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1. amy DIA mm N m kgf m Ibf ft REMARKS Front axle bolt 1 14 73 5 7 5 54 Front axle pinch bolt 2 8 20 2 0 15 Front brake disc bolt 6 6 20 2 0 15 ALOC bolt replace with a new one Front spoke 36 BC 3 2 3 7 0 4 2 7 Top bridge pinch bolt 4 8 32 3 3 24 Bottom bridge pinch bolt 4 8 32 3 3 24 Front brake hose guide bolt 2 6 10 1 0 7 Front brake hose clamp bolt 2 6 10 1 0 7 Fork protector socket bolt 6 6 7 0 0 7 5 2 ALOC bolt replace with a new one Front brake caliper mounting bolt 2 8 30 3 1 22 ALOC bolt replace with a new one Fork center bolt 1 8 20 2 0 15 Apply locking agent to the threads Fork rod lock nut Right side 1 10 20 2 0 15 Fork inner damper rod lock nut Left side 1 10 20 2 0 15 Fork cap 2 50 35 3 6 26 Handlebar switch housing screw 4 5 2 5 0 3 1 8 Front master cylinder holder bolt 2 6 9 8 1 0 7 2 Steering stem adjusting nut 1 26 Apply engine oil to the threads See page 16 24 Steering stem nut 1 24 103 10 5 76 See page 16 24 Clutch lever pivot bolt 1 6 1 0 0 1 0 7 Apply grease to the sliding surface Clutch lever pivot nut 1 6 5 9 0 6 4 4 REAR WHEEL SUSPENSION THREAD TORQUE ITEM DIA mm N m kgf m Ibf ft REMABKS Rear axle nut 1 16 88 9 0 65 U nut Driven sprocket nut 6 10 50 5 1 37 U nut Rear brake disc bolt 4
2. 20 7 LIGHTS METERS SWITCHES EXCEPT E TYPE Turn the ignition switch ON and engine stop switch C7 Push and hold both the A button 1 and B button 2 until the hour digits 3 start blinking Push the B button until the desired hour is displayed NOTE Push and hold to advance the hour fast Push the A button then the minute digits 4 start blinking Push the B button until the desired minute is displayed NOTE Push and hold to advance the minute fast Push both the A button and B button to complete the setting NOTE The time can also be set by turning the ignition switch OFF VS SENSOR 20 8 SYSTEM INSPECTION NOTE Before starting this inspection check for speedometer system inspection page 20 5 Do not disconnect the speedometer 16P connector during inspection After inspection reposition the dust cover securely Shift the transmission into neutral Turn the ignition switch ON and engine stop switch C7 With the speedometer 16P connector 1 connected measure the voltage between the speedometer 16P connector terminals CONNECTION White red Green black Slowly turn the rear wheel by hand There should be 0 V to 5 V pulse voltage If pulse voltage appears replace the speedometer page 20 5 If pulse voltage does not appear check the following White red wire for open or short circuit Green black wire for
3. 20 2 SYSTEM 20 2 HEADLIGHT 20 3 POSITION LIGHT 20 3 TURN SIGNAL LIGHT nne 20 4 BRAKE TAILLIGHT eeeeeene 20 5 20 5 VS SENSOR 20 8 HIGH COOLANT TEMPERATURE 20 9 IGNITION 20 10 HANDLEBAR 20 11 BRAKE LIGHT 5 20 12 NEUTRAL SWITCH 20 12 SIDESTAND 20 13 CEUTGH SWITCH 2e 20 14 FUEL GAUGE FUEL LEVEL SENSOR 20 14 HORN 20 15 TURN SIGNAL RELAY 20 15 20 1 LIGHTS METERS SWITCHES SERVICE INFORMATION GENERAL Note the following when replacing the halogen headlight bulb Wear clean gloves while replacing the bulb Do not put fingerprints on the headlight bulb as they may create hot spots on the bulb and cause it to fail If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the headlight bulb A halogen headlight bulb becomes very hot while the headlight is ON and remains hot for a while after it is turned OFF Be
4. 17 6 17 2 SHOCK 17 7 COMPONENT LOCATION 17 3 SWINGARM 17 10 REAR WHEEL erenrnnnnnnnnn 17 4 DRIVE CHAIN 17 12 17 1 REAR WHEEL SUSPENSION SERVICE INFORMATION GENERAL Raise the rear wheel off the ground by supporting the frame securely when servicing A box or work stand is required to support the motorcycle The shock absorber contains nitrogen under high pressure Do not allow fire or heat near the shock absorber Before disposal of the shock absorber release the nitrogen 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 Use only Honda Genuine replacement bolts and nuts for all suspension linkage and swingarm pivot mounting points ordinary bolts lack adequate strength for these applications Also take note of the installation direction of these bolts since they must be installed correctly For hydraulic brake system service page 18 3 After the rear wheel installation check the brake operation by applying the brake pedal For drive chain information page 3 12 TROUBLESHOOTING Soft suspension Incorrect suspension adjustment Weak shock absorber spring Oilleakage
5. 19 2 CHARGING SYSTEM INSPECTION 19 4 SYSTEM 19 3 ALTERNATOR CHARGING COIL 19 5 SYSTEM DIAGRAM 19 3 REGULATOR RECTIFIER 19 6 19 1 BATTERY CHARGING SYSTEM SERVICE INFORMATION GENERAL AWARNING The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging 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 f 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 physician immediately e Always turn OFF the ignition switch before disconnecting any electrical component Some electrical components may be damaged if 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 2 weeks Fora battery remaining in a stored motorcycle disconnect the negative battery cable from the
6. s a a NEEDLE BEARING 0 8 1 2 mm 0 03 0 05 in DUSTSEAL e 20 26 20 20 X 26 X 4 5 Sam DUST SEAL 20 X 26 X 4 5 4 A 72 COLLAR SWING NEEDLE BEARING 3 2 ARM SIDE 17 X 24 X 17 x 7 SHOCK LINK COLLAR 2 5 DUST SEAL 17 X 24 X 5 7 DUST SEAL 8 17 X 24 X 5 DUST SEAL E S I7X24X5 2 G NEEDLE BEARING 17 X 24 X 25 NEEDLE BEARING 17 X 24 X 25 sus 25 COLLAR SHOCK SHOCK LINK LLAR SHOCK LINK SIDE ABSORBER SIDE INSPECTION Inspect the following parts for damage abnormal wear deformation or crack Collars Shock arm Needle bearings Shock link BEARING REPLACEMENT SHOCK ARM Press the shock absorber and shock link side needle j bearings 1 out of the shock arm using the special tool SHOCK ABSORBER SHOCK LINK SIDE 2 TOOLS Shock link and shock absorber side 2 Driver 07949 3710001 3 Attachment 22 x 24 mm 07746 0010800 1 3114 4 Pilot 17 mm 07746 0040400 3 14 5 Fork seal driver attachment 07746 0010300 DA 27 2 mm Sn 17 8 Press the bearing with the marked side facing up Press in the bearing with the marked side facing up Press the swingarm side needle bearings 1 out of the shock arm using the special too
7. Test probe 07ZAJ RDJA110 9 Is there continuity YES Replace the ECM with a known good one and recheck Open circuit in Green black wire Open circuit in Green wires 4 49 PGM FI SYSTEM REMOVAL INSTALLATION Remove the reserve tank cover page 2 4 Turn the ignition switch OFF Disconnect the ECM 33P Black connector 1 Remove the rubber holder 2 and ECM 3 Remove the ECM from the rubber holder Installation is in the reverse order of removal 4 50 SERVICE INFORMATION 5 2 5 2 SYSTEM 5 3 SYSTEM DIAGRAM 5 3 5 IGNITION SYSTEM IGNITION SYSTEM INSPECTION 5 4 IGNITION TIMING 5 6 IGNITION erre 5 6 IGNITION SYSTEM SERVICE INFORMATION GENERAL When servicing the ignition system always follow the steps in the troubleshooting table page 5 2 A faulty ignition system is often related to poorly connected or corroded connections Check those connections before proceeding TROUBLESHOOTING Inspect the following before diagnosing the system Faulty spark plug Loose spark plug cap or spark plug wire connection Water got into the spark plug cap Leaking the ignition coil secondary v
8. 20 13 SKID PLATE See eee eee eee eee eee eee eee eee eee 2 5 SPARK PLUG 3 5 SPECIFICATIONS weer eee eee 1 4 SPEEDOMETER 20 5 STARTER CLUTCH 13 7 STARTER MOTOR eee eee eee eee eee eee eee eee eee 6 4 STARTER RELAY SWITCH 6 8 STATOR CKP SENSOR 13 4 STEERING HEAD BEARINGS 3 20 STEERING STEM 16 21 SUB FRAME Peete eee eee ee eee eee eee eee eee eee 2 12 SUSPENSION eee eee eee eee eee eee eee eee eee eet 3 19 SWINGARM 17 10 SYSTEM DIAGRAM BATTERY CHARGING SYSTEM 19 3 ELECTRIC STARTER SYSTEM ween 6 3 IGNITION SYSTEM ween 5 3 SYSTEM FLOW PATTERN ween eee ee eeeeeeeeeeeeeeeeeeeeneeeeeeeneees 9 3 SYSTEM LOCATION BATTERY CHARGING SYSTEM 19 3 ELECTRIC STARTER SYSTEM sassnssussuusasssussuascunseuseus 6 3 IGNITION SYSTEM saassssasssussusssunssussussensuAsasssussussassassHun 5 3 LIGHTS METERS SWITCHES sasanssassussanssassunsensussans 20 2 SYSTEM TESTING sassnssassunssssussuusesssusssssesssassusssusuasausouesos 9 4 TAIL COVER LIGHT UNIT sassanssussasssssensasauscussuaseuscunssssaus 2 8 THERMOSTAT sassansenssasssssensuussuscussansussunsussauscu
9. ALTERNATOR STARTER CLUTCH SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Starter driven gear I D 34 000 34 013 1 3386 1 3391 34 033 1 3399 O D 51 705 51 718 2 0356 2 0361 51 685 2 0348 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Crankshaft Runout 0 03 0 001 Connecting rod big end radial clearance 0 004 0 016 0 0002 0 0006 0 05 0 002 Connecting rod big end side clearance 0 05 0 50 0 002 0 020 0 85 0 033 Main journal oil clearance 0 018 0 045 0 0007 0 0018 0 075 0 0030 Main journal O D 33 985 34 000 1 3380 1 3386 33 975 1 3376 Main journal bearing support I D 38 000 38 018 1 4961 1 4968 38 036 1 4975 Transmission Gear 1 0 M5 M6 23 000 23 021 0 9055 0 9063 23 07 0 908 23 020 23 041 0 9063 0 9071 23 09 0 909 G2 25 000 25 021 0 9843 0 9851 25 04 0 986 C3 C4 28 000 28 021 1 1024 1 1032 28 04 1 104 Bushing O D M5 M6 22 959 22 980 0 9039 0 9047 22 91 0 902 22 984 23 005 0 9049 0 9057 22 47 0 885 C2 24 959 24 980 0 9826 0 9835 24 90 0 980 C3 C4 27 959 27 980 1 1007 1 1016 27 95 1 100 Gear to bushin M5 M6 C2 re ae C3 C4 0 020
10. Caliper cylinder 1 0 27 000 27 050 1 0630 1 0650 27 060 1 0654 Caliper piston O D 12 657 12 684 0 4983 0 4994 26 935 26 968 1 0604 1 0617 26 89 1 0587 Rear Specified brake fluid DOT 3 or DOT 4 Brake pad wear indicator To groove Brake disc thickness 4 3 4 7 0 17 0 19 4 0 0 16 Brake disc warpage 0 3 0 01 Master cylinder D 12 700 12 743 0 5000 0 5017 12 755 0 5022 Master piston O D 12 645 0 4978 Caliper cylinder D 27 000 27 050 1 0630 1 0650 27 060 1 0654 Caliper piston O D 12 657 12 684 0 4983 0 4994 26 935 26 968 1 0604 1 0617 S 26 89 1 0587 Brake pedal height 64 65 2 52 2 56 GENERAL INFORMATION BATTERY CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type YTX7L BS Capacity 12 V 6 Ah 10 HR Current leakage 0 34 mA max Voltage Fully charged 13 0 13 2 ORIGO T adm Below 12 3 V Charging current Normal 0 6 A 5 10h Quick 3 A 1 h Alternator Capacity 0 34 kW 5 000 rpm Charging coil resistance 20 C 68 F 0 1 1 00 LIGHTS METERS SWITCHES SPECIFICATIONS ITEM SPECIFICATION Bulbs Headlight 12V 60 55 W Position light 12V 5W Brake taillight 12V 21 5W Fron
11. 1 SERVICE 3 2 MAINTENANCE SCHEDULE 3 2 FUEL rera eer Da eat 3 3 THROTTLE 3 3 AIR CLEANER ornetur tnam knot 3 4 CRANKCASE BREATHER 3 4 SPARK 3 5 VALVE 3 6 ENGINE Oll rani inii 3 9 ENGINE OIL 020 442222 3 10 ENGINE IDLE 3 10 RADIATOR COOLANT 3 11 COOLING 3 11 SECONDARY AIR SUPPLY 3 11 3 MAINTENANCE DRIVE CHAIN 3 12 DRIVE CHAIN SLIDER 3 14 BRAKE FLUID 24 4 22422 3 15 BRAKE PADS WEAR 3 16 BRAKE SYSTEM 3 17 BRAKE LIGHT SWITCH 3 17 HEADLIGHT AIM 3 18 CLUTCH SYSTEM nnne 3 18 SIDESTAND 2 3 19 SUSPENSION 3 19 NUTS BOLTS 3 19 WHEELSV TIRES eene 3 20 STEERING HEAD BEARINGS 3 20 3 1 MAINTENANCE SERVICE INFORMATION GENERAL Place the motorcycle on level surface before
12. Fork spring Slider bushings Guide bushings Back up rings Measure each part according to FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS page 1 8 Replace any part if it is out of service limit 16 11 FRONT WHEEL SUSPENSION STEERING ASSEMBLY Before assembly wash all parts with a high flash point or non flammable solvent and wipe them off completely O RING j Gm OUTER TUBE j fi H WEAR RING FORK ROD LEFT SIDE FORK CAP 85 3 6 kgf m 26 Ibf ft O RING c IN OUTER TUBE WEAR RING 16 12 SPRING SEAT REBOUND SPRING 7 GUIDE BUSHING RIGHT SIDE FORK CAP LOCK NUT 35 N m 3 6 kgf m 26 20 N m 2 0 kgf m 15 Ibf ft STOPPER RING t FORK SPRING Ff INNER DAMPER FORK PIPE SLIDER BUSHING OIL SEAL STOPPER RING FORK PIPE LOCK NUT 20 N m 2 0 kgf m 15 Ibf ft n 2 SLIDER BUSHING GUIDE BUSHING BACK UP RING s f OIL SEAL STOPPER RING s DUST SEAL 20 N m 2 0 kgf m 15 Ibf ft FRONT WHEEL SUSPENSION STEERING Wrap the end of the fork pipe with tape 1 Coat new fork oil seal 2 and dust seal 3 lips with recommended fork oil Install the dust seal and stopper ring 4 onto the fork ca pipe Install the oil seal onto the fork pipe with its marked side facing the dust seal Remove the tape from the end of the fork pipe Instal
13. IDENTIFICATION COLOR BEARING INSTALLATION Apply engine oil to new bearing 1 surface Set new bearings to the metal installer as shown TOOL Metal installer set 070MF KYJ0100 Tighten the bolts 2 alternately in several steps Set the bearings 1 and special tools assembly on inside of the crankcase fitting the bearing edge in the crankcase main journal Align the mating line of the bearings with the index mark 2 on the crankcase as shown Set the crankcase and special tools on the hydraulic press TOOLS 1 Metal installer set 070MF KYJ0100 2 Base 42 mm 07GAF SD40200 Make sure the metal installer mating line is aligned with the index mark on the crankcase 14 9 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Press the bearings 1 until the metal installer flange 2 is fully seated Make sure the bearing mating line is aligned with the v index mark on the crankcase Check the oil clearance page 14 7 NOTE After selecting new bearings recheck the oil clearance Incorrect clearance can cause severe engine damage Install the following Crankshaft page 14 6 Transmission page 14 11 Balancer shaft page 14 14 TRANSMISSION REMOVAL DISASSEMBLY Separate the crankcase halves page 14 4 Pull the shift fork shaft 1 and remove it from the shift forks Remove the shift forks 2 and shift drum 3
14. IGNITION SYSTEM SYSTEM LOCATION IGNITION SWITCH ENGINE STOP SWITCH CLUTCH SWITCH ECM BANK ANGLE SENSOR BATTERY MAIN FUSE 30 A FI IGN FUSE 10 A X IGNITION COIL QI Sty 1 lt SPARK PLUG Ww CKP SENSOR SIDESTAND NEUTRAL SWITCH SWITCH IGNITION SWITCH SIDESTAND BI Black R W SWITCH pee Green MAIN FUSE 30 A BUB En O Orange R Red BATTERY FI IGN FUSE 10 A ha A W White o o BANK ce Y Yellow ENGINE STOP eee Br Brown SWITCH IGNITION COIL G R G BI NEUTRAL R Bu G DIODE Lg R Lt NEUTRAL SPARK PER SWITCH PLUG IGNITION SYSTEM IGNITION SYSTEM INSPECTION Avoid touching the spark plug and tester probes to prevent electric shock NOTE If there is no spark at the plug check all connections for loose or poor contact before measuring the peak voltage Use a commercially available digital multimeter with an impedance of 10 MO DCV minimum The display value differs depending upon the internal impedance of the multimeter If using the Imrie diagnostic tester model 625 follow the manufacturer s instructions Connect the peak voltage adaptor 1 to the digital multimeter 2 or use the Imrie diagnostic tester TOOL Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multimeter impedance 10 MO DCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE
15. Probable cause Open or short circuit in Gray blue wire between the sensor unit and ECM Open circuit in Green white wire between the sensor unit and ECM Faulty sensor unit Faulty ECM 4 33 PGM FI SYSTEM 4 34 1 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 8 Is the sensor unit power line normal YES GO TO STEP 2 NO Replace or repair the abnormal circuit IAT Sensor Output Voltage Inspection Turn the ignition switch OFF Connect the ECM 33P Black connector Disconnect the sensor unit 5P connector 1 page 4 44 Turn the ignition switch ON and engine stop switch Measure the voltage at the sensor unit 5P connector of the wire side Connection Gray blue Green white Standard 4 75 5 25 V Is the voltage within 4 75 5 25 V YES GO TO STEP 5 NO GOTO STEP 3 IAT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector Check for continuity between the sensor unit 5P connector 1 of the wire side and ground Connection Gray blue Ground Is there continuity YES Short circuit Gray blue wire NO GOTO STEP 4 IAT Sensor Output Line Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and sensor unit 5P connector 2 of the wire side Connection Gray blue Gray blue TOOL Test probe 07ZAJ RDJA110 Is
16. 4 46 REMOVAL INSTALLATION Drain the coolant page 9 5 Disconnect the ECT sensor 3P connector 1 Remove the ECT sensor 2 and sealing washer 3 Installation is in the reverse order of removal Replace the sealing washer with a new one TORQUE ECT sensor 25 2 5 kgf m 18 Ibf ft Fill the cooling system with recommended coolant page 9 5 INSPECTION Remove the ECT sensor 1 page 4 46 Heat the coolant with an electric heating element Suspend the ECT sensor in heated coolant and check the continuity through the sensor as the coolant heats up Soak the ECT sensor in coolant up to its threads with at least 40 mm 1 6 in from the bottom of the pan to the bottom of the sensor Keep temperature constant for 3 minutes before testing A sudden change of temperature will result in incorrect readings Do not let the thermometer 2 or ECT sensor touch the pan CONNECTION A B Temperature 20 C 68 F 80 C 176 F Resistance 2 8 2 6 0 31 0 33 kO Replace the ECT sensor if it is out of specifications by more than 10 Install the ECT sensor page 4 46 PGM FI SYSTEM O2 SENSOR Do not get grease oil or other materials in the Oz sensor air hole The sensor be damaged if dropped Replace it with a new one if dropped REMOVAL INSTALLATION NOTE Handle the O2 sensor with care Do not service the gt sensor wh
17. Drill into the shock absorber at the center punch mark to purge the nitrogen gas Once all the nitrogen gas has been purged from the shock absorber and it is no longer under pressure the item can be disposed of SHOCK LINKAGE REMOVAL INSTALLATION Raise the rear wheel off the ground by placing a work stand or box under the frame and support the swingarm Remove the rear brake pedal return spring 1 Remove the following Shock absorber lower mounting nut bolt 1 Shock link to shock arm nut bolt washer 2 Shock arm to swingarm nut bolt washer 3 Shock arm 4 Shock link to frame nut bolt 5 Shock link 6 Installation is in the reverse order of removal Apply engine oil to the shock arm to swingarm nut threads Before tightening the nuts to the specified torque install all the nuts bolts and washers TORQUE Shock link to frame nut 44 4 5 kgf m 32 Ibf ft Shock arm to swingarm nut 74 N m 7 5 kgf m 55 Ibf ft Shock link to shock arm nut 44 4 5 kgf m 32 Ibf ft Shock absorber lower mounting nut 44 4 5 kgf m 32 Ibf ft 17 7 REAR WHEEL SUSPENSION DISASSEMBLY ASSEMBLY Disassemble and assemble the shock linkage as following illustration Install the swingarm side shock arm dust seals to the specified depth Install other dust seals until they are fully seated on the bearings 0 8 1 2 mm 0 03 0 05 in
18. TORQUE 3 0 N m 0 3 kgf m 2 2 Ibf ft Connect the IACV Black connector 1 and injector 2P Gray connector 2 Install the wire band 3 to the clamp stay 7 13 FUEL SYSTEM Connect the sensor unit 5P connector 1 Install the fuel tank page 7 8 Adjust the throttle grip freeplay page 3 3 NOTE If the sensor unit is removed perform the TP sensor reset procedure page 4 45 INJECTOR 7 14 REMOVAL Remove the fuel tank page 7 8 Disconnect the injector 2P Gray connector 1 Remove the bolts 2 and injector assembly 3 from the throttle body Remove the injector joint 1 O ring 2 cushion ring 3 and seal ring 4 from the injector 5 Check the removed parts for wear or damage and replace them if necessary 1 3 INSTALLATION Apply engine oil to a new O ring 1 and a new seal ring 2 Install a new cushion ring 3 and seal ring to the injector 4 being careful not to damage them Install the O ring to the injector gt 7 m 2 4 9 3 Be careful not to damage the seal IACV ring FUEL SYSTEM Install the injector 1 into the injector joint 2 being careful not to damage the O ring 1 NOTE Align the injector body with the injector joint tab 3 as A shown Install the injector assembly 1 to the throttle body Install and tighten the injector joint mounting bolts 2 alternately t
19. 1 2 7 FRAME BODY PANELS EXHAUST SYSTEM DISASSEMBLY ASSEMBLY U TYPE ONLY Remove the nuts 1 bolts 2 collars 3 license holder plate 4 and license plate stay 5 Remove the stopper rubber 6 Remove the nuts 7 and rear side reflectors 8 Assembly is in the reverse order of disassembly TORQUE Rear side reflector mounting nut 1 5 N m 0 2 kgf m 1 1 REAR UPPER FENDER REMOVAL INSTALLATION Remove the seat page 2 3 Remove the hook bolts 1 and collars 2 Slightly spread the side covers 3 and release the bosses 4 and tabs 5 Remove the rear upper fender 6 Installation is in the reverse order of removal TORQUE Hook bolt 21 N m 2 1 15 Ibf ft TAIL COVER LIGHT UNIT 2 8 REMOVAL INSTALLATION Remove the following Rear upper fender page 2 8 Rear fender page 2 7 Disconnect the brake taillight 6P Black connector 1 Remove the bolts A 2 bolts B 3 and tail cover light unit 4 Installation is in the reverse order of removal 2 6 1 13 FRAME BODY PANELS EXHAUST SYSTEM DISASSEMBLY ASSEMBLY Remove the following Rear fender page 2 7 Rear turn signal units page 20 4 Disassemble and assemble the tail cover light unit as following illustration BRAKE TAILLIGHT REFLECTOR MOUNTING NUT MOUNTING SCREWS SOCKET BOLTS 1 5 N m 0 2 kgf m 1 1 Ibf ft 4 5 N m 0 5
20. 4 3 kgf m 31 DUST SEAL Ng DRIVEN SPROCKET NUTS n 50 N m 5 1 kgf m 37 Ibf ft 9 vA WV YRS DRIVEN SPROCKET DISTANCE COLLAR DRIVEN SPROCKET BOLTS BRAKE DISC DUST SEAL BEARING 6303U BEARING REPLACEMENT Install the remover head 1 into the bearing From the opposite side of the wheel install the bearing remover shaft 2 and drive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS 1 Bearing remover head 17 07746 0050500 2 Bearing remover shaft 07746 0050100 Pack new bearing cavities with grease Drive in a new right side brake disc side bearing 1 squarely with the sealed side facing up until it is fully seated TOOLS 2 Driver 07749 0010000 3 Attachment 42 x 47 mm 07746 0010300 4 Pilot 17 mm 07746 0040400 Install the distance collar Drive in a new left side bearing with the sealed side facing up until its inner race is fully seated on the distance collar REAR WHEEL SUSPENSION WHEEL CENTER ADJUSTMENT Adjust the hub position so that the distance from the right end surface 1 of the hub center to the side of rim 2 is within the following specification as shown WHEEL HUB TO RIM DISTANCE 26 9 1 0 mm 1 06 0 04 in WHEEL RIM RUNOUT Radial 2 0 mm 0 08 in or less Axial 2 0 mm 0 08 in or less Tighten the spokes in 2 or 3 progressive st
21. After installation apply engine oil to the bearing rotating area Apply locking agent to the mainshaft bearing setting plate bolt 1 threads page 1 15 Install the setting plate 2 with its OUTSIDE mark 3 facing out Install and tighten the bolts securely LEFT CRANKCASE SIDE Remove the snap ring 1 Remove the countershaft oil seal 2 from the left crankcase 14 16 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Drive out the countershaft bearing 1 1 Remove the mainshaft needle bearing 1 using the special tools TOOLS 2 Bearing remover set 17 mm 07936 3710300 Remover handle 07936 3710100 3 Remover weight 07741 0010201 3 Remove the balancer shaft bearing 1 using the special tools TOOLS 2 Bearing remover set 20 mm 07936 3710600 3 Remover handle 07936 3710100 4 Remover weight 07741 0010201 Drive in new bearings into the left crankcase until they are fully seated using the special tools TOOLS e Mainshaft needle bearing 2 Driver 07749 0010000 3 Attachment 28 30 07946 1870100 4 Pilot 17 07746 0040400 5 Countershaft bearing marked side facing up Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 Pilot 22 mm 07746 0041000 1 6 Balancer shaft bearing marked side facing up Driver 07749 0010000 2 73 6 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 After installation apply engine oil
22. Remove the mainshaft assembly 1 countershaft assembly 2 together 14 10 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Disassemble the mainshaft countershaft assembly 2 NOTE Keep track of the disassembled parts gears bushings washers and snap rings by sliding them onto a tool or a piece of wire Do not expand the snap ring more than necessary for removal To remove a snap ring expand the snap ring and pull it off using the gear behind it assembly 1 and INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Replace if necessary Transmission gears Transmission bushings Transmission bearings Shift drum journal Shift forks Shift fork shaft Measure each part and calculate the clearance according to CRANKCASE CRANKSHAFT TRANS MISSION BALANCER SPECIFICATIONS page 1 7 Replace any part if it is out of service limit ASSEMBLY INSTALLATION Clean all parts in solvent and dry them thoroughly Apply molybdenum oil solution to the gear bushing entire surface M5 C1 C2 C3 gear bushing outer surface M6 C4 to ensure initial lubrication Assemble all parts into their original positions NOTE nstall the washers and snap rings 1 with the chamfered edge facing the thrust load side Confirm the inner side of snap rings and washer when you detect the chamfered side Do not reuse worn snap ring which could easily s
23. Shift the transmission into neutral and disconnect the spark plug cap page 3 5 Connect a known good spark plug 1 to the spark plug cap 2 and ground it to the cylinder head as done in a spark test With the ignition coil primary wire connected connect the peak voltage adaptor or Imrie tester to the ignition coil primary terminal 1 and ground TOOL Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multimeter impedance 10 MO DCV minimum CONNECTION Green red Ground Shift the transmission into neutral Turn the ignition switch ON and engine stop switch CZ Crank the engine with the starter motor with the throttle grip fully opened and read ignition coil primary peak voltage PEAK VOLTAGE 100 V minimum If the peak voltage is abnormal follow the checks described in the troubleshooting table page 5 2 2 CKP SENSOR VOLTAGE Remove the reserve tank cover page 2 4 Disconnect the ECM 33P Black connector 1 Connect the peak voltage tester or adaptor probes to the ECM 33P Black connector 1 terminals of the wire harness side TOOLS Imrie diagnostic tester model 625 or Peak voltage adaptor 2 07HGJ 0020100 with commercially available digital multimeter impedance 10 MQ DCV minimum Test probe 07ZAJ RDJA110 CONNECTION Blue yellow White yellow Shift the transmissio
24. Inspect the valve seat face for Damaged face Replace the valve and reface the valve seat Uneven seat width Bent or collapsed valve stem Replace the valve and reface the valve seat Contact area too low or too high area Reface the valve seat REFACING Reface the valve seat using the following tools TOOLS Cutter holder 4 5 mm 07781 0010600 Seat cutter 27 5 mm 45 EX 07780 0010200 Seat cutter 33 mm 45 IN 07780 0010800 Flat cutter 27 mm 32 EX 07780 0013300 Flat cutter 30 mm 32 IN 07780 0012200 Interior cutter 30 mm 60 07780 0014000 Interior cutter 37 5 mm 60 IN 07780 0014100 VALVE SEAT WIDTH 0 90 0 10 mm 0 035 0 043 in NOTE e Follow the refacer manufacturers operating instructions Be careful not to grind the seat more than necessary 1 Use a 45 seat cutter remove any roughness or irregularities from the seat 2 Use a 32 flat cutter remove the top 1 4 of the existing valve seat material 3 Use a 60 interior cutter remove the bottom 1 4 of the existing valve seat material 4 Using a 45 seat cutter cut the seat to the proper width 5 After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure NOTE Excessive lapping pressure may deform or damage the seat Change the angle of lapping tool 1 frequently to prevent uneven seat wear Do not allow lapping co
25. REMOVAL INSTALLATION Drain the coolant page 9 5 Remove the left fuel tank shroud page 2 4 Release the spark plug wire 1 and radiator siphon hose 2 from the guides 3 Disconnect the fan motor 2P Black connector 4 COOLING SYSTEM Disconnect the siphon hose 1 from the radiator Loosen the water hose band screws 2 and disconnect the upper and lower water hoses 3 Remove the radiator guard 4 by releasing the bosses 5 Remove the radiator mounting bolts 6 and radiator 7 Installation is in the reverse order of removal Tighten the hose band screw to the specified range Fill the system with the recommended coolant page 9 5 A 0 1 mm 0 0 04 in DISASSEMBLY ASSEMBLY Disassemble and assemble the radiator as following illustration RADIATOR CAP SCREW COOLING FAN 8 5 N m 0 9 kgf m 6 3 Ibf ft FAN MOTOR RADIATOR CAP 4 2 7 N m 0 3 kgf m 2 0 RADIATOR FAN MOTOR SHROUD 1 0 N m 0 1 kgf m 0 7 Ibf ft 9 7 COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check the bleed hole 1 of the water pump for signs of coolant leakage If water leaks through the bleed hole replace the mechanical seal page 9 9 If oil leaks through the bleed hole replace the oil seal page 9 9 Make sure that there are no continuous coolant leakage from the bleed hole while operating the engine NOTE A small amount of weepi
26. necessary to 2 Valve spring compressor 07757 0010000 remove the cotters 3 Valve spring compressor attachment 07959 KM30101 Mark all parts during Remove the following amp EN 2 vs Spring retainer i 2 ey 06 Outer inner valve springs installed in their Valve original locations Stem seal Spring seat INSPECTION Inspect the following parts for damage abnormal wear deformation burning or clogs in oil passages Cylinder head Inner outer valve springs Valves Valve guides guide Measure each part and clearance according to CYLINDER HEAD VALVES SPECIFICATIONS page 1 6 Replace any part if it is out of service limit 10 13 CYLINDER HEAD VALVES Do not use a torch to heat the cylinder head it may cause warping 10 14 VALVE GUIDE REPLACEMENT NOTE Refinish the valve seats whenever the valve guides are replaced to prevent uneven seating Chill new valve guides in a freezer section of refrigerator for about an hour Heat the cylinder head to 130 140 C 266 284 F with a hot plate or oven Do not heat the cylinder head beyond 150 C 302 F Use temperature indicator sticks available from welding supply stores to be sure the cylinder head is heated to the proper temperature To avoid burns wear insulated gloves when handling the heated cylinder head Support the cylinder head and drive out the valve guides from th
27. 0 062 0 0008 0 0024 0 10 0 004 Ci 0 015 0 057 0 0006 0 0022 0 10 0 004 Bushing 1 0 5 20 000 20 021 0 7874 0 7882 20 05 0 789 C2 22 000 22 021 0 8661 0 8670 22 07 0 869 C3 25 000 25 021 0 9843 0 9851 25 04 0 986 Mainshaft at M5 bushing 19 959 19 980 0 7858 0 7866 19 91 0 784 countershaft O D atC1 bushing 19 959 19 980 0 7858 0 7866 19 91 0 784 at C2 bushing 21 959 21 980 0 8645 0 8654 21 91 0 863 at C3 bushing 24 959 24 980 0 9826 0 9835 24 90 0 980 p E E M5 C1 C2 C3 0 020 0 062 0 0008 0 0024 0 10 0 004 clearance Shift fork Shift fork shaft O D 11 957 11 968 0 4707 0 4712 11 95 0 470 shift fork Shift fork 12 000 12 018 0 4724 0 4731 12 05 0 474 shaft Shift fork claw thickness 4 93 5 00 0 194 0 197 4 82 0 190 Shift drum Shift drum O D Left side 13 966 13 984 0 5498 0 5506 13 94 0 549 14 000 14 027 0 5512 0 5522 14 06 0 554 Shift drum to shift drum journal Left side 0 016 0 061 0 0006 0 0024 0 08 0 003 clearance 1 7 GENERAL INFORMATION FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire thread depth 3 0 0 12 Cold tire pressure Driver on
28. 0 27 0 03 0 011 0 001 Valve valve Valve stem O D IN 4 475 4 490 0 1762 0 1768 4 46 0 176 guide EX 4 465 4 480 0 1758 0 1764 4 45 0 175 Valve guide 1 0 IN EX 4 500 4 512 0 1772 0 1776 4 540 0 1787 Stem to guide IN 0 010 0 037 0 0004 0 0015 0 07 0 003 clearance EX 0 020 0 047 0 0008 0 0019 0 08 0 003 Valve guide height IN EX 13 8 14 0 0 54 0 55 Valve seat width IN EX 0 90 1 10 0 035 0 043 1 50 0 059 Valve spring Free length Inner 34 58 1 361 32 85 1 293 Outer 40 37 1 589 38 35 1 510 Rocker arm Arm I D IN EX 10 000 10 015 0 3937 0 3943 10 10 0 398 rocker arm Shaft O D IN EX 9 972 9 987 0 3926 0 3932 9 91 0 390 snan Armo snan IN EX 0 013 0 043 0 0005 0 0017 0 10 0 004 clearance Camshaft Cam lobe height IN 30 931 31 171 1 2178 1 2272 30 911 1 2170 EX 30 839 31 079 1 2141 1 2236 30 819 1 2133 Camshaft journal O D 19 959 19 980 0 7858 0 7866 Oil clearance 0 020 0 062 0 0008 0 0024 0 10 0 004 Cylinder Camshaft journal area I D 20 000 20 021 0 7874 0 7882 0 05 0 002 CYLINDER PISTON SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder 1 0 76 000 76 010 2 9921 2 9925 76 04 2 994 Out of round 0 010 0 0004 0 010 0 0004 0 05 0 002 Piston piston Piston O D at 11 mm 0 4 in
29. 1 Route the VS sensor wire through the guide 2 Install and tighten the starter motor terminal nut 3 with starter motor cable terminal 4 Install the rubber cap 5 Install and tighten the starter motor mounting bolt 6 with ground terminal 7 Connect the clutch cable 1 to the clutch lifter arm 2 Install clutch cable guide 3 and tighten the bolts 4 15 8 ENGINE REMOVAL INSTALLATION Close the harness band 1 and secure the wires Connect the VS sensor 3P Blue connector 2 Connect the following Alternator connector 1 sensor neutral switch Black connector 2 Secure the alternator wire 3 with the clamp 4 Connect the Oz sensor cap 1 Take care not to tilt the O2 sensor cap when connecting the cap to the Oz sensor Do not turn the sensor cap after connecting it Connect the ECT sensor 3P connector 2 Connect the following Spark plug cap 1 PAIR air supply hose 2 Install the following Brake pedal page 18 12 Gearshift pedal page 12 17 Exhaust pipe muffler page 2 11 Throttle body page 7 13 Skid plate page 2 5 Frame guard page 2 6 Inspect the following Drive chain slack page 3 12 Throttle grip freeplay page 3 3 Clutch lever freeplay page 3 18 Fill the engine with the recommended engine oil page 3 9 Fill the recommended coolant and bleed the
30. 4 Release the rubber cap 1 TE Remove the starter motor terminal nut 2 and starter motor cable 3 Remove the stater motor mounting bolts 4 and ground terminal 5 Remove the starter motor 6 Remove the O ring 1 Installation is in the reverse order or removal Apply engine oil to a new O ring 6 4 ELECTRIC STARTER SYSTEM DISASSEMBLY ASSEMBLY Disassemble and assemble the starter motor as following illustration The coil may be damaged if the magnet pulls the armature against the motor case gu RING MOTOR CASE GP sea RING FRONT COVER gem 4 9 0 5 kgf m 3 6 Ibf ft O RING NEGATIVE BRUSH 3 7 N m 0 4 kgf m 3 250 gt 2 7 INSULATOR TERMINAL STOPPER 1 A REAR COVER BRUSH HOLDER SPRING ARMATURE POSITIVE BRUSHES TERMINAL BOLT Upon assembly align the index lines on the covers and motor case Align ELECTRIC STARTER SYSTEM Do not use emery or sand paper on the commutator 6 6 INSPECTION Check the oil seal 1 of the front cover for deterioration or damage Check the bearing 2 and needle bearing 3 for wear damage Replace the starter motor as an assembly if necessary Clean the metallic debris off between commutator bars 1 Check the commutator bars of the armature for discoloration wear or damage Replace the starter motor as an assembly if necessary Check for continuity betwee
31. 4 12 DTC 7 1 ECT SENSOR LOW VOLTAGE 1 ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the ECT sensor with the HDS pocket tester Is about 0 V indicated YES GOTO STEP 2 NO Intermittent failure 2 ECT Sensor Inspection Turn the ignition switch OFF Disconnect the ECT sensor 3P connector Turn the ignition switch ON and engine stop switch Check the ECT sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 4 NO GOTO STEP 3 3 ECT Sensor Resistance Inspection Turn the ignition switch OFF Measure the resistance at the ECT sensor 1 terminals Standard 2 3 2 6 20 C 68 F Is the resistance within 2 3 2 6 20 C 68 F YES Replace the ECM with a known good one and recheck NO Faulty ECT sensor 4 ECT Sensor Short Circuit Inspection Turn the ignition switch OFF Check for continuity between the ECT sensor 3P connector 1 of the wire side and ground Connection Yellow blue Ground Is there continuity YES Short circuit in Yellow blue wire Replace the ECM with a known good and recheck PGM FI SYSTEM 1 Y Bu 4 13 PGM FI SYSTEM DTC 7 2 ECT SENSOR HIGH VOLTAGE 4 14 1 ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Wet Las Check the ECT sensor with the HDS pocket tester Is about 5 V indicated Y
32. Black connector 3 and position light 2P Black connector 4 Installation is in the reverse order of removal TORQUE Headlight cowl mounting bolt 8 5 N m 0 9 kgf m 6 3 Ibf ft FRONT FENDER REMOVAL INSTALLATION Remove the four bolt washers 1 front fender 2 and collars 3 Installation is in the reverse order of removal 2 5 FRAME BODY PANELS EXHAUST SYSTEM FRAME GUARD REMOVAL INSTALLATION Remove the socket bolts 1 and frame guard 2 Installation is in the reverse order of removal DRIVE SPROCKET COVER REMOVAL INSTALLATION Remove the bolts 1 and drive sprocket cover 2 Installation is in the reverse order of removal DRIVE CHAIN COVER U TYPE ONLY REMOVAL INSTALLATION Remove the socket bolts 1 and drive chain cover 2 Installation is in the reverse order of removal 2 6 FRAME BODY PANELS EXHAUST SYSTEM TOOL BOX REMOVAL INSTALLATION Remove the following Seat page 2 3 Left side cover page 2 3 Remove the two mounting bolts 1 and tool box 2 Installation is in the reverse order of removal DISASSEMBLY ASSEMBLY Disassemble and assemble the tool box as following illustration TOOL BOX TOOL BOX COVER SPECIAL WASHER LOCK SPRING LOCK UNIT REAR FENDER REMOVAL INSTALLATION Remove the bolts 1 and rear fender 2 Kj Cup Installation is in the reverse order of removal AK
33. Remove the trim clips 1 socket bolt 2 and reserve tank cover 3 Installation is in the reverse order of removal Align the cover boss 4 with the hole 5 of the stay FUEL TANK SHROUD Right side only Right side Left side 2 4 REMOVAL INSTALLATION Remove the reserve tank cover page 2 4 Remove the side cover page 2 3 Remove the socket bolt A 1 socket bolts B 2 and fuel tank shroud 3 Installation is in the reverse order of removal DISASSEMBLY ASSEMBLY Remove the four screws 1 and separate the grille 2 and front shroud 3 from the rear shroud 4 by releasing its tabs 5 and boss 6 from the slots and hole of the rear shroud Remove the two screws 1 and separate the front shroud 3 from the rear shroud 4 by releasing its tabs 5 boss 6 from the slots and hole of the rear shroud Assembly is in the reverse order of disassembly TORQUE Fuel tank shroud assembly screw 0 9 N m 0 1 kgf m 0 7 Ibf ft 2 Right side only 1 Right side only ON 3 1 6 FRAME BODY PANELS EXHAUST SYSTEM SKID PLATE REMOVAL INSTALLATION Remove the two bolts 1 and skid plate 2 Installation is in the reverse order of removal Align the rear side of the skid plate with the frame slot 3 HEADLIGHT COWL REMOVAL INSTALLATION Remove the four bolt washers 1 and headlight cowl 21 Disconnect the headlight 3P
34. Sticking caliper piston 18 2 5 5 COMPONENT LOCATION FRONT 1 5 N m 0 2 kgf m 1 1 Ibf ft 30 N m 3 1 kgf m 22 Ibf ft 34 N m 3 5 kgf m 25 Ibf ft 9 8 N m 1 0 kgf m 7 2 Ibf ft Ory 09 34 Nm 3 5 kgf m 25 Ibf ft REAR 1 5 N m 0 2 kgf m 1 1 Ibf ft 84 N m 3 5 kgf m 25 Ibf ft e X 10 N m 1 0 kgf m 7 ar 18 3 BRAKE SYSTEM BRAKE FLUID REPLACEMENT AIR BLEEDING BRAKE FLUID DRAINING For front brake Turn the handlebar until the master cylinder reservoir is level before removing the reservoir cap Remove the screws 1 reservoir cap 2 set plate 3 and diaphragm 4 For rear brake Remove the bolt 1 and reservoir 2 Remove the cover screws 3 reservoir cover 4 set plate 5 and diaphragm 6 Connect a bleed hose 1 to the bleed valve 2 Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out of the bleed valve Tighten the bleed valve TORQUE 5 4 0 6 kgf m 4 0 Ibf ft BRAKE FLUID FILLING AIR BLEEDING Close the bleed valve Fill the reservoir to the upper level line 1 with DOT 3 or DOT 4 brake fluid from a sealed container Connect a commercially available brake bleeder to the bleed valve Operate the brake bleeder and loosen the bleed valve Check the fluid level automatic refill system is not used add fluid when often while bleeding the fluid level in the r
35. When disassembling the PGM FI system parts note the location of the O rings Replace them with new ones upon reassembly e Use a digital tester for PGM FI system inspection The following color codes are used throughout this section Bu Blue G Green Lb Light Blue O Orange R Red Black Gr Gray Lg Light Green P Pink W White IGNITION SWITCH ENGINE STOP SWITCH ECM DLC BANK ANGLE SENSOR FUEL PUMP INJECTOR O2 SENSOR ECT SENSOR SE CENSOR VS SENSOR CRE SENSOR SAT SENSOR TP SENSOR Y Yellow Br Brown PGM FI SYSTEM PGM FI SYSTEM DIAGRAM FAN FUSE 10 R W BIW IGNITION SWITCH ENGINE STOP SWITCH ALTERNATOR R W R W BI R FI IGN FUSE 104 BIG BI Bu METER TAIL R W RW p 8 STARTER RELAY fe REGULATORY SWITCH MAIN STARTER SWITCH RECTIFIER FUSE 65 30 A Y R BI Bu CKP SENSOR 000 O STARTER 1 MOTOR Br TT BI Bu 1 E G BIW Y R Br R BI Bu BATTERY FUEL 1 PUMP 1 GR RELAY
36. and tighten them to the specified torque TORQUE 30 3 1 kgf m 22 Ibf ft Install the front wheel page 16 4 Left side only Inspect the wear rings 1 for wear or damage Replace the wear ring if it is 1 5 mm 0 06 in flat N with the outer tube DISASSEMBLY NOTE e Clean the fork assembly the sliding surface of the fork pipe and bottom of the slider around the center bolt before disassembling the fork Left side Hold the fork pipe in a vise with soft jaws or shop towels Loosen the fork center bolt 1 but do not remove it yet Left side only 16 8 FRONT WHEEL SUSPENSION STEERING Right side fork cap Completely loosen the fork cap bolt 1 and lower the bolt is under spring outer tube 2 1 pressure use care when loosening it 2 Pour out the fork fluid by pumping the fork pipe up and down several times gt nid Right side Push the fork 1 down and compress the fork spring then remove the stopper ring 2 from the groove in the fork pipe Right side only Remove the fork rod assembly 3 Right side Loosen the lock nut 1 while holding the fork cap 2 with a wrench then remove the fork cap Right side only Remove the O ring 3 from the fork cap groove Remove the spring seat 4 and rebound spring 5 16 9 FRONT WHEEL SUSPENSION STEERING Right side Remove the fork spring 1 Ri
37. from the right crankcase INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Replace if necessary Crankshaft Connecting rod Timing sprocket Measure each part according to CRANKCASE CRANKSHAFT TRANSMISSION BALANCER SPECIFICATIONS page 1 7 Replace any part if it is out of service limit CRANKSHAFT RUNOUT Place the crankshaft on V blocks Set the dial indicator on the crankshaft Rotate the crankshaft two revolutions 720 and read the runout SERVICE LIMIT 0 03 mm 0 001 in 1 14 in 0 24 in INSTALLATION Apply molybdenum oil solution to the connecting rod big end sliding surface Apply molybdenum oil solution to the crankshaft main journal bearing sliding surface Install the crankshaft 1 into the right crankcase Assemble the crankcase page 14 18 14 6 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER MAIN JOURNAL BEARING BEARING INSPECTION Remove the following Crankshaft page 14 6 Transmission page 14 10 Balancer shaft page 14 14 Clean off any oil from the bearings Check the main journal bearings 1 for unusual wear damage or peeling and replace them if necessary 4 OUTSIDE MAIN JOURNAL OIL CLEARANCE MEASUREMENT Measure and record the main journal bearing 1 0 at POINT between the bearing groove and crankcase outside end of the bearing and 90 degrees to the index mark 2 Clean off
38. in sequence listed below until you find cause Symptom Diagnosis procedure Also check for Engine cranks but won t start Inspect the IACV page 7 16 No fuel to injector No MIL blinking 2 Inspect the fuel supply system page 7 4 Clogged fuel filter 3 Inspect the ignition system page 5 4 Pinched or clogged fuel feed hose Faulty fuel pump Faulty fuel pump circuits ntake air leak Contaminated deteriorated fuel Faulty injector Engine cranks but won t start 1 ECM power ground circuits malfunction Opencircuit in the power input No fuel pump operation sound page 4 49 and or ground wire of the ECM when the turning the ignition 2 Inspect the fuel supply system page 7 4 Blown main fuse 30 A ON Blown FI IGN fuse 10 A Engine stalls hard to start 1 Inspect the engine idle speed page 3 10 Restricted fuel feed hose rough idling 2 Inspect the IACV page 7 16 Contaminated deteriorated fuel 3 Inspect the fuel supply system page 7 4 ntake air leak 4 Inspect the battery charging system page Faulty MAP sensor 19 4 Restricted fuel tank breather hose 5 Inspect the ignition system page 5 4 Afterburn when engine braking 1 Inspect the PAIR system page 7 17 is used 2 Inspect the ignition system page 5 4 Backfiring or misfiring during acceleration Inspect the ignition system page 5 4 Poor performance driveability 1 Inspect
39. intake side EX mark exhaust side Apply engine oil to the camshaft holder mounting bolt 1 threads and seating surface Install and tighten the camshaft holder mounting bolts to the specified torque TORQUE 12 1 2 kgf m 9 Ibf ft NOTE From inside to outside tighten the bolts in a crisscross pattern in several steps Be careful not to let Install the cam chain guide 1 and bolts 2 the cam chain guide bolts fall into the crankcase 1 Tighten the cam chain guide bolts securely 10 10 Remove the tensioner stopper 1 from the chain tensioner lifter Apply engine oil to a new O ring 1 and install it to the cam chain tensioner lifter Install and tighten the cam chain tensioner lifter plug 2 to the specified torque TORQUE 4 2 N m 0 4 kgf m 3 1 Inspect the valve clearance page 3 6 Install the cylinder head cover page 10 5 ROCKER ARM NOTE The rocker arm can be serviced with the engine installed in the frame The intake and exhaust rocker arm service procedures are the same REMOVAL INSTALLATION Remove the camshafts page 10 6 Remove the bolt 1 and sealing washer 2 CYLINDER HEAD VALVES 10 11 CYLINDER HEAD VALVES 10 12 Remove the rocker arm shaft 1 using a 6 mm bolt 2 while holding the rocker arm 3 Remove the rocker arm Apply molybdenum oil solution to the rocker arm inner surface roller surface slipp
40. 12V 21W STARTER SWITCH s Dle IGNITION SWITCH 6 10A HEAD T Uu LEFT HANDLEBAR SWITCH COLOR Gr 21 2 CLEANER 3 4 CLEANER HOUSING 7 10 ALTERNATOR CHARGING COIL sassassanssusssssanssussussensen 19 5 BALANCER sassassanssussussenssassuncunsuasassasssanasscussussasscussussunn 14 14 BANK ANGLE SENSOR sasssssanssussussanssussascensenssascuscensuass 4 48 BATTERY sussnssanssssusssassussunssansuscussussauseussussassesscunsenseusuunen 19 4 BRAKE FLUID sasanssuessasausssssusssussussansussussuansuseussuusaussusuuuen 3 15 BRAKE FLUID REPLACEMENT AIR BLEEDING 18 4 BRAKE LIGHT SWITCH LIGHTS METERS SWITCHES sassssssussussuassenssassuusenes 20 12 MAINTENANCE sasssnssussanssseussussauseussunsuscussussanssussuneeus 3 17 BRAKE PAD DISC sasssususssansussussussenscussussensssssussenseuseusecus 18 5 BRAKE PADS WEAR sassssssussassussussanseuseussaneuscensuasauseussos 3 16 BRAKE PEDAL sassssssussansuseuscuasausenscussansenssAsasseussussausenss 18 12 BRAKE SYSTEM sasausssusususanssusssssanssussussenssussussenssaseusenscus 3 17 BRAKE TAILLIGHT sussnssanauusanssesuuseusssusussanssussussenssuseuscune 20 5 CABLE amp HARNESS ROUTING 1 17 CHAIN TENSIONER seassusaussussussenssassuscenssasauseussunen 1 1 7 CAMSHAFT sasssssussussanssus
41. 2 Release the wire band 3 from the clamp stay Loosen the throttle cable A adjuster lock nut 1 and adjuster 2 then disconnect the throttle cable A 3 from the throttle drum and cable stay Loosen the throttle cable B nut 4 then disconnect the throttle cable B 5 from the throttle drum and cable stay Loosen the connecting hose band screw 1 and insulator band screws 2 then remove the throttle body assembly 3 FUEL SYSTEM FUEL SYSTEM DISASSEMBLY ASSEMBLY Do not remove the sensor unit unless it is replaced The throttle body sensor unit is factory pre set Do not disassemble in a way other than shown in this manual Do not snap the throttle valve from full open to full close after the throttle cable has been removed It may cause incorrect idle operation Do not damage the throttle body It may cause incorrect throttle valve operation Do not loosen or tighten the white painted nut and screw 1 of the throttle body Loosening or tightening it can cause throttle valve and idle control failure Always clean around the throttle body before each sensor removal to prevent dirt and debris from entering the air passage Remove the following Sensor unit page 4 44 Injector page 7 14 IACV page 7 15 Clean the air passage of the throttle body using compressed air Cleaning the air passages and sensor hole with a piece of wire will damage the throttle body Check the air passage f
42. 23 top bridges Tighten the stem nut to the specified torque TORQUE 103 10 5 kgf m 76 Ibf ft Make sure the steering stem moves smoothly without play or binding Install the steering stem cap 1 16 25 FRONT WHEEL SUSPENSION STEERING Install brake hose guide 1 and tighten the bolt 2 to the specified torque TORQUE 10 1 0 kgf m 7 Ibf ft Install the meter stay 1 and tighten the bolts 2 Secure the ignition switch wire with the harness bands 3 Connect the ignition switch 3P Brown connector 4 Install the following Front wheel page 16 4 Handlebar page 16 19 Headlight cowl page 2 5 Front fender page 2 5 STEERING BEARING PRE LOAD Raise the front wheel off the ground by placing a work stand or box under the frame Position the steering stem straight ahead Hook a spring scale to the outer tube between the fork top and bottom bridges Make sure there is no cable wire harness or hose interference Pull the spring scale keeping it at a right angle to the steering stem Read the scale at the point where the steering stem just starts to move STEERING BEARING PRE LOAD 10 6 21 2 N 1 08 2 16 kgf 2 38 4 77 If the readings do not fall within the limits readjust the steering bearing 16 26 17 REAR WHEEL SUSPENSION SERVICE 17 2 SHOCK ABSORBER
43. 3 9 Drain the coolant page 9 5 Remove the following Water pipe page 9 13 Frame guard page 2 6 Brake pedal page 18 12 Remove the bolts 1 and clutch cable guide 2 then disconnect the clutch cable 3 from the clutch lifter arm 4 Loosen the water hose band screw 1 and disconnect the water hose 2 Remove the bolt 3 and rear brake light switch holder 4 Loosen the right crankcase cover bolts 1 in a crisscross pattern in 2 or 3 steps and remove the bolts Be careful not to let Remove the right crankcase cover 2 while turning the the return spring fall clutch lifter arm 3 counterclockwise to disengage the into the crankcase lifter arm spindle from the lifter piece Remove the dowel pin A 1 dowel pin B 2 and gasket 3 12 4 CLUTCH GEARSHIFT LINKAGE Remove the collars 1 and O rings 2 DISASSEMBLY Remove the return spring 1 from the right crankcase cover Remove the clutch lifter arm 1 from the right crankcase cover INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Replace if necessary Oil seal Clutch lifter arm needle bearing Clutch lifter arm Return spring Crankshaft bearing 12 5 CLUTCH GEARSHIFT LINKAGE BEARING REPLACEMENT CRANKSHAFT BEARING Remove the crankshaft bearing 1 using the special tools TOOLS 2 Remover weight 07741 0010201 3
44. 4P Black connector 1 of the wire side and ground Connection Blue white Ground Brown white Ground Brown black Ground Blue black Ground Is there continuity YES Short circuit in Blue white or Brown white wire Short circuit in Brown black or Blue black wire NO GOTO STEPS 3 IACV Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and IACV 4P Black connector 2 of 2 the wire side Connection Brown white Brown white Bu W Blue white Blue white Q Brown black Brown black 2 d Y Blue black Blue black e TOOL Buw Br W Test probe 07ZAJ RDJA110 r Is there continuity 4 Iu YES GOTO STEP 4 00 Open circuit in Blue white Brown white wire Open circuit Brown black Blue JJ black wire Biji N u 59 1 4 25 PGM FI SYSTEM 4 IACV Resistance Inspection Turn the ignition switch OFF Disconnect the IACV Black connector 1 page 7 15 Measure the resistance at the IACV side connector Connection A Blue black D Blue white B Brown black C Brown white Standard 110 150 25 C 77 F Is the resistance within 110 150 25 77 YES Replace the ECM with a known good one and recheck NO Faulty IACV 1 DTC
45. 6 6 Ibf ft After installing the stud bolts check that the length from the bolt head to the crankcase surface is within specification T 142 0 1 0 mm 5 6 0 04 in Be careful not to damage the piston and rings When cleaning the cylinder mating surface place a shop towel over the cylinder opening to prevent dust or dirt enter the crankcase PISTON INSTALLATION Apply engine oil to the piston ring grooves Apply engine oil to the piston ring entire surface Carefully install the piston rings into the piston ring grooves with the markings 1 facing up NOTE Do not confuse the top ring 2 and second ring 3 To install the oil ring 4 install the spacer 5 first then install the side rails 6 Stagger the piston ring end gaps 120 apart from each other Stagger the side rail end gaps as shown Apply engine oil to the piston pin hole inner surface and sliding surface Clean any gasket material from the cylinder mating surface 1 of the crankcase Apply molybdenum oil solution to the connecting rod small end inner surfaces Apply molybdenum oil solution to the piston pin 1 outer surfaces Install the piston 2 with its IN mark 3 facing intake side Install the piston pin CYLINDER PISTON 20 mm 0 8 in OR MORE 11 5 CYLINDER PISTON Install new piston pin clips 1 into the grooves of the piston pin
46. 8 42 4 3 31 ALOC bolt replace with a new one Rear spoke 32 BC 3 2 3 7 0 4 2 7 Shock absorber upper mounting nut 1 10 54 5 5 40 U nut Shock absorber lower mounting nut 1 10 44 4 5 32 U nut Shock link nut 2 10 44 4 5 32 U nut Shock arm to swingarm nut 1 12 74 7 5 55 U nut Apply engine oil to the threads Swingarm pivot nut 1 14 88 9 0 65 U nut Rear brake hose guide mounting screw 2 5 1 2 0 1 0 9 Chain slider mounting screw 4 5 4 3 1 ALOC screw replace with a new one Chain case stay mounting screw 1 6 4 2 0 4 3 1 ALOC screw replace with a new one Chain guide mounting bolt 2 6 10 1 0 7 ALOC bolt replace with a new one Chain slider guide mounting nut 2 6 2 5 0 3 1 8 U nut 1 13 GENERAL INFORMATION BRAKE SYSTEM THREAD TORQUE DIA N m kgf m Ibf ft REMARKS Brake caliper bleed valve 2 8 5 4 0 6 4 0 Master cylinder reservoir cover screw 4 4 1 5 0 2 1 1 Rear master cylinder reservoir mounting 1 6 10 1 0 7 bolt Front brake pad pin 1 10 17 2 1 8 13 Rear brake pad pin 1 10 17 2 1 8 13 Brake hose oil bolt 4 10 34 3 5 25 Front master cylinder holder bolt 2 6 9 8 1 0 7 2 Front brake light switch screw 1 4 1 2 0 1 0 9 Rear master cylinder mounting bolt 2 6 14 1 4 10 ALOC bolt replace with a new one Rear master cylinder push
47. Bearing remover set 12 mm 07936 1660101 Drive in a new crankshaft bearing 1 into the right crankcase cover with the marked side facing up until it is fully seated using the special tools TOOLS 2 Driver 07749 0010000 3 Attachment 28 x 30 mm 07946 1870100 4 Pilot 12 mm 07746 0040200 After installation apply engine oil to the bearing CLUTCH LIFTER ARM NEEDLE BEARING Remove the oil seal 1 from the right crankcase cover Remove the clutch lifter arm needle bearings 2 using the special tools TOOLS 3 Bearing remover set 12 mm 07936 1660101 4 Remover weight 07741 0010201 12 6 CLUTCH GEARSHIFT LINKAGE Install the bearing remover head 1 to the pilot collar 2 as shown 1 TOOLS Bearing remover head 10 mm 07746 0050200 2 Pilot collar 16 mm 07PAF 0010620 2 DA 6 5 7 5 mm the specified depth using the special tools as shown TOOLS 0 26 0 30 in 2 Bearing remover head 10 mm 07746 0050200 3 Pilot collar 16 mm 07PAF 0010620 After installation apply engine oil to the bearing Install a new oil seal 1 to the right crankcase cover as shown 0 5 1 0 mm 0 02 0 04 in ASSEMBLY Apply grease to the clutch lifter arm oil seal lips 1 Apply molybdenum oil solution to the clutch lifter arm 2l sliding surface Install the clutch lifter arm to the right crankcase cover 2 12 7 CLUTCH GEARS
48. Bu SYSTEM MIL CIRCUIT TROUBLESHOOTING NOTE Before starting the inspection check the speedometer power input line page 20 6 With The Ignition Switch ON The MIL Does Not Come On If the engine can be started but the MIL does not come on when the ignition switch is turned ON and engine stop switch check as follows Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 50 Ground the following terminal of the wire harness side 1 ECM Black connector 1 with a jumper wire 2 1 CONNECTION White blue Ground TOOL Test probe 07ZAJ RDJA110 Turn the ignition switch and engine stop switch the MIL should come on W Bu Ifthe MIL comes on replace the ECM with a known good one and recheck the MIL indication 2 MIL does come on check for open circuit the White blue wire between the speedometer and ECM Black connector If the wire is OK replace the speedometer With The Ignition Switch ON The MIL Does Not Go Off Within A Few Seconds Engine starts Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 50 Turn the ignition switch ON and engine stop switch f the MIL comes on check for short circuit in the White blue wire between the speedome
49. CYLINDER PISTON SERVICE INFORMATION GENERAL This section covers maintenance of the cylinder and piston To service these parts the engine must be removed from the frame Take care not to damage the cylinder wall and piston Be careful not to damage the mating surfaces when removing the cylinder Do not tap the cylinder too hard during removal Camshaft and rocker arm lubricating oil is fed through an oil passage in the cylinder Clean the oil passage before installing cylinder Clean all disassembled parts with cleaning solvent before inspection use compressed air to dry the parts TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Leaking or damaged cylinder head gasket Worn stuck or broken piston rings Worn or damaged cylinder and piston Loose spark plug Compression too high overheating or knocking Excessive carbon built up on piston or combustion chamber Excessive smoke Faulty cylinder piston and piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Abnormal noise piston Worn piston pin or piston pin hole Worn or damaged cylinder piston or piston ring Worn connecting rod small end COMPONENT LOCATION 4 2 N m 0 4 kgf m 3 1 Ibf ft 11 2 CYLINDER PISTON CYLINDER PISTON CYLINDER REMOVAL Remove the following Water pipe page 9 13 Cylinder head page 10 13 Lift the cylinder 1 and r
50. NT A O sensor cap terminal Black white TOOL Test probe 07ZAJ RDJA110 Q Is there continuity BIW YES GOTO STEP 4 NO Open circuit in Black or Black white wire 4 Sensor Inspection Replace the Oz sensor with a known good one page 4 47 Connect the ECM 33P Black connector Start the engine and warm up the engine up to coolant temperature is 80 C 176 C Test ride the motorcycle and recheck the sensor with the HDS pocket tester Is the DTC 21 1 indicated YES Replace the ECM with a known good and recheck NO Faulty original O2 sensor DTC 29 IACV NOTE Before starting the inspection check for loose or poor contact on the 4P Black connector and recheck the MIL blinking ECM Bu W Bu BI Br W Br BI Probable cause Open or short circuit in wires Blue white Blue black Brown white Brown black between the IACV and ECM Faulty IACV Faulty ECM 4 24 PGM FI SYSTEM 1 Recheck DTC Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch Lae Check the IACV with the HDS pocket tester Is the DTC 29 1 indicated YES GOTO STEP 2 NO Intermittent failure Loose or poor contact on the 4P Black connector 2 IACV Short Circuit Inspection Disconnect the ECM 33P Black connector page 1 4 50 Check for continuity between the IACV
51. Place the wheel between the fork legs while inserting the brake disc between the brake pads Install the front axle from the right side of the vehicle then tighten it to the specified torque TORQUE 73 5 7 5 kgf m 54 Ibf ft With the front brake applied pump the forks up and down several times to seat the axle and check the brake operation Tighten the axle pinch bolts to the specified torque TORQUE 20 2 0 kgf m 15 Ibf ft INSPECTION Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Replace the bearings if they do not turn smoothly quietly or if they fit loosely in the hub Inspect the following parts for damage abnormal wear deformation looseness or bend Front axle Spoke Wheel rim Measure each part according to FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS page 1 8 Replace any part if it is out of service limit FRONT WHEEL SUSPENSION STEERING DISASSEMBLY ASSEMBLY Disassemble and assemble the front wheel as following illustration cm RIGHT DUST SEAL E LEFT WHEEL BEARING 6202U S RIGHT WHEEL BEARING 6202U Vas veS 7 4 DISTANCE COLLAR Z ce a Sk BRAKE DISC BOLTS ay 20 Nm 2 0 kgf m 15 Ibf ft LEFT DUST SEAL BRAKE DISG BEARING REPLACEMENT Install the remover head 1 into the bearing F
52. Remove the pad pin 1 Pull the pad pin out of the caliper body while pushing in the pads against the pad spring Align Remove the brake pads 1 Install the brake pads into the caliper so their ends rest into the pad retainer on the bracket properly BRAKE SYSTEM Apply silicone grease to a new stopper ring 1 and install it into the pad pin 2 groove Make sure the pad Install the pad pin by pushing in the pads against the spring is installed pad spring to align the pad pin holes in the pads and correctly caliper body Always replace the brake pads Tighten the pad pin to the specified torque to ensure even disc TORQUE 17 2 N m 1 8 kgf m 13 Ibf ft pressure Operate the brake lever to seat the caliper pistons against the pads REAR BRAKE PAD REMOVAL INSTALLATION Remove the pad pin plug 1 and pad pin 2 Remove the brake pads 3 Apply silicone grease to a new stopper ring 1 and install it into the pad pin 2 groove Install the brake pads 3 into the caliper Make sure the pad Install the pad pin by pushing in the pads against the spring is installed pad spring to align the pad pin holes in the pads and correctly caliper body Always replace the brake pads in pairs to ensure even disc TORQUE 17 2 N m 1 8 kgf m 13 Ibf ft pressure Tighten the pad pin to the specified torque Install the pad pin plug 4 Operate the brake pedal to seat the caliper pistons a
53. STEM NUT 103 N m 10 5 kgf m 76 Ibf ft HOSE GUIDE SS UPPER STEERING S BEARING TOP BRIDGE SN LOWER OUTER RACE uw SS LOWER STEERING BEARING METER STAY LOWER DUST SEAL STEERING STEM 10 N m 1 0 7 Ibf ft HOSE GUIDE Apply 3 5 0 0 11 0 18 oz of specified grease Urea based multi purpose grease with extreme pressure lt gt agent example Kyodo Yushi EXCELITE EP2 or ww equivalent to each new bearing and fill it up Apply specified grease to a new upper dust seal 1 lip Insert the steering stem 2 into the steering head pipe and install the following while holding the stem upper steering bearing 3 upper dust seal Apply engine oil to the steering stem adjusting nut 1 threads Install and tighten the adjusting nut to the initial torque using the special tool TOOL 2 Stem socket wrench 07916 KA50100 TORQUE 29 5 N m 3 0 kgf m 22 Ibf ft 16 24 FRONT WHEEL SUSPENSION STEERING Turn the steering stem 1 right and left lock to lock several times to seat the bearings Completely loosen the adjusting nut 2 Retighten the adjusting nut 1 to the specified torque using the special tool TOOL 2 Stem socket wrench 07916 KA50100 TORQUE 6 5 N m 0 7 kgf m 4 8 Ibf ft Install the top bridge 1 washer 2 and stem nut 3 2 3 Temporarily install the outer tube into the bottom
54. TO STEP 5 NO STEP 4 1 Lg BI RS 4 MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector Check for continuity between the sensor unit 5P connector 1 terminal of the wire side and ground Connection Light green black Ground Is there continuity YES Short circuit Light green black wire 5 MAP Sensor Inspection Replace the sensor unit with a known good one page 4 44 Erase the DTC s page 4 5 Turn the ignition switch OFF Connect the sensor unit 5P connector Turn the ignition switch ON and engine stop switch nen T Check the MAP sensor with the HDS pocket tester Is DTC 1 1 indicated YES Replace the ECM with a known good one and recheck NO Faulty original sensor unit MAP sensor DTC 1 2 MAP SENSOR HIGH VOLTAGE 1 MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop switch Las Check the MAP sensor with the HDS pocket tester Is about 5 V indicated YES GOTO STEP 2 NO Intermittent failure Loose or poor contact on the sensor unit 5P connector Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 8 Is the sensor unit power line normal YES GO TO STEP NO Replace or repair the abnormal circuit PGM FI SYSTEM 1 4 11 PGM FI SY
55. air page 9 5 15 9 16 FRONT WHEEL SUSPENSION STEERING SERVICE INFORMATION 16 2 16 2 COMPONENT LOCATION 16 3 FRONT 16 4 16 6 HANDLEBAR rennen 16 16 STEERING STEM e 16 21 16 1 FRONT WHEEL SUSPENSION STEERING SERVICE INFORMATION GENERAL A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Raise the front wheel off the ground by supporting the frame securely when servicing For hydraulic brake system service page 18 3 After the front wheel installation check the brake operation by applying the brake lever TROUBLESHOOTING Hard steering Steering bearing fork pipe too tight Worn or damaged steering head bearings Worn or damaged steering head bearing races Damaged steering stem Insufficient tire pressure Faulty front tire Steers to one side or does not track straight Bent fork leg Damaged or loose steering head bearings Worn wheel bearings Bent front axle Wheel installed incorrectly Bent frame Worn swingarm pivot components page 17 10 Front wheel wobbles Bent rim Worm or damaged wheel bearings Faulty front tire Low tire pressure Loose or broken spokes Loose front axl
56. and 9 times check the following before MIL troubleshooting Before starting the inspection check for loose or poor contact on the sensor unit 5P connector and ECM 33P Black connector 5V SENSOR UNIT Y R ECM G W Probable cause Open circuit Yellow red wire between the sensor unit and ECM Open circuit in Green white wire between the sensor unit and ECM Faulty ECM 1 Sensor Unit Power Input Voltage Inspection Turn the ignition switch OFF 1 Disconnect the sensor unit connector 1 page 4 44 Turn the ignition switch and engine stop switch aA C Teler T Measure the voltage at the wire harness side YR r G W Connection Yellow red 4 Green white T Standard 4 75 5 25 V PLAN If the voltage within 4 75 5 25 V YES Turn the ignition switch OFF Connect the sensor unit 5P connector and start the MIL troubleshooting page 4 29 NO GOTO STEP 2 2 Sensor Unit Input Voltage Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector 1 page 4 50 Check for continuities between the ECM 33P Black connector and sensor unit connector 2 of the wire side VR m R Connection Yellow red Yellow red arin Green white Green white TOOL G W Test probe 07ZAJ RDJA110 Q Is there continuity ho Y
57. and engine stop switch or idling The MIL will stay ON when the engine speed is over 2 100 min rpm 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 3 seconds One long blink is the equivalent of ten short blinks For example when two long blinks are followed by five short blinks the MIL is 25 two long 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 from the lowest number to highest number MIL Check When the ignition switch is turned ON and engine stop switch the MIL will stay on for a few seconds then go off If the MIL does not come on troubleshoot the MIL circuit page 4 43 CURRENT DTC STORED DTC The DTC is indicated in two ways according to the failure status n case the ECM detects the problem at present the MIL will come on and the MIL will start to blink as its DTC when the sidestand is lowered It is possible to readout the MIL blink pattern as the current DTC n 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 stored DTC by following the DTC readout procedure page 4 5 PGM FI SYSTEM HDS POCKET TESTER INFORMATION The HDS pocket tester can readout the DTC freeze data current data and oth
58. any oil from the crankshaft journals Measure and record the crankshaft main journal O D SERVICE LIMIT 33 975 mm 1 3376 in Calculate the oil clearance between the crankshaft main journal and main journal bearing SERVICE LIMIT 0 075 mm 0 0030 in If the clearance exceeds the service limit select the main journal bearing page 14 7 BEARING SELECTION Remove the following Crankshaft page 14 6 Transmission page 14 10 Balancer shaft page 14 14 Set a special tool and hydraulic press on the outside of the crankcase TOOLS 1 Driver 30 x 36 mm 07HMF KR10101 2 Base 42 mm 07GAF SD40200 Press the main journal bearings 1 toward the inside of the crankcase 14 7 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Measure and record the crankcase main journal bearing support I D at 90 degrees to the index mark 1 gt SERVICE LIMIT 38 036 mm 1 4975 in Depending upon the results of the above measurements there are four possible scenarios for main journal bearing selection Crankshaft and crankcase are replaced Crankcase only is replaced Crankshaft only is replaced Main journal bearings only are replaced Carefully refer to the following instructions and tables for main journal bearing selection Record the bearing support I D code 1 letter NOTE Letters A B or C on each crankcase is the code for the crankcase main journal bearing support I D Cr
59. battery terminal The maintenance free battery must be replaced when it reaches the end of its service life The battery can be damaged if 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 after 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 often results from problems in the battery itself which may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte level goes down quickly Before troubleshooting the charging system check for proper use and maintenance of the battery Check if the battery is frequently under heavy load such as having the headlight and taillight ON for long periods of time without riding the motorcycle The battery will self discharge when the motorcycle is not in use For this reason charge the battery every 2 weeks to prevent sulfation from occurring For alternator removal page 13 4 BATTERY CHARGING Turn power ON OFF at the charger not at the battery terminal For battery charging do n
60. black wire between the sensor unit and ECM Open circuit in Green white wire between the sensor unit and ECM Faulty sensor unit Faulty ECM 1 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 8 Is the sensor unit power line normal YES GO TO STEP 2 NO Replace or repair the abnormal circuit 2 MAP Sensor Output Voltage Inspection Turn the ignition switch OFF Connect the ECM 33P Black connector Disconnect the sensor unit 5P connector 1 page 1 4 44 Turn the ignition switch ON and engine stop switch Tiel 1 e Measure the voltage at the sensor unit connector GW Lg BI of the wire side A lt Connection NA Light green black Green white Standard 4 75 5 25 V Is the voltage within 4 75 5 25 V YES Faulty sensor unit MAP sensor NO GOTO STEP 3 4 29 PGM FI SYSTEM 3 MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF 1 Disconnect the ECM 33P Black connector Check for continuity between the sensor unit 5P connector 1 terminal of the wire side and ground p lt Connection Light green black Ground Is there continuity YES Short circuit in Light green black wire GOTO STEP 4 as 4 MAP Sensor Output Line Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and sensor un
61. components If there is any doubt put on eye protection Use other protective wear when necessary for example gloves or safety shoes Handling hot or sharp parts can cause severe burns or cuts Before you grab something that looks like it can hurt you stop and put on gloves Protect yourself and others whenever you have the vehicle up in the air Any time you lift the vehicle either with a hoist or a jack make sure that it is always securely supported Use jack stands Make sure the engine is off before you begin any servicing procedures unless the instruction tells you to do otherwise This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Burns from hot parts or coolant Let the engine and exhaust system cool before working in those areas Injury from moving parts If the instruction tells you to run the engine be sure your hands fingers and clothing are out of the way Gasoline vapors and hydrogen gases from batteries are explosive To reduce the possibility of a fire or explosion be careful when working around gasoline or batteries Use only a nonflammable solvent not gasoline to clean parts Never drain or store gasoline in an open container Keep all cigarettes sparks and flames away from the battery and all fuel related parts 0 1 HOW TO USE THIS MANUAL How To Use This Manual This manual describe
62. hole NOTE piston pin clips may lead to serious engine Set the piston pin clip the groove properly Do not align the clip s end gap 2 with the piston cut out 3 CYLINDER INSTALLATION Install the dowel pins 1 and a new gasket 2 Apply engine oil to the cylinder 1 inner surface and piston 2 sliding surface Be careful not to Route the cam chain 3 through the cylinder and install damage the piston the cylinder over the piston while compressing the rings and cylinder piston rings with your fingers wall install the following Cylinder head page 10 17 Water pipe page 9 13 11 6 CYLINDER PISTON CAM CHAIN TENSIONER REMOVAL INSTALLATION Remove the cam chain tensioner lifter plug 1 and O ring 2 Turn the cam chain tensioner lifter shaft fully in clockwise and secure it using the special tool TOOL 3 Tensioner stopper 070MG 0010100 Remove the cam chain tensioner lifter mounting bolts 4 Remove the cam chain tensioner lifter 5 and gasket 6 Install a new gasket 1 on the cam chain tensioner lifter 2 and install them to the cylinder Install and tighten the cam chain tensioner lifter mounting bolts 1 Remove the tensioner stopper 2 from the cam chain tensioner lifter Apply engine oil to a new O ring 3 and install it to the cam chain tensioner lifter Install and tighten the cam chain tensioner lifter plug 4 to the specified torque T
63. kgf m 3 3 Ds RIGHT TAIL COVER 9 REAR REFLECTOR T COLLARS 4 6 0 f 8 BRAKE TAILLIGHT UNIT REAR TURN SIGNAL UNIT STAY LEFT TAIL COVER SCREW REAR LOWER FENDER REMOVAL INSTALLATION Remove the following Seat page 2 3 Side covers page 2 3 Tail cover light unit page 2 8 Release the wire bands 1 2 9 FRAME BODY PANELS EXHAUST SYSTEM Remove the rear lower fender mounting bolt 1 Remove the bolts 1 helmet holder 2 and rear lower fender 3 NOTE Use a drill or an equivalent tool when removing the helmet holder mounting bolts Installation is in the reverse order of removal Replace the helmet holder mounting bolts with new ones 2 ay 1 2 10 FRAME BODY PANELS EXHAUST SYSTEM EXHAUST PIPE MUFFLER REMOVAL INSTALLATION Remove the following Seat page 2 3 Right side cover page 2 3 Remove the exhaust pipe muffler as following illustration Installation is in the reverse order of removal MUFFLER FRONT MOUNTING BOLT BOLT 32 Nm 3 3 kgf m 24 Ibf ft SOCKET BOLTS 5 MUFFLER PROTECTOR a MUFFLER De d s y BAND BOLT 22 5 N m 2 3 17 GASKET 3 GASKET JOINT NUTS SOCKET BOLTS 18 N m 1 8 kgf m 12 N m 1 2
64. mounting bolt 2 5 5 1 0 5 3 8 setting plate torx screw 2 4 2 1 0 2 1 5 PAIR check valve cover bolt 2 5 5 2 0 5 3 8 COOLING SYSTEM THREAD TORQUE MEM QTY DIA mm N m kgf m Ibf ft REMARKS Water hose band screw 4 9 7 Fan motor shroud mounting bolt 3 6 8 5 0 9 6 3 Fan motor screw 3 4 2 7 0 3 2 0 Cooling fan nut 1 3 1 0 0 1 0 7 Apply locking agent to the threads Water pump impeller 1 7 10 1 0 7 CYLINDER HEAD VALVES THREAD TORQUE STEM DIA mm N m kgf m Ibf ft REMARKS Cylinder head cover bolt 2 6 10 1 0 7 Camshaft holder mounting bolt 8 6 12 1 2 9 Apply engine oil to the threads and seating surface Cylinder head mounting nut 4 10 45 4 6 33 Apply engine oil to the threads and seating surface Cam chain tensioner lifter plug 1 6 4 2 0 4 3 1 CYLINDER PISTON THREAD TORQUE QTY DIA mm N m kgf m Ibf ft REMARKS Cylinder stud bolt 4 10 See page 11 4 Cam chain tensioner lifter plug 1 6 4 2 0 4 3 1 1 11 GENERAL INFORMATION CLUTCH GEARSHIFT LINKAGE THREAD TORQUE QTY DIA mm N m kgf m Ibf ft REMARKS Clutch center lock nut 1 16 108 11 0 80 Lock nut replace with a new one and stake Apply engine oil to the threads and seating surface Clutch lifter plate bolt 5 6 2 1 2 9 Shift drum stopper plate bolt 1 6 0 1 0 7 Apply locking agent
65. open circuit If the wires are OK check the VS sensor page 20 9 3 4 LIGHTS METERS SWITCHES VS SENSOR INSPECTION Remove the left side cover page 2 3 Check for loose or poor contact of the VS sensor 3P Blue connector 1 Disconnect the VS sensor 3P Blue connector Turn the ignition switch ON and engine stop switch Q Measure the voltage between the VS sensor 3P Blue connector terminals at the wire side CONNECTION Black red Green black STANDARD Battery voltage If battery voltage appears replace the VS sensor If there is no voltage check the following Black red wire for open circuit Green black wire for open circuit Speedometer page 20 5 REMOVAL INSTALLATION Remove the left side cover page 2 3 Disconnect the VS sensor 3P Blue connector 1 Remove the VS sensor wire from the guide 1 Remove the bolt 2 VS sensor 3 and O ring 4 Installation is in the reverse order of removal Replace the O ring with a new one Apply engine oil to a new O ring 20 9 LIGHTS METERS SWITCHES HIGH COOLANT TEMPERATURE INDICATOR 20 10 SYSTEM INSPECTION Before starting the inspection check for loose or poor contact on the speedometer 16P connector ECT sensor 3P connector and ECM 33P Black connector Turn the ignition switch ON and engine stop switch C7 Check that the high coolant temperature indic
66. rear turn signal 2P connector 1 Right side Light blue Left side Orange Remove the nut 2 and rear turn signal unit 3 Installation is in the reverse order of removal TORQUE Turn signal unit mounting nut 21 N m 2 1 kgf m 15 Ibf ft NOTE Align the flats of the turn signal unit and turn signal unit 3 stay 20 4 LIGHTS METERS SWITCHES BRAKE TAILLIGHT NOTE For brake taillight removal installation page 2 8 BULB REMOVAL INSTALLATION Remove the rear fender page 2 7 Remove the brake taillight mounting screws 1 and collars 2 Remove the hook bolts 3 and collars 4 Pull the tail cover light unit 5 rearward while pulling up the rear upper fender 6 Turn the bulb socket 1 counterclockwise and remove it While pushing in the bulb 2 turn it counterclockwise to remove it Installation is in the reverse order of removal TORQUE Hook bolt 21 N m 2 1 kgf m 15 Ibf ft Brake taillight mounting screw 4 5 N m 0 5 3 3 Ibf ft SPEEDOMETER REMOVAL INSTALLATION Remove the headlight cowl page 2 5 Release the wire bands 1 from the meter stay Remove the screws 2 washers 8 and speedometer 4 by disconnecting the speedometer 16P connector 5 Remove the mounting rubbers 6 Installation is in the reverse order of removal TORQUE Speedometer mounting screw 1 0 N m 0 1 kgf m 0 7 Ibf ft 20 5 LIGHTS M
67. replace the speedometer assembly page 20 5 FUEL LEVEL SENSOR INSPECTION Remove the fuel pump unit page 7 9 Connect the ohmmeter to the following terminals of fuel pump 3P connector FULL CONNECTION Red black Black white Inspect the resistance of the float at the full and empty positions Float position FULL EMPTY EME Resistance 9 110 213 2190 Replace the fuel pump unit if fuel level sensor is out of specification Install the fuel pump unit page 7 9 HORN INSPECTION Remove the reserve tank cover page 2 4 Disconnect the connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V battery is connected across the horn terminals he BATTERY 20 15 LIGHTS METERS SWITCHES REMOVAL INSTALLATION Remove the reserve tank cover page 2 4 Disconnect the wire connectors 1 from the horn 2 Remove the bolt 3 and horn Installation is in the reverse order of removal 2 3 TURN SIGNAL RELAY INSPECTION STANDARD INSPECTION Check the following Battery condition Burned out bulb or non specified wattage Blown TURN HORN STOP fuse 10 A Ignition switch and turn signal switch function Loose connector If above items are normal remove the reserve tank cover page 2 4 INPUT VOLTAGE INSPECTION Disconnect the turn signal relay 3P Black connecto
68. rod lock nut 8 17 2 1 8 13 Brake lever pivot bolt 6 1 0 0 1 0 7 Apply 0 1 g 0 004 oz of silicone grease to the sliding surface Brake lever pivot nut 1 6 5 9 0 6 4 4 Front brake caliper mounting bolt 2 8 30 3 1 22 ALOC bolt replace with a new one Front brake caliper bracket pin 1 8 17 2 1 8 13 Rear brake reservoir stay mounting 1 6 1 5 0 2 1 1 screw BATTERY CHARGING SYSTEM THREAD TORQUE ITEM O TY DIA mm N m kgf m Ibf ft REMARKS Battery holder plate bolt 2 6 7 0 0 7 5 2 LIGHTS METERS SWITCHES THREAD TORQUE ITEM DIA mm N m kgf m Ibf ft REMARKS Headlight unit mounting screw 4 5 1 2 0 1 0 9 Turn signal unit mounting nut 4 10 21 2 1 15 Brake taillight mounting screw 3 6 4 5 0 5 3 3 Hook bolt 4 8 21 2 1 15 Speedometer mounting screw 3 5 1 0 0 1 0 7 Ignition switch mounting bolt 2 8 24 2 4 18 One way bolt replace with a new one Neutral switch 10 12 1 2 9 Sidestand switch mounting bolt 6 10 1 0 7 ALOC bolt replace with a new one 1 14 GENERAL INFORMATION LUBRICATION amp SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant Three bond 1207B 1215 or equivalent Left crankcase mating surface See page 14 18 Alternator CKP sensor wire grommet sealing surface Liquid sealant Three bond 5211C 1207B 1215 SS KE45 or equivalent Cylinder head semi circular cut out Engine oil Oil pump rotor entire
69. 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 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 if necessary C Clean 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 a dealer ANNUAL REGULAR REFER TO NOTE 1 000 1 12 24 36 48 CHECK REPLACE PAGE ITEMS x1000mi 0 6 8 16 24 32 FUEL LINE feu nra 1 3 3 THROTTLE OPERATION eu 3 3 AIR CLEANER NOTE2 R R 34 CRANKCASE BREATHER NOTE 3 gt 3 4 SPARK PLUG R 3 5 VALVE CLEARANCE 3 6 ENGINE OIL RTR IRIRIR R 3 9 ENGINE OIL FILTER R R R 3 10 ENGINE IDLE SPEED pu qr ur 1 3 10 RADIATOR COOLANT NOTE 5 1 3 YEARS 2 11 COOLING
70. surface Oil pump shaft outer surface Water pump shaft outer surface Cam chain whole surface Cylinder inner surface Piston pin hole inner surface ring groove and sliding surface Piston ring entire surface Clutch disc entire surface Gearshift spindle shaft outer surface Starter one way clutch sprag Starter driven gear sliding surface Each oil seal lips Each bearing rotating area Each gear teeth Each O ring Multi purpose grease Each oil seal lips clutch lifter arm gearshift spindle countershaft water pump Molybdenum oil solution a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease Valve stem sliding surface Camshaft lobes and journal Rocker arm shaft outer surface Rocker arm inner surface roller surface and slipper surface Piston pin outer surface Clutch outer guide whole surface Clutch lifter arm sliding surface Starter reduction gear inner surface Starter reduction gear shaft outer surface Crankshaft main journal bearing sliding surface Connecting rod big end sliding surface Connecting rod small end inner surface Left crankshaft needle bearing rotating surface Balancer driven gear and sub gear sliding surface Shift fork inner surface and guide pin Shift fork shaft outer surface Shift drum journal outer surface and grooves M5 C1 C2 C3 gear bushing
71. the camshaft Replace the camshaft if the difference from the standard value is larger than that of the cylinder head and camshaft holders CYLINDER HEAD VALVES INSTALLATION Be careful not to Rotate the crankshaft counterclockwise and align the jam the cam chain mark 1 on the flywheel with the index notch 2 on and timing sprocket the left crankcase cover on the crankshaft when rotating the crankshaft Be careful not to Install the shims 1 in their original locations on the the shims fall into valve retainer the crankcase ower the rocker arms 2 Each camshaft has an identification mark IN mark 1 intake camshaft EX mark 2 exhaust camshaft Apply molybdenum oil solution to the camshaft 1 lobes and journal surfaces Apply engine oil to the cam chain 2 whole surface Install the camshafts into the cylinder head while installing cam chain onto the cam sprockets NOTE Install the camshaft with its lobes facing up 10 9 CYLINDER HEAD VALVES Align the outside index line IN 1 and EX 2 marks 1 2 on the cam sprockets with the cylinder head top surface 1 3 2 as shown Check that the punch marks 3 of the cam sprockets is facing up as shown Install the camshaft holders Note the correct locations with the identification marks 1 as shown mark right camshaft holder L mark left camshaft holder IN mark
72. the oil strainer screen thoroughly nonflammable or high flash point solvent until all accumulated dirt has been removed Blow dry it with compressed air to clean completely Before installing the strainer it should be examined closely for damage and make sure the sealing rubber is in good condition Install the oil strainer screen with the thin edge facing in and flange side facing up as shown Install the right crankcase cover page 12 8 REMOVAL DISASSEMBLY Remove the right crankcase cover page 12 4 Remove the oil pump driven gear 1 Remove the oil pump mounting bolts 1 and oil pump assembly bolt 2 Remove the oil pump cover assembly 3 OIL STRAINER SCREEN DIRECTION CRANKCASE LUBRICATION SYSTEM Remove inner rotor assembly from the oil pump cover 1 while holding oil pump shaft 2 5 2 4 Remove the oil pump shaft and lock pin 3 from the inner rotor 4 Remove the outer rotor 5 and washer 6 Remove the dowel pins 1 from the oil pump body 2 Remove the oil pump body 1 by releasing it from the cam chain guide hook 2 and pressure relief valve 3 Remove the dowel pins 4 and O ring 5 INSPECTION Inspect the following parts for damage abnormal wear deformation or burning pump driven gear pump shaft Lock pin Inner rotor Outer rotor Oil pump body Measure th
73. the packing 1 from the fuel pump unit 2 2 Install new packing onto the fuel pump unit Always replace the packing with a new one Be careful not to pinch the dirt and debris between the fuel pump unit and packing Install the fuel pump 1 into the fuel tank Install and tighten the fuel pump mounting nuts 2 to the specified torque in the sequence as shown TORQUE 12 N m 1 2 kgf m 9 Ibf ft Install the fuel tank page 7 8 INSPECTION Check the fuel pump unit 1 for wear or damage replace it if necessary 1 FUEL SYSTEM FUEL PUMP RELAY INSPECTION Remove the left side cover page 2 3 Remove the dust cover 1 Remove the fuel pump relay 2 Connect a ohmmeter to the fuel pump relay 1 terminals Connect a 12 V battery to the fuel pump relay 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 fuel pump relay AIR CLEANER HOUSING 7 10 REMOVAL INSTALLATION Remove the sub frame page 2 12 Remove the bolts 1 and air cleaner housing Installation is in the reverse order of removal TORQUE Air cleaner housing mounting bolt 7 0 N m 0 7 kgf m 5 2 Ibf ft THROTTLE BODY REMOVAL Remove the fuel tank page 7 8 Disconnect the sensor unit 5P connector 1 Disconnect the IACV 4P Black connector 1 and injector 2P Gray connector
74. there continuity YES Replace the ECM with a known good one and recheck circuit in Gray blue wire 1 2 Gr Bu Gr Bu PGM FI SYSTEM 5 IAT Sensor Resistance Inspection Turn the ignition switch OFF Connect the sensor unit 5P connector Disconnect the ECM 33P Black connector 1 Measure the resistance at the ECM 33P Black connector of the wire side Connection Gray blue Green white Standard 1 13 1 88 20 C 68 F Is the resistance within 1 13 1 88 20 4 68 F YES Replace the ECM with a known good one and recheck G W Gr Bu NO Faulty sensor unit IAT sensor 1 MIL 11 BLINKS V8 SENSOR NOTE Before starting the inspection check for loose or poor contact on the VS sensor 3P Blue connector and recheck the MIL blinking ECM To SPEEDOMETER WEM NY VS SENSOR G BI R T P W R WR Probable cause Open or short circuit in Pink or White red wire between the VS sensor and ECM Faulty VS sensor Faulty ECM 1 Speedometer Inspection Inspect the speedometer page 20 8 Is the speedometer normal YES GOTO STEP 2 NO Replace or repair the abnormal circuit 4 35 PGM FI SYSTEM 2 VS Sensor Signal
75. to each bearing rotating area 14 17 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Apply grease to a new countershaft oil seal 1 lips Install the countershaft oil seal with its marked side facing up until it is flush with the snap ring groove Make sure the snap Install the snap ring 2 ring is firmly seated in the groove CRANKCASE ASSEMBLY Clean the oil passages of each crankcase using a compressed air Check the oil passage for clogs Clean the left and right crankcase mating surfaces thoroughly being careful not to damage them and check for damage Apply a light but through coating of sealant Three bond 1207B 1215 or equivalent to left crankcase mating surface except the oil passage area Apply engine oil to a new O ring 1 Install the dowel pins 2 and O ring 14 18 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Do not force the Install the left crankcase 1 on the right crankcase 2 crankcase halves being careful not to damage the oil seal lips together If there is excessive force required something is wrong Remove the left crankcase and check for misaligned parts Install the crankcase bolts 1 Tighten the bolts in a crisscross pattern in 2 or 3 steps Be careful not to Install the woodruff key 1 into the balancer shaft damage the groove groove and balancer shaft Align the balancer gear 1 and balancer sub gear 2 3 holes and install a 3 m
76. to the threads Shift drum stopper arm bolt 1 6 10 1 0 7 Apply locking agent to the threads Gearshift spindle return spring pin 1 8 30 3 1 22 Apply locking agent to the threads Primary drive gear lock nut 1 16 108 11 0 80 Apply engine oil to the threads and seating surface ALTERNATOR STARTER CLUTCH p THREAD TORQUE ITEN DIA N m kgf m Ibf ft REMABKS Stator mounting socket bolt 3 6 10 1 0 7 CKP sensor mounting socket bolt 2 6 10 1 0 7 Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 in from tip Flywheel bolt 1 12 128 13 1 94 Apply engine oil to the threads and seating surface Starter clutch socket bolt 6 8 30 3 1 22 Apply locking agent to the threads CRANKCASE CRANKSHAFT TRANSMISSION BALANCER THREAD TORQUE DIA mm N m kgf m Ibf ft REMARKS Balancer shaft nut 1 14 44 4 5 32 Apply engine oil to the threads and seating surface Cam chain tensioner pivot bolt 1 6 10 1 0 7 Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 in from tip ENGINE REMOVAL INSTALLATION THREAD TORQUE ITEM QTY DIA mm N m kgf m Ibf ft REMARKS Rear engine mounting nut 2 10 45 4 6 33 Front engine mounting nut 2 10 55 5 6 41 Engine hanger plate bolt 2 8 27 2 8 20 Drive sprocket fixing plate bolt 2 6 10 1 0 7 1 12 FRONT WHEEL SUSPENSION STEERING GENERAL INFORMATION THREAD TORQUE
77. to the inner damper and tighten it until it stops Hold the fork cap with a wrench then tighten the lock nut to the specified torque TORQUE 20 2 0 kgf m 15 Ibf ft Completely extend the outer tube 1 2 Install and tighten the fork cap 2 into the outer tube Tighten the fork cap to the specified torque after installing the fork leg into the steering stem page 16 7 HANDLEBAR REMOVAL Remove the following Wire bands 1 Rearview mirrors 2 16 16 Keep the reservoir upright to prevent air from entering the hydraulic system Bolts 1 Bracket holder 2 Clutch lever bracket 3 Clutch switch connectors 4 Screws 1 Left handlebar switch housing 2 Left handlebar grip 1 Brake light switch connectors 1 Bolts 2 Master cylinder holder 3 Brake master cylinder 4 FRONT WHEEL SUSPENSION STEERING 16 17 FRONT WHEEL SUSPENSION STEERING Screws 1 Right handlebar switch 2 Screws 1 Throttle housing cover 2 Bolts 1 Handlebar upper holders 2 Handlebar 3 Pull out the handlebar 1 from the throttle pipe 2 Remove the following Throttle cables 3 Throttle pipe Throttle housing 4 16 18 Align the punch mark on the handlebar with the top edge of the lower holder FRONT WHEEL SUSPENSION STEERING INSTALLATION Apply grease to the cable rolling area of the throttle pipe 1 fl
78. type 2 6 1 5 0 2 1 1 U nut only Rear reflector mounting nut 1 5 1 5 0 2 1 1 U nut Brake taillight mounting screw 3 6 4 5 0 5 3 3 Exhaust pipe protector socket bolt 2 6 12 1 2 9 Muffler protector cover screw 5 4 1 5 0 2 1 1 Muffler front mounting bolt 1 8 32 3 3 24 Muffler band bolt 1 8 22 5 2 3 17 Exhaust pipe joint nut 2 8 18 1 8 13 Exhaust pipe stud bolt 2 8 See page 2 11 Air cleaner connecting hose band screw 1 4 1 5 0 2 1 1 Sub frame upper mounting nut 2 8 27 2 8 20 Sub frame lower mounting bolt 2 8 27 2 8 20 Rear master cylinder reservoir mounting 1 6 10 1 0 7 bolt Sidestand pivot bolt 1 10 10 1 0 7 See page 2 14 Sidestand pivot lock nut 1 10 30 3 1 22 U nut See page 2 14 MAINTENANCE THREAD TORQUE QTY DIA mm N m kgf m Ibf ft REMARKS Throttle cable A adjuster lock nut throttle body side 1 6 3 0 0 3 2 2 Air cleaner cover screw 4 5 1 2 0 1 0 9 Spark plug 1 10 16 1 6 12 Crankshaft hole cap 1 30 8 0 0 8 5 9 Apply engine oil to the threads Timing hole cap 1 14 6 0 0 6 4 4 Apply engine oil to the threads Engine oil drain bolt 1 12 24 2 4 18 Drive chain adjuster lock nut 2 8 27 2 8 20 UBS nut Rear axle nut 1 16 88 9 0 65 U nut Drive sprocket fixing plate bolt 2 6 10 1 0 7 Driven sprocket nut 6 10 50 5 1 37 U nut Rear master cylinder reservoir mounting 1 6 10 1 0 7 bolt Master cylinder reservoir cover screw 4 4 1 5 0 2 1 1 Rear master cylin
79. 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 If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil leaks TROUBLESHOOTING Engine oil level too low high oil consumption Oil consumption External oil leaks Worn valve guide or stem seal Worn piston rings Improperly installed piston rings Worn cylinder Engine oil contamination Oil not changed often enough Worn valve guide or stem seal Worn piston rings Improperly installed piston rings Worn cylinder Oil emulsification Faulty cylinder head gasket Leaky coolant passage Entry of water Faulty water pump mechanical seal LUBRICATION SYSTEM OIL FILTER OIL PUMP PRESSURE RELIEF VALVE BW AA AM MAINSHAFT 8 3 LUBRICATION SYSTEM DIAGRAM CAMSHAFT ROCKER ARM CRANKSHAFT OIL STRAINER SCREEN COUNTERSHAFT LUBRICATION SYSTEM ENGINE OIL STRAINER SCREEN Be careful not to damage the oil strainer screen OIL PUMP REMOVAL INSTALLATION Remove the right crankcase cover page 12 4 Pull the oil strainer screen 1 out of the crankcase Wash
80. wire GOTO STEP 3 IACV Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and IACV Black connector 2 of the wire side Connection Brown white Brown white Blue white Blue white Brown black Brown black Blue black Blue black TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a known good and recheck NO Open circuit in Blue white or Brown white wire Open circuit in Brown black or Blue black wire 1 1 2 Bu W Br W EY Bu BI O 1 MIL 54 BLINKS BANK ANGLE SENSOR NOTE PGM FI SYSTEM Before starting the inspection check for loose or poor contact on the bank angle sensor 2P connector and recheck the MIL blinking From ENGINE STOP SWITCH lt 7 BI Bu BANK ANGLE SENSOR Probable cause Open circuit in Black blue wire between the engine stop switch and bank angle sensor Open or short circuit in Red blue wire between the bank angle sensor and ECM Faulty bank angle sensor Faulty ECM 1 Bank Angle Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the bank angle sensor 2P connector 1 page 4 48 Turn the ignition switch ON and engine stop switch Went Lae Measure the voltage between the bank angle sensor 2P connector of the wire side and ground Connection Bl
81. 0 N m 1 0 kgf m 7 Driven sprocket nut 2 50 N m 5 1 kgf m 37 Ibf ft Install the drive sprocket cover page 2 6 DRIVE CHAIN SLIDER U type only Remove the drive chain cover page 2 6 Remove the drive sprocket cover page 2 6 Check the drive chain slider 1 for wear or damage The drive chain slider must be replaced if it is worn to the wear limit indicator 2 or wear limit line 3 For drive chain slider replacement page 17 10 3 14 BRAKE FLUID Spilled fluid can damage painted plastic or rubber parts Place a rag over these parts whenever the system is serviced NOTE 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 When the fluid level is low check the brake pads for wear page 3 16 A low fluid level may be due to wear of the brake pads If the brake pads are worn and caliper pistons are pushed out this accounts for a low fluid level If the brake pads are not worn and fluid level is low check the entire system for leaks page 3 17 FRONT BRAKE Turn the handlebar to the left so that the reservoir is level and check the front brake fluid level through the sight glass If the level is near the LOWER level line 1 fill the recommended brake fluid Remove the following Screws 2 Reservoir cover 3 Set plate 4 Diaphragm 5 Add DOT 3 or
82. 1 Lg R G R G R 29 NLSW 1 Br 5 DIODE FLR 8 i NEUTRAL CLUTCH BI Bu 1 SWITCH SWITCH or S FIIND 18 25 SSTAND O DOWN TWND 22 m SIDESTAND SWITCH 11 mm d ECM EMPERATURE INDICATOR VS SENSOR PCP 23 BIR BIW FAN 54 TET CONTROL BANK ANGLE RELAY SENSOR TS VSP 7 dj Bu SENSOR UNIT N BI Bu gt 1 pe 12 3 MAP SENSOR PB lt lt INJECTOR IGNITION COIL SPARK PLUG 8 u THL G R E TP SENSOR GPlS 1 3 E 9 28 000000 IAT SENSOR PAIR CONTROL 7 TW SOLENOID VALVE Biga KLINE 30 SCS CONNECTOR ECT SENSOR L SG 505 15 gt VCC G IACV1A DLC 21 IACV1B BIW 02 IACV2A O2 SENSOR IACV2B 9 pat Pez 2 G G 29 B Br Brown Black 1 r3 Lc 11 Y Yellow _ MIL number Bu Blue Engine does not start EHEBDBBEBE oe i i detecting MIL ae 12 22 White OOOOOOOOO O Orange Short terminals for la Light green reading MIL a e e Gr Gra ECM 33P BLACK CONNECTOR eme ECM side of the male terminals PGM FI SYSTEM PGM FI 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 troubleshooti
83. 2 P W 1 P W PGM FI SYSTEM 21 gt SENSOR NOTE Before starting the inspection check for loose or poor contact on the O2 sensor 1P Black connector or O2 sensor cap and recheck the MIL blinking ECM O2 SENSOR Probable cause Open or short circuit in Black white or Black wire between the O sensor and ECM Faulty O sensor Faulty ECM DTC 21 1 O2 Sensor 1 O2 Sensor System Inspection Start the engine and warm up the engine up to coolant temperature is 80 C 176 F Test ride the motorcycle and check the O sensor with the HDS pocket tester Is the DTC 21 1 indicated YES GOTO STEP 2 NO Intermittent failure 2 O Sensor Short Circuit Inspection Turn the ignition switch OFF 1 Disconnect the ECM 33P Black connector page 4 50 1 L Disconnect the sensor 1 page 4 47 3 Check for continuity between the O sensor j terminal 2 and ground 2 Connection O sensor cap terminal Ground Is there continuity YES Short circuit in Black or Black white wire STEP 4 23 PGM FI SYSTEM 3 O Sensor Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and O2 sensor cap terminal 2 of the 2 wire side 1 b Connection
84. 2 Remove the bolt 3 battery holder plate 4 and battery 5 Connect the Install the battery in the reverse order of removal positive cable first TORQUE and then the negative cable Battery holder plate bolt 7 0 N m 0 7 kgf m 5 2 Ibf ft NOTE Install the battery holder plate by aligning its hook with the slit of the battery case For digital clock setting procedure page 20 7 VOLTAGE INSPECTION Measure the battery voltage using a commercially available digital multimeter z VOLTAGE 20 68 F Fully charged 13 0 13 2 V Under charged Below 12 3 V If the battery voltage is below 12 3 V charge the battery BATTERY TESTING Refer to the instructions that are appropriate to the battery testing equipment available to you TOOL Battery tester BM 210 or BATTERY MATE or equivalent CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the left side cover page 2 3 With the ignition switch turned OFF disconnect the negative cable 1 Connect the ammeter probe to the wire harness negative cable and ammeter probe to the battery negative terminal 2 With the ignition switch turned OFF check for current leakage NOTE 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 the fuse in the tester While measuring current do n
85. 3 5 kgf m 25 Ibf ft Fill and bleed the hydraulic system page 18 4 DISASSEMBLY ASSEMBLY Disassemble and assemble the front brake caliper as following illustration BRACKET PIN BOOT e PISTONS CALIPER BRACKET P S P DUST SEALS BLEED VALVE e 5 4 N m 0 6 kgf m 4 0 Ibf ft Pow PISTON SEALS 2 17 2 Nem 1 8 kgf m 13 Ibf ft 00L S43 BODY BRACKET PIN BOOT j 2 STOPPER RING D d PAD PIN G 17 2 Nem 1 8 13 Ibf ft PAD SPRING ew BRAKE PADS 18 10 BRAKE SYSTEM INSPECTION Check the following parts for scoring scratches deterioration or damage Caliper cylinders Caliper pistons Measure the parts according to BRAKE SYSTEM SPECIFICATIONS page 1 8 and replace if necessary REAR BRAKE CALIPER REMOVAL INSTALLATION Drain the brake fluid from the rear brake hydraulic system page 18 4 When removing the Remove the oil bolt 1 sealing washers 2 and brake bolt cover the hose 3 end of the hose to prevent contamination Remove the rear wheel page 17 4 Remove the rear brake caliper 1 from the slide rail 2 of swingarm Installation is in the reverse order of removal Replace the sealing washers with new ones TORQUE Oil bolt 34 N m 3 5 kgf m 25 Fill and bleed the hydraulic system page 18 4 18 11 B
86. 33 2 EEPROM 1 Recheck DTC Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch Recheck the ECM EEPROM Is the DTC 33 2 indicated YES Replace the ECM with a known good and recheck NO Intermittent failure DTC 54 BANK ANGLE SENSOR NOTE Before starting the inspection check for loose or poor contact on the bank angle sensor 2P connector and recheck the MIL blinking ECM From ENGINE STOP SWITCH V BI Bu R Bu BANK ANGLE SENSOR Probable cause Open circuit in Black blue wire between the engine stop switch and bank angle sensor Open or short circuit in Red blue wire between the bank angle sensor and ECM Faulty bank angle sensor Faulty ECM 4 26 DTC 54 1 BANK ANGLE SENSOR LOW VOLTAGE 1 Recheck DTC Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch an ta Check the bank angle sensor with the HDS pocket tester Is the DTC 54 1 indicated YES STEP 2 NO Intermittent failure Bank Angle Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the bank angle sensor 2P connector 1 page 4 48 Turn the ignition switch ON and engine stop switch Measure the voltage between the bank angle sensor 2P connector of the wire side and ground Connection Black blue Ground Standard Battery voltage Is there battery voltage YES GOTOSTEP3 O
87. 36 07HMF KR10101 9 10 COOLING SYSTEM INSTALLATION Apply engine oil to the water pump shaft 1 outer surface Install the water pump shaft to the right crankcase cover Install the plain washer 1 and impeller 2 to the water pump shaft Hold the water pump shaft and tighten the water pump impeller 1 to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the right crankcase cover page 12 8 Install a new O ring 1 to the water pump cover 2 Install the water pump cover 9 11 COOLING SYSTEM Install and tighten the bolts 1 drain bolt 2 and a new sealing washer 3 securely Fill the recommended coolant and bleed the air page 9 5 RADIATOR RESERVE TANK REMOVAL INSTALLATION Remove the right fuel tank shroud page 2 4 Place an approved container under the radiator reserve tank 1 Disconnect the overflow hose 2 and siphon hose 3 from the reserve tank Remove the bolts 4 and radiator reserve tank Installation is in the reverse order of removal Fill the reserve tank with coolant page 9 5 FAN CONTROL RELAY 9 12 INSPECTION Remove the left side cover page 2 3 Remove the dust cover 1 Remove the fan control relay 2 Connect a ohmmeter to the fan control relay 1 terminals Connect a 12 V battery to the fan control relay terminals as shown There should be continuity only when 12 V battery is connected If there is
88. 7 0 03 mm 0 011 x 0 001 in ADJUSTMENT NOTE The valve clearances can be adjusted without removing the camshafts The intake and exhaust valve clearance service procedures are the same Remove the bolt sealing washer and rocker arm shaft page 10 11 Slide the rocker arm 1 and remove the shims 2 NOTE Do not allow the shims to fall into the crankcase Mark all shims to ensure correct reassembly in their original locations shims be easily removed with a tweezers magnet MAINTENANCE Sixty nine different Measure the shim 1 thickness and record it thickness shims are available from the thinnest 1 200 mm thickness shim B C D the thickest 2 900 mm thickness shim in increments of 0 025 mm 1 Calculate the new shim thickness using the equation below A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness NOTE Make sure of the correct shim thickness measuring the shim by micrometer Inspect the valve seat if the calculated dimension is over 2 900 mm 1 80 mm 1 825 mm 1 85 mm 1 875 mm Install the shims Install the newly selected shim 1 on the valve spring their original retainer Install the rocker arm shaft while aligning the hole of the rocker arm 2 and cylinder head page 10 11 Rotate the camshafts by turning the crankshaft counterclockwis
89. 74 7 5 kgf m 55 Ibf ft Rear brake hose guide mounting screw 1 2 0 1 kgf m 0 9 DISASSEMBLY ASSEMBLY Disassemble and assemble the swingarm as following illustration Apply Honda Bond A or equivalent to the swingarm rubber cap mating surface with swingarm CHAIN CASE STAY SCREW 4 2 N m 0 4 kgf m 3 1 Ibf ft SWINGARM RUBBER CAPS CHAIN SLIDER COLLAR 9 ies SEALS SWINGARM SCREWS amp 4 2 N m 0 4 kgf m 3 1 Ibf ft 17 11 REAR WHEEL SUSPENSION BEARING REPLACEMENT Remove the pivot bearings 1 and dust seals 2 using the special tool TOOLS 3 Bearing remover 20 mm 4 Remover weight Remover handle 07936 3710600 07741 0010201 07936 3710100 Apply grease to the needle rollers of new bearings 1 and new dust seal 2 lips Install the dust seals to the specified depth with the marked side facing in Press the needle bearings to the specified depth with the marked side facing up using the special tools TOOLS 3 Driver 07949 3710001 4 Attachment 24 x 26 mm 07746 0010700 5 Pilot 20 mm 07746 0040500 6 Fork seal driver attachment 07747 0010400 20 mm 3 4 3 4 5 Left side 27 0 27 5 1 06 1 08 in Right side 32 0 32 5 mm 1 26 1 28 in 1 7 0 7 5 mm 2 0 28 0 30 in 2 1 12 0 12 5 mm 0 47 0 49 in DRIVE CH
90. ABLE STARTER MOTOR CABLE SIDESTAND SWITCH WIRE ALTERNATOR WIRE BATTERY NEG TIVE A CABLE RY BATTERY CASE DRAIN HOSE yo CRANKCASE N BREATHER HOSE 36 N SIDESTAND SWITCH WIRE Viewed from the lower side NEUTRAL SWITCH DRIVE SPROCKET 477 COVER NEUTRAL SWITCH At AN o DRAIN HOSE J SIDESTAND NIA 4 SWITCH WIRE I him o LEFT CRANKCASE COVER RESERVE TANK OVERFLOW HOSE FUEL TANK BREATHER HOSE 1 24 GENERAL INFORMATION Viewed from the front side SUB FRAME STARTER MOTOR CABLE FUEL PUMP RELAY STARTER MAIN WIRE MOTOR CABLE HARNESS FAN CONTROL RELAY WIRE BANDS LR STARTER RELAY NY SWITCH 4P RED CONNECTOR Ts BATTERY NEGATIVE BATTERY POSITIVE CABLE CABLE REAR BRAKE LIGHT PS SWITCH WIRE REAR BRAKE HOSE 1 25 GENERAL INFORMATION MAIN WIRE HARNESS BRAKE TAILLIGHT BLACK CONNECTOR RIGHT REAR TURN SIGNAL 2P LIGHT BLUE LEFT REAR TURN SIGNAL CONNECTOR 2P ORANGE CONNECTOR 1 26 GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide CO oxides of nitrogen NOx and hydrocarbons HC Control of oxides of nitrogen and hydrocarbons is very important because under certain conditions they react to form photochemical smog when subject to sunlight Carbon monox
91. AIN GUIDE REMOVAL INSTALLATION Remove the two nuts 1 screws 2 and chain slider guide 3 Remove the bolts 4 and drive chain guide 5 Installation is in the reverse order of removal Replace the chain guide mounting bolts with new ones TORQUE Chain guide mounting bolt 10 N m 1 0 kgf m 7 Ibf ft Chain slider guide mounting nut 2 5 N m 0 3 kgf m 1 8 Ibf ft 17 12 18 BRAKE SYSTEM SERVICE 18 2 FRONT MASTER 18 7 18 2 REAR MASTER 18 8 COMPONENT 18 3 FRONT BRAKE 18 10 BRAKE FLUID REPLACEMENT REAR BRAKE 18 11 AIR BLEEDING 18 4 BRAKE 441 18 12 BRAKE PAD DISC 18 5 18 1 BRAKE SYSTEM SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation of brake pad dust regardless of material composition could be hazardous to your health Avoid breathing dust particles Never use an air hose or brush to clean brake assemblies Use an OSHA approved vacuum cleaner Spilled brake fluid will severely damage the plastic parts and painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir c
92. ANDLEBAR 14P GRAY CONNECTOR SWITCH 9P BLACK CONNECTOR FRONT BRAKE HOSE THROTTLE CABLES CLUTCH CABLE POSITION LIGHT 2P BLACK CONNECTOR IGNITION SWITCH WIRE 2 lt HEADLIGHT BLACK CONNECTOR CONNECTORS RIGHT FRONT TURN SIGNAL 2P LIGHT BLUE LEFT FRONT TURN SIGNAL 2P ORANGE WIRE CLAMP Viewed from the upper side Viewed from the OAS LEFT FRONT TURN SIGNAL RIGHT FRONT TURN right side LEFT FRONT TURN 2P ORANGE CONNECTOR E is 57 BLUE SIGNAL WIRE METER STAY LEFT FRONT TURN N SIGNAL WIRE ep 40 y IGNITION RIGHT FRONT TURN SWITCH WIRE ENERO SIGNAL WIRE 1 18 GENERAL INFORMATION CLUTCH CABLE THROTTLE CABLES RADIATOR SIPHON HOSE RESERVE TANK OVERFLOW HOSE WATER HOSE BAND pe gt Front 0 30 GENERAL INFORMATION GROUND POINT ECM 33P BLACK CONNECTOR PAIR CONTROL SOLENOID VALVE 2P BLACK CONNECTOR y Shy BANK ANGLE SENSOR W 2P CONNECTOR JUNCTION BOX 4 2 2 TURN SIGNAL RELAY 3P RADIATOR SIPHON HOSE REGULATOR RECTIFIER BEACH CONNECTOR 5P CONNECTOR FUEL HOSE FUEL PUMP 3P BLACK CONNECTOR 1 20 GENERAL INFORMATION Viewed from the front side PAIR AIR SUCTION HOSE CRANKCASE BREATHER HOSE VS SENSOR 3P HOSE CLAMPS BLUE CONNECTOR GROUND POINT RESERVE TANK PAIR AIR OVERFLOW HOSE SUCTION HOSE REAR BRAKE LIGHT SWITCH WIRE M PAIR AIR SUPPLY HOSE CRANKC
93. ASE BREATHER HOSE WIRE BAND ai CLUTCH CABLE GUIDE Viewed from VS SENSOR S SENSO the front side PAIR AIR RESERVE TANK SUCTION HOSE OVERFLOW HOSE 1 21 GENERAL INFORMATION RADIATOR SIPHON HOSE CLUTCH CABLE PAIR AIR SUCTION HOSE SPARK PLUG WIRE PAIR AIR SUPPLY HOSE FUEL PUMP 3P 4 8 RESERVE TANK OVERFLOW HOSE FUEL TANK BREATHER HOSE To FUEL TANK FUEL INJECTOR 2P GRAY CONNECTOR IACV BLACK CONNECTOR FUEL TANK BREATHER HOSE HOSE BAND amu FUEL TANK BREATHER HOSE SUB FRAME 1 22 GENERAL INFORMATION Viewed from the rear side PAIR AIR SUCTION HOSE PAIR AIR SUPPLY HOSE PAIR CONTROL SOLENOID VALVE RADIATOR SIPHON HOSE DLC PAIR AIR SUCTION HOSE FAN MOTOR 2P BLACK CONNECTOR PAIR AIR SUPPLY HOSE FUEL PUMP 3P BLACK CONNECTOR WATER HOSE BAND 55 30 Left lt Oz SENSOR 1P BLACK CONNECTOR SPARK PLUG WIRE WATER HOSE BAND 90 30 Front ECT SENSOR 3P CONNECTOR SENSOR UNIT 5P CONNECTOR 1 23 GENERAL INFORMATION CONNECTORS ALTERNATOR 3P REAR BRAKE LIGHT SWITCH 3P BLACK FUEL TANK SIDESTAND SWITCH GREEN BREATHER HOSE VS SENSOR 3P SENSOR NEUTRAL SWITCH 3P BLACK BLUE CONNECTOR ECT SENSOR 3P CONNECTOR gt WIRE CLAMP Viewed from the upper side BATTERY NEGATIVE C
94. Black connector 1 Turn the ignition switch ON and engine stop switch Lae Measure the voltage at the ECM 33P Black connector of the wire side Connection White red Ground TOOL Test probe 07ZAJ RDJA110 Slowly turn the rear wheel by hand There should be 0 V to 5 V pulse voltage Is there 0 5 V pulse voltage YES Replace the ECM with a known good one and recheck NO Open or short circuit in White red wire 1 W R PGM FI SYSTEM DTC 12 INJECTOR NOTE Before starting the inspection check for loose or poor contact on the injector 2P Gray connector and recheck the MIL blinking ECM From ENGINE STOP SWITCH INJECTOR BI Bu P W Probable cause Open circuit in Black blue wire between the engine stop switch and injector Open or short circuit in Pink white wire between the injector and ECM Faulty injector Faulty ECM DTC 12 1 INJECTOR 1 Injector System Inspection Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch Start the engine and check the injector with the HDS pocket tester Is the DTC 12 1 indicated YES 2 NO Intermittent failure Loose or poor contact on the injector 2P Gray connector 2 Injector Input Voltage Inspection Turn the ignition switch OFF 1 Disconnect the injector 2P Gray conne
95. CRI EO DE 18 NO 7 18 do fe 25 wid wid Sz d d i lt i 1 i 05 WA WA ES Ez i Z LoS 2es s 8 NO eu de 200 i 1 ESOS i n n zo 8 na Em Ja Sk 18 9 WA 552 wie u a Ma 5 mo 19 5 ona o 82 5 0 A lt ain a 9 n fno WM 2 NOI wid 9 18 5 NYNL TNYNL S wn TVu Ln3N HORN RIGHT REAR TURN SIGNAL LIGHT 12V 21W LEFT REAR TURN SIGNAL LIGHT 12V 21W BRAKE TAILLIGHT 12V 21 5W GN G 2P Lb 6P BI E 1 HEADLIGHT 12V 60 55W ng g ng g ng g o o giz gt gt j 53 gt TERNATOR SENSOR a m INJ ECTOR JOINT 119 OHI FRAME 4 FRAME GROUND GROUND GROUND GROUND Wo 1 REGULATOR gt gt gt RECTIFIER ais HORN SWITCH SIDESTAND SWITCH Zo sex ei Wo PE I
96. Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector and sensor unit connector 1 page 4 44 Check for continuity between the sensor unit 5P connector of the wire side and ground Connection Yellow Ground Is there continuity YES Short circuit in Yellow wire NO GOTO PGM FI SYSTEM 3 TP Sensor Output Line Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and sensor unit 5P connector 2 of the wire side Connection Yellow Yellow TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GO TO STEP 4 Open circuit in Yellow wire 2 1 4 TP Sensor Resistance Inspection Connect the sensor unit 5P connector Check that the resistance varies in accordance with the throttle operation at the ECM 33P Black connector of the wire side Connection Yellow Green white lt Fully closed Fully open position G W Resistance increases H Fully open Fully closed position Resistance decreases Is the resistance normal YES Replace the ECM with a known good one 1 and recheck 1 Faulty sensor unit TP sensor MIL 9 BLINKS IAT SENSOR ECM SENSOR UNIT IAT SENSOR Gr Bu G W
97. DER HEAD VALVES Do not rotate the camshaft when using plastigauge Be sure the dowel pins in the camshaft holder align the holes in the cylinder 10 8 head CAMSHAFT OIL CLEARANCE Wipe any oil from the journals of the camshaft cylinder head and camshaft holders Lay a strip of plastigauge 1 lengthwise on top of each camshaft journal Install each camshaft holder to the correct locations with the identification marks 1 mark right camshaft holder L mark left camshaft holder IN mark intake side EX mark exhaust side Apply engine oil to the camshaft holder mounting bolt 1 threads and seating surface Failure to tighten the camshaft holder in a crisscross pattern may cause a camshaft holder to break Tighten all camshaft holder mounting bolts to the specified torque TORQUE 12 1 2 kgf m 9 Ibf ft NOTE From inside to outside tighten the bolts in a crisscross pattern in several steps Remove the camshaft holders and measure the width of each plastigauge The widest thickness determines the oil clearance SERVICE LIMIT 0 10 mm 0 004 in When the service limit is exceeded measure the camshaft journal O D and camshaft journal area of cylinder head and camshaft holders then compare the measurement with the standard value page 1 6 Replace the cylinder head and camshaft holders as a set if the difference from the standard value is larger than that of
98. DOT 4 brake fluid from a sealed container to the casting ledge 1 Install the diaphragm set plate and reservoir cover Install and tighten the cover screws to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 1 Ibf ft MAINTENANCE 3 15 MAINTENANCE REAR BRAKE Support the motorcycle on a level surface and check the rear brake fluid level Check the brake fluid level If the level is near the LOWER level line 1 fill the recommended brake fluid 4 Remove the bolt 2 and reservoir 3 Remove the cover screws 4 reservoir cover 5 set plate 6 and diaphragm 7 Add DOT 3 or DOT 4 brake fluid from a sealed container to the UPPER level line 8 Install the diaphragm set plate and reservoir cover Install and tighten the cover screws to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 1 Ibf ft 1 Install the reservoir and tighten the bolt to the specified torque while pushing the reservoir against the stopper 9 TORQUE 10 1 0 kgf m 7 Ibf ft BRAKE PADS WEAR FRONT BRAKE PADS Check the front brake pads for wear Always replace the Replace the front brake pads if either pad is worn to the brake pads as a set wear limit groove 1 9 fo assure even dise front brake pad replacement page 18 5 REAR BRAKE PADS Check the rear brake pads for wear Always replace the Replace the rear brake pads if eit
99. ECTION Check the operation of the pressure relief valve by pushing on the piston 1 Disassemble the pressure relief valve by removing the snap ring 2 Remove the washer 1 spring 2 and piston 3 Check the piston for wear sticking or damage Check the spring for fatigue or damage Assemble the pressure relief valve in the reverse order lt of disassembly 7 Install the snap ring with the chamfered edges facing the thrust load side Make sure the snap ring is seated in the groove Q SERVICE 9 2 9 2 SYSTEM FLOW 9 3 SYSTEM TESTING nete recien 9 4 COOLANT REPLACEMENT 9 5 THERMOSTAT eene 9 5 9 COOLING SYSTEM RADIATOR COOLING 9 6 WATER PUMP 9 8 RADIATOR RESERVE 9 12 FAN CONTROL RELAY 9 12 WATER PIPE sesssrsssssssncsscnseesceseessessrsassseusease 9 13 9 1 COOLING SYSTEM SERVICE INFORMATION GENERAL AWARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap Using coolant with silicate inhibitors may cause p
100. ES GOTO STEP 2 NO Intermittent failure Loose or poor contact on the ECT sensor 3P connector ECT Sensor Inspection Turn the ignition switch OFF Disconnect the ECT sensor 3P connector 1 Connect the ECT sensor 3P connector terminals at the wire side with a jumper wire 2 Connection Yellow blue Green white Turn the ignition switch ON and engine stop switch Check the ECT sensor with the HDS pocket tester Is about 0 V indicated YES Inspect the ECT sensor page 4 46 NO GOTO 3 ECT Sensor Open Circuit Inspection Turn the ignition switch OFF Remove the jumper wire Disconnect the ECM 33P Black connector 1 Check the continuities between the ECM 33P Black connector and ECT sensor 3P connector 2 of the wire side Connection Yellow blue Yellow blue Green white Green white TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a known good one and recheck NO Open circuit in Yellow blue wire e Open circuit Green white wire 2 1 ee T G W 2 Y Bu G W 1 PGM FI SYSTEM DTC 8 TP SENSOR SENSOR UNIT TP SENSOR Y R Y G W ECM Probable cause Open circuit in Yellow red wire between the sensor unit and ECM Open or short circuit in Yellow wire between the sensor unit and ECM Open circuit in Green white wire b
101. ES Replace the ECM with a know good one 2 1 and recheck Open circuit in Yellow red wire Open circuit in Green white wire PGM FI SYSTEM DTC TROUBLESHOOTING DTC 1 MAP SENSOR 4 10 SENSOR UNIT MAP SENSOR Y R ECM Lg Bl G W Probable cause Open circuit in Yellow red wire between the sensor unit and ECM Open or short circuit in Light green black wire between the sensor unit and ECM Open circuit in Green white wire between the sensor unit and ECM Faulty sensor unit Faulty ECM DTC 1 1 MAP SENSOR LOW VOLTAGE 1 MAP sensor system inspection Turn the ignition switch ON and engine stop switch Check the MAP sensor with the HDS pocket tester Is about 0 V indicated YES GOTO STEP 2 NO Intermittent failure Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 8 15 the sensor unit power line normal YES GOTO STEP 3 NO Replace or repair the abnormal circuit MAP Sensor Output Voltage Inspection Turn the ignition switch OFF Connect the ECM 33P Black connector Disconnect the sensor unit 5P connector 1 page 4 44 Turn the ignition switch ON and engine stop switch ta Measure the voltage at the sensor unit 5P connector of the wire side Connection Light green black Green white Standard 4 75 5 25 V Is the voltage within 4 75 5 25 V YES GO
102. ETERS SWITCHES 20 6 SYSTEM INSPECTION NOTE Check for loose or poor contact terminals at the speedometer 16P connector When the ignition switch is turned ON check that the meter segments turn on If the speedometer does not show the initial function perform the power and ground line inspection of the speedometer page 20 6 If the speedometer shows the initial function but speedometer does not move when running check the speedometer VS sensor system inspection page 20 8 POWER GROUND LINES INSPECTION Remove the speedometer page 20 5 NOTE Do not disconnect the speedometer 16P connector 1 during inspection After inspection reposition the dust cover 2 securely Remove the dust cover With the speedometer 16P connector connected check the following at the wire harness side connector POWER INPUT LINE Measure the voltage between the speedometer 16P connector 1 and ground CONNECTION Black Ground There should be battery voltage with the ignition switch turned ON If there is no battery voltage check the following Open circuit in the Black wire Open circuit in Black red wire between the fuse box and ignition switch Blown METER TAIL fuse 10 A GROUND LINE Check for continuity between the speedometer 16P connector 1 and ground CONNECTION Green Ground There should be continuity at all times If there is no continui
103. F Test ride the motorcycle and recheck the MIL blinking Does the MIL blink 21 times YES Replace the ECM with a known good one and recheck NO Faulty original O2 sensor MIL 29 BLINKS IACV NOTE Before starting the inspection check for loose or poor contact on the 4P Black connector and recheck the MIL blinking ECM Bu w m BrW j Br BI 34 Probable cause Open or short circuit in wires Blue white Blue black Brown white Brown black between the IACV and ECM Faulty IACV Faulty ECM 4 39 PGM FI SYSTEM 4 40 1 IACV Resistance Inspection Turn the ignition switch OFF Disconnect the IACV Black connector 1 page 7 15 Measure the resistance at the IACV side connector Connection A Blue black D Blue white B Brown black C Brown white Standard 110 150 25 C 77 F Is the resistance within 110 150 25 77 YES GO STEP 2 NO Faulty IACV IACV Short Circuit Inspection Disconnect the ECM 33P Black connector page 4 50 Check for continuity between the IACV 4P Black connector 1 of the wire side and ground Connection Blue white Ground Brown white Ground Brown black Ground Blue black Ground Is there continuity YES Short circuit Blue white or Brown white wire Short circuit in Brown black or Blue black
104. GNITION COIL az z ECT SENSOR BI O2 SENSOR ENGINE STOP SWITCH TURN SIGNAL SWITCH SENSOR UNIT IACV mI Eee z S lc Joc JOJO 2 Jor 22 eso ii e 5 2 5 2 5 o gt be Eu Eo uis Es auo gt len 5 lec 5 g 2 00 Lg COLOR BI O DIMMER SWITCH COLOR BI G SS HET iia Zu wia Za 5 8 9586 la 2 t 29 a 5wsa 2 PZO Oe Ar Sater 3999 ona e st i wig ao Na 1967 za g Ex zu Tor a gt gt m H 2 oia EE 51 51 51 770 i i 55 0 9 0 9 0 9 wd 49 2 1 Qu Toc qi a 5 MoO 19 o_o 2 ese 0 o 592 AE i i MM ng ng i ng o i Ca n MB MS 5 A ss T a i M TL SES 1 an 1 425224221 202262 414 212086112020 j oo o E a 8 E 5 E a amp 5 amp a 2 P ag 5 o o LEFT FRONT TURN SIGNAL LIGHT 12V 21W POSITION LIGHT 12V 5W
105. HEEL SUSPENSION Apply grease to the needle rollers of new bearings 58 62mm Press in the bearing Carefully press the needle bearing in the pivot until the 0 23 0 24 in with the marked depth from the link outer surface is 5 8 6 2 mm 0 23 side facing up 0 24 in 4 2 TOOLS 2 3 14 2 Driver 07749 0010000 3 Attachment 22 x 24 mm 07746 0010800 4 Pilot 17 mm 07746 0040400 pe E 1 m sd dq 1 8 6 2 mm 52 0 23 0 24 in SWINGARM REMOVAL INSTALLATION Remove the following Rear wheel page 17 4 Drive chain guide page 17 12 Remove the shock arm to swingarm nut 1 washer 2 and bolt 3 Remove the screws 1 and brake hose guides 2 Remove the bolts 1 and drive chain case 2 17 10 REAR WHEEL SUSPENSION Remove the swingarm pivot nut 1 1 Remove the swingarm pivot bolt 2 then remove the u swingarm from the frame My Remove the swingarm dust seal caps 1 Installation is in the reverse order of removal Apply thin coat of grease to the pivot bolt outer surface Apply grease to the dust seal cap lips and fill the gap between the caps collar and needle bearings with grease Align the drive chain case slot with the swingarm hook Apply engine oil to the threads of shock arm to swingarm nut TORQUE Swingarm pivot nut 88 N m 9 0 kgf m 65 Ibf ft Shock arm to swingarm nut
106. HIFT LINKAGE Install the return spring 1 to the right crankcase cover by aligning the spring short end with the hole of the clutch lifter arm and long end with the groove of the right crankcase cover INSTALLATION Be careful not to Clean any gasket material from the mating surfaces of 7 5 7 damage the mating the right crankcase and cover surfaces Apply engine oil to new O rings 1 Install the collars 2 and O rings Install the dowel pin A 1 dowel pin B 2 and a new gasket 3 Be careful not to let Install the right crankcase cover 1 while turning the the return spring fall clutch lifter arm 2 clockwise to engage the lifter arm into the crankcase spindle groove with the lifter piece flange Install and tighten the bolts 3 in a crisscross pattern in 2 or 3 steps 12 8 CLUTCH CLUTCH GEARSHIFT LINKAGE Connect the water hose 1 and tighten the water hose band screw 2 page 9 7 Install the rear brake light switch holder 3 and tighten the bolt 4 Connect the clutch cable 1 to the clutch lifter arm 2 Install the clutch cable guide 3 and bolts 4 Tighten the bolts securely Install the following Brake pedal page 18 12 Frame guard page 2 6 Water pipe page 9 13 Adjust the clutch lever freeplay page 3 18 Fill the engine with the recommended engine oil page 3 9 Fill the recommended coolant and bleed the air page 9 5 REMOVAL Remov
107. HOW USE THIS MANUAL A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified professional technicians Attempting service or repairs without the proper training tools and equipment could cause injury to you or others It could also damage the vehicle or create an unsafe condition This manual describes the proper methods and procedures for performing service maintenance and repairs Some procedures require the use of specially designed tools and dedicated equipment Any person who intends to use a replacement part service procedure or a tool that is not recommended by Honda must determine the risks to their personal safety and the safe operation of the vehicle If you need to replace a part use Honda Genuine parts with the correct part number or an equivalent part We strongly recommend that you do not use replacement parts of inferior quality For Your Customer s Safety Proper service and maintenance are essential to the customer s safety and the reliability of the vehicle Any error or oversight while servicing a vehicle can result in faulty operation damage to the vehicle or injury to others AWARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed Follow the procedures and precautions in this manual and other service materials carefully For You
108. Hg 4 11 connector 700 hPa MAP sensor or its circuit malfunction ECT sensor circuit low voltage less than 0 078 V Hard start at a low temperature 7 1 7 ECT sensor or its circuit malfunction Pre program value 8092 1769 4 13 Cooling fan turns on ECT sensor circuit high voltage more than 4 922 V Hard start at a low temperature 4 30 7 2 7 Loose or poor contact of the ECT sensor Pre program value 80 C 1 76 F 4 11 connector Cooling fan turns on ECT sensor or its circuit malfunction TP sensor circuit low voltage less than 0 215 V Poor engine acceleration 8 1 8 Loose or poor contact of the sensor unit Pre program value 0 4 15 connector 4 32 TP sensor or its circuit malfunction 8 2 8 TP sensor circuit high voltage more than 4 922 V Poor engine acceleration 4 16 TP sensor or its circuit malfunction Pre program value 0 9 1 9 IAT sensor circuit low voltage less than 0 078 V Engine operates normally 4 18 IAT sensor or its circuit malfunction Pre program value 35 C 95 F IAT sensor circuit high voltage more than 4 922 V Engine operates normally 4 33 9 2 9 Loose or poor contact of the sensor unit Pre program value 35 C 95 F 4 18 connector IAT sensor or its circuit malfunction VS sensor malfunction Engine operates normally 11 1 Loose or poor contact of the VS sensor 1 connector ae VS sensor or its circuit malfunction 12 1 Injector circuit malfunction Engin
109. Line Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector 1 1 Turn the ignition switch ON and engine stop switch ry Measure the voltage at the ECM 33P Black connector of the wire side Connection White red Ground W R 07ZAJ RDJA110 Slowly turn the rear wheel by hand There should be 0 V to 5 V pulse voltage Is there 0 5 V pulse voltage YES Replace the ECM with a known good and recheck NO Open or short circuit in White red wire MIL 12 BLINKS INJECTOR NOTE Before starting the inspection check for loose or poor contact on the injector 2P Gray connector and recheck the MIL blinking ECM From ENGINE STOP SWITCH INJECTOR Probable cause Open circuit in Black blue wire between the engine stop switch and injector Open short circuit in Pink white wire between the injector and ECM Faulty injector Faulty ECM 4 36 1 Injector Input Voltage Inspection Turn the ignition switch OFF Disconnect the injector 2P Gray connector 1 page 7 14 Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P Gray connector of the wire side and ground Connection Black blue Ground Standard Battery voltage Does the standard voltage exist YES GO TO S
110. M TP SENSOR RESET PROCEDURE NOTE If the sensor unit is removed reset the throttle valve fully closed position as following 1 2 3 4 8 9 Erase the DTC page 4 5 Turn the ignition switch OFF Remove the dummy connector Short the DLC 1 using the special tool TOOL 2 SCS connector 070PZ ZY30100 Disconnect the ECT sensor 3P connector 1 Short the ECT sensor 3P connector terminals of the wire harness side with a jumper wire 2 Connection Yellow blue Green white Turn the ignition switch ON and engine stop switch then MIL will start blinking Disconnect the jumper wire while the MIL blinking within 10 seconds After disconnection of the jumper wire the MIL will start short blinking Check if the MIL blinks If the MIL begins short blink 0 3 seconds the TP sensor is reset successfully CTS within 10 sec 0 3 0 1 Ly eei MIC ON di MIL OFF RESET RECEIVING PATTERN SUCCESSFUL PATTERN If the MIL remains ON the TP sensor is not reset repeat the reset procedure from step 1 Turn the ignition switch OFF Connect the ECT sensor 3P connector 10 Install the dummy connector to the DLC 4 45 PGM FI SYSTEM ECT SENSOR Remove the ECT sensor while the engine is cold Wear insulated gloves and adequate eye protection Keep flammable materials away from the burner
111. NE INSPECTION NOTE Before starting the inspection check for loose or poor contact on the ECM 33P Black connector and recheck the MIL blinking ENGINE DOES NOT START MIL does not blink 1 ECM Power Input Voltage Inspection Disconnect the ECM 33P Black connector 1 1 page 4 50 1 Turn the ignition switch and engine stop switch Measure the voltage at the ECM 33P Black connector of the wire side and ground Connection Black blue Ground Standard Battery voltage TOOL Test probe 07ZAJ RDJA110 Does the standard voltage exist YES GOTO STEP 2 NO Open circuit in Black blue wire Faulty ignition switch Blown main fuse 30 A Blown FI IGN fuse 10 Faulty engine stop switch 2 Sensor Unit Power Line Inspection Turn the ignition switch OFF Check for continuity between the ECM 33P Black connector 1 of the wire side and ground lE Connection Yellow red Ground 1 TOOL Test probe 07ZAJ RDJA110 Y R Is there continuity YES Short circuit in Yellow red wire GOTO STEP 3 ECM Ground Line Inspection Turn the ignition switch OFF Check for continuity between the ECM 33P Black connector 1 of the wire side and ground G TE Connection Green black Ground 90 iii 1 Green Ground COE ur Green Ground G TOOL
112. NT BALANCER TRANSMISSION BEARING Remove the following Crankshaft page 14 6 Balancer shaft page 14 14 Transmission page 14 10 RIGHT CRANKCASE SIDE Remove the bolts 1 and mainshaft bearing setting plate 2 Drive out the mainshaft bearing 3 shift drum bearing 4 and balancer shaft bearing 5 Remove the countershaft bearing 1 using the special tools TOOLS 2 Bearing remover set 17 mm 07936 3710300 Remover handle 07936 3710100 3 Remover weight 07741 0010201 14 15 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Drive in new bearings into the right crankcase until they are fully seated using the special tools TOOLS 1 Mainshaft bearing marked side facing up 2 Driver 07749 0010000 3 Attachment 52 x 55 mm 07746 0010400 4 Pilot 20 mm 07746 0040500 5 Countershaft bearing sealed side facing down Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 17 mm 07746 0040400 6 Shift drum bearing marked side facing up Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 After installation apply engine oil to each bearing rotating area Drive in a new balancer shaft bearing into the right 3 4 crankcase until it is fully seated using the special tools TOOLS CU 1 Balancer shaft bearing marked side facing up 2 Driver 07749 0010000 3 Attachment 42 x 47 mm 07746 0010300 4 Pilot 20 mm 07746 0040500
113. ON sasssnssussusasssussunsenssussuassausenss 4 2 PGM FI TROUBLESHOOTING INFORMATION 4 4 POSITION LIGHT sasssussussasaussussussensessususaussussussanssuscuscunsen 20 3 PRESSURE RELIEF VALVE 8 7 PRIMARY DRIVE GEAR 12 17 RADIATOR COOLANT 3 11 RADIATOR RESERVE TANK sussussassansussuasassssssusuusessous 9 12 RADIATOR COOLING FAN sassnssassassansuassuseussussussenssussunee 9 6 REAR BRAKE CALIPER sasssssusssssenscussussenssassuncunsessunses 18 11 REAR FENDER sasssssasssssanssussussensuassuscussussauseussusseusuussansens 2 7 REAR LOWER FENDER sasssusaussaseussassussanssussussenscussusseusen 2 9 REAR MASTER CYLINDER sassassenssassunssnsussuusanssussussensen 18 8 REAR UPPER FENDER sassassanssansuseusssansuscussussuARSuSuasssunsans 2 8 REAR WHEEL sassnssasssssenssansuscussussanscussussenssussassenseuseuseuse 17 4 REGULATOR RECTIFIER sassassanssussussussusssusaussuscuscunsussn 19 6 RESERVE TANK COVER 2 4 RIGHT CRANKCASE COVER 12 4 ARM 10 11 SEAT sassanssussansuseussussasscussussenscussuascuscussussenssussussenseuseuseunson 2 3 SECONDARY AIR SUPPLY SYSTEM FUEL SYSTEM sasssnssssussaussassuassanssuscunsenssassuscunseuseusenes 7 17 MAINTENANCE 3 11 SENSOR UNIT sassussasssssenssasausesssussessenssascuscunssaseuseussensens 4 44 SENSOR UNIT POWER LINE INSPECTION 4 8 SERVICE INFORMATION ALTERNATOR STARTER CLUTCH 13 2 BATTERY CHARGING SYSTEM sasssunanssassussanssuseus
114. ORQUE 4 2 N m 0 4 kgf m 3 1 Ibf ft INSPECTION Check the cam chain tensioner lifter 1 operation The cam chain tensioner lifter shaft should not go into the cam chain tensioner lifter body when it is pushed When it is turned clockwise with a tensioner stopper or a screwdriver 2 the cam chain tensioner lifter shaft should be pulled into the cam chain tensioner lifter body The cam chain tensioner lifter shaft should spring out of the cam chain tensioner lifter body as soon as the stopper tool is released 11 7 12 CLUTCH GEARSHIFT LINKAGE SERVICE 12 2 12 2 COMPONENT LOCATION 12 3 RIGHT CRANKCASE COVER 12 4 CRUTCH ie Gaia 12 9 GEARSHIFT 12 14 PRIMARY DRIVE 12 17 12 1 CLUTCH GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL This section covers service of the clutch and gearshift linkage All services can be done with the engine installed in the frame Engine oil viscosity and level have an effect on clutch disengagement Oil additives also effect clutch performance and are not recommended When the clutch does not disengage or the motorcycle creeps with the clutch lever pulled in inspect the engine oil level before servicing the clutch system T
115. R HEAD VALVES CYLINDER PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR STARTER CLUTCH CRANKCASE CRANKSHAFT TRANSMISSION BALANCER ENGINE REMOVAL INSTALLATION FRONT WHEEL SUSPENSION STEERING REAR WHEEL SUSPENSION BRAKE SYSTEM BATTERY CHARGING SYSTEM LIGHTS METERS SWITCHES WIRING DIAGRAM INDEX SERVICE RULES nnne 1 2 MODEL IDENTIFICATION 1 2 SPECIFICATIONS sists 1 4 TORQUE VALUES 1 9 1 GENERAL INFORMATION LUBRICATION amp SEAL POINTS 1 15 CABLE amp HARNESS ROUTING 1 17 EMISSION CONTROL SYSTEMS 1 27 GENERAL INFORMATION SERVICE RULES 1 Use genuine Honda or Honda recommended parts and lubricants or their equivalents Parts that do not meet Honda s design specifications may cause damage to the motorcycle Use the special tools designed for this product to avoid damage and incorrect assembly Use only metric tools when servicing the motorcycle Metric bolts nuts and screws are not interchangeable with English fasteners Install new gaskets O rings cotter pins and lock plates when reassembling When tightening bolts or nuts begin with the larger diameter or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is speci
116. RAKE SYSTEM DISASSEMBLY ASSEMBLY Disassemble and assemble the rear brake caliper as following illustration RETAINER BRACKET PIN BOOT DUST SEAL is G PISTON SEAL cen VALVE v 5 4 N m 0 6 4 0 Ibf ft 2 CALIPER BODY A Sn S LF J STOPPER RING fe CALIPER BRACKET SZ BRAKE PADS PAD wa 17 2 N m 1 8 kgf m e CALIPER PISTON e D 13 Ibf ft PAD SPRING BRACKET PIN BOOT PAD PIN PLUG INSPECTION Check the following parts for scoring scratches deterioration or damage Caliper cylinder Caliper piston Measure the parts according to BRAKE SYSTEM SPECIFICATIONS page 1 8 and replace if necessary BRAKE PEDAL REMOVAL INSTALLATION Remove the following Brake light switch return spring 1 Brake pedal return spring 2 18 12 BRAKE SYSTEM Cotter pin 1 Joint pin 2 Brake rod joint 3 Stopper pin 4 Washer 5 Brake pedal 1 Dust seals 2 Installation is in the reverse order of removal Replace the dust seals and cotter pin with new ones Install the dust seals in shown direction Apply grease to the brake pedal pivot sliding surface and dust seal lips 18 13 19 BATTERY CHARGING SYSTEM SERVICE INFORMATION 19 2 54 0 ORE 19 4
117. ROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the freeplay Clutch lever too hard to pull in Damaged kinked or dirty clutch cable Improperly routed clutch cable Damaged clutch lifter mechanism Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle creeps with clutch disengaged Excessive clutch lever freeplay Clutch plate warped Engine oil level too high improper oil viscosity or additive used Loose clutch center lock nut Clutch slips Clutch lifter sticking Worn clutch discs Weak clutch springs No clutch lever freeplay Engine oil level too low or oil additive used Hard to shift Misadjusted clutch cable Damaged or bent shift fork Bent shift fork shaft Incorrect engine oil viscosity Bent or damaged gearshift spindle Damaged shift drum stopper plate Damaged shift drum guide grooves page 14 11 Transmission jumps out of gear Worn shift drum stopper arm Worn or broken gearshift spindle return spring Bent shift fork shaft Worn or damaged shift drum stopper plate Damaged shift drum guide grooves page 14 11 Worn gear dogs or dog holes page 14 11 Gearshift pedal will not return Weak or broken gearshift spindle return spring Bent gearshift spindle 12 2 CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 12 N m 1 2 kgf m 9 12 3 CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil page
118. S BOLTS FASTENERS Check that all chassis nuts screws and bolts are tightened to their correct torque values page 1 9 Check that all cotter pins safety clips hose clamps and cable stays are in place and properly secured MAINTENANCE 2 3 19 WHEELS TIRES Support the motorcycle using a safety stand or hoist raise the front wheel off the ground Hold the front fork leg and move the front wheel sideways with force to see if the wheel bearings are worn For front wheel service page 16 4 Support the motorcycle using a safety stand or hoist raise the rear wheel off the ground Hold the swingarm and move the rear wheel sideways with force to see if the wheel bearings are worn For rear wheel service page 17 4 Check the tire pressure with a tire pressure gauge when the tires are cold Fronttire page 1 8 Rear tire page 1 8 Check the tires for cuts embedded nails or other damage Check the front and rear wheels for trueness Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the service limits Fronttire page 1 8 Rear tire page 1 8 Inspect the wheel rims and spokes for damage Tighten any loose spokes to the specified torque using the special tool TOOL Spoke wrench 5 8 x 6 1 mm 07701 0020300 TORQUE 3 7 N m 0 4 kgf m 2 7 Ibf ft STEERING HEAD BEARINGS 3 20 Support th
119. SSION BALANCER CRANKCASE SEPARATION Refer to Service Information page 14 2 for removal of amp necessary parts before disassembling the crankcase Remove the tensioner pivot bolt 1 collar 2 and cam chain tensioner 3 Remove the cam chain 4 and timing sprocket 5 Check the cam chain tensioner 1 for excessive wear or damage replace it if necessary Install a 3 mm 0 12 in O D pin 1 into the hole 2 of the balancer driven gear assembly 3 Insert the gear holder 1 between the balancer drive gear 2 and balancer driven gear assembly 3 TOOL Gear holder M2 5 07724 0010100 Loosen the balancer shaft nut 4 Remove the nut washer 5 balancer driven gear assembly and balancer drive gear NOTE For balancer driven gear disassembly page 14 14 14 4 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Remove the woodruff key 1 from the balancer shaft Loosen the crankcase bolts 1 in a crisscross pattern in 2 or 3 steps and remove the bolts Place the crankcase assembly with the right crankcase down Do not pry the Carefully separate the left crankcase 1 from the right crankcase halves crankcase 2 while tapping them at several locations with a screwdriver with a plastic hammer Remove the dowel pins 1 and O ring 2 1 14 5 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER CRANKSHAFT REMOVAL Separate the crankcase halves page 14 4 Remove the crankshaft 1
120. STEM 3 MAP Sensor System Inspection 2 Turn the ignition switch OFF Disconnect the sensor unit 5P connector 1 Connect the sensor unit 5P connector terminals at the wire side with a jumper wire 2 Connection Light green black Green white Y Bu G W Probable cause Open or short circuit in Yellow blue wire between the ECT sensor and ECM Open circuit in Green white wire between the ECT sensor and ECM Faulty ECT sensor Faulty ECM 2 G W Lg BI Turn the ignition switch ON and engine stop switch Check the MAP sensor with the HDS pocket tester Is about 0 V indicated YES Faulty sensor unit MAP sensor 1 NO GOTO STEP 4 MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF Remove the jumper wire Disconnect the ECM 33P Black connector 1 Check the continuity between the ECM 33P Black connector and sensor unit 5P connector 2 of the wire side Connection Lg BI Light green black Light green black TOOL Test probe 07ZAJ RDJA110 Is there continuity 2 N YES Replace the ECM with a known good one and recheck circuit in Light green black wire DTC 7 ECT SENSOR NOTE Before starting the inspection check for loose or poor contact on the ECT sensor 3P connector and recheck the MIL blinking ECT SENSOR ECM
121. SYSTEM tle on ed 3 11 SECONDARY AIR SUPPLY SYSTEM hop ay SI 3 11 DRIVE CHAIN NOTE 4 EVERY 1 000 km 600 mi 3 12 l L DRIVE CHAIN SLIDER NOTE 4 KT 1 3 14 BRAKE FLUID NOTE 5 1 2YEARS 32 15 BRAKE PADS WEAR ete ei 3 16 5 5 1 3 17 BRAKE LIGHT SWITCH a a il 3 17 HEADLIGHT AIM Je se 3 18 CLUTCH SYSTEM 3 18 SIDESTAND 3 19 SUSPENSION 1 3 19 NUTS BOLTS FASTENERS NOTE 4 e desee ied 3 19 WHEELS TIRES NOTE 4 EVERY 6 000 km 3 20 4 000 mi STEERING HEAD BEARINGS 3 20 Should be serviced by a dealer unless the owner has proper tools service data and is mechanically qualified n the interest of safety we recommend these items be serviced only by a dealer Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out NOTES At higher odometer readings repeat the frequency interval established here Service more frequently when riding in unusually wet or dusty areas Service more frequently when riding in rain or at full throttle Service more frequently when riding OFF ROAD Replacement requires mechanical skill INSPECTION Remove the right fuel tank shroud page 2 4 Check the quick connect fitting 1 for looseness Check the fuel feed hose 2 for deterioration damage
122. TEP 2 NO Open circuit in Black blue wire Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector Check for continuity between the injector 2P Gray connector 1 of the wire side and ground Connection Pink white Ground Is there continuity YES Short circuit Pink white wire NO GOTO STEP 3 Injector Resistance Inspection Measure the resistance between the injector side connector 1 terminals Standard 11 13 20 C 68 F Is the resistance within 11 13 20 68 lt YES GO TO STEP 4 NO Faulty injector Injector Signal Line Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and injector 2P Gray connector 2 of the wire side Connection Pink white Pink white TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a known good one and recheck NO Open circuit Pink white wire PGM FI SYSTEM 1 T 1 rd a 1 1 2 P W P W 4 37 PGM FI SYSTEM MIL 21 BLINKS SENSOR NOTE Before starting the inspection check for loose or poor contact on the Oz sensor 1P Black connector or O2 sensor cap and recheck the MIL blinking O2 SENSOR r3 BI
123. V SENSOR UNIT 1 Y R G W Probable cause Open circuit in Yellow red wire between the sensor unit and ECM Open circuit in Green white wire between the sensor unit and ECM Faulty ECM Sensor Unit Power Input Voltage Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P connector 1 page 7 11 Turn the ignition switch ON and engine stop switch nen Measure the voltage at the wire harness side Connection Yellow red Green white Standard 4 75 5 25 V If the voltage within 4 75 5 25 V YES Turn the ignition switch OFF Connect the sensor unit connector and start the DTC troubleshooting page 4 10 NO GOTO STEP 2 Sensor Unit Input Voltage Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector 1 page 4 50 Check for continuity between the ECM 33P Black connector and sensor unit 5P connector 2 of the wire side Connection Yellow red Yellow red Green white Green white TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a know good one and recheck NO Open circuit in Yellow red wire ECM 1 1 Y R J G w ZA NW 9 Y R 2 HL L 1 5 9 9 4 3 1 PGM FI SYSTEM e Open circuit in Green white wire BEFORE MIL TROUBLESHOOTING NOTE When the MIL blinks 1 8
124. W ECM Probable cause Open or short circuit in Black white or Black wire between the O sensor and ECM Faulty O sensor Faulty ECM 1 Sensor System Inspection Start the engine and warm up the engine up to coolant temperature is 80 C 176 F Test ride the motorcycle and recheck the MIL blinking Does the MIL blink 21 times YES GO TO STEP 2 NO Intermittent failure 2 O Sensor Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 50 Disconnect the Oe sensor cap 1 page 4 47 Check for continuity between the O sensor cap terminal 2 and ground Connection O sensor cap terminal Ground Is there continuity YES NO Short circuit in Black or Black white wire GO TO STEP 3 4 38 1 2 3 O2 Sensor Open Circuit Inspection PGM FI SYSTEM Check for continuity between the ECM 33P Black connector 1 and O2 sensor cap terminal 2 of the wire side Connection O sensor cap terminal Black white TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GOTO STEP 4 NO Open circuit in Black or Black white wire 1 2 ss 9 BIW 4 O2 Sensor Inspection Replace the Oz sensor with a known good one page 4 47 Connect the ECM 33P Black connector Start the engine and warm up the engine up to coolant temperature is 80 C 176
125. a wire type feeler gauge 1 iridium center electrode use a wire type feeler gauge to check the spark plug gap Make sure that the 1 0 mm 0 039 in plug gauge does not insert between the gap Do not adjust f the gauge can be inserted into the gap replace the spark plug gap If plug with a new one the gap is out of specification replace with a new one VALVE CLEARANCE INSPECTION NOTE nspect and adjust the valve clearance while the engine is cold below 35 C 95 F After the valve clearance inspection check the engine idle speed page 3 10 nspection and adjustment can be done with the engine installed in the frame Remove the cylinder head cover page 10 4 Remove the timing hole cap 1 and crankshaft hole cap 2 TOOL Timing cap wrench 07709 0010001 Rotate the crankshaft counterclockwise and align the T mark 1 on the flywheel with the index notch 2 on the left crankcase cover MAINTENANCE Make sure that the outside index lines IN 1 and EX 2 marks on the cam sprockets are flush with the cylinder head top surface and facing outward as shown If the IN and EX marks are facing inward turn the crankshaft counterclockwise one full turn 360 and realign the T mark with the index notch Check the valve clearance by inserting a feeler gauge 1 between the rocker arm and shim VALVE CLEARANCE 0 16 0 03 mm 0 006 0 001 in EX 0 2
126. ack blue Ground Standard Battery voltage Is there battery voltage YES GO TO STEP 2 NO OOpencircuit in Black blue wire 1 4 41 PGM FI SYSTEM 4 42 2 Bank Angle Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 50 Check for continuity between the bank angle sensor 2P connector 1 of the wire side and ground Connection Red blue Ground Is there continuity YES Short circuit in Red blue wire NO GOTO Bank Angle Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF Check for continuity between the bank angle sensor 2P connector 1 and ECM 33P Black connector 2 of the wire side Connection Red blue Red blue TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GO TO STEP 4 NO Opencircuit in Red blue wire Bank Angle Sensor Inspection Replace the bank angle sensor with a known good one page 4 48 Connect the bank angle sensor 2P connector and 33P Black connector Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch Check if the MIL blinks Does the MIL blink 54 times YES Replace the ECM with a known good one and recheck NO original the bank angle sensor 1 R Bu R
127. aft Worn rocker arm and or shaft Worn rocker arm and valve stem end Worn cam sprocket teeth Worn and loose cam chain Worn or damaged cam chain tensioner Faulty cylinder piston or piston rings page 11 3 Rough idle Low cylinder compression Faulty fuel system 10 2 CYLINDER HEAD VALVES COMPONENT LOCATION lt 2 2 2 N x o 2 x i o 2 PN lt 2 o N 2 Em 4 2 N m 0 4 kgf m 3 1 Ibf ft 10 3 CYLINDER HEAD VALVES CYLINDER COMPRESSION Warm the engine to normal operating temperature Stop the engine Remove the spark plug page 3 5 Install the compression gauge 1 into the spark plug hole Turn the ignition switch ON and engine stop switch G Shift the transmission into neutral To avoid Open the throttle all the way and crank the engine with discharging the the starter motor until the gauge reading stops rising battery do not STANDARD le the start motor for more than 1 294 KPa at 490 rpm 13 2 kgf cm 188 psi 7 seconds ow compression can be caused by Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston ring or cylinder High compression can be caused by Carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL Remove the following 11 2 Spar
128. and ECM 6 Faulty sidestand switch or neutral switch or related wires 7 Faulty CKP sensor Measure peak voltage 8 Faulty ECM in case when above No 1 through 7 are normal Initial voltage is normal but there is no 1 Incorrect peak voltage adaptor connections peak voltage while cranking the 2 Faulty peak voltage adaptor engine 3 Faulty CKP sensor 4 Faulty ECM in case when above No 1 through 3 are normal Initial voltage is normal but peak 1 The multimeter impedance is too low below 10 MO DCV voltage is lower than the standard 2 Cranking speed is too slow Battery is undercharged value 3 The sampling timing of the tester and measured pulse were not synchronized System is normal if measured voltage is over the standard voltage at least once 4 Faulty ECM in case when above No 1 through 3 are normal Initial and peak voltages are normal 1 Faulty spark plug or leaking ignition coil secondary current but no spark jumps 2 Faulty ignition coil CKP sensor Peak voltage is lower than standard 1 The multimeter impedance is too low below 10 MO DCV value 2 Cranking speed is too low Battery is undercharged 3 The sampling timing of the tester and measured pulse were not synchronized System is normal if measured voltage is over the standard voltage at least once 4 Faulty CKP sensor in case when above No 1 through 3 are normal No peak voltage 1 Faulty peak voltage adapter 2 Faulty CKP sensor
129. and right drive chain adjuster plate 4 Push the wheel forward and derail the drive chain 1 from the driven sprocket Support the caliper Remove the following so it does not hang Axle 2 from the brake Left chain adjuster plate 3 hose Do not twist _ Rear wheel the brake hose _ Side collars 4 NOTE Do not operate the brake pedal after removing the wheel To do so will cause difficulty in fitting the brake disc between the brake pads Remove the rear brake caliper bracket 1 from the guide rail 2 of the swingarm Install the rear wheel in the reverse order or removal Apply thin coat of grease to the axle outer surface Adjust the drive chain slack page 3 12 INSPECTION Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Replace the bearings if they do not turn smoothly quietly or if they fit loosely in the hub Inspect the following parts for damage abnormal wear deformation looseness or bend Rear axle Spoke Wheel rim Measure each part according to REAR WHEEL SUSPENSION SPECIFICATIONS page 1 8 Replace any part if it is out of service limit 17 4 REAR WHEEL SUSPENSION DISASSEMBLY ASSEMBLY Disassemble and assemble the rear wheel as following illustration BEARING 63080 BRAKE DISC por ro lt 42
130. ange Connect the throttle cables 2 to the throttle pipe Insert the handlebar 3 into the throttle pipe Install the handlebar and upper holders 1 with the punch marks 2 facing forward Install the bolts 3 tighten the front bolts first then tighten the rear bolts securely Install the throttle housing cover 1 by aligning its boss with the hole of the handlebar Install the screws 2 tighten the upper screw first then tighten the lower screw S Check the throttle grip for smooth operation 2 1 2 Install the right handlebar switch cover 1 by aligning its boss with the hole of the handlebar 16 19 FRONT WHEEL SUSPENSION STEERING Install and tighten the upper screw 1 first then tighten 1 the lower screw 2 the specified torque 1 TORQUE 2 5 N m 0 3 kgf m 1 8 Ibf ft 2 If the left handlebar grip 1 was removed apply Honda Bond A or equivalent to the inside surface of the grip and to the clean surface of the handlebar 3 Allow the adhesive Wait 3 5 minutes and install the grip Rotate the grip to dry for 1 hour for even application of the adhesive before using Position the handlebar grip so that the projection 2 of the grip is aligned with the punch mark 3 of the handlebar Install the left handlebar switch cover 1 by aligning its boss with the hole of the handlebar Install and tighten the upper screw 1 first then tighten the lowe
131. ap make sure the master cylinder reservoir is horizontal first A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Always use fresh DOT 3 or 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 Never allow contaminants dirt water etc to enter an open reservoir Once the hydraulic system has been opened or if the brake feels spongy the system must be bled Always check brake operation before riding the motorcycle TROUBLESHOOTING Brake lever pedal soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pad disc Worn caliper piston seal Worn master cylinder piston cups Worn brake pad disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped deformed brake disc Sticking worn caliper piston Sticking worn master cylinder piston Bent brake lever pedal Brake lever pedal hard Clogged restricted brake system Sticking worn caliper piston Sticking worn master cylinder piston Caliper not sliding properly Warped deformed brake disc Bent brake lever pedal Brake drags Contaminated brake pad disc Misaligned wheel Badly worn brake pad disc Warped deformed brake disc Caliper not sliding properly Clogged restricted fluid passage
132. ar 5 and cam chain tensioner pivot bolt Tighten the cam chain tensioner pivot bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7 Install the removed parts page 14 2 in the reverse order of removal 14 21 15 ENGINE REMOVAL INSTALLATION SERVICE 15 2 ENGINE REMOVAL 15 4 COMPONENT 15 3 ENGINE 15 7 15 1 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION GENERAL When removing installing the engine tape the frame around the engine beforehand for frame protection When installing the engine be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence If you make mistake in torque or sequence loosen all mounting fasteners then tighten them again to the specified torque in the correct sequence The following components can be serviced with the engine installed in the frame Oil pump page 8 4 Throttle body page 7 11 Camshaft page 10 6 Water pump page 9 8 Clutch page 12 9 Gearshift linkage page 12 14 Stator CKP sensor page 13 4 Flywheel page 13 5 Starter motor page 6 4 The following components require engine removal for service Cylinder head valves page 10 13 Cylinder piston page 11 3 Cranks
133. ation 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 damage the throttle body It may cause incorrect throttle valve operation Seal the intake ports with tape or a clean cloth to keep dirt and debris from entering the engine after the throttle body has been removed Prevent dirt and debris from entering the throttle bore and air passages after the throttle body has been removed Clean them using a compressed air if necessary Do not loosen or tighten the white painted nut and screw of the throttle body Loosening or tightening them can cause throttle valve and idle control failure Forfuel level sensor inspection page 20 15 Before disconnecting the fuel feed hose relieve fuel pressure from the system by disconnecting the quick connect fitting from the system page 7 4 TROUBLESHOOTING Engine won t start Deteriorated fuel Bent or kinked fuel hose fuel tank breather hose Clogged fuel filter Faulty fuel pump or its drive circuit Intake air leak Faulty injector Faulty IACV Faulty ignition system Faulty ECM Faulty bank angle sensor or its related circuit Faulty fuel pump relay or its related circuit Faulty engine stop switch or its related circuit Blown FI IGN fuse 10 A Engine stall hard to start rough idling Deteriorated fuel Bent or kinked fuel hose fuel tank breather hose Faulty IACV I
134. ator 1 comes ON If the high coolant temperature indicator blinks follow the PGM FI troubleshooting for ECT sensor page 4 30 If the high coolant temperature indicator does not come ON at all or remains ON inspect as follows Remove the reserve tank cover page 2 4 Turn the ignition switch OFF Disconnect the ECM 33P Black connector 1 Turn the ignition switch ON and engine stop switch Q Check that the high coolant temperature indicator remains OFF f the indicator comes ON check for short circuit in the Green blue wire between the speedometer and f the wire is OK replace the speedometer with known good one and recheck Turn the ignition switch OFF Ground the following terminal of the wire harness side ECM Black connector 1 with a jumper wire 2 CONNECTION Green blue Ground TOOL Test probe 07ZAJ RDJA110 Turn the ignition switch and engine stop switch Cz the high coolant temperature indicator should come on f the indicator does not come ON check for open circuit in the Green blue wire between the speedometer and ECM f the indicator comes on with the Green blue wire grounded but does not come ON with the ECM 33P Black connector connected replace the ECM with a known good one and recheck LIGHTS METERS SWITCHES IGNITION SWITCH INSPECTION Remove the headligh
135. ays with the shock rubber Remove the starter relay switch from the shock rubber Installation is in the reverse order of removal NEUTRAL DIODE INSPECTION Remove the left side cover page 2 3 Open the fuse box cover and remove the neutral diode 1 Check for continuity between the neutral diode terminals When there is continuity a small resistance value will register If there is continuity in direction shown by the arrow the neutral diode is normal SERVICE 7 2 7 2 COMPONENT LOCATION 7 3 FUEL LINE 7 4 FUEL TANK cts 7 8 FUEL PUMP UNIT eere 7 8 7 FUEL SYSTEM FUEL PUMP 7 10 AIR CLEANER HOUSING 7 10 THROTTLE BODY RnRIAEAMSHsswsl 7 11 INJECTOR cseteris Ron be a escas 7 14 er SOR ia 7 15 SECONDARY AIR SUPPLY SYSTEM 7 17 7 1 FUEL SYSTEM 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 Do not snap the throttle valve from full open to full close after the throttle cable has been removed It may cause incorrect idle oper
136. baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper maintenance Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer PON gt 1 29 2 FRAME BODY PANELS EXHAUST SYSTEM SERVICE INFORMATION 2 2 2 2 2 3 SIDE COVER 2 3 RESERVE TANK COVER 2 4 FUEL TANK SHROUD 2 4 SKID 4 4442 22 2 5 HEADLIGHT COWL enn 2 5 FRONT FENDER nnnnn 2 5 FRAME GUARD nnn 2 6 DRIVE SPROCKET 2 6 DRIVE CHAIN COVER U TYPE ONLY 2 6 TOOL BOX cene ee testis 2 7 REAR FENDER eere 2 7 REAR UPPER 2 8 TAIL COVER LIGHT UNIT ee 2 8 REAR LOWER 2 9 EXHAUST PIPE MUFFLER 2 11 SUB FRAME 2 12 lt 2 14 2 1 FRAME BODY PANELS EXHAUST SYSTEM SERVICE INFORMATION GENERAL This section covers removal and installation of the body panels sub frame and ex
137. connector 070PZ ZY30100 3 Turn the ignition switch ON and engine stop switch C7 4 Remove the special tool from the DLC 5 The MIL will light for approximately 5 seconds While the MIL lights 4 short the DLC terminals again with the special tool The self diagnostic memory is erased if the MIL goes off and starts blinking NOTE The DLC must be jumped while the MIL lights If not the MIL will not start blinking Note that the self diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking 4 5 PGM FI SYSTEM CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR Always clean around and keep any foreign material away from the ECM 33P Black connector before disconnecting it faulty PGM FI system is often related to poorly connected or corroded N NS terminals Check those connections before proceeding In testing at ECM 33P Black connector wire harness side terminal always use the test probe 1 Insert the test probe into the connector terminal then attach the digital multimeter probe to the test probe TOOL 1 Test probe 07ZAJ RDJA110 1 PGM FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms check the MIL blinking refer to the MIL code index page 4 7 and begin the appropriate troubleshooting procedure If there are MIL blinking stored in the ECM memory do the diagnostic procedure for the symptom
138. ctor Disconnect the sensor unit 5P connector 1 Turn the ignition switch ON and engine stop switch Lae Measure the voltage at the sensor unit 5P connector of the wire side Connection Yellow red Green white Standard 4 75 5 25 V Is the voltage within 4 75 5 25 V YES Replace the ECM with a known good one and recheck Open circuit in Green white wire Open circuit Yellow red wire DTC 9 IAT SENSOR SENSOR UNIT IAT SENSOR Gr Bu PGM FI SYSTEM Y G W 1 1 an YR r L 4 G W G W Probable cause Open or short circuit in Gray blue wire between the sensor unit and ECM Open circuit in Green white wire between the sensor unit and ECM Faulty sensor unit Faulty ECM ECM 4 17 PGM FI SYSTEM DTC 9 1 IAT SENSOR LOW VOLTAGE 1 IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch Lae Check the IAT sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 2 Intermittent failure 2 IAT Sensor Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P connector Turn the ignition switch ON and engine stop switch Check the IAT sensor with the HDS pocket tester Is about 0 V indicated YES GOTO STEP 3 NO Faulty sensor unit IAT sensor 3 IAT Sensor Voltage Input Lin
139. ctor 1 En Turn the ignition switch ON and engine stop switch gt Lee Measure the voltage between the injector 2P Gray BI Bu connector of the wire side and ground Connection Black blue Ground 9 Standard Battery voltage PA Does the standard voltage exist YES STEP NO or short circuit in Black blue wire 4 21 PGM FI SYSTEM 4 22 3 Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF Check for continuity between the injector 2P Gray connector 1 of wire side and ground Connection Pink white Ground Is there continuity YES Short circuit in Pink white wire NO GOTO STEP 4 Injector Resistance Inspection Measure the resistance between the injector 2P Gray connector 1 terminals Standard 11 13 20 68 F Is the resistance within 11 13 20 68 lt YES GOTOSTEP 5 NO Faulty injector Injector Signal Line Open Circuit Inspection Disconnect the ECM 33P Black connector 1 Check the continuity between the ECM 33P Black connector and injector 2P Gray connector 2 of the wire side Connection Pink white Pink white TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a known good one and recheck Open circuit in Pink white wire 1 1 code D 71 TN
140. d If there is continuity under following conditions the ground circuit is normal When the transmission is in neutral In neutral there is a slight resistance due to the diode When the transmission is in gear with the clutch lever pulled in and sidestand retracted STARTER RELAY INPUT VOLTAGE Connect the starter relay switch 4P Red connector 1 Turn the ignition switch ON and engine stop switch CZ Measure the voltage between the following terminal at the starter relay switch Red connector and ground CONNECTION Yellow red Ground STANDARD Battery voltage If the battery voltage appears only when the starter switch is pushed with the ignition switch ON and engine stop switch C the starter relay input voltage is normal ELECTRIC STARTER SYSTEM OPERATION CHECK Remove the starter relay switch page 6 9 Connect a fully charged 12 V battery to the starter relay switch as shown There should be continuity between the cable terminals when the battery is connected and no continuity when the battery is disconnected REMOVAL INSTALLATION Remove the left side cover page 2 3 4115 Disconnect the battery negative terminal page 19 4 Disconnect the starter relay switch 4P Red connector 1 Release the starter relay switch 2 from the air cleaner housing Pull back the rubber cover 3 Remove the bolts 4 and cables 5 Remove the starter relay switch from the st
141. d in the groove Sp BOOT Sw PIVOT BOLT Align 1 0 N m 0 1 kgf m 0 7 Ibf ft MASTER SEPARATOR PISTON SNAP RING SPRING 0 PASS STOPPER RING BRAKE LEVER MASTER CYLINDER PIVOT NUT LE BRAKE LIGHT SWITCH 5 9 N m 0 6 kgf m DUST COVER 4 4 Ibf ft 1 2 N m 0 1 kgf m 0 9 Ibf ft INSPECTION Check the following parts for scoring scratches deterioration or damage Master cylinder Master piston Piston cups Spring Boot Measure the parts according to BRAKE SYSTEM SPECIFICATIONS page 1 8 and replace if necessary REAR MASTER CYLINDER REMOVAL INSTALLATION Drain the brake fluid from the rear brake hydraulic system page 18 4 Release the reservoir hose 1 from the clamp 2 When removing the Remove the following oil bolt cover the p end of the hose to bolt 3 prevent contamination Sealing washers 4 Brake hose 18 8 BRAKE SYSTEM Cotter pin 1 Joint 2 Master cylinder mounting bolts 3 Snap ring 1 Hose joint 2 O ring 3 Rear master cylinder 4 Installation is in the reverse order of removal Replace the O ring master cylinder mounting bolts cotter pin and sealing washers with new ones Apply brake fluid to the joint O ring TORQUE Rear master cylinder mounting bolt 14 1 4 kgf m 10 Ibf ft Oil bolt 34 3 5 kgf m 25 Ibf ft Fill and bleed
142. der push rod lock nut 1 8 17 2 1 8 13 Front spoke 36 BC 3 2 3 7 0 4 2 7 Rear spoke 32 BC 3 2 3 7 0 4 2 7 PGM FI SYSTEM THREAD TORQUE ary DIA mm N m kgf m Ibf ft REMARKS Sensor unit torx screw 3 5 3 4 0 3 2 5 ECT sensor 1 12 5 2 5 18 sensor 1 12 5 2 5 18 Bank angle sensor mounting nut 2 6 0 0 9 6 6 1 10 IGNITION SYSTEM GENERAL INFORMATION THREAD TORQUE DIA mm N m kgf m Ibf ft REMARKS Timing hole cap 1 14 6 0 0 6 4 4 Apply engine oil to the threads ELECTRIC STARTER TORQUE DIA N m kgf m Ibf ft REMARKS Negative brush screw 5 3 7 0 4 2 7 Starter motor assembly bolt 5 4 9 0 5 3 6 FUEL SYSTEM THREAD TORQUE QTY DIA mm N m kgf m Ibf ft REMARKS Fuel pump mounting nut 6 6 12 1 2 9 For tightening sequence page 7 9 Air cleaner housing mounting bolt 3 6 7 0 0 7 5 2 Insulator band screw 2 5 4 2 0 4 3 1 See page 7 13 Air cleaner connecting hose band screw 1 4 1 5 0 2 1 1 Throttle cable stay screw 2 5 3 4 0 3 2 5 Clamp stay screw 1 5 3 4 0 3 2 5 Throttle cable A joint nut grip side 1 10 1 5 0 2 1 1 Throttle cable B joint nut grip side 1 12 1 5 0 2 1 1 Throttle cable B nut throttle body side 1 6 3 0 0 3 2 2 Injector joint
143. e Short Circuit Inspection Check for continuity between the sensor unit 5P 1 connector 1 of the wire side and ground m Connection Gray blue Ground Is there continuity L YES Short circuit in Gray blue wire eT NO Replace the ECM with a known good one and recheck DTC 9 2 IAT SENSOR HIGH VOLTAGE 1 IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the IAT sensor with the HDS pocket tester Is about 5 V indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the sensor unit 5P connector 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 8 Is the sensor unit power line normal YES GOTO STEP 3 NO Replace or repair the abnormal circuit 4 18 3 IAT Sensor Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P connector 1 Connect the IAT sensor terminals at the wire side with a jumper wire 2 Connection Gray blue Green white Turn the ignition switch ON and engine stop switch Check the IAT sensor with the HDS pocket tester Is about 0 V indicated YES Faulty sensor unit IAT sensor STEP 4 IAT Sensor Voltage Input Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector 1 Check for continuity between the ECM 33P Black connector and sensor unit 5P connector 2 of the
144. e Vehicle Identification Number V I N 1 is stamped on the right side of the steering head The throttle body identification number 1 is stamped on the lower left side of the throttle body The engine serial number 1 is stamped on the lower left side of the crankcase The Registered Number Plate except U type Compliance plate U type 1 is stamped on the left front side of the steering head The color label 1 is attached on the frame behind rear brake master cylinder reservoir When ordering color coded parts always specify the designated color code 1 GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2 195 mm 86 4 in Overall width 815 mm 32 1 in Overall height 1 195 mm 47 0 in Wheelbase 1 445 mm 56 9 in Seat height 875 mm 34 4 in Footpeg height 365 mm 14 4 in Ground clearance 255 mm 10 0 in Curb weight 143 kg 315 Ibs Maximum weight capacity 159 kg 351 Ibs FRAME Frame type Twin tube Front suspension Telescopic fork Front axle travel 222 mm 8 7 in Rear suspension Swingarm Rear axle travel 240 mm 9 4 in Tire size Front 3 00 21 51P Rear 120 80 18M C 62P Tire brand Front GP 21F Z IRC Rear GP 22R IRC Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 27935 Trail le
145. e careful not to Remove the woodruff key 2 damage the key groove and crankshaft 13 5 ALTERNATOR STARTER CLUTCH INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Replace if necessary Starter reduction gear shaft Starter reduction gear Woodruff key Needle bearing INSTALLATION Apply molybdenum oil solution to the needle bearing 1 rotating area Install the needle bearing onto the crankshaft Clean any oil from the crankshaft taper surface Be careful not Install the woodruff key 2 onto the crankshaft damage the key groove and crankshaft Install the flywheel while aligning the woodruff key on the crankshaft with flywheel keyway A Apply engine oil to the flywheel bolt 1 threads and seating surface Install the washer 2 and bolt Hold the flywheel with a special tool and tighten the bolt to the specified torque TOOL 3 Flywheel holder 07725 0040001 TORQUE 128 N m 13 1 kgf m 94 Ibf ft 13 6 ALTERNATOR STARTER CLUTCH Apply molybdenum oil solution to the starter reduction gear shaft 1 outer surface and starter reduction gear 2 inner surface Install the shaft and starter reduction gear Install the left crankcase cover page 13 3 STARTER CLUTCH REMOVAL Remove the flywheel page 13 5 Make sure that the starter driven gear 1 turns counterclockwise smoothly and does turn clockwise Remov
146. e chain 1 with a chain cleaner designed specifically for O ring chains or a neutral detergent Use a soft brush if the drive chain is dirty Do not use a steam cleaner high pressure cleaner wire brush volatile solvent such as gasoline and benzene abrasive cleaner or a chain cleaner NOT designed specifically for O ring chains to clean the drive chain Inspect the drive chain for possible damage or wear Replace any drive chain that has damaged rollers loose fitting links or otherwise appears unserviceable Be sure the drive chain has dried completely before lubricating Lubricate the drive chain with drive chain lubricant 2 designed specifically for use with O ring chains 80 90 gear oil or equivalent Do not use a chain lubricant NOT designed specifically for use with O ring chains to lubricate the drive chain Wipe off the excess oil or drive chain lubricant MAINTENANCE 113 2 3 13 MAINTENANCE SPROCKET INSPECTION Remove the drive sprocket cover page 2 6 Inspect the drive and driven sprocket teeth for wear or 4 damage replace if necessary Never use a new drive chain on worn sprockets Both chain and sprockets must be in good condition or new replacement chain will wear rapidly Check the attaching bolts and nuts on the drive and driven sprockets If any are loose tighten them to the specified torque TORQUE Drive sprocket fixing plate bolt 1 1
147. e combustion chamber side of the cylinder head TOOL 1 Valve guide driver 07HMD ML00101 While the cylinder head is still heated take off a new valve guides 1 from the freezer Adjust the valve guide driver to the valve guide height and drive in the valve guide from the camshaft side TOOL 2 Valve guide driver 07743 0020000 SPECIFIED HEIGHT IN EX 13 8 14 0 mm 0 54 0 55 in Let the cylinder head cool to room temperature Ream a new valve guides TOOL 1 Valve guide reamer 4 5 mm 07HMH ML00101 NOTE Use cutting oil on the reamer during this operation Take care not to tilt or lean the reamer in the guide while reaming Otherwise the valves may be installed slanted causing oil leakage from the stem seal and improper valve seat contact This may prevent valve seat refacing Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise Clean the cylinder head thoroughly to remove any metal particles after reaming and reface the valve seat page 10 15 VALVE SEAT INSPECTION REFACING INSPECTION Clean the intake and exhaust valves thoroughly to remove carbon deposits Apply a light coat of Prussian Blue to the valve seats Tap the valve against the valve seat several times using a hand lapping tool 1 without rotating the valve to make a clear pattern Remove the valve and inspect the valve seat face width
148. e continuity YES Short circuit Yellow blue wire NO GOTO STEP 4 ECT Sensor Resistance Inspection Measure the resistance at the ECT sensor 1 terminals Standard 2 3 2 6 20 C 68 F Is the resistance within 2 3 2 6 20 C 68 F YES STEP 4 NO Faulty ECT sensor ECT Sensor Open Circuit Inspection Check for continuity between the ECM 33P Black connector 1 and ECT sensor 3P connector 2 of the wire side Connection Yellow blue Yellow blue Green white Green white TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a known good one and recheck Open circuit in Yellow blue wire Open circuit in Green white wire PGM FI SYSTEM 1 1 4 31 PGM FI SYSTEM MIL 8 BLINKS TP SENSOR 4 32 ECM SENSOR UNIT TP SENSOR 1 Y R Probable cause Open circuit in Yellow red wire between the sensor unit and ECM Open or short circuit in Yellow wire between the sensor unit and ECM Open circuit in Green white wire between the sensor unit and ECM Faulty sensor unit Faulty ECM Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 8 Is the sensor unit power line normal YES GO TO STEP 2 NO Replace or repair the abnormal circuit TP Sensor Output Line Short
149. e does not start 12 Loose or poor contact of the injector connector Injector fuel pump and ignition 4 21 4 36 Injector or its circuit malfunction coil shut down 21 1 Oe sensor malfunction Engine operates normally 21 Loose or poor contact of the sensor connector 4 23 4 38 sensor or its circuit malfunction 29 1 IACV circuit malfunction Stalls hard to start 29 Loose or poor contact of the IACV connector rough idling 4 24 4 39 or its circuit malfunction 33 2 ECM EEPROM malfunction Engine operates normally 4 26 Bank angle sensor circuit low voltage less than Engine operates normally 54 1 0 35 V Bank angle sensor does not 54 Bank angle sensor or its circuit malfunction operate 4 27 The engine keeps running when the vehicle falls 4 41 Bank angle sensor circuit high voltage more than Engine operates normally 54 2 4 5 V Bank angle sensor does not 54 Loose or poor contact of the bank angle sensor operate 4 28 connector The engine keeps running Bank angle sensor or its circuit malfunction when the vehicle falls PGM FI SYSTEM SENSOR UNIT POWER LINE INSPECTION BEFORE DTC TROUBLESHOOTING NOTE When the DTC displays 1 1 1 2 8 1 8 2 9 1 and 9 2 check the following before DTC troubleshooting Before starting the inspection check for loose or poor contact on the sensor unit 5P connector and ECM 33P Black connector 5
150. e engine and let it idle IDLE SPEED 1 450 100 min rpm The ignition timing is correct if the F mark 2 on the flywheel aligns with the index notch 3 on the left crankcase cover Apply engine oil to a new O ring and install it to the timing hole cap Apply engine oil to the timing hole cap threads Install and tighten the timing hole cap to the specified torque TORQUE 6 0 N m 0 6 kgf m 4 4 Ibf ft IGNITION COIL REMOVAL INSTALLATION Disconnect the spark plug cap 1 Disconnect the primary wire connectors 2 from the ignition coil Release the spark plug wire 3 from the guides 4 on the fan motor shroud Remove the bolts 5 spacers 6 and ignition coil 7 Installation is in the reverse order of removal 6 ELECTRIC STARTER SYSTEM SERVICE INFORMATION 6 2 6 2 SYSTEM 6 3 SYSTEM DIAGRAM 6 3 STARTER MOTOR 6 4 STARTER RELAY SWITCH 6 8 NEUTRAL DIODE 6 9 ELECTRIC STARTER SYSTEM SERVICE INFORMATION GENERAL When servicing the starter system always follow the steps in the troubleshooting flow chart page 6 2 A weak battery may be unable to turn the starter motor quickly enough or su
151. e fasteners Wheel turns hard Faulty wheel bearings Bent axle Brake drag page 18 2 Soft suspension Weak fork springs Low fluid level in fork Wrong type of fluid in fork Low tire pressure Stiff suspension Bent fork pipes Fork pipe binds High fluid level in fork Incorrect fluid weight high viscosity Clogged fork fluid passage High tire pressure Front suspension noise Loose fork fasteners Worn slider or fork pipe bushing Low fluid level in fork 16 2 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 103 N m 10 5 kgf m 76 10 1 0 kgf m 7 Ibf ft 32 N m 3 3 kgf m 24 Ibf ft 10 N m 1 0 7 Ibf ft 20 N m 2 0 kgf m 15 Ibf ft 73 5 7 5 54 10 N m 1 0 7 7 0 N m 0 7 kgf m 5 2 Ibf ft 6 30 N m 3 1 kgf m 22 Ibf ft 16 3 FRONT WHEEL SUSPENSION STEERING FRONT WHEEL 16 4 REMOVAL INSTALLATION Raise the front wheel off the ground by placing a work stand or box under the frame Loosen the axle pinch bolts 1 on the right fork leg and remove the front axle 2 Remove front wheel and side collars 3 NOTE Do not operate the brake lever after removing the wheel To do so will cause difficulty in fitting the brake disc between the brake pads Apply thin coat of grease to the axle outer surface Install the side collars to the both sides of the wheel
152. e motorcycle using a safety stand or hoist raise the front wheel off the ground Check that the handlebar moves freely from side to side Make sure the control cables do not interfere with the handlebar rotation Check for steering stem bearings by grabbing the fork legs and attempting to move the front fork forward to backward If the handlebar moves unevenly binds or has vertical movement inspect the steering head bearings page 16 21 SERVICE 4 2 PGM FI SYSTEM 4 2 PGM FI SYSTEM 4 3 PGM FI TROUBLESHOOTING INFORMATION enne 4 4 PGM FI SYMPTOM 4 6 4 7 SENSOR UNIT POWER LINE INSPECTION ern 4 8 4 PGM FI SYSTEM DTC TROUBLESHOOTING 4 10 MIL TROUBLESHOOTING 4 29 MIL CIRCUIT TROUBLESHOOTING 4 43 SENSOR UNIT 4 44 ECT SENSOR 4 46 On SENSOR aks 4 47 BANK ANGLE 4 48 can sus dud nlc naan 4 49 4 1 PGM FI SYSTEM SERVICE INFORMATION GENERAL A faulty PGM FI system is often related to poorly connected or corroded connectors Check those connections before proceeding
153. e oil pump clearances according to LUBRICATION SYSTEM SPECIFICATIONS page 1 5 If any of the measurement is out of the service limit replace the oil pump as an assembly 8 5 LUBRICATION SYSTEM ASSEMBLY OIL PUMP BODY O RING g DOWEL PINS OIL PUMP COVER OIL PUMP DRIVEN GEAR ROTOR LOCK PIN OIL PUMP SHAFT i OUTER ROTOR WASHER OIL PUMP ASSEMBLY BOLT OIL PUMP MOUNTING BOLTS INSTALLATION Install the dowel pins 1 Apply engine oil to a new O ring 2 Install the O ring to the oil pump assembly 3 Install the oil pump assembly while aligning its slit with cam chain guide hook and its hole with the pressure relief valve Install and tighten the oil pump mounting bolts 1 If the oil pump was disassembled tighten the oil pump 7 assembly bolt 2 LUBRICATION SYSTEM Apply engine oil to the oil pump driven gear 1 teeth Install the oil pump driven gear while aligning the flats of the oil pump driven gear and oil pump shaft Install the right crankcase cover page 12 8 PRESSURE RELIEF VALVE REMOVAL INSTALLATION Remove the oil pump page 8 4 Remove the oil pressure relief valve 1 and O rings 2 Apply engine oil to new O rings Install the O rings to the oil pressure relief valve grooves Install the oil pressure relief valve into the right crankcase with the piston side facing outside Install the oil pump page 8 6 PRESSURE RELIEF VALVE INSP
154. e several times Recheck the valve clearance Install the cylinder head cover page 10 5 Apply engine oil to new O rings 1 and install them to each hole cap Apply engine oil to timing hole cap 2 and crankshaft hole cap 3 threads Install and tighten the timing hole cap and crankshaft hole cap to the specified torque TOOL Timing cap wrench 07709 0010001 TORQUE Timing hole cap 6 0 N m 0 6 kgf m 4 4 Ibf ft Crankshaft hole 8 0 0 8 kgf m 5 9 Ibf ft MAINTENANCE ENGINE OIL OIL LEVEL INSPECTION Hold the motorcycle in an upright position Start the engine and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes Check the oil level through the inspection window oil filler cap 2 and fill the crankcase with the recommended oil up to the upper level line 3 RECOMMENDED ENGINE OIL Honda 4 stroke motorcycle oil or an equivalent API classification SG or higher except oils labeled as energy conserving on the circular API service label Viscosity SAE 10W 30 JASO T 903 standard MA Check that the O ring 4 is in good condition replace it if necessary Apply engine oil to the O ring Install the oil filler cap ENGINE OIL CHANGE Warm up the engine Stop the engine and remove the oil filler cap 1 Place an oil pan under the engine to catch the engine oil then remove the engine oil drain bolt 1 sealing washer 2 Drain the engine oil co
155. e shift drum holes Install the shift drum stopper plate 3 while aligning its pin holes 4 with the dowel pins Apply locking agent to the shift drum stopper plate bolt 1 threads Install and tighten the shift drum stopper plate bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Apply grease to a new gearshift spindle oil seal lip 1 Install the gearshift spindle oil seal to the specified depth as shown 0 5 1 0 mm 0 02 0 04 in 12 16 PRIMARY CLUTCH GEARSHIFT LINKAGE Apply engine to the gearshift spindle shaft 1 outer Align Install the gearshift spindle assembly and washer 2 to the crankcase by aligning the return spring ends with the spring pin Install the gearshift pedal 1 onto the gearshift spindle r while aligning the punch marks Install and tighten the pinch bolt 2 securely Install the following Clutch assembly page 12 11 Drive sprocket cover page 2 6 1 Qt DRIVE GEAR REMOVAL Remove the clutch assembly page 12 9 Temporarily install the washer 1 clutch outer guide 2 needle bearing 3 and clutch outer 4 Insert the gear holder 5 between the primary drive and driven gears TOOL Gear holder M1 5 07724 0010200 Loosen the primary drive gear lock nut 6 Remove the clutch outer needle bearing clutch outer guide and washer Remove the lock nut and wash
156. e the right crankcase cover page 12 4 1 2 Loosen the clutch lifter plate bolts 1 in a crisscross pattern in 2 or 3 steps Remove the clutch lifter plate bolts and clutch springs 2 Remove the clutch lifter plate 3 Remove the clutch discs 4 and plates 5 Remove the clutch lifter piece 1 judder spring 2 and spring seat 3 12 9 CLUTCH GEARSHIFT LINKAGE Unstake the clutch center lock nut 1 Hold the clutch center 1 with the special tool and loosen the clutch center lock nut 2 TOOL 3 Clutch center holder 07724 0050002 Remove the clutch center lock nut and washer 4 Remove the washer 1 and clutch outer 2 Remove the needle bearing 1 clutch outer guide 2 and washer 3 from the mainshaft 12 10 CLUTCH GEARSHIFT LINKAGE INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Replace if necessary Clutch lifter bearing Clutch springs Clutch center Clutch discs plates Clutch outer Clutch outer guide needle bearing Mainshaft Measure each part according to CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS page 1 7 Replace any part if it is out of service limit Replace the clutch springs as a set Replace the clutch discs and plates as a set CLUTCH LIFTER BEARING REPLACEMENT Drive out the old bearing from the clutch lifter plate 1 2 ns c 3 Drive in a n
157. e the starter driven gear while turning it counterclockwise Hold the flywheel with a special tool and remove the starter clutch socket bolt 1 2 TOOL 2 Flywheel holder 07725 0040001 Remove the starter clutch outer and starter one way clutch INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Replace if necessary Starter driven gear Measure each part according to ALTERNATOR STARTER CLUTCH SPECIFICATIONS page 1 7 Replace any part if it is out of service limit 13 7 ALTERNATOR STARTER CLUTCH INSTALLATION STARTER DRIVEN GEAR STARTER CLUTCH OUTER E STARTER ONE WAY CLUTCH FLYWHEEL Apply engine oil to the starter one way clutch 1 sprag Install the starter one way clutch to the starter clutch outer 2 Install the starter clutch assembly to the flywheel 3 as shown Apply locking agent to the starter clutch socket bolts 1 threads Install the starter clutch socket bolts Hold the flywheel with a special tool and tighten the socket bolts to the specified torque TOOL 2 Flywheel holder 07725 0040001 TORQUE 30 N m 3 1 kgf m 22 Ibf ft 13 8 ALTERNATOR STARTER CLUTCH Apply engine oil to the starter driven gear 1 sliding surface Install the starter driven gear while turning it counterclockwise Make sure that the starter driven gear turns counterclockwise smoothly and does turn clockwise I
158. ectifier SCR shorted triple phase full wave rectification Lighting system Battery PGM FI SYSTEM SPECIFICATIONS GENERAL INFORMATION ITEM SPECIFICATIONS Fuel injector resistance 20 C 68 F 11 130 IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATION Spark plug SIMR8A9 Spark plug 0 80 0 90 mm 0 031 0 035 Ignition coil peak voltage 100 V minimum CKP sensor peak voltage 0 7 V minimum Ignition timing F mark 10 BTDC at idle ELECTRIC STARTER SPECIFICATION Unit mm in ITEM STANDARD SERVICE LIMIT Starter motor brush length 11 8 12 3 0 46 0 48 6 5 0 26 FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number GQ32A Engine idle speed 1 450 100 min rpm Throttle grip freeplay 2 6 mm 0 08 0 24 in Fuel pressure at idle 343 kPa 3 5 kgf cm 50 psi Fuel pump flow at 12 V 83 cm 2 81 US oz 2 92 Imp oz minimum 10 seconds PAIR control solenoid valve resistance 20 C 68 F 20 240 LUBRICATION SYSTEM SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 1 4 liters 1 5 US qt 1 2 Imp qt At oil filter change 1 5 liters 1 6 US qt 1 3 Imp qt At disassembly 1 8 liters 1 9 US qt 1 6 Imp qt Recommended engi
159. ed hose 2 from the hose clamps 3 Disconnect the fuel tank breather hose 4 and remove the fuel tank Install the fuel tank in the reverse order of removal Connect the quick connect fitting page 7 5 FUEL PUMP UNIT SYSTEM INSPECTION Turn the ignition switch ON and engine stop switch C and confirm that the fuel pump operates for 2 seconds If the fuel pump does not operate inspect as follows Turn the ignition switch OFF Disconnect the fuel pump Black connector 1 Turn the ignition switch ON and engine stop switch Q Measure the voltage at the fuel pump 3P Black connector terminals of the wire side CONNECTION Brown red Green STANDARD Battery voltage There should be standard voltage for a few seconds 1 If there is standard voltage replace the fuel pump unit If there is no standard voltage inspect the following Main fuse 30 A FI IGN fuse 10 A Ignition switch page 20 11 Engine stop switch page 20 1 1 Fuel pump relay page 7 10 Open circuit Brown red or Green wire FUEL SYSTEM REMOVAL INSTALLATION NOTE Do not disassemble the fuel pump Remove the fuel tank page 7 8 Clean around the fuel pump Loosen the fuel pump mounting nuts 1 in a crisscross pattern in 2 or 3 steps and remove the nuts Remove the fuel pump unit 2 from the fuel tank being careful not to damage the fuel level sensor float arm Remove
160. emove it being careful not to damage the piston with the stud bolts NOTE Attach a piece of wire to the cam chain to prevent it from falling into the crankcase Do not tap the cylinder too hard and do not damage the mating surface with a screwdriver Remove the dowel pins 1 and gasket 2 PISTON REMOVAL Place a clean shop Remove the piston pin clips 1 with pliers towel over the crankcase to prevent the piston pin clips from falling into the crankcase Push the piston pin 1 out of the piston 2 and connecting rod and remove the piston 11 3 CYLINDER PISTON 11 4 Spread each piston ring 1 and remove it by lifting up a point opposite the gap NOTE Do not damage the piston ring by spreading the ends too far Be careful not to damage the piston when removing the piston ring INSPECTION Inspect the following parts for scratch damage abnormal wear deformation burning or clogs in oil passages Oylinder Piston Piston rings Piston pin Connecting rod small end Measure each part and calculate the clearance according to CYLINDER PISTON SPECIFICATIONS page 1 6 Replace any part if it is out of service limit STUD BOLT REPLACEMENT Thread two nuts onto the stud bolt 1 and tighten them together and use a wrench on them to turn the stud bolt out Install new stud bolts into the crankcase and tighten them to the specified torque TORQUE 9 0 N m 0 9 kgf m
161. enter into the combustion chamber This motorcycle s spark plug is equipped with an iridium center electrode Replace the spark plug if the electrodes are contaminated MAINTENANCE Check the air cleaner housing drain plug 1 If necessary remove the drain plug from the air cleaner and drain the deposits into a suitable container Reinstall the drain plug securely REMOVAL INSTALLATION Disconnect the spark plug cap 1 Remove the spark plug 1 using a spark plug wrench 2 Inspect or replace the spark plug as described in the maintenance schedule page 3 2 Install and hand tighten the spark plug to the cylinder head then tighten the spark plug to the specified torque using a spark plug wrench TORQUE 16 1 6 kgf m 12 Ibf ft Connect the spark plug cap securely INSPECTION Check the following and replace if recommended spark plug page 3 6 NOTE Insulator 1 for damage Center electrode 2 and side electrode 3 for wear Burning condition coloration necessary 2 If the electrodes are contaminated with accumulated objects or dirt replace the spark plug MAINTENANCE Always use Replace the plug if the center electrode 1 is rounded specified spark as shown in the illustration plugs on this motorcycle SPECIFIED SPARK PLUG NGK SIMR8A9 To prevent Check the spark plug gap between the center and side damaging the electrodes with
162. entire surface M6 C4 gear bushing outer surface Locking agent Mainshaft bearing setting plate bolt threads Coating width 6 5 1 0 mm 0 26 0 04 in from tip 1 15 GENERAL INFORMATION FRAME MATERIAL LOCATION REMARKS Urea based multi purpose grease with extreme Steering head bearing inner race and outer race rolling surface 3 5 g 0 11 0 18 oz pressure agent example Kyodo Yushi EXCELITE EP2 or equivalent Steering head bearing dust seal lips Multi purpose grease Sidestand pivot sliding surface Axle outer surface Throttle pipe flange cable groove Shock linkage needle bearing rotating area Shock linkage collar whole surface Swingarm pivot needle bearing rotating area Swingarm pivot collar whole surface Swingarm pivot bolt outer surface Swingarm cap lips Gap between the swingarm caps pivot collar and bearings Brake pedal pivot sliding area Main step pivot pin sliding area Pillion step pivot pin sliding surface Each dust seal lips Each O ring Silicone grease Brake pad pin stopper ring surface Brake caliper bracket pin boots 0 4 g 0 01 oz minimum Brake caliper dust seal whole surface Brake lever contacting area with master piston 0 1 g 0 004 oz Rear master cylinder push rod contacting area with master cylinder piston and boot 0 1 g 0 004 oz Mast
163. eps TOOL Spoke wrench 5 8 x 6 1 mm 07701 0020300 TORQUE 3 7 N m 0 4 kgf m 2 7 Ibf ft SHOCK ABSORBER 17 6 REMOVAL INSTALLATION Raise the rear wheel off the ground by placing a work stand or box under the frame Remove the sub frame page 2 12 Remove the upper mounting nut 1 and bolt 2 Remove the lower mounting nut 3 bolt 4 and shock absorber 5 Installation is in the reverse order of removal TORQUE Shock absorber upper mounting nut 54 N m 5 5 kgf m 40 Ibf ft Shock absorber lower mounting nut 44 N m 4 5 kgf m 32 Ibf ft INSPECTION Inspect the following parts for damage abnormal wear deformation oil leakage or bend Damper rod Damper unit Bushing If the shock absorber is replaced refer to shock absorber disposal procedure page 17 7 2 34 REAR WHEEL SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper case to mark the drilling point as shown Wrap the shock absorber 1 inside a plastic bag Support the shock absorber upright in a vise as shown Through the open end of the bag insert a hand drill with a sharp 3 mm drill bit NOTE Point the drill hole away from you to prevent debris getting in your eyes Hold the bag around the hand drill and briefly run it 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
164. er 7 Remove the primary drive gear 1 12 17 CLUTCH GEARSHIFT LINKAGE INSTALLATION Apply engine oil to the primary drive gear 1 teeth Install the primary drive gear while aligning its punch mark with the crankshaft punch mark Install the washer 1 Apply engine oil to the primary drive gear lock nut 2 threads and seating surface then install it Temporarily install the washer 1 clutch outer guide 2 needle bearing 3 and clutch outer 4 Insert the gear holder 5 between the primary drive and driven gears TOOL Gear holder M1 5 07724 0010200 Tighten the primary drive gear lock nut 6 to the specified torque TORQUE 108 N m 11 0 kgf m 80 Ibf ft Install the clutch assembly page 12 11 12 18 13 ALTERNATOR STARTER CLUTCH SERVICE INFORMATION 13 2 STATOR CKP SENSOR 13 4 13 2 FLYWHEEL eeeenne en 13 5 COMPONENT 13 2 STARTER CLUTCH 13 7 LEFT CRANKCASE COVER 13 3 13 1 ALTERNATOR STARTER CLUTCH SERVICE INFORMATION GENERAL This section covers the removal and installation of the flywheel alternator and starter clutch These services can be done with the engine installed in the frame TROUBLESHOOTING Starter motor turns but engine does not turn Faul
165. er ECM condition How to connect the HDS pocket tester Turn the ignition switch OFF Remove the dummy connector 1 from the DLC 2 Connect the HDS pocket tester to the DLC Turn the ignition switch ON and engine stop switch check the DTC and freeze data NOTE Freeze data indicates the engine conditions when the first malfunction was detected ECM reset The HDS pocket tester can reset the ECM data including the DTC freeze data and some learning memory After the ECM reset perform the TP sensor reset procedure page 4 45 DTC READOUT Start the engine and check the MIL NOTE When the ignition switch is turned ON and engine stop switch the MIL will stay on for a few seconds then go off If the MIL stays on or blinks read the DTC freeze data and follow the troubleshooting index page 4 7 To read the DTC with the MIL blinking refer to the following procedure Reading DTC with the MIL Turn the ignition switch OFF Remove the dummy connector from the DLC 1 Short the DLC terminals using the special tool TOOL 2 SCS connector 070PZ ZY30100 Turn the ignition switch ON and engine stop switch read note the MIL blinks and refer to the DTC index page 4 7 NOTE If the ECM has any DTC in its memory the MIL will start blinking ERASING DTC 1 Turn the ignition switch OFF 2 Remove the dummy connector from the DLC 1 Short the DLC terminals using the special tool TOOL 2 SCS
166. er cylinder boot 0 1 g 0 004 oz DOT 3 or DOT 4 brake fluid Brake master piston sliding area and piston cups Rear master cylinder hose joint O ring Brake caliper piston sliding area and piston seal Fork fluid Fork cap O ring Fork oil seal lips Fork dust seal lips Fork guide bushing and slider bushing surface Honda Bond A or equivalent Left handlebar and throttle pipe outer surface grip rubber contacting area Air cleaner connecting hose mating surface with air cleaner housing Swingarm rubber cap mating surface with swingarm 1 16 GENERAL INFORMATION CABLE amp HARNESS ROUTING FRONT BRAKE HOSE CLUTCH CABLE THROTTLE CABLES LEFT HANDLEBAR gt SWITCH WIRE y NE oy EAA S S EO D S E I E f or QN z 1 2 Lf X RIGHT HANDLEBAR WIRE BANDS SWITCH WIRE gt S AS Front lt E HANDLEBAR 3 0 Ky rp HANDLEBAR 7 11 SWITCH WIRE 3 THROTTLE CABLES 7 B Align the lower end of outer rubber with the lower end of hose clamp GENERAL INFORMATION SPEEDOMETER Viewed from the front side RIGHT HANDLEBAR SWITCH WIRE Ow IGNITION SWITCH WIRE WIRE CLAMP CONNECTOR BOOT IGNITION SWITCH 3P BROWN CONNECTOR SPEEDOMETER 16P LEFT HANDLEBAR SWITCH RIGHT H
167. er surface and rocker arm shaft outer surface Install the rocker arm and rocker arm shaft NOTE The rocker arms are identified by the stamped marks IN Intake rocker arm 4 EX Exhaust rocker arm 5 Install a new sealing washer 1 and bolt 2 Install the camshafts page 10 9 INSPECTION Inspect the following parts for damage abnormal wear deformation burning or clogs in oil passages Rocker arm Rocker arm shaft Measure each part and clearance according to CYLINDER HEAD VALVES SPECIFICATIONS page 1 6 Replace any part if it is out of service limit 4 CYLINDER HEAD VALVES CYLINDER HEAD REMOVAL Remove the following Engine page 15 4 Camshaft page 10 6 Be careful not to Remove the cylinder head bolts 1 nuts 2 washers the cylinder head 8 and cylinder head 4 bolts and nuts fall NOTE into the crankcase Attach a piece of wire to the cam chain to prevent it from falling into the crankcase Do not tap the cylinder head too hard and do not damage the mating surface with a screwdriver Remove the following Dowel pins 1 Gasket 2 chain guide A 3 DISASSEMBLY Remove the following Spark plug page 3 5 Oz sensor page 4 47 Rocker arm page 10 11 To prevent loss of Remove the valve spring cotters 1 using the special tension do not tools 2 the valve TOOLS springs more than
168. es preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean zl vou WILL be KILLED or SERIOUSLY HURT if you don t follow instructions SL You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions A CAUTION You CAN be HURT if you don t follow instructions Instructions how to service this vehicle correctly and safely As you read this manual you will find information that is preceded by a symbol The purpose of this message is to help prevent damage to your vehicle other property or the environment ALL INFORMATION ILLUSTRATIONS DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING Honda Motor Co Ltd RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES MOTOR SCOOTERS OR ATVS Honda Motor Co Ltd SERVICE PUBLICATION OFFICE Date of Issue June 2012 HOW USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it would be explained specifically in the
169. es 19 2 BRAKE SYSTEM sussnssassussansussussasusussusssanssussussenseussusen 18 2 CLUTCH GEARSHIFT LINKAGE sesssssasssussussausesusuuss 12 2 COOLING SYSTEM sasssssunssasaussussanseusenssancussenssaseuseussos 9 2 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER sasssnssussanssssusssssanssuscussensuAsauseussuasauseussussans 14 2 INDEX CYLINDER HEAD VALVES 10 2 CYLINDER PISTON 1 1 2 ELECTRIC STARTER SYSTEM 6 2 ENGINE REMOVAL INSTALLATION 15 2 FRAME BODY PANELS EXHAUST SYSTEM 2 2 FRONT WHEEL SUSPENSION STEERING 16 2 FUEL SYSTEM See eee eee eee eee eee eee eee eee eee 7 2 IGNITION SYSTEM 5 2 LIGHTS METERS SWITCHES CL nna 20 2 LUBRICATION SYSTEM 8 MAINTENANCE T A n 3 2 PGM FI SYSTEM 00000000 4 2 REAR WHEEL SUSPENSION 17 2 SERVICE RULES 1 2 SHOCK ABSORBER wee eee eee eeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeseeeeeenee 17 6 SHOCK LINKAGE nna 17 7 SIDE COVER PORE eee eee ee eee eee eee eee eee eee eee eee eee eee 2 3 SIDESTAND FRAME BODY PANELS EXHAUST SYSTEM 2 14 MAINTENANCE 3 19 SIDESTAND SWITCH were eee
170. eservoir is low the brake to prevent air from being pumped into the system Close the bleed valve and operate the brake lever or pedal If it still feels spongy bleed the system again Perform the bleeding procedure until the system is completely flushed bled 18 4 BRAKE SYSTEM If a brake bleeder is not available use the following procedure Connect a bleed hose to the bleed valve Pressurize the system with the brake lever or pedal until lever or pedal resistance is felt Do not release the 1 Squeeze the brake lever or depress the brake pedal lever or pedal until open the bleed valve 1 4 turn and then close it the bleed valve has 2 Release the brake lever or pedal slowly and wait been closed several seconds after it reaches the end of its travel 3 Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose After bleeding the system completely tighten the bleed valve to the specified torque TORQUE 5 4 0 6 kgf m 4 0 Ibf ft Fill the reservoir to the upper level line with DOT 3 or DOT 4 brake fluid Install the diaphragm set plate and reservoir cover and tighten the screws to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 1 For rear brake Install the reservoir and bolt then tighten it to the specified torque while pushing the reservoir against the stopper TORQUE 10 N m 1 0 kgf m 7 Ibf ft BRAKE PAD DISC FRONT BRAKE PAD REMOVAL INSTALLATION
171. eterioration damage or loose connections Make sure that the hoses are not kinked pinched or cracked DRIVE CHAIN Never inspect and adjust the drive chain while the engine is running 3 12 DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF support the motorcycle on its sidestand and shift the transmission into neutral Check the slack in the drive chain lower run midway between the sprockets DRIVE CHAIN SLACK 25 35 mm 1 0 1 4 in Excessive chain slack 50 mm 2 0 in or more may damage the frame ADJUSTMENT Loosen the rear axle nut 1 Loosen the lock nuts 2 and turn the adjusters 3 until the correct drive chain slack is obtained 2 00 00 Ie a ey p 05 O4 Make sure the same index lines 1 on both adjusting plates 2 are aligned with punch mark 3 in the swingarm Tighten the axle nut to the specified torque TORQUE 88 9 0 kgf m 65 Ibf ft Hold the drive chain adjusters 4 and tighten the lock nuts 5 to the specified torque TORQUE 27 2 8 kgf m 20 Ibf ft Recheck the drive chain slack and free wheel rotation Check the drive chain wear indicator label attached on the left swingarm If the drive chain adjuster cut out 1 reaches red zone 2 of the indicator label replace the drive chain with a new one CLEANING AND LUBRICATION Clean the driv
172. etween the sensor unit and ECM Faulty sensor unit Faulty ECM DTC 8 1 TP SENSOR LOW VOLTAGE 1 TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester when the throttle fully closed Is about 0 V indicated YES Intermittent failure Loose or poor contact on the sensor unit 5P connector NO GOTO STEP 2 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 8 Is the sensor unit power line normal YES GO TO STEP NO Replace or repair the abnormal circuit 3 TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the sensor unit 5P connector 1 Check for continuity between the sensor unit 5P connector of the wire side and ground Connection Yellow Ground Y Is there continuity YES Short circuit in Yellow wire 2 4 4 15 PGM FI SYSTEM 4 16 4 TP Sensor Output Line Open Circuit Inspection Disconnect the ECM 33P Black connector 1 Check for continuity between the ECM 33P Black connector and sensor unit 5P connector 2 of the wire side Connection Yellow Yellow TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GO TO STEP 5 NO Opencircuit in Yellow wire 5 TP Sensor Inspection Replace the sensor unit with known good one page 4 44 Connect the senso
173. ew bearing 2 squarely with its marked side facing up TOOLS 4 4 5 3 Driver 07749 0010000 role 41 15 4 Attachment 28 x 30 mm 07946 1870100 5 Pilot 12 mm 07746 0040200 After installation apply engine oil to the bearing 0 INSTALLATION CLUTCH CLUTCH PLATE CLUTCH DISC DISC A B White paint Larger 1 0 CLUTCH PLATE A CLUTCH LIFTER PIECE SPRING SEAT BEARING JUDDER SPRING CLUTCH LIFTER PLATE PAG CLUTCH SPRING WASHER NEEDLE BEARING D 12 N m 1 2 kgf m 9 CLUTCH OUTER WASHER LOCK NUT WASHER CLUTCH CENTER 108 N m 11 0 kgf m 80 Ibf ft 12 11 CLUTCH GEARSHIFT LINKAGE Install the washer 1 to the mainshaft Apply molybdenum oil solution to the clutch outer guide 2 whole surface and install it to the mainshaft Apply engine oil to the needle bearing 3 rotating area and install it to the clutch outer guide Install the clutch outer 1 and washer 2 Apply engine oil to a new clutch center lock nut 1 threads and seating surface Install the clutch center 2 washer 3 and lock nut Hold the clutch center 1 with the special tool and tighten the lock nut 2 to the specified torque TOOL 3 Clutch center holder 07724 0050002 TORQUE 108 N m 11 0 kgf m 80 Ibf ft 12 12 CLUTCH GEARSHIFT LINKAGE Be careful not to Stake the lock nut 1 into the mainshaft groove damage the mainshaft threads Install the clutch lifte
174. fied Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation Route all electrical wires as shown in the Cable and Harness Routing page 1 17 Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind ABBREVIATION Throughout this manual the following abbreviations are used to identify the respective parts or systems on oF Abbrev term Full term CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memory IACV Idle Air Control Valve IAT sensor Intake Air Temperature sensor MAP sensor Manifold Absolute Pressure sensor MIL Malfunction Indicator Lamp PAIR Pulse Secondary Air Injection PGM FI Programmed Fuel Injection SCS connector Service Check Short connector TP sensor Throttle Position sensor VS sensor Vehicle Speed sensor DESTINATION CODE Throughout this manual the following codes are used to identify individual types for each region DESTINATION CODE REGION E U K F France ED European direct sales U Australia New Zealand MODEL IDENTIFICATION SERIAL NUMBERS LABELS GENERAL INFORMATION Th
175. from pin 75 960 75 980 2 9905 2 9913 75 89 2 988 ring Piston pin hole I D 17 002 17 008 0 6694 0 6696 17 030 0 6705 Piston pin O D 16 994 17 000 0 6691 0 6693 16 980 0 6685 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 02 0 001 Piston ring end Top 0 28 0 38 0 011 0 015 0 40 0 016 gap Second 0 40 0 55 0 016 0 022 0 70 0 028 Oil side rail 0 20 0 70 0 008 0 028 1 10 0 043 Piston ring to ring Top 0 040 0 080 0 0016 0 0031 0 10 0 004 groove clearance Second 0 015 0 050 0 0006 0 0020 0 09 0 004 Cylinder to piston clearance 0 020 0 050 0 0008 0 0020 0 09 0 004 Connecting rod small end I D 17 016 17 034 0 6699 0 6706 17 06 0 672 Connecting rod to piston pin clearance 0 016 0 040 0 0006 0 0016 0 10 0 004 1 6 GENERAL INFORMATION CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Clutch lever freeplay 10 20 0 4 0 8 Clutch Spring free length 41 5 1 63 37 5 1 48 Disc thickness Disc A B 2 30 2 50 0 091 0 098 2 27 0 089 Plate warpage Plate A B 0 30 0 012 Clutch outer guide 20 000 20 021 0 7874 0 7882 20 04 0 789 Mainshaft O D at clutch outer guide 19 967 19 980 0 7861 0 7866 19 947 0 7853
176. from damper unit Low tire pressure Stiff suspension ncorrect suspension adjustment Bent shock absorber damper rod Damaged suspension or swingarm pivot bearings Bent swingarm pivot or frame High tire pressure Steers to one side or does not track straight Drive chain adjusters not adjusted equally Bent axle Bentframe Worn swingarm pivot components Rear suspension noise Loose suspension fasteners Worn or damaged suspension pivot bearings Faulty shock absorber Rear wheel wobbles Bent rim Worn or damaged rear wheel bearings Faulty rear tire Low tire pressure Loose or broken spokes Worn or damaged swingarm bearings Bent frame or swingarm Axle fastener not tightened properly Wheel turns hard Faulty wheel bearings Bent axle Drive chain too tight page 3 12 Brake drag page 18 2 17 2 REAR WHEEL SUSPENSION COMPONENT LOCATION 54 N m 5 5 kgf m 40 Ibf ft 88 N m 9 0 kgf m 65 Ibf ft 44 N m 4 5 kgf m 32 Ibf ft 1 2 Nem 0 1 kgf m 0 9 Ibf ft 88 9 0 kgf m 65 Ibf ft 74 N m 7 5 kgf m 55 Ibf ft 10 1 0 kgf m 7 Ibf ft 2 5 N m 0 3 kgf m 1 8 Ibf ft 17 3 REAR WHEEL SUSPENSION REAR WHEEL REMOVAL INSTALLATION Loosen the axle nut 1 P Raise the rear wheel off the ground by placing a wor stand or box under the frame Loosen the lock nuts 2 and turn in the drive chain adjusters 3 completely Remove the axle nut
177. gainst the pads BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc according to BRAKE SYSTEM SPECIFICATIONS page 1 8 and replace if necessary 18 6 BRAKE SYSTEM FRONT MASTER CYLINDER When removing the oil bolt cover the end of the hose to prevent contamination REMOVAL INSTALLATION Drain the brake fluid from the front brake hydraulic system page 18 4 Remove the following Right rearview mirror 1 Oil bolt 2 Sealing washers 3 Brake hose 4 Brake light switch connectors 5 Bolts 1 Master oylinder holder 2 Master cylinder 3 Installation is in the reverse order of removal Replace the sealing washers with new ones Align the edge of the master cylinder with the punch mark on the handlebar Install the master cylinder and holder with its UP mark 4 facing up Tighten the upper bolt first then tighten the lower bolt TORQUE Front master cylinder holder bolt 9 8 N m 1 0 kgf m 7 2 Ibf ft Oil bolt 34 3 5 25 Ibf ft Fill and bleed the hydraulic system page 18 4 18 7 BRAKE SYSTEM DISASSEMBLY ASSEMBLY Disassemble and assemble the front brake master cylinder as following illustration Replace the master piston spring piston cups and snap ring as a set Do not allow the piston cup lips to turn inside out Becertain the snap ring is firmly seate
178. ge 7 17 Check that air does not flow A to B when the 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 control solenoid valve terminals Measure the resistance between the connector terminals STANDARD 20 24 20 C 68 F If it is out of standard replace the PAIR control solenoid valve PAIR CHECK VALVE REMOVAL INSTALLATION Remove the bolts 1 and PAIR check valve cover 2 2 7 18 FUEL SYSTEM Remove the PAIR check valve 1 and baffle plate 2 1 from the cylinder head cover 1 2 Installation is in the reverse order of removal TORQUE PAIR check valve cover bolt 5 2 N m 0 5 kgf m 3 8 7 19 8 LUBRICATION SYSTEM SERVICE 8 2 ENGINE OIL STRAINER 8 4 8 2 OIL PUMP ecc dd YO Rd eR 8 4 LUBRICATION SYSTEM DIAGRAM 8 3 PRESSURE RELIEF 8 7 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
179. ght side only Left side Loosen the lock nut 1 while holding the fork cap 2 with a wrench then remove the fork cap Leit side only Remove the O ring 3 from the fork cap groove 3 Left side Remove the following Fork center bolt 1 Sealing washer 2 Left side only Left side Inner damper 1 Left side only 4 1 16 10 Be careful not to scratch the fork pipe sliding surface Do not damage the slider bushing especially the sliding surface To prevent loss of tension do not open the slider bushing more than necessary FRONT WHEEL SUSPENSION STEERING Dust seal 1 Stopper ring 2 Check that the fork pipe 3 moves smoothly in the outer tube 4 If the movement is not smooth check the fork pipe for bend or bushing for wear or damage If they are normal inspect the outer tube Using quick successive motions pull the fork pipe 1 out of the outer tube 2 The guide bushing will be forced out by the fork pipe bushing Carefully remove the slider bushing 1 by prying the slot with a screwdriver until the slider bushing can be pulled off by hand Remove the following Guide bushing 2 Back up ring 3 Oil seal 4 Stopper ring 5 Dust seal 6 3 2 1 INSPECTION Inspect the following parts for damage abnormal wear bend deformation scoring and teflon coating wear Fork pipes Outer tubes
180. haft page 14 6 Transmission page 14 10 Balancer page 14 14 15 2 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION E 27 2 8 20 Ibf ft 10 N m 1 0 kgf m 7 45 4 6 kgf m 33 TE 1 95 N m 5 6 41 s 45 N m 4 6 kgf m 33 15 3 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL Drain the engine oil page 3 9 Drain the coolant page 9 5 Remove the following Frame guard page 2 6 Skid plate page 2 5 Throttle body page 7 11 Exhaust pipe muffler page 2 11 Gearshift pedal page 12 14 Brake pedal page 18 12 Disconnect the following Spark plug cap 1 PAIR air supply hose 2 Disconnect the O sensor cap 1 and ECT sensor connector 2 Disconnect the following Alternator 3P connector 1 sensor neutral switch 3P Black connector 2 Release the alternator wire 3 from the clamp 4 Open the harness band 1 and release the wires Disconnect the VS sensor 3P Blue connector 2 15 4 ENGINE REMOVAL INSTALLATION Remove the bolts 1 and clutch cable guide 2 then disconnect the clutch cable 3 from the clutch lifter arm 4 4 Remove the starter motor mounting bolt 1 and ground terminal 2 Release the rubber cap 3 Remove the starter motor terminal nut 4 and starter motor cable terminal 5 D
181. haust system Always replace the gaskets when removing the exhaust system Always inspect the exhaust system for leaks after installation TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler SEAT FRAME BODY PANELS EXHAUST SYSTEM REMOVAL INSTALLATION Remove the hook bolts 1 and collars 2 Remove the seat 3 by pulling it rearward and releasing the hooks Installation is in the reverse order of removal TORQUE Hook bolt 21 N m 2 1 kgf m 15 Ibf ft SIDE COVER Right side Left side REMOVAL INSTALLATION Remove the socket bolt 1 and collar 2 Remove the socket bolt 1 Release the boss 3 from the frame grommet then remove the side cover 4 by pulling it rearward Installation is in the reverse order of removal Align the cover grooves with the tabs of the fuel tank shroud DISASSEMBLY ASSEMBLY LEFT SIDE ONLY Remove the screws 1 and separate the side lower cover 2 from the left side cover 3 by releasing its slots 4 and holes 5 from the hooks and bosses of the side cover Assembly is in the reverse order of disassembly TORQUE Left side cover assembly screw 0 9 N m 0 1 kgf m 0 7 Ibf ft 1 02 1 2 Right side only 3 2 3 FRAME BODY PANELS EXHAUST SYSTEM RESERVE TANK COVER REMOVAL INSTALLATION
182. he frame and engine Place the engine in the frame then loosely install all the bolts 1 collars 2 washers 3 and nuts Tighten the rear lower engine mounting nut 4 to the specified torque TORQUE 45 N m 4 6 kgf m 33 Ibf ft Tighten the front lower engine mounting nut 5 to the specified torque TORQUE 55 N m 5 6 41 Ibf ft Tighten the front upper engine mounting nut 6 to the specified torque TORQUE 55 N m 5 6 kgf m 41 Ibf ft With the engine hanger plate 1 in position tighten the engine hanger plate bolts 2 to the specified torque TORQUE 27 2 8 kgf m 20 Ibf ft Tighten the rear engine hanger upper mounting nut 3 to the specified torque TORQUE 45 4 6 kgf m 33 Ibf ft Install the drive chain 1 over the drive sprocket 2 with the 14T mark 3 of the sprocket facing out Install the drive sprocket to the countershaft Install the fixing plate 4 Rotate the fixing plate and align the holes in the plate with the bolt holes in the sprocket Install and tighten the drive sprocket fixing plate bolts 5 to the specified torque TORQUE 10 N m 1 0 kgf m 7 15 7 ENGINE REMOVAL INSTALLATION Install the rear brake light switch holder 1 while aligning its tab with the frame hole Install and tighten the bolt 2 Connect the water hoses 1 and tighten the water hose band screws 2 page 9 7 Connect the crankcase breather hose
183. heck DTC Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch en Lae Check the bank angle sensor with the HDS pocket tester Is the DTC 54 2 indicated YES GO TO STEP 2 NO Intermittent failure Bank Angle Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the bank angle sensor 2P connector 1 page 4 48 Turn the ignition switch ON and engine stop switch Measure the voltage between the bank angle sensor 2P connector of the wire side and ground Connection Black blue Ground Standard Battery voltage Is there battery voltage YES GO TO STEP 3 NO Opencircuit in Black blue wire Bank Angle Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF Check for continuity between the bank angle sensor 2P connector 1 and ECM 33P Black connector 2 of the wire side Connection Red blue Red blue TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Inspect the bank angle sensor page 4 48 NO Opencircuit in Red blue wire 1 1 2 PGM FI SYSTEM MIL TROUBLESHOOTING MIL 1 BLINK MAP SENSOR ECM SENSOR UNIT MAP SENSOR E Y R gt Lg BI G W Probable cause Open circuit in Yellow red wire between the sensor unit and ECM Open or short circuit in Light green
184. heck for continuity between each wire terminal of the alternator stator side connector and ground There should be no continuity Replace the alternator stator if the resistance is out of specification or if any wire has continuity to ground For stator replacement page 13 4 19 5 BATTERY CHARGING SYSTEM REGULATOR RECTIFIER REMOVAL INSTALLATION Remove the radiator reserve tank page 9 12 Disconnect the regulator rectifier 5P connector 1 Remove the bolts 2 and regulator rectifier 3 from the reserve tank stay Install the regulator rectifier in the reverse order of removal SYSTEM INSPECTION Remove the right fuel tank shroud page 2 4 Turn the ignition switch OFF Disconnect the regulator rectifier 5P connector 1 and check it for loose contacts or corroded terminals If the charging voltage reading page 19 5 is out of the specification check the following at the wire harness side connector 1 4 Terminal Specification Battery charging Red white Battery voltage line and ground should register Charging coil line Yellow and 0 1 1 00 at Yellow 20 C 68 F Ground line Green and Continuity should ground exist If all components of the charging system are normal and there are no loose connections at the regulator rectifier connector replace the regulator rectifier unit 19 6 20 LIGHTS METERS SWITCHES SERVICE
185. her pad is worn to the brake pads as a set wear limit groove 1 fo assure even disc For rear brake pad replacement page 18 6 et NS pressure 7 gt 3 16 BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal and check that no air has entered the system If the lever or pedal feels soft or spongy when operated bleed the air from the system For brake air bleeding page 18 4 Inspect the brake hose 1 and fittings for deterioration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut 1 and turn the push rod 2 until the correct pedal height is obtained For standard push rod length page 18 9 After adjustment tighten the push rod lock nut to the specified torque TORQUE 17 2 N m 1 8 kgf m 13 Ibf ft BRAKE LIGHT SWITCH The front brake light 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 NOTE Hold the switch body and turn the adjuster 2 Do not turn the switch body MAINTENANCE 2 3 17 MAINTENANCE HEADLIGHT AIM Adjust the headlight aim as specified by local laws and regulations Support the motorcycle in an uprig
186. ht position Adjust the headlight aim horizontally by turning the horizontal beam adjuster 1 Adjust the headlight aim vertically by turning the vertical beam adjuster 2 CLUTCH SYSTEM The adjuster may be damaged if it is positioned too far out leaving minimal thread engagement Measure the clutch lever freeplay at the end of the clutch lever FREEPLAY 10 20 mm 0 4 0 8 in 10 20 mm 0 4 0 8 in Minor adjustment is made with the minor adjuster 1 at the clutch lever Loosen the lock nut 2 and turn the adjuster Tighten the lock nut while holding the adjuster Recheck the clutch lever freeplay If the adjuster is threaded out near its limit and the correct freeplay cannot be obtained turn the adjuster all the way in and back out one turn then perform the 13 adjustment at major adjuster as follows Major adjustment is made with the major adjuster 1 on the clutch cable w Loosen the lock nut 2 and turn the adjuster to adjust the freeplay Tighten the lock nut while holding the adjuster If proper freeplay cannot be obtained or the clutch slips during test ride disassemble and inspect the clutch page 12 9 3 18 SIDESTAND INSPECTION Support the motorcycle using a safety stand or hoist Check the sidestand spring 1 for damage or loss of tension Check the sidestand 2 for movement and lubricate the sidestand pivot if necessar
187. ide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems page 1 28 to reduce carbon monoxide oxides of nitrogen and hydrocarbons CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner housing and throttle body AIR CLEANER HOUSING THROTTLE BODY X d CRANKCASE MI 7 BREATHER HOSE LJ FRESH AIR BLOW BY GAS 1 27 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a pulse secondary air supply system three way catalytic converter and PGM Fl system SECONDARY AIR SUPPLY SYSTEM The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port Fresh air is drawn into the exhaust port by the function of the PAIR 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 PGM FI unit and the fresh air passage is opened closed according to running c
188. ile holding the slide valve 2 as shown The slide valve should move back and forth Install the IACV page 7 15 7 16 FUEL SYSTEM 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 PAIR check valve page 7 18 Check that the reed valve 1 is clean and free of carbon deposits If the reed valve is carbon fouled inspect the following Reed valve for deterioration or damage Rubber seat 2 for crack deterioration or damage Reed valve stopper 3 for damage or deformation Replace the PAIR check valve if necessary Start the engine and open the throttle slightly to be certain that air is sucked in through the air supply hose If the air is not drawn in check the air supply hoses 1 for clogs If the hoses are normal inspect the PAIR control solenoid valve 2 page 7 17 lt gt FRESH AIR EXHAUST GAS PAIR CONTROL SOLENOID VALVE REMOVAL INSTALLATION Remove the right fuel tank shroud page 2 4 Disconnect the PAIR control solenoid valve 2P Black connector 1 7 17 FUEL SYSTEM Remove the bolts 1 collars 2 and PAIR control solenoid valve 3 from the stay Disconnect the air supply hoses 4 from the PAIR control solenoid valve Installation is in the reverse order of removal INSPECTION Remove the PAIR control solenoid valve pa
189. ile it is hot Do not use an impact wrench while removing or installing the O2 sensor or it may be damaged Remove the left fuel tank shroud page 2 4 Disconnect the O2 sensor 1P Black connector 1 Remove the wire band 2 from the frame Disconnect the O2 sensor cap 1 Remove the sensor 2 Installation is in the reverse order of removal TORQUE Oz sensor 25 N m 2 5 kgf m 18 Ibf ft Take care not to tilt the Oz sensor cap when connecting the cap to the O sensor Do not turn the sensor cap after connecting it 4 47 PGM FI SYSTEM BANK ANGLE SENSOR 4 48 REMOVAL INSTALLATION Remove the reserve tank cover page 2 4 Disconnect the bank angle sensor 2P connector 1 Remove the bank angle sensor mounting nuts 2 bolts 3 bank angle sensor 4 and plate 5 Remove the collars 6 and mounting rubbers 7 from the bracket Installation is in the reverse order of removal Install the bank angle sensor with its UP mark 8 facing up TORQUE Bank angle sensor mounting nut 9 0 N m 0 9 kgf m 6 6 Ibf ft SYSTEM INSPECTION Remove the bank angle sensor page 4 48 Connect the bank angle sensor 2P connector Place the bank angle sensor horizontal as shown Start the engine Incline the bank angle sensor 70 5 to the left or right The bank angle sensor is normal if the engine stops PGM FI SYSTEM ECM ECM POWER GROUND LI
190. ing retainer 1 4 12 Compress the valve spring using the special tools and install the valve cotters 2 TOOLS 3 Valve spring compressor 4 Valve spring compressor attachment 07757 0010000 07959 KM30101 Tap the valve stems gently with two plastic hammer to firmly seat the cotters firmly Install the following Spark plug page 3 5 sensor 4 47 Rocker arm page 10 11 INSTALLATION Clean any gasket material from the cylinder mating surfaces Install the following Dowel pins 1 New gasket 2 Cam chain guide A 3 Route the cam chain through the cylinder head and install the cylinder head 1 onto the cylinder Apply engine oil to the new cylinder head mounting nut 2 threads and seating surface Install and tighten the new cylinder head mounting nuts with new washers 3 in a crisscross pattern in two or three steps to the specified torque TORQUE 45 N m 4 6 kgf m 33 Ibf ft Install and tighten the cylinder head bolts 4 securely Install the following Camshaft page 10 9 Engine page 15 7 10 17 11 CYLINDER PISTON SERVICE INFORMATION 11 2 CYLINDER PISTON 11 3 11 2 CHAIN TENSIONER 11 7 COMPONENT LOCATION 11 2
191. ing surfaces when servicing Clean the oil passages before assembling the crankcase halves Prior to assembling the crankcase halves apply sealant to their mating surfaces Wipe off excess sealant thoroughly The main journal bearing inserts are select fit and are identified by color codes Select replacement bearing from the code tables After selecting a new bearing recheck the oil clearance Incorrect oil clearance can cause major engine damage ee TROUBLESHOOTING Excessive engine noise Worn seized or chipped transmission gear Worn or damaged transmission bearing Worn or damaged connecting rod big end bearing Worn main journal bearing Worn connecting rod small end Worn balancer shaft bearing Improper balancer timing Hard to shift Bent shift fork Bent shift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Bent shift fork claw Damaged gearshift spindle Loose shift drum stopper arm bolt Transmission jumps out of gear Worn gear dogs or dog holes Damaged shift drum guide groove Worn shift fork guide pin Worn shift fork groove in gear Worn shift fork shaft Bent shift fork shaft Weak or broken gearshift spindle return spring Engine vibration Excessive crankshaft runout Improper balancer timing 14 2 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER COMPONENT LOCATION 10 1 0 7 Ibf ft 44 N m 4 5 kgf m 32 Ibf ft 14 3 CRANKCASE CRANKSHAFT TRANSMI
192. ioner lifter plug 1 and O ring 2 Turn the cam chain tensioner lifter shaft fully in clockwise and secure it using a tensioner stopper 1 to prevent damaging the cam chain TOOL Tensioner stopper 070MG 0010100 Be careful not to let Remove the bolts 1 and cam chain guide B 2 2 the cam chain 2 guide bolts fall into the crankcase 10 6 careful not to let the camshaft holder bolts fall into the crankcase Remove the bolts 1 and camshaft holders 2 NOTE From outside to inside loosen the bolts in a crisscross pattern in several steps or the camshaft holder might break Attach a piece of Remove the camshafts 1 by removing the cam chain wire to the cam chain to prevent it from falling into the crankcase 2 from the cam sprockets Lift the rocker arms 1 Remove the shims 2 NOTE Do not allow the shims to fall into the crankcase Mark all shims to ensure correct reassembly in their original locations The shims can be easily removed with a tweezers a magnet INSPECTION Inspect the following parts for damage abnormal wear deformation burning or clogs in oil passages Cam sprocket Camshaft Camshaft holder dowel pin Cam chain guide B Measure each part according to CYLINDER HEAD VALVES SPECIFICATIONS page 1 6 Replace any part if it is out of service limit 1 2 2 CYLINDER HEAD VALVES 10 7 CYLIN
193. isconnect the crankcase breather hose 6 Release the VS sensor wire from the guide 7 Loosen the water hose band screws 1 and disconnect the water hoses 2 Remove the bolt 1 and rear brake light switch holder 2 15 5 ENGINE REMOVAL INSTALLATION The jack height must be continually adjusted to relieve stress for ease of bolt removal During engine removal hold the engine securely and be careful not to damage the frame and engine Loosen the rear axle nut 1 lock nuts 2 and drive chain adjusters 3 Push the rear wheel forward and make the drive chain slack fully Remove the bolts 1 fixing plate 2 and drive sprocket 3 Remove the rear engine hanger upper mounting nut 1 and bolt 2 Remove the bolts 3 and engine hanger plate 4 Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal Remove the following Front upper engine mounting nut 1 washer 2 two collars 3 bolt 4 Front lower engine mounting nut 5 washer collar bolt 6 Rearlower engine mounting nut 7 bolt 8 From the right side of the vehicle slightly lift up the engine and turn its lower rear side out of the frame then remove the engine from the frame 71 68 61 15 6 ENGINE REMOVAL INSTALLATION ENGINE INSTALLATION During engine installation hold the engine securely and be careful not to damage t
194. it 5P connector 2 of the wire side Connection Light green black Light green black TOOL Lg BI Test probe 07ZAJ RDJA110 Lg Bl Is there continuity YES Replace the ECM with a known good one and recheck Open circuit in Light green black wire MIL 7 BLINKS ECT SENSOR NOTE Before starting the inspection check for loose or poor contact on the ECT sensor 3P connector and recheck the MIL blinking 2 1 ECM ECT SENSOR G W Probable cause Open or short circuit in Yellow blue wire between the ECT sensor and ECM Open circuit in Green white wire between the ECT sensor and ECM Faulty ECT sensor Faulty ECM 4 30 1 ECT Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the ECT sensor 3P connector 1 page 4 46 Turn the ignition switch ON and engine stop switch nen 4 Measure the voltage at the ECT sensor 3P connector of the wire side and ground Connection Yellow blue Ground Standard 4 75 5 25V Is the voltage within 4 75 5 25 V YES GO TO STEP 3 GOTO STEP 2 ECT Sensor Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 50 Check for continuity between the ECT sensor 3P connector 1 of the wire side and ground Connection Yellow blue Ground Is ther
195. k plug cap page 3 5 PAIR check valve page 7 18 Fuel tank page 7 8 Ignition coil page 5 6 Remove the three bolts 1 and ground terminal 2 from the radiator reserve tank stay Remove the cylinder head cover bolts 1 rubber seals 2 cylinder head cover 3 and packing 4 112 10 4 INSTALLATION Apply sealant Three bond 5211C 1207B 1215 SS KE45 or equivalent to the cylinder head semi circular cut outs as shown Install a new packing 1 into the cylinder head cover 2 groove Install the cylinder head cover onto the cylinder head Check the rubber seals 1 are in good condition replace them if necessary Install the rubber seals to the cylinder head cover with their UP marks 2 facing up Install and tighten the cylinder head cover bolts 1 to the specified torque TORQUE 10 N m 1 0 kgf m 7 CYLINDER HEAD VALVES 2 2 10 5 CYLINDER HEAD VALVES Set the radiator reserve tank stay and ground terminal 1 1 in position 112 i Install and tighten the three bolts 2 4 Install the following Ignition coil page 5 6 PAIR check valve page 7 18 Fuel tank page 7 8 Spark plug cap page 3 5 CAMSHAFT REMOVAL Remove the cylinder head cover page 10 4 Make sure the piston is at TDC Top Dead Center on the compression stroke page 3 6 Remove the cam chain tens
196. kgf m 9 13 Ibf ft EXHAUST PIPE EXHAUST PIPE PROTECTOR STUD BOLT REPLACEMENT Remove the exhaust pipe page 2 11 Thread two nuts onto the stud bolt and tighten them together and use a wrench on them to turn the stud bolt out 777777 Install and tighten new stud bolts to the specified torque TORQUE 9 0 N m 0 9 kgf m 6 6 Ibf ft After installation check that the length from the bolt head to the cylinder head surface is within specification 22 0 0 5 mm 0 87 0 02 in 2 11 FRAME BODY PANELS EXHAUST SYSTEM SUB FRAME REMOVAL INSTALLATION Remove the following Seat page 2 3 Side covers page 2 3 Muffler page 2 11 Fuel tank page 7 8 Battery page 19 4 Remove the bolt 1 and reservoir 2 Disconnect the PAIR air suction hose 3 and crankcase breather hose 4 from the air cleaner housing Remove the wire bands 1 Remove the following from the air cleaner housing Starter relay switch 2 Fuse box 3 Relay box 4 Wire clips 5 Open the harness band 1 and release the wires Disconnect the battery case drain hose 2 Release the wire bands 1 Disconnect the brake taillight 6P Black connector 2 2 12 FRAME BODY PANELS EXHAUST SYSTEM Loosen the air cleaner connecting hose band screw 1 Remove the sub frame lower mounting bolts 1 Remove the sub frame upper mounting nuts 1 and bolts 2 Pull the s
197. l TOOLS Swingarm side 2 Driver 3 Attachment 24 x 26 mm 4 Pilot 20 mm 5 Fork seal driver attachment 27 2 mm 07949 3710001 07746 0010700 07746 0040500 07746 0010300 Apply grease to the needle rollers of new bearings 1 Carefully press each needle bearing in the pivot until the depth from the arm outer surface is 5 8 6 2 mm 0 23 0 24 in TOOLS Shock Link and Shock Absorber side 2 Driver 07749 0010000 3 Attachment 22 x 24 mm 07746 0010800 4 Pilot 17 mm 07746 0040400 5 Fork seal driver attachment 07746 0010300 27 2 mm Apply grease to the needle rollers of new bearings 1 Carefully press each needle bearing in the pivot until the depth from the arm outer surface is 8 8 9 2 mm 0 35 0 36 in TOOLS Swingarm side 2 Driver 07749 0010000 3 Attachment 24 x 26 mm 07746 0010700 4 Pilot 20 mm 07746 0040500 5 Fork seal driver attachment 07746 0010300 27 2 mm SHOCK LINK Remove the needle bearing 1 from the shock link using the special tools TOOLS 2 Bearing remover 17 mm 3 Remover weight Remover handle 07936 3710300 07741 0010201 07936 3710100 3 4 REAR WHEEL SUSPENSION SWINGARM SIDE 3 4 SHOCK ABSORBER SHOCK LINK SIDE 5 8 6 2 mm 0 23 0 24 in 2 Y 3 14 1 umm SWINGARM SIDE 8 8 9 2 mm 0 35 0 36 in 2 1 Y 17 9 REAR W
198. l the back up ring 1 guide bushing 2 and slider bushing 3 NOTE careful not to damage the slider bushing coating Do not open the slider bushing more than necessary Install the back up ring with its flange side facing toward the guide bushing Remove the burrs from the bushing mating surface being careful not to peel off the coating Coat the guide bushing and slider bushing with recommended fork oil and install the fork pipe 1 into the outer tube 2 Drive in the oil seal 1 into the outer tube using the special tool TOOL 2 Fork seal driver 43 2 mm 07YMD MCF0100 16 13 FRONT WHEEL SUSPENSION STEERING Install the stopper ring 1 into the groove in the outer tube 2 being careful not to scratch the fork pipe 3 Install the dust seal 4 into the outer tube Left side Install the inner damper 1 into the fork pipe Left side only Left side Apply looking agent to the fork center bolt 1 threads Let side and install it with a new sealing washer 2 2 Left side the left fork pipe in a vise with soft jaws or shop towels Tighten the fork center bolt 1 to the specified torque TORQUE 20 2 0 kgf m 15 16 14 Right side Right side FRONT WHEEL SUSPENSION STEERING Pour the specified amount of recommended fork fluid into the fork pipe RECOMMENDED FORK FLUID Honda ULTRA CUSHION OIL 10W or equivalen
199. ly 150 kPa 1 50 kgf cm 22 psi Driver and passenger 150 kPa 1 50 kgf cm 22 psi E Axle runout 0 2 0 01 Wheel runout Radial 2 0 0 08 Axial 2 0 0 08 Wheel hub to rim distance 23 45 1 0 0 92 0 04 Fork Spring free length Right side only 575 0 22 64 Pipe runout 0 20 0 008 Recommended fork fluid Honda ULTRA CUSHION OIL 10W or equivalent Fluid level Right 122 4 8 Left 38 1 5 Fluid capacity Right 658 2 5 cm 22 3 0 08 05 2 23 2 0 09 2 Left 683 2 5 cm 23 1 0 08 US oz 24 0 0 09 Imp oz Steering head bearing pre load 106 212 1 08 2 16 kgf 2 38 4 77 108 REAR WHEEL SUSPENSION SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire thread depth 3 0 0 12 Cold tire pressure Driver only 150 kPa 1 50 kgf cm 22 psi Driver passenger 150 kPa 1 50 kgf cm 22 psi Axle runout 0 2 0 01 Wheel rim runout Radial 2 0 0 08 Axial 2 0 0 08 Wheel hub to rim distance 26 9 1 0 1 06 0 04 Drive chain Size link DID520VF 106LE Slack 25 35 1 0 1 4 BRAKE SYSTEM SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 3 or DOT 4 Brake pad wear indicator groove Brake disc thickness 3 3 3 7 0 13 0 15 3 0 0 12 Brake disc warpage 0 3 0 01 Master cylinder 1 0 12 700 12 743 0 5000 0 5017 12 755 0 5022 Master piston O D 12 645 0 4978
200. m 0 12 in pin 3 into the hole 3 14 19 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Install the balancer driven gear assembly while aligning the woodruff key the balancer shaft with balancer driven gear keyway ER ST 2 2 Apply engine to the balancer shaft nut 1 threads and seating surface Install the washer 2 and balancer shaft nut Apply engine oil to the balancer drive gear 3 teeth and install it while aligning its wide groove with the punch mark on the crankshaft NOTE Install the balancer drive gear with its OUT mark 4 facing out Align the punch marks of the balancer drive gear and balancer driven gear Insert the gear holder 1 between the balancer drive 6 gear 2 and balancer driven gear 3 TOOL 1 Gear holder M2 5 07724 0010100 Tighten the balancer shaft nut 4 to the specified torque TORQUE 44 4 5 kgf m 32 Ibf ft Remove a 3 mm 0 12 in O D pin 5 from the balancer driven gear assembly 14 20 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Install the timing sprocket while aligning its wide groove FS Ali with the punch mark on the crankshaft ign i Apply engine oil to the cam chain 1 whole surface Install the cam chain through the crankcase Install the cam chain over the timing sprocket 2 Apply locking agent to the cam chain tensioner pivot bolt 3 threads page 1 12 Install the cam chain tensioner 4 coll
201. mpletely Install a new sealing washer onto the drain bolt Install and tighten the drain bolt to the specified torque TORQUE 24 2 4 kgf m 18 Fill the engine with the recommended engine oil page 3 9 ENGINE OIL CAPACITY 1 4 liters 1 5 US qt 1 2 Imp qt at draining 1 5 liters 1 6 US qt 1 3 Imp qt at oil filter change 1 8 liters 1 9 US qt 1 6 Imp qt at disassembly Install the oil filler cap Check the oil level page 3 9 Make sure there are no oil leaks MAINTENANCE ENGINE OIL FILTER REPLACEMENT Drain the engine oil page 3 9 Remove the following Bolts 1 Oil filter cover 2 Gasket 3 Spring 4 Remove the oil filter 1 Install a new oil filter with the OUT SIDE mark 2 facing out NOTE Installing the oil filter backwards will result in severe engine damage Install the oil filter spring 3 into the oil filter cover 4 Install a new gasket 5 and oil filter cover Install the cover bolts and tighten them Fill the engine with the recommended engine oil page 3 9 Make sure there are no oil leaks ENGINE IDLE SPEED NOTE nspect the idle speed after all other engine maintenance items have been performed and are within specifications Before checking the idle speed inspect the following items No MIL blinking Spark plug condition page 3 5 Secondary air supply system condition page 3 11 Crankcase b
202. mpound to enter the guides After lapping wash any residual compound off the cylinder head and valve and recheck the seat contact CYLINDER HEAD VALVES 1 lt gt gt AS 4 7 y f 7 JJ o 7 P ft 10 15 CYLINDER HEAD VALVES ASSEMBLY INNER SPRING SHIM a COTTERS RETAINER OUTER SPRING 4 INTAKE VALVE EXHAUST VALVE 4 Clean the cylinder head assembly with solvent and 775 w g blow through all oil passages with compressed air Install the spring seats 1 new valve stem seals 2 2 Apply molybdenum oil solution to each valve stem sliding surface To avoid damage Insert the intake and exhaust valves 3 into the valve the seal turn the guides valve slowly when inserting Install the inner valve spring 1 and outer valve spring 2 with the tightly wound coils should facing the combustion chamber 3 2 1 3 10 16 Grease the cotters to ease installation To prevent loss of tension do not compress the valve spring more than necessary Support the cylinder head above the work bench surface to prevent valve damage Do not allow dust and dirt to enter the crankcase Be careful not to let the cylinder head bolts washers and nuts fall into the crankcase CYLINDER HEAD VALVES Install the spr
203. n into neutral Turn the ignition switch ON and engine stop switch CZ Crank the engine with the starter motor and measure the CKP sensor peak voltage PEAK VOLTAGE 0 7 V minimum If the peak voltage measured at the ECM 33P Black connector is abnormal measure the peak voltage at the CKP sensor connector Turn the ignition switch OFF Remove the left side cover page 2 3 Disconnect the CKP sensor neutral switch 3P Black connector 1 and connect the tester probes to the connector terminals of the CKP sensor side CONNECTION Blue yellow White yellow In the same manner as at the ECM 33P Black connector measure the peak voltage and compare it to the voltage measured at the ECM 33P Black connector NOTE If the peak voltage measured at the ECM is abnormal and the one measured at the CKP sensor is normal the wire harness has an open or short circuit or loose connection If the peak voltage of the CKP sensor side is lower than standard value follow the checks described in the troubleshooting table page 5 2 For CKP sensor replacement page 13 4 Install the removed parts in the reverse order of removal IGNITION SYSTEM 2 IGNITION SYSTEM IGNITION TIMING Warm up the engine Stop the engine and remove the timing hole cap using the special tool TOOL Timing cap wrench 07709 0010001 Connect the timing light 1 to the spark plug wire Start th
204. n pair of commutator bars 1 There should be continuity Check for continuity between each individual commutator bar 1 and the armature shaft 2 There should be no continuity CONTINUITY 1 1 ELECTRIC STARTER SYSTEM Check for continuity between the positive brushes 1 and cable terminal 2 There should be continuity CONTINUITY 2 Check for continuity between the positive brushes 1 and rear cover 2 There should be no continuity NO CONTINUITY 3 2 Check for continuity between the positive and negative brushes 31 There should be no continuity Measure the brush length SERVICE LIMIT 6 5 mm 0 26 in Check the bushing 1 of the rear cover for wear or damage Replace the starter motor as an assembly if necessary ELECTRIC STARTER SYSTEM STARTER RELAY SWITCH INSPECTION Remove the left side cover page 2 3 Shift the transmission into neutral Turn the ignition switch ON and engine stop switch CZ Push the starter switch The coil is normal if the starter relay switch 1 clicks If you don t hear the starter relay switch CLICK inspect the starter relay switch using a procedure below GROUND LINE Disconnect the starter relay switch 4P Red connector 1 Check for continuity between the following terminal of the wire harness side and ground when the starter switch is pushed CONNECTION Green red Groun
205. ne oil Honda 4 stroke motorcycle oil or an equivalent API classification SG or higher except oils labeled as energy conserving on the circular service label Viscosity SAE 10W 30 JASO T 903 standard MA Oil pump rotor Tip clearance 0 15 0 006 0 20 0 008 Body clearance 0 15 0 22 0 006 0 009 0 35 0 014 Side clearance 0 02 0 09 0 001 0 004 0 10 0 004 1 5 GENERAL INFORMATION COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1 02 liters 1 08 US qt 0 90 Imp At draining 0 74 liter 0 78 US qt 0 65 Imp qt Reserve tank 0 16 liter 0 17 US qt 0 14 Imp qt Radiator cap relief pressure 93 2 122 6 kPa 0 95 1 25 kgf cm 13 5 17 8 psi Thermostat Begin to open 81 84 178 183 Fully open 95 C 203 F Valve lift 4 5 mm 0 18 in minimum Recommended coolant High quality ethylene glycol antifreeze containing silicate free corrosion inhibitors Standard coolant concentration 1 1 mixture with distilled water CYLINDER HEAD VALVES SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder compression at 490 rpm 1 294 kPa 13 2 kgf cm 188 psi Valve clearance IN 0 16 0 03 0 006 0 001
206. ner 5 Hold the connector with one hand and squeeze the retainer tabs 2 with the other hand to release the locking pawls 8 Pull the connector off and remove the retainer NOTE Absorb the remaining fuel in the fuel feed hose from flowing out with a shop towel Becareful not to damage the hose or other parts Do not use tools f the connector does not move keep the retainer tabs pressed down and alternately pull and push the connector until it comes off easily 6 To prevent damage and keep foreign matter out cover the disconnected connector and pipe end with the plastic bags 1 QUICK CONNECT FITTING INSTALLATION NOTE 1 Always replace the retainer and joint rubber of the quick connect fitting when the fuel feed hose is disconnected Replace the retainer and joint rubber with the same manufacturer s item that was removed Do not bent or twist fuel feed hose Insert a new retainer 1 into the connector 2 NOTE Align new retainer locking pawls with the connector grooves FUEL SYSTEM 2 ta ee Align FUEL SYSTEM 2 Set a new joint rubber 1 to the joint 2 as shown Press the quick connect fitting 3 onto the pipe until both retainer pawls lock with a CLICK NOTE Align the quick connect fitting with the joint hard to connect put a small amount of engine oil on the joint end 3 Make sure the c
207. ng If the MIL was on but then went out the original problem may be intermittent Opens and Shorts Opens and Shorts are common 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 work but not the way it s supposed to If the MIL has come on Refer to DTC READOUT page 4 5 If the MIL did not stay on If the MIL did not stay on but there is a driveability problem do the SYMPTOM TROUBLESHOOTING page 4 6 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 trouble in the system When any abnormality is detected by the self diagnosis function running capability is maintained by pre programed value in the simulated program map When any abnormality is detected in the injector the fail safe function stops the engine to protect it from damage MIL Blink Pattern e DTC can be read from the ECM memory by the MIL blink pattern The MIL will blink the current DTC in case the ECM detects the problem at present when the ignition switch ON
208. ng from the bleed hole is normal REMOVAL Drain the coolant page 9 5 Remove the bolts 1 drain bolt 2 sealing washer 3 water pump cover 4 and O ring 5 Remove the right crankcase cover page 12 4 Hold the water pump shaft and remove the impeller 1 and plain washer 2 Remove the water pump shaft 1 from the right crankcase cover COOLING SYSTEM Check the water pump shaft 1 for wear or damage replace it if necessary BEARING MECHANICAL SEAL OIL SEAL REPLACEMENT BEARINGS MECHANICAL SEAL Remove the water pump shaft bearings 1 using the special tools 2 TOOLS 2 Remover weight 07741 0010201 3 Bearing remover set 12 mm 07936 1660101 COOLING SYSTEM Remove the mechanical seal 1 and oil seal 2 from the right crankcase cover Apply grease to a new oil seal 1 lips Install the oil seal to the right crankcase cover as shown 0 0 02 in Drive in a new Drive in new bearings 1 into the right crankcase cover bearing squarely using the special tools as shown with the marking side facing up TOOLS 2 Driver 07749 0010000 3 Attachment 28 x 30 mm 07946 1870100 4 Pilot 12 mm 07746 0040200 After installing the bearing lubricate it with engine oil Press a new mechanical seal 1 until it is fully seated to the right crankcase cover using the hydraulic press and special tool TOOL 2 Oil seal driver 30 x
209. ngth 113 mm 4 4 in Fuel tank capacity 7 7 liter 2 03 US gal 1 69 Imp gal ENGINE Cylinder arrangement Single cylinder inclined 20 from vertical Bore and stroke 76 0 x 55 0 mm 2 99 x 2 17 in Displacement 249 6 15 23 cu in Compression ratio 10 7 1 Valve train Chain driven DOHC with rocker arm Intake valve opens at 1 0 mm 0 04 in lift 20 BTDC closes at 1 0 mm 0 04 in lift 35 ABDC Exhaust valve opens at 1 0 mm 0 04 in lift 40 BBDC closes at 1 0 mm 0 04 in lift 0 TDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Viscous paper filter Engine dry weight 34 5 kg 76 1 lbs FUEL DELIVERY Type SYSTEM Throttle bore 36 mm 1 4 in DRIVE TRAIN Clutch system Multi plate wet Clutch operation system Cable operating Transmission Constant mesh 6 speeds Primary reduction 2 807 73 26 Final reduction 2 857 40 14 Gear ratio 1st 3 333 40 12 2nd 2 117 36 17 3rd 1 571 33 21 Ath 1 304 30 23 5th 1 115 29 26 6th 0 962 26 27 Gearshift pattern Left foot operated return system 1 N 2 3 4 5 6 ELECTRICAL Ignition system Computer controlled digital transistorized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator r
210. no continuity when the 12 V battery is connected replace the fan control relay COOLING SYSTEM WATER PIPE REMOVAL INSTALLATION Drain the coolant page 9 5 Remove the bolts 1 and water pipe 2 Remove the O rings 1 from the water pipe 2 Installation is in the reverse order of removal Replace the O ring with new ones Fill the system with the recommended coolant page 9 5 9 13 10 CYLINDER HEAD VALVES SERVICE INFORMATION 10 2 10 2 COMPONENT LOCATION 10 3 CYLINDER 5 10 4 CYLINDER HEAD COVER 10 4 CAMSHAE T5355 popu n E Ee RE ERBEN ERAS S 10 6 ROCKER ARM 10 11 CYLINDER 10 13 10 1 CYLINDER HEAD VALVES SERVICE INFORMATION GENERAL This section covers service of the cylinder head valves rocker arms and camshaft The camshaft and rocker arm service can be done with the engine installed in the frame The cylinder head service requires engine removal Becareful not to damage the mating surfaces when removing the cylinder head cover and cylinder head Do not tap the cylinder head cover and cylinder head too hard during removal When disassembling mark and store the disassembled parts to e
211. nstall the flywheel page 13 6 13 9 14 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER SERVICE INFORMATION 14 2 MAIN JOURNAL 14 7 14 2 TRANSMISSION 14 10 COMPONENT LOCATION 14 3 14 14 CRANKCASE 14 4 CRANKCASE BEARING REPLACEMENT 14 15 CRANKSHAFT 14 6 CRANKCASE ASSEMBLY 14 18 14 1 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER SERVICE INFORMATION GENERAL This section covers crankcase separation for service of the crankshaft transmission and balancer The crankcase must be separated to service the crankshaft balancer and transmission To service these parts the engine must be removed from the frame The following components must be removed before separating the crankcase Camshaft page 10 6 Cylinder head page 10 13 Cylinder piston page 11 3 Clutch page 12 9 Gearshift linkage page 12 14 Oil pump page 8 4 Primary drive gear page 12 17 Flywheel page 13 5 Neutral switch page 20 13 Starter motor page 6 4 Engine page 15 4 Be careful not to damage the crankcase mat
212. nsure that they are reinstalled in their original locations Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection Camshaft and rocker arm lubricating oil is fed through oil passage in the cylinder head stud bolt hole and camshaft holder Clean the oil passage before assembling them TROUBLESHOOTING Engine top end problems usually affect engine performance These problems can be diagnosed by a compression test or by tracing top end noise with a sounding rod or stethoscope e Ifthe performance is poor at low speeds check for white smoke in the crankcase breather hose If the hose is smoky check for a seized piston rings Compression too low hard starting or poor performance al low speed Valves Incorrect valve adjustment Burned or bent valve Incorrect valve timing Weak valve spring Uneven valve seating Valve stuck open Oylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Faulty cylinder piston or piston rings page 11 3 Compression too high over heating or knocking Excessive carbon build up on piston head or combustion chamber Excessive smoke Worn valve stem or valve guide Damaged stem seal Faulty cylinder piston or piston rings page 11 3 Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged camsh
213. ntake air leak Faulty ignition system Faulty MAP sensor Faulty charging system Backfiring or misfiring during acceleration Faulty ignition system Engine lacks power Bent or kinked fuel hose fuel tank breather hose Clogged fuel filter Faulty fuel pump or its drive circuit Faulty injector Faulty ignition system Clogged air cleaner element FUEL SYSTEM COMPONENT LOCATION 7 0 N m 0 7 kgf m 5 2 27 2 8 kgf m 20 Ibf ft 7 0 N m 0 7 kgf m 5 2 101 0 3 0 N m 0 3 kgf m 2 2 8 0 N m 0 3 kgf m 2 2 Ibf ft 27 N m 2 8 kgf m 20 Ibf ft 7 3 FUEL SYSTEM FUEL LINE INSPECTION FUEL PRESSURE RELIEVING NOTE Before disconnecting fuel feed hose relieve pressure from the system as follows 1 Disconnect the fuel pump 3P Black connector 1 a A CO I QUICK CONNECT FITTING REMOVAL NOTE Do not bend or twist fuel feed hose 1 2 3 Start the engine and let it idle until the engine stalls Turn the ignition switch OFF Disconnect the battery negative cable page 19 Turn the ignition switch OFF 4 1 Relieve the fuel pressure page 7 4 Remove the three bolts 1 and lift up the fuel tank 2 from the frame Check the fuel quick connect fitting 1 for dirt and clean if necessary Place a shop towel 2 over the quick connect fitting 4 Pull and release the joint rubber 1 from the retai
214. o the specified torque TORQUE 5 1 0 5 kgf m 3 8 Ibf ft Connect the injector 2P Gray connector 3 while amp aligning its groove with the tab of the injector joint Install the fuel tank page 7 8 REMOVAL Remove the fuel tank page 7 8 Disconnect the IACV 4P Black connector 1 Remove the IACV torx screws 2 set plate 3 and IACV 4 Remove the O ring 5 from the IACV INSTALLATION Turn the slide valve 1 clockwise until lightly seated on IACV 7 15 FUEL SYSTEM Install a new O ring 1 to the IACV 2 Install the IACV by aligning its slide valve slot with the pin in the throttle body Install the set plate 1 by aligning its slot with the IACV tab then tighten the torx screws 2 to the specified torque TORQUE 2 1 N m 0 2 kgf m 1 5 Ibf ft Connect the IACV 4P Black connector 3 Install the fuel tank page 7 8 INSPECTION NOTE The IACV is installed on the throttle body and is operated by the step motor When the ignition switch is turned ON the IACV operates for a few seconds Check the step motor operating sound with the ignition switch turned ON and engine stop switch CZ If the IACV does not sound with no MIL blinking inspect as follows Remove the IACV page 7 15 If the idling is unstable check the condition of the O ring Temporarily connect the IACV 4P Black connector 1 Turn the ignition switch ON and engine stop switch wh
215. oltage Initial voltage of the ignition primary coil is the battery voltage with the ignition switch turned ON and engine stop switch C The engine is not cranked by the starter motor a Unusual condition Probable cause Check in numerical order Ignition coil No initial voltage with the ignition 1 Faulty ignition switch primary voltage switch turned ON and engine stop 2 An open circuit in Black blue wire between the ignition coil switch C Other electrical and engine stop switch components are normal 3 An open circuit in Black green or Black red wires between the engine stop switch and ignition switch 4 Loose or poor connection of the primary terminal or an open circuit in the primary coil 5 Faulty ECM in case when the initial voltage is normal with the ECM connector disconnected 6 Faulty engine stop switch Initial voltage is normal but it drops by 1 Incorrect peak voltage adaptor connections System is 2 4 V while cranking the engine normal if measured voltage is over the specifications with reverse connections 2 Battery is undercharged Voltage drops largely when the engine is started 3 No voltage between the Black blue wire and body ground at the ECM connector or poor connection of the ECM connector 4 An open circuit or loose connection in Green or Green black wire at the ECM 5 An open circuit or loose connection in Green red wire between the ignition coil
216. ondition ECT IAT TP MAP sensor and engine revolution No adjustments to the secondary air supply system should be made although periodic inspection of the components is recommended AIR CLEANER HOUSING PAIR CONTROL SOLENOID VALVE m ML THROTTLE BODY EXHAUST PORT FRESH AIR 4 EXHAUST GAS THREE WAY CATALYTIC CONVERTER This motorcycle is equipped with a three way catalytic converter The three way catalytic converter is in the exhaust system Through chemical reactions it converts HC CO and NOx in the engine s exhaust to carbon dioxide CO nitrogen and water vapor No adjustment to these systems should be made although periodic inspection of the components is recommended 1 28 GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Local law may prohibit the following acts or the causing there of 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 vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Removal of or puncturing of the muffler
217. onnection is secure and that the pawls 1 are firmly locked into place check visually and by pulling the connector 4 Make sure the joint rubber 2 is positioned between the retainer 3 and joint flange 4 as shown 5 Reposition the fuel tank 1 and tighten the three bolts 2 FUEL PRESSURE NORMALIZATION 1 Connect the fuel pump 3P Black connector 1 Connect the battery negative cable page 19 4 2 Turn the ignition switch ON and engine stop switch Do not start the engine The fuel pump will run for about 2 seconds and fuel pressure will rise Repeat 2 or 3 times and check that there is no leakage in the fuel supply system Turn the ignition switch OFF 1 3 FUEL SYSTEM FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting page 7 4 Attach the special tools as follows TOOLS 1 Fuel pressure gauge 07406 0040004 2 Pressure gauge manifold 07ZAJ S5A0111 3 Hose attachment 9 mm 9 mm 07ZAJ S5A0120 4 Hose attachment 8 mm 9 mm 07ZAJ S7C0100 5 Attachment joint 8 mm 9 mm 072 57 0200 Temporarily connect the battery negative cable and fuel pump 3P Black connector Start the engine and let it idle Read the fuel pressure STANDARD 343 kPa 3 5 kgf cm 50 psi If the fuel pressure is higher than specified replace the fuel pump assembly If the fuel pressure is lower than specified ins
218. or clogs Disassemble and assemble the throttle body as following illustration 8 4 N m 0 3 kgf m 2 5 Ibf ft THROTTLE BODY ia 3 4 0 3 kgf m 2 5 Ibf ft 7 12 THROTTLE CABLE STAY CLAMP STAY 8 4 N m 0 3 kgf m 2 5 Ibf ft Ag SEAL RING OC THROTTLE BODY INJECTOR CUSHION RING 5 1 0 5 3 8 INJECTOR JOINT LEX 2 1 0 2 kgf m 1 5 Ibf ft PLATE 9 O RING aoe FUEL SYSTEM Install the throttle body insulator 1 to the throttle body by aligning the tab of the throttle body with the groove of the throttle body insulator NOTE Install the throttle body insulator with KZZ mark 2 facing the cylinder head Align the insulator band hole with the insulator boss INSTALLATION Install the throttle body assembly 1 to the cylinder head by aligning the tab of the cylinder head with the groove of the throttle body insulator Tighten the insulator band screws 2 to the specified torque TORQUE 4 2 N m 0 4 kgf m 3 1 Ibf ft After tightening the insulator band screws check that the band ends are seated with each other Tighten the air cleaner connecting hose band screw 3 to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 1 Connect the throttle cables 1 to the throttle drum and throttle cable stay Tighten the throttle cable B nut 2 to the specified torque
219. or leakage Check the quick connect fitting for dirt and clean if necessary Replace the fuel pump packing if necessary page 7 9 THROTTLE OPERATION Check for any deterioration or damage to the throttle cable Check the throttle grip for smooth operation Check that the throttle opens and automatically closes in all steering positions If the throttle grip does not return properly overhaul and lubricate the throttle grip housing If the throttle grip still do not return properly replace the throttle cable With the engine idling turn the handlebar all the way to the right and left to ensure that the idle speed does not change If idle speed increases check the throttle grip freeplay and throttle cable connection Measure the throttle grip freeplay at the throttle grip flange FREEPLAY 2 6 mm 0 08 0 24 Throttle grip freeplay can be adjusted at either end of the throttle cable Minor adjustment is made with the upper adjuster 1 at throttle housing Loosen the lock nut 2 and turn the adjuster Tighten the lock nut securely while holding the adjuster Recheck the throttle operation MAINTENANCE MAINTENANCE Major adjustment is made with the lower adjuster 1 at the throttle body Loosen the lock nut 2 and turn the adjuster Tighten the lock nut to the specified torque while holding the adjuster TORQUE 3 0 N m 0 3 kgf m 2 2 Ibf ft Recheck the throttle opera
220. ork protectors 2 2 1 Left side only Left side Left side FRONT WHEEL SUSPENSION STEERING Remove the bolt 1 and brake hose guide 2 Am 14 Loosen the fork top bridge pinch bolts 3 1 If you will disassemble the fork loosen the fork 4 but do not remove it Loosen the fork bottom pinch bolts 1 while supporting the fork leg Pull the fork leg down and remove it out of the fork bridges INSTALLATION Install the outer tube into the bottom and top bridges Align the top of the outer tube with the upper surface of 5 the top bridge Tighten the bottom bridge pinch bolts 1 to the specified torque TORQUE 32 N m 3 3 kgf m 24 Ibf ft Tighten the fork cap 2 to the specified torque if it was removed TORQUE 35 N m 3 6 kgf m 26 Ibf ft Tighten the top bridge pinch bolts 3 to the specified torque TORQUE 32 N m 3 3 kgf m 24 Ibf ft Install the brake hose guide 4 and tighten the bolt 5 to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft 16 7 FRONT WHEEL SUSPENSION STEERING Install the fork protectors 1 Install and tighten the new socket bolts 2 to the specified torque TORQUE 7 0 N m 0 7 kgf m 5 2 Ibf ft Install the brake hose clamp 1 to the left fork leg and tighten the bolts 2 to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the brake caliper 3 with new mounting bolts 4
221. oss reference the crankshaft and crankcase codes to determine the replacement bearing color BEARING SUPPORT MAIN JOURNAL O D 33 985 34 000 mm 1 3380 1 3386 in Crankshaft replaced 1 0 CODE Crankcase replaced BEARING SUPPORT I D 33 975 33 985 mm 1 3376 1 3380 in 38 000 38 006 mm C Brown B Black 1 4965 1 4968 in 0 0788 0 0789 in A 1 996 1 999 mm 1 999 2 002 mm 0 0786 0 0787 0 0787 0 0788 B Black A Blue B 2 epi 1 999 2 002 mm 2 002 2 005 mm 0 0787 0 0788 in 0 0788 0 0789 in 7 A Blue 0 5 G Pink C 38 012 38 018 mM 2 002 2 005 mm 2 005 2 008 mm 0 0789 0 0791 38 018 38 024 1 4968 1 4970 O S Pink 2 005 2 008 mm 0 0789 0 0791 in O S F Yellow 2 008 2 011 mm 0 0791 0 0792 in 38 024 38 030 mm 1 4970 1 4972 in O S F Yellow 2 008 2 011 mm 0 0791 0 0792 in O S E Green 2 011 2 014 mm 0 0792 0 0793 in 38 030 38 036 mm 1 4972 1 4975 in O S E Green 2 011 2 014 mm 0 0792 0 0793 in O S D Red 2 014 2 020 mm 0 0792 0 0795 14 8 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER BEARING THICKNESS O S D Red Thick O S E Green 0 5 F Yellow O S G Pink Middle A Blue B Black l C Brown Thin
222. ot 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 preferred BATTERY TESTING Refer to the instruction of the Operation Manual for the recommended battery tester for details about battery testing The recommended battery tester puts a load on the battery so the actual battery condition can be measured RECOMMENDED BATTERY TESTER BM 210 or BATTERY MATE or equivalent TROUBLESHOOTING Unusual condition Probable cause Check in numerical order Battery Battery is damaged or weak 1 Faulty battery 2 Current leakage higher than specified value Faulty ignition switch Shorted wire harness Faulty alternator charging coil Faulty regulator rectifier Open circuit or loose connection in the wire harness OU Poo 19 2 BATTERY CHARGING SYSTEM SYSTEM LOCATION REGULATOR RECTIFIER BATTERY MAIN FUSE 30 A ALTERNATOR SYSTEM DIAGRAM MAIN FUSE 30 A 1 1 o BATTERY REGULATOR RECTIFIER ALTERNATOR Y Yellow G Green R Red W White 19 3 BATTERY CHARGING SYSTEM BATTERY REMOVAL INSTALLATION Remove the left side cover page 2 3 Turn the ignition switch OFF Disconnect the negative cable 1 first and then the positive cable
223. ot turn the ignition switch ON and engine stop switch to A sudden surge of current may blow the fuse in the tester SPECIFIED CURRENT LEAKAGE 0 34 mA max 19 4 BATTERY CHARGING SYSTEM If current leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Remove the left side cover page 2 3 Be sure the battery is in good condition before performing this test Warm up the engine to normal operating temperature Connect the multimeter between the battery positive terminal 1 and negative terminal 2 NOTE To prevent a short make absolutely certain which are the positive and negative terminal or cable Do not disconnect the battery or any cable in the charging system without first turning the ignition switch OFF Failure to follow this precaution can damage the tester or electrical components With the headlight high beam measure the voltage on the multimeter when the engine runs at 5 000 rpm STANDARD Measured BV lt Measured CV lt 15 5 V BV Battery Voltage Charging Voltage ALTERNATOR CHARGING COIL INSPECTION Remove the left side cover page 2 3 Disconnect the alternator 3P connector 1 Measure the resistance between the Yellow wire terminals of the alternator side connector STANDARD 0 1 1 0 20 C 68 F C
224. over stator is magnetically attracted to the Connect the neutral switch connector 3 and set the flywheel be careful wire into the left crankcase cover groove during installation Tighten the bolts in a crisscross pattern in 2 or 3 steps Connect the following Alternator connector 1 sensor neutral switch 3P Black connector 2 Secure the alternator wire 3 with the clamp 4 Install the following Gearshift pedal page 12 17 Drive sprocket cover page 2 6 Left side cover page 2 3 Fill the engine with the recommended engine oil page 3 9 STATOR CKP SENSOR REMOVAL INSTALLATION Remove and install the stator CKP sensor as following illustration Apply locking agent to the CKP sensor mounting bolt threads as specified page 1 12 Apply sealant to the alternator CKP sensor wire grommet sealing surface page 1 15 10 N m 1 0 kgf m 7 10 1 0 kgf m 7 Ibf ft TH STATOR CKP SENSOR 1 1 s LEFT CRANKCASE COVER 13 4 ALTERNATOR STARTER CLUTCH FLYWHEEL REMOVAL Remove the left crankcase cover page 13 3 Remove the starter reduction gear 1 and shaft 2 Hold the flywheel with the special tool and remove the flywheel bolt 1 and washer 2 TOOL 3 Flywheel holder 07725 0040001 Remove the flywheel 1 using the special tool TOOL 2 Flywheel puller 07733 0020001 Remove the needle bearing 1 B
225. p if it does not hold pressure or if relief pressure is too high or too low It must hold the specified pressure for at least 6 seconds RADIATOR CAP RELIEF PRESSURE 93 2 122 6 kPa 0 95 1 25 kgf cm 13 5 17 8 psi Pressurize the radiator engine and hoses using the tester and check for leaks Excessive pressure can damage the cooling system components Do not exceed 122 6 kPa 1 25 kgf cm 17 8 psi Repair or replace components if the system will not hold the specified pressure for at least 6 seconds Remove the tester Install the radiator cap and tighten the screw COOLING SYSTEM COOLANT REPLACEMENT REPLACEMENT AIR BLEEDING Remove the radiator cap page 9 4 Remove the drain bolt 1 and sealing washer 2 on the water pump cover and drain the coolant from the system Install and tighten the drain bolt with a new sealing washer When filling the Fill the system with the recommended coolant through system or reserve the filler opening tank with a coolant checking coolant RECOMMENDED ANTIFREEZE 4 High quality ethylene glycol antifreeze containing level support the Ei motorcycle silicate free corrosion inhibitors level surface STANDARD COOLANT CONCENTRATION 1 1 mixture with distilled water Bleed air from the system as follows 1 Shift the transmission into neutral Start the engine and let it idle for 2 3 minutes 2 Snap the th
226. page 20 13 SIDESTAND SWITCH INSPECTION Remove the left side cover page 2 3 Disconnect the sidestand switch 3P Green connector Check the continuity between the following terminals of the switch side connector CONNECTION Green white Green The switch is normal if there is continuity when the sidestand is retracted and no continuity when the sidestand is lowered 20 13 LIGHTS METERS SWITCHES REMOVAL INSTALLATION Remove the sub frame page 2 12 Disconnect the sidestand switch 3P Green connector 1 Release the wire from the clamps 2 Remove the two bolts 1 and switch cover 2 Remove the mounting bolt 1 and sidestand switch 2 Installation is in the reverse order of removal Replace the sidestand switch mounting bolt with a new one Align the switch groove with the spring pin of the frame TORQUE Sidestand switch mounting bolt 10 N m 1 0 kgf m 7 Ibf ft CLUTCH SWITCH Disconnect the clutch switch wire connectors and check 1 for continuity between the switch terminals 1 10 There should be continuity with the clutch lever squeezed and no continuity with the clutch lever released 20 14 LIGHTS METERS SWITCHES FUEL GAUGE FUEL LEVEL SENSOR FUEL GAUGE INSPECTION If the fuel gauge 1 is indicated as shown check for an open circuit in wire harness and the fuel level sensor If the wire harness and fuel level sensor are good
227. pect the following Fuelline leaking Pinched or clogged fuel feed hose or fuel tank breather hose Fuel pump unit page 7 8 Clogged fuel filter After inspection relieve the fuel pressure page 7 4 Remove the fuel pressure gauge attachment and manifold from the fuel pump Connect the quick connect fitting page 7 5 FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick connect fitting page 7 4 Wipe off spilled out Connect the special tool to the fuel pump joint gasoline TOOL 1 Hose attachment 8 mm 9 mm 072 57 0100 Place the end of the hose into an approved gasoline container Temporarily connect the battery negative cable and N fuel pump Black connector Turn the ignition switch ON and engine stop switch C7 Measure the amount of fuel flow NOTE The fuel pump operates for 2 seconds Repeat 5 times to meet the total measuring time Return fuel to the fuel tank when the first fuel is flowed Amount of fuel flow 83 2 81 US 2 92 Imp 02 minimum 10 seconds at 12 V If fuel flow is less than specified inspect the following Fuel pump unit page 7 8 Clogged fuel filter Connect the quick connect fitting page 7 5 FUEL SYSTEM FUEL TANK REMOVAL INSTALLATION Relieve the fuel pressure and disconnect the quick connect fitting page 7 4 Lift up the fuel tank 1 and release the fuel fe
228. pen circuit in Black blue wire Bank Angle Sensor Signal Line Short Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector page 4 50 Check for continuity between the bank angle sensor 2P connector 1 of the wire side and ground Connection Red blue Ground Is there continuity YES NO Short circuit in Red blue wire GOTO STEP 4 Bank Angle Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF Check for continuity between the bank angle sensor 2P connector 1 and ECM 33P Black connector 2 of the wire side Connection Red blue Red blue TOOL Test probe 07ZAJ RDJA110 Is there continuity YES GOTO STEP 5 NO OOpencircuit in Red blue wire PGM FI SYSTEM 1 1 1 2 4 27 PGM FI SYSTEM 4 28 5 Bank Angle Sensor Inspection Replace the bank angle sensor with a known good one page 4 48 Connect the bank angle sensor 2P connector and ECM 33P Black connector Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch Check the bank angle sensor with the HDS pocket tester 16 DTC 54 2 indicated YES Replace the ECM with a known good and recheck Faulty original the bank angle sensor DTC 54 2 BANK ANGLE SENSOR HIGH VOLTAGE Rec
229. pin in the groove Check that the snap rings are seated in the grooves and align their end gaps with the grooves of the spline 2 INCORRECT CORRECT 14 11 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER MAINSHAFT THRUST WASHER M5 GEAR BUSHING 5 GEAR 267 PLINE WASHER 5 5 SNAP RING M3 M4 GEAR 21 23T SNAP RING a gt SPLINE WASHER Q 4 6 GEAR BUSHING 6 GEAR 27 WASHER M2 GEAR 17T THRUST WASHER COUNTERSHAFT THRUST WASHER C1 GEAR 40T C1 GEAR BUSHING a C5 GEAR 297 SNAP RING SPLINE WASHER C4 GEAR 30T GEAR 337 C3 GEAR BUSHING COUNTERSHAFT C2 GEAR 36T THRUST WASHER 14 12 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Check the gears for freedom of movement or rotation on each shaft Each gear teeth 1 Apply engine oil to the transmission gear teeth Engage the mainshaft assembly 1 and countershaft assembly 2 2 Install the mainshaft assembly 1 and countershaft assembly 2 together into the right crankcase Make sure the three thrust washers are installed mainshaft left only countershaft both ends Each shift fork has an identification marks 1 is for the right shift fork L is the left shift fork and C is for the center shift fork Apply molybdenum oil solution to the shift fork inner surfaces and guide pins Install the shift forks 1 into the shifter gear g
230. pper arm 4 Washer 5 Return spring 6 INSPECTION Check the return spring 1 and spindle arm spring 2 for fatigue or damage replace them if necessary Check the gearshift spindle 3 for wear or bend Check the spindle arm 4 for wear damage or deformation Replace the gearshift spindle as an assembly if necessary Inspect the gearshift spindle needle bearing and replace if necessary GEARSHIFT SPINDLE NEEDLE BEARING REPLACEMENT Remove the gearshift spindle needle bearing 1 using the special tools TOOLS 2 Remover weight 07741 0010201 3 Bearing remover shaft 15 mm 07936 KC10100 4 Bearing remover head 14 mm 07WMC KFG0100 Drive in a new gearshift spindle needle bearing 1 into the left crankcase with the marked side facing up until it is fully seated using the special tools TOOLS 2 Driver 07749 0010000 3 Pilot 20 mm 07746 0040500 After installation apply engine oil to the bearing CLUTCH GEARSHIFT LINKAGE CLUTCH GEARSHIFT LINKAGE INSTALLATION Apply locking agent to the shift drum stopper arm bolt 1 threads Install the return spring 2 washer 3 and stopper arm 4 while hooking the return spring at the stopper arm groove Install and tighten the bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Check the stopper arm for proper operation Move the stopper arm 1 out of the way using a screwdriver Install the dowel pins 2 into th
231. pply adequate ignition current TROUBLESHOOTING Unusual condition Probable cause Check in numerical order Starter motor Starter motor does not turn 8 ATO OT ACLS Loose or poor contact on related connectors and terminals Blown fuse Weak battery Faulty starter relay switch Faulty starter motor Faulty engine stop switch Loose connection open or short circuit in starter motor cable Faulty starter switch Open circuit in starter relay switch ground circuit 10 Open or short circuit in starter relay switch power circuit 11 Loose contact or open circuit in related wires Starter motor turns only when the 1 Loose or poor contact on related connectors and terminals transmission is in neutral Starter 2 Faulty clutch switch motor does not turn when the 3 Faulty sidestand switch transmission is in any gear with the 4 Loose contact or open circuit in related wires sidestand retracted and clutch lever pulled in Starter motor turns only when the 1 Loose or poor contact on related connectors and terminals transmission is in any gear with the 2 Faulty neutral diode sidestand retracted and clutch lever 3 Faulty neutral switch pulled in Starter motor does not turn 4 Loose contact or open circuit in related wires when the transmission is in neutral with the sidestand lowered and clutch lever released Starter motor turns slowly 1 Low battery voltage 2 Poorly connected battery terminal cable 3 Poorl
232. r 1 from the relay Turn the ignition switch ON and check the voltage between the following terminals of the wire harness side connector CONNECTION Black orange Green STANDARD Battery voltage If there is no battery voltage inspect the following Opencircuit in Green wire Open circuit in Black orange wire between the turn signal relay 3P Black connector and fuse box SIGNAL LINE INSPECTION Short the following terminals of the turn signal relay 3P Black connector with a jumper wire CONNECTION Black orange Gray Turn the ignition switch and turn signal switch ON Check that the turn signal lights come ON f the turn signal lights do not come ON check for open circuit in Gray wire f the turn signal lights come ON replace the turn signal relay with a known good one and recheck 20 16 REMOVAL INSTALLATION Remove the reserve tank cover page 2 4 Disconnect the turn signal relay 3P Black connector 1 from the turn signal relay 2 Remove the turn signal relay from the frame Installation is in the reverse order of removal LIGHTS METERS SWITCHES 20 17 21 WIRING DIAGRAM WIRING 21 2 21 1 WIRING DIAGRAM WIRING DIAGRAM RIGHT HANDLEBAR SWITCH MAIN FUSE 30A J UNCTION BOX 12 gt MWY WY Wo WA a EE Ez unu
233. r 3 and top bridge 4 Loosen the steering stem adjusting nut 1 using the special tool TOOL 2 Stem socket wrench 07916 KA50100 While holding the steering stem remove the adjusting nut Remove the following Upper dust seal 1 Upper steering bearing 2 Steering stem 3 Inspect the bearings and outer races for wear or damage If necessary replace them as a set page 16 23 16 22 Always replace the bearings and races as a set FRONT WHEEL SUSPENSION STEERING BEARING REPLACEMENT Remove the upper and lower bearing outer races 1 2 using the special tools TOOLS 2 Ball race remover 07948 4630100 3 Remover shaft 07953 KA50000 Install the stem nut 1 onto the stem to prevent the threads from being damaged when removing the lower bearing 2 Remove the lower bearing and lower dust seal 3 with a chisel or equivalent tool being careful not to damage the stem Apply specified grease page 16 24 to a new lower dust seal 1 lip and install it over the steering stem Press a new lower bearing 2 using a special tool TOOL 3 Driver 28 mm 07946 4300101 Drive in new upper and lower bearing outer races 1 into the steering head pipe TOOLS 2 Driver 07749 0010000 3 Driver attachment 42 x 47 mm 07746 0010300 16 23 FRONT WHEEL SUSPENSION STEERING INSTALLATION 10 N m 1 0 7 Ibf ft STEM CAP ADJUSTING NUT M UPPER DUST SEAL
234. r obstructions with compressed air or low water pressure Replace the radiator if the air flow is restricted over more than 20 of the radiating surface Inspect the water hoses for cracks or deterioration and replace them if necessary Check the tightness of all water hose band screws page 9 7 SECONDARY AIR SUPPLY SYSTEM NOTE 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 1 The secondary air supply system introduces filtered air into 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 considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water 1 2 MAINTENANCE 3 11 MAINTENANCE If the hoses show any signs of heat damage inspect the PAIR check valve in the cylinder head cover for damage page 7 18 Remove the right fuel tank shroud page 2 4 Check the PAIR air supply hose 1 between the PAIR control solenoid valve 2 and cylinder head cover for deterioration damage or loose connections Make sure that the hoses are not cracked Check the air suction hose 3 between the air cleaner and PAIR control solenoid valve for d
235. r Safety Because this manual is intended for the professional service technician we do not provide warnings about many basic shop safety practices e g Hot parts wear gloves If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice we recommended that you do not attempt to perform the procedures described in this manual Some of the most important general service safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures Only you can decide whether or not you should perform a given task A WARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this manual carefully Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields any time you hammer drill grind pry or work around pressurized air or liquids and springs or other stored energy
236. r piece 1 Install the spring seat 2 and judder spring 3 in the direction as shown Apply engine oil to the entire surface of clutch discs Install the clutch disc B 4 and clutch plate B 5 e Clutch disc B larger 1 0 Clutch plate B white paint on outer circumference Install the clutch discs A 6 and plates A 7 alternately starting with the clutch disc 1 5 white paint E 6 b ZA Install the clutch lifter plate 1 Install the clutch springs 2 and bolts 3 Tighten the clutch lifter plate bolts to the specified torque in a crisscross pattern in 2 or 3 steps TORQUE 12 N m 1 2 kgf m 9 Ibf ft Install the right crankcase cover page 12 8 12 13 CLUTCH GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL Remove the following Drive sprocket cover page 2 6 Clutch assembly page 12 9 Remove the pinch bolt 1 and gearshift pedal 2 Clean off any dirt from the gearshift spindle serration Pull out the gearshift spindle assembly 1 and washer 2 from the crankcase Remove the gearshift spindle oil seal 1 Be careful not to let Remove the shift drum stopper plate bolt 1 the removed parts fall into the crankcase 12 14 Be careful not to let Remove the following the removed parts fall into the crankcase Shift drum stopper plate 1 Dowel pins 2 Shift drum stopper arm bolt 3 Shift drum sto
237. r screw 2 to the specified torque TORQUE 2 5 N m 0 3 kgf m 1 8 Ibf ft 16 20 FRONT WHEEL SUSPENSION STEERING Align the edge of Install the brake master cylinder 1 and holder 2 with the master cylinder the UP mark 3 facing up with the punch Install the bolts 4 and tighten the upper bolt first then mark on the tighten the lower bolt to the specified torque handlebar TORQUE 9 8 N m 1 0 kgf m 7 2 Ibf ft Connect the brake light switch connectors 5 1 Align Align the edge of Install the clutch lever bracket 1 and holder 2 the bracket with the Install the bolts 3 and tighten the upper bolt first then punch mark on the tighten the lower handlebar Connect the clutch switch wire connectors 4 Secure the wires with the wire bands 1 Install each rearview mirror 2 and tighten the lock nut Check the throttle grip freeplay page 3 3 STEERING STEM REMOVAL Remove the following Front fender page 2 5 Headlight cowl page 2 5 Handlebar page 16 16 Front wheel page 16 4 Disconnect the ignition switch 3P Brown connector 1 Release the ignition switch wire from the harness bands 2 Remove the bolts 3 and meter stay 4 16 21 FRONT WHEEL SUSPENSION STEERING Remove the bolt 1 and brake hose guide 2 Remove the steering stem cap 1 Loosen the steering stem nut 2 Remove the fork legs page 16 6 Remove the stem nut washe
238. r unit 5P and ECM 33P Black connectors Erase the DTC s page 4 5 Turn the ignition switch ON and engine stop switch Check the sensor with the HDS pocket tester 15 DTC 8 1 indicated YES Replace the ECM with a known good and recheck NO Faulty original sensor unit TP sensor DTC 8 2 TP SENSOR HIGH VOLTAGE 1 TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester Is about 5 V indicated YES GOTO STEP 3 NO GO TO STEP 2 2 TP Sensor Inspection Check that the TP sensor voltage increases continuously when moving the throttle from fully closed to fully opened using the data list menu of the HDS pocket tester Is the voltage increase continuously YES Intermittent failure NO Replace the TP sensor sensor unit with a known good one and recheck 2 1 3 Sensor Resistance Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector 1 Measure the resistance at the ECM 33P Black connector of the wire side Connection Yellow Green white Standard 0 29 0 71 20 C 68 F Is the resistance within 0 29 0 71 YES GO TO STEP 4 NO Faulty sensor unit TP sensor TP Sensor Power Input Voltage Inspection Connect the ECM 33P Black conne
239. reather system condition page 3 4 Air cleaner element condition page 3 4 The engine must be warm for accurate idle speed inspection This system eliminates the need for manual idle speed adjustment compared to previous designs Start the engine and let it idle Check the idle speed IDLE SPEED 1 450 100 min rpm If the idle speed is out of the specification check the following ntake air leak or engine top end problem page 10 2 Throttle operation and freeplay page 3 3 ACV operation page 7 16 3 10 RADIATOR COOLANT COOLING 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 with the motorcycle in an upright position If the level is low remove the reserve tank cap 3 and fill the tank to the UPPER level line with a 1 1 mixture of distilled water and antifreeze RECOMMENDED ANTIFREEZE High quality ethylene glycol antifreeze containing silicate free corrosion inhibitors Check to see if there are any coolant leaks when the coolant level decreases very rapidly If the reserve tank becomes completely empty there is a possibility of air getting into the cooling system Be sure to remove any air from the cooling system page 9 5 SYSTEM Check the radiator air passages for clogging or damage Straighten bent fins and remove insects mud or othe
240. released REAR Remove the left side cover page 2 3 Disconnect the rear brake light switch 3P Black connector 1 Check for continuity between the switch side terminals There should be continuity with the brake pedal 2 depressed and no continuity when the brake pedal released 20 12 LIGHTS METERS SWITCHES NEUTRAL SWITCH REMOVAL INSTALLATION Drain the engine oil page 3 9 Remove the gearshift pedal page 12 14 Disconnect the neutral switch wire connector 1 Remove the neutral switch 2 and sealing washer 3 Installation is in the reverse order of removal Replace the sealing washer with a new one TORQUE Neutral switch 12 1 2 kgf m 9 Ibf ft Fill the engine with the recommended engine oil page 3 9 INSPECTION Make sure that the neutral indicator come on with the ignition switch ON and transmission is in neutral If the neutral indicator does not come on inspect as follows Remove the drive sprocket cover page 2 6 Disconnect the neutral switch wire connector Check for continuity between the switch terminal and engine ground There should be continuity with the transmission is in neutral and no continuity when the transmission is into gear If the continuity inspection is normal check for open circuit in Light green red wire between neutral switch wire connector and neutral indicator If the continuity inspection is abnormal replace the neutral switch
241. remature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage Add cooling system at the reserve tank Do not remove the radiator cap except to refill or drain the system All cooling system services can be done with the engine installed in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with a cooling system tester TROUBLESHOOTING Engine temperature too high Faulty indicator 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 fan control relay Faulty water pump Engine temperature too low Thermostat stuck open Faulty fan control relay Coolant leak Faulty water pump mechanical seal Deteriorated O ring Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hoses Damaged radiator COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR WATER HOSE SIPHON HOSE RESERVE TANK WATER HOSE WATER PIPE WATER PUMP 9 3 COOLING SYSTEM SYSTEM TESTING RADIATOR CAP SYSTEM PRESSURE INSPECTION Loosen the cap screw 1 and remove the radiator cap 2 Wet the sealing surfaces of the radiator cap 1 then install the cap onto the tester 2 Pressurize the cap using the tester Replace the radiator ca
242. rom the opposite side of the wheel install the remover shaft 2 and drive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS Bearing remover head 15 07746 0050400 2 Bearing remover shaft 07746 0050100 Pack new bearing cavities with grease Drive in a new left side brake disc side bearing 1 squarely with the sealed side facing up until it is fully seated TOOLS 2 Driver 07749 0010000 3 Attachment 32 x 35 mm 07746 0010100 4 Pilot 15 mm 07746 0040300 Install the distance collar Drive in a new right side bearing with the sealed side facing up until its inner race is fully seated on the distance collar 16 5 FRONT WHEEL SUSPENSION STEERING FORK 16 6 WHEEL CENTER ADJUSTMENT Adjust the hub position so that the distance from the left end surface 1 of the hub center to the side of rim 2 is within the following specification as shown WHEEL HUB TO RIM DISTANCE 23 45 1 0 mm 0 92 0 04 in WHEEL RIM RUNOUT Radial 2 0 mm 0 08 in or less Axial 2 0 mm 0 08 in or less Tighten the spokes in 2 or 3 progressive steps TOOL Spoke wrench 5 8 x 6 1 mm 07701 0020300 TORQUE 3 7 N m 0 4 kgf m 2 7 Ibf ft REMOVAL Remove the front wheel page 16 4 Remove the following from the left fork leg Bolts 1 Brake hose clamp 2 Brake caliper mounting bolts 3 Brake caliper 4 Socket bolts 1 F
243. rooves with the identification marks facing up left crankcase side Apply molybdenum oil solution to the shift drum 2 journal outer surface and grooves then install it while aligning the shift fork guide pins with the guide grooves 14 13 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Apply molybdenum oil solution to the shift fork shaft 1 outer surface and insert it through the shift forks into the right crankcase After installation check for smooth transmission e operation Assemble the crankcase page 14 18 BALANCER BALANCER SHAFT REMOVAL INSTALLATION Separate the crankcase halves page 14 4 1 Remove the balancer shaft 1 from the right crankcase Install the balancer shaft into the right crankcase Assemble crankcase page 14 18 BALANCER DRIVEN GEAR DISASSEMBLY ASSEMBLY Disassemble and assemble the balancer driven gear as following illustration SPRING WASHER P FP A BALANCER DRIVEN SUB GEAR WASHER BALANCER DRIVEN GEAR SNAP RING Align BALANCER DRIVEN GEAR WASHER SNAP RING SPRINGS BALANCER DRIVEN WASHER SUB GEAR SPRING WASHER 14 14 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER INSPECTION Inspect the following parts for scratch damage abnormal wear and deformation Replace if necessary Balancer driven gear Balancer driven sub gear Springs Balancer shaft Balancer drive gear CRANKCASE BEARING REPLACEME
244. rottle 3 4 times to bleed air from the system 3 Stop the engine and add the coolant 4 Install the radiator cap and tighten the cap screw Remove the reserve tank cap 1 and fill the reserve tank to the UPPER level line 2 Install the reserve tank cap THERMOSTAT REMOVAL INSTALLATION Drain the coolant page 9 5 Remove the bolts 1 and thermostat cover 2 COOLING SYSTEM Wear insulated gloves and adequate eye protection Keep flammable materials away from the electric heating element Do not let the thermostat or thermometer touch the pan or you will get false reading Remove the thermostat 1 from the cylinder head Installation is in the reverse order of removal NOTE Install the thermostat with the bleed hole 2 facing up When installing the thermostat align the tab of the seal ring 3 with the groove of the thermostat cover Fill and bleed the cooling system page 9 5 INSPECTION Visually inspect the thermostat 1 for damage Check the seal ring 2 for damage and replace if necessary 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 THERMOSTAT BEGIN TO OPEN 81 84 178 183 F VALVE LIFT 4 5 mm 0 18 in minimum at 95 C 203 F Replace the thermostat if the valve open at a temperatures other than those specified RADIATOR COOLING FAN
245. s the service procedures for the CRF250L Sections 1 and 3 apply to the whole motorcycle Section 2 illustrates procedures for removal installation of components that may be required to perform service described in the following sections Section 4 through 20 describe parts of the motorcycle grouped according to location Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition Performing the first scheduled maintenance is very important It compensates for the initial wear that occurs during the break in period Find the section you want on this page then turn to the table of contents on the first page of the section Most sections start with an assembly or system illustration service information and troubleshooting for the section The subsequent pages give detailed procedure Refer to the troubleshooting in each section according to the malfunction or symptom In case of an engine trouble refer to PGM FI section troubleshooting first Your safety and the safety of others is very important To help you make informed decisions we have provided safety messages and other information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing this vehicle You must use your own good judgement You will find important safety information in a variety of forms including Safety Labels on the vehicle Safety Messag
246. senssassuscussussussanssussussenssassuscessussuuses 13 5 FORK sussnssassssssssanssssesssussuscussuuseuseussansessassussenssussuscunsenssus 16 6 FRAME GUARD sasssssssssnsenssassuscensuascuscussusseuseussansenssussuseues 2 6 FRONT BRAKE CALIPER sassanssnssanssssansuasenssussensenseusous 18 10 FRONT FENDER sussnssanssssunssansuscussussuussussussenseussasseuseussusen 2 5 FRONT MASTER CYLINDER 18 7 FRONT WHEE FUEL GAUGE FUEL LEVEL SENSOR FUEL LINE 3 3 FUEL LINE INSPECTION sassnssassunsssssssuusanssussussenssuscuscunsen 7 4 FUEL PUMP RELAY sussussasssssusssasaussenssassuscunsssseuseussuuseus 7 10 FUEL PUMP UNIT sasssnsenssanssssussaseuscussussenssussussenssassuscusson 7 8 FUEL TANK sasanssausancussussussenssuscussenssASausesssussasRaRSSAUSARSSSSEN4EN 7 8 FUEL TANK SHROUD 2 4 GEARSHIFT LINKAGE 12 14 HANDLEBAR 16 16 HANDLEBAR SWITCH 20 11 HEADLIGHT sasssnssussasanssussussussusssuscussussussanssussussenseuscuscuss 20 3 HEADLIGHT AIM sassanssussanssssenssansuscuusussasssussussenssussuscunsen 3 18 HEADLIGHT COWL sasssssusssssanssussussunssusuaseussussussenssussunsens 2 5 HIGH COOLANT TEMPERATURE INDICATOR 20 10 HORN sussussasaussussussuusssssassussussussaussussussanssussussunssascuseussus 20 15 IACV sussnssassussssssasa
247. ssunsenseussunes 9 5 TH ROTTLE BODY suassussussussasssenssansensensuascuscensuasauseussunseus 7 11 THROTTLE OPERATION 3 3 TOOL BOX sasanssssssusanssussunsensassuscunssASaSuscusZsausasseussussauseussuuon 2 7 TORQUE VALU ES sasssussussussnssussusesssussuusenssuususeanssassuscunsen 1 9 TRANSMISSION sassnssassssssussusuusanssussusssanscussussenssaseuscussos 14 10 TROUBLESHOOTING ALTERNATOR STARTER CLUTCH 13 2 BATTERY CHARGING SYSTEM sassusssusassenssusssusenssas 19 2 BRAKE SYSTEM sussnsssssuusanssussasssssussusesuseussunsenseuseunes 18 2 CLUTCH GEARSHIFT LINKAGE sassssssussuassanscussusseusen 12 2 COOLING SYSTEM sassssssnssassuscussanseuseussuscusnsensuaseuseussos 9 2 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER sasssssussuusanssussunsenssassensensuaseuscensussauscusuusones 14 2 CYLINDER HEAD VALVES sasssusassussunseussansuscuusussanson 10 2 CYLINDER PISTON sassssssnsussanseussanseusanscussussenssuscuscuse 1 1 2 ELECTRIC STARTER SYSTEM sassnssussussansssssansauseussus 6 2 FRAME BODY PANELS EXHAUST SYSTEM 2 2 FRONT WHEEL SUSPENSION STEERING 16 2 FUEL SYSTEM sasssnssussasanssussussanssassussasSSARSSSSSRSSEsSHHSSSRSEN 7 2 IGNITION SYSTEM sussussusssssussussausseusussasssussussanseussussens 5 2 LUBRICATION SYSTEM sassssssssussssssussuscussenssaseuseussunes 8 2 REAR WHEEL SUSPENSION sasssssussussansenssassuscensuass 17 2 TURN SIGNAL LIGHT suassanssssussusseussussussenssassusceunssassuscuse 20 4 TURN SIGNAL RELAY sasssusussussu
248. sure to let it cool down before servicing 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 following color codes are used throughout this section Bu Blue G Green Lb Light Blue O Orange R Red Y Yellow Black Gr Gray Lg Light Green P Pink W White SYSTEM LOCATION IGNITION SWITCH FRONT BRAKE LIGHT SWITCH SPEEDOMETER ENGINE STOP SWITCH DIMMER SWITCH STARTER SWITCH CLUTCH SWITCH FUEL LEVEL SENSOR HORN SWITCH TURN SIGNAL SWITCH TURN SIGNAL RELAY HORN NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH SIDESTAND SWITCH VS SENSOR 20 2 HEADLIGHT BULB REMOVAL INSTALLATION Remove the headlight cowl page 2 5 Remove the dust cover 1 Unhook the bulb retainer 2 and remove the headlight bulb 3 Avoid touching halogen headlight bulb Fingerprints can create hot spots that cause a bulb to break Install the bulb while aligning its tabs with the slots of the headlight unit Hook the bulb retainer into the headlight unit groove Install the dust cover tightly against the headlight unit Install the headlight cowl page 2 5 HEADLIGHT UNIT REMOVAL INSTALLATION Remove the headlight cowl page 2 5 Remove the screws 1 and headlight unit 2 from the headlight cowl Installation is in the reverse order of removal TORQUE Headlight uni
249. sussanssussussusssAssuscussussessasSsausassunu 10 6 CHARGING SYSTEM INSPECTION sassnssassusssusuasauseusuos 19 4 CLUTCH suasassanssussusssenssassussanssussusnsenssASSsssssSASSSSSSSSSASHHRSESSAN 12 9 CLUTCH SWITCH sussnssansssssussasasssuussassusssusuesauseussussensen 20 14 CLUTCH SYSTEM sasssnssussasssssusssascussusssaseuseussussenseuseuscuse 3 18 COMPONENT LOCATION ALTERNATOR STARTER CLUTCH n 13 2 BRAKE SYSTEM sassanssnssansassensusssusssensussanssensessanseusuuses 18 3 CLUTCH GEARSHIFT LINKAGE sassussussussanssansussonsuus 12 3 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER sassasssussusasssussussanssassussenssuseuscussusseuseussuuneuus 14 3 CYLINDER HEAD VALVES sasanssasssssunssassuscuscussassensen 10 3 CYLINDER PISTON sanssnsenssassussussussausenssussussenssassuscuse 11 2 ENGINE REMOVAL INSTALLATION 15 3 FRONT WHEEL SUSPENSION STEERING 16 3 FUEL SYSTEM suassssasssuusussenscussussunsesssansussussaseussuseussuns 7 3 REAR WHEEL SUSPENSION 17 3 COOLANT REPLACEMENT 9 5 COOLING SYSTEM sassssssnssansssssussassuscunsuasauseussusseuseusuuuse 3 11 CRANKCASE ASSEMBLY sasssssassussssssussaseussensussanseusous 14 18 CRANKCASE BEARING REPLACEMENT 14 15 CRANKCASE BREATHER sassssssssunsensssssunsussusssascussussussuns 3 4 CRANKCASE SEPARATION saassasssssusssaneussussussanssuscuscune 14 4 CRANKSHAFT sasssussussusasssassussenssanauscussussauseussassesseussuneous 14 6 CYLINDER COMPRESSION sassussasaussunsuasauscussussauseu
250. suuuon 10 4 CYLINDER HEAD sussnssasaussussussassenssansessensuascuscenssssensanse 10 13 CYLINDER HEAD COVER sussnssasasssussussassenssassunsensuusuusen 10 4 CYLINDER PISTON sassasssnssanssssensasauscussussanseussunseuseusuuues 11 3 DRIVE CHAIN suasassanssusssssenssassunsussusseusesssAssusscunssascuscussunen 3 12 DRIVE CHAIN GUIDE 17 12 DRIVE CHAIN SLIDER sussussasssssasssussuscsssussussanssuscussensuass 3 14 DRIVE SPROCKET COVER sesssusanssassansunssassuscuscussussanseuss 2 6 DTC INDEX sassansasnssussussensuansuscunsussssseussusssssenssaAusuassanssassusosss 4 7 DTC TROUBLESHOOTING sassussasssssanssassunsenssascuscussussaus 4 10 ECM sasasssssussusanssussusEasSSSSSEHESESSASSESSSRSSASSESRSSESEsSSSRSESSEN4SSRESESSEN 4 49 ECT SENSOR sassnssassunsesssussusesssuusussaussussussenssassuscusseusausen 4 46 EMISSION CONTROL SYSTEMS 1 27 IDLE SPEED sussnssassussensuasusssenssusaussuscusseuseusuusuon 3 10 ENGINE INSTALLATION sassanssussansussenssansunsenssassunsensussous 15 7 ENGINE OIL sasssssussussanssussussenssussussusssassuscussussesseusZssssauseussns 3 9 ENGINE OIL FILTER sussussassusssanssassussenssansunsenssansuscussuusous 3 10 ENGINE OIL STRAINER SCREEN sassnssasanssussunsenssussuseeus 8 4 ENGINE REMOVAL sassussasssssenssansuscenssancuscussussenseussuscussen 15 4 EXHAUST PIPE MUFFLER sussussasssssenssunsensenssascunsonsuusaus 2 11 FAN CONTROL RELAY sassnssunssusassssssussauscussusseusesscussunsen 9 12 FLYWHEEL sasssnssussussus
251. t FORK FLUID CAPACITY Right side 658 2 5 cm 22 3 0 08 US oz 23 2 0 09 Imp oz Left side 683 2 5 cm 23 1 0 08 US oz 24 0 0 09 Imp 02 Slowly pump the fork pipe several times to remove the trapped air from the lower portion of the fork pipe Compress the fork pipe fully and leave it for 5 minutes to remove air bubbles from the fluid Measure the oil level from the top of the fork pipe by supporting the fork leg vertically FORK OIL LEVEL Right side 122 mm 4 8 in Left side 38 mm 1 5 in Install the fork spring 1 with the tapered side facing up Right side only Loosen the lock nut 1 until it stops Right side only Install the rebound spring 2 to the fork rod Install the spring seat 3 in the shown direction Apply recommended fork oil to a new O ring 4 and install it to the fork cap 5 Install the fork cap to the fork rod and tighten it until it stops Hold the fork cap with a wrench then tighten the lock nut to the specified torque TORQUE 20 N m 2 0 kgf m 15 Ibf ft 16 15 FRONT WHEEL SUSPENSION STEERING Right side Push the fork cap 1 down and compress the fork spring then install the stopper ring 2 into the groove in the fork pipe Right side only Left side Loosen the lock nut 1 until it stops Left side Apply recommended fork oil to a new O ring 2 and install it to the fork cap 3 Install the fork cap
252. t cowl page 2 5 Disconnect the ignition switch 3P Brown connector 1 Check for continuity between the switch side connector terminals in each switch position according to the chart page 21 2 REMOVAL INSTALLATION Remove the top bridge page 16 21 Remove the ignition switch mounting bolts 1 and ignition switch 2 NOTE Use a drill or an equivalent tool when removing the ignition switch mounting bolts Install the ignition switch onto the top bridge Install and tighten new ignition switch mounting bolts to the specified torque TORQUE 24 2 4 kgf m 18 Install the top bridge page 16 24 HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH Remove the headlight cowl page 2 5 2 Disconnect the right handlebar switch 9P Black connector 1 Check for continuity between the switch side connector terminals in each switch position according to the chart page 21 2 20 11 LIGHTS METERS SWITCHES LEFT HANDLEBAR SWITCH Remove the headlight cowl page 2 5 Disconnect the left handlebar switch 14P Gray connector 1 Check for continuity between the switch side connector terminals in each switch position according to the chart page 21 2 BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors and check for continuity between the switch terminals 1 There should be continuity with the brake lever squeezed and no continuity with the brake lever
253. t mounting screw 1 2 0 1 kgf m 0 9 POSITION LIGHT BULB REMOVAL INSTALLATION Remove the headlight cowl page 2 5 Pull out the bulb socket 1 from the headlight case Remove the bulb 2 from the socket Installation is in the reverse order of removal LIGHTS METERS SWITCHES 1 20 3 LIGHTS METERS SWITCHES TURN SIGNAL LIGHT Left side only BULB REMOVAL INSTALLATION Remove the screw 1 and turn signal light lens 2 by releasing its tab 3 2 3 While pushing in the bulb 4 turn it counterclockwise to remove it Installation is in the reverse order of removal 4 Check that the packing is installed in position and is good condition replace it with a new one if necessary i 4 FRONT TURN SIGNAL UNIT REMOVAL INSTALLATION Remove the headlight cowl page 2 5 Disconnect the front turn signal 2P connector 1 Right side Light blue Left side Orange Release the wire from the wire band 2 Release the wire from the wire band 3 Remove the nut 4 and front turn signal unit 5 Installation is in the reverse order of removal TORQUE Turn signal unit mounting nut 21 N m 2 1 kgf m 15 Ibf ft l D 3 Left side onl NOTE Align the flats of the turn signal unit and speedometer stay REAR TURN SIGNAL UNIT REMOVAL INSTALLATION Remove the rear fender page 2 7 Disconnect the
254. t turn signal light 12V 21Wx2 Rear turn signal light 12V 21Wx2 Instrument light LED Turn signal indicator LED High beam indicator LED Neutral indicator LED MIL LED Fuse Main fuse 30A Sub fuse 10Ax5 5Ax1 TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE N m kgf m Ibf ft FASTENER TYPE kgf m Ibf ft 5 mm bolt and nut 5 2 0 5 3 8 5 mm screw 4 2 0 4 3 1 6 mm bolt and nut 10 1 0 7 6 mm screw 9 0 0 9 6 6 Include SH flange bolt 6 mm flange bolt 8 mm head large 8 mm bolt and nut 22 2 2 16 flange and nut 12 1 2 9 10 mm bolt and nut 34 3 5 25 8 mm flange bolt and nut 27 2 8 20 12 mm bolt and nut 54 5 5 40 10 mm flange bolt and nut 39 4 0 29 GENERAL INFORMATION ENGINE amp FRAME TORQUE VALUES Torque specifications listed below are for important fasteners Others should be tightened to standard torque values listed above FRAME BODY PANELS EXHAUST SYSTEM THREAD TORQUE DIA N m kgf m Ibf ft REMARKS Hook bolt 4 8 21 2 1 15 Left side cover assembly screw 2 4 0 9 0 1 0 7 Right fuel tank shroud assembly screw 4 4 0 9 0 1 0 7 Left fuel tank shroud assembly screw 2 4 0 9 0 1 0 7 Headlight cowl mounting bolt 4 6 8 5 0 9 6 3 Rear side reflector mounting nut U
255. ter and ECM If the White blue wire is OK replace the ECM with a known good one and recheck Ifthe MIL turns off check the following Check the continuity between the ECM 33P Black 1 connector 1 of the wire side and ground 1 CONNECTION Blue Ground STANDARD Nocontinuity TOOL ii Test probe 07ZAJ RDJA110 Bu If there is continuity check for short circuit in the Blue wire between the DLC and ECM If there is no continuity replace the ECM with a known good one and recheck 4 43 PGM FI SYSTEM SENSOR UNIT REMOVAL INSTALLATION Remove the left fuel tank shroud page 2 4 Disconnect the sensor unit 5P connector 1 Remove the torx screws 2 and sensor unit 3 from the throttle body Remove the O ring 1 Install a new O ring to the throttle body properly NOTE If the O ring is not installed properly the idle air will leak and engine idle speed will be unstable Install the sensor unit 2 to the throttle body by aligning the following of the TP sensor with the boss of the throttle valve IAT sensor of the sensor unit with the hole of the p throttle body Install and tighten the sensor unit torx screws 1 to the 1 specified torque TORQUE 3 4 0 3 kgf m 2 5 Ibf ft Connect the sensor unit 5P connector 2 Install the left fuel tank shroud page 2 4 Perform the TP sensor reset procedure page 4 45 4 44 PGM FI SYSTE
256. text without the use of the symbols Replace the part s with new one s before assembly Use the recommend engine oil unless otherwise specified E Use molybdenum oil solution mixture of the engine oil and molybdenum grease in a ratio of 1 1 Use multi purpose grease lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Example e Molykote G n Paste manufactured by Dow Corning U S A Honda Moly 60 U S A only Rocol ASP manufactured by Rocol Limited U K Rocol Paste manufactured by Sumico Lubricant Japan Use silicone grease Apply locking agent Use a medium strength locking agent unless otherwise specified Apply sealant Use DOT 3 or DOT 4 brake fluid Use the recommended brake fluid unless otherwise specified Use fork or suspension fluid 5 GENERAL INFORMATION FRAME BODY PANELS EXHAUST SYSTEM MAINTENANCE PGM FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER SYSTEM FUEL SYSTEM LUBRICATION SYSTEM COOLING SYSTEM CYLINDE
257. the fuel supply system page 7 4 Faulty pressure regulator fuel and poor fuel economy 2 Inspect the air cleaner element page 3 4 pump 3 Inspect the ignition system page 5 4 Faulty injector Faulty MAP sensor Idle speed is below 1 Inspect the engine idle speed page 3 10 specifications or fast idle too low 2 Inspect the IACV page 7 16 No MIL blinking 3 Inspect the ignition system page 5 4 Idle speed is above 1 Inspect the engine idle speed page 3 10 ntake air leak specifications or fast idle too 2 Inspect the throttle operation and freeplay Engine top end problem high No MIL blinking page 3 3 Air cleaner element condition 3 Inspect the IACV page 7 16 4 Inspect the ignition system page 5 4 MIL never comes ON at all the MIL circuit page 4 43 MIL stays ON No DTC set Inspect the DLC circuit page 4 43 2 Inspect the MIL circuit page 4 43 4 6 DTC INDEX PGM FI SYSTEM DTC Refer Refer MIL Function Failure Symptom Fail safe function to to blinks DTC MIL MAP sensor circuit low voltage less than 0 195 V Engine operates normally 1 1 1 MAP sensor or its circuit malfunction Pre program value 525 mmHg 4 10 700 hPa MAP sensor circuit high voltage more than 3 848 V Engine operates normally 4 29 1 2 1 Loose or poor contact of the sensor unit Pre program value 525 mm
258. the hydraulic system page 18 4 DISASSEMBLY ASSEMBLY Disassemble and assemble the rear brake master cylinder as following illustration Replace the master piston spring piston cups and snap ring as a set Do not allow the piston cup lips to turn inside out Becertain the snap ring is firmly seated in the groove Standard push rod length 64 65 mm 2 52 2 56 in MASTER CYLINDER MASTER PISTON e Je SNAP RING SPRING 9 BOOT PISTON CUPS 4 SX PUSH ROD LOCK NUT 17 2 N m 1 8 kgf m 13 Ibf ft PUSH ROD ASSEMBLY BRAKE IONE 18 9 BRAKE SYSTEM INSPECTION Check the following parts for scoring scratches deterioration or damage Master cylinder Master piston Piston cups Spring Measure the parts according to BRAKE SYSTEM SPECIFICATIONS page 1 8 and replace if necessary FRONT BRAKE CALIPER REMOVAL INSTALLATION Drain the brake fluid from the front brake hydraulic system page 18 4 c 4 Ly 3 When removing the Remove the following oil bolt cover the Oil bolt 1 0831052 Sealing washers 2 Pa prevent _ Brake hose 3 contamination _ Brake caliper mounting bolts 4 Brake caliper 5 Installation is in the reverse order of removal Replace the brake caliper mounting bolts and sealing washers with new ones TORQUE Brake caliper mounting bolt 30 3 1 kgf m 22 Ibf ft Oil bolt 34
259. tion AIR CLEANER REMOVAL INSTALLATION NOTE The viscous paper element cannot be cleaned because the element contains a dust adhesive f the motorcycle is used in unusually wet or dusty areas more frequent inspections are required Remove the right side cover page 2 3 Remove the screws 1 and air cleaner cover 2 Remove the air cleaner element 3 by releasing its grooves from the housing Inspect the air cleaner element in accordance with the maintenance schedule page 3 2 or any time it is excessively dirt or damaged Install the air cleaner element in the reverse order of removal NOTE After installing air cleaner element make sure the air cleaner element grooves are secure Check that the condition of the packings replace them if necessary TORQUE Air cleaner cover screw 1 2 0 1 kgf m 0 9 Ibf ft CRANKCASE BREATHER Service more frequently when ridden in rain at full throttle or after the motorcycle is washed or overturned Check the crankcase breather hose 1 for deterioration damage or loose connection Make sure that the hoses are not kinked pinched or cracked Replace the crankcase breather hose if necessary 2 Service if the deposits level can be seen in the air cleaner housing drain plug SPARK PLUG Clean around the spark plug base with compressed air before removing the spark plug and be sure that no debris is allowed to
260. ty check for an open circuit in the Green wire BACK UP VOLTAGE LINE Measure the voltage between the speedometer 16P connector 1 and ground CONNECTION Red Ground There should be battery voltage at all times If there is no battery voltage check the following Open circuit in the Red wire Blown ODO CLOCK fuse 5 A Blown main fuse 80 A Open circuit in Red white wire between the fuse box and starter relay switch SPEEDOMETER DIGITAL CLOCK SET PROCEDURE E TYPE Turn the ignition switch ON and engine stop switch C7 Push and hold both the A button 1 and B button 2 until the speed and mileage units 3 start blinking Push the B button to select either mph amp mile or km h amp km for the speedometer odometer and trip meter Push the A button to confirm the unit setting and then the display moves to the clock setting The hour digits 4 will start blinking Push the B button until the desired hour is displayed NOTE Push and hold to advance the hour fast Push the A button then the minute digits 5 start blinking Push the B button until the desired minute is displayed NOTE Push and hold to advance the minute fast Push both the A button and B button to complete the setting NOTE The time can also be set by turning the ignition switch OFF LIGHTS METERS SWITCHES 1
261. ty starter clutch Damaged reduction gear Damaged starter driven gear Damaged or faulty starter motor pinion gear COMPONENT LOCATION 128 N m 13 1 kgf m 94 Ibf ft 13 2 y x 2 rel ff p j D 2 2 em Com AC io 7 1 A oy Nga Su ALTERNATOR STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Drain the engine oil page 3 9 Remove the following Left side cover page 2 3 Drive sprocket cover page 2 6 Gearshift pedal page 12 14 Disconnect the following Alternator 3P connector 1 CKP sensor neutral switch 3P Black connector 2 Release the alternator wire 3 from the clamp 4 Disconnect the neutral switch connector 1 and release the wire from the left crankcase cover groove The left crankcase Loosen the left crankcase cover bolts 2 in a crisscross cover stator is pattern 2 or steps and remove the bolts and left magnetically crankcase cover 3 attracted to the flywheel be careful during removal Remove the dowel pins 1 and gasket 2 INSTALLATION Be careful not to Clean any gasket material from the mating surfaces of damage the mating the left crankcase and cover Install the dowel pins 1 and new gasket 2 ALTERNATOR STARTER CLUTCH The left crankcase Install the left crankcase cover 1 and bolts 2 c
262. ub frame assembly rearward then disconnect the air cleaner connecting hose from the throttle body Remove the sub frame Install the sub frame in position connect the air cleaner connecting hose to the throttle body Tighten the band screw to the specified torque TORQUE 1 5 N m 0 2 kgf m 1 1 Ibf ft Loosely install all the mounting fasteners Tighten the upper mounting nut first then the lower bolts to the specified torque TORQUE Sub frame upper mounting nut 27 2 8 kgf m 20 Ibf ft Sub frame lower mounting bolt 27 N m 2 8 kgf m 20 Ibf ft Install the removed parts in the reverse order of removal TORQUE Rear master cylinder reservoir mounting bolt 10 1 0 kgf m 7 2 13 FRAME BODY PANELS EXHAUST SYSTEM SIDESTAND 2 14 REMOVAL INSTALLATION Remove the sidestand switch page 20 14 Remove the return spring 1 and sub spring 2 Remove the pivot lock nut 8 pivot bolt 4 and sidestand 5 Apply grease to the sidestand pivot bolt sliding surface Install the sidestand and pivot bolt then tighten it to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Turn the pivot bolt counterclockwise about 45 90 Install the pivot lock nut and tighten it to the specified torque while holding the pivot bolt TORQUE 30 N m 3 1 kgf m 22 Ibf ft Install the return spring and sub spring as shown Install the sidestand switch page 20 14 2
263. usesssussussenssuscussunsusssanen 20 16 VALVE CLEARANCE sassansenssaseussussussessesssansessessuAsauscussuuos 3 6 VS SENSOR sasssnssussasssssussussassesssanseasseussaseuscunsuaseuscussunseus 20 8 WATER PIPE sassasssssusssanssenssascuscussussansssssussenssussuscusseusuusen 9 13 WATER PUMP sasssssassusssanssussussanssassussensuasauscussensunssussuscussen 9 8 WHEELS TIRES sussnssasasssussussansesssassussenssascuscussusseuseussusen 3 20 WIRING DIAGRAM sasssssanssusenssussansenssussancussenssaseussuscuscuse 21 2
264. ussussassusssesnssessuusanssussussenssassuscessusseuseuseus 7 15 IGNITION COIL sassansssssussussanssussussenssassussenssassuscunssssausenssus 5 6 IGNITION SWITCH sassassenssansuscussussensessuaseuscenssascuscussenee 20 11 IGNITION SYSTEM INSPECTION sasanssassunsssssussaneuseensunen 5 4 IGNITION TIMING sassnssassunssssssssssenssassuscunsussuusenssussussenssuso 5 6 INJECTOR sussussassusssanssussussusssAnssssssssssassSESSAsSSSSSESSARSSHRSSSSEN 7 14 LEFT CRANKCASE COVER sesssusaussussusssenssassusesnsussausones 13 3 LUBRICATION amp SEAL POINTS sasssnsuusussanssussussenseussuses 1 15 LUBRICATION SYSTEM DIAGRAM sasssssanssussussanssassuncene 8 3 MAIN JOURNAL BEARING sansansssssasenssenssascuscunsuasensensous 14 7 MAINTENANCE SCHEDULE sassassuussssssssuussascsusenssascunsenss 3 2 MIL CIRCUIT TROUBLESHOOTING 4 43 MIL TROUBLESHOOTING sassassanssussunsessusssuseussussussenseuse 4 29 MODEL IDENTIFICATION sasansssssussanssussuscussusSussasSSATSARRHUR 1 2 NEUTRAL DIODE sussussasssssssssusuuscussessussasssussussanssussuscenseuss 6 9 NEUTRAL SWITCH sussnssassssssnssassuscenssassuncensuasauseuseussous 20 13 NUTS BOLTS FASTENERS sassaussussussauseussunseuseussuusousen 3 19 O2 SENSOR saasssssussusssssanssasasssussunsensenssascussensuascuscussussens 4 47 OIL PUMP sussussssasssassanseszanssansuscunsuusauseussunsussensusseuseussunsens 8 4 PGM FI SYMPTOM TROUBLESHOOTING 4 6 PGM FI SYSTEM DIAGRAM sasssnssussansuscussusseuseussassenseusuus 4 3 PGM FI SYSTEM LOCATI
265. wire side Connection Gray blue Gray blue TOOL Test probe 07ZAJ RDJA110 Is there continuity YES Replace the ECM with a known good and recheck Open circuit in Gray blue wire DTC 11 VS SENSOR NOTE Before starting the inspection check for loose or poor contact on the VS sensor 3P Blue connector and recheck the MIL blinking VS SENSOR G GBI BI R W R PGM FI SYSTEM 2 Gr Bu G W 1 Gr Bu Gr Bu 2 ECM To SPEEDOMETER NC Probable cause Open or short circuit in Pink or White red wire between the VS sensor and ECM Faulty VS sensor Faulty ECM wR 4 19 PGM FI SYSTEM DTC 11 1 VS SENSOR 4 20 1 VS Sensor System Inspection Erase the DTC s page 4 5 Test ride the motorcycle Stop the engine Turn the ignition switch ON and engine stop switch Check the VS sensor with the HDS 15 DTC 11 1 indicated YES GOTO STEP 2 NO Intermittent failure Loose or poor contact on the VS sensor 3P Blue connector Speedometer Inspection Inspect the speedometer page 20 5 Is the speedometer normal YES GO TO STEP 3 NO Replace or repair the abnormal circuit VS Sensor Signal Line Inspection Turn the ignition switch OFF Disconnect the ECM 33P
266. y Check the sidestand ignition cut off system Sit astride the motorcycle and retract the sidestand Start the engine Shift the transmission in gear and lower the sidestand The engine should stop as the sidestand is lowered If there is a problem with the system check the sidestand switch page 20 13 SUSPENSION Loose worn or damaged suspension parts impair motorcycle stability and control Loose worn or damaged suspension parts impair motorcycle stability and control FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brake 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 For fork service page 16 6 REAR SUSPENSION INSPECTION Check the action of the rear shock absorber by compressing the rear end several times Check the entire shock absorber assembly for leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts For shock absorber service page 17 6 Support the motorcycle using a safety stand or hoist raise the rear wheel off the ground Check for worn swingarm bearings by grabbing the swingarm ends and attempting to move it side to side Replace the bearings if any looseness to noted For swingarm service page 17 10 NUT
267. y connected starter motor cable 4 Faulty starter motor 5 Poorly connected battery ground cable Starter motor turns but engine does 1 Starter motor is running backwards not turn Case assembled improperly Terminals connected improperly 2 Faulty starter clutch 3 Damaged or faulty starter idle gear and or reduction gear Starter relay switch Clicks but engine does not turn over Crankshaft does not turn due to engine problems ELECTRIC STARTER SYSTEM SYSTEM LOCATION ENGINE STOP SWITCH STARTER SWITCH IGNITION SWITCH CLUTCH SWITCH BATTERY MAIN FUSE 30 A FI IGN FUSE 10 A STARTER MOTOR NEUTRAL SWITCH STARTER RELAY SIDESTAND SWITCH SWITCH MAIN FUSE BUR 1 30 A e IGNITION SWITCH FUSE 10 STARTER MOTOR p BIG STARTER SWITCH ENGINE STOP SWITCH BI Bu NEUTRAL DIODE i as Lg R SWITCH ay BI Black NEUTRAL Lg BI Ec n Bu Blue SWITCH G Green Lg Light green R Red To NEUTRAL um Y Yellow INDICATOR W White O Orange 6 3 ELECTRIC STARTER SYSTEM STARTER MOTOR REMOVAL INSTALLATION Always turn the ignition switch OFF before servicing the starter motor The motor could suddenly start causing serious injury Remove the cam chain tensioner lifter page 11 7 Remove the bolts 1 and clutch cable guide 2 Disconnect the clutch cable 3 from the clutch lifter arm

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