é HONDA SHOP MANUAL NPS50 — NPS505 TYPE CODE ~ Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE E U,K., Ireland F France EUROPEAN DIRECT SALES ED (Belgium, Denmark, Germany, Greece, Italy, Spain. Holland, Luxembourg, Austria, Portugal, Finland, Sweden, Switzerland, Hungary. Bulgaria, Czecho. Slovakia, Norway, Iceland, Russia, Poland, Slovenia, Ukraine, Croatia. Latvia, Macedonia, Rumania, Ismel) A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualitied, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle 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 vehicle. if you need to replace a part, use genuine Honda 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 5 Safety . AWARNING Proper service and maintenance are essential to the customer‘s safety and . ' the reliability of the vehicle. Any error or oversight while sen/icing a vehicle Improper service or repairs can create an ‘ i n dama e to the vehicle, or in‘ur to others. unsafe condition that can cause your customer can result In faulty operat o v g I y or others to be seriously hurt or killed. For Your Safety Follow the procedures and precautions in this Because this manual is intended for the professional service technician, we manual and other service materials carefully. do not provide warnings about many basic shop safety practices (e.g., Hot 7 7 7 artsewear loves . If you have not received shop safety training or do not feel confidegnt ab)out your knowledge of safe servtcing practice. we AWARNING recommended that you do not attempt to perform the procedures described Failure to properly follow inslrucfions and in "“5 manual. precautions can cause you to be seriously hurt Some of the most important general service safety precautions are given or k'ned' . ‘ below. However, we cannot warn you oi every conceivable hazard that can Follow the procedures and precautions in this arise in performing service and repair procedures. Only you can decide manual carefully whether or not you should perform a given task. 7 ' 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 salety equipment. When performing any service task. be especially careful of the following: - Flead 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 vehicle up in the air. Any time you lift the vehicle. 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 Possibl'ity 0' a fire 0’ ”9‘05”"! 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 cigarettes, sparks and flames away from the battery and all fuel-related parts. HOW TO USE THIS MANUAL This service manual describes the service procedures for the NPSSD Follow the Maintanance Schedule lSeDIIorl 4) recommendations to ensure that the vehicle is in peak operating condition Performing the tirst scheduled maintenance is very important it compensates lor the initial wear that occurs dultng the bleakrln peilod Sections r and 4 apply to the whole motorcycle Section 3 illustrates procedures tor rsmovalhnstailation of components that may be required to pei-iorm servlce described in the loilowmg sections Sectlon 5 through 19 describe parts or the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the lirsi page at the section CONTENTS GENERAL INFORMATION TECHNICAL FEATURE FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM _|_A_A_A \Immh FUEL SYSTEM M05! ietllDHS start With an assembly or system Illustration, SENICE Z mlom’lallorl and troubleshooting lor the section The subsequent pages — glve detailed procedure é COOLING SYSTEM ,_ ll you are ROI familiar Willi Ihts motorcycle, read Technical Feature In Section 2 g ENGINE REMOVAL/INSTALLATION ll you dDH‘I know lhe source Dl We ITOUDIE, go IO section 2T E CYLINDER HEADNALVES Troubleshootan a E KICKSTARTER/DRIVE PULLEY/ DRIVEN PULLEY/CLUTCH Your salety, and the salety oi others, is very important To help you g make lrlforrned decisions wo have provlded salety messages and _ other inlormatiori throughout this manual or course, it is not (5 FINAL REDUCTION practical or possible to warn you about all the hazards assoclated z wl|h servicing this vehlcle ui ALTERNATOR/STARTER You must use your own good iuogenrent. You Will tind important safety iriicrmation in a variety or iorms including CHANKSHAFT/PISTON/CYLINDER . Safety Labels — on the vehicle - Safety Messages 7 preceded by a salety alert symbol 1 and m FRONT WHEEL/BRAKE] one of three signal words, DANGER, WARNING, or CAUTION a SUSPENSION/STEERING These signal words mean :3 vou WILL be KILLED or SERIOUSLY I ADANGER HUFIT ifyou don't loliow instructions. 0 REAR WHEEUBRAKE/SUSPENSION You CAN be KILLED orSERIOUSLY HUFIT BATTERY/CHARGING SYSTEM M ii you don't loliow lnstiumions, 3:. You CAN pa HURT if you don‘t follow 9 ACAUTION ms‘mmms- E IGNITION SYSTEM - Instructions _ how to scririce thls vehicle correctly and salety 8 ELECTRIC STARTER 4 in As you read this mahuai. you will rind inlormation that is preceded by a m symbol The purpose or this message is to help prevent damage to your vehicle, other property, or the envlrorlment, ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor 00., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANV OBLI- GATION WHATSOEVER. N0 PART OF THIS PUBLICATION MAY BE REPRODUCED WITH» OUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE 0F MAINTE- NANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE LlGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX _a (Om Date of Issue: July. 2004 ©Honda Motor 00., Ltd. 1. GENERAL INFORMATION SYMBOLS The symbols used throughout this manual show specific service procedures. if supplemenlary information is requned pertaining to these symbols, it would be explained specifically in the Iext without lhe use of the symbols. n Replace the parl(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixlure ol the engine oil and molybdenum grease in a ratio of 1:1) Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manulactured by Mitsubishi Oil. Japan Use molybdenum disullide paste (containing more than 40% molybdenum disulfide. NLGI #2 or equivalent), Example: Molykote® G»n Paste manulactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Fiocol ASP manufactured by Roccl Limited. UK. Rocol Paste manufactured by Sumico Lubricant. Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwrse specified. Use Fork or Suspension Fluid. SERVICE RULES ............................................ 1.2 MODEL IDENTIFICATION“ --------------- 1-2 GENERAL SPECIFICATIONS ------------------------- 1-4 LUBRICATION SYSTEM SPECIFICATIONS ........................................... 1.5 FUEL SYSTEM SPECIFICATIONS ----------------- 1-5 COOLING SYSTEM SPECIFICATIONS 1-5 CYLINDER HEAD/VALVES SPECIFICATIONS ........................................... 1.5 KlCKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS------------ 1-6 FINAL REDUCTION SPECIFICATIONS --------- 1-6 CRANKSHAFI'IPISTON/CYLINDER $PECIFICATIONS-- ............................... 1.7 FRONT WHEEL/BRAKE/SUSPENSION/ STEERING SPECIFICATIONS ------------------------- 1-7 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS ............................................ 1.7 BATTERY/CHARGING SYSTEM SPECIFICATIONS ............................................ 1.3 IGNITION SYSTEM SPECIFICATIONS ---------- 1-8 LIGHTS/METERS/SWITCHES SPECIFICATIONS ............................................ 1.3 STANDARD TORQUE VALUES --------------------- 1-9 ENGINE & FRAME TORQUE VALUES -- -9 LUBRICATION & SEAL POINTS ------------------ 1-12 CABLE & HARNESS ROUTING ------------------- 1-15 EMISSION CONTROL SYSTEMS ---------------- T-25 1-1 GENERAL INFORMATION SERVICE RULES The frame serial number is stamped on the right side of the frame. 1. Use genuine Honda or Honda~recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the scootert . Use the special tools designed for this product to avoid damage and incorrect assembly. _ . Use only metric tools when servicing the scooter. Metric bolts, nuts and screws are not interchangeable with English fasteners. . install new gaskets, O»rings, cotter pins, and lock plates when reassembling. . When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified . Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. . After reassembly, check all parts for proper installation and operation. a Route all electrical wires as shown in the Cable and Harness Routing (page 1'15). GENERAL INFORMATION one can mum FRAME SERIAL NUMBER MODEL IDENTIFICATION The engine serial number is stamped on the left side of the belt case. ENGINE SERIAL NUMBER The throttle body identification number is stamped on the 1th side of the throttle body. The color label is attached as shown. When ordering colorvcoded parts, always specify the designated color code. COLOR LABEL 1-2 1-3 GENERAL INFORMATION GENERAL SPECIFICATIONS GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS . Unit: mm 1in) ITEM STANDARD SERVICE LIMITi Engine oil capacity At draining -. 0.6 liter 10.6 US qt, 0.5 Imp qt) — At disassembly 0.7 liter 10.7 US qt, 0.5 Imp qt) l » Recommended engine oil Honda “4‘5TROKE MOTORCYCLE ~ OIL" or equivalent API service classification: SJ except oils labeled as energy conserving the circularAPI service label Viscosity: SAE 10W-3O 1Use 10W—30 regardless of atmospheric tempera- ture) i<¥A¥ui .2, _____ __ JASO: MA or MB Oil pump rotor Tip clearance 0.1510005) 0.2010008) Body clearance 0.15 7 0.2010006 r 0.008) 02210009) 7 7» ”A W 7 Side clearance 0.05 7 0.1010002 r 0004) 0.1210305) FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number GQLOA Idle speed 2,000 :100 min" lrpm) Throttle grip free play 2—6 mm 11/16— 1/4 in) IAT (Intake Air Temperature) sensor resistance [20° C/ 2.4 — 2.7 k 9 68° Fl ECT [Engine Coolant Temperature) sensor resistance W 7 7 7 7,477.71?! 120D (3/68“ F) Fuel injector resistance 120° 068° F) 11.1 r 12.3 $2 IAC (Idle Air Control) valve resistance 120°C/E85'F‘)’ "' 120 — 140 o PCV control solenoid valve resistance (20" Clea“ F) 30 — 34 Q Fuel pressure at idle 294 kPa 13.0 kgf/cm , 43 psi) Fuel pump flow (at 12 V) 42 cm (1.4 US oz, 1.5 Imp oz)/10 second? COOLING SYSTEM SPECIFICATIONS ITEM STANDARD Coolant capacity Radiator and engine 028 liter (0.30 US qt, 0.25 Imp qt) Reserve tank 0.24 liter 10.25 us qtozfi’mp qt) Radiator cap relief pressure 100— 137 kFa 11.1 — 1.4 kgf/cm,16— 20 psi) Thermostat Begin to open 74—7B°C(165— 7_27°Fl " Fullyo 1119:7931? ° 3.5 mm (01 in) minimum Recommended antifreeze High quality ethylene glycol antifreeze containing corro- sion protection inhibitors Standard coolant concentration 1:1 mixture with soft water ITEM SPECIFICATION WMENSIONS Overall length 7 1,860 mm 173.2 in) Overall width 735 mm 128.9 in) Overall height 1,025 mm (40.4 in) Wheelbase 1,265 mm 149.8 in) Seat height 735 mm 128.9 in) Ground clearance 145 mm 15.7 in) Dry weight 84 kg 1185 lbs) Curb weight 89 kg 1196 lbs) Maximum weight capacity 112 kg 1247 lbs) iFRAME Frame type Under bone Front suspension Telescopic fork Front wheel travel 55 mm 12.2 in) Front axle travel 49 mm (1.9 in) Rear suspension Unit swing Rear axle travel 65 mm 12.6 in) Front tire size 120/90-10 57J Rear tire size 130/90—10 61 J Tire brand Front/Rear: KENDA K761 Front brake Internal expanding shoe Rear brake Internal expanding shoe Caster angle 26° 30' Trail length 75 mm 13.0 in) Fuel tank capacity 4.8 liter 11:27 US gal, 1.06 Imp gal) ENGINE Bore and stroke 37.8 X 44.0 mm 11.49 X 1.73 in) Displacement 49.4 cm“13,01 cu»in) Compression ratio 12: 1 Valve train Chain drive and OHC Intake valve opens 10" BTDC1at1 mm lift) closes 15° ABDC1at 1 mm lift) Exhaust valve opens 20° BBDC1at1 mm lift) Closes 10" ATDC1at1 mm lift) Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Oiled paper element Engine dry weight 211 kg 146.5 lbs) _ FUEL DELIVV Type PGM»FI [Programmed Fuel Injection) ERY SVSTEM Throttle bore 18 mm 10.7 in) 7DFI|VE TRAIN Clutch system Dry, automatic centrifugal clutch Primary reduction 3.500 Final reduction 3.916 Gear ratio 2.850 A 1.200 V ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor and kick starter Charging system Triple phase output alternator Lighting system Battery 1 -4 GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM ( mfiuTRD: SERVICE LIMIT Cylinder compression 1,275 kPa named/057. 185 psi) — at 950 rpm i i Cylinder head warpage ., . . i 7 .7 7 7 0.05 (0 02) Valve, valve Valve clearance JN 7019 :003 (0.004 :0 Willi ‘ guide EX 0.21':0’.03(0.00830.(m) ‘ Valve stem 0.0. IN 3.475 4 3.490 (0.1388 , 0. fl) 7 i 3.465 (0.1354) EX " 346573.480 (0.1%11 7770) 3.455 (0.1360) Valve guide 1.0. lN/EX 3.500 — 3.512 (0.1370 7 0. 83) 3.54 (0.138) Stem»to-guide IN 0.0 37 0.0004 70.0015) 0.075 (0.0030) clearance EX 0.02 - 0 47 0.0008 fy019) 0.035 (0.0033) Valve guide projection IN 9.30 7 9.5010366 — 0.374) 5 above cylinder head EX 9.30 , 9.50 (0.366 — 0.374) 7 Valve seat width lN/EX 0.8 (0.03) 1.3 (0.05) Valve spring free length IN/EX 37.11 (1.461) 35.8 (1.41) Rocker arm Rocker arm |.D. IN/EX 10.000 _ 10.015 (0.3937 — 0.3943) 10.10 (0.400) Rocker arm shaft 0.0. IN/EX 9.972 — 9.987 (0.3926 — 0.3932) 9.91 (0.390) Side spring free length 16.0 (0.63) , . , 14.5 (0.57) Camshaft Cam lobe height IN "37077 if . 268 (1212084122153) . 3075(1211) EX 29.9308730.1708(1.17a3841.18782) 29.90 (1.177) KICKSTARTER/DRIVE' PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS Unit: mm (in) f ITEM STANDARD SERVICE LIMITi Clutch Clutch outer 1.0. 107.0 — 107.2 (4.21 — 4.22) 107.5 (4.23) Lining thickness , . 2.0 (0.00) Drive belt width 18.15 (0.715) 1715 (0.68) Movable drive face Bushing 1.0. 20.035 — 20.085 (0.7808 , 0.7907) 20.13 (0.793) Boss 0.0. 20.010 — 20.025 (0.7078 , 0.7804) 19.97 (0.780) Weight roller 0.0. 15.92 — 16.08 (0.627 — 0.033) 15.4 (0.61) Driven pulley Face spring free length 85.78 (3.377) . 781.5 (3.21) Driven race 0.0. 33.930 — 33.930 (1.3358 — 1.3378) 33.70 (1.327) Movable driven race ' 34.0154 34.035 (1.3392 — 1.3400) 34.29 (1.350) |.D. FINAL REDUCTION SPECIFICATIONS ITEM SPECIFICATIONS 0.1 liter (0.11 US qt, 0.09 "“0 qt) Recommended final reduction oil ‘iFinal reduction oil capacity (at disassembly) Hypoid gear oil #90 1-6 fl GENERAL INFORMATION CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS Unit: mm (in) 7 ITEM STANDARD SERVICE LIMIT ’ Crankshatt I Connfiti’ng rod side clearance 0.107040 (07.004— 0.016) ’ 0.60 (0020* Conneaing rod radial clearance 0.004 r 0.010 (0.0002 — 0.0006) ’ 7 0.05 (0.002) * Runout — 0.10 (0.004) Cylinder 1.0. 38.000 , 391310 (1.4900 —1.4964) 30.04 (1.4966) Out~of»round — 0.05 (0.002) Taper — 0.0510002) . Warpage — 0.05 (0.002) Piston, piston Piston 0.0. 37.975 , 37.995( 1.4951 — 1.4959) 3792 (1.493) P)". piston Piston 0.D. measu-rement point 10 mm (0.4 in) from bottom of skirt — “n95 Piston pin here 1.0. 10.002 , 10.008 (0.3930 —0.3940) 10.04 (0.395) Piston pin 00. 9.994 410.000 (0.3935 — 0.3937) 9.98 (0.393) Fiston—to-piston pin clearance 0.002 a 0.014 (0.0001 —0.0006) 0.04 (0.002) Piston ringsws Top 0.015 , 0.045 (0.0006 — 0.0018) 0.00 (0.003) ring groove clear- Second 0.015 , 0050100006 — 0.0020) 7 0.00 (0.003) ance Piston ring end __Top 0.05 — 0.15 (0.002 ~ 0006) 0.740 (0.016) gap Second 0.05 , 0.17 (0.002 — 0.007) 0.40 (0.016) 011 01040.00 (0004—0024) 0.00 (0.031) (side rail) Cylindersmspiston clearance 0.005 — 0.035 (0.0002 — 0.0014) 0.08 (0.003) Connecting rod smallend 10. 10.013 ~10.028(O.3942 — 0.3940) 10.05 (0.396) Connecting rodsto~piston pin clearance 0.013 — 0.034 (0.0005 7 0.0013) 0.00 (0002) FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 0.8 (0.03) Cold tire pressige 175 kPa (1.75 kgr/cm , 25 psi) , Axle runout — 0.20 (0.008) Wheel rim runout Radial m 2.0 (0.08) Axial 7 , 2.0 (0.08) Brake Front brake lever free play 10 — 20 (3/8 7 13/16) m Drum |.D. 95.0 (3.74) 95.5 (3.76) Fork Spring free length 128.5 (5.06) 125.9 (4.96) REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS ,. Unit: mm (in) ) ITEM STANDARD V SERVICE LIMIT Minimum tire tread depth — 0.8 (0.03) Cold tire pressure 175 kPa (1.75 kgj/cm , 25 psi) Wheel rim runout Radial 2.0( )— Axial 2.0 (0.08) Brake Rear brake lever free play 10 — 20 (3/8 — 13/16) Drum l.D. 95.0 (3.74) 1-7 GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS 7 ITEM 7 i SPECIFICATIONS Battery Capacity 7 12V 7 6 Ah Current leakage 7 0.17mA max. Voltage (20 "(E/68 Fully charged 13.0 713.2V “ F) Needs charging Below 12.3v iCharging current Normei 0.6A/5 , 10h Quick 3A/1h Alternator Capacity . 21o W/5,ooo min" (rprn) Charging coil resistance (20 ”C/SS “F) . 0.05 , 0.2 o IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Spark plug F Standard ER8EHEN (NGK) Spark plug gap 0.60 i 0.70 mm (0.024 f 0.028 in) Ignition coil peak voltage 100V minimum Ignition timing (”F” mark) 15”BTDC at 2,000 min" (rpm) LIGHTS/ METERS/ SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight (high/low beam) 12V735/35W X 2 Brake/tail light 12V»21/5W Front turn signal light 12V»21W X 2 Rearturn signal light 12V—21W X 2 Speedometer light 12v.1.7w Malfunction indicator lamp (MIL) LED Water temperature indicator LED Fuel reserye indicator LED 7 Fuse Main fuse 20A Sub fuse 15A X 2 ECT (Engine Coolant TemperaA }_ At 50°C/122 DF 6907860 51 ture) sensor resistance At 130 "C /266 " F 68 - 83 £2 1-8 GENERAL INFORMATION ' TORQUE ’ ' ' TORQUE . FASTENER TVPE , N-m “(9.1“, "1”” FASTENER TVPE N1“ (kgf-rn, IbI-ft) 5 mm hex bolt and nut 5.2 (0.53, 3.8) 5 mm screw 4.2 (0.43, 3.1) 6 mm hex bolt and nut 9.8 (1.0, 7) 6 mm scrEW 3.8 (0.9, 6.5) 8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (B mm head) 8.8 (0.9, 6.5) 10 mm hex bolt and nut 34 (3.5, 25) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9) 12 mm hex bolt and nut 54 (5.5, 40) 8 mm flange bolt and nut 26 (2.7, 20) 10 mm flange bolt and nut 39 (4.0, 29) 0 Torque specifications listed below are for specified fasteners. - Others should be tightened to standard torque values listed above. NOTE: 1. Apply oil to the threads and seating surface. 2. Apply sealant to the threads. 3. Apply a locking agent to the threads. 4. ALOC bolt: replace with a new one. 5. U—nut. ENGINE MAINTENANCE , THREAD TORQUE "EM 7 oTv DIA. (mm) N-m (kgf-m,_lbf-ft) REMARKS Spark plug 1 8 8.8 (0.9, 6.5) Engine oil drain bolt 1 12 25 (2.5, 18) #Engine oil strainer cap 1 30 20 (2.0, 14) LUBRICATION SYSTEM , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m Ikgr-m, lbf-ft) REMARKS Oil pump cover screw 1 3 2.0(0.2, 1.4) FUEL SYSTEM , THREAD TORQUE ”EM 0 TV DIA. (mm) NAm (kgf-m, IbI-ft) REMARKS Fuel feed hose stay bolt 2 S 10 (1.0, 7) ECT (Engine Coolant Temperature) sensor 1 12 18 (1.8, 13) PCV control solenoid valve bolt 1 5 5.9 (0.6, 4.3) 7' Insulator band screw 2 5 2.9 (0.3, 2.1) COOLING SYSTEM ‘ , THREAD TORQUE . ITEM 0 Tv DIA. It'll") N'm (kgf‘m. lbw) REMARKS Coolant drain bolt 1 1D 0.9 (0.1, 0.7) Radiator cover screw 4 4 0.9 (0.1, 0.7) CYLINDER HEAD/VALVES ' " T" THREAD TORQUE ”E” on DIA. (mm) N-m (kgr-m, lbf-ft) REMARKS Cylinder head bolt 4 6 12 (1.2, 9) NOTE 1 Cam sprocket bolt 2 5 8.8 (0.9, 6.5) NOTE 1 _Cam chain tensioner lifter screw 1 6 4.2 (0.43, 3.1) KlCKSTARTER/DRIVE PULLEY/DRIVEN PULLEV/CLUTCH ' i ' . THREAD TORQUE "EM o W ) DIA. (mm) Nam (kgf-m, lbf-ft) REMARKS ‘ Clutch outer nut 1 10 39 (4.0, 29) Prive pulley face nut 1 12 32 (3.3, 24) NOTE 1 i GENERAL INFORMATION FINAL REDUCTION ’ , THREAD TORQUE K ITEM OTv DIA (mm, Mm (kgf-m, mm REMAR 5 Final reduction oil'check bolt 1 s 13 (1.3, 9) ALTERNATOR/STARTER . THREAD TORQUE RKs ”EM ° T: DIA. (mm) N-m lkgf-M, Ihf-ft) “EMA Stator socket bolt 3 _ 6 12 (1.2, 9) Flywheel nut 1 12 4414.5,33) iRadiatDr cooling fan bolt 3 6 7.8 (0.8, 5.8) ( CRANKSHAFT/PISTON/CVLINDER F " THREAD TORQUE . ARKs ITEM 0 TV DIA. (mm) N-m (kgf-m, lbf-ft) REM 7 Crankcase bolt 9 e 12 (1.2, 9) NOTE 1 Insular" dam”: 5 :1 mm (0.2 :o,o4 in) FRAME FRAME/BODV PANELS/EXHAUST SVSTEM . THREAD TORQUE "EM QTY DIA. (mm) N-m (kgfrm, lbf-ft) REMARKS Muffler protector bolt 2 5 . 5.2 (0.53, 3.8) MAINTENANCE ’ , THREAD TOROUE ”EM 0 TV DIA. (mm) NAm (kgrm, lbI-ft) REMARKS Air cleaner housing cover screw 7 5 1.2 (0.12, 0.9) FUEL SVSTEM , THREAD TORQUE ITEM 0 TV DIA. (mm) Nm (“SI-m: M“) REMARKS Bank angle sensor mounting screw 2 4 1.2 (0.12, 0.9) Breather hose joint screw 1 4 0.8 (0.08, 0.6) Fuel pump unit mounting nut 7 6 12 (1.2, 9) . FRONT 7 Oz sensor 1 18 44 (4.5, 33) ENGINE MOUNTING GENERAL INFORMATION THREAD TOROU E 1-10 ~ 'TEM . ,. 07" DIA. (mm) N-m lkgf-m, lbf-ft) REMARKS Engine hanger link bolt (frame side) 2 10 39 (4.0, 29) __Engine mounting nut (engine side) 1 10 49 (5.0, 36) NOTE 5 FRONT WHEELIBRAKE/SUSPENSIONISTEERING , THREAD TORQUE ”EM ° W DIA. (mm) Nrm (kgpm, lbf-ft) REMARKS Front axle nut 1 1O 44 (4.5, 33) NOTE 5 Front brake arm bolt 1 5 6.0 (0.62, 4.5) Front/rear brake lever pivot bolt 1/1 5/5 1,0 (0.11, 0.8) Front/rear brake lever pivot nut 1/1 5/5 5.2 (0.53, 3.8) Handle post nut 1 10 39 (4.0, 29) Steering stern lock nut 1 BCI 69 (7.0, 51) 7 REAR WHEEL/BRAKE/SUSPENSION , THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf—m, lbf-ft) REMARKS Flear axle nut 1 14 118 (12.0, 87) NOTE 1, 5 Rear brake arm bolt 1 5 5010.51.37) NOTE 4 l Rear shock absorber mounting bolt (UPPER) 1 10 40 (4.1, 30) (LOWER) 1 s 26 (2.7, 20) ) LIGHTS/METERS/SWITCHES l . THREAD TORQUE ”EM 0 TV DIA. (mm) N-m (kgf-m, Ibf-ft) REMARKS Turn signal light mounting nut 4 10 9.8 (1.0, 7) OTHERS , THREAD TORQUE M _. ”EM 0" DIA.In1m) N-m (kgf—m, lbf-ft) REMARKS V, iFrvont/rear frame assembly bolt 4 10 44 (4,5, 33) V l I l l l GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE GENERAL INFORMATION LOCATION MATERIAL REMARKS LOCATION MATERIAL REMARKS Trankcase dowel pin Crankcase mating surface Liauid sealant _ (Three Bond 12073 or equlvV alentl Do not apply sealant to the sensor threads head. See page 13-12 See page 11712 Oil pump drive, driven gearteeth and sliding sur- face Oil pump driven gear sliding surface Stator base bearing area Camshaft bearing Rocker arm shaft sliding surface Cylinder head bolt threads and seating surfaces 16 X 119 mml Piston pin outer surface Piston and cylinder sliding surfaces Piston ring groove, pin hole of piston Cam sprocket bolt threads and seating surfaces Drive pulley face nut threads and seating surface Piston ring whole surface Each transmission gear teeth crankcase bolt threads and seating surface Connecting rod big and bearing Connecting rod small end hole Crankshaft main journal bearings Timing sprocket teeth of crankshaft Cam chain Oil seal lips and outer surfaces Cam sprocket gear teeth Each O-ring whole surface Engine oil Fill up 3 cc. Fill up 2 cc per each bearing. Kiokstarter spindle seating surface Kicksterter driven gear seating surface/friction spring sliding surface Molybdenum disulfide paste Apply 0.2 7 0.59. Valve stem lvalve guide sliding surface) Camshaft cam lobes disulfide oil la mixture of 1/2 engine oil and 1/2 molybde- num disulfide grease) Final shaft seating ’silfré'c’e fbelt case sidel ‘ Molybdenum Apply 0.3 — 0.5g. Countershaft se tinig‘surface dISUIIldE grease Apply 0.5 —1.Dg. Rocker arm sliding and slipper surface Molybdenum i Driven face bearing Multipurpose grease 1-12 1-13 GENERAL INFORMATION FRAME LOCATION MATERIAL :1 REMARKS Front wheeiaust seal lips Front brake panel dust seal lips Rear brake cam Rear brake anchor pin Throttle grip pipe flange cable groove Brake lever pivots Main stand pivot Multi—purpose ‘ grease Front brake cam Front brake anchor pin Multi-purpose grease [Daphne eponex No.2 or equivalent) ’Speedometer gear teeth Multirpurpose grease (Daphne eponex No.0 or equivalent) Steering stem bearings and race sliding surface Urea based multi» purpose grease with extreme pressure (example: EXCE» LIGHT EP2 manufacV lured by KYODO YUSHI, japan], Shell stamina EP2 or equivalent Apply 3 r 59 per each bearing. Fork spring Fork rebound spring Fork guide bushing sliding surface Fork dust seal lips Bearing grease class 2 grade 3 (CHU- KYOU KASEII or equivalent Apply grease 6.5 — fig. Front/rear brake cam felt seal Rear axle nut threads and seating surface Engine oil iThrottle cable casing inside Brake cable casing inside Cable lubricant Handlebar grip rubber inside Air cleaner connecting hpse-to-housing mating area Honda bond A or equivalent 1-14 GENERAL INFORMATION CABLE & HARNESS ROUTING RIGHT HANDLEBAR SWITCH WIRE REAR BRAKE LIGHT REAR BRAKE CABLE SWITCH WIRE FRONT BRAKE LIGHT SWITCH WIRE LEFT HAN DLEBAR SWITCH WIRE lGNlTlO HORN-WIRE N SWITCH WIRE A: RIGHT HANDLEBAR SWITCH WIRE B: FRONT BRAKE LIGHT SWITCH WIRE C: THROTTLE CABLE D: FRONT BRAKE CABLE E: REAR BRAKE LIGHT SWITCH WIRE F: LEFT HANDLEBAR SWITCH WIRE G: REAR BRAKE CABLE H: SPEEDOMETER LIGHT WIRES l: SPEEDOMETER CABLE WEN LEFT TURN SIGNAL WIRE SPEEDOMETER CABLE FRONT BRAKE CABLE LEFT HEAD RIGHT WIRE HEAD RIGHT 3P [REDl CONNECTOR RIGHT HEAD RIGHT WIRE RIGHT HEAD RIGHT WIRE gig ":C) RIGHT TURN SIGNAL WIRE 1-15 GENERAL INFORMATION LEFT TURN SIGNAL WIRE HEADLIGHT WIRE RIGHT TURN I I 1‘ SIGNAL WIRE 1!“ A: " F '/ ECNI 21F IELACKI CONNECTOR I \ ' I CONNECTOR I GROUND CABLE .1 " AN: MAIN WIRE HARNESS RESISTOR BANK ANGLE SENSOR WIRE LED DRIVE UNIT WIRE / 5“ , SPEEDOMETER CABLE Q ‘ TURN SIGNAL CONNECTORS/ HEADLIGHT 3P (REDI CONNECTOR FRONT BRAKE CABLE GENERAL INFORMATION INDICATORS: — FUEL — WATER TEMPERATURE DATA LINK CONNECTOR BANK ANGLE SENSOR WIRE TURN SIGNAL RELAV FUEL PUMP WIRE 1-16 1-17 GENERAL INFORMATION BOOT A FRONT BRAKE LIGHT SWITCH CONNECTORS r REAR BRAKE LIGHT SWITCH CONNECTORS — SPEEDOMETER 3P (BLACK) CONNECTOR — SPEEDOMETER CONNECTORS LED DRIVE UNIT — RIGHT HANDLEBAR SWITCH 2P (RED) CONNECTOR , 4P IBLACKI CONNECTOR — LEI-T HANDLEBAR SWITCH 2? (NATURAL) CONNECTOR 7 AP INATURAL) CONNECTOR BANK ANGLE SENSOR 3P INATU HAL) CONNECTOR THROTTLE CABLE RESISTOR 2P INATURAL) CONNECTOR REAR BRAKE CABLE 1-18 IGNITION SWITCH WIRE HEADLIGHT RELAY HORN WIRE MAIN WIRE HARNESS GENERAL INFORMATION FUSE BOX 1-19 GENERAL INFORMATION BOOT — REAR TURN SIGNAL CONNECTORS —TA|L/BRAKE LIGHT CONNECTORS CRANKCASE BREATHER HOSE IGNITION COIL PRIMARY WIRES SIPHON HOSE BOOT r ALTERNATOR/STARTER 6P (NATURAL) CONNECTOR — ALTERNATOR/STARTER 3P (BROWNI CONNECTOR lNJECTOR/ECT SENSOR WIRE PAIR CHECK SOLENOID VALVE WIRE GROUND CABLE FUEL FEED HOSE SPARK PLUG WIRE REAR BRAKE CABLE THROTTLE CABLE 1-20 GENERAL INFORMATION BOOT A REAR TURN SIGNAL CONNECTORS r TAIL/BRAKE LIGHT CONNECTORS SPARK PLUG WIRE INJECTOR/ECT SENSOR WIRE CRANKCASE BREATHER HOSE THROTTLE CABLE Oz SENSOR 4P (BLACK) CONNECTOR FUEL FEED HOSE OVERFLOW HOSE MAIN WIRE HARNESS 1-21 GENERAL INFORMATION REAR BRAKE CABLE FUEL PUMP WIRE MAIN WIRE HARNESS ALTERNATOR/ STARTER WIRES FUEL FEED HOSE THRO'I'I'LE CABLE I , ’ ,2 MAIN WIRE HARNESS MAIN WIRE HARNESS (To ignition coil) INJECTOR 2P (BLACK) CONNECTOR ALTERNATOR/ MAIN WIRE HARNESS STARTER WIRES PAIR CHECK ITo throttle bodyi SOLENOID . H VALVE WIRE MAIN WIRE ' I HARNESS rs WATER HOSES THROTTLE BODY SPARK PLUG WIRE FRAME .@ 0 MAIN WIRE HARNESS OVERFLOW HOSE CRANKCASE BREATHER HOSE IGNITION COIL AIR SUCTION HOSE PRIMARY WIRE GENERAL INFORMATION SPARK PLUG WIRE GROUND CABLE REAR BRAKE CABLE BOOT r REAR TURN SIGNAL CONNECTORS TAIUBRAKE LIGHT WIRE vTAlL/BRAKE LIGHT CONNECTORS TAIUBRAKE LIGHT WIRE LEFT TURN SIGNAL WIRE RIGHT TURN SIGNAL WIRE 1 J2 1 -23 GENERAL INFORMATION SIPHON HOSE OVERFLOW HOSE MAIN WIRE HARNESS WATER HOSES FUEL FEED HOSE 02 SENSOR WIRE WATER HOSES ALTERNATOR/STARTER WIRES GENERAL INFORMATION 1 -24 EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of oxides of nitrogen and hydrocarbons is vew important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various system, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. BiOWrby gas is returned to the combustion chamber through the air cleaner and throttle body. THROTTLE BODV AIR CLEANER <1: FRESH AIR {— BLOWVBY GAS PCV CONTROL SOLENOID VALVE 1 -25 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean fuel injection setting, No adjustment should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system. THREE-WAY CATALYSTIC CONVERTER This motorcycle is equipped with threerway catalystic converter, The three-way catalystic converter is in the exhaust system. Through chemical reactions, they convert HC, (:0, and N0x in the engine’s exhaust to carbon dioxide (602), dinitrogen (N2), and water vaper. 2. TECHNICAL FEATURES MAGNETIC-COUPLING WATER PUMP ------- 2-2 PGM-Fl [Programmed Fuel lniection) SYSTEM ......................................................... 2.3 ENGINE MANAGEMENT SYSTEM --------------- 2-4 PCV (Positive Crankcase Ventilation) '---------2-7 1-25 2-1 TECHNICAL FEATURES MAGNETIC-COUPLING WATER PUMP This scooter uses a magneticmupiing water pump. Magnetic forces drive the impeller via the plastlc case, whlch separ rates the coolant from the engine oil. A plastic collar acts as a bearing. Compared to a conventional type water pump, this pump eliminates the mechanical seal, oil seal and ball bearing, allow- ing for a compact pump with reduced friction. MAGNETiDRlVEN SIDEI MAGNET (DRIVE SIDE) CAMSHAFT CAM SPROCKET \ IMPELLER /\ /\ PLASTIC COLLAR WATER PUMP SHAFF PLASTIC CASE 2-2 TECHNICAL FEATURES PGM-Fl (Programmed Fuel lniection) SYSTEM SENSOR INTEGRATED MODULE THROTTLE BODY This scooter is equipped with the throttle body integrated with the following sensors and device. This throttle body realizes a compact design with simplified inspection capabilities. - MAP (Manifold Absolute Pressurei sensor: detects the intake air pressure - TP (Throttle Position) sensor: detects the throttle opening position . IAT (Intake Air Temperature) sensor: detects the intake air temperature - IACV (Idle Air Control Valve): controls the engine idle speed and enhances the startrup ability This throttle body is undecomposable because it is precisely adjusted in the factory preset. MAP SENSOR IACV THROTTLE BODY MAP PASSAGE HOLE TP SENSOR IAT SENSOR IAT PASSAGE HOLE IACV BYVPASS PASSAGE BANK ANGLE SENSOR The bank angle sensor detects excessive bank angle and interrupts the ignition/fuel system control. The conventional bank angle sensor sys- tem controls the power source supply for the injector, ignition coil and MAINFUSE m ‘GN'MNSW‘M fuel pump directly through the engine stop relay. This bank angle sen- “mm-"TEE W sor sends out the signal of bank angle status to the ECM, then the ECM stops to control the ignition/fuel system. \I FAIL-SAFE FUNCTION OF OVERHEAT ECM wwmsswm BANKANGIESENSDR When the coolant temperature exceeds 120°C I248°Fl. the ECM detects as overheated engine and controls the fuel injection to reduce mmwm the engine speed below 5,000 min" (rpmi. at the same time, the cool- E‘ ant temperature indicator turns on. The ECM also controls as over— mm W heated engine even incase of the ECT sensor failure. gxmgmfifilw fi—Un; 2-3 TECHNICAL FEATURES ENGINE MANAGEMENT SYSTEM This scooter is equipped with the combined alternator/starter and the regulator/rectifier integrated ECM (Engine Control Module) that controls the PGMVFI, charging, ignition and electric starter system. ' he AC enerator, starter motor and CKP sensor. This component uses no brush, result- ittrgeiii":ganglia?Itighzuanncél:‘asiasetnancerfgee. This alternator/starter unit consists of the flywheel wrth sensor magnet and stator with position sensors. The ECM adjusts current to the stator coil to tum the flywheel when starting, and to increase charging current under 3,500 min" (rpm) to enhance charging capability. The flywheel is designed with inner magnets integrated in the rotor core. The stator is designed with 3 crankshaft angle (phase) sensors and Crankshaft Position sensor. These sensors are hall IC type. FLYWHEEL CRANK ANGLE SENSOR MAGNET STATOR CORE SENSOR UNIT CRANK POSITION SENSOR MAGNET CRANK POSITION SENSOR CRANKANGLE SENSOR (PHASE) :1 SENSOR MAGNET TECHNICAL FEATURES CHARGING SYSTEM This brushaless alternator/starter operates as a 3-phase AC generator. ALTERNATOR/STARTER: When functioning as an alternator, the magnetic flux from the magnet ‘_{ ROTATION D|RECTION passes through the rotor core, reducing the magnetic force to allow _.. TORQUE low-friction spinning of the alternator/starter. A volts aiternating current is output to the regulator/rectifier integrated in the ECM. ELECTRIC STARTER SYSTEM The alternator/starter also functions as a starter motor by applying cur» rent to the stator coil from the ECM to turn the flywheel. The 3 crankshaft angle sensors are attached to the stator to detect crankshaft angle phase. Signals from a magnet that is integrated in the outer circumference of the flywheel boss are received by the sensor and sent to the ECM. When functioning as a starter motor, the magnetic flux occurs from the magnet and from the rotor core due to the strong motor drive current, multiplying the magnetic force and providing a high torque from the alternator/starter. IGNITION/FUEL INJECTION TIMING CONTROL STARTER MOTOR: <—I ROTATION DIRECTION ‘—i TORQUE E S 5/ U V This system uses the CKP sensor (phase PCB) along with the crankshaft angle sensor (phase W) so as to detect the refer- ence position of crankshaft (Top Dead Centrei. The ECM recognizes the position of TDC as following timing. - At the moment of the phase W signal picking up even when the phase PCB signal is high. If the problem occurs at 3crankshaft angle (phase U, V and W) sensors and CKP sensor (phase PCB], the ECM stops to con- trol the ignition/fuel system as fail-safe function as well as the conventional type CKP sensor. SENSOR MAGNETIC PATTERN 20" 10” 30° SENSOR MAGNET .- CRANK ANGLE (PHASEI CRANK POSITION SENSOR OUTPUT SIG NAL SENSOR UNIT 2-5 TECHNICAL FEATURES STARTING CONTROL FOR KICK STARTER This system is for the securement of the staning ability by kick starter when an emergency arises (9.9.: low battery Voltr age). The ECM is booted up immediately after kick starting then controls the fuel pump, injector and ignition coil with a generr ated electric power supply. This series of functions capacitate to start the engine by kick starter with insufficient electric power source. OPERATION . Operate the kick starter. 2, Rotate the flywheel and start to generate electric power. 3. Boot up the ECM/CPU. 4 5 . ECM drives the fuel pump. . ECM detects the ignition/injection timing then starts the engine. SPARK PLUG g ‘ E ‘ _ Ignition IGNITION COIL ' : ‘ INJECTOR FUEL PUMP ECM O 50 100 150 200 ' ELAPSEDTIME FROM KICK START (1 mSec) TECHNICAL FEATURES PCV (Positive Crankcase Ventilation) This system allows to ventilate in the crankcase according to inject the air. To ventilate in the crankcase prevents the stag- nant blowiby gas that contains gasoline or water vapor and allows for keeping the performance of engine oil under the driving condition with low engine oil temperature. The PCV system consists of the air cleaner, solenoid valve and lead valve. The lead valve prevents to rerflow the blow-by gas to the air cleaner case. The solenoid valve secures the engine idle speed by control the air mass flow depending on the throttle opening and engine speed. REED VALVE PCV CONTROL SOLENOID VALVE 1. The ECM control to choke airflow with the solenoid valve so as to keep the stable idle speed. @779 2. When increase the throttle opening and engine speed, the ECM 3 control to open the solenoid valve so to ventilate in the crankcase. g SOLENOIDVALVE "ON' L E FULL-OPENED u m < 9 ”6 E - s w < a a n J m u I: a 9 E “(A 2 a: 5 03 I 5 E . 2 L3 ._ MVSYERESISAREA U, z 3 j 1‘ l 1 —-l........... i 3 8 a mtmsm n 2000 2900 3400 7700 7900 lDLE ENGINE SPEED lr/mi’nl 2-7 3. FRAME/BODY PANELS/ EXHAUST SYSTEM MEMO BODY PANEL LOCATIONS ........................... 3.2 FRONT COVER ............................................... 3.5 SERVICE INFORMATION 3.3 FLOOR STEP ................................................... 3.7 TROUBLESHOOTING ........ UNDER COVER ............................................... 3.3 SEAT-- ..... 3.4 REAR FENDER ................................................ 3-8 SEAT RAIL-- 3.5 MUFFLER .......................................... 3.9 INNER COVER-um 3-5 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS SEAT SEAT RAIL REAR FENDER MUFFLER U NDER COVER FLOOR STEP INNER COVER 3-2 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL ' This section covers removal and installation of the body panels, exhaust system and seat rail. I Always replace the exhaust pipe gasket with a new one after loosening or removing the exhaust pipe joint nuts. - When installing the exhaust system, loosely install all of the muffler fasteners. Always tighten the exhaust joint first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly. - Always inspect the exhaust system for leaks after installation. TORQUE VALUES Muffler protector bolt 5.2 N-m (0.52 kgf‘m, 3.3 Ibf‘ft) TROUBLESHOOTING Excessive exhaust noise - Broken exhaust system ' Exhaust gas leak Poor performance - Deformed exhaust system - Exhaust gas leak - Clogged muffler FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Open the seat by unhooking the seat hook, Remove the two nuts and seat. INSTALLATION Install the seat to the frame hooks and seat hinges by aligning the seat hinge tabs with the frame hook grooves as shown. Tighten the nuts securely. Close the seat. SEAT HOOK HINGE FRAME/BODY PANELS/EXHAUST SYSTEM SEAT RAIL REMOVAL/INSTALLATION Remove the six bolts and seat rail, Installation is in the reverse order of removal. INNER COVER Be careful not to damage the tabs, slots and wires, REMOVAL Remove the four screws and inner cover. INSTALLATION Install the inner cover to the front cover by aligning the inner cover tabs with the front cover slots‘ Tighten the four screws. BOLT SEAT HAIL SCREW INNER COVER FRAME/BODY PANELS/EXHAUST SYSTEM FRONT COVER REMOVAL/INSTALLATION Remove the inner cover (page 3-5)t Disconnect the headlight/horn 3P (Redl and turn sig- nal light connectors. Remove the three bolts and headlight bracket assembly. Remove the two screws and front cover, HEADLIGHT BRACKET ASSEMBLY FRONT COVER CONNECTORS Install the removed parts in the reverse order of removal. 3-6 FRAME/BODY PANELS/EXHAUST SYSTEM FLOOR STEP REMOVAL Remove the following: , Seat rail (page 3-5). — Inner cover (page 3-5). Remove the front mud guard. Remove the four screws, eight bolts/washers and floor step. FRONT MUD GUARD FLOOR STEP BOLTS/WASHERS SCREWS INSTALLATION Be careful not to Install the floor step onto the frame. damage the W/feS, Install and tighten the eight bolts/washers and four cables and hoses. screws. .- Be talent/norm Install the front mud guard by aligning its tabs with deform the front the floor step slots as shown. MUD GUARD TAB mudguard Install the following: 7 Inner cover(page 3~5lt A Seat rail (page 35). 3-7 FRAM E/BODY PANELS/EXHAUST SYSTEM UNDER COVER REMOVAL/INSTALLATION Remove the following: — Floor step (page 3»7l. — Fuel tank (page 6-52l. Release the main wire harness and throttle cable from the guide of the under cover. Remove the bolts and cable guide. Be careful not to Remove the brake cable clamp bolt/washer while damage the brake holding the clamp. cab/e Remove the under cover. Route the Wlle hair Install the removed parts in the reverse order of ness, cables and remova I, hoses ploper/y (page 1-15). REAR FENDER REMOVAL/INSTALLATION Release the crankcase breather hose from the clamp Remove the bolt, bolts/washers and rearfender. Installation is in the reverse order of removal. BOLTS UNDER COVER CABLE GUIDE GUIDES THROTTLE CABLE BRAKE CABLE BREATHER HOSE REAR FENDER BOLT BOLTS/WASHERS FRAME/BODY PANELS/EXHAUST SYSTEM M U FFLER REMOVAL Disconnect the 02 sensor 4P (Black) connector. _ 4P lBLACKl CONNECTOR Remove the two exhaust pipe joint nuts. Remove the rear fender bolt, two muffler mounting bolts and muffler. Remove the gasket. MOUNTING BOLTS A ‘ INSTALLATION Replace the gasket with a new one. Installation is in the reverse order of removal. @ GASKET FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER PROTECTOR REMOVAL/INSTALLATION The muff/er promo With the muffler Inna/led 0'1 the TORQUE: 52 Min (0.53 kgI-m. 3.1 Ibf-ftI engme Remove the socket bolts and muffler protector. tor can be synced Installation Is in the reverse order of removal. 4. MAINTENANCE SERVICE INFORMATION ------------------------------ 4-2 MAINTENANCE SCHEDULE ------------------------- 4-3 FUEL LINE ...................................................... 4.4 THROTTLE OPERATION -------------------------------- 4-4 AIR CLEANER ................................................. 4.5 ENGINE BREATHER ...................................... 4-6 SPARK PLUG ................................................. 4.5 VALVE CLEARANCE ...................................... 4-8 ENGINE OlL--- .................................... 4.10 ENGINE OIL STRAINER SCREEN --------------- 4-11 RADIATOR COOLANT- COOLING SYSTEM ...................................... 4.12 BRAKE SHOES WEAR .................................. 4.13 BRAKE SYSTEM BRAKE LOCK OPERATION -------------------------- 4—14 HEADLIGHT AIM .......................................... 4.14 SUSPENSION -------- NUTS, BOLTS, FASTENERS ------------------------ 4-15 WHEELS/TIRES ............................................ 4.15 STEERING HEAD BEARINGS 3-10 4-1 MAINTENANCE SERVICE INFORMATION GENERAL Place the motorcycle on a level ground surface before starting any work. - Gasoline is extremely flammable and is explosive under certain conditions. 0 Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. ' If the engine must be running to do 5 enclosed area. . The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area Or with an exhaust evacuation system in an enclosed area. ome work, make sure the area is well ventilated. Never run the engine in an SPECIFICATIONS if ITEM 7 SPECIFICATIONS Throttle gripfree play 276mm(1/16—1/4in) ' Spark plug NGK i l Standard ' ER8EH-N Spark plug gap 0.60 — 0.70 mm (DOM—0.028 in) Valve clearance IN 010 10.03 mm (0.004 t 001 in) EX ‘021 10.03 mm (0.008 t .001 in) 7 Engine oil capacity After draining 0.6 liter (0.6 US qt, 0.5 Imp qt) ' At disassembly _ 0.7 liter (0.7 US qt, 0.6 Imp qt) i Honda "4nSTROKE MOTORCYCLE OILII or equivalent 7 Recommended engine oil AFl service classification: SJ except oils labeled as energy conserving the circular AFl service label Viscosity: SAE iow-ao (Use 10W-30 regardless of atmospheric temperature) JASO: MA or MB 2000 :100 min" (rpm) ingine idle speed Wrake leVer free play Front 10 , 20 mm (3/8 — 13/16 in) Rear 10—20 mm (3/5413/16in) Tire size Front 120/90—10 57J Rear ‘ 130/904061J Cold tire pressure Front 175 kPa (1.75 kgf/cm , 25 psi) Rear 175 kPa (1.75 kgf/cmz, 25 psi) Minimum tire tread depth Front 0.8 mm (0.03 in) Rear 0.8 mm (0.03 in) TORQUE VALUES Spark plug 8.8 N-m (0.9 kgf~m, 6.5 |bf~ftl Engine oil drain bolt 25 N-rTi (2.5 kgf-m,18|bf‘ftl Engine Oil strainer cap 20 N-m (2.0 kgf-m,14lbf«ftl TOOLS Spark plug wrench O7OMA-GEZOIOO MAINTENANCE MAINTENANCE SCHEDULE Perform the Prenride inspection in the Owner’s Manual at each scheduled maintenance period. l: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate The following items require some mechan' ' ' ' . . lcal knowledge. Certain items attic " ' more technical information and tools. Consult an authorized Honda deale‘i? ularly those marked and H) may require FREQUENCY wHiéi—iEVER E> _ gloflig/lTES ODOMETER READING ITEMS _ (NOTE 1) . x1,000 mi 0.6 2.5 5 7.5 REFER To x1.ooo km 1 4 s 12 PAGE - . \ Q Month 6 12 1s * FUEL LINE I \ * THROTTLE OPERATION l i I 44 AIR CLEANER NOTE 2 R 4‘4 CRANKCASE BREATHER NOTE 3 C c C 4.5 * SPARK PLUG R 2-: * VALVE CLEARANCE ' - 7 ENG'NE OIL EVERY 15‘00: m. i:4,00t;km)lR 4.3 * ENGINE OIL STRAINER SCREEN 4‘10 RADIATOR COOLANT NOTE 4 C 411 * COOLING SYSTEM 4’12 BRAKE SHOES WEAR i | i 4‘12 BRAKE SYSTEM l | l l 4.13 * BRAKE LOCK OPERATION | | | | 4'13 * HEADLIGHT AIM | i i 4.14 ** CLUTCH SHOES WEAR | 4‘14 * SUSPENSION l i | 10-14 * NUTS, BOLTS, FASTENERS | | 4.14 H WHEELS/TIRES I l l 4,15 H STEERING HEAD BEARINGS l | 2-1: Should be serviced b an a th ' ' mechanically qualified]. u orized Honda dealer, unless the owner has proper tools and service data and is In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer Honda recommends that an authorized H - o - . ‘ ' carried out. nda dealer should road test your motorcycle after each periodic maintenance is H NOTES: 1. At higher odometer reading repeat at the fre ' ' _ , . quency intervals established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Service more frequently when riding in rain or at full throttle. 4. Replace every 2 years. Replacement requires mechanical skill. 4-2 MAINTENANCE FUEL LINE Remove the floor step (page 3—7]. Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary THROTTLE OPERATION Check the throttle cable for any deterioration or damage. Check that the throttle opens smoothly and auto, matically closes completely in all steering positions. If the throttle grip does not return properly, lubricate the throttle cable and overhaul and lubricate the throttle grip housing. For cable lubrication: Disconnect the throttle cable at its upper end. Thoroughly lubricate the cable and its pivot point with a commercially available cable lubricant or a light weight oil. Reusmgadam- If the throttle grip still does not return properly, aged or abnormal/y replace the throttle cable. m bS/mek/Wked With the engine idling, turn the handlebar all the '0, “3: f0“ way to the right and left to ensure that the idle ”eve” ”my speed does not change. It idle speed increases. Y”;Dfn“:sgdnja°fi9’: check the throttle grip free Play and throttle cable ’0 n V ea connection. to a loss Of throttle cantrolwht/ending Measure the throttle grip free play at the throttle grip flange. FREE PLAV: Z — 6 mm [1116- 1/4 in) Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustment is made with the upper adjuster. Remove the dust cover. Loosen the lock nut, turn the adjuster as required and tighten the lock nut. 246 mm (1/16—1/4inl DUST COVER ADJUSTER 4-4 Major adjustment is made with the lower adjuster. Loosen the lock nut, turn the adjusting nut as required and tighten the lock nut while the throttle cable against to the connecting hose. Check the clearance between the throttle cable and connecting hose is 0 , 5 mm l0 - 0.2 in). Recheck the throttle operation. AIR CLEANER NOTE‘ 0 The viscous paper element type air cleaner can not be cleaned because the element contains a dust adhesive. - If the scooter is used in unusually wet or dusty areas, more frequent inspections are required. Remove the seven screws and air cleaner cover. Replace the element in accordance with the mainte— nance schedule or any time it is excessively dirty or damaged. ADJUSTING NUT MAINTENANCE 075mm(0-0.2inl LOCK NUT SCREWS 4-5 MAINTENANCE ENGINE BREATHER ‘ NOTE . Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or ‘ overturned. Service if the deposit level can be seen in the transparent section of the drain hose. ‘ . l . Remove the engine breather drain hose and dram ‘ deposits into a suitable container, then install the DRAIN HOSE // engine breather drain hose securely. ‘2 SPARK PLUG i Be carefulnotto Open the fuel tank cap lid and remove the plug damage the tabs maintenance Iidt andslots. . Disconnect the spark plug cap and clean around the spark plug bases. NOTE: ' Clean around the spark plug bases with com- pressed air before removing the plug, and make sure that no debris is allowed to enter the coms bustion chamber. Remove the spark plug using special tool. TOOL: Spark plug wrench 070MA—GEZD1DO This motorcycles spark plug equipped With ”Ida lum center elecs trade Replace the spark plug ii the electrodes is Coll- taminated, Always use speci- fled spark plug pp this motorcycle To plevent damag inp the l'rlrilurn cenr tei electrode, use a Wire type fee/er gauge to check the spark plug gap Do not adjust (he spark plug gap it the gap is our of speclflcatlon, replace With a new one, Check the following and replace if necessary (rec ommended spark plug: page 4-2). - Insulator for damage - Electrodes for wear ' Burning condition, coloration If the electrodes is contaminated with accumulated objects or dirt, replace the spark plug. Replace the plug if the center electrode is rounded as shown in the illustration. If necessary, adjust the gap by bending the side electrode carefully. SPECIFIED SPARK PLUG: Standard: ERBEH-N (NGK) Check the gap between the center and side eleo trodes with a wire type feeler gauge. Make sure that the ‘D 0.8 mm (0.03 inl plug gauge does not insert between the gap. If the gauge can be inserted into the gap, replace the plug with a new one. Install the spark plug to the cylinder head and hand tighten, then torque to specification. TOOL: Spark plug wrench D7DMA-GEZO100 TORQUE: 8.8 MI" (0,9 kgf-m, 6.5 lbf-ft) Install the spark plug cap. MAINTENANCE INSULATOR ELECTRODE ROUNDED ELECTRODE WIRE TYPE FEELER GAUGE 4-6 MAINTENANCE Be careful not to Install the plug maintenance lid. damage the tabs Close the fuel tank cap lid. and slots VALVE CLEARANCE INSPECTION NOTE: - Inspect and adjust the valve clearance while the engine is cold (below 35" Cl95° Fl. Remove the following: — Radiator cover (page 777) — Belt case cover (page 10-6) — Cylinder head cover (page 9-6) Rotate the drive pulley (crankshaft) counterclockr wise and align the "T" mark on the flywheel with the index mark on the crankcase. Make sure the index line on the cam sprocket aligns with the index mark on the stopper plate and the lobe of the camshaft faces the cylinder side (TDC on the compression stroke). If the lobe of the camshaft is not aligned, rotate the drive pulley (crankshaft) counterclockwise one revo» lution and realign the index line with the index mark. Measure the valve clearance by inserting a feeler gauge between the rocker arm and shim. VALVE CLEARANCE: IN: 0.10 10.03 mm (0004:0001 in) EX: 0.21 10.03 mm (0.008 $0.001 in) PLUG MAINTENANCE LID MAINTENANCE ADJUSTMENT Move the rocker arm to the spring side and remove the shim. NOTE. - Do not allow the shims to fall into the crankcase. - Mark all shims to ensure correct reassembly in their original locations. - The shims can be easily removed with tweezers or a magnet. Clean the valve shim Contact area with compressed air. Measure the shim thickness and record it. NOTE: - Sixtyrnine different shim thicknesses are avail- able in increments of 0.025 mm (from 1.200 mm to 2.900 mm). Calculate the new shim thickness using the equa tion below, A=(B~CJ+D New shim thickness ecorded valve clearance pecified valve clearance . Old shim thickness - Make sure of the correct shim thickness by mea» suring the shim with a micrometer. 1.30 mm 1,325 mm 1.35 mm 1.875 mm O Reface the valve seat if carbon deposits result in a calculated dimension of over 2.900 mm. Install the newly selected shim on the spring retainer. Rotate the camshaft by rotating the drive pulley (crankshaft) counterclockwise several times. Recheck the valve clearance. install the following: — Cylinder head cover (page 9-23( — Belt case cover (page 10~6l — Radiator cover (page 7-8) MAINTENANCE ENGINE OIL OIL LEVEL CHECK Start the engine and let it idle for 3-5 minutes. Stop the engine and wait 2-3 minutes, Support the scooter with its center stand on a level surface, Remove the oil filler cap/dipstick and wipe the oil from the dipstick with a clean cloth. Insert the dipstick without screwing it in, remove it and check the oil level. If the oil level is below or near the lower level line on the dipstick, add the recommended oil to the upper level. RECOMMENDED ENGINE OIL: Honda "4-STROKE MOTORCYCLE OIL" or equiva- lent API service classification: SJ except oils labeled as energy conserving the circular API service label Viscosity: SAE 10W-30 (Use 10W-30 regardless of atmospheric temperature) JASO: MA or MS Reinstall the oil filler cap/dipstick. For engine oil change, page 4—10. OIL CHANGE NOTE. - Change the oil with the engine warm and the scooter placed on its center stand to assure com- plete and rapid draining. Warm up the engine to normal operating tempera— ture. Stop the engine and remove the oil filler cap/dip- stick. OIL FILLER CAP/DIPSTICK C UPPER LEVEL LOWER LEVEL OIL FILLER CAP/DIPSTICK I, 4-10 Remove the drain bolt and washer, and drain the . oil. Install the oil drain bolt with a new sealing washer and tighten it to the specified torque. TORQUE: 25 N-m (2.5 kgI-m, 18 lbf-ft) Fill the crankcase with the recommended oil (page 440i. OIL CAPACITY: 0.6 liter (0.6 US qt, 0.5 Imp qt) at draining 0.7 liter (0.7 US qt, 0.6 Imp qt) at disassembly Check the engine oil level (page 4710). Install the oil filler cap/dipstick. Make sure there are no oil leakage. ENGINE OIL STRAINER SCREEN Drain the engine oil (page 4-10). Remove the oil strainer cap and O-ring. Remove the spring and oil strainer screen. Clean the oil strainer screen. Coat a new O-ring with engine oil. Install the oil strainer screen and spring into the crankcase as shown. Install and tighten the oil strainer cap with a new 0- ring. TORQUE: 20 N-m (2.0 kgI-m, 14 lbf-ftl Fill the crankcase with the recommended engine oil (page 4-10). V .5— MAINTENANCE SPRING STRAINER SCREEN 4-11 MAINTENANCE RADIATOR COOLANT Support the scooter with its center stand on a level surface. Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" and "LOWER" level lines with the scooter upright on a level surface. If the level is low, remove the reserve tank cap and fill the tank to the "UPPER“ level line with a 1:1 mix» ture of distilled water and antifreeze (coolant mix- ture preparation: page 7-5). Using coolant with silicate inhibitors may cause pre— mature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. Check to see if there are any coolant leaks when the coolant level decreases very rapidly. if the reserve tank becomes completely empty, there is the possibility of air getting into the cooling system (page 7-71. COOLING SYSTEM Check for coolant leakage from the water pump, water hoses and hose joints. Check the water hoses for cracks or deterioration and replace if necessary. Check that all hose clamps are tight. Remove the radiator cover (page 7.7,. Check the radiator air passage for clogs or damage. Straighten bent fins with a small, flat blade screw- driver and remove insects, mud or other obstruc- tions with compressed air or low pressure water. Replace the radiator if the airflow is restricted over more than 20% of the radiating surface. Install the radiator cover (page 78). UPPER L 4-12 BRAKE SHOES WEAR FRONT Check the wear indicator position when the brake lever applied. If the indicator aligns with the reference mark, inspect the brake drum (page 14-10). Replace the brake shoes (page 1440) if the drum ID. is within the service limit, REAR Check the wear indicator position when the brake lever applied. It the indicator aligns with the reference mark, inspect the brake drum (page 15-5). Replace the brake shoes (page 156) if the drum ID. is within the service limit. BRAKE SYSTEM Measure the brake lever free play at the end of the lever. FREE PLAV: 10 — 20 mm (3/8 — 13/16 in) Make sure the cur- Adjust the brake lever free play by turning the brake ouron the ad/ustlng arm adjusting nuts nut (5 seated on the [OintD/n. MAINTENANCE 10-20 mm (3/8—13/16in) ADJUSTING NUT 4-13 MA'NTENANCE MAINTENANCE BRAKE LOCK OPERATION REAR Check the action of the shock absorber by com» pressing it several times. BRAKE LOCK Check the entire shock absorber assembly for dam- age or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to page 1578 for shock absorber service. Check the brake lock operation. NOTE: - The brake lock will not function if the rear brake lever is not adjusted properly (page 4-13). Raise the rear wheel off the ground and support the H EADLIGHT AIM scooter securely. Support the scooter with its center stand on a level surface Check for worn engine mounting bushings by grab- bing the rear wheel and attempting to move the wheel side-toiside. Replace the bushings if any looseness is noted Adjust the headlight Adjust the headlight aim vertically by loosening the (page 8-4). aim as specified by headlight guard mounting bolts. local /aws and reguV lations. NUTS, BOLTS, FASTENERS Check that all chassis nuts, bolts and screws are tightened to their correct torque values (page 1—9). Check that all cotter pins. safety clips, hose clamps and cable stays are in place and properly secured. Adjust the headlight aim horizontally by loosening the headlight mounting bolts. WHEELS/TIRES Check the tire pressure with a tire pressure gauge when the tires are cold. RECOMMENDED TIRE PRESSURE: FRONT: 175 kPa (1.75 kgf/cmz. 25 psil REAR: 175 kPa (1.75 kgf/emz, 25 psil SUSPENSION FRONT Loose, worn or Check the action of the forks by operating the front damagedsuspen- brakes and compressing the front suspension sevV sum parts Impair eral times. scooterstabilityand Check the entire forks assembly for damage or control loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to page 14-14 for fork service. TIRE PRESSURE GAUGE 4-14 4-15 MAINTENANCE 5. LUBRICATION SYSTEM Check the tires for cuts, embedded nails or other damage Check the front wheel and rear wheel for trueness ‘ (refer to page 147 and page 15-4). Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits, l MINIMUM TREAD DEPTH: FRONT: 0.8 mm (0.03 in) REAR: 03 mm (0.03 in) r, Raise the wheel off the ground and support the 5900“” securely. LUBRICATION SYSTEM DIAGRAM ------------- 5-2 TROUBLESHOOTING --------- ‘ Check for worn wheel bearings by grabbing the , wheel and attempting to move the Wheel Side ‘0 SERVICE INFORMATION ......................... 5.3 OIL pump ............................ l sidet ‘ Replace the bearings if any looseness is noted i Refer to front wheel bearing replacement (page 14- ' 7). Refer to rear final gear shaft bearing replacement [page 11-9l. STEERING HEAD BEARINGS Check that the con Raise the front wheel off the ground and support trul cab/es do not the scooter securely. interfere mm hanr Check that the handlebar moves freely from side»to- dlebar rotatan, side. If the handlebar moves unevenly, binds, or has ver tical movement, inspect the steering head bearings (page 14-23). \ 4-16 5-1 LU BRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARM SHAFT ooa ROCKER ARM OIL STRAINER PISTON OIL PUMP CRANKSHAFT ‘— Di fl LUBRICATION SYSTEM SERVICE INFORMATION GENERAL 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. I The oil pump can be serviced with the engine installed in the frame. - The service procedures in this section must be performed with the engine oil drained. - When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. - 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. SPECIFICATIONS 7 Unit: mm (in) ITEM 7 STANDARD l SERVICE LIMIT Engine oil capacity At draining 0.6 liter (0.6 US qt, 0.5 Imp qt) e At disassembly 0.7 liter (0.7 US qt, 0.6 Imp qt) 7 Recommended engine oil Honda‘"4-STHOKE MOTORCYCLE OIL“ r 7 or equivalent APl service classification: SJ except oils labeled as energy conserving the circular APl service label Viscosity: SAE 10W-30 (Use 1OW-30 regardless of atmospheric tempera~ turel JASO: MA or MB Oil pump rotor Tip clearance ‘ 015 (0.006) 0.20 (0.008) Body clearance 0.15 > 0.20 (0.006 —- 0.008) 0.22 (0.009) l Side clearance 0.05 — 0.10 (0.002 a 0.004) 0.12 (0.005) TORQUE VALUES Oil pump cover screw 2.0 N-m (0.2 kgf-m, 1.4 lbf~ftl TROUBLESHOOTING Engine oil level too low ' Oil consumption ' External oil leak - Worn piston ring or incorrect piston ring installation - Worn cylinder O Worn valve guide or seal Oil contamination - Oil not changed often enough O Faulty cylinder head gasket I Worn piston ring LUBRICATION SVSTEM OIL PUMP REMOVAL When remcwng Drain the engine oil (page 4-10). and installing the oil Drain the coolant from the cooling system (page 7» pump, do not allow 6). dust or d’" to enter Remove the following: the engine ~ Radiatorlpage 7713) , Alternator/starter (page 12-4) Remove the four bolts and stator base. Remove the dowel pins, O-ring and oil seal. Remove the oil pump driven gear, Be calefulnot to Remove the bolts and oil pump from the crankcase. y drop the bolts into the crankcase, OIL PUMP STATOR BASE ’ . LUBRICATION SYSTEM DISASSEMBLY Remove the screw and oil pump cover. SCREW COVER Remove the oil pump outer rotor and inner rotor. INNER ROTOR OUTER ROTOR INSPECTION NOTE: ' Measure each clearance at several points and use the largest reading to compare the service limit. Temporarily install the outer, inner rotors and driven gear into the oil pump body. TIP CLEARANCE! Measure the tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) Measure the pump body clearance. BODY CLEAR : SERVICE LIMIT: 0.22 mm (0.009 in) ANCE LUBRICATION SYSTEM Measure the side clearance using a straight edge and feeler gauge. “ SIDE CLEARANCE: m. , 3“,. SERVICE LIMIT: 0.12 mm (0.005 in) ASSEMBLY Dip all parts in clean engine oil before assembly. OIL PUMP DRIVEN GEAR OIL PUMP BODY OIL PUMP COVER OUTER ROTOR Q INNER ROTOR 0 SCREW 2.0 N‘m (2.0 kgf-m, 14 lbf-ft) Install the outer rotor and inner rotor into the oil F75 ROTOR pump body. Install the oil pump cover onto the oil pump body. Install and tighten the oil pump cover screw to the specified torque. TORQUE: 2‘0 Nrm (0.2 kgf-m, 1.4 lbf-h) INSTALLATIO N Install the oil pump by aligning the dowel pin and screw with the grooves of the crankcase. Install and tighten the mounting bolts securely. Apply engine oil to the drive gear and driven gear . sliding surface/gear teeth. Install the driven gear by aligning the cut-outs of the driven gear and oil pump inner rotor. fill LUBRICATION SYSTEM SCREW COVER DRIVEN GEAR «‘— 5-7 LUBRICATION SYSTEM Apply engine oil to a new oil seal lip and install it into the stator baset Coat a new O-ring with oil and install it into the Sta» tor base. Apply engine Oil to the Oil pump driven gear sliding surface of the stator base. Install the dowel pins into the crankcase. Install the stator base on the crankcase and tighten the four bolts securely. Install the following: , Alternator/starter (page 125) — Radiator (page 7-15) Fill and bleed the cooling system (page 7'7). After installation, fill the crankcase with the recom- mended engine oil [page 4-10) and check that there are no oil leeks. DOWEL PINS 6. FUEL SYSTEM (Programmed Fuel Injection) 5-8 COMPONENT LOCATION ----------------------------- 6-2 AIR CLEANER HOUSING- 5-53 SERVICE INFORMATION .............................. 5.3 THROTTLE BODY ......................................... 6-55 TROUBLESHOOTING .................................... 6-5 INTAKE PIPE ................................................. 5.50 SYSTEM LOCATION -------------------------------------- 6-6 INJECTOR- 6-61 SYSTEM DIAGRAM ....................................... 6-7 MAP SENSOR ............................................... 6-62 PGM-Fl SELF-DIAGNOSIS ECT SENSOR ................................................ _ INFORMATION .............................................. 5.3 6 63 TP SENSOR ---------- - MIL CODE INDEX ----------------------- -s-12 6 64 BANK ANGLE SENSOR ............................... . THROTTLE BODY (SENSOR) POWER 6 65 LINE INSPECTION ....................................... 5.14 MAIN RELAY ____________ 6 66 M"— TROUBLESHOOT'NG """""""""""""" 5'15 ECM (ENGINE CONTROL MODULEI- 6-67 DTC CODE INDEX" 6-28 ENGINE IDLE SPEED .................................... 6-69 DTC TROUBLESHOOTING -------------------------- 6-31 .Ac VALVE ...................... g 69 FUEL “”5 'NSPECT'O” """"""""""""""" 5‘46 :CV CONTROL SOLENOID VALVE/ EED VALVE- - FUEL PUMP --------- 6-50 6 7° 0 SEN ................................................... . FUEL TANK .................................................. 6-52 2 SO“ 6 72 6-1 FUEL SYSTEM (Programmed Fuel Injection) COMPONENT LOCATIONS 10 N~m (1.0 kgf-m, 7 [bf-ft) FUEL SYSTEM (Programmed Fuel Injection) SERVICE INFORMATION GENERAL Before disconnecting fuel feed hose, relieve pressure from the system by disconnecting the quick connect fitting in the fuel pump (page 8-46l. Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend, resulting in loss of vehicle control. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. Do not apply commercially available carburetor cleaners to the inside of the throttle bore, which is coated with molyb- denum. Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incor~ rect idle operation. Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering the intake port after the throttle body has been removed. Do not damage the throttle body. It may cause incorrect throttle valve. Prevent dirt and debris from entering the throttle bore and fuel feed hose, clean them using compressed air. The throttle body is factory pre—set. Do not disassemble in a way other than shown in this manual. Do not push the fuel pump base under the fuei tank when the fuel tank is stored. Do not loosen or tighten the white painted bolts, nuts and screws of the throttle body with engine control module (ECMl. Loosening or tightening them can cause ECM malfunction. Always replace the packing when the fuei pump is removed. - It is impossible to disassemble the fuel pump after removing it. The programmed fuel injection (PGMVFI) system is equipped with the Self-Diagnostic System described (page 6—3). If the malfunction indicator lamp (MILl blinks, follow the Self-Diagnostic Procedures to remedy the problem. When checking the PGM-FI, always follow the steps in the troubleshooting flow chart (MIL trouble shooting:page 6715 or DTC trouble shooting:page 6-31l. The PGM—FI system is provided with fai|»safe function to secure a minimum running capability even when there is any trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making use of the numerical values of a situation preset in advance in the simulated program map. It must be remem- bered, however, that when any abnormality is detected in injector the fail safe function stops the engine from the stand- point of protecting it. Refer to PGM»FI system iocation (page GVGl. A faulty PGMVFI system is often related to poorly connected or corroded connectors. Check those connections before proceeding. The vehicle speed sensor sends digital pulse signal to the ECM (PGM-Fl unit) and computation. Refer to procedures for vehicle speed sensor inspection (MIL troubleshooting:page 6—15 or DTC trouble shooting:page 6731i When disassembling the programmed fuel injection parts, note the location of the O-rings. Replace them with new ones upon reassembly. Use a digital tester for PGM-FI system inspection. Refer to procedures for fuel level sensor inspection (page 1910). SPECIFICATIONS ITEM "s‘PECIFICATIoMs Throttle body identificationvnumber GoLo _ Idle speed 2,000 1100 m (rpm) :hrottle grip free play 7 Viz—Smm (1/16~1/4in) IAT (We Air Temperature] sensor resistance (20“ C77 ‘ 7 7 W 7 2.4 — 2.7 kn 68" F) ECT (Engine Coolant Temperaturel sensor resistance 2.4 3217 kg (20° C/68° Fl Fuel injector resistance (20°C/68° F) 11.1 — 12.3 (2 IAC (Idle Air Controll resistance (20“ C /68° Fl 120 — 140 Q PCV control solenoid_va|ve resistance (EEC/68:1: , rig) ‘ Fuel pressure 294 kPa (3.0 kgf/cmz, 43 psil , Fuel pump flow (at 12 Vl 3 1.4 US 01:71.5 imp oz) minimum/10 seconds 6-3 FUEL SYSTEM (Programmed Fuel Iniectlonl FUEL SYSTEM (Programmed Fuel Injection) TORQUE VALUES TROUBLESHOOTING Fuel feed hose stay bolt 10 NW! (1.0 kgf‘mi 7 lbf'fli Engine won't to start ECT sensor 18 Nm (1-8 kgf‘mi13lbf'fli - Intake air leak PCV control solenoid valve bolt 5.9 N-m (0.6 kgf-m, 4.3 lbf-ft) - Fuel contaminated/deteriorated Insulator band screw 23 N~m (0.3 kgf‘m, 2.1 IbI-ftI - Pinched or clogged fuel feed hose Bank angle sensor mounting screw 12 Nm (0.12 kgf-m, 0.9 lbf-ftI - Faulty fuel pump Breather hose joint screw 0.8 N-m (0.08 kgf-m, 0.6 lbf—ftI ' Clogged fuel filter Fuel pump unit mounting nut 12 N-m (1.2 kgf‘m, 9 lbf-ftl Tightening order: See page 6-50 ' Faultv IAC (Idle Air Control) valve Ozsensor 44 N-m (4.5 kgi-m, 33 lbf-ftI ° C‘9999d.‘".|e°t°r 0 Sticking injector needle TOOLS 0 Faulty fuel pump operating system 7.. Engine stall, hard to start, rough idling DLC short connector ECM test harness Fuel pressure gauge - Intake air leak 07DPZ~ZY3OIDO 070MZVGEV0100 0740670040004 O Fuel contaminated/deteriorated 0 Pinched or clogged fuel feed hose 0 Faulty IAC (Idle Air ControlI valve Backfiring or misfiring during acceleration I Ignition system malfunction Poor performance (drive ability) and poor fuel economy ' Pinched or clogged fuel feed hose - Faulty pressure regulator Pressure gauge manifold ‘ Fuel attachment hose A Fuel attachment hose B 07ZAJ-SSAO‘I‘I‘I 07ZAJ7$5A0120 07ZAJ-55A0130 Fuel attachmentjoint B 02sensor wrench Test probe I 07ZAJ-SSAO150 O7LAA-PT50101 O7ZAJ-RDJA‘IIO 6-4 6-5 FUEL SYSTEM (Programmed Fuel lniecfion) FUEL SYSTEM (Programmed Fuel lniection) MIL MAIN RELAY ECM IGNITION SWITCH COOLANT TEMPERATURE INDICATOR/FUEL RESERVE INDICATOR MAIN FUSE/ BANKANGLE SUB FUSE THROTTLE BODY SENSOR — MAP SENSOR r TF SENSOR — IAT SENSOR — IAC VALVE BATTE RY Q (‘5)t17IUB) PCV SOLENOID VALVE , "1 ' I- ‘ £1 ’ ,- DLC FUEL PUMP/FUEL RESERVE SENSOR INJECTOR ECT SENSOR CKP SE OR 02 SENSOR NS “I Battery ' l14l PAIR reed valve I2) Ignmqri switch (15) PAIR control solenoid valve FULL NAME ABBREVIATIONS I (3) Mai" (“59 ‘20 AI . (16) W3 valve 7' ' Manifold absolute sensor MAP sensor %;A_ 3:153?” A) 7 (17) IAT sensor Throttle position sensor TF3 sensor (6) Subf e ‘15 A) 7 , (18) , MAP sensor Intake air temperature Sensor IAT sensor (7, Fuel “3:1 (Eli TP sensor Engine coolant temperature sensor ECT sensor (8, Fuel $5952 sensor :22; ganniéjrngciilsensor ' I , gaenaklgifgfc‘pglsifiznesensor |(f‘lfPVsaegzor (9i ‘ Injector (22I Malfunction indicator lamp IMILI Malfunction indicator Iamp MIL (10) 02 sensor 123) Coolant temperature indicator Data link connector DLC WI Spark plug 124) Fuel reserve indicator Erma controi module ECM :13; 5%: :22: 125) I Data Imk connector IDLCI 6-6 I 6-7 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI SELF-DIAGNOSIS INFORMATION SELF-DIAGNOSTIC PROCEDURE Place the scooter on its centerstand. Start the engine and let it idle. NOTE. - If the ECM detects any problem at the moment, the MIL will be following status depending on engine speed: 7 under 2,500 min‘ (rpm): MIL blinks as detec- tion item. 7 over 2,500 min" (rpm): MIL turns on (stay lit). I If the engine will not start, turn the starter motor for more than 10 seconds and check that the MIL brink. If the malfunction indicator lamp (MIL) does not light or blink, the system has no memon/ of prob- lem data. If the MIL blinks, note how many times the MIL blinks (page 6712) or read the Diagnosis Trouble Code (DTC) with the Honda Diagnosis System (HDS) pocket tester, and determine the cause of the prob- lem (page 6-28). If you wish to read the PGM-FI memory for trouble data, perform the following: DTC (With the HDS Pocket tester) ‘ Diagnosis Trouble Code (DTC) is segmentalized from the MIL code. One or two figures in front of a hyphen are equal to the MIL code. One figure behind hyphen is a code on the basis of symptom. Therefore, in case ECT sensor, the ECM has two kind of trouble data, ECT sensor voltage is lower (DTC 7.1) or higher (DTC 7-2) than specified value. Remove the inner cover (page 375). Turn the ignition switch "OFF". Disconnect the connector cover from the Data Link Connector (DLC). Connect the Honda Diagnosis System (HDS) pocket tester to the DLC. Turn the ignition switch "ON“. Check the Diagnostic Trouble Code (DTC) and note it. Also, check the freeze data. Refer to the DTC index (page 6-28) and begin the appropriate troubleshooting procedure. - For specific operations, refer to the user’s mane ual that came with the Honda Diagnosis System (HDS) pocket tester. MALFUNCTION INDICATOR LAMP (MIL) Even If the ECM has memory data, the MM does not blink When the engine running FUEL SYSTEM (Programmed Fuel lniection) MIL code (Without the HDS Pocket tester) Remove the inner cover (page 3-5). Turn the ignition switch "OFF". Disconnect the connector cover from Data Link Con- nector (DLC) terminals Connect the special tool to the Data Link Connector (DLC). TOOL: DLC short connector 070PZ-ZV30100 CONNECTION: Brown — Blue/Green Turn the ignition switch "ON". if the ECM has no self diagnosis memory data, the MIL will illuminate, when you turn the ignition switch "0N“. If the ECM has self diagnosis memory data, the MIL will start blinking when you turn the ignition switch "ON". Note how many times the MIL blinks, and determine the cause of the problem (page 6-12). DATA LIN CON NECTOR V FUEL SYSTEM (Programmed Fuel Injection) SELF-DIAGNOSIS RESET PROCEDURE Reset the selfrdiagnosis memory data in either of 2 ways; With the HDS Pocket tester Use the Honda Diagnosis System (HDS) pocket tester to clear the ECM memory. See the Honda Diagnosis System (HDS) pocket tester user's mane ual for specific instruction. Without the HDS Pocket tester 1. Turn the ignition switch “OFF“. 2. Remove the inner cover (page 3-5). 3. Connect the special tool to the Data Link Connec— tor (DLC). TOOL: DLC short connector 070PZ-ZY301DO CONNECTION: Brown — Blue/Green 4. Turn the ignition switch “ON“. 5. Disconnect the DLC short connector from the Data Link Connector (DLC). 6. The MIL lights about 5 seconds. While the indicator lights, short the Data Link Connector (DLC) again with the DLC short cone nector. Self-diagnosis memory data is erased, if the MIL turn off and start blinking. - The data link connector must be jumped while the indicator lights. If not, the MIL will not start blinking. Note that the self diagnosis memory data cannot be erased if you turn off the ignition switch before the MIL starts blinking. - If the MIL blinks 20 times, the data has not been erased, so try again. TEST HARNESS CONNECTION Remove the inner cover (page 35). Disconnect the ECM 21P (Black) and 21)“ (Gray) con- nectors from the ECM. DLC SHORT C ONNEC l \x ‘ * TO R i > _ \s RV ECM 21F (GRAY) CONNECTOR 6-10 FUEL SYSTEM (Programmed Fuel Injection) Connect the ECM test harnesses between the main wire harness and the ECM. TOOL: ECM test hamess 070MZ-GEV0100 TEST HARNESS TERMINAL LAYOUT The ECM connector terminals are numbered as shown in this illustration. The ECM test harness terminals are numbered as shown in this installation. Because signal of the ECM is outputted from the same position of the ECM test harness terminal. ECM TEST HARNESSES ECM 21F (GRAY) CONNECTOR (View from the terminal side) 21F (BLACK) CONNECTOR 21 (View from the terminal side) ECM TEST HARNESSES TERMINALS A (BLACK? TEST PROBE CONNECTION Connect the test probe between the ECM 21F con- nector and the digital multimeter when inspecting continuity or voltage at the ECM 21F connectors. TOOL: Test probe 07ZAJ-RDJA110 ECM 21F CONNECTOR TEST PROBE 6-11 FUEL SYSTEM (Programmed Fuel Injection) MIL CODE INDEX I The PGMvFI MIL denotes the failure codes (the number of blinks from 0 to 52), it is equivalent to ten blinks. For example, equals 12 blinks. Follow code 12 trou I When more than one failure occurs, example; if the indicator blinks once, then seven times are repea 15) after 7 (page 6-17) troubleshooting. bleshooting (page 6-21). the MIL shows the blinks in the order of lowes a 1.3 second illumination and two blinks (0.5 second x 2 When the indicator lights for 1.3 seconds ) of the indicator t number to highest number. For t, two failures have occurred. Follow codes 1 (Page 6- MIL Detection Item Causes Symptoms “a” No blinks ECM malfunction I Faulty ECM I Engine does not start — No blinks ECM power/ I Blown sub-fuse (15 A) (Starter/ I Engine does not start 6-67 ground circuit ignition/fuel pump) malfunction . Open circuit at the power input wire of the ECM I Open circuit in bank angle senr sor related circuit O Faulty bank angle sensor O Open circuitin main relay related wires I Faulty main relay I Faulty ignition switch No blinks MIL circuit mal— I Faulty ECM I Engine operates nor- — function I Open or short circuitin MIL wire mally I MlL does not blink Stay Iit Data link circuit O Short circuit in data link connecV O Engine operates nor— » malfunction ‘ tor wire mally O Faulty ECM 1 Blink MAP sensor cir— O Loose or poor contact on throttle I Poor performance at idle 6-15 cuit malfunction body 32F connector speed I Open or short circuit in MAP sen- sor wire O Faulty MAP sensor 7 Blinks ECT sensor cir- I Loose or poor contact on ECT O Hard start at a low tem- 6-17 cuit malfunction sensor 2P (Black) connector perature (Simulate using I Open or short circuit in ECT sen- numerical values; 90 °C/ sor wire 194 ° F) O Faulty ECT sensor O Low engine speed I Coolant temperature indicator turns on 8 Blinks TP sensor circuit I Loose or poor contact on throttle O Poor engine response 6—18 malfunction body 32F connector and performance when O Open or short circuit in TP sens operating the throttle sor wire quickly (Simulate using I Faulty TP sensor numerical values; Throtr tle opens 0°) 9 Blinks IAT sensor circuit . Loose or poor contact on throttle O Engine operates norr 6-19 malfunction body 32F connector mally (Simulate using O Open or short circuit in IAT sena numerical values; 25 °C/ sor wire 77 ° F) I Faulty IAT sensor 12 Blinks Injector circuit O Loose or poor contact on injector I Engine does not start 6721 malfunction 2P (Black) connector I Open or shon circuit in injector wire O Faulty injector 2" Blinks 02 sensor circuit I Loose or poor contact on 02 sen- ‘ Engine operates "0F 5'22 malfunction sor 4P (Natural) connector maIIV I Open or short circuit in Oz sensor wire L Faulty 02 sensor 6-17 FUEL SYSTEM (Programmed Fuel Injection) MIL Detection Item Causes Symptoms “a“? 23 Blinks ()2 sensor heater . Loose 0, poor contact on 02 sen» Engine operates nor- 57th ‘ malfunction sor 4P (Natural) connector me”)! i I Open or short circuit in Oz sensor heater wire 29 BI‘ k Idl I Faulty 02 sensor In 5 e air control O Loose o ' (IAC)-valve mal- body SZLPCOioirnceiToarCt 0" ”Home Egggfierformance at “1'9 ' 625 function I Open or short circuit in IAC valve wire . I Faulty IAC valve 52 Blinks Crankshaft posi- I Loose or poor contact on alterna» Engine does not start 646 tion (CKP) sensor/ alternator mal- function tor/starter 6? (Natural) connector Open or short circuit in CKP sens sor/alternator wire Faulty CKP sensor/alternator Starter motor does not operate 6-13 L SYSTEM (Pro rammed Fuel Injection) FUEL SYSTEM (Programmed Fuel Injection) FUE 9 3. Throttle Body Output Voltage Inspection THROTTLE BODY (SENSOR) POWER Connect the test harness to ECM connectors LINE INSPECTION (page 6—10l. _ . Turn the ignition switch “ON". ' ‘f/Vngcviwgsngellobr:"MkTL1t’rguabrIgsth3ntlfisgl check the Measure the voltage at the test harness termir o . - Before starting the inspection, checl; for‘iicése o)r nals, oor contact on the ECM 21P (Black , 21 ray, 2P (Black) and throttle body 32F connectors, then CONNECTION: B1 (+l —- B15 I—I recheck the MIL blinking. STANDARD: 4-75 - 5-25 V 7*“ ... 1. Throttle Bod ln ut Voltage Inspection Is the voltage within 4.75 _ 5.25 V? O O OO O O 0 <5 00 O O O O V P 0000000 0000000 Remove the floor Step (page 3-7)- 32F CONNECTOR VES - GO TO STEP 4. 0000000 OOOQOOO Turn the ignition switch "OFF“. ' N0 — Recheck the ECM with a new one, and Dlsconnect the throttle body 32F connector. recheck. 4. Throttle Body Power Line Continuity Inspection Turn the ignition switch “OFF“. Check for continuity between the test harness .7 terminals and ground. . \ GOCOOOO CONNECTION: BI - Ground B15 — Ground Is there continuities? VES — Loose or poor Contact on the ECM conr . . - u u t . Turn the‘ignltlon swrtch ON . nec ors N0 — - Open circuit in Yellow/Red wire. ' ess side 32F . . . . . Measure the voltage at the Wire harn , Open “mm In Green/Pink wlre. connector terminals. CONNECTION: Yellow/Red (+I — Green/Blue (—) STANDARD: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? YES — Refer to MIL troubleshooting (page 6- 15). N0 — GO TO STEP 2. MIL TROUBLESHOOTING MIL 1 BLINKS (MAP SENSOR) 0 Before starting the inspection, check for loose or poor Contact on the throttle body 32F connector and recheck the MIL blinking, 1. Throttle Body Power Line Inspection Check the throttle body power line inspection 2. Throttle Body Output Voltage Line Short Circuit (page 6-14l. Inspection Is the throttle body power line normally? VES - GO TO STEP 2. N0 — Replace or repairthe abnormal circuit. 2. MAP Sensor Output Voltage Inspection Disconnect the throttle body 32F connector. Turn the ignition switch "0N". Measure the voltage at the wire harness side. CONNECTION: Light green/Vellow I+I — Green] Blue I-l STANDARD: 4.75 — 5.25 V Is the voltage within 475 — 5.25 V7 VES — Faulty throttle body (MAP sensorl. NO — GO TO STEP 3. Turn the ignition switch "OFF“. Check for continuity between the throttle body 32F connector wire harness side and ground. CONNECTION: Yellow/Red — Ground Is there continuity? VES — Short circuit in Vellow/Red wire. NO — GO TO STEP 3. 5-14 l 6-15 FUEL SYSTEM (Programmed Fuel lniection) 3. MAP Sensor Short Circuit Inspection Check for continuity between the throttle body 32F connector wire harness side and ground. CONNECTION: Light green/Yellow — Ground Is there continuity? YES — Short circuit in Light green/Yellow wire. N0 — GO TO STEP 4. . MAP Sensor Output Voltage Inspection Connect the test harness to ECM connectors (page 6-10). Connect the throttle body 32F connector. Turn the ignition switch "ON“. Measure the voltage at the test harness termi- nals. CONNECTION: B11 (+) — B15 (—) STANDARD: 2.7 — 3.1 V (20° (2/68‘7 F) Is the voltage within 2.7 - 3.1 v7 YES — Loose or poor contact on the ECM con» nectors. NO - GO TO STEP 5. . MAP Sensor Circuit Continuity Inspection Turn the ignition switch "OFF". Disconnect the throttle body 32F connector. Check for continuity between the test harness terminal and throttle body 32F connector wire harness side terminal. CONNECTION: B11 — Light Green/Yellow Is there continuity? VES - Replace the ECM with a new one, and recheck. NO — Open circuit or poor contact in Light green/Yellow wire. 0000000 0000000 0000 0000000 000000 0000000 ‘\ ‘ ,3/4 FUEL SYSTEM (Programmed Fuel lniection) MIL 7 BLINKS (ECT SENSOR) - Before starting the inspection, check for loose or poor contact on the ECT sensor 2P (Black) con- nector and recheck the MIL blinking. 1. ECT Sensor Output Voltage Inspection Turn the ignition switch “OFF". Connect the test harness to ECM 21F (Biacki and 21F (Gray) connector (page 5-10). Turn the ignition switch “0N". Measure the voltage at the test harness termi- nals. CONNECTION: B3 (-0-) - B15 (-I STANDARD: 2.9 - 3.4 V (20" C/68° F) Is the voltage within 2.3 — 3.4 V? YES - Loose or poor contact on the ECM con- nectors. NO — GO TO STEP 2. 2. ECT Sensor Input Voltage Inspection Turn the ignition switch "OFF". Disconnect the ECT sensor 2P (Black) connector (page 6-63). Turn the ignition switch "ON” then measure the voltage at the ECT sensor connector of the wire harness side and ground. CONNECTION: Pink (+) - Ground (—) STANDARD: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? NO - GO TO STEP 5, YES — GO TO STEP 3. 3. ECT Sensor Open circuit Inspection Turn the ignition switch "OFF". Check for continuity between the test harness terminals and ECT sensor 2P (Black) connector of the wire harness side. CONNECTION: B3 — Pink B15 — Green/Blue Is there continuities? NO — GO TO STEP 4. YES — - Open circuitin Pinkwire. . Open circuit in Green/Blue wire. 0000000 0000000 000000 0000000 00 0000 00613000 P (BLACK) CONNECTOR 2P (BLACK) CON NECTOR 5-16 6-17 FUEL SYSTEM (Programmed Fuel Injection) 4. ECT Sensor Short Circuit Inspection Check for continuity between the ECT sensor 2P (Black) connector of the wire harness side and ground, CONNECTION: Pink — Ground Green/Blue — Ground Is there continuities? NO — - Short circuit in Pink wire. . Short circuit in Green/Blue wire. VES — GO TO STEP 5.. 5t ECT Sensor Resistance Inspection Measure the resistance between the ECT sensor terminals. STANDARD: 2.4 — Z._7 k9. (20° 6/68“ F) Is the resistance within 2.4 — 2.7 («”20 ”6/68 ”F)7 VES — - Loose or poor contact of the ECT 2P (Black) connector (from step 2). - Replace the ECM with a new one, and recheck (from step 4). N0 — Faulty ECT sensor. MIL 8 BLINKS (TP SENSOR) Before starting the inspection, check for loose or poor contact on the Throttle body 32F connector and recheck the MIL blinking. 1. Throttle Body Power Line Inspection Check the throttle body power line inspection (page 6-14). Is the throttle body power line normally? YES - GO TO STEP 2. N0 — Replace or repairthe abnormal circuit. 2. TP Sensor Short Circuit Inspection Turn the ignition switch “OFF“. Check for continuity between the throttle body 32F connector of the wire harness side and ground. CONNECTION: Yellow/Blue — Ground Is there continuity? YES — Short circuit in Yellow/Blue wiret NO — GO TO STEP 3. , V . /. 2P (BLACK) CONNECTOR ECT SENSOR 6-18 FUEL SYSTEM (Programmed Fuel Iniection) 3. TP Sensor Output Voltage Inspection Connect the test harness to ECM 21F (Black) and 21P (Gray) connector (page 6-10). Connect the throttle body 32F connector. Turn the ignition switch “ON“. Measure the voltage at the test harness termi- nals. CONNECTION:B‘I8 (+) — B15 (—) STANDARD: *0.3 — 0.7 V (throttle fully closed) *4.1 —4.8 V (throttle iullv opened) 0 O O O O O om‘do NOTE: 000 000 0000000 ' A voltage marked * refers to the value of the 00 000 0090000 ECM output voltage (STEP 3) when the volt- age reading shows 5 V. When the ECM output voltage reading shows other than 5 V, derive the TP sensor output voltage at the test harness as follows: In the case of the ECM output voltage is 4.75 V: 0.3 x 4.75/50 : 0.28 V 0.7 x 4.75/5. .67 V Thus, the solution is "0.28 - 0.67 V" with the throttle fully closed. Replace 0.3 and 0.7 with 4.1 and 4.8 respec- tively, in the above equations to determine the throttle fully opened range. Is the voltage at the standard value? YES — Loose or poor contact of the ECM 21P (Black) and 21P (Gray) connectors. N0 - GO TO STEP 4. 4. TP Sensor Output Line Inspection Turn the ignition switch "OFF". Disconnect the throttle body 32F connector. Check for continuity between the test harness and the throttle body 32F connector of the wire harness side. CONNECTION: 318 — Yellow/Blue Is there continuity? YES — Faulty throttle body (TP sensor) NO — Open or short circuit in Yellow/Blue wire. \< 32F CONNECTOR MIL 9 BLINKS (IAT SENSOR) ' Before starting the inspection, check for loose or poor contact on the Throttle body 32F connector and recheck the MIL blinking. 1. Throttle Body Power Line Inspection Check the throttle body power line inspection (page 6—14). Is the throttle body power line normally? YES — GO TO STEP 2. N0 - Replace or repair the abnormal circuit. 6-19 FUEL SYSTEM (Programmed Fuel Injection) 2. IAT Sensor Output Voltage Inspection Disconnect the throttle body 32F connector. Turn the ignition switch “0N". Measure the voltage at the throttle body 32F connector of the wire harness side. CONNECTION: Gray/Blue (+) — Green/Blue (—) STANDARD: 4.75 — 5.25 V Is the voltage within 4.75 — 5.25 V? N0 - GO TO STEP 6. YES — GO TO STEP 3. . IAT Sensor Short Circuit Inspection Check for continuity between the throttle body 32F connector of wire harness side and ground. CONNECTION: Gray/Blue — Ground Is there continuity? VES — Short circuit in Gray/Blue wire. NO - GO TO STEP 4. . IAT Sensor Output Voltage Inspection Connect the test harness to ECM ZlP (Black) and ZiP (Gray) connector (page 6-10). Connect the throttle body 32F connector, Turn the ignition switch "ON". Measure the voltage at the test harness termi- nals. CONNECTION: 310 (+) — B15 (—) STANDARD: 2.9 — 3.4 V (20” C/GB" F) Is the Voltage within 2.9 — 3.4 V? VES — Loose or poor contact of the ECM 21P (Black) and 21P (Gray) connectors. N0 — GO TO STEP 5. . IAT Sensor Circuit Inspection Turn the ignition switch “OFF". Disconnect the throttle body 32F connector. Check for continuity between the test harness and throttle body 32F connector of the wire harr ness side. CONNECTION: B10 — Gray/Blue Is there continuity? VES — GO TO STEP 6. N0 — Open or poor contact in Gray/Blue wire. 32F CONNECTOR 6-20 FUEL SYSTEM (Programmed Fuel Injection) 6. IAT Sensor Resistance Inspection Disconnect the test harness connectors from the ECM. Connect the throttle body 32F connector. Measure the resistance at the test harness termi— nals. CONNECTION: BIO - 315 STANDARD: 2.4 — 2.7 kfl (20° CIGS" F) Is the resistance within 2.4 — 2.7 kfli20 90/68 ”F)? YES - . Loose or poor contact of the throttle body 32F connector (from step 2). - Replace the ECM with a new one, and recheck (from step 4). NO — Faulty throttle body (IAT sensor) MIL 12 BLINKS (INJECTOR) 0 Before starting the inspection, check for loose or poor contact on the injector 2P (Black) connector and recheck the MIL blinking. 1. Injector Input Voltage Inspection Remove the plug maintenance lid (page 4-6). Turn the ignition switch "OFF". Disconnect the injector 2? (Black) connector. Turn the ignition switch "ON" then measure the voltage between the injector connector of the wire harness side and ground. CONNECTION: Red/Black (+) - Ground I-I Does the battery voltage exit? NO —- - Open circuitin Red/Black wire. - Faulty main relay - Replace the ECM with a new one, and recheck. VES — GO TO STEP 2. 2. Injector Signal Line Short Circuit Inspection Turn the ignition switch "OFF". Check for continuity between the injector 2P (Black) connector of the wire harness side and ground. CONNECTION: Pink/Blue — Ground Is there continuity? NO — Short circuit in Pink/Blue wire. VES — GO TO STEP 3. f0000 0000000 000000 0000650 0000000 0000000 P(BLACK) CONNECTOR ’7‘ . ,, . r ' it?” 2P (BLACK) CONNECTOR / J ,l C44 6-21 FUEL SYSTEM (Programmed Fuel Injection) 3. Injector Signal Line Open Circuit Inspection Connect the test harness to ECM 21? (Black) and 21F (Gray) connector (page 6-10). Check for continuity between the test harness terminal and injector 2P (Black) connector of wire harness side. CONNECTION: A8 — Pink/Blue Is there continuity? YES — GO TO STEP 4. NO — Open or poor Contact in Pink/Blue wire. 4. Injector Resistance Inspection Measure the resistance of the injector ZP (Black) connector terminals. STANDARD: 11.1 — 12.3 kflIZD“ C/BaD F) Is the resistance within 11.1 — 12.3 k!) {20°C/ 68°F}? YES — Replace the ECM with a new one. and recheck. N0 7 Faulty injector. MIL 21 BLINKS (02 SENSOR) 0 Before starting the inspection, check for loose or poor contact on the 02 sensor 4? (Black) connecV tor and recheck the MIL blinking. 1. 02 Sensor Output Voltage Inspection Connect the test harness to ECM 21F (Black) and 21? (Gray) connector (page 6-10). Start the engine and warm up the engine up to coolant temperature is 80 ”C (176 °F), then let it idle. Check the voltage at the test harness terminals. CONNECTION: 317 (+) — 315 (—) STANDARD: 0.3 —- 0.6 V Is the voltage within 0.3 - 0.6 V? YES — Check the fuel pressure (page 6749), if the system is correct. N0 — GO TO STEP 2. 2P (BLACK) CONNECTOR 6-22 FUEL SYSTEM (Programmed Fuel Injection) 2. Oz Sensor Open Circuit Inspection Turn the ignition switch "OFF“. Disconnect the 02 sensor 4P (Black) connector. Check for continuity between the test harness terminals and the 02 Sensor connector terminals of the wire harness side. CONNECTION: B17 — Black/Orange B15 — Gray/Blue Is there continuities? NO — - Open circuit in the Black/Orange (Black) wire. - Open circuit in the Gray/Blue (Gray) wire. YES — GO TO STEP 3. 3. 02 Sensor Short Circuit Inspection Connect the 01 sensor 4P (Black) connector. Check for continuity between the test harness terminal and ground. CONNECTION: B17 — Ground Is there continuity? YES — Short circuit in the Black/Orange (Black) wire. NO — GO TO STEP 4. 4. 0: Sensor Inspection 4P (BLACK) CONNECTOR 0000000 0000000 0000000 0000000 0000000 0000000 Replace the 02 sensor with a known good one (page 6772). Reset the ECM (page 640). Turn the ignition switch “ON“. Warm the engine until the coolant temperature is 80 ”C (176 ° F), the let it idle. Check the voltage at the test harness terminal. CONNECTION: B17 (+) — B15 (-) STANDARD: 0.3 — 0.6 V Is the voltage within 03 — 0.6 V? VES — Faulty original 02 sensor. N0 — Check the fuel supply system 6-23 FUEL SYSTEM (Programmed Fuel Iniection) MIL 23 BLINKS (Oz SENSOR HEATER) - Before starting the inspection, check for loose or poor Contact on the 02 sensor 4P (Black) connec- tor and recheck the MIL blinking. 1. 02 Sensor Heater Resistance Inspection Turn the ignition switch "OFF". Disconnect the 02 sensor 4F (Black) connector. Measure the resistance at the 02 sensor connec- tor terminals. CONNECTION: White — White Is the resistance within 10 — 40 {1(2000/58 I’FI? N0 — Faulty 02 sensor. VES — GO TO STEP 2. 2. 02 Sensor Heater Circuit Inspection Turn the ignition switch "ON". Measure the voltage at the 02 sensor 4P (Black) connector of wire harness side. CONNECTION: Red/Black (+) — Ground (—) Does the battery voltage exit? NO — Open or short circuit in the Red/Black wire. VES — GO TO STEP 3. . 3. Oz Sensor Heater Open circuit Inspection 2 Turn the ignition switch “OFF“. Connect the test harness to ECM 21F (Black) and 21P (Gray) connector (page 6710). Check for continuity between the test harness terminal and Oz sensor 4P (Black) connector of the wire harness side. CONNECTION: A16 — White Is there continuity? NO — Open circuit in White wire. YES — GO TO STEP 4. 4P (BLACK) CONNECTOR 4P (BLACK) CONNECTOR 6-24 FUEL SYSTEM (Programmed Fuel Injection) 4. 02 Sensor Heater Short circuit Inspection Check for continuity between the test harness terminal and ground. Connection: A16 — Ground Is there continuity? VES — Short circuit in the White wire. NO — Replace the ECM with a new one, and recheck. MIL 29 BLINKS (IAC VALVE) - Before starting the inspection, check for loose or poor contact on the throttle body 32F connector and recheck the MIL blinking. 1. IAC Valve Short circuit Inspection Remove the floor step (page 3-7). Turn the ignition switch “OFF". Disconnect the throttle body 32F connector. Check for continuities between the throttle body 32F connector and ground. Connection: Black/Brown — Ground Brown/Green — Ground Green/Red — Ground Green/Orange — Ground Are there continuities? VES — 0 Short circuit in Black/Brown or Brown/Green wire. - Short circuit in Green/Red or Green/ Orange wire. NO — GO TO STEP 2. 2. IAC Valve Circuit Continuity Inspection Connect the test harness to ECM 21P (Black) and 21P (Gray) connector (page 6710). Check for continuities between the test harness and the throttle body 32F connector. Connection: A5 — Black/Brown A12 — Brown/Green A19 — Green/Red A11 — Green/Orange Are there continuities? YES - GO TO STEP 3. NO - - Open or loose contact in Black/ Brown or Green/Red wire. - Open or loose contact in Brown/ Green or Green/Orange wire. OOOOOOO OOOOOOO OOOOOOO OOOOOOO OOQOOOO 0(99000 ' S2 32F CONNECTOR BBSBBBBBBEBBUBBE BBBBBBBEBBBBEEEQ 32F CONNECTOR 6-25 FUEL SYSTEM (Programmed Fuel Injection) 3. IAC Valve Resistance Inspection Disconnect the test harness from the ECM. Connect the throttle body 32F connector. Measure the resistance at the test harness termi- nals. CONNECTION: A5 — A19 A12 — A11 STANDARD: 120 — 140 {2(20‘I 0/68D F) Is the resistance within 1211 — 14a flame/68°F)? YES — Replace the ECM with a new one, and recheck. NO — Faulty throttle body (IAC valve). MIL 52 BLINKS (CKP SENSOR/ALTER- NATOR) I Before starting the inspection, check for loose or poor contact on the alternator/starter 6P (Natural) connector and recheck the MIL blinking. 1. CKP Sensor Short Circuit Inspection Connect the test harness to ECM 21P (Black) and ZIP (Gray) connectors (page 6-10). Check for continuities between the test harness terminalland ground. Connection: 820 — Ground 814 — Ground B12 — Ground 36 — Ground A7 — Ground Are there continuities? YES — Short circuit between the starter and ECM. N0 — GO TO STEP 2. 2. CKP Sensor Circuit Inspection Disconnect the alternator/starter 6P (Natural) connector. Check for continuities between the test harness and alternator/starter 6P (Natural) connector. Connection: 520 — Blue/Vellow B14 — White/Black B12 — White/Red 88 — Blue/Green I36 — White/Green A7 — Brown/Vellow Are there continuities? VES — GO TO STEP 3. N0 — Open circuit between the starter and ECM. {5000000 0000000 . 00000 00' 00 (2)600000‘ 6P (NATURAL) CON NECTOR FUEL SYSTEM (Programmed Fuel Injection) 3. ECM Output Voltage ICKP Sensor Power Line) Inspection Measure the battery voltage (page 1676). Connect the alternator/starter 6P (Natural) con- nector. Turn the ignition switch "ON". Measure the voltage at the test harness termi- nals. CONNECTION: A7 (+) — BB (—) STANDARD: Battery voltage: actual value ~ about 2.0 V (20°C/68“ F) Is the voltage about 2.0 V7 VES — GO TO STEP 4. NO — GO TO STEP 5, 4. CKP Sensor Output Voltage Inspection Remove the belt case cover (page 10-6). Measure the voltage at the test harness termi» nals with turning the crankshaft. CONNECTION: 320 (+) — BB (—) B14 (+) - B8 H 812 (+) — BS (—) BS (+) — BB I-I STANDARD: Repeat no voltage (below 0.5 V) to exist voltage (5 — 10 V) Are the voltages at the standard value? YES - Faulty alternator/stator. N0 —- GO TO STEP 6. 5. ECM Power/Ground Line Inspection Check the ECM power/ground line (page 6767). Is the ECM normally? YES — Replace the ECM with a new one, and recheck. N0 — Replace or repairthe abnormal circuit. 6. Alternator/Stator Inspection Remove the alternator/stator (page 12-4). Check the stator and flywheel for wear or dam, age in visual. Are the stator and the flywheel normally? VES — Replace the stator and flywheel. NO — Replace the abnormal parts. 0 0 0000000 J00 O 6-26 6-27 FUEL SYSTEM (Programmed Fuel Injection) DTC CODE INDEX . The Diagnostic Trouble Codes (DTC) are based upon Malfunction Indicator Lamp (MIL) codes and are displayed as hyphenated numbers. The digits in front of the hyphen are equal to an MIL code and Indlcate the Function Failure. The digit behind the hyphen details the symptom. For example, in the case of the TP sensor, the ECM stores two levels of information, a function failure and a detail of the symptom: (08 A 1) : TP sensor voltage — lower than the specified value or (08 , 2): TP sensor voltage — higherthan the specified value. O The MAP, ECT, TP and IAT sensor can be mean diagnosis according to the sensor output voltage value, If the failure occurs, the ECM determines the failure function, the output voltage is high or low compared to the stan» dard voltage, then read out the DTC to the H05 pocket tester. For example: . — If the input voltage line (A) on the MAP sensor is opened, the ECM detects the output voltage Is about 5 V, then the DTC 1»2 (MAP sensor circuit high voltage) will be read out _ — If the input voltage line (B) on the TP sensor is opened, the ECM detects the output voltage Is 0 V, then the DTC 84 (TP sensor circuit low voltage) will be read out. 5V MAP SENSOR 5V TP SENSOR OUTPUT VOLTAG E OUTPUT VOLTAGE 5V 5V ECT SENSOR IAT SENSOR OUTPUT VOLTAGE OUTPUT VOLTAG E 6-28 FUEL SYSTEM (Programmed Fuel Injection) DTC Detection Item Causes Symptoms Rier — ECM malfunction O Faulty ECM O Engine does not start ~ ‘ O MIL does not blink - ECM power input O Blown subrfuseius A) (Starter/ O Engine does not start 6767 circuit malfuncA ignition/fuel pump) O MIL does not blink tion O Open circuit at the power input wire of the ECM O Open circuit in bank angle sensor related circuit O Faulty bank angle sensor O Open circuit in main relay related wires . Faulty main relay O Faulty ignition switch — MIL circuit male O Faulty ECM O Engine operates nor- ~ function O Open or short circuit in MIL wire mally O MIL does not blink — Data link circuit O Short circuit in data link connector O Engine operates norr , malfunction O Faulty ECM malty O MIL stays lit 1-1 MAP sensor cirs O Short circuit in MAP sensor wire O Engine operates norr 6'31 cuit low voltage O Faulty MAP sensor mally 1-2 MAP sensor cir- O Loose or poor contact on throttle O Engine operates norr 6732 cuit high voltage body 32F connector mally O Open circuit in MAP sensor wire O Faulty MAP sensor 771 ECT sensor cir- O Short circuit in ECT sensor wire O Hard start at a low tem- 6-33 cuit low voltage O Faulty ECT sensor perature (Simulate using numerical values; 90 “Cl 194 ° F) O Low engine speed O Coolant temperature indicator turns on 7-2 ECT sensor cir— - Loose or poor contact on ECT sen— O Hard stan at a low tem- 6-34 cuit high voltage sor 2P (Black) connector perature (Simulate using O Open circuit in ECT sensor wire numerical values; 90 ”C/ O Faulty ECT sensor 194 ° F) O Low engine speed O Coolant temperature , indicator turns on 871 TP sensor circuit O Short circuit in TP sensor wire O Poor engine perfor- 6-35 low voltage O Faulty TP sensor mance and response when operating the throttle quickly (SimuV late using numerical vale _ L ues; Throttle opens 0°) 8-2 TP sensor circuit O Loose or poor contact on throttle O Poor engine perfor- 6-36 high voltage body 32F connector 5 mance and response I Open circuit in TF sensor wire ‘ when operating the O Faulty TP sensor throttle quickly (Simu- late using numerical vale ues; Throttle opens 0°) 9-1 IAT sensor circuit O Short circuit in IAT sensor wire O Engine operates nor- 6-37 low voltage O Faulty IAT sensor mally [Simulate using numerical values; 25 “Cl 77 ° F) 9-2 IAT sensor circuit O Loose or poor Contact on throttle O Engine operates norr 5—38 high voltage body 32F connector melly (Simulate using O Open circuit in [AT sensor wire numerical values; 25 ° C/ O Faulty IAT sensor 77 °F) 12-1 Injector circuit O Loose or poor contact on injector O Engine does not start 638 malfunction 2P (Black) connector O Open or short circuit in injector wire O Faulty injector 6-29 FUEL SYSTEM (Programmed Fuel Injection) 77* i ‘ 7 i S m toms Reter DTC j Detection Item Causes y p 6 4t: jfi Oz sensor circuit 0 Loose or poor Contact on 02 sen- ‘ Entire operates ”0|“ * malfunction sor 4P (Natural) connector ma Y I Open or short circuit in 02 sensor wire - Faulty Oz sensor ' - 641 23—1 02 sensor heater - Loose or poor Contact on o; sen- . Englllne operates nor malfunction sor 4P (Natural) connector ma Y 0 Open or short circuit in 02 sensor heater wire - Faulty Oz sensor 4 7 29-1 Idle air control - Loose or poor contact on throttle ' Poor performance at Idle 6-42 (IAC) valve mal- body 32F connector _ speed function 0 Open or short circuit In IAC valve wire - Faulty IAC valve ' - I Engine does not start 6-44 - Crankshaft osI- 0 Loose or poor contact on aiterna 52 1 tion (CKP) sinsor tor/stator 6P (Natural) connector - Starter motor does not malfunction - Open or short circuit in CKP sensor operate wire - Faulty CKP sensor . . 524 Alternator male - Loose or poor contact on alterna» I Engine does not start 6 44 function tor/stator 6P (Natural) connector Open or short circuit in alternator wire Faulty alternator Starter motor does not operate 3. MAP Sensor Input Line Inspection FUEL DTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLT- AGE) 1. MAP Sensor System Inspection Turn the ignition switch “0N“. Check the MAP sensor with the HDS pocket tester. Is about a vindicated? YES — GO TO STEP 2. NO — - Intermittent failure. - Loose or poor contact on the throttle body 32F connector. 2. MAP Sensor Input voltage Inspection Turn the ignition switch "OFF". Disconnect the throttle body 3ZP connector. Turn the ignition switch "ON“. Measure the voltage at the throttle body 32F connector wire harness side. CONNECTION: Yellow/Red (+) — Green/Blue (—) STANDARD: 4.75 — 5.25 V Is the Voltage within 4.75 - 5.25 V7 YES — GO TO STEP 4. N0 — GO TO STEP 3. Turn the ignition switch "OFF". Disconnect the ECM 21F (Gray) connector. Check for continuity between the ECM 21F (Gray) connector wire harness side and throttle body 32F connector wire harness side. CONNECTION: Yellow/Red — Yellow/Red TOOL: Test probe 07ZAJ-RDJA11O Is there continuity? VES - Replace the ECM with a new one, and recheck. NO - Open circuit in Yellow/Red wire. SYSTEM (Programmed Fuel Injection) 32PCONNECTOR “ ’\ 21F (GRAY) R CONNECTO / _ ,. t- ‘ 32F CON NECTOR . MAP Sensor Output Line Short Circuit Inspec- tion Check for continuity between the throttle body 32F connectorwire harness side and ground. CONNECTION: Light green/Yellow — Ground Is there continuity? YES — Short circuit in Light green/Yellow wire NO — GO TO STEP 5. 6-30 FUEL SYSTEM (Programmed Fuel Injection) 5. MAP Sensor Inspection Replace the throttle body with a new one (page 6755) Connect the ECM 21F (Gray) connector and throttle body 32F connector. Reset the ECM (page 6710). Turn the ignition switch "0N“. Check the MAP sensor with the HDS pocket tester. Is the DTC 1-1 indicated? YES — Replace the ECM with a new one, and recheck. N0 — Faulty original throttle body (MAP sen- sorl. DTC 1-2 (MAP SENSOR HIGH VOLT- AGE) - Before starting the inspection, check for loose or poor contact on the throttle body 32F connector and recheck the DTC. 1. MAP Sensor System Inspection 1 Turn the ignition switch "ON". Check the MAP sensor with the HDS pocket tester. Is about 5V indicated? VES — GO TO STEP 2. NO — - Intermittent failure. 0 Loose or poor Contact on the throttle body 32F connector. 2. MAP Sensor System Inspection 2 Turn the ignition switch "OFF". Disconnect the throttle body 32P connector. Connect the throttle body 32F connector termii nels at the wire harness side with a jumper wire. CONNECTION: Light green/Yellow — Green/Blue Turn the ignition switch “0N". Check the MAP sensor with the HDS pocket tester. STANDARD: About 0 V Is about 0 vindicated? YES — Faulty throttle body [MAP sensor). N0 — GO TO STEP 3. 3. MAP Sensor Input Voltage Inspection Turn the ignition switch "OFF". Remove the jumper wire. Turn the ignition switch “0N". Measure the voltage at the throttle body 32F connector wire harness side. CONNECTION: Vellow/Red (+I — Green/Blue I—l STANDARD: 4.75 —- 5.25 V Is the Voltage within 4.75 - 5.25 V? VES — GO TO STEP 4. NO — Open circuit In Green/Blue wire. JUMPER WIRE 3. ECT Sensor Output Line Short Circuit Inspection 6-32 FUEL SYSTEM (Programmed Fuel Injection) 4. MAP Sensor Output Line Open circuit Inspec- tion Disconnect the ECM 21 P (Gray) connector. Check for continuity between the ECM 21F (Gray) connector of the wire harness side and throttle body 32F connector of the wire harness side. CONNECTION: Light green/Yellow - Light green/Vellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? VES — Replace the ECM with a new one, and recheck. N0 — Open circuit in Light green/Yellow wire. DTC 7-1 ECT SENSOR - AGE) I LOW VOLT 1. ECT Sensor System Inspection Turn the ignition switch "ON". Check the ECT sensor with the HDS pocket tester. Is about 0 vindicated? VES — GO TO STEP 2. NO — - Intermittent failure. - Loose or poor contact on the ECT sensor 2P (Black) connector. 2. ECT Sensor Inspection Turn the ignition switch "OFF". Disconnect the ECT sensor 2P (Black) connector. Turn the ignition switch "ON". Check the ECT sensor with the HDS pocket tester. Is about 0 Vindicated? VES - Faulty ECT sensor. N0 — GO TO STEP 3. Turn the ignition switch "OFF“. Check for continuity between the ECT sensor 2P (Black) connector terminal of the wire harness side and ground. CONNECTION: Pink — Ground Is there continuity? VES - Short circuit in Pink wire‘ NO — Replace the ECM with a new one, and recheck. FUEL SYSTEM (Programmed Fuel lniection) DTC 7-2 (ECT SENSOR HIGH VOLT- AGE) 0 Before starting the inspection, check for loose or poor contact on the ECT sensor 2F (Black) con— nectar and recheck the HDS pocket tester. 1. ECT Sensor System Inspection Turn the ignition switch "ON". Check the ECT sensor with the HDS pocket tester. ls about 5 vindicated? VES — GO TO STEP 2. NO — 0 Intermittentfailure. - Loose or poor contact on the ECT sensor 2P (Black) connector. 2. ECTSensorlnspection Turn the ignition switch "OFF". Disconnect the ECT sensor 2P (Black) connector. Connect the ECT sensor 2P (Black) connector ter— minals with a jumper wire. CONNECTION: Pink — Green/Blue Turn the ignition switch "ON". Check the ECT sensor with the HDS pocket tester. Is about 0 V indicated? VES — Faulty ECT sensor. NO — GO TO STEP 3. 3. ECT Sensor Output Line Inspection Turn the ignition switch "OFF". Disconnect the jumper wire. Disconnect the ECM 21F (Gray) connector. Check for continuity between the ECM 21 P (Gray) connector and ECT sensor 2P (Black) conr nector of the wire harness side. CONNECTION: Pink — Fink Green/Blue — Green/Blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuities? YES - Replace the ECM with a new one, and recheck. NO — . Open circuit in Pink wire. 0 Open circuit in Green/Blue wire. 2P (BLACK) CONNECTOR ) , ./ . S \ i JUMPER WIRE ECM 21P (GRAY) CONNECTOR . / my) , TEST PROBE 3. TP Sensor Circuit Inspection / , 2P (BLACK) CONNECTOR 4. TP Sensor Output Line Open Circuit Inspection FUEL SYSTEM (Programmed Fuel Injection) DTc 8-1 (TP SENSOR LOW VOLTAGE) - Before starting the inspection, check for loose or poor contact on the throttle body 32F connector and recheck the HDS pocket tester. . TP Sensor System Inspection Turn the ignition switch "ON“. Check the TF sensor with the HDS pocket tester when the throttle fully closed. Is about 0V indicated? YES — - Intermittent failure. I Loose or poor contact on the throttle body 32F connector. N0 — GO TO STEP 2. 2. TP Sensor Input voltage Turn the ignition switch "OFF“. Disconnect the throttle body 32F connector. Turn the ignition switch "ON". Measure the voltage at the throttle body 32F connector terminals of the wire harness side. CONNECTION: Yellow/Red (+l — Green/Blue (-l STANDARD: 4.75 —- 5.25 V Is the voltage within 4.75 - 5.25 V? YES — GO TO STEP 4. NO — GO TO STEP 3. Disconnect the ECM 21 P (Gray) connector. Check for continuity between the ECM 21F (Gray) connector and throttle body 32F connecV tor. CONNECTION: Yellow/Red — Yellow/Red TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? VES — Replace the ECM with a new one, and recheck. TEST PROBE NO — Open circult In Yellow/Red Wire. 32F CONNECTOR Turn the ignition switch "OFF". Check for continuity between the ECM 21F (Gray) connector and throttle body 32F connec- tor. CONNECTION: Yellow/Blue — Yellow/Blue TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? VES — GO TO STEP 5. NO — Open circuit in Yellow/Blue wire. 6-34 FUEL SYSTEM (Programmed Fuel Injection) 5. TP Sensor Output Line Open Circuit Inspection Check for continuity between the throttle body 32F connector terminal of the wire harness side and ground. CONNECTION: Yellow/Blue — Ground Is there continuity? VES — Short circuit in Yellow/Blue wire. NO - GO TO STEP 6. 6. TP Sensor Output Line Short Circuit Inspection Replace the throttle body with a new one. Turn the ignition switch "ON". Reset the ECM (page 6-10). Check the TP sensor with the HDS pocket tester. Is DTC 8-1 indicated? VES — Replace the ECM with a new one, and recheckt N0 —,Faulty original throttle body (TP sensor) DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Turn the ignition switch "ON'K Check the TP sensor with the H05 pocket tester. Is about 5Vindicated? YES — GO TO STEP Z No — ' Intermittent failure. 0 Loose or poor contact on the throttle body 32F connector. 2. TP Sensor Resistance Inspection Turn the ignition switch “OFF". Disconnect the throttle body 32F connector. Measure the resistance at the throttle body ter- minalst CONNECTION: VellowlBlue — Green/Blue STANDARD: 4 — 6 (“20° CI68° F) Is the resistance within 4 - 6 .(Z!20”C/68”F)? YES - GO TO STEP 3. NO — Faulty throttle body (TP sensor). 3. IAT Sensor Output Line Short Circuit Inspection 6-36. FUEL SYSTEM (Programmed Fuel Injection) 3. TP Sensor Input Voltage Inspection Turn the ignition switch “ON". Measure the voltage at the throttle body 32F connector terminals of the wire harness side. CONNECTION: Yellow/Red I+) - Green/Blue (—) STANDARD: 4.75 — 5.25 V Is the voltage 4.75 — 5.25 W VES — Replace the ECM with a new one, and recheck. N0 — Open circuit in Green/Blue wire. 32F CONNECTOR DTC 9-1 (IAT SENSOR LOW VOLTAGE) 1. IAT Sensor System Inspection Turn the ignition switch "ON". ‘ Check the IAT sensor with the HDS pocket tester. Is about 0V indicated? VES — GO TO STEP 2 N0 — - Intermittent failure. - Loose or poor Contact on the throttle body 32F connector. 2. IAT Sensor Inspection Turn the ignition switch "OFF“. Disconnect the throttle body 32F connector. Turn the ignition switch “ON". Check the IAT sensor with the HDS pocket tester. Is about 0V indicated? VES - GO TO STEP 3. NO — Faulty throttle body (IAT sensor). Turn the ignition switch “OFF". Check for continuity between the throttle body 32F connector terminal of the wire harness side and ground. CONNECTION: Gray/Blue — Ground Is there continuity? VES — Short circuit in Gray/Blue wire. N0 — Replace the ECM with a new one, and recheckt 6-37 FUEL SYSTEM (Programmed Fuel Injection) DTC 9-2 (IAT SENSOR HIGH VOLTAGE) 2. Injector Circuit Resistance Inspection Turn the ignition switch “OFF". FUEL SYSTEM (Programmed Fuel Injection) ' Before starting the inspection, check for loose or poor contact on the throttle body 32F connector and recheck the HDS pocket tester. . IAT Sensor System Inspection Turn the ignition switch "ON". Check the IAT sensor with the HDS pocket tester. Is about 5Vindicated7 YES — GO TO STEP 2. NO — - Intermittent failure. - Loose or poor contact on the throttle body 32F connector. Disconnect the injector 2P (Black) connector. Measure the resistance at the injector connector terminals. CONNECTION: Pied/Blue — Pink/Blue STANDARD: 11.1 —12.3 kfl(20° 0/68" F) Is the resistance within 11.1 - 12.3 kn {2000/ 58”F)7 YES — GO TO STEP 3. NO — Faulty injector. Z. IAT Sensor Inspection Turn the ignition switch “OFF. 3. Injector Input Voltage Inspection Disconnect the throttle body 32F connectort JUMPER WEE 2" Turn the ignition SWi‘Ch ”0N“- Connect the throttle body 32F connector termi- ‘ Measure the voltage between the injector con» nals with a jumper wire. hector of the wire harness side and ground. CONNECTION: Gray/Blue - Green/Blue CONNECTION: Red/Black (4-) — Ground (—) Turn the ignition switch LON". S It Does the battery voltage exit? ' t t t . Check the IATZensor Wit t 9 HD poc e es er VEs _ GO TO STEP 4’ ' ' ted? ’5 about on ma N0 - - Open circuit in Red/Black wire. VES — Faulty throttle body (IAT sensor) o Faulty main re|ay_ NO — GO TO STEP 3 - Replace the ECM with a new one, ' 7.. and recheck. 32F CONNECTOR 3. IAT Sensor Output Line Inspection Disconnect the ECM 21F (Gray) connector. 4. Injector Signal Line Short circuit Inspection Check for continuity between the throttle body Turn the ignition switch “OFF"t 32F connector terminals of the wire harness side _ and ECM 21F (Gray) connector terminals of the Disconnect the ECM 21F (Black) 00""9‘3‘07- wire harness sidev Check for continuity between the ECM 21F CONNECTION: Gray/BIue—Gray/Blue (Black) connector of the wire harness side and Green/Blue — Green/Blue ground. CONNECTION: Pink/Blue - Ground TOOL: Test probe 07ZAJ-RDJA110 TOOL: . . . Test probe 07ZAJ-RDJA110 Are there continuities? , Is there continuity? YES — Replace the ECM With a new one, and recheck. 3” CONNECTOR ves — Short circuit in Pink/Blue wire. N0 — - Open circuit in Gray/Blue wire. NO — GO TO STEP 5. . Open circuit In Green/Blue WIre' 5. Injector Signal Line Open Circuit Inspection DTC 12-1 (INJECTOR) 1. Injector System Inspection Reset the DTC (page 6-10). Start the engine and check the injector with the HDS pocket tester. Is the DTC 12-1 indicated7 YES - GO TO STEP 2. NO — ' Intermittent failure. 0 Loose or poor contact on the injector 2P connectort 6-38 Check for continuity between the ECM 21F (Black) connector of the wire harness side and injector 2P (Black) connector of the wire harness sidet CONNECTION: Pink/Blue - Pink/Blue TOOL: Test probe o1ZAJ—RDJA11D Is there continuity? YES — Replace the ECM with a new one, and recheck NO — Open circuit in Pink/Blue wire. INJECTOR FUEL SYSTEM (Programmed Fuel Injection) DTC 21-1 (02 SENSOR) 0 Before starting the inspection, check for loose or poor contact on the 02 sensor 4P (Black) connec- tor and recheck the HDS pocket tester. 1. 02 Sensor System Inspection Start the engine and warm up the engine up to coolant temperature is 80 °C (176 “F). Check the 02 sensor with the HDS pocket tester. STANDARD: 0.3 — 0.5 V Is the Voltage within 0.3 - 0.6V? YES — Check the fuel pressure (page 6749). If the system is correct, GO TO STEP 3. N0 — GO TO STEP 2. Z. 02 Sensor Open Circuit Inspection Turn the ignition switch "OFF“. Disconnect the ECM 21 P (Gray) connector and 02 sensor 4P (Black) connector. Check for continuity between the ECM 21F (Gray) connector of the wire harness side and Oz sensor 4P (Black) connector ot the wire harness side. CONNECTION: B17 - Black/Orange ‘ 315 — Green/Blue TOOL: Test probe 07ZAJ-RDJA110 Are there continuities? YES — GO TO STEP 3. NO — - Open circuit in Black/Orange wire. . Open circuit in Green/Blue wire. 3. Oz Sensor Short circuit Inspection Connect the 02 sensor 4P (Black) connector and Disconnect the ECM 21F (Gray) connector. Check the continuity between the ECM 21F (Gray) connector of the wire harness side and ground. CONNECTION: Black/Orange — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity7 YES — Short circuit in Black/Orange wire N0 — GO TO STEP 4. 21F (GRAY) CONNECT 21 P (GRAY) CONNECTOR TEST PROBE ' 6-40 FUEL SYSTEM (Programmed Fuel Injection) 4. 0: Sensor Inspection Replace the 02 sensor with a new one (page 6- 72). Reset the ECM (page 6-10). Start the engine and warm up the engine up to coolant temperature is 80 °C (176 °F). Check the 02 sensor with the HDS pocket tester. STANDARD: 0.3 — 0.6 V Is the voltage within 0.3 - 0.6 V7 YES — Faulty original 02 sensor. N0 — Check the fuel supply system. DTC 23-1 (02 SENSOR HEATER) - Before starting the inspection, check for loose or poor contact on the 02 sensor 4P (Black) connec- tor and recheck the HDS pocket tester. 1. Oz Sensor Heater System Inspection Reset the DTC (page 6710). Start the engine and check the 02 sensor heater with the HDS pocket tester. Is the DTC 23-1 indicated? VES — GO TO STEP 2. N0 — - Loose or poor contact on the 02 Sen sor 4P (Black) connector. 0 Intermittent failure. 2. Oz Sensor Heater Resistance Inspection Turn the ignition switch "OFF“. Disconnect the 02 sensor 4? (Black) connector. Measure the resistance at the 02 sensor 4P (Black) connector terminals of the sensor side. CONNECTION: White — White Is the resistance within 10 - 40 0(2050/68 ”Fl? YES — GO TO STEP 3. N0 — Faulty Oz sensor. 3. 02 Sensor Heater Power Input Line Inspection Turn the ignition switch "ON" then measure the voltage between the 02 sensor 4P (Black) con- nector of the Wire harness side and ground. CONNECTION: Red/Black (+l — Ground (—l Does the battery voltage exit? VES — GO TO STEP 4. N0 — Open circuit in the Red/Black wire. 4P (BLACK) CON NECTOR 6-41 FUEL SYSTEM (Programmed Fuel Injection) 4. 02 Sensor Heater Open circuit Inspection Turn the ignition switch "OFF". Disconnect the ECM 21F (Black) connector. Check for continuity between the ECM 21F (Black) connector and 02 sensor 4P (Black) con- nector of the wire harness side. CONNECTION: White — White TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? VES — GO TO STEP 5. NO — Open circuit in White wire. 5. Oz Sensor Heater short circuit Inspection Connect the ECM 21F (Black) connector. Check for continuity between the 02 sensor 4P (Black) connector of the wire harness side and ground. CONNECTION: White — Ground Is there continuity? VES — Short circuit in White wiret N0 —‘ Replace the ECM with a new one, and recheck. DTC 29-1 (IAC VALVE) I Before starting the inspection, check for loose or poor contact on the throttle body 32F connector and recheck the HDS pocket tester. 1. Recheclt DTC Reset the DTC (page 6-10). Start the engine and recheck the idle air control (IAC) valve with the HDS pocket tester. Is the DTC 29-1 indicated? VES - GO TO STEP 2. N0 — Intermittent failure. 2. IAC Valve Short Circuit Inspection Turn the ignition switch "OFF". Disconnect the throttle body 32F connector. Check for continuities between the throttle body 32F connector of the wire harness side and ground. CONNECTION: Black/Brown — Ground Brown/Green —- Ground Green/Red — Ground Green/Orange - Ground Are there continuities? YES - - Short circuit in Black/Brown or Brown/Green wire. - Short circuit in Green/Red or Green! Orange wire. N0 — GO TO STEP 3. 32F CONNECTOR \‘EBBBBBBBBBBSEBES BBBBBBBEBBBBEEEE 6-42 3t FUEL SYSTEM (Programmed Fuel Injection) IAC Valve Circuit Continuity Inspection Disconnect the ECM 21F (Black) connector. Check for continuities between the ECM 21F (Black) connector of the wire harness side and thgottle body 32F connector of the wire harness Sl e. CONNECTION: Black/Brown — Black/Brown Brown/Green — Brown/Green Green/Red - Green/Red Green/Orange » Green/Orange 21F (BLACK) CONNECTOR TOOL: Test probe 07ZAJ-RDJA110 32F CONNECTOR Are there continuities? YES — GO TO STEP 4. NO - - Open or loose contact in Black/ Brown wire or Green/Red wire. . Open or loose Contact in Brown/ Green or Green/Orange wire. . IAC Valve Resistance Inspection Connect the throttle body 32F connector. Measure the resistance at the ECM 21P (Black) “Hm-AC“ CONNECTOR connector of the wire harness side. CONNECTION: Black/Brown — Green/Red Brown/Green — Green/Orange STANDARD: 120— 140 QiZO°CI68°Fi TOOL: Test probe 07ZAJ-RDJA110 (two required) Is the resistance within 120 - 140 0(20 “C/EEOF)? VEs — Replace the ECM with a new one, and recheck. N0 — Faulty throttle body (IAT valve). 6-43 T' FUEL SYSTEM (Programmed Fuel Injection) DTC 52—1 (CKP SENSOR), 52-2 (ALTER- NATOR) I Before starting the inspection, check for loose or poor contact on the alternator/starter 6P (Natural) connector and recheck the DTC. 1. CKP Sensor Short Circuit Inspection Disconnect the ECM 21P (Black) and 21F (Gray) connectors. Check for continuities between the ECM 21F (Black) and 21F (Gray) connectors of the wire harness side and ground. Connection: Blue/Yellow - Ground White/Black — Ground White/Red -— Ground White/Green - Ground l Brown/Yellow — Ground l TOOL: Test probe 07ZAJ-RDJA110 (two required) Are there continuities? YES — Short circuit between the stator and ECM. N0 —. GO TO STEP 2. l 2. CKP Sensor Circuit Inspection ( Disconnect the alternator/stator 6P (Natural) con» hector. Check for continuities between the Z1P (Black) and 21P (Gray) connectors of the wire harness side and the alternator/starter 6P (Natural) conv nector of the wire harness side. Connection: Blue/Yellow — Blue/Yellow White/Black — White/Black White/Red — White/Red Blue/Green — Blue/Green White/Green — White/Green Brown/Yellow — Brown/Yellow TOOL: Test probe 07ZAJ-RDJA11D Are there continuities? YES — GO TO STEP 3. NO — Open circuit between the stator and ECM. 21F (BLACK) CONNECTOR TEST PROBES 21F (GRAY) CONNECTOR 21 P (BLACK) CONNECTOR 21P (GRAY) CONNECTOR 6P (NATURAL) CONNECTOR ~_—_J FUEL 3. ECM Output Voltage (CKP Sensor Power Line) Inspection Measure the battew voltage (page 16-6). Connect the alternator/starter 6P (Natural) conr nector. Tum the ignition switch “0N". Measure the voltage at the test harness termi» nals. CONNECTION: Brown/Vellow (+) — Blue/Green STANDARD: Battery voltage: actual value — about 2.0 V (20° CIGS" F) Is the voltage standard value? YES — GO TO STEP 4. NO — GO TO STEP 5. 4. CKP Sensor Output Voltage Inspection Remove the belt case cover (page 1076). Disconnect the ECM 21? (Gray) connector. Measure the voltage at the ECM 21? (Gray) con— nector terminals of the wire harness side with turning the crankshaft. CONNECTION: Blue/Yellow (+) — Blue/Green (—) White/Black (+) — Blue/Green (—) White/Red (+) — Blue/Green (—) White/Green (+) - Blue/Green (-) STANDARD: Repeat no voltage (below 0.5 V) to exist voltage (5 — 10 V) TOOL: Test probe 07ZAJ-RDJA110 Are the voltage at the standard value? VES — Faulty alternator/starter. NO — GO TO STEP 6. 5‘ ECM Power/Ground Line Inspection Check the ECM power/ground line (page 6-67). Is the ECM normally? YES — Replace the ECM with a new one, and recheck. NO — Replace 0r repairthe abnormal circuit, 6‘ Alternator/Statorinspection Remove the alternator/stator (page 12-4). Check the stator and flywheel for wear or damr age in visual. Are the stator and the flywheel normally? YES — Replace the stator and flywheel. NO — Replace the abnormal parts. SYSTEM (Programmed Fuel lniection) 6? (NATURAL) CON NECTOR 6-44 6-45 FUEL SYSTEM (Programmed Fuel Iniection) FUEL LINE INSPECTION RE URE RELIEVING/QUICK Egfil-NIIECTSFSITTING REMOVAL - Before disconnecting fuel feed hose, relieve pres- sure from the system by disconnecting the quick connect fitting in the fuel pump. 1. Turn the ignition switch "OFF". Remove the floor step (page 3-7) 2. Disconnect the fuel pump 5P IBlackI connector. 3. Start the engine, and let it idle until the engine stalls. 4. Turn the ignition switch "OFF". 5, Disconnect the battery negative cable and then positive cable. 5. Remove the nut and fuel feed hose from the stay. 7. Check the fuel quick connect fitting for dirt, and clean if necessary. Place a shop towel over the quick connect fitting. 5P IBLACKI CONNECTOR QUICK CONNECT FITTING 1. Clean around the fuel hose joint. Insert a new retainer into the connector joint with CONNECTOR 1W FlETAINER 7 .. FUEL SYSTEM (Programmed Fuel Injection) 8. Hold the connector with one hand and squeeze the retainer tabs with the other hand release RETAINER TABS them from the locking pawls. Pull the connector off. Prevent the remaining fuel in the fuel feed hose from following out with a shop towel. ' Be careful not to damage the hose or other parts. 0 Do not use tools. 0 If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes of easily. LOCKING PAWLS CONNECTOR 9. To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags. PLASTIC BAGS CONNECTOR QUICK CONNECT FITTING INSTALLA- TION ' Always replace the retainer of the quick connect fining when the fuel feed hose is disconnected. ' If any retainer need replacing, use the same man- ufacture’s retainer as the ones being removed (The several manufactures feature different retainer specifications). aligning the two hooks of the retainer with the two holes on the connector joint. HOLE/TAB 6-46 6-47 FUEL SYSTEM (Programmed Fuel Injection) Do norbent or twrst 2. Align the quick connect fitting with the pipe and fuel feed hose Do not start the engine. 3. Make sure the connection is secure and that the align the new retainer locking pawls with the connector grooves. Then press the quick connect fitting onto the pipe until both retainer pawls lock With a "CLICK“. If it is hard to connect, put a small amount of engine oil on the pipe end. pawls are firmly locked into place; check visually and by pulling the connector. 4. Connect the fuel pump 5P (Black) connector. the nut securely. 6. Temporally connect the positive cable and nega- tive cable to the battery. 5. Install the fuel feed hose to the stay and tighten NUT/STAV FUEL FEED HOSE ~i - 7. Turn the ignition switch "ON". The fuel pump will run for about 2 seconds, and fuel pressure will rise. ‘ Repeat 2 or 3 times. and check that there Is no leakage in the fuel supply system. Install the floor step (page 377). LOCKING PAWLS CONNECTOR CONNECTOR 5P (BLACK) CON NECTOR W/pe off smiled out gasoline FUEL SYSTEM (Programmed Fuel Injection) FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting (page 6-46). Attach the fuel pressure gauge set and pressure gauge. TOOLS: Fuel pressure gauge Pressure gauge manifold Fuel attachment hoseA Fuel attachment hose B Fuel attachment joint B 07406-0040004 07ZAJ-SSA0111 07ZAJ-55A0120 07ZAJ-SSA0130 07ZAJ-SSA0150 Temporally connect the positive cable and negative cable to the battery. Start the engine and let it idle. Read the fuel pressure. IDLE SPEED: 2,000 i 100 min" (rpm) FUEL PRESSURE: 294 kPa (3.0 kgf/cmz, 43 psi) If the fuel pressure is higher than specified, replace the fuel pump assembly. If the fuel pressure is lower than specified, inspect the following: — Fuel line leaking — Fuel pump (page 6750) , Clogged fuel filter [Assembly of the fuel pump) After inspection, remove the fuel pressure gauge and pressure gauge set from the fuel pump. Connect the quick connect fitting (page 6-47). FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick connect fitting (page 6-46). Turn the ignition switch "OFF". Connect the special tool to the fuel pumpjointt TOOL: Fuel attachment hose 3 07ZAJ-85A0130 Place the end of the hose into an approved gasoline container. Measure the amount of fuel flow with the ignition switch turning "0N“. NOTE: The fuel pump operates for two seconds. Repeat 5 times so that the total measuring time. Amount of fuel flow: 42 cm3 (1.4 US 02, 1.5 Imp 02) minimum I10 seconds at 12 V If the fuel flow is less than specified. inspect the fol- lowing: ~ Fuel pump (page 6-50). — Clogged fuel filter (Assembly of the fuel pump) Connect the quick connect fitting (page 6747). PRESSURE GAUGE MANIFOLD FUEL PRESSURE GAUGE 6-49 FUEL SYSTEM (Programmed Fuel lniection) FUEL SYSTEM (Programmed Fuel Injection) FUEL PUMP Be carafe/motto Remove the fuel pump unit assembly and packing. damage the fue/ PACKING INSPECTION _ level sensor ‘ i Referto the fuel Turn the ignition switch “ON“ and confirm that the ‘ ‘ reserve sensor fuel pump operates for a few seconds. l l l l 5P (BLACK) CONNECTOR inspect/on (page 19 If the fuel pump does not operate, inspect as fol- “ 70). lows: Turn the ignition switch "OFF". ‘ Remove the floor step (page 3-7l. {L Disconnect the fuel pump 5P (Black) connectort ‘ l i ( FUEL PUMP UNIT ASSEMBLV INSPECTION Check the fuel pump unit for wear or damage. FUEL PUMP UNIT ASSEMBLY Turn the ignition switch "ON" and measure the v0“. ‘ Check the fuel strainer screen for wear or damage. age between the terminals. K Replace the fuel pump unit if necessary CONNECTION: Red/Black (+) — Green (-) ' There should be battery voltage for a few seconds. ' If there is battery voltage, replace the fuel pump. 1 If there is no battery voltage, inspect the following: i A Main fuse 20A ; - Sub fuse 15 A . _ Mam may (page 6-66) ; :LRTRAINER SCREEN - Bank angle sensor (page 6-65) h ' ECM (page 6'67) 5P (BLACK) CONNECTOR . INSTALLATION Always Ieplace the Install the new packing to the fuel tank. l l REMOVAL _ packing when the Apply engine oil to the inside of the packing. - It is impossible to disassemble the fuel pump 1%me after removing it. I removed. CI a ound th f I um . Be careful not to e?" r e ”e p p _ ‘ 5P (BLACK) CONNECTOR l pinch the din and Relieve the fuel pressure and disconnect the quick . debris between the connect fitting (page 6-46)t . fuelpump and l Disconnect the fuel pump 5? (Black) connector. I flack/"9- Remove the fuel pump wire from the clamp. Be carer/ not to Install the fuel pump unit to the fuel tank damage the fuel level sensor Remove the nuts and set plate. 6-50 6-51 FUEL SYSTEM (Programmed Fuel Injection) Install the set plate aligning the holes on the set plate with the tabs on the fuel pump unit. Install and tighten the nuts in the sequence shown. TORQUE: 12 Ne!“ (1.2 kgf‘m, 9 Ibl-ft) Connect the fuel pump 5P (Black) connector. Install the fuel pump wire to the clamp. Connect the quick connect fitting (page 6r47l. FUEL TANK REMOVAL Relieve the fuel pressure and disconnect the quick connect fitting (page 646). SET PLATE 5P (BLACK) CONNECTOR SHOP TOWEL QUICK CON NECT FITI'ING 6-52 FUEL SYSTEM (Programmed Fuel Injection) Remove the holes on the fuel tank from the tabs on the frame, then remove the fuel tank. INSTALLATION Installation is in the reverse order of removal. Connect the quick connect fitting (page 6*47l. FUEL TANK FUEL FEED HOSE AIR CLEANER HOUSING REMOVAL Disconnect the crankcase breather hose and air suc- tion hose from the air cleaner housing. 6-53 FUEL SYSTEM (Programmed Fuel Injection) Loosen the connecting hose band screw and remove the connecting hose from the throttle body. Remove the bolts and air cleaner housing. INSTALLATION Install the air cleaner housing and tighten the bolts securely. Install the connecting hose to the throttle body. Tighten the connecting hose band screw securely. 6-54 FUEL SYSTEM (Programmed Fuel Injection) Connect the crankcase breather hose and air suction hose to the air cleaner housing. THROTTLE BODY REMOVAL Before disconnecting fuel feed hose, relieve pres sure from the system by disconnecting the quick connect fitting in the fuel pump (page 6416). Disconnect the throttle body 32? connector. Remove the harness clamp from the throttle body. Loosen the throttle cable lock nut and adjusting nut then disconnect the throttle cable from the throttle drum and cable bracket. 1 . HARNESS CLAMP . LADJUSTING NUT _THROTTLE DRUM 6-55 FUEL SYSTEM (Programmed Fuel Injection) Loosen the connecting hose band screw. Loosen the insulator band screw and remove throt- tle body. Loosen the insulator band screw and remove insu- lator from the intake pipe. FUEL SYSTEM (Programmed Fuel Injection) Be careful not to damage the insular tor Be careful not to damage the lnSLl/E- tor and connecting hose I The throttle body is factory ore-set. Do not disas- semble in a way other then shown in this man- ual. - Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle operation. . Do not damage the throttle body, It may cause incorrect throttle valve. I Do not loosen or tighten the white painted bolts, nuts and screws of the throttle body. Loosening or tightening them can cause throttle body mal- function, RIGHT SIDE VIEW: LEFT SIDE VIEW: WHITE PAINTED WHITE PAINTED INSTALLATION Install the insulator to the intake pipe by aligning the boss of the intake pipe and groove of the insula- tor with its "THROT. BODY." mark facing the throttle body. Install the throttle body into the insulator by alignr ing the boss of the throttle body and groove of the insulator. 6-56 FUEL SYSTEM (Programmed Fuel Injection) Install and tighten the insulator band screw to spec- ified torque. TORQUE: 2.9 Ntm (0.3 kgf-m, 2.1 Ihf-ft) Install the connecting hose into the throttle body. Tighten the band screw securely. Connect the throttle cable to the throttle drum and cable bracket Adjust the throttle grip free play (page 4,4)_ Connect the throttle body 32? connector. Install the harness clamp to the throttle body. INSULATOR SCREW W I u ‘II II u l *3 32F CONNECTOR \\ , 1 6-58 4, Disconnect the ECT sensor 2P (Black) connector. 5. Turn the ignition switch "ON". FUEL SYSTEM (Programmed Fuel lniection) THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE - If the throttle body is replaced, reset the throttle valve fully closed position as following. Remove the floor step (page 3-7I. 1. Reset the selfldiagnosis memory (page 6-10). 2. Turn the ignition switch "OFF". 3. Connect the special tool to the Data Link Conneo tor (DLC). TOOL: DLc short connector o7oPZ-ZY30100 ( . DATA LINK CONNECTOR Short the ECT sensor 2P (Black) connector termi— 2P (BLACK) CQTPECTOB I nals of the wire harness side using the jumper *7 i r’ ! fl wire. \\ , CONNECTION: Fink - Green/Blue JUMPER WIRE Disconnect the iumpe, wire while the ML bunk MALFUNCTION INDICATOR LAMP (MILI ing (10 seconds). If the MIL begins short blink (0.3 secondsI. the throttle valve fully closed position is reset. If the MIL stays lit, the throttle valve fully closed position is not reset, repeat the reset procedure from the step 1. 6-59 FUEL SYSTEM (Programmed Fuel Injection) INTAKE PIPE REMOVAL Remove the throttle body (page 6-55l. Remove the followings: , Bolts , Intake pipe — O-ring INSTALLATION Apply oil to a new O-ring to the groove on the intake pipe. Install the intake pipe. Install and tighten the bolts securely. Install the throttle body (page 6-57). “VA FUEL SYSTEM (Programmed Fuel Injection) INJECTOR REMOVAL Before disconnecting fuel feed hose, relieve pres- sure from the system by disconnecting the quick connect fitting in the fuel pump (page 6-46). Relieve the fuel pressure and disconnect the quick connect fitting (page 6-46]. Clean around the injector with compressed air before removing, and be sure that no debris is allowed to enter the engine. Disconnect the injector 2P (Black) connector. Remove the bolts and the fuel feed hose/injector assembly. FUEL FEED HOSE STAY BOLTS INJECTOR ASSEMBLY ‘ .- ... _ Remove the injector from the fuel feed hose. Remove the O—ring and seal ring from the injector. FUEL FEED HOSE INJECTOR INSTALLATION Coat a new O-ring and seal ring with engine oil. 7% SEAL RING Replace the 0-nng Install a new O-ring and seal ring, being careful not @ and seal flflg With to damage them. new ones as a set. ‘2 7% O»R|NG 6-60 6-61 FUEL SYSTEM (Programmed Fuel lniection) FUEL SYSTEM (Programmed Fuel Injection) fAélégdnhtgseeljoss of the injector and groove of the fuel FUEL FEED HOSE 7 . EcT SENSOR Install the injector into the fuel feed hose, being V REMOVAL/ INSTALLATION careful not to damage the O-ring. Remove the floor step (page 3-7). _ ‘ Drain the coolant (page 7-7). L” i’ Hep/acethe ECT Disconnect the ECT sensor 2P (Blackl connector sensor While the from the sensor. engine is cold Install the fuel feed hose/injector assembly to the cylinder head, being careful not to damage the seal ring. Install and tighten the bolts to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-ft) Connect the injector 2P (Black) connector. Remove the ECT sensor and Orring. Install the quick connect fitting (page 6-47). FUEL FEED SE V FUEL FEED HOSE! * STAY BOLTS INJECTOR ASSEMBLY .— .s...—. ts- MAP SENSOR OUTPUT VOLTAGE INSPECTION / Connect the test harness to the ECM (page 6-10). Install a new O-ring and ECT sensor. Measure the voltage at the test harness terminals (V) Tighten the ECT sensor [0 the specified toque. (page 6-15). TORQUE: 13 N-m (1.8 kgf-m,13lbf-ft) CONNECTION: B11 (+) — B15 (—i 35 _ C STANDARD: 2‘7_ 3.1 V . I onnec’t the ECT sensor 2P (Blackl connector. nstall the floor ste ( a e 3-7. The MAP sensor output voltage (above) is mea- 3-1 _ _ p p g . ) sured under the standard atmosphere (1 atm = 3,0 .\ Fl” the coollng system With recommended coolant 1,030 hPal. \} (page 7—6). l The MAP sensor output voltage is affected by the 2-7 \K} . distance above sea level, because the output volt» 25 _ \\\ ‘ age is changed by atmosphere. ‘ { Check the sea level measurement and be sure that \ the measured voltage falls within the specified \ value. 2.0 ' 1‘5 ' 1.0 ‘ 0.5 ' 0 500 1,000 1,500 2,000 :m 1 6-62 6-63 FUEL SYSTEM (Programmed Fuel Injection) TP SENSOR INSPECTION Inspect the throttle body power input line (page 6- 14). OUTPUT VOLTAGE INSPECTION (WITH THROTTLE FULLY OPEN) 6-10). Turn the ignition switch "ON“t Measure the record the output voltage at the test harness terminals. CONNECTION: B18 (+) — B15 (-i MEASURING CONDITION: At throttle fully open OUTPUT VOLTAGE INSPECTION (WITH THROTTLE FULLY CLOSED) Turn the ignition switch "ON". Measure the record the output voltage at the test harness terminals. CONNECTION: E18 (+) — B15 (—) MEASURING CONDITION: At throttle fully close CALCULATE RESULT COMPARISON Compare the measurement to the result of the fol- lowing calculation. With the throttle Iully open: Measured input voltage x 0.89 V = V0 The sensor is normal if the measurement output voltage measured in step 1 is withIn 8% of V0. With the throttle fully closed: Measured input voltage x 0.1 V = V0 The sensor is normal it the throttle closed output voltage measured in step 2 is within 8% of Vct Using an analog meter, check that the needle of the volt meter swings slowly when the throttle Is opened gradually. @0006 00000 i\co 0 Connect the test harness to ECM connectors (page OC UOOUO do co co 6-64 FUEL SYSTEM (Programmed Fuel Injection) BANK ANGLE SENSOR INSPECTION Turn the ignition switch "OFF". Remove the inner cover (page 375). Support the motorcycle securely on its center stand. Turn the ignition switch “0N“. Do not disconnect Measure the voltage at the bank angle sensor 3P the bank angle sen- (Natural) connector terminals with its connected. sor 3P (Natura/ con- CONNECTION STANDARD t net: or Red Green , Blue/Green Battery voltage EWOrange ~ Blue/Green 0 — 0.9 V Turn the ignition switch "OFF". Do not disconnect Remove the screws and bank angle sensor. the bank angle son- 50! 3P (Natural Conr hector Ifyou check thIs Place the bank angle sensor is normal position as test, theigmr/on shown, and ignition switch "ON“ then measure the SWIlch ”OFF', then voltage at the bank angle sensor 3P (Natural) con- turn the Ignmon nector. sztch 'ON“. CONNECTION: Red/Orange (+) — Blue/Green (-l STANDARD: N0 voltage Incline the bank angle sensor approximately 60D to the left or right with keep the ignition switch "0N" then measure the voltage at the bank angle sensor 3P (Natural) connector. CONNECTION: Red/Orange (+) — Blue/Green (—) STANDARD: 4 V or more REMOVAL/ INSTALLATION Remove the inner cover (page 3-5). Disconnect the bank angle sensor 3P (Natural) con» nector. 3P (NATURAL) CONNECTOR r I a? \ >\ (fly/7 "X \i I SCREWS 60° BANK ANGLE POSITION L1 = © NORMAL POSITION (approXImate(y) 50" 3F (NATURAL) CONNECTOR 4 W” FUEL SYSTEM (Programmed Fuel lniection) Remove the two screws and bank angle sensor. Install the bank angle sensor with its ”UP" mark fac- ing up. _ . Tighten the mounting screws to the specIerd torque. TORQUE: 1.2 N-m (0.12 kgf-m, 0.9 Ibf-ft) Home the sensor Connect the bank angle sensor 3P (Natural) connec- wI/e correct/y (page tor. 7-15! MAIN RELAY INSPECTION Remove the inner cover (page 375). Disconnect the main relay from the relay connector. Connect the ohmmeter to the fuel pump relay con- nector terminals. CONNECTION: A — B Connect the 12V battew to the following fuel pump relay connector terminals. CONNECTION: C (+) - D (-I MAIN RELAY *I FUEL SYSTEM (Programmed Fuel Injection) There should be continuity only when the 12V bat- tery is connected. If there is no continuity when the 12V battery is con nected, replace the fuel pump relay. ECM (ENGINE CONTROL MODULE) _IIE_FoI¥l“POWER/GROUND LINE INSPEC- Hemove the inner cover (page 3-5). Turn the ignition switch "OFF". Disconnect the ECM 5P (Black) connector. Check for loose or poor contact on the ECM 5P (Black) connector. Engine does not start (MIL no blinks) 1. ECM Power Input Voltage Inspection Disconnect the ECM 5P (Black) connector. Turn the ignition switch "ON". Measure the voltage between the ECM 5? (Black) connector of the wire harness side and ground. CONNECTION: Red (+) — Ground (—) Does the battery voltage exit? VES — GO TO STEP 2. NO — GO TO STEP 3. MAIN RELAY BA'I'I'ERY CTO R //;\ 5? (BLACK) CONNE / / 5P (BLACK) CONNECTOR 6-66 6-67 FUEL SYSTEM (Programmed Fuel Injection) 2. ECM Ground Line Inspection Turn the ignition switch “OFF". Check for continuity between the ECM 5P (Black) connector of the wire harness side and ground. CONNECTION: Green — Ground Is there continuities? VES — Replace the ECM with a new one, and recheck. NO - Open circuit in the Green wire. 3. Main Relay Inspection 1 Turn the ignition switch "OFF". Remove the main relay (page 6-66). Turn the ignition switch "ON". Measure the voltage at the main relay connector of the wire harness side. CONNECTION: Red/Green (-0-) — Green/White (—) Does the battery voltage exit? YES — GO TO STEP 4. NO — 0 Open circuit in Red/Green or Green/ White wire between the ECM and the main relay. 0 Replace the ECM with a new one, and recheck. 4. Main Relay Inspection 2 Turn the ignition switch "OFF". Jump the main relay connector terminals. CONNECTION: Red — Red/Black Turn the ignition switch “ON". Measure the voltage at the ECM connector of the wire harness side and ground, CONNECTION: Red (+l — Ground (-) Does the battery voltage exit? YES — Inspect the main relay (page 6-66). N0 — . Open circuit in Red or Red/Black wire between the battery and the ECM. I Blown the main fuse (20 A). REMOVAL/ INSTALLATION Remove the inner cover (page 38). Disconnect the ECM 22F (Black), 22F (Gray) and SP (Black) connectors. 5P 21 P (BLACK) CON NECTOR 6-68 FUEL SYSTEM (Programmed Fuel Injection) Remove the bolts and the ECM. ENGINE IDLE SPEED NOTE: - Inspect the idle speed after all other engine mainr tenance items have been performed and are within specifications. - The engine must be warm for accurate idle speed inspection and adjustment. - This system eliminates the need for manual idle speed adjustment from the previous designs. - Make sure the malfunction indicator lamp (MIL) does not indicate any failure codes before inspecting the engine idle speed. Support the scooter with its center stand on a level surface. Warm up the engine to normal operating tempera— ture. Remove the plug maintenance lid and connect a tachometer. Check the idle speed. IDLE SPEED: 2,000 1100 min" (rpm) If the engine hard to start or engine idle speed is out of specification, Check that the MIL blinks (page 6-8). IAC VALVE INSPECTION 7. I If the engine hard to start or engine idle speed is out of specification, check that the MIL blinks (page 6-8). Turn the ignition switch "OFF". Check the IAC valve (step motor) operating sound immediately after the ignition switch turning "ON". 6-69 FUEL SYSTEM (Programmed Fuel lniection) PCV CONTROL SOLENOID VALVE/ REED VALVE REMOVAL/ INSTALLATION Remove the throttle body (page 6755). Disconnect the PCV control solenoid valve 2P (Black) connector. Disconnect the air suction hose. Disconnect the air suction hose. Remove the bolts and the PCV control solenoid valve/stay. Remove the reed valve cover and reed valve. Remove the nuts, bolts, solenoid valve from the stay. Installation is in the reverse order of removal. Tighten the PCV control solenoid valve bolts to the specified torque. TORQUE: 5.3 N-m (0.6 kgf-m, 4.3 let) 2P (BLACK) CON NECTOR FUEL SYSTEM (Programmed Fuel Injection) INSPECTION Remove the PCV control solenoid valve and reed valve lpage s-7ol. PCV CONTROL SOLENOID VALVE Check that the air should flow (A) to (B), only when the 12 V battery is connected to the PCV control PCV VALVE solenoid valve terminals. Check the resistance between the terminals of the PCV control solenoid valve. PCV VALVE STANDARD: 30 — 34 9 (20° 0/68“ F) If the resistance is out of specification, replace the PCV control valve. REED VALVE Check the followings: VALVE STOPPER — Reed valve for wear or damage 7 Valve seat for wear or damage — Valve stopper for damage Check the no clearance between the reed valve and valve seat. w Replace the reed valve as an assembly, if necessary. VALVE SEAT REED VALVE 6-70 6-7 1 FUEL SYSTEM (Programmed Fuel Injection) 02 SENSOR REMOVAL - Handle the 02 sensor with care. . Do not get grease, oil or other materials in the 02 sensor air hole. ' Do not use an impact wrench while removing or installing the 02 sensor. - Be careful not to damage the sensor wire. Do notserwce the Remove the muffler protector (page 340). 0’ ”"5” ””93; Disconnect the 02 sensor 4P (Black) connector. Remove the 02 sensor using the special tool. TOOL: . Oz sensor wrench 07LAA-PT50101 INSTALLATION Install the new sealing washer to the 02 sensor. 4..., 4P (BLACK) CON NECTOR N . SEARING WASHER 02 SENSOR 6-72 FUEL SYSTEM (Programmed Fuel lniection) Tighten the 02 sensor to the specified torque. TOOL: 0: sensor wrench o7LAA-PT50101 Oz SENSOR WRENCH TORQUE: 44 N-m (4.5 kgf-m, 33 lbf-ft) Connect the 02 sensor 4P (Black) connector. 4P Install the muffler protector (page 340). ( 6-73 MEMO SYSTEM FLOW PATTERN ............................ 7.2 SERVICE INFORMATION .............................. 7.3 TROUBLESHOOTING .................................... 7.4 COOLANT SYSTEM TESTING---------------------- 7—5 7. COOLING SYSTEM COOLANT REPLACEMENT ---------------- WATER PUMP/THERMOSTAT ---------- HAD|ATOR ........................................... RADIATOR RESERVE TANK-m- ............ 7.6- ............ 7.3 ......... 7.13 .....7.15 COOLING SYSTEM SYSTEM FLOW PATTERN RESERVE TANK RADIATOR WATER PUMP THERMOSTAT 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 in the frame ' Avoid spilling coolant on painted surfaces. - After servicing the system, check for leaks with a cooling system tester. I When the coolant temperature exceeds 120 "C (248 “FI, the coolant temperature indicator will turn on. The ECM will then control the ignition and reduce engine speed below 5,000 min" (rpm). At this time, check the cooling system and engine for leaks or damage. If even/thing is OK, then check the coolant indicator circuit and ECT sensor (page 1943). D This scooter features a magnetic»coupling water pump, SPECIFICATIONS i ' '7 ITEM _ _ STANDARD Coolant capacity iFladiator and engine 018 liter (0.30 US qt, 0.25 Imp qt) Reserve tank 7 0.24 liter (0.25 US qt, 0.21 Imp qt) __ Recommended antifreeze , Standard coolant concentration E Radiator cap relief pressure 108 ~ 137 kPa (1,1 , 1.4 kgf/cmz, 16 , 20 psi) Thermostat Jegin to open ‘ 74 — 78 ° C (165 — 172 ° F) jnyopen ' 100°C(Z12“FI I Valvelift "3.5 mm (0,1 iniminimum High quality ethylene glycol antifreeze containing corroa sion protection inhibitors 1:1 mixture with soft water TORQUE VALUES Coolant drain bolt Radiator cover screw Fuel feed hose stay bolt 0.9 N‘m (0.1 kgf—m, 0.7 Ibf-ft) 0.9 NAm (0.1 kgf-m, 0.7 Ibf-ft) 10 N-m (1.0 kgf-m, 7 Ibf-ft) 7-2 7-3 COOLING SYSTEM TROUBLESHOOTING Engine temperature too high I Thermostat stuck closed - Faulty radiator cap - Insufficient coolant _ . Passage blocked in radiator, hoses or water Jacket - Air in system 0 Faulty water pump 0 Faulty ECT sensor Engine temperature too low I Faulty ECT sensor ~ Thermostat stuck open Coolant leak - Deteriorated O-rings I Faulty radiator cap O Damaged or deteriorated cylinder head gasket I Loose hose connection or clamp - Damaged or deteriorated hoses COOLANT SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the four screws and radiator cover. Remove the radiator cap. Pinch the siphon hose with a hose clamp. Test the coolant gravity using a hydrometer [see below for "Coolant specific gravity chart“). For maximum corrosion protection, a 1:1 solution of ethylene glycol and distilled water is recommended (page 7-6). Look for contamination and replace the coolant if necessary. Install the removed parts in the reverse order of removal. COOLING SYSTEM HYDHOMETER COOLANT SPECIFIC GRAVITV CHART Coolant temperature “C P F) 0 51015 20 25 30 35 404550 (32) (41) (50) (59) (as) (77) (86) (95) (104) (113) (122) 5 1.009 1.009 1.000 1.000 1.007 1.006 1.005 1.003 1.001 0.999 0.997 10 1.013 1.017 1,017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005 15 1.028 1.027 1.026 T025 1.024 1.022 1.020 1.018 1.016 1.014 1.012 g 20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019 .2 25 1.045 1.044 1.043 1.042 1.040 1.033 1.036 1.034 1.031 1.028 1.025 E 30 1.053 1.052 1.051 1.047 1.046 1.045 T1043 1.041 1.033 1.035 1.032 g 35 1.063 1.052 1.060 1.053 1.056 1.054 1.052 1.049 1.046 1.043 1.040 g 40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047 L, 45 1.000 1.079 1.070 1.074 1.072 1.069 1.066 1.063 1,060 1.057 1.054 50 1,000 1.094 1.032 1.000 1.077 1.074 1.071 1.068 1.065 1.062 1.059 55 1.095 1.093 1.091 1,009 1.035 1.032 1.079 1.076 1.073 1.070 1.067 60 1.100 1.096 1.095 1.092 1.039 1.086 1.033 1.000 1.077 1.074 1.071 7-5 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap. Wet the sealing surfaces of the cap, then install the cap onto the tester. Pressurize the radiator cap using the tester. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. The cap must hold the specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108 - 137 kPa (1.1 — 1.4 kgf/cm2,16-20 psi) Pressurize the radiator, engine and hoses using the tester, and check for leaks, Repair or replace components if the system will not hold the specified pressure for at least 6 seconds Remove the tester and install the radiator cap. Excessive pressure can damage the cooling system components. Do not exceed 137 kPa (1.4 kgf/cm’, 20 psi). COOLANT REPLACEMENT PREPARATION 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. NOTE: - The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usaget Therefore, for best performance change the coolant regularly as specified in the maintenance schedule. Mix only distilled, low mineral water with the rec- ommended antifreeze. RECOMMENDED ANTIFREEZE: High quality ethylene glycol antifreeze containing corrosion protection inhibitors RECOMMENDED MIXTURE: 1:1 (distilled water and recommended antitreezel RADIATOR CAP TESTER 0 ANTIFHEEZE SOLUTION IETHYLENE GLYCOL BASE SOLUTION) LOW MINERAL OR DISTILLED WATER COOLANT REPLACEMENT/AIR BLEEDING NOTE: - When filling the system or reserve tank with coolant, or checking the coolant level, place the scooter on its center stand on a flat, level surface. Remove the four screws and radiator cover. Remove the radiator cap, Drain the coolant from the system by removing the drain bolt and O-ring. Remove the cylinder drain bolt with sealing washer and drain the coolant from the cylinder. «9" §fl SEALING Remove the reserve tank cap and drain the coolant from the reserve tank. Reinstall the drain bolt with a new O-ring onto the radiator. TORQUE: 0.9 NM (0.1 kgI-m, 0,7 lbf—ftl Reinstall the drain bolt with a new sealing washer onto the cylinder. COOLING SYSTEM 7-6 7-7 COOLING SYSTEM Fill the reserve tank with the recommended coolant to the upper level line. UPPER LEVEL LINE ‘ Fill the system with the recommended coolant “ through the filler opening to the filler neck. _, Ffl-LER NECK Bleed air from the system as follow: 1. Start the engine and let it idle for 2 ——3 minutes. 2. Snap the throttle three or four times to bleed air from the system. 3. Stop the engine and add coolant to the proper level if necessary. Reinstall the radiator cap. 4. Check the level of coolant in the reserve tank and fill it to the upper level if the level is low. Install the radiator cap and reserve tank cap. Install the radiator cover and tighten the screws to the specified torque. TORQUE: 0.9 M"! (0.1 kgf-m, 0.7 lbf-ft) WATER PUMP/THERMOSTAT REMOVAL WATER PUMP Drain the coolant from the cooling system (page 7- 7). Remove the floor step (page 3-7). Remove the bolts and fuel feed hose stays. Disconnect the water hoses from the water pump. Remove the wire band from the water pump stay. Disconnect the water hoses. Remove the bolts and water pump. Remove the O»ring from the water pump. THERMOSTAT Remove the bolts, stay and thermostat cover. COOLING SYSTEM w my * ’p WATER HOSES a COOLING SYSTEM COOLING SYSTEM Remove the rubber seal from the thermostat cover. IN I N RUBBER SEAL STALLAT 0 Remove the thermostat, WATER PUMP at? O-RING THERMOSTAT ‘ THERMOSTAT SEAL RING THERMOSTAT INSPECTION Visually inspect the thermostat for damage. THERMOSTAT STAY THERMOSTAT COVER Keep flammable Heat a pan of water with an electric heating element THERMOSTAT materials away to operating temperature for 5 minutes. Coat a new seal ring with coolant and install it into M» from the electr/c Suspend the thermostat in the heated water to the groove of the thermostat GROOVE/TAB THERMOSTAT heat/n9 element check its operation. Install the thermostat into the water pump, aligning the tab of the thermostat with the groove of the Do not let the there Replace the thermostat it the valve stays open at water pump, mostat or there room temperature, or if it responds at temperatures momerer touch the other than those specified‘ pan, or Vou will get . THERMOSTAT BEGINS TO OPEN: t r d V ”a we ’"95 14- 78 °c (165 — 172 °F) VALVE LIFT: 3.5 mm (0.1 in) minimum at 100 BC (212 °F) \ THERMOSTAT THERMOMETER r Install a new rubber seal into the thermostat cover 1 groove. 7-10 7-11 COOLING SYSTEM Install the thermostat housing cover to the water pump. Install the stay to the thermostat housing cover aligning the tab on the stay with the stopper on the ‘ thermostat housing cover and tighten the bolts . securely. i WATER PUMP ‘ Clean the inside of the outer magnet and the water pump magnet, and check that no nuts or bolts are r» magnetically attached to the magnet. Coat a new O—ring with engine oil and install it into the groove of the water pump. Install the water pump into the cylinder head and tighten the bolts securely. ‘ Connect the water hoses. i Install the wire band onto the stay. :. WATER PUMP MAGNET WATER PUMP WATER HOSES 7-12 COOLING SYSTEM Connect the water hoses. , _ , ‘1‘. may.“ 42' . Install the fuel feed hose stay and tighten the bolts to the specified torque. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-ft) Install the floor step (page 3-7). Fill and bleed the cooling system [page 7-8). RADIATOR REMOVAL Be careful not to Drain the coolant from the cooling system (page 7- ‘ damage the radiator 7). fins while servicing . ~ the radiator, Dlsconnect the water hose from the radiator. Remove the rear fender bolt/washer. COOLING SYSTEM Remove the radiator mounting bolts. Disconnect the siphon hose and water hoses from the radiatort Remove the radiator from the water pipe. Remove the water pipe and O-rings. ““mvv _ RADIATOR MOUNTING BOLTS -‘\ m SIPHON HOSE i WATER PIPE COOLING SYSTEM INSTALLATION WATER HOSE SIPHON HOSE WATER HOSE Coat the new O-rings with coolant and install them into the grooves of the water pipe. Install the water pipe and align the guide of the crankcase with the water pipe as shown. Connect the siphon hose and water hose. 7-14 7-15 COOLING SYSTEM Install the radiator onto the crankcase, aligning the “_—“_‘“ water pipe with the pipe joint of the radiator. RAD'ATOR MOUNT'NG OHS Install and tighten the radiator mounting bolts 1 securely. Install and tighten the rear fender bolt securely. Connect the water hoses. Fill and bleed the cooling system (page 7-8). RADIATOR RESERVE TANK REMOVAL/INSTALLATION Drain the coolant from the radiator reserve tank (page 7—7). Remove the radiator reserve tank cap. Remove the bolt. Remove the radiator reserve tank by releasing its grommet from the frame stay. Disconnect the siphon hose from the reserve tank. Installation is in the reverse order of removal. COOLING SYSTEM SIPHON HOSE anaemia; 7-16 7-17 MEMO ‘ 8. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATIONS ........................... 3.2 ENGINE REMOVAL ........................................ 3.4 SERVICE INFORMATION ------------------------------ 8-3 ENGINE INSTALLATION -------------------------------- 8-7 a 8-1 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION COMPONENT LOCATIONS SERVICE INFORMATION GENERAL 39 NI-m (4.0 kgf-m, 29 Ibf—ft) - During engine removal and installation, Support the scooter using a hoist or equivalent. 39 N-m (4.0 kgf-m, 29 lbf-ftl ' Supportthe engine using a jack or other adjustable support to ease of engine mounting bolt removal. - When removing/installing the engine, tape the frame around the engine beforehand for frame protection. ' The following components require engine removal for service. , Crankshaft/piston/cylinder (page 1373) - The following components can be serviced with the engine installed in the frame. — Kick starter/drive pulley/driven pulley/clutch (page 103) — Final reduction (page 11-3) — Alternator/starter (page 12-3) — Cylinder head/valves (page 9-3) — Water pump (page 7-3) — Throttle body (page 6755) — Oil pump (page 574) SPECIFICATION ITEM SPECIFICATIONS Engine dry weight _ 21.1 kg (46.5 lbs) Coolant capacity Radiator and engine 0.28 liter (0.30 US qt, 0.25 Imp qt) Engine oil Capacity At draining 0.6 liter (0.8 US qt, 0.5 Imp qt) At disassembly 0:7Aliter (0.7 US qt, 0.6 Imp qt) 49 N-m (5.0 kgf—m, 36 Ibrft) TOROU E VALU ES Engine hanger link bolt (frame side) 39 N-m (4.0 kgf-m, 29 lbf-ft) Engine mounting nut (engine side) 49 N-m (5.0 kgf-m, 36 IbI-ft) U-nut Rear shock absorber mounting bolt (upper) 40 N-m (4.1 kgf-m, 30 |bf>ft) ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the floor step (page 3-7). Drain the engine oil [page 440]. Relieve the fuel pressure and disconnect the quick connect fitting (page 6746). Drain the coolant from the cooling system (page 7» ‘Y 7). Install the radiator cover to prevent the radiator fin from damage. Remove the spark plug cap from the spark plug . (page 4-6). Disconnect the ECT sensor 2P (Black) connector. Remove the injector/fuel feed hose (page 6-61). Disconnect the crankcase breather hose from the cylinder head cover and hose guide. Remove the wire band from the stay. Disconnect the alternator/starter 3? (Natural) and GP lBrown) connectors. Remove the alternator/starter wire from the wire bands. Remove the throttle body (page 6755). INJECTOR/FUEL FEED HOSE ENGINE REMOVAL/INSTALLATION Disconnect the 0: sensor 4P (Black) connector. Disconnect the siphon hose and water hose from the radiator. Disconnect the PCV solenoid valve 2P (Black) con nector. Remove the spark plug wire from the wire bands. Rergove the bolt, ground cable and harness/cable gm 6 GROUND i CABLE HARNESS/ PLUG WIRE . CABLE GUIDE! Remove the rear brake cable from the brake arm (page 1575). Remove the rear brake cable from the cable holder and the clamp. _CABLE HOLDER 8-5 ENGINE REMOVAL/INSTALLATION » - w Place a floor rack or other adjustable support under UPPER MOUNTING BOLT the frame. Remove the rear shock absorber upper mounting bolt. ~ - \ Remove the engine mountlng nut. \ MOUNTING NUT I ‘ x Pull out the engine mounting bolt, then remove the ‘ l ‘ engine from the frame. \\ Check the bushings for wear, deterioration or dam- age. Remove the pivot caps, bolts and engine hanger link. 8-6 Check the rubber stopper of the engine hanger link for damage, wear or deterioration, Check the bushings for wear, deterioration or dam age. ENGINE INSTALLATION NOTE: O Before installing the engine, route the wires, hoses and cables properly [page 1-15). - The jack height must be continually adjusted to relieve stress from the mounting fasteners. Install the engine hanger link, aligning the rubber stopper with the frame. Install and tighten the engine hanger link bolts to the specified torque. TORQUE: 39 N-m (4.0 kgf-m, 29 Ibf-ft) Install the pivot caps. ENGINE REMOVAL/INSTALLATION HANGER LINK RUBBER STOPPER BUSHINGS RUBBER STOPPER ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION Set the engine to the frame and install the engine \\ ‘ ‘ Connect the PCV solenoid valve 2P (Blackl connecr P' w' tor. CONNECTOR mounting bolt from the left side. Tighten the engine mounting nut to the specified torque. TORQUE: 49 Nm (5.0 kgf-m, 36 lbf-ft) Tighten the rear shock absorber upper mounting Connect the OzsensorAP(Blacklconnector. bolt to the specified torque. TORQUE: 40 MM (4.1 kgf-m, 30 Ibf-ft) Connect the siphon hose and water hose to the radi- ator. Install the brake cable to the clamp and the cable Install the throttle body (page 6-55). holder. Install the rear brake arm adjusting nut, joint pin and spring. Install the alternator/stator wire to the wire bands. Connect the alternator/stator 3P (Brown) and GP (Natural) connectors. Install harness/cable guide and ground wire. Install and tighten the bolt securely. Install the spark plug wire to the wire bands. SPARK HARNESS/ PLUG WIRE CABLE GUI E 3P IBROWN) CONgECTOR ENGINE REMOVAL/INSTALLATION H h ' b dt th I . l v Insta t 6 Wire an o e s ay REATHER HOSE Install the crankcase breather hose to the hose \ guide and cylinder head cover. Install the injector (page 6—61). Connect the ECT sensor 2P (Black) connector. Install the removed parts in the reverse order of removal. After installing the engine, check the following: — Rear brake lever free play (page 443) — Throttle grip free play (page 4-4) Fill the crankcase with the recommended engine oil (page 4-10). Install the quick connect fitting (page 6-47). Fill and bleed the cooling system (page 7-8). INJECTOR/FUEL I FEED HOSE 9. CYLINDER HEAD/VALVES 8-10 COMPONENT LOCATIONS-n 9-2 CYLINDER HEAD DISASSEMBLY --------------- 9-11 SERVICE INFORMATION ------------------------------ 9-3 VALVE GUIDE REPLACEMENT ------------------- 9-14 TROUBLESHOOTING ------------------------------------ 9-5 VALVE SEAT lNSPECTION/REFACING ------ 9-15 m CYLINDER COMPRESSION TEST 9-6 CYLINDER HEAD ASSEMBLY --------------------- 9-18 CYLINDER HEAD COVER REMOVAL ----------- 9-6 CYLINDER HEAD INSTALLATION --------------- 9-19 CAMSHAFI'IROCKER ARMS REMOVAL ----- 9-7 CAMSHAFI'IROCKER ARM INSTALLATION ............................................. 9.20 CYLINDER HEAD REMOVAL -------------- - 9-10 CYLINDER HEAD COVER INSTALLATION ............................................. 9.23 9-1 CYLINDER HEAD/VALVES COMPONENT LOCATIONS 12 N-m (1.2 kgfrrn, 9 Ibf-ft) 8.8 N-m (0.9 kgf-m, 6.5 lbf-ft) 18 N-m (1.8 kgf«m,13lbf-ft) / CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL - This section covers service ofthe cylinder head, valves, rocker arms and camshaft. I The cylinder head and valves can be serviced with the engine installed in the frame. - When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca- tions. - Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. 0 Camshaft and rocker arm lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the cylinder head. 0 Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. SPECIFICATIONS Unit: mm (in) ITEM STANDARD ) SERVICE LIMIT Cylinder compression 1,275 kPa (13.0 kgf/cmz, 185 psi) l — at 950 rpm Cylinder head warpage — 0.05 (0.002) Valve, valve Valve clearance IN 0.10 10.03 (0004:0001) — guide EX 0.21 10.03 (0.008 i0.001) — Valve stem CD. IN 3.475 — 3.490 (0.1368 — 0.1374) 3.465 (0.1364) EX 3.465 — 3.480 (0.1364 — 0.1370) 3.455 (0.1360) Valve guide |.D. ‘ IN/EX 3500—3512(01378—01383) 3.5401139) Stem»to-guide | IN 0.010 — 0.037 (0.0004 — 0.0015) 0.075 (0.0030) clearance ‘ EX 0.020 — 0.047 (0.0008 — 0.0019) 0.085 (0.0033) Valve guide projection IN 9.30 — 9.50 (0.366 — 0.374) — above Cylinder head EX 0.30 — 9.50 (0.366 — 0.374) — Valve seat width IN/EX 0.8 (0.03) 1.3 (0.05) Valve spring free length IN/EX 37.11 (1.461) 35.8 (1.41) Rocker arm l Rocker arm |.D. IN/EX 10.000 , 10.015 (0.3937 , 0.3943) 10.10 (0.400) Rocker arm shaft 0.D. IN/EX 9.972 7 9.987 (0.3926 — 0.3932) 9.91 (0.390) Side spring free length 16.0 (0.63) 14.5 (0.57) Camshaft Cam lobe height IN 30.7867 7 31.0268 (1.21208 4122153) 30.75 (1.211) l EX 29.9308 — 30.1703 (1.17838 - 1.18782) 29.90 (1.177) TORQU E VALU ES Cylinder head bolt 12 N-m (1.2 kgf-m. 9 lbfvft) Apply oil to the threads and flange surface. Cam sprocket bolt 8.8 Nvm (0.9 kgf-m, 6.5 lbf-ft) Apply oil to the threads and flange surface. Cam chain tensioner lifter screw 4.2 N-m (0.43 kgf-m, 3.1 lbf-ftl Spark plug 8.8 N-m (0.9 kgf-m, 6.5 lbf-ft) _ ECT sensor 18 N-m (1.8 kgf-m, 131bf-ft) CYLINDER HEAD/VALVES TOOLS Valve spring compressor 07757-0010000 Seat cutter, 15 mm (45° IN) 07VMH»GCRO100 or equivalent commercially avail» able Seat cutter, 13 mm (45° EX) 07VMH-GCRD3OD or equivalent commercially availa able Flat cutter, 13 mm 132“ EX) 07VMH7GCR0400 or equivalent commercially avail» able Flat cutter, 15 mm (32° INl 07VMH-GCRDZDO or equivalent commercially avail» able Interior cutter, 13 mm (60" Ex) 07VMH‘GCR0500 or equivalent commercially avail- able Interior cutter, 17 mm (60" IN) 07780-0014500 O or equivalent commercially avail— able Cutter holder, 3.5 mm 07HMH-KT70200 or equivalent commercially avail- able Valve spring compressor attach- ment 07DME-MCW0100 Valve guide driver 07HMD-K170100 /,C/) 44/ / Valve guide reamer, 3.510 mm O7HMH-KT701D1 Cam chain tensioner stopper 070MG»0010100 Spark plug wrench O70MA»GEZO1OO Q Compression gauge attachment 07N MJ-M'I70101 TROUBLESHOOTING CYLINDER HEAD/VALVES I Engine top»end problems usually affect engine performance. These problems can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod or stethoscope. . if the performance is poor at low speeds, check for white smoke in the engine breather drain hose. If the hose is smoky, check for a seized piston ring (page 13»8l. Compression too low, hard starting or poor performance at low speed - Valves: , Incorrect valve clearance , Burned or bent valve ~ Incorrect valve timing - Broken valve spring — Uneven valve seating - Cylinder head: — Leaking or damaged head gasket — Warped or cracked cylinder head — Loose spark plug - Worn cylinder, piston or piston rings (page 13-8) Compression too high, overheating or knocking ' Excessive carbon build—up on piston head or on combustion chamber Excessive smoke - Worn valve stem or valve guide - Damaged stern seal I Worn cylinder, piston or piston rings (page 13-8) Excessive noise Incorrect valve clearance Sticking valve or broken valve spring Worn or damaged camshaft Worn or damaged cam chain Worn cam sprocket teeth Worn rocker arm and/or shaft Worn or damaged cam chain tensioner Worn cylinder, piston or piston rings (page 13-8) Rough idle - Low cylinder compression 9-5 CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Warm up the engine to normal operating tempera- ture. Stop the engine and remove the spark plug cap and spark plug [page 46). Connect a compression gauge and attachment to the spark plug hole. TOOL: Compression gauge attachment o7NMJ-MT70101 To avoid discharging Open the throttle all the way and crank the engine the battery, do not with the kick starter or electric starter until the operate the starter gauge reading stops rising. _ _ motor farmers The maximum reading is usually reached Within 4, than 7 seconds 7 seconds when using electric starter. COMPRESSION PRESSURE: 1,275 kPa (13.0 kg/cm’, 185 psi) at: 950 rpm Low compression can be caused by: r Blown cylinder head gasket , Improper valve adjustment 7 Valve leakage r Worn piston ring or cylinder High compression can be caused by: 7 Carbon deposits in the combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL Remove the floor step (page 3-7). Disconnect the engine breather hose. Remove the bolts and cylinder head cover. Remove the Orring from the cylinder head cover. - COMPRESSION GAUGE ATTACHMENT ' I BREATHER HOSE HEAD COVER nun—“A O-RING HEAD COVER CAMSHAFT/ROCKER ARMS REMOVAL Remove the following: — Fuel tank (page 6-52] — Belt case cover (page 106) — Water pump (page 7-8) — Cylinder head cover (page 9-6) Rotate the drive pulley (crankshaft) counterclock- wise and align the index line on the cam sprocket with the index mark on the stopper platel Make sure the cam lobe faces the cylinder side (TDC on the compression stroke). If the cam lobe is lacing the rocker arm side (TDC on ‘ exhaust stroke), rotate the crankshaft counterclocki wise 360° (one full turn] so the cam lobe faces the . cylinder side. Move the rocker arms to the spring side and remove the shims. NOTE: 0 Do not allow the shims to fall into the crankcase. 0 Mark all shims to ensure correct reassembly in their original locations. - The shims can be easily removed with tweezers or a magnet. Remove the screw and O-ring from the cam chain tensioner lifter. Turn the tensioner shaft clockwise with a special tool to hold the tensioner in the fully retracted posi- tiun. TOOL: Cam chain tensionar stopper o70MG-0010100 Remove the two bolts and outer magnet while hold» ing the crankshaft. Remove the cam sprocket from the camshaft and cam chain from the cam sprocket. Attach a piece of wire to the cam chain to prevent it from falling into the crankcase. CYLINDER HEAD/VALVES CAM SPROKET 9-6 9-7 CYLINDER HEAD/VALVES Loosen the outside cylinder head bolts. Remove the bolts and stopper plate. Remove the camshaft while pressing down on the valve side of the rocker arm. Remove the intake rocker arm shaft, Daring, intake rocker arm and spring. . Remove the exhaust rocker arm shaft, exhaust i rocker arm and spring. Refer to page 9-13 for cam chain tensioner and cam 0 .i chain guide removal. SPRING INSPECTION CAMSHAFI' Check the camshaft bearing for wear or damage. Turn the bearing outer race with your finger. The bearings should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the camshaft. Replace the camshaft assembly if the race does not turn smoothly and quietly, or if it fits loosely on the camshaft. ROCKER ARM Check the cam lobe for excessive wear and damage. Measure the height of each cam lobe. SERVICE LIMITS: IN: 30.75 mm (1.211 in) EX: 29.90 mm (1.177 in) ROCKER ARM/SHAFT Check the rocker arm shafts and rocker arms for wear or damage. Check the oil holes for clogging. Measure the ID. of each rocker arm. SERVICE LIMITS: IN/EX:10.10 mm (0.400 in) Measure the CD. of each rocker arm shaft. SERVICE LIMITS: INIEX:9.91 mm (0.390 in) SIDE SPRING Measure the free length of the side springs. SERVICE LIMITS: INIEX:14.5 mm (0.57 in) CAM CHAIN TENSIONER LIFI'ER :fmove the two bolts and tensioner lifter (page 9- Check the tensioner shaft end for wear or damage. CYLINDER HEAD/VALVES TENSIONEH LIFTER SHAFT END CYLINDER HEAD/VALVES Check the lifter operation: , The tensioner shaft should not go into the body when it is pushed. — When it is turned clockwise with a screwdriver, the tensioner shaft should be pulled into the body. The shaft should spring out of the body as soon as the screwdriver is released. TENSIONER SHAFT TENSIONER LIFTER CYLINDER HEAD REMOVAL Remove the following: — Muffler lpage 3-9) — Injector (page 6-61] — Camshaft/rocker arm (page 9-7) Disconnect the ECT sensor 2P (Black) connector (page 6-63). NOTE: - Loosen the spark plug and ECT sensor when disV assembling the cylinder head. Remove the intake pipe bolts. Disconnect the water hoses. Be carefulnor to Remove the bolts and cylinder head. damage the mating surface Remove the gasket and dowel pins. Remove the O-ring from the intake pipe groove. CYLINDER HEAD DISASSEMBLY Remove the followings: — Spark plug (page 4—6) , ECT sensor (page 6-63) Remove the bolt and stay. To pleventloss of Remove the valve spring cotters using the special tension, do not tools. compress the valve springs more than TOOLS: necessary m Valve spring compressor remove the Carters. Valve spring compressor attachment 07757-0010000 070ME-MCW0100 CYLINDER HEAD/VALVES CYLINDER HEAD STAY \s .n. VALVE SPRING COTI'ERS COMPRESSOR ATTACHMENT 9-10 9-11 CYLINDER HEAD/VALVES Mark all parts dur» mg disassembly so back lli therr original (DEBUG/15. Avoid damaging the mating and valve seat surfaces. Remove the valve spring compressor, then remove the following: thev can be placed _ Retainers — Valve springs — Stem seals — Spring seats — Valves Remove the carbon deposits from the combustion chamber and clean off the head gasket surface. INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head (or warpage with a straight ‘ edge and feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) VALVE SPRING Measure the free length of the valve springs. SERVICE LIMITS: INIEX: 35.3 mm (1.41 in) VALVE SPRING SPRING SEAT RETAINER a o\ .o '\ . STEM SEAL COMBUSTION CHAMBER i}. o .\\_ 9-12 Inspect and reface the valve seats whenever the valve guides are replaced {page 9-74}. CYLINDER HEAD/VALVES VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Check each valve for bends, burns, scratches or abnormal wear. Measure each valve stem OD. and record it. SERVICE LIMITS: IN: 3.465 mm (0.1364 in) EX: 3.455 mm (0.1360 in) Ream the valve guide to remove any carbon build up before measuring the guide. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockr wrse. TOOL: Valve guide reamer, 3.510 mm 07HMH-KT70101 REAMER Measure each valve guide In and record it. SERVICE LIMITS: INIEX:3.54 mm (0.139 in) Subtract each valve stem OD. from the correspond— ing guide ID. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.075 mm (0.0030 in) EX. 0.095 mm (0.0033 in) If the stem-to-guide clearance exceeds the service limit, determine if a new guide with standard dimensions would bring the clearance within toler- ance. If so, replace any guides as necessary and ream to fit. If the stem-to-guide clearance exceeds the service limit with new guide, also replace the valve. CAM CHAIN TENSIONER/GUIDE Remove the oil pump (page 5-4). Remove the dowel pin and cam chain tensioner. Remove the cam chain guide from the cylinder and crankcase grooves. 9-13 CYLINDER HEAD/VALVES Be sure to wear heavy gloves to avoid burns when hand/mg the heated cylinder head. Using a torch to heat the cylinder head may cause warpage. Check the tensioner and guide for excessive wear or damage. If necessary, replace them using the following pro» cedure. GUIDE TENSIONER Installation is in the reverse order of removal. r__,_.,, Align the tab on the cam chain guide with the e. TENSIONE’B groove on the crankcase. VALVE GUIDE REPLACEMENT Chill the replacement valve guides in a freezer for 3 about 1 hour. ' Heat the cylinder head to 130 °C — 140 °C (275 °F - , 290 "Fl with a hot plate or oven. Do not heat the cyla inder head beyond 150 QC (300 ”F). Use tempera- ture indicator sticks, available from welding supply stores, to be sure the cylinder head is heated to the - proper temperature. VALVE GUIDE DRIVER Support the cylinder head and drive the valve guides out of the cylinder head from the combus- tion chamber side. TOOL: Valve guide driver Drive the new guides into the cylinder head from ’ V, K the camshaft side while the cylinder head is still . heatedt ' 07HMD-KT70100 VALVE GUIDE DRIVER TOOL: Valve guide driver o7HMD-K'l70100 VALVE GUIDE PROJECTION: INIEX: 9.30 — 9.50 mm (0.366 — 0.374 in) Let the cylinder head cool to room temperature. 9-14 Ream the new valve guides after installation. REAMER Takecare not to nIr Insert the reamer from the combustion chamber ar/eah the reamer side of the head and also always rotate the reamer Iii the guide while clockwise. reaming mm.- U H' 'l ,hgiggmgfg’u’nfi; Valve guide reamer. 3.510 mm 07HMH-KT70101 ”"5 operation. Clean the cylinder head thoroughly to remove any metal particles after reaming and reface the valve seat as described below. VALVE SEAT INSPECTION/REFACING INSPECTION Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats. Tap the valve against the valve seat several times using a handrlapping tool, without rotating the valve, to make a clear pattern. CYLINDER HEAD/VALVES LAPPING TOOL The Valves cannot Remove the valve and inspect the valve seat iace. be ground. Ifthe The valve seat contact should be within the speci- valve face l5 burned fied width and even all around the circumference. orbad/y worn or In: STANDARD: 0.3 mm (0.03 IIII contacts the sear _ mm,” Wm SERVICE LIMIT: 1.3 mm (0.05 ml I the ”ah/9 If the valve seat width is not within specification. h reface the valve seat (page 9-15]. I SEAT WIDTH Inspect the valve seat face for: - Damaged face: — Replace the valve and reface the valve seat - Uneven seat width: , Bent or collapsed valve stem: Replace the valve and reface the valve seat DAMAGED FACE UNEVEN SEAT WIDTH 9-15 CYLINDER HEAD/VALVES Reface the seat With a 45" cutter whenevera valve gurde is replaced. 0 Contact area (too low or too high areal: — Reface the valve seat REFACING NOTE: 0 Follow the refacing manufacturer's operating instructions. - Be careful not to grind the sear more than neces- sary. If the contact area is too high on the valve, the seat must be lowered using a 32D flat cutter. If the contact area is too low on the valve, the seat must be raised using a 60° interior cutter. Refinish the seat to specifications, using a 45” finish cutter. Use a 45“ seat cutter. remove any roughness or irregularities from the seat. TOOLS: Seat cutter, 13 mm (45° EX) Seat cutter, 15 mm (45" IN) Cutter holder. 3.5 mm 07VMH-GCRO300 07VMH-GCR01DO 07HMH-KT70200 or equivalent commercially available TOO LOW TOO HIGH Q g \45 w G \i‘” CONTACT TOO HIGH OLD SEAT WIDTH ROUGHNESS 3-4 9-16 Excessive lepp/ng pressure may deform or damage the sear. Do not al/ow lap ping compound to enter the guides. Using a 32" flat cutter, remove 1/4 of the existing valve seat material. TOOLS: Flat cutter, 13 mm (32D EX) Flat cutter, 15 mm (32“ IN) Cutter holder, 35 mm 07VMH-GCR0400 07VMH»GCR0200 D7HMH-KT70200 or equivalent commercially available Using a 60° interior cutter, remove 1/4 of the exist- ing valve seat material. TOOLS: Interior cutter, 13 mm (60“ Ex) Interior cutter, 17 mm (60" IN) Cutter holder, 3.5 mm 07VMH-GCR0500 0778043014600 07HM H-KT70200 or equivalent commercially available Using a 45" seat cutter. cut the seat to the proper width. VALVE SEAT WIDTH: 0.8 mm (0.03 in) Make sure all pitting and irregularities are removed. After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pres- sure. Change the angle of the lapping tool frequently to prevent uneven seat wear. After lapping, wash any residual compound off the cylinder head and valve and recheck the seat con- tact. CYLINDER HEAD/VALVES OLD SEAT WIDTH OLD SEAT WIDTH so; $\Sts mm (0.03 in) LAPPING TOOL 9-17 CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY SPARK PLUG 8.8 N-m (0.9 kgfvm, 6.5 Ibfvft) Blow through all oil passages in [he cylinder head with compressed air. Apply engine oil to the inner surface of new stem seals. Install the spring seats and stem seals. Lubricate the valve stem sliding surface with molyb— denum oil solution. Insert the valves into the guide while turning it slowly to avoid damage to the stem seals. Install the valve springs with the tightly wound coils facing the combustion chamber. Install the spring retainers. ECT SENSOR . 18 Nm (1.8 kgf-m,13lbfsftl SPRING SPRING SEAT 4‘! STEM SEAL @ VALVE GUIDE 3 INTAKE VALVE '72 VALVE SPRING \ RETAINER E , 0 SPRING SEAT . ‘g STEM SEAL COMBUSTION CHAMBER —-> IlMNWll 9-18 CYLINDER HEAD/VALVES Grease the cone/s Install the valve spring cutters using the special to ease installation tools. To prevent loss of TOOLS: tensmn d0 "0! Valve spring compressor CDWWGSS the valve Valve spring compressor spnng more than attachment necessary to remove the cutters. 07757-001000!) 070M E-MCW0100 Support the cylinder head so the Valve heads will not contact anything that cause damage. Tap the valve stems gently with two plastic ham» mers as shown to seat the cotters firmly. Install the stay and tighten the bolt securely. Install the followings: — Spark plug (page 4-6l — ECT sensor (page 6-63) CYLINDER HEAD INSTALLATION Clean the mating surface of the cylinder and cylin» der head. Install the cam chain, earn chain guide and ten» sioner (page 9—13) Install the dowel pins and a new gasket onto the cyl— inder. Coat a new O-ring with oil and install it into the groove of the intake pipe. VALVESFRING CO'I'I'ERS COMPRESSOR ATTACHMENT 9-19 CYLINDER HEADNALVES Route the cam chain through the cylinder head and install the cylinder head onto the cylinder. Loosely install the cylinder head mounting bolts. Connect the water hoses. Install the intake pipe bolts and tighten them securely. Install the following: - Muffler (page 3-9) — Camshaft/rocker arm (page $20) CAMSHAFT/ROCKER ARM INSTALLATION ROCKER ARM ASSEMBLY The mark on the rocker arm have a following mean- ings: A IN: Intake rocker arm — EX: Exhaust rocker arm "IN" MARK CYLINDER HEAD ROCKER ARMS "EX" MARK CYLINDER HEAD/VALVES Intake rocker arm shaft has Orring. Replace the Orring with a new one and apply oil it. INTAKE ROCKER ARM SHAFT fl? / \/K EXHAUST ROCKER ARM SHAFT Apply molybdenum oil solution to the sliding and slipper surfaces of the rocker arms. '73 ROCKER ARMS Install the rocker arms and side springs as shown. Install the intake Apply engine oil to the sliding surfaces of the rocker I shaft with the cut arm shafts and install it to the cylinder head. ‘ out facing outside. . CUT-OLIT Apply oil to the camshaft bearings. w, IW Apply molybdenum oil solution to the cam lobes. SHAFT ~ Install the camshaft with the cam lobe facing the cylinder side while pressing down the valve side of the rocker arms. 9-21 CYLINDER HEAD/VALVES Apply engine oil to the cylinder head bolt threads and seating surfaces. Install the stopper plate onto the cylinder head as shown. Install the bolts and tighten them in a crisscross pate ‘ tern in two or three steps to the specified torque. TORQUE: 12 N-m (1.2 kgt-m, 9 Ibf-ft) If the cylinder head is removed, tighten the outside cylinder head bolts. Turn the drive pulley (crankshaft) counterclockwise and align the "T" mark on the flywheel with the index mark on the crankcase while holding the cam chain. Make sure the cam lube faces the cylinder side (TDC on the compression stroke)‘ Install the cam sprocket onto the cam chain, align» ing the index line on the cam sprocket with the index mark on the stopper plate. Apply engine oil to the cam sprocket bolt threads and seating surfaces. Apply engine oil to the cam sprocket gear teeth. Clean the inside of the outer magnet and check that , no nuts or bolts are attached to the magnet. Install the outer magnet and bolts. Tighten the bolts to the specified torque while hold» ing the crankshaft. TORQUE: 8.3 NM (0.9 kgf-m, 6.5 lbf-ft) Install the valve shims in their original locations noted during the removal. CYLINDER HEAD/VALVES Turn the tensioner shaft clockwise with a special tool to hold the tensioner in the fully retracted posi tion. TOOL: Cam chain tensionar stopper 070MG-0010100 Install a new gasket to the cam chain tensioner Ii er. Install the cam chain tensioner on the cylinder and tighten the bolts securely. Remove a special tool to cancel the lock of the ten suoner lifter, Coat a new O-ring with oil. Install and tighten the lifter screw to the specified torquet TORQUE: 4.2 N-m (0.43 kg‘f—m, 3.1 lbt-ft) Make sure the index line on the cam sprocket aligns . with the index mark on the stopper plate when the V "T" mark on the flywheel is aligned with the index mark on the crankcase. Install the following: Water pump (page 7-11) Fuel tank (page 6752I Belt case cover Ipage 10-6) 9-22 — Cylinder head cover (page 9-23) CYLINDER HEAD COVER INSTALLATION Clean the gasket groove of the cylinder head cover. Coat the new O-ring with oil and install it into the grooves of the cylinder head cover. HEAD COVER 9-23 CYLINDER HEAD/VALVES Install the cylinder head cover to the cylinder head. Install the bolts and tighten them in a crisscross pat- tern in two or three steps. Connect the engine breather and air supply hoses. Install the floor step (page 37), 10. KICKSTARTER/ DRIVE PULLEY/DRIVEN PULLEY/CLUTCH COMPONENT LOCATIONS--- 10-2 KICKSTARTER ---------------------------------------------- ‘IO«6 SERVICE INFORMATION - 10-3 DRIVE PULLEY .............................................. 10.9 TROUBLESHOOTING ------------ 10-5 CLUTCH/DRIVEN PULLEY ------------------------- 10-12 BELT CASE COVER ------------------------ n 9-24 10-1 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH COMPONENT LOCATIONS KlCKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SERVICE INFORMATION GENERAL ' This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch. - These services can be done with the engine installed in the frame. I Avoid getting grease and oil on the V-belt and pulley drive faces in order to prevent belt slippage. - Do not apply grease to the movable drive face and weight rollers. SPECIFICATIONS l Unit: mm (in) l ITEM STANDARD SERVICE LIMIT Clutch ‘ Clutch outer 1.0. 107.0 — 107.2 (4.21 — 4.221 ‘1075 (4.231 ‘ Lining thickness - 2.0 (0.08) ‘ Drive belt width 18.15 (0.715) 17.15 (0.631 Movable drive iace Bushing ID. 20035 — 20.085 (0.7888 — 0.79071 20.13 (0.7931 Boss 0.0. 20010 — 20.025 (0.7878 — 078841 19.97 (0.786) Weight roller 0.0. 15.92—16.0310527—0033) 15.4 (0.611 Driven pulley Face spring face length 85.78 (3.3771 81.5 (3.21) Driven face 00. 33.930 — 33.930 (1.3358 — 1.3373) 33.70 (1.3271 Movable driven face LD. 34.015 — 34.035 (1.3392 — 1.34001 34.29 (1.3501 TORQUE VALUES Drive pulley face nut 32 N-m (3.3 kgf-m, 24Ibf-f11 Apply oil to thethreads and flange surface Clutch outer nut 39 N-m (4.0 kgf-m, 29 lbftftl 10-2 I 10-3 KlCKSTARTER/DRIVE PULLEV/DRIVEN PULLEV/CLUTCH TOOLS Universal holder 077250030000 Remover weight 0774170010201 Attachment, 22 x 24 mm 077460010800 Pilot, 12 mm 07746-0040200 CCJ Pilot, 17 mm 077460040400 ([5 Driver 0774970010000 Snap ring pliers 07914-SA50001 Remover handle 07936-3710100 Bearing remover, 17 mm 07936-3710300 Driver 07936-3710001 Clutch spring compressor 07LME7GZ40201 Puller attachment O7YMC-GC80100 10-4 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEV/CLUTCH TROUBLESHOOTING Engine starts but scooter won’t move 0 Worn drive belt - Damaged ramp plate - Worn or damaged clutch shoe 0 Broken driven face spring Engine stalls or scooter creeps - Broken clutch shoe spring Poor performance at high speed or lack of power I Worn drive belt - Weak driven face spring - Worn weight rollers . Contaminated pulley faces 10-5 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH BELT CASE COVER REMOVAL Remove the air cleaner housing bolt (page 653). Remove the bolts, clamp and belt case cover. w BELT CASE COVER f3 \\ V . ' Remove the rubber seal and dowel pins from the belt case cover, RUBBER SEAL INSTALLATION Check the rubber seal and replace it if necessary. Clean the rubber seal groove of the belt case cover. Install the dowel pins and the rubber seal to the belt case cover. Install the belt case cover to the belt case by align- ing the dowel pins with the holes. Install and tighten the belt case cover bolts and clamp in a crisscross pattern in two or three steps. Install the air cleaner housing bolt (page 6-53). KICKSTARTER DISASSEMBLY Remove the belt case cover (page 10-6)4 Remove the kickstarter driven gear by turning the kickstarter pedal clockwise. DRIVEN GEAR \ . 10-6 KICKSTARTER/ DRIVE PU LLEY/ DRIVEN PULLEY/CLUTCH When disassemr Remove the bolt and kickstarter pedal, blmg the kick- starter, mark the pedal position to ensure correct @557 Remove the snap ring and washer. semblv In yrs ongr TOOL: nal local/an . , Snap nng pllers 07914-SA50001 Release the hook and of the return spring from the belt case cover stopper. Remove the kickstarter spindle, return spring, collar and spindle bushing. INSPECTION Check the kickstarter spindle and spindle gear for wear or damage. SPINDLE SPRING Check the return spring for fatigue or damage. Check the collar and bushing forwear or damage. COLLAR é? BUSHING /~ Check the kickstarter driven gear and ratchet plate RATCHET PLATE for wear or damage. DRIVEN GEAR Check the friction spring for fatigue or damage. SPRING 10-7 KlCKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Check the 'ournals of the belt case cover for wear 0 - damage. J r JOURNALS ASSEMBLY KICKSTARTER PEDAL SPINDLE BUSHING COLLAR ll RETURN SPRING SNAP RING WASHER KICKSTARTER SPINDLE STARTER DH'VEN GEAR Install the spindle bushing and collar onto the belt case cover. GROOVE Install the return spring as shown. Apply molybdenum paste 0.2 — 0.5 g to the kick- starter spindle sliding surface. Install the kickstaner spindle to the belt case cover and hook the return spring end to the groove of the kickstarter spindle. 1 0-8 KICKSTARTER/DRIVE PULLEY/ DRIVEN PULLEY/CLUTCH Install the thrust washer and snap ring in the groove of the spindle. TOOL: Snap ring pliers o7914-SA50001 Hook the return spring end onto the stopper on the belt case cover. Install the kickstarter pedal to its original position as marked during removal. PEDAL Install and tighten the bolt securely. Apply molybdenum paste to the kickstarter driven gear journal and spring surface. Turn and hold the kickstarter pedal. Install the kickstarter driven gear, aligning the spring end with the groove of the belt case cover and the kickstarter gear with the driven gear. Install the belt case cover (page 1045). DRIVE PULLEY REMOVAL Remove the belt case cover (page 10-6l. DRIVE PULLEY FACE NUTNVASHER EELT Be carefu/notto Hold the drive pulley face with special tool and . ,i/ , damage the belt loosen the drive pulley face nut. case mating sur- face TOOL: Universal holder 07725-0030000 Remove the nut, washer, ratchet plate and drive pul- ley face. Remove the drive belt from the crankshaft. RATCHET PLATE UNIVERSAL H’BLDEJQ 1 0-9 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the movable drive face assembly while holding the back of the ramp plate. _ Remove the drive face boss from the movable drive face assembly. Remove the ramp plate and weight rollers. RAMP PLATE INSPECTION DRIVE BELT Check the drive belt for cracks, separation, abnor- mal or excessive wear. Measure the drive belt width. SERVICE LIMIT: 17.15 mm (0.68 in) DRIVE BELT WEIGHT ROLLER Check each roller for wear or damage. Measure the weight roller 0.D. WEIGHT ROLLER SERVICE LIMIT: 15.4 mm (0.61 in) KICKSTARTER/ DRIVE PULLEV/ DRIVEN PULLEY/CLUTCH MOVABLE DRIVE FACE Check the drive face boss for wear or damage. Measure the boss 0.D. SERVICE LIMIT: 19.97 mm (0.736 in) Measure the face bushing LD. SERVICE LIMIT: 20.13 mm (0.793 in) <— DRIVE FACE DRIVE FACE BOSS ASSEMBLY Clean any oil and grease from the pulley faces and weight rollers. RAMP PLATE WEIGHT ROLLER Install the weight rollers on the movable drive face. Install the ramp plate. INSTALLATION Clean any oil and grease from the pulley faces and the drive belt. Install the drive face boss into the movable drive face assembly, Install the movable drive face assembly onto the crankshaft while holding the ramp plate. Install the drive belt onto the drive face boss. Install the drive pulley face. ratchet plate. 10-10 KICKSTARTER/ DRIVE PULLEY/ DRIVEN PULLEY/CLUTCH Install the washer. Apply oil to the drive pulley face nut threads and seating surface, then install the nut. Hold the drive pulley face with the special tool and tighten the nut to the specified torque. TOOL: Universal holder 07725-0030000 TORQUE: 32 N-m (3.3 kgf-m, 24 lbf-ft) Install the belt case cover (page 1076). CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley [page 10-9). Hold the clutch outer with the special tool and loosen the clutch outer nut. TOOL: Universal holder 07725-0030000 Remove the nut and clutch outer. Remove the clutch/driven pulley assembly. Remove the drive belt from the driven pulley. DISASSEMBLY Set the clutch spring compressor onto the clutch/ driven pulley, aligning the bosses with the holes in the clutch. Hold the clutch spring compressor in a vise. TOOL: Clutch spring compressor CLUTCH SPRING COMPRESSOR 07LME-6240201 CLUTCH/DRIVEN PULLEY ASSEMBLY KlCKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH To prevent loss of Compress the clutch/driven pulley and remove the tens/an, do not stopper ring. compress the clutch spnng more ”WWW ACAUTION remove ihe Stop- Do not remove the special tool when the stop- pernng per ring is removed. If so, some parts may pop out. — STOPPER RING Install the gear puller or equivalent tool and special tool as shown. TOOL: Puller attachment 07YMC-GCSO100 Loosen the clutch spring compressor gradually and tighten the gear puller gradually. Repeat this procedure and remove the clutch assembly from the driven face. Remove the following: DRIVEN FACE SPRING CLUTCH - Clutch assembly ASSEMBLY , Spring collar — Driven face spring — Spring seat — Movable driven face — Driven face CLUTCH DISASSEMBLY Remove the E-clips and washers. Remove the clutch shoes and shoe springs. E-CLIPS/WASHERS SHOES SPRINGS 10-12 10-13 KICKSTARTERIDRIVE PULLEY/DRIVEN PULLEYICLUTCH Remove the rubber dampers from the drive plate. RUBBER DAMPERS ‘ DRIVE PLATE INSPECTION CLUTCH OUTER Check the clutch outer for wear or damage. Measure the clutch outer I.D4 SERVICE LIMIT: 107.5 mm (4.23 in) CLUTCH OUTER “ CLUTCH SHOE LINING Check the clutch shoe for wear or damage, Measure the thickness of each shoe. SERVICE LIMIT: 2.0 mm (0.08 in) CLUTCH SHOE DRIVEN FACE SPRING Measure the driven face spring free length. SERVICE LIMIT: 81.5 mm (3.21 in) ‘__-———-———> CLUTCH SPRING KICKSTARTER/ DRIVE PU LLEY/ DRIVEN PULLEY/CLUTCH DRIVEN FACE/MOVABLE DRIVEN FACE Check the driven face for scratches, scoring or dam— age. MOVABLE DRIVEN FACE Measure the driven face boss OD. SERVICE LIMIT: 33.70 mm (1.327 in) Check the movable driven face for scratches, scor- ing or damage. Check the guide grooves for stepped wear or dam- age. Measure the movable driven face I.D. SERVICE LIMIT: 34.29 mm (1.350 in) DRIVEN FACE DRIVEN FACE BEARING REPLACE- MENT R moveth ' ' th 'I‘ '- e esnaprlng usmg ESPSCIa 0° BEARING SNAP RING TOOL: Snap ring pliers 07914-SA50001 Remove the driven face needle bearing using the special tools. TOOL: Bearing remover, 17 mm 07936-3710300 Remover handle 07936-3710100 Remover weight 0774141010201 BEARING REMOVER Remove the snap ring, then remove the ball hear- ing. TOOL: Snap ring pliers 07914-SA50001 Apply grease to a new ball bearing. Press the ball bearing into the driven face with the DRIVER marked side facing up. TOOLS: Driver 07949-3710001 @fi Attachment. 22 x 24 mm o7745-oo1osoa ~‘ "fi‘ Pilot, 12 mm 07746-0040200 BALI- PEARING ATTACH MENT/PI LOT 10-15 KICKSTARTER/ DRIVE PULLEY/ DRIVEN PU LLEY/ CLUTCH Install the snap ring to the groove in the driven face securely. TOOL: Snap ring pliers 07914-SA50001 Apply grease to a new needle bearing. Press the needle bearing into the driven face with the marked side facing up. TOOLS: Driver 07745-0010000 Attachment, 22 X 24 mm 07746-001080!) Pilot, 17 mm 0774641040400 Install the snap ring to the groove of the driven face securely. TOOL: Snap ring pliers 07914-SA50001 DRIVER Iw rfil NEEDLE BEARING - DRIVEN FACE SNAP RING BALL BEARING ATTACHMENT SNAP RING KICKSTARTER/DRIVE PU LLEY/DRIVEN PULLEY/CLUTCH ASSEMBLY Clean any oil and grease from the pulley faces and clutch outer. E-CLIP CLUTCH SHOE SPRINGS WASHER LEI} ”fir NEEDLE BEARING RUBBER DAMPERS at! La“ BALL BEARING SNAP RINGS DRIVE PLATE DRIVEN FACE MOVABLE DRIVEN FACE SPRING SEAT SPRING COLLAR DRIVEN FACE SPRING Install the rubber dampers onto the drive plate. RUBBER DAMFEHS DRIVE PLATE Install the shoe springs into the clutch shoes as shown. LONG SHORT LONG SPRING 10-17 KlCKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH To plevenl‘ loss of tensron, do not compress the clutch spring more than necessary to install the stopper ring Be careful not to damage the Spline Install the clutch shoes assembly into the drive platet Install the washers and E-clips. E-CLIPS/WASHERS SHOES SPRINGS Assemble the movable driven face, spring seat and driven face. MOVABLE DRIVEN FACE DRIVEN FACE Install the driven face spring and spring collar. Install the clutch assembly while aligning the tab of the movable driven face with the hole of the drive plate. CLUTCH ASSEM BLY TAB COLLAR Set the clutch spring compressor over the clutch/ driven pulley assembly and compress the driven face spring. TOOL: Clutch spring compressor 07LME-GZIwZO1 “fin— CLUTCH/DRIVEN PULLEY ASSEMBLY Align the spline of the driven face with the spline of the drive plate while compressing the clutch spring compressor. CLUTCH SPRING COMPRESSOR KICKSTARTER/DRIVE PULLEY/DRIVEN PU LLEY/CLUTCH Install the stopper ring securely. _ STOPPER RING Remove the clutch/driven pulley assembly from the spring compressor. INSTALLATION Rotate the movable driven face clockwise and install the drive belt into the driven pulley, CLUTCH/DRIVEN PULLEY ASSEMBLY Do not get any oil and grease on the driven face ' inside. Install the clutch/driven pulley assembly onto the driveshaft. Clean any oil and grease from the inside of the clutch outer. Install the clutch outer and clutch outer nutt I-Iold the clutch outer with the special tool and tlghten the clutch outer nut to the specified torque. TOOL: Universal holder 077250030000 TORQUE: 39 MM (4.0 kgf-m, 29 lbf-ft) Install the drive pulley (page 10-11l. 10-18 10-19 11. FINAL REDUCTION MEMO COMPONENT LOCATIONS-n - 11-2 SERVICE INFORMATION ............................ 11.3 TROUBLESHOOTING .................................. 11.4 FINAL REDUCTION OIL-- FINAL REDUCTION DISASSEMBLY- -11—5 BEARING REPLACEMENT --------------------------- "-9 FINAL REDUCTION ASSEMBLY ---------------- 11-10 11-1 FINAL REDUCTION COMPONENT LOCATIONS FINAL REDUCTION SERVICE INFORMATION GENERAL 0 This section covers maintenance of the final reduction. I These services can be done with the engine installed in the frame. - When installing the drive shaft, be sure to use the special tool; position the special tool against the bearing inner race and pull the drive shaft into the bearing. SPECIFICATIONS ITEM SPECIFICATIONS Final reduction oil capacityrlat disassemblyl 0.1 liter (0.11 US gtfifla Imp qt] Recommended final reduction ail - _ Hypoid gear oil #90 TORQUE VALUES Final reduction oil check bolt 13 N-m (1.3 kgf-m, 9 lbf—ftl TOOLS Bearing remover weight Attachment, 32 x 35 mm 07741-0010201 Attachment, 37 x 40 mm 07746-0010100 07746-0010200 V K ’5 l C) ,, __ 0' \V t k / I \J/ \ , / Pilot, 12 mm Pilot, 17 mm 7 Driver 0774543040200 07746-0040400 0774970010000 11-2 11-3 FINAL REDUCTION U niversal bearing puller 0793174630000 rqf l of or equivalent commercially availr able Bearing remover set, 12 mm 079364660101 Bearing remover head,12 mm 079364660110 Bearing remover shaft 07936-1 6601 20 Assembly collar 07965-GM00100 Assembly shaft 07965‘GM00300 1, f , l- Case puller 07SMC-001000’l TROUBLESHOOTING Engine does start but scooter won't move I Damaged transmission - Seized transmission . Faulty drive and driven pulleys/clutchlpage10A3l Abnormal noise . Worn, seized or chipped gears 0 Worn or damaged transmission bearing Oil leak - Oil level too high - Worn or damaged oil seal 11-4 FINAL REDUCTION OIL LEVEL CHECK Make sure the final reduction case has no oil leaks. Support the scooter with its center stand on a level surface. Warm up the engine to normal operating tempera- ture, Remove the final reduction oil check bolt and check whether the oil flows out from the check bolt hole. If the level is low loil does not flow out), add the rec- ommended oil. RECOMMENDED FINAL REDUCTION OIL: Hypoid gear oil #90 Install the final reduction oil check bolt with a new sealing washer and tighten it to the specified torque. TORQUE: 13 N-m (1.3 kgf-m, 9 lhf-ftl FINAL REDUCTION DISASSEMBLY TRANSMISSION DISASSEMBLY Remove the following: - Clutch/driven pulley (page 10-12) — Rearwheellpage15-4l — Rear brake lpage15—5) Remove the air cleaner housing bolts. Remove the brake cable from the cable holder. f HOLDER FINAL REDUCTION BRAKE CABLE 11-5 FINAL REDUCTION Remove the seven bolts and hose clamp. _ It TRANSMISSION CASE Remove the transmission case and drain all oil to w ' the suitable container from the transmission case. Remove the dowel pins. Clean any sealant from the transmission case mat- ing surface. Remove the thrust washers and countershafl. COUNTERSHAFI' Remove the final gear shaft, counter gear and side washer. Clean the transmission case mating surface. FINAL GEAR SHAFT COUNTER 9 GEAR FINAL REDUCTION DRIVESHAFI' REMOVAL Remove the driveshaft using the special tool. TOOL: Case puller D7SMC-0010001 Remove the driveshafl oil seal and hearing If the bearing is left on the driveshah, remove it using the special tool. TOOL: Universal bearing puller 079314630000 or equivalent commercially available INSPECTION Remove the oil seal. Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the case. Remove and discard the bearing if the races do not turn smoothly and quietly, or if they fit loosely in the case. , BEARING DRIVESHAFT / OIL SEAL ll 11-6 11-7 FINAL REDUCTION Check the countershaft and final gear shaft sliding 1“ surfaces for wear or damage. FINAL GEAR SHAFT SLIDING SURFACE COUNTERSHAFT SHAFT SLIDING SURFACE Check the driveshaft. final gear shaft, countershaft COUNTER GEAR FINAL GEAR SHAFT l and counter gear for wear or damage. \ DRIVESHAFT COUNTERSHAFT Coat each gear teeth with oil. 11-8 FINAL REDUCTION BEARING REPLACEMENT DRIVESHAFT BEARING (6203) DRIVE SHAFT DRIVESHAFI' BEARING [6201] :( FINAL GEAR SHAFT BEARING (6203UUI j OIL SEAL FINAL GEAR SHAFT OIL SEAL Be Ca/sl‘ulnol to Remove the final gear shaft oil seal and bearing. ‘ ’ ,- , BEARING damage the trans- mlSSIDn case mat- ing surface Remove the driveshaft bearing using ihe special tools. TOOLS: Bearing remover set, 12 mm 079364660101 - Bearing remover head, 12 mm 07936-166011!) — Bearing remover shaft 079364660120 — Remover weight 07741-0010201 REMOVER HEAD 11-9 FINAL REDUCTION ASSEMBLY FINAL REDUCTION Drive new driveshaft bearing into the transmission case using the special tool. DRIVER TOOLS: Driver 07749-0010000 Attachment, 32 X 35 mm 077450010100 Pilot. 12 mm 07746-0040200 g :H BEARING ’ Dri 9 new final ear shaft bearin into the transmis- - s- v g g A'I'l'ACHMENT/ ,' DRIVER sion case using the special tool. a PILOT TOOLS: Driver 07748-0010000 Attachment, 37 X 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 g. )3 x :3! ;E BEARING Apply oil to a new final gear shaft oil seal lip and outer surface. Install the final gear shaft oil seal. Drive a new driveshaft bearing into the belt case using the special tools. TOOLS: Driver 0774941010000 Attachment, 37 X 40 mm 0774641010200 Pilot. 17 mm 07746-0040400 FINAL REDUCTION Install the drive shaft intn the belt case. Position the assembly collar against the driveshaft bearing inner race. ‘ Thread the assembly shaft onto the driveshaft. Hold the assembly shaft and draw the driveshaft into the bearing inner race by turning the nut. TOOLS: Assembly shaft 07965-GM00300 Assembly collar 07965-GM00100 Apply oil to a new driveshaft oil seal lip and outer surface. Install the driveshaft oil seal. Apply molybdenum grease 05 — 1.0 g to the counr tershaft sliding surface. Install the side washer, counter gear and final gear shaft into the transmission case. FINAL GEAR SHAFT SIDE WASHER COUNTER GEAR 11-11 FINAL REDUCTION Install the countershart into the transmission case. Install the thrust washers onto the countershaft and final gear shaft. Apply sealant to the transmission case mating sur- face as shown. install the dowel pins. Apply molybdenum grease 0.5 — 1.0 g to the noun 1 tershait sliding surface. ‘ Apply molybdenum grease 0.3 7 0.5 g to the final gear shaft sliding surface. Install the transmission case. COUNTERSHAFT Install the clamp, bolts and tighten them in a criss» cross pattern in two or three steps. Install the air cleaner housing and tighten the bolt securely. Install the brake cable through the cable holder. Install the following: — Rear brake (page 15-6l , Rearwheel (page 15-4) , Clutch/driven pulley (page 10-19) Fill the final reduction with the recommended final reduction oil (page 11-5). rHOLDER FINAL REDUCTION . '— ‘ TRANSMISSION CASE \i ‘ ,' . BRAKE CABLE ‘ 11-12 11-13 12. ALTERNATOR/STARTER W MEMO COMPONENT LOCATIONS ------------------------- 12—2 SERVICE INFORMATION ---------------------------- 12-3 ALTERNATOR/STARTER ............................. 12.4 12-1 ALTERNATOR/ STARTER ALTERNATOR/STARTER COMPONENT LOCATIONS SERVICE INFORMATION GENERAL - Always turn the ignition switch to “OFF“ beiore servicing the alternator/starter. The alternator/starter could suddenly start when the ignition switch is turned to "ON“, causing serious injury. - This section covers the removal and installation of the flywheel, alternator/starter and CKP sensorl - These services can be done with the engine installed in the frame. - Refer to page 16»9 for alternator/starter inspectionl TORQUE VALUES Flywheel nut 44 N-m (4.5 kgf—m, 33 Ibf-ft) 12 N-m (12 kgf-m, 9 HM) Stator bolts 12 N-m (1,2 kgf—m, 9 mm Radiator cooling fan bolt 7.8 N-m (0.8 kgf‘m, 5.8 lbf-ft) TOOLS Universal holder Flywheel puller 0772543030000 0773343010000 44 Nrm (4.5 kgf-m, 33 lbf—ft) 7.8 N-m (0.8 kgf‘m, 6.8 lbf-ft] is 12-2 12-3 Y R TA ER ALTERNATO IS RT ALTERNATOR/STARTER ALTERNATOR/STARTER Remove the flywheel using the special tool. REMOVAL { glee: I H . . yw ee pu er 077330010000 Remove the followrng. 6P (NATURAL 7 Floor step (page 3-7) ‘7 — Radiator (page 7-13) Disconnect the alternator/starter 6P (Natural) and SP (Brownl connectors. _‘F<:_\ \ Remove the wire band from the water pump stay. 3p (BROWN) CONNECTOR Remove the grommets from the crankcase groove. Release the wires from the wire bands. Remove the bolt and clamp. Remove the socket bolts and stator. Remove the three bolts and cooling fan. Remove the woodruff key from the crankshaft. INSTALLATION Clean any oil from the tapered portion of the crank- shaft and flywheel. Hold the flywheel with the special tool and loosen the flywheel nut. TOOL: Universal holder 07725-0030000 Install the woodruff key in the crankshaft key groove. Remove the flywheel nut and washer. FLYWHEEL N NVASHER 1 2-4 1 2-5 ALTERNATOR/STARTER ALTERNATOR/ STARTER Install the stator aligning the its groove to the pin on the stator base. Install and tighten the socket bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf—m, 9 lbf-fl) Install the wire clamp properly as shown. Route the alternator/starter wires under the guide of the stator base. Tighten the bolt securely. Install the grommet to the crankcase groove prop- erly. Install the wire band to the water pump stay. Clean any oil from the tapered portion of the flvr wheel |.D. Install the flywheel onto the crankshaft, aligning the key way with the woodruff key. Before lnstalllng the flywheell check that no nuts or bolts are magnetically attached to the flywheel. Install the washer and flywheel nut. Hold the flywheel with the special tool and tighten ’ the flywheel nut to the specified torque. TOOL: Universal holder 07725-0030000 TORQUE: 44 NM (4.5 kgf-m, 33 lbf-ft) Install the cooling fan and tighten the bolts to the specified torque. TORQUE: 7.8 N-m (0.3 kgf-m, 5.8 lbf-I‘t) Route and clamp the alternator/starter wire properly (page 145). Connect the alternator/starter 3P (Brown) and GP INaturaI) connectors, Installthe following: — Radiator (page 745) — Floor step (page 3-7) 12-7 MEMO 13. CRANKSHAFT/PISTON/CYLINDER COMPONENT LOCATIONS- - 13-2 CRANKCASE SEPARATION- SERVICE INFORMATION - 13-3 CRANKSHAFT/PlSTON-m -----13-6 13-4 CRANKCASE ASSEMBLY-u- TROUBLESHOOTING ---------- 13-1 CRANKSHAFT/PlSTON/CYLINDER COMPONENT LOCATIONS 25 Nm (2.5 kgf-m,18|bf-ft) we“ IL 1 CRANKSHAFI'IPISTON/CYLINDER SERVICE INFORMATION GENERAL ' This section covers the crankcase separation to service the crankshaft, piston and cylinder. - The following parts must be removed before separating the crankcase. — Oil pump (page 5-4) — Water pump (page 7-8) — Throttle body (page 6-55) — Engine (page 874) — Cylinder head (page 9-10) , Drive pulley (page 1079) , Alternator/Starter (page 124) ' Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves. ' Take care not to damage the cylinder wall and piston. - Clean all disassembled pans with clean solvent and drythem using compressed air before inspection. SPECIFICATIONS Unit: mm (in) ITEM l STANDARD SERVICE LIMIT Crankshaft iConnecting rod side clearance 0.10 , 0.40 (0.004 , 0.016) 0.60 (0.024) Connecting rod radial clearance 0.004 770.016 (0.0002 — 0.0006) 0.05 (0.002) Runout , 0.10 (0.0039) Cylinder |.D. 38.000 — 38.010 (1.4900 — 1.4964) 38.04 (1.4966) Tuber-round ~ 0.05 (0.002) Taper , 0.0501002) Warpage , 0.05 [0.002) Piston, Piston O.D. 37.975 ~37995 (1.4951 — 1.4959) 37.92 (1.493) DISK)” ring. fiPiston 0.0. measurement point 10 mm (0.39 in) from bottom of skin — piston Pl" Piston pin bore I.D. 10.002 ~ 10.008 (0.3938 — 0.3940) 10.04 (0.395) Piston pin O.D. 9.994 a 10.000 (0.3935 — 0.3937) 9.98 (0.393) Pistonvto-piston pin clearance 0.002 — 0.014 (0.0001 A 0.0006) 0.04 (0.002) Piston ring-to-ring Top 0.015 — 0.045 (0.0006 —- 0.0018) 0.08 (0.003) groove clearance Second 0.015 — 0.050 (0.006 — 0.0020) 0.08 (0.003) Piston ring end gap Top 005 — 0.15 (0.002 — 0.006) 0.40 (0.016) Second 0.05 — 0.17 (0.002 — 0.007) 0.40 (0.015) Oil (Side rail) 0.10 — 0.60 (0.004 — 0.024) 0.80 (0.031) Cylinder-torpiston clearance 0.005— 0.035 (0.0002 — 0.0014) 0.08 (0.003) Connecting rod small end ID. 10013 — 10.028 (0.3942 — 0.3948) 10.05 (0.396) Connecting rodrto-piston pin clearance 0.013 — 0.034 (0.0005 — 0.0013) 0.06 (0.002) TORQUE VALUES Crankcase bolt 12 Nm (1.2 kgf-m, 9 Ibf-ft) Apply oil to the threads and seating surface 6v“ ith/ (“w a?“ g. of/ ‘ (i (3\_fl W! :l'ER'c new 1' at; \ (f((((((((((( Engine oil drain bolt 25 N-m (2.5 kgfvm, 18 lbf-ft) id 12 N-m (1.2 kgf-m, 9 Ibf-ft) .., 13-2 13-3 F" ORANKSHAFT/PlSTON/CYLINDER TROUBLESHOOTING Compression too low, hard starting or poor perlormance at low speed - Worn, stuck or broken piston ring 0 Worn or damaged cylinder and piston - Cylinder head/valve problem (page 9-3) Compression too high, overheating or knocking - Excessive carbon build»up on piston head or on combustion chamber Excessive smoke - Worn cylinder, piston or piston ring 0 Improper installation of piston rings - Scored or scratched piston or cylinder wall - Cylinder head/valve problem (page 9-3) Abnormal noise 0 Worn piston pin or piston pin hole - Worn connecting rod small end - Worn cylinder, piston or piston rings - Worn crankshaft bearing - Worn connecting rod big end bearing 13-4 CRANKSHAFT/PlSTON/CYLINDER CRANKCASE SEPARATION Remove the engine from the frame (page 874). Remove the following: — Cylinder head/cam chain (page 9710) — Oil pump (page 54) r Drlve pulley (page 10-9) Remove the cam chain from the timing sprocket. Remove the water hose from the crankcase. WATER HOSE Remove the four bolts and belt case. Remove the rubber seal. Remove the four bolts and center stand from the crankcase. CENTER STAND A 13-5 CRANKSHAFT/PISTON/CYLINDER Remove the drain bolt and sealing washer. Loosen the crankcase bolts in a crisscross pattern in two or three steps. Remove the crankcase bolts. CRAN KCASE BOLTS Be carefu/notto Place the front crankcase facing down and separate damage the crank— the front and rear crankcase halves. case mating sur— , face, Remove the dowel pins and oil seal. . DOWEL PINS Clean any sealant from the crankcase mating sur» face, CRANKSHAFT/ PISTON CRANKSHAFT REMOVAL fig‘g’arate the front and rear crankcase halves (page SGS Remove the crankshaft and piston from the front crankcase. Remove the set rings. W, has allot: PISTON REMOVAL Remove the piston pin clips with pliers. Remove the piston pin out of the piston. PISTON PIN PISTON \ \ 13-6 Do not damage the Spread each piston ring and remove them by lifting piston ring by up at a point opposite the gap. spreading the ends too far. Neverusea Wire Clean carbon deposits from the ring grooves with a brush, it Wi/i scratch ring that will be discarded. the glaove. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance With a feeler gauge. SERVICE LIMIT: 0.60 mm (0.024 in) Set the crankshaft on V-blocks and read the runout points as shown, using a dial indicator. Actual runout is 1/2 of total indicator reading. SERVICE LIMIT: 0.05 mm (now in) CRANKSHAFT/PISTON/CYLINDER PISTON RING ‘ ’ PISTON RING H1733 ‘ FEELER GAUGE CRANKSHAFT 13-7 CRANKSHAFT/PISTON/CYLINDER Turn the outer race of the crankshaft bearings with your finger. The bearing should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the crankshaft. Replace the crankshaft assembly if the bearings do not turn smoothly, quietly, or if they fit loosely on the crankshaft. Set the crankshaft on a turning stand or V-blocks and measure the runcut using a dial indicator. SERVICE LIMIT: 0.10 mm (0.0039 in) Check the timing sprocket teeth for wear or damage. PISTON/CYLINDER INSPECTION Inspect the piston rings for movement by rotating the rings. The rings should be able to move in their ‘ grooves without catching. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring»to»groove clearance. SERVICE LIMITS: Tap: 0.08 mm (0.003 in) Second: 0.08 mm (0.003 in) BEARING 50 mm 55 mm - TIMING SPROCKET PISTON RING PISTON ’ FEELER GAUGE Insert each piston ring into the bottom of the cylin- der squarely using the piston. Measure the ring end gap. SERVICE LIMITS: 0.40 mm (0.016 in) 0.80 mm (0.031 in) Measure the piston pin bore |.D. Take the maximum reading to determine I.D. SERVICE LIMIT: 10.04 mm (0.395 in) Measure the piston pin CD. at piston and connect- ing rod sliding areas. SERVICE LIMIT: 9.98 mm (0.393 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.04 mm (0.002 in) Measure the connecting rod small end I.D. SERVICE LIMIT: 10.05 mm (0.396 in) Calculate the connecting rod-torpiston pin clear- ance. SERVICE LIMIT: 0.06 mm (0.002 in) Measure the piston O.D. at the point 10 mm (0.39 in) from the bottom of skirt and 90° to the piston pin hole. SERVICE LIMIT: 3192 mm (1.493 in) Calculate the cylinder-to-piston clearance (cylinder l.D.: see below). SERVICE LIMIT: 0.08 mm (0.003 in) ORANKSHAFT/PISTON/CYLINDER .1 PISTONRING 7, mm 10 mm (0.39 in) 13-8 13-9 CRANKSHAFT/PISTON/CYLINDER Inspect the cylinder bore for wear or damage. Measure the cylinder ID. in the X and Y axes at three levels. Take the maximum reading to determine the cylin» der wear. SERVICE LIMIT: 30.04 mm (1.4966 in) Calculate the taper and out-of»ruur\d at three levels in the X and V axes. Take the maximum reading to determine both measurements. SERVICE LIMITS: Taper: 0.05 mm (0.002 in) Out-of-round: 0.05 mm (0.002 in) TOP MIDDLE BOTTOM Check the cylinder for warpage with a straight edge 711‘ and feeler gauge in the directions shown. ’ SERVICE LIMIT: 0.05 mm (0.002 in) Be careful not to damage the piston and rings. Be carefu/ not to damage the crank case matlflg sure race. CRANKSHAFI'IPISTON/CYLINDER PISTON INSTALLATION Coat the piston and each piston ring with oil. Carefully install the piston rings into the piston ring grooves with their markings facing up NOTE: ' Do not confuse the top and second rings. 0 To install the oil ring, install the spacer first, then install the side rails. Stagger the piston ring end gaps 120 degrees apart from each other. Stagger the side rail end gaps as shown. TOP RING SECOND RING Apply engine oil to the connecting rod small end, " .. piston pin and piston pin bore. IN MARK Install the piston with the "IN" mark facing the intake side. Install the piston pin and new piston pin clips. NOTE: O Make sure the piston pin clips are seated securely. 0 Do not align the piston pin clip end gap with the piston cutrout. CRANKSHAFT INSTALLATION Clean the insides of the crankcases and check for cracks or other damage. Clean the crankcase mating surface. Dress any minor roughness or irregularities with an oil stone if necessary. Install the set rings into the crankcase grooves. PISTON SET RINGS 13-10 13-11 CHANKSHAFT/PISTON/CVLINDER CRANKCASE ASSEMBLY Apply engine oil to the connecting rod big end hear- ing (3 cmzl, crankshaft main journal bearings (2 cm3 each), cylinder wall, piston and piston ring outer surface. Install the piston with the "IN" mark facing the intake side while compressing the piston rings with your fingers. Align the crankshaft bearing grooves with the set rings. While installing the piston, being careful not to damage the top surface of the cylinder, especially around the cylinder bore. Apply oil to a new crankshaft oil seal lip and outer surface. Install the crankshaft oil seal until it is flush with the crankcase surface. Install the dowel pins into the front crankcase. Apply sealant to the rear crankcase mating surface as shown. Install the rear crankcase over the front crankcase. DOWEL PINS FRONT CRANKCASE _ . 13-12 Apply engine oil to the crankcase bolt threads and seating surfaces. Install the bolts and tighten them in a crisscross pat- tern in two or three steps. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) Install a new sealing washer and drain bolt. Tighten the drain bolt to the specified torque. TORQUE: 25 N-m (2.5 kgf-m, 18 lbi-ft) Install the center stand, bolts and tighten the bolts securely. Clean the belt case mating surface of the crankcase. Install a new rubber seal onto the crankcase. Install the belt case and tighten the bolts securely. GRANKSHAFI'IPISTON/CYLINDER '75 CRANKCASE BOLTS (‘9 WASHER/ ‘ DRAIN BOLT ““k ‘ CENTER STAND 13-13 GRANKSHAFI'IPISTON/CYLINDER 14. FRONT WHEEL/BRAKE/SUSPENSION/STEERING Connect the water hose, Apply oil to the cam chain and inslall it to the timing sprocket securely. Install the following: - Drive pulley (page 10-11) — Oil pump (page 5-7) - Cylinder head/cam chain (page 9719) Install the engine into the frame (page 8—7). WATER HOSE IMING SPROCKET COMPONENT LOCATIONS ......................... 14.2 FRONT BRAKE ............................................ 14.10 SERVICE INFORMATION ............................ 14.3 FORK ........................................................... 14.14 TROUBLESHOOTING ---------------------------------- 14-5 HANDLEBAR--~ ---14-1s FRONT WHEEL ............................................ 14.5 STEERING STEM ........................................ 14.23 13-14 14-1 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WH EEL/BRAKE/SUSPENSION/STEERING COMPONENT LOCATIONS SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health. 0 Avoid breathing dust particles. ' Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. I This section covers the front wheel, fork, handlebar, brake and steering. I When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist. I Use only tires marked “TUEELESS” and tubeless valve stems on rims marked “TUBELESS TIRE APPLICABLE". . Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth A , 0.8 (0.03) Cold tire pressure 175 kPa (1.75 kgf/cmz, 25 psi) , Axle runout — 0.20 (0.008) Wheel rim Radial * ~ 72.0 (0.08) runout Axial — 2.0 (008) Brake Front brake lever free play 10 — 20 (3/8 , 13/16) — Brake drum |.D. 95.0 (3.74) 95.5 (3.76) “Fork spring free length V 125;? (4.96) : TORQUE VALUES 39 Nm 14-0 kgf-m, 29 IN“) Front axle nut 44 Nm (4.5 kgf-m, 33 lbf-l‘t) U~nut Front brake arm bolt 6.0 N-m (0.62 kgf-m, 4.5 Ibf-ft) FrontJrear brake lever pivot bolt 1.0 N~m (0.11 k f-m, 0.8 Ibf-lt) 44 N'"‘ ”'5 kgf'm’ 33 ”3”” Front/rear brake lever pivot nut 52 N-m (0.53 kggl-m, 3.8 let) Handlebar post nut 39 Nvm (4.0 kgf-m, 29 lbf‘ft) U-nut Steering stem lock nut 69 N-m (7.0 kgI-m, 51 lbf-It) l 14-2 14-3 FRONT WHEEL/BRAKE/SUSPENSION/STEERING TOOLS Bearing remover shaft 07746~0050100 Bearing remover head, 10 mm 07746-0050200 Pilot, 1!) mm 07748-0040100 8 Attachment, 28 x 30 mm 079464870100 Driver 07749-0010000 Socket wrench, 32 mm 07916-KM10000 /\ Fork seal driver, 27 mm 079474180001 Adjustable bearing remover set 07JAC-PH80000 /' Remover head 07JAC-PH80100 Remover shaft 07JAC-PH800200 Remover weight 07741-0010201 Lock nut wrench, 45 x 54 mm O7SMA7GBC0100 L: .7177 14-4 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Installer shaft Stem race installer, 26 x 47 mm 07VMF—K230200 O7XMF—GEE0100 / Stem race installer, 29 x 50 mm D7XM F-GEE 200 TROUBLESHOOTING Hard steering ‘ Steering top cone race too tight I Faulty steering head bearing ' Bent steering stem ' insufficient tire pressure O Faulty tire Steers to one side or does not track straight - Bent fork - Bent axle - Wheel installed incorrectly - Bent frame 0 Worn wheel bearings ' Worn or damaged engine mounting bushings (page 8—2) Front wheel wobbles - Bent rim - Worn or damaged front wheel bearings Front wheel hard to turn - Faulty wheel bearings . Brake drag (page 1440) - Bent front axle Soft suspension . Weak fork spring I Low tire pressure Suspension noisy - Loose fork fasteners I Faulty front fork Poor brake performance - Incorrect adjustment of brake lever - Contaminated brake shoes 0 Worn brake shoes I Worn brake cam ° Worn brake drum 14-5 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WHEEL REMOVAL Loosen the front axle nut. Disconnect the speedometer cable from the brake panel by pushing the cable tab. Remove the O-ring from the speedometer cable. Remove the adjusting nut and brake cable from the joint pin and cable holder. Remove the joint pin from the brake arm. Support the scooter securely using a hoist or equiv- alent and raise the front wheel off the ground. Remove the front axle nut. Remove the front axle, side collar and front wheel. Remove the brake panel from the left side of the wheel. Refer to page 14-10 for brake panel disassemblv. — SPEEDOMETER CABLE Replace the wheel bearings in pairs FRONT WH EEL/BRAKE/SUSPENSION/STEERING INSPECTION AXLE Place the axle in V»b|ocks and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) WHEEL Check the rim runout by placing the wheel in a turn- ing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. DISASSEMBLY Remove the dust seal. WHEEL BEARING ‘ w\ DUST SEAL l 1 4-6 1 4-7 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Replace the wheel Install the bearing remover head into the bearing. bearings ln pairs. From the opposite side of the wheel, install the Do not reuse old bearing remover shaft and drive the bearing out of bearings the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover shaft 07746-0050100 Bearing remover head, 10 mm 07746-0050200 ASSEMBLY gm? ,6»: DUST SEAL DISTANCE COLLAR Q”: E BEARING lszooui Pack the new bearing cavities with grease. Drive a new left bearing (brake drum side) squarely with the sealed side facing up until it is fully seated. Install the distance collar. Drive a new right bearing squarely with the sealed side facing up until it is fully seated using the spe- cial tools. TOOLS: Driver 07749-0010000 Attachment, 28 X 30 mm 079464370100 Pilot, 10 mm 0774643040100 6:5 REMOVER HEAD ~a r-fiii BEARING [6200U) A'l'l'ACHMENT/ PILOT DRIVER . 2W ,6“ ‘~ BEARING Route the cable properly FRONT WHEEL/BRAKE/5USPENSION/STEERING Apply grease to new dust seal lips. -‘fi DUSTSE @@ ./ AL Install the dust seal into the left wheel hub until it is flush with the wheel hub. INSTALLATION Install the brake panel aligning the tabs of the speedometer gear with the grooves of the wheel BRAKE PANEL hub. Install the front wheel between the fork legs align- Ing the brake panel groove with the left fork leg tab. Install the color and front axle from the right side. Install the axle nut and tighten it to the specified torque. TORQUE: 44 NM (4.5 kgf-m. 33 lbf-ft) —COLOR _AXLE NUT Install the joint pin into the brake arm. Connect the brake cable through the cable holder to BRAKE CABLE thejoint pin and install the adjusting nut. HOLDER ADJUSTING NUT 1 4-8 14-9 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Coat a new O-ring with oil and install it on the speedometer cable. {Mt - m.— SPEEDOMETER CABLE Connect the speedometer cable into the brake panel by aligning the tab of the speedometer cable with the hole of the brake panel. Adjust the from brake lever free play (page AM 3). FRONT BRAKE REMOVAL Remove the brake panel from the front wheel (page 14-6). INSPECTION Measure the front brake drum I.D. SERVICE LIMIY: 95.5 mm (3.76 in) DISASSEMBLY NOTE 0 Always replace the brake shoes as a set. - Mark all parts during disassembly so they can be placed back in their original locations. Remove the brake shoes and springs by spreading the brake shoes. BRAKE SHOES 14-10 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ' Remove the dust seal and speedometer gear. DUST SEAL SPEEDOMETER GEAR Remove the bolt, nut and brake arm. BRAKE ARM Remove the wear indicator plate and return spring. INDICATOR PLATE RETUFlN SPRING Remove the felt seal. ‘ Remove the brake earn from the brake panel. BRAKE éAM FELT SEAL 14-11 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY 6.0 N-m (0.62 kgf-m. 4.5 Ibf-ft) : E FELT SEAL (DAPHNE EPONEX No.0 0R fl EQUIVALENT) SPEEDOMETER GEAR (DAPHNE EPONEX No.0 4°: @ OR EQUIVALENT) DUST SEAL / SHOES BRAKE ARM INDICATOR PLATE RETURN SPRING E (DAPHNE EPONEX No.0 0R ‘ EQUIVALENT) I I I I I (DAPHNE EPONEX No.2 rfii on EQUIVALENT) BRAKE CAM Apply grease (Daphne eponex No.2 or equivalent) to the brake cam. Install the brake cam into the brake panel. BRAKE CAM Apply oil to the felt seal and install it to the brake BRAKE CAM cam. FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the return spring, aligning its end with the brake panel hole as shown. INDICATOR PLATE Install the wear indicator onto the brake cam by aligning its wide tooth with the wide groove of the brake cam. Install the brake arm by aligning the punch marks on the brake arm and brake cam. Install the brake arm pinch bolt and nut as shown and tighten the bolt to the specified torque. TORQUE: 6.0 N-m (0.62 kgf-m, 4.5 lbf-ft) Apply grease (Daphne eponex No.0 or equivalent) to the speedometer gear and pinion gear sliding surface. Install the speedometer gear. Apply grease (Daphne eponex No.0 or equivalent) to a new dust seal lip and install it into the brake panel, Apply grease to the anchor pin and brake cam slid- ing surfaces. 14-12 14-13 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Measure the fork spring free length. SERVICE LIMIT: 125.9 mm (4.96 in) ASSEMBLY E : BEARING GREASE CLASS 2 GRADE 3 (CHUKYOU KASEll fi FORK SPRING OR EQUIVALENT RUBBER STOPPER (RIGHT SIDE ONLY) @ffim BOTTOM CASE DUST SEAL r \\ ®\ FORK CAP “L SNAP RING O DUST SEAL SNAP RING \ GUIDE BUSHING I 1 REBOUND SPRING FORK TUBE ,fii 1.5 , 2.0 9 Apply 6.5 — 8.0 g of grease (Bearing grease class 2 grade 3 or equivalent) to the following parts. FORK TUBE , rebound spring rfiI — guide bushing inner surface REBOUND SPRING ,& GUIDE BUSHING fl FRONT WHEEL/BRAKE/SUSPENSION/STEERING RIghtS/de only Install the rubber stopper into the bottom case as shown, BOTTOM CASE Apply grease (Bearing grease class 2 grade 3 or equivalent) to the fork spring tightly wound end. RUBBER STOPPER (RIGHT SIDE ONLY) Install the rebound spring and guide bushing to the fOrk kube, BOTTOM CASE GUIDE BUSHING Install the fork tube into the bottom case. REBOUND SPRING FORK TUBE/V Press the fork tube into the bottom case until the snap ring groove is visible. SNAP RING Install the snap ring into the groove in the bottom 1. 5 z. Dg case. Fill up the bottom case inside with grease (Bearing grease class 2 grade 3 or equivalent) 1.5 — 2.0 g. Coat a new dust seal lip with grease lBearing grease class 2 grade 3 or equivalent) and install it into the g'fi DUST SEAL bottom case. Install the fork cap. FORK CAP FORK SP Install the fork spring with the tapered end facing RING up. 14-16 14-17 FRONT WHEEL/BRAKE/5USPENSION/STEERING Route the cables proper/v HANDLEBAR INSTALLATION Install the set plate and cable guide when they are removed. Install the fork into the steering stern and align the groove of the fork tube with the upper bolt hole of the stem, then install the upper pinch bolt. Tighten the fork pinch bolts securely. Install the front wheel (page 14-9). 4mm um. UPPER FORK PINC BOLTS REMOVAL Remove the inner cover lpage 3-5). 9P (NATURAL) 2P (RED) Disconnect the front and rear brake light switch con- CONNECTOR CONNECTOR nectors. Disconnect the right and left handlebar switch 2P (Redl and 9? (Natural) connectors. Remove the speedometer (page 194 0]. Remove the wire bands and rearview mirrors. Loosen the front brake adjusting nut. Remove the dust cover. Remove the front brake lever pivot nut and bolt. Disconnect the brake cable from the brake lever and remove the lever. PIVOT NUT/BOLT DUST COVER BRAKE LEVER BRAKE CABLE \ FRONT WHEEL/BRAKE/SUSPENSION/STEERING Loosen the throttle cable lock nut. SWITCH/THROTTLE HOUSING Remove the screws and right handlebar switch! throttle housing. LOCK NUT Disconnect the throttle cable from the throttle pipe. Remove the throttle cable from the lower housing. THROTTLE CABLE THROTTLE PIPE LOWER HOUSING Loosen the rear brake adjusting nut. Remove the dust cover. BRAKE CABLE PIVOT NUT/BOLT Remove the rear brake lever pivot nut and bolt. " Dlsconnect the brake cable from the brake lever and remove the lever. DUST COVER BRAKE LEVER l SCREWS Remove the screws and left handlebar switch hous- Ing. SWITCH HOUSING 14-18 14-19 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the handlebar post nut cap, nut, bolt, set- ting collar and handlebar post from the steering stem, CAP/NUT INSTALLATION ‘ Route the times Install the handlebar post to the steering stem. and cab/95 WWW Install the bolt, setting collar and nut. Tighten the nut to the specified torque. TORQUE: 39 N-m (4.0 kgf-m, 29 Ibf-ft) , Install the nut cap. l If the handlebar grips were removed, apply Honda Bond Aor Honda Hand Grip Cement (U.S.A. only) to ‘ the inside of the grip and to the clean surfaces of the throttle pipe and left handlebar. Allow the adheslve Wait 3 - 5 minutes and install the grip. _ to dry for 1 hour Rotate the grip for even application of the adheslve. before uslng. Install the left handlebar switch housing aligning its locating pin with the hole of the handlebar. A. HANDLEBAR POST / FRONT WHEEL/BRAKE/SUSPENSION/STEERING Tighten the forward short screw first, then the rear long screw. SCREW (SHORT) SWITCH HOUSING SCREW lLONG) Install the brake cable and dust cover as shown. BRAKE CABLE DUST COVER Connect the brake cable to the rear brake lever. Apply grease to the brake lever pivot bolt sliding PIVOT NUT/ surface. Install the rear brake lever by tightening the pivot bolt and nut to the specified torque. TORQUE: Brake lever pivot bolt: 1.0 N‘m (0.11 kgl-m, 0.8 Ibi-fll Brake lever pivot nut: 5.2 N-m (0.53 kgl-m, 3.8 Ibf-ftl install the dust seal securely. Apply grease to the throttle cable end. Install the throttle cable to the lower housing. nghtly tighten the throttle cable lock nut. Apply grease to the sliding surface of the throttle plpe. Install the throttle pipe to the handlebar. Connect the throttle cable end to the throttle pipe. \ LOCK NUT LOWER HOUSING 14-20 14-21 l —l FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WHEEL/BRAKE/SUSPENSION/STEERING r r n th ‘ ht handlebar switch/throttle housing III-mm Connectthe right and left handlebar switch ZPIRed) ariisgzing i‘tasrllogcating pin with the hole of the handle- SWITCH/THROWLE and BF (Natural) connectors. 9P (NATURALI 2p (RED) ban [HOSING > r Connect the front and rear brake light switch cone CONNECTOR CONNECTOR nectors. Install the inner cover (page 35). Adjust the front and rear brake lever free play (page 4-13). Adjust the throttle grip free play (page 44). PIN/HOLE :;?:\;en the forward short screw first, then rear long SCREW ILONGI SWITCH/THROTTLE STEERING STEM - HOUSING REMOVAL Remove the following: “Alum — Front wheel (page 14-5) ' ' CAELE GU'DE * Fork (page 1444) “ x r Handlebar (page 1418) Remove the fork lower pinch bolts and cable guide. SCREW (SHORT) Apply grease to the pivot screw sliding surface. BRAKE CABLE Connect the brake cable to the front brake levers LOWER PINCH BOLTS Install the brake lever by tightening the pivot screw and nut to the specified torque. PIVOT NUT/ SCREW TORQUE: ‘ Brake lever pivot bolt: 11) N-m (0.11 kgf-m, 0.8 lbf-ft) Remove the bolts and front fender, Brake lever pivot nut: 5.2 N-rn (0.53 kgf-m, 3.3 Ith) Install the dust cover securelyt BRAKE LEVER DUST COVER \ Home the Wires Install the wire ba nds. and cables properly Install the rearview mirrors. HEARVlEW M‘RRORS FRONT FENDER Install the speedometer (page 19-10l. Remove the stem cover. STEM COVER WIRE BANDS 14-22 14_23 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the steering stem lock nut using the special tool. TOOL: Socket wrench, 32 mm 07916-KM10000 Remove the lock washer. Loosen the top cone race using the special tool. TOOL: I Look nut wrench, 45 X 54 mm 07SMA—GBCD100 Hold the steering stern and remove the steering top cone race, Remove the upper bearing: Remove the steering stem and lower bearing. LOCK NUT - ' ’ LOCK WASHER STEERING STEM k — ” SOCKET WRENCH UPPER BEARING Always replace the bearings and races as 5 ser FRONT WHEEL/BRAKE/SUSPENSION/STEERING BEARING REPLACEMENT Remove the upper/lower bearing outer races using the special tools. TOOLS: Adjustable bearing remover set 07JAc-PH80000 -Remover head 07JAc-PH80100 —Remover shalt 07JAC-PH80200 -Remover weight 0774141010201 Install a new lower bearing outer race using the spe— cial tools as shown. TOOLS: Stem rac nstaller, 26 X 47 mm 07XMF-GEE01OO Stern race installer, 29 X 50 mm D7XMF-GEE0200 Installer shaft 07VMF-K230200 Install a new upper bearing outer race using the special tools as shown. TOOLS: Stem race installer, 26 X 47 mm 07XMFl-T-H— su/v wm aum my filBu Isumou swrrcn win wlslm/v alw a V am “21”" ”‘5” m e . 1 LL C lei—fl -7l Ls—P‘F—EIL‘ %— R/BI E— R Bu/V Wu: 6 HIV R/Bn STARTERRELAV FUSE ISA FUSE m may BRAKE LIGHT swncu FusE 15A BI tg— Buy 2 } aArrEm 7 —— we ——0/ snRrEn swrrcn ALTERNATOR/STARTER ELECTRIC STARTER SERVICE INFORMATION GENERAL - Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is turned to “ON" and current is present. When servicing the electric starter, always follow the steps in the troubleshooting sequence on (page 18-4). This scooter has adopted an alternator/starter that functions like both an alternator and starter motor. A weak battery may be unable to turn the starter quickly enough, or supply adequate ignition current. For the alternator/starter removal/installation, See page 124. Refer to page 18-6 to check the stator and main relay. Refer to page 19-16, page 19-18 and page 19»18to check the ignition switch, starter switch and brake light switch, TOOLS ECM test harness Test probe 070M27GEV0100 D7ZAJ-RDJA110 $33 18-2 18-3 ELECTRIC STARTER TROUBLESHOOTING Alternator/Starter does not turn (Flywheel does not: turn) 1. Fuse Inspection Check for a blown main fuse (20A) and sub fuses (15Al. ls either fuse blown? ves — Replace the fuse. NO — GO TO STEP 2. . Battery Inspection Check if the battery is fully charged and is in good condition. Also check that there is no loose termir nals or connections. Is the battery in good condition? VES — GO TO STEP 3. NO — Fully charge or replace the battery. . Starter Relay Operation Check With the ' nition switch turned to "ON", squeeze the brake lever, push the starter switch and check for a ' lic ' sound from the starter relay. Is a "Click" heard? VES — GO TO STEP 4. N0 — GO TO STEP 9, BatteryGround Circuit Inspection Check the battery ground circuit at the ECM (page 16—8). Check for continuity between the Green wire terminals of the wire harness and body ground. Dues continuity exist? VES — GO TO STEP 5. NO — Open circuit in the Green wire between the ECM 5P (Black) and ZIP (Black) connectors and battery. . Stator Coil Inspection Check the stator coil resistance at the ECM side (page 16-9l. Is the resistance held Within the standard? YES — GO TO STEP 6. NO — ' Open circuit in the Red/Yellow, Red/Blue and RedNVhite wires between the ECM 5P (Black) connector and alternator 3P (Brown) connector. ' Faulty stator coil. ' Loose or poorly connected stator related connector. . Starter Relay Circuit Inspection Inspect the starter relay circuit at the ECM (page 1876i Is the starter relay circuit in good condition? VES - GO TO STEP 7. NO ~ ' Open circuit in the Red wire between the ECM 5P (Black) connector and starter relay. . Starter Relay Inspection Check the operation of the starter relay (page 1876). Is the starter relay in good condition? VES — I GO TO STEP 8. (if from step 6) I GO TO STEP 10. (if from step 9) N0 — Faulty starter relay. 18-4 ELECTRIC STARTER B. CKP Sensor Circuit Inspection Inspect the CKP sensor circuit at the alternator/starter 6P (Naturall connector side (page 18-8). Does continuity exist.7; Is the voltage normal? N0 — 0 Open circuit in the Green wire between the alternator/starter 6P (Natural! connector and ground. - Open circuit in the Brown/Vellow, White/Red, White/Green and White/Black wires between the alternator/starter 6P1Naturallconnector and ECM ZIP (Gray) connector. 0 Faulty ECM. VES — Faulty angle sensor (replacement of stator assembly required). 9. Starter Switch Circuit Inspection Inspect the starter switch circuit at the ECM side (page 188). Is the starter switch circuit normal? VES — GO TO STEP 7. NO — Open circuit in the Green/Yellow wire between the brake light switch and starter switch. - Faulty starter switch. - Open circuit in Yellow/Green wire between the starter switch and ECM. I Loose or poorly connected connector of starter switch circuit. 10. Starter Relay Battery Voltage Line Inspection Inspect the starter relay battery voltage line (page 1,877). Is the battery voltage line normal? VES — GO TO STEP 11. NO — 0 Open circuit in the Red/Green wire between the starter relay and ignition switch. - Loose or poorly connected connector. 11. Starter Relay Ground Line Inspect the starter relay coil ground line (page 18-7). Is the starter relay ground circuit in good condition? YES — Replace the ECM and inspect again. No — Open circuit in the Yellow wire between the starter relay and ECM. 18-5 ELECTRIC STARTER ELECTRIC STARTER STARTER RELAY RELAY CIRCUIT INSPECTION NOTE: REMOVAL/INSTALLATION I Make sure the main relay and relative circuit is Remove the inner cover (page 375l. FUSE BOX normal before performing this inspection. Disconnect the battery negative la) cable and Remove the starter relay. remove the fuse box cover (page 1676). Connect the fuse box/battery positive l+l cable and FUSE BOX negative H cable. BATTERY VOLTAGE LINE Measure the voltage between the Red/Green wire terminal of the starter relay connector and ground. Remove the terminal bolt and disconnect the fuse box/battery positive l+) cable. Remove the starter relay from the fuse box Install the removed pans in the reverse order of removal. If battery voltage is present only when the ignition switch is turned to "ON“, the circuit is normal. OPERATION INSPECTION Remove the starter relay. Check for continuity between the A and D terminals. C B GROW? ”I“? . There should be continuity at- the terminals. There Turn the ignition sWItch to "OFF". should be no continuity when the battery is con- Disconnect the ECM 21F lEIack) connector and nected to E (+) and C 1—) terminals of the starter checl< the connector for loose contacts or corroded reiay, terminals. Check for continuity between the Yellow wire termi- D , rials of the ECM 21F (Black) connector and starter relay switch connector. TOOL: Test probe D7ZAJ-RDJA110 E h Id b ' ' . A STARTER RELAY There 3 cu e continuity Check for continuit between the A and B terminals. There should be I10 continuity at the terminals. STARTER RELAV There should be continuity when the battery is con nected to E (4-) and C l—) terminals of the starter relay. BATTERY STARTER CIRCUIT INSPECTION Turn the ignition switch to "OFF". Disconnect the ECM 5P (Black) connector and check the connector for loose contacts or corroded termi- rials. Check for continuity between the Red wire terminals of the starter relay connector and ECM 5P (Black) connector, It is normal if there is continuity. 18-6 l 18-7 ELECTRIC STARTER ECM (ENGINE CONTROL MODULE) STARTER SWITCH CIRCUIT INSPEC- TION NOTE: . Make sure the brake light circuit is normal before performing this inspection (page 1948). Remove the front cover (page 36). Disconnect the ECM 21F (Gray) connector and brake light switch connectors and check the connector for loose contacts or corroded terminals. Connect the test harness to ECM connector. TOOL: ECM test harness o7oMZ-GEV0100 Check ior‘continuity between the test harness and the Green/Yellow wire terminal of the brake light switch connector wire harness side. CONNECTION: 321 — Green/Yellow There is usually no continuity, there should be con- tinuity when pushing the starter switch. ANGLE SENSOR CIRCUIT INSPECTION Remove the floor step (page 37]. Disconnect the pulse alternator/starter 6P (Natural) connector and check the connector for loose con tacts of corroded terminals. Check for continuity between the Green wire termi- nal ofthe harness side and ground. There should be continuity. Turn the ignition switch to “ON". Measure the voltage between the following termir nals of harness side: STANDARD: Brown/Yellow(+l and Green(-) terminalsmbout 10 V White/Red(+) and Green(-) termini about 8.5 V WhitelGreeni+l and GraenI-I termi ls: about 8.5 V White/Black“) and Green(-) teminals: about 8.5 V 18-8 19. LIGHTS/METERS/SWITCHES SYSTEM LOCATION .................................... 19.2 SERVICE INFORMATION ---------------------------- 19-3 HEADLIGHTS ............................................... 19.4 TURN SIGNAL LIGHT- 19-5 BRAKE/TAIL LIGHT ..................................... 19.7 SPEEDOMETER ........................................... 19.9 FUEL RESERVE INDICATOR/ FUEL RESERVE SENSOR -------------------------- 19-10 COOLANT TEMPERATURE INDICATOR/ ECT SENSOR .............................................. 19.13 IGNITION SWITCH ..................................... 19.15 HANDLEBAR SWITCHES --------------------------- 19-17 BRAKE LIGHT SWITCH ------------------------------ 19—18 HORN - 9.19 HEADLIGHT RELAy .................................... 19.19 19-1 LlGHTS/METERS/SWITCHES SYSTEM LOCATION FRONT BRAKE SPEEDOMETER LIGHT SWITCH REAR BRAKE LIGHT SWITCH IGNITION SWITCH i LED DRIVE UNIT RESISTOR HORN TURN SIGNAL RELAY FUEL RESERVE SENSOR LIGHTS/ METERS/ SWITCHES SERVICE INFORMATION GENERAL Check the battery condition before performing any inspection that requires proper battery voltage. - A continuity test can be made with the switches installed on the scooter. - Route the wires and cables properly after servicing each component (page 1715). . The following color codes are indicated through out this section. Bu: Blue G: Green Lg: Light Green W: White Bl: Black Gr: Gray 0: Orange Y: Yellow Br: Brown Lb: Light Blue R: Red SPECIFICATIONS _ T "7 ITEM SPECIFICATIONS Bulbs Headlight thigh/low beam) 12V—35/35W X 2 Brake/tail light 12V—21/5W Front turn signal light 12V»21W X 2 Rearturn signal light 12V—21W X 2 Speedometer light 12V—1.7W _M_aifunmion indicator lamp (MIL) LED _Water temperature indicator LED Fuel reserve indicator LED Fuse Main fuse 20A Syhfuses 15A X 2 ECT (Engine Coolant Tern pera— At 50 D(2/122 ° F 690 — 860 Q turel sensor resistancf: "7 At 130 DC /266 ° F 68 — 83 D. TORQUE VALUES Turn signal light mounting nut 9.8 N-m 11.0 kgf-m, 7 lbf~ftl ECT sensor 18 N'm (1‘8 kgf-m, 13 Ibf-ftl TOOLS ECM test harness D7DMZ-GEV01OO [ 19-2 1 9-3 LIGHTS/METERS/SWITCHES H EADLIGHTS HEADLIGHT BULB REPLACEMENT Remove the dust cover from the headlight unit. Unhook the bulb socket tab from the groove on the headlight unit. Push the headlight bulb in, turn it counterclockwise and remove it. Install the headlight bulb in the reverse order of removal. INSPECTION NOTE' ° The headlights can turn on after starting the engine. - Make sure that the following items are normal before this inspection. — Sub fuse (15A) 7 Starter relay operation (page 18-6] — Headlight relay - Dimmer switch (page 19-18] Headlight is not turned on 1. Headlight circuit Inspection 1 Remove the front cover (page 3v6]. Turn the ignition switch to "ON“. Measure the voltage between the Black/Yellow wire terminal (+) of the left handlebar switch 9P (Natural) connector at the harness side and body ground H. The battery voltage should come on. Does the battery voltage come on? YES — GO TO STEP 2. NO — - Open or short circuit in the wire har- ness. I Poorly connected terminal. GROOVE HEADLIGHT UNIT TAB BULB 9P (NATURAL) CONNECTOR 19-4 2. Headlight Circuit Inspection 2 Install the front cover (page 3-6). With the headlight 3P (Red) connector plugged in, ground the Green wire terminal with a jumper wire. The headlight circuit is normal it the headlight is turned on when the ignition switch is turned to ”ONH_ Are the headlights turned on? VES — ° Open circuit in Green wire between the headlight and ECM. - Faulty ECM NO - - Open circuit in the Blue and/or White wire between the left handlebar switch 9P (Natural) connector and headlight 3P (Red) Connector. I Check the dimmer switch (page 19» 18). REMOVAL/INSTALLATION Remove the headlight bulb (page 19-4l. Remove the bolts and headlight. Install the removed parts in the reverse order of removal. Adjust the headlight aim (page 4—14). TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal light lens. While pushing the bulb in, turn it counterclockwise to remove it, and replace it with a new one. Make sure the rubber seal is installed in position and is in good condition, and replace it with a new one if necessary. Install the lens by aligning its hook with the slot of the turn signal light, and tighten the screw. LlGHTS/METERS/SWITCH ES 3P (REDl CONNECTOR HEADLIGHT RUBBER SEAL ‘JUVMPER WIRE 19-5 LlGHTS/METERS/SWITCHES INSPECTION NOTE: - The turn signal lights can be operated with the ignition switch turned to "ON" even though the engine is not started. The lights will not work if the battery voltage falls below the prescribed limit. However, they will be ready for operation after starting the engine. ' Check the sub fuse 115A) before performing this inspection. All the turn signal lights do not operate. 1. Turn Signal Relay Inspection Remove the inner cover (page 3-5). Disconnect the turn signal relay 3P (Blackl ccnr nector. Using the jumper wire, short the Black and Gray wire terminals. Turn the ignition switch to "ON", and operate the turn signal switch. Do tum signals light up? No — GO TO STEP 2. YES — . Faulty turn signal relay. ‘ . Poorly connected terminal. 2. Turn Signal Switch Inspection Inspect the turn signal switch for continuity (page 19-18). Does continuity exist? NO - Faulty turn signal switch. VES — - An open circuit in the Black and/or Gray wire of the turn signal relay. I An open circuit in the Green/Black wire between the turn signal light and ECM. - Faulty ECM. REMOVAL/ INSTALLATION FRONT Remove the inner cover (page 3-5). Disconnect the turn signal light connectors. Remove the clamp. Remove the nut and turn signal light. Route the Wires Install the turn signal light to the headlight bracket properly and tighten the nut to the specified torque. TORQUE: 9.8 Na!“ (1.0 kgf-m, 7 lbf-ft) Installation is in the reverse order of removal. REAR Release the wires from the clamp. Disconnect the turn signal light connectors. Remove the nut and turn signal light. Install the turn signal light to the tail light bracket and tighten the nut to the specified torque. TORQUE: 9.8 N-m (1.0 kgf-m, 7 lbi-ft) Route the WIIES installation is in the reverse order of removal. properly BRAKE/TAIL LIGHT BULB REPLACEMENT Remove the screws and brake/tail light lens. While pushing the bulb in, turn it counterclockwise to remove it, and replace it with a new one. Make sure that the rubber seal is installed in posi tion and is in good condition. Replace it with a new one if necessary. Install the brake/tail light lens and tighten the screws. LlGHTS/METERS/SWITCHES NUT LENS SCREWS RUBBER SEAL 19-7 LIGHTS/METERS/SWITCHES INSPECTION NOTE. - Normally, the tail light will come on when the ignition switch is turned to “ON" even when the engine is not started, with the brake light ready for operation. The lights will not work when the battery voltage falls below the prescribed limit, but will go on or be ready for operation after starting the engine. Brake/tail light does not operate 1. Operation of The Lights Inspection Check if the tail light and brake light do not oper- ate. Which Iight does not operate? Tail Light— - Open circuit in the Black wire between the sub fuse and tail light connectors. I Faulty main relay. - Blown sub fuse (15A). ‘ Faulty ECM. Brake light— GO TO STEP 2. Both tail light and brake light— - Open circuit in the Green/Black wire between the ECM and brake/tail light connectors. I Faulty ECM. 2. Brake Light Switch Inspection Turn the ignition switch to “ON". Squeeze the front or rear brake lever and check the operation of the brake light. Da either brake light not operate oven if its brake lever is squeezed? NO — Inspect the brake light switch (page 19- 18). VES — GO TO STEP 3. 3. Brake Light Circuit Inspection Remove the front cover (page 3-6]. CONNECTOR With the ignition switch turned to "ON", check that the battery voltage is present between the Black wire connector of the brake light switch and body ground. The brake light switch circuit is normal it battery voltage is present. ls battery voltage present? NO — 0 Open circuit in the Black wire. I Faulty main relay - Blown sub fuse 115Al. - Faulty ignition switch lpage 19-16) ' Faulty ECM. VES — - Open circuit in the Green/Yellow wire between the brake light switch and brake light. LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Release the wires from the clamp. Disconnect the brake/tail light connectors. CONNECTORS ' Remove the bolt and tail light cover. TAIL LIGHT COVER ’3‘? Route the Wire har- Remove the bolts/washers and brake/tail light. (I . . . nefiagzrfjwy Installation Is In the reverse order of removal. BRAKE/TA”- LIGHT BOLTS/WASHERS SPEEDOMETER BULB REPLACEMENT Remove the speedometer (page 19—10). Remove the bulb socket from the speedometer and replace the bulb with a new one. Installation is in the reverse order of removal. SPEEDOMETER BULB SOCKET 19,-9 LIGHTS/METERS/SWITCH ES REMOVAL/ INSTALLATION Remove the front cover (page 3-5I Disconnect the speedometer light connectors, 3P (Black) connector, then release the wires from the clamp. Disconnect the speedometer cable from the speed- I omterl Remove the nuts, washers and speedometer. I Home We cab/es Installation is in the reverse order of removal. and Wile harness proper/V (page 17 I 15! FUEL RESERVE INDICATOR/FUEL RESERVE SENSOR Fuel reserve sensor removal/installation is refer to page 6-50. LED DRIVE UNIT BATTERY/GROUND LINE INSPECTION NOTE: I Make sure thefollowing items are normal, before performing this inspection — Main fuse (20A), sub fuse 115A) 7 Main relay A Ignition switch (page 19716I — ECM (page 16—8I Remove the inner cover (page 375). Turn the ignition switch to "ON". Measure the voltage between the Black wire termi— nal of the LED drive unit 4P (Blackl connector and Ground. There should be battery voltage only when the ignir tion switch turns to "ON“. If there is no voltage, check for an open or short cir- cuit in the wire harness. Check the continuity of Green/Black wire between the LED drive unit and ECMt There should be continuity. CONNECTORS SPEEDOMETER SPEEDOMETER NUTS/ CABLE WASHERS 4P IBLACKI CON NECTOR SYSTEM INSPECTION NOTE‘ - Make sure the battery and ground line of the LED drive unit is normal. before performing this inspection. When the fuel reserve indicator does not light. 1. Fuel Reserve Sensor Line Inspection Ground the EIueNVhite wire terminal of the LED drive unit 4P (Blacki connector with a jumper wire. Turn the ignition switch to "ON", check that the fuel reserve indicator lights. Does the indicator light? NO — GO TO STEP 2. VES — I An open circuit in the BlueNVhite wire between the LED drive unit 4P [Black] and fuel reserve sensor. ' Open circuit in the Green/Black wire between the fuel reserve sensor and ECM. I Faulty fuel reserve sensor. 2. Fuel Indicator Line Inspection Ground the Blue/White wire terminal of the LED —— drive unit 4? (Black) connector with a jumper Wire. Measure the voltage between the Gray/Red 1+) and Green/Blue (—) wire terminals of the fuel reserve indicator 4P (Natural) connectort Is there approx. 3V? N0 — Faulty LED drive unit. YES — Faulty LED. LlGHTS/METERS/SWITCHES 4P (BLACK) CONNECTOR W 4PINATURALI CONNECTOR 19-10 19-11 l LIGHTS/METERS/SWITCHES LIGHTS/METERS/SWITCHES I When the indicator always lights during a operation INDICATOR UNIT REMOVAL/INSTAL- l 1. Resistor Line Inspection 1 LATION . I Turn the ignition switch to "ON“. . Rem‘we ”‘9 '"ne' ”"9' ”“96 3’5)- l Measure the voltage between the Black wire ter— RES'STOR Disconnect the LED indicator unit 4P (Natural) con- minal of the resistor 2P (Natural) connector and nectar. Ground. Remove the screws and the indicator unit. Does the voltage exist? N0 — Open circuit in the Black wire between the resistor 2P (Natural) connector and main wire harness. VES — GO TO STEP 2. Installation is in the reverse order of removal. Install the inner cover (page 3-5). LED INDICATOR UNIT REMOVAL/ INSTALLATION Remove the inner cover (page 3.5)? 2. Resistor Line Inspection 2 Check the continuity of Blue/White wire between the resistor and LED drive unit. Disconnect the LED indicator unit 4P (Natural) con- Is there continuity? nector. NO — Open circuit in wire harness Remove the screws and the LED indicator unit. VES - GO TO STEP 3, Installation is in the reverse order of removal. Install the inner cover (page 35). 2P (NATURAL) CONNECTOR 3. Resistor Inspection COOLANT TEMPERATURE INDICATOR] Disconnect the resistor 2P (Natural) connector. — Measure the resistance between the Black and 2? (NATURAL) CONNECTOR ECT SENSOR Green wire terminals of the resistor 2F (Natural) NOTE: connector. - When the coolant tern erature exceeds 120 °C STANDARD: 64—72 kmzo='0/ss° F) (248 OF), the coolant (3.1mm indicator Wm COOLANT TEMPERATURE INDICATOR turn on. The ECM will then control the ignition and reduce engine speed below 5,000 min" (rpm). At this time, check the cooling system and engine for leaks or damage. If everything is OK, check the following. - Make sure the battery and ground line ofthe LED drive unit is normal (page 19-13), before per— forming this inspection. Is the resistance within the standard? N0 — Faulty resistor VES - - Short circuit in the Blue/White wire. 0 Faulty fuel reserve sensor. 19-12 19-13 l LlGHTS/METERS/SWITCHES LlGHTS/METERS/SWITCHES SYSTEM INSPECTION When the indicator always lights during in operation ‘l When “‘9 000'“! temPBrafl-"E indicator ”095 “M 1. Coolant Temperature Indicator Circuit Inspec- I lIght. . tion (short circuit) 1. Coolant Temperature Indicator Circuit lnspec- Remove the inner cover (page 3.5)‘ ““1 Turn the ignition switch to "ON" (engine not COOLANT TEMPERATURE INDICATOR R th ’ 375. startedl and check that the indicator Ii hts. emove e Inner cover(page I 4P (BLACK) CONNECTOR . . - 9 Does the indicator lights? NO - GO TO STEP 2. VES — Short circuit of Light green/Red wire between the LED drive unit and ECM. Ground the Light green/Red wire terminal of the LED drive unit 4P (Blacki connector with a jumper wire. Turn the ignition switch to "ON", check that the I indicator lights. Does the indicator light? NO — GO TO STEP 2. ( VES - GO TO STEP 3. 2. ECT Sensor Circuit Inspection Remove the floor step (page 3.7)_ 2. Coolant Temperature Indicator Circuit Inspec- tion 2 Remove the front cover (page 376). Disconnect the ECT sensor 2P (Black) connector. Ground the Pinkwire of the 2P (Blackl connector wire harness side with a suitable jumper wire. Start the engine, check that the indicator lights. Ground the Light green/Red wire terminal of the . . . , LED drive unit 4P (Black) connector with a Doesfhemdlcatorliyht- iumperwire. N0 —- - Open circuit of Pink wire between Measure the voltage between the Pink (+) and the ECM and ECT sensor. Blue/Black (—) wire terminals of the water indicar - Faulty ECM, tor unit 4P (Natural) connector. Is there approx. 3 V? NO — GO TO STEP 3. VES - Faulty LED YES — Inspect the ECT sensor (page 19-15). 4P (N ATURAL) ECT SENSOR INSPECTION CONNECTOR Remove the floor step (page 3-7). Drain the coolant from the cooling system (page 7- 3. ECT Sensor Circuit Inspection 6). Connect the test harness to ECM (page 6-10)- 7 Disconnect the ECT sensor 2P (Black) connector and TOOL: / gggggg—g] remove the ECT sensor (page 6-63). ECM test harness 070M2-GEV0100 9999000 Keep all flammable Suspend the ECT sensor in a pan of coolant (1:1 marshals away mixture) on an electric heating element and mea- ECT SENSOR Check for continuity between the test harness and LED drive unit 4P (Black) connector of the wire harness side. from the electric sure the resistance between the ECT sensor termi- heatmg eier nal and body as the coolant heats up. mem. Wear protecV CONNECTION: As— Light green/Red [Ive clothing, ”0:: k h ECT _ I _ h d . . ,nsuiatedg/Wes - oa t e sensor In coo ant up to Its t rea s I5 (hora Wilflmllffl and Eyepmemm with at least 40 mm (1.57 inl from the bottom of NO — - Open circuit in the Light green/Red the pan to the bottom of the sensor. wire between the ECM and LED drive O Keep the temperature constant for 3 minutes unit. before testing. A sudden change of temperature will result in incorrect reading. Do not let the YES — : IFrL‘sLfitevctEtgfiECT sensorlpage 19-15% —— thermometerorECT sensor touch the pan. ' Measure the resistance between the ECT sensor ter- minal and its threads. Temperature 50°C (122° F) 130°C (266° F) Resistance 690 — 860 Q 68 — 83 n If the resistance is out of above range, replace the ECT sensort 19-14 19-15 LlGHTS/METERS/SWITCHES Install the new O-ring to the ECT sensor. Install and tighten the ECT sensor with a new seal- ing washer. TORQUE: 18 N-m (1.8 kgf-m, 13 Ibf-fl) Connect the ECT sensor 2? (Black) connector. Fill and bleed the cooling system (page 7.7). Install the floor step (page 3-7). IGNITION SWITCH INSPECTION Remove the front cover (page 36). Disconnect the ignition switch 3P (Black) connector. Check for continuity between the connector termi- nals in each switch position. Continuity should exist between the color code wires as follows: BAT2 BAT1 0N O——O (OFF) OFF LOCK COLOR R/G R/Bu REMOVAL/INSTALLATION Remove the front cover (page 3-6). Remove the bolt and ignition switch cap. 19-16 Disconnect the ignition switch 3P (Black) connector. Remove the two screws and ignition switch. Use the new screws and install the removed parts in the reverse order of removal. HANDLEBAR SWITCHES Remove the front cover (page 3-6). Disconnect the right handlebar switch 2P (Red) con- nector and left handlebar switch 9P (Natural) con- nector. Check for continuity between the connector termi~ nals in each switch position. Continuity should exist between the color code wires as shown in the charts below. LIGHTS/METERS/SWITCHES IGNITION SWITCH 3P (BLACK) \‘C O””\\ CONNECTOR \\ 9P (NATURAL) CONNECTOR L‘ . «1/ 19-17 l i LlGHTS/METERS/SWITCH ES LEFT HANDLEBAR SWITCH TURN SIGNAL SWITCH W R N :9 COLOR Gr Lb o DIMMER SWITCH HL Lo Hi ED lNl ED COLOR Bl w Bu HORNSWITCH HO BATZ FREE PUSH o——o COLOR Lg Bl RIGHT HANDLEBAR SWITCH STARTER SWITCH CDI ST FREE START O——O COLOR Y/G G/Y BRAKE LIGHT SWITCH Remove the front cover lpage 36). Disconnect the brake light switch wire connectors and check for continuity between the switch side terminals. There should be continuity with the brake lever squeezed, and there should be no continuity when the brake lever is released DIMMER SWITCH HORN SWITCH TURN SIGNAL SWITCH STARTER SWITCH CONNECTORS HORN INSPECTION Disconnect the horn connector from the horn. Connect a 12V battery to the horn terminals The horn is normal if it sounds when the 12V battery is connected across the horn terminals. HEADLIGHT RELAY Remove the inner cover (page 375). Remove the headlight relay. Check for continuity between the A and B terminals. There is usually no continuity, there should be con- tInuity when the battery is connected to C (H and D (7) terminals. LlGHTS/METERS/SWITCHES CONNECTOR 19-18 19-19 20. WIRING DIAGRAMS MEMO E, F, ED type (English, French, E, F, ED type (Italian, Spanish, Dutch) ------- 20-4 Germany) ..................................................... 20.3 20-1 WIRING DIAGRAMS E, F, ED type (Italian, Spanish, Dutch) a‘cmm‘aam ‘K‘ cw KKKKKKKK- KKK KKKK‘KKK W: K KKK KKK AKKKM ‘H K“ “H “P WKKKKKK ‘ ‘ N KKK KK KKKKWKKKK éLK‘Kl“‘K‘K‘K;.K 5mm» K K-K,K LJL KKKKKK KKKKKAK K KA “””“"‘ “" / K’J’H\(KLMK\: K\‘\‘K\K”IHLRH \KQ K‘«.KKKK;K‘AKKK “am" ~ AYNKIRLU‘K :H‘K.L‘M< KKKKKKKKKK ,KKK KKKKKKKoK-KK KKK-,KK KKKKKKKKKKKKKW K.KKK.KKKK.KKKKK , K KKKKKKKKKLK KKKK ArnnKKK KK. K KKK‘KK Kéi K K KKKKK I”, H ' ‘ 1 1K J KKKKKKK WMWWNWKKKKKKK KK mwmwc AWL mummmfini‘ '” " > s KKKKKKKKK 4 ¥ . KKmKKKKKKK KKKHKK-KK KKK KK KKKKKKK K g, , KKKK K. 'K" K KMMKH=KEEK KK\KK K [En K'K'K‘KKKKKK ’ a KKKK‘KKK K KKKKKKKKLKKK'KKKKK/KKKK’K A” ”KKKK» KKK ,KK :(nj 3 1 KKKKKK KKK K KKK Kw : LK“K H n \<‘ nu wag; KKKKKK 3K “$1339me KKKK KKKsKmSKKK’uK’KKKKKK KKaKLKK‘ KEKK‘KKKKK KKKKKKK tip?“ .KS; KK“K KKKKKKK KK ATV: JAjRLAMK‘JK .KAKKKK KZKK KK smflnm whfigq‘ .m RKKK ‘ , KK K ":9: KKK , KKKKK h WC; ’1—.A KKK—J :KNKKKK m KK’K. sKKSKK K. mm mum N u KKK‘KKKKKmaK ’ KKKKK.‘ KKK Km KKAKK‘KKséKeKKKA’ KN . \MI' Kr Hyscka»K:\K\KzAcKaer [me 1"”; * "7‘ L KKKKM» mm WWW WW KK KK~KKKKKK K Y W D“ K ~ Q g‘FVK‘V‘::‘N“"’“‘ \KKTKKNA uKKT AKKKK_K_K,TKKKKK LAKKKKKKKKKmaK K‘KuKKMK ‘ ‘K‘K‘KKK‘K ’ mmwm COKKKKKDMKKK‘ I K-HKVKK‘KNKGW WK W .K 0 KKKK KKK KKKKK KKKaKKK ‘nK u BK NWO Br KKAKKKKKKAK aK NEGRO uK BASVANO ‘ m mm KKK mm 7 ' KKE‘ * v u filkflNL‘U’KL v AMARKLLD a ANANANJAUO v {JP} 0 mum? m 00 ; M20 w m K KK KK AZKK KK KKKKKKKKO K KKKKKK KK Km m- 0-0-0 'w 00 W" K, KU vK CYLINDER HEADNALVES ELECTRIC STARTER ENGINE REMOVAL/INSTALLATIO FINAL REDUCTION ----- FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEL/BRAKE/SUSPENSION/ STEERING ------ FUEL SYSTEM (Programmed Fuel Injection)- IGNITION SYSTEM ---- KICKSTARTER/DRIVE PULLEY/ DRIVEN PULLEY/CLUTCHv LIGHTS/METERS/SWITCHES LUBRICATION SYSTEM- MAINTENANCE REAR WHEEL/BRAKE/SUSPENSION SERVICE RULES SPARK PLUG -- SFEEDOMETER - STANDARD TORQUE VALUES - STARTER RELAY STEERING HEAD BEARINGS STEERING STEM STEP FLOOR SUSPENSION , SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM ELECTRIC STARTER FUEL SYSTEM (Programmed Fuel Injectlonl- IGNITION SYSTEM ----- \lmh wAmmgloozxia-ny gum www wwwuwwwww an; SYSTEM FLOW PATTERN ------ SYSTEM LOCATION FUEL SYSTEM (Programmed Fuel Injection LIGHTS/METERS/SWITCHES THRO'I'I'LE BODY--- THRO'I'I'LE BODY (SENSOR) POWER LINE INSPECTION ---- THROTTLE OPERATION TP SENSOR TROUBLESHOOTING FINAL REDUCTION ------ BATTERY/CHARGING SYSTEM COOLING SYSTEM ----- CRANKSHAFT/PISTON/CYLINDE CYLINDER HEAD/VALVE ELECTRIC STARTER- FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEL/BRAKE/SUSPENSION/ STEERING--- FUEL SYSTEM (Programmed Fuel Injection IGNITION SYSTEM ------ KICKSTARTER/DRIVE PULLEY/ DRIVEN PULLEY/CLUTCH LUBRICATION SYSTEM . REAR WHEEL/BRAKE/SUSPENSION TURN SIGNAL LIGHT UNDER COVER VALVE CLEARANC VALVE GUIDE REPLACEMEN VALVE SEAT INSPECTION/REFACING WATER PUMP/THERMOSTAT WHEELSFI'IRES WIRING DIAGRAMS E, F, ED type (English, French, German )‘ E, F, ED type (Italian, Spanish, Dutch) 22-2 HONDA The Power of Dreams , Published by Honda Motor 00"le (P) Honda Motor Co ,Lxdr 2004 (9) A450.2004.7.5 EQGEZUO Primed m Japan