Manual de Reparatie Honda CBR 1000 RR

HOW TO USE THIS MANUAL CONTENTS
This service manual describes the servic e procedures lor the

CBR 1000 RR-4. GENERAL INFORMATION
Follow the Maintenance SChedule (Section 4) recomm endations to
ensure that the vehicle is in peak operating conditio n and the emiss ion TECHNICAL FEATURES
levels are within the stand ards set by the U.S. Environmental Pr otection
Agency, California Air Resources Board and Transport Canada . FRAME/BODY PANELS/EXHAUST
Perl orm ing the first scheduled maintenance is very impor tant. 1\
SYSTEM
co m pens ates for the initial we a r that occ urs du ring t he break-in pe rio d.
MAINTENANCE
Sectio ns 1 and 4 apply to the whole motorcycle. Secti on 3 illustrates
procedures tor remov al/insta llation of compo nents thai may be requ ired
10perform service descr ibed in the following sections. LUBRICATION SYSTEM
Sectio n 5 through 20 descri be pari s of the motorcycle , grouped
acco rding to location.
Find the section you want on this page , then turn to the table of co ntents z
on the first page of the sectio n.

II:
COOLING SYSTEM
Most sectio ns start with an ass embly or system illustra tion , service I-
information and troubleshooting lor the section. The subsequent pages w ENGINE REMOVAUINSTALLATION
give detailed procedure.
>
If you are not familiar with this motorcycle , read Technical Featu res in
0:
Section 2 .
c CYLINDER HEADNALVES
If you don't knOW" the source 'of the trouble, go to section 22 c
z CLUTCH/STARTER CLUTCH
TroubleShooting .

w
z ALTERNATOR
Your safety, and the safety of othe rs, is very importa nt. To help you
make informed decisions we have provide d safety messages and
othe r informalion throughout this manual. Of course, it is not
az
practical or possible to warn you about all the hazar ds associated
w TRANSMISSION/GEARSHIFT LINKAGE
with ser vicing this vehicle.
You must use your own good jud gement. CRANKCASE/CRANKSHAFT/BALANCER/
You will find important safety information in a variety of forms PISTON/CYLINDER
including : .
Safety Labels - on the vehicle FRONT WHEEUSUSPENSION/
Safety Messages - preceded by a safety alert sym bol & and (J) STEERING
one of three signal words , DANGER, WARN ING , or CAUT ION. Cii
These signal words mean : (J) REAR WHEEUSUSPENSION
~ You WILL be KILLED or SERIOUSLY

J:
~ HURT if you don't fellow instructions. o HYDRAULIC BRAKE
~ You CAN be KILLED o r SERIOUSLY HU RT
~ if you don't follOW" instructions.
BATTERY/CHARGING SYSTEM
~ You CAN be HURT if you don 't follow
~ instructions. ..J

o
IGNITION SYSTEM
Instructions - how to serv ice this vehicle correct ly and safely.
0: ELECTRIC STARTER
As you read this manual , you will find information mat is preceded by a I-
U
CNOnC(] symbol . The purpose of this message is to help prevent W
damage to your vehicle, other property, Of the envi ronment. ..J LIGHTS/METERS/SWITCHES
w
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
Date of Issue: March, 2004
Contents
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supp lementary information is required pertaining to
these symbols, it would be explained specifically in the text without th e use of the symbols.
S~ Rep lace the part(s) with new one(s) before assembly.
-, Use recomme nded engin e oil, unless otherwise specified.
~ Use molybd enum oil solution (mixtur e of the engine oil and molybdenum grease in a ratio of 1 : 1).
_-$iiiffi Use mult i-purp ose grease (Lithium base d multi-purpose grease NLGI #2 or eq uivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum dis ulfide, NLGI #2 or
equivalent).
~ Examp le: Molykote BR-2 plus man ufactured by Dow Co rning U.S.A.
MUlti-p urpose M-2 manufactured by Mitsubishi Oil, Japa n
Use molybdenum disulfide pas te (containing more than 40% molybd enum disulfide, NLGI #2 or
equivalent).
Exampl e: Molykote G-n Paste manufactu red by Dow Corning U.S.A.
~ Honda Moly 60 (U.S.A. only)
Rocol ASP manufacture d by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
~ Use silicone grease.
0 Apply a locking agent. Use a midd le strength locking age nt unless otherwise specified.
MJ
",,'Uill Apply sea lant.
I Use DOT 4 brake fluid. Use the recom mended brake fluid unless otherw ise spec ified.
.. Use Fork or Suspension Fluid.
Contents
1. GENERAL INFORMATION

SERVICE RULES 1-2 REAR WHEEL:/SUSPENSION
SPECIFICATIONS .. 1-9
MODEL IDENTIFiCATION.. 1-2
HYDRAULIC BRAKE
GENERAL SPECiFiCATIONS .................. 1-4 SPECIFICATIONS..........................1-10
LUBRICATION SYSTEM BATTERY/CHARGING SYSTEM

SPECiFiCATIONS.................... 1-6 SPECIFICATIONS........................ 1-10
FUEL SYSTEM (Programmed Fuel IGNITION SYSTEM SPECIFICATIONS ........ 1-10

Injection) SPECiFiCATIONS 1-6
ELECTRIC STARTER SPECIFICATIONS ....1-10
COOLING SYSTEM SPECIFICATIONS ......... 1-6
LIGHTS/METERS/SWITCHES
CYLINDER HEADIVALVES SPECIFICATIONS............................ 1-11
SPECiFiCATIONS ........................ 1-7
STANDARD TORQUE VALUES .............. 1-12
CLUTCH/STARTER CLUTCH
SPECiFiCATIONS ................................ 1-7 ENGINE & FRAME TORQUE VALUES ......1-12
TRANSMISSION/GEARSHIFT LINKAGE LUBRICATION & SEAL POINTS ................ 1-20

SPECIFICATIONS 1-8
. CABLE & HARNESS ROUTING .. 1-24
CRANKCASE/CRANKSHAFT/BALANCER/
PISTON/CYLINDER SPECIFICATIONS 1-8 EMISSION CONTROL SYSTEMS ........ 1-36
FRONT WHEEl/SUSPENSION/STEERING EMISSION CONTROL INFORMATION

SPECiFiCATIONS ............................ 1-9 LABEL (U.S.A. ONLY)......................1-39
1-1
Contents Chapter 1
GENERAL INFORMATION
SERVICE RULES
1. Use ge nu in e Hon da or Ho nda-reco mmen ded p arts and lubricant s o r the ir equ iva lent s. Part s that don't meet Hon da's
design spe ci fi cat ions ma y cause damage to the motorcycle .
2. Us e th e speci al too ls designed fo r t his pr oduct to avoid damage and inco rrec t assembly.
3. Us e only metri c tools when servicing the motorcycle. Met ric bolt s, nuts an d screws a re not inte rcha ngea ble w ith
Eng lish fa st en er s.
4. Insta ll new ga skets, Ovrinqs, cotter pins, and lock plates when reassem blin g .
5. Wh en tightening bolts o r nuts, begin with the larger diameter or inner bolt first . Then t ight en to the spec ified torque
diag onally in in crem ent al steps unless a parti cular seque nce is sp eci fied .
6. Clean parts i n cle ani ng solve nt upon disassembly. Lubri cate an y slidi ng surfaces before reassembly.
7. After reassem bly, check all parts f or proper in sta llation and o pe ratio n.
S. Rou t e all electrical w ir es as shown in the Cab le an d Harness Routing (page 1-24).
MODEL IDENTIFICATION
1-2
Contents Chapter 1
GENERAL INFORMATION
The frame serial number is stamped on the right side of the stee ring
head .
The engine serial number is stamped on the rear side of the lower
crankcase.
The th rottle body ide ntificatio n num ber is stamped o n the intake side
of the throttl e body as shown .
THROTTLE BODY IDENT IFICATION " NUMBER
The co lor label is attached on th e rear f end er B as shown. W hen

ordering co lo r-coded parts, always specify the desig nated color co de.
1-3
Contents Chapter 1
GENERAL INFORMATION
Th e Ve hicl e Ident ification Number (VIN ) is locat ed on the left side of
the ma in frame on th e Safet y Certi fication Labe ls. VEHICLE IDENTIFICATiON NUMBER (VIN)
GENERAL SPECIFICATIONS
ITE M SPECIFICATIONS
DIMENSIONS Overa ll lengt h 2,035 mm (80.1 in )
Overa ll width 720 mm (28.3 in )
Overa ll heig ht 1,120 mm (44.1 in)
Wheelbase 10405 mm (55.3 in )
Seat heig ht 820 mm (32.3 in )
Ground clea rance 130 mm (5.1 in)
Dry weig ht A, CM type : 180 kg (397 Ibs)
AC type: 181 kg (399 Ibs)
Curb weight A, CM type: 210 kg (463 lbs)
AC ty pe: 211 kg (465 Ibs)
M ax imum w e ight A. AC t ype : 166 kg (366 Ibs )
capac ity CM type : 170 kg (375 Ibs )
FRAME Frame typ e Diamond
Fro nt suspens ion Telescopi c fork
Front axle tra vel 110 mm (4.3 in)
Rea r suspension Swinga rm
Rear axle tra ve l 135 mm (5.3 in)
Front ti re size 120170 ZR17 M /C (58W)
Rear t ire size 190 /50 ZR17 M /C (73W)
Front tire brand Bridgesto ne: BT014F RADIAL G
Pirell i: DiAB LO CORSA H
Rear tire bra nd Bridgestone: BT014R RA DIAL G
Pirel li: DIABLO CORSA H
Front brake Hydraulic do uble disc
Rear brake Hydraulic singl e disc
Caster a ng le 23 0 4 5'
Trail length 102 m m (4.0 in )
Fuel tank capacity 18.0 liter (4.76 US gal, 3.96 Imp gal )
1-4
Contents Chapter 1
GENERAL INFORMATION
ITEM SPECIFICATIONS
EN GINE Cyl inde r arra ngement 4 cylinde rs in-line, inclined 28 from vertica l
Bo re and stroke 75.0 x 56.5 mm 12.95 x 2.22 in )
Displacem ent 998.4 em ' (60.92 cu-ln]
Co m pression rat io 11 .9: 1
Valve t rain Chain dr iven, DO HC
Intake o pe ns: at 1 mm 10.04 in ) lift 18' BTDC
va lve closes: at 1 mm 10.04 in ) lift 46' A BDC
Exh aust ope ns: at 1 mm (0.04 in) lift 39' BBDC
valve closes: at 1 mm (0.04 in) lift 11 ' ATDC
Lubrication system Fo rced pressu re and w et sump
Oil pump type Trochoid
Cooling system Liquid coo led
Air f iltration Paper eleme nt
Engi ne d ry weight 65.8 kg (145.1 Ibs)
Fir ing o rder 1 -2 -4 - 3
FUEL DELIVERY Ty pe PG M -FI (Prog ram m ed Fu el Inj ection )
SYSTEM Th rottle bo re 44.0 mm (1.73 in)
DRIVE TRAIN Clutch system Multi-p late, we t
Clutch ope ration system Hydraulic o pe rati ng
Transm issio n Constan t mes h, 6-speed s
Pri m ary re duction 1.604 (77/48T)
Final reduc tion 2.562 (16/41T)
Gear ratio 1st 2.538 (33 /13T)
2nd 1.941 133/17T)
3rd 1.578 130/19T)
4th 1.380 (29/2 1T)
5th 1.250 (25/20T)
6t h 1.160 (29/25T)
Gear shift pattern 1 - N-2 -3 -4 -5-6
ELECTRICAL Ign ition syste m Co mpute r-co nt rolle d d igital transisto rized
w ith elect ric adva nce
Starting system Electr ic starte r motor
Charging syste m Triple phase o utp ut alternator
Reg ulator/rectifier SCR shorted/triple pha se, full wave rect ifica-
tio n
Lighting system Battery
1-5
Contents Chapter 1
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STAN DARD SERVICE LIMIT
Eng i ne oil capacity After draining 3.0 lit er (3.2 US qt. 2.6 Im p qt ) -
After oi l f ilter change 3. 1 lit er (3.3 US qt, 2.7 Imp qt )
After disassembly 3.8 lit er (4.0 US qt, 3.3 Imp qt )
Recommen ded eng ine oil Pro Ho nda GN4 o r HP4 (w it h out molyb- -
denum additives ) 4stroke oil (U.S.A.
and Canada), or Honda 4- stroke oil
(Canada only), or an equ ivalent motor
oi l
API se rv ice classificat ion: SG or Higher
except oils labeled as ene rgy co nserv-
ing on the circular A PI service labe l
JASO T 903 sta nda rd : MA
Viscosity: SA E 10W-40
Oil pressure at EOP (engine oil pre ssure ) switch 490 kPa 15.0 kgfle m ' , 7 1 p si) at
6,000 rpm /(80C/176 F )
Oil pump Tip clearance 0. 15 (0.006 ) 0.20 (0.008)
Body clearance 0.15 - 0.21 (0.006 - 0.008 ) 0.3510.014)
Side clearance 0.04 0.0910.0 02 0.004 ) 0.17 (0.007)
FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS

ITEM S PECIFICATIONS
Throttl e bo dy identifi ca- I A, CM typ e GQAOC
t ion numbe r I A C type GQAOB
Starter valv e vacuum diff erenc e 20mm Hg
Base t hr ott le va lve for sy nchronizat io n No .1
Idle speed 1,200 100 rpm
.
Throttle grip free play 2 - 4 mm (1/16 - 3/16 in)
Intake air temperat ure sensor resistance (at 20C/68 F) 1 4 kQ
Engine coolant temperature sensor resistance 2.3 2.6 kQ
(at 20C/68 F )
Fuel injection resistance I Primary injector 10.5 14.5 Q
(at 20C 168' F) I Secondary injector 10.5 - 14.5 Q
PAIR control solenoid valve resistance (at 20 C/68F ) 20 24 Q
CM P (Cam shaft position) sensor peak voltage (at 20CI 0.7 V m inimum
68' F)
CKP (Crankshaft position ) sensor peak voltage (at 20CI 0.7 V min imum
68'F)
M anifold absolute pressure at idle 150 250 m m Hg
Fuel pressure at idle 343 kPa (3.5 kgf/em ' , 50 psi )
Fuel pump f low (at 12V ) 189 em (6.4 US oz, 6.7 Imp oz) mi nimum /10 seconds
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 3.15 lit er (3.33 US qt. 2.77 Im p qt )
I Reserve tank 0.4 liter 10.42 US qt , 0.35 Imp qt )
Radiator cap relief pressure 108 - 137 kPa 11.1 - 1.4 kgf/em ' , 16 - 20 ps i)
The rmost at Begin to open 80 84 C (176 183 OF)
Full y op en 90 C 1194 ' F)
Valve lift 8 mm (0.3 in) m inimum
Recom me nded antifreeze High qual ity ethy lene glyco l ant ifreeze conta ining corrosion
protection inhibitors
Standard coolant concentration 1:1 mixture with distilled w ater
1-6
Contents Chapter 1
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit mm (in)
ITEM STANDARD SERVICE LIM IT
Cylinder co m pression 1,098 kPa (11.2 kgflc m ' , 159 psi ) at 350 -
rpm
Valve clearance IN 0.1 6 + 0.03 (0.006 0.001 ) -
EX 0.30 0 .03(0.012 + 0.0 01) -
Camshaft Cam lo be heig ht IN 37.02 - 37.10 (1.457 1.461 ) 37.00 (1.457)
EX 36 .66 - 36 .74 (1.44 3 - 1.446 ) 36 .64 (1.443)
Runout 0 .05 (0 .002)
Oil cle aran ce 0.020 0.062 (0 .00 08 0 .0024) 0 .10 (0.0 04)
Valve lifter Valve lifter 0 .0 . 25.978 - 25.993 (1.0228 - 1.0233 ) 25.97 (1.022)
Valve lifter bo re 1. 0 . 26 .010 26 .026 (1.0240 1.0246) 26.04 (1.0 25)
Valve , Valve stem 0 .0 . IN 3.97 5 3.990 (0.1565 0 .1571 ) 3 .965 (0.1561)
va lve g uide EX 3.96 5 - 3.980 (0.156 1 - 0 .1567) 3 .955 (0.1557)
Valve guide 1. 0 . iN/EX 4.0 00 4 .01.2 (0. 1575 0 .1580) 4.04 (0 .159 )
Ste m -ta -guide clear an ce IN 0.010 - 0.037 (0 .00 04 0.00 15) 0 .075 (0.0 030 )
EX 0.02 0 - 0.047 (0.0008 - 0 .0019 ) 0.085 (0.00 33 )
Valve gu ide project ion IN 16.I 16.4 (0.63 0.6 5) -
above cylinde r head EX 15.5 - 15.8(0.61 0.62 )
Valve sea t w idt h IN 0.90 - 1.10 (0. 035 - 0 .043) 1.5 (0.06)
EX 0.90 1.10 (0 .03 5 0 .043) 1.5 (0.06)
Valve sp ring IN 39 .5 (1.56) 38 .7 (1.52)
fre e leng th EX 39 .5 (1.56) 38 .7 (1.52)
Cylinder head wa rpage - 0 .10 (0.0 04)
CLUTCH/STARTER CLUTCH SPECIFICATIONS

Unit : mm (in)
ITEM STANDARD SERV ICE LIMIT
Spe cified clutch fluid DOT 4 brak e flu id -
Clutch master cylinde r Ma ster cyl inde r 1.0. 12,700 - 12.743 (0. 5000 0.5017) 12.7 55 (0. 5022)
Mast er piston 0 .0 . 12.657 - 12.684 (0.4983 - 0.4994) 12.645 (0.4 978)
Clutch Spring free length 56.8 (2.24 ) 55 .7 (2.19 )
Disc A thickness 3.72 3.88 (0.146 0.153 ) 3.4 (0.13 )
Disc 8 th ickness 3.22 3.38 (0.127 0.133) 2.9 (0.11)
Plate warpage - 0 .30 (0.012)
Clutch ou te r guide A 1. 0 . 27.993 28.003( 1.102 1 1.1025) 28.012 (1.1028)
(Wit ho ut 10 m a rk) 0 .0 . 35.00 4 - 35.012 (1.378 1 1.3784 ) 34.99 4( 1.3777)
Clutch o ute r guide 8 1. 0 . 27.993 - 28. 003 (1.102 1 - 1.1025 ) 28. 012 (1.1028 )
(With iD ma rk) 0 .0 . 34.996 - 35 .004 (1.377 8 - 1.37 81) 34.986( 1.3774)
Prim ary d rive n gea r 1. 0 . A 41.008 41.0 16(1.6145 -1.6 148 ) 4 1.026 (1.6152)
B 41.0 00 - 41.0 08 (1.6142 - 1.6145 ) 41.018 (1.6149)
Oil pump drive spro cket 1. 0 . . 28.000 28.021 (1.1024 - 1.1032 1 28 .030 (1.103 5)
gu ide 0 .0. 34 .975 34 .99 1 (1.377 0 1.3776) 34 .965 (1.376 6)
Oil pump dri ve sprock et I.D. 35 .025 - 35 .145 (1.3789 1.38 37 ) 35.155 (1.384 11
Main shaft 0 .0. at clutch oute r guide 27.980 - 27.990 (1.1016 - 1.10201 27.96 (1.1011
Ma inshaft 0.0 . at oil pump drive sprocket guide 27.980 27.990 (1.1016 - 1.10201 27.96 (1.101)
Start er idle gear I Ge ar 1.0 . 10.013 -1 0 .035 (0.3942 - 0 .39511 10.05 (0.396)
I S ha ft 0 .0 . 9.991 - 10.000 (0.3933 0.3937 ) 9.98 (0.393)
Starter driven gear boss 0. 0 . 45 .657 - 45.67 3 (1.7975 1.798 1) 4 5.642 (1.7969)
1-7
Contents Chapter 1
GENERAL INFORMATION
TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS
Un it: m m (in)
S hift for k 1.0. 12.0 0 0 12.018 (0.4724 - 0.47311 12.03 (0.474)
I Claw thick ness 5.93 - 6.00 (0.233 0.236) 5.9 (0. 23)
S hift fo rk shaft 0 .0. 11 .957 - 11.968 (0.470 7 - 0.4712) 11 .95 (0.470)
Transm ission Gear 1.0. M5, M6 3 1.0 00 31.025 (1.220 5 - 1.221 5) 31.04 (1.222)
Cl 28 .000 28.02 1 (1.1024 1.1032 ) 28.04 (1.104 )
C2,C3, C4 33 .000 - 33 .025 (1.2992 - 1.3002) 33 .04 (1.301)
Gea r bus ing 0. 0. M5, M6 30 .955 30 .980 (1.2187 1.2197 ) 30 .935 (1.2179)
C2 32 .955 - 32 .980 (1.2974 - 1.2984) 32 .935 (1.2967)
C3, C4 32 .950 - 32 .975 (1.2972 - 1.2982) 32 .930 (1.2964)
Gear-ta-bush ing M5, M6 0.020 - 0.0 70 (0.00 08 0.0028) 0 .10 (0.0 041
clearance C2 0.020 - 0.070 (0.00 08 - 0.0028) 0 .10 (0.0041
C3, C4 0.025 - 0.075 (0.00 10 - 0.0 030) 0.11 (0.004)
Gear bus hing 1.0. M5 27.985 28.006 (1.1018 1.1026) 28 .016 (1.1030)
C2 29 .985 - 30.006( 1.1018 - 1.1026) 30 .021 (1.1819)
Mai nsh aft 0 .0. at M5 27.96 7 27.980 (1.1011 1.1016) 27.957 (1.10 07)
Coun tershaft 0 .0. at C2 29 .967 29 .980 (1.1798 1.18031 29 .960 (1.1795)
Bus h ing to s haft M5 0 .00 5 - 0 .039 (0.0002 0 .0 015 ) 0.06 (0.0021
clearance C2 0 .005 - 0 .039 (0.0002 - 0 .0 015) 0.06 (0.002)
CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER
SPECIFICATIONS
Un it: mm (in)
ITEM STANDARD SERVICE LIMIT
Cra nksha ft Connecting rod side clea ran ce 0.05 0.20 (0.00 2 - 0 .008) 0.25( 0.0 98)
Crankpin be ar ing o il clea ran ce 0.030 - 0 .052 (0.0 012 - 0.0 020 ) 0.06 (0.002)
M ain jo urna l bearing oil cleara nce 0.019 0.037 (0.0007 0.0 015) 0.05 (0.002 )
Runo ut 0 .05 (0.00 2)
Piston, pisto n Pis to n 0 .0 . at 4.0 (0. 16) from bot- 74 .960 - 74.980 (2.9512 - 2.9 520) 74.895 (2.9486)
rings to m
Pisto n pi n bore 1.0 . 17.002 - 17.0 08 (0.6694 - 0.66 96) 17.030 (0. 6705)
Piston pin 0 .0 . 16.994 17.0 00 (0.6690 0 .6693 ) 16 .980 (0.668 5)
Piston-to-pist on pin clear ance 0.002 - 0.014 (0.0001 0.0006 1 0.04 (0.002)
Piston ring end Top 0.22 - 0.32 (0.009 - 0.013) 0.52 (0.020)
gap Second 0.48 - 0.63 (0.019 0.02 51 0.82 (0.032)
Oil 0.2 - 0.7 (0.01 - 0.03) 1.0 (0.04)
(side rai l)
Piston ring-ta- ring Top 0 .050 0 .08 5 (0 .0 020 0.0033 ) 0.125 (0.0 049 )
groove clea rance Second 0 .015 - 0 .050 (0.00 06 - 0.0020) 0.075 (0.0 030)
Cylinde r 1. 0 . 75 .000 - 75 .015 (2.9528 2.9533 1 7 5.15 (2.959)
Out of round 0.10 (0.004)
Tap er - 0 .10 (0.0 04)
Warpage - 0 .10 (0.004)
Cylinder-ta-pi ston clearance 0 .020 0 .055 (0.0 008 0.0022) 0 .10 (0.004)
Connecting rod small end 1.0. 17.030 -17.042 (0.6705 - 0.6709) 17.048 (0.6712)
Connecting rod -to -pist on pin clea ra nce 0 .030 0.046 (0.00 12 0.0018) 0 .07 (0.003)
1-8
Contents Chapter 1
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: m m (i n)
IT EM STANDARD SERVICE LIMIT
Minimum tire tread depth - 1.5 (0.06)
Cold tire pr es- I Up to 90 kg (200 Ibs) load 250 kPa (2.50 kgl/cm'. 36 psi)
sure I Up to max imum we ight capacity 250 kPa (2.50 kqf/c m", 36 p si) -
Axle ru no ut - 0.2 10.008)
Whe el rim I Radial - 2.0 (0.08)
runout I Ax ial 2.0 (0.08)
Wheel balance weight - 60 9 (2.10l)
max .
Fo rk Spri ng Iree length 218.2 (8.59) 213.8 (8.42)
Fork pipe runout 0.20 (0.008)
Recommended fork fluid Pro Hon da Suspe nsion Fluid, 555 5 or -
equiva lent
Flui d level 90 (3.5) -
Fluid capac ity 466 2.5 cm' (15.8 0.08 US oz, 16.4 -
0.09 Im p o z)
Pre-load adjuste r initia l settin g 7 turns from m inim um -
Reb ound adjuste r initial setting 2 turn s out from full hard
Comp ression adjuster initial 2 turn s out from full hard -
sett ing
Steering head bearing pre-loa d 12 - 19 N (1.2 - 1.9 kgf) -
REAR WHEEL/SUSPENSION SPECIFICATIONS

U nit : mm (i n )
ItEM STANDARD SERVICE LIMIT
M inimum tire tread dept h 2.0 (0.08)
Cold tire I Up t o 90 kg (200 tbs} loa d 290 kPa (2.90 kqf/crrr', 42 psi) -
pressure I Up to maximum weight capacity 290 kPa (2.90 kgl /cm . 42 psi )
Axle run out 0.2 (0.01)
Wheel Radial - 2.0 (0.08)
rim Axial 2.0 (0.08)
runo ut
W heel bala nce we ight 60 9
(2 .1 oz) m ax.
Drive Sizelli nk I DID DID50VM 2-114YB
chain I RK RK50GFOZl -114LJFZ -
Slack 25 35 (1 1-3/8)
Sho ck Spr ing pre-loa d adjuster standard posi- Position 4
absorber tion
Reb ound dam ping adjuster init ial set- 2 - 1/2 tu rns out from full hard
ting
Compression da mpi ng adjuster initial 9 clicks out from full hard
setting
1-9
Contents Chapter 1
GENERAL INFORMATION
HYDRAULIC BRAKE SPECIFICATIONS
Unit: mm (i n)
ITEM STANDARD SERV ICE LIMIT
Fro nt Specified brake fluid DOT 4
Brake disc th ickness 5.0 (0.20) 4.0 (0.161
Bra ke disc ru nout 0.30 (0.0121
Ma ster cyl inder 1.0. 17.460 17.503 (0.6874 0.6891) 17.515 (0.6896 )
M aster piston 0 .0. 17.321 17.367 (0.6819 0.6837) 17.309 (0.68 15)
Calipe r cylind er 1.0. A 32.080 - 32.130 (1.2630 - 1.2650) 32.140 (1.2654)
B 30.280 30.330 (1.1921 1.194 1) 30.34 0 (1.1945)
Caliper piston 0 .0 . A 3 1.967 - 32.000 (1.258 5 1.2598) 3 1.957 (1.2581)
B 30.167 - 30.200 (1.1877 - 1.18901 30.157 (1.1873)
Rear Specified brake fluid DOT 4
Brake peda l height 75 (3.0)
Brake disk thickness 5.0 (0.20) 4.0 (0.16)
Brake disc ru nout 0.30 (0.012)
Maste r cylinde r 1.0. 15.870 -15.913 (0.6248 0.6265) 15.925 (0.6270)
Maste r piston 0.0. 15.827 - 15.854 (0.6231 - 0.62421 15.815 (0.6226)
Cali per cy linder I.D. 38.180 - 38.230 (1.503 1 1.5051) 38.24 (1.506)
Caliper piston 0 .0. 38.098 - 38.148 (1.4999 1.5019) 38.09 (1.5001
BATTERYICHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Batt ery Capacity 12V 8.6 Ah
Cu rrent leakage 2.0 rnA max .
Vol ta ge Ful ly cha rg ed 13.0 13.2 V
(20CI68F) Needs Below 12.4 V
charg ing
Cha rging current Normal 0.9 Al5 10 h
Qu ick 4.5 Al l h
A ltern at or Capacity 0.344 kW/5.000 rpm
Ch arg ing coil resistance (2 0C/68 F) O.I 1.0 Q
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spa rk plug (Iridium) I NGK IM R9C9 HES
I DENSO VU H27ES
Spa rk plug gap 0.80 0.90 mm (0.031 0.035 in)
Ignition coil peak voltage 100 V minimum
Ignition pulse generator peak voltag e 0.7 V minimum
Ignition timing ("F"mark) 8 12' BTDC at idle
ELECTRIC STARTER SPECIFICATIONS

U nit: mm (in)
ITEM STANDARD SERVICE LIMI T
Starter motor brush length 12.0 - 13.0 (0.47 - 0.51) 6.5 (0.26)
110
Contents Chapter 1
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Hea dlig ht I Hi 12V - 55 W
I lo 12V - 55 W
Positio n light 12V - 5 W
Brakelta il lig ht l ED
Front turn signal /runn ing light 12V - 2318 W x 2 (32/3 cp )
Rear tu rn sig nal light 12V 23W x 2
Instrument light lED
Turn signa l ind icator lED
High beam indicator lED
Neutral indicator lED
Malfunction ind icato r la m p (Mil) lED
Fuse Ma in fu se 30A
PGM-FI fu se 20A
Sub fuse 10 A x 4, 20 A x 2
Tachometer peak vo ltage 10.5 V min imum
ECT sensor resi stance I 80 C (176 OF) 2.1 - 2.6 kfl
I 120 -c 1248 OF) 0.65 - 0.73 kfl
1-11
Contents Chapter 1
GENERAL INFORM ATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FAST ENER TYPE FASTENER TYPE
Nm (kg f 'm, Ibf.ft ) N 'm (kgf 'm, Ibf.ft)
5 mm hex bolt and nut 4.9 (0.5, 3.6) 5 m m screw 3.9 (0.4, 2.9)
6 m m hex bo lt a nd nut 9.8 (1.0, 7 ) 6 mm screw 8.8 (0.9, 6.5)
8 mm he x bolt a nd nut 22 (2.2, 16) 6 mm flang e bo lt 9.8 (1.0, 7)
10 mm he x bo lt and nut 34 (3.5, 25) (8 mm h ead, sma ll flan ge)
12 mm hex bo lt and nut 54 (5.5, 40) 6 mm flan ge bol t 12 (1.2, 9)
(8 m m h ead , large fla nge)
6 m m flan ge bolt 12 (1.2, 9)
(10 mm head ) and nu t
8 m m flan ge bo lt and nut 26 (2.7, 20)
10 mm flang e bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

Torque specifications listed below are for impo rtant faste ners.
Others should be tightened to standard torqu e va lues listed above .
NOT E:
'l . App ly sea lant to th e threads .
2. Apply a locking agent to th e thr eads.
3. Stake .
4. App ly oil to the thr eads and flange surface.
5. U-n ut .
6. ALOe bol t/scr ew: repla ce w ith a new on e.
7. App ly g rease to the t hreads.
8. Apply molybden um disulfide oil to the th reads and seating surface
9. CT bolt
ENGINE
MAINTEN AN CE:
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm ) N m (kgf m , Ibfft)
Spa rk plug 4 10 16 (1.6, 12)
Timing hole cap 1 45 18 (1.8, 13) NOTE 7
Engine oil filter cartri dge 1 20 26 (2.7, 20) NOTE 4
Engine oil drain bolt 1 12 29 (3.0, 22)
LUBRICATION SYSTEM:
THREAD TORQUE
ITEM Q'TY REMARKS
DIA .(m m) Nrn [kgf-m, lbf -ttl
Oil pump asse mbly flang e bolt 3 6 12 (1.2, 9) NOTE 9
Engine oil drai n base bolt 1 6 12 (1.2, 9) NOT E 2
Oil filter boss 1 20 See pa ge 1-15
FUEL SYSTEM (Pro gra m med Fuel Inj ection):

THREAD TORQUE
ITEM Q'TY REMARKS
DIA.(mm) Nrn (kgf' m , Ibf ft)
EeT (Engi ne Coolant Temper atur e)/therm o senso r 1 12 23 (2.3, 17)
Throttle bo dy insu lator ban d screw 8 5 See page 1-15
Serv ice chec k bolt 1 6 12 (1.2, 9)
Starte r valve lock nut 4 10 1.8 (0.18, 1.3)
Start er va lve sy nchronization plate screw 4 3 0.9 (0.09, 0.7)
Fuel pipe mounting bolt 3 6 9.8 (1.0, 7)
Fast idle w ax unit link plate screw 1 3 0.9 (0.09, 0.7)
Fast idle wax unit m oun ting screw 2 6 4.9 (0.5, 3.6)
1-1 2
Contents Chapter 1
GENERAL INFORMATION
COOLING SYSTEM:
THREAD TORQUE
ITEM Q'TV REMARKS
DIA .(mm) Nm (kglm, Ibf.ft)
Water pump assembly flang e bolt 2 6 12 (1.2, 9 ) NOTE 9
Therm ostat housing cover flange bolt 2 6 12 (1.2, 9 ) NOTE 9
ENGINE REMOVAL/INSTALLATION:
THREAD TORQUE
ITEM Q'TV REMARKS
DIA .(mm) Non (kgl.m, Ibf.ft)
Drive sprocket special bolt 1 10 54 (5.5, 40)
CYLINDER HEADIVALVES:
THREAD TORQUE
ITEM Q'TV REMARKS
DIA . (mm) N'm (kglm, Ibf.ft)
Cylinder head mo unting bolt/washer 10 9 51 (5.2,38) NOTE 8
Cams haft ho lder fl ange bol t 20 6 12 (J.2, 9)
Cylinder head sea ling bolt 2 18 27 (2.8 , 2O) NOTE 2
Cylind er head cover bolt 4 6 9.8 (1.0, 7 )
Breath er plate flange bolt 3 6 12 (1.2, 9) NOTE 2
PAIR reed v alve cove r bo lt 4 6 12 (1.2, 9) NOTE 2
Thrott le insulator socket bolt 8 6 12 (1.2, 9)
Cam sprocket fla nge bolt 4 7 20 (2.0, 14 ) NOTE 2
e M P (cams haft positio n) sensor roto r bolt 2 6 12 (1.2, 9) NOTE 2
Cam cha in tension er pivot bolt 1 6 9.8 (1.0,7) NOTE 2
Cam chai n guid e torx bolt 1 6 12 (1.2, 9 ) NOTE 2
Exhaust pipe stud bo lt 8 8 See page 1-15
CLUTCH/STARTER CLUTCH :
THREAD TORQUE
ITEM Q'TV REMARKS
DlA . (mm) Nm [kgf-m, Ibfft)
Clutch ce nte r lock nut 1 25 127 (13.0,94) NOTE 3, 4
Clutch spring bo lt/w asher 5 6 12 (1.2, 9 )
Oil pu mp dr iven sprocket bo lt 1 6 15 (1.5,11) NOTE 2
Starter clutch outer bolt 1 10 83 (8.5, 61 ) NOTE 4
ALTERNATOR:
THREAD TORQUE
ITEM Q'TV REMARKS
DIA .(mm) Nm [kqf-m, lbf-tt)
Stato r w ire clamp flange bolt 1 6 12 (1.2, 9) NOTE 9
Flywh eel flange bolt 1 1O 103 (10.5, 76 ) NOTE 4
Stat or mounting socket bolt 4 6 12 (1.2, 9 )
TRANSMISSION/GEARSHIFT LINKAGE :
THREAD TORQUE
ITEM Q'TV REMARKS
DIA .(mm) Nrn (kgfm, lbf-ft]
Transmi ssion holder flang e bolt 6 8 29 (3.0, 22 1
Bearin g set plate bolt 2 6 12 (1.2, 9 ) NOTE 2
Shift drum center socket bolt 1 8 23 (2 .3, 17 ) NOTE 2
Shift drum stopp er arm pivot bolt 1 6 12 (1.2, 9 )
Gearshift spindle ret urn spring pin 1 8 23 (2.3,17)
Shift dr um bolt/w ashe r 1 6 12 (1.2, 9) NOTE 2
Shift d rum stopper plate fl ange bo lt 1 6 12 (1.2, 9) NOTE 2
1-13
Contents Chapter 1
GENERAL INFORMATION
CRANKCASE/CRANKSHAFT/ BA LA NCER/ PISTON/CYLIN DER:
THREAD TORQUE
ITEM Q'TV REM AR KS
D1A. (mm ) Nrn [k qf- m, Ibf.ft)
Crankcase 7 mm bol t 12 '7 18 (1.8, 13)
8 m m bol t 6 8 24 12.4, 17)
9 m m bol t (mai n jo urna l bolt) 10 9 See page 1321 NOTE 4
Low er cran kcase seali ng bolt 1 22 59 (6 .0, 43) NOTE 2
Low er cra nkca se socket bolt 1 10 12 (1.2, 9) NOTE 2
Low er crankcase sealin g bo lt 1 20 29 13.0, 22) NOTE 2
Lower crankcase socket bolt 1 8 23 (2.3. 17) NOTE 2
Connecting rod bolt (new bolt) 8 8 See pa ge 132 1 NOTE 4
Connecting rod bolt (retightening) 8 8 Seepage 13 12 NOTE 4
ELECTRIC STARTER:
THREAD TORQU E
ITEM Q'TY REM ARKS
DIA .(mm) Nm {kqf-m , Ibf-ft]
Starter mo to r term inal nut 1 6 12 (1.2, 9)
LIGHTS / METE RS/SWITCHES:

THREAD TORQUE
ITEM Q'TY REMARKS
D1A. (mm ) Nrn (kglm, lbf-tt ]
Oil pressu re sw itch 1 PT 1/8 12 11.2,9) NOTE 1
Oil pressu re sw itch wire te rminal screw 1 4 2.0 (0 .2, 1.4)
Neutral switch 1 10 12 (1.2, 9)
1-14
Contents Chapter 1
GENERAL INFORMATION
Oil filter boss:
14 .9 0.5 m m
10 .59 0 .04 in)
Insulator clamp (Throttl e body side) :
7 1 mm (0.3 0.04 in)
Exhaust pip e stu d bolt:
1
1I1I1 11 11 11 ~ l1 l1 l1 l i l
l
42.5 0.5 mm
- (1.67 0.04 in )
1-15
Contents Chapter 1
GENERAL INFORMATION
FRAME
FRAME /BODY PANELS /EXHAUST SYSTEM:
THBEAD TORQUE
ITEM Q'TV REMARKS
DIA.(mm) Nm (kgfm, lbf -ft)
Seat rai l fl an ge socket bo lt/f lange nut 2 10 59 (6.0, 43)
Seat ra il spe cia l bolt/fl ang e nut 2 10 59 (6.0,43)
Seat rail asse mbly flan ge bolt/nut 2 8 30 (3.1, 22)
Seat rai l brace socket bolt 4 8 26 (2.7, 20)
Passeng er seat b racket spe cial bolt 2 8 26 (2.7, 2O)
Passen ger seat bra cket socket bolt 2 8 26 (2.7, 2O)
Rider seat br acket m oun tin g bolt/nut 4 6 9.8 (1.0, 7 )
Ride r footp eg bracket socket bo lt 4 8 37 (3.8, 27)
Bank se nsor 2 6 11 (1.1, 8 )
Passeng er footpeq bracket socket bo lt 4 8 26 (2.7, 2O)
Exh aust pipe joint nut 8 7 12 (1.2, 9)
Exha ust pipe m ou ntin g bolt 1 8 23 (2.3, 17)
Exhaust joi nt pipe clamp SH bo lt 1 6 9.8 (1.0, 7 )
Ex haust valve pu lley nut 1 6 4 .9 (0.5, 3. 6)
Ex haust valve retainin g screw 2 4 1.5 (0.15, 1.1)
Exhaust valve pulley ho using flan ge S H bo lt 2 6 9.8 (1.0, 7 )
Exhau st pipe cla mp bolt 1 8 18 (1.8, 13)
Up per cowl stay f lange bolt 2 8 32 (3.3, 24 )
Cowl stay mou ntin g bolt 2 6 12 (1.2, 9)
W indsc ree n m ou nting screw 6 5 0.5 (0.0 5, 0.4 )
M idd le cow l pan screw 2 5 1.5 (0. 15, 1.1 )
Mi ddle cowl spe cia l screw 2 6 9 .8 (1.0, 7)
Und er cowl pan screw 6 5 1.5 (0.15, 1.1)
U nd er cowl special screw 4 6 9. 8 (1.0, 7)
Inner cowl spec ia l screw 1 6 9.8 (1.0, 7)
Front fe nder pan screw 6 6 12 (1.2, 9)
Rearv iew m irror socket bolt 4 6 6.8 (0.7, 5.1)
MAINTENANCE:
--
THREAD TORQ UE
IT EM Q'TV REMARKS
DIA .(mm) Nm [kqf-m, lbf-ttl
T hrott le cab le adjuster lock nut 2 6 5.4 (0.55, 4. 0)
1-16
Contents Chapter 1
GENERAL INFORMATION
FUEL SYSTEM IProgrammed Fuel Inje ct ion I:
THREAD TORQUE
ITEM Q'TY REM A RKS
D1A. lmm) N 'm (kgfm , Ibf.lt)
Fuel fil ler cap socket bol t
Fuel feed hose ba njo bolt (fu el t ank side) ,
3 4
12
1.8 (0.18, 1.3)
22 (2.2, 16) Yellow paint
Fuel hose sealing nu t It hrottle body side) 1 12 22 (2.2, 16)
Fuel pump flange nut 6 6 12 (1.2, 9)
Fuel ta nk m ounting bolt (front) 2 8 26 (2.7, 20)

Fuel ta nk mounting bolt (rea r) 2 6 9.8 (to, 7 )
Fuel rail jo int hose bolt 2 6 9.8 (t o, 7 ) Yellow paint
Fuel rail joint hose seali ng nut 1 12 22 (2.2, 16) Yellow paint
Air cleane r housing/air fun nel pan screw 6 5 4.4 (0.45 , 3.3)
Top ai r cleane r housing mo unting screw 6 5 1.2 (0.12, 0.9)
M idd le air cleaner housing mo unting screw 8 5 1.2 10.12, 0.9)
IAT senso r mounting screw 2 5 1.2 (0. 12, 0.9)
Ai r intake d uct jo int screw 2 5 2.5 10.25, 1.81
Air intak e d uct cove r screw 6 4 1.2 (0.12, 0.9)
Seco ndary injector base m ou nting bo lts 5 5 5.4 (0.55, 4.0)
Bank a ngle sensor mo unting screw 2 4 1.5 (0. 15, 1.1)
COOLIN G SYSTEM:
THR EA D TORQ UE
ITEM QTY REMARKS
DIA.(mm) Nm [kqf-m, Ibf.ft)
Cooling fan nut 1 5 2.9 (0.3, 2.2) NOT E 2
Fan motor nut 3 5 4.9 10.5, 3.6)
Fan m otor bracket m oun ting bolt 3 6 8.8 (0.9, 6.5)
ENGINE REMOVAL/INSTALLATION:
THREAD TORQUE
ITEM Q'TY REMAR KS
D1A. l m m ) Nrn [k qf -rn, Ibfft)
Engine hange r adjusting bolt 2 20 15 (1.5, 11)
Engine hang er adjusting bolt lock nut 2 20 54 (5.5, 40)
Rear up per engi ne hange r nut
Rear low e r eng ine hanger nut ,
1 12
12
64 (6.5, 47)
64 (6.5, 47)
See page 8-
9
Front engine hanger bolt 2 12 64 (6.5, 47 )
Midd le engine hanger bo lt 2 12 64 (6.5, 47 1
CLUTCH /STARTER CLUTCH :

THREAD TORQUE
ITEM Q'TY REMARKS
D1A. (mm) Nm [k qf -m, Ibf ft)
Clutch master cylinder o il cup screw 1 4 1.5 (0.15, 1.1) NOTE 2
Clutch lev er piv ot bolt 1 6 1.0 (0.1, 0.7)
Clutch lever piv ot nut 1 6 5.9 (0.6, 4.3)
Clutch sw itch screw 1 4 1.0 (0.1, 0.7)
Clutc h hos e o il bolt 2 10 34 (3.5, 25)
Clutch master cylinde r holde r bo lt 2 6 12 (1.2, 9)
Maste r cylind er bleed va lve 1 8 5.9 (0.6, 4.3)
1-17
Contents Chapter 1
GENERAL INFORMATION
TRA NSMISSION/GEARSHIFT LINKAGE:
THREAD TORQUE
ITEM Q'TV REMARKS
DIA .(mm) N'm [kqf-m, lbf-ft}
Gears hift peda l pivot bo lt 1 '8 22 (2.2, 16)
Gearshift pe dal link pinch bolt 1 6 9.8 (1.0, 7)
Link arm lock nut 2 6 9.8 (1.0, 7)
FRONT WHEEl/SUSPENSION/STEERING:
THREAD TORQUE
ITEM Q'TV REMARKS
DIA.( mm) Nm Ikgf-rn. Ibf.ft)
Han dlebar we ight m ou nting screw 2 6 9.8 (1.0, 7 ) NOTE 6
Han dlebar pinc h bolt 2 8 26 (2.7, 20)
Front axle bolt 1 18 78 (8.0, 58)
Front axle ho lder pinch bolt 4 8 22 (2.2, 16 )
Front brake disc bolt 12 6 20 (2.0, 14) NOTE 6
Fork socket bolt 2 10 34 (3. 5, 25 )
Fork bo lt 2 46 34 (3.5, 25)
Fork dam per lock nut 2 14 25 (2.6, 19 )
Fork co mpressio n adj uste r plug bo lt 2 14 18 (1.8,1 3)
Fork to p bridge pi nch bolt 2 8 23 (2.3, 17 )
Fork bott om bridge pinch bo lt 4 8 23 (2.3, 17 )
Ste er ing dam per seco nd arm nut 1 6 12 (1.2, 9) NOTE 5
Steering dam per seco nd arm bolt 1 6 8 .8 (0.9, 6.5 )
Steerin g damper m ounti ng bo lt 3 6 8 .8 (0.9, 6.5 )
Stee ring stem adj ust ing nut 1 26 20 (2.0, 14)
See pag e
Steer ing stem adj ust ing lock nut 1 26 - 14-42
Steering stem nut 1 24 103 (10.5, 76)
REAR WHEEL/S USPENSION:
THREAD TORQUE
ITEM Q'TV REMARKS
DIA .(mm) Nm (kgf'm, Ibfft)
Rea r axle nut 1 22 113 (11.5, 83) NOTE 5
Rear brak e disc bolt 4 8 42 (4.3, 3 1) NOTE 6
Fina l driven sprock et nut 6 10 64 (6.5, 47 ) NOTE 5
Rea r shoc k absorbe r upper m ountin g nut 1 10 44 (4.5, 33) NOTE 5
Rea r shock a bsor be r low er m oun tin g nut 1 10 44 (4 .5, 33 ) NOTE 5
Shock link-t o-fram e pivot nut 1 10 44 (4 .5, 33) NOTE 5
. Shock arm-to -shock link nut 1 10 44 (4.5, 33) NOTE 5
Shock ar m-to-swinga rm nut 1 10 44 (4.5, 33) NOTE 5
D rive cha in case flange bolt 3 6 12 (1.2, 9)
Swinga rm pivot adj ust ing bolt 1 36 15 (1.5, 11)
Swingarm pivot adj ust ing bo lt lock nut 1 36 64 (6.5, 47 1
Swinga rm pivot nut 1 22 113 (11.5, 83)
D riv e cha in slider bo lt 3 6 8.8 (0 .9, 6 .5) NOTE 2
1-18
Contents Chapter 1
GENERAL INFORMATION
HYDRA ULI C BRAKE:
THR EAD TORQUE
IT EM QTY REM ARKS
DIA . (mm ) Nrn [kqf-m, Ibf ft)
Brake hose oil bolt 5 10 34 (3.5, 25)
Rear brake cal ipe r pad pin 1 10 18 (1.8, 131
Rear calipe r ble ed va lve 1 8 5.9 10.6. 4.3)
Rear brake caliper slide pin bolt 1 12 27 (2.8. 201
Rear brake caliper mounting bolt 1 8 23 (2.3. 171
Rear brake hose cla m p bol t 1 5 3.9 (0.4. 2.91
Rear mast er cylinder push rod joint nut 1 8 18 11 .8, 131
Rear bra ke reservoir hose jo int screw 1 4 1.5 (0.15. 1.1) NOT E 2
Rear maste r cyli nder reservoir cap screw 2 4 1.5 (0.15. 1.1)
Rear master cyl inder reservoir m oun tin g bo lt 1 6 12 (1.2. 9)
Rear maste r cy linde r m o unting bo lt 2 6 9.8 (1.0. 71
Brake pedal piv ot bolt 1 8 18 (1.8. 131
Frontbrake calipe r m o unt ing bolt 4 10 45 (4.6. 33) NOT E 6
Frontbrake cali pe r asse mb ly bo lt 8 8 23 (2.3,17) NOTE 2
Frontbrake calipe r pa d pin 2 10 16 (1.6. 12)
Fro nt
cali pe r bleed va lve 2 8 7.8 10.8. 5.81
Frontbrake hose clamp 1 6 8.8 (0.9, 6.5)
Frontbrake hose 3-way joint bo lt 1 6 9.811.0. 7)
Front brak e ho se clamp (left side) 1 6 9.81 1.0.71
Frontmaster cylinde r reservoi r cap screw 2 4 1.5 (0.15, 1.11
Frontmaster cylinde r reservoir stay bol t 1 6 12 (1.2. 9)
Frontbra ke ligh t swi tch screw 1 4 1.0 (0.1. 0.7)
Frontm aster cylinder reser vo ir mo un t ing nut 1 6 5.9 (0.6, 4.31 N OT E 5
Frontbrake lever pivot bo lt 1 6 1.0 (0.1, 0.7)
Frontbrake leve r pivot nut 1 6 5.9 10.6. 4.31
Fro nt
m aster cylind er bleed valve 1 8 5.9 10.6. 4.3)
Frontma ster cyli nd e r ho lder bolt 2 6 12 11.2,9 1
LIG HTS /METERS/SWITCHES:

THREAD TORQ UE
ITEM Q'TV REMARKS
DlA. (mm) Nm [kqt-m. Ibfft)
Ignit io n switch mounting one -way bolt 2 8 26 (2.7, 20)
Right handlebar swi tch screw 2 4 0.9 (0.09, 0.7)
Combinati on m ete r assem bly screw 3 5 1.0 (0.1, 0.71
Side stand switch special bolt 1 6 9.8 (1.0, 7} NOTE 6
OTHERS :
THREAD TORQUE
ITEM Q'TV REMARKS
DIA . (m m ) Nm (kgfm , lbf -ft ]
Side stand socket bo lt 2 10 54 15.5, 40)
Side stand pivot bolt 1 10 9.8 11.0,7)
Si de sta nd pivot nut 1 10 29 (3.0. 221
Chapter 1 1-19
Contents
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
LOCATION MATERIAL REMARKS
Crankcase matin g surface Liquid sealant
(T hree Bond 1207B o r
equi val ent )
o o
0 0
E~
E", 0
0 EE EE
~o
, E~
, E",
, ~ 00 ~o ~o
,
~s 0
, ~
, ~
~ ~S 00
-!
E~ 0
E'" EE EE
~ o
, 0 E'" E",
, ~
0
~o
, ~
, ~ o
~ , 0 0
$2'9- ;=s , ~
~
0
Oil pan m ating surfac e
1-20
Contents Chapter 1
GENERAL INFORMATION
Right crankcase cover mating surface Liquid sealant
(Three Bo nd 1207B or
equiva lent)
Alternator cover mating surface
Oil pressure switch th read s

Do not appl y sealant to
the thread hea d 3 - 4 mm
(0.' - 0.2 in)
Cylind er head semi-circ ular cut-ou t Sea lant
1-21
Contents Chapter 1
GENERAL INFORMATION
LOCATION MATERIA L REMARK S
Ma in journal beari ng surface Molybden um d isulfide o il
Piston pin sliding surface (a m ixt u re of 1/2 eng ine
Connect ing rod bearing surface oi l and 1/2 molybde nu m
Connecti ng rod sma ll end inner surface d isulfid e g rease
Crankshaft thrust surface
Camshaft lobes/journa ls and thrust surface Do not apply mating sur-
f ace of the camshaft holder
Valve stem (valve guide sliding surface)
Valve li ft e r oute r sl iding surface
Wa ter pump shaft th rust washer sliding su rface
Clutch outer/prima ry driven gear sliding surface
Clutch outer gu ide slid ing surface
Oil pump drive sprocket and collar slid ing surface
M3/4, C5, C6 sh ifter gear (shift fork grooves)
Starter reduction gear shaft sl iding surface
Starter idle gear shaft sliding surface
Cylinde r head special bolt (after re moving a nti - rust oil
add itive)
Clutch j o i nt p iece sliding surface Engi ne o il
Clu tch lifter rod outer area
Piston and pisto n ring sliding area
Oil straine r pack ing
Clutch disc surface
Starter one-wav clutch sliding surface
Flywheel bo lt threads and seating surface
Clutch center lo ck nut t hreads and seat ing surface
Oil f ilter cartridge th reads and Ovrinq
Camshaft ho l der bo lt threads and seat ing surface
Starter clutch outer bo lt threads and seating surface
Connecting rod bolt t hreads and seati ng surface
Each gear teeth and rotating surface
Each bearing
Each Oring
Ot he r rotat ing area and sl iding su rface
Timing ho le cap threads M u lt i-pu rpose g rease
Balancer damper rubber f itting area
Each oil seal lips
Lo w er crankcase 22 mm sea ling bolt threads Lo ckin g age nt
Lower crankcase 20 mm seali ng bolt threads
Lower crankcase 10 mm seali ng bolt th reads
Lower crankcase 8 m m seal ing bolt th reads
Cam chain guide A bolt threads
CMP (Camshaft positio n) senso r rotor bol t t hreads
Cylinder head sea ling bolt t hreads
Cy linder head cover b reat he r j o int threads
Oi l orifice bolt threads Coating w idth: 6.5 1 mm
Oi l pump d riven sprocket bolt threads Coati ng w id t h: 6.5 1 mm
Shift drum bearing set p late bo lt t hreads Coating w idth: 6.5 1 mm
Oi l filter boss stud thread Coati ng w id th: 6.5 1 mm
Mainshaftlcou ntershaft bea ring set plate bolt threads Coating w idth : 6.5 1 mm
Cam sprocket bolt threads Coating width : 6.5 1 mm
Cylinder head cover breather plate bolt t hread s Coating width: 6.5 1 mm
Sh ift drum center bo lt t hreads Coati ng widt h: 6.5 1 mm
Cam chain tensioner pivot bolt th reads Coating width: 6.5 1 mm
Spindle plate tightening bolt threads Coating width: 6.5 1 mm
Shift drum stopper plate bolt t h reads Coating width: 6.5 1 mm
Oil pan d ra in base bolt threads Coating width : 6.5 1 mm
Gearsh ift sp indle cove r bo lt threads
Ji;f1
---~
I[\ \'
APPI Y IOCkmg agent ~ )
>~
1-22
Contents Chapter 1
GENERAL INFORMATION
FRAME
Side st and pivot M u lt i-purp ose grease
Rid er footpeg sliding area
Passenger peg sliding area
Rear brake pedal pi vot sli di ng area
Th rott le gri p p ipe sl iding su rf ace
Passenger seat catch hook slidi ng area
Gear sh ift pedal pivot slidi ng ar ea
Fro nt w heel d ust seal lips
Rear w he el du st seal li ps
Fin al dri ven f lange O-rin g
Rear shock absorbe r pivot dust sea l lips
Steering head bea ri ng adjusting nut threads U rea based multi-purpose 0.1 - 0.3 9
Upper and lower stee ring he ad bea ri ng grease with extreme pres- 3 - 5 9 (each)
St eeri ng head du st seal lips sur e (exa m ple : EXCE-
LIGHT EP2 m anuf actured
by KYODO YUS HI, Japan) ,
She ll st am ina EP2 o r
eq uiva le nt
Swingarm pivot bea ri ngs M Ulti -purp ose grease
Swi nga rm pivot d us t seal lips (She ll A lv ania EP2 o r
Shock arm and shock link needl e bea ri ng s eq uiva lent)
Shock arm and shock link dust sea l lips
Gea rs hift peda l link t ie-rod ball join ts
Thr ott le cable A, B cable ins ide Cable lubrica nt
Exhaust valve cable A, B cable inside Molybdenum oi l
Hand leb ar g rip rubbe r inside Honda bond A,
Pro Honda Handgr ip
Cem ent (U .S.A. onl y) or
eq uiv alent
Front brake lev er pivot/adjuster/pus h rod sliding area Silicone grease
Front brake push rod and piston contacting area
Rear brake calipe r boot ins ide
Rear brak e ma st er pi st on-to-pu sh ro d co ntact area
Brake cali per d ust seals
Clutch lever sliding area and pi st on co ntact area
Clutch pivot bus hing and piston contact area
Brake master piston and cups DOT 4 brake fl uid
Brake calipe r pisto n and pisto n sea ls
Fork cap O-r ing Pro Hond a Suspension
Fo rk dust sea l and oil seal li ps Flu id 5 5- 55 or equ iva lent
Rear brake reservoir hose jo int screw threads Locki ng agent
Fro nt master cylinder oil cup stay mounting bolt
threads
Front bra ke calipe r asse m bly bolt t hr eads
Rear bra ke cali pe r pin bol t th reads
Clutch oil cup tig ht en ing screw th read s
1-23
Contents Chapter 1
GENERAL INFORMATION
CABLE & HARNESS ROUTING
THROTTLE CABLES
CLUTCH HOS E
IGNITION
SWITC H WIRE
LEFT HANDLEBA R
SWITCH WIRE
RIGHT HA NDLEBAR
SW ITCH WIRE
FRONT BRAKE HOSE HORN WIR E
FRONT SUB- HA RNESS

12P (GRAY) CONN ECTOR
COMBIN ATION METER

POSITION LIGHT M ULTI-CONNE CTOR
2P( NAT URAL) CONNECTOR
RIGHT TURN SIGNAL 3P

(LIGHT BLU E) CON NECTOR
BANK ANG LE SENSOR

3P (GREEN ) CONNECTO R
FRONT SUB -HARNESS 12P

(GRAY) CON NECTOR
HEADLIG HT SOCKET
1-24 Chapter 1
Contents
GENERAL INFORMATION
T HROTTL E CA BLES
CLUTCH HOSE
HORN WIRE ----f~~~~:t/I_-L
FRONT BRA KE HOSE
1-25
Contents Chapter 1
GENERAL INFORMATION
T HROTT LE CA BLES
ECM
FRONT BRAK E HOSE
MAIN W IRE
HARN ESS
RADIATOR
SIPHON HOSE
RAD IATOR OVERFLOW

HOSE
1-26
Contents Chapter 1
GENERAL INFORMATION
SECONDARY INJECTOR
FUEL HOSE
VS (VEHICLE SPEED) SEN SOR

3P( NATU RA L) CON N ECTO R
CMP (CA M SHA FT POSITION) SENSOR
2P (BLACK) CONNECTOR
Contents Chapter 1 1-27

GENERAL INFORMATION
SECONOARY
INJ ECTORS
PRIM ARY
INJE CTORS
No.1 No.2 No.3 No.4
lAC T HERM A L VA LVE
ECT SENSOR 3P (GRAY) CONNECTOR
1-28
Contents Chapter 1
GENERAL INFORMATION
REGULATOR/RECTIFIER 2P
(NAT U RA L) CONNECTO R
SIDE STAN D 2P (G REEN)

CONN ECTOR
FU EL TAN K
BREATH ER HOSE
CLUTCH HOS E
-.
CM P (CA M SHA FT
POSITION) SENSO R 2P
(BLACK) CONN ECTOR
SID E STAND
SWITCH W IRE
1-29
Contents Chapter 1
GENERAL INFORMATION
IGNITIO N COIL SU B-HA RNESS
ECM
MAIN WIR E
HARN ESS
RA DIATOR SIPHON HOSE
ENGINE SUB-HARNESS
CKP (CRANKSHA FT RADI ATOR OVERFLOW
POSITION ) SENSOR HOSE
W IRE
1-30
Contents Chapter 1
GENERAL INFORMATION
REAR BRAK E LIGHT SWI TCH

2P (BLACK) CONN ECTOR
CKP (CRA N KSHA FT POSITION ) IGNITION COIL SUB -HARN ESS

SENSOR 2P (RED) CONNECTOR 6P(NATU RALI CONN ECTOR
REAR BRAKE LIGHT RAD IATOR SIPHON HOSE

SW ITCH WIRE
RADIATOR OVERFLOW
HOSE
1-31
Contents Chapter 1
GENERAL INFORMATION
EGCV SERVOM OTOR 6P

(NAT U RA LI CON N ECTOR
VEHICLE SPEED SENSO R 3P

EGCV SERVOMOTOR (NATU RAL) CON NECTOR
EGCV CONTROL
CAB LES FUEL TAN K
BREATH ER HOS E
NEUT RAL SW ITCH
1-32
Contents Chapter 1
GENERAL INFORMATION
MAI N W IRE HARNESS TUR N SIGNAULICEN SE

STARTER RELAY
SEAT LOCK CABL E LIGHT CON NECTORS
SWITCH
STA RTER MOTOR

GROUND CABL E
..----..-,
STARTER MOTOR TAIUBRAKE LIGHT
CA BLE CONN ECTO R
REAR BRA KE LIGHT

REAR BRA KE HOSE SWITCH W IRE
1-33
Contents Chapter 1
GENERAL INFORMATION
CALIFORNIA TYPE:
THROTTLE BODY EVAP PURGE CONTROL

FUEL TANK-TO- 5-WAY JOINT SOLENOID VALVE 2P (NATURAL)
CANISTER HOSE CONNECTOR
EVAP PURGE
CONTROL
EVAP CAN ISTER SOLENOID VALVE
1-34
Contents Chapter 1
GENERAL INFORMATION
EVAP PURG E
CONT ROL
To fuel tank To 5-way joint SO LENO ID VALVE
CAN ISTER-TO-SOLENOID
DRAIN HOSE EVA P CA NISTER VA LVE HOS E
1-35
Contents Chapter 1
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Envir onm ent al Pro tecti o n Agency (EPA), T ranspo rt Canada and California Air Resources Boad (CA RBI req uire
manufactu rers to certify that t heir moto rcycles comply with applicable- exhaust emissions standa rds durin g t heir useful
life , when operate d and ma intained acco rding to the instructio ns provided.
The EPA also req ui res t hat moto rcycles built after J an u ary 1. 1983 co mply w ith applicabl e noise em iss io n sta nda rds f o r
one year or 6,000 km (3,730 miles) afte r th e time of sale t o th e ulti mate pu rchaser, whe n o perated and m ain tain ed
according t o the instru ct io ns prov ided.
Compl iance with th e t erm s of t he Distributor' s Lim it ed W arra nty fo r Hon da M o t o rcy cle Emi ssi on Control Syste m is
necessary i n o rder to keep t he em ission sy stem warranty in effect .
SOURCE OF EMISSIONS
T he com bust io n proce ss prod uces carbo n m o no xide. ox ides of nitrogen and hy d ro car bon s. Co nt ro l of hydrocarbon s and
ox ides of nitrogen is ve ry import ant beca use, u nder ce rtai n co nd it io ns, th ey react to form ph otochem ical smog w he n
su bject t o su nli ght. Carb on m on o xid e do es no t reac t in the same wa y . but it is tox ic.
Hon da Motor Co., Ltd. utilizes lean inject ion sett ings as w ell as ot he r system s, to redu ce ox ides of nitrogen, carbo n
monoxide an d hydroca rbo ns .
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging cran kcase em issions in to th e atmosphere.
Blow-by gas is ret urned to the combustion chamber throu gh t he ai r cleane r and throttle body.
AI R CLEAN ER HOU SING
c::;::2.-- - - - - THROTTLE BODY
FRESH A IR 0
BLOW-BY GAS
1-36
Contents Chapter 1
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
Th e ex haus t em ission control sy stem is com posed of a seco nda ry air su p p ly sys te m. a o xidat io n catalytic converte r and a
lean fuel injectio n setting . No ad ju stm ent s sho u ld be ma de ex cept id le sp eed adj u st ment with th e th rottle stop scr ew. Th e
ex ha ust em issi o n co nt ro l sys t em is sepa rate from the cra nk case emissio n control sy st em .
SECONDARY AIR SUPPLY SYSTEM
Th e pulse secon d ary ai r supply sy st em introduces fil t er ed air into t he ex ha ust gases in t he exha ust port. Fresh ai r is drawn
into the ex haust port by the f u nct ion of th e PA IR (Pu lse Secondary A ir Injecti on ) control v alve.
Th is char ge of fr esh air pro motes burn ing of t he unburned ex haust ga ses and cha nges a con sider ab le am o un t of
hy dro carb on s and car bon monoxi de into r elativ ely harmless ca rbo n di ox id e and wa te r va po r.
The reed val ve pr ev ents rever se air fl ow through th e system . The PAIR con trol v alve is operate d by th e so lenoid v alve. Th e
so le noid va lve is co nt ro lled by th e PGM -Fl u n it, and t he f res h air passag e is op ened/closed accordi ng t o ru nning co nd ition s
(ECT/IATfTP/MAP senso r and eng ine revolut io n).
N o adj ust ment s t o th e seco ndary air sup pl y sys tem should b e m ade, alt hough periodi c ins pec t io n of the com po nent s is
recom mended.
AIR CLEANER HOUSING
PAIR CHECK VALVE
i-'c;:-- - __ THROTTLE BODY
EXHAU ST PORT
PAIR CONTROL VALVE
FRESH AIR
EXHAUST GAS . .
OXIDATION CATALYTIC CONVERTER (CALIFORN IA TYPE ONLY)

Th is motorcycle is eq uip pe d with a oxidat io n cata lytic co nve rte r.
T he ox id at io n cata lytic converter is in t he exhaust sy st em. Through ch emical reaction s, it con v erts HC, CO, and NOx in th e
engine 's ex ha ust to car bo n diox ide (C0 2), dinitrogen (N2), and w ate r va p or.
No adjustment to these systems should be ma de alt hough periodic inspectio n of the compo nent s is recomme nded.
Chapter 1 1-37
Contents
GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY)
This model com plies w ith CARB evaporat ive emis sion requi rem ents. Fu el va po r from t h e fuel t an k is rout ed int o th e
evaporat iv e em iss io n (EVAP) ca niste r wh ere is it absorbed an d sto red w hile the engi ne is stopped . Whe n th e eng ine is
runni ng and t he eva p orati v e em iss io n (EVA P) pu rge control so lenoid va lve is open, fuel v apo r in the EVA P canister is
d rawn in to th e eng ine through the th ro ttle body .
FUEL TANK
IIII
EVAP PURGE
CONTROL
SOLENOID VALVE
THROTILE BODY EVAP CANISTER
NOISE EMISSION CONTROL SYSTEM

TAMPERING WIT H THE NO ISE CONTROL SYSTEM IS PROHIBITED: U.S. Federal Law proh ibits o r Canad ian Provin cial Law
may pr ohibit th e follow ing act s or the ca us ing there of: (1) T he rem o val o r rend eri ng inoperative by any person. ot her th an
for purp oses of mai nte nance, repai r o r replacement, of an y device o r ele m ent of des ign in co rp orat ed into any new ve hicl e
fo r th e purpose of noise control prior to its sa le o r deli v ery t o th e ultimate purchaser or whi le it is in use; (2) t he u se of the
ve hicle aft er suc h device or elem ent of des ign has been rem o ved or rendered inoperati ve by an y pe rso n.
AMONG THOSE ACTS PRESUM ED TO CON STITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Rem ova l of, o r pun cturing of the muffler, baffl es,h eader pipes or any othe r com ponent wh ich co nducts ex haust ga ses.
2. Rem o v al o f, o r puncturing of an y pa rt of the intake system .
3. Lack of pr op er m aint ena nce.
4. Repl acin g any m oving parts of the v ehicl e, o r parts of t he ex haus t o r intake syste m, w ith parts other then th ose spe ci -
tied by t he manufacturer.
1-38 Contents Chapter 1

GENERAL INFORMATION
EMISSION CONTROL INFORMATION
LABEL (U.S.A. ONLY)
An Em issio n Control Inf o rm atio n Label is loca te d on th e 'st oraqe ,------------------~
compartment as shown. EMISSION CONTROL IN FORMATION LABEL
1-39
Contents Chapter 1
MEMO
Contents Chapter 1
2. TECHN ICAL FEATURES
..
HESD (Hond a Electronic Steering RADIAL-MOUNTED FRONT BRAKE
Damper) 2-2 CALIPER 2-5
EGCV (Exhaust Gas Control Valve)............ 2-6
Chapter 2 2-1
Contents
TECHNICAL FEATURES
HESD (Honda Electronic Steering Damper)

This m ot or cycl e is eq ui pped with the Ho nda Electro nic St eeri ng Damper (HESD).
Th e HESD system co nsists of th e fo ll ow ing compo ne nts.
- Stee ring damper asse mbly with lin ear so le noid
- VS (vehicle speed) senso r
- ECM
- Malfunction indicator lamp (M IL) and HESO ind icator
The stee ring damper assem bly is installed o n the main frame near t he steering hea d pi pe and the linkage arm is installed
on the top fork br idge.
The damping characteristics are au to matically co ntrolled by the ECM r - - - - -- - - - - - -- - - - - - --,
HESD DAMPI NG CHARACTERISTICS:
in response to vehicle speed and acceleration and offers optimum han-
dling over a wide range of riding conditions. DAMPING
CHARAC-
TERISTICS
HESO employs a hydraulic rotary dam pe r unit. The hyd ra ulic o il is
filled into the steering damper an d is sealed per m anentl y . Th e steering
damper unit is not serviceab le.
Each co mponent of HESD fu nct io ns as fol lows.

- Damper oil cha m b er/V ane
The dam per oil cha m be r is d ivi ded in tw o by a movi ng va ne co nnec t ed intern ally t o th e linkage arm . The edge of the
va ne is cove red w it h an oi l seal so t hat th e left and ri ght cha m be rs are sea led f ro m each ot her. Th er ef or e oil m oves
betwee n t he left and rig ht side s of th e ch amb er v ia ch eck va lve co nt ro lled hy drauli c passages.
Ch eck v alve
Four one-way chec k va lves en sure th at o il fl ow s throu gh th e m ain va lve in only one d irection , w het her t he va ne is
m ove d left o r right.
Accumul at or
Acc umulator co mpensates f o r t em peratu re-indu ced cha nges i n o il vo lume.
M ain valve/Lin ear sole noid
Th e openi ng of th e main v alve is co nt ro ll ed by a lin ear solenoid t hat receives its con t rol sig nals f rom the ECM. Th e
da mpi ng characteristics are va rie d by th e ma in va lve/l inea r so lenoid.
Reli ef v alve
The relief va lve controls and sets a li mit t o th e m aximum dampin g f o rce.
VAN E
DAMPER OIL CHAM BER
ACCU MU LATOR
RELIEF VALVE M AI N VA LVE/LINEA R SOLENO ID

TECHNICAL FEATURES
DAMPER OIL FLOW DIAGRAM
W HEN THE STEERING MOVES TO LEFT: W HEN THE STEERING MOVES TO RIGHT:
2-3
Contents Chapter 2
TECHNICAL FEATURES
CONTROL SYSTEM
Receiv ing the sig nal fro m the VS sens or, t he ECM calc ulat es t he v ehicle spe ed and rat e of accelerat io n. T he ECM o ut puts
th e con t rol curr ent t o th e linear sole no id coil base d up o n th e v ehicl e speed and accelerat io n. The linear so lenoid depresses
t he m ain va lve acco rd in g t o th e con t ro l curr ent w hich passe s t hroug h t he linear soleno id, an d co ntrols t he dampin g char-
acte ristics of HESD.
.,," "..
BATIERY
ECM
MI L AN D TURNING TURNING
HESD LEFT RIGHT
~ I N DICATOR
~
QV-n
~I Q I ~
0 0
CHECK
VALVES 'i-... ~
CHECK
Y VALVES
b=~=====~=
E=L1E=F==1=LV==E=d~="M"~>O"
SYSTEM CONTROL
(0' :
: VS (VEHICLE :
SPEED)
SENSOR
LINEAR SOLENOID/MAIN VALVE
....... SENSOR ..... ................... STEERING DAMPER .
SELF-DIAGNOSTIC SYSTEM
The HESD syste m is equipped with a self-d ia gnostic and f ail-sa fe sys te m t h at is linked t o th e PGM -FI sy stem .
Wh en t he ECM detects any f ail ure of the lin ear so leno id o r VS sensor, it stops con t ro lli ng t h e linear so lenoid and in f orm s
t he rider of sys t em trouble by tu rn in g on th e M IL and d isplayi ng th e HESD in d icat or. If th e m alfun ct ion ind icato r lam p (M IL)
bli nks, follow t he Se lf- Diaq nostic Procedu res (pa ge 69) to rem edy the pro bl em .
The fail-safe system secures a m in imum run ning capa bi lity w hen t he re is any trouble in t h e system. When any ab no rm al it y
is detected by t he self-diagnosis funct ion, t he ECM stops th e HESD sys tem control by sh utting off the cu rre nt supply to the
linear solenoid and the HESD will operate under minimum dam pin g cha racte ristics.
The HESD sys t em is also eq uipped wit h the Functio n Test M ode so t hat a t ec hn ician can co m pare the m inimum w it h m ax-
im um dam ping character istics witho ut rid in g. Th e HESD system is set t o m inim um dampi ng at no ve hicl e spee d under
no rma l co nd iti ons. By usin g t he Functi o n Test M od e, th e ECM op erat es t he linear so len oid wi th ma xim um cu rre nt so th e
HESD system is t em p orar ily set t o m axi m um dam pin g.

TECHNICAL FEATURES
RADIAL-MOUNTED FRONT BRAKE CALIPER
The CBR1000RR's new front brake system fea tures a set of radial-m oun t ed cali pe rs.
These cali pe rs f eatu re distin cti v e turret-like m ounts t hat are perpendicular t o t he f ron t axl e, on to w hich t he caliper s bo lt
str aight down. Th e calipe r hal v es are held t og et her by t hree lat era l bo lt s f o r a m ore rig id design t hat pr ovid es both st ro n-
ger g ri p an d more eve n pressu re dist ri bution across t he enti re surface area of th e pa ds fo r hig hly efficie nt br aki ng wi th
excellent feel at the lever.
Along with t hese new rad ial-m ou nt ed fro nt br ake calipe rs, the new front brake system features a new ly developed vertical
piston lay o ut master cy linde r. This system mi nimizes lo st m oti o n an d m ov es the lever piv ot farther away from the end of
the lever w hi ch off ers high b rakin g effi cie ncy w it h excellent f eel and cont ro ll abi lity.
Chapter 2 2-5
Contents
TECHNICAL FEATURES
EGCV (Exhaust Gas Control Valve)
Th is motorcycl e is equi ppe d w ith th e EGCV that provides high perform an ce and d riveability esp ecially at lo w to middle
speed ra nge by va ryi ng t he ex hau st gas flow.
Th is syste m consists of th e va ria ble exhaust co nt rol v alve lo cated in the muffler and a servom otor lo cated under the fu el
tan k.
The v ariable exhaust co nt rol v alve is o pe rated by cables from the servom o to r that is co nt ro ll ed by ECM .
Basi cally, the EGCV is po sit ioned middle at low to middle speed rang e and opens fully at high spe ed range .
EGCV OPENING ANGLE:
Ignition Gear position EGCV opening an gl e
Engin e speed
switch (Clutch switch OFF) from fully closed
ON N eutral Approx.50
ON Neutral Idle Approx.50
ON Wit h ou t neut ra l Id le Approx .80
ON With out n eutral 5.000 - 6.00 0 rp m Approx. 75 - 90
ON With ou t n eutra l over 6.000 rpm Approx.90
NOTE :
It is necessary to ins pect t he EGCV co ndit io n and ca ble adjust ment in accordanc e w ith th e m ain t enan ce schedul e
(page 4-41. .
EGCV SERVO MOTOR EGCV PULLEY
EGCV CONTROL
CAB LES
2-6
Contents Chapter 2
3. FRAME/BODY PANELS/EXHAUST SYSTEM
..
BODY PANEL LOCATIONS 3-2 UPPER COWL ..............3-12
SERVICE INFORMATION 3-3 TOP SHELTER..................3-16
TROUBLESHOOTING 3-3 FRONT FENDER 3-19
RIDER SEAT 3-4 REAR FENDER 3-19
PASSENGER SEAT 3-4 SEAT RAIL3-27
REAR SEAT COWL 3-5 EXHAUST PIPE/MUFFLER..........3-30
UNDER COWLS/MIDDLE COWLS .. 3-7
3-1
Contents Chapter 3
FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS
FRONT SIDE COVER
W IN DSCREEN
RIDER SEAT
PASSE NGER SEAT
REAR SEAT COW L

UP PER COW L
FRONT FENDER
REAR FENDER A
U ND ER COW L MIDDLE COWL
o
IN NER MIDDLE COWL

SERVICE INFORMATION
GENERAL
This sectio n covers removal a nd insta llat ion of the body pane ls, ex haust syste m a nd seat rail.
Se rious burn s m ay result if t he exhaust system is not allowed to cool before components are removed or serviced .
Always replace the exhaust pipe gaskets wi th a new one after remov ing th e exhaust pipe f ro m t he engine.
When installing the exhaust system, loo sely install all of the exhaust pipe fasteners. Always tighten the exhau st pipe
clamps first. then tighten the mounting fasteners .
Always inspect the exhaust system for leaks afte r installation.
TORQUE VALUES
Seat ra il flange socket bolt/flange nut 59 Nrn (6.0 kqf-rn, 43 lbf- ft)
Sea t rail specia l bolt/flange nut 59 Nm (6.0 kqf-m, 43 Ibfft)
Seat rail assembly flange nut 30 Nm (3.1 kqf-m, 22 Ibfft)
Seat rail brace socket bolt 26 Nm (2.7 kqf-rn , 20 lbf-ft)
Passenger seat bracket special bolt 26 N m (2.7 kgfm, 20 Ibfft )
Passenge r seat bracket socket bolt 26 Nm (2.7 kqf-rn, 20 Ibfft)
Rider seat bracket m ou nti ng bolt/ nut 9.8 Nm (1.0 kqf-m , 7 lbf-ft}
Rider f oot peg bracket socket bolt 37 Nm (3.8 kgfm , 27 Ibf ft )
Bank se nso r 11 Nm 11.1 kqf-rn, 8 Ibf ft )
Passenge r foo tpe g br acket socket bolt 26 Nrn (2.7 kqf-rn, 20 lbf -tt)
Exhaust pipe jo int nut 12 N m (1.2 kgfm, 9Ibfft)
Exhaust pipe mounting bolt 23 Nm (2.3 kqf-rn, 17 Ibfft )
Exhaust joint pipe clamp SH bolt 9.8 Nm (1.0 kgfm , 7 Ibfft)
Exhaust valve pulley nut 4.9 N m (0.5 kqf -m, 3.6 Ibfft)
Exhaust valve reta ini ng screw 1.5 Nm (0.15 kqf-rn , 1.1 Ibfft )
Exh au st valve pu lley housi ng fla nge S H 9.8 Nm (1.0 kgf m, 7 Ibfft)
bol t
Muffl er pipe clamp bo lt 18 Nm 11.8 kgf m , 13 Ibf ft )
Upper cowl stay f lange bo lt 32 Nrn (3.3 kqf-m. 24 Ibfft )
Cowl stay mounti ng bolt 12 Nm (1.2 kqf-m, 9 lbf -tt l
Windscreen mounting screw 0.5 Nm (0.05 kgfm, 0.4 lbf-tt)
Middle cow l pan screw 1.5 Nm (0.15 kqf-rru L'l Ibf-ft}
M idd le cowl special screw 9.8 Nm (1.0 kqf-m, 7 lbf-ft)
Upper cowl pan screw 1.5 Nm 10.15 kqf-m, 1.1 lbf -ft ]
U pp er cowl special screw 9.8 Nrn (1.0 kqf-m. 7 lbf-ft)
Inne r cow l specia l screw 9.8 Nm (1.0 kqf-m , 7 Ibfft )
Front fend er pa n screw 12 Nm 11.2 kqf-m, 9 Ibfft)
Rea rview m irror socket bolt 6.8 Nm (0.7 kqf-rn, 5.1 lbf-ttl
TROUBLESHOOTING
Exce ssive exhaust no ise
Broken ex haust syste m
Exh au st gas leak
Poor performance
Defo rme d exhaust syste m
Exhaust gas leak
Clogged muffler
3-3
Contents Chapter 3
RIDER SEAT
REMOVALIINSTALLATION
Rem ov e th e t w o seat mou nting pan screws and col- r - - -- - - - - - - - - ---------,
lars. PAN SCREW S
Rem ove the seat by pull in g it bac kward . RIDER SEAT
Install th e seat hook s unde r th e seat bracket o n t he
seat rail. HOOKS
Install t he co lla rs and seat m ountin g pan sc rews,
tig hten th e screws .
PASSENGER SEAT
Un hoo k t he pas seng er seat loc k u sin g the ig nit io n , - - -- - - - - - - - - -- - -- ,
key. PA SSENGER SEAT
Remove t he passe nge r seat by pull ing it fo rward.
Inst all t he passeng er seat in t he rev erse o rder of
re mova l.
IGN ITION KEY
3-4
Contents Chapter 3
REAR SEAT COWL
REMOVAL
Remove t he fo ll ow ing:
REAR SEAT COWL
- Rider seat (pag e 3-4)
- Passen ger seat (page 34 )
Rem ov e t he fo ur special screws .
Carefully pull ou t both sides of the rear .seat cowl ,
t he n rem ov e it upwa rd .
f---::;;~~
L
Disconn ect th e t ail/b rake li gh t co nne cto r.
TA IUBRAKE LIGHT CONNECTOR
DISASSEMBLY/ASSEMBLY
Rem ov e the screws and ta i l/brake ligh t unit.
TA IU BRA KE LIGHT UNIT
Remove the two screws, trim clip and a ir duet.

Install the air duct and ta il/brake lig ht un it in t he
rev er se o rde r of rem ov al.
3-5
Contents Chapter 3
INSTALLATION
PASSENGER SEAT
RIDER SEAT
REAR SEAT COWL
Make sure that the Connect th e ta il/brake lig ht co nnector.

mating surfaces of Install the rear seat cowl over the seat rail and rea r REA R SEAT COWL
the cow! bottom fe nde r bei ng careful not t o d amag e th e w ir e har-
are seated onto the ness.
rear fender prop- Align t he t ai l/b rake light bolt st uds w ith t he grom-
ertv before tighten- m et s on the rear fender as shown.
ing the cone .
Install and tighten the rear seat cowl mounti ng
sc rews.
In st all t he remo v ed parts in th e rev er se o rde r of
rem ov al.
TAIUBRAKE LIGHT CONNE CTOR
3-6
Contents Chapter 3
FRAME/BODY PANELS /EXHAUST SYSTEM
UNDER COWLS/MIDDLE COWLS
REMOVAL
Be careful not to Rem ov e the spec ia l screw and f our trim clips from
damage the tabs t he bottom of th e u nder cowls.
and groo ves.
TRI M CLIPS
Remove the six tri m cl ip s from the inner lower co w l

and inne r middle cow l.
TRIM CLIPS
Rem ove the un der cowl-to -m iddle cowl pan screws .

Rem ov e t he un der cowl mount ing spe cia l screws PA N SCREWS
and th en remove t he under cowls and inner low er
cowl.
SPECIAL SCREWS
3-7
Contents Chapter 3
Remove t he m iddle cowl-to-Inn er m iddle cowl trim
clips.
Rem ove the midd le cowl-ta- upper cowl pan screws .

SPECIAL SCREWS PAN SCREWS
Rem ov e th e middl e cowl-to -inner mid d le cowl spe-
cia l screws and mi ddle cowl mounting special
screw.
M IDDLE COW L
Rem o v e t he m id dl e cowl w hil e rel easin g t he ho o ks

o n t he u p per cowl. HOO KS
Di sco n nect the t u rn sign al co n nector.
TURN SIGNAL CONNECTOR
3-8
Contents Chapter 3
Rem ove the inner m iddle cowls
INSTALLATION
RIGHT MIDDLE COWL
LEFT M IDDLE COWL
~ , ~,
~j
INNER LOWER COW L
LEFT UNDER COW L
3-9
Contents Chapter 3
Install the inner m idd le cow ls.
INNER MID DLE COWL
Con ne ct the turn signal conne ctor.

HOOKS
Install the m idd le cowl onto the upper cowl while
aligning the slits in the middle cowl with the hooks
on the upper cowl.
TURN SIGNAL CONN ECTOR
Install and tighte n the upper cow l-to-m iddle cowl ~================~
PAN SCREW S
pan screws to the specified to rque. SPECIAL SCREWS
TORQUE: 1.5 Nm (0.15 kgfm .l.llbf.ft)

Install and tighte n the midd le cow l special screw s to
the specified to rque.
TORQUE: 9.8 Nm (1.0 kqf-m, 7 Ibf.ft)
MIDD LE COW L

Install th e trim clips.
TRIM CLIPS
Install the right and left under cowls by aligning the

botto m end. PAN SCREWS
Install and tighten the under cow l-to- m iddle cow l

pan screw s to the specified torqu e.
TORQUE: 1.5 Nrn (0.15 kglm ,l.l lbllt)
Install and tighten the under cowl mounting special
screw to the specified torque.
TORQUE: 9.8 Nm (1.0 kqf-m, 7 Ibllt)
SPECIA L SCREWS
Secure the bottom of the under cow ls using the fou r

trim clips and pan screw .
Tigh ten the specia l screw to the specified to rque.
TORQUE: 9.8 Nm (1.0 kqf-m, 7 IblIt) . . ~~ \ Y/it y
~~~"
TRIM CLIPS
~//~I
!j :#
TRIM CLIPS
3-11
Contents Chapter 3
Secure the under cowl betw een the inner lower
cowl and inner mi ddle cow l using th e six tr im clips.
TRIM CLIPS
UPPER COWL
WINDSCREEN REMOVAL
Remove the under cow ls/m idd le cowls (page 3-7).
Rem ove the screws, plastic a nd rubber was hers,
then remove the wi ndscree n. SCREW
PLASTI C WAS HER

WI NDSCREEN
UPPER COWL REMOVAL

Remove t he rea rview mirror m oun tin g soc ket bolts
and rearview mirrors. REARVIEW MI RROR
SOC KET '~_~~

BOLTS '
3-1 2
Contents Chapter 3
Discon nect the comb ination meter m ult i-connector.
COMBINATION M ETER MU LTI-CONN ECTOR
Relea se the uppe r cow l off t he rearview m irror bolt

hol e studs and bosses of th e upper cowl f ro m th e GROM M ETS
meter stay g rommets, then rem o v e th e upper cowl
assembly.
~. ------- ;/
-~
BOSS ES
Disconn ect th e fron t sub- ha rne ss multi -con nect or.
See page 20-5 for hea dlight unit re mova l/insta lla-
tion .
SU B-HARN ESS MULTI-CONN ECTOR

INSTALLATION
WIN DSCREEN
REARVIEW M IRROR
/ 0.5 Nm (0.05 kqf-rn, 0.4I bfft)
'if
U PPER COW L

Con nect th e front su b-ha rnes s connectors. combi-
nation meter mu lti-connecto r.
SUB-HARNESS M ULTI-CONNECTOR
Inst all t he upper cowl, alig ning t he bos ses w ith the
grommets o n t he upper cowl stay. GROMM ETS
----=~-
0~~_~2f::::._<7-;/
BOSSES
Conn ect t he co mbi nation m eter mul t i-conn ecto r.
COMBINATION METER MU LTI-CONN ECTOR
Alig n t he rearvi ew m irror bolt hole studs of up per

cowl wit h t he rea rview mir ro r s tay . REARVIEW MIRROR
Inst all the rearvi ew mirro r and t ig ht en th e so cket
bo lts to the specified to rq ue.
TORQUE: 6.8 Nm (0.7 kqf-m, 5.1 Ibfft )
SO CKET~_~~
BOLTS '
3-15
Contents Chapter 3
Install the cowl sett ing nuts into the wi ndscree n
holes.
Install the wi ndscreen, then install the rubber and SCREW
plastic was hers and screw s.
Tighten the screws to the specified torque.
PLASTIC WASH ER
WI NDSCREEN
TORQUE: 0.5 Nm (0.05 kq f-rn, 0.4 Ibl-ft)
Install the m iddle cow ls/unde r cowls (page 3-71.
"' ~\
I
# ' ,
J~' -
>",<-. RUBBER
j WASH ER
TOP SHELTER
Rem ove th e rider seat (p age 3~ 4l .
Rem ove the front side cove r specia l screws.
Rem ove both front side cove rs by releasing the tabs
f ro m the to p shel te r.
FRONT SIDE COVER

Remove the spe cial scr ews, mounting screws/wash
er s a nd top shelter.
TOP SH ELTER
Remov e the screw s and center co v er f ro m th e t op

s he lte r. TA B/GROOVE
Insta ll th e ce nte r cove r, align th e tab of the center
co ver into the groove of the top shelter, the n tighten
the screws.
3-17
Contents Chapter 3
Be careful nor to let Inst all t he to p shelter o nto the fu el ta nk .
the collars fait into
Ali g n the fue l f ill er ho le fl an ge o n th e t op she lte r
the fram e.
with th e rubber on t he f uel f ill cap.
TO P SHELTER
Inst all and t igh t en th e speci al sc rew s and m o unting
screws/wa she rs. SPECIA L
SCREWS
Install t he fro nt side cover w hile alig ning its t abs

wi th the groo ves in th e top s hel ter. SPECIA L SCREW
Install and t ig ht en the special screw on both side s.

\
~--------
Install the ri der seat (page 3-4) . .
~ ~~
0: "~
\~ ~
TABS
FRONT SIDE COVER

FRO NT FENDER
REMOVAL/INSTALLATION
Rem o v e t he fro nt br ake ho se 3-w ay joi nt bo lt and , - -- - - - - - - - - - - -- - -,
h ose cl amp n ut. 3WAY J OINT BOLT
Remove the pan screws, front fender, reflect o rs and

grommets from the fo rk legs.
Inst all t he front f end er in the rev erse order of
rem oval.
TORQUE :
Front fender pa n sc re w :
12 N' m 11.2 kqf -m, 9 lbf-ttl
Fro nt brake h o se cla m p n ut:
9.8 N m (1.0 kqf- m , 7 Ibfft)
Fro nt bra ke hose 3-w ay joi nt bolt :
9.8 Nm (1.0 kqf-m, 7 Ibfft)
FRONT
FEND ER
PAN SCREWS
I
.. ~
~.
HOSE CLA M P NUT
REAR FENDER
REAR FENDER A REMOVAL - -
Remov e the rea r cowl (page 3-5).
Discon nect the tu rn si g na l and license lig ht co nnec- BOLTSI
tors. WAS HERS
Rem ov e the rear f ende r A mounting bol t s, was h ers
an d rear fender A assem bly.
CONNECTORS REAR FEND ER A
Contents
3-19
Chapter 3
REAR FENDER A DISASSEMBLY
Remove the nuts and license light unit.
Remo ve the nut, retainer and rear turn signal unit.
LICENSE
LIGHT UN IT
RETA IN ER
T URN SIGNA L U NIT
Rem ove the screw and left rea r fender bracket , har- ~================~
ness guide and cover.
HARN ESS GU IDE COVER
REAR FENDER B REMOVAL

Rem ov e t he ba tte ry (pa ge 17-5).
PAN SCREW/CO LLAR REAR END COVER
Rem ove the pa n screws , m uffl er rear end cover and
collar.
PA N -SCREWS
3-20
Contents Chapter 3
Remov e th e pan sc rews and pa ssenger seat rear
hook. PASSENGER SEAT REAR HO OK
Remove t he f lange bolts and passe nge r seat hooks.

Remov e the passenger seat hoo k special bo lt s, t hen
remove th e pass enger se at bra cket .
Unhook t he seat lock cable from t he seat lock lever,

th en rem o v e th e pass en g er seat bracket . SEAT LOCK LEV ER
SEAT LOCK CA BLE
Disconnect t he seat lock cable from the seat lock key

cylinder.
Rem ov e th e ret ainer and re m ov e th e seat lo ck key
cy linder fr om the rear fe nde r B.
3-2 1
Contents Chapter 3
Remove th e bolts an d nut s, t he n remove t he rider
seat bracket fro m th e seat rai l.
Release the w i re harness clamp and release th e

main w ire harness and starter motor cables .
Rem ove t he rea r f ender B-t a-h eat prot ect or t rim
clips.
Remove the rear fende r 8 from the seat ra il.

REAR FENDE R B
3-22
Contents Chapter 3
Remove the m uffler and m uffler heat protecto r
(p age 3-30).
Remove the heat protector from the seat rail and
frame.
REAR FENDER B INSTALLATION

26 N'm (2.7 kqf -rn, 20 Ib fft)
9.8 Nrn (1.0 kqf-rn, 7 Ibfft ) REAR FEN DER 8
HEAT PROTECTO R
Install the heat prote cto r onto the seat rail and
fram e.
Insta ll t he m uffler and m uff le r heat protecto r (page
3-36) .
3-23
Contents Chapter 3
Instal l th e rear fe nde r B int o the seat ra il.
REAR FENDER B
Inst all t he rea r f en der Bcto-h eat p ro tector t rim clips

and secure them .
Secure t he mai n w ire harness an d st arter m otor

ca bles with w ire clamp.
Inst all th e ri der seat br ack et onto t he seat rai l.

Inst all and t igh t en t he ri d er seat b racket mo u nti ng
bo lt s and nu t s to t he sp ecified torque .
TORQUE : 9.8 Nm (1.0 kqf-rn, 7 Ibftt)

Inst all th e seat lo ck key cylin der into the rear f end er
B and sec u re it w it h ret ain er.
Connect the seat lock cable t o th e seat lock key cy l-
inder and clamp it with cab le cla mp.
Ho ok t he seat lock cab le to t he sea t loc k lev er .

SEAT LOCK LEVER
SEAT LOCK CABLE

Inst all the passen ger seat b racket .
Instal l the passeng er seat b rac ket special bo lts.
Install t he passe nger seat ho oks and flang e bo lt .
Tighten th e passeng er seat b racke t sp ecial b olts and
fl ange bo lt s t o th e specified torqu e.
TORQUE: 26 Nrn (2.7 kqf- m , 20 Ibf.ft)
Inst all t he passenge r seat rear ho o k and t ig ht en t he

pa n screw securely.
3-25
Contents Chapter 3
Install the collar Install the muffler rea r end cover and col lar.
between the muf- PAN SCREW /CO LLAR REAR END COVER
Insta ll and tig hte n the pan screws.
fler and {ear
fender B. Insta ll the batt ery (page 17-51.
REAR FENDER A ASSEMBLY

When install ing th e grom m ets and col lars, note th e
installa tion direction of the grom m et s and colla rs.
Route the turn signa l and ta il light w ire into th e left
harn ess guide.
SCREW -----~. ;
Install the cove r a nd bracket and tighten the screw
secur ely .
HARNE SS GUI DE COVER
Install th e rig ht cove r onto th e rea r fe nder A bracket,

ti ght en the screw .
Insta ll the turn signa l bracket o nto the rear fe nder A
bracket, then assemble th e rea r fe nder A, brackets
and lice nse light. LICENSE
LIGHT UN IT
Install and tighten the lice nse light mou ntin g nuts.
Insta ll a nd tig hte n the rea r tu m signa l un it m o unt ing
nuts .
RETAIN ER
T URN SIGNAL UN IT
3-26
Contents Chapter 3
REAR FENDER A INSTALLATION
Install the rear fender A assem bly, wa shers and
bolts, then tighten the bolts securely.
Connect the tu rn signal and license light connec-
BOLTI
tors.
W ASHERS
Ins tall the rear cowl (page 3-51,
CONN ECTORS REAR FENDER A
SEAT RAIL
REMOVAL
Rem ove the followin g:
HEAT PROTECTOR REAR FENDER B
M u ff ler (page 3-301
- Rear fende r A and B (p age 3-19 1
- Fuel t ank (page 6-361
Remo ve the bolt and rear brake reservoi r.
Remove the socket bolts and left passenger footpeg

bracket.
3-27
Contents Chapter 3
Remove t he seat rail m o u nt in g specia l bolts a nd
SEAT RAI L
nuts, t hen re m ove the seat ra il assem b ly .
Remove the socket bo lts and seat rai l brace.
Remove the seat ra il asse mbly b o lt s/n ut s, the n sep-

arate the right and left seat rai l.
Replace the seat Assemb le the seat ra il by in st al lin g the seat rail
rail as an assembly. asse mbly flange bol ts/nuts.
3-28
Contents Chapter 3
Install the seat rail bra ce a nd then install t he socket
bolts .
INSTALLATION
SEAT RAIL BRACE
59 Nm (6 .0 kqf-rn, 43 lbf-ft] 30 N m
(3.1 kqf-m , 22lbfftl
LEFT SEAT RAIL
59 N m (6.0 kqf-m, 43 lb f -ft )
Af7/ 26 Nm (2.7 kqt-rn . 20 Ibfftl
Install the seat rail to the frame.

SEAT RAIL
Install the upper mounting bolts/nuts and lower
mounting bolts/coll ars/n uts.
Tighte n the bo lts and nuts to t he spec if ied torqu e.
TORQUE :
Upper m oun t in g fl ange nut:
59 Nm (6.0 kqf-m , 43 lbf-tt)
Lower mounting fl ange nut :
59 Nrn (6.0 kqf-m , 43 Ibf.ft)
Tig hten t he four seat rail brace socket bolts and seat
rail assem bly flang e nut s to th e specified to rqu e.
TORQUE:
S e at rail brace socke t bolt:
26 Nm (2. 7 kgf-m , 20 Ibf ft)
Seat rail as sembly flang e nut :
30 Nrn (3.1 kqf- m, 22 Ibfft )
3-29
Contents Chapter 3
Install the left passenger foot peg bracket and
tig hte n the socket bolts to the specified torque.
TORQUE: 26 Nm (2.7 kgf'm, 20 lbf-ft]
Install the rear brake reservoir and tighten the bolt.

HEAT PROTECTOR REAR FEND ER S
Install the following :
- Muffler (p age 3-30)
- Rear fender (page 3-19)
- Fue l t ank (page 6-36)
EXHAUST PIPE/MUFFLER
REMOVAL
Remove the following:
- Top she lter (p age 3-16)
- U nder cowls/midd le cowls (page 3-7)
- Rear seat cowl (page 3-5)
- Rear fe nde r A (page 3-19)
Remove the radiator lower mo unt ing bolt .
LOWER MOUNTING SOLT
Avoid damag ing the radiator fins, remove the bolt

and radiator lower bracket from the engine .
3-30
Contents Chapter 3
Rem ov e the radiato r rese rve tank mounting bol t
and filler neck m ount in g bol t.
Disconnect t he fan motor 2P (Black) co nnecto r.
Loos en the radi at or uppe r m ou nt ing bo lt.
M ov e th e radi ato r to t he right and release th e radi a-

to r grommet f rom the brac ket bo ss, the n move t he
ra diato r downward.
3-31
Contents Chapter 3
Remo ve the muffler guard mounting pan screw, col-
lar and screw.
Remo ve the muffler guard bo ss from the seat rail
brack et grommet. then rem ov e the muffler guard .
Remove t h e soc ket bo lt s and right passenger foot-

peg bra cke t.
Rem ov e t he socket bol t s and righ t f oot peg bracket .
Remove t he pa n screw and ex haust pi pe heat ...-- ....,.=

g ua rd.

Loosen t he m uffler ban d f lange bo lt .
Rem ov e the exhaust pipe joint nuts.
Rem ove the exhaust pipe m o unti ng bo lt/washe r,

th en rem ov e th e exh aust pipe,
BOLTIWASHER
Remove the bo lt a nd e xha ust jo int pipe clamp.

Rem ove the exhaust joint pip e, gask et and flange .
3-33
Contents Chapter 3
Remove the pa n screws, mu ffle r rea r end cover and PAN SCREW /COLLAR REA R EN D COVER
collar.
PAN SCREWS
Rem ov e t he bo lts and ex ha ust valve cove r.
Bend th e lock t ab an d rem ov e th e nut fro m t he pul-

ley .
Rem ov e t he pu lley f rom th e shaft.
Loosen t he cable adjuste r lo ck nut and rem ov e t he
exhaust va lve control cables from the pul ley.
Rem o ve the muffler f ro nt mo unti ng bolt and co lla r.

Rem ove th e muffler rear mounting bolt s, th en REAR MOUNTING BOLTS
remove th e m uffle r assembl y.
M UFFLER \,.
Rem ove the muffler heat guard fro nt mou nting bolt
and nut.
Remove the muffler heat guard rear mountin g bolts,

REAR MOU NTING BOLTS
then rem ove the mu ffl er heat guard. \
\
\
\
\
\
M UFFLER HEAT GUARD
3-35
Contents Chapter 3
INSTALLATION
M UFFLER HEAT GUARD
9.8 N'm (1 0 kqf -rn,

7 I bfft)
GASKET ~
. _. GA SKET
37 Nrn 13.8 kqf-rn, 27 Ibfft ) J ~/

EJ
, .~
~
~A\
/ [
a
,
12 N'm (1.2 kqf-rn, 9 Ibfft )
EXH AUST PIPE HEAT GUA RD
/
23 Nm (2.3 kq f-rn. 17 lbf -ft ]
EXHAUST PIPE
3-36
Contents Chapter 3
Install th e m uffle r heat gu ard int o the seat rail, t hen
REAR M OUNTIN G BOLTS
install the muffler h eat gu ard rea r m ou nti ng bo lts . \
\
\
,
v.
,
Instal l t he muffler he at g uard f ro nt m ou nt ing bo lt

and nut.
Tighten th e nut securely .
Install th e mu ffl er assembly and tempo rarily insta ll REAR MO UNTI NG BOLTS
the m uffler rear mount ing bo lts .
MU FFLER ~
Inst al l th e muffler fr on t m ounting co ll ar and bo lt.

T ighte n th e mu ffler fro nt m o u nt ing bolt secu re ly .
T ighten the muffl er rear m ount in g bolts sec u rely.
3-37
Contents Chapter 3
Route the exhaust valve control cab le properly, and
hook the cab le ends with the drive pulley .
Install the pulley onto the exhaust val ve shaft and
tighten the nut.
Bend the lo ck tab o ve r the nut.
Adjust the exhaust va lve co nt rol cabl es and tighten
the lock nuts securely (p age 4-35 ).
Install th e exh aust v alve cover and tighten t he b olt s.
Install the collar Inst all t he m uff le r rea r en d cove r and co ll ar .

PAN SCREW/COLLA R REAR END COVE R
between the
Inst all and tighten t he pa n screws secure ly.
mu ffler and rear
fender B.
Install the ex haust pipe joint flange and new gasket

onto the exh aust j oint pip e.
3-38
Contents Chapter 3
Inst all th e exha ust joint pipe cla m p w hile alig ning
its boss with th e g roove on t he muffler p ipe .
Inst all and t emporarily tig hten th e SH bolt .
Inst all new gas ket s onto t he exhaust po rt s of th e

cy linder h ead .
Inst all a new gasket on to the exh aust pi pe.
Insta ll the exhaust p ip e assembly into t he joint pipe
and cy li nder head.
In st all t he exha ust pipe jo int nuts.
Install th e exhaust pi pe mounting b olt/washe r.
BOLTIWASHER
3-39
Contents Chapter 3
First tighten the exhau st pipe joint nuts to the speci-
fied torque.
TORQUE: 12 Nm (1.2 kqf-m, 9 Ibf.ftl
Tigh ten the exhaust pipe mo unting bo lt/ w ash er.
TORQUE: 23 Nm 12.3 kqf-m , 17 lbf.ft}
BOLTIWAS HER
Tighten the exhaust pipe clam p SH bolt to the spec-

ified to rque.
TORQUE: 9.8 Nm 11 .0 kqf-m , 7 Ibfft)
Tigh t en th e muffler band fl ange b olt t o the spe cifi ed

to rque.
TORQUE: 18 Nrn 11.8 kqf-m , 13 Ibf-ft]

Install the ex haust pipe heat g uard while aligning its
t ab s wi t h t he g ro ov es on the ex ha ust p ip e. 1,..;.;.;;.. ...
Inst all and ti g ht en the ex ha ust p ipe heat g u ard

m o u nting pan sc rew .
In st all t he right footp eg br acket ont o t he f ra m e and

ti ghten t h e socket bo lt s to th e spec if ied torqu e.
TORQUE : 37 Nm {3.8 kqf-m, 27 Ibfltl
Inst all t he r ight passeng er footpeg bracket o nto t he

seat rail , the n ti ght en the socket bo lt s to t he spe ci-
t ied to rque .
TORQUE: 26 Nm (2.7 kq f -m , 20 1bflt)

Install th e m uffler guard w hile alig ning it boss with
the gro m met o nto t he seat ra il.
Insta ll the pa n screw, co lla r and screw, then tighten I,.;::~~~~,.

the screws secu re ly .
Inst all t he radia to r o nto t he bracket wh ile ali gnin g

th e g ro m met and frame boss.
Inst all and tighten the radiator upper m ounting bolt.

Install the radiato r lower bracket to the engine and
tight en th e bolt.
Insta ll and tighten the radiato r lower mounting bolt.
LOW ER MO UNTIN G BOLT

Connect the fan motor 2P (Black) connector.
Install and tighten the radiator reserve tank m o un t-

ing bolt and filler nec k mount ing bo lt.
Install the following:
- Top shel ter (page 3-161
- Under cowl s/middle cowls (page 3-7)
- Rear fender A (page 3-27)
- Rear seat cowl (page 3-5)
3-43
Contents Chapter 3
MEMO
Contents Chapter 3
4. MAINTENANCE
..
SERVICE INFORMATION 4-2 BRAKE FLUID 4-30
MAINTENANCE SCHEDULE 4-4 BRAKE PAD WEAR 4-31
FUEL LINE 4-5 BRAKE SYSTEM 4-3 2
THROTTLE OPERATION 4-7 BRAKE LIGHT SWITC H 4-33
AIR CLEANER 4-8 HEADLIGHT AIM ....................................4- 33
SPARK PLUG 4-8 CLUTCH SYSTEM .. 4-33
VALVE CLEARANCE .. 4-16 CLUTCH FLUID 4-34
ENGINE OIL/OIL FILTER 4-21 EXHAUST GAS CONTROL VALVE

CABLE 4-34
ENGINE IDLE SPEED 4-24
SIDE STAND .... 4-36
RADIATOR COOLANT .............................. 4-24
SUSPENSION .. .. 4-37
COOLING SySTEM 4-24
NUTS, BOLTS, FASTENERS 4-41
SECONDARY AIR SUPPLY SySTEM ........ 425
WHEELS/TIRES .. 4-41
EVAPORATIVE EMISSION CONT ROL
SYSTEM (CALIFORNIA TYPE ON LY) ......... 4-26 STEERING HEAD BEARINGS 4-41
DRIVE CHAIN 4-26
4-1
Contents Chapter 4
MAINTENANCE
SERVICE INFORMATION
GENERAL
Place the mo torcycle on a level grou nd before starti ng a ny w ork .
The exha ust contains poiso nous carbon monoxide gas that ma y cause loss of consciousness and m ay lead to death .
Run th e eng ine in an open area o r w ith an exhaust evacuatio n syste m in and e nclosed area.
SPECIFICATIONS
ITEM SPECIFICATIONS
Thrott le grip free play 2 4 mm (1/ 16 3116 in )
Spark plug I NGK IMR9C-9HES
I DENSO VUH27ES
Spark pl ug gap 0.80 - 0.90 mm (0.031 - 0.035 in)
Valve IN 0.16 0.03 m m (0.006 0.001 in)
clearance EX 0.30 + 0.03 mm (0.012 + 0.001 in )
Engine oil Atter drai ning 3.0 liter (3.2 US qt , 2.6 Im p qt)
ca pacity After oil filte r cha nge 3. 1 liter (3.3 US qt, 2.7 Im p qt)
Recom m ended eng ine oil Pro Honda GN4 o r HP4 (w itho ut moly bde num add itives) 4-
stroke oil (U.S.A. and Canada ). o r Honda 4str oke oil (Canada
o nly) , or an equ iva lent motor oil
AP I serv ice classificat io n: SG or Higher
ex ce pt oil s labeled as energy conserving on th e circular A PI
serv ice label
JASO T 903 standard: MA
Viscosity: SAE 10W-40
Engine idle speed 1,200 100 rpm
Driv e chai n slack 25 35 mm (1 1-3/8 in)
Recomm end ed brake f luid DOT4
Recomm ended clutch fluid DOT 4
Tir e size Fron t 120n O ZR 17 M /C (58W)
Rea r 190/50 ZR 17 M /C (73W)
Tire brand Bridgestone Front BT014F RADIAL G
Rear BT014R RADIA L G
Pirelli Fron t DIA BLO CORSA H
Rear DIABLO CORSA H
Tire ai r U p to 90 kg Fro nt 250 kPa (2.50 kqf/crrr', 36 ps i)
pressure (200 Ibs) load Rea r 290 kPa (2.90 kgf/c m' , 42 psi)
Up to m aximum Front 250 kPa (2.50 kg f/cm , 36 psi)
weig ht cap acity Rear 290 kPa 12.90 kq f/crrr', 42 psi)
M inimum tire tread depth Fro nt 1.5 m m (0.06 in)
Rear 2.0 mm (0.08 in )
TORQUE VALUES
Fuel tank fron t mounting bolt 26 Nm (2.7 kqf -rn, 20 Ibf ft)
Spark plug 16 Nm (1.6 kgf'm, 12 Ibfft)
Tim ing hole cap 18 N'm (1.8 kqf -rn, 13 Ibfft ) Apply grease to t he threads
Engine oil filter cartridge 26 Nrn (2.7 kgf 'm, 20 Ibfft) App ly clean engine oil to the O-ring
Engine oil dra in bolt 29 N'm (3.0 kqf -rn, 22 lb t -ft)
Cyli nder head cover bolt 9.8 Nrn (1.0 kq f-rn. 7 fbf ft)
Rear axle nut 11 3 Nrn (11. 5 kqf -rn, 83 Ibfft ) U-nu t
Drive sprocket special bo lt 54 Nm (5.5 kgf'm, 40 Ibfft )
Final driven sprocket nut 64 N'm (6.5 kqf-m, 47 lb f-ft } U-nut
Rear m aster cylinde r pu sh rod jo int nut 18 Nrn (1.8 kqf -rn, 13 Ibf ft )
4-2
Contents Chapter 4
MAINTENANCE
TOOLS
Oil filter wrench Drive chai n tool set Cam chain tens ioner holder
07HAAPJ70101 07HMHMR10103 07ZMGMCAA400
or 07NMGMY90100
SCS service connector

070PZZY30100
4-3
Contents Chapter 4
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ri de inspection in th e Own er 's M a nual at each scheduled main ten ance pe riod.
I: Inspect and Clean, A djust, Lubricate or Replace if necessary. C: Clea n.:R: Replace. A: Adjust. L: Lubricate.
Th e fo llowi ng item s requ ire some m echanical know led ge. Ce rtain item s (parti cularly th ose marked * a nd ** ) m ay requ ire
mo re tec hnica l infor matio n and t ools. Co nsult thei r au th orized Ho nda dealer.
FREQUENCY ODOM ETER READ ING (NOT E 1)

REFER TO
x 1,000 m i 0.6 4 8 12 16 20 24
PAGE
ITEM S NOTE x 100 km 10 64 128 192 256 320 384
* FUEL LINE I I I 45
* T HROTILE OPERATION I I I 4-7
if> * AIR CLEAN ER NOTE 2 R R 4-8
:0 * SPARK PLU G EVERY 16,000 m i (25,600 krn ): I, 4-8
ur
!:: EVERY 32,00 0 m i (51,200 km ]: R
0
w * VA LVE CLEARANC E I 4-16
~ ENGINE OIL R R R R 421
~
ur ENG INE OIL FILTER R R R R 4-2 1
cc ENG IN E IDLE SPEED
z * I I I I I I I 4-24
0 RADIA TOR COOLA NT NOTE 3 I I R 4 24
Vi
!!! * COOLING SYSTEM I I I 424
:0
ur
* SECONDARY AIR SU PPLY SYSTEM 1 I I 4-25
* EVA PORATIVE EM ISSION CONTRO L NOTE 4 I I 4-26
SYSTEM
** EXHA UST GAS CONTRO L VALVE CAB LE EVERY 16,000 mi (25,600 km) : I 43 4
if> DRIVE CHAIN EVERY 500 mi (800 krn]: I, L 4 26
:0 BRAKE FLUID
ur NOTE 3 I I R 1 I R 4-30
!:: BRAKE PAD WEAR I I I I I 1 4-31
0
w BRAKE SYSTEM 1 I I I 4-32
~
~ * BRAKE LIGHT SW ITCH I I I 433
ur
* HEA DLIGHT A IM 1 I I 4-33
"'0z CLUTCH SYSTEM I I 1 I I I I 433
Vi SIDE STAND I I I 4-36
!!!* SUSP ENSION I I I 4-37
:0
ur * N UTS, BOLTS, FASTENERS I I I I 4-41
Z ** WH EELSfTlRES I I I 4-41
0
z ** ST EERING HEAD BEA RIN GS I I I I 4-41
* Should be serviced by a n auth orized Hon da deale r, unless the ow ner has proper too ls and service data and is
m echan ically qualified.
* * In the interest of safety, we reco mmend ed th ese item s be se rviced only by an aut ho rized Honda deal er.
NOTES:
1. At high er odo mete r readi ng, repeat at the freque ncy inte rval estab lished he re.
2. Se rvice more fre quency if the m otorcycle is ridd en in unusually wet or dusty are as.
3. Replace eve ry 2 yea rs, or at indicated odomete r int erval, wh icheve r comes first . Repl acement requires m echanical skill.
4. California type only.
4-4
Contents Chapter 4
MAINTENANCE
FUEL LINE
Rem ove t he t op shelte r (pag e 3- 16),
FUEL TANK
Rem ove the fuel tank front mounting bolts.
Disconnect the fuel tank drain hose from the hose

joint as shown.
Lift the fue l tank as show n.
DRA IN HOSE
Support the fuel tan k using a suitable suppo rt as

show n.
4-5
Contents Chapter 4
MAINTENANCE
Check t he f uel li nes for de te rioration , damage or
leakage. Replace t he fue l line if necessary.
Chec k t he fuel rai ls and f ue l ho se joints for damage
or leakage. Rep lace t he m if nec essary.
Ch eck the f uel pump mou nting area for leakag e.
Repl ace th e fu el pu mp packin g if necessary.
Check t he pri mary/seco nda ry i njectors for dam age
or le akaqe, Rep lace t hem if necessa ry .
Remove t he sui table support, t hen lower t he f ue l

ta nk.
NOTE : RED LINE (BREATHER HOSE)
Route th e hoses, wires and h arne ss prope rly
(page 1-24).
Be careful n ot to damage t he harness an d h oses.
Aft er in st all i ng t he fue l ta nk , make su re t he dra in ,
breat her and fuel hoses are not kinked o r bou nd .
Con nect t he d ra in hose to the j oi nt pipe.
4-6
Contents Chapter 4
MAINTENANCE
Inst all and tighten t he f uel t ank fr ont m ountin g b olts
t o the spec ifi ed torqu e. FUEL TANK
TORQUE: 26 Nm (2.7 kqt -m . 20 jbf-tt)

Install the removed parts in the reverse order of
rem ov al.
THROTTLE OPERATION
Check f o r sm oot h th ro ttl e o per ation at fu ll ope ning
and automatic full closing in all steering pos itions.
Check the t h rottle cables and replace them if they
are deteriorat ed, kinked o r damaged.
Lubricat e th e t hrottle cab les, if throttle o pe ratio n is
not sm oo th .
M easur e the fre e play at th e throttl e g rip flan ge.
FREE PLAY: 2 - 4 mm 11/ 16 - 3/16 in)
Throttle g rip free play ca n be adjuste d at either end

of th e t hrottle cable.
Minor adjustment is made w ith the upper adjuster.
A dj ust th e free play by loosening the loc k nut and
turn in g the adjuste r.
M aj or adj us tme nt is ma de with th e lower adj ust er.

Remove the air clea ner housing (page 6-40).
Ad just the free play by loosening th e lock nut and
turning th e adju st er.
Afte r adjust ment, tighten th e lock nut securely.
Recheck the throttl e operatio n.
Replace any damag ed parts, if necessary .

MAINTENANCE
AIR CLEANER
Remove th e top she lte r (pa ge 3-16 ).
Disconnect t he IAT senso r 2 P (Gray) co n nector.
Remove t he screw s and air clea ne r hou sin g cove r.
Rep lace th e ai r clea ne r e le ments in acco rda nce w it h

the m ai nt enan ce sche d ul e (p ag e 4-4) .
Install t he air cleaner eleme nts w h ile al ig ning t h eir

bosses w it h th e grooves in the air cl eaner hou sin g .
Inst all the removed parts in tt h e reverse order of
re moval.
SPARK PLUG
REMOVAL
Be careful not to Remove t he u nder co w ls/ mi dd le cowls (pag e 3-7).
damage the radiator
Remove t he radiat or lower mou nting bo lt.
fins.
LOWER MOUNTING BOLT
4-8
Contents Chapter 4
MAINTENANCE
Avoid damaging the Rem ov e th e bo lt and r adi ato r lower br acket fro m
radiator fins. th e engine.
Rem ove the coo lant reserv e t ank m o un t ing bolt and
fill er neck m ou ntin g bo lt.
Disconnect the f an motor 2P (Black) co nnecto r.
Rem ove the rad iator upper m ou nt ing bolt.
4-9
Contents Chapter 4
MAINTENANCE
Move t he radiator to t he ri g ht and release the rad ia -
to r g ro mmet f ro m t he bracket boss. th en move t he
radiat or dow nw ar d .
Discon nect th e eM ? sen sor 2P (Black) co nnec to r.
Remove t he tw o trim clip s and air int ake gri ll.
Disconn ect th e vac uum hose fro m th e va r iable air

intake d iaph rag m.
4-1 0 Contents Chapter 4

MAINTENANCE
Remove the ai r duct mounting bolts .
Remov e t he int ake a ir du ct m ounti ng screws.

Remove the inta ke air du ct from the air cleaner
housin g.
Clean aro und the Disco nnect th e di rect ig nitio n coil connecto rs .
spark plug bases DIRECT IGNITION COIL S CON NECTO RS
Remove the di rect ign it ion co il s fr om th e spark
w ith compressed
p lugs.
air before remov-
ing, and be sure
that no debris is
allow ed to ent er
the combu stion
cham ber.
Rem ov e t he spa rk pl ug u sing t h e equ ipped spa rk

p lug w ren ch o r an equ iva len t.
Insp ect o r repl ace as d esc r ibed in t he mai nte nance
schedule (page 4-4 ).
4-11
Contents Chapter 4
MAINTENANCE
INSPECTION
Chec k the fol lowing an d rep lace if nec essary (rec-
om me nded spa rk plu g : page 4-2) INSULATOR CENTER ELECTRODE
Insulator fo r dam age

Electr odes for wear
Burn ing co nditio n, colora ti on
This motorcycle 's If t he e lect rodes are co nta m inate d w ith accumu-
spark plug is lated objects or dirt, rep lace th e spark plug.
equipped w ith irid-
ium center etec-
trode. Replace the
spar k plug if the
electrod es are con -
taminated. SIDE ELECTRODE
Replace the plug if the center electrode is rounded

ROUN DED ELECTRODE
as shown in the illustration.
Always use speci-
fied spar k plugs on
this m otorc ycfe.
SPECIFIED SPARK PLUG:
NGK : IMR9C9HES
DENSO: VUH27ES r/
To pre vent damag- Check th e gap betwee n th e center and side elec-
ing the iridium con- trade s wit h a wi re ty pe feeler gau ge . WI RE TYPE FEELER GAU GE
ter electrode, use a
wire type feeler
gauge to ch~-~k th~-
spar k plug gap.
00 not adjust the

spark plug gap. If
does not Insert betwee n t he ga p.
.
M ake su r.e t hat th e lj> 1.0 m m (0.04 In) plug gauge
If t he gaug e can be inse rted into t he gap, replace th e

plug w it h a new one .
a/ x
the gap is out of
specification,
replace the plug
with a new one
INSTALLATION
Instal l the spar k plug in t he cyl inder head and hand
ti ght en, t hen torq ue to spec if icat io n.
TORQUE : 16 Nm (1.6 kqf-m, 12 Ibf.ft)
4-12
Contents Chapter 4
MAINTENANCE
Install t he di rect ignition coils .
Co nnect each connector to each direct ignition co il. DIRECT IGNITION COILS CONN ECTORS
Rem ov e the rig ht fro nt side cover (page 3-16).

Inst all the int ake air duc t assembly, w hi le alig nin g
it s tab w it h t he low er ai r cl ean er hou si ng base.
M ake sure t h at th e in t ake ai r du ct is proper ly seated
o n t he ho us ing.
Inst all and t ig hten th e int ake air duct mount i ng

screws.
TORQUE: 2.5 Nrn (0.25 kqt -rn, 1.8 Ibl lt)
Inst all and tig hten th e air du ct moun t ing bo lt s.
4-13
Contents Chapter 4
MAINTENANCE
Co n nect t he v acuum ho se to t he v ari abl e air in tak e
diap hr agm.
Insta ll t he ai r int ake gr ill a nd secu re it with t rim

cl ips.
Inst all the radi ator on to the bracket whil e al igning

the g ro m met and fram e bos s.
__=~~
Insta ll and t igh te n th e rad iat o r upper mounting bolt. ...~=
4-14
Contents Chapter 4
MAINTENANCE
Insta ll the radiat or lower bracket to the eng ine and
tighten t he bo lt.
Install and tig ht en the rad iat or lower m ounting bolt.
LOWER MOUNTING BOLT
Con nect th e fa n m ot or 2P (Black) co nnector.
Install and tighten th e rad iator reserve t ank m ou nt -

ing bolt and filler neck mounti ng bo lt.
4-15
Contents Chapter 4
MAINTENANCE
Conne ct t he CMP senso r 2P (Black) connector.
Remove t he unde r cowls/m iddl e cowls (page 3-7).
VALV E CLEA RANCE

IN SPECTION
Inspect and adjust Remove the cy lin de r head co ver (page 9-6 ).
the valve clearance
Remove t he cam chain tenstoner lifter sea ling bolt
while the engine is
and sea ling washer.
cold (below 35 DC/
SEALING WAS HER
95"F)
SEALING BOLT
Turn t he t ensi on er lift er shaft full y in (cloc kw ise)

and se cure it using t he spe ci al t 60 1t o p rev en t dam - CA M CHA IN TENSIONER HOLDER
aging t he cam chain.
TOOL:
Cam chai n ten sioner hold er 07ZMG -MCAA400 or
07NMG-M Y90100
Remo ve t he tim ing hol e cap and O-r ing .
4-16
Contents Chapter 4
MAINTENANCE
Turn t he cra nkshaft clockwise, alig n th e "T" m ar k on
the crankshaft position sensor roto r with the index
mark on t he right crankcase cover.
Th e ti m ing marks ("IN" and "EX ") on t he ca m

sprockets m ust be fl us h wit h t he cyli nder head sur-
face and faci ng outward as shown.
If th e ti mi ng ma rks on the cam sprockets are facing
inward, tu rn th e crankshaft clockwise one fu ll turn
(360) and realign the timing ma rks with the cylin -
der head surface so they are facing outward.
Insert the fe ele r gau ge betw een t he v alv e lift er and

ca m lo be.
Record the clear- Che ck t he v alve cleara nce for the No.1 and No .3 cy l-
ance for each valve inder intake valves usin g a feeler ga uge.
for reference in
shim selec tion if
VALVE CLEARANCE:
adj ustme nt is IN: 0.16 0.03 mm (0.006 0.001 i n)
required.
NO .3 INTAK E VALVES
NO .1 INTAKE VALVES
Turn t he cra nks haft clockwise 1/2 turn (180), alig n

t he index line on t he c ranksh aft posit ion senso r
rot o r so t hat it i s facin g up as shown.
4-17
Contents Chapter 4
MAINTENANCE
Record the clear- Check t he va lve clea ra nce f o r the No.2 and No .4 cvl-
ance for each valve inder exhaust valves using a fee ler gauge. NO.4 EX HA UST VALVES
for re ference in NO.2 EX HAUST VALVES
shim select ion If VALVE CLEARANCE:
adjus tm ent is EX: 0.30 0.03 mm (0.012 0.001 in)
required.
Turn the crankshaft clockwise 1/2 turn (180), alig n

th e "T" mark on the cra nkshaft position senso r roto r
with t he index mark o n the right c rankcase cove r.
Reco rd the clear- Check t he val ve clearance for the No .2 and No .4 cyl-
ance for each valve inder in take valves us ing f eeler gauge.
for reference in
shim se lection if VALV E CLEA RANC E:
adjustment is IN: 0.16 0 .03 mm (0.006 0.001 i n )
required.
NO.2 INTAKE VA LVES

NO.4 INTAKE VA LVES
Turn t he cra nksh aft clockwise 1/2 tu rn (180), alig n

th e index line on the cra nks haft p ositi on se nsor
rotor so that it is faci ng u p as shown.
4-18
Contents Chapter 4
MAINTENANCE
Reco rd the c1ear- Check the v alve clearance f or the No .1 and No.3 cyl -
ance for each valve inder exhaust valves using a feeler gauge. NO.1 EXHAUST VALVES
for refere nce in
shim selec tion if VA LVE CLEARA NCE:
adjustment is EX: 0.30 0.03 mm (0.012 0 .001 in)
required
ADJUSTMENT
It is not necessary Remove t he cams hafts (page 9-81.
to remove the cam
Remove the valve lifters and shims.
sprocket from the
camshaft except Shim m ay stick to the inside of the v alv e lift er.
when replacing the Do not allow the shim s t o fall into th e crankcase .
camshaft and/or M ark all valve lifters and shims t o ensure corr ect
cam sprocket. reassem bly in their origina l locat ions.
T he valv e lifter can be eas ily rem ov ed with a
valve la pping tool or magnet.
T he sh ims ca n be easily rem ov ed with a twee-
zers or m ag net .
Clean the valve shim contact ar ea in th e va lve lift er

with co mp ressed air .
M easure the shim t hi ckness and reco rd it .
4-19
Contents Chapter 4
MAINTENANCE
Sixty-nine different Calculate the new shim thickness using th e equa-
thickness shims are tion below.
availab le from the A= (B-C)+D
thinnest 1.200mm A: Ne w shim thickness
thickness s him to B: Recorded valve clea ran ce
eeee
the thick e st 2.900 C: Specified valve clea rance
mm thickness shim D: Old shi m t hickness
in intervals of 0.025
Make sure of the correct shim th ickness by mea-
mm
suri ng the shim by m icrom ete r.
Reface the valve seat if carbon deposit result in a 1.85 mm 1.87 5 mm
1.80 m m 1.825 mm
calculated dimension of over 2 .900 m m .
Install the shims Insta ll the new ly selected shim on the va lve spring
and valve lifters in retai ner.
theirorigi nafloca- App ly mo lybde nu m dis ulfide oil to th e valve lift ers.
tions Instal l the va lve lifte rs into the v alve lifte r holes.
Inst al l th e cams hafts (page 9-26) .
Rotate the cams hafts by rotating the crankshaft
clockwise several times.
Reche ck the v alve clea rance .
Rem ove the cam chai n te nsion e r ho lder too l.

CAM CHA IN TEN SIONER HOLDER
Insta ll the new sealing w asher a nd cam cha in

tensioner lifter sealing bo lt.
Tighten the bolt securely. S~
SEALING WASH ER
/ G2@
\
SEALING BOLT
4-20
Contents Chapter 4
Check that the D- A pply grease t o t he ti ming ho le cap th read s.
ring is in good con- Ti gh t en th e t imin g hol e cap to t he spec if ied to rque.
ditio n, replace if
TORQUE: 18 N m (1.8 kqf-m, 13 lbf-ft)
necessary.
Inst all the rem ov ed parts in th e reverse ord er of
remova l.
ENGINE OIL/OIL FILTER

OIL LEVEL INSPECTION
Sta rt th e engine and let it id le for 3 - 5 m inutes.
Stop the engi ne and w ait 2 - 3 minutes.
Hold th e m otorcycle in an upright pos ition.
Check t he oi l lev el th rou gh t he inspect ion window .
If the level is below the lo w er level line, rem ove th e

oil fi ll er ca p and f ill th e crankcase wi t h th e recom -
mended oi l up t o the upper level line as follows:
Rem o ve the oil filler cap .
4-21
Contents Chapter 4
MAINTENANCE
Fill the recommended engine o il up to the upper
level line.
Other visco sities RECOMMENDED ENGINE OIL:
shown in the chart Pro Honda GN4 or HP4 (w it ho ut molybdenum SA! 201-40 201-50
may be us ed when additives) a-stroke oil or equivalent motor oil
the averag e rem- API service classification: SG or high er I~
perature In your
riding area is w it hin
JASO T 903 st andard : MA
Viscosity; SAE 10W-40
, .,
the indicated range.
Rein st al l th e oil fi ller cap.
o 20 40 60 80
- 20 10 o 10 20 30 400C
ENGINE OIL & FILTER CHANGE

Change the engine Start the engine and let it id le fo r 3 - 5 minutes.
oil with the warm Stop the engine and wait 2 - 3 minutes.
and the motorcycle Hold the motorcycle in an upright position.
on level ground to
Remove the under cowls (page 3-7) .
assure complete
draining. Remove the oil filler cap .
Rem ov e th e dra in bolt a nd sea ling was he r, d rain th e

oil comp letely .
Rem ov e and discard th e oil f ilt e r cart ridge usi ng t he

special tool.
TOOL :
Oil filter wrench 07HAA-PJ70101

MAINTENANCE
Chec k t hat t he sea ling was her o n t he dra in bol t is i n
go od co nd it io n, and replace if neces sary.
Install and tighte n the d rai n boll.
TORQUE: 29 Nm 13.0 kqf-m , 22 lbf -ft]
Ap pl y cle an engine oi l t o th e oil filter ca rt ri dge

threads and new O rin g.
Install the new oi l fi lter and tighte n it to th e specified

t orque .
TOOL:
Oil filter wre nch 07HAAPJ70101
TORQUE: 26 Nrn 12.7 kqf-m, 20 Ibfft)
Install the radi ato r reser v oir tank and bolt .
Fill th e cra nkcase w ith rec o m me nd ed engine o il.
OIL CAPACITY:
3.0 liter (3.2 US qt. 2.6 Imp qt) after draining
3.1 liter (3.3 US qt, 2.7 Imp qtl after oil filter ch an ge
Check t hat the a-rin g o n th e o il f iller cap is in good
co nditio n, and repla ce it if necessary .
Install t he oil fill er cap.
St art th e engine and let it idl e fo r 3 - 5 m i nut es.
Stop the engine and wait 2 - 3 m inu t es and rec heck
the oil lev el.
M ake su re th ere are no o il leaks.
Install th e under cowls {page 3-71.
4-23
Contents Chapter 4
MAINTENANCE
ENGINE IDLE SPEED
Inspect an d adju st t he id le speed after all other , . Iiii=:' ':'''T ....~----'l!';;
engine ma intenance items have bee n performed
and are w ithin specifica tio n.
The eng ine m ust be wa rm f or acc urate idl e
speed ins pec tio n and adjust ment.
Wa rm t he engi ne f or about 10 m in utes.
Turn th e th rottle sto p scr ew as req uired t o obtai n
t he spe cified id le speed.
IDLE SPEED: 1.200 100 rpm
RADIATOR COOLANT
Check t he coo lant lev el of th e reserv e t an k with th e ,-- - - - -- - - - - - - - - - - -- ,
engine ru nni ng at no r mal ope rati ng tem pe rature. U PPER LEVEL LINE
Th e level should be betw een the "U PPER" and

"LOW ER" level li nes.
If necessary , add reco mmended coo lan t.
RECOMMENDED ANTIFREEZE:
High q ua lity ethy le ne g lyco l a nti freeze containi n g
co rrosio n protection inh ibitor s .
LOWER LEVEL LIN E
Remo ve t he unde r cowls/m iddle cow ls (page 3-7).

Rem o v e t he reserve t ank fill er ca p and fill t o t he
"U PPER" lev el line with 1:1 m i xtu re of d ist illed water
and ant ifreeze.
Rei nstall the filler cap .
In st all the under cowls/middle cowls (page 3-9 ).
COOLING SYSTEM
Rem ov e t he under cowls/m idd le cow ls (page 3-7) .
Check th e rad iato r air passages f or clog g ing o r dam-
age .
St raighten bent fins, and rem o v e in sects. mud o r
other obstru ctions with compressed air o r low
water pr essure.
Replace the radiato r if the air flow is rest ricted ov er
m or e than 20% of the radiat ing surface.
4-24
Contents Chapter 4
MAINTENANCE
Insp ect the rad iator hoses fo r cracks o r deteri o ra-
t ion, and replace them if necessa ry .
Check the tig htness of all hos e clam ps and fasten -
e rs .
SECONDARY AIR SUPPLY SYSTEM

This model is equipped built-in secon dary air
supply syste m. Th e p ul se seco nd ary ai r supp ly PAIR REED VA LVE
sy st em is loca t ed on th e cyl ind er head co ver.
Th e seco ndary air supply syste m int rodu ces f il-
te red ai r into exha ust gases in t he ex haust port.
The secondary air is d rawn into t he ex haust po rt
w hen ev er th er e is nega t ive pr essu re pulse in the
exhaust syst em . T his charged seco ndary air pro-
m ot es burning of the unburned exh aust gas es
and change s a co nsiderable amount of hy drocar-
bon s and ca rbon mon o xide int o relatively harm-
less ca rbo n dioxide and wa te r.
EXH AU ST PORT
Rem ov e the ai r cleane r housing (page 6-40) .

If the hoses show Check th e PA IR (pulse seco ndary air i njectio n) hoses
any signs of heat betw een the PAIR con tro l so lenoid v alv e and cvlin-
damage, inspect der head cove r f or det er ioratio n, da m age o r loos e
the PAIR reed co nnect ions. M ake su re th at t he h oses ar e not
valves in the PAIR cra cked .
check valves for
Check t he ai r suction hose betwee n th e air cl eaner
damage .
hou si ng and PAIR con tro l so lenoid va lve f o r deteri o-
ratio n, dam age or loose con nect ion s.
M ake su re th at the hoses are not ki nked, pin ch ed or
cracked .
4-25
Contents Chapter 4
MAINTENANCE
EVAPORATIVE EMISSION CONTROL
SYSTEM (CALIFORNIA TYPE ONLY)
Check th e hoses between th e fu el t an k, EVA? ca nis-
t er, EVA? purge co nt rol sole noid v alve fo r d et eri ora -
t ion , damage or loose con nection .
Chec k t he EVA ? ca niste r fo r cla cks or othe r damage .
Refer t o t he Cab le & Harn ess Rout in g (page 1-24) for
hose con nec tio ns .
EVAP
CA NISTER
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
Turn th e ig nit io n switch OFF, plac e th e motor cycle
on it s sid e sta nd and shift t he t ra nsm ission int o neu-
t ra l.
Check th e slac k in t he d ri v e cha in low er run midway
be tween t he sprockets.
CHA IN SLACK: 25 - 35 m m (1 - 1-3/ 8 in )
I NOTICE I
Excessive chain slack, 50 rom (2.0 in) or m ore, ma y
damage the fram e.
Lubri cat e the d riv e chai n w it h #80 - 90 gear oi l o r
chain lubric a nt desig ned speci fica lly f o r u se w it h D -
ri ng chains . W ip e off th e excess o il o r cha in lubri-
ca nt.
ADJUSTMENT
Lo o sen the rea r axle nu t .
Turn bot h adjusting bol t s until t he co rrect d rive ~;;,;,;;;;,;.,;,;;.~
cha in slac k is obta ine d.
M ak e sure t he ind ex m ar ks on bo th ad ju stin g pl at es
are alig ned w it h th e end o f t he swing a rm.
Ti g ht en the rear axle nut to t he specified torq u e.
TORQU E: 113 N -m 111.5 kqf- m , 83 Ibfftj
4-26
Contents Chapter 4
MAINTENANCE
Rech eck the d ri ve chain slack and fr ee wheel rot a-
tio n.
Lubricat e th e drive chain with #80 - 90 ge ar oil or
d rive chain lubric ant desig ned speci f ica lly for use
with O-r ing chai ns. W ip e off t he exc ess o il o r chain
lubricant.
Che ck the d rive chain w ear ind icato r label attached
on th e left d rive chai n adju sting plate.
If the swi ng arm in dex mark reaches red zo ne of th e
indicato r label, replace t he dri ve ch ain wit h a new
on e (page 4- 28 1.
CLEANING AND LUBRICATION

Clea n t he chain with non -fl ammable or high flash
point solvent and w ipe it dry .
Be su re the chai n has dr ied completely before lubri-
cati ng.
Inspect t he dri ve chain f or possible dam age o r w ear.
Rep lace any chain that has da m aged ro lle rs, loose
fi tting links, o r oth erwise ap pea rs un serv iceabl e. CLEAN
Inst allin g a new chain o n badly worn sproc kets wi ll
cause the new chain to wear q uic kly. SOFT BRASH
Inspect and rep lace sp rocket as necessary.
00 C 0
W IPE A ND DRY 6 "t.--=~
Lub ricat e the d ri ve chain w it h #80 - 90 gear o il or

drive chain lubrica nt desig ned specif ically fo r use LUBRICATE
with O-ring chains. Wi pe off the excess o il o r chain
lubricant.
SPROCKET INSPECTION
Insp ect the driv e an d d ri ven sprock et teeth f or wea r
or dam age, repl ace if necessary .
Never use a new drive chain o n wo rn sprocket s. WEAR
Both cha in and sprockets must be in good cond i-
tion , o r t he new repla cem ent chai n w il l we ar rap-
idl y.
NO RMAL
4-27
Contents Chapter 4
MAINTENANCE
Check the attaching bolts and nuts on th e drive and
driven sp ro ckets.
If an y are lo o se. to rque them .
TORQUE :
Drive sprocket s pecia l b olt:
54 Nm (5.5 kq-m , 40 Ibf.ft)
Final driv en s p roc ket nut:
64 Nm (6.5 kqf-m, 47 Ibfft)
REPLACEMENT
This m ot o rcycle u ses a drive chain with a st aked ,-- - - - - - - - - - - - - -- - - ----,
maste r li n k.
Lo osen the drive cha i n (pa ge 4-26) .
When using the Assemble th e speci al tool as sho w n.
special tool, follow
the manufacturer 's
TOOL:
ins truction. Drive cha in too l set 07H MH-MR10l03 or
07HM H-MR10l0C
(U.S.A.o nly)
DRIVE CHAIN TOO L SET
Lo cat e th e cri mped pin end s of th e ma st er link from

th e o utside o f t h e ch ai n, and remove t he link with
t he drive chai n t ool set.
TOOL:
-- MASTER LINK
Drive chai n t o ol s et 07HMH-MR10103 or

07HMH-MR1010C
(U .S.A .only)
Remove th e dr iv e c hai n.
DRIVE CHAIN TOO L SET
4-28
Contents Chapter 4
MAINTENANCE
Include the master Rem ov e th e exc ess drive chai n li n ks f ro m t he new
lin k w hen you d rive chai n wit h t he d rive cha in too l set.
coun t the drive
cham links. STANDARD LINKS: 114 LINKS
REPLACEMENT CHAIN
DID : DIDsOVM2-120ZB 1 LIN K
RK: RKsOGFOZ1-120LJFZ

...-- - - - 1' 4 LINK S - - - -_
Never reuse the old d rive cha in, master lin k. ~=================~
PLATE
mast er link plate and O-rings.
Insert the master Asse mble the new master li n k. a -rings and plate.
link from the inside
of the drive chain,
and install the plate
w it h the identifi ca-
tion mark facing the
outside .
Ass embl e and set t he d rive chai n too l set .
TOOL:
Drive ch ain tool set 07HMH-MR10l03 or
07HM H-M R101OC
(U.S.A .only)
Make su re t h at th e master li n k pi ns are ins talled

properly . MASTER LIN K PINS
M easu re t he m ast er link p in leng t h p roj ect ed f ro m
t he p late.
STANDARD LENGTH:
DID: 1.15 - 1.55 mm (0.045 - 0.061 in)
RK: 1.2 - 1.4 m m (0.05 - 0.06 in)
Stake t h e master link pins.
4-29
Contents Chapter 4
MAINTENANCE
Ma ke su re th at t he pin s a re stake d properly by m ea -
su ri ng th e dia me te r of t he stake d area usi ng a slid e SLIDE CA LIPER
cal iper.
DIAMETER OF THE STAKED AREA:

DID : 5.50 - 5.80 mm (0.217- 0.228 in)
RK: 5.30 - 5.70 mm (0.209 - 0.224 in )
A drive chain w ith a Aft er sta king, chec k th e staked area of t he mas te r ~===================~
clip-type master link lin k for crac ks.
must not be used If the re is any crac king, replace the mas te r li nk, 0-
ri ng s an d p late. GOO D NO GOO D
(O\
~ ~
~
'bvJb
\$;jj
f{j'Jf W ~/.
....--....:::=~~
CRACKED
BRAKE FLUID
I NOTICE
Spilled fl u id can da m ag e p ainted, p lastic or rubber
parts. Place a rag over these parts wh en ever th e
system is se rviced.
Do not m i x different t yp es of fl u id, as t hey are
not co m pati ble w ith e ach ot he r.
Do no t al low f orei g n m at eri al to e nter the system
w hen fil lin g the rese rvo ir.
W he n t he f luid level is low , ch eck t he bra ke pads f or
wea r (page 4 ~31 ). A low fl ui d lev el may be du e t o
wea r of th e br ake pads. If th e bra ke pads are worn,
t he calipe r piston is pus hed ou t, an d t his acco u nts
f or a low reserv oir lev el. If the bra ke pad s are not
wo rn and th e fl uid lev el is low , check ent ire syste m
fo r leaks (page 4-32) .
FRONT BRAKE
Tu rn th e hand leb ar so that th e reser v oir is lev el and
check th e f ron t bra ke flu id lev el.
If t he level is near th e low er lev el lin e, chec k th e
b rake p ad wea r (pa ge 4-31 ).
4-30
Contents Chapter 4
MAINTENANCE
REAR BRAKE
Place th e motorcy cl e on a lev el surface, and suppo rt
it an upr ig ht pos ition.
Chec k t he rear brak e flu id lev el.
If th e level is ne ar t he lower level lin e, check the
bra ke pad wear (p age 4-31 ).
.
...
LOWER LEVEL LINE.
,-
BRAKE PAD WEAR
FRONT BRAKE PADS
Check t he bra ke pad s for wea r.
Repl ace the brake pads if eithe r pad is wo rn t o th e
bottom of wea r lim it groove.
Refer t o brak e pa d re p lacem ent (page 16-11).
REAR BRAKE PADS

Chec k the brake pad s fo r w ear.
Repl ace t he brake p ads if eit he r pad is wo rn t o t he
bott o m of w ea r lim it g roove.
Ref er t o bra ke pad repl acem en t (page 16- 13 ).

MAINTENANCE
BRAKE SYSTEM
INSPECTION
Firm ly apply t he brake lever or pedal, an d check th at
no air has entered the syste m.
If t he lever or pe da l fee ls soft or spon gy w he n ope r-
ated, bleed th e ai r fro m t he system (p ag e 16-8),
Inspect t he brake hose and fitt ings for dete rioratio n,
crac ks and sig ns of leakage.
Tig hte n any loose fitt ings.
Replace hoses and fitti ngs as req uired.
Refer the pro cedure fo r b rake b leeding (page 16-7).
BRAKE LEVER ADJUSTMENT

Align the allo w T he distance bet w een the to p of th e bra ke lever and
m ark on the brake t he grip can be adjusted by tu rning the adj uste r.
lever with the inde x
number on the
adjuster,
BRAKE PEDAL HEIGHT ADJUSTMENT

Loosen the Jock nut and tu rn t he pus h rod until th e
co rrect pedal heigh t is o btained .
Make su re the push rod t hr ea ds can be seen

through the pedal jo int hole. LOCK NU T
Afte r adjustment, tighten th e lock nut to th e speci-
fi ed torq ue .
TORQUE: 18 Nrn (1.8 kqf-rn, 13 lbf-ttl
HOLE
X
PEDA L JO INT
,"
M
I II
"
4-32
Contents Chapter 4
MAINTENANCE
BRAKE LIGHT SWITCH
The front brake Adjust the bra ke light switch so that t he brake light
light switch does comes on just prior to the brak e actually being
nor require adjust- engaged.
m enlo If th e light fa ils t o com e on , adj ust th e switc h so t hat
the li ght co m es on at the pro pe r ti m e.
Hold th e sw itc h bo dy and tu rn the adju st er. Do not
tu rn the swi tc h body.
HEADLIGHT AIM
Place th e m ot o rcycle on a leve l surface.
Adjust the hea dlight Adjust the head li ght aim vertically by t urning the
aim as spe cified by vertica l beam adjust i ng screw.
local laws and requ - A clockw ise rotati o n moves t h e beam up and coun -
lations. te rclockwise rotat ion moves t he beam down.
A dj ust the head lig ht aim ho rizontall y by tu rning t he

ho ri zon tal bea m adjusting screw.
Left Headligh t: A clockw ise rot ation m ov es th e be am towa rd the
rig ht and cou nter c lockw ise ro tat ion moves t he
beam t ow ard t he left side of th e r ider.
Righr Headlight: A clockwise rot ati o n moves the bea m t ow ar d the
left and count ercl ockwi se rotation moves the beam
towa rd the ri gh t side of the rider.
HORIZONTAL BEAM ADJU STING SCREW
CLUTCH SYSTEM
CLUTCH LEVER ADJUSTMENT
The d ist an ce between t he ti p o f the clutch lev er and
t he g rip can be adjusted by turn ing th e adju ster.
4-33
Contents Chapter 4
MAINTENANCE
CLUTCH FLUID
I NOTICE
$piJI ed fl uid can d amage pain ted, plastic o r rubber
parts. Place a rag ove r th ese pa rts when ever th e
system is servic ed.
Do no t m ix differe nt types of f luid, as th ey ar e
not co m pat ible w ith ea ch o the r.
Do not all o w f o re ign mater ial t o ent er t he system
whe n filling the reser v oi r.
When the fluid level Turn t he handl eb ar to the right so t hat the reserv o ir
is tow. check entire is lev el and check th e clutch f luid lev el.
sys tem for leaks.
Fir ml y apply th e clutch lev er, and ch eck th at no air
has ente red th e syste m.
If th e lev er f eels soft or spo ngy whe n operated,
blee d the air from the system.
In spect the clutch hose an d fitt ings for dete rioratio n,

crac ks an d si g ns of leak ag e.
Tigh t en any loose fitti ngs .
Replace hoses and fi tting s as req uired .
Ref er th e proced ure fo r cl utc h fl uid bleed ing (pag e
10-6).
EXHAUST GAS CONTROL VALVE

CABLE
OPERATING INSPECTION
Rem ov e t he left m idd le cowl (page 3-7).
Turn th e ig nit io n sw it ch to "O N" .
Sho rt th e Dat a Lin k Co nn ector (OLe) t erm ina ls us in g
t he speci al t ool.
TOOL :
SCS se rvice connector 070PZ-ZY30100

MAINTENANCE
M ake sure that the EGCV (Ex haust Gas Cont ro l
Va lve) cable gu ide pull ey index li ne is alig ned wi th
th e EGCV housing index line as sho w n.
If th e pull ey index lin e is n ot w ith in the to ler ance,
adjust the EGCV co nt ro l cab les .
Turn th e ignit ion switch OFF and rem o v e t he SCS
service co nnecto r.
IN DEX LINES
BEARING INSPECTION
M ov e th e exhaust va lve pulley w ith yo ur hand , , .- -- - - - - - - - - - ----------,
check th e ex h aust va lve shaft for ex cess ive play.
If th er e is ex cessi ve pl ay, replace the ex ha ust v alve
shaft beari ngs w ith new ones .
CABLE ADJUSTMENT
1. Fully loosen th e sp ring equipped si de cable lock , .- - - - - - - - - - - - -- - - ------,
nut and adju sting nu t . LOCK NUT
2. Sho rt the Data Link Conn ect or (OLe ) te rm ina ls

u sing the special too l (p age 4-34 ).
A DJUSTING NUT
3. Loosen th e adjusti ng cable lock nu t and adjust - ~=================~

LDCK NU T
in g n ut.
4. A dj ust the pu ll ey posit ion by turnin g t he adjust -
in g nut.
5. T ighten th e lock nut securely .
A DJ USTING NU T

MAINTENANCE
6. Move the cable several times a nd rec heck the
index li ne. LOCK NUT
7 . Seat th e adjusting nut to th e housing and t ight e n

the lock nut securely.
-:
ADJ USTING NUT
SIDE STAND
Supp ort th e motorcycle on a lev el su rface .
Check th e sid e stand sp ri ng for d am ag e o r loss of
te nsio n. -
Chec k the sid e sta nd assembly fo r f reedom of
movem ent and lub ricate th e side st a nd p ivot if nec -
es sa ry.
Check t he side stand ig ni tion cut- off system :

- Si t ast ri de the motorcycle and raise the side
stand.
Start the e ng ine w ith the t ransmission in neutra l,
the n shift t he t rans m ission into gear, with the
clutch lever squeezed .
M ov e t he side stand f ul l down.
The engine sho uld stop as th e sid e stand is lo w -
e red.
If t here is a pro blem w ith the system, check t he side
sta nd switch (page 20-22 ).
4-36
Contents Chapter 4
MAINTENANCE
SUSPENSION
FRONT SUSPENSION INSPECTION
Che ck the act ion of the f orks by ope rat ing the f ront
bra kes and co m pressin g t he fro nt sus pe ns io n sev-
eral times.
Check t he enti re assem bly fo r signs of leaks, dam -
a g e o r loose fastene rs.
Replace dam ag ed co m po nen ts wh ich cannot be
repa ire d.
Tighten all nuts and bolts.
Refe r to f o rk service (p ag e 14-2 1).
Check for worn steering stem bearin gs by grabbing

the fr ont fo rk leg s and att em pt ing t o m o ve the fro nt
fo rk fro nt to back.
Rep la ce the bea rings if any lo o se ness is noted .
FRONT SUSPENSION ADJUSTMENT

SPRING PRELOAD ADJUSTER
Spring pre -lo ad can be adjusted by turn in g the
adju st er.
TURN CLOCKWISE :
Increase th e spring pre-l o ad
TURN COUNTERCLOCKWISE:
Decrea se th e s p ring pre-l o ad
PRELOAD ADJUSTER ADJ USTABLE RANGE:

15 turn s
PRE-LOAD ADJUSTER STANDARD POSITION :

7 turn s in from m inim u m
4-37
Contents Chapter 4
MAINTENANCE
COMPRESSION AND REBOUND DAMPING
ADJUSTERS
I NOTICE I
Do not turn the adjusters more than the given posi-
tions or the adj usters may be damaged.
All damping adjustments are refe renced f rom the
full hard position.
Be sure t h at the rebound and compression
adjusters are firmly located in a detent, and not
between pos itions.
To adjust both The compression and rebound damping can be
sides equally, set adjusted by turni ng the adjusters.
the right and le f t
damping adjusters DIRECTION H: Inc rease th e d ampi ng f orce
to the same oost- DIRECTION S: Decr ease th e dampin g force
cion.
Turn t he co m pressio n adju ster clockwise u ntil it

stops (f uJI hard posit ion), t hen t urn t he adj uster
co un tercloc kw ise.
COMPRESSION ADJUSTER STANDARD POSITION:

2 turns out from full h ard
Turn the rebo und adjuste r clockwise until it stops

(fu ll hard position), then turn the adjuster counter-
clockwise.
REBOU ND ADJUSTER STANDARD POSITIO N:

2 turns o ut from f uJI ha rd
4-38
Contents Chapter 4
MAINTENANCE
REAR SUSPENSION INSPECTION
Support the motorcycle secu rely and raise t he rear
wheel off th e groun d .
Ho ld t he swi ngarm and m ov e the rear w hee l side
w ays w ith f o rce to see if the ax le bea ring s are w o rn.
Check f or worn sw inga r m bea ring s by g rab bi ng t he

rea r e nd of t he swin g arm a nd att empting to m ov e
th e sw ing ar m si de to side .
Repl ace t he bearings if any ar e looseness is not ed .
Check th e act ion of t he sho ck abso rbe r by co rn-

pr essin g it seve ral t imes.
Check the ent ire shock absorber asse m bly f or sig ns
of leaks, damage or loose fastene rs .
Repl a ce damaged components which cannot be
repaired.
Tight en all nu ts and bol ts.
Ref er to the shock absorber service (page 15-14).
t
4-39
Contents Chapter 4
MAINTENANCE
REAR SUSPENSION ADJUSTMENT
COMPRESSIO N AND REBOUND DAMPING
ADJUSTERS
I NOTICE I
Do no t turn the adju s te rs more tha n the given poei-
tions or the adjusters m ay be damaged.
All damping adj ustments ar e refer enced fro m the
f ull hard p os it ion.
The co mpressi o n and reb ound d amping can be
adjusted by turni ng the ad ju ster s.
DIRECTION H: In crea se th e dampin g force

DIRECTIO N S: Decrease the damping force
Turn th e co m p ressio n adj us te r clockwise until it

sto ps (full ha rd position), th en turn th e adjust er
co u nte rcloc kwise.
COM PRESSION ADJUSTER STANDARD POSITION :
9 clicks o ut from full hard
Tu rn t he reb oun d adjuster clo ckw ise u ntil it stops

(ful l hard pos itio n ), t he n t u rn t he ad j ust er co u nt er-
clockw ise.
REBOU ND ADJUSTER STANDARD POSITI ON :

2 - 1/ 2 turn s ou t from full hard
REBOUND A DJ UST ER
4-40
Contents Chapter 4
MAINTENANCE
NUTS, BOLTS, FASTENERS
Check that a ll chassis nut s and bolts are tighte ned
to their correct torqu e val ues (page 112 ).
Check that all safety clips, hose clam ps and cable
stays are in place and pro perly secured .
WHEELS/TIRES
T ire pre ssure should be checked when th e tires are
COLD.
RECOMMENDED TIRE PRESSURE AND TIRE SIZE:
FRONT REAR
T ire pressure kPa
25012.50.36) 290 (2.90, 42)
(kgf/ cm ', p si)
120n O ZR 17 190/50 ZR 17
Tire size
MIC 158W ) MIC (73WI
BT014F BT014R
Bridgestone
Tire RA DIAL G RAD IAL G
bland DIAB LO DIAB LO
Pirelli
CORSA H CORSA H
Check the tires fo r cuts, embedded nails, or othe r L = "..::;.,..:= = ..:::::r..oa_ _

damage.
Check th e fro nt whe el (page 14- 16) and rear w hee l
(page 157) for truen ess.
Measure the tread depth at the cente r of the tires.
Replace the tires wh en the tread dep th reaches the
followi ng limits .
MINIMUM TREAD DEPTH:
FRONT: 1.5 mm 10.06 in)
REAR: 2.0 mm (0.08 in)
STEERING HEAD BEARINGS

Check th at th e contro l cables do not inte rfe re with
handleb ar rotation .
Support the m otorcycle securely and raise the front
whee l off th e ground .
Check that th e ha ndle ba r moves fr eely from side t o
side.
If the handlebar m oves unevenl y, binds, or has ve r-
tical mo vement, inspect the stee ring head bearings
(page 14-351.
4-41
Contents Chapter 4
MEMO
Contents Chapter 4
5. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM 5-2 OIL STRAINER/PRESSURE RELIEF VALVE5-6

SERVICE INFORMATION 5-3 OIL PUMp 5-8
TROUBLESHOOTING 5-4 OIL COOLER5-13
OIL PRESSURE INSPECTION 5-5
5-1
Contents Chapter 5
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM

" " " v " v "
CAMSH AFTS
..
PISTON -_.~~~~
PISTON OIL JET
CRANKSHAFT
OIL COOLER
r BALANC ER
MAINSHAFT
J .
EOP SWITCH
- COUNTERSHAFT
OIL FILTER CA RTRIDGE
OIL PUMP
OIL PRESSURE RELIEF VALVE
OIL STRA INER
5-2
Contents Chapter 5
LUBRICAT ION SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Used engine oil may cause skin cance r if repeatedly left in contact with the skin for pro longed pe riods. Alt hough this is
unlikely unless you handle used oil on a daily basis, it is still advisa ble to tho roughly wash your hands wi th soap and
water as soon as possible afte r handling used oil.
The oil pum p can be serviced w ith the eng ine installed in the fram e.
T he service procedures in this section m ust be perform ed w ith the engine oil draine d.
W hen rem oving and installing the oil pump , use care not to allow du st or dirt to enter th e engine.
If any portion of the oil pu mp is wo rn beyon d th e specified service limits, replace the oil pum p as an assem bly.
Afte r the oil pump has been installed, check th at there are no oil leaks and that oil pre ssure is correct .
SPECIFICATIONS
Unit: mm (in)
Engine oil capacity Aft er drain ing 3.0 lit er (3.2 US qt , 2.6 Im p qt )
After oil filter change 3.1 lit er (3.3 US qt , 2.7 Imp qt ) -
Afte r disassembly 3.8 lite r (4.0 US qt. 3.3 Imp qt )
Recom me nded engine oil Pro Honda GN4 or HP4 (without moly b-
de num additives) 4-stroke oi l (U .S.A.
and Canada), or Honda a- st ro ke oil
(Canada only) , or an equivalent motor
oil
API service classification: SG or Highe r
except oils labeled as energy conse rv-
ing on th e circular API service label
JASO T 903 st anda rd: MA
Viscosity: SAE 10W-40
Oil pressure at EOP (engine oil pressure) switch 490 kPa (5.0 kgl/cm', 71 psi) at
-
6,000 rpm/(80 'c/176'F)
Oil pump Tip clea rance 0.15 (0.006) 0.20 (0.0081
Body clearance 0. 15 0.2 1 (0.006 - 0.0081 0.35 (0.014)
Side clearance 0.04 - 0.09 (0.002 - 0.004) 0.17 (0.007)
TORQUE VALUES
Engine oil filte r cartridge 26 Nrn (2.7 kqf -rn, 20 Ibf.ftl Apply clea n engine oil to the O-ring
Engine oil drain bolt 29 Nm (3.0 kqf-rn , 22 lbf -ft]
Engine oil drain base bolt 12 N'm (1.2 kqf-m, 9 Iblft) Apply a locking agent to the threads
Oil pu mp assembly flange bol t 7.8 N'm (0 .8 kgl m , 5.8 Iblft) CT bolt
Oil filte r boss Seepage 1-15
EOP (engine oil pressure) switch 12 Nm (1.2 kgl' m, 9 Iblft) App ly sealant to the threads
EO? (eng ine oil pressure) switch wi re 2.0 Nrn (0.2 kqf -rn. 1.4 Ibl ft)
termin al screw
Oil pump driven sprocket bolt 15 Nrn (1.5 kqf- rn, 11 lbf-tt! Appl y a loc ki ng age nt to th e thre ads
5-3
Contents Chapter 5
LUBRICATION SYSTEM
TOOLS
Oil pressure gauge set Oil pr essur e gauge att achment
07506 3000001 07406-0030000
o r equivalent commercially av ail - o r eq uivalent com mercia lly ava il-

able in U.S.A . (MT37A) ab le in U.S.A. (AT77A HI
TROUBLESHOOTING
Oil lev el too low
Oi l co ns u m pt io n
Ext ern al o il leak
Wo rn pisto n rin g s
Im p ro p er ly i nst alle d pist o n rings
Wo rn cy li nde rs
Wo rn v alve ste m sea ls
Wo rn v alve g ui de
Low oil pressure
Oil lev el low
Clog ged o il st raine r
Intern al oil leak
In cor rect oi l be ing used .
No oil pressu re
O il lev el t o o lo w
Oil pressure relief va lv e st uck ope n
Broken o il pump drive chain
Brok en oil pump d rive o r drive n sp rocket
Da mag ed o il p u mp
Int ern al oi l leak
Hig h o il p ress u re
Oil press ure reli ef val ve stuck closed
Clogged oi l f il t er , o il coole r gall ery o r m et eri ng ori fi ce
Incorrect oil being used
Oil co nt am in ati o n
Oil or f ilter not changed ofte n en ough
Worn pisto n ring s
Oil em ul si ficatio n
Bl ow n cyli nder head gasket
Leaky coolant passage
Ent ry of water

LUBRICATION SYSTEM
OIL PRESSURE INSPECTION
If the oil pressure Rem ov e the un d er cowls (page 3-7),
indicator light
Rem ov e t he screw and discon nect t he EOP switch
remains on a few
seconds, ch eck the
wire .
Remove the EO? swit ch whi le holding the switch
ind icator system
base.
before check ing the
oil pressure .
Install the oil pressure gauge attachm ent to the ~~:::~~:;~~~~

switch ba se.
Connect t he oi l pressure gauge t o t he oi l pressure
g a uge attac h me nt .
TOOLS:
Oil pre s s ur e ga uge set 07506-3000001 or
equ iva le nt
co mm er cially avail-
ab le in U.S.A .
(M T37A )
Oil pressu re gaug e atta ch- 07406-00300 00 o r
m ent equiv ale nt
co m m e rcia llyavail-
ab le in U.S.A .
(AT77AHI
Che ck th e oi l level (page 4-21 ).
W arm . t he engine to no r mal ope rating t emp erature
(ap p roxim at ely 80C'17 6F) and increa se the engin e
spe ed to 6,000 rpm and read t he o il p res sure.
OIL PRESSURE:
490 kPa (5.0 k9f/ cm', 71 p si ) at 6,000 rpml
(80 C/176Fj
Stop the eng ine and remove t he too ls.

Apply a sealant t o the EO? sw itc h thread s as shown. ,..-- - - -- - -- - -- - -- - - - - - - ,
Do not apply sealant t o t he thread he ad
3 - 4 mm (0. 1 - 0.2 in)
I ..
EOPSWITC H
5-5
Contents Chapter 5
LUBRICATION SYSTEM
Insta ll and t igh t en t h e EO? switch to the specifie d
to rq ue w hile ho ldi ng th e switc h b ase.
TORQUE: 12 N'rn (1.2 kqf-m , 9 lbf.ttl
Co nnect th e EO? switch wire terminal t o the switc h

and t igh t en the screw to the specified torque .
TORQUE: 2.0 Nm (0.2 kq f-m , 1.4 Ibllt)

Inst all t he dust cove r.
Inst all the u nd er cowl s (p age 3-7) .
OIL STRAINER/PRESSURE RELIEF

VALV E
REMOVAL
Dr ain th e en gi ne o il (pag e 4 ~ 2 2 ) .
Rem o ve the ex ha ust pipe (page 330).
Remove the o il pa n SH f lan ge bo lts and o il pan.
Remove the oil strainer and packing .

Clean the oi l straine r screen.
5-6
Contents Chapter 5
LUBRICATION SYSTEM
Remov e t he pr essur e rel ief v alve and O-ring .
INSPECTION
Check t he operat io n of t he pressure relief val v e by
pus hing o n th e piston .
Disassemble the relief valve by removi ng the snap PISTON
~ W~""
ring.
Insp ect t he pisto n fo r wea r, un smooth mov em ent or
da ma ge.
Inspe ct the spring fo r fatigue or damage.
Asse mble t he reli ef va lve in the reve rse ord er o f d is-
assembly.
"""AI
SNAP RING
...--0
INSTALLATION
A pply o il t o a new pa ckin g and inst all it onto th e oil
strainer flange. OIL STRAINER
Install the oil st rainer into the oil pump wh ile align-
in g t he oil strain er bo ss with t he g roove of t he oi l
pump.
Ap ply oil t o a new O- ring and in stall it o nto the reli ef

va lve.
Insta ll t he reli ef valve into the crankcase.
5-7
Contents Chapter 5
LUBRICATION SYSTEM
If the oi l pan dra in base is rem o ved , insta ll th e fol-
lo w in g: BOLT OIL PA N
DRAIN BASE
- Install a n ew O-ring int o th e oil pan d ra in base
groove.
Inst all th e oil pa n d rai n base onto the oil pa n, and
tem po rar ily insta ll and tigh ten the oil d ra in bolt.
A pp ly a locki ng agen t t o th e oil pa n d rai n base
mounting bo lt t hrea ds .
Install and ti ghte n the oil pan drain ba se mount-
ing bolt to the speci fi ed to rque .
TORQU E: 12 Nrn (1.2 kqf-m, 9 Ibf lt)
~
~ O-RING
Clean the oil pa n matin g surfa ce thoro ughly .

Do not apply more Apply sealant (Three Bond 12078 o r an eq uivalent)
sealant than nece s- to t he m at ing surf ace.
eerv.
. ",,'mill
Inst al l the oil pan o nto th e low er crankcase .
Inst all th e oil pan SH f lan ge bo lts.
Tighten t he bolts in a cr isscross pattern in two or
t hr ee steps.
In stall the ex ha ust pipe (p age 3-36) .
Fill the cra nkcas e w ith t h e recommend ed oil (page
4-22 ).
After install ation, check t hat th ere are no oil leaks.
OIL PUMP
REMOVAL
Drain the eng ine o il (page 4-22).
Remove the clutc h (page 10-16 ).
To gain access to Remove the bolt, w ashe r and oil pum p driv en
the oil pump driven sprocket .
sprocket bolt, first
rem ove the oil pan.

LUBRICATION SYSTEM
Rem ove th e oi l pan (page 5-6).
Remove th e following :
- Oil pump mo unt ing bolts
- Oil p u m p assembly
Do w el pins
- Oi l pass colla r/O vri n q
DISASSEMBLY
Rem ov e the oil pu m p asse m b ly bo lts .
ASSEM BLY BOLTS
Rem ove the oil pum p cove r and dow el pi ns.

OIL PUMP BODY
Remove the thrust wa sher, drive pi n, oil pump

shaft, o uter ro tor and in ner ro to r from the o il pu mp
bo dy.
Clea n all dis asse m b ly pa rts th o rou gh ly .
OIL PUM P
SHA FT
INNER ROTOR DRIVE PIN
5-9
Contents Chapter 5
LUBRICATION SYSTEM
INSPECTION
If any portion of the Tempo rar ily inst all th e o uter an d in ner rot o rs in to
oil pump is worn t he oil pu mp body.
TIP CLEARANCE:
beyond the service Tempora ri ly in st all the d riv e pi n and oil pum p shaft . .
limit, replace the oil
M easur e th e roto r tip clear an ce.
pump as an assem-
bly. SERVICE LIMIT: 0.20 mm 10.008 in)
Me asure th e pump bod y clearance.

BODY CLEARAN CE:
SERVICE LIMIT: 0.35 mm 10.014 in)
M easure th e side clear an ce using a st raig ht edge

and fe eler ga uge .
SERVICE LIMIT: 0.17 mm (0.007 in)

LUBRICATION SYSTEM
ASSEMBLY
INNER ROTOR
DRIVE PIN
OUTER ROTOR
OIL PUMP SHAFT
WA SHER
~--
DOW EL PINS
OIL PUMP BODY
12 Nrn (1.2 kqf -rn, 9 lbf -ft)
Dip all part s in clean eng ine oil.

Install the outer roto r into th e oil pump body .
Install the inne r rotor into the oute r rotor w ith its
drive pin groove faci ng the oil pump cover .
DRIVE PIN GROOVE
Install the oil pump shaft through the inner rotor

and oil pum p body.
Install th e drive pin into the hole in the oil pum p
shaft and align th e drive pin with th e gro ove in the
inner rotor.
Install the thrust was her.
OIL PU M P
SHAFT
DRIVE PIN
5-11
Contents Chapter 5
LUBRICATION SYSTEM
Install the dowel pins in t o th e oil pu mp cover.
OIL PUMP BOOY
Install the oil pump cover to the oil pump body.
Install and t ig ht en the oil pump assembly bolts to

the specified torque .
TORQUE: 12 Nm {1.2 kqf-m, 9 lbf-tt)

Check the oi l pump operation by turning th e pum p
sh aft.
If necessary, reassembl e the oil pump.
ASS EMBLY BOLT S
INSTALLATION
Install the dowel pi ns.
Apply oil to a new O-ring and install it w ith the oil
pa ss coll ar.
. Install the oil pump assembly onto the crankcase

w hi le align in g the oil pump shaft lug with th e wa te r
pum p shaft groov e by tu rn ing t he oil pump shaft.
5-12
Contents Chapter 5
LU BRICATI ON SYSTEM
Insta ll and tighten th e th ree flan ge bol ts secu rely.
A ppl y oil to t he o il pump d riven sprocke t an d d rive

chai n
Insta ll t he driv en sprocket w it h it s "OUT" m ark fac-
i ng out.
A pply a loc ki ng age nt t o th e oil pum p driven

sp rock et bolt threads.
Insta ll an d tig hten t he driv en sprocket bo lt/washe r
t o the specified t orque.
TORQUE : 15 Nm (1.5 kg!in . 11 Ibf.ft)
Insta ll th e oil pan (pa ge 5-7).
Inst all th e rig ht cra nkcase cov er (page 10-34).
A ft er in stallatio n, fi ll t he crankcase w ith th e recom -
mended oil (pag e 4-22) and chec k that th ere is no oi l
leaks.
Che ck th e oi l pressure (page 5-5 ).
OIL COOLER
REMOVAL
Drain th e engine oil (p age 4-22).
Dra in th e coo lant f ro m the sys te m (pa ge 76 ).
Remove t h e ex haust pipe (pa ge 3-30) .
Lo osen the hose clamp screws and disco nnect the
oi l coo ler w ater hoses from th e oil cool er.

LUBRICATION SYSTEM
Remove the t h ree bolts and oil cooler.
Rem ov e the O-rin g f ro m th e oil coo le r.
INSPECTION
Check t he o il coo ler fo r damage.
INSTALLATION
Coat a new O-ring w it h e ng ine oil a nd install it into
the oil cool er groove.
Inst all t he oil coo ler o n t h e cran kcase.

Inst all a nd tighten the three bolts.
Connect th e oil cooler water hoses into t he oil

coo le r an d tighte n th e ho se clam p sc rews sec u rely.
Install t he ex h au st pi p e (pag e 3-36).
Fill the crankca se wit h th e rec omm end ed oi l (page
4-22) and check that th ere is no oil leaks.
Fill th e co o li ng sys t em and bleed any air (page 7-6).
5-1 4
Contents Chapter 5
6. FUEL SYSTEM (Programmed Fuel Injection)
COMPONENT LOCATION .. 6-2
SERVICE INFORMATION 6-3

IDLE AIR CONTROL (lAC)
THERMAL VALVE ................................6-56

IDLE AIR CONTROL (lAC) VALVE 6-57
TROUBLESHOOTING 6-6
lAC VALVE SYNCHRONIZATION 6-61
SYSTEM LOCATION .. 6-7
MAP SENSOR 6-64
SYSTEM DIAGRAM 6-8
IAT SENSOR .. 6-65
PGM-FI SELF-DIAGNOSIS
INFORMATION 6-9 ECT SENSOR 6-65
MIL CODE INDEX .................................. 6-13 CMP SENSOR .. .. 6-66
MIL TROUBLESHOOTING 6-15 BANK ANGLE SENSOR ......................6-67
FUEL LINE INSPECTION 6-31 ENGINE STOP RELAY ..6-68
FUEL PUMP UNIT 6-33 ENGINE CONTROL MODULE (ECM) ..........6-69
FUEL CUT-OFF RELAy .... 6-35 PAIR CONTROL SOLENOID VALVE 6-71
FUEL TANK 6-36 EVAP PURGE CONTROL SOLENOID VALVE

(CALIFORNIA TYPE ONLY) 6-72
AIR CLEANER HOUSING 6-40
INTAKE AIR DUCT .. 6-73
SECONDARY INJECTOR ........................ 6-43
EGCV (Exhaust Gas Control Valve}- ........6-76
THROTTLE BODy 6-47
EGCV SERVOMOTOR 6-78
PRIMARY INJECTOR 6-54
6-1
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Injection)
COMPONENT LOCATION
4.4 Nm (0 .45 kqf -rn, 3.3 lbf-ft)
5.4 Nm (0.55 kqf-m, 4 .0 Ibfft)
1.2 Nm (0.12 kqf-m ,

0.9 Ibl ft)
1.2 Nrn (0 .12 kqf-rn.

0.9 lbf -tt)
1.2 Nrn (0. 12 kqf-rn,

0.9 Ibl ft)
22 Nvm (2.2 kqf-rn , 16Iblft)
6-2
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Inj ect ion)
SERVICE INFORMATION
GENERAL
Be sure to reli eve th e fuel pressure w hile the engi ne is OFF.
Bending or twisti ng th e control cables w ill im pai r smooth o perat ion and cou ld cause the cables t o stick o r bind, result-
ing in loss of ve hicle con trol.
W ork in a w ell ve nt ilate d area. Smoking o r allow in g flames o r spark s in th e wo rk ar ea o r wh ere gasoli ne is stored can
cau se a fire or exp losio n.
Do no t apply commercia lly avail able car bu reto r cleane rs to the in side of th e throttle bo re, w hi ch is co ated with mo lyb-
denum.
Do not snap the t hrottl e va lv e from full ope n t o full clo se after th e throttle cable ha s been re m oved. It m ay cause inco r-
reet idle operation .
Sea l the cy linder head intake ports with tape or a clea n clo t h to keep dirt and debris fr o m entering t he intake po rt s after
th e throttle bod y has been rem oved .
Do not apply ex cessive f orce to t he f uel pip e on the thro ttle bod y wh ile rem ov ing o r in st alling th e throttle bo dy.
Do not damag e t he t hrottle body . It may cause inc orrect throttle and idl e val ve sy nchron izat ion.
Prev ent dirt and de bris f ro m ent eri ng th e throttle bore, fu el hos e and return hose, clean them using co m pressed air.
Th e throttl e body is f act ory pr e-set . Do not disassem ble in a way ot her than shown in this m anu al.
Do not push the fuel pu m p base un de r the fuel ta nk w hen th e f uel t ank is stored.
Always rep lace the packing whe n the fuel pump is removed.
Th e programmed fuel in jecti on (PGM-FI) system is equipped with a Self-Diagnostic System, described page 6-9. If the
m alf unction indicator lamp (MI Ll bl inks, f oll ow th e Self-Diag nost ic Procedures to re m edy th e problem .
W hen ch ecking th e PGM-Fl, alw ays follow t he step s in the tro ubleshooting fl ow chart (page 6-15).
Th e PGM -FI sys tem is provided with f ail -saf e f unctio n to secure a mi nim um ru nni ng capabilit y w hen th ere is any tro u-
ble in t he syst em . W hen any abno rma lity is detected by the self- diag nosis fu nct ion , run ni ng capa bili ty is secured by
using num erical va lues pr eset in advance in the pro gr am m ap. It mu st be rem em bered , however, th at w hen any abnor-
m ality is detected in 8 in jecto rs and/or the CKP (Cran kshaft Positi o n) sensor and CM P (Camshaft Positi o n) sensor, t he
fail safe function stops the engine to protect it f ro m damage.
Refer to PGM-FI system loca tio n Ipage 6-7).
A f aulty PGM -FI system is ofte n rela te d t o poorl y con nected o r corro ded co nnecto rs. Che ck those co nnect io ns befo re
proceeding .
Refe r to procedures for fuel re serve sen sor in sp ecti on (pag e 20-17).
The ve hicle spee d sensor sends a digi tal pu lse sig nal t o th e ECM (PGM-FI unit) fo r com puta tio n. Refer t o pr ocedur es f or
vehicle speed sensor inspection (page 20-12) .
When disassembling the programmed fuel injection parts, note the location of the O-rings. Replace them wit h new ones
upon reassembly .
Before disconnecting the f uel hose , release the fuel press ure by loosen ing th e fuel hose banjo bo lt at the fue l t ank.
A lways replace th e seali ng w ashe rs w he n the fuel ho se ban jo bo lt is rem oved o r loosened.
Use a di gita l t est m et er fo r PGM -Fl sys tem inspect ion .
SPECIFICATIONS
ITEM SPECIFICATIONS
T hro tt le body identiflca- I A, CM type GQA OC
t ion number I AC ty pe GQAOS
Idl e air cont ro l (lAC) va lve vac uum difference 20 m mHg
Base throttle va lv e fo r sy nchronization No. 1
Idl e spee d 1,20 0 100 rpm
Thr ottle gri p f ree play 2-4m m( 1/16 3/16 in)
Intake air t em per ature senso r resistance (at 20C/68F) 1 4 kn
Engine coolant t em per at ure sensor resist ance 2.3 - 2.6 kn
(at 20C/68F)
Fuel in jec tio n res ist ance I Prim ary in ject or 10.5 14.5 n
(at 20C 168 F) I Secondary in j ecto r 10.5 14.5 n
PAIR contro l solenoi d valve resista nce (at 20 C/68 F) 20 - 24 n
CM P (Camshaft positi on ) senso r pea k vo ltage (at 20CI 0.7 V mi ni m um
68F)
CKP (Crankshaft posi tio n) senso r peak vol tage (at 20C/ 0.7 V minimum
68F)
M anifold absol ute pr essure at idle 150 250 m m Hg
Fuel pr essure at id le 343 kPa 13.5 kgf/em ' , 50 ps i)
Fuel pump f lo w (at 12V) 189 em 16.4 US OZ, 6.7 Imp oz) m inim um/l0 seco nds
6-3
Contents Chapter 6
FUEL SYSTEM {Programmed Fuel Injection}
TORQUE VALUES
ECT (Engine Coolant Tem peratu re)/ 23 Nm 12.3 kgfm, 17 Ibf.ftl
thermo sensor
Th rottle body insulator band screw See page 1-15
Serv ice check bolt 12 Nm (1.2 kgfm, 9 Ibf.ft)
lAC valve lock nut 1.8 Nm 10.18 kqf-rn. 1.3Ibf.fl )
lAC valve synchronization plate screw O.S Nrn (O.OS kgfm, 0.7 Ibfft )
Fuel pipe mounting bolt S.8 Nm (1.0 kqf- m, 7 Ibfft)
lAC thermal valve link plate screw O.S Nrn 10.OS kqf- rn, 0.7 lbf-ft]
lAC thermal valve mounting screw 4.S Nm 10.5 kgfm , 3.6 lbf- ft}
Fuel filler cap socket bolt 1.8 N'rn 10.18 kq f-rn, 1.3 Ibfft)
Fuel feed hose banjo bolt (fuel tank side) 22 Nrn (2.2 kgf-m , te tbf-tt Yellow paint
Fuel hose sealing nut (throttle body side) 22 Nm (2.2 kgfm, 16 lbfftl
Fuel pump flange nut 12 Nm (1.2 kqf-m , 9 lbfftl See page ' 17 fo r tightening
sequence
Fuel tank mounting bolt (fro nt) 26 Nm (2.7 kqf-rn, 20 lbf-ft )
Fuel tank mounting bolt (rear) 9.8 Nm (1.0 kq f-rn, 7 lbf- ft)
Fuel rail joint hose SH bolt 9.8 Nm (1.0 kq f -m, 7 Ibf ft) Yellow paint
Fuel rail joint hose sealing nut 22 Nm (2.2 kqf-rn, 16 lbfft l Yellow pai nt
Air cleane r housi ng/ai r funne l pan screw 4.4 Nm (0.45 kqf -rn, 3.3 Ibfft )
To p air cleaner housing mounti ng screw 1.2 Nrn 10.12 kqf- rn. O.S lbfftl
M iddle air clea ner hous ing mo unting 1.2 Nrn 10.12 kqf-m, O.S lbf ft )
screw
IAT sensor mou nting screw 1.2 Nm 10.12 kg fm , O.S lbf ftl
Ai r int ake duct jo int screw 2.5 Nrn (0.25 kgf m, 1.8 lbf-tt l
Air intake duct flap screw 1.2 Nm 10.12 kqf-rn, O.S lbfft l
Seco nda ry injecto r base m ounting bolt 5.4 Nm 10.55 kgf m , 4.0 lbf-ft )
Bank ang le sensor mounting screw 1.5 Nrn 10.15 kqf-rn, 1.1 lb fft l
6-4
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Injecti on)
TOOLS
Fuel pressu re gauge Peak vo ltage ad aptor ECM te st harn ess, 32 P
07406-0040003 07HGJ-0020100 070M Z-0010201
or 07406-004000B (not avai lable in U.S.A.) (tw o required )

or 07406-004000A wi th com mercially avai lable d igita l
(U.S.A. on ly) m ultim et er (im pedance 10 M nJD CV
mi nimum )
SCS serv ice connecto r Igni tionM ate peak vo ltage teste r Vacuu m gauge set
070PZ-ZY30100 MTP07-0286 (U.S.A . on ly) 07LMJ-0 01000B
o r 07LMJ -001000A
tnspect ion adapto r

07GM J- M L80100

TROUBLESHOOTING
Eng ine won't start
Intake air leak
Fue l contaminated/dete rio rated
Pinched or clog ged fuel hose
Faulty fuel pump un it
Clogged fu el til ter/stra in er
Clo gged fue l in jecto r fi lt er
Sticki ng fue l inje ctor needl e
Fau lty f ue l pum p operat ing sy stem
Engine stalls, hard to start. rough idling
Int ake air leak
Fue l co nt am i nat ed/ de t eriorate d
Pi nch ed or cl ogged fu el hose
Idle speed m isadju sted
lA C va lve sy nc hro nization misa djust ed
Backfiring or misfiring during acceleration
Ig nit io n system malfunction
Poor performa nce (drive ability) and poor fuel economy
Pinched or clogge d fue l hose
Faul ty p ress u re reg u lat o r
6-6
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel In jection)
SYSTEM LOCATION
PAIR CONTROL SOLENO ID VA LVE
IAT SENSOR
ECM
FUEL PUMP
ECT SENSO R
DLC
CMP SENS OR
EGCV SERVOMOTOR
CKP SENSOR
VS SENS OR
FULL NAME ABBREVIATIONS

M anifold absolute pressu re sensor MAP sensor
Throttle position senso r TP sensor
Intake air tempe rat ure se nsor IAT sensor
Engine coolant tem perature sensor Ee l se nsor
Cam shaft positio n se nsor CMP se nsor
Cranks ha ft posi t io n senso r CKP senso r
Vehicle speed senso r VS sensor
Eng ine control module ECM
6-7
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Injection )
SYSTEM DIAGRAM
'"
'"
I
.i,
'31 ,<I _.t::1 '61 I r-
cgJ. ~= '" I I
171 I \91 -
'" (10)
~I IIiil
II
t~l t~t t~t t~t t~t ?t ~ W""
" I
I"'" "" I I
=
=-
==-
-~
=
III
,3>
(34 )
t-
111361
.,[
(1) Eng ine st op relay (20 ) EVA P purge contro l solenoid valve
(2) PGM -FI fuse (20A) (21) Fuel indicator
(3) Engine sto p switch (22) Fuel pump unit
(4) Su b-fu se (l OA) (23 ) Prim a ry injector
(5 ) Ig nition swi tch (24) CMP (cam sh aft position) sensor
(6) Ma in fu se A (30A ) (25) Di rect ignition coil/spark plug
(7) Bank ang le senso r (26) M A P sensor
(8) DLC (da ta link con nector) (27) PA IR chec k v alv e
(9) Batt ery (28) ECT se nso r
(10) EVAP canist er (29) CKP (cran kshaft p osition ) sensor
(11 ) HESD (Honda Elect ro nic Stee ri ng Damper) (30) EGCV servo m ot o r
(12) Fuel cut -off relay (31) Water tem per atu re LCD
(13) IAT sen sor (32) Sp eedometer
(14 ) Secon dary injecto r (33) VS (ve hic le spe ed ) senso r
(15) Intake duct diaphragm (34 ) Neutral switch
(16) Intake air control solenoid valve (35) Clutch switc h
(17) Vacuum chamber (36) Sid e stand switch
(18) PAIR co ntrol solenoid va lv e (37) M alf uncti on indicator lamp (M IL)
(19) TP se nso r (38) Tach om et er

PGM-FI SELF-DIAGNOSIS
INFORMATION
SELF-DIAGNOSTIC PROCEDURE
Place th e mot orcy cl e o n it s sid e st and .
MA LFUN CTION INDICATOR LAM P (M IL)
Sta rt th e eng ine and let it id le.
NOTE:
If the en gine will not start, turn the starter m otor for
m o re than 10 seconds and check that th e M IL bli nks.
The M IL will blink If t he m alf unct ion in dicat o r lam p (M IL) does not
only w ith the side li ght or bli nk, the system has no m em ory of prcb-
sta nd down and lem data.
with the engine off
If the m alfunction indicator bl inks, note how man y
(engine stop switch
t im es th e MI L blinks and determine th e cause o f t he
is RUN) or engine
problem (page 6-13).
revs are below
5,000 pm. In an y If yo u wis h t o read t h e PGM -FI m em o ry f or tro uble PGM-FI INDICATOR
ot her cond ition. the data, perform the fo llowing:
M IL will illuminate
and stay on.
T urn t he ig nitio n sw itc h OFF.

Rem ov e t he left m idd le cowl (p age 3 w7 ),
Disconn ect the Data Link Conn ecto r (o LC).
Turn the ig nit io n sw itc h OFF.

Remove t he left middle cowl (pag e 3-7 ),
Sho rt the Data Lin k Conn ect or (OLC) te r mi nals u sin g
the spec ia l t ool.
TOOL:
SCS se rv ice con nector 070PZ-ZY30100
Co nne ct ion : Brown - Green
Turn t he ignit io n switch O N and engi ne stop sw itch

"() ".
7
DATA LINK CONN ECTOR
o
6-9
Contents Chapter 6
Even if the PGM-Ff If t he ECM has no se lf diag nosis m em ory da t a, th e
has m em ory data, MIL w il l illum in at e, whe n you turn t he ig nit io n MALFUNCTION IN DICATOR LA MP (M IL)
the M IL does not sw itc h ON.
blink w hen the
If the ECM ha s self diagn osis m em ory data, the MIL
en gine is running.
wi ll start blinking wh en yo u turn the igniti on switc h
ON.
Note ho w m an y t im es t he M IL blin ks, an d det erm in e
t he cause of the problem (p age 6- 13).
PGM -FI INDI CATOR
SELF-DIAGNOSIS RESET PROCEDURE

Reset t he self- diag nosis m em ory dat a as fo llow s;
1. Turn t he eng ine stop sw it ch "~" and igni ti on
swi tc h OFF. SCS SERVICE CON N ECTOR
""';i
2. Short t he Data Link Connector (OLe ) te rm i na ls
usin g a special tool.
TOOL:
SCS service connector 070PZ-ZY30100
Connection: Brown - Green

3. Turn th e ignitio n switc h ON.
4. Rem ov e t h e speci al t oo l from the Data Link Co n-
nector (DLC). "--
DATA LIN K CON NECTOR
5. Th e M IL li ghts ab ou t 5 seconds. W hile t he i ndi ca- ~=================~

tor li ghts, sho rt th e Data Lin k Connector (DLC)
ag ain wit h t he special tool,
Se lf-d iag nosis m em o ry d at a is e rase d, if t he MIL
turn s off a nd st art s b li n king .
Th e Data Li n k Co n necto r (OLC) mu st be j u m ped
wh ile the in di cator i s li t . If not, the M IL w ill not
st art bli n king .
No t e t hat th e self d ia gn o si s m em ory d at a ca n not
be erased if yo u tu rn off t he ignit i on sw itc h
before th e M IL starts b li nking .
(0)(0)
If t he MIL b li n ks 20 times, th e d at a ha s not be en
era sed, so try aga in.
6-10
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Inject io n)
PEAK VOLTAGE INSPECTION
PROCEDURE
Use th is procedure for th e crankshaft position
senso r and cams haft positi on sensor inspection.
Check all system connections befo re ins pectio n.
If the syste m is d isco nnected , inco rrec t pea k vo lt-
ag e m ight be measured .
Check cylind er co m press io n and check th at all
spark plugs ar e in st all ed co rrect ly .
Use the recom m end ed digital mul ti mete r or
co m mercially ava ilable dig ital multi mete r wit h
an im pedance of 10 MnJDCV m inimum.
If the Ign iti on Mate peak vo lt ag e te st er is u sed ,
fo llow t he ma n ufactu re r 's instructio n .
Th e dis play va lue differs depending upon the
intern al impedan ce of t he m ulti me te r.
D isconnect the fue l pum p connector bef o re
checking the pea k vo lta ge .
Lift and support the fuel tank (page 4-5) .
Disconn ect th e fu el pump u nit 3 P (Blac k) co n necto r.
Co nnect t he peak vo ltage adaptor to the d i g it al rnul-

t imeter. ... DIGITAL MU LTIM ETER
TOOLS :
Ig nition M ate peak vol t age t est erMTP07-0286
\fr==,
(U.S.A . o nly ) or liP I.
\~
Peak voltage ada pto r 07HGJ -0020100
(n ot ava ilable in
U.S.A. )
wit h commerci a ll y availab le digital mu ltimeter
................
(imped anc e 10 M Q/DCV mini m u m )
PEA K VOLTAGE ADA PTOR "
TEST HARNESS CONNECTION

Rem ov e t he under cowls/mid d le cowls (page 3-7).
Disconnect the ECM 32P (Black) and 32P (light gray)
co nnecto rs fro m t he ECM (page 6-69 ).
6-11
Contents Chapter 6
Con nect the ECM test h arn esses between t he main
wire harn ess and t he ECM . ECM TEST HARNE SSES
TOOLS:
ECM test harness, 32P 070MZ-0010201
(two req uired)
TEST HARNESS TERMINAL LAYOUT

The ECM con nector te r minals are nu mbe red as
shown. VIEW FROM WIRE HARNESS SIDE:
A : 32P (BLACK) CONN ECTOR
A' \
0000000000(:000
A16 8' 816
0000000000000
A17 A32 617
B: 32 P (LIG HT GRAY) CONNECTOR
Th e ECM t est harn ess termi na ls are t he sam e lay out

as f or the ECM co nnecto r term inal s as shown. FOR 32P (BLAC K) CON NECTOR
11 ' J i " ! i :wtrfn n r rrm rrrn $ i j I i!O J! i' I:!" JI, 6 !
000 0000000000000 00000000000000 00

0 000000000000000 0 00000 0000000000
ill 1. Ii lilt! 2ll Jio$i i!! ill &:In" ", I jj Jl " lQ l' l' jJil?p1 ?!1 ,oX, l' 1I1
FOR 32 P (LIGHT GRAY) CONNECTOR
6-1 2
Contents Chapter 6
MIL CODE INDEX
Th e PGM- FI MIL denot es th e f ai lure codes (t he num ber of blink s from 0 t o 49 ). W hen the indi cato r light s fo r 1.3 seco nd s.
it is equiva lent t o t en bli nks. For exa mple, a ' .3 seco nd illu mi nati o n and two blinks (0.5 second x 2) of the ind icato r
eq ua ls 12 blinks. Fol low co d e 12 t roubl esho otin g (page 6-24 ).
Wh en m ore than on e fa ilure occurs, the MI L sh ows t he blinks in t he o rder of lowest number to hi ghest num ber. For
example if the indicator bli nks once, t hen t w o times , tw o failures have occu rred. Fo llow cod es 1 (page 6- 15) and 2 (page
6-16) t ro ublesh oot ing.
Refer
M IL Function Failure Cau ses Sympt om s
to
No bli nks ECM mal fu ncti on Faulty ECM Engin e does not start 6-69
No bli nks ECM powerl Ope n circuit at th e po w er in put Engine does not start 6-69
gro und circuits wi re of t he ECM
m alfu nct ion Faulty bank angle sensor
Open circuit in ba nk angl e sen-
sor related ci rcuit
Faulty eng in e stop relay
Open circu it in eng ine sto p relay
related wires
Faulty en gin e sto p switc h
Open circ uit in engine sto p
switch related wi res
Fau lty ign ition switc h
Blow n PGM -FI fuse (20 AI
Blow n sub-fuse (10 A ) (Sta rte r.
Bank angle sensor)
No bli nks ECM outpu t line
m alfu nct ion
ECM o ut put voltage line (Yellowl
Red w ire ) sho rt circuit
Engi ne does not sta rt -
No blinks MIL circ uit mal - Faulty ECM Engine ope rates no r- 6-9
fun cti on Open or sho rt circuit in M IL w ire mally
Stay s lit Data link ci rcuit Sho rt circ uit in data link connec- Engin e ope rate s nor- -
m alfunction to r ma lly
Faulty ECM
Short circ uit in data li nk connec-
to r wi re
1 Blin k - MAP senso r ci r- Loose or poor co nt act on MAP Eng in e ope rates nor- 6-1 5
cuit malfu nct io n senso r co nnector m ally
Open or sho rt ci rcuit in MAP sen-
so r w ire
Fault y M AP sensor
2 Bli nks MAP sensor per - Loose o r po or co nnectio n of th e Engine opera tes no r- 6-16
form ance prob- MAP sen sor vacuum ho se mally
lem Fau lty MAP sensor
7 Blin ks ECT sensor cir- Loose or poor co ntact on ECT Hard sta rt at a low tem- 6-17
cuit mal function sensor perature (Simu lat e us ing
Open or sho rt circuit in ECT sen- numerical va lues; 90 OCt
so r wi re 194 OF)
Faulty ECT senso r
8 Blinks TP sensor ci rcuit Loose or poor cont act o n TP sen- Poor engine perfor- 6-19
m alfu ncti on sor connector ma nce res po nse and
Op en or sho rt circuit in TP sen- w hen ope rating th e
sor wi re th ro ttle quickly (Sim u-
Faulty TP sensor late using numeri cal val-
ues; Throttle ope ns 01
9 Blink s IAT senso r circuit Loose o r poor co ntact on IAT Eng ine ope rate s no r- 6-21
malfunction sensor mally (Simulate using
Op en or short circuit in IAT sen- numerica l val ue s; 25 OCt
so r w ire 77 OF)
Fault y IAT sensor
11 Bli nks VS (Vehicle Loose o r poor co nt act o n VS sen- Engine op er ate s no r- 6-22
spee d ) sensor cir- sor co nnec tor m all y
cuit malfu nct io n Open o r sho rt circu it in VS sen-
HESD does not functio n
sor w ire
Faulty VS sensor

Refer
MI L Fun ct ion Failu re Cau ses Symptoms
to
12 Bli nks No .1 pri mary 0 Loose o r po or co ntact o n No .1 0 Engin e does not start 6-24
injecto r circuit p rimary i nject or co n nect o r
mal fu nc ti o n 0 Op en or sh o rt ci rcu it in No. 1 prl-
mary injecto r w ire
0 Fau lt y No. 1 prim a ry injector
13 Blinks No .2 prim ary 0 Lo o se or poor co nta ct on No .2 0 Eng in e does not start 6-25
in j ect or circu it p rimary inj ecto r co n ne ct o r
m alfu ncti on 0 Open o r sho rt circ u it in No .2 pri -
m a ry injector w ire
0 Faul ty No .2 prim a ry injector
14 Bli nks No .3 pri mary 0 Lo o se or po o r co ntact on No.3 0 Eng ine d o es not start 6-25
injecto r circ ui t prima ry inj ect o r co n necto r
m alfu ncti on 0 O pen o r sh o rt circu it in N o .3 p ri -
m a ry inj ecto r w ire
0 Fau lty No.3 prim a ry inj ecto r
15 Blinks No.4 prima ry 0 Loo se o r poor co nt act on No.4 0 Eng in e d o es not start 6-25
inj ector circuit prim ary inj ect o r co nnecto r
m alfunct ion 0 Open o r sho rt circu it in No.4 pri-
m ar y inj ect o r wire
0 Fau lty No .4 pri m ary inj ect or
16 Blin ks No .1 seco nda ry 0 Lo o se o r poor contact o n No.1 0 Engin e doe s n ot start 6-25
inj ect o r circuit seco ndary inject or co n necto r
malfu nct i on 0 Open o r short circ ui t in No. 1 sec-
ondary injecto r w ire
0 Faul ty No.1 seconda ry inj ect or
17 Bli nks No.2 seco ndary 0 Lo o se or poo r co ntac t o n No.2 0 Eng i ne d o es not sta rt 6-25
in jecto r ci rc ui t seco nda ry in j ect o r co n nect o r
malfun ction 0 Op en or short circu it in No.2 sec-
ondary i njector wire
0 Fau lty No .2 seco nda ry inj ecto r
18 Blinks CMP (Cam shaft 0 Lo os e or poor con ta ct on CMP 0 Eng ine d oe s not start 6-26
p o sit io n) senso r, sensor
no sig nal 0 Op e n or sho rt ci rcuit in CM P sen-
sor
0 Fau lty ca msha ft positio n se nsor
19 Bli nks CKP (Crankshaft 0 Lo o se or po or co ntact on CKP 0 Eng in e does not sta rt 6-27
position) senso r, sensor
no sig nal 0 O pen o r short circu it in CKP sen-
so r
0 Faul ty cr ankshaft p os it io n sensor
33 Blinks EEPROM in ECM 0 Fau lty ECM 0 Eng ine o perates no r- 6-28
malfunct ion ma lly
34 Blinks EGCV POT 0 Fau lty EGCV servo mo t o r POT 0 Eng in e o pe rat es nor- 6-28
(pot ent io m ete r) mall y
m alfunction
35 Blinks EGCV servo m otor 0 EGCV se rv o m oto r lo ck 0 Eng i ne ope rates nor- 6-30
ma lfu nct io n ma lly
48 Blin ks No.3 seco nda ry 0 Lo o se o r po or co ntact o n No.3 0 Eng in e d o es not start 6-25
injecto r circ ui t seco ndary i njector co n ne ct or
malfu ncti o n 0
Op en or sho rt circ uit in No .3 sec-
on d ary i nje cto r wi re
0 Faulty No.3 seconda ry inj ect o r
49 Blinks No.4 seco nda ry 0 Lo o se o r poor contact on No. 4 0 Eng in e d oe s not start 6-25
injector circuit second a ry injector con nector
m alfu nction 0 Op en or short circuit in No .4 sec -
on dary injector wire
0 Fau lty No.4 se con dary inj ector
51 Blinks HESD linear sole - 0 Lo o se or poo r co ntact on HESD 0 Eng ine o pe rat es nor- 14-7
noid malfunct io n sole noid co n nec to r m all y
0 Open o r short ci rcuit in HESD 0 HESD does not functi o n
so lenoid wire
0 Fau lty HESD solenoi d

MIL TROUBLESHOOTING
MIL 1 BLINK (MAP SENSOR)
Bef ore sta rting the in sp ect ion, check f o r loose o r
po or co nt act o n the MAP sensor 3P (Black) con -
ne cto r and rec heck th e M IL blinking .
1. MAP Sensor Output Voltage Inspection
Turn th e ign iti on switch OFF.
Connect th e ECM test ha rne s s to ECM co nnec-
to rs (page 6-11).
Turn t he ig nit ion switch ON and engi ne sto p Ij l J' , j I I au ,. tlH''',, ' j I I ) I ! I ", 11 Ji J1 ij " ii,
switch " () ". 0 000000000000000 0 0000000000 0000
M easure t he volt age at the t est harn ess t ermi- 0 000000000000000 000000000 0 0000
nals. j 11R II ill 11 II i) , ,5 Sif t! ifJfliID
Connection: B12 1+) - B26 (-)
Is the voltage within 2.7- 3.1 V7
YES _ . Interm itte nt f ail ure
Loose o r po or conta ct o n the ECM
co nnecto rs
NO _ . Ab out 5 V
GO TO STEP 2.
A bout 0 V
GO TO STEP 3.
2. MAP Sensor Output line Inspection
Tu rn t he ig nition switc h OFF.
Discon nect th e M A P senso r 3P (Black) co nnec- 3P (BLACK) CONNECTOR
to r. L- J
Turn t he ig nition swit ch ON and en g ine sto p
sw itch " () ".
Me asure th e vo lt age at th e wi re harness si de . @
Conn ection: Blu e/b lack (+) - Gr ay/black (-)
Is the voltage within 4.75 - 5.25V7
YES - Faul t y MAP senso r
NO _. Ope n circuit in Blue/b lack w ire
Op en circuit in Gray/black wire
3. MAP Sensor Input Voltage Inspection

M easure th e vo ltage at th e wi re h arn ess si de.
Connection: Yellow/red (+) - Ground (-)
YES - GO TO STEP 4.
NO - GO TO STEP 5.
6-15
Contents Chapter 6
4. MAP Sensor Output Line Short Circuit Ins pec-
ti on
Check fo r co nti nuity between t he M AP sensor 3P
3P( BLACKjCONNECTOR
(Black) connecto r t ermi nal of t he w i re harn ess
side and ground.
Connection: Blue/black - ground
..
Is th ere continuity?
YES - Short circu it in Blue /black w ire
NO - Faulty MAP senso r
5. MAP Sensor Input Lin e Inspection

Turn the ignition swit ch OFF.
Di sconn ect the ECM 32P co nnec tors.
Check fo r co nti nuity at the Yellow/red w ire
616 B1 A16 Al
betwee n the MAP sen so r 3P (Black) co nnec to r
te rm inal and th e ECM 32P (Lig ht g ray) co nnec-
OD:JDDOOD:JD:JDOD
to r. ODOODOOOoaOO
Connection: 818 - Yellow /red 632 A17
Is there continuity?
YES - Replace the ECM w it h a known good
on e , and re ch eck .
NO - Op en circuit in Yell o w /re d w ire
MIL 2 BLINKS (MAP SENSOR)

Bef or e st art ing t he ins pect io n, chec k f o r loose or
poo r con t act o n th e M AP sen sor 3P (Black) co n-
necto r and rech eck th e M IL bli nking .
1. MAP Sensor Hose Inspection
Turn t he ign itio n switch OFF
Check f o r con nectio n and inst all atio n of the MAP
senso r vacu um hose.
Is the MAP sensor hose connection correct?
YES - GO TO STEP 2.
NO - Corr ect th e hose connectio n or in st all a-
tion
VA CUUM HOSE

2. MAP Sensor Output Voltage In sp ection
Connect th e ECM test harness t o ECM con nec-
tors (pag e 6-11 ).
Turn th e ignition swit ch ON and engin e stop iI !l !Ji.
swit ch " n ". , j
~ OOOO OOOOOOOoo o oOjl

I ! I I it II it a ij.$ ' " ' , ! I :I j
1100000000000 ooooJ I
I , I I .. !$i ll
M easu re the vo lt ag e at t he te st harn ess termi-

110000 0 0 0 0 0 0 0 0 0 0 0 0 11 110 0 000000 0 0 ooo~ 1
na ls.
j J! II Ii til t! " Ill _15I",,' ti >OJ! 3iI
Connection: 812 (+) - 8 18 1-)

Is the voltage within 2.7- 3. 1 V?
YES - GO TO STEP 3.
No - Fau lty MA P sensor
3. MAP Sensor Output Voltage Inspection At Idle

Start the engine.
Measure th e vo lt ag e at t h e te st harn ess termi -
na ls.
Connection: 812 (+) -81 8 (-)
11 ! .
, , ,, I l IIl!J " " 'i " .iI
,.,, , . j i I 0 '9 11 ,*,11.15 ,11
Standard: 2.7 V maximum

0 0 000000000000 0 0
00 0 0000 0 00000 00 0
0 0 0 000 0 00 0 0
0000~ 1
0 00000 0 000 0 0 00
Is the voltage less than 2.7 Vl ,n" lt2Q iJ tll" " " S"fi ri ", :Jl p '
YES - Repl ace the ECM w it h a known good

one, and rech eck
NO - Faul ty MAP se nso r
eL&- EEl
MIL 7 BLINKS (ECT SENSOR)

Bef o re st art ing th e in spection . che ck f or lo o se o r
poor co nt act o n the EeT sensor 3P (Gray ) co n-
nector and rec heck th e MIL blinki ng.
1. Eel Sensor Output Voltage Inspection
Tu rn t he ignition switch OFF.
Con nect ECM the te st harness to ECM co n nec-
tors (p ag e 6-11 ).
j I t J . Ii ! I ill" " .'K,SH i i! J I II I 19J! It IJ 11" It!
IIo ooooooooooooooo~ I Ioooooooooooooooo~ I

11
Turn the igni ti on switc h ON and .eng ine st op
switch " n ". 00 0 0 0 0 000000 0000 0 0 0 0 0 0000 000 0 0
M easure t he volta ge at t he ECM t est harn ess ter-
mi nal s. , i1 ,I Hllilfj "" 'liS,." Ii iiW]u[l
I
Connection: 827 1+)- 8 26 I-I
St andard: 2 .7 - 3 .1 V (20' C/ 68' F)
Is the voltage within 2.7- 3. 1 V7 e V EEl

YES _ . Int er m itte nt fail u re
Lo o se or poo r co ntact on t he ECM
co nnectors
No - GO TO STEP 2.
6-17
Contents Chapter 6
2 . ECT Sensor Input Voltag e Inspection
Tu rn the ign ition s w itch OF F.
Disconn ect the Ee l sensor 3P (Gray ) connecto r. 3P IGRAYICONNECTOR
Tu rn the ig nitio n switc h ON a nd engi ne stop

switch " n ".
Measu re t he voltage at th e w ire ha rnes s side of
Eel senso r co n nector.
Connection: Blue/yellow (+) - q round (-)
YES - GO TO STEP 3.
NO - GO TO STEP 4.
3. Eel Sen sor Resistance Inspection

Tu rn the ign ition switch O FF.
ECT SENSOR
Di sconnect t he Eel sensor 3P (Gray) co nnect o r.
Measure t he resistan ce at th e Ee l senso r te rm i -
nals.
~I
Connection: Blue/yellow (+1 - Gray/ black H
(sensor sid e terminals)
Standard: 2.3 - 2.6 kO (20' C/68'FI
Is the resistance within 2.3 - 2.6 kil (20 'C168 "Fj 7
NO - Fa ulty Eel se ns o r.
YES - GO TO STEP 4.
4. Eel Sen sor Open Cir cuit In sp ecti on

Tu rn t he ig nit io n switch OFF.
Check f o r co nti nuity at th e Pink and Green/
orange wires betwee n th e ECT sensor 3P (Gray)
co nnect or t erminal and t he ECM 32P (Lig ht g ray)
co nnector te rm ina l.
Connection: 827 - Blue/y ellow
B26 - Gray/ black
YES - GO TO STEP 5.
NO _ . Open circuit in Blu e/y ell ow
Open ci rcuit in Gray/bl ack w ire
3P (GRAYlCONN ECTOR
5. Eel Sensor Out put Lin e Short Circuit Inspection

Check f or co nti nui ty bet ween th e ECT senso r 3P
3P (GRAYICONNECTOR
(Gray ) con necto r termina l of the wire harness
side and ground.
Conn ection: Blu e/yellow - gr ound
YES - Sho rt circ uit in Blu e/y ell o w wi re
NO - Repl ace t he ECM wit h a known good
o ne, and recheck

FUEL SYSTEM (Program m ed Fuel Injection )
MI L 8 BLINKS (TP SENSOR)
Bef ore sta rti ng the inspection, chec k f or loose or
poor contact on the T P sensor 3P (Black) connec-
to r and rech eck the M IL bli nking .
1. TP S en sor Out put Vo ltage
Tu rn the ignit ion switch OFF.
Co nnect th e ECM test harn ess t o ECM co nnec-
tors (pag e 6-111.
, ,, , ,on e-n-n-mn , , ,
II
I
I I I II l I 19""I>111$ "!
Turn t he igni tion switch ON and engine stop oooooooooooooooo~ 110 0 0 0 0 0 0 0 0 0 0 0 0 0 0 011
switch n n ". 000000 0000000000 000000000 000 00
Measure the TP senso r output voltage at the test I II ' ! l i 6 h tJh$lt lt B S lCti Ji!
harness term inals.
Connection: B30 (+1 - B26 H
Standard : * 0.4 - 0.6 V (throttle fully close d !
* 4.2 - 4.8 V (throttl e fully op en ed) e----(J) $
NOTE:
A voltage ma rked * refers to the value of the
ECM output voltage (STEP 3) w hen the volt-
age rea ding shows 5 V.
W he n t he ECM output vo ltage read ing shows
ot he r th an 5 V , de rive t he TP senso r o ut p ut
voltage at t he tes t ha rness as fo llows:
In the case of the ECM ou tpu t voltage is 4.75
V:
0.4 X 4.75 /5.0 = 0.38 V
0.6 X 4.75/5.0 = 0.57 V
T hu s, t he sol ution is "0.38 - 0.57 V" with th e
t hrott le fu lly closed.
Repl ace 0.4 and 0.6 w ith 4.2 and 4.8 resp ec-
tively, in the above equa tions to determ ine
the th rott le fully opened range.
Is th ere stan dard vo ltage?
YES _ . Int erm itt ent fai lu re
Loose or poor co ntac t on the ECM
co nnectors
NO - GO TO STEP 2.
2. TP Sensor Input Voltage Ins pectio n
Turn the ignition switch OFF.
Disco nnect the T P sensor 3P (Blac k) con nec to r. 3P (BLACK) CONNECTOR =~::1
T urn th e igni t ion switch ON an d eng ine stop I . '~.' I

swi t ch " () ,'.
Measure t he voltage at the wire harn ess side.
Con n ect ion: Yellow/red (+) - Gr ay / bl ack (-)
Is the vo ltage within 4. 75 - 5.25 V?
o
YES - GO TO STEP 4.
NO - GO TO STEP 3.

3. ECM Output Voltage Inspection
Turn t h e ig nit io n sw it ch OFF.
Con nect th e ECM test h arn ess t o ECM co nnec-
tors Ipage 6- 11).
i I I j I ! I 1 ,9 " it"""" , i 1 t. j , "! I 1 @IiIl'i,' "II'
Turn the ignit ion sw it ch ON and eng ine sto p 110000000000000000 0000 00000000000
sw itc h"n ". 0000000000000000 o 0000000 000000
M easur e t he vol t ag e at th e t est harn ess t erm i- i J! " ' T ,w :o ' S tlH"'fi)j ti l
nals.
Connection: B18 1+) -B26 H
Is the voltage within 4.75 - 5.25V?

YES _. Open ci rcui t in Yellow/red w ire
Open ci rcuit in Gray/bla ck wire
NO - Repla ce th e ECM w it h a known good
one, and recheck.
4. TP Sensor Output line Inspection
Chec k f or co ntinuity betwee n th e TP senso r 3P
(Black) co nnecto r t erm in al of t he wire harness 3P (BLAC K) CONNECTOR
side and ECM 32 P (Li g ht gray) co n necto r.
Connection: Red/yellow - 830
YES - GO TO STEP 5.
NO - Ope n circuit in Red/y ell o w wi re
5. TP Sen sor Out p ut Line Short Circuit Ins pecti on

Turn t he ig nitio n swit ch OFF.
3P (BLACK) CONN ECTOR
Chec k f or co nti nui ty bet w een th e TP senso r 3P
(Blac k) connecto r t erm in al of th e wire harn ess
side and g ro u nd.
Connection: Red/yellow (+) - ground (-)
YES - Sho rt ci rcuit in Red/y ell ow wi re
NO - Fau lty TP sensor

MIL 9 BLINKS (lAT SENSOR)
Bef ore st art in g the inspectio n, check f or loose or
poor con t act on the IAT sensor 2P (Gray) con nec-
t or and rech eck t he M IL blinkin g .
1. IAT Senso r Output Voltage Inspection
Turn t he ig nit ion sw it ch OFF.
Connect t he ECM test harness to ECM connec-
to rs (p ag e 6-11 ).
I , J , i t i i i i " D " Ri" i I t i j t I I i i l ,, " u IS ii '
Tu rn the ig nitio n switc h ON and e ngine stop
switch " () ". 0000 00000 0000 0 0 00 0 0 0 0 00000 00
0000 0 0 0 0 0 0 000000 0 0 00000 0 00000 0
Me as ur e t he v o lta ge a t th e test ha rn ess te rmi -
nal s.
Connection : 8 8 1+1 -826 (-)

Standard: 2.7 - 3.1 V (20 'C/68'FI
Is th e voltage within 2 .7 - 3. 1 V? e
YES _ . Int er mi t t en t fa ilure
Loose or poor contact on the ECM
connectors
NO - GO TO ST EP 2.
2. IAT Sensor Input Voltage Inspection
Turn the ign it ion swi tc h OFF.
2P (GRAYj CONNECTOR
Disconn ect the IAT senso r 2P (Gray) co nnector.
Turn the ignition swit ch ON and engine stop
switch " n ".
M easur e th e vo lta ge at t he w ire ha rne ss side of
IAT senso r connect o r.
Connection: Gray /blue - Gray /black
Is the voltag e within 4.75 - 5.25V?
YES - GO TO STEP 3.
NO - GO TO STEP 4.
3. IAT S ensor Re si stance Insp ection

Turn t he ign it ion sw itch OFF.
Disconn ect th e IA T senso r 2P (Gray ) co nnec to r.
c=J'
M easure th e resi st an ce at th e IAT sensor te rm i-
na ls (at 20 - 30 'C/68 - 86' F).
Standard: 1 - 4 kQ 120 - 30'C/68 - 86 F)
Is the resistance within 1 - 4 k f}?

NO - Faul ty IA T se nso r.
YES - GO TO STEP 4.
IAT SENSO R
6-21
Contents Chapter 6
4. IAT Sensor Open Circuit Inspection
Turn the ignit ion switc h OFF.
Check fo r co nti nuity at the Gray /b lue and Gr ay!
black w ires betwee n the IAT sensor 2P (Gray) ,,! ,, ! j ' j j ",iI"'"" '" I ! , I I f l . . . Ii !1!J 8" III
connect or t ermi nal and th e ECM 32P (Lig ht gray) 0000000000000000 000000 0 0000000
connector. 000000000 0 0 0 0 0 0 0 00000 00 0 000000
Are there continuity? I J! \I "'" fj fift "6 8" ":tI l' if l
YES - GO TO ST EP 5.
NO _. Open ci rc uit in Gray/blue wire
Open ci rcu it in Gray/black w ire
5. IAT Sensor Output line Short Circuit Inspection

Che ck fo r co ntin uity between th e IAT senso r 2P
(Gray ) co nnecto r termina l of th e w ire harness 2P (GRAY) CONNECTOR
side and g round .
Connection: Gray/blue - ground
YES - Sho rt circ uit in Gray /blue wire
NO - Repl ace th e ECM with a known good
one, an d rec hec k.
MIL 11 BLINKS (VS SENSOR)

Bef o re st art ing t he inspection , check f o r loose o r
poor co ntac t on the VS sensor co nnecto r and
rech eck the MIL bl in king.
1. Vehicle Speed Sensor Pul se Inspection
Turn the ig nit io n switch OFF.
Con nect the ECM test harn ess to the ECM co n-
ne ctors (page 6-11).
I j t. 4 I ! I I OIl " " u ti A " 1 I i l ' ! i l l it !J jJ II lt l
Support th e motorcycle sec urel y and place the
rear wheel off the ground . 000 ooooooooooo~1 11 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 011
000 000000000000] 11 0 0 0 0 0 0 0 0 0 0 0 0000 ] 1 I
Shift t he t ransm issio n into gear.
Measure the voltage at t he te st harness term i-
nal s with the ignition switch ON and eng in e sto p
sw it ch "n. wh ile slow ly turn ing th e rear wheel
by hand. 8 L-- - --{ V }-- - ----'
Connection: B25 (+) - A4 (-I
Standard: Repeat 0 to 5 V
/s there standard voltage?
YES _. Inte rmittent fai lu re
Loose o r poor co nt act on t he ECM
connectors
NO - GO TO STEP 2.
6-22
Contents Chapter 6
2. Combinati on Meter Ins pection
Check for operation of speed ometer.
Doe s the speedometer operate normally?
YES - Op en or sh ort ci rcuit in th e Brown/w hite
wire
NO - GO TO STEP 3.
SPEEDOM ETER
3. VS Sensor In p ut V ol t age In spection

Turn th e ig nition swit ch OFF.
Disconnect t he VS senso r 3P (Nat u r al) connec- 3P (NAT URALICONNECTO R
tor.
Turn the ig nit ion switch ON and engine stop
switch " () ".
Me as ure th e vo lt age at t he w ire harn ess sid e.
Co nn ect ion : Pink (+ ) - Gre en /bla ck (-)
C5i
1(----1"""\'<- 1
Is there battery voltage?

YES - GO TO STEP 4.
NO _ . Ope n circ uit in t he Pink w ire
Open ci rcuit in t he Green or Green!
black wire
4. VS S en s or Si gn a l Line Sho rt Circu it Inspectio n
Turn the ig nit io n swit ch OFF.
Check fo r co nt inuity bet w een t h e t est harn ess
and th e g ro un d.
'I " " " " ''!! '!''!,,' ''' ,! f " " " ' ID n1jjj,"' ii'
Connection: 8 25 - grou nd
Is th er e con tinuit y?
YES - Short circ uit in th e Pink w ire
NO - Ins pect the VS senso r (page 20-11I
6-23
Contents Chapter 6
MIL 12 BLINKS (No. 1 PRIMARY INJEC-
TOR) A: 32P (BLACK ) CONNEC TOR
rTlTT1~'"
Mil INJEC - POWER SIGNAL SIGNAL POWER IN PUT LINE
TOR INPUT LINE LINE ATECM
12 No .1
Lower
Black/white Pin k/yellow Al l
""',!lII i It) I i j i I H I! It" I. ,. 1]
0 000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00000 0 00
0
13 No .2 Black/white Pin k/blue A12
00000 0 0 0 0 0 0 0 0 0 0 0 0000000000 0 0 000 0
Lower
i ll .. ri Slh HhiUi8tt3ijil., # 1 ,,! yl l b " jj b8 t!8& *,ij ,
14 No .3 Black/white Red/wh ite A 13
Low er
15 No.4 Black/w hit e Yellow/r ed A14
Lower
16 No .1 Black/white Pin k/y ell ow A9 B: 32P (LIGHT GRLONN ECTOR
Upper
17 No .2 Blacklwhite Pin k/b lu e Ala
Upper
48 No .3 Blacklwhite Pin k/g re en A15
Upper
49 No .4 Black/white Pi nk/b lack A 16
Upper
1. Inject or Circu it Resi sta nce Ins pection

Turn the ig nitio n switch OFF.
Con nect t he ECM t est harn ess to t he ECM con -
nect or s (page 6-11).
'illllll~
. " j i !. " . " l' U Ji " lIi ., j j . i t I . IDll Jl flJi" '"
Measu re the resistance at th e test ha rness term i- 110 0 0 0 0 0 0 0 0 0 00000

na ls . ~ 000 0 0 000 0
110 00000 1 0 000000
0 0 0 0 0 0 0 000
0 0 0 0 000
000
Co nn ecti on: POWER INPUT LINE - SIGNAL AT I .l U i
ECM
YES - GO TO STEP 4.
NO - GO TO STEP 2.
2. Inj ector Resist ance Insp ectio n

Disconnect th e NO.1 p ri m ary injector 2P connec-
tor and measure the resistance of the No.1 pri - NO.1 PRIM ARY INJECTOR 2P CONN ECTOR
mary injector 2P connector termina ls.
c:J
Is the resis tan ce w ithin 10.5 - 14.5 fl (20 "C/
68 "F)?
YES
NO
- GO TO STEP 3.
- Faulty injector


3. Inj ector Input Voltag e In specti on
Tu rn the ig nitio n switc h ON and engine sto p
sw itch " n ". NO.1 PRIM A RY INJECTOR 2P CONN ECTO R
Measure t he v o lt ag e be twee n t he No . 1 p ri mary

i nject or co n necto r of the wi re harn ess side and
g ro u nd .
Con nect ion : POWER INPUT LINE (+ ) - ground H
Is th ere batter y voltage?
YES - Open circ uit in SIG NA L LIN E w ire
NO - Op en circ uit in POWER INPUT LIN E w ire
4. Injec tor Sig nal line Short Circuit Ins pect ion
Check fo r cont in ui ty betw een t h e t est harness , -- - - - - - - - -- - - - - - ----.
termin als and grou nd .
Co nn e ct ion: SIG NAL AT ECM - gro u nd l I t i f I i ! 1 1 . 11 1. 1>'11 11" i ! I f 1 I In ,tll!J" ij i
Is th ere continuity? 0000 0 00 0 0 0 00000 000000000000000011

0000000000 00000 0000000000000000
YES _ . Short ci rc uit in th e SIGNAL LINE wi re
LlLJiJD'lli1illt:h1i1lli10!lliill
Fau lty in j ecto r
NO - Rep lace t he ECM with a known good
one, and rech eck
MIL 13 BLINKS
(No.2 PRIM ARY INJECTOR)
(page 6-24 )
MIL 14 BLINKS
(No.3 PRIMARY INJECTOR)
(page 6-24)
MIL 15 BLINKS
(No.4 PRIMARY INJECTOR)
(page 6-24 )
MIL 16 BLINKS
(No.1 SECONDARY INJECTOR)
(pa ge 6-24)
MIL 17 BLINKS
(No.2 SECONDARY INJECTOR)
(pag e 6-24)
MI L 48 BLINKS
(No .3 SECONDARY INJECTOR)
(p ag e 6-24 )
MIL 49 BLINKS
(No .4 SECONDARY INJECTOR)
(p age 6-24)
6-25
Contents Chapter 6
MIL 18 BLINKS (CMP SENSOR)
Before st art ing t he inspect ion, ch eck fo r loose or
poo r contact on t he eM? sen so r co nnecto r and
recheck the MIL bl inking.
1. eM? S ens o r Pea k Vo lta ge In s p ect io n at ECM
Turn the ig nition switc h OFF.
Co nne ct th e ECM t est harness to the ECM co n-
nec ta rs (page 6-1 1).
! t t j 1 ft , t 111 Jf Jl!! IS Ii , I! j :I 4 t ! 1 t '9 11 Ill! lUi, "
Tu rn t he ignit ion swit ch ON and eng in e sto p !
switch " n ". 00000 0 0000000000 00 000 0 0 0 0 0 0 0

Crank t he engine w it h t h e sta rte r moto r, and 0000000 00 0 0000 0 0 0 0 000 0 00 000000
measu re th e eM ? se nsor peak vo lt age at t he t est :ID 1 19 1011 1' ,, "
harn ess t erm ina ls.
Conn ection : B10 1+1 - A31 I-I e

Is t he vol tage more than 0.7 V (20 'C/68 OF)?
YES _. Int er m ittent f ailu re
Loose or poor co nt act on t he ECM
co nnect o rs
NO - GO TO STEP 2.
2. eMP S ensor Peak Voltag e Insp ecti on
T urn the ig nit io n switch OFF.
Discon nect the eM ? sen sor 2P (Black) con nector.
T urn the ig ni t io n switc h ON and engine stop
switch " n ".
Cran k t he eng in e w ith th e st arte r motor, and
m easur e the CMP sen so r pea k vo lt age at t h e
CM P se nsor 2P (Black conn ect o r.
Conn ection: Gr ay (+) - White/ bl ack H

Is the vo ltage m o re tha n 0.7 V (2 0 'C/ 68 "F)?
YES - Op en o r short ci rcu it i n the W hi te /black
wire or Gray wire
NO - Faulty CM P sens or
6-26
Contents Chapter 6
M IL 19 BLINKS (CKP SENSOR)
Before starting th e inspection , check f o r loose or
poor con ta ct on the CKP sensor connecto r and
rech eck th e M IL bl inki ng .
'l . CKP Sensor Peak Voltage In spection at ECM
Turn t he igni t io n s w itc h OFF.
Connect the ECM te st harness t o the ECM con-
nectors (page 6-11).
I! t" . f t I I IOtt,' ' ' Ii!'!. '
Tu rn the ign it ion switc h ON and eng ine stop 00000000000000 00
switch " () ". 00000000000000 0
Crank the en gine w ith th e starter motor, and
measure t he CKP sensor peak voltage at th e tes t
harn ess te rm inals.
Connection: B11 !+) - A31 H e

Is the voltage more than 0.7 V (20 "G/68 OF)?
YES - . Intermitte nt failure
connecto
Loose or rspoor co nt act on th e ECM L --'
NO - GO TO STEP 2.
2. CKP Sensor Peak Voltage In spection
Turn th e ig nitio n s witch OFF.
Di scon nect t he CKP sensor 2P (Red) con nec tor .
Turn the ignition swit ch ON and engine stop
switch " () ".
Crank the eng ine with the starte r motor, and
m easure the CKP senso r pea k vo ltage at t he CKP
sen sor 2P (Red) connector.
Connection : Yellow !+l - White/black H

Is th e vo ltage more t han 0.7 ~ (20 C/ 68 OF)?
YES - Op en or short circuit in the Yellow,
Wh ite /bla ck w ire
NO - Faul ty CKP senso r
6-27
Contents Chapter 6
MIL 33 BLINKS (EEPROM)
1. Recheck MIL Blinks 1
Reset the self -d iagno sis m emory data (page 6-
10). .
Turn th e ign it ion swi tch ON and engine sto p
sw it ch" n ".
Chec k t hat th e MIL bl ink s.
Does th e MIL blink 33 times?
YES - Repla ce t he ECM w it h a known good
one, an d recheck.
NO - GO TO STEP 2.
Turn th e igniti o n switch OFF.
Short th e dat a link conn ect or with t he SCS ser -
vice co nnect o r (070PZ-ZY30 100).
Tu rn th e ig nit ion sw it ch ON and engi ne sto p
swlt ch " n ".
Check tha t th e M IL bl in ks.
Do es the MIL blink 33 times?
YES - GO TO STEP 3.
NO - Intermitte nt failure
~0
DATA LINK CONN ECTOR

Reset t he self- diag nosis m em o ry dat a (pa ge 6-
10).
Tu rn the ig nit io n switc h ON and e ngi ne sto p
switc h ." n ".
Check that th e M IL blink s.
Does the MIL blink 33 times?
YES - Rep lace t he ECM wit h a known good
one , and rech eck.
NO - Interm itt ent fai lure
MIL 34 BLINKS (EGCV POT)

Befo re sta rti ng t he in spect ion, check fo r loose or
poor con tac t on t he EGCV se rvomotor connecto r
and rech eck the MI L blinking.
1. EGCV POT Output Voltag e
Tu rn the ignition switch OFF.
Co nnect the ECM tes t ha rness to ECM co nnec-
t ors (page 6-11).
Turn the ig ni ti o n sw itc h ON and engine stop I I t I I 1 , I IRIi Jl '"' .. ,$ III II t ' I j I I 'PUll Ii .. II I" '
sw itc h " n ,'. 00 0 0 00 0000000000 0 0000 0 0 00000. 0 0 0

Measu re th e EGCV POT out put v oltage at th e 00000 000000 00000 0000000 0 ,0 0 0000
t est harn ess te rm ina ls. I " II Ii .. ' I tl ll 1. itKifjfinOOD
Connection: B24 (+) - B26 H
Standard : 2.0 - 2.1 V
Is there standard voltage?
YES _. Int er m itt ent failu re
e
Loose or poor contact on the ECM
co nnect o rs
NO - GO TO STEP 2.
6-28
Contents Chapter 6
2. EGCV POT Input Voltag e Inspection
Tu rn the ign iti o n switch OFF.
Disconne ct the EGCV se rv o m ot o r 6P (Nat ural) 6P INAT URA L) CONNECTOR
con necto r.
Turn th e igniti on switch ON and en gine st op
switch " () ".
Measure the v ol ta ge at th e w ire h arness side .
Co nnection : Yellow/red (+) - Brown /black H
Is the voltage within 4.75 - 5.25 Vl

NO - GO TO STEP 3.
3 . ECM Output Voltage Inspect ion

Turn th e ig nitio n sw itch OFF.
Connect the EGCV se rv om ot o r 6P (N at u ral) co n-
nector.
I! ? 1 ! , I , I I .. " Jf" Ii ,S II i j ) j ) i , I ! I i 'p 1l 11 " II II Iii
Turn the ignition switch ON and eng ine stop 0 0 000 0 000 0 0 0 0 0 0 0 0 00000000000.01 1
switch "' () "'. 00000 0 000 0 0 0 0 0 0 0
Measure the v ol tage at the t est ha rness te rmi- J 11 Ii 'i II! II n Il flU !' II " tI 'Ill' ti l " 8 SiI '))21
nal s.
Connection: ara 1+I-B26 H
Is th e voltage within 4.75 - 5.25V7
YES _. Open ci rcuit in Yel low/red wire
Op en cir cuit in Green /o ra nge wire
NO - Repl ace t h e ECM with a known good L -..J
o ne, and rech eck.
4. EGCV POT Output Line Inspe ction
Check for co nt inui ty betwee n the EGCV se rvo-
m ot or 6P (Natural) connect or t erm in al o f t he
wi re harness side and ECM 32P (Lig ht gr ay) co n- i ! I ,0 " it 11 i, II Ii
i ' I , I ! I . ,0 n 1l " " I" " j ,
necto r.
Connection: Light green/black - 824 I r oooooooooooooooo~ I 0000000 900 0 000011
0000000000000000
Is there continuity? 117jl K'" ti h 5I.S a n d a ilil Ii i
YES - GO TO STEP 5.
NO - Open ci rcuit in Light green/b la ck wire
5. EGCV POT Output line Short Circuit Inspection

T urn the ig nit ion sw it ch OFF.
6P INATU RALI CONN ECTO R
Check f o r co nt in uity between th e EGCV servo-
m oto r 6P (Na t u ral) co n necto r t erm ina l of t he
w ire ha rn ess si de and ground.
Connection: Light green /black (+) - ground (-)
YES - Short circuit in Li ght gree n/b lack wire
NO - Faulty EGCV se rv o m ot o r
6-29
Contents Chapter 6
MIL 35 BLINKS (EGCV SERVOMOTOR
LOCK)
Bef ore starting t he ins pection, c hec k fo r loose or .
po o r co nta ct o n t he EGCV se rvo moto r co nnector
and recheck the M IL blinkin g.
1. EGCV Op eratin g Inspection
Disconn ect the EGCV co nt rol ca ble s f rom t h e , - - -- - -- - -- - - - - - - -----,
exhaust v alve pulley (pa ge 6-76 ).
Turn t he ig nition switch ON .
Chec k th e EGCV servo motor pu lley rotation
w hen short in g t he OLe wit h t h e SCS service co n-
nect or (page 6-9).
Does th e EGCV servom ot or pulley operat e cor-
re ctly?
YES _. Check th e EGCV cab les bin ding ,
st icki ng o r lo ck.
Check t he EGCV at muffler side .
NO - GO TO STEP 2.
2. EGCV S ervomotor Inspection

Turn th e ignit ion switch to OFF.
Rem ov e t he EGCV servomot o r (page 6-78 ).
Connect th e 12 V battery to th e EGCV servom o-
to r connect or t er mi nals and c heck t he servomo-
t or function.
Conn ecti on: Red (+) - Bl u e (-)
c c
Does th e EGCV se rvom otor operate n ormally?
e
NO - Faulty EGCV se rv o m ot o r
3. ECM Output Line In sp ectio n

Con nect th e ECM te st h arn ess t o ECM con nec-
tors (p age 6-11).
Check for co nti nui ty between th e EGCV se rv o- Ii t i . i , I , 'O!I it II U ,. " I
Ii " . t I I j " Ji "" ,Sii i
I II
50
m ot o r 6P (Na t ural) co nnecto r t erminals of th e
0 0 000 0 0 0000000 ) 00 00000000000
w ire harness side an d ECM 32P (Black) co nnec-
000000 00000000 oooooooooooooooC?J I
tor.
i ltjj m v pp MBal!H " ~ ~ ij i
Co nn ectio n: Red (+) - A7 H
rei9
Blue (+) - A 8 H
Is there continuit y?
Q
YES _. Open circuit in Red w ir e 1' 1
Ope n circuit in Blue w ir e I I I I
NO - Replace th e ECM w ith a known good
o ne, and rech ec k.
6-30
Contents Chapter 6
FUEL SYSTEM {Programmed Fuel lnject ionl
FUEL LINE INSPECTION
FUEL PRESSURE IN SPECTION
Before disco nne ct ing fue l hos es, rel ease th e fu el pressu re by loos-
en ing th e fue l fe ed hose ba nj o bo lt at the fue l t ank.
Failu re to re lease th e fu el press ur e co uld resul t in fu el sp ill ing on t o
paint ed o r plast ic parts, w hic h w il l be damaged .
Always re plac e th e seali ng w ashe rs wh en th e fuel f eed hose banj o
bo lt is rem o ve d o r loosened.
Rem ov e the seat (pag e 3-4).
Disconnect th e battery negati v e cable from t he battery te rm inal.
Lift and su pport th e fue l t ank (p age 4- 51 .

Cove r t he service check bol t o n th e seco nda ry inj ect or fue l rail with a
rag or shop t o w el.
Sl owly loosen t he serv ice check bolt and catc h th e remai nin g fu el
using an ap prov ed ga so line co nt ai ner.
Rem ov e th e serv ice che ck bol t and seali ng w asher.
Attac h th e fuel pre ssure ga uge to t he fuel rail.

FUEL PRESSURE GAUGE
TOOL:
Fuel pressure gaug e 07406-0040003 or
0740 6-o 04000B o r
07406-o04000A
(U .S.A. on ly)
Conn ect t he batt ery negat iv e cab le.
Start th e en gine.
M easure the fue l pressure at idle speed.
IDLE SPEED: 1,200 100 rpm
STAN DARD: 343 kPa (3.5 kgf/e m'. 50 psi)
If t he fuel pr essu re is high er tha n speci fie d. replace t he fuel pum p unit
(page 6-34 1.
If th e fuel pressure is low er t han sp ecifi ed. inspect t he foll ow ing :
- Fuel line le aki ng
- Fu el straine r (pag e 6-34)
6-31
Contents Chapter 6
A lways replace the After ins pe ctio n, rem o v e t he pr essure gau g e and
sealing wash er rein st all an d ti gh t en t he serv ice c hec k bolt us in g a
whe n the service new sea ling was her.
check bolt is
removed or loos- TORQUE: 12 Nrn (1.2 kqf-rn, 9 Ibl-ft)
ened.
Rem o ve the suitable suppo rt and close th e fu el t an k
(page 4-5).
In st all th e rem oved parts in th e rev er se order of
removal.
FUEL FLOW INSPECTION

Rem ov e th e left mid dle co w l (page 3-7 )
Rem ov e t h e relay box fr om th e br ack et .
Release the reta iner s (brow n ) and remove the re lay

co nnecto r ba se.
Remove the fuel cut-off relay from the connector.
Jum p t he Bro w n and Black/wh it e w ire te rmi nals o f

the wire harn ess side usi ng a j umper w ire.
JUM PER W IRE
6-32
Contents Chapter 6
Do not apply exces- Remove t he f uel pi pe joint m ou nting bo lts, th en dis-
sive force or the connect the f uel jo int hose from t he secondary
fuel rail may be in jecto r fuel rail.
dam aged.
Place an approved gaso line containe r and drain
the gasoline.
W ipe off spill ed gasoli ne.
Turn the ign ition switc h ON f or 10 seconds.

FUEL JOINT HOSE
Measu re the amoun t of fuel flow.
Amount of fuel flow :
189 em " 16.4 US OZ , 6.7 Imp QZ) minimum
'10 seconds at 12 V
If the fue l flo w is less than sp ecifi ed, in spect th e fol-
lowing :
- Pin ched or clogged fue l hose
- Fuel pump un it (page 6-331
After in sp ecti on , install a new O-ri ng int o th e groove

of the f uel joi nt hose .
Be caref ul nor to Insta ll th e fuel j oi nt hose t o th e secondary inj ect or
damage the O-ring fu el rail, tighten the tw o bolt to the spe cifie d to rque .
while instalfing the
TORQUE : 9.8 Nm (1.0 kqf-m, 7 Ibf.ft)
fuel joint hose to
the fu el rail. Sta rt t he engine and check for fu el leaks.
FUEL PUMP UNIT

INSPECTION
Turn th e ig nit ion switc h ON and co nf irm th at th e
fuel pump op erates f o r a few seco nds.
If the fu el pump does not opera te, inspect as fol -
low s:
Lift and suppo rt the fu el tank (page 4-51.
Discon nect t he fue l pump unit 3P (Black) con nector.
6-33
Contents Chapter 6
Tu rn the ignition sw itch O N and measur e t he volt -
age betwee n the term inals. 3P (BLACK) CON NECTOR
Connection: Brown (+) - Green (-)
Th ere shou ld be batter y vo ltage f or a few seco nds.

If the re is battery voltage a few seconds, replace t he
fuel pu m p un it.
If the re is no battery vo ltage, inspect t he fo llowi ng:
- M ai n fuse 30A
- Sub fuse 10A
- Eng ine sto p sw itch (page 20-19)
- Fuel cut-o ff relay (pa ge 6-351
- Eng ine sto p relay (page 6-68)
- Bank ang le senso r (page 6-6 7)
- ECM (page 6-70)
REMOVAL
Befo re disconnecting fuel hoses, release t he fu el
press ure by looseni ng t he fuel feed hose banjo
bolt at the fuel tank.
Failu re to release the f uel pressure cou ld resu lt in
fue l spil ling onto painted o r plastic parts , wh ich
wil l be da mag ed.
Always re place t he sealing washers w hen the
fue l feed hose ba njo bo lt is rem oved or loos-
ened.
Rem ove th e fuel ta nk (pag e 6-36 ).
Remove th e f uel pump unit m ountin g nuts, cla m p,
fu el hose gu ide and breath er hose gui de.
CLA M P BREATHER HOSE GUIDE

Be careful no~ to __ Removethe f uel pump unit and packing .
FUEL PUMP UN IT
damage the pump
wire and tuet tevel
gauge.
IN SPECTION
Che ck the f ue l pum p u nit fo r wea r or dama ge,
FUEL STRA INER SCREEN
re place it if necessary .
Clea n th e fuel stra ine r screen w ith no n-f lam m able
or high flash po int so lvent.
FUEL PUMP UN IT ASS EMBLY
6-34
Contents Chapter 6
INSTALLATION
A lway s replace the Place a new pac ki ng o nto th e fu el pump un it .
FUEL PUMP UNIT
packing w ith a new
one.
Be careful not to Insta ll the fuel pump un it i nt o th e fuel t an k.
dam age the p ump
wire and fuel level
gauge.
Insta ll the ho se guid es and cla mp an d tighten th e ,..-- - - - - - - - - - - - - - - - ----,

fue l pu mp unit mountin g nuts in t he spe cifie d
sequ ence as shown.
TORQUE: 12 Nm (1.2 kqf-m , 9Ibfft)

Inst all the fuel t ank (page 6-381.
BREATHER HOSE GU IDE
FUEL CUT-OFF RELAY

INSPECTION
Rem ov e th e f ue l cut-off relay from t he re lay bo x
(page 6-32) . FUEL CUT-OFF RELAY BATIERY
Connec t th e ohmm et er to th e fu el cut-off relay con-

nector ter m in als .
Connection: A - B
Co nnect the 12 V batt ery to th e f o llo w in g fuel cut-off
rel ay co n nec tor t erm in als. A C
LJ
~
Connection: C (+) - D (-I
There sho uld be conti nui ty on ly w he n the 12 V b at-
t ery is connected . If th er e is no co nti nuity w he n the
12 V batt ery is co nnected, replace t he fuel cut-off B D
relay.
6-35
Contents Chapter 6
FUEL SYSTEM (Programmed Fuellnjectionl
FUEL TA NK
REMOVAL
Remove the top she lte r (page 3-16).
Remove t he fuel tan k f ron t m ounting bolts.
Disconnect the fu el tank drai n hose f rom t he h ose ~~~~~~~~~~~~~~~~~

j oint as shown.
Lift the fu el tank as shown.
DRAIN HOSE
Support the f uel t ank us ing a su itable supp ort.
6-36
Contents Chapter 6
Di sconn ect th e fue l pum p un it 3P (Black) co nnec t o r. f
Disconne ct t he fue l t ank dr ain h ose and breather

hose.
Cove r th e fue l hose banj o bolt w it h a rag or sho p

t ow el.
Slow ly loosen t he banjo bolt and catch the rema in -
ing fuel usin g a approved gas oline co nta ine r.
Remove the fu el hose banjo bolt and sea ling was h-
ers, then disconnect the fu el hose.
Bef ore disconnectin g fu el ho ses, release t he fu el
p ress ure by loosening the fu el fe ed ho se ba njo
bo lt at the fu el tan k.
Failu re to release the fu el pressure could result in
fu el spill ing on to pain ted or pl ast ic parts. which
w ill b e damaged.
Alway s replace th e sealing w ash er s w he n th e
fuel fee d hose ba njo bolt is rem ov ed or loos- ....
ened.
""'_;L
Rem ov e the sui table support and clo se the f uel tank .
Remov e the fu el tan k piv ot bolts, colla rs an d fue l
t ank.
Refer to pro cedu res f or fu el pump unit rem ov al
(page 6-34 ).
6-37
Contents Chapter 6
INSTALLATION
FUEL TANK
DRAIN HOSE
In stal l t he f ue l tank, co lla rs and pivot bo lts Into t he

fra me an d t ighten th e bo lts secure ly .
Open an d suppo rt the fue l t ank (pa ge 4-5).
Align the fue l hose Install the new sea ling w as hers and t ig hten the fu el
evetet ioint with the hose banjo bolt t o th e sp ecif ied to rque .
stopper on the tue!
pump mounrmg TORQUE: 22 Nm (2.2 kqf -m , 16 Ibfft l
stay.
6-38
Contents Chapter 6
Route the hoses Conn ect the f uel tank d rain hose and bre ather ho se.
properly (page 1-
24).
Co nnect t h e fu el pu mp unit 3P (Black) co nnect o r.
Rem ov e the suita ble support and close the fuel ta nk

on th e frame .
NOTE : RED LINE (BREATHER HOSE )
Route the h os es, wi re s and h arn ess prop erly
(p ag e 1-24 ).
Be caref ul n ot to damage th e h arn ess and hoses.
Do not twi st th e br eath er hose or proper fu el
supply would be obstruct ed . Check the red line
o n th e breath er hose.
After install ing t h e fuel t ank, mak e sure th e drain,
br eather an d fu el ho ses are not kinked or boun d .
6-39
Contents Chapter 6
Install and ti gh t en th e fuel tan k front mount ing bo lts
to the specified torq ue.
TORQUE : 26 N m (2.7 kqf-rn. 20 Ibfft)
Ti ghten t he fuel t ank rear mounti ng bo lts to th e

speci fied to rque .
TORQUE : 9.8 Nm (1.0 kqt -m , 7 Ibfft)
Install the top shelte r (page 3-16).
AIR CLEANER HOUSING

REMOVAL
Rem ove the air clea ne r elements (page 4-81.
Remove the screws and sub harness clamps.
Remove the fi ve bolts and seco ndary inj ect o r
m ounti ng bracket from the air cleane r housing .
Remo ve th e eight screws and upper ai r c leane r

housing.
Rem ove th e air f unnel/ai r cl ea ne r hou sing m ounting

screw s, th en remove the air fun nels.
6-40
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Inj ect io n)
Remo ve the ai r cleaner housing mounting screws.
Disconn ect th e PAIR air suction hose from the air

cleaner housing .
Disconn ect the crankcase breat her hose fr om th e air

cleane r hou sing.
Rem ov e the air cleaner housing .
Remove the oil sepa ratio n cham ber from the lower
OIL SEPARATION CHAM BER
air cleane r housing.
6-41
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Inj ect ion )
INSTALLATION
Inst al l t he oil sep aratio n chambe r to t he low er air
OIL SEPARATIO N CHAMB ER
cle aner housi ng.
Co nnect the cr an kcase breather hose to t he ai r

cl eaner ho usi ng .
Co nnect the PAIR ai r suction hose to the air cl ean er

hou sing.
Insta ll t he air c leaner hous ing onto t he th rott le bod y
---- and air intake d uct. --~ -----
Inst all the lower air clea ner h ou sin g o nto t he ai r

int ake duct, tig hten th e mou nt ing screws.
TORQUE: 1.2 N m (0.12 kq f -rn , 0.9 lbf-ttl
6-42
Contents Chapter 6
Install th e air funnels in th eir proper locations.
Install and ti g hten th e air fun ne l/ai r cle ane r h ou sing
m ounting sc rews.
TORQUE: 4 .4 Nm {O.45 kqf- m, 3.3 lbf-ttl
Insta ll th e upper air cleaner hou sing and ei g ht

screws.
Tig hte n the s crews.
TORQUE: 1.2 Nm (0.12 kqf-rn, 0.91bf.ft)
Inst all th e secon da ry injector mounting br acket onto

th e ai r cle aner h ousing .
Tight en the bolt s t o th e spec ified t orqu e.
TORQUE: 5.4 Nm (0.5 5 kqf-m , 4 Ibf.ftl
Insta ll the ai r cleane r elem ent (p-age 4-8) .
SECONDARY INJECTOR
INSPECTION
St art th e eng ine and let it idl e.
Confirm the injecto r operat in g sounds w ith a so und- SOUNDING ROD
in g rod o r stet hoscope.
NOTE:
Th e secondary inj ectors operate wit h fo llowin g co n-
ditions.
- Engi ne spe ed is over 5,500 r pm
- T hr ott le ope nin g is over 200{ 1/4)
6-43
Contents Chapter 6
REMOVAL
Before disconnecting fuel hoses, release the fuel
pressure by loosening the fuel feed hose banjo
bol t at the fuel tank.
Fail u re to release the f uel pressure could result in
fuel spill ing onto paint ed o r plastic pa rts, which
will be da maged.
Always repl ace t he sea ling washe rs when the
fue l feed hose ban j o bo lt is rem o v ed or loos-
e ne d.
Rem ov e t he w ire ba nd .
Rem ov e th e h arn ess cla mp sc re ws.
Discon n ect th e seco nd ary inj ect o r co nne ct o rs.
Lift and support t he f ue l t an k (pa ge 4-5) .
Do not apply exces- Remove th e fuel hose j o in t m o unt in g bo lt s, then

s iva torce or the disconnect the fuel j o int hose f rom t he secondary
fue l rail m ay be injector fuel rail.
damaged.
Rem ov e t h e t h ree f uel rai l m o u nt in g bo lts.
Remove the f uel rail /seco nda ry inject or asse mbly

f rom t he m ount ing br ac ket.
c
FUEL RA IU SECONDA RY INJECTOR ASSEMB LY
6-44
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Inj ection)
Remove t he injectors f ro m the fuel rail.
Remove t he du st sea ls.
Rem o v e the O-r ing and cus hion rin g.

DUST SEA L
O-RING
I
/o
CUS HION RING
INSTALLATION
Apply oi l to a new O-rin g .
DUST SEAL
Replace the seal Install the new cus hion ring, and O-ring, being care-
ring, cushion ring ful not to damage the Oring .
and O-ring w ith
S~ ,
new ones as a se t.
O-RING
~
0
/
S CUSHION RING
Install t he fue l in jectors int o the fuel rai l, bein g care -

ful not to damage the O-ring a nd cus hion ring .
Check the dust seal for wear or damage, replace it If
necessary.
6-45
Contents Chapter 6
In st all th e f u el rail/second ary inj ect o r assem bly on to
the mounting b rac ket, being careful not t o damage
the sea l ring.
Ti ght en th e fu el rail m ounting b olt s t o the specif ied

to rq ue.
TORQUE: 9.8 N m n.o kgf-m , 7 Ib/ft)
Afte r insp ect ion, inst all a new O-ri ng into t he g roov e
of t he fu el j oint hose.
Be careful no r to Insta ll t he fu el j oi nt hose to th e sec o ndary inject o r
damage the O-ring fue l ra il, tighte n th e tw o bo lt to the specified to rq ue .
while installing the
fuel joint hose to
TORQUE: 9.8 Nm n .o kgf-rn, 7 lbf-ft}
the fuel rail. St art t he eng ine an d chec k fo r leaks.
Conn ect th e seco nd ary inject or co nnectors.

Inst all and t ig hte n t he h arn ess cl am p screw s.
Secur e th e w ire harn ess to t he f ue l rail using a wi re
ban d .
Inst all t he rem oved pa rt s in th e reverse or d er of
rem ov al.
6-46
Contents Chapter 6
FUEL SYSTEM (Program m ed Fuel Injection)
THROTTLE BODY
REMOVAL
Before disconnecting fuel hoses, releas e the fuel
p ressure by looseni ng th e service check bol t at
t he seco nd ar y inj ect o r fu el rail.
Failu re t o release t he f ue l p ressure co u ld result i n
fu el spi lling onto paint ed or pl astic parts, which
will be damaged.
A lways replace the sealing washe rs when the
service chec k bo lt is rem ov ed or lo o sened .
Drai n t he cool ant from th e co o ling sy st em
(page 7-6) .
Remove t he following :
- Under cowls/middle cowls (page 3-71
- Fuel tank (page 6-36)
- Air cl eaner h ou sing (page 6-40)
Unfast en t he wi re ban d s and re lease t he wi re har -
ness f ro m t he fuel rail.
Remove the sealing nut, sealing washers and fuel
joint ho se from the primary inj ect or fuel rail.
Di scon nect t he M AP sens o r 3P (Black) con nector.

Disconn ect th e prim ary f u el i njecto r conn ect o rs
from t he injectors.
Disconnect t he EVA P vacuum hose from the vac-
uum junction lAC type only).
Discon nect the vacuum cham be r hose f rom t he
t hrott le bo dy.
Disco n nect the TP sensor 3P (Black) connector.
6-47
Contents Chapter 6
Remove t he f uel feed hose sealing nut while h old-
ing t he fuel rai l.
Loosen th e hose cla mp sc rews and disconnect th e

wate r hoses from the idl e ai r control (lAC) th erm al
va lve.
Loosen the lo ck nu t s and disconnect t he thrott le

ca b le e nds f rom th e t hrottl e dru m.
Rem ov e t he t hrottle stop sc rew kn ob from t he

clamp o n t he by pass h ose.
6-48
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Inj ecti on)
Loose n t he engi ne side insul at o r band screws usin g
a lo ng phillips screwd rive r.
Do not hold the fuel Rem ove the th rott le body fr om the cy linder. head.
rail on the thro ttle
Seal the cyli nder head int ake po rts w it h ta pe o r a
body to remove the
clean cloth t o kee p d irt and debri s f rom en te ring
thrott le bod y- or it
th e in ta ke po rt s after the th rottl e bod y has been
may be damaged .
rem oved . If debris is all owed t o ent er th e ports
the engine m ay be dam ag ed .
Do no t snap the th rott le valve from f ully open to
f ully clo sed afte r th e thr ottle cable has be en
re m oved . It may cause inco rrec t id le ope rat io n.
Do not dama ge t he thrott le body . It m ay cau se

in co rr ect th rottle and id le valve sy nchronizat io n.
The th ro ttle body is fac to ry p re-set. Do not d isas-
semble in a w ay other tha n sho wn in th is m an-
ual.
Do not loosen o r tig ht en th e painted white bolts
and sc re w s of th e thro tt le body. Loosenin g o r
ti gh tening th em can cause th rott le and id le va lv e
syn chro nizatio n failure.
TOP VIEW:
9.8 N'm (1.0 kqf-m , 7 lb f-tt !
6-49
Contents Chapter 6
REAR VIEW:
0.9 Nm (0.09 kqf-m, 0.7 lbf-ft) 0.9 Nrn (0.09 kqf-rn, 0.7 lbf-ft ]
PAINTED WHITE PAINTED WHITE
o o
PAINTED WHITE
3 N vm (0.35 kq f-rn , 2.5 lb f-tt)
PAINTED WHITE
PAI NTED W HIT E PAINTED WHITE 0.9 Nm (0.09 kgf m , 0.7 lb f -ttl
6-50
Contents Chapter 6
THROTTLE BODY VACUUM HOSE
ROUTING
EXCEPT CALIFORNIA TYPE:
CALIFORNIA TYPE:
6-51
Contents Chapter 6
INSTALLATION
Ad just th e in sulator band angle as shown.
Ap pl y o il t o th e i nsul ato r ins ide surfaces for eas e of
th rottle bo dy insta llatio n.
Do not hold the fuel Inst all th e th rottle body int o th e ins ulators .
rail on the uvoute
body to install the
tnronie body.
Tight en the t hro tt le body side insulat o r b and screw

so that the in sulato r ban d d ista nce is 7 1 m m (0.3 7 1 m m to .S 0.04 in)
0.04 in ).
Route th e th rottle stop sc rew knob prope rly , instal l

it onto th e clam p.
6-52
Contents Chapter 6
Route the throttle Con nect th e throttle cable ends t o th e t hrottl e dru m .
cables properly
(page 124) .
Conn ect th e water hoses to t he lA C th erm al va lve

and t igh te n t he hose clamp screws.
Inst all the fuel fe ed hose to t he fue l rail with new ~::::~~::=~::~~~~~~~':'
sealing was hers.
Inst al l and tighten the sealin g nut t o th e speci fie d
torqu e w hile hold ing the fu el rai l.
TORQUE : 22 Nrn 12 .2 kqf -m, 16 Ibf.ft)
Conn ect the TP senso r 3P (Black) connector.
6-53
Contents Chapter 6
Co nnect t he p rimary f ue l in jector con nec t ors to t he
injecto rs.
Connect t he EVAP vacu um hose to th e vac uum
j u nct io n l A C t y pe o n ly).
Connect the va cuum cha m be r ho se to t he thrott le
body.
Con nec t th e MAP se nsor co nn ect o r.
Inst all th e f ue l joi nt h ose t o t he pr ima ry inj ect o r fu el

rail wit h new sea li ng was he rs.
Inst all t he sea ling nut.
Tig hten t he se ali ng n ut to th e speci fied t o rqu e w hile
holdi ng the fu el ra il secu rely .
TORQUE: 22 Nm (2.2 kqf-m, 16 lbf-ft]
Secu re t he wi re harn es s to th e f ue l rail u sin g w ir e

ba nds .
Inst all the rem ov ed p arts in t he reve rse o rder of
rem ov al.
After ins ta llation , ad just the t h rott le g rip free pl ay
(page 4-7).
PRIMARY INJECTOR
INSPECTION
St art t he engi ne a nd let it idle.
Confirm the i njector o pe rating so und s w ith a sound - SOU ND ING ROD
in g ro d o r ste thoscope.
6-54
Contents Chapter 6
FUEL SYSTEM (Program m ed Fuel Inj ect ion)
REMOVAL
Rem o v e th e throttl e bod y (page 6-47 ).
Re m ov e t he bolts and f uel rai l/p r im ary . in jector
assemb ly .
Re m ov e t he injectors from the fuel rai l.
INJECTOR
Rem ov e t he seal rin g, O-r in g and cushio n ring.

INSTALLATION
Apply oil to the new O-ring.
Replace the seal Install the new seal rin g, cush ion rin g and O- ring.
ring, cu shion ring bein g ca ref u l not to dam ag e t he O-rin g.
and O-ring w ith
new ones as a set. S~
SEAL RING
~
S
CU SHION RING
II
Inst all the fu el inject o rs into th e fuel rail, bei ng care-
FUEL RAIL
ful not to damage th e O-ring and cus hio n ring .
INJECTOR

FUEL SYSTEM (Programmed Fue l Injection)
Install the fuel rail/primary injector assembly o nto
t he throttle body, being ca refu l not to damage the FU EL INJECTORS
sea l rings.
Tighten the fuel rail mounting bolts to the specified

t orqu e.
TORQUE : 9.8 Nm (1.0 kqf .rn , 7 Ibfft)
Inst all th e th rottle body (page 652 ).
IDLE AIR CONTROL (lAC) THERMAL

VALVE
Do not loo sen or Remove the throttle body (p age 6-47 ).
rem ove the th er-
Remove the thermal valve mounting screws.
ma l valve shaft lock
nu t and adjus ting
nut.
Rel ease the t hermal valve shaft joint p iece from the
t her m al valve link arm, then remove t he therma l
valve assembly.
6-56
Contents Chapter 6
Insta ll the thermal v alve shaft j oint pi ece to the ther-
m al v alve link arm .
Tig ht en th e t hermal valve m ou nt in g screws to th e

specified torque.
TORQUE : 4.9 Nm (0.5 kqf-rn, 3.6 Ibf.ft)
IDLE AIR CONTROL (lAC) VALVE

DISASSEMBLY
Rem ov e t he th rottle body (p age 6-47).
Rem ove the fuel rail and primary inj ectors
(page 6-55) .
Tu rn each lA C valve adj usting screw in , recording
t he number of tu rns until it seats ligh tly .
No .1I2 lAC valv e:

Rem o v e the lAC valve arm screws an d lAC v alv e
arm.
Rem o v e the screw and lAC valve ar m .
6-57
Contents Chapter 6
No .3/ 4 lAC valve:
Remove th e lAC valve arm screws and lAC valve
ar m.
Remov e t he lA C va lve shaft and three co lla rs.

VA LVE SHAFT
COLLARS
M ark the lAC valve s Loosen t he lock nut and remove t he lAC valves.
durin g disassembly
so th ey can be
placed back in their
origin al locations.
Check th e lAC v alv e fo r scratches, scorin g or other

damage , re place it if nece ss ary.
lAC VALVE
6-58
Contents Chapter 6
FUEL SYSTEM (Programmed Fue l Inject ion)
Do not apply corn- Clean the lAC valve bypasses using com pressed air.
mercialfy available
carburetor cleaners
to the inside of the
throttle bore. wh ich
is coated w ith
molybdenum .
ASSEMBLY
FUEL RAIL MAP SENSOR
9.8 Nm (1.0 kqf-m . 7 lb f .tt]
INJECTOR \I,
~i
<'"
lAC VALVE
lA C TH ERMAL VALVE
5 Nrn 10.5 kqf-m , 3.6 lbf-tt) 0.9 Nrn (0.09 kqf .m , 0.7 lbf-ft]
0.9 N'm (0.09 kqf -rn, 0.7 Ibllt )
6-59
Contents Chapter 6
Inst all the lAC v alv es into th e va lve holes .
- lA C VA LVE
Ti gh t en th e lAC va lve lo ck nu t to t he specified

t o rq ue.
TORQUE: 1.8 Nm (0.18 kq f -m, 1.3 lbf -ft ]
Inst all th e three col la rs and lA C v alve sh aft .

VA LVE SHA FT
COLLAR S
No .1/2 lAC valve:

In st all th e No.1/2 lA C va lve arm to th e lAC va lv es.
LIN K ARM
In st all and ti g hten th e lA C va lve arm mou nt ing
scr ews t o th e speci f ied to rq ue.
TORQUE : O.g Nm (O.Og kqf-rn, 0.7 lbf.tt)
Inst a ll the th e rm a l va lve lin k arm and t ig hte n the

screw to t he spec ified t o rque.
TORQUE: 0.9 Nm (0.09 kqf-m, 0.7 Ibfft)
6-60
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Injectio n)
No.3/ 4IAC v alv e:
Install the No.3 /4 lAC va lve arm o nto t he lAC va lves.
Insta ll and ti ght en the lAC va lve arm m ounti ng
screws to the sp ecifi ed t orqu e.
TORQUE : 0.9 Nm (0.09 kqt-rn. 0.7 Ibf.ft)
Inst all the lAC th ermal va lve (page 6-56 ).
Turn the lAC valve sc rew until it seats lightly, th en

back it o ut as noted du ring rem ov al.
Insta ll t he t hrott le bod y (page 6-52 ).
lAC VALVE SYNCHRONIZATION

Sy nc hro nize the lA C v alves with the engine at
norma l operating tem perat ure and with the
transmission in neutra l.
Use a t ach om et er with graduatio ns of 50 rpm or
smaller th at will accu rate ly indicate 50 rpm
cha nge.
Lift and suppo rt th e l uel t ank (page 4-5).
Disconn ect the each v acuum hose from the 5w ay
jo in t .
6-61
Contents Chapter 6
Connect th e v acuum hoses to the vac uu m ga uge .
VACUUM GAUG E
TOOL:
Vacuum gau ge set 07LMJ-001010B or
07LM J-001000A
(U.S.A. only)
Connect a tac ho mete r.
Disconnect t h e PA IR ai r suction hoses from th e reed ~==================~

A IR SUCTION HOSE PLUG
va lve covers, then plug the co vers .
PA IR REED VA LVE COVER
Sta rt th e engine and ad just t he idle spee d w ith t he

t hrott le sto p screw .
IDLE SPEED: 1,200 100 rp m
The No .1 lAC valve Match each in t ake v acu um pressu re wit h the No.1
cannot be adjusted. lAC valve.
it is the base lAC
valve. lAC VALV E VACUUM DIFFERENCE:20 m mH g

FUEL SYSTEM (Program m ed Fue l Injection)
Rem ov e the plu gs and connect t he PAI R air suct io n
A IR SUCT ION HOSE PLUG
hoses to the reed valve covers.
PAIR REED VALVE COVER
Adj ust the idle speed if the idle speed differs fro m ~;;;;;;;;~~:-:;;;;;;;;;;;~;;;;;:;;:;;~
t he specified speed .
IDLE SPEED: 1.200 100 rpm
Remov e the va cuum gau ge from the va cuum hoses.

Con nect t he each vac uum hoses to t he 5-w ay j o int.
Reset the ECM fail ure code (page 6-10).
6-63
Contents Chapter 6
MAP SENSOR
OUTPU T VOLTAGE INSPECTION
Connect the test ha rness to t he ECM (page 6- 11).
Measure the vo ltage at t he test ha rne ss te rmi na ls
(page 6-12 ). IV)
Connection : 815 1+) - 817 (-I 3.5

STANDARD: 2.7 - 3.1 V
The M AP senso r o utput vo ltage (above ) is mea - 3 .1

sured under t he standard at m osp here (1 at m = 3. 0
1,013 hPal . 2 .76 3
2. 7
The MAP senso r outp ut vo ltage is affected by th e 2.6
distance above sea level, beca use t he output volt- 2.5 2 .46 2.5
age is cha nge d by at mosphe re .
Chec k t he sea level measurement and be su re t hat
the me asu red vo ltage fal ls w ithin the specified 2 .1
2. 0
value.
1.5
1.0
0.5
o 500 1,00 0 1,500 2, OOO:m

(1,6 50) (3, 3 00) (4,950) 16,600) (f eet)
Lift and suppo rt the f ue l t a nk (page 4-5 ).
Disco nn ect the M AP se nso r 3P (Black) co nnecto r.
Discon nect th e vac uum hose f ro m t he MAP senso r.
Rem ov e t he scre w an d M AP senso r f ro m th e pri -
mary in j ect or f uel rai l.
In st allat ion is in the rever se orde r of re mova l.
3P (BLACK) CON NECTOR

l
6-64
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Injectio n)
IAT SENSOR
Lift a nd suppo rt th e f u el tan k (page 4-5).
Disco nn ect the IAT se nso r 2P (Gray) connector.
Rem ov e the screws and IAT sensor f ro m the air

clea ner housing.
Inst allation is in the reverse ord er of re mova l.
TORQUE: 1.2 N m (0.12 kqf-m , 0.9 Ibf.ft l
ECT SENSOR
Replace the Ecr REMOVAL/INSTALLATION
sensor w hile the Drain t he coolant from the sys tem (page 76) .
engine is cold.
Lift and support th e fu el ta nk (pa ge 4-51.
D isco n nect the 3P (G ray) co n ne ctor fro m th e EeT
se nso r.
Rem ov e the EeT sensor and sealing washe r.
Always rep lace a In stall a new sealing w ash er and Ee T se nsor.

sealing w asher w ith Tighten t he EeT sen so r t o th e sp ecifie d to rq ue.
a ne w one.
TORQUE : 23 Nrn (2.3 kgf-m, 17 Ibfft)
Con nect t he EeT senso r 3P (Gray) co nnect or.

Fill the coo li ng sy st em w ith reco m m ended coo lant
(p ag e 7-61.
6-65
Contents Chapter 6
CMP SENSOR
Rem ove the under cowls/m idd le cowls (page 3-7 ).
Lift and support the fuel tank (p age 4- 5).
Disconn ect t he eMP sensor 2P (Black) conn ector.
Remov e the bolt and eMP sensor from the cylinde r

head.
Apply oil to a new O-r ing and instal l it ont o t he cam -

s ha ft po s itio n se nso r groo ve .
Install th e eMP se nsor into th e cyli nde r he ad .
Tig hten th e mounting bol t securely .
Connect the eMP sensor 2P (Black) connector .

Install the removed parts in the reverse ord er of
removal.

BANK ANGLE SENSOR
INSPECTION
Rem ov e th e headl ight un it (page 20- 5).
BANK ANGLE SENS OR
Disco nn ect th e ba nk ang le senso r 3P (G reen) co n-
nector and conn ect t he spe ci al t o o l between t he
co n necto rs .
TOOL:
Inspection adaptor 07GMJ -ML80100
Rein st all the headl i g ht unit an d ban k ang le sensor
o nto the upper cowl (pa ge 3-12 ).
Conn ect t he front su b-ha rn ess mu lti -connect o r.
Tu rn th e ignition switc h ON and eng ine stop switch
" () ".
IN SPECTION A DAPTO R
M easure th e vo ltage between th e fo llowing t er m i-
nals of the test ha rn e s s .
T ERM INAL STANDARD
White/black (+1- Gr een (-) Batte ry vo ltag e
Red/white (+1- Green (-) 0- 1V
Do nor disconnect Turn the ignit i o n switc h O FF.
the bank angel sen-
Rem ov e the upp er cowl (page 3-121.
sor connector dur-
ing inspection. Rem ov e th e flan g e nuts and ban k angl e senso r.
Re inst all the upp er co w l and co n nect the fro nt su b-
harn ess multi-conn ecto r .
Place th e bank ang le senso r horizontal as shown,

and t u rn t he ig nit io n sw itc h ON . 60' BANK ANGLE POSITI ON
The ba nk a ngle sen sor i s norma l if t he engi ne st o p

relay clic ks an d power supply is closed .
Incl ine t he ba nk a nge l senso r approxi ma t ely 60
d egrees to the left o r rig ht wit h th e ig niti o n sw it ch
ON.
Th e bank ang le senso r is norm al if th e engine stop
o
NORMAL
POSITION
lapP<OXim"e~
~
~
rela y clicks and pow er su pp ly is ope n .
If yo u repeat this t est , fi rst t urn th e ig nition switc h
~
OFF, t hen tu rn t he igniti o n sw it ch ON .
:\ 60 (app roxi mately)
6-67
Contents Chapter 6
FUEL SYSTEM (Programmed Fue l Inj ectio n )
Remove the bank ang le sensor mounti ng nut and
sensor fro m the headlig ht unit.
Remove t he headli g ht unit (page 20-5 ).

Disco nnect the bank angle sens o r 3P (Green) co n-
necto r.
3P(GREEN) CONN ECTOR
Install the bank Installation is in the reverse orde r of remova l.
..
angle sensor with
Tight en the mounting screws to the specified
its " UP" mark tee-
to rq ue.
mgup.
TORQUE: 1.5 Nvm (0.15 kqf-rn, 1.1Ibf.ftJ
UP
ENGINE STOP RELAY

INSPECTION
Remove th e left middle cowl lpage 3-7)
Re move rel ay box f rom the bracket.

Relea se the ret ainers (Blue ) and rem ov e t he relay
co nnecto r base.
Remove the en gin e stop relay from the co nne ct o r.
ENGIN E STOP
RELAY
CONNECTOR (BLU E)
Co nnec t t he oh mmete r to t he en gin e stop relay con - ~================~

BA TIERY
nect or terminal s. EN GINE STOP RELAY
Conn ect io n: A - B
Co nnec t a 12 V batte ry t o the f oll ow ing en gi ne sto p
~~;~~l:
II : : J==;~;t~l
relay co n necto r te rminals.
Con n ecti on: C 1+)- D H
~l
The re sh o uld be co nt i nu ity on ly when t h e 12 V bat-
tery is connect ed .
If th er e is no co nt inui ty when the 12 V battery is
co nnected, rep lace the en gi ne sto p rela y.
B 0
ENGINE CONTROL MODULE (ECM)

Rem ov e t he un der cowl s/mi ddle cowls (pag e 3-7) .
Disco nn ect t he ECM 32P [Black] and 32P (Lig ht gray)
connectors.
Rem ov e t he ho lder band and ECM .
Inst all at ion is in the rev erse order of removal.

FU EL SYSTEM (Programmed Fuel Injection)
ECM POWER/GROUND LIN E
INS PECTION
ENGINE DOES NOT START (Mil DOES NOT BLINK)
1. ECM Power Input Volta ge In spection
Dis con nect t he ECM 32P (Black) and 32P (lig ht
g ray) co nnect o rs.
Turn the ignition switch ON and eng in e stop I j , , i , i t ,0H '1 IllLlUU r-r-s , i i . '. " 11" " " '"
sw itc h " () ".
M easu re th e vo ltag e at t he ECM 32P (light gray) DOOOOOOOOOOOOOOO 000000000000000
conn ect or termi nal and g ro u nd . 0000000000000000 000000000 000000
J1 ,. II!!! ,," "" ,. ?I , -Ii:znur:m
Connection: 815 (+) - ground (-)
B16 1+) - ground I-I
Is there battery vo ltage? 8 V l-=---'
Ei:l
YES - GO TO STE P 2.
NO - GO TO STEP 3.
2. ECM Ground Line Inspection

Tu rn th e ign it io n switch O FF.
Check f o r co nt inui ty betwe en t he ECM 32P
(Blac k) co n nect or t erminals and ground.
rr-r-r-r 1 1 ' 1 " 0 11 " ' 3 1! ' 5 '" , i I Ii ! " ,0 11", 1 .. " ,, 1
Connection : A4 (+) - ground (-)
A 18 (+) - ground (-) DOD 0000000 00000 00000000 00000000
A 19 (+) - ground (-)
o 0 0000000 00000 0000000 0 0 0 0 00000
, , ,,, ,i ,p p', II ' ll< ,\ 'I/ tllU lP IJ III
Are there co ntinuities ?
YES - Rep lace th e ECM wi th a know good o ne,
and reche ck.
NO - . Ope n circ uit in t he Gr een/pin k (A 18)
wi re
- . Ope n circu it in t h e Green /pi nk (A 4)
wi re
3. Engine Stop Rela y Inspection 1
Tu rn the ig nitio n switch OFF.
Remove t he eng ine sto p rel ay f rom t he relay
co n nector base.
T urn the i gniti o n switch O N and eng ine stop
swit ch" () ".
M easu re t he vo ltage at t he eng ine sto p rel ay
co n ne cto r term ina ls.
Connection: Black (+) - Red /bl ue (-)
Is there b attery voltage?
YES - GO TO STEP 4.
NO - In spect t he ban k ang le se nso r (pa g e 6-
67)
6-70
Contents Chapter 6
4. Engi ne Stop Relay Inspection 2
Turn th e ignition switch OFF.
Ju m p t he engi ne sto p relay co nnecto r term inal s.
Co nnection: Red/white - Black/white
Turn the ignition switch ON .
M easure the v o lt age at the ECM connect o r ter-
mina l and ground .
Connection : B15 1+1- ground H
B16 (+) - ground H
Is there battery voltage ?
YES - Inspect t he engine stop relay (page 6-
68)
NO - Open ci rc u it in p ower input line (Black! L.JUMPER W IRE ----'
wh ite or Red/white) between the battery
and th e ECM
PAIR CONTROL SOLENOID VALVE

Remove th e air cleaner hou sin g (page 6-40) ,
Disconnect t he PAIR cont ro l soleno id va lve 2P
(Black) co nnecto r.
Disco nn ect the PAIR air sucti on hoses and remove
the PAIR co nt ro l sol enoid v alve.
Inst all ati o n is in the reve rse order of re moval.
INSPECTION
Remove the PAIR cont rol solenoid v alve .
Chec k tha t ai r f lows (A ) to (BI w he n th e 12 V batt ery
is connected to the PAIR contro l so lenoid valve ter- (B)
m inals. Air sho uld not flow (A ) to (B) whe n there is
no voltag e applied to the PAIR valve t er m in als.
6-71
Contents Chapter 6
Chec k t he resist an ce between the t ermin als of th e
-.
PA IR control solenoid valve. PA IR SOL ENOID VA LVE
STA NDARD : 20 - 24 o (20 C/ 68 OF)

If the resista nce is o ut of spe cification, re pl ace th e
m
PA IR co ntrol solenoid va lve .
Jf
EVAP PURGE CONTROL SOLENOID
VALVE (CA LIFORNIA TYPE ONLY)
Disconnect the EVA? caniste r-to-fuel t ank hose from , -- - - - - - - - - -- - - - - ---,
t he canister.
Disconn ect th e EVA? canister-tc-purpe cont ro l sole-
noid valve hose.
CAN ISTER-TO-FU EL
Rem ove t he mou nting bolt s and EVA? canis te r fro m
TANK HOSE 2P CONNE CTOR
th e bracket.
BOLTS
Disconn ect th e purge cont ro l soleno id valve-t o- ~================~

HOSE
thr ottl e body hose from th e so lenoid valve. to thr ottle
Rem ov e the bo lt s and caniste r br acket/ sol en oid body
va lve as an asse m bly from t he f ram e.
Remove the bolts an d EVA ? pu rge co ntrol so len oi d
v alv e from the bracket.
Installation is in t he reve rse o rder of remova l.
6-72
Contents Chapter 6
INSPECTION
Remo v e the EVA ? purge co ntrol solenoid valve .
Check t hat air shou ld not fl ow (A) t o (8). only wh en
the 12 V battery is connected to the EV A? purg e ~ ]
control solenoid va lve te rm inal.
[ L'-, =
(A ) I
VT I r
(S )
Check the resistance betwee n the term inals of the EVAP PURGE CONTROL
EVA? pu rge contro l sole noid valve. SOLENOID VALVE
STANDARD : 30 - 34 n (20 C / 6 8 of )
If the resistance is out of specif icat ion, replace t he

EVA? purge cont rol solenoid valve.
I"" 1li
@
~
00 "
11,==
~Q~
I-n
INTAKE AIR DUCT
INTAKE AIR DUCT CONTROL
SOLENOID VALVE
Removaillnstallation
Remo ve the left m iddle cowl (page 3-7 }.
Disconn ect the vacuu m hoses and conne cto r f rom
the byp ass control solenoid va lve .
Remove the bolt and bypass contro l solen oid valve .
6-73
Contents Chapter 6
Inspection
Hern o v e th e bypass con t rol so le no id va lve .
SOLEN OID
Chec k th at the air sho uld flow (A I to (B). only w he n . VA LVE
th e 12 V battery is connecte d to t he bypass con t ro l
solenoid valve termi nal.
o
$ - 9
0
~~~(AI I
(BI
Check the resist ance betw een the termina ls of t he

bypass control so lenoid va lve.
~=~====~=:::':========~
BYPA SS CONTROL SOL ENOI D VALVE
STANDARD: 28 - 32 n (20 C/ 68 OF)

If t he resi st ance is o ut of specif icat io n, rep lace t h e
bypass control so lenoid v alve.
VACUUM CHAMBER/ONE-WAY
VALVE
Re m ov al /In st al lati on
Rem o ve th e left mi d d le co w l (pa g e 3-7 ).
Discon nect t he v acu u m hoses and th e vacu u m
cha mber.
Route the vacuum Install at ion is in t he rev er se o rde r of rem o v al.
hoses correctly.
Inspection
Check t he v acu u m cham be r for da mage and
scratches, replace if necessary. VACUUM CHAM BER ON E-WAY VALVE
Check t he o ne-wa y valve ope ra tio n in th e vacu u m

chamber as fo llows:
- A ir should fl ow (AI to (B) (B)
- A ir should not f low (B) to (A)
If the o pe ration is inco rre ct , repl ace th e vacu u m (A)
cham be r/one-wa y v al v e assem bl y .

INTAKE AIR DUCT DIAPHRAGM/FLAP
Rem ov e t he int ake air d uct f rom t he air clea ne r
hou sing (page 4-8).
Remove the screws an d air du ct cove r.
SCREWS
Unhook th e diaphrag m ro d fro m the fl ap v alve, t hen

remove the flap va lve.
Remove t he di aphrag m f ro m t he int ake ai r d u ct .
Inst all th e diaph ragm int o th e intake air duct.
Ho o k th e diaphrag m rod with the flap valve hole as
shown.
Place t he flap v alve o nto t he inta ke air duct.
Install t he air d uct cove r and tig hten t he sc rews t o

t he sp ecifie d t o rqu e.
TORQUE : 1.2 N vm 10.12 kq f- m , O.9Ibfftl

Inst all the i nt ake a ir d uct to th e air cl ean e r hou sin g
(page 4-8).
SCREWS
6-75
Contents Chapter 6
FUEL SYSTEM (Programmed Fuel Inj ect io n)
EGCV (Ex haust Gas Control Valve)
EGCV cont rol cable adjustment (page 4-351.
DISASSEMBLY
Disconnect the co nt rol cables f rom the pu lley.
CONTROL CABL ES
Bend up the tabs of the lock washer.

Hol d t he pulley and lo o sen the pulley nut.
Remove t he lock washer, pu lley, stoppe r arm,
spring co llar and retu rn spring.
Rem ov e th e bo lt s an d p u lley h ou sing .

PULLEY HOUSI NG
BOLTS
Bend up the tabs of the lock washer.
A~
Remove the butterfly valve reta ining screw s, lock
washer and butterfly valve.
~ X
~~.
P\
SCREWS
BUTIERFLY VALVE
LOCK WAS HER

Remov e the bearing cap .
BEARING CAP
Push t he ex ha ust v alv e shaft and re move the outer
bea rin g.
'0 VALVE SHAFT
! .' "
Re m o ve t he in ne r b ea rin g .
, I ,
~ / ;. I'~" .
~ ( , j;.
.. .~ .~
INNER BEARIN G
ASSEMBLY
Press th e new inne r bea rin g into the exhau st shaft
!~ BEARING CA P
pi v ot .
...... \...
!
Insta ll t he exhaust v alve sha ft, then p res s t he new ([) VALVE SHA FT
s~
outer bea ri ng int o th e exhaust v alve shaft piv ot.
Install th e new b earing cap secu rely .
0,
~ '. ,
c 0,;, ~
" S
INNER BEARING
Note the direction
of the b utterfly
valve .
Install th e butter f ly v alve int o the muffler pipe.
Place the new lo ck washe r on to th e bu tterfl y v alve
and then install and tighten the ret aini ng screw s t o
the specified t orque .
/@":-
- :- --=-
--~_.
TORQUE: 1.5 Nm (0.15 kgf m , 1.1 lbt-ttl
p '~
Bend up t he tabs of t he lock wash er and secure the
screw head . " "~
~
~'
~~:)
, ,
~ BUTIERFLY VALVE
SCREWS ~ LOCK WAS HER
Inst all th e pu ll ey housing onto t he muffler pipe, ~=================~

ti g ht en in sta ll and tighten t he hous ing bo lt s to th e PULLEY HOUSIN G
speci fied t orqu e.
TORQUE: 9.8 Nm (1.0 kqf-m, 7 Ibfft)
BOLTS
6-77
Contents Chapter 6
Insta ll the retu rn sp r in g o nto th e h ou sin g w hile
ali g ni ng its end wit h the hou sin g bo ss.
Inst all the sp ring co ll ar.
Inst all th e stop pe r ar m onto the v al v e shaft.
Inst all th e pulley and th en insta ll the new lock
washe r while alig ning it s t ab s wit h t he pu lley as
show n.
Install and t ight en th e pu lley nut t o the sp ecified
torque .
TORQUE: 4.9 Nm 10.5 kqf-m, 3.6 Ibl-ftl
Bend up the t ab s of t he lock washer and secu re the
nut.
Connect th e control cables to the pulley.

Adjust the cont ro l ca ble (pag e 4-35).
CONTROL CABLES
EGCV SERVOMOTOR
REMOVAL
Lift and support th e f ue l ta nk (page 4-51-
Discon nect t he servom ot or 6P (Natu ral) co n necto r.
Remove th e bo lt and middle cow l stay/cable p rotec-

to r.

FUEL SYSTEM (Programmed Fuel Injection )
Rem o v e th e serv om ot or m ounting bo lt and pull out
the se rvo m oto r from t he br acket .
Disconnect t he EGCV cont ro l cables from the serv o- .... - - - ==-

m ot o r pulley, then rem ov e t he servomotor.
Remove t he bolt and servomoto r bra cket.
BOLT
INSPECTION
Conn ect the 12 V battery to t he serv om oto r 6P (Na t-
ur al) con nector t er mi n als and chec k t hat the m ot or
op e ration .
Connection: Red I+J - Blue (-J
If t he servo m oto r .does not turn , rep lace th e servo-

m otor wit h a new o ne . c o
is
6-79
Contents Chapter 6
Measure th e resistance betw een the se rvo moto r 6P
(Na tu ral) co nnecto r t ermin als.
Connection: Yellow Ired - Green/orange

Stand ard : 5 kQ
Connection: Light green/pink - Green/orang e

Standard: 0 - 5 kQ
If t he resi st an ce is ou t of rang e, rep lace the se rv o -
motor .
INSTALLATION
Connect the servomoto r 6P (N at ural) co nnector.
~3X28mmBO LT
If youuse a new Short t he DLC (pa ge 6-9 1.
servomotor. it is nor
Turn the ig nit io n switc h t o "ON" .
necessary to do
The servomoto r turn s. th en stops.
this procedure.
Sec ure th e servom ot or pulley at t his p osit io n using
a 3 x 28 rn m bo lt as sh ow n.
Co nnect t he EGCV con t ro l ca bles to eac h po sition .

Rem ov e t he 3 m m soc ket b olt fr om t he servomoto r
pu lley.
A dju st th e EGCV co nt ro l cables (pa ge 4-35 ).
Install t he servomotor onto the b racket.

Install and tighten t he serv o m ot o r mounting bolt.
6-80
Contents Chapter 6
Install the middle cowl stay/cable pro t ecto r and
tighten the bo lt secure ly .
Co nnect the serv om ot o r 6P (Na t ural) connector.

Inst al l the rem oved parts in the reverse o rder of
rem oval.
6-81
Contents Chapter 6
MEMO
Contents Chapter 6
7. COOLING SYSTEM
SYSTEM FLOW PATTERN .. 7-2
SERVICE INFORMATION 7-3

THERMOSTAT
RADIATOR
7-8.
7-10
TROUBLESHOOTING 7-4 WATER PUMP .. 7-17
SYSTEM TESTING 7-5 RADIATOR RESERVE TANK 720
COOLANT REPLACEMENT 7-6 FAN CONTROL RELAY 7-21
7-1
Contents Chapter 7
COOLING SYSTEM TTERN
SYSTEM FLOW PA
RADI ATOR RESERVE TANK
RAD IATOR
lA C THERM AL VALVE
THERMOSTAT
UPPER RADIATOR HOSE
OIL COOLER
WAT ER PUM P
7-2
Contents Chapter 7
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
AWARNING ' .
Removing the radiator cap while the engine is hot can allow the coo lant to spray out, serio usly scalding you.
Always let the engine and radiator cool down befo re removi ng the rad iator cap.
I NOTICE I
Using coolant with silicate inhibitors may cause premature wear of wate r pump seals or blockage of radiator passages.
Using tap wa ter may cause engine damage.
Ad d coo ling syste m at the reserv e tank. Do not rem ove the radiator cap except to refill or drain the system .
A ll cool ing system services can be don e wi th the engine insta lled in the fr am e.
Avo id spilling coolant on pai nted surfac es.
Afte r servici ng the system, check for lea ks with a cooling system tester .
Refer to the Eel sensor inspection (page 20- 14 ).
SPECIFICATIONS
ITEM SPECIFICATIONS
Coo lant capacity Radiator and engi ne 3. 15 liter (3.33 US qt, 2 ,77 Imp qt)
I Reserve ta nk 0.4 lit er (0 .42 US q t. 0,35 Im p qt )
Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4 kgf /em ' , 16 - 20 psi)
Therm ostat Begin to open 80 - 84 C (176 183 OF)
Fully open 90 C (194 OF)
Valve lift 8 m m (0.3 in) min im um
Recommende d antifreeze High quality ethylene glycol antifreeze containing corrosion
prote ction inhibitors
Standard coolant concentration 1:1 m ixture wit h distilled wa ter
TORQUE VALUES
Wa ter pump assem bly flange bolt 12 N'm (1.2 kqf-rn, 9 Ibf ft ) CT bolt
Thermostat housing cover flange bolt 13 N,m (1.3 kqf -rn. 10 Ibf.ft ) CT bol t
ECT (Engine Coolan t Tempe ratu re)! 23 Nm (2.3 kqf-rn. 17 Ibf,ftl
th erm o sensor
Coolin g fa n nut 2.9 Nrn (0.3 kqf-rn. 2.2 lbf -ft ) Ap ply a locking age nt to the thread s
Fan mo to r nut 4.9 Nm (0 .5 kqf-rn, 3.6 lbf -ft )
Fan motor bracket mounting bolt 8,8 Nm (0.9 kqf- m, 6.5 Ibf.ft)
7-3
Contents Chapter 7
COOLING SYSTEM
TROU BLESHOOTING
Engine t emp erature too hig h
Faulty tempe rature gauge or Ee l sensor
The rmostat st uck close d
Faulty radiator cap
Insuff ici ent coo lant
Passage blocked in radiator,hoses o r wa te r jacket
Air in system
Faulty coo li ng fan m ot o r
Faulty fan co nt ro l rel ay
Faulty wate r pum p
Engine t emperature too low
Faul ty te mp erat u re g auge o r EeT senso r
T he rm o st at stu ck open
Fau lty coo li ng fan co nt rol relay
Coolant leak
Fau lty wate r pu mp m echa nical sea l
Deteriorated O-ri ngs
Faulty rad iator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Dam aged or deteriorated hose
;'
7-4
Contents Chapter 7
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Rem ove the rig ht side under cow l/mi ddle cow l
(pa g e 3-7 ).
Remo ve th e radiator cap.
T est th e coola nt grav ity usi ng a hyd rometer (see

below for "Coolant gravity chart").
For maxim um corrosion protection, a 1:1 solution of
ethylene glycol and distilled w ater is recom men ded
(pag e 7-31.
Look for conta mi nation and replace the coolant if
necessary .
COOLANT GRAVITY CHART

Coolant temperature "C (OF)
0 5 10 15 20 25 30 35 40 45 50
(32) (41) (SOl (59) (68 ) (77) (861 (951 (104 ) (113) (122)
5 1.009 1.009 1.008 1.0 08 1.007 1.0 06 1.005 1.003 1.001 0.9 99 0.997
10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005
15 1.02 8 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
'$ 20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
.2 25 1.045 1.044 1.04 3 1.042 1.040 1.03 8 1.036 1.034 1.03 1 1.028 1.025
~ 30 1.0 53 1.052 1.051 1.047 1.04 6 1.045 1.043 1.041 1.038 1.035 1.032
C 35 1.063 1.062 1.060 1.058 1.056 1.054 1.05 2 1.049 1.046 1.043 1.04 0
'"0
'0 40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
u 45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.064 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.06 7
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071
7-5
Contents Chapter 7
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cap (p ag e 7-5) .
Before Installing the Pres s u re test the radiator ca p.
cap in the tester, Rep lace the rad iat or cap jf it do es not ho l d pressure,
wet the sealing sur- o r if re lief pressu re is too h igh o r too low.
faces. It m ust hold specified p ress u re fo r at least 6 sec -
onds.
RADIATOR CAP RELIEF PRESSURE :
108 - 137 kPa 11 .1 - 1.4 kg f /em' , 16 - 20 psi)
TOOLS (Commercially available):

Cooling System Pressure Pump STV26232
Cooling System Adapter OTCJ 33984A
Pressu re t he radi at or, e ng in e an d hoses, and ch eck

fo r leaks .
I NOTICE
Excessive pressure can damage the cooling system
components. Do n ot exceed 13 7 kPa ( 1.4 kgf/cm 2 , 20
psi).
Repair o r rep lace co mponents if t he system will not
ho ld specifi ed pressu re for at least 6 seconds .
COOLA NT REPLACEMENT
PREPARATION
The effectiv eness of coo lant decreases wi t h the
accu mulation of ru st o r lf there is a chan ge in the
mix ing pro po rt ion d u ri ng usage. T he refo re , f o r
best perfo rmance change t he coo lant regu la rly
as specified in the m a inten ance sc hedu le .
Mix o nly d ist illed water wit h t he an ti f reeze.
RECOMMENDED ANTIFREEZE:
AN TIFREEZE
SOLU TION
(ETHYLENE
J,r7
6
High quality ethylene gly col antifreeze co nta in ing DIST ILLED
GLYCOL BASE WATER
corrosion protection inhibitors
SO LUTIO N)
RECOMMENDED MIXTURE:
1:1 (Distilled water and ant if re eze )
REPLACEMENT/AIR BLEEDING
When filling the Remove the under cowls/middle cow ls (pag e 3-7).
system or reserve
Remove the ra d iat o r cap.
tank with a coolant
(checking coolant
level) , place the
motorcycle in a ver-
tical position on a
flat, level surface.
7-6
Contents Chapter 7
COOLING SYSTEM
Rem ove t he dra in bo lt o n the water pump cover and
drain th e syst em coo lan t.
Reinst all the d rai n bo lts wit h new sealing w ashe rs.
Tighten th e w ate r pum p d rai n bolt to t he spec ified
t orque.
TORQUE: 12 Nm 11 .2 kqf-m, g Ibf.ft l
Discon nect th e sip hon ho se f rom th e radiator.

Dra in the reserv e ta nk cool ant .
Empty the coo lant and rinse t he in side of th e
reserv e t ank w ith w at er.
Connec t t he rad iat or siphon hose.
Fil l th e system w ith t he recom m end ed coo lant

t hro ugh t he f il ler ope ni ng u p t o f iller neck.
Rem ove the rad iat o r reser ve tan k cap and fill the
reserv e tank to the upper level line.
Bleed air fro m th e system as foll ow s:
1. Sh ift th e tran sm ission into neutral. St art th e
eng in e and let it id le f or 2 - 3 m inutes.
2. Sn ap the thr ottle three to fo ur ti me s to bl eed air
from th e system .
3. Stop t he eng ine and add coola nt up t o the pro per
level if nec essa ry. Rein stall th e radiator cap .
4. Chec k the lev el of coola nt in th e reserve tank and
fill to th e upper level if it is lo w .
Inst all th e radiat o r reserve ta nk cap .
Instal l th e und er cowls/midd le cowls (pa ge 3-7).
7-7
Contents Chapter 7
COOLING SYSTEM
THERMOSTAT
REMOVAL
Dr ain the coo la nt (pa ge 7-6 ).
Rem ov e t he th ro ttle bod y (p age 6-47) .
Rem ove the bolts and the rmos tat hou sing cover.
Rem ove the thermostat from the housing .
INSPECTION
Wea r insulated gloves a nd adeq uate eye protectio n.
THE RM OSTAT
Keep flam mable mat erial s aw ay fro m th e electric
heating eleme nt.
Vis ually inspect the thermosta t for da mage.
Check f or damag e of the sea l ring.
Do not let the ther -Heat the wa ter with an electric heat ing element to
mostat or ther- ope rati ng te m perature for 5 minutes.
mometer touch the Suspend the the rmostat in heate d wa ter to check its
pan, or Vou will get opera t ion.
false reading
Replace the the rmostat if th e valve stays open at
room tem perature, or if it respo nds at t em peratures
other than th ose specified.
THERMOSTAT BEGIN TO OPEN :
80 - 84 C (176 - 183 OF)
VALVE LIFT:
8 mm (0.3 in) minimum at 9 5 C (203 OF)
THERM OSTAT

COOLING SYSTEM
THERMOSTAT HOUSING REMOVAL
Disco nn ect the Eel sensor co nnecto r.
If necessary, rem ov e t he Ee l se nsor from t he th er-
m osta t ho us ing (page 20-141.
If n ecess a ry , d i sconn ect t he fa st id le w ax u ni t w at er
hose and bypass hose from t he t her m ostat ho using.
Rem ov e th e bol t s and th erm ost at hou sin g from t he
cy li nde r head .
Remov e the O-ring f rom the housing.
THERMOSTAT HOUSING
INSTALLATION
Inst al l a new O-ring into th e g ro ov e of t he t herm o-
stat ho us ing .
Install the t herm ost at hou sing onto th e cy li nder
head .
Inst all and tig hten the the rmostat housing moun t ing
bolts securely.
Connect th e f ast id le wax unit wate r hose and
bypass hose if it has been rem o v ed .
Inst all t he Ee l se nso r if it has bee n removed (page
20-14).
Co nnect th e ECT se nso r conn ect or.
ECT SENS OR
THERMOSTAT INSTALLATION
Install th e the rmostat into t he ho us ing w ith its air
bl eed hole fa cing rearward .
Contents 7-9
Chapter 7
COOLING SYSTEM
Inst all the th er m o st at ho u sin g co ve r o nt o th e hous-
ing. ,~~
Inst all and tig hten th e hou sing co ver bolts t o th e !.I
specif ied torq ue .
TORQUE: 13 Nm (1.3 kqf-rn, 10 Ibf.ft)
Fill th e syste m w ith the reco m me nde d coola nt and

bleed an y air (page 7-6).
RA DIATOR
REMOVAL
Rem ove the under cow ls/midd le co wls (pa ge 37).
Dr ain the co olan t (page 7-6 ).
Loosen th e hose cla mp screw and disconn ect th e
lower radi at or hose.
Rem ov e th e bolts and air guide/reserv e tank lower

bracket from the radia to r.
Remove the bo lt and rad iator overflow hose guide.
Disco nn ect t he sip hon h o se and f ill er neck joint

hose f rom t he radiator.

COOLING SYSTEM
Disco nnect the f an m otor 2P (Black) connect o r.
-Rernove the rad iat or lowe r mounting bolt.
LOWER MOUNTING BOLT
Rem ove t he radi at or upper mo unti ng bol t and

was her.
-
UPPER MOU NTING BOLTIWASHER
Be careful no t to M ove th e rad iator asse m bly to th e right and release

damag e the radiator the radi at or upper grommet from th e bra cket boss,
fins. th en rem ove th e rad iator assembl y.
7-11
Contents Chapter 7
COOLING SYSTEM
DISASSEMBLY
Unhook th e hooks f ro m the radi at o r bo sses, then
remove t he radiat o r grill.
RADIATOR GRILL HOOKS
Rem ove th e t hree bo lts and coolin g f an motor

assembl y from t he rad i at o r.
Rem ov e t he nut and coo ling f an .
Release the f an motor connect or from t he fan m ot or

bracket. .

COOLING SYSTEM
Remove the nuts and fan motor from the fan motor
BRACKET
bracket .
Refer to the fan control relay information
(page 7-2 1).
ASSEMBLY
2.9 N 'm (0.3 kqf-rn , 2.2 Ibfft l
@
COOLING FA N RAOIATOR
FAN MOTOR
~
FA N M OTOR BRACKET
~
)
ii
7.8 N m (0.8 kgfm, 5.8 Ibfft l
Install th e fa n motor onto the fan m ot or bra cket and

BRAC KET
tighte n the nuts to the specified torqu e.
TORQUE : 4.9 Nm (0.5 kqf-m, 3.6 Ibf.fIJ
7-13
Contents Chapter 7
COOLING SYSTEM
Inst al l t he fa n m oto r con nect or onto t he fa n moto r
bracket boss.
In stall the cooling fan onto th e fa n motor shaft by

aligning t he f lat su rf aces . . Alig n
COOLING FAN
Apply a lo cki ng agent to the cool ing fan nut threa d s.

Inst all and t igh t e n t he n ut to th e specif ie d torq u e.
TORQU E: 2.9 Nm (0.3 kqf-m , 2.2 Ibf.ftl
Insta ll the f an m otor assembly onto the rad i at o r.

Install and t ighten the t hree bo lt s to th e specified
torqu e .
TO RQU E: 8.8 Nm 10.9 kq f -m , 6.5 Ibf ft j

COOLING SYSTEM
Inst all th e rad iato r gri ll o nto t he rad iat or, and in st all
t he hoo ks secure ly .
RADIATOR GRILL HOOKS

INSTALLATION
Be careful not to Insta ll th e radiato r asse m bly, alig ning it s up pe r
damage the radiator g ro m me t w it h t he fram e bra cket boss.
fins.
Inst all th e rad iat o r upper mounting bo lt and wa sher,

ti ght en the bol t secu rely .
In stall and ti ght en th e radiator lo w er m ou nting bolt.
LOWER MOUNTING BOLT
7-15
Contents Chapter 7
COOLING SYSTEM
Connect the fa n m otor 2 P (Black) connecto r.
Con nect the f ill er neck j oint ho se and tighten th e r:-,-....,....,......,.=,-

ho se cl am p scr ew.
Connect the siphon h ose to th e filler neck and
secure it with clip .
Route the radiator Inst all t he air g uide /re ser v e tan k lo w er brac ket onto
drain hose and over t he rad iat or, t ig hten th e b olts secure ly .
flow hose into the Inst all t he rad iato r ove rf low hose guide onto t he
bracket. rad iato r, tig hte n the bo lt.
Connect the lower rad iator hose an d t i ghten th e

hose cl am p screw.
Fill th e syst em w ith the reco m me nded coo la nt
(pag e 7-6).
In st all th e under co wls/midd le cowls (pa ge 3-7).

COOLING SYSTEM
WATER PUMP
MECHANICAL SEAL INSPECTION
Rem ov e the u nder cowls (page 3-7).
In spect t he ins pect ion ho le f or sig ns of co o lant leak-
age .
If th ere is leakage. th e mech anical seal is defe cti ve
and re place th e wa te r pum p as an asse m bly .
REMOVAL
Drain th e coo la nt (p age 7-6 ).
Disco nn ect the lower radi ato r hose an d by pass hose
f rom t he w ate r pump cover.
Remove the flange bo lt s, sealing washer.
Rem ov e the water pum p cover assem bly

Remove the O-ring f rom the wa te r pu m p bo dy.
7-17
Contents Chapter 7
COOLING SYSTEM
Remove the separator plate from the water pump
cover.
Remove the dowel pins and O-ring from the water
pump cover .
SEPARATOR
Disco nnect the water jo int hose from the wate r . . , . - - - --...",.,
pump body.
Remove the water pump body f rom the crankcase.
INSTA LLATION
WATER PUMP COVER
~ WA TER PU M P BODY
S
12 Nrn 11.2 kqf-rn. 9 Ibf.ftl

COOLING SYSTEM
Ap ply engi ne oil to a new O-ring and insta ll it onto
t he stepped portio n of the wate r pump bo dy .
Insta ll t h e water pump b ody int o t he cr ankcase
w hil e al ig nin g th e w ater pump shaft g roove wi th th e
oil pump shaft end .
A lign the wa te r pump shaft groove w it h t he oil

pu mp shaft end by tu rning th e wa t er pum p impel - ~. .,;,;;;.;.;.
ler.
Ali gn the m o un t in g bo lt holes in th e water pump ...

and crankcase an d m ake sure th e water pu mp is
-----::;:::=
securely in stalled.
Connect t he join t ho se t o the wate r pump body,
t ighten the cl amp screw.
Instal l a new O-ring into th e groove in t he wate r

pu m p cover.
Install th e dowel pin s.
Insta ll th e separ ato r o nto th e w ater pu mp cove r.
SEPARATOR
Contents 7-19
Chapter 7
COOLING SYSTEM
Install the new O-ring into t he wa ter pump bo dy
groove.
Install th e wa ter pump cover assembly o nto the
wa te r pump body .
Inst all a new seali ng wa sh er and f la nge bo lts.

Tig hten the flan ge bo lt s t o t he specified torque.
TORQUE : 12 Nrn (1.2 kqf-m, 9 Ibf.ft)
Connect th e lo w e r rad iat o r hose and bypass hose, :;==~===:::~;:;;

then t igh t en the clam p sc re ws.
Fill th e system with t he recomm en ded coolant
(page 7-61.
Install t he under cowls (p age 3-7 ).
RADIATOR RESERVE TANK

REMOVAL
Remove the right side under cowl/middle cowl
(page 3-7 1.
Discon nect the siphon hose and drai n the coolant
fro m the reserve ta n k.
Remove th e bo lt and radi at or reserve tan k.
Inst all atio n is in the rev er se o rde r of rem oval.
7-20
Contents Chapter 7
COOLING SYSTEM
FAN CONTROL RELAY
INSPECTION
Rem ov e the u nd er cow ls/m id d le cow ls (p age 3-7 ).
Remove the relay box f ro m th e b racket .
Release t he retai ne rs (b ro w n ) and remove t he re lay

conn ector base. FAN CONTROL
RELAY
Remov e t he fan control rela y fr om the connect o r
base.
/ -#I!
~
..", .. :<tY '
. 'I . ~/
/(
CONN ECTOR (BROWN)
Co nnect th e ohmm eter t o the f an co nt ro l rela y co n -
nector terminals. FAN CONTROL RELAY BATIERY
Connection: A - B
Conn ect a 12 V battery t o the f oll o wing engin e sto p
.
relay co nn ect or te rmin al s.
Connection: C 1+1 - 0 H LJ
~'
The re shou ld be co ntin uity o nly w he n th e 12 V bat-
te ry is co n necte d.
If th er e is no cont inuity w hen the 12 V battery is
conn ected . rep lace th e fan contro l rel ay .
B D
Contents 7-21
Chapter 7
MEMO
Contents Chapter 7
8. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION 8-2 ENGINE REMOVAL 8-4
SERVICE INFORMATION .. 8-3 ENGINE INSTALLATION 8-9 . .

ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
54 N'm (5.5 kgf'm , 40 lbf.ft) 15 N-rn (1.5 kqf-rn, ' 1 IbH tl

SERVICE INFORMATION
GENERAL
A hoist or equivalent is required to support the motorcycle wh en removing and installi ng th e engine.
A floor jack or other adjustable support is requir ed to support and maneuver the engine.
Do not use the oil fi lter and oil cooler as a jacking point .
Wh en using the lock nut w rench fo r the adjusting bolt lock nut, use a deflecting bea m type torque w rench 20 inches
long . The lock nut w rench increases the torque w rench's leverage, so the torque w rench reading will be less than the
torque actually applied to the lock nut. The specification given is the actual torq ue applied to the lock nut, not the read-
ing on the torque wr ench. Do not ove rtighte n the lock nut. The specification later in the text gives both actual and indi-
cated.
The following compon ents can be serviced w ith the engine installed in the fram e.
- Alte rnator (pa ge 11-4)
- Clutc h (page 10-16)
- Cam shaft (page 9-8)
- Gearshift linkage (p age 12-11)
- Oil coole r (page 5-131
- Oil pump (page 5-8)
- Trans mission/ge arshift linkage (page 12-11)
- Wa te r pump (page 7-171
The following compon ents requ ire engine removal for service.
- Cy linde r head (p age 9-13)
- Cran kshaft (page 13-7 )
- Pist o n/cylin der (page 13-15 )
W hen installing the engine, be sure to tighten the engine mounting fasteners to the specified torq ue in the specified
sequence. If yo u mistake the torq ue or sequence, loosen all mo unt ing fasteners, then tighten them again to the speci-
fied torq ue in the correct sequence.
SERV ICE DATA

ITEM SPECIFICATIONS
Engine dry weight 65.8 kg (145.1 Ibs)
Engin e oil capacity I Afte r disassem bly 3.8 liter (4.0 US qt . 3.3 Imp qt )
Coolant capacity I Radiator and engi ne 3.55 liter (3.75 US qt , 3.12 fmp qt )
TORQUE VALUES
Engine hanger adjusting bolt 15 N'm (1.5 kqf -m, 11 lbf-ft)
Engine hanger adj usting bolt lock nut 54 Nm 15.5 kqf -m, 40 lbfft)
Rear upper engine hanger nut 64 Nrn 16.5 kqf -m, 47 lbf-ft )
Rear lower engine hang er nut 64 Nm 16.5 kq f -m , 47 l bt -ft )
Front engine hanger bolt 64 N' m 16.5 kqf -rn, 47 Iblft )
Midd le engine hanger bolt 64 Nm 16.5 kqf-rn, 47 lbf-ft}
Drive sprocket special bolt 54 Nm (5.5 kqf-rn . 40 lbf-ft }
Starter moto r termin al nut 9.8 N'm (1.0 kqf-m, 7 lbf -tt )
TOOLS
Lock nut w rench, 20 mm
07VMA-MBB0100
~I
or 07VMA-MBB0101
8-3
Contents Chapter 8
ENGINE REMOVAL
Remove the fol lowing :
- Un d er co wl s/mid dle cowl (page 3-7 )
- Exhaust pipe (page 3-30)
- Fuel ta n k (p age 6-36)
- Radiat or reserv e tan k (pa ge 7-20)
- A ir cle an er ho usi ng (pag e 6-40)
- Th rott le bod y (page 6-47)
Dis co n nect t he f ol l owin g con necto rs:
- Ve hicle spee d sen sor 3P (Natu ra l) connect or
- Engi ne sub-ha rn es s 2 P (Blac k) connector
Remove the te rmina l nu t and disconnect the starte r

motor cable f rom t he sta rter motor.
Remove the starter m ot or mou nt i ng bolt and sta rte r
motor groun d cab le .
Discon nect the ca mshaft position sensor 2P (B lac k)

connector.
Disconnect the alternator 3P (N at u ral) co nnecto r

and side sta nd switch 2P (G reen) con necto r.

ENGINE REMOVAl/INSTALLATION
Discon nect t he fo llowi ng co nnec to rs:
Crankshaft position sensor 2P (Red) connector
- Rear brake light switch 2P (Black) connector
- Ignitio n coil sub-harness 5P (Natu ral) connector
Remo ve th e ign it ion co il sub-ha rness 5P (Natural)
co nn ecto r fro m th e sta y .
Rem ove the rear brake light switch wi re from the

cla mps o n the right crankca se cover.
~::==::===:;==~~=~
Rem ov e t he pin ch bo lt and di scon nect the gear shift ~~~~:~:;~~;;;:~~~~~:;...

arm f ro m t he gea rshi ft spi ndle.
Remove the bolt, washer, wave washer and gear

shift pedal assembly.
8-5
Contents Chapter 8
Dis con nect the PAIR co nt ro l va lv e ai r hose s fr om
th e ree d va lve cove r.
Discon nect t he cr a nkcase b rea the r hose fro m the
cyl inder head cove r.
Disconn ect the upper rad i at or ho se from t he th er-

m e st at hou si n g cove r.
Disconn ect th e ECT sensor 3P (Gray) co n ne cto r.
Loosen the ho se clamp screw a nd d iscon nect the

radiator hose f rom t he wate r pump.
Loo sen t he ho se cl am p screws and disconnect the
wate r ho ses f ro m t he o il coo le r.
Rem o v e t he rad iator assem bly .
Rem o v e th e two bolts, drive sp roc ket cover and

guid e pl at e (pag e 12-7).
Loose n t he re ar axle nut .
Tu rn th e d rive chai n ad ju st ing bo lt s make the drive
chain slack fu lly.
Re m ov e the drive sprocket specia l bo lt , washer and
driv e sp rocket .
8-6
Contents Chapter 8
Rem ove th e bolt and ra diator low er stay f rom the oil
pan.
LOW ER STAY BOLT
Support the engine u sin g a jack or other adj ustable

support t o ease of engine hanger bolt s rem oval.
Rem ove t he left f ro nt eng ine ha nge r bolt and mid-
die engine ha nger bo lt.
Rem ove the right f ront eng ine hange r bolt and m id-
dle engine hanger bolt and dist ance col la rs.
Remove the rear lower eng ine hanger nut while

ho ldi ng the hanger bo lt .
8-7
Contents Chapter 8
Remove the re ar engi ne hanger lock nut using th e
special too l.
TOOL :
Lock nut wrench, 20 mm 07VMAMBB0100 o r
07VMAMBB010l
Turn th e engine hanger adju st ing bolt counterctock-

wise fully by looseni ng the rear engin e hanger bolt.
Remove th e rear u p pe r engi ne han g er nut w hi le

hol d ing th e h a nger bol t .
Loosen the rear upper eng ine hanger adjust ing bolt
lock nut using the special tool.
TOOL :
Lo ck nut wrench, 20 m m 07VMAMBB0100 or
07V M A MBB010l
8-8
Contents Chapter 8
Turn th e eng ine han g er adj us ting bolt co u nte rcl ock-
wise f u lly by loosening t he rear eng ine han g er bolt.
Support the en gine using a ja ck or othe r adjustable
supp ort to ease engi n e ha nger bo lts re m ov a l.
Remove the fo llow ing :
- Rear lower eng ine ha nger bolt
- Rear upper eng in e hanger bol t and co ll ars
Car efull y lower the ad justable su p po rt, the n remove
t he engine f rom the f ra me .
ENGINE INSTALLATION
REAR UPPER HAN GER BOLT UPPER ADJUSTING BOLT
LOCK NU TS
~:1~CO'~"
""~"''' """
.s->:
REAR LOWER HANGER BOLT
/ HANGER NUT
FRONT HANGER BOLT

,/
M IDD LE
HA NGER BOLT
MIDD LE HANGER
BOLT
Y
,
DISTANCE COLLARS
LOW ER A DJUSTING BOLT REAR LOWE R

HANG ER NUT
FRONT HA N GER BOLT
Not e th e di rect ion of th e ha nger bolts/co llar s.

W he n tightenin g t he Jock nut w it h the loc k nut
wrenc h, refer to the t or qu e w re nch read ing infor-
matlon in "SERVICE IN FORMATION" (pag e 83) .
T he jack height m ust be con tinua lly adju sted to
re lieve st ress from the mou nt ing f ast en er s.
Rou t e t he w ir e and cab les properl y (page 1-24 ).
Be su re to ti ghten al l engi ne mounting fa st ene rs
to t he sp ecif ied torqu e in th e specifie d seq u enc e
described on t he f ollowing page. If you mi stake
t he t ightening torq ue or sequ ence, loosen all
moun ting f ast eners, t hen t ig hte n t hem ag ain to
t he spec ified torque in th e sp ecif ied seque nce.
8-9
Contents Chapter 8
Install t he rea r u pp er and re ar lower engine han ge r
adj ustin g bolts f u lly from t he inside of the frame.
Carefu lly instal l t he engine into t he f rame.

Do not inte rchange Install the colla rs and rea r u p per engi ne ha nger bo lt
the upper and lower fro m th e rig ht side .
hanger bolts. The
A lign the flats of the rear u ppe r ha ng er bo lt head
upper hanger bolt is
w ith the ad j usting bolt bos s.
not hollow.
Inst all th e rea r lower eng ine ha nger bolt f ro m t he

right side.
A lign the f lat s of the rea r lo w er han ger bo lt head
with th e adjusting bo lt boss.
The front hanger Inst a ll the d istance collars, right front engi ne ha nger
bol t is hollow. bolt an d mid d le eng ine h ang e r bolt.

Install the left front eng ine hanger bolt and m iddle
engi ne hange r bolt.
Tu rn the uppe r and lower engine hanger adjusting

bolt by turni ng the hange r bolt until the adjusting
bolt is seated on the engine .
T ighten the rear low er eng ine hanger adjusting bolt
to the specified torque by turning the hanger bolt.
TORQ UE: 15 Nrn (1.5 kqf-rn, 11 fbllt)
REA R LOW ER ENGIN E HA NGER BOLT
Install the rear low er engine hanger adjust ing bolt

lock nut .
Hol d th e adj usti ng bolt by hold i ng the hanger bo lt
and tighten the lock nut to the specified torqu e.
TOOL :
Lock nut wrench, 20 mm 07VMA-MBB0100 or
07VMA-MBB0101
TORQUE :
Actual: 54 Nm (5.5 kgl m, 40 Ibllt)
Indicat ed: 49 Nm (5.0 kqf-m, 39 Ibllt)
Tighten the rear uppe r engine hanger adjusting bolt ... ~ ~~__~__~__~~~
to the specif ied torq ue by turn ing the hange r bolt .
TORQUE : 15 Nm (1.5 kqf-m , 11 lbf-tt)
8-11
Contents Chapter 8
Instal l the rear low er engi ne hang er adjusting bo lt
lock nut.
Hold the adju sting bolt by ho ld ing the hanger bo lt
and tighten the lock nut to the specified to rque.
TOOL:
Lock nut wrench , 20 mm 07VMA-MBB0100 or
07VMA-MBB0101
TORQUE :
Actual : 54 Nm (5.5 kqf-m, 40 lbf-ft)
Indicated: 49 Nm (5.0 kqf-rn. 39 lbf-tt)
T ig hten the rea r low e r e ngi ne han ger nut to t he

specif ied tor qu e while holdi ng the hange r bolt .
TORQUE: 64 Nrn (6.5 kqf- rn, 47 lb f -ft]
Tig hte n t he rear u pper eng ine hanger nut to t he

specified torq ue while holding the hanger bolt.
TORQU E: 64 Nrn (6.5 kqf -m, 47 lbf-tt]
Install and tig hten the left side fron t engine hanger
bolt to the specified torque.
TORQUE : 64 Nrn (6.5 kqf-rn, 47 lbf-ft]

Install and tighten the left side midd le engine
hange r bo lt to t he spec ified to rque.
TORQUE: 64 Nrn (6.5 kqf-rn, 47 lbf-ft]
8-12
Contents Chapter 8
Inst all and t igh t en th e rig ht si de front engi ne hanger
bo lt t o th e spe cifi ed t orq u e.
TORQUE : 64 N m (6.5 kqf-m. 47 Ibf.lt)

Inst all and tighten the righ t side m iddle engine
h anger bolt to the sp ecifi ed torq ue.
TORQUE: 64 Nm (6.5 kqf-rn, 47 Ibf.tt)
Inst all the drive sprocket w ith t h e ma rks fac ing ou t .

Inst all the w ashe r and spe ci al bolt, tig ht en t he spe -
ciaI b olt t o th e s pecifie d torque.
TORQUE : 54 N 'm (5.5 kqf-m, 40 Ibfft)
Install t he d rive spro cket cover and cl utch slave cyl -

in d er (page 12-1 1).
Insta ll th e gea rshi ft pe da l assem bly ont o t he f ram e,

then inst all th e wa sher and p ivot bo lt .
Tighten t he pivot bolt to the specifie d t o rque .
TORQUE : 26 Nm (2.7 kqf -m, 20 Ibfft)
Inst all the gearshift pedal link to the gearshift spi n- ,...~~~~~.
di e w hile alig ning its slit wit h t he punc h m ar k o n the
gea rshift sp indle.
Install and t ig hten t he pin ch bolt t o the sp ecified
t orq ue.
TORQUE : 9.8 Nvm (1.0 kqf-m, 7lbfftJ
8-13
Contents Chapter 8
Install th e rad iator on to the frame .
Connect the radi at o r hose and tighten the clamp
sc rew secu rely.
Connect the oil coole r hose and t ig ht e n th e clamp '
screw secu rely .
Con nect t he u p per rad iat o r ho se to t he th erm o st at

housing cove r an d t i g hten the clam p sc rew
secu rely .
Connect the ECT sensor 3P (Gray) connecto r.
Conn ect th e PA IR con t rol val v e air hoses to t he reed

va Ive cove r.
Connect th e crankcase br eath er hose to t he cy linder
hea d cover.
Rout e the rea r brake lig ht switch wi re pr operly an d

cl am p it with wire cl am ps on the r ight cra nkcase
cover .
BRAK E LIGHT SWITCH WIRE
8-14
Contents Chapter 8
ENGINE REMOVAl/INSTALLATION
Conne ct t he fo llowing co nnect o rs:
- Crank shaft posit ion sensor 2P (Red) co nnec t o r
Rear brake light sw itc h 2P (Black) con nector
- Ign itio n coil sub-ha rness 5P (Nat ural) connecto r
Conne ct the alt ernator 3P (Nat ural) connecto r and

side sta nd swit ch 2P (Gree n) co nnect o r.
Con nect the cams h aft position se nsor 2P (Black)

co nnec tor.
~::~::;;:;~~~~
Route t he starter motor cable and ground cabl e -~--

pro perly .
Connect th e g ro und ca ble w it h th e starte r moto r
mounting bo lt , tighten the moun ti ng bolt.
Connect the starte r motor cable t o th e starter motor
ter m in al, ti ghten the t er m inal nut to t he s pecified
torq ue.
TORQUE : 12 N'm (1.2 kq f .rn, 9 Ibf.ft)

Connect the fol lowing connectors :
- Veh icle speed senso r 3 P (N atural) connector
- Engine sub-harness 2P (Black) connector
- Th rottle body (page 6-47)
- Air cleaner housing (page 6-40)
- Radiato r reserve tank (page 7-20)
- Radiator (page 7- 101
- Fuel t ank (page 6-36)
- Exhaust pi pe (page 3-30)
- Under cow ls/m iddle cowl (page 3-7)
Adjust the drive cha in slack (page 4-261.
Pour recom m ended eng ine oil up to the proper level
(pag e 4-22).
Fill the cooling system with the recommended cool-
ant and bleed any air (page 7-61.

9. CYLINDER HEAD/VALVES
COMPONENT LOCATION 9-2 CYLINDER HEAD INSPECTION 9-16
SERVICE INFORMATION 9-3 VALVE GUIDE REPLACEMENT 9-18
TROUBLESHOOTING 9-5 VALVE SEATINSPECTION/REFACING 9-19 . .
CYLINDER COMPRESSION TEST 9-6 CYLINDER HEAD ASSEMBLY ..................9-22
CYLINDER HEAD COVER REMOVAL ........ 9-6 CYLINDER HEAD INSTALLATION ............9-24
CYLINDER HEAD COVER DISASSEMBLY .. 9-7 CAMSHAFT INSTALLATION 9-26
CAMSHAFT REMOVAL .. 9-8 CYLINDER HEAD COVER ASSEMBLY ........9-31
CYLINDER HEAD REMOVAL 9-13 CYLINDER HEAD COVER

INSTALLATION .. 9-32
CYLINDER HEAD DISASSEMBLy 9-14
CAM CHAIN TENSIONER L1FTER 9-34
9-1
Contents Chapter 9
CYLINDER HEADIVALVES
COMPONENT LOCATION
9.8 Nm (10
. k gf.m , 7 Ibf.ft)
/
9.8 Nrn (1.0 kgf'm,7 lbf-ft)
9-2
Contents Chapter 9
SERVICE INFORM ATIO N
GENERA L
T his section cove rs serv ice of th e cyli nde r he ad, va lves and ca ms haft .
The camshaft services can be done wi th the engine install ed in the frame. The cylinder head service requires engine
rem ov al.
W hen disassembling, mark and store the disassem bled parts to ensure that they are reinstalled in their origina l loca-
t io ns.
Clea n all d isassem bled pa rts w ith clean ing solve nt and dry th em by blowing them off with co m pressed air befo re
inspectio n.
Cams haft lub ricating oil is fed throug h oi l passages in th e cyl inder head . Clean the oil passag es bef o re assembling cyl-
inder head.
Be ca reful not to dam age t he m ating surfac es wh en rem ov ing t he cylind er hea d cove r a nd cy linde r head.
SPECIFICATIONS
U nit" mm (in)
Cylind er com p ressio n 1,098 kPa (11.2 kgf/cm , 159 p si)
at 350 r pm
Valv e clearance IN 0.16 0.03 (0.006 0.001) -
EX 0.30 0.03 (0.012 0.001) -
Camshaft Cam lobe height IN 37.02 - 37.10 (1.457 -1.461) 37.00 (1.457)
EX 36.66 36.74 (1.443 1.446) 36.64 (1.443)
Runout 0.05 (0.002)
Oil clearance 0.020 - 0.062 (0.0008 - 0.0024) 0. 10 (0.00 4)
Valve lifter Valv e lifte r 0 .0. 25.978 25.993 (1.0228 -1. 0233) 25.97 (1.022)
Valve lifte r bore 1.0. 26.010 26.026 (1.0240 1.024 6) 26.04 (1.025)
Valve , Valve ste m 0 .0. IN 3.975 - 3.990 (0. 1565 - 0.1571 ) 3.965 (0.1561)
valve guide EX 3.96 5 3.980 (0. 1561 - 0.1567) 3.955 (0. 1557)
Valve g uide 1. 0 . IN/EX 4.000 4.012 (0. 1575 0.1580 ) 4.04 (0.159)
Stem- to-g uide clea rance IN 0.010 - 0.037 (0.0004 - 0.0015) 0.075 (0.0030)
EX 0.020 - 0.047 (0.0008 - 0.0019) 0.085 (0.0033)
Valv e gu ide project io n IN 16.1 - 16.4 (0.63 - 0.65)
above cylinde r head EX 15.5 - 15.8 (0.61 - 0.62) -
Valve seat w idth IN 0.90 1.10 (0.035 0.043) 1.5 (0.06)
EX 0.90 1.1 0 (0.035 0.043 ) 1.5 (0.06)
Valve spring IN 39.5 (1.56) 38.7 (1.52)
f ree length EX 39.5 (1.56) 38.7 (1.52)
Cylinde r head wa rpage 0. 10 (0.00 4)
TO RQUE VALUES
Cy linde r head m ou nting bo lt/w asher 51 Nrn (5.2 kqf -m , 38 lbf -ft] App ly m olyb denum disulfid e oil to t he
t hre ads a nd seating surface
Camshaft holder fla nge bo lt 12 Nm (1.2 kq f-m, 9 Ibf ft ) Appl y oi l t o th e threa ds
Cyli nde r head sea ling bo lt 27 Nm (2.8 kqf -m . 20 Ibf ft )
Cylinder hea d cove r bolt 9.8 Nrn (1.0 kq f-m, 7 lbf -ft ]
Breath er plate flange bolt 12 Nm (1.2 kgfm, 9 Ibfft ) A pply a locking agent t o t h e th reads
CT bolt
PA IR reed valve cove r bolt 12 Nm (1.2 kgfm , 9 Ibf ft ) App ly a locking agent to the th reads
Thr ott le body insulato r socket bolt 12 Nrn (1.2 kqf -m. 9 Ibfft)
Cam sprocket f lange bolt 20 Nm (2.0 kgf m , 14 Ibfft) App ly a locking age nt to the t hrea ds
Cam chain ten sion er pivot bo lt 9.8 Nm (1.0 kqf-rn, 7 Ibf ft) Ap p ly a locking agen t to the t hreads
Cams haft positio n sensor rotor bolt 12 Nm (1.2 kgf m , 9 Ibf ft) Ap ply a locking agent to the thr ea ds
Cam chain te nsio ne r lifter m ou ntin g 9.8 Nm (1.0 kq f -rn, 7 Ibfft )
socket bo lt
Cam chain gu ide to rx bo lt 12 Nm (1.2 kgf m, 9 Ibfft )
Exhau st pi pe stud bo lt See page 1-15
Spark plug 16 Nm (1.6 kg fm, 12 Ibfft)
9-3
Contents Chapter 9
TOOLS
Comp ression gauge attachment Cam cha in tensioner hold er Valve spring comp resso r
07RM JMY50100 07Z MG-MCAA400 07757-0 010000
or equivalent commercially avail- or 07NMGMY90100

able in U.S.A.
Valve spring compressor attachment Tappet ho le protecto r Valve guide drive r

07959-KM30101 07HMGM R70002 07GM D-KD0100
U.S.A. o nly;
M ake y our o wn t oo l (p age 9-15)
Valve guide driver Valve guide reamer, 4.00 m m Valve seat cutte r, 29 m m (45 0 IN )
07743-0020000 07MM H-M V90100 07780 0010300
Not available in U.S.A. 07MMHMV901OA (U.S.A . only) or equivalent commercially avail-

able in U.S.A .
Valve seat cutter, 27.5 mm (4 5 0 EX ) Flat cutter, 30 mm 1320 IN) Flat cutter, 27 mm 1320 EX )
07780-0010200 07780 0012200 07780-0013300
or eq uivalent com m e rcially avail- or equiva le nt comme rcially ava il- or equ iva le nt com merc ially av ail-
able in U.S.A. able in U.S.A. ab le in U.S.A.

Interio r cutte r, 30 m m (60 0 IN ) Cutte r hold er

07780-0014000 07JM H-KY20200
or equiv alent co m me rciall y av ail- or eq ui v alent comme rcially av ail -

able i n U.S.A. able in U.S.A .
TROUBLESHOOTING
Engin e to p-e nd pr oblem s u su ally affect engine perf orman ce. These pr ob lem ca n be di agnosed by a co m pre ssion t est or
by t raci ng eng ine noises t o t he top-e nd with a so u nding rod st eth oscop e.
If the pe rfo rma nce is poor at low speeds, check f or w hi te smoke i n t h e c rankcase br eath er hose. If the h ose is smoky,
check fo r a seized pi ston ri ng (page 13- 16).
Com pr essi on t oo low, hard sta rting or poo r perform an ce at lo w speed
Va lves:
- Incorrect va lve ad justm en t
- Burned or be nt va lve
- Incor rect valve t im ing
- Bro ken v alve sp ring
- Un ev en v alv e seat in g
Cyl inder hea d:
- Leaki ng or da maged head gasket
- Wa rped or cracked cylinde r head
Worn cyli nder, pist on or piston rings (p age 13-16)
Compression t oo hi gh , ov erheati ng or knock ing
Excessive ca rbo n build-up o n pi st on crown or on co m bustion chamber
Excessiv e sm oke
Cyli nder head :
- Worn v alve st em or va lve guide
- Damaged ste m seal
Wo rn cyli nde r, piston o r pist o n ri ngs (page 13-16 )
Excessiv e noise
Cyli nde r head:
- Inco rrect va lv e adjustment
- Sticking valve or bro ken v alv e spring
- Dam aged or wo rn cams haft
- Loose or wo rn cam chain
- Worn o r damaged cam c hai n
- W orn o r da m age d cam c ha in te nsione r
- Worn cam sproc ket t eet h
W orn cy li n der, pisto n or pisto n rings (page 13-16)
Rou gh id le
Lo w cyl inder comp res sion
9-5
Contents Chapter 9
CYLINDER COMPRESSION TEST
Wa rm th e engine to no rm al o pe rat ing t emperature.
Sto p the e ng ine a nd remove the all direct ign ition
co il/spa rk pl u g ca ps an d spa rk p lugs (pag e 4-81.
Lift an d suppo rt th e f ue l t an k (page 4-5 ).
Dis co nnect th e f uel p ump un it 3P (Black) connecto r.
Install a comp ressio n ga uge into th e spa rk plug

COM PRESSION GAU GE
hole.
TOOL:
Compression gauge 07RMJ-MY50100 or
attach m ent equivalent commer-
cially avai la b le in
U.S.A.
Op en th e t hrottle all th e w ay and crank th e eng ine
with the sta rte r moto r un til th e gaug e re a ding sto ps
ri sin g.
Th e m axim u m readi ng is usua lly reach ed w it hin 4 -
7 seco nds.
Compression pressure:
1,098 kPa (11.2 kgflcm' , 159 psi) at 350 rpm
Lo w co m p ressio n can be caus ed by:

- Blown cy li nde r head g asket
- Impro pe r v alve adj ustment
- Va lve leakage
- Wo rn pisto n ring o r cylind e r
High comp ressio n can be caused by:
- Carbon de po sits in com b ustion cham be r or on
pi sto n h ead
CYLINDER HEAD COVER REMOVAL

Remove the t hrott le body (page 6-47) .
Remove t he crankcase b rea the r hose.
Di sconnect the PAIR air hoses from the cylinde r
head and remove the PAI R control solenoid valve
(pag e 6-71) .

Disconnect the ignitio n coil connectors and remove DIRECT IGN ITION COILS
the direct ignitio n coils.
Rem ove th e cyl inder head cover bo lt s. CYLINDER HEAD COVER

Rem ove the cylinder head cove r from the cylinder
head .
CYLINDER HEAD COVER

DISASSEMBLY
Rem ove the cylinde r head cove r packing .
PACKING
Rem ove the bolts and PAIR check valve cover.

PAIR CHECK VALVE COVERS
BOLTS
Contents 9-7
Chapter 9
Remove t he PAIR check va lves f rom the cyl inder
head cove r.
Chec k th e PAIR check va lve for wea r or damage,
replace if necessa ry .
Remove the po rt plates from t h e cylin der head

cover.
CAMSHAFT REMOVAL
Remove the cy linder head cover (page 9-6).
Avo id damaging the e M? (ca m sh aft positio n ) se n-
sor w hile rem ov ing the cams hafts, remove the bolt
and eM ? senso r from th e cylinder head.
Rem ov e t he tim ing ho le cap an d O- ri ng .
9-8
Contents Chapter 9
Turn t he c rankshaft cloc kwise . align the "T " mark on
th e ignit ion pul se g en erator rotor w it h th e index
mark on th e right crankc ase cover.
The t im ing m arks ("IN" and "EX") on the cam

spr ocket s m ust be flu sh wit h the cy lin der head sur-
f ace and fac ing outwa rd as sho w n.
If the t iming m a rks on the ca m sp rocket are f aci ng
inward, t urn the cran kshaft clockwi se one ful l t urn
(360) and real ign th e tim ing m ar ks w it h t he cy lin-
der hea d surfa ce so t hey ar e fac i ng o utw ard.
Rem o v e the cam chain tensto ner lift er sea li ng bo lt ~~~~~~::~:;:~=~~~

and sealing was her.
Turn th e tens ioner litter shaft fully in (cl ockw ise)

and secure it usi ng the specia l t ool t o pr event dam- CAM CHA IN TE NSION ER HOLDER
a ging th e ca m cha in.
TOOL :
Cam ch ain ten eloner holder 07ZMG-MCAA400 or
07NMG-MY90100
9-9
Contents Chapter 9
Rem ove th e bo lt s an d cam chain gu ide B.
It is not neces sary If you p la n t o rep lace the camshaft and/o r cam
to remove the cam sprocket, loose n the cam sproc ket bo lts as f o llow s:
sprocket from the
camshaft except
w hen replacing the
camshaft and/or
cam sprocket.
Be careful nor to - Remove the cam sp roc ket b o lts f ro m t he intake

drop the cam an d ex ha ust camshaft s.
sprock e t bolts and
cam sprocket into
the crankca se.
Turn th e cran kshaft clockwise o ne full turn

CA M SPROC KET BOLTS
(360), remove t he ot he r ca m sprocket bo lts f rom
t he ca ms hafts.
- Remove th e cam sprocket s from th e cams haft s.
- Remove th e bolts and CM P sensor rot or f ro m t he

ex haust cams haft.

Suspend the cam Loosen and remove the camshaft holder bo lts!
chain with a piece washe rs. the n remove the camshaft holders an d
of w ire to p revent camsh afts.
the chain from faIl-
ing into the crank-
NOTE:
case. From outside to inside, loosen t he bolts in a cr iss-
cross pattern in several steps or t he camshaft holder
mig ht bre ak.
Do not fo rci bly remove th e dowe l pins from t he
camshaft ho lders.
Rem ove the valve lifters and shims.

Be careful not to damage t he val ve lift er bore.
Shim may stic k to th e inside of th e valve lift er.
Do not allow the shims to fall into t he crankcase.
Ma rk all va lve litt er s and shims t o ens ure correct
reassembl y in th ei r o rig inal locatio ns.
Th e valve lifter can be easily re m ove d w ith a
va lve lappin g too l or magnet.
Th e shims can be easily removed with a twee-
zers or magnet.
INSPECTION
CAMSHAFT
Check the cam and journal surfaces of the cam shaft
for scoring, scrat ches o r ev idence of insufficient
lubricatio n.
Check t he oi l ho les in t he camshaft f or clogg ing .
Support both sides of the camshaft (at journals)
w ith V-blocks and check the cams haft ru n out with a
dial g auge.
SERVICE LIM IT: 0.05 mm (0.002 in)
Using a micro m eter , mea sure eac h cam lo be height.
SERVICE LIMITS:
IN : 37.00 m m (1.457 in)
EX: 36.64 m m (1.443 in)
9-11
Contents Chapter 9
CAMSHAFT HOLDERS
Insp ect th e bearing surface of the each camshaft
CA MS HAFT HOLDER A
hol der for sco ring, scratc hes , or ev ide nce of in suffi -
cient lubricat ion .
Inspect th e oil o rif ices of the hold ers fo r clogg ing.
CAMS HA FT HOLDER 8
CAMSHAFT HOLDER C
CAMSHAFT OIL CLEARANCE

Do not rotate the Wi pe any oil fro m the journa ls of th e cams haft, cy l-
camshaft when inde r head and camshaft ho lder s.
usin g p lastigauge. Lay a st rip of plastiga uge leng thw ise on t op of each
cam shaft journal.
Be sure the dowel In st all the each cams haft ho ld er to the co rrect lo ca-
pins in the cam tio ns w ith th e id entifi cat ion marks.
shaft holder align
- "RIO mark: cent er ca mshaft hol d er (Ho lde r A )
th e holes in the CVI-
- "L" ma rk: left cam shaft holder (Hold er 8 1
inder head.
App ly engi ne oil t o the th reads and seatin g su rfa ces
of th e cam shaft holde r bo lt s.
Inst all the twenty holder bo lt s w it h th e eight seali ng
was hers.
Finger ti ghten the bolts.
First g radua lly tig hten the fo ur bol ts (N o.5 - NO.6 - :~~::::~.;;.;.~::;;~;---..;.."",,
N o.7 - No .8) in the numeri cal o rde r cast on the cam -
shaft holders.
Gradually tigh t en the ot he r cam sha ft ho lde r bo lts
unt il the cams haft ho lde rs lightl y co nta ct th e cy li n-
der head surface.
I NOTICE I
Failure to ti gh ten th e camshaft holder in a crisscro ss
p attern might cause a cam sh aft holder to break.
Tig ht en all camshaft holder bo lt s in th e nume rica l
orde r cast o n t he cam shaft holders.
TORQUE: 12 N'm (1.2 kgf-m, 9 Ibfft)

Remove the cams haft holde rs and measu re the
w idth of eac h plastigauge.
The w ides t thickness determ in es the oil clearance .
SERVICE LIM IT: 0.10 m m (0.004 in)
W he n the serv ice lim it s are exceede d, repl ace the
cams haft and rech eck th e o il clea rance .
Repla ce th e cy linder h ead and cams haft holders as
a set if th e clea ra nc e stil l exceed s the service limit .
CYLINDER HEAD REMOVAL

Remo v e t he eng ine from t he fra m e (page 8-4).
Remov e t he cams hafts (page 9-8l.
Rem o v e the bol ts, t he rmostat housing and Oring.
Tilt the engine and drain the co o lant f rom t he cy lin-
der head and cyli nder.
Rem ov e th e bolts, sea li ng was he rs. cam chai n

tensioner lifter and gasket.
GASK ET
Rem ov e th e tw o 6 m m bolt s.
Loosen the 9 mm Rem ov e th e te n 9 m m bo lts /washers.
bolts in a criss-
Remov e t h e cylinde r head .
cross pattern in two
or three steps.
9-1 3
Contents Chapter 9
Remove the gasket and dowel pins.
Remove th e f oll owing:

- Right cra n kcase cover (pag e 10-15 )
- Sta rter clutch (page 10-28)
Remove the torx bo lt, was he r, cam chain gu id e a nd
pivot col la r.
Rem o v e the socket bo lt. cam ch ain te ns io ne r a nd
wa sh er.
Remove th e cam chain an d t im ing sprocket f ro m t he ~;:;:;~;::::;:;;~~~

cran ksh aft.
CYLINDER HEAD DISASSEMBLY

Remove the cylin de r head (page 9-13 ).
Remove the bolts and thrott le body in sul at ors fr om
the cy li nd er head .

Remove th e spa rk plugs f rom t he cyl inde r head.
Inst all t he tappet h ol e protector into th e va lve li fte r
bore.
TOOL:
Tapp et hol e protector 07HMG-MR70002
(not availab le in
U.S.A.)
A n equivalent t oo l ca n easily be ma d e f rom a p lastic

35 mm f ilm conta iner as shown.
TOP VIEW
25 mm I.D.
(whe n co m p re ssed)
To prevent loss of Rem ov e th e valve s p ri ng cotters u sin g the specia l

tension. do not to ols as shown .
compress the valve
sp rings m ore thanTOOLS:
necess ary to Valve sp ring co m p resso r 07757-0010000
- remove the cotters. Valve sp ri ng compressor
atta chment 07959 -KM30101
Ma rk all par ts dur- Rem ov e the f o llowin g :

ing d isass embly so
- Spring reta iner
they can be placed
- Valve springs
back in their original
- Va lve
tocs tions.
- Stem sea l
- Val ve sp ri ng seat
VALVE SPRING
9-15
Contents Chapter 9
CYLINDER HEAD INSPECTION
CYLINDER HEAD
Avoid damaging the Rem ove carbo n deposits f rom the co m bustion
gasket surface. cha m be rs .
Chec k the sp ark plu g hole and va lve areas f or
cracks.
Check the cyl inde r he ad fo r wa rpage with a straight

edge and fee ler gauge.
SERVICE LIMIT: 0.10 mm (0.004 in )
VALVE LIFTER BORE

Inspect each v alv e lifter bore f or scratc hes o r abno r-
ma l wear .
M easu re the eac h v alv e lift er b o re I.D.
VALVE LIFTER
Inspect each valve lifte r fo r scratches or abnormal
wear.
Measure the eac h v alve lifter 0 .0 .

VALVE SPRING
M easur e the fr ee length of t he va lve sp rings.
SERVICE LIMITS:
IN : 38.7 mm (1.52 in)
EX: 38.7 mm (1.52 in)
Repl ace t he sprin gs if they are sh orter than th e ser-

vice limit s.
VALVEIVALVE GUIDE
Check that the valve moves sm oothly in th e g uide.
Inspe ct each valve fo r bending, burning o r abnor-
mal stem wea r.
Measu re and record each va lve ste m O.D.
SERVICE LIMITS:
IN : 3.965 mm (0.1561 in)
EX: 3.955 mm (0.1557 in)
Ream th e guides to remove any car bo n deposits

before chec king cle arance s.
Insert the reamer from the combustion cham ber
side of th e cy linder head and alwa ys rotate th e
ream er cloc kw ise.
TOOL:
Valve guide rea m er, 4.00 mm 07MMH -MV90100
Meas u re and record each val ve guide 1.0.
SERVICE LIMIT: IN /EX: 4.04 mm (0. 159 in)

Subt ract each valve ste m 0 .0 . from the co rrespo nd-
ing guide J.D. t o obtain the st em- t o- guide cleara nce.
SERVICE LIMIT:
IN: 0.075 mm (0.0030 in )
EX: 0.085 mm (0.0033 in)
Reface the valve If t he stern-to- quide clea ra nce is out of sta nda rd,
seats w henever the det erm ine if a new gui de wi t h st anda rd dime nsi ons
valve guide s are wou ld br ing the cleara nce w it hin t ol er ance. If so,
replaced (page 9- repla ce any gu id es as necessary and rea m to fi t.
20). If th e stern -t o-q uide cl earance excee ds the service
limit w ith the new g uides. replace th e valves and
guides.
9-17
Contents Chapter 9
CAM CHAIN TENSIONER/CAM CHAIN
GUIDE
Insp ect t he cam ch ai n t en sion er and cam chain
-.
gu ide f o r excessiv e w ear or damag e, re p lace t h em if CAM CHA IN TE NSIONE R
necessary .
CAM CHAIN GUI DE
Inspect the cam chai n tensioner B f or excessive

wea r o r damage, replace it if ne cessary.
VALVE GUIDE REPLACEMENT

Chill the repl acem ent v alve guides in t he f reezer 1"'-----,.
section of a ref rige rator fo r about an ho u r.
Do nor use a torch Heat the cyli nd er head to 100 - 150C (212 - 300F)
to hea r the c ylinder with a hot plate o r ove n.
head; it may cause To avoi d burn s, w ear h e avy gloves w he n handlin g
wa rping. th e h eat ed cy li nder head.
Su p po rt t h e cyli nde r head and d ri v e out t h e v alve
guides f rom comb us tio n cham ber side of th e cy li n-
de r h ead .
TOOL:
Valve guide driver 07JMD-KY20100
(not available in
U .S.A .)
Dri ve in th e gu id es t o th e spe cif ie d d epth f ro m t h e ..._ - - .

top of th e cy linder head .
TOOL:
Valve guide driver 07743 -0020000
(not available in
U.S.A .)
9-18
Contents Chapter 9
SPECIFIED DEPTH:
IN : 16 ,1 - 16,4 mm (0,63 - 0 ,65 in)

EX: 15,5 - 15,8 mm (0,61 - 0 ,62 in )
Let th e cyl inde r head coo l to room te mperature.
Use cutting oil on Ream the new va lve gui des afte r in sta llation.
the reamer during Insert the re amer from the co mbustion cha mber
this operation. side of the head and al so always rota te th e re am er
cl ockwise.
TOOL:
Valve guid e ream er, 4.00 mm 07MMHMV90100
Clea n th e cy lind er head th o rou gh ly t o rem ov e any

metal pa rt icles.
Reface t he valve seat (page 9-2 0),
VALVE SEAT INSPECTION/REFACING

Clea n t he in t ake and ex haust v alve s th o roug h ly to
re m o v e carbon d ep o si t s.
Apply a light coating of Prussian Blu e to the valve
seats.
Ta p the valves an d seat s usi ng a rubber ho se o r
other ha nd-lap ping too l.
Rem ov e th e v alve a nd in sp ect th e va lv e seat f ace.

The v alv e seat co ntact sh o u ld be w ithi n the sp eci-
f ied w idth and ev en all a round t he circu m f eren ce.
STANDARD:
IN: 0.90 - 1.10 mm (0,035 - 0 ,043 in)
EX: 0.90 -1 .10 mm (0,035 - 0 ,043 in)
SERVICE LIMIT:
IN : 1.5 mm (0,06 in)
EX: 1,5 mm (0.06 i n)
.If'
If t he seat w idth is not w it hin specif icat io n , refa ce
the va lve seat (p ag e 9-20), SEAT WID TH
9-19
Contents Chapter 9
Inspect the valve seat f ace f or:
Un ev en seat w idth:
- Repla ce the v alv e and refac e the v alv e seat .
Dama ged f ace:
- Repla ce th e v alv e and refa ce t he v alve seat .
DAMAGED FACE UNEVEN SEAT W IDTH
The valves cannot Contact area (to o high o r to o low)

be ground. If a - Refa ce the v alv e seat.
valve face is burned
or badly worn or if it
contacts the seat
unevenly. replace
the valve.
TOO LOW
VALVE SEAT REFACING

Foflow the refa cing Va lve seat cutters/g r in de rs or eq uiva lent va lve seat
manufacrurer's ref aci ng eq u ip ment a re recom m en d ed to co rrec t
operating mstruc- w orn va lve seats.
lions.
0
9 / "
/
45
~
Y~~\320 6 --~;
'"
If the cont act area is too high o n the v alv e, t he seat
mu st be lowered using a 32-d egree flat c utt er. CONTACT TOO HIG H /$: SEAT WI DTH
~~
If the co ntact area is too Iowan the v al v e. the seat
mu st be rais ed using a 60-d egree int er io r cutte r.
! '---- 320
CONTACT TOO LOW OLD SEAT WI DTH
~ -~ ~ 6QO

Reface the seat Use a 45-deg re e cutter t o rem o v e any rou ghness o r
w it h a 45-degree irregul aritie s from th e seat. ROUGHNESS
cu tt er whe never a
valve guide is TOOLS :
replaced . S eat cutter, 29 mm (I N) 07780-0010300
S e at cutte r. 27.5 m m lEX) 077 80-0010200
Cutter hold er 07JMH-KY20200 or
eq uiva lent commer-
cially available in
U.S.A.
Use a 32-degree cutter t o rem ov e the to p 1/4 of t he

exis t ing va lv e seat m at erial.
TOOLS:
Flat c utte r. 30 mm (IN) 077 80-0012200
Flat c utter. 27 m m (EX) 077 80 -0013 300
Cutter ho ld er 07J MH-KY2020 0 o r
eq uiva le nt commer-
cia lly av ailable in
U.S.A.
Use a 50-degre e cutt er to remo ve the botto m 1/4 of ~=================~

th e ol d seat.
-~_ / ,
TOOLS: OLD SEAT WID TH
Interior c u tte r, 30 mm (IN)
Interior cutter, 30 mm (EX )
Cutter h old er
077 80-0014000
07780-0014000
07JMH-KY20200 or
-, /
eq u iv ale nt c o m mer-
cia lly availabl e in
U.S.A . \
\
- - -- - - -
G
ooL
- -' ~
Using a 45-deg ree seat cutte r, cut the seat t o th e

p rope r w idth.
M ake sure th at all pittin g and ir regularit ies are
rem ov ed. / " 1.0 m m (0.04 in)
Refin ish if n ecessary. <,
/
9-2 1
Contents Chapter 9
Afte r cutt ing th e seat, app ly lap pi ng comp ound t o
th e valve f ace, a nd lap t he val ve us ing lig ht p res-
su re.
Excess ive lappin g p ress ure m ay d ef orm or da m - .
age t he seat.
Ch ange t he an gle of lap p ing tool freq ue nt ly t o
pr event uneven seat we ar.
Do not allow lap p ing com pou nd t o ente r th e
g uides.
Afte r lapp ing, w ash all residu al co m po u nd off t he
cyl inde r head and valve.
CYLINDER HEAD ASSEMBLY
~ VA LVE LIFTER
t - S HIM
~d . COTTERS
~
, SPRING RETAIN ER
~~ VALVE SPRING
~~
~ ~ STEM SEAL
SPRING SEAT
VA LVE GUIDE
/~
EXH AU ST VA LVE INTAKE VA LVE
' Blow t hroug h a ll o il passag es in the cy lind er he ad

w it h co mpresse d air.
Inst a ll th e ta ppet hole protector int o t he valve lifter
bor e .
TOOL:
Tappet hol e protecto r 07HMG-MR70002 or
refer to page 9-15 for
alternative tool
9-22
Contents Chapter 9
Inst al l the v alv e sp ri ng seats.
Inst all th e new ste m seals.
Lubricate the va lve ste ms w it h m o ly bdenum oi l
sol ution.
Insert th e va lv e into th e va lv e gui de w hile t urn ing it
slowly t o avoid da mage to the stem seal. ~ STEM SEA L
RETAI NER "S.:

"': I(~ SPRING SEAT
VALVE SPRING
The exhaust valve Inst all t he valve sp r ings wi t h t he tightly wou nd co il s

springs have facing th e com bus tio n cha m be r.
orange paint ma rks
Inst al l th e v alv e spri ng ret ainer.
and the intake valve
springs have gra y
paint marks.
Grease the cotters Inst al l th e v al v e cotte rs us ing the sp ecial too l as

to ease installation. sho w n.
NOTE:
To prev ent loss of tensio n. do not com press the
v alv e sp ring m o re than necessary.
TOOLS:
Valve spring co m pr essor 07757-0010000
Valv e spring co mpressor
atta chment 07959-KM30101
Support the cylin- Tap the valve stems ge nt ly with two plastic ham-
der head abo ve the m ers as show n t o seat t he co tte rs fi rm ly .
work bench sur -
Inst all and t ig ht en the spark plu gs.
face to pre vent pos-
sible valve dam age. TORQUE: 16 Nen (1.6 kq f-m, 12Ibf it)
9-23
Contents Chapter 9
Instal l a new O-r ing into the groove of t he i nsu lato r.
Install the insulato r o nto t he cy lin der head.
~
S O-RING
Inst all and t ig hten th e insu lator m o un ting soc ket

bol ts to the s pecified torque.
TORQUE: 12 N vm 11 .2 kqf-m . 9Ibf.fl)
CYLINDER HEAD INSTALLATION

Insta ll t he t im i ng sp roc ket by al ig ning th e wide
splines between the crankshaft and sprocket.
Inst all the cam chain.
9-24
Contents Chapter 9
Apply a locking agen t to the cam chain guide torx
bo lt threads. PIVOT COLLAR
Instal l the pivot collar, cam chain guide, w asher and
to rx bolt . \
WAS HER
/ TORX BOLT
CA M CHAIN GUID E . ~
o /~
UW
Apply a locking age nt to the cam chain t en sio ner SOCKET BOLT
socket bolt threads .
Install the washe r, cam chai n tensioner and socket
bol t .
o WAS HER
1!iE3
CA M CHAIN TENS ION ER
T ighten the cam chain guide torx bolt to the speci- r-::-:-:~::":":,,:,:,:-:;:;".~::::::;:;;:;;
tied torque.
TORQUE : 12 Nm (1.2 kqf-m , 9 Ibf.ft)
Tighten the cam chain ten sioner socket bolt to the

specified torque.
TORQUE: 9.8 Nm (1.0 kqf-m, 7 Ibfft)
In st all th e st arter cl utch (p age 10-32) and rig ht

crankcase cove r (page 10-34 ).
Install the dowel pins and a new cylinder head gas-

ket as shown .
9-25
Contents Chapter 9
Apply m o ly bdenum di su lfid e o il solut io n t o t he
th reads and seat in g surface of th e 9 m m bol t s/w ash-
ers and inst all the m.
Install th e two 6 m m fl an ge bo lts.
Tighten t he 9 mm bo lts in a cr is scr oss patte rn in tw o
or th ree steps to t he s pe cified torq ue.
TORQUE: 47 Nm (4.8 kqf-m , 35 lbf-tt)
Tight en t he 6 mm f lang e bo lts .
Inst all t he cam cha in t en si on er lifter o nto th e cyl in-

der head wi t h a new gasket.
Inst all and tig hte n th e soc ket bol t s to t he sp ecifi ed
t o rq ue .
TORQUE : 9.8 Nm (1.0 kqf-m, 7 Ibfft)
Insta ll th e engine into t he frame (p age 8-9).
CAMSHAFT INSTALLATION
Apply mol ybde num o il so lu t i o n t o the oute r su rfa ce . -- - -__- ':"'''''''''
of the eac h va lve lifte r.
Instal! the shims Insta ll -the shims on the ret ainers and va lve lift ers
and valve lifters in into the va lve li ft er bo res.
their original loca-
tions.
Each cam shaft has an identificatio n ma r k.

"EX" M A RK
.... ym
lt..
IN: Intake camsh aft
EX: Exhaust cams haft
~ "IN" M A RK

If th e cam sproc kets are remov ed , install the cam
sprockets onto t he camshafts. NO.1 CYLIND ER CAM LOBES
Install the inta ke cam sproc ket wi t h th e timing

ma rk (IN) f aci ng outward and t he No .1 ca m lo bes
fa cing up an d out as shown .
Install the exhaust cam sprocket with t he tim ing
ma rk (EX) facing outwa rd and th e No. 1 cam
lob es f acing up and out as shown .
Clean and app ly a loc king agen t to t he cam sprocket

bolt t hreads.
Insta ll th e ca m sprockets and bo lt s.
Exhaust cam shaft Clean and apply a lock in g age nt to the CM P sensor
only: roto r bo lt t hreads.
Ins tall the eM? Install t h e CMP sensor rotor and bo lt s.
sen sorrotor w ith
the No. 1 cylin der
cam lobes facing up
and rotor OUT"
ma rk facing ou r as
s hown.
"OUT" MARK
Turn the cranksha ft clo ckwise and alig n t he "T"

mark on t he crankshaft position sen sor rotor w ith
the index mark on th e r ig ht crankcase cover.
9-27
Contents Chapter 9
A pply m o lybdenum oi l sol ution to t he cam sh aft
journ al of th e cyl inder head .
Inst all the cam cha in ove r t he cam sprockets and

th en insta ll th e in t a ke a nd ex ha ust camsha fts . INTAKE CA M SHAFT
Inst al l th e each ca mshaft t o th e co r rect lo cat ion s IDENTIFICATION MARKS

w it h th e ide nti f ication m arks.
"IN" : Intake ca msha ft
"EX": Exh aust cam sh aft
M ake su re that th e ti m ing ma rks on t he cam

sproc kets are f acin g outward and flu sh w it h t he CYLINDER HEAD UPPER SURFACE
cylinde r head up per surface as shown.
Coat new O- ring s w it h o il and in st all t he m int o t he

g rooves in th e cams haft hold er s.
Ap pl y mol ybdenum oi l solution to t he ca ms haft
j ournal s of t he ca m sha ft ho lde rs.
Be sure the dowe l Inst all the each ca msha ft hold e r o nto t he ca ms ha fts.
pins in the cam-
shaft holder align
properly with the
holes in the cyl inder
head pr operly.
g~ a -RIN GS

Not e th e co rrect lo cat ion s w it h the ident if icatio n
m ar ks as sh own.
- No m ar k: rig ht cams haft holder
- "R" mark: cent er camshaft holder
- "L" ma rk : left camshaft ho lder
IDENTIFICAT ION MARKS
Appl y eng ine oil t o th e thre ads and seati ng surfaces

01t he cams haft hold er bolt s.
Inst all th e twenty holder b olt s with new eight seal-
i ng wa she rs as show n.
Fing er t i gh t en th e bolts.
First g radua lly t ig hten the lou r bo lt s (No.5 - No.6 - ~:::::::;;::;;.:..:;=:==

No.7 - No.8) in the numeric al ord er cast on t he earn-
shaft h olders.
Graduall y tig ht en th e othe r camshaft holder bo lts
un ti l t he ca ms haft hol d er s lig htly co nta ct the cylin-
der head surf ace .
I NOTICE I
Failure to tighten the cam sha h ho lder in a crisscross
pattern might caus e a cams ha ft hol der to break.
Tig hten all cam sh aft holder bol t s in the nu m eri ca l
ord er cast on th e cams h aft holders.
TORQUE: 12 Nrn (1.2 kqf-rn, 9 lbf-ttl
In case th e cam sprocket s w ere remov ed, apply a

lockin g agent t o t he cam sprocket bolt t hreads.
Tig ht en the ca m sp rocket bo lts t o th e specified
t o rque.
TORQUE: 20 Nm (2.0 kqf-rn, 14 lbf-ff}
9-29
Contents Chapter 9
Tu rn the crankshaft clockwise one full turn (360)
and tighten t he other cam sprocket bo lts.
In case the cams haft positio n sensor rot or was

re moved, t ig hte n th e ca ms ha ft posi tion se nso r rotor
bo lts t o t he specified to rque .
TORQUE: 12 Nm (1.2 kqf-m, 9 lbf-ttl
Inst all th e cam cha in guide B, and tig hte n t he bo lt s.
Rem ove the specia l too l fro m th e cam ch ain

t en sion e r lifte r. CAM CHAIN TENSION ER HOLDER
9-30
Contents Chapter 9
Insta ll a new sea ling wa she r and tight en t he sealing
bo lt . CAM CHA IN TENSIONER LIFTER
Recheck t he va lve tim ing .
BOLT
J'~ \c/
Apply oil t o a new O-ring, and insta ll it o nt o the
eM? senso r.
Install th e eM? se nso r into th e cy linde r head.
Ins t all an d t ig ht en t he mou nt in g bolt sec u re ly.

Conn ect t he e M? sensor 2P (Black) con nector.
Install th e cy li n de r head co v er (pag e 9-32) .
CYLINDER HEAD COVER ASSEMBLY

Insta ll the PAIR check v alv e port plates into t he cy l-
ind er head cove r.
9-31
Contents Chapter 9
Insta ll th e PAIR che ck va lv es int o t h e cy li n de r head
cove r.
A pply a locking age nt t o th e PAIR check valve cover

moun ting bo lt t hreads. PAIR CHECK VA LVE COVERS
Inst all the PAIR chec k valve cover and , t ighten th e
bolts t o the speci fie d t orqu e.
TORQUE : 12 Nm (1.2 kqf-m , 9lbfftl
BO LTS
Inst all th e new cyl inder head cover packi ng into th e

~ PA CKIN G
~
cy linder head cover g rooves .
CYLINDER HEAD COVER

INSTALLATION
Apply sealan t to the cy linder head semi-circula r cut-
outs as shown.

Install the cylind er head cover onto the cylinder
head . "U P" M ARK
Install the wa shers to the cylinder head cover w ith
their "UP" ma rk facing up . .
In stall and tig ht en th e cy linde r head cove r bolts to CYLI NDER HEAD COVER
the specified torqu e.
TORQUE : 9.8 Nm (1.0 kqf-m , 7 Ibf.ft)
Install the direct ignition coils and connect the igni-

DIRECT IGN ITION COILS
tion coil conne ctor s.
Connect the PAIR air hoses onto the reed valve cov-
ers.
Connect the PAIR control solenoid valve 2P (Black)
connecto r (page 6-71) .
Install the cran kcase breath er hose to the cylinde r
head cove r.
Inst all th e t hrottle body (page 6-47) .
9-33
Contents Chapter 9
CAM CHAIN TENSIONER LIFTER
REMOVAL
Remove the cam cha in t en sio ner sealing bolt and
sealing washe r. CAM CHA IN TENSION ER LIFTER
BOLT
').~ \ci
,
SEALING WAS HER
Turn the tensioner shaft fu ll y in (clockw ise) and

secure it using t he specia l too l to prevent damagi ng CAM CHAI N TENSIONER HOLDER
the cam chain.
TOOL:
Cam chain tensioner holder 07 ZMG -MCAA400 o r
07NMG -MY90100
Remove the bolts, seal ing washers, cam chain

tensione r lift er and gasket. TENS ION ER LIFTER
GASK ET
INSTALLATION
Note the installation Ins tall a new gasket onto t he cam chain t ensio ner
TENSIONER LIFTER
direction of the lifter.
gasket.
Install t he cam chain te nsioner lifter into the cylin-
der head .
GASK ET
9-34
Contents Chapter 9
Install the sealing was hers and bolts, tighten the
socket bolts. TENSION ER LIFTER
-- ~ ..
g SEA LING WAS!HERS ~"C J--_.BOLTS
.J
Remove the special tool. CAM CHAIN TENSION ER HOLDER
Instal l a new seali ng was he r and tigh ten the sealing CAM CHAIN TENSION ER LIFTER
bolt securely.
Install th e throttle body (page 6-521.
BOLT
oS~
..
SEALING WAS HER
9-35
Contents Chapter 9
MEMO
Contents Chapter 9
10. CLUTCH/STARTER CLUTCH
COMPONENT LOCATION 10-2 CLUTCH SLAVE CYLINDER 10-13
SERVICE INFORMATION 10-4 RIGHT CRANKCASE COVER REMOVAL 10-15
TROUBLESHOOTING 10-5 CLUTCH : 10.16.
CLUTCH FLUID REPLACEMENT/ STARTER CLUTCH , 10-28

AIR BLEEDING 10-6
RIGHT CRANKCASE COVER
CLUTCH MASTER CyLINDER.... 10-8 INSTALLATION ...................................... 10-34
10-1
Contents Chapter 10
~LOUMTCH/STARTER CLUTCH
PONENT LOCATION
. kgf.m , 25 lbf-ft]
34Nm(35
10-2
Contents Chapter 10
15 Nrn 11.5 kgfm

11 Ibf ft l '
127 Nrn 113.0 kqf- m -,

94 lbf- ft] ,
12 N m (1.2 kqf-rn
9 lbfft l '
10-3
Contents Chapter 10
SERVICE INFORMATION
GEN ERAL
I NOTICE
SpiJIed fluid will severe ly damage instrument lenses and painted surface s, It is also harmful to some ru bber pans. Be care-
ful wh enever you remo ve the reserv oir cap; ma ke sure the reservoir is horizontal first.
This section cove rs service of the clutch and starter clutch. All serv ice can be done w ith the engi ne installe d in the
frame.
Tr ansm ission oil viscosity an d lev el have an effect on clutch disengage me nt. When the clutch does not dise ngage or th e
motorcycle creeps with clutch disengaged, inspect the transm ission oil level before servicing the clutch system.
SPECIFICATIONS
Unit : mm (in)
S pe cified clutch flu id DOT 4 b ra ke flu id -
Clutch master cylinde r M aster cylinder 1. 0 . 12.700 - 12.743 (0. 5000 - 0 .5017 ) 12.7 55 (0.50221
M aster piston 0 .0. 12.657 -1 2 .684 (0.4983 - 0 .4994) 12.645 (0.4978)
Clutch Sprin g free length 56 .8 (2. 241 55 .7 (2.19)
Disc A thickness 3.72 - 3.88 (0.146 - 0.153 ) 3 .4 (0.13)
Disc B thi ckness 3.22 - 3. 38 (0.127 - 0.13 3) 2.9 (0.11)
Plate w a rpage 0 .30 (0.012)
Clutch oute r guide A 1.0. 27.993 - 28.003 (1.102 1 - 1.1025) 28.012 (1.10281
(Wit hout ID m ark ) O.D. 35 .004 - 35. 012 (1.378 1 - 1.3784) 34 .994 (1.37771
Clutch out er gu ide B 1.0. 27.993 - 28 .003(1 .102 1 -1 .1025) 28.012 (1.1028 1
(With ID ma rk) O.D. 34 .996 - 35 .004 (1.3778 - 1.37 81) 34.986( 1.3774)
Primary driven gear 1.0 . A 41.008 - 41.016(1.6145 -1.6148 1 4 1.026 (1.6152)
B 41.000 41.008 (1.6142 - 1.6145) 41.0 18 (1.6149 )
Oil pump dr ive sprocket 1. 0 . 28.000 - 28 .021 (1.102 4 - 1.1032) 28.030 (1.1035)
guide 0. 0 . 34 .975 - 34.99 1 (1.3770 - 1.377 6) 34 .965 (1.376 6)
Oil pump drive sprocket I.D . 35.025 35. 145( 1.378 9 - 1.3837 ) 35 .155( 1.3841)
Ma inshaft O.D. at clutch outer guide 27.980 - 27.990 (1.1016 - 1.1020 ) 27.96 (1.101)
M ainshaft 0 .0 . at oil pum p dr ive sprocket guid e 27.980 - 27.990 (1.1016 - 1.1020 ) 27.96 (1.101 )
Sta rte r idle gea r I Gea r I.D. 10.013 10.03 5 (0.3942 - 0.395 1) 10 .05 (0.396)
I Shall 0 .0. 9.991 - 10.0 00 (0.3 933 - 0.3937 ) 9.98 (0.393)
Sta rter driven gea r boss 0 .0. 45 .657 - 45 .673 (1.7975 -1 .7981 ) 4 5.642 (1.79691
TORQUE VALUES
Clutch center lock nut 127 N'm (13.0 kqf-rn, 94 Ibfll ) Ap ply o il to th e thread
Sta ke the nut
Clutch spring bo lt/washer 12 Nrn (1.2 kqf-m, 9 lb f -tt)
Oil pump driven sprocket bolt 15 Nm (1.5 kqf-rn, 11 Ibfll) Apply a locking age nt to the threads
Starter clutch outer bolt 83 N'm (8.5 kq f-rn, 61 Ibfll) Apply oil to the threads and flange surface
10-4
Contents Chapter 10
TOOLS
Snap ring pliers Clutch cente r hold e r Gea r ho lder, M2.5
07914-SA50001 07724-005000 2 0772 4-0010100
or equiva lent commercially avail- or 07724-001A 100 (U.SA only )

a ble in U.S.A.
TROUBLESHOOTING
Clu tch lever soft or spongy
Ai r in hy drau lic syst em
Low f luid level
Hydraulic syst em leaking
Clutch lever too ha rd to pull in
Sticking m ast er cy lind er piston
St icking slave cylin de r
Clog ged hydra uli c syste m
Damaged clut ch lifter m ech anism
Faulty clut ch lifter bearin g
Clut ch lift er p iece i nsta lle d impro pe rl y
Clutch slips when acce le ra t ing
Hydraulic sys tem s ticking
Wo rn clutc h di sc
Wea k clutc h sp ri ngs
T ransm issio n o il m ix ed with m o lybd en u m o r g ra p h ite ad d it iv e
Clutch will not disengage or motorcycle creeps wi th clutch disengaged
Air in hydraulic system
Low flu id lev el
Hyd raulic syste m leaki ng o r cl o g g ed
Clut ch p late wa rp ed
Lo ose cl utch lock n ut
Oil lev el t o o h igh
Improper oi l viscosity
Dam ag ed cl utch lifter mechanism
Clu tch li ft er piece inst all ed im p roperly
Hard to shift
Im pro per clutc h o per ation
Im pro per o il v iscosity
10-5
Contents Chapter 10
CLUTCH FLUID REPLACEMENTI AIR
BLEEDING
CLUTCH FLUID DRAINING
Su ppo rt th e m oto rcy cle on its s ide stand.
Turn t he handlebar t o t he rig ht until t he rese rvoi r is
para lle l to the gro u nd, befo re rem o vin g t he reser -
voi r cap .
Remove th e screw an d stop per plate.
Rem ove t he reserv oi r cap, set pl at e and di ap hr agm .
Con nect a bleed hos e t o th e bleed v alve of t he

clutc h slave cy li nder.
Loosen the bleed valve and pum p th e clutch lev er
until flui d stops flow in g out of t he bl eed valve .
-- CLUTCH FLUID FILLING/AIR -----

BLEEDING
Use only DOT 4 Fil l the reserv oi r with DOT 4 Brake f lui d f rom a
brake fluid from a sealed con taine r.
sealed container.
Co nnect a comme rcia lly avai lable brake bleede r t o
the bleed va lve.
Do not mi x different Pump t he br ake blee de r and loo sen t he bleed valve .
types of flu id. Thev
A dd brake flu id w he n t he fl uid lev el in t he reserv oir
are not compatible.
is low.
Check the flu id level often wh ile bleed ing th e
clutch to prevent air f ro m be i ng pumped in t o th e
syste m .
Whe n u sin g a brake bleeding t oo l, fol low th e
ma nu facturer's ope rati ng instructio n.
If air is entering the Repeat th e ab ove proce dures un t il new fluid flows
bleeder from out of th e bleed v alve and ai r bu bbl es do not appea r
around th e ble ed in the plastic hose.
valve threads, seal
Close t he bleed va lve and ope rate th e clutch lev er.
the threads with
If it is still spongy, bleed t he system aga in.
teflon tape.
10-6
Contents Chapter 10
CLUTCH /STARTER CLUTCH
If a brake bleeder is not ava ilable, u se t he f oll ow ing
procedure.
Pump the clutch lever until lever resistance is felt.
Connect a bleed hose to the bleed valve and bleed
the system as follows :
1. Squeeze th e clutc h lev er , open th e bleed va lv e l '
4 of a t urn and the n close it. Do no t release th e
clutch lever un til the bleed va lve has been
closed .
2. Release the clutch lever slowly and wait several
seconds aft er it reac hes th e end of it s trav el.
Repeat steps 1 and 2 until air bubbles do not appear

in the bleed hose.
Tighten the bleed v alve to th e spe cified t orqu e.
TORQUE : 9 Nm (0.9 kqt- m. 6.5 IbUt )
Fill t he reserv oir to th e up pe r lev el lin e w it h DOT 4

bra ke fluid from a sea led co ntai ne r.
Install the diaph ragm and set plate.
Install and tighten the reservoi r cap .

Insta ll the stopper plat e and tighten the screw.
Check the clutc h o pe ratio n (page 4-33).
10-7
Contents Chapter 10
CLUTCH MASTER CYLINDER
REMOVAL
I NOTICE
Spilled fluid can damage painted, plastic, or rubber
parts. Place a shop towel over these parts wheneve r
the system is serviced.
Dra in the clutch hy drau lic system (page 10-61.
Disconnect the clutch switch w ire connecto rs.
Remove t he clutch hose oil bolt, sealing was hers
and clutch hose eyelet.
Remove the bolts fro m the master cylinder holder

and remove the master cylinder assembly.
DISASSEMBLY
Remove the pivot bolt/n ut and clutch lever assem -
bly. PIVOT BOLT
PIVOT NUT CLU TCH LEVER
10-8
Contents Chapter 10
Remove the screw and clutc h switch .
SCREW CLUTC H SWITCH
Remove the screw an d oil cup and O-ri ngs from t he

master cy li nder body.
SCREW
Remove the boot and pus h ro d .
PUSH ROD BOOT
Remove the snap ring from the m ast er cyl inde r

body using the special t ool as shown.
TOOL :
Snap ring pli ers 07914-SA50001
10-9
Contents Chapter 10
Remove the master piston assembly and spring .
MASTER CYLIN DER
Clean the inside of the cylinder and reservoir with
brake fluid.
PISTON CUPS A
~ SPRING
o \ MA STER PISTON
INSPECTION
Check the piston boot, primary cup and secondary
cup for fatigue or damage.
Check the maste r cylinder and piston for abnorma l
scratches.
Measure the master cylinder 1.0.
Measu re the maste r piston 0 .0 .
SERVICE LIMIT: 12.645 m m (0.4978 in)
ASSEMBLY
RESERVOIR CAP
DIAPHRAGM PLATE
DIAPHRAGM
1.0 Nm (0.1 kqf-rn ,

0.7 Ibfft)
M~\.o ~~~x
C~~
OIL CU P --.I,~~
~I O-RINGS ~--~
~
MASTER PISTON
i ~
SNAP RING
PUSH ROD
BOOT
5.9 N'm (0.6 kqf-m, 4.3 Ibfft)

1.0 Nrn (0.1 kqf-m, 0.7 Ibfft )
10-10
Contents Chapter 10
Coa t all parts with clea n b rake fl ui d b efore assem-
bly. MASTER CYLIN DER
Dip the pis to n in b rake f luid.
In st all the pr im ary and secondary cups o.nto th e
m ast er pist on .
When ins talling th e Insta ll th e s p ring a nd maste r piston asse mbly into
cups, do not allow t h e maste r cyl inde r.
the lips to turn
inside out.
MAS TER PISTON
Be certain the snap Inst all t he snap ri ng u sin g the speci al tool.
ring is firmly seated
in the groove. TOOL:
Sn ap ring pliers 07914-SA50001
Ap p ly cl ean br ake fl u id t o t he O-ri ngs a nd in sta ll

t hem oi l cu p and m ast er cy li nde r body groov es.
Inst all the oil pup onto t he m ast er cyl i nde r bo dy.
Ins ta ll and t ighten t he o il cup m ounting screw to th e

OIL CUP
specified to rque .
TORQUE: 1.5 N 'm (0.15 kgf m ,1 .1Ibf.ft)
. . . -.-1
SCREW

App ly sili cone grease to the bo ot inside and t ip of
th e push ro d .
Insta ll th e clutc h switch and tighte n th e scr ew to th e

specif ied torqu e.
TORQUE: 1 Nvm (0.1 kqf -m, 0.7 Ibfft)
SCREW CLUTCH SWI TCH
App ly silicone grea se to th e t o p of t he pus h ro d,

CLUTCH LEVER ASSEM BLY
t hen in st all the joi nt piece and clutc h lever ass em-
-~~
bly.
JOINT PIECE
App ly sili con e grease to the cl utch le ver pi vot slid - ~, PIVOT BOLT
jng surf ace. ~
Install and tig ht en the piv ot bo lt to th e spec ified

tor que.
TORQUE: 1 Nm (0.1 kqf-rn, 0.7 lbf -tt )
Ho ld the pi vot bolt and tighten the pivot nut to t he
speci fied torque .
TORQUE: 5.9 Nrn (0.6 kqf-m, 4.3 lbf-ft]
PIVOT NUT CLUTCH LEVER
10-12
Contents Chapter 10
INSTALLATION
Place the master cy linder assembly onto t he handle-
bar.
Align the en d of t he master cylinde r w it h th e punch
m ark on the handl ebar .
Instal l t he m ast er cy linder hol der wi t h th e "U P"
mark faci ng up .
Tighten t he u pp er bolt f irst, then th e lower bo lt.
TORQUE: 12 Nm (1.2 kqf-rn, 9 Ib/!t)
In st all the cl ut ch hose eyelet the oi l bo lt and new

sealing was he rs.
Wh il e pus hi ng the cl utch ho se against t he sto ppe r
and ti g ht en th e o il bo lt to the specifie d to rque .
TORQUE: 34 N m (3.5 kqf-rn, 25 lbf-ft]
Co n nect the clutch switch connect or s.

Fill t he re servoir t o th e upper lev el an d bleed th e
hydraulic system (pa ge 10-6 ).
CLUTCH SLAVE CYLINDER

REMOVAL
Dr ai n the clutch hy drau lic sys tem (pag e 10-6 ),
Avoid spilling fluid Remov e the clutch ho se oil bo lt , sealing wa shers
on painted, plastic, and bra ke hose eyelet .
or rubber parts.
Remov e the bolts and clutch slav e cy li nder assem -
Place a shop tow el
bly .
over these parts
whe never the SVs-
tem is ser viced
Remove the g asket and dowel p in s.

DISASSEMBLY
Remove th e sl av e cy li nder piston an d spr ing.
If th e pi ston is hard to remov e, rem ov e t he f ol low - SLAV E CYLIND ER
ing :
Place a sho p t owel ov er t he pi sto n to cushion t he
pisto n w he n it is ex pell ed, and po siti on the cy linder
with th e piston down .
Do not use high A pply sma ll sq uirts of air pressu re t o t he flu id inl et
pressure air or bring to remove the piston .
the nozzle to close
to the inlet.
SPRING
INSPECTION
Check t he pi st on spri ng fo r weakness or dam age.
Inspect the oil seal and O-rin gs f or da mage or dete- SLAV E CYLIND ER
rioratio n, replace if ne cessary .
Clean the O-r in g groov es with clea n bra ke fl uid .
Check th e slave cy li nder for sco ring o r ot he r da m -
age.
Check t he slave cy linder pist on for sc ratc hes , sco r-
ing or ot he r dam age.
OIL SEAL
ASSEMBLY
OIL SEAL
I PISTON
/
,Q)
~ =...
SLAV E CYLIN DER
S~
ORINGS
SPRING

Lub rica te th e piston wit h br ake fl uid .
App ly silicone grease to the new O-ri ngs and install SLAVE CYLIND ER
them to the slave cylinder pist o n grooves.
Install the spring int o t he boss of th e piston -.
Insta ll t he sp ring and piston into the slave cy li n de r.
S ~ ,..-'tlliJII
~,
a -RINGS
(/
h I
SPRIN G PISTON
INSTA LLATION
Inst all the dowel pins and new gasket.
App ly sil ico ne g rease t o th e t o p of th e push rod .
Install t he sl ave cyl inder onto th e left cra nkcase rear
cove r.
Install a nd tight en th e S H bo lts .

In st all th e clutch ho se eye let wi t h th e o il bolt a nd
new seali ng was hers.
Wh il e pushing the clutch h ose ag ainst t he -st opp er,
t ight en the o il bolt to the speci f ied t o rq ue.
TORQUE: 34 Nm (3.5 kgfm , 25 Ibf.ft)
Fill the reservoir t o t he upper level and bleed t he
hyd raulic system (pa ge 10-61.
RIGHT CRANKCASE COVER REMOVAL

Remove the under cowl s/mi dd le cow ls (pa ge 3-7 )
Drain t he engin e oil (pag e 4 ~ 2 2 ) .
Disconnect th e crankshaft pos it io n se nsor 2P (Red )
co n nector .
10-15
Contents Chapter 10
Be careful no r to Remove the rig ht crankcase cove r bol ts. wire
drop the thrust! clam p s and rig ht cra n kcase cove r.
wave was hers into
the crankcase.
Rem ove the thrust washe r and wave wa sher from

th e sta rte r idle gea r.
Do not tum the Rem ov e t he dowel pins.

crankshaft counter-
Clean off any seala nt f ro m t he rig ht cra nkcase cove r
cloc kwis e after
mati ng su rf aces.
-r em ovinq the righ t
crankcase cover to
pre vent the starter
red uction gear from
damage.
CLUTCH
REMOVAL
Rem ov e the right crankcase cover (page 10-15 ).
Prevent damaging the starter reduct io n gear shaft.
remove the starter idle gear and shaft from the
crankcase.

Remove the clutch spring bolts, springs in a cri ss-
cross pattern in two t o th ree steps, then rem ove the
pressure plate .
Rem ove the clut ch lifter piece and lifte r ro d.
Rem ove the fo ll owin g :

- Tw o clutch disc A
- Six clutch disc B
- Seven clutch plat es
Fricti on sprin q
- Spring seat
U nstake the clutch cente r lock nut .
10-17
Contents Chapter 10
Ho ld t he clutch cente r w it h th e spec ia l t ool an d
re move t h e clutch ce nt er lock nu t .
TOOL:
Clutch center ho lder 07724-{)050 002 or
equ ivale nt co m m e r-
cially available in
U.S.A.
Discard the loc k nut .
Rem ov e th e lock washe r, t h rust w asher an d cl utch

ce nte r.
Remove the t hrust was he r.
Pull out the clutch outer gu ide, t he n rem ove the ;=;;:;;;";::;:~~:-:::~;';;-;:~~~~7.;;-;:;r.1
needle bea ri ng.

Rem ove th e cl ut ch oute r.
Remove t he oil pump d riven sprocket boltlwasher.

Togain access to Remove the oil pump drive/driven sprocket and
the oil pump driven drive chain as an asse m bly .
sprocket tirst
remove the oil pan.
INSPECTION
Clutch lifter bearing
Turn th e inner race of th e lifter beari ng w it h you r
~_ _..L
;,;,IFTER BEA RING
finger.
The bearing should turn smoothly and freely with -
out excess ive play.
If necessary, replace the bearing .
Clutch spri ng
Replace the clu tch M easu re the clutc h spr i ng free lengt h.
sprmgs as a set.
SERVICE LIMIT: 55 .7 mm (2.19 in)
10-19
Contents Chapter 10
Clutch center
Check th e grooves of th e clutc h cent er f o r da m age
or we ar caused by t he cl utch plates.
Rep la ce it if ne cessary .
Clutch lifter piece

Check the cl utc h lifter pi ece fo r dam age or abnormal
wea r.
Clutch lifter rod

Chec k the clutc h rod for ve nd or ot her da m age .
Clutch di sc
Replace the clu tch Replace t he clu tc h d iscs if t hey show signs of sco r-
discs and plates as ing or discoloration.
a set.
Measu re t he disc t hickn ess of each d isc.
SERVICE LIMIT:
A: 3.4 mm (0.13 in)
B: 2.9 mm (0.11 in)

Rep lace the clutch

discs and plates as
Clutch plate
Check the plates f or discolo ratio n.
Check th e plate wa rpage on a surface pl ate using a
r-------.. . ;;~~2
a set . fe eler gau ge.
Friction s pring/spring seat

Check th e f rict io n spri ng and spring seat fo r defor-
mat io n, wa rpage o r da mage; rep lace as nece ssar y .
A damage d or warped spring seat w ill cause t he
friction sp ring to be pr essed unevenly.
A damaged f ric tio n spri ng also causes t he wea k
co ntact betwee n the d iscs and pla tes o r uneven
d isc/plat e contact .
SPRING SEAT FRICTION SPRING
Clutch o ute r/ p rima ry drive n ge ar

Check the slots of th e cl utch ou t er for da mage o r
wea r cau sed by t he clutch d iscs. CLUTCH OUT ER
Check the prim ary driv en gear f or abnormal wea r or

dam age.
M easure th e 1.0. of th e prima ry driv en gea r.
SERVICE LIMITS:
A: 41.026 mm (1.6152 in)
B: 41.018 mm (1.6149 in )
Repla ce the clutch oute r asse m bly if necessar y .

Wh en th e clutch out er assem bly is repl aced, be sure
to select t he need le bear ing acc o rding t o th e se lec-
ti v e fit ta ble (page 10-221.
Clutch oute r gu ide/n eed le be ar ing
M easure th e 0 .0. and 1.0. of the clut ch ou t er g uide.
SERVICE LIMITS:
A (w it ho ut 10 mark):
0 .0.: 34.994 mm (1.3777 in )
1.0.: 28.012 mm (1.1028 i n)
B (with 10 m ark):
0 .0.: 34.986 mm (1.3774 in)
1.0.: 28.012 mm (1.1028 in )

Check t he needl e bearing for wear or damage.
Replace t he bea ring if necessary.
W he n t he cl utch o ut er guide and /or needl e bearing
is replaced, be su re t o sele ct the need le beari ng
acco rdi ng t o th e selective fit t able (page 10-22) .
Oil pump driv e sp ro cke t /sp ro c ket g uid e

M easure t he 0 .0. and 1. 0 . of t he o il pump drive
s proc ket g u ide .
SERVICE LIMITS:
0 .0.: 34.965 mm (1.3766 in)
1.0.: 28.030 mm (1.1035 in)
M easure th e 1. 0 . of th e oil pump driv e sprocket.
M ainsh aft
Measure th e m ain sh aft 0 .0 . at clutch outer guide
and oi l p um p drive sp rocket g ui de slidin g su rfaces.
SERVICE LIMITS:
Oil pump drive s p ro cket
guide p osition: 27.96 mm (1.101 in)
Clut ch outer guide position:27.96m m (1.101 in )
NEEDLE BEARING SELECTION

The prim ary driv en gear has 1.0. co de letter as
sho w n.
10-22
Contents Chapter 10
The clutch out er guide has 0 .0. code len er as
show n. D.D .CDD E LEITER
Cross-reference the primary driven gear and clutch

outer guide codes to determin e the replacement
needle bearing.
Refer to the selection tab le below for bearing selec-
tion .
NEEDLE BEARING SELECTION TABLE :

CLUTCH OUTER GUIDE 10 MARK
GUIDEA GUIDE B
(Without ID m ar k) (With ID m a rk)
35.004 - 35 .012 m m 34 .996 - 35 .004 mm
(1.3 781 - 1.3784 in) (1.3778 -1.3781 in)
PRIM ARY A 4 1.008 - 41.016 m m
NEEDLE BEARING A
DRIVEN GEAR (1.6 145 - 1.6 148 in) NEEDLE BEARI NG B
1.0. MARK B 41.0 00 - 41.008 mm
(1.6 142 - 1.614 5 in ) NEEDLE BEARING C NEEDLE BEARI NG B
10-23
Contents Chapter 10
INSTALLATION
OIL PUM P DRIVE SPROCKET GUIDE
DRIVEN SPROCKET
DRIVE SPROCKET
CLUTCH CENTER 15 Nm (1.5 kqf-m, 11 Ibf.ft)
CLUTCH OUTER
WAS HER \~~ V
SPRING SEAT ~@ .
~4t", ~o,
!'I ~ S P R I N G
~
~ .....
i) ~~~'<>---
--- 'jt/
DISC A
"J~ 127 Nrn (13.0 kgfm ,

/. '0 94 Ibf.ft)
CLUTC H DISCS!
CLUTCH PLAT ES
DISC A
""
~>
~~
SPRING
, 2 Nm (1.2 kqf-rn , 9 Ibf.ft )
10-24
Contents Chapter 10
Install the oil pump drive sprocket gu ide.
Install the oil p ump Insta ll th e oil pump driv e/dri v en sprocket and d rive
driven sprocke t chain as an assem bl y .
w ith its ' OUT' mark
Ap ply a locking age nt t o the thread s of the oil pum p
facing out.
driven spro cket bo lt .
Install t h e oil pump d riv en sproc ket bolt, washe r
and ti ghten th e bolt t o th e specified to rq ue .
TORQUE : 15 Nm (1.5 kqf -rn, 11 Ibfft)
Apply mo lybdenum oil so lut io n t o t he clutch oute r

slidi ng surf ace.
Ma ke sur e the Install the clutch o ute r w hi le aligning t he bosses o n
st arter reduction the oil pump drive sproc ket w ith holes in th e clutch
gear is installed outer.
be fore installing the
clutch.
Ap ply m olybdenum oil so lution to the clu t ch outer

guide sliding surface.
Ins tall the clutch Inst all the cl utch outer gu ide and needle bearing
outer guide with it s onto the ma inshaft (Refer to th e needle bear ing
grooves facingoul. selec t ion: page 1023).
10-25
Contents Chapter 10
Install t he th rust washe r.
Install t he clutch cente r and thru st w asher.

In st all th e loc k wa sh er w ith it s "OUT" m ark f acin g
o ut.
App ly oil t o t he th reads and seating surface of a

new clu tch ce nte r lock nu t, th en install it onto t he
mai ns haft.
Ho ld the clutch center with the speci al t ool and
tig hte n the lock nut to the s p ecified torqu e .
TOOL :
Clutch center hol der 07724-0050002 o r
equiva lent co mmer-
cially avail abl e in
U.S.A.
TORQUE: 127 N m (13.0 kqf-m, 94 Ibf.ft )
Be careful no r to Sta ke t he lock nut in to the m ain sha ft g roove w ith a

dam age the punch.
mainshaft threads.
10-26
Contents Chapter 10
Install th e spring seat and f rict io n spring onto the
clutch ce nter as shown.
Coat t he clu tch discs and plates with clean engine CLUTC H PLATE 8
CLUTCH
oil. . DISCA
Surface treatment Fir st install t he cl utch d isc A {la rge r I.D. di sc i int o t he CLUTCH DISC A
of clutch plate B is clutch outer , and th en i nstall t he cl utch plate B. CLUTCH DISC B
different from that Sta ck th e six clu t ch di scs (8) and pl at es (A) alter-
of plate A. nately.
SPRING SEAT CLUTCH PLATE A
FRICTION SPRIN G
Insta ll t he cl utc h di sc A (la rge r I.D. disc) and set th e

tab s of it in th e sh allow slots of th e cl ut ch ou ter.
Instal l the push rod and cl ut ch lifter piece in to t he

m ain shaft.
10-27
Contents Chapter 10
Inst all th e p ressu re p late .
Install th e cl ut ch sp rin g s and sp ri ng bo lts.
Tight en th e bolts to the sp eci f ied torqu e in a criss-
cross patte rn in two to th ree st ep s.
TORQUE : 12 Nm (1.2 kqf-m, 9 Ibf.ft)
Make sure the Inst all th e starter idle ge ar an d sha ft .

sta rter motor is
In stall th e ri gh t crankcase cove r (page 10-34 ).
installed before
insralfing the starte r
idle gear and shaft
STARTER CLUTCH
REMOVAL
Rem ove t he clutch (page 10-161.
STARTER REDUCTION GEAR
Rem ove the starter redu ct i o n g ear from t he cra n k- .. 1
case.
Te mpora rily insta ll t he prim ary d riven gear.

Insert the gear holder bet w een th e primary drive
an d d rive n gea r as show n.
TOO L:
Gear h older, M2 .5 07724-0010100 or
07724 -001 A100
(U.S.A . only)
Rem ove th e start er clutch outer specia l b olt and
was her .
Remov e the tempo rari ly i nst alle d parts.
Rem o ve th e st a rt e r cl utch out er assembl y .
10-28
Contents Chapter 10
Remove the th ru st washer.
INSPECTION
Check the operation of the one-way clutch by tum-
ing the dr iven gear.
You should be able to turn the d riven gea r clock-
wise smoothly, but the gear should not t urn co un -
terclockwise.
DISASSEMBLY
Rem ov e t he starter d riven gear by turning it co un-
te rclockwise.
Remove th e nee dle bea ri ng.
Rem ov e t he snap ring and one-wa y clutc h.

SNAP RING
Check the starter clutch outer inn er surface and one-

STARTER CLUTCH OUTER
way clutch for abnormal wear or damage and
replace them if necessary. ONE-WAY CLUTCH
10-29
Contents Chapter 10
Check the starter driven gear for abn orm al wea r or
damage.
M easure the sta rter driven gear boss 0 .0.
Check the starter reduction gea r for wear or damage

and replace it if necessary. STARTER REDUCTION GEAR
Check the starter idle gear and shaft for wear or

damage, replace them if necessary.
SERVICE LIMITS:
Sh alt 0. 0 .: 9.98 mm (0.393 in)
Gear 1.0.: 10.05 mm (0.396 in)
10-30
Contents Chapter 10
ASSEMBLY
STA RTER DRIVEN GEA R
SNA P RING
NEEDLE BEA RING
~ ONE-WAY CLUTCH
Apply oi l t o th e o ne-way dutc h. IDENTIFICATION ONE-WAY CLUTCH

Install the one -way clutch into the starte r clutch M ARK
oute r wi th its identification m ark (w hite paint) facing
out . ~
STARTER CLUTCH OUTER
Install the snap ring into the starter clutch oute r ONE -W AY CLUTC H SNA P RING
groove securely.
10-31
Contents Chapter 10
Install the starter driven ge ar into the starter clutch
outer while tu rn ing the st arter d riven gea r clock-
wise.
Insta ll the needle bearin g.

Rech eck the o ne-w ay clutch operation (page ' 0-291.
INSTALLATION
Inst all the thru st wash er into the crankshaft.
Install the starter clutch outer assembly int o the

crankshaft wh ile alig ning t he wide teeth of the
crankshaft and th e st arter clutch asse m bly.
10-32
Contents Chapter 10
A pply o il t o th e sta rte r cl utc h outer spe cial bo lt
threa ds and seating su rf ace .
Install th e w ashe r and sta rte r clutc h out er spec ial
bolt.
Tempora rily install the fo llowing:

- Oil pump dri ve ge ar guid e
- Oil p u m p drive gea r
- Clutch o ute r
Clutch outer gu ide
- Clutch ou te r need le bea ri ng
Be carefu l not to A ttac h the ge ar holder bet ween th e p rimary d rive
drop the gear ge ar and driven gear.
holder into the
TOOL:
crankcase.
Gear holder, M2.5 07724-0010100 or
07724-001A 100
(U.S.A. only)
Tighten t he st arte r clutch specia l bolt t o t he speci -
fi ed t orqu e.
TORQUE: 83 N m (8.5 kqf-m , 61 Ibfltl
Rem o v e th e t em porar il y insta lle d parts.
Apply moly bde nu m oi l sol utio n to the starter reduc-
tio n g ear slidi ng su rface.
Insta ll th e st arte r redu ct ion g ear in t o th e cran kca se.
Inst all th e c lutch (page 10-24).
10-33
Contents Chapter 10
RIGHT CRANKCASE COVER
INSTA LLATION
App ly seal a nt t o the mating su rf ace of th e rig ht r - -- - - - - - - - - - - - - -----,
cra nkcase cove r.
Insta ll th e tw o dowel pins.
Inst all the wave was he r and t hrust was he r o nto the
sta rte r idle gea r.
Inst all the rig ht cra n kcase cov er w hi le alig ning th e

starter id le ge ar shaft and red ucti on gea r shaft with
the hol es in the rig ht cra nkcase co ve r, then align the
d owe l pins w it h th e cover hol es .
In stall th e wire clamps and rig ht cran kcase cove r
bo lts .
Tigh ten the rig ht cr ankcase cove r bo lts cr isscross
pa tte rn in two o r thr e e steps.

Connect the crankshaft positio n sensor 2P (Red)
connector.
Add th e recomm end ed en gine oil (page 4-221.
Install t he m idd le cowls/under cowls (page 3-71.
10-35
Contents Chapter 10
MEMO
Contents Chapter 10
11. ALTERNATOR
COMPONENT LOCATION .. 11-2 STATOR 11-4
SE RVICE INFORMATION 11-3 FLyWHEEL .. 11-5
ALTERNATOR COVER REMOVAL 11-4 ALTERNATOR COVER INSTALLATION ...... 11-7
EI
11-1
Contents Chapter 11
ALTERNATOR
COMPONENT LOCATION
o..._~;::- - 12 Nrn (1.2 kqf -rn,

6 9Ibfft)

ALTERNATOR
SERVICE INFORMATION
GENERAL
This section covers service of the alternator stator and flyw heel. All service can be done w ith the engine installed in the
frame .
Refer to procedure s for alternato r stato r inspection (page 17-8 ).
Refer to proced ures for starter motor servicing (page 196).
TORQUE VALUES
Stato r w ire clam p fl ange bo lt 12 Nm 11.2 kqt-rn , 9 lbf -ft ]
Flywhee l I lange bol t 103 Nrn 110.5 kqf -rn. 76 lbf -tt ) Ap ply oil t o th e t h read s
Stator mount ing socket bolt 12 N'm 11.2 kq f -rn, 9 Ibllt )
TOOLS
Flywheel holder Rotor pulle r
070M B MELC10 0 07733-0 020 001
or 07933-3950 000 (U.S.A. o nly )
11-3
Contents Chapter 11
ALTERNATOR
ALTERNATOR COVER REMOVAL
Rem ove the u nde r cowls/m iddle cow ls (pa ge 3-7) .
Disco nn ect the alte rna to r 3P (W hite) co nnect or.
The alternator co ver Remove th e alt ernat o r cover SH bo lt s an d alt e rnato r

(stator) is magneti- cover.
eal/y a ttrac ted to
Engin e oi l wi ll ru n out w he n t he alte rna to r co ver
the flywheel, be
is rem o ved . Set a cl ea n o il p an und er th e eng ine
careful during
and add t he recomm end ed o il t o t he speci f ied
removal
level afte r inst all at io n.
Rem ov e the d ow el pi ns.

Clean off any sealant f rom the right crankcase cover
mating surfaces.
STATOR
REMOVAL
Remove t he bol t and stat or wi re clamp.
Remove t he alte rnator wi re gro mmet from th e alt e r-
nato r cove r. BOLT
Rem o ve t he socket bolt s and sta to r.
GROM M ET W IRE CLAM P STATOR
114
Contents Chapter 11
ALTERNATOR
INSTALLATION
WIR E CLAM P
12 Nm (1.2 kqf -rn, 9Ib/ft )
ALTERNATOR COVER
-:
STATOR
12 N' m (1.2 kqfm , 9 Ib/ ft )
Install th e stato r into the alte rnato r cove r.

A pply sealan t to th e wire grommet. then install the BO LT
w ire grom m et into the a lternator cover groove
secure ly.
Install and tig ht en the socket bolts to the specified
torque .
TORQUE: 12 Nm (1.2 kqf -rn, 9 Ibf.ft)
Install th e wi re clam p a nd tig hten the flange bolt to
the specified tor qu e.
TORQUE: 12 Nrn (1.2 kqf-m , 9 Ibf.ft)
W IRE CLAM P STATOR
FLYWHEEL
REMOVAL
Remov e the alternato r cove r (page 11-4 ).
Hold th e flywheel using the specia l tool, then
remove the"flywh eel bo lt.
TOOL:
Flywheel h older 070MB-MElC100
Remo ve th e was her.
11-5
Contents Chapter 11
ALTERNATOR
Remove the flyw hee l using the specia l tool.
TOOL:
Rotor puller 07733 -0020001 or
07933-3950000
(U.S .A. only)
INSTALLATION
Clean any oil from the cra nkshaft ta per.
Install the flywheel.
Apply oil to the f lyw heel bolt th reads and seating

surface.
Install the washer and flywheel bolt .
Ho ld the flyw heel using th e specia l too l, t hen

tighten the bolt to the specified to rque.
TOO L:
Flywhe el holder 070MB-MElCl00
TORQUE : 103 Nm (10.5 kqf -m, 76 Ibfft)
11 -6
Contents Chapter 11
ALTERNATOR
ALTERNATOR COVER INSTALLATION
A pply a seal ant t o t he m at in g surface of th e alt erna -
to r cove r.
Install th e dowel pin s.
The altern ator cover Insta ll th e alternato r cover.

(stator) is magne ti- Install an d t ighten th e SH bolts securely .
cally attracted to
the flywheel. be
careful during
mstenetion.
Co nn ect t he alte rnato r 3 P (W hi t e) co nnector.

Inst all th e und er cowls/m idd le cow ls (page 3-7) .

MEMO
Contents Chapter 11
12. TRANSMISSION/GEARSHIFT LINKAGE
COMPONENT LOCATION 12-2 GEARSHIFT SPINDLE 12-7
SERVICE INFORMATION 12-4 TRANSMISSION 1211
TROUBLESHOOTING 12-6
lEI
12-1
Contents Chapter 12
TRANSMISSION/GEARSHIFT LINKAGE
COMPONENT LOCATION
9.8 Nm 11.0 kqf-rn . 7 lbf-ft ]
54 Nm 15.5 kg fm , 40 Ibfft)
\
\ \
\
12-2
Contents Chapter 12
29 Nrn (3 .0 kgf m, 22 lbf-ft ]
12-3
Contents Chapter 12
SERVICE INFORM ATION
GENERAL
This section covers the transmission and gear shift linkage service . Th ese service can be done engine installed in the
frame .
SPECIFICATIONS
Unit: mm (i n)
S hift fork 1.0. 12 .0 0 0 - 12.018 (0.472 4 - 0.473 1) 12.03 10.474)
I Claw thickness 5.93 6.00 (0.233 0. 236) 5.9 (0.23)
S hift fork s ha ft 0.0. 11.957 - 11.968 (0 .4707 - 0.4712 ) 11.95 10.470)
Transmission Gear I.D. M5 , M6 31.000 31.025( 1.2205 - 1.2215) 31.04 (1.222)
Cl 28 .000 28 .021 (1.102 4 1.10 32 ) 28.04 11.104 )
C2,C3,C4 33 .000 - 33. 025 (1.29 92 -1.3002) 33.04 11.3 01)
Gear busing 0 .0 . M5, M6 30.955 30 .980 (1.2 187 1.2 197 ) 30.935 (1.2 179)
C2 32 .955 32 .980 (1.2974 1.2984 1 32.935 (1.2967 )
C3,C4 32.9 50 - 32.975 (1.2972 - 1.2982) 32. 930 (1.2964)
Gear-to-bush inq M5 ,M6 0.0 20 0.070 (0.0008 0.00281 0.10 (0.004)
clearan ce C2 0.020 0.070 10.0 008 0.0028) 0.10 (0.004)
C3,C4 0.02 5 - 0.075 10.0010 - 0 .0030) 0.11 (0.004)
Gear bush ing 1.0 . M5 27.98 5 28 .006 (1.1018 1.102 6) 28.016 (1.1030)
C2 29.985 - 30 .0 06 (1.1018 - 1.1026) 30.02 1 (1.18 19)
Ma inshaft 0 .0 . a t M5 27.967 - 27.980 (1.1011 - 1.101 6) 27.957 (1.10 07)
Counte rs ha ft 0 .0. a t C2 29 .967 - 29 .980 (1.17 98 1.1803) 29.960 (1.1795)
Bushing to shaft M5 0.005 0.039 (0.0002 - 0.0 015) 0.06 (0.002)
cle arance C2 0.005 - 0.039 (0.0 0 02 - 0.0015 ) 0.0610.0 02 )
TORQUE VALUES
Tran sm ission holder flange bolt 29 Nrn 13.0 kq f- m. 22 lbf-ft )
Bearing set plate bo lt 12 N'm (1.2 kqf- rn. 9 Ibfft) Apply a lo cking agent to t he t hr eads
Shift drum center socket bolt 23 N 'm (2.3 kqf-rn , 17 Ibfft) Ap p ly a locking agen t to th e threads
Shift drum stopper arm pivot bolt 12 Nrn 11.2 kqf-rn, 9 lbf -ft]
Gear shift spind le return spring pin 23 Nrn (2.3 kqf-rn, 17I bfft )
Shift drum bolt/washer 12 Nm 11.2 kqf- rn, 9 lbt-ft) Apply a locking agent to the threads
Shift drum stoppe r plate flange bolt 12 Nm 11 .2 kqf- rn, 9 Ibfft) Apply a locking age nt to the th reads
Dri ve sprocket specia l bolt 54 Nm (5.5 kq f -rn, 40 Ibfft)
Gearshift pedal pivot bolt 26 Nm 12.7 kq f-rn, 20 lbf-ft )
Gear shift pedal link pinch bo lt 9.8 N 'm (1.0 kqf-rn, 7 Ibfft)
Link arm lock nut 9.8 Nrn (1.0 kqf-rn, 7 lbf -tt l
12-4
Contents Chapter 12
TOOLS
Bearing remo ve r handle Bearing rem ov er set. 20 m m Remover w eight
07936-3710100 07936-37 10600 077 41-00 1020 1
or 07936-371 020A (U.S .A. o nly )
Driv er Atta chment, 42 x 47 mm Attachme nt, 52 x 55 mm

077 49-00 10000 07746-0 01030 0 07746-00 10400
Atta ch ment, 62 x 68 mm Atta chme nt, 42 x 47 mm Pilot, 20 mm

07746-00 10500 07746-001030 0 07746-0 040 50 0
,
:;:":.::-::-:_":.~=:::=-..:'C.~<:~.
":-::,:,."::.-:,"",~;;,:::.y
Pilot, 25 mm Pilot, 28 m rn
07746-0040600 07746-0 041100
12-5
Contents Chapter 12
TROUBLESHOOTING
Hard to s hift
Im pro pe r cl utc h opera t io n
Incor rect engine oil weig ht
Bent shift fork
Bent shift fork shaft
Bent shift fo rk claw
Dam aged shift drum cam groove
Bent gears hift spi ndle
Transmission jumps out of gear
Worn gear dogs
Worn gear shifter groove
Bent shift fo rk shaft
Broken shift d rum stopper arm
Broken shi ft d rum stopper arm sp ring
Worn or bent shift f or ks
Brok en gearshift spindle retu rn spring
Excessi ve e n gin e noise
Wom or da maged tra ns missio n gear
W orn or dam aged tran sm ission bear ings
12-6
Contents Chapter 12
GEARSHIFT SPINDLE
REMOVAL
Remove the pin ch bolt and d iscon nect the qea r shift . .--~........
arm from the gear shift spindle.
Remove the clutch slave cylinder (page 10-13).

Remove the bolts and left crankcase rear cover.
Remove the gasket, guide plate and dowel pins.
Loosen the rear axle n ut.

Turn the drive chain adjusting bolts make the drive
chain slack f ully.
Rem ov e t he d riv e sp roc ket speci al b olt , was he r and
d ri v e sproc ket.
12-7
Contents Chapter 12
Remove the bolts and gearshift li nkage cover.
Remove the gasket and dowel pins.
Remove th e gearshift sp indle and washers .
INSPECTION
Check the gearshi ft sp in dle for wear, dama ge or
GEARSH IFT SPIN DLE
bends.
Check the ret urn spri ng for fatigue or damage.
If the snap rings are rem ov ed, in st all t hem w it h th eir
cha mfe red side facing t he t hr ust washers.
RETURN SPRING
12-8
Contents Chapter 12
Check t he du st seal f or wea r o r da mage.
Check t he needle bea ring for w ear or damage.
INSTALLATION
Install th e gearshift spindle and w ash er s.
Inst all a dowel pins and new gask et .
Install th e gearsh ift linkage cove r bein g carefu l not

to damage the oil sea l li p s.
Apply a locking Instal l and t igh ten t he link age cover bo lts .
agent to the
threads of the bolt
indicated.
12-9
Contents Chapter 12
Install the drive sprocket w ith its m ark fac ing out.
Inst all the washer and specia l bo lt. tighte n th e spe-
cial bolt to the spec ified to rque.
TORQUE: 54 N m (5.5 kqf-m , 40 Ibf.ft)
Inst all the dowel pins, guide plate and new gasket.
Insta ll the left cran kcase rear cove r and ti ght en the
mo unting bolts .
Inst all t he clu tc h slave cyl in de r (page 10-13).
Install the gearshift arm to the gea rshift spind le,

while alig ning its slit with the pu nch ma rk on to the
sp indle.
Inst all the gea rshift arm to the gea rshift spindle,
tig hten the pinch bolt.
TORQUE: 9.8 Nm 11 .0 kqf-m, 7 Ibfft)
12-1 0
Contents Chapter 12
TRANSMISSION /GEARSHIFT LINKAGE
If the gearshift pedal has been removed, install the
wash er, gea rshift peda l and pivot bolt o nto t he - 'Dr""--.:II
f rame .
Tig ht en t he pivot bo lt t o th e spec if ied t orqu e.
TORQUE: 26 Nm (2.7 kqf-rn, 20 Ibfft)
TRANSMISSION
REMOVAL
Rem ov e the fo llowi ng :
- Righ t cran kcase cove r (page 10- 15)
- Clutch (page 10- 161
- Oi l pump d ri ve sp ro cket/c ha in/d riven sproc ket
(page 10-191
- Driv e sproc ket (page 12-7)
Replace the trans- Remove the t ransm ission bearing hold er m ounting
mission bearing bolts.
holder and crank -
case as a set.
Be careful not to fall Pul l out t he bearin g hold er/t ransmi ssio n asse mbly
the oil orifice into f ro m t he cra nkcase .
the crankcase.
Remov e th e d owel pins and o il o ri fice .
DISASSEMBLY
Rem ov e the sh ift fo rk shafts and shift fo rks.
12-11
Contents Chapter 12
TRA N SM ISSION / GEA RSHIFT LINKAGE
Remove the ma ins haft and countershaft asse mbly.
MAINS HAFT/COUN TERSHAFT
Remove the socket bolt, stopper arm, retu rn spring

and washe r.
Remove t he gearshift cam bol t.

BOLT
Remove t he gearshift cam and d ow el pins.

Remove t he flange co llar.
12-12
Contents Chapter 12
Remove the shift drum fro m the bea ring holder.
SHIFT DRU M
Disassem ble the mainshaft and counte rshaft

COUNTERSHAFT
assemb ly .
MAINSHAFT
INSPECTION
Check the shift for k guide p in for abno rmal wea r or
damage
M easure the shift for k 1.0.
M easure the shift fork claw thickness.
M easure the shift fork shaft 0 .0.
12-13
Contents Chapter 12
Turn the outer race of th e shift drum bea ring wi th
yo ur finger.
The bea ring should turn smoothly and free ly wit h-
out ex cessive play .
If ne cessary re place the bea rin g.
Inspect the shift drum guide grooves fo r abnorma l

wear o r da mage .
Check the gea r dogs, dog hole s and tee th fo r abno r-

mal wea r or lack of lub ricat ion.
Measure the 1. 0 . of each gear.
~~ SERVICE LIMITS:
M5 ; M6: 3 1.04 m m (1.222 in)
C1: 28.04 mm (1.104 in)
C2, C3, C4: 33 .04 mm (1.301 in)
M easure the 0 .0 . of each gea r bushi ng .
SERVICE LIMITS:
M5 , M6: 30 .935 mm (1.2179 in)
C2: 32 .935 mm (1.2967 in )
C3, C4: 32 .930 mm (1.2964 in)
M easure the 1. 0 . of each gear bushing.

SERVICE LIMITS:
M5 : 28.016 mm (1.1030 in )
C2: 29.960 mm (1.1795 in)
Calculate the qea r-to-b us hinq clearance .

SERVICE LIMITS:
M5, M6: 0.10 mm (0.004 in)
C2: 0.10 mm (0.004 in)
C3, C4: 0.11 mm (0.004 in )
12-14
Contents Chapter 12
Check t he ge a r shifte r g roove fo r abno rma l wea r o r
dam age .
Chec k th e main sh aft and cou ntershaft f or ab norm al

w ear or damage .
Measure t he mai ns haft 0 .0 . at t he M 5 gea r.
Measu re t he co untershaft 0 .0. at th e C2 g ear.

SERVICE LIMIT: 29 .960 mm (1.1795 in)
Calculate the gear bus hi ng- ta- shaft clearance.

SERVICE LIMITS:
M5 : 0.06 mm (0.002 in )
C2: 0.06 mm (0.002 in)
Tu rn the o ute r race of eac h t ransmi ssi o n bea ring

w it h your f in g er.
The b earing should t urn sm o ot h ly and f reely w it h-
o ut excessive play .
If ne cessary repla ce th e bearing .
TRANSMISSION BEARING
REPLACEMENT
Replace the trans- Remove the bolts and shift drum bea ring set pla tes.
mission bearing SET PLATES
Rem ov e t he bo lt s and m ainshaft bearing set pl at e.
ho lder and crank-
case as a set.
12-15
Contents Chapter 12
Remove the bolt and counte rshaft bea ring set plate.
Remove the counte rshaft bea ring using the special ~~:::~~~::::::;;~;;;':~:7~~:~
tools .
TOOLS:
Bearing remover handle 07936-3710100
Bearing remover set 07936-3710600
Remover weight 07741 -0010201 or
07936-371020A
(U.S.A. only)
Drive out th e counter shaft bearing and shift dru m
bearing.
Bearing locations
MA IN SHA FT BEARING
1f 'tf
-. ~
=
11' <>
,~~
0
SHIFT DRUM BEARING
/' -- ~ '
~
""~~.
. . \::=>I- .
-c: ~ '--- .-//
/ ~~
COUN TERSHA FT BEARING
12-16
Contents Chapter 12
Driv e eac h be aring int o the bea ri ng hold er using t he
spe cia l to ols.
DRIVER
TOOLS:
Mainshaft bearing:
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 28 mm 07746-0041100
Countershaft bearing:
Driver 07749 -0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot. 20 mm 07746-0040500
Shift drum bea rin g:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 25 mm 07746-0040600
A p p ly a locki ng agent t o the cou nte rshaft bearing
set plate bolt thre ad s.
Ins t all the set plate an d t ighten th e bolt to t he speci-
f ie d t orqu e.
TORQUE: 12 Nm (1.2 kqf-m , 9 IbHI)
Apply a lo cking ag ent t o t he main shaft bearing set

SET PLATES
pl ate bo lt threads and shi ft drum be ari ng set plate
bo lt th reads.
Install t he main sh aft bea r in g set p lat e w it h its " M EL
OUTSIDE" ma rk fa cing QuI .
Install and t ig hten t h e bearin g set plate bo lts to t he
specif ie d torqu e.
TORQUE: 12 N 'm (1.2 kqf-m, 9 Ibfft)
12-17
Contents Chapter 12
TRANSMISSION/GEARSHIFT
ASSEMBLY LINKAGE
Malnshatt:
M2 GEAR (17T)
M6 GEAR (25T)
M4/3 GEAR (21/19T)
M5 GEAR (20T)
MAINS HA FT/M l GEAR (13T )
Count ershaft
C4 GEA R (29T)
C5 GEAR (25T)
C1 GEAR (33T)
COUN TERSHA FT
12-18
Contents Chapter 12
Coat eac h gea r wit h cl ean engine oil a nd check f or

OIL HOLES
smooth movement .
Assemble the tran smission gear and shafts.
Always install the thru s t washe r and sna p ring
wit h th e chamfere d (rolled) edg e fac in g away
f ro m th e thru st loa d.
Inst a ll t he snap ring so th at it s end gap align s
w ith t he gr oo v e in the splines.
M ake su re th at the sna p rin g is fully se ate d in the
shaft g roove a fter insta lling it.
Ali g n th e o il ho les between t he shaft , g ear and co l-

OIL HOLES
lar .
12-19
Contents Chapter 12
Align the lock washer tabs with the spline washer
grooves.
App ly mo lybdenu m oil solution to the shift fork

groo ves in the M3. C4 and C5 gear.
COU NTERSHA FT ASSEM BLY MA IN SHAFT ASS EM BLY
SHIFT FORKSHAFTS
SHIFT DRUM
RIGHT/LEFT SHIFT FORKS
COLLAR
BEARING HOLD ER

TRANSMISSION/GEARSHIFT LINKA GE
Install the sh ift d rum int o th e bearin g hold er.
SHIFT DRUM
Install th e f lange co ll ar w it h it flang e faci ng in.
Install th e dowel p ins o nt o the gearshift cam .

Install th e g earshi ft cam o nt o t he ge ars h ift d ru m.
App ly a locking agent to th e sh ift drum cam f la ng e

b olt th read s.
Ti ght en th e bol t sec u re ly .
Contents 12-21
Chapter 12
Install t he foll owin g:
- Was her
Return sp ring
Stoppe r arm
- Pivo t bolt
Tighten t he sto p pe r arm pi v ot bol t to t he specified
to rq ue .
TORQUE : 12 Nm (1.2 kqf -rn, 9 lbf-ttl
Inst all t he m ainsh aft and count ersha ft as an asse m -

bly to t he bearing ho ld er.
The shift f ork s hav e locat io n m ar ks:

IDENTIFICATION MA RKS
- "RL" f or rig ht and left
- "C" for cent er
Install the shi ft f orks in t o the shi ft drum g uide

groove with t he identificatio n marks facing up .
12-22
Contents Chapter 12
INSTALLATION
Install the oil o rifice w ith its small 1.0. side facing in.
Install the dowel pins.
Turn the shift drum wh ile turning the mai nshaft. P.ir.=~"""!!
position t he tran sm issio n into neutral .
Insta ll t he beari ng holder/t ransmiss io n assem bly
into the crankcase .
Install and t ight en t he be ari ng holder m oun ting

bolts to t he specified torque.
TORQUE : 29 Nm (3.0 kqf-m, 22 lbf-ft ]

Inst al l t he fo llowing:
- Dri v e sprocket (page 12-9)
- Clutch (page 10-16)
Right crankcase cove r (page 10-34)
12-23
Contents Chapter 12
MEMO
Contents Chapter 12
13. CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER
COMPONENT LOCATION.... 13-2 MAIN JOURNAL BEARING.... 13 9
SE RVICE INFORMATION 13-3 CRANKPIN BEARING 13-1 2
TROU BLESHOOTING 13-4 PISTON/CYLINDER 13- 15
CRANKCASE SEPARATION .. 135 CRANKCASE ASSEMBLY 13-21
CRANKSHAFT 13-7 BALANCER ....13-28
EI
13-1
Contents Chapter 13
COM PONENT LOCATION
20 Nrn (2.0 kqf- rn, 14lbfft) + 150"
24 Nrn (2.4 kqf-m, 17 lbf-ft)

/
24 N'm (2 4 kgf m,
17 Ibf ft)
18 Nm (1.8 kqf-m,
13 lbf-ft }
13-2
Contents Chapter 13
CRANKCASE/CRANKSHAFT/BALANCER/PISTON / CYLINDER
SERVICE INFORMATION
GENERAL
T he crankcase mu st be separated to service the following: .
- Cra nksha ft (pag e 13-7)
- Piston/connecting rod/cylinder (page 13-1 5)
The following com ponents m ust be removed before separating the crankcase:
- Eng ine (pag e 8-4)
- Clutc h (pa ge 10-16)
- Cy linde r hea d (page 9-13)
- Flywheel (page 11-5)
- Ge arshift lin kag e/transm issio n (page 12-1 1)
- Oil pa n (page 5-61. o il pu m p (p ag e 5-8) a nd oil co o le r (pa ge 5-13 )
- S ta rte r clutc h (page 10-28)
- St a rter moto r (p age 19-6)
- Wate r pump (pa ge 7-17)
Replace the crankcase and transmission bearing ho lde r as an assembl y.
Be careful not to dam age th e crankcase ma ting surfaces whe n servicing .
Prior to assembl ing the crankcase halves, apply sealant to their ma ting surfaces. W ipe off excess sealant thoro ughly.
The crankcase mu st be sepa rated to service the crankshaft. cylinde r and piston/con necting rod. Refer to procedures for
crankcase separation (page 13-5) an d assemb ly (page 13-21 ).
M ark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassem-
b ly.
T he crankpin and main journal bear ing inserts are select fit and ar e ide ntified by color codes . Select replacement bear-
ings from the code tables. Afte r select ing new bearings, recheck th e oil clearance w ith a plastiga uge. Inco rrect oil clear-
ance can cause major eng ine dam age.
Clean the oil jets in the uppe r crankcase wi th com pressed air before installing the pistons
SPECIFICATIONS
U nit' mm (in)
Cra nks haft Connecting rod side clearance 0.05 0.20 (0.0 02 - 0.008) 0. 25 (0.09 8 )
Cran kpin bearing oil cleara nce 0.030 0 .052 (0.00 12 - 0.0 020) 0. 06 (0.0021
Ma in journa l be aring oil cleara nce 0.019 - 0 .037 (0.0 007 - 0.00 15) 0.05 (0.002 )
Runout 0.05 (0. 002)
Piston, piston Pisto n 0 .0. at 4.0 (0.16) from bot- 74.960 74.980 (2.95 12 2.9520) 74.895 (2.9486)
rings to m
Piston pin bo re 1. 0 . 17.002 - 17.0 08 10.6694 - 0.66961 17.030 10 .6705)
Piston pin 0.0. 16.994 - 17.000 (0 .669 0 - 0.6693) 16 .980 (0.6 685)
Piston -to-piston pin clea rance 0.00 2 - 0 .014 (0.0 001 - 0.0 006 ) 0 .04 (0.002 1
Piston ring end Top 0.22 - 0 .32 (O.OO g 0.013) 0.52 (0.020)
gap S econd 0.48 - 0 .63 (0.019 - 0 .025) 0.82 (0.032 1
Oil 0.2 0.7 (0.01 0.03) 1.0 (0 .041
Is id e ra il)
Piston ring-to-rin g To p 0.0 50 - 0 .08 5 (0.0 020 0.0033) 0.12510.0049)
groo ve clearance Second 0.015 - 0 .05 0 (0.00 06 0.0020) 0.07 5 (0.0030)
Cylinder 1. 0. 75.00 0 - 7 5.015 (2.9528 - 2.95 33) 75.15 (2.9 591
Out of round - 0.10 (0.004)
Taper - 0.10 (0.004)
Wa rp ag e - 0. 10 (0.00 4)
Cylinde r-to-pisto n clearance 0.020 0 .055 10.0008 0.0022) 0.10 (0.004)
Con necting rod small end 1.0. 17.030 17.042 (0.6705 0.6 709 ) 17.048 (0. 6712)
Connecting rod-to-piston pin clea rance 0.030 - 0.0 46 10.0012 - 0.00181 0.07 (0.0 03)
13-3
Contents Chapter 13
TORQUE VALUES
Cra nkcase 7 m m bolt 18 N'm (1.8 kqf -rn, 13 Iblltl
8 mm bo lt 24 N'm (2.4 kqf- rn. 17 lbf-ft]
9 mm bolt (main jo urnal bolt ) See page 13-21 Apply o il t o the th reads and seat in g su rf ace
Lower crankcase seali n g bolt 59 N'm (6.0 kq f-rn, 43 Ibl lt l Ap p ly a lock ing age nt t o th e threads
Lo w er cra nkcase socke t bo lt 12 Nm (1.2 kq f-rn, 9 lbf-ft] Ap pl y a locking age nt t o th e t h read s
Low er cra nkcase sealin g bo lt 29 Nm (3.0 kqf -rn, 22 Ibllt l Ap ply a lockin g ag ent t o the threads
Lo w er c rankcase socket bo lt 23 Nm (2.3 kqf-rn, 17 lbf-ft] App ly a lo ckin g ag ent to the th rea ds
Co nnecting ro d bo lt (new bolt) See pag e 13-8 Apply o il t o the t h read s a nd seat ing surfa ce
Co n necti ng rod bolt (ret ig hteni ng) See page 13-12 App ly o il t o t he t h re ads a nd seati ng surface
TROUBLESHOOTING
Cylinder compression is too low, hard to starting or poor performance at low speed
Leaking cyl inde r head gasket
Worn, st uc k o r b roken piston ring
Worn or dama ge d cylinde r and piston
Cylinder compression too high, overheating or knocking
Excessive carbon built-up on pisto n he ad o r combustion cham ber
Exc essiv e smoke
Worn cyli nder, p isto n o r piston rin g
Im prop er in st all at i o n of piston ring s
Sco red o r scr atc he d p iston o r cyli n der wa ll
Abnormal noise
Wo rn piston p in or pisto n p in ho le
W orn co n necti ng rod small end
W o rn cy linde r, p iston o r pi st on ring s
W o rn main jo u rna l bearings
W orn cra nkpi n bea ri ng s
Engine vibration
Excessiv e cran ks haft runout
Incor rect ba lancer ti min g
13-4
Contents Chapter 13
CRANKCASE/CRANKSHAFT/BALANCER/PISTON /CYLINDER
CRANKCASE SEPARATION
Ref er t o Serv ice Information See page 13-3 f or
removal of ne cessary pa rts before sepa rati ng the
crankcas e. .
Remove th e t ermin al screw and term inal ey elet
from th e oil pr essure switc h.
Disconn ect th e neutral switc h co nnecto r, the n

remove t he engin e sub-harness,
Remove the bo lts , water hose jo int a nd O-ring.
Rem ov e th e bo lt s, oil inspectio n wi ndow and O-ring

fro m t he crankcase.
OIL INSPECTION W INDOW
13-5
Contents Chapter 13
CRAN KCAS E/CRAN KSHAFTIBALANCER/PISTON/CYLI N DER
Loosen the 7 mm bo lts (six ) and sea ling washer in
two to th ree steps.
Lo o sen t he 8 mm bo lt s (five) in t w o to t hree steps.
Remove the 8 mm bolts, 7 mm bo lts and sea ling
washe r.
Place t he e ng ine upsid e down.

Loosen t he 8 mm bo lt and 7 mm bolts (six) in a
crisscross pattern in two t o three steps.
Loose n th e 9 mm bo lt s (m ain journa l bo lts) in a
cr iss -cross pattern in two to t hree s teps, then
remove the bo lts .
Separate the lower cra nkcase f rom the upper crank -
case .
Rem ove the t hree dowel pins an d two oil o rifices.

Clean any seala nt off fro m t he cran kcas e m at ing f" .. ;z:==~~~~~~~~~j!:
I' u,,tl;;.::::
surf ace. ~
Remove t he m ainshaft bearin g and clutch lifter ro d

oil sea l fro m t he uppe r crankcase.
13-6
Contents Chapter 13
CRANKSHAFT
SIDE CLEARANCE INSPECTION
Separate the crankcase ha lves (page 13-5) . .
M easure the co nnect ing rod side clearance.
If the clearance exceeds t he se rvice limit, rep lace
the connecting ro d .
Recheck and if still ou t of li m it, replace the crank -
shaft.
REMOVAL
I NOTICE
Befo re removal, position aI/ the pistons at TOC (Top
Dead Cente r) to preven t damaging the crankpin w it h
the conn ecting rod.
Ma rk t he beari ng caps and bea ri ngs as yo u rem ov e
them to indicate the co rrec t cylinder fo r reassembly.
Remove the connecting rod bearing cap bolts and
bearing cap s.
Tap the si de of th e cap lig htly if th e bear ing cap is
hard to remove.
Positi on all t he pistons at T DC (Top Dead Cente r),
then remove the cranks haft.
Remove t he main journa l beari ngs from both t he

crankcase hal v es.
13-7
Contents Chapter 13
INSPECTION
Support t he cran kshaft o n both e nd jou rna ls.
Set a dial gauge o n t he cente r m ain j ou rn al of th e
cranks haft.
Rotate the crankshaft two revo lu ti on s and re ad t he M EASU RE POINT
runout.
Check t he p ri ma ry drive gear teeth f or ab nor ma l

wear or dam age.
PRIMARY DRIVE GEA R
INSTALLATION
Apply molybden um oil sol ut ion to the mai n j ou rn al
bearing sl iding surfaces on t he upper crankcase and
t he crankpin bea ri ng sliding su rfaces on t he con-
necting rods .
The b earing tabs Inst all the main jo urna l bearings in t o t he up per
sho uld be aligned crankcase.
with the grooves in
th e cran kcase.
App ly m o ly bd en um o il solutio n to the thrust sur-

fa ces of the crankshaft as sh own .
NOTICE
Position all the pistons at TOC (Top Dead Center) to
prevent damag ing the crankpin with the connecting
rod.
Install the cra n kshaft o nto t he u pper cra n kcase .
Set t he connect ing rods on to t he cra n kp ins.
Ap ply m o lybdenu m oil solution to the cran kp in
bearing sli ding surfaces o n t he connect ing rod be ar-
in g caps .
Inst all th e conn ecti ng ro d beari ng ca ps, alig ning the
d ow el pins w ith the hol es in t he con nectin g ro ds.
Be su re each part is insta lle d in it s o riginal positio n,
as noted d u ring rem o v al.
13-8
Contents Chapter 13
The connecting rod App ly oil to new co nnecti ng rod bearing cap bol t
bolts cannot be threads and seating su rfaces, and inst all the bolts.
reuse d. Once the
connecting rod
bolts have b een
loos en ed replac e
them w ith new
ones.
Tighten the bolt s in two or three steps alternately ,

the n t igh t en th e bol t s t o th e speci fied torque.
TORQ UE: 20 Nrn (2.0 kqf-m. 14 Ibf-ft]

Further tighten the co n nec tin g ro d bearing cap bolts
90 deg rees.
Assemble t he u pper and lower cra nkcase (page 1 3~
211.
MAIN JOURNAL BEARING

I NOTICE I
Do not interchange th e bearing inse rts. They m ust
be installed in their original locations or the co rrect
bearing oil clearance m ay no t be obtained, res ult in g
in eng ine damage.
Rem ov e t he c ran ks haft (page 13-7 ).
BEARING INSPECTION
Inspect the main journ al bearing in serts on th e
upp er and lower crankcase halv es for unusu al we ar
o r peeling. -~ ..
MAIN JOURNAL BEARING S
Check th e bearin g ta bs f or dam age.

.'
13-9
Contents Chapter 13
CRANKCASE /CRANKSHAFT/BALANCER/PISTON/CYLINDER
OIL CLEARANCE INSPECTION
Clean off any oil from th e beari ng inse rts and m ai n
jo urnals .
Install th e cran kshaft onto th e upper cr ankcase.
Put a strip of p last i gaug e le ng t hw ise on eac h ma in
jou rn al avo iding the oi l hol e.
Do not rot at e the crank sh aft d urin g in spect ion .
Insta ll th e low er crank case on to th e upp er cran k-

case, then install the crankca se 9 m m bolts (mai n
jo u rn al bo lts ).
Tighten t he 9 m m bo lt s in nu m erical o rder t o the
spec ified torq ue.
TORQUE: 20 Nrn (2.0 kqf-m , 14 Ibf ft)
Furt he r t ig hte n the 9 mm bo lts 150 de grees.
Remove t he cra nkcase 9 mm bolts (m ai n journa l

bo lts) an d lower crankcase , measure the com-
p ressed plastigauge at its widest point o n each
ma in journal t o determ ine the oil clearance.

If t he oil clea ra nce ex ceed s t he se rvice li mi t, select a
rep lacem ent beari ng.

Le tters (A, 8 or C! BEARING SELECTION
on the left side of Reco rd the cra nkcase bearing support I.D. code let -
upper crankcase te rs f rom the pad on the left side of the upper crank-
are the codes for case as s how n.
the bearing sup-
port 1.0.$ from tett
to right.
Num bers (I , 2 or 3) Record t he correspo nding main jou rnal 0.0. code
on the crank w eight nu mbers fro m th e crank weig ht.
are the codes for
the main journal
0.0.5 from left to
right.
Cross ref er ence t he ma in jou rna l and beari ng sup -

port co des to d et erm in e the repl acement bearing
colo r code.
M AIN JOURNAL BEARING SELECTION TABLE:
BEARING SUPPORT I.D .CODE
A B C
37.000 - 37.006 m m 37.006 - 37.012 mm 37.012 -37.018 mm
(1.4567 - 1.4569 in) (1.4569 - 1.4572 in) (1.4572 - 1.4574 in )
M AIN JO URN AL 34 .000 - 34.006 mm
1 Red Pin k Yell ow
0 .0. CODE (1.3386 - 1.3388 in)
33.994 - 34.000 mm
2 Pink Yell ow Green
(1.3383 - 1.3386 in )
33.988 - 33.994 m m
3 Yellow Gr ee n Brown
(1.3381 - 1.3383 in )
BEARING THI CKNESS: IDENT IFICATION COLOR

Brown: Thickest
Green:
Yellow:
Pin k:
Red: Thinn est
NOTICE
After sel ect ing new bearings, rech eck th e clearance
with a p las tigauge. Incorre ct cl earance can cause
se vere en g ine da mage.
13-11
Contents Chapter 13
BEARING INSTALLATION
Clean t he bea ring ou ter surfaces and crankcase
be arin g su pp o rt s.
App ly molybdenum oil soluti o n t o th e ma in j ourna l
bearing s liding surfaces on th e uppe r cra nkcase.
Install th e ma in jou rn al bearing i nse rts o nto the
cra nkc ase bearing supports, alig ning each t ab s with
eac h groove s.
CRA NKPIN BEARING

I NOTICE I
Do not interchange the bearing inserts. They must
be inst alled in their original location s or the correct
bearing oil clearance may not be o bta ined, resulting
in eng ine damage.
Remove th e cra nkshaft (p age 13-7).
BEARING INSPECTION
Chec k th e bear in g inserts f o r unu su al w ear or peel -
ing .
Check the bea ri ng t ab s f or dam age.
CRANKPIN BEARING INSERTS
OIL CLEARANCE INSPECTION

Clea n off any oil fr om th e be aring in serts an d c ra nk-
pins.
Carefully inst all the cranks ha ft o nto t he upp er c rank-
case .
Set t he connecti ng rod s on t o th e crankpins .
Put a strip of pla st igauge leng thwise on eac h crank-
pin avoidi ng the oil hol e.
Do not rotate the cranksh aft d uring in specti on .
13-12
Contents Chapter 13
CRANKCASE/CRANKSHAFT/BALANCER/PISTON /CYLINDER
Caref ully insta ll the con necti ng ro d b earin g caps.
ali gning t he dowel pins wit h th e hol es in t he con -
necti ng rods.
Use the rem oved Apply oil to the con necting rod bea ri ng cap bo lt
conn ecting rod threads and seating surfaces and install the bolts.
bolts when cnecx- Tighten the bolts in two o r three steps alternately,
ing the oil clear- then tighte n th e bol ts t o the specified t orque.
ance.
TORQUE : 14 Nm (1.4 kqt-m, 10 Ibf.tt)
Furt her tighte n the co nnectin g rod bearin g cap bolts

90 degrees.
Rem ov e t he bear ing ca ps a nd m easure th e co rn -

pr essed plast igauge at it s w idest point on t he crank-
pi n t o dete rmi ne t he oil clea rance.
SERVICE LIM IT: 0.06 mm 10.002 in )
If the oil clearance exceeds the service limit, select
the correct replacem ent bea r ings.
BEARING SELECTION
Num bers (1 or 2) on Reco rd th e co nnec ti ng rod J. D. code number (1 o r 2)
the connecting rods or m easur e t he 1. 0 . w ith t he connecting rod bearin g
are the codes for cap installed w ithout bearing inserts.
the connecting rod
1.0.
CON NECTIN G ROD 1. 0 . CODE

Letters (A or B) on If you are re plac ing th e cra nkshaft, record the corre-
the crankweight are sponding crankpin 0 .0 . code lett er (A or 8) .
the codes for the
crankpin OD.s
If you are reus ing the crankshaft. measure the
crankpin 0. 0. w ith a micrometer.
from left to right.
13-13
Contents Chapter 13
Cross-reference the connecting rod and cran kpin
codes to dete rmine the replacem ent bea ring color.
CRANKP IN BEARING SELECTION TA BLE:
CONN ECTING ROD I.D.CODE
1 2 3
39 .500 - 39 .506 mm 39.506 - 39 .512 mm 39 .512 - 39 .518 mm
(1.5551 - 1.5554 in ) (1.5554 - 1.5556 in ) (1.5556 - 1.5558 in )
CRANK PIN 36.497 36.503 mm
A Yellow Green Brown
O.D.CODE (1.4369 - 1.4371 in )
36 .491 36 .497 mm
B Green Brown Black
(1.4367 - 1.4 369 in )
36.485 36 .491 mm
C Brown Black Blue
(1.4364 - 1.4367 in )
BEARING THIC KNESS : IDENTIFICATION COLOR

Blu e: Th ickest
Black :
Brow n:
Green:
Yellow : Th inn est
NOTICE
After selecting new bea rings, recheck the clearance
with a plastiga uge. Incorrect clearan ce can cause
severe engine dama ge.
BEARING INSTALLATION
Clea n the beari ng oute r surfaces, connecting rod
bearing cap and connectin g rod.
Inst all the crankpin bearing inse rts onto the bearin g
cap and connecting rod , align ing eac h tab w ith each
groove.
BEARINGS
13-14
Contents Chapter 13
CRANKCASE/CRANKSHAFT/BALANCER/P ISTON/CYLINDER
PISTON / CYLINDER
PISTON/CONNECTING ROD
REMOVAL
NOTICE
Th is moto rcycle is equipped w ith al uminum cy l-
in der sleeves . Before piston remo val , p lace a
clean shop to we l a round th e connecting rod to
prevent damaging the cyli nder sleeve.
Do not try to remove the pist onlc on necting rod
assembly from bo ttom of the cylinder; the
assembly will ge t st uck in the gap bet ween the
cyli nde r liner and the up p er crankc ase.
Do not in ter chan ge th e bearing in serts. They
must be ins talled in their original locations or the
correct bearing oil clea ra nce ma y not be
obtained, resulting in engine d amage.
Mark a/l parts as Rem ov e t he bo lt s and co nnect in g rod bearin g caps .
you remove them
to indicate the cor-
rect cylinder for
reassembly.
Do not try to Rem o v e th e pisto n/co nnecting rod ass em bly from
remove the con- t he t o p o f the cy linde r.
necting rod/piston
assembly from the
bottom of the cylin-
der; the assem bly
w ill be locke d so
that the oil ring
expands in the gap
between the cylin-
der liner and the
upper crankcase.
PISTON REMOVAL
Remove th e piston pi n clip wit h plie rs .
Push the piston pin out ofthe pisto n and co nnect ing _ - - -- - - ......_...:.PISTON PIN
rod , and rem ov e the piston.
13-1 5
Contents Chapter 13
PISTON DISASSEMBLY
Be careful not to Spread each piston ring end and remove t he m by ...--~----...
damage the piston lift ing up at a poin t o pposit e th e g ap .
rmg by spreading
the ends too far.
Never use a w ire Clean ca rbon de posits from th e piston ring grooves
brus h; It w ill scratch w ith a ring that will be disca rded .
the groove.
PISTON INSPECTION
Insp ect t he pi st o n rin gs fo r move ment by ro t ati ng
t he rings . Th e ring s should be ab le to m o v e in the ir
grooves without catch ing.
Push the ring un t il th e ou te r su rfa ce of the p iston
ri ng is nearl y flush w it h the piston and measure t he
rin q-t o-rlnq groove clearance .
SERVICE LIM ITS:
Top: 0.125 mm (0.004 9 in )
S econd: 0.075 mm (0.003 0 in )
Push the rings into Insert t he pisto n ri ng squ ar ely into t he t op of the cy l-
th e cylinder w ith ind er and m easure the ri ng e nd ga p.
the top of th e pis-
ton to be sure they SERVICE LIMITS:
are squarely in the To p: 0.52 mm (0.020 in)
cylinder . S e cond : 0.82 mm (0.032 in)
Oil (s ide rail) : 1.0 mm (0.04 in)

M easure the piston pin bore.
Meas ure the 0 .0 . of the piston pin.
Calculate the piston-to-piston pin clearance.

M easure the diam ete r of the piston at 4.0 mm (0.16

in) fro m the bottom and 90 degrees to the piston pin
hol e.
CONNECTING ROD INSPECTION

M easure the connecti ng rod small end 1. 0.

Calculate the connecting rod-to-piston pin clear-
ance.
13-17
Contents Chapter 13
CYLINDER INSPECTION
Inspect t he cy linde r bore fo r wear or damage.
M easure t he cy linder 1.0. in X and Y axis at t h ree
leve ls.
Take th e m ax imum read in g to determine the cy li n-
d er wear.
Calc ulate t he pi sto n-to-cyl inder clearance .
Take a maxim u m readin g t o determine the clea r-
ance .
Refer to the procedures for measurement of t he pis-
ton O.D.lpage 13-17 1.
SERVICE LIM IT: 0.10 mm (0.004 in )
Calculate the taper and out-of-round at th ree levels -

in X and Y axis. Take the maximum read ing to
determine them .
y -- - -- '>; J
SERVICE LIMITS: TOP
Tape r: 0.10 mm 10.004 in)
Out-of-round: 0.10 mm (0.004 in)
<, ,
/
- - --
-"-
-,,-
.- ,
/
/
<,
/
Th e cy li nder mu st be reb o red and an overs ize p is- MIDDLE

to n fi tted if t he serv ic e limit s are exceeded.
<,
,
- - ._---
.- - - -- ,
/
/
-,
Th e following oversize piston is av ailabl e : /
0.25 mm 10.010 in) BonOM -, ,

--
/
/
The pi st on t o cylinde r clearance for t he ove rsize pis- - "-

ton m ust be: 0.Q1 5 - 0.050 m m 10.0006 - 0.0020 in },
Inspect t he t op of t he cyl i nder for wa r pag e.
SERVICE LIMIT: 0.10 mm 10.004 in )
PISTON OIL JET REPLACEMENT

Always replace tne Remove the bolts and piston oil jets from the upper
O-ring w hen tne oil crankcase.
jers are removed.
Inspect the oil jets for clogs, and rep lace it if neces-
sary.
BOLTS
13-18
Contents Chapter 13
Install the oil jet collar onto the o il jet.
OIL JET
OIL JET COLLAR
The piston oil j et has identification marks (A or B) o n

the body.
Inst all th e oil jet A int o the No .2 an d 3 cyl inde r, an d
the oil j et B int o th e No .1 an d 4 cy lin der as shown.
App ly a loc kin g age nt to t he pisto n oi l jet m o unting
bol t thread s.
Inst all and tight en t he pist on oi l jet m ountin g bolt s.
PISTON ASSEMBLY
Clean the pist o n ring grooves th or ough ly and in stal l
th e piston rings.
TOP RING
Apply oil to t he piston rings.
SECOND RING
Avoid piston and piston ring damage during
installation.
Install the piston rings with the marking (R: top
ring, RN : second ring) facing up .
Do not mix the top and second rings; to p ring is
narrow er than the second ring in wid th.
To install the oil r ing, ins ta ll the sp acer fi rst , the n
insta ll the side rails.
St agger th e pi st on r ing end gaps 120 0 ap art from
each ot her.
Stagger t he side rai l end gaps as shown.
Afte r installation, the rings shou ld rotate freely in
the ring groove.
SIDE RAILS
13-19
Contents Chapter 13
PISTON INSTALLATION
Apply molybdenum oil solution to t he connecting
PISTON
rod small end inner surfaces and piston pi n oute r
surfaces.
Assemble the piston and connecting ro d with t he
jou rnal bearing tab faci ng to t he piston "dot " m ark.
CONNECT IN G ROD "DOT'" MARK
Insta ll the piston pin an d secu re it us ing new p ist o n

pin clips.
Make sure that the piston pin cli ps are seated
securely.
Do not align the piston pin clip end gap with t he
piston cut-out.
Co at t he cyli nder wa lls, p ist o ns and p isto n ri ng s

w it h engine oil. PISTON RING COM PRESSOR
Install the piston! Install the piston/connect ing rod assemblies into the
connecting rod cylinders using a co mmercially available piston rin g
assembly w ith the co m p ressor tool.
pist on "IN " mark fac-
ing the int ake side.
TOOL (Commercially availabl e):
~~
Pisto n ring compressor RC40C
Wh en reusing the connecting ro ds, they must be
inst all ed in th eir original lo cations.
NOTICE
While instafling th e piston. be careful not to dem - ~r~
age the top surface of the cylinder, esp eciall y
around the cylinder bore.
Be careful not to damage the cylinder sleeve and
crankpin w it h the connecting rod.
M ake sure the pis- Use t he ha nd le of a pl ast ic ham m er o r eq uiva le nt
ton ring compres- t o o l to tap the piston int o the cy linder.
sor tool sirs flush
Install the crankshaft (page 13-81.
on the top surface
of the c ylinder.
13-20
Contents Chapter 13
Apply m o ly bd enu m o il sol utio n to the cran kp in
beari ng sliding surface on th e bea ring cap s.
Inst all the con ne cti ng rod bearin g caps, align ing the
dowel pin s with th e holes in th e con necting ro ds .
The conn ecting rod A pply oi l t o new con necti ng ro d bearin g ca p bolt
bolts cannot be thread s an d seating su rfaces, and inst all the bo lt s.
reus ed. Once the
connecting rod
bolts have been
loosened replace
them with ne w
ones
Tig ht en t he bo lts in two or three steps altern at ely .
TORQUE : 20 N m (2.0 kqf -m, 14 Ibfft)
Furth er t ighten the co n nect ing rod bear in g cap bolt s i3']~::~~
90 degrees.
As sem bl e th e cra nkcas e hal v es (p ag e 1321).
CRANKCASE ASSEMBLY
Replace the trans- Apply a lig ht, but t h o rough, coa t ing of liquid sea lant
mission bearing to th e cran kcase mating su rf ace. Do n ot ap p ly sea l- .,(lmID
holde r and crank-
case as a set.
ant to the cran kcase 8 mm bolt (mai n journal bolt)
area and th e oil passag e area as shown.
- c
- -::
- 0
0
u
,
rl
b'JJ1 -W0"
""
13-21
Contents Chapter 13
Install the mainshaft bea ring while aligning it locat -
ing pi n w ith th e crankcase ho le.
Insta ll th e clutc h lifter rod oi l seal.
Align the cut -outs Inst all the oil or ifi ces in t he upp er cra nkcase.
bet we en the oil ori-
fice and crankcase .
Inst all the t hree do w el pi ns .
13-22
Contents Chapter 13
BALANCER TIMING ALIG NMENT/LOWER
CRAN KCASE INS TALLATION
1. Avoid damag in g the ba lancer drive and driven
gear, tu rn t he ba lan cer shaft and pla ce the pun ch
mark fac ing d own, t o set th e bala ncer back lash at
ma xim um .
2. Remove th e sealing bo lt and seali ng w asher

f rom the l ow er cra nkcase.
3. T em po rar ily inst all th e spe cia l bo lt o r equi v alen t

into t he seali ng bolt ho le, hold t he balancer
we ig ht sec u re ly .
Make su re the specia l bolt tip into the balancer
weight ho le.
Sp eci al bolt. 6 x 18 mm : 9000 4MM5-000
BA LA NCER WEIGHT
4 . Place the crankshaft o nto t he up per crankcase so

that t h e No.1 pisto n at TOe (Top Dead Cen te r). W IDE SPLINE
Sl ight ly turn t he cra nkshaft clockwise and ali g n

t he cra nksha ft 5th s pline ce nte r (fro m t he wide
sp li ne) w it h th e ",6," mark o n t he upper c rankcase
as show n.
"6" MARK
13-23
Contents Chapter 13
5. Carefully place the low er cra n kcas e onto the
up per cran kcase. LOWER CRANKCASE
NOTE:
Th e crankshaft will slightly m o v e counte rcl oc kwise
w hen e ng ag ing the balan cer g ears.
6. Check t hat th e u pp er and lo wer cr an kcase seat s ~=================~

properly.
Tem po rarily ins tafJ Check that the crankshaft 5th sp line ce nt er aligns
the sta rte r clu tch with the next "bJ." ma rk on t he upper crankca se
assemb ly to cnecx as sho w n.
the TDC. Make sure t he No .1 piston at TDC (To p Dead
Cente r).
If the crankshaft is n ot in t he proper position ,
reassembl e t he crankcase h al ve s from the begin -
ning .
7. Rem ov e t he te m po rari Iy i nst aIIed speciaI bo It ~:::::;:;::::;:;;;:;::~:;;:;;;;:;:::::::;:;:;:~

;0,
fro m th e bala nce r wei g ht . ~
I$:!
:':;
I ... :JI]~.
Inst all a new sealing wa sher and bo lt , t ight en t he ~
bol t sec urely.
Install new cra nkcase 9 mm bo lts (ma in j ou rn al

bo lts ).
Loosely in stal l all the lower crankcase bo lts.
Make sure t he u p per and lo w er cra n kcase are
seated securely.
Tighten the cra nkcase 9 m m bolts (mai n jou rn al
bolts ) usi ng t he Plasti c Regio n Tig ht eni ng
M etho d de scribed on ne xt p ro cedu re .
Do not reuse t he crankcase 9 m m bolts (m ain
jou rna l bolts), because the co rrect axi al tensi on
w ill not be obtained.
Th e c rankcase 9 mm bolts (mai n j ournal bolts)
are pr e-coat ed w it h an o il add itive fo r axial t en -
sio n sta bil ity. Do not rem o v e th e o il additiv e
fro m th e new 9 mm bolts (ma in j ournal bolts)
su rface.

PLASTIC REGION TIGHTENING M ETHOD :
Tighten the crankcase 9 mm bolts (m ain journal ,---------;=----r~----r=--------,
bolts) in numerical ord er in the illustration in two t o
three steps to the spe cified torque.
TORQUE : 20 N m (2.0 kqf-rn, 14 lbf-ft]
Furth er ti gh t en t he crankcase 9 mm bolts (m ain ~::::-:::::;------:::~-----------'

j ou rn al bol ts) 150 degrees.
Tighten t he 8 m m bo lt to t he spec if ied t orqu e.
TORQUE : 24 N m (2.4 kqf-m, 17 Ibl lt)
From the inside to ou tsid e. ti g ht en the 7 mm bo lt s

to the specified t orq ue.
TORQUE : 18 N m (1.8 kqf-m , 13 Ibllt)
Place t he engine w it h t he low er side do wn .

Inst all t he up per cra nkcase 8 mm bo lt s, sealing
w as her a nd 7 mm bo lts.

The seal ing w ash er locatio ns are in dicated on th e
upper crankcase using th e b. ma rk .
II II
S~
SEALING WASHE::.R:..a...._iL.=..;;.;=~
Tigh t en the 8 m m bolt in a cr issc ross patt ern in 2 - 3
steps.
TORQUE : 24 Nrn (2.4 kqt -m , 17 Ibl lt)
Tighten the 7 m m bolt in a crisscross pattern in 2 - 3
steps.
TORQUE : 18 Nm (1.8 kqt -rn, 13 Ibl lt)
Set the ini tial balancer backlash adjustment
(page 13-33).
Apply oil t o a new O-rin g an d i nst all it into the o il

inspection wi nd ow gr oove.
Inst all t he o il ins pectio n wi ndow o nt o th e low er
cra nkcase.
S~
O-RING
Inst all an d t ig hten t he bolt s sec urely.
OIL INSP ECTION WINDOW

Inst all a new O-rin g int o th e w at er hose joi nt
groo ve.
Install th e w ater hose joint to the cra nkcase. tig hte n

t he two bo lt s secu re ly .
Route the eng ine sub -ha rn ess properl y, co nnect th e

neutral sw it ch co n necto r.
A pply a sealant t o th e oi l press ure switc h t hreads as

shown. Do not apply sealant to the thread head
3 - 4 mm (0 .1 - 0 .2 in )
.. ..
Il
"-
OIL PRESSUR E SWI TCH
13-27
Contents Chapter 13
Ti gh t en t he o il pr essu re sw itc h to th e specified
t orqu e w hile hol di ng t he swit ch base.
TORQUE: 12 Nm (1.2 kqf-rn, 9 Ibf.ft)
Install th e term inal eyelet t o t he oil pressure switch ,

tig hte n the te rm inal screw to t he s pecified to rque.
TORQUE: 20 N m 10.2 kqf-rn, 1.4 Ibf.ftl
Inst all th e rem ov ed pa rt s in th e reve rse orde r of
rem o v al.
BALANCER
REMOVAL
Sep arat e the crankcase hal ves (page 135 ).
PINCH BOLT
Loosen th e ba lancer sh aft pi nch bolt.
Remove t he balan cer shaft ho ld er bol t an d balancer
ho lder.
Pull t he balancer shaft ou t an d rem ov e th e bal ancer

weig ht assembly fro m the lower cra nkcase.
DISASSEMBLY
Rem ove th e O-ring fro m th e balancer shaft.
13-28
Contents Chapter 13
Remove t he w as he rs and need le bearing s from t h e
balancer we igh t assembly.
NEEDLE BEARING S
Rem ov e t he ba lancer gea r asse m b ly f ro m t he ba l-

a ncer weigh t.
Remo ve the d amp er ru b ber s f rom t he balan cer

BAL AN CER GEA R DAMPER RUB BERS
gea r.
INSPECTION
Rep lace the bet- Che ck t he n eedle bea ring fo r wea r or d am ag e,
NEEDLE BEA RINGS
ancer w eight bst- repla ce if necessary.
~~i".~
ancer shaft, needle
bearing as a set
13-29
Contents Chapter 13
Check the balance r weight and gea r for wear or
BALANCER GEAR DAM PER RUBBERS
damage .
Check the damper rubb ers for fat igue or damag e,
replace if necessary.
BALANCER BEARING SELECTION

The ba lancer The balan cer weight has two I.D . code letters as
we ight and needle shown . I.D.CODE LEITE RS
bea rings are se lect The m arking identify each 1.0. of the balan cer
fitted. w eight as show n.
GEAR SIDE I.D. W EIGHT SIDE I.D.
Refe rence the ba lancer weight 1. 0 . code letters to

dete rm ine the replaceme nt bea ring color. GEAR I.D. CODE
SIDE I.D. LEITERS
Refer to the se lection tabl e below fo r bea ring selec-
f~~~\/ i
t ion .
WEIGHT
'~ / SIDE I.D.
BALANCER BEARING SELECTION TA BLE:

BA LANCER W EIGHT I.D. CODE
A B C
27.000 - 27.004 mm 26.991 - 26.996 mm 26.987 - 26.99 1 mm
(1.0630 - 1.0631 in ) (1.0626 - 1.0628 in) (1.0624 - 1.0626 in )
BALA NCER 17. 990 17.996 mm
SHA FT I (0.7083 - 0.7085 in )
Blue White Gre en
13-30
Contents Chapter 13
DISASSEMBLY
NEEDLE BEARING
WASHER B
BA LANC ER WE IGHT
DAM PER RU BBERS
BA LA NCER GEAR
WASHER A
BALA NCER SHA FT
HOLDER
Install the damp er ru bbe rs into the bal ancer gear.

A LIG NING MARKS
Assemb le t he balancer gear and weight while align -
ing th e align ing m ar ks.
Apply oil to th e needl e bearing, install t hem into th e

balan cer weig ht. WAS HER A
Insta ll the was he r A and B.
'e
, NEEDLE BEARINGS
13-31
Contents Chapter 13
Install a new O- ring to t he ba lancer shaft.
INSTALLATION
Install the balance r we ight int o t he lower cra nkcase.
In st all the balance r shaft.
Turn the bala ncer shaft and place the punch m ar k ~~~~~~~;:;::::;:;~;:
on t he shaft faci ng down.
PUN CH MARK
Inst all the balancer shaft hol der.

$~
Install the ba lancer ho lder bo lt and ba lance r ho lder
pinch bo lt.
Asse mble t he cra nkcase halv es (page 13-21 ).
13-32
Contents Chapter 13
INITIAL BACKLASH ADJUSTMENT
Install th e en g ine into t he frame (page 8-9).
Adjust the backlas h Loosen the balancer shaft ho lder pi nch bo lt "
w hile the eng ine is
co ld (below 35OC/
95 "F) and the
e ngine is no r run-
ning.
PINCH BOLT
Excessive fo rce can Turn th e balancer shaft clockwise until resistance is :==================~
cause balancer f elt, th en bac k it o ff o ne g raduatio n usi ng th e sl ot as 1. 2. 3.
gear, bearing and a m easu reo
shaf t damage . Do
no t turn the shaft
more than neces-
sary.
UNTIL ONE
RESISTAN CE GRA DUATION
IS FELT
FINAL BACKLASH ADJUSTMENT

Warm up th e eng ine and let it id le.
BA LA NCER SHA FT
If the balancer gear noises ar e excessive. adjust t he
balancer back lash as f oll ow s:
Tu rn th e balan cer gear shaft co unt ercloc kw ise until
t he gears begi n to m ake a "w hining" noise. Then
turn the gea r shaft clockwise until the gear "w hin-
in g" noise disappea rs.
Tighten th e balancer shaft pin ch bo lt.
Aft er all g ear backlas h adjustm ents are done, s nap
th e th rottl e and make sure th e gear noises are not
excessive.
If t h e gear "w hine" noise is excessive. the back las h PINCH BOLT
is t oo sma ll.
If th e gea r "rattli ng" noise is excessive . t he backla sh
is ex cessive.
13-33
Contents Chapter 13
MEMO
Contents Chapter 13
14. FRONT WHEEL/SUSPENSION/STEERI NG
COMPONENT LOCATIO N .. 14-2 HANDLEBARS 14-9
SERVICE INFORMATION 14-3 FRONT WHEEL 14-16
TROUBLESHOOTING 14-6 FORK ....................................14-21
HES D (Ho nda Electron ic Steering Damper) STEERING DAMPER...... ................ ....14-34
TROUBLESHOOTING 14-7
STEERING STEM .................. .............. 14-35
14-1
Contents Chapter 14
FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION
103 Nm (10.5 kqf- m , 76 Ibf.ft)
23 N ' m 8.8 Nrn (0.9 kqf -m , 6.5 lbf -ft ]

(2.3 kqf -rn, 17 Ibf ft )
26 Nm ~-'r- 23 N'm 12.3 kqf-rn , 17 lb f -tt )

(2.7 kgf 'm , 20 lbfft)
45 Nm (4.6 kqf-rn, 33 lbf -ft ]
78 Nrn
18.0 kqf -rn, 58 Ibfft)
22 Nm (2.2 kqf-rn , 16 Ibfft l
14-2
Contents Chapter 14
SERVICE IN FORM ATION
GENERAL
W he n servicin g t he fro nt whee l, fo rk or steering ste m, support the m ot orcycl e secure ly using a ho ist or equival ent.
A contaminated bra ke d isc or pad reduces stop ping pow er. D iscard co ntam inated pads and clea n a co ntam inated d isc
with a high qua lity brak e degreasing age nt .
After the f ront wh eel installation , check the brake ope ration by applying t he brak e lever.
Use only tir es marked "TUBELESS" and tubeless valves on rim marked "T UBELESS TIRE APPLICABL E".
Ref er to th e bra ke syst em info rmation (page 16-4) .
SPECIFICATIONS
Unit' mm (in)
ITEM STANDARD SERVICE LIMI T
Minimum ti re tread d epth 1.5 10.06)
Cold tir e pr es- Up to 90 kg 1200 Ibs ) load 250 kPa 12.50 kgl/em' , 36 psi)
su re Up to maximum weight capac ity 250 kPa (2.50 kgl/em ' , 36 psi ) -
Axle runout 0.2 (0.008)
Whe el rim Radia l 2.0 (0.08)
ru nout A x ia l - 2.0 (0.08)
W he el ba lance we ight 60 g(2.10z)
max.
Fork S pring free le ngt h 218.2 18.59) 213.8 18.42)
Tube ru nou t 0.20 10.0081
Recom me nded fo rk fluid Pro Hond a Sus pe nsio n Fluid, 55 55 o r -
equiva lent
Fluid lev el 90 (3.5) -
Flu id capacity 466 2.5 em 115.8 0.08 US OZ, 16.4 -
0.09 Im p ozi
Pre- load adjuster ini tia l setti ng 7 t urn s from minimum -
Rebound adj uste r initial setting 2 turn s ou t fr om fu ll ha rd
Comp ression adjuste r initial 2 t urns out f rom full hard -
setting
Steerin g head be aring pr e-lo ad 12 - 19 N 11.2 -1.9 kg!) -
TORQUE VALUES
Handl ebar w eight mounting screw 9.8 Nrn 11.0 kqf-rn. 7 Ibf.ft) ALoe screw; replace with a new on e
Handlebar pinch bo lt 26 N' m 12.7 kqt -rn, 20 Ibf.ft)
Fron t axle bolt 78 Nm 18.0 kqf- m , 58 lb f -ft]
Front axle holde r pinch bo lt 22 Nrn (2.2 kqf -rn, 16 lbf-ft)
Front brake di sc bolt 20 N-m (2.0 kqf-rn, 14 lbf-ft] ALoe bo lt; rep lace w ith a new one
Fork socket bo lt 34 Nm (3.5 kqf-rn, 25 lb f -ft]
Fork bolt 34 Nm 13.5 kq f-m , 25 lb f -tt]
Fork da mper lock nut 25 N'm 12.6 kqf- rn. 19 Iblft )
Fork comp ressio n adjuster plug bolt 18 Nrn 11 .8 kqf -rn, 13Ibl-ft)
Fork to p bridge pinch bolt 23 Nrn (2.3 kqf-rn , 17 lb f -ttl
Fork bottom bridge pin ch bolt 23 Nm 12.3 kqf-rn , 17 Iblftl
Stee ring damper second ar m nut 12 Nrn 11.2 kqf- rn, 9 Iblft) U-n ut
Stee ring dampe r seco nd ar m bo lt 8.8 N-m 10 .9 kqf-rn, 6.5 lbf -ft )
Stee rin g damper mounting bolt 8.8 Nm 10.9 kqf-rn, 6.5 Iblft)
Ste ering stem adjusting nut 20 Nrn (2.0 kqf-rn, 14 lbf-ft)
Ste ering stem ad justing lock nut See page 14-42
Steering stem nut 103 N ' m (10.5 kqf- rn. 76 Ibl ft )
14-3
Contents Chapter 14
TOOLS
Attach ment, 42 x 47 mm Pilot, 25 mm Bear ing rem over head , 25 mm
07746-00 10300 07746-0040600 07746-0050800
~:co," ": .
' _ .. /
Driver Stee ring stem socket Drive r shaft assembly

07749-0010000 07916 -37 10101 07946-K M90301
07916 -37 10100 (U.SA on ly )
Bea ring remover, A Asse m bly base Ste e ring stem driver
07946-KM 90401 079 46 -KM90600 07946 -MBOOOOO
Dr iv er attach m ent (upper) Drive r attachment (low er) Bear ing remover shaft
070M F-MC J 0100 070MF-MCJ0200 07GG D-0010100
14-4
Contents Chapter 14
Bearin g rem over, 8 Fork damp er holder Fo rk seal driver

07NM F-MT7011 0 07Y M B-M CF0101 07YMD-MCF0100
or 07Y MB -MC FA100 (U.S.A . on ly ) or 07NMD-KZ3010A (U.S.A. only )
Damper rod holder Ma in bearing dri ver attachm ent Fork seal driver weig ht
070MB-M EL020 0 0794 6-ME90200 07947-KA50100
o r 070M B-M ELC200
Oil seal drive r Instal ler shaft Inst aller attachme nt A

079 65-M A 60000 07VM F-KZ30200 07VM F-MAT0100 (U.S.A . o nly)
Installer attachment B Rem over attachm ent E Rem over attachment F

07VM F-MAT02 00 (U.S.A. only) 07AM F-MELA100 (U.S.A. o nly) 07AM F-M ELA 200 (U.S.A. on ly )
14-5
Contents Chapter 14
TROUBLESHOOTING
NOTE :
If th ere is any probl em wit h stee ring, rem ov e the stee ri ng d amper (page 14 34) a nd inspect the steering co ndition. Che ck
th e HESD by us in g th e Fun ct ion Test (pa ge 14-7 ) i n case of no fau lty pa rt s with th e steering .
Har d steering
Faulty steer in g da mper (HESD)
Steering st em adj usti ng n ut too tig ht
Wo rn o r damaged stee ri ng head bearing s
Bent st eering stem
Insuffici ent tire pressure
St ee rs to o ne side o r does not t rac k straig ht
Faulty steerin g damper IHESDI
Unevenly adju st ed right an d left forks
Damaged or loose steering head bea rings
Bent fo rk legs
Bent ax le
W h eel insta lled incorrect ly
Bent fram e
Worn o r damag ed whee l bea rin gs
W orn or damag ed swinga rm pivot bearings
Front wheel wobb ling
Bent rim
W orn o r d am ag ed f ront wh eel bearings
Fau lty t ire
Unba lan ced fro nt t ire and whe el
Fro nt wheel ha rd to t urn
Faulty f ront wh eel bearings
Bent front axle
Fro nt b rake d rag
Soft susp en si o n
Insuffici ent fluid in fork
Incorrect f o rk flui d w eight
Weak f or k springs
Insuffi cient t ir e pressure
Stiff suspens io n
Bent fork le gs
To mu ch fluid in fork
Inco r rect fork flu id we ight
Clogged fo rk f luid passage
Front sus p ens ion n o ise
Insuffi cien t f lu id in fork
Loo se fo rk fa st eners
Incorrect fork f luid we ight
14-6
Contents Chapter 14
HESD (Honda Electronic Steering Damper) TROUBLESHOOTING
The HESD (Ho nda Electroni c Ste ering Dam pe r) sy st em is equipp ed wi th a SelfDiagn ost ic System
that is li nked to th e PGM -FI system. If t h e ma lfu nct ion indicat or lamp (M IL) blin ks (page 6-9). fo llow
the Sel f-Diagnostic Procedures to reme dy the pro blem (Refer to MIL t rou bles hooti ng ; page 14-8 ).
The HESD system is al so equ ipped with a Function Test Mod e t hat m akes it p ossibl e to ch eck the
HESD under ma xi mum damping cha racte ris tics . If th er e is any ab no rm al co nd ition in the HESD sy s-
t em witho ut M IL blinkin g, fo ll ow th e HESD fun ctio n test and check th e HESD f unctio n.
Th e HESD system in clu des a fai l-safe fun ct ion to secure a m inim um runn ing cap abili ty w he n th er e is
any trou ble in the sy stem. W hen any abnorma lity is de tect ed by t he self -diag nos is f un ctio n, the ECM
sto ps t he HESD sy stem control by shutti ng off t he cur rent supply to t he linear sol enoid and the HESD
w ill operate under m inimum dam pin g characte ris tics accor d in gly .
Refe r to system dia gram in th e PGM -FI sy st em (p ag e 6-8 ).
Refer t o PGM -FI sel f -dia g nosis inform at ion f or se lf -diagnosis proc edure and reset pr ocedure in the
PGM-FI system (p age 6-9) .
Refer t o t est harness connection (page 6-1 1) and t ermin al location (page 6-12).
Ref er to M IL co de i nfo rmation (page 14-8 ) befo re startin g tro ublesho ot ing .
A f aulty HESD sy ste m is often related to po or ly co nnecte d o r corroded co nnec to rs. Chec k t hose co n-
nect ions before proceed ing .
If th e foll owing sy m pt om s occur to the HESD, ch eck t he M IL blinking and perform the t roubl esh oot ing
in acco rda nce w it h MIL blinks.
M IL bli nk 11 time s (page 6-22)
M IL blink 51 t im es (page 14-8)
M IL does no t blink, although HESD does not wo rk .
- Wh en t he vehi cle speed rises, t he damping fo rce does no t incre ase .
- Alth ou gh ve hicle is no t run ning , th e dam ping f orce is st ro ng (hard ste er ing).
HESD FUNCTION TEST
NOTE:
Th e HESD system is also equ ip ped with a Fu nct ion Test Mode so tha t a t echn ician ca n compare t he
mi ni mum w ith m aximu m dampin g cha rac te ristics witho ut ri din g. Th e HESD syste m is set to min i-
mum damping at n o ve hicle speed un der normal co nditi ons. By using th e Fu nction Test Mode, t he
ECM ope rates th e linea r solenoid with maximu m current so t he HESD system is tempo rari ly set to
m axim um dampin g.
It is not possible t o use the HESD Function Test Mode w hen an y probl em s occ u r (M IL blinking ).
Before pe rfo rm ing th e HESD function tes t, rem ov e t he HESD unit from th e vehic le (page 14-34 ) and
ch ec k the fo llowing .
- Stee rin g stem pre- load (pag e 14-44)
- W ear or damage of stee ring head bearing (p age 14-35)
- HESD-to- st eerin g linkage (page 14-34)
HESD FUNCTION TEST PROCEDURE
Support th e motorcycle secu rely usi ng a ho ist or equival en t and raise t he fro nt w heel o ff the ground .
Befo re fun ctio n the tes t, ch eck th e fee l fo r mini m um dampi ng cha racteri stics by m o v in g the st eering
ri ght and leh qu ickly several tim es. Op er at e th e st eerin g qu ickl y and at a uniform force during th e
t est.
Perfo rm t he HESD f unction test as f o llo w s:
1. Low er the side sta nd (side sta nd switch OFF).
2. Sh ift th e tran smi ssion int o any gear other th an neu tral.
3. Open the th ro ttl e grip full y.
4. Turn the ignition swit ch ON with keep ing th e sta te of 1 - 3.
Th e HESD ind icat or starts bl ink in g and t he HESO system ente rs th e Fun ctio n Test M ode for 10 sec-
o nds.
Make sure that the damping characteristics (force ) changes, by means of co m paring the minimum
da mping cha racte rist ics before Function Test with the maximu m damping characte ristics under the
Fun ct ion Test.
If the HESO da m pi ng characte ristics (force) in Functio n Test M ode does not cha nge at all , replace the
HESD unit with a new o ne (pa ge 14-34) .
14-7
Contents Chapter 14
MIL TROUBLESHOOTING
M IL Refer
Cau ses Symptoms
Blinks to
Loose o r poor contac t on speed sensor Eng ine operates normally
co nnector HESD does no t fu nctio n
11 Ope n or short circ uit in speed senso r - ECM does not co nt ro l th e
6-22
wi re lin ear so le noid
Faulty spe ed sens o r - Minimum d amping cha r-
acteri stics
Loose o r p oor co nt act o n lin ear sole- Engi ne o pera tes no rm all y
no id co nne cto r HESD does no t function
51 Open o r short circ ui t i n linear sol en o id - ECM does not co nt ro l the
14-8
w ir e lin ear so le no id
Fa ulty lin ear so le no id - Mi nimum d amp ing char-
acteri sti cs
MI L 51 BLINKS (LINEAR SOLENOID)

Before sta rti ng th e ins pec t ion, check f o r loose o r p oor cont act on th e linea r sol enoid connecto r and
rech eck t he MI L blin kin g.
1. Lin ear Solenoid Circuit Inspection
Tu rn the ignit io n switc h OFF.
Di sconn ect t he ECM co n nect o rs and co nnect th e
ECM test harn ess t o th e ECM co nnecto rs at t he
w ire harn ess side (page 6-11).
M easure t he re sistan ce at t he t est harness t e rmi - 0
nal s.
Connection : 82 - 83
Is the resistance within 6.0 - 8.0 f2 (20 "CI68 "Fj7 , I t j t I III Ii " il!4 l i l i l
Yes - GO TO STEP 3 000000 0 0 0 0 0 0 0 0 00 o 000 0000000000

000 000000000000 0 000000 0 0 0 0 0 00000
No - GO TO STEP 2 LllJLJlJ:1lt1 ?i ZHl?!ili !!II "]j])! Ui ! !1 II " >0" l U ll' 1$8" Ii ")j! 'Ii
2. lin ear Solenoid Resistance Inspection

Remove th e st ee ring da mper (p ag e 14-34) and
STEERING DA M PER
disconnect t he lin ear solenoid 2P con nector.
Measure the resistan ce at t he linear so len o id t er-
mi nal s.
Is the resistance within 6.0 - 8.0 n (2 0OCI 68 Fj?
Yes - O pen circ ui t in W hi t e/green o r W hit e/
bl ue w i re
No - Faulty linea r so le noid
2P CONN ECTOR

3. Linear Solenoid Short Circuit In spection
Check fo r co nt inuity bet w een the t est harness
and bo dy g ro und .
Connection s: 82 1+)- body ground H
83 (+) - body ground H
Yes - Short circuit in W hit e/gree n or Wh it e!
blu e wire 'I t l " " " !.!! "I' ''''l''
No - Repla ce the ECM w ith a kno wn good o 0000000000000
0000000000000000
o ne, and reche ck
illJllfIDillluGu__iLH1i1IWJU
HANDLEBARS
REMOVAL
Support the m o t or cy cl e securely u sing a hoist or
eq uivalent and raise t he f ro nt w hee l of th e ground . .
Hold the handl eb ar we ig ht and rem ov e th e mou nt -
ing screw, t hen rem o ve both hand lebar weig hts!
washe rs.
Disco nn ect th e clutc h sw it ch co nnecto rs f rom th e

switch .
Keep the clu tch Rem ove t he m aster cylinde r hold er bolts, ho lde r
mas rer c yfinder and clut ch master cylinder ass embly.
upright to pre vent
air from ent ering
th e hydraulic sys-
tem.
Rem ove th e scr ews an d left handleb ar sw it ch.
14-9
Contents Chapter 14
Rem ov e t h e left ha ndl eb ar gri p and sw itc h end
cove r.
Dis connect the front brake lig ht switch co nnectors

f rom the switch.
Keep the brake Remove t he master cyl inder ho lder bolts, hol d er
mas ter cylinder and bra ke maste r cyl inde r assembly.
upright to prevent
air from ente ring
the hydraulic svs-
rem.
Rem ov e t he screw s and rig ht han dl eb ar sw itc h .
Rem ov e t he screws and throttle cab le hou sin g

cove r.

Rem ov e t he HESD un it (page 14-34).
Loosen th e to p br id g e pin ch bo lts an d hand lebar
pi nch bo lts.
Remove th e ste ering st em nu t and top br idge.
Rem ov e the han dl eb a rs f rom th e f o rk sli ders.
Rem o v e th e thrott le cab le hou sing/thro tt le pi pe

from t he right handlebar.
INSTALLATION
Ma ke sure th at th e hand leb ar st op per rin g is
installed in the fork slider groove properly. --.....~
Apply greas e to t he sli ding surface of t he thrott le

p ip e.
Install th e throttl e cab le hou sing/th rottle pi pe t o the
right handl ebar.
14-11
Contents Chapter 14
FRONT WHEEL/SUSPEN SION /STEERING
Instal l the right and left ha ndlebars onto t he fo rk
sliders .
Install the top bridge w hile aligning its holes wit h
the hand lebar stopper pi ns. ..~~-.
Insta ll the steering stem nut and t ighten it to t he

specified tor que .
TORQUE: 103 Nm (10.5 kqf-m, 76 Ibf.ftl

T ighten t he to p bridge pinc h bo lts to the specified
to rque .
TORQUE: 23 Nm (2.3 kqf- m , 17 lbf-tt l
Seat the ha ndleba r upper su rface wit h th e top
bridge lower surface, the n ti ghte n the handlebar
pinch bo lts to the specified to rqu e.
TORQUE: 26 Nm (2.7 kqf-m , 20 IbfIt)
Install the stee ring dam pe r (pag e 14-34 ).
HANDLEBAR W EIGHT REPLACEM ENT
Straighten the weight retaine r tab by the screw -
RETAIN ER RING
driver or punch.
RUBBE R CUSH ION
Apply lubricant Temporari ly inst all the ha ndl ebar we ight and screw ,
spray through the the n rem ove th e inn er we ig ht by turning t he han dle-
tab locking hole to bar we ight.
the rubber for easy
removal.
RETAINER TAB
INNER W EIGHT
HAN DLEBAR WEIGHT
Remove the han dl eb ar weight fro m t he inner

RUBB ER CUSH IONS
weight.
Disca rd the retaine r ring .
~
~
Install the new retainer ring o nto t he inner weight.
Install the ha nd lebar w eig ht ont o the inn er we ight \ HA NDLEBA R
w hile a lig ning t he bosse s a nd grooves eac h othe r.
Install and te mporari ly tighte n t he mounting screw .
~ WEIGHT
INNER WEIGH: 7~t

s
RETAIN ER RING SCREW
14-1 2
Contents Chapter 14
In sert t he handl eba r we ight asse mbly in to th e han-
RETAINER RING
dle bar.
RU BBER CUS HION
Turn the han dlebar w eig ht and ho ok th e reta in er
ring tab wit h the ho le in t he han dl eb ar.
Remo v e th e m ou nting sc rew and hand lebar weig ht.
RETAIN ER TAB
IN N ER W EIGHT
HAND LEBAR W EIGHT
If you rem ov e th e rig ht ha nd le bar g rip from th e

throttle p ipe, install it in accordan ce w ith f ollo w ing
p ro cedure.
App ly Pro Ho nd a Han dg rip Cemen t or equiva lent
adhesive to the inside of the ha nd leb ar g rip and to
the clea n surfaces of the th rottle pipe.
Wa it 3 - 5 m in ut es and inst all the g rip.
Allow the adhesive Rotate the grip for even a pplica tion of t he adhesive,
to dry for an hour an d alig n the inn er groove of t he grip w ith th e index
before using . li ne of t h rott le p ipe .
GRIP
Inst all t he t hrottl e ca b le hou sing cove r t o t he th ro t-

tl e pi pe f lan ge , align ing it s lo cat in g pin w it h the ho le
in t h e handl ebar.
Inst all and t ig hte n th e housing cove r screws

sec u rely .
14-13
Contents Chapter 14
Inst all t he right ha nd lebar switch, alig ning it s loc at -
ing pin with t he hole in the hand lebar.
Tig ht e n the screws to the s peci fied to rque.

TORQUE: 0.9 Nrn (0.09 kqfm, 0.7 Ibf.fl)
Inst all the fro nt bra ke maste r cy lind er and ho lde r

with th e "U P" m ark faci ng up.
Alig n t he end of th e m ast er cylinder w it h t he punc h
m ark o n the handl eb ar , and ti ghte n th e upp er bolt
first, then lower bolt.
TORQUE: 12 Nm 11 .2 kqf-m , 9 lbf-tt)
Co n nect t he front br a ke lig ht sw itc h connectors.

Chec k the throttl e grip operation and fr ee p lay (p ag e
4-7 ).
Insta ll the sw itch end cover to t he left handlebar.

Ap p ly Pro Ho nda Handgrip Cement or eq u iva le nt to
the inside su rf ace of the handlebar gr ip and to t he
clean su rface of th e han d leba r. Wa it 3 - 5 m inutes
and insta ll th e grip.
Allow th e adhesive Rotate t he grip fo r eve n app lication of t he adhes ive .
to dry for an hour
before using.
HANDLEBAR GRIP
14-14
Contents Chapter 14
Make sure that the Insta ll t he left han d leb a r sw itc h, ali gn ing it s locat in g
switch end plate is pin wit h the hol e in the handl ebar.
installed into the
handlebar switch
g roov e .
Ti g ht en th e forward sc rew first the n th e rear sc rew.
Install t he clutch m ast er cy linder and ho lder wi t h

the "UP" m ark faci ng up .
Al ign the e nd o f th e m ast er cylind er w it h the pu nc h
ma rk o n the h and lebar, an d tig hten the upper bo lt
first, th en lower bolt.
TORQU E: 12 Nm (1.2 kqf-m, 9 Ibf.ft)
Co nnect t he clu t ch switch co n ne cto rs.
Insta ll th e washer an d ha ndl eb a r w eight o n bot h

handl eb ars. al ig ni ng w it h each han dl eb ar and ha n-
d leba r we ig ht cu to ut.

FRONT W HEEl/SUSPENSION/STEERING
Tighten the new moun t ing screws to t he specifi ed
torque .
TORQ UE: 9.8 Nm (1.0 kqt -rn, 7 lbf.tt }
FRONT W HEEL
REMOVAL
Support the m ot orcycl e secu rely us ing a hoist o r
equivalent , and raise th e front wheel off the ground .
Rem ov e t he bra ke cal iper mounting bolts and both
brake calipers.
Do not operate th e Supp ort th e brake calipe r w it h a piece of w ire so
brake fever after the th at it does not ha ng f ro m th e brake hose. Do not
brake caliper is tw ist t he b rak e hose .
remo ved.
Loosen the rig ht ax le ho ld er pin ch bolts.

Rem o ve t he axle bo lt.
Loo sen t h e left axle hol der pin c h bolts.

Rem ove th e axle and fr ont whe el.

Rem ove the right and left sid e collars. J
INSPECTION
A xl e
Set the ax le o n V-blocke and m easu re t he runou t .
Actual runo ut is 1/2 t he total indi cato r read ing .
Wh eel bearin g
Turn t he inner race of each bear in g with yo ur finger.
The bea rings sh ould turn smoothl y and quietly.
Also che ck that th e bearing o ut er race fits tightl y in
the hub.
(~
. ~~
d~:--'
Remov e and discard the bearings if th ey do not t urn
smoothly, quietly, or if they fit loosely in the hu b.
Replace tne bear- Replace th e wh eel bear ings, if ne cessary (page 14-
ings in pairs. 18 ). --r'--..
J
~- .~
~=------
WH EEL BEA RING
Wh eel rim run ou t

Chec k the rim ru nout by placing t he w he el in a t urn-
ing stand .
Sp in the whee l by hand. and read the run out using a
dial indicator.
Act ual ru no ut is 1/2 the t ot al indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in )
A xial : 2.0 mm (0.08 in)
G
14-17
Contents Chapter 14
FRONT WH EEL/SUSPENSION/STEERING
For optimum bal- Wheel balance
ance, the tir e bal- W heel bala nce direct ly affects t he stability, han -
ance mark (a paint
dl ing and over all safety of t he motorcycle.
dot on the side
Always check b alance w hen t he tire has been
wall) must be
removed from th e rim .
located next to the
valve stem.
Remount the tire if
necessary.
Note the rotating di rection marks on the whee l and

tire .
Rem ove th e dust sea ls fro m the w heel.

M oun t th e w hee l, t ire and br ake d iscs asse mbly i n
an inspection sta nd.
Spin the w heel, allow it to stop, and mark the lowest
(heaviest ) poi nt of th e w hee l with a cha lk . Do t h is
two or th ree times to ve rify t he heaviest area.
If t he w heel is balanced, it w ill not stop cons istent ly
in t he sa me posi tion.
To balance th e w heel, in st all the w heel weig hts on
the highest side of th e rim , the side opposite the
cha lk marks. Ad d j ust enough weight so the wheel
wil l no lo nger stop in t he same position whe n it is
spun. Do not add more tha n 60 grams to the wheel.
NOTE: INSP ECTION
L-- STAN D --'
This model is equippe d with the new shape wheel
weight made of zi nc spelter. This wheel weight is
incompatible with the conventional one in case of
installation to the wheel.
DISASSEMBLY
Remove the bolts and brake discs.
Remove the dust seals.

Inst all th e bea ring rem ov er head int o the bearing .
Fro m the o pposite side, insta ll t he bearing rem ov er
shaft and d rive th e bear ing out of th e w he el hub.
Rem ov e the d ist an ce co llar an d driv e o ut t he other
bea ring .
TOOLS :
Bear ing remover head, 25 mm 077460050 800
Bear ing rem ov er sh aft 07GGD-0010100
ASSEMBLY
RIGHT BRA KE DISC
S~
RIGHT W HEEL BEA RING
S~ .~
RIGHT DUST SEAL
S~ .--
. --'Imm{ LEFT DUST SEAL
LEFT BRA KE DISC
Never install the old Dr iv e in a new rig ht w heel bear ing sq uarely u ntil it
bearings. Once the is full y seat ed usin g t he sp ecial too ls.
bearings have been Insta ll th e dist ance co lla r, t hen d riv e in new left
removed, the bear- w hee l bear i ng us ing t he same t ool s.
ings mus t be
replaced with new TOOLS :
ones . Drive r 0774 9-0010000
Attach ment , 42 x 47 mm 077 46-0010300
Pilot, 25 mm 07746-0040600
14-19
Contents Chapter 14
Do not get greas e Install th e brake discs w ith th e arrow ma rk facing

on the brake discs t he no rmal rotating d irection.
or stopp ing power Install new disc bo lts and t ig ht en t hem in a criss-
w ill be reduced cross pattern in two or t hree steps.
TORQUE: 20 Nm 12.0 kqt-m , 14 Ibfftl
Apply g rease to new d us t seal lips.

Inst all th e dust seals in t o th e wheel hu b.
INSTALLATION
Install t he right an d left side co ll ars.
Insta ll the fron t w heel between t h e f ork legs .

App ly a thin lay er of g rease to th e fron t axle surf ace .
Inst all the fro nt ax le fro m t he left side. -
Ins ta ll t he a xle bo lt.

Hol d th e ax le an d tig hten t he ax le bolt to th e speci-
f ied torq ue.
TORQUE : 78 Nm (8.0 kqf-m, 58 Ibf-ttl
Tigh ten the rig ht ax le ho ld er pin ch bo lt s t o the spec-

ified tor qu e.
TORQUE : 22 N 'm 12.2 kqf-m, 16 lbf-ttl

Inst all t he both br ake calipers and t ighten th e n ew
m ou nt ing bo lts to t h e specifi ed to rqu e.
TORQUE : 45 N ' m 14.6 kgf m , 33 Ibf.ft)
W ith th e fro nt brake ap pli ed , pump th e fo rks up and

down several t im es t o seat t he ax le and che ck bra ke
operation.
Tighte n t he left ax le ho ld er p inch bo lt s to t he speci-

fi ed to rqu e.
TORQU E: 22 Nm 12.2 kqf-m, 16 Ibf.ft)

Reche ck t he front brake operat io n.
FORK
REMOVAL
Remov e t he foll owi ng :
- Front w hee l (pa ge 14- 16)
- Fron t fe nder (p age 3-19)
Lo o sen th e handleba r pinch bol t and f or k to p br id g e
pi nc h bo lt . ...._~
When t he fo rk leg wi ll b e d isassem bl ed, loosen the
f ork bo lt, b ut do not remove it y et.
14-21
Contents Chapter 14
Keep the front While hol ding t he fork leg, loosen the fork bott om
brake and clu tch bridge pinch bolts and rem ove the f ork slider f ro m
ma ster cylin der t he h and lebar and fo rk br id ge s.
uprigh t.
DISASSEMBLY
Be careful not to Rem ov e the hand lebar stopper ri ng .
scratch the fork Rem ov e the stopper ring and pre-load adju ster.
slider.
Rem o ve t he O ~ri n g from t he dam per rod adjust

case.
Rem ove the fork bol t from the fo rk sli de r.
Pus h t he fork sli de r slowly down, and gently seat

th e d ust seal on to th e ax le ho ld er.
14-22
Contents Chapter 14
Ho ld t he da mper ro d ad j ust case , t he n lo o sen th e
-o;;'M PER ROD ADJ UST CASE
lo ck n ut .
Remove the lock nut and fork bolt.
LOCK NUT
Remov e the fo llow ing :

- Joint co ll ar
- Spr ing co llar
- Fo rk spring
SPRING COLLAR
Rem ove t he O-rin g f rom t he da m per ro d ad j us t

case.
Pour out the fork fluid by pumping th e fork tu b e sev -

eral tim es.
Pour out the fork fluid from the fork damper by
pu m ping t he d amp er rod severa l t imes.
14-23
Contents Chapter 14
Remove the compression ad juster f ro m the ax le
holder.
Ho ld the axle holder in a vise w it h soft j aw s o r a

shop towel.
Hold the for k damper with t he fork damper ho lder,
then remove the fo rk socket bolt and sea ling
washe r.
TOOL:
For k damper ho lder 07YM B-MCF010l or
07 YMB-MCFA100
(U.S.A. only)
Remo v e th e fo rk damper assem bly from t he f ork

FORK DAMPER
slide r.
FORK SLIDER
Remove t he dust sea l.

DUST SEAL

Do not scratch the Rem ov e the oil seal stopper ri ng .
fork tube sliding
surface.
Pull the fork tube out until you feel re sistance from ,
the slider bushing . Then move it in and out, t appin g
the bus hi ng ligh t ly until t he fo rk t ube sep ar at es
f rom th e f ork slide r.
The slide r bush ing w ill be forced out by the f o rk
tube bushing .
Remo v e t he fork t ub e bus hing, sli de r bu shing, back-

up r ing, oil seal , stop per ri ng and dus t sea l from th e BACK-U P RING
f ork tube.
17"'"
SLIDER BUSHING
INSPECTION
For k sp ri ng
Measu re the f ork sp ring fr ee length .
14-25
Contents Chapter 14
FRONT WHEEL/SUSPENSION/STEERI NG
Fork t ub e/ sli der/ damper
Check the fork sli de r for damag e or def ormati on .
FORK DAM PER
Check t he fo rk d amper fo r bend o r damag e.
Repl ace any com po nent s whic h are damaged.
7
FORK SLIDER
Chec k the oil loc k va lve fo r wea r or da mage.

Replace the fork da m pe r asse mb ly, if any co m po-
nent s ar e damaged .
Chec k th e f o rk tu be fo r sco re m arks , scr at ches, or

excessiv e or abnor m al we ar. DIAL GAU GE
Place th e f or k tube o n V-blocks and m easure the
ru nout.
Actual runout is 1/2 the tota l indi cato r rea ding .
FORK TUBE
For k tube bus hing

Vis ually in spect t he sl ider and fork tube bu shings.
Replace th e bu shings if th er e is ex cess ive sco ri n g or
scratching , or if the t eflon is w orn so tha t the copper BUSHIN G
surf ace appears on more t han 3/4 of t he ent ire sur-
face. BACK-UP RIN G
Check t he back-up ring; replace it if th ere is any dis -
tortion at th e poi nts shown .
CHECK POINTS
COPPER SUR FACES
14-26
Contents Chapter 14
ASSEMBLY
FORK TUBE BUSHING
~\C1
~
HANDLEBAR
STOPPER RING
\(] ....
!~
O-RING 0
...---
STOPPER RING
PRE-LOAD
: CK-UP RING
\ ~ADJ USTE R
@ (:):)
r a~ LOCKNUT
S OILSEAL - - - - g
,m,;;",,~
25N m
~ ~1 2. 6 kq f-rn, 19Ibllt)
~ '" N FORK BOLT

$~ / ~...
.... /
DUST SEAL
SLIDER
BUSHING O-RING a 34Nm
~ kqf -rn, 25 lbf -ft)
~~USTING PLATE
FORK TUBE
. ~TOPPER RING
JOINT COLLAR
FORK
SLIDER
o COMPRESSION FORK SPR ING

um ADJUST ER
34 Nvrn 13.5 kqf-rn, 25 Ibf-ft] 18 N'm (1.8 kqf-m , 13 lbf.tt) FORK DAMPER
Before assembly, was h all parts w it h a hi gh f lash

or non -flammabl e sol vent and wipe them dry.
W hen ins talling t he f or k dus t seal and oil seal ,
wra p t he edg e and groove of t he f ork tub e wi t h
ta pe.
-1
Ap p ly fork f lu id t o new dust seal an d o il seal li p s.
BACK-UP RING
Install the oil seal Inst all th e d ust seal , st op per r ing and o il seal.
j
SLIDER BUSHING
with its marked
side facing toward
the axle holder.
....
!~ -:M
DUST SEAL
Remove the burrs Inst all t he back-u p ring , slide r b us hing an d fork t u be p..;.... ;.;,;-r.
n~~~
from the slider bushing.
bushing mating sur - Ins tall th e f o rk t u be int o th e fo rk slider.
-
face, being careful
not to peel off the
coating.
....
~~-:M
OIL SEAL
14-27
Contents Chapter 14
Drive th e oil seal in u sing th e special tool. ....
TOOL:
Fork seal drive r, 43 mm 07YMD-MCF0100 or
07N M D-KZ3010A
(U.S.A . only)
Do not scrat ch the Install the stopper ring into the fo rk slid er groove
fork tube slidmg securely.
surface.
Inst all t he dust seal int o the fo rk sli de r.

. . DUST SEAL
Insta ll the f ork dam per assembly int o the f o rk sli de r.

FORK DAMP ER
14-28
Contents Chapter 14
App ly a locking agent to th e for k socke t bo lt
th reads.
Install th e socket bolt w it h a new sealing was her.
SOCKET
BOLT
I
e~
SEALING WA SHER
Hold the axl e ho lder in a vi se w ith soft jaw s o r a

shop towel.
Ho ld th e fo rk dam per w ith the fo rk damper holder,
then tig hten the fork socket bolt to the specified
to rque.
TOOL :
Fork damp er holder 07YMB-MCF0101 or
07YMB-MCFA100
(U .S.A . only )
TORQUE : 34 Nrn (3.5 kqf-m , 25 lbf-ttl
Apply fork fluid to new Ovrinq and install it to t he

comp ressio n adjuster.
Install the compre ssio n adjuster to the ax le holde r.
TORQUE : 18 Nm (1.8 kqf-m , 13 Ibllt)
Pour the specified a m oun t of recom m end ed fo rk

flu id into t he lark leg .
RECOMMENDED FORK FLUID :

Pro Honda Su spension Fluid , 55-55 or equivalent
FORK FLUID CAPACITY:
466 2.5 em ' (15.8 0.08 US oz , 16.4 0.09 Imp o z)
14-29
Contents Chapter 14
Bleed th e air f ro m the fo rk leg as fo llows:
FORK DAMPER
1. Extend t he fo rk, co v er th e t op of t he fo rk sli de r
w ith your han d and com press th e fo rk leg slowly.
2. Remove yo u r hand and ex te nd t he fork slowly .
Repeat above proced ure 2 or 3 ti mes.
3. Pump t he f ork damper ro d slowly 8 - 10 ti mes.
Slowly pus h the fork sli der, and gently seat the dust
seal o nto the axle ho lde r and lea v e it f o r 5 mi nutes.
Be sure the oil level Afte r the oil lev el st abi lizes, measure the oil level
is the sam e in the from top of t he fo rk slider .
both forks.
FORK OIL LEVEL: 90 mm (3.5 in)
90mm
(3.5 in )
Ap ply fo rk f luid t o new O-ring .

Extend the fo rk damper and in stall t he O ring to th e
damper rod adjust case gro ov e.
In stall the fork spring into the fork slide r wit h t he

TAPERED END --....
tape red end fa cing up .
FORK SPRING

Attach th e handle Ext end th e f ork dam p er fully and install th e damper
DAMPER ROD
to the damper rod rod ho ld er o nto the dam per rod adjust case.
HOLDER
hofder after install-
ing the spring collar TOOL:
JOINT COLLAR
and joint colfar. Dam per rod hol der 070MB-MEL0 200 or
/
070MB-MELC200
Install th e spr in g colla r and jo int colla r.
SPRING COLLAR
Atta ch the h and le to th e da m per rod hold er, t hen

DA M PER ROD
lower the sp ri ng colla r w hile pulling up t he damper
rod holder. HANDLE t HOLDER
Atta ch th e 14 mm wrench to t he damper rod adju st
cas e as shown .
M ake su re that the damper rod adj ust case is firmly
fi xed , t hen rem ov e the damper ro d holder.
<;
Y
Ap ply fork f lu id to new O-r ings an d in st al l t hem to

WR ENCH
FORK BOLT
the fork bolt.
/
e ~
. . . O-RINGS
Turn the pre-loa d adj ust ing plate cloc kwise until it
seats lightl y.
14-31
Contents Chapter 14
Install the fork bolt to the damper rod adj ust case
while aligning the grooves of the adjust ing plate
with th e damper rod adjust case .
Inst all the lock n ut t o t he d am pe r ro d adj us t case .

LOCK N UT
Hold t h e damper rod adj ust case and tighten t he
lock nu t.
Remov e th e 14 mm wrench from the damper rod
adjust case.
Ho ld t he damper rod adju st case, and the n tighten

DAM PER ROD AD J UST CAS E
the lock nut t o t h e specif ie d torq ue.
TORQUE : 25 Nm {2.6 kqfm , 19 lbf-ttl
Tighten the fork Install t he fork bolt to the fo rk slider.

bolt after instafling Install new O-r ing to the damper rod adj ust case .
the fork slider into
the fork brid ges.

Install the handlebar stopper ring.
Install the pre -load adjuste r and stoppe r ring .
INSTALLATION
Install the fork leg thro ugh the botto m bridge, han-
dleba r and t o p br idge (page 14-44).
Position the top end of the fork slider flush with the
upper surface of the top bridge as shown .
Tighten the bottom bridge pinch bolts to the speci-

fied torque.
TORQUE : 23 Nm (2.3 kqf-m , 17 Ibfft)
= __==
If the fork bolt was loosened, tighten it to the speci- ... = .,.."..
tied torque.
TORQUE : 34 Nrn 13.5 kqf-m, 25 Ibfft)
Tighten the top bridge pinch bolt to the specified 0:.,...._

torque .
TORQUE: 23 Nrn (2 .3 kqf-m, 17 Ibfft)
Tighten the handle bar pinch bolt to the specified
torq ue.
TORQUE : 26 Nrn 12.7 kqf-rn , 20 Ibfftl
Inst all the f oll ow in g:
- Fro nt w hee l (page 14-20)
- Fro nt f ender (page 3-19)
Adjust the pre-load and com pression/re bound
damping adjusters (pag e 4-37 ).
14-33
Contents Chapter 14
STEERING DAMPER
Remove the t o p shelter (p age 3-16 ).
Remove the bolts and steering damper top cover.
Remove the bolts and steering linkage cover.
Remove the second arm bolt/w ashers, thr ee mount -

ing bolts and steer ing dampe r unit.
Di sco nnect t he 2P (Black) conn ecto r f rom t he stee r-

ing dam per un it.
...
2P (BLA CK) CONN ECTOR
14-34
Contents Chapter 14
Con nect the 2P (Black) connecto r.
Install a washer Install the steer ing damper ont o the top bridge , th en
bet ween the sr ee-- install the was hers and steering dam per second ....
ing damper second arm bolt.
arm and top bridge .
Install the steerin g damper m ou ntin g bolts, and

t ighten th e second arm bolt and m ounting bolts to
the specified torqu e.
TORQUE: 8.8 Nm 10.9 kqf-m, 6.5 Ibf!t)

Install the rem oved part s in th e rev erse o rde r of
rem ov al.
STEERING STEM
REMOVAL
Remov e the follow ing:
- Front whe el (p age 14-1 6)
- Fro nt fen der (p age 3-1 9)
- Upp er cowl (page 3- 12 )
- Top sh elt er Ipage 3- 16 )
- Steering damper (page 14-34 )
Rem ove the steeri ng stem nut .
Rem ov e th e f o rk le gs (page 14-21 ).
Remove t he bolts and wi nd prot ecto r,

Rem ove the bolt and horn unit.
14-35
Contents Chapter 14
Rem ov e the bolt and f ront bra ke ho se cl amp.
Straigh ten th e t abs of the lock w as her .

Rem ov e the lock nut and lock was he r.
Rem ove th e st eeri ng ste m adjusting nut usin g th e ......"!!!!~""'~

s pec ia l to ol.
TOOL:
St eeri ng st em soc ket 079 1637 10101 o r
079163710100
Remove t he f oll ow in g:
- Du st seal
- Uppe r be ari ng in ne r race
- Upper bearin g
- Steering stem
- Low er be ar ing

OUTER RACE REPLACEMENT
Alwa ys rep /ace the Repla ce th e races usin g t he spec ial too ls as r - - - - - -- - -- - - - -- - - - ---,
bea rings and races described in th e f ollowing pro ced ure.
as a set.
TOOLS : (Not avail able in U .S.A .)
(1) Driver attachment (u pp er ) 070MF-MCJ0100
(21 Driver attachm ent (lower ) 070MF-MCJ0200
(31 Driver shaft assembly 07946-KM90301
(41 Bearing rem ov er, A 07946-KM90401
(51 Bearing rem ov er, B 07NMF-MT70110
(6) As sembly b ase 07946-KM90600
N UT A (3) (6)
N UT B (1) (4 )
DRIVER
SHAFT
(2) (5)
Note the installation Inst all the specia l t ool s into th e stee ring head as
direction of the sho w n. DRIVER UPPER OUT ER
assembly base; the ATIACHM ENT RA CE
Ali gn t he beari ng rem ov er A with t he g roove s in t he (upp er)
sma ll I. D. s ide fac- N UTA
st eeri ng head .
ing the upper
Lig ht ly tighten t he nut B wi th a wrench.
attachment
Ho lding t he d riv er sh aft wi t h a w rench, turn the nut
A grad uall y t o re move t he upper o ute r race.
A SSEMBLY
BASE
NUT B
BEARING
REMOVER A
t t
DRIVER
ATIACHM ENT
(lower)
14-37
Contents Chapter 14
Note the installation In stall the special tool s into t h e ste ering head as
direction of the sho w n an d rem o v e the lower outer race u sing the DRIVER DRIVER SHAFT
assembly base; the sa m e procedu re as for th e upper oute r ra ce. ATIACHM ENT
large /.D. side tee- (u p pe r)
ing the lower
attachment.
BEARING
REM OVER B
NUT B
ASSEM BLY
BAS E
LOWER NUTA
OUTER RACE
DRIVER
ATIAC HM ENT
(lo we r)
Remove any burrs f rom t h e o ute r race i nst allat io n

su rfac e of the stee ring h ead.
DRIVER
Note th e insta llation Inst all a new upper oute r race w it h the special too ls ATIAC HM ENT DRIVER SHAFT
direction of the as show n . (uppe r)
assembly base ; the Hol d the dri ver shaft w ith a w re nc h an d tu rn the nut
large 1.0. side ts c- A gra du ally un til u pper o ute r race is full y seated .
ing the low er
attachment.
e ~
UPPER
OUT ER RACE
DRIVER
ATIACHMENT
(lower)
ASSEM BLY
BASE
NUT A
14-38
Contents Chapter 14
FRONT WHEEl/SUSPENSION/STEERING
Remov e any bu rrs from th e o ut er race installat ion
surface of the stee ri ng head . NUT A
Note the installation Inst all a new lo w er o ut er race with th e special tools
directi on of theas sho w n.
asse mb ly base; the Ho ld th e dri ver sha ft w ith a w re nch and turn the nut AS SEMB LY
sm all /D. side tee- A g rad ua lly unti l lower o ut er race is f ully seat ed. BAS E
ing the upper
atta chm ent .
DRIVER
ATTACHMEN T- - _ --I!
(upper)
~
~
LOWE R
OU TER RACE
DRIVER
ATTACHM ENT DRIVER SHAFT
(lower)
OUTER RACE REPLACEMENT

(U.S.A . only)
Replace t he stee rin g hea d bearing outer races usin g
M A IN BEARING UPPER NUT
t he spe ci al too ls list ed be low .
DRIVER ATTACH-
TOOLS: MENT ~
Main be aring d river atta chment 07946-ME90200
Fork seal driver w eight 07947-KA50100
Oil s ea l driver 07965-MA60000
Installer shaft 07VMF-KZ30200 FORK SEA L
Installer attachme nt A
Installer attachm ent B
Remover atta chme nt E
07VMF-MAT0100
07VMF-MAT0200
07AMF-MELA100
----..
DRIVER W EIGHT
Remover atta ch me nt F 07AMF-MELA200

Inst all t h e speci al t ools int o th e stee ri ng h ead as
show n. UPPER
Alig n remover atta chmen t E with t he groov es in t he OUTER
RACE
ste eri ng h ead .
Whil e holdin g the insta lle r shah w it h a w ren ch , tu rn
t he uppe r nu t gradua lly to remo v e the upper bear-
in g outer rac e. REMO VER
ATTACHM ENT E
IN STALLER
SHA FT
14-39
Contents Chapter 14
FRONT WHEEL/SUSPEN SION/STEERING
Install the spec ial tools into t he stee ri ng head as
show n.
A lign remover attachmen t F w ith t he grooves in th e
stee ring head.
Wh ile holding the installe r shaft w ith a w rench, turn
the lower nut g rad ually t o rem ove the lower bea ri ng
outer race .
INSTA LLER - -++-.J
SHAFT
REM OVER
ATIACHMENT F
OIL SEAL
ORIVER LOWER
OU TER
RACE
-> '::::::
MAIN BEARING
DRIVER ATTACH-
~ ~
M ENT LOW ER NU T
Install a new upper bearing outer race w ith t he spe-

cia I tools as shown.
Wh ile hold ing th e installer shaft w ith a wr ench, turn
the low er nut grad ually unti l the race is ful ly seate d.
rc-nr.- - UPPER
OUT ER
RACE
INSTA LLER
SHA FT
INSTA LLER
ATTACHME NT B
OIL SEAL
DRIVER
---
FORK SEAL
DRIVER WE IGHT
~ ---'l=rr
M AI N BEARING
DRIVER ATIAC H-
~ ~
M ENT LOWER NU T
14-40
Contents Chapter 14
In sta ll a new low er bea r ing ou t er race w it h th e spe-
cial tools as shown. MAIN BEARIN G
DRIVER ATIACH-
While holding th e ins ta lle r s haft with a w re nc h, turn UPPER NU T
th e u pp er nu t gradua ll y until t he rac e i s fully se at ed . MENT~
FORK SEA L
-----...
DRIVER W EIGHT
INSTA LLER
ATIAC HM ENTA
INSTALLER
SHA FT
UPPER
OUTER
RACE
INSTALLER
ATIAC HM ENT B
LOWER INNER RACE REPLACEMENT

Tem po rar il y install t he steeri ng stem nut o nto t h e
st e m to pr eve nt the t hre a ds fro m be ing d a maged DUST SEAL
wh en rem ovi np the lower bearing inn e r race fro m
the ste m.
Rem o v e the lower bear in g inner race wit h a chisel
o r equiva lent t o o l, being careful not to d a ma g e t h e
st em.
Rem ov e the du st seal.
LOWER INNER RACE
A p ply specif ied g re ase (page 1-23) t o new d ust sea l

lips and inst all it over th e steering ste m . STEERING STEM DRIVER
Inst all new lo w er bearin g in ne r ra ce usin g a sp ecia l
tool and a hyd raulic pr ess.
TOOL :
Steerin g st em driver 0794 6-MBOOOOO S ~ _.$IDffi
DUST SEA U
-.
LOW ER INNE R RACE
14-41
Contents Chapter 14
INSTALLATION
LOCK NUT
: BEARINGS
~..!ijij.ffi : BEARING RACES
: DUST SEALS
UPPER BEARIN G ~OCK WAS HER
1f2:f\
STEERING STEM
UPPER OUTER RACE ~ A DJUSTING NUT
~ \ ~-------- UPPER DUST SEAL
~~
0 / ---- ------
-> UPPER INNER RACE
Apply specified grease (p age ' -23) to the up per and

low er bear ings, bearing races and upper dust sea l
lips.
Install the lowe r bea ring onto the stee ring stem.
Insert the stee ring ste m into th e stee ring head pipe.
Install the up per bea ring, inner race and upper du st
sea I. I-:==:;-;::~:
App ly specified grease (page 1-23 ) to the steer ing

stem adjusting nut threads.
Install and tighten the steering stem adju sting nut to
the initia l torq ue.
TOOL:
St e ering s te m so cket 07916-3710101 or
07916-3710100
TORQUE: 20 N'm (2.0 kqt -m, 14 rblltl

Mov e the st eering ste m right and left, lock-to-lo ck,
seve ra l ti m es to seat t he bearings.
Make sure th at t he st eering st em moves smoothly
w it hout play or binding, then loosen th e ad ju stin g
nut. .
Ret ighten the ste eri ng ste m adj usting nut t o t he

sp ecifie d t o rqu e.
TORQUE: 20 Nrn (2.0 kqf-rn , 14 Ibf ft)

Rech eck that the stee ri ng stem m ov es smoot hly
w it hout pla y or binding.
Insta ll a new lo ck washer onto the st eering stem .

!~ ~ LOCK NUT
Align the t abs o f t he lock w ashe r with t he gr oo v es in
the adjust ing nu t and be nd tw o opposite t ab s ..... ~.......--
(sho rte r) down into th e adj ust ing nut g ro ov e. LOCK W~
Do not over tigh ten Install an d f inger tig ht en the lock nut.
the lock nut until Hold the adjust ing nut and furt her tighten th e lock
the lock wash er nut no more t h an 1/4 tu rn (goo), enough to alig n it s
being flat. g rooves wi t h t he lock washe r tabs.
Ben d t he loc k washe r ta bs up into th e lock nut
g ro oves .
14-43
Contents Chapter 14
FRONT WHEEL/SUSPENSION /STEERING
In stall th e front brake hose cla m p and tighten the
bolt t o t he specifi ed torqu e.
TORQUE: 8.8 Nm (0.9 kqf- rn , 6.5 Ibf.ft)
Install t he horn unit and tighten t he bolt sec u re ly .

HOR N UNIT" -WIN D PROTECTOR
Instal l t he wi nd protector and t ighten the bo lts .
Inst all t he f ol low ing:

- Fo rk leg s (page 14-331
- Ha nd leb ar s (pag e 14-11)
Instal l t he t o p brid g e and stee ring ste m nut.
Tighten th e ste ering st em nut t o t he specified
torq ue .
TORQUE: 103 N-m (10.5 kqf -rn. 76 lb f -ft]
Install the fo llo w ing:

- Ste erin g damper (pag e 14 -34)
T op shelter (page 3-16 )
- Up pe r co w l (pag e 3-12 )
- Fro nt fende r (pag e 3-19 )
- Fro nt wh eel (pag e 14-20)
STEERING HEAD BEARING PRE-LOAD
Su p po rt th e m ot or cy cl e securely u sin g a hoist or , - -- - - -- - - - - - - - - - - -----,
equi val en t a nd raise th e fro nt w he el off t he g ro und .
Po sit io n t he stee ring st em to th e st ra ig ht ahead
po sit ion .
Make sure that Ho ok a sprin g sca le t o th e fork sl id er and m easu re
there is no cable or the stee ring head be ar ing pre-load.
wire harness int er- Th e p re -load should be w ith in
fer enee. 12 - 19 N (1.2 - 1.9 kg!) .
If th e read ings do not fall w ithin the limits. read ju st
the steering ste m adjusting nut (page 14-42 ).
14-44
Contents Chapter 14
15. REAR WHEEL/SUSPENSION
COMPONENT LOCATION 152 SHOCK ABSORBER 15 14
SERVICE INFORMATION 15-3 SUSPENSION LINKAGE 15-17
TROUBLESHOOTING 15-6 SWINGARM 15-20
REAR WHEEL .. 15-7
15-1
Contents Chapter 15
REAR WHEEL/SUSPENSION
COMPONENT LOCATION
54 Nrn (5.5 kgf. m , 40 lbf-ft)
__- 64 Nrn (6.5 kqf-m. 47 Ibf ft )
15 Nrn (1.5 kqf-m , 11 Ibf.ft)
44 Nrn (4.5 kqf-m. 33 lbf-ft)
44 N' m (4.5 kqfrn, 33 lbf -ft)

113 Nm (11. 5 kq f-rn . 83 lb f .tt )
44 Nm (4.5 kqf-m, 33 lbf -ft )
44 N 'm (4.5 kqf -rn, 33 Ibf ft l

REAR WHEEL/SUSPENS ION
SERVICE INFORM ATION
GENERAL
A contam inate d bra ke disc or pad reduces sto pping pow er. Discard con ta m inated pads and clean a contami nated disc
with a high qual ity brake degreasing agent .
After the rear whee l installation, check the brake ope ration by applyi ng the brake pedal.
The shock absorb er conta ins nitrogen under high pre ssure. Do not al low fire or heat near the shock absorbe r.
Before disposal of the shock ab sorber, release the nitr ogen (pag e 1 5 ~1 6 ) .
When servicing the rear wheel and suspension, support the m otor cycle using a safety stand or hoist .
Use on ly t ires m ark ed "TU BELESS" and t ub eless valves on rim m ar ked "TUB ELESS TIRE APPLICAB LE".
Use ge nuine Honda replacem ent bo lts and nuts for all suspe nsion pivot a nd m ounting point.
When installing the swingarm, be sure to tighten the swi nga rm pivot fastene rs to the specified to rque in the specified
sequence. If yo u mistake the tightening 'torque or sequence, loosen all pivot fasteners, the n tighten them again to the
specified torque in th e cor rect sequence .
W hen using the lock nut w renc h for the swinga rm pivot use a 20-in ch long defl ecting beam typ e tor que w rench. T he
lock nut wrench increases the torque wrench's leverage, so the torque w renc h reading will be less than the to rque actu-
ally applied to th e lock nut. Th e specificatio n give n on this page is actua l to rque applied to the lock nut, not the readin g
on the torque w rench w hen used w ith th e lock nut wrench. The pro cedu re later in the text gives the actua l and indica ted
torque.
Refer to the brake system infor mation (page 16-4).
SPECIFICATIONS
Unit : mm (in)
ITEM STA NDARD SERV ICE LIMIT
Minimum tire tread depth - 2.0 (0.08 )
Cold tire I U p to 90 kg (200 Ib s) loa d 290 kPa (2.90 kgf/em", 42 psi)
pressur e I Up to m aximum we ight capacity 290 kPa (2.90 kgf/em", 42 psi) -
Axle runout - 0.2 (0.011
Wheel rim I Radi al - 2.0 (0.08)
runout I Axia l - 2.0 (0.08 )
Wheel balance weight - 60 g
(2. 1 oz) max.
Drive chain Sizel link I DID DID50VM2-114YB
- I RK RK50GFOZ 1-114LJFZ
Slack 25 - 35 (1 -1-318) -
Shock Spring pre-loa d adju ster sta nda rd position Position 4
absorber Rebound damping adjuster initial setting 2- 1/2 turns out from full hard
Compression damping adjuster ini tial setti ng 9 cl icks o ut f rom f u ll hard -
TORQUE VALUES
Rear axle nut 113 Nm (11. 5 kqf -m . 83 lbf-ft] U- nut
Rear brake disc bolt 42 Nrn (4.3 kqf-m, 31 lbf -ft] A LOC bolt; replace wi th a new one
Final drive n sprocket nut 64 N m (6.5 kgf m , 47 lbf-ft) U-nut
Rear shock absorber upp er m ount ing nut 44 Nrn (4.5 kqf -rn . 33 lbf-tt} U- nut
Rea r shock abso rbe r lower mounting nut 44 N'm (4.5 kqf-m, 33 lbf-ft) U-nut
Shock link-to- fr ame pivot nut 44 Nm (4.5 kqf-m, 33 Ibfft ) U-nut
Shock arm -to -shock link nut 44 N'm (4.5 kqf -m. 33 Ibfft ) U-nut
Shock arm-to-swingarm nut 44 N'm (4.5 kqf-m, 33 Ibfft l U-n ut
Drive chain case flange bolt 12 Nrn (1.2 kqf-m, 9Ibfft)
Sw inga rm pivot adjusting bo lt 15 N 'm (1.5 kqf-rn, 11 Ibf ft)
Swlngarm pivo t adj usting bolt lock nut 64 Nrn (6.5 kg fm , 47 Ib fft ) See page 15-29
Swingarm pivot nut 113 Nm (11.5 kqf-m. 83Ibfft)
Drive chain slider bolt 8.8 Nm (0.9 kqf -rn, 6.5 lbf-tt) Ap p ly a locking agent to the th reads
15-3
Contents Chapter 15
REAR WHEE L/SUSPENSION
TOOLS
Rem ov er weight Attachm ent, 32 x 35 mm Attachmen t, 42 x 47 mm
07741 -0010201 07746-0010100 07746-00 10300
'~,~/
~~
07936-371020A (U.S .A. o nly ) o r

07936-37 10200 (U.S .A. on ly)
Atta chm ent, 52 x 55 mm Attachme nt, 24 x 26 mm Att achm ent , 22 x 24 mm

07746-0010400 07746-0010700 07746-00 10800
o r 07746-00 1A800 (U.S .A. on ly)
Attachm ent, 40 x 42 mrn Pilot, 17 mm Pilo t, 25 mm

07746-0010900 07746-00 40 400 07746-0040600
Pilot, 28 rnm Pilot, 19 m m Bearing remover head, 25 mm

07746-0041100 07746-004 1400 07746-0050800
15-4
Contents Chapter 15
Driver Remove r handle Bearing rem over, 17 mm

07749-0010000 07936-3710100 07936-3710300
Attachment, 28 x 30 m m Ball race remove r Driver

07946 -1870100 07948-4630100 079 49-37 10001
Driver Bearing rem over shaft Bearing driver

070GD-0010100 07GG D-00 10100 07G M D-KT80 100
or 070GD-001A 100 (U.S.A. only)
Pilot. 32 mm Attachment, 42 mm Swingarm lock nut wrench,

07MAD-PR90200 07QAD-POA0100 5.8 x 47 mm
07YMA-MCF0100
-a )
::::::::-:-:---:::::>
o r 07YMA-M CFA100 (U .S.A. o nly)
15-5
Contents Chapter 15
REAR WHEEl/SUSPENSION
Attachme nt, 34 mrn

07ZM D-M BW0 100
o r 07ZM D-M BW A 100 (U.S .A . on ly )
TROUBLESHOOTING
Soft suspens i o n
Wea k shock ab sorber spring
Incorrect sus pension adj ust me nt
Oil leakage from dam pe r un it
Insufficient ti re p ressure
Stiff su spen sion
Incorrect suspen sion adjustment
Dam age d rear sus pe nsion piv ot bearin gs
Bent d amper ro d
Bent swing ar m pi v ot
Tir e press ure too hi g h
Rear wh eel wobbling
Bent rim
Worn or damag ed rear wh ee l bea ring s
Fau lt y rear tire
Un bala nced rea r t ire and whee l
Insuffic ient rear tire press u re
Faulty swin g ar m pivot bear in g s
Rear wh e el hard to turn
Fault y rear w heel bearin gs
Bent rea r axle
Rear brake d rag
Drive chai n too tight
Rear suspe nsion noise
Fau lty rear shock abso rbe r
Lo o se rear su spe ns io n fastene rs
Wo rn rear su spension pi vot be aring s
Steers to one side o r does not track st ra ig ht
Bent rear ax le
Axl e al ignment/chain adj ust m ent not eq ual o n both sides

REAR WHEEL
REMOVAL
Loosen th e lock nuts and drive ch ain adju sti ng
bolts. (p age 4-26 )
Loosen the rear axle nut.
Support the m ot orcy cl e using a saf ety st and or ho ist
and ra ise the rear wh eel o ff the ground.
Remov e th e axl e nut , wash er and dri v e ch ain adjust-
ing pla te.
Push th e rear wheel fo rward and der ai l th e d riv e

cha in from the d rive n sproc ket.
Do not operate the Remo ve the rear ax le an d d riv e chai n adju sting
brake pedal after plate from th e left si de , th en rem o ve th e rear wh eel.
remo ving the {ear
wh eel.
Remove the side coll ars.
INSPECTION
Axle
Place the axle on V-blocks and m easure th e run out.
Actual runout is 1/2 the total ind icator read ing .
15-7
Contents Chapter 15
Wh ee l bearing
Turn the inner race of ea ch bear in g wit h yo u r fi ng e r.
Bearings sho uld t u rn sm ooth ly an d qu ietly . A lso
check t h at the bearing o uter race f it s t ig htly in th e
hub o r d rive n fl ange.
Replace the wheel Remove and discard the bearings if th e races do not
bearings in pairs. t urn sm oot h ly and qu iet ly , or if they fit lo o sely in the
hub o r driven flange .
Rem ov e th e w hee l bearings, if nec essa ry (page 15-
10 ).
W HEEL BEA RIN G
Wheel rim ru nout

Check th e rim run out by placing th e wh eel in a tru -
ing st a nd .
Sp in th e w heel slo w ly and read th e r unout usi ng a
di al indicator.
Act u al ru nout is 1/2 the tot al in dicato r reading .
SERVICE LIMITS:
Rad ial: 2 .0 mm (0.08 in )
Axial : 2 .0 mm (0.08 in)
Dr iv en sp ro cke t
Chec k t he co ndi t io n of th e fina l d ri v en sproc ket
teeth .
Repla ce th e sprocket if worn o r d ama g ed .
GOOD REPLACE
If t he fin al driven sprocket requires re pl acem e nt,
inspect th e drive cha in and driv e sp ro cket .
Ne v er in st all a new drive cha in o n a worn
sprocket o r a w orn ch ain o n new sprockets. Both
o X
~~~
ch ain and sp roc ket must be in g ood co nd iti o n o r
th e repl acement cha in o r sp rock et w ill wear ra p-
id ly.
Wh eel b al anc e
Refe r to th e wheel bal an ce se rvi ci ng (pag e 14- 18).
DISASSEMBLY
Rem ov e th e rig ht du st seal.
Remove th e bo lts and brake di sc.
15-8
Contents Chapter 15
If you wilf aiees- Remove the left dust seal.
se mble the driven
flange, loos en the
d riven sprocke r
nut s and bolts
before rem oving
the driven flange
from the wheel
hub.
Rem ov e the d ri v en fl ange assem bly fro m th e left L._-:=::::::~~

w heel hu b.
Remov e the wh eel ru bber dampers and O-ring .
Driv en fl an ge b earin g rem oval

Rem ov e the nuts, washer. bolts and driven sprocket
from the driven flange .
15-9
Contents Chapter 15
Dr iv e t he driv en f lang e co llar o ut of t he driv e n
f lang e bear ings usin g th e sp ecial too ls.
TOOLS :
Driver 07749-0010000
Pilot, 28 rnm 07746-0041100
Dr ive ou t the d riv en fl an g e bea rin g s using th e spe -

cia l to ols.
TOOLS:
Dri v er 07749-0010000
Atta chment. 4 0 x 42 mm 07746-0010900
Pilot, 28 mm 07746-0041100
Wh e el bearing removal
Install the bearin g rem o v er head i nt o the bearing .
From th e o pposite sid e, ins ta ll th e bearing remo v er
shaft and d rive th e beari ng out of t he wheel hub.
Rem o ve the distance col lar an d d ri ve out the oth er
be a ring .
TOOLS:
Bearing remover he ad. 25 mm 07746-0050800
Bearin g remover shaft 07GGD-0010100
15-10
Contents Chapter 15
ASSEMBLY
DISTAN CE COLLAR
~
~
LEFT W HEEL BEAR IN G
BRAK E DISC
~ ...w:;;,
~~~
RIGHT DUS T SEA L
DRIVEN SPROCKET
Never install the old Wh ee l bearing ins t a llati on

bearings, once the In st all t he right w hee l be a rin g p rev io usly .
bearings has been
remo ved, the bear- Dri v e in a new right be a ri ng sq ua re ly , un t il it is fu lly
ings mus t be seated .
replaced w ith new
TOOLS:
ones.
Driv er 07749-0010 000
Attach m e nt, 52 x 55 mm 07746-0010400
Pilot. 25 mm 077 46 -00 40600
Inst all th e d i st ance collar
Driv e in a new left bea ring squarely.
TOOLS:
Dri v er 07749-0010000
Attachm e nt, 42 x 47 m m 07746-0010300
Pilot, 25 mm 07746-0040600
15- 11
Contents Chapter 15
Driven flange bearing installation
Press t he d riven f la ng e co lla r i n th e new driv en
flange bearings u nti l it is fu lly sea ted .
TOOLS :
Driver 077490010000
Attachment, 32 x 35 mm 077460010100
Pilot. 25 mm 077460040600
DRIVEN
FLAN GE
BEARINGS
Driv e the new driven flange bear ing s with the colla r
into the dri ven f lange usin g th e specia l tools. DRIVER
TOOLS :
Driver 077490010000
Attachm ent, 52 x 55 mm 077460010400
Pilot, 25 mm 07746-0040600
Install t he wh eel ru bber d am pers into the left whe el

hub.
Ap p ly g rease t o new O-ring and i nsta ll it to th e
groove of th e w heel h u b.
Install t he driven f lange assemb ly into the left wheel

hub.
fnst alf the washers If th e driven sp rocket was rem ov ed , insta ll t he
with their cham- driven sprocket bolts. driv en sprocket, washe rs and
fered side facing nut s.
toward the Tig ht en the nu ts to th e speci fied to rque.
sprocket.
TORQUE: 64 Nrn (6.5 kqf -m, 47 Ibf-ft]
A pply grease to new du st seal li ps. t he n inst all it to
the driven f la nge.

Install the brake d isc w ith it s rotating direction m ark
fa cing out.
Tighten the new brake di sc bo lt s to the sp ecified
torque.
TORQUE: 42 Nm (4.3 kq f -m, 31 Ibf.lt l
Apply grease to new du st seal lips, then insta ll it to
the right wheel hu b.
INSTALLATION
Insta ll th e sid e co ll ars .
M ake sure t hat the rear brake caliper bracket is posi-

tion ed in t he gu ide of th e sw inga rm .
Be careful not to Place t he rea r wheel in t he sw in garm .

damage the brake Inst al l t he drive chain ove r the dr iven sp ro cket.
pads . App ly a thin coat of grease to t he rear ax le.
Inst all t he dr ive cha in adj usting pla te and rear axle
from t he left side.
15-1 3
Contents Chapter 15
Instal l th e adj u sti ng pla t e, w as he r and ax le nu t.
Adj ust th e d rive chai n slack (page 4-26).
Tighten the axle nut to t he specified torque.
TORQUE : 113 N m (11.5 kqt -m, 83 lbf-ft]
SHOCK ABSORBER
REMOVAL
Sup p ort the m ot orcy cl e sec ure ly u sing a saf ety
stan d or ho i st and ra ise t he rea r wheel off the
ground.
Rem ove th e bol t s/nuts and shock link .
BOLTS/NUTS
Remov e the sho ck ab sorbe r lowe r m o unting bol t/

nut .
Remove the shock ab sorber u pper m ounting bo lt / ::~~~~;:.:~~~~~~-,~~

nut.
Remove t he shock absorbe r to dow nw ar d th ro u g h
the swinga rm .
15-14
Contents Chapter 15
INSPECTION
Visually inspect the shock ab sorber for damage .
Check t he following: DAMPER UNIT
- Damper rod for bends o r da mage

- Dam per un it f or deformation or oil leaks RUBBER BUM PER
- Rubber bumper fo r wea r or damage
Inspect all the othe r parts for wea r or damage.
If necessary, replace th e shock ab so rbe r as an
assembly .
DA M PER ROD
SPHERICAL BEARING REPLACEMENT

Rem ove t he d ust seal s.
STOPPER RING
Remove th e stopper ring from t he left sid e pivot.
Prepare the m etal pipe (as a base holder; I.D. 27 mm

BEARING DRIVER
or ot her suitable collar) for the sphe rical bearing
(17 mm COLLAR I
rem ov al.
Press the sph er ica l bear in g out of the shock
absorber pivot using the metal pipe and specia l
tool .
TOOLS: SPHERICAL _--;,~
Bearing d river 07GMD-KT80100 BEARING
(U se only 17 mm co llar)
BASE HOLDER
Press new sp he rica l beari ng into the shock absorber

BEARING DRIVER (17 mm COLLAR )
piv ot from the left sid e until it is fully seated, using
the special tool and hydra ul ic pres s.
TOOLS:
"'>
Bearing driver 07GMD-KT80100
(Us e only 17 m m coll ar)
I
SPHERICAL
BEARING
15-15
Contents Chapter 15
Instal l a new stoppe r r ing int o the g roove of th e
The le ft pivot dus t

shock absorber pivot secure ly .
Apply grease to t he new dust sea l lips and insta ll
e~ STOPPER RING
seal 0 .0. is larger them into the shock a bsorber p ivot.

than right pivot dus t
seal 0.0.
SHOCK ABSORBER DISPO SAL

PROCEDURE
Do not remo ve the Remove the shock abso rbe r reservoi r cap .
RESERVOIR CAP
valve core until Put on safety glasses, the n re lease t he nitro gen
pressure IS from t he rese rvo ir by dep res sing t he va lve core. \ <;
release d.
Poin t the valve away from you to p revent debris U) ~-
/'
getting in yo u r eyes.
Before dispo sal of the sho ck abso rbe r, re lease
the nit roge n by press ing t he valve co re. The n
rem ov e the valve from the shock absorbe r reser -
vo ir.
VA LVE CORE
INSTALLATION
Set the shock abso rber to t he upper mou nt with the
rebo und damping adj u st er fac ing le ft.
Install the upper mou nti ng b ol t and n ut.
Inst all t he low er mo u nt ing bolt a nd nu t .

Tigh t en t he upper and lower mounting nu ts to t he
specified torq ue.
TORQU E: 44 Nm (4.5 kq f -m , 33 lbf-ft]
15-16
Contents Chapter 15
Install t he shock link to the frame and shock arm.
Install the sh ock link bo lt s and nuts.
Tight en th e nuts to the sp ecifie d torque .
TORQUE: 44 Nm {4.5 kqf -rn. 33 Ibf.fl l
BOLTS/NU TS
SUSPENSION LINKAGE
REMOVAL
Support the moto rcycle securely using a safety
sta nd or hoist and raise th e rear w hee l off the
ground .
Remove the bolts, nuts and sho ck link.
SHOCK LINK BOLT/NUT

Rem ov e th e followi ng:
- Shock arm bo lt/n ut (swingarm side)
- Shock absorber lower m o unting bolt/nu t
- Shock arm
Rem ove the pi v ot col lar and d ust seal s from the
shock link .
Check the dust seals and piv ot collar fo r wear, dam -
age or fatigue.
Check th e needle bea rings for damage or loose fit .
Check th e shock li nk f or cracks or damage.
If th e needle bearings are damaged , replace th em .
15-17
Contents Chapter 15
Remove the fo llowing:
- Thr ust was he rs
- Dust sea ls
- Side collars
- Pivot co llars
Ch eck the dust sea ls, thru st washers and collars fo r
wear, damage o r f at ig u e.
Chec k th e needle bea rin gs fo r da mage or loose fit.
Check the shock arm for cra cks or damage.
If t he need le bearings are d am aged, replace the m .
BEARING REPLACEMENT
SHOCK LINK NEEDLE BEARING
Remove th e ne edle bearings from the shock link
usin g t he spec ia l tools.
TOOLS :
Remover handle 07936-3710100
Bearing remover, 17 mm 07936-3710300
Remover weight 07741 -0010201 or
07936-371020A ,
07936-3710200
(U.S .A. onlv]
Pack the new need le bearings wit h m ulti -p u rpose

grease (Shell A lvan ia EP2 or equiva lent).
4.8 - 5.2 mm
Press the needle Press the new need le bearings into the shock lin k (0.19 - 0.20 i n )
bearings into the pivot so that the need le b ea rin g surface is 4.8 - 5. 2
shock link with the mm (0.19 - 0.20 in ) below th e end of t he shock lin k
marked side facing su rface, us ing the specia l tools and a hy drau lic
out. p res s.
TOOLS:
e~ (
Driver 07749 -0010000
Attachment. 24 x 26 mm 07746-0010700
Pilot, 17 mm 07746-0040400
NEEDLE BEARING
SHOCK ARM N EEDLE BEAR ING

Press th e needle beari ng s (shock lin k side,
swingarm side ) ou t of the shock arm us ing the spe-
cial too ls and a hy d rau lic press .
TOOLS :
Dri ve r 07949-3710001
Attachment , 22 x 24 mm 07746-0010800 or
07746-001A800
(U.S.A. only)
Pil ot, 17 mm 07746-0040400
15-18
Contents Chapter 15
Press the need le bea ring (shock absorbe r side) out
of th e shock arm usi ng t he spec ial tools and a
hyd rau lic pre ss.
TOOLS:
Drive r 079 49-37 10001
Attachment, 24 x 26 mm 07746-0010700
Pilot, 19 m m 0774 6-0041400
Pack the new needle bear ing s wit h m u lt i-purpose

grease (Shell Alvania EP2 or equivalent) . 4.8 - 5.2 mm
Press the needle Press th e new needl e bear ing s int o th e pivot (shoc k 10.19 - 0.20 in )
bearings into the link si de an d swi nga rm side) so th at t he need le
shock arm with the bearing su rface is 4.8 - 5.2 mm 10.19 - 0.20 in)
marked side facing be low t he end of the shock arm surface, using the
out. speci al tools an d a hyd raulic press.
TOOLS :
Driv er 07749 -0010000
Attachm e nt, 24 x 26 mm 07746-001 0700
Pilot, 17 mm 07746-0040400
S~
NEEDLE BEARING
Pack t he new needle be ar ing wi th mu lti -pu rp ose

grease (Shell Alva nia EP2 o r equivalent) .
I 5.35 - 5.6 5 mm
10.211 - 0.222 in)
Press the new needle bearing int o the shock
absorbe r side pi v ot so th at the need le bearing sur-
face is 5.35 - 5.65 m m 10.211 - 0.22 2 in) be low the
end oft he shock arm surface, usi ng the special tools
and a hyd raulic press.
TOOLS :
Driv er 07749 -0010000
Atta ch m ent, 24 x 26 mm 07746 -0010700
Pilot, 19 mm 0774 6-0 041400
INSTALLATION
A pp ly multi-pu rp ose grease (She ll Al v an ia EP2 or
equivalent) to the dust sea l lips, co ll ars and need le SIDE COLLARS WASH ERS
---' - ' ' a~

bearings.
M ake sure t he need le bear ing rollers oft he sh ock
abs orbe r side are in p osi tio n before in sta lling.
- N um ber of need le rollers : 27
~Y~ wm
Install t he pivot colla rs, side collars, dust seals an d
thru st washers to th e sho ck ar m.
DUS T SEALS
PIVDT
COLLARS
15-1 9
Contents Chapter 15
Apply multi-purpo se g rease (Shell Alva nia EP2 or
equivalent) to the dust seal lips, pivot collar and DU ST SEA LS
needle beari ngs.
1
Install the pivot collar and dust seals to the shock .
link .
SHOCK LIN K
Loosely install the followi ng:

- Shock arm
- Shock arm bolt/nut (sw ingarm side)
- Shock absorber low er mounting bo lt/ nut
Tighten the shock absor ber lowe r moun ting nut to
the speci f ied torq ue .
TORQ U E: 44 Nrn {4.5 kqf -m, 33 lbf-tt)

- Shock li nk
- Shock arm bolt/nu t (shock link sid e)
- Sho ck link bo lt/ nut (fr ame side)
Ti ghten the nuts to the specified to rque.
TORQU E:
Sho ck link-to -frame pivot nut :
44 Nrn (4.5 kqf-m, 33 lbf-ft ]
Shock arm -to -shock link nut :
44 Nrn (4.5 kqf- rn, 33 lbf-tt)
Shock ar m -to -sw ingarm nut:
44 N m (4.5 kqf -m. 33 lbf-tt)
SWINGARM
REMOVAL
Remove the fol lowi ng:
BRA KE HOSE GU IDE
- Rear whee l (page 15-7)
-
-
Shock absorber (p age 15-14)
Suspension linkage (page 15-17)
Rem ove the bolt and rea r brake hose guide fr om th e
swingarm .
/
15-20
Contents Chapter 15
Rem ove the bo lt and gea rsh ift arm f ro m the gear
sh ift spindle.
It is nor necessary Remove t he cl utc h slave cy lin de r (page 10-13).
to drain the clut ch
hydraulic system in
order to remove the
swinqsrm .
Remov e th e cl utc h lifter rod .

Remove the bo lt s and drive sprocket co ve r.
Rem ov e t he gasket , sp ace r an d dowel pi n.
Rem ov e t he bolt, w ashe r and d ri v e sprocke t.
15-21
Contents Chapter 15
Remove t he swi ngarm pivot nut and washe r.
Ho ld the swinga rm pi v ot sha ft and rem ov e the

swinga r m piv ot lock nut from th e ri gh t pivot using
the spec ial tool.
TOOL :
Swi ngann lock nut w rench,
5.8 x47 m m 07YMAMCF0100 o r
07YMA MCFA 100
(U .S.A . on ly)
Loo sen the sw in ga rm pivot adj ust ing bolt w ith th e

pivot shaft.
Be careful so that Remove t he swing arm pi v o t shaft and t he swi ng-

the pi vot collars do arm .
not damage the
main frame .

DISASSEMBLYIINSPECTION
Rem ov e t he bo lt s and rear inner f en der.
Rem ov e th e tw o bo lt and d rive chain case A.
Rem ove th e bolt . tr im cl ip and d rive cha in cas e B.
Remove the three bolts, col lars and d rive chain

slide r.
Check th e driv e chai n slider f or wea r or dam age .
BOLTS/COL LARS
15-23
Contents Chapter 15
Rem o v e the piv ot col lars and dust sea ls.
Remov e t h e distance collar from the swin garm left
side pivo t.
Check t he dust sea ls fo r damage o r fatigu e.
Check t he pivot coll ar and distance co lla r for w ear
or damage.
Tu rn the inn er race of right sid e pi vot ball bearing

with yo u r fing er.
Th e bear ing sho uld turn sm oothly and quietly . Als o
check th at th e b ea ring ou ter race fits t ightly in t he
sw ingarm pi vot.
Rem o ve and disca rd the bearing if the races do not
turn smoothly and quietly, or if they fit loosely in th e
sw ing arm pi vo t .
BEAR ING
PIVOT BEARING REPLAC EMENT

Rem ov e th e snap ring f rom t he swi nga rm right side
SNA P RING
pivot .
Rem o v e th e left pi vot bear ing need le roll er s before

rem oving th e ri g ht pivot bear ing s.
Press t he right pivot needle and ball bear ing s out of
th e sw ing ar m pi vot us ing th e spec ia l tools and a
hydrau li c pre ss.
TOOLS :
Driver 070GD -00 10l00 or
070GD -001A100
(U .S.A . only)
Attachment, 28 x 30 m m 07946- 1870100
Pil ot , 25 m m 07746-00 40 600

Attach the specia l too ls in t o the left pi v ot needle
ATIACHM ENT
bea ring cage as shown.
Press the left pi vot needl e bea ri ng cage out of the
sw ing arm pivot, u sing th e spec ial t ools and a
hyd raul ic p re ss .
TOOLS:
Driver 070GD-0010100 o r
070GD0 01A100
(U.S.A . on ly)
Atta chm ent, 34 mm 07ZMD -MBW0100
or
07ZMDMBWA100
(U.S.A . only)
Ball rac e remov er 07948-4630100
Pack th e new ba ll bearin g cav ities with gre ase (She ll

Al v ania EP2 or equiva lent). DRIVER
Pre ss th e ba ll bea ring into the swi nga rm righ t pivot
until it is fully seated , using the specia l t ools and a
hydraulic press.
TOOLS:
Driver 077490010000
Attachment, 40 x 42 mm 07746-0010 900
Pilot, 25 mm 07746-0040600
ATIACHM ENT/PILOT BALL BEA RING
Pack th e new needl e bear ing wi th gr ease (She ll

A lva nia EP2 o r equiva le nt) .
Press the needle bearing into the swi nga rm ri ght
pivot u nt il it is f ully seated o nto the ball bea rin g,
u sing th e special too ls, rem ov ed .rig ht pivot col lar
and a hy dr auli c press. ---
TOOLS:
Driver 077490010000
Attachm ent, 42 mm 07QADPOA0100
I
NEEDLE BEARIN G
Inst all the snap ri ng in t o the right swinga rm pivot

groove secu rely . SNAP RING
15-25
Contents Chapter 15
Press the needle Pack the new need le bear ing wi th grease (Shell
DRIVER
bearing into the Alva nia EP2 or equivalent).
swingarm with the
Press the needle beari ng into the left sw ingarm
marked side facing
-
pivot until the depth t ro m the sw ingarm pivot sur- 7.0 -8.0 mm
our.
face is 7.0 - 8.0 m m (0. 28 - 0.31 in ), using th e sp ecial (0.28 - 0.31 in)
too ls and a hydra ulic press . <AS'2b
TOOLS : ' !mi'
Driver 07749-0010000
Attachment, 40 x 42 mm 07746-0010900
Pilot . 32 mm 07MAD-PR90200
ATIACHM ENT/PILOT N EEDLE BEA RIN G
ASSEMBLY
RIGHT PIVOT COLLA R IN NER FEN DER
~ --. DUST SEA L ""
SNAP RING ~f}'()

~ RIGHT PIVOT N EEDLE ,DO
...
p ' BEARIN G ~
~
~.
RIGHT PIVOT -------
BEARING
~ mnffi
LEFT PIVOT
N EEDL E
BEA RING
DUST SEA L
LEFT PIVOT
DRIVE CHA IN CASE B
COLLA R
8.8 Nm (0.9 kqf-rn. 6.5 lbf-ft ) -
Install the distance colla r from the left side pivot .

PIVOT COLLA R
Apply grease (Shell Alva nia EP2 or equivalent ) to
new dust seal lips.
Install the dust seals and pivot collars into the
sw ingarm pivot.
7
-'0
.......-
DU ST SEALS
15-26
Contents Chapter 15
Insta ll th e drive chai n sli d er ali gning it s slit with t he
bos s on th e sw in g ar m .
Install the drive cha in slide r mount ing bol t (front ).

Instal l t he co lla rs and new driv e chain sli d er m ount-
ing bolts (rear ).
T ig ht en the bol t s to th e specif ied torque.
TORQUE: 8.8 Nm (0.9 kqf-m, 6.5 Ibfft)
Install t he dr ive ch ain case B and t igh te n th e bolt

secu rely .
Inst all the trim clip .
In sta ll the dri ve chai n case A and tig hten t he bo lts

sec u re ly .
15-27
Contents Chapter 15
Ins ta ll t he rear in ne r fe nder and tig hten th e b olt s
sec u re ly.
INSTALLATION
Make su re that t he adj usting bo lt does not protrude
inside of the f ra me pivot.
A p pl y a th in coat of g rease (She ll A lv ani a EP2 o r

equ iva le nt) to th e swin ga rm pi v ot sh aft slid ing su r-
face.
Install the swingarm to the frame.
Inst al l the swl nqa r rn pivot shaft f ro m th e rig ht side.
Tight en the adjusting bolt w ith the pivot sh aft .
TORQUE: 15 Nrn (1.5 kqf-m , 11 Ibfft)

Inst al l th e was her and sw i nga rm piv ot nut, and
tigh te n the nu t to the specified to rq ue .
TORQUE: 113 Nm (11.5 kqf-m , 83 Ibf.ft)
Refer to torque Hold t he swinga rm pivot s haft, t igh t en the pivot

w rench reading adj ust ing bo lt lo ck n ut t o the spec if ied torq ue.
informa tion on page
TOOL :
15-3 'Service Infor-
mation', Swingarm lock nut wrench,
5.8 x47mm 07YMAMCF0100 or
07YMAMCFA 100
(U.S.A . only)
TORQUE:
Actual: 64 N m {6.5 kqt-m , 47 Ibf.ftl
Indicated: 58 Nm (5.9 kqf-m, 43 Ibf.ft)
Insta ll the driv e sprocket w it h its ma r ks fa ci ng ou t.

Install the washer and sprocket bolt, then tighten
the bolt to the specified torque.
TORQUE: 54 Nrn (5.5 kqf -rn, 40 lbf-tt}
Install t he dowel pins. space r and new d rive

sprocket cove r gas ket .
15-29
Contents Chapter 15
Inst all the drive sprocket cove r and tighte n the bolts
secu rely.
Install the clutch lilter ro d.
Install th e gearshift arm aligning it s slit with th e

punch m ar k o n the gearshift spindle.
Tighten th e ge arshift arm pinch bolt securely .
Install t he clutch slave cylinde r (page 10-151.
Install the brake Inst all t he rear br ake hose guide and t ig ht en th e bol t
hose guide secu rely.
between the inner
Insta ll the fo llo wi ng :
fender and swing
arm . - Sho ck absorber (page 15-161
- Suspensio n li nkage (page 15-19)
- Rear w hee l (page 15-13)

16. HYDRAULIC BRAKE
COMPONENT LOCATION .. 16-2 FRONT MASTER CYLINDER .... 16 15
SERVICE INFORMATION 16-4 REAR MASTER CYLINDER 16-2 1
TROUBLESHOOTING .. 166 FRONT BRAKE CALIPERS 1627
BRAKE FLUID REPLACEMENT/ REAR BRAKE CALlPER 1631

AIR BLEEDING 167
BRAKE PEDAL .. 1634
BRAKE PAD/DISC 16-11
EI
16-1
Contents Chapter 16
HYDRAULIC BRAKE
COMPONENT LOCATION
FRONT:
9.8 Nm (t o kqf-rn, 7 lbf -ft ]
34 Nm (3.5 kq f-rn. 25 lbf -ft ]
45 Nrn (4. 6 kq f-m , 33 lbf-ft }
16-2
Contents Chapter 16
HYDRAULIC BRAKE
REAR:
3.9 Nm lOA kqf -rn, 2.9 Ibf.ft)
34 Nrn (3.5 kqf -rn. 25 lbf-ft )
9.8 Nrn
(1.0 kqf -rn, 7 Ibfftl
9.8 Nm (1.0 kqf -rn, 7 lbf -ft ) ----------...

1;j
37 N'm 13.8 kqf-m, 27 Ibfft )
16-3
Contents Chapter 16
HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL
ACAUTION
Frequent inha lation of brake pad dust, regard less of m ater ial composition, coul d be hazardou s to your health .
Avoid brea thing dust pa rticles.
Never use an air hose or brush to clea n brake assemblies. Use an OSHA-approved vac uum clea ner.
NOTICE
Spilled brake fluid will seve rely damage inst rument lenses and pain ted surfaces. It is a/50 harm ful to some rubber pans.
Cover these surfaces with a shop tow el befo re servici ng the brake syste m. Be careful wh ene ver you rem ove the reservoir
cap; make sure the reservoirs are horizontal first.
A contam inated brake disc or pad redu ces sto pping power . Discard contami nate d pads and clean a contam inat ed disc
wit h a high quali ty brake degreasing agent.
Check the brake syste m by applyi ng th e brake lever or ped al after th e air bleeding.
Never allow contam inants (dirt, w ater, e tc. ) to get into an open reservoir.
Once the hydr aulic syste m has been open ed, or if the brake feels spo ngy, the system mu st be ble d.
Always use fresh DOT 4 brake fluid fr om a seal ed container wh en servicing the system . Do not m ix different types of
fluid; they may not be com patible.
Always check brake opera tion before ridin g the motor cycle.
SPECIFICATIONS
Uni t : mm (in)
ITEM STANDARD S ERVICE LIMIT
Front Specified brake fl uid OOT4 -
Brake disc thickness 5.0 (0. 20 ) 4.0 (0.16)
Brake disc runout - 0 .30 (0 .012)
Maste r cylinder 1. 0 . 17.460 - 17.503 (0 .6874 - 0.689 11 17.515 (0.6896)
Ma ster piston O.D . 17.321 17.367 (0.68 19 0.6837) 17.309 (0.68 15)
Calipe r cylinder I.D. A 32.080 - 32. 130 (1.2630 - 1.26501 32 .140 (1.2654)
B 30. 280 - 30.330 (1.1921 1.194 1) 30.340 (1.194 5)
Calipe r piston 0. 0 . A 31.96 7 32 .00 0 (1.2585 1.2598) 31.95 7 (1.258 1)
B 30 .167 30 .200 (1.1877 - 1.1890) 30.157 (1.1873)
Rear Specified b rake fluid OOT4 -
Brak e peda l hei g ht 75 (3.0) -
Brake disk thickness 5.0 (0.201 4. 0 (0.161
Brake disc runo ut - 0.30 (0. 012)
M aster cylinder 1.0. 15.870 15.913 (0.6248 0.6265) 15.925 (0.6 270)
Master piston 0 .0. 15.827 - 15.854 (0.6231 - 0.6242) 15.815 (0 .622 6)
Ca lipe r cy lind e r 1.0. 38.180 38.230 (1.5031 1.50 51 I 38 .24 (1.506)
Caliper piston 0 .0. 38 .098 - 38. 148 (1.4999 1.5019) 38 .09 (1.500 )
16-4
Contents Chapter 16
HYDRAULIC BRAKE
TORQUE VALUES
Brake hose oil bolt 34 N 'm 13.5 kqf- rn, 25 Ibfft )
Rear brake caliper pad pin 18 Nm (1.8 kqf -rn, 13I bfft )
Rear caliper ble ed valve 5.9 Nrn 10.6 kqf-rn, 4.3 Ibfft)
Rear brake calipe r slide pin bolt 27 Nrn 12.8 kqf -rn, 20 Ibfft)
Rear brake calipe r m ou nting bo lt 23 Nm (2.3 kqf-rn , 17 Ibfft )
Rear brake hose clamp bo lt 3.9 N' m IDA kgf' m, 2.9 Ibf ft )
Rea r master cylinde r pu sh rod joint nut 18 Nrn 11.8 kqf -rn, 13 lbf ft l
Rear brake reservoir hose jo int screw 1.5 Nrn (0.15 kqt-rn, 1.1 lbf- ft] App ly a locking age nt to the threads
Rear master cylinde r reservoir cap screw 1.5 Nrn (0. 15 kqf-rn , 1.1 lbf-ft]
Rear master cylinder reservoi r mounting 12 Nrn 11.2 kqf-rn , 9Ibfft )
bolt
Rear master cyl inde r mounting bolt 9.8 Nm 11.0 kqf-rn. 7 Ibfft)
Brake ped al piv ot bo lt 18 Nrn 11.8 kqf-m. 13 lbf-ft}
Front brake calip er mounting bolt 45 N' m 14.6 kqf -rn, 33 Ibfft ) ALoe bo lt: replace w it h a new o ne
Front brake caliper asse mbl y bolt 23 N 'm 12.3 kqf-rn. 17 Ibfft ) Apply a locking age nt to the t hreads
Front brake caliper pad pin 16 Nm 11.6 kqf-m, 12 lbf-tt l
Front caliper bleed valv e 7.8 N 'm (0.8 kqf -rn, 5.8 Ibfft)
Front brake hose clamp 8.8 N'm 10.9 kqf-rn, 6.5 Ibfft )
Front brake hose 3-way joi nt bolt 9.8 Nrn (to kqf-m, 7 Ibfft)
Front brake hose clamp (left side) 9.8 Nm 11.0 kqf -rn, 7 Ibfft )
Front maste r cyli nde r reservoir cap screw 1.5 N m (0. 15 kqf-rn, 1.1 lbfft )
Front master cylinder reservoir stay bo lt 12 Nrn (1.2 kq f-m, 9 lbf -ft ]
Front brake light sw itch screw 1.0 N 'm (0.1 kqf-rn, 0.7 Ibfft)
Front master cylinder reservoir mounting 5.9 Nrn (0.6 kqt-m, 4.3 tbf -tt ) U-nut
nut
Front brake lever pivot bolt 1.0 Nrn 10.1 kqf- rn, 0.7 lbf-ft)
Front brake lever pivot nut 5.9 N ' m (0.6 kg f ' m , 4.3 Ibf ft )
Front master cylind e r bleed valve 5.9 Nm (0.6 kq f.rn , 4.3 lbf. tt )
Fro nt master cylinder holder bo lt 12 N ' m (1.2 kqf-rn, 9 Ibfft )
TOOLS
Snap ring pliers
079 14-S A5 0001
16-5
Contents Chapter 16
HYDRAULIC BRAKE
TROUBLESHOOTING
Brake lev er /ped al soft or spongy
Air in hydraulic system
Leaking hydraulic system
Contaminated brake pad /disc
Wo rn caliper pisto n sea l
Worn m ast er cy linder piston cups
Worn brake pad /d isc
Co nta mi nated cali per
Cal ipe r not sli di ng pr op erly (re ar)
Low brake fl uid lev el
Clogge d fluid pas sage
Warped/d efo rmed brake di sc
St ick ing/worn cali per piston
St ick ing /wo rn master cy li nder p iston
Co ntaminat ed maste r cylinde r
Bent br ake lev er/p edal
Bra ke lever/pedal ha rd
Clogged/restricted hy drau lic system
Sticking/worn caliper piston
Caliper not sliding properly (rearl
Clogged/restricted fluid passage
Worn caliper piston seal
Sticking/worn m ast er cylinder piston
Ben t brake lever/peda l
Br ake dra gs
Contami nated br ake pad /disc
Misalign ed whee l
Clogg ed/r estricted br ake hose j oint
W arp ed/d ef ormed brak e di sc
Calipe r not sliding proper ly (rea r)
Clogged/ rest rict ed hy dr aul ic sys te m
Sticking/worn cal ipe r piston
Clogged master cylinder port
Sticki ng mast er cyl inder pis to n
16-6
Contents Chapter 16
HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/
AIR BLEEDING
I NOTICE
Spill ed flu id can damage painted, plastic, or rubber
parts. Place a shop to wel over these parts w hene ve r
Do not allow f oreign ma te rial to ente r th e system
when filling the reservo ir.
BRAKE FLUID DRAINING

FRONT :
Befor e re mo ving th e reservoir ca p, t urn the handle-
bar until the reservo ir is parallel to t he gro und . r SCR~
Remove the scr ew s, reservo ir cap , set plate and dia- _..:;::.~~r\ RESERVOIR CAP
ph rag m .
L~
Connect the bl eed h ose to th e mas t er cyl inde r bleed

va lve.
Loose n th e master cy linder bl eed va lve, and pu mp
the brake lev er.
Stop pumping the brake lever unti l no m o re fluid
flows out of t he bleed valve.
Conn ect the bleed hose to the caliper bleed v alve.

Loo sen the calipe r bl eed val ve . and pump th e bra ke
lever.
Stop pumping t he brake lever until no more flu id
f lows o ut of th e b leed v alv e.
Perform th is o peratio n for the o t he r sid e brak e cal i-
per .
16-7
Contents Chapter 16
HYDRAULIC BRAKE
REAR:
Rem ov e the rear seat cowl (page 3-5).
Remove the screws , reserv oir cap , set plate an d di a-
phragm.
Co nnect a bleed hose to th e ca liper blee d v alv e.

Loosen th e bleed va lv e and pump the bra ke ped al.
Sto p pump ing t h e b rake pe da l until no m ore f luid
flows out of the blee d v alve .
BRAKE FLUID FILLING/AIR BLEEDING

NOT E:
Use only DOT 4 bra ke fl u id from a sealed co n-
ta iner .
Do not m ix differ ent type s of fl ui d. Th ey are not
co mpatible.
Do not allow fo rei gn m ateri a l to enter t he system
when filling the reserv oir.
FRONT:
Close the bleed va lv es. /
UPPER LEVE L LINE

Fill th e reservoir wi t h DOT 4 bra ke fluid fr om a y--
seale d contai ne r.
16-8
Contents Chapter 16
HYDRAULIC BRAKE
1. Con nect a comme rcially available brake bleeder
t o the ma ster cylinde r bleed va lve.
If nor using an auto- Ope rat e t he brake blee der and loosen t he ble ed
matic refill s ystem, va lve .
add brake fluid
Check the flui d level often wh ile bleeding th e
when the fluid level
bra kes to prev ent air f ro m bei ng pum ped in t o th e
in the reservoir is
system .
low.
If air is en t erin g the bleed er from around the
blee d va lve threads, sea l th e t hreads with t efl on
tape.
W he n usin g a br ake bleed in g t oo l, foll ow th e
m anufa cturer 's operating in structi ons.
Rep eat above pr oced ure until ai r bubbles do not
appear in the bleed hose.
Close t he m aster cy linder bleed va lve .
TORQU E: 5.9 Nrn (0.6 kqf-m, 4.3 Ibf ft)
2. Connect a brake bleed er to the ca liper bl eed
va lv e.
Op erate th e bra ke bl eeder and loosen th e bl eed
va lve .
Rep eat above pro ced ure un t il ai r bubb les do not
appear in the bleed hose.
Clo se th e bleed va lve and pe rfo rm air bleeding
f or t he ot her si de caliper bleed v al ve.
Clo se the ca li pe r bleed va lves.
TORQU E: 7.8 Nm (0.8 kqt -m, 5.8 Ibf ft)
3. Perform th e bleed ing pr ocedur e at the m ast er
cy li nde r bl eed v alv e aga in until the syste m is
com plet ely flu sh ed/b led.
Ope rate t he brake leve r. If it still fee ls spongy,
bleed the system again .
Fill the fro nt bra ke rese rvo ir t o the up pe r lev el with
DOT 4 brake fluid f rom a sealed containe r.
Inst all the diaphragm, set plate, reserv o ir cap and ~
screws.
Tig ht en the scr ews to th e speci fie d torqu e.
TORQUE : 1.5 Nvm (0.15 kqf -rn, 1.1Ibf ft)
REAR:
Fill the reservo ir w ith DOT 4 brake fluid fr om a
sealed co nt aine r.
16-9
Contents Chapter 16
HYDRAULIC BRAKE
Conn ect a comm erci ally av ai lab le b rake bleed er to
t he bl eed valve .
If not using an auto- Op erat e the b rake b leeder and loo sen t he b le ed
matic refill system , va lve .
add brake fluid
Check th e fluid level oft en w hile bleeding the
wh en the fluid level
b rakes to preve nt air fro m being pu m ped in t o the
in the reservoir is
system.
low.
If air is ent er ing th e b lee der fro m aro u n d th e
b leed va lv e t h read s. sea l th e thread s with t efl o n
ta pe .
When using a brake bleeding tool, f oll ow t he
manufacturer's ope rating inst ruct io ns.
Rep eat above procedu re until air bubbles do not
appea r in t he bleed ho se.
Close t he bleed v alve.
TORQUE: 5.9 Nm (0.6 kqf-rn, 4.3 Ibf.ft)
Ope rat e the bra ke pedal. If it st ill f eels spongy, ble ed
the sy stem aga in .
Fill th e rear brake reservoi r t o th e upper leve l wi t h
DOT 4 bra ke fluid f rom a sea led co ntaine r.
Inst all the d iap hrag m , set plate, rese rv o ir cap and
screws.
Tighten the screws t o th e specif ie d t orqu e.
TORQUE: 1.5 Nm (0.15 kgfm .1.1Ibfltl
Install the rear seat cowl (pag e 3B).
RESERVOIRCA~
If t he br ake bleede r is not avai lable, perform t he t ot-
lowing proced u res: BLEED HOSE
Con nect a clea r b leed ho se to the ble ed valve .

Press u rize t he sy ste m with th e b rake lever or ped al
until t he re are no air bubbles in t he f luid f low ing out
of th e reservoir sm all hol e and lev er or ped al resis-
tance is felt.
Do not rel ease the 1. Sq ueeze the b rake lever o r push the b rake pe da l,
brake lever or pedal ope n t he bleed v alve 1/2 t u rn and t hen clos e t he
unt il the bleed valve va lve.
has been clo sed . 2. Release the brake lev er or pedal slo w ly and wait
sev era l seconds aft er it reaches the end of it s
travel.
3. Repeat st ep s 1 and 2 until bubb les cease t o
ap pear in th e flu id co m ing out of t he bl eed valv e.
4. Tight en t he bl eed valves .
TORQUE:
Front caliper bl eed v alve:
7.8 Nm (0.8 kqf-rn, 5.8 tbf.tt)
Front master cylinder bl eed valve:
5.9 Nrn (0.6 kqf-m, 4.3 lbf.tt)
Rear caliper bl eed valve :
5.9 Nrn (0.6 kqf -m, 4.3 lbf .tt)
5. Fil l the reserv oi r t o t he up pe r level li ne wit h DOT
4 brake f luid f rom a sea led conta iner.
Inst all t h e diaphragm, set p lat e an d reserv oir
cap .

HYDRAULIC BRAKE
BRAKE PAD/DISC
Always replace the FRONT BRAKE PAD REPLACEMENT
brake pads in pairs Loo sen the pad pins.
to assure even disc Rem ov e the calipe r moun t ing bol ts and bra ke cali-
pressure. pe r.
Discard t he br ake caliper mou nt in g bo lts.
Check the brake Push t he caliper pisto ns all t he way in to al lo w

fluid level in the installatio n of new b rake pads.
brake master cylin -
der reservoir as this
opera tion causes
the level to rise.
Rem o v e the pad pins. brake pads and pad spr ing.
Clea n t he insid e of t he ca li pe r especia lly arou nd t he

caliper pisto ns .
16-11
Contents Chapter 16
HYDRAULIC BRAKE
Install the pad spring with it s bent side downwa rd.
Install t he new br ake pads w it h t he cut portion of

the sh ims t ow ar d ent rance side of th e bra ke d isc
whi ch rota tes norma l d irect io n.
Inst all t h e pad pi ns w hile pus h ing t he br ake pad up

into t he ca lipe r.
Be careful not to In st all t he b rake calip er to t he fo rk leg so tha t th e ~~=~

damage the pads. disc is posit ioned between t he pads (page 16-30).
Tig hte n the new b rake cali pe r mounting bolts to the
specified torque.
TORQUE : 45 Nm (4.6 kqf- rn, 33 Ibf.ft)
Ti g ht en th e pad pins to the spec ified to rque.

TORQU E: 16 N m {1.6 kqf-rn , 12 Ibl ltl

HYDRAULIC BRAKE
REAR BRAKE PAD REPLACEMENT
Check the brake Push the caliper p ist on all th e wa y i n by pushin g th e
fluid level in the caliper body in ward t o allow in st allation of new
brake mas ter cvtin- brak e pads .
der reservoir as this
operat io n cau ses
the level fO rise.
Remove the pad pi n.

Remove the caliper mo unti ng bolt.
Pivot the calipe r up, and rem ove th e bra ke pads.
Clea n t he insid e of th e ca li p er especial ly aroun d th e

cali pe r pis t o n.
M ake sure th e pa d spri ng is in pl ace.
16-13
Contents Chapter 16
HYDRAULIC BRAKE
Install t he new brake pa ds.
Lo w er t he cali per w hil e pushing th e pads aga inst
th e pad spr ing so th at th e pa d ends are pos it io ned
onto the retain er o n th e ca lipe r bracket.
Inst all new O- ring to th e pad pin groove.
Inst all the pad pin.
Ti g ht en the cali per mounting bolt to the specified

torque .
TORQUE : 23 Nm (2.3 kqf-m, 17 Ibfft)
Tig hten the pad pin to the specified torque.

TORQU E: 18 Nm (1.8 kqf-rn, 13 Ibfft)
BRAKE DISC INSPECTION

Vis ual ly insp ect t he brake d iscs f o r dam age o r
cracks.
M easure the b rake disc thickness with a microme-
ter. :
SERVICE LIMITS:
FRONT: 4.0 m m (0.16 in)
REAR: 4.0 m m (0.16 in)
Replace the bra ke disc if th e smallest measurement

is less than the service li mit.
Measure the brake d isc warpage w ith a dial indica -

tor.
SERVICE LIMITS:
FRONT: 0.30 mm (0.0012 in)
REAR: 0.30 mm (0.0012 in)
Check the wheel bea rings fo r excessive play (page

14-17 and 15-8), if t he warpage exceeds t he service
limit.
Replace the brake disc if the wheel bearings are nor-
mal.
16-14
Contents Chapter 16
HYDRAULIC BRAKE
FRONT MASTER CYLINDER
I NOTICE I
Spilled fluid can damage painted, plastic, o r ru bber
part s. Place a sh op tow el over these parts whenever
the s ystem is serviced.
REMOVAL
Drain the f ront hydraulic sys tem (p age 16-7).
Disco nnect the brake light sw itch co nnect o rs.
Avoid sp iffing flui d Remove the bra ke hose o il bolt. seali ng was he rs
on pa inted, plastic. and bra ke hose eyelet joint.
or rubber parts.
Remo ve the bolts fr om t he m aste r cy li nde r holder

and rem ove th e mast er cyl ind er asse m bly.
DISASSEMBLY
Remo ve the du st cover and snap r ing.
TOOL:
Snap ri ng pliers 07914- SA50001
Remov e t he bolt an d br ake rese rv o ir f rom th e m as-
ter cyl ind e r.
Rem ov e the O-rin g from th e reserv oi r j oint.
SNAP RING
BOLT O-RIN G '\
16-15
Contents Chapter 16
HYDRAULIC BRAKE
Remove the pivot bolt/nut and brake lever assern -
PIVOT BOLT
bly.
Rem ov e th e screw and brake light sw it ch .

BRA KE LIGHT SW ITCH
Be careful not ro Rem ov e th e bo ot and pu sh rod .

BOOT
damage the boot.
PUSH ROO
Rem ove the snap ring fr om th e m ast er cy li nde r

body using the special t oo l as shown.
TOOL :
Sn ap ring pli ers 07914SA50001
Remove the master piston, sprin g and spri ng gui de

from th e master cyli nd er bo dy .
SNAP RING PLIERS

~.iL

HYDRAULIC BRAKE
INSPECTION
Clean the ins ide of the cy linder and reserv o ir with
clean br ake fl uid.
Check th e pi st o n boo t, pisto n cups for dam age o r
deterioratio n.
Chec k t he master cy linde r and pist o n f o r abn o rm al
scratc hes. M A STER PISTON
Check t he spr ing fo r f atig ue or dama ge.
I
PISTON CUPS
o
M easu re t he m aster cyli nde r 1. 0 .
M easu re t he m ast er cy lin de r pist on 0. 0 .
SERVICE LIMIT: 17.309 mm (0.68 15 in)
16-17
Contents Chapter 16
HYDRAULIC BRAKE
ASSEMBLY
1.5 Nrn 10.15 kqf -rn, 1.1 lbf-ft )
1.0 Nm 10.1 kq f-m . 0.7 Ibf.ft) ~

,~ .',' 5.9 Nm 10.6 kqf-rn , 4.3Ibfft) /" 7)
."
~ RESERVOIR CA P .,' .
I i I r-r-- -. '
MASTER CYLIN DER

\ I' j 0; .
..
\ ")8
~
,~ )F;
S PR IN G
SPRING GUIDE . ~/ 7'~ !
'lirF~
\.\).L! "">" J!f\
'q;
1.
~--t ,/' 1 \~<"_~~I),'
1"',~~",,,,,", < ~~~ e:::::~O' );.. ';J
'"' o",~f
SW ITCH ' \, ~
I.~~ ---- SNAP RIN G
(ffj ci!!
".,. ~ ~PHRAGM
~ "H~"
~~~~ ;;Jj FLOAT
I 0 ,~ RESERVOIR
BRAK E LEVER
BOOT
\_--.J
" v\ ;~
\~- _! @ 12 N'm 11.2 kqf -m , 9 lbf-ft)
Keep the piston, cups, spring , snap ring and boot

as a set; do not substitute individual parts .
Coat the master pisto n a nd piston cups wit h clean
bra ke flu id. SPRING
Install the spring guide into the spring.
When installing the Install the spring guide/sp ring and master piston
cups, do not aI/ow into the m aste r cylinder.
Y
the lips to turn
inside out.
Be certain the snap Install the snap ring with the spec ial too l.
SPRING GU IDE I 0
ring is firm lv sea ted
in the groove. TOOL:
Snap ring p liers 07914SA50001
16-18
Contents Chapter 16
HYDRAULIC BRAKE
Apply silico ne g rease to co nt act surfa ces of th e
pus h rod and m aster piston. BOOTIPUS H ROD
Inst all the boot w ith the pu sh ro d.
Insta ll the brak e lig ht switch and tig hten t he screw

t o th e spec if ied t o rque. BRAKE LIGHT SW ITCH
TORQUE: 1.0 Nm (0.1 kqf-m, 0.7 lbf -ft }
SCREW
Apply silic one grease to pu sh ro d tip.

Insta ll the bra ke lever by alig ning th e hol e of brake
lev er w it h the push rod .
A pply sili co ne gre ase to the brak e lev er pivot bol t

slid ing surf ace .
In sta ll the bra ke lever pi v ot bo lt an d nut.
Tighten the pivot bol t t o the specified t orqu e.
TORQUE: 1.0 Nrn (0.1 kqf-m, 0.7Ibfft)
Hol d th e piv ot bo lt and t ig ht en the pivot nu t to the
specified t o rq ue.
TORQUE : 5.9 Nm (0.6 kqf-m, 4.3 Ibf ft)

HYDRAULIC BRAKE
Apply b ra ke fluid to ne w O-rin g and install it t o t he
reserv oir hose joint.
Install t he m aster cy linder reser vo ir jo int in t o t he

m aster cyl inde r an d secur e th e joint with th e sn ap
ring .
TOOL :
Sn ap ring p lie rs 07914-SA50001
Install t he du st cove r.
Install th e reservo ir stay o nto th e m aste r cy linder
and tig hten t he mou nting bo lt to th e speci f ied
to rqu e. SN AP RING
Install the ma s ter

cylinder holder w ith
TORQUE: 12 Nm (1.2 kqf-m , 9 Ib f ft )
Jnstall the m aster cy li nder assembly, m ast er cy lin -

der hold er and bolts.
BOLT '\
MASTER CYLINDER
its 'UP' mark facin g Al ign th e end o f the m ast er cylinder with the pu nch
up m ark on th e han dle ba r (page 14-14 ).
Tig ht en th e uppe r bolt first, t hen the lower bolt to
the specified torque .
TORQUE : 12 Nm (1.2 kqf-m, 9 Ibf ft)
Inst all th e brake hose eyel et w it h t he oil bo lt an d

new sea ling was hers.
Push the eyelet joint aga in st th e st o pper, then
tighten th e oil bolt to the sp ecified torq ue .
TORQUE: 34 Nrn (3.5 kgfm , 25 Ib fft)
Connect th e brak e li ght switch co nnect o rs.

Fill brake flu id and bleed air fro m th e front brake
hy draul ic syst em (p age 16-8) .

HYDRAULIC BRAKE
REAR MASTER CYLINDER
I NOTICE I
Sp illed fluid can dam age painted, p lastic, or ru b ber
p arts. Place a shop towel o ver th ese parts wh en ev er
REMOVAL
Rem ov e th e bolt s and exhau st pi pe pro tec to r.
Drain the rear hy drau lic sy stem (page 167 ).

Rem ov e the bolts and passen ger peg b racket .
Rem ov e the bo lt a nd rear m aste r cyli nder reservoi r.
16-21
Contents Chapter 16
HYDRAULIC BRAKE
Avo id spilling fluid Remove the brake hose oil bo lt , seal ing washers
on painted, plastic, and brake hose eyelet joint .
or rubber parts.
Lo o sen t he rear maste r cy linder m ou nt ing bolts.

Rem ov e t he bo lts and righ t f oot p eg bracket. t hen
rem ov e the master cy li nder m ount ing bolt s, step
gua rd and re ar maste r cylinder from the right foot-
peg bracket.
Rem ov e and di scard t he brake ped al j oi nt cotter pin .

Rem ove t he nut, w ash ers , j oi nt bo lt and rear m aster
cy linde r.
DISASSEMBLY
Rem ov e t he screw and reser v oi r ho se jo int fro m t he
RESERVOIR HO SE JO INT O-RING
m ast er cy li nde r.
Remove t he O-rin g from t he reserv oi r joi nt.

HYDRAULIC BRAKE
Be careful nor to Remov e th e boot f rom the m ast er cylin der bo dy.
damage the boot. Rem ov e th e snap ri ng us in g th e spe cial to ol. BOOT SNAP RIN G PLIERS
I
TOOL :
Snap rin g p liers 07914-SA50001
Rem ov e the pu sh ro d , m aste r p isto n, pr imary cup
and spring .
INSPECTION
Clea n the m aster p isto n, spring and inside of the
cylinder wi t h clean bra ke flu id . SPRING PRIMARY CUP
"W'OA~,"e
Check t he p us h rod boot, prim ary cu p and seco nd -
ary cup f or da m age o r det eri oratio n.
Chec k t he m ast er cy linder an d pist on fo r abnormal /
sc ratc hes .
Check t he sprin g for fa t igue or damage.
/ BOOT
/
MASTER PISTON PUS H ROD AS SEM BLY
Me asur e t he m ast er cy linde r 1.0.
SERVICE LIM IT: 15.925 mm 10.6270 in)
M easu re the maste r cy linde r piston 0 .0.
16-23
Contents Chapter 16
HYDRAULIC BRAKE
ASSEMB LY
M ASTER CYLINDER
~
e O-RING
PUSH ROD
SPRING ~SNAPRING
DIA PHRAGM
I ._____@
8
eEl
" - - - BOOT
<J I
PRIMARY
~
CUP
\
PEDAL JO INT
RESERVOIR
MASTER PISTON
Keep the pisto n, cups, spring , snap ring a nd boot

as a set; do not subst itute individu al parts. SPRING
Coat t he master pisto n and pisto n cups wi th clean

brake fluid. SECONDARY CUP
Install the prima ry cup to th e spring.
When inst alling the
cup s, do not at/ow
the lip s to turn
ins ide out
Instal l t he sp ring/primary cup and master pisto n
into the master cyli nder.
App ly silicone grease to the piston contact a rea of
I
PRIMARY CUP ~
the push rod.
Insta ll the push rod assemb ly into the master cvtln-
de r.
MASTE R PISTON PUSH ROD AS SEMB LY
Instal l the snap ring using the special tool.

SNAP RIN G PLIERS
Be certain the snap TOO L:
I
ring is firmlv seated Snap ring pliers 07914-SA 50001
in th e g roove.
Apply silico ne grease to the push rod boot inside.
Install the boot into the maste r cylinder.
16-24
Contents Chapter 16
HYDRAULIC BRAKE
If the push rod joi nt is disa ssembled, adju st the
push rod leng th so tha t the dista nce betw een th e
centers of the master cylinde r low er mountin g bolt
ho le and join t pin hol e is 75 mm 13.0 in]. After
adju st me nt, tight en th e jo int nut to the specified
torque.
TORQUE: 18 Nm (1.8 kqf-rn. 13 Ibf ftl
App ly brake fluid to new O- ring a nd install it onto

the reservoir joint.
Insta ll the reserv oir joint to th e ~ast er cylinde r.
App ly a locking agent to the reserv oir joint screw

thread s. RESERVOIR HOSE JOINT
Tighten the screw to the specif ied torque.
TORQUE: 1.5 Nrn 10.15 kgfm . l .llbf ft)
" ilillJ SCREW
INSTALLATION
Connect th e push rod lower joint to the brake pedal
and install the joint bolt and nut w ith washers.
Tighten th e nut and secure it with new cotter pin.
~
~
COITER PIN
16-25
Contents Chapter 16
HYDRAULIC BRAKE
Install the step gua rd and rea r m aster cyli nder t o t he
rig ht foot peg b racket, then t ig hten th e maste r cy li n-
der mounti ng bo lts.
Put the bracke t in at Install the right footpeg bracket an d t ig hten t he
the ho ok of the bolts to t he spe cified torq ue.
heat gu ard.
TORQU E: 37 Nm (3.8 kqf-m , 27 lbf-tt]
Tighte n t he rear master cyl in de r mounti ng bolts to

the sp ecified to rque.
TORQUE: 9.8 Nm (1.0 kqf-rn, 7lbfftl
Ins tal l t he brake hose wit h t he oil bolt and new seal-
ing washers.
Push t he ey elet join t agai nst t he stoppe r, t he n
tig hten the oil bo lt to the specified torq ue .
TORQUE: 34 Nrn (3.5 kqf-m , 25 Ibfftl
Inst all the rese rvoir and tighten the bo lt to t h e spec -

if ied torque.
TORQU E: 12 Nrn (1.2 kqf. m , 9Ibfft)
Install the passenge r peg bracket and t ighten t he

bolts to t he specified torq ue .
TORQUE: 26 Nrn (2.7 kqf-rn, 20 Ibfft)
16-26
Contents Chapter 16
HYDRAULIC BRAKE
Inst all t he ex ha ust pipe prote ct or and tig ht en the
bo lt s secure ly .
Fill brake fluid and bleed air t he rear brake hydraulic
syste m (page 16-8).
FRONT BRAKE CA LIPERS

I NOTICE I
Sp illed fluid can damage p ain ted, p lastic, or ru bber
parts. Place a shop to w el over these parts w henever
the sys tem is serviced.
REMOVAL
Drai n t he fro nt brake hy drau li c sy st em (p age 167 ).
Avoid spilfing fluid Remove t he brake hose o il bo lt , sealing w ash ers
on painted, plastic, and brake hose ey elet join t.
or rubb er parts . Rem ov e the caliper m ounting bolt s and brake cali -
pe r.
Remove t he brake pad s (page 16-11).
DISASSEMBLY
Install a corr u gat ed ca rdbo ard o r soft w ood sheet
b etwe en t he cali pe r pistons.
Do no t use high App ly sma ll squir t s of air pr essure t o the f lui d inl et
pressure air or bring to remove t he pistons.
the nozzle too clos e
to the inle t.
16-27
Contents Chapter 16
HYDRAULIC BRAKE
Rem ov e t he three cal ipe r assem bly torx bo lts and
separate t he caliper halves. ASSEM BLY BOLTS
M ark th e pistons to Rem o ve the followi ng:

ensure correct reas- PISTON B
- Jo int sea l
sembly.
- Ca lipe r piston A
- Caliper piston B
JOINT SEAL PISTON A

Be careful not to Push th e du st sea ls and pisto n seals in and lift th em
damage the piston o ut.
sliding surface . Clea n th e seal grooves with cle an brak e flu id.
INSPECTION
Check t he cal iper cylinde r f or scoring o r other dam-
age. CYLIND ER A CYLINDER B
Measure the caliper cylinde r 1. 0 .
SERVICE LIMITS:
Cylinder A: 32 .140 mm (1.2654 in )
Cylinder B: 30 .340 mm (1.1945 in )

HYDRAULIC BRAKE
Check th e caliper pistons for scratches, scoring or
ot her da mage .
Mea sure the caliper piston 0 .0 .
SERVICE LIM ITS:
Pist o n A : 31.957 mm 11.2 581 in )
Pist o n B: 30.157 mm (1.1873 in)
ASSEMBLY
7.8 Nm (0.8 kg f-m , 5.8 Ib f ft )
!~ .liD
..... ~
16 Nrn 11.6 kqf-rn. 12 Ibfft ) PISTON SEA L
Coat new piston seals wi th clean brake fluid.

Coat new dust seal s w ith silicone gr ease.
Install the piston and dust seals into the grooves of
eI PISTON SEAL
th e caliper body.
Coat the caliper pistons w ith clean brake fluid and
install them into the caliper cylinder wi th their open
ends tow ard th e pad .
I PISTON A PISTON B
16-29
Contents Chapter 16
HYDRAULIC BRAKE
install t he new joint seal into t he f luid passa ge o n
the caliper.
STJ~
J OI NT SEA L
Assembl e the calipe r halv es.

Apply a locking agent to t he calipe r assembly to rx n ASS EM BLY BOLTS
bolt t hreads.
Ui1D
Install and t ighten t he cali pe r assem bly to rx bolts to
t he specified to rque.
TORQUE: 23 Nm {2.3 kqf-m , 17 Ibf ft J
INSTALLATION
Inst all t he brak e pads (page 16-11) .
Make sure that the Instal l the caliper to th e cal iper bracket .
dowel pins are T ight en the ne w caliper m o unt in g bo lts to the speci -
ins talled into the fied tor qu e.
calip er brac ket
TORQUE : 45 Nm (4.5 kqf-rn, 33 lbf-tt )
properly.
Instal l the bra ke hose eye let joi nt to t he calipe r body
w ith two new seali ng washe rs and oil bo lt.
Push th e brak e hose ey elet joint to t he sto ppe r o n

the caliper, then t ig hten the oil bolt to th e specif ied
to rque.
TORQU E: 34 Nrn (3.5 kqf-m , 25 Ibfft)

Fill bra ke fluid and bleed air fro m th e f ront brake
hy d raul ic system (page 16-8 ),

HYDRAULIC BRAKE
REAR BRAKE CALIPER
I NOTICE I
Spilled fl uid can dam ag e painted, plas tic, o r rubber
pa rts. Place a shop tow el o ver these parts w henev er
the sys tem is se rv iced.
REMOVAL
Drain the rear brake hydraul ic system (p ag e 16-7).
Avoid spilling fluid Remove the oil bo lt, seal ing washers and b rake
on painted, plastic, h os e eye let jo int .
or rubber parts.
Rem ov e t he caliper mounti ng bolt an d t he br ake

pads (pag e 16-13).
Piv ot the caliper up and rem ov e it from th e calipe r
bracket.
DISASSEMBLY
Remove the pad sprin g , coll ar and boot fr om th e
caliper bo dy. PAD SPRING
BOOT COLLAR
16-31
Contents Chapter 16
HYDRAULIC BRAKE
Place a shop t o we l ov er t he pisto n.
Do not use high Positi o n the caliper body wit h the pis to n down and
pressure air or bring app ly small sq ui rts of air p ressur e to the fluid in let
the nozzle too close to remove the pist on .
to the inlet.
Be careful not to Push the dust sea l and piston seal in and lift them
PISTON SEAL
damage the piston o ut .
sliding surface. Clean th e seal g rooves wi t h clean brake fluid.
INSPECTION
Check t he cali per cyl inde r fo r scori ng or ot he r dam-
age .
M easur e t he caliper cy li nde r l.D .
SERVICE LIM IT: 38.24 mm (1.506 in )
Check the cali pe r pisto n for scratches, scoring or

other da mage.
Measu re the cali pe r pist o n 0 .0.

HYDRAULIC BRAKE
ASSEMBLY
CA LIPER PISTON
~
;
\ -
fP
TOWARD THE ew BRAKE PAD
SPACER
CALIPER PISTON
27 N-m (2_8 kqf-rn, 20 lbfft)
Coat a new piston seal w it h clea n bra ke fluid.

Coat a new du st seal with silicone g rease . !~ " PISTON SEAL
Install the piston seal and d ust seal int o the groove . . .... II
of the caliper body.
Coat the cali pe r piston with clean brake fluid and
ins tall it into th e calipe r cy linder with its open end
towa rd the pa d.
Inst all t he pad spring int o t he caliper bod y .

Apply silicone grease to the inside of the boot and / COLLAR
ins tall the bo ot a nd co llar into th e ca lipe r.
If the boot is ha rd o r dete rio rated, re pla ce it with a I
new one.
~/
BOOT
~
PADSPRING~

HYDRAULIC BRAKE
INSTA LLATION
M ake sure t hat th e pad ret ain er is in st alled o n the
caliper bracket pro pe rly.
Ap ply silicone grease to the cal ipe r pin and insta ll
the ca liper o nto the bracket.
Install the rea r brake pads and tig hte n th e ca li pe r
moun t ing bol t and pad pin (page 16-13).
Insta ll the br ake hose ey elet join t to the caliper body

with new seali ng was he rs and o il bolt.
Push th e brake hose eyel et joint to th e stopper o n
th e caliper, th en t ighten t he oil bolt to th e specified
torqu e.
TORQUE : 34 Nrn (3.5 kqf-m , 25 lbf-ft]
Fill br ake fl uid and bleed air from the rear bra ke
hydraulic syste m (page 16-81.
BRAKE PEDAL
REMOVAL
Remove t he rig ht mi d dle cowl (pa ge 3-7),
Disconne ct t he rear bra ke lig ht switch 2P con nec tor
and relea se the lig ht sw it ch wire f rom t he cla m ps .
Rem ov e t he ex hau st pip e protecto r (page 16-21).

Rem ov e t he right f ootpeg bracket socket bolts and
bracke t assem bly f rom th e fram e.

HYDRAULIC BRAKE
Remo v e and discard the br ake pedal joint cott er pin.
Remove the nut, wa she rs and joint bolt, and discon-
nect t he push rod lower joi nt fro m the brake pedal.
Un hook the br ake li ght switch sp ring and brak e
peda l ret urn sp ring f rom the bra ke pedal.
Remove t he snap ring and t hrust w asher, th en
remove the brak e pedal and wave was her.
INSTALLATION
e ~
COTTER PIN
/
SW ITCH SPRIN G
BRAKE LIGHT
SW ITCH
SN AP RING
-:
,%'
~<""~} ,
RETURN SPRING
BRACKET WAVE WASHER

THRU ST WASH ER
BRA KE PEDAL
Apply grease to the sliding surface of the brake

peda l and pivot shaft.
Inst all th e wave w ash er, br ake pedal, thru st was her
and snap rin g o nto the bra ke pedal pivot .
Connect t he pu sh rod low er joint t o th e bra ke pedal
and in st all the joi nt bolt and nu t wit h was hers.
Ti g ht en the nut and sec ure it wit h new cotte r pi n.
Install t he brake ped al return sp ring and brake light
sw it ch spri ng.
16-35
Contents Chapter 16
HYDRAULIC BRAKE
Put the bracket in at Inst all t he right f ootpeg brack et t o the fram e and
the hook of the tighten t h e bo lts t o th e specified torq ue .
heat guard.
TORQ UE: 37 N m (3.8 kqf-m , 27 Ibf.ft)
Route the rear bra ke light switch w ire p ro pe rly .

Conn ect th e 2P (Blac k) conn ector an d secu re t he
brake lig ht sw itch wire to the w ire clamp.
Inst all t he ri ght middle cowl I paqe 3-9).

17. BATTERY/CHARGING SYSTEM
SYSTEM DIAGRAM .... 17-2 CHARGING SYSTEM INSPECTION 17-7
SERVICE INFORMATION 17-3 ALTERNATOR CHARGING COIL 17-8
TROUBLESHOOTING 17-4 REGULATOR/RECTIFIER ...... 17-8
BATTERy .. .. 17-5
17-1
Contents Chapter 17
SYSTEM DIAGRAM
BATT ERY
MAIN FUSE
REGU LATOR/RECT IFIER
ALTE RNATOR
MIAINF~OA)
tt>

R- 8 f--
3P Y Y Y 2P BATTERY
G R
REGULATOR/RECTIFIER
-'-
ALTERNATOR
R RED
y yELLDW
G GREEN

SATTERY/CHARGING SYSTEM
SERVICE INFORMATION
GENERAL
. AWARNING
Th e battery gi ves o ff ex plosive gases; keep sp ar ks, flames and cigarettes aw ay. Provide ad equate v ent il ati o n w he n
cha rg ing.
The batte ry co nta ins sulfu ric acid (electrolyte ). Contact wit h skin o r eyes may ca use seve re burns. Wea r protecti ve
clothing and a face shield.
- If electrol yte gets on y ou r skin , flush with water.
- If electro lyte gets in yo ur eyes. flush w ith wa t er for at least 15 minutes and call a ph ys ici an im m edi ate ly.
Electrolyte is po isonous.
- If swallowed, dr ink la rge qu antiti es of wa t er o r milk and call yo ur loc al Poison Control Center o r a call a phy sician
immediat ely.
NOTICE
A lways turn o ff the ig ni tion switch before disconn ecting any electrical co mponent.
Some ele ctricst compo nents may be damaged i f terminals o r co nnecto rs ar e co nnec ted o r disconnected wh ile the igni-
tion switch is ON a nd cu rren t is p res en t.
For exte nde d sto rage, remove th e batter y, gi ve it a full charge , and sto re it in a cool , dr y spa ce. For m aximum se rv ice
lif e, charge the stored batt ery ev ery t w o w eeks.
For a battery remai ning in a sto red moto rcycle, disco nnect t he negat iv e b att ery ca ble fro m the batte ry term inal.
The maintena nce free b att ery mu st be replaced w hen it reach es the en d of it s service life.
The battery can b e dama ged lf overch arged or u nde rcha rged , or if left to di scha rge fo r a long p eriod. Th ese sam e con-
d it io ns co nt ri bu te t o sho rten ing t he "life sp an" of th e battery . Ev en under normal use, t he performance of th e batt ery
deter ior ates afte r 2 - 3 ye ars.
Battery vo ltage m ay recover aft er battery cha rgi ng, but under heav y load , b atte ry v ol ta ge will drop qu ickly an d eve nt u-
all y di e out. For t his reaso n, th e cha rging sy st em is often sus pected as th e prob lem . Battery overcharg e often resu lt s
fro m problems in the battery it self, w hich may appea r to be an ove rc ha rg ing symptom. If o ne of t he batte ry cell s is
shorted and b att ery voltage does no t inc rease, the reg u lator/rect ifier supp lies excess vo lt age to the batte ry . U nder th ese
cond it ions, the elect rolyte lev el goe s do wn quickly .
Bef or e troubl eshoot ing the chargi ng sy stem , ch eck f or proper us e and maintenan ce of the batt ery . Check if th e batte ry
is fr equ ently under heavy load , suc h as having th e headli gh t and tailli ght ON fo r long peri ods of tim e w ith out ridi ng th e
motorcycle.
Th e battery wi ll self-disc harge w he n th e motorcycle is no t in use. For th is reason, charge th e batt ery eve ry two weeks t o
preven t sulfation fro m oc curri ng.
When checking the charging sy ste m, always fo llow the steps in the tro ubles hooting fl ow cha rt (p age 174 ).
Fo r batte ry chargi ng , do not ex ceed the charg ing cu rrent and t ime spec if ied on the batte ry . Use of exce ssive current or
ch ar ging tim e may dama ge the battery .
Refer to (p age 114 ) for alt ern ato r remov al and disassembl y.
BATIERY TESTING
Refer to the in stru ction of the Op eration M anual fo r th e recommende d batte ry tester. The reco m m ended battery t ester
puts a "loa d" on th e battery so that t he actu al battery condition of the lo ad can be measu red .
Recommen ded battery t est er: BM210 o r BATTERY MATE or eq uivalent
SPECIFICATIONS
ITEM SPECIFICATIONS
Batt ery Capacity 12 V - 8.6 Ah
Cu rrent leakage 2.0 rnA max.
Voltage Fully charged 13.0 -13.2 V
(20'C/68' F) Needs Below 12.4 V
cha rging
Char ging curre nt Nor mal 0 .9 N 5 - 10 h
Qui ck 4 .5 N l h
Alternat or Capaci ty 0.344 kW/5,000 rpm
Chargi ng coi l resistance (20C/68 F) 0.1 - 1.0 n
17-3
Contents Chapter 17
BATTERYICHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove th e battery (pag e 17-5).
Check th e b attery co ndition using th e recom mende d battery te ste r.
RECOMMENDED BATTERY TESTER:
BM210 o r BATTERY MATE or eq uivalent
Is the battery in good co ndi tio n?

NO - Faulty battery
YES - GO TO STEP 2.
2. CURRENT LEAKAGE TEST
Install th e batte ry (pa ge 17-5).
Chec k th e battery current leakage (Leakag e test; See page 17-7).
Is the current le akage below 2.0 rnA?
YES - GO TO ST EP 4 .
NO - GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTED
Disconn ect th e regu lat or /rect if ier 2P co nnec to r and rec heck the batt ery cu rrent leakage.
Is th e current leakage below 2.0 rnA ?
YES - Faulty regulat or /r ecti fier
NO _. Shorted wire harness
Faulty ig ni tio n sw it ch
4. ALTERNATOR CHARGING COIL INSPECTION
Chec k th e alte rn at or cha rg ing coil (page 17-8 ).
Is the alterna tor cha rging coil res is tan ce w ith in 0.1- 1.0 n (20 OC/68 Of=)?
NO - Fau lt y charging coil
YES - GO TO STEP 5.
5. CHARGING VOLTAGE INSPECTION
Measure and record t he batt ery v olt age using a dig ita l mu lti meter (page 17-5 ).
Start t he eng ine and m easu re the cha rging v o lta ge (pag e 17-7 ).
Compare t he mea surement to result of the fo llow in g cal cula t io n.
STANDARD :
Measured b attery Voltage < Measured charging voltage < 15.5 V
Is the m easured charging voltage within the s tan dard voltage?
YES - Fault y battery
NO - GO TO STEP 6.
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the volt age at th e reg ul at o r/r ect if ier connect or (p age 178 ).
Are the results of checked voltage correct?
YES - Faulty regul at or/rectifier
NO - . Open ci rcu it in relat ed w ire
Lo ose o r po or contact s of relat ed t ermin al
Sho rt ed w ire harness
17-4
Contents Chapter 17
BATTERY
Alw ays turn the REMOVALIINSTALLATION
ignition switch OFF Rem ov e th e ri der seat (page 3-4).
before removing
the battery. Rem ov e t he batte ry holder ba nd .
Disconn ect t he neg at iv e cab le fi rst , t he n th e po siti v e
cab le.
Re move t he batt e ry fro m the batt er y tray .
Connect the posi- Inst all th e batte ry in the rev erse o rde r of rem ov al.
tive cable first and After install ing th e ba ttery, coat the te r m inals wit h
then the negative cle an grease.
cable.
VOLTAGE INSPECTION
Measu re th e b atte ry voltage using a com mercially
availa ble d ig ita l rn u ft tm et er .
VOLTAGE:
Fully cha rg ed: 13 .0 - t3 .2 V
Under charged : Below t2.3 V
BATTERY TESTING
A lways cle ar t he work area of f la m ma b le materi als , - -- - - - - - - - - - - -- - - ----,
suc h as gasoline. brake fluid , elect ro lyte, or cloth
tow els whe n operating t h e t est er, the heat gener- BATIERY
ated by the t est er m ay cause a f ire.
Rem ov e the battery (page 17-51.
Secu rely co nnect t he teste r's positive (+) cab le first,
g .o
then con nect the ne gative H cable. ~OOOOO e
TOOL: RED
Battery te ster BM-2tO-AH (U.S .A. only) or BM-2tO
TESTER
BLACK
For accurate test Set the temperature switch to "HIGH" o r "LOW "
res ults, be sure the
tester's cables an d
clamps are in goo d
working condition
and that a secure
connection can be
made at the
d epend i ng o n the ambient tem p erature.
g
rn e Ell
battery. 8oO O
u u
HIGH
15C 160F) or hi gh er
LOW
15C 160F1or low er
17-5
Contents Chapter 17
For the first check, Push in the approp ria te test button fo r 3 seco nds
DO NOT charge the and read the cond it ion of th e battery on the meter.
battery before rest - TEST BUTIONS
To av oid damaging the tester. o nly t est batteries
ing; rest it in a n "as
with an amperage ratin g of less than 20 Ah .
is' condition.
Tester damage can result f rom o ve rheat ing w hen:
- The test button is pushed in fo r more t ha n 3 sec -
onds .
- Th e teste r is used w ithout bein g allowed to co o l
fo r at least 1 m inute w h en t est ing m ore t han o ne
batte ry.
- M ore than 10 co nsecuti v e t est s are perform ed
wi th ou t all owing at least a 3D-minute cool-d own
per iod . .
Th e result of a t est o n th e m et er scale is re lat iv e to ~=================~

th e amp. hour ratin g of t he batt ery . ANY BATIER Y YELLOW
REAOING IN THE GREEN ZONE IS OK. Batt er ies (- 1)
sh ould only be charged if they regi st er in t he YEL- GREEN
LOW or RED zone . (+ 1, +2 , +3 )
BATTERY CHARGING
Rem ov e th e batte ry (page 17-5).
Clean th e bat te ry te r minals and posit io n th e bat -
tery as far away from th e charge r as the lead s BATIERY
will per mit.
Do not place batteries below t he charqer gases
from th e batt ery ma y corrod e and dam age th e
charge r.
>
g .
Do not pla ce batteries o n top of the cha rg er . Be
sure th e air ve nt s are n ot bl ock ed .
gooooo e o
TOOL:
Christi e battery charger M C1012/ 2 (U.S.A. onl y) TESTER
BLACK
1. Turn the Power Switc h to the OFF pos iti on.

BATIERY AM P HR.
2. Set th e BATIERY AMP HR. SELECTOR SWITCH SELECTOR SWITCH
f or th e size of t he battery bein g cha rge d.
5.5 to 9.0
3. Set the TIMER to th e positi on indicated by th e 3.5 to 5.0 9.5 t o 16.0
Ho nda Batt ery Tester;
RED-3, RED-2, or YELLOW -l . 16.5 to 30
If y ou are charging a new batt ery, set the sw it ch o t o 0.3
to the NEW BATI pos ition.
4. Attach the clam ps to the b attery term inals; RED
to Posit iv e. BLACK to Negative.
Set the app ropriate am p. hour rating .

Connect t he battery cables on ly when t he Power
Switch is OFF. TIM ER
-.
NEWBATI Trickle
5. Turn the Pow e r Switc h to the ON position .
6. W he n the ti m er reac hes th e "T rickle" posit io n,
the cha rg ing cy cle is comp let e. Turn the Po w er
Swi tch OFF and disconnect t he clamps . Th e
charger will automatically switch to th e "Tric kle"
m ode afte r th e set charg ing ti me has elapsed.
7. Let th e battery cool f or at least 10 m inutes or
un t il gassing subsi des afte r cha rg ing .
8. Re-t est the battery using the Honda Battery
Tester and recharg e if ne cessary using the above
steps.
CHARGING SYSTEM INSPECTION

Do not disconnect CURRENT LEAKAGE INSPECTION
the battery or any
Remove the driver seat (page 3-4) .
cable in the charg-
ing syst em without Turn the ignit ion sw itc h OFF and disc onnect t he ba t-
firs t switching off t ery negative cab le from th e batt ery.
the ignition switch. Connect the ammeter (+ ) probe to th e ne gative
Failure to follow this cab le and the ammeter H probe to th e battery H
precaution can termi na l.
dam age the tes ter W it h t he ig nit ion sw itc h OFF, chec k for cu rre nt leak-
or electrical compo- age.
nents . When measuring cu rrent using a tester, set it to a
high range, and the n br ing t he range dow n t o an
app rop ria te level. Cu rrent flow hi gh er t han the
range selecte d m ay blowo ut th e fu se in t h e
tester.
While measuring current, do not turn t he ignit io n
swi t ch on. A sudde n surge o f curre nt may blow
out th e fu se in th e t ester .
SPECIFIED CURRENT LEAKAGE: 2.0 rnA ma x.
If current leakage ex ceed s the sp ecified v alu e, a

shorted circu it is likely.
Locat e the short by d isconnecting conn ections one
by one and m easuring t he cu rrent.
CHARGING VOLTAGE INSPECTION
Be sure the battery is in go od cond ition before per-
forming th is te st .
Wa rm up th e engine to normal op erating tempera-
t ur e.
Stop t he engi ne, an d co nnect t he m ultimete r
between t he positi v e and negativ e term inals of the
battery.
To prevent a short, make absolutely certain
w hic h are t he positi v e an d negat iv e term ina ls or
cab le.
Restart the engine.
W ith the h ead lig ht on Hi b eam , m easure t he vol t age
on t he m ul ti mete r when th e engine runs at 5,000
rpm .
St and ard :
M easured BV < M easured CV < 15.5 V at 5.000 rpm
BV = Battery Vol t age (pa ge 17-5)
CV = Ch ar ging Voltag e
17-7
Contents Chapter 17
BATTERYICHARGING SYSTEM
ALTERNATOR CHARGING COIL
It is not necessary INSPECTION
to remove the sta- Rem ove the lef t m id d le co w l (pag e 3-71.
tor coil to make this
test. Rem ov e th e wire ba nd an d d isco nn ect th e alt ern a-
to r 3P (N at u ral) co nnect or.
Che ck t he res istance be twee n t h ree Ye ll o w t erm i-

nal s of t he alte rn ato r si de co n ne ctor.
STANDARD: 0.1 - 1.0 n (at 20 'C/68'FI
Che ck f or cont in uity betwee n each ter mi nal a nd

g rou nd .
There sho ul d be no con t inu ity.
If resistance is out of sp ecifi cation, o r if a ny wire has
continuity to ground, rep lace t he a lte rn at o r stator.
Ref e r to pa g e 11-4 f or sta to r rem ov al.
REGULATORIRECTIFIER
WIRE HARNESS INSPECTION
Rem o ve the left m idd le cow l (p ag e 3-7) .
Rem ove t h e w ir e band and discon nect t h e regula-
to r/rectifie r 2P (Na t u ral) connecto r and alte rn at or 3 P
(Natu ra l) conn ect o r.
Ch eck th e con nect a rs for lo o se contacts or co rroded
t erm inals.
If th e regu lat ed v o lt ag e read in g (page 17-7 ) is o ut o f
the spe cificatio n , check th e fo llowi ng at th e w ir e
harn ess side co n nect o r.

BATTERY/CHARG ING SYSTEM
BATTER Y LINE
M ea sure th e vo ltage bet w ee n t he red wi re t er m ina l
and g reen w ire terminal ,
Th e re s hou ld be ba ttery vo ltag e at a ll t ime.
GROUND LINE
Check t he co nt in u ity betw een th e g ree n wi re te rrni-
nal a nd groun d.
There sho u ld be co nti n uity at all t ime.
If al l com po nents of t he cha rg ing sy st e m are no rmal
an d t h ere a re no lo o se co n nec t io ns at the regu lator!
rect if ier co nnecto rs, repl ace th e reg u lato r/r ecti f ier
u nit (page 17-9).
Disconnect the alternator 3 P (Na tu ral) connector
and regulato r/ rectif ier 2P (Na t ural) connector (page
17-8 ).
Rem ov e t he reg u lat o r/r ect if ier m o u nt i ng bolts.
Rem ov e th e reg ul ator/r ect if i er u nit a nd heat g uard

plate.
In sta ll th e regu lat o rlrecti f i er u nit in t he reve rse
o rder of rem ova l.

MEMO
Contents Chapter 17
18. IGNITION SYSTEM
SYSTEM DIAGRAM 18-2 IGNITION SYSTEM INSPECTION 18-5
SERVICE INFORMATION 18-3 CKP (CRANKSHAFT POSITION) SENSOR .. 18-7
TROUBLESHOOTING 18-4 IGNITION TIMING 18-7
EI
18-1
Contents Chapter 18
IGNITION SYSTEM
SYSTEM DIAGRAM
ENGINE STOP SWI TCH
IGNITION SW ITCH
DIRECT IGN ITION COIL
BATIERY
CLUTCH SW ITCH
SPARK PLUG
RELAY BOX
(ENGINE STO P RELAY)
CKP (CRA NKSHA FT POSITION ) SENSOR
SIDE STA ND SWITC H

NEUTRAL SW ITCH
ENGINE STOP
RELAY
RIW~
SIDE STA ND SWITCH ENGINE STO P SWITCH
UP
!3i=5"i: BIIW RlBu L 6 1-----0---0- WIB] RIW
DOWN
~
To B ank angl~
IGNITION SWITCH FUSE
(1OA ) ~ PGM-Fl
CLUTCH SWITC H
sensor -
R i FUSE
(20A)
---~-G1R ----O~GIW
, -- - - -GlR
i
.
MAIN FUS E P OA}
0
RN
6P
BIIW- - --+-+--+
1T1.'"~
DIO DE
BATIERY
RIY
NEUTRAl~
SWITCH
Lg
I J
-lJ-L-L-L..L_L-lY_Wj'B
-,' fu
LI! ! ! !
CKP SENSOR
SPARK PL UGS
Bl .... BLACK y YEUDW'
DIRECTlGNmON COILS Bu .. . BLUE G GREEN
19 ... UGHTGREEN R REO
W ... WHITE

IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
NOTICE
The ECM may be damaged if dropped. A lso if the co nnector is disconnected when current is flowing, the excessive vo/t-
age may damage the module. Always tu rn off th e ignition switch before se rvicing.
Use spark plug of the correct hea t range. Using spa rk p lug with an incorrect heat ran ge ca n damage the engine.
Some elect rical co mponents may be dam aged if t ermi nal s o r co nnectors are co nnecte d o r di scon nected w hile th e iqni-
tio n switch is ON and cur re nt is prese nt .
When servicing the ig nit io n system, always follow t he steps in t he troubleshoot ing sequence (page 18-4) .
This motorcycle's Ignition Con trol Module oeM) is built in to the En gine Con trol Module (Ee M) .
The ignition timing does no t normally need to be adjusted since th e ECM is factory preset .
A faulty ig nition system is often related t o poor connect ions. Check th ose connections before proceed ing . Ma ke sure t he
battery is adequ ately cha rge d . Using th e sta rte r m ot o r with a w eak battery result s in a slower engine cran king speed as
we ll as no spark at th e spa rk plu g.
This motorcycle fe at ures direct ig nit ion coils, wh er e t he ign iti on coi l and spark plug cap are in t egrat ed . Th ere are f our
di rect ignit ion coi ls.
This motorcycle's spark plug is equipped w ith iridium type electrode. Do not use spark plugs other than specified.
Refer to the CM? (camshaft position) sensor inspection (page 6-66 ) and ECM inspection (page 6-69) .
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark pl ug (Iridium) I NGK IM R9C-9HES
I OENSO VUH27 ES
Spark plug gap 0.80 - 0.90 mm (0.031 - 0.035 in )
Igniti o n coi l pea k voltage 100 V minimum
CKP (cran ksha ft posi tion ) sensor peak vo ltage 0.7 V mi ni m um
Igni ti o n t iming ("F"m ark ) 8' 12' BTDC at idle
TORQUE VALUES
T im ing hole cap 18 Nm 11.8 kqf-rn, 13Ibf.ft) Apply grease to th e threads
TOOLS
IgnitionMate peak voltage tester Peak vo ltage adaptor ECM test harn ess. 32P
MTP07-0286 (U.S.A. only) 07HGJ-0020100 070M Z-0010201
(not available in U.S.A.)
(two req ui red )

wit h co m mercia lly ava ilable dig ital
m ultimeter (impedance 10 MnJDCV
mini mum)

IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose direct ig nition coil and spa rk plug connection
- Loose direct ig nition coil connectors
- Water got into the direct ignition coil (shorting the ign ition coil secondary voltage)
If there is no spark at any cy linder, temporarily exchange the direct ign it ion coil with t he ot her good one and perform
t he spark test. If there is spark, t he exchanged direct ign ition co il is fa ulty.
"Initial voltage" of t he i g n it i on p rimary coi l is the battery vo ltage with the ig n it io n sw itch tu rned ON and eng ine stop
switch turned" n" (The eng ine is not cranked by the starte r moto r).
No spark at all plu gs

Unusual conditi on Pro bab le cau se (Ch eck in numeri cal ord er)
Ign it ion coil No initial voltage with t he ignition 1. Faulty engine stop re lay.
pr imary volt- ON and engi ne stop switch t urned 2. An open circuit in Black/white wi re between the direct
age "n " (ot her electrica l components ig nit io n coi l and engine stop re lay.
3. Loose or poor con nect of the direct ignition coil connec-
are normal)
tors, or an open circuit in prima ry coi l (Check at t he
ECM co nnector).
4. Faulty ECM (in case when t h e initial voltage is norma l
wh ile disconnecting ECM connectors)
Initial vo ltage is n or m al, but it 1. Incorrect peak voltage adaptor connections.
d rops down to 2 - 4 V wh ile crank- 2. Undercharged battery.
ing the eng ine. 3. No voltage between the Black/white (+) and body
ground (-) at the ECM multi-connector or loose n ECM
connection .
4. An open circuit o r loose connection in Green wire.
5. An open circuit o r loose con nection in Blue/black, Yet-
low /w hit e, Red/blu e and Red/yel low wires between the
direct ignitio n coils and ECM .
6. Faulty side stand switch or neutra l sw itch.
7. An open ci rcuit or loose.connection in No. 6 related cir-
cuit wires.
- Side sta nd sw itch li ne: Green/wh it e wire
- Neutral switch line:Light green wire
8. Faulty CKP sensor (Measure the peak voltage).
9. Faulty ECM (in case when above No.1 - 8 are no rmal).
In itial vo ltage is no rma l, but no 1. Faulty peak vo ltage adaptor connections.
pea k voltage wh ile cranking the 2. Faulty p eak voltage adaptor.
engine. 3. Faulty ECM (in case when above No .1 and 2 are no r-
ma l).
In itial vo ltage is no rma l, but peak 1. The m ultimeter impedance is too low; below 10 MO l
voltage is lower than standard DCV.
valve. 2. Cranki ng speed is too low (Battery is undercharged).
3. The sampli ng timing of t he teste r and measured p u lse
were not synchronized (Sy st em is norma l if measured
vo ltage is ove r the specification at least once).
4. Faulty ECM (in case when above No.1 - 3 are no rmal).
Initial and pea k voltage are no rm al, 1. Faulty spark pl ug or leaki ng ig nit ion coil secon dary cu r-
but does not spa rk. rent ampere.
2. Faulty direct ignition coil (s).
CKP senso r Peak voltage is lower t han standard 1. The multi meter im ped ance is too low; below 10 MOl
val ue . DCV.
2. Cranki ng speed is too low (Battery is undercharged).
3. The sampling timing of the tester and measured pulse
were not sy nch roni zed (System is nor m al if measured
vo ltage is ove r the specification at least o nce) ,
4. Faulty ECM (i n case when above No .1 - 3 are no rma l).
No peak voltage . 1. Faulty peak voltage adaptor.
2. Faulty CKP sensor.
18-4
Contents Chapter 18
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
If there is no spa rk at any pl ug, check all connec-
t io ns f or loose or poor contact befo re me asu ring
eac h pea k volt age.
Use reco m men ded dig ita l mu ltim eter or co m -
mercially avail able digital multi meter wit h an
impedance of 10 MQ/DCV minimum .
T he display val ue di ffers depend ing upo n t he
inte rna l im pedance of th e m ult im eter.
If the Im rie diag nostic tester (mode l 625) is used ,
follow the manufacturer's instructio n.
Connect the peak voltage teste r o r peak voltage
DIGITA L MULTIM ETER
ada pto r to t he d ig it al rnultimeter.
TOO LS:
Ign ition Mate pea k voltag e t ester MTP0 7-0286
(U.S.A. o nly) or 1-1
Peak volt age ada pto r 07HGJ-0020100
(not availab le in
U.S.A.)
wi t h commercially avai lable d igital multimeter
@
<
(i m pe dance 10 M Q/D CV m in imum )
PEAK VOLTA GE A DAPTOR
IGNITION COIL PRIMARY PEAK

VOLTAG E
Che ck all system co nnecti ons befor e inspec t io n.
If the system is disconn ect ed, inco rrect pe ak vo lt-
age migh t be measured .
Check cylinder compression and check that the
spark plugs are in stalled co rrectly.
Rem o v e t he di rect ig niti on coil s f ro m t he spa rk
plugs (page 4-8).
Connect the direct ignition coil 2P co nnectors to th e
direct ignitio n coil.
Conn ect known-good spa rk pl ugs t o the di rect igni-
ti on coil and g ro u nd t he spa rk pl ug t o th e cyli nd er
hea d as do ne in a spa rk t est.
KNOWN-GOO D SPARK PLUG
Co nnect t he ECM t est harness to the ECM co nnec-

to rs (page 6-11 ).
A2 A3
Con nect the pea k voltage tes ter or adaptor pr o bes Al
to the t est harness terminals . B16
CONN ECTIONS: i 1 4 i , ii i 11 IZ ':11*" Iii
No.1 ignit ion co il: 00 0000000 0 000 000000000000000

81 6(+) - A 17 (-) o 00 0 0 00000000 0 000000000000000
No .2 ig nit ion coi l:

816 (+) -A 1 {- ) '------',;-----,s
No .3 ign it io n coil :
8161+) -A2{-) IJIII"=- ..JEB
No.4 igniti on coil:
61 6 1+1- A3 1-)
18-5
Contents Chapter 18
IGNITION SYSTEM
Av oid touching th e Turn the ig nit ion switch ON and eng ine stop switch
spark plug s and "n ".
tes ter pro be s to Chec k fo r initial vo lt age at t his time.
pre vent electric Battery voltage sho uld be present .
shoc k. If the in itial volta ge cannot be measu red , check the
po w er supp ly ci rcu it (refe r to t he t ro ub les h ooting,
page 184).
Shift t he trans m ission into neu tral.
Cran k the engi ne w it h th e sta rte r m ot o r and read t he
ig niti on coil pr ima ry pea k vo ltage .
PEAK VOLTAGE: 100 V minimum
If t he pea k vo ltage is abnor mal, check fo r an open

circ uit o r poor con nection in Blue/b lack , Yel lo w!
wh it e, Red/blue and Red/ye llow w ires.
If not defects are f o u nd in the harn ess, refer to t he
troubles h ooting chart (page 184 ).
CKP (CRANKSHAFT POSITION)
SENSOR PEAK VOLTAGE
Chec k al l syste m co nnec tions befo re in spe ct io n.
If the sys tem is disco nnected, incorrect peak v o lt-
age migh t be m easur ed .
Check cyl inder comp ress io n and check t hat t he
spark plugs are ins talled correct ly .
Remove t he ri gh t m iddle cowl (page 3-7).
ECM
Discon nect th e ECM 32P (Lig ht gray) con nector
fro m th e ECM .
32P (LIGHT GRAY) CON NECTOR
Connect the pea k voltage tes ter or adaptor pro bes

PEA K VOLTAGE A DA PTOR
to t he con nec tor ter m inal of t he w ire harne ss si de
and bod y ground.
TOOLS:
IgnitionMate peak voltage tester MTP0 7-0286
(U .S.A . only) or
Peak voltage adaptor 07HGJ0020100
(not avail able in
U .S.A .)
with commercially available d igital mu ltimeter
(impedance 10 Mn/DCV minimum)
CONNECTION :
32P (LIGHT GRAY) CON NECTOR
Yellow termina l (+) - body ground H
Cran k th e eng ine wit h t he starter moto r and read t he
peak vol tage.
PEAK VOLTAG E: 0.7 V minimum
If t he peak v o lt age measured at ECM co nnector is
ab no rma l, m easu re t he peak vo ltage at the CKP sen-
sor connector.
18-6
Contents Chapter 18
IGNITION SYSTEM
Rem ov e the rig ht middle cow l (pa ge 3-7)
2P (RED) CONNECTOR
Disconn ect t he CKP sen sor 2P (Red) conn ector and
connect th e tester pro bes to th e termi nal (Yell ow
and Yellow/white).
In the same manner as at t he ECM connector. m ea-
sure th e peak voltage and co m pa re it to the vo lt age
m easured at t he ECM co nnec t o r.
If th e peak voltag e measu red at t he ECM is
ab normal and t he one m eas ured at t he CKP sen-
sa r is no rma l, ch eck t he 2P (Red) co nnec to r f or
loose co nnectio n and t h e w ire harness fo r an
open circuit o r loose co nnect ion.
If bot h peak vol tage measu red are abn orma l,
check each ite m in th e troubl esho otin g chart
(page 18-4). If all it ems are norm al, t he CKP sen - L -----'
sa r is fau lty. See f o llow in g st ep s fo r CKP [cran k-
shaft po sit io n) se nso r re placement.
CKP (CRANKSHAFT POSITION) SEN-

SOR
REPLACEMENT
Remove t he right crankcase cover (p age 10 15).
Remove t he w ir e grom me t from th e cove r.
Rem o v e t he bo lts and CKP sensor.
App ly sea lant to the g rommet seat ing surface.
Inst all a new CKP sensor and th e gr ommet into t he
cove r g ro ov e properl y .
T ig ht en th e m ount ing bo lts sec ure ly. .,(lmJll
Route t he CKP senso r wir e into th e groove of th e
rig ht cran kcase cove r. GROM M ET
Inst all th e was he r and bo lt. th en tighte n th e bolt
secu rely.
Inst all th e right cra nkcase co ver (page 10-34 ).
IGNITION TIMING
Remove the under cowls (p age 3-7).
Wa rm up the engine.
Stop the engine and rem o v e t he t im ing ho le cap.
18-7
Contents Chapter 18
IGNITION SYSTEM
Read the insrruc- Rem ove the i nt ake air du ct (refe r to t he spark p lu g
(ions for tim ing fight removal; pa g e 4-8) a nd co n nect th e tim ing ligh t to
operation. th e No. 1 di rect ig nitio n coil co n nec tor wi re .
St art t he engi ne, let it id le and check t he igniti on
ti m ing.
IDLE SPEED: 1,200 100 rpm
The ignition tim ing is co r rect if t he " Fit m ar k on th e

CK P senso r rotor aligns w ith t he ind ex m ark on t he
ri ght cran kcase cove r at id le.
Increase t he engine speed by tu rn ing t he t hrott le
stop screw and m ake su re th e "F" m ark begin s to
m o v e counterclockwise .
Apply oil to th e Ovrinq .

Check that the 0- Ap ply g rease t o th e ti mi ng hol e cap th reads an d
ring is in good con- insta ll t he O-r ing and ti mi ng ho le cap .
ditian, replace it if
necessary
Tig hte n t he t im ing hol e ca p t o -the spec if ied torque .
TORQUE: 18 Nrn (1.8 kqf-rn, 13 Ibf.ft)
Rem o ve th e un der co w ls (pag e 37 ).
18-8
Contents Chapter 18
19. ELECTRIC STARTER
SYSTEM DIAGRAM.. 19-2 STARTER MOTOR 19-6
SERVICE INFORMATION 19-3 STARTER RELAY SWITCH 19-13
TROUBLESHOOTING 19-4 DIODE .. 19-14
19-1
Contents Chapter 19
ELECTRIC STARTER
SYSTEM DIAGRAM
ENG INE STOP SWITCH
IGN ITION SWITC H
STARTER SW ITCH
STARTER RELAY SW ITCH/

MAIN FUSE
FUSE BOX/DIODE
STARTER M OTOR
SIDE STAND SW ITCH

NEUT RAL SW ITCH
STARTER RELAY SW ITCH
STA RT ER
M OTOR MAIN
EEl e
BATIE RY
FUSE
I30A)
CLUTCH IGNITION
I
SW ITCH
<,
BI -{) ~ BI -~- G/R
1
G/R SWITCH
>
R--<Y" 0- R/BI ~R:J
FUSE 10A
GAN VIR
I
~
SI D E STAN~P g~~~~H i L---S-TA-RT-~ BII R
G/R
ODO WO
SWITCH
~
L A
Lg ---~l----l
-
BI
Y
BLACK
YELLOW
G GREEN
NEUTRAL Lg LIGHT GREEN
R RED
SWITCH
W WHITE
19-2
Contents Chapter 19
ELECTRIC STARTER
SERVICE INFORMATION
GEN ERAL
I NOTICE
If the current is kept flowi ng through the sta rter motor to turn it wh ile the eng ine is not cranking over, the starter m otor
may be dam aged .
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious
injury .
The starter motor can be serviced wi th the engine in the fra me.
Whe n checking the starter system. alw ays follow the steps in the troubleshooting flow chart (page 19-4).
A w eak battery may be unabl e to turn the starter motor quickly enough , or supply adequate ignit ion current.
Refer to the starter clutch servicing (page 1028).
Refer to the foll ow ing com ponents informations.
- Ig nition swit ch (p age 20-18 )
- Starter sw itc h (page 20-19)
- Ne ut ral switc h (page 20-21)
- Side sta nd swi t ch (pag e 20-221
- Clut ch switc h (p age 20-211
SPECIFICAT IONS
Unit : mm (in)
Starter motor bru sh length 12.0 - 13.0 10.47 - 0.51) 6.510 .261
TORQUE VALUES
Starte r m otor ter m inal nut 12 Nm 11.2 kqf- rn, 9 Ibf.ftl
19-3
Contents Chapter 19
ELECTRIC STARTER
TROUBLESHOOTING
Starter motor does not turn
1. Fus e Inspection
Check for blown main fuse or sub fuse.
Is the fuse b lown ?
YES - Replace th e fuse
NO - GO TO STEP 2.
2. Battery Inspect io n
M ake sure the batte ry is f ully cha rge d and in good co nd it io n.
Is the battery in good co ndition ?
YES - GO TO STEP 3.
NO - Replace t he battery
3. Starter Relay Switch Operation
Check th e sta rte r relay switch operation.
You should hea r the relay "CLICK" when t he engine sta rte r switch button is depress ed.
Is there a " CLICK"?
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. Starter Motor Inspection
App ly batte ry vo lt ag e t o the st a rte r m oto r d ir ect ly and chec k the o pe ratio n.
Does the starter motor turn?
YES _. Poorl y co nne ct ed sta rt er motor cabl e
Faul ty start er rel ay sw it ch (pag e 19 3) 41
NO - Fault y st arte r moto r (pag e 19-61

5. Rel ay Coil Ground Wir e lin es Ins p ection
Disconn ect the sta rte r relay switch con n ector, and check th e relay co il groun d w ire lines as below f or
continuity:
1. Green/Red terminal - clutc h diode - neutral swi tch line (with t he transmission in n eutral and
clutch lev er released) .
2. Green/Red terminal - clutch switch - side stand switch line (in any gea r except ne utra l. and wi t h
the clutch lever pulled in and the side stand up .
NO _. Faulty neut ra l switch (page 20-21)
Fau lty clutch d iode (page 19- 14)
Faulty clutc h switc h (page 20-21 )
Faulty sid e sta nd switch (page 2022)
Loose or poor co ntac t co nnector
Op en ci rcui t in wire ha rn ess
YES - GO TO STEP 6.
6. Starter Relay Voltage Inspection
Co nnect t he sta rte r relay swi tc h con nec to r.
W ith t h e ig nitio n sw it ch ON and the sta rt er switc h pushed, me asu re the vo ltage at th e sta rter relay
switch co nnector (between Yellow/Red (+) and body g ro und (-ll.
Is the start er relay switch operation correct?
NO -. Fau lty ignition switch (page 20-18)
Faulty starter switch (page 20- 19)
Loose o r poor co nt act co nnector
Ope n ci rcuit in wire harn ess
YES - GO TO STEP 7.

ELECTRIC STARTER
7. St arter Relay S w itch Continu ity Inspection
Disconnect the starter relay sw itch 4P co nnector and cables.
Connect a fully cha rge d 12 V battery po sit ive w ir e to t he relay switch Yellow/red w ir e t erm in al and
negative wire to the Gr een/red w ir e t er minal.
Check t he co nti nuit y between t he starter relay swi tc h large term ina ls whi le th e batte ry connected .
Is there continuit y?
NO - Fault y st art er relay sw it ch
YES - Loose or po or contact of th e st art er relay sw itc h 4P connecto r
The sta rt e r motor turns when the tran smission is in neutra l, but does not turn with t he tran smiss ion in
any po sition except neutral, with th e sid e stand u p and the clutch lever pull ed in.
1. Clutch Switch Insp ection
Check t he clu tch switch operat ion.
Is the clutch switch operation norm al?
NO - Fau lty clutch switch
YES - GO TO STEP 2.
2. Side Stan d Switch Inspection
Check t he sid e st and sw itch ope rat io n.
Is th e s ide stand s w it ch operation normal?
NO - Faulty side stand sw itch (p age 20-2 21
YES - Open ci rcuit in wire harness
Loose or p oor co nt act co nnect o r
Starter motor turns engi ne slo w ly
Low battery vo ltage
Poo rly co nnected batt ery te rm inal cables
Poor ly co nnec ted sta rte r mo t o r cab le
Fault y sta rte r motor
Poor ly co nn ecte d batte ry grou nd cable
St art er motor t urn s, but eng ine does not turn
St arter motor is running backwa rd s
- St arter m ot or assembl ed im pro perly
- Term inals co nnect ed improperly
Fau lt y sta rte r clutch
Damag ed o r f aulty sta rt er d riv en gear, idle gear an d/or redu cti on gear
Starter re lay sw itch "Clicks" , but eng in e does not turn over
Cranks haft does no t tu rn due to engin e pr oblem s
19-5
Contents Chapter 19
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
W ith the ignition sw it ch OFF, rem ove th e nega-
ti v e cab le at th e battery befo re servi cing t h e
sta rter m o t or.
Rem o ve the EGCV servo m o t o r (page 6-78 ).
Rem o ve th e ru bber cap , te r m ina l nut and st arter
m otor cable.
Rem ove the tw o m ounti ng bolts and ground cable.
Rem ove th e sta rte r motor fr o m t he crankcase.

Rem o ve the a-rin g from t h e sta rte r moto r.

ELECTRIC STARTER
DISASSEMBLY
Rem ov e the f o llowin g:
CAS E BOLTS/a-R INGS
- Starter motor case bo lts/Ovrinqs
Record the location - Fro nt cove r

and number of - Seal rin g FRONT COVER
shims . - Lock was he r
- In sulated washe r
- Shi mts)
SHIMIS ) LOCK WAS HER
Record the location - Rea r cove r assemb ly

and number of - Sea l ring SEA L RING REAR COVER AS SEMBLY
shims. Shim ts)
- A rm at u re
ARMATURE
INSPECTION
Check the b ush ing in t he rear cove r fo r wea r o r
damage.
BUSHING

ELECTRIC STARTER
Check the oil seal and need le bea ring in t he fr ont
cover f o r det eri o rat io n, wear or damage. OIL SEAL
Do not use emery Check the commutator bars of the armature f or di s-

or sand paper on co loratio n. ARM ATUR E
the commutetor.
COMMUTATOR BA RS
Chec k f o r co nti n ui ty between pair s of com mut ator

bars.
There sho uld be cont inui ty .
Check fo r continu it y between each co m m uta t or bar

and the armature shaft.
Th ere shoul d be no co nti nu ity.
19-8
Contents Chapter 19
ELECTRIC STARTER
Chec k fo r co nt in u ity betw een th e insul at ed br us h
and cab le te rm ina l.
There sho ul d be co nt inuity.
IN SULATED BRUSH
Check fo r continuity betwe en the cable terminal and

t he rear cove r.
There should be no co nti nuity .
Record the location Rem ove the f o llo w ing :

and number of insu-
- Nut
lators .
- Was he r
- In su lato rs
- O-r ing
- Brush ho lder assembly
Remove the b rush spring s and brushes f rom the

bru sh holder. BRUSH HOLDER BRUSHES
Contents 19-9
Chapter 19
ELECTRIC STARTER
Inspect th e brushes for damage and meas ure the
br ush length.
ASSEMBLY
REAR COVER
....
S!1 a-RING~ ~/~. h ') e
I
BRUSH SPRING
INSU LATORS ~(j) :' ~,/ ,tiJ " ARMATURE
WAS HER ~"" ,tiJ
/ '- ~~~ /-._ BRUSH

S~ SEAL RING
NUT // "' -,
e.. ~ Q
/' \
~ ,i r
~
SHIMS
INSULATED WASH ER
LOCK WAS HER
FRONT COVER
Install the brushes and brush springs to the brush BRUSH HOLDER BRUSHES
holder,
BRUS H SPRINGS
19-10
Contents Chapter 19
ELECTRIC STARTER
Install th e cable te rm inal and b rus h ho ld er into t he
rea r cove r, alignin g t he ho lder t ab with t h e rea r
cover groove.
Install the insulators Instal l th e fo llowing :

properly as noted
- New O-ring
durin g removal.
- Insulators S~
- W asher O-RING
- Nut
/ WAS HER
BRUS H HOLDER
jo~
P o/
I. NUT
INSU LATORS
Install t he ar mature in the m oto r case.

A RMATU RE
W he n in st alli ng th e ar ma t ure int o th e m ot or case,
hold t he arm atu re ti g htl y to keep th e m agn et of t h e
case from pulling th e armat ure ag ains t it.
I NOTICE I
The co il m ay be damag ed jf the magnet pulls the
armature against the case.
MOTOR CASE
Install the shims Inst all a new seal ring on to t he motor case .
properly as noted Inst all th e shim (s) o nto t he arm at ure sh aft . SEAL RING REAR COVER ASSEMB LY
\
during remova l, Ap ply t h in co at of g rease t o th e arma tu re shaft end.
Inst all the rear cover assem bly, w hile pu shing in th e
bru shes int o t he bru sh hold er and alig ni ng th e
bru sh ho lder t ab with th e m ot o r case groo ve.
ARMATURE SHIM IS I
19-11
Contents Chapter 19
ELECTRIC STARTER
InSTall the shims Ins ta ll the shim (s) an d ins u lated w as he r onto th e
FRONT COVER
properly as noted a rmature s ha ft.
during remo val. Install a new seal ring o nt o the motor case .
A pp ly grease to th e oil sea l lip and nee dle bearing i n
th e fr ont cove r.
Inst all th e lock washer to the front cove r w it h th e
lo ck washe r tabs fa cing t o th e front cover, and
ins ta ll the m o nto the arma ture s haft .
SHIM (S) LOCK WA SHER
M ake su re t he in dex lines are aligned .

Inst all th e new O-rin gs onto th e m o tor case bolt s.
Inst all and t igh t en the cas e bolts secu re ly. S~
a-RINGS
Align
INSTALLATION
Coa t a new O ~r i ng w ith oil and ins tall it into the
sta rte r motor groove.
Inst all the st arter m otor into th e crankcase.
Ro ut e t he sta rte r motor cable and ground cable

prope rly (page 1-24 ).
Install t he grou nd cabl e and m ou nt ing bo lt s, and
t ight en the bolts secure ly.

ELECTRIC STARTER
Install the starter motor cable t o the te rmi nal, t hen
tighte n the te rmi na l n ut t o the specified t o rq ue.
TORQUE : 12 Nm 11 .2 kqt- rn, 9 Ibf.f t l

Insta ll the rubber cap securely .
Insta ll the EGCV servo motor (page 6-80 ).
STARTER RELAY SWITCH

OPERATION INSPECTION
Rem ov e t he dri v er seat (pag e 3-4 ).
Shi ft the transmiss ion into neut ral.
T urn t he ig nit ion swi tc h O N and eng ine stop sw itc h
"0 ".
Press t he starter switch butto n.
The coil is no r mal if the starte r relay switch clic ks.
If you don' t hea r the switc h "cl ick", inspect t he relay
switch using t he proced ure below.
GROUND LINE INSP ECTION

Disconn ect th e st arte r rel ay switch 4P co n ne ctor:
RELAY SW ITCH 4P CONN ECTOR
Check f o r continu ity between the Gre en/red wire
(g ro u nd line ) and body ground.
If the re is co nt inuity w hen the t ra nsmission IS In
neutral and clutch lever released or w hen t he cl utch
leve r pu ll ed and the side stand up, t he g ro und cir-
cuit is no r m al (In neutral, there is a sl ight resi st ance
due to the d iode).
STARTER RELAY VOLTAGE

INSPECTION
Con nect the starter relay switc h 4P co nn ector.
Sh ift t he t rans m ission into neutra l.
Measu re t he vo ltag e betwee n t he Ye llow/re d wire
termina l (+) and ground (-).
If t he battery voltage appears o n ly w hen t he start er
switch is pushed w ith the ign iti on switch ON and
eng ine stop switch " n ",
it is normal.
4P CONNE CTOR

ELECTRIC STARTER
CONTINUITY INSPECTION
Disconnect th e starter relay swi tch 4P connecto r , -- -- - - -- - - - - - - - - ---.
and cables.
Connect a full y charged 12 V battery positive w ire t o
t he relay switc h Yellow/red w i re te rminal and nega -
tive wi re to the Gr een/red wi re t erm inal.
There sho uld be co nt inuity between t he lar ge t erm i-
o 0
nals w hile th e battery is co nn ected , and no co nt inu-
it y w he n th e batte ry is d iscon nect ed.
BATIE RY
STARTER RELAY SWI TCH
DIODE
Remove th e left mid dle cowl (p age 3-7 )
Open the fuse box and remove the diode.
Install t he diode in the reve rse order o f rem ov al.
INSPECTION
Check f or co nt inui ty between the diode t erm in als.
W hen th ere is continuity, a sm all resist ance value
will reg ister.
If th ere is cont inuity, in one direct ion, the diode is
no rmal.
~I i ,,,+ C
!
C B
19-14
Contents Chapter 19
20. LIGHTS/METERS/SWITCHES
SYSTEM LOCATION...... 20-2 EOP (ENGINE OIL PRESSURE) SWITCH ..20-15
SERVICE INFORMATION 20-3 FUEL RESERVE SENSOR 2017
HEADLIGHT...................................... 20-5 IGNITION SWITCH 20 18
POSITION LIGHT 20-6 HANDLEBAR SWITCHES 20-19
TURN SIGNAL 20-7 BRAKE LIGHT SWITCH 20-20
TAIl/BRAKE LIGHT 20-8 CLUTCH SWITCH ..20-21
LICENSE LIGHT 20-9 NEUTRAL SWITCH ........................20-21
COMBINATION METER .. 20-10 SIDE STAND SWITCH 20-22
SPEEDOMETERIVEHICLE SPEED HORN ..........................................2024

SENSOR 20-11
TURN SIGNAL RELAY 20-24
TACHOMETER 20-13
HEADLIGHT RELAY .... 20-25
ECT SENSOR 20-14
E

L1GHTS/M ET ERS/ SW ITCHES
SYSTEM LOCATION
RIGHT HAN DLEBAR SWITCH
IGNITION SW ITCH
HORN
LEFT ECT SENSOR
HANDLEBAR
SW ITCH
VEHICLE SPEED SENSOR IVSS)
EOP (EN GINE OI L PRESSURE) SW ITCH
NEUTRAL SW ITCH
SIDE STAND SW ITCH
REAR BRAKE LIGHT SWI TCH

SERVICE INFORMATION
GENERAL
NOTICE
A halogen headlight bulb becomes very hot while the headligh t is ON, and remains hot for a while after it is turned OFF.
Be sure to let it cool down before servicing.
Note the following w hen replacing the halogen headlight bulb.
- Wear clean gloves while replacing the bulb. Do no t put finger prints 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 w ith a cloth moistened with den atured alcohol to prevent its early
failure.
- Be sure to install the dust cover aft er replacing the bulb.
Use an electric heating element to heat the wate r/coolant m ixtur e fo r the ECT sensor inspection. Keep flamma ble mate-
rials aw ay from the electric heating elemen t. Wea r protective clothi ng, insulated gloves and eye protectio n.
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 mo torcyc le.
The fo llowing color codes are used through out this section.
Bu = Blue G = Gree n Lg = Light Green R = Red
BI = Black Gr = Gray 0= Orang e W=White
Br = Brown Lb = Lig ht Blue P = Pink Y = Yellow
SPECIFICATIONS
IT EM SPECIFICATION S
Bulbs Headlig ht I Hi 12V-55W
I Lo 12V -55W
Position light 12 V 5W
Tail/brake li ght LED
Front turn signa l lig ht 12 V - 23/8 W (32/3 cp) x 2
Rear tu rn signal light 12 V - 23 W x 2
Instrum ent light LED
Turn signal indicator LED
High beam indicato r LED
Neutral indicator LED
Ma lfunction indicator lamp (M IL) LED
Fuse Mai n fuse 30 A
PGM -FI fuse 20 A
Sub fuse lOA x 4, 20 A x 2
Tachometer peak voltage 10.5 V mi nimum
ECT sensor resistance I 80C (176F) 2.1 - 2.6 kO
I 120C (248FI 0.65 0.73 kO
TORQUE VALUES
EOP (Engine Oil Pressure) switch 12 Nrn (1.2 kqf-rn , 9 Ibf.ft) Apply sealant to the threads
EOP switch wire terminal screw 2.0 Nm (0.2 kqf-rn . 1.4 lb t.tt)
Ne utral switch 12 Nm (1.2 kpf- rn. 9 lbHt)
Ignition switch mo unting one-way bolt 26 Nrn (2.7 kqf- m. 20 lb f -ft )
Right handlebar switch screw 0.9 Nrn (0.09 kgfm , 0.7 Ibf.ft)
Combination meter assembly screw 1.0 Nm (0.1 kqf- rn. 0.7 lbfft)
Side stand switch special bolt 9.8 Nrn (1.0 kqf -rn. 7 Ibf.ft) ALoe bolt; replace w ith a new one
Contents Chapter 20
20-3
TOOLS
Peak volt age adapto r IgnitionMate pea k vo ltage teste r Inspection adaptor
07HGJ-0020100 MTP07-0286 (U.S.A. o nly) 07GMJ -M L80100
(not avail able in U.S.A.)
w ith commercially ava ilable digital

m u lt im et er (im peda nce 10 M OJDCV
minimum )

HEADLIGHT
BULB REPLACEMENT
Discon nect t he head light b ulb co n necto r.
Rem ov e t he d ust cov er.
Un hook the b u lb retainer and rem o ve t he headl igh t :;=;;;;~~

bulb/so cket.
Rem ove t he headlight bu lb from the so cket .

BULB SOCK ET
Instal l new bu lb int o th e so cket .
\
I NOTICE I
Avoid touching th e halog en headligh t bulb. Fing er
prints can cr eate hot sp ots that cause a bulb to _ _......-,;;:;
break.
If you touch the bulb w ith yo ur bare ha nds, cl ean it
w ith a cl oth m oisten ed w ith den atured alc oh ol to
/
prevent earl y bu lb fai lu re.
In st all th e new head light b ulb /so cket aligni ng its t ab

w it h th e g roov e in th e head light un it , and ho ok t he
bulb reta iner properly.
20-5
Contents Chapter 20
LIGHTS/ M ETERS/ SW ITCHES
Inst all the d ust cove r tightly against t he headl ig ht
un it with its arrow ma rk f aci ng up.
Conn ect t he head lig ht bul b connector.
Rem o ve the u ppe r cowl (pag e 3-12),
Remove th e nut s and bank an gl e se nso r.
Rem ov e t he f iv e sc rew s/w ashers and hea d light unit.

Rout e the wire har- In st all the hea dlig ht un it in the reve rse o rd er of
ness properly rem ov al.
(page 1-24).
POSITION LIGHT
BULB REPLACEMENT
Remove t he w in dsc ree n (page 3- 12),
Rem ov e t he sc rews an d posit ion light le ns.
20 -6
Contents Chapter 20
Rem o v e th e bu lb from t he so cket, and re place it
w ith new o ne.
Inst all th e removed pa rts in the rev erse ord er of
removal.
TURN SIGNAL
BULB REPLACEMENT
Rem ov e t he scr ew , tu rn signal li g ht len s an d seal
rubber.
While pushing in, turn the bulb cou nterclockwise to

remove it and replace with new one.
Inst all th e seal ru bb er o nt o t he turn sig nal lig ht

case.
Inst al l the lens by alig ni ng th e len s ta b with t he turn
signal light case g roove, and tig hte n th e screw
secu rely.

For front turn signal li ght re m ov al, remove th e mi d-
d le cowl s (pag e 3-7).
Rem ov e the nut, setting plate and th e turn si gn al
lig ht from the middle cowl.
Inst all th e turn signa l light in the rev er se o rde r of
rem oval.
Fo r rear t u rn si g nal removal. see rear f en d er A di s-
assem bly (page 3-20 ).
TAI L/ BRAK E LIGHT

INSPECTION
Tu rn th e ig n it io n switch ON , an d che ck th e t ailli ght
o pe rat io n.
Check that all LED in th e ta il/brake lig ht un it light
illuminate w it h t he front b rake lev e r and/or rear
b rak e pedal applied.
If any LE D d o e s not turn on, repla ce th e ta il/brake
li g ht assem b ly.
Remove the rea r seat cowl (page 3-5 ).
TAIUBRAKE LIGHT U NIT
Remove the tail/b rake light unit mountin g scre ws.
Pull ou t t he ta bs f ro m the g ro oves of rear sea t co w l,
th en rem ove the tai l/brake light unit.
Install th e t ail/brake light un it o nto th e rear seat
cowl w hi le alig ni ng the tab s w it h groove o f th e rear
seat cowl.
Inst allat ion is in the re verse o rde r of re m ova l.
SCREWS
20-8
Contents Chapter 20
LICENSE LIGHT
BULB REPLACEMENT
Remove the two nuts a nd wire cla m p.
Remove th e two screws and joint plate.

Remove the two nuts and lens cover.
Turn the license light bulb socket coun terclockwise

and remo v e it fro m t he len s cover.
Rem ov e t he bulb fro m the soc ket, repl ace it wit h
new one.
Inst all th e lice nse li gh t bul b soc ket and lens co v er in

th e reve rse o rder of rem o v al.
SEA L RUBBER LENS COVE R
20-9
Contents Chapter 20
COMBINATION METER
Rem ove th e upper co wl (page 3-12).
Remove th e t hree screws/wa shers and co m bin at io n
met er from th e br acket .
Inst all t he co m bi na t io n m et er in the rev erse o rd er of
rem ov al.
Remove t he screws.
Rem ove the m et er up per case, circuit board and

lower case.
As sem ble the m eter upper case, circuit board and
lower case, then t igh t en the sc rews to the specifie d
to rq ue.
TORQU E: 1.0 N 'm (0.1 kgf -m , 0.7 lbf-tt]
LOWER CAS E
20-10
Contents Chapter 20
POWER/GROUND LINES INSPECTION
Check the following at the w ire harness si de co n-
nector terminals of the com bination m et er.
Pow er in put lin e
M easu re t he v o lta ge betwe en th e B rown/w h ite w ire
term inal (+) and body grou nd I-I .
The re sho uld be battery vo ltage with th e ig nitio n
switch ON .
If the re is no voltaqe, check the sub-fuse 110 AI and
an ope n circuit in Brownlwhite wi re.
Back-up voltag e line
Measure t he voltage betwe en t he Red /gr een w ire
terminal (+1 and body grou nd H .
There should be battery voltage at all times.
If the re is no voltage , check t he sub -fuse (10 A) and
an op en circuit in Red/g reen wire.
Groun d line
Measure t he contin uity betwee n the G reen wire ter-
minal (+1and body ground (- ). VIEWED FROM TERMINAL SIDE:
There should be continuity at all times. ~
If the re is no cont in uity, check for o pen circuit in
Gree n wi re.
Sen sor g r o u nd li n e
Measure the continuity between t he Green /black
wire terminal (+l and body ground (-) .
The re sho ul d be continu ity at all times.
If th ere is no contin uity, chec k fo r open circ uit in
Green/bla ck wi re.
SPEEDOMETER/VEHICLE SPEED
SENSOR
SYSTEM INSPECTION
Check t hat t he tachometer and coolant temperatu re
meter function properly.
If t hey do not fun cti on , perfo rm th e po w er and
gro und line ins pec t io n of t he co mbina t ion me te r
(page 20-11).
If they function, rem ov e the dust cover and dis-
connect t he com bination me ter 20P (Blackl con -
nectar. Shift th e tran sm ission into neutral and
turn t he ig nition switch ON .
Measur e t he v o lt age betw een t he Pink (+) and
Gr een/black (-) wire t erm in als of the w ire ha r-
ness side connector.
Slowly turn the rear wheel by hand .
Th ere should be 0 to 5 V pu lse vo ltaqe.
- If pulse v oltage appea rs, replace th e com binat io n
m eter printe d circuit board (page 2010 ).
- If pu lse vo ltage does not appea r, chec k fo r ope n
or short circuit in the Pink wire.
If the Pink wire is OK, check the vehicle speed
sensor I page 20-12) .
20-11
Contents Chapter 20
VEHICLE SPEED SENSOR (VSS)
INSPECTION
Lift and support the f ue l t an k (page 4-5).
Disco nnect t he VSS 3P (Na t ural) con nect or.
Measu re t he voltage between t he Brow n/w hite (+)
and Gree n/black (- ) wi re t erm i nal s at the harness
si de 3P connecto r.
CONNECTION: Brown /white (+) - Green /b lack (-)
STANDARD: Battery voltage
There sho uld be battery vo lt age w ith t he igni t ion

switch ON.
If there is no vol tag e, chec k f or open circ uit in
relat ed wires .
If t he re is voltage, check t he VSS as fol lows.
3P (NATURA L) CONNECTOR
Support the moto rcy cle sec u rely using a saf ety
sta nd or ho ist, and raise the rear w hee l off t he 3P (NATURAl)
grou nd. CON NECTOR
Con nect t he inspection adaptor to t he senso r 3P

con nec to rs. RED CLIP (+)
TOOL: (PINK W IRE)
Inspection adaptor 07GMJ-ML80100
Measure t he v oltage betw een the Red cl ip (+) and
White clip I-I .
CONNECTION : Red clip (+) - White cli p (-)
STANDARD: Repeat 0 to 5 V INSPECT ION W HITE CLIP (-)
ADAP TO R (GREEN/BLACK WIR E)
Shift the transmission into neutral an d tu rn t he ig ni-
t ion switch ON.
Slo wly t u rn the rear w hee l by hand .
The re shou ld be 0 t o 5 V p u lse vo lt age .
If the pulse vo ltage does n ot appear, rep lace the
VSS (page 20-12).
Lift and support t he f ue l t an k (pag e 4-5 ).
Remove the VSS 3P (Nat u ral) co nnecto r from the
stay and discon nect t he co nn ect or.
Remove t he bolt, sta y and VSS.
i
n
}\
/1
3P (NATU RAL) CON NECTOR
20-12
Contents Chapter 20
Check the condition of the O-r ing, repl ace it if neces-
sary.
Install the VSS in to the u pper crankcase.
Inst all the stay and t ighten th e bolt secu re ly.

Roure the EGCV Co nnect th e VSS 3P (Natu ral) co nnec t or and in stall
servo motor cable it to t he stay .
and fuel tank
brea ther tube prop-
erly (page 1-24).
3P(NATURALICONN ECTOR
TACHOMETER
SYSTEM INSPECTION
Check fo r loos e or poo r contact ter min a ls at t he
combination meter 20P (Blac k) connector and
front sub-harness 22P co nnector.
Turn the ignition switch ON, check that t he tachom -
eter needle moves to full scale and the n ret urn s t o
zero .
If th e need le does no t show ini tia l fun ct io n, check
the co mbinat io n m et er power inp ut line
(page 20-11).

Remove t he windscree n (page 3-12) and ex pose the
20P (BLACK) CON N ECTO R
combination meter 20P (Black) co nnector.
Connect the peak voltage tester or adaptor probes
to the tachomete r Yellow/g reen terminal and body
ground .
TOOLS :
IgnitionMate peak voltage tester MTP-0286
(U.S .A . only) or
Peak v oltage adaptor 07HGJ-0020100
[not availab le in
U .S.A .I
with commercially available digital multimeter
(imp ed anc e 10 MQ/DCV m inimum)
CONNECTION : Yell ow / gree n (+1 - bod y ground (-)
Start the engi ne a nd me asure t he ta ch ometer inp ut

peak voltage.
PEAK VOLTAGE: 10.5 V minim um
If the peak voltage is normal, replace the co mbina-

tion m eter p rinted ci rcuit board (p ag e 20-10).
If the measu red value is bel ow 10.5 V. rep lace the
ECM (page 6-691.
If the va lue is 0 V, check for contin uity betwee n th e
co m bination meter zap (Black) co nnecto r and ECM
32P (Lig ht gray) co nnecto r Ye llow/g reen te rmi na ls.
If the re is no continuit y, ch eck th e wire h arness and
front sub- h arn ess f o r an open ci rcu it.
If t he re is co nti nuit y, replace the ECM (page 6-69).
ECT SENSOR
Drain th e coo lan t (page 7-6 ).
Disco nn ect th e 3P co nnector and rem ov e th e ECT
se nso r fro m t he the r mostat ho usin g .
20-14
Contents Chapter 20
Alwa ys replace the Install t he ECT sen sor with new sea ling washer and
sealing wash er with tighten it t o th e specified t orqu e.
a new one.
TORQUE: 23 Nm (2.3 kqf-m, 17 Ibf.ft)
Co nn ect the ECT sen sor 3P connect or.
Fil l the system wit h recom m ended coo lant and
bleed the air (page 7-61.
INSPECTION
Susp end the ECT sen sor in a pan of coolant (50 - 50
m ixture) on an ele ctric heati ng el ement an d m ea-
sure t he resistance th roug h the sensor as t he co ol -
ant h eats up.
Soak the EeT senso r in co olant up to it s thread s
w it h at least 40 mm (1.6 in ) fro m th e bottom of
the pa n t o t he bo tto m of th e sens o r.
Keep the t emperature con st ant fo r 3 minutes
bef or e testing . A sudde n ch an ge of t emp erature
w il l resu lt in incorrec t readi ngs. Do no t let the
th erm ometer o r ECT sen so r to uc h t he pan .
Repla ce th e sen so r if it is o ut of sp ecif icat io n by
m o re than 10% at any t emper ature list ed.
ECT SENSOR
Temp erature 120'C (248'F)
Resistance 2.1 2.6 kQ 0.65 - 0.73 kQ
ECT SENSOR TERMINAL
EOP (ENGINE OIL PRESSURE) SWITCH

INSPECTION
If th e oil pressure warn ing indicator stays o n w hile , - - -- - - - - - - - - -- - - - - - - - ,
th e eng ine is run ning, chec k th e eng ine oil level
before t hi s i nspectio n (page 421).
M ake sur e that t he oil pressure w arn ing indicator
com es o n with th e ig nit io n switch ON .
20-15
Contents Chapter 20
If the indica to r do es not co me on , in sp ect as fol-
lows:
Rem o ve t he under cowls (pag e 3-7) .
Remov e th e d ust co v er.
Rem ove th e te r m ina l scre w and EOP swi tc h wire.
Sh ort t he EOP switch w ire to g round using a jumper

wire.
Th e o il pressure w arn ing i ndicato r sho uld come on
wh en t h e ig ni tio n swit ch is O N .
If th e ind icator does not come on , che ck t he sub -
fuse (10 Al and wi re s fo r a loose co nnectio n o r an
open circuit .
Con nect t he w ir e to t he EOP switch and start th e
engi ne, an d make su re th e indica tor g oes out.
If th e in dica to r does not go o ut, check the oi l pr es-
sure (page 5-51.
If the o il p ress u re is norma l, rep lace the EOP switch
(page 20-16 1.
Insta ll the under cowls (p age 3-71 .
Rem ove th e under cowls (pag e 3-7).
Release th e rear brake li ght sw itc h wi re from th e
clamp .
Rem ov e the d u st co v er, t er m ina l sc rew and w ir e.
Rem ov e t he EOP sw it ch w hile h o ld in g switch base.
Apply se alan t to t he EOP swi tch threads as shown.

Do not app ly sea la nt t o the thread
head 3 - 4 mm (0. 1 - 0 .2 in) .
. I
. .-
20-16
Contents Chapter 20
Insta ll th e EOP sw itc h onto th e switch base, t ight en
t he EOP switch to th e sp ecifie d t or qu e whi le ho ldin g
the sw itc h base.
TORQUE: 12 N'rn (1.2 kqf-rn, 9lbf.ftl
Conn ect th e EOP switch wire t o the sw itc h and

t ig ht en th e scr ew t o th e specified torq ue.
TORQUE : 2.0 Nrn (0.2 kq f-m, 1.4 Ibf.ft)

Insta ll t he dust cove r.
Clam p t he rear brake light switch wi re pr ope rly .

Inst all t he u nd er cowl s (page 3-9).
FUEL RESERVE SENSOR

FUEL RESERVE SENSOR INSPECTION
Fuel re serve indi cator doe s not g o off
Lift and su p po rt th e fuel t an k (pa ge 4-5 1.
Discon nect t he f uel p ump u nit 3P (Black) co nnecto r.
Tu rn t he igniti on switc h ON and chec k t he fu el
reserve indicato r.
If the indic ato r g oes o ff, repl ace t he f uel pu m p u ni t
(p age 6-34 1.
If t he indicat o r is sti ll on , check f or short circuit in
Bro wn/bl ack w ire bet w een t he fu el pump unit con -
nector an d co m bi natio n m et er.
20-17
Contents Chapter 20
Fuel re s erve in d icat or does n ot co me on
Before this inspection, perform the powe r and
grou nd line i nspectio n of the comb inatio n met e r
(page 20-11).
Disconn ect th e fu el pu mp unit 3P (Black) connect o r
and short th e wire harn ess sid e co nnect or Bro wn/
. b lac k and Gr een te rm inals w it h a j u m per wire.
Turn th e ign it io n swi tc h ON and c heck the indica t or.
If the indi cator co mes o n, replace th e fuel pump unit
(pag e 6-34) .
If the indicator does not come on, check for open
ci rcuit in Brow n/b lack wire between the fuel pump
unit connector and combination meter.
If they are OK, replace the combinatio n meter
(page 20-10 ).
IGNITION SWITCH
INSPECTION
Remov e t he air cleane r housi ng (page 6-40 ).
Rem o v e the trim clips and co n nector cove rs.
Disconnect the ignition switch wire 2P (Brown) con-

nector.
Check for contin uity between the wi re ter m inal s o f

t he ignition switch co n necto r in each switch po si-
t io n.
Co nti nu ity sho ul d ex ist bet w een t he co lo r co de d
w ires as f ol low :
<. IG BAT l KEY
ON 0--0 KEY ON
OFF KEY OFF

KEY OFF
LOCK LOCK PIN
COLOR R/BI R -
20-18
Contents Chapter 20
LIGHTS /METERS/SWITCHES
Rem ov e th e air clea ner housi ng (pag e 6AD) and
conn ector cov ers (pa ge 20-18).
Disconn ect th e ig nition sw it ch w ire 2P (B rown ) con-
nect o r.
Remove the t o p b ridge (p age 14- 11).

Rem ov e the mou nti ng bolts and ig nit ion switch.
In st all th e ign it io n swi tc h t o t he to p bri dge.
Ti g ht en th e new ig ni ti on sw itc h m ou nt ing bo lt s to
th e s pecifie d tor qu e .
TORQUE: 26 N vm (2.7 kqf -m , 20 lbf-ft]
In st all the rem o v ed parts in t he rev erse o rde r of

re moval.
HANDLEBAR SWITCHES
Rem ov e the air clea ne r housing (p ag e 6-40).
Disconn ect t he handlebar swit ch conne ctors .
- Right handlebar sw it ch: 8P (Na tural) co n necto r
- Left han dlebar sw itch: 12P (Gray) co n nec t or
Check f or contin ui ty between th e wire te r m inals o f
the hand leba r swi tc h con nect o r.
Co ntinuity sh ou ld ex ist betw een th e co lo r cod ed
wire termi nals as f oll ow s:
ENGINE STOP SWITCH:
<, IG BAT
OFF
RUN V KJ
COLO R BI W/ BI
STARTER SWITCH:
<, BAT ST H/L

FREE 0 -0
PUSH 0- f--O
COLOR BI/R Y/ R Bu/W
20-19
Contents Chapter 20
TURN SIGNAL SWITCH:
<, W R L P PR PL
R If- ~ ('. -,
N 0- --0- --0
L -n If- --{)
COLOR Gr Lb 0 Sr/W Lb/ W O/W
DIMMER SW ITCH:
<, HL Lo H;
Lo
(N) v
Hi 0 -0
COLOR Su/W W
HORN SW ITCH:
~ Ho SAT
FREE
PU SH 0- --0
COLOR S WIG
BRAKE LIGHT SWITCH

FRONT
Disconnect the front brake lig ht switch connectors
and chec k fo r contin uity between the ter minals .
There should be continuity w ith the brake leve r
app lied, and the re shoul d be no con tinuity w he n the
brake lever is release d.
REAR
Remove the right rnlddle cowl (page 3-7 ).
Disconnect the rear brake light switch 2P (Black)
connector.
20-20
Contents Chapter 20
Check f o r co ntinuity between the te rm i nals.
There should be cont in uity with the br ake pedal
applied, and there should be no continuity when the
brake pedal is released.
CLUTCH SWITCH
Disconnect t he clut ch switch connectors.
There should be continuity w it h th e clutch lev er
applied, and t here sho uld be no co nti nu ity when t he
clutc h lever is rel eased.
N EUTRA L SWITCH
Remove the exhaust pipe (page 3-30).
Discon nect the neutral switch co nnecto r fro m th e
switch.
Shih th e tran smi ssi on into neut ra l an d chec k f or

co nt inuity betw een t he Lig ht g reen wi re and bo dy
gro und .
There sho uld be con t inu ity w it h the t ran sm ission in
neut ral. and no co nt in uity w he n t he t ran smi ssio n is
in ge ar.

SIDE STAND SWITCH
INSPECTION
Remove t he lef t under and middle cowls (p age 3-7 ).
Remove th e wire ban d and pull out t he 2P (Green )
connecto r f rom t he connector boot.
Disco nnect the side stand switch 2P (Gree n) connec-

t or .
Check fo r con t inu ity between the wire t erm in als of
the side sta nd switch 2P (Green) connector.
Continuity sho uld exis t only when t he side stand is
up.
REMOVAL
--- - - Rem ov e the w ire ba nd and pullout t he 2P (Green)
co nnector f rom th e co nnector b oot (p age 20-22).
Disco nnect the side sta nd sw itch 2P (Green) connec-
tor.
Remove t he b olt and side sta nd switch.

INSTALLATION
Route the side stand sw itch wire properly
(page 1-24) .
Install the side sta nd swi tch by aligning t he switch
pi n wi t h the side stand hole and switch groove with
t he ret urn sp ring ho ldin g pi n.
Secure the s ide sta nd switch wit h a new bolt.

TORQUE: 9.8 Nm (1.0 kqf-m , 7 Ibfft)
Con nec t th e si d e sta nd switc h 2P (Gree n) co n nector.

Inst all th e 2P (Green) co nnecto r into the con nec tor
boot with regu lator/re ctifier 2P connecto r.
Bu ndl e th e co n nect or boots in th e w ire band .

Inst al l th e mid d le and und er co w ls (p age 3-9).
20-23
Contents Chapter 20
HORN
Disconn ect th e w ire co nnectors from the h orn .
Co nnect a 12 V batt ery to th e h orn t erm inal direct ly.
Th e horn is no rmal if it sou nd s w hen t he 12 V bat -
t ery is conn ect ed across t he horn terminal s.
TURN SIGNAL RELAY

INSPECTION
1. Re lated Circu it Inspectio n
Check t he fo llowing
- Burned bul b o r non-sp ecified wattage
- Blown fuse
- Ig nition switch (page 20-18) and t urn signal
switch f un ct ion (page 20-20 )
- Loose co nnec to r
Check th e above it ems .
Are t he above it em s in good condit ion 7
NO - Replace or rep air t he fa iled part{ s)
YES - GO TO STEP 2.
2. Turn Sign a l Circu it Inspectio n
Remove the u pper cowl (p ag e 3-12). th e n
re move the head lig ht unit fro m t he upper cowl
(p age 20-6) .
Dis connect the t urn sig na l 2P (Blac k) connecto r

and sho rt t he Gray and W hit e/g reen termi nals of
the wi re h arn ess sid e co nnec to r with a jum pe r
w ire.
Co nnect th e fro nt sub -h arn ess 22P con nec t or.
Turn t he ign ition sw it c h ON and check the tu rn
sig nal li ght by tu rni ng the t urn sig na l sw itc h on .
Does the ligh t co me on ?
YES _. Faulty turn sig na l rel ay
Loose or poor contact of the con nec-
to r te rm ina ls
NO - Op en cir cui t in relat ed w ires
20-24
Contents Chapter 20
L1GHTS/METERS/SWITCHE ~
HEADLIGHT RELAY
INSPECTION
Rem ove th e left m iddle cowl (page 3-7).
Remov e the relay box from the bra cket.
Rem ove the relay box (Blue) co nnect o r fro m th e

relay bo x, and th en remove t he head lig ht relay.
Conn ect an ohm m ete r to the fol lowing head light

HEAD LIGHT RELAY BATIERY
re lay termina ls .
CONNECTION: Black lred - Blue
Connect a 12 V batte ry to th e fo llow ing head light

relay termin al s.
CONNECTION: Whit e - Gre en
BI/R W
There sh ould be co nti nuity on ly w hen the 12 V bat-
~~~
t ery is connected.
If there is no conti nu ity w hen t he 12 V battery is
co nnect ed, repla ce th e headl ight relay .
Bu G
20-25
Contents Chapter 20
MEMO
Contents Chapter 20
21. WIRING DIAGRAM
A, AC, CM type .. .... 21-3
EI
21-1
Contents Chapter 21

WIRING DIAGRAM
A, AC, CM type :
PAIR SOLENO ID VALVE

INTAKE "'fRDUCT CONTROL SOLENOI D VAlVE
ECM
Ie
I lidl,!! 1111' I
'l ~ " " " r -
"''' ' ' '
RIGHT FRONTTURNSIGN.&.l. UGHT
12V32J3cp(23J8~~~~f. i= l--
POsmONLIGHT
r-
HEADUG~81 _
12VS5 W ~i1 li liu
I II 1ICfNSE 1IGHT
8r/ \~rt!-=C1J 12V51'1
RlGil REAR ruRN SIGIW.. uen

HEAOUGHT~ , _
12V55W~ --:'i=
~ l!=[))1 2V23W
12V3213ql(21'8~~.; -
III u :~iW-\:il ow, ""
TAlLL I"'!
LEFT FRONTTURNSIGNALLIGHT r-
BANKANGLE t1:Jll&-
SENSOR L..Jii/I. :.... ; 61 m ~~~ 1 2V23W
l EFT REAR TURN SIGNAL LIGHT
~c-
- FUSl: BOX
A 21:lA (HEADL IGHT STARTER)
B lOA tNEun w . OIL - TEll? r ACK)MfTER
TlIlN SIl1W. RElAY SPEEDOMETER POSITl OH IiETER LIGHT
TAI U IGHT)
C 10,\ (TURN SI GtW. FRONT. REAR BRAKE HORN)
ol OA (BANK ANGl...E SENSOR)
E lOA (FAN lIIOTOO)
F lOA (ODOMETER)
'-
at ..... ll...M:\'i
y YEl.LO'Il
1l1 Illl\l'!!\t
o ..... llRAItGE
Bu BUJE Lb L1Q1T SUE
G GREEN 19 L1Q1T 3RffN
r-- -- - - - - - - Sll Tett lmTINU ITY - - - - - - - -- - - A RED
, illiTE
P
Gt
P!I
GRAY
UiIlE s,~
, I ! Al l I P "
f1PIj SIG/l"l SlII TO' _ ~ ~ I 'CH IGlfIT I SlIITCt'
PflPl.. " Il. LO HI ji G' II KEY

00 "
: PP-H:~ co <>--<l
LO Il
-
L
. . ,." .. I '
.... . 1' .. ~
o030Z-MEL-67oo (A, eM t ype)
-7700 (Ae ty pe)

Contents Chapter 21
22. TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT LOW AND

TO START 22-2 IDLE SPEED 22-5
ENGINE LACKS POWER 22 -3 POOR PERFORMANCE AT HIGH SPEED 22-6
POOR HANDlING ....22 -6
Contents 22-1
Chapter 22
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Spark Plug Inspection
Rem ov e and inspect spark plug .
Are the spark plugs in go od condition?
NO _. Inco r rect spark pl ug heat range
Inco r rect spa rk p lug gap
D irty air cleaner
YES - GO TO STEP 2.
2. Spark Test
Perform spa rk te st .
A re there good sparks?
NO _. Lo o se o r discon nected i gn iti on system w ire
Faulty ig nitio n co il
Broken or shorted di rect ignitio n co il co nnector wire
Fau lty i gnition pul se generator
Fau lty en g ine stop switch
Faulty eng ine contro l m o dul e (ECM)
3. Fuel Pump Inspection
Check fo r ope ration of the f uel pu mp and inspect t he fuel flow.
Is the fuel pump unit normal?
NO - Fault y fuel pump u nit (page 6-33).
4. Programm ed Fuel Injection Sy stem Inspection
Check t he fuel injectio n system.
Is the fue l injection system normal?
NO - Faul t y f u el inj ect io n system (pag e 6-54, 6A3).
5. Cylinder compression In spection
Test the cylinder co mp ress i on .
Is the compression specified?
NO _ . Valve stuck open
Worn cyli n d er and piston rings
Damaged cy linde r head gasket
Seized valves
Im pr o p er va lve t iming
YES - GO TO STEP 6.
6. Engine Start Co nd iti o n
Sta rt by fo llowing no rma l p roce d ure.
Did the en gine s tart but s tops ?
YES Leaking intake ma n ifo ld
Leaki ng inta ke pipes
Faulty starte r valves
Im p ro p er i g ni ti o n t imi ng (Fa u lty ECM o r ig nit i on p uls e ge nerator)
Conta m inated f ue l
22-2
Contents Chapter 22
TROUBLESHOOTING
ENGINE LACKS POWER
1. Driv e Train In sp ect io n
Raise w heel off th e g ro un d and spi n by hand .
Did t he wheel spin fre el y?
NO - . Brak e dr agg ing
Wo rn or damaged w heel bearin gs
YES - GO TO STEP 2.
2. Tire Pr essure Ins p ecti on
Check the tire pressure.
Is the tire pressure correct?
NO _ . Faul ty tire valve
Pun ctured t ir e
YES - GO TO STEP 3.
3. Clutch In spection
Accele rate rapid ly, shift f rom first to secon d .
Did th e eng ine speed ch an ge acc ordingly when clutch is rele as ed?
NO - . Clutch slipping
Worn clutch discs/plates
Warped clutch discs/plates
Weak clutch sp ring
Additive in engine oil
YES - GO TO ST EP 4 .
4. Eng ine Perfo rm an ce Inspe cti on
Acce lerate li g ht ly .
Did th e Engin e speed increase ?
NO - . Dirty air clea ner
Restricted fuel flow
Clogged muffler
YES - GO TO STEP 5.
5. Sp ar k Plu g In sp ection
Remove and inspect spa rk p lugs.
Ar e the spark plugs in good co ndition?
NO _ . Plug s not serviced fr eque nt ly e no ug h
Incor rect spar k plu g heat rang e
Inco r rect spar k plu g gap
YES - GO TO STEP 6.
6. Eng in e Oil Ins pecti on
Check the o il lever and condition .
Is the en gine oil in good co ndition?
NO _ . Oil level too hig h
O il level t o o low
Co nta m ina te d oi l
YES - GO TO STEP 7.
7. Igniti on Timing In sp ection
Check th e ignit io n t iming.
Is the ignition tim ing as s pecified ?
NO _ . Faulty engine control module (ECM)
Faulty ig n iti o n pulse generator
Improper va lve timing
YES - GO TO STEP 8.
22-3
Contents Chapter 22
TROUBLESHOOTING
8 . Cylinder compression Inspection
Test the cy li nde r com press io n.
Is the compression as specified?
NO -. Valve clea ra nce t oo small
Valve st u ck o pen
Wo rn cy linder and p iston rings
Dam ag ed cyli nder head gasket
Improper valve timing
YES - GO TO STEP 9.
9. Fuel Pump In spectio n
Inspect t he fuel flow.
/5 the fuel pump unit normal?
NO - Fau lty fuel pump unit (page 6-33 ).
YES - GO TO STEP 10.
10. Programmed Fuel Injection System Ins pect io n
Check th e fu el inject io n syste m .
Is the fuel injection s ys te m normal?
NO - Fau lt y f uel injection sys te m (pag e 6-54, 6-4 3).
, 1. lubrication Inspection
Rem ov e cy li nd e r head cove r and in sp ect lu b r ica tio n.
Is the valve train lubricated properly?
NO _. Fau lty oil pum p
Fau lty pr essure reg ul at o r v a lv e
Clo gged o il st rainer
Clogg ed o il pass ag e
12. Ov er Heating In spection
Chec k for eng ine over heat in g .
Is the engine over heating ?
YES Co o la nt lev el t o o lo w
Fan m ot or not wo rk ing
Thermostat stuck closed
Ex cessiv e car bo n bui ld-up in co m b ustion cham ber
Use of po or q u ality f uel
Wron g type of fue l
Clutch slipping
NO - GO TO STEP 13.
13. Eng in e Knocking Inspection
Accelerate or r un at high speed .
Is the engine knocking?
YES _ . Worn piston and cylinder
Wro ng t yp e o f f u el
Excessiv e ca rbon buil d-up in combus tion cha m be r
Ig n it ion tim in g too advance (Faulty ECM )
Fau lty ig ni t io n pu lse generator
Fau lty cam pulse generator
NO _. Eng in e does not kno ck
22-4
Contents Chapter 22
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Spark Plug Inspection
Rem ov e and ins pect sp ark plugs.
Are the spark plugs in good condition 7
NO - . Plu gs no t serviced freq uently enoug h
Incorrect spark plug heat range
Incorr ect spark plu g ga p
YES - GO TO STEP 2.
2 . Ignition Timing Inspection
Chec k th e ign iti o n ti mi ng .
Is the ignition timing as specified?
NO - . Faulty engi ne cont rol mod ule (ECM)
Faul ty ignition pulse generator
Faulty cam pulse ge nerator
Faul ty vehicle spee d sensor
Im prope r va lve tim ing
YES - GO TO STEP 3.
3. Fuel Pump Inspection
Inspect the fue l fl ow .
Is the fuel pump unit normal?
NO - Faulty fuel pump unit (page 6-331.
YES - GO TO STEP 4.
4. Programmed Fuel Injection System Inspection
Chec k t h e fu el inj ect ion sys te m .
Is the fuel injection system normal?
NO - Faulty fuel injection system (page 6-54, 6-43) .
YES - GO TO STEP 5.
5. Starter Valve Synchronization Inspection
Check the sta rte r va lve sy nc hro niza t io n.
Is th e starter valve synchronization as specified ?
NO - Ad ju st th e starter valve sy nc hronizat io n (page 6-6 1).
YES - GO TO STEP 6.
6. Intak e Pip es Le ak ing Ins pectio n
Check fo r leaks at the intake manifold pi pes.
Are th ere leaks?
YES _ . Loose in su lat or
Dam aged ins ulat o r

TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1. Ign it ion Timing Inspectio n
Check th e ignit io n ti m ing .
Is the ig n it io n timing as specified?
NO _. Faulty eng in e contro l modu le (EeM)
Fau lty ign iti on pulse generator
Fau lt y cam pul se gen erator
Fau lt y ve h icle sp eed sen sor
Improper va lve timin g
YES - GO TO STEP 2.
2. Fue l Pump Ins pect io n
Inspect t he f uel f lo w .
Is the fu el pump unit op eration norm al?
NO - Faulty fue l pump unit (page 6-33).
YES - GO TO STEP 3.
3 . Programm ed Fuel In j ect io n System In spection
Check t he fuel inj ect ion sys te m.
Is the fu el injection s ystem normally ?
NO - Fault y fue l injection sy stem (page 6-54, 6-43).
YES - GO TO STEP 4 .
4. Valv e Timin g Inspection
Check t he va lve t im ing.
Is the valve timing correct?
NO - Cam shafts not in st alled p roperl y
YES - GO TO STEP 5.
5. Va lve S p rin g In s p e ct io n
Check for the valve springs.
Is the va l ve sp r in g free l en gth as specifie d ?
NO - Fau lty v alve springs
YES - Not weak
POOR HANDLING
St eering is heavy
Faulty steeri ng damper (HESDI
Stee ring ste m adj ustin g n ut too tight
Dam ag ed stee ri ng head bea rin gs
Insufficient tire p re ssure
Either wh eel is w ob b li ng
Excessiv e whee l bea ring p lay
Bent rim
Sw ingarm p iv ot beari ng excessive ly worn
Be nt fr am e
The motorcycl e pull s to o ne sid e
Fro nt and rear w hee l not alig ned
Faulty sh oc k abso rber
Bent fo rk
Ben t swingarm
Ben t axle
Ben t frame
22-6
Contents Chapter 22
23. INDEX
AIR CLEANER 4-8 DIODE 19-14
AIR CLEANER HOUSING 6-40 DRIVE CHAIN 4-26
ALTERNATOR CHARGING COIL 17-8 ECT SENSOR
A LTERNATOR COVER INSTALLATION 11-7 FUEL SYSTEM (Pro g ram m ed Fuel Inject io n) 6-65
ALTERNATOR COVER REMOVA L 11-4 LIGHTS/METERS/SWITCHES 20-14
BALANCER 13-28 EGCV (Exhaust Gas Control Valve )
BANK ANGLE SENSOR 6-67 FUEL SYSTEM (programmed Fuel Injecti o n) 6-76
BATTERY 17-5 TECHNICA L FEATURES ..2-6
BATT ERY/CHARG ING SYSTEM SPECIFICATIONS 1-10 EGCV SERVOMO TOR 6-78
BODY PANEL LOCATIONS 3-2 ELECTRIC START ER SPECIFICAT IONS 1-10
BRAKE FLUID _ 4-30 EM ISSION CONTROL IN FORMATION LABEL
BRAKE FLUID REPLACEMENT/A IR BLEEDING 16-7 (U.S.A. ON Ly) .... 1-39
BRAKE LIGHT SW ITCH EMISSION CONTROL SYSTEMS 1-36
LIGHTS/METERS/SW iTCHES 20-20 ENGINE & FRAME TORQUE VALUES 1-12
M AIN TENANCE 4-33 ENGINE CONTROL MODULE (ECM ) 6-69
BRAKE PAD WEAR 4-31 ENGINE IDLE SPEED 4-24
BRAKE PADIDISC _ 16-11 ENGINE INSTALLAT ION _ 8-9
BRAKE PEDAL 16-34 ENGINE OIUO IL FILTER.. 4-21
BRAKE SYSTEM 4-32 ENGINE REMOVAL 8-4
CAB LE & HARNESS ROUTING .. 1-24 ENGINE STOP RELAY 6-68
CAM CHAIN TENSIONER LIFTER 9-34 EOP (ENGINE OIL PRESSURE) SW iTCH 20-15
CAMSHAFT INSTALLAT ION 9-26 EVAP PURGE CONTROL SOLENOID VALVE
CAMSHAFT REMOVA L9-8 (CA LIFORNIA TYPE ONLY ) 6-72
CHARGING SYSTEM INSPECTION 17-7 EVAPORATIVE EM ISSION CONTROL SYSTEM
CKP (CRANKSHA FT POSITION ) SENSOR 18-7 (CA LIFORNIA TYPE ONLy) .... 4-26
CLUTC H 10-16 EXHAUST GAS CONTROL VALVE CABLE 4-34
CLUTCH FLUiD 4-34 EXHAUST PIPE/MUFFLE R 3-30
CLUTCH FLUID DRAINING 10-6 FA N CONTROL RELAy 7-21
CLUTCH FLUID RE PLACEMENT/AIR BLEEDING 10-6 FLYWHEEL 11-5
CLUTCH MASTER CYLINDER ..10-8 FORK 14-21
CLUTCH SLAVE CYLINDER 10-13 FRONT BRAKE CALIPERS 16-27
CLUT CH SWIT CH 20-21 FRONT FENDER.. 3-19
CLUTCH SYSTEM 4-33 FRONT MASTER CyLIN DER 16-15
CLUTCH/STARTER CLUTCH SPECIFICATIONS 1 -7 FRONT W HEEL 14-16
CMP SENSOR 6-66 FRONT WHEEUSUSPENS ION/STEERING
COMBINATION METER 20-10 SPECiFiCAT IONS 1-9
COMPONENT LOCATION FUEL CUT-OFF RELAY 6-35
ALTERNA TOR ..1 1-2 FUEL LINE 4-5
CLUTCH/STAR TER CLUTCH/GEARSH IFT FUEL LINE INSPECTION .. 6-31
LINKAGE 10-2 FUEL PUM P UN IT........... 6-33
CRANKCASE/CRANKSHAFT/BALANCER/ FUEL RESERVE SENSOR 20-17
PISTON /CYLINDER _ 13-2 FUEL SYSTEM (Pro gram me d Fuel Injection )
CYLINDER HEA DN ALVES 9-2 SPECiFiCAT IONS 1-6
ENGINE REMOVAUINSTALLAT ION 8-2 FUEL TA NK 6-36
FRONT WH EEUSUSPENSION/STEERING 14-2 GEARSHIFT SPiNDL E12-7
FUEL SYSTEM (Program me d Fuel Inj ect io n) 6-2 GENERAL SPECiFiCATIO NS .. 1-4
HYDRA ULIC BRAKE .... 16-2 HAND LEBAR SWITCHES 20-19
REAR WHEEL SUSPENSION 15-2 HAND LEBARS 14-9
TRAN SMISS ION/GEARS HIFT LIN KA GE 12-2 HEADLIGHT 20-5
COOLANT REPLACEMENT 7-6 HEADLIGHT AIM 4-33
COOLING SYSTEM 4-24 HEA DLIGHT RELAy ..20-25
COOLING SYSTEM SPECIFICATIONS 1-6 HESD (Honda Electronic Steering Damper ) 2-2
CRANKCASE ASSEMBLy 13-21
CRANKCASE SEPARATION .... 13-5
CRANKCA SE/CRANKSHAFT/BALA NCER/
~~g~ ~~~~~~~~~~~n.i.c .S.t~~r.i.n.9. .~a.IT1.p.~ r)
HORN
14-7
20-24
EI
PISTON /CYLINDE R SPECIFICAnONS 1-8 HYDRAULIC BRAKE SPECIFICATIONS 1-10
CRANKPIN BEARING .. 13-12 lA C VA LVE SYNCHRON IZATION 6-61
CRANKSHAFT 13-7 IAT SENSOR 6-65
CYLINDER COMPRESSION TEST 9-6 IDLE A IR CONTROL (lAC) THERMAL VALVE 6-56
CYLIND ER HEAD ASSEMB Ly.... 9-22 IDLE A IR CONTRO L (lAC) VAL VE 6-57
CYLINDER HEAD COVER ASSEMB Ly 9-31 IGNITION SWITC H 20- 18
CYLINDER HEAD COVER DiSASSEMBLy 9-7 IGNITION SYSTEM INSPECTION 18-5
CYLINDER HEAD COVER INSTALLATION 9-32 IGNITION SYSTEM SPECIFICATIONS 1-10
CYLINDER HEAD COVER REMOVAL .. 9-6 IGNITION TIM ING 18-7
CYLINDER HEAD DiSASSEMBLy .... 9-14 INTAK E AIR DUCT ..6-73
CYLINDER HEAD INSPECTION 9-16 LICENSE LIGHT 20-9
CYLIND ER HEAD INSTA LLATION 9-24 LIGHTS/M ETERS/SW ITCHES SPECIFICATIONS 1 -11
CYLINDER HEAD REMOVAL 9-13 LUBRICATION & SEA L POINT S ....1 -20
CYLINDER HEADN A LVES SPECIFICAT IONS 1-7 LUBRICATION SYSTEM DIAGRAM 5-2
23-1
Contents
INDEX
LUBRICATION SYSTEM SPECIFICATIONS 1-6 STANDARD TORQU E VA LUES 1-12
MAIN JOURNAL BEARING 13-9 STARTER CLUTCH ...... .. 10-28
MAINTE NANC E SCHEDULE 4-4 STARTER MOTO R .. .. 19-6
MAP SENSO R6-64 STARTER RELAY SWITC H 19-13
M/L CODE IN DEX 6-13 STATOR 11-4
MI L TROUBLESHOOTING 6-15 STEERING DA M PER .. 14-34
M ODEL IDENTIFICATION 1-2 STEERING HEAD BEARIN GS 4-41
NEUTRA L SWi TCH...................... 20-21 STEERING STEM 14-35
NUTS , BOLTS, FASTENERS .. 4-41 SUS PENSi ON .. ........ .... ....4-37
OIL COOLER 5-13 SUS PENSIO N LINKAGE .. 15-17
OIL PRESSURE INSPECTION 5-5 SWINGARM ........ .. .... 15-20
OIL PUMP 5-8 SYST EM D IAGRAM
OIL STRAIN ER/PRESSURE RELIEF VA LVE 5-6 BATIERY/CHARGING SYSTEM 17-2
PAIR CONTROL SOLENOID VA LVE 6-71 ELECTRIC STARTER........ 19-2
PASSENG ER SEAT .. .. 3-4 FUEL SYSTEM (Prog ram me d Fuel lnject io n) 6-8
PGM- FI SELF-DIAGNOSIS INFORMATION 6-9 IGNITION SYSTEM 18-2
PISTON/CYLIND ER .. ...... 13-15 SYST EM FLOW PATIERN 7-2
POSITION LIGHT 20-6 SYSTEM LOCATION
PRIMA RY INJ ECTOR.... .......... 6-54 FUEL SYSTEM (Prog rammed Fuell njectio n) ..........6-7
RADIA L-M OUN TED FRONT BRAKE CALIPER 2-5 LIGHTS/METERS/SW ITCHES ......20-2
RADIATOR 7- 10 SYSTEM TESTING .. 7-5
RADIA TOR COOLANT...... .......... 4-24 TACHOM ETER 20-13
RADIATOR RESER VE TANK 7-20 TAI U BRAKE LIGHT .. ...... .. .. ..20-8
REAR BRAKE CALIPER 16-31 THERM OSTAT ........ ...... 7-8
REAR FENDER 3- 19 THROTILE BODY...... ...... .. 6-47
REAR MASTER CYLINDER 16-21 THROTILE OPERATION .. .... ........4-7
REAR SEAT COWL 3-5 TOP SHELTER 3-16
REAR W HEEL...... ...... .. .... 15-7 TRANSM ISSION 12-11
REAR W HEEUSUSP ENSION SPECIFICATIONS 1-9 TRA NSMISSION/GEA RSHIFT LINKAGE
REGULATOR/RECTIFIER 17-8 SPECIFICATIO NS ..............: ................ 1-8
RIDER SEAT .... 3-4 TROUBLESHOOTING ........ ............5-4
RIGHT CRANKCASE COVER INSTA LLATION 10-34 BATIE RY/CHARGI NG SYSTEM 17-4
RIGHT CRA NKCASE COVER REMOVAL 10-15 CLUTCH/G EARSHIFT LINKA GE .. 10-5
SEAT RAIL 3-27 COOLING SYSTEM 7-4
SECONDARY AIR SUPPLY SYSTEM 4-25 CRANKCASE/CRANKSHAFT/BALAN CER/
SECONDA RY INJ ECTOR............ .. .. 6-43 PISTON /CYLINDER .............. 0 .. .. .. .. 13-4
SERVICE INFORMATION CRANKCAS EfTRA NS M ISSION 12-6
ALTERNATOR 11-3 CYLINDER HEADNALVES ........ ........9-5
BATIERY/CHARGING SySTEM 17-3 ELECTRIC STARTER.. .... ...... 19-4
CLUTCH/STA RTER CLUTCH/GEARS HIFT ENGINE DOES NOT START OR IS HARD
LINKAGE ............................ .. 10-4 TO START ...................... .. ..22-2
COOLING SYSTEM .. .... 7-3 ENGINE LACKS POWER 22-3
CRANKCAS E/CRANKS HAFT/BA LANC ER/ FRA M E/BODY PANELS/EXHAUST SYSTEM 3-3
PISTON /CYLINDER 13-3 FRONT W HEEUSUS PENSION/STEERING 14-6
CRANKCASEfT RANS M ISSION 12-4 FUEL SYSTEM (p rogr amm ed Fuel lnjection) 6-6
CYLINDER HEADNALVES 9-3 HYDRA ULI C BRAKE .. 16-6
ELECTRIC STARTER 19-3 IGNITION SYST EM 18-4
ENGIN E REMOVAUINSTA LLAT ION 8-3 POOR HANDLING .............. .. 22-6
FRAM E/BODY PANELS/EXHAUST SYSTEM 3-3 POOR PERFORMANCE AT HIGH SPEED 22-6
FRONT W HEEUSUSPEN SION /STEERING 14-3 POOR PERFORMANCE AT LOW AND
FUEL SYSTEM (Program m ed Fue/ lnj ect ion } 6-3 IDLE SPEED .................. .. 22-5
HYDRAULI C BRAKE.. .......... .. 16-4 REAR W HEEL SUSPENSIO N 15-6
IGNITION SYSTEM 18-3 TURN SIGNAL.... .... ..20-7
LIGHTS/M ETERS/SWi TCHES .. .. .. 20-3 TURN SIGNAL RELAY 20-24
LUBRICATION SYSTEM 5-3 UNDER COW LS/M IDDLE COWLS 3-7
MAINTENANCE 4-2 UPPER COW L........ .... ......3-12
REAR W HEEL SUS PENSION 15-3 VA LVE CLEARA NCE 4- 16
SERVICE RULES .. .. 1-2 VAL VE GUIDE REPLACEMENT ..9-18
SHOCK A BSORBER 15-14 VA LVE SEAT INSPECTION/RE FA CING 9-19
SIDE STAND 4-36 WATER PUM p 7-17
SIDE STA ND SWiTCH 20-22 W HEELSfTlRES .......... ............4-41
SPARK PLUG 4-8 WIR ING DIAGRAM
SPEEDOM ETERNEHICLE SPEED SENSOR 20-11 A, AC, CM type 21-3
23 -2
Contents

Manual de Reparatie Honda CBR 1000 RR

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Manual de Reparatie Honda CBR 1000 RR

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HOW TO USE THIS MANUAL CONTENTS

This service manual describes the servic e procedures lor the

Date of Issue: March, 2004

S~ Rep lace the part(s) with new one(s) before assembly.

-, Use recomme nded engin e oil, unless otherwise specified.

~ Use silicone grease.

",,'Uill Apply sea lant.

.. Use Fork or Suspension Fluid.

LUBRICATION SYSTEM BATTERY/CHARGING SYSTEM

FUEL SYSTEM (Programmed Fuel IGNITION SYSTEM SPECIFICATIONS ........ 1-10

TRANSMISSION/GEARSHIFT LINKAGE LUBRICATION & SEAL POINTS ................ 1-20

FRONT WHEEl/SUSPENSION/STEERING EMISSION CONTROL INFORMATION

THROTTLE BODY IDENT IFICATION " NUMBER

The co lor label is attached on th e rear f end er B as shown. W hen

FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

CLUTCH/STARTER CLUTCH SPECIFICATIONS

REAR WHEEL/SUSPENSION SPECIFICATIONS

BATTERYICHARGING SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES

FUEL SYSTEM (Pro gra m med Fuel Inj ection):

LIGHTS / METE RS/SWITCHES:

Insulator clamp (Throttl e body side) :

7 1 mm (0.3 0.04 in)

Exhaust pip e stu d bolt:

Fuel ta nk m ounting bolt (front) 2 8 26 (2.7, 20)

CLUTCH /STARTER CLUTCH :

LIG HTS /METERS/SWITCHES:

Oil pan m ating surfac e

Alternator cover mating surface

Oil pressure switch th read s

Cylind er head semi-circ ular cut-ou t Sea lant

FRONT BRAKE HOSE HORN WIR E

FRONT SUB- HA RNESS

COMBIN ATION METER

RIGHT TURN SIGNAL 3P

BANK ANG LE SENSOR

FRONT SUB -HARNESS 12P

HORN WIRE ----f~~~~:t/I_-L

FRONT BRA KE HOSE

FRONT BRAK E HOSE

RAD IATOR OVERFLOW

VS (VEHICLE SPEED) SEN SOR

Contents Chapter 1 1-27

No.1 No.2 No.3 No.4

lAC T HERM A L VA LVE

ECT SENSOR 3P (GRAY) CONNECTOR

SIDE STAN D 2P (G REEN)

IGNITIO N COIL SU B-HA RNESS

RA DIATOR SIPHON HOSE

REAR BRAK E LIGHT SWI TCH

CKP (CRA N KSHA FT POSITION ) IGNITION COIL SUB -HARN ESS

REAR BRAKE LIGHT RAD IATOR SIPHON HOSE

EGCV SERVOM OTOR 6P

VEHICLE SPEED SENSO R 3P

NEUT RAL SW ITCH

MAI N W IRE HARNESS TUR N SIGNAULICEN SE

STA RTER MOTOR

REAR BRA KE LIGHT

THROTTLE BODY EVAP PURGE CONTROL

AI R CLEAN ER HOU SING

c::;::2.-- - - - - THROTTLE BODY