SERVQLCPMANUAL How TO use THIS MANUAL How To Use This Manual This manual describes the service procedures for the VFR1200F. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the US. Environmental Protection Agency (EPA) and Caliiornia Air Resources Board (CARE) and Transpon Canada. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 4 apply to the whole vehicle. Section 3 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections Section 5 through 22 describe pans of the motorcycle, grouped according to location. Find the section you want on this page. then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. If you are not familiar with this motorcycle. read Technical Feature in section 2. If you don't know the source of the trouble, go to Troubleshooting section 24. Your safety, and the safety of others. is very important. To help you make iniormed decisions we have provided saiety messages and other information throughout this manual. Of course. it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: - Safety Labels — on the vehicle ‘ Safety Messages — preceded by a safety alert symbol /3\ and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT ifyou don’t follow instructions. m You CAN be KILLED or SERIOUSLY HURT if you don‘t follow instructions. RCAUTION You CAN be HURT it you don't follow instructions, ~ Instructions — how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a "Wit" symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment now To USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specific service prooedures. if supplementary information is required pertaining to these symbols. it would be explained specifically in the text without the use oi the symbols. ‘ w Replace the part(s) with new one(s) before assembly. ~v 7% Use the recommend engine oil, unless otherwise specified. ’7E Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). a Use multi-purpose grease (lithium based multi—purpose grease NLGl #2 or equivalent), Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NOGI #2 or equivalent), fl Example: - Molykote® BR—2 plus manufactured by Dow Corning U.S,A. - Mum-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or equivalent). Example: m - Molykote® G»n Paste manufactured by Dow Corning U.S,A, ' Honda Moly 60 (USA. only) - Rocol ASP manufactured by Roool Limited, U.K. - Rocol Paste manufactured by Sumioo Lubricant. Japan ' fi Use silicone grease. Q Apply a locking agent. Use a medium strength locking agent unless otherwise specified, JIM Apply sealant a Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified, a Use fork or suspension fluid. CONTENTS GENERAL INFORMATION TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM U1 FUEL SYSTEM (PGM-FI) COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEADNALVES CLUTCH/GEARSHIFT LINKAGE _\ o ALTERNATOR/STARTER CLUTCH _\ _x CRANKCASEITRANSMISSION CRANKSHAFT/PISTONICYLINDER FINAL DRIVE CHASSIS FRONT WHEEL/SUSPENSIONISTEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE _\ ‘1 ANTI-LOCK BRAKE SYSTEM (ABS) ELECTRICAL BATTERY/CHARGING SYSTEM IGNITION SYSTEM N o ELECTRIC STARTER N .- LIGHTS/METERSISWITCHES N N WIRING DIAGRAMS N w TROUBLESHOOTING INDEX _._. 4.. was “N \I w» MEMO 1. GENERAL INFORMATION SERVICE RULES ........................................ ..1_2 MODEL IDENTIFICATION .......................... ..1_3 GENERAL SPECIFICATIONS -------------------- --1-5 LUBRICATION SYSTEM SPECIFICATIONS ....................................... ..1_6 FUEL SYSTEM (PGM Fl SPECIFICATIONS- COOLING SYSTEM SPECIFICATIONS ----- --1-6 CYLINDER HEADNALVES SPECIFICATIONS ....................................... ..1_7 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS ....................................... ..1.1 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS -- CRANKCASE/TRANSMISSION SPECIFICATIONS ....................................... ..1_3 CRANKSHAFTIPISTONICYLINDER SPECIFICATIONS ....................................... ..1_g FINAL DRIVE SPECIFICATIONS ------- -- --1-9 FRONT WHEEL/SUSPENSIONISTEERING SPECIFICATIoNs ....................................... "1.9 REAR WHEEL/SUSPENSION SPECIFICATIONS ..................................... ..1_1o HYDRAULIC BRAKE SPECIFICATIONS--- 1-10 BATTERY/C HARGING SYSTEM $PEC|F|CAT|ONS .................................. .. 1-10 IGNITION SYSTEM SPECIFICATIONS ---- --1-11 ELECTRIC STARTER SPECIFICATIONS--1-11 LIG HTS/M ETERSISWITCHES SPECIFICATIONS ..................................... ..1_11 STANDARD TORQUE VALUES --------------- --1-12 ENGINE 8. FRAME TORQUE VALUES-'----1-12 LUBRICATION 8x SEAL POINTS ------------- --1-19 CABLE & HARNESS ROUTING --------------- -~1-22 EMISSION CONTROL SYSTEMS ------------ --1-32 1-1 GENERAL INFORMATION SERVICE RULES 1. Use Honda genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings. cotter pins. and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricata any sliding surfaces before reassembly. 7. After reassembly. check all parts for proper installation and operation. 8. Route all electrical wires as show in the Cable and Harness Routing (page 1~22). 9. Do not bend or twist control cables, Damaged control cables will not operates smoothly and may stick or bind. ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbrev. term Full term PGM-Fl Programmed Fuel Injection MAP sensor Manifold Absolute Pressure sensor ECT sensor Engine Coolant Temperature sensor IAT sensor Intake Air Temperature sensor CKP sensor Crankshaft Position sensor CMP sensor Camshaft Position sensor EOP sensor Engine Oil Pressure sensor VS sensor Vehicle Speed sensor ECV Exhaust Control Valve ECV POT Exhaust Control Valve Polentiometer EGCA Exhaust Gas Control Actuator ECM Engine Control Module EEPROM Electrically Erasable Programmable Read Only Memory DLC Data Link Connector SCS connector Service Check Short connector HDS Honda Diagnostic System DTC Diagnostic Trouble Code MIL Malfunction Indicator Lamp PAIR Pulse Secondary Air Injection EVAP ’ Evaporative Emission TBW Throttle by Wire TCP sensor Throttle Control Position sensor TP sensor Throttle Position sensor GENERAL INFORMATION MODEL IDENTIFICATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N) [1] is stamped on the right side of the steering head. The engine serial number [1] is stamped on the right side of the lower crankcase. The throttle body identification number [1] is stamped on the right side oi the throttle body as shown. GENERALWFORMAHON LABEL The Safety Certification Label [1] is located on left side of the frame. The color label [1] is attached on the rear fender, When ordering color» coded parts. always specify the designated color code. The Emission Control Information Label [1] is attached on the rear fender. 1-4 GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,250 mm (83.6 in) Overall width 755 mm (29.7 in) Overall height 1.220 mm (48.0 in) Wheelbase 1,545 mm (60.8 in) Seat height 810 mm (31.9 in) Fooaneg height 362 mm (14.3 in) Ground clearance 125 mm (4.9 in) Curb weight 268 kg (591 lbs) Maximum weight capacity 196 kg (433 lbs) FRAME Frame type Diamond Front suspension Telescopic Iork Front axle travel 108 mm (4.25 in) Rear suspension Swingann Rear axle travel 130 mm (5.12 in) Front tire size 120/7OZR17M/C(58W) Rear tire size 190/552R17M/C(75W) Front tire brand BT021F N (Bridgestone) ROADSMART CQ K (Dunlop) Rear tire brand BT021R N (Bridgestone) ROADSMART K (Dunlap) Front brake Rear brake Caster angle Trail length Fuel tank capacity Hydraulic double disc Hydraulic single disc 25.5" 101 mm (4.0 in) 18.5 liter (4.89 US gal. 4.07 Imp gal) Clutch operation system Transmission Primary reduction Secondary reduction ‘ Final driven side Side gear case side Final reduction Gear ratio 1st 2nd 3rd 4th 5th 5th Gearshift pattern ENGINE Cylinder arrangement 76“ V Bore and stroke 81.0 X 60.0 mm (3.19 X 2.36 in) Displacement 1237 cm° (75.45 cu~in) Compression ratio 12.0 : 1 Valve train Chain driven. OHC Intake valve opens at 1 mm (0.04 in) lifl 15° BTDC closes at 1 mm (0.04 in) lift 35° ABDC Exhaust valve opens at 1 mm (0.04 in) lift 43° BBDC closes at 1 mm (0.04 in) lift 14° ATDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Paper filter Engine dry weight 88.8 kg (195.8 lbs) Firingorder 1-2-4-3 FUEL DELIVERY Type PGM-Fl (Programmed Fuel Injection) SYSTEM Throttle bore 44 mm (1.7 in) DRIVE TRAIN Clutch system Multi—plate. wet Hydraulic operating Constant mesh. 6-speeds 1.73s (73/42) 0.949 (37/39) 1.118 (19/17) 2545 (23/11) 2.600 (39/15) 1.736 (33/19) 1.363 (30/22) 1.160 (29/25) 1.032 (32/31) 0.939 (31/33) Left foot operated return system, 1-N-2-3«4-5-6 GENERAL INFORMATION ITEM SPECIFICATIONS ELECTRICAL Ignition system Starting system Charging system Regulawr/recflfier Computer-controlled digital transistorized with electric advance Electric starter motor Triple phase output alternator F ET shorted/triple phase. full wave rectification Lighting system Battery LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine all After draining 3.0 liter (3.2 US qt. 2.6 lmp qt) — cade After draining/filter change 3.2 liter (3.4 US qt. 2.8 Imp qt) — After disassemny 4.0 liter (4.2 US qt. 3.5 Imp qt) — Recommended engine oil Fro Honda GN4 4-stroke oil (U.S.A. and Canada) or equivalent motor oil APl sen/ice classification: SG or Higher — JASO T903 standard: MA \fisoosity: SAE 10W-30 Oil pressure (at oil filter cartridge) 100 kPa (1.0 kgl/cm . 15 psi) at _ 1,100 rpm/(80°C/176°F) Oil pump rotor Feed pump Tip clearance 0.15 (0.006) 0.20 (0008) Body clearance 0.07 — 0.20 (0.003 — 0.010) 0.34 (0.013) Side clearance 0.04 — 0.09 (0.002 - 0.004) 0.12 (0.005) Scavenge pump Tip clearance 0.15 (0.006) 0.20 (0008) Body clearance 0.07 — 0.20 (0.003 — 0.010) 0.34 (0.013) Side clearance 0.04 — 0.09 (0.002 — 0.004) 0.12 (0.005) FUEL SYSTEM (PGM—FI) SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number GNHDB Idle speed 1.150 t 100 min" (rpm) Throttle grip freeplay 2 —4 mm (1/16-3/16 in) IAT sensor resistance (at 20°C/68°F) 1 —- 4 k5) ECT sensor resistance (at 20°C/68°F) 2.3 — 2.6 m Fuel injector resistance (at 20°C/68°F) 11.6 — 12.4 (2 PAIR solenoid valve resistance (at 20°C/68°F) 23 — 27 Q CKP sensor peak voltage (at 20°CI68°F) 0.7 V minimum Fuel pressure at idle 343 kPa (3.5 kgf/cm . 50 psi) Fuel pump flow (at 12V) 320 cm“ (10.8 US oz. 11.3 lmp oz) minimum/10 seconds COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 3.6 liter (3.8 US qt. 3.2 imp qt) Reserve tank 1.0 liter (1.1 US qt. 0.9 Imp qt) Radiator cap relief pressure 108 — 137 kPa (1.1 — 1.4 kgf/cm . 16 —20 psi) Thermostat Begin to open 80 — 84°C (176 — 153°F) Fully open 95°C (203°F) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate free corrosion inhibitors Standard coolant concentration 50 % mixture with distilled water 1-6 GENERAL INFORMATION CYLINDER HEADNALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression 1.600 kPa (16.32 kgI/om , 232 psi) 31 300 rpm — Valve IN 016 t 0.03 (0.006 t 0.001) — clearance EX Valve side 0.30 1 0.02 (0.012 2 0.001) — Roller Side 021 i 0.02 (0.003 t 0.001) — Camshaft Cam lobe height IN 37.12 — 37.20 (1.461 — 1.465) 37.10 (1.461) EX 34.36 — 34.94 (1.372 —1.376) 34.34 (1.372) Runout - 0.05 (0.002) Oil clearance 0.020 — 0.062 (0.0008 - 0.0024) 0.10 (0.004) Valve liner Valve lifter O.D. 23378—28993 (1.1409 — 1.1415) 28.97 (1.141) Valve lifler bore ID. 29.010 — 29.026 (1.1421 — 1.1428) 29.04 (1.143) Valve. Valve slam CD. IN 4.475 — 4.490 (0.1762 — 0.1768) 4.465 (0.1758) valve guide EX 4.465 — 4.430 (0.1758 — 0.1764) 4.455 (0.1754) Valve guide I.D. IN/EX 4.500 — 4.512 (0.1772 - 0.1776) 4.540 (0.1787) Stem-Io-guide IN 0010 — 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 IN 13.40 — 13.70 (0.528 — 0.539) — projection above EX 22.50 — 22.80 (0.886 — 0.893) — cylinder head _ Valve seat width IN/EX 0.90 — 1.10 (0.035 — 0.043) 1.5 (0.06) Valve IN Outer 37.06 (1.459) 36.30 (1.429) spring Inner 33.24 (1.309) 32.50 (1.280) free length EX 43.01 (1.693) 42.30 (1.665) Cylinder head warpage — 0.10 (0.004) CLUTCH/GEARSHIFT LIN KAGE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Specified clutch fluid DOT 4 brake fluid — Clulcn master cylinder Cylinder 12.700 — 12.743 (0.5000 — 0.5017) 12.755 (05022) ID. V_ . Pislon 013. 12.657 — 12.684 (0.4983 — 0.4994) 12.645 (0.4978) Clutch Spring Iree height 670 (0.264) 5.70 (0.224) Disc thickness Disc A. C 3.22 — 3.33 (0.127 — 0.133) 3.1 (0.12) Disc B 3.72 — 3.88 (0.146 — 0.153) 3.6 (0.14) Plate warpage - 0.30 (0.012) Clutch outer guide |.D. 23.000 — 28.021 (1.1024 — 1.1032) 28.030 (1.1035) O.D. 34.975 — 34.991 (1.3770 —1.3776) 34.955 (1.3766) Oil pump drive sprocket LD. 35.025 — 35.145 (1.3789 —1.3837) 35.155 (1.3841) Mainshafl CD. at clutch outer guide 27.980 - 27.990 (1.1016 —1.1020) 27.96 (1.101) GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unil: mm (in) ITEM STANDARD SERVICE LIMIT Starler driven gear boss O.D. 51.699 — 51.718 (2.0354 — 2.0361) 51.59 (2.031) CRANKCASEITRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear I.D, M5, M6 31.000 — 31.025 (1.2205 — 1.2215) 31.04 (1.222) 01 35,000 — 35.025 (1.3780 - 1.3789) 35.04 (1380) C2 30.000—30.021(1.1811-1.1819) 30.04 (1.183) C3, C4 33.000 — 33.025 (1.2992 —1.3002) 33.04 (1.301) Gear busing 0.0, M5 30.955 — 30.980 (1.2187 - 1.2197) 30.935 (1.2179) M6 30,950 — 30.975 (1.2185 — 1.2195) 30.93 (1218) C3, 01 32.950 — 32.975 (1.2972 -1.2982) 32.93 (1.296) Gear»to»bushing M5 0.020 — 0.070 (0.0008 — 0.0028) 0.10 (0.004) clearance M6 0025 — 0.075 (0.0010 - 0.0030) 0.11 (0004) C3, C4 0.025 - 0.075 (0.0010 - 0.0030) 0.11 (0004) Gear bushing I.D. M5 27.985 — 28.006 (1.1018 — 1.026) 28.016 (1.1030) Mainshafl CD. at M5 27367—27380 (1.1011 — 1.1016) 27.957 (1.1007) Bushing—1Hhafl M5 0.005 — 0.039 (0.0002 — 0.0015) — clearance snm fork. Fork |.D. 12.000 — 12.018 (0.4724 — 0.4731) 12.03 (0.474) f0rk 503“ Claw thickness 5.93 — 6.00 (0.233 — 0.236) 5.9 (0.23) Shifl fork shafl O.D. 11,957 — 11.958 (0.4707 — 0.4712) 11.95 (0.470) Oulpul Final driven gear LD, 30.000 — 30.013 (1.1811 — 1.1816) 30.03 (1.182) drive train Flnal driven I,D. 25.026 — 25.041 (0.9653 — 0.9859) 25.05 (0.986) gear bushing 0.0, 29959 — 29.980 (1.0220 —1.0228) 29.95 (1179) Final shafl OD. 24.980 — 24.993 (0.4707 — 0.4712) 24.962 (0.9828) Final driven gear-io-bushing 0.020 — 0.054 (0.0008 — 0.0021) 0.079 (0.0031) clearance Final driven gear 0.033 — 0.061 (0.0013 — 0.0024) 0.090 (0.0035) bushing-lushafl clearance Final shall damper spring free length 114.5 (4.51) 110 (4.3) Final shall/output shafl gear backlash 0.08 — 0.23 (0.003 — 0.009) 0.40 (0.016) Backlash difference between — 0.10 (0.004) measurements GENERAL INFORMATION CRANKSHAFT/PlSTON/CYLINDER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod side clearance 0.15 — 0.30 (0.006 — 0.012) 0.40 (0.016) Runcut — 0.05 (0.002) Main journal bearing oil clearance 0.017 — 0.035 (0.0007 — 0.0014) 0.05 (0.002) Cylinder I.D. 81.000 — 81.015 (3.1890 — 3.1896) 81.025 (3.1900) Out of round — 0.10 (0.004) Taper — 0.10 (0.004) Warpage — 0.10 (0.004) Piston, Piston O.D. at 8.0 mm (0.31 in) from piston rings bomm 80.960 — 80.980 (3.1874 — 3.1882) 80.89 (3.185) Piston pin hole I.D. 13.002 — 18.008 (0.7087 — 0.7090) 18.02 (0.709) Piston pin O.D. 17.994 — 13.000 (0.7084 - 0.7087) 17.98 (0.708) Piston-to—piston pin clearance 0.002 — 0.014 (0.0001 — 0.0006) 0.04 (0.002) Piston ring end gap Top 0.15 — 0.25 (0.006 — 0.010) 0.45 (0.013) Second 0.320 — 0.470 (0.0126 — 0.0185) 0.65 (0.026) Oil (side rail) 0.20 — 0.70 (0.005 — 0.028) 0.9 (0.04) Piston ring-towing Top 0.015 — 0.050 (0.0006 — 0.0020) 0.065 (0.0026) groove clearance Second 0.015 — 0.045 (0.0006 — 0.0018) 0.06 (0.002) Cylinder-to-piston clearance 0.020 — 0.055 (0.0008 — 0.0022) 0.10 (0.004) Connecting rod small end |.D. 18.010 — 18.042 (0.7091 — 0.7103) 18.05 (0.711) Connecting rod-tepiston pin clearance 0.010 — 0.048 (0.0004 — 0.0019) 0.06 (0.002) Crankpin bearing oil clearance 0.034 — 0.052 (0.0013 — 0.0020) 0.06 (0.002) FINAL DRIVE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Recommended final drive all Hypoid gear oil, SAE #80 - Final drive oil After draining 200 cm3 (6.8 US 02, 7.0 Imp oz) — capacity After disassemny 240 cm3 (8.1 US oz. 8.4 Imp oz) — Final gear backlash 0.05 — 0.15 (0.002 — 0.006) 0.30 (0.012) Backlash difference between measurements — 0.10 (0.004) Final gear assembly preload 0.1 — 2.9 Nm (1 — 29 kgf-cm. — 0.1 — 2.1 Ibf‘fl) FRONT WHEELISUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 1.5 (0.06) Cold tire Up to 90 kg (200 lb) load 250 kPa (2.50 kgf/cm , 36 psi) — pressure Up to maximum weight capacity 250 kPa (2.50 kgf/cm , 36 psi) ~ Axle runout — 0.2 (0.01) Wheel Radial — 2.0 (0.08) rim runout Axial — 2.0 (0.03) Wheel balance weight _ 60 g (2.1 oz) max. Fork Spring free length 232.8 (9.17) 228.1 (8.98) Tube runout 0.20 (0.008) Pre-load adjuster initial setting 9 mm (0.4 in) from top surface of fork bolt Rebound damping adjuster initial 6 clicks from fully hard position setting Recommended fork fluid KHL 1540 (KY3) — Fluid level 160 (6.3) - Fluid capacity 497 x 3 cm’ (16.3 1 0.1 us oz, _ 17.5 3: 0.1 Imp oz) Steering head bearing pre-Ioad 16.7 — 20.6 N (1.7 — 2.1 kgf, 3.7 — 4.6 Ibf) GENERAL INFORMATION REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 2.0 (0.08) Cold tire Up to 90 kg (200 lb) load 290 kPa (2.90 kgf/cmz, 42 psi) — Pressure Up to maximum weight capacity 290 kPa (2.90 kgf/cm . 42 psi) — Wheel rim Radial - 2.0 (0.08) runout Axial — 2.0 (0.08) Wheel balance weight 60 g _ (2.1 oz) max. Shock absorber Spring pre»load adjuster standard 11 clicks out from lower position ~ position Rebound adjuster initial setting 3/4 turn out from full hard HYDRAU LIC BRAKE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 brake fluid — Brake disc thickness 4.5 t 0.1 (0.18 t 0.004) 3.5 (0.14) Brake disc warpage — 0.20 (0008) Master cylinder ID. 15870 — 15.913 (0.6248 — 0.6265) 15.925 (0.6270) Master piston CD. 15327 — 15.854 (0.6231 — 0.6242) 15.815 (0.6226) Right caliper cylinder |.D. Upper 25.400 - 25.450 (1.0000 — 1.0020) 25.460 (1.0024) Middle 25.400 — 25.450 (1.0000 — 1.0020) 25.460 (1.0024) Lower 25.400 — 25.450 (1.0000 — 1.0020) 25.460 (1.0024) Right caliper piston O.D. Upper 25.318 — 25.368 (0.9968 — 0.9907) 25.310 (0.9965) Middle 25.318 — 25.368 (0.9968 — 0.9987) 25.310 (0.9965) Lower 25.31 S — 25.368 (0.9968 — 0.9987) 25.310 (0.9965) Left caliper cylinder |.D. Upper 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) Middle 30.230 — 30.280 (1.1902 — 1.1921) 30.290 (1.1925) Lower 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) Lefl caliper piston O.D. Upper 26.918 — 26.968 (1.0598 — 1.0617) 26.910 (1.0594) Middle 30.148—30.198(1.1869— 1.1889) 30.140 (1.1866) Lower 26318—26968 (1.0598— 1.0617) 26.910 (1.0594) Rear Specified brake fluid DOT 4 brake fluid — 'Master cylinder push rod length 67.5 :t 1 (2.66 :t 0.04) — Brake disc thickness 6.0 1 0.2 (0.24 t 0.008) 5.0 (0.20) Brake disc warpage — 0.30 (0012) Master cylinder I.D. 17.460 — 17.503 (0.6874 — 0.6391) 17.515 (0.6896) Master piston OD. 17.417 — 17.444 (0.6857 — 0.6868) 17.405 (0.6852) Caliper cylinder |.D. Front 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) Rear 27.000 — 27.050 (1.0630 - 1.0650) 27.060 (1.0654) Caliper piston OD. Front 26.918 — 26.968 (1.0598 — 1.0617) 26.910 (1.0594) Rear 26913-26363 (1.0598— 1.0617) 26.910 (1.0594) BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V — 11.2 Ah Current leakage 1.2 mA max. Voltage Fully charged 13.0 — 13.2 V (20 cm F) 2:35an Below 12.3 v Charging current Normal 1.1 NS — 10 h Quick 5.5 A/ h Alternator Capacity 057 kW/5,000 rpm Charging coil resistance (20°C/68°F) 0.1 — 1.0 0 1-10 GENERALMFORMAflON IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Spark plug lMRQE-QHES (NGK) VUH27ES (DENSO) Spark plug gap 0.80 — 0.90 mm (0.031 — 0.035 in) CKP sensor peak voltage 0.7 V mlnimum Ignition timing ("F"mark) 8.4“ BTDC at idle ELECTRIC STARTER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.0 (0.47) 6.5 (0.26) LlGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight Hi 12 V — 55 W Lo 12 V — 55 W Brake/taillight 12 V — 21/5 W Taillight 12 V — 5 W Position light LED Front turn signal light 12 V — 21 W x 2 Rear turn signal light 12 V—21 Wx2 License light 12V — 5 W Instrument light LED Turn signal indicator LED High beam indicator LED Neutral indicator LED Low Oil pressure indicator LED PGM-FI malfunction indicator LED High coolant temperature indicator LED ABS indicator LED Fuse Main Iuse A 50 A ' B 30 A PGM~FI fuse 10 A Subiuse 30Ax3,20Ax2,15Ax1,10Ax4 Tachometer peak voltage 10.5 V minimum ECT sensor resistance 80°C (176°F) 2.1 — 2.6 kn 120°C (248°F) 0,65 — 0.73 kg Open air temperature sensor resistance (25°C/77’F) 3 — 7 kn 1-11 GENERAL INFORMATION TORQUE TORQUE FASTENER TYPE N1" (Wm mm) FASTENER TYPE N.,,, “99",, My.) 5 mm hex bolt and mi 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4. 3.1) 6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9. 6.6) 8 mm hex bolt and nut 22 (2.2. 16) 6 mm flange bolt (8 mm head. small flange) 10 (1.0, 7) 10 mm hex bolt and nut 34 (3.5, 25) 6 mm flange bolt (8 mm head. large flange) 12 (1.2, 9) 12 mm hex bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9) 8 mm flange bolt and nut 27 (2.8, 20) 10 mm flange bolt and nut 39 (4.0, 29) ENGINE & FRAME TORQUE VALUES ‘ Torque specifications listed below are for important fasteners. o Others should be lightened to standard torque values listed above. EN GIN E MAINTENANCE THREAD TORQUE "EM QTY DIA. (mm) N-m (kgt-m, lbf-fl) REMARKS Spark plug 4 10 16(1.6, 12) Timing hole cap 1 45 17 (1.7, 13) Apply grease to the threads Engine oil fllter cartridge 1 20 26 (2,7, 19) Apply engine oil to the threads. Valve adjusting screw lock nut 8 5 10 (1.0, 7) Apply engine oil to the threads. Engine oil drain bolt 1 14 29 (3.0, 21) LUBRICATION SYSTEM . THREAD TORQUE "EM Q TY DIA. (mm) N-m (kgf-m, lbt-fl) REMARKS Oil filter boss 1 20 See page 4-14 Oil pump mounting bolt 6 6 12 (1.2, 9) Oil pump dn‘ven sprocket bolt 1 6 15 (1.5, 11) Apply a locking agent to the threads. Oil pump cover bolt ‘ 8 6 11 (1.1. 8) Oil pump chain guide bolt 1 6 12 (1.7, 9) Apply a locking agent to the threads. Oil cooler bolt 1 20 59 (6.0, 44) Apply engine oil to the threads. FUEL SYSTEM (PGM-FI) THREAD TORQUE "EM '3'" DIA. (mm) N-m (kgf-m, [bf-It) REMARKS ECT sensor 1 12 25 (2.5. 18) Throttle body insulator band screw 4 5 See page 6-77 TCP sensor throttle cable stay screw 2 5 3.4 (0.3, 2.5) Knock sensor 1 8 24 (2.4, 18) Knock sensor bridge bolt 2 8 24 (2.4. 18) Oz sensor 2 18 24.5 (2.5, 18) Fuel rail mounting bolt l 8 5 5.1 (0,5. 3.8) COOLING SYSTEM THREAD TORQUE ITEM Q'TY DIA' (mm) N1“ (kghu‘ “1H” REMARKS Water pump cover flange bolt 2 6 13 (1.3, 10) CT bolt. 1-12 CYLINDER HEADNALVES GENERAL INFORMATION THREAD TORQUE "EM QTY DIA. (rum) N~m (kgf-m, Ibf-ft) REMARKS Cylinder head sealing bolt 4 12 32 (3.3, 24) Apply a locking agent to the threads. Cylinder head sealing bolt 2 18 27 (2.8, 20) Apply a locking agent to the threads. Insulator socket bolt 8 6 12 (1.2, 9) Front PAIR check reed valve cover 2 6 13 (1.3, 10) CT bolt. Fronl breather plate flange bolt 2 6 13 (1.3, 10) Apply a locking agent to the threads. CT bolt. Rear PAIR check reed valve cover 4 5 6.9 (0.7, 5.1) CT bolt. Cylinder head bleeding joint 2 8 12 (1.2. 9) Apply a locking agent to the threads. Rocker arm shalt socket bolt 14 6 13 (1.3, 10) Apply engine oil to the threads. Cam chain tensioner bolt 4 6 12 (1.2, 9) Cam chain tensioner base special bolt 2 6 1D (1.0. 7) Apply a locking agent to the threads. Front cylinder head cover bolt 4 5 12 (1.2. 9) Rear cylinder head oover bolt 3 6 12 (1.2, 9) Cam chain tensioner pivot socket bolt 2 6 12 (1.2.9) Apply a locking agent to the threads. Rear cam chain guide set plate bolt 1 6 12 (1.2, 9) Apply a locking agent to the threads. Camshafl holder bolt 12 6 12 (1.2. 9) Apply engine oil to the threads. Cam sprocket bolt (front) 2 7 2D (2.0, 15) Apply a locking agent to the threads. Cam sprocket UBS bolt (rear) 2 7 20 (2.0. 15) Apply a locking agent to the threads. UBS bolt. Cylinder head mounting bolt 13 10 57 (5.8. 42) Cylinder head stud bolt (exhaust pipe stud bolt) 8 6 See page 3-27 CLUTCH/GEARSHIFT LINKAGE THREAD TORQUE , . "EM QTY DIA. (mm) N-rn (kgf-m, Ibf-ft) REMARKS Clutch center lock nut 1 25 186 (19.0, 137) Apply engine oil to the threads. Stake. Change guide plate bolt 2 6 12 (1.2, 9) Apply a locking agent to the threads. Shift drum center pin bolt 1 B 23 (2.3, 17) Apply a looking agent to the threads. Gearshift spindle return spring pin 1 8 23 (2.3, 17) Right crankcase cover rubber plate bolt 3 G 12 (1.2. 9) Apply a locking agent to the threads. Gearshifl spindle plate bolt 1 6 12 (1,2, 9) Apply a locking agent to the threads. CKP sensor rotor/primary drive gear flange bolt 1 12 98 (10.0, 72) Apply engine oil to the threads and flange surface. Left hand threads. Clutch slave cylinder mounting bolt 3 6 12 (1.2. 9) Clutch slave cylinder bleeder screw 1 8 9.0 (0.9. 6.6) 1-13 GENERAL INFORMATION ALTERNATORISTARTER CLUTCH THREAD TORQUE "EM QTY DIA. (mm) N-m (kgf-m. rum) REMARKS Flywheel flange bolt 1 12 137 (14.0, 101) Apply engine oil to the threads and seating surlaoe. Alternator oover sealing bolt 2 8 23 (2.3, 17) Starter clutch torx bolt 6 6 16 (1.6, 12) Apply a locking agent to the threads. Stator socket bolt 4 6 12 (1.2, 9) Apply a locking agent to the threads. Stator wire holder socket bolt 1 6 12 (1.2, 9) Apply a locking agent to the threads. CRANKCASEITRANSMISSION , THREAD TORQUE ITEM Q TY DIA. (mm) "m (kme M“) REMARKS Main journal 9 mm bolt 6 9 25 (2.5, 18)+270° Countershaft socket bolt 1 1O 67 (6.3. 49) Apply engine oil to the threads and seating surface. Mainshafl bearing set plate and oil pump chain 3 6 12 (1.2, 9) Apply a locking agent guide bolt to the threads. Lower crankcase 8 mm bolt 4 8 24 (2.4, 18) Lower crankcase 7 mm bolt 6 7 18(1.B, 13) Lower crankcase 6 mm bolt 8 6 12 (1.2, 9) Lower crankcase sealing bolt 1 22 59 (6.0, 44) Apply a looking agent to the threads. Upper crankcase sealing bolt 1 22 59 (6.0, 44) Apply a locking agent to the threads. Final shafl socket bolt 1 1O 67 (6.8, 49) Apply engine oil to the threads. Side gear case mounting bolt 5 8 32 (3.3, 24) UBS bolt Side gear case bearing holder bolt 7 8 31 (3.2, 23) UBS bolt Side gear case lock nut 2 30 235 (24.0, 173) Stake. Side gear case lock nut (final shafl side) 1 64 98 (10.0, 72) Stake. Side gear case lock nut (output shaft side) 1 64 175 (17.8, 129) Stake, CRANKSHAFTIPISTONICYLINDER THREAD TORQUE ITEM ow BIA (mm) "I," (mm, mm REMARKS Connecting rod bearing cap bolt 8 B 27 (2.8, 20)+120° Apply engine oil to the threads and seating surface. Oil jet mounting bolt 2 6 12 (1.2, 9) Apply a locking agent to the threads. IGNITION SVSTEM , THREAD TORQUE "E" Q TY DIA. (mm) N~m (kgfm, IbMt) REMARKS CKP sensor mounting bolt 2 6 12 (1.2, 9) Apply a locking agent to the threads. ELECTRIC STARTER THREAD TORQUE ITEM QTY DIA. (mm) N-m (kgfm, Ibf-fl) REMARKS Starter motor terminal nut 1 6 12 (1.2, 9) Negative brush mounting screw 1 5 3.7 (0.4, 3.0) Starter motor cable nut 1 6 1D (1.0, 7) Starter motor case bolt 2 — 4.9 (0.5, 3.6) LlGHTS/METERSISWITCHES . THREAD TORQUE "E" Q TY DIA. (mm) N-m (kgf~m, let) REMARKS EOP sensor 1 1O 22 (2.2, 16) 1-14 GENERAL INFORMATION FRAME MAINTENANCE THREAD TORQUE ITEM Q'TY DIA. ("um N'm “(army lbw!) REMARKS Air cleaner element screw 2 4 0.8 (0.1, 0.6) Air cleaner cover screw 6 4 0.8 (0.1. 0.6) FRAME BODY PANELS/EXHAUST SYSTEM THREAD TORQUE ITEM Q'TY DIA. (mm) N.m( my lbw!) REMARKS Seat rail upper mounting flange bolt/nut 2 10 34 (3.5, 25) Seat rail lower mounting flange bolt 2 10 34 (3.5. 25) Seat rail assembly flange bolt 1 8 30 (3.1. 22) Rear fender mounting bolt (short) 3 8 32 (3.3. 24) Rear fender mounting bolt (long) 1 B 32 (3.3, 24) Center cross mounting bolt 4 6 12 (1.2, 9) Exhaust pipe joint special nut B 6 12 (1.2. 9) EGCA cable joint nut 1 12 21 (2.1. 15) Exhaust pipe muffler band 3 8 17 (1.7, 13) Muffler upper guard bolt 3 6 10 (1.0, 7) Muffler rear guard bolt 3 5 5.2 (0.5, 3.3) Cowl stay bolt 2 3 32 (3.3. 24) FUEL SYSTEM , THREAD TORQUE ITEM 0 TY BIA. (mm’ Mm (kgfim‘ lM‘n) REMARKS Fuel filler cap bolt 3 4 1.8 (0.2. 13) Fuel pump mounting nut 6 6 12 (1.2. 9) Air cleaner case screw 8 4 0.8 (0.1. 0.6) Resonator screw 4 4 0.8 (0.1, 06) Bank angle sensor mounting bolt 2 4 1.5 (0.2, 1.1) IAT sensor 2 5 1.1 (0.1. 0.8) MAP sensor 2 4 1.1 (0.1, 0.8) Air funnel mounting screw 8 5 4.2 (0.4. 3.1) COOLING SYSTEM . THREAD TORQUE "EM 0 W DIA. (mm) N-m (kgfm, Ibf-Il) REMARKS Fan motor shrr ud mounting bolt 3 6 8.4 (0.9, 6.2) Cooling fun nut 2 5 2.7 (0.3, 20) Fan motor mounting bolt 6 5 5.1 (0.5. 3.8) ENGINE MOUNTING . THREAD TORQUE "EM ‘3 TY DlA. (mm) N-m (kgr~m, lbf-tt) REMARKS Front engine hanger bolt 2 12 54 (5.5, 40) Upper engine hanger bolt 2 12 54 (5.5. 40) Rear upper engine hanger nut 1 12 54 (5.5. 40) Rear lower engine hanger nut 1 12 84 (8.6. 62) Engine hanger adjusting bolt 2 18 5.0 (0.5, 3.7) 1-15 GENERAL INFORMATION CLUTCH/GEARSHIFT LINKAGE . THREAD TORQUE "E" Q TY DlA. (mm) N-m (kgfm, lbf-II) REMARKS Clutch master cylinder holder bolt 2 6 12 (1.2, 9) Clutch master cytinder reservoir cap screw 2 4 1.5 (0.2. 1.1) Clutch lever pivot bolt 1 B 1.0 (0.1, 0.7) Clutch lever pivot nut 1 6 5.9 (0.6. 4.4) Clutch lever switch screw 1 4 1.2 (0.1, 0.9) Clutch hose oil bolt 2 10 34 (3.5. 25) Gearshift pedal pivot bolt 1 8 22 (2.2, 16) Gearshift arm pinch bolt 1 6 1D (1.0, 7) ALOC bolt: replace with a new one. Link arm lock nut 2 6 10 (1.0, 7) FINAL DRIVE THREAD TORQUE , "EM QTY DIA. (mm) N-m (kgr-m, lbf-tt) REMARKS Final gear case cover 10 mm bolt 2 10 62 (6.3, 46) Apply a locking agent to the threads. Final gear case oover 8 mm bolt 6 8 25 (2.5, 18) Apply a locking agent to the threads. Ring gear shaft bearing retainer 1 75 221 (22.5, 163) Replace with a new one and stake. Apply grease or gear oil to the threads. Final gear case bolt 1 75 221 (22.5, 163) ALOC bolt: replace with a new one. Apply grease or gear oil to the threads. Pinion gear bearing retainer 1 75 235 (24.0, 173) Replace with a new one and stake. Pinion gear lock nut 1 35 206 (21.0. 152) Replace with a new one and stake. Final gear assembly stud bolt 4 12 See page 14-23 Apply a locking agent to the threads. Final gear assembly mounting nut 4 12 88 (9.0, 65) Final drive oil drain bolt 1 8 12 (1.2, 9) Final drive all filler gap 1 20 8.0 (0.8, 5.9) Rear brake disc flange mounting screw 2 6 9.0 (0.9, 6.6) FRONT WHEEL/SUSPENSIONISTEERING THREAD TORQUE ITEM Q'TY DIA- mun) Mm (kghm lbflt) REMARKS Handlebar weight mounting screw 2 6 10 (1.0, 7) ALOC bolt: replace with a new one. Front axle bolt 1 18 79 (8.1. 58) Front axle holder pinch bolt 2 8 22 (2.2, 16) Fork socket bolt 2 8 20 (2.0. 15) Apply a locking agent to the threads. Fork bolt 2 42 22 (2.2. 16) Fork damper rod lock nut 2 — 15.5 (1.6. 11) Steering stern nut 1 24 103 (10.5, 76) Steering bearing adjusting nut ‘ 1 26 45 (4.6, 33) Steering bearing adjusting lock nut 1 26 See page 15—38 Fork top bridge pinch bolt 2 8 22 (2.2. 16) Fork bottom bridge pinch bolt 2 8 27 (2.8. 20) Left handlebar switch housing screw 2 5 2.5 (0.3. 1.8) Right handlebar switch/throttle housing screw 2 5 2.5 (0.3, 1.8) 1-16 GENERAL INFORMATION REAR WHEELISUSPENSION THREAD TORQUE ITEM Q'TY Du. (mm) “m (kgf'm’ lbflfl) REMARKS Rear wheel nut 5 12 108 (11.0. 80) Rear shock absorber bracket mounting nut 1 10 42 (4.3. 31) U-nut Rear shock absorber upper mounting nut 1 10 44 (4.5. 32) U-nut Rear shock absorber lower mounting nul 1 10 44 (4.5. 32) U-nut Shock arm-lo—shpck link plate nut 1 12 64 (6.5. 47) U-nut Shock arrn-to-frarne pivot nut 1 12 64 (6.5. 47) U-nul Shock link plate—lo-swingarrn nut 1 12 64 (6.5. 47) U-nut Swingarm pivot adjust bolt 1 36 15 (1.5. 11) Swingarrn pivot nut 1 22 108 (11.0. 80) U-nut HYDRAULIC BRAKE THREAD TORQUE ITEM QTY M (mm N'm «gm, lbw) REMARKS Brake caliper bleed valve 4 B 5.4 (0.6. 4.0) Front master cylinder reservoir cap screw 2 4 1.5 (0.2. 1.1) Front brake caliper mounting bolt 4 1D 45 (4.6. 33) ALOC bolt: replace with a new one. Pad pin 3 1O 18(1.B,13) Front brake disc bolt 10 6 20 (2,0. 15) ALOC bolt: replace with a new one. Rear brake disc bolt 5 8 42 (4.3. 31) ALOC bolt: replace with a new one. Front brake light switch screw 1 4 1.2 (0.1. 0.9) Front brake lever pivot bolt 1 6 1.0 (0.1. 0.7) Front brake lever pivot nut 1 6 5.9 (0.6. 4.4) Front master cylinder holder bolt 2 6 12 (1.2. 9) Brake hose oil bolt 6 10 34 (3.5. 25) Rear master cylinder push rod joint nut 1 8 13 (1.8, 13) Rear master cylinder mounting nut 2 6 12 (1.2. 9) Rear master cylinder reservoir hose joint screw— 1 4 1.5 (0.2. 1.1) Apply a locking agent washer to the threads. Rear brake galjper main slide pin 1 12 23 (2.3. 17) Rear brake caliper sub slide pin 1 0 13 (1.3, 9) Rear brake caliper mounting bolt 2 10 45 (4.6. 33) ALOC bolt: replace with a new one. Rear brake reservoir mounting bolt 1 6 12 (1.2. 9) Rear brake pipe clamper bolt 2 6 10 (1.0. 7) ALOC bolt: replace with a new one. Rear brake pipe stay nut 1 6 4.0 (0,4. 3.0) Brake hose (2/3 way joint) 2 6 10 (1.0. 7) PCV mounting bolt 2 6 10 (1.0. 7) Brake hose damper slay boll 2 6 10 (1.0. 7) 1-17 GENERAL INFORMATION ANTI-LOCK BRAKE SYSTEM (ABS) THREAD TORQUE "EM QTY DIA (mm) N-m (kgt-m, tbf-lt) REMARKS Front wheel pulser ring mounting boll 5 5 7.0 (0.7, 5.2) ALOC bolt: replace with a new one. Rear wheel pulser ring mounting boil 5 5 7.0 (0.7. 5.2) ALOC bolt: replace with a new one. Brake pipe joint nut 2 10 14 (1.4, 10) Apply engine oil to the threads and seating surface. Delay valve mounting bolt 1 6 10 (1.0, 7) LIGHTS/METERS/SWITCHES , THREAD TORQUE "EM Q TY DIA. (mm) N-m (kgf~m, lbf-lt) REMARKS Sidestand switch bolt 1 6 10 (1.0. 7) ALOC bolt: replace with a new one. Meter screws 3 5 1.0 (0,1. 0.7) Taillight SH bolt 1 6 .0 Front turn signal cover screws 2 4 Ignition switch mounting bolt 2 8 Replace wim a new one. OTHERS , THREAD TORQUE "EM Q TV DIA. (mm) N~m (kr-m, lbf-ft) REMARKS Rider footpeg bracket socket bolt 2 8 34 (3.5, 25) Rider foolpeg bracket socket bolt 2 1O 34 (3.5, 25) Rider footpeg cap bolt 2 6 12 (1.2, 9) Rider footpeg special bolt 2 5 5.1 (0.5. 3.8) Passenger footpeg bracket flange bolt 4 8 32 (3.3. 24) Passenger lootpeg special bolt 2 6 5.1 (0.5. 3.8) Passenger footpeg lock nut 2 6 12 (1.2. 9) Inner layer cowl stay bolt 2 B 18 (1.8, 13) Sidestand bracket mounting bolt 2 10 39 (4.0. 29) Sidestand pivot bolt, . 1 10 10 (1.0. 7) After tighten the pivot bolt to the specified torque, return the bolt 45" to 90". Sidestand nut 1 10 29 (3.0, 21) 1-18 LUBRICATION & SEAL POINTS GENERAL INFORMATION ENGINE MATERIAL LOCATION REMARKS Liquid sealant (Three crankcase mating surface See page 12-23 Bond 12073 or Oil pan mating surface See page 5—6 eqUivalem) Right crankcase cover mating surface See page 10-32 Altemator oover mating surface See page 11—6 CKP sensor wire grommet Three Bond 1211 or 12073 Stator wire grommet seating surface Three Bond 1211 or 12073 Liquid sealant Cylinder head semi-circular cut-out See page 9—7 (Three Bond 52116. SSKE45T or equivalent) Engine oil Piston and piston ring sliding surface Clutch disc entire surface Flywheel bolt threads and seating surface Clutch center lock nut threads and seating surface Oil filter cartridge threads and O-ring surface Camshaft holder bolt threads and seating surface Valve stem seal inner surface Valve adjusting screw lock nut threads Valve adjusting screw threads Primary drive gear flange bolt Countershaft socket bolt Final shaft socket bolt Rocker arm shaft bolt Connecting rod bolt threads and seating surface Spark plug hole seal ring inner surface Each gear teeth and rotating surface Each bearing rolling surface Each O-ring whole surface Other rotating area and sliding surface Except water pump cover and water joint O-ring Molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease) Main journal bearing surface Piston pin sliding surface Connecting rod bearing surface Connecting rod small end inner surface Rocker arm pivot and valve slipper Camshaft lobes, journals and thrust surface Camshaft thrust surface Valve stem (valve guide sliding surface) Exhaust valve stem end Valve lifler outer sliding surface Clutch outer/primary driven gear sliding surface Primary drive gear/sub-gear sliding surface M3IM4,CS,CG shifter gear (shift fork grooves) Starter reduction gear sliding surface Do not apply mating surface of the camshaft holder Multi-purpose grease Timing hole cap threads Gear position sensor small O-ring Each oil seal lip 1-19 GENERAL INFORMATION MAYERIAL LOCATION REMARKS Locking agent Cylinder head 12 mm and 18 mm sealing bolt threads Upper crankcase 22 mm sealing bolt threads Lower crankcase 22 mm sealing bolt threads Cylinder head cover breather plate bolt threads Mainshafl bearing set plate/oil pump chain guide bolt threads Oil pump driven sprocket bolt threads Oil jet mounting bolt threads Gearshift spindle plate bolt threads Starter clutch bolt threads CKP sensor mounting bolt threads Stator wire holder socket bolt threads Stator socket bolt threads Change guide plate bolt threads Cam chain tensioner pivot socket bolt threads Rear cam chain guide set plate bolt threads Cam chain tensioner base special bolt threads Right crankcase cover rubber plate bolt threads Oil filter boss threads (crankcase side) Cam sprocket bolt threads Shilt drum center pin bolt thread Coating width 6.5 1 1.0 mm except 3.0 — 4.0 mm from tip Coating width 6.5 i 1.0 mm except 2.0 21.0 mm from tip Coating width 6.5 1: 1.0 mm except 2.0 t 1.0 mm from tip Coating width 6.5 :t 1.0 mm except 2.0 11.0 mm from tip Coating width 6.5 t 1.0 mm except 2.0 t 1.0 mm from tip Coating width 6.5 1 1.0 mm except 2.0 21.0 mm from tip Coating width 65 2 10 mm except 2.0 t 1.0 mm from tip Coating width 6.5 t 1.0 mm except 2.0 11.0 mm from tip Coating width 6.5 1 1.0 mm except 2.0 1: 1.0 mm from tip Coating width 6.5 t 1.0 mm except 2.0 :10 mm from tip Coating width 6.5 1 1.0 mm except 2.0 11.0 min from tip Coating width 55 i 1.0 mm except 2.0 t 1.0 mm from tip Coating width 6.5 t 1,0 mm except 2.0 21.0 mm from tip Coating width 4.0 t 1.0 mm except 2,0 2 1.0 mm from tip 1-20 FRAME GENERAL INFORMATION MATERIAL LOCATION REMARKS Multi-purpose grease Sidestand pivot sliding area Final gear case O»ring (3 places) Final gear case oil seal lips (2 places) Ring gear shaft bearing retainer threads Final gear case threads Rider footpeg sliding area Passenger footpeg sliding area Throttle grip pipe/cable end Rear brake pedal pivot sliding area Clutch lever pivot Change pedal pivot sliding area Front wheel dust seal lips Seat catch hook sliding area Molybdenum disultide grease Swingann pivot dust seal lips Swingarrn ball bearing Swingann pivot needle bearings Shock arm needle bearings Shock arm pivot dust seal lips Final drive shalt splines (output shaft and joint shaft) Final drive pinion joint splines Shock absorber pivot dust seal lips shock absorber needle bearing 1.09—1.59 Urea based multi-purpose grease with extreme pressure agent (example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan), Shell Stamina EP2 or equivalent) Upper and lower steering head bearing Steering head dust seal lips Steering head bearing adjusting nut threads Apply 3 v 5 g each Apply 0.1 - 0.3 g each Cable lubricant Throttle cable A, B casing inside MORI LG or equivalent Exhaust valve cable SHELL ALVANIA N02 Change pedal ball joints or equivalent Honda bondfi“ Handlebar grip rubber inside or equivalent Brake caliper bracket retainer Silicone grease Brake caliper slide pin sliding surfaces Front brake lever pivot/adjusterlpush rod sliding area Front brake Iever-to—master piston contact area Rear master cylinder push rod-to-master piston contact area Clutch master piston contact area Apply 0.1 9 Clutch lever pivot Apply 0.1 9 Clutch lever joint pieoe-to-push rod contact area Apply 0.1 9 DOT 4 brake fluid Brake pipe threads Brake and clutch master cylinder inside Brake and clutch master pistons and cups Brake caliper pistons and piston seals Fork fluid Fork cap O-ring Fork dust seal and oil seal lips Locking agent Brake caliper slider pin threads Final gear case oover bolt threads 8 places Final gear case stud bolt 4 places Hypoid gear oil #80 Final drive gear case inside 200 cm3 (Full) 240 cm3 (Exchange) 1-21 GENERAL INFORMATION CABLE & HARNESS ROUTING RIGHT POSITION LIGHT 1P COMBINATION METER ZOP LEFT TURN SIGNAL 2P CONNECTOR (GRAY) CONNECTOR (ORANGE) CONNECTOR LEFT POSITION LIGHT 1P CONNECTOR .i EIT RIGHT TURN SIGNAL 2P (LIGHT BLUE) CONNECTOR FRONT SUB—HARNESS 4P (GRAY) CONNECTOR HEADLIGHT 3P FRONT SUB~HARNESS ZSP (BLACK) CONNECTOR (BLACK) CONNECTOR LEFT TURN SIGNAL 2P LEFT POSITION LIGHT 1P FRONT SUB—HARNESS 4P (ORANGE) CONNECTOR CONNECTOR (GRAY) CONNECTOR OPEN AIR TEMPERATURE SENSOR ’ 2P (BLACK) CONNECTOR /\l\ TURN SIGNAL RELAY OPEN AIR TEMPERATURE SENSOR FRONT SUB-HARNESS 23P LEFT FAN MOTOR 2P (BLACK) CONNECTOR (BLACK) CONNECTOR GROUND POINT 1 -22 GENERAL INFORMATION THROTTLE CABLES FRONT BRAKE HOSE CLUTCH HOSE RIGHT HANDLEBAR SWITCH WIRE DELAV VALVE LEFT HANDLEBAR SWITCH WIRE ABS MODULATOR FRONT WHEEL SPEED SENSOR 2P ENGINE SUB-HARNESS 5P (BLUE) CONNECTOR (BLACK) CONNECTOR RIGHT FAN MOTOR 2P (BLACK) CONNECTOR OIL COOLER WATER HOSE STARTER MOTOR CABLE No.2l3 02 SENSOR OIL COOLER WATER HOSE No.1/4 02 SENSOR 1 -23 GENERAL INFORMATION FRONT BRAKE HDSES HORN CONNECTORS FRONT BRAKE HOSE FRONT WHEEL SPEED FRONT WHEEL SPEED SENSOR WIRE SENSOR WIRE FRONT WHEEL SPEED SENSOR WIRE FRONT WHEEL SPEED SENSOR WIRE ' FRONT WHEEL SPEED FRONT BRAKE HOSE SENSOR WIRE 1 -24 GENERAL INFORMATION FUEL TANK OVERFLOW HOSE FUEL HOSE RADIATOR To fuel tank OVERFLOW HOSE EVAP PURGE CONTROL VALVE To throttle I body // EVAP CANISTER DRAIN HOSE EVAP CANISTER Q; DRAIN HOSE RADIATOR RESERVE TANK OVERFLOW HOSE LEFT HANDLEBAR SWITCH 1GP HEADLIGHT RELAY (GRAY) CONNECTOR RIGHT HANDLEBAR SWITCH 1OP (GRAV) CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR CMP SENSOR 3P (BLACK) CONNECTOR INJECTOR SUB-HARNESS 12P (BLACK) CONNECTOR No2 DIRECT IGNITION COIL 2P (WHITE) CONNECTOR FUEL PUMP 2P I (BROWN) CONNECTOR KNOCK SENSOR 3P (BLACK) CONN ECTOR GROUND POINT FUEL LEVEL SENSOR 2P NoIs DIRECT IGNITION COIL 2P (BLACK) CONNECTOR (WHITE) CONNECTOR 1 -25 GENERAL INFORMATION IAT SENSOR 2P (GRAY) IGNITION SWITCH 2P AIR SUPPLV HOSE CONNECTOR (BROWN) CONNECTOR CRANKCASE BREATHER HOSE SIPHON HOSE WATER HOSE PAIR AIR SUCTION HOSE MAIN w|RE HARness No.1 INJECTOR 2P ECM THROTTLE CABLES No.4 INJECTOR 2p (GRAY) CONNECTOR (GRAY) CONNECTOR MAP SENSOR 3P (BLACK) CONNECTOR TCP SENSOR 6P (BLACK) CONNECTOR INJECTOR SUB-HARNESS 12P (BLACK) CONNECTOR CMP SENSOR 3P (BLACK) CONNECTOR KNOCK SENSOR 3P LEFT HANDLEBAR (BLACK) CONNECTOR SWITCH 10F (GRAY) CONNECTOR RIGHT HANDLEBAR SWITCH 1DP HEADLIGHT RELAY (GRAY) CONNECTOR No.2 INJECTOR 2P - (GRAY) CONNEcToR No.3 INJECTOR 2P PAIR CONTROL SOLENOID VALVE 2P (GRAY) CONNECTOR (BLACK) CONNECTOR 1 -26 GENERAL INFORMATION No.1 DIRECT IGNITION COIL 2P (WHITE) CONNECTOR NoA DIRECT IGNITION COIL 2P (WHITE) CONNECTOR ECT SENSOR 3P (GRAY) CONNECTOR ‘ , <5? \// AIR BLEED HOSE KNOCK SENSOR EOP SENSOR 3P (BLACK) CONNECTOR RADIATOR RESERVE TANK OVERFLOW HOSE ENGINE SUB-HARNESS 6P FRONT WHEEL SPEED (BLACK) CONNECTOR SENSOR 2P (BLU E) CONNECTOR SIPHON HOSE RIGHT FAN MOTOR 2P / (BLACK) CONNECTOR CKP SENSOR 2? (BLACK) CONNECTOR 1 -27 GENERAL INFORMATION No.1/4 02 SENSOR 4P (BLUE) CONNECTOR TBW6P(BLACK) ALTERNATOR CONNECTOR WIRE GEAR POSITION SENSOR 8P (BLACK) CONNECTOR LEFT FAN MOTOR 2P (BLACK) CONNECTOR No.2/3 02 SENSOR 4P (BLACK) CONNECTOR SIDESTAND SWITCH 2P (BLACK) CONNECTOR fib \ ‘ RADIATORHOSE OILCOOLER I r V :i f\, WATER HOSE * “ i?- l No.2/3 Oz SENSOR No.1l4 02 SENSOR SIDESTAND SWITCH WIRE SIDESTAND SWITCH GROUND POINT EGCA 6P (BLACK) STARTER MOTOR BATTERY CABLE CONNECTOR CABLE STARTER RELAY SWITCH DLC BANK ANGLE SENSOR 3P / (BLACK) CONNECTOR BATTERY NEGATIVE (—) FUSE BOX BATTERY POSITIVE (+) TERMINAL TERMINAL 1-28 GENERAL INFORMATION GROUND WIRE (RED) FAN MOTOR/FUEL PUMP/ENGINE STOP/TBW RELAYS MAIN WIRE HARNESS STARTER MOTOR CABLE ,, } ,r : ~' ‘1‘ BA'I'I’ERY WIRE ‘ A. I ‘ ‘ “ ‘ T (GREEN) ,/ A "I ALTERNATOR WIRES (YELLOW) -1! ,: W v V r T /4-—I REAR COMBINATION , 3 . 6P (BLACK) CONNECTOR mg/ ‘ GROUND POINT MAIN WIRE HARNESS EGCA 5P (BLACK) REAR BRAKE LIGHT SWITCH CONNECTOR 2P (BLACK) CONNECTOR REAR BRAKE RESERVOIR CO, REAR BRAKE LIGHT SWITCH EGCA CABLE 1 -29 GENERAL INFORMATION REAR WHEEL SPEED SENSOR MAIN WIRE HARNESS 2P (ORANGE) CONNECTOR YELLOW PAINT REAR WHEEL SPEED REAR BRAKE HOSE sENSOR WIRE REAR WHEEL SPEED J SENSOR WIRE REAR BRAKE HOSE REAR WHEEL SPEED SENSOR WIRE 1 -30 GENERAL INFORMATION LICENSE LIGHT 3P (WHITE) CONNECTOR LICENSE LIGHT WIRE EVAP PURGE CONTROL SOLENOID VALVE 2P (Black) TO fuel tank FU EL TANK OVERFLOW HOSE \ l/y/ / // “ _,, To Ihrome body WV ‘ / EVAP CANISTER DRAIN HOSE 1-31 GENERAL INFORMATION EMISSION CONTROL SYSTEMS EXHAUST EMISSION REQUIREMENT The US. Environmental Protection Agency (EPA), California Air Resources Board (CARB) and Transport Canada require manufacturers to certify that their motorcycle comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided. NOISE EMISSION REQUIREMENT The EPA also requires that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6.000 km (3,730 miles) after the time of sale to me ultimate purchaser, when operated and maintained according to the instructions provided. WARRANTY COMPLIANCE Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of carbon monoxide, oxides of nitrogen and hydrocarbons is very important because. under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way. but it is toxic. Uncontrolled fuel evaporation also releases hydrocarbons to the atmosphere. Honda Motor Co“ Ltd. utilizes various system to reduce carbon monoxide, hydrocarbons, and oxides of nitrogen. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. BlowJoy gas is returned to the combustion chamber through me air cleaner and throttle body. AIR CLEANER HOUSING THROTTLE BODY « BLOW>BY GAS <2 FRESH AIR 1 -32 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a secondary air injection system, a three-way catalytic converter and PGM—FI system. SECONDARY AIR SUPPLY SYSTEM The secondary air supply system introduces filtered air into the exhaust gases in Ihe exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse Secondary Air Injection) control valve. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevents reverse air flow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid valve is controlled by the ECM, and the fresh air passage is opened/closed according the running condition (ECT/IATITP/ MAP sensor and engine revolution). No adjustments to the secondary air supply system should be made. although periodic inspection of the components is recommended AIR CLEANER HOUSING PAIR CONTROL VALVE THROTTLE BODY PAIR CHECK ‘VALVE EXHAUST PORT « EXHAUST GAS <3: FRESH AIR THREE-WAY CATALYTIC CONVERTER This motorcycle is also equipped with three-way catalytic converter. and two heated oxygen sensors. The three-way catalytic converter is in the exhaust system. Through chemical reactions, they convert HC. CO, and NOx in the engine's exhaust to carbon dioxide (002), nitrogen (N2), and water vapor. No adjustment to these systems should be made although periodic inspection 01 the components is recommended. 1 -33 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM This model complies with Califomia Air Resources Board evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body. EVAP PURGE CONTROL SOLENOID VALVE THROTTLE BODY EVAP CANISTER FUEL VAPOR 4:. FRESH AIR NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. Federal Law and Canadian provincial Law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement. of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; (2) the use of the vehicle afler such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED T0 CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1 . Removal or puncturing of the muffler. baffles. header pipes or any other component which conducts exhaust gases. 2. Removal or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4. Replacing any moving pans of the vehicle, or parts of the exhaust or intake system, with parts other then those specified by the manufacturer, FUEL PERMEATION EMISSION CONTROL SYSTEM This motorcycle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA). California Air Resources Board (CARB), and Environment Canada (EC). The fuel tank, Iuel hoses, and fuel vapor charge hoses used on this motorcycle incorporate fuel permeation control technologies Tampering with the fuel tank, fuel hoses. or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations. 1 -34 2. TECHNICAL FEATURES THROTTLE BY WIRE (TBW) SYSTEM ------ --2-2 COMPACT FINAL GEAR CASE ----------------- -- 2-4 SEALED—LOW AIR PRESSURE FRONT MONOBLOCK SIX PISTON CRANKCASE .............................................. ..2.3 OPPOSED CALIPER ................................. .. 2,5 OFFSET—PIVOT SWINGARM --------------------- "2.4 2-1 TECHNICAL FEATURES V THROTTLE BY WIRE (TBW) SYSTEM OUTLINE This motorcycle is equipped with an electronically controlled Throttle By ere (T BW) system. The system utilizes various sensors and controls to improve engine responsiveness and operation by providing fuel delivery that is smoother and more precise, The system is comprised of the throttle valves. throttle valve motor, TP (Throttle Position) sensorv TCP (Throttle Control Position) sensor. and ECM. The TBW system also utilizes information from the MAP, ECT, Gear Position, and Rear Wheel Speed sensors. THROTTLE VALVES ECM THROTTLE VALVE MOTOR TP SENSOR TCP SENSOR TBW system includes follow functions: v 1. Engine idle control function: When the engine is idling, the ECM automatically controls the throttle valve to maintain the proper idle speed according to engine loads. 2. intake air control function: The ECM controls the amount of intake air according to vehicle speed and driving conditions, which eliminates the need for a variable induction system and also reduces air induction noise. 3. Aoceleratio . control function: When the rider operates the throttle grip. the ECM controls the throttle valve opening based on signals from the TCP and other sensors. 4. Fail—safe function: The TBW system includes a fail-sate function that limits the engine or vehicle speed it a component of the system malfunctions TECHNICAL FEATURES OPERATION When the rider operates the throttle grip. the TCP sensor detects the throttle grip position and sends the information to the ECM. The ECM processes this information and that from the TP and other sensors to activate the throttle valves via the throttle valve motor. THROTTLE VALVE THROTTLE GRIP MOTOR MAP SENSOR ECT SENSOR GEAR POSITION SENSOR REAR WHEEL SPEED SENSOR TCP SENSOR M TPS 1 TPS 2 APS 1 TBW+M APS Z TBW-M TP SENSOR SEALED—LOW AIR PRESSURE CRANKCASE OUTLINE This molorcycle's engine utilizes a sealed-low air pressure crankcase design. This feature reduces friction and mechanical pumping (windege) losses. and allows for a more compact engine. Similar in design to racing engines, the engine uses an ail scavenge pump to create low air pressure in the sealed crankcase chamber while also pumping oil from the chamber to lubricate the transmission. SEALED—VACUUM CRANKCASE SCAVENGE PUMP TECHNICAL FEATURES OFFSET-PIVOT SWINGARM OUTLINE This motorcycle's chassis includes an offset-pivot swingarm. This design allows for optimum swingann and driveshall lengths without extending the overall length of the motorcycle It also helps to eliminate torque»induoed shafldrive jacking common on 7 conventional shafldnve designs. The oflset design places the driveshafl below the swingaml pivot point, to align with the output shaft, and utilizes a constant velocity joint to manage length variations. CONSTANT VELOCITY JOINT DRIVE SHAFT OFFSET PIVOT SWINGARM SWINGARM PIVOT COMPACT FINAL GEAR CASE OUTLINE This motorcycle utilizes a compact final gear case design, The size and weight oftne final gear case was reduced by using a smaller ring gear, which was made possible by offsetting the ring and pinion gear shafts. PINION GEAR SHAFT RING GEAR RING GEAR SHAFT FINAL GEAR CASE 2-4 TECHNICAL FEATURES FRONT MONOBLOCK SIX PISTON OPPOSED CALIPER OUTLINE This molorcycle's braking system includes front wheel, radially mounted. six—piston calipers, which improve braking perlormance. The six-piston calipers have (our separate brake pads, two on each side of the caliper‘ The upper pads on both sides of each caliper are operated by one piston each and the lower. larger pads are operated by Mo pistons each. The upper two opposed brake pads of the lefl caliper are combined with the rear brake and are only operated When the rear brake pedal is applied. The rest of the brake pads are operated by the front brake lever‘ LEFT UPPER SIDE BRAKE PAD (REAR BRAKE LINE) RIGHT SIDE BRAKE PADS (FRONT BRAKE LINE) LEFT LOWER SIDE BRAKE PAD (FRONT BRAKE LINE) MEMO 3. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS '- SERWCE INFORMATION ........................... ..3_3 TROUBLESHOOTING ---------- -- SEAT ............................................................ “3.4 REAR COWL ............................................... ..3_4 GRAB RAIL ................................................. ..3_4 TURN SIGNAL COVER/REAR CENTER COWL .......................................................... ..3_5 HNAL GEAR COVER ................................. ..3_5 FIVOT pLATE COVER ................................ ..3_5 INNER LOWER COWL ---------- -~3.s UNDER COWL ............................................ ..3_6 REARV|EW MIRROR .................................. "3.5 mm»; COWL ........................................... .. 3.1 FUEL TANK COVER. ........................ .. 3,8 UPPER S|DE COWL ................................... ..3_9 UPPER CENTER COWL/WINDSCREEN 3-10 FRONT FENDER ....................................... ..3_11 REAR FENDER- --3-11 SEAT RAIL ................................................ ..3_15 MUFFLER ................................. .. ..3.21 EXHAUST plpE ........................................ .. 3.24 .............................................. .. 3-1 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS FUEL TANK COVER UPPER SIDE COWL UPPER CENTER COWL WINDSCREEN ‘ FRONT FENDER REAR FENDER PIVOT PLATE COVER MIDDLE COWL INNER LOWER COWL REARVI R EW MIRRO GRAB RAIL TURN SIGNAL COVER] REAR COWL \ REAR CENTER COWL SIDESTAND UNDER COWL FINAL GEAR COVER SERVICE INFORMATION GENERAL fire or explosion. FRAME/BODY PANELS/EXHAUST SYSTEM Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a This section covers removal and installation of the body panels. exhaust system and sidestand. Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. Always replace the exhaust pipe gaskets after removing the exhaust pipes from the engine. When installing the exhaust system. looser install all of the exhaust pipe fasteners. Always tighten the exhaust clamps first. then tighten the mounting fasteners. It you tighten the mounting fasteners first, the exhaust pipe may not seat properly. - Always inspect the exhaust system for leaks after installation. TORQUE VALUES Rear fender stay mounting bolt (short) Rear fender stay mounting bolt (long) Seat rail assemny flange bolt Center cross plate mounting bolt Passenger tootpeg bracket flange bolt Seat rail upper mounting flange bolt/nut Seat rail lower mounting flange bolt Rear brake reservoir tank mounting bolt EGCA cable joint nut Muffler rear guard bolt Mulfler upper guard bolt Exhaust pipe mufller band Exhaust pipe joint special nut Rider footpeg bracket socket bolt Sidestand pivot bolt Sidestand pivot nut TROUBLESHOOTING Excesslve exhaust noise ' Broken exhaust system ' Exhaust gas leak Poor pertormain‘ce 1 Deformed exhaust system ' Exhaust gas leak - Clogged muffler 32 N»m (3.3 kgfm, 24 let) 32 N»m (3.3 kgf~m, 24 mm) 30 N-m (3.1 kgf~m. 22 mm) 12 N-m (1.2 kgf-m, 9 lbf‘ft) 32 N-m (3.3 kgf-m. 241nm) 34 Nm (3.5 kgf-m. 25151-11) 34 N-m (3.5 kgf-m, 251mm 10 N~m (1.0 kgf‘m. 7 151-11) 21 N~m (2.1 kgf-m. 15 lbf‘ft) 5.2 N1m (0.5 kgrm, 3.3 lbf-ft) 1o N-m (1,0 kgrm. 7 lbf~fl) 17 N-m (1.7 mm, 13 mm) 12 Nm (1.2 kgt-m. 91min) 34 Nm (3.5 kgf-m, 25 mm) 29 N-m (3.0 kgf-m, 21 Ibf-ft) See page 3—30 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION Unlock the seat [1] using the ignition key [2]. Pull the seat back and remove it Install the seat while aligning its hooks [3] with the retainers on the fuel tank and seat rail, Push the seat lorward, then down to lock it. REAR COWL REMOVAL/INSTALLATION Remove the seat (page 3-4), Remove the clips [1]. special screws [2], collars [3]. and rubber washers [4]. Be care/ulnolto Release the hooks [5], tabs [6] and remove the rear damage the hooks cowls [7]. and (abs' Installation is in the reverse order of removal. GRAB RAILd a REMOVAL/INSTALLATION Remove the rear oowls (page 34), Remove the bolts [1] and washers [21‘ Remove the grab rails [3]. Installation is in the reverse order of removal. 3-4 COWL Be careful not to damage the tabs FRAME/BODY PANELS/EXHAUST SYSTEM TURN SIGNAL COVERIREAR CENTER REMOVAL/INSTALLATION Remove the seat (page 3-4). Remove the two special screws [1] and two long special screws [2]. Release the tabs and remove the turn signal covers [3] and rear center cowl [4]. Installation is in the reverse order of removal. FINAL GEAR COVER REMOVAL/INSTALLATION Remove the trim clip [1] and special bolts [2]. then remove the final gear cover [3], Installation is in the reverse order of removal. PIVOT PLATE COVER REMOVAL/INSTALLATION Remove the special bolt [1]. Release the pivot plate oover tab [2] from the seat rail, Slide the pivot plate cover [3] rearward and remove the pivot plate cover. Installation is in the reverse order at removal. 3-5 FRAME/BODY PANELS/EXHAUST SYSTEM INNER LOWER COWL REMOVAL/INSTALLATION Becarefulnotto Remove the clips [1], special bolts [2] and inner lower damage the tabs. oowl [3]. Installation is In the reverse order of removal. UNDER COWL REMOVAL/INSTALLATION Release the boss [1] on the engine heat guard [2] from the engine heat guard stay grommet [3] and remove the engine heal guard. Remove the special bolts [4], washers [5] and collars [6]. Release the hooks [7] on the middle cowls from the under cowl [8] and remove the under cowl. installation is in the reverse order of removal. REARVIEW MIRROR Be care/ill nor to damage the tabs and bosses. REMOVAL/INSTALLATION Remove the trim clips [1] and front upper cover A [2] by releasing its tabs [3] end boss [4] from the grommet [5] of upper cover B. FRAME/BODY PANELS/EXHAUST SYSTEM Disconnect the turn signal light 2P connector [1] and position light 1P connector [2]. Remove the nuts [3] and rearview mirror [4]. Installan’on is in the reverse order of removal. MIDDLE COWL REMOVAL/ INSTALLATION Remove the inner lower cowl (page 3-6), Becarefulnolto For each side, remove the two special bolts [1] and damage the tabs three clips [2]. 5"" mm" Remove the middle oawl [3] lorward by release the three hooks [4] and two bosses [5]. Installation is in the reverse order of removal. FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1] and layer cowl [2] from the middle cowl [3]. Remove the screw [1] and inner layer cowl [2] by releasing the tabs [3]. Remove the bolt [1], screw [2] and front panel cowl [3] by releasing the tabs [4]. Installation is in the reverse order of removaL FUEL TANK COVER REMOVAL/INSTALLATION Remove the following: — seat (page 34) — middle oowl (page 3-7) Remove the trim clip [1] and let! knee guard [2] by releasing the hook [3] and tabs [4]. In the same manner, remove the right knee guard. FRAME/BODY PANELS/EXHAUST SYSTEM Remove the two trim clips [1] and four socket bolts [2]. Release the bosses [3] on the fuel tank covers [4] from the fuel tank and remove the fuel tank covers. Installation is in the reverse order of removal. UPPER SIDE COWL Be carelul no! to damage the labs and bosses. LEFT UPPER SIDE COWL REMOVAL] INSTALLATION Remove the following: — left rearview mirror (page 3-6) — lefl fuel tank cover (page 3-8) Remove the front upper cover 0 [1] by releasing its boss [2] from the grommet [3] of windscreen. Remove the three socket bolts [1] and left upper side cowl [2] by releasing the seven hooks [3] and bosses [4] Remove the screw [1] and open air temperature sensor [2] from the inner cowl [3]. Remove the turn signal relay [4], 23F (Black) connector [5] and 4P (Gray) connector [6] from the left inner cowl, Disconnect the 23F connector and 4P connector. Release the three tabs [7] and remove the inner oowl‘ Installation is in the reverse order of removal. FRAME] BODY PANELS/EXHAUST SYSTEM R|GHT UPPER SIDE COWL REMOVAL! INSTALLATION Remove the following: — right rearview mirror (page $6) - right fuel tank cover (page 3—8) - right front upper DOVEI C (page 3-9) Remove the three socket bolts [1] and right upper side cowl [2] by releasing the three hooks [3]. Installation is in the reverse order of removall UPPER CENTER COWL/WINDSCREEN Be careful not to damage the tabs and bosses‘ REMOVAL/INSTALLATION Remove the upper side oowls (page $9). Remove the upper center cowl [1]Mindscreen [2] assembly (onward by releasing the two bosses [3], three tabs [4] and two hooks [5]. Remove the screws [6] and windscreen by releasing the two tabs H] from the upper center oowl. Installation is in the reverse order of removal. 3-10 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the front brake hose clamp nut [1] and clamp bolt [2]. Remove lhe special screws [3]. fender [4]. collars [5] and front reflectors [6] Irom the fork legs. installation is in the reverse order of removal REAR FENDER REMOVAL Remove the following: battery (page 19-6) bank angle sensor (page 6-81) grab rails (page 3-4) rear combination light (page 22—9) — pivot plate covers (page 3-5) Remove the fuse box [1], DLC [21 and starter relay switch [3] from the rear fender B, llll Release the rear brake light switch 2P (Black) 7 connector [1] from the connector stay [2]. Remove the tapping screws [11 and seat lock cover [2]. 3-11 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the bolt [1] and seal catch body [2]. Remove the relay stay mounting bolthasher [1], rear lender mounting long boll/washer [2], collar [3] and relay stay [4]. Remove the rear lender mounting short bolls [5}. Release me rear lender labs [1] from the center cross plate. Pull and remove the rear lender backward. 3-12 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLYIASSEMBLY COLLAR CAM PLATE SEAT LOCK REAR FENDER B BOLTS FENDER STAY A COLLARS REFLECTORS CONNECTER STAY SEI’ PLATE SET SPRING LICENSE LIGHT BRACKET INSTALLATION SCREWS RELAYS/RELAY STAY SEAT LOCK COVER A WASHER ' 32 N-m (3.3 kgl-m, 24 Ibf-fl) COLLAR BOLT (long) 32 N-m (3.3 kgf-m, 24 mm) TABS 3-13 FRAME/BODY PANELS/EXHAUST SYSTEM Whileinstalllngthe Install the rear fender by aligning its front tabs [1] with near fender. route the center cross plate. the main wire harness and battery cables property (page 1-22). Loosely install the rear fender mounting short bolts [1]. relay stay [2], collar [3] relay stay mounting bolt/washer [4] and rear fender mounting long boll/washer [5]. Tighten the rear tender mounting short bolts to the specified torque. TORQUE: 32 N-m (3.3 kgf'm, 24 let) Tighten the rear fender mnunting long bolt/washer to the specified torque. TDRQUE:32 N-m (3.3 kgf-m, 24 lbf-ft) Tighten the relay stay mounting bolt/washer securely. Apply grease to the seat catch hook sliding area. Install the seat catch body [1] and tighten the mounting bolt [2] securely. Install the seat lock cover [1] and tighten the tapping screws [2] securely. 3-14 FRAM EIBODY PANELS/EXHAUST SYSTEM Install the rear brake light switch 2P (Black) connector [1] to the connector stay [21‘ Install the starer relay switch [1], DLC [2] and fuse box [3] onto the rear fender. ’ Install the following: rear combination light (page 22-9) grab reils(page 3-4) pivot plate covers (page 3-5) bank angle sensor (page 6-81) battery (page 1945) lllll SEAT RAIL REMOVAL Remove the regulator/rectifier (page 19-8). Remove the relays [1] from the relay stay [2]. Disconnect the EGCA 6P (Black) connector [11‘ Remove the mounting bolts [2] and EGCA servo motor [3]. 3-15 FRAME/BODY PANELS/EXHAUST SYSTEM Keepme rear brake Remove the bolt [1] and rear brake reservoir tank [2] Ieserve tank upright form the seat rail. to pre vent air from entering the hydraulic system. Remove the muffler mounting nut/bolt [1]. washers [2] and muffler from the right passenger bracket [3]. Remove the bolt [1] and the pre—load adjuster [2]. Remove the bolt [3], EGCA cable guide [4]. Remove the ball [1] and pre-load adjuster bracket [2]. 3-16 FRAMEIBODY PANELS/EXHAUST SYSTEM Remove the brake pipe joint mounting bolt [1]. brake hose stay mounting bolt [2] and brake hose stay [3]. Release the center cross plate tabs [1] and remove the rear heal guard [2]. Remove the fuel tank pivot nut [1], washers [2] and pivot bolt [3]. Remove the seat rail lower mounting bolts [4]. Remove the seat rail upper mounting bolt/nut [5]. and then remove the seat rail assembly from the frame, Remove the flange bolts [1] and right passenger tootpeg bracket [21‘ In the same manner, remove the left passenger foolpeg bracket. 3-17 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the flange Dolls [1] and center cross plate [2]. Remove the seal rail assembly flange bolt [1] and separate lhe seal rails [2]. [2] Assembly is in lhe reverse order of disassembly. TORQUE: Seal rall assembly flange bolt: 30 N-m (3‘1 kgf-m, 22 lbl~ft) Center cross plate mountan bolt: 12 N~m (1.2 kgf‘m, 9 Ibl-fl) Passenger footpeg bracket flange boll: 32 N-m (3.3 kgf'ln, 24 Ibf-fl) [1] INSTALLATION EGCA SERVO MOTOR 12 N!!! (1.2 kgl-m, 9 mm 32 N-m (3,3 kgfm,24lb1-fl) RESERVO'R TANK 30 N1" (31 kgl-m. 22mm) 34 N-m (3.5 kgf'm, 25 |bf~fl) SEAT RAILS 12 Nm (1.2 kgf~m. 9 lbffl) 34 N~m (3.5 kgf‘m. 25 mm) CENTER CROSS PLATE PASSENGER REAR HEAT GUARD PRELOAD FOOTPEG BRACKET ADJUSTER BRACKET PRE»LOAD ADJUSTER 3-18 FRAMEIBODY PANELSIEXHAUST SYSTEM Install the seat rail assembly. upper mounting bolt/nut [1]. Install the lower mounting bolts [2]. Hold the upper mounting bolts and tighten the flange nuts to the specified torque TORQUE:35 N-m (3.6 kgf'm. 261bf-ft) Tighten the lower mounting bolts to the specified torque. TORQUEz35 N'm (3.6 kgf-m,26lb1-fl) Install the fuel tank pivot bolt [3]. washers [A] and pivot nut [5]. Install the rear heat guard [1] by aligning its slits [2] with the tabs [3] of center cross plate. Install the pre-Ioad adjuster bracket [1] by aligning its hole with the boss of left paseenger tootpeg bracket. Tighten the mounting bolt [2] securely. Install the brake hose stay [1] by aligning its hole with the boss of right seat rail. Tighten the mounting bolt [2] securely. Install the brake pipe joint [3] to the brake hose stay and tighten the mounting bolt [4] securely. 3-19 FRAME/BODY PANELS/EXHAUST SYSTEM install the pre-load adjuster [1] and tighten the mounting bolt [2] securely. Install the EGCA cable guide [31 and tighten the mounting bolt [4] securely. install the mulfler, mounting bolt [1]I washers [2] and nut [3]. Hold the muffler mounting bolt and tighten the nut to securely. Install the rear brake reservoir tank [1] and tighten the mounting bolt [2] to the specified torque. TORQUE212 N-m (1.2 kgf-m, 9 lbf-fl) install the EGCA servo motor [1] and tighten the mounting bolts [2]. Connect the EGCA 6P (Black) connector [3]. 3-20 FRAME/BODY PANELS/EXHAUST SYSTEM Route the wire lnslall the relays [1] to the relay say [2], nemess properly . _ (page #22)- lnslall the regulator/rectifier (page 19 8). MUFFLER REMOVAL Remove the right rear cowl (page 3—4). Release the EGCA cable [1] from the cable guides [2]. Turn the EGCA pulley [1] clockwise and disconnect the EGCA cable [2] from the EGCA pulley. Loosen the muffler band bolt [1]. Remove the muffler bracket mounting nut [2], bolt [3] and washers [4], 3-21 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the muffler [1] and gasket [2] from the exhaust pipe [3]. DISASSEMBLY/ASSEMBLY Remove the muffler rear guard. muffler upper guard and valve cover. Disconnect the EGCA cable [1] from the ECV pulley [2]. Loosen the joint um and dismnnect the EGCA cable from the muffler. Remove the following: — three bolts and muffler rear guard — three bolts, washer and muffler upper guard — three special bolts and valve cover Assembly is in the reverse order of disassembly, TORQUE: EGCA cable jolnt nut: 21 N-m (2.1 kgbm, 15 lbf~ft) Muffler rear guard bolt: 5.2 N~m (0.5 kgf~m, 3.8 lbf-ft) Mufiler upper guard bolt: 10 N-m (1.0 kgf-m, 1 IbM!) EGCA CABLE JOINT NUT 21 N~m (2.1 kgf‘m. 15 Ile) 10 N-m (1.0 kgrm, 7 lbf-fl) VALVE COVER WASHER MUFFLER UPPER GUARD 5.2 N-m (0.5 kgf-m, 3.8 lbf~fl) 10 N~m (1.0 kgf-m, 7 Ibf-fl) 3-22 FRAMEIBODY PANELS/EXHAUST SYSTEM INSTALLATION Install a new gasket [1] and muffler [2] to the exhaust pipe [3]. Install the muffler mounting bolt [1]. washers [2] and nut [3]. Hold the muffler mounting bolt and tighten the nut securely. Tighten the muffler band bolt [1] to the specified torque‘ TORQUE:17 N-m (1.1 kgf-m, 13 Ibf-fl) 3-23 FRAMEIBODY PANELS/EXHAU ST SYSTEM Connect the EGCA cable to the EGCA pulleyl Turn the EGCA pulley counterclockwise lo the specified angle as shown. Check lhe EGCA and EVC operation (page 4-17). Route the EGCA cable [1] lo the cable guides [21‘ Install the right rear cowl (page 341 EXHAUST PIPE REMOVAL Remove the following: — muffler (page 3-21) — radiator (page 7-9) — right pivot plate cover (page 35) — EVAP purge contrgl solenoid valve/canisler (Page 6—91) — under cowl (page 3-6) Remove the right rider loolpeg holder mounting bolts [1] and right rider Ioolpeg holder [2]. Remove the right rider footpeg holderl PULLEY ANGLE: ® lilllllllllllilil O 3-24 FRAM EIBODY PANELS/EXHAUST SYSTEM Remove the muffler heat guard plate mounting bolts [1] and muffler heat guard plate [2]. Remove the tank heat protector mounting bolts [1] and exhaust pipe upper protector [2] Loosen the rear exhaust pipe band bolts [1]. Release the 02 sensor wire clips [1] from the clip stays. 3-25 FRAME/BODY PANELS/EXHAUST SYSTEM Remove (he 02 sensor 4P (Blue) connector [1] and 02 sensor 4? (Black) oonnemor [2] from (he conneclor stay. Disconnect the Ozsensor 4P (Blue) connemor and O2 sensor 4P (Black) oonneclor. Remove the iron! exhausl pipe joint special nuts [1]. Remove me from exhausl pipe mounting bolt [1], washer [2] and exhaust pipe [3]. Remove the rear exhaust pipe joint special nuts [1] and rear exhausl pipes [2]. 3-26 F RAMEIBODY PANELS/EXHAUST SYSTEM Remove the exhaust pipe gaskets [1] from the front and rear cylinder heads. INSTALLATION EXHAUST PIPE UPPER PROTECTOR MUFFLER HEAT GUARD PLATE MUFFLER CANISTER TRAY FRONT EXHAUST PIPES If the exhaust pipe stud bolts are loose, lighten them. Be sure to verify the distance from the top of the stud to the cylinder head as shown. SPECIFIED LENGTH: 23.5 — 24.5 mm (0.93 — 0.96 In) 12 Nm (1.2 kgf~m, 9 lbf-ft) 23.5 — 24.5 mm (0.93 — 0.96 in) 3-27 FRAME/BODY PANELS/EXHAUST SYSTEM Always replace the Install new exhaust pipe gaskets [1] onto the front and exhaust pipe rear exhaust ports of the {rent and rear cylinder heads. gaskets with new ONES, Install the rear exhaust pipes. Install the exhaust pipe joint nuts [1], but do not tighten them yet. Install the hunt exhaust pipe. Install the exhaust pipe joint nuts [1]. but do not tighten them yet. install new exhaust pipe gaskets [1] to the exhaust pipes. Joint the exhaust pipes and rear exhaust pipes. but do not tighten the band bolts [2] yet. 3-28 FRAME/BODY PANELS/EXHAUST SYSTEM Loosely install the exhaust pipe, washer [1] and mounting bolt [2]. Tighten the front and rear exhaust pipe joint nuts to the > specified torque. TORQUE:12 N-m (1.2 kgf‘m, 9 Ibf-fl) Tighten the rear exhaust pipe band bolts to the specified torque. TORQUE: 17 N-m (1.7 kgf-m, 13 let) Tighten the exhaust mounting bolt securelyr Connect the 02 sensor 4P (Black) connector [1] and 0: sensor 4P (Blue) connector [2]. Install the Ozsensor 4P (Blue) connector and 02 sensor 4P (Black) connector to the connector stay. Install the 02 sensor wire clips [1] to the clip stays. Install the exhaust pipe upper protector [1]. Tighten the exhaust pipe upper protector mounting bolts [2] securely. 3-29 FRAME/BODY PANELS/EXHAUST SYSTEM Install the muffler heat guard plate [1]. Tighten the muffler heat guard plate mounting bolts [2] securely, Install the right rider tootpeg holder [1]. Tighten the right rider tootpeg holder mounting bolts [2] to the specified torque. TORQUEz34 N-m (35 kgf-m, 25 lbffl) Install the following: muffler (page 3—21) radiator (page 79) right pivot plate cover (page 3-5) EVAP purge control solenoid valve/canister (page 6-91) — under cowl (page 3-6) SIDESTAND REMOVALIINSTALLATION Remove the sidestand switch (page 22-22). Support the motorcycle securely using a hoist or equivalent. Remove the sidestand return spring [1] Remove the sidestand pivot nut [Z] and bolt [3], men reiho‘ve the sidestand [4]. Install the sidestand and return spring in the direction as shown. Apply grease to the sidestand pivot bolt sliding surface. Install and tighten the pivot bolt to the specified. TORQUE: 1D N-m (1.0 kgf-m, 1 Ibf-tt) Qger tightening the pivot bolt. return the pivot bolt 45° to Install and tighten the sidestand pivot nut to the specified torque while holding the sidestand pivot bolt. TORQUEZD N-m (3.0 kgf-m, 21 Ibf'ft) Install the sidestand switch (page 22-22). 3-30 4. MAINTENANCE SERVICE INFORMATION "4-2 MAINTENANCE SCHEDULE --------------------- "4-4 FUEL LINE ................................................... ..4_5 THROTTLE OPERATION- "4-5 AIR CLEANER ............................................. "4.5 SPARK FLUG .............................................. "4.7 VALVE CLEARANCE--- "4-9 ENGINE OIL/OIL FILTER .......................... "4.12 RADIATOR cooLAN-I' ............................. ..4_15 COOLING OYSTEM--- 4-16 SECONDARY AIR SUPPLY SYSTEM ------ "4-16 EVAPORATIVE EMISSION CONTROL SYSTEM .................................................... ..4_11 EGCA CABLE 4-17 FINAL DRIVE OIL -- 4-20 BRAKE FLUID .......................................... "4.21 BRAKE PADS WEAR ............................... .. 4.22 BRAKE SYSTEM 4-23 BRAKE LIGHT SWITCH --------------------------- -- 4-24 HEADLIGHT AIM ...................................... ..4_24 CLUTCH SYSTEM - ---4-25 CLUTCH FLUID ........................................ "4.25 SIDESTAND .............................................. "4.26 SUSPENSION ........................................... ..4_26 NUTS, BOLTS, FASTENERS ------------------- --4-2a WHEELstEs ........................................ "4.23 STEERING HEAD BEARINGS ----------------- ~-4-29 4-1 MAINTENANCE SERVICE INFORMATION GENERAL - Place the motorcycle on level ground belore starting any work. - Gasoline is extremely flammable and is explosive under certain conditions. 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. ' 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, SPECIFICATIONS ITEM SPECIFICATIONS Throttle grip freeplay 2 — 4 mm (1116 — 3/16 in) Spark plug NGK lMRSE-SHES DENSO VUH27ES Spark plug gap 0.80 — 0.90 mm (0.031 — 0.035 in) Valve clearance IN 016 : 003 mm (0.006 1 0.001 in) EX Valve 0.30 2 002 mm (0.012 t 0.001 in) side Roller 021 1 002 mm (0.008 t 0.001 in) side Engine oil capacity After draining 3.0 liter (3.2 US qt. 2,6 Imp qt) After draining/oil filter change 3.2 liter (3.4 us qt. 2.8 Imp qt) Recommended engine oil Pro Honda GN4 4—stroke oil (USA and Canada) or an equivalent motor oil API service classification: 86 or higher JASO T 903 standard: MA Viscosity: SAE 10W—30 Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate free corrosion inhibitors Recommended final drive oil Hypoid gear oil, SAE #80 Final drive oil After draining 200 an (6.8 US oz. 7.0 Imp oz) ESPECIW After disassemny 240 cm (8.1 US 02, 8.4 Imp oz) Recommended brake fluid DOT 4 brake fluid Recommended clutch fluid DOT A brake fluid Fork Pre-load adjuster standard position 9 mm (0.4 in) from top surface of fork bolt . Rebound damping adjuster standard position 6 clicks out from full hard Rea. suspension Spring pro-load adjuster standard position 11 clicks out from lower position Rebound adjuster standard position 3/4 turn out from full hard Tire size Front 120/7OZR17M/C(58W) Rear 190/552R17M/C(73W) Tire brand Bridgestone Front BT021F N Rear BT021R N Dunlop Front ROADSMART 00 K Rear ROADSMART K Tire air pressure Up to 90 kg (200 lb) Front 250 kPa (2.50 kgf/cm , 35 psi) Ioad Rear 290 kPa (2.90 kgflcm , 42 psi) Up to maximum Front 250 kPa (2.50 kgf/cm . 36 psi) weight capacity Rear 290 kPa (2.90 kgf/cm .42 psi) Minimum tire tread depth Front 1.5 mm (0.06 in) Rear 2.0 mm (0.08 in) MAINTENANCE TORQUE VALUES Air cleaner element screw 0.8 N-m (0.1 kgf-m. 0.6 lbf~fl) Air cleaner cover screw 0.8 N~m (0.1 kgl~m. 0.6 Ibf-fl) Spark plug 16 N»m (1.6 mm, 12 Ile) Valve adjusting screw lock nut 10 N-m (1.0 kgf~m. 7 Hum) Apply engine oil lo the threads. Ti ’ng hole cap 17 N~m (1.7 kgf-m, 13 Math) Apply grease to the threads. Engine oil drain bolt 29 Nm (3.0 kgf-m. 21 lbf-ft) Engine oil filter cartridge 26 N-m (2.7 kgf~m, 19 Ibt-ft) Apply engine oil to the threads. Final drive oil filler cap 8.0 MM (0.8 kgl‘m. 5.9 Ibf-fl) Final drive oil drain bolt 12 N-m (1.2 kgf‘m, 9 lbf~fl) Rear master cylinder push rod joint nut 18 N‘m (1.8 kgf~m. 13 lbt-fl) TOOLS Tappet adjusting wrench Tappel lock nul wrench Oil filter wrench 07908-3290100 07908—3290200 07HAA»PJ70101 or 07AAA-PLCA1OO (U.S.A only) SCS conneclor 070PZ-ZY30100 MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner‘s Manual at each scheduled maintenance period. I: Inspect and clean, adjust, lubricate or replace it necessary. C: Clean. R: Replace. A‘ Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked ' and ") may require more technical information and tools. Consult an authorized Honda dealer. FREQUENCY ODOMETER READING (NOTE 1) REFER x 1,000 mi 0.6 4 B 12 16 20 24 T0 ITEMS NOTE x1000 km 1.0 6.4 12.8 19,2 25.6 32.0 33.4 PAGE " FUEL LINE | I I 4-5 ' THROTTLE OPERATION | | | 4—5 * AIR CLEANER (NOTE 2) | | 4—6 2 ' SPARK PLUG EVERY 16.000 mi (25,600 Km) I, 4-7 Lu EVERY 32,000 mi (51,200 Km) R I: - VALVE CLEARANCE | i l I 4.9 B ENGINE OIL INITIAL = 600 mi (1000 km) or 1 month: R 4—12 ’- REGULAR = EVERY 8,000 mi (12,800 km) or a 12 months: R It ENGINE OIL FILTER R R R R 4-12 6 RADIATOR COOLANT (NOTE 3) I l R 4-15 5 ‘ COOLING SYSTEM I l I 4-16 g ' SECONDARY AIR SUPPLY SYSTEM | | I 4—16 Lu " EVAPORATIVE EMISSION CONTROL l | 4-17 SYSTEM *" EXHAUST GAS CONTROL EVERY 16,000 mi (25,600 Km) I 4-17 ACTUATOR CABLE :0 FINAL DRIVE OIL I I R 4~20 E BRAKE FLUID (NOTE 3) I I R | I R 421 '2 BRAKE PADS WEAR I I I I I I 4-22 B BRAKE SYSTEM I I l I 423 I; ‘ BRAKE LIGHT SWITCH | I I 4-24 m ' HEADLIGHT AIM | | | 4—24 B! CLUTCH SYSTEM I | | 4-25 5 CLUTCH FLUID (NOTE 3) I | R | R 4—25 (7) SIDESTAND I I | 4-26 2 * SUSPENSION I I I 4-26 Lil “ NUTS, BOLTS. FASTENERS I I I I 4-28 5 " WHEELS/TIRES | | l 4-28 2 " STEERING HEAD BEARINGS | | I I 4-29 " Should be serviced by an authorized Honda dealer. unless the owner has proper tools and service data and is mechanically qualified “ In the interest of saiety, we recommend these items be serviced only by an authorized Honda dealer NOTES: 1. At higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Replace every 2 years, or at the indicated odometer intervals, whichever comes first. Replacement requires mechanical skill. 4-4 MAINTENANCE FUEL LINE Remove the fuel tank oovers (page 3—8). Remove the two fuel tank mounting bolts [1]. Lift the fuel tank [1]. Support the fuel tank using a suitable support as shown. Check the fuel line [1] for deterioration, damage or leakage Replace the fuel line if necessary. Also check the fuel line fittings for leakage Be careful not to Remove the support. then close the fuel tank. pinch the air vent Install the fuel tank mounting bolts. and overflow hoses. Tighten the bolts securely. Install the fuel tank covers (page 3-8), THROTTLE OPERATION Check for smooth throttle operation and automatic complete closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables if throttle operation is not smooth Measure the fr‘eeplay at the throttle grip flange. FREEPLAY: 2 — 4 mm (1/16 — 3/16 in) MAINTENANCE Throttle grip freeplay can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster [1]. Adjust the treeplay by loosening the lock nut {2] and turning the adjuster. Major adjustments are made with the lower adjuster on the throttle body. Remove the right middle cowl (page 3—7). Adjust the freeplay by loosening the lock nut [1] and turning the adjuster [2]. After adjustment, tighten the lock nut securely. Recheck the throttle operation. Replace any damaged parts, it necessary. Install the right middle oowl (page 37). AIR CLEANER Lift and support the fuel tank (page 4-5). Release the tabs [1] from the air cleaner housing. Remove the air ducts [2] from the air cleaner housing. Disconnect the IAT sensor 2P (Gray) connector [1]. Remove lhe screws [2] and air cleaner cover [3]. MAINTENANCE Remove the air cleaner element mounting screws [1] and air cleaner element [2], Clean the air cleaner element using compressed air from the throttle body side any time it is excessively dirtyt Installaficn is in the reverse order of removaL TORQUE: Alr cleaner element screw: 0.8 N-m (0.1 kgf-m, 0.6 Ibf'ft) Alr cleaner cover screw: 0.3 N-m (0t1 kgf'm, 0.6 lbf-fl) SPARK PLUG REMOVAL Front cylinder: Remove the air cleaner housing (page e63). Clean around the Disconnect the direct ignition coil connectors [1]. sparkplug bases Remove the direct ignition coils [2] lrom the spark with compressed air plugs. before remov’ihg‘.‘ and be sure that no debris is allowed to enter the combustion chamber, Remove the spark plug using the spark plug wrench [1]. inspect or replace as described in the maintenance schedule (page 44). MAINTENANCE Rear cylinder: Lift and suppon the fuel tank (page 4.5), Clean around the Disconnect the direct ignition coil connectors [1L spark plug bases Remove the heat guard rubber [2]. with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber: Remove the direct ignition coils [1] from the spark plugs. Remove the spark plug using the spark plug wrench [2]. Inspect or replace as described in the maintenance schedule (page 4-4). INSPECTION Check the lollowing replace it necessary. - Insulator {1] (or damage [2] r Center electrode [2] and side electrode [3] for wear ' Burnt condition, coloration [3] This motorcycles if the electrodes are contaminated with accumulated spark plugs are objects or dirt, replace the spark plug. equipped with an iridium center electrode Replace [1] the spark plug r‘Ithe electmde is contaminated. Always use Replace the plug it the center electrode is rounded as specified spark shown [1] in the illustration. [1] plugs on (his momma/a SPECIFIED SPARK PLUG: NGK: IMRDE-QHES DENSO: VUH27ES To prevent damaging the iridium center electrode, use a wire type feeler gauge (0 check the spark plug gap. Du no! adjust the spark plug gap. If the gap is out of specification. replace it with a new ane. Check the gap between the center and side electrodes with a wire type feeler gauge [1]. Make sure that the ‘9 1.0 mm (0.04 in) plug gauge does not insert between the gap. II the gauge can be inserted into the gap, replace the plug with a new one. INSTALLATION Front and rear cylinder: Install and hand tighten the spark plugs to the cylinder head. then tighten the spark plugs to the specified torque. TORQUE:16 NM (1.6 kgi-m, 12 lbf-ft) Install the removed pans in the reverse order of removal. VALVE CLEARANCE Inspect and adjust the valve clearance while the engine is cold (below 350/95‘F}, INSPECTION Remove the cylinder head cover (page 9-7). Remove the timing hole cap [1] and O-ringl Turn the crankshaft clockwise. align the “MT RT" mark [1] on the CKP sensor rotor with the index mark [2] on the right crankcase cover. Make sure that the No.2 piston is at TDC (Top Dead Center) on the compression stroke. MAINTENANCE Front cylinder: Rear cylinder: MAINTENANCE Record the clearance for reference in shim selection if ed/ustmenl is required. Insert the teeler gauge [1] between the No.2 rocker arm roller and cam lobe. Check the valve clearance for the exhaust valves using a teeter gauge. VALVE CLEARANCE: EX: Valve side 0.30 1 0.02 mm (0.012 at 0.001 in) Roller side 0.21 t 0.02 mm (0.003 2 0.001 in) Insert the teeter gauge [1] between the valve lifter and the cam lobe. Check the valve clearance for the intake valves using a teeter gauge. VALVE CLEARANCE: m: 0.16 x 0.03 mm (0.006 t 0.001 in) Turn the crankshaft clockwise 104°, align the "MT FT" mark on the CKP sensor rotor with the index mark on the right crankcase cover. Check the valve clearance for the No.4 cylinder. Tum the crankshafl clockwise 256°. align the "MT RT” mark on the CKP sensor rotor with the index mark on the right crankcase cover. Check the valve clearance for the No.3 cylinder. Turn the crankshafl clockwise 104"I align the "MT FT" mark on the CKP sensor rotor with the index mark on the right crankcase cover. Check the valve clearance for the No.1 cylinder. 4-10 MAINTENANCE ADJUSTMENT Intake valve side: Remove the camshaft (page 9—11). - The shim [1] may stick to the inside of the valve lifter [2], Do not allow the shim to fall into the crankcase - Mark all valve lifters and shims to ensure correct reassembly in their original locations. - The valve lifter can be easily removed with a valve lapping tool or magnet. - The shims can be easily removed with tweezers or a magnet. Clean the valve shim contact area in the valve lifter [1] with compressed air. sixty-nine different Measure the shim [1] thickness and record it. thickness shims are available from the thinnest 1200 mm thickness shim to the l‘hl'd‘esl 2.900 mm thickness shim in intervals 0/ 0.025 mm. Calculate the new shim thickness using the equation below. A = (B — C) + D A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness ' Make sure of the correct shim thickness by measuring the shim with a micrometer [2]. - Retaoe the valve seat if carbon deposit result in a calculated dimension of over 2,900 mm. 1.825 mm 1.85 mm 1.875 mm 4-11 MAINTENANCE lnstall the shims Install the newly selected shim [1] on the valve retainer. 5”" ’5”, Apply molybdenum disulfide oil to the valve lifler [2]. 9 Install the valve lifter into the valve lifler holes. locations. Install the camshaft (page 9-11). Recheck both the intake and exhaust valve clearance (page 49) Exhaust valve side: Adjust by loosenan the lock nut [1] and turning the adjusting screw [2] until there is a slight drag on the leeler gauge, TOOL: Tappet adjusting wrench [3] 07908-3290100 Tappet lock nut wrench [4] 07908-3290200 Apply engine oillo Hold the adjusting screw and tighten the lock nut to the the lock nutthresds specified torque. and seating . _ ‘ . Wm TORQUE. 10 N m (1.0 kgi m, 7 Im a) Afler tightening the lock nut, recheck the valve clearance (page 49). Apply oil to a new O-ring [1] and install it to the crankshaft hole cap [2]. Apply grease to the timing hole cap threads. Tighten the crankshafl hole cap to the specified torque. TORQUE: 17 N-m (1.1 kgr-m, 13 rum) Install the remove parts in the reverse order of removal. ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION Start the engine and let it idle for 3 - 5 minutes, Stop the engine and wait 2 — 3 minutes. Hold the motorcycle in an upright position. Check the oil level through the inspection window [1]. 4-12 MAINTENANCE It the level is below the lower level line [1], remove the oil filler cap [2] and fill the crankcase with the recommended oil up to the upper level line [3]l other visoosilies RECOMMENDED ENGINE OIL: shown in the chaff Pm Honda 6N4 4-etroke oi U.S.A. and Canada) or may ‘78 used When equivalent motor ell the average API service classification: 56 or higher temperature in your #60 T903 standard: MA riding area is within viscosity: SAE 1ow-30 m. the indicated range. Reinstall the filler cap. —30 -20 -10 0 1 0 20 30 4O 50’!) l_._.J_I_I___L.—l—|———J -20 D 20 40 60 80 100 120T ENGINE OIL & FILTER CHANGE Remove the under cowl [1] (page 345). Warm up the engine. Change the engine Stop the engine and remove the oil filler cap [2]. oil when the engine is warm and the motorcycle is on level ground to assure complete draining. Remove the drain bolt [1] and sealing washer [2], then drain the oil completely. 4-1 3 MAINTENANCE Remove and discard Ihe oil filter cartridge [1] using the special tool. YOOL: 0" filter wrench [2] 07HAA-PJ70101 07MA-PLCA1 00 (U.S.A. only) Install the drain bolt [1] with a new sealing washer [21‘ Tighten the drain bolt to the specified torque. TORQUE:29 Nvm (3.0 kgf-m, 21 Ibi-fl) Check that the oil filter boss [1] extends from the crankcase a! the specified laugh as shown‘ Om / SPECIFIED LENGTH: 16.0 - 17.0 mm (0.63 - 0.67 In) \ 16.0 — 17.0 mm (0.63 — 0.67 in) Apply oil to new oil filter cartridge [1] threads and O-ring [2]. 4-14 MAINTENANCE Install the oil filter cartridge [1] and tighten it to the specified torque. TOOL: Oil filter wrench [2] 07HAA-PJ10101 07AM-PLCA100 (U.S.A. only) TORQUEZG N-m (2.7 kgf-rn, 19 lbf-ft) Fill the crankcase with recommended engine oil. OIL CAPACITY: 3.0 llter (3.2 US qt, 2.6 Imp qt) after draining 3.2 llter (3.4 us qt, 2.8 Imp qt) after draining/filter change Check that the O-n‘ng on the oil filler cap [1] is in good condition. and replace it il necessary. Install the oil filler cap. Check me oil level (page 4—12). Check that there are no oil leaks. Install the under cowl (page 3-6). RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" [1] and 'LOWER“ [2] level lines. If necessary. add the recommended coolant, RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high qual- ity ethylene glycol antlfreeze containing silicate free corrosion Inhibitors Open the right engine heat guard. Remove the reserve tank filler cap [1] and till to the "UPPER" level line with 1:1 mixture of distilled water and antifreeze. Reinstall the filler cap. Closes the right engine heat guard. 4-15 MAINTENANCE COOLING SYSTEM Remove the inner lower oowl (page 3-6). Check the radiator air passages for clogging or damage Straighten bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure Replace the radiator if the air flow is restricled over more than 20% of the radiating surface. inspect the radiator hoses [1] for cracks or deterioration, and replace it necessary Check the tightness of all hose clamps and fasteners. SECONDARY AIR SUPPLY SYSTEM Ifthe hoses show any signs of heat damage, Inspect the PAR check valve [3] in (he PAIR reed valve coverfor damage. - This model is equipped with a built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover mi The secondary air supply system introduces filtered air into the exhaust gases in the exhaust port [2], The secondary air is drawn into the exhaust port "Whenever there is negative pressure pulse in the exhaust system. This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relativer harmless carbon dioxide and water. Lift and support the fuel tank (page 4-5)r Check the PAIR hoses between the PAIR control solenoid valve and cylinder head cover for deterioration, damage or loose connections Make sure that the hoses are not cracked. 4-1 6 MAINTENANCE Check the air suction hose [1] between the air cleaner housing and PAIR control solenoid valve [2] for deterioration. damage or loose connection Make sure that the hoses are not kinked. pinched or cracked. EVAPORATIVE EMISSION CONTROL SYSTEM Check the hoses between the fuel tank, EVAP canister [1]. EVAP purge control solenoid valve [2] for deterioration, damage or loose connection. Check the EVAP canister for cracks or other damage. Refer to the cable and Harness routing for hose connections (page 1-22). EGCA CABLE OPERATING INSPECTION Clear the DTC's (page 6-12). ~ A. Start the engine Stop the engine and check the ECV [1] is closed fully. If the ECV is closed fully, it is normaL it the ECV is not closed fully, adjust the EGCA cable (page 448). Remove the seat (page 34). Remove the DLC l1] and dummy connector [2] from the rear fender stay [3]. Remove the dummy connector from the DLC. MAINTENANCE Connect the special tool to the DLC [1]. TOOL: SOS connector [2] 070PZ-ZY30100 Turn the ignition switch ON and engine stop switch . n n‘ lfthe ECV [1] opens fully, it is normal. CABLE INSPECTION Remove the right rear cowl (page 3-4) Turn the EGCA pulley [1] clockwise and disconnect the EGCA cable [2] Irom the EGCA pulley. Check the EGCA cable length with the ECV closed position. - Check the length of the EGCA cable with the ECV “ciesed position while pulling the EGCA cable STANDARD LENGTH: 54.5 —- 57.5 mm (2.15 - 2.26 i If the cable length is out of the specification, adjust the ‘ cable length. 54.5 —- 57.5 mm (215 — 2.26 in) v/ 4-1 8 CABLE ADJUSTMENT Remove the right rear cowl (page 3-4), Loosen the lock nut [1] and tum the adjust {2] to the EGCA cable length with the EGCA closed position ' Keep the EGCA cable straight when adjust the cable length. - Check the length of the EGCA cable wiih the ECV closed position while pulling the EGCA cable. STANDARD LENGTH: 54.5 - 57.5 mm (215 — 2.26 In) Connect the EGCA cable [1] to the EGCA pulley [2]. Turn the EGCA pulley counterclockwise to the specified angle as shown. lnslallation is in the reverse order of removal 54.5 - 57.5 mm (2.15 - 2.26 in) PULLEY ANGLE: MAINTENANCE u Illllllllllllllll O 4-19 MAINTENANCE FINAL DRIVE OIL OIL LEVEL CHECK Place the motorcycle on its sidestand. Remove the oil filler cap [1] from the final gear case. Check that the oil level is to the lower edge of the oil filler hole, RECOMMENDED OIL: Hypoid gear oil, SAE #80 Coat a new O—ring [1] with oil and install it onto the oil filler cap [2]. Install and tighten the final drive oil filler cap to the specified torque. TORQUEsz‘) NM (0.8 kgf-m, 53 IBM!) OIL CHANGE Support the motorcycle securely and raise the rear wheel off the ground, Remove the oil filler cap [1] and drain bolt [2] sealing , washer [31 Irom the final gear case, slowly turn the rear wheel and drain the oil. After the oil is completely drained, install the drain bolt with a new sealing washer and tighten it to the specified torque, TORQUE: 12 Min (1.2 kgf-m. 9 Ibfft) Fill the gear case with recommended oil to the lower ‘2 edge of the tiller hole (page 440). OIL CAPACITY: 200 cm“ (6.8 us oz, 7.0 Imp 02) after draining 240 cm’ (8.1 US oz, 8.4 Imp oz) after disassemny 4-20 MAINTENANCE BRAKE FLUID NOTICE - Do not mix different types of fluid, as they are not compatible with each other. - Do not allow foreign material to enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic or rubberpenfs, Place a shop towel over these parts whenever the system is serviced When the fluid level is low. check the brake pads for wear (page 4-22). A low fluid level may be due to wear of the brake pads If the brake pads are worn, the caliper piston is pushed out, and this amounts for a low reservoir level. If the brake pads are not worn and the fluid level is low. check entire system for leaks (page 4-23), FRONT BRAKE Turn the handlebar so that the reservoir is level and check the front brake fluid reservoir level through the sight glass [1], If the level is near the lower level line [2]. check the brake pad wear (page 4—22). REAR BRAKE Remove the right rear cowl (page 34). Place the motorcycle on a level surface, and support it in an upright position. Check the rear brake fluid reservoir level If the level is near the lower level line [1], check the brake pad wear (page 422). I ' \ \ rut 4-21 MAINTENANCE BRAKE PADS WEAR FRONT BRAKE PADS NOTE: - The front brake caliper oi the new brake system has the 4 separate brake pads‘ The small brake pads [1] of left caliper are combined with the rear brake pedal. Inspect the conventional brake pads [2] or combined brake pads individually, — Conventional brake: Always replace all the right brake pads and left large brake pads with the set to assure even disc pressure. — Combined brake: Always replace the left small brake pads in pairs to assure even disc pressure ‘ After the brake pad replacement, check the brake operation by applying the brake lever or pedal. Check the conventional brake pads [1] or combined brake pads [2] individually [or wear. Replace the conventional brake pads as a set: if either pad worn to the bottom of the wear limit groove [3]. Replace the combined brake pads it either pad is worn to the bottom of the wear limit groove [4]. Refer to brake pad replacement (page 1744). REAR BRAKE PADS Check the brake pad [1] for wear, Replace the brake pads if either pad is worn to the bottom of the wear limit groove [2]. Refer to brake pad replacement (page 17-16). 4-22 BRAKE SYSTEM Align the “5 mark [2] on the brake lever Wflh the index number on the adjuster. INSPECTION Support the motorcycle securely and raise the front wheel [1] off the gmund using a safety stand or a hoist. Apply the rear brake pedal [2], Make sure the front wheel does not turn while the rear brake pedal is applied Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feels salt or spongy when operated, bleed the air from the system (page 11-7). inspect the brake hose [1] and fillings [2] for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. Refer the procedure lor brake bleeding (page 17-7). BRAKE LEVER ADJUSTMENT The distance between the top of the brake lever and the grip can be adjusted by turning the adjuster [1], MAINTENANCE l2) 4-23 MAINTENANCE BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut [1] and tum the push rod [2] until the correct pedal height is obtained. ' When adjusting the push rod length, do not extend it more than 5.5 mm (0.22 in). After adjustment, tighten the lack nut to the specified torque. TORQUEz18 N-m (1.8 kgf-m, 13 mm) MAXIMUM BRAKE LIGHT SWITCH The trout brakelighl Adjust the brake light switch [1] so that the brake light switch does not comes on just prior to the brake actually being require adjustment. engaged. If the light fails to come on, adjust the switch so that the light comes on at the proper time. Hold the switch body and turn the adjuster [2]. Do not turn the switch body. HEADLIGHT AIM Place the motorcycle on a level surface. Adjust the headlight Adjust the headlight beams vertically by turning the beam as specified vertical beam adjuster [1]. by MS] “fie” Adjust the headlight beams horizontally by turning the ’99“ '°"5- horizontal beam adjusters [2]. 4-24 MAINTENANCE CLUTCH SYSTEM CLUTCH LEVER ADJUSTMENT Align the "A" mark The distance between the top 0' the clutch lever and [2] on the brake the grip can be adjusted by turning the adjuster [11, level with the index numberon the adjuster. CLUTCH FLUID - Do not mix different types of fluid, as they are not ~ compatible with each other. ' Do not allow foreign material to enter the system when filling the reservoir: - Avoid spilling fluid on painted, plastic or rubber parts Place a shop towel over these parts whenever the system is serviced. When the fluid level Turn the handlebar to the right so that the reservoir is T is low [2], check level and check the fluid level at the clutch master entire system for cylinder reservoir through the sight glass [1]. ’93” Firmly apply the clutch lever. and check that no air has entered the system. If the lever teels soft or spongy when operated, bleed the air from the system (page 1045). |nspect the clutch hose [1] and fittings [2] for deterioration. crews and signs of leakage * Tighten any loose fittings ix Replace hoses and fittings as requiredi Refer the procedures for dutch bleeding (page 10-6). 4-25 MAINTENANCE SIDESTAND SUSPENSION Loose, worn or damaged suspension parts impair motorcycles stability and control. Check the sidestand spring [1] for damage or loss of tension. Check the sidestand [2] for movement and lubricate the sidestand pivot if necessary, Check the sidestand ignition cut-off system: — Sit astride the motorcycle and raise the sidestand. — Start the engine with the transmission in neutral, then, with the clutch lever fully squeezed. shift the transmission into gear. - Move the sidestand full down. — The engine should stop as the sidestand is lowered. If there is a problem with the system. check the sidestand switch (page 22-22). FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension several times. Check the entire assembly for signs of leaks. damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to the fork service (page 15—19). FRONT SUSPENSION ADJUSTMENT SPRING PRE—LOAD ADJUSTER Spring pre-load can be adjusted by turning the adjuster [1]. T' IRN CLOCKWISE: Increases the spring pre-load TURN COUNTERCLOCKWISE: Decreases the spring pro-load PRE-LOAD ADJUSTER ADJUSTABLE RANGE: A -14 mm (0.2 — 0.6 in) PRE-LOAD ADJUSTER STANDARD POSITION: 9 mm (0.4 in) from top surface of fork bolt 4-26 REBOUND DAMPING ADJUSTER Turn the rebound adjuster [1] clockwise until it stops (Iully hard position), then turn the adjuster counterclockwise. REBOUND ADJUSTER ADJUSTABLE RANGE: 11 clicks or more REBOUND ADJUSTER STANDARD POSITION: 6 cllcks out from fully hard REAR SUSPENSION INSPECTION Check the action of the shock absorber by compressing it several times. Check the entire shock absorber assembly for signs 01 leaks. damage or loose fasteners Replace damaged components which cannot be repaired. Tighten all nuts and bolts For shock absorber service (page 16-6). Support the motorcycle secume and raise the rear wheel off the ground. Check lcr worn swingarm bearings by grabbing the rear swingarm and attempting to move the swingarm side to side, Replace the bearings it any are Iooseness is felt. REAR SUSPENSION ADJUSTMENT SPRING PRE-LOAD ADJUSTER Spring pre-load can be adjusted by turning the adjuster dial [1}. TURN CLOCKWISE: Increases the spring pre-load TURN COUNTERCLOCKWISE: Decreases the spring pre-load PRE—LOAD ADJUSTER ADJUSTABLE RANGE: 25 clicks PRE-LOAD ADJUSTER STANDARD POSITION: 11 clicks out from lower position MAINTENANCE MAINTENANCE REBOUND DAMPING ADJUSTER o Always start on fully hard when adjusting the damping. - Do not turn the adjuster screws more than the given positions or the adjusters may be damaged. The rebound damping can be adjusted by turning the adjuster [1], DIRECTION H: Increases the damping force DIRECTION s: Decreases the damping force Turn the rebound adjuster dockwise until it stops, then turn the adjuster counterclockwise. REBOUND ADJUSTER STANDARD POSITION: 3/4 turn out from fully hard NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-12). Check that all safely clips, hose clamps and cable stays are in pleas and property securedi WHEELS/T IRES Support the motorcycle securely and raise the front wheel off the ground. Hold the front fork leg and move the front wheel sideways forcefully to see if the wheel bearings are worn. For front wheel service (page 15-13) 4-28 MAINTENANCE Support the motorcycle securely and raise the rear wheel off the ground. Hold the swingarm and move the rear wheel sideways with the force to see if the final gear bearings are worn. For rear wheel service (page 16-5). Check the tire pressure with attire pressure gauge when the tires are cold. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FRONT REAR psi) 250 (2,50, 36) 290 (2.90. 42) Tire Bridgestone BT021F N BT021R N bra“ D”“'°" SMngAgQ K 552;? K Check the tires for cuts. embedded nails. or other damage. check the wheel for trueness: — tront Wheel (page 15-13) — rear wheel (page 16-5) Measure the tread depth at the center of the tires, Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH: a - FRONT: 1.5 mm (0.06 in) REAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS Support the motorcycle securely and raise the front wheel otf the ground. Check that the handlebar moves freely from side to side. Make sure the control cables do not interfere with the handlebar rotation. If the handlebar moves unevenly, binds, or has vertical movement. inspect the steering head bearings (page 1530). 4-29 MAINTENANCE Check for steering stern head bearings by grabbing the fork legs and anempting to move the from fork side to side. Replace the bearings if any Iooseness is noted (page 1540). 4-30 LUBRICATION SYSTEM DIAGRAM ---------- --5-2 SERVICE INFORMATION ........................... ..5_3 TROUBLESHOOTING ................................. "5,4 OIL PRESSURE INSPECTION ------------------- “5-5 5. LUBRICATION SYSTEM 0|L STRAINER ........................................... .. 5.5 cm pUMp ................................................... .. 5.1 0|L COOLER ............................................ .. 5.13 5-1 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT PISTON ALTERNATOR \' \'/ \'/ \'/ 1 { A 1‘s 4‘» a} p EOP SENSOR II II \ \r H d—T—P \\ PISTON OIL JET CRANKSHAFT MAINSHAFT ‘1 COUNTERSHAFT OIL COOLER OIL FILTER CARTRIDGE ‘ FINAL SHAFT PRESSURE OIL STRAINER RELIEF VALVE OIL PUMP (FEED PUMP) OIL PUMP (SCAVENGE PUMP) LUBRICATION SYSTEM SERVICE INFORMATION GENERAL ACAUTION Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. - The oil pump can be 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. - It any portion of the oil pump is worn beyond the specified service limits. replace the oil pump as an assembly. - Alter the oil pump has been installed. check that there are no oil leaks and that oil pressure is correct. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil After draining 3.0 liter (3.2 US qt, 2.6 Imp qt) — capacity After draining/filter change 3.2 liter (3.4 US qt. 2.8 Imp qt) — After disassemny 4.0 liter (4.2 US qt, 3.5 Imp qt) — Engine oil Pro Honda GN4 4»stroke oil (USA. and Canada) or equivalent motor oil APl service classification: 56 or higher — JASO T 903 standard: MA Viscosity: SAE 10W>30 Oil pressure (at oil filter cartridge) 100 kPa (1.0 kgf/cm , 15 psi) at _ 1,100 rpm/80°C (176°F) Oil pump rotor Feed pump Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.07 — 0.20 (0.003 — 0.010) 0.34 (0.013) Side clearance 0.04 — 0.09 (0.002 — 0.004) 0.12 (0.005) Soavenge pump Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.07 — 0.20 (0.003 — 0.010) 0.34 (0.013) Side clearance 0.04 — 0.09 (0.002 — 0.004) 0.12 (0.005) TORQUE VALUES Oil filter cartridge 26 N~m (2.7 kgf-m, 19 |bf~tt) Apply engine oil to the threads and packing. Oil filter boss See page 4»14 Oil pump cover bolt 11 N-m (1.1 kgf'm. 8 Ibf-n) Oil pump mounting bolt 12 Nm (12 Min 9 lbt~ft) Oil cooler bolt 59 N‘m (6.0 kgftm. 44 lbt~ft) Apply engine oil to the threads. LUBRICATlON SYSTEM TOOLS Oil pressure gauge set 075068000001 or equivalent commercially available in U.S.A. Oil pressure gauge attachment 07406—003000!) $@ or equivalent commercially available in U.S.A. Oil pressure attachment O7DMJ-0010100 or 07AMJ-001A100 (USA only) Oil filler wrench 07HAA-PJ70101 or 07AAA-PLCA100 (U.SA. only) TROUBLESHOOTING OII level (on low ' Oil consumption External oil leak Worn piston rings Improperly installed piston rings Wom cylinders a -r Worn stern seals Worn valve guide Low oll pressure ' Oil level low - Clogged oil strainer - lnlemeloilleak ~ Incorrect oil being used No oil pressure Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pump Internal oil leak High oil pressure * ' Oil pressure relief valve stuck closed - Clogged oil filter, gallery or metering orifice . Incorrect oil being used Oil contamination ~ Oil or filter not changed often enough ~ Worn piston rings Oil emulslflcation ' Blown cylinder head gasket ‘ Leaky coolant passage - Entry oi water 5-4 LUBRICATION SYSTEM OIL PRESSURE INSPECTION Remove the under cowl (page 3'6). Remove the oil filter cartridge [1] using the special tool. TOOL: on filter wrench [2] 07HAA—PJ70101 or 07MA—PLCA1 00 (U.S.A. only) Apply engine oil to the O-ring and install the oil pressure attachment [1] onto the oil filter boss. TOOL: oil pressure attachment 07oMJ-0010100 or 07AMJ-001A100 (U.S.A. only) Reinstall the oil filter cartridge and tighten it, TOOL: Oil filter wrench 01HAA-PJ10101 or 07AM-PLCA100 (U.S.A. only) TORQUE: 26 N-m (2.7 kgf'm. 19 lbf-It) Install the oil pressure gauge [2] and attachment [3] to the oil pressure attachment. TOOLS: Oll pressure gauge 075064000001 Oil pressure gauge attachment 07406-0030000 or equivalent commercially available in U.S.A. Check the engine oil level and add the recommended all if necessary (page 4-12)4 Start the engine and warm it up to normal operating temperature (approximately 80°C/176°F). Check the oil pressure at 1,100 rpm. OIL PRESSURE: 100 We (1 .o kgflcm’, 15 psi) at 1,100 rpm! 80°C (116'?) Stop the engine. then remove the special tools and oil filter cartridge. Apply engine oil to Reinstall the oil filter cartridge [1] and tighten it the threagsjnrgl TOOL: ‘ Oil filter wrench D7HAA-PJ70101 or 07W-PLCA100 (U.$.A. only) TORQUE: 26 NM (2.7 kgf'm, 19 lbf-ft) Check the engine oil level and add the recommended oil if necessary (page 4-12). Make sure that there are no oil leaks. install the under cowl (page 3-6). 5-5 LUBRICATION SYSTEM OIL STRAINER REMOVAL Drain the engine oil (page 4—13). Remove the exhaust pipe (page 3-24). Remove the bolts [1] and oil pan [2]. Remove the oil strainer [1] and packing [2]. Check the oil strainer for damage or contamination, INSTALLATION Apply engine oil to new oil strainer packing [1] and install it onto the oil strainer [2]. Install the oil strainer aligning its lug [3] with the groove [4] on the oil pump. Clean the oil pan and lower crankcase mating surface thoroughly. being careful not to damage them. Donal apply mare Apply sealant (ThreeBond 12073 or an equivalent) to sealant than the mating surface. necessary. LUBRICATION SYSTEM Carefully install the oil pan {1] onto the lower crankcase. Install the bolts [2] and tighten them in a crisscross pattern in 2 — 3 steps. Install the exhaust pipe (page 3-27). Fill the crankcase with recommended oil (page 442). After installation. check that there are no oil leaks. OIL PUMP REMOVAL Remove the clutch assembly. oil pump drive and driven sprockets (page 10-14). Remove the oil pan and oil strainer (page 5-6). Remove the water pump mounting bolts [1]. Disengage the water pump shaft [1] from the oil pump shaft [2]. Remove the mounting bolts [1] and oil pump [2]. Remove the gasket [3], LUBRICATION SYSTEM Inspect the oil passage [1] for clogs, DISASSEMBLY Remove (he bolts [1] and oil pump cover A (scavenge pump side) [2]. Remove the oil pressure relief vaive [1L Remove the dowel pins [2], inner rotor [3]. outer rotor [4] and drive pin [5]. Remove the bolts [1] and oil pump cover B (feed pump side) [21‘ [11 if any portion 0/ the oil pump is warn beyand the service limit, replace the oil pump as an assembly. Remove the dowel pins [1], inner rotor [2], outer rotor [3]. drive pin [4] and oil pump shaft [5]. Clean the all disassembled pans thoroughly. INSPECTION Temporarily install the oil pump shaft, install the outer and inner rotors into the oil pump body. Measure the rotor tip clearance for the feed and scavenge pump. SERVICE LIMITS: Feed pump: 0.20 mm (0.008 in) Scavenge pump: 0.20 mm (0.008 In) Measure the pump body clearance for the feed and scavenge pump. SERVICE LIMITS: Feed pump: 0.34 mm (0.013 in) Scavenge pump: 0.34 mm (0.013 in) Measure the side clearance for the feed and scavenge pump using a straight edge and feeler gauge. SERVICE LIMITS: Feed pump: 0.12 mm (0.005 in) Scavenge pump: 0.12 mm (0.005 in) LUBRICATION SYSTEM TIP CLEARANCE (teed pump shown): BODY CLEARANCE (feed pump shown): SIDE CLEARANCE (feed pump shown): LUBRICATION SYSTEM Check the operation of the oil pressure relief valve [1] 2 by pushing on the piston [2]. l 1 / I‘I ASSEMBLY DRIVE PIN OIL PUMP BODY OIL PUMP SHAFT RELIEF VALVE DOWEL PINS DRIVE PIN FEED PUMP OUTER ROTOR FEED PUMP INNER ROTOR DOWEL PINS OIL PUMP COVER B 11 Am (1.1 kgf—m, 8 lbf-fl) 11 N~m(1.1kgi-m, B mm) SCAVENGE PUMP OIL PUMP COVER A OUTER ROTOR SCAVENGE PUMP INNER ROTOR Install the oil pump Install the drive pin [1] mm the oil pump shall [2] and shafi With Its driven inslall Ihem ID the oil pump body (feed pump side). Sprocket” "‘7‘ Install the feed pump inner rolor [3] while aligning its groove with the drive pinl 5-10 Install the feed pump outer rotor [1] and dowel pins [2], Install the oil pump cover B [1] and cover bolts [2]. Tighten the bolts to the specified torque TORQUE: 11 N'm (1.1 kgt‘m. 8 Ibfifl) Install the drive pin [1] into the oil pump shaft, Install the scavenge pump inner rotnr [2] while aligning its groove with the drive pin. Install the outer mtor [1]. Apply engine on to new O»ring [2] and install it into the reliel valve groove. Install the pressure relief valve [3] into the oil pump body. LUBRICATION SYSTEM [2] 5-11 LUBRICATION SYSTEM Install the dowel pins [1]. Install the oil pump cover A [1] and bolts [2]. Tighten the bolts to the specified torque. TORQUE: 11 N-m11.1 kgf-m,8lbf~ft) INSTALLATION Install a new gasket [1] onto the oil pump. Install the oil pump [1] and mounting bolts {2]. Tighten the bolts to the specified torque. TORQUE: 12 N‘m (1.2 kf-m, 9 lbf'ft) 5-12 LUBRICATION SYSTEM Engage the water pump shaft [1] with the oil pump shaft [2]. Install the water pump mounting bolts [1] and tighten them securely. Install the oil strainer and oil pan (page 5—6). Install the oil pump drive. driven sprocket and clutch assembly (page 1040). Fill the crankcase with recommended engine oil (page 4-1 3). OIL COOLER REMOVAL/INSTALLATION Remove the following: — under oowl (page 16) — lefl middle cowl (page 3»7) Drain the engine oil (page 4-13). Drain the coolant from the system (page 7-6). Loosen the hose band screws [1] and disconnect the water hoses [21mm the oil cooler. Remove the oil cooler bolts [1]. sealing washer [2] and oil cooler [3]. LUBRICATION SYSTEM Rafe/to 'CABLE & HARNESS ROUTING” for hose bend screw direction (page 1-22), Check the oil cooler [1] tor damage. Apply engine oil to new 0mg [2] and install it into the oil cooler groove. Install the oil cooler aligning its groove [3] with the lug [4] on the lower crankcase. Apply engine oil to sealing rubber of a new sealing washer[5]. Apply engine oil to the oil cooler bolt threads and seating surface Install the sealing washer and oil cooler bolt [6]. Tighten the oil cooler bolt [1] to the specified torquei TORQUE: 59 N-m (6.0 kgf-m, 44 Ibfl’l) Connect the water hoses [1] to the oil cooler and tighten the hose band screws [2]. Fill the crankcase with the recommended engine oil (page 4-12)‘ Fill and bleed the cooling system (page 7-5)‘ Install the following: — lefl middle cowl (page 3-7) — under cowl (page 3-6) [1] 5-14 6. FUEL SYSTEM (PGM-Fl) COMPONENT LOCATION "6-2 SERVICE INFORMATION ........................... "6.3 PGM-FI SYMPTOM TROUBLESHOOTING ................................. ..6_5 PGM-FI SYSTEM LOCATION --------------------- "6-6 PGM-Fl SYSTEM DIAGRAM ....................... "5,7 PGM-Fl CONNECTOR LOCATION ------------- "6-3 PGM-Fl TROUBLESHOOTING |NF0RMATI0N .......................................... "540 DTC INDEX-u 6.14 DTC TROUBLESHOOTING ---------------------- --s-1s 6-59 MIL CIRCUIT TROUBLESHOOTING-- FUEL I_INE INSPECTION .......................... "6,50 FUEL pUMp UNIT ..................................... "6.54 FUEL pUMp RELAY ................................. "5.51 FUEL TANK ............................................... ..5_67 AIR CLEANER HOUSING ......................... "563 THROTI'LE BODY/TCP SENSOR] INJECTOR- ----s-71 ENGINE IDLE SPEED ............................... "5.73 KNOCK SENSOR 6-79 MAP SENSOR ........................................... "5.19 IAT SENSOR ............................... .. 6.30 ........................................... .. CMI: SENSOR ........................................... "6.80 BANK ANGLE SENSOR ........................... ..6_81 ENGINE STOP RELAY ............................. "5.33 TBW RELAY ............................................. .. 5.34 ECM ........................................................... .. 6.34 SECONDARY AIR SUPPLY SYSTEM 6-87 02 SENSOR ............................................... "6.89 EGCA .................................. “5.90 EVAP PURGE CONTROL SOLENOID ................................... .. FUEL SYSTEM (PGM-FI) COMPONENT LOCATION 0.3 N~m (0.1 kgf~m, 0.6 lbw) FUEL SYSTEM (PGM-Fl) SERVICE INFORMATION GENERAL 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. Be sure to relieve the fuel pressure while the engine is OFF. Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind. resulting in loss of vehicle control. Do not apply commercially available carburetor cleaners to the inside of the throttle bore. The TPS sensor uses a magnetic field. The TPS sensor may cause incorrect TBW operation when a strong magnet is placed close to the sensor. if this occurs. keep the TPS sensor away from the magnet and turn the ignition switch to OFF and ON for restarting the TPS sensor. The TBW system will return to correct operation Do not snap the throttle drum of the TCP sensor from fully open to fully closed after the throttle cable has been removed as this may cause incorrect operation. Do not snap the throttle valve from fully open to fully closed by hand as this may cause incorrect operation. Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed. Do not apply excessive force to the fuel rail on the throttle body while removing or installing the throttle body. Do not damage the throttle body as this may cause Incorrect throttle synchronization. Prevent dirt and debris from entering the throttle bore and air passages after the throttle body has been removed. Clean them using compressed air if necessary. The throttle body is factory pre-set. Do not disassemble it in a way other than shown in this manual. Do not push the fuel pump base under the fuel tank when the fuel tank is stored. Always replace the packing when the fuel pump is removed. The programmed fuel injection system is equipped with a Self—Diagnostic System (page 510). Self-Diagnostic Procedures to remedy the problem. When cheating the PGM-Fl system. always follow the steps in the troubleshooting flow chart (page 6-5). The PGM-Fl system has a fail-safe function to secure a minimum running capability even when there a malfunction in the system. When any abnormality is detected by the self-diagnosis function. running capability is secured by making use of the numerical values of a situation preset in advance in the simulated program map. It must be remembered, however. that when any abnormality is detected in four injectors and/or the CKP sensor and CMF' sensor, the fail safe function stops the engine to protect it from damage. Refer to PGM—FI system location (page 6-6). A faulty PGM-Fl system is often related proceeding. Refer to procedures for fuel level sensor inspection (page 22-16). The rear wheel speed sensor sends digital pulse signals to the ECM (PGM-FI unit) for computation. Refer to procedures for rear wheel speed sensor inspection (page 18—17). When disassembling the PGM«FI parts. note the location of the O-rings. Replace them with new ones upon reassembly. Before disconnecting the fuel feed hose, relieve fuel pressure from the system by disconnecting the quick connect fitting of the fuel tank. ~ - Use a digital tester for PGM-Fl system inspection. If me MIL blinks. the to poorly connected or corroded connectors. Check those connections before SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number GNHDB Idle speed 1,150 i 100 rpm Throttle grip freeplay 2 —4 mm (1/16 - 3/16 in) lAT sensor resistance (at 20°CISB°F) 1 — 4 k9 ECT sensor resistance (at 20°CI68°F) 2.3 — 2.6 kn Fuel injector resistance (at 20“CI68°F) 11.6 — 12.4 9 PAIR solenoid valve resistance (at 20°C/68°F) 23 — 27 Q CKP sensor peak voltage (at 20°C/63°F) 0.7 V minimum Fuel pressure at idle 343 kPa (3.5 kgf/crn . 50 psi) Fuel pump flow (at 12V) 320 cm3 (10.8 US oz, 113 Imp oz) minimum/10 seconds 6-3 FUEL SYSTEM (PGM-Fl) TORQUE VALUES ECT sensor 25 N-m (2.5 kgf-m, 18 Ibl‘ft) Throttle body insulator band screw See page 646 Knock sensor 24 N-m (2.4 kgf-m, 13 mm) 0: sensor 245 N-m (2.5 kgf—m, 18 let) Fuel rail mounting bolt 5.1 N'm (0.5 kgf—m. 3.8 lbfrfl) Fuel filler cap bolt 1.8 N-m (0.2 kgf~m. 1.3 lbf'fl) Fuel pump mounting nut 12 NM (1.2 kgf-m. 9 Ibf-fl) Air cleaner case screw 0.8 N-m (0.1 kgf‘rn. 0.6 lbf-fl) Resonator screws 08 Nm (0.1 kgflrn, 0.6 Ibf-fl) Bank angle sensor mounting bolt 1.5 N-m (0.2 kgfrm. 1.1 Ith) IAT sensor 1.1 Nam (01 kgftm, 0.8 let) MAP sensor 1.1 N~m (0.1 kgf~m. 0.8lbfr1t) Air funnel mounting screw 4.2 N-m (0.4 kgt-m. 3.1 lbf‘ft) TCP sensor throttle cable stay screw 3.4 Ntm (0.3 kgf-m. 2.5 lbf~fl) Front PAIR check reed valve cover 13 N-m (1.3 kgf—m. 10 Ith) CT bolt Rear PAIR check reed valve cover 6.9 N-m (0.7 kgf‘m, 5.1 Ibf-ft) CT bolt TOOLS Peak voltage adaptor lgnitionMate peak voltage tester Attachment joint. 8 mrn/9mm 07HGJ-0020100 (Not available MTF’07—0286 (U.S.A. only) 07ZAJ-S7C0200 in U.S.A.) (Not available in USA.) with commercially available digital mul— timeter (impedance 10 MO/DCV mini- mum) or peak voltage tester Test probe Fuel pressure gauge Pressure gauge manifold 07ZAJ-RDJA11D “ V 074060040004 07ZAJ-S5AO1 1 1 (Not available in U.S.A.) Hose attachment. 8 mm/Bmm Hose attachment. 9 mm/9mm SCS connector O7ZAJ-S7CD1OO 07ZAJ-SSA0120 D7OPZ—ZY 30100 (Not available in U.S.A.) (Not available in U.S.A.) 6-4 FUEL SYSTEM (PGM-FI) Pressure manifold hose 07AMJ—HW3A100 (USA, only) Adaptor, male 07AAJ—SSMA200 (USA only) Adaptor. female 07AAJ-56MA400 (U,S.A. only) PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms. check the DTC or MIL blinking, refer to the DTC index (page 6-14) and begin the appropriate uoubleshooting procedure. If there are no DTC/MIL blinking stored in the ECM memory, do the diagnostic procedure for the symptom, in sequence listed below. until you find the cause. Symptom Diagnosis procedure Also check for Engine cranks but won't start (No DTC and MIL blinking) 1. Crank the starter for more than ten seconds and chew the DTC (page 64 2) and execute the trouble- shooting acoording to the DTC. No fuel to injector — Clogged fuel filter — Pinched or clogged fuel feed hose — Pinched or clogged fuel tank air vent hose (page 6-60). 2. Inspect the fuel supply system - Faulty fuel pump (page 6-60). — Faulty fuel pump circuits o intake air leak - Contaminated/deteriorated fuel - Faulty injector - Faulty TBW system ' Faulty ignition system Engine cranks but won‘t start 1. ECM power/ground circuits mel- - Open circuit in the power input and/or (No fuel pump operation sound function (page 6-85). ground wire of the ECM when turning the ignition ON) 2. Inspect the fuel supply system Faulty bank angle sensor or related circuit Faulty engine stop relay or related circuit Faulty engine stop switch or related circuit Engine stalls. hard to start, rough idling . Check the idle speed. 2. Inspect the fuel supply system 3, Inspect the battery charging sys- Restricted fuel tank air vent hose tern (page 19-7). Faulty ignition system Faulty TBW system Faulty battery charging system (page 6-60). Restricted fuel feed hose Contaminated/deteriorated fuel Intake air leak Afterbum when engine braking is used check the PAIR system (page 4-16). Faulty PAIR system — Faulty PAIR control solenoid valve — Faulty PAIR check valve — Clogged hose of the PAIR system Faulty ignition system Backfiring or misflring during acceleration Check the ignition system. Faulty ignition system Poor performance (driveability) and poor fuel economy 1. Inspect the fuel supply system (page 6—60). Pinched or clogged fuel feed hose Faulty pressure regulator 2. Inspect the air cleaner element - Faulty lnjedor (page 4-6). ‘ Faulty ignition system ~ Clogged air cleaner element Idle speed is below - 1. Check the idle speed. - Faulty TBW system specifications or fast idle too 2. Check the TBW system. - Faulty fuel supply system low (No DTC and MIL blinking) - Faulty ignition system Idle speed is above 1. Check the idle speed, - Faulty TBW system specifications or fast idle too 2. Check the throttle operation and - Faulty ignition system high (No DTC and MIL freeplay - Intake air leak blinking) 3. Check the TBW system. - Engine top end problem O Air cleaner condition MIL stays 0N but no DTCs set, Troubleshoot the MIL circuit - Faulty MIL circuit or MIL never comes ON at all (page 6—59). MIL stays ON at all Inspect the DLC circuit. - Short circuit in the DLC related wire (No DTC set) FUEL SYSTEM (PGM-Fl) PGM-FI SYSTEM LOCATION IAT SENSOR INJECTOR TCP SENSOR CMP SENSOR FUEL PUMP ENGINE STOP/TBW RELAYS EGCA EOF' SENSOR MAP SENSOR \ ECT SENSOR TP SENSOR/THROTTLE VALVE MOTOR ‘ BANK ANGLE SENSOR Oz SENSORS R PEED SENSOR KNOCK SENSOR EAR WHEEL S DLC GEAR POSITION SENSOR CKP SENSOR FUEL SYSTEM (PGM-Fl) PGM-FI SYSTEM DIAGRAM ruse 30A rusz «m ma. °_° BANK ANGLE FUSE m SENSOR ENGINE $10? RELAV R mg w m mama fl REGULAYOR/ RECTIFIER FUSEMM FAN MOYOR ma vomk RELAY ©(B4) ECM ALTERNATOR ©l12’ MAP SENSOR @035) TBW REuY © (33) EDP SENSOR ©(7) Ec-r SENSOR ©(9) w SENSOR ©(25‘56) KNOCK SENSOR © 1% 11 8) cm: SENQDR FUEL pump 23 01 SENSOR m4 22 4 m SENSOR am @ EX? 11st m sensoa comammou max (12) mm ImEcwR (13) No.2 INJECTOR ABS MODULAYOR © (H (7415.763 EEZSOR No.3 0112mm (151 mu umzcvox © 1»: sausom @ (11) (711213717519) 51mm: aw: PURGE comm SOLEan VALVE W MO‘IOR REAR WHEEL SPEED SENSOR PAIR SDLENDVD VALVE IGNFVIDN COIL/SPARK PLUG mew me we»: menu we“ (21‘?) gm; Posmm 5mm S‘DESTAND 5me © ( ):DTC/Manumber 1% :Engine does not start when detecfing DTC / MIL :Shon terminals for reading DTC I MIL ECM up {BLUE} ooNNEcroR A ECM w mum CONNECTOR c ECM 33? 1mm) CONNECTOR n FUEL SYSTEM (PGM-Fl) PGM-Fl CONNECTOR LOCATION NOTE21 Lift and support fuel tank (page 4-5). NOTE:2 Remove the fuel rail (page 6-71). ECM 33F (GRAY) CONNECTOR ECM 33F (BLACK) CONNECTOR ECM 33F (BLUE) CONNECTOR (NOTE 1) (NOTE 1) (NOTE 1) \1—1 m H Ir J) I I) II V 1 l I) 3: I A l I I vl u r t T x x r CMP SENSOR 3P IAT SENSOR 2P (GRAV) (BLACK) CONNECTOR CONNECTOR (NOTE 1) (NOTE 1) KNOCK SENSOR 3P (BLACK) CONNECTOR (NOTE 1) INJECTOR 2P (GRAV) TCP SENSOR 6P CONNECTORS (NOTE 2) (BLACK) CONNECTOR (NOTE 2) NOTES Remove the throttle body (page 6-71). ECT SENSOR 3P (GRAY) CONNECTOR (NOTE 3) \ EOP SENSOR 3P (BLACK) CONNECTOR (NOTE 3) FUEL SYSTEM (PGM-Fl) NOTE:4 Remove the engine heal guard (page 11—4)‘ NOTE:5 Remove the radiator (page 79). NOTE:6 Remove the righT middle cowl (page 3-7). MAP SENSOR 3P (BLACK) CONNECTOR mim\ Lama???) NOTE 1) ( (NOTE 1) GEAR POSITION SENSOR 8P (BLACK) CONNECTOR (NOTE 4) N02/3 02 SENSOR 4P (BLACK) and No1/4 02 SENSOR 4P (BLUE) CONNECTORS (NOTE 5) CKP SENSOR 2P (BLACK) CONNECTOR (NOTE 6) Remove the rear wwl (page 3—41 Remove the seal (page 3-4). NOTE:9 Remove the canister tray (page 6-91). EGCA 6P (BLACK) CONNECTOR (NOTE 7) DLC (NOTE 3) REAR WHEEL SPEED SENSOR 2P (ORANGE) CONNECTOR (NOTE 9) \@ FUEL SYSTEM (PGM-Fl) PGM-Fl TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. if the MIL does not come on. check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out, the original problem may be intermittent. Opens and Shorts "Opens" and "Shorts' are oommon electrical terms. An open is a break in a wire or at a connection. A short is an accidental connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With ECMs this can something mean something may work. but not the way it’s supposed to. If the MIL has come on Refer to DTC READOUT (page 641). If the MIL did not stay on If the MIL did not stay on. but there is a driveability problem, do the PGM-Fl SYMPTOM TROUBLESHOOTING (page 6—5). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The PGM-FI system is equipped with the self—diagnostic system. When any abnormality occurs in the system, the ECM turns on the MIL and stores a DTC In its erasable memory. FAIL—SAFE FUNCTION The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is a malfunction in the system. When any abnormality is detected by the setf-diagnosis function, running capability is maintained by pro-programmed values in the simulated program map. When any abnormality is detected in the injector(s), CKP sensor and/or CMF' sensor. the fail— safe function stops the engine to protect it from damage. DTC (Diagnostic Trouble Code) ' The DTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the ECM with the HDS pocket tester. The digits in front of the hyphen are the main code, they indicate the component of function failure. The digits behind the hyphen are the sub oode, they detail the specific symptom of the component or function failure. For example, in the case of the MAP sensor: — DTC 01 — 1 (MAP sensor voltage) - (lower than the specified value) — DTC 01 — 2 — (MAP sensor voltage) — (higher than the specified value). The MAP, ECT, EOP. TP sensor. TCP sensor and IAT sensor diagnosis will be made according to the voltage output of the efiected sensor. It a failure occurs, the ECM determines the Function Failure, compares the sensor voltage output to the standard value, and then outputs the corresponding DTC to the HDS 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 displayed. — II the input voltage line (B) on the TP sensor is opened, the ECM detects the output voltage is 5 V, then the DTC 71—1 (TP sensor circuit low voltage) will be displayed. 5V 5V MAP SENSOR TCP SENSOR 5V OUTPUT VOLTAGE TP SENSOR OUTPUT VOLTAGE OUTPUT VOLTAGE 5V 5V IAT SENSOR ECT SENSOR OUTPUT VOLTAGE OUTPUT VOLTAGE 6-10 FUEL SYSTEM (PGM-FI) MIL Blink Pattern - If the HDS pocket tester is not available. DTC can be read from the ECM memory by the MIL [1] bllnk pattern. - The number of MIL blinks is the equivalent the main code of the DTC (the sub code cannot be displayed by the MIL). - The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for 1.3 seconds. the short blinking lasts for 0.5 seconds. One long blink is the equivalent often short blinks. For example, when two long blinks are lollowed by five short blinks. the MIL is 25 (two long I blinks = 20 blinks. plus five short blinks). - When the ECM stores more than one DTC. the MIL will indicate them by blinking In the order irorn me lowest number to highest number. MIL Check When the ignition switch is turned ON and engine stop switch " 0 ". the MIL will stay on for a few seoonds. then go oft. lfthe MIL does not come on. troubleshoot the MIL circuit (page 6-59). CURRENT DTC/FREEZE DTC The DTC is indicated in two ways according to the failure status. - In case the ECM detects the problem at present. the MIL will oorne on and the MlL will start to blink when the sidestand is lowered. It is possible to readout the MIL blink pattern as the current DTC. . in case the ECM does not detect any problem at present but has a problem stored in its memory. the MIL will not light and blink. If it is necessary to retrieve the past problem. readout the freeze DTC by lollowing the DTC readout procedure. HDS POCKET TESTER INFORMATION - The HDS can readout the DTC. lreeze date. current data and other ECM condition. How to connect the HDS Pocket Tester Turn the ignition switch OFF. Remove the seat (page 3-4). Remove the dummy connector [1] Irom the DLC [2]. Connect the HDS pocket tester to the DLC. Turn the ignition switch ON. check the DTC and freeze data. dioates the engine oonditions when the first matfunction ECM reset The HDS can reset the ECM date including the DTC. freeze data and some learning memory. DTC READOUT Start the engine and check the MIL [1]. ~ It the engine will not start. tum the starter motor for more than 10 seconds and check that the MIL blinks. ~ When the ignition switch is turned ON. the MIL will stay on for a lew seconds. then go ofl. It the MIL stays on or blinks, connect the HDS Pocket Tester to the DLC (page 641). . Read the DTC. freeze data and follow the troubleshooting index (page 6-14). To read the DTC with Ihe MIL blinking. refer to the following procedure. 6-11 FUEL SYSTEM (PGM-Fl) Reading DTC with the MIL Turn the ignition switch OFF. Remove the seat (page 34). Remove the dummy connector and short DLC [1] terminals using the special tool [2]. TOOL: SCS connector 070PZ-ZY30100 CONNECTION: Brown — Green Make sure the engine stop switch is turned to ' O ". Tum the ignition switch ON and engine stop switch ” n ", reed. note the MIL blinks and reter to me troubleshooting index (page 6-14), NOTE: If the ECM has any DTC in its memory, the MIL will start blinkingr CLEARING DTC Connect the HDS Pocket Tester to the DLC (page 6-11). Clear the DTC with the HDS while the engine is stopped, To clear the DTC without HDS. refer to the following procedure, How to clear the DTC with $08 connector 1‘ Remove the seat (page $41 2. Turn the ignition switch OFF. Make sure the engine stop switch is turned to " 0 3‘ Remove the dummy connector and short the Brown and Green wire terminals of the DLC [1] terminals using the special tool [21‘ TOOL: scs connector 070PZ-ZY30100 CONNECTION: Brown - Green 4. Turn the ignition switch 0M 5. Remove the special‘tool from the DU; 6. The MIL will light for approximately 5 seconds. W..ile the MIL lights, short the DLC terminals again with the special tool. The sen-diagnostic memory is erased ii the malfunction indicator goes off and starts blinking. NOTE: - The DLC must bejumped while the MIL lights. If not. the ML will not start blinking - Note that the self-diagnostic memory cannot be erased iithe ignition switch is turned "OFF" belore the MIL starts blinkingt 6-12 FUEL SYSTEM (PGM-Fl) CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR Always clean around and keep any foreign material away from the ECM connector before disconnecting it, A faulty PGM—Fl system is Often related to poorly connected or corroded connections. Check those connections before proceeding. In testing at ECM connector (wire harness side) terminal, always use the test probe. Insert the test probe [1] into the connector terminal. then attach the digital multimeter probe to the test probe. TOOL: Test probe 07ZAJ-RDJA110 [1] The ECM connector terminals (wire harness side) are numbered as shown _ in (he mustratian WIRE HARNESS SIDE TERMINAL LAYOUT. BLACK CONNECTOR mam-m. n m m. BLUE CONNECTOR GRAY CONNECTOR 6-13 FUEL SYSTEM (PGM-Fl) DTC IN DEX DTC Refer (MIL Function Failure Symptom/Faileafe function to blinks) (arc) 1—1 (1) MAP sensor circuit low voltage (less than 02 V) - Engine operates normally 6—16 - MAP sensor or its circuit malfunction v Fa ate value: 760 mmHg/1.013 hPa 1-2 (1) MAP sensor circuit high voltage (more than 3.9 V) - Ine operates normally 6-17 - Loose or poor contact of the MAP sensor - Fail-sale value: 760 mmHg/1.013 hPa connector - MAP sensor or Its circuit malfunction 2»1 (2) MAP sensor performance problem - Engine operates normally 6-18 - Loose or poor connection of me MAP sensor vacuum hose - Faulty MAP sensor 7-1 (7) ECT sensor circuit low voltage (less than 0.07 V) ' Hard to start at a low temperature 6-19 - ECT sensor or its circuit malfunction ' Fail-safe value: 85°C/185°F ' Cooling fan turns on 7-2 (7) ECT sensor circuit high voltage (more than 4.93 V) - Hard to start at a low temperature 6-20 . Loose or poor contact of the ECT sensor connector - Fail-safe value: 85"C/185°F . ECT sensor or its circuit malfunction - Cooling fan turns on 9-1 (9) IAT sensor circuit low voltage (less than 0.07 V) - Engine operates normally 6-21 - IAT sensor or its circuit malfunction - Pre-program value: 35°C/95°F 9-2 (9) IAT sensor circuit high voltage (more than 4.93 V) ' Engine operates normally 6»22 - Loose or poor contact of the IAT sensor connector - Fail»safe value: 35°CIBS°F - IAT sensor or its circuit malfunction 11—1 (11) Rear wheel speed sensor no signal ~ Engine operates normally 6—23 - Loose or poor contact of the rear wheel speed sensor connector - Rear wheel speed sensor or its circuit malfunction 12—1 (12) No. 1 injector circuit malfunction ‘ Engine does not start 6-24 - Loose or poor contact of the injector connector ' Injectors. fuel pump and ignition shut - Injector or its circuit malfunction down 13-1 (13) No. 2 Injector circuit malfunction - Engine does not start 6-26 - Loose or poor contact of the injector connector - Injectors, fuel pump and ignition shut - Injector or its circuit malfunction down 14-1 (14) No. 3 injector circuit malfunction - Engine does not start 6-26 r Loose or poor contact of the injector connector - Injectors. fuel pump and ignition shut ' Injector or its circuit malfunction down 15-1 (15) No. 5 injector circuit malfunction - Engine does not start $26 - Loose or poor contact of the injector connector ~ Injectors. fuel pump and ignition shut ‘ Injector or its circuit malfunction down 18—1 (18) CMP sensor no signal - Engine does not start 6«26 - Loose or poor contact of the CMP sensor - Injectors. fuel pump and ignition shut connector down . CMP sensor or its circuit malfunction 19.1 (19) CKP sensor no signal - Engine does not start 6-27 O Loose or poorcontact of the CKP sensor connector - Injectors. fuel pump and ignition shut ' CKP sensor or its circuit malfunction down 21»1 (21) No.1/4 0: sensor malfunction ~ Engine operates normally 6—28 - Loose or poor contact of the 02 sensor connector - 02 sensor or its circuit malfuncu‘on 22-1 (22) No.2/3 02 sensor malfunction - Engine operates normally 6-30 ‘ Loose or poor contact of the 02 sensor connector ' 02 sensor or its circuit malfunction 23-1 (23) No.1/4 02 sensor heater.circuit malfunction - Engine operates normally 6-31 ~ Loose or poor contact of the 02 sensor heater connector - Oz sensor heater or its circuit malfunction 24-1 (24) No.2/3 02 sensor heater circuit malfunction ‘ Engine operates normally 6-32 ‘ Loose or poor contact of the 02 sensor heater connector - 02 sensor heater or its circuit malfunction 25-1 (25) Knock sensor circuit malfunction ' Engine operates normally 6-34 ' Loose or poor contact of the knock sensor connector - knock sensor or its circuit malfunction 6-14 FUEL SYSTEM (PGM-Fl) DTC Refer (MIL Function Failure SymptomIFaiI-safe function to blinks) (pro) 252 (25) Knock sensor circuit malfunction ~ Engine operates normally 6-35 - Loose or poor contact of the knock sensor connector - knock sensor or its circuit malfunction 34-1 (34) ECV POT low voltage malfunction - Engine operates normally 6-36 ‘ Loose or poor contact of the EGCA connector . ECV or its circuit malfunction 34-2 (34) ECV POT high voltage malfunction - Engine operates normally 6-38 - ECV or its circuit malfunction 35-1 (35) EGCA POT malfunction - Engine operates normally 6-39 - Loose or poor contact of the EGCA connector ~ ECV or its circuit malfunction ' EGCA lock 41-1 (41) Gear position sensor malfunction - Engine operates normally 640 . Loose or poor contact of the gear position sensor connector - Gear position sensor or its circuit malfunction 56-1 (56) Knock sensor IO malfuncti n - Engine operates normally 6-40 O Knock sensor or its circuit malfunction 71-1 (71) TP sensor 1 low voltage (less than 0.096 V) . Vehicle speed limit: approximately 120 6-41 - TP sensor 1 or its circuit malfunction kmlh (75 mph) 71—2 (71) TP sensor 1 high voltage (more than 4.762 V) - Vehicle speed limit: approximately 120 6-42 - Loose or poor contact of the TBW connector kmlh (75 mph) - TP sensor 1 or its circuit malfunction 72-1 (72) TP sensor 2 low voltage (less than 0.063 V) - Vehicle speed limit: approximately 120 6-43 - TP sensor 2 or its circuit malfunction kmlh (75 mph) 72-2 (72) TP sensor 2 high voltage (more than 4.761 V) - Vehicle speed limit: approximately 120 6-44 - Loose or poor contact of the TBW connector km/h (75 mph) - TP sensor 2 or its circuit malfunction 734 (73) TP sensor 1-2 voltage correlation failure - Engine operates at idle speed 6-45 - TP sensor or its circuit malfunction 73-2 (73) TP sensor 1—2 short circuit - Engine operates at idle speed 6-46 ' TP sensor or its circuit malfunction 74-1 (74) TOP sensor 1 low voltage (less than 0.137 V) ' Engine operates at idle speed 6-47 ' Loose or poor contact of the TCP sensor connector - TCP sensor 1 or its circuit malfunction 74-2 (74) uTCP sensor 1 high voltage (more than 4.902 V) - Engine operates at idle speed 6-43 - TCP sensor 1 or its circuit malfunction 75-1 (75) TCP sensor 2 low voltage (less than 0.137 V) ' Engine operates at idle speed 6—49 - Loose or poor contact of the TCP sensor connector ~ TCP sensor 2 or its circuit malfunction 75-2 (75) TOP sensor 2 high voltage (more than 4.902 V) ~ Engine operates at idle speed 6-51 - TCP sensor 2 or its circuit malfunction 76-1 (76) TOP sensor 1—2 voltage correlation failure ~ Engine operates at idle speed 6-52 ' TCP sensor malfunction 77-1 (77) TBW return spring failure ~ Vehicle speed limit: approximately 120 ($53 kmlh (75 mph) 78-1 (78) TBW motor failure ~ Engine operates at idle speed 6-54 - TBW motor circuit malfunction 79-1 (79) TBW system control correlation failure ~ Engine operates at idle speed 6-55 - TBW system or its circuit malfunction 83-1 (83) EOP sensor low voltage (less than 0.059 V) ' Engine operates normally 6—55 ' EOP sensor or its circuit matfunction - Oil pressure indicator stays an 83-2 (83) EOP sensor high voltage (more than 4.93 V) - Engine operates normally 666 - Loose or poor contact of the EOP sensor - Oil pressure indicator stays on connector - EOP sensor or its circuit malfuncu’on 84—1 (84) ECM processor failure - Engine idle speed 663 854 (85) TBW relay failure (ON side) - Vehicle speed limit: approximately 120 6-58 ~ TBW relay or its circuit malfunction kmlh (75 mph) 85—2 (85) TBW relay failure (OFF side) - Engine operates at idle speed 6-59 - TBW relay or its circuit malfunction 6-15 FUEL SYSTEM (PGM-Fl) DTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLTAGE) I Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) connector and ECM 33F connectors. then recheck the DTC‘ 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch . Q t Check the MAP sensor with the HDS. Is about 0 V or below indicated? YES — GO TO STEP 2. NO — intermittent failure 2. MAP Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the MAP sensor 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch .. Q .. Measure the voltage at the wire sidet Connection: Yellowlred (+) — Gray/white (-) Is the voltage wlthln L75— 5.25V? YES - GO TO STEP 4. N0 —- GO TO STEP 3. 3. MAP Sensor Input Llne Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Gray) connector [1]. “Check for continuity at the Yellow/red wire between the MAP sensor 3P (Black) connector [2] and ECM 33F (Gray) connector. Connection: D23 - Yellow/red TOOL: Test probe 07ZM-RDJA110 Is there ccntlnulty? YES — Replace the ECM with a known good one, and recheckt NO — Open circuit in Yellow/red wire Gray/white I1] Yellow/red D28 Yellow/red [2] 6-16 FUEL SYSTEM (PGM-Fl) A. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF, [1] Check for continuity between the MAP sensor 3P (Black) connector [1] at the wire side and ground. \ { Connection: Light greerflyellow — Ground Is there continuity? YES — Short circuit in Light green/yellow wire NO - GO TO STEP 5. Q) Light green/yellow " 5. MAP Sensor Inspection Replace the MAP sensor with a known good one (page 6—79). Clear the DTC's (page 6-12), Turn the ignition switch ON and engine stop switch i Q Check the MAP sensor with the HDS, ls DTC 1-1 Indicated? YES — Replace the ECM with a known good one. and recheck. NO - Faulty original MAP sensor DTC 1-2 (MAP SENSOR HIGH VOLTAGE) ' Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) connector and ECM 33P connectors, then recheck the DTC. 1‘ MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop switch . Q u. check the MAP sensor with the HDS. Is about 5 Vlndlcated? YES — GO TO STEP 2. NO — Intermittent failure 2. MAP Sensor System Inspection 2 Turn the ignition switch OFF. Disconnect the MAP sensor 3P (Black) connector [1]. Connect the MAP sensor 3P (Black) connector terminals at the wire side with e Jumper wire. Connection: Light green/yellow — Gray/white Turn the ignition switch ON and engine stop switch . Q Check the MAP sensor with the HDSr Is about 0 Vlndlcated? YES — Faulty MAP sensor NO - GO TO STEP 3‘ Gray/while Light green/yellow 6-17 FUEL SYSTEM (PGM-Fl) 3. MAP Sensor Input Voltage Inspection Turn the ignition switch OFF. Remove the jumper wire. Turn the ignition switch 0N and engine stop switch . Q .‘ Measure the voltage at the MAP sensor 3P (Black) connector [1] at the wire side. Connection: Yellow/red (+) — Gray/white (—) Is the voltage within 4. 75 - 5.25V? YES - GO TO STEP 4. N0 — . Open circuit in Gray/white wire ‘ Open cirwit in Yellow/red wire 4. MAP Sensor Output Llne Open Clrcuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Check for continuity at the Light green/yellow wire between the MAP sensor 3P (Black) connector [2] and ECM 33F (Black) connector. Connection: C15 — Light Green/yellow TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one, and recheck. NO - Open circuit in Light green/yellow wire DTC 2-1 (MAP SENSOR) - Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) rgonnector and ECM 33F connectors, then recheck the DTC. 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch . Q ._ Start the engine and check the MAP sensor with the HDS at idle speed. ls 1.6 Vindlcered? YES — Intermittent failure NO — GO TO STEP 2, Gray/white Yellow/red 1:!— fl Q’; m (9 C15 Ligm green/yellow [2] © 6-18 FUEL SYSTEM (PGM-FI) 2. Manifold Absolute Pressure Test Turn the ignition switch OFF. Check for connection and installation of the MAP sensor [1] vacuum hose [2]. Is the MAP sensor vacuum hose connection correct? YES — GO TO STEP 3‘ NO - Correct the hose installation 3. MAP Sensor System Inspection Replace the MAP sensor with a known good one (page 6-79). Turn the ignition switch ON and engine stop switch .. a "I Start the engine and check the MAP sensor with the HDS at Idle speedl Is the reading changed? YES - Faulty original MAP sensor N0 - Replace the ECM with a known good one. and recheck, DTC 7-1 (ECT SENSOR LOW VOLTAGE) - Belore starting the inspection, check tor loose or poor contact on the ECT sensor 3P (Gray) connector and ECM 33F connectors, then recheck the DTC. 1. ECT Sensor System Inspection Turn the ignition switch 0N and engine stop switch .. Q n} Check the ECT sensor with the HDS. is about 0 Vindicated? YES — GO TO STEP 2. NO — intermittent failure 2. E61 Sensor Inspection Turn the ignition switch OFF, Disconnect the ECT sensor 3P (Gray) connector. Turn the ignition switch ON and engine stop switch .. Q Check the ECT sensor with the HDS. Is about 0‘ Vindlcated? VES — GO TO STEP 4. NO — GO TO STEP 3. 6-19 FUEL SYSTEM (PGM-Fl) 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor [1] terminals. Connection: Bluelyellow (1-) - Gray (—) (Sensor side terminals) Standard: 2.3 - 2.6 k D (20°CI68°F) Is the resisbnce withln 2.3 - 2.5 k0 (mm/68°97 YES — Replace the ECM with a known good one. and recheck. NO —- Feulty ECT sensor 4. ECT Sensor Output Line short Circuit Inspection Turn the ignition switch OFF. Check for continuity between the ECT sensor 3P (Gray) connector [1] at the wire side and ground. Connection: Blue/yellow - Ground Is there continuity? YES - Short circuit in Blue/yellow wire N0 - Replace the ECM with a known good one, and recheck. DTC 7-2 (ECT SENSOR HIGH VOLTAGE) - Belore starting the inspection, check for loose or poor contact on the ECT sensor 3P (Gray) connector and ECM 33P connectors. then recheck the DTC. 1. ECT Sensor System Inspection ‘ Turn the ignition switch 0N and engine stop switch . Q Check the ECT sensor with the HDS. Is about 5 V indicated? YES - GO TO STEP 2. N0 - Intermittent failure 2. ECT Sensor inspection Turn the ignition switch OFF. Disconnect the ECT sensor 3P (Gray) connector [1]. Connect the ECT sensor terminals with a jumper wire [2]. Connection: Blue/yellow - Gray Turn the ignition switch ON and engine stop switch . Q it Check the ECT sensor with the H08. ls about 0 vindicated? YES - Inspect the ECT sensor (page 22-15). No - GO TO STEP 3. [1] Blue/yellow Blue! ellow / {1] Gray \ [2] 6-20 FUEL SYSTEM (PGM-FI) 3. ECT Sensor Llne Inspection Turn the ignition switch OFF. Remove the jumper wire. Disconnect the ECM 33P (Black) connector [1] and 33P (Gray) connector [2]. Check for continuity at the Blue/yellow and Gray] white wires between the ECT sensor 3P (Gray) connector [3] and ECM 33F connectors. Connection: 621 - Bluelyellow D26 — Gray/white (:21 [1] / l3] Blue/yellow TOOL: Test probe DTZAJ-RDJM 10 Are there continuity? YES - Replace the ECM with a known good one, and recheck. [2] NO — . Open circuit in Bluayeliow wire O Open circuit in Gray/white wire S2 [3] 026 Gray/white DTC 9-1 (IAT SENSOR LOW VOLTAGE) - Before starting the inspection. check for loose or poor contact on the IAT sensor 2P (Gray) connector and ECM 33F connectors. then recheck the DTC. 1. IAT Sensor System Inspection Turn the ignition switch 0N and engine stop switch " Q Check the IAT sensor with the HDS. Is about 0 V indlcated? YES — GO TO STEP 2‘ N0 — Intermittent failure 2. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Gray) connector. Turn the ignition switch ON and engine stop switch -- o Check the IAT sensor with the HDS. Is about 0 V indicated? YES - GO TO STEP 3‘ N0 — Faulty IAT sensor 6-21 FUEL SYSTEM (PGM-Fl) 3. IAT Sensor Output Line short circuit Inspection Turn the ignition switch OFF. Check for continuity between the IAT sensor 2P (Gray) connector [1] at the wire side and groundi Connection: Gray/blue - Ground Is there cantinuitfl / [1] YES — Short circuit in Gray/blue wire NO — Replace the ECM with a known good one. and recheck. Gray/blue DTC 9-2 (IAT SENSOR HIGH VOLTAGE) - Before starting the inspection, check for loose or poor contact on the IAT sensor 2P (Gray) connector and ECM 33P connectors. then recheck the DTC 1. lAT Sensor System Inspection Turn the ignition switch ON and engine stop switch -- 0 Check the IAT sensor with the HDS. Is about 5 vindicated? YES - GO TO STEP 2. NO — intermittent failure 2. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Gray) connector [1]. Connect the IAT sensor terminals with a jumper wire [2]. " Connection: Gray/blue - Graylwmte Gray/blue Turn the ignition switch ON and engine stop switch . Q .‘ Check the IAT sensor with the HDS. Is about 0 Vlndicated7 YES — Faulty lAT sensor N0 - GO TO STEP 3. [2] Gray/white 6-22 3. IAT Sensor Llne lnspectlon Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1] and 33F (Gray) connector [2]. Check for continuity at the Gray/blue and Gray/white wire between the IAT sensor 2P connector [3] and ECM 33F connectors. Connection: C31 -Graylblue D26 - Graylwhlte TOOL: Test probe 01ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one, and recheck. — - Open circuit in Gray/blue wire ~ Open circuit in Gray/white wire N0 DTC 11-1 (REAR WHEEL SPEED SENSOR) 1 Before starting the inspection, check for loose or poor oontect on the rear wheel speed sensor 2P (Orange) connector and ECM 33F connectors. then recheck the DTC. . Rear Wheel Speed Sensor System Inspection Clear the DTC's (page 642). Test ride the motorcycle, Stop the engine. Turn the ignition switch ON and engine slop switch .. Q .. Check the rearwheel speed sensor with the H05, Is DTC 11—1 indlcated? NO - GO TO STEP 2. YES - |nterrnitlent failure . Rear wheel Speed Sensor Inspection Check for operation 0! rear wheel speed sensor (page 18-17). Does the rear wheel speed sensor operate normally? YES — GO TO STEP 3. N0 — Faulty rear wheel speed sensor. FUEL SYSTEM (PGM-Fl) [1] Gray/blue [2] Gray/white [3] 6-23 FUEL SYSTEM (PGM-FI) 3. Rear Wheel Speed Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFF, Disconnect the ECM 33F (Black) connector [1]. Check Ior oontinuity between the ECM 33F (Black) oonnector at the wire side and ground. Connection: 027 - Ground TOOL: Test probe 07ZAJ-RDJA110 Is there contlnulty? YES — Short circuit in the Pink/green wire NO — GO TO STEP 4. 4. Rear Wheel Speed Sensor Line Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 26F connector [1] (page 18-5). Check for continuity at the Pink/green wire between the ABS modulator 26F connector and ECM 33F (Black) connector [2]. Connection: (:21 - Pink/green TOOL: 'Iest probe 07ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one. and recheck. N0 - Open circuit in Pink/green wire DTC 12-1 (No.1 INJECTOR) ~ Before starting the inspection. check for loose or poor contact on the injedor 2P (Gray) connectors " and ECM 33F connectors. then recheck the DTC, DTC IN- POWERINPUT SIGNAL SIGNAL JEC- LINE LINE AT ECM TOR 12—1 No.1 Black/white Red/yellow DB 13—1 No.2 Black/white Red/blue D7 14-1 No.3 Black/white Red/green D6 15-1 NOA Blacklwhite Red/black D5 1. Injector System Inspection Clear the DTC's (page 6—12). Start the engine and check the injector with the H05 Is the DTC 12-1 lndlcated? YES — GO TO STEP 2. NO — Intermittent Iailure [1] [2] Pink/green 9 C27 6-24 2. Injector Input Voltage Inspection Turn the ignition switch OFF. Disconnect the injector 2P (Gray) connector. Turn the ignition switch ON and engine stop switch .Qr Measure the voltage between the injector 2P (Gray) connector [1] of the wire side and ground. Connection: Blacklwhite (+) — Ground (—) Is there battery voltage? YES — GO TO STEP 3. NO - Open circuit in Black/white wire 3. Injector Resistance Inspection Turn the ignition switch OFF. Disconnect the injector 2P (Gray) connector, Measure the resistance oi the injector terminals. Is the resistance withln 11.6 — 12.4 D (20°C/ 68°F)? YES — GO TO STEP 4. N0 — Faulty injector 4. Injector Signal Line Open circuit lnspectlon Disconnect the ECM 33F (Gray) connector [1]. Check the continuity between ECM 33F (Grey) connector [1] and injector 2P (Gray) connector [2]. Connectlon: SIGNAL LINE - SIGNAL AT ECM TOOL: T93! probe 072AJ-RDJA11D Is there confinulty? YES — GO TO STEP 5. NO — Open circuit in SIGNAL LINE wire FUEL SYSTEM (PGM-Fl) [1] F < I I Black/white Red/yellow 08 D7 [2] Red/blue Red/black Red/green 6-25 FUEL SYSTEM (PGM-Fl) 5. Injector Signal Line Short Circuit Inspection Check for continuity between the injector 2P (Gray) connector [1] of the wire harness side and ground. Connection: SIGNAL LINE — Ground Is there continuity? YES - ' Short circuit in SIGNAL LINE wire ' Faulty injector NO — Replaoe the ECM with a known good one. and recheck. DTC 13-1 (No.2 INJECTOR) (page 6>24) DTC 14-1 (No.3 INJECTOR) (page 6~24) DTC 15-1 (No.4 INJECTOR) (page 6-24) DTC 18-1 (CMP SENSOR) Before starting the inspection. check for loose or poor contact on the 0MP sensor 3P (Black) connector and ECM 33F connectors, then recheck the DTC. . 0MP Sensor System Inspection 1 Clean the DTC’s (page 642). Crank the engine for ten seconds or more. Is DTC 18-1 indicated? YES —- GO TO STEP 2, , ,NO - Intermittent failure . CMP Sensor System Inspection 2 Turn the ignition switch OFF. Disconnect the CMP sensor 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch .. Q Measure the voltage at the wire harness side. Connection: Gray (+) — Ground (—) Is the voltage within 4. 75 - 5.25V? YES — GO TO STEP 3. N0 — GO TO STEP 4. [1] No.1: Red/yellow No.2: Red/blue No.3: Red/green No.4: Red/black [1] 6-26 FUEL SYSTEM (PGM-FI) 3. CMP Sensor Input Voitage Inspection Measure the voltage at the CMP sensor 3P (Black) connector [1] wire sidei Connection: Yellowlred (+) - Gray/white (—) Is the Voltage wlthln 4, 75 — 5.25V? YES — Faulty CMP sensor N0 - - Open circuit in Yellow/red wire - Open circuit in Gray/white wire 4. CMP Sensor Signal Line Open Circuit inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Check the continuity at the Gray wire between the CMP sensor 3? (Black) connector [2] and ECM 33F (Black) connector. Connection: C18 - Gray TOOL: Test probe O7ZAJ-RDJA1 1 0 Is there continuity? YES — Replace the ECM with a known good one. and recheck. NO — Open circuit in Gray wire DTC 19-1 (CKP SENSOR) - Before starting the inspection. check for loose or poor contact on the CKP sensor 2P (Black) connector and ECM 33F connectors. then recheck the DTC. 1. CKP sensor Peak Voltage Inspection Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Black) connector [1]. Turn the ignition switch ON and engine stop switch .. Q ._ Crank the engine with the starter motor, and measure the CKP sensor peak voltage at the CKP sensor 2P (Black) connector. Connection: Yellow 1+) — White/yellow (—) TOOL: [2] ignitionMate peak voltage MTP07-0286 tester (U.s.A. only) or Peak voltage adaptor o7HGJ—0020100 (Not available In U.S.A.) with commercially available digital multimeter (impedance 10 MDIDCV minimum) or peak volt- age tester Is the volmge more than 0‘7 V (20“6/68"F)? YES - GO TO STEP 2. NO - Faulty CKP sensor [1] Gray/white Yellow/red [1] C18 Gray [2] White/yellow l—I / l: \ :l \ Veilow 9 ® 6-27 FUEL SYSTEM (PGM-FI) 2. CKP sensor Circuit Inspection Turn the Ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Check for continuity at the Yellow and White/yellow wire between the CKP sensor 2P (Black) connector [2] and ECM 33F (Black) connectors Connection: C7 - Yellow C28 - White/yellow ‘roou Test probe 07ZAJ-RDJA110 Is there contlnulty? YES — Short circuit in Yellow wire NO - ~ Open circuit in Yellow wire ' Open circuit in White/yellow wire DTC 21-1 (No.1l4 Oz SENSOR) ~ Belore starting the inspection, check for loose or poor contact on the 02 sensor 4P (Blue) connector and ECM 33F connectors, then recheck the DTC. . 0: Sensor System Inspection Warm the engine until the coolant temperature is "80°C (176°F). Check the 02 sensor with the HDS‘ Standard: 0.1 V - 0.3 V Is the voltage as speclfleifi YES — ‘ Check the fuel pressure (page 6—62)‘ ' If the system is coma-01. GO TO STEP 4‘ N0 - GO TO STEP 2. m C7 Yellow C28 [1] [2] / $2 White/yellow 6-28 . Oz Sensor Open Clrcult Inspection Turn the ignition switch OFF. Disconnect the 02 sensor 4P (Blue) connector [1], ECM 33F (Blue) connector [2] and ECM 33F (Gray) connector [3]. Check the continuity between the 02 sensor 4P (Blue) connector and ECM 33F (Blue), ECM 33F (Gray) connectors. Connection: A20 — Blacklred D26 - Gray/white room Test probe 072AJ-RDJA110 Is there continuity? YES — GO TO STEP 3. N0 — ~ Open circuit in Black/red wire - Open circuit in Grey/white wire . 02 Sensor System short Circuit Inspection Connect the 02 sensor 4P (Blue) connector and disconnect the ECM 33F connectors. Check the continuity between the ECM 33F (Blue) connector [1] and ground. Connection: A20 - Ground TOOL: Test probe 07ZAJ-RDJA110 Is there contlnulty? YES — Short circuit in Black/red wire NO —- GO TO STEP 4. . Oz Sensor Inspection Replace the 02 sensor with a known good one (page 6—89). Clean the DTC's (page 6—12). Turn the ignition switch ON and engine stop switch .. Q .' Warm the,engine until the coolant temperature is 80”C(176°F). Check the 02 sensor with the HDS. Is DTC 21-1 Indicated? NO YES — Faulty original 02 sensor - Replace the ECM with a known good one. and recheck. FUEL SYSTEM (PGM-Fl) A20 l2] / Black/red oze 1 [3] l ] Gray/white / [1] A20 (Black/red) 6-29 FUEL SYSTEM (PGM-Fl) DTC 22-1 (No.2l3 02 SENSOR) - Before starting the inspecu‘on. check for loose or poor contact on the 0: sensor 4P (Black) connector and ECM 33P connectors. then recheck the DTC. 1. 02 Sensor System Inspection Warm the engine until the coolant temperature is 80°C (176°F). Check the 02 sensor with the HDS‘ Standard: 0.1 V — 0.3 V Is the volhge as specified? YES - ' Check the fuel pressure (page 6452). - lithe system is correct, GO TO STEP 4. N0 — GO TO STEP 2. 2. O2 Sensor Open Circuit Inspection Turn the ignition switch OFF. Disconnect the 02 sensor 4P (Black) connector [1] and ECM 33P (Blue) connector [2] and ECM 33F (Gray) connector [3]. Check the continuity between the 0: sensor 4P (Black) connector and ECM 33p (Blue), ECM 33F (Gray) connectors. Connection: A21 - Blacklblue D26 - Gray/white TOOL: Test probe 01ZAJ-RDJA110 Is there contlnuity? YES — GO TO STEP 3‘ N0 - o Open drcuit in Black/blue wire ~ Open circuit in Gray/white wire 3. 0: Sensor System Short Circuit Inspection Connect the 02 sensor 4P (Black) connector. Check the continuity between the ECM 33F (Blue) connector [1] terminal and ground‘ Connection: A21 — Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — Short circuit in Black/blue wire NO — GO TO STEP 4. A21 [2) Black/blue [1] D26 [3] Gray/white [1] A21 (Black/blue) 6-30 FUEL SYSTEM (PGM-Fl) A. 02 Sensor Inspection Replace the 0: sensor with a known good one (page 6—89). Clean the DTC's (page 6-12). Warm the engine until the coolant temperature is 80°C (176°F). Check the 02 sensor with the HDS. ls DTC 22-1 indicated? NO - Faulty original 02 sensor YES — Replace the ECM with a known good one, and recheck. DTC 23-1 (No.1l4 02 SENSOR HEATER) - Before starting the inspection. check for loose or poor contact on the 02 sensor (Blue) connector and ECM 33F connectors, then recheck the DTC. 1. 0: Sensor System Inspection Clean the DTC’s (page 6-12). Start the engine and check the 02 sensor heater with the HDS. Is the DTC 23-1 indicated? YES — GO TO STEP 2‘ NO — Intermittent failure 2. Oz Sensor Healer Resistance Inspection Turn the ignition switch OFF. [1] Disconnect the 02 sensor 4P (Blue) connector [1] and measure the resistance at the sensor side COMBO“- White H White Connection: White - White (Sensor side terminals) Is the resistance within 10 - 40 .0 (20°C/68°F)? VES — GO TO STEP 3. NO - Faulty 02 sensor 3. 02 Sensor Heater Input Voltage Inspection Turn the ignition switch 0N and engine stop switch [1] .. Q Measure the voltage between the 02 sensor 4P (Blue) connector [1] at the wire side and ground. Connection: Black/white - Ground ® Is there the battery voltage? YES — Go TO STEP 4. NO — Open circuit in Black/white wire Black/white 6-31 FUEL SYSTEM (PGM-Fl) 4. 0: Sensor Heater Open circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector [1]. Check the continuity between the ECM 33F (Black) connector and 0: sensor 4P (Blue) connector [2]. Connection: C3 - Ground TOOL: Yes! probe 07ZAJ-RDJA110 Is there continuity? YES - Open circuit in White wire N0 — GO TO STEP 5. 5. Oz Sensor Heater Short Circuit inspection Check for continuity between the 02 sensor 4P (Blue) connector [1] and ground. Connection: White — Ground Is there continuity? YES — Short circuit in White wire N0 - Replace the ECM with a known good one. and recheck [1] _ _ H =‘ White Connection: White — White (Sensor side terminals) Is Hie resistance within 10 — 40 {I (MW/68°F)? YES - GO TO STEP 3. N0 - Faulty Oz sensor White DTC 24-1 (No.2l3 02 SENSOR HEATER) - Before starting the inspection. check for loose or poor contact on the 0: sensor 4P (Black) connector and ECM 33F connectors. then recheck the DTC. 1. _ Qz Sensor System Inspection Clear the DTC's (page 6-12) Start the engine and check the 02 sensor heater with the H08, Is the DTC 24-1 indicated? YES - GO TO STEP 2. NO — Intermittent failure 2. 0: Sensor Heater Resistance Inspection Turn the ignition switch OFF. [1] Disconnect the 02 sensor 4P (Black) connector [1] and measure the resistance at the sensor side connector. White 6-32 FUEL SYSTEM (PGM-Fl) 3. Oz Sensor Heater Input Voltage Inspection Turn the ignition switch ON and engine stop switch [1] . Q Measure the voltage between 02 sensor 4P (Black) (9 connector [1] at the wire side and ground. Connection: Black/white - Ground Is there the battery voltage? YES — GO TO STEP 4‘ I No — Open circuit in Black/white wire 9? Blacwwh'le 9: 4. 0: Sensor Heater Open circuit Inspection Tum the ignition switch OFF. [1] 04 Disconnect the ECM 33F (Black) connector [1]. Check the continuity between the ECM 33P (Black) connector and 02 sensor 4P (Black) connector [2]. Connection: (:4 - Ground TOOL: Test probe 07ZAJ-RDJA11D Is there continuity? YES — Open circuit in While/red wire NO — GO TO STEP 5. White/red [2] 5. 02 Sensor Heater short Circuit Inspection Check for continuity between the 0: sensor 4P 1] (Black) connector [1] and ground. [ Connection: White/red — Ground Is there contlnulty? YES — Short circuit in White/red wire NO — Replace the ECM with a known good one, and recheck. gs? White/red 6-33 FUEL SYSTEM (PGM-FI) orc 25-1 (KNOCK SENSOR N0 INPUT VOLTAGE) - Before staning the inspection, check for loose or poor Contact an the knock sensor 3P (Black) connector and ECM 33F connectors, then recheck the DTC. 1t Knock Sensor System Inspection Clean the DTC’s (page 6-12). Place the motorcycle on its sidestand. Start the engine and recheck the knock sensor with the H05. Is DTC 25-1 lndlcated? YES — GO TO STEP 2. NO - Intermittent tailure Z. Knock Sensor Input Voltage Inspection Turn the ignition switch OFF‘ Disconnect the knock sensor 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch n 0 ._ Measure the voltage at the wire side. Connection: Yellow/red (4-) — Ground (-) Is the voltage within 4. 75 — 5.25 V? YES —- GO TO STEP 4. N0 — GO TO STEP 3. 3. Knock Sensor Input Line Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Gray) connector [1], Check for continuity at the Yellow/red wire between the knock sensor 3P (Black) connector [2] and ECM ,_33P (Gray) connector‘ Connection: 028 - Yellow/red TOOL: 1th probe 07ZAJ-RDJA1 10 Is there contlnulty? YES - Replace the ECM with a known good one, and recheck. N0 — Open circuit in Yellow/red wire l1] Yellow/red [z] D28 6-34 FUEL SYSTEM (PGM-Fl) 4. Open clrcuit Detection Line Inspection Turn the ignition switch OFF, m Disconnect the ECM 33F (Black) connector [1]. Check the continuity between the knock sensor 3P (Black) connector [2] and the ECM 33p (Black) connector: Connection: 630 — Gray Gray TOOL: Yest probe 07ZM-RDJA110 Is there continulty? YES - GO TO STEP 5‘ N0 - Open circuit in Gray wire C30 5. Knock Sensor Inspection Check for continuity at the knock sensor 3P (Black) connector [1] terminals. [1) yellow/red Gray Connection: Yellowlred — Gray (Sensor side terminals) 1141. Is there continuity? u YES — Replace the ECM with a known good one, and recheck. N0 — Faulty knock sensor DTC 25-2 KNOCK SENSOR LOW VOLTAGE - Before starting the inspection. check for loose or poor contact on the knock sensor 3P (Black) connector and ECM 33P connectors, then recheck the DTCr 1. Knock Sensor System Inspection Clean the DTC’s (page 6-12). Place the motorcycle on its sidestand. Start the engine and recheck the knock sensor with the HDS. Is the DTc 25-2 indicated? YES - GO TO STEP 2‘ N0 — Intermittent iailure 6-35 FUEL SYSTEM (PGM-Fl) 2. Knock Sensor Output Line Short Clrcult Inspection1 Turn the ignition switch OFF. Disconnect the knock sensor 3P (Black) connector [1]. Check for continuity at the Blue wire between the knock sensor 3P (Black) connector [1] at the wire wire side and ground. Connection: Blue - Ground Is there continuity? YES — Short circuit in blue wire NO - GO TO STEP 3. 3. Knock Sensor Output Line Shon Circuit Inspectionz Check for continuity between the knock sensor 3P (Black) connector [1] of the sensor side and ground. Connection: Blue — Ground (Sensor side termlnals) Is there continuity? YES - Faulty knock sensor N0 — Replace the ECM with a known good one, and recheck DTC 34-1 (ECV POT LOW VOLTAGE) - Beiore starting the inspection, check for loose or poor contact on the EGCA 6P (Black) connector and ~ ECM 33F connectors. then recheck the DTC 1. ECV POT System Inspection Turn the ignition switch ON and engine stop switch " Q .4 Check the ECV POT with the HDS provided ECV closed. Is the indicated voltage with/n 0.6 — 2.2 V? YES — Intermittent failure N0 - GO TO STEP 2. [1) Blue 1] Blue 6-36 FUEL SYSTEM (PGM-FI) 2. ECV POT Input Voltage Inspection Turn the ignition switch OFF‘ Disconnect the EGCA 6P (Black) connector [1], [1] Turn the ignition switch 0N and engine stop switch /\ J3 .0". Measure the voltage at the wire harness side. Connection: Yellow/red (+) — Graylwhite (—) P)!\ Is the voltage within 4.75 - 5.25 V? yellow/red e Gray/while YES - GO TO STEP 4‘ NO — GO TO STEP 3. 3t ECV POT Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Gray) connector [1]. [1] Yellow/red Check the continuity between the EGCA 6P (Black) connector [2] and ECM 33F (Gray) connector. Connection: DZB —YelIowlred TOOL: Test probe OTZAJ-RDJA110 Is there confinulty? YES - Replace the ECM with a known good one, and recheck. NO - Open circuit in Yellow/red wire 028 4‘ ECV POT Output Line Open Circuit Inspection Turn the ignition switch OFF. ‘ Disconnect the ECM 33? (Black) connector [1]. [1] LIE?“ green/Maw Check for continuity at the Light green/black wire between the EGCA 6P (Black) connector [2] and ECM 33F (Black) connector. Connection: C26 - Light green/black [2] TOOL: Test probe OTZAJ-RDJA1 10 Is there continuity? YES - GO TO STEP 5. N0 — Open circuit in Light green/black wire 5. ECV POT Output Llne Short Circuit Inspection Check for continuity between the EGCA 6P (Black) _ connector [1] at the wire side and ground [11 nght green/black Connection: Light greenlblack - Ground /fi/ Is there oontinuliy? A, YES - short drcuit in Light green/black wire I I N0 — GO TO STEP 6‘ 3‘) 6-37 FUEL SYSTEM (PGM-Fl) 6. ECV POY Inspection Replace the EGCA with a known good one. Clean the DTC‘s (page 642). Turn the ignition switch 0N and engine stop switch , Q Check the Ecv POT with the HDS. Is the DTC 34-1 indicated? YES - Replace the ECM with a known good one. and recheck. NO — Faulty original EGCA DTC 34-2 (ECV POT HIGH VOLTAGE) - Before starting the inspection, check tor loose or poor contact on the EGCA 6P (Black) connector and ECM 33F connectors, then recheck the DTC. 1. ECV POT System Inspection Turn the ignition switch ON and engine stop switch .. n -' Check the ECV POT with the HDS. ls about 5V indicated? YES — GO TO STEP 2. N0 — tntenniltent tailure 2. ECV P01 Resistance Inspection Turn the ignition switch OFF. Disconnect the EGCA 6P (Black) connector [1]. Measure the voltage at the ECV POT side. Connection: Yellow/red - Graylwhite (EGCA side terminals) Is the resistance within 3.5 - 6.5 kD (20"6/68'5? YES - GO TO STEP 3. if no - Faulty EGCA 3. ECV POT Input Voltage Inspection Turn the ignition switch ON and engine stop switch . Q Measure the voltage at the EGCA 6P (Black) connector [1] wire side. Connection: Yellowlred (+) - Grayiwhite (—) Is the Voltage within 4.75 — 5.25 V? YES - Replace the ECM with a known good one, and recheck, NO - Open circuit in Gray/white wire [1]\r/ L4 rxJ G'ay/Whi'e Yellow/red [1] i Yellow/red (*3 @ Gray/white 6-38 DTC 35-1 (EGCA LOCK) ' Before starting the inspection, check for loose or poor contact on the EGCA 6P (Black) connector and ECM 33P connectors, then recheck the DTC, 1. EGCA Operating inspection Disconnect the EGCA cable from the EGCA pulley (page 6-90). Turn the ignition switch ON and engine stop switch .. Q .I check the EGCA pulley rotation when shorting the DLC with the SOS connector. Does the EGCA pulley operate correctly? YES - - Check the EGCA cable binding, sticking or lock. ~ Check the ECV at muffler side, NO — GO TO STEP 2. 2. EGCA inspection Turn the ignition switch OFF. Remove the EGCA (page 680). Connect a 12V battery to the EGCA 6P (Black) connector [1] terminals and check the servomotor function. Connection: Red (+) - Blue (-) (EGCA side terminals) Does the EGCA operate normally? YES - GO TO STEP 3. N0 - Faulty EGCA 3. ECM Output Line Inspection Disconnect the ECM 33F (Gray) connector [1]. Check (or continuity at the Red and Blue wires between the EGCA 6P (Black) connector [2] and ECM 33F (Gray) connector. Connection: Red- DA Blue - D9 TOOL: Test probe 07w-RDJA11O Is there continuity? YES — Replace the ECM with a known good one, and recheck. - Open circuit in Blue wire Blue m \r FUEL SYSTEM (PGM-FI) i BATTERY Red 6-39 FUEL SYSTEM (PGM-Fl) DTC 41-1 (GEAR POSITION SENSOR) O Before starting the inspection, check Ior loose or poor contact on the gear position sensor 8P (Black) connector and ECM 33P connectors, then recheck the DTC, 1. Gear Position Sensor System Inspection Clear the DTC’s (page 6-12), Turn the ignition switch ON and engine stop switch . Q .' Is the DTC 41-1 indicated? YES — GO TO STEP 2. N0 - Interrnittentfailure 2. Gear Position Sensor Inspection 1 Disconnect the ECM 33F (Gray) connector [1]. Check for continuity between each terminal of the wire side connector and ground, when shifting the transmission into the gear, There should be continuity in each gear position as follows: Neutral: D31 - Ground 1st: Dis-Ground 2nd: 030 - Ground 3rd: 020 - Ground 4th: D21 — Ground 5th: D22 — Ground 6th: D29 - Ground TOOL: Test probe D7ZAJ-RDJA110 Is there continuity? YES — Replace the ECM with a known good one. and recheck. NO — Check the gear position sensor (page 22-21). DTC 56-1 (KNOCK SENSOR IC) 1. Knock Sensor System Inspection Clean the DTC's (page 642). Place the motorcycle on its sidestandr Stan the engine and recheck the knock sensor with the HDS. Is the DTC 56-1 Indicated? YES — Replace the ECM with a known good one. and recheck, N0 - Intermittent failure D22 030 D19 D29 I1] 6-40 FUEL SYSTEM (PGM-FI) DTC 71-1 (TP SENSOR 1 LOW VOLTAGE) ' Belore starting the inspection, check for loose or poor contact on the TBW 6P (Black) connector and ECM 33P connectors, then recheck the DTC, 1. YP Sensor1 System Inspection Turn the ignition switch 0N and engine stop switch .. a n} Check the TP sensor with the HDS when the throttle is fully closed. Is about 0.096 V or below indicated? YES — GO TO STEP 2. NO - - lnterrnittent failure - Loose or poor contact on the TBW 6P (Black) connector 2. TP Sensor 1 Input Voltage Inspection Tum the ignition switch OFF. Disconnect the TBW 6P (Black) connector [1]. [1] Turn the ignition switch ON and engine stop switch Light green Yellow "On- Measure the voltage at the wire side. Connection: Yellow H) — Light green (—) Is the voltage within 4. 75 — 5.25V? YES — GO TO STEP 4, NO — GO TO STEP 3. 6 3. TP Sensor1 Input Line Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Gray) connector [1]. Check for continuity at the Yellow wire between the TBW 6P (Black) connector [2] and ECM 33P (Grey) oonnector. Connection: D27 — Yellow TOOL: Test probe 07ZAJ-RDJA110 Is there continulty? [1] [2] Yellow YES - Replace the ECM with a known good one, and recheck. D27 NO - Open circuit in Yellow wire 6-41 FUEL SYSTEM (PGM-FI) TP sensor 1 cannot be replaced. lithe TP sensor 1 is faulty, replace the throttle body. 4. TP Sensor 1 Output Line Short Circuit Inspection Check for continuity between the TBW 6P (Black) connector [1] at the wire side and ground. [1] Connection: Bluelblack — Ground Is there continuity? YES — Short circuit in Blue/black wire N0 - GO TO STEP 5. Blue/black é" 5. TP Sensor1 Inspection Replace the throttle body (page 6-71). Clear the DTC‘s (page 6-12). Turn the ignition switch ON and engine stop switch .. Q Check the TP sensor 1 with the HD& Is DTC 71-1 indicated? YES - Replace the ECM with a known good one. and recheck. NO — Faulty original throttle body DTC 71 -2 (TP SENSOR 1 HIGH VOLTAGE) ‘ Before starting the inspection, check for loose or poor contact on the TBW 6P (Black) connector and ECM 33F connectors. than recheck the DTC. 1. TP Sensor1 System Inspection Turn the ignition switch ON and engine stop switch 7 -. Q .' Check the TP sensor with the HDS. Is about 4.762 V or above indicated? YES — GO TO STEP 2. NO — - Intennittentiailure - Loose or poor contact on the TBW connector 2. TP Sensor 1 Line inspection Turn the ignition switch OFFr Disconnect the ECM 33F (Black) connector [111 “1 Check for continuity at the Blue/black wire between the TBW 6P (Black) connector [2] and ECM 33F (Black) connector. Connection: 013 — Blualblack TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 3. NO — Open circuit in Blue/black C13 [2] Blue/black 6-42 TP sensor 1 cannot be replaced. If the TP sensor 1 is faulty, replace the throttle body. 3. TBW Ground Llno inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Gray) connector [1], Check for continuity at the Light green wire between the TBW 6P (Black) connector [2] and ECM 33F (Grey) connector. Connection: 025 - Light green TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. NO — Open circuit in Light green wire 4. TP Sensor Inspection Replace the throttle body (page 6-71). Clean the DTC's (page 6—12). Turn the ignitlon switch ON and engine stop switch . Q ._ check the TP sensor 1 with the HDS. Is DTC 71-2 indicated? YES — Replace the ECM with a known good one, and recheck. NO — Faulty original throttle body DTC 72-1 (TP SENSOR 2 LOW VOLTAGE) - Before starting the inspection, check for loose or poor contact on the TBW 6P (Black) connector and ECM 33F connectors, then recheck the DTC. 1. TP Sensor 2 system Inspection Turn the ignition switch 0N and engine stop switch .. Q Check the TP sensor with the H05 when the throttle is fully closed, ls about 0.063 V or below lndlcated? YES - GO TO STEP 2. N0 - - Intermittentfailure - Loose or poor contact on the TBW connector 2. TP Sensor 2 Input Voltage Inspection Turn the ignition switch OFF. Disconnect the TBW 6P (Black) connector [1]. Turn the ignition switch ON and engine stop switch Mgsine the voltage at the wire harness side. Connection: Yellow (fl — Light green (—) Is the voltage wlthln 4.75 - 5.25V? YES — GO TO STEP 4. N0 — GO TO STEP 3. FUEL SYSTEM (PGM-FI) [1] 025 [2} Light green [1] Light green Vellcw h fl 9 (9 6-43 FUEL SYSTEM (PGM-Fl) TP sensor 2 cannot be replaced. If the TP sensor 2 Is faully, replace the throttle body, 3. TP Sensor 2 Input Llne Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Gray) oonnector [1]. Check for continuity at the Yellow wire between the TBW 6P (Black) connector [2] and ECM 33F (Gray) connector. Connection: 027 - Yellow TDOL: Test probe OTZAJRDJM 10 Is there continuity? YES — Replace the ECM with a known good one. and recheck. NO — Open circuit in Yellow wire .TP Sensor 2 Output Llne short Circuit Inspection Check for continuity between the TBW 6P (Black) connector [1] at the wire side and ground Connection: Blualwhite - Ground Is there continuity? YEs — Short circuit in Blue/white wire N0 - GO TO STEP 5. TP Sensor Inspection Replace the throttle body (page 6J1). Clear the DTC's (page 6-12). Turn the ignition switch ON and engine stop switch .On‘ ‘ Check the TP sensor 2 with the HDS‘ Is DTC 72-1 indicated? YES — Replace the ECM with a known good one, and recheck NO — Faulty original throttle body DTC 72-2 (TP SENSOR 2 HIGH VOLTAGE) Before starting the inspection, check tor loose or poor contact on the TBW 6P (Black) connector and ECM 33F connectors, then recheck the DTC . TP Sensor 2 System Inspection 1 Turn the ignition switch 0N and engine stop switch u. a ._ Check the TP sensor with the HDS. Is about L761 V or above indicated? YES - GO TO STEP 2. NO — ~ Intennittenttailure - Loose or poor contact on the TBW connector i1! [2] Yellow D27 i1] \ Blue/white % 6-44 FUEL SYSTEM (PGM-Fl) 2. TP Sensor 2 Line Inspection 2 Turn the ignition switch OFF. . Disconnect the ECM 33F (Black) connector [1]. l1] Blue/white Check for continuity at the Blue/white wire between the TBW 6P (Black) connector [2] and ECM 33F (Black) connector, Connection: C24 - Blue/white TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES - GO TO STEP 3. NO — Open circuit in Blue/white 024 3. TBW Ground Line Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Gray) connector [1]t Check for continuity at the Light green wire between the TBW sensor 6P (Black) connector [2] and ECM 33F (Gray) connector. Connection: D25 — Light green [1] D25 Light green TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES - GO TO STEP 4. NO — Open circuit in Light green wire [2] 4. TP Sensor Inspection TP sensor 2 Replace the throttIe body (page 6-71). cannot be Clean the DTC's (page 6-12). replaced, II the Turn the ignition switch ON and engine stop switch TP sensor 2 is ,, O I, Why, replace - I Ihe "7mm Check the TP sensor 2 With the HDS. body. Is the DTC 72-2 indicated? YES — Replace the ECM with a known good one, and recheck. N0 - Faulty original throttle body DTC 73-1 (TP SENSOR 1—2 VOLTAGE CORRELATION FAILURE) ‘ Before starting the inspection, check ior loose or poor contact on the TBW 6P (Black) connector and ECM 33F connectors. then recheck the DTC. 1. TP Sensor 1-2 System Inspection Clearthe DTC‘s (page 6-12). Tum the ignition switch ON and engine stop switch ,. Q .. Check the TP sensor with the HDS. Is the DTC 73-1 indicated? YES - GO TO STEP 2. NO — Intermittent failure 6-45 FUEL SYSTEM (PGM-Fl) 2. Throttle Valve Operation Inspection Turn the ignition switch OFF. Remove the air cleaner housing (page 6-68). Turn the ignition switch 0N and engine stop switch "0.. Visually check the throttie valve, Does the valve fully close posltlon? YES — GO TO STEP 4. N0 — GO TO STEP 3. 3. TP sensor 1 and TP sensor 2 Short circuit lnspeotionz Disconnect the TBW 6P (Black) connector. Check for continuity between the ECM 33F (Black) connector terminal C13 and 024. Connection: 013 - C24 C13 (Blue/black) TOOL: Test probe 07ZAJ-RDJA11D Is there continuity? YES - - Short circuit in Blue/black wire - Short circuit in Blue/white wire NO — GO TO STEP 4. 024 (Blue/white) 4. IF Sensor Inspection TP sensors Replace the throttle body (page 6—71). cannot be Clear the DTO'S (page 6-12). replaced. Inns Turn the ignition switch 0N and engine stop switch TP sensors are .. Q .. fau’fy' replace Check the TP sensor with the HDS. the throttle body. Is the DTC 73-1 indicated? YES - Replace the ECM with a known good one. and recheck. ” NO — Faulty original throttle body DTC 73-2 (TP SENSOR 1—2 SHORT CIRCUIT) Perform the troubleshooting according to the DTC 73—1 (page 6—45). 6-46 FUEL SYSTEM (PGM-Fl) DTC 74-1 (TCP SENSOR 1 LOW VOLTAGE) - Before stoning the inspection, check for loose or poor contact on the TCP sensor 6P (Black) connector and ECM 33F connectors. then recheck the DTC. 1. TOP Sensor 1 System Inspection Turn the ignition switch ON and engine stop switch . Q Check the TCP sensor 1 with the HDS when the throttle is fully closed. Is about 0.137 V or below indicated? YES — GO TO STEP 2. NO - - lnterrnittentfeilure - Loose or poor oontact on the TCP sensor 6P (Black) connector 2. V00 1 Input Voltage inspection Turn the ignition switch OFFr Disconnect the TCP sensor 6P (Black) [11 connector [1}. \ Turn the ignition switch ON and engine stop switch ‘ L Measure the voltage at the wire side. Connection: Yellowlred (+) - Green/black (—) TOOL: Green/black Yellow/red Test probe o7ZAJ-RDJA110 6 ® Is the voltage wlthln 4. 75 — 5.25V? YES - GO TO STEP 3. NO ~ GO TO STEP 5. 3. TCP Sensor 1 Output Line Short circuit lnspecu‘on Check for continuity between the TCP sensor 6P ‘ (Black) connector [1] at the wire side and ground. [‘1 Whlte/black Connection: White/black — Ground \ TOOL: 1 I Test probe O‘IZAJ-RDJA110 A I l L Is there continuity? YES — Short circuit in White/black wire N0 — GO TO STEP 4. 6-47 FUEL SYSTEM (PGM-FI) 4. TCP Sensor 1 Output Line Open Circuit lnspectlon Check for continuity at the White/black wire between the TCP sensor 6P (Black) [1] connector and ECM 33P (Black) connector [2]. Connection: CM — Whitelblack TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 6. NO — Open circuit in White/black wire 5. VCC 1 Line Open Circult Inspection Check for continuity at the Yellow/red wire between the TCP sensor 6P (Black) connector [1] and ECM 33P (Gray) connector [2]. Connection: D16 — Yellow/red TOOL: Test probe o7ZAJ-RDJA110 Is there continuity? YES - GO TO STEP 6. NO - Open circuit in Yellow/red wire 6. TOP Sensor lnspectlon Replace the TCP sensor (page 6-75). Clear the DTC's (page 6-12). Turn the ignition switch ON and engine stop switch .. Q .._ * Check the TCP sensor with the HDS. Is the DTC 74-1 ind':ated? YES - Replace the ECM with a known good one. and recheck NO — Faulty original TCP sensor DTC 74-2 (TCP SENSOR 1 HIGH VOLTAGE) ‘ Bebre starting the inspection. check for loose or poor contact on the TCP sensor 6P (Black) connector and ECM 33F connectors, then recheck the DTC. 1. TOP $ensor1 System Inspection Turn the ignition switch ON and engine stop switch .. Q ._ Check the TCP sensor 1 with the HDS when the throttle is fully closed Is about 4.902 V or above indicated? YES — GO TO STEP 2. NO - - Intermittentfailure - Loose or poor contact on the TCP sensor 6P (Black) connector I2] White/black [1] C14 [2] Yellow/red [1] D16 6-48 FUEL SYSTEM (PGM-FI) 2. Vet: 1 Input Voltage Inspection Turn the ignition switch OFF, [11 Disconnect the TCP sensor 6P (Black) Green/“30k “I'M/'9“ connector [1]. Turn the ignition switch ON and engine stop switch .. Q 1 Measure the voltage at the wire side. Connection: Yellowlred (+) - Green/black (-) Li— TOOL: Test probe 072AJ-RDJA110 e 6) Is the voltage within 4.75— 5.25V? YES - GO TO STEP 4. N0 — GO TO STEP 3. 3. V00 1 Line Open Circuit Inspection Check for conflnuity at the Yellow/red and Green! black wire between the TCP sensor 6P (Black) D15 connector [1] and ECM 33F (Gray) connector [2]. Connection: D16 — Yellow/red D14 — Greenlblack Yellow/red TOOL: Test probe 07ZM-RDJA1 10 Is there continuity? YES — GO TO STEP 4, N0 - . Open circuit in Yellow/red wire [2] D14 . Open circuit in Green/black wire [1] Green/black 4. TOP Sensor Inspection Replace the TCP sensor (page 6—75) Clear the DTC's (page 6-12). Tum the ignition switch ON and engine stop switch .. Q Check the TCP sensor with the HDS. Is the DTC 74-2 Indicated? YES - Replace the ECM with a known good one, and recheck NO - Faulty original TCP sensor DTC 75-1 (TCP SENSOR 2 LOW VOLTAGE) ~ Before starting the inspection, check for loose or poor contact on the TCP sensor 6P (Black) connector and ECM 33P connectors. then recheck the DTC. 1. TOP Sensor 2 System Inspection Turn the ignition switch ON and engine stop switch .. Q .1 Check the TCP sensor 2 with the HDS when the throttle is fully closed. Is about 0.137 V or below indlcated? YES — GO TO STEP 2. N0 — ' Intermittentfailure ' Loose or poor contact on the TOP sensor 6P (Black) connector 6-49 FUEL SYSTEM (PGM-Fl) 2. V66 2 input Voltage Inspection Turn the ignition switch OFFt Disconnect the TCP sensor 6P (Black) connector [1]. Turn the ignition switch 0N and engine stop switch .. Q u} Measure the voltage at the wire side. Connection: Yoliowlred (+) — Gray (-) TOOL: Test probe 01ZAJ-RDJA110 Is the Voltage within 4. 75 - 5.25V7 YES — GO TO STEP 3. NO — GO TO STEP 5. 3. TOP Sensor 2 Output Line short circuit Inspection Check for continuity between the TCP sensor 6P (Black) connector [1] at the wire side and ground. Connection: White/blue — Ground TOOL: Test probe 072AJ-RDJA110 Is there continuity? YES - Short circuit in White/blue wire NO - GO TO STEP 4. 4. TOP Sensor 2 Output Line Open Circuit inspection Check ior continuity at the White/blue wire between the TCP sensor 6P (Black) connector [1] and ECM 7 3_3P (Black) connector [2]. Connection: 025 — Whitelbiue TOOL: Test probe 072AJ-RDJA110 Is there cant/nulty? YES - GO TO STEP 6‘ N0 — Open circuit in White/blue wire I1] \ Gray Yellow/red \ X' J l i E 9 G) [1] \ 1| 4 ‘4 L White/blue [2] White/blue C25 6-50 FUEL SYSTEM (PGM-Fl) 5. VCC 2 Line Open Circuit Inspection Check for continuity at the Yellow/red wire between the TCP sensor 6P (Black) connector [1] and ECM [2] [1] Yellow/red 33F (Gray) connector [2]. Connection: D17 — Yellow/red TOOL: Test probe 07ZAJ-RDJA1 10 Is there continuity? YES — GO TO STEP 6. N0 - Open circuit in Yellow/red wire 6. TOP Sensor Inspection Replace the TOP sensor (page 6-75). Clear the DTC's (page 642). Turn the ignition switch ON and engine stop switch .. Q "I Check the TCF| sensor with the HDS. Is the DTC 75-1 lndlcated? YES — Replace the ECM with a known good one, and recheck. N0 - Faulty original TCP sensor DTC 15-2 ("rep SENSOR 2 HIGH VOLTAGE) ~ Before starting the inspectionI check for loose or poor contact on the TCP sensor 6P (Black) connector and ECM 33P connectors. then recheck the DTC. 1. TOP Sensor 2 System Inspection Turn the ignition switch ON and engine stop switch it Q Check the TCP sensor 2 with the HDS when the throttle is fully closed. Is about 4.902 V or above indicated? YES — GO TO STEP 2. NO - - lnterrnittentteilure - Loose or poor contact on the TCP sensor connector 2. V00 2 Input Voltage Inspection Turn the ignition switch OFF. Disconnect the TCP sensor 6P (Black) [11 Yellow/red connector [1]. \ Turn the ignition switch ON and engine stop switch 1 “I . Q . 4 LI Measiire the voltage at the wire side. Connection: Yellow/red 1+) — Gray (-) TOOL: Gray Test probe OYZAJ-RDJA110 9 ® Is the voltage withln 4.75 — 5.25V? YES — GO TO STEP 4, NO — GO TO STEP 3. 6-51 FUEL SYSTEM (PGM-Fl) 3i VCC 2 Line Open Circuit Inspeotion Check for continuity at the Yellow/red and Gray wire between the TCP sensor 6P (Black) oonnector [1] and ECM 33? (Gray) connector [2]. Connection: D11 — Yellow/red 9 D15 — Gray 2] D17 Yellow/red TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — GO TO STEP 4. N0 — - Open circuit in Yellow/red wire O Open circuit in Gray wire D15 4. TOP sensor Inspection Replace the TCP sensor (page 6-75). Clear the DTC’s (page 6-12; Turn the ignition switch ON and engine stop switch .. Q Check the TCP sensor with the HDS, Is the DTC 75-2 Indicated? YES - Replace the ECM with a known good one, and recheck. N0 — Faulty original TCP sensor DTC 76-1 (TCP SENSOR 1-2 VOLTAGE CORRELATION FAILURE) ~ Before starting the inspection, check for loose or poor contact on the TCP sensor 6P (Black) connector and ECM 33F connectors, then recheck the DTC. 1. TCP Sensor System Inspection Check for smooth throttle operation and automatic "full closing in all steering positions Clean the DTC‘s (page 642). Turn the ignition switch ON and engine stop switch .. Q . Open the throttle and check the TCP sensor with the HDS. Is the DTC 764 indicated? YES — GO TO STEP 2‘ NO - Intermittent failure 6-52 Be careful not to damage the throttle valves. 2. TOP Sensor 1 and TCP Sensor 2 short Circuit Inspection 2 FUEL SYSTEM (PGM-Fl) Disconnect the TCP sensor 6P (Black) connector. [1] Check for continuity between the ECM 33P (Black) connector terminal 014 and 025. Connection: C14 - 625 TOOL: Test probe 07ZAJ-RDJM10 Is there continuity? YES - - Short circuit in White/black wire - Short circuit in White/blue wire NO - GO TO STEP 3. C14 C25 3. TOP sensor Inspection Replace the TCP sensor (page 6-75). Clear the DTC's (page 6-12). Turn the ignition switch ON and engine stop switch .. Q check the TCP sensor with the HDS. Is the DTC 78-1 Indicated? YES — Replace the ECM with a known good one. and recheck. N0 — Faulty original TCP sensor DTC 77-1 (TBW RETURN SPRING FAILURE) - Before starting the inspection. check for loose or poor contact on the TBW 6P (Black) connector and ECM 33P connectors, then recheck the DTC. 1. TBW System Inspection Clear the DTC's (page 6-12). Start the engine and let it idle. Turn the ignition switch OFF. and wait 10 seconds. Turn the ignition switch ON and engine stop switch .. Q .. Check the DTC's with the HDS. Is the DTC 77-1 Indicated? VES — GO To STEP 2. NO — intermittent leilure 2. Throttle Valve Inspection Remove the air cleaner housing (page 6-68). Open the throttle valve with fingers. Does the throttle valve return? YES - Recheck the DTC‘s with the HDS NO — GO TO STEP 3. 6-53 FUEL SYSTEM (PGM-Fl) TB W return spring cannot be replaced. II the TBW return spring is iaulty, replace the throttle body. TBW motor cannot be replaced. If the TBW motor is faulty, replace the throttle DOW- 3. Throttle body Inspection Replace the throttle body (page 6-71) Clear the DTC's (page e12i Turn the ignition switch ON and engine stop switch .. n .' Check the DTC'S with the HDS, Is the DTC 77-1 Indicated? YES - Replace the ECM with a known good one. and recheck. NO - Faulty original throttle body DTC 78-1 (TBW MOTOR FAILURE) ~ Before starting the inspection, check for loose or poor contact on the TBW 6P (Black) connector and ECM 33F connectors, then recheck the DTC. 1. Recheck DTC Clear the DTC's (page 6-12) Tum the ignition switch ON and engine stop switch " Q , Check the TBW motor with the HDS, Is the DTC 78-1 Indlcated? YES - GO TO STEP 2‘ NO - Intermittent failure 2. TBW Motor Line Open Circuit Inspection Disconnect the ECM 33F (Blue) connector [1]. Check Ior continuity between the ECM 33P (Blue) oonnector A9 and A10. Connection: A9 — A1 0 TOOL: Test probe DYZAJ-RDJM 10 Wis there continuity? YES - GO TO STEP 3. NO —- - Open circuit in Blue/red wire - Open circuit in Blue wire 3. Throttle body Inspection Replace the throttle body (page 6»71)4 Clear the DTC: (page 6—12). Turn the ignition switch 0N and engine stop switch . Q "‘ Check the DTC'S with the HDS. Is the DTC 78-1 Indicated? YES - Replace the ECM with a known good one, and recheck. NO — Faulty original throttle body A10 [1) 6-54 DTC 79-1 (T BW SYSTEM CONTROL CORRELATION FAILURE) - Before starting the inspection, check for loose or poor contact on the TBW 6P (Black) connector and ECM 33F connectors, then recheck the DTC. 1. Recheck DTC Clear the DTC'e (page 5—12). Turn the ignition switch ON and engine stop switch Cgch the TBW system with the Hos‘ Is the 010 79-1 Indicated? YES - GO TO STEP 2. NO - Intermittent failure 2. Throttle body Inspection Replace the throttle body (page 6—71). Clear the DTC‘s (page 6-12), Turn the ignition switch ON and engine slop switch . Q it Check the DTC‘s with the HDS. Is the DTC 79—1 indicated? YES — Replace the ECM with a known good one, and recheck. N0 - Faulty original throttle body. DTC 83-1 (EOP SENSOR LOW VOLTAGE) ~ Before starting the inspection. check tor loose or poor contact on the EOP sensor 3P (Black) and ECM 33? connectors, then recheck the DTC, t. EOP Sensor System Inspection Clear the DTC‘s (page 6-12). Turn the ignition switch ON and engine stop switch . Q .. Check the EOP sensor with the HDS. Is the DTC 83‘1 ind/cared? YES — GO TO STEP 2. N0 - Intermittent lailure 2. EOP Sensor Input Voltage Inspection FUEL SYSTEM (PGM-Fl) Turn the ignition switch OFFt Disconnect the EOP sensor 3P (Black) [1] oonnector [1]. Turn the ignition switch ON and engine stop switch n Q .' Measure the voltage at the wire side. Connection: Yellowlred (+) — Grey (—) Is the Voltage within 4. 75 - 5.25V? YES — GO TO STEP 4. NO - GO TO STEP 3, Gray Yellow/red 6-55 FUEL SYSTEM (PGM-FI) 3. EOP Sensor Input Llne Inspection Turn the ignition switch OFF. Disconnect the ECM 33F (Gray) connector [1]. Check for continuity at the Yellow/red wire between the EOP sensor 3P (Black) connector [2] and ECM 33F (Gray) oonnecton Connection: D28 - Yellow/red TOOL: Test probe 07ZAJ-RDJA1 10 Is there continuity? YES - Replace the ECM with a known good one. and recheck. NO — Open circuit in Vellow/red wire 4. EOP Sensor Output Line Short Circuit Inspection Check for continuity between the EOP sensor 3P (Black) connector [1] at the wire side and ground. Connection: Blue/red - Ground Is there continuity? YES — Short circuit in Blue/red wire NO - GO TO STEP 5. 5. EOP Sensor Inspection Replace the EOP sensor with a known good one. Clear the DTC's (page 6-12). Turn the ignition switch ON and engine stop switch " Q Check the EOP sensor with the HDS. Is the DTC 83-1 indicated? YES — Replace the ECM with a known good one' and recheck. NO - Faulty original EOP sensor DTC 83-2 (EOP SENSOR HIGH VOLTAGE) - Before starting the inspection, check for loose or poor contact on the EOP sensor 3P (Black) and ECM 33F connectors, then recheck the DTC. 1. EOP Sensor System Inspection 1 Clear the DTC‘s (page 642). Turn the ignition switch ON and engine stop switch Chneck the EOP sensor with the HDS. Is the DTC 83-2 Ind/cared? YES — GO To STEP 2. NO - Intermittent failure [1] (D28) Yellow/red [1] 6-56 2. EOP Sensor Input Voltage Inspection Turn the ignition switch OFF. Turn the ignition switch 0N and engine stop switch .. Q Measure the voltage at the EOP sensor 3P (Black) connector [1] at the wire harness side. Connection: Yellow/red (+) - Gray (-) Is the voltage within 4. 75 — 5.25V? YES - GO TO STEP 3. N0 — O Open circuit in Yellow/red wire O Open circuit in Gray wire 3. EOP Sensor Circuit lnspectIon Disconnect the ECM 33F (Black) connector [1]. Check for continuity at the Blue/red wire between the EOP sensor 3P (Black) connector [2] and ECM 33F (Gray) connector. Connection: cs - Bluelred Output Llne Open TOOL: Yes! probe 07ZM-RDJA110 Is there continuity? YES - GO TO STEP 4. NO - Open circuit in Blue/red wire 4. EOP Sensor Inspection Replace the EOP sensor with a known good one. Clear the DTC’s (page 6-12). Tum me ignition switch ON and engine stop switch .. Q Check the EOP sensor with the HDS. Is the DTC 83-2 indicated? YES - Replace the ECM with a known good one, and recheck NO - Faulty original EOP sensor FUEL SYSTEM (PGM-Fl) [1] Gray Yellow/red U o o n [11 6 Q0 (9 C3 Blue/red [Z] 6-57 FUEL SYSTEM (PGM-Fl) DTC 84-1 (ECM PROCESSOR FAILURE) . Before starting the inspection, check for loose or poor contact on the ECM 33F connectors and recheck the DTC, 1. Recheck DTC Clear the DTC’s (page 6-12). Turn the ignition switch 0N and engine stop switch . Q ". Recheck the ECM processor malfunction with HDS. Is the DTC 84-1 Indlcated? YES — Replace the ECM with a known good one, and recheck. N0 — Intermittent failure DTC 85-1 (TBW RELAY FAILURE - ON SIDE) - Before starting the inspection. check for loose or poor contact on the TBW relay connector and ECM 33F connectors, then recheck the DTC 1. Recheck DTC inspect the TBW relay (page 6-84). Clear the DTC's (page 6-12), Turn the ignition switch 0N and engine stop switch .. 0 v.’ Check the TBW relay with the HDS. ls DTC 85-1 indicated? YES — GO TO STEP 2. NO - Intermittent failure 2. TBW Relay Voltage inspection Remove the TBW relay (page 6-84). Turn the ignition switch ON and engine stop switch V Mgsore the voltage at the TBW relay terminals. Connection: White/black - Ground Is there battery voltage? YES —- GO TO STEP 3. NO — Blown TBW fuse White/black 6-58 FUEL SYSTEM (PGM-Fl) 3. TBW RELAY Line Open circuit Inspection Check the continuity between the ECM 33F (Blue) [1]. ECM 33p (Biack) [2] connectors and TBW relay "1 connector [3] terminals. Connection: A7 — Brownlgreen A8 — Brownlgreen 2] C5 - Violetlwhite VioleI/white ‘ TOOL: Test probe 07ZAJ—RDJA1 10 Is there continuity? YES - so 10 STEP 4. \ N0 — - Open circuit in Violet/white wire Brown/green [3] - Open circuit in Brown/green wire 4. TBW RELAY LIne Short circuit Inspection Disconnect the ECM 33F connectors. Check the continuity between the ECM 33F (Blue) [1], ECM 33F (Black) [2] connectors and ground, Connection: A7 - Ground A8 — Ground C5 - Ground [2] TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? YES — ‘ Short circuit in Violetlwhite wire . Short circuit in Brown/green wire NO — Replace the ECM with a known good one. and recheck. DTC 85-2 (13w RELAY FAILURE - OFF SIDE) Periorm the troubles shooting according to the DTC 85~1 (page 6-58). MIL CIRCUIT TROUBLESHOOTING If the engine can be started but the MIL does not come on when the ignition switch is turned ON and the engine stop switch is in “ 0 ”, check as follows: ‘ If they do not iunction, check the combination meter power input line (page 22-11). ' If they function properly. check as follows: Turn the ignition switch to OFF, disconnect the ECM 33F (Grey) connector [1]. Check ior open circuit in the White wire between the combination meter ZOP connector [2] and ECM. TOOL: Test probe 07ZAJ-RDJA1 1 0 [1] Ii the wire and combination meter are OK. replace ECM. 6-59 FUEL SYSTEM (PGM-Fl) FUEL LINE INSPECTION FUEL PRESSURE RELIEVINGIQUICK CONNECT FITTING REMOVAL Before disconnecting the fuel hose, relieve pressure from the system as follows. 1. Turn the ignition switch OFF. Lift and support the fuel tank (page 45). Remove the quick connect fitting cover [1] (fuel pump side only). . Disconnect the fuel pump 2P (Brown) connector [2]. . Start the engine, and let it idle until the engine stalls, . Turn the ignition switch OFF. . Dlsoonnect the battery negative (—) cable (page 1945). 6. Check the fuel quick connect fitting tor dirt, and clean if necessary. Place a shop towel over me quick connect fitting. 7. Pull and release the rubber cap [1] from the retainer (throttle body side only). a. Hold the connector [2] with one hand and squeeze the retainer tabs [3] with the other hand to release them from the looking pawls [4]. Pull the connector oft, then remove the rubber cap (throttle body side only) and retainer from the tuel joint, Absorb the remaining fuel in the fuel hose trorn flowing out with a shop towel. Be careful not to damage the hose or other parts, Do not use tools It the connector does not move, keep the retainer tabs pressed down. and alternately pull and push the connector until it comes ofi easily. 0-ch 9. To prevent damage and keep foreign matter out. cover the disconnected connector and tuel joint with plastic bags [1]. FUEL TANK SIDE [2] [1] 6-60 FUEL SYSTEM (PGM-FI) QUICK CONNECT FITTING INSTALLATION ' Always replace the retainer and rubber cap of the quick connect fitting when the fuel hose is disconnected. - Do not bend or twist the fuel hose. - If any retainer needs replacing. use the same manufacturer‘s retainer as the ones being removed (The various manufactures feature different retainer specification). 1. insert a new retainer [1] into the connector [2]. - Align new retainer looking pawls with the connector grooves. THROTTLE BODY SIDE shown: @ [t] v 2. Install a new rubber cap [1] and seat it onto the lust joint [2] as shown (throttle body side only). \ THROTTLE BODY SIDE Align the quick connect fitting with the lust joint. 1 Then press the quick connect fitting onto the pipe v [1] [1] % until both retainer pawts lock with 3 'CLICK“. If it is hard to connect. put a small amount of engine oil on the pipe end. FUEL TANK SIDE 3. Make sure the connection is secure and that the pawl: are firmly locked into place by pulling on the connector and visually checking. 4. Make sure the mbber cap [1] (throttle body side only) is in place (between the flange [2] and retainer tab [3]). 6-61 FUEL SYSTEM (PGM-Fl) 5. Connect the fuel pump 2P (Brown) connector [1], 6. Connect the battery negative (—) cable to the battery (page 19-6; 7. Install the quick connect fitting cover [2] (fuel pump side only), B, Turn the ignition switch ON and engine stop switch "0“. The fuel pump will run tor about 2 seconds, and fuel pressure will rise. Repeat 2 or 3 times. and check that there is no leakage in the luel supply system. Installation is in the reverse order of removal, FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting [1] (page 6-60). Attach the fuel pressure gauge. hoses, attachment joint and manifold, , TOOLS: Fuel pressure gauge [1] 074060040004 Pressure gauge manifold [2] 072AJ-SSA0111 Hose attachment, [3] 07ZAJ-85A0120 9 mml9 rnm Hose attachment, [4] 07ZM$7C0100 8 rum/9 mm Attachment joint, [5] MUM-5700200 8 min/9 mm U.S.A. TOOLS: Fuel pressure gauge 014064040005 Pressure manilold hose 07AMJ-HW3A100 Adaptor, male 07AAJ-SGMA200 Adaptor, female o7AAJ-SGMA400 Temporarily connect the battery negative (—) cable to the battery Connect the luel pump 2? (Brown) connector. Start the engine and let it idle‘ Read the fuel pressure. Standard: 343 kPa (3.5 kgllem’, 50 psl) 6-62 Wrap a shop towel around the attachment to soak up any spilled fuel. If the fuel pressure is higher than specified. replace the fuel pump assembly (faulty fuel pump or fuel pressure regulator) It the fuel pressure is lower than specified, inspect the following: — fuel line leaking — pinched or clogged fuel hose or fuel tank breather hose — fuel pump (page 6—64) — clogged fuel strainer screen (Assembly of the fuel pump: page 6—65) Alter inspection, relieve the fuel pressure by disconnecting the quick connect fitting (page 6~60). Remove the fuel pressure gauge. hoses attachment joint and manifold. Connect the quick connect fitting [1] (page 6—61). FUEL FLOW INSPECTION Remove the Iefl rear cowl (page 34). Remove the fuel pump relay with the terminal color as shown on the illustration. Jump the Brown and White/black wire terminals at the wire harness side [1] using a jumper wire [2]. FUEL SYSTEM (PGM-FI) l‘ [2] olol [1] 6-63 FUEL SYSTEM (PGM-FI) Disconned the quick connect fitting from the fuel joint (page 6—60)‘ Attach the hose attachment [1] to the fuel joint. TOOL: Hose attachment, 8 min/9 mm 07ZAJ-S1CD1DIJ U.S.A. TOOLS: Fuel pressure gauge 0740643040003 Pressure manifold hose o'lAMJ-HW3A100 Adaptor, female 07AAJ-SGMA400 - Place an approved gasoline container and drain the gasoline. - Wipe off spilled gasoline. Connect the fuel pump 2P (Brown) connector (page 6-62) Connect the battery negative (—) cable (page 19-6), Turn the ignition switch ON and engine stop switch “(T for 10 seconds. Measure the amount of fuel flow. Amount of fuel flow: 320 cm‘ (10.8 us oz, 11.3 Imp oz) minimum/10 sec- onds at 12 V If the fuel flow is less than specified. inspect the following: — clogged fuel strainer screen (Assembly of the fuel pump: page 6-66) — pinched or dogged fuel hose — fuel pump unit (page 6—64) Disconnect the hose attachment from the fuel joint. Connect the quick connect fitting (page 6-61). FUEL PUMP UNIT INSPECTION Turn the ignition switch ON and engine stop switch '0" then confirm that the fuel pump operates for a few seconds lithe fuel pump does not operate. inspect as follows: Turn the ignition switch OFFt Lift and support the fuel tank (page 4-5) Disconnect the fuel pump unit 2P (Brown) connector [1], 6-64 Be careful not to damage the pump wire and fuel level gauge. Turn the ignition switch ON and engine stop switch '0", measure the voltage between the luel pump unit 2P (Brown) connector [1] terminals on the wire side. Connection: Brown (fl — Green (—) There should be battery voltage for a few seconds, If there is battery voltage for a few seconds, replace the fuel pump unit. If there is no battery voltage. inspect the following: — main fuse 30 A — sub fuse (BANK ANGLE 10 A) — subfuse(Fl10A) . — engine stop switch (page 22—18) — fuel pump relay (page 667) — engine stop relay (page 6-33) — bank angle sensor (page 6—81) — ECM (page 6455) REMOVAL Remove the fuel tank (page 6-67), Disconnect the overflow hoses [1] from the fuel tank. Remove the fuel pump unit mounting nuts [1] and clamp [2], Remove the fuel pump unit [1] and packing [2]t FUEL SYSTEM (PGM-Fl) Brown Green ® 6-65 FUEL SYSTEM (PGM-Fl) INSPECTION Check the fuel pump unit for wear at damage, replace it if necessary. Clean the fuel strainer screen [1] with non-flammable or high flash point solvent. INSTALLATION Always replace the Place a new packing onto the fuel pump unit [2]. old packing wlm new one. Be carelulnot to Install the fuel pump unit to the fuel tank. damage the pump wire and fuel level gauge Install the clamp [1] and tighten the fuel pump mounting nuts [2] to the specified torque in the specified sequence as shown. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-fl) Route the hoses Connect the overflow hoses to the fuel tank securely. pmpefly (Page 1'22). Install the fuel tank (page 6—68), 6-66 FUEL SYSTEM (PGM-Fl) FUEL PUMP RELAY INSPECTION Remove the left rear cowl (page 3—4). Blacwme Remove the fuel pump relay with the terminal color as I‘ shown on the illustration, “ENE Connect an ohmmeter to the luel pump relay [1] terminals. Connect a 12 V battery to the fuel pump relay connector terminals as shown, There should be continuity only when 12 V battery is connected. If there is no continuity when the 12 V battery is connected, replace the luel pump relay. Install the removed pans in the reverse order of removal. FUEL TANK REMOVAL Relieve the fuel pressure and disconnect the quick connect fitting [1] (page 6-60) Disconnect the fuel level sensor 2P (Black) connector [21‘ Disconnect the air vent hose [1] from the fuel tank. 6-67 FUEL SYSTEM (PGM-FI) Remove the luel tank pivot bolt. washer and mounting nut [1], then remove the fuel tank [2]. INSTALLATION Install the fuel tank in the reverse order 0! removal NOTICE Route the hoses, wires and harness properly. Be careful not to damage the hamess and hose. After installing the fuel tank, make sure the drain, air vent, overflow hose and fuel hoses are not kinked or bound AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the fuel tank (page 6-67) Release left side and right side connectors [1] and relay [2] form the air cleaner housingl 6-68 Remove the air cleaner element (page 4—6), Pull up the heat guard rubber [1] from the air cleaner housing. Release wire harness [2] from the air cleaner housing guidest Disconnect the PAIR air hose [1] from the air cleaner ‘ housing. Release the PAIR control solenoid valve [2] from the air cleaner housing. Disconnect the MAP sensor 3P (Black) connector [1] and MAP sensor vacuum hose [2]. Remove the air funnel/air cleaner housing mounting ’ screws [1], then remove the air funnels [2]. FUEL SYSTEM (PGM-FI) 6-69 FUEL SYSTEM (PGM-FI) Disconnect the PAIR air hose [1] from the air cleaner housing [2] then. remove the air cleaner housing. installation is in the reverse order of removal. TORQUE: Air funnel mounting screw: 4.2 N-m (0.4 kgf-m, 3.1 lbf'f!) DISASSEMBLYIASSEMBLY Remove the screws [1] thenI remove the upper air cleaner housing [2], Remove the air cleaner housing packings [3]. [3] Remove the MAP sensor mounting screw [1], then remove the MAP sensor [2] from air cleaner housingt Assembly is in the reverse order of disassemblyl [1] TORQUE: Air cleaner case screw: 0.8 N-m (0.1 kgf-m, 0.3 lbi‘fl) MAP sensor mounting screw 1.1 MM 10.1 mm, 0.3 Ham) [2] 6-70 FUEL SYSTEM (PGM-FI) THROTTLE BODY/TCP SENSOR] INJECTOR REMOVAL NOTICE ' Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resultan in loss of vehicle control. Remove the lollowing: — fuel tank (page 6—67) — air cleaner housing (page (H38) Disconnect purge control solenoid valve-tmlhrottle valve hose from the EVAP purge control solenoid valve (page 6-91). Relieve the fuel pressure and disconnect the quick connect fittings [1] from the fuel rail (page 6—60). Release the clip [1] from the throttle body. Disconnect the injector sub-hamess 12P (Black) connector [1] and TBW 6P (Black) connector [2]. 6-71 FUEL SYSTEM (PGM-Fl) Remove the fue| rail mounting bolts [1] then, remove ' the fuel rails [2]. Remove the fuel rails from the fuel rail joint [1]. Remove the O-rings [2] from the luel rail joints. Disconnect the injector 2P (Gray) oonneciors [1]. Remove Ihe injectors [1] Irom the Ihrottle body. Remove the seal rings [2] and O—rings [3] from each iniecior. 6-72 FUEL SYSTEM (PGM-FI) Loosen the throttle body side insulator band screws (4 places) [1] using a long type phillips screwdriver through the frame hole. Remove the throttle body from the insulators. Do not snap the Loosen the lock nuts, adjusting nuts and disconnect the throttle drum ofma throttle cables [1] Irom throttle drum of the TCP sensor rCP sensor from [2]. then remove the throttle body. "gig; Seal the cylinder head intake ports with tape or a clean ‘ cloth to keep dirt and debris from entering the intake :::,;‘:g’fega; ports afler the throttle body has been removed. may cause incorrect operation. 6-73 FUEL SYSTEM (PGM-FI) ' Do not damage the throttle body. it may cause incorrect throttle operation. - The throttle body is facton pie-set. Do not disassemble in a way other than shoum in this manuai ' Do not loosen or tighten the white painted bolts and screws of the throttle body. Loosening or tightening them can cause throttle synchronization failure. PAINTED WHITE PAINTED WHITE PAINTED WHITE PAINTED WHITE 5.1 N-rn (0.5 kgI-m, 3,8 Ibf-fl) PAINTED WHITE PAINTED WHITE PAINTED WHITE PAINTED WHITE 3.4 N~m (0.3 kgf'mv 2.5 IbI-fl) 6-74 FUEL SYSTEM (PGM-Fl) INSPECTION Measure the resistance belween the injector connector terminals. Standard: 11.6— 12.4 0 (ZO‘CIGB‘T) DISASSEMBLYIASSEMBLY Remove the clamps [1] from the throttle body, Do not snap the Remove the clip [1] and disconnect the TCP sensor 6P throttle valve [3] (Black) connector [2]. mm fully open to fully closed by hand, It may cause incorrect apemtion. Remove the throttle cable stay screws [1], then remove the throttle cable stay [2]. 6-75 FUEL SYSTEM (PGM-FI) Remove the TCP sensor mounting bolts [1]. Remove the TOP sensor [2]. Remove the TCP sensor stay mounting bolts [1]. then remove the TCP sensor stay [2]. Assembly is in the reverse order at disassembly. Tighten the TCP sensor throttle cable stay screws [1] to the specified torque. TORQUE:3.4 N~m (0.3 kgf-m, 2.5 lbf-ft} INSTALLATION Route the throttle Connect the throtfle cable ends [1] to the throtfle drum cables proper/y of the TCP sensor [2]. (page 1-22), 6-76 install the throttle body into the insulators, tighten the throttle body side insulator band so that the insulator band distance is 4 11 mm (0.2 i 0.04 in). Apply small amount of engine oil to new O-rings [1]. Install new seal rings [2] and new O-rings to each injectors [3]. Install the injectors [3] to the throttle body. Connect the injector 2P (Gray) connectors [1]. Apply engine oil to new O-rings [1] at the fuel rail joints [2]. Install the O-rings onto the Iuel rail joints. Install the fuel rails to the iuel rail joints. FUEL SYSTEM (PGM-Fl) 4 :1 mm (0.2 1 004 in) 6-77 FUEL SYSTEM (PGM-FI) Install the Iuel rails [11 onto the throttle body. Install and tighten the fuel rail mounting bolts [2] to the specified torque, TORQUE:5.1 N-m (0.5 kf-m, 3.3 lbf-ft) Install the clip [1] to the throttle body. Connect the quick connect fittings [1] (page 6-61). Install the following: — air cleaner housing (page 6—68) — fuel tank (page 6-68) Connect purge oontrol solenoid valve-to-throttle valve hose to the EVAP purge control solenoid valve (page 6—91). ENGINE IDLE SPEED IDLE SPEED INSPECTION ' Inspect the idle speed after all other engine maintenance items have been performed and are within specifications. . Belore checking the idle speed, inspect the Iollowing items. — no DTC and MIL blinking — spark plug condition (page 4-5) — air cleaner condition (page 4-7) ' The engine must be warm for accurate idle speed inspection. ' This system eliminates the need for manual idle speed adjustment compared to previous designs, ' Use a tachometer with graduations ol 50 rpm or smaller that will accurately indicate a 50 rpm change. 6-78 FUEL SYSTEM (PGM-Fl) Lift and support the fuel tank (page 4—5). Start the engine and warm it up to coolant temperature 80°C (176°F). Stop the engine and connect a tachometer according to the tachometer manufacturers operating instructions. Start the engine and let It idle, Check the idle speed. ENGINE IDLE SPEED: 1,150 1 100 rpm If the idle speed is out of the specification, check the following: ~ Throttle operation and throttle grip freeplay (page 4-5) - Intake air leak or engine top—end problem (page 9-3) - Check the DTC's (page 644) KNOCK SENSOR REMOVAL/INSTALLATION Remove the throttle body (page 6-71). Disconnect the knock sensor 3P (Black) connector [1]. Remove the bolt [1] and knock sensor [2]t Route the wire Installation is in the reverse order ol removal. “mp9” TORQUE: (page 1-22} Knock sensor mounting bolt: 24 N‘m (2.4 kgf-m, 18 lbf‘fl) MAP SE NSOR REMOVAL/INSTALLATION Remove the air cleaner housing (page 6—63). Remove the screw [1] and MAP sensor [2] from the air cleaner housing. Install the removed parts in the reverse order 01 removal. TORQUE: MAP sensor mounting screw: 11 N-m (0.1 kgf-m, 0.3 [bf-fl) 6-79 FUEL SYSTEM (PGM-Fl) IAT SENSOR REMOVAL/INSTALLATION Lift and support the fuel tank (page 4-5). Disconnect the IAT sensor 2? (Gray) connector [1]. Remove the screws [2] and lAT sensor [3] from the air cleaner housing cover. Installation is in the reverse order of removal. TORQUE: IAT sensor mountlng screw: 1.1 N-m (0.1 kgf-m, 0.3 lbf-ft) ECT SENSOR REMOVAL/INSTALLATION Replace the ECT Drain the coolant from the system (page 7-6), sensor while the engine is cold Remove the throttle body (page 6-71). Disconnect the ECT sensor 3P (Gray) connector [1]. Remove the ECT sensor [2] and sealing washer [3]. Always replace the Install a new sealing washer and ECT sensors sealing washer with Tighten the ECT sensor to the specified torque. ‘3 "e" W ronoums N-m (2.5 mm, 13 Ibf-ft} Installation is in the reverse order of removal. CMP SENSOR REMOVAL Remove the throttle body (page 6-71). Disconnect the CMP sensor 3P (Black) connector [11‘ 6-80 FUEL SYSTEM (PGM-Fl) Remove the bolt [1] and CMP sensor [2]. INSTALLATION Apply oil to a new O-ring [1] and install it onto the CMP sensor [2]. Install the CMP sensor into the cylinder head. Tighten the mounting bolt securely. Route the wine Route the CMP sensor wire, connect the CMP sensor property 3P (Black) connector [1]. (Page 7'22" Install the throttle body (page 6-76), BANK ANGLE SENSOR REMOVAL/INSTALLATION Disconnect the bank angle sensor 3? (Black) connector [1]. Remove the bolts/washers [2] and bank angle sensor [3]. 6-81 FUEL SYSTEM (PGM-FI) Install the bank installation Is in the reverse order of removal. angle sense! with "Ma" and n. . . H , . ghten the bank angle sensor mounting bolts "3 UP "75"“ mfg to the specified torque. TORQUE: 1.5 N‘m (0.2 kgf-m, 1.1 lbf-tt) "UP" MARK BANK ANGLE SENSOR INSPECTION SYSTEM INSPECTION Remove the bolts/washers [1] and bank angle sensor [2]. Place the bank angle sensor horizontal as shown. and 60. BANK ANGLE POSITION ignition switch ON. The bank angle sensor is normal if the engine stop relay clicks and there is no power supply. 0 Q Incline the bank angle sensor approximately 60” to the Ian or right with the ignition switch ONt . Theabank angle sensor is normal if the engine stop NORIMIALN (appmx'ma‘sjfl 50' relay clicks and there is power supply P03 T 0 It you repeat th' test, first tum the ignition switch OFF, then turn the ignition switch ON, If the engine stop relay does not click, inspect the bank angle sensor line as tollows: ( r . t I a roxrma e INPUT LINE INSPECTION pp y Disconnect the bank angle sensor 3P (Black) connector (page 6—81). Turn the ignition switch ON. Measure the voltage between the bank angle sensor 3P ® (Black) connector [1] at the wire side and ground. Connection: Whltelyellow (+j — Ground (—) There should be battery voltage. White/yellow If there is no battery voltage, inspect the following: — battery — main fuse (30A) 9 T — Sub fuse (BANK ANGLE 10A) [1] — ignition switch — wire harness open circuit 6-82 FUEL SYSTEM (PGM-Fl) GROUND LINE INSPECTION Turn the ignition switch OFF. [1] Measure the voltage between the bank angle sensor 3P (Black) connector [1] at the wire side and ground. Connection: Green H) - Ground (—) There should be continuity. If there is no continuity. inspect the Green wire open circuit. Green ENGINE STOP RELAY COIL LINE INSPECTION Turn the ignition switch ON and engine stop switch 1 M Q "I I I \ Measure the voltage between the bank angle sensor 3P (Black) connector [1] at the wire side and ground. (a V Connection: Red/blue h) - Ground H I There should be battery voltage. Red/blue If there is no battery voltage. inspect the lollowing: — red/blue wire open circuit — engine stop switch 6 — engine stop relay It all items are normal, replace the bank angle sensor with a know good one and recheck, ENGINE STOP RELAY INSPECTION Remove the left rear oowl (page 3-4). Red/blue Remove the engine stop relay with the terminal oolor as shown on the illustration. Red/whlte Connect an ohmmeter to the engine stop relay [1] terminals. Connect a 12 V battery to the engine stop relay connector terminals as shown. There should be continuity only when 12 V battery is connected. If there is no continuity when the 12 V battery is connected, replace the engine stop relay. Install the removed parts in the reverse order of removal. FUEL SYSTEM (PGM-Fl) TBW RELAY INSPECTION Remove the left rear cowl (page 3-4). Viola/white Remove the TBW relay with the terminal color as shown on the illustration. While/bier: Connect an ohmmeter to the TBW relay [1] terminals Connect a 12 V battery to the TBW relay connector [1 ] terminals as shown. There should be continuity only when 12 V battery is connected If there is no continuity when the 12 V battery is :7” connected, replace the TBW relay. E} Install the removed parts in the reverse order of removal. r.1 ECM REMOVAL/INSTALLATION Lift and support the fuel tank (page 4-5). Release the ignition switch 2P (Brown) connector [1] fromthe ECM stay. Lift and support the fuel tank (page 4—5). Remove the ignition switch 2P (Brown) connector from the ECM stay. Pull out the ECM [1] irom the air cleaner stay. Disconnect the ECM 33F (Blue), 33F (Black) and 33F (Gray) connectors [2]. installation is in the reverse order of removal. 6-84 POWER/GROUND LINE INSPECTION ENGINE DOES NOT START (MIL DOES NOT BLINK) 1. ECM Power Input Voltage Inspection Pull out the ECM (page 6—84). Disconnect the ECM 33F connectors Turn the ignition switch ON and engine stop switch "on Measure the voltage at the ECM 33F (Blue) connector [1] terminals and ground. Connection: A11 (+) — Ground (—) A22 (+J — Ground (-l TOOL: Test probe 072AJ-RDJA1 10 Is there battery voltage? YES — GO TO STEP 2. NO - GO TO STEP 3. 2. ECM Ground Line lnspecfion Turn the ignition switch OFF. Check for continuity between the ECM 33F (Blue) [1] and 33F (Gray) {2] connector terminal and ground. Connection: A4 - Ground A5 - Ground A15 - Ground A26 - Ground A27 — Ground D23 — Ground D24 - Ground TOOL: Test probe o1ZAJ-RDJA1 1 0 Is there continuity? YES - Replace the ECM with a known good one, and recheck. ND - Open circuit in Ground line FUEL SYSTEM (PGM-FI) l2] A15 6-85 FUEL SYSTEM (PGM-FI) 3. Engine Slop Relay Inspection 1 Turn the ignition switch OFFt Remove the engine stop relay (page 6-83). Turn the igniu’on switch ON and engine stop switch "0". Measure the voltage at the engine stop relay connector [1] terminals. Connection: Black (1-) - Red/blue (—) Is there battery Voltage7 YES - GO TO STEP 4. NO — ~ Inspect the bank angle sensor (page 6—81). ~ inspect the engine stop switch (page 22.13). ' Blown fuse (BANK ANGLE 10 A) . Engine Stop Relay Inspection 2 Tum the ignition switoh OFF. Jump the engine stop relay connector [1] terminals. Connecti n: Redlwhite— Black/white Tum the ignition switch ON. Measure the voltage at the ECM 33F (Blue) connector [2] terminals and ground. Connection: A11 (*i— Ground (-) A22 (fl — Ground (-) TOOL: Test probe 07ZAJ-RDJA1 1 0 Is there battery voltage? YES — O Inspect the engine stop relay (page $83) - Inspect the bank angle sensor (page 6—81) - Inspect the engine stop switch N0 —Open circuit in power input line (Black! W" white. Red/white) between the battery and ECM Red/blue JJ Black [1] Red/white 99 A11 A22 Black/while [Z] / 6-86 SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to coolant temperature is 80°C (176“F). Stop the engine. Remove the air cleaner element (page 4-6), Check that the secondary air intake port [1] is clean and free of carbon deposits, If the port is carbon fouling. check the PAIR check valves (page 6-89), Start the engine and open the throttle slightly to be certain that air is sucked in through the air intake port. If the air is not drawn in, check the air suction hoses for clogs end PAIR solenoid valve FUEL SYSTEM (PGM-Fl) PAIR CONTROL SOLENOID VALVE INTAKE PORT EXHAUST PORT <3: FRESH AIR « EXHAUST GAS 6-87 FUEL SYSTEM (PGM-FI) PAIR CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Lift and support the fuel tank (page 4-5). Disconnect the PAIR control solenoid valve 2P (Black) connector [1]. Disconnect the PAIR air suction hoses. Installation is in the reverse order of removal. INSPECTION Remove the PAIR control solenoid valve. Check that air does not flow (A) to (B) when a 12 V battery is connected to the PAIR control solenoid valve terminals. Air should flow (A) to (B) when there is no voltage applied to the PAIR valve terminals. Check the resistance between the terminals of the PAIR oentrol solenoid valve [1]. Standard: 23 — 27 Q (20°CI68°F) It the resistance is out of specification, replace the PAIR control solenoid valve. (B) <— (A) — —> (B) 6-88 FUEL SYSTEM (PGM-Fl) PAIR CHECK VALVE REMOVALIINSTALLATION Front: Remove the engine heat guard (page 9-9). Rear: Lift and support fuel tank (page 4-5). Remove the bolts [1], PAIR check valve covers [2] end PAIR check valves [3] from the cylinder head covers. Installation is in the reverse order of removal. TORQUE: Front PAIR check reed valve cover bolt: 13 um (1.3 kgf-m,1olbf-ft) Rear PAIR check reed valve cover bolt: 6.9 N-m (0.7 kgf-rn, 5.1 [bf-ft) INSPECTION Check the reed [1] for damage of fatigue. Replace if necessary Replace the PAIR check valve if the seat mbber [2] is cracked, deteriorated or damaged or if there is clearance between the read and seat, 02 SENSOR REMOVAL/INSTALLATION O Do not sen/ice the O2 sensor while it is hot. - Handle the 02 sensor with cars. - Do not get grease, oil or other materials in the 02 sensor air hole. Remove the radiator (page 7-9) Disconnect the 02 sensor 4? (Blue) [1] and AP (Black) [2] connectors. 6-89 FUEL SYSTEM (PGM-Fl) EGCA Remove the O2 sensors [1] using the special tool. TOOL: FRXM17 (Snap on) or equivalent [2] o Be careful not to damage the sensor wire, - Do not use an impact wrench while removing or installing the 02 sensor, Installation is in the reverse order of removal. TORQUE: 02 sensor: 24.5 N-m (2.5 kgf-m, 18 Ihf-ft) REMOVAL/INSTALLATION Remove the rear cowl (page 34). Disconnect the servo motor 6P (Black) oonnector [1]. Release the EGCA control cable [2] lrorn the wire guides. Remove the bolts [3], collar and EGCA [4]. Disconnect the EGCA control cables [1] from the servo motor pulley [2L Installation is in the reverse order of removal. Check the operation 0! the EGCA cable (page 4-17). INSPECTION Connect a 12 V battery to the servo motor 6P (Black) connector [1] terminals and check that the motor operation, Connection: Red (1-) — Blue (-) (EGCA‘side terminals) It the servo motor does not turn, replace the servo motor with a new one: [1] Blue I l (9 ® BATTERY 6-90 FUEL SYSTEM (PGM-Fl) Measure the resistance between the servo motor 6P [1] Brown (Black) connector [1] terminals. Connection: Yellow/red — Green Standard: 5 kn V. J3 (EGCA side terminals) ' ' ' ' ' ‘ " Connection: Brown-Green Standard: 0 - 5 k0 i (EGCA side terminals) If the resistance is out of range. replace the servo J' “MW/rad motori Green EVAP PURGE CONTROL SOLENOID VALVE/CANISTER REMOVAL/INSTALLATION Remove the fuel tank (page “57). Remove the EVAP canister band [1]. Disconnect the following from the canister: — fuel tank breather hose (to fuel tank) [2]. — canistervto-purge oontrol solenoid valve hose [3]. — EVAP canister drain hose [4]. Remove the canister [5]. Disconnect the following: — EVAP purge control solenoid valve 2P (Black) connector [1]. — canister-topurge oontrol solenoid valve hose [2] from the EVAP purge control solenoid valve — purge control solenoid valve-to-throttle valve hose [3] from the EVAP purge control solenoid valve Remove the bolts [1], then remove the canister tray [1]. FUEL SYSTEM (PGM-Fl) Remove the bolts and nut [1], then remove the EVAP purge control solenoid valve [21‘ Installation is in the reverse order 0! removal INSPECTION Remove the EVAP purge control solenoid valve (page 6-91 ). Check that air should not flow (A) to (B), only when a 12V battery is connected to the EVAP purge control solenoid valve terminals Check the resistance between the terminals of the EVAP purge control solenoid valve [1], STANDARD: 30 — 34 D (20°Cl68°F) It the resistance is out of specification, replace the EVAP purge control solenoid valve (A) 6-92 7. COOLING SYSTEM .......................... "1.2 ........................... "7.3 ................................. "7.3 SYSTEM TESTING ...................................... ..1.4 COOLANT REPLACEMENT ----------------------- --1-5 THERMOSTAT ............................................ ..-,_7 CYLINDER HEAD BLEEDING JOINT -------- "7-8 RADIATOR .................................................. "7.9 RADIATOR RESERVE TANK 7-12 WATER pUMp .......................................... ..1_13 FAN MOTOR RELAY ----------- -- ---7-15 7-1 COOLING SYSTEM COMPONENT LOCATION SIPHON HOSE RADIATOR CAP AIR BLEED HOSE BLEEDING JOINTS THERMOSTAT RADIATOR RESERVE TANK RADIATOR OVERFLOW HOSE ==>=>=p=p OIL COOLER WATER PUMP COOLING SYSTEM SERVICE INFORMATION GENERAL 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. NOTICE 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. Afler servicing the system. check for leaks with a cooling system tester. Reler to inspection for the ECT sensor (page 22-14). SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 3.6 liter (3.8 US qt, 3.2 Imp qt) Reserve tank 1.0 liter (1.1 US qt. 0.9 Imp qt) Radiator cap relief pressure 108 — 137 kPa (1.1 — 1.4 kgflcm , 16 — 20 psi) Thermostat Begin to open 30 — 34°C (176 ~1B3°F) Fully open 95°C (203T) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze Pro Honda HP coolant or equivalent high quality ethylene glycol antifreeze containing silicatefree corrosion inhibitors Standard coolant concentration 50% mixture with distilled water TORQUE VALUES Water pump cover flange bolt 13 N-m (1.3 kgl~m. 101bf-ft) CT bolt Fan motor shroud mounting bolt 8.4 N'm (0.9 kgf~m. 6.2 lbf~tt) Cooling tan not 2.7 N‘m (0.3 kgf~m. 2.0 lbffi) Apply a locking agent to the threads. Fan motor mounting bolt 5.1 N~m (0.5 kgf—m. 3.8 Ibl-tt) Cylinder head bleeding joint 12 N'm (1,2 kgftm. 9 |bf~tt) Apply a locking agent to the threads. TROUBLESHOOTING Engine temperature too high ' Faulty temperature gauge or ECT sensor . Thermostat stuck closed ~ Faulty radiator cap - Insufficient coolant ~ Passage blocked in radiator. hoses or water jacket ‘ Air in system - Faulty cooling fan motor - Faulty tan motor relay ' Faulty water pump Engine temperature too low ~ Faulty temperature gauge or ECT sensor ‘ Thermostat stuck open ' Faulty fan motor relay Coolant leak Faulty water pump mechanical seal Deteriorated O-rings Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hose COOLING SYSTEM SYSTEM TESTING The engine must be cool before removing the radiator cap: or severe scalding may result. COOLANT (HYDROMETER TEST) Remove lhe right middle cowl (page 3-7). Remove the radialor cap [1]. Test the coolant gravity using a hydromeler [1] (see below lor “Coolant gravity chart”). For maximum corrosion protection. a 50 — 50 % solution 0! ethylene glycol and distilled water is recommended (page 7-5). Look for contamination and replace the coolant if necessary. COOLANT GRAVITY CHART Coolant temperature °C °F) 0 5 10 15 20 25 30 35 40 45 50 (32) (41) (50) (59) (68) (77) (86) (95) (104) (113) (122) 5 1.009 1.009 1.008 1.003 1.007 1.006 1.005 1.003 1.001 0.999 0.957 10 1.018 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 1.025 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 B 25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025 g 30 1.053 1.052 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.032 g 35 1.063 1.062 1.060 1.058 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 0 45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054 50 1.086 1.084 1.082 1.030 1.077 1.074 1.071 1.068 1.065 1.062 1.059 55 1.095 1.093 1.091 1.088 1.035 1.082 1.079 1.076 1.073 1.070 1.067 60 1.100 1.098 1.095 1.092 1.069 1.086 1.033 1.080 1.077 1.074 1.071 7-4 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 74). Before installing the Pressure test the radiator cap [1]. cap in the fester12], Replace the radiator cap if it does not hold pressure. or wet the sealing ii relief pressure is too high or too low. surfaces. It must hold the specified pressure for at least six .. seconds. RADIATOR CAP RELIEF PRESSURE: 108 - 137 ItPa(1.1—1.4 kgflcm’, 16 - 20 psl) Pressure test the radiator, engine and hoses. and check for leaks. NOTICE Excessive pressure can damage the cooling system components. Do not exceed 137 kPa (1.4 kgf/cm’, 20 psi). Repair or replace components ifthe system will not hold the specified pressure for at least 6 seconds. COOLANT REPLACEMENT PREPARATION - The eflectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore. tor best "" performance change the coolant regularly as ANT'FREEZE specified in the maintenance schedule. SOLUTION I O Mix only distilled. low mineral water with the W antifreeze RECOMMENDED ANTIFREEZE: (ETHYLENE Low MINERAL Pro Honda HP coolant or equivalent high quallty GLVCOL BASE OR DISTILLED ethylene glycol antifreeze containing silicate-free SOLUTION) WATER corrosion Inhibitors RECOMMENDED MIXTURE: 1 : 1 (distilled water and antifreeze) COOLANT COOLING SYSTEM REPLACEMENT/AIR BLEEDING NOTE: Refer to procedure for the radiator reserve tank removal/installalion (page 7—12). Remove the following: — under cowl (page 3-6) — right middle cowl (page 3-7) Remove the radiator cap. Remove the drain bolt [1] and sealing washer [2] on the water pump cover and drain the system coolant. Reinstall the drain bolt (water pump Dover bolt) with a new sealing washer. TORQUE: 13 Min (1.3 kgf-m, 10 "19“) Whenever checking Fill the system with the recommended coolant through orsdding coolant to the filler opening up to filler neck [1]. the system, place the motorcycle in a vertical position on V_ _. a flat, level surface. Remove the radiator reserve tank cap [1] and till the reserve tank to the upper level line (page 4-15). Bleed air lrorn the system as lollows: 1. Shin the transmission into neutral. Start the engine and let it idle for 2 — 3 minutes. 2. Snap the throttle 3 — 4 times to bleed air from the system. 3. Stop the engine and add coolant up to the proper level it necessary. Reinstall the radiator cap. 4. Check the level 0! coolant in lhe reserve tank and fill to the upper level if it is low. COOLING SYSTEM THERMOSTAT REMOVAL/lNSTALLATlON Drain the coolant (page 7—6). Remove the throttle body (page 6-71), Disconnect the ECT sensor 3P (Gray) connector [1]. Disconnect the breather hose [2] from the thermostat cover. Remove the bolts [3] and thermostat cover [4]. Remove the thermostat [1] and washer [2] trom the upper crankcase. At the installation of the thermostat, turn the bleeding plug [1] in the direction as shown. Install a new Orring [1] into the groove of the thermostat cover [2]. install the removed parts in the reverse order of removal. COOLING SYSTEM Do not let the then-nostat or thermometer touch the pan, or you will get 3 [else reading. INSPECTION Visually inspect the thermostat [1] tor damage. Check the seal ring [2] for deterioration or damage. Wear Insulated gloves and adequate eye protection. Keep flammable materials away trom the electric heating element Heat the water with an electric heating element to operating temperature for 5 minutes. Suspend the thermostat [1] in heated water to check its operation. Replace the thermostat if the valve stays open at room temperature, or if it responds at temperatures other than those specflied. THERMOSTAT BEGIN TO OPEN: 80 -— 84°C (176 — 183°F) VALVE LIFT: 8 mm {0.3 In) mlnlmum at 95°C (203°F) CYLINDER HEAD BLEEDING JOINT REMOVALIINSTALLATION Remove the throttle body (page 6—71). Disconnect the air bleed hose [1] from the cylinder head bleeding joint [2L Remove the bleeding joint and sealing washer [3], Clean the threads of the bleeding joint and apply a _ ' locking agent. Install the bleeding joint with a new sealing washer‘ TORQUE: 12 Nm (1.2 kgi~m, 9 lbf-ft) Connect the air bleed hose to the bleeding joint securely. Install the throttle body (page 6-76) [1] 7-8 COOLING SYSTEM IN SPECTION Check the bleeding joint for clogs. NOTE: - Air can be easily passed in both direction of the bleeding joint. - Water can be easily passed in the direction of the arrow. and is difficult to pass in the opposite direction, RADIATOR REMOVAL/INSTALLATION Remove the following: — under cowl (page 3-6) — inner lower cowl (page 345) — right and left middle oowls (page 3:!) Drain the coolant (page 7—6). Disconnect the right fan motor 2P (Black) connector [1]. Remove the CKP sensor 2P (Black) connector [2] from the fan motor shroudt Loosen the hose band screws and disconnect the filler neck joint hose [3] and right radiator hose [4]. Disconnect the left fan motor 2P (Black) connector [1]. Loosen the hose band screw and disconnect the left radiator hose [2]. Remove the radiator right mounting bolt [1]. COOLING SYSTEM Remove the radiator left and upper mounting bolts [1]. Remove the wire clip [1] from the fan motor shroud. Be careful not to Release the upper mount grommel [2] from the boss demagerhe radiator and then remove the radiator [3]. Com. install the radiator in the reverse order of removaL NOTE: ' Route the wires and hoses properly (page 1-22). - Set the boss in the radiator grommet securely. ' Tighten the hose band screws as shown. Fill and bleed the cooling system (page 7-5) Install the following: — right and left middle oowls (page 3~7) — inner lower cowl (page 3—6) — under oowl (page 3—6) (_\ r0—1.0mm(0—0.04in) D ISASSEMB LY Remove the bolts [1] and fan motor shroud [2], [2] 7-10 COOLING SYSTEM Remove the nut [1] and cooling fan [2] from the fan motor. [2] & Remove the fan motor 2P (Black) connector [1] from the fan motor shroud tab. [1] V Remove the mounting bolts [1] and fan motor [2]. Remove another fan motor in the same manner. 7-11 COOLING SYSTEM ASSEMBLY RAD] 5.1 N~m (0.5 kgf~m. 3.8 lbf-fl) QM 2.7 N-m (0.3 ngm, 2.0 lhf-fl) FAN MOTOR SHROUD z. ATOR I COOLING FAN 8.4 N‘m (0.9 kgf-m. 6.2 lbf-fl) FAN MOTOR Assembly is in the reverse order of disassembly. N 0T E: Nole the installation direclion of me fan motor wire. TORQUE: Fan molar mounting hon: 5.1 N-m (0.5 kgf-m, 3.8 lbf-fl) Cooling Ian nut (apply a locking agent): 2.7 N-m (0.3 kghn, 2.0 lbf-lt) Fan motor shroud mounting bolt: 3.4 N-m (0.9 kgrm, 3.2 Ibf-ft) RADIATOR RESERVE TANK REMOVALIINSTALLATION Remove the swingarrn (page 16-12). Remove the radialor reserve tank mounting bolt [1]. Pull the reserve tank boss [2] from the frame and drain the coolant from the liller neck. Disconnect the siphon hose [3] and overflow hose [4] from the reserve tank [5]. 7-12 COOLING SYSTEM Installation is in the reverse order of removal. Fill the system with the recommended coolant to the upper level line (page 75) Install the reserve tank cap [1], lnstall the swingarm (page 16-19). WATER PUMP MECHANICAL SEAL INSPECTION Remove the under cowl (page 3—6). Check the bleed hole [1] of the water pump tor signs of coolant ieakage. NOTE: - A small amount of coolant weeping from the bleed hole is normalt - Make sure there is no continuous coolant leakage from me bleed hole while the engine is winning Replace the water pump as an assembly if necessary, REMOVAL Drain the coolant (page 7—6). Loosen the hose band screws and disconnect the water hose [1], water bottom hose [2], radiator hose [3] and oil cooler hose [4]. Remove the following: — cover bolts [1] and sealing washer [2] — water pump mounting (small head) bolts [3] — water pump cover/body [4] COOLING SYSTEM INSTALLATION Apply engine oil to a new 0 and socket bolt. Tighten the socket bolt to the specified torque. TORQUE: 12 N'm (1.2 kgf'm, 9 "9"!) Apply a locking agent to the threads of the tensioner V base special bolt [5] (page M 9). Align the bolt holes and install the tensioner base special bolt. Tighten the bolt to the specified torque. TORQUE: 10 Nm (1.0 kgf-rn, 7 Ibf-ft) Install the front cam chain guide [1]. Set the groove on the cam chain guide to the guide [2] on the crankcase and align the lugs [3] with the grooves on the crankcase. Install the following: — primary drive gear (page 10-31) — cylinder heads (page 9-30) 9-33 MEMO 10. CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION ........................ "10.2 SERVICE |NFORMAT|ON ......................... "10.4 TROUBLESHooTING ............................... "10.5 CLUTCH FLUID REPLACEMENT] AIR BLEEDmG ........................ "10.5 CLUTCH MASTER CYLINDER ----------------- "10-7 CLUTCH SLAVE CYLINDER“ ---- “10-11 RIGHT CRANKCASE COVER REMOVAL"" "1043 CLUTCH .................................................. "1044 GEARSHIFT LINKAGE ------- -- "10-25 m PRIMARY DRIVE GEAR ------------------------- “10-30 RIGHT CRANKCASE COVER INSTALLATION ...................................... ..10_32 10-1 CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 1 lbf-fl) g 98 NM (10.0 kgf-m, 72 Ibl-ft) . . 10-2 CLUTCH/GEARSHIFT LINKAGE 1.5 Ntm (0.2 kgl-m. 1.1 Ibf‘fl) 12 N-m (1.2 kgf-m, 9 lbf-ft) Wfi 34 Nm (3.5 mm. 25 lbf-fl) 12 N-m (1.2 kgf-m, 9 lbf-fl) 34 N~m (3.5 kgflm. 25 mm) 10-3 CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL NOTICE Spilled clutch (brake) fluid will severer damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal first. This section covers service of the dutch. primary drive gear and gearshifl linkage. All service can be done with the engine installed in the frame. DOT 4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in this section. Do not use other types of fluid as they are not compatible. Never allow contaminants (dirt, water. etc.) to get into an open reservoir. Once the hydraulic system has been opened. the system must be bled. Always use fresh DOT 4 brake fluid lrom a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible. Engine oil viscosity and level and the use of oil additives have an effect on clutch disengagement. Oil additives of any kind are specifically not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch lever tully activated. inspect the engine oil viscosity and level before servicing the clutch system. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Specified clutch fluid DOT 4 brake fluid — Clutch master cylinder LD. 12.700 — 12.743 (0.5000 — 0.5017) 12.755 (0.5022) Clutch master piston O.D. 12.657 —- 12.684 (0.4983 — 0.4994) 12.645 (0.4978) Clutch Spring tree height 6.70 (0.264) 5.70 (0.224) Disc thickness Disc A, C 3.22 — 3.38 (0.127 — 0.133) 3.1 (0.12) Disc B 3.72 — 3.88 (0.146 — 0.153) 3.6 (0.14) Plate warpage — 0.30 (0.012) Clutch outer guide I.D. 28.000 — 28.021 (1.1024 — 1.1032) 28.030 (1.1035) O.D. 34.975 — 34.991 (1.3770 — 1.3776) 34.965 (1.3766) Oil pump drive sprocket ID. 35025 — 35.145 (1.3789 —1.3837) 35.155 (1.3841) Mainshafl OD. at Clutch outer guide 27.980 — 27.990 (1.1016 — 1.1020) 27.96 (1.101) TORQUE VALUES Clutch center lock nutr Change guide plate bolt Shift drum oenter pin bolt Gearshitt spindle return spring pin Right crankcase cover rubber plate bolt CKP sensor rotor/primary drive gear flange bolt Gearshift spindle plate bolt Oil pump driven sprocket bolt Clutch slave cylinder mounting bolt Clutch slave cylinder bleeder screw Clutch hose oil bolt Clutch master cylinder reservoir cap SUSW Clutch master cylinder holder bolt Clutch lever pivot bolt Clutch lever pivot nut Clutch lever switch screw Gearshift arm pinch boll Oil pump chain guide bolt Gearshift pedal pivot bolt 186 NM (19.0 kgtvm. 1 37 lbt~fl) 12 N-m (1.2 kgt~m, 9 lbf-lt) 23 N~m (2.3 kgt-m. 17 lbf-ft) 23 N~m (2.3 kgf-m, 17 lbt-ft) 12 Nm (1.2 kgt-m, 9 Ibf'tt) 93 N-m (10.0 kgf-m. 72 mm) 12 N~m (1.2 kgt-m, 9 Ile) 15 Nm (1.5 kgtrm. 11 lefl) 12 Nm (1.2 kgt-m. 9 Ibf'tl) 9.0 N~m (0.9 kgf~m. 6.6 leI) 34 Nm (3.5 kgtrm, 25 Ibf1fl) 1.5 N~m (0.2 kgf'm. 1.1 lbt-ft) 12 N-m (1.2 kgi-m, 91111-11) 1.0 NM (0.1 kgt-m, 0.7 10111) 5.9 N'm (0.6 kgr-m, 4.4 lbf-ft) 1.2 N-m (0.1 kgf-m.0.9|bt1ft) 10 N‘m (1.0 kgt«m,7lbf‘1't) 12 Nm (1.2 kgt1m.9lbt-tt) 22 Nm (2.2 (gm, 1s lbf'tt) Apply oil to the thread and flange surface. Stake the nut. Apply a locking agent to the threads. Apply a locking agent to the threads. Apply a locking agent to the threads. Apply oil to the threads and seating surface. Left-hand threads Apply a locking agent to the threads. Apply a locking agent to the threads. ALOC bolt: replace with a new one. Apply a locking agent to the threads. 10-4 CLUTCH/GEARSHIFT LINKAGE TOOLS Clutch center holder Snap ring pliers Gear holder, M2.5 070MB-MFL0100 07914~SA50001 07724-0010100 l i l or 070MB-MFLA1OO (U.SrA, only) or O7724—001A100 (USA only) TROUBLESHOOTING clutch lever soft or spongy ‘ Air in hydraulic system - Law fluid level - Hydraulic system leaking Clutch lever hard to pull In - Slicking master cylinder piston - Sticking slave cylinder piston . Clogged hydraulic system . Damaged clutch litter mechanism - Faulty clutch liner bearing - Clutch lifter piece installed improperly clutch slips when accelerating - Slicking master cylinder piston Sticking slave cylinder piston Clogged hydraulic system Worn clutch disc Weak clutch spring Engine oil mixed with molybdenum or graphite additive clutch wlll notrdisengage or motorcycle creeps wlth the clutch lever iully activated Air in hydraulic system Low clutch fluid level Hydraulic system leaking or clogged Clutch plate warped Loose clutch center lock nut Oil level too high Improper oil viscosity or oil addifive used Damaged clutch lifter mechanism Clutch lifter piece installed improperly Hard to shift - Improper clutch operation ' Improper oil viscosity 10-5 CLUTCH/GEARSHIFT LINKAGE CLUTCH FLUID REPLACEMENT/AIR BLEEDING CLUTCH FLUID DRAINING Turn the handlebar to the right until the reservoir is parallel to the ground, before removing the reservoir cap. Remove the screws [1]. reservoir cap [2]. set plate [3] and diaphragm [4]r Connect a bleed hose [1] to the bleed valve [2] of the clutch slave cylinder. Loosen the bleed valve and pump the clutch lever until fluid stops flowing out of the bleed valve. CLUTCH FLUID FILLING/BLEEDING Close the bleed valve. Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder [1] to the bleed valve [2]. If air is entering the Operate the brake bleeder and loosen the bleed valve. b’eede’m’m - Check the fluid level oflen while bleeding the clutch amund the bleed . . . valve mleads'seel to prevent an from bemg pumped Into the mullingfiyg' - When using a brake bleeding tool, follow the p ‘ manufacturer‘s operating instruction. If an automatic refill system is not used, add brake fluid when the fluid level in the reservoir is low. Repeat the above procedures until new fluid flows out of the bleed valve and air bubbles do not appear in the plastic hose. Close the bleed valve. TORQUE: 9.0 MM (0.9 kgf-m, 6.6 Ibf-ft) 10-6 Do not allow foreign material to enter the system when filling the reservoir. It a brake bleeder is not available, use the following procedure. Pump the clutch lever until lever resistance is felt. Connect a bleed hose [1] to the bleed valve [2] and bleed the system as follows: 1. Squeeze the clutch lever. open the bleed valve 114 of a turn and then close it. Do not release the clutch lever until the bleed valve has been dosed. 2. Release the clutch lever slowly and wait several seconds after it reaches the end oi its travel. Repeat steps 1 and 2 until air bubbles do not appear in the bleed hose. Tighten the bleed valve to the specified torque. TORQUE: 9.0 N-m (0.9 kgf'm, 6.6 Ibf‘ft) Fill the reservoir to the casting ledge with DOT 4 brake fluid from a sealed container. Install the diaphragm [1]. set plate [2] and reservoir cap [3]. and tlghten the cap screws [4] to the specified torque. TORQUE: 1.5 N-m (0.2 kgf-m. 1.1 Ibf'ft) Check the clutch operation (page #25). CLUTCH MASTER CYLINDER Avoid spilling fluid on painted, plastlc. or rubber pans. Place a shop towel over these parts whenever servicing the system. RE MOVAL Drain the clutch hydraulic system (page 10-6). Remove the float [1] from the master cylinder. ' Disconnect the clutch switch wire connectors [2]. Remove the clutch hose oil bolt [3] and sealing washers [4], then disconnect the clutch hose [5], Remove the holder bolts [1], holder [2] and clutch master cylinder [3]. CLUTCH/GEARSHIFT LINKAGE CLUTCH/GEARSHIFT LINKAGE DISASSEMBLY Remove the nut [1], pivot bolt [2] and clutch lever assemblyml Remove the screw [1] and clutch switch [2], Remove the boot [3] and push rod [4]. Remove the snap ring [1] from the master cylinder body using the special tool as shown, TOOL: Snap ring pliers [2] 01914-SA50001 Remove the master piston assembly and spring from the master cylinder‘ Clean the inside of the cylinder and reservoir with brake fluid. INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder I.D. SERVICE LIMIT: 12.755 mm (0.5022 in) Measure the master piston OD. SERVICE LIMIT: 12.645 mm (0.4973 In) [2] [4] \ 10-8 CLUTCH/GEARSHIFT LINKAGE ASSEMBLY 1t0 N-m (0.1 Iggf‘m, 0.7 lbf-I’t) xfil MASTER CYLINDER SNAP RING SPRING J PUSH ROD MASTER PISTON JOINT PIECE CLUTCH LEVER SWITCH 1.2 N-m (0.1 kgI-m. 0.9 lbl-R) CLUTCH LEVER 5.9 N‘m (0.6 kgf-m, 4.4 lbI-fl) ,fil BOOT Coat the master piston and piston cups with clean brake fluid. Install the spring [1] to the master piston [2]. [3] i o>& I2] [1] When install/Hg the cups, do not allow the lips to (ya; inside out. Install the spring and master piston assembly into the master cylinder [3]. Be certain the snap Install the snap ring [1] using the special tool. ring is firmly seated in the groove, [1] TOOL: Snap ring pliers [2] 07914«SA50001 10-9 CLUTCH/GEARSHIFT LINKAGE Apply silicone grease to the boot inside. lip of the push rod and master piston end. Install the push rod [1] and boot [21‘ Install the clutch switch [1] by aligning its boss [2] with the hole [3] on the master cylinder. Install and tighten the screw to the specified torque. TORQUE: 1.2 N-m (0.1 kgf-m, 0.9 lbf-ft) Apply silicone grease to the top of the push rod [1]. Install the joint piece [2] into me clutch lever [3]. Install the clutch lever assembly [3] by aligning the hole of the joint piece [2] with the tip of the push rod [1L Apply silicone grease to the clutch lever pivot bolt sliding surface. install and tighten the pivot bolt [1] to the specified torque. TORQUE: 1.0 N-m (0.1 kgf-m, 0.1 let) Install the pivot nut [2]. Hold me pivot bolt and tighten the pivot nut to the specified torque. TORQUE: 5.9 NM (0.6 Kgf~m, 4.4 Ibf-ft) 10-10 Install the master cylinder holder with its "UP" mark facing up. INSTALLATION Install the master cylinder [1], holder [2] and holder bolts [3], Align the end of the master cylinder with the punch mark [4] on the handlebar. Tighten the upper bolt first, then the lower bolt. TORQUE: 12 N-m (1.2 kgi-III, 9 lbf'ft) Connect the clutch hose [1] with the oil bolt [2] and new sealing washers [3]. While pushing the clutch hose stopper [4] against the master cylinder body. tighten the oil bolt to the specified torque. TORQUE: 34 N1“ (3.5 kgf-m. 25 Ibf‘fl) Connect the clutch switch connectors [51. ‘ Install the float [6] into the master cylindert Fill the reservoir to the upper level and bleed the hydraulic system (page 10-6). CLUTCH SLAVE CYLINDER Avoid spilling fluid on painted, plastic, or rubber parts. Place a shop towel over these parts whenever servicing the system. DO not use high pressure air or bn'ng the nozzle (0 close (0 the inlet. REMOVAL Drain the clutch hydraulic system (page 10-6), Remove the hose oil bolt [1], sealing washers [2] and clutch hose eyelet [3]. Remove the bolts [4] and clutch slave cylinder assembly [5]. Remove the gasket and dowel pins. DISASSEMBLY Plaoe a shop towel over the piston. Position the slave cylinder body with the piston down and apply small squirts oi air pressure to the fluid inlet to remove the piston. Remove the slave cylinder piston and spring CLUTCH/GEARSHIFT LINKAGE 10-11 CLUTCH/GEARSHIFT LINKAGE INSPECTION Check the piston spring [11for weakness or damage. Check the slave cylinder [2] for scoring or other damage Check the slave cylinder piston [3] Ior scratches, scoring or other damages ASSEMBLY Apply silicone grease to new oil seal lip and install the oil seal [1] into the piston. Apply clean brake fluid to the piston outer surface. Apply silicone grease to new O-rings [2] and install them into the piston grooves Install the spring [1] to the boss of the piston [2]. Install the spring and piston min the slave cylinder [3]. IN STALIATION Install the dowel pins [1] and a new gasket [2]. Apply silicone grease to the top of the push rod [3]. [2] [3] [2] 10-12 Install the slave cylinder [1] onto the crankcase, Install the mounting bolts [2] and tighten them to the specified torque TORQUE: 12 N-m (1.2 ngM, 9 lbf-f!) Install the clutch hose eyelet with the oil bolt [3] and new sealing washers [4]. While pushing the clutch hose [5] against the stopper and tighten the oil bolt to the specified torque. TORQUE: 34 N-m (3.5 kgf‘m, 25 Ibf-ft) Fill the reservoir to the upper level and bleed the hydraulic system (page 10-6). RIGHT CRANKCASE COVER REMOVAL Remove the following: — under cowl (page 36) — right middle oowl (page 3-7) Drain the engine oil (page 4-13), Suppomhe right Remove the bolts [1], under cowl stay [2] and right crankcase coverso crankcase cover [3]. that it does not hang from the CKP sensor wire. Remove the dowel pins [1]. Reler to procedure lor the CKP sensor removal/ installation (page 20—8). RIGHT CRANKCASE COVER RUBBER REPLACEMENT Remove the crankcase cover from the CKP sensor (page 20-8). Remove the bolts [1], plate A [2], rubber A [3], plate B [4] and rubber B [5]. Install the rubber A. plate A, rubber B and plate B onlo the right crankcase cover. Apply a locking agent to the threads of the rubber plate bolts (page 1-19). Install the plate bolts and tighten them to the specified torque TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-fl) CLUTCH/GEARSHIFT LINKAGE CLUTCH/GEARSHIFT LINKAGE CLUTCH REMOVAL Remove the right crankcase cover (page 10-13; If the oil pump chain and sprockets will be removed, loosen the oil pump driven sprocket bolt [1]. Remove the snap ring [1] and clutch litter seal [21‘ Remove the clutch lifter plate/liner beefing [3]. lifter piece [4] and lifler rod [5]. Be carsfll/natto Unstake the clutch center lock nut [11‘ damage the mainshafr threads. Hold the pressure plate [1] with the special tool and remove the clutch center lock nut [2] and washer [3]. TOOL: (Hutch center holder [4] 07DMB-MFL0100 or 070MB-MFLA1OD (U.S.A. only) 10-14 CLUTCH/GEARSHIFT LINKAGE Remove the clutch spring holder [1], clutch spring seat B [2] and clutch springs [3]. Remove the clutch spring seat [11‘ Remove the pressure plate [2], clutch discs [3], clutch plates [4], judder spring [5] and spring seat [6]. Remove the clutch center [1] and thrust washer [2]. To align the sub-gear teeth with the primary drive gear teeth beiore removing the clutch outer. temporarily install a suitable socket bolt (6 x 10 mm) [1] to the primary drive gear, and then tighten it securely to retain the sut‘rgear. NOTE: For ease of the clutch outer installation, do not remove the socket bolt. 10-15 CLUTCH/GEARSHIFT LINKAGE Remove the clutch outer [1] and needle bearing [2]. Remove the bolt [1] and oil pump chain guide [2]. Remove the oil pump driven sprocket bolt [1], Remove the oil pump drive sprocket [2], driven sprocket [3] and drive chain [4] as an assembly. Remove the clutch outer guide [5]. INSPECTION Clutch litter bearan Turn the inner race of the lifter bearing [1] with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate. Replace the bearing if the Inner race does not turn smoothly, quietly, or it the outer race fit loosely in the pressure plate 10-16 Replace the clulch springs as a sat. clutch lifter rod Check the clutch liner rod [1] for bending or damage. clutch spring Check the clutch spring [1] (or damage or distortion. Measure the height 0! the clutch spring. SERVICE LIMIT: 5.70 mm (0.224 in) Clutch center Check the clutch center cogs [1] for wear or damage. Check the grooves [2] for nicks. indentations or abnormal wear made by the clutch plates. Check the rivets [3] and stopper ring [4] for loosening. CLUTCH/GEARSHIFT LINKAGE l1] [1] 10-17 CLUTCH/GEARSHIFT LINKAGE Clutch pressure plate check the pressure plate cogs [1] for wear or damage. [1] Check the grooves [2] for nicks, indentations or abnormal wear made by the clutch plates. [3] Check the rivets [3] for loosening. [2] Clutch disc Juddar springlsprlng seat Replace lhe clutch Replace the clulch disc if they show signs of scoring or Check the judder spring [1] and spring seat [2] for wear [1 discs and plates as discoloration. or other damage. replace if necessary ]\ a 59" Measure the disc thickness of each disc SERVICE LIMITS: Disc NO: 3.1 mm (0.12 In) Disc B: 3.6 mm (0.14 In) Clutch plate Replace the clutch Check each disc plate for warpage on a surface plate discs and plates as using a feeler gauge. a set, SERVICE LIMIT: 0.30 mm (0.012 in) Replace if necessary. [2] 10-18 Clutch outer/needle bearing Check the slots [1] of the clutch outer Ior damage or wear caused by the clutch discs. Check the primary driven gear [2] for wear or damage. Replace if necessary. Check the clutch outer needle bearing [1] tor wear or damage. replace if necessary, Clutch outer guideloll pump drlve sprocket Measure the ID. of the clutch outer guide [1]. SERVICE LIMITS: I. 28.030 mm (1.1035 In) O.D 34.965 mm (1.3768 in) Check the oil pump drive sprocket teeth for wear or damage. Measure the ID. of the oil pump drive sprocket [2], SERVICE LIMIT: 35.155 mm (1.3341 in) Malnshaft Measure the mainshafl 0.0. at the clutch outer guide. SERVICE LIMIT: 21.96 mm (1.101 in) CLUTCH/GEARSHIFT LINKAGE I1] CLUTCH/GEARSHIFT LINKAGE Oll pump chaln gulda Check the oil pump chain guide [1] for excessive wear or damage, replace iI necessary. I1] INSTALLATION L T H PRING HOLDER C U c S CLUTCH SPRINGS SPRING SEAT LIFI’ER PLATE LIFTER PIECE OIL PUMP CHAIN GUIDE SPRING SEAT B CLUTCH LIFI'ER SEAT ® SNAP RING LIFTER ROD d 186 Mm (19.0 WM“, 137 lbf-l'l) OUTER GUIDE OIL PUMP CHAIN/ SPROCKETS 7a em 15 N-m (1.5 kgf‘m, NEEDLE BEARING 11 Ibm) CLUTCH CENTER] PRESSURE PLATE ASSEMBLY THRUST WASHER lnstall the clutch outer guide [1] onto the mainshaft‘ Install the driven Install the oil pump drive sprocket [2], driven sprocket sprocket with its [3] and oil pump chain [4] as an assembly. "OUT. ma’kw] Apply a locking agent to the threads of the oil pump lacing out and align » _ (he I,“ 0mg she” drrven sprocket bolt [5] (page 1 19). and sprocket, Tighten the driven sprocket bolt to the specified torque. YORQUE: 15 N-I'n (1V5 kgf-m, 11 Ibf-fl) 10-20 CLUTCH/GEARSHIFT LINKAGE Install the oil pump chain guide [1] by aligning its cut~out with the boss [2] on the crankcase. Apply a locking agent to the threads of the oil pump chain guide bolt [3] (page 1-19). Install and tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 ngm, 9 Ile) Lubricate the sliding surfaces between the clutch ouler and primary driven gear with molybdenum disulflde oil, Install the clutch outer [1) onto the mainshaft and align the holes on the outer with the bosses on the oil pump drive sprocket [2]t Apply engine oil to the needle bearing [1]. Install the needle bearing into the clutch outer. Remove the socket bolt [1] from the primary drive sub- geaL Do not forget to remove the socket bolt after installing the clutch outer, 10-21 CLUTCH/GEARSHIFT LINKAGE lnstall the thrust washer [1]t clutch discs/plates assemny DISC B JUDDER SPRING CLUTCH (Black) CENTER DISC C (Blue) DISC A (Green) PRESSURE PLATE NOTE: Replace the clutch discs/plates as an assembly, Coat the clutch discs and plates with clean engine oil. Stack the clutch Install the following onto the clutch center. dlscs and plates as spring seat 5mm" judder spring clutch disc B (large I.D.) clutch plate B seven clutch discs C seven clutch plates A and C clutch disc A lDENTlFlCATlON OF CLUTCH DISC: O Clutch disc A: Green paint on the tab ' Clutch disc B: Black paint on the tab (large I,D,) - Clutch disc 0: Blue paint on the lab IDENTIFICATION OF CLUTCH PLATE: ~ Clutch plate A: Silver (thin) - Clutch plate B: Gray (thick/thin) ' Clutch plate C: Silver (thick) I l 10-22 CLUTCH/GEARSHIFT LINKAGE Install the pressure plate [1] while aligning the clutch plates with the grooves of the pressure plate, and engage the cogs [2] of the pressure plate and clutch center. For ease of the clutch center/pressure plate installation, 2 temporarily install suitable bolts (6 x 35 mm) [1] to the l 1 pressure plate [2] loosely. Clutch center/pressure plate/clutch spring installation Install the clutch center/pressure plate assembly [1] by aligning the clutch disc tabs with the grooves of the clutch outer one by one. Install the tabs 0! the clutch disc A into the clutch outer shallow slots [2] as shown. Remove the temporarin installed 6 mm bolts [3]. Do not forget to remove the 6 mm bolts after installing the clutch center/pressure plate assembly. Install the clutch spring seat [1] with its ooncave side (black paint) [2] facing out. 10-23 CLUTCH/GEARSHIFT LINKAGE Install the clutch springs [1], spring seat B [2] and clutch spring holder [3]. NOTE: Be certain to align the splines of the clutch spring holder with the mainshafl. Apply clean engine oil to the thread and seating surface ot a new clutch center lock nut [1). Install the washer [2] and clutch center lock nut. Hold the pressure plate [3] with the special tool, then tighten the lock nut to the specified torque. TOOL: Clutch center holder [4] 070MB-MFL0100 Dr 070MB-MFLA1 00 " (U.S.A. only) TORQUE: 136 N-m (19.0 kgf~m, 137 lbffl) NOTE: Hold the clutch center holder securely so that the centers of the mainshatt and pressure plate should not be misaligned. or installation of the clutch lifter/litter piece becomes difficult Be careful not to Stake the lock nut [1] into the mainshatt groove with a damage the punch. mainslvafl.‘ threads. Install the clutch lifler rod [1]. 10-24 CLUTCH/GEARSHIFT LINKAGE Install the lifter bearing [1] into the clutch liner [2]. Install the clutch litter piece [3] into the Iifler bearing‘ Install the clutch lifter plate/lifter piece [1], Afferinstallingme Install the clutch litter seat [2] and snap ring [3] snap n'ng, always securely. mlelen‘musgroove NOTE: to be sure it is Iully , I . 595,94 Do not align the snap nng ends With the slots on the pressure plate. Install the right crankcase cover (page 10-32) GEARSHIFT LINKAGE REMOVAL Remove the clutch (page 10-14). Remove the pinch bolt [1] and gearshift arm [2] lrorn the spindle. Remove the gearshift spindle [1] and shifter collar [2]. CLUTCH/GEARSHIFT LINKAGE Remove the bolts [1] and change guide plate/drum shifter assembly [21‘ Remove the following: — shifl dmm center pin [1] shift drum center [2] washer [3] shift drum stopper arm [4] stopper arm collar [5] retum spring [6] dowel pin [7] llllll Remove the dowel pins [1] and shift drum bearing set plate [2]. INSPECTION Remove the drum shifter [1], ratchet pawls [2], plungers [3] and plunger springs [4] from the guide plate [5]. Clean the ratchet pawls. plungers. springs and drum shifter with clean engine oill Check each part for wear or damage‘ [2] [WM] [1] 10-26 CLUTCH/GEARSHIFT LINKAGE Check the gearshift spindle [1] for bend, wear or 1 damage [ I Check the relum spring [2] for fatigue or damage l2] GEARSHIFT SPINDLE OIL SEALINEEDLE BEARING REPLACEMENT Check the following: — gearshift spindle oil seal [1] for deterioration or damage — needle bearing [2] for wear or damage Remove the bolt [3] and spindle plate [4], then replace the oil seal and needle bearing if necessary. Apply grease to new oil seal lip and install the oil seal. Apply a locking agent to the spindle plate bolt threads (page 1-19), Install the spindle plate and bolt, and tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9|I1f-t‘t) INSTALLATION install the dowel pins [1] and shift drum bearing set plate [2], Hook the spring Install the return spring [1]. stopper arm collar [2] and end to the stopper shift drum stopper arm [3]. arm groove. CLUTCH/GEARSHIFT LINKAGE Align the cutout“) Install the shin drum center [2] while holding the stopper on the shit? drum center with the dowel pin. Install the dowel pin [1] into the shift dmm. arm [3] using a screwdrivert Apply a locking agent to the threads of the shifl drum center pin bolt. Install the shift drum center pin bolt and tighten it to the , specified torque. TORQUE: 23 um (2.3 kgf-m, 11 lbt-ft) Assemble the guide plate [1]. drum shifter [2], plunger springs [3], plungers [4] and ratchet pawls A [5] and B [6] as shown, NOTE: Do not interchange the ratchet pawls A and B, [S [6] Install the washer [1] onto the stopper arm collar. Install the change guide plate/drum shifter assembly [2]. Apply a locking agent to the change guide plate bolt threads (page 1-19) Install the change guide plate bolts [3] and tighten them to the specified torque. TORQUE: 12 N-m (1.2 kgf'm, 9 lbf-ft) 10-28 Align the spindle an'n hole with the shifter collar, also the Mum spring ends with the spn'ng pin. Install the shifter collar [1] onto the drum shifter. Install the washer [2] and gearshift spindle [3]. Install the gearshift arm [1] onto the spindle, aligning the slit ol the arm with the punch mark [2] on the spindle. Install new gearshift arm pinch bolt [3] and tighten it to the specified torque. TORQUE: 10 Nm (1.0 kgf-m, 7 lbf-ft) Install the clutch (page 10-20). GEARSHIFT PEDAL REMOVAL] INSTALLATION Remove the gearshift arm from the spindle (page 1045). Remove the pivot bolt [1]. wave washer [2]. gearshift pedal [3] and washer [4]. Apply grease to the gearshift pedal sliding surface of the pivot bolt [1]. Install the washer [2], gearshift pedal [3]. wave washer [4] and pivot bolt. Tighten the pivot bolt to the specified torque. TORQUE: 22 N-m (2.2 kgf'm, 16 lbf-fl) Install the gearshift arm to the spindle with a new pinch bolt (page 10-29). CLUTCH/GEARSHIFT LINKAGE rfim m 1 0-29 CLUTCH/GEARSHIFT LINKAGE PRIMARY DRIVE GEAR Do not remove the 6 mm socket bolt that retains the sub« gear belore removal. Primary drive gear flange boll has left- hand threads. REMOVAL Remove the clutch assemny (page 10—14). Temporarily install the clutch outer and needle bearing onto the mainshaft. Install the gear holder [1] between the primary drlve and driven gears. then loosen the primary drive gear flange bolt [2]. TOOL: Gear holder, M2.5 07724-001010!) or 07724-001A1 00 (U.S.A. only) Remove the flange bolt [2], special washer [3], CKP sensor rotor [4] and primary drive gear/sub-gear [5]. Remove the gear holderl DISASSEMBLYIASSEMBLY Remove the socket bolt [1], then remove the sub—gear [2] and damper springs [3]. Inspect the damper springs [1] for Iatigue or other damage, replace it necessary. [2] [3] Inspect the primary drive gear [2] and sub-gear [3] teeth [or wear or damage, [1] 10-30 CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the damper springs [1] into the primary drive gear [2] grooves. '7i / Apply molybdenum oil solution to the sliding surfaces of the primary drive gear and sub—gear. Align the holes of Install the sub—gear [2] onto the primary drive gear [3]. BI the primer drive gear and subvgear. Install the primary drive gear assembly [1] by aligning its wide groove with the wide tooth on the crankshaft. Temporarin install the primary drive gear bolt [1] and special washer [21 so that the sub-gear does not disengage irom the primary drive gear. Press [he sulrgear Align the sub—gear teeth with the primary drive gear against the primary teeth using a screwdriver. then install the socket bolt drive gearfin-nly. (6 x 10 mm) to the primary drive gear and tighten it securer to retain the sub—gear. Remove the primary drive gear bolt and special washeri Install the CKP sensor rotor [1] by aligning its wide ‘ groove with the wide tooth oi the crankshaft, 1 0-31 CLUTCH/GEARSHIFT LINKAGE Temporarily install the clutch outer and needle bearing. Apply engine oil to the threads and sealing surIace of the primary drive gear bolt [1]. The primary drive Install the special washer [2] and primary drive gear gear bolt has leII- bolt [1]. "‘"d Weed“ Install the gear holder [31 between the primary drive and driven gears as shown. TOOL: Gear holder, M25 0712441010100 or 07724-001A1oo (U.S.A. only) Tighten the bolt to the specified torque. TORQUE: 98 N-m (10.0 kgl‘m, 72 IbNt) Remove the gear holders Donotlorgel to Install the clutch assembly (page 10-20). remove the temporarily installed socket bolt. RIGHT CRANKCASE COVER INSTALLATION Clean the mating surfaces of the crankcase and right crankcase cover, being careIul not to damage theme Dana! apply more Apply sealant (ThreeBond 12073 or an equivalent) to sealant than the right crankcase cover mating sudaces as shown. necessary. Install the dowel pins [1], 1 0-32 CLUTCHIGEARSHIFT LINKAGE Install the right crankcase cover [1]. under cowl stay [2] and cover bolts [3L Tighten the bolls in a crisscross pattern in 2 or 3 steps. Add the recommended type and amount of engine oil (page 4-13). Install the removed pans in the reverse order of removal. 10-33 MEMO 11. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ------------------------ --11-2 ALTERNATOR COVERISTATOR ------------ --11.4 ----11-3 FLYWHEEL ------ -- SERVICE INFORMATION TROUBLESHOOTING -------- -- ---11-3 STARTER CLUTCH 11-11 11-1 ALTERNATORISTARTER CLUTCH COMPONENT LOCATION 11-2 ALTERNATORISTARTER CLUTCH SERVICE INFORMATION GENERAL - This section covers service of the alternator stator, flywheel, starter clutch and starter gears. All service can be done with the engine installed in the frame. ' Refer to procedure for starter motor servicing (page 2145). ' ReIer to procedure for stator inspection (page 19-7). SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear boss O.D4 51.699 — 51.718 (2,0354 — 20361) 51.59 (2,031) TORQUE VALUES Stator socket bolt 12 N-m (1.2 kgf-m. 9 lot-ft) Apply a locking agent to the threads Stator wire holder socket bolt 12 N-m (1.2 kgf-m, 9 lot-fl) Apply a locking agent to the threads, Flywheel flange bolt 137 Mm (14.0 kgl-m, 101 Ibt-ft) Apply engine oil to the threads and seating surface. Starter clutch bolt 16 N-m (1.6 kgf-m, 12 Ibf-fl) Apply a locking agent to the threads. Gearshift arm pinch bolt 10 N-m (1.0 kgt-m, 7 Ibf-fi) ALOC bolt; replace with a new one. TOO LS Flywheel holder Rotor puller 07725—0040001 07733-0020001 or equivalent commercially available or 07933-3950000 (U.S.A. only) A TROUBLESHOOTING Engine does not turn - Faulty starter clutch - Damaged starter reduction gear [flu 11-3 ALTERNATORISTARTER CLUTCH ALTERNATOR COVERISTATOR REMOVAL Remove the following: — under cowl (page 3—6) — battery (page 19—6) Drain the engine oil (page 4-13). Drain the coolant (page 7-6). Remove the pinch bolt [1] and gearshift arm [216mm the gearshift spindle. Remove the bolt [1] and left engine heat guard [2]. Remove the bolts [1] and terminal cover [2]. Remove the terminal bolts [1] and disconnect the alternator wires [2] from the regulator/rectifier. 11-4 ALTERNATOR/STARTER CLUTCH Remove the alternator wire clip [1] from the rear heat guard. Release the alternator wire [1] from the rear fender rib [2]. Loosen the hose band screw [1] and disoonneci the waler hose [2]. Wanamaker Remove the bolts [1], wire clip stays [2] and alternator Dover (stator) is cover [3]. magnetically attracted to the flywheel. be careful during removal 11-5 ALTERNATORISTARTER CLUTCH Remove the dowel pin [1] and oil orifice/O»an [21‘ Check the orifice for clogs. Remove the socket bolt [1] and stator wire holder [2]. Remove the alternator wire grommet [3] lrom the alternator cover [4], Remove the socket bolts [5] and stator [6]. INSPECTION Check the orifices [1] for clogs and clean them if necessary. INSTALLATION Install the stator [1] into the alternator cover [2]. Apply sealant (ThreeBond 1211, 12073 or equivalent) to the wire grommet [3], then install the wire grommet into the alternator cover groove securely. Apply a locking agent to the stator socket bolt threads (page 1-19). Install and tighten the stator socket bolts [4] to the specified torque. ' TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-ft) Apply a locking agent to the wire holder socket bolt threads (page 1-19). install the wire holder [5] and socket bolt [6]. and tighten it to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-fl) 11-6 Be careful not to install the oil on'lice wrong side out, Do no! apply more sealant than necessaly, The altemetor cover (stator) is magnetically attacth to the flywheel, be careful during installation. Clean the mating surfaces at the crankcase and alternator cover, being careful not to damage them. Install the oil orifice [1] with its small I.D. side facing the crankcase. Apply engine oil to new O-n'ng [2] and install it onto the nil orifice [1]. Install the dowel pin [31‘ Apply sealant (T hreeBond 12073 or an equivalent) to the alternator cover mating surface as shown. Be careful not to apply sealant to the orifice hole [1] on the altemetor cover. Install the alternator cover [1]. wire clip stays [2] and alternator cover bolts [3]. Tighten the bolts securelyt Connect the water hose [1] and tighten the hose band screw [2] securely. ALTERNATORISTARTER CLUTCH [1]/[21 (D [21/[3] 11-7 ALTERNATORISTARTER CLUTCH Route the alternator wire properly (page 1-22), Install the alternator wire clip [1] to the rear heat guard. Install the alternator wire [1] in the rear tender rib [2]. Connect the alternator wires [1] to the regulator/rectifier with the terminal bolts [2]. [1]/[2 Install me terminal cover [1] and bolts [2], Tighten the bolts securely. 11-8 ALTERNATOR/STARTER CLUTCH Install the Iefl engine heat guard [1] and lighten the bolt [2] securely. Install the gearshift arm [1] onto the spindle, aligning the slit of the arm with the punch mark [2] on the spindle, Install a new gearshitt arm pinch bolt [3] and tighten it to the specified torque. TORQUE: 10 NM (1.0 kgf~m, 7 Ibf-fi) Install the following: — under oowl (page 3-6) — battery (page 19-6) Fill the crankcase with the recommended engine oil (page 4-13). Fill and bleed the cooling system (page 7—6). FLYWH EEL REMOVAL Remove the alternator cover (page 114). Remove the starter reduction gear [1] and shaft [2]. Hold the flywheel [1] with the special tool and loosen the flywheel flange bolt [2]. TOOL: Flywheel holder [3] 0772543040001 or equivalent com- mercially available Remove the flywheel flange bolt and washer [4]. 11-9 ALTERNATORISTARTER CLUTCH Remove the flywheel [1] using the special tool. TOOL: Rotor puller [2] 07733-0020001 or 079334950000 (U.S.A. only) Check the needle bearing [1] for wear or damage. Refer to inspection for the starter clutch and starter reduction gear (page 11-11). INSTALLATION Apply engine oil to the needle bearing [1) and starter driven gear contacting surface. Clean any oil from the tapered area [2] of the crankshaft and flywheel, Install the flywheel [1] onto the crankshaft. Apply engine oil to the flywheel flange bolt threads and seating surface. Install the Washer [21 and flywheel bolt [3]. Hold the flywheel using the special tool, then tighten the I bolt to the specified torque. TOOL: Flywheel holder [4] 07725-0040001 . or equivalent com- mercially available TORQUE: 137 N-m (14.0 kgf'm, 101 lbf-ftl 11-10 Apply molybdenum oil solution to the starter reduction gear and shafl sliding surface. Inatall the reduction gear [1] and shalt [2]. Install the alternator cover (page 11—6). STARTER CLUTCH REMOVAL Remove the flywheel (page 11-9). Remove the starter driven gear [1] while turning it oountercluokwise. Hold the flywheel [1] with the special tool and remove the starter clutch bolts [2]. TOOL: Flywheel holder [3] 0172543040001 or equivalent com- mercially available Remove the starter clutch assembly from the flywheel. Remnve the one-way clutch from the starter clutch outerr INSPECTION Check the sprag [1] of the one-way clutch for abnormal wear or damage, ALTERNATOR/STARTER CLUTCH » r . IE] . ’ y : [1] 11-11 ALTERNATORISTARTER CLUTCH Check the starter driven gear [1] and starter clutch ouler [Z] for abnormal wear or damage. Measure the starter driven gear boss OD. SERVICE LIMIT: 51.59 mm (2.031 In) Check the starter reduction gear [1] and shaft [2] for abnormal wear or damage. INSTALLATION Install the one-way clutch [1] into the starter clutch outer [2] with the flanged side toward the flywheel. Install the starter clutch assemny onto the flywheel [3]. Apply a locking agent to the starter clutch bolt threads and install the bolts [1] (page 149) Hold the flywheel [2] with the special tool and tighten the bolts to the specified torque, TOOL: Flywheel holder [3] 077250040001 or equlvalent com- mercially available TORQUE: 16 N-m (1.6 kgt-rn, 12 lbf-ft) [1] l2] [1] l2] an [1] [2! 11-12 Install the slaner driven gear [1] while turning it counterclockwise. Make sure that the starter driven gear (urns counterclockwise smoome and does not (um clockwise. Install the flywheel (page 11-10), ALTERNATOR/STARTER CLUTCH 11-13 MEMO 12. CRANKCASEITRANSMISSION. COMPONENT LOCATION ........................ ..12_2 > SERVICE INFORMATION ------------------------- --12-3 TROUBLESHOOTING ............................... "12,5 s|DE GEAR CASE .................................... "12.5 CRANKCASE SEPARATION ----------------- --12-14 TRANSMHSSION ..................................... .. 124 5 SHIFT FORKS/SHIFT DRUM ------------------ --12-21 CRANKCASE ASSEMBLY --------------------- -~12-23 1 2-1 CRANKCASEITRANSMISSION COMPONENT LOCATION 25 N-m (2,5 kgi-m. 18 Ibf-fl) + 270° 24 Nm (2.4 kgf-m. 13 mm) 12 Ntrn (1.2 kgr-m, 9 mm) ?? F 32 N-m f0 (3.3 kgf‘m. 24 lbf-n) ‘ (6.8 kgrm, 49 Ith) 24 N-m (2‘4 kgf-m. 1B IbY-fl) 12-2 CRANKCASEITRANSMISSION SERVICE INFORMATION GENERAL The main Journal 9 mm bolts are tightened using the Plastic Region Tightening Method. Always use new main journal 9 mm bolts when assembling. The main journal 9 mm bolt is precoated with an oil additive for axial tension stability. Do not remove the oil additive from the new 9 mm bolt surface. Must be follow the tightening procedure for crankcase bolt tightening (page 12-23). The crankcase must be separated to service the following: — Crankshaft (page 13-5) — Piston/connectlng rod (page 13-13) — Transmission (page 12-15) The following components must be removed before separating the crankcase: — Carn chain tensioners (page 9-31) — Clutch (page 10-14) — Cylinder head (page 920) — Engine (page 8-4) — EOP sensor (page 22-16) — Flywheel (page 11-9) — Gearshift linkage (page 10-25) — Oil pump (page 57) — Side gear case (page 12-6) — Starter motor (page 21-6) — Thermostat (page 7-7) — Water pump (page 7»1 3) Be carelul not to damage the crankcase mating surlaoes when servicing. Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe ofl excess sealant thoroughly. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear LD. M5. M6 31.000 — 31.025 (1.2205 - 1.2215) 31.04 (1.222) 01 35.000 - 35.025 (1.3780 — 1.3789) 35.04 (1.330) C2 30000—30021 (1.1811 —1.1819) 30.04 (1.183) C3. C4 33.000 — 33.025 (1.2992 —1.3002) 33.04 (1301) Gear busing OD. M5 30.955 — 30.980 (1.2187 — 1.2197) 30.935 (1.2179) M6 30950—30975 (1 .2185— 1.2195) 30.93 (1.218) CS. C4 32.950 — 32.975 (1.2972 —1.2982) 32.93 (1.296) Gear—lo-bushing M5 0020 — 0.070 (0.0008 — 0.0028) 0.10 (0.004) clearance MG 0 025— 0.075 (0.0010 — 0.0030) 0.11 (0.004) CS, C4 0025— 0.075 (0.0010 — 0.0030) 0.11 (0.004) Gear bushing |.D. M5 27935-20006 (1.1018-1.026) 28.016 (1.1030) Mainshaft CD. at M5 27.967 — 27.980 (1.1011 —- 1.1016) 27.957 (1.1007) Bushing-to-shafl M5 0005 — 0.039 (0.0002 — 0.0015) — clearance Shin fork. Fork ID. 12000 — 12.018 (0.4724 — 0.4731) 12.03 (0.474) Iork shaft Claw thickness 5.93 — 6.00 (0.233 — 0.236) 5.9 (0.23) Shift fork shalt CD. 11957 — 11.968 (0.4707 - 0.4712) 11.95 (0.470) Output drive Final driven gear ID. 30000 - 30.013 (1.1811 — 1.1316) 30.03 (1.182) train Final driven gear ID. 25026 — 25.041 (0.9853 — 0.9859) 25.05 (0.986) bushing 0.D, 29.959 — 29.980 (1.0220 —1.0228) 29.95 (1.179) Final shaft 0.0. 24,930 — 24.993 (0.4707 — 0.4712) 24.962 (0.9828) Final driven gear-to-bushing 0.020 — 0.054 (0.0006 — 0.0021) 0.079 (0.0031) clearance Final driven gear bushing-to»shaft 0.033 — 0.061 (0.0013 — 0.0024) 0.090 (0.0035) clearance Final shaft damper spring Iree length 114.5 (4.51) 110 (4.3) Final shall/output shafl gear backlash 0.08 — 0.23 (0.003 — 0.009) 0.40 (0.016) Backlash difference between — 0.10 (0.004) measurements 12-3 CRANKCASEITRANSMISSION TORQUE VALUES Main journal 9 mm bolt 8 mm 7 mm 6 mm Countershafl socket bolt Crankcase bolt. Malnshafl bearing set plate bolt Side gear case mounting bolt Final shaft socket boll 25 N-m (2.5 kgf‘m. 18 lbf‘ft) + 270” 24 N-rn (2,4 kgi-m, 13 mm) 13 Nm (1.8 kgf-m. 13 Ibf-fl) 12 N-m (1.2 kgnn. 9 Ibl-fl) 67 N-rn (6.8 mm, 49 Ibf~fl) 12 N~m (1.2 kgf‘m, 9 lbl-fl) 32 N~m (3.3 kgf~m, 24 Ibf-ft) 57 N~m (6.8 kgf~m. 49 lbf-fl) Replace with a new one. See page 12-23 Apply engine oil to the threads and seat- ing surface. Apply 3 looking agent to the threads. UBS bolt Apply engine oil to the threads and seat- ing surface TOOLS Spline holder Damper spring compressor Clutch center holder 070MB-MCSO100 07964-ME90000 07724-0050002 Q Nol available in USA Equivalent commercially available in USA or 07965-1 660300 é Driver Attachment, 62 x 68 mm Pilot, 22 mm 07749-0010000 07746-001050!) 077460041000 Assemny collar Threaded adaptor Compressor seat 07965-166030A 07965-KA30000 07967~9690200 12-4 Assembly bolt Snap n'ng pliers 07965-1 660200 079145670100 U.S.A. Equivalent commercially available in CRANKCASEITRANSMISSION TROUBLESHOOTING Excessive noise in side gear case ' Worn or damaged output shaft and final shafl gears ' Worn or damaged side gear case bearings Hard to shift - Improper clutch operation (page 10-4) ' Incorrect engine oil weight « Bent shift forks - Bent shift tork shaft ‘ Bent shift lork claw - Damaged shift dmm cam grooves . Bent gearshift spindle Transmission jumps out of gear Worn gear dogs Worn gear shifter groove Bent shift fork shaft Broken shift drum stopper arm Broken shift drum stopper arm spring Worn or bent shift forks Broken gearshift spindle return spring Excessive engine noise . Wom or damaged transmission gears ‘ Worn or damaged transmission bearings - Worn main journal bearings - Worn crankpin bearings 12-5 CRANKCASEITRANSMISSION SIDE GEAR CASE SIDE GEAR CASE - Do not disassemble the side gear case other than the description of this manual. ' Replace the side gear case as an assembly. Description of side gear case assembly: DAMPER SPRING DAMPER CAM FINAL SHAFT OUTPUT SHAFT REMOVAL Remove the engine from lhe frame (page M). Remove the following: — oil pan/oil strainer (page 5—6) — oil pump (page 5—7) Hold the outpul shaft [1] with the special tool. TOOL: Spline holder [2] o10MB-MCSO100 FINAL DRIVEN GEAR 12-6 CRANKCASEITRANSMISSION Remove the final shaft sockel bolt [1} and washer [2] while holding the output shaft. Remove the 6 mm bolts [1]. 8 mm bolls [2] and sealing washers. Hold the final driven gear [1] and remove the side gear case assembly [2]. Remove the bushing, final driven gear and washer. Remove the gasket [1] and dowel pin [2], 12-7 CRANKCASEITRANSMISSION DISASSEM BLY Except U.S.A.: Set the damper spring compressor [1] onto the damper cam [2] and final shaft [3], Compress me damper spring [4] by turning the compressor bolt clockwise until the snap ring [5] can be removed. TOOL: Damper spring compressor o7964-ME90000 Remove the snap ring from the final shaft groove using a oommercially available snap ring pliers. Remove the spring compressor, snap ring. damper cam and damper spring from the final shaft. U.S.A. only: Place the threaded adaptor [1] in the end of the final shaft [2] and tighten the adaptor. Place the compressor seat [3] over the threaded adaptor with the stepped side facing upward. Install the assembly bolt [4] through the assembly collar [5] and attach it to the threaded adaptor. Center the compressor seat with the damper cam [B]. then begin to tighten the 23 mm nut of the assembly bolt until the snap ring [7] is visible so it can be removed. TOOLS: Assemny bolt Assembly collar 07965—1 660200 07965-186030A or 07965-1 660300 07967-9690200 07965-KA30000 0791 11-56701 01 (Equivalent commercially available in U.S.A.) Compressor seat Threaded adaptor Snap ring pliers Remove the snap ring from the final shah groove using the'snap ring pliers. Remove the special tools, snap ring. damper cam and damper spring from the final shaft. INSPECTION DAMPER CAM Check the projections [1] oi the damper cam for damage or excessive wear. 12-8 FINAL DRIVEN GEAR Check the gear teeth for damage or excessive wear, and the gear dog holes for damage. Measure the final driven gear LD. SERVICE LIMIT: 30.03 mm (1.182 in) BUSHING Check the final driven gear bushing for wear or damage. Measure the bushing ID. and OD. SERVICE LIMITS: O.D.: 29.95 mm (1.179 In) I.D.: 25.05 mm (0.986 In) Calculate the geaHo-bushing clearance. SERVICE LIMIT: 0.079 mm (0.0031 In) FINAL SHAFT Measure the CD. of the final shaft at the bushing sliding area. SERVICE LIMIT: 24.962 mm (0.9828 In) Calculate the bushing-to-shaft clearance. SERVICE LIMIT: 0.090 mm (0.0035 In) DAMPER SPRING Measure the damper spring free length. SERVICE LIMIT: 110 mm (4.3 in) CRANKCASEITRANSMISSION CRANKCASEITRANSMISSION BACKLASH INSPECTION Turn the final shaft and check that the output shaft and final shaft tum smoothly and quietly without binding. ll the shafts do not turn smoothly or quietly. the gears and/or beaan may be damaged or faulty. Replace the side gear case as an assembly. Set the side gear case in a vise with soft jaws. Set a horizontal type dial indicator on the final shaft as shown. Hold the output shaft with the special tool and rotate the final shaft [1] until gear slack is taken up. TOOL: Spline holder [2] ("OMB-M6501 00 Turn the final shalt back and forth to read backlash. STANDARD: 0.08 — 0.23 mm (0.003 —- 0.009 in) SERVICE LIMIT: 0.40 mm (0.016 in) Remove the dial indicator. Turn the drive gear shaft 120" and measure backlash. Repeat this procedure once more. Compare the difierence of the three measuremenm. Backlash difference between measurements: SERVICE LIMIT: 0.10 mm (0.004 In) If the difference in measurements exceeds the service limit, it indicates that the bearing is no installed squarely or the case is deformed. Replace the side gear case as an assembly. 12-10 Install the bearing wlth its marked side facing up. CRANKCASEITRANSMISSION OIL SEAL REPLACEMENT Check the oil seals [1] for deterioration or damage. Remove the snap ring [2] and replace the oil seal if necessary. Apply grease to new oil seal lips. Install the oil seal into the side gear case until the snap ring groove appears. Install the snap n'ng. FINAL SHAFT BEARING REPLACEMENT Separate the crankcase halves (page 12-14). Drive the final shafi bearing [1] out of the lower crankcase. Drive in the final shatt bearing until it is flush with the crankcase surface using the special tools. TOOLS: Driver [1] 077494010000 Attachment, 62 x 60 mm [21 0774641010500 Fuel, 22 mm [3] 071464041000 NOTE: This is temporary position. The bearing becomes proper position after tightening the final shaft socket bolt. CRANKCASEITRANSMISSION Install the damper spring with its tapered and facing gear case. ASSEMBLY Install the damper spring [1], damper cam [2] and snap ring [3] onto the final shalt [4]. NOTE: install the snap ring with the chamfered edges facing the thrust load side. Except U.s.A.: Set the damper spring compressor [1] onto the damper earn [2] and final shalt [3]. Compress the damper spring [4] by turning the compressor bolt clockwise until the snap ring groove appears. TOOL: Damper spring compressor 07964—ME90000 Install the snap ring [5] into the final shaft groove. using a commercially available snap ring pliers. Loosen and remove the damper spring compressor. NOT E: - Do not reuse worn snap ring which could easily spin in the groove. - Check that the snap ring is seated in the groove. U.S.A. only: Place the threaded adaptor [1] in the end of the final shaft [2] and tighten the adaptor. Place the compressor seat [3] over the threaded adaptor with the stepped side facing upward. install the assembly bolt [4] through the assembly collar [5] and attach it to the threaded adaptor. Center the compressor seat with the damper cam [6], then begin to tighten the 23 mm nut of the assembly bolt until the snap ring [7] is visible so it can be installed into the groove. Install the snap ring into the groove in the shah. TOOLS: Assembly bolt 07965-166020!) Assembly collar 07965-166030A or 07965-1 660300 Compressor seat 0796743690200 Threaded adaptor 07965-KA30000 Snap ring pliers 07914—5670101 (Equivalent commercially avail- able in U.S.A.) install the snap ring into the final shaft groove using the snap ring pliers. Loosen and remove the special tools. NOTE: - Do not reuse worn snap ring which could easily spin in the groove. - Check that the snap ring is seated in the groove. [5] ll] [3] 12-12 CRANKCASEITRANSMISSION INSTALLATION Install the dowel pin [1] and new gasket [2]. Apply engine oil to the sliding surface of the final driven gear and bushing. Install the side gear case [1] into the crankcase hole, and then install the washer [2], final driven gear [3] and bushing [4] through the final shalt. NOTE: - Install the washer with its concave side facing final driven gear. - Install the final driven gear by aligning the damper cam projections [5] with the final driven gear hole. Install the final shaft end into the bearing [6] and set the I» side gear case assembly onto the crankcase. Apply engine oil to the side gear case 8 mm bolt threads and seating surface. lnstallnewsealing Install the 8 mm bolts [1], 6 mm bolts [2] and new washers at the A" sealing washers [3]. markedmmm' Tighten the 8 mm bolts to the specified torque. TORQUE: 32 N-m (3.3 kgf-m, 24 mm) Tighten the 6 mm bolts securely. Hold the output shaft [11with the special tool, TOOL: Spline holder [2] 070MB-MCSO100 12-13 CRANKCASEITRANSMISSION Apply engine oil to the final shalt socket bolt threads and seating surface. Install the washer [1] and final shat! socket bolt [2]. Tighten the socket bolt to the specified torque, while holding the output shaft. TORQUE: 87 N-m (6.8 kgf-m, 49 Ibi-fl) CRAN KCASE SEPARATION Refer to Service Information for removal of necessary parts before separating the crankcase (page 12-3). Remove the bolts [1] and cylinder water joint [2] from the upper crankcase Remove the O-ring [3] from the cylinder waterjoint, Remove the bolts [1] and mainshaft bearing set plate [2]. Remove the upper crankcase 8 mm bolts [1] and sealing washer [2], 12-14 CRANKCASEITRANSMISSION Remove the crankcase 6 mm bolts, 7 mm bolts, 8 mm ' » bolts, sealing washer and main journal 9 mm bolts Separate the lower crankcase [1] from the upper crankcase. Remove the dowel pins [1] and oil orifices [2]. TRANSMISSION REMOVAL Separate the crankcase halves (page 12-14). Remove the set ring [1] from the mainshaft bearing. Remove the mainshall [2] and oountershaft [3] assemblies from the upper crankcase. DISASSEMBLY Hold the final drive gear [1] with the special tool and loosen the countershaft socket bolt [2]. TOOL: Clutch center holder [3] 07724—0050002 , (Equivalent commercially avail- able in USA.) Remove the socket bolt and washer [4]. then disassemble the countershaft. Disassemble the mainshaft. 12-15 CRANKCASEITRANSMISSION INSPECTION Check the gear dogs, dog holes and teeth for abnormal wear or lack of lubrication. Measure the ID. of each gear. SERVICE LIMITS: M5. M6: 31.04 mm (1.222 In) 01: 35.04 mm (1.380 In) CZ: 30.04 mm (1.183 in) 03. 04: 33.04 mm (1.301 in) Measure the OD. of each gear bushing. SERVICE LIMITS: M5: 30.935 mm (1.2179 in) M6: 30.93 mm (1.218 In) C3, 04: 32.93 mm (1.296 In) Measure the ID. of the gear bushing. SERVICE LIMIT: M5: 28.016 mm (1.1030 in) Calculate the gear-to—bushing clearance. STANDARDS: M5: 0.020 — 0.070 mm (0.0008 — 0.0028 in) M6: 0.025 — 0.015 mm (0.0010 — 0.0030 in) 63, C4: 0.025 - 0.075 mm (0.0010 - 0.0030 in) Check the shin fork groove [1] of the shifter gear Ior excessive wear or damage. Check the final drive gear [1] for wear or damage. [1] [1] 12-16 Check the mainshaft [1] and countershaft [2] for abnormal wear or damage. Measure the mainshafl 0.0. at the M5 geart SERVICE LIMIT: 27.957 mm (1.1007 In) Calculate the gear bushing-to-shaft clearance STANDARD: M5: 0.005 - 0.039 mm (0.0002 — 0.0015 In) Turn the outer race oi each bearing [1] with your linger‘ The bearings should tum smoothly and quietly. Also check that the bearing inner race fits tightly on the shaft. Remove and discard the bearing, if the race does not tum smoothly, quietly. or fits loosely on the shaft. Check the friction damper [1] for wear or damage. Replace the mainshafl and Motion damper as an assembly ii the triction damper is faulty. CRANKCASEITRANSMISSION {1] M. q [2] b ‘ [1] CRANKCASEITRANSMISSION ASSEM BLY Mainshafl: MAINSHAFT/M1 GEAR (1ST) M3/4 GEAR (22/25T) @@ M6 GEAR (333T) M5 GEAR (31T) M2 GEAR(19T) 12-18 CRANKCASEITRANSMISSION Countershaft: C6 GEAR (31T) CZ GEAR (33T) 5i N~m (6.8 kgf-m. C3 GEAR (30T) 49 lbitfl) COUNTERSHAFT cs GEAR (327) C1 GEAR (39T) Assemble the transmission gear and shafls. NOTE: - Coat each gear teeth, sliding surface and bearing with clean engine oil and check for smooth movement. Align the look washer tabs [1] with the spline washer grooves [2]. . Always install the thrust washer and snap ring with the chamfered edge facing away from the thrust road‘ ~ Install the snap ring so that its end gap aligns with the groove in the splines. - Make sure that the snap ring is fully seated in the shafl groove after installing it. 12-19 CRANKCASEITRANSMISSION Apply molybdenum oil solution to the bearing contact surface of the countershaft, then install the countershafl bearing [1]. Apply engine oil to the counteishatt socket bolt threads and seating surface. Install the washer [2] and oountershaft socket bolt [3]. Hold the final drive gear [4] with the special tool and tighten the countershaft socket bolt to the specified torque. TOOL: Clutch center holder [5] 0172443050002 (Equivalent commercially avall- able in USA.) TORQUE: 67 Min (6.8 kgf-m, 49 lbf-ft) Coat each gear with clean engine oil and check for smooth movementr Apply molybdenum oil solution to the shift fork grooves in the M3I4. C5 and CG gear. INSTALLATION Install the dowel pin [1] into the upper crankcase holer Install the countershaft bearing set ring [2] into the upper crankcase groove, Install the countershaft [3] onto the upper crankcase, aligning the shifter grooves (05 and 06 gears) with the f shift forks [4]. Align the hole on the needle bearing [5] with the dowel pin [1]. and also the groove in the ball bearing [6] with ' the set ring [2]. Install the mainshaft bearing set ring [1] into the groove on the crankcase. Install the mainshafl [2] onto the upper crankcase. aligning the M3/M4 gear shifter groove with the shift fork [31‘ Make sure that each gear engages properlyr 12-20 SHIFT FORKS/SHIFT DRUM REMOVAL Remove the transmission (page 12-15). Pull the shin Iork shafls [1] out and remove the shitt 1 forks [2]. Remove the shift dmm [1] and bearing [2]. INSPECTION Check the shift fork guide pin for abnormal wear or damage Measure the shift fork LD. * SERVICE LIMIT: 12.03 mm (0.474 In) Measure the shift fork daw thickness. SERVICE LIMIT: 5.9 mm (0.23 In) Measure the shill fork shaft O.D. SERVICE LIMIT: 11.95 mm (0.470 in) CRANKCASEITRANSMISSION 12-21 CRANKCASEITRANSMISSION Install the bearing with its marked side facing out Install the shin folks with its “RAGE” mark lacing clutch slde. Inspect the shift drum grooves [11for wear or damage. [1] Turn the outer race of the shllt drum bearing [1] with your linger. The bearing should turn smoothly and freely without excessive play It necessary, replace the bearing‘ INSTALLATION Install the shift drum [1] and bearing [21‘ Set the guide pins of the center shift fork (small) [1] and A right/left shift forks (large) [2} onto the shift drum guide pin grooves, and then install the shift fork shafts [3] into 1' the crankcase holes [4] securely. NOTE: The right and left shifl forks are the same parts. Install the transmission (page 12-20). [1] 1 2-22 CRANKCASE ASSEMBLY Clean the upper and lower crankcase mating surfaces thoroughly, being careful not to damage them, Do not applymore Apply a light, but thorough, coating of liquid sealant sealant than (ThresBond 12073 or an equivalent) to the crankcase necessary. mating surlaoe except to the main journal 9 mm bolt area and the oil passage area as shown Check the oil orifices [1] and crankcase oil passages for clogs, and clean them it necessary lnstalltne oil orifices Install the oil orifices onto the upper crankcase. with their large 1.0. side rec/17g the upper crankcase Install the dowel pins [1]. Apply molybdenum oil solution to the main journal bearing sliding surlaces [1] on the lower crankcase. CRANKCASE/TRANSMISSION CRANKCASEITRANSMISSION Install the 3 mm bolt with new sealing washer onto "A" marked ball hole. Install the lower crankcase onto the upper crankcase. Install the lollowing: new main journal 9 mm bolts [1] 3 mm bolts [2] and a new sealing washer [3] — 7 mm bolts [4] 6 mm bolts [5] Make sure the upper and lower crankcase are sealed securely. - Tighten the main journal 9 mm bolts using the Plastic Region Tightening Method. - Do not reuse the main journal 9 mm bolts, because the correct axial tension will not be obtained. ' The main journal 9 mm bolts are pre-coated with an oil additive for stability oi axial tension. Do not remove the oil additive from the new 9 mm bolts surlaoes. Tighten the main joumal 9 mm bolts in the numerical order in several steps, then tighten them to the specified torque. TORQUE: 25 Nm (2.5 kgf'm, 18 lbf'fl) Further tighten the main journal 9 mm bolts 270” (example; 90° at three times) in numerical order. TOOL: Commerclally torque angle gauge adapter [1] TASSO 112" or TASSE 3/8“ drive Tighten the lower crankcase bolts in a crisscross pattern in several steps. TORQUE: 8 mm bolt: 24 N-m (2.4 kgl‘mv 18 lbf-ftl 7 mm bolt: 18 N-rn (1.8 kgfm, 13 Ibf-ftl 6 mm bolt: 12 Nm (1.2 kgf-m, 9 lbf-ft) 12-24 The sealing washer Install the upper crankcase 8 mm bolts [1] with a new location is indicated sealing washer [2]. on the upper . _ Emma” Using a Tighten the 8 mm bolts to the specmed torque. ~A~ Mark. TORQUE: 24 Min (2.4 kgf'm, 18 lbf~ftl Apply a locking agent to the threads of the mainshafl bearing set plate bolts (page 1-19). lnstallthe sei plats Install the mainshafl bearing set plate [1] and bolts [2]. with its "OUTSIDE" Tighten the bolts to the specified torque. mark facing out. TORQUE; 12 N~m (1.2 kgt-m, 9 lbI-fl) Install a new O—ring [1] into the water joint groove. Install the cylinder water joint [2] to the upper crankcase, Install and tighten the water joint mounting bolts securely. Install the removed parts in the reverse order 0! removal CRANKCASEITRANSMISSION 1 2-25 MEMO 13. CRANKSHAFI'IPISTONICYLINDER MAIN JOURNAL BEARING ----------------- --13-7 SERVICE INFORMATION ---13-3 CRANKPIN BEARING -------------- -- 13-10 TROUBLESHoo-HNG . . . . . . . . . . . . "13.4 plSTON/cyLINDER ................................ "13.13 13-1 CRANKSHAFTIPISTONICYLINDER COMPONENT LOCATION 27 N-m (2.8 kgf-rn, 20 lbw) + 120° 1 3-2 SERVICE INFORMATION GENERAL CRANKSHAFTIPISTONICYLINDER . The crankcase must be separated to service the crankshaft and piston/connecfing rod. Reler to procedures for the crankcase separation (page 12-14). ' Mark and store the connecting rods, bean‘ng caps, pistons and beefing inserts to be sure of meir correct locations for reassembly. - The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bearings from the code tables. After selecting new bearings, recheck the oil clearance with a plastigauge. Incorrect cil clearance can cause major engine damage. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod side clearance 0.15 — 0.30 (0.006 — 0.012) 0.40 (0.016) Runout — 0.05 (0.002) Main journal bearing oil clearance 0.017 — 0.035 (0.0007 - 0.0014) 0.05 (0.002) Cylinder ID. 81.000— 81.015 (3.1390— 3.1896) 81.025 (3.1900) Out 01 round — 0.10 (0.004) Taper — 0.10 (0.004) Warpage — 0.10 (0.004) Piston, Piston CD. at 8.0 mm 0.31 in from piston rings bottom I ) 80.960 — 80.980 (3.1574 — 3.1882) 80.89 (3.185) Piston pin hole |.D. 18.002 — 18.008 (0.7087 — 0.7090) 18.02 (0.709) Piston pin O.D. 17.994 — 18.000 (0.7084 — 0.7087) 17.98 (0.708) Piston-to-piston pin clearance 0.002 — 0.014 (0.0001 — 0.0006) 0.04 (0.002) Pislon ring end gap Top 0.15 — 0.25 (0.006 - 0.010) 0.45 (0018) Second 0.320 — 0.470 (0.0126 — 0.0185) 0.65 (0.026) Oil (side rail) 0.20 — 0.70 (0.003 — 0.028) 0.9 (0.04) Piston ring»to-ring Top 0.015 — 0.050 (0.0006 - 0.0020) 0.065 (0.0026) grooVe Clearance Second 0.015 — 0.045 (0.0006 - 0.0018) 0.06 (0.002) Cylinder-to-piston clearance 0.020 — 0.055 (0.0008 — 0.0022) 0.10 (0.004) Connecting rod small end LD. 18.010 — 18.042 (0.7091 — 0.7103) 18.05 (0.711) Connecting rod-to-piston pin clearance 0.010 a 0.048 (0.0004 — 0.0019) 0.06 (0.002) 0.034 — 0.052 (0.0013 — 0.0020) 0.06 (0.002) Crankpm bearing oil clearance TORQUE VALUES Connecting rod bearing cap bolt Oil jet mounting bolt Main journal 9 mm bolt 12 N-m (1.2 kgf-m. 9lb1-ft) 25 N-m (2.5 kgf‘rn. 18 Ibf-ft) + 270“ 27 N~m (2.8 kgf‘rn,20lb1>fl)+ 120‘ Apply engine oil to the threads and seating surface. See page 136 Apply a locking agent to the threads. See page 1&8 13-3 CRANKSHAFTIPISTONICYLINDER TROUBLESHOOTING Cylinder compression ls too low, hard to starting or poor performance at low speed o Leaking cylinder head gasket - Worn, stuck or broken piston ring - Worn or damaged cylinder and piston Cylinder compression loo highY overheats or knocks - Excessive carbon built-up on piston head or combustion chamber Excessive smoke - Worn cylinder, piston or piston rings - Improper installation oi piston rings - Scored or scratched piston or cylinder wall Abnormal noise O Worn piston pin or piston pin hole - Worn connecting rod small end ' Worn cylinder, piston or piston rings - Worn main journal bearings ~ Worn crankpin bearings Engine vibration ' Excessive orankshatt runout 13-4 CRANKSHAFTIPISTONICYLINDER CRAN KS HAFT SIDE CLEARANCE INSPECTION Separate the crankcase halves (page 12-14). Measure the connecting rod side clearance using a feeler gauge [1]. SERVICE LIMIT: 0.40 mm (0.016 in) It the clearance exceeds the service limit, replace the connecting rod. Recheck and it still out of limit. replace the crankshaft. REMOVAL Separate the crankcase halves (page 12-14). Mark the bearing caps and bearings as you remove them to indicate the correct cylinder for reassembly. Be caraluinorto Remove the connecting rod bearing cap bolts [1] and damage the bearing caps [2]. crankpin, main Tap the side of the bearing cap lightly it it is hard to [carnal and bearing remove. inserts. NOTICE Before removing the crankshaft position all the pistons at TDC (Top Dead Center) to prevent the connecting rod from damaging the crankpin. - Remove the crankshaft [1]. INSPECTION Place the crankshaft on a stand or V-blocks. Set a dial gauge on the center main journal of the orankshafl‘ Rotate the crankshafl two revolutions and read the DIAL GAUGE SET PO'NT mnout. SERVICE LIMIT: 0.05 mm (0.002 In) 1 13-5 CRANKSHAFT/PISTON/CYLINDER Check the crankshaft needle bearing [1] for wear or damage. INSTALLATION NOTICE Before installing the crankshaft, position all the pistons at TDC (Top Dead Center) to prevent the connecting rod from damaging the crankpin. Apply molybdenum all solution to the main journal bearing sliding surfaces and crankpin bearing sliding surfaces on the connecting rods. Install the crankshaft and set each connecting rod onto the crankpins. Apply molybdenum oil solution to the crankpin bearing sliding surlaces on the bearing caps. Install the bearing caps [1] by aligning its pins with the holes on the connecting rod [2]. Apply engine oil to the bearing cap bolt threads and sealing surface. Install the bearing cap bolts [1] and tighten them alternately 2 or 3 steps. Tighten the bearing cap bolts [1] to the specified torque. TORQUE: 21 N~m (2.8 kgf~m, 20 Ibf-fl) 13-6 CRANKSHAFTIPISTONICYLINDER Further tighten the bearing cap bolts 120“. TOOL: Commercially torque angle gauge adaptor [1) TA360 1/2" or TA358 3I8" drive I1] Assemble the crankcase halves (page 1221). MAIN JOURNAL BEARING NOTICE Do not interchange the bearing insane. They must be installed in their on'ginal locations or the conect bearing oil clearance may not be obtained, resulting in engine damage Remove the crankshaft (page 135). BEARING INSPECTION Inspect the main journal bearing inserts [1] on the upper and lower crankcase for unusual wear or peeling. Check the bearing tabs for damage. OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and main journals. Be careful not to Install the crankshafl onto the upper crankcase. damage the crankoin with the connecting md. Put a strip of plastigauge [1] lengthwise on each main journal avoiding the oil holet 1 3-7 CRANKSHAFTIPISTON/CYLINDER Do not rotate the crankshaft during inspection. Letters (A, B or C) an the Ielt side of upper crankcase are the codes for the beefing support l.D.s from left to right. Install the dowel pins into the lower crankcase (page 12-23). Carefully install the lower crankcase on the upper crankcase. Install the main journal 9 mm bolts [1] and tighten them in numerical order as shown. TORQUE: 25 N-m (2.5 kgf-m, 1s Ibf-f!) Further tighten the main journal 9 mm bolts 270° (example; 90" at three times) in numerical order. TOOL: Commercially torque angle gauge adaptor [1] TA360 1I2" or TA358 3/8" drive Remove the 9 mm bolts and lower crankcase Measure the compressed plastigauge at its widest point on each main journal to determine the oil clearance. SERVICE LIMIT: 0.05 mm (0.002 In) If the oil clearance exceeds the service limit, select the correct replaoement bearings. BEARING SELECTION Record the crankcase bearing support I.D. code letters on the left side of the upper crankcase as shown. 13-8 CRANKSHAFTIPISTONICYLINDER Numbers (1, 20/3) Record the corresponding main journal O.D. code [1] on the crank weight from rhe crank weight. are me “mm ’0’ Cross relerence the main journal and bearing support the main joumal , _ 00.8 from [en to codes to determine the replacement beaan color code. right. MAIN JOURNAL BEARING SELECTION TABLE: BEARING SUPPORT |.D. CODE A B 0 42.000 — 42.006 mm 42.006 — 42.012 mm 42.012 — 42.018 mm (1.6535 —1.6538 in) (1.6538 — 1.6540 in) (1.6540 - 1.6542 in) MAIN JOURNAL 1 39.000 — 39.006 mm E D C O.D. CODE (1.5354 — 1.5357 in) (Yellow) (Green) (Brown) 2 38.994 — 39.000 mm D C B (1.5352 - 1.5354 in) (Green) (Brawn) (Black) 3 38.988 — 38.994 mm C B A (15350 — 1.5352 in) (Brown) (Black) (Blue) Bearing insert has a polar code [1] to identify its rhickness. BEARING THICKNESS: A (Blue): Thick B (Black): C (Brwn): Middle D (Green): E (Yellow): Thln NOTICE ,, . After selecting new bearings, recheck the dearancs with a plasrigauge. Incorrect clearance can cause severe engine damage. BEARING INSTALLATION Clean the bearing outer surfaces and crankcase r bearing supports. Insrall the maln journal bearing inserts [1] onto the crankcase bearing supports, aligning each cab with each groove. 13-9 CRANKSHAFTIPISTONICYLINDER CRANKPIN BEARING Be careful not to damage the crankpin with the connecting rod. Do not rotate the crankshaft during inspection. Do not interchange the healing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 135i BEARING INSPECTION Check the bearing inserts [1] tor unusual wear or peeling. Check the bearing tabs for damage. OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and crankpinst Install the crankshaft onto the upper crankcase Set the oonnecting rods onto the crankpinst Put a strip of plastigauge [1] lengthwise on each crankpin avoiding the oil hole. Carefully install the bearing caps [1] by aligning its pins with the holes on the connecting rod Apply engine oil to the bearing cap bolt threads and seating surfaces and install them. Tighten the bolts [2] gradually and alternately in 2 or 3 steps, YORQUE: 27 N-m (2.8 kgf-m, 20 lbf-ft) [1] 13-10 Numbers (1, 2 or 3) on the connecting rods are the codes for the connecting rod LD. Letters (A, s or C) on the crank weight are the nodes for me crankpln 0.0.5 from left to right. Further tighten the bolts 120°. TOOL: Commercially torque angle gauge adapter [1] TA360 1/2” or TA358 3/ " drive Remove the bolts and bearing caps. Measure the compressed plastigauge at its widest point on the crankpin to determine the oil clearance SERVICE LIMIT: 0.00 mm (0.002 In) If the oil clearance exceeds the service limit. select the correct replacement bearings. BEARING SELECTION Record the connecting rod LD. code (1. 2 or 3) [1] or measure the ID. with the bearing cap installed without bearing inserts. If you are replacing the crankshaft, record the corresponding crankpin O.D. code (A, B or C) [1]. It you are reusing the crankshafl, measure the crankpin 0D. with micrometer. Cross-reference the crankpin and rod codes to determine the replacement bearing color. CRANKSHAFT/PlSTON/CYLINDER CRANKSHAFTIPISTON/CYLINDER CRANKPIN BEARING SELECTION TABLE: CONNECTING ROD l.D. CODE 1 2 3 44.500 — 44.506 mm 44.506 — 44.512 mm 44.512 — 44.518 mm (1.7520 — 1.7522 in) (1.7522 - 1.7524 in) (1.7524 — 1.7527 in) CRANK PIN OD, A MAW—41.503 mm E D 0 CODE (1.6337 — 1.6340 in) (Yellow) (Green) (Brown) B 41.491 — 41,497 mm D C B (1.6335 — 1.6337 in) (Green) (Brown) (Black) 0 41.485 — 41.491 mm C B A (1.6333 — 1.6335 in) (Brown) (Black) (Blue) Bearing insert has a color code [1] to identify its [1] lhiokness. BEARING THICKNESS: A (Blue): Yhick B (Black): T C (Brown): Mlddla D 16reen): E (Yellow): Thln NOTICE After selecting new bearings, recheck the clearance with a Mast/gauge. lnoonect clearance can cause severe englne damage. BEARING INSTALLATION Clean the bearing outer surfaces, bearing cap and 1 connecting rod, [ 1 install lhe crankpin bearing inserts [1] onto the bearing cap and connecting rod. aligning each tab with each groove. 13-12 PISTON/CYLINDER Mark all the parts as you remove them to indicate the correct cylinder for reassembly. PISTON/CONNECTING ROD REMOVAL NOTICE - This motorcycle is equipped with aluminum cylinder sleeves. Before piston removal place a clean shop towel around the connecting rod to prevent damaging the cylinder sleeve, Do nol try to remove the piston/connecting rod assembly from the bottom ol_ the cylinder, the assembly will get stuck in the gap between the cylinder liner and the upper crankcase. Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the following: — transmission (page 1245) — crankshaft (page 13-5) Remove the piston/connecting rod assembly [1] from the top of the cylinder. PISTON OIL JET REMOVAL/INSTALLATION Remove the bolt [1] and piston oil jet [2]. Check the piston oil jet tor clogs or damage. Clean the oil passage on the upper crankcase and oil jet with compressed air. Apply oil to new O—ring [1] and install it to the oil jet groove, . Install the piston oil jet [2]. Clean the threads of the piston oil jet mounting bolt and apply a locking agent (page 1—19). Instali the mounting bolt and tighten it to the specified torque. TORQUE: 12 N-m (1.2 kgf‘m, 9 Ibf'ft) CRANKSHAFTIPISTONICYLINDER CRANKSHAFT/PISTONICYLINDER PISTON REMOVAL Remove the piston pin clip [1] with pliers. Push the piston pin [2] out of the piston [3] and connecting rod [4]. then remove the piston PISTON RING REMOVAL Do not damage the Spread each piston ring and remove it by lifting up at a 7 piston ring by point opposite the gap. spreading the ends too far. Clean carbon Remove any carbon deposits from the piston ring deposits [mm the grooves. n‘nggrooves wit/73 ring that willbe discarded. Never use a wine brush: it will scratch the groove. .7 ~ PISTON INSPECTION Temporarily install the piston rings to their proper position with the mark facing up inspect the piston rings for movement by rotau’ng the rings The rings should be able to move in their grooves without catching. Measure the piston ring-to-ring groove clearance with the rings pushed into the grooves SERVICE LIMITS: top: 0.065 mm (0.0026 in) Second: 0.06 mm (0.002 in) 13-14 Insert the piston ring [1] into the bottom of the cylinder squarely using the piston. and measure the ring and gap. SERVICE LIMITS: Top: 0.45 mm (0.015 in) Second: 0.65 mm (0.026 in) Oil (side rail): 0.9 mm (0.04 In) Measure lhe piston OD. at a poinl 8.0 mm (031 in) lrom the bottom and 90“ to the piston pin hole. SERVICE LIMIT: 80.89 mm (3.185 In) Measure the piston pin hole |.D. SERVICE LIMIT: 18.02 mm (0.105 in) Measure the piston pin CD. at piston and connecting rod sliding areas. SERVICE LIMIT: 17.98 mm (0.708 in) Calculate the piston—to—piston pin clearance. SERVICE LIMIT: 0.04 mm (0.002 in) CONNECTING ROD INSPECTION Measure the connecting rod small and ID. SERVICE LIMIT: 18.05 mm (0.711 in) Calculate the connecting rod—to-piston pin clearance. SERVICE LIMIT: 0.06 mm (0.002 int CRANKSHAFTIPISTONICYLINDER 8.0 mm (0.31 in) 13-15 CRANKSHAFT/PlSTON/CYLINDER CONNECTING ROD SELECTION The weight code [1] stamped on the connecting rod using an alphabetical code. The replacement connecting rod is available only weight code B. If the original connecting rod weight code is either A or 0. you can use weight code B connecting rod. CYLINDER INSPECTION Inspect the top of the cylinder for warpage with a straight edge and feeler gauge. SERVICE LlMlT: 0.10 mm (0.004 In) Inspect the Cylinder bore for scratches or wear. Measure the cylinder ID. in an X and Y axis at three levels. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 81.025 mm (3.1500 in) Céldulate the cylindento-piston clearance. Take a maximum reading to determine the clearance. Refer procedures for measurement of the piston O.D. (page 13—15). SERVICE LIMIT: 0.10 mm (0.004 In) Calculate the cylinder taper and out of round in an X and Y axis at three levels. Take the maximum reading to determine them. SERVICE LIMITS: Taper: 0.10 mm (0.004 In) Out of round: 0.10 mm (0.004 in) The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded. The following oversize pistons are available: 0.25 mm (0.010 in) 0.50 mm (0.020 in) The cylinder to piston clearance for the oversize piston must be: 0.020 — 0.055 mm (0.0005 — 0.0022 in). I1] TOP MIDDLE BOTTOM 13-16 PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with their marking lacing up. ' Apply oil to the piston rings. - Avoid piston and piston ring damage during installation Install the piston rings with the marking facing up. — Top ring: 'R' mark — Second ring: "RN‘ mark Do not interchange the top and second rings. stagger the piston ring end gaps 120“ apart from each other. stagger the side rail end gaps as shown PISTON INSTALLATION Apply molybdenum oil solution to the connecting rod small end inner surfaces, piston pin holes and piston pin outer surtaoes. Assemble the piston [1] and connecting rod [2]. ~ install the oonneoting rod [2] with its "MGE" mark facing the 'F“ or 'R“ mark on the piston crown, Apply molybdenum oil solution to the piston pin outer surface and connecting rod small end inner surface, install the piston pin [1] into the piston [21 and connecting rod [3]. Secure the piston pin using new piston pin clips [4]. - Make sure that the piston pin clips are seated securely, - Do not align the piston pin clip end gap with the piston cut—out. CRANKSHAFTIPISTONICYLINDER TOP RING ("R‘ MARK) SECOND RING ('RN" MARK) —> —> g OlL RING SIDE RAILS SPACER 20 mm Or more "F'I MARK r "R" MARK in) t ton ( n P's ) (rear piston) [2] "MGE" mark 73 "R" mark 13-17 CRANKSHAFTIPISTONICYLINDER Apply engine oil to the cylinder wall, piston and piston ' rings, ‘ Set the piston/connecting rod assembly [1] into the cylinder while holding the connecting rod. - The piston has an identification mark [2]. — Front piston (#1 and #4): 'F“ mark — Rear piston (#2 and #3): "R" mark Install the piston/connecting rod assembly [1] into the cylinder carefuin so that the connecting rod does not interfere in the piston oil jet [2]. While installing the piston, be careful not to damage the top surface of the cylinder, especially around the cylinder bore. Make sure the ring Install the piston rings into the cylinder bore using a oompressorlool sits commercially available piston ring compressor tool [1]. flush with top suflace 0/ the cylinder. Turn each piston "IN' mark [1] to the intake side of the cylinder. install the following: — crankshaft (page 13—6) — transmission (page 12—20) 13-18 COMPONENT LOCATION -- SERVICE INFORMATION ------------------------- --14-3 TROUBLESHOOTING-"- FINAL DRIVE REMOVAL .......................... "14.5 14. FINAL DRIVE FINAL DRIVE DISASSEMBLYI mspEc-HON ............................................. "14,8 FINAL DRIVE ASSEMBLY --------------------- "14-19 FINAL DRIVE INSTALLATION --------------- --14-23 14-1 FINAL DRIVE COMPONENT LOCATION 9.0 N~m (0.9 kgf~m. 6.6 Hum) 45 N-m (4,6 kgf-m.33lb1-fl) 14-2 FINAL DRIVE SERVICE INFORMATION GENERAL - The tinal gear assembly and final drive shaft must be removed together. - Replaoe the ring and pinion gears as a set. v Perform the gear oontact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The extension lines from the gear engagement surfaoes should intersect at one point. Protect the gear case with a shop towel or soft jaws while holding it in a visa. Do not clamp the gear case too tightly or it could be damaged. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Recommended final drive all Hypoid gear oil. SAE #80 — Final drive oil Afler draining 200 cm3 (6.8 US oz, 7.0 Imp oz) — capacity After disassemny 240 cm3 (8.1 US oz, 3.4 lmp oz) — Final gear backlash 0.05 — 0.15 (0.002 — .006) 0.30 (0.012) Backlash difference between measurements — 0.10 (0.004) Final gear assemny preload 0.1 — 2.9 N-rn (1 — 29 kgi-cm, - 0.1 —2.1 lbf'fl) TORQUE VALUES Final gear ease cover 10 mm bolt 62 Nm (6.3 kgi-m. 4G |bf~It) Apply a locking agent to the threads. Final gear case cover 8 mm bolt 25 N-m (2.5 kgt—m. 18 rum) Apply a locking agent to the threads. Ring gear shaft bearing retainer 221 N-m (22.5 kgf~m, 163 Ibf‘fl) Replace with a new one and stake. Apply grease or gear oil to the threads. Final gear case bolt 221 Mm (225 kgf-m. 163 lbI-lt) ALOC bolt: replace with a new one. Apply grease or gear oil to the threads. Pinion gear bearing retainer 235 Mm (240 kgI-m, 173 Ith) Replace with a new one and stake. Pinion gear lock nut 206 Mm (21.0 kgtvm. 152lb1-tt) Replace with a new one and stake. Final gear assembly stud bolt See page 14-23 Apply a locking agent to the threads. Final gear assembly mounting nut 88 N~m (9.0 kgf'm. 65 lbf-ft) Rear brake disc flange mounting screw 9.0 Ntm (0.9 kgfm, 6.6 |bf~ft) 1 4-3 FINAL DRIVE TOOLS Involute spline holder Bearing race insert attachment Lock nut wrench 42/56 070MB-MGE0100 079314630301 O70MA-MGEO100 (Need to find alternative tools for USA) or 070MB»MGEA100 (U.S,A. only) or O70MA-MGEA100 (USA. only) Not available in U.$.A, Pinion shaft attachment Sliding shaft 12 Remover weight O7OMC~MGE0100 077360010101 07741-0010201 y or 070MC—MGEA1OD (USA. only) Use a wmmercially available 3/8" X 16 or 07936-371020A (U.S.A. only) thread Slide Hammer in USA. only Driver, 40 mm ID. Bearing remover, 35 mm Remover handle 07746-0030100 0793645710400 07936-3710100 Driver Attachment. 62 x 68 mm Pilot, 35 mm 07749—0010000 0774643010500 07746-0040800 14-4 FINAL DRIVE Bearing remover, 20 mm 07935-3710600 077460010100 Attachment, 32 x 35 mm Pilot, 19 mm 077460041400 Aliachment, 70 mm D7LAD-PW50500 07GAD-SD401 01 Attachment, 78 x 90 mm Attachment, 78.5 mm 07JME-MR10100 Not available in USA. Base 105x 115 x65 mm 07ZMF—MCA03DO DTZME-MCAA1DO X or ovzmeizickAsoo (U.S.A, only) Bearing clip compressor, 35 mm TROUBLESHOOTING Excessive noise Worn or damaged bearings Worn ring gear and shall Worn p on gear and Shah Worn pinion gear and ring gear splines Worn or damaged universal joint and constant velocity joint Excessive backlash between pinion and ring gears Oil level too low OII leak O Oil level too high ~ Damaged seals ‘ ~ Lease case cover bolts Excessive rear wheel backlash . Worn drive shaft splines . Excessive backlash between pinion and ring gears - Excessive play in final drive case bearings Worn or damaged universal joint and constant velocity joint Excessive play or worn universal joint bearing 1 4-5 FINAL DRIVE FINAL DRIVE REMOVAL Drain the final drive all (page 4-20). Remove the lollowing: — rear wheel (page 165) — rear brake caliper (page 17-34) Remove the rear brake disc flange mounting screws [1]. Remove the rear brake disc flange [1], O-ring [2] and dowel pins [3]. Open the drive shaft boot [1], Rotate the drive shaft {2] slowly until the snap ring [3] appears as shown. Remove the snap ring from the output shalt groove and slide the drive shaft rearward, Remove the final gear case assembly mounting nuts [1]. 14-6 Pull the final gear case assemny [1] out the swingarm gently. NOTE: Be careful not to tear the constant velocity joint boot [2]. Remove the dowel pins [3] (mm the final gear case assembly. Remove the drive shaft assembly from the final gear case by gently turning the constant velocity joint [1] and pulling it NOTE: Do not pull the drive shaft [2] because the constant velocity joint boot [3] may tears Remove the stopper ring [1] from the drive shalt assembly Remove the snap ring [1] from the universal joint. FINAL DRIVE 14-7 FINAL DRIVE INSPECTION Replace the drive Check the operations of the universal joint [1] and snail as an constant velocity joint [2] assembly. They should move smoothly without binding or nolse. Check the constant velocity joint boot [3] for tears or other damage. Check the drive shaft for bend or damage, Check the splines [4] of the drive shaft for damage or wear. I! the splines of the drive shefl are damaged, check the output shafl (side geer case) and pinion gear splines (final gear case) also. Turn the pinion gear using the special tool. and check that the pinion and ring gears turn smoothly and quietly without binding. TOOL: Involute spline holder [1] o10MB-MGE0100 or 070MB—MGEA100 (U.S.A. only) It the gears do not turn smoothly or quietly. the gears and/or bearing may be damaged or faulty‘ They must be checked after disassembly; replace faulty parts as required. FINAL DRIVE DISASSEMBLY/ INSPECTION NOTE: Perform the backlash inspection and contact pattern check whenever you replace the pinion gear. ring gear, bearings and gear case The extension lines from the gear engagement surtaoes should intersect at one point [1]? " 14-8 BACKLASH INSPECTION Hold the final gear case assembly in a vise with soft jaws. Remove the oil filler cap. Install the special tool into the pinion gear to hold it. TOOL: Involute spline holder [1] 070MB—MGE0100 or 070MB—MGEA1 00 (U.S.A. only) Set a horizontal type dial indicator [1] on the ring gear [2], through the oil filler hole. Turn the ring gear back and forth to read the backlash. STANDARD: 0.05 — 0.15 mm (0.002 - 0.006 In) SERVICE LIMIT: 0.30 mm (0.012 in) Remove the dial indicator. Turn the ring gear 120° and measure the backlash. Repeat this procedure once more. Compare the difference of the three measurements. SERVICE LIMIT: 0.10 mm (0.004 in) If the difference in measurements exceeds the service limit. it indicates that the bearing is not installed squarely, or the case is deformed. Inspect the bearings and case. If the backlash is excessive. replace the ring gear shaft shim [1] with a thinner one. If the backlash is too small, replace the ring gear shaft shim with a thicker one. Change the ring gear shaft shim thickness in an opposite amount of what the ring gear shim [2] was changed; ifthe ring gear shim was replaced with a 0.12 mm (0.005 in) thicker one, replace the ring gear shaft shim with a 0.12 mm (0.005 in) thinner one. For ring gear shalt shim replacement (page 14.10). For ring gear shim replacement (page 14-12). SHAFI' SHIMS: RING GEAR SHIMS: A:1.73 mm (0.068 In) A: 1.82 mm (0.012 in) B: 1.76 mm (0.069 In) B: 1.88 mm (0.074 In) C:1.79 mm (0.070 In) 021.94 mm (0.076 in) D: 1.82 mm (0.072 in) D: 2.00 mm (0.079 in) E: 1.35 mm (0.073 in) E: 2.06 mm (0.081 in) F: 1.88 mm (0.074 In) F: 2.12 mm (0.003 in) 6:1.91 mm (0.075 In) G: 2.18 mm (0.086 in) H: 1.94 mm (0.076 In) H: 2.24 mm (0.088 In) I: 1.97 mm (0.078 in) I: 2.30 mm (0.091 in) J: 2.00 mm (0.079 in) J .36 mm (0.093 in) K: 2.03 mm (0.080 in) K. 2.42 mm (0.095 in) L: 2.06 mm (0.081 in) L: 2.48 mm (0.098 in) M:2.54 mm (0.100 In) N: 2.60 mm (0.102 In) P: 2.66 mm (0.105 In) M:2.09 mm (0.032 in) N: 2.12 mm (0.083 In) 012.15 mm (0.085 in) P: 0.45 mm (0.018 in) FINAL DRIVE 14-9 FINAL DRIVE Keep dust and am out oltlle case and cover. FINAL GEAR CASE SEPARATION Loosen the 8 mm [1] and 10 mm [2] cover belts in a crisscross pattern in several steps and remove them. Pry the gear case cover [3] and remove it trorn the C359. GEAR TOOTH CONTACT PATTERN CHECK Description of the tooth: COAST SIDE TOE (inside 0! gear) (contacts when engine braking is applied) ll DRIVE SIDE HEEL (out side of gear) / v (contacts when engine power is applied) Clean the sealing material off the mating surfaces of the gear case and cover. being careful not to damage them. Apply a thin coat of Pmssian Blue to the pinion gear teeth [1]. Select the replacement shaft shim [2] (page 14-9). Install the shaft shim, [1] Apply Pmssian Blue Install the case cover [1]. 10 mm bolts [2], 8 mm bolts [3] and tighten the bolts in a crisscross pattern in several steps until the cover evenly touches the gear case. Tighten the 10 mm bolts to the specified torque in several steps alternately. TORQUE: 62 N-m (6.3 kgf-nl, 46 Mt!) Tighten the 8 mm bolts to the specified torque in a crisscross pattern in several times TORQUE:25 N-m (2.5 kgf-m. 18 [bf-ft) 14-10 FINAL DRIVE Remove the oil filler cap. Rotate the ring gear several times in normal direction of rotation. Check the gear tooth contact pattem through the oil filler hole. Contact is normal tithe Prussian Blue is translerrsd to the approximate center of each tooth and slightly towards the face. If the paltems are not correct. remove and replace the pinion gear shim [1] with a suitable one (page 14-14). Replace the pinion gear shim with a thinner one ii the contact pattern is too high. toward the face. Replace the pinion gear shim with a thicker one if the contact pattern is too low, toward the flank, PINION GEAR SHIMS: A: 1.32 mm (0.052 ln) B: 1.38 mm (0.054 in) (311.44 mm (0.057 In) D: 1.50 mm (0.059 in) E: 1.56 mm (0.081 in) F: 1.62 mm (0.064 in) 6:1.68 mm (0.066 in) For pinion gear shim replacement (page 14-14). Normal: [1] \m L J__ 7 ( HEEL TOE TOE HEEL K " K ‘h FACE t “2 FACE FLANK DRIVE COAST FLANK SIDE SIDE Too High: FACE @ 4% FACE DRIVE COAST SIDE SIDE Too Low: DRIVE COAST FLANK FLANK SIDE SIDE 14-11 FINAL DRIVE Be sure to wear insulated gloves when handling the heated gear case, RING GEAR REMOVAL/SHIM RE PLAC EMENT Separate the final gear case (page 1440), Press the ring gear [1] out of the gear case cover using the special tool and hydraulic press TOOL: Bearan race insert attachment [2] 079314630301 Not available in U.S.A. (Need to find allamatlva tools) Remove the snap ring [1] and oil seal [2]. Heat the gear case cover to 80°C (176”F) evenly using a heat gun. NOTE: Do not use a torch to heat the gear case cover, it may cause warping. Tap the gear case lightly and remove the ring gear bearings [11‘ It the bearings remained on the ring gear, remove them as follows: Remove the ring gear bearings [1] using a commercially available bearing puller [2]. [2] l1] 14-12 Select the replacemeni shim (page 14-9). PINION GEAR REMOVAL Remove ihe stopper ring [1] and oil seal [2]. Becarefulnolio Unsiake the pinion gear look nut [1] and bearing damage the plnian retainer [2]. gear and gear case. Hold the gear case in a vise with salt jaws. Hold the pinion gear and remove the pinion gear look nut [1] using ihe special iools. TOOLS: Involuie spline holder [2] D70MB-MGE0100 or DYDMB-MGEA1 00 (U.S.A. only) Lock nul wrench 42/56 [3] o10MA-MGE010I! or 070MA-MGEA100 (U.s.A. only) FINAL DRIVE iii Unsiake 14-13 FINAL DRIVE Remove the pinion gear bearing retainer [1] using the special tool. TOOL: Lock nut wrench 42/56 [2] o70MA-MGE0100 or 070MA-MGEA1 00 (USA. only) Remove the pinion ear assembi 1 usin the special tools. 9 y i i 9 TOOLS: ’ Pinion shall attachment [2] 070MC-MGE0100 Sliding shall 12 [3] 07736-0010101 (Use a commercially available 3/8" x 16 thread Slide Hammer In U.s.A. only) Remover weight [4] 0774147010201 or 07936-371020A (U.S.A. only) Remove the special tools from the pinion gear assembly. PINION GEAR BEARING/SHIM REPLACEMENT Remove the pinion gear shim [1] from the gear case. Select the replacement shim (page 14-11). Pull the pinion gear bearing [1] from the pinion gear with a commercially available bearing puller. 14-14 Be careful not to damage the gear easel Drive a new bearing [1] with the marked side facing up using the special lool. TOOL: Driver, 40 mm LD. [2] 07746-0030100 CASE BEARING REPLACEMENT RING GEAR BEARING Hold ihe gear case in a vise with sofljaws. Remove the gear case bolt [1] from the gear case using the special tool. TOOL: Lock nut wrench 42156 [2] 07oMA-MGE0100 or 070MA—MGEA1 00 (U.S.A. only) Remove the O-ring [1] from the gear case bolt [2}. Unslake the ring gear shaft bearing retainer [1]. FINAL DRIVE 14-15 FINAL DRIVE Be sure to wear insulated gloves when handling the heated gear case. The lock nut wrench (60 mm off-set from the center) increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the retainer. Remove the ring gear shaft bearing retainer [1] using the special tool. TOOL: Lock nu! wrench 42156 [2] 070MA-MGE0100 or 070MA-MGEA100 (U.S.A. only) Heat the gear case to 80°C (176°F) evenly using a heat gun. NOTE: Do not use a torch to heat the gear case; it may cause warping. Remove ring gear shaft bearing [1] from me gear case using the special tools. TOOLS: Bearing remover, 35 mm [2] 07936-3710400 Remover handle 07936-3710100 Remover weight [3] 07741 -0010201 or 07936-371 020A (U.S.A. only) Drive a new ring gear shaft bearing [1] into the gear case until it is fully seated using the special tools. TOOLS: Driver [2] 077490010000 Attachment, 62 x 63 mm [3] 077460010500 Pllot. 35 mm [4] 07746-0040800 Hold the gear case in a vise with soft jaws. Apply grease or gear oil to a new ring gear shafl bearing retainer [1] threads. Install the ring gear shalt bearing retainer. Tighten the retainer to the specified torque using the special tool: TOOL: Lock nu! wrench 42/56 [2] 070MA-MGE0100 or . 070MA-MGEA100 (U.S.A. only) TORQUE: 221 Mm (225 kgi~m,163lbf-fl) 14-16 Be careful nut to damage the gear case. The lack ml! wrench (60 mm nfl-set from the center) increases the torque wrench's Ievemge, so the torque wrench reading will be less than the torque actually applied tb the gear case bolt, Stake the ring gear shaft bearing retainer [1]. Apply oil to a new O-ring and install it onto a new gear case bolt [2]. Apply grease or gear oil to the gear case bolt threads. Install the gear case bolt to the gear case. Tighten the gear case bolt [1] to the specified torque using the special tool. TOOL: Lock nut wrench 42/56 [2] 01oMA-MGE01DO or 070MA-MGEA1 00 (U.S.A. only) TDRQUE:221 N~m (22.5 kgf-m, 163 lbf-ft) PINION GEAR SHAFT BEARING Rotate the stopper ring [1] until the end of the stopper ring appears in the access hole [21‘ Strike gently near the end 0' the ring with a punch to bend the end upward, Grasp the end of the ring with needle-nose pliers and pull the stopper ring out through the access hole, FINAL DRIVE 14-17 FINAL DRIVE Be sure to wear insulated gloves when handling the heated gear case. Tape the clip oompressorto the driver for bearing installatibn. Heat the gear case to 80°C (176°F) and remove the needle bearing [1] using the special tools. NOTE: Do not use a torch to heat the gear case; it may cause warpith TOOLS: Bearing remover, 20 mm [2] 01936-3110600 Remover handle 0793641110100 Remover weight [3] 0774141010201 or 07936-371 020A (U. . . only) Install a new stopper ring [1] into the groove of a new bearing [2] securelyt Install the bearing into the special tool until the bearing is flush with the end of the IooL TOOL: Bearing clip compressor, 35 mm [3] Freeze the needle bearing with the tool on ice or in a freezer. Heat the gear case to 30°C (176°F) 07ZME-MCAA1 00 Remove the needle bearing [1] {mm the freezer and drive it into the gear case unlil it is lully seated using the special tools. TOOLS: Driver [21 0774941010000 Attachment, 32 x 35 mm [3] 017450010100 Pllot, 19 mm [4] 077464041400 Only strike the driver once If you strike it more than 030% the stopper ring may slip out 0! the groove ll this happens, remove the ring and bearing. and install a new one again. Make sure the stopper ring [1] is secume set in the groove of the gear case. [3] ~a [2] 14-18 FINAL DRIVE FINAL DRIVE ASSEMBLY SNAP RING % grfi OIL SEAL $2”! \ RING GEAR BEARINGS am 8 mm BOLTS 25 Nm (2.5 kgf'm. 18 |bf~fl) QIll 10 mm BOLTS 62 Nm (6.3 kgf~m, 46 mm) CASE COVER RING GEAR FINAL GEAR CASE $27! RING GEAR SHAFT BEARING RING GEAR SHAFT SHIM $2 STOPPER RING PINION GEAR PINION GEAR @ BEARING SHIM E5? LOCK NUT 206 NM (21.0 kgf~m, 152 IDHI) STOPPER RING \ \ a, '7! PINION GEAR Q® v SHAFI' BEARING AR PINION GE 9! CASE BOLT W 221 N~m (22.5 kgI-m, v RETAINER ,6. RETAINER 163 le-fl) 235 N1" (240 kgf'm, 221 Mm (225 kgf~m, 9? fl OIL SEAL 173 mm) 163 Ibf-fl) PINION GEAR INSTALLATION Install the pinion gear shim [1] and pinion gear assembly [2] into the gear case. 14-19 FINAL DRIVE Make sure that the pinion gear shaft sets into the needle bearing properly. The lock nu! wrench (60 mm off-set from the center) increases the torque wranch's leverage, so the torque wrench reading will be less than the torque actually applied ta Ina retainen The lock nut wrench (60 mm off-set from the center) increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut Be careful no! to damage the pinion gear and gear case Drive the pinion gear assembly [1] into the gear case until it is fully seated using the special tools TOOLS: Driver [2] 077490010000 Attachment, 70 mm [3] 07LAD-PW50500 Hold the gear case in a vise with soft jaws. Install a new pinion gear bearing retainer [1]. Tighten the retainer to the specified torque using the special tool, YOOL: Lock nut wrench 42/56 [2] 010MA-MGE0100 or O70MA-MGEA100 (U.S.A. only) TORQUE:235 N-m (24.0 kgf-m, 173 lbf-f!) Insta|l a new pinion gear lock nut [1]. Hold the pinion gear and tighten the lock nut to the specified torque using the special tools. TOOLS: Involute spline holder [2] Lock nut wrench 42/56 [3] 070MB-MGE0100 o1oMA-MGE01oo or o70MA-MGEA100 (use only) T5RQUE:206 N~m (21.0 kgl-m, 152 lbf-ft) Stake the pinion gear lock nut [1] and bearing retainer [2], [2] 14-20 Be sure to wear insulated gloves when handling the heated gear case. Apply grease to a new oil seal [1] lips‘ Install the oil seal and set the stopper ring [2] into Ihe gear case groove securely. RING GEAR INSTALLATION Heat the gear case cover to 80°C (176“F) evenly using a heat gun. NOTE: Do not use a torch to heat the gear case cover: it may cause warping. Install the ring gear bearings [11 and drive them into the gear case cover until they are lully seatedt Apply grease to a new oil seal [1] lips. Drive a new oil seal until it is lully seated using the special tools. TOOLS: Driver [2] 0774941010000 Attachment, 78 x 90 mm [3] o7GAD-SD40101 Attachmeng 78.5 mm [4] D7JME-MR10100 (Not avallable In u_s.A.) Set the snap ring [1] into the gear case groove securely. FINAL DRIVE 14-21 FINAL DRIVE Install the shim [1] onto the ring gear [2]. Support the bearing inner race with the special tool and press the ring gear into the bearings using a hydraulic press YOOL: Base 105 x 115 x 35 mm [3] 07ZMF-MCAO3OO or 07ZMF-MCAA300 (U.S.A. only) FINAL GEAR CASE ASSEMBLY NOTE; When the gear set, bearing and/or gear case has been replaced, check the tollowing: - tooth contact pattern (page 14-10) - gear case backlash (page 149) Keep dust and din Clean the mating surface of the gear case [1] and cover our ofthe case and [2]. being careful not to damage them. “we” Apply liquid sealant to the mating surface of the gear case. Install the shafi shlm13]. Install the gear case onto the case cover. Clean and apply a locking agent to the threads of the case cover 10 mm bolts [1] and 8 mm bolts [2], lnstalt the bolts. and tighten them in a crisscross pattern in several steps until the cover evenly touches the gear case Tighten the two 10 mm bolts to the specified torque in several steps alternately. ronouemz N-m {6.3 kgf-m, as Ibf-ft) Tighten the six 8 mm bolts to the specified torque in a crisscross pattern in several steps. TORQUE:25 N~m (2.5 kgl-m, 18 lbf-ft) Check that the gear assembly turns smoothly without blnding using the special tool. TOOL: i lnvolute spline holder [1] o70MB-MGE0100 Measure the final gear assembly preload. STANDARD: 0.1 — 2.9 N-m (1 — 29 kgt-cm, 0.1 — 2.1 Ith) It the preload reading does not fall within the specification, check the bearings for proper installation 14-22 FINAL DRIVE INSTALLATION Check that the gear case stud bolts are tight, I! any are loose, remove them and clean their threads with oontact cleaner. then install them using a locking agent (page 1-21). After installing, be sure to measure the distance from the top of each stud to the gear case surface as shown Apply molybdenum disullide grease to the splines [1] of the drive shalt assembly. Install a new snap ring [1] into the universal joint groove. Install a new stopper ring [1] into me drive shalt groove. 37— 39 mm STUD BOLT f___.———4 (1 ,45 — 1.53 in) FINAL DRIVE Du [1] 14-23 FINAL DRIVE Apply 1.0 — 1.5 g (0.04 e 0.05 oz) 01 molybdenum disulfide grease to the pinion shaft splines. Make sure the install the drive shaft assembly [1] into the pinion shaft stoppern'ngis until the stopper ring seats in the pinion shalt spline sealed pmperly by groove. pulling on the drive shaitlightly. Apply grease to the splines of output shaft Install the dowel pins [1] to the final gear case assembly. Insert the final drive assembly [2] into the swingarm and align the drive shafl splines with the output shaft ' splines. Install the final gear case assembly mounting nuts [1] and tighten them to the specified torque in a crisscross pattern in several steps. TORQUE: 38 N-m (9.0 kgf-m, 65 IM-fl) Set the snap ring [1] into the output shafl groove [2] securely. Install the drive shaft boot [3] securelyt 14-24 FINAL DRIVE Install the two dowel pins [1] to the ring gear‘ Apply oil to a new O—ring [2] and install it to the ring gear groove securely. Do nor get grease Apply grease to rear brake disc flange [3] inner surface on the brake disc or stopping pnwer will be reduced. Be carelulnol to Install the rear brake disc flange to the final gear case pinch the final year by aligning the disc flange holes with the dowel pins. case oil seal lips. Install the rear brake disc flange mounting screws [1] to the specified torque. TORQUE: 9.0 MM (0.9 kgf-m, 6.6 IbMt) Install the lollowing: — rear brake caliper (page 17-37) — rear wheel (page 1&5) Fill the final gear case with the recommended gear oil (page 4-20). 14-25 MEMO 15. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION ........................ "15.2 FRONT WHEEL ...................................... "1543 SERV|CE "FORMATION ......................... "15.3 FORK ....................................................... "15.19 TROUBLESHOOTING" STEERING STEM ................................... "15,30 HANDLEBARS .......................................... ..15_7 1 5-1 FRONT WHEELISUSPENSIONISTEERING COMPONENT LOCATION 79 N-m (3.1 kgfivm, 58 mm) 15-2 FRONT WHEELISUSPENSIONISTEERING SERVICE INFORMATION GENERAL - When servicing the front wheel. fork or steering stem, support the motorcycle using a safety stand or hoist. ' A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. After the front wheel installation. check the brake operation by applying the brake lever and pedal. Refer to the brake system information (page 17-4). Use only tires marked "TUBELESS' and tubeless valve stems on rim marked "TUBELESS TIRE APPLICABLE". SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 1.5 (0.06) Cold tire Up to 90 kg (200 lb) load 250 kPa (2.50 kgf/cm . 36 psi) — pressure Up to maximum weight capacity 250 kPa (2.50 kgf/cm , 36 psi) — Axle runout — 0.2 (0.01) Wheel Radial — 2.0 (0.08) rim runout Axial — 2.0 (0.08) Wheel balance weight _ 60 g (2.1 oz) max. Fork Spring free length 232.8 (9.17) 223.1 (8.98) Tube runout — 020 (0.008) Preload adjuster initial setting 9 mm (0.4 in) from top surface of fork bolt — Rebound damping adjuster initial 6 clicks from fully hard position setting Recommended fork fluid KHL 15-10 (KYB) — Fluid level 160 (6.3) -— Fluid capacity 497 t 3 cm (16.8 i 0.1 US oz. _ 17.5 g 0.1 Imp oz) Steering head bearing pro—load 16.7 — 20.6 N (1.7 — 2.1 kgf. 3.7 — 4.6 lbf) — TORQUE VALUES Handlebar weight mounting screw 10 N-m (1.0 kgfm. 7 Ibt-ft) ALOC screw; replace with a new one. Left handlebar‘switch housing screw 2.5 N-m (0.3 kgf-m. 1.8 Ibf-ft) Clutch master cylinder holder bott 12 NM (1.2 kgf-m, 9 Ibf-fl) Right handlebar switch/throttle housing screw 2.5 N‘m (0.3 kgf-m. 1.8 lbf-ft) Front brake disc bolt 20 Nm (2.0 kgf‘m, 14 mt") ALOC bolt; replace with a new one. Front wheel pulser ring mounting bolt 70 N-m (0,7 kgf-m. 5.2 lbf-ft) ALOC bolt; replace with a new one. Front axle bolt 79 Nm (8.1 kgf‘m. 53 Ibf-ft) Front axle holder pinch bolt 22 N-m (2.2 kgf-m. 16 lbf-ft) Front brake caliper mounting bolt 45 Nm (4.6 kgt‘m, 33 lbf-fl) ALOC bolt; replace with a new one. Fork socket bolt 20 N-m (2.0 kgf-m, 15 Ibf-ft) Apply a locking agent to the threads. Fork damper rod lock nut 15.5 N~m (1.6 kgf-m. 11 [bf-fl) Fork bottom bridge pinch bolt 27 N-m (2.3 kgf-m. 20 lbf-ft) Fork bolt 22 N'm (2.2 kgf-m. 16 lbf‘fl) Fork top bridge pinch bolt 22 N'm (2.2 kgf‘m, 16 lbf-ft) Steering bearing adjusting nut » Steering bearing adjusting lock nut v Brake hose clamper stay bolt 10 N~m (1.0 kgf~rn, 7 lbf-ft) Steering stern nut 103 Nm (10.5 kgfm, 76 |bf~ft) See page 15-37 See page 15-37 15-3 FRONT WHEEL/SUSPENSIONISTEERING TOOLS Bearing remover head. 25 mm Bearing remover shafl Driver 07746-0050800 07GGD>0010100 07749-0010000 1?! Attachment, 52 x 55 mm Pilot, 25 mm Spring collar holder 07746—0010400 077460040600 070MF-MBZC1 10 NOTE: This tool is a part of fork damper install set (PIN 070MF-MBZC100) (Not available in U.S.A.) Fork spring compressor Stopper plate Fork rod stopper 07AMC-MFJA1OD (USA, only) 070MF»MBZC130 O7AMB-KZ3A100 (U.S.A. only) X a NOTE: This tool is a part of fork damper install set (P/N 070MF—MBZC100) (Not available in USA.) Fork damper holder Fork seal driver Damper rod holder 07YMB-MCF0101 07YMD-MCF0100 070MF-MBZC120 or 07YMB—MCFA1OD (U.S.A. only) or 07NMD-K23010A (USA only) NOTE: This tool is a part of fork damper install set (PIN 070MF-MBZC100) (Not available in U.S.A.) 15-4 FRONT WHEEL/SUSPENSIONISTEERING Damper rod holder 070MF-MBZA120 (USA only) Steering stem socket 0791643710101 Installer attachment, 47 x 5.5 mm 07946-KM90100 (nol available in USA.) installer altachmenl, 55 x 6 mm 07946—KM90200 (not available in U.S.A.) Installer shaft 07946-KM90301 9% (Not available in USA.) Remover attachment. 43 mm 07946-KM90401 9% (not available in U.S.A,) Remover anachmenl, 47 mm 07946-KM90500 (not available in U.S.A.) Base, 48.4/56 07946-KM90600 (r at available in USA.) Main bearing inslaller, 50 x 54 mm 07946-ME90200 Fork seal driver weight. 45.5 x 54.3 mm 07947-KA50100 Oil seal driver, 58 x 72 mm 07965-MA60000 Installer shaft 15 x 370L 07VMF-K230200 (U.S.A. only) ® 15-5 FRONT WHEEL/SUSPENSIONISTEERING Installer attachment A 07VMF-MAT0100 (U.S.A. only) Installer attachment B ONMF-MATOZOO (USA only) Remover attachment A 07VMF-MAT0300 (USA. only) Remover attachment B OTVMF-MAT0400 (USA. only) Steering stern driver 079463 1oa N-m (1110 mm. so Ile) 45 N-m (4.5 kgf-rn. 33 luv-fl) 1 6-2 REAR WHEEL/SUSPENSION SERVICE INFORMATION GENERAL Riding on damaged rims impairs safe operation at the vehicle. The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Belore disposal of the shock absorber, release the nitrogen (page 16-8). When servicing the rear wheel, shock absorber, or swingarm. raise the rear wheel off the ground by supporting the frame securely. - Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE". Use only Honda Genuine replacement bolts and nuts for all suspension pivot and mounting points. For brake system inlormation (page 17-4). SPECIFICATIONS Unlt: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth - 2.0 (0.08) Cold tire Up to 90 kg (200 lb) load 290 kPa (2.90 kgf/cm .42 psi) — pressure Up to maximum weight capacity 290 kPa (2.90 kgflcm , 42 psi) — \ Wheel rim Radial — 2.0 (0.08) - runout Axial — 2.0 (0.08) 5 Wheel balance weight _ 60 g , (2.1 oz) max. ‘ Shock absorber Spring pre-load adjuster standard 11 clicks out from lower position _ position Rebound adjuster initial setting 3/4 turn out from lull hard TORQUE VALUES Rear wheel nut 108 Mm (11.0 kgf-m. 80 lbl‘ft) Exhaust pipe muffler band 17 N~m (1.7 kgf~m. 13 Ibf-ft) Rear shock absorber bracket mounting nut 42 N-m (4.3 kgt~m. 31 lbflt) U-nut Rear shock absorber upper mounting nut 44 N-rn (4.5 kgtlm. 32 lbf-lt) U-nut Rear shock absorber lower mounting nut 44 N-m (4.5 kgftm. 32 lbf-fl) U-nut Shock arrn—to-shock link plate nut 64 N-m (6.5 kgf‘m. 47 lbi-fl) U-nut Shock ann-to«frame pivot nut 64 N-m (6.5 kgf-m. 47 mm) U»nut Shock linkrplate-to-swingarm nut 64 N-m (6.5 kglvm, 47 lbf-fl) U-nut Swingarm pivot adjust bolt 15 N-m (1.5 kgt-m. 11 mm) Swingarm pivot nut 103 N~m (11.0 kgf~m, 30 let) U-nut Rear brake pipe clamper bolt 10 N-m (1.0 kgl‘m, 7 Ibivft) ALOC bolt: replace with a new one. 1 6-3 REAR WHEEL/SUSPENSION TOOLS 07746—001 O1 00 07MAD-PR90200 Driver handle. 15 x 280L Attachment. 22 x 24 mm Pilot. 17 mm 07949-3710001 07746—0010800 077460040400 Attachmemv 24 x 26 mm Pilot. 20 mm ' Pivot guide 07746—0010700 07746-0040500 O70MG»MGE0100 or 070MG»MGEA100 (USA. only) Attachment. 32 x 35 mm Pilot. 32 mm Aflachment, 40 x 42 mm 07746-0010900 or D7OMG-MGEA100 (U.S.A. only) Pilot. 25mm 07746-0040600 Driver handle, 15 x135L 07749-0010000 16-4 REAR WHEEL REMOVAL/INSTALLATION Remove the right rear cowl (page 34). Remove the muffler mounting nut [1]. bolt [2] and washers [3]. Release the EGCA cable [1] from the hooks [2] and guide [3]. Loosen the muffler band bolt [1]. Swing the muffler to outside until the stopper [2] of muffler contacts the frame [3]. Support the motorcycle securely and raise the rear wheel ofi the ground. Remove the wheel nuts [1] and rear wheel. Installation is in the reverse order of removal, TORQUE: Rear wheel nut: 108 Mm (11.0 kgf~m, 80 Ibf'fl) Mumer band bolt: 17 N-m (1.7 kgfm,13lbf‘ft) After installation. inspect the exhaust system for leaks. Check the EGCA operation (page 4-17). REAR WHEEL/SUSPENSION 1 6-5 REAR WHEEUSUSPENSION INSPECTION Wheel Rim Runout Remove the wheel center cap. Check the rim mnout by placing the wheel in a trueing stand [1]. Spin the wheel slowly and read the runout using a dial indicator. Actual mnout is 1/2 the total indicator reading. SERVICE L|MITS: Radlal: 2.0 mm (0.08 in) Axlal: 2.0 mm (0.08 In) For wheel balance servicing (page 15-14). SHOCK ABSORBER REMOVAL Remove the muffler (page 3—21). Lift and support the fuel tank (page 46), Support the motorcycle securely and raise the rear wheel off the ground. Remove the bolt [1] and ore-load adjuster [2] from the bracket. Remove the shock arm bolt/nut [1] (link plate side), Remove the shock absorber lower mounting bolt/nut [2]. ' Remove the shock absorber upper mounting nul [1] and lower the shock absorber/upper bracket assembly. 1 6-6 REAR WHEEL/SUSPENSION Remove the shock absorber upper mounting bolt/nut [1], then remove the shock absorber upper bracket [2]. [2] INSPECTION Check the damper unit [11, reservoir hose [2] and [3] reservoir for leakage or other damage. Check the upper bushing [3] lor wear or damage. Replace the shock absorber assembly if neoessary, I1] 4 Remove the lower pivot collar [4]. l 1 Check the needle bearing, pivot collar and dusl seals tor wear or damage. [21 NEEDLE BEARING REPLACEMENT Remove the pivot collar [1] and dust seals [2]. Press the needle bearing [1] out of the shock absorber lower mount using the special tools and a hydraulic press. TOOLS: Drlver handle, 15 x ZBOL [2] 07949-311 0001 Attachment, 22 X 24 mm [3] 0774643010800 Pilot, 17 mm [4] 077460040400 16-7 REAR WHEEL/SUSPENSION Press the needle bearing into the lower mount with the marked side facing up. Pack a new needle bearing [1] with molybdenum disulfide grease. Press the needle bearing into the lower mount so that the needle bearing surface is 6.0 mm (024 in) from the end of the lower mount using the special tools and a hydraulic press. TOOLS: Driver handle. 15 x 280L [2] 07949—371001“ Attachment, 22 X 24 mm [3] 0174643010800 Pilot, 17 mm [4] 0774641040400 Apply molybdenum disulfide grease to new dust seal [1] lips, install them into the lower mount. install the pivot collar [2]. SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper to mark the drilling point. Wrap the damper unit inside a plastic bag. Support the damper in a vise as shown. Through the open end of the bag. insert a drill motor with a sharp 2 — 3 mm (5/64 — 1/8 in) drill bit - Point the valve away from you to prevent debris getting in your eyes. Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start, [2] 6.0 mm (024 in) [31/14] 1 6-8 INSTALLATION Install the upper bracket [1] to the shock absorber. Install the mounting bolt [2] againsl the stopper [3] of upper bracket. install the mounting nut [1] and tighten it to the specified torque. TORQUEzM N-m (4.5 kgf-m, 32 lbf-f!) Install the shock absorber/upper bracket assembly into the frame with the rebound damping adjuster lacing to the left side. install and tighten the upper bracket nut [1] to the specified torque. TORQUE142 N-m (4.3 kgf-m, 31 lbl-ft) Install the shock absorber lower mounting bolt from the left side through the link plates [1]. Install and tighten the lower mounting nut [2] to the specified torque. TORQUE“ N-m (4.5 kgf-m, 32 Ibifll Install the shock arm bolt from the left side through the shock arm [3] and link plates. Install and tighten the shock arm nut [4] to the specified torque. TORQUE: 64 N-m (6.5 kghn, 47 lbf-f!) REAR WHEELISUSPENSION [1] 1 6-9 REAR WHEEL/SUSPENSION SUSPENSION LINKAGE Do not service the suspension linkage While the exhaust system is hot Install the ore—load adjuster [1] onto the bracket and tighten the mounting bolt [2] securely. Close the fuel tank (page 45). Install the muffler (page 3-23)‘ REMOVAL Support the motorcycle securely and raise the rear 7 wheel oil the ground. Remove the following: shock absorber lower mounting bolt/nut [1] shock arm boll/nut (link plate side) [2] shock arm bolt/nut (frame side) [3] shock arm [4] shock link pate-to—swingarm bolt/nut [5] shock link plates [6] llllll INSPECTION Remove the pivot collars [1] and dust seals [2]. Check the dust seals and collars for wear. damage or fatigue. Check the needle bearings for damage or loose fit Check the shock arm [3] for cracks or damage. [3] SHOCK ARM BEARING REPLACEMENT Remove the pivot collars and dust seals. Press the needle bearings [1] out of the shock arm ‘ using the special tools and a hydraulic press. TOOLS: Driver handle. 15 x ZBOL [2] 079496710001 [3144] Attachment 24 x 26 mm [3] 0774643010700 Pilot, 20 mm [4] 07746-004050” 16-10 Press the needle bearing mm the shock arm with the marked side facing up. (0.30 — 0.32 in) from the end of the shock arm using the Pack new needle bearings [1] with molybdenum disulfide grease. Press the needle bearings into the shock arm so that the needle bearings surface are 7.6 — 8.1 mm special tools and a hydraulic press. TOOLS: Driver handle, 15 x 280L [2] 07949-3710001 Attachment 24 x 26 mm [3] 07146-0010700 Pilot, 20 mm [4] 077460040500 Apply molybdenum disulfide grease to new dust seal [1] lips, install them into the shock arm [2]. Install the pivot collars [3]. INSTALLATION Install the following: — shock arm [1] — shock arm bolt/nut (frame side) [2] — shock link plates [3] with their arrow mark [4] facing to the ionuard — shock link plateto—swingarm bolt/nut [5] — shock arm bolt/nut (link plate side) [6] — shock absorber lower mounting boIfJnut [7] Tighten the shock arm nut (frame side) to the specified torque. TORQUE164 NM (6.5 kgf-m, 47 [bf-f!) Tighten the shock link plate-to»swingarm nut to the specified torque. TORQUE“ N‘m (6.5 kgf-m, 47 |bf'f!) Tighten the shock arm nut (link plate side) to the specified torque. TORQUE“ N~m (6.5 kgf-m, 41 mm) Tighten the shock absorber lower mounting nut to the specified torque. TORQUE“ N-m (4.5 kgf-m, 32 lbffl) REAR WHEELISUSPENSION [31/[4] 7.6 — 6.1 mm (030 ~ 0.32 in) 16-11 REAR WHEEIJSUSPENSION SWINGARM REMOVAL Remove the following: rear exhausi pipe (page 3—24) shock absorber (page 16-6) suspension linkage (page 16-10) final drive (page 14-6) Becamfu/ not to Remove the bolt [1]. stay [2] and brake pipe joint [3] bend Ordamage the from the swingarrn‘ Drake pipe. Remove the bolts [1] and wire clampers [2] from the swingarm. Remove Ihe swingerm pivot nul [1] and washer [2]. Remove the swingarm pivot bolt [1] and washer [2]. 16-12 REAR WHEEL/SUSPENSION Remove Ihe adjust bolt [1] using me special tool. TOOL: Plvot guide [2] 010MG-MGE0100 or 070MG-MGEA1 00 (U.S.A. only) Remove the special tool, adjust bolt and pull the swingarm rearward slighlly, Be careful/vane Remove the bolt [1], wire clamper [2] and brake pipe bend or damage joint [3], then remove the swingarm [4]. the brake pipe. DISASSEMBLY/INSPECTION Release the four tabs [1] and remove the joint boot [2]. Remove the bolts [1] and drive shaft cover [2]. 16-13 REAR WHEELISUSPENSION Remove the grommets [1] from the swingarm, Remove the clips [1] from the swingarrnl Remove the pivot collars [1] and dust seals [2] from the swingarm pivot Check the dust seals and pivot collars for wear or damage Remove the dust seals [1] and shock link plate pivot collar [2] from the swingavm. Check the dust seals and pivot collar for wear or damage. 16-14 REAR WHEEL/SUSPENSION PIVOT BEARING REPLACEMENT Remove the right pivot needle bearing [1] from the right swingarm pivot using the special tool and a hydraulic press. TOOLS: Drlver handle, 15 x 280L [2] 07949-3710001 Attachment 32 x 35 mm [3] 07746-0010100 Pllot. 32 mm [4] 07MAD-PR90200 Remove the snap ring [116mm the left swingarm pivot. Remove the left pivot needle bearing [1] and pivot ball bearing [2] from the left swingarm pivot using the special tool and a hydraulic press. TOOLS: Driver handle, 15 x 280L [3] 07949-3710001 Attachment 40 x 42 mm [4] 07746-0010900 Pilot, 25 mm [5] 077460040600 Press the bell Pack a new left ball bearing [1] with molybdenum bearing into the disulfide grease. swingann with the Press the ball bearing in lefl swingarrn pivot until it is marked side facing fully seated using the special tools and a hydraulic up. press. TOOLS: Driver handle, 15 x 135L [2] 07749-001000!) Attachment 40 x 42 mm [3] 077460010900 Pilot, 25 mm [4] 07746-0040600 16-15 REAR WHEEL/SUSPENSION Press the needle bearing into the swingerm with the marked side facing up. Pack a new lefl needle bearing [1] with molybdenum disulfide grease. Press the needle bearing in left swingarm pivol until it is lully sealed using the special tools and a hydraulic press. TOOLS: Driver handle. 15 x 135L [2] Attachment 40 x 42 mm [3] 0774943010000 07748-001 0900 Install the snap ring [1] into the groove securely, Pack a new right needle bearing [1] with molybdenum disulfide grease Press the needle bearing in right swingarm pivol until it is fully sealed using the special tools and a hydraulic press. TOOLS: Driver handle, 15 x 135L [2] 017490010000 Attachment 40 x 42 mm [31 0774547010900 Pilot, 32 mm [4] 01MAD-PR90200 SHOCK LINK PLATE BEARING REPLACEMENT Remove the shack link plale needle bearing [1] from the swingarm using the special tool and a hydraulic press. TOOLS: Driver handle, 15 x 2001. [21 070494710001 Attachment 24 x 26 mm [31 0774041010700 Pilot, 20 mm [4] 077400040500 [SI/[4] 16-16 REAR WHEEL/SUSPENSION Press me needle Pack a new shock link plate needle bearing [1] with hearing into the molybdenum disulfide grease, swings/m wirhthe Press the needle bearing in swingarm so that the marked side facing needle bearing surface is 8‘0 - 805 mm (0.31 — 0.33 in) up, from the end of swingarm surface, using the special tools and a hydraulic press, 8.0 — 8.5 mm («131 — 0.33 In) TOOLS: -' Driver handle, 15 x 280L [2] 079404710001 Attachment 24 x 26 mm [3] 07746-001010!) 7 Pllot, 20 mm [41 077460040500 ’ v fl [1] ASSEM B LY g ’fil GROMMETS NEEDLE BEARING 2? Ail-I SNAP RING BALL BEARING PIVOT COLLAR\‘®\‘ / e? m/@@ DUST SEAL @\ SWINGARM DRIVE SHAFT COVER JOINT BOOT NEEDLE BEARING NEEDLE gamma 3 SWINGARM PIVOT @ i COLLARS SHOCK LINK PLATE V PIVOT COLLAR DUST SEALS gm DUST SEAL Install the shock link plate pivot collar [1] to the swingarm‘ Apply molybdenum disulfide grease to new dust seal [2] lips. then install the dust seals into the swingarm. 16-17 REAR WHEEL/SUSPENSION Apply molybdenum disulfide grease to new dust seal [1] lips. Install the dust seals and pivot collars [2] to the swingam'l pivot. Install the clips [1] to the swingarm securely. Install the grommets [1] to the swingarm securely. Install the drive shaft cover [1] and tighten the bolts [2] securely. 16-18 REAR WHEEL/SUSPENSION Install the joint boot [1] by aligning its slits with the four tabs [2] of the drive shaft cover. INSTALLATION Be careful not to Set the swingarm [1] into the frame. bend or damage Install the brake pipe joint [2], wire clamper [3] with the the brake pipe. speed sensor wire and lighten the bolt [4] securely. Set the swingarrn into the frame and install the adjust bolt [1] with special tool. TOOL: Pivot guide [2] 070MG-MGE0100 or 070MG-MGEA100 (U.S.A. only) Tighten the adjust bolt [1] to the specified torque. TORQUE: 15 N-m (1.5 kgf-m,11 le!) 16-19 REAR WHEELISUSPENSION Route the brake hose and speed sensor wlre Pmperly (page 1-22)- Bs careful not to bend or damage the brake pipe. Install the swingarrn pivot bolt [1] and washer [2] from the left side while pushing out the special tool [3]. Install the washer [1] and pivot nut [2]. and tighten the pivot nut to the specified torque while holding the pivot bolt, ‘romusnoe N-m (11.0 kgfm, so lbf-ft) Install the wire dampers [1] with the brake hose and speed sensor wire. Push the wire clampers against the stoppers of swingarm, then tighten new bolts [2] to the specified torque romuzno N-m (1.0 kgf-mfl mm) Install the wire damper [3] with the speed sensor wire. Push the wire clamper against me stopper 0! swingarm, thgrttighten the bolt securely. Install the brake hose joint [1] and stay [2], and tighten the bolt [3] securely. Secure the speed sensor and brake hose with the clip [4]. Install the following: — final drive (page 14-23) — suspension linkage (page 16—1 1) — shock absorber (page 16-9) - rear exhaust pipe (page 3-27) 16-20 17. HYDRAULIC BRAKE COMPONENT LOCATION - --------- --11.2 SERVICE INFORMATION ------------------------ "17-4 TROUBLESHOOTING ............................... "17,5 BRAKE FLUID REPLACEMENT] AIR BLEEDING ............ .. .17_7 BRAKE pAD/Dlsc .................................. “17.14 FRONT MASTER CYLINDER ---------------- "17-18 REAR MASTER CYLINDER/BRAKE LIGHT SWITCH/BRAKE FEDAL ........................ "11.23 FRONT BRAKE CALIPER ...................... ..11_29 REAR BRAKE CALIPER ----------- -- --17-34 pcv ......................................................... "17.33 DELAY VALVE ........................................ .. 11.33 17-1 HYDRAULIC BRAKE COMPONENT LOCATION FRONT: 1.5 N~m (0.2 kgl-m. 1.1 mm) 45 N-m (4.6 kgf~m. 33 mm) 17-2 REAR: HYDRAULIC BRAKE Y (3.5 kgf~m. 25 Ibi-ft) 34 N-m (3.5 kgf‘m. 25 Ile) 18 N-m (1.8 kgf‘mx13lbf-fl) 17-3 HYDRAULIC BRAKE SERvaINFORMAHON GENERAL ACAUHON Frequent inhalation of brake pad dust, regardless of material oomposition could be hazardous to your health. - Avoid breathing dust parficles. ‘ Never use an air hose or brush to clean brake assemblies. Use an OSHA»approved vacuum cleaner. Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the from reservoir is horizontal first. This model is equipped with a Combined Brake System. The system air bleeding procedure must be followed (page 17-7). A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Check the brake system by applying the brake lever or pedal afler the air bleeding. Never allow oontaminants (e.g., dirt, water) to enter an open reservoir. Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible. Once the hydraulic system has been opened, or 'rfthe brake feels spongy, the system must be bled. This section covers service of the standard brake components of the brake system. For Anti-look Brake System (ABS) service, see page 18-4. . Always check brake operation before riding the motorojcle. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 brake fluid — Brake diso mickness 4.5 t 0.1 (0.13 x 0.004) 3.5 (0.14) Brake disc warpage — 0.20 (0008) Master cylinder |.D. 15.870 — 15.913 (0.6248 — 0.6265) 15.925 (0.6270) Master piston OD. 15.827 — 15.354 (0.6231 — 0.6242) 15.815 (0.6226) Right caliper cylinder |.D. Upper 25.400 — 25.450 (1.0000 — 1.0020) 25.460 (1.0024) Middle 25.400 — 25.450 (1.0000 — 1.0020) 25.460 (1.0024) Lower 25.400 — 25.450 (1.0000 — 1.0020) 25.460 (1.0024) Right caliper piston OD. Upper 25.318 — 25.368 (0.9963 — 0.9987) 25.310 (0.9965) A ' Middle 25.318 — 25.368 (0.9968 — 0.9987) 25.310 (0.9965) Lower 25.31 B — 25.368 (3.9968 — 0.9987) 25.310 (0.9965) Left caliper cylinder |.D. Upper 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) Middle 30.230 — 30.280 (1.1902 — 1.1921) 30.290 (1.1925) Lower 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) Lefl caliper piston O.D. Upper 26.918 — 26.966 (1.0598 -1.0617) 26.910 (1.0594) Middle 30.148— 30.198 (1.1869— 1.1889) 30.140 (1.1866) Lower 26.918 — 26.968 (1.0598 — 1.0617) 26.910 (1.0594) Rear Specified brake fluid DOT 4 brake fluid — Master cylinder push rod length 67.5 1 1 (2.66 t 0.04) — Brake disc thickness 6.0 :t 0.2 (0.24 i 0.008) 5.0 (0.20) Brake disc warpage — 0.30 (0.012) Master cylinder I.D. 17.460 — 17.503 (0.6374 — 0.6891) 17.515 (0.6896) Master piston CD. 17417 — 17.444 (0.6857 — 0.6868) 17.405 (0.6352) 27.000 — 27.050 (1.0630 —1.0650) 27.060 (1.0654) 27.000 — 27.050 (1.0630 — 1.0650) 27.060 (1.0654) 26.918 — 26.968 (1.0598 — 1.0617) 26.910 (1.0594) Caliper cylinder I.D. Front Rear Caliper piston O.D. Front Rear 26.918 — 26.968 (1.0598 — 1.0617) 26.910 (1.0594) 17-4 TORQUE VALUES Brake caliper bleed valve Front master cylinder reservoir cap screw Front brake caliper mounting bolt Pad pin Rear brake disc bolt Front brake light switch screw Front brake lever pivot bolt Front brake lever pivot nut Front master cylinder holder bolt Brake hose oil bolt Rear master cylinder push rod joint nut Rear master cylinder mounting nut Rear master cylinder reservoir hose joint screw-washer Rider tootpeg bracket socket bolt Rear brake caliper main slide pin Rear brake caliper sub slide pin Rear brake caliper mounting bolt Brake pipe joint nut PCV mounting nut TOOL Snap ring pliers D7914-SA50001 5.4 Nrm (0.6 kgf~m, 4.0 Ibf-ft) 1.5 N-m (0,2 kgf'm, 1.1 mm) 45 N-m (4.5 kgf-m, 33 Ibf-tl) 1a N-m (1.8 kgf-m. 13 lbf-ft) 42 Nm (4.3 mm, 31 lbftt) 1.2 N‘m (0.1 kgf‘m, 0.9 Ibf-fl) 1.0 N-m (0,1 kgf-m. 0.7 Ibt-fl) 5.9 N-m (0.6 kglm, 4.4 |bf~tt) 12 Nm (1.2 kgf'm, 9 lbf‘ft) 34 N~m (3.5 kgf-m, 25 Ibf-fl) 13 N-m (1.8 kgf‘m, 13 lbt-ft) 12 N~m (1.2 kgf~m, 9 lbf‘tt) 1.5 Nlm (0.2 kgt-m. 1.1 M41) 34 N‘m (3.5 kgt-m, 25 mm) 23 N‘m (2.3 kgf-m, 17 mm) 13 N-m (1.3 kgr-m, 9 Ibf-tt) 45 N-m (4.6 kgrm, 33 Ibf-ft) 14 N-m (1.4 kgI-m, 10 (bin) 10 Nm (1.0 kgf~m, 7 Ibf-ft) HYDRAULIC BRAKE ALOC bolt: replace with a new one ALOC bolt: replace with a new one. Apply a locking agent to the threads. Apply a locking agent to the threads. ALOC bolt: replace with a new one. Apply brake fluid to the threads. 17-5 HYDRAULIC BRAKE TROUBLESHOOTING Brake Ieverlpedal soft or spongy Air in hydraulic system Low brake fluid level Leaking hydraulic system Clogged fluid passage Contaminated brake pad/disc Worn caliper piston seals Worn master cylinder piston cups Worn brake pad/disc Contaminated caliper Caliper not sliding properly (rear) Warped/deiormed brake disc Siicking/wom caliper piston Sticking/worn master piston Contaminated master cylinder Bent brake lever/pedal Brake lever/pedal hard - Clogged/restricted hydraulic system - Sticking/wom caliper piston ‘ Caliper not sliding properly (rear) - Clogged/restricted fluid passage Worn caliper piston seal Sticking/worn master piston Bent brake lever/pedal Brake drag Contaminated brake pad/disc Misaligned wheel Clogged/restricted brake hose Joint Warped/deformed brake disc Caliper not sliding properly (rear) Clogged/restricted brake hydraulic system Sticking/worn caliper piston Clogged master cylinder port 1 7-6 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING Spilled fluid can damage painted, plastic, or rubber parts. Place a rag over these pens whenever the system is serviced, NOTE: - Do not allow foreign material to enter the system when filling the reservoir, ~ When using a commercially available brake bleeder, follow the manufacturer‘s operating instructions. BRAKE FLUID DRAINING LEVER BRAKE LINE: Turn the handlebar until the Iront master cylinder reservoir is level belore removing the reservoir cap. Remove the screws [1] and reservoir cap [2]. Remove the set plate [3] and diaphragm [4]. Connect a commercially available brake breeder [1] to the left Iront brake caliper oenter bleed valve [2]. Loosen the valve and operate the air bleed tool. Drain the brake fluid. Connect a commercially available brake breeder [1] to the right front brake caliper bleed valve [2]. Loosen the valve and operate the air bleed tool. Drain the brake fluid. 1 7-7 HYDRAULIC BRAKE PEDAL BRAKE LINE: Place the motorcycle on a level surface. Remove the right rear cowl (page 3-4). Remove the reservoir cap [1]. Remove the set plate [2] and diaphragm [3). Connect a commercially available brake bleeder [1] to the left front brake caliper upper bleed valve [2]. Loosen lhe bleed valve and operate an air bleed tool. Drain the brake fluid ' Connecl a commercially available brake bleeder [11 to lhe rear brake caliper bleed valve [2L Loosen the bleed valve and operale an air bleed tool. Drain the brake fluid‘ 17-8 HYDRAULIC BRAKE BRAKE FLUID FILLING/BLEEDING NOTE: O Use only DOT 4 brake fluid from a sealed container. ' DD not mix different types of fluid, they are not compatible - Check the fluid level oflen while bleeding to prevent air from being pumped into the system. - If air is entering the bleeder Irom around the bleed valve threads, seal the threads with leilon tape, LEVER BRAKE LINE: FRONT MASTER CYLINDER ABS MODUIATOR LEFT FRONT CALIPER RIGHT FRONT CALIPER Tighten the from brake caliper bleed valves securely and fill the reservoir to the upper level line [1] with DOT 4 brake fluid irom a sealed container. 1 7-9 HYDRAULIC BRAKE If an automatic refill system is not used. add brake fluid when the fluid level in the reservoir is low. Connect a commercially available brake bleeder [1] to ' the left front brake caliper center bleed valve [2]. Loosen the bleed valve and operate the brake bleeder until air bubbles do not appear in the breed hose Close the bleed valve to the specified torque. TORQUE:5.4 N-m (0.6 kgf‘m, 4.0 le’t) Connect a commercially available brake bleeder [1] to the right iront brake caliper bleed valve [2]. Loosen the bleed valve and operate the brake bleeder until air bubbles do not appear in the breed hose. Close the bleed valve to the specified torque TORQUE:5.4 N-m (0.6 kgf‘m, 4.0 “1970 Perform the bleeding procedure until the system is completely flushed/bled. Operate the brake lever. It it is still spongy, bleed the system again, If a brake bleeder is not available. use the following procedure: Fill the reservoir with DOT 4 brake fluid from a sealed container, Connect a bleed hose [1] to the left front caliper center bleed valve [2]. Pressurize the system with the brake lever until lever resistance is felt 17-10 HYDRAULIC BRAKE Donatreieesethe 1. Squeeze the brake lever [1], open the left tront lever until the bleed caliper center bleed valve 1/4 turn and then close it. valve has been closed 2. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. 3. Repeal steps 1 and 2 until air bubbles do not appear in the bleed hose, Alter bleeding the air completely. tighten the Iett v front caliper center bleed valve to the specified torque. TORQUE: 5.4 N-m (0.6 kgf-m, 4.0 lbf-f!) Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a bleed hose [1] to the right front caliper bleed , valve [2]. Do not release the 1. Squeeze the brake lever, open the right front caliper lever until the bleed bleed valve 1/4 turn and then dose it. van/e "55,559? 2. Release the brake lever slowly and wait several 6 e ‘ seconds after it reaches the end 01 its travel. 3. Repeat steps 1 and 2 until air bubbles do not appear in the bleed hose. After bleeding the air completely. tighten the right front caliper bleed valve to the specified torque. TORQUE: 5.4 N-In (0.6 kgf~m, 4.0 lhf-ft) Fill the reservoir to the upper level line with DOT 4 brake fluid. Install the diaphragm [1] and set plate [2]. Install the reservoir cap [3} and tighten the screws [4] to the specified torque. TORQUE: 1.5 N-m (0.2 kgf~m,1.1 Ibf~ft) 17-11 HYDRAULIC BRAKE PEDAL BRAKE LINE: ABS MODULATOR DELAY VALVE I REAR CALlPER If an automatic refill Tighten the Ian front brake caliper upper and rear brake system is notused, caliper bleed valves secume and fill the reservoir to the add brake fluid "UPPER" level [1] with DOT 4 brake fluid lrorn a sealed when the fluid level containerr in the reservoir is low. Connect a commercially available brake bleeder [1] to me lefl front brake caliper upper bleed valve [2]. Loosen the bleed valve and operate the brake bleeder until air bubbles do not appear in the breed hose. Close the bleed valve to the specified torque. TORQUE:5.4 N-m (0.6 kgf-m, 4.0 mm) 17-12 Do not release the pedal until the bleed valve has been dosad Connect a commercially available brake bleeder [1] to the rear brake caliper bleed valve [2]. Loosen the bleed valve and operate the brake bleeder ' until air bubbles do not appear in the breed hose. Close the bleed valve to the specified torque. TORQUE: 5.4 N-m (0.6 kgf‘mY 4.0 IbMt) Perform the bleeding procedure until the system is completely flushed/bled. Operate the brake pedal. If it is still spongy, bleed the system again. If a brake bleeder is not available. use the following procedure: Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a bleed hose [1] to the lefl front caliper upper bleed valve [2]. Pressurize the system with the brake pedal until pedal resistance is felt. 1. Operate the brake pedal, open the bleed valve 1/4 turn and then close it. 2. Release the brake pedal slowly and wait several seconds after it reaches the end of its travel. 3. Repeat steps 1 and 2 until a sufficient amount of the fluid flows out of the caliper upper bleed valve. Alter bleeding the air completely. tighten the lefl front caliper upper bleed valve to the specified torque. TORQUE:5.4 N-m (0.6 kgf-m. 4.0 Ibf-ft) Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a bleed hose [1] to the rear caliper bleed valve [2]. 1. Operate the brake pedal. open the bleed valve 1/4 turn and then close it. 2. Release the brake pedal slowly and wait several seconds after it reaches the end of its travel. 3. Repeat steps 1 and 2 until a sufficient amount of the fluid flows out of the caliper bleed valve. After bleeding the air completely, tighten the rear caliper bleed valve to the specified torque. TORQUE: 5.4 NM (0.6 kgf-m, 4.0 lbf-ft) Fill the reservoir to the upper level line with DOT 4 brake fluid. Install the diaphragm [1], set plate [2] and reservoir cap [31- . Install the right rear oowl (page 3-4). HYDRAULIC BRAKE HYDRAULIC BRAKE BRAKE PAD/DISC FRONT BRAKE PAD REPLACEMENT NOTE: - The front brake caliper oi the new brake system has the 4 separate brake pads. The small brake pads [1] of left caliper are combined with the rear brake pedal Inspect the conventional brake pads [2] and combined brake pads individually. — Conventional brake: Always replace the right all brake pads and left large brake pads with the set to assure even disc pressure. — Combined brake: Always replace the left small brake pads in pairs to assure even disc pressure, ~ After the brake pad replacement, check the brake operation by applying the brake lever or pedal. Loosen the pad pins [1]. Remove the caliper mounting bolts [2] and brake caliper [3]. Checkthebrake Push the caliper pistons all the way in to allow fluid level in the installation of new parts reselvo/r as this operation causes the level to rise. brake pads [3] and pad springs. 17-14 HYDRAULIC BRAKE Clean the inside of the caliper [1] especially around the caliper pistons. Install the large pad spring [1] and small pad spring [2] to the brake caliper as shown. Install new large brake pads [1], new small brake pads [2] to the brake caliper. Install the pad pins [31 through the pad springs while pushing in the brake pads against the pad springs. - Install the brake caliper [1] to the fork leg so that the disc is positioned between the pads. NOTE: - Be careful not to damage the brake pads, - Make sure that the dowel pins [2] are installed into the caliper bracket properlyt 17-15 HYDRAULIC BRAKE I « Check the brake fluid level in the reservnir as this opemtlon causes the level Io rise. Always replace the brake pads in pairs. lnstall and tighten new brake caliper mounting bolts [1] z to the specified torque. l TORQUEMS N-m (4.6 kgf-m, 33 let) Tighten the pad pin [2] to the specified torque, TORQUE118 N-m (1.8 kgf-m, 13 Ibf-ft) Operate the brake lever and pedal to seat the caliper pistons against the pads. REAR BRAKE PAD REPLACEMENT Push the caliper pistons all the way in to allow installation of new brake pads. Remove the pad pin [1] and brake pads [2]. Make sure the pad spring is installed correctly. Install new brake pads [1] into the caliper so their ends rest into the pad retainer [2] on the bracket property. 17-16 HYDRAULIC BRAKE Coat the stopper ring [1] on the pad pin [2] end with the silicone grease. Install the pad pin by pushing in the pads [3] against the pad spring to align the pad pin holes in the pads and caliper body. Tighten the pad pin to the specified torque. TORQUE: 18 N-m (1.3 kgf'm, 13 [bf-ft) Operate the brake pedal to seat the caliper pistons against the pads. BRAKE DISC INSPECTION \fisualty inspect the disc for damage or cracks. Measure the brake disc thickness at several points. SERVICE LIMITS: FRONT: 3.5 mm (0.14 In) REAR: 5.0 mm (0.20 In) Measure the brake also warpege with a dial indicator. SERVICE LIMITS: FRONT: 0.20 mm (0.008 In) REAR: 0.30 mm (0.012 In) Check the bearing for excessive play, if the warpage exceeds the service limit. Replace the brake disc ii the bearings are normal. 17-17 HYDRAULIC BRAKE REAR BRAKE DISC REMOVAL] INSTALLATION NOTE: For front brake disc removal/installation. refer to the front wheel disassemny (page 15-15). Remove the following: — rear wheel (page 16-5) — rear brake caliper (page 17-34) Remove the mounting bolts [1] and rear brake disc [2] from the flange. Install the rear brake disc with new mounting bolts. Tighten the mounting bolts to the specified torque. TORQUE242 N~m (4.3 kgf-m, 31 lbf-ft) Install the removed parts in the reverse order of removal. FRONT MASTER CYLINDER REMOVAL Drain lhe lever brake line hydraulic system (page 17—7). Disconnect the brake light switch wire connectors [1]. Avoid spilling fluid Remove the brake hose oil bolt [1]. sealing washers [2] on painted, plastic. and brake hose eyelet [3]. or rubber pans. 17-18 HYDRAULIC BRAKE Remove the bolts [1], master cylinder holder [2] and master cylinder assembly [3]. Remove the float [4] from the master cylinder. DISASSEMBLY Remove the pivot bolt [1]/nut [2] and brake lever assembly [3], Remove the screw [1] and brake light switch [2]. Remove the boot [3]. Remove the snap ring [1] from the master cylinder body using the special tool as shown. TOOL: Snap rlng pliers [2] o1914-SA50001 Remove the master piston, spring and spring guide. 17-19 HYDRAULIC \@ BRAKE INSPECTION Clean the inside of the cylinder, reservoir and plslon with brake fluid, Check the piston cups [1] for damage or deterioration. Check the master cylinder [2] and piston [3] for abnormal scratches. Check the spring [4] for fatigue or damage Measure the master cylinder |.D. SERVICE LIMIT: 15.925 mm (0.6270 In) Measure the master cylinder piston OD, SERVICE LIMIT: 15.815 mm (0.6226 In) ASSEMBLY a MASTER PISTON SPRING W SNAP RING PISTON CUPS SPRING GUIDE BRAKE LEVER 5.9 N-m (0.6 kgf-m, 4.4 Ibf-fl) [4] I1] \I’ [2] 0 I3] 1.0 N-m (0.1 kgf-m. 0.7 Ibf-fl) MASTER CVLINDER BRAKE LIGHT SWITCH 1.2 N-m (0,1 kgf-m, 0.9 Ibffl) 17-20 When installing the cups, do not allow the lips in mm inside out. as certain the snap ring is firmly seated in me groove. NOTE: Keep the piston, cups, spring. snap ring and boot as a set; do not substitute individual parts, Coat the master piston [1] and piston cups [2] with clean brake fluid before assembly. Install the spring guide [3] into the spring [41‘ Install the spring guide/spring and master piston into the master cylinder [5]. Install the snap ring [1] using the special tooll TOOL: Snap ring pliers [2] 01914$A50001 Apply silicone grease to the inside of the boot [1] and install it to the master cylinder [2]. Install the brake light switch [1] by aligning its boss with the hole. install and tighten the screw lo the specified torque. TORQUE: 13 N-m (0.1 kgf-m, 0.9 IM'ft) HYDRAULIC BRAKE [5| 17-21 HYDRAULIC BRAKE Apply silicone grease to the Contact surtaoes [1] of the brake lever and piston tip. Apply silicone grease to the brake lever pivot bolt sliding surface. Install the brake lever assembly [1). tighten the pivot bolt [2] to the specified torque. TORQUE: 1.0 N-m (0.1 kgf-m, 0.7 lbf-ft) Hold the pivot bolt and tighten the pivot nut [3] to the specified torque. TORQUE:5.9 N-ni (0.6 kgrm, 4.4 lbf'ft) Place the master cylinder assembly [1] on the handlebar. Align the end of the master cylinder with the punch mark on the handlebar. Install the master cylinder holder [2] with the "UP" mark facing up. Tighten the upper bolt [3] first, then the lower bolt [4] to the specified torque. TQBQUE212 MM (12 kgf-m, 9 lbf-ft) Install the float [5] into the master cylinder. Install the brake hose eyelet [1] with the oil bolt [2] and new sealing washers [3]. Push the eyelet joint stopper [4] against the master cylinder. then tighten the oil bolt to the specified torque. TORQUE: 34 N-m (3.5 kgf-m, 25 lbf-ft) xfil [1] 17-22 HYDRAUUCBRAKE Connect the brake light switch wire connectors 11]. Fill brake fluid and bleed air from the lever brake line hydraulic system (page 17-9). REAR MASTER CYLINDER/BRAKE LIGHT SWITCH/BRAKE PEDAL REMOVAL Drain the pedal brake line hydraulic system (page 17- 8 . Remove the right pivot plate cover (page 3~5). Disconnect the rear brake light switch 2P (Black) connector [1], Avoid spilling fluid Remove the brake hose oil bolt [1]. sealing washers [2] on painted, plastic. and brake hose eyelet joint [3]. or rubber pans. Remove the socket bolts [1] and right footpeg bracket assembly [2]. 17-23 HYDRAULIC BRAKE Remove the screw-washer [1] and reservoir hose joint [2] {mm the master cylinder. Remove the O—ring [3] from the reservoir hose joint DISASSEMBLY Unhook the brake light switch spring [1] and brake pedal return spring [2]. Remove the brake pedal joint cotter pin [3], snap ring/ set plate [4) and brake light switch [5]. Remove the brake pedal joint pin [1]. Remove the master cylinder mounting nuts [1], brake light switch cover [2] and master cylinder [3], Remove the bolt [4] and master cylinder stay [51‘ Remove the brake pedal [6] from the footpeg bracket. 1 7-24 HYDRAULIC BRAKE Remove the boot [1]. Remove the snap ring [211mm the master cylinder body using the special tool as shown. TOOL: Snap rlng pliers [3] 07914-SA50001 Remove the push rod/master piston, primary cup and spring. INSPECTION Clean the inside of the cylinder [1] with brake fluid. Check the piston boot [2], primary cup [31, secondary cup [4] and spring [5] for fatigue or damage. [3] Check me master cylinder and piston [6] for abnormal [4] scratches. [2] I11 [6] Measure the master cylinder l.D. SERVICE LIMIT: 17.515 mm (0.6896 in) Measure the master cylinder piston 0.D. SERVICE LIMIT: 17.405 mm (0.6352 in) / 17-25 HYDRAULIC BRAKE ASSEMBLY BRAKE LIGHT SWITCH MASTER MASTER CYLINDER CYLINDER STAY FOOTPEG BRACKET BRAKE LIGHT SWITCH COVER MOUNTING NUTS 12 N~m (1.2 kgf~m, 9 Ibffl) a PRIMARY CUP MASTER PISTON/ PUSH ROD ASSEMBLV JOINT PIN BRAKE PEDAL g COTTER PIN a SECONDARY CUP SNAP RING SET PLATE NOTE: Keep the piston, cups, spring. snap ring and boot as a set; do not substitute individual parts. Coat the master piston [1]. primary cup [2] and secondary cup [3] with clean brake fluid belore assembly. a Install the primary cup to the spring [4]. [2] [3] When installing the Install the spring/primary cup and master piston/push cups, do note/law rod assembly the lips to tum inside out Be certain the snap Install the snap ring [1] using the special tool, ring is [inn/y seated in the groove. TOOL: Snap ring pliers [Z] 07914-SA50001 Apply silicone grease to the push rod boot [3] inside, Install the boot into the master cylinder. 17-26 If the push rod is disassembled. adjust the push rod length so that the distance between the centers of the master cylinder lower mounting hole and joint pin hole is 67.5 11 mm (266 t 0.04 in)i After adjustment, tighten the lock nut [1] to the specified torque. TORQUE11B N-m (1.8 kgf‘m, 13 Ith) Apply grease to the brake pedal pivot sliding surtece. Install the brake pedal [1] to the brake pedal shaft. Install the master cylinder stay [2] by aligning its hole with the boss of toatpeg bracket [3]. Install and tighten the bolt [4] securely, Install the master cylinder [5], brake light switch cover [6]. Install and tighten the master cylinder mounting nuts [7] to the specified torque, TORQUE: 12 N-m (1.2 kgf-m. 9 lbf-fl) Install the brake pedal joint pin [1]. Secure the brake pedal joint pin with a new cotter pin [1]. Install the set plate [2] and secure the brake pedal pivot with the snap ring [3]. Install the brake light switch [4] and hook the brake light switch spring [5] and brake pedal return spring [6]. HYDRAULIC BRAKE 67.5 x 1 mm (2.66 1: 0.04 in) 1 7-27 HYDRAULIC BRAKE INSTALLATION Apply brake fluid to a new O-ring [1] and install it onto the reservoir hose joint [2], Install the reservoir hose jainl into the master cylinder [3]. Apply a locking agent to the reservoir hose joint screw- washer [4] threads. Install and lighten the screw-washer to the specified torque. TORQUE: 1.5 MM (0.2 kgf-m. 1.1 lbi-ft) Install the right toolpeg bracket assembly [1] to the frame and tighten the socket bolts [2] to the specified ’ torque. TORQUE“ N-m (3.5 kgf'm, 25 "7"!) Install the brake hose with the oil bolt [1] and new sealing washers [2]. Push the eyelet joint stopper [3] against the master cylinder body, then tighten the oil bolt to the specified torque. TORQUEIM NM (3.5 kgfim, 25 "1"!) Route the brake light switch wire properly (page 1-22). Connect the rear brake light switch 2P (Black) connector [1]. Install the right pivot plate cover (page 3«5). Fill brake fluid and bleed air from the pedal brake line hydraulic system (page 17-12). 17-28 HYDRAULIC BRAKE FRONT BRAKE CALIPER N OTE: When removing the oil bolt, cover the end of the hose to prevent contamination LEFT CALIPER REMOVAL Drain the brake fluid from the hydraulic systems (page 1 7-7). Remove the oil bolts [1], sealing washers [2] and brake hoses [3], Remove the brake pads (page 17~14)t RIGHT CALIPER REMOVAL Drain the brake fluid from the hydraulic systems (page 17-7). Remove the oil bolt [1], sealing washers and brake hose [2]. Remove the brake pads (page 17-14). DISASSEMBLY OUTSIDE PISTONS REMOVAL N OT E: Mark the pistons to ensure correct reassembly. Place a shop towel over the pistons. Do not use high Position the caliper body with the outside pistons facing pressure airarbn'ng down and apply small squirts of air pressure to the the nozzle too close center fluid inlet [1] lo remove the pistons. the inlet. 17-29 HYDRAULIC BRAKE Left caliper only: Do not use high pressure airor bring the nozzle too close the inlet. Lefl caliper only: Apply small squirts of air pressure to the upper fluid inlet [1] to remove the piston (combined brake). INSIDE PISTONS REMOVAL Remove the center bleed valve [1] and upper bleed valve [2} (left caliper only). [2] (Left caliper only) Plaoe a shop towel over the pistons. Position the caliper body with the inside pistons facing down and apply small squirts of air pressure to the center bleed outlet [1] to remove the pistons Apply small squirts of air pressure to the upper bleed outlet [1] to remove the piston (combined brake), 17-30 Be careful not to damage the piston sii'dlng surface. Push the dust seals [1] and piston seals [2] in and lift them out from the inside and outside caliper cylinders. Clean me seal grooves. caliper cylinders and pistons with clean brake fluid. INSPECTION Check the caliper cylinders and pistons for scoring, scratches or damage. Measure the left caliper cylinder |.D. SERVICE LIMITS: Upper: 27.060 mm (1.0654 In) Center: 30.200 mm (1.1925 in) Lower: 21.060 mm (1.0654 in) Measure the right caliper cylinder LD. SERVICE LIMITS: Upper: 25.460 mm (1.0024 in) Center: 25.460 mm (1.0024 in) Lower: 25.460 mm (1.0024 In) Measure the lefl caliper piston O.D. SERVICE LIMITS: Upper: 26.910 mrn (1.0594 in) Center: 30.140 mm (1.186 Lower: 26.910 mm (1.0594 In) Measure the right caliper piston O.D. SERVICE LIMITS: Upper: 25.310 mm (0.9965 In] Center: 25.310 mm (0.9965 Int Lower: 25.310 mm (0.9955 In} HYDRAULIC BRAKE [2] [1] LEFT CALIPER shown: LEFT CALIPER PISTONS shown: 17-31 HYDRAULIC BRAKE ASSEMBLY LEFT cALIPER LARGE PAD SPRING CENTER BLEED VALVE 5.4 N-m (0.6 kgf‘m, 4.0 [bf-f!) SMALL PAD SPRING LARGE PAD SPRING LOWER PISTONS (27 mm O.D. bronze color) MIDDLE PISTONS (30 mm 0.0. bronze color) { @ b” a UPPER PISTONS /® (27 mm 0,D. sliver color) SMALL PAD SPRING PAD PINS 18 N-m (1,6 kgf-m,13IbI-fl) UPPER BLEED VALVE 5.4 N-m (0‘6 kgf‘m, 4I0 Ibf-fl) SMALL BRAKE PADS (combined brake) LARGE BRAKE PADS (conventional brake) g zfil DUST SEALS @ e PISTON SEALS RIGHT CALIPER PAD PINS 18 N-m (1.3 kgf‘m,13lbf>fl) LARGE PAD SPRING BLEED VALVE 5.4 N-m (0.6 kgf~m. 4.0 lbi~fl) LARGE PAD SPRING SMALL PAD SPRING ‘ . U a msmNs /® ' SMALL PAD SPRING (25 mm OLD.) SMALL BRAKE PADS LARGE BRAKE PADS 92 rfil DUST SEALS 9" a PISTON SEALS 17-32 Coat new piston seals [1} with clean brake fluid. Coat new dust seals [2] with silicone grease. Install the piston and dust seals into the seal grooves in the caliper. Coat the caliper pistons [3] with clean brake fluid and install them into the caliper cylinders with the opening toward the pads. NOT E: Do not confuse the left upper pistons (combined brake) and left lower pistons (conventional brake). — Upper pistons: sliver color — Lower pistons: bronze color Install the center bleed valve [1] and upper bleed valve [2] (left caliper Orlly), and tighten them to the specified torque. TORQUE: 5.4 MM (0.6 kgf-m, 4.0 [bf-ft) LEFT CALIPER INSTALLATION Install the brake pads (page 17-14). Connect the brake hoses [1] to the caliper with the oil bolts [2] and new sealing washers [3]. Push the brake hose eyelet joints against the caliper body. then tighten the oil bolts to the specified torque. TORQUE!“ N-m (3.5 kgf-rn, 25 Ibf-fti hf [1] HYDRAULIC BRAKE «9 v [2] Fill brake fluid and bleed air from the hydraulic systems - . (page 17-9). RIGHT CALIPER INSTALLATION Install the brake pads (page 17-14). Connect the brake hose [1] lo the caliper with the oi bolt [2] and new sealing washers [3]. Push the brake hose eyelet joint against the caliper body, then tighten the oil bolt to the specified torque. TORQUE“ N‘m (3.5 kgf-m, 25 lbI-fl) Fill brake lluid and bleed air from the hydraulic systems (page 174)). [2] (Left caliper only) 17-33 HYDRAULIC BRAKE REAR BRAKE CALIPER REMOVAL N 0T E: When removing the oil bolt, cover the end of the hose to prevent contamination. Remove the final gear oover (page 3-5). Drain the brake fluid from the pedal brake line hydraulic system (page 17%). Remove the oil bolt [1], sealing washers [2] and brake hose [3]. Remove the brake pads (page 17-16). Be careful nDtIo Remove the mounting bolts [1] and caliper damage the wheel assembly [2]. rim when removing the caliper assembly. Remove the mounting bolts [1] and rear wheel speed sensor [2], 1 7-34 Do not use high pressure air or bring the nozzle too close the inlet. ” Be careful not 10 damage the piston sliding surface. D ISASS EMBLY Remove the following: — caliperbracketm — pad retainer [2] — pad spring [3] — pin boots [4] Place a shop towel over the pistons. Position the caliper body with the pistons facing down and apply small squirts ol air pressure to the fluid inlet [1] lo remove the pistons. Push the dust seals [1] and piston seals [2] in and lift them out. Clean the seal grooves. caliper cylinders and pistons with clean brake fluid INSPECTION Check the caliper cylinders and pistons for scoring. scratches or damage. Measure the caliper cylinder |.D. SERVICE LIMIT: 27.060 mm (1.0654 in) Measure the caliper piston O.Dr SERVICE LIMIT: 26.910 mm (135!“ In) HYDRAULIC BRAKE l3] [4] [1] 17-35 HYDRAULIC BRAKE CALI PER BRACKET SUB SLIDE FIN 13 N-m (1.3 kgfrm, 9 lbf~fl) BRACKET PIN BOOT ASSEMBLY ,fil CALIPER PIN BOOT v DUST SEALS PISTON SEALS Coal new piston seals [1] with clean brake fluid. Coat new dust seals [2] with silicone grease. install the piston and dust seals into the seal grooves in the caliper. Goat the caliper pistons [3] with clean brake fluid and install them into the caliper cylinders with the opening toward the pads. Apply silicone grease to the inner surface of the pin boots [1]. Install the caliper pin boot to the caliper. Install the bracket pin boot to the bracket. Apply Honda bond A or equivalent to the installing suriaoe of the pad retainer [2]. Install the pad retainer to the bracket [3]. Install the pad spring [4] in the caliper. Assemble the caliper bracket and the caliper body. a PISTONS PAD SPRING MAIN SLIDE PIN 23 NH! (2.3 kgf~m. 17 lbi-i'l) BLEED VALVE 5.4 N-m (0.6 kgf-m, 4.0 lbi-fl) é. v [4] (a [11 17-36 HYDRAULIC BRAKE INSTALLATION Install the rear wheel speed sensor [1] and tighten the mounting bolts [2] securely. Becarelul no! to Install the rear caliper assembly [1] to the final gear A damage the wheel case. "’7' “Gum’s/(“9r Install and tighten new mounting bolts [2] to the seams specified torque. assembly. YORQUEMS N~m (4.6 kgI-m, 33 lbf-ft) A Install the brake pad (page 17-16) Install the brake hose eyelet to the caliper body with new sealing washers [1] and oil bolt [2]. Push the brake hose eyelet stopper [3] against the caliper body, then tighten the oil bolt to the specified torque. " TORQUE: 34 NM (3.5 kgf-nl, 25 Ibf-fl) Install the final gear cover (page 3-5), Fill brake lluid and bleed air trorn the pedal brake Ilne \ hydraulic system (page 17»1 2). Check the rear wheel speed senser clearance (page 18-24). 17-37 HYDRAULIC BRAKE PCV Apply brake fluid to the bmke pipe/Din! nut threads. REMOVAL/INSTALLATION NOTE: - When removing the brake pipe joint nut, cover the end of the plpe to prevent contamlnation, - Be careful not to bend or damage the brake pipes. Drain the brake fluid {tom the hydraulic syslems (page 17-7). Remove the following: — Ielt pivot plate cover (page 3-5) — canister tray (page 6-91) Remove the brake pipe joint nuts [1]. Remove the mounting bolt/washerlnut [2] and PCV/stay assembly [3]. Remove the mounting bolts/nuts [1] and PCV [2] Irom the slay. Installation is in the reverse order of removal, YORQUE: Brake pipe jolnt nut: 14 "m (1.4 kgf-m. 1D lbf-it) PCV mounting nut: 10 N1" (1.0 kgf-rn. 1 lbf-ft) DELAY VALVE For delay valve removalfinstallation. refer to ABS modula.or removal/installation (page 1B~27). 17-38 18. ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LOCATION - - - - - - - - - - "18-2 ABS INDICATOR PROBLEM CODE INDEX ...................................................... "13.10 ABS SYSTEM DIAGRAM"- ---- "18-3 ABS TROUBLESHOOTING -------------------- “1841 SERVICE INFORMATION ......................... ..13_4 WHEEL SPEED SENSOR ...................... "13.24 ABS CONNECTOR LOCATIONS ------------- --18-5 ABs MODULATOR ................................. "13.27 ABS TROUBLESHOOTING INFORMATION .......................................... ..13_7 18-1 ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM LOCATION ABS INDICATOR ABS DLC FUSE BOX MODULATOR o x 0 I ‘ ‘3 0 0) \ ' ‘n‘ FRONT WHEEL ‘ SPEED SENSOR FRONT WHEEL SPEED SENSOR 4 2P (BLUE) CONNECTOR REAR WHEEL SPEED SENSOR 2P (ORANGE) CONNECTOR REAR WHEEL SPEED SENSOR 18-2 ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM DIAGRAM MAIN FUSE IGNITION 30A SWITCH J- R R/BI , R 1 STOP] 6 9 ABS INDICATOR TAIL/ .- METER BATTERY FUSE 15A BUB! ABS POWER FUSE GIEI 0,5 __I R 30A _ L ABS 3% FUSE . A ©(11/12) o ABS MAIN FRONT WHEEL “’3' FUSE SPEED SENSOR 10A 0 E: 2%: FRONT {WSWEE (9m) PULSER RING ” TIRE @(42) 13/14) FRONT WHEEL SEQEE‘f/SHEENESLOR / REAR BRAKE O IZ— R/BII — LIGHT SWITCH I—G/Bu— REAR L PULSER RING BRAKEITAILLIGHT DLC I—Im I—I _ a, OIBu ECM (— _| 7 Eu GK) Br : Brawn ‘ > V I: Bl : Black @( ) : Number 0! ABS Indlcator blInks V : Yelluw d} : Short Ienninals [or reading DTC 2H nflflnmmmm ' i "a" mmmmmmmmzai R 3 Red 0 : Orange mwxlgmmwécmk p ; pmk 18-3 ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION GENERAL The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing. the excessive voltage may damage the control unit. Always tum off the ignition switch before servicing. - This section covers service of the Anti-lock Brake System. For conventional brake service, see page 17-4. - Pre-start self—diagnosis starts when the ignition switch is turned ON. The ABS modulator control unit receives signals and detects Whether the ABS system functions normally. Prerstert self-diagnosis starts when the vehicle speed goes above 10 kmlh (6 mph) approximately. The ABS system and the vehicle running condition are monitored constantly alter pre-start self< diagnosis until the ignition switch is turned OFF. When the ABS modulator control unit detects a problem, the ABS indicator blinks to notify the rider 0! the problem. To detect the faulty part. retrieve the problem code by shorting the DLC terminals. Read "ABS Troubleshooting Information" carefully, inspect and troubleshoot the ABS system according to the Diagnostic Troubleshooting flow chart. Observe each step of the procedures one by one. Write down the problem code and probable taulty pan before stoning diagnosis and troubleshooting. Use a fully charged battery. Do not diagnose with a charger connected to the banery. When the ABS control unit detects a problem. it stops the ABS function and switches back to the conventional brake operation. and the ABS indicator blinks or stays on. Take care during the test ride, Troubles not resulting from a faulty ABS (eg. brake disc squeak, unevenly worn brake pad) cannot be recognized by the ABS diagnosis system. When the wheel speed sensor and/or pulser ring is replaced, check the clearance (air gap) between both components. The ABS control unit (ECU) is mounted on the modulator (the modulator with the built-in ECU). Do not disassemble the ABS modulatort Replace the ABS modulator as an assembly when it is faulty. Be careful not to damage the wheel speed sensor and pulser ring when removing and installing the wheel. The tollowing color codes are used throughout this section. Bu = Blue G = Green Lg = Light Green R = Red BI = Black Gr = Gray 0 = Orange W = White Br = Brown Lb = Light Blue P = Pink Y = Yellow TORQUE VALUES Rear brake pipe clamper bolt 10 N-m (1,0 kgt-m, 7 Ibf~ft) ALOC bolt: replace with a new one. Rear wheel pulser ring mounting bolt 7.0 N»m (0.7 kgf-m. 5.2 Ibf‘l't) ALOC bolt: replace with a new one. Delay valve mounting bolt 10 N-m (1.0 kgf-m. 7 lot-ft) Brake pipejoint nut 14 N~m (1.4 kgf~m. 10 lbf‘fl) Apply brake fluid to the threads, TOOLS SOS connector Test probe OTOPZ-ZY30100 07ZAJ»RDJA110 18-4 ANTI-LOCK BRAKE SYSTEM (ABS) ABS CONNECTOR LOCATIONS N OT E: Remove the right middle cowl (page 3-7). ABS MODULATOR 26F CONNECTOR N OT E: Remove khe seat (page 3—4)‘ o i ‘r DLC 4P (RED) CONNECTOR \ 18-5 ANTI-LOCK BRAKE SYSTEM (ABS) N 0T E: Remove the radiator (page 7-9). All!“ 373’s 1 (if. . FRONTWHEEL SPEED SENSOR 2P (BLUE) CONNECTOR N 0T E: Remove me canisker tray (page 6-91). [1‘ 3 fl ‘5 w 7 (Y ll REARVWHEEL SPEED SENSOR />\ ’ 2P (ORANGE) CONNECTOR N OTE: Remove me seat (page 3—4)‘ ABS MAIN FUSE (10A) ABS SOLENOID FUSE (30A) ABS POWER FUSE (30A) 18-6 ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality. the problem and the problematic part can be detected by retrieving the problem code. When the vehicle is running, pulse signals generated at the front/rear wheel speed sensors are sent to the ABS control unit. When the ABS control unit detects that vehicle speed goes approximately 10 km/h (6 mph) or more, the pump motor is temporarily operated to check it the ABS system tunctions normally. It the system is normal, pro-start self—diagnosis is complete and the ABS indicator goes off. If a problem is detected. the ABS indicator blinks or comes on and stays on to notify the rider of the problem. The sell-diagnosis is also made while the motorcycle is running. and the indicator blinks when a problem is detected, When the indicator blinks. follow the specified procedure to retrieve the problem code. If the ABS indicator does not come on when the ignition switch is turned ON, or the ABS indicator stays on after the pre~start self— diagnosis procedure is complete, the ABS indicator may be faulty. Follow the troubleshooting (page 18-11). Pre—start self—diagnosis when normal: IGNITION 0N SWITCH OFF ENGINE Running Stop VEHICLE 0 Approx. 10 km/h (6 mph) SPEED PUMP 0N ------------------------------------------------------------------------ -- MOTOR r _ OFF ABS INDICATOR OFF _| .— Pre-start selwiagnosls completes if the control unit has no problem code. PRE-START SELF-DIAGNOSIS PROCEDURE 1. Turn the ignition switch ON and engine stop switch to '0". 2. Make sure the ABS indicator comes on, 3. Start the engine. 4 . Ride the motorcycle and increase the vehicle speed to approximately 10 km/h (6 mph). 5, The ABS is normal if the ABS indicator will go 0". ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE INDICATION PATTERN - The ABS indicator indicates the problem code by blinking a specified number of times. The indicator has two types of blinkings. a long blink and short blink. The long blink lasts tor1.3 seconds. the short blink lasts for 0.3 seconds. When one long blinks occur. and two short blinks, that problem code is 12 (one long blink = 1 blink. two short blinks = 2 blinks). Then, go to troubleshooting and see problem code 12. - When the ABS control unit stores six problem codes, the ABS indicator shows the problem codes in the order from the latest problem code to earliest problem code. IGNITION SWITCH 1.3 sec; faltem repeated 2 2590.. 365%.! : : l .Msec, E I ON K—H : —>: ‘— : "" "—l l_l_l_Lll I" INDICATOR OFF _ . . sensiqu 0.4 sec 3.6 sec. 0.4% e__y_./ Laestmrrbemoblemoode Eaiestmnbeploblemoode (ExarrpeCodetz) (EmplocmeZi) When the problem code is not stored: I Zsec. , 3.65m ABS 0“ "" ' ' INDICATOR 0FF__ L__I PROBLEM CODE READOUT NOTE' ~ The problem code is not erased by turning the ignition switch to OFF while the problem code is being output. Note that turning the ignition switch to ON again does not indicate the problem code. To show the problem code again. repeat the problem code retrieval procedures from the beginning. Do not apply the tront or rear brake during retrieval. - After diagnostic troubleshooting, erase the problem code(3) and perform the Dre-start sell-diagnosis to be sure that there is no problem in the ABS indicator (indicator is operating normally). 1. Turn the ignition switch OFF. Remove the seat (page 3-4). Remove the dummy connector [1] from the DLC. 2. Short the DLC terminals using the special tool. TOOL: SCS connector [1] O70PZ-ZY3010IJ CONNECTION: Brown — Green 1 8-8 CLEARING PROBLEM CODE 1. . Turn the ignition switch ON. . Tum the ignition switch OFF and remove the special tool, . Turn the ignition switch ON and engine stop switch to '0" while . Release the brake lever immediately after the ABS indicator is off. The r Squeeze the brake lever immediately after the ABS indicator is on. The . Release the brake lever immediately after the ABS indicator is off. . Turn the ignition switch to OFF and remove the special tool. ANTI-LOCK BRAKE SYSTEM (ABS) The ABS indicator starts problem code indication. Note how many times the ABS indicator blinks. and determine the cause of the problem (page 18—10). Connect the dummy connector to the DLCT Install the seat (page 3—4). Turn the ignition switch OFF. Remove the seat (page 3—4). Remove the dummy connector and short DLC terminals using the special tool. TOOL: SCS connector [1] 07DPZ-ZY30100 CONNECTION: Brown — Green squeezing the brake lever [1]. The ABS indicator should come on tor 2 seconds and go off. ABS indicator should come on. ABS indicator should go off. When code erasure is complete, the ABS indicator blinks 2 times and stays on. It the ABS indicator does not blink 2 times. the data has not been erased, so try again. It the ABS indicator blinks 2 times and blinks, faulty ABS system. go to ABS trouble shooting (page 1841). Connect the dummy connector to the DLC. Install the seat (page 3-4). 18-9 ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR PROBLEM CODE INDEX NOT E: - The ABS indicator might blink in the following cases Correct the faulty part. — Incorrect tire pressure — Tires not recommended for the motorcycle were installed (incorrect tire size). - Deformation of the wheel or tire The ABS indicator might blink while riding under the following conditions This is temporary tailure, Be sure to erase the problem code (page 18-10). Then, test ride the motorcycle above 10 km/h (6 mph) and check the problem code by retrieving the self-diagnosis system (page 18-8). Ask the rider for the riding conditions in detail when me motorcycle is brought in for inspection. — The motorcycle has continuously mn bumpy roads — The front wheel leaves the ground for a long time when riding (wheelie). — Only either the front or rear wheel rotates, — The ABS operates continuouslyi — The ABS control unit has been disrupted by an extremely powerful radio wave (electromagnetic interterenoa). Pg$:m Function failure aged"); Symptom/FaiI-sate function R21)” ABS indicator circuit malfunction ' ABS indicator never come ON at all 18-11 _ - Indicator related wires ' ABS indicator stays ON at all - Combination meter 18-12 ' ABS modulator Front wheel speed sensor circuit mal— ' Stops ABS operation 1 1 function 0 0 1 3—1 5 - Wheel speed sensor or related wires Front wheel speed sensor malfunction O Wheel speed sensor, pulser ring or 12 related wires 0 18-15 - Electromagnetic interference - Riding condition Rear wheel speed sensor circuit mal- . Stops ABS operation 13 lunaion O 0 18-17 - Wheel speed sensor or related wires Rear wheel speed sensor malfunction ‘ Stops ABS operation - Wheel speed sensor, pulser ring or 14 related wires 0 18-17 - Electromagnetic interteranoe - Riding condition Stops ABS operation Wheel slipping - Stops ABS operation 21 - Riding condition 0 18-19 - Incorrect tire size 31 Solenoid valve malfunction - Stops ABS operation 32 1 8-1 9 33 34 O O 37 38 42 Front wheel speed sensor/Wheelie O - Stops ABS operation 18-15 - Riding condition (wheelie) 51 Motor/Stick O - Stops ABS operation 52 Motor/Run O 0 ~ Stops ABS operation 18-20 53 Motor/Stop O 0 ' Stops ABS operation 54 Valve relay/Abnormal voltage 0 O - Stops ABS operation 1B»21 61 Power oircuil/Under-vottage O O - Stops ABS operation 18-22 62 Power cirwithver—voltage O 0 O Stops ABS operation 81 CPU (ABS control unit) 0 O - Stops ABS operation 1344 (A) Pre-start self-diagnosis (page 1&7) (B) Ordinary self—diagnosis: diagnoses while the motorcycle is running (after pre-start self-diagnosis) 18-10 ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING NOTE: - Perform inspection with the ignition switch turned OFF. unless othenivise specified. - Refer to the ABS connector locations (page 18-5), All connector diagrams in the troubleshooting are viewed from the terminal sidet - Use a fully charged batteryi Do not diagnose with a charger connected to the badery. - When the ABS modulator assembly is detected to be faulty. recheck the wire harness and connector connections closely beiore replacing it. . After diagnostic troubleshooting, erase the problem code (page 18-9). Then test ride the motorcycle above 10 km/h (6 mph) and check the other problem code by retrieving the self-diagnosis system (page 18—8; NO PROBLEM CODE FAILURE ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) 1. Combination Meter Powerlground Line Inspection Check the combination meter power and ground lines (page 22-11) Are the wlres normal? YES - GO TO STEP 2, NO — Open circuit in related wires 2. Indicator Operation Inspection Remove the right middle cowl (page 3-7). Pull up the lock lever [11 and disconnect the ABS modulator 26F connector [2]. Turn the ignition switch ON and check the ABS indicator. Does the indicator come on? YES - Faulty ABS modulator. NO - GO TO STEP 3. 3. Indicator Signal Llne Short Circuit Inspection Check for continuity between the ABS modulator 26F connector [1] of the wire harness side and ground, TOOL: Orange/green Test probe 07ZAJ-RDJA110 CONNECTION: Orange/green - Ground Is there continuity? CED] b YES — Short circuit in Orange/green wiret N0 — Faulty combination meter. I11 18-11 ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR STAYS 0N (Indicator does not go off when the motorcycle Is running, Problem code is not Indicated by the retrieval procedure) 1. Fuse Inspection Remove the seat (page 34)‘ Remove the fuse box cover [1]. Check the ABS MAIN fuse (10 A) [1] in the fuse box. Is the fuse blown? YES — GO TO STEP 2, NO — GO TO STEP 3. 2. ABS Power Input Line short Circult Inspection Disconnect the ABS modulator 26F connector (page 18-11) Check tor continuity between the ABS modulator roonnector [1] of the wire harness side and ground with ABS MAIN Iuse removed. TOOL: Test probe 07ZAJ-RDJA1 10 EDI] CONNECTION: Orangelblue - Ground Is there continuity? Orange/blue VES — Short circuit in Orange/blue wire between the fuse box and ABS modulator‘ NO — Intermittent failure Replace the ABS MAIN fuse (10 A) with a new one, and recheck. 13-12 ANTI-LOCK BRAKE SYSTEM (ABS) 3. ABS Power Input Line Open Circuit Inspection Install the ABS MAIN fuse. Disconnect the ABS modulator 26F connector Green, grange/ (Page 1841). orange ue Measure the voltage between the ABS modulator [1] / _,-——- oi the wire harness side with the ignition switch We" °”- min 3 TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Orange/blue (+) — Green/orange (_ (9 ® m Is there battery voltage? YES -GOTOSTEF4. N0 - - Open circuit in Orange/blue wire between the fuse box and ABS modulator. - Open circuit in Green/orange wire between the ABS modulator and body ground. 4. Service Check Line Short Circuit Inspection Turn the ignition switch OFF, [1] Disconnect the ECM 33F (Gray) connector (page 6—84). Remove the dummy connector from the DLC [1] (page 18-8). Check for continuity between the DLC and ground, CONNECTION: Brown - Ground Is there continuity? LJ YES — Short circuit in Brown wire between the Brown service cheek connector and ABS modulator. NO — GO TO STEP 5. 7 18-13 ANTI-LOCK BRAKE SYSTEM (ABS) 5. Indicator Operation Inspection Remove the upper center cowl (page IMO). With the combination meter 20F connector [1] connected, short the Orange/black wire terminal of the combination meter and ground wilh a jumper wire. Check the ABS indicator with the ignition switch turned ON. CONNECTION: Orangelblack — Ground Does the ABS Indicator go off? YES — GO TO STEP 6. N0 — Faulty combination meterr . Indicator Signal Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire from the combination meter 20P connector. Short the Orange/green wire terminal of the ABS modulator 26F connector [1] and ground with a jumper wire. ‘ Check the ABS indicator with the ignition switch turned ON. TOOL: Test probe 07ZAJ-RDJA110 CONNECYION: Orange/green — Ground Does the ABS Indicator go off? YES — Faulty ABS modulator. NO - Open circuit in Orange/green and/or Orange! black wires between the combination meter and ABS modulatorr Orange/black [1) (Connector connected) Orange/green mm: / T [1] 18-14 ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 11, 12 or 42 (Front Wheel Speed Sensor) NOTE: . The ABS indicator might blink under unusual riding or conditions (page 18-10), This is temporary failure. Erase the problem code (page 18-9). Then test ride the motorcycle above 10 km/h (6 mph) and check the problem code by retrieving the self-diagnosis system (page 18-8). . it the problem code 12 is indicated. check the front brake for drag, 1. Speed Sensor Air Gap inspection Measure the clearance (air gap) between the sensor and pulser ring (page 18-24) Is the air gap correct? YES -GO TO STEP 2. N0 -Check each part for defamation and looseness and correct accordingly‘ Recheck the air gap. 2. Speed Sensor Condition Inspection Inspect the area around the (rent wheel speed sensor [1]: Check that there is no iron or other magnetic deposits between the pulser ring [2] and wheel speed sensor, and check the pulser ring slots for ‘ obstructions. Check installation condition of the pulser ring or wheel speed sensor for Iooseness. Check the pulser ring and sensor tip for deformation or damage (e,g,, chipped pulser ring teeth). Are the sensor and pulser ring In good condition? YES — GO TO STEP 3. N0 — Remove any deposits. Install properly or replace faulty part 3. Speed Sensor Input Voltage Inspection Disconnect the front wheel speed sensor 2P (Blue) connector [1], Measure the voltage at the front wheel speed sensor 2P (Blue) connector of the wire harness side with the ignition switch turned 0N. CONNECTION: Red/yellow (+) — Greenlyellow (—) Is there battery Voltage? YES — Faulty front wheel speed sensor. N0 — GO TO STEP 4. t‘l Green/yellow Red/yellow 18-15 ANTI-LOCK BRAKE SYSTEM (ABS) 4. Speed Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ABS modulator 26F connector (page 18-11). Check for continuity at the Red/yellow and Green] yellow terminals between front wheel speed sensor 2P (Blue) connector [1) and ABS modulator 26P connector {2]. TOOL: Test probe OTZAJ-RDJM 10 CONNECTION: Red/yellow - Red/yellow Greenlyellow — Green/yellow Is there continuity? YES — GO TO STEP 5. NO -0pen circuit in wire between the ABS modulator and speed sensor, 5. Speed Sensor Llne Short Circuit Inspection Check for continuity at the front wheel speed sensor 2P (Blue) connector [1] of the wire harness side and ground CONNECTION: Redlyellow — Ground Is there contlnuity? YES — Short circuit in Red/yellow wire. NO — GO TO STEP 6. 6. Failure Reproduction with a New Speed Sensor Replace the front wheel speed sensor with a new one (page 1&25). ‘ Connect the ABS modulator 26F connector. Erase the problem code (page 18—9). Test ride the motorcycle above 10 km/h (6 mph). Retrieve the problem code (page 18-8). Dose the Indicator blink 11, 12 or 42 times? YES — Faulty ABS modulator. NO - Faulty removed lront wheel speed sensor. [2] Green/yellow _ © . (n (can: :fl 9 Red/yellow [1] ‘2 Red/yellow 18-16 ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 13 or 14 (Rear Wheel Speed Sensor) NOTE: - The ABS indicator might blink under unusual riding or conditions (page 18-10). This is temporary failure. Erase the problem code (page 18-9). Then test ride the motorcycle above 10 krn/h (6 mph) and check the problem code by retrieving the self-diagnosis system (page 18-8). It the problem code 14 is indicated, check the rear brake for drag. 1. Speed Sensor Alr Gap Inspection Measure the clearance (air gap) between the sensor and pulser ring (page 18—24). Is the air gap correct? YES - GO TO STEP 2. NO —Check each pan for deformation and Iooseness and correct accordingly. Recheck the air gap. 2. Speed Sensor Condition Inspection Inspect the area around the rear wheel speed sensor [1]: Check that there is no iron or other magnetic deposits between the pulser ring [2] and wheel speed sensor. and check the pulser ring slots lor obstructions. Check installation condition of the pulser ring or wheel speed sensor for looseness. Check the pulser ring and sensor tip for deformation or damage (2.9., chipped pulser ring teeth). Are the sensor and pulser rlng in goon condlr10n7 YES - GO TO STEP 3‘ N0 — Remove any deposits. Install properly or replace faulty part. 3. Speed Sensor Input Voltage Inspection Disconnect the rear wheel speed sensor 2P 1 (Orange) connector [1]. I 1 Measure the voltage at the rear wheel speed sensor \ 2? (Orange) connector of the wire harness side with the ignition switch turned ON. 1 CONNECTION: Redlblue (+) — Green/blue 1-) Is there battery voltage? YES — Faulty rear wheel speed sensor. N0 — GO TO STEP 4‘ Green/blue Red/blue 18-17 ANTI-LOCK BRAKE SYSTEM (ABS) 4. Speed Sensor Llne Open circuit Inspection Turn the ignition switch OFF. 2 Disconnect the ABS modulator 26P connector 1 H (page 1M1). [ 1 Red/blue Check for continuity at the Redblue and Green/blue terminals between rear wheel speed sensor 2P (Orange) connector [1] and ABS modulator ZGP connector [2]. ‘ TOOL: i {ED—J: Test probe OTZAJ-RDJA110 @ CONNECTION: Red/blue — Red/blue Green/blue Green/blue — Green/blue Is there continuity? YES - GO TO STEP 5. N0 —Open circuit in wire between the ABS modulator and speed sensor. 5. Speed Sensor LIne Short circuit Inspection Check for continuity at the rear wheel speed sensor [1 2P (Orange) connector [1] of the wire harness side 1 and ground. CONNECTION: Red/Blue — Ground Is there continuity? YES — Short circuit in Red/blue wire. ® Red/blue NO _ GO TO STEP 6. 6. Failure Reproductlon wlih a New Speed Sensor Replace the rear wheel speed sensor with a new .. one (page 18-26). Connect the ABS modulator 26P connector. Erase the problem code (page 18-9). Test ride the motorcycle above 10 km/h (6 mph). Retrieve the problem code (page 18-8). Dose the Indicator blink 13 or 14 times? YES — Faulty ABS modulelor. NO - Faulty removed rear wheel speed sensor. 18-18 PROBLEM CODE 21 (Wheel slipping) NOTE: - The ABS indicator might blink under unusual riding or conditions (page 18-10). This is temporary failure. Erase the problem code (page 1&9). Then test ride the motorcycle above 10 kmlh (6 mph) and check the problem code by retrieving the sell-diagnosis system (page 1&8). - Check the Iollowing and correct the Iaulty part. — Incorrect tire pressure. — Tires not recommended for the motorcycle were installed (incorrect tire size). — Deformation of the wheel or tire. 1. Failure Reproduction if the above items are normal. recheck the problem oode indication: Erase the problem code (page 18-9). Tesl ride the motorcycle above 10 kmlh (6 mph). Retrieve the problem code (page 18—8). Does the indicator blink 21 times? YES — Faulty ABS modulator. N0 — Tire size is normal (temporary failure). PROBLEM CODE 31, 32, 33, 34, 37 or 38 (Solenoid Valve) 1. Failure Reproduction Erase the problem code (page 1&9). Test ride the motorcycle above 10 kmlh (6 mph). Retrieve the problem code (page 18—8), Does the indicator blink 31, 32, 33, 34, 37 or 38 times? YES — Faulty ABS modulator. NO —Solenoid valve failure). is normal (temporary ANTI-LOCK BRAKE SYSTEM (ABS) 18-19 ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 51, 52 or 53 (Pump Motor) 1. Fuse Inspection Remove the fuse box cover (page 18-12). Check the ABS POWER fuse (30 A) [1] in the fuse 7 box for blown. Is the fuse blown? YES — GO TO STEP 2. NO — GO TO STEP 3. 2. Motor Power Input Line Short Circuit Inspection Disconnect the ABS modulator 26F connector m (page 13-11). Check for continuity between the ABS modulator 26F connector [1] of the wire hamess side and ‘ ground with ABS POWER fuse removed. W 3 TOOL: DEED Test probe 07ZAJ-RDJA1 10 CONNECTION: Red — Ground @ Red Is there continuity? YES — Short circuit in Red wire between the fuse box and ABS modulator. NO — Temporary failure. Replace the ABS POWER fuse (30 A) with a new one and recheck. 3. Motor Power Input Line Open Circuit Inspection ,_,|JIstall the ABS POWER fuse. 1 Disconnect the ABS modulator 26F oonnector Blue Red 2] (page 18-11). Measure the voltage at the ABS modulator 26F connector [1] from the wire harness side with the mm mm o~- W3 There should be battery voltage at all times. TOOL: Test probe 07ZAJ-RDJA110 <9 (<) (9 CONNECTION: Red (+) _ Blue (—) Is there battery voltage? YES - GO TO STEP 4. N0 — O Open circuit in Red wire. ~ Open circuit in Blue wire, 18-20 4. Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 26F connector. Erase the problem code (page 1&9). Test ride the motorcycle above 10 kan (6 mph) Retrieve the problem code (page 18—8). Does the indlcator blink 51, 52, or 53 times? YES — Faulty ABS modulator. NO — Pump motor is normal (temporary failure). PROBLEM CODE 54 (Valve Relay) 1. Fuse Inspection Remove the fuse box cover (page 1842). Check the ABS SOLENOID fuse (30 A) in the fuse 7 box for blown. Is the fuse blown? YES — GO TO STEP 2. NO — GO TO STEP 3‘ . Relay Power Input Line Short circuit Inspection Disconnect the ABS modulator 26F connector (page 1&11). Check for continuity between the ABS modulator 26F connector [1] of the wire harness side and ground with ABS SOLENOID fuse removed. TOOL: Test probe 01ZAJ-RDJA11D CONNECTION: Orange — Ground Is there continuity? YES - Short circuit in Orange wire between the fuse box and ABS modulator. NO - Temporary lailure. Replace the ABS SOLENOID fuse (30 A) with a new one and recheck, ANTI-LOCK BRAKE SYSTEM (ABS) [1] Orange 18-21 ANTI-LOCK BRAKE SYSTEM (ABS) 3. Relay Power Input Line Open Circult Inspection Install the ABS SOLENOID fuse (30 A). Disconnect the ABS modulator 26P connedor (page 18-11). Measure the voltage at the ABS modulator 26P connector [1] from the wire harness side. There should be battery voloage at all times. TOOL: Test probe 01ZAJ-RDJA110 CONNECTION: Orange (+) — Green/crane (—) Is there battery voltage? YES - GO TO STEP 4. NO — ~ Open circuit in Orange wire. ' Open circuit in Green/orange wire. 4 Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 26F connector. Erase the problem code (page 18-9). Test ride the motorcycle above 10 km/h (6 mph). Retrieve the problem code (page 18—8). Does the Indicator blink 54 times? YES — Faulty ABS modulator. NO — Valve relay is normal (temporary failure). PROBLEM CODE 61 or 62 (Power Circuit) 1. Fuse Inspection Remove the fuse box cover (page 18-12). ’Check the ABS MAIN luse (10 A) in the fuse box, Is the fuse blown? YES — GO TO STEP 2. N0 - GO TO STEP 3, Orange Green/orange {WW M \ I1] 18-22 2. ABS Power Input Line Short circuit Inspection Disconnect the ABS modulator 26F connector (page 1841). Check for continuity at the ABS modulator connector [1] of the wire harness side and ground with ABS MAIN fuse removedt TOOL: Test probe OYZAJ-RDJA110 CONNECTION: Orange/blue - Ground Is there continuity? YES — Short circuit in Orange/blue wire between the fuse box and ABS modulator. NO — Intermittent Iailure. Replace the ABS MAIN fuse (10 A) with a new one, and recheck. 3. ABS Power Input Line Open Clrcuit Inspection Install the ABS MAIN fuse. Disconnect the ABS modulator 26F connector (page 18-11). Measure the voltage at the ABS modulator [1] ot the wire hamess side with the ignition switch turned 0N. TOOL: Yest probe 07ZAJ-RDJA110 CONNECTION: Orange/blue (+) — Greenlorange (—) Is there battery voltage? YES - GO TO STEP 4. NO - - Open circuit in Orange/blue wire. ~ Open circuit in Greeruorange wire. 4, Failure Reproduction Tum the ignition switch OFF. Connect the ABS modulator 26F connector. Erase the problem code (page 1&9), Test ride the motorcycle above 10 km/h (6 mph). Retrieve the problem code (page 13-8). Does the indicator blink 61 or 62 times? YES - Faulty ABS modulator. N0 — Power circuit is normal (temporary failure). ANTI-LOCK BRAKE SYSTEM (ABS) [1] CED] Orange/blue Green/orange Orange/blue mtflml ® 9 ® [1] 18-23 ANTI-LOCK BRAKE SYSTEM (ABS) PROBLEM CODE 81 (CPU; ABS Control Unit) 1. Failure Reproduction Erase the problem code (page 18-9). Test ride the motorcycle above 10 km/h (6 mph). Retrieve the problem code (page 1&8). Does the indlcator blink 81 times? YES —- Faulty ABS modulator. NO - CPU is normal (temporary failure). WHEEL SPEED SENSOR INSPECTION Support the motorcycle securer using a hoist or equivalent and raise the wheels of! the ground. Measure the clearance (air gap) between the sensor and pulser ring at several points by turning the wheel slowly. It must be within specification, STANDARD: 0.4 - 1.2 mm (0.02 — 0.05 In) The sensor air gap cannot be adjusted. If it is not within specification, check each installation part for deformalion, looseness and damage. 1 8-24 ANTI-LOCK BRAKE SYSTEM (ABS) REMOVAL/INSTALLATION FRONT Remove the radiator (page 7—91 Remove the front wheel speed sensor 2P (Blue) connector [1] from the frame and disconnect it. Release the front wheel speed sensor wire [1] from me clamps [2]. Remove the bolt [3] and wire clamp stay [4} Remove the bolts [1] and wire clamps. Remove the mounting bolts [2] and front wheel speed sensor [3]. Check that there is iron or other magnetic deposits between the pulser ring [1] and front wheel speed sensor [2]. Remove any deposits. Check the sensor tip tor delormation or damage (e.g., chipped pulser ring teeth). Replace the front wheel speed sensor if necessary. Route the sensor Installation is in the reverse order of removal. thawing; After installing the speed sensor, measure the page ' ' clearance (airgap) between the sensorand pulserring (page18-24). 18-25 ANTI-LOCK BRAKE SYSTEM (ABS) Replace the rear bake pipe damper balls with new ones. REAR Remove the following: — canister tray (page 661) — left engine heat guard (page 1143) Remove the rear wheel speed sensor 2P (Orange) connector [1] lrorn the harness protector and diseonnectlt, Remove the bolt [2] and wire clamper [3] from the swingarm. Remove the bolts [1] and wire dampers [2]. Remove the caliper assembly (page 17—34). Remove the bolts [1] and rear wheel speed sensor [2]. Check that there is no iron or other magnetic deposits between the pulser ring and rear wheel speed sensor [11‘ Remove any deposits. Check the sensor tip for deformation or damage (etgn chipped pulser ring teeth) Replace the speed sensor if necessary. Installation is In the reverse order of removal - For proper speed sensor wire installatian, refer to swingarm installation (page 1649). ‘ TORQUE: Rear brake pipe clamper bolt: 10 N-m (1.0 kgt-m, 7 lbf-ft) After installing the speed sensor. measure the clearance (air gap) between the sensor and pulser ring (page 1&24). 18-26 Front: Rear: Replace the pulsar ring mounting bolts with new ones. PULSER RING REMOVAL] INSTALLATION Refer to front wheel disassemb|y (page 15-15). Remove the rear brake disc flange (page 14-6). Remove the bolts [1] and pulser ring [2]i Installation is in the reverse order of removal TORQUE: Pulsar ring mountlng bolt: 7.0 NM (0.7 kgf-m, 5.2 lbf-ft) ABS MODULATOR REMOVAL NOTE: - When removing the brake pipe joint nut. cover the end of the pipe to prevent contamination. ' Be careful not to bend or damage the brake pipes Drain the brake fluid from the hydraulic systems (page 17-7). Loosen the brake pipe joint nuts [1] and disconnect the brake pipes. Disconnect the ABS modulator 26F connector [2] (pull the lock lever up to disconnect it). Remove the bracket mounting bolts [3]. washers [4], oollars [5] and ABS modulator/bracket [6], Loosen the brake pipe joint nuts [1] and disconnect the brake pipe [2]. Remove the mounting bolts [3] and delay valve [4]. ANTI-LOCK BRAKE SYSTEM (ABS) [2] 18-27 ANTI-LOCK BRAKE SYSTEM (ABS) Remove the modulator mounting bolts [1] and modulator [2] trom the bracket. INSTALLATION Install the modulator [1] to the bracket and tighten the mounting bolts [2] securely. Install the delay valve [1] to the bracket and tighten mounting bolts [2110 the specified torque. TORQUE: 10 N'm (1.0 kgf~m, 7 lbf-it) Apply brake fluid to the brake pipe joint nut [3] threads. Connect the brake pipe [4] and tighten the brake pipe joint nut to the specified torque. TURQUE:14 N-m (1.4 kgf-m, 10 lbf-ft) Install the collars [1]I ABS modulator/bracket [2], washers [3] and tighten the bracket mounting bolts [4]. Apply brake fluid to the brake pipe joint nut threads [5]. Connect the brake pipes and tighten the brake pipe joint nuts to the specified torque. TORQUE: 14 N-m (1.4 kgf-m, 10 lbfvft) Connect the ABS modulator 26F connector [6] and push down the lock lever. Fill brake fluid and bleed air from the hydraulic systems (page 17-9). [6] l4] 18-28 19. BATTERY/CHARGING SYSTEM SYS‘rEM LocA'noN ................................. "19.2 BA'ITERY ...................................... .. SYSTEM DIAGRAM ---------------------------------- --19-2 CHARGING SYSTEMINSPECTION . SERVICE INFORMATION ----19-3 ALTERNATOR CHARGING COIL ------------ "19-7 TROUBLESHOOTING----- REGULATOR/RECTIFIER ------------------------ «19-3 19-1 BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY ALTERNATOR ' REGULATOR/RECTIFIER MAIN FUSE A (50 A) SYSTEM DIAGRAM R: Red Y: Yellow G: Green 7 - MAIN FUSE A (50A) rL' rL' :o)o we: 9 (-B BATTERY G R v Y Y Y {L g Z: {L A REGULATOR/RECTIFIER ALTERNATOR 19-2 BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL AWARNING - The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging. I - The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. — If electrolyte gets on your skin. flush with water. — If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. - Electrolyte is poisonous. — If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician imme- diately. NOTICE - Always turn OFF the ignition switch before disconnecting any electrical component. ' Some electrical components may be damaged it terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. - For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life, charge the stored battery every two weeks. For a battery remaining in a stored motorcycle. disconnect the negative battery cable from the battery terminal. The maintenance free battery must be replaced when it reaches the end of its service life, The battery can be damaged it overcharged or undercharged. or if left to discharge for a long period. These same conditions contribute to shortening the life-span of the battery. Even under normal use, the performance of the battery deteriorates after 2—3 years. Battery voltage may recover alter battery charging, but under heavy load, battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge otten results from problems in the battery itself, which may appear to be an overcharging symptom. It one of the battery cells is shorted and battery voltage does not increase. the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is trequently under heavy load. such as having the headlight and taillight on for long periods of time without riding the motorcycle. The battery will seltdischarge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sultation from occurring. When checking the charging system, always follow the steps in the troubleshooting flow chart (page 195). For alternator removal and disassembly, refer to see 114, BATTERY CHARGING « Turn power ON/OFF at the charger, not at the battery terminal. - For battery charging. do not exceed the charging current and time Specified on the battery. Using excessive current or extending the charging time may damage the battery. ' Quick charging should only be done in an emergency; slow charging is preterred. BATTERY TESTING Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery testing. The recommended battery tester puts a load on the battery so that the actual battery condition can be measured. Recommended battery tester: Micro 404XL (U.S.A. only), BM-21o or equivalent SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity l 12 V — 11.2 Ah Current leakage 1.2 mA max. Voltage Fully charged 13.0 —13.2 V (20 Clea F) 3:319 Below 12.3 v Charging current Normal 1.1 N5 — 10 h Quick 5.5 A/ h Alternator Capacity 0.57 kW/5.000 rprn Charging coil resistance (20°C/68"F) 0.1 — 1.0 D 19-3 BATTERYICHARGING SYSTEM TOOLS Motorcycle battery analyzer Micro 404XL (USA. only) or BM~21D or equivalent Christie battery charger MC1012/2 (USA, only) 19-4 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 19—6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: Micro AMXL (U.S.A. only), Bin-210 or equivalent Is the battery in good condition? YES - GO TO STEP 2. NO - Faulty battery. 2. CURRENT LEAKAGE TEST Install the battery (page 1943). Check the battery current leakage test (page 19—6). Is the current leakage below 1.2 mA .9 YES - GO TO STEP 4. N0 — GO TO STEP 3. 3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER WIRES Disconnect the regulator/rectifier wires and recheck the battery current leakage. Is the current leakage below 1.2 mA ? VES - Faulty regulator/rectifier, NO - ' shorted wire harness. ~ Faulty ignition switch. 4. ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil (page 19-7). Is the alternator charging coil resistance withln 0.1 - 1.0 D (20 “6/68 °F)? YES — GO TO STEP 5. NO — Faulty charging coil. 5. CHARGING VOLTAGE INSPECTION Measure and record the battery voltage using a digital multimeter (page 19-6). Start the engine. Measure the charging voltage (page 19-7). Compare the measurement to result ol the following calculation. STAN DARD: Measured BV < Measured CV < 15.5 V - BV= Battery Voltage - CV: Charging Voltage Is the measured charging voltage within the standard voltage? YES — Faulty battery. N0 — GO TO STEP 6. 6. REGULATORIRECTIFIER SYSTEM INSPECTION Check the continuity and resistance at the regulator/rectifier wires (page 19—8). Are the results of checked resistance and continuity correct? YES — Faulty regulator/rectifier. NO —- - Open circuit in related wire. - Loose or poor contacts ol related terminal, - shorted wire harness. 19-5 BATTERYICHARGING SYSTEM BATTERY Always turn the ignition switch OFF before removing the battery. Connect the positive terminal first and then the negative cable. REMOVAL/INSTALLATION Remove the seat (page 3-4). Remove the battery holder band [11. Disconnect the negative cable [2] and then the positive cable [3], and remove the battery [4]. Install the battery in the reverse order of removal with the proper wiring as shown. VOLTAGE INSPECTION Measure the battery voltage using a digital multimeter. VOLTAGE: Fully charged: 13.0 —13.2 V Under charged: Below 12.3 V TOOL: Digital multimeter Commercially avallable in USA. CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Tum the ignition switch OFF and disconnect the negative battery cable [1] from the battery. Connect the ammeter (4») probe [2] to the negative cable and the ammeter (—) probe [3] to the battery (—) terminal [4]. With the ignition switch off, check for cunent leakage. - When measuring current using a tester. set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester. While measuring current. do not turn the ignition on. A sudden surge oi current may blow out the fuse in the tester. SPECIFIED CURRENT LEAKAGE: It current leakage exceeds the specified value. a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. 1.2 mA max. 19-6 BATTERY/CHARGING SYSTEM CHARGING VOLTAGE INSPECTION Be sure the battery is in good condition before performing this test. Do not disconnect Warm up the engine to normal operating temperature. the batter or any Stop the engine, and connect the multimeter as shown. camel" "'9 - To prevent a short, make absolutely certain which 77 charging system . . . . Wham first are the positive and negative terminals or cable. switching off the Restart the engine. ignition switch. With the headlight on Hi beam, measure the voltage on Fellure to follow this the multimeter when the engine runs at 5,000 rpm. precaution can I damage the (ester Smndard' 0, mm, Measured BV < Measured CV < 15.5 V components. - BV = Battery Voltage (page 19-6) - CV = Chargan Voltage ALTERNATOR CHARGING COIL INSPECTION Remove the battery (page 19-6). Remove the terminal cover (page 11-4). Itisnatnecessary Remove the socket bolts [1] and disconnect the la remove the stator alternator wires [2]. call to conduct mls test. Check the resistance between all three Yellow wires [1]t STANDARD: 0.1 — 1.0 0 (at 20° Clea" F) Check for continuity between all three Yellow wires and ground. There should be no continuity. If readings are far beyond the standard, or ii any wire 7 has continuity to ground, replace the alternator stator (page 11—4). 19-7 BATTERY/CHARGING SYSTEM REGU LATORIRECTIFIER SYSTEM INSPECTION NOTE: Before system inspection. check for blown the main fuse A (50 A). Remove the battery (page 19-6), Remove the terminal cover (page 11-4). Remove the socket bolts [1] and disconnect the alternator wires [2], battery wire [3] and ground wire [4]. It the regulated voltage reading (page 19-7) is out of the specification, measure the voltage between wire terminals as follows: Item Terminal Specification Battery Red [1] and Continuity should charging battery positive exist line cable [2] Charging ooit line Yellow and 0.1 — 1.0 0 Yellow at (20u CIGB° F) Ground line Green and Continuity ground should exist It all components of the charging system are normal and there are no loose connections at the regulator] rectifier wires, replace the regulator/rectifier unitr REMOVAL/INSTALLATION Remove the rear lender (page 341). Remove the terminal cover (page 114). ‘ Remove the socket bolts [1] and disconnect the 3 alternator wires [2], battery wire [3] and ground wire [4]. g 1 Remove the regulator/rectifier unit mounting bolts [5] and regulator/rectifier [6], removalr NOTE: At installation, align the holes of the regulator/rectifier with the collars on the rear heat guard. 1 9-8 20. IGNITION SYSTEM SYSTEM LOCATION --------------------------------- --2o—2 IGNITION SYSTEM INSPECTION ------------ -- 20-5 SYSTEM DIAGRAM .................................. "20.2 CKp SENSOR ........................................... "20.3 SERVICE INFORMATION ......................... "20.3 IGNITION TIMING ..................................... ..20_3 ............................... -.20_4 20-1 IGNITION SYSTEM { SYSTEM LOCATION ENGINE STOP SWITCH IGNITION SWITCH ECM , EMP SENSOR CLUTCH SWITCH _ MAIN FUSE EI — (30 A) DIRECT IGNITION COIL SPARK PLUG CKP SENSOR GEAR POSITION SENSOR SIDESTAND SWITCH FUSE BOX/DIODE BI: Black ECM G: Green Gr: Gray R: Red I I I T I} I J WSW) CMP SENSOR Y1 Yell?” V, I R/Bu V Gr I—Y/R Y/REjJQ Bum. W” I G' G' Lg; LighI green FCJlI G/W R’Y 2P Bl Y/W suw (Bleade g Bl & I v W/Y “*3 61" 1UP (Gray) CLUTCH SWITCH . ¢ DIODE ENGINE STOP RELAY , : Lg ww avw ___ R/W ij Bins, A Rm CKP SENSOR i 10mm” ‘ ' " BI Bl Bl/W GM _ Lg RIB” 8; ck WN ENGINE STOP SWITCH G 2P ( a ) I—N R/BI—o/ o— R (Black) Lg F1l3iE IGNITION SWITCH FUSE 3 5‘ Z N ( ) MAIN FUSEB (10A) 5 I To Bank angle sensor (30A) 7 E 4 4 E .. SIDESTAND ‘ BATTERY DIRECT IGNITION COILS SWITCH GEAR POSITION SENSOR T 20-2 IGNITION SYSTEM SERVICE INFORMATION GENERAL ' Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. When servicing the ignition system, always follow the steps in the troubleshooting sequence (page 20-4). This motorcycles ICM is built into the ECM. The ignition timing does not normally need to be adjusted since the ECM is factory preset. ' The ECM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the module. Always turn off the ignition switch before servicing. ' A faulty ignition system is often related to poor connections Check those connections before proceeding. Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug. Use spark plugs of the correct heat range, Using spark plugs with an incorrect heat range can damage the engine. This motorcycle features direct ignition coils. where the ignition coils and spark plug caps are integrated. Refer to the following components information — CKP sensor (page 20—8) — Clutch switch (page 22-20) - ECM (page 6—84) — Engine stop switch (page 22-18) — Engine stop relay (page 6-83) — Gear position sensor (page 22-21) — ignition switch (page 22-17) — Sidestand switch (page 22-22) SPECIFICATIONS ITEM SPECIFICATIONS Spark plug IMRQE-QHES (NGK) VUH27ES (DENSO) Spark plug gap 0.30 — 0.90 mm (0.031 — 0.035 in) CKP sensor peak voltage 0.7 V minimum Ignition timing ("F”mark) 3.4“ BTDC at idle TORQUE VALUES Spark plug 16 Nm (1.6 kgf-m. 12 lbf-fl) Timing hole cap 17 N~m (1.7 kgfrm, 13 lbf-tt) Apply grease to the threads. CKP sensor mounting bolt 12 N~m (1.2 kgf~m, 9 Ibt-ft) Apply a locking agent to the threads. TOOLS Peak voltage adaptor IgnitionMate peak voltage tester Test probe 07HGJ-00201DO (not available in MTP07-0286 (UtS.Ar only) D7ZAJ-RDJA11O U.S.A.) with commercially available digital mul- timeter (impedance 10 MOIDCV mini- mum) 20-3 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. — Faulty spark plug — Loose direct ignition coil and spark plug connection — Loose direct ignition coil connectors — Water got into the direct ignition coil (shorting the ignition coil secondary voltage) If there is no spark at one cylinder, temporarily exchange the direct ignition coil with the other good one and perform the spark test. If there is spark. the original direct ignition coil is faulty. "Initial voltage" of the ignition primary coil is battery voltage with the ignition switch tumed ON and engine stop switch turned "(7” (The engine is not cranked by the starter motor). No spark at all plugs Unusual condition Probable cause (Check in numerical order) Ignition coil No initial voltage with the ignition 1. Faulty engine stop switch. primary switch ON and engine stop switch 2. Loose or poor connect of the direct ignition ooil primary wire voltage turned '0" (other electrical compo- terminal, or an open circuit in primary coil (Check at the nents are normal). ECM connector). 3. Faulty ECM (in case when the initial voltage is normal while disconnecting ECM connector). Initial voltage is normal. but it drops 1. Undercharged battery. down to 2 — 4 V while cranking the en- 2. An open circuit or loose connection in ECM Green/red wire. gine. 3. An open circuit or loose connection in Blue/black. Yellowl white, Red/blue and Red/yellow wires between the direct ig- nition coils and ECM. 4. Faulty sidestand switch. clutch switch or gear position sen— sor. 5. An open circuit or loose connection in No. 4 related circuit WIISS. — Clutch switch line: Green/white wire — Sidestand switch line: Green/white wire — Gear position sensor line: Light green wire 6. Faulty CKP sensor (measure the peak voltage). 7. Faulty ECM (in case when above No. 1 — 6 are normal). 8. Faulty direct ignition coil. Initial voltage is normal. but does not 1. Faulty spark plug or leaking ignition coil secondary current spark. ampere. 2. Faulty direct ignition coil (5). 3. Faulty CKP sensor. 4. Faulty 0MP sensor. CKP sensor Peak voltage is lower than standard 1. The multimeter impedance is too low; below 10 MQIDCV value. 2. Cranking speed is too low (battery under charged). 3. The sampling timing of the tester and measured pulse were not synchronized (system is normal it measured voltage is over the standard voltage at least once). 4. Faulty CKP sensor (in case when above No. 1 - 3 are normal). No peak voltage. 1. Faulty peak voltage adaptor. 2. Faulty CKP sensor. 20-4 IGNITION SYSTEM IGNITION SYSTEM INSPECTION If there is no spark at any plug. check all connections for loose or poor contact before measuring each peak voltage. - Check all spark plug condition belore measuring each peak voltage (page 4-7). - Use the recommended digital multimeter or commercially available digital multimeter with an impedance 0610 MQ/DCV minimum. - The display value differs depending upon the internal impedance of the multimeter. . II the peak voltage tester (USA. only) is used. Iollow the manuiacturefs instruction Connect the peak voltage tester or peak voltage adaptor [t] to the digital multimeter [2]. TOOL: IgnitionMate peak voltage tester MTPD7-0286 (U.S.A. only) or Peak voltage adaptor 07HGJ-0020100 (Not available in U.S.A.) with commercially available dIgltal multimeter (im- pedance 10 mmocv minimum) IGNITION COIL INITIAL VOLTAGE ' Check all system connections belore inspection. It the system is disconnected. incorrect initial voltage might be measured. ' Check cylinder compression and check that the spark plugs are installed correctly. Disconnect the direct ignition coils from the spark plugs (page 4»7). Connect the direct ignition coil 2P (White) connectors [11 to the direct ignition coil [2]. Shift the transmission into neutral. Connect a known—good spark plug [3] to the direct ignition coil and ground the spark plug to the cylinder head as done in a spark lest. Disconnect the direct ignition coil 2P (White) connector [1], “I Turn the ignition switch ON and engine stop switch "0". Measure the initial voltage. Connection: Blacklwhlta (1-) - Ground (-) standard: Battery voltage ' Black/white 20-5 IGNITION SYSTEM CKP SENSOR PEAK VOLTAGE Check all system connections before inspection. If the system is disconnected, incorrect peak voltage might be measured. - Check cylinder compression and check that the spark plugs are installed correctly. Lift and support the fuel tank (page 4-5). Remove the ECM [1] trom the air cleaner housing (page 6-84), Disconnect the ECM 33F connectors [2] from the ECM. Connect the peak voltage tester or peak voltage adaptor [1] probes to the ECM 33F (Black) connector terminal at the wire side [2]. Connection: (:7 (+) - 628 H TOOLS: IgnitionMate peak voltage tester MTPo7-0286 (U.S.A. only) or 07HGJ-0020100 (Not available in U.S.A.) with commercially available digital multimeter (Im- pedance 10 MQIDCV minimum) Test probe (2 requires) Peak voltage adaptor 07ZAJ-RDJA1 10 Crank the engine and read the peak voltage. Peak voltage: 0.7 V minimum It peak voltage measured at ECM connector is abnormal. measure the peak voltage at the CKP sensor 2P (Black) connector. Remove the middle cowt (page 3-7). Disconnect the CKP sensor 2P (Black) connector [1] and connect the tester probes to the terminal (Yellow and White/yellow). in the same manner as at the ECM connector. measure the peak voltage and compare it to the voltage measured at the ECM connector. - if the peak voltage measured at the ECM is abnormal and the one measured at the CKP sensor is normal. check the 2P (Black) connector for loose connection and the wire harness for an open circuit or loose connection. - if both peak voltage measured are abnormal, check each item in the troubleshooting chart (page 20—4). If all items are normal. the CKP sensor is faulty. For CKP sensor replacement (page 20-8). 20-6 CMP SENSOR INSPECTION SYSTEM INSPECTION Remove the throttle body (page 6-71), Disconnect the CMP sensor 3P (Black) connector [1]. Turn the ignition switch 0N and engine stop switch "0", Measure the voltage at the CMP sensor 3P (Black) connector wire harness side [2]. Connection: Gray (e) — Ground (—) Standard: 4.15 — 5.25 V If there is specification. check the input voltage inspection (page 204). If there is out of specification. check the signal line inspection (page 20«7). INPUT VOLTAGE INSPECTION Disconnect the CMP 3P (Black) connector. Turn the ignition switch 0N and engine stop switch "0'. Measure the voltage at the CMP sensor 3P (Black) connector wire harness side [1]. Connection: Yellow/red (+) — Greenlwhite (—) Standard: 4.75 — 5.25 V If it is within specification. replace the CMP sensor (page 6—80). If it is not within specification, replace the main wire harness. SIGNAL LINE INSPECTION Turn the ignition switch OFF. Disconnect the ECM 33F (Black) connector. Check for continuity between the CMP 3P (Black) connector wire harness side [1] and EcM 33F (Black) connector wire harness side [7]. Connection: C18 — Gray standard: Continuity If there is continuity, replace the ECM with a new one. It there is no continuity, replace the main wire harness. IGNITION SYSTEM Gray [2] [1] Green/white Yellow/red l2] [1] Gray 20-7 IGNITION SYSTEM CKP SENSOR REMOVAL/INSTALLATION Remove the right middle cowl (page 3-7). Disconnect the CKP sensor 2P (Black) connector [1]. Remove the CKP sensor wire from the clip on the frame. Remove the right crankcase cover (page 10-13)‘ Remove the CKP sensor mounting bolts [1]. Release the wire grommet [2] from the right crankcase oover groove, then remove the CKP sensor [3]. Apply sealant (T hreeBond 1211, 12078 or equivalent) to the grommet. then install it into the groove of the cover. Apply a locking agent the CKP sensor mounting bolt threads, Tighten the CKP sensor mounting bolts to the specified torque. TORQUE21Z N~m (1.2 kgf-m, 9 lbf'ft) Installation is in the reverse order of removals IGNITION TIMING Warm up the engine. Stop the engine and remove the timing hole cap [1]. Read the Connect the timing light [1] to the No.1 direct ignition instructions for ooilwirei liming light I ' . opemim Start the engine and let It idle. IDLE SPEED: 1,150 i: 100 rpm The ignition timing is correct if the index mark [2] on me right crankcase cover aligns the 'F" mark [3] on the CKP sensor rotor as shown Increase the engine speed by turning the throttle grip and make sure the "F" mark begins to move counterclockwise when the engine speeds at approximately 2,400 rpm, 20-8 Apply engine oil to a new O-ring [1] and insIall it to the crankshaft hole cap [2]. Apply grease to the Iiming hole cap threads. Tighten the timing hole cap to me specified torque‘ TORQUE: 17 Min (1.7 kgf-m,13IM-ft) IGNITION SYSTEM 20-9 MEMO 21. ELECTRIC STARTER SYSTEM LOCATION----- .21.2 STARTER MOTOR ................................... "214; - 1-2 STARTER RELAY SWITCH ------------------- --21-13 SYSTEM DIAGRAM ---- ~- SERVICE INFORMATION .. "21.3 DIODE ..................................................... .. 21 _15 TROUBLESHOOTING--- ---- --21.4 21 -1 ELECTRIC STARTER SYSTEM LOCATION ENGINE STOP SWITCH IGNITION SWITCH STARTER SWITCH CLUTCH SWITCH BATTERY STARTER RELAY SWITCH/MAIN FUSE STARTER MOTOR GEAR POSITION SENSOR FUSE BOX/DIODE SIDESTAND SWITCH SYSTEM DIAGRAM STARTER RELAY SWITCH BATTERY BI: Black A (3: Green R: Red 6-) 6 Y: Yellow STARTER MOTOR W: White Gr: Gray Br: Brown _: \_ MAIN FUSE B (30A) _:_ Lg: “gm green CLUTCH SWITCH ‘P (Blank) f/fi’ IGNITION SWITCH 5. WR 2? (Brown) 1m3 (Gmy) G/W R/Bl ENGINE STOP SWITCH G/R FUSE (10 A) G/W L9 — 1 W/Y W/Y -0/c>- BI 8P (Black) Y/R YIR G - IOP (Bray) STARTER SWITCH -- 2P (Black) I.- FUSE (15 A) Lg ’— Lg/BI —®— BI/Br 3 54 2 N IE NEUTRAL INDICATOR . 5 ‘ DIODE ' . UP = GEAR POSITION — SIDESTAND SENSOR SWITCH 21-2 ELECTRIC STARTER SERVICE INFORMATION GENERAL Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. When checking the starter system, always follow the steps in the troubleshooting flow chart (page 214). A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. It the current is kept flowing through the starter motor to turn it while the engine is not cranking over. the starler motor may be damaged. - Refer to the following components information. — Clutch switch (page 22-20) — Engine stop switch (page 22—18) — Gear position sensor (page 22-21) — Ignition switch (page 22-17) — Sidestand switch (page 22-22) — Starter switch (page 22-18) SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Staner motor brush length 12.0 (0.47) 6.5 (0.26) TORQUE VALUE Starter motor cable nut 10 N-m (1.0 kgf~m, 7 Ibf~ft) Starter motor terminal nut 12 N-m (1.2 kgf‘m, 9 Ibt-ft) Negative bmsh mounting screw 3.7 N-m (0.4 kgf~m. 2.7 Ibf-ft) Starter motor case bolt 4.9 N~m (0.5 kgf-mI 3.6 let) 21 -3 ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 1‘ Fuse lnspecdon Check tor blown main fuse B (30 A) or sub fuses (Bank angle 10 A, Stopltail/meter 15 A). Is the fuse blown? YES - Replace the fuse, NO - GO TO STEP 2‘ 2. Battery Inspection Make sure the battery is lully charged and in good condition. Is the battery in good condition? YES - GO TO STEP 3‘ NO — Charge or replace the battery (page 19-6). 3. Starter Relay Switch Operation check the starter relay switch operation. You should hear the relay “CLICK” when the starter switch button is depressed. Does the relay “CLICK”? YES - GO TO STEP 4. NO — GO TO STEP 5. 4. Starter Motor Inspection Apply battery voltage to the starter motor directly and check the operation. Does the starter motor turn? YES - ~ Poorly connected starter motor cable. - Faulty starter relay switch (page 21—13). NO — Faulty starter motor (page 21—6). 5. Relay Coil Ground ere Lines Inspection Check the ground line ol the starter relay switch (page 21-14). 1. Green/red terminal - diode — gear posilion sensor line (with the transmission in neutral and clutch lever released). 2. Green/red tenninal/clutoh switch — sidestand switch line (in any gear except neutral. and with the clutch " ‘ lever pulled in and the sidestand up). Is the ground Ilne normal? YES — GO TO STEP 6. NO - - Faulty gear position sensor (page 22-21). ~ Faulty diode (page 21-15). ‘ Faulty clutch switch (page 22-20). ‘ Faulty sidestand switch (page 22-22). - Loose or poor contact connector. - Open circuit in wire harness. 6. Relay Coil Power Input Llne Inspection Check the power input line of the starter relay switch (page 21—14). Is the power Input Ilne normal? YES - GO TO STEP 74 NO — Faulty ignition switch (page 22-17). Faulty engine stop switch (page 22-18) Faulty starter switch (page 22-13). Blown main or sutHuse. Loose or poor contact connector. Open circuit in wire harness. 21-4 1. Starter Relay Switch Continuity Inspection Check the starter relay switch operation (page 21 -14). Is there battery voltage? YES - Loose or poor contact starter relay switch connector. N0 — Faulty starter relay sim‘tch. ELECTRIC STARTER The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position except neutral, with the sidestand up and the clutch lever pulled In. 1. Clutch Switch inspection Check the clutch switch operation, Is the clutch switch operation normal? YES - GO TO STEP 2. N0 — Faulty clutch switch (page 10-8). 2. Sidestand Switch inspection Check the sidesland switch operation. Is the sldesknd swltclr operation normal? YES — - Open circuit in wire harness - Loose or poor contact connector. N0 — Faulty sidesland switch (page 22-22). Starter motor turns engine slowly - Low battery voltage - Poorly connected battery terminal cable o Poorly connected starter motor cable - Faulty starter motor - Poor connected battery ground cable starter motor turns, but engine does not turn - Starter motor is running backwards — Case assembled improperly — Terminals connected improperly - Faulty starter clutch - Damaged or faulty starter drive gear Starter relay switch “Clicks”, but engine does not turn over - Crankshaft does not turn due to engine problems 21 -5 ELECTRIC STARTER STARTER MOTOR REMOVAL Remove the oil cooler (page 5-13). Disconnect the battery negative (—) terminal (page 19%). Remove the rubber cap [1]. Remove the starter motor cable nut [2] and the starter motor cable [3] from the staner motor. Remove the starter motor mounting bolts [4], Pull the starter motor [5] out of the crankcase. Remove the O-ring [1] from the starter motor [2]. D ISASSEM BLY Remove the following: — starter motor case boltsIO-rings [1] — front cover [1] — seal ring [2] I1} [1] 21-6 — startermotorcaseh] — seal ring [2] — errnature[3] — rear ooverlA] Remove the brushes [1] and springs [2] from the brush holdert Remove the stopper [3] from the rear cover [4]. Check for continuity between the starter motor cable terminal [1] and positive bmshes [2]. There should be continuity. Check for oontinuity between the positive brushes [1] and the rear cover [2]. There should be no continuity. Check for continuity between the positive and negative brushes [3]. There should be no continuityt ELECTRIC STARTER [3] [1] [2} [4] [1]/[2] CONTINUITV: [1] NO CONTINUITY: [2] 21-7 ELECTRIC STARTER Remove lhe following: — screw [1] — negative brushes [2] — tenninalnut[3] washer [1] insulator [2] lerminal stopper [3] O-rlng [4] Illl — terminal bolt [1] — positive brushes [2) — brush holder[3] INSPECTION Inspect the brushes for damage and measure the brush length. SERVICE LIMIT: 6.5 mm (0.26 in) 21 -8 Do not use emery or sandpaper on the commutator. Check the commutator bars [1] for damage or abnormal wear. Check the commutator bars of the armature [2] for discoloration. Clean any metal debris from between commutator bars. Replace the annature with a new one if necessary. Check for continuity between pairs of commutator bars [1]. There should be continuity. Check tor continuity between eaoh commutator bar [1] and the armature shaft [2]. There should be no continuity. Check the oil seal [1] and ball bearing [2] In the {rent cover for deterioration. wear or damage. Check the ball bearing rotates smoothly. ELECTRIC STARTER [2] [1] CONTINUITY: [1] NO CONTINUITY: l2] ; I [2] [1] l1! 21-9 ELECTRIC STARTER Check the bushing [1] in the rear cover [2] for wear or damage. ASSEMBLY __ Ak. _f_ WGRING 49was gfmaelbn) g 7BO,R.NG v FRONT COVER @ SEAL RING MOTOR CASE ARMATURE N ‘ POSITIVE BRUSH 3.7 N»m (0.4 kgfm, 2.7 lbl-fl) TERMINAL WP STOPPER NEGATIVE BRUSH / INSULATOR 7— -- SPRING 12 Nm (1.2 kgf'm. BRUSH HOLDER 9 lbf-ft) STOPPER REAR COVER g O'R'NG WASHER Install the following: — brush holder[1] - positive brushes [2] — leminalboMS] [1] . [31 V/ [2] 21-10 ELECTRIC STARTER — newO—ring [1] — terminal stopperIZ] g [1] — insulator [3] — washer [A] [4] /°f°e [2 Isl Install and Iighten the Ierrninal ml [1] to me specified torque. TORQUE: 12 Nm (1.2 kgf-m, 9 lbl~ft) Install the negative brushes [1] and tighlen Ihe screw [2] to the specified torque. TORQUE: 3‘7 N-m (0.4 kgf-m, 2.7 Ibf-ft) Install the brush springs [1] to me brush holder grooves Install the brushes [2] lo the bmsh holder. Install Ihe stopper [3] to the rear cover. 21-11 ELECTRIC STARTER Install the armature [1] to the rear cover [2]. Install a new seal ring [1] onto the starter motor case [2]. Install the starter motor case with its groove [3] to the stopper [4] on the rear cover. NOTICE The coil may be damaged it the magnet pulls the armature against the case. Install a new seal ring [1] onto the starter motor easel Install the front cover [2] to the starter motor case. NOTICE When installing the fmnt cover, take care to prevent damaging the dust seal lip with the annature shaft. Align the index marks [1] on the front cover. starter motor case and rear cover. [41 [3] l2] 21-12 ELECTRIC STARTER Install new O-n'ngs [1] to the starter motor case bolts [2]. Install and tighten the starter motor case bolts to the specified torque. TORQUE: 4.9 N-m (0.5 kgi-m, 3.6 lbf-ft) INSTALLATION Coat a new O-ring [1] with engine oil and install it into the starter motor groove. Install the starter motor [1] into the crankcase. Install and tighten the starter motor mounting bolts [2] securely. Route the starter motor cable [3]. Install the starter motor cable, then tighten the cable nut [4] to the specified torque, TORQUE: 10 N-m (1.0 kgf-m, 1 lbf-ft] Install the rubber cap [5] securely. Install the removed parts in the reverse order of removal. STARTER RELAY SWITCH OPERATION INSPECTION Remove the seat (page 3-4), Shift the transmission into neutral. Tum the ignition switch ON and englne stop switch to non. - Press the starter switch button. The OOiI is normal if the starter relay switch [1] clicks. If you don't hear the switch 'CLICK", inspect the relay switch using the prooedure below. 21-13 ELECTRIC STARTER GROUND LINE INSPECTION Disconnect the starter relay switch 4P (Black) connector [1]. [1] Green/red Check for continuity between the Green/red wire (ground line) and ground. If there is continuity when the transmission is in neutral . fl or when the clutch is disengaged and the sidestand switch is retracted. the ground circuit is normal (in neutral, there is a slight resistance due to the diode). INPUT LINE INSPECTION Disconnect the starter relay switch 4P (Black) connector [1]. Red Yellow/red Check for continuity between the Red wire and Yellow/ red wire. If there is continuity when the starter switch is pushed with the ignition switch ON and engine stop switch at “O”. the input line is normal. CONTINUITY INSPECTION Remove the starter relay switch. Connect a fully charged 12 V battery positive wire to the relay switch Yellow/red wire terminal and negative wire to the Green/red wire terminal. Connect an ohmmeter to the starter relay switch large terminals. There should be continuity between the large terminals when the battery is connected, and no continuity when the battery is disconnected. e BATTE RY REMOVALIINSTALLATION Remove the seat (page 3-4). Disoonned the battery negative cable (page 19-6). Remove the starter relay switch cover [1], Disconnect the starter relay switch 4P (Black) connector [2]. . Remove the terminal bolts [3] and disconnect the starter relay switch cables [4]. Pull the starter relay switch [5] out from the stay. Installation is in the reverse order of removal. 21-14 ELECTRIC STARTER DIODE REMOVAL/INSTALLATION Remove me seat (page 3-4). Open the fuse box cover and remove the diode [1]. Installation is in the reverse order of removal. INSPECTION Check for continuity between the diode terminals. When there is continuity, a small resistance value will register. If there is continuity, in one direction, the diode is B normal. 21-15 MEMO 22. LlGHTS/METERSISWITCHES SYSTEM LOCATION --------------------------------- --22-2 HIGH COOLANT TEMPERATURE INDICATOR/ECT SENSOR --------------- "22-14 SERVICE INFORMATION " """""""" "22-3 LOW OIL PRESSURE INDICATOR/EOP TROUBLESHOOTING ............................... ..22_5 SENSOR “2246 HEADLIGHT ' 226 FUEL LEVEL SENSOR ........................... "22.15 TURN SIGNAL ........................................... "22:, IGN|TION SWITCH-- FOSITION LIGHT ......... .. 22% HANDLEBAR SWITCHES ---------------------- --22-18 REAR COMBINATION LIGHT .................. ..22_3 BRAKE LIGHT SWITCH ---------------- '- LICENSE LIGHT ........................................ "22.9 CLUTCH SWITCH --------------------------- "22-20 COMBINATION METER .......................... "2240 GEAR POSITION SENSOR ------------------ "22-21 SPEEDOMETERIREAR WHEEL SPEED SIDESTAND SWITCH ............................. "22.22 sENsoR .................................................. ..22_12 HORN ...................................................... "22.23 TACHOMETER ........................................ "2243 HEADLIGHT RELAY ............................... ..22_24 OPEN AIR TEMPERATURE SENSOR "'"22-14 ........................... "22.24 - 22 22-1 LIGHTS/METERSISWITCHES SYSTEM LOCATION FRONT BRAKE LIGHT SWITCH IGNITION SWITCH CLUTCH SWITCH HEADLIGHT RELAV OPEN AIR TEMTERATURE SENSOR ECT SENSOR FUEL LEVEL SENSOR TURN SIGNAL RELAY HORN EOP SENSOR GEAR POSITION SENSOR REAR BRAKE LIGHT SWITCH SIDESTAND SWITCH 22-2 LIGHTS/METERSISWITCHES SERVICE INFORMATION GENERAL . A halogen headlight bulb becomes very hot while the headlight is ON. and will remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing. ‘ Use an electric heating element to heat the water/coolant mixture for the ECT sensor inspection. Keep flammable materials away from the electric heating element. Wear protective clothing, insulated gloves. and eye protection Note the following when replacing the halogen headlight bulb. — Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. — It you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. — Be sure to install the dust cover efler replacing the bulb. 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 motorcycle. The low oil pressure indicator might come on while the front wheel leaves the ground when riding (wheelie). The following color codes are used throughout this section. Bu = Blue G = Green Lg = Light green R = Red Bl = Black Gr = Gray 0 = range W = White Br = Brown Lb = Light blue P = Pink Y = Yellow SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight Hi 12 V - 55 W Lo 12 V — 55 W Taillight 12 V—5W Brake/taillight 12 V — 21/5 W Position light LED Front tum signal light 12V—21Wx2 Rear turn signal light 12 V — 21 W x 2 License light 12 V — 5 W Instrument light LED Turn signal indicator LED High beam indicator LED Neutral indicator LED Low oil pressure indicator LED PGM-Fl malfunction indicator LED High coolant temperature indicator LED ABS indicator LED Fuse Main fuse A 50 A B 30 A PGM-FI fuse 10 A Subfuse 30Ax3.20Ax2.15Ax1.10Ax4 Tachometer peak voltage 10.5 V minimum ECT sensor resistance 80°C (176°F) 2.1 — 26 k0 120°C (248°F) 0.65 — 0.73 k0 Open airtemperature sensor resistance (25°C/77°F) 3 — 7 n TORQUE VALUES Ignition switch mounting bolt Sidestand switch bolt EOP sensor Meter screw Taillight SH bolt Front turn signal cover screw 24 N-m (2.4 kgf‘m. 1a Mir) 10 N»m (1.0 kgf‘m. 7 Ibf‘fl) 22 N-m (2.2 kgf-m. 16 |bf~It) 1.0 N»m (0.1 kgf'm. 0.7 lbf~fl) 9.3 N‘m (1.0 kgf-m. 7.2 let) 1.5 N-m (0,2 kgf-m. 1,1 mm) Replace with a new one. ALOC bolt: replace with a new one. 22-3 LIGHTS/METERSISWITCHES TOOLS Peak voltage adaptor O7HGJ-0020100 (not available in U.S.A) wi1h commercially available digilal mul- timeter (impedance 10 MQ/DCV mini— mum) IgnilionMale peak voltage tester MTPO7—0286 (U.S.A. only) Test probe 07ZAJ-RDJA1 10 g“) 22-4 LIGHTSIMETERSISWITCHES TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER The odometeritrip meter indicates "—--— Faulty EEPROM in ECM The speedometer operation Is abnormal 1. Fuse Inspection Check for blown main fuse or sub fuse. is the fuse blown? YES — Replace the fuse NO — GO TO STEP 2, 2. Battery Inspection Make sure the batlery is fully charged and in good condition, Is the battery In good condition? YES - GO TO STEP 3. N0 — Charge or replace the battery (page 196), 3. Rear Wheel Speed Sensor Inspection (between the speed sensor and ABS modulator) Check for loose or poor contact of the rear wheel speed sensor 2P (Orange) connector. Inspect the rear wheel speed sensor (page 18-24). is the rear wheel speed sensor normal? YES — GO TO STEP 4. NO — ' Faulty rear wheel speed sensor - Open or short circuit between rear wheel speed sensor and ABS modulator - Faulty ABS modulator 4. Speed Sensor signal Llne Inspection With the ignition switch OFF. check ior continuity of the Pink/green wire between the terminals oi the ABS modulator and speedometer. is there continuity? YES — GO TO STEP 5. .77.. N0 - Open circuit in Pink/green wire 5. Speed Sensor Signal Inspection Support the motorcycle using a hoist or other support to raise the rear wheel off the ground. Measure the output voltage (sensor signal) at the speedometer with the ignition switch ON while slowly turning the rear wheel by your hand. CONNECTION: Plnklgreen (4-) - Green (—) STANDARD: Repeat 0 to 5 V is the voltage within specified value? YES - Faulty speedometer NO - - Faulty speed sensor - Loose speed sensor mounting bolts 22-5 LlGHTSIMETERS/SWITCHES HEADLIGHT Avoid touching halogen headlight bulb. Finger prints can create hot spots that cause a bulb to break. BULB REPLACEMENT Turn the socket cover [1] counterclockwise and remove it from the headlight unit. Disconnect the headlight bulb connector [2]. Unhook the bulb retainer [3] and remove the headlight bulb [4]. If you touch the bulb with your bare hands, clean it with cloth moistened with denatured alcohol to prevent early bulb failure. Install a new headlight bulb aligning its tabs with the groove in the headlight unit. Hook the bulb retainer into the headlight unit groove. Connect the headlight connectors. Install the bulb socket while aligning its aligning mark [5] with the aligning mark on the headlight unit. Turn the bulb socket clockwise until its look. REMOVALIINSTALLATION Remove the upper center ooml (page (H 0). Remove the bolls/washers [1] and right/left front upper cover B [2]. Remove the nuts [1] and headlight unit [2]. 22-6 Disconnect the headlight 3P (Black) connector [1]. Installation is in the reverse order of removal. TURN SIGNAL Be careful not to damage the boss and labs. BULB REPLACEMENT FRONT: Remove the screw [1] and turn the reerview mirror [2] for ease removal ol the front cover as shown. Release the front cover boss [1] then, release the tabs in the specified sequence lollcwing. 1. Side tab [2] 2. Upper/inner tab [3] 3. Upper/outer tab [4] Remove the front cover [5]. Turn the bulb socket [1] counterclockwise and remove it While pushing in. turn the bulb [2] caunterclockwise to remove it and replace with a new one. Installation is in the reverse order of removal. TORQUE: Front turn signal cover screw: 1.5 N‘m (0.2 kgf-m, 1.1 Ibf-fl) LlGHTS/METERSISWITCHES [2] 22-7 LIGHTS/METERSISWITCHES REAR: Remove the turn signal cover (page 3-5). Turn the bulb socket [1] counterdockwise and remove it from the rear combination light unlt. While pushing in the bulb [2] counterclockwise to remove it and replace it with a new one. Install the turn signal bulb socket in the reverse order of removal. POSITION LIGHT INSPECTION Turn the ignition switch ON, and check the position light [1] operation, Check that the LED in the position light illuminate with the ignition switch ON‘ If the LED does not turn on, replace the front oover assembly (page 22-7). REAR COMBINATION LIGHT BRAKE/TAILLIGHT BULB REPLACEMENT Remove the seat (page 3-4). Remove the taillight bulb socket [1] from the rear combination light unit. Remove the taillight bulb [2] from the bulb socket and replace it with a new one. Install the taillight bulb socket in the reverse order of removal. Turn the brake/taillight bulb socket [3] counterclockwise, then remove it from the rear combination light unit. Remove the brake/taillight bulb [4] from the bulb socket and replaoe It with a new one. Install the brake/taillight bulb socket in the reverse order of removal. I3] 22-8 LlGHTSIMETERS/SWITCHES REMOVAIJINSTALLATION Remove the left rear cowl (page 3-5). Remove the turn signal cover/rear center cowl (page 3« 5). Disconnect the rear combination light 6P (Black) connector [1]t Disconnect the license light 1P (While) connector [1]. Remove the bolts/collars [2]. Remove the tabs [1] on the rear combination light [2] from the grommets [3] of the rear fender. Installation is in the reverse order of removal. LICENSE LIGHT BULB REPLACEMENT Remove the screws [1]. license light cover/lens [2]. Remove the license light bulb [3] and replace with a new one. Installation is in the reverse order at removal. 22-9 LlGHTS/METERSISWITCHES COMBINATION METER REMOVAL/INSTALLATION Remove the headlight unit (page 2245). - Remove the combination meter connector dust cover [1]. Disconnect the combination meter 20F connector [2], Remove the screws [3] and combination meter [4]. Insta|lation is in the reverse order at removal. DISASSEMBLYIASSEMBLY Remave the screws [1] end lower case [2]. Remove the print board [1] from upper case [2]t [1] [2] Check the print board [1] for damage. Assembly is in the reverse order of disassembly. TORQUE: Meter screw: 1.0 N-m (0.1 kgt-m, 0.1 Ibf-fl) 22-10 COMBINATION METER SYSTEM INSPECTION ' Check for loose or poor contact terminals at the combination meter 20F connector and subvharness 23 P (Black) connector. Turn the ignition switch ON, check that the tachometer needle [1] move to full scale and then returns to zero. if the needle does not show initial function, check the combination meter power input line (page 22-11), POWER/GROUND LINE INSPECTION Remove the upper center oowl (page 3-10). Remove the dust cover [1] and disconnect the combination meter 20F connector [2]. Check the following at the wire harness side connector terminals of the combination meter. Power Input line Measure the voltage between the Black/brown wire terminal (4») and Ground (—). There should be battery voltage with the ignition switch ON. If there is no voltage, check for open circuit in Black] brown wirei Back-up voltage line Measure the voltage between the White/green wire terminal (+) and Ground (—)l There should be battery voltage at all times, It there is no voltage, check for open circuit in White/ green wire, Ground Ilne Measure the continuity between the Green/black wire terminal and Ground. There should be continuity. "there is no continuity. check for open circuit in Green/ black wire. r LlGHTS/METERS/SWITCHES 22-11 LlGHTS/METERSISWITCHES TXD LINE INSPECTION Remove the upper center cowl (page 3-10). Check the combination meter TXD line, it followings: — MIL does not operate properly (page 6—11). — combination meter does not indicate gear position. Check the combination meter power/ground line inspection (page 22-11). Turn the ignition switch to OFF, disconnect the ECM 33F (Gray) connector [1] and combination meter 20F connector [2]. Check the White wire for continuity between the combination meter 20P connector and ECM. There should be continuity. TOOL: Test probe D7ZAJ—RDJA1 10 If there is continuity. replace the print board (page 22-10). If there is no continuity. replace the wire harness. SPEEDOMETER/REAR WHEEL SPEED SENSOR SYSTEM INSPECTION Perform the combination meter system inspection (page 22-11) It the system tails the inspection, perform the power and ground line inspection of the combination meter (page 2241). Check the followings function properly: — tachometer — coolant temperature gauge — indicators Remove the dust cover [1} If the system fails the inspection, shifl the transmissim into neutral, the combination meter 20F connector [2] is connected. then turn the ignition switch ONt Measure the voltage between the Pink/green wire terminal (+) and Green/black wire terminal (—) of the wire harness side connector [1]. Slowly turn the rear wheel by hand. There should be 0 to 5 V pulse voltage. — If pulse voltage appears, replace the combination meter print board. — it pulse voltage does not appear. check tor open or short circuit in Pink/green wire. It the Pink/green wire is OK. check for the rear wheel speed sensor signal line (page 22—13). Wh ite [2] Green/black N l E Pink/green |ll>§ §5§§ 6% éégfi 6; zaEKSSES sagassfisségfifi mum I ENGINE STOP] swam: SWIYCH zaa§a§§§w InF 0MP SENSOR EVAPTFURGE é; 33:5 LIGHT SWIYCH ms- SENSOR EGCA aggg Rm Ifi-I‘ 15w mu FAN MomR RELAV FUEL UNIT 29 WEE M R m 3555 $5? 35% § CLUTCH DIouIE FUSE A Ace ms MAIN HEAD LIGHT BANK ANG|£ am: I mu METER WW I FuEL 0100K rm ABS SOL ABS POWER ma INJEcmRs 29 w 5% LICENSE ucm 12v 5w mom REAR Tum SIGNAL new 12V 21w 30A 2.: isé TAILLIGHT G Izv 5w 5* BRAKE I 5? TAILIJGHT m 12v 21w: 5w FIFusE WA as»; gmmzw mmru EM o ‘29 Izvnm .p ammo sums" m MOTOR m Esxg K (ENGINE) ’ HTIERV ALTERNAYOR AMI REGULATOR! REC'I’IFIER MAIN FUSE 50A 0 553$ ENGINE STOP RELAY BLACK YELLOW u aLuE GREEN RED WHITE \IIOLE‘I Oil level too high o Oil level too low ‘ Contaminated oil YES — GO TO STEP 7. TROUBLESHOOTING 24-3 TROUBLESHOOTING 7. 1 1 1 Ignition Ti ing Inspection Check the ignition timing. Is the ignition timing as specified? NO - ' Faully ECM ~ Faulty CKP sensor - Faulty 0MP sensor - Faulty knock sensor ~ Faulty rear wheel speed sensor - Improper valve timing YES - GO TO STEP 8. . cyllnder compression Inspection Test the cylinder compression. Is the compression as specified? No — - Valve clearance too small . Worn cylinder and piston rings O Damaged cylinder head gasket - Improper valve timing YES — GO TO STEP 9. . Fuel Pump Inspection Check for operation of the fuel pump. inspect the fuel pressure and fuel flow. Is the fuel pump unlt normal? NO - Faulty fuel pump unit (page 6—62) YES — GO TO STEP 10, PGM-FI System Inspection 0. .. Check the fuel injection system Is the fuel Injection system normal? N0 — Faulty fuel injection system. YES - GO TO STEP 11‘ . lubrication Inspectlon Remove cylinder head cover and inspect lubrication. . Is the valve train lubricated properly? N NO — ~ Oil level too low - Faulty oil pump drive mechanism - Feultyoil pump YES - GO TO STEP 12. .Over Heating Inspection Check for engine over heating. Is the engine overheating? YES - - Coolant level too low - Fan motor not working (Faulty fan motor relay) - Thermostat stuck closed - Excessive carbon build—up in combustion chamber ' Use of poor quality fuel - Clutch slipping NO — GO TO STEP 13‘ 24-4 TROUBLESHOOTING 13. Engine Knocking Inspection Accelerate or run at high speed. Is the engine knocking? YES - - Worn piston and cylinder . Wrong type of fuel . Thermostat stuck closed - Excessive carbon build-up in combustion chamber - Ignition timing too advance (Faulty ECM) - Faulty CKP sensor - Faulty CMP sensor - Faulty knock sensor - Faulty rear wheel speed sensor N0 - - Engine does not knock POOR PERFORMANCE AT IDLE AND LOW SPEED 1. Spark Plug lnspectlon Remove and inspect spark plugs. Are the spark plugs in good condition? No — - Plugs not serviced frequently enough - Incorrect spark plug heat range - Incorrect spark plug gap YES — GO TO STEP 2. 2. Ignltion Timing Inspection Check the ignition timing, Is the ignition tlmlng as specified? NO — - Faulty ECM ' Faulty CKP sensor . Faulty CMP sensor « Improper valve timing - Faulty knock sensor . Faulty rear wheel speed sensor YES — GO TO STEP 3. 3. Fuel Pump Inspection Check for operation of the fuel pump. inspect the fuel pressure and fuel flow. is the fuel pump unit normal? NO - Faulty fuel pump unit (page 6-62) YES - GO TO STEP 4. A. PGM-FI System Inspection Check the fuel injection system. Is the fuel Injection system normal? N0 — Faulty fuel injection system YES - GO TO STEP 5. 5. Intake Plpe Leaking Inspection Check for leaks intake manifold pipe. Are there leaks? YES - ~ Loose insulator o Damaged insulator 24-5 TROUBLESHOOTING POORPERFORMANCEATPHGHSPEED 1. ignition Timing Inspection Check the ignition timing. Is the ignition timing as specified? No —- - Faulty ECM - Faulty CKP sensor . Faulty CMP sensor - Improper valve timing YES — GO TO STEP 2. . Fuel Pump Inspection check for operation of the fuel pump. inspect the fuel pressure and fuel flow. Is the fuel pump unit normal? N0 - Faulty fuel pump unit (page 6-62) YES - GO TO STEP 3. . PGM-FI System inspection check the fuel injection system is the fuel injection system normal? N0 — Faulty iuei injection system. YES — GO TO STEP 4, . Valve Timing Inspection Check the valve timing. Is the Valve timing correct? NO - Camshafts not installed properly YES - GO TO STEP 5. . Valve Spring Inspection Check the valve springs Is the valve spring free length as specified? NO - Faulty valve spring . YES - Not weak POOR HANDLING Steering ls heavy Steering bearing adjustment nut too tight Damaged steering head bearings Either wheel is wobbling Excessive wheel bearing play Bent rim Improper installed wheel hub Swingarm pivot bearing excessiver worn Bent frame The motorcycle pulls to one side Front and rear wheel not aligned Faulty shock absorber Bent fork Bent swingarm Bent axle Bent frame 24-6 ABS CONNECTOR LOCATIONS ABS INDICATOR PROBLEM CODE INDEX 13.10 ABS MODULATOR 1&2, ABS SYSTEM DIAGRAM ABS SYSTEM LOCATION ABS TROUBLESHOOTING ABS TROUBLESHOOTING INFORMATION AIR CLEANER ‘‘‘ ‘- AIR CLEANER HOUSING ALTERNATOR CHARGING COIL - ALTERNATOR COVER/STATOR-- ALTERNATOR/STARTER CLUTCH SPECIFICATIONS 1-8 BANK ANGLE SENSO -81 BATTERY-m- 9-5 BATTERY/CHARGING SYSTEM SPECIFICATIONS -10 BODY PANEL LOCATIONS BRAKE FLUIDW‘" BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE LIGHT SWITCH LIGHTS/METERS/SWITCHE 22-20 MAINTENANCE >- 24 BRAKE PAD WEAR- >22 BRAKE PAD/DISC 17-14 BRAKE SYSTEM N -23 CABLE & HARNESS ROUTING ~22 CAM CHAIN TENSIONER" -31 CAMSHAFTIROCKER ARMS- ~11 CHARGING SYSTEM INSPECTION~ 9«6 CKP SENSOR 0-8 CLUTCH-~--- 10-14 CLUTCH FLUID -25 CLUTCH FLUID REPLACEMENT/AIR BLEEDING- CLUTCH MASTER CYLINDER ‘ CLUTCH SLAVE CYLINDE CLUTCH SWITCH CLUTCH SYSTEM -25 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS 1.7 CMP SENSOR COMBINATION METER COMPACT FINAL GEAR CASE COMPONENTLOCATION ALTERNATOR/STARTER CLUTCH 1-2 CLUTCH 0—2 CRANKCASE/TRANSMISSION CRANKSHAFT/PlSTON/CYLINDER CYLINDER HEADNALVES -2 ENGINE REMOVAL/INSTALLATION -2 FINAL DRIVE ---- -- 4-2 FRONT WHEEUSUSPENSION/STEERING 5»2 FUEL SYSTEM (F'GMvFI 6-2 HYDRAULIC BRAKE" 7-2 REAR WHEEUSUSPENSION 6-2 COOLANT REPLACEMENT 7-5 COOLING SYSTEM----- -16 COOLING SYSTEM SPECIFICATIONS 1—6 CRANKCASE ASSEMBLY - 12-23 CRANKCASE SEPARATIO CRANKCASE/TRANSMISSION SPECIFICATIONS CRANKPIN BEARING - CRANI28 CYLINDER HEAD BLEEDING JOINT 7—8 CYLINDER HEAD COVER 9-7 CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSPECTION CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVALW CYLINDER HEADNALVES SPECIFICATION 1-7 DELAY VALVE ‘ 17-38 DIODE 21-15 DTC INDEX 6~14 DTC TROUBLESHOOTING ECM-m ECT SENSOR FUEL SYSTEM (PGM~FI EGCA EGCA CABLE ELECTRIC STARTER/STARTER CLUTCH SPECIFICATIONS"- EMISSION CONTROL SYSTEMS - ENGINE & FRAME TORQUE VALUES ENGINE DOES NOT START OR IS HARD TO START“- ENGINE IDLE SPEE ENGINE INSTALLATION ENGINE LACKS POWER 4~3 ENGINE OIUOIL FILTER >12 ENGINE REMOVAL 8-4 ENGINE STOP RELAY —83 EVAP PURGE CONTROL SOLENOID VALVE] CANISTER EVAPORATIVE EMISSION CONTROL SYSTEM 4-17 EXHAUST PIPE FAN MOTOR RELAY FINAL DRIVE ASSEMBL FINAL DRIVE DISASSEMBLY/INSPECTIO FINAL DRIVE INSTALLATION FINAL DRIVE OlL----- FINAL DRIVE REMOVAL FINAL DRIVE SPECIFICATION FINAL GEAR COVER FLYWHEEL FORK”... FRONT BRAKE CALIPER FRONT FENDERW" FRONT MASTER CYLINDER FRONT MONOBLOCK SIX PISTON OPPOSED CALIPER 2-5 FRONT WHEEL- 1543 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS“ FUEL LEVEL SENSOR 22-16 FUEL LINE 4—5 FUEL LINE INSPECTION ~60 FUEL PUMP RELAY ~67 FUEL PUMP UNIT 434 FUEL SYSTEM (PGM-FI) SPECIFICATION FUEL TANK-«w FUEL TANK COVER 3-3 GEAR POSITION SENSOR 22-21 GEARSHIFT LINKAGEW 1&25 GENERAL SPECIFICATIONS 1-5 GRAB RAIL 34 HANDLEBAR SWITCHES HANDLEBAR HEADLIGHT" HEADLIGHT AIM HEADLIGHT RELAY HIGH COOLANT TEMPERATURE INDICATOR] ECT SENSOR LIGHTS/METERS/SWITCHES HORN HYDRAULIC BRAKE SPECIFICATION IAT SENSOR----- INDEX IGNITION SWITCH IGNITION SYSTEM INSPECTION- IGNITION SYSTEM SPECIFICATIONS IGNITION TIMING‘W INNER LOWER COWL KNOCK SENSOR FUEL SYSTEM (PGM-Fl) LICENSE LlGHT~--- LIGHTS/METERS/SWITCHES SPECIFICATION LUBRICATION & SEAL POINTS LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM SPECIFICATIONS MAIN JOURNAL BEARING- MAINTENANCE SCHEDUL MAP SENSOR MIDDLE COWL- MIL CIRCUIT TROUBLESHOOTING MODEL IDENTIFICATION MUFFLER-w" 3—21 NUTS, BOLTS FASTENERS 4 4-28 02 SENSOR 6~89 OFFSET—PIVOT SWINGARM 2-4 OIL COOLER-~- - 5-13 OIL PRESSURE INSPECTION 5-5 OIL PUMP " 5~7 OIL STRAINE 5-6 OPEN AIR TEMPERATURE SENSO 22-14 PCV- 17—38 PGM—FI CONNECTOR LOCATION PGM-FI SYMPTOM TROUBLESHOOTIN PGM-FI SYSTEM DIAGRAM PGM-FI SYSTEM LOCATION- 6-6 PGM-FI TROUBLESHOOTING INFORMATIO 6~10 PISTON/CYLINDER" 13-13 PIVOT PLATE COVE 3~5 POOR HANDLING POOR PERFORMANCE AT HIGH SPEED POOR PERFORMANCE AT IDLE AND LOW SPEED -- POSITION LIGH PRIMARY DRIVE GEA RADIATOR-"- RADIATOR COOLAN RADIATOR RESERVE TAN REAR BRAKE CALIPER-- 17—34 REAR COMBINATION LIGH REAR COWL" REAR FENDER REAR MASTER CYLINDER/BRAKE LIGHT SWITCH/ BRAKE PEDAL REAR WHEEL REAR WHEEL/SUSPENSION SPECIFICATIONS REARVIEW MIRRORW REGULATOR/RECTIFIER RIGHT CRANKCASE COVER INSTALLATION RIGHT CRANKCASE COVER REMOVAL“ SEALED—LOW AIR PRESSURE CRANKCASE SECONDARY AIR SUPPLY SYSTEM FUEL SYSTEM (PGM>FI)~~- SERVICE INFORMATION ALTERNATOR/STARTER CLUTCH ' ANTI-LOCK BRAKE SYSTEM (ABS) BATTERY/CHARGING SYSTEM CLUTCH ' COOLING SYSTE CRANKCASE/TRANSMISSION ‘ CRANKSHAFT/PlSTON/CYLINDER~ 3-3 CYLINDER HEADNALVES 3 ELECTRIC STARTER/STARTER CLUTCH 1-3 ENGINE REMOVAL/INSTALLATION 8-3 FINAL DRIVE 4-3 FRAME/BODY PAN ELSIEXHAUST SYSTEM 3-3 FRONT WHEEL/SUSPENSION/STEERING 5-3 FUEL SVSTEM (PGM-FI) 6-3 HYDRAULIC BRAKE 7-4 IGNITION SYSTEM- 0-3 LlGHTS/METERS/SWITCH E 2-3 LUBRICATION SYSTEM 5-3 MAINTENANCE 4-2 REAR WHEEL/SUSPENSIO 6-3 SERVICE RULES 1-2 SHIFT FORKS/SHIFT DRUM- 12-21 SHOCK ABSORBER 6-6 SIDE GEAR CASE 2-6 SIDESTAND -30.4»26 SIDESTAND SWITCH - 22~22 SPARK PLUG 4-7 SPEEDOMETER/REAR WHEEL SPEED SENSOR 22-1 STANDARD TORQUE VALUES ~12 STARTER CLUTC 11-11 STARTER MOTOR 1-6 STARTER RELAY SWITCH 21-13 STEERING HEAD BEARINGS 4~29 STEERING STEM' 1560 SUSPENSION -- >26 SUSPENSION LINKAGE- 16-10 SWINGARM SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM 9-2 ELECTRIC STARTER/STARTER CLUTCH- 1-2 IGNITION SYSTEM-W 0»2 SYSTEM FLOW PATI'ERN- 7-2 SYSTEM LOCATION BATTERY/CHARGING SYSTEMW" 9 ELECTRIC STARTER/STARTER CLUTCH~ 1-2 IGNITION SYSTEM-W 0—2 LIGHTS/METERS/SWITCHE 2-2 SYSTEM TESTING 74 TACHOMETER 22-13 TBW RELAY ~> -84 THERMOSTA 7-7 THROTTLE BODY/INJECTORIAP SENSOR UNIT THROTTLE BY WIRE (TBW) SYSTEM- THROTTLE OPERATION 4-5 TRANSMISSION“ 12-15 TROUBLESHOOTING ALTERNATOR/STARTER CLUTCH - 1-3 BATTERY/CHARGING SYSTEM 9-5 CLUTCH 0-5 COOLING SYSTEM4 7-3 CRANKCASE/TRANSMISSION- ~12-5 CRANKSHAFT/PISTON/CYLINDER - 13-4 CYLINDER HEADNALVES 9-6 ELECTRIC STARTER/STARTER CLUTCH- ~21-4 FINAL DRIVE - 14-5 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEL/SUSPENSION/STEERING HYDRAULIC BRAKE IGNITION SYSTEM-- LIGHTS/METERS/SWITCHES LUBRICATION SYSTEM TURN SIGNAL-w" TURN SIGNAL RELAY- UNDER COWL UPPER CENTER COWLIWIND SCREEN UPPER SIDE COWL- VALVE CLEARANCE VALVE GUIDE REPLACEMENT VALVE SEAT INSPECTION/REFACING- WATER PUMP WHEEL SPEED SENSOR WHEELS/TIRES“ WINKER COVER/CENTER COWL WIRING DIAGRAM-"-