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A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and
the reliability of the vehicle. Any error or oversight while servicing a vehicle
can result in faulty operation, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we
do not provide warnings about many basic shop safety practices (e.g., Hot
parts – wear gloves). If you have not received shop safety training or do not
feel confident about your knowledge of safe servicing practices, we
recommended that you do not attempt to perform the procedures described
in this manual.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can
arise in performing service and repair procedures. Only you can decide
whether or not you should perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an
unsafe condition that can cause your customer
or others to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt
or killed.
Follow the procedures and precautions in this
manual carefully.

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Table of Contents

   Summary of Contents for Honda GL1800

  • Page 1 Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 2: How To Use This Manual

    HOW TO USE THIS MANUAL CONTENTS This service manual describes the service procedures for the GL1800/ GENERAL INFORMATION GL1800A. Follow the Maintenance Schedule (Section 3) recommendations to FRAME/BODY PANELS/EXHAUST ensure that the vehicle is in peak operating condition and emission levels...
  • Page 3 ® Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
  • Page 4 1. GENERAL INFORMATION SERVICE RULES ············································ 1-2 BRAKE SYSTEM SPECIFICATIONS·············1-10 MODEL IDENTIFICATION······························ 1-2 BATTERY/CHARGING SYSTEM SPECIFICATIONS··········································1-10 GENERAL SPECIFICATIONS························· 1-4 IGNITION SYSTEM SPECIFICATIONS ········1-11 LUBRICATION SYSTEM SPECIFICATIONS · 1-6 STARTER/REVERSE SYSTEM SPECIFICATIONS··········································1-11 FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS··········································· 1-6 LIGHTS/METERS/SWITCHES SPECIFICATIONS··········································1-11 COOLING SYSTEM SPECIFICATIONS ·········...
  • Page 5: Service Rules

    SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA’s design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
  • Page 6 GENERAL INFORMATION The frame serial number is stamped on the right side of the steering head. The engine serial number is stamped on the right side of the crankcase. ENGINE SERIAL NUMBER The Vehicle Identification Number (VIN) is located on the left side of the frame near the steering head.
  • Page 7: General Specifications

    GENERAL INFORMATION The color label is attached on the back of the fuel fill compartment lid. When ordering color-coded parts, always specify the designated color COLOR LABEL code. GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,635 mm (103.7 in) Overall width 945 mm (37.2 in) Overall height 1,455 mm (57.3 in)
  • Page 8 GENERAL INFORMATION ITEM SPECIFICATIONS ENGINE Cylinder arrangement Flat six Bore and stroke 74.0 x 71.0 mm (2.91 x 2.80 in) Displacement 1,832 cm (111.8 cu-in) Compression ratio 9.8 : 1 Valve train Silent cam chain driven, OHC Intake valve opens –5°...
  • Page 9 90° C (194° F) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors Standard coolant concentration 1:1 mixture with recommended antifreeze and soft water...
  • Page 10 GENERAL INFORMATION CYLINDER HEAD/VALVE SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 300 rpm 1,383 kPa (14.1 kgf/cm , 201 psi) – Valve clearance 0.15 (0.006) – 0.22 (0.009) – Camshaft Cam lobe height 41.610 – 41.690 (1.6382 – 1.6413) 41.58 (1.637) 41.680 –...
  • Page 11 GENERAL INFORMATION GEARSHIFT LINKAGE/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Output shaft Damper spring free length 66.0 (2.60) 64.0 (2.52) Shaft O.D. 22.008 – 22.021 (0.8665 – 0.8670) 21.99 (0.866) Gear bushing I.D. 22.026 – 22.041 (0.8672 – 0.8678) 22.05 (0.868) O.D.
  • Page 12 60 g (2.1 oz) max. Fork Spring free length 335.3 (13.20) 328.6 (12.94) Tube runout – 0.20 (0.008) Recommended fluid Pro-Honda Suspension Fluid SS-8 – Fluid level 128 (5.0) – 529 ± 2.5 cm (17.9 ± 0.08 US oz, Fluid capacity Left –...
  • Page 13 GENERAL INFORMATION BRAKE SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT 4 – Front Brake disc thickness 4.5 (0.18) 3.5 (0.14) Brake disc runout – 0.30 (0.012) Master cylinder I.D. 14.000 – 14.043 (0.5512 – 0.5529) 14.055 (0.5533) Master piston O.D.
  • Page 14: Ignition System Specifications

    GENERAL INFORMATION IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Spark plug Standard BKR6E-11 (NGK), K20PR-U11 (DENSO) For cold climate BKR5E-11 (NGK), K16PR-U11 (DENSO) (below 5° C/41° F) For extended high speed BKR7E-11 (NGK), K22PR-U11 (DENSO) riding Spark plug gap 1.0 – 1.1 mm (0.039 – 0.043 in) Ignition coil signal peak voltage 2.5 –...
  • Page 15 GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) 8 mm bolt and nut 22 (2.2, 16)
  • Page 16 GENERAL INFORMATION COOLING SYSTEM THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Water pump cover sealing plate bolt 13 (1.3, 9) Water pump cover bolt 13 (1.3, 9) CYLINDER HEAD/VALVE THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Cylinder head bolt 44 (4.5, 33) NOTE 1...
  • Page 17 GENERAL INFORMATION BATTERY/CHARGING SYSTEM THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Alternator mounting bolt 29 (3.0, 22) IGNITION SYSTEM THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Ignition pulse generator bolt 12 (1.2, 9) NOTE 3 STARTER/REVERSE SYSTEM THREAD TORQUE...
  • Page 18 GENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Center fresh air visor socket bolt 1 (0.1, 0.7) Exhaust pipe joint nut 12 (1.2, 9) Exhaust pipe mounting bolt 26 (2.7, 20) Exhaust pipe band bolt 26 (2.7, 20) Muffler band bolt 26 (2.7, 20)
  • Page 19 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Handlebar weight mounting screw 10 (1.0, 7) NOTE 7 Handlebar mounting bolt 26 (2.7, 20) Front brake disc bolt 20 (2.0, 14) NOTE 7 Front pulser ring bolt (ABS model only) 8 (0.8, 5.8) NOTE 7 Front axle bolt...
  • Page 20 GENERAL INFORMATION BRAKE SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Brake caliper bleed valve 6 (0.6, 4.3) Front fork anti-dive plunger bleed valve 6 (0.6, 4.3) Front master cylinder reservoir cap screw 2 (0.2, 1.4) Brake pad pin 18 (1.8, 13) Brake hose oil bolt 34 (3.5, 25)
  • Page 21 GENERAL INFORMATION LIGHTS/METERS/SWITCHES THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Side stand switch bolt 10 (1.0, 7) Ignition switch mounting bolt 25 (2.5, 18) NOTE 8 AUDIO SYSTEM THREAD TORQUE ITEM Q’TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Antenna base mounting bolt 14 (1.4, 10) OTHERS...
  • Page 22 GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Crankcase mating surface Sealant Coating area 11 – 21 Rear crankcase cover gasket mating surface (case side) Coating area 10 – 21 Gearshift linkage cover gasket mating surface (case Coating area 10 – 7 side) Front crankcase cover gasket mating surface (case side) Coating area 8 –...
  • Page 23 GENERAL INFORMATION LOCATION MATERIAL REMARKS Oil filter boss threads (crankcase side) Locking agent Oil strainer bolt threads Cylinder head 14 mm sealing bolt threads Cylinder head 10 mm sealing bolt threads Cam sprocket bolt threads Shift drum joint bolt threads Clutch outer lock nut threads Oil pump driven sprocket bolt threads Primary driven gear bearing setting plate bolt threads...
  • Page 24 Throttle cable outer inside Cable lubricant Reverse control cable outer inside Trunk lid seal rubber seating surface Honda Bond A or equiva- Trunk panel seal rubber seating surface lent Trunk light cover rubber seating surface Saddle bag cover seal rubber seating surface...
  • Page 25 GENERAL INFORMATION LOCATION MATERIAL REMARKS Final drive pinion joint nut threads Locking agent Final gear case cover bolt threads Final gear case stud bolt threads (case side) Fork center bolt threads Fork anti-dive plunger case bolt threads Rear brake light/cruise cancel switch holder screw threads Secondary master cylinder push rod joint lock nut threads...
  • Page 26 GENERAL INFORMATION CABLE & HARNESS ROUTING CONNECTORS: • Cruise cancel switch 2P (Blue) • Ignition pulse generator 2P (Red) • Reverse shift actuator 2P (White) • Reverse limit switch 3P (Red) • Gear position switch 6P (Black) IGNITION PULSE GENERATOR WIRE REVERSE LIMIT SWITCH WIRE To oil pressure switch REVERSE SHIFT ACTUATOR...
  • Page 27 GENERAL INFORMATION SPARK PLUG WIRES (see next page) No. 5 HOSE (to EVAP purge CRUISE CANCEL control solenoid valve) SWITCH (throttle) No. 15 HOSE (to air cleaner housing) REVERSE SHIFT CABLE (“R” side) REVERSE SHIFT CABLE (“N” side) THROTTLE CABLES PRESSURE REGULATOR VACUUM HOSE AIR CLEANER HOUSING...
  • Page 28 GENERAL INFORMATION No. 5 No. 2 No. 3/4 No. 1/2 IGNITION IGNITION COIL COIL No. 5/6 IGNITION COIL SPARK PLUG WIRES No. 4 No. 6 No. 5 No. 3 No. 2 No. 1 45° 45° 10° 45° View from the lower side: No.
  • Page 29 GENERAL INFORMATION No. 5 SPARK PLUG WIRE No. 1 HOSE (from fuel tank-to-EVAP canister) No. 3 SPARK PLUG WIRE No. 4 HOSE (from EVAP purge control No. 1 SPARK soleniod valve-to- PLUG WIRE EVAP canister) No. 5 SPARK PLUG WIRE No.
  • Page 30 GENERAL INFORMATION AIR CLEANER DRAIN HOSE No. 6 SPARK PLUG WIRE No. 4 SPARK PLUG WIRE No. 6 SPARK PLUG WIRE No. 4 SPARK No. 2 SPARK PLUG WIRE PLUG WIRE No. 2 SPARK PLUG WIRE CLUTCH HOSE AIR CLEANER GEAR POSITION DRAIN HOSE SWITCH WIRE...
  • Page 31 GENERAL INFORMATION *: ABS (Anti-lock Brake System) model No. 1/2 IGNITION COIL CONNECTOR “1” No. 5/6 IGNITION COIL CONNECTOR “5” FRONT WHEEL SPEED SENSOR 2P (Orange)* MODULATOR CRANK No. 3/4 IGNITION COIL POSITION SENSOR 3P CONNECTOR “3” FRONT ABS MODULATOR* (Gray)* MODULATOR REAR ABS MODULATOR*...
  • Page 32 GENERAL INFORMATION No. 1 HOSE (from fuel tank) No. 4 HOSE (from EVAP purge control soleniod valve) NOC SENSOR (right cylinder; No. 1) 1P (Black) RIGHT HORN (low) Front EVAPORATIVE (EVAP) EMISSION CANISTER GEARSHIFT OPTIONAL 2P (Gray) LINKAGE (for left and right fog lights) COVER KNOCK SENSOR (left cylinder;...
  • Page 33 GENERAL INFORMATION Right side: FUEL HOSE (from fuel tank) ENGINE SUB-WIRE HARNESS FUEL HOSE (to left fuel rail) Front RADIATOR STAY No. 1 No. 3 No. 5 FUEL RAIL FUEL INJECTOR 2P (Black) Left side: RADIATOR STAY FAN MOTOR CONDENSOR PRESSURE REGULATOR FUEL HOSE VACUUM HOSE...
  • Page 34 GENERAL INFORMATION *: ABS (Anti-lock Brake System) model RIGHT RADIATOR BRAKE PIPE (to delay valve) CLIP* BRAKE PIPES* To front calipers From front master cylinder Standard Front model BRAKE PIPE (from rear master FRONT ABS MODULATOR* cylinder) Front “OUT” side “IN”...
  • Page 35 GENERAL INFORMATION *: ABS (Anti-lock Brake System) model RADIATOR BREATHER HOSE (to right radiator filler neck) BRAKE PIPE (from rear master cylinder)* LEFT RADIATOR PROPORTIONAL CONTROL VALVE BRAKE PIPE (from secondary (PCV) master cylinder-to-PCV) Front REAR ABS MODULATOR* “IN” side Front “OUT”...
  • Page 36 GENERAL INFORMATION CONNECTORS: • Vehicle speed sensor 3P (White) • Right O ² sensor 4P (White) (cylinders 1-3-5) • Rear master cylinder brake light switch 3P (White) • Rear master cylinder cruise cancel switch 2P (Red) • Engine sub-wire harness 4P (Gray) 45°...
  • Page 37 GENERAL INFORMATION BRAKE PIPES SENSOR WIRE Left ALTERNATOR 4P CONNECTOR SIDE STAND SWITCH WIRE 3P (Green) CONNECTOR Left 20 – 50 mm WATER HOSE SENSOR WIRE 50° Front LEFT O SENSOR ALTERNATOR SIDE STAND SWITCH (cylinders 2-4-6) TERMINALS ADIATO ESE VE TANK SIPHON HOSE CLAMP ESE VE TANK B EATHE HOSE...
  • Page 38 GENERAL INFORMATION Section A: MAIN WIRE HARNESS Rear Rear HEAT GUARD WATER HOSES RUBBER 3 places: 4 places: WATER HOSES SIPHON HOSE Engine ground point WATER PUMP FUEL TANK Front DRAIN HOSE Frame ground point STARTER MOTOR CABLE GROUND CABLE 1-35...
  • Page 39 GENERAL INFORMATION BRAKE PIPE: BRAKE PIPE (standard model) ABS model: To front and rear modulators. (from rear master cylinder-to- Standard model: To rear brake caliper and delay valve. rear brake caliper; lower side) CLIP (standard model) rom rear master SIPHON HOSE cylinder UEL RETURN HOSE UEL HOSE...
  • Page 40 GENERAL INFORMATION STARTER RELAY CONNECTORS (2P Red, 2P Blue RELAY BOX and 2P White) STARTER RELAY STARTER RELAY MAIN WIRE Front SWITCH A SWITCH B HARNESS BATTERY BOX STAY REVERSE Inside REGULATOR Inside BATTERY 20P (White) GROUND CABLES FRAME GROUND CABLE Inside FENDER...
  • Page 41 GENERAL INFORMATION ’01, ’02: SUSPENSION LEVEL ACTUATOR To main wire harness ACTUATOR CONTROL MOTOR To main wire 2P (Blue) harness ACTUATOR ANGLE SENSOR 3P (Gray) RADIO ANTENNA WIRE OIL HOSE (to rear suspension) REAR FENDER After ’02: SUSPENSION LEVEL ACTUATOR To main wire To main wire ACTUATOR CONTROL MOTOR...
  • Page 42 GENERAL INFORMATION ‘01 – ‘03: *: ABS (Anti-lock Brake System) model REAR WHEEL SPEED BRAKE PIPE SENSOR* (ABS model) REAR BRAKE CALIPER Identification marks (Yellow paint) REAR WHEEL SPEED SENSOR WIRE* BRAKE PIPE (clamp at white tape (standard model) position) REAR WHEEL SPEED SENSOR WIRE*...
  • Page 43 GENERAL INFORMATION After ‘03: * : ABS (Anti-lock Brake System) model Identification marks REAR BRAKE CALIPER (Yellow paint) REAR WHEEL BRAKE PIPE SPEED SENSOR* (ABS model) BRAKE HOSES BRAKE PIPES BRAKE HOSES BRAKE PIPE 45 mm (standard model) REAR WHEEL SPEED SENSOR WIRE* (clamp REAR WHEEL SPEED at white tape position)
  • Page 44 GENERAL INFORMATION FUEL ANK DRAIN HOSE o EVAP canister Front No. 1 HOSE ’01, ’02: 2P (Gray) UEL LEVEL SENSOR WIRE (clamp at black tape position) UEL HOSE UEL LEVEL SENSOR COVER UEL HOSE UEL RETURN HOSE 5P (Gray) UEL PUMP UEL LEVEL SENSOR WIRE 1-41...
  • Page 45 GENERAL INFORMATION After ’02: UEL LEVEL 2P (Gray) SENSOR WIRE (clamp at black tape position) UEL HOSE UEL LEVEL SENSOR COVER UEL HOSE UEL RETURN HOSE 5P (Gray) PASSENGER HEADSET WIRE UEL PUMP UEL LEVEL SENSOR WIRE 1-42...
  • Page 46 GENERAL INFORMATION ’01: To turn signal FAIRING FAIRING relay (in meter) ST A Y ST A Y 3P connector WIRES WIRES Front To meter OPTIONAL 3P (White) (16P Black and Front SPEAKER (for grip heater) TURN SIGNAL/ 20P Black connectors) TURN SIGNAL/ 2P (Blue) SPEAKER...
  • Page 47 GENERAL INFORMATION After ’01: To turn signal FAIRING FAIRING relay (in meter) STAY STAY 3P connector WIRES WIRES Front To meter OPTIONAL 3P (White) Front (16P Black (for grip heater) (’02 only) TURN SIGNAL/ LEFT FRONT and 20P Black TURN SIGNAL/ RUNNING LIGHT SPEAKER WIRE connectors)
  • Page 48 GENERAL INFORMATION ’01: 4P (Black) IGNITION SWITCH CLOCK ADJUSTING/ LCD CHANGE SWITCH Front AUDIO UNIT 26P (Black) 26P (Gray) RADIO ANTENNA 34P (Black), CONNECTOR 34P (Gray) 22P (Gray) CRUISE/REVERSE CONTROL MODULE (see below) ENGINE CONTROL 6P (Black) MODULE (ECM) CONNECTORS: 22P (Black) •...
  • Page 49 GENERAL INFORMATION ’02: 4P (Black) IGNITION SWITCH CLOCK ADJUSTING/ LCD CHANGE SWITCH Front AUDIO UNIT 26P (Black) 26P (Gray) RADIO ANTENNA 34P (Black), CONNECTOR 34P (Gray) 22P (Gray) CRUISE/REVERSE CONTROL MODULE (see below) ENGINE CONTROL 6P (Black) MODULE (ECM) CONNECTORS: 22P (Black) •...
  • Page 50 GENERAL INFORMATION After ’02: 4P (Black) CLOCK ADJUSTING/ IGNITION SWITCH LCD CHANGE SWITCH Front AUDIO UNIT 26P (Black) 26P (Gray) RADIO ANTENNA 34P (Black), 34P (Gray) CONNECTOR 22P (Gray) CRUISE/REVERSE CONTROL MODULE (see below) DRIVER HEADSET 6P (Red) 6P (Black) ENGINE CONTROL MODULE (ECM) CONNECTORS:...
  • Page 51 GENERAL INFORMATION ’01, ’02: IGNITION SWITCH FAN MOTOR SHROUD BANK ANGLE SENSOR 3P (Green) To meter switch CRUISE ACTUATOR BAROMETRIC PRESSURE (BARO) SENSOR CRUISE ACTUATOR/ 3P (Black) BARO SENSOR WIRE 2P (Black) 6P (Black) CONNECTORS: INTAKE AIR • Ignition switch TEMPERATURE 4P (White) IGNITION...
  • Page 52 GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE CRUISE LEFT HANDLEBAR ACTUATOR Front LEFT HANDLEBAR SWITCH WIRE WIRE SWITCH WIRE BARO SENSOR WIRE BRAKE PIPE (ABS model) RADIATOR CB TRANSCEIVER BREATHER WIRE HOSE (from left radiator) TURN SIGNAL CANCEL IGNITION SWITCH MAIN WIRE RIGHT HANDLEBAR UNIT WIRE WIRE...
  • Page 53 GENERAL INFORMATION ‘03: IGNITION SWITCH FAN MOTOR SHROUD DRIVER HEADSET 5P (Red) BANK ANGLE SENSOR 3P (Green) To meter switch CRUISE ACTUATOR BAROMETRIC PRESSURE (BARO) SENSOR CRUISE ACTUATOR/ 3P (Black) BARO SENSOR WIRE 2P (Black) CONNECTORS: INTAKE AIR · Ignition switch TEMPERATURE 6P (Black) 4P (White)
  • Page 54 GENERAL INFORMATION RIGHT HANDLEBAR CRUISE ACTUATOR SWITCH WIRE LEFT HANDLEBAR WIRE SWITCH WIRE LEFT HANDLEBAR Front SWITCH WIRE BARO SENSOR BRAKE PIPE WIRE (ABS model) RADIATOR BREATHER CB TRANSCEIVER HOSE (from WIRE left radiator) PASSENGER TURN SIGNAL CANCEL IGNITION SWITCH HEADSET WIRE UNIT WIRE WIRE...
  • Page 55 GENERAL INFORMATION After ‘03: AUDIO UNIT WIRES NOISE FILTER FAN MOTOR IGNITION SWITCH SHROUD BANK ANGLE SENSOR 3P (Green) DRIVER HEADSET 5P (Red) To meter switch CRUISE ACTUATOR BAROMETRIC PRESSURE (BARO) SENSOR CRUISE ACTUATOR/ 3P (Black) BARO SENSOR WIRE 2P (Black) CONNECTORS: INTAKE AIR ·...
  • Page 56 GENERAL INFORMATION RIGHT HANDLEBAR CRUISE ACTUATOR SWITCH WIRE LEFT HANDLEBAR WIRE SWITCH WIRE LEFT HANDLEBAR Front SWITCH WIRE BARO SENSOR BRAKE PIPE WIRE (ABS model) RADIATOR BREATHER CB TRANSCEIVER HOSE (from WIRE left radiator) PASSENGER TURN SIGNAL CANCEL IGNITION SWITCH HEADSET WIRE UNIT WIRE WIRE...
  • Page 57 GENERAL INFORMATION ‘01 – ‘03: IGHT HANDLEBA SWITCH WI E SWITCH WI E B AKE HOSE B AKE LIGHT/C UISE CANCEL SWITCH WI E TH OTTLE CABLES THROTTLE CABLES BRAKE HOSE 1-54...
  • Page 58 GENERAL INFORMATION After ‘03: RIGHT HANDLEBAR SWITCH WIRE SWITCH WIRE BRAKE HOSE BRAKE HOSE BRAKE LIGHT/CRUISE CANCEL SWITCH WIRE THROTTLE CABLES THROTTLE CABLES 1-55...
  • Page 59 GENERAL INFORMATION ‘01 – ‘03: EFT HAND EBAR SWITCH WIRE SWITCH WIRE C UTCH HOSE C UTCH HOSE C UTCH CRUISE C UTCH SWITCH WIRE SWITCH WIRE After 03: LEFT HANDLEBAR SWITCH WIRE CLUTCH CRUISE SWITCH WIRE CLUTCH SWITCH WIRE CLUTCH SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE...
  • Page 60 GENERAL INFORMATION TURN SIGNAL CANCEL UNIT IRE IRE BAND (white tape position) LEFT HANDLEBAR CLUTCH HOSE S ITCH IRE RIGHT HANDLEBAR S ITCH IRE BRAKE HOSE TURN SIGNAL CANCEL UNIT 7P (Green) LEFT HANDLEBAR RIGHT HANDLEBAR S ITCH IRE S ITCH IRE 1-57...
  • Page 61 GENERAL INFORMATION : ABS (Anti-lock Brake System) model TURN SIGNAL CANCEL UNIT WIRE BRAKE HOSE CLUTCH HOSE RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLES BRAKE HOSE (from front master cylinder) CLUTCH HOSE Standard model BRAKE PIPE (from rear master cylinder-to-rear FRONT WHEEL SPEED modulator “W”...
  • Page 62 GENERAL INFORMATION *: ABS (Anti-lock Brake System) model CLUTCH HOSE THROTTLE CABLES* RADIATOR BREATHER HOSE BRAKE PIPE (from rear master cylinder-to-rear modulator “W” [IN])* BRAKE PIPE (to PCV) From secondary master cylinder tandard model: THROTTLE CABLE 1-59...
  • Page 63 GENERAL INFORMATION *: ABS (Anti-lock Brake System) model CRUISE CANCEL SWITCH (throttle) Standard model BRAKE PIPE (from rear master cylinder)* BRAKE PIPE (to rear brake caliper; lower side)* REAR ABS MODULATOR* BRAKE PIPE BRAKE PIPES* (to rear brake caliper; upper side) BRAKE PIPE (from secondary PROPORTIONAL CONTROL master cylinder)
  • Page 64 GENERAL INFORMATION *: ABS (Anti-lock Brake System) model Clamp at white tape position BRAKE HOSE FRONT WHEEL SPEED SENSOR WIRE* DELAY VALVE CLIP* BRAKE HOSES CLAMPS* FRONT WHEEL SPEED SENSOR* RIGHT FRONT BRAKE CALIPER STOPPER 1-61...
  • Page 65 GENERAL INFORMATION RAKE PIPES DELAY VALVE SECONDARY MASTER CYLINDER RAKE HOSES LEFT FRONT RAKE CALIPER RAKE HOSE (for anti-dive) ANTI-DIVE PLUNGER 1-62...
  • Page 66 GENERAL INFORMATION ’01, ’02: CONTROL UNIT WIRE TRUNK LOCK CONTROL UNIT ANTENNA WIRE OPTIONAL 5P CONNECTOR (for passenger headset) CONNECTORS: To radio antenna • Trunk sub-harness 14P (White) SUSPENSION • Diodes LEVEL ACTUATOR WIRE SUB- HARNESS PASSENGER HEADSET WIRE ANTENNA WIRE CONTROL UNIT WIRE...
  • Page 67 GENERAL INFORMATION After ’02: CONTROL UNIT WIRE TRUNK LOCK CONTROL UNIT ANTENNA WIRE OPTIONAL 5P CONNECTOR (for passenger headset) To radio antenna CONNECTORS: • Trunk sub-harness 14P (White) SUSPENSION • Diodes LEVEL ACTUATOR WIRE SUB- HARNESS PASSENGER HEADSET ANTENNA WIRE WIRE CONTROL UNIT WIRE...
  • Page 68 GENERAL INFORMATION ABS CONTROL UNIT LICENSE LIGHT SADDLEBAG OPENER SADDLEBAG CABLE OPENER CABLE TRUNK SUB- HARNESS 5P (Brown) 5P (Black) 12P (Black) 14P (White) FENDER MAIN WIRE HARNESS SADDLE- 1-65...
  • Page 69 GENERAL INFORMATION 8P (White) (trunk open switches and actuators) STAY BRAKE/TAILLIGHT CONNECTORS TRUNK SUB- HARNESS Front SADDLEBAG OPENER CABLE Front LICENSE LIGHT WIRE LICENSE LIGHT RIGHT SADDLEBAG TRUNK SUB- WIRE HARNESS FRAME SADDLEBAG BOOT OPENER Front CABLE LEFT SADDLEBAG RIGHT SADDLEBAG WIRE FRAME WIRE...
  • Page 70 GENERAL INFORMATION Left saddlebag shown: To main wire harness SADDLEBAG OPENER CABLE OPEN SWITCH 2P (White) SADDLEBAG OPEN SWITCH SADDLEBAG OPEN SWITCH TURN SIGNAL LIGHT BRAKE/TAILLIGHT SADDLEBAG LID CATCHES • TRUNK ACTUATOR • LOCK/UNLOCK ACTUATOR • TRUNK OPEN SWITCHES SADDLEBAG OPENER CABLE TURN SIGNAL/ BRAKE/TAILLIGHT...
  • Page 71 GENERAL INFORMATION Inside of trunk lid: Clamp at blue tape position PTI NAL 2P (White) (for high mount brake light) PTI NAL 2P (Red) (for trunk light) TRUNK L CK C NTR L UNIT CLAMPS 18P (White) ’01: After ’01: TRUNK LOCK CONTROL TRUNK LOCK CONTROL UNIT WIRE...
  • Page 72: Emission Control Systems

    Carbon monoxide does not react in the same way, but is toxic. Honda Motor Co., Ltd., utilizes PGM-FI, two three-way catalytic converters (one in each exhaust pipe) and two heated oxygen sensors (one in each exhaust pipe) to reduce carbon monoxide, hydrocarbons, and oxides of nitrogen.
  • Page 73 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) The exhaust emission system is composed of a lean fuel injection setting and a secondary air supply system, no adjust- ments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system.
  • Page 74 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM This model complies with California Air Resources Board (CARB) evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is stopped. When the engine is running and the EVAP purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body.
  • Page 75 GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS An Emission Control Information Label is located on the reverse side of the right engine side cover as shown. MISSION CONTROL INFORMATION LAB L It gives basic tune-up specifications. (U.S.A.: 1 label/ Canada: 2 labels) VACUUM HOSE ROUTING DIAGRAM LABEL The Vacuum Hose Routing Diagram Label is located on the reverse side of the right engine side cover.
  • Page 76: Table Of Contents

    2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION ······························ 2-2 INNER FAIRING ············································2-10 TROUBLESHOOTING ···································· 2-2 FRONT FAIRING ···········································2-10 TOP SHELTER···············································2-11 BODY PANEL LOCATIONS ··························· 2-3 SIDE COVER··················································· 2-5 REAR FENDER A···········································2-13 ENGINE SIDE COVER···································· 2-5 TRUNK LOWER COVER ·······························2-13 SEAT······························································· 2-5 TRUNK ··························································2-13 FRONT FENDER COVERS ·····························...
  • Page 77: Service Information

    FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM GENERAL • This section covers removal and installation of the body panels and exhaust system. • Always replace the gaskets when removing the exhaust system. • Always inspect the exhaust system for leaks after installation. TORQUE VALUES Saddlebag/trunk stay bolt 26 N·m (2.7 kgf·m, 20 lbf·ft)
  • Page 78: Body Panel Locations

    FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS " & (10) (11) (12) (13) (17) (14) (16) (15) WINDSHIELD GARNISH (page 2-8) (10) TRUNK (page 2-13) WINDSHIELD (page 2-8) (11) TOP SHELTER (page 2-11) REARVIEW MIRROR (page 2-7) (12) METER PANEL (page 2-7) SEAT (page 2-5) (13) FRONT FAIRING (page 2-10)
  • Page 79 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL REMOVAL CHART The following chart shows the removal order for the body components. FRONT FAIRING (12) METER PANEL (6) CENTER INNER FAIRING (7) FRONT LOWER FAIRING (3) MIRRORS (1) WINDSHIELD GARNISH (9) INNER FAIRINGS (2) WINDSHIELD (13) FRONT FAIRING TOP SHELTER (4) SEAT...
  • Page 80: Side Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER ROMMETS Remove the side cover by releasing the four bosses BOSSES from the grommets. Install the side cover in the reverse order of Be careful not to removal. dislodge the grommets. SIDE COVER ENGINE SIDE COVER ROMMETS Release the two bosses from the grommets, free the front portion from the tab of the injector cover and...
  • Page 81: Front Fender Covers

    FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER COVERS Remove the four setting bolts, two rubber washers and front fender A. Remove the four setting bolts and the front fender covers. Installation is in the reverse order of removal. IGHT F ONT FENDE COVE LEFT F ONT FENDE COVE F ONT FENDE A...
  • Page 82: Meter Panel

    FRAME/BODY PANELS/EXHAUST SYSTEM METER PANEL Remove the speaker covers by releasing the four tabs for each cover. Remove the two trim clips and setting bolts. Release the four bosses from the grommets, discon- nect the multi-display control switch 4P connector and remove the meter panel.
  • Page 83: Windshield

    FRAME/BODY PANELS/EXHAUST SYSTEM WINDSHIELD WINDSHIELD GARNISH Remove the left and right rearview mirrors MOUNTING RUBBERS (page 2-7). BOSSES WASHERS Remove the two bolts, washers and mounting rubbers. Release the four bosses from the grommets and remove the windshield garnish. BOLTS Installation is in the reverse order of removal.
  • Page 84 FRAME/BODY PANELS/EXHAUST SYSTEM CENTER FRESH AIR VISOR Remove the following from the windshield: BOLTS – two socket bolts GRILLE – two cap nuts – four thrust washers – center fresh air grille by releasing the tab. – center fresh air visor WASHERS –...
  • Page 85: Inner Fairing

    FRAME/BODY PANELS/EXHAUST SYSTEM INNER FAIRING Remove the following: ETTING BOLT – center inner fairing (page 2-10) – windshield garnish (page 2-8) Remove the setting bolt, two setting screws and front fairing garnish. ETTING CREW FRONT FAIRING GARNI H Remove the screw, three trim clips and inner fairing. TR M CL PS Install the inner fairing, align the trim clip holes, and install the three trim clips and screw.
  • Page 86: Top Shelter

    FRAME/BODY PANELS/EXHAUST SYSTEM Disconnect the six headlight connectors. Remove the two 5 x 19 mm, four 5 x 12 mm and two 6 mm setting bolts. Remove the three flange bolts and collars and move the front fairing forward. Disconnect the bank angle sensor and open air tem- perature sensor connectors, and remove the front fairing.
  • Page 87 FRAME/BODY PANELS/EXHAUST SYSTEM RIGHT FAIRING POCKET Insert the ignition key into the lock cylinder and RIGHT FAIRING POCKET open the fairing pocket lid by turning the key TRIM CLIPS clockwise. Remove the four trim clips by pushing the center pins in. Disconnect the opener cable and remove the right fairing pocket.
  • Page 88: Rear Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER A Remove the flange bolt and four setting bolts. LANGE Release the tabs from the saddlebags, being careful BOLT not to damage them and remove rear fender A. Install rear fender A cover in the reverse order of removal.
  • Page 89 FRAME/BODY PANELS/EXHAUST SYSTEM TRUNK LOCK COVER Open the trunk lid. RUNK OPENER COVER Remove the two self-tapping screws, three screws and trunk lock cover. Install the trunk lock cover in the reverse order of SELF- removal. APPING SCREWS SCREWS TRUNK Remove the following: –...
  • Page 90: Saddlebags

    FRAME/BODY PANELS/EXHAUST SYSTEM SADDLEBAGS Perform the following procedure for both the left and right saddlebags. Remove the following: – seat (page 2-5) – left and right side covers (page 2-5) – rear fender A (page 2-13) – trunk lower cover (page 2-13) –...
  • Page 91: Rear Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER B Remove the left and right saddlebags (page 2-15). Remove the following from the rear fender: – two screws and relay box assembly – starter relay switches A and B – power control relays 1 and 2 –...
  • Page 92: Saddlebag/trunk Stay

    FRAME/BODY PANELS/EXHAUST SYSTEM SADDLEBAG/TRUNK STAY FOOTREST UNDER COVER Remove the side cover (page 2-5). Remove the three bolts and footrest under cover. OOTREST UNDER COVER BOLTS SADDLEBAG/TRUNK STAY Remove the following: – left and right footrest under covers – trunk (page 2-13) –...
  • Page 93: Exhaust System

    FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST SYSTEM FRONT EXHAUST PIPE PROTECTOR Perform the following procedure for both the left and right exhaust pipe protectors. Remove the following: – front lower fairing (page 2-6) – bolt, two nuts and four fiber washers Remove the lower portion of the protector from the Do not lose the studs, release the four hooks from the tabs and hook rubbers on the...
  • Page 94 FRAME/BODY PANELS/EXHAUST SYSTEM Loosen the exhaust pipe band bolts. Remove both exhaust pipe joint nuts. Put on gloves, then remove both exhaust pipe Do not damage the mounting bolts, washers and exhaust pipes. sensors while Remove the exhaust pipe joint gaskets. removing the Separate the exhaust pipes and remove the gasket.
  • Page 95 FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER INSTALLATION Install both exhaust pipes with new gaskets. Loosely tighten all nuts and bolts. ASKETS RI HT EXHAUST PIPE LEFT EXHAUST PIPE LEFT MUFFLER ASKETS RI HT MUFFLER Tighten the exhaust pipe band bolts. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft) Tighten the exhaust pipe joint nuts.
  • Page 96 FRAME/BODY PANELS/EXHAUST SYSTEM Tighten the exhaust pipe mounting bolts. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft) Install the mufflers with new gaskets. MOUNTING OLT Tighten the muffler band bolts. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft) Tighten the muffler mounting bolts. Install the removed parts in the reverse order of PROTECTOR OLT removal.
  • Page 97 MEMO...
  • Page 98 3. MAINTENANCE SERVICE INFORMATION ······························ 3-2 FINAL DRIVE OIL ··········································3-15 MAINTENANCE SCHEDULE ························· 3-4 BRAKE FLUID················································3-16 BRAKE PAD WEAR·······································3-17 FUEL LINE ······················································ 3-5 THROTTLE OPERATION································ 3-5 BRAKE SYSTEM ···········································3-18 AIR CLEANER················································· 3-6 BRAKE LIGHT SWITCH ································3-18 CRANKCASE BREATHER ······························ 3-7 HEADLIGHT AIM ··········································3-19 SPARK PLUG ·················································...
  • Page 99: Service Information

    Valve clearance Intake 0.22 ± 0.03 mm (0.009 ± 0.001 in) Exhaust Recommended engine oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA...
  • Page 100 MAINTENANCE TOOL Oil filter wrench 07HAA-PJ70101 or 07HAA-PJ70100...
  • Page 101: Maintenance Schedule

    Should be serviced by your dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by your Honda dealer. NOTES: 1. At higher odometer readings, repeat at the frequency interval established here.
  • Page 102: Fuel Line

    MAINTENANCE FUEL LINE Remove the air cleaner housing (page 5-57). FUEL LINES Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary. Install the air cleaner housing (page 5-57). THROTTLE OPERATION Check for any deterioration or damage to the throt- tle cables.
  • Page 103: Air Cleaner

    MAINTENANCE Major adjustments are made with the lower The lower adjuster ADJ USTING NUT adjusting nut. is located near the left frame rail/steer- Remove the top shelter (page 2-11). ing head area. Loosen the lock nut, turn the adjusting nut as required and tighten the lock nut.
  • Page 104: Crankcase Breather

    MAINTENANCE Remove the four bolts and control unit holder. CREW Disconnect the intake air temperature (IAT) sensor connector. Remove the seven screws and air cleaner cover. CONNECTOR COVER IR CLE NER ELEMENT Replace the air cleaner element in accordance with the maintenance schedule or any time it is exces- sively dirty or damaged.
  • Page 105: Spark Plug

    MAINTENANCE Remove the plug from the air cleaner housing drain hose and drain the deposits into a suitable con- tainer, then reinstall the plug securely. RAIN HOSE PLUG LUGS/BOLTS Install the left cylinder head side cover and tighten the socket bolts. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the rubber plugs.
  • Page 106: Valve Clearance

    MAINTENANCE VALVE CLEARANCE INSPECTION • Inspect and adjust the valve clearance while the engine is cold (below 35° C, 95° F). LUGS/BOLTS Remove the cylinder head side covers (page 3-7). Remove the bolt and wire clamp, spark plug wires from the clip, and the three rubber plugs. Then remove the six socket bolts (left cylinder head cover), five socket bolts (right cylinder head cover), and cylinder head cover.
  • Page 107 MAINTENANCE Rotate the crankshaft counterclockwise 120° and 3.4 MARK 5.6 MARK align the T3.4 mark with the index mark. Check the No. 4 cylinder valve clearance. Rotate the crankshaft counterclockwise 120° and align the T5.6 mark with the index mark. Check the No.
  • Page 108: Engine Oil

    MAINTENANCE Install the newly selected shims on the valve retainers. Install the valve lifters and camshafts (page 8-28). Rotate the camshafts by rotating the crankshaft counterclockwise several times. Recheck the valve clearances. Install a new gasket into the groove in the cylinder head cover.
  • Page 109: Engine Oil Filter

    PPER upper level mark. LEVEL RECOMMENDED ENGINE OIL: LOWER Pro Honda GN4 or HP4 (without molybdenum LEVEL additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA Viscosity: SAE 10W-40 •...
  • Page 110: Radiator Coolant

    If the level is low, fill the tank to the upper level hole with a 1:1 mixture of distilled water and antifreeze (coolant preparation: page 6-6). PPER RECOMMENDED ANTIFREEZE: LEVEL Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free LOWER corrosion inhibitors LEVEL 3-13...
  • Page 111: Cooling System

    MAINTENANCE Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. Check to see if there are any coolant leaks when the coolant level decreases very rapidly. If the reserve tank becomes completely empty, there is a possibility of air getting into the cooling system.
  • Page 112: Evaporative Emission Control

    MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM Remove the air cleaner housing (page 5-57). Check the evaporative emission (EVAP) canister, which is located in front of the engine, for cracks or UEL TANK damage. Check the hoses between the fuel tank, EVAP canis- ter, EVAP purge control valve solenoid and throttle body for deterioration, damage or loose connec- tions.
  • Page 113: Oil Change

    MAINTENANCE OIL CHANGE Remove the oil filler cap and drain bolt from the final gear case, slowly turn the rear wheel and drain IL FILLER CAP the oil. After the oil is completely drained, install the drain bolt with a new sealing washer and tighten it. TORQUE: 2.0 N·m (20 kgf·m, 14 lbf·ft) Fill the final gear case with the recommended oil to the correct level (page 3-16).
  • Page 114: Brake Pad Wear

    MAINTENANCE ASTING LEDGE If the fluid level is near the “LOWER” level mark, remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge. Install the diaphragm, set plate and reservoir cap and tighten the cap screws.
  • Page 115: Brake System

    MAINTENANCE BRAKE SYSTEM RAKE HOSES Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feels soft or spongy when operated, bleed the air from the system. Refer to page 15-8 for air bleeding procedures. Inspect the brake hoses, pipes and fittings for deteri- oration, cracks, damage or signs of leakage.
  • Page 116: Headlight Aim

    MAINTENANCE HEADLIGHT AIM Remove the inner fairings (page 2-10). Start the engine and move the headlight beams to the highest position by turning the headlight beam adjusting knob clockwise fully. EAM ADJUSTING KNO Stop the engine and place the motorcycle on a level surface.
  • Page 117: Reverse Operation

    MAINTENANCE Turn the handlebar to the right side so that the res- ervoir is level and check the clutch reservoir fluid level through the sight glass. ASTING LEDGE If the level is near the “LOWER” level mark, remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge.
  • Page 118: Suspension

    MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by applying the front brakes and compressing the front suspension several times. Check the entire assembly for leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts.
  • Page 119: Wheels/tires

    MAINTENANCE WHEELS/TIRES Check the tire pressure with the tire pressure gauge when the tires are cold. RECOMMENDED TIRE PRESSURE: Up to 90 kg (200 lbs) load: Front: 250 kPa (2.50 kgf/cm , 36 psi) Rear: 280 kPa (2.80 kgf/cm , 41 psi) Up to maximum weight capacity: Front: 250 kPa (2.50 kgf/cm , 36 psi)
  • Page 120 4. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ············· 4-2 OIL PRESSURE CHECK ··································4-5 SERVICE INFORMATION ······························ 4-3 OIL STRAINER/PRESSURE RELIEF VALVE ·····························································4-6 TROUBLESHOOTING ···································· 4-4 OIL PUMP························································4-7...
  • Page 121: Lubrication System Diagram

    LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM AMSHAFT ALTERNATOR DRIVEN GEAR PISTON RANKSHAFT ONNE TING ROD OUTPUT SHAFT LUT H REGULATOR VALVE OUNTERSHAFT LUT H MAINSHAFT OIL FILTER OIL PUMP RELIEF VALVE OIL STRAINER...
  • Page 122 – After disassembly 4.6 liters (4.9 US qt, 4.0 Imp qt) – Recommended engine oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent motor oil – API service classification SG or higher JASO T 903 standard: MA Viscosity: SAE...
  • Page 123 LUBRICATION SYSTEM TROUBLESHOOTING Oil level too low • Oil consumption • External oil leak • Worn piston rings • Improperly installed piston rings • Worn cylinders • Worn stem seals • Worn valve guide Low oil pressure • Oil level low •...
  • Page 124: Oil Pressure Check

    LUBRICATION SYSTEM OIL PRESSURE CHECK Remove the left exhaust pipe protector (page 2-18). If the engine is cold, the pressure reading will be abnormally high. Warm up the engine to normal operating tempera- ture before checking the oil pressure. Stop the engine. Remove the switch cover and disconnect to the oil pressure switch wire by removing the terminal screw.
  • Page 125: Oil Strainer/pressure Relief

    LUBRICATION SYSTEM OIL STRAINER/PRESSURE RELIEF VALVE Separate the crankcase (page 11-6). OIL STRAINER Remove the strainer bolt and oil strainer from the oil pump. Remove the oil strainer packing. Clean the oil strainer thoroughly. Apply engine oil to the new packing and install it onto the oil pump.
  • Page 126: Oil Pump

    LUBRICATION SYSTEM Check the operation of the pressure relief valve by pushing on the piston. Disassemble the relief valve by removing the snap ring. NAP RING Inspect the piston for wear, unsmooth movement PI TON or damage. Inspect the spring for fatigue or damage. Assemble the relief valve in the reverse order of disassembly.
  • Page 127 LUBRICATION SYSTEM IL PUMP Remove the three mounting bolts and oil pump from the crankcase. Remove the three dowel pins and two O-rings. DISASSEMBLY IL PUMP C VER B Remove the three oil pump assembly bolts and oil pump cover B. D WEL PINS Remove the dowel pins from the oil pump body.
  • Page 128 LUBRICATION SYSTEM IL PUMP C VER A Remove oil pump cover A from the oil pump body. Remove the dowel pins from the cover. D WEL PINS FEED PUMP SIDE: OUTER ROTOR HAFT Remove the following from the oil pump body. –...
  • Page 129 LUBRICATION SYSTEM Measure the pump side clearance for the feed and scavenge pumps. SERVICE LIMIT: 0.12 mm (0.005 in) ASSEMBLY Dip all parts in clean engine oil. OUTER ROTOR B OIL PUMP COVER A INNER ROTOR B OIL PUMP COVER B DOWEL PINS DRIVE PIN OIL PUMP BODY...
  • Page 130 LUBRICATION SYSTEM Install the inner rotor onto the oil pump shaft. NNER ROTOR Install the drive pin into the pump shaft hole and align the drive pin with the groove in the inner rotor. Install the thrust washer onto the shaft. DR VE P N WASHER OUTER ROTOR...
  • Page 131 LUBRICATION SYSTEM Install the oil pump assembly bolts and tighten the bolts to the specified torque. TORQUE: 13 N·m (1.3 kgf·m, 9 lbf·ft) -RINGS Install the three dowel pins. Coat the new O-rings with engine oil and install them. D WEL PINS IL PUMP Install the oil pump with the three mounting bolts.
  • Page 132 5. FUEL SYSTEM (Programmed Fuel Injection) COMPONENT LOCATION ····························· 5-2 THROTTLE BODY ·········································5-58 SERVICE INFORMATION ······························ 5-3 FUEL INJECTORS·········································5-61 FUEL PUMP RELAY······································5-66 TROUBLESHOOTING ···································· 5-5 SYSTEM LOCATION······································ 5-6 BARO/MAP SENSORS·································5-67 SYSTEM DIAGRAM······································· 5-7 IAT SENSOR ·················································5-68 PGM-FI (PROGRAMMED FUEL INJECTION) CAMSHAFT POSITION SENSOR·················5-68 SYSTEM ·························································...
  • Page 133: Component Location

    FUEL SYSTEM (Programmed Fuel Injection) COMPONENT LOCATION FUEL SYSTEM (Programmed Fuel Injection)
  • Page 134: Service Information

    FUEL SYSTEM (Programmed Fuel Injection) SERVICE INFORMATION GENERAL • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. • Be sure to relieve the fuel pressure with the ignition switch turned to “OFF.” •...
  • Page 135 FUEL SYSTEM (Programmed Fuel Injection) TORQUE VALUES Fuel hose joint bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Fuel rail mounting bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Pressure regulator 27 N·m (2.8 kgf·m, 20 lbf·ft) Pressure regulator stay bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Fuel rail banjo bolt 33 N·m (3.4 kgf·m, 25 lbf·ft) Sealing bolt...
  • Page 136: Troubleshooting

    FUEL SYSTEM (Programmed Fuel Injection) TROUBLESHOOTING Engine cranks but won’t start • No fuel in tank • No fuel to injector – Clogged fuel filter – Pinched or clogged fuel feed hose – Pinched or clogged fuel tank breather tube –...
  • Page 137: System Location

    FUEL SYSTEM (Programmed Fuel Injection) SYSTEM LOCATION RELAY BOX PRESSURE IAT SENSOR REGULATOR FUEL PUMP BARO SENSOR IAC VALVE MAP SENSOR ALTERNATOR BANK ANGLE SENSOR EVAP PURGE CONTROL SOLENOID VALVE PAIR CONTROL SOLENOID VALVE TP SENSOR FUSE BOX FUEL INJECTOR CAMSHAFT ECT SENSOR POSITION...
  • Page 138: System Diagram

    FUEL SYSTEM (Programmed Fuel Injection) SYSTEM DIAGRAM Fuel injectors (13) ECT sensor Ignition coils (14) MAP sensor Spark plugs (15) Alternator Pulse secondary air (PAIR) control solenoid (16) TP sensor valve PAIR check valve (17) Camshaft position sensor (18) IAT sensor Knock sensors (19) IAC valve...
  • Page 139: Pgm-fi (programmed Fuel Injection)

    FUEL SYSTEM (Programmed Fuel Injection) PGM-FI (PROGRAMMED FUEL INJECTION) SYSTEM SELF-DIAGNOSTIC DATA INDICATION PROCEDURE Place the motorcycle on its side stand. Turn the ignition switch to “ON” and engine stop switch to “ .” The malfunction indicator lamp (MIL) comes on for a few seconds, then goes off.
  • Page 140 FUEL SYSTEM (Programmed Fuel Injection) Turn the ignition switch to “ON.” Make sure the engine stop switch If the ECM has no problem data in its memory, the is turned to “ .” MIL will come on and stay on. If the ECM has problem data in its memory, the MIL will start blinking.
  • Page 141 FUEL SYSTEM (Programmed Fuel Injection) After ‘03: 1. Turn the ignition switch to “OFF.” 2. Remove the dummy connector and short the Make sure the SCS SERVICE CONNECTOR Brown and Green wire terminals of the Data Link engine stop switch Connector (DLC) using the special tool.
  • Page 142 FUEL SYSTEM (Programmed Fuel Injection) IGITAL MULTIMETER Connect the peak voltage adaptor to the digital multimeter. TOOLS: Ignitionmate Peak voltage MTP07-0286 (U.S.A. tester only) or Peak voltage adaptor 07HGJ-0020100 with commercially available (not available in digital multimeter (impedance U.S.A.) 10 MΩ/DCV minimum) PEAK VOLTAGE A APTOR TEST HARNESS CONNECTION RAY CONNECTOR...
  • Page 143 FUEL SYSTEM (Programmed Fuel Injection) Terminal Conversion Chart ERMINALS FOR 22P BLACK CONNEC OR 22P black connector Test pin box terminal No. terminal No. 22P gray connector Test pin box terminal No. terminal No. ERMINALS FOR 22P GRAY CONNEC OR MALFUNCTION INDICATOR LAMP (MIL) CHECK If the engine can be started but the MIL does not...
  • Page 144: Pgm-fi Self-diagnosis Malfunction Indicator Failure Codes

    FUEL SYSTEM (Programmed Fuel Injection) PGM-FI SELF-DIAGNOSIS MALFUNCTION INDICATOR FAILURE CODES • The PGM-FI malfunction indicator lamp (MIL) denotes the failure codes (the number of blinks from 0 to 41). The MIL has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.5 seconds.
  • Page 145 FUEL SYSTEM (Programmed Fuel Injection) Number of MIL Symptoms Refer to Cause blinks (Fail-safe contents) page • Loose or poorly connected vehicle speed • Engine operates normally sensor connector • Open or short circuit in vehicle speed sen- 5-24 sor wire •...
  • Page 146 FUEL SYSTEM (Programmed Fuel Injection) Number of MIL Symptoms Refer to Cause blinks (Fail-safe contents) page • Open or short circuit in left O sensor • Engine operates normally heater wire • Faulty left O sensor 5-42 Blinks • Loose or poorly connected right knock •...
  • Page 147: Pgm-fi Troubleshooting

    FUEL SYSTEM (Programmed Fuel Injection) PGM-FI TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) 1. MAP Sensor Power Input Line Voltage Inspection Light green/yellow reen/red 8P RAY Remove the top shelter (page 2-12). CONNECTOR Turn the ignition switch to “OFF.” Disconnect the engine sub-wire harness 8P connector.
  • Page 148 FUEL SYSTEM (Programmed Fuel Injection) 4. MAP Sensor Harness Continuity Inspection Light green/yellow AP SENSOR Turn the ignition switch to “OFF.” CONNECTOR Remove the air cleaner housing (page 5-57). Yellow/red Disconnect the MAP sensor 3P connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 149 FUEL SYSTEM (Programmed Fuel Injection) 7. MAP Sensor Connection Inspection Turn the ignition switch to “OFF.” Remove the test harnesses and connect the ECM connectors. Place the motorcycle on its side stand. Start the engine, let it idle and check that the MIL blinks.
  • Page 150 FUEL SYSTEM (Programmed Fuel Injection) 3. ECT Sensor Resistance Inspection Turn the ignition switch to “OFF.” P GRAY CONNECTOR Yellow/blue Connect the ECT sensor 3P connector. Disconnect the engine sub-wire harness 6P gray connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 151 FUEL SYSTEM (Programmed Fuel Injection) 2. TP Sensor Input Voltage Inspection Measure the voltage between the main wire har- ness side 8P gray connector terminals. Connection: Yellow/red (+) – Green/red (–) Standard: 4.75 – 5.25 V Is the voltage within 4.75 – 5.25 V? –...
  • Page 152 FUEL SYSTEM (Programmed Fuel Injection) 6. TP Sensor Harness Short Circuit Inspection Check for continuity between the following wire terminal and ground at the wire harness side TP sensor 3P connector. • Yellow/red • Green/red • Light green Is there continuity? –...
  • Page 153 FUEL SYSTEM (Programmed Fuel Injection) MIL 9 BLINKS (IAT SENSOR) 1. IAT Sensor Connection Inspection Remove the top shelter (page 2-12). Turn the ignition switch to “OFF.” AT SENSOR CONNECTOR Green/red Disconnect the IAT sensor 2P connector. Gray/blue Check the connector for loose contacts or cor- roded terminals.
  • Page 154 FUEL SYSTEM (Programmed Fuel Injection) MIL 10 BLINKS (BARO SENSOR) 1. BARO Sensor Connection Inspection Remove the top shelter (page 2-12). Light green/black Turn the ignition switch to “OFF.” ellow/red Disconnect the BARO sensor 3P connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 155 FUEL SYSTEM (Programmed Fuel Injection) 5. BARO Sensor Voltage at ECM Turn the ignition switch to “OFF.” Connect the BARO sensor 3P connector. Connect the test harness set to the ECM connec- tors (page 5-11). Turn the ignition switch to “ON.” Measure the voltage at the test pin box terminals.
  • Page 156 FUEL SYSTEM (Programmed Fuel Injection) 3. Vehicle Speed Sensor Line Voltage Inspection Measure the voltage between the wire harness side 3P connector terminals. Connection: Brown/white (+) – Green (–) Standard: Battery voltage Does battery voltage exist? – Open circuit in the Green wire. –...
  • Page 157 FUEL SYSTEM (Programmed Fuel Injection) MIL 12 BLINKS (No. 1 INJECTOR) 1. Injector Connection Inspection Remove the right injector cover (page 5-61). Brown Turn the ignition switch to “OFF.” Pink/blue o. 1 I JECTOR CO ECTOR Disconnect the No. 1 injector 2P connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 158 FUEL SYSTEM (Programmed Fuel Injection) 5. No. 1 Injector Control Line Short Circuit Inspection Turn the ignition switch to “OFF.” CM 6P BLACK CONN CTOR Disconnect the ECM 6P black connector. (viewed from the terminal side) Check for continuity between the Pink/blue wire terminal of the wire harness side 6P connector and ground.
  • Page 159 FUEL SYSTEM (Programmed Fuel Injection) 3. No. 2 Injector Short Circuit Inspection Check for continuity between the No. 2 injector terminal and ground. Is there continuity? – Faulty No. 2 injector. – GO TO STEP 4. 4. No. 2 Injector Power Input Line Inspection Turn the ignition switch to “ON.”...
  • Page 160 FUEL SYSTEM (Programmed Fuel Injection) 2. No. 3 Injector Resistance Inspection Turn the ignition switch to “OFF.” Disconnect the No. 3 injector 2P connector. NJECTOR TERM NALS Measure the resistance between the No. 3 injector terminals. Standard: 11.1 – 12.3Ω (at 20° C/68° F) Is resistance within 11.1 –...
  • Page 161 FUEL SYSTEM (Programmed Fuel Injection) MIL 15 BLINKS (No. 4 INJECTOR) 1. Injector Connection Inspection Remove the left injector cover (page 5-61). Brown Red/black Turn the ignition switch to “OFF.” o. 4 I JECTOR CO ECTOR Disconnect the No. 4 injector 2P connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 162 FUEL SYSTEM (Programmed Fuel Injection) 5. No. 4 Injector Control Line Short Circuit Inspection Turn the ignition switch to “OFF.” CM 6P BLACK CONN CTOR Disconnect the ECM 6P black connector. (viewed from the terminal side) Check for continuity between the Red/black wire terminal of the wire harness side 6P connector Red/black and ground.
  • Page 163 FUEL SYSTEM (Programmed Fuel Injection) 3. No. 5 Injector Short Circuit Inspection Check for continuity between the No. 5 injector terminal and ground. Is there continuity? – Faulty No. 5 injector. – GO TO STEP 4. 4. No. 5 Injector Power Input Line Inspection Turn the ignition switch to “ON.”...
  • Page 164 FUEL SYSTEM (Programmed Fuel Injection) MIL 17 BLINKS (No. 6 INJECTOR) 1. Injector Connection Inspection Remove the left injector cover (page 5-61). Brown Turn the ignition switch to “OFF.” Light green o. 6 I JECTOR CO ECTOR Disconnect the No. 6 injector 2P connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 165 FUEL SYSTEM (Programmed Fuel Injection) 5. No. 6 Injector Control Line Short Circuit Inspection Turn the ignition switch to “OFF.” CM 6P BLACK CONN CTOR Disconnect the ECM 6P black connector. (viewed from the terminal side) Check for continuity between the Light green wire terminal of the wire harness side 6P Light green connector and ground.
  • Page 166 FUEL SYSTEM (Programmed Fuel Injection) 2. Camshaft Position Sensor Connection Inspection Turn the ignition switch to “OFF.” Remove the ECM test harness and connect the ECM connectors. Reset the self-diagnostic memory (page 5-9). Check that the engine can be started by cranking it with the starter motor for 10 seconds or more.
  • Page 167 FUEL SYSTEM (Programmed Fuel Injection) MIL 19 BLINKS (IGNITION PULSE GENERATOR) 1. Ignition Pulse Generator Peak Voltage Inspection at ECM Remove the top shelter (page 2-12). Turn the ignition switch to “OFF.” CM 22P GRAY CONN CTOR Disconnect the ECM 22P gray connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 168 FUEL SYSTEM (Programmed Fuel Injection) 4. Ignition Pulse Generator Peak Voltage Inspection Turn the ignition switch to “OFF.” Remove the air cleaner housing (page 5-57). Disconnect the ignition pulse generator 2P connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 169 FUEL SYSTEM (Programmed Fuel Injection) 3. Right Sensor Signal Line Continuity Inspection Connect the test harness set to the ECM connec- tors (page 5-10). Check for continuity between the wire harness Black/red side O sensor 4P connector and test pin box terminals.
  • Page 170 FUEL SYSTEM (Programmed Fuel Injection) MIL 22 BLINKS (LEFT O SENSOR) 1. Left O Sensor Connection Inspection Remove the top shelter (page 2-12). Green/red Black/orange Turn the ignition switch to “OFF.” Disconnect the left O sensor 4P connector. Check the connector for loose contacts or cor- roded terminals.
  • Page 171 FUEL SYSTEM (Programmed Fuel Injection) 5. Left O Sensor Output Voltage Inspection Connect the left O sensor 4P connector. Start the engine, snap it from idle to 5,000 rpm No. 8 (–) and measure the voltage between the test pin box terminals.
  • Page 172 FUEL SYSTEM (Programmed Fuel Injection) 4. Right O Sensor Heater Power Input Line Inspection Turn the ignition switch to “ON.” SENSOR CONNECTOR Measure the voltage between the wire harness (viewed from the terminal side) side connector terminal and ground. Connection: Black/yellow (+) – Ground (–) Standard: Battery voltage Does battery voltage exist? –...
  • Page 173 FUEL SYSTEM (Programmed Fuel Injection) MIL 24 BLINKS (LEFT O SENSOR HEATER) 1. Left O Sensor Connection Inspection Remove the top shelter (page 2-12). Black/yellow Turn the ignition switch to “OFF.” Disconnect the left O sensor 4P connector. Check the connector for loose contacts or cor- White roded terminals.
  • Page 174 FUEL SYSTEM (Programmed Fuel Injection) 5. Left O Sensor Heater Control Line Short Circuit Inspection Turn the ignition switch to “OFF.” SENSOR CONNECTOR Disconnect the ECM 22P black connector. (viewed from the terminal side) Turn the ignition switch to “ON.” Measure the voltage between the wire harness White lack/yellow...
  • Page 175 FUEL SYSTEM (Programmed Fuel Injection) 2. Right Knock Sensor Line Short Circuit Inspection Turn the ignition switch to “OFF.” Disconnect the right knock sensor 1P connector and ECM 22P gray connector. Check for continuity between the wire harness side knock sensor 1P connector terminal and ground.
  • Page 176 FUEL SYSTEM (Programmed Fuel Injection) 2. Left Knock Sensor Line Short Circuit Inspection Turn the ignition switch to “OFF.” Disconnect the left knock sensor 1P connector and ECM 22P gray connector. Check for continuity between the wire harness side knock sensor 1P connector terminal and ground.
  • Page 177 FUEL SYSTEM (Programmed Fuel Injection) 2. IAC Valve Ground Line Short Circuit Inspection Turn the ignition switch to “OFF.” Check for continuity between the Green wire ter- minal of the main wire harness side 8P connec- tor and ground. Is there continuity? –...
  • Page 178 FUEL SYSTEM (Programmed Fuel Injection) 6. IAC Valve Harness Short Circuit Inspection Check continuity between the following wire ter- minal and ground at the wire harness side IAC valve 3P connector. • Black/yellow • Green • Light blue Is there continuity? –...
  • Page 179 FUEL SYSTEM (Programmed Fuel Injection) MIL 33 BLINKS (E -PROM) 1. ECM Connectors Connection Inspection Remove the top shelter (page 2-12). CM CONN CTORS Turn the ignition switch to “OFF.” Disconnect the ECM connectors. Check the connector for loose contacts or cor- roded terminals.
  • Page 180 FUEL SYSTEM (Programmed Fuel Injection) MIL 41 BLINKS (GEAR POSITION SWITCH) 1. Neutral and Overdrive Indicator Inspection Check that the neutral indicator and overdrive indicator function properly. Are the neutral indicator and overdrive indicator functioning properly? – Inspect the neutral indicator system (page 20-26).
  • Page 181 FUEL SYSTEM (Programmed Fuel Injection) 5. Gear Position Switch – 3rd Gear Line Continuity Inspection Shift the transmission into 3rd gear. Check for continuity between the White/red wire terminal of the wire harness side connector and ground. Is there continuity? –...
  • Page 182 FUEL SYSTEM (Programmed Fuel Injection) 8. 1st Gear Selected, Side Stand Retracted Line Short Circuit Inspection Check for continuity between the Blue/red wire terminal (–) of the wire harness side connector and ground (+) with the clutch lever released. Recheck with reverse connections. Is there continuity? –...
  • Page 183: Fuel Line Inspection

    FUEL SYSTEM (Programmed Fuel Injection) FUEL LINE INSPECTION FUEL PRESSURE INSPECTION OLTS Remove the front fairing (page 2-10). Remove the two bolts and left injector cover. INJECTOR COVER ACUUM HOSE Pinch the pressure regulator vacuum hose using a hose clamp. HOSE CLAMP EALING WA HER Cover the sealing bolt with a rag or shop towel.
  • Page 184 FUEL SYSTEM (Programmed Fuel Injection) If the pressure is lower than specified pressure, inspect the following: – clogged fuel filter – pressure regulator – fuel pump (page 5-54) After inspection, remove the fuel pressure gauge. EALING WA HER Install the sealing bolt with a new sealing washer and tighten it.
  • Page 185: Fuel Pump

    FUEL SYSTEM (Programmed Fuel Injection) FUEL FLOW INSPECTION Remove the seat (page 2-5). UEL RETURN HOSE Disconnect the fuel return hose from the fuel tank When the fuel and plug the joint pipe of the fuel tank immediately. return hose is dis- connected, gaso- line may spill out of HOSE JOINT...
  • Page 186 FUEL SYSTEM (Programmed Fuel Injection) 2. Turn the ignition switch to “OFF” and disconnect the fuel pump 5P connector. Green rown Turn the ignition switch to “ON.” Measure the voltage between the brown (+) and green (–) wire terminals of the wire harness side connector.
  • Page 187: Fuel Tank

    FUEL SYSTEM (Programmed Fuel Injection) ASE GASKET Remove the base gasket. Install a new base gasket. Install the fuel pump assembly into the fuel tank and align the lugs on the pump base with the grooves in the fuel tank. Install the retainer plate and a new retainer ring.
  • Page 188: Air Cleaner Housing

    FUEL SYSTEM (Programmed Fuel Injection) Disconnect the following: Tilt the fuel tank to RAIN HOSE SEAT HOOK – fuel pump 5P connector (page 5-54) the right and – fuel return hose (page 5-54) remove it from the – fuel feed hose (page 5-54) left side of the –...
  • Page 189: Throttle Body

    FUEL SYSTEM (Programmed Fuel Injection) To remove the air funnels, remove the screws from SCREWS the air funnels and turn the air funnels as shown and remove them. “R” MARK “L” MARK • The left air funnel has an “L” mark and the right air funnel has an “R”...
  • Page 190 FUEL SYSTEM (Programmed Fuel Injection) DISASSEMBLY/ASSEMBLY • Do not loosen or tighten the white painted bolts, nuts and screws of the throttle body. Loosening or tightening them can cause throttle and idle valve synchronization failure. • The parts of the throttle body not shown in this manual should not be disassembled.
  • Page 191 FUEL SYSTEM (Programmed Fuel Injection) CABLE STAY/MAP SENSOR CREW MAP EN OR Remove the two screws and cable stay. Remove the two screws, MAP sensor and O-ring. Install the cable stay and tighten the screws. TORQUE: 4 N·m (0.4 kgf·m, 2.9 lbf·ft) CABLE TAY CREW Install a new O-ring into the throttle body groove.
  • Page 192: Fuel Injectors

    FUEL SYSTEM (Programmed Fuel Injection) Connect the following: Connect the hoses TP SENSOR AP SENSOR – Evaporative emission (EVAP) No. 5 hoses to their correct joint – pressure regulator vacuum hose pipes. – MAP sensor connector – TP sensor connector –...
  • Page 193 FUEL SYSTEM (Programmed Fuel Injection) BOLT Cover the sealing bolt with a rag or shop towel. Remove the sealing bolt to relieve the fuel pressure. Remove the two bolts and radiator stay. EALING BOLT RADIATOR TAY Disconnect the injector connectors. ONNE TORS Left side: Remove the four bolts, fuel feed hose joint EED HOSE JOINT...
  • Page 194 FUEL SYSTEM (Programmed Fuel Injection) Clean around the injectors with compressed air FUEL RAIL ASSEMBLY before removing the fuel rail assembly. Remove the three bolts and fuel rail assembly from the intake manifold. Seal the injector ports in the intake manifold with tape or clean cloth to keep dirt and debris from entering the engine.
  • Page 195 FUEL SYSTEM (Programmed Fuel Injection) Install the fuel rail mounting bolts and tighten them. FUEL RAIL ASSEMBLY TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) BOLTS Left side: Coat new O-rings with oil and install them into the -RINGS fuel feed hose joint and pressure regulator stay. Right side: Right side: Coat new O-rings with oil and install them into the fuel feed hose joints.
  • Page 196 FUEL SYSTEM (Programmed Fuel Injection) PRESSURE REGULATOR REPLACEMENT Remove the radiator stay (page 5-61). PRESSURE REGULATOR Hold the pressure regulator and loosen the nut. Remove the pressure regulator and joint pipe from the pressure regulator stay. Disconnect the vacuum hose and fuel return hose ACUUM HOSE from the pressure regulator.
  • Page 197: Fuel Pump Relay

    FUEL SYSTEM (Programmed Fuel Injection) FUEL PUMP RELAY SYSTEM INSPECTION • Perform the fuel pump inspection (page 5-54) before this inspection. ELAY BOX Remove the seat (page 2-5). Remove the two screws and remove the relay box. Remove the relay blocks from the relay box. UEL PUMP RELAY 1.
  • Page 198: Baro/map Sensors

    FUEL SYSTEM (Programmed Fuel Injection) 4. Turn the ignition switch to “OFF.” Measure the voltage between the Black/yellow FUEL PUMP RELAY CONNECTOR wire terminal (+) and Brown/black wire terminal of the fuel pump relay connector. Turn the ignition switch to “ON.” lack/yellow rown/black There should be battery voltage for a few...
  • Page 199: Iat Sensor

    FUEL SYSTEM (Programmed Fuel Injection) BARO SENSOR REPLACEMENT ARO SENSOR Remove the top shelter (page 2-11). Disconnect the BARO sensor 3P connector. Remove the screw and BARO sensor. Installation is in the reverse order of removal. • For the MAP sensor, remove the throttle body (page 5-58) and replace the sensor (page 5-68).
  • Page 200: O 2 Sensor

    FUEL SYSTEM (Programmed Fuel Injection) Coat a new O-ring with engine oil and install it onto a new camshaft position sensor. Install the camshaft position sensor into the left cyl- inder head and tighten the bolt securely. Install the injector cover (page 5-61). -RING SENSOR REPLACEMENT...
  • Page 201: Vehicle Speed Sensor

    FUEL SYSTEM (Programmed Fuel Injection) VEHICLE SPEED SENSOR REPLACEMENT Remove the following: – top shelter (page 2-12) – right front exhaust pipe protector (page 2-18) Disconnect the vehicle speed sensor 3P connector. P CONNECTOR OLTS Remove the two bolts and the vehicle speed sensor from the crankcase.
  • Page 202: Ecm (engine Control Module)

    FUEL SYSTEM (Programmed Fuel Injection) ECM (ENGINE CONTROL MODULE) POWER/GROUND LINE INSPECTION Connect the test harness set to the ECM connectors (page 5-11). GROUND LINE Check for continuity between the test pin box No. 9 o. 20 o. 9 terminal and ground, between the No. 19 terminal and ground, and between the No.
  • Page 203 FUEL SYSTEM (Programmed Fuel Injection) o. 15 AIR SUPPLY HOSE Remove the air cleaner housing (page 5-57). Temporarily install the fuel tank. Connect the ECM, IAT sensor and BARO sensor connectors. Start the engine and open the throttle slightly to be certain that air is sucked in through the No.
  • Page 204 FUEL SYSTEM (Programmed Fuel Injection) Remove the six bolts and check valve covers/hoses OSES from the cylinder. BOLTS COVERS Remove the PAIR check valves from the cylinder. AIR CHECK VALVE Check the reed for damage or fatigue. Replace if STOPPE necessary.
  • Page 205: Evaporative Emission (evap) Control

    FUEL SYSTEM (Programmed Fuel Injection) EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM • Refer to the Vacuum Hose Routing Diagram and Cable & Harness Routing (page 1-23) for hose connections and routing. EVAP CANISTER REMOVAL/ INSTALLATION OLTS Remove the front lower fairing (page 2-6). Disconnect the No.
  • Page 206: Engine Idle Speed

    FUEL SYSTEM (Programmed Fuel Injection) ENGINE IDLE SPEED • Make sure the malfunction indicator (MIL) does not indicate any failure codes before inspecting the engine idle speed. Shift the transmission into neutral and place the motorcycle on its center stand on a level surface. Start the engine, warm it up to the normal operating temperature and let it idle.
  • Page 207 FUEL SYSTEM (Programmed Fuel Injection) HIGH ENGINE IDLE SPEED • Make sure that the charging system is in good condition before proceeding. 1. Stop the engine and allow it to cool until the coolant temperature gauge needle moves below the “C” line. 2.
  • Page 208 FUEL SYSTEM (Programmed Fuel Injection) 6. Stop the engine, and remove the tape from the throttle body. Start the engine and check the idle speed. IDLE SPEED: 1,500 – 1,600 rpm • If the idle speed is out of specification, replace the IAC valve.
  • Page 209 MEMO...
  • Page 210 6. COOLING SYSTEM COMPONENT LOCATION ····························· 6-2 COOLANT REPLACEMENT····························6-6 SERVICE INFORMATION ······························ 6-3 RADIATOR/COOLING FAN····························6-8 TROUBLESHOOTING ···································· 6-4 WATER PUMP/THERMOSTAT····················6-17 SYSTEM TESTING········································· 6-5...
  • Page 211 COOLING SYSTEM COMPONENT LOCATION COOLING SYSTEM RIGHT RADIATOR EFT RADIATOR RESERVE TANK THERMOSTAT DRAIN BO T WATER PUMP...
  • Page 212 Fully open 90° C (194° F) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors Standard coolant concentration 1:1 mixture with distilled water TORQUE VALUES Water pump cover sealing plate bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)
  • Page 213 COOLING SYSTEM TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or ECT sensor • Thermostat stuck closed • Faulty radiator cap • Insufficient coolant • Passages blocked in radiator, hoses or water jacket • Air in system • Faulty cooling fan motor •...
  • Page 214: System Testing

    COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the right fairing pocket (page 2-12). Remove the radiator cap. ADIATO CAP YDROMETER Test coolant specific gravity using hydrometer. STANDARD COOLANT CONCENTRATION: 50% Look for contamination and replace the coolant if necessary. COOLANT GRAVITY CHART Coolant temperature °...
  • Page 215: Coolant Replacement

    Mix only distilled, low mineral water with the rec- ommended antifreeze. RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors RECOMMENDED MIXTURE: 1:1 (distilled water and recommended antifreeze)
  • Page 216 COOLING SYSTEM REPLACEMENT/AIR BLEEDING • When filling the system or reserve tank with coolant, or checking the coolant level, place the motorcycle on its center stand on a flat, level surface. Remove the following: – left engine side cover (page 2-5) –...
  • Page 217 COOLING SYSTEM ILLER NECK Fill the system with the recommended coolant through the filler opening up to the filler neck. Install the radiator cap. Bleed air from the system as follows: 1. Shift the transmission into neutral. Start the engine and let it idle for 2 – 3 minutes. 2.
  • Page 218 COOLING SYSTEM +4-9 Remove the two screws attaching the connector holder to the air duct. )14 ,7+6 Remove the three trim clips and air duct. RIM CLIPS ADIATO G ILLE Remove the radiator grille from the radiator by releasing the four hooks from the tabs. Disconnect the siphon hose.
  • Page 219 COOLING SYSTEM Loosen the band screws and disconnect the drain hose, upper and lower radiator hoses. OLTS Remove the two mounting bolts and the right radia- tor assembly. LEFT RADIATOR P BLACK CONNECTOR Disconnect the left radiator fan motor 2P black Be careful not to connector.
  • Page 220 COOLING SYSTEM Remove the three trim clips and air duct. Remove the radiator grille from the radiator by releasing the four hooks from the tabs. Loosen the band screws and disconnect the bleed hose, drain hose, upper and lower radiator hoses. OLTS Remove the two mounting bolts and the left radia- tor assembly.
  • Page 221 COOLING SYSTEM COOLI G FA Remove the nut and cooling fan from the fan motor. FAN MOTOR Remove the three bolts and fan motor from the shroud. OLTS ASSEMBLY ONDENSER SHROUD FAN MOTOR RADIATOR FAN NUT OOLING FAN 6-12...
  • Page 222 COOLING SYSTEM Route the fan motor wire and condenser wire AN MOTOR through the shroud. Install the fan motor onto the shroud with the drain hose facing down as shown, then install the three bolts and tighten them securely. DRAIN HOSE BOLTS OOLING FAN Install the cooling fan onto the motor shaft, aligning...
  • Page 223 COOLING SYSTEM OLTS Install the two mounting bolts and tighten them. TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) PPER RADIATOR HOSE Connect the drain hose, upper and lower radiator hoses and tighten the band screws securely. LOWER RADIATOR HOSE DRAIN HOSE Install the filler neck onto the shroud and tighten the LEED HOSE FILLER NECK...
  • Page 224 COOLING SYSTEM IR DUCT Install the right air duct and secure it with the three trim clips. • The right air duct has an “R” mark. TRIM CLIPS +4-9 Install the connector holder onto the air duct and tighten the screws securely. Connect the right fan motor 2P white connector.
  • Page 225 COOLING SYSTEM LEED HOSE Connect the bleed hose, drain hose, upper and UPPER RADIATOR HOSE lower radiator hoses, and tighten the band screws securely. DRAIN HOSE LOWER RADIATOR HOSE RIM CLIPS Install the left radiator grille onto the radiator. • The left radiator grille has an “L” mark. Install the left air duct and secure it with the three trim clips.
  • Page 226: Mechanical Seal Inspection

    COOLING SYSTEM WATER PUMP/THERMOSTAT MECHANICAL SEAL INSPECTION Remove the radiator reserve tank (page 6-8). Check for signs of coolant leakage from the inspec- tion hole in the water pump by looking the clutch cover. If there is leakage, the water pump mechanical seal is defective and the water pump should be replaced.
  • Page 227: Thermostat Inspection

    COOLING SYSTEM -RING Remove the water pump from the rear crankcase cover. Remove the O-ring from the water pump. WATER PUMP Remove the lock pin and water pump shaft joint OCK PIN PUMP SHAFT JOINT from the pump shaft if necessary. THERMOSTAT INSPECTION Visually inspect the thermostat for damage.
  • Page 228 COOLING SYSTEM Coat a new O-ring with engine oil and install it into -RING the groove in the water pump. Install the water pump into the rear crankcase cover while aligning the flat end of the pump shaft joint with the slot in the starter clutch bolt. Install a new O-ring onto the water pump groove.
  • Page 229 COOLING SYSTEM ATER HOSES Connect the water hoses to the water pump and tighten the hose band screws securely. Install the alternator (page 17-18). Install the starter/reverse motor (page 19-23). Fill and bleed the cooling system (page 6-6). 6-20...
  • Page 230 7. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ····························· 7-2 ENGINE REMOVAL ········································7-5 SERVICE INFORMATION ······························ 7-3 ENGINE INSTALLATION······························7-11...
  • Page 231 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION...
  • Page 232 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • A floor jack or other adjustable support is required to support and maneuver the engine. • A hoist or equivalent is required to support the motorcycle when removing and installing the engine. Supporting the engine using the engine oil filter will damage the engine. •...
  • Page 233 ENGINE REMOVAL/INSTALLATION TOOLS Lock nut wrench Lock nut wrench, 20 mm 07908-ME90000 07VMA-MBB0101 or 07GMA-KT7A200 (U.S.A. only)
  • Page 234: Engine Removal

    ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Support the motorcycle securely on its center stand. Drain the engine oil before removing the engine if the clutch cover gearshift linkage cover and engine rear cover are to be removed (page 3-12). Remove the following: –...
  • Page 235 ENGINE REMOVAL/INSTALLATION TAY BOLT Remove the bolt and rear brake reservoir stay. Slide the rubber cap off the reverse switch terminal, and remove the nut and reverse switch wire. REVER E WITCH TERMINAL Slide the rubber cap off the starter motor terminal, and remove the terminal nut and starter/reverse motor cable.
  • Page 236 ENGINE REMOVAL/INSTALLATION KNOCK SENSOR Disconnect the connectors from both knock sensors. Disconnect connectors from both horns. EVAP CANISTER BRACKET Disconnect the No. 1 and No. 4 hoses from the EVAP canister. Remove the wire band. Remove the two bolts, EVAP canister bracket and coolant drain joint from the engine.
  • Page 237 ENGINE REMOVAL/INSTALLATION Remove the mounting bolts and both engine NGIN GUARD guards. OLTS Remove the mounting bolts and both driver footpegs. FOOTPEG Remove the two bolts and fuel feed hose joint from the right fuel rail. EED HOSE JOINT OLTS Place a floor jack or other adjustable support under the engine.
  • Page 238 ENGINE REMOVAL/INSTALLATION Loosen the three right sub-frame mounting bolts. LEFT CENTER LEFT FRONT Remove the left center engine hanger bolt and nut. Remove the left front engine hanger bolt and nut. ANGER BOLT ANGER BOLT AND NUT AND NUT Remove the left rear engine hanger bolt. Loosen the left center engine hanger adjusting bolt OCK NUT WRENCH lock nut using the special tool.
  • Page 239 ENGINE REMOVAL/INSTALLATION Loosen the left front engine hanger adjusting bolt lock nut using the special tool. TOOL: Lock nut wrench 07908-ME90000 or 07GMA-KT7A200 (U.S.A. only) Remove the lock nut. Loosen the left front engine hanger adjusting bolt. Loosen the left rear engine hanger adjusting bolt lock nut using the special tool.
  • Page 240: Engine Installation

    ENGINE REMOVAL/INSTALLATION Remove the right rear engine hanger bolt. Remove the three bolts and right sub-frame. ANGER BOLT JOINT BOOT • A hoist or equivalent is required to support the motorcycle when removing the engine. Remove the joint boot from the engine side. Be careful not to Move the engine forward slightly and remove the damage the wire...
  • Page 241 ENGINE REMOVAL/INSTALLATION Use a floor jack or other adjustable support to care- OINT BOOT fully maneuver the engine into place. Apply 1 g (0.04 oz) of molybdenum disulfide grease to the output shaft splines. Install the engine in the frame while engaging the Be careful not to universal joint splines with the output shaft splines.
  • Page 242 ENGINE REMOVAL/INSTALLATION 3. Tighten the right front engine hanger bolt. TORQUE: 64 N·m (6.5 kgf·m, 47 lbf·ft) IGHT F ONT ENGINE HANGE BOLT 4. Tighten the right center engine hanger bolt. TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft) IGHT CENTE ENGINE HANGE BOLT 5.
  • Page 243 ENGINE REMOVAL/INSTALLATION 7. Install the lock nut onto the left rear engine hanger adjusting bolt. Hold the adjusting bolt and tighten the lock nut using the special tool. TOOL: Lock nut wrench 07908-ME90000 or 07GMA-KT7A200 (U.S.A. only) TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft) 8.
  • Page 244 ENGINE REMOVAL/INSTALLATION 11.Install the lock nut onto the left front engine hanger adjusting bolt. Hold the adjusting bolt and tighten the lock nut using the special tool. TOOL: Lock nut wrench 07908-ME90000 or 07GMA-KT7A200 (U.S.A. only) TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft) 12.Install and tighten the left rear engine hanger bolt.
  • Page 245 ENGINE REMOVAL/INSTALLATION Route the fuel feed hose properly page 1-23. Coat a new O-ring with oil and install it into the fuel feed hose joint groove. Install the fuel feed hose joints onto the fuel rail and tighten the joint bolts. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) OLTS Apply grease to the rider footpeg sliding areas.
  • Page 246 ENGINE REMOVAL/INSTALLATION Connect the clutch hose to the clutch slave cylinder EALING with the oil bolt and new sealing washers, and WA HER tighten the oil bolt. TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Fill bleed clutch hydraulic system (page 9-7). OIL BOLT Install the coolant drain joint and EVAP canister Route the canister...
  • Page 247 ENGINE REMOVAL/INSTALLATION Connect the alternator 4P connector. Install the alternator cable and nut onto the alterna- tor terminal and tighten the nut securely. Install the rubber cap onto the alternator terminal. Connect the side stand switch 3P green connector and install the wire band. Install the starter/reverse motor cable and nut onto the motor terminal and tighten the nut securely.
  • Page 248 ENGINE REMOVAL/INSTALLATION Connect the left engine sub-wire harness 4P gray and 6P gray connectors. ONNE TORS Connect the ignition pulse generator 2P red connector. Connect the reverse shift actuator 3P red and 2P white connectors. Connect gear position switch black connector.
  • Page 249 MEMO...
  • Page 250 8. CYLINDER HEAD/VALVE COMPONENT LOCATION ····························· 8-2 CYLINDER HEAD DISASSEMBLY ···············8-16 SERVICE INFORMATION ······························ 8-3 VALVE GUIDE REPLACEMENT ···················8-19 VALVE SEAT INSPECTION/REFACING ······8-19 TROUBLESHOOTING ···································· 8-5 CYLINDER COMPRESSION··························· 8-6 CYLINDER HEAD ASSEMBLY ·····················8-22 CYLINDER HEAD COVER REMOVAL ··········· 8-6 CYLINDER HEAD INSTALLATION···············8-24 CAMSHAFT REMOVAL ·································...
  • Page 251: Component Location

    CYLINDER HEAD/VALVE COMPONENT LOCATION CYLINDER HEAD/VALVE...
  • Page 252: Service Information

    CYLINDER HEAD/VALVE SERVICE INFORMATION GENERAL • This section covers service of the camshaft, cylinder head and valves. • The camshaft, cylinder head and valves can be serviced with the engine installed in the frame. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
  • Page 253 CYLINDER HEAD/VALVE TOOLS Valve spring compressor Valve guide driver, 5.0 mm Valve guide reamer, 5.0 mm 07757-0010000 07942-MA60000 07984-MA60001 or 07942-8920000 or 07984-MA6000D Valve seat cutter, 33 mm (45° IN) Valve seat cutter, 29 mm (45° EX) Flat cutter, 35 mm (32° IN) 07780-0010800 07780-0010300 07780-0012300...
  • Page 254: Troubleshooting

    CYLINDER HEAD/VALVE TROUBLESHOOTING Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. Compression too low, hard starting or poor performance at low speed •...
  • Page 255: Cylinder Compression

    CYLINDER HEAD/VALVE CYLINDER COMPRESSION Warm up the engine to normal operating tempera- ture. Stop the engine. Remove the seat (page 2-5) and disconnect the 5P P CONNECTOR gray connector from the fuel pump. Remove the spark plug caps and spark plugs (page 3-8).
  • Page 256: Camshaft Removal

    CYLINDER HEAD/VALVE CAMSHAFT REMOVAL Remove the following: Right camshaft: – right inner fairing (page 2-6) OLT AND WASHER – cylinder head cover (page 8-6) Remove the cam chain tensioner lifter bolt and sealing washer. Wind the string clockwise around the tool. Insert the rod through the ring and screw the rod into the tool.
  • Page 257 CYLINDER HEAD/VALVE Remove the following: Left camshaft: ONNE TORS – front lower fairing (page 2-6) – left horn connectors – bolt and left horn – cylinder head cover (page 8-6) BOLT HORN Remove the cam chain tensioner lifter bolt and Keep some rags sealing washer.
  • Page 258 CYLINDER HEAD/VALVE The timing marks on the cam sprocket must be Left camshaft shown: flush with the cylinder head surface and make sure the rear end cam lobe is facing outward (TDC on TIMING MARKS exhaust stroke). If the rear end cam lobe is facing inward (TDC on compression stroke), rotate the crankshaft counter- clockwise 360°...
  • Page 259 CYLINDER HEAD/VALVE Loosen the camshaft holder bolts in a crisscross pattern in several steps from the outside to inside AMSHAFT HOLDER to prevent damaging the camshaft holder and camshaft. Remove the camshaft holder. Remove the cam chain off the cam sprocket, being careful not to damage the cylinder head and cam- shaft and then remove the camshaft.
  • Page 260 CYLINDER HEAD/VALVE CAMSHAFT JOURNAL Check the camshaft journal surfaces of the cam- shaft holder and cylinder head for scoring, scratches or evidence of insufficient lubrication. CAMSHAFT OIL CLEARANCE Wipe any oil from the journals of the cylinder head, Do not rotate the camshaft and camshaft holder.
  • Page 261: Cam Chain Removal

    CYLINDER HEAD/VALVE CAM SPROCKET REPLACEMENT Remove the following: – cam sprocket bolts SPROCKET – cam pulse rotor and spacer (left camshaft only) SPACER ROTOR (TIMING MARKS) – cam sprocket (“OUT”) The camshafts have the following identification marks: L: left cylinder camshaft R: right cylinder camshaft Install the cam sprocket with the timing marks fac- ing out and align the bolt holes.
  • Page 262 CYLINDER HEAD/VALVE BOLT AND COLLA – tensioner pivot bolt and collar – right cam chain tensioner and washer IGHT TENSIONE – tensioner arm bolts WASHE – left cam chain tensioner LEFT TENSIONE BOLTS – right cam chain guide ASHER BOLT –...
  • Page 263: Cylinder Head Removal

    CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL Remove the following: – engine side covers (page 2-5) – left and right radiators (page 6-8) – air cleaner housing (page 5-57) – exhaust pipe (page 2-18) – camshafts (page 8-7) Remove the socket bolts and the left and right fuel rail covers.
  • Page 264 CYLINDER HEAD/VALVE – twelve intake manifold bolts (from the left and right cylinder head) Raise the intake manifold assembly and set suitable OLTS wooden blocks between the crankcase and mani- fold to support it. MANIFOLD ASSEM LY Remove the following from the cylinder head: –...
  • Page 265: Cylinder Head Disassembly

    CYLINDER HEAD/VALVE Remove the following: OWEL PINS O-RING – cylinder head gasket – two dowel pins – O-ring from the water hose joint pipe GASKET CYLINDER HEAD DISASSEMBLY Make a lifter bore protector from a plastic 35-mm film container by cutting the bottom and side wall of the container.
  • Page 266 CYLINDER HEAD/VALVE INSPECTION CYLINDER HEAD Remove the carbon deposits from the combustion chamber, being careful not to damage the gasket OMBUSTION HAMBER surface. Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge.
  • Page 267 CYLINDER HEAD/VALVE VALVE SPRING Measure the valve spring free length. SERVICE LIMITS: IN/EX: 37.0 mm (1.46 in) VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Check the valve for bends, burns or abnormal wear. Measure each valve stem O.D. and record it. SERVICE LIMITS:IN: 4.96 mm (0.195 in) EX: 4.95 mm (0.195 in) Ream the valve guide to remove any carbon build-...
  • Page 268: Valve Guide Replacement

    CYLINDER HEAD/VALVE VALVE GUIDE REPLACEMENT Chill the new valve guides in a freezer for about an hour. Heat the cylinder head to 130–140° C (275–290° F) AL E GUIDE Be sure to wear with a hot plate or oven. Do not heat the cylinder heavy gloves to DRI ER head beyond 150°...
  • Page 269 CYLINDER HEAD/VALVE Remove the valve and inspect the valve seat face. The valve cannot be The valve seat contact should be within the speci- ground. If the valve fied width and even all around the circumference. face is burned or badly worn or if it STANDARD: 0.9 –...
  • Page 270 CYLINDER HEAD/VALVE If the contact area is too high on the valve, the seat must be lowered using a 32° flat cutter. If the contact area is too low on the valve, the seat must be raised using a 60° interior cutter. Using a 45°...
  • Page 271: Cylinder Head Assembly

    CYLINDER HEAD/VALVE Using a 45° seat cutter, cut the seat to the proper width. Make sure all pitting and irregularities are removed. After cutting the seat, apply lapping compound to Excessive lapping the valve face, and lap the valve using light pressure may pressure.
  • Page 272 CYLINDER HEAD/VALVE Blow out all oil passages in the cylinder head with compressed air. Install the valve spring seats. Install new stem seals. Lubricate the valve stem sliding surface with PRING molybdenum oil solution. Insert the valve into the guide while turning it RETAINER slowly to avoid damaging the stem seal.
  • Page 273: Cylinder Head Installation

    CYLINDER HEAD/VALVE Support the cylinder head so the valve heads will not contact anything and possibly get damaged. Tap the valve stems gently with two plastic ham- mers to seat the cotters firmly as shown. CYLINDER HEAD INSTALLATION OWEL PINS Clean the gasket mating surfaces of the crankcase, O-RING manifold and cylinder head thoroughly, being care-...
  • Page 274 CYLINDER HEAD/VALVE Install new manifold gaskets onto the left and right cylinder heads, and align the bolt holes in the cylin- der head and gasket. lign G SKET Carefully remove the support blocks and place the manifold assembly onto the cylinder heads. Be sure to align the bolt holes in the manifold and OLTS gaskets, and install the twelve bolts.
  • Page 275: Cam Chain Installation

    CYLINDER HEAD/VALVE Install the guide and tighten the two bolts. Route the wires and hose properly LUG CA S If the spark plugs were removed, install the spark (page 1-23). plugs and tighten them. TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) Connect the spark plug caps.
  • Page 276 CYLINDER HEAD/VALVE – left cam chain tensioner with two bolts – right cam chain tensioner with washer (between crankcase and tensioner), pivot collar and bolt TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) – ignition pulse generator rotor (align the groove with the key) –...
  • Page 277: Camshaft Installation

    CYLINDER HEAD/VALVE Install the following: GASKET – two dowel pins – new gasket OWEL PINS RONT CRANKCASE COVER – front crankcase cover – twelve bolts TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the camshafts (page 8-28). CAMSHAFT INSTALLATION • When either is serviced, the other cylinder head cover must be removed and the other camshaft position must be checked.
  • Page 278 CYLINDER HEAD/VALVE The camshafts have the following identification marks: DENT F CAT ON MARK CAM PULSE L: left cylinder camshaft (installed cam pulse rotor) ROTOR: LEFT R: right cylinder camshaft R GHT Rotate the crankshaft counterclockwise and align Be careful not to the 1.2 TF mark on the ignition pulse generator jam the cam chain 1.2 TF MARK...
  • Page 279 CYLINDER HEAD/VALVE Apply molybdenum oil solution to the camshaft journals, thrust surfaces and cam lobes. Install the camshaft while installing the cam chain Be careful not to onto the cam sprocket in its proper location so that damage the the timing marks on the sprocket are flush with the cylinder head and cylinder head surface.
  • Page 280 CYLINDER HEAD/VALVE Install the dowel pins and camshaft holder. CAMS AFT OLDER Apply oil to the threads and seating surfaces of the camshaft holder bolts and install them. Tighten the holder bolts in several steps according to the numerical order cast on the camshaft holder (1 thru 8).
  • Page 281: Cylinder Head Cover

    CYLINDER HEAD/VALVE CYLINDER HEAD COVER INSTALLATION Clean the gasket mating surfaces of the cylinder head and cover thoroughly, being careful not to ASKET damage them. Install a new gasket into the groove in the cylinder head cover. Install the special washers onto the head cover bolts with the “UP”...
  • Page 282 CYLINDER HEAD/VALVE Install the cylinder head side cover and tighten the OLTS AND PLUGS five bolts. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the five rubber plugs. Fill and bleed the cooling system if the cylinder head was removed (page 6-6). CYLINDER HEAD SIDE COVER 8-33...
  • Page 283 MEMO...
  • Page 284 9. CLUTCH COMPONENT LOCATION ····························· 9-2 CLUTCH MASTER CYLINDER························9-8 SERVICE INFORMATION ······························ 9-4 CLUTCH SLAVE CYLINDER ·························9-12 TROUBLESHOOTING ···································· 9-6 CLUTCH·························································9-14 CLUTCH FLUID REPLACEMENT/AIR BLEEDING ······················································ 9-7...
  • Page 285 CLUTCH COMPONENT LOCATION CLUTCH...
  • Page 286 CLUTCH...
  • Page 287 CLUTCH SERVICE INFORMATION GENERAL • The clutch system can be serviced with the engine installed in the frame • DOT 4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in this section. Do not use other types of fluid as they are not compatible.
  • Page 288 CLUTCH TOOLS Snap ring pliers Driver Attachment, 32 x 35 mm 07914-SA50001 07749-0010000 07746-0010100 Pilot, 17 mm Shaft holder Clutch outer holder 07746-0040400 07PAB-0010200 07JMB-MN50100 or 07924-PJ40001 (U.S.A. only) Lock nut wrench, 46 mm 07JMA-MN50100...
  • Page 289 CLUTCH TROUBLESHOOTING Clutch lever pressure stiff • Sticking piston • Clogged hydraulic system Clutch slips • Stuck piston • Clogged hydraulic system • Discs worn • Weak clutch spring • Clutch regulator valve stuck open (section 10) • Low oil pressure (section 4) Clutch will not disengage or motorcycle creeps with clutch disengaged •...
  • Page 290 CLUTCH CLUTCH FLUID REPLACEMENT/AIR BLEEDING CLUTCH FLUID DRAINING Remove the EVAP canister (page 5-74). SC EWS Turn the handlebar to the right until the reservoir is Do not allow for- level. eign material to Remove the two screws, reservoir cap, set plate and enter the system.
  • Page 291: Clutch Master Cylinder

    CLUTCH If a brake bleeder is not available, use the following LEED VALVE procedure: Pump the clutch lever until lever resistance is felt. Connect a bleed hose to the bleed valve and bleed the system as follows: LEED HOSE 1. Squeeze the clutch lever, open the bleed valve 1/4 of a turn and then close it.
  • Page 292 CLUTCH Remove the following: – holder cap MASTER YLINDER – holder bolts – master cylinder holder HOLDER – clutch master cylinder BOLTS – screw and clutch switch LUT H SWIT H – screw and cruise switch – pivot nut BOLT –...
  • Page 293 CLUTCH Check the master cylinder and piston for scoring, scratches or damage. Measure the master cylinder I.D. SERVICE LIMIT: 14.055 mm (0.5533 in) Measure the master piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in) ASSEMBLY IVOT BOLT S RING RIMARY CU CLUTCH SWITCH MASTER ISTON...
  • Page 294 CLUTCH Install the snap ring into the groove in the master Make sure the snap cylinder using the special tool. ring is firmly seated in the groove. TOOL: Snap ring pliers 07914-SA50001 LIERS SNA RING Apply silicone grease to the push rod contacting area of the master piston.
  • Page 295: Clutch Slave Cylinder

    CLUTCH Install the holder cap into the holder bolts. Connect the clutch hose to the master cylinder with the oil bolt and new sealing washers. WAS ERS Be sure to rest the hose joint pin against the stopper CONNECTORS and tighten the oil bolt. TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Connect the clutch switch and cruise switch connectors.
  • Page 296 CLUTCH – piston If piston removal is hard, place a shop towel over Do not use high the piston, position the cylinder body with the pis- pressure air or bring ton down and apply small squirts of air pressure to the nozzle too close the fluid inlet.
  • Page 297: Clutch Cover Removal

    CLUTCH Apply grease to the lips of a new oil seal and install it into the crankcase. OWEL PINS Install the lifter rod. Install the dowel pins. OIL SEAL Install the slave cylinder onto the gearshift linkage M UNTING B LTS WASHERS cover and tighten the mounting bolts.
  • Page 298 CLUTCH – gasket – snap ring ASKET – oil seal SNAP RIN AND OIL SEAL CLUTCH DISASSEMBLY Remove the following: – stopper ring – clutch lifter plate A TOPPER RING LIFTER PLATE A Unstake the clutch center lock nut. Be careful not to damage the Shift the transmission into any gear except neutral.
  • Page 299 CLUTCH – lock washer CLUTCH PRING – spring guide – clutch spring PRING – spring seat WA HER PRING GUIDE – clutch center assembly from clutch outer LUT H ENTER ASSEMBLY – splined washer PLINED WA HER – stopper ring IFTER P ATE B –...
  • Page 300 CLUTCH – pressure plate from clutch center PRESSURE – O-ring O-RING PLATE – clutch piston from pressure plate – O-ring LUT H PISTON – ’01 – ’03: DISCS AND PLATES three clutch discs C, four clutch discs A and six clutch plates After ’03: clutch disc C, six clutch discs A and six clutch...
  • Page 301 CLUTCH INSPECTION LIFTER JOINT PIECE, LIFTER BEARING Check the lifter joint piece for damage or abnormal wear and the oil passages in the joint piece for debris. EARING Turn the lifter joint piece in the lifter bearing with your finger. The bearing should turn smoothly and SNAP RING quietly.
  • Page 302 CLUTCH JUDDER SPRING, SPRING SEAT Check the judder spring and spring seat for distor- PRING EAT tion, wear or damage. JUDDER PRING CLUTCH SPRING, LIFTER SPRING Check the clutch and lifter springs for distortion. Measure the height of the clutch spring. SERVICE LIMIT: 4.6 mm (0.18 in) Measure the height of the lifter spring.
  • Page 303 CLUTCH CLUTCH OUTER Check the slots in the clutch outer for nicks, indenta- tions or abnormal wear made by the clutch discs. LUT H OUTER CLUTCH OUTER REMOVAL Remove the engine from the frame (section 7). Unstake the clutch outer lock nut. Be careful not to nstake damage the pri-...
  • Page 304 CLUTCH Apply locking agent to the threads of a new clutch outer lock nut and install it. OCK NUT Hold the clutch outer with the special tool and tighten the lock nut. UTER TOOLS: H LDER Clutch outer holder 07JMB-MN50100 Lock nut wrench, 46 mm 07JMA-MN50100 TORQUE: 186 N·m (19.0 kgf·m, 137 lbf·ft)
  • Page 305 CLUTCH CLUTCH ASSEMBLY PRESSURE PLATE O-RING CLUTCH DISC B CLUTCH PISTON LIFTER PLATE B CLIP WIRE CLUTCH PLATES (7 pcs.) LIFTER SPRING CLUTCH CENTER O-RING STOPPER RING SPRING SEAT CLUTCH DISCS A CLUTCH DISC C ’01 – ’03: CLUTCH DISCS C After ’03: JUDDER SPRING CLUTCH DISCS A...
  • Page 306 CLUTCH Install the seven discs and six clutch plates alter- nately, starting with the disc. DISCS ’01 – ’03: First, install four discs A, then three discs C; alter- PLATES nating between discs and plates. After ’03: First, install six discs A, then disc C; alternating between discs and plates.
  • Page 307 CLUTCH Install the lifter spring with the concaved side facing out. Install the stopper ring into the ring groove in the Make sure the stop- pressure plate. per ring is seated securely. STOPPER RING IFTER SPRING STOPPER IFTER SPRING RING Install the splined washer onto the mainshaft.
  • Page 308: Clutch Cover Installation

    CLUTCH Apply engine oil to the threads and seating surface of a new lock nut, and install it. Shift the transmission into any gear except neutral. Apply the rear brake and tighten the lock nut. TORQUE: 127 N·m (13.0 kgf·m, 94 lbf·ft) If the engine was removed from the frame, hold the output shaft with the special tool and tighten the lock nut.
  • Page 309 CLUTCH Clean the gasket mating surfaces of the clutch cover I E AND and rear crankcase cover thoroughly, being careful O-RING not to damage them. Install the scavenge oil strainer. Coat a new O-ring with engine oil and install the oil through pipe and O-ring.
  • Page 310 10. GEARSHIFT LINKAGE/TRANSMISSION COMPONENT LOCATION ··························· 10-2 CRANKCASE COVER BEARING REPLACEMENT ··········································10-19 SERVICE INFORMATION ···························· 10-4 PRIMARY GEARS/OUTPUT SHAFT INSTALLATION···········································10-20 TROUBLESHOOTING ·································· 10-7 REAR CRANKCASE COVER GEARSHIFT LINKAGE ································· 10-8 INSTALLATION···········································10-24 REAR CRANKCASE COVER REMOVAL ··· 10-11 TRANSMISSION DISASSEMBLY ··············10-26 PRIMARY GEARS/OUTPUT SHAFT TRANSMISSION ASSEMBLY ····················10-33 REMOVAL ··················································...
  • Page 311: Component Location

    GEARSHIFT LINKAGE/TRANSMISSION COMPONENT LOCATION GEARSHIFT LINKAGE/TRANSMISSION 10-2...
  • Page 312 GEARSHIFT LINKAGE/TRANSMISSION 10-3...
  • Page 313: Service Information

    GEARSHIFT LINKAGE/TRANSMISSION SERVICE INFORMATION GENERAL • The gearshift linkage can be serviced with the engine installed in the frame with the exception of the gearshift spindle. The engine must be removed from the frame to service the primary gears and output shaft. Refer to section 7 for engine removal and installation.
  • Page 314 GEARSHIFT LINKAGE/TRANSMISSION TORQUE VALUES Shift drum stopper arm pivot bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Shift drum joint bolt 27 N·m (2.8 kgf·m, 20 lbf·ft) Apply locking agent to the threads. Mainshaft bearing lock nut 186 N·m (19.0 kgf·m, 137 lbf·ft) Apply engine oil to the threads and seating surface/stake the nut.
  • Page 315 GEARSHIFT LINKAGE/TRANSMISSION Attachment, 78 x 90 mm Attachment, 30 mm I.D. Pilot, 16 mm 07GAD-SD40101 07746-0030300 07746-0041300 Pilot, 20 mm Pilot, 25 mm Pilot, 28 mm 07746-0040500 07746-0040600 07746-0041100 Pilot, 30 mm Driver, 22 mm I.D. Bearing remover, 12 mm 07746-0040700 07746-0020100 07936-1660110...
  • Page 316: Troubleshooting

    GEARSHIFT LINKAGE/TRANSMISSION Shaft holder Lock nut wrench, 30 x 64 mm Clutch outer holder 07JMB-MN50200 07916-MB00002 07JMB-MN50100 or 07916-MB00001 TROUBLESHOOTING Hard to shift • Improper clutch operation (section 9) • Incorrect engine oil viscosity • Damaged gearshift cam • Bent shift forks •...
  • Page 317: Gearshift Linkage

    GEARSHIFT LINKAGE/TRANSMISSION GEARSHIFT LINKAGE DISASSEMBLY • Refer to page 10-26 “Transmission Disassembly” for gearshift spindle service. Drain the engine oil (page 3-16). Remove the EVAP canister (page 5-74). Shift the transmission into neutral. Remove the following: Do not disconnect – three bolts and clutch slave cylinder the clutch hose.
  • Page 318 GEARSHIFT LINKAGE/TRANSMISSION – shift drum cam (lift stopper arm with a screwdriver) – dowel pin – pivot bolt – stopper arm – return spring – washer ASSEMBLY Install the return spring onto the crankcase as shown. Install the washer (between the arm and crankcase) PRING and stopper arm with the bolt.
  • Page 319 GEARSHIFT LINKAGE/TRANSMISSION Install the gear position switch with the bolts. Install the wire grommet into the cover groove securely. DOWEL PINS Apply sealant to the mating areas of the crankcase ASKET as shown. Install the two dowel pins and a new gasket. Make sure the pin groove in the shift drum joint faces down (transmission is in neutral).
  • Page 320: Rear Crankcase Cover Removal

    GEARSHIFT LINKAGE/TRANSMISSION Install the two dowel pins. Install the slave cylinder and tighten the three bolts. Release the clutch lever from the handlebar. Install the EVAP canister (page 5-74). Fill the crankcase with the recommended engine oil (page 3-11). REAR CRANKCASE COVER REMOVAL Remove the following: –...
  • Page 321 GEARSHIFT LINKAGE/TRANSMISSION Remove the following: – sixteen cover bolts in a crisscross pattern in sev- EA C ANKCASE COVE eral steps – two dowel pins – oil orifice and O-ring OWEL PINS ORIFICE AN O-RING – clutch regulator valve and O-ring –...
  • Page 322: Primary Gears/output Shaft

    GEARSHIFT LINKAGE/TRANSMISSION PRIMARY GEARS/OUTPUT SHAFT REMOVAL EDUCTION GEA Remove the rear crankcase cover (page 10-11). AND SHAFT Remove the following: Do not disassemble – starter reduction gear and shaft the driven gear assembly. – plain washer FRICTION SPRING – friction spring –...
  • Page 323 GEARSHIFT LINKAGE/TRANSMISSION Remove the following: – primary driven gear (align the gear teeth of the scissor gears [primary drive gear and sub-gear] by inserting a screwdriver into the gear holes and prying the scissor gear) – spline washer – primary drive gear LTERN TOR DRIVE GE R –...
  • Page 324 GEARSHIFT LINKAGE/TRANSMISSION Temporarily install the clutch outer onto the pri- mary driven gear boss. Hold the clutch outer with the special tool and loosen the oil pump driven sprocket bolt. TOOL: Clutch outer holder 07JMB-MN50100 Remove the clutch outer. Remove the following: –...
  • Page 325 GEARSHIFT LINKAGE/TRANSMISSION DRIVEN GEAR BOSS BEARING REPLACEMENT Press the needle bearing out of the primary driven gear boss. TOOLS: DRIVER Driver 07749-0010000 Attachment, 28 x 30 mm 07946-1870100 Pilot, 28 mm 07746-0041100 ATTACHMENT PILOT EARING Press a new needle bearing into the driven gear Install the needle boss until the depth from the outer surface (oil bearing with the...
  • Page 326 GEARSHIFT LINKAGE/TRANSMISSION – thrust washer – damper lifter SPRING – damper spring – reverse driven gear LIFTER ASHER REVERSE DRIVEN GEAR Check the damper lifter for wear or damage. Measure the damper spring free length. SERVICE LIMIT: 64.0 mm (2.52 in) AMPER SPRING AMPER LIFTER Check the output shaft, gear bushing and final...
  • Page 327 GEARSHIFT LINKAGE/TRANSMISSION Install the following onto the output shaft: – reverse driven gear (with dished side facing spring) PRING – damper spring – damper lifter LIFTER – thrust washer REVER E DRIVEN GEAR WA HER – final driven gear (by aligning its grooves with lifter lugs) ROOVES –...
  • Page 328: Crankcase Cover Bearing

    GEARSHIFT LINKAGE/TRANSMISSION CRANKCASE COVER BEARING REPLACEMENT Remove the bolts and bearing setting plates. EVE SE SHIFTE SHAFT Heat the crankcase cover to 80° C (176° F) and remove the needle bearing of the reverse shifter shaft from the rear crankcase cover using the spe- cial tools.
  • Page 329: Primary Gears/output Shaft

    GEARSHIFT LINKAGE/TRANSMISSION Drive a new primary driven gear bearing into the crankcase with the sealed side facing up. TOOLS: Driver 07749-0010000 Attachment, 78 x 90 mm 07GAD-SD40101 Apply locking agent to the threads of the setting SETTING PLATES (“OUT SIDE”) plate bolts.
  • Page 330 GEARSHIFT LINKAGE/TRANSMISSION Stake the lock nut into the countershaft groove in Be careful not to two places. damage the countershaft threads. take Install the oil separate plate and tighten the two bolts. IL SEPARATE PLATE Apply engine oil to the needle bearing in the pri- DRIVEN mary driven gear boss.
  • Page 331 GEARSHIFT LINKAGE/TRANSMISSION Install output shaft assembly onto UTPUT SHAFT ASSEMBLY crankcase. LTERN TOR Install the alternator drive gear by aligning the bolt DRIVE GE R holes in the crankshaft and gear. Apply engine oil to the threads and seating surface of the drive gear bolts and install them.
  • Page 332 GEARSHIFT LINKAGE/TRANSMISSION Apply engine oil to the needle bearing and sprag clutch contacting surfaces. Install the bearing and the starter driven gear while turning gear clockwise. Install the starter clutch assembly, washer and bolt. The final starter STARTER CLUTCH ASSEM LY clutch bolt has left- hand threads.
  • Page 333: Rear Crankcase Cover

    GEARSHIFT LINKAGE/TRANSMISSION EDUCTION GEA Apply molybdenum oil solution to the outer surface AND SHAFT of the reduction gear shaft. Install the starter reduction gear and shaft with the large gear side facing out. REAR CRANKCASE COVER INSTALLATION Clean the gasket mating surfaces of the crankcase cover and crankcase thoroughly, being careful not to damage them.
  • Page 334 GEARSHIFT LINKAGE/TRANSMISSION Coat a new O-ring with engine oil and install it into the groove in the clutch regulator valve. REGULAT R VALVE Install the regulator valve into the crankcase cover. -RING EA C ANKCASE COVE Install the crankcase cover onto the crankcase. Install the 16 cover bolts and tighten them in a criss- cross pattern in several steps.
  • Page 335: Transmission Disassembly

    GEARSHIFT LINKAGE/TRANSMISSION Install a new oil seal until it is fully seated. TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Coat a new O-ring with engine oil and install it into the bearing holder groove. Pack grease into the oil seal lip cavity and install the bearing holder, being careful not to damage the seal lips.
  • Page 336 GEARSHIFT LINKAGE/TRANSMISSION – fork shaft – shift forks ORK SHA T SHI T ORKS – shift drum assembly HIFT DRUM COUNTERSHAFT: Remove the three bolts and countershaft setting plate. ETTING PLATE Slide the countershaft off the crankcase and remove the rear side bearing. EARING 10-27...
  • Page 337 GEARSHIFT LINKAGE/TRANSMISSION Remove the C1 gear (front end gear) to avoid inter- ference with the crankcase. Remove the countershaft assembly out of the 1 GEAR crankcase. OUNTERSHAFT ASSEMBLY Remove the front side bearing and oil pass plate. Disassemble the countershaft. EARING Clean all disassembled parts in solvent thoroughly.
  • Page 338 GEARSHIFT LINKAGE/TRANSMISSION GEARSHIFT SPINDLE: Remove the following: – bolt and lock washer (straighten washer tabs) – gearshift spindle B – thrust washer – spindle arm – gearshift spindle A – oil seal PINDLE A INSPECTION Check the gearshift spindles for bends. Check the spindle arm and spindle plates for wear PL TE or damage.
  • Page 339 GEARSHIFT LINKAGE/TRANSMISSION Measure the shift fork shaft O.D. SERVICE LIMIT: 13.90 mm (0.547 in) Check the shift drum guide grooves and reverse lock cam for abnormal wear or damage. BEARING Check the shift drum bearings for smooth rotation. Remove the following and replace any faulty part if necessary: –...
  • Page 340 GEARSHIFT LINKAGE/TRANSMISSION Measure the gear I.D. SERVICE LIMITS: M4: 31.04 mm (1.222 in) M5: 35.04 mm (1.380 in) C2, C3: 33.04 mm (1.301 in) Measure the gear bushing O.D. SERVICE LIMITS: M4: 30.93 mm (1.218 in) M5: 34.93 mm (1.375 in) C2, C3: 32.93 mm (1.296 in) Calculate the gear-to-bushing clearance.
  • Page 341 GEARSHIFT LINKAGE/TRANSMISSION MAINSHAFT BEARING REPLACEMENT Unstake the lock nut with a drill or grinder. Be careful not to damage the main- Hold the mainshaft and loosen the lock nut using shaft threads. the special tools and a breaker bar. TOOLS: Shaft holder 07JMB-MN50200 07916-MB00002 or...
  • Page 342: Transmission Assembly

    GEARSHIFT LINKAGE/TRANSMISSION Stake the lock nut into the mainshaft groove. Be careful not to damage the take mainshaft threads. TRANSMISSION ASSEMBLY • Align the lock washer tabs with the splined washer grooves. • Always install the thrust washer and snap ring with the chamfered (rolled) edge facing away from the thrust load (see the illustration on page 10-34).
  • Page 343 GEARSHIFT LINKAGE/TRANSMISSION COUNTERSHAFT ASSEMBLY Apply engine oil to the gear teeth, sliding surfaces, bushings and bearing. Apply molybdenum oil solution to the gear shifter grooves. Assemble the countershaft except the C1 gear (front end gear). Install the oil pass plate and front side bearing into the right crankcase.
  • Page 344 GEARSHIFT LINKAGE/TRANSMISSION Insert the countershaft assembly into the hole (bear- OUNTERSHAFT ing support) in the crankcase and support it, being ASSEMBLY careful not to damage the gear teeth. Install the C1 gear onto the countershaft. Install the countershaft assembly into the bearing in the  /-)4 crankcase.
  • Page 345 GEARSHIFT LINKAGE/TRANSMISSION SHIFT DRUM AND SHIFT FORK ASSEMBLY Install the shift drum assembly from the front side of the crankcase to seat its bearings into the bearing HIFT DRUM supports properly. The shift forks have the following identification marks: F: front shift fork DENT F CAT ON MARK C: center shift fork R: rear shift fork...
  • Page 346 GEARSHIFT LINKAGE/TRANSMISSION MAINSHAFT ASSEMBLY Apply engine oil to the gear teeth, sliding surfaces, bushings and bearing. Apply molybdenum oil solution to the gear shifter groove. Assemble the mainshaft. See NOTE on page 10-33. Install the dowel pin into the crankcase. Install the mainshaft assembly by properly aligning the hole in the needle bearing with the dowel pin.
  • Page 347 GEARSHIFT LINKAGE/TRANSMISSION Apply locking agent to the setting plate bolt threads. Install the setting plate with the “OUTSIDE” mark facing out and tighten the two bolts. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft) GEARSHIFT SPINDLE ASSEMBLY Apply engine oil to the needle bearings (four places).
  • Page 348 11. CYLINDER/PISTON/CRANKSHAFT COMPONENT LOCATION ··························· 11-2 CRANKSHAFT REMOVAL··························11-13 SERVICE INFORMATION ···························· 11-3 MAIN JOURNAL BEARING························11-14 CRANKSHAFT INSTALLATION ·················11-16 TROUBLESHOOTING ·································· 11-5 CRANKCASE SEPARATION························ 11-6 PISTON/CONNECTING ROD INSTALLATION···········································11-17 PISTON/CONNECTING ROD REMOVAL ··· 11-7 CRANKCASE ASSEMBLY ··························11-22 CRANKPIN BEARING ································ 11-11 11-1...
  • Page 349: Component Location

    CYLINDER/PISTON/CRANKSHAFT COMPONENT LOCATION CYLINDER/PISTON/CRANKSHAFT 11-2...
  • Page 350: Service Information

    CYLINDER/PISTON/CRANKSHAFT SERVICE INFORMATION GENERAL • The crankcase must be separated to service the piston/connecting rod, crankcase and crankshaft. • Avoid damaging the pistons against the transmission gears or crankcase when separating the crankcase halves because the pistons will fall as the crankcase is pulled off them. •...
  • Page 351 CYLINDER/PISTON/CRANKSHAFT TOOLS Piston base Piston base spring Piston pin pilot 07973-6570500 07973-6570600 07PAF-0010300 or Pilot base insert 07973-6570400 (U.S.A. only) Piston base head Pilot collar, 18 mm Adjustable piston pin driver head 07PAF-0010400 07PAF-0010640 07PAF-0010700 or 07JGF-001010A (U.S.A. only) or 07KMF-MT20200 (U.S.A. only) or 07973-6570210 (U.S.A.
  • Page 352: Troubleshooting

    CYLINDER/PISTON/CRANKSHAFT TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed • Leaking cylinder head gasket • Worn, stuck or broken piston ring • Worn or damaged cylinder and piston Compression too high, overheating or knocking • Excessive carbon build-up on piston head or combustion chamber Excessive smoke •...
  • Page 353: Crankcase Separation

    CYLINDER/PISTON/CRANKSHAFT CRANKCASE SEPARATION Remove the following: – engine (section 7) – PAIR check valves (section 5) – cylinder head and cam chain (section 8) – gearshift linkage (section 10) – reverse shifter/shift drum lock arm (section 18) – primary gears and output shaft (section 10: If you OLTS plan to service the transmission, remove the final drive gear)
  • Page 354: Piston/connecting Rod Removal

    CYLINDER/PISTON/CRANKSHAFT Remove the dowel pins and oil pipe. Clean any sealant from the crankcase mating sur- face. OWEL PINS OIL PIPE PISTON/CONNECTING ROD REMOVAL Separate the crankcase halves (page 11-6). SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. SERVICE LIMIT: 0.40 mm (0.016 in) If the clearance exceeds the service limit, replace the connecting rod.
  • Page 355 CYLINDER/PISTON/CRANKSHAFT Remove the bearing cap nuts and bearing caps on Any ridge on the Left side: EARING CAP the left side connecting rods. cylinder must be Push the piston/connecting rod assemblies out removed with an through the top of the left cylinder bores (No. 2, 4 automotive type and 6).
  • Page 356: Cylinder Inspection

    CYLINDER/PISTON/CRANKSHAFT Insert each piston ring into the bottom of the cylin- der squarely using the piston crown. Measure the ring end gap. SERVICE LIMITS: Top: 0.5 mm (0.02 in) Second: 0.6 mm (0.02 in) Oil (side rail): 0.9 mm (0.04 in) Measure the piston O.D.
  • Page 357: Piston Removal

    CYLINDER/PISTON/CRANKSHAFT The cylinder must be rebored so the clearance for an oversize piston is 0.010 – 0.045 mm (0.0004 – 0.0018 in). Check the top of the cylinder for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) PISTON REMOVAL Assemble the special tools (piston base assembly) PRING...
  • Page 358: Crankpin Bearing

    CYLINDER/PISTON/CRANKSHAFT CONNECTING ROD SELECTION If a connecting rod requires replacement, you Letter A, B, C, D or should select a rod with the same weight code as E on the rod is the the original. code for the con- necting rod weight. ONNE TING ROD WEIGHT ODE CRANKPIN BEARING BEARING INSPECTION...
  • Page 359 CYLINDER/PISTON/CRANKSHAFT Remove the bearing caps and measure the com- pressed plastigauge at its widest point on each crankpin to determine the oil clearance. SERVICE LIMIT: 0.06 mm (0.002 in) If the oil clearance exceeds the service limit, select the correct replacement bearings. BEARING SELECTION Record the connecting rod I.D.
  • Page 360: Crankshaft Removal

    CYLINDER/PISTON/CRANKSHAFT BEARING INSTALLATION Clean the bearing outer surfaces, bearing caps and connecting rods. Install the crankpin bearing inserts onto the bearing EARING INSERTS caps and connecting rods, aligning each tab with each groove. TA AND GROOVE CRANKSHAFT REMOVAL Remove the piston/connecting rod assemblies of M IN JOURN L BE RING C P BOLT the right cylinder and the bearing caps on the left cylinder connecting rod (page 11-7).
  • Page 361: Main Journal Bearing

    CYLINDER/PISTON/CRANKSHAFT CRANKSHAFT INSPECTION Hold both ends of the crankshaft and set a dial indi- cator on a main journal. Rotate the crankshaft two revolutions and read the runout at two points. Actual runout is 1/2 the total indicated reading. SERVICE LIMIT: 0.03 mm (0.001 in) Measure the main journals and crankpins with a The crankshaft can- micrometer for out-of-round and taper.
  • Page 362 CYLINDER/PISTON/CRANKSHAFT The installation position of each main journal bear- ing cap is identified with a dot mark that is aligned ARROW with the journal number 1, 2, 3 and 4, as viewed from the front of the engine. Carefully install the dowel pins and main journal bearing caps onto the corresponding journals with the arrow facing toward the upper side of the engine.
  • Page 363: Crankshaft Installation

    CYLINDER/PISTON/CRANKSHAFT Record the main journal O.D. code numbers. Numbers 1, 2 or 3 on the front side of Cross reference the main journal and bearing sup- the crankshaft are port codes to determine the replacement bearing the codes for the color code.
  • Page 364: Piston/connecting Rod

    CYLINDER/PISTON/CRANKSHAFT Apply molybdenum oil solution to the main journal Be careful not to bearing sliding surfaces on the left crankcase and damage the main journal bearing caps. crankpins with the Carefully install the crankshaft onto the left connecting rod crankcase. bolts if the left cyl- inder pistons are Apply molybdenum oil solution to the crankpin...
  • Page 365 CYLINDER/PISTON/CRANKSHAFT Install the pilot collar into the piston base assembly. ISTON IN DRI- Place a 12-mm flat Set the piston and connecting rod over the pilot washer on the top VER ASSEMBLY collar. of the adjustable ISTON IN piston pin driver TOOLS: CONNECTING ROD head.
  • Page 366: Piston Ring Installation

    CYLINDER/PISTON/CRANKSHAFT PISTON RING INSTALLATION Carefully install the piston rings into the piston ring Be careful not to STOPPER AND GROOVE grooves with the markings facing up. damage the piston and rings. • Do not confuse the top and second rings. •...
  • Page 367 CYLINDER/PISTON/CRANKSHAFT PISTON/CONNECTING ROD INSTALLATION LEFT CYLINDER SIDE Slip short sections of rubber hose over the connect- “L” MARK ing rod bolts to prevent damaging the crankpin. Apply engine oil to the left cylinder wall, piston and piston rings. Install the left piston/connecting rod assemblies Be careful not to (No.
  • Page 368 CYLINDER/PISTON/CRANKSHAFT RIGHT CYLINDER SIDE Cover the transmission gears and crankcase mating surfaces with shop towels to prevent damaging the BEARING CA pistons during installation. Apply molybdenum oil solution to the crankpin bearing sliding surfaces on the connecting rods and bearing caps. ISTON/CONNECTING ROD Install the right piston/connecting rod assemblies and bearing caps (No.
  • Page 369: Crankcase Assembly

    CYLINDER/PISTON/CRANKSHAFT CRANKCASE ASSEMBLY Clean the left and right crankcase mating surfaces. Temporarily install the ignition pulse generator bolt. Turn the crankshaft and position the front piston Be careful that the (No. 1) to the top dead center (highest position) right cylinder pis- while holding the right cylinder pistons.
  • Page 370 CYLINDER/PISTON/CRANKSHAFT Have an assistant turn the support blocks on their sides. Set both cylinders (No. 3 and 5) of the right crank- case straight onto the pistons and let the crankcase rest onto the support blocks. Remove piston base A. Pull the cords of the piston ring compressors to sep- arate the two halves and remove the remaining compressors.
  • Page 371 CYLINDER/PISTON/CRANKSHAFT Apply sealant to the crankcase mating surface as shown. Have an assistant hold the right crankcase while you remove the support blocks and apply sealant to the areas where the support blocks were. Lower the right crankcase and place it onto the left crankcase.
  • Page 372 12. FINAL DRIVE COMPONENT LOCATION ··························· 12-2 FINAL DRIVE DISASSEMBLY/ INSPECTION ·················································12-9 SERVICE INFORMATION ···························· 12-3 CASE BEARING REPLACEMENT···············12-14 TROUBLESHOOTING ·································· 12-6 FINAL DRIVE ASSEMBLY ··························12-17 FINAL DRIVE REMOVAL ····························· 12-7 FINAL DRIVE INSTALLATION ···················12-22 12-1...
  • Page 373: Component Location

    FINAL DRIVE COMPONENT LOCATION FINAL DRIVE 12-2...
  • Page 374: Service Information

    FINAL DRIVE SERVICE INFORMATION GENERAL • Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The extension lines from the gear engagement surfaces should intersect at one point. • Protect the gear case with a shop towel or soft jaws while holding it in a vise. Do not clamp the gear case too tight or it could get damaged.
  • Page 375 FINAL DRIVE TOOLS Driver Attachment, 42 x 47 mm Attachment, 52 x 55 mm 07749-0010000 07746-0010300 07746-0010400 Attachment, 62 x 68 mm Pilot, 30 mm Driver, 40 mm I.D. 07746-0010500 07746-0040700 07746-0030100 Attachment, 25 mm I.D. Bearing remover, 20 mm Bearing remover, 30 mm 07746-0030200 07936-3710600...
  • Page 376 FINAL DRIVE Collar set "C" Holder plate Pinion puller base 07924-ME40020 07924-9690103 07HMC-MM80110 or 07924-9690101 (modified) or 07HMC-MM8011A (U.S.A. only) Puller shaft Retainer wrench Oil seal driver 07931-ME40000 07910-4630100 07948-SC20200 or 07931-ME4010B and or 07749-0010000, 07946-ME90200 07931-HB3020A (U.S.A. only) and 07947-KA50100 Assembly base Bearing clip compressor, 35 mm Driver...
  • Page 377: Troubleshooting

    FINAL DRIVE TROUBLESHOOTING Excessive noise • Worn or scored pinion and splines • Worn pinion and ring gears • Excessive backlash between pinion and ring gears • Oil level too low Oil leakage • Clogged breather • Oil level too high •...
  • Page 378: Final Drive Removal

    FINAL DRIVE FINAL DRIVE REMOVAL Drain the final drive gear case oil (page 3-15). ’01 – ’03: Remove the following: – right muffler (page 2-18) – rear wheel (page 14-14) Remove following from final drive assembly: – ’01 – ’03: two bolts and wheel speed sensor –...
  • Page 379 FINAL DRIVE Remove the four nuts, washers and final drive assembly. Remove the two dowel pins. INSPECTION Remove the joint shaft assembly from the pinion joint by pulling it. This will force the stopper ring at INION JOINT the joint shaft past the groove in the pinion joint. JOINT SHAFT Check the dust seal for fatigue, wear or damage.
  • Page 380: Final Drive Disassembly

    FINAL DRIVE FINAL DRIVE DISASSEMBLY/ INSPECTION BACKLASH INSPECTION Before inspecting the backlash, modify the special 27 mm 27 mm tool at four places as shown. Be sure the modified areas on the plate fit properly around the stud bolts. 7 mm TOOL: Holder plate 07924-9690103 or...
  • Page 381 FINAL DRIVE RIGHT RING GEAR SHIMS: A (thinnest): 1.82 mm (0.072 in) D (standard): 2.00 mm (0.079 in) I (thickest): 2.30 mm (0.091 in) For ring gear shim replacement, see page 12-12. FINAL GEAR CASE SEPARATION Loosen the eight cover bolts in a crisscross pattern in two or three steps and remove them.
  • Page 382 FINAL DRIVE Install the case cover and tighten the bolts in several steps until the cover evenly touches the gear case. Then, while rotating the pinion gear, tighten the bolts to the specified torque in a crisscross pattern in several steps. TORQUE: 10 mm bolt: 62 N·m (6.3 kgf·m, 46 lbf·ft) 8 mm bolt: 25 N·m (2.6 kgf·m, 19 lbf·ft) ormal:...
  • Page 383 FINAL DRIVE RING GEAR BEARING/SHIM REPLACEMENT Remove the following: – two screws (using an impact driver – Be careful SCREWS not to damage the screw head.) SI E FLANGE – final side flange – two dowel pins OWEL PINS – oil seal IL SEAL –...
  • Page 384 FINAL DRIVE PINION GEAR REMOVAL Place the gear case in a vise with soft jaws. Be careful not to PINION HOLDER Install the washers. damage the mating Install the special tools. surface of the case. Remove the pinion joint nut. TOOLS: Place the washers under the holder...
  • Page 385: Case Bearing Replacement

    FINAL DRIVE PINION BEARING/SHIM REPLACEMENT Pull the pinion bearing from the shaft with a com- mercially available bearing puller. Remove the pinion shim. Install the shim and a new bearing onto the pinion gear. INION SHIM • When the gear set, ring gear bearing, and/or gear case has been replaced, use a 1.50 mm (0.059 in) INNER RACES thick shim for initial reference.
  • Page 386 FINAL DRIVE Remove the needle bearing using the special tools. TOOLS: EMOVE Bearing remover, 30 mm 07936-8890200 Remover handle 07936-3710100 Remover weight 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) U.S.A. only: Adjustable bearing puller, 20-40 mm 07736-A01000B or 07736-A01000A Slide hammer, 3/8" x 16 mm thread (commercially available in U.S.A.) Remove the bearing cage and bearings from the inside of the pinion bearing to allow the special tool...
  • Page 387 FINAL DRIVE Install the stopper ring into the groove securely. RIVER Place the needle bearing in a freezer. Heat the gear case to 80° C (176° F). COMPRESSOR Remove the needle bearing from the freezer and drive it into the gear case using the special tools. TOOLS: Driver 07949-3710001...
  • Page 388: Final Drive Assembly

    FINAL DRIVE FINAL DRIVE ASSEMBLY PINION JOINT REATHER CAP GEAR CASE JOINT NUT STOPPER RING STOPPER RING RING GEAR NEEDLE JOINT SHAFT EARING PINION NEEDLE ASSEM LY EARING SNAP RING PINION GEAR PINION SHIM RING GEAR INNER RACES RING GEAR SHIM (RIGHT) SNAP RING RING GEAR EARING...
  • Page 389 FINAL DRIVE Drive a new oil seal into the pinion retainer with the flat side facing down using the special tool. INION RETAINER TOOLS: OIL SEAL Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Pack grease into the seal lip cavity. Coat a new O-ring with grease and install it into the retainer groove.
  • Page 390 FINAL DRIVE Install the washers. Place the washers Install the special tools. under the holder Tighten the pinion joint nut. plate (on the top and bottom stud TOOLS: bolts, on the oil Pinon holder 07924-ME40010 drain bolt side) to Collar set “C” 07924-ME40020 compensate for the Holder plate...
  • Page 391 FINAL DRIVE Select the left side shim as follows. Measure the height of the ring gear boss from the SIDE FLANGE: ING GEA bearing (A) and the depth of the side flange from the flange end (B) as shown, and record them. Calculate the shim thickness using the equation below.
  • Page 392 FINAL DRIVE FINAL GEAR CASE ASSEMBLY • When the gear set, bearing, and/or gear case has been replaced, check the tooth contact pattern (page 12-10) and gear backlash (page 12-9). Clean the mating surface of the gear case and cover, Keep dust and dirt being careful not to damage them.
  • Page 393: Final Drive Installation

    FINAL DRIVE FINAL DRIVE INSTALLATION Check that the gear case stud bolts are tight. If any are loose, remove them, clean their threads with contact cleaner, then install using locking agent. After installing, be sure to measure the distance from top of each stud to the gear case surface as shown.
  • Page 394 FINAL DRIVE Clean the mating surfaces of the brake disc and final drive assembly, and make sure that no foreign materials enter the final drive assembly. Install the brake disc onto the stud bolts. Install new screws and tighten them. TORQUE: 9 N·m (0.9 kgf·m, 6.5 lbf·ft) +4-9 Install the brake caliper with new bolts and tighten...
  • Page 395 MEMO...
  • Page 396 13. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION ··························· 13-2 FRONT WHEEL ···········································13-16 SERVICE INFORMATION ···························· 13-3 FORK ···························································13-24 TROUBLESHOOTING ·································· 13-6 STEERING STEM········································13-41 HANDLEBAR ················································ 13-7 13-1...
  • Page 397: Component Location

    FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION FRONT WHEEL/SUSPENSION/STEERING 13-2...
  • Page 398: Service Information

    FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL • Riding on damaged rims impairs safe operation of the vehicle. • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. •...
  • Page 399 FRONT WHEEL/SUSPENSION/STEERING TOOLS Bearing remover shaft Bearing remover head, 20 mm Driver 07GGD-0010100 07746-0050600 07749-0010000 Attachment, 42 x 47 mm Pilot, 20 mm Fork seal driver 07746-0010300 07746-0040500 07KMD-KZ30100 07KMD-KZ3010A (U.S.A. only) Needle bearing remover Steering stem socket Main bearing driver attachment 07946-KA50000 07916-3710101 07946-ME90200...
  • Page 400 FRONT WHEEL/SUSPENSION/STEERING Installer attachment A Remover attachment A Remover attachment B 07VMF-MAT0100 07VMF-MAT0300 07VMF-MAT0400 Installer attachment B Inner driver handle, 40 mm Attachment, 35 mm 07ZMF-MCAA100 07746-0030100 07746-0030400 13-5...
  • Page 401: Troubleshooting

    FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering • Steering bearing adjustment nut too tight • Worn or damaged steering head bearings • Worn or damaged steering head bearing races • Bent steering stem • Insufficient tire pressure • Faulty front tire Steers to one side or does not track straight •...
  • Page 402 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR LEFT HANDLEBAR REMOVAL Remove the meter panel (page 2-7). CREW Remove the two screws and handlebar center cover. HANDLEBAR CENTER COVER Hold the handlebar weight and remove the mount- ing screw and the weight. Remove the holder cap from the clutch master cylin- der holder bolts.
  • Page 403 FRONT WHEEL/SUSPENSION/STEERING Remove the left handlebar mounting bolts. CREW Remove the two screws and handlebar setting plate. PLATE +4-9 Remove the two screws from the left handlebar switch. SCREW Remove the screw, setting plate and the left handle- bar switch. Remove the left handlebar grip.
  • Page 404 LEFT HANDLEBAR INSTALLATION Clean the inside surface of the left handlebar grip and the outside surface of the handlebar. Apply Honda Bond A or equivalent to the inside sur- face of the left handlebar grip and to the outside ANDLEBAR GRIP surface of the left handlebar.
  • Page 405 FRONT WHEEL/SUSPENSION/STEERING CREW Install the handlebar setting plate and tighten the Route the wires screws. and hose properly (page 1-23). PLATE Place the left handlebar onto the top bridge and align the bolt holes securely, then install the handle- bar mounting bolts and tighten them to the speci- fied torque.
  • Page 406 FRONT WHEEL/SUSPENSION/STEERING Install the handlebar outer weight onto the inner weight, aligning the bosses and grooves. Install a new mounting screw and tighten it while holding the weight. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the handlebar center cover (page 13-7). Install the meter panel (page 2-7).
  • Page 407 FRONT WHEEL/SUSPENSION/STEERING LAMP Release the throttle cables from the handlebar clamp. THROTTLE ABLES OLTS Remove the right handlebar mounting bolts. PLATE Remove the two screws and handlebar setting plate. CREW OLDER Remove the two bolts, holder and the brake master Keep the brake cylinder assembly.
  • Page 408 Clean the inside surface of the throttle grip and the outside surface of the throttle pipe. Apply Honda Bond A or equivalent to the inside sur- face of the throttle grip and to the outside surface of HRO LE GRIP the throttle pipe.
  • Page 409 FRONT WHEEL/SUSPENSION/STEERING Apply grease to the throttle grip pipe flange and sliding surface. Connect the throttle cables to the throttle grip pipe Route the cables flange and install the throttle grip onto the properly handlebar. (page 1-23). Install the right handlebar switch, aligning its locat- ing pin with the hole in the right handlebar.
  • Page 410 FRONT WHEEL/SUSPENSION/STEERING PLATE Install the handlebar setting plate and tighten the Route the wires screws. and hose properly (page 1-23). CREW OLTS Place the right handlebar onto the top bridge and align the bolt holes securely. Then install the han- dlebar mounting bolts and tighten them to the spec- ified torque.
  • Page 411: Front Wheel

    FRONT WHEEL/SUSPENSION/STEERING Install the holder cap onto the brake master cylinder holder bolts. Install the handlebar outer weight onto the inner weight, aligning the bosses and grooves. Install a new mounting screw and tighten it while holding the weight. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install and secure the handlebar center cover with CREW the two screws.
  • Page 412 FRONT WHEEL/SUSPENSION/STEERING ALIPER MOUNTING BOLTS Remove the clamp bolt and speed sensor wire clamp. Remove the two brake caliper mounting bolts and Support the brake right front brake caliper. caliper so that it does not hang from the brake hoses. Do LAMP BOLT not twist the brake hoses.
  • Page 413 FRONT WHEEL/SUSPENSION/STEERING INSPECTION AXLE Set the front axle in V-blocks. Turn the front axle and measure the runout using a RONT AXLE dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) WHEEL RIM Check the rim runout by placing the wheel in a tru- ing stand.
  • Page 414 FRONT WHEEL/SUSPENSION/STEERING RONT PULSER RING Remove the three bolts and front pulser ring from the right wheel hub. BOLTS RAKE DISCS Remove the six brake disc bolts and brake disc from the right wheel hub. Remove the six brake disc bolts and brake disc from the left wheel hub.
  • Page 415 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY EARING DISC OLTS RAKE DISC (6004) DUST SEAL PULSER RING (A S MODEL ONLY) RAKE DISC DISC OLTS PULSER RING OLTS EARING (A S MODEL ONLY) (6004) DUST SEAL DISTANCE COLLAR Drive in a new right bearing squarely with the marked side facing up until it is fully seated.
  • Page 416 FRONT WHEEL/SUSPENSION/STEERING PULSER RING Install the pulser ring onto the right wheel hub. Install new pulser ring bolts and tighten them in a crisscross pattern in two or three steps. TORQUE: 8 N·m (0.8 kgf·m, 5.8 lbf·ft) OLTS WHEEL BALANCE ROT TING DIRECTION •...
  • Page 417 FRONT WHEEL/SUSPENSION/STEERING Apply grease to new dust seal lips and install the Do not get grease dust seals until they are flush with the wheel hub. on the brake discs or stopping power UST SEALS will be reduced. INSTALLATION Install the side collars. Be careful not to damage the wheel speed sensor and...
  • Page 418 FRONT WHEEL/SUSPENSION/STEERING ALIPER MOUNTING BOLTS Install the right front brake caliper with new mount- ing bolts so the disc is positioned between the pads, being careful not to damage the pads. Tighten the mounting bolts. TORQUE: 31 N·m (3.2 kgf·m, 23 lbf·ft) LAMP BOLT Install the speed sensor wire clamp and tighten the bolt.
  • Page 419 FRONT WHEEL/SUSPENSION/STEERING Check the clearance between the brake disc and cal- EELER GAUGE iper bracket on each side after installation. The clearance should be at least 0.7 mm (0.28 in). If the feeler gauge cannot be inserted easily, loosen the axle holder bolts and pull the fork outward or push inward to adjust the clearance.
  • Page 420 FRONT WHEEL/SUSPENSION/STEERING BOLTS – two front fender B mounting bolts from the right fork leg – front fender B – delay valve mounting bolt DELAY VALVE BOLT RONT ENDER B BOLTS – two bolts and anti-dive plunger case – oil hose joint attaching bolt BOLTS –...
  • Page 421 FRONT WHEEL/SUSPENSION/STEERING LEFT FORK LEG DISASSEMBLY Remove the two bolts and front fender mounting XLE HOLDER BOLTS plate. Remove the axle holder bolts. PL TE EEDLE BEARI GS Remove the joint collar. Check the dust seals for wear, damage or fatigue. Check the needle bearings for damage or loose fit.
  • Page 422 FRONT WHEEL/SUSPENSION/STEERING Hold the fork slider in a vise with a soft jaws or shop If the fork piston towel and remove the center bolt and sealing turns with the cen- washer. ter bolt, tempo- rarily install the fork spring, spring seat, spacer and fork cap.
  • Page 423 FRONT WHEEL/SUSPENSION/STEERING Remove the oil seal, back-up ring and guide bush- ing from the fork tube. Carefully remove the slider bushing by prying the Do not remove the slot with a screwdriver until the bushing can be slider bushing pulled off by hand. unless it is neces- sary to replace it with a new one.
  • Page 424 FRONT WHEEL/SUSPENSION/STEERING Visually inspect the slider and guide bushings. Replace the bushings if there is excessive scoring or USHING scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire ACK-UP RING surface.
  • Page 425 FRONT WHEEL/SUSPENSION/STEERING Install a new slider bushing if the bushing has been Be careful not to IL SEAL removed. damage the coat- ing of the bushing. Do not spread open GUIDE BUSHING • Remove the burrs from the bushing mating sur- the bushing more face, being careful not to peel off the coating.
  • Page 426 UST SEAL install the dust seal. Pour the specified amount of the recommended fork fluid into the fork tube. RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-8 FORK FLUID CAPACITY: ORK LUID 529 ± 2.5 cm (17.9 ± 0.08 US oz, 18.6 ±...
  • Page 427 FRONT WHEEL/SUSPENSION/STEERING PACER Install the spring seat and spacer. PRING EAT Coat a new O-ring with fork fluid and install it into Tighten the fork cap the fork cap groove. after installing the Install the fork cap into the fork tube. fork tube into the fork bridges.
  • Page 428 FRONT WHEEL/SUSPENSION/STEERING RIGHT FORK DISASSEMBLY Remove the two bolts and front fender mounting plate. Remove the axle holder bolts. XLE HOLDER BOLTS PL TE ORK CAP Remove the fork cap from the fork tube. Hold the fork damper lock nut and remove the fork cap from the fork damper.
  • Page 429 FRONT WHEEL/SUSPENSION/STEERING Hold the fork slider in a vise with soft jaws or a shop If the fork damper towel and remove the center bolt and sealing turns with the cen- washer. ter bolt, tempo- rarily install the fork spring, spring seat, spacer and fork cap.
  • Page 430 FRONT WHEEL/SUSPENSION/STEERING IL SEAL Remove the oil seal, back-up ring and guide bush- ing from the fork tube. Carefully remove the slider bushing by prying the Do not remove the SLIDER BUSHING slot with a screwdriver until the bushing can be slider bushing pulled off by hand.
  • Page 431 FRONT WHEEL/SUSPENSION/STEERING Visually inspect the slider and guide bushings. Replace the bushings if there is excessive scoring or USHING scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire ACK-UP RING surface.
  • Page 432 FRONT WHEEL/SUSPENSION/STEERING Install the fork tube into the fork slider. ORK DAMPER OIL LOCK PIECE Hold the fork slider in a vise with soft jaws or a shop If the fork damper towel. turns with the cen- Apply locking agent to the center bolt threads. ter bolt, tempo- Install the center bolt with a new sealing washer rarily install the fork...
  • Page 433 FRONT WHEEL/SUSPENSION/STEERING Pour the specified amount of the recommended fork fluid into the fork tube. RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-8 FORK FLUID CAPACITY: ORK LUID 485 ± 2.5 cm (16.4 ± 0.08 US oz, 17.1 ± 0.09 Imp oz)
  • Page 434 FRONT WHEEL/SUSPENSION/STEERING Coat a new O-ring with fork fluid and install it into the fork cap groove. Install the fork cap onto the fork damper. Hold the fork damper and screw the fork cap onto it. -RING Hold the fork damper lock nut and tighten the fork cap to the specified torque.
  • Page 435 FRONT WHEEL/SUSPENSION/STEERING Tighten the bottom bridge pinch bolts to the speci- fied torque. TORQUE: 29 N·m (3.0 kgf·m, 22 lbf·ft) OTTOM RIDGE PINCH OLTS ORK CAPS Tighten the fork caps to the specified torque. TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft) Tighten the top bridge pinch bolts to the specified torque.
  • Page 436: Steering Stem

    FRONT WHEEL/SUSPENSION/STEERING Install the following: – delay valve and mounting bolt ENDER BOLTS – front fender B – four fender mounting bolts with brake hose clamp TORQUE: Delay valve mounting bolt: DELAY 12 N·m (1.2 kgf·m, 9 lbf·ft) VALVE DELAY VALVE BOLT RONT ENDER B ENDER BOLTS CLAMP...
  • Page 437 FRONT WHEEL/SUSPENSION/STEERING Remove the steering stem nut cap and disconnect the turn signal cancel unit connector. ONNE TOR Loosen the steering stem nut. Remove the fork legs (page 13-24). Remove the steering stem nut and top bridge. Remove the following: OLTS –...
  • Page 438 FRONT WHEEL/SUSPENSION/STEERING TEERING BEARING ADJU TMENT NUT Straighten the lock washer tabs. Remove the steering bearing adjustment nut, lock nut and lock washer. LOCK NUT LOCK WA HER Remove the steering bearing adjustment nut using the special tool. TOOL: Steering stem socket 07916-3710101 or 07916-3710100 TEERING TEM OCKET...
  • Page 439 FRONT WHEEL/SUSPENSION/STEERING – lower bearing from the steering stem OWER BEARING STEERING STEM STEERING BEARING REPLACEMENT Replace the steering bearing outer races using the Always replace the special tools listed below. bearings and races MAIN BEARING as a set. DRIVER ATTACHMENT PPER N T TOOLS: Main bearing driver attachment 07946-ME90200...
  • Page 440 FRONT WHEEL/SUSPENSION/STEERING Install the special tools into the steering head pipe as shown. NSTALLER Align remover attachment B with the groove in the ATTACHMENT A steering head. While holding the installer shaft with the wrench, turn the lower nut gradually to remove the lower bearing outer race.
  • Page 441 FRONT WHEEL/SUSPENSION/STEERING Install a new lower bearing outer race and the spe- cial tools as shown. PPER N T MAIN BEARING While holding the installer shaft with the wrench, turn the upper nut gradually until the outer race bot- DRIVER ATTACHMENT toms on the steering head pipe.
  • Page 442 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION CONNECTOR STEM NUT CAP HY RAULIC HOSE CLAMP TOP BRI GE STEERING STEM NUT UPPER INNER RACE LOWER OUTER RACE LOCK NUT LOCK WASHER LOWER BEARING STEERING BEARING LOWER INNER RACE A JUSTMENT NUT UPPER OUTER RACE UST SEAL UPPER BEARING WIN PROTECTOR...
  • Page 443 FRONT WHEEL/SUSPENSION/STEERING UST SEAL Apply grease to a new dust seal lip and install it. TEERING BEARING ADJU TMENT NUT Apply engine oil to the steering bearing adjustment nut threads and install it. 1. Tighten the steering bearing adjustment nut to the specified torque.
  • Page 444 FRONT WHEEL/SUSPENSION/STEERING Install a new lock washer and bend the two opposite tabs down into the grooves in the steering bearing adjustment nut. Install and finger tighten the lock nut all the way. Hold the steering bearing adjustment nut and fur- ther tighten the lock nut, within 90 degrees, to align its grooves with the tabs of the lock washer.
  • Page 445 FRONT WHEEL/SUSPENSION/STEERING Tighten the steering stem nut to the specified torque. TORQUE: 103 N·m (10.5 kgf·m, 76 lbf·ft) Remove the fork legs. Make sure that the steering stem moves smoothly, without play or binding. Install the forks legs (page 13-24). Connect the turn signal cancel unit connector and install the steering stem nut cap.
  • Page 446 14. REAR WHEEL/SUSPENSION COMPONENT LOCATION ··························· 14-2 SHOCK ABSORBER····································14-16 SERVICE INFORMATION ···························· 14-3 SUSPENSION LINKAGE ····························14-18 TROUBLESHOOTING ·································· 14-5 SWINGARM ················································14-22 REAR WHEEL ············································· 14-14 SUSPENSION LEVEL RELAY·····················14-29 14-1...
  • Page 447: Component Location

    REAR WHEEL/SUSPENSION COMPONENT LOCATION REAR WHEEL/SUSPENSION 14-2...
  • Page 448 • The damper unit is filled with nitrogen gas under high pressure, do not try to disassemble. • Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points. • When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the...
  • Page 449 REAR WHEEL/SUSPENSION TOOLS: Attachment, 32 x 35 mm Attachment, 42 x 47 mm Attachment, 24 x 26 mm 07746-0010100 07746-0010300 07746-0010700 used with 3/8" x 16 mm thread slide hammer (commercially available in U.S.A.) Attachment, 22 x 24 mm Attachment, 28 x 30 mm Pilot, 17 mm 07746-0010800 07946-1870100...
  • Page 450 REAR WHEEL/SUSPENSION Lock nut wrench, 9 x 45 mm 07ZMA-MCA0100 TROUBLESHOOTING Soft suspension • Weak shock absorber spring • Incorrect suspension adjustment • Oil leakage from damper unit • Insufficient tire pressure Hard suspension • Incorrect suspension adjustment • Damaged rear suspension pivot bearings •...
  • Page 451 REAR WHEEL/SUSPENSION SHOCK ABSORBER SPRING PRE-LOAD ADJUSTMENT SYSTEM • This electric shock absorber spring pre-load adjustment system functions with the following conditions: – The ignition switch is turned to “ON” or “ACC.” – The motorcycle is stopped. – The transmission is in neutral. –...
  • Page 452 REAR WHEEL/SUSPENSION Suspension level actuator operates and the pre- load position varies between 0 and 25 on the multi- display with the manual height switch but the sus- pension level does not vary • Pre-load adjustment hydraulic system leakage; replace the shock absorber as an assembly (page 14-16).
  • Page 453 REAR WHEEL/SUSPENSION 3. Manual Height Switch Harness Short Circuit Inspection Remove the combination meter (page 20-17). Check the following wires for continuity to ground at the panel switch 14P gray connector. IRE HARNESS SIDE 14P CONNECTOR (viewed from the terminal side) –...
  • Page 454 REAR WHEEL/SUSPENSION 6. Angle Sensor Signal Line Inspection Combination Meter Measure the angle sensor resistance between the Yellow/red and Blue/green wire terminals of the combination meter 16P black connector. Bu/G STANDARD: 0.4 – 5.4 kΩ (20° C/68° F) Is the resistance within the specified value? –...
  • Page 455 REAR WHEEL/SUSPENSION 8. Angle Sensor Power Input and Ground Line Inspection at Angle Remove the right saddlebag (page 2-15). ANGLE SENSOR CONNECTOR Disconnect the angle sensor connector. Measure the angle sensor resistance between the Black/red and Blue/green wire terminals of the sensor side connector.
  • Page 456 REAR WHEEL/SUSPENSION 11. Suspension Level Relay Control Line Inspection Turn the ignition switch to “ON” or “ACC.” Measure the voltage between the following wire terminal (+) of the meter 20P black connector and ground (–). – Red – Green/red – Green/yellow There should be battery voltage.
  • Page 457 REAR WHEEL/SUSPENSION Suspension level cannot be memorized with the memory switch 1. Memory Switch 1 and 2 Operation Inspection Remove the left fairing pocket (page 2-11). Disconnect the panel switch 14P gray connector. Check for continuity between the wire terminals of the switch side connector in either MEMO 1 or MEMO 2 switch positions.
  • Page 458 REAR WHEEL/SUSPENSION 3. Memory Switch 1 and 2 Control Line Continuity inspection Check the following wires for continuity between the panel switch 14P gray connector and combi- nation meter 16P black connector. Br/W Lg/Y – Brown/yellow – Brown/blue Is there continuity? –...
  • Page 459: Rear Wheel

    REAR WHEEL/SUSPENSION REAR WHEEL REAR WHEEL REMOVAL Remove rear fender A (page 2-13). Set the rear wheel on the ground and loosen the five rear axle nuts while applying the rear brake. Put the motorcycle on its center stand and support the motorcycle securely.
  • Page 460 REAR WHEEL/SUSPENSION WHEEL RIM INSPECTION Remove the axle cap from the rear wheel. Check the rim runout by placing the wheel in a tru- ing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BALANCE...
  • Page 461: Rear Wheel Installation

    REAR WHEEL/SUSPENSION REAR WHEEL INSTALLATION Check the wheel bolt holes for wear, cracks or other damage. Clean the mating surfaces of the rear wheel and brake disc, and remove any foreign material. Install the rear wheel by aligning the bolt holes in the rear wheel with the stud bolts of the final drive assembly.
  • Page 462 REAR WHEEL/SUSPENSION HOCK AB ORBER NUT AND BOLT Remove the shock absorber upper mounting nut A EMBLY and bolt. Release the actuator hose from the clamp. Remove the shock absorber assembly. ACTUATOR HO E INSPECTION Check the damper unit for leakage or other damage. Check the upper joint bushing and damper rubber for wear or damage.
  • Page 463: Suspension Linkage

    REAR WHEEL/SUSPENSION INSTALLATION HOCK AB ORBER BOLT AND NUT Install the shock absorber assembly in the frame by Route the wires A EMBLY inserting the upper mounting bolt from the left side. and hose properly Install the upper mounting nut. (page 1-23).
  • Page 464 REAR WHEEL/SUSPENSION Remove the pivot collars and dust seals from the shock arm. SHOCK ARM INSPECTION Check the dust seals and collars for wear, damage or fatigue. Check the needle bearings for damage or loose fit. If the needle bearings are damaged, replace them (page 14-19).
  • Page 465 REAR WHEEL/SUSPENSION Shock absorber side: Driver 07749-0010000 Attachment, 24 x 26 mm 07746-0010700 Pilot, 17 mm 07746-0040400 SHOCK ARM INSTALLATION DUST SEALS Apply grease to new dust seal lips and install them into the shock arm pivots until they are fully seated. Install the pivot collars into the shock arm pivots.
  • Page 466 REAR WHEEL/SUSPENSION Remove the pivot collar and dust seals from the shock link. SHOCK LINK INSPECTION Check the dust seals and collar for wear, damage or fatigue. Check the needle bearings for damage or loose fit. If the needle bearings are damaged, replace them (page 14-21).
  • Page 467: Swingarm

    REAR WHEEL/SUSPENSION UTS A D BOLTS Install the shock link onto the frame by inserting the mounting bolts from the left side. Install the mounting nuts and tighten the nuts to the specified torque. TORQUE: Shock arm-to-frame nut: 64 N·m (6.5 kgf·m, 47 lbf·ft) Shock arm-to-shock link nut: 64 N·m (6.5 kgf·m, 47 lbf·ft) Install the rear wheel (page 14-16).
  • Page 468 REAR WHEEL/SUSPENSION Remove the left pivot bolt. EFT PIVOT BO T IGHT PIVOT BOLT Remove the right pivot bolt. Remove the shock arm-to-shock link nut and bolt. Remove the two screws and brake light/cruise can- cel switch assembly from the rear master cylinder. JOINT BOOT Remove the joint boot off the engine.
  • Page 469 REAR WHEEL/SUSPENSION Remove the joint boot. Check the joint boot for tears or other damage and replace it if necessary. Remove the drive shaft from the swingarm. 418- 50).6 Remove the shock arm-to-swingarm nut and bolt and shock arm from the swingarm. SHOCK ARM UT A D BOLT INSPECTION...
  • Page 470 REAR WHEEL/SUSPENSION Check that the universal joint moves smoothly with- out binding or noise. Check the splines for wear or damage. NIVERSAL JOINT PIVOT BEARING OUTER RACE REPLACEMENT Punch or drill a 1/2 inch hole into the grease holder of the bearing race. Insert the threaded end of the slide hammer into the hole and attach the special tools as shown.
  • Page 471 REAR WHEEL/SUSPENSION Apply grease to the tapered needle rollers and dust EAL LIP seals lips of new bearings and install them into the swingarm pivots. ROLLER INSTALLATION HOCK ARM BOLT AND NUT Install the shock arm onto the swingarm by insert- ing the mounting bolt.
  • Page 472 REAR WHEEL/SUSPENSION Install the joint boot onto the swingarm with one joint boot tab facing up vertically as shown. Remove the joint shaft from the final gear case (page 12-10) and temporarily install it into the drive shaft to ease installation of the drive shaft. Set the swingarm into the frame and engage the Route the wires, splines of the drive and output shafts securely.
  • Page 473 REAR WHEEL/SUSPENSION Retighten the right pivot bolt to the same torque. TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft) Install the left pivot lock nut. Hold the left pivot bolt while tightening the left pivot Refer to torque lock nut to the specified torque. wrench reading information on TOOL:...
  • Page 474: Suspension Level Relay

    REAR WHEEL/SUSPENSION Install each swingarm pivot bolt cover. OLTS Install and tighten the mounting bolts. Install the final gear case (page 12-21). Install the shock absorber (page 14-18). PIVOT OLT COVER SUSPENSION LEVEL RELAY SYSTEM INSPECTION ELAY BOX Check that the audio system and multi-display func- tions properly.
  • Page 475 REAR WHEEL/SUSPENSION 4. Turn the ignition switch to “OFF” and remove the suspension level main relay. Measure the voltage between the Brown wire terminal (+) of the suspension level main relay connector and ground (–). rown • If there is battery voltage, go to step 5. •...
  • Page 476 REAR WHEEL/SUSPENSION 8. Turn the ignition switch to “ON” or “ACC.” Measure the voltage between each Light green/ black wire terminal (+) of the suspension level UP and DOWN relay connectors and ground (–). • If there is battery voltage, follow the trouble- ight green/black shooting flow chart on (page 14-10).
  • Page 477 MEMO...
  • Page 478 15. BRAKE SYSTEM (Standard) SYSTEM LOCATION···································· 15-2 REAR MASTER CYLINDER/BRAKE PEDAL ·························································15-19 SERVICE INFORMATION ···························· 15-3 SECONDARY MASTER CYLINDER ···········15-24 TROUBLESHOOTING ·································· 15-5 FRONT BRAKE CALIPER ····························15-27 BRAKE FLUID REPLACEMENT/AIR BLEEDING ···················································· 15-6 REAR BRAKE CALIPER·······························15-34 BRAKE PAD/DISC······································ 15-13 DELAY VALVE ············································15-38 FRONT MASTER CYLINDER ·····················...
  • Page 479: System Location

    BRAKE SYSTEM (Standard) SYSTEM LOCATION BRAKE SYSTEM (Standard) RONT MASTER CYLINDER PROPORTIONAL CONTROL VALVE (PCV) REAR BRAKE CALIPER SECONDARY MASTER CYLINDER REAR MASTER CYLINDER REAR MASTER CYLINDER DELAY VALVE RESERVOIR RIGHT RONT BRAKE CALIPER LE T RONT BRAKE CALIPER 15-2...
  • Page 480: Service Information

    BRAKE SYSTEM (Standard) SERVICE INFORMATION GENERAL Frequent inhalation of brake lining dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. •...
  • Page 481 BRAKE SYSTEM (Standard) TORQUE VALUES Brake caliper bleed valve 6 N·m (0.6 kgf·m, 4.3 lbf·ft) Front fork anti-dive plunger bleed valve 6 N·m (0.6 kgf·m, 4.3 lbf·ft) Front master cylinder reservoir cap screw 2 N·m (0.2 kgf·m, 1.4 lbf·ft) Brake pad pin 18 N·m (1.8 kgf·m, 13 lbf·ft) Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
  • Page 482: Troubleshooting

    BRAKE SYSTEM (Standard) TROUBLESHOOTING Brake lever/pedal soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contaminated brake pad/disc • Worn caliper piston seals • Worn master cylinder piston cups • Worn brake pad/disc • Contaminated caliper •...
  • Page 483: Brake Fluid Replacement/air

    BRAKE SYSTEM (Standard) BRAKE FLUID REPLACEMENT/AIR BLEEDING • A contaminated brake disc or pad reduces stop- ping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. • Do not allow foreign material to enter the system when filling the reservoir.
  • Page 484 BRAKE SYSTEM (Standard) Connect a commercially available brake bleeder to the bleed valve of the front caliper at the position as shown. Loosen the bleed valve and pump the brake bleeder until no more fluid flows out of the bleed valve. RAKE LEEDER Tighten the bleed valve.
  • Page 485 BRAKE SYSTEM (Standard) Connect a commercially available brake bleeder to the bleed valve of the brake pedal brake line as shown. Loosen the bleed valve and pump the brake bleeder until no more fluid flows out of the bleed valve. RAKE LEEDER Perform the above procedure at each remaining valve of the brake pedal brake line.
  • Page 486 BRAKE SYSTEM (Standard) BRAKE BLEEDER AVAILABLE 1. Connect a commercially available brake bleeder Check the fluid level to the bleed valve of the front caliper at the posi- often while bleed- tion as shown. ing the brake to pre- Pump the brake bleeder and loosen the bleed vent air from being valve.
  • Page 487 BRAKE SYSTEM (Standard) AIR BLEEDING Air bleeding procedure is performed in the same way as in the fluid feeding procedure without using a bleeder tool (page 15-9). Repeat this procedure until air bubbles do not appear in the plastic hose of each bleed valve. Make sure that the bleed valves are closed and operate the brake lever.
  • Page 488 BRAKE SYSTEM (Standard) FLUID FEEDING • It is not a problem if the fluid flowing out of the bleed valve contains air bubbles because the lines will be bled in next steps (“Air Bleeding”). Fill the reservoir with DOT 4 brake fluid from a sealed container.
  • Page 489 BRAKE SYSTEM (Standard) BRAKE BLEEDER NOT AVAILABLE 1. Connect a bleed hose to the upper side bleed valve of the left front caliper. Pump the brake pedal several (5 – 10) times Do not release the quickly, then depress the brake pedal all the way brake lever until the and loosen the bleed valve 1/4 turn.
  • Page 490: Brake Pad/disc

    BRAKE SYSTEM (Standard) After bleeding air completely, tighten the bleed valves. TORQUE: 6 N·m (0.6 kgf·m, 4.3 lbf·ft) Fill the reservoir to the upper level line with DOT 4 brake fluid from a sealed container. ESE VOI CAP Install the reservoir cap. Check the pedal brake operation (page 3-18).
  • Page 491: Brake Disc Inspection

    BRAKE SYSTEM (Standard) REAR BRAKE PAD REPLACEMENT Push the caliper piston all the way in to allow Always replace the installation of new brake pads by pushing the brake pads in pairs caliper body inward. to ensure even disc pressure. Remove the pad pin plug and loosen the pad pin.
  • Page 492: Front Master Cylinder

    BRAKE SYSTEM (Standard) Measure the brake disc warpage with a dial indicator. SERVICE LIMIT: 0.30 mm (0.012 in) Check the bearing for excessive play, if the warpage exceeds the service limit. Replace the brake disc if the bearings are normal. For brake disc removal/installation, see section 13 or 14.
  • Page 493 BRAKE SYSTEM (Standard) – piston boot – snap ring TOOL: Snap ring pliers 07914-SA50001 – master piston – primary cup – spring Clean the master cylinder, reservoir and master pis- PRING ton in clean brake fluid. INSPECTION Check the piston cups and boot for wear, deteriora- tion or damage.
  • Page 494 BRAKE SYSTEM (Standard) ASSEMBLY PIVOT OLT MASTER PISTON SNAP RING RAKE LIGHT/CRUISE SPRING CANCEL SWITCH RAKE LEVER SCREW Coat the master piston and piston cups with clean Do not allow the brake fluid. piston cup lips to Install the primary cup onto the spring. turn inside out.
  • Page 495 BRAKE SYSTEM (Standard) Apply silicone grease to the push rod contacting area of the master piston. Install the boot into the master cylinder and the piston groove. Apply silicone grease to the brake lever contacting surface of the piston. Apply silicone grease to the brake lever pivot. Install the brake lever and pivot bolt, and tighten it.
  • Page 496: Rear Master Cylinder/brake

    BRAKE SYSTEM (Standard) REAR MASTER CYLINDER/BRAKE PEDAL REMOVAL Drain the brake fluid from the pedal brake hydraulic system (page 15-6). Remove the two screws and brake light/cruise cancel switch assembly from the master cylinder. WITCH A EMBLY Remove the snap ring and disconnect the reservoir When removing the IL B LT hose joint from the master cylinder.
  • Page 497 BRAKE SYSTEM (Standard) DISASSEMBLY Remove the following from the master cylinder: – cotter pin – joint pin OTTER PIN – pivot arm JOINT PIN PIVOT ARM – boot (from the master cylinder) – snap ring TOOL: Snap ring pliers 07914-SA50001 –...
  • Page 498 BRAKE SYSTEM (Standard) ASSEMBLY ISTON/ USH ROD ASSEMBLY COTTER IN JOINT IN S RING IVOT ARM Coat the master piston and piston cups with clean Do not allow the brake fluid. piston cup lips to Install the primary cup onto the spring. turn inside out.
  • Page 499 BRAKE SYSTEM (Standard) If the push rod joint is reinstalled, adjust the push rod length so the distance from the center of the lower mounting bolt hole to the center of the joint pin hole is 106 mm (4.2 in) After adjustment, tighten the joint nut.
  • Page 500 BRAKE SYSTEM (Standard) Apply grease to the pivot shaft groove of the pivot arm. ASTER CYLINDER Place the master cylinder/pivot arm assembly into the frame while pushing the water hose aside and insert the pivot arm into the pivot hole, being care- ful not to damage its splines.
  • Page 501: Secondary Master Cylinder

    BRAKE SYSTEM (Standard) Install the footpeg and tighten the bolts. TORQUE: 26 N·m (2.7 kgf·m, 20 lbf·ft) OOTPEG Apply locking agent to the threads of the switch holder screws. Install the brake light/cruise cancel switch assembly with the screws. Adjust the switch position so that the brake light comes on when pushing the brake pedal slightly and the push rod moves 0.7 –...
  • Page 502 BRAKE SYSTEM (Standard) – oil bolt and sealing washers (while holding the MASTER CYLINDER master cylinder firmly) – front side brake hose – secondary master cylinder IL B LT – pivot collar (from the caliper bracket) – boot (from the master cylinder) –...
  • Page 503 BRAKE SYSTEM (Standard) ASSEMBLY PU H ROD PRING MA TER CYLINDER Coat the master piston and piston cups with clean Do not allow the brake fluid. piston cup lips to Install the primary cup onto the spring. turn inside out. Install the spring and master piston into the master PRING cylinder.
  • Page 504: Front Brake Caliper

    BRAKE SYSTEM (Standard) Connect the brake hose to the master cylinder with the oil bolt and new sealing washers, and tighten IL B LT the oil bolt while holding the master cylinder firmly. TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) SEALING Install the master cylinder onto the fork leg with WASHERS...
  • Page 505 BRAKE SYSTEM (Standard) Remove the two mounting bolts (lower pivot and upper joint bolts) and brake caliper. Remove the pivot collars from the fork and caliper bracket. Check the pivot bearings and dust seals in the fork leg for wear or damage. For pivot bearing replacement, see page 13-23.
  • Page 506 BRAKE SYSTEM (Standard) – assembly bolts – caliper body B ODY A Place a shop towel over the pistons. Position the caliper body with the piston facing Do not use high down and apply small squirts of air pressure to the pressure air or bring fluid inlets to remove the pistons.
  • Page 507 BRAKE SYSTEM (Standard) Measure the caliper piston O.D. SERVICE LIMITS: Left caliper: Upper/lower: 22.56 mm (0.888 in) Center: 26.91 mm (1.059 in) Right caliper: Upper/center: 25.31 mm (0.996 in) Lower: 22.56 mm (0.888 in) ASSEMBLY RIGHT CALIPER CALIPER RACKET PAD SPRING CALIPER PIN OOT PAD RETAINER RACKET PIN OOT...
  • Page 508 BRAKE SYSTEM (Standard) LEFT CALIPER ALIPER BRA KET ALIPER PIN BOOT PAD SPRING PAD RETAINER PISTON (22 mm O.D.) PISTON BRA KET PIN BOOT (27 mm O.D.) PAD PIN PAD PIN PISTON (22 mm O.D.) PLUG DUST SEALS PISTON SEALS BRAKE PADS Coat new piston and dust seals with clean brake Left caliper shown:...
  • Page 509 BRAKE SYSTEM (Standard) Install the pad spring onto the caliper body properly as shown (page 15-37). RACKET Check the caliper and bracket pin boots and replace them if they are hard, deteriorated or damaged. Install the boots into the caliper and bracket. Apply silicone grease to the inside of the boots and install the caliper bracket over the caliper body.
  • Page 510 BRAKE SYSTEM (Standard) Connect the brake hoses to the caliper with the oil Route the brake bolts and new sealing washers, and tighten the oil hoses properly EALING WA HER bolts. (page 1-23). TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Tighten the pad pin and install the pad pin plug.
  • Page 511: Rear Brake Caliper

    BRAKE SYSTEM (Standard) Connect the brake hoses to the caliper with the oil Route the brake bolts and new sealing washers, and tighten the oil hoses properly SEALING WASHERS bolts. (page 1-23). TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Tighten the pad pin and install the pad pin plug. TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) Fill and bleed the lever and pedal brake hydraulic IL B LTS...
  • Page 512 BRAKE SYSTEM (Standard) – assembly bolts ODY A – caliper body B Place a shop towel over the pistons. Position the caliper body with the pistons facing down and apply small squirts of air pressure to the fluid inlets to remove the pistons. Push the dust and piston seals in and lift them out.
  • Page 513 BRAKE SYSTEM (Standard) Measure the caliper piston O.D. SERVICE LIMITS: Upper/lower: 22.56 mm (0.888 in) Center: 26.91 mm (1.059 in) ASSEMBLY RAKE PADS PAD SPRING PISTON (22 mm O.D.) PISTON (27 mm O.D.) PISTON (22 mm O.D.) PISTON SEALS PAD PIN PAD RETAINER PAD PIN PLUG DUST SEALS...
  • Page 514 BRAKE SYSTEM (Standard) Assemble the caliper body halves with new assem- bly bolts and tighten them. TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) Install the pad spring onto the caliper body properly as shown. AD S RING Check the caliper and bracket pin boots and replace them if they are hard, deteriorated or damaged.
  • Page 515: Delay Valve

    BRAKE SYSTEM (Standard) Connect the brake hoses to the caliper with the oil bolts and new sealing washers as shown, and tighten the oil bolts. TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Tighten the pad pin and install the pad pin plug. TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) Fill and bleed the pedal brake hydraulic system (page 15-11).
  • Page 516 BRAKE SYSTEM (Standard) PROPORTIONAL CONTROL VALVE (PCV) REMOVAL Remove the left radiator (page 6-10). Drain the brake fluid from the pedal brake hydraulic JOINT NUTS system (page 15-6). Loosen the joint nuts to disconnect the brake pipes When removing the from the PCV.
  • Page 517 MEMO...
  • Page 518 16. BRAKE SYSTEM (ABS) SYSTEM LOCATION···································· 16-2 BEFORE TROUBLESHOOTING····················16-8 SERVICE INFORMATION ···························· 16-3 TROUBLESHOOTING·································16-10 SYSTEM WIRING CONNECTIONS/ WHEEL SPEED SENSOR····························16-29 LOCATIONS ················································· 16-4 ABS MODULATOR ·····································16-31 BEFORE STARTING TROUBLESHOOTING ·································· 16-5 16-1...
  • Page 519: System Location

    BRAKE SYSTEM (ABS) SYSTEM LOCATION BRAKE SYSTEM (ABS) BS CONTROL UNIT RE R BS MODUL TOR RE R WHEEL SPEED SENSOR FRONT BS MODUL TOR FRONT WHEEL SPEED SENSOR 16-2...
  • Page 520: Service Information

    BRAKE SYSTEM (ABS) SERVICE INFORMATION GENERAL • This section (15-B) covers service of the Anti-lock Brake System (ABS). For other service (conventional brake) of the brake system, see section 15-A. • When the ABS control unit detects a problem, it stops the ABS function and switches back to the conventional brake operation, and the ABS indicator blinks or it stays on.
  • Page 521 BRAKE SYSTEM (ABS) SYSTEM WIRING CONNECTIONS/LOCATIONS Refer to page 16-5 for the parts that must be removed for service. For example: REAR MODULATOR CONTROL MOTOR 2P Electric component – Center inner fairing (page 2-6) The part that must be removed for service 16-4...
  • Page 522 BRAKE SYSTEM (ABS) BEFORE STARTING TROUBLESHOOTING SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the problematic part can be detected by outputting the problem code. When the vehicle speed is approximately 10 km/h (6 mph) or more, the wheel speed sensor signal is sent to the ABS con- trol unit (ECU), then the ABS pre-start self-diagnosis system operates the control motor on the modulator, checks the crank angle condition with the ABS control unit and thus detects whether the modulator operation is normal, and it completes...
  • Page 523 BRAKE SYSTEM (ABS) RETRIEVAL/ERASURE OF PROBLEM CODE • After retrieval, the ABS indicator indicates the problem code by blinking a specified number of times. • The problem code is not erased by turning the ignition switch to “OFF” while the problem code is being output. Note that turning the ignition switch to “ON”...
  • Page 524 BRAKE SYSTEM (ABS) PROBLEM CODE INDICATION PATTERN When the problem code is not stored: 16-7...
  • Page 525: Before Troubleshooting

    BRAKE SYSTEM (ABS) BEFORE TROUBLESHOOTING SYMPTOM-TO-SYSTEM CHART • Before performing any ABS troubleshooting, check the pre-start self-diagnosis (page 16-5). Probable faulty part Fuse Modulator Check part and system Front wheel 16-10 speed sensor system Rear wheel 16-12 speed sensor system Front control 16-14 motor system...
  • Page 526 BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLESHOOTING FLOW CHART Be careful not to damage the wheel speed sensor and pulser ring when servicing. • The connector number (number in parenthesis) indicates the connector location as shown on page 16-4. All connector diagrams in the flow charts are viewed from the terminal side. •...
  • Page 527: Troubleshooting

    BRAKE SYSTEM (ABS) TROUBLESHOOTING Problem Code 2 and 8: Front wheel speed sensor system and ABS control unit 1. Wheel Pulser Air Gap Inspection Check the area around the front wheel speed sensor. Measure the air gap between the speed sensor and pulser ring (page 16-29).
  • Page 528 BRAKE SYSTEM (ABS) 6. Speed Sensor Line Short Circuit Inspection at ABS Control Unit Disconnect the ABS control unit 12P connector (8). Check for continuity between the Black/white or Green/orange terminal of the connector (8) and ground. Is there continuity? –...
  • Page 529 BRAKE SYSTEM (ABS) Problem Code 3 and 9: Rear wheel speed sensor system and ABS control unit 1. Wheel Pulser Air Gap Inspection Check the area around the rear wheel speed sensor. Measure the air gap between the speed sensor and pulser ring (page 16-29).
  • Page 530 BRAKE SYSTEM (ABS) 6. Speed Sensor Line Short Circuit Inspection at ABS Control Unit Disconnect the ABS control unit 12P connector (8). Check for continuity between the Black/ orange or Blue/yellow terminal of the connector (8) and ground. Is there continuity? NO (NORMAL) –...
  • Page 531 BRAKE SYSTEM (ABS) Problem Code 4: Front modulator control motor system 1. Motor Fuse No. 3 Inspection Check the front control motor fuse (No. 3; 30A). (10) Is the fuse blown? – GO TO STEP 3. – GO TO STEP 2. –...
  • Page 532 BRAKE SYSTEM (ABS) 5. Modulator Motor Ground Circuit Inspection at ABS Control Unit Check for continuity between the Green terminal of the connector (9) and ground. Is there continuity? – Open circuit in the Green wire (ground). – GO TO STEP 6. 6.
  • Page 533 BRAKE SYSTEM (ABS) 8. Modulator Motor Inspection by Removing Front and Rear Modulators Connect the control unit 5P connector (9). Dis- connect the (3), (4) and (5) connectors from the front and rear modulators. Connect the (5) and (4) connectors to the front modulator, and the (2) and (3) connectors to the rear modulator con- versely.
  • Page 534 BRAKE SYSTEM (ABS) 4. ABS Control Unit Battery Voltage Inspection • Disconnect the ABS control unit 5P connector (7). Measure the voltage between the Red/ green terminal (+) of the connector (7) and ground (–). There should be battery voltage at all times.
  • Page 535 BRAKE SYSTEM (ABS) 7. Wire Harness Open Circuit Inspection Between ABS Control Unit and Rear Modulator Short the Brown/light green and Red/black ter- minals of the connector (7) with a jumper wire. Check for continuity between the Brown/light green and Red/black terminals of the connector (5).
  • Page 536 BRAKE SYSTEM (ABS) 3. Crank Angle Sensor Input Voltage Inspection Disconnect the front modulator crank angle sen- sor connector (3). Measure the voltage between the Orange/green (+) and Pink/black (–) terminals of the connector (3) with the ignition switch turned to “ON.” Standard: 4.5 – 5.5V. Is voltage within standard range? –...
  • Page 537 BRAKE SYSTEM (ABS) 6. Modulator Inspection by Replacing the Front and Rear Modulators Connect the control unit 12P connector (8). Dis- connect the (2), (4) and (5) connectors from the front and rear modulators. Connect the (5) and (4) connectors to the front modulator, and the (2) and (3) connectors to the rear modulator con- versely.
  • Page 538 BRAKE SYSTEM (ABS) Problem Code 7: Rear modulator crank angle sensor system 1. ABS Indicator Checking Turn the ignition switch to “ON” and check the ABS indicator. Is the indicator blinking? – GO TO STEP 2. – GO TO STEP 3. 2.
  • Page 539 BRAKE SYSTEM (ABS) 5. Open Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator Ground the White/blue terminal of the connector (8) with a jumper wire. Check for continuity between the White/blue terminal of the connec- tor (4) and ground. Is there continuity? –...
  • Page 540 BRAKE SYSTEM (ABS) 8. Open Circuit Inspection Between ABS Control Unit and Angle Sensor Modulator or Faulty ABS Control Unit Short the Orange/white and Pink/white terminals of the connector (8) with a jumper wire. Check for continuity between the Orange/white and Pink/white terminals of the connector (4).
  • Page 541 BRAKE SYSTEM (ABS) 4. Modulator Inspection by Replacing the Front and Rear Modulators Disconnect the (2), (3), (4) and (5) connectors from the front and rear modulators. Connect the (5) and (4) connectors to the front modulator, and the (2) and (3) connectors to the rear modu- lator conversely.
  • Page 542 BRAKE SYSTEM (ABS) 4. Modulator Inspection by Replacing the Front and Rear Modulators Disconnect the (2), (3), (4) and (5) connectors from the front and rear modulators. Connect the (5) and (4) connectors to the front modulator, and the (2) and (3) connectors to the rear modu- lator conversely.
  • Page 543 BRAKE SYSTEM (ABS) Problem Code 14: Power circuit 1. Battery Charging System Inspection • Ask the rider about the following when the motorcycle is brought in for inspection. This problem code will light up to indicate battery discharge. – Ask whether the motorcycle has been run with large capacity electric load accesso- ries.
  • Page 544 BRAKE SYSTEM (ABS) Problems Not Detected by ABS Control Unit (ABS indicator stays on) 1. Check Battery System Check the battery for charging condition. Is voltage within standard range? NO (low or no voltage) – Check the charging system (section 16). –...
  • Page 545 BRAKE SYSTEM (ABS) 5. Open Circuit Inspection Between ABS Control Unit and Indicator Connect the 5P connector (7). Disconnect the ABS control unit 5P connector (9). Measure the voltage between the Yellow/blue terminal (+) of the connector (9) and ground (–) with the igni- tion switch turned to “ON.”...
  • Page 546: Wheel Speed Sensor

    BRAKE SYSTEM (ABS) 8. ABS Indicator Checking Perform the pre-start self-diagnosis and check the ABS indicator. Does the indicator go off or stay on? GOES OFF–Normal (temporary failure). The ABS control unit has been disrupted by an extremely powerful radio wave. Check the connector and wire harness for loose connection.
  • Page 547 BRAKE SYSTEM (ABS) Remove the sensor wire from the clamps and clips. Remove the two bolts, clamp and speed sensor. Installation is in the reverse order of removal. Route the wire properly TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) (page 1-23). After installation, check the air gap (page 16-29).
  • Page 548: Abs Modulator

    BRAKE SYSTEM (ABS) ABS MODULATOR REMOVAL Drain the hydraulic brake system (page 15-6). Remove the ignition coils (page 18-8). Disconnect the control motor 2P (black) and crank angle sensor 3P (gray) connectors from each modulator. Loosen the joint nuts to disconnect the brake pipe When loosening from each modulator.
  • Page 549 BRAKE SYSTEM (ABS) INSTALLATION Install the modulators onto the stay with the mount- Route the wires ing bolts. properly (page 1-23). TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the modulator/stay assembly, being careful not to interfere with the brake pipes and tighten the two stay bolts.
  • Page 550 17. BATTERY/CHARGING SYSTEM SYSTEM LOCATION···································· 17-2 BATTERY·······················································17-6 SYSTEM DIAGRAM····································· 17-2 CHARGING SYSTEM INSPECTION·············17-9 SERVICE INFORMATION ···························· 17-3 ALTERNATOR·············································17-10 TROUBLESHOOTING ·································· 17-5 17-1...
  • Page 551 BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM 17-2...
  • Page 552 BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 553 BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Battery Capacity 12 V – 18 Ah – Current leakage 5 mA max. – Voltage Fully charged 13.0 – 13.2 V – (20° C/68° F) Needs charging Below 12.3 V – Charging current Normal 1.8 A x 5 –...
  • Page 554 BATTERY/CHARGING SYSTEM TROUBLESHOOTING Battery is damaged or weak 1. Battery Inspection Remove the battery (page 17-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH, BM-210 or BATTERY MATE Is the battery voltage within 13.0–13.2 V? –...
  • Page 555: Voltage Inspection

    BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the left side cover (page 2-5). Remove the trim clip and battery plate. Remove the bolt and lower the battery holder. With the ignition switch turned to “OFF,” discon- nect the negative (–) cable first, then disconnect the positive (+) cable.
  • Page 556: Battery Testing

    BATTERY/CHARGING SYSTEM BATTERY TESTING Remove the battery (page 17-6). Securely connect the tester’s positive (+) cable first, For accurate test ATTERY then connect the negative (–) cable. results, be sure the tester’s cables and TOOL: clamps are in good Battery tester BM-210-AH or BM-210 working condition (U.S.A.
  • Page 557: Battery Charging

    7. Let the battery cool for at least 10 minutes or time has elapsed. until gassing subsides after charging. 8. Retest the battery using the Honda battery tester and recharge if necessary using the above steps. 17-8...
  • Page 558: Charging System Inspection

    BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Remove the left side cover (page 2-5). Turn the ignition switch to “OFF,” and disconnect the negative (–) cable from the battery. Connect the ammeter (+) probe to the negative (–) cable and the ammeter (–) probe to the battery (–) terminal.
  • Page 559 BATTERY/CHARGING SYSTEM WIRE HARNESS INSPECTION P CONNECTOR Remove the left side cover (page 2-5). Remove the left engine side cover (page 2-5). Disconnect the battery negative (–) cable from the Be sure to discon- battery. nect the battery Pull the rubber cap off the alternator terminal, negative cable to remove the nut and disconnect the alternator cable.
  • Page 560 BATTERY/CHARGING SYSTEM Remove the O-ring from the alternator. -RING DISASSEMBLY Mark the front and rear housings before disassem- bly to identify their original position. Remove the four bolts and separate the front hous- ing/rotor from the rear housing/stator. Remove the four screws and separate the rotor from IL SEAL SCREWS the front housing.
  • Page 561 BATTERY/CHARGING SYSTEM Remove the spring washer from the rear housing. PRING CREW Remove the three screws and separate the stator WA HER coil and regulator/rectifier assembly from the rear housing. INSPECTION ROTOR COIL Inspect the slip rings for discoloration. LIP RING Measure the O.D.
  • Page 562 BATTERY/CHARGING SYSTEM ROTOR BEARING Turn the outer race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the rotor shaft. Replace the bearings if the races do not turn smoothly, quietly, or if they fit loosely on the shaft (page 17-15).
  • Page 563 BATTERY/CHARGING SYSTEM Heat the soldering iron (capacity: about 32 W) and Work quickly to use a low-temperature (180° – 200° C) solder to sol- avoid heat damage der the brushes. to the regulator/rectifier. • Make sure that solder does not enter the brush holder or the brush will not operate properly.
  • Page 564 BATTERY/CHARGING SYSTEM RECTIFIER See the wire diagram on page 17-2 for terminal locations. Check for continuity in each direction between: – B and P terminals – E (ground) and P terminals All diodes should have continuity in only one direction. If any of the diodes fail, replace the regulator/ rectifier assembly.
  • Page 565 BATTERY/CHARGING SYSTEM ASSEMBLY ROTOR RETAINER RONT HOUSING RONT BEARING REAR HOUSING OIL SEAL TERMINAL SPRING WASHER REGULATOR/RECTI IER STATOR COIL Heat a high-amperage soldering iron (capacity: oin with solder REGULATOR/RECTIFIER about 110 W). Using a high-temperature (300° C), high lead content Work quickly to solder, join the stator and regulator/rectifier by sol- avoid heat...
  • Page 566 BATTERY/CHARGING SYSTEM Install the stator coil and regulator/rectifier assem- HOLE bly into the rear housing, while inserting the pin holding the brushes into the hole in the housing. Align the marks on the rear housing and stator. EA HOUSING Install the three screws and tighten them securely. +4-9 Install the terminal and nut, and tighten the nut.
  • Page 567 BATTERY/CHARGING SYSTEM IL SEAL SCREWS Install the rotor into the front housing. Install the four screws and tighten them securely. R T R Install the spring washer into the rear housing. PRING WA HER Install the front housing/rotor into the rear housing/ FRONT HOUSING stator, while aligning the marks on the front hous- ing and stator.
  • Page 568 BATTERY/CHARGING SYSTEM Install the alternator into the rear case and tighten the three mounting bolts. TORQUE: 29 N·m (3.0 kgf·m, 22 lbf·ft) 4P CO ECTOR Connect the alternator cable and tighten the termi- nal nut securely. Install the rubber cap properly. Connect the alternator 4P connector.
  • Page 569 MEMO...
  • Page 570 18. IGNITION SYSTEM SYSTEM LOCATION···································· 18-2 IGNITION COIL ·············································18-7 SYSTEM DIAGRAM····································· 18-2 IGNITION PULSE GENERATOR···················18-9 PGM-FI IGNITION RELAY ··························18-11 SERVICE INFORMATION ···························· 18-3 TROUBLESHOOTING ·································· 18-4 BANK ANGLE SENSOR ·····························18-13 IGNITION SYSTEM INSPECTION ··············· 18-5 IGNITION TIMING ······································18-14 18-1...
  • Page 571: System Location

    IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM GN T ON SW TCH REVERSE REGULATOR ENG NE CONTROL ENG NE STOP SW TCH ASSEMBLY MODULE (ECM) RELAY BOX BANK ANGLE GN RELAY) SENSOR GN T ON CO LS SPARK PLUGS BATTERY GN T ON PULSE S DE STAND SW TCH GENERATOR GEAR POS T ON...
  • Page 572: Service Information

    IGNITION SYSTEM SERVICE INFORMATION GENERAL • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is “ON” and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting table on page 18-4. •...
  • Page 573: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. – Faulty spark plug. – Loose spark plug cap or spark plug wire connections. – Water in the spark plug cap (Leaking the ignition coil secondary voltage). • If there is no spark at any cylinder, temporarily exchange the ignition coil with a known-good one and perform the spark test.
  • Page 574: Ignition System Inspection

    IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark present at the plugs, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter (impedance 10 MΩ/DCV minimum). • The display value differs depending upon the internal impedance of the multimeter.
  • Page 575 IGNITION SYSTEM Connect the peak voltage tester or adaptor probes to the wire harness side connector terminal and GN T ON CO L CONNECTOR ground. (viewed from the terminal side) CONNECTION: No. 1 & 2 ignition coil: Yellow/white (+) – Ground (–) No.
  • Page 576: Ignition Coil

    IGNITION SYSTEM Disconnect the ignition pulse generator 2P red con- nector and connect the peak voltage tester or adap- tor probes to the ignition pulse generator side connector terminals. CONNECTION: Yellow (+) – White/yellow (–) In the same manner as at the ICM connector, mea- sure the peak voltage and compare it to the voltage measured at the ECM connector.
  • Page 577 IGNITION SYSTEM 2. Measure the voltage between the Black/yellow wire terminal (+) of the ignition coil 4P connector GN T ON CO L CONNECTOR and ground (–). (viewed from the terminal side) There should be battery voltage. • If there is no voltage, repair the open circuit in the Black/yellow wire between the ignition coil and PGM-FI ignition relay.
  • Page 578: Ignition Pulse Generator

    IGNITION SYSTEM SPARK PLUG WIRE Disconnect the spark plug wires from the ignition coils. Remove the No. 3 & 4 ignition coil. Remove the wire clamp from the stay and remove the stay from the No. 2 and No. 5 spark plug wires. SPARK PLUG WIRES...
  • Page 579 IGNITION SYSTEM GROMMET Remove the two bolts, wire retainer, grommet and BOLTS the ignition pulse generator from the front crank- case cover. Clean the gasket mating surfaces of the crankcase and cover thoroughly, being careful not to damage them. Apply sealant to the grommet seating surface of a new ignition pulse generator.
  • Page 580: Pgm-fi Ignition Relay

    IGNITION SYSTEM Connect the ignition pulse generator 2P red connec- tor securely. Install the following: – air cleaner housing (page 5-57) – front lower fairing (page 2-6) P RED CONNECTOR PGM-FI IGNITION RELAY SYSTEM INSPECTION • If the PGM-FI malfunction indicator lamp (MIL) stays on and there is no ignition coil input volt- age, perform this inspection.
  • Page 581 IGNITION SYSTEM GM-FI IGNITION RELAY 2. Turn the ignition switch to “OFF” and remove the PGM-FI IGNITION relay. Turn ignition switch to “ON.” Measure the voltage between the Black wire ter- minal (+) of the relay connector and ground (–). There should be battery voltage.
  • Page 582: Bank Angle Sensor