — Sub fuse ENG STOP 7.5 A — Fuel pump relay (page 7-10) — Fuel pump relay related circuit — Open circuit in the Yellow/red or Green wire — ECM/PCM power/ground line (page 4-40) REMOVAL Remove the fuel tank (page 7-6). [3] Disconnect the quick connect fitting from the fuel pump unit (page 7-4). Clean around the fuel pump unit. Loosen the fuel pump unit mounting nuts [1] and cap nut [2] in a crisscross pattern in 2 or 3 steps and remove them. Remove the fuel pump unit [3] and packing [4]. FUEL SYSTEM DISASSEMBLYIINSPECTION Remove the screws [1], Black wire terminals [2], and stoppers [3]. Disconnect the White wire connector [4] and Blue wire connector [5]. Remove the fuel pump filter assembly [1] and O-ring [2] from the fuel pump stay [3]. Remove the chamber [1] by releasing the tabs [2]. Remove the fuel pump [1] and O-ring [2]. Visually inspect the suction filter [3] for dirt, debris, or any clogging. Replace fuel pump unit as an assembly if necessary. Remove the pressure regulator [4] and O»ring [5] from the fuel filter assemny [6]. 7-8 FUEL SYSTEM ASSEMBLY Replace the fuel filter assembly [1] with a new one. Install a new O-ring [2] to the pressure regulator [3]. Install the pressure regulator. \v in? g A Install a new O-ring [1] to the fuel pump [2]. Install the fuel pump. [2] / [5] 7 NOTE \ ’r 9n ‘ # . Align the Blue wire [3] with the fuel filter groove. . Lead the Black wire [4] through the hole of the fuel Ali filter assemny as shown. Insert the fuel pump filter [5] edge between the fuel pump and pressure regulator. Install the chamber [1]. NOTE . Set the Blue wire [2] as shown. Install a new O-ring [1] to the fuel pump stay [2]. Install the fuel pump unit assembly [3] by aligning the groove with the fuel pump stay tab. FUEL SYSTEM Install the stoppers [1], Black wire terminals [2], and screws [3]. Tighten the screws to the specified torque. TORQUE: 1.0 N-m (0.1 kgf-m, 0.7 Ibf-fl) Connect the White wire connector [4] and Blue wire connector [5]. INSTALLATION Install a new packing [1] onto the fuel pump unit [2]. NOTE . Always replace the packing with a new one. . Be careful not to pinch any dirt or debris between the fuel pump unit and packing. . Align the packing tab with the fuel pipe. Install the fuel pump unit [1] into the fuel tank. Install and tighten the fuel pump unit mounting nuts [2] and cap nut [3] to the specified torque in the sequence as shown. TORQUE: 12 N-m (1.2 kgf'm, 9 Ibf'ft) Install the fuel tank (page 7-6). FUEL PUMP RELAY REMOVAL/INSTALLATION Remove the right side cover (page 2-11). Release the relay connectors from the frame and remove the relay cover [1]. Remove the fuel pump relay [2]. Installation is in the reverse order of removal. [Z] 7-10 FUEL SYSTEM RELAY INSPECTION Remove the fuel pump relay (page 7-10). Refer to Fl relay inspection (page 4-44). AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the following: Le" side shawn- — Frontoover(pageZ-7) — Fuel tank (page 7-6) Release the left/right tabs [1] of the air cleaner duct from the inner cover. Left side only: Release the front No.1 sub harness 12F (Black) [2] and No.2 sub harness 12F (Gray) [3] connectors from the connector stays. Release the wire band [1] and clamp [2]. CRF1000D: Release the wire band [1] and clamp [2]. Release the clamp [3]. 7-11 FUELSYSTEM Loosen the connecting hose band screws [1] Remove the following: — Bolts [2], collarsA [3], and collars B [4] — Bolthasher [5] Disconnect the connecting hose and pull the air cleaner housing [6] upward. Disconnect the following: — Crankcase breather hose [7] — Airsuction hose [8] — IAT sensor 2P (Blue) connector [9] Remove the air cleaner housing. Installation is in the reverse order of removal. NOTE . Tighten the connecting hose band screws [1] to the specified range. TORQUE: Connecting hose band screw: 1.5 N-m (0.2 kgf'm, 1.1 lbf-ft) THROTTLE BODY REMOVAL Remove the air cleaner housing (page 7-11). Disconnect the fuel feed hose from the fuel rail (page 7» Loosen the band screws (throttle body side) [1]. 12 mm (0.5 in) 7-12 FUEL SYSTEM Disconnect the MAP sensor 3P (Black) connector [1]. Disconnect the IACV 4P (Black) connector [2]. Disconnect the throttle body by pulling it upward. Disconnect the injector 2P (Black) [1] and 2P (Blue) [2] connectors. Loosen the throttle cable A adjuster lock nut [1] and adjusting nut [2] then disconnect the throttle cable A [3] irom the throttle drum and cable stay. Loosen the throttle cable B lock nut [4] then disconnect the throttle cable B [5] irom the throttle drum and cable ‘ stay. Disconnect the TP sensor 3P (Black) connector [1] and \ \ remove the throttle body [2]. 7-13 FUEL SYSTEM DISASSEMBLYIASSEMBLY . Do not remove the sensor unit unless it ts replaced. . Do not loosen or tighten the white painted nuts and screws [1] and nuts [2] of the throttle body. > ’ Loosening or tightentng it can cause throttle valve TX and idle control failure. . Always clean around the throttle body before each sensor removal to prevent dirt and debris from entering the air passage. NOTE . MAP sensor removal/installation (page 4-41) . IACV removal/installation (page 746) . Fuel injector removal/installation (page 7-17) . If the O-ring is not installed properly, the idle air will leak and engine idle speed will be unstable. THROTTLE BODY SETTING PLATE THRO'I'I'LE BODY SE'ITING THROTTLE BODY PLATE SCREWS “I? SET PLATE SEAL IACV HOLDER IACV HOLDER SCREWS 3.4 N'm (0.3 kgt~m, 2.5 lbf-ft) INSTALLATION Connect the TP sensor 3P (Black) oonnector [1]. 7-14 FUEL SYSTEM Connect the throttle cables [1] to the throttle drum and throttle cable stay. Tighten the throttle cable B lock nut [2] to the specified torque. TORQUE:8.5 N-m (0.9 kgf-m, 6.3 Ibf‘ft) Temporarily tighten the throttle cable A adjuster lock nut [31- Connect the injector 2P (Black) [1] and 2P (Blue) [2] y connectors. Install the throttle body [1]. NOTE . Make sure that the band screws (throttle body side) 3 [2] is in position as shown. ~ . Align the insulator grooves with the throttle body lugs. Tighten the insulator band screws (throttle body side) to the specified range as shown. 1411.0mm 1411.0mm (0.6 1 0.04 in) (0.6 1 0.04 in) 7-15 FUEL SYSTEM Connect the MAP sensor 3P (Black) connector [1]. Connect the IACV 4P (Black) connector [2]. Adjust the throttle grip freeplay (page 3-3). Connect the fuel feed hose to the fuel rail (page 7-4). Install the air cleaner housing (page 7-11). IACV REMOVAL Remove the fuel tank (page 745). Clean the throttle body to prevent dirt and debris from entering the IACV passage. Disconnect the IACV 4P (Black) connector [1]. Remove the screws [2], setting plate [3], IACV [4], and O-ring [5]. INSPECTION NOTE . The IACV is installed on the throttle body and is operated by the stepping motor. When the ignition switch is turned ON, the IACV operates for a few seconds. Remove the fuel tank (page 745). Turn the ignition switch ON and check the IACV. If the step motor operating sound is heard, the IACV is normal. If the IACV does not sound with no MIL blinking, inspect as follows: 1. Remove the IACV (page 7-16). Check the IACV [1] for wear or damage. 2. Connect the IACV 4P (Black) connector [2]. 3. Turn ignition switch ON, the inde valve [3] should move back and forth. 4. After inspection, install the IACV (page 7-17). 7-16 FUEL SYSTEM INSTALLATION Turn the slide valve [1] clockwise until it is lightly seated on the IACV. Install a new O-ring [1] onto the IACV [2]. Install the IACV into the throttle body by aligning the valve slit with the guide pin in the throttle body. Install the setting plate [3] by aligning its cut»out with the tab of IACV. Install and tighten the screws [4] to the specified torque. TORQUE: 2.1 N-m (0.2 kgf-m, 1.5 Ibf‘ft) Connect the IACV 4P (Black) connector [5]. Install the fuel tank (page 7-6). FUEL INJECTOR REMOVAL/DISASSEMBLY Remove the ECM/PCM (page 4-39). Clean around the tuel injector base with oompressed air betore removing the fuel injector, and be sure that no debris is allowed to enter into the combustion chamber. Disconnect the fuel injector 2P (Black) [1] and 2P (Blue) [2] connectors. ,‘ Remove the bolts [3] and fuel injector assembly [4]. Disassemble the following: — Seal rings [1] — Fuel injectors [2] — O-rings[3] — Fuel injectorjoints[4] — O-rings[5] — Fuel rail [6] FUEL SYSTEM ASSEMBLY/INSTALLATION Apply engine oil to new O-rings and seal rings. Assemble the following: — Seal rings[1] — Fuel injectors [2] — O-rings[3] — Fuel injectorjoints [4] — 0-rings[5] — Fuel rail [6] NOTE . Align the injector connectors with the fuel joint tabs to position them upright. Install the fuel injector assembly [1]. NOTE . When installing the fuel injector, be careful not to , damage the seal ring. Install and tighten the bolts [2] to the specified torque. TORQUE: 5.1 N-m (0.5 kgf-m, 3.8 Ibf‘ft) Connect the fuel injector 2P (Black) [3] and 2P (Blue) I [4] connectors. Install the ECM/PCM (page 4439). SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature. Stop the engine. Remove the air cleaner housing (page 7-11). Check that the secondary air intake port [1] of the element holder is clean and free of carbon deposits. Check the PAIR reed valve if the port is carbon fouled (page 7»21). 7-18 Temporarily install the fuel tank (page 7-6). Temporarily connect the IAT sensor 2P connector (page 7-12). Lift the fuel tank (page 3-3) Start the engine and open the throttle slightly to be certain that air is sucked in through the disconnected air suction hose [1]. (Black) If the air is not drawn in, check the air suction hose and air supply hose [2] for clogs and PAIR control solenoid valve [3]. For PAIR control solenoid valve removal/installation (page 749). PAIR CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the air cleaner housing (page 7-11). Disconnect the 2P (Black) connector [1]. Disconnect the suction hose [2] and air supply hose [3] and remove the PAIR control solenoid valve [4]. Installation is in the reverse order of removal. PAIR CONTROL SOLENOID VALVE INSPECTION Remove the PAIR control solenoid valve (page 749). Check the air flow through the solenoid valve. Air should flow trom input hose fitting (A) to output hose Iitting (B). Connect a 12 V battery to the 2P connector [1] of the PAIR control solenoid valve. Air should not flow when the battery is connected. FUEL SYSTEM <3: FRESH AIR 6 ‘— EXHAUST GAS I 7-19 FUEL SYSTEM Measure the resistance at the 2P connector [1] of the PAIR control solenoid valve. STANDARD: 24 — 28 fl (20“CIGS“F) If the resistance is out of the specification, replace the PAIR control solenoid valve. PAIR REED VALVE REMOVAL] INSTALLATION Remove the cylinder head cover (page 10-4). Remove the bolts [1]. Remove the PAIR reed valve cover [1] NOTE . When installing the cover, align the boss of the cover with the hole of the reed valve. Remove the PAIR reed valves [1] and port plates [2]. Installation is in the reverse order of removal. NOTE . Install the reed valves and port plates as shown. TORQUE: PAIR reed valve cover bolt: 12 N-m (1.2 mm, 9 lbf-ft) [1] 7-20 FUEL SYSTEM PAIR REED VALVE INSPECTION Remove the PAIR reed vatves (page 7-20). Check the reed valve [1] for damage or tatigue. Replace if necessary. Replace the PAIR check valve if the rubber seat [2] is cracked, deteriorated or damaged. or it there is ctearance between the reed and seat. 7-21 MEMO 8. COOLING SYSTEM SERVICE INFORMATION ---------------------- ~- 8-2 TROUBLESHOOTING -- .a.2 SYSTEM FLOW PATI'ERN -------------------- ~- 8-3 SYSTEM TESTING ------------------------------- ~- 8-4 COOLANT REPLACEMENT ------------------ ~- 8-4 THERMOSTAT .................................... .. 8.5 RADIATOR~ .M n RADIATOR RESERVE TANK --------------- -- 8-10 WATER PUMP .................................. .. 8.10 FAN CONTROL RELAY ---------------------- .. 3.11 8-1 COOLING SYSTEM SERVICE INFORMATION GENERAL AWARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. Using coolant With silicate corrosion Inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. ~ Add coolant 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 installed in the frame. ~ Avoid spilling coolant on painted surfaces. ~ After servicing the system, check for leaks With a cooling system tester. ~ Refer to the ECT sensor inspection (page 22-18). TROUBLESHOOTING Engine temperature too high ~ Faulty temperature gauge or ECT sensor ~ Thermostat stuck closed ~ Faulty radiator cap ~ Insufficient coolant ~ Passage blocked in radiator, hoses or wateriacket ~ Air in system ~ Faulty cooling fan motor ~ Faulty fan control relay ~ Faulty water pump Engine temperature too low ~ Faulty temperature gauge or ECT sensor ~ Thermostat stuck open ~ Faulty fan control relay Coolant leak ~ Faulty water pump mechanical seal ~ Deteriorated O»rings ~ Faulty radiator cap ~ Damaged or deteriorated cylinder head gasket ~ Loose hose connection or clamp ~ Damaged or deteriorated hose ~ Damaged radiator COOLING SYSTEM SYSTEM FLOW PATTERN CRF1000D shown: LEFT RIGHT RADIATOR RADIATOR CAP RADIATOR THERMOSTAT \ WATER PUMP RADIATOR RESERVE TANK 8-3 COOLING SYSTEM SYSTEM TESTING RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the right middle cowl (page 2-6). Remove the radiator cap [1]. Wet the sealing surfaces oi the cap, then install the cap onto the tester [1]. Pressure test the radiator cap. Replace the radiator cap it it does not hold pressure, or if reliei pressure is too high or too low. It must hold specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 1oa — 137 kPa(1.1— 1.4 kgf/cm2,16 — 20 psi) Install the tester to the radiator. Apply pressure to the radiator, engine, and hoses and check (or leaks. Excessive pressure can damage the cooling system components. Do not exceed 137 kPa (1.4 kgf/cmz, 20 psi). Repair or replace components if the system will not hold specified pressure for at least 6 seconds. COOLANT REPLACEMENT REPLACEMENT/AIR BLEEDING NOTE . When filling the system or reserve tank with coolant or checking the coolant level, place the motorcycle in an upright position on a flat, level surface. Remove the radiator cap (page 8-4). CRHOOIA CRF1000D: Remove the EOP sensor cover (page 13» ' 53) Remove the drain bolt [1], sealing washer [2], and drain the coolant. Reinstall the drain bolt with a new sealing washer. Tighten the drain bolt to the specified torque. TORQUE:13 N-m (1.3 kgf*m,10lbf-ft) Remove the radiator reserve tank (page 840). Empty the coolant and rinse the inside of the reserve tank with water. Install the radiator reserve tank (page 840). CRF1000D: COOLING SYSTEM Fill the system with the recommended coolant through the filler opening up to filler neck [1]. Remove the radiator reserve tank cap [2] and fill the reserve tank to the upper level line. Bleed air from the system as follows: 1. Shift the transmission into neutral. Start the engine and let it idle for 2 — 3 minutes. 2. Snap the throttle 3 or 4 times to bleed air from the a system. 3. Stop the engine and add coolant up to the filler neck if necessary. 4. Install the radiator cap. 5. Check the level of coolant in the reserve tank and fill to the upper level line it it is low (page 314). NOTE . When air bleeding is insufficient, level o1 coolant in the reserve tank will decrease. If so, till to the upper level line with coolant. After installation, check that there are no coolant leaks. Install the removed parts in the reverse order of removal. THERMOSTAT REMOVAL/INSTALLATION Drain the coolant (page 8-4). Disconnect the upper radiator hose [1] by loosening the hose band screw [2]. Remove the bolts [3] and thermostat cover [4]. Remove the thermostat [1] lrom the upper crankcase. Installation is in the reverse order of removal. NOTE . Install the thermostat air bleed hole [2] facing up. . Align the thermostat ribs with the slits oi the upper crankcase. . Tighten the hose band screw to the specified range (page 8-8). TORQU E: Thermostat cover bolt: 12 N-m (1.2 ngm, 9 left) COOLING SYSTEM Do not let the thermostat or thermometer [2) touch the pan, or you will get e false leading. INSPECTION Visually inspect the thermostat [1] for damage. Check the thermostat rubber [2] for damage and replace if necessary. Visually inspect the thermostat [1] for damage. Replace the thermostat if the valve stays open at room temperature. Heat a container of water with an electric heating element for 5 minutes. Suspend the thermostat in heated water to check its operation. THERMOSTAT BEGIN TO OPEN: 30 — 84°C (176 —183°F) VALVE LIFT: 3 mm (0.3 in) minimum at 95“C (203°F) Replace the thermostat if the valve opens at a temperature other than those specified. RADIATOR REMOVAL/INSTALLATION LEFT RADIATOR Drain the coolant (page 8-4). Remove the left Inner cover (page 2-8). Remove the horn (page 22-28). Remove the bolts [1], washers [2], and wire clamp [3]. COOLING SYSTEM Release the connector clip [1] lrorn the radiator shroud. Release the air cleaner housing drain hose [2] from the clamp [3]. Loosen the hose band screws [1] and disconnect the upper radiator hose [2] and radiator hose B [3] lrorn the left radiator. Disconnect left tan motor 2P (Black) connector [1] and remove the left radiator assembly [2]. RIGHT RADIATOR Drain the coolant (page 8-4). Remove the right Inner cover (page 2-8). Remove the bolts [1] and washers [2]. 8-7 COOLING SYSTEM Release the siphon hose [1]. Release the connector clip [2] irom the radiator shroud. Release the linear solenoid wire [3] and main wire harness [4] irom the clamp [5]. Release the air cleaner housing drain hose [6] from the , clamp [7]. Loosen the hose band screws and disconnect the lower radiator hose [1], radiator hose A [2], and B [3] irorn the right radiator. Disconnect right fan motor 2P (Black) connector [1] and remove the right radiator assemny [2]. Installation is in the reverse order of removal. NOTE . Tighten the water hose band screws to the specified range as shown. . Route the hoses and wires properly (page 1-26). Fill the recommended coolant mixture to the filler neck and bleed the air (page 8-4). \_. 0 r 1 mm (o 7 0.04 in) COOLING SYSTEM DISASSEMBLYIASSEMBLY FAN MOTORS am: FAN MOTOR SHROUD BOLTS 3%???) :ianOngLIf‘vfi)Nu-rs 5.5 N-m(0.9 kgf-m,6.3\bfvfl) , ' ' 9 ‘ ‘ FAN MOTOR MOUNTING SCREWS 2.7 NM (0.3 kgf-m, 2.0 \bf-I’t) COOLING FANS LEFT RADIATOR GRILL LEFT RADIATOR LEFT RADIATOR SHROUD ®\ GROMMETS RIGHT FAN MOTOR SHROUD , , COLLARS RIGHT RAD‘ATOR GRILL RIGHT RAD‘ATOR SHROUD RIGHT RADIATOR NOTE . ATign the cooling Ian and Ian motor shaft flat surfaces. . Apply locking agent to the cooling fan mounting nut threads. 8-9 COOLING SYSTEM RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the shock absorber (page 18-8). Remove the rear wheel (page 18-4). Remove the radiator reserve tank mounting bolt [1]. Remove the radiator reserve tank [2] by releasing the boss [3] from the frame. Disconnect the siphon hose [4] and drain the coolant. Installation is in the reverse order of removal. Fill the system with the recommended coolant to the upper level line (page 8-4). Install the shock absorber (page 1&8). WATER PUMP MECHANICAL SEAL INSPECTION Check the bleed pipe [1] of the water pump for signs of coolant leakage. NOTE . A small amount oi coolant weeping from the bleed I] pipe is normal. . Make sure that there is no continuous coolant leakage from the bleed pipe while operating the engine. 1 CRF1OOUIA: Replace the water pump as an assembly if necessary. REMOVAL/INSTALLATION Remove the right crankcase oover. — CRF1000/A (page 124) — CRF1000D (page 1352) Remove the drain bolt [1] and sealing washer [2]. Remove the water pump cover bolts [3] and water pump body [4]. [1]/[2] 8-10 COOLING SYSTEM Install a new O-ring [1] into the groove in the water pump body [2]. CRF1OODD shown: Install the dowel pins [3] and water pump body. Apply locking agent to the water pump cover bolts threads (page 1-20). Install and tighten the bolts [1] to the specified torque. TORQUE:13 N-m (1.3 kgf*m,10lbf-ft) CRF1OODD shown: Install the drain bolt [2] and a new sealing washer [3] and tighten the bolt securely. TORQUE:13 N-m (1.3 kgfrm,10lbf-ft) Install the right crankcase cover (page 2-11). FAN CONTROL RELAY REMOVAL/INSTALLATION Remove the pillion seat (page 2-11). Release the fan control relay [1] and cover [2]. Remove the relay cover and disconnect the relay from the relay connector. Installation is in the reverse order of removal. RELAY INSPECTION Remove the tan control relay (page 8-11). Re1er to Fl relay inspection (page 4-44). 8-11 MEMO 9. LUBRICATION SYSTEM SERVICE INFORMATION ---------------------- ~- 9-2 TROUBLESHOOTING -------------------------- ~- 9-2 LUBRICATION SYSTEM DIAGRAM -------- -- 9-3 OIL PRESSURE INSPECTION --------------- ~- 9-5 OIL PUMP (CRF1000/A) ------------------------ -- 9-5 OIL PUMP (CRF1000D) ------------------------ -- 9-7 OIL STRAINER ------------------------------------ -- 9-8 LUBREAHONSYSTEM 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. This section covers sen/ice of the oil pump and oil strainer. The oil pump and oil strainer can be serviced With the engine installed in the frame. The service procedures in this section must be performed with the engine oil drained. When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. If any portion of the oil pump is worn beyond the specified service limits. replace the oil pump as an assembly. After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct. TROUBLESHOOTING Oil level too low ~ Oil consumption ~ External oil leak ~ Worn piston rings ~ Improperly installed piston rings ~ Worn cylinders ~ Worn valve stem seals ~ Worn valve guide Low oil pressure ~ Oil level low ~ Clogged oilstrainer ~ Faulty oil pump ~ Internal oil leak ~ Incorrect oil being used ~ Oil pressure relief valve stuck open No oil pressure ~ Oil level too low ~ Oil pressure relief valve stuck open ~ Damaged oil pump ~ Internal oil leak High oil pressure ~ Oil pressure relief valve stuck closed ~ Clogged oil filter, oil gallery, or metering orifice ~ Incorrect oil being used Oil contamination ~ Oil orfilter not changed often enough ~ Worn piston rings Oil emulsification ~ Blown cylinder head gasket ~ Leaky coolant passage ~ Entry of water LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CRF1000IA ROCKER ARM SHAFT CAMSHAFT I“ PISTON ’ CRANKSHAFT PISTON OIL m ALTERNATOR H ‘ I L , MAI NSHAFT EOP SWITCH ENGINE OIL FILTER CLUTCH COUNTERSHAFT SCAVENGE PUMP REAR OIL FILTER SCREEN BALANCER SHAFT ENGINE OIL PRESSURE OIL PAN OIL RELIEF VALVE STRAINER 9-3 LUBRICATION SYSTEM CRF1000D ROCKER ARM SHAFT CAMSHAFT No.1 No.2 LINEAR LINEAR SOLENOID SOLENOID , VALVE VALVE PISTON “‘11 NO-Z CLUTCH CLUTCH EOP EOP SENSOR SENSOR CRANKSHAFT \ ALTERNATOR OIL JETS L \V; ‘1' H \l, ‘ EOP SENSOR I— '_ L. h r. :2 I J . MAINSHAFT \ —. _. <— ENGINE OIL FILTER | p y I \ ¥ - I No.2 CLUTCH No.1 CLUTCH COUNTERSHAFT DCT OIL CLUTCH LINE PUMP EOP SENSOR SCAVENGE PUMP ~ DCT OIL FILTER OIL FILTER SCREEN S y . S ‘ u . REAR BALANCER T m SHAFT ENGINE OIL . 4, PRESSURE RELIEF VALVE 51;, DOT OIL PRESSURE OIL RELIEF VALVE OIL pAN STRA'NER ENGINE OIL FEED PUMP LUBRICATION SYSTEM OIL PRESSURE INSPECTION Remove the engine oil filter cartridge (page 342). Apply engine oil to the O-ring and install the oil pressure attachment [1] onto the oil filter boss. TOOL: Oil pressure gauge attachment 070MJ-0010101 Apply engine oil to the O-ring and install the engine oil tilter cartridge [2] onto the oil pressure attachment. TOOL: Oil filter wrench 07HAA-PJ70101 TORQUE: 26 N-m (2.7 kgfrm, 19 lbf-ft) Connect the oil pressure gauge [3] and attachment [4] to the oil pressure gauge attachment. TOOLS: Oil pressure gauge set 07506-3000001 or equivalent commercially available Oil pressure gauge attachment 07406-0030000 or equivalent commercially available Fill the engine with the recommended engine oil (page 342). Warm the engine to normal operating temperature (approximater 80°C/176‘F) and increase the engine speed to 5,000 min" (rpm) and read the oil pressure. STANDARD: 499 — 037 kPa (5.1 — 0.5 kgflcm‘, 72 — 92 psi) at 5,000 min" (rpm)l(80°Cl176°F) Stop the engine and remove the tools. Install the engine oil filter cartridge (page 342). OIL PUMP (CRF1000IA) REMOVAL/INSTALLATION Remove the oil strainer (page 9-8). Remove the bolts [1] and oil pump [2]. Installation is in the reverse order of removal. NOTE . Align the oil pump driven shaft end with the oil pump drive shaft groove. LUBRICATION SYSTEM DISASSEMBLYIASSEMBLY NOTE . Dip aII pans in clean engine OII. FLANGE BOLT (e x 75 mm) 12 N-m(12 kgfm, 9 Ibl-fl) FLANGE BOLTs (6 x 55 mm) 12 Nm (1.2 kgf-m, 9 lbffl) FLANGE BOLT (6 x 35 mm) 12 N m (1.2 kgI-m. 9 lbf-fl) \\ DRIVE PIN OIL PUMP BODY A OIL PUMP SHAFT SEALING BOLT (6 x 22 mm) ENGINE OIL FEED Ij 30 N.m(31kgfmvzz‘m.fl) PUMP OUTER ® 4 ROTOR \ \ ENGINE OIL FEED ENGINE OIL PUMP INNER ROTOR PRESSURE \ RELIEF VALVE OIL PUMP BODY C DOWEL PINS f DOWEL PINS DRIVE Pm FLANGE BOLT (6 x 20 mm) 12 Nm (1.2 kgf-m‘ 9 lbffl) OIL PUMP BODY B SCAVENGE PUMP INNER ROTOR SCAVENGE PUMP OUTER ROTOR FLANGE BOLT (e x 40 mm) 12 Nm (1.2 kgf-m, 9 lbffl) OIL PUMP INSPECTION Re'er to CRF1 000D OiI pump inspection (page 9-8). PRESSURE RELIEF VALVE INSPECTION Remove the pressure relief valve (page 9-6). Re'er to pressure relief valve (CRF‘IOOOD) Inspection (page 9-8). LUBRICATION SYSTEM OIL PUMP (CRF1000D) REMOVAL/INSTALLATION Remove the Oil Strainer (page 9-8). [2]- InstallatiOn iS in the reverse order Of remoVaI. NOTE . AIign the Oil pump driven Shaft end with the Oil pump drive Shaft groove. TORQUE:16 N-m (1.6 kgf'm,12lbf-ft) DISASSEMBLYIASSEMBLY NOTE 1 Dip aII parts in clean engine OiI. FLANGE BOLT (s x 95 mm) DCT OIL PRESSURE 12 N-m (1.2 kgf-m. 9 lbI-I't) RELIEF VALVE FLANGE BOLTS (e x as mm) Gm 0”- PUMP BODY SEALING BOLT (24 mm) 30 N-m (3.1 kgf-m. 22 lbI-I't) 12 N-m (1.2 kgf-m. 9 lbI-I't) FLANGE BOLT (6 x 65 mm ) 12 Nm (1.2 kgf-m, 9mm) ENGINE OIL FEED PUMP OUTER ROT% \ < \ Q ENGINE OIL FEED PUMP INNER ROTOR DRIVE PIN DOWEL PINS/Q DOWEL PINS DCT OIL PUMP OUTER ROTOR DCT OIL PUMP INNER ROTOR DRIVE PIN DOWEL PINS / OIL PUMP BODYA OIL PUMP SHAFT ENGINE OIL \/ PRESSURE Q RELIEF VALVE SEALING BOLT (22 mm) 30 N-m (3.1 kgf-m. 22 lbf-fl) OIL PUMP BODY B INNER ROTOR FLANGE BOLT (6 x 20 mm) SCAVENGE PUMP 12 N-m (1.2 kgf-m, 9 lbf-fl) OUTER ROTOR FLANGE BOLT (e x 40 mm) 12 NM (1.2 kgf-m, 9 |le) OIL PUMP BODY c LUBRICATION SYSTEM OIL PUMP INSPECTION NOTE . If any portion of the oil pump is worn beyond the service limit, replace the oil pump as an assembly. Inspection the following parts for damage, abnormal wear, deformation, or burning: — Oilpump shaft — Drive pin — Inner rotor — Outer rotor — Oilpump body Measure the oil pump clearances aooording to LUBRICATION SYSTEM SPECIFICATIONS (page 1»7). If any of the measurement is out of the service limit, replace the oil pump as an assembly. PRESSURE RELIEF VALVE INSPECTION Remove the pressure relief valve (page 9-7). Check the operation of the valve by pushing on the piston [1]. — Engine oil pressure relief valve [2] — DCT oil pressure relief valve (CRF1000D only) [3] OIL STRAINER REMOVAL/INSTALLATION Drain the engine oil (page 3-12). steps, and remove the bolts and oil pan [2]. Remove the oil strainer [1] and seal ring [2]. Clean the oil strainer and check for damage, replace it if necessary. NOTE . Align the oil strainer boss with the oil pump groove. . Always replace the seal ring with a new one. . Apply engine oil to a new seal ring. Remove the following: — Oiljoints [1], O»rings [2], and back up rings [3] — Gasket[4] — O-rings[5] NOTE . Always replace the O-rings, back up rings, and gasket with new ones. . Apply engine oil to new O-rings. Install new O-rings and back up rings to the oil joints as shown. LUBRICATION SYSTEM Remove the oil filter screen [1]. Clean the oil filter screen and check for damage, replace it if necessary. NOTE . Install the oil lilter screen into the oil pan as shown. Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12). MEMO 10. CYLINDER HEADNALVEICAMSHAFT SERVICE INFORMATION -------------------- .. 10.2 TROUBLESHOOTING ------------------------ .. 10.2 COMPONENT LOCATION ------------------- -- 10-3 CYLINDER COMPRESSION ---------------- -- 10-4 CYLINDER HEAD COVER ------------------- -- 10-4 ROCKER ARM ---------------------------------- -. 10.5 CAM CHAIN TENSIONER LIFTER """" " 10-8 CAMSHAFT ...................................... .. 10_9 10 CYLINDER HEAD ----------------------------- "10.13 |NsuLAToR .................................... "10.19 10-1 CYLINDER HEADNALVE/CAMSHAFT SERVICE INFORMATION GENERAL ~ This section covers service of the valves, rocker arms and camshaft. These services can be done With the engine installed in the frame. ~ When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. Rocker arm, valve and camshaft lubricating oil is fed through oil passage in the cylinder head. Clean the oil passages before assembling cylinder head. ~ Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. TROUBLESHOOTING ~ Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing noises to the top-end with a sounding rod or stethoscope. ~ If the performance is poor at low speeds, check for a white smoke in the crankcase breather hose. If the hose is smoky, check for seized piston ring (page 15-13). Compression too low, hard starting or poor performance at low speed ~ Valves: — lnoorrect valve clearance — Burned or bent valve — lnoorrect valve timing — Broken valve spring — Uneven valve seating — Valve stuck open ~ Cylinder head: — Leaking or damaged cylinder head gasket — Loose spark plug — Warped or cracked cylinder head ~ Cylinder/piston problem (page 15-2) Compression too high. overheating or knocking ~ Excessive carbon build-up on piston head or combustion chamber Excessive smoke ~ Worn valve stem or valve guide ~ Damaged stern seal ~ Cylinder/piston problem (page 15-2) Excessive noise Incorrect valve clearance Sticking valve or broken valve spring Excessively worn valve seat Worn or damaged camshaft Worn rocker arm and/or shaft Worn rocker arm follower or valve stem end Loose or worn cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Cylinder/piston problem (page 15-2) Rough idle ~ Low cylinder compression 10-2 CYLINDER HEADNALVEICAMSHAFT COMPONENT LOCATION 10 Nm (1.0 kgl-m, 7 lbf-fl) 20 NM (2.0 kgf-m, 15 mm) 12 NM (1.2 kgf-m, 9 |le) 13 Nm (1.3 kgl-m,13|bf-fl) 23 NM (2.3 kgl-m,17lbfvfl) 10-3 CYLINDER HEADNALVE/CAMSHAFT CYLINDER COMPRESSION Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug caps and remove the spark plugs (page 3-5). i Disconnect the fuel pump unit 3P (Black) connector " (page 7-4). Install the compression gauge [1] into the spark plugs hole. Turn the ignition switch ON. I CRF1000/A: Shift the transmission into the neutral position. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising. O The maximum reading is usually reached within 4 — 7 [1] seconds. COMPRESSION PRESSURE: 1,245 kPa (12.7 kgflcm‘, 181 psi) 31500 rpm Low compression can be caused by: — Blown cylinder head gasket — Improper valve adjustment — Valve leakage — Worn piston ring or cylinder High compression can be caused by: — Carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL Remove the ignition coil tray (page 5—9). Remove the bolts [1]. Remove the cylinder head cover [1] to the right side as shown. 10-4 CYLINDER HEADNALVE/CAMSHAFT Remove the plug pipe seals [1] and cylinder head cover packing [2]. INSTALLATION Install new plug pipe seals [1]. Install a new cylinder head cover packing [2]. NOTE . Install the plug pipe seals with their "OUT SIDE“ marks [3] facing up. Clean the cylinder head [1] mating surface thoroughly. Apply liquid sealant (T352110 manufactured by ThreeBond, KE45T manufactured by Shin-Etsu Silioone or an equivalent) to the cylinder head oover packing [2] as shown. NOTE . Do not apply more liquid sealant than necessary. Check that the mounting rubbers [1] are in good condition, and replace them if necessary. NOTE . Install the mounting rubbers with their "UP" marks [2] facing up. [2] [1] 10-5 CYLINDER HEADNALVE/CAMSHAFT ROCKER ARM Insert the cylinder head oover [1] from the right side as shown. Install the cover on the cylinder head securely. Install the bolts [1] and tighten them to the specified torque. TORQUEHD N-m (1.0 kgf-m, 7 Ibf’ft) Install the ignition coil tray (page 5-9). REMOVAL Remove the cylinder head cover (page 10-4). Remove the crankshaft hole cap and the timing hole cap (page 3-8). Turn the crankshaft counterclockwise and align the "T1" mark [1] on the flywheel with the index mark [2] 01 the alternator oover. Make sure that the index lines [3] on the cam sprocket align with the upper surlace oi the cylinder head and the punch mark [4] on the sprocket is visible. Remove the rocker arm shafl stopper bolt [1], sealing washer [2], and rocker arm shaft bolts [3]. 10-6 CYLINDER HEADNALVE/CAMSHAFT Temporarily install a 6 mm bolt [1]. Remove the rocker arm shaft [2] by pulling it. Remove the rocker arms A [3] and B [4]. Remove the 6 mm bolt. INSPECTION Inspect the iollowing parts for damage, abnormal wear, deformation, burning. — Rocker arm — Rocker arm shaft Measure each part according to CYLINDER HEAD/ VALVE/CAMSHAFT SPECIFICATIONS (page 1»7). Replace any part it it is out of the service limit. INSTALLATION Turn the crankshaft counterclockwise and align the "T1" mark [1] on the flywheel with the index mark [2] oi the alternator oover. Make sure that the index lines [3] on the cam sprocket align with the upper surIace oi the cylinder head and the punch mark [4] on the sprocket is visible. The rocker arms have the iollowing identification marks: — "A" mark: rocker arm A [1] — "B" mark: rocker arm B [2] [1] [2] 10-7 CYLINDER HEADNALVE/CAMSHAFT Apply molybdenum oil solution to the rocker arm sliding Z 4 area and thrust surface. I 1 ;i ;i I I Apply molybdenum 0" solution to the rocker arm shaft , outer surface. Temporarily install a 6 mm bolt [1]. Install the rocker arms A [2] and B [3]. Install the rocker arm shaft [4]. NOTE . Install the rocker arm shaft by aligning its grooves with the bolt holes of the cylinder head. Apply engine oil to the rocker arm shaft bolt threads and seating surface. Install and tighten the shaft bolts [5] to the specified torque. TORQUEHZ N-m (1.2 kgf-m, 9 Ibf-ft) Remove the 6 mm bolt. Install the stopper bolt [6] and a new sealing washer [7] . and tighten the bolt to the specified torque. TORQUE:18 N-m (1.8 kgf-m,13lbf-ft) Install the cylinder head cover (page 10-5). CAM CHAIN TENSIONER LIFTER REMOVAL/INSTALLATION Remove the cam chain tensioner lifter plug [1] and sealing washer [2]. Turn the cam chain tensioner lifter shaft fully in (clockwise) and secure it using the special tool. TOOL: Tensioner holder B [1] 07DMG-001D100 Remove the cam chain tensioner lifter mounting bolts [2]- Remove the cam chain tensioner lifter [3] and gasket [4]- 10-8 CYLINDER HEADNALVE/CAMSHAFT Install a new gasket [1] on the cam chain tensioner lifter [2] and install them to the cylinder. Install and tighten the mounting bolts [3]. Remove the tensioner holder B [4]. Install and tighten the plug [5] with a new sealing washer [6]. INSPECTION Check the cam chain tensioner lifter [1] operation: — The cam chain tensioner lifter shaft should not go into the lifter body when it is pushed. — When it is turned clockwise with the tensioner holder or a screwdriver [2], the shaft should be pulled into the lifter body. The shaft should spring out of the lifter body as soon as the tensioner holder is released. CAMSHAFT REMOVAL Remove the rocker arms (page 10-6). Turn the crankshaft counterclockwise and align the "T2" mark [1] on the flywheel with the index mark [2] of the alternator oover. Make sure that the punch mark [3] on the cam sprocket align with the upper surface of the cylinder head as shown. Release the cam chain tension (page 10-8). Be carefulnotlolet Loosen the camshaft holder bolts [1] gradually in a the camshaft holder crisscross pattern in 2 or 3 steps, and remove them. [70”: iaumm the Remove the camshaft holders [2] with the dowel pins. crankcase. NOTE . Do not forcibly remove the dowel pins from the camshaft holders. CYLINDER HEADNALVE/CAMSHAFT Attach a piece or wire to the cam chain to prevent it Iron-i raiiing into the crankcase. Do not rotate the camshaft during inspection. Remove the cam sprocket bolts [1] and disassemble the camshaft [2] and cam sprocket [3]. Release the cam chain [4] from the cam sprocket. Remove the camshaft. Remove the valve lifters [1] and shims [2]. NOTE . Do not allow the shims to fall into the crankcase. . Mark all valve lifters and shims to ensure correct reassemny in their original locations. . The shims can be easily removed with a tweezers or a magnet. INSPECTION Inspect the following parts for damage, abnormal wear, deformation, burning, or clogs in oil passages. — Cam sprocket — Camshaft — Camshaft holder/dowel pin — Valve lifter Measure each part aocording to CYLINDER HEAD! VALVE/CAMSHAFT SPECIFICATIONS (page 1»7). Replace any part if it is out of the service limit. CAMSHAFT OIL CLEARANCE Wipe any oil from the journals of the cylinder head, camshaft and camshaft holder. Install the camshaft onto the cylinder head (page 10» 11). Lay a strip of plastigauge [1] lengthwise on each camshaftjournal and be sure to avoid the oil passages. 10-10 CYLINDER HEADNALVE/CAMSHAFT Carefully rotate the crankshaft while holding the cam chain to avoid jamming the cam chain agalnst the timing sprocket of the crankshaft. Install camshaft holders/dowel pins [1] in the correct locations, being careful not to drop the plastigauge. Apply engine oil to the threads and seating surfaces of the camshaft holder bolts [2] and install them. Tighten the bolts to the specified torque. TORQUE:12 N-m (1.2 kgf-m, 9 Ibf’ft) Remove the camshaft holders and measure the compressed plastigauge at its widest point on the camshaft to determine the oil clearance. SERVICE LIMIT: 0.10 mm (0.004 in) If the oil clearance exceeds the service limit, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft holder as a set if the oil clearance still exceeds the service limit. INSTALLATION Turn the crankshaft counterclockwise and align the "T2" mark [1] on the flywheel with the index mark [2] ot the alternator cover. Install the valve lifters [1] and shims [2]. NOTE . Do not allow the shims to tall into the crankcase. . Install all valve lifters and shims in their original locations. 10-11 CYLINDER HEADNALVE/CAMSHAFT Apply molybdenum oil solution to the camshaft journal cam lobes, and thrust surfaces. Put the camshaft [1] onto the cylinder head. Apply engine oil to the cam chain whole surlace. Install the cam chain [2] over the cam sprocket [3] Assemble the camshaft and cam sprocket. Make sure that the punch mark [4] on the cam sprocket align with the upper surface of the cylinder head as shown. Make sure that the camshaft end [5] is in position as shown. Apply locking agent to the cam sprocket bolts threads L (page 1»21). Install and tighten the cam sprocket bolts [6] to the specified torque. TORQUE:20 N-m (2.0 kgf-m, 15 lbt-it) Apply molybdenum oil solution to the camshaft holders inside and install them in their original locations. — Camshaft holder A/dowel pins [1] — Camshaft holders B/dowel pins [2] NOTE . Align the groove of the camshaft holder A with the tab of the camshaft. 10-12 CYLINDER HEADNALVE/CAMSHAFT Apply engine oil to the camshaft holder bolt [1] threads and seating surlaces and install them. Tighten the bolts to the specified torque. TORQUEHZ N-m (1.2 kgf-m, 9 Ibf-ft) Apply the cam chain tension (page 10-8). Install the removed parts in the reverse order of removal. CYLINDER HEAD Do not tap the cyllnder head too hard and do not damage the mating surface wlth a screwdnvel. REMOVAL Remove the engine (page 16-5). Remove the camshaft (page 10-9). Remove the 6 mm bolts [1]. Loosen the cylinder head bolts [2] in a crisscross pattern in 2 or 3 steps, and remove them. Remove the cylinder head [3]. Remove the gasket [1] and dowel pins [2]. Remove the cam chain guide [1]. 10-13 CYLINDER HEADNALVE/CAMSHAFT To prevent loss or tension, do not compress the Valve spn'ngs more than necessary. Mark all the parts so they can be placed hack in their original locations. DISASSEMBLY Install the tappet hole protector into the valve lifter bore. A tool can easily be made from a plastic 35 mm film container or equivalent as shown. Remove the valve cotters [1] using the special tool as shown. TOOLS: Valve spring compressor [2] 07757-0010000 Remove the lollowing: — Spring retainers [1] — Valve springs [2] — Intake valves [3] — Exhaust valves [4] — Stern seals (Intake side) [5] — Stern seals (Exhaust side) [6] — Spring seats [7] Remove carbon deposits from the combustion chamber [1]- 15mm TOP VIEW 10-14 CYLINDER HEADNALVE/CAMSHAFT Do not use a torch to hear the cylinder head: It may cause Warping. Use cutting all on the reamer during this operation. INSPECTION Inspect the lollowing parts for damage. abnormal wear. delormation, burning or clogs in oil passages. — Cylinderhead — Valve springs — Valves — Valveguides Measure each part according to CYLINDER HEAD/ VALVE SPECIFICATIONS (page 1-7). Replace any part it it is out of service limit. NOTE . Ream the valve guide using the valve guide reamer to remove any carbon build up before measuring the guide (page 10-15). . Refer to valve seat inspection (page 10-16). VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section 01 a refrigerator for about an hour. Heat the cylinder head to 100 — 150”C (212 — 302°F) with a hot plate or oven. To avoid burns. wear heavy gloves when handling the heated cylinder head. Support the cylinder head and drive out the valve guides from combustion chamber side of the cylinder head. TOOL: Valve guide driver 5.5 mm [1] 07742-0010100 NOTE . Mark the guides with a permanent marker at the specified height. Drive the guides to the marked line and check with a pair of caiipers. Adjust the valve guide driver [1] to the specilied depth. SPECIFIED DEPTH: IN: 17.7 —15.0 mm (0.70 — 0.71 in) EX:17.8 — 15.1 mm (0.70 — 0.71 in) TOOL: Valve guide driver 07743-0020000 While the cylinder head is still heated. drive new valve guides [2] from the camshaft side until the exposed height is specified value. Let the cylinder head cool to room temperature. Ream new valve guides after installation. Insert the reamer [1] lrom the combustion chamber side of the cylinder head and always rotate the reamer clockwise. TOOL: Valve guide reamer, 5.5 mm 07984-2000001 . Take care not to tilt or lean the reamer in the guide while reaming. Clean the cylinder head thoroughly to remove any metal particles. Relace the valve seat (page 10-16). 10-15 CYLINDER HEADNALVE/CAMSHAFT The valves cannot be ground. lithe valve face is burned. badly worn, or III! contacts the seat unevenly, replace the valve. VALVE SEAT INSPECTION/REFACING Disassemble the cylinder head (page 10-14). Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or other hand-lapping tool [1]. Measure the valve seat width according to CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS (page 1-7). Inspect the valve seat face for: . Uneven seat width: — replace the valve and reface the valve seat. . Damaged face: — replace the valve and reface the valve seat. a Contact area (too high or too low) — reface the valve seat. REFACING Reface the valve seat using the following tools. TOOLS: Cutter holder, 5.5 mm 07781-0010101 Seat cutter, 40 mm (45" IN) 07780-0010500 Seat cutter, 35 mm (45" EXI 07780-0010400 Flat cutter, 42 mm (32° INIEX) 07780-0013000 Interior cutter, 34 mm (60" lN/EX) 07780-0014700 STANDARD: IN: 1.1—1.3 mm (0.04 — 0.05 inI EX: 1.3 — 1.5 mm (0.05 — 0.06 inI SERVICE LIMITS: IN: 1.5 mm (0.06 ml EX: 1.9 mm (0.07 ml NOTE . Follow the refacer manufacturer’s operating instructions. . Be careful not to grind the seat more than necessary. 1. Use a 45” seat cutter. remove any roughness or irregularities from the seat. 2. Use a 32” flat cutter, remove the top 1/4 of the existing valve seat material. 3. Use a 60° interior cutter. remove the bottom 1/4 of the existing valve seat material. 4. Using a 45" seat cutter. cut the seat to the proper width. Make sure that all pitting and irregularities are removed. 5. After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure. NOTE . Excessive lapping pressure may deform or damage the seat. a Change the angle of lapping tool [1] frequently to prevent uneven seat wear. a Do not allow lapping compound to enter the guides. After lapping, wash any residual compound off the cylinder head and valve and recheck the seat contact. Assemble the cylinder head (page 10-17). ’ Yd seal width \ Va seat Width X 60° 10-16 CYLINDER HEADNALVE/CAMSHAFT ASSEMBLY VALVE COVERS \49 Q9 \ SPRING RETAINER />@ 3! STEM SEAL .3; . 8/ (EXHAUST SIDE) 9 I g VALVE SPRING ’7: /Je STEM SEAL \ 9 (INTAKE SIDE) SPRING SEAT VALVE GUIDE EXHAU ST VALVE Blow through the oil passage in the cylinder head with compressed air. Install the spring seats [1]. Apply engine oil to the inside 01 new stem seals (intake side) [2]/(exhaust side) [3] and install them. Apply molybdenum oil solution to the valve stem sliding area and stem end. V Insert the intake valves [4] and exhaust valves [5] into the valve guide while turning it slowly to avoid damage [II to the stern seal. 5 [2] ,- Install the valve springs [6] with the tightly wound ooiIs iacing the oomhustion chamber. [7] [5] j [a] [7] Install the valve spring retainers [7]. COMBUSTION CHAMBER SIDE 10-17 CYLINDER HEADNALVE/CAMSHAFT Install the tappet hole protector into the valve lifter bore (page 10-14). Install the valve cotters [1] using the special tool as shown. TOOLS: Valve spring compressor [2] NOTE . To prevent loss of tension, do not compress the valve springs more than necessary. 07757-0010000 Tap the tool gently to seat the valve ootters Iirmly using a hammer. NOTE . Support the cylinder head above the work bench surface to prevent valve damage. Install the following: — Thermostat (page 8-5) — Cam chain tensioner lifter (page 10-8) — Spark plugs (page 3-6) INSTALLATION Install the cam chain guide [1]. NOTE . Align the cam chain guide end [2] with the groove in the crankcase. . Align the cam chain guide tabs with the grooves in the crankcase. Install the dowel pins [1] and a new gasket [2]. 10-18 CYLINDER HEADNALVE/CAMSHAFT Route the cam chain [1] through the cylinder head and install the cylinder head [2] onto the cylinder. Apply molybdenum 0“ solution to the cylinder head bolts threads and seating surface. Apply engine oil to the cylinder head bolt washers. Install and tighten the cylinder head bolts [3] in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE:83 N-m (8.5 kgfrm, 61 lbf-ft) Install and tighten the 6 mm bolts [4] securely. Install the camshaft (page 10-9). Install the engine (page 1640). INSULATOR Remove the throttle body (page 7-12). Loosen the band screws [1] and remove the insulators [2]. Installation is in the reverse order of removal. NOTE . Align the insulator grooves [3] with the upper crankcase lugs [4]. . Install the insulators with the stamped mark side facing up. . Make sure that the band screws is in position as shown. ‘ . Tighten the insulator band screws to the specified range as shown. [Z] I3] 1211.0mm f 12t1.0mm (0.5 1 0.04m) (05 t 0.04 in) c [1] No.1 wlinder side: No.2 cylinder side: 10-19 MEMO 11. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION -------------------- .. 11.2 TROUBLESHOOTING ------------------------ .. 11.2 COMPONENT LOCATION ------------------- -- 11-3 ALTERNATOR COVER ----------------------- -~ 11-4 STATORICKP SENSOR ---------------------- -~ 11:] FLYWHEEL ...................................... .. 11;, STARTER CLUTCH ........................... .. 11.9 11-1 ALTERNATOR$TARTERCLUTCH SERVICE INFORMATION GENERAL ~ This section covers service of the alternator and starter ciutch. All service can be done with the engine installed in the irame. ~ For alternator inspection (page 2143). For CKP sensor inspection (page 5-7). For starter motor service (page 66). TROUBLESHOOTING Starter motor turns, but engine does not turn ~ Fauity starter clutch ~ Damaged starter reduction gear/shaft ~ Damaged starter idie gear/shaft ~ Damaged or iauity starter motor pinion gear ~ Damaged starter driven gear 11-2 ALTERNATORISTARTER CLUTCH COMPONENT LOCATION 12 Nm (1A2 kgf'm. 9 mm) 11-3 ALTERNATORISTARTER CLUTCH ALTERNATOR COVER REMOVAL/INSTALLATION (CRF1000/A) Drain the engine oil (page 3-12). Remove the left rear cover (page 240). Remove the gearshift spindle cover (page 1247). Disconnect the EOP switch terminal (page 2249). Disconnect the VS sensor 3P (Black) connector (page 442). Remove the connector cover (page 5-8). Disconnect the alternator assembly 6P (Black) connector [1]. Disconnect the alternator 3P (Gray) connector [1]. Release the alternator assembly wire [2] from the wire clamp [3]. Release the wire clip [4]. Release the alternator assembly wire from the frame. Remove the tollowing: — Dipstick [1] — Alternator cover bolts (6 x 28 mm) [2] — Alternator cover bolt (6 x 30 mm) [3] and alternator assembly wire cover stay A [4] — Alternator cover bolt (6 x 30 mm) [5] and alternator assembly wire cover stay B [6] NOTE . Loosen the bolts in a crisscross pattern in 2 or 3 steps. Remove the alternator cover [7]. NOTE . The a|temator cover (stator) is magnetically attracted to the flywheel, be caretul during removal. [31/ [4] 11-4 ALTERNATORISTARTER CLUTCH Remove the dowel pins [1] and oil joint [2]. NOTE . Install the oil joint with the narrow hole side iacing out. Clean off any sealant from the alternator cover mating suriaces. Installation is in the reverse order of removal. NOTE . Apply liquid sealant (TB1207B manufactured by Three bond or equivalent) to the alternator cover mating suriace as shown. . Do not apply more liquid sealant than necessary. . Route the wires properly (page 1-26). TORQUE: Alternator cover bolt: 12 N-m (1.2 ngm, 9 left) Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12). REMOVAL/INSTALLATION (CRF1000D) Drain the engine oil (page 3-12). Disconnect the EOP sensor 3P (Black) connector (page 22-20) Remove the following: — Left rear cover (page 2-10) — Shift control motor cover (page 1341) — Connector cover (page 58) Disconnect the alternator assembly 6P (Black) connector [1]. Disconnect the alternator 3P (Gray) connector [1]. Release the alternator assembly wire [2] from the wire clamp [3]. Release the wire clip [4]. Release the alternator assembly wire from the frame. ALTERNATORISTARTER CLUTCH Disconnect the EOP sensor 3P (Black) connector [1]. Remove the iollowing: — Dipstick [2] — Alternator cover bolts (6 x 28 mm) [3] — Alternator cover bolt (6 x 30 mm) [4] and alternator assembly wire cover stay A [5] — Alternator cover bolt (6 x 30 mm) [6] and alternator assembly wire cover stay B [7] NOTE . Loosen the bolts in a crisscross pattern in 2 or 3 steps. Remove the alternator cover [8]. NOTE . The alternator cover (stator) is magnetically attracted to the flywheel, be careiul during removal. Remove the dowel pins [1] and oil joint [2]. NOTE . Install the oil joint with the narrow hole side facing I out. Clean off any sealant from the alternator cover mating surlaces. Installation is in the reverse order of removal. NOTE . Apply liquid sealant (TB1207B manufactured by Three bond or equivalent) to the alternator cover mating surlace as shown. . Do not apply more liquid sealant than necessary. . Route the wires properly (page 1-26). Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12). 11-6 STATORICKP SENSOR Route the wires properly (page 1- REMOVAL/INSTALLATION Remove the alternator cover. — CRF1000/A (page 114) — CRF1000D (page 11-5) Release the wire grommet [1] from the alternator cover groove. Remove the CKP sensor mounting bolts [2]. Remove the stator mounting bolts [3]. Remove the stator [4]]CKP sensor [5] assembly. Apply a locking agent to the stator mounting bolts threads (page 1-20). Install the stator/CKP sensor assemny and bolts. Tighten the stator mounting bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbfrfl) Apply a locking agent to the CKP sensor mounting bolt threads (page 1-20). Install the CKP sensor mounting bolts and tighten them to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbfrfl) Apply liquid sealant (TB1207B manufactured by Three bond or equivalent) to the grommet as shown, then install it into the groove ot the cover. Install the alternator cover. — CRF1000/A (page 114) — CRF1000D (page 11-5) FLYWHEEL REMOVAL Remove the alternator cover. — CRF1000/A (page 114) — CRF1000D (page 11-5) Remove the starter gear shaft [1] and starter reduction gear B [2]. Remove the starter reduction gear shaft [3] and starter reduction gear A [4]. Hold the flywheel [1] using the special tool and loosen the flywheel mounting bolt [2]. TOOL: Flywheel holder [3] Remove the bolt and washer [4]. 0772541040001 ALTERNATORISTARTER CLUTCH [4] ALTERNATOR/STARTER CLUTCH Remove the flywheel [1] using the special tool. TOOL: Rotor puller [2] 07733-0020001 Remove the needle bearing [1]. Remove the woodmff key [2]. NOTE . Be careful not to damage the key groove and crankshaft. INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or deformation. — Starter reduction gear shaft — Starter reduction gear — Woodruff key — Needle bearing Replace if necessary. INSTALLATION Install the woodruff key [1]. NOTE . Be careful not to damage the key groove and crankshaft. Apply engine oil to the needle bearing rotating area. Install the needle bearing [2]. 11-8 ALTERNATORfiTARTERCLUTCH Clean any oil from the crankshaft and flywheel tapered area thoroughly. Install the flywheel [1] to the crankshaft. N OT E . Align the woodruff key with flywheel keyway. Apply engine oil to the flywheel mounting bolt threads and seating surface. ' Install the washer [1] and flywheel mounting bolt [2]. Hold the flywheel [3] using the special tool and tighten the flywheel mounting bolt to the specified torque. TOOL: Flywheel holder [4] 077254040001 TORQUE: 137 N-m (14.0 kgf-m, 101 lbf-ft) Apply molybdenum oi| solution to the starter reduction gear shafts outer surfaces. Install the starter reduction gearA [1] and shaft [2]. Install the starter reduction gear B [3] and shaft [4]. Install the alternator cover. — CRF1000/A (page 114) — CRF1000D (page 11-5) STARTER CLUTCH REMOVAL Remove the flywheel (page 11-7). Make sure that the starter driven gear [1] turns counterclockwise smoothly and does not turn clockwise. Remove the starter driven gear while turning the starter driven gear counterclockwise. 11-9 ALTERNATORISTARTER CLUTCH Hold the flywheel [1] using the special tool and remove the starter clutch torx bolt [2]. TOOL: Flywheel holder [3] 0772541040001 Remove the starter clutch assembly [1]. Remove the starter one-way clutch [2] from the starter clutch outer [3]. INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or detormation. — Starter driven gear — Starter clutch outer — Starter one-way clutch Measure each part according to ALTERNATOR] STARTER CLUTCH SPECIFICATIONS (page #8). Replace any part it it is out of service limit. INSTALLATION Apply engine oil to the starter one«way clutch sliding surlace. Install the starter one-way clutch [1] to the starter clutch outer [2]. Install the starter clutch assembly [3]. [2] 11-10 Hold the flywheel [1] using the special tool. TOOL: Flywheel holder [2] 077254040001 Apply locking agent to the starter clutch socket bolt threads (page 1-21). Install and tighten the starter clutch torx bolt [3] to the specified torque. TORQUE: 29 N-m (3.0 kgf-m, 21 lhf-ft) Install the starter driven gear [1] into the starter clutch outer while turning the starter driven gear counterclockwise. Recheck the one»way clutch operation (page 11-9). Install the flywheel (page 11-8). ALTERNATORISTARTER CLUTCH 11-11 MEMO 12. CLUTCH/GEARSHIFT LINKAGE (CRF1000IA) SERVICE INFORMATION -------------------- .. 12.2 TROUBLESHOOTING ------------------------ .. 12.2 COMPONENT LOCATION ------------------- -- 12-3 RIGHT CRANKCASE COVER -------------- -~ 12-4 CLUTCH .......................................... .. 12_8 PRIMARY DRIVE GEAR -------------------- --12-15 GEARSHIFT LINKAGE ---------------------- ..12.17 GEARSHIFT PEDAL ------------------------- --12-21 12-1 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) SERVICE INFORMATION GENERAL ~ This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. ~ Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle creeps With clutch disengaged, inspect the engine oil level before servicing the clutch system. ~ When using the lock nut wrench, use a deflecting beam type torque Wrench 50 mm (2.0 in) long. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading Will be less than the torque actually applied to the lock nut. The specification given below is the actual torque applied to the lock nut, not the reading on the torque wrench when used With the lock nut wrench. The procedure later in the text gives both actual and indicated torque readings. TROUBLESHOOTING Clutch lever is too hard to pull in ~ Damaged, kinked or dirty clutch cable ~ Improperly routed clutch cable ~ Damaged clutch lifter mechanism ~ Faulty clutch lifter bearing ~ Clutch lifter piece installed improperly Clutch slips when accelerating ~ Clutch lifter sticking ~ Worn clutch discs ~ Weak clutch springs ~ No clutch lever freeplay ~ Engine oil mixed with molybdenum or graphite additive Clutch will not disengage or motorcycle creeps with clutch disengaged Excessive clutch lever freeplay (page 3-22) Clutch plate warped Engine oil level too high, improper engine oil viscosity or additive used Loose clutch center lock nut Damaged clutch lifter mechanism Clutch lifter rod installed improperly Worn clutch outer slot and clutch center grooves Improper clutch operation Hard to shift ~ Incorrect clutch cable adjustment ~ Improper clutch operation ~ Improper engine oil viscosity ~ Damaged or bent shift forks (page 14-15) ~ Bent shift fork shaft (page 14-15) ~ Bent shift fork claw (page 14-15) Loose shift drum center bolt Damaged shift drum center Damaged shift drum guide grooves (page 14-15) Damaged or bent gearshift spindle Damaged clutch cam Transmission jumps out of gear ~ Worn shift drum stopper arm ~ Weak or broken shift drum stopper arm return spring ~ Loose shift drum center bolt ~ Damaged shift drum center ~ Bent shift fork shaft (page 14-15) ~ Damaged or bent shift forks (page 14-15) ~ Worn gear engagement dogs or slots — Mainshaft (page 14-16) — Countershaft (page 14-15) Gearshift pedal will not return ~ Weak or broken gearshift spindle return spring ~ Damaged or bent gearshift spindle 12-2 CLUTCH/GEARSHIFT LINKAGE (CRF1000IA) COMPONENT LOCATION 23 Nm (2.3 kgl1m,17lbf-fl) 12 N-m (1.2 kgf-m. 9 lbf-fl) 12 N~m (1.2 kgl1m,9lbf'fl) 123 Nm (13.1 kgfm, 94 lbf-fl) 12 Nm (1.2 kgf-m. 9 lbf~fl) 12 Nm (1.2 kgf'm. 9 mm) 12-3 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-12). Drain the coolant (page 8-4). Remove the bolts [1] and engine right side rear cover [2]- Loosen the lock nuts [1] and release the clutch cable [2] lrom the clutch lifter lever [3]. Loosen the hose band screws [1] and disconnect the water hoses [2]. Remove the bolts [1]. Be carelulnot to Remove the right crankcase cover [2] while turning the drop the return clutch lifter lever [3] counterclockwise to disengage the spring. lifter lever slit from the clutch lifter pin. 12-4 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the dowel pins [1] and gasket [2]. Remove the O-ring [1]. CLUTCH LIFTER LEVER Remove the clutch lifter lever [1] and return spring [2]. Remove the oil seal [3]. Check the needle bearings [4] and replace if necessary. Installation is in the reverse order of removal. NOTE . Coat new bearings with engine oil and install them to the specified depth as shown. . Replace the oil seal with a new one and install it to the specified depth as shown. . Apply grease to a new oil seal lips. . Align the return spring end with the clutch lifter lever groove. . Align the return spring hook with the right crankcase cover groove. 6.5 7 7.5 mm (0.26 7 0.30 in) 0.3 7 0.8 mm (0.017 0.03m) 09.4 7 70.4 mm (2.73 7 2.77m) 12-5 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) INSPECTION Inspect the following parts for scratch, damage. abnormal wear and deformation. Replace if necessary. — Clutch lifterlever — Return spring INSTALLATION Clean the right crankcase cover mating surIaces thoroughly. Apply liquid sealant (TB1207B manufactured by Three Bond or equivalent) to the right crankcase cover mating surIace as shown. Install the dowel pins [1] and new gasket [2]. Goat a new O-ring [1] with engine oil and install it onto the groove oi the water pump cover. 10715mm (0.44.6 in) 10715 mm (0.4416 in) 12-6 CLUTCH/GEARSHIFT LINKAGE (CRF1000IA) Remove the crankshaft hole cap and the timing hole cap (page 3-8). Rotate the crankshaft counterclockwise and align the "T1" mark on the flywheel with the index mark on the alternator cover (page 3-8). Make sure that the index line and mark are lined up. — Primary drive gear index line [1] — Crankcase "V" mark [2] Make sure that the front balancer shaft end [3] is in position as shown. Install the crankshaft hole cap and the timing hole cap (page 340). Rotate the water pump shaft and align the shaft slit with the pump cover index lines as shown. Turn the clutch lifter lever [1] clockwise so that the lever slit [2] is in position as shown. Install the right crankcase cover [1] by holding the clutch lifter lever [2]. Install the bolts [3] and tighten it in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) 12-7 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Connect the water hoses [1] and tighten the hose band screws [2] to the specified range (page 8-8). Connect the clutch cable [1] with the clutch lifter lever [21- lnstall the bolts [1] and engine right side rear cover [2] and tighten the bolts to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 let) Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12). Fill the recommended coolant mixture to the filler neck and bleed the air (page 8-4). Adjust the clutch cable freeplay (page 3-22). CLUTCH REMOVAL Remove the right crankcase cover (page 12-4). Loosen the set plate bolts [1] in a crisscross pattern in 2 or 3 steps, and remove the bolts, set plate [2], and clutch springs [3]. 12-8 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Be careful no! to damage the mainshafi threads. Remove the following: Clutch pressure plate [1] Clutch spring seats [2] Clutch disc B [3] Clutch plate C [4] Clutch lifter pin [5] Clutch discs A [6] (2 pcs) Clutch plates A [7] (5 pcs) Clutch discs C [8] (5 pcs) Clutch plate B [9] Judder spring [10] Judder spring seat [1 1] NOTE . When removing the clutch discs and plates, note the number of the clutch discs and plates. Unstake the clutch oenter lock nut [1]. Install special tools and loosen the clutch oenter lock nut [1] while holding the clutch center with the special tool. TOOLS: Clutch center holder PD. 43 .135[2] Lock nut wrench 30 x 40 mm [3] 079163690000 07724-0050002 Remove the lock nut. Remove the lock washer [1], washer [2], and clutch center [3]. [101 [11] CLUTCH/GEARSHIFT LINKAGE (CRF1000IA) Line up the primary drive gear and sub gear teeth by inserting a suitable pin [1] into the holes of gears. Hold the primary drive gear and sub-gear with a 6 mm bolt [2]. Remove the washer [1] and clutch outer [2]. Remove the washer [1] and clutch outer guide [2]. INSPECTION Check the following of the clutch pressure plate [1] for scratch, damage, abnormal wear and deformation. Cam areas [2] Grooves Disc sliding surface — Bearing [3] Replace the clutch pressure plate if necessary. For bearing replacement (page 12-11) 12-10 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Check the following of the clutch center [1] for scratch, damage, abnormal wear and deformation. — Cam areas [2] — Grooves [2] — Disc sliding surface Replace the clutch center if necessary. Check the following of the clutch outer [1] for scratch, damage, abnormal wear and deformation. [2] — Grooves — Needle bearing[2] — Primary driven gear [3] Replace the clutch outer if necessary. For bearing replacement (page 12-12) Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary. — Clutch springs — Clutch spring seats — Clutch lifterpin — Clutch discs/plates — Judderspring — Judderspring seat — Clutchouterguide Measure each part according to CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (page 1-3). Replace any part if it is out of service limit. NOTE . Replace the clutch springs as a set. . Replace the clutch discs and plates as a set. CLUTCH PRESSURE PRATE BEARING REPLACEMENT Drive bearing out. Goat a new bearing with engine oil. Drive the bearing [1] into the clutch pressure plate with its marked side facing up until it is fully seated using special tools. TOOLS: Driver [2] 077494010000 Attachment, 32 x 35 mm [3] 07746-0010100 Pilot, 17 mm [4] 07746-0040400 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) CLUTCH OUTER NEEDLE BEARING REPLACEMENT Remove the needle bearing [1] out using a hydraulic press and special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 42 mm [3] 07QAD-POA0100 Goat a new needle bearing with engine oil. Install the needle bearing [1] into the Clutch outer with the marked side taCing up to the specified range using a hydraulic press and special tools as shown. 0000 r 0.20 mm TOOLS: Driver [2] 077490010000 “1°00 ’ 0°03 W) Attachment, 42 x 47 mm [3] 077464010300 Pilot, 35 mm [4] 077400040300 INSTALLATION CLUTCH CENTER CLUTCH CENTER NUT 120 N-m (13.1 kgl‘m, 94 lbf-ft) LOCK WASHER CLUTCH DISC A CLUTCH PLATE B CLUTCH Discs C " 5 ‘7. CLUTCH \) ( PCS) DISC A / CLUTCH PLATES A (5 PCS) CLUTCH LIFTER F'IN CLUTCH PRESSURE PLATE CLUTCH PLATE C 12-12 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Apply molybdenum oil solution to the clutch outer guide entire suriace. Install the clutch outer guide [1] and washer [2]. Apply engine oil to the clutch outer needle bearing. Apply molybdenum oil solution to the primary driven gear teeth and clutch outer sliding area. Install the clutch outer [1] and washer [2]. Remove the 6 mm bolt [3]. Install the clutch center [1], washer [2], and lock Washer [31- NOTE . Install the lock washer with its "OUT" mark [4] iacing out. Apply engine oil to a new clutch center lock nut threads and seating suriace. Install special tools and tighten the clutch oenter lock nut to the specified torque by holding the clutch center with the special tool. TOOLS: Clutch center holder 07724-0050002 PD. 43 .135[2] Lock nut wrench 30 x 40 mm [3] 07916-9690000 TORQUE: Actual: 128 N-m (13.1 mm, 94 let) lndicated:116 N-m (11.3 kgf-m, as lbf-ft) 12-13 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Be care/MI not to Stake the clutch center lock nut [1] into the mainshaft damage the groove. mainshai‘l threads. Apply molybdenum oil solution to the entire surface of judder spring seat and judder spring. Install the judder spring seat [1] and judder spring [2] onto the clutch center [3] as shown. Apply engine oil to the entire surface of clutch discs. Install the clutch disc A [4] and plate B [5] onto the clutch center. NOTE . Clutch disc A: smaller lining width than disc B . Clutch plate B: surface treatment difference from clutch plate A Install the clutch discs 0 [6] (5 pcs) and plates A [7] (5 pcs) alternately, starting with the disc C. Install the clutch disc A [8]. Install the clutch lifter pin [1]. Install the spring seats [2] onto the clutch pressure plate [3] grooves. NOTE . Make sure that the spring seats are Iully seated in the pressure plate grooves. Apply engine oil to the entire surface of clutch disc B. Install the clutch disc B [4] onto the clutch pressure plate. Install the clutch plate C [5] by aligning its tabs with the pressure plate grooves. Put the clutch pressure plate assembly onto the clutch center [6] by aligning each cam area and insert them by rotating counterclockwise. Install the clutch disc B tabs into the shallow slots of the clutch outer [7] as shown. 12-14 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Install the clutch springs [1], set plate [2] and set plate bolts [3]. Tighten the set plate bolts in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 0.9 lbt-fl) PRIMARY DRIVE GEAR REMOVAL Remove the following: — Cylinder head (page 10-13) — Rear balanoer (page 14-9) — Clutch (page 12-8) Remove the cam chain tensioner pivot bolt [1], cam chain tensioner [2], and washer [3]. Remove the bolts [4], cam chain guide plate [5], and cam chain [6]. Line up the primary drive gear and sub gear teeth by inserting a suitable pin [1] into the holes of gears. Hold the primary drive gear and sub-gear with a 6 mm bolt [2]. Temporarily install the clutch outer [1]. Install the special tool between the primary drive and driven gears, and remove the primary drive gear bolt [2] and washer [3]. TOOL: Gear holder, 2.5 [4] 07724-0010100 Remove the gear holder and clutch outer. CLUTCH/GEARSHIFT LINKAGE (CRF1000IA) Remove the timing sprocket [1]. Remove the primary drive gear and sub-gear [2]. Remove the 6 mm bolt [3]. DISASSEMBLYIASSEMBLY Remove the primary drive sub-gear [1] and springs [2]. Installation is in the reverse order of removal. NOTE - Apply molybdenum oil solution to the sliding surfaces of the primary drive gear and sub-gear. - Install the sub-gear onto the primary drive gear [3] in the position as shown. - Make sure that the index line on the primary drive sub-gear aligns with the wide tooth of the primary drive gear. INSPECTION Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary. — Primary drive gear — Primary drive sub-gear — Springs INSTALLATION Install the primary drive gear and sub-gear [1] by aligning index line on the sub-gear with the wide tooth of the crankshaft. Line up the primary drive gear and sub gear teeth and hold the primary drive gear and sub-gear with a 6 mm bolt [2] (page 12-15). 12-16 CLUTCHIGEARSHIFT LINKAGE (CRF1000IA) Install the timing sprocket [1] with its punch mark [2] -, n A :— facing out as shown Temporarily install the clutch outer [1]. Apply engine oil to the primary drive gear bolt threads and seating surface. Install the washer [2] and primary drive gear bolt [3]. Install the special tool between the primary drive and driven gears, and tighten the bolt to the specified torque. TOOL: Gear holder, 2.5 [4] 07724-0010100 TORQUE: 103 N-m (10.5 kgf-m, 76 lhf-ft) Remove the gear holder and clutch outer. Remove the 6 mm bolt [5]. Apply locking agent to the cam chain tensioner pivot bolt threads (page 140). Install the washer [1], cam chain tensioner [2], and cam chain tensioner pivot bolt [3]. Tighten the bolt to the specified torque. TORQUE:23 N-m (2.3 kgf-m, 17 Ibf-fl) Install the cam chain [4]. Apply locking agent to the cam chain guide plate bolts threads (page 1-20). ' Install the cam chain guide plate [5] and bolts [6] and tighten the bolts securely. Install the removed parts in the reverse order of removal. GEARSHIFT LINKAGE REMOVAL Remove the following: — Clutch (page 12-8) — Gearshift arm (page 12-21) Remove the bolts [1] and gearshift spindle cover [2]. Release the wire clip [3] Clean off any dirt from the gearshift spindle serration [4]- CLUTCH/GEARSHIFT LINKAGE (CRF1000IA) Remove the bolt [1] and set plate [2]. Pull the gearshift spindle assembly [1] and thrust washer [2] out of the crankcase. Remove the shift drum center bolt [1]. Remove the shift drum center [1] while holding the stopper arm [2] using a screwdriver as shown. 12-18 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Remove the following: — Dowel pin [1] Shift drum stopper arm pivot bolt [2] Shift drum stopper arm [3] Return spring [4] Washer [5] Remove the oil seal [1]. INSPECTION Inspect the following parts for damage, abnormal wear and deformation. Replace if necessary. — Shift drum oenter — Shift drum stopper arm — Return spring — Gearshift spindle INSTALLATION Install a new oil seal [1] until it is fully seated and apply grease to the oil seal lips. 12-19 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Apply locking agent to the shift drum stopper arm bolt threads (page 1-20). Install the washer [1], return spring [2], shift drum stopper arm [3], and pivot bolt [4]. Tighten the pivot bolt to the specified torque. TORQUEHZ N-m (1.2 kgf-m, 9 Ibf-ft) Check the stopper arm for proper operation. Install the dowel pin [5]. Hold the stopper arm [1] using a screwdriver. Install the shift drum center [2] by aligning its slot with the dowel pin. Apply locking agent to the shift drum oenter bolt threads (page 1»21). Install and tighten the shift drum oenter bolt [1] to the specified torque. TORQUE:23 N-m (2.3 kgf-m, 17 lhf-ft) Install the thrust washer [1] onto the gearshift spindle [2]. Install the gearshift spindle into the crankcase by aligning the return spring ends with the spring pin. . M ‘4.» \E .1. 12-20 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) Apply locking agent to the set plate bolt threads (page 1.20). Install the set plate Install the set plate [1] and bolt [2] and tighten the bolt to With its punch mark the specified torque. [3] [WW °“" TORQUE: 12 N-m (1.2 kgf'm, 9 lbfrft) Install the wire clip [1]. Install the gearshift spindle cover [2] and bolts [3] and tighten the bolts to the specified torque. TORQUEHZ N-m (1.2 kgf'm, 9 Ibfrft) Route the wire harness properly (page 1-26). Install the following: — Clutch (page 12-12) — Gearshift arm (page 12-21) GEARSHIFT PEDAL REMOVAL/INSTALLATION Remove the pinch bolt [1] and gearshift arm [2] from the ‘ gearshift spindle [3]. Remove the pivot bolt [4] and gearshift pedal [5]. Remove the dust seals [6]. Check the dust seals and tie-rod ball joint dust oover for deterioration or damage, replace them if necessary. Installation is in the reverse order of removal. NOTE . Apply grease to the dust seal lips. . Install the dust seals with the seal lip side facing out. . Apply grease to the gearshift pedal pivot sliding area » (grease groove) of the pivot bolt. . Align the slit of the gearshift arm with the punch mark on the spindle 12-21 CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) When adjusting the gearshiit pedal height, perform procedures as follows: The gearshift arm Loosen the lock nuts [1]. lgff‘g‘r’éflflgafi: Adjust the tIe-rod [2] length so that the distance ' between the baii Joint ends is standard iength as shown. After adjustment tighten the iock nuts secureiy. 10.2 mm (0.40 in) 100 27187.2mm (7 33 e 7.37 in) <— [2] 10.2 mm (0.40 in) 12-22 13. DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SERVICE INFORMATION -------------------- -- 13-2 DCT SYMPTOM TROUBLESHOOTING 13-3 COMPONENT LOCATION ------------------- -- 13-4 SYSTEM LOCATION .......................... .. 13.5 SYSTEM DIAGRAM ........................... .. 13.6 DCT TROUBLESHOOTING INFORMATION .................................. .. 13.7 DTC INDEx- .1340 DTC TROUBLESHOOTING ---------------- ~-13-15 MODE/SHIFT INDICATOR CIRCUIT TROUBLESHOOTING ----------------------- ~-13-43 AIM SWITCH TROUBLESHOOTING ---- ~‘13-49 CLUTCH OIL FEED PIPE ------------------- ~-13-5o RIGHT CRANKCASE COVER ------------- “123-52 LINEAR SOLENOID VALVE --------------- --13-so DUAL CLUTCH/PRIMARY DRIVEN GEAR ............................................. "13.53 PRIMARY DRIVE GEAR -~ -13-70 SHIFT CONTROL MOTOR/REDUCTION GEARS ........................................... "13.71 GEARSHIFT LINKAGE ---------------------- --13-74 - MAINSHAFT SENSOR ----------------------- --13-7s TR SENSOR ------------------------------------ --13-79 SHIFT SPINDLE ANGLE SENSOR -- -13-79 CLUTCH EOP SENSOR --------------------- --13-so EOT SENSOR ---------------------------------- --13-s1 NEUTRAL SWITCH --------------------------- --13-82 CLUTCH INITIALIZE LEARNING (pCM) ............................................. "13.32 13-1 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SERVICE INFORMATION GENERAL ~ This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (DCT). A faulty DCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding. Read the "DCT Troubleshooting Information“ carefully, and inspect and troubleshoot the DCT system according to the DTC. Observe each step of the procedures one by one. Note the DTC and probable faulty part before starting diagnosis and troubleshooting. ~ The PCM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may damage the PCM. Always turn off the ignition switch before servicing. ~ If the PCM is replaced, perform the following procedure. — Key Registration Procedure (page 23-3) — Clutch Initialize Learning Procedure (CRFlODOD) (page 13-82) The drive mode AT or MT are changed electrically with the NM switch. Be sure to use the recommended tires, and the specified drive and driven sprocket to operate the dual clutch transmission system normally. For VS sensor service (page 4-42). For oil pump service (page 9-7). The following color codes are used throughout this section. B Black Bu = Blue Gr = Gray 0 = Orange R Red W = White Br = Brown G = Green Lg = Light green P = Pink V = Violet Y = Yellow For DCT System Troubleshooting ~ The DCT system is controlled by the PCM. Therefore, some detection items are shared in the PGM-FI and DCT systems, and they may affect the operation of both systems. ~ Before starting any troubleshooting, check the following items and refer to the appropriate troubleshooting. — MIL blinks or DTC for the PGM-Fl system (page 4-6). — Shift indicator blinks or DTC for the DCT system (page 13-7) — Symptom of the DCT system operation (page 13-3) — TXD line (page 22-14) Refer to the "PGM-FI Troubleshooting Information" for the "CIRCUIT INSPECTION" information (page 4-7). The gearshift mechanism included the following items. If the gearshift mechanism is faulty, refer to each component service. — Shift oontroi motor/reduction gears (page 13-71) — Gearshift linkage (page 13-74) — Shift drum/shift fork (page 14-15) Shift Control Motor Function Procedures NOTE ~ If the PCM has a DTC, the function test does not work. ~ The function test is not for the quality check of the shift control motor. Conduct a test of the shift control motor when the following items have been serviced or replaced. — Shift control motor — Reduction gears — TR sensor — Shift spindle angle sensor Connect the MCS (page 4-6), and perform the shift control motor function test. Linear Solenoid Valve Function Procedures NOTE ~ If the PCM has a DTC, the function test does not work. ~ The function test is not for the quality check of the linear solenoid valve. ~ Do not open the throttle while testing the linear solenoid valve function. Conduct a test of the linear solenoid valves when the linear solenoid valves have been serviced or replaced. Connect the MCS (page 4-6), and perform the linear solenoid valve function test. 13-2 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DCT SYMPTOM TROUBLESHOOTING Check the shirt indicator "—" blinking ol the combination meter (page 13-7). If the shift indicator "—" is blinking. reIer to the DTC Index (page 13-10) and begin the appropriate troubleshooting procedure. If there are n blinking, inspect the engine oil condition and follow the symptom troubleshooting described below. CLUTCH SLIPS AND MOTORCYCLE DOES NOT ACCELERATE Check the clutch clearance (page 13-68). EXCESSIVE NOISE OR VIBRATION AROUND THE DCT SYSTEM Inspect the following components: — Clutch clearance — Dual clutch needle bearings for wear or damage Primary drive/sub-gear for wear or damage — Primary driven gear for wear or damage — Eacn Iastener is tightened to the correct torque value Replace the damaged components if necessary and tighten the loose Iasteners to the speciIied torque. 13-3 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) COMPONENT LOCATION 12 N-m (1.2 kgrm, 9 mm) 12 Mm (192 kgf'm, 9 mm) 5 NM (0.5 kgf-m, 3.7 mm) 12 Nm (1.2 kgf-m, 9 lbf'fl) 12 Mm (192 kgf-m, 9 |bf~fl) 13-4 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SYSTEM LOCATION N-D SWITCH AIM SWITCH LINEARSOLENOID VALVE OUTER MAINSHAFT SHIFT sPlNDLE I r; SENSOR ANGLE SENSOR .. VS SENSOR SHIFT UP SWITCH SHIFT DOWN SWITCH FRONT WHEEL SPEED SENSOR No.1 CLUTCH EOP SENSOR FUSE BOX 1 7 DOT MAIN 7.5 A CKP SHIFT CLUTCH SENSOR CONTROL LINE EOP MOTOR SENSOR EOT SENSOR REAR WHEEL No.2 CLUTCH NEUTRAL SWITCH SPEED SENSOR EOP SENSOR TR SENSOR INNER MAINSHAFT SENSOR 13-5 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) SYSTEM DIAGRAM \LLUMHSYOF mom BRAKE new 57777577 7 5A 5777: am REAR ERAKE new SWWCH 77 7577777077 MNNFUSE SWWCH 10A 77 72757 ENG s7ov 7 5A 7m 57 ENGWE smp 57777577 °_° E7 RELAY 7LLUM77smP 75A 9:7 mm 7 5A 9:7 M 3m SWWCH NEUYRAL swwcH (5271 75272) 57 STARTER RELAY vs SENSOR - (1171) ERWWHEEL 7 SPEED SENSOR , , -<67r1> 6 REAR WHEEL SPEED SENSOR _ (5571) EH7E7 CONTROL MOTOR - (2477,3171) Na 7 L‘NEAR soLENom VALVE -(5577 5572) Na 2 L‘NEAR soLENom VALVE - (5577 5672) w SENSOR -7794) smn mm - (4277) No 7 amen DoEs No7 msENGAGE w SWWCH -7474) 45847 No 2 mm DOES No7 D‘SENGAGE NM swwcH ' (594) 777 MNNSHAFTIEOUNTERSHAFT SPEED me -7544) PCM _ (7H 727“ mm - (977 972 4977,4972) UNE EOP “WE REW SENSOR -( 271) 7577777077 HOLD REL/W - (47474772) 23.1 5&5? ' ‘3“ No 7 mm ms -( Er ) - (4577,4572) g3; ggggg: Nu iggutfH sts sH7E7 szmE ANGLE SENSOR -(21712772‘2242377) G) No 7 amen eukEssunE -(614 5115145614,!7‘24 5227 N02 amen owxEssunE - (5371 537275373 6374,6471 54727 EnonE/w WHEEL SPEED o 725mm: G) -(27r7,51r157727 ' (554) O GEARSH‘FTMECHAN‘SM - (577175772) OUTER MNNSHAFT _ _ _ _ _ SENSOR YFSENSDR - (5477) “(5" 5'2) a up \NNERMNNSHAFT um SENSOR smEsmNn - (53717 a sw77cH 57 am EOTSENSOR Er Bmw” -(4477,4472) Eu Ema a Green (37 Gray m L7gmbme -( ) :DTC o Orawge P Pmk R Red u: an: my W WM readmgmc cowmm comma WWW v M; 7pm sum 7ch sum 7ch s7uE7 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DCT TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "IntermIttent failure" means a system may have had a faIIure. but it checks OK now. If the shift IndIcator — does not come on, check for poor contact or Ioose pins at aII connectors reIated to the circuit that you are troubleshooting. If the shIft indicator "—" was on, but then went out, the orIginaI problem may be IntermIttent. Opens and Shorts "Opens" and "Shorts" are common eIectrical terms. An open Is a break In a wire or at a connection. A short is an achdentaI connection of a Wire to ground or to another wire. In simple electronics, thIs usually means something WIII not work at aII. With PCMs this can sometimes mean somethIng works, but not the way it’s supposed to. If the shift indicator "—" has come on Refer to DTC READOUT (page 13-8). If the shift indicator "—" did not stay on If the shift indicator "—" did not stay on, but there Is a driveability probIem, do the SYMPTOM TROUBLESHOOTING (page 13-3). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The DCT system Is equipped WIth the self-diagnostic system. When any abnormality occurs In the DCT system, the PCM have the shIft indicator innkIng "—" and stores a DTC in Its erasable memory for the relevant system faIIure. FAIL-SAFE FUNCTION The DCT system Is provIded WIth a fail-safe function to secure a mInimum runnIng capability even when there is trouble in the system. When the PCM detects a probIem in the DCT system, the PCM stops the gearshIft functIon, and hold the gear posItion. AIso, the shIft indicator innks "—" to indicate the DTC. Shift indicator Check When the ignition switch Is turned ON WIth the engine stop switch to off. CURRENT DTC/STORED DTC The DTC is IndIcated in two ways according to the failure status. the shift IndIcator wiII stay on for a few seconds, then go - If the PCM detects a current problem, the shift indicator — will come on and begin to blink when the sidestand is lowered. The shift indicator "—" blink pattern wiII indicate the current DTC. - If the PCM does not detect any current but has a problem stored in its memory, the shift IndIcato WIII not light and blink. If it is necessary to retrieve the past problem, readout the stored DTC by foIIOWIng the DTC readout procedure (page 13-8). DTC (Diagnostic Trouble Code) ~ The DTC is composed of a main code and a sub code and It is dIspIayed as a hyphenated number when retrieved from the PCM with the MCS. The digits in front of the hyphen are the main code, they IndIcate the component of function failure. The digits behind the hyphen are the sub code, they detail the specifIc symptom of the component or function faIIure. For example, in the case of the shift spIndIe angle sensor: — DTC 21 — 1 = (Shift spindle angle sensor voltage) — (Iower than the specified value) — DTC 21 — 2 = (Shift spindle angle sensor voltage) — (higher than the specierd vaIue) 13-7 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Shift indicator‘ ink Pattern If the MOS is not available, th The number of shift indicator shift indicator "—"). ~ The shift indicator "—“ has two types of biinks, a long blink and short blink. The long blinking lasts for 1.2 seconds, the short biinking lasts for 0.4 seconds. One long biink is the equivalent of ten short biinks. For example, DTC 14 and DTC 8 are indicated in the following blink pattern. ~ When there isn’t a DTC, the shift indicator "—" lights for2 seconds at intervals of 3 seconds (page 13-9). TC can be read from the PCM memory by the shift indicator — blink pattern. blinks is the equivalent of the main code of the DTC (the sub code cannot be displayed by the 0.4 sec. 0.4 sec. 0.4 sec 2 sec. 1 2 sec. 2 sec. 1 2 sec. ON Wflii “/ flmm\ OFF 2 5 sec. 2.5 sec. \0 4 sec- 2.5 sec. 10-4 59° 2 5 sec. 2 5 sec. \0-4 59°- 4 > 4 4 >i DTC i4 DTC a DTC 14 One long biink =10 blinks‘ Eight short blinks plus four short blinks p p Pattern repeated 1 cycle MCS INFORMATION Refer to the PGM-FI system (page 4-6). NOTE The front wheel speed sensor signal can be disabled with the MOS for testing. Never ride the motorcycle with the PCM in this mode. DTC READOUT NOTE ~ It the shift indicator blinks, check the PGM-Fl DTC (page 4-9). Ifthere is any problem in the PGM-Fl system, troubleshoot it first. Then recheck the DCT system after erasing the PGM-Fl DTC. ~ After performing diagnostic troubleshooting, erase the DTC(s) (page 13-9) and test-ride the motorcycle to be sure that the problem(s) have been removed. Read the DTC and stored data with the M08, and follow the troubleshooting index (page 13-10). To read the DTC without the MOS, use the following procedure. Reading DTC with the shift indicator “—" 1. Turn the ignition switch OFF. Remove the main seat (page 2-4). 2. Connect the $08 connector to the DLC (page 4-6). 3. Make sure the engine stop switch is turned to "0“. While pushing the shift switch (+) [1], turn the ignition switch 0N. Read and note the shift indicator "—" blinks and refer to the troubleshooting index (page 13-10). NOTE ~ It the PCM has no DTC in its memory, the shift indicator "—" will start biinking (page 13-8). 4. Release the shift switch (+). 13-8 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) ERASING DTC Connect the MOS to the DLC (page 4-6). Erase the DTC with the M08 while the engine is stopped. To erase the DTC without MCS, refer to the following procedure. How to erase the DTC without M65 1. Connect the $08 connector to the DLC (page 4-6). Make sure the engine stop switch is turned to Whiie pushing the shift switch (+) [1], turn the ignition switch ON and engine stop switch "a". 2. Push the shift switch (—) [2]. 3. Push the shift switch (+). 4. The self-diagnostic memory is erased if the shift indicator "—" goes off and starts blinking as shown. 2 sec. 2 sec. 2 sec. ON \i i C/ i OFF “ r 4 3 sec. 3 sec. 3 sec. ‘ —> —> Pattern repeated 1 cycle NOTE Note that the self-diagnostic memory cannot be erased if the ignition switch is turned to "OFF" before the shift indicator "—" starts blinking. 5. Turn the ignition switch OFF. 6. Remove the special tool from the DLC. 13-9 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC INDEX If the MOS is not used, perform all of the inspection on the corresponding main code (digits In front of hyphen) of the DTC. DTC Function Failure Symptom/Fail-safe function Refer to page 8-1 TP sensor low voltage (less than 0.112 V) O Loose or poor contact of the TP sensor connector O TP sensor or Its circuit malfunction Gearshift function does not works 4-16 8-2 TP sensor high voltage (more than 4.971 V) O TP sensor or Its circuit malfunction Gearshift function does not works 4-18 9-1 Clutch line EOP sensor low voltage (less than 0.298 V) O Clutch line EOP sensor or its circuit malfunction O Faulty POM Gearshift function works normally 13-15 9-2 Clutch line EOP sensor high voltage (more than 4.702 V) O Loose or poor contact of the clutch line EOP sensor connector O Clutch line EOP sensor or its circuit malfunction O Faulty POM Gearshift function works normally 13-16 VS sensor malfunction - Loose or poor contact of the VS sensor connector - VS sensor or its circuit malfunction - Faulty POM Gearshift function does not works 4-21 19-1 OKP sensor no signal - Loose or poor contact of the OKP sensor connector - Electromagnetic interference at OKP sensor - CKP sensor or its circuit malfunction - Faulty POM Gearshift function does not work Engine does not operate 13-17 Shift spindle angle sensor low voltage (less than 0.308 V) - Loose or poor contact of the shift spindle angle sensor connector - Shift spindle angle sensor or its circuit malfunction - Faulty POM Gearshift function does not work 13-18 Shift spindle angle sensor high voltage (more than 4.976 V) - Shift spindle angle sensor or its circuit malfunction - Faulty POM Gearshift function does not work 13-20 22-1 Shiftspindle operation malfunction (afteroperating gearshift mechanism) - Gearshift mechanism malfunction - Shift spindle angle sensor malfunction Gearshift function does not work 13-20 Shift spindle operation malfunction (while operating gearshift mechanism) - Gearshift mechanism malfunction - Shift spindle angle sensor malfunction Gearshift function does not work 13-21 24-1 Shift control motor drive circuit - Shift control motor or its circuit malfunction - Shift control motor drive circuit in the POM malfunction Gearshift function does not work 13-22 Shift drum position malfunction - TR sensor malfunction - Gearshift mechanism malfunction - Faulty POM Gearshift function does not work 13-23 Shift control motor low voltage (less than 9.016 V) - Ignition hold relay circuit in the POM malfunction - Blown fuse DOT M 30 A - Loose or poor contact of the PCM 33P (Blue) connector Gearshift function does not work 1 3-24 32-1 Fail safe relay circuit malfunction - POM (DOT drive circuit) power input line malfunction - Blown fuse DOT M 30 A - Fail safe relay in the POM malfunction Gearshift function does not work 13-25 Ignition hold relay malfunction - POM (DOT drive circuit) sub power input line malfunction - Blown sub fuse DCT MAIN 7.5 A - Ignition hold relay in the POM malfunction Gearshift function does not work 13-25 N-D sWitch malfunction - Loose or poor contact of the N-D sWitch connector - N-D sWitch or its circuit malfunction - Faulty POM N-D sWitch does not work 13-26 13-10 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC Function Failure Symptom/Fail-safe function R3292? Shift sWItch malfunction - Shift switch does not work 424 ~ Loose or poor contact of the shift switch connector 13_27 ~ Shift sWitch or Its circuit malfunction ~ Faulty PCM EOT sensor iow voitage (iess than 0.088 V) - Gearshift function works normally 44-1 ~ EOT sensor or its circuit malfunction 13-29 ~ Faulty PCM EOT sensor high voltage (more than 4.903 V) - Gearshift function works normally 44_2 ~ Loose or poor contact of the EOT sensor connector 13_30 ~ EOT sensor or its circuit malfunction ~ Faulty PCM No.1 ciutch EOP sensor iow voitage (iess than 0.298 V) - Gearshift function does not work 47-1 ~ No.1 clutch EOP sensor or its circuit malfunction 13-31 ~ Faulty PCM No.1 ciutch EOP sensor high voltage (more than 4.702 V) - Gearshift function does not work ~ Loose or poor contact of the No.1 ciutch EOP sensor 47-2 connector 13-32 ~ No.1 clutch EOP sensor or its circuit malfunction ~ Faulty PCM No.2 ciutch EOP sensor iow voitage (iess than 0.298 V) - Gearshift function does not work 48-1 ~ No.2 clutch EOP sensor or its circuit malfunction 13-31 ~ Faulty PCM No.2 ciutch EOP sensor high voltage (more than 4.702 V) - Gearshift function does not work ~ Loose or poor contact of the No.2 ciutch EOP sensor 48-2 connector 13-32 ~ No.2 clutch EOP sensor or its circuit malfunction ~ Faulty PCM Clutch iirie low oil pressure (when clutch is engaged) - Gearshift function does not work ~ Engine oil level low 494 ~ Faulty oil pump ~ Faulty ciutch oil circuit ~ Ciutch line EOP sensor malfunction ~ Faulty PCM 13 33 Clutch line low oil pressure (when engine is running) - Gearshift function does not work _ ~ Engine oil level low ~ Faulty oil pump 49—2 ~ Faulty ciutch oil circuit ~ Ciutch line EOP sensor malfunction ~ Faulty PCM TR sensor low voltage (less than 0.117 V) - Gearshift function does not work 514 ~ Loose or poor contact of the TR sensor connector 13_34 ~ TR sensor or its circuit mailunction ~ Faulty PCM TR sensor high voltage (more than 4.976 V) - Gearshift function does not work 51-2 ~ TR sensor or its circuit mailunction 13-36 ~ Faulty PCM Neutrai switch stuck OFF - Gearshift function works normally 524 ~ Loose or poor contact of the neutrai sWitch connector - Shift indicator biinking 13_36 ~ Neutral switch or its circuit malfunction ~ Faulty PCM Neutrai switch stuck ON - Gearshift function does not work 52-2 ~ Neutral switch or its circuit malfunction 13-37 ~ Faulty PCM Inner mainshaft speed low - Gearshift function does not work ~ Loose or poor contact of the inner mainshaft sensor connector 53—1 ~ Inner mainshaft sensor or its circuit maifunction 13—37 ~ Eiectromagneticinterference ~ Faulty PCM Outer mainshaft speed low - Gearshift function does not work ~ Loose or poor contact of the outer mainshaft sensor 544 connector 1340 Outer mainshaft sensor or its circuit malfunction Eiectromagnetic interference Faulty PCM 13-11 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC Function Failure Symptom/Fail-safe function Refer to page No.1 linear solenoid valve current lailure O Loose or poor contact of the No.1 linear soienoid vaive connector O No.1 iinear solenoid valve or its circuit malfunction O No.1 iinear solenoid valve drive circuit in the PCM malfunction O Faulty POM Gearshift function does not work No.1 linear solenoid vaive driver in the PCM faiiure O Loose or poor contact of the No.1 linear soienoid vaive connector O Loose or poor contact of the POM 33F connector O No.1 iinear solenoid valve or its circuit malfunction O No.1 iinear solenoid valve drive circuit in the PCM malfunction O Faulty POM Gearshift function does not work 13-42 56-1 No.2 linear solenoid valve current lailure O Loose or poor contact of the No.1 linear soienoid vaive connector O No.2 iinear solenoid valve or its circuit malfunction O No.2 iinear solenoid valve drive circuit in the PCM malfunction O Faulty POM Gearshift function does not work 56-2 No.2 linear solenoid vaive driver in the PCM faiiure O Loose or poor contact of the No.2 linear soienoid vaive connector O Loose or poor contact of the POM 33F connector O No.2 iinear solenoid valve or its circuit malfunction O No.2 iinear solenoid valve drive circuit in the PCM malfunction O Faulty POM Gearshift function does not work 13-43 Gearshift mechanism malfunction O Gearshift mechanism malfunction - TR sensor or its circuit malfunction O Faulty POM Gearshift function does not work 1 3-44 Gear position malfunction (jumps out of gear) - Gearshift mechanism malfunction - TR sensor or its circuit malfunction - Faulty POM Gearshift function does not work 1 3-44 58-1 No.1 clutch does not disengage (when shifting gear) - No.1 clutch sticking - Faulty ciutcn oil circuit Gearshift function does not work Engine does not operate 59-1 No.2 clutch does not disengage (when shifting gear) - No.2 clutch sticking - Faulty ciutcn oil circuit Gearshift function does not work Engine does not operate 1 3-44 No.1 clutch oii pressure malfunction (at clutcn initiai diagnosis) - No.1 clutch EOP sensor malfunction - Faulty ciutcn oil circuit - Faulty POM Gearshift function does not work 61-2 No.1 clutcn no oil pressure - No.1 clutch EOP sensor malfunction - Faulty ciutcn oil circuit - No.1 iinear solenoid valve or its circuit malfunction - Faulty POM Gearshift function does not work 61-3 No.1 clutcn oii pressure degradation - No.1 clutch EOP sensor malfunction - Faulty ciutcn oil circuit - No.1 iinear solenoid valve malfunction - Faulty POM Gearshift function does not work No.1 clutcn oii pressure canceling maifunction - No.1 clutch EOP sensor malfunction - Faulty ciutcn oil circuit - Loose or poor contact of the No.1 linear soienoid vaive and clutch EOP sensor connectors - No.1 iinear solenoid valve malfunction - Faulty POM Gearshift function does not work Engine does not operate 13-45 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC Function Failure Symptom/Fail-safe function R3292? No.1 ciutch oil pressure high - Gearshift function does not work ~ No.1 clutch EOP sensor malfunction 62-1 ~ Faulty ciutch oil circuit ~ No.1 linear soienoid vaive maifunction ~ Faulty PCM No.1 ciutch oil pressure high (Prevention of motorcycie - Gearshift function does not work 13-45 creeps) 62_2 ~ No.1 clutch EOP sensor malfunction ~ Faulty ciutch oil circuit ~ No.1 linear soienoid vaive maifunction ~ Faulty PCM No.2 clutch oil pressure malfunction (at ciutch initial - Gearshift function does not work diagnosis) 63-1 ~ No.2 clutch EOP sensor malfunction ~ Faulty ciutch oil circuit ~ Faulty POM No.2 ciutch no oil pressure - Gearshift function does not work ~ No.2 clutch EOP sensor malfunction 63-2 ~ Faulty ciutch oil circuit ~ No.2 linear soienoid valve or its circuit maifunction ~ Faulty PCM No.2 ciutch oil pressure degradation - Gearshift function does not work 1345 ~ No.2 clutch EOP sensor malfunction 63-3 ~ Faulty ciutch oil circuit ~ No.2 linear soienoid vaive maifunction ~ Faulty PCM No.2 ciutch oil pressure canceling maifunction - Gearshift function does not work ~ No.2 clutch EOP sensor malfunction - Engine does not operate ~ Faulty ciutch oil circuit 63-4 ~ Loose or poor contact of the No.2 linear solenoid valve and clutch EOP sensor connectors ~ No.2 linear soienoid valve or its circuit maifunction ~ Faulty PCM No.2 ciutch oil pressure high - Gearshift function does not work ~ No.2 clutch EOP sensor malfunction 64-1 ~ Faulty ciutch oil circuit ~ No.2 linear soienoid vaive maifunction ~ Faulty PCM No.2 ciutch oil pressure high (Prevention of motorcycie - Gearshift function does not work 13-45 creeps) 64_2 ~ No.2 clutch EOP sensor malfunction ~ Faulty ciutch oil circuit ~ No.2 linear soienoid vaive maifunction ~ Faulty PCM Front and rear wheel speed signal maifunction - Gearshift function does not work ~ Front wheel speed sensor or its circuit maifunction 65-1 ~ VS sensor or its circuit maifunction 13-46 ~ Faulty ABS modulator ~ Faulty PCM Rear wheel speed sensor no signai - Gearshift function does not work ~ Rear wheei speed sensor or its circuit maifunction ~ Loose or poor contact of the rear wheei speed sensor 664 connector ‘ 4_33 ~ Eiectromagnetic interference at rear wheei speed sensor ~ Faulty ABS modulator ~ Faulty rear puiser ring ~ Faulty PCM Front wheel speed sensor no signal - Gearshift function does not work ~ Front wheel speed sensor or its circuit maifunction ~ Loose or poor contact of the front wheel speed sensor connector 67-1 ~ Eiectromagnetic interference at front wheei speed 4-35 sensor Faulty ABS modulator Faulty front puiser ring Faulty PCM 13-13 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC Function Failure Symptom/Fail-safe function Refer to page 68-1 No.1 clutch operation maifunction (clutch slips) O VS sensor malfunction O Faulty No.1 clutch O Faulty PCM Gearshift function does not work 13-47 69-1 No.2 clutch operation maifunction (clutch slips) O VS sensor malfunction O Faulty No.2 clutch O Faulty PCM Gearshift function does not work 13-47 Inner mainshaft/countershaft speed ratio failure O VS sensor or its circuit malfunction O Inner mainshaft sensor or its circuit malfunction O Faulty PCM Gearshift function does not work 72-1 Outer mainshaft/countersnalt speed ratio failure O VS sensor or its circuit malfunction O Outer mainshaft sensor or its circuit maifunction O Faulty PCM Gearshift function does not work 13-48 84-1 CPU in the PCM malfunction O Faulty PCM Gearshift system stops 13-48 13-14 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) DTC TROUBLESHOOTING NOTE O If the PCM is replaced. perform the following: — Key Registration Procedure (page 23-6) — Clutch Initialize Learning Procedure (page 13-82) DTC 9-1 (CLUTCH LINE EOP SENSOR LOW VOLTAGE) 1. Clutch Line EOP Sensor System Inspection Connect the M08 and start the engine. Check the clutch line EOP sensor with the MOS. Is about 0 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Clutch Line EOP Sensor Inspection Stop the engine. Disconnect the clutch line EOP sensor 3P (Gray) connector (page 13-80). Turn the ignition switch ON. Check the clutch line EOP sensor with the MOS. Is about 0 vindicated? YES — GO TO STEP 3. NO — Faulty clutch line EOP sensor 3. Clutch Line EOP Sensor Input Voltage Inspection Measure the voltage at the wire harness side 3P (Gray) connector [1]. Connection: Yellow/red (1-) — Gray/black (—) Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 5. NO — GO TO STEP 4. 4. Clutch Line EOP Sensor Input Line Open Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33P (Black) connector (page 4-39). check for continuity between the Wire harness side 3P (Gray) connector [1] and 33P (Black) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Yellow/red — 327 Is there continuity? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Open circuit in the Yellow/red wire Gr/Bl 13-15 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 5. Clutch Line EOP Sensor Output Line Short Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side 3P (Gray) connector [1] and ground. Connection: Red/green — Ground Is there continuity? YES — Short circuit in the Red/green wire N0 — Replace the PCM With a known good one (page 4-39) and recheck. DTC 9-2 (CLUTCH LINE EOP SENSOR HIGH VOLTAGE) NOTE O Before starting the inspection, check for loose or poor contact on the clutch line EOP sensor 3P (Gray), POM 33P (Black) and 33F (Gray) connectors, and recheck the DTC. 1. Clutch Line EOP Sensor System Inspection Check the clutch line EOP sensor with the MOS. Is about 5 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Clutch Line EOP Sensor Inspection Turn the ignition sWItch OFF. Disconnect the clutch line EOP sensor 3P (Gray) connector (page 13-80). Connect the Wire harness side 3P (Gray) connector [1] terminals With a jumper wire [2]. Connection: Red/green — Gray/black Turn the ignition switch ON. Check the clutch line EOP sensor with the MOS. Is 0 vindicated? YES — Faulty clutch line EOP sensor NO — GO TO STEP 3. 3. Clutch Line EOP Sensor Ground Line Open Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33P (Black) connector (page 4-39). Check Ior continuity between the wire harness side 3P (Gray) connector [1] and 33P (Black) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Gray/black — 313 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the Gray/black Wire GrlBl " R/G [2] 13-16 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 4. Clutch Line EOP Sensor Output Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39). Check Ior continuity between the Wire harness side 3P (Gray) connector [1] and 33P (Blue) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Red/green — A27 Is there continuity? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Open circuit in the Red/green Wire DTC19-1 (CKP SENSOR NO SIGNAL) 1. CKP sensor Peak Voltage Inspection Disconnect the alternator assembly 6P (Black) connector (page 5-7). [1] Temporarily connect the battery cables. Turn the ignition sWitch ON with the engine stop EB m switch ii Crank the engine with the starter motor and V L l measure the CKP sensor peak voltage at the CKP 9 sensor side 6P (Black) connector [1]. WW TOOLS: Peak voltage adaptor [2] 07HGJ-0020100 v —‘ with commercially available digital multimeter (impedance 10 MQIDCV minimum) Connection: Yellow (4-) — White/yellow (—) [2] Is the voltage more than 0,7 V7 YES — GO TO STEP 2. NO — Faulty CKP sensor 2. CKP sensor Line Open Circuit Inspection Turn the ignition sWitch OFF. 2 Disconnect the PCM 33F (Gray) connector (page 4- I I 39). Check Ior continuity between the Wire harness side @ 6P (Black) connector [1] and 33F (Gray) connector [2]- TOOL: F Test probe D7ZAJ-RDJA110 3’. o Connection: Yellow — C8 W/Y C16 White/yellow — C16 @ U Is there continuity? YES — GO TO STEP 3. [1] NO — ~ Open circuit in the Yellow Wire ~ Open circuit in the White/yellow Wire 13-17 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. CKP sensor Line Short Circuit Inspection Check for continuity between the wire harness side 6P (Biack) connector [1] and ground Connection: Yellow — Ground Is there continuity? YES — Short circuit in the Yeilow wire N0 — Replace the PCM With a known good one (page 4-39) and recheck. DTC 21-1 (SHIFT SPINDLE ANGLE SENSOR LOW VOLTAGE) NOTE O Before starting the inspection, check for ioose or poor contact on the shift spindle angie sensor 3P (Biue), PCM 33P (Black) and 33P (Gray) connectors, and recheck the DTC. 1. Shift Spindle Angle Sensor System Inspection Check the shift spindie angle sensor with the MOS. Is about 0 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Shift Spindle Angle Sensor Input Voltage Inspection Turn the ignition sWItch OFF. Disconnect the shift spindle angle sensor 3P (Blue) connector (page 13-79). Turn the ignition switch ON. Measure the voltage at the wire harness side 3P (Biue) connector [1]. Connection: Yellow/red (1-) — Gray/black (—I Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 3. NO — GO TO STEP 4. 3. Shift Spindle Angle Sensor Input Line Open Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33P (Biack) connector (page 4-39). Check for continuity between the wire harness side 3P (Biue) connector [1] and 33P (Black) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Yellow/red — 527 Is there continuity? YES — GO TO STEP 5. NO — Open circuit in the Yellow/red wire [2] 13-18 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Shift Spindle Angle Sensor Ground Line Open Circuit Inspection Check Ior continuity between the ere harness side 3P (Blue) connector [1] and 33F (Black) connector m [2] [2]- TOOL: Test probe D7ZAJ-RDJA110 E Connection: Gray/black— B13 I Is there continuity? l 0 A t A w . . . YES — Replace the PCM with a known good one GrlBl B13 (page 4-39) and recheck. Q NO — Open circuit ln the Green/white ere U 5. Shift Spindle Angle Sensor Signal Line Open Circuit Inspection Turn the ignition sWItch OFF. 1 2 Disconnect the PCM 33P (Blue) connector (page 4- l ] l 1 39). Check Ior continuity between the ere harness side 3P (Blue) connector [1] and 33P (Blue) connector [2]- TOOL: Test robe D7ZAJ-RDJA110 ’ n W \ J I r I A28 Connection: White — A25 A Is there continuity? ® YES — GO TO STEP 6. NO — Open circuit in the White wire 6. Shift Spindle Angle Sensor Output Line Short Circuit Inspection Check Ior continuity between the ere harness side 1 SP (Blue) connector [1] and ground. I 1 Connection: White — Ground Is there continuity? YES — Short circuit ln the White wire 1 J W NO — GO TO STEP 7. 7. Shift Spindle Angle Sensor Inspection Replace the shift spindle angle sensor with a known good one (page 13-79). Connect the 3P (Blue) connector, 33F (Black) connector and 33F (Blue) connector. Check the shlltsplndle angle sensor with the MOS. Is about 0 vindicated? YES — Replace the PCM Wlth a known good one (page 4-39) and recheck. NO — Faulty orlglnal shlltsplndle angle sensor 13-19 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 21-2 (SHIFT SPINDLE ANGLE SENSOR HIGH VOLTAGE) 1. Shift Spindle Angle Sensor System Inspection Check the shift splndle angle sensor with the MOS. Is about 5 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Shift Spindle Angle Sensor Inspection Replace the shift spindle angle sensor with a known good one (page 13-79). Check the shift splndle angle sensor with the MOS. Is about 5 vindicated? YES — Replace the PCM with a Known good one (page 4-39) and recheck. NO — Faulty orlglnal shift spindle angle sensor DTC 22-1 (SHIFT SPINDLE OPERATION MALFUNCTION: AFTER OPERATING GEARSHIFT MECHANISM) 1. Shift Spindle Angle Sensor System Inspection Check the shift splndle angle sensor with the MOS. Is Low voltage (about 0 I0 or High voltage (about 5 V) indicated? YES — - About 0 V: See DTC 21-1 (page 13-18). - About 5 V: See DTC 21-2 (page 13-20). NO — GO TO STEP 2. 2. Shift Control Motor/Reduction Gear Condition Check the shlft control motor and reductlon gears are Installed properly and are not damaged (page 13-71). Are the shift control motor and reduction gears in normal condition? YES — GO TO STEP 3. NO — Install the shift control motor and reduction gears properly or replace faulty parts. 3. Shift Control Motor Inspection Remove the shift control motor (page 13-71). Connect a fully charged 12 V battery [1] to the shlft control motor [2] 2P connector to check the motor operation. Change the battery connectlon to check the reverse operation. Does the shift control motor turn in both directions? YES — GO TO STEP 4. NO — Faulty shift control motor [2] 13-20 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Shift Spindle Angle Sensor System Inspection Remove the shilt spindle angle sensor WltI’l the connector connected (page 13-79). Turn the ignition switch ON. While turnlng the shift spindle angle sensor shaft, check the shlft spindle angle sensor voltage with the MOS. When turning the shaft clockwise: Voltage increase When turning the shaft counterclockwise: Voltage decrease Does the voltage vary properly? YES — GO TO STEP 5. NO — Faulty shlft spindle angle sensor 5. Shift Spindle Angle Sensor Condition Inspection Check that the shift spindle angle sensor is installed properly and is not damaged. Is the shift spindle angle sensor in normal condition? YES — GO TO STEP 6. NO —lnstall the shift spindle angle sensor properly or replace it (page 13-79). 6. DTC Recheck Recheck the DTC with the MOS. Is DTC 22-1 indicated? YES — Replace the PCM WltI’l a known good one (page 4-39) and recheck. NO — lntermlttent failure DTC 23-1 (SHIFT SPINDLE OPERATION MALFUNCTION: WHILE OPERATING GEARSHIFT MECHANISM) Reler to DTC 22-1 (page 13-20). 13-21 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 24-1 (SHIFT CONTROL MOTOR DRIVE CIRCUIT) 1. Shift Control Motor Line Open Circuit Inspection Disconnect the foilowing: — PCM 33P (Blue) connector (page 4-39) — Shift control motor 2P (Biack) connector (page 13-71) Check lor continuity between the wire harness side 2P (Black) connector [1] and PCM 33F (Blue) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Pink/blue — A12 Pink/blue — A13 Yellow/blue — A23 Yellow/blue — A24 Is there continuity? YES — GO TO STEP 2. NO — - Open circuitinthe Pink/blue Wire - Open circuit in the Yellow/blue wire 2. Shift Control Motor Line Short Circuit Inspection Check for continuity at the Wire harness side shift control motor 2P (Biack) connector [1] terminals and ground. Connection: Pink/blue — Ground Yellow/blue — Ground Is there continuity? YES — - Short circuit in the Pink/blue Wire - Short circuit in the Yellow/blue Wire NO — GO TO STEP 3. 3. Shift Control Motor Inspection Remove the shift oontroi motor (page 13-71). Connect a fully charged 12 V battery [1] to the shift control motor [2] 2P connector to check the motor operation. Change the battery connection to check the reverse operation. Does the shift control motor turn in both directions? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Faulty shift oontroi motor [2] 13-22 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) DTC 27-1 (SHIFT DRUM POSITION MALFUNCTION) 1. TR Sensor System Inspection Check the TR sensor with the MOS. Is Low Voltage (about 0 l0 or High voltage (about 5 V) indicated? YES — ~ About 0 V: See DTC 51-1 (page 13-34). ~ About 5 V: See DTC 51-2 (page 13-36). NO — GO TO STEP 2. 2. Shift Control Motor/Reduction gear condition Check the shift control motor and reduction gears are instaiied properly and are not damaged (page 13-71). Are the shift control motor and reduction gears in normal condition? YES — GO TO STEP 3. NO — Instali the shilt control motor and reduction gears properly or repiace faulty parts. 3. Shift Control Motor Inspection Remove the shift controi motor (page 13-71). Connect a fully charged 12 V battery [1] to the shift control motor [2] 2P connector to check the motor operation. Change the battery connection to check the reverse operation. Does the shift control motor turn in both directions? YES — GO TO STEP 4. NO — Faulty shift control motor [2] 4. TR Sensor System Inspection Remove the TR sensor With the connector connected (page 13-79). Turn the ignition switch ON. While turning the TR sensor shaft, check the TR sensor voltage with the MOS. When turning the shaft clockwise: Voltage increase When turning the shaft counterclockwise: Voltage decrease Does the voltage vary properly? YES — GO TO STEP 5. NO — Faulty TR sensor 5. TR Sensor Condition Inspection Check that the TR sensor is instalied properiy and is not damaged. Is the TR sensor in normal condition? YES — GO TO STEP 6. NO — Install the TR sensor properiy or replace it (page 13-79). 13-23 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 6. DTC Recheck Recheck the DTC with the MOS. Is DTC 27-1 indicated? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Intermittent failure DTC 31-1 (SHIFT CONTROL MOTOR LOW VOLTAGE) NOTE O Before starting the inspection, check for loose or poor contact on the shiit control motor 2P (Black) and PCM 33F (Blue) connectors, and recheck the DTC. 1. DTC Recheck Erase the DTCs (page 13-9). Check the DTC with the MOS. Is DTC 32-1 or 37-1 indicated? YES — - DTC 32-1 indicated (page 13-25). - DTC 37-1 indicated (page 13-25). NO — GO TO STEP 2. 2. Shift Control Motor Line Open Circuit Inspection Disconnect the following: — PCM 33P (Blue) connector (page 4-39) — Shift control motor 2P (Black) connector (page 13-71) Check (or continuity between the wire harness side 2P (Black) connector [1] and PCM 33F (Blue) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Pink/blue — A12 Pink/blue — A13 Yellow/blue — A23 Yellow/blue — A24 Is there continuity? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — - Open circuitinthe Pink/blue Wire - Open circuit in the Yellow/blue wire 13-24 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 32-1 (FAIL SAFE RELAY CIRCUIT MALFUNCTION) NOTE O Before starting the inspectlon, check for loose or poor contact on the PCM 33F (Blue) connector, and recheck the DTC. 1. Shift Control Motor Power Supply Voltage Inspection Check the shlft control motor power supply voltage with the MCS. Is there battery voltage? YES — GO TO STEP 2. NO — ~ Open circult in the Red/white Wire between the PCM 33F (Blue) connector and fuse DCT M 30 A ~ Blown fuse DCT M 30 A 2. DTC Recheck Recheck the DTC with the MOS. Is DTC 32-1 indicated? YES — Replace the PCM Wlth a known good one (page 4-39) and recheck. NO — lntermlttent failure DTC 37-1 (IGNITION HOLD RELAY MALFUNCTION) NOTE O Before starting the inspectlon, check for loose or poor contact on the PCM 33F (Blue) connector, and recheck the DTC. 1. PCM (DCT Drive Circuit) Sub Power Voltage Inspection Check the PCM sub power voltage with the MOS. Is the battery Voltage indicated? YES — GO TO STEP 2. NO — ~ Open clrcuit in the Brown/black Wire between the PCM 33F (Blue) connector and fuse box ~ Blown sub fuse DCT MAIN 7.5 A 2. DTC Recheck Recheck the DTC with the MOS. Is DTC 37-1 indicated? YES — Replace the PCM Wlth a known good one (page 4-39) and recheck. NO — lntermlttent failure 13-25 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 41 -1 (N-D SWITCH MALFUNCTION) 1. N-D Switch Power Input Voltage Inspection Disconnect the right handlebar switch 6P (Black) connector (page 22-24). Turn the ignition sWItcn ON with the engine stop switcn' .. Measure the voltage between the Wire harness side 6P (Black) connector [1] and ground. Connection: Yellow/red (1-) — Ground (—) Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 3. NO — GO TO STEP 2. . N-D Switch Power Input Line Open Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33P (Black) connector (page 4-39). Check Ior continuity between the wire harness side 6P (Black) connector [1] and 33F (Black) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Yellow/red — 327 Is there continuity? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Open circuit in the Yellow/red wire . N-D Switch Inspection Turn the ignition sWItch OFF. Check Ior continuity at the switch side 6P (Black) connector [1] in each switch position. Connection: N switch: Light green/yellow — Yellow/red D switch: Blue — Yellow/red Is there continuity with the switch pushed and no continuity with the switch released? YES — GO TO STEP 4. NO — Faulty N-D switch (<3 [1] [2] 13-26 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 4. N-D Switch Output Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39). Check Ior continuity between the Wire harness side 6P (Black) connector [1] and 33F (Blue) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Light green/yellow — A19 Blue — A20 Is there continuity? YES — GO TO STEP 5. NO — ~ Open circuit in the Light green/yellow Wire ~ Open circuit in the Blue Wire 5. N-D Switch Output Line Short Circuit Inspection Check Ior continuity between the wire harness side 6P (Black) connector [1] and ground. Connection: Light green/yellow — Ground Blue — Ground Is there continuity? YES — ~ Short circuit in the Light green/yellow Wire ~ Short circuit in the Blue Wire N0 — Replace the PCM with a known good one (page 4-39) and recheck. DTC 42-1 (SHIFT SWITCH MALFUNCTION) 1. Shift Switch Power Input Voltage Inspection Disconnect the LeIt handlebar switch 12F (Black) connector (page 22-23). Turn the ignition swncn ON with the engine stop switch Measure the voltage between the Wire harness side 12F (Black) connector [1] and ground. Connection: Yellow/red (1-) — Ground (—) Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 3. NO — GO TO STEP 2. HR we 13-27 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. Shift Switch Power Input Line Open Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33F (Black) connector (page 4-39). Check Ior continuity between the wire harness side 12F (Black) connector [1] and 33F (Black) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Yellow/red — 327 Is there continuity? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Open circuit in the Yellow/red wire . Shift Switch Inspection Turn the ignition sWItch OFF. Check for continuity at the sWItch side 12F (Black) connector [1] in each switch position. Connection: "1-" switch: Green/blue — Yellow "—" switch: Light green/red — Yellow Is there continuity with the switch pushed and no continuity with the switch released? YES — GO TO STEP 4. NO — Faulty shift switch . Shift Switch Input Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39) Check Ior continuity between the wire harness side 12F (Black) connector [1] and 33F (Blue) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Green/blue — A31 Light green/red — A30 Is there continuity? YES — GO TO STEP 5. NO — - Open circuitinthe Green/blue wire - Open circuit in the Light green/red wire [1] G/Bu Lg/R I [2] 13-28 5. DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) Shift Switch Input Line Short Circuit Inspection Check Ior continuity between the Wire harness side 12F (Black) connector [1] and ground. Connection: Green/blue — Ground Light green/red — Ground Is there continuity? YES — ~ Short circuit in the Green/blue Wire ~ Short circuit in the Light green/red Wire N0 — Replace the PCM with a known good one (page 4-39) and recheck. DTC 44-1 (EOT SENSOR LOW VOLTAGE) 1. EOT Sensor System Inspection Check the EOT sensor with the MCS. Is about 0 vindicated? YES — GO TO STEP 2. NO — Intermittent Iailure . EOT Sensor Inspection Turn the ignition sWItch OFF. Disconnect the EOT sensor 2P (Black) connector (page 13-81). Turn the ignition switch ON. Check the EOT sensor with the MCS. Is about 0 vindicated? YES — GO TO STEP 3. NO — Faulty EOT sensor . EOT Sensor Input Line Short Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check the continuity between the wire harness side 2P (Black) connector [1] and ground. Connection: Blue/green — Ground Is there continuity? YES — Short circuit in the Blue/green wire N0 — Replace the PCM with a known good one (page 4-39) and recheck. G/Bu 1 [i] I—I’ D Lg/R @ 13-29 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 44-2 (EOT SENSOR HIGH V0 LTAG E) NOTE O Before starting the inspection, check for loose or poor contact on the EOT sensor 2P (Black) and PCM 33F (Blue) connectors, and recheck the DTC. 1. EOT Sensor System Inspection Check the EOT sensor with the MCS. Is about 5 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. EOT Sensor Inspection Turn the ignition sWitch OFF. Disconnect the EOT sensor 2P (Black) connector (page 13-81). Short the Wire harness side 2P (Black) connector [1] terminals With a jumper Wire [2]. Connection: Blue/green — Gray/black Turn the ignition switch ON. Check the EOT sensor with the MCS. Is about 0 vindicated? YES — Faulty EOT sensor NO — GO TO STEP 3. 3. EOT Sensor Input Line Open Circuit Inspection Turn the ignition sWitch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check Ior continuity between the wire harness side EOT sensor 2P (Black) connector [1] and PCM 33F (Blue) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Blue/green — A29 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the Blue/green Wire 4. EOT Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33P (Black) connector (page 4-39). Check Ior continuity between the wire harness side 2P (Black) connector [1] and 33F (Black) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Gray/black— 313 Is there continuity? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Open circuit in the Gray/black Wire [2] [1] B13 [2] 13-30 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 47-1 or 48-1 (No.1 or No.2 CLUTCH EOP SENSOR LOW VOLTAGE) 1. Clutch EOP Sensor System Inspection Connect the M08 and start the engine. Check the clutch EOP sensor With the MCS. Is about 0 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Clutch EOP Sensor Inspection Stop the engine. Disconnect the clutch EOP sensor 3P (No. No.2: Black) connector (page 13-80). Turn the ignition switch ON. Check the clutch EOP sensor With the MCS. Is about 0 vindicated? YES — GO TO STEP 3. NO — Faulty clutch EOP sensor 3. Clutch EOP Sensor Input Voltage Inspection Gray. Measure the voltage between the wire harness side 3P connector [1]. Connection: Yellow/red (1-) — Gray/black (—) Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 5. NO — GO TO STEP 4. 4. Clutch EOP Sensor Input Line Open Circuit Inspection Turn the ignition sWitch OFF. 1 2 Disconnect the PCM 33F (Black) connector (page [ l [ 1 4-39). Check Ior continuity between the Wire harness side 3P connector [1] and 33F (Black) connector [2]. TOOL: 7 Test probe D7ZAJ-RDJA110 n '— n ‘ I H H l 1 Connection: Yellow/red — 327 Y/R B27 Is there continuity? [Q YES — Replace the PCM with a known good one U (page 4-39) and recheck. NO — Open circuit in the Yellow/red Wire 13-31 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 5. Clutch EOP Sensor Output Line Short Circuit Inspection Turn the ignition sWitch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check for continuity between the wire harness side sensor 3P connector [1] and ground. Connection: No.1 clutch EOP sensor: Yellow/green — Ground No.2 clutch EOP sensor: Black/green — Ground Is there continuity? YES — - Short circuit in the Yellow/green wire - Short circuit in the Black/green wire N0 — Replace the PCM With a known good one (page 4-39) and recheck. DTC 47-2 or 48-2 (No.1 or No.2 CLUTCH EOP SENSOR HIGH VOLTAGE) NOTE O Before starting the inspection, check for loose or poor contact on the clutch EOP sensor 3P (No.1: Gray, No.2: Black), and PCM 33P (Blue) and 33F (Black) connectors, and recheck the DTC. 1. Clutch EOP Sensor System Inspection Check the clutch EOP sensor With the MOS. Is about 5 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Clutch EOP Sensor Inspection Turn the ignition sWitch OFF. Disconnect the clutch EOP sensor 3P connector (page 13-80). Short the wire harness side 3P connector [1] terminals With a Jumper Wire [2]. Connection: No.1 clutch EOP sensor: Yellow/green — Gray/black No.2 clutch EOP sensor: Black/green — Gray/black Turn the ignition switch ON. Check the clutch EOP sensor With the MOS. Is about 0 vindicated? YES — Faulty clutch EOP sensor NO — GO TO STEP 3. [1] WE or BIIG [1] Gr/Bl YIG or Bl/G [2] 13-32 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 3. Clutch EOP Sensor Ground Line Open Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33F (Black) connector (page 4-39). Check Ior continuity between the Wire harness side clutch EOP sensor 3P (Gray) connector [1] and PCM 33F (Black) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Gray/black — B13 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the Gray/black Wire 4. Clutch EOP Sensor Output Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- m [2] Check Ior continuity between the Wire harness side 3P connector [1] and 33F (Blue) connector [2]. @ TOOL: A33, Test probe D7ZAJ-RDJA11O V/G LA ‘ “ . , . . Connection: ‘. , . , ( No.1 clutch EOP sensor: BUG _" Yellow/green — A33 A32 fl No.2 clutch EOP sensor: ® Black/green — A32 Is there continuity? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — ~ Open circuit in the Yellow/green wire ~ Open circuit in the Black/green wire DTC 49-1, 49-2 (CLUTCH LINE LOW OIL PRESSURE) 1. Clutch Line EOP Sensor System Inspection Check the clutch line EOP sensor with the MOS. Is Low Voltage (about 0 I0 or High voltage (about 5 V) indicated? YES — ~ About 0 V (while engine running): See DTC 9-1 (page 13-15). ~ About 5 V: See DTC 9-2 (page 13-16). NO — GO TO STEP 2. 2. Engine Oil Level Inspection Check the engine oil level (page 3-11). Is the engine oil level correct? YES — GO TO STEP 3. NO — Add the recommended oil to the upper level. 13-33 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. Clutch Line Oil Filter Condition Inspection Check the clutch oil Iilter (page 3-13). Is the oil filter in good condition? YES — GO TO STEP 4. NO — Replace the clutch oil filter. 4. Clutch Line EOP Sensor Inspection Replace the clutch line EOP sensor with a known good one (page 13-80). Erase the DTC (page 13-9). Test-ride the motorcycle above 2.000 mm" (rpm) and stop the engine. Check the DTC with the MOS. Is DTC 49-1 or 49-2 indicated? YES — GO TO STEP 5. NO — Faulty original clutch line EOP sensor 5. PCM Inspection Replace the PCM With a known good one (page 4- 39). Test-ride the motorcycle above 2.000 mm" (rpm) and stop the engine. Check the DTC with the MOS. Is DTC 49-1 or 49-2 indicated? YES — - Oil pressure relief valve stuck open - Damaged oil pump - Internal oil leak in the clutch oil line NO — Faulty original PCM DTC 51-1 (TR SENSOR LOW VOLTAGE) NOTE O Before starting the inspection, check for loose or poor contact on the TR sensor 3P (Black). PCM 33F (Blue) and 33P (Black) connectors, and recheck the DTC. 1. TR Sensor System Inspection Check the TR sensor with the MOS. Is about 0 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. TR Sensor Input Voltage Inspection Turn the ignition sWItch OFF. Disconnect the TR sensor 3P (Black) connector (page 13-79). Turn the ignition switch ON. Measure the voltage at the Wire harness side 3P (Black) connector [1]. Connection: Yellow/red (1-) — Gray/black (—) Y/R Gr/BI Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 5. NO — GO TO STEP 3. 13-34 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. TR Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33F (Black) connector (page 4-39). Check ior continuity between the wlre harness side 3P (Black) connector [1] and 33F (Black) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Yellow/red — 527 Is there continuity? YES — GO TO STEP 4. NO — Open circuit ln the Yellow/red wire 4. TR Sensor Ground Line Open Circuit Inspection Check ior continuity between the wlre harness side 33F (Black) connector [1] and SP (Black) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Gray/black — B13 Is there continuity? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Open circuit ln the Gray/black wire 5. TR Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check ior continuity between the wlre harness side 3P (Black) connector [1] and 33F (Blue) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: White — A15 Is there continuity? YES — GO TO STEP 6. NO — Open circuit in the White wire 6. TR Sensor Output Line Short Circuit Inspection Check ior continuity between the wlre harness side 3P (Black) connector [1] and ground. Connection: White — Ground Is there continuity? YES — Short circuit ln the White wire NO — GO TO STEP 7. [i] [2] . YIR 327 [1] l2]\ @— W ‘ A U. A GrlBl m B13 ® [1] [2] l i 4‘ 4. . w A18 13-35 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 7. TR Sensor Inspection Replace the TR sensor with a known good one (page 13-79). Connect the 3P (Black) connector, 33F (Black) connector and 33F (Blue) connector. Check the TR sensor with the MOS. Is about 0 vindicated? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Faulty orlginal TR sensor DTC 51-2 (TR SENSOR HIGH VOLTAGE) 1. TR Sensor System Inspection Check the TR sensor with the MOS. Is about 5 vindicated? YES — GO TO STEP 2. NO — Intermittent failure 2. TR Sensor Inspection Replace the TR sensor with a known good one (page 13-79). Turn the ignition switch ON. Check the TR sensor with the MOS. Is about 5 vindicated? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Faulty orlginal TR sensor DTC 52-1 (NEUTRAL SWITCH STUCK OFF) NOTE O Before starting the inspectlon, check for loose or poor contact on the neutral switch termlnal and POM 33F (Black) connector, and recheck the DTC. 1. DTC Recheck Recheck the DTC with the MOS. Is DTC 52-1 indicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Neutral Switch Line Open Circuit Inspection Turn the ignition sWItch OFF. Disconnect the PCM 33P (Black) connector (page 4-39). Remove the neutral switch connector (page 13-82). Check Ior continuity between the wire harness side 33F (Black) connector [1] and neutral switch terminal [2]. Connection: B15 — Light green TOOL: Test probe D7ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 3. NO — Open circuit in the Light green wire [2] 13-36 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 3. Neutral Switch Inspection Replace the neutral switch With a known good one (page 13-82). Connect the PCM 33F (Black) connector. Turn the ignition switch ON. Recheck the DTC with the MOS. Is DTC 52-1 indicated? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Faulty original neutral switch DTC 52-2 (NEUTRAL SWITCH STUCK ON) 1. Neutral Switch Line Short Circuit Inspection Remove the neutral switch terminal (page 13-82). Check for continuity between the neutral switch terminal and ground. Connection: Light green — Ground Is there continuity? YES — Short circuit in the Light green Wire NO — GO TO STEP 2. 2. Neutral Switch Inspection Replace the neutral switch With a known good one (page 13-82). Install the neutral sWitch terminal (page 13-82). Check the DTC with the MOS. Is DTC 52-2 indicated? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Faulty original neutral switch DTC 53-1 (INNER MAINSHAFT SENSOR SPEED LOW) NOTE O Before starting the inspection, check for loose or poor contact on the inner mainshaIt sensor 3P (Black), PCM 33F (Blue) and 33F (Black) connectors, and recheck the DTC. 1. DTC Recheck Erase the DTC (page 13-9). Test-ride the motorcycle and stop the engine. Check the DTC with the MOS. Is DTC 53-1 indicated? YES — GO TO STEP 2. NO — Intermittent Iailure 13-37 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. Inner Mainshatt Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the inner mainshaft sensor 3P (Black) connector (page 13-78). Turn the ignition switch ON. Measure the voltage at the wire harness side 3P (Biack) connector [1]. Connection: Blacklbrown(+) — Gray/black (—) Is there about batter voltage? YES — GO TO STEP 5. NO — GO TO STEP 3. . Inner Mainshaft Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Blue) connector (page 4- 39). Check tor continuity between the wire harness side 3P (Blue) connector [1] and 33P (Biue) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: Black/brown — A15 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the Black/brown wire . Inner Mainshaft Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33F (Biack) connector (page 4-39). Check tor continuity between the wire harness side 3P (Black) connector [1] and 33F (Black) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Gray/black — B13 Is there continuity? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Open circuit in the Gray/black wire [i] [2] [2] 13-38 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 5. Inner Mainshaft Sensor Output Line Inspection Measure the voltage between the Wire harness side 1 SP (Black) connector [1] and ground. [ 1 Connection: Pink (+t — Ground (—) Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 8. f—"iZJAL P NO — GO TO STEP 6. 1 . 6E 6. Inner Mainshaft Sensor Output Line Open Circuit Inspection Turn the ignition sWItch OFF. 1 2 Disconnect the PCM 33P (Blue) connector (page 4- l 1 [ 1 39). Check Ior continuity between the Wire harness side 3P (Black) connector [1] and SP (Blue) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Pink — A1 Is there continuity? YES — GO TO STEP 7. NO — Open circuit in the Pink wire 7. Inner Mainshaft Sensor Output Line Short Circuit Inspection Check Ior continuity between the Wire harness side 1 SP (Black) connector [1] and ground. I 1 Connection: Pink — Ground Is there continuity? YES — Short circuit in the Pink wire N0 — Replace the PCM with a known good one (page 4-39) and recheck. 8. Inner Mainshaft Sensor Inspection Turn the ignition sWItch OFF. Replace the inner mainshaft sensor With a knoWn good one (page 13-78). Erase the DTC (page 13-9). Test-ride the motorcycle and stop the engine. Check the DTC with the MOS. Is DTC 53-1 indicated? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Faulty original inner mainshaft sensor 13-39 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. Outer Mainshaft Sensor Input Line Open Circuit DTC 54-1 (OUTER MAINSHAFT SENSOR SPEED LOW) NOTE O Before starting the inspection, check for loose or poor contact on the outer mainshaft sensor 3P (Black), PCM 33F (Blue) and 33F (Black) connectors, and recheck the DTC. 1. DTC Recheck Erase the DTC (page 13-9). Test-ride the motorcycle and stop the engine. Check the DTC with the MOS. Is DTC 54-1 indicated? YES — GO TO STEP 2. NO — Intermittent failure 2. Outer Mainshaft Sensor Input Voltage Inspection Turn the ignition swnch OFF. Disconnect the outer mainsnaIt sensor 3P (Black) [1] connector (page 13-78). Temporarily install the removed electrical parts in the reverse order of removal. Turn the ignition switch ON. Measure the voltage at the Wire harness side 3P (Black) connector [1]. Connection: White (1-) — Gray (—I Is there about batter voltage? YES — GO TO STEP 5. NO — GO TO STEP 3. Inspection Turn the ignition swnch OFF. 1 2 Disconnect the PCM 33P (Blue) connector (page 4- [ 1 [ 1 39). Check Ior continuity between the wire harness side 3P (Black) connector [1] and 33F (Blue) connector [2]. TOOL: Test probe D7ZAJ-RDJA110 Connection: White — A26 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in the White Wire 13-40 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 4. Outer Mainshaft Sensor Ground Line Open Circuit Inspection Disconnect the PCM 33F (Black) connector (page 4.39). m [21 Check tor continuity between the Wire harness side 3P (Black) connector [1] and 33F (Black) connector [2] TOOL: Test probe D7ZAJ-RDJA110 r“ R . Connection: Gray — B13 Is there continuity? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Open circuit in the Gray Wire 5. Outer Mainshaft Sensor Output Line Inspection Measure the voltage between the wire harness side 3P (Black) connector [1] and ground. Connection: Pink (+t — Ground (—) Is the voltage within 4. 75 — 5.25 V? YES — GO TO STEP 8. NO — GO TO STEP 6. 6. Outer Mainshaft Sensor Output Line Open Circuit Inspection Turn the ignition sWItch OFF. 1 2 Disconnect the PCM 33P (Blue) connector (page 4- [ 1 [ 1 39). Check tor continuity between the Wire harness side 3P (Black) connector [1] and 33F (Blue) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Pink — A25 Is there continuity? YES — GO TO STEP 7. NO — Open circuit in the Pink wire 13-41 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 7. Outer Mainshaft Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side 3P (Black) connector [1] and ground Connection: Pink — Ground Is there continuity? YES — Short circuit in the Pink Wire N0 — Replace the PCM With a known good one (page 4-39) and recheck. 8. Outer Mainshaft Sensor Condition Inspection Turn the ignition sWItch OFF. Replace the outer mainshaft sensor with a known good one (page 13-78). Erase the DTC (page 13-9). Test-ride the motorcycle and stop the engine. Check the DTC with the MOS. Is DTC 54-1 indicated? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Faulty original outer mainshaft sensor DTC 55-1, 55-2 (No.1 LINEAR SOLENOID VALVE) NOTE O Before starting the inspection, check for loose or poor contact on the linear solenoid valve 4P (Black) and PCM 33P (Blue) connectors, and recheck the DTC. 1. DTC Recheck Recheck the DTC with the MOS. Is DTC 55-1 or 55-2 indicated? YES — GO TO STEP 2. NO — Intermittent failure 2. No.1 Linear Solenoid Valve Inspection Turn the ignition sWItch OFF. Disconnect the linear solenoid valve 4P (black) connector (page 13-60). Measure the resistance at the linear solenoid valve side 4P (black) connector [1]. Connection: Yellow — White/red Is the resistance within 5.0 — 5.6 fl (20”CI68“FI? YES — GO TO STEP 3. NO — Faulty linear solenoid valve [1] 13-42 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 3. No.1 Linear Solenoid Valve Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39)_ [1] [2] Check lor continuity between the Wire harness side 4P (black) connector [1] and 33P (Blue) connector % [21- A6 TOOL: V ii Test probe D7ZAJ-RDJA110 Connection: Yellow — A6 White/red — A7 A7 Is the continuity normal? —@— YES — GO TO STEP 4. NO — ~ Open circuit in the Yellow Wire ~ Open circuit in the White/red Wire 4. No.1 Linear Solenoid Valve Line Short Circuit Inspection Check for continuity between the wire harness side 1 AP (biack) connector [1] and ground. I 1 Connection: Yellow — Ground White/red — Ground Is there continuity? a Y YES — ~ Short circuit in the Yellow Wire ~ Short circuit in the White/red Wire W/R N0 — Replace the PCM with a known good one (page 4-39) and recheck. Q DTC 56-1, 56-2 (No.2 LINEAR SOLENOID VALVE) NOTE O Before starting the inspection, check for loose or poor contact on the linear solenoid vaive 4P (Black) and PCM 33P (Blue) connectors, and recheck the DTC. 1. DTC Recheck Recheck the DTC with the MOS. Is DTC 56-1 or 56-2 indicated? YES — GO TO STEP 2. NO — Intermittent failure 2. No.2 Linear Solenoid Valve Inspection Turn the ignition sWitch OFF. 1 Disconnect the linear solenoid valve 4P (biack) [ ] connector (page 13-60). Measure the resistance at the linear solenoid valve side 4P (black) connector [1]. Connection: Blue — Gray Standard: 5.0 — 5.6 n are/65°F) Is the resistance within 5.0 — 5.6 fl (20“CIGB“FI? Gr YES — GO TO STEP 3. NO — Faulty linear soienoid valve 13-43 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. No.2 Linear Solenoid Valve Input/ground Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- 39). Check Ior continuity between the wire harness side 4P (black) connector [1] and 33F (Blue) connector [2]- TOOL: Test probe D7ZAJ-RDJA110 Connection: Blue — A8 Gray — A9 Is the continuity normal? YES — GO TO STEP 4. NO — - Open circuitinthe Blue Wire - Open circuit in the Gray Wire 4. No.2 Linear Solenoid Valve Input/ground Line Short Circuit Inspection Check for continuity between the wire harness side 4P (black) connector [1] and ground. Connection: Blue — Ground Gray — Ground Is there continuity? YES — - Short circuit in the Blue Wire - Short circuit in the Gray wire N0 — Replace the PCM With a known good one (page 4-39) and recheck. DTC 57-1 (GEARSHIFT MECHANISM MALFUNCTION) ReIer to DTC 27-1 (page 13-23). DTC 57-2 (GEAR POSITION MALFUNCTION; JUMPS our OF GEAR) ReIer to DTC 27-1 (page 13-23). DTC 58-1 or DTC 59-1 (No.1 or No.2 CLUTCH DOES NOT DISENGAGE; WHEN SHIFTING GEAR) 1. Clutch Condition Inspection Remove the dual clutch assembly and inspect the clutch for sticking (page 13-63). Is the No.1 clutch stuck? YES — Faulty clutch NO — GO TO STEP 2. A9 [1] 13-44 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. Clutch Oil Line Inspection Check the clutch oil passages in the right crankcase cover and mainshaft for clogging. Is the oil passage clogged? YES — Clean the oil passage. N0 — Replace the PCM With a known good one (page 4-39) and recheck. DTC 61 -1, 61-2, 61-3, 61-4, 62-1, 62-2 (No.1 CLUTCH OIL PRESSURE MALFUNCTION) 1. DTC Recheck Recheck the DTC with the MOS. Is DTC 47-1, 47-2, 55-1 or 55—2 indicated? YES — DTC 47-1 is indicated (page 13-31). DTC 47-2 is indicated (page 13-32). DTC 55-1 is indicated (page 13-42). DTC 55-2 is indicated (page 13-42). NO — GO TO STEP 2. 2. No.1 Clutch EOP Sensor Inspection Replace the No.1 clutch EOP sensor With a known good one (page 13-80). Erase the DTC (page 13-9). Test-ride the motorcycle and stop the engine. Check the DTC with the MOS. Is DTC 61-1, 61-2, 61-3, 61-4, 62-1 or 62-2 indicated? YES — GO TO STEP 3. NO — Faulty original No.1 clutch EOP sensor 3. PCM Inspection Replace the PCM With a known good one (page 4- 39). Test-ride the motorcycle and stop the engine. Check the No.1 clutch EOP sensor with the MOS. Is DTC 61-1, 61-2, 61-3, 61-4, 62-1 or 62-2 indicated? YES — ~ Faulty No.1 linear solenoid valve ~ Clogged No.1 clutch oil line ~ Internal oil leak in the No.1 clutch oil line NO — Faulty original PCM DTC 63-1, 63-2, 63-3, 63-4, 64-1, 64-2 (No.2 CLUTCH OIL PRESSURE MALFUNCTION) 1. DTC Recheck Recheck the DTC with the MOS. Is DTC 48-1, 48-2, 56-1 or 56-2 indicated? YES — DTC 48-1 is indicated (page 13-31). DTC 48-2 is indicated (page 13-32). DTC 56-1 is indicated (page 13-43). DTC 56-2 is indicated (page 13-43). NO — GO TO STEP 2. 13-45 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 2. No.2 Clutch EOP Sensor Inspection Replace the No.2 clutch EOP sensor With a known good one (page 13-80). Erase the DTC (page 13-9). Test-ride the motorcycle and stop the engine. Check the DTC with the MOS. Is DTC 63-1. 63-2, 63-3, 634, 64-1 or 64-2 indicated? YES — GO TO STEP 3. NO — Faulty original No.2 ciutch EOP sensor 3. PCM Inspection §;)place the PCM With a known good one (page 4- Test-ride the motorcycle and stop the engine. Check the No.2 clutch EOP sensor with the MOS. Is DTC 63-1. 63-2, 63-3, 634, 64-1 or 64-2 indicated? YES — - Fauity No.2 linear solenoid valve - Ciogged No.2 clutch oii line - Internal oil leak in the No.2 clutch oil line NO — Faulty original PCM DTC 65-1 (FRONT AND REAR WHEEL SPEED SIGNAL MALFUNCTION) NOTE O Before starting the inspection, check that the tire sizes are correct, and the drive and driven sprockets are the specified ones. 1. DTC Recheck Erase the DTC (page 13-9). Test-ride the motorcycle above 20 km/h (12 mph) for more than 20 seconds. Stop the engine. Check the DTC with the MOS. Is DTC 11-1 or 67-1 indicated? YES — - DTC 11-1 is indicated (page 4-21). - DTC 67-1 is indicated (page 4-35). NO — GO TO STEP 2. 2. Front Wheel Speed Sensor Condition Inspection Inspect the area around the front wheel speed sensor. Check that there is no iron or other magnetic deposits between the pulser ring and wheel speed sensor, and check the puiser ring siots for obstructions. Check installation condition ol the puiser ring or wheei speed sensor for iooseness. Check the pulser ring and sensor tip for deformation or damage. Are the sensor and pulser ring in good condition? YES — GO TO STEP 3. NO — Remove any deposits. Install properiy or replace laulty part. 13-46 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 3. VS Sensor Condition Inspection Remove the VS sensor (page 4-42). Check the VS sensor for damage or contaminated. Is the VS sensor in good condition? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Replace the VS sensor with a known good one and recheck. DTC 68-1 (No.1 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS) 1. DTC Recheck Erase the DTC (page 13-9). Test-ride the motorcycle above 20 km/h (12 mph) for more than 20 seconds. Stop the engine. Check the DTC with the MOS. Is DTC 11-1 indicated? YES — Refer to DTC 11-1 troubleshooting (page 4-21). NO — GO TO STEP 2. 2. Clutch Condition Inspection Disassemble and check the No.1 clutch assembly (page 13-63). Is the No.1 clutch in good condition? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Replace the faulty part. DTC 69-1 (No.2 CLUTCH OPERATION MALFUNCTION; CLUTCH SLIPS) 1. DTC Recheck Erase the DTC (page 13-9). Test-ride the motorcycle above 20 km/h (12 mph) for more than 20 seconds. Stop the engine. Check the DTC with the MOS. Is DTC 11-1 indicated? YES — Refer to DTC 11-1 troubleshooting (page 4-21). NO — GO TO STEP 2. 2. Clutch Condition Inspection Disassemble and check the No.2 clutch assembly (page 13-63). Is the No.2 clutch in good condition? YES — Replace the PCM With a known good one (page 4-39) and recheck. NO — Replace the faulty part. 13-47 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DTC 71 -1, 72-1 (INNER, OUTER MAINSHAFTICOUNTERSHAFT SPEED RATIO FAILURE) 1. DTC Recheck1 Check the DTC with the MOS. Is DTC 53-1, 54-1 or 66-1 indicated? YES — - DTC 53-1 is indicated (page 13-37). - DTC 54-1 is indicated (page 13-40). - DTC 11-1 is indicated (page 4-21). NO — GO TO STEP 2. 2. DTC Recheck 2 Erase the DTC (page 13-9). Test-ride the motorcycle above 20 km/h (12 mph) for more than 20 seconds. Stop the engine. Check the DTC with the MOS. Is DTC 71-1 or 72-1 indicated? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Intermittent failure DTC 84-1 (CPU IN THE PCM MALFUNCTION) 1. DTC Recheck Erase the DTC (page 13-9). Check the DTC with the MOS. Is DTC 84-1 indicated? YES — Replace the PCM with a known good one (page 4-39) and recheck. NO — Intermittent failure MODE/SHIFT INDICATOR CIRCUIT TROUBLESHOOTING If the mode indicator does not operate, check that the combination meter shows following when the ignition sWItch is turned ON with the engine stop switch — MIL, engine oil pressure, engine coolant temperature, and torque control indicator stay on — HISS, torque control OFF. SID/G indicator do not come on — Current/average fuel mileage displays "— —.—" (when running the engine) — Remaining fuel displays " —.—" — Available driving distance displays " — —" — Shift indicator "—" is blinking — Torque control level and engine coolant temperature gauge displays blinking If so, check the TXD line (page 22-14). If not so, replace the combination meter. 13-48 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) AIM SWITCH TROUBLESHOOTING lithe engine can be started but AT/MT mode cannot be changed, perform this troubleshooting. NOTE O Before starting the inspection, check for loose or poor contact on the right handlebar switch and POM 33F connectors, and recheck the NM switch operation. O If the PCM is replaced, perform the Clutch Initialize Learning Procedure (page 13-82). 1. NM switch Power Input Voltage Inspection Disconnect the right handlebar switch 6P (Black) connector (page 22-24). Turn the ignition sWItch ON With the engine stop switch Measure the voltage between the wire harness side 6P (Black) connector [1] and ground. Connection: Yellow/white (+I — Ground (—) Is there battery voltage? YES — GO TO STEP 2. NO —Open circuit in the Yellow/white wire between the right handlebar sWItch i connector and Iuse box (ENG STOP 7.5 A) 2. NM switch Inspection Turn the ignition SWItch OFF. Check for continuity at the switch side right [1] handlebar SWItch 6P (Black) connector [1] in each switch position. BI/W Connection: Blacklwhite — Blue/black Is there continuity with the switch pushed and ' no continuity with the switch released? YES — GO TO STEP 3. NO — Faulty A/M switch BuIBI 3. NM switch Input Line Open Circuit Inspection Disconnect the PCM 33P (Blue) connector (page 4- m [2] Check for continuity between the wire harness side right handlebar switch 6P (Black) connector [1] and fl PCM 33F (Blue) connector [2]. Connection: Blue/black — A17 [ TOOL: 1 tau/BIT Test probe D7ZAJ-RDJA110 Is there continuity? fl ® YES — Replace the PCM (page 4-39) with a Known good one and recheck. A17 NO — Open circuit in the White/yellow wire 13-49 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) CLUTCH OIL FEED PIPE REMOVAL Remove the Iollowing: Bolts [1] Sealing washers [2] Feed pipe cover [3] O-ring [4] — Inner clutch oil feed pipe [1] NOTE . Be careIuI not to bend or damage the inner clutch oil feed pipe. — Bolts [1] — Feed pipe guide plate [2] — O-rings[3] — Outer clutch oil feed pipe [1] — O-ring [2] NOTE . Be careful not to bend or damage the outer clutch oil feed pipe. 13-50 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) INSPECTION Inspect the following parts for scratches, bending or clogging. — Inner clutch oil feed pipe — Outer clutch oil feed pipe Measure each part according to DUAL CLUTCH TRANSMISSION SPECIFICATIONS (page 1»8). Replace any part iI it is out of service limit. INSTALLATION Apply engine oil to a new O-ring [1] and install it to the outer clutch oil Ieed pipe [2]. Install the outer clutch oil feed pipe into the right crankcase cover by aligning the Ieed pipe bosses with the right crankcase cover grooves. Apply engine oil to new O-rings [1] and install them to the feed pipe guide plate grooves. Install the feed pipe guide plate [2] by aligning its pin with the right crankcase cover hole. Install and tighten the bolts [1] to the specified torque. TORQUE: 5.0 N-m (0.5 kgf-m, 3.7 lbf-fl) 13-51 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Install the inner clutch oi| feed pipe [1] to the feed pipe guide plate by aligning the Ieed pipe bosses with the guide plate grooves. Apply engine oil to a new O-ring [2] and install it to the Ieed pipe oover groove. Install the feed pipe cover [3]. Install the following: — New sealing washers [1] — Bolts [2] Tighten the bolts to the specified torque. TORQUEHZ N-m (1.2 kgf-m, 9 Ibf-ft) RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-12). Drain the coolant (page 8-4). Remove the bolts [1] and engine right side rear cover [2]. Remove the bolt [1], shift spindle angle sensor [2], and O-ring [3]. 13-52 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the bolts [1] and clutch EOP sensor cover [2]. Disconnect the iollowing: — Clutch line EOP sensor 3P (Gray) connector [1] — No.1 Clutch EOP sensor 3P (Gray) oonnector [2] — No.2 Clutch EOP sensor 3P (Black) connector [3] Remove the bolt [4] and wire stay [5]. Release the linear solenoid valve wire [1] and main wire harness [2] irorn the clamps [3]. Disconnect the linear solenoid valve 4P (Black) connector [4]. Remove the Clutch 0" teed pipe (page 13-50). Loosen the hose band screw [1]. Disconnect the radiator lower hose [2]. DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the bolts [1]. Loosen the hose band screw [2]. Disconnect the water pipe [3] and remove the O»ring [4]- Do not allow duster Remove the bolts [1] and right crankcase cover [2]. dirt to enter the oil passages. oil joint. Remove the O-ring [1]. 13-54 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Check the bearings and replace if necessary (page 13» 55). — Bearing (40 x 52 x 7 mm) [1] — Bearing (6304) [2] BEARING REPLACEMENT Remove the bearings using special tools. TOOLS: Remover weight 07741-0010201 Bearing (40 x 52 x 7 mm) [1]: Bearing remover shaft 07JAC-PH30200 Adjustable bearing puller, 20 — 40 mm 07JAC-PHBO100 Bearing (6304) [2] : Bearing remover set, 20 mm 07936-3710600 Remover handle 07936-3710100 Apply engine oil to a new bearings. Drive in the bearings with the marking side Iacing up until it is Iully seated using special tools. TOOLS: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Bearing (40 x 52 x 7 mm) [1]: Pilot, 40 mm 07746-0040900 Bearing (6304) [2] : Pilot, 20 mm 07746-0040500 INSTALLATION Clean the right crankcase cover mating suriaces thoroughly. Apply liquid sealant (TB1207B manufactured by Three Bond or equivalent) to the right crankcase cover mating suriace as shown. 10 r 15 mm (M e 0.6 in) 10715 mm ((147015 in) 13-55 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Apply engine oil to new O-rings [1] and new back up rings [2] and install them onto the oil joint [3] as shown. Install the oil joint into the crankcase hole. Install the dowel pins [1] and new gasket [2]. Goat a new O-ring [1] with engine oil and install it onto the groove of the water pump cover. Remove the crankshaft hole cap and the timing hole cap (page 3-8). Rotate the crankshaft counterclockwise and align the "T1" mark on the flywheel with the index mark on the alternator cover. Make sure that the index line and marks are lined up. — Primary drive gear index line [1] — Oil pump drive gear punch mark [2] — Crankcase "V" mark [3] Make sure that the front balancer shaft end [4] is in position as shown. Install the crankshaft hole cap and the timing hole cap (page 340). 13-56 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Rotate the water pump shaft and align the shaft slit with the pump oover index line as shown. Install the right crankcase cover [1]. Install the bolts [2] and tighten them in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) Coat a new O-ring [1] with engine oil and install it onto the water pipe [2]. Install the water pipe [1]. Tighten the hose band screw [2] to the specified range (page 8»8). Install the bolts [3] and tighten them to the specified _ torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) 13-57 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Connect the radiator lower hose [1]. Tighten the hose band screw [2] to the specified range (page 8%). Install the clutch oil feed pipe (page 1351). Connect the linear solenoid valve 4P (Black) connector [1]- Clamp the linear solenoid valve wire [2] and main wire harness [3] with the clamps [4]. NOTE . Route the wire properly (page 1-26). Install the wire stay [1] and bolt [2], and tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 let) Connect the following: — Clutch line EOP sensor 3P (Gray) connector [3] — No.1 Clutch EOP sensor 3P (Gray) connector [4] — No.2 Clutch EOP sensor 3P (Black) connector [5] Install the clutch EOP sensor cover [1] and bolts [2] and tighten the bolts to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 let) 13-58 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Apply engine oil to a new O-ring [1] and install it onto 1- V ' ~ ‘ fl '1‘ “ the shift spindle angle sensor [2]. ‘ ' Install the shift spindle angle sensor. NOTE . Align the flat surfaces of the shift spindle angle sensor and gearshift spindle end. Install the bolt [1] and tighten it to the specified torque. TORQUEHZ N-m (1.2 kgf-m, 9 Ibf-ft) NOTE . Route the hoses and wires properly (page 1-26). Install the engine right side rear cover [1] and bolts [2] and tighten the bolts to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-lt) Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12). Fill the recommended coolant mixture to the filler neck and bleed the air (page 8-4). 13-59 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) LINEAR SOLENOID VALVE REMOVAL NOTE . Keep dust and dirt away from all the parts. . Be careful not to damage the mating surlaces of the valve body components. Drain the engine oil (page 3-12). Remove the right middle oowl (page 2-6). Remove the clutch EOP sensor cover (page 13-80). Release the linear solenoid valve wire [1] from the clamps [2]. Disconnect the linear solenoid valve 4P (Black) connector [3]. Remove the bolts [1] and linear solenoid valve body [2]. Remove the Separator plate [1], dowel pins [2], and O- ring [3]. Remove the O»ring [4] and spool valve filter/packing [5]. Remove the packing lrorn the Spool valve filter. Check the Spool valve filter and replace if necessary. 13-60 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) DISASSEMBLYIASSEMBLY 4mm VALVE BODY STOPPER PLATE Q1m STDPPER PLATE BOLT LINEAR SOLENOID VALVE BODY COVER BOLTS 12 N-m (1.2 kgf~m. 9 lbl‘fl) VALVES COVER 12 N-m (1.2 kgfm, 9 let) NOTE . Clean all the parts with compressed air. Make sure that there is no dust or lint on any parts. . Apply locking agent to the solenoid valve stopper plate bolt threads (page 1-20). INSTALLATION Goat a new O»ring [1] with engine oil, and install it onto the linear solenoid valve body. Install the dowel pins [2] and separator plate [3] onto the linear solenoid valve body. 13-61 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Goat a new packing [1] with engine oil and install it onto the spool valve filter [2]. Install the spool valve filter/packing onto the right crankcase cover as shown. Install the O-ring [3]. Install the linear solenoid valve body [4]. Install the bolts [1] and tighten it to the specified torque. TORQUEHZ N-m (1.2 kgf-m, 9 Ibf’ft) Connect the linear solenoid valve 4P (Black) connector Clamp the linear solenoid valve wire [2] with the clamps [3]- Install the clutch EOP sensor cover (page 1380). Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12). 13-62 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) DUAL CLUTCH/PRIMARY DRIVEN GEAR REMOVAL Remove the right crankcase cover (page 13-52). Align the gear teeth of the primary drive gear and sub- ‘ gear [1] by prying the gears through the holes [2] and , hold them with a 6 mm bolt [3]. Remove the dual clutch assembly [1] from the mainshafl. Remove the seal rings [1] from the mainshaft grooves. DISASSEMBLY Remove clutch guide 1 [1], clutch guide 2 [2], and washers [3] irom the clutches. DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the clutch assemblies [1] and O-rings [2] from 1 the primary driven gear. [ 1 NOTE . The No.1 clutch assembly (for inner mainshaft) and No.2 clutch assembly (for outer mainshaft) are the same parts. Remove the iollowing: [1] — Snap ring [1] — End plate [2] — Clutch discs [1] — Clutch plates A [2] [4] [3] [1] — Clutch plate B [3] — Wave spring [4] Toplevenlloss of Set the special tools onto the clutch as shown and spring tension, do remove the snap ring [1] by compressing the return no! compress the spring assembly. spring assembly [2] more than TOOL: necessary_ Clutch compressor set [2] 07LAE-PX40000 Remove the special tools. 13-64 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Be careful not in damage the piston sliding surface. Remove the return spring retainer [1], O-ring [2], and return spring [3]. Wrap a shop towel around the clutch guide [1]. Apply air pressure to the 0" hole [2] while closing the other holes with a tape [3] to remove the clutch piston [41- Remove the clutch piston [1] and O»rings [2]. Clean all the parts in solvent thoroughly and blow dry them with compressed air. INSPECTION Inspect the following parts for scratches, damage, abnormal wear and deformation. Replace if necessary. — Clutch guide — Clutch piston — Return spring — Return spring retainer — Wave spring — Clutch discs — Clutch plates — End plale Measure each part according to DUAL CLUTCH TRANSMISSION SPECIFICATIONS (page 1»8). Replace any part if it is out of service limit. NOTE - Replace the clutch discs and plates as a set. 13-65 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) ASSEMBLY CLUTCH PLATES A (2 pcs) I CLUTCH DISCS (3 pcs) CLUTCH PLATE B END PLATE PRIMARY DRIVEN GEAR SNAP RING CLUTCH GUIDE CLUTCH PISTON SNAP RING WAVE SPRING RETURN SPRING RETAINER Clean the inner surface of the clutch guide thoroughly and blow through the 0" holes. Coat new O-rings [1] with engine oil and install them into the clutch guide and piston grooves. Place the piston [2] into the clutch guide [3]. Push the piston in the clutch guide to ensure proper seating. 13-66 To prevent loss 0/ spring tension, do no! compress the spring assembly more than necessary. DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Goat a new O»ring [1] with engine oil and install it into the return spring retainer groove. Install the return spring [2] and spring retainer [3] in the clutch guide. Place the snap ring [1] onto the clutch. Set the special tools onto the clutch as shown and install the snap ring into the clutch guide groove [2] by compressing the return spring. TOOL: Clutch compressor set [3] 07LAE-PX40000 Make sure that the snap ring is fully seated in the clutch guide groove. Remove the special tools. Install the wave spring [1]. Coat the clutch discs with engine oil. Install the clutch plate B [2], plate A [3], and discs [4] alternately, starting with the plate B. NOTE . Clutch plate B: surface treatment difference from clutch plate A. Install end plate [1] with the marking side lacing out. Install the snap ring [2]. Make sure that the snap ring is fully seated in the clutch guide groove. Check the clutch initial clearance (page 13458). 13-67 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Coat new O-rings [1] with engine oil and install them into the grooves in the primary driven gear [2]. Apply molybdenum oil solution to the primary driven gear teeth, friction springs, and boss sliding area. Install the clutch assemblies [3] onto the primary driven gear. Apply engine oil to the needle bearings in the primary driven gear. NOTE . The primary driven gear has the index line [1] on its flange for the installation direction. The dual clutch assembly should be installed with the index line facing the outside. Line up the clutch disc tabs. Install the washer [2] onto the clutch assembly. Install clutch guide 1 [3] into the clutch on the index |ine side by aligning the gear teeth with the clutch disc tabs. Turn over the dual clutch assembly while holding clutch guide 1. Apply engine oil to the needle bearings in the primary driven gear. Line up the clutch disc tabs. Install the washer [1] onto the clutch assembly. Install clutch guide 2 [2] into the clutch by aligning the gear teeth with the clutch disc tabs. CLUTCH INITIAL CLEARANCE Set a dial indicator on the end plate [1] with the plate lowered. Lift the end plate against the snap ring and read the clearance, and record it. Perform this inspection at the three points in 120° apart. STANDARD: 0.9 — 1.1 mm (0.035 — 0.043 in) If the clearance is not within the standard value, select the replacement end plate as follows: [3] 0.9 r 1.1 mm (0.035 7 0.043 In) 13-68 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the snap ring and end plate (page 13-63). Measure the flange thickness of the end plate [1] at several points and record it. Calculate the new plate thickness using the equation below. Choose a new plate as close to this dimension as possible. A=(B—1.0)+C A: New plate thickness B’ Recorded clearance C: Old plate thickness If the calculated Select the end plate from the table below. dimension is over the thickestplale Mark [1] Thickness thickness. replace 10 2,4 mm the clutch discs and 11 2.5 mm plates as a set. 1 2.6 mm 2 2.7 mm 3 2.8 mm l 4 2.9 mm 5 3.0 mm y/ 6 3.1 mm 7 3.2 mm b; 8 3.3 mm V 9 3.4 mm Install the removed parts in the reverse order of removal. INSTALLATION Apply engine oil to new seal rings [1] and install them into the mainshaft grooves. Push in the seal rings to seat them into the grooves. Install the dual clutch assembly [1] onto the mainshaft, being careful not to damage the seal rings. Remove the 6 mm bolt [2] to free the primary drive gear and sub-gear [3]. Install the right crankcase cover (page 13-55). DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) PRIMARY DRIVE GEAR REMOVAL Remove the right crankcase cover (page 13-52). Hold the primary drive gear and sub-gear with a 6 mm bolt (page 13-63). Install the special tool between the primary drive and driven gears, and loosen the primary drive gear nut (left-hand thread) [1]. TOOL: Gear holder, 2.5 [2] 077244010100 Remove the primary drive gear nut, washer [3], and primary drive gear/sub-gear [4] from the crankshaft. Remove the 6 mm bolt [5]. DISASSEMBLYIASSEMBLY Remove the primary drive sub—gear [1] and springs [2]. Installation is in the reverse order of removal. NOTE . Apply molybdenum oil solution to the sliding surfaces oi the primary drive gear and sub-gear. . Install the sub-gear onto the primary drive gear [3] in the position as shown. . Make sure that the index line on the primary drive sub-gear aligns with the wide tooth of the primary drive gear. INSPECTION Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary. — Primary drive gear — Primary drive sub-gear — Springs INSTALLATION Apply molybdenum 0" solution to the primary drive gear , sliding surface. Install the primary drive gear/sub—gear [1] onto the crankshaft by aligning their wide grooves with the wide tooth. Hold the primary drive gear and sub-gear with a 6 mm 1 bolt (page 13-63). 13-70 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Apply engine oil to the primary drive gear nut threads . . " - V— and seating suriace. » ‘3 m Install the washer [1] and primary drive gear nut [2]. Install the special tool between the primary drive and driven gears, and tighten the nut (left-hand thread) to the specified torque. TOOL: Gear holder, 2.5 [3] 077244010100 TORQUE: 118 N-m (12.0 kgf-m, B7 lhfrfl] Remove the 6 mm bolt [4] to free the primary drive gear and sub-gear. Install the right crankcase cover (page 13-55). SHIFT CONTROL MOTOR/REDUCTION GEARS REMOVAL Remove the bolts [1] and shift control motor cover [2]. Disconnect the shift control motor 2P (Black) connector ‘ Remove the torx bolts [2], shift oontrol motor [3], and O- ring [4]. Remove the torx bolts [1] and reduction gear cover [2]. 13-71 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Do not use a torch to heat the upper crankcase; it may cause warping. Remove the dowel pins [1] and gasket [2]. Remove the reduction gears [3]. Check the bearings and replace if necessary. — Radial ball bearing (69922) [1] — Radial ball bearing (60722) [2] — Radial ball bearing (69622) [3] Heat the reduction gear cover to 80°C (176°F) evenly using a heat gun. Tap the reduction gear cover lightly and remove the bearings. Apply engine oil to new bearings. Drive in new bearings squarely with the marking side lacing up until they are fully seated. Check the bearings and replace if necessary (page 14- 19). — Radial ball bearing (60722) [1] — Radial ball bearing (69622) [2] 13-72 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) INSTALLATION Apply 2 — 4 g (0.07 — 0.14 oz) of specified grease to the reduction gearjournals [1] and teeth. SPECIFIED GREASE: UNIREX N3 manufactured by ExxonMohil or equivalent Install the reduction gear B [2] by aligning the gear ends with the ribs of the crankcase. Install the reduction gear C [3] by aligning each clinched tooth of the gear C and gearshift spindle. Check that the punch marks on the gear C and gear B tooth line up as shown. Install reduction gear A [4]. Install the dowel pins [1] and gasket [2]. Install the reduction gear cover [1] and torx bolts [2]. then tighten the torx bolts. TORQUE: 14 N-m (1.4 kgf-m, 10 lhf-ft) 13-73 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Goat a new O»ring [1] with engine oil and install it into "3 ' the groove in the shift oontrol motor [2]. g Install the shift control motor onto the shift control motor cover. ' Install the torx bolts [1] and tighten it to the specified ‘ torque. TORQUE: 14 N-m (1.4 kgf'm, 10 lhf-ft) Connect the shift control motor 2P (Black) connector [2]. Install the shift oontrol motor cover [1] and bolts [2] and tighten the bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbfrft) NOTE . Route the wire properly (page 1-26) GEARSHIFT LINKAGE REMOVAL Remove the following: — Shift control motor/reduction gears (page 13-71) — Dual clutch (page 13-63) — Gearshift spindle [1] — Washer [2] — Drum shifter collar [3] 13-74 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) — Bolts [1] — Drum shifter guide plate/drum shifter assembly [2] Guide plate distance collar [1] Dowel pin [2] (if necessary) Slopper arm side collar [3] Shift drum center bolt [4] Shift drum center [5] Shift drum stopper arm [1] Slopper arm collar [2] Slopper arm return spring [3] Shift drum center dowel pin [4] Dowel pin [5] (if necessary) Remove the 0" seal [1]. Check the gearshifl spindle needle bearing [2] and replace if necessary (page 1449). 13-75 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) INSPECTION Inspect the following parts for scratch, damage. abnormal wear, or deformation. Gearshift spindle, spindle arm, return spring Drum shifter guide plate Drum shifter Ratchet pawls Plungers Plunger springs Replace if necessary. INSTALLATION Install the oil seal [1] until it is in position as shown. Apply grease to the 0“ seal lips. Install the following: — Dowel pin [1] — Shift drum center dowel pin [2] — Stopper arm return spring [3] Stopper arm collar [4] Shift drum stopper arm [5] 13-76 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Hold the shift drum stopper arm [1] with a screwdriver and install the shift dmm center [2] by aligning the groove [3] with the dowel pin [4]. Apply locking agent to the threads of the shift drum center bolt [1] (page 1-21). Install the shift drum center bolt and tighten it to the specified torque. TORQUE: 31 N-m (3.2 kgf-m, 23 lhf-ft) Install the stopper arm side collar [2], dowel pin [3], and guide plate distance collar [4]. Install the plunger springs [1], plungers [2], and ratchet pawls [3] into the drum shifter [4] and set them in the drum shifter guide plate [5]. Install the drum shifter guide plate/dmm shifter assemny [1]. Apply locking agent to the threads of the guide plate bolts [2] (page 1-20). Install the bolts and tighten them. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) [5] [4] 13-77 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Install the drum shifter collar [1] onto the drum shifter. Install the washer [2] onto the gearshift spindle [3] and insert the spindle into the crankcase while aligning the return spring ends with spring pin and the spindle arm hole with the drum shifter collar. Install the following: — Dual clutch (page 13-69) — Reduction gears/shift control motor (page 13-73) MAINSHAFT SENSOR INNER MAINSHAFT SENSOR REMOVAL/INSTALLATION Support the motorcycle using a satety stand or hoist, raise the rear wheel off the ground. Remove the rear shock absorber (page 1&8). Release the inner mainshaft sensor 3P (Black) connector [1] from the connector clip stay and disconnect it. Remove the bolts [2], inner mainshaft sensor [3], and O-ring [4]. Installation is in the reverse order of removal. NOTE . Replace the O-ring with a new one. . Apply engine oil to a new O»ring. OUTER MAINSHAFT SENSOR REMOVAL/INSTALLATION Remove the battery box (page 21-6). Disconnect the outer mainshafl sensor 3P (Black) connector [1]. Remove the bolt [2] and outer mainshafl sensor [3], and O-ring [4]. Installation is in the reverse order of removal. NOTE . The outer mainshaft sensor and VS sensor are the same parts. . Replace the O-ring with a new one. . Apply engine oil to a new O»ring. 13-78 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) TR SENSOR REMOVAL/INSTALLATION Remove the left rear cover (page 2-10). Remove the shift control motor oover (page 13-71). Support the motorcycle using a saiety stand or hoist, raise the rear wheel off the ground. Remove the rear shock absorber (page 1&8). Release the TR sensor 3P (Black) connector [1] from the oonnector clip stay and disconnect it. Remove the following: — Bo|t[1] — Sensoroover[2] — TR sensor[3] — 0-ring[4] Installation is in the reverse order of removal. NOTE . Always replace the O»ring [1] with a new one. . Apply engine oil to a new O»ring. . Align the flat surfaces of the TR sensor and shift drum end. . Route the wires properly (page 1-26). TORQUE: 12 N-m (1.2 kgf-m, 9 let) SHIFT SPINDLE ANGLE SENSOR REMOVAL/INSTALLATION Support the motorcycle using a saiety stand or hoist, raise the rear wheel off the ground. Remove the rear shock absorber (page 1&8). Release the shift spindle angle sensor 3P (Blue) connector [1] irom the connector clip stay, and disconnect it. DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Remove the bolts [1] and engine right side rear cover [2]. Remove the bolt [1], shift spindle angle sensor [2], and O-ring [3]. Installation is in the reverse order of removal. NOTE . Always replace the O»ring [1] with a new one. . Apply engine oil to a new O»ring. . Align the flat surfaces oi the shift spindle angle sensor and gearshift spindle end. . Route the hoses and wires properly (page 1-26). TORQUE: Shift spindle angle sensor bolt: 12 N-m (1.2 mm, 9 lbf-ft) Engine right side rear cover bolt: 10 N-m (1.0 mm, 7 lbf-ft) CLUTCH EOP SENSOR REMOVAL/INSTALLATION Drain the engine oil (page 3-12). Remove the bolts [1] and clutch EOP sensor cover [2]. 13-80 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) Disconnect the 1ol|owing: M4: _ V s — Clutch line EOP sensor 3P (Gray) connector [1] — No.1 Clutch EOP sensor 3P (Gray) oonnector [2] — No.2 Clutch EOP sensor 3P (Black) connector [3] Remove the clutch EOP sensors [4] and O-rings from the right crankcase cover. NOTE . These three clutch EOP sensors are the same parts. Installation is in the reverse order of removal. NOTE . Replace the O»ring [1] with a new one. . Coat a new O-ring with engine oil. . Route the wire properly (page 1-26). TORQUE: No.1/No.2 clutch EOP sensor: 20 N-m (2.0 kgfrm, 15 mm) Clutch line EOP sensor: 20 N-m (2.0 kgfrm, 15 mm) Clutch EOP sensor cover bolt: 10 N-m (1.0 kgf-m, 7 lbf-ft) EOT SENSOR REMOVAL/INSTALLATION Disconnect the 02 sensor 4P (Black) oonnector (page 2.17). Drain the engine oil (page 3-12). Remove the bolt [1] and connector stay [2]. Disconnect the EOT sensor 2P (Black) connector [3]. Remove the EOT sensor [4] and sealing washer [5] 1rom the crankcase. Installation is in the reverse order of removal. NOTE . Apply engine oil to the EOT sensor threads and seating suriace. . Replace the sealing washer with a new one. TORQUE: 15 N-m (1.5 kgfrm, 11 lhf-ft) 13-81 DUAL CLUTCH TRANSMISSION (DCT) (CRF1ODDD) NEUTRAL SWITCH REMOVAL/INSTALLATION Release the rubber cap [1]. Remove the nut [2] and disconnect the neutral switch terminal [3]. Remove the neutral switch [4] and sealing washer [5]. Installation is in the reverse order of removal. NOTE . Apply engine oil to the neutral switch threads and seating surlace. . Replace the sealing washer with a new one. TORQUE: Neutral switch: 12 N'm (1.2 ngm, 9 lbf-ft) Neutral switch terminal nut: 1.7 N-m (0.2 kgfrm, 1.3 lbf-ft) CLUTCH INITIALIZE LEARNING (PCM) NOTE . If the PCM and/or clutch assembly are replaced. perform this procedure. . Before starting this procedure, check the following: — PGM-FI system and DCT system have no DTC. — Engine idle speed is normal. — Transmission is in neutral and cooling fan stops. . Do not operate the throttle during clutch initialize learning 1. Warm up the engine to the normal operating temperature (engine oil temperature: 50 — 110”C/122 — 230°F) and stop it. NOTE lithe PCM is replaced with a new one, when the ignition switch is turned on the "D" and "S" indicators [1] will come on to indicate that the clutch initialization learning procedure is necessary. Furthermore, it the large “L“ (extremely low oil temperature indicator) [2], or small “L“ (low oil temperature indicator) [3] is displayed on the shift indicator, the engine must be warmed before proceeding. Extremely low all tern perature: [2] \' l [1] Low oil temperature: 13-82 DUAL CLUTCH TRANSMISSION (DOT) (CRF1000D) 2. Turn the ignition switch GM with the engine stop switch "3" while pushing the D switch [1] of the N-D switch. The MIL [2] will come on. Release the D switch after the MIL goes off. . When only the dual clutch assembly is replaced: No indication appears on the shift indicator [3]. . When the PCM is replaced: The "D" and "S" indicators [4] come on. 3. Operate the N-D switch [1] in the sequence as follows: — Push the D switch — Push the D switch — Push the N switch — Push the D switch — Push the N switch . When only the dual clutch assembly is replaced: The PCM is ready to clutcn initialize learning when the "D" and "S" indicators [2] lights, and the “—" [3] is displayed on the shift indicator and blinks an interval of 2 seconds. When the PCM is replaced: The PCM is ready to clutcn initialize learning when the “—" is displayed on the shift indicator and blinks an interval of 2 seconds. NOTE When the engine is not warmed up enough. the large "L" [4] (extremely low oil temperature) or small "L" [5] (low oil temperature) is displayed on the shift indicator. _ If so. warm up the engine until the “L“ on the shift [2] indicator goes off. Stop the engine and perform steps 2 and 3 again. 13-83 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) 4. Start the engine and let it idle. The "—" [1] on the shift Indicator starts blinking an inten/al of 2 seconds. The Clutch Init lize Learning is successful, when the —". "D" and "S indicators [2] go ofl. Stop the engine. NOTE The clutch initialize learning is unsuccessful, if the starts blinking an interval of 0.5 second or it goes off. and the "D" and "S" indicators stay on. Perlorm the initialize learning procedure lrorn step 2 again. 5. Stop the engine. 6. Restart the engine, push switch and check that the D sWItch ol the N-D indicator comes on. - [2] 13-84 14. CRANKCASEITRANSMISSIONIBALANCER SERVICE INFORMATION -------------------- -- 14-2 TROUBLESHOOTING ------------------------ .. 14.3 COMPONENT LOCATION ------------------- -- 14-4 BALANCER -------------------------------------- -~ 14-6 CRANKCASE SEPARATION -------------- --14-13 TRANSMISSION ------------------------------- --14.15 CRANKCASE ASSEMBLY ----------------- -.14.27 14-1 CRANKCASE/TRANSMISSIONIBALANCER SERVICE INFORMATION GENERAL (CRF1000IA) ~ The crankcase must be separated to service the following: — Transmission — Crankshaft (page 15-4) — Piston/cylinder (page 15-12) ~ The folloWing components must be removed before separating the crankcase: — Engine (page 16-5) — Clutch (page 12-8) — Gearshift linkage (page 12-17) — Primary drive gear (page 12-15) — Balancer (page 14-6) — Flywheel (page 11-7) — Cylinder head (page 10-13) — Oil pump (page 9-5) — Starter motor (page 6-5) — VS sensor (page 4-42) — Gear position switch (page 22-25) ~ Be careful not to damage the crankcase mating surfaces when servicing. ~ Clean the oil passages before assembling the crankcase halves. ~ Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly. GENERAL (CRF1000D) ~ The crankcase must be separated to service the following: — Transmission — Crankshaft (page 15-4) — Piston/cylinder (page 15-12) ~ The folloWing components must be removed before separating the crankcase: — Engine (page 16-5) — Dual clutch (page 13-63) — Gearshift linkage (page 13-74) — Primary drive gear (page 13-70) — Balancer (page 14-6) — Flywheel (page 11-7) — Cylinder head (page 10-13) — Oil pump (page 9-5) — Starter motor (page 6-5) — Shift control motor/reduction gears (page 13-71) — Mainshaft sensors (page 13-78) — VS sensor (page 4-42) — Neutral switch (page 13-82) ~ Be careful not to damage the crankcase mating surfaces when servicing. ~ Clean the oil passages before assembling the crankcase halves. ~ Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly. 14-2 TROUBLESHOOTING Hard to shift Improper clutch operation Incorrect engine oil weight Bent sh ift fork Bent shift fork shaft Bent shift fork claw Damaged shift drum groove Bent gearshift spindle — CRF1000/A (page 12-17) — CRF‘IOOOD (page 13-74) Transmission jumps out of gear - Worn gear dogs Worn gear shifter groove Bent shift fork shaft Worn or bent shift forks Broken shift drum stopper arm — CRF1000/A (page 12-17) — CRF‘IOOOD (page 13-74) Broken shift drum stopper arm return spring — CRF1000/A (page 12-17) — CRF‘IOOOD (page 13-74) - Broken gearshift spindie return spring — CRF1000/A (page 12-17) — CRF‘IOOOD (page 13-74) Excessive engine noise - Worn or damaged transmission gear - Worn or damaged transmission bearings - Incorrect balancer installation ORANKCASEITRANSMISSION/BALANCER 14-3 CRAN KCASE/TRANSMISSIONIBALANCER COMPONENT LOCATION CRF1000IA: 43 Nm (4.4 kgf-m, 32 mm) 39 Nm (4.0 kgf'm, 29 mm) 24 N-m (2.4 kgf~m, 15 1131-11) 24 Nm (2.4 kgf-m, 13 mm) 24 Nm (2.4 kgf-m.1albf'fl) 1 12 Nm (1.2 kg1-m. 9 lbf'fl) 8" f \ 12N1m(1.2kgf'm,9lbf~fl) 12 Nm (1.2 kgf-m, 9 lbf'fl) 14-4 CRANKCASEITRANSMlSSION/BALANCER CRF1ODDD: 43 Nm (4.4 kgrm, 32 lbfrfl) 24 NM (24 Wm. 18 mm) 39 N~m (4.0 kgf'm, 29 lbf~ft) 24 N~m (2.4 kgf‘m, 1a lbf'fl) 24 Nm (2.4 kgf~m,18|bf-fl) 24 Nm (2.4 kgrm, 1s lbf-fl) 12 N~m (1.2 kgrm, 9 mm) 12 Nm (12 kgf'm, 9 leI) 12 N-m (1.2 kgf~m. 9 let) 14-5 CRAN KCASEITRANSMISSIONIBALANCER BALANCER FRONT BALANCER REMOVAL Remove the flywheel (page 11-7). Install the special too| between the front balancer drive and driven gears. TOOL: Gear holder, 2.5 [1] 07724-0010100 Remove the front balancer gear bolt [2] and washer [3]. Line up the front balancer driven gear and sub gear teeth by inserting a suitable pin [1] into the holes of gears. Remove the front balancer driven gear [2]. Remove the left front balancer [1]. Remove the right crankcase cover. — CRF1000/A (page 124) — CRF1000D (page 1352) Remove the front balancer bearing set plate bolts [1] and set plate [2]. Remove the front balancer shaft/bearing assemny [3]. Remove the left front balancer bearing. 14-6 CRAN KCASEITRANSMISSIONIBALANCER FRONT BALANCER DRIVEN GEAR DISASSEMBLV Remove the front balancer driven gear (page 1445). To prevent loss of Set the special tools onto the front balancer driven gear spring tension, do [1] as shown and remove the snap ring [2] by not compress the compressing the return spring assembly. spring assembly T°0L_ 1h $253: Clutch compressor set [3] 07LAE-PX40000 Remove the special tools. Disassemble the following: — Washer [1] — Friction spring [2] — Front balancer sub driven gear [3] — Springs [4] — Front balancer driven gear [5] INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or deformation. — Balancerdriven gear — Balancerdriven sub-gear — Springs — Balancershaft — Balancershaft bearings Replace if necessary. FRONT BALANCER DRIVEN GEAR ASSEMBLY Assemble the following: — Front balancer driven gear [1] Springs [2] — Front balancer sub driven gear [3] — Friction spring [4] — Washer [5] NOTE . Apply molybdenum oil solution to the balancer driven gear, sub driven gear, friction spring, and washer sliding surface. . Install the sub driven gear by aligning its boss as shown. . Install the friction spring as shown. 14-7 CRAN KCASE/TRANSMISSION/BALANCER To prevent loss 0/ spring tension, up not compress the spring assembly more than necessary. Place the snap ring [1] onto the front balancer driven gear assembly [2]. Set the special tools onto the front balancer driven gear assembly as shown and install the snap ring into the its guide groove by compressing the friction spring. TOOL: Clutch compressor set [3] NOTE . Install the snap ring with the chamfered edge lacing opposite side of the washer and make sure that it is firmly seated in the groove. 07LAE-PX40000 Remove the special tools. INSTALLATION Install the left front balancer bearing with the marked side facing out. Install the right front balancer shaft/bearing assembly ‘ [1]- Apply locking agent to the front balancer bearing set plate bolts threads (page 1-20). Install the set plate [2] with its "OUTSIDE" mark [3] lacing out. Install the front balancer bearing set plate bolts [4] and tighten them to the specified torque. TORQUEHZ N-m (1.2 kgf-m, 9 Ibf-ft) Install the right crankcase cover. — CRF1000/A (page 1245) — CRF1000D (page 1355) Install the left front balancer [1] by aligning its wide tooth with the front balancer shaft clinched tooth. Apply molybdenum oil solution to the front balancer driven gear sliding area and thrust surface. Line up the front balancer driven gear and sub gear teeth by inserting a suitable pin [1] into the holes of gears. Install the front balancer driven gear [2]. NOTE . Align the front balancer driven gear wide tooth with the front balancer shaft clinched tooth. . Make sure that the balancer driven gear index line ‘ [3] is positioned between the balancer drive gear index lines [4]. [2] [1] 14-8 CRANKCASE/TRANSMISSIONIBALANCER Install the special tool between the front balancer drive I) and driven gears. ’ TOOL: Gear holder, 2.5 [1] 07724-0010100 Apply engine oil to the front balanoer shaft bolt threads and seating surface. Install the washer [2] and front balanoer gear bolt [3]. Tighten the bolt to the specified torque. TORQUE: 103 N-m (10.5 kgf-m, 76 Ihf-fl) Install the flywheel (page 11-7). REAR BALANCER REMOVAL/DISASSEMELY Remove the right crankcase oover. — CRF1000/A (page 124) — CRF1000D (page 13-52) CRF1000/A: Line up the primary drive gear and sub gear teeth (page 12-10). Remove the bolts [1] and rear balanoer shaft holder [2]. CRF1000D shown Remove the dowel pins [1]. Line up the rear balanoer driven gear and sub gear teeth by inserting a suitable pin [1] into the holes of gears. Remove the rear balancer driven gear assembly [2]. 14-9 CRAN KCASE/TRANSMISSIONIBALANCER To prevent loss or spring tension, do not compress the spn'ng assembly more than necessary. Disassemble the following: — Collar [1] — Thrust spring [2] — WashersA [3] — Thrust bearing [4] — Rear balancer shaft [5] — Needle bearing [6] — Rear balanoer driven gear assembly [7] — Washer B [8] — Bolt[1] — Washer [2] — Setplate[3] — Oilpump drivengear[4] REAR BALANCER DRIVEN GEAR DISASSEMELY Remove the rear balancer driven gear (page 14-9). Set the special tools onto the rear balanoer driven gear [1] as shown and remove the snap ring [2] by compressing the return spring assembly. TOOL: Clutch compressor set [3] 07LAE-PX40000 Remove the special tools. Disassemble the following: — Washer [1] — Friction spring [2] — Rear balanoer sub driven gear [3] — Springs [4] — Rear balanoer driven gear [5] [6] [7] 14-10 To prevent loss or spring tension, do not compress the spn'ng assembly more than necessary. CRANKCASEITRANSMISSIONIBALANCER INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or deiormation. — Balancerdrivengear — Balancer sub driven gear — Springs — Balancershafl — Bearings Replace it necessary. REAR BALANCER DRIVEN GEAR ASSEMBLY Assemble the following: — Rear balancer driven gear [1] — Springs [2] — Rear balancer sub driven gear [3] — Friction spring [4] — Washer [5] NOTE . Apply molybdenum oil solution to the balancer driven gear, sub driven gear, friction spring, and washer sliding surface. . Install the sub driven gear by aligning its boss as shown. Install the iriction spring as shown. Place the snap ring [1] onto the rear balancer driven gear assembly [2]. Set the special tools onto the front balancer driven gear assembly as shown and install the snap ring into the its guide groove by compressing the iriction spring. TOOL: Clutch compressor set [3] 07LAE-PX40000 NOTE . Install the snap ring with the chamfered edge iacing opposite side of the washer and make sure that it is firmly seated in the groove. Remove the special tools. ASSEMELVIINSTALLATION Apply molybdenum oil solution to the oil pump driven gear shaft outer surface. Install the oil pump driven gear [1]. Apply locking agent to the bolt threads (page 1-20) Install the set plate [2], washer [3], and bolt [4] and tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf'ft) 14-11 CRAN KCASE/TRANSMISSIONIBALANCER If you are replacing the rear balancer driven gear and/or needle bearing, record the corresponding balancer driven gear |.D. code [1] from the balancer weight. If you are reusing the rear balancer driven gear. measure the balancerjournal ID. with a micrometer. Cross-reference the balancer journal ID. and needle bearing codes to determine the replacement needle bearing color code [1]. NEEDLE BEARING 0.D.: 91015-MJP-GS10-M1 91016-MJP-GS10-M1. 91017-MJP-GS10-M1:Thlnnest REAR BALANCER NEEDLE BEARING SELECTION TABLE: a 7 —7. (1.0630 — 1.0532 in) (1.0628 — 1.0530 in) 15- Assemble the following: — Washer B [1] — Rear balancer driven gear assemny [2] — Needle bearing [3] — Rear balancer shaft [4] — WashersA [5] — Thrust bearing [6] — Thrust spring [7] — Collar [8] NOTE . Coat the shaft, bearings, and gear teeth with engine oil. . Apply molybdenum oil solution to the thrust spring sliding surlace. . Apply molybdenum oil solution to the rear balancer driven gear sliding area and thrust surlace. . Install the friction spring as shown. Insert the rear balancer driven gear assemny shaft end [1] into the hole [2] of the lower crankcase. NOTE . Engage the oil pump drive [3] and driven gear [4]. 5mm 5 1 b c 7. mm . — . mm (1.0627 — 1.0628 in) 11- 5 [5] 14-12 CRANKCASE/TRANSMISSIONIBALANCER Line up the rear balanoer driven gear and sub gear teeth by inserting a suitable pin [1] into the holes of gears. Install the rear balancer driven gear assembly [2]. NOTE . Make sure that the index line [3] on the balancer drive gear is positioned between the index lines [4] on the balancer driven gear as shown. Install the dowel pins [1]. Install the bolts [1] and rear balancer shaft holder [2] and tighten the bolts to the specified torque. TORQUE:29 N-m (3.0 kgf-m, 21 Ibf-fl) CRF1000/A: Remove the 6 mm bolt from the primary drive gear. Install the right crankcase oover. — CRF1000/A(page12»6) — CRF1000D(page13-55) CRANKCASE SEPARATION For Service Information Ior removal of the necessary parts before separating the crankcase (page 14-2). Remove the bolts [1], water hose flange [2], and O»ring [3]. 14-13 CRAN KCASE/TRANSMISSIONIBALANCER CRF10000: Remove the cam chain tensioner pivot bolt [1], cam chain tensioner [2], and washer [3]. Remove the bolts [4], cam chain guide plate [5], cam chain [6], and timing sprocket [7]. Place the engine upside down. Loosen the crankcase bolts in a crisscross pattern in 2 or 3 steps, and remove the bolts and washers. — 6 x40 mm bolt (Blue paint) [1] — Five 6 x 35 mm bolts [2] — Two 6 mm bolts [3] and sealing washers [4] — Seven 8 mm bolts [5] — Two 8 mm bolts [6] and sealing washers [7] — 10 mm bolt [8] Loosen the crankcase main journal bolts [1] in a crisscross pattern in 2 or 3 step, and remove them. Separate the lower crankcase [2] lrom the upper crankcase. NOTE . Do not pry the crankcase ha|ves with a screwdriver. Remove the dowel pins [1], oiljointA [2], and 0" joint B [3]. Clean any sealant off from the crankcase mating surlace. Clean the oil orifices in solvent thoroughly. Check the oil orilices for clog, and replace them if necessary. [61/ [7] [31/ [4] [2] 14-14 CRANKCASE/TRANSMlSSION/BALANCER TRANSMISSION REMOVAL/DISASSEMBLY COUNTERSHAFT Separate the crankcase halves (page 14-13). Remove the countershafi assembly [1]. Remove the dowel pin [2]. Disassemble the countershaft assembly. Clean all disassembled parts in solvent thoroughly. NOTE . Keep track of the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece of wire. . Do not expand the snap ring more than necessary for removal. To remove a snap ring, expand the snap ring and pull it off using the gear behind it. SHIFT FORKISHIFT DRUM CRF1000/A: Remove the oountershafi (page 14-15). Remove the shift drum bearing setting bolt [1] and washer[2]. CRF10000: Remove the oountershafi (page 14-15). Remove the shift drum bearing setting bolt [1] and washer[2]. CRF1000/A: Remove the following: — Shift fork shaft [1] — Countershaft shift forks [2] — Mainshaft shift fork [3] CRAN KCASEITRANSMISSIONIBALANCER CRF10000: Remove the following: — Countershaft shift fork shaft [1] — Countershaft shift forks [2] — Mainshaft shift fork shaft [3] — Mainshaft shift forks [4] Remove the shift drum bearing setting bolt [1] and washer[2]. Remove the shift drum bearing [1] and shift drum [2]. MAINSHAFT Remove the shift forks/shift drum (page 14-15). Remove the mainshaft bearing set plate bolts [1] and set plate [2]. 14-16 CRANKCASEITRANSMISSIONIBALANCER Remove the right mainshaft bearing [1] from the upper crankcase. Remove the mainshafl assembly [1]. Disassemble the mainshaft assembly. Clean all disassembled parts in solvent thoroughly. NOTE . Keep track of the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece of wire. . Do not expand the snap ring more than necessary for removal. To remove a snap ring, expand the snap ring and pull it off using the gear behind it. INSPECTION Inspect the following parts for scratch, damage, abnormal wear, or deformation. Transmission gears Transmission bushings Transmission bearings Shift drum/bearing Shift forks Shift fork shafts Measure each part according to CRANKCASE/ TRANSMISSION SPECIFICATIONS. — CRF1000/A (page 1-3) — CRF1000D (page 1-9) Replace any part if it is out of service limit. CRF1OODD shown: 14-17 CRAN KCASE/TRANSMISSIONIBALANCER Drive in a new bearing squarely with the marking side facing toward the inside anhe crankcase. Drive in the needie bearing squarely with the marking side facing toward the outside onhe crankcase. UPPER CRANKCASE BEARING REPLACEMENT Remove the lollowing: — Transmission (page 14-15) — Crankshaft (page15-4) — Piston (page 15-12) LEFT MAINSHAFT BEARING Remove the left mainshaft bearing [1] using the special tools. TOOLS: Bearing remover shaft set, 25 mm Remover weight 07936-ZV10100 07741-0010201 Apply engine oil to a new left mainshaft bearing. Drive in the left mainshaft bearing until it is fully seated using the special tools. TOOLS: Driver, 15 x 280L Attachment, 52 x 55 mm Pilot, 25 mm 079494710001 07746-001 0400 07746-0040600 Install the removed parts in the reverse order of removal. SHIFT DRUM NEEDLE BEARING (CRF10000) Drive out the shift drum needle bearing [1]. Apply engine oil to a new needle bearing. Drive in the needle bearing until it is in position as shown using the special tools. TOOLS: Driver, 15 x 280L 079494710001 Pilot, 12 mm 07746-0040200 Install the removed parts in the reverse order of removal. 115.1 a 116.1 mm (4.534.57 in) «9 v [1] la 14-18 CRANKCASEITRANSMISSIONIBALANCER Do not use a torch to heat the upper crankcase; it may cause warping. Do not use a torch to heat the upper crankcase; it may cause warping. SHIFT CONTROL MOTOR REDUCTION GEAR BEARING (CRF1ODOD) Heat the upper crankcase to 80°C (176°F) evenly using a heat gun. Tap the upper crankcase lightly and remove the bearings. — Radial ball bearing (60722) [1] — Radial ball bearing (69622) [2] Apply engine oil to new bearings. Drive in the bearings squarely with the marking side lacing up until they are fully seated. Install the removed parts in the reverse order of removal. GEARSHIFT SPINDLE NEEDLE BEARING (cnr1ooon) Heat the upper crankcase to 80°C (176°F) evenly using a heat gun. Tap the upper crankcase lightly and remove the gearshift spindle needle bearing [1]. Apply engine oil to a new needle bearing. Drive in the needle bearing with the marking side facing toward the outside of the crankcase until it is in position ' as shown. TOOLS: Seal driver, 14 x 22 mm 07PPD-YE10100 Install the removed parts in the reverse order of removal. 17.7 713.2 mm (0.70 a 0.72 in) 14-19 CRAN KCASE/TRANSMISSIONIBALANCER TRANSMISSION ASSEMBLY Apply engine oil to the gear teeth. rotating surface and bearing. Apply molybdenum oil solution to the spline bushing outer surface, bushing inner and outer surIace. shift fork grooves. Assemble the mainshaft and countershaft. MAINSHAFT (cRF1000/A) M6 GEAR (SZT) M2 GEAR (18T) LOCK WASHER M6 GEAR SPLINE BUSHING WASHER SPLINE WASHER SPLINE WASHER SNAP RING MSIMA GEAR (25/26T) ‘ SNAP RING V SPLINE WASHER M5 GEAR (BOT) {2} M5 GEAR BUSHING THRUST WASHER MAINSHAFT/M1 GEAR (15T) ;l : Gear teeth, rolalmg surfaces : Bushing surfaces, needle bearmg surfaces‘ and shifler gear grooves/spline area 14-20 CRANKCASEITRANSMISSIONIBALANCER MAINSHAFT (CRF1000D) NEEDLE BEAR‘NG @ SEAL RINGS OUTER MAINSHAFT/MZ GEAR (21T) NEEDLE BEARING THRUST WASHER M6 GEAR BUSHING M6 GEAR (3m SF'L‘NE WASHER SNAP RING BUSHING V M5 GEAR (37T) THRUST WASHER \NNER MAINSHAFT/M1 GEAR (1ST) 7! : Gear leelh. rolafing surfaces : Bushing surfaces, needle bearing sur'aces. and shifler gear grooves/spline area 14-21 CRAN KCASE/TRANSMISSIONIBALANCER COUNTERSHAFT (CRF1ODDIA) c1 GEAR (431,) THRUST WASHER C1 GEAR BUSHING NEEDLE BEARING THRUST WASHER c5 GEAR (aaT) \\ ' c4 GEAR (BZT) /\ 9% COLLAR c4 GEAR BUSHING ' LOCK WASHER SF'LINE WASHER ® SPLINE WASHER SNAP RING cs GEAR (37T) C6 GEAR (SIT) C3 GEAR BUSHING COUNTERSHAFT COUNTERSHAFT BEARING SET RING OIL SEAL r631 C2 GEAR BUSHING 02 GEAR (SAT) 7! : Gear IeeIh, roxaxing surfaces : Bushing surfaces, needle bearing surfaces, and shifler gear grooves/spline area 14-22 CRANKCASEITRANSMISSIONIBALANCER COUNTERSHAFT (CRF1ODDD) C2 GEAR (37T) THRUST WASHER NEEDLE BEARING c2 GEAR BUSHING THRUST WASHER ce GEAR (ao‘r) SNAP RING c4 GEAR (am C4 GEAR SPLINE BUSHING LOCK WASHER c1 GEAR (4m C1 GEAR BUSHING COUNTERSHAFT BEARING SET RING '6 OIL SEAL ; I : Gear feefh. rofaling surfaces : Bushing surfaces. needle bearing surfaces. and shifler gear grooves/spline area 14-23 CRAN KCASEITRANSMISSION/BALANCER NOTE . Align the lock washer tabs with the spline washer grooves. . Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load. . Install the snap rings [1] so that the end gap aligns with the groove of the splines. . Make sure that the snap rings are fully seated in the shaft groove after installing them. INSTALLATION MAINSHAFT Install the mainshaft assembly [1] into the upper crankcase. Apply engine oil to the right mainshaft bearing [1]. Install the right mainshaft bearing into the upper crankcase. NOTE . Install the bearing into the crankcase with the marked side facing out. Apply locking agent to the mainshaft bearing set plate bolts threads (page 1-20). Install the mainshaft bearing set plate [1]. Install the mainshaft bearing set plate bolts [2] and tighten them to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) CORRECT [1] INCORRECT CRF1000D shown? ' 14-24 CRANKCASE/TRANSMISSIONIBALANCER SHIFT DRUM/SHIFT FORK Apply engine oil to the shift drum bearing. Install the shift drum [1] and shift drum bearing [2] into the lower crankcase. Apply locking agent to the shift drum bearing setting bolt threads (page 140). Install the shift drum bearing setting bolt [1] and Washer [21- Tighten the bolt to the specified torque. TORQUE:12 N-m (1.2 kgf-m, 9 Ibf-ft) The shift forks have the following identification marks: CRF1000/A: — "C" mark [1]: mainshaft shift fork — No mark [2]: left/right countershaft shift fork CRF1000D: — "L" mark [3]: left mainshaft shift fork — "R" mark [4]: right mainshaft shift fork — "C" mark [5]: countershaft shift fork CRF 1 0000: [3] 14-25 CRAN KCASE/TRANSMISSIONIBALANCER CRF1000/A: CRF10000: CRF1000/A: CRF10000: Apply molybdenum oil solution to the shift fork shaft outer surface. Install the mainshaft shift fork [1] into the M3/M4 gear with the identification marks facing toward the right side of the engine. Install the oountershaft shift forks [2] with the identification marks facing toward the left side of the engine. Insert the mainshaft shift fork shaft [3]. NOTE . Make sure that each shift fork guide pin is positioned in the correct guide grooves of the shift drum. Install the following with the identification marks facing toward the right side of the engine: — Left mainshaft shift fork [1] into the M3 gear — Right mainshaft shift fork [2] into the M4 gear Apply molybdenum oil solution to the shift fork shafts outer surface. Insert the mainshaft shift fork shaft [3]. Install the oountershaft shift forks [4] with the identification marks facing toward the left side of the engine, then insert the shaft [5]. NOTE . Make sure that each shift fork guide pin is positioned in the correct guide grooves of the shift drum. Apply locking agent to the shift drum bearing setting bolt threads (page 140). Install the washer [1] and shift drum bearing setting bolt [2]- Tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) Apply locking agent to the shift drum bearing setting bolt threads (page 140). Install the washer [1] and shift drum bearing setting bolt [2]- Tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) 14-26 CRANKCASEITRANSMISSIONIBALANCER COU NTERSHAFT Install the dowel pin [1] onto the upper crankcase hole. Install the countershaft assembly [2]. NOTE . Align the needle bearing cap hole with the dowel pin. . Align the set ring [3] with the upper crankcase groove. . Align the oil seal [4] flange with the upper crankcase groove. . Apply grease to the oil seal lips. Install the removed parts in the reverse order of removal. CRANKCASE ASSEMBLY Apply liquid sealant (TB1207B manufactured by Three Bond or equivalent) to the crankcase mating surface as shown. NOTE . Do not apply more liquid sealant than necessary. . Do not apply liquid sealant to the crankcase main journal bolts area and the oil passage area. Install the dowel pins [1], oiljointA [2], and oil joint B [3] 1 onto the upper crankcase. [ 1 NOTE . Install the oil joint A with its narrow hole side lacing upper crankcase. [2] Apply molybdenum oil solution to the main journal bearing sliding surlaces on the lower crankcase. Install the lower crankcase onto the upper crankcase. Make sure the upper and lower crankcases are seated securely. Apply molybdenum oil solution to the crankcase main journal bolt threads and seating surfaces. Install the crankcase main journal bolts [1]. Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE:43 N-m (4.4 kgfrm, 32 lbf-ft) 14-27 CRAN KCASE/TRANSMISSIONIBALANCER CRF10000: Install the following: — 6 x40 mm bolt (Blue paint) [1] — Five 6 x 35 mm bolts [2] — Two 6 mm bolts [3] and new sealing washers [4] — Seven 8 mm bolts [5] — Two 8 mm bolts [6] and new sealing washers [7] — 10 mm bolt [8] Tighten the crankcase bolts in a crisscross pattern in 2 or 3 steps. TORQUE: Crankcase 6 x 40 mm bolt: 12 N-m (1.2 mm, 9 lbf-ft) Crankcase 8 mm bolt: 24 N-m (2.4 kgf-m,18lbf-ft) Crankcase 10 mm bolt: 39 N-m (4.0 mm, 29 lbf-ft) Apply locking agent to the cam chain tensioner pivot bo|t threads (page 140). Install the washer [1], cam chain tensioner [2], and cam chain tensioner pivot bolt [3]. Tighten the bolt to the specified torque. TORQUE:23 N-m (2.3 kgf-m, 17 lbf-ft) Install the timing sprocket [4] with its punch mark [5] facing outside as shown Install the cam chain [6]. Apply locking agent to the cam chain guide plate bolts threads (page 1-20). Install the cam chain guide plate [7] and bolts [8] and tighten the bolts securely. Coat a new O»ring [1] with engine oil and install it into the groove in the water hose flange [2]. Install the water hose flange and bolts [3] and tighten the bolts securely. Install the following: CRF1000/A: — Primary drive gear (page 1246) — Clutch (page 12-12) — Gearshift linkage (page 12-19) — Front/rear balancer (page 14-6) — Flywheel (page 11»7) — Cylinder head (page 10-13) — Oil pump (page 9-5) — Starter motor (page 65) — VS sensor (page 4-42) — Gear position switch (page 22-25) CRF1DODD: — Primary drive gear (page 1340) — Dual clutch (page 13-69) — Gearshift linkage (page 13-76) — Front/rear balancer (page 14-6) — Flywheel (page 11»7) — Cylinder head (page 10-13) — Oil pump (page 9-5) — Starter motor (page 65) — Shift control motor/reduction gears (page 13-73) — Mainshaft sensors (page 1348) — VS sensor (page 4-42) — Neutral switch (page 13-82) 14-28 15. CRANKSHAFTIPISTONICYLINDER SERVICE INFORMATION -------------------- n 15.2 TROUBLESHOOTING ------------------------ -~ 15.2 COMPONENT LOCATION ------------------- -- 15-3 CRANKSHAFT .................................. .. 15_4 MAIN JOURNAL BEARING ----------------- -~ 15-6 CRANKPIN BEARING ------------------------ -~ 15-9 PISTON/CYLINDER .......................... "15.12 15-1 CRANKSHAFWPBTOMCYUNDER SERVICE INFORMATION GENERAL ~ The crankcase must be separated to service the crankshaft and pistons and connecting rods. ~ Mark and store the connecting rods. bearing caps, and bearing inserts to be sure oftheircorrect locations for reassembly. ~ The crankpin and main iournal bearing inserts are select fit and are identified by color codes. Select replacement bearings from the code tables. After selecting new bearings, recheck the oil clearance With plastigauge. Incorrect oil clearance can cause major engine damage. ~ Clean the oil passages in the upper crankcase With compressed air before installing the pistons. TROUBLESHOOTING Cylinder compression is too low, hard to starting. or poor performance at low speed ~ Leaking cylinder head gasket ~ Loose spark plug ~ Worn, stuck or broken piston ring ~ Worn or damaged cylinder and piston Cylinder compression too high. overheating, or knocking ~ Excessive carbon built-up on piston head or combustion chamber Excessive smoke ~ Worn cylinder, piston, or piston ring ~ Improper installation of piston rings ~ Scored or scratched piston or cylinder wall Abnormal noise ~ Worn piston pin or piston pin hole ~ Worn connecting rod small end ~ Bent connecting rod ~ Worn cylinder, piston, or piston rings ~ Worn main journal bearings ~ Worn crankpin bearings Engine vibration ~ Excessive crankshaft runout 15-2 CRANKSHAFTIPISTONICYLINDER COMPONENT LOCATION 120° 22 Nm (2A2 kgf'm, 16 mm) + CRF1000D shown: 15-3 CRAN KSHAFTIPISTONICYLINDER CRANKSHAFT Separate the crankcase halves (page 14-13). SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. SERVICE LIMIT: 0.35 mm (0.014 in] If the clearance exceeds the service limit, replace the connecting rod. Recheck and if still out 0' limit, replace the crankshaft. REMOVAL Mark the bearing caps and bearings as you remove them to indicate the correct cylinder for reassembly. Remove the crankpin bearing cap bolts [1] and bearing caps [2]. Remove the crankshaft [3]. INSPECTION Support the crankshaft [1] on both end journals [2]. Set a dial gauge on the crankshaft. Rotate the crankshaft two revolutions (720°) and read the runout. SERVICE LIMIT: [3]: 0.05 mm (0.002 in) Check the balancer drive gear teeth for abnormal wear or damage. [3] i'l [2] [Z] 15-4 Be care/MI not to damage the crankpin, main fall/775i and bearing inserts. INSTALLATION Apply molybdenum oil solution to the main journal bearing [1] sliding surfaces on the upper crankcase and crankpin bearing [2] sliding surfaces on the connecting rods. Apply molybdenum oil solution to the thrust surfaces of the crankshaft as shown. Install the crankshaft [1] onto the upper crankcase and set the connecting rods onto the crankpins. Apply molybdenum oil solution to the crankpin bearing sliding surfaces on the crankpin bearing caps [2]. Install the crankpin bearing caps. NOTE . Align the ID. code number on the crankpin bearing caps and connecting rods. Apply engine oil to new crankpin bearing cap bolt threads and seating surfaces. Install and tighten the crankpin bearing cap bolts [1] to the specified torque in 2 or 3 steps alternately. Further tighten the bolts 120°. TORQUE: 22 N-m (2.2 kgfrm, 16lhf-ft)+120“ Assemble the crankcase halves (page 14-27). CRANKSHAFTIPISTONICYLINDER 15-5 CRANKSHAFTIPISTONICYLINDER MAIN JOURNAL BEARING Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 15-4). BEARING INSPECTION Inspect the main journal bearing inserts [1] on the upper and lower crankcase halves for unusual wear or peeling. Check the bearing tabs for damage. OIL CLEARANCE INSPECTION Clean off any oil Irom the bearing inserts and main 7 journals. Install the crankshaft [1] onto the upper crankcase. Put a strip of plastigauge [2] lengthwise on each main journal avoiding the oil hole. NOTE . Do not rotate the crankshaft during inspection. Install the dowel pins [1]. 15-6 CRANKSHAFT/PISTON/CYLINDER Letters (A, 5 ar C) on the left side of upper crankcase are bearing support I. D. codes from left :0 right. Numbers (1, 2 or 3) on the crank weight are main journal 0.0. codes from left :0 right. Install the lower crankcase onto the upper crankcase. Make sure that the upper and lower crankcase are seated securely. Apply molybdenum oil solution to the crankcase main journal bolt threads and seating surfaces. Install the crankcase main journal bolts [1]. Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque. TORQUE“ N-m (4.4 kgf-m, 32 lbf-ft) Remove the bolts and lower crankcase. Measure the compressed plastigauge at its widest point on each main journal to determine the oil clearance. SERVICE LIMIT: 0.05 mm (0.002 in) If the oil clearance exceeds the service limit, select a replacement bearing. BEARING SELECTION Record the crankcase bearing support |.D. code letters [1] from left side of the upper crankcase as shown. If you are replacing the crankshaft, record the corresponding main journal OD. code numbers [1] from the crank weight. If you are reusing the crankshaft, measure the main journal OD. with a micrometer. 15-7 CRAN KSHAFTIPISTONICYLINDER Cross-reference the main journal and bearing support codes to determine the replacement bearing color code [1]- MAIN JOURNAL BEARING THICKNESS: Thickest I E: Yellow: Thinnest [1] MAIN JOURNAL BEARING SELECTION TABLE: BEARING SUPPORT |.D. CODE A B C 47.000 — 47.006 mm 47.000 — 47.012 mm (1.8504 — 1.3503 in) (1.8506 — 1.3509 in) 47012—47018 mm (1.3509— 1.3511 in) MAIN JOURNAL 44.004—44.010mm O.D. CODE 1 (1.7324 — 1.7327 in) E (Ye"°"") D (6'99") C (3mm) 43.998 — 44.004 mm 2 (1.7322 _1-7324in) D (Green) C (Brown) B (Black) 43.992 —43.998 mm 3 (1.7320 _1-7322in) C (Brown) B (Black) A (Blue) After selecting new bearings, recheck the clearance with a plasligauge. Incorrect clearance can cause severe engine damage. BEARING INSTALLATION Clean the bearing outer surfaces and crankcase bearing supports. Install the main journal bearing inserts [1] onto the crankcase bearing supports, aligning each tab with each groove. 15-8 CRANKSHAFTIPISTONICYLINDER CRANKPIN BEARING Do not Interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 15-4). BEARING INSPECTION Check the bearing inserts [1] for unusual wear or peeling. Check the bearing tabs for damage. OIL CLEARANCE INSPECTION Clean off any oil lrom the bearing inserts and crankpins. Carefully install the crankshaft [1] onto the upper crankcase. Set the connecting rods onto the crankpins. Put a strip 01 plastigauge [2] lengthwise on each crankpin avoiding the oil hole. NOTE . Do not rotate the crankshaft during inspection. Install the crankpin bearing caps [1]. NOTE . Align the ID. code number on the crankpin bearing caps and connecting rods. 15-9 CRAN KSHAFTIPISTONICYLINDER Apply engine oil to the crankpin bearing cap bolt (reuse) threads and seating surfaces. Install and tighten the crankpin bearing cap bolts [1] to the specified torque in 2 or 3 steps alternately. Further tighten the bolts 90‘. TORQUE: 22 N-m (2.2 kgfrm, 16 lhf-ft) + 90" Remove the bearing caps and measure the compressed plastigauge at its widest point on the crankpin to determine the oil clearance. SERVICE LIMIT: 0.065 mm (0.0026 in) If the oil clearance exceeds the service limit. select the correct replacement bearings. BEARING SELECTION Numbers (1, 2, 3 ar Record the connecting rod |.D. code number [1] or 4) on the measure the ID. with the crankpin bearing cap installed connecting rods are without bearing inserts. the connecting rod I.D. codes. Letters(A,E,Car If you are replacing the crankshaft, record the D) on the crank corresponding crankpin O.D. code letter [1]. weightare the crankpin 0.0. codes from left to fight. If you are reusing the crankshaft, measure the crankpin 0D. with a micrometer. 15-10 CRAN KSHAFTIPISTONICYLINDER Cross-reference the connecting rod and crankpln codes to determine the replacement bearing color code [1]. CRANKPIN BEARING THICKNESS: A: Blue: Thickest B: Black: . Yellow: Thinnest CRANKPIN BEARING SELECTION TABLE: CONNECTING ROD |.D. CODE 1 2 3 47.000 — 47.003 mm (1.3504 — 1.8506 in) 47.003 — 47.012 mm (1.8506 — 1.3509 in) 47012—47013 mm (1.3509— 1.3511 in) CRANKPIN 43.992 — 43.998 mm 0.0. CODE A (1.7320 — 1.7322 in) E (Ye"°wl D (6'99") C (Bmwr‘) 43.986 —43.992 mm B (1-7312 _1-7320in) D (Green) C (Brown) B (Black) 43.980 —43.986 mm C (1-7314 _1-7312in) C (Brown) B (Black) A (Blue) After selecting new bearings, recheck the clearance with a plasligauge. Incorrect clearance can cause severe engine damage. BEARING INSTALLATION Clean the bearing outer surfaces, crankpin bearing cap and connecting rod. Install the crankpin bearings [1] onto the bearing cap and connecting rod, aligning each tab with each groove. 15-11 CRAN KSHAFTIPISTONICYLINDER PISTON/CYLINDER Be care/Ml not to damage the piston ring by spreading the ends too far. PISTON/CONNECTING ROD REMOVAL . Before piston removal, place a clean shop towel around the connecting rod to prevent damaging the cylinder sleeve. . Do not tn/ to remove the piston/connecting rod assembly from bottom of the cylinder; the assembly will get stuck in the gap between the cylinder liner and the upper crankcase. . Do not interchange the hearing inserts. They must he installed in their original locations or the correct heating oil clearance may not he obtained, resulting in engine damage. Remove the lollowing: — Transmission (page 14-15) — Crankshaft (page15-4) Remove the piston/connecting rod assembly [1] from the top of the cylinder. PISTON REMOVAL Remove the piston pin clips [1] with pliers. Push the piston pin [2] out of the piston [3] and connecting rod [4], and remove the piston. PISTON RING REMOVAL Spread each piston ring ends and remove them by lifting up at a point opposite the gap. Clean carbon deposits from the piston ring grooves with a ring that will be discarded. NOTE . Never use a wire brush; it will scratch the groove. 15-12 CRAN KSHAFTIPISTONICYLINDER INSPECTION Inspect the following parts for scratches. damage. abnormal wear, or deformation. — Cylinder — Piston — Piston rings — Piston pin — Connecting rod small end Measure each part and calculate the clearance according to CRANKSHAFTIPISTONICYLINDER SPECIFICATIONS (page 1-9). Replace any part if it is out of service limit. PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings. NOTE . Apply engine oil to the piston ring entire surfaces and piston ring grooves. ; a . Avoid piston and piston ring damage during q [1] installation. Install the piston rings with the marked side facing up. — "R" mark: top ring [1] — “RN” mark: second ring [2] To install the oil ring [3], install the spacer [4] first. then install the side rails [5]. —> [1] —> VII/A [2] we: m , _ a 20 mm (0.8 in) Stagger the piston ring end gaps 120” apart from each other. ’7! [2] Stagger the side rail end gaps as shown. After installation, the rings should rotate freely in the 7! ring groove. [AI PISTON INSTALLATION Apply engine oil to the piston pin hole inner surface. Apply molybdenum oil solution to the connecting rod small end inner surface. Assemble the piston [1] and connecting rod [2] with the connecting rod “MJP” mark [3] facing to the piston “MJP” mark [4] side. 2] \ [3] '7a 15-13 CRAN KSHAFTIPISTONICYLINDER Install the piston/ connecting rod assembly with the "IN" mark [3] racing the intake side. Make sure the plston ring compressor toot sits flush on the top surface oflhe cylinder. Apply molybdenum oil solution to the piston pin outer surtace. Install the piston pin [1] and secure it using new piston pin clips [2]. NOTE . Make sure that the piston pin clips are seated securely. . Do not align the piston pin clip end gap with the piston cut-out [3]. PISTON/CONNECTING ROD INSTALLATION Apply engine oil to the piston and cylinder sliding surtace. Install the piston/connecting rod assemblies [1] into the cylinders using a oommercially available piston ring compressor tool [2]. When reusing the connecting rods, they must be installed in their original locations. . While installing the piston, be careful not to damage the top surface of the cylinder, especially around the cylinder bore. . Be careful not to damage the cylinder sleeve with the connecting rod bolt threads. Use the handle 01 a plastic hammer or equivalent tool to tap the piston into the cylinder. Install the following: — Crankshatt(page15-5) — Transmission (page 14-24) PISTON OIL JET REMOVAL] INSTALLATION Remove the piston oil jets [1] and O-rings [2]. Apply engine oil to new O-rings and install them onto the piston oil jets. Install the piston 0“ jets into the holes 01 upper crankcase as shown. 15-14 16. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION -------------------- -- 16-2 ENGINE REMOVAL --------------------------- -~ 16-5 COMPONENT LOCATION ------------------- -- 16-3 ENGINE INSTALLATION ------------------- --1e-1o 16-1 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL ~ A hoist or equivalent is required to support the motorcycle when removing and installing the engine. ~ When removing/installing the engine, tape the lrame around the engine belorenand lor lrame protection. ~ When installing the engine, be sure to tighten the engine mounting lasteners to the specified torque in the specified sequence. If you mistake the torque or sequence, loosen all mounting fasteners, then tighten them again to the specilied torque in the correct sequence. ~ The followmg components can be serviced with the engine installed in the lrame. — Starter motor (page 6-5) — Throttle body (page 7-12) — Water pump (page 8-10) — Oil pump (CRF1000/A) (page 9-5) — Oil pump (CRF‘IDOOD) (page 9-7) — Rocker arm (page 10-6) — Camshaft (page 10-9) — Clutch (CRF1000/A) (page 12-8) — Dual clutch (CRF10000) (page 13-63) — Primary drive gear (CRF1000/A) (page 12-15) — Primary drive gear (CRF‘IOOOD) (page 13-70) — Shift oontrol motor/reduction gears (CRF1000D) (page 13-71) — Gearshilt linkage (CRFiOOO/A) (page 12-17) — Gearshilt linkage (CRF10000) (page 13-74) — Flywheel (page 11-7) — Stator/CKP sensor (page 11-7) — Balancer (page 14-6) ~ The followmg components require engine removal for service. — Cylinder head/valves (page 10-13) — Transmission (page 14-15) — Crankshaft (page 15-4) — Piston/cylinder (page 15-12) 16-2 ENGINE REMOVAL/INSTALLATION \ 5 kgrm, 32 lbf-fl) a 44 N m (4. X >= (3.3 kgrm, 24 mm) 32 Nm COMPONENT LOCATION CRF1000IA m w 9 5 .m m. 2. w m N 0 8 ) (4.5 kgf-m, 32 lbf~fl (4.5 kgrm, 32 mm) 44 N-m 44 Nm 54 Nm M (5.5 kgf-m, 40 mm) @fié (4.5 kgf'm, 32 lbf~fl) (4.5 kgrm, 32 mm) (3.3 kgrm, 24 mm) 16-3 ENGINE REMOVAL/INSTALLATION CRF1000D 32 Mm (323 kgf-m, 24 mm) 80 Nm (3.2 kgrm, 59 lbf-fl) 4“ N'"‘ (425 kgf'm, 32 mm) / 44 Nm K 32 Mm (425 kgf-m, 32 mm) (3.3 kgf'm. 24 lbl‘fl) 44 Nm 44 N 44 Nm w (4.5 kgf~m. 32 mm) (45 mm, 32 mm) (45 kgf'm, 32 mm) J \ r \ \ ‘ 7‘ s ’ / ' ~ ® 32 Nm (3.3 kgf-m, 24 mm) 12 Nm 1.2 k I‘m, 9 lbf-fl 10 N-m ( g ) (1‘0 kgf'm, 7 mm) 16-4 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Support the motorcycle using a safety stand or hoist. Remove the following: — Muffler/exhaust pipe (page 2-16) — Engine oil iilter (page 3-12) — Ignition coil tray (page 5-9) — Radiator (page 8-6) — Radiator reserve tank (page 8-10) — Gearshift spindle cover (CRF1000/A) (page 12-17) — Shift pedal (CRF1000/A) (page 12-21) — Rear brake pedal (page 19-15) — Battery box (page 2145) — EOP switch (CRF1000/A) (page 22-19) — EOP sensor (CRF1000D) (page 22-20) Remove the connector cover [1] by releasing its bosses [2] and slit [3] from the connector clip stay. Disconnect the iollowing connectors: — Rear brake switch 2P (Gray) connector [1] — Sidestand switch 2P (Black) connector [2] — Alternator assembly 6P (Black) connector [3] — Gear position switch 8P (Black) (CRF1000/A) [4] — Shift spindle angle sensor 3P (Blue) connector (CRF1000D) [5] — Inner mainshafl sensor 3P (Black) connector (CRF1000D) [6] — TR sensor 3P (Black) connector (CRF1000D) [7] — Neutral switch terminal (CRF1000D) [8] Release the 02 sensor wire clip [9] from the connector clip stay. CRF1000D: Release the shift spindle angle sensor wire clip [10] from the connector clip stay. 16-5 ENGINE REMOVAL/INSTALLATION Remove the bolts [1] and connector clip stay [2]. Release the luel tank drain hose [1] and breather hose [2] lrom the bracket [3]. Remove the bolts [4] and bracket. Release the alternator assembly wire from the frame: — CRF1000/A (page 114) — CRF1000D (page 115) Disconnect the lollowing: — VS sensor 3P (Black) connector [1] — Outer mainshaft 3P (Black) oonnector (CRF1000D) ‘ [2] — Shift control motor 2P (Black) connector (CRF1000D) [3] 16-6 ENGINE REMOVAL/INSTALLATION Loosen the hose band screw [1] and disconnect the radiator upper hose [2]. Disconnect the ECT sensor 2P (Black) connector [3]. CRF1000/A: Remove the bolt [1] and clutch cable holder [2]. Disconnect the clutch cable [3] from the clutch lifter lever [4]. CRF10000: Disconnect linear solenoid 4P (Black) connector [1]. Remove the wire band [2]. CRF10000: Remove the bolts [1] and clutch EOP sensor cover [2]. Release the linear solenoid wire [3] and main wire harness [4] lrorn the clamp [5]. 16-7 ENGINE REMOVAL/INSTALLATION CRF10000: Disconnect the Vollowing: — Clutch line EOP sensor 3P (Gray) connector [1] — No.1 clutch EOP sensor 3P (Gray) connector [2] — No.2 clutch EOP sensor 3P (Black) connector [3] Remove the bolt [4] and stay [5]. CRF1000D: Disconnect the EOT sensor 2P (Black) connector [1]. CRF1000D: Remove the EOT sensor [2]. Release the 02 sensor 4P (Black) connector clip [3] trom the stay [4]. Remove the bolt [5] and stay. Remove the drive sprocket bolt [1], washer [2], and drive sprocket [3] from the countershafl and drive chain. Remove the bolts [1] and left/right heel guards [2]. 5d ‘0 fl. 16-8 Remove the following: Front lower bolt (10 x 138 mm) [1] Front lower nut (10 mm) [2] Right lower frame bolts (front side, 10 x 20 mm, 10 x 40 mm) [a] Right lower frame bolts (rear side, 10 x 60 mm, 10 x | 75 mm) [4] Right lower frame [5] Support the engine using a jack or other adjustable support. Remove the following: Rear lower bolt (10 x 153 mm) [1] Collar (left side, "L" mark) [2] Rear lower nut (10 mm) [3] Collar (right side, black) [4] Remove the following: Front upper bolts (8 x18 mm) [1] Stay [2] Remove the following: Front middle bolt (10 x 100 mm) [1] Collar (left side, long) [2] Front middle nut (10 mm) [3] Collar (right side, short) [4] Front middle bolts (8 x 87 mm) [5] Front middle nuts (8 mm) [6] Stay (left side) [7] Stay (right side) [8] 16-9 ENGINE REMOVAL/INSTALLATION Remove the following: — Rear upper bolt (8 x 217 mm) [1] — Collar (left side) [2] — Rear upper nut (8 mm) [3] — Collar (right side, long) [4] — Rear upper bolts (8 x 25 mm) [5] — Collars (right side, short) [6] — Slay (right side) [7] Remove the swingarm pivot nut [1], pivot bolt [2]. Pull the swingarm rearward. Dim‘ng englne Carefully maneuver the engine and remove it out of the removal, hold the frame to the right. engine securelyand NOTE be Care/MI not to y , damage the game . Note the direction of the bolts. Endangina . Mark and store all the bolts, nuts, and collars to ensure that they are reinstalled in their original locations. ENGINE INSTALLATION Place the jack or other adjustable support under the engine. Dim‘ng englne Place the engine in the frame, then loosely install all the lnstallation, hold the bolts, nuts and collars into the correct position. engine securelyand NOTE be Care/MI not to y ‘ damage the game . All the bolts and nuts loosely install, then tighten the and engine_ bolts and nuts to the specified torque in the specified sequence. . Carefully align the mounting points with the jack to prevent damage to engine, frame, water hoses, brake pipes, wires, and cables. . Route the hoses, wires, and cables properly (page 1-26) . The jack height must be continually adjusted to relieve stress for ease bolt installation. Loosely install the following. — Right lower frame [1] — Front lower bolt (10 x 138 mm) [2] — Front lower nut (10 mm) [3] — Right lower frame bolts (rear side, 10 x 60 mm, 10 x _ 75 mm) [4] — Right lower frame bolts (front side, 10 x 20 mm, 10 x ‘ 40 mm) [5] ‘ Tighten the right lower frame bolts (rear side) first, then front side bolts to the specified torque. TORQUE: 44 N-m (4.5 kgfrm, 32 lhf-ft) Remove the jack under the engine, plaoe the motorcycle in an upright position. 16-10 ENGINE REMOVAL/INSTALLATION Tighten the swingarm pivot nut to the specified torque. TORQUE: 80 N-m (8.2 kgf-m, 59 Ihf-fl) NOTE . Apply engine oil to the swingarm pivot nut [1] threads and seating surface. . Apply a thin coat of grease to the swingarm pivot bolt [2] sliding surface. Tighten the rear lower nut (10 mm) [1] to the specified torque. TORQUE: 44 N-m (4.5 kgf-m, 32 lhf-ft) Tighten the front lower nut (10 mm) [1] to the specified torque. TORQUE: 44 N-m (4.5 kgf-m, 32 lhf-ft) Tighten the front middle nuts (8 mm) [1] to the specified torque. TORQUE: 32 N-m (3.3 kgf-m, 24 lhf-ft) Tighten the front middle nuts (10 mm) [2] to the specified torque. TORQUE: 44 N-m (4.5 kgf-m, 32 lhf-ft) 16-11 ENGINE REMOVAL/INSTALLATION Tighten the front upper bolt (right side) [1] first, then the left side bolts [2] to the specified torque. TORQUE: 32 N-m (3.3 kgf-m, 24 lhf-ft) Tighten the rear upper bolts (8 x 25 mm) [1] to the specified torque. TORQUE: 32 N-m (3.3 kgf-m, 24 lhf-ft) Tighten the rear upper nut (8 mm) [2] to the specified torque. TORQUE: 32 N-m (3.3 kgf-m, 24 lhf-ft) Install the left/right hee| guards [1] and bolts [2], and tighten the bolts securely. Install the drive sprocket [1] to the drive chain and countershaft with the mark [2] side facing outside. Install the washer [3] and drive sprocket bolt [4]. Tighten the drive sprocket bolt to the specified torque. TORQUE: 54 N-m (5.5 kgf-m, 40 lhf-ft) 16-12 ENGINE REMOVAL/INSTALLATION Install the stay [1] and bolt [2], and tighten the bolt securely. Install the 02 sensor 4P (Black) connector clip [3] to the stay. CRF1000D: Install the EOT sensor [4] and a new sealing washer [5], and tighten it to the specified torque. TORQUE: 15 N-m (1.5 kgf-m, 11 lhf-ft) CRF1000D: Connect the EOT sensor 2P (Black) connector [6]. m [4]/[5]\4I CRF10000: Connect the following: 7" . 'LL — Clutch Iine EOP sensor 3P (Gray) connector [1] — No.1 clutch EOP sensor 3P (Gray) connector [2] — No.2 clutch EOP sensor 3P (Black) connector [3] Install the stay [4] and bolt [5], and tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-lt) CRF10000: Install the clutch EOP sensor cover [1] and bolts [2], and tighten the bolts to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-lt) Clamp the linear solenoid wire [3] and main wire harness [4] with the wire clamp [5]. CRF10000: Connect linear solenoid 4P (Black) connector [1]. Install the wire band [2]. 16-13 ENGINE REMOVAL/INSTALLATION CRF1000/A: Connect the clutch cable [1] to the clutch lifter arm [2]. Install the clutch cable holder [3] and bolt [4] and tighten the bolt securely. Connect the ECT sensor 2P (Black) connector [1]. Connect the radiator upper hose [2] and tighten the hose band screw [3] to the specified range (page 8»8). Connect the following: — VS sensor 3P (Black) connector [1] — Outer mainshaft 3P (Black) connector (CRF1000D) [2] — Shift control motor 2P (Black) connector (CRF1000D) [3] 16-14 ENGINE REMOVAL/INSTALLATION Jill V Install the bracket [1] and bolts [2], and tighten the bolts securely. Install the fuel tank drain hose [3] and breather hose [4] to the bracket. Install the connector clip stay [1] and bolts [2], and tighten the bolts securely. [1]; Install the 02 sensor wire clip [1] to the connector clip stay. CRF1000D: Install the shift spindle angle sensor wire clip [2] to the connector clip stay. Connect the following connectors: — Rear brake switch 2P (Gray) connector [3] — Sidestand switch 2P (Black) connector [4] [5] — Alternator assembly 6P (Black) connector [5] — Gear position switch 8P (Black) (CRF1000/A) [6] — Shift spindle angle sensor 3P (Blue) connector (CRF1000D) [7] — Inner mainshafl sensor 3P (Black) connector (CRF1000D) [8] — TR sensor 3P (Black) connector (CRF1000D) [9] — Neutral switch terminal (CRF1000D) [10] mum m 16-15 ENGINE REMOVAL/INSTALLATION Install the connector cover [1] by aligning its bosses [2] and slit [3] with the connector clip stay holes and tab. Install the alternator assembly wire onto the frame: — CRF1000/A (page 114) — CRF1000D (page 115) Install the following: — Muffler/exhaust pipe (page 2-16) — Engine oil filter (page 3-12) — Ignition coil tray (page 5-9) — Radiator (page 8-6) — Radiator reserve tank (page 8-10) — Shift pedal (CRF1000/A) (page 12-21) — Gearshift spindle oover (CRFiODO/A) (page 12-21) — Rear brake pedal (page 19-15) — Battery box (page 2145) — EOP switch (CRF1000/A) (page 22-19) — EOP sensor (CRF1000D) (page 22-20) Install the removed parts in the reverse order of removal. 16-16 17. FRONT WHEEL/SUSPENSIONISTEERING SERVICE INFORMATION -------------------- .. 17.2 TROUBLESHOOTING ------------------------ .. 17.2 COMPONENT LOCATION ------------------- -- 17-3 HANDLEBAR .................................... .. 17.4 FRONT WHEEL -------------------------------- “17.10 FORK ............................................. "17.14 STEERING STEM ----------------------------- "17.22 17-1 FRONT WHEELISUSPENSIONISTEERING SERVICE INFORMATION GENERAL ~ When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist. ~ Aluminum taper handle is equipped in this motorcycle. The scratches or bend of the handlebar may cause breakage. Replace the damaged handlebar With a new one. ~ A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Do not operate the brake lever and pedal after removing the caliper and front wheel. After the front wheel installation, check the brake operation by applying the brake lever. For brake system information (page 19-2). TROUBLESHOOTING Hard steering ~ Steering head bearing adiustment nut too tight ~ Worn or damaged steering head bearings ~ Bent steering stem ~ Insufficient tire pressure ~ Faulty tire Steers to one side or does not track straight ~ Damaged or loose steering head bearings ~ Loose steering stern adjusting nut ~ Bent forks ~ Unevenly adjusted right and left forks ~ Bent axle ~ Worn or damaged wheel bearings ~ Bent frame Front wheel wobbling ~ Bent rim ~ Bent spoke ~ Worn or damaged front wheel bearings ~ Insufficient tire pressure ~ Faulty tire ~ Unbalanced front tire and wheel Front wheel hard to turn ~ Faulty front wheel bearing ~ Bent front axle ~ Front brake drag Soft suspension ~ Insufficient fluid in fork ~ Incorrect fork fluid weight ~ Weak fork springs ~ Insufficient tire pressure Stiff suspension ~ Bent fork pipes ~ Too much fluid in fork ~ Incorrect fork fluid weight ~ Clogged fork fluid passage Front suspension noise ~ Insufficient fluid in fork ~ Loose fork fasteners 17-2 FRONT WHEELISUSPENSIONISTEERING COMPONENT LOCATION CRF1000D (ED model) shown: CRF1000: 22 N-m (2A2 kgfvm, 16 \bf-fl) ' 25 Mn (25 kgfvm.18|bf-ft) 45 Mm (415 kgf-m. 33 mm) 22 N-m (2.2 kgf-m.16|bl-fl) so N-m (6.1 kgf-m, 44 mm) 17-3 FRONT WHEELISUSPENSIONISTEERING HAN DLEBAR REMOVAL Remove the rearview mirrors [1]. Remove the knuckle guards (page 2-5). Remove the wire clamp [1] and disconnect the front brake light switch connectors [2]. Remove the bolts [1], holder [2], and front brake master cylinder [3]. Remove the screw/washers [1] and separate the right handlebar switch housing [2]. Remove the switch housing/throttle grip pipe [3]. 17-4 FRONT WHEEL/SUSPENSIONISTEERING CRF1000/A: Remove the wire clamp [1] and disconnect the clutch switch connectors [2]. CRleloD: Remove the wire clamp [1] and disconnect the parking brake switch connectors [2]. CRF1000/A: Remove the bolts [1], holder [2], and clutch lever assembly [3]. CRleloD: Remove the bolts [1], holder [2], and parking brake lever assembly [3]. 17-5 FRONT WHEELISUSPENSIONISTEERING Remove the screw/washers [1] and left handlebar switch housing [2]. Remove the handlebar grip [3] if it necessary. Remove the caps [1]. Remove the bolts [2], handlebar upper holders [3], and ' handlebar [4]. Check the handlebar for scratches or bend. If the handlebar is damaged, replace with a new one (page 17-7). HANDLEBAR WEIGHT REMOVAL] INSTALLATION Remove the Iollowing: Handlebar weight bolt [1] Rubber [2] (except CRF1000) Handlebar weight A [3] Snap ring [4] Handlebar weight rubbers [5] Handlebar weight B [6] O-ring [7] Installation is in the reverse order of removal. NOTE . Always replace the handlebar weight bolt, O-ring. snap ring, and handlebar weight rubbers with new ones. . Install the handlebar weight mbbers as shown. TORQUE: Handlebar weight bolt: 55 N'm (5.6 ngm, 41 lbf‘ft) CRF1OOU: a [7] v [11v CRF1000A/D: 17-6 FRONT WHEEL/SUSPENSIONISTEERING HANDLEBAR LOWER HOLDER REMOVAL/INSTALLATION Remove the handlebar (page 17-4). Temporarily install the handlebar [1] and handlebar upper holders [2] that you removed and tighten the socket bolts [3]. Remove the nuts [4], washers [5], lower holders [6]/ handlebar assembly, washers [7], and damper rubbers [8] lrorn the top bridge. Remove the handlebar from the lower holders. Install the damper rubbers, washers, and lower holders to the top bridge. Temporarily install the handlebar on the lower holders to secure the lower holders. Install the washers and nuts and tighten the nuts to the specified torque. TORQUE: 39 N-m (4.0 kgfrm, 29 lbf-ft) Remove the handlebar from the lower holders. INSTALLATION NOTE . The scratches or bend of the handlebar may cause breakage. Replaoe the damaged handlebar with a new one. . Route the hoses, cables, and wires properly (page 1-26). Clean the inside surfaoe of the handlebar grip [1]. [1] Apply Honda Bond A or an equivalent to the inside surlace oi the grip and outside surfaoe of the handlebar [2]- Wait 3 — 5 minutes and install the grip. Allow the adhesive Rotate the grip tor even application oi the adhesive. . to dry for 1 hour \ before using. 17-7 FRONT WHEELISUSPENSIONISTEERING Place the handlebar [1] on the lower holders while aligning its paint mark [2] on the handlebar with the > edge of the lower holders. Install the handlebar upper holders [3]. Install the socket bolts [4]. Tighten the iront bolts first, then tighten the rear bolts to the specified torque. TORQUE: 32 N-m (3.3 kgf'm, 24 Ibf-ft] Install the caps [5]. Install the left handlebar switch housing [1] by aligning its locating pin with the hole in the handlebar. Tighten the upper screw/washer [2] iirst, then the lower screw/washer [3] to the specified torque. TORQUE:2.5 N‘m (0.3 kgf-m, 1.8 let) CRF1000/A: Install the clutch lever assembly [1] by aligning its end with the paint mark [2] on the handlebar. Install the holder [3] with its punch mark [4] iacing up. Tighten the upper bolt [5] first, then the lower bolt [6]. CRleloD: Install the parking brake lever assembly [1] by aligning its end with the paint mark [2] on the handlebar. Install the holder [3] with its punch mark [4] iacing up. Tighten the upper bolt [5] first, then the lower bolt [6]. 17-8 FRONT WHEEL/SUSPENSIONISTEERING CRF1000/A: Install the wire clamp [1] and connect the clutch switch connectors [2]. CRleloD: Install the wire clamp [1] and connect the parking brake switch connectors [2]. Apply grease to the throttle pipe flange groove. Install the right handlebar switch housing/throttle pipe [1] aligning its location pin with the hole in the handlebar. Tighten the upper screw/washer [1] iirst, then the lower screw/washer [2] to the specified torque. TORQUE:2.5 N-m (0.3 kgt-m, 1.8 left) 17-9 FRONT WHEELISUSPENSIONISTEERING Install the front brake master cylinder [1] by aligning its end with the paint mark [2] on the handlebar. Install the holder [3] with its ' P" mark [4] facing up. Tighten the upper bolt [5] first, then the lower bolt [6] to the specified torque. TORQUE:9.B N‘m (1.0 kgf-m, 7.2 lbfrft) Install the wire clamp [1] and connect the front brake light switch connectors [2]. Install the knuckle guards (page 2-5). Install the rearview mirrors [1]. FRONT WHEEL REMOVAL Remove the front brake caliper mounting bolts [1] and slide the brake caliper/bracket assembly [2]. NOTE . Do not suspend the brake caliper/bracket assembly from the brake hose. Do not twist the brake hose. . Do not operate the brake lever after removing the front wheel. 17-10 FRONT WHEEL/SUSPENSIONISTEERING ED model: Remove the axle cap [1]. (R‘gm side, Remove the Iront axle nut [2]. Loosen the left Iront axle holder pinch bolts [3]. b Loosen the right front axle holder pinch bolts [4]. {I k Support the motorcycle using a saIety stand or hoist, raise the tram wheel off the ground. ’ Remove the front axle [5], Iront wheel, and side collars [e]. INSPECTION Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the outer race fits tightly in the wheel hub. Inspect the Iollowing parts for damage, abnormal wear, deformation, or bend. — Front axle — Front wheel Measure each part according to FRONT WHEEL/ SUSPENSION/STEERING SPECIFICATIONS (page 1» 10). Replace any part it it is out of service limit. WHEEL BALANCE NOTE . Carefully check balance before installing the wheel. . The wheel balance must be checked when the tire is remounted. Note the rotating direction mark [1] on the tire, and upon 3 tire installation, always til the tire so that the mark faces I I in the normal rotating direction. NOTE . For optimum balance, the tire balance mark [2] (light mass point: a paint dot on the side wall) must be located next to the valve stem [3]. Remount the tire if necessary. Mount the wheel, tire, and brake disc assembly on an inspection stand [1]. Spin the wheel, allow it to stop, and mark the lowest (heaviest) part at the wheel with chalk. Do this 2 or 3 times to verify the heaviest area. lithe wheel is balanced. it will not stop consistently in the same position. To balance the wheel. install a new balance weight on the lightest side of the rim, on 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 g (2.1 oz) to the wheel. 17-11 FRONT WHEELISUSPENSIONISTEERING DISASSEMBLYIASSEMBLY a? v FRONT BRAKE DISC BOLTS 20 NM (2.0 kgfvm. 15 |le) fig DUST SEAL E§ v BEARING (GOOAUU) «5" v PULSER RING BOLTS (Except CRF1000) 7.0 N-m (0.7 kgfvm. 5.2 lbfvft) RlGHT BRAKE DISC DISTANCE COLLAR % v BEARING (GOOAUU) PULSER RING (Except CRF1000) DUST SEAL ‘3’ 402’ ram ~03 FRONT BRAKE DISC BOLTS 20 Nm (2.0 kgf-m,15lbfvft) LEFT BRAKE DISC NOTE A InStall the duSt Seals until they are flush with the wheel hub Surface. A Apply grease to the duSt Seal IipS. A InStall the brake disc with the ":;>“ mark [1] facing the normal rotating direction. 17-12 FRONT WHEEL/SUSPENSIONISTEERING WHEEL CENTER ADJUSTMENT Place the rim [1] on a work bench. 1 Place the hub [2] in the center of the rim, and begin the [ ] lacing with new spokes. Adjust the hub position so the distance irorn the hub left 23-5 - 30-5 mm end surface to the side 01 the rim is 28.5 — 30.5 mm (1.12— 1.20 in) (1.12— 1.20m) as shown. ._. WHEEL BEARING REPLACEMENT Replace the wheel Install the bearing remover head [1] into the bearing [2]. healmgs m pairs. Do not reuse old bearings. From the opposite side, install the bearing remover shaft [3] and drive the bearing out of the wheel hub. TOOLS: Bearing remover head, 20 mm 07746-0050600 Bearing remover shaft 07746-0050100 Remove the distance collar and drive out the other bearing. Never install the old Drive in a new left bearing [1] squarely with the marked hearings. Once the side facing up until fully seated. bearings have been removed, the hearings must be Drive in a new right bearing squarely with the marked replaced with new side facing up until it is seated on the collar. anes. Install the distance collar. TOOLS: Driver [2] 07749-0010000 Attachment, 42 x 47 mm [3] 07746-0010300 Pilot, 20 mm [4] 07746-0040500 N OT E Replace the wheel hearings in pairs. 17-13 FRONT WHEELISUSPENSIONISTEERING INSTALLATION Install the side collars [1] to the front wheel. Apply a thin coat of grease to the front axle sliding surface. Install the front wheel between the forks. Align the surfaces of Install the front axle [2] from right side. the axle and right Ti , . ghten the rIght front axle holder pInch bolts [4] to the Wk [3] as Show," specified torque. TORQUE: 22 N-m (2.2 kgf'm, 16 lbf-ft) Install and tighten the axle nut [5] to the specified torque. TORQUE: 60 N-m (6.1 kgf'm,44lbf-ft) Loosen the right front axle holder pinch bolts. Tighten the left front axle holder pinch bolts [6] to the specified torque. TORQUE: 22 N-m (2.2 kgf'm, 16 Ibf-ft) Install the front brake calipers (page 19-18). With the front brake applied, pump the forks up and down several times to seat the axle and check brake operation. Tighten the right front axle holder pinch bolts to the specified torque. TORQUE: 22 N-m (2.2 kgf'm, 16 lbf-ft) ED model: Install the axle cap [7]. Check the clearance gap between the front wheel speed sensor bracket and pulser ring (page 20-21). FORK REMOVAL Remove the following: — Front fender (page 2-9) — Front wheel (page 1740) — Front speed sensor (CRFiOOOA/D) (page 20-20) Loosen the top bridge pinch bolts [1]. Be careful not to If the fork will be disassembled, loosen the fork bolts [2] damage the fork at this point, but do not remove yet. b0” when [omen/V7? Loosen the fork bottom bridge pinch bolts [3] by holding I ' the forks then remove it. 17-14 FRONT WHEEL/SUSPENSIONISTEERING When disassembling the fork, turn the pre»load adjuster [1] and rebound adjuster [2] counterclockwise to the softest position (be sure to record the number of turns trorn the starting position). DISASSEMBLY Be careful not to Remove the tork bolt [1]. damage the folk bolt when removing it. Push the outer pipe [1] slowly down, and gently seat the dust seal [2] onto the axle holder [3]. / [1] [2] Attach the special tool to the spring collar holes [1]. TOOL: Spring collar holder [2] 070MF-MEZC11D Compress the spring collar [3] with the spring collar holder. Insert the special tool between the lock nut [4] and spring collar. TOOL: Stopper plate [5] 070MF-MBZC130 17-15 FRONT WHEELISUSPENSIONISTEERING Be carelulnot to Loosen the lork bolt [1] while holding the lock nut [2]. damage the folk bolt when loosening it. Remove the lollowing: — Fork bolt assembly [1] — O-ring [2] — Spring seatstopper[3] Remove the stopper plate [4] and spring collar holder [5]- Remove the spring collar [6]. Pour out the fork fluid by pumping the outer pipe [1] several times. Pour out the fork lluid from the fork damper by pumping the damper rod [2] several times. Remove the lork spring [3]. Hold the axle holder in a vise with soft jaws or a shop towel. Remove the fork center bolt [1] and sealing washer [2]. [4] [6] [5] 17-16 Do not scratch the [ark pipe sliding surface. FRONT WHEEL/SUSPENSIONISTEERING Remove the fork damper assembly [1] and centering plate [2]. Remove the dust seal [1]. Remove the oil seal stopper ring [2]. Pull the slide pipe assembly [1] out until you feel resistance from the slider bushing. Then move it in and out, tapping the bushing lightly until the outer pipe [2] separates from the slide pipe assembly. The guide bushing will be forced out by the slider bushing. Remove the following: — Slider bushing [1] — Guide bushing [2] — Back-up ring [3] — Oilseal [4] — Stopperring[5] — Dustsea|[6] NOTE . Do not remove the slider bushing unless it is necessary to replace with a new one. [2] [1] [5] [3] 17-17 FRONT WHEELISUSPENSIONISTEERING INSPECTION Inspect the Iollowing parts for damage, abnormal wear. detormation, looseness or bend. — Fork bolt assembly — Outer pipe/slide pipe assembly — Fork dumper — Spring seatstopper — Spring collar — Fork spring — Guide bushing — Slider bushing — Back-up ring Measure each part according to FRONT WHEEL/ SUSPENSION/STEERING SPECIFICATIONS (page 140). Replace any part it it is out of service limit. ASSEMBLY FORK DAMF-ER LOCK NUT FORK BOLT ASSEMBLY FORK DAMPER . , . 35 N-m 3.6 k f-m. 26 Ibm SLIDE PIPE 20 N m (2.0 kgf m. 15 Ibf n) I g ) ASSEMBLY I 5 SPRING SEAT I , STOPPER SLIDER ‘ BUSHING ‘ FORK AXLE HOLDER v I F'INCH BOLTS SS'SfiNG 22 Nm (2.2 kgfvm,16lbfvfl) BACK-UF- W STOPPER RING / DUST SEAL f I 9' 4. SEALING l I‘ I SPRING COLLAR FORK CENTER BOLT WASHER 34 Nm (3.5 kgf-m, 25 lbfvfl) CENTERING FLATE FORK SF-RING . Before assembly, wash all parts with a high flash point or non»flammable Solvent and blow them dry. . When installing the fork dust seal and oil seal, wrap the edge and groove OI the slide pipe with tape [1]. 17-18 FRONT WHEEL/SUSPENSIONISTEERING Install the all seal with its marked side lacing to wan1 the axle holder. See illustration for correct seating. Do not scratch the fork pipe sliding surface. Apply Iork fluid to new dust seal and oil seal lips. Install the dust seal [1], stopper ring [2] and oil seal [3]. Install the back-up ring [4], guide bushing [5]. Install the slider bushing [6] if it is removed. NOTE . Remove any burrs from the bushing mating surface, being careIuI not to peel off the coating. . Do not open the slider bushing slit more than necessary. Install the slide pipe assemny [7] into the outer pipe [8]. Put the guide bushing [1], back-up ring [2] and oil seal [3] on the outer pipe. Put the special tool on the 0“ seal. TOOL: Fork seal driver, 45.2 mm [4] 07KMD-K230100 Drive the oil seal with the guide bushing and back-up ring into the outer pipe until the stopper ring groove [5] is visible using the special tools. Install the stopper ring [1] into the groove securely. Install the dust seal [2]. Install the Iork damper assembly [1] and centering plate [2]. [3] [6] [3] g! % é [2] [1] 17-19 FRONT WHEELISUSPENSIONISTEERING Install the socket bolt [1] with a new sealing washer [2]. ’ ’ I ’ [II/[2] @ Hold the axle holder In a vise wrth soft Jaws or a shop [I v towel. Tighten the center bolt to the specified torque. TORQUE: 34 N-m (3.5 kgf'm, 25 Ibf-ft) Pour the specified amount of reoommended fork fluid. RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W (SS—47) FORK FLUID CAPACITY: 721 t 2.5 cm3 (24.4 t 0.1 us 02, 25.4 t 0.1 Imp oz) Bleed the air from the fork as follows: 1. Extend the fork, cover the top of the outer pipe [1] with your hand and compress the fork slowly. 2. Remove your hand and extend the fork slowly. Repeat above prooedure 2 or 3 times. 3. Install the special tool to the fork damper rod [2]. TOOL: Damper rod holder [3] D7DMF-MBZC120 Pump the fork damper rod slowly 8 — 10 times. Slowly push the outer pipe [1], and gently seat the dust seal [2] onto the axle holder [3] and leave it for 5 minutes. [1] Be sure the oil/eve! After the oil level stabilizes, measure the oil level from IS the same in the the top of the outer pipe. hoth forks. FORK FLUID LEVEL: 95.0 mm (3.74 in) [3] [2] 17-20 Be careful not to damage the fork man when llghtenlng il. FRONT WHEEL/SUSPENSIONISTEERING Install the fork spring [1] into the slide pipe assembly with the tightly wound side facing down. Install the spring collar [2] and spring seat stopper [3]. Clench the lock nut [1] until it is fully seated. Attach the special tool to the spring collar holes [2]. TOOL: Spring collar holder [3] 070MF-MEZC11D While pulling the damper rod holder [4] up, compress the spring collar [5] with the special tool. Insert the special tool between the lock nut and spring seat stopper [6]. TOOL: Stopper plate [7] 070MF-MEZC13D Remove the damper rod holder. When installing the fork bolt assembly [1], turn the rebound adjuster [2] counterclockwise to the softest position. Apply fork fluid to a new O»ring [3] and install it to the fork bolt assembly. Install the fork bolt assembly to the fork damper until it is fully seated. Tighten the fork bolt to the specified torque while holding the lock nut [1]. TOROUE:20 N-m (2.0 kgf'm, 15 lbf-ft) Remove the stopper plate [2] and spring collar holder [3]- / [3] /{11 [1] Down 17-21 FRONT WHEELISUSPENSIONISTEERING Tighten the [ark bolt Install the fork bolt [1]. [1] alter Installing the [ark slider Into the steering stem. INSTALLATION Install the torks through the bottom bridge and top bridge so that the end of the outer pipe [1] is aligned with the top bridge [2] upper surface. Tighten the bottom bridge pinch bolts [3] to the specified torque. TORQUE:25 N-m (2.5 kgfrm, 18 lbf-ft) Be carefulnotto If the fork bolt [4] is loosened, tighten it to the specified ( damage the fork torque. "°” “"9” "We"? TORQUE: 35 N-m (3.6 kgfrm, 26 lbf-ft) Tighten the top bridge pinch bolts [5] to the specified torque. TORQUE:22 N-m (2.2 kgfrm, 16 lbf-ft) Return the pre»load and rebound damping adjusters to the original positions as noted during disassembly. — Front speed sensor (CRF1000A/D) (page 20-20) — Front wheel (page 1744) — Front fender (page 2-9) STEERING STEM REMOVAL Remove the air cleaner case (page 7-11). Remove the handlebar lower holder (page 17-7). Disconnect the immobilizer receiver 4P (Black) [1] and ignition switch 2P (Brown) [2] connectors. 17-22 FRONT WHEEL/SUSPENSIONISTEERING Remove the wire band [1]. [3] [2] [4] [1] Remove the bolt [2]. Release the wire clips [3] from the stay [4]. Release the iollowing: — Handlebar switch wire clips [1] Front brake hose A [2] Throttle cables [3] Clutch cable [4] (CRF1000/A) Parking brake cable [4] (CRF10000) Remove the steering stem nut [1]. Remove the forks (page 17-14). Remove the top bridge [2]. Remove the bolt [1] and brake hose clamp [2]. 17-23 FRONT WHEELISUSPENSIONISTEERING Loosen and remove the steering stem adjusting nut [1] using the special tool. TOOL: Steering stem socket [2] 07916-KA50100 Remove the iollowing: — Upper dust seal [1] Upper inner race [2] Upper bearing [3] Steering stem [4] Lower bearing [5] BEARING REPLACEMENT Replace the Remove the upper outer race using a special tool. bearing outer and lime! races as a TOOLS: set. Remover attachment [1] 07953-MJ10100 Remover handle [2] 07953-MJ10200 Remove the lower outer race using the special tool and suitable shaft. TOOL: Bearing remover [1] 079464710500 17-24 FRONT WHEEL/SUSPENSIONISTEERING Temporarily install the steering stem nut [1] onto the steering stem [2] to prevent the threads from being damaged when removing the lower inner race [3] from the steering stem. 2] [4] Remove the lower inner race with a chisel or equivalent tools, being careful not to damage the steering stern. Remove the lower dust seal [4]. Apply specified grease to a new lower dust seal lips (page 143). Install the dust seal [1] to the steering stem [2]. Install a new lower inner race [3] using a hydraulic press and special tool. TOOL: Inner driver, 30 x 36 x 300 L [4] 07946-M300000 Drive in a new upper outer race [1] using the special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 42 x 47 mm [3] 07746-0010300 Drive in a new lower outer race [1] using the special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 52 x 55 mm [3] 07746-0010400 17-25 FRONT WHEELISUSPENSIONISTEERING INSTALLATION r-fin @ :BEARINGS, BEARING RACES,DUST SEALS ‘ LOWER BEARING LOWER OUTER RACE \ /\ \. LOWER INNER RACE/g / LOWER DUST SEAL t». STEERING STEM 10 Nm (1.0 kgf'm, 7 mm) Apply specified grease (page 1-23) to the upper and lower bearings and bearing races. Install the following: — Lower bearing [1] — Steering stem [2] — Upper bearing [3] — Upper inner race [4] — Upper dust seal [5] Apply 0.10 — 0.30 g (0.004 — 0.011 oz) of urea based multi»purpose extreme pressure grease NLGI #2 (EXCELITE EP2 manufactured by KYODO YUSHI 00., LTD. or equivalent) to the steering stern adjusting nut [1] threads. Tighten the adjusting nut to the initial torque by holding the steering stern. TOOL: Steering stern socket [2] 07916-KA5D100 TORQUE:15 N-m (1.5 kgfrm, 11 lbf-ft] FRONT BRAKE HOSE CLAMP MOUNTING BOLT STEERING STEM NUT STEERING STEM ADJUSTING NUT 17-26 FRONT WHEEL/SUSPENSIONISTEERING Move the steering stem [1] right and left, lock-to-Iock. five times to seat the bearings. Retighten the steering stem adjusting nut [1] to the specified torque using a special tool. TOOL: Steering stem socket [2] 07916-KA50100 TORQUE:15 N-m (1.5 kgf'm, 11 Ibf-ft) Recheck that the steering stern moves smoothly without play or binding. Install the brake hose clamp [1] and bolt [2] and tighten the bolt to the specified torque. TORQUE: 10 N-m (1.0 kgf'm, 7 lbfrft) Install the top bridge [1]. Install the steering stem nut [2], but do not tighten it yet. Install the forks (page 17-22). Tighten the steering stem nut to the specified torque. TORQUE:100 N'm (10.2 kgf'm, 74 Ibf-ft) Turn the steering stem left and right, Iock»to-Iock several times to make sure the steering stern moves smoothly without play or binding. 17-27 FRONT WHEELISUSPENSIONISTEERING Install the following: — Clutch cable [1] (CRF1000/A) Parking brake cable [1] (CRF1ODOD) Throttle cables [2] Front brake hose A [3] Handlebar switch wire clips [4] Install the stay [1]. NOTE . Align the boss of stay with the hole of the frame. Install the bolt [1] and tighten it securely. Install the wire clips [2] to the stay [3]. Install the wire band [4]. Connect the immobilizer receiver 4P (Black) [1] and ignition switch 2P (Brown) [2] connectors and install them to the ignition coil tray. Install the air cleaner case (page 7-11). Install the handlebar lower holder (page 17-7). 17-28 18. REAR WHEEL/SUSPENSION SERVICE INFORMATION -------------------- -- 18-2 SHOCK ABSORBER -------------------------- -- 18-8 TROUBLESHOOTING ------------------------ -~ 18-2 CUSHION LINKAGE --------------------------- -~ 18-9 COMPONENT LOCATION ------------------- -- 18-3 SWINGARM ------------------------------------- --1s-12 REAR WHEEL ----------------------------------- -~ 18-4 18-1 REAR WHEEL/SUSPENSION SERVICE INFORMATION GENERAL ~ When servicing the rear wheel and suspension, support the motorcycle using a safety stand or hoist. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. After the rear wheel installation, check the brake operation by applying the brake pedal. Use Honda Genuine replacement bolts and nuts for all suspension pivot and mounting point. For brake system information (page 19-2). For wheel balance inspection (page 17-11). For driven sprocket inspection (page 3-17). TROUBLESHOOTING Steers to one side or does not track straight ~ Drive chain adjusters not adjusted equally ~ Bent axle ~ Bent frame ~ Worn swmgarm pivot components Rear wheel wobbling Bent rim Unbalanced tire and wheel Faulty tire Worn wheel bearings Worn driven flange bearings Insufficient tire pressure Damaged suspension or swingarm pivot bearings Wheel nut not tightened properly Bent frame or swingarm Bent spoke Wheel turns hard ~ Faulty wheel bearings Faulty driven flange bearings Bent axle Brake drag (page 19-2) Drive chain too tight (page 3-16) Soft suspension Improper shock absorber spring preload Incorrect suspension adjustment Weak shock absorber spring Oil leakage from damper unit Insufficient tire pressure Faulty tire Stiff suspension Incorrect suspension adjustment Bent damper rod Damaged bushing Damaged shock absorber or swmgarm pivot bearing Improperly tightened swingarm pivot Bent swingarm pivot or frame Tire pressure too high Faulty suspension linkage Rear suspension noisy ~ Loose suspension fasteners ~ Worn shock absorber mount bushings ~ Faulty rear shock absorber 18-2 REAR WHEEL/SUSPENSION COMPONENT LOCATION 54 Nm (5.5 kgl-m, 40 lbf-fl) 50 NM (3.2 kgf-m, 59 mm) / 10 Nm (1.0 kgf-m, 7 lbf-fl) Q m \ (0‘1 kgfvm, 0.9 mm) 55 MM 18-3 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a saIety stand or hoist, raise the rear wheel off the ground. Fully slacken the drive chain (page 3-16). Push the rear wheel forward. Derail the drive chain [1] from the driven sprocket. Remove the rear axle nut [2], washer [3], and right adjusting plate [4]. Remove the rear axle [5], left adjusting plate [6], rear wheel, and side oollars [7]. NOTE . Do not suspend the brake caliper/bracket assembly from the brake hose. Do not twist the brake hose. . Do not operate the brake pedal after removing the rear wheel. . CRF1000D: Do not operate the parking brake lever aIter removing the rear wheel. INSPECTION Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the outer race fits tightly in the wheel hub. Inspect the Iollowing parts for damage, abnormal wear. deformation or bends. — Rear axle — Rear wheel Measure each part according to REAR WHEEL/ SUSPENSION SPECIFICATIONS (page 1-26). Replace any part it it is out of service limit. Refer to the wheel balance service (page 17-11). 18-4 REAR WHEEL/SUSPENSION DISASSEMBLYIASSEMBLY NOTE Install the driven sprocket on the driven flange with the stamped mark facing out. :39 E $9 DRIVEN FLANGE @ BU’ST SEAL BEARING 63/22 / cw PULSER RING BOLTS BRAKE DIsc BOLTS / ,/ v (CRF1000A/D) 42 Nvm 7.0 N-m (0.7 kgfvm, 5.2 lbl-fl) (m Wm. 31 lbw DRIVEN ‘ / . SPROCKET ‘ / REAR WHEEL x o I . DISTANCE COLLAR B V PULSER RING (CRF1000A/D) REAR BRAKE DISC DUST SEAL BEARING 6204 (UU) DISTANCE COLLAR DRIVEN SPROCKET NUTS 100 Mm (10.2 kgf m. 74 Ibfvfl) DAMPER § RUBBERS $1 BEARING 6204 (UU) NOTE . Install the rear wheel dust seal [1] until to the specified range as shown. . Install the driven flange dust seal until it is flush with the wheel hub surface. . Apply grease to the dust seal lips . Install the brake disc with the “:;>“ mark facing the normal rotating direction. 1.5725 mm (0.06 r 0.10 in [1] WHEEL CENTER ADJUSTMENT Place the rim [1] on a work bench. 1 Place the hub [2] in the center of the rim, and begin the [ ] lacing with new spokes. w 5622657231223 ‘ Adjust the hub position so the distance Irom the hub left / ‘ ( ' _ ' In) end surface to the side of the rim is 5.2 — 7.2 mm (0.205 v — 0.283 in) as shown. 18-5 REAR WHEEL/SUSPENSION WHEEL BEARING REPLACEMENT Drive out the rear wheel distance collar B [1] by using —' the special tools. TOOLS: Driver [2] 07749-0010000 Attachment, 22 x 24 mm [3] 07746-0010800 Pilot, 17 mm [4] 07746-0040400 Drive out the bearing [5]. Replace the wheel Install the bearing remover head [1] into the bearing. hearings m pairs. From the opposite side, install the bearing remover Do not reuse old shaft [2] and drive out the bearing trom the wheel hub. bearings. TOOLS: Bearing remover head, 20 mm 07746-0050600 Bearing remover shaft 07GGD-0010100 Remove the distance collar and drive out the other bearing. Neverinslalllhe old Drive in a new right side bearing [1] squarely until it is — hearing. once the tully seated. hearing has been removed, the TOOLS: bearing mus: [79 Driver [2] 07749-0010000 replaced with new Attachment, 42 x 47 mm [3] 07746-0010300 07195- Pilot, 20 mm [4] 07746-0040500 Install the distance collar. Drive in a new left side bearing squarely until it is seated on the distance collar. Drive in the rear wheel distance collar B [1] to a new bearing [2]. TOOLS: Driver [3] 07749-0010000 Attachment, 23 x 30 mm [4] 07946-1370100 Pilot, 20 mm [5] 07746-0040500 18-6 Be careful no! to damage the make pads. Drive in the bearing/collar [1] squarely with its collar side facing down until it is fully seated. TOOLS: Driver [2] 07749-0010000 Attachment, 52 x 55 mm [3] 077464010400 Pilot, 22 mm [4] 07746-0041000 INSTALLATION Install the brake bracket [1] to the swingarm. NOTE . Align the bracket groove with swingarm tab. Install the side collars [1] to the rear wheel. Apply a thin opat oi grease to the rear axle outer surlace. Install the rear wheel in the swingarm aligning the brake disc between the brake pads. Install the drive chain [2] over the driven sprocket. Install the rear axle [3] from the left side through the left adjusting plate [4], swingarm and rear wheel. Install the right adjusting plate [5], washer [6], and rear axle nut [7]. Adjust the drive chain slack (page 346). Tighten the nut to the specified torque. TORQUE: 100 Mm (10.2 kgf‘m, 74 Ibf'fl] Check the clearance gap between the rear wheel speed sensor bracket and pulser ring (page 20-23). REAR WHEEL/SUSPENSION [4] 18-7 REAR WHEEL/SUSPENSION SHOCK ABSORBER REMOVAL/INSTALLATION Remove the reg ulator/rectitier (page 21 -8). Support the motorcycle using a saiety stand or hoist, raise the rear wheel off the ground. Remove the lower cushion arm bolt [1] and nut [2]. Remove the shock absorber lower mounting bolt [3] and nut [4]. Remove the shock absorber upper mounting bolt [1] and nut [2]. Remove the rear shock absorber [1] by lifting the swingarm [2]. Installation is in the reverse order of removal. TORQUE: Shock absorber upper mounting nut: 54 N-m (5.5 mm, 40 lbf-ft) Shock absorber lower mounting nut: 44 N-m (4.5 mm, 32 lbf-ft) Lower cushion arm nut: 55 N-m (5.6 mm, 41 lbf-ft) INSPECTION Visuall ins ect the shock absorber ior wear or damagfi, "’ [41 {21 {11 [31 Check the following: — Damper rod [1] for bends or damage — Damper unit [2] for deformation or oil leaks — Rubber bumper [3] for wear or damage — Bushing [4] for wear or damage Replace the shock absorber assembly if necessary. 18-8 REAR WHEEL/SUSPENSION CUSHION LINKAGE REMOVAL Support the motorcycle using a salety stand or hoist, raise the rear wheel off the ground. Remove the sidestand (page 2-19). Remove the following: — Cushion connecting rod mounting nut [1] and bolt [2] — Rear shock absorber lower mounting nut [3] and bolt [4] — Upper cushion arm nut [5] and bolt [6] — Cushion arrn/connecting rod [7] DISASSEMBLYIINSPECTION Disassemble the cushion arm [1] and connecting rod [2] by removing the lower cushion arm nut [3] and bolt [4]. Remove the collars [1] and dust seals [2] lrom the cushion arm [3]. [2] \ [3] Check the collars and dust seals lor wear or damage 0 and replace if necessary. ‘ Check the cushion arm lor cracks or damage and replace if necessary. Check the needle bearings lor damage or loose fit. [11 \ Remove the oollar [1] from the cushion connecting rod 2] [21. I Check the collar for wear or damage and replace if » / necessary. . \ . Check the cushion connecting rod for cracks or damage and replace if necessary. Check the needle bearings lor damage or loose fit. REAR WHEEL/SUSPENSION BEARING REPLACEMENT CUSHION ARM Remove the needle bearings (17 x 24 x 30 mm) [1] and (20 x 26 x 20 mm) [2] using the special tools. TOOLS: Remover weight [3] 07741-0010201 Remover handle [4] 07936-3710100 Needle bearing (17 x 24 x 30 mm): Bearing remover set, 17 mm [5] 07936-3710300 Needle bearing (20 x 26 x 20 mm): Bearing remover set, 20 mm [5] 07936-3710600 Remove the needle bearing (17 x 24 x 17 mm) [1] using the special tools and hydraulic press. TOOLS: Driver handle 15 x 230L [2] 07949-3710001 Attachment, 22 x 24 mm [3] 07746-0010800 Never install the old Apply molybdenum disultide grease to new needle bearing, once the bearings rotating area. hearing has been removed, the bearing must be replaced with a new one. Install the needle bearings (17 x 24 x 17 mm) [1] and (20 x 26 x 20 mm) [2] with its marked side facing up to the specified range using the special tools and hydraulic press as shown. TOOLS: Driver handle 15 x 280L [3] 07949-3710001 Attachment, 22 x 24 mm [4] 07746-0010800 Needle bearing (17 x 24 x 30 mm): Pilot, 17 mm [5] 07746-0040400 Needle bearing (20 x 26 x 20 mm): Pilot, 20 mm [5] 07746-0040500 Install the needle bearings (17 x 24 x 30 mm) [6] with its marked side tacing up until it is flush with the cushion Need“, bearing Needle bearings arm surface using the special tools and hydraulic press. (17 x 24 x 17 mm) (20 x 25 x 20 mm): TOOLS: Driver handle 15 x 230L [3] 07949-3710001 ' Q - 0,217 0.22 'n Attachment, 32 x 35 mm [4] 07746-0010100 (0'23 0’24 In) ( I ) 7 Pilot, 17 mm [5] 07746-0040400 “ ‘ 77 l % )_J h l v [21 zfil I16" 5.3 r 5,7 mm 18-10 REAR WHEEL/SUSPENSION CUSHION CONNECTING ROD Remove the needle bearings (17 x 24 x 30 mm) [1]. [4] [3] TOOLS: Bearing remover set, 17 mm [2] 07936-3710300 Remover weight [3] 07741-0010201 Remover handle [4] 07936-3710100 Never install the old Apply molybdenum disullide grease to new needle bearing, once the bearings rotating area. hearing has been removed, the bearing must be replaced with a new [31/ [4] Install the needle bearings (17 x 24 x 30 mm) [1] with its marked side lacing up until it is flush with the cushion arm surlace using the special tools and hydraulic press as shown. one. TOOLS: Driver [2] 07949-0010000 Attachment, 32 x 35 mm [3] 07746-0010100 Pilot, 17 mm [4] 07746-0040400 ASSEMBLY/INSTALLATION Install the dust seals [1] into the cushion arm [2] until they are lully seated. fl [1] [2] Apply molybdenum disulflde grease to dust seal lips. Install the collars [3]. [3] Install the collar [1] into the cushion connecting rod [2]. 18-11 REAR WHEEL/SUSPENSION Assemble the cushion arm [1] and connecting rod [2] by installing the lower cushion arm nut [3] and bolt [4] as shown. NOTE . Assemble the cushion arm and connecting rod with "UP" mark [5] of the arm facing up. Tighten the nut to the specified torque. TORQUE: 55 N-m (5.6 kgf'm, 41 Ibf-ft) Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground. Apply engine oil to the cushion connecting rod mounting nut threads and seating surface. Install the following: — Cushion arm/connecting rod [1] — Upper cushion arm nut [2] and bolt [3] — Rear shock absorber lower mounting nut [4] and bolt 5 — glshion connecting rod mounting nut [6] and bolt [7] TORQUE: Upper cushion arm nut: 14 Nm (7.5 ngm, 55 lbf‘ft) Rear shock absorber lower mounting nut: 44 Nm (4.5 ngm, 32 lbf‘ft) Cushion connecting rod mounting nut: 45 Nm (4.5 ngm, 33 lbf‘ft) Install the sidestand (page 2-19). SWINGARM REMOVAL Remove the left rear cover (page 240). Remove the rear wheel (page 18-4). Remove the socket bolts [1] and drive chain case [2]. 18-12 REAR WHEEL/SUSPENSION Remove the socket bolts [1] and left/right heel guards [2]- Remove the bolt [1] and brake hose clamp [2]. Remove the screws [3] and brake hose guide [4]. Remove the screw [5] and brake hose clamp [6]. CRF10000: Remove the bolt [1] and parking brake cable guide [2]. Remove the upper cushion arm nut [1] and bolt [2]. 18-13 REAR WHEEL/SUSPENSION Remove the swingarm pivot nut [1], pivot bolt [2], and swingarm [3]. DISASSEMBLYIASSEMBLY PIVOT DISTANCE Q? (fill 8" fall RIGHT COLLAR NEEDLE BEARING DUST SEAL (24 x 31 x 23 mm) oFronl , d. SNAP g :39 RING v D .6. BEARING I DUST SEAL sous LOCK NUTS &\ PIVOT COLLAR A 27 Nm (2.5 kgf'm, 20 lbf~fl) NEEDLE BEARING SWINGARM DRIVE CHAIN PIVOT DISTANCE ADJUSTING LEFT COLLAR v BOLTS 215' ram «en DUST SEAL REAR SWINGARM CAPS (5 pcS) CHAIN SLIDER I K WASHERS B DRIVE CHAIN GUARD 8" DRIVE CHAIN SLIDER SCREWS g COLLARS 4'2 N“ (0‘4 mm“ 3'1 “7”” DRIVE CHAIN GUARD BOLTS 10 Nm (1.0 kgl‘m, 7 lbf-ft) NOTE . Install the dust Seals until it iS flush with the swingarm SurlaCe. . Apply ThreeBond 1521 or an equivalent to the swingarm Cap mating Surface. 18-14 REAR WHEEL/SUSPENSION INSPECTION Inspect the Iollowing parts for damage, abnormal wear, or deformation and replace it necessary. — Dustseals — Pivotcollars — Swingarm — Bearings — Drivechain slider PIVOT BEARING REPLACEMENT Remove the snap ring [1] from the right pivot. Remove the ball bearing 6003 [1] out of the right pivot using a hydraulic press and special tool. TOOLS: Driver, 15 x 280L [2] 07949-3710001 Attachment, 22 x 24 mm [3] 07746-0010800 Pilot, 17 mm [4] 07746-0040400 Remove the needle bearing (24 x 31 x 28 mm) [1] out of the right pivot using the special tool. TOOLS: Driver, 15 x 280L [2] 07949-3710001 Attachment, 28 x 30 mm [3] 07946-1 B70100 Pilot, 22 mm [4] 07746-0041000 18-15 REAR WHEEL/SUSPENSION Remove the needle bearing [1] out of the left pivot using a hydraulic press and special tool. TOOLS: Driver [2] 07749-0010000 Attachment, 32 x 35 mm [3] 07746-0010100 Pilot, 25 mm [4] 07746-0040600 Apply molybdenum disulfide grease to a new needle bearing rotating area. Install the needle bearing [1] into the left pivot with the marked side 1acing up to the specified range using a hydraulic press and special tools as shown. TOOLS: Driver [2] 07749-0010000 Attachment, 32 x 35 mm [3] 07746-0010100 Pilot, 25 mm [4] 07746-0040600 Apply molybdenum disulfide grease to a new needle bearing (24 x 31 x 28 mm) rotating area. Install the needle bearing (24 x 31 x 28 mm) [1] into the right pivot with the marked side facing up to the specified range using a hydraulic press and special tools as shown. TOOLS: Driver, 15 x 280L [2] 07949-3710001 Attachment, 23 x 30 mm [3] 07946-1370100 Pilot, 22 mm [4] 07746-0041000 Apply molybdenum disulfide grease to a new ball bearing rotating area. Install the ball bearing 6003 [1] into the right pivot with the marked side facing out until it is 1ully seated using a hydraulic press and special tools as shown. TOOLS: Driver [2] 07749-0010000 Attachment, 32 x 35 mm [3] 07746-0010100 Pilot, 17 mm [4] 07746-0040400 - — — [3]/[4] ‘ [1] 5.0 7 5.5 mm (0.20 e 0.22 in) (0.15 e 0.20 in) 4.5 r 5.0 mm 18-16 REAR WHEEL/SUSPENSION Install the snap ring [1] into the right pivot groove securely. NOTE . Do not reuse the snap ring which could easily spin in the groove. . Make sure that the snap ring is firmly seated in the groove. INSTALLATION Apply a thin coat of grease to the swingarm pivot bolt sliding surface. Set the drive chain [1] onto the swingarm [2] and install the swingarm to the frame. Install the swingarm pivot bolt [3] from the left side. Apply engine oil to the swingarm pivot nut threads and seating surface. Install the swingarm pivot nut [4]. Tighten the swingarm pivot nut to the specified torque. TORQUE: BO N-m (8.2 kgf-m, 59 Ibf-ft) Set the cushion arm and install the upper cushion arm bolt [1] from the left side. Install and tighten the upper cushion arm mounting nut [2] to the specified torque. TORQUE: 74 N-m (7.5 kgf-m, 55 lbf-fl) CRF10000: Install the parking brake cable guide [1] and bolt [2]. Tighten the bolt to the specified torque. TORQUEHD N-m (1.0 kgf-m, 7 Ibf-ft) 18-17 REAR WHEEL/SUSPENSION Route the hose, Install brake hose clamp [1] and a new screw [2] and wire, and cable tighten the screw to the specified torque. proper! pa 9 1- y( 925)_ TORQUE:1.2 N-m (0.1 kgf-m, 0.9 Ibf-fl) Install brake hose guide [3] and new screws [4] and tighten the screws to the specified torque. TORQUE:1.2 N-m (0.1 kgf-m, 0.9 lbf-fl) Install the bolt [5] and brake hose clamp [6] and tighten the bolt to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-lt) Install the left/right heel guards [1] and socket bolts [2] and tighten the bolts securely. Install the drive chain case [1] and socket bolts [2] and tighten the bolt securely. Install the rear wheel (page 18-7). Install the left rear cover (page 2-10). 18-18 19. HYDRAULIC BRAKE SERVICE INFORMATION -------------------- -- 19-2 TROUBLESHOOTING -- -~ 19-2 COMPONENT LOCATION ------------------- -- 19-3 BRAKE FLUID REPLACEMENT/AIR BLEEDING --------------------------------------- -~ 19-6 BRAKE PAD/DISC ----------------------------- -- 19-8 FRONT MASTER CYLINDER -------------- ~-19-13 REAR BRAKE PEDAL ----------------------- --19-15 REAR MASTER CYLINDER- 49.15 FRONT BRAKE CALIPER ------------------ "19.13 REAR BRAKE CALIPER -------------------- --19-2o PARKING BRAKE LEVER (CRF1000D) ------------------------------------- --19-22 PARKING BRAKE CALIPER (CRF1000D) ------------------------------------- --19-23 19-1 HYDRAUUCBRAKE SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. - Avoid breathing dust particles. - Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilling brake fluid Will severely damage instrument lenses and painted surface. It is also harmful to some rubber parts. Ele careful whenever you remove the reservoir cover; make sure the front reservoir is horizontal first. ~ A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Check the brake system by applying the brake lever or pedal after the air bleeding. Never allow contaminates (dirt, water, etc.) to get into an open reservoir. Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid, they may not be compatible. Always check brake operation before riding the motorcycle. This section covers service of the conventional brake components of the brake system. For Anti-lock Brake System (ABS) service (page 20-2). TROUBLESHOOTING Brake lever/pedal soft or spongy ~ Air in hydraulic system ~ Low brake fluid level ~ Leaking hydraulic system ~ Clogged fluid passage ~ Contaminated brake pad/disc ~ Worn caliper piston seals ~ Worn master cylinder piston cups ~ Worn brake pad/disc ~ Contaminated caliper ~ Caliper not sliding properly ~ Warped/deformed brake disc ~ Sticking/worn caliper piston ~ Sticking/worn master piston ~ Contaminated master cylinder ~ Bent brake lever/pedal Brake lever/pedal hard ~ Clogged/restricted hydraulic system ~ Sticking/worn caliper piston ~ Caliper not sliding properly ~ Clogged/restricted fluid passage ~ Worn caliper piston seal ~ Sticking/worn master piston ~ Bent brake lever/pedal Brake drag Contaminated brake pad/disc Misaligned wheel Clogged/restricted brake hose Joint Warped/deformed brake disc Caliper not sliding properly Clogged/restricted brake hydraulic system Sticking/worn caliper piston Clogged master cylinder port 19-2 HYDRAULIC BRAKE COMPONENT LOCATION FRONT: 34 N-m (3.5 kgf'm. 25 let) 45 Nm (4.6 kgf-m, 33 mm) L ‘ iv 34 Nm (3.5 kgf'm. 25 mm) 19-3 HYDRAULIC BRAKE REAR: 10 Nm (1.0 kgrm, 7 lbf-fl) 3/ 34 Nm (3.5 kgf‘m, 25 lbf'fl) 35 Nm (3.6 kgf-m, 26 mm) 34 Mm (325 kgf-m, 25 mm) 22 Nm (2.2 kgrm, 1e lbf'fl) 19-4 HYDRAULIC BRAKE CRF1ODDD: 31 N-m (3.2 kgf-m. 23 let) 9 N-m (0A9 kgfvm, 6.6 mm) 31N-m(3.2 kgfvm, 23 \bf-fl) 19-5 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING me brake: Rear brake: BRAKE FLUID DRAINING Turn the handlebar until the reservoir is parallel to the ground. Remove the Iollowing: — Screws [1] — Reservoir cap [2] — Set plate [3] Diaphragm [4] Support the motorcycle in an upright position. Remove the mounting bolt [1] and release the rear brake reserve tank [2] from the rear frame. Remove the screws [3], reservoir cap [4], set plate [5], and diaphragm [6]. Temporarily install the reserve tank and bolt, and tighten the bolt. Connect a bleed hose to the caliper bleed valve [1]. Loosen the bleed valve and pump the brake lever/pedal ’ until no more fluid flows out of the bleed valve. Tighten the bleed valve. 19-6 HYDRAULIC BRAKE If air enters the bleeder from around the bleed valve threads, seal the threads wIIh teflon (ape. BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir with DOT 4 brake fluid to the upper level line [1] from a sealed container. Connect a commercially available brake bleeder to the bleed valve [2]. Operate the brake bleeder and loosen the bleed valve. If an automatic refill system is not used, add fluid when the fluid level in the reservoir is low. . Check the fluid level often while bleeding the brake to prevent air from being pumped into the system. . When using a brake bleeding tool, follow the manufacturer’s operating instructions. Perform the bleeding procedure until the system is completely flushed/bled. Close the bleed valve and operate the brake lever/ pedal. If it still feels spongy, bleed the system again. After bleeding the system completely, tighten the brake caliper bleed valve to the specified torque. TORQUE: 5.4 N‘m (0.6 kgf-m, 4.0 left) Fill the reservoir with DOT 4 brake fluid to the upper level line from a sealed container. If the brake bleeder is not available, perform the following procedure. Fill the reservoir with DOT 4 brake fluid to the upper level line [1] from a sealed container. Pump up the system pressure with the brake lever/ pedal until the lever/pedal resistance is felt. Connect a bleed hose to the bleed valve [2]. 1. Squeeze the brake lever/pedal all the way and loosen the bleed valve 1/4 turn. Wait several seconds and then close the bleed valve. NOTE . Do not release the brake lever/pedal until the bleed valve has been closed. 2. Release the brake lever/pedal slowly and wait several seconds after it reaches the end of its travel. 3. Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose. After bleeding the system completely, tighten the brake caliper bleed valve to the specified torque. TORQUE: 5.4 N‘m (0.6 kgf-m, 4.0 left) Fill the reservoir with DOT 4 brake fluid to the upper level line from a sealed container. 19-7 HYDRAULIC BRAKE From brake: Install the diaphragm [1], set plate [2], and reservoir cap [3] and tighten the screws [4] to the specified torque. TORQUE: 1.5 N-m (0.2 kgf-m, 1.1 lbf-fl) Rearbrake: Remove the mounting bolt [1] and rear brake reserve tank [2]. Install the diaphragm [3], set plate [4], reservoir cap [5], and screws [6] and tighten the screws to the specified torque. TORQUE:1.5 N-m (0.2 kgf-m, 1.1 lbf-fl) Install the rear brake reserve tank and mounting bolt and tighten the bolt to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-It) BRAKE PAD/DISC NOTE . Always replace the brake pads in pairs to assure even disc pressure. . Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise. FRONT BRAKE PAD REMOVAL] INSTALLATION Do natoperate the Remove the brake caliper mounting bolts [1] and brake brake lever after calipers [2]. removing the brake caliper. Right side shown: ' 19-8 HYDRAULIC BRAKE Remove the brake pads [1]. Right side shown: Check the pad spring [2] and replace it necessary. Align the padlugs Install new brake pads to the brake caliper so their ends with the caliper Seat against the pad spring. grooves. Install the brake caliper [1] and new mounting bolts [2]. Tighten the bolts to the specified torque. TORQUE:45 N-m (46 kgf-m, 33 Ibf'ft) Operate the brake lever to seat the caliper pistons against the pads. REAR BRAKE PAD REMOVAL] INSTALLATION Remove the brake pad pin [1] and rear brake caliper mounting bolt [2]. Do not operate the Lift the caliper and remove the brake pads [3]. brake pedal after removing the hrake pads. 19-9 HYDRAULIC BRAKE Make sure that the retalner and pad spring are installed la the brake callper. |nsta|| new brake pads [1] to the brake caliper so their ends seat against the retainer. Lower the caliper. Loosely install a new rear brake caliper mounting bolt 2 . Check that the brake pad pin stopper ring [3] is in good condition, replace it if necessary. Apply silicone grease to the brake pad pin stopper ring and install it to the brake pad pin [4] groove. Install the brake pad pin by pushing the pads to align the brake pad pin holes of the pads and brake caliper. Tighten the rear brake caliper mounting bolt [1] to the specified torque. TORQUE: 22 N-m (2.2 kgf-m, 16 Ibf-ft) Tighten the brake pad pin [2] to the specified torque. TORQUE: 17 N-m (1.7 kgf-m, 13 Ibf-ft) Operate the brake pedal to seat the caliper pistons against the pads. PARKING BRAKE PAD/PIN REPLACEMENT (CRF1000D) REMOVAL Loosen the parking brake pad pins [1]. Remove the socket bolts [1] and parking brake caliper 7 cover [2]. 19-10 HYDRAULIC BRAKE Remove the brake caliper mounting bolts [1] and caliper [2] Irom the bracket. Remove the pad pins [1] and pads [2]. INSTALLATION Make sure the pad spring is installed in position. Install new parking brake pads [1]. Install new pad pins [2]. Install the parking brake caliper [1] and new mounting bolts [2] and tighten the bolts to the specified torque. TORQUE: 31 N-m (3.2 kgf-m, 23 lbf-it) 19-11 HYDRAULIC BRAKE Install the parking brake caliper cover [1] and socket 7 bolts [2] and tighten the bolts to the specified torque. TORQUE: 9 N-m (0.9 kgf-m, 6.6 lhfrfl) Tighten the pad pins [1] to the specified torque. TORQUE: 17.2 N-m (1.8 kgf-m, 13 Ibf’fl) Check the parking brake lock operation (page 3-21). BRAKE DISC INSPECTION Visually inspect the brake discs for damage or cracks. Measure the brake disc according to HYDRAULIC BRAKE SPECIFICATIONS (page 140) and replace it necessary. 19-12 HYDRAULIC BRAKE FRONT MASTER CYLINDER When removing the oil bolt, cover the end oi the brake hose to prevent contamination. REMOVAL/INSTALLATION Drain the brake fluid from the front brake line hydraulic system (page 1945). Disconnect the brake light switch connectors [1]. Remove the brake hose oil bolt [2], sealing washers [3], and brake hose [4]. Remove the bolts [5], holder [6], and master cylinder [7]- lnstallation is in the reverse order of removal. NOTE . Always replace the sealing washers with new ones. . Install the brake hose eyelet joint against the master cylinder stopper. . Install the master cylinder holder with the "UP" mark [8] facing up. . Align the end of the master cylinder with the handlebar punch mark. When tightening the front master cylinder holder bolts, tighten the upper bolt first, then the lower bolt to the specified torque. TORQUE: Front brake master cylinder holder bolt: 9.3 N-m (1.0 kgf'm, 7 lel) Brake hose oil bolt: 34 N-m (3.5 kgf'm, 25 lbf'fl) Fill the reservoir to the upper level and bleed the front brake system (page 195/). 19-13 HYDRAUUCBRAKE BRAKE LEVER FRONT BRAKE LEVER PIVOT BOLT 1.0 N m (0.1 kgfvm. 0.7 lbf-ft) DISASSEMBLYIASSEMBLY NOTE . When removing and instaliing the snap ring, use the special toOI. TOOL: Snap ring pliers 07914-SA50001 . Instali the snap ring with the chamlered edge facing the thrust IOad side and be certain it is firmly seated in the groove. DO not reuse the snap ring which could easily spin in the groove. . Replace the piston and cups as a set. . Do not ailow the piston cup lips to turn inside out. . Aiign the switch boss with the master cylinder hOIe properly. . MASTER PISTON [a BOOT SNAP RING KNUCKLE GUARD HOLDER INSPECHON Inspect the loliowing parts lor scoring, scratches, deterioration, Or damage. — Mastercylinder — Masterpiston — Piston cups — Spring — Boot Measure each part according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-10). Replace any part il it is out of service |imit. . PRIMARY CUP MASTER CYLINDER SPRING BRAKE LIGHT SWITCH FRONT BRAKE LIGHT SWITCH MOUNTING SCREW COLLAR 1.2 N-m (0.1 kgf m. o 9 Ibfvfl) FRONT BRAKE LEVER PIVOT NUT 5.9 N-m (o e kgfvm, 4.4 ibl-fl) 19-14 HYDRAULIC BRAKE REAR BRAKE PEDAL REMOVAL/INSTALLATION § 4‘} JOINT PlN COTfER PlN BRAKE PEDAL PlNCH BOLT BRAKE PEDAL <25» MIDDLE ARM RETURN SPRING RlGHT STEP BRACKET STEFI BRACKET MOUNTlNG BOLTS DUST SEALS 35 N-m (3,6 kgf'm. 26 lbf'fl) NOTE . Align the brake pedal slit with the middle arm punch mark. Always replace the cotter pin with a new one. Always replace the dust seal with a new one. Apply grease to the dust seal lips. Apply grease to the middle arm pivot sliding surlace. 19-15 HYDRAULIC BRAKE REAR MASTER CYLINDER REMOVAL/INSTALLATION Drain the rear brake line hydraulic system (page 1945). Remove the bolt [1] and heel guard [2]. Avoid spilling fluid Remove the 0“ bolt [1], sealing washers [2] and brake on painted, plastic, hose [3]. ormbbe’pans' Remove the hose clamp [4] and rear master cylinder hose [5]. Remove the cotter pin [1] and joint pin [2], and disconnect the brake rod joint [3] from the middle arm [4]- Remove the bolts [5] and rear master cylinder [6]. Installation is in the reverse order of removal. NOTE . Always replace the cotter pin and sealing washers with a new one. . Tighten rear master cylinder mounting bolts and brake hose oil bolt to the specified torque. TORQUE: Rear master cylinder mounting bolt: 14 N-m (1.4 kgf-m,10lbf-ft) Brake hose oil bolt: 34 N-m (3.5 mm, 25 lbf-ft) 19-16 HYDRAULIC BRAKE QInn HOSE JOINT SCREW 1.5 Mn (02 kgfvm.1.1 mm) DISASSEMBLYIASSEMBLY NOTE . When removing and instalIing the snap ring, use the special tool. TOOL: Snap ring pliers 07914—SA50001 . InstaII the snap ring with the chamlered edge facing the thrust load side and be certain it is firmly seated in the groove. Do not reuse the snap ring which could easily spin in the groove. Replace the piston, spring, and cup as a set. Do not aIlow the piston cup lips to turn inside out. Apply locking agent to the rear master cylinder hose joint screw threads (page 1-20). HOSE JOINT MASTER CYLINDER When the push rod has been disassembIed. adjust the push rod length so that the distance from the center of the master cylinder lower mounting boIt hole to the center of the joint pin hole is standard length as shown. It the length is adjusted to the longer position, make sure that the lower end of the push rod thread [1] is visible inside the joint. After adjustment. tighten the push rod Iock nut [2] to the specified torque. TORQUE: 17.2 N-m (1.8 kgf‘m,13lbfrft) SPRING PRIMARY PISTON CUP MASTER PISTON . SECONDARY PISTON CUP zfii 0.10 g (0.004 oz) PUSH ROD LOCK NUT 17.2 NM (1.8 kgf-m.13lbf~tt) PUSH ROD [2] [11/1332 03.0 7 35.0 mm (3,284.35 in) 19-17 HYDRAULIC BRAKE INSPECTION Check the following parts for scoring, scratches. deterioration. or damage. — Mastercylinder — Masterpiston — Piston cups — Spring — Boot Measure the parts according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-10). Replace any part if it is out of service limit. FRONT BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the front brake line hydraulic system (page 19-6). Avoid spilling fluid Remove the oil bolt [1] and sealing washers [2] and on painted, plastic, disconnect the brake hose [3]. or rubber pans. Place a shop towel overlhese pans Install the brake caliper onto the fork. wheneverihe Install and tighten new brake caliper mounting bolts to system ls serviced. the specified torque. TORQUE:45 N-m (4.6 kgf'm, 33 lbf-ft) Remove the bolts [4] and front brake caliper [5]. Install the brake hose to the caliper body with new sealing washers and oil bolt. Push the hose eyelet against the stopper on the caliper body, then tighten the oil bolt to the specified torque. TORQUE: 34 N-m (3.5 kgf'm, 25 lbf-ft) Fill and bleed the brake fluid to the front brake line hydraulic system (page 19-7). 19-18 HYDRAULIC BRAKE DISASSEMBLYIASSEMBLY NOTE . Be careful not to damage each piston. . Do not use high pressure air or bring the nozzle too close to the inlet. . Mark the pistons to ensure correct reassembly. . Be careful not to damage the piston sliding surface. . Instail each piston seal, dust seal and caiiper piston in their proper locations. . Piston A: larger O.D. . Piston B: smaiierOD. BLEED VALVE . as; 5.4 N m (0.6 kgfvm. 4.0 lbf-ft) ~a PISTON SEAL A ,fii ED? PAD SPRiNG DUST SEAL A § PISTON A . xfii 9 (larger on.) DUST SEAL A PISTON SEAL B flat? if DUST SEAL B Air-I40? I9? PISTON SEAL A PISTON SEAL B DUST SEAL B PISTON B '3’ . (smaller 0 D.) a 2’? . ~’ INSPECTION Check the following parts for Scoring, scratches. deterioration. or damage. — Calipercylinders — Caliper pistons Measure the parts according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-10). Replace any part it it is out of service limit. 19-19 HYDRAULIC BRAKE REAR BRAKE CALIPER Avold spllllng fluid on painted. plastic, or rubber pans. Place a shop towel over these parts whenever the system is serviced. REMOVAL/INSTALLATION Drain the brake fluid Vrom the pedal brake line hydraulic system (page 1945). Remove the oil bolt [1], sealing washers [2] and brake hose [3]. Remove the brake pads (page 19-9). Lift the rear brake caliper [4] and remove it by pulling right. NOTE . Check the caliper pin boot [5] {or deteriorated or damaged, replace it with a new one if necessary. . If the pad retainer [6] is removed, apply ThreeBond 1521 or an equivalent to the retainer seating surface. Apply 0.4 g (0.01 oz) of silicone grease to the sliding area of the caliper pin bolt [7]. Install the rear brake caliper. Install the brake pads (page 19-9). Install the brake hose eyelet to the caliper body with new sealing washers and oil bolt. Push the hose eyelet joint against the caliper body, then tighten the oil bolt to the specified torque. TORQUE: 34 N-m (3.5 kgfrm, 25 lhf-ft) Fill brake fluid and bleed air from the rear brake line hydraulic system (page 19-7). 19-20 HYDRAULIC BRAKE DISASSEMBLYIASSEMBLY NOTE . Be careful not to damage the piston sliding surface . When removing the caliper piston with compressed air, place a shop towel over the piston to prevent damaging the piston and caliper body. Do not use high pressure or bring the nozzle too close to the fluid inlet. . Install the piston with the opening toward the pads. . Apply 0.4 g (0.01 oz) oi silioone grease to the sliding area of the caliper sleeve. . Apply 0.4 g (0.01 oz) oi silicone grease to the rear brake caliper pin bolt sliding surface. CALIPER BODY BLEED VALVE 5.4 N m (o e kgf-m. 4.0 lot-ft) m 0.4 g (o 01 oz) ’ . CALIPER PiN BOLT . CALIPER PISTON gm DUST SEAL STOPPER RING m . ED? PISTON SEAL BRAKE PAD FIN 17 N-m (1.7 kgf-m. 13mm) BRAKE PADS PAD SPRING CALIPER SLEEVE SLEEVE BOOT E 0.4 g (0.01 oz) m 0.4 g (0.01 OZ) PAD SPRING INSPECTION Check the following parts for scoring, scratches. deterioration, or damage. — Calipercylinder — Caliper piston Measure the parts according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-10) and replace if necessary. 19-21 HYDRAULIC BRAKE PARKING BRAKE LEVER (CRF1000D) REMOVAL Remove the knuckle guard (page 2-5). Remove the rearview mirror (page 17-4). Disconnect the parking brake switch connectors [1]. Remove the bolts [1], holder [2], and parking brake lever assembly [3]. Loosen the lock nut [4] and disconnect the parking brake cable by turning the adjuster [5]. Installation is in the reverse order of removal. Check the parking brake Iock operation (page 3-21). DISASSEMBLYIASSEMBLY PARKING BRAKE STOPPER STAY FLANGE BOLT 11.9 N'm (1.2 Kgrm, 9 lbf-ft) f6. N PARKING BRAKE STOPPER We STAY HEX BOLT I LOCK LEVER PIVOT BOLT STOPPER STAY \ 0‘9 23 NT,“ (02 kgfrm. 1.7 mm) 6.9 N‘m (0.7 kgf'm, 5.1 lbf~fl) LOCK LEVER RETURN ‘I ERREK‘IEGTBRAKE LEVER SPRING * I , (a , a $6 >9 PARKING BRAKE LEVER F'IVOT BOLT 1.0 N-m (0.1 kgf~m. 0.7 lbl-ft) ‘ o I J I /Efi‘/ PARKING BRAKE SWITCH §.\ PARKING BRAKE SWITCH MOUNTING scREw 1.2 N~m (0.1 kgf-m, 0.9 mm KNUCKLE GUARD HOLDER PARKING BRAKE LEVER PIVOT NUT 5‘9 NT" (0-6 WT“, 4-4 lbf-fl) PARKING BRAKE LEVER NOTE . Apply locking agent to the parking brake switch mounting screw threads (page 1-20). 19-22 HYDRAULIC BRAKE INSTALLATION Install the parking brake lever assembly [1] by aligning its end with the paint mark [2] on the handlebar. Install the holder [3] with its punch mark [4] lacing up. Tighten the upper bolt [5] first, then the lower bolt [6]. Connect the parking brake cable [7] to the brake lever. Check the brake lock operation (page 3-21). Connect the parking brake switch connectors [1]. Install the knuckle guard (page 25). Install the rearview mirror (page 17-10). PARKING BRAKE CALIPER (CRF1000D) REMOVAL/INSTALLATION Remove the parking brake pads (page 19-10). Release the parking brake cable [1] lrorn the cable stay [2] of the caliper body and disconnect it from the brake arm [3]. Installation is in the reverse order of removal. 19-23 HYDRAULIC BRAKE DISASSEMBLY Remove the caliper pin bolt [1]. Remove the Vollowing: — Caliper bracket [1] — Pad spring [2] — Bracket pin boot [3] — Caliper pin boot [4] — Collar [5] Remove the adjuster lock nut [1] while holding the brake arm [2]. Remove the brake arm. Remove the brake shaft boot [3]. Remove the push rod [1] while holding the brake shaft [2]- Remove the push rod/piston assembly. 19-24 HYDRAULIC BRAKE Remove the dust seal [1]. Clean the caliper cylinder and brake shafl sliding surlace. INSPECTION Inspect the following parts for scoring, scratches, or damage. — Calipercylinder — Caliper piston Replace i1 necessary. ASSEMBLY xfil 0.4 g(0.01oz)mImmum PUSH ROD F'AD SPRING BRACKET 0.4 g (0.01 oz) minimum BRACKET PIN BOOT )fii 0.4 g (0.01 oz) minimum BRAKE SHAFT PISTON xfil 0.4 g (0.01 oz) minimum {a 93 0.4 g (0.01 oz) minimum BRAKE SHAFT BOOT DUST SEAL gr fife-I xfii 4 g & CALIPER F'IN BOOT % COLLAR CALIPER PIN BOOT E 0.4 g (0.01 oz) minimum BRAKE ARM ADJUSTER LOCK NUT 17.2 N~m (1.5 kgf-m,13lbf~fl) CALIPER PIN BOLT v 22 N-m (2.2 kgf~m,16|bf-fl) 19-25 HYDRAULIC BRAKE Apply silicone grease to new dust seal lips. Install the dust seal [1] into the seal groove in the caliper. Apply 0.4 g minimum of silioone grease to the parking brake shaft outer surface. Install the parking brake shaft [1] to the caliper [2] and screw it in completely. Make sure that the punch mark [3] of the brake shaft is positioned opposite the index line [4]. Apply 0.4 9 minimum of silicone grease to the push rod rolling surface and piston sliding surface. Turn the brake shaft [1] clockwise and align the punch mark [2] with the index line [3]. Install the push rod [4] while holding the brake shaft. Apply 0.4 9 minimum of silioone grease to the brake shaft boot lips. Install the brake shaft boot [1] to the caliper groove. Install the brake arm [2] by aligning the punch marks as shown. 19-26 HYDRAULIC BRAKE Install the adjuster lock nut [1]. Tighten the adjuster lock nut to the specilied torque while holding the brake arm [2]. TORQUE: 17.2 N-m (1 .B kgf‘m,13lbf‘ft) Apply 0.4 g minimum of silicone grease to the bracket and caliper pin boot insides. Install the following: — Bracket pin boot [1] — Caliper pin boot [2] — Collar [3] — Pad spring [4] — Caliper bracket [5] Tighten the parking brake caliper pin bolt [1] to the specified torque. TORQUE:22 N-m (2.2 kgf-m, 16 lbf-ft) [2] [1] [5] 19-27 MEMO 20. ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000Afl3) SERVICE INFORMATION -------------------- -- 20-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING ----------------------- --2o-1o SYSTEM LOCATION -------------------------- -- 20-3 DTC TROUBLESHOOTING ---------------- --2o-12 SYSTEM DIAGRAM --------------------------- .. 20.4 WHEEL SPEED SENSOR ------------------ ..2o.2o ABS TROUBLESHOOTING INFORMATION ---------------------------------- -- 20.5 ABS MODULATOR ........................... “20.24 011; INDEX ....................................... .. 204; 20-1 ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000AID) SERVICE INFORMATION GENERAL ~ The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing, the excessive voltage may damage the control unit. Always turn off the ignition switch before servicing. ~ Spilling brake fluid will severely damage plastic pans and painted surfaces. It is also harmful to some rubber pans. ~ The ABS control unit is integrated in the ABS modulator. Do not disassemble the ABS modulator. Replace the ABS modulator as an assembly when the it is faulty. ~ The ABS control unit performs pre-start self-diagnosis to check whether the ABS functions normally until the motorcycle speed reaches 10 km/h (6 mph). After pre-start self-diagnosis, the ABS control unit monitors the ABS functions and motorcycle running condition constantly until the ignition switch is turned OFF (ordinary self-diagnosis). ~ When the ABS control unit detects a problem, it stops the ABS function, switches back to the conventional brake operation, and turns on or blinks the ABS indicator. Take care during the test-ride. ~ When the ABS control unit detects a problem in the rear ABS off indicator circuit, it stops the rear ABS off mode function, switches back to the normal ABS operation, and turns on or blinks the ABS indicator and goes off rear ABS off indicator. ~ Read "ABS TROUBLESHOOTING INFORMATION“ carefully, inspect and troubleshoot the ABS according to the diagnostic troubleshooting flow chart. Observe each step of the procedures one by one. Write down the DTC and probable faulty part before starting diagnosis and troubleshooting. ~ Use a fully charged battery. Do not diagnose with a charger connected to the batteny. ~ After troubleshooting, erase the DTC and test-ride the motorcycle to check that the ABS indicator operates normally during pre- start self-diagnosis (page 20-5). ~ Problems not caused by the faulty ABS (e.g. brake disc squeak, unevenly worn brake pad) cannot be detected by the ABS diagnosis system. ~ Before wheel speed sensor servicing, check the following: — Iron or other magnetic deposits between the pulser ring and wheel speed sensor — Pulser ring slots for obstructions — Installation condition of the pulser ring or wheel speed sensor for looseness — Pulser ring and sensor tip for deformation or damage ~ Be careful not to damage the pulser ring when removing and installing the wheel. ~ For pulser ring service: — Front pulser ring (page 17-12) — Rear pulser ring (page 18-5) ~ The following color codes are used throughout this section. BI = Black Bu = Blue Br = Brown G = Green O = Orange P = Pink R = Red V = Violet W = White Y = Yellow 20-2 ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000AID) SYSTEM LOCATION REAR ABS SWITCH CRF1000A: FUSE BOX 3 — ABS MAIN 7.5 A ABS MAIN so A CRFmUD: FUSE BOX 1 "r/ [I '1 W} . —ABSMAIN7.5A O 1 . r‘; ¢ FRONT WHEEL SPEED SENSOR ABS MODULATOR REAR WHEEL SPEED SENSOR 20-3 ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D) SYSTEM DIAGRAM MNN FUSE 30A FRONT ERAKE LIGHT SWTTcH \GNmON \ mflm swwcH T n U 52:?“ 75A RTaT BVR cw e N ‘ mam U REARERAKE LIGHTSWWTCH AES MAW (W W m m |BLs A : ’ K3 N ; m a (5452p EVGT ET WT‘Bu ABS _‘ H E‘ "‘9 ‘3 TNDTcAToR wT‘G REARAES aATTERv ‘ M099“ 2 or; _ TNDTcAToR AESMATN M w 3“ R R’V N n ‘ 15 EAT COMETNATTON METER (571‘572p POWERsuPFW w REL” we 5 GTT‘Eu scs 1A (54) G/Bu REARAES r®1 PUMFMOTOR __ m CANCELSWWTCH E ((5,1) : e \c RTBT a 15 MODESW —:— SOLENO‘DVALVE (371,372,373 34) W :I , _ _ _ _ _ _ . . . _ . . . _ . . . _ w wwsm Eu (14,172 175’ ' 5 vaam I . TTREsIZE - m FRONTWHEEL - - - - — -W @| I Eu ( («am my (172 44,472) . . (3ND FRONTPULSERRWG REARWHEEL ABS MODULATOR (24) g on: 5mm \ermmaTs fur Teadmg Dre 4]): SPEED sENsoR )(174,473) : REAR RuLsER Rm (033) (273) ABS MODULATOR 19F TaTacx) coNNEcToR (MODULATOR sum (84) ET ET mack Eroww ame Green Orange ka Red \leel wme VeHow omgv <§—<— [4] EOP SENSOR REMOVAL] INSTALLATION (CRF1000D) Drain the engine oil (page 3-12). Remove the bolts [1] and alternator assembly wire cover [2]. Drain the engine oil (page 3-12). Disconnect the EOP sensor 3P (Black) connector [1]. Remove the EOP sensor [2]. 22-20 Installation is in the reverse order of removal. TORQUE: EOP sensor: 22 N-m (2.2 kgf'm, 1e lbfrft) NOTE 2 Replace the O-ring with a new one. 2 Apply engine oil to the O»ring [1]. 2 Route the wire properly (page 1-26). Fill the engine oil with the recommended engine oil . (page 342). FUELLEVELSENSORWUELRESERVE SENSOR SYSTEM INSPECTION The fuel meter indicates the warning display. When an open or short circuit occur in the fuel meter system, the fuel gauge indicators will be displayed as shown with the ignition switch turned ON. Check the following: — Red/black wire between the fuel reserve sensor and combination meter for open or short circuit — Green wire between the fuel reserve sensor and ground for open circuit — Red/black wire between the fuel level sensor and combination meter for open or short circuit — Green wire between the fuel level sensor and ground for open circuit If they are normal, inspect the fuel level sensor (page 22-21) If the fuel level sensor is normal, replace the fuel pump unit with a new one and recheck (page 7-7). Fuel meter does not operate properly. NOTE 2 Check the initial function of the combination meter. (page 2242). Inspect the fuel level sensor (page 22-21) If the fuel level sensor is normal, replace the combination meter (page 22-12) and recheck. FUEL LEVEL SENSOR INSPECTION Remove the fuel level sensor (page 22-22). Connect the ohmmeter to the fuel level sensor 2P (Black) connector [1]. CONNECTION: Red/blue — Green Inspect the resistance of the float [2] at the full and empty positions. LIGHTS/METERSISWITCHES FULL EMPTY Resistance 6.4 — 10.4 D 204.8 — 210.8 0 If it is out of specification, replace the fuel level sensor (page 22-22). [2] FULL EMPTY 22-21 LIGHTS/METERSISWITCHES FUEL LEVEL SENSOR REMOVAL] INSTALLATION Remove the fuel tank (page 745). Remove the nuts [1]. Remove the Iuel reserve sensor [2] and O»ring [3]. Installation is in the reverse order of removal. NOTE . Replace the O-ring with a new one. . Apply engine oil to a new O»ring. . Align the sensor plate hole [4] with the tank boss. PARKING BRAKE INDICATOR/SWITCH (CRF1000D) SYSTEM INSPECTION If the parking brake indicator does not operate properly, check the combination meter initial operation (page 22» 12). If the combination meter system inspection is OK, check the parking brake switch line as follows: Turn the ignition switch OFF. Disconnect the parking brake switch connectors [1]. Connect the connector terminals with a jumper wire. The parking brake indicator should come on with the ignition switch turned ON. If the indicator does not come on, check ior open circuit in the Green/yellow and Green wires. If the indicator comes on, check the parking brake switch (page 22-22). PARKING BRAKE SWITCH INSPECTION Disconnect the parking brake switch connectors [1] and check ior continuity between the terminals. There should be continuity with the parking brake lever 7 applied, and there should be no continuity with the parking brake lever released. 22-22 LIGHTS/METERSISWITCHES IGNITION SWITCH INSPECTION Remove the fuel tank (page 745). Disconnect the ignition switch 2P (Brown) connector [1]. Check for oontinuity between the wire terminals of the ignition switch connector in each switch position. ReIer to the wiring diagram for the terminals and switch status. — CRF1000 (page 24-2) — CRF1000A (page 24-3) — CRF1000D (page 24-4) REMOVAL/INSTALLATION Remove the top bridge (page 17»22). Remove the harness cover [1]. Remove the bolts [2] and ignition switch [3]. NOTE . Use a drill or an equivalent tool when removing the ignition switch mounting bolts. Installation is in the reverse order of removal. NOTE . Replace the switch mounting bolts with new ones. TORQUE:26 N-m (2.7 kgfrm, 19 lbf-ft) HANDLEBAR SWITCHES LEFT HANDLEBAR SWITCH INSPECTION Remove the left middle cowl (page 2-6). CRF1000D shown: Disconnect the Iollowing: — CRF1000: 12p (Gray) [1] and 4P (Black) [2] connectors — CRF1000A: 10F (Gray) [1] and SP (Black) [2] connectors — CRF1000D: 10P (Gray) [1] and 12p (Black) [2] connectors Check for oontinuity between the wire terminals of the handlebar switch connector in each switch position. [2] ReIer to the wiring diagram for the terminals and switch status. — CRF1000 (page 24-2) — CRF1000A (page 24-3) — CRF1000D (page 24-4) 22-23 LIGHTS/METERSISWITCHES RIGHT HANDLEBAR SWITCH INSPECTION Remove the right middle oowl (page 2-6). Disconnect the Iollowing: — CRF1000/A: 8P (Gray) connector [1] — CRF1000D: 8P (Gray) [1] and SP (Black) [2] connectors Check for oontinuity between the wire terminals of the handlebar switch connector in each switch position. Reier to the wiring diagram for the terminals and switch status. — CRF1000 (page 24-2) — CRF1000A (page 24-3) — CRF1000D (page 244) BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors [1] 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 released. REAR Remove the connector cover (page 5-8). Disconnect the rear brake light switch 2P (Gray) connector [1]. CRF1OODD shown: CRF1OODD shown: 22-24 LIGHTS/METERSISWITCHES Check for continuity between the rear brake light switch V , V v ~I 2P (Gray) connector [1] terminals. There should be continuity with the brake pedal applied, ’ and there should be no continuity with the brake pedal released. CLUTCH SWITCH (CRF1000IA) Disconnect the clutch switch connectors and check (or continuity between the terminals [1]. There should be continuity with the clutch lever applied. and there should be no continuity with the clutch lever released. GEAR POSITION SWITCH (CRF1000/A) REMOVAL/INSTALLATION Remove the left rear cover (page 2-10). Remove the rear shock absorber (page 1&8). Disconnect the gear position switch 8P (Black) connector [1]. Shift the transmission into neutral. Remove the bolt [1], the gear position switch [2], and O» ring [3]. Installation is in the reverse order of removal. NOTE . Replace the O-ring with a new one. . Apply engine oil to a new O»ring. . When installing the gear position switch, shift the transmission into neutral. - . Align the switch pin with the shift drum slot, being careiul not to damage the switch pin. TORQUE: 10 N-m (1.0 kgf-m, 7 let) LIGHTS/METERSISWITCHES SYSTEM INSPECTION If the gear position switch indicator does not operate properly, check the combination meter initial operation (page 22-12). It the combination meter system inspection is OK. check the gear position switch line as follows: Disconnect the combination meter 32F (Gray) connector (page 22-12) Check tor continuity between the wire harness side 32F (Gray) connector [1] and ground. CONNECTION: 1st: Brown — ground Neutral: Light green — ground 2nd: Red — ground 3rd: Blacklyellow — ground 4th: Yellow — ground 5th: Blacklorange — ground 6th: Blue/white — ground There should be continuity only at the terminals that correspond to the each gear position (open circuit inspection). There should be no continuity at the other terminals (short circuit inspection). You must test each of the seven wires in each change pedal position. Therefore, you need to make 49 tests, between the wire harness side 32P (Gray) connector and ground. lithe test result is abnormal, check the gear position switch (page 22-26). SWITCH INSPECTION lithe gear position switch system inspection (page 22- 26) is abnormal, check the gear position switch as iollowing. Disconnect the gear position switch 8P (Black) connector (page 22-25). Check for continuity between the switch side 8P (Black) connector [1] and ground. CONNECTION: 1st: Brown — ground Neutral: Light green — ground 2nd: Red — ground 3rd: Blacklyellow — ground 4th: Yellow — ground 5th: Black — ground 6th: Blue — ground There should be continuity only at the terminals that correspond to the each gear position, and there should be no continuity at the other terminals. You must test each of the seven wires in each change pedal position. Therefore, you need to make 49 tests, between the switch side 8P (Black) connector and ground. lithe test results is normal, open and/or short circuit in the combination meter 32F (Gray) and SP (Black) connectors. If the test results are abnormal, replace the gear position switch (page 22-25). Bi/O [1] Y LIGHTS/METERSISWITCHES SIDESTAND SWITCH REMOVAL/INSTALLATION Remove the left rear cover (page 2-10). CRF1000D: Remove the shift control motor cover (page 13-71). Remove the connector cover (page 5-8). Disconnect the sidestand switch 2P (Black) connector [1]- Remove the bolt [1] and sidestand switch [2]. Installation is in the reverse order of removal. NOTE . Replace the bolt with a new one. . Align the sidestand switch tab [3] with the sidestand hole [4]. . Align the sidestand switch groove [5] with the return spring holding pin [6]. TORQUE: 10 N-m (1.0 kgfrm, 7 let) INSPECTION Disconnect the sidestand switch 2P (Black) connector 1 (page 22-27). I 1 Check for oontinuity at the switch side 2P (Black) connector [1]. CONNECTION: Green/white — Green There should be oontinuity with the sidestand retracted G/W — G and no continuity with the sidestand lowered. 22-27 LIGHTS/METERSISWITCHES HORN REMOVAL/INSTALLATION Turn the ignition switch OFF. Disconnect the wire connectors [1] from the horn [2]. Remove the bolt [3] and horn. Installation is in the reverse order of removal. NOTE . Rest the horn stay [4] against the stopper [5]. INSPECTION Disconnect the wire connectors from the horn (page 22» 28). Connect the 12 V battery to the horn [1] terminal directly. The horn is normal it it sounds when the 12 V battery is connected across the horn terminals. 22-28 LIGHTS/M ETERSISWITCHES HSTC (Honda Selectable Torque Control) SYSTEM NOTE O The HSTC system utilizes various PGM-Fl/ABS components. If any of the related items and/or circuit has problem. the system will fail and the torque control indicator remains on in order to notify the rider of the problem. O If any DTC or ABS problem code is indicated. repair the malfunction part(s) first. SYSTEM INSPECTION PRE-START SELF-DIAGNOSIS PROCEDURE 1. Turn the ignition switch ON and engine stop switch 2. The torque control indicator turns ON. 3. Start the engine. 4. Test ride the motorcycle and increase the motorcycle speed to approximately 10 km/h (6 mph). 5. The system is normal if the indicator goes off. TORQUE CONTROL INDICATOR REMAINS ON AFTER THE PRE-START SELF DIAGNOSIS IS COMPLETED, OR IT TURNS AND REMAINS ON WHILE RIDING. Check the followmg: — No PGM-Fl DTC indicated (page 4-9) — No DCT DTC indicated (CRFIOOOD) (page 13-10) — No ABS DTC (page 20-8) — Combination meter TXD line (page 22-14) If all of the above items are normal. replace the combination meter (page 22-12) and recheck the torque control indicator. TORQUE CONTROL CAN NOT BE TURNED OFF OR CAN NOT CHANGE LEVEL BY PRESSING THE TORQUE CONTROL SWITCH Check the followmg: — Yellow and Yellow/white Wire between the left handlebar swnch and fuse box 1 (sub fuse ENG STOP 7.5 A) for open or short circuit. — Blue/black Wire between the left handlebar switch and ECM/PCM for open or short circuit. — Left handlebar switch (page 22-23) If all of the above items are normal, replace the ECM/ PCM (page 4-39) With a new one and recheck. TORQUE CONTROL SWITCH INSPECTION Refer to the left handlebar switch inspection (page 22- 23). TORQUE CONTROL SWITCH REMOVAL/INSTALLATION Refer to the left handlebar swnch removal/installation. — REMOVAL (page17-4) — INSTALLATION (page 17-7) 22-29 LlGHTS/METERSISWITCHES REAR ABS SWITCH (CRF1000AID) NOTE . For the rear ABS ofl mode system technical feature (page 1-50). . If the rear ABS switch and related circuit has problem, the system will get back the normal ABS mode. In order to notify the rider ot the problem, the rear ABS off indicator goes off and ABS indicator comes on. . If the ABS DTC 8-2 is indicated, refer to the ABS TROUBLESHOOTING DCT 9-2 (page 20-12). REAR ABS SWITCH REMOVAL] INSTALLATION Remove the right inner panel cover (page 2-8). CRF1000A: Remove the two screws [1] and rear ABS switch [2]. CRF1000D: Remove the four screws [1] and rear ABS 1 switch [2]/G switch [3] assembly. Installation is in the reverse order of removal. INSPECTION PRE-START SELF-DIAGNOSIS PROCEDURE 1. Turn the ignition switch ON and engine stop switch 2. If the system is normal, the rear ABS off indicator comes on and goes off after approximately 2 seconds. REAR ABS CAN NOT BE TURNED OFF OR ON BY PRESSING THE REAR ABS SWITCH Check the following: — Red/black wire between the rear ABS switch 2P (CRF1 000A) or 4P (CRF‘IOOOD) connector and ABS modulator for open or short circuit. — Green wire between the rear ABS switch 2P (CRFIDOOA) or 4P (CRFIODOD) oonnector and ground Ior open circuit. — Rear ABS switch (page 22-31) It all of the above items are normal, replace the ABS modulator with a new one (page 2044) and recheck. REAR ABS IS TURNED OFF OR ON WITHOUT PRESSING THE REAR ABS SWITCH Check the following: — Red/black wire between the rear ABS switch 2P (CRF1 000A) or 4P (CRF‘IOOOD) connector and ABS modulator for short circuit. — Rear ABS switch (page 22-31) It all of the above items are normal, replace the ABS modulator with a new one (page 2044) and recheck. CRF1000D shown: 22-30 LIGHTS/METERSISWITCHES REAR ABS SWITCH INSPECTION Remove the right middle cowl (page 2-6). Disconnect the Iollowing: “ ‘ — CRFiODOA: Rear ABS switch 2P (Black) connector — gllRFmOOD: Rear ABS/G switch 4P (Black) connector [1] Check for continuity between the switch side terminals. Connection: CRF1DDOA: Red — Black CRF1000D: Red/black — Green There should be continuity with the switch pushed, and ‘ there should be no oontinuity with the switch released. If the switch operate properly, open circuit in the Iollowing wires: CRF1UUUA: CRF1000D: — Red/black wire between the switch and ABS modulator — Green wire between the switch and ground If the switch does not operate properly, replace the switch (page 22-30). G SWITCH (CRF1000D) NOTE . For the G ride system technical feature (page 1-52). G SWITCH REMOVAL/INSTALLATION ReIer to the REAR ABS SWITCH REMOVAL/ INSTALLATION (page 22-30). INSPECTION G SWITCH INSPECTION Check the following: — No DCT DTC indicated (page 13-10) — Combination meter TXD |ine (page 22-14) If all 01 the above items are normal, check the G switch as Iollowing. 22-31 LIGHTS/METERSISWITCHES Remove the right middle oowl (page 2-6). Disconnect the rear ABS/G switch 4P (Black) connector [1]- Check for continuity between the switch side terminals. Connection: Blue/black — Green/black There should be continuity with the switch pushed, an there should be no continuity with the switch released. If the switch operate properly, open circuit in the lollowing wires: — Blue/black wire between the switch and POM — Green/black wire between the switch and ground If the switch does not operate properly, replace the switch (page 22-30). 22-32 23. IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION -------------------- .. 23.2 SYSTEM LOCATION -------------------------- -- 23-2 SYSTEM DIAGRAM ........................... .. 23.3 KEY REGISTRATION PROCEDURES 23-3 DIAGNOSTIC CODE INDICATION -------- -- 23-7 TROUBLESHOOTING ------------------------ -~ 23-8 HISS INDICATOR ............................. ..23.1o ECM (CRF1000/A)/PCM (CRF1000D) --~--23-1o IMMOBILIZER RECEIVER ------------------ "23-10 23-1 IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION GENERAL ~ When checking the HISS, follow the steps in the troubleshooting Ilow chart (page 23-8). ~ Keep the immobilizer key away from the other motorcycle‘s immobilizer key when using it. The jamming of the key code signal may occur and the proper operation of the system will be obstructed. ~ The key has built-in electronic part (transponder). Do not drop and strike the key against a hard material object, and do not leave the key on the dashboard in the car, etc. where the temperature will rise. Do not leave the key in the water for a prolonged time such as by washing the clothes. The ECM/PCM as well as the transponder keys must be replaced it all transponder keys have been lost. The system does not Iunction with a duplicated key code is registered into the transponder with the HISS. The ECM/PCM can store up to tour key codes. (The tour keys can be registered.) II the PCM is replaced, perform the following procedure. — Key Registration Procedure (page 2343) — Clutch Initialize Learning Procedure (CRFiODOD) (page 1382) Do not modify the HISS as it can cause the system failure. (The engine cannot be started.) ReIer to the ignition system inspection (page 5-6). ReIer to the ignition switch servicing (page 22-23). SYSTEM LOCATION CRF1000D shown: 7 IGNITION SWITCH r IMMOBILIZER RECEIVER ENGINE STOP SWITCH STARTER RELAY SWITCH 7 MAIN FUSE 30 A 7 Fl FUSE 15 A H|SS 2P (Red) CONNECTOR Fl RELAY ECM/PCM BATTERY CKP SENSOR FUSE BOX 1 r CLOCK TURN 7.5 A 7 ENG STOP 7.5 A 23-2 IMMOBILIZER SYSTEM (HISS) SYSTEM DIAGRAM MAIN CLOCK FUSE TURN COMBINATION METER so A 7.5 A ‘ R “A R/W HISS INDICATOR Bl/Gr BI ENGINE f 7 H1 H1 IGNITION 33}, STOP ® 9 (D SW‘TCH 7_5A SWITCH I “VERY w R/BI w wry 4/07 BI G l R/Bl J— R/W T T Fl FUSE 15 A m CKP SENSOR I I I—I Gr/Bl F, v W/Y Y/R Bu/O Bu/O Y/R BWV h? v W/Y Bl Black I—[u—‘I G HISS 2F' (Red) 5 Bl CONNECTOR Guerefn Y/R O/Bu R R9“ G/O F' T T WC 0 Orange ‘ I P Pink IMMOBILIZER R Red W: White RECEIVER ECM/PCM Y Yellow KEY REGISTRATION PROCEDURES When the key has been lost, or additional spare key is required: 1. Obtain a new transponder key. 2. Grind the key in accordance with the shape of the original key. 3. Apply 12 V battery voltage to the CKP sensor lines oi the ECM/PCM using the special tool (page 23-7). 4. Turn the ignition switch ON with the original key. The HISS indicator comes on and it remains on. The code of the original key recognized by the ECM/PCM. If there is any problem in the HISS, the system will enter the diagnostic mode and the indicator will remain on for approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 5. Disconnect the red clip of the inspection adaptor irom the battery positive (+) terminal ior two seconds or more, then connect it again. The indicator remains on for approx. two seconds. then it blinks iour times repeatedly. ON OFF . . . . . . . . . . . . . . , . . . . .. 2 sec. - The HISS enters the registration mode. Registrations of all key except the original key inserted in the ignition switch are cancelled. (Registration of the lost key or spare key is cancelled.) The spare key must be registered again. 6. Turn the ignition switch OFF and remove the key. 23-3 IMMOBILIZER SYSTEM (HISS) 7 9. . Turn the ignition switch ON with a new key or the spare key. (Never use the key registered in previous steps.) The indicator comes on for two seconds then it blinks {our times repeatedly. lHiiiLiiiiiilL The new key or spare key is registered in the ECM/PCM. It there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten seconds, then it will indicate the diagnostic code (page 23-7). Keep the other transponder key away from the immobilizer receiver more than 50 mm (2.0 in). ON OFF . . . . . . . . . . . . . . , . . . , .. 2 sec. . Repeat the steps 6 and 7 when you continuously register the other new key. The ECM/PCM can store up to four key codes. (The four keys can be registered.) Turn the ignition switch OFF, remove the inspection adaptor and connect the HISS 2P (Red) connector. 10.Turn the ignition switch ON with the registered key. The HISS returns to the normal mode. 11.Check that the engine can be started using all registered keys. When the ignition switch is faulty: 1 2 3. 4 (9ch . Obtain a new ignition switch and two new transponder key. . Remove the ignition switch (page 22-23). Apply 12 V battery voltage to the CKP sensor lines oi the ECM/PCM using the special tool (page 23-7). . Set the original (registered) key near the immobilizer receiver so that the transponder in the key can communicate with the receiver. . Connect a new ignition switch to the wire harness and turn it ON with a new transponder key. (keep the ignition switch away from the receiver.) The HISS indicator comes on and it remains on. The code of the original key recognized by the ECM/PCM. It there is any problem in the HISS, the system will enter the diagnostic mode and the indicator will remain on for approx. ten seconds, then it will indicate the diagnostic code (page 23-7). . Disconnect the red clip of the inspection adaptor from the battery positive (+) terminal {or two seconds or more, then connect it again. The indicator remains on for approx. two seconds then it blinks four times repeatedly. . The HISS enters the registration mode. Registrations of all key except the original key set near the receiver are cancelled. ON OFF. .. .. , .. .. 2 sec. . Turn the ignition switch OFF and remove the key. . Install the ignition switch onto the top bridge (page 22-23). . Turn the ignition switch ON with a first new key. The indicator comes on for two seconds then it biinks four times repeatedly. ON lHiiiLiiiiiilL The first key or spare key is registered in the ECM/PCM. It there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten seconds, then it will indicate the diagnostic code (page 23-7). OFF . . . . . . . . . . . . . . , . . . , .. 2 sec. 23-4 IMMOBILIZER SYSTEM (HISS) 10.Tum the ignition switch OFF and disconnect the red clip of the inspection adaptor from the battery positive (+) terminal. 11.Tum the ignition switch ON (with the first key registered in step 9). The HISS indicator comes on for two seconds then it goes off. - The HISS returns to the normal mode. 12.Tum the ignition switch OFF and connect the red clip of the inspection adaptor to the battery positive (+) terminal. 13.Turn the ignition switch ON (with the iirst key registered in step 9). The HISS indicator comes on and it remains on. - The code ifthe iirst key is recognized by the ECM/PCM. - If there is any problem in the HISS, the system will enter the diagnostic mode and the indicator will remain tor approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 14.Disconnect the red clip of the inspection adaptor from the battery positive (+) terminal tor two seconds or more, then connect it again. The indicator remains on for approx. two seconds then it blinks four times repeatedly. - The immobilizer system (HISS) enters the registration mode. Registration of the original key used in step 4 is cancelled. 15.Tum the ignition switch OFF and remove the key. 16.Tum the ignition switch ON with a second new key. (Never use the key registered in previous step.) The indicator comes on for two seconds then it blinks four times repeatedly. - The second key or spare key is registered in the ECM/PCM. - If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten seconds, then it will indicate the diagnostic code (page 23-7). - Keep the other transponder key away from the immobilizer receiver more than 50 mm (2.0 in). 17.Repeat the steps 15 and 16 when you continuously register the other new key. The ECM/PCM can store up to four key codes. (The tour keys can be registered.) 18.Tum the ignition switch OFF, remove the inspection adaptor and connect the HISS 2P (Red) connector. 19.Tum the ignition switch ON with the registered key. - The HISS returns to the normal mode. 20.Check that the engine can be started using all registered keys. When all keys have been lost: 1. Obtain a new ECM/PCM and new key set. 2. Replace the ignition switch with a new one (page 22-23). 3. Replace the ECM/PCM with a new one (page 4-39). 4 . Turn the ignition switch ON with a first new key and engine stop switch "5“. The HISS indicator comes on for two seconds, then it blinks four times repeatedly. - The first key is registered in the ECM/PCM. - If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 5. Turn the ignition switch OFF and remove the first key. 6. Turn the ignition switch ON with a second new key. The HISS indicator comes on for two seconds, then it blinks four times repeatedly. ~ The second key is registered in the ECM/PCM. ~ It there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten seconds, then it will indicate the diagnostic code (page 23-7). 7. Turn the ignition switch OFF and remove the second key. - The system (ECM/PCM) will not enter the normal mode unless the two keys are registered in ECM/PCM. ~ The third new key cannot be continuously registered. When it is necessary to register the third key, follow the procedures “When the key has been lost, or additional key is required“ (page 23-3). 8. Check that the engine can be started using all registered keys. 9. Replace the remaining key set parts. 23-5 IMMOBILIZER SYSTEM (HISS) When the ECMIPCM is faulty: 1. Obtain a new ECM/PCM and two new transponder keys. 2. Grind the keys In accordance with the shape ol the original key (or use the key number plate when all key have been lost). 3. Repiace the ECM/PCM With a new one (page 4-39). 4 . Turn the ignition sWitch ON With a first new key and engine stop sWitch The HISS indicator comes on for two seconds, then it blinks four times repeatedly. ~ The first key is registered in the ECM/PCM. ~ ll there is any problem in the registration, the system Wi|| enter the diagnostic mode and the indicator Wili remain for approx. ten seconds, then it Will indicate the diagnostic code (page 23-7). 5. Turn the ignition switch OFF and remove the first key. 6. Turn the ignition sWitch ON With a second new key. The HISS indicator comes on lor two seconds, then it blinks four times repeatedly. ~ The second key is registered in the ECM/PCM. ~ ll there is any problem in the registration, the system Will enter the diagnostic mode and the indicator Wili remain for approx. ten seconds, then it Will indicate the diagnostic code (page 23-7). 7. Turn the ignition sWitch OFF and remove the second key. ~ The system (ECM/PCM) Will not enter the normai mode unless the two keys are registered in ECM/PCM. ~ The third new key cannot be continuously registered. When it is necessary to register the third key, follow the procedures "When the key has been lost, or additionai key is required" (page 23-3). 8. Check that the engine can be started using all registered keys. 23-6 IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE INDICATION Remove the main seat (page 2-4). Release the main harness wire clip [1] fro of the ETC tray. Release the HISS 2P (Red) connector [3] [4] ofthe ETC tray and disconnect it. Connect the special tools to the wire harness side 2P (Red) con nector. Connect the Red clip ot the adaptor to the 12 V battery positive (+) terminal and Black clip to the negative (—) 7 terminal. TOOLS: Inspection adaptor [1] Test harness adaptor [2] 07DMZ-M Turn the ignition switch ON with the properly registered key and engine stop switch "C". The HISS indicator will come on tor seconds then it will start blinking to diagnostic code if the system is abnormal. The blinking frequency is repeated. The HISS indicator remains on when t 07XMZ-MBW01 01 m the hole [2] from the stay E60101 approx. ten indicate the he system is normal. (The system is in the normal mode and the diagnostic code does not appear.) DIAGNOSTIC CODE When the system (ECM/PCM) enters the diagnostic mode from the normal mode: J—lflflflJ—L BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE ECM/PCM data Faulty ECM/PCM Replace the ECM/ ON -----—U-L|-L|—L|-|— is abnormal POM OFF -- — <—>— 10 sec. Code signals Faulty receiveror Follow the cannot send or wire harness troubleshooting receive (page 2&8) J—lfllllllL Identification code does not match Secret code does not match Jamming by the other transponder Keep the other motorcycle‘s transponder key away from the immobilizer receiver more than 50 mm (2.0 in) 23-7 IMMOBILIZER SYSTEM (HISS) When the system (ECM/PCM) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Registration is The key is Use a new key or overlapped already cancelled key OFFWHUU W L 3.25:?“ 10 sec. Code signals Communication Follow the cannot send or fails troubleshooting receive (page 23-8) Registration is The key is Use a new key impossible already registered on the other system TROUBLESHOOTING The HISS indicator comes on for approx. two seconds then it goes off. when the ignition switch is turned ON with the properly registered key and the HISS functions normally. If there is any problem or the properly registered key is not used, the indicator will remains on. HISS indicator does not come on when the igniti n switch is turned ON 1. Combination Meter Initial Operation Inspection Check the combination meter initial operation (page 22-12). Is the initial operation displayed? YES — GO TO STEP 2. NO — Check the combination meter power and ground lines (page 22-12). 2. TXD Line Inspection Check the combination meter indication when the TXD line is abnormal (page 22-14). Does the combination meter shows the communication line faulty operation? YES — Check the TXD line (page 22-14). NO — Check the ECM/PCM power/ground lines (page 4-40). HISS indicator remains on with the ignition switch turned ON 1. Immobilizer Receiver Jamming Inspection Check that there is any metal obstruction or the other vehicles transponder key near the immobilizer receiver and key. Is there any metal obstruction or the other transponder key? YES — Remove it and recheck. NO — GO TO STEP 2. 2. First Transponder Key Inspection Turn the ignition switch ON with the spare transponder key and check the HISS indicator. The indicator should came on for 2 seconds then go off. Is the indicator go off? YES — Faulty first transponder key NO — GO TO STEP 3. 23-8 IMMOBILIZER SYSTEM (HISS) 3. Diagnostic Code Inspection Perform the diagnostic code Indication procedure (page 23-7). Check that the HISS indicator comes on then it starts blinking. Is the indicator brinks or stay lit? BRINKS—Read the diagnostic code (page 23-7). STAY LIT—GO TO STEP 4. 4. TXD Line Inspection Check the TXD line (Black Wire) between the ECM/PCM and combination meter connectors (page 22-14). Is the inspection normal? NO — Open or short circuit in Black wire YES — GO TO STEP 5. 5. CKP sensor Line Open Circuit Inspection Check the CKP sensor lines (page 23-10). Is there continuity? YES — ~ Open circuit in the Yellow Wire ~ Open circuit in the White/yellow Wire NO — Faulty PCM Diagnostic code J—lflflflfl is indicated (Code signals cannot send or receive) 1. Immobilizer Receiver Power Input Line Inspection Check the immobilizer receiver power input line (page 23-11). Is the input line normal? YES — GO TO STEP 2. NO — Open or short circuit in the Yellow/red Wire 2. Immobilizer Receiver Ground Line Inspection Check the immobilizer receiver ground line (page 23-11). Is the ground line normal? YES — GO TO STEP 3. NO — ~ CRF1000/A: Open circuit in the Gray/black wire ~ CRF1000D: Open circuit in the Gray wire 3. Immobilizer Receiver Signal Line Inspection Check the immobilizer receiver signal lines (page 23-11). Are the signal lines normal? YES — GO TO STEP 4. NO — Open or short circuit in the Pink or Blue/orange wire 4. Immobilizer Receiver Inspection Replace the immobilizer receiver With a Know good one (page 23-12). Perform the diagnostic code indication procedure (page 23-7). Is the Diagnostic code indicated? YES — Replace the PCM With a known good one and recheck. NO — Faulty original immobilizer receiver 23-9 IMMOBILIZER SYSTEM (HISS) HISS INDICATOR POWER INPUT LINE INSPECTION Inspect the combination meter power/ground line (page 22-12). HISS INDICATOR LINE INSPECTION Inspect the combination meter TXD |ine (page 22-14). ECM (CRF1000IA)/PCM (CRF1000D) CKP SENSOR LINE INSPECTION Disconnect the Iollowing: — CRF1000/A: Alternator connector (page 11-4) — CRF1000D: Alternator connector (page 11-5) — ECM/POM 33F (Gray) connector (page 4-39) Check for continuity between the 6P (Black) [1] and 33F (Gray) [2] connectors. CONNECTION: Yellow — 08 White/yellow — C16 assembly 6P (Black) assembly 6P (Black) TOOL: Test probe 07ZAJ-RDJA110 There should be continuity. IMMOBILIZER RECEIVER Remove the fuel tank (page 7»6). Turn the ignition switch OFF. Disconnect the immobilizer receiver 4P connector [1]. (Black) CRF1000/A: [1] C8 Y I. g? . l l 0 W/Y m C16 ® CRF1000D: [11 n ® ca Y 1 o' p o l- l 0 W/Y m C16 ® [2] [2] 23-10 IMMOBILIZER SYSTEM (HISS) POWER INPUT LINE INSPECTION Turn the ignition switch ON and engine stop sWitch Measure the voltage between the Immobilizer receiver 4P (Black) connector [1] and ground at the Wire side. CONNECTION: Yellow/red (1-) — Ground (—) There should be approx. 5 V. GROUND LINE INSPECTION Check Ior continuity between the immobilizer receiver 4P (Black) connector [1] and ground at the Wire side. CONNECTION: CRF1DOO/A: GrlBl (+) — Ground (—I CRF1000D: Gr 1+) — Ground (—i There should be continuity at all times. SIGNAL LINE INSPECTION Turn the ignition switch ON and engine stop sWitch Measure the voltage between the immobilizer receiver 4P (Black) connector [1] and ground at the Wire side. CONNECTION: Pink (+) — Ground (—) There should be approx. 5 V. Disconnect the ECM/PCM 33F (Gray) connector (page 4-39). Check Ior continuity between the immobilizer receiver 4P (Black) [1] and 33P (Gray) [2] connectors at the wire side. CONNECTION: Blue/orange — 621 TOOL: Test probe 07ZAJ-RDJA110 There should be continuity. [1] [1] .l Gr/Bl or Gr [1] a; 4 [2] 23-11 IMMOBILIZER SYSTEM (HISS) Check for continuity between the PCM 33F (Gray) connector [1] and ground at the wire side. CONNECTION: 621 — Ground TOOL: Test probe 07ZAJ-RDJA110 There should be no continuity. REMOVAL/INSTALLATION Remove the top bridge (page 17-22). Remove the harness cover [1]. Remove the screws [2] and the immobilizer receiver [3]. Installation is in the reverse order of removal. REPLACEMENT PARTS FOR PROBLEM Replacement parts Ignition ECMIPCM switch Key set Seal} lgck assembly 0y In er Problem Transponder Immobilizer Key receiver One Key has been lost. or additional 0 spare key is required All key has been lost 0 O ECM/PCM is faulty o o Immobilizer 0 receiver is faulty Ignition switch is faulty 0 Seat lock is faulty O 23-12 24. WIRING DIAGRAM WIRING DIAGRAM (CRF1000) ------------- -~ 24-2 WIRING DIAGRAM (CRF1000D) ----------- -~ 24-4 WIRING DIAGRAM (CRF1000A) ----------- -~ 24-3 24-1 WIRING DIAGRAM (CRF1000) ENGINE STOP & STARTER SWITCH IGNITION SWITCH HAZARDSWITCH am ‘e __ yo. me w w am I6 51 0» ON m 0» mm LOCK :axs IIIII \ww fl WIRING DIAGRAM Bl BIack Br Brawn v YeHow 0 Orange METERSELECTSWITCH METERSETSWITCH TURNSIGNALLIGHTSWITCH DIMMERSWH’CH PASSINGSWITCH HORNSWH’CH Bu Bme Lb Lugmsme w mu DOWN 3:1 mm w R L p w w um LL) m mm m kmvz no (3 Green Lg ngmGreen up we R LL) we: we: R Red P Pmk N wsu one N [Ny wen Ono we” o__o w wrme Gr Gray DOWN L m 24-2 WIRING DIAGRAM WIRING DIAGRAM (CRF1000A) REAR ABS SWITCH mm: GNI} ENGINE STOP 8. 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BANK ANGLE SENSO BATTERY' BODY PANEL LOCATIONS BRAKE FLUID ............. ., BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE LIGHT SWITCH LIGHTS/METERS/SWITCHES- MAINTENANCE ............. ,. BRAKE LOCK OPERATION (CRFIODOD) BRAKE PAD/DISC BRAKE PADS WEAR BRAKE SYSTEM -' BRAKE/TAILLIGHT CABLE & HARNESS ROUTING CAM CHAIN TENSIONER LIFTER CAMSHAFT ................... .. CHARGING SYSTEM INSPECTION CLUTCH (CRFmOO/A) ............. .. CLUTCH EOP SENSOR (CRFIOOODI CLUTCH INITIALIZE LEARNING (PCM)' CLUTCH OIL FEED PIPE (CRF‘IDOOD) 1 0-8 > 13-80 > 13-82 > 13-50 CLUTCH OIL FILTER (CRFIODOD) 3-13 CLUTCH SWITCH (CRFIOOO/A) '22-25 CLUTCH SYSTEM (CRFIODOIA) 3-22 COMBINATION METERMH '22-12 COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH - - ' > > - - ' > - - ' > -- 11-3 CLUTCH/GEARSHIFT LINKAGE (CRFIODOIA) 12-3 CRANKCASE/TRANSMISSION/BALANCER' 14-4 CRANKSHAFT/PISTON/CYLINDER'-- 15-3 CYLINDER HEAD/VALVE/CAMSHAFT 10-3 DUAL CLUTCH TRANSMISSION (DCT) (CRFmOOD) .......................... ,, ENGINE REMOVAL/INSTALLATION -' FRONT WHEEL/SUSPENSION/STEERING ' 13-4 16-3 FUEL SYSTEM~-- HYDRAULIC BRAKE 19-3 REAR WHEEL/SUSPENSION 18-3 COOLANT REPLACEMENT 8-4 COOLING SYSTEM" 3-15 CRANKCASE ASSEMBL 14-27 CRANKCASE BREATHER “3-5 CRANKCASE SEPARATION 14-13 CRANKPIN BEARING 15-9 CRANKSHAFT CUSHION LINKAGE- CYLINDER COMPRESSION CYLINDER HEAD ----- ~ 10-13 CYLINDER HEAD COVER 10-4 DCT SYMPTOM TROUBLESHOOTING I DCT TROUBLESHOOTING INFORMATIO DIAGNOSTIC CODE INDICATION DRIVE CHAIN DRIVE CHAIN SLIDER- DTC INDEX ANTI-LOCK BRAKE SYSTEM (ABS) ------ ~ DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D) PGM-FI SYSTEM - DTC TROUBLESHOOTING ANTI-LOCK BRAKE SYSTEM (ABS) (CRFmooA/D) ..................................... .. 2042 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D)- 13-15 PGM-FI SYSTEM »4-11 DUAL CLUTCH/PRIMARY DRIVEN GEAR 13-63 ECM (CRF1000/A)/PCM (CRF1000D) IMMOBILIZER SYSTEM (HISS)- 23-10 PGM-FI SYSTEM «1-39 ECT SENSOR -- >4-41 EMISSION CONTROL SYSTEMS - 1-47 ENGINE IDLE SPEED~- 3-14 ENGINE INSTALLATION ENGINE OIL >>>>> *- ENGINE OIL FILTER > ENGINE OIL PRESSURE INDICATOR/EOP SWITCH (CRF1000/A)/EOP SENSOR (CRF‘IDOOD) 22-19 ENGINE REMOVAL ------- ~ -16-5 EOT SENSOR (CRF1000D)- 13-81 ETC TRAY ........ ,. FAN CONTROL RELAY FI RELAY ~ «143 FLYWHEEL - 11-7 FORKw- 17-14 FRONT BRAKE CALIPER' FRONT COVER 2-7 FRONT FENDER - 2-9 FRONT MASTER CYLINDER 19-13 FRONT SPOILER FRONT WHEEL FUEL INJECTOR - FUEL LEVEL SENSOR/FUEL RESERVE SENSOR FUEL LINE FUEL LINE INSPECTION » FUEL PUMP RELAY FUEL PUMP UNIT FUEL TANK-~- G SWITCH (CRF1000D) GEAR POSITION SWITCH (CRF1000/A GEARSHIFT LINKAGE CLUTCH/GEARSHIFT LINKAGE (CRF1000/A) 12-17 DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D)-‘ »- GEARSHIFT PEDAL (CRF1000/A)- 12-21 HANDLEBAR ---- ~ -17-4 HANDLEBAR SWITCHES' 22-23 HEADLIGHT > - HEADLIGHT AIM - HEADLIGHT RELAY HIGH COOLANT TEMPERATURE INDICATOR/EC SENSOR ....... .. .. HISS INDICATOR HORN ........... .. HSTC (Honda Selectable Torque COnIrOI) SYSTEM IACVW IAT SENSOR IGNITION COIL 5-9 IGNITION SWITCH 22-23 IGNITION SYSTEM INSPECTION 5-6 IGNITION TIMING ------ ~ 5-10 IMMOBILIZER RECEIVER INNER COVER“ ~ 2-8 INNER PANEL COVER - 2-8 INSULATOR >>>>> ~ 10-19 KEY REGISTRATION PROCEDURES '23-3 KNUCKLE GUARD (CRF1 DODA/D) ' INDEX LEFT REAR COVER - LICENSE LIGHT~-- LINEAR SOLENOID VALVE (CRFIODOD LUBRICATION a. SEAL POINTS“- LUBRICATION SYSTEM DIAGRAM- MAIN JOURNAL BEARING MAIN SEAT ........ .. MAINSHAFT SENSOR (CRFIOOOD) MAINTENANCE SCHEDULE » MAP SENSOR MIDDLE COWL“ MIL CIRCUIT TROUBLESHOOTING MODE/SHIFT INDICATOR CIRCUIT TROUBLESHOOTING (CRFIODODL MODEL IDENTIFICATION ~ MUFFLER/EXHAUST PIPE NEUTRAL DIODE (CRFIOOO/A) NEUTRAL SWITCH (CRFIODOD NUTS, BOLTS, FASTENERS‘ 02 SENSOR ....... .. OIL PRESSURE INSPECTION OIL PUMP (CRF1000/A)- OIL PUMP (CRFIDOOD) OIL STRAINER -- OPEN AIR TEMPERATURE SENSOR- PARKING BRAKE CALIPER (CRFIODODL PARKING BRAKE INDICATOR/SWITCH (CRFmODD) ....... .. PARKING BRAKE LEVER (CRFIOOOD PGM-FI SYMPTOM TROUBLESHOOTING PGM-FI TROUBLESHOOTING INFORMATION PILLION SEAT--- PISTON/CYLINDER PRIMARY DRIVE GEAR CLUTCH/GEARSHIFT LINKAGE (CRFIODO/A) 12-15 DUAL CLUTCH TRANSMISSION (DCT) (CRFIODOD) RADIATOR-u ~ RADIATOR COOLANT RADIATOR RESERVE TANK‘ REAR ABS SWITCH (CRF1oooA/D)» REAR BRAKE CALIPER- REAR BRAKE PEDAL I REAR CARRIER REAR FENDER A REAR FENDER B REAR MASTER CYLINDER REAR WHEEL ---- -- 18-4 REGULATOR/RECTIFIER~ > 21-8 RIGHT CRANKCASE COVER CLUTCH/GEARSHIFT LINKAGE (CRFIODO/AI-m 12-4 DUAL CLUTCH TRANSMISSION (DCT) (CRFIODOD) ROCKER ARM SECONDARY AIR SUPPLY SYSTEM FUEL SYSTEM MAINTENANCE- SERVICE INFORMATION ALTERNATOR/STARTER CLUTCH ----------------- ~ 11-2 ANTI-LOCK BRAKE SYSTEM (ABS) (CRFmOOA/D) ..................... ,. ,, 204 BATTERY/CHARGING SYSTEM > 21-2 CLUTCH/GEARSHIFT LINKAGE > 12-2 COOLING SYSTEM ............. ,. .s_2 CRANKCASE/TRANSMISSION/BALANCER 14-2 CRANKSHAFT/PISTON/CYLINDER CYLINDER HEAD/VALVE/CAMSHAFT > DUAL CLUTCH TRANSMISSION (DCT) (CRFmOOD) ................................................ ., 134 ELECTRIC STARTER ---- »- ENGINE REMOVAL/INSTALLATION FRAME/BODY PANELS/EXHAUST SYSTEM- FRONT WHEEL/SUSPENSION/STEERING FUEL SYSTEM -- HYDRAULIC BRAKE‘ IGNITION SYSTEM-H IMMOBILIZER SYSTEM (HISS)- LIGHTS/METERS/SWITCHES LUBRICATION SYSTE MAINTENANCE - PGM-FI SYSTEM REAR WHEEL/SUSPENSION- SERVICE RULES ............. ,. SHIFT CONTROL MOTOR/REDUCTION GEARS (CRHOODD) .................... ,. SHIFT SPINDLE ANGLE SENSOR (CRFIOOOD) SHOCK ABSORBER SIDE COVER ---- -- SIDESTAND FRAME/BODY PANELS/EXHAUST SYSTEM- MAINTENANCE SIDESTAND SWITCH SKID PLATE (CRFIOOOA/D)- SPARK PLUG ------ -- SPECIAL TOOL LIST - SPECIFICATIONS -- SPEEDOMETER/VS SENSOR STARTER CLUTCH STARTER MOTOR - STARTER RELAY (CRFIODOD STARTER RELAY SWITCH STATOR/CKP SENSOR STEERING HEAD BEARINGS » STEERING STEM SUSPENSION SWINGARM .................... ,. SYSTEM DIAGRAM ANTI-LOCK BRAKE SYSTEM (ABS) (CRFmOOA/D) ............. ,. BATTERY/CHARGING SYSTEM DUAL CLUTCH TRANSMISSION (DCT) (CRFIOOOD) ELECTRIC STARTER IGNITION SYSTEM-H IMMOBILIZER SYSTEM (HISS)- PGM-FI SYSTEM ---- -- SYSTEM FLOW PA'I'I'ERN SYSTEM LOCATION ANTI-LOCK BRAKE SYSTEM (ABS) (CRFmOOA/D) ............. ,. BATTERY/CHARGING SYSTEM DUAL CLUTCH TRANSMISSION (DCT) (CRFmOOD) ....... ,, ELECTRIC STARTER IGNITION SYSTEM ------- »- IMMOBILIZER SYSTEM (HISS)- LIGHTS/METERS/SWITCHES PGM-FI SYSTEM SYSTEM TESTING - TACHOMETER TANK FRONT COVER TANK REAR COVER - TANK SIDE COVER-1* TECHNICAL FEATURES THERMOSTAT THROTTLE BODY THROTTLE OPERATION TORQUE VALUES-~- Amswowquwwwmm nmmmmmmmmmmmmm TR SENSOR (CRF1000D)- TRANSMISSION ------- »- TROUBLESHOOTING ALTERNATOR/STARTER CLUTCH - BATTERY/CHARGING SYSTEM CLUTCH/GEARSHIFT LINKAGE COOLING SYSTEM ---- -- CRANKCASE/TRANSMISSIoN/BALANOER- CRANKSHAFT/PISTON/CYLINDER CYLINDER HEAD/VALVE/CAMSHAFT ELECTRIC STARTER FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEL/SUSPENSION/STEERING A FUEL SYSTEMM- HYDRAULIC BRAKE IGNITION SYSTEM """""" " IMMOBILIZER SYSTEM (HISS) LUBRICATION SYSTEM REAR WHEEL/SUSPENSION """"""" “ TURN SIGNAL LIGHT/RELAY(CRF1000A/D) TURN SIGNAL LIGHT/RELAY/DIODE (CRF1000) VALVE CLEARANC VS SENSOR WATER PUMP WHEEL SPEED SENSOR (CRF1000A/D WHEELS/TIRES WINDSCREEN " WIRING DIAGRAM (CRF1000)“ WIRING DIAGRAM (CRF1000A) WIRING DIAGRAM (CRF1000D) HONDA The Power of Dreams © Honda Motor Co., Ltd. 2015 Published by Honda Motor Co., Ltd. Book number: 62MJP000 Printed in Japan 2015.09.G