Honda 954 Service Manual

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Summary of Contents for Honda 954

Page 2: How To Use This Manual
HOW TO USE THIS MANUAL This service manual describes the service procedures for the CBR954RR. Follow the Maintenance Schedule (Section 3) recommendations t o ensure that the vehicle is in peak operatlng condition. Performing the first scheduled maintenance is very important. It compen- sates for the initial wear that occurs during the break-in period.
Page 3 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl #2 or equivalent). 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.
Page 4 TOOLS SERVICE RULES 1 . Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage t o the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
Page 5 GENERAL INFORMATION (2) The engine serial number is stamped on the right side of the upper crankcase. of the steering head. VEHICLE IDENTIFICATION NUMBER (VIN) THROTTLE BODY ID~NTIFICATION NUMBER The Vehicle Identification Number (VIN) is located o n The throttle body identification number is stamped o n the intake side of the throttle body as shown.
Page 6: Specifications
3.96 Imp gal) Fuel tank capacity 4 cylinders in-line, inclined 30" f r o m vertical ENGINE Cylinder arrangement 75.0 x 54.0 (2.95 x 2.13 in) 954 cm3 (58.2 cu-in) Displacement 11.5: 1 Compression ratio Chain driven, DOHC Valve train 25' BTDC...
Page 7 GENERAL INFORMATION GENERAL (Cont’d) ITEM SPECIFICATIONS PGM-FI (Programmed Fuel Injection) Throttle bore 42 mm (1.7 in) TRAIN DRIVE Clutch system Multi-plate, w e t Clutch operation system Cable operating Transmission Constant mesh, 6-speeds Primary reduction 1.520 (73/48) Final reduction 2.687 (43/16) Gear ratio 1 st 2.692 (35/13)
Page 8 3.7 liter (3.9 US qt, 3.3 Imp qt) A t disassembly 4.0 liter (4.2 US 3.5 Imp Pro Honda GN4 or HP4 (without molybde- n u m additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher...
Page 9: Cylinder Head/Valves
182°F) Fully open 95°C (203°F) Valve lift 8 rnm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors Standard coolant concentration Unit: mm (in) CYLINDER HEADNALVES ITEM STANDARD...
Page 10 Unit: m m (in) ITEM STANDARD SERVICE LIMIT Clutch lever free play 20 (3/8 13/16) Clutch spring free length 48.8 (1.92) 47.4 (1.87) Clutch disc thickness 2.92 3.08 (0.115-0.121) 2.6 (0.10) Clutch plate warpage 0.30 (0.012) I.D. 25.000 25.021 (0.9843 0.9851) 25.03 (0.985) Clutch outer guide...
Page 11 GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Side clearance 0.05 - 0.20 (0.002 - 0.008) 0.30 (0.012) 0.03 (0.001) Main journal oil clearance 0.017 - 0.035 (0.0007 - 0.0014) 0.045 (0.0018) 31.000 - 31.025 (1.2205 - 1.2215) Gear I.D. M5, M 6 31.04 (1.222) 26.000 26.021 (1.0236...
Page 12 255.8 (10.07) 250.8 (9.87) Spring direction With the tapered end facing u p Fork pipe runout 0.20 (0.008) Recommended fork oil Pro Honda Suspension Fluid SS-8 Fluid level 73 (2.9) Fluid capacity 2.5 cm3 (17.3 0.08 US 18.1 0.09 Imp...
Page 13 GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Front Specified brake fluid Honda DOT 4 Brake Fluid Brake disc thickness 4.5 (0.18) 3.5 (0.14) Brake disc runout 0.30 (0.012) Master cylinder I.D. 17.460 - 17.503 (0.6874 - 0.6891) 17.515 (0.6896) Master piston O.D.
Page 14 GENERAL INFORMATION Starter motor brush length 10.0 10.5 (0.39 - 0.41) 3.5 (0.14) ITEM SPECIFICATIONS Bulbs 5 5 w 12V - 3 2 / 3 ~ p (23/8W) X 2 Front turn signal light Rear turn signal light License light Instrument light LED X Turn signal indicator...
Page 15 GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE 4 (0.4, 2.9) 5 m m hex bolt and nut 5 (0.5, 3.6) 5 mm screw small flange) 34 (3.5, 25) 12 (1.2, 9) 6 mm flange bolt (8 m m head, 12 m m hex bolt and nut 54 (5.5, 40) large flange)
Page 16: Table Of Contents
GENERAL INFORMATION ENGINE (Cont’d) TORQUE REMARKS ITEM CYLINDER HEADNALVES: Cylinder head cover bolt PAIR reed valve cover flange bolt 12 (1.2, 9) NOTE 2 NOTE 2 Breather plate flange bolt 12 (1.2, 9) Camshaft holder flange bolt 12 (1.2, 9) NOTE 5 Cylinder head sealing bolt 27 (2.8, 20)
Page 17 GENERAL INFORMATION ENGINE (Cont'd) ITEM REMARKS Q'TY DIA. NOTE Ignition pulse generator rotor mounting bolt ELECTRIC STARTER: Starter motor terminal nut Neutral switch Insulator clamp (Throttle body side): insulator clamp (Cylinder head side): m m (0.5 0.04 in) m m (0.3 0.04 in) Exhaust 1-14...
Page 18: Frame
GENERAL INFORMATION FRAME TORQUE REMARKS ITEM FRAME BODY PANELWEXHAUST SYSTEM: 26 (2.7, 20) Upper cowl stay mounting bolt 7 (0.7, 5.1) Upper cowl stay mounting bolt 1.5 (0.15, 1.1) Upper cowl pan screw 1.5 (0.15, 1.1) Lower cowl pan screw 1.5 (0.15, 1.1) Rear cowl truss screw NOTE7...
Page 19 GENERAL INFORMATION FRAME (Cont'd) TORQUE THREAD REMARKS ITEM Q'TY DIA. (mm) NOTE 8 Gearshift pedal link pinch bolt FRONT WHEEL/SUSPENSION/STEERING: Handlebar pinch bolt 26 (2.7, 20) NOTE 8 Handlebar weight mountign screw (1.0, 7) 13-30 Steering stem nut See page Steering stem adjusting nut Steering stem lock nut Fork top bridge pinch bolt...
Page 20 GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available in U.S.A. 2. Alternative tool. 3. Newly designed tool. 4. Not available i n U.S.A. REF. SEC. DESCRIPTION TOOL NUMBER REMARKS ECM test harness, 26P Fuel pressure gauge NOTE 2: 07406-OO4000A 07406-0040003 (U.S.A.
Page 21 GENERAL INFORMATION DESCRIPTION REF. SEC. TOOL NUMBER REMARKS Race remover NOTE 4 Driver attachment NOTE 4 Compression gauge attachment 07RMJ-MY50100 Fork damper holder handle Installer attachment, A U.S.A. only Installer attachment, 07VMF-MAT0200 U.S.A. only Remover attachment, A 07VMF-MAT0300 U.S.A. only Remover attachment, 07VMF-MAT0400 U.S.A.
Page 22 GENERAL INFORMATION LUBRICATION & SEAL POINTS REMARKS MATERIAL LOCATION Liquid sealant Crankcase mating surface (Three Bond 1207B or pressure switch threads not apply sealant to the thread m m (0.1 0.2 in) 1-19...
Page 23 GENERAL INFORMATION ENGINE (Cont'd) REMARKS MATERIAL LOCATION Cylinder head semi-circular cut-out Sealant Molybdenum disulfide Main journal bearing surface oil (a mixture of 1/2 Piston pin sliding surface engine oil and 1/2 Connecting rod bearing surface Connecting rod small end inner surface m o I ybdenum d isulfide Crankshaft thrust surface grease...
Page 24 GENERAL INFORMATION REMARKS MATERIAL LOCATION Multi-purpose grease Timing hole cap threads Each oil seal lip Locking agent Upper crankcase sealing bolt threads Lower crankcase sealing bolt threads Cam chain guide mounting bolt threads Cam pulse generator rotor bolt threads Cylinder head sealing bolt threads Cylinder head cover breather joint threads Coating width: 6.5 1 m m...
Page 25 Rear brake caliper slide pin surface Rear brake caliper slide pin threads Locking agent Rear master cylinder hose joint screw threads Driven sprocket stud bolt threads Handlebar grip rubber inside Honda Bond Fork fluid Fork cap O-ring Fork oil seal lips 1-22...
Page 26 GENERAL INFORMATION CABLE & HARNESS ROUTING BANK ANGLE SENSOR RIGHT TURN ~ I G N A L HEAD LIGHT CONNECTOR (Hi) CON N ECTORS HEAD LIGHT CONNECTOR 1-23...
Page 27 GENERAL INFORMATION CLUTCH CABLE MAIN HORN WIRE 1-24...
Page 28 GENERAL INFORMATION FRONT 1-25...
Page 29 GENERAL INFORMATION ' I -26...
Page 30 GENERAL INFORMATION EXCEPT CALIFORNIA TYPE: STARTER MOTOR'GROUND CABLE 1-27...
Page 31 GENERAL INFORMATION CALIFORNIA TYPE: PAIR CONTROL SOLENOID VALVE 2P (NATURAL) CONNECTOR GROUND 1-28...
Page 32 GENERAL INFORMATION LOWER FAST UNIT 1-29...
Page 33 GENERAL INFORMATION THROTTLE STOP CONTROL CABLE FUEL TANK AIR VENT HOSE EGCV C O N T ~ O L CABLES 1-30...
Page 34 GENERAL INFORMATION PAIR SUCTION HOSE SIPHON HOSE FUEL TANK AIR VENT HOSE FUEL TANK OVERFLOW IGNITI O N PULSE GENERATOR WIRE RESERVOIR TANK OVERFLOW HOSE 1-31...
Page 35 GENERAL INFORMATION INJECTOR CONNECTORS 1-32...
Page 36 GENERAL INFORMATION IAT SENSOR H CONNECTOR KE VALVE SERVO MOTOR CONNECTOR MAP SENSOR SPEED SENSOR VACUUM HOSE CONNECTOR FUEL HOSE 1-33...
Page 37 GENERAL INFORMATION REAR BRAKE LIGHT SWITCH CON N ECTOR BATTERY NEGATIVE FUSE ECM 26P (LIGHT GRAY) CONNECTOR ECM 26P (BLACK) CON N ECTOR ALTERNATOR 3P (WHITE) CONNECTOR 1-34...
Page 38 GENERAL INFORMATION HEADLIGHT RELAY CONNECTOR BOOT: REAR TURN SIGNAL LIGHT CONNECTOR LICENSE LIGHT CONNECTOR CONNECTOR REAR BRAKE LIGHT SWITCH WlRE SENSOR WIRE (California type only) REAR BRAKE LIGHT SWITCH 1-35...
Page 39 GENERAL INFORMATION REAR BRAKE HOSE RESERVOIR HOSE REAR BRAKE SWITCH 1-36...
Page 40: Crankcase Emission Control System
Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean injection settings as well as other systems, t o reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system t o prevent discharging crankcase emissions into the atmosphere.
Page 41 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emis- sion control system.
Page 42 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with 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 evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body.
Page 43 GENERAL INFORMATION EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL LABELS An Emission Control Information Label is located on the storage compartment as shown. The seat must be removed t o read it. It gives base tune-up specifications. N C O ~ T R O L I N FO R MATI EM I LABEL (Canada only) VACUUM HOSE ROUTING DIAGRAM...
Page 44 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS COWL COVER D U C T...
Page 45 EL EXHAUST SYST 2, FRAME/BODY P BODY PANEL LOCATIONS LOWER COWL SERVICE INFORMATION 2- 1 INNER MIDDLE COWL TROUBLESHOOTING WINDSCREEN SEAT FRONT FENDER PILLION SEAT/REAR COWL REAR FENDER DUCT COVER SEAT RAIL 2-1 1 UPPER COWL MUFFLER/EXHAUST PIPE 2-1 3 SERVICE INFORMATION GENERAL This section covers removal and installation of the...
Page 46 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL BOLTS Remove the t w o seat mounting bolts behind the seat. COLLARS Slide the seat back and then off. Remove the mounting collars. I NSTALLATI 0 N Install the collars into the seat bottom plate as shown. Align the seat hook with the fuel tank rear bracket and install the seat.
Page 47 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the t w o trim clips. Remove the screws, special screws, setting bolts, COI- lars and spacers. Push down the pillion seat mounting bracket and SETTING BOLT SCREWS carefully spread the bottom of both sides of the rear cowl, then remove from the seat rail.
Page 48 FRAME BODY PANELS/EXHAUST SYSTEM Connect the tail light connector. Install the rear cowl over the seat rail being careful not to damage the wire harness. SETTING BOLT SCREWS Install the spacers, setting collars and setting bolts. Install the special screws and truss screws. COLLAR Install the t r i m clips.
Page 49 UPPER COWL BOLTS REMOVAL Remove the duct cover (page 2-41. Remove the socket bolts and rearview mirrors. Disconnect the turn signal light connectors. Remove the nuts, set plates and turn signal lights from the inner middle cowl. Remove the t r i m clips. Remove the windscreen-to-upper cowl bracket screws.
Page 50 IN STALL AT10 N TURN SIGNAL LIGHT Connect the headlight connectors t o the headlight sockets o n the upper cowl. Install the upper cowl onto the upper cowl stay while aligning the headlight unit bosses w i t h the upper cowl stay grommets.
Page 51 LOWER COWL Remove the t r i m clip f r o m the inner middle cowl. Remove the four t r i m clips from the lower cowl. Remove the upper cowl-to-lower cowl screws. Remove the lower cowl mounting screw, special bolts and then remove the lower cowl.
Page 52 WINDSCREEN WINDSCREEN SCREWS Remove the rearview mirrors (page 2-5). Remove the screws, n y l o n washers and rubber washers. Remove the windscreen b y pulling out the setting nuts f r o m the upper cowl bracket. Windscreen mounting fasteners are plastic screws. Do not overtighten the screws.
Page 53: Rear Fender
FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REAR FENDER A REMOVAL/ INSTALLATION Remove the rear cowl (page 2-2). CON N ECTORS Disconnect the turn signal light connectors and license light connector. Remove the nuts, set plates and turn signal lights. Remove the nut and reflector, then remove rea fender A.
Page 54 Disconnect the turn signal connectors and license light connector. CON N E ~ T O R S Remove the headlight relay, engine stop relay and fan HEADLIGHT RELAY FAN CONTROL RELAY control relay f r o m the rear fender. ENGINE STOP RELAY Remove the reflector mounting nut.
Page 55: Rear Fender Installation
REAR FENDER INSTALLATION CONNECTORS Install the rear fender aligning its lower groove w i t h the seat rail brace. Connect the license light connector and turn signal connectors. Install the removed parts i n the reverse order of removal. SEAT RAIL REMOVAL...
Page 56 Remove the socket bolts and left pillion bracket. Remove the bolts and regulator/rectifier. Remove the fuel tank rear bracket bolts. Remove the seat rail mlounting 8 mm bolts, 10 mm I N STALL AT1 0 N 39 N * m (4.0 kgf-m, 29 Ibf-ft) 39 N - m 39 N-rn (4.0 kgf-m, 29 Ibf-ft) PILLION FOOTPEG...
Page 57 boll :s a md Install the seat rail and tighten the mounting nuts t o the specified torque. TORQUE: m m bolt: 39 N . m (4.0 nut: 39 N-m (4.0 kgf-m, 29 Install the regulator/rectifier, tighten the bolts. Install the left pillion footpeg bracket and tighten the socket bolts t o the specified torque.
Page 58 Remove the gasket. Disconnect the sensor 4P (Natural) connector. Remove the sensor wire f r o m the frame. Remove the sensor wire clamp. Caiifornia :ype CLAMP COLLARS Remove the right step guard mounting bolts and col- lars. Rele sensor wire f r o m the right step guard. SENSOR WIRE RIGHT STEP GUARD 2-1 4...
Page 59 Remove the t w o bolts and EGCV (Exhaust Gas Control Valve) pulley cover. Disconnect the EGCV control cables f r o m the pulley. CONTROL CABLES PULLEY Remove the exhaust pipe joint nuts. Remove the following: - Exhaust pipe mounting bolt/nut - Washer - Collar - Exhaust pipe...
Page 60 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Non-California type: 12 N-m (1.2 kaf-m, 12 N*m (1.2'kgf*rn, 9 Ibf-ft) EXH A U S T PIPE California type: 2-16...
Page 61 Install the exhaust pipe mounting rubber and collar into the lower bracket hole. NTI N G RU BB Check the protrusion of the exhaust pipe stud bolt (page 1-14). Install the n e w exhaust pipe gaskets onto the exhaust ports of the cylinder head.
Page 62 FRAME/BODY PANELS/EXHAUST SYSTEM Connect the EGCV control cables to the cable pulley. CONTROL CABLES PUL L EY the bolts t o Install the EGCV pulley cover and tighten the specified torque. TORQUE: 12 N-m (1.2 kgfsm, 9 Ibf-ft) Clamp the 0 2 sensor wire to the right step guard. Install the rear master cylinder, collars and right step guard, then tighten the mounting bolts.
Page 63 Route the 0 2 sensor wire into the frame. Connect the sensor 4P (Natural) connector. Install the new gasket onto the exhaust pipe shown. Install the muffler. Temporarily install the muffler mounting bolt/nut and muffler joint nuts. Tighten all of the muffleriexhaust pipe mounting tighten exhaust pipe ~ o i n t nuts...
Page 64 3. MAINTE DRIVE CHAIN 3-20 SERVICE INFORMATION BRAKE FLUID 3-24 MAINTENANCE SCHEDULE 3-25 BRAKE PAD WEAR FUEL LINE BRAKE SYSTEM 3-25 THROTTLE OPERATION 3-26 BRAKE LIGHT SWITCH AIR CLEANER HEADLIGHT AIM 3-27 SPARK PLUGS 3-27 CLUTCH SYSTEM VALVE CLEARANCE 3-10 SIDE STAND 3-28 ENGINE OIL/OIL FILTER...
Page 65 At oil filter change 3.7 liter (3.9 US qt, 3.3 Imp qt) 40 - 50 mm (1.6 - 2.0 in) Drive chain slack Recommended brake fluid Honda DOT 4 Brake Fluid Rear Rear Front Pilot SPORT E Pilot SPORT E...
Page 66 5-93 CONTROL CABLE EVERY 500 mi (800 km): I, L 3-20 Should be serviced b y an authorized Honda dealer, unless the owner has proper tools and service data and is mechani- cally qualified. In the interest of safety, w e recommend these items be serviced only b y an authorized Honda dealer.
Page 67 MAINTENANCE FUEL Remove the front fuel tank mounting bolts and washers. Remove the right and left duct cover mounting bolts. Remove the seat and then remove the fuel tank sup- After fueiiine FUEL TANK SUPPORT ROD inspection, mstaii port rod f r o m the seat. the rod ends into the seat properly as shown...
Page 68: Throttle Operation
MAINTENANCE Check the fuel lines for deterioration, damage or leak- age. Replace the fuel line if necessary. Install the fuel tank in the reverse order of removal. THROTTLE OPERATION Check for smooth throttle grip full opening and auto- matic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged.
Page 69: Air Cleaner
MAINTENANCE Major adjustments are made with the lower adjuster. Remove the air cleaner housing (page 5-64). Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Recheck the throttle operation. Replace any damaged parts, if necessary.
Page 70 Remove the radiator lower mounting b o l t h u t . Remove t h e radiator upper m o u n t i n g b o l t a n d washer. Remove the radiator grommet f r o m the frame boss by moving t o the right, then move the radiator forward.
Page 71 MAINTENANCE Remove the spark plug using the equipped spark plug wrench or an equivalent. Inspect or replace as described i n the maintenance schedule. INSPECTION ELECTRODE Check the following and replace if necessary (recom- mended spark plug: page 3-2) Insulator for damage Electrodes for wear Burning condition, coloration the electrodes are contaminated with accumulated...
Page 72 MAINTENANCE Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification. TORQUE: 12 N-m (1.2 If using the new plug, install as follows: Install and hand tighten the new spark plug, then tighten it about 1/2 turn after the sealing washer con- tacts the seat of the plug hole.
Page 73 MAINTENANCE Install a n d tighten the radiator lower m o u n t i n g Connect the fan motor wire (Black) connector. Install the lower cowl (page 2-7). VALVE CLE CHAIN TENSIONER LIFTER BOLT INSPECTION inspect and adjust the valve Remove t h e cylinder head cover (page 8 the engine is coid...
Page 74 MAINTENANCE Remove the timing hole cap and O-ring. Turn the crankshaft clockwise, and align the "T" mark o n the ignition pulse generator rotor with t h e index mark on the right crankcase cover. The timing marks ("IN" and "EX") on the cam sprock- ets must be flush with the cylinder head surface and facing outward as shown.
Page 75 MAINTENANCE Turn the crankshaft clockwise 1/2 turn (180"), align the index line o n the ignition pulse generator rotor so that it is facing up as shown. Check the valve clearance for the No.2 and No.4 cylin- Record the ciear- ance for each der exhaust valves using a feeler gauge.
Page 76 MAINTENANCE Turn the crankshaft clockwise turn (ISO"), and align the index line on the ignition pulse generator rotor so facing up as shown. Check the valve clearance for the cylin- Record the dear- der exhaust valves using a feeler gauge. vaive for refer- VALVE CLEARANCE: EX: 0.27...
Page 77: Clearance C
MAINTENANCE Measure the shim thickness and record it. SHIM Sixty-five different shim thicknesses Calculate the n e w shim thickness using the equation from 1200 New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness Make sure o f the correct shim thickness b y measur- ing the shim w i t h a micrometer.
Page 78: Oil Level Inspection
Fill the recommended engine oil up t o the upper level line. RECOMMENDED ENGINE OIL: Other viscosities shown In the Pro Honda GN4 or HP4 (without molybdenum chart may be additives) $-stroke oil or equivalent motor oil used when the API service classification: SG or higher...
Page 79 MAINTENANCE Remove the drain bolt and drain the oil completely Remove and discard the oil filter cartridge using the special tool. TOOL: Oil filter wrench Check that the sealing washer on the drain bolt is in good condition, and replace if necessary. Install and tighten the drain bolt.
Page 80 MAINTENANCE filter and tighten t o the specified Install the new oil torque. TOOL: Oil filter wrench (2.7 kgf-m, 20 I b f W TORQUE: 26 N-m Fill the crankcase with the recommended engine oil. OIL CAPACITY: 3.5 liter (3.7 US qt, 3.1 Imp qt) at draining 3.7 liter (3.9 US qt, 3.3 Imp qt) at oil filter change Install the oil filler cap.
Page 81 The level should be between the "UPPER" and "LOWER" level lines. If necessary, add the recommended coolant. RECOMMENDED ANTIFREEZE: Pro Honda Coolant an equivalent high quali- ty ethylene glycol antifreeze containing corrosion protection inhibitors. LOWER LEVEL LINE Remove the lower cowl (page 2-71.
Page 82 MAINTENANCE SECONDARY AIR SUPPLY SYSTEM PAIR REED VALVE This model is equipped with a built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover. The secondary air supply system introduces fil- tered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there are negative pressure pulses in the exhaust system.
Page 83: Drive Chain
MAINTENANCE DRIVE CHAIN Never inspect and Turn the ignition switch t o ”OFF”, place the motorcy- cle on its side stand and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets. 2.0 in) CHAIN SLACK: rnrn (1.6...
Page 84: Cleaning And Lubrication
MAINTENANCE CLEANING AND LUBRICATION NON-FLAMMABLE OR HIGH FLASH-POINT SOLVENT Clean the chain with non-flammable or high flash- point solvent and wipe dry. Be sure the chain has dried completely before lubri- cating. Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fit- ting links, or otherwise appears unserviceable.
Page 85 MAINTENANCE REPLACEMENT This motorcycle uses a drive chain w i t h a staked mas- ter link. Loosen the drive chain (page 3-20). Assemble the special tool as shown. turer's instruction (U.S.A. only) DRIVE CHAIN-TOOL S ET Locate the crimped pin ends of the master link f r o m MASTER LINK the outside the chain, and remove the link w i t h the...
Page 86 MAINTENANCE Route the drive chain through the swingarm as shown. O-RINGS PLATE Never reuse the old drive chain, master link, master link plate and O-rings. Assemble the new master link, O-rings and plate. insert the master inside of the drive chain, and instaii the plate with the identification mark...
Page 87: Front Brake
MAINTENANCE Make sure the pins are staked properly by measuring SLIDE CALIPER the diameter of the staked area using a slide caliper. DIAMETER OF THE STAKED AREA: DID: 5.50 5.80 (0.217 0.228 5.45 5.85 mm (0.215 0.230 After staking, check the staked area of the master link drive with chain...
Page 88: Brake Pad Wear
MAINTENANCE BRAKE PAD WEAR WEAR INDICATOR FRONT BRAKE PADS Check the brake pads for wear. Replace the brake pads if either pad is w o r n t o the bottom o f the wear limit groove. Refer t o page 15-8 for brake pad replacement. REAR BRAKE PADS Check the brake pads for wear.
Page 89: Brake Lever Adjustment
MAINTENANCE BRAKE LEVER ADJUSTMENT The distance between the top of the brake lever and the grip can be adjusted turning the adjuster. brake /ever with the inaex number on the adiuster BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height obtained.
Page 90 MAINTENANCE HEADLIG HT AIM Place the motorcycle o n a level surface. light beam as specified by Iocai Adjust the headlight beam vertically by turning the laws and regula- vertica I beam adjuster. tions A clockwise rotation moves the beam u p and counter- clockwise rotation moves the beam down.
Page 91: Side Stand
MAINTENANCE SIDE STAND Support the motorcycle o n a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly for smooth movement and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system: - Sit astride the motorcycle and raise the side stand.
Page 92 MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS Do not turn the adjuster screws more than the given positions or the adjusters may be damaged. Always start on full hard when adjusting the damping. Be sure that the rebound and compression adjusters are firmly located in a detent, and not between posi- tions.
Page 93: Rear Suspension Adjustment
MAINTENANCE Check for w o r n swingarm bearings b y grabbing the rear swingarm and attempting t o move the swingarm side t o side. Replace the bearings if any looseness is noted. Check the action of the shock absorber b y compress- ing it several times.
Page 94 MAINTENANCE Turn the rebound adjuster clockwise until stops, then turn the adjuster counterclockwise. REBOUND ADJUSTER STANDARD POSITION: turns from full hard BOLTS, FASTE Check that all chassis nuts and bolts are tightened t o their correct torque values (page 1-12). Check that all safety clips, hose clamps and cable stays are in place and properly secured.
Page 95: Steering Head Bearings
MAINTENANCE STEERING HEAD BEARINGS Check that the control cables do not interfere with handlebar rotation. Support the motorcycle securely and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has verti- cal movement, inspect the steering head bearings (Section 13).
Page 96 LUBRICATION SYSTEM DIAGRAM CAMSHAFTS CRANK S HAFT OIL FILTER CARTRIDGE PUMP OIL STRAINER...
Page 97 A t disassembly 4.0 liter (4.2 US 3.5 Imp qt) Recommended engine oil Pro Honda GN4 or HP4 (without molybde- n u m additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher JASO T 903 standard:...
Page 98 LUBRICATION SYSTEM TORQUE VALUES 29 N * m (3.0 kgf-m, 22 Ibfeft) Oil drain bolt 74 N - m (7.5 kgf-m, 54 lbf-ft) Oil cooler mounting bolt CT bolt 8 N * m (0.8 kgf-m, 5.8 Ibf*ft) Oil pump assembly flange bolt Apply a locking agent t o the threads.
Page 99 LUBRICATION SYSTEM OIL PRESSURE INSPECTION Check the oil level (page 3-15). indicator light Warm u p the engine t o normal operating temperature Sto'p the engine and remove the crankcase sealing system before bolt. checking the pressure. Connect an oil pressure gauge and attachment t o the GAUGE crankcase.
Page 100 LUBRICATION SYSTEM Remove the pressure relief valve and O-ring. Remove the oil strainer and gasket. Clean the oil strainer screen. INSPECTION Check the operation of the pressure relief valve by pushing o n the piston. Disassemble the relief valve by removing t h e snap ring.
Page 101: Oil Pump
Apply oil t o the new O-ring and install it onto the relief valve. Install the relief valve into the crankcase. Clean the oil pan mating surface thoroughly. Apply Three Bond 12078 or an equivalent to the mat- Do not apply ing surface.
Page 102 LUBRICATION SYSTEM and oil three flai Remove the DISASSEMBLY ASS E M B LY BOLT DOWEL PINS Remove the dowel pins. Remove the oil pump assembly bolt and p u m p cover. OIL PUMP COVER Remove the thrust washer, drive pin, oil p u m p shaft, INNER ROTOR OUTER ROTOR outer rotor and inner rotor from the oil p u m p body.
Page 103 LUBRICATION SYSTEM Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.014 Measure the side clearance using a straight edge and feeler gauge. SERVICE LIMIT: 0.10 mm (0.004 ASSEMBLY PINS INNER ROTOR OUTER ROTOR (0.8 kif-rn, 5.8 I b f W...
Page 104 LUBRICATION SYSTEM Install the outer and inner rotors into the oil p u m p INNER ROTOR OUTER ROTOR rotor with its body. punch mark facing Install the oil pump shaft through the inner rotor and pump oil pump body. cover.
Page 105: Oil Cooler
LUBRICATION SYSTEM Apply oil t o the clutch outer guide, oil p u m p drive sprocket, driven sprocket and drive chain. Install the clutch outer guide, driveidriven sprocket pump driven and drive chain as an assembly. sprocket wfth "OUT" mark fac- ing outward Apply a locking agent t o the oil p u m p driven sprocket...
Page 106 LUBRICATION SYSTEM INSTALLATION WATER HOSES O I L F I L T ~ R CARTRIDGE 26 N - m (2.7 kgf-m, 20 I b f W LOCK WASHER Coat a new O-ring with engine oil and install it into the oil cooler groove.
Page 107 LUBRICATION SYSTEM Tighten the oil cooler mounting bolt t o the specified torque. TORQUE: 74 N-m (7.5 Connect the oil cooler water hoses, and tighten the hose bands securely. Install the oil filter cartridge and fill the crankcase w i t h t h e recommended oil (page 3-16).
Page 109 5-81 MAP SENSOR SERVICE INFORMATION 5-82 IAT SENSOR TROUBLESHOOTING 5-82 ECT SENSOR SYSTEM LOCATION 5-83 CAM PULSE GENERATOR SYSTEM DIAGRAM 5-84 TP SENSOR PGM-FI (PROGRAMMED FUEL INJECTION) SYSTEM 5-85 BANK ANGLE SENSOR PGM-FI SELF-DIAGNOSIS MALFUNC- 5-86 ENGINE STOP RELAY TION INDICATOR LAMP (MIL) 5-87 5-10 ECM (ENGINE CONTROL MODULE)
Page 110 FUEL SYSTEM (Proarammed Fuel Iniection) not apply commercially available carburetor cleaners t o the inside of the throttle bore, which is coated with molybde- num. Do not snap the throttle valve from full open t o full closed after the throttle cable has been removed. It may cause incorrect idle operation.
Page 111 FUEL SYSTEM (Programmed Fuel Injection) TORQUE VALUES 23 N * m (2.3 kgf-m, 17 I b f W ECT (Engine Coolant Ternperature)/thermo sensor See page 1-14 Throttle body insulator band screw 3 N-m (0.35 kgfom, 2.5 I b f W Throttle cable bracket mounting screw Fuel pipe mounting bolt Pressure regulator mounting bolt...
Page 112 SYSTEM FUEL (Programmed Fuel Injection) SYSTEM LOCATION PAIR SOLENOID VALVE TP SENSOR IGNITION PULSE GENERATOR FULL NAME ABBREVIATIONS Manifold absolute Dressure sensor Throttle position sensor Intake air temperature sensor Engine coolant temperature sensor Engine control module...
Page 113 FUEL SYSTEM (Programmed Fuel Injection) SYSTEM DIAGRAM Cam pulse generator Engine stop relay PAIR check valve Main fuse B (20A) ECT sensor Engine stop switch Ignition pulse generator Sub-fuse (10A) Water temperature Ignition switch Fuel cut-off relay Main fuse A (30A) Fuel p u m p Bank angle sensor Vehicle speed sensor...
Page 114 FUEL SYSTEM (Proclrarnrned Fuel Iniection) PGM-FI (PROGRAMMED FUEL MALFUNCTION INDICATOR LAMP (MIL) INJECTION) SYSTEM SELF-DIAGNOSTIC PROCEDURES Place the motorcycle o n its side stand. Start the engine and let it idle. If the malfunction indicator lamp (MIL) does not light The malfunction indicator lamp or blink, the system has n o memory of problem data.
Page 115 FUEL SYSTEM (Programmed Fuel Injection) Turn the ignition switch to "ON" and engine stop switch to "RUN". If the ECM has no self diagnosis memory data, the MIL will illuminate, when you turn the ignition switch to "ON". If the ECM has self diagnosis memory data, the MIL will start blinking, when you turn the ignition switch to "ON".
Page 116 FUEL SYSTEM (Programmed Fuel Injection) PEAK VOLTAGE INSPECTION PROCE- 3P (BLACK) CONNECTOR DURE Use this procedure for the ignition pulse generator and cam pulse generator inspection. Check all system connections before inspection. If the system is disconnected, incorrect peak voltage might be measured.
Page 117 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM 26P (Black) and 26P (Light gray) connectors f r o m the unit. 26P (BLACK) CONNECTOR Connect the ECM test harnesses between the main wire harness and the ECM. TOOL: test harness, (two required) Install the battery and connect the positive terminal, then connect the negative terminal.
Page 118 FUEL SYSTEM (Programmed Fuel Iniection) PGM-FI SELF-DIAGNOSIS MALFUNCTION INDICATOR LAMP (MIL) FAILURE CODES The PGM-FI malfunction indicator lamp (MIL) denotes the failure codes (the number of blinks from 0 t o 35). The MIL has t w o 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. When t w o long blinks occur, and one short blink, that problem code is 21 (two long blinks 20 blinks, one short blink blink).
Page 119 FUEL SYSTEM (Programmed Fuel Injection) Refer t o Symptoms Number of PGM-FI Causes (Fail-safe contents) MI L bli n ks Engine operates normally Loose or poor contact on vehicle speed sensor connector 5-24 Open or short circuit in vehicle speed sensor connector Blinks Faulty vehicle speed sensor...
Page 120 FUEL SYSTEM (Programmed Fuel Injection) BLINK PGM-FI MIL (MAP SENSOR) Does not blink Connect the MAP sensor connector. Loose or poor contact o n the MAP sensor connec- Place the motorcycle o n its side stand. Start the engine and check that the MIL blinks. blink Turn the ignition switch t o "OFF".
Page 121 FUEL SYSTEM (Programmed Fuel Injection) Out of range Open or short circuit i n Light greenpellow wire Measure the voltage between the terminals of Loose or poor contact on the ECM connectors the wire harness side. Connection: Light green/Yellow Standard: 4.75 5.25 Voltage exists Turn the ignition switch t o "OFF".
Page 122 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 2 BLINKS (MAP SENSOR) Turn the ignition switch to "OFF". Out of range Disconnect the vacuum hose from the MAP sen- Check the hose installation sor. Connect the vacuum gauge between the throttle body and the MAP sensor using a 3-way joint.
Page 123 FUEL SYSTEM (Programmed Fuel Injection) range Faulty MAPsensor "ON". Turn the ignition switch Measure the voltage at the test harness termi- nals (page 5-9). Measure the voltage at the test harness termi- nals (page 5-91. Connection: Standard: 2.7 maximum Voltage exists Replace the ECM with a new one, and inspect again...
Page 124 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 7 BLINKS (ECT SENSOR) Turn the ignition switch to "OFF". Loose or poor contact o n the ECT sensor connec- Connect the ECT sensor connector. Place the motorcycle o n its side stand. Turn the ignition switch t o "ON".
Page 125 FUEL SYSTEM (Programmed Fuel Injection) range Loose or poor contacts on the ECM connector Measure the voltage between the ECT sensor connector terminal of the wire harness side and ground. Connection: Pink/White Ground Standard: 4.75 5.25 V Voltage exists Out of range Measure the voltage at the ECT sensor connec- Open or short circuit i n Green/Orange wire Loose or poor contacts o n the ECM connector...
Page 126 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 8 BLINKS (TP SENSOR) Turn the ignition switch t o "OFF". Disconnect the TP sensor 3P connector. Check for loose or poor contact on the TP sen- sor connector. Place the motorcycle on its side stand. Start the engine and check that the MIL blinks.
Page 127 FUEL SYSTEM (Programmed Fuel Injection) Out of range Open or short circuit i n Greedorange wire Loose or poor contact on the ECM connectors of the wire harness side. Connection: Yellow/Red Standard: 4.75 5.25 V Turn the ignition switch to ”OFF”. Disconnect the ECM connectors.
Page 128 FUEL SYSTEM (Programmed Fuel Injectian) Connect the test harness t o the ECM connec- Open or short circuit in Redflellow wire Check for continuity between the test harness terminal and the sensor connector terminal. Connection: Red/Yellow Standard: Continuity Connect the sensor connector.
Page 129 FUEL SYSTEM (Programmed Fuel Injection) Normal Replace the ECM with a new one, and inspect it Turn the ignition switch t o "ON". again Measure the voltage at the test harness termi- nals. Connection: B22 Standard: *0.4 (throttle fully closed) 4.8 V (throttle fully open)
Page 130 FUEL SYSTEM (Programmed Fuel Injection) Turn the ignition switch to "OFF" Disconnect the IAT sensor 2P connector. Check for loose or poor contact on the IAT sen- sor connector. Does not blink Connect the IAT sensor 2P connector. Loose or poor contact on the IAT sensor connector Place the motorcycle on its side stand.
Page 131 FUEL SYSTEM (Programmed Fuel Injection) range Open or short circuit in GrayiBlue wire Loose or poor contact on the ECM connectors the wire harness side. Connection: Ground Standard: 4.75 5.25 Out of range Open or short circuit in Greedorange wire Measure the voltage between the terminals Loose or poor contact on the ECM connectors the wire harness side.
Page 132 FUEL SYSTEM (Programmed Fuel Injection) eck for loose or poor contact on the vehicle Does not blink Loose or poor contact on the vehicle speed sensor Connect the vehicle connector Start the engine. With the side stand and keep the engine rev more than 5,000 r p m about 20 seconds or more.
Page 133 FUEL SYSTEM (Programmed Fuel Injection) Connect the vehicle speed sensor connector. Disconnect the ECM connectors. Connect the test harness to the wire harness connectors. Abnormal Support the motorcycle securely and place the Open or short circuit in Pink/Green wire rear wheel off the ground. Shift the transmission into gear.
Page 134 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 12 BLINKS (No.1 INJECTOR) Turn the ignition switch to "OFF". Disconnect the No.1 injector 2P connector. Check for loose or poor contact on the No.1 injector 2P connector. Loose or poor contact on the No.1 injector connec- Connect the No.1 injector 2P connector.
Page 135 FUEL SYSTEM (Programmed Fuel Injection) Continuity Faulty No.1 injector Check for continuity between the No.1 injector and ground. Connection: Ground Standard: continuity Out of range Turn the ignition switch t o "ON". Measure the voltage between the No.1 injector connector the wire harness side and ground.
Page 136 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors. Out of range Measure the resistance at the test harness ter- Open circuit in BlackWhite and/or P i n W e l l o w wire minals.
Page 137 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL BLINKS (No.2 INJECTOR) Check for loose or poor contact on the injector 2P connector. Does not blink Connect the No.2 injector 2P connector. Loose or poor contact o n the N o 2 injector connec- Place the motorcycle on its side stand.
Page 138 FUEL SYSTEM (Programmed Fuel Injection) Continuity Faulty No.2 injector Check for continuity between the No.2 injector and ground. Connection: Ground Standard: continuity No continuity Out of range Open or short circuit in Blackwhite wire Turn the ignition switch t o "ON". Measure the voltage between the No.2 injector connector of the wire harness side and ground.
Page 139 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the connectors. Connect the test harness t o the wire harness connectors. Out of range Open circuit i n Blackwhite and/or Pink/Blue wire Measure the resistance at the test harness ter- minals. Connection: A16 Standard: 9 Normal Continuity...
Page 140 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL BLINKS (NO.3 INJECTOR) Turn the ignition switch t o "OFF". Disconnect the No.3 injector 2P connector. Check for loose or poor contact o n the No.3 injector 2P connector. t o r Place the motorcycle on its side stand. Turn the ignition switch t o "ON".
Page 141 FUEL SYSTEM (Programmed Fuel Injection) Continuity Faulty No.3 injector Check for continuity between the No.3 injector and ground. Connection: Ground Standard: N o continuity No continuity Out of range Turn the ignition switch t o "ON". Measure the voltage between the No.3 injector connector of the wire harness side and ground.
Page 142 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors. Out of range Open circuit i n Black/White and/or Pink/Green wire Measure the resistance at the test harness ter- minals. Connection: A4 Standard: 9 Normal Check for continuity between the test harness...
Page 143 Injection) FUEL SYSTEM (Programmed Fuel PGM-FI MIL BLINKS (NO.4 INJECTOR) Does not blink Loose or poor contact o n the No.4 injector connec- Connect the No.4 injector connector. Place the motorcycle on its side stand. Turn the ignition switch t o "ON". Check that the blinks.
Page 144 FUEL SYSTEM (Programmed Fuel Injection) Continuity Check for continuity between the No.4 injector Faulty No.4 injector and ground. Connection: Ground Standard: No continuity No continuitv Out of range Open or short circuit i n Blackwhite wire Turn the ignition switch to "ON". Measure the voltage between the No.4 injector connector of the wire harness side and ground.
Page 145 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the ECM connectors. Connect the test harness the wire harness connectors. range Open circuit in Blackwhite and/or Pink/Black wire Measure the resistance at the test harness ter- minals. Connection: 15 R [2OoC/68'F) Standard: 9 Normal Continuity Short circuit i n Pink/Black wire...
Page 146 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 18 BLINKS (CAM PULSE GENERATOR) Turn the ignition switch to "OFF". Does not blink Loose or poor contact on the cam pulse generator Place the motorcycle on its side stand. Turn the ignition switch to "ON" and check that the MIL blinks.
Page 147 Fuel FUEL SYSTEM (Programmed Injection) Crank the engine with the starter motor, and measure the cam pulse generator peak voltage at the cam pulse generator connector. Connection: Gray Black Standard: 0.7 V minimum (2OoC/68'FF) Normal Connect the cam pulse generator 2P connector. Disconnect the ECM connectors.
Page 148 FUEL SYSTEM (Proqrammed Fuel Iniection) PGM-FI MIL 19 BLINKS (IGNITION PULSE GENERATOR) Turn the ignition switch to "OFF". Disconnect the ignition pulse generator 2P con- n ecto r. Check for loose or poor contact on the ignition pulse generator 2P connector. Loose or poor contact on the ignition pulse gener- Connect the ignition pulse generator 2P con-...
Page 149 FUEL Fuel SYSTEM (Programmed Injection) Crank the engine with the starter motor, and measure the ignition pulse generator peak volt- age at the ignition pulse generator 2P connec- Connection: Yellow Standard: 0.7 minimum (20"C/68"F) Normal Connect the ignition pulse generator 2P con- nector.
Page 150 FUEL SYSTEM (Proarammed Fuel Iniection) ( 0 2 Turn the ignition switch t o "OFF". Disconnect the sensor connector. Check for loose or poor contact on the sen- connector. Disconnect the ECM connectors.. Connect the test harness to ECM connectors. continuity Open circuit in sensor Orangewhite wire...
Page 151 FUEL SYSTEM (Programmed Fuel Injection) Continuity Short circuit in sensor Orangewhite wire Check the continuity between the sensor connector terminal and ground. Connect the sensor connector. Turn the ignition switch t o "ON" and warm up the engine until the coolant temperature is 80°C Operate the throttle grip and snap the engine speed from idle t o 5,000 rpm.
Page 152 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 23 BLINKS SENSOR HEATER/CALIFORNIA TYPE ONLY) Disconnect the sensor connectors. Check for loose or poor contact on the 0 2 sen- sor connector. Loose or poor contact on the sensor connector Turn the ignition switch to "OFF". Out of range Faulty sensor...
Page 153 FUEL (Programmed Fuel Injection) SYSTEM Continuity Faulty Ozsensor Check for continuity White terminal and ground. Connection: White Ground Standard: N o continuity Normal Turn the ignition switch t o "ON". Disconnect the ECM 26P connector. Measure the voltage at the sensor wire har- ness side connector terminals.
Page 154 FUEL SYSTEM (Programmed Fuel Injection) No voltage Open circuit i n Blackwhite wire between the Measure the voltage at the sensor wire har- sensor and engine stop relay ness side connector terminal and ground. Connection: Black/White Ground Standard: Battery voltage Battery voltage Turn the ignition switch t o "OFF".
Page 155 FUEL SYSTEM (Programmed Fuel Injection) No voltage Open circuit in Black/Green wire between the ECM connector and sensor connector Measure the voltage at the test harness termi- nals. Connection: B20 Standard: Battery voltage Battery voltage Replace the ECM and inspect again 5-47...
Page 156 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 33 BLINKS (E2-PROM) "OFF". Turn the ignition switch t o Disconnect the ECM connectors. Check for loose or poor contact of the ECM con- 33 blinks Reset the self-diagnosis memory data (page 5-7). Connect the ECM connectors.
Page 157 FUEL SYSTEM (Programmed Fuel Injection) 33 times No problem Short the service check connector with a jumper wire (page 5-6). Turn the ignition switch "ON" and check the MIL blinks. Reset the self-diagnosis memory data (page problem Turn the ignition switch to "ON" and check the MIL blinks.
Page 158 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 34 BLINKS (EGCV AND AIR INTAKE VALVE SERVO MOTOR VOLTAGE) Turn the ignition switch t o "OFF". Disconnect the servo motor 6P connector. Check for loose or poor contact o n the servo motor 6P connector.
Page 159 Fuel FUEL SYSTEM (Programmed Injection) Abnormal Faulty servo motor Measure the resistance at the servo motor 6P connector terminals. Connection: Light greedpink Standard: 0 5 kR (20"C/68"F) Normal Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors.
Page 160 FUEL SYSTEM (Programmed Fuel Injection) PGM-FI MIL 35 BLINKS (EGCV AND AIR INTAKE VALVE SERVO MOTQR) Turn the ignition switch t o "OFF". Disconnect the servo motor 6P connector. Check for loose or poor contact on the servo motor 6P connector. Loose or poor contact o n the servo motor 6P con- Connect the servo motor 6P connector.
Page 161 (Programmed Fuel FUEL SYSTEM Injection) Abnormal Faulty servo motor Remove the servo motor (page 5-95). Connect the 12 V battery to the servo motor connector terminals and check the servo motor function. Connection: Red Blue Normal Disconnect the ECM connectors. Connect the test harness t o the wire harness connectors.
Page 162: Fuel Pressure Inspection
FUEL SYSTEM (Programmed Fuel Injection) FUEL PRESSURE INSPECTION NOTICE Before disconnecting fuel hoses, release the fuel pressure by loosening the fuel hose banjo bolt at the fuel tank. Always replace the sealing washers when the fuel hose banjo bolt is removed or loosened. Remove the seat (page 2-21, Disconnect the battery negative cable f r o m the bat- tery terminal.
Page 163 FUEL SYSTEM (Programmed Fuel Injection) Remove the fuel hose banjo bolt and attach the fuel BANJO BOLT pressure gauge with the following Honda genuine parts. Banjo bolt, 12 mm Parts No. 90008-PD6-010 Sealing washer, 12 mm Parts No. 90428-PD6-003 Sealing washer, Parts No.
Page 164 FUEL SYSTEM (Programmed Fuel Injection) FUEL FLOW INSPECTION Remove the seat (page 2-2). Open and support the front end of the fuel tank (page Remove the ECM cover and disconnect the fuel cut-off relay connector. J u m p the Brown and Blackwhite wire terminals of JUMPER WIRE FUEL CUT-OFF RELAY the wire harness side using a jumper wire.
Page 165: Fuel Pump
FUEL SYSTEM (Programmed Fuel Injection') FUEL PUMP INSPECTION Turn the ignition switch t o "ON" and confirm that the fuel pump operates for a few seconds. If the fuel p u m p does not operate, inspect as follows: Open and support the front end of the fuel tank (page 3-4).
Page 166 FUEL SYSTEM (Programmed Fuel Injection) FUEL FILTER REPLACEMENT Disconnect the fuel hoses f r o m the fuel filter. Remove the screws and fuel filter. Note the direction Install the fuel filter in the reverse order of removal. the fuel fiirer INSTALLATION Place a new packing onto the fuel pump.
Page 167: Fuel Tank
(Programmed FUEL SYSTEM Fuel Injection) Connect the ohmmeter t o the fuel cut-off relay con- BATTERY FUEL CUT-OFF RELAY nector terminals. CONNECTION: Black/White Brown Connect the 12V battery t o the following fuel cut-off relay connector terminals. CONNECTION: Brown/Black There should be continuity only when the 12V battery is connected.
Page 168 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the fuel tank air vent hose and overflow hose. Hold the fuel pipe nut and remove the fuel hose seal- ing nut and sealing washers, then disconnect the fuel hose. Do not apply excessive force to the fuel pipe. Always hold the fuel pipe nut while removing the fuel hose sealing nut.
Page 169 Fuel FUEL SYSTEM (Programmed Injection) Remove the fuel tank bracket bolts and then remove BOLTS Place the fuel tank upside down. Be careful not to BANJOBOLT FUEL RETURN HOSE damage the fuel tank. Remove the fuel hose banjo bolt and sealing washers, then remove the fuel hose from the fuel pump.
Page 170 FUEL SYSTEM (Programmed Fuel Injection) Connect the fuel hose t o the fuel pump with new seal- BANJOBOLT FUEL RETURN HOSE ing washers. with the stopper Install and tighten the fuel hose banjo bolt t o the spec- ified torque. TORQUE: 22 N-m (2.2 Connect the fuel return hose t o the fuel pump.
Page 171 FUEL SYSTEM Fuel Iniection) Connect the fuel return hose the pressure regulator. Connect the fuel hose banjo t o the throttle body with new sealing washers. While pushing the fuel hose banjo stopper t o the throttle body, install and tighten the sealing nut t o the specified torque.
Page 172: Air Cleaner Housing
FUEL SYSTEM (Programmed Fuel Injection) Install and tighten the duct cover-to-fuel tank bolts. AIR CLEANER HOUSING REMOVAL Remove the air cleaner element (page 3-6). Remove the EGCV and air intake valve servo motor mounting bolt. Remove the servo motor assembly from the bracket and disconnect the intake valve control cable f r o m the servo motor pulley.
Page 173 FUEL SYSTEM (Programmed Fuel Injection) Remove the air funneliair cleaner housing mounting screws, then remove the air funnels. Disconnect the crankcase breather hose and PAIR control valve air suction hose f r o m the air cleaner INSTALLATIQN AIR CLEANER HOUSING Install the air funnels in their proper locations.
Page 174 FUEL SYSTEM (Programmed Fuel Injection) Connect the MAP sensor connector and vacuum hose. Connect the sensor connector. Connect the variable air intake control cable t o t h e serve motor pulley. Install the servo motor onto the bracket, tighten the SERVO MOTOR bolt securely.
Page 175: Throttle Body
FUEL SYSTEM (Programmed Fuel Injection) THROTTLE BODY REMOVAL not snap the NOTICE throttle valve from Before disconnecting the fuel hose, release the fuel pressure b y loosening the fuel hose banjo bolt. throttle been removed Always replace the sealing washers when the fuel may cause incor- hose banjo bolt is removed or loosened.
Page 176 FUEL SYSTEM (Programmed Fuel Injection) Loosen the engine side insulator band screws. Remove the throttle body from the cylinder head. Do not hold the fuel pipe on the throttle body while removing the throttle body. Do not snap the Remove the insulators from the throttle body. INSULATORS throttle valve from fuii open to fuii...
Page 177 FUEL SYSTEM (Programmed Fuel Injection) REAR VIEW: RIGHT SIDE VIEW: THROTTLE DRUM VIEW: (0.35 kgf-m, 2.5 Ibf-ft) WHITE PAINTED WHIT E PAINTED STARTER VALVE LINK VIEW: THROTTLE LINK VIEW: WHITE PAINTED 1 N*m (0.09 kgf-m, 0.7 Ibf-ft)
Page 178 FUEL SYSTEM (Proarammed Fuel Iniection) THROTTLE BODY VACUUM HOSE ROUTING California type:...
Page 179 FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION I N S U LATO Check the insulator band angle. Apply oil to the insulator inside surfaces for ease of throttle body installation. not hold the fuel pipe on the throttle while body installing the throttle body.
Page 180 FUEL SYSTEM (Programmed Fuel Injection) Connect the fast idle unit water hoses t o the unit, then tighten the hose bands securely. Connect the throttle cable ends t o the throttle drum. Install the throttle cable guide bracket t o the throttle body, then tighten the bolts t o the specified torque.
Page 181 FUEL SYSTEM (Programmed Fuel Injection) Remove the injectors from the fuel pipe. FUEL INJECT0 Remove the seal ring, O-ring and cushion ring. O-RING CUSHION RING SEAL RING N STAL LATlO N Apply oil t o the new O-ring. Install the new seal ring, cushion ring and O-ring, being careful not t o damage the O-ring.
Page 182 FUEL SYSTEM (Programmed Fuel Injection) Install the fuel pipe assembly onto the throttle body, FUEL INJECTORS being careful not t o damage the seal rings. Install and tighten the fuel pipe mounting bolts t o the FUEL PIPE ASSEMBLY specified torque. TORQUE: 7 Ibf-ft) Install the throttle body (page 5-71).
Page 183 FUEL SYSTEM (Programmed Fuel Injection) Hold the fuel pipe securely, tighten the pressure regu- VACUUM HOSE PRESSURE REGULATOR lator mounting bolts t o the specified torque. TORQUE: 10 (1.0 kgf-m, 7 Ibf-ft) Connect the vacuum hose t o the pressure regulator FAST IDLE WAX UNIT REMOVAL not ioosen or...
Page 184 FUEL SYSTEM (Programmed Fuel Injection) STARTER VALVE STARTER VALVE DISASSEMBLY Turn each starter valve adjusting screw in, counting the number of turns until it seats lightly. Record the number of turns. Remove the fuel pipe and injectors (page 5-72). Remove the starter valve a r m screws and starter valve arm.
Page 185 FUEL SYSTEM (Programmed Fuel Injection) Clean t h e starter valve bypass using compressed air. apply com- carburetor clean- ers to the inside of the throttle bore, which coated wilh Remove the starter valve shaft a n d three’ collars. COLLARS ASSEMBLY PRESSURE REGULATOR...
Page 186 FUEL SYSTEM (Programmed Fuel Injection) Install the three collars and starter valve shaft. COLLARS Install the starter valve assembly into the valve hole Tighten the starter valve lock nut t o the specified torque. TORQUE: 2 N - m (0.18 kgf-m, 1.3 Ibf-ft) Compress the thrust spring and install the No.3/4 starter valve arm onto the starter valves.
Page 187 FUEL SYSTEM (Programmed Fuel Injection) Install the No.l/2 starter valve arm t o the starter valves. Install and tighten the starter valve arm mounting screws t o the specified torque. TORQUE: 1 N - m (0.09 kgf-m, 0.7 Ibf-ft) Install the fast idle wax unit link arm and tighten the screw t o the specified torque.
Page 188 FUEL SYSTEM (Programmed Fuel Injection) Disconnect the PAIR air suction hoses f r o m the reed PLUG AIR SUCTION HOSE valve covers and plug the cover. PAIR REED ALVE COVER Start the engine and adjust the idle speed. IDLE SPEED: 1,200 The No 7 starrer Adjust each intake vacuum pressure w i t h the No.1 adjusted, it is the...
Page 189: Output Voltage Inspection
FUEL SYSTEM (Programmed Fuel Injection) Adjust the idle speed if the idle speed differs f r o m the specified speed. IDLE SPEED: 1,200 Remove the vacuum gauge from the vacuum hoses. VACUUM HOSES Connect the each cylinder vacuum hose t o the 5-way joint.
Page 190: Ect Sensor
FUEL SYSTEM (Programmed Fuel Injection) MAP SENSOR REMOVAL/INSTALLA- Remove the air cleaner housing (page 5-64). Remove the screw and MAP sensor f r o m the air cleaner housing. Installation is in the reverse order of removal. IAT SENSOR REMOVAL/ INSTALLATION Remove the air cleaner housing (page 5-64).
Page 191 FUEL SYSTEM (Programmed Fuel Injection) CAM PULSE GENERATOR REMOVAL/ Remove the air cleaner housing (page 5-64). Disconnect the cam pulse generator (Natural) con- nector. Remove the bolt and cam pulse generator f r o m the cylinder head. Install the new O-ring onto the cam pulse generator. Install the cam pulse generator into the cylinder head.
Page 192 FUEL SYSTEM (Proqrarnmed Fuel Iniection) INSPECTION Remove the ECM cover (page 5-87). Disconnect the ECM 26P (Black) and 26P (Light gray) connectors. Check the connector for loose or corroded terminals. Connect the ECM test harness between the ECM and main wire harness. TOOL: ECM test harness, 26P 070MZ-0010100...
Page 193 FUEL SYSTEM (Programmed Fuel Injection) 4. CALCULATE RESULT COMPARISON Compare the measurement to the result of the follow- ing calculation. With the throttle fully open: Measured input voltage X 0.824 The sensor is normal if the measurement output volt- age measured in step 2 is within 10% of Vo. With the throttle fully closed: Measured input voltage X 0.1 The sensor is normal if the throttle closed output volt-...
Page 194 FUEL SYSTEM (Programmed Fuel Injection) Connect the bank angle sensor 3P (Green) connector 60" BANK ANGLE POSITION and place the bank angle sensor horizontal as shown, and ignition switch to "ON". The bank angle sensor is normal if the engine stop relay clicks and power supply is closed.
Page 195 FUEL SYSTEM (Programmed Fuel Injection) Connect the ohmmeter t o the engine stop relay con- nector terminals. CONNECTION: Red/White Connect the 12 V battery t o the following engine stop relay connector terminals. CONNECTION: Red/Orange Black There should be continuity only when the 12 V battery is connected.
Page 196 FUEL SYSTEM (Programmed Fuel Injection) Connect the test harness between the main wire har- TOOL: ECM test harness, 26P ( t w o required) GROUND LINE Check for continuity between the ECM test harness connector B1 terminal and ground, between the B14 terminal and ground, between the A26 terminal and qround, and between the B2 terminal and qround.
Page 197 FUEL SYSTEM (Programmed Fuel Injection) INSPECTION Remove the PAIR solenoid valve. Check that the air should not f l o w (A) t o only when the 12 V battery is connected to the PAIR sole- noid valve terminals. Check the resistance between the terminals of the PAIR SOLENOID VALVE PAIR solenoid valve.
Page 198 FUEL SYSTEM (Programmed Fuel Injection) Check the resistance between the terminals o f the EVAP purge control valve. STANDARD: If the resistance is out of specification, replace the EVAP purge control valve. EVAP PURGE C O N ~ R O L VALVE SENSOR (California type only) REMOVAL...
Page 199 SYSTEM FUEL (Programmed Fuel Injection) Remove the sensor unit. Be careful not to damage the sensor wire. Do not use an impact wrench to remove or install sensor. Install the sensor unit. Tighten the unit to the specified torque. TORQUE: RIGHT STEP GUARD Clamp the sensor wire t o the right step guard.
Page 200 FUEL SYSTEM (Programmed Fuel Injection) Route the 0 2 sensor wire into the frame. Connect the 0 2 sensor (Natural) connector. EGCV A N D AIR INTAKE VALVE I N S PECTlO N Before operating inspection, check that the PGM-FI MIL does not indicate an EGCV failure.
Page 201 FUEL SYSTEM (Programmed Fuel Injection) Check that the EGCV cable pulley is moved t o 180" (pulley index line facing down) at about 8,000 rpm. Also check that the intake flap valve is opened at the same time. If the intake and EGCV position is incorrect, adjust the cables (see below).
Page 202 FUEL SYSTEM (Programmed Fuel Injection) Adjust the EGCV position by loosening the No.1 ADJUSTING NUT adjusting cable lock nut and turning the adjusting nut. Move the cable several times and recheck the index line. Hold the No.1 cable adjusting nut, then tighten the lock nut securely.
Page 203 FUEL SYSTEM (Programmed Fuel Injection) EGCV AND AIR INTAKE VALVE SERVO 6P (NATURAL) CONNECTOR MOTOR REMOVAL Remove the fuel tank (page 5-59). Disconnect the servo motor 6P (Natural) connector. Remove the servo motor mounting bolt and pull out the servo motor from the bracket. Disconnect the intake air valve and EGCV control cables f r o m the servo motor pulley, then remove the servo motor.
Page 204 FUEL SYSTEM (Programmed Fuel Injection) Measure the resistance between the servo motor 6P (Natural) connector terminals. Connection: YellowIRed Standard: 5 k R Connection: Light greenlPink Standard: 0 5 k R If the resistance is out of range, replace the servo motor.
Page 205 FUEL SYSTEM (Programmed Fuel Injection) Connect the servo motor 6P (Natural) connector. EGCV OPERATING INSPECTION Disconnect the EGCV control cables (page 2-15). Turn the EGCV pulley f r o m 0 t o 180" and check for smooth operation. If operation is not smooth, check for carbon deposits i n the EGCV and valve body (page 5-99).
Page 206 FUEL SYSTEM (Programmed Fuel Injection) Remove the bolts, rear exhaust pipe and gasket. REAR EXHAUST PIPE DISASSEMBLY N U , T Turn the EGCV cable guide pulley counterclockwise, and seat its tab with the stopper on the valve cover. Loosen and remove the nut, then remove the valve cable guide pulley.
Page 207 FUEL SYSTEM (Programmed Fuel injection) Remove the EGCV from the valve body. Remove carbon deposits from the EGCV and valve body. Do not use any cleaning solution to clean the EGCV bushings. not apply any lubricant to the EGCV bushings. Check that the EGCV for wear or damage.
Page 208 FUEL SYSTEM (Programmed Fuel Injection) Press the valve cover side EGCV bushing out using REMOVER the following tool. TOOL: Remover, 14 x 16 m m 07Y MF-MCJ0400 BUSHING Press the EGCV bushing in using the special tool. Press the EGCV INSTALLER SHAFT bushing until end is projected...
Page 209 FUEL SYSTEM (Programmed Fuel Injection) Install the EGCV into the EGCV body. Install the metal gasket and EGCV cover. EGCV cover with its down VALVE COVER Install the EGCV cable stay and tighten the four EGCV cover mounting bolts t o the specified torque. TORQUE: 12 N*m (1.2 kgfom, THRUST WASHER B...
Page 210 FUEL SYSTEM (Programmed Fuel Injection) Install the thrust spring onto the EGCV cover. M a k e sure the spring thrust Install the spring retainer assembly onto the thrust boss Install the valve cable guide pulley aligning its cut-out with the the valve shaft tab as shown. Install the valve cable guide pulley flange nut.
Page 211 FUEL SYSTEM (Programmed Fuel Injection) INSTALLATION REAR EXHAUST PIPE VALVE BODY Install the metal gasket and rear exhaust pipe onto the EGCV body. METAL'GASKET Tighten the EGCV mounting bolt to REAR EXHAUST PIPE torque. TORQUE: 14 N-m (1.4 kgf-m, 10 I b f W Install the metal gasket and front exhaust pipe onto FRONT EXHAUST PIPE VALVE BODY...
Page 212 FUEL SYSTEM (Programmed Fuel Injection) Install the exhaust pipe assembly (page 2-16). Connect the EGCV control cables and adjust the con- trol cables (page 5-93). Remove the EGCV cover front upper bolt. Install EGCV cable guide pulley cover and tighten the bolts t o the specified torque.
Page 213 FUEL SYSTEM (Programmed Fuel Injection) Remove the intake valve shaft holder mounting AIR GUIDE B AIR GUIDE A screws and holder. Remove air guides A and B mounting screws. Remove the intake valve flap/shaft assembly, air guides A and B. SCREWS ASSEMBLY CABLE...
Page 214 FUEL SYSTEM (Programmed Fuel Injection) Install air guides A and 8, then tighten the mounting AIR GUIDE A AIR GUIDE screws. Install the intake valve shaft holder plate with its "UPPER" mark facing up. install and tighten the mounting screws. ASSEMBLY SCREWS Open the intake valve flap by hand, connect the intake...
Page 215: System Flow Pattern
COOLING SYSTEM SYSTEM FLOW PATTERN LOWER...
Page 216 6. COOLING SYSTEM SYSTEM FLOW PATTERN THERMOSTAT SERVICE INFORMATION 6- 1 RADIATOR WATER PUMP 6-13 TROUBLESHOOTING RADIATOR RESERVE TANK 6-16 SYSTEM TESTING COOLANT REPLACEMENT FAN CONTROL RELAY 6-1 7 SERVICE INFORM AT1 GENERAL Removing the radiator cap while the engine is hot can cause the coolant t o spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
Page 217 Begin t o open 95°C (203°F) Fully open 8 mm (0.3 in) m i n i m u m Pro Honda HP Coolant o r an equivalent high quality ethylene Recommended antifreeze glycol antifreeze containing corrosion protection inhibitors Standard coolant concentration TORQUE VALUES 12 N * m (1.2 kgf-m, 9 Ibf-ft)
Page 218 COOLING SYSTEM SYSTEM COOLANT (HYDROMETER TEST) Remove the right duct cover (page 2-4). Remove the radiator cap. Test the coolant specific gravity using a hydrometer (see below for "Coolant gravity chart"). For maximum corrosion protection, a solution o f ethylene glycol and distilled water is recommended (page Look for contamination and replace the coolant if nec- essary.
Page 219: Coolant Replacement
M i x only distilled, l o w mineral water with the anti- freeze. RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high quali- ty ethylene glycol antifreeze containing corrosion protection inhibitors RECOMMENDED MIXTURE:...
Page 220 COOLING SYSTEM Remove the lower cowl (page 2-7) Remove the drain bolt o n the water p u m p cover and drain the system coolant. Remove the cylinder drain bolt and drain the coolant f r o m the cylinder. Reinstall the drain bolt with a new sealing washer.
Page 221: Thermostat Removal
COOLING SYSTEM THERMOSTAT THERMOSTAT REMOVAL Drain the coolant (page Remove the throttle body (page 5-67). Remove the bolts and thermostat housing cover. Remove the thermostat f r o m the housing. I NSPECTIO N THE R M STAT SEAL RING Wear insulated gloves and adequate eye protection.
Page 222: Thermostat Housing Removal
COOLING SYSTEM THERMOSTAT HOUSING REMOVAL Disconnect the sensor connector. Remove the bolts and thermostat housing f r o m the cy I i nde r head Disconnect the fast idle wax unit water hose and bypass hoses f r o m the thermostat housing. THERMOSTAT HOUSING INSTALLATION Connect the fast idle wax unit water hose and bypass hoses.
Page 223 Install the thermostat housing cover onto the hous- ing. Install and tighten the housing cover bolts. Fill the system with the recommended coolant and bleed any air (page 6-5). REMOVAL Remove the following: - Lower cowl (page 2-7) - Inner middle cowl (page 2-7) Drain the coolant (page Disconnect the siphon hose and air bleed hose f r o m the radiator.
Page 224 Remove the radiator upper mounting bolt and washer. Slide the radiator to the right, then release the upper grommet from the frame boss. Remove the radiator assembly. Be carefui tor core DISASSEMBLY Remove the three bolts and cooling fan/motor assembly. Remove the nut, cooling fan and distance collar.
Page 225 Remove the flange nuts and fan motor from the fan motor shroud. ASSEMBLY 3 N * m (0.27 kgf-m, 2.0 I b f W Install the fan motor onto the fan motor shroud with FLANGE NUT FAN MOTOR the drain hose facing as shown. Tighten the flange nuts t o the specified torque.
Page 226 COOLING SYSTEM Install the distance collar onto the fan motor shaft. Install the cooling fan onto the fan motor shaft b y aligning the flat surfaces. Apply a locking agent t o the cooling fan nut threads. Install and tighten the nut t o the specified torque. TORQUE: 3 N-m (0.27 kgf-m, 2.0 ibf-ft) Install the cooling fadmotor assembly onto the radiator.
Page 227 and upper mounting bolt, then Install the washer tighten the bolt. tighten Install the radiator lower mounting b o l t h u t , the nut securely. Connect the fan motor (Black) connector. Connect the lower radiator hose and tighten clamp screw securely.
Page 228 SEAL INSPECTION Remove the lower cowl (page 2-7). Inspect the inspection hole for signs of coolant leakage. If there is leakage, the mechanical seal defective and replace the water p u m p as an assembly. REMOVAL Drain the coolant (page 6-41, Disconnect the lower radiator hose, bypass hose and oil cooler water hose f r o m the water p u m p cover.
Page 229 COOLING SYSTEM Disconnect the water n p -t o -water joint hose from the water p u m p body. INSTALLATION water pump-to-water joint I Connect the water p u m p and tighten the clamp screw. 6-14...
Page 230 COOLING SYSTEM Apply engine oil t o a new O-ring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while align- ing the water p u m p shaft groove with the oil p u m p shaft end.
Page 231: Radiator Reserve Tank
COOLING SYSTEM RADIATOR RESERVE TANK REMOVAL Remove the lower cowl (page 2-7). Disconnect the siphon hose and drain coolant f r o m the reserve tank. Remove the radiator reserve tank lower mounting bolt. Remove the reserve tank upper mounting bolt and reserve tank.
Page 232 COOLING SYSTEM Route the overflow hose properly (page 1-29). Install and tighten the reserve tank upper mounting bolt. Install and tighten the lower mounting bolt. Connect the siphon hose to the reserve tank order Install the removed parts in the reverse removal.
Page 233 ENGINE REMOVAL/I NSTALLATIO N 39 N-m (4.0 kgf-m,...
Page 234 7. ENGINE RE OVAL/INSTALLATION SE RVl CE IN FORMATION ENGINE INSTALLATION LOWER BRACKET REMOVAL 7 -2 LOWER BRACKET INSTALLATION 7-12 ENGINE REMOVAL SERVICE INFORMATION GENERAL During engine removal and installation, support the motorcycle using a hoist or equivalent. Support the engine using a jack or other adjustable support t o ease of engine hanger bolts removal. Do not use the filter as a jacking point.
Page 235 ENGINE RE MOVAL/I NSTALLATION LOWER BRACKET REMOVAL 2P (GREEN) CONNECTOR Open and support the front end of the fuel tank (page 3-4). Remove the following: - Muffler/exhaust pipe (page 2-13) - Suspension linkage (page 14-9) - Rear shock absorber (page 14-11) Disconnect the side stand 2P (Green) connector.
Page 236 ENGINE REMQVAL/I NSTALLATION Loosen the lower bracket rear pinch bolt. Remove the lower bracket rear socket bolt and nut, then remove the lower bracket f r o m the engine. Drain the engine oil (page 3-15). Drain the coolant (page 6-41. Remove the following: - Fuel tank (page 5-59) - EGCV and air intake valve servo motor (page 5-95)
Page 237 ENGINE REM QVAL/I NSTALLATIQ N Disconnect the Ignition pulse generator 2P (Red) connector. Disconnect the alternator 3P (White) connector. 3P (WHITE) CONNECTOR Disconnect the air bleed hose and upper radiator hose f r o m the thermostat housing cover. Remove the thermostat housing cover and thermo- stat (page 6-6).
Page 238 ENGINE REMOVAL/INSTALLATIO N Remove the starter motor mounting bolt and starter motor ground cable. Remove the terminal nut and starter motor cable. Remove the bolts and clutch cable guide, then dis- connect the clutch cable from the clutch lifter lever. Remove the radiator lower mounting bracket bolthut.
Page 239 GIN E RE MOVAL/I NSTAkLATlO N Support the engine using a jack or other adjustable support t o ease engine hanger bolts removal. Remove left side o f the front (10 mm) and middle (12 Remove the right side the front (10 mm) and mid- dle (12 mm) engine hanger bolts and distance collars.
Page 240 Note the direction of the hanger bolts. Use a floor jack or other adjustable support t o care- fully maneuver the engine into place. Install the engine into the frame. Be careful damage the cam chain tensioner Install the rear engine hanger socket bolt and nut. lifter Install the right side of the front (10 m m ) and middle (12 mm) engine hanger bolts w i t h the distance collars.
Page 241 ENGINE RE M OVAL/I NSTALLATION Hold the rear engine hanger socket bolt, then tighten the nut t o the specified torque. TORQUE: 54 N-m (5.5 kgf-m, 40 Ibf-ft) Tighten the rear engine hanger pinch bolt t o the spec- ified torque. TORQUE: 26 N-m (2.7 kgf-m, 20 Ibfoft) Tighten the left side o f the front (10 mm) and middle (12 mm) engine hanger bolt t o the specified torque.
Page 242 ENGINE REMOVAL/INSTALLATION Connect the lower radiator hose t o the radiator hose three-way joint and tighten the hose band screw. Install the radiator reserve tank and mounting bolts, then tighten the bolts. Connect the siphon hose t o the reserve tank. Install the radiator lower mounting bolthut, then tighten the nut securely.
Page 243 install a new O-ring into the thermostat housing groove. Install the thermostat housing to the cylinder head. Install and tighten the thermostat housing mounting bolts. Connect the ECT sensor connector. Install the thermostat and thermostat housing cover THERMOSTAT RADIATOR H O S E (page 6-71.
Page 244 Connect the ignition pulse generator 2P (Red) con- nect o r. Connect the speed sensor 3P (Natural) connector and engine sub-harness 2P (Blue) connector - Ignition coil/spark plug sub-harness - PAIR control solenoid valve assembly (page 5-88) - Lower bracket (page 7-12) Throttle body (page 5-71) - EGCV and air intake valve servo motor (page 5-96) - Fuel tank (page 5-61)
Page 245 ENGINE REMOVALANSTALLATION P I N CH 'Bo L T S 26 N - m (2.7 kgf-m, 20 I b f W Install the lower bracket onto the engine. Temporarily install the front and rear 10 mm bolts and nuts. Temporarily tighten the 10 mm nuts. Install the swingarm (page 14-23).
Page 246 ENGINE REMOVAL/INSTALLATION Tighten the front mm socket bolt and nut t o the specified torque. TORQUE: 42 N * m (4.3 kgf-m, 31 Ibf-ft) SOC K ET BOLT/NUT Tighten the front pinch bolt t o the specified torque. TORQUE: 26 N - m (2.7 kgf-m, 20 Ibf-ft) Hold the rear mm socket bolt an,d tighten the nut t o the specified torque.
Page 247 ENGINE REMOVAL/ INSTALLATION Install the side stand bracket assembly, tighten the SIDE STAND BRACKET new bolts t o the specified torque. TORQUE: 33 Ibf-it) (4.5 kgf-m, Route the side stand wire properly, connect the side stand switch 2P (Green) connector. Install the following: - Rear shock absorber (page 14-13) - Suspension linkage (page 14-11)
Page 248 CYLINDER HEAD/VALVES...
Page 249 8. CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT SERVICE INFORMATION 8-17 VALVE SEAT INSPECTION/ TROUBLESHOOTING 8-18 CYLINDER COMPRESSION TEST CYLINDER HEAD ASSEMBLY 8-20 CYLINDER HEAD COVER REMOVAL CYLINDER HEAD INSTALLATION 8-22 CYLINDER HEAD COVER CAMS HAFT IN STALLATI 0 N DISASSEMBLY 8-24 CYLINDER HEAD COVER ASSEMBLY 8-29 CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL...
Page 250: Cylinder Head Sealing Bolt 1
CYLINDER HEADNALVES SPECIFICATIONS Unit: m m (in) ITEM STANDARD Cylinder compression 1,196 kPa (12.2 kgf/cm2, 174 psi) a t 350 rpm Valve clearance 0.16 0.03 (0.006 0.001) 0.27 0.03 (0.011 0.001) 36.74 - 36.98 (1.446 1.456) 36.72 (1.446) Cam shaft Cam lobe height 36.43 (1.434) 0.04 (0.002)
Page 251 CYLINDER HEADNALVES TOOLS or equivalent commercially available i n U.S.A. 07RMJ-MY50100 Compression gauge attachment 07757--0010000 Valve spring compressor 07959-KM30101 Valve spring compressor attachment not available in U.S.A. Tappet hole protector or refer t o page 8-13 for alternative tool (U.S.A. only) M D-M L O O 1 0 1 Valve guide driver, 4.5 mm or 07H MH-ML001 OA (U S.A.
Page 252 CYLINDER HEADNALVES CYLINDER COMPRESSION TEST 3P (BLACK) CONNECTOR Warm up the engine to normal operating tempera- ture. Stop the engine and remove all the direct ignition Open and support the front end of the fuel tank (page Disconnect the fuel pumpireserve sensor 3P (Black) connector.
Page 253 CY LlNDER HEAD/VALVES CYLINDER HEAD CQVER REMOVAL Remove the following: - Lower cowl (page 2-71 - Air cleaner housing (page 5-64) Remove the heat guard rubber. Disconnect the fan motor 2P (Black) connector. Disconnect the cam pulse generator 2P (natural) con- nector (page 5-83).
Page 254 Remove the bolts and PAIR reed valve covers f r o m the cylinder head. Remove the cylinder head cover bolts and washers. Remove the cylinder head cover rearward. PACKING Remove the cylinder head cover (page 8-5). Remove the cylinder head cover packing.
Page 255 Remove the bolts and breather separator and gasket. BOLTS Check the PAIR check valves for wear or damage, replace if necessary. Remove the cylinder head cover (page 8-5). Avoid damaging the c a m pulse generator while removing the camshafts, remove the bolt and cam pulse generator from the cylinder head.
Page 256 CY LlNDER HEAD/VALVES "T" Turn the crankshaft clockwise, align the mark on the ignition pulse generator rotor w i t h the index mark on the right crankcase cover. Make sure the No.1 piston at TDC (Top Dead Center) on the compression stroke. Remove the cam chain tensioner lifter sealing bolt CAM CHAIN TENSIONER LIFTER BOLT...
Page 257 CYLINDER HEAD/VALVES If you plan t o replace the camshaft and/or cam sprock- et, loosen the cam sprocket bolts as follows: cam sprocket from the camshaft except when replacing the camshaft and/or cam sprocket - Remove the cam sprocket bolts f r o m intake and Be careful not t o exhaust camshafts.
Page 258 Remove the valve lifters and shims. Be carefui not t o damage the valve lifter bore. Shims may stick t o the inside the valve lifters. Do not allow the shims to fall into the crankcase. Mark all valve lifters and shims t o ensure correct reassembly in their original locations.
Page 259 CAMSHAFT OIL CLEARANCE not rotate the camshaft during Wipe any oil f r o m the journals of the camshaft, cylin- der head and camshaft holders. strip of plastigauge lengthwise on t o p o f each camshaft journal. Install the camshaft holders and tighten the bolts i n a crisscross pattern i n t w o three steps.
Page 260: Cylinder Head Removal
CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Remove the engine f r o m the frame (page 7-31. Remove the camshaft (page 8-7). Remove the cylinder drain bolt and sealing washer. Drain coolant f r o m cylinder head and cylinder block. Reinstall a n e w sealing washer and drain bolt.
Page 261: Cylinder Head Disassembly
CYLINDER HEAD/VALVES Remove the right crankcase cover and ignition pulse generator rotor (page 17-6). Remove the socket bolt, washer, cam chain guide and collar. Remove the socket bolt, cam chain tensioner and washer. Remove the cam chain and timing sprocket f r o m the crankshaft.
Page 262: Cylinder Head
CYLINDER HEAD/VALVES Remove the valve spring cotters using the special VALVE SPRING COMPRESSOR tools as shown. TOOLS: Valve spring compressor 07757-0010000 Valve spring compressor attachment prevent loss of tension, do not compress the valve springs more than necessary to remove the cotters. Remove the following: Mark parts dur-...
Page 263: Valve Spring
CYLINDER HEAD/VALVES CAM CHAIN TENSIONER/CAM CHAIN CAM CHAIN TENSIONER GUIDE VALVE SPRING Measure the free length the inner and outer valve springs. SERVICE LIMITS: Outer: 36.1 m m (1.42 in) Exhaust: 37.6 m m (1.48 in) Replace the springs they are shorter than the ser- vice limits.
Page 264 CYLINDER HEAD/VALVES Inspect each valve for bends, burns or abnormal stem wear. Check valve movement in the guide, measure and record each valve stem O.D. SERVICE LIMITS: IN: 4.465 mm (0.1758 EX: 4.455 mm (0.1754 Ream the guides t o remove any carbon deposits before checking clearances.
Page 265: Valve Guide Replacement
CYLINDER HEADNALVES VALVE GUIDE REPLACEMENT about 1 hour. Heat the cylinder head t o 100 150°C (212 - with a hot plate or oven. To avoid burns, wear heavy gloves when handling the heated cylinder head. Do not use a torch to heat the cylinder head; m a y cause warpage.
Page 266: Valve Seat Inspection
CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/ Clean the intake and exhaust valves thoroughly t o remove carbon deposits. Apply a light coating o f Prussian Blue t o the valve seats. Lap the valves and seats using a rubber hose or other hand-lapping tool.
Page 267 CYLINDER HEAD/VALVES Use a 32-degree cutter to remove the t o p 1-/4 of the existing valve seat material. TOOLS: Flat cutter, 30 m m (32" 07780-0012200 Flat cutter, 28 m m (32" Cutter holder, 4.5 m m 07781-0010600 U.S.A. equivalent commercially available in Use a 60-degree cutter to remove the bottom 114 of the old seat.
Page 268: Cylinder Head Assembly
CY LlNDER HEADNALVES If the contact area is t o o low on the valve, the seat must be raised using a 60-degree inner cutter. CONTACT TOO LOW OLD SEAT Refinish the seat t o specifications, using a 45-degree finish cutter. After cutting the seat, apply lapping compound t o the valve face, and lap the valve using light pressure.
Page 269 CYLINDER HEAQ/VALVES Clean the cylinder head assembly with solvent and b l o w out all oil passages with compressed air. Install the tappet hole protector into the valve lifter bore. TOOL: Tappet hole protector (Not available in U.S.A.) or refer to page 8-13 tool for alternative...
Page 270 Install the valve cotters using the special tool as VALVE SPRING COMPRESSOR shown. prevent loss tension, do not compress the valve spring more than necessary. TOOLS: Valve spring compressor 07757-001 0000 Valve spring compressor attachment plastic hammers Tap the valve stems gently with t w o Support the cyhn- der head above as shown t o seat the cotters firmly.
Page 271 CYLINDER HEAB/VALVES Apply a locking agent to the cam chain guide socket bolt threads. Install the collar, cam chain guide, washer and socket bolt. Apply a locking agent t o the cam chain tensioner CAM CHAIN socket bolt threads. Install the washer, cam chain tensioner and socket bolt.
Page 272 CYLINDER HEAD/VALVES Install the cylinder head. If using a new bolt, remove the anti-rust additive f r o m Apply molybdenum disulfide oil t o the threads and seating surface of the 9 mm bolts/washers and install them. Apply oil t o the 8 mm bolt threads and seating sur- face.
Page 273 CYLINDER HEADNALVES If the cam sprockets are removed, install the cam NO.l CYLINDER CAM LOBES sprockets onto the camshafts. Install the intake cam sprocket w i t h the timing mark (IN) facing outward and the No.1 cam lobes facing up and out as shown.
Page 274 CYLINDER HEAD/VALVES Apply molybdenum disulfide oil t o the camshaft jour- nals the cylinder head and camshaft holder. Install the cam chain over the cam sprockets and then install the intake and exhaust camshafts. Install each camshaft to the correct location with the identification marks.
Page 275: Cam Pulse Generator Rotor Bolt 2
CYLINDER HEADNALVES First gradually tighten the four bolts (No.5 - No.6 - BOLTS camshaft holders. Gradually tighten the other camshaft holder bolts until the camshaft holders lightly contact the cylinder head surface. Tightening the camshaft holder bolts on only one-side might cause a camshaft holder to break.
Page 276 CYLINDER HEAD/VALVES Remove the cam chain tensioner holder f r o m the cam CAM CHAIN TENSIONER HOLDER chain tensioner lifter. Install a new sealing washer and tighten the sealing CAM CHAIN TENSIONER LIFTER BOLT bolt. Recheck the valve timing. Apply oil t o the new O-ring, and install it onto the cam pulse generator.
Page 277 CYLINDER HEAD/VALVES CYLINDER HEAD COVER ASSEMBLY BREATH E R S E PARATO R Install the new gasket and crankcase breather separa- t o r t o the cylinder head cover. Apply a locking agent t o the crankcase breather sepa- BREATHER S E PA RAT0 R rator mounting bolt threads.
Page 278: Cylinder Head Cover Installation
CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION Install the cylinder head packing into the groove of the cylinder head cover. Apply sealant to the cylinder head semi-circular cut- outs as shown. Install the cylinder head cover onto the cylinder head. Install the washers w i t h their "UP mark facing up. MARK 8-30...
Page 279 CYLINDER HEAD/VALVES Install and tighten the cylinder head cover special bolts t o the specified torque. TORQUE: 10 N*m (1.0 kgf-m, 7 Ibf-ft) Install the PAIR reed valve covers onto the cylinder head cover. Apply a locking agent t o the PAIR reed valve cover mounting bolt threads.
Page 280 Connect the fan motor (Black) c Install the heat guard rubber onto the cylinder head cover. Install the air cleaner housing (page 5-65). CAM CHAIN TENSIONER LIFTER CAM CHAIN TENSIONER LIFTER BOLT REMOVAL Remove the fuel tank (page 5-59). Remove the throttle body (page 5-67). Remove the cam chain tensioner sealing bolt and sealing washer.
Page 281 CYLINDER HEAD/VALVES Remove the bolts and cam chain tensioner lifter. GASKET Remove the gasket. TENSION ER LIFT ER BOLTS INSTALLATION GASKET Install the cam chain tensioner lifter into the cylinder GASKET head. Install and tighten the mounting bolts. TE NSlO N E R LIFTER BOLTS Remove the cam chain tensioner holder.
Page 282 CYLINDER HEAD/VALVES Install a new sealing washer and tighten the sealing CAM CHAIN TENSIONER LIFTER BOLT bolt securely. Install the throttle body (page 5-71). Install the fuel tank (page 5-61).
Page 283 12 N-m (1 12 N-m (1.2'kgf-m, 9 Ibf-ft)
Page 284: Clutch Center Lock Nut
9. CLUTCH/GEARSHIFT LIN SERVICE INFORMATION CLUTCH TROUBLESHOOTING GEARSHIFT LINKAGE 9-12 RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER REMOVAL INSTALLATION 9-17 S E RVI CE I N FORM ATI GENERAL This section covers service of the clutch, gearshift linkage, shift d r u m and shift forks. All service can be done w i t h the engine installed in the frame.
Page 285 TOOLS Clutch center holder 07724-0050002 or equivalent commercially available in U.S.A. Driver 07749-0010000 Attachment, 42 x 47 m m 07746-0010300 Pilot, 35 mm 07746-0040800 TROUBLESHOOTING Transmission jumps out of gear Clutch lever too hard t o pull in Worn shift d r u m stopper arm Damaged clutch lifter mechanism Weak or broken shift arm return spring Faulty clutch lifter bearing...
Page 286 RIGHT CRANKCASE COVER REMOVAL 2P (RED) CONNECTOR Drain the engine (page 3-15). Remove the lower cowl (page 2-7). Open and support the front end o f the fuel tank (page Disconnect the ignition pulse generator 2P (Red con- nector. Remove the bolts and clutch cable bracket, then dis- connect the clutch cable end f r o m the clutch lifter lever.
Page 287 CLUTCH LIFTER LEVER Remove the clutch lifter lever, return spring and wash- er from the right crankcase cover. Check the lifter lever spindle for wear or damage. Check the return spring for fatigue or damage. WAS H ER LIFT E R LEVER Check the lifter lever oil seal and needle bearings for wear or damage.
Page 288 Unstake the clutch center lock nut. Hold the clutch center w i t h the clutch center holder, then remove the lock nut. TOOL: Clutch center holder 07724-0050002 (Equivalent commer- cially available in U.S.A.) Discard the lock nut. Remove the lock washer, thrust washer and clutch center.
Page 289 Align the primary drive gear and sub-gear teeth w i t h PRIMARY DRIVE GEARISUB-GEAR a screwdriver as shown. Pull out the clutch outer. CLUTCH OUTER Remove the oil p u m p driven sprocket bolt/washer. Remove the oil p u m p drive/driven sprocket and drive chain as an assembly.
Page 290 Clutch center Check the grooves of the clutch center for damage or wear caused b y the clutch plates. Replace if necessary. Clutch lifter piece Check the clutch lifter piece for damage abnormal wear. Clutch disc Replace the clutch discs if they show signs of scoring or discoloration.
Page 291 Judder spring/spring seat JUDDER SPRING Check the judder spring and spring seat for deforma- tion, warpage or damage; replace as necessary. damaged or warped spring seat will cause the A damaged judder spring also causes the weak con- tact between t h e discs and plates or uneven SPRIN G S E AT Clutch outer/clutch outer guide Check the slots of the clutch outer for damage o r wear...
Page 292 CLUTCH OUTER NEEDLE BEARING REPLACEMENT Press the needle bearing out of the clutch outer using the special tools. TOOLS: Driver 07749-0010000 Attachment, 42 47 m m 07746-0010300 Pilot, 35 mm 07746-0040800 Press a new needle bearing into the clutch outer Press rhe needle that the casing of the needle bearing is flush with the clutch outer surface as shown.
Page 293 install the oil Install the clutch outer guide, and then install the pump driveidriven sprocket and drive chain as an sprocket with "OUT" mark fac- Apply a locking agent t o the threads of the oil p u m p driven sprocket bolt.
Page 294 Install the clutch center. Install the thrust washer. Install the lock washer with its "OUT" mark facing out. Apply oil t o the new lock nut threads, then install it. Hold the clutch center with the clutch center holder, then tighten the lock nut t o the specified torque. TOOL: Clutch center holder 07724-0050002...
Page 295 Install the green outer clutch disc i n the shallow slot on the clutch outer. Install the lifter bearing into the pressure plate. Install the clutch lifter piece into the lifter bearing. Install the pressure plate. Install the clutch springs and spring bolts. Tighten the bolts in a crisscross pattern in t w o t o three steps, then tighten the bolts to the specified torque.
Page 296: Gearshift Linkage Inspection
Pull the gearshift spindle assembly and thrust washer out of the crankcase. Remove the following: Stopper arm socket bolt - Stopperarm - Return spring - Washer - Dowel pins Socket bolt Gearshift cam GEARSHIFT LINKAGE INSPECTION Check the gearshift spindle for wear, damage or bends.
Page 297 Remove the shift fork shaft and shift forks. SHIFT FORK SHAFT Remove the shift d r u m bearing shift drum. DRUM SHIFT DRUM/SHIFT FORK INSPECTION Check the shift fork and fork shaft for wear or damage. Measure the I.D. of the shift fork. SERVICE LIMIT: 12.03 mm (0.474 in) Measure the shift fork claw thickness.
Page 298 Turn the outer race of the shift drum bearing with your finger. The bearing should turn smoothly and freely without excessive play. If necessary replace the bearing. SHIFT DRUM H I FT FORK I NSTALLATIO M IDENTIFICATION MARKS The shift forks have location marks. "...
Page 299 Apply a locking agent to the threads of the set plate bolts. Install and set plates and bolts, tighten the bolts t o the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) Install the gearshift linkage (see following steps). GEARSHIFT LINKAGE INSTALLATION Install the following: Washer...
Page 300 Install the thrust washer and gearshift spindle assem- bly into the crankcase while aligning the spring ends with the crankcase stopper pin. Install the gearshift pedal link aligning its slit with the punch mark on the gearshift spindle. Install and tighten the pinch bolt to the specified torque.
Page 301 Install the t w o dowel pins. Install the right crankcase cover while turning the lifter arm clockwise t o engage the lifter arm groove w i t h the lifter piece flange. Install the right crankcase cover bolts. Tighten the bolts crisscross pattern i n t w o t o three steps securely.
Page 302 103 N* 16 N-m...
Page 303: Alternator Wire Clamp Bolt
10. ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL SERVICE INFORMATION 10-1 10-3 STARTERCLUTCH TROUBLESHOOTING 10-1 10-5 ALTERNATOR COVER REMOVAL 10-2 FLYWHEEL INSTALLATION 10-7 STATOR 10-2 ALTERNATOR COVER INSTALLATION 10-8 SERVICE INFORMATION GENERAL This section covers service of the alternator, flywheel and starter clutch. in the frame.
Page 304 3P (WHITE) CONNECTOR Remove the ECM cover (page 5-87). Remove the lower cowl (page 2-71. Disconnect the alternator 3P (White) connector. The alternator cover (stator) is magnetically attached to the care- ful during removal Remove the alternator cover SH bolts and alternator cover.
Page 305: Flywheel Removal
I NSTALLAT f Install the stator into the alternator cover. Apply sealant t o the wire grommet, then install the wire grommet into the alternator groove securely. Install and tighten the stator mounting socket bolts t o the specified torque. TORQUE: 12 N-m (1.2 kgf-m,...
Page 306 Hold the flywheel using the flywheel holder, then remove the flywheel bolt. TOOL: Flywheel holder 07725-0040000 (Equivalent commer- cially available in U.S.A.) Remove the washer. Remove the flywheel using the special tool. TOOL: Rotor puller 07733-0020001 or 07933-3950000 (U.S.A. only) Remove the woodruff key.
Page 307 STARTERCLUTCH clockwise. Hold the flywheel with a flywheel holder, and remove TORX BOLTS the starter clutch mounting torx bolts. TOOL: Flywheel holder 07725-0040000 (Equivalent commercially available in U S A . ) Remove the starter one-way clutch assembly. Check the starter driven gear for abnormal wear or damage.
Page 308 ASSEMBLY GEAR 16 N-m (1.6 kgf-in, 12 Ibf-ft) Apply oil t o the starter one-way clutch. Install the one-way clutch into the clutch outer w i t h the flange side facing out. CLUTCH OUTER Install the starter one-way clutch assembly onto the ONE-WAY CLUTCH ASSEMBLY flywheel.
Page 309: Flywheel Installation
Apply a locking agent to the starter clutch outer mounting bolt threads. Hold the flywheel with a flywheel holder, and tighten the starter clutch mounting torx bolts. TOOL: Flywheel holder 07725-0040000 (Equivalent commer- cially available in Install the starter driven gear into the one-way clutch. FLYWHEEL INSTALLATION Clean any oil f r o m the crankshaft taper.
Page 310: Alternator Cover Installation
Hold the flywheel using the flywheel holder, then tighten the bolt t o the specified torque. TOOL: Flywheel holder 07725-0040000 (Equivalent commer- cially available in TORQUE: 103 N-m (10.5 kgf-m, 76 Ibf*ft) Apply molybdenum disulfide oil to the starter idle gear shaft.
Page 311 The aiternator Install the alternator cover. cover (stator) is Install and tighten the SH bolts t o the specified attached to the torque. TORQUE: 12 N*m (1.2 kgf-m, Connect the alternator 3P (White) connector. 3P (WHITE) CONNECTOR install the lower cowl (page 2-7). Install the ECM cover (page 5-87).
Page 312 20 N-m (2.0 kgf-m, 150” 39 N*m (4.0 kgfmm, 29 18 Ibf*ft)
Page 313 SERVICE INFORMATION 11-1 11-4 TROUBLESHOOTING 11-2 CRANKCASE COMBINATION 11-12 CRANKCASE SEPARATION 11-3 SERVICE INFORMATION GENERAL NOTICE The main journal 9-mm bolts tightening method uses the Plastic Region Tightening Method (page 11-12). Always use a new main journal 9-mm bolts (page 11-12). The main journal 9-mm bolts is pre-coated with an oil additive for axial tension stability.
Page 314: Mainshaft Bearing Set Plate Bolt 3
SPECIFICATIONS Unit: m m (in) ITEM STANDARD SERVICE LIMIT Cylinder 75.15 (2.959) 75.000 75.015 (2.9528 2.9533) 0.10 (0.004) Taper 0.10 (0.004) 0.05 (0.002) Piston, piston Piston mark direction "0" mark facing toward the intake side rings Piston O.D. 74.960 - 74.980 (2.9512 - 2.9520) 74.895 (2.949) Piston O.D.
Page 315 CRANKCASE S EPARATI Refer to Service Information (page 11-1) for removal of necessary parts before separating the crankcase. Remove the mainshaft bearing set plate bolts and plate. Remove the upper crankcase 8 mm washers and m m bolt. Remove the lower crankcase 6 mm bolts (ten), 8 mm BOLTS...
Page 316: Piston Removal
BEARING CAP they can be NOTICE replaced not interchange the bearing inserts. They must be installed in their original locations or the correct bear- ing oil clearance may not be obtained, resulting in engine damage. Remove the nuts and connecting rod bearing cap. Remove the pistonkonnecting rod assembly from the top of the cylinder.
Page 317 Temporarily install the piston rings to their proper position with the mark facing up. Measure the piston ring-to-ring groove clearance with the rings pushed into the grooves. SERVICE LIMITS: Top: 0.08 mm (0.003 in) Second: 0.06 mm (0.002 in) Inspect the piston for wear or damage. Insert the piston ring squarely into the bottom of the Push the rings cylinder and measure the ring end gap.
Page 318: Cylinder Inspection
Measure the piston pin bore. SERVICE LIMIT: 17.03 mm (0.670 in) Measure the O.D. o f the piston pin. SERVICE LIMIT: 16.98 mm (0.669 in) Calculate the piston-to-piston pin clearance. STANDARD: 0.002 0.014 mm (0.0001 0.0006 in) CYLINDER INSPECTION Inspect the t o p o f the cylinder for warpage. SERVICE LIMIT: 0.05 mm (0.002 in) Inspect the cylinder bore for wear o r damage.
Page 319 Calculate the taper and out-of-round at three levels i n axes, Take the m a x i m u m reading t o determine them. SERVICE LIMITS: Taper: 0.10 rnm (0.004 in) Out-of-round: 0.10 rnm (0.004 in) The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded.
Page 320 CRAN KCAS E/PISTON/CY LlN DER Install the bearing caps and connecting rods on a cor- rect crankpins, and tighten the cap nuts to the speci- fied torque. (3.6 Remove the connecting rod caps and measure the compressed plastigauge on each crankpin. SERVICE LIMIT: 0.062 (0.0024...
Page 321 Cross-reference the crankpin and rod codes t o deter- IDENTIFICATION COLOR mine the replacement bearing color. BEARING THICKNESS: A (Blue): Thick (Black): C [Brown): D (Green) E (Yellow) Thin CONNECTING ROD I.D. CODE 39.000 - 39.006 39.006 - 39.012 39.012 - 39.018 (1.5354 1.5357) (1.5357...
Page 322: Piston Installation
PISTON ASSEMBLY Clean the piston ring grooves thoroughly and install SECOND RING TOP RING the piston rings. Apply oil to the piston rings. Avoid piston and piston ring damage during instal- lation. Install the piston rings with the marking (R: top ring, RN: second ring) facing up.
Page 323 Apply oil to the cylinder sleeves and piston rings. Install the piston/connecting rod assembly into the cylinder using a commercially available piston ring compressor tool. When reusing the connecting rods, they must be installed in their original locations. While installing the piston, being careful not to damage the top surface of the cylinder, especially around the cylinder bore.
Page 324 CRANKCASE COMBINATl ON Apply a light, but thorough coating of liquid sealantto the crankcase mating surface except to the main bear- ing journal bolt (lower crankcase bolt, 9 area and the oil passage area as shown. Install the three dowel pins. COLLARS OIL ORIFICES Install oil orifices aligning their cut-out...
Page 325 CRAN KCASE/PISTON/CY Ll NDER Tighten the 6 mm bolts securely. Tighten the 10 mm bolt, and then 8 mm bolts to the 6 mm BOLTS specified torque. TORQUE: 25 N*m (2.5 kgf*m, 18 Ibf.ft) 8 mm bolt: 8 mm BOLTS The sealing wash- ers and 6 mm...
Page 326 Apply a locking agent t o the mainshaft bearing set plate bolt threads. Install the mainshaft bearing set plate with its "OUT- SIDE'' mark facing out. Tighten the mounting bolts to the specified torque. TORQUE: 12 Nom (1.2 kgforn, 9 Ibfrft) Install the removed parts i n the reverse order of removal.
Page 327 (1.2...
Page 328 12-1 CRANKSHAFT 12-3 SERVICE INFORMATION 12-2 TRANSMISSION TROUBLESHOOTING 12-9 SERVICE INFORMATION GENERAL The crankcase must be separated t o service the crankshaft and transmission. Refer t o section 11 for crankcase separa- ti on/assem bly. Be careful not t o damage the crankshaft main journal and journal bearing while removing or installing the crankshaft. Mark and store the disassembled parts t o ensure that they are installed in their original locations.
Page 329 TORQUE VALUES Connecting rod bearing cap nut Apply oil to the threads and seating surface 35 N * m (3.6 kgf-m, 26 Ibf-ft) Crankcase 9 m m bolt (main journal bolt) See page 12-7 TOOLS Inner driver, 40 m m I.D. 07746-0030100 Attachment, 25 m m 07746-0030200...
Page 330 CRANKSHAFT REMOVAL Separate the crankcase halves (page 11-3). Remove the connecting rod bearing cap nuts and bearing caps. Remove the crankshaft. Before removai pos tion a// the pistons to prevent damag- ing the crankpin with the connect- ing rod bolt threads Remove the main journal bearings f r o m both the...
Page 331 PRIMARY DRWE SUB-GEAR REMOVAL FRICTION SPRING Remove the special snap ring and friction spring. Remove the primary drive sub-gear and springs. PRIMARY DRIVE SUB-GEAR INSTALLATION B-GEAR Install the springs into the primary drive gear as shown. Install the primary drive sub-gear onto the primary drive gear, aligning the holes between the gear.
Page 332 Install the friction spring and new special snap ring. You must use a n e w special snap ring. Using a snap ring other than specified or reusing the original snap ring can cause severe engine damage. FRICTION SPRING install a new special snap ring with its large tab fac- ing t o the right and the chamfered side facing Make sure the new special snap ring end gap is aligned with the right angle of the crankshaft cut-...
Page 333 If the special tool is not available, prepare a suitable collar, washer and 10 mm flange bolt (example; fly- wheel bolt) for the bearing installation. Assemble the above items, and screw the bolt gradu- ally, until the new needle bearing is properly installed. I NSPECTIQ N CRANKSHAFT RUNOUT Support the crankshaft o n both ends.
Page 334 Assemble the crankcase halves. PLASTIC REGION TLGHTENING METHOD: Install the removed main journal 9 m m bolts. Tighten the main journal 9 m m bolts as follow: Tighten the 9 m m bolts in numerical order i n the illus- tration t o the following torque.
Page 335 The numbers 2 or31 on the numbers from the crank weight. crank weiaht are Cross reference the case and journal codes t o deter- mine the replacement bearing color codes. right CODE BEARING THICKNESS: IDENTIFICATION COLOR B (Brown): Thick C (Green): D (Yellow): E (Pink): (Red):...
Page 336 Install the main journal bearings into the upper and The bearing tabs should be abgned lower crankcase. with the grooves in the case. Apply 'molybdenum disulfide oil t o the upper and lower main journal bearings. Install the crankshaft. Before instaaiia- the pistons at TDC (Top Dead Center) to prevent...
Page 337 Remove the dowel pins and countershaft bearing set ring. Disassemble the mainshaft and countershaft. Check the gear dogs, dog holes and teeth for abnor- mal wear or lack of lubrication. Measure the I.D. of each gear. SERVICE LIMITS: M5, M6: 31.04 mm 1.222 in) 1.025 in)
Page 338 Measure the O.D. of the mainshaft and countershaft. CLUTCH OUTER GUIDE SERVICE LIMITS: 27.957 (1.1007 in) Clutch outer guide: 24.96 (0.983 in) 29.96 (1.180 in) BEARING REPLACEMENT Do not try to remove the coun- tershaft bearing Turn the outer race of each bearing with your finger. from the shaft if The bearings should turn smoothly and quietly.
Page 339 ASSEMBLY M2 GEAR (15T) M6 GEAR (21T) M5 GEAR (21T) COUNTERSHAFT 12-12...
Page 340 Assemble the transmission gear and shafts. Coat each gear with clean engine oil and check for smooth movement. Apply molybdenum disulfide oil to the shift fork grooves in the M3/4, C5 and C6 gear. INSTALLATION Install the dowel pins in the upper crankcase holes. Install the countershaft bearing set ring into the upper crankcase groove.
Page 341 Install the mainshaft and countershaft b y aligning the countershaft bearing groove w i t h the set ring on t h e crankcase, and aligning the bearing cap holes w i t h the dowel pins. Also align the countershaft bearing stopper pin w i t h the groove in the crankcase.
Page 342 FRONT WHEEL/SUSPENSlQN/STEEWlNG 103 N*m (10.5 kgf-m, 76 30 N-m 78 N*n...
Page 343 Spring free length 255.8 (10.07) 250.8 (9.87) With the tapered end facing up Spring direction 0.20 (0.008) Fork pipe runout Pro Honda Suspension Fluid SS-8 Recommended fork fluid Fluid level 73 (2.9) Fluid capacity 2.5 om3 (17.3 0.08 US 18.1 0.09 Imp oz)
Page 344 TORQUE VALUES Handlebar pinch bolt 26 N-m (2.7 kgfom, 20 ibfmft) Handlebar weight mounting screw ALOC bolt Front master cylinder holder bolt 12 N -m (1.2 kgf-m, 9 I b f W Clutch lever bracket pinch bolt 12 N*m (1.2 kgf-m, 9 I bf-ft) 103 N -m (10.5 kgf-m, 76 Ibf-ft) Steering stem nut See page 13-33...
Page 345 FRONT WHEEL/SUSPENSlON/STEERlNG TROUBLESHOOTING Wheel turns hard Hard steering Faulty or damaged steering head bearings Faulty wheel bearing Bent front axle Insufficient tire pressure Steering head bearing adjustment nut too tight Brake drag Soft suspension Steers to one side or does not track straight Unevenly adjusted right and left fork legs Insufficient fluid in fork Weak fork springs...
Page 346 FRONT WHEEL/SUSPENSlON/STEERlNG HANDLEBARS REMOVAL Remove the screw and right handlebar weight. Disconnect the front brake switch wires connectors MASTER CYLINDER from the switch. Remove the master cylinder holder bolts, holder and Keep the brake master cylinder assembly. master cylinder upright Remove the right handlebar switch housing screws.
Page 347 FRONT WHEEL/SUSPENSlON/STEERlNG Remove the screws and left handlebar switch housing SWITCH HOUSING Remove the screw and handlebar weight. Remove the handle grip from the handlebar. Loosen the clutch lever bracket pinch bolt Loosen the top bridge pinch bolts and handlebar pinch bolt.
Page 348 FRONT WHEEL/SUSPENSION/STEERlNG INSTALLATION Apply grease to the sliding surface of the throttle pipe. Install the clutch lever bracket t o the left handlebar, and also the throttle pipe to the right handlebar. Install the handlebars onto the fork sliders. Install the top bridge while aligning its holes with the TOP BRIDGE handlebar stopper pins.
Page 349 FRONT WHEEL/SUSPENSION/STEERlNG HANDLEBAR WEIGHT REPLACEMENT RUBBER RETAINER RING Remove the grip rubber f r o m the handlebar. CUSHION Straighten the weight retainer tab b y the screwdriver or punch. Temporarily install the handlebar weight and screw, Apply iubncant through rhe then remove the inner weight by turning the handle- bar weight.
Page 350 FRONT WHEEL/SUSPENSION/STEERl" Tighten the clutch lever bracket pinch bolt by aligning the punch marks on the left handlebar and clutch lever bracket. TORQUE: 12 N-rn (1.2 Install the left handlebar switch housing aligning its locating pin with the hole in the handlebar. Tighten the forward screw first, then the rear screw.
Page 351 FRONT WHEEL/SUsPEN$lON/sTEERlNG Tighten the forward screw first, then the rear screw. SWITCH HOUSING Install the master cylinder by aligning the end of the MASTER CYLINDER master cylinder with the punch mark on the handle- bar. Install the master cylinder holder with the "UP" mark facing up.
Page 352 FRONT WHEEL/SUSPENSION/STEERlNG Remove the mounting bolts and both brake calipers. not operate brake lever after the brake Support the brake caliper with piece of wire so it does not hang f r o m the brake hose. not twist the removed brake hose Loosen the right axle pinch bolts.
Page 353 FRONT WHEEL/SUSPENSlON/STEERlNG INSPECTION Axle Set the axle in V-block and measure the runout, Actual runout is 1/2 the total indicator reading. LIMIT: SERVICE 0.20 m m (0.008 in) Wheel bearing Turn the inner race of each bearing w i t h y o u r finger. The bearings should turn smoothly and quietly.
Page 354: Note
FRONT WHEEL/SUSPENSION/STEEalNG the direction of rotation marks o n the wheel and Note tire. Remove the dust seals f r o m the wheel. Mount the wheel, tire and brake discs assembly i n an inspection stand. Spin the wheel, allow it t o stop, and mark the lowest (heaviest) point of the wheel with chalk.
Page 355 FRONT WHEEL/SUSP€NSlON/STEERlNG ASSEMBLY Drive i n a new right bearing squarely. Never install the oid bearings Install the distance collar, then drive in the left bearing Once the beanngs using the special tool. have been removed, the TOOLS: beanngs must be Driver 07749-0010000 replaced with...
Page 356 FRONT WHEEL/SUSPENSION/STEERlNG I N STA L LATlO N Install the right and left side collars. Install the front wheel between the fork legs. Apply a thin layer o f grease t o the front axle surface. Install the front axle f r o m the left side. Hold the axle and tighten the axle bolt t o the specified torque.
Page 357 FRONT WHEEL/SUSPENSION/STEERlNG With the front brake applied, p u m p the fork u p and down several times to seat the axle and check brake operation. Check the brake operation by applying the brake lever. specified torque. TORQUE: 22 N-m (2.2 Check the clearance between the brake disc and caliper bracket o n each side after installation.
Page 358 FRONT WHEEL/SU§PENSlON/STEERlNG Loosen the fork bottom pinch bolts and remove the fork slider from the fork t o p bridge and steering stem. DISASSEMBLY Be carefulnot to PRE-LOAD ADJUSTER scratch the fork Remove the handlebar stop ring. dust sea/ Remove the stopper ring and pre-load adjuster. Remove the fork bolt f r o m the fork slider.
Page 359 FRONT WHEEL/SUSPENSlON/STEERlNG Hold the damper rod adjuster case, then loosen the ROD AD J U S T CASE lock nut. Remove the lock nut and fork bolt from the damper LOCK NUT rod. Remove the following: FORK SPRING - Spring collar Fork spring SPRING C ~ L L A R Pour out the fork flujd by pumping the fork pipe sev-...
Page 360 FRONT WHEEL/SUSPENSlON/STEERlNG Remove the fork damper assembly and centering FORK DAMPER plate f r o m the fork pipe. CENTERING PLATE Remove the dust seal. Remove the oil seal stopper ring. nor scrarch pipe did- ing surface Pull the fork slider out until you feel resistance f r o m the slider bushing.
Page 361 FRONT WHEEL/SUSPENSlON/STEERlNG Remove the fork pipe bushing, slider bushing, back- u p ring, oil seal, stopper ring and dust seal f r o m the fork pipe. BACK-UP RING STOPPER RING N S P ECTlO N Fork spring Measure the fork spring free length. SERVICE LIMIT: 250.8 mm (9.87 Fork pipe/slider/damper...
Page 362 FRONT WHEEL/SUSBENSION/STEERlNG Place the fork pipe in V-blocks and measure the I I P C runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 (0.008 in) Fork pipe bushing Visually inspect the slider and fork pipe bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire sur-...
Page 363 FRONT WHEEL/SUSPENSlON/STEERlNG Before assembly, wash all parts with a high flash- SLIDER BUSHING FORK PIPE point or non-flammable solvent and wipe them dry. BUSHING Install the dust seal, stopper ring, new oil seal, back- with its marked up ring, and slider bushing. OIL SEAL side facing up.
Page 364 Fork damper holder handle TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft) Pour the specified amount of the recommended fork fluid into the fork pipe. RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-8 FORK FLUID CAPACITY: 2.5 cm3 (17.3 0.08 US 18.1 0.09 Imp...
Page 365 FRONT WHEEL/SUSPENSlON/STEERlNG Bleed the air follows: FORK. DAMPER 2. Cover the top of the fork slider with your hand and compress the fork slowly. 3. Pump the fork pipe and fork damper slowly 8 times. Slowly push down the fork slider, and gently seat the dust seal onto the axle holder and leave it for 5 min- utes.
Page 366 Apply fork fluid t o the new O-rings and install them onto the fork bolt. Turn the adjusting plate clockwise until seats lightly. ADJUSTING PLATE Push down the spring collar, then install the fork bolt ADJUSTING PLATE t o the damper rod adjust case while aligning the groove of the adjusting plate with the damper rod adjust case.
Page 367 FRONT WHEEL/SUSPENSlON/STEERlNG Install the fork bolt to the fork slider. Tighten the fork FORK BOLT bolt after the fork shder into the fork bridges Install the handlebar stopper ring. PRE-LOAD ADJUSTER STOP RING Install the pre-load adjuster and stop ring. I NSTALLATlO N TOP BRIDGE Install the fork leg through the bottom bridge, handle-...
Page 368: Steering Stem
FRONT WHEELISUSPENSIONISTEERING If the fork bolt was loosened, tighten it t o the specified OP BRIDGE PINCH BOLT torque. TORQUE: (2.2 kgf-m, 16 Ibf-ft) Tighten the handlebar pinch bolt t o the specified torque. TORQUE: (2.7 kgf-m, 20 Ibf-ft) Tighten the t o p bridge pinch bolt t o the specified torque.
Page 369 FRONT WHEEL/SUSPENSlON/STEERlNG Remove the steering stem adjusting nut using t h e special tool. TOOL: Steering stem socket 07916-3710101 or 0791 6-371 01 00 Remove the following: - Dust seal - Upper bearing - Steering stem OUTER RACE REPLACEMENT the bearings and races as a set Replace the races using the special tools as described in the following procedure.
Page 370: Note
FRONT WHEEL/SUSPENSlON/STEEi?ING Install the ball race remover into the head pipe as shown. Align bearing remover A with the groove i n the steer- ing head. Lightly tighten nut B w i t h a wrench. Note the instaiia- the assembly Holding the driver shaft with a wrench, turn nut A base.
Page 371 FRONT WHEEL/SlJSPENSlON/STEERlNG Install a new upper outer race and the ball race DRIVER SHAFT remover as shown. ATTACHMENT Hold the driver shaft with a wrench and turn nut A gradually until the groove in driver attachment A aligns with the upper end of the steering head. This will allow you to install the upper outer race.
Page 372 FRONT WHEEL/SUSPENSION/STEERlNG U.S.A. only: UPPER NUT Replace the steering head bearing outer races using the special tools listed below. TOOLS: Main bearing driver attachment 07946-ME90200 Fork seal driver body seal driver 07965-MA60000 Installer shaft Installer attachment A 07VMF-MAT0100 Installer attachment B 07VMF-MAT0200 Remover attachment A 07VMF-MAT0300...
Page 373 FRONT WHEEL/SUSPENSlON/STEERlNG Install a new upper bearing outer race and the special UPPER NUT tools as shown. While holding the installer shaft with the wrench, turn INSTALLER the lower nut gradually until the groove in installer ATTACHMENT A attachment A aligns with the upper end of the steer- ing head.
Page 374 FRONT WHEEL/SUSPENSlON/STEERlNG LOWER BEARING REPLACEMENT Temporarily install the steering stem nut onto the stem t o prevent the threads f r o m being damaged when removing the lower bearing f r o m the stem. Remove the lower bearing with a chisel or equivalent tool, being careful not t o damage the stem.
Page 375 FRONT WHEEL/SUSPENSION/STEERlNG Apply grease t o the upper and lower bearings and bearing races. Insert the steering stem into the steering head pipe. Install upper bearing and dust seal. Apply oil t o the bearing adjustment nut threads. Install and tighten the stem adjusting nut t o the initial torque.
Page 376 FRONT WHEEL/SUSPENSION/STEERlNG Install the new lock washer onto the steering stem. LOCK NUT Install and tighten the steering stem lock nut. Align the tabs of the lock washer w i t h the grooves in the lock nut and bend t w o opposite tabs (shorter) down into the adjusting nut groove.
Page 377 FRONT WHEEL/SUSPENSlON/STEERlNG STEERING HEAD BEARING PRE-LOAD Jack-up the motorcycle t o raise the front wheel ground. Position the steering stem straight ahead. Hook a spring scale t o the fork pipe and measure the Make sure there is no cable or wire steering head bearing pre-load.
Page 378 14-0...
Page 379 Refer to section 15 for brake system information. Use only tires marked "TUBELESS" and tubeless valves on rims marked "TUBELESS TIRE APPLICABLE". Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point. SPECIFICATIONS Unit: m m (ir...
Page 380: Note
REAR WHEEL/SUSPENSION 113 N-m (11.5 kgf-m, 83 Ibf-ft) U-nut Rear axle nut 42 N * m (4.3 kgf-m, 31 Ibf-ft) ALOC bolt Rear brake disc mounting bolt U-nut Driven sprocket nut 64 N*m (6.5 kgfsm, 47 Ibf-ft) U-nut 93 N-m (9.5 kgf-m, 69 Ibf-ft) Shock absorber upper bracket mounting nut 44 N*m (4.5 kgf-m, 33 IbfW U-nut...
Page 381: Rear Wheel
REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a safety stand o r hoist, raise the rear wheel off the ground. Adjust the drive chain slack fully (page 3-20). Remove the axle nut and drive chain adjusting plate. Push the rear wheel forward. Remove the drive chain from the driven sprocket.
Page 382 REAR WHEEL/SUSPENSION Wheel bearing Turn the inner race of each bearing w i t h your finger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly i n the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub.
Page 383 REAR WHEEL/SUSPENSION Remove the driven flange assembly from the left flange, ioosen the driven sprocket nuts before removing the driven flange from the wheel hub Remove the wheel rubber dampers. Remove the O-ring. Driven flange bearing removal Loosen the driven sprocket nuts. Remove the driven flange from the wheel hub, then remove the driven sprocket nuts and sprocket.
Page 384 REAR WHEEL/SUSPENSION Wheel bearing removal Install the bearing remover head into the bearing. From the opposite side install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing.
Page 385 REAR WHEEL/SUSPENSION Install the distance collar Drive i n new left side bearing using the special tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 25 m m 07746-0040600 Install the driven flange collar into a new driven flange bearing (27 x 52 23.8).
Page 386 REAR WHEEL/SLIISPENSION Install the driven flange assembly into the left wheel hub. If the driven sprocket was removed, install the driven sprocket and tighten t h e nuts. TORQUE: 64 N.m (6.5 kgf-m, 47 Ibf-ft) Apply grease t o the dust seal lips, then install it into the driven flange.
Page 387 REAR WHEEL/SUSPENSIQN Place the rear wheel into the swingarm. Install the drive chain over the driven sprocket. Install the drive chain adjusting plate and axle f r o m t h e left side. Install the drive chain adjusting plate and axle nut. Adjust the drive chain stack (page 3-20).
Page 388 REAR WHEEL/SUSPENSION SHOCK LINK BEARING REPLACEMENT Remove the pivot collar and dust seals. PIVOT COLLAR Press out the needle bearing out of the shock link using the special tools. TOOLS: Driver 07949-3710001 Attachment, 22 x 24 07746-0010800 Pilot, 17 m m 07746-0040400 ATTACH ME NT/P I LOT Press ?he needie...
Page 389: Shock Absorber
REAR WHEEL/SUSPENSION INSTALLATION Install the shock link into the lower bracket, install the mounting bolthut. Hold the socket bolt and tighten the nut t o the speci- fied torque. TORQUE: 44 N-m (4.5 kgf-m, 33 Ibf-ft) Install the shock arm plates with its "FR" mark facing forward.
Page 390: Needle Bearing Replacement
REAR WHEEL/SUSPENSIQN I NSPECTI O N DAMPER Visually inspect the shock absorber for damage. Check the: Damper rod for bends or damage Damper unit for deformation or oil leaks Rubber bumper for wear or damage Inspect all the other parts for wear or damage. If necessary, replace the shock absorber as an assem- bly.
Page 391 REAR WHEEL/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Remove the damper reservoir cap. RESERVOIR CAP Put on safety glasses, then release the nitrogen f r o m not remove the valve core the reservoir b y depressing the valve core. until pressure released.
Page 392 REAR WHEEL/SUSPENSIQN REMOVAL Remove the rear wheel (page 14-3) Remove the t w o SH bolts and drive sprocket cover and spacer. Remove the drive sprocket bolt, washer and drive sprocket Remove the bolts and inner fender. Remove the screws and brake hose guides. 14-14...
Page 393 REAR WHEEL/SUSPENSION Remove the shock absorber lower mounting b o l t h u t . Remove the shock arm plate-to-swingarm bolt/nut. ER MOUNTING BOLTiNUT Remove the right main footpeg bracket socket bolts and main footpeg bracket. Release the 0 2 sensor wire from the wire guide behind the right step guard.
Page 394 REAR WHEEL/SUSPENSIQN Hold the pivot bolt using a special tool, then loosen and remove the swingarm pivot nut using the same tool. TOOL: holder, 27 mm Remove the pivot bolt and then remove the swingarm from the lower bracket and engine. DRIVE CHAIN CASE A Remove the SH bolt, trim clip and drive chain case A Remove the...
Page 395 REAR WHEEL/SUSPENSION Remove the three SH bolts and drive chain slider. Check the drive chain slider for wear or damage. Remove the pivot collar and dust seals f r o m the swingarm left pivot. Check the dust seals and collar for damage or fatigue. Remove the side collar and dust seals f r o m the swingarm right pivot.
Page 396 REAR WHEEL/SUSPENSION PIVOT BEARING REPLACEMENT Remove the snap ring from the swingarm right pivot. Remove the right pivot bearings (radial ball bearing and needle bearing) f r o m the swingarm pivot using the special tools and hydraulic press. TOOLS: Driver shaft Driver attachment, 25 x m m 07YMD-MCJ0100...
Page 397 REAR WHEEL/SUSPENSION Install the snap ring into the groove securely. Remove the left p i v o t needle bearing f r o m t h e swingarm pivot using the special tools. TOOLS: Driver 07749-0010000 Attachment, 40 42 m m 07746-0010900 Pack a new needle bearing w i t h grease.
Page 398 REAR Remove the shock arm pivot needle bearing using the NEEDLE BEARING REMOVER special tool. TOOL: Needle bearing remover Install the shock arm pivot needle bearing into the swingarm so the needle bearing surface is lower 5.5 6.0 m m (0.22 0.24 in) f r o m the end of the pivot sur- face using the same tool.
Page 399 REAR WHEEL/SUSPENSION ASSEMBLY DRIVE CHAIN CASE B DRIVE CHAIN CASE A RIGHT PIVOT BEARING (6905) (32 X 42 DRIVE CHAIN SLIDER (32 X 42 Apply grease to the dust seal lips, then install the dust seals and side collar into the right swingarm pivot. Apply grease to the dust seal lips, then install the dust left seals and pivot collar into the...
Page 400 REAR WHEEL/SUSPENSION Install the drive chain slider aligning its tabs w i t h the boss on the swingarm as shown. Apply a locking agent t o the drive chain slider bolt threads. Install the collars and bolts, then tighten the bolts t o the specified torque.
Page 401 REAR WHEEL/SUSPENSION Apply a thin coat of grease t o the swingarm pivot bolt surface. Install the swingarm between the lower bracket and engine, then install the pivot bolt from the left side. Install the swingarm pivot nut. Hold the pivot bolt using a special tool, tighten the swingarm pivot nut t o the specified torque using the same tool.
Page 402 REAR WHEELISUSPENSION Clamp the sensor wire t o the wire guide behind the SENSOR WIRE right step guard. Install the right main footpeg bracket onto the lower bracket and tighten the socket bolts to the specified torque. TORQUE: 39 N-m (4.0 kgfom, 29 Ibfaft) Install the shock arm plate-to-swingarm bolt/nut, then tighten the nut t o the specified torque.
Page 403 REAR WHEEL/SUSPENSION Install the drive sprocket with its "ML7" mark facing out. Install the washer and special bolt, then tighten the bolt t o the specified torque. TORQUE: 54 N-m (5.5 Install the spacer and drive sprocket cover, tighten the SH bolts.
Page 404 HYDRAULIC BRAKE FRONT: 34 N-m 15-0...
Page 405 15. HYDRAULIC BRAKE SERVICE INFORMATION 15-2 REAR MASTER CYLINDER 15-17 15-3 FRONT BRAKE CALIPER 15-21 TROUBLESHOOTING REAR BRAKE CALIPER 15-25 BRAKE FLUID REPLACEMENT/ AIR BLEEDING 15-4 BRAKE PEDAL 15-28 BRAKE PAD/DISC 15-8 FRONT MASTER CYLINDER 15-12 REAR: 15-1...
Page 406 31.965 - 31.998 (1.2585 - 1.2598) 31.953 (1 2580) Lower (Piston B) 30.082 - 30.1 15 (1.1843 - 1.1856) 30.074 (1.1840) Rear Specified brake fluid Honda DOT 4 Brake Fluid Brake disc thickness 4.0 (0.16) 5.0 (0.20) Brake disc runout 0.30 (0.012) Master cylinder I.D.
Page 407 HYDRAULIC BRAKE TORQUE VALUES U-nut 6 N - m (0.6 kgf-m, 4.3 Ibf-ft) Front brake master cylinder cup mounting nut Front master cylinder bracket bolt Brake lever pivot bolt Brake lever pivot nut Front brake light switch screw ALOC bolt 30 N*m (3.1 kgf-m, 22 Ibf-ft) Front brake caliper mounting bolt ALOC bolt...
Page 408 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR Do not allow foreign material to enter the system when filling the reservoir, Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. BRAKE FLUID DRAiNlNG For the front brake, turn the handlebar until the reser- voir is parallel to the ground, before removing the reservoir cap.
Page 409: Note
HYDRAULIC BRAKE Connect a bleed hose t o the caliper bleed valve. Loosen the bleed valve and p u m p the brake lever or pedal. Stop pumping the lever or pedal when m o r e fluid flows out of the bleed valve. BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir with DOT 4 brake fluid f r o m a sealed container.
Page 410 HYDRAULIC BRAKE Connect a commercially available brake bleeder t o the bleed valve. Operate the brake bleeder and loosen the bleed valve. If an automatic refill system is not used, add fluid when the fluid level in the reservoir is low. Perform the bleeding procedure the system is until...
Page 411 HYDRAULIC BRAKE the brake /ever or open the bleed valve 112 turn and then close the pedai untii the valve has been closed. Repeat steps 1 and 2 until bubbles cease t o appear i n the fluid coming out of the bleed valve. Tighten the bleed valve.
Page 412 HYDRAULIC BRAKE On the front brake, install the reservoir cap, and tight- en the screws. Tighten the master cylinder reservoir mounting nut securely. On the rear brake, install the reservoir cap securely, then install the reservoir onto the frame and tighten the mounting bolt.
Page 413 HYDRAULIC BRAKE Remove the Clean the inside of the caliper especially around the caliper pistons. Install the new brake pads. Install the pad spring with its arrow mark facing up (page 15-23). Push the pad spring, then install the pad pin. Install the brake caliper to the fork leg so the disc is Be careful not damage the pads.
Page 414 HYDRAULIC BRAKE REAR BRAKE PAD REPLACEMENT the brake pads in pairs Check the brake fluid level i n the brake master cylin- der reservoir as this operation causes the level t o rise. sure Push the caliper pistons all the w a y in b y pushing the caliper body inward t o allow installation of new brake pads.
Page 415: Brake Disc Inspection
HYDRAULIC BRAKE Make sure the brake pad spring is in place. Install the new brake Dads. Lower the caliper while pushing the pads against the pad spring so the pad ends are positioned onto the retainer on the caliper bracket. Install the pad pin.
Page 416 HYDRAULIC BRAKE Measure the brake disc warpage w i t h a dial indicator. SERVICE LIMIT: 0.30 mm (0.012 in) Check the wheel bearings for excessive play, warpage exceeds the service limit. Replace the brake disc if the wheel bearings are nor- mal.
Page 417 HYDRAULIC BRAKE Remove the pivot b o l t h u t and brake lever assembly. PIVOT BOLT BRAKE 'LEVER Remove the screw and brake light switch. SCREW BRAKE LIGHT SWITCH Remove the boot. Remove the snap ring the master cylinder body from SNAP RING using the special tool as shown.
Page 418 HYDRAULIC BRAKE INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder I.D. SERVICE LIMIT: 17.515 mm (0.6896 Measure the master cylinder piston O.D. SERVICE LIMIT: 17.309 mm (0.6815 in) ASSEMBLY...
Page 419 HYDRAULIC BRAKE Coat all parts w i t h clean brake fluid before assembly. MASTER CYLINDER SPRING Keep the pisron, cups, spring, snap ring and boot as a set do not sumti- tute indiv/duai Dip the piston in brake fluid. When instaiiing the cups, do Install the spring into the piston.
Page 420 HYDRAULIC BRAKE Apply silicone grease t o the contact surfaces of the brake lever and piston tip. Install the brake lever assembly, tighten the pivot bolt PIVOT BOLT t o the specified torque. TORQUE: Hold the pivot bolt and tighten the pivot nut to the specified torque.
Page 421: Rear Master Cylinder
HYDRAULIC BRAKE Place the master cylinder assembly on the handlebar. Align the end of the master cylinder w i t h the punch mark on the handlebar. Install the master cylinder holder with the “UP” mark facing up. Tighten the upper bolt first, then the lower bolt. Install the brake hose eyelet with the oil bolt and new sealing washers.
Page 422 HYDRAULIC BRAKE Remove and discard the brake pedal joint cotter pin. Remove the joint pin. Remove the master cylinder mounting bolts, collars (California type only), step guard and master cylinder. DISASSEMBLY RESERVOIR JOINT Remove the screw and reservoir hose joint from the master cylinder.
Page 423 HYDRAULIC BRAKE INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder I.D. SERVICE LIMIT: 15.925 mm (0.6270 in) Measure the master cylinder piston O.D. SERVICE LIMIT: 15.815 (0.6226 in)
Page 424 BRAKE HYDRAULIC Coat all parts w i t h clean brake fluid before assembly. Keep the piston cups spring, snap ring and boo? as a MASTER PISTON set, do not substi- tute individual parts ASSEMBLY Dip the piston i n brake fluid. When instaiiing Install the spring t o the primary cup.
Page 425: Front Brake Caliper
HYDRAULIC BRAKE INSTALLATION Place the master cylinder onto the main footpeg bracket, install the collars (California type only), step guard and master cylinder mounting bolts. Connect the brake pedal to the push rod lower joint. Install the joint pin andsecure it w i t h a new cotter pin. Clamp the 0 2 sensor wire t o the wire guide behind the OIL BOLT right step guard.
Page 426 HYDRAULIC BRAKE DISASSEMBLY Install corrugated cardboard or equivalent between the pistons. Apply small squirts of air pressure t o the fluid inlet to Do not use high pressure air or remove the pistons. bnng rhe nozzle too close to the inlet Remove the following: Mark the pistons...
Page 427 HYDRAULIC BRAKE INSPECTION Check the caliper cylinder for scoring or other dam- age. Measure the caliper cylinder I.D. SERVICE LIMITS: Cylinder A (Upper): 32.05 mm (1.262 in) Cylinder B (Lower): 30.29 mm (1.193 in) Check the caliper pistons for scratches, scoring or other damage.
Page 428 HYDRAULIC BRAKE Coat the new piston seals w i t h clean brake fluid. Coat the new dust seals with silicone grease. Install the piston and dust seal into the groove o f the caliper body. Coat the caliper pistons w i t h clean brake fluid and install t h e m into the caliper cylinder w i t h their open ends toward the pad.
Page 429: Rear Brake Caliper
HYDRAULIC BRAKE Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque. TORQUE: (3.5 Fill and bleed the front brake hydraulic system (page REAR BRAKE CALIPER REMOVAL Drain the rear brake hydraulic system (page 15-4). Remove the oil bolt, sealing washers and brake hose Avoid spiiiing fiwd eyelet joint.
Page 430 HYDRAULIC BRAKE Place a shop towel over the piston. Position the caliper body w i t h the piston d o w n and Do not use high pressure air or apply small squirts of air pressure t o the fluid inlet t o bring the nozzle remove the piston.
Page 431 HYDRAULIC BRAKE ASSEMBLY Coat the new piston seal with clean brake fluid. Coat the new dust seal w i t h silicone grease. Install the piston seal and dust seal into the groove of the caliper body. Coat the caliper piston with clean brake fluid and install it into the caliper cylinder w i t h its opening end toward the pad.
Page 432 HYDRAULIC BRAKE Install the pad retainer into the bracket. INSTALLATION Apply silicone grease t o the caliper pin and install the caliper onto the bracket. Install the rear brake pads (page 15-11). Install and tighten the caliper mounting bolt t o the specified torque.
Page 433 HYDRAULIC BRAKE Apply grease to the sliding surface of the brake pedal and footpeg. Assemble the brake pedal, footpeg and wave washer. Install a new footpeg mounting bolt and tighten it t o the specified torque. TORQUE: 44 N-m (4.5 kgfom, 33 I b f W Attach the brake pedal return spring.
Page 434 HYDRAULIC BRAKE Clamp the sensor wire t o the wire guide behind the SENSOR WIRE right step guard. Install the right main footpeg bracket assembly onto the lower bracket. Install and tighten the right main footpeg bracket socket bolts to the specified torque. TORQUE: (4.0 kgf-m, RIGHT...
Page 435 SYSTEM DlAGRAM REG U LATORI RECTIFIER ALTERNATOR G..GREEN 16-0...
Page 436 SYSTEM DIAGRAM 16-0 CHARGING SYSTEM INSPECTION 16-6 SERVICE INFORMATION ALTERNATOR CHARGING COIL 16-7 TROUBLESHOOTING 16-3 REG U LATOR/RECTI FI E R 16-7 BATTERY 16-4 SERVICE INFORMATION GENERAL The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.
Page 437: Note
The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every weeks t o pre- vent sulfation f r o m occurring. When checking the charging system, always follow the steps i n t h e troubleshooting f l o w chart (page 16-3). For battery charging, do not exceed the charging current and t i m e specified o n the battery.
Page 438 TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK Incorrect Faulty battery Remove the battery (page 16-4). Check the battery condition using the recom- mended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH or BM-210 (U.S.A. only) Correct Incorrect Disconnect the regulatorhectifier connector and Install the battery (page 16-4). recheck the battery current leakage.
Page 439 BATTERY NEGATIVE TERMINAL POSITIVE TERMINAL RE MOVAL/IN STALLATI O N Remove the seat (page 2-21, Always turn the ignition switch to "OFF" before Remove the battery holder band. removing the bat- Disconnect the negative cable and then the positive terv cable, and remove the battery.
Page 440 "OFF" and disconnect the clamps. EW BATT 7. Let the battery cool for at least 10 minutes or until gassing subsides after charging. 8. Retest the battery using the Honda battery tester and recharge necessary using the above steps.
Page 441: Charging Voltage Inspection
CHARGING SYSTEM INSPECTION NEGATIVE CABLE A M M,ETER CURRENT LEAKAGE INSPECTION Turn the ignition switch off and disconnect the nega- tive battery cable from the battery. Connect the ammeter probe to the ground cable and the ammeter probe to the battery terminal.
Page 442: Alternator Charging Coil
ALTERNATOR CHARGING COIL (WHITE) CONNECTOR INSPECTION Remove the ECM cover (page 5-87). Do not disconnect the battery Disconnect the alternator 3P (White) connector. cable in the charg- ing system with- Check the resistance between all three Yellow termi- out first switching nals.
Page 443 3P (WHITE) CONNECTOR Remove the rear cowl (page 2-2). Remove the ECM cover (page 5-87). Disconnect the alternator 3P (White) connector. Disconnect the regulator/rectifier 6P (Natural) connec- tor. 6P (NATURAL) CONNECTOR Remove the regulator/rectifier unit mounting SH bolts and regulator/rectifier. Install the regulatorhectifier unit in the reverse order wire in the seat raii properiy...
Page 444: Ignition System
IGNITION SYSTEM SYSTEM DIAGRAM ENGINE STOP SWITCH Tachometer ENGINE STOP RELAY CLUTCH SWITCH SENSOR DIODE (RED) NEUTRAL IGNITION PULSE GENERATOR SWITCH ... BLACK ..GREEN BLUE SPARKPLUGS ..... YELLOW ..'IGNITION COILS ..ORANGE LIGHT GREEN ...
Page 445 IGNITION SYSTEM 17-0 IGNITION SYSTEM INSPECTION 17-4 SYSTEM DIAGRAM 17-6 SERVICE INFORMATION 17-1 IGNITION PULSE GENERATOR 17-3 IGNITION TIMING 17-8 TROUBLESHOOTING SERVICE INFORMATION GENERAL Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is turned to "ON"...
Page 446 IGNITION SYSTEM TORQUE VALUES Apply grease to the threads. 18 N-m (1.8 kgf-m, 13 Ibf-ft) Timing hole cap 12 N-m (1.2 kgf-m, 9 Ibf*ft) Spark plug Apply oil to the threads. Ignition pulse generator rotor special bolt 59 N-m (6.0 kgf-m, 43 Ibf-ft) TOOLS 07HGJ-0020100 (not available in U.S.A.) Peak voltage adaptor...
Page 447 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. Faulty spark plug Loose spark plug cap or spark plug wire connection Water got into the direct ignition coil (leaking the ignition coil secondary voltage) spark test. If there is spark, the exchanged direct ignition coil is faulty. "Initial voltage"...
Page 448 IGNITION SYSTEM SYSTEM INSPECTION DIGITAL M U LTIMETER If there is no spark at any plug, check all connec- tions for loose or poor contact before measuring each peak voltage. Use recommended digital multimeter or commer- cially available digital multimeter w i t h an imped- ance of 10 MQ/DCV minimum.
Page 449 IGNITION SYSTEM With the ignition coil sub-harness 4P (Black) connec- 4P (BLACK) CONNECTOR tor connected, connect the peak voltage adaptor or terminal and ground. CONNECTION: Body ground Body ground Body ground Body ground PEAK VOLTAGE ADAPTOR Turn the ignition switch to "ON" and engine stop Avoidtouching switch to "RUN".
Page 450 IGNITION SYSTEM Connect the peak voltage tester or peak voltage-adap- PEAK VOLTAGE ADAPTOR tor probes t o the connector terminal of the wire har- ness side and ground. TOOLS: Peak voltage adaptor 07HGJ-0020100 (not available in with commercially available digital multimeter (impedance 10 M W D C V minimum) CONNECTION: Yellow terminal...
Page 451 IGNITION SYSTEM Remove the right crankcase cover (page 9-3). from Remove the wire grommet the cover. Remove the bolts and ignition pulse generator. Shift the transmission into 6th gear and apply the rear if the engine out of the frame, brake.
Page 452: Ignition Timing
iftheengines Shift the transmission into 6th gear and apply rear out of the frame, brake. t o the specified torque. TORQUE: 59 N-m (6.0 kgf-m, 43 Ibf-ft) then tlghten the Install the ignition pulse generator into the cover. Apply sealant t o the wire grommet, then install it into the groove of the cover.
Page 453 Connect the timing light t o the direct ignition coil Read wire. for timing operation Start the engine and let it idle. IDLE SPEED: 1,200 The ignition timing is correct if the "F" mark aligns with the index mark on the ignition pulse generator rotor cover.
Page 454 ELECTRIC STARTER SYSTEM DIAGRAM ENGINE STOP SWITCH RELAY SWITCH/ SIDE STAND SWITCH NEUTRAL INDICATOR SIDE STAND ..SWITCH ..GREEN ..YELLOW ..WHITE ..BLACK ..BLUE ..BROWN ..LIGHT GREEN 18-0...
Page 455 18. ELECTRIC STARTER 18-4 SYSTEM DIAGRAM 18-0 STARTER MOTOR SERVICE INFORMATION 18-1 STARTER RELAY SWITCH 18-10 TROUBLESHOOTING DIODE 18-11 18-2 SERVICE INFO R MATI 0 N GENERAL ausing s ri- "OFF" before servicing the starter mo Always turn the ignition switch t o ous injury.
Page 456 ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn Check for blown main or sub fuses before servicing. Make sure the battery is fully charged and in good condition. C I i c k" h ea rd Apply battery voltage t o the starter motor direct- Check the starter relay switch operation.
Page 457 ELECTRIC STARTER The starter motor turns when the transmission is in neutral, but does not turn with the transmission i n any position except neutral, with the side stand up and the clutch lever pulled in. Normal Faulty clutch switch Normal Check the side stand switch.
Page 458: Starter Motor
ELECTRIC STARTER STARTER MOTOR STARTER MOTOR CABLE REMOVAL Drain the coolant (page Remove the throttle body (page 5-67). Remove the thermostat housing (page 6-7). With the ignition switch turned t o "OFF", remove negative cable at the battery before servicing starter motor.
Page 459 ELECTRIC STARTER Remove the following: REAR COVER SEAL RING - Rear cover assembly Seal ring Shims Record the h a - Armature and number of shims ARM ATU RE SHIMS INSPECTION BUSHING Check the oil seal and needle bearing i n the front OIL SEAL cover for deterioration, wear or damage.
Page 460 ELECTRIC STARTER pairs of commutator Check for continuity between bars. There should be continuity. Check for continuity between each commutator bar and the armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal (the indigo colored wire or the insulat- ed brush holder).
Page 461 ELECTRIC STARTER Remove the following: BRUSH HOLDER - Nut - Washer - Insulators - O-ring Brush holder assembly - Brushkerminal Inspect the brushes for damage and measure the brush length. SERVICE LIMIT: (0.14 ASSEMBLY REAR COVER...
Page 462: Note
ELECTRIC STARTER Install the brushes into the brush holder. ALIGN Install the cable terminal and brush holder into the Install the following: - N e w O-ring Insulators Washer I N S U LATORS WASHER Install the armature in the motor case. When installing the armature into the motor case, hold the armature tightly t o keep the magnet of the case f r o m pulling the armature against it.
Page 463: Note
ELECTRIC STARTER Install the shims and insulated washer onto the arma- Install the insula- tors properly as ture shaft. noted during Install a new seal ring onto the motor case. removal. Apply grease t o the oil seal lip and needle bearing i n the front cover.
Page 464: Operation Inspection
ELECTRIC STARTER Install a new O-ring into the thermostat housing groove. Install the thermostat housing to the cylinder head. Install and tighten the mounting bolts. Install the following: - Thermostat housingithermostat (page 6-7). - Throttle body (page 5-71). Fill the system with the recommended coolant (page STARTER RELAY SWITCH OPERATION INSPECTION Remove the seat (page 2-21.
Page 465 ELECTRIC STARTER STARTER RELAY VOLTAGE INSPECTION Connect the starter relay switch connector. Shift the transmission into neutral. Measure the voltage between the Yellow/Red wire ter- minal and ground If the battery voltage appears only when the starter switch is pushed with the ignition switch t o " ON" and engine stop switch at "RUN", it is normal.
Page 466 SYSTEM LOCATION HEADLIGHT RELAY FRONT BRAKE LIGHT SWITCH ENGINE STOP RELAY IGNITION SWITCH LIGHT SWITCH...
Page 467: Note
LIGHTS/ ETERS/SWITCHES OIL PRESSURE SWITCH 19-14 SYSTEM LOCATION 19-0 FUEL RESERVE SENSOR 19-15 SERVICE INFORMATION 19-1 19-16 TROUBLESHOOTING IGNITION SWITCH 19-3 19-17 HEADLIGHT HANDLEBAR SWITCHES 19-4 TURN SIGNAL BRAKE LIGHT SWITCH 19-18 19-6 CLUTCH SWITCH 19-1 8 19-6 19-18 NEUTRAL SWITCH LICENSE LIGHT 19-7 19-19...
Page 468 SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight 5 5 w 12V - 55W Front turn signal light 12V - 3 2 1 3 ~ ~ Rear turn signal light 12V - 32cp (23W) x 2 License light 12V - 5W Instrument light LED x 2 Turn signal indicator High beam indicator...
Page 469 TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER The odometer/trip meter operates normally, but the speedometer does not operate Faulty speedometer The speedometer operates normally, but the odometerltrip meter does not operate Faulty odometerhrip meter Abnormal Check for loose or poor contact of the speed Loose or poor contact of related terminals Open circuit i n Black/Brown or GreeniBlack wires sensor 3P (Natural) connector.
Page 470 HEADLIGHT BULB REPLACEMENT Disconnect the headlight bulb connector. Remove the dust cover. Avoid touching Unhook the bulb retainer and remove the headlight the halogen head- bul bkocket. light bulb Finger prints can create If you touch the bulb w i t h your bare hands, clean hot spots that with cloth moistened with denatured alcohol t o pre- cause a bulb...
Page 471 Hook the bulb retainer into the headlight unit groove. Install the dust cover tightly against the headlight unit with its arrow mark facing up. Connect the headlight connector. Remove the upper cowl (page Remove the seven screws and headlight unit. Install the headlight unit in the reverse order of rem ova I.
Page 472 TURN SIGNAL TURN SIGNAL LENS BULB REPLACEMENT For turn signai unit Remove the screw and turn signal lens. and 2-9 SCREW While pushing in, turn the bulb counterclockwise t o remove it and replace with a new one. Install the turn signal lens i n the reverse order removal.
Page 473: License Light
Remove the brakeitail light unit mounting screws. Pull out the bosses f r o m the grommet, then remove the brakehail light unit. BOSS LICENSE LIGHT BULB REPLACEMENT Remove the screws, packing and lens. Pull out the license light bulb and replace it w i t h a n e w one.
Page 474 Remove the combination meter mounting screw. SCREW Release the combination meter case bosses f r o m the bracket grommets, then remove the combination meter. DISASSEMBLY REAR COVER Remove the screws and combination meter rear cover. SCREWS Remove the combination meter print board assembly PRINT BOARD f r o m the front cover.
Page 475 SCREW Install the combination meter onto the bracket. nation meter case bosses w/?h the Install and tighten the mounting screw. meter bracke?. Connect the combination meter multi-connector. COMBINATION METER Install the bank angle sensor (page 5-86) Install the upper cowl (page 2-6). M U LTI-CO'N N ECTOR VOLTAGE INSPECTION Open and support the front end of the fuel tank (page...
Page 476 Remove the upper cowl (page 2-51. MULTI-CONNECTOR Check for loose or poor connection of the combina- tion meter multi-connector. With the ignition switch turned t o "ON" and measure the voltage at the multi-connector terminals. Connection: BlacklBrown Standard: Battery voltage If there is no voltage, repair or replace the wire har- ness.
Page 477 Remove the bolts and speed sensor. Check the O-ring i n good condition, replace nec- essary. Install the speed sensor into the upper crankcase. Install and tighten the mounting bolts securely. Route the sensor wire. Connect the speed sensor (Natural) connector.
Page 478 TACHOMETER INSPECTION Remove the upper cowl (page 2-5). Check for loose or poor contact terminals of the c o m Connect the peak voltage adaptor to the tachometer TOOLS: PEAK V ~ L T A G E ADAPTOR Peak voltage adaptor (not available in U.S.A.) with commercially available digital multimeter...
Page 479 Suspend the ECT/thermo sensor in a pan of coolant (50 - 50 mixture) an electric heating element and measure the resistance through the sensor as the coolant heats up. Soak the ECT/thermo sensor in coolant u p t o its 40 mm threads w i t h at least (1.6 in) f r o m the b o t t o m...
Page 480: Oil Pressure Switch
OIL PRESSURE SWITCH I NSPECTI 0 N If the oil pressure warning indicator stays on while the engine is running, check the engine oil level before inspection. Make sure that the oil pressure warning indicator comes on with the ignition switch turned t o "ON". OIL P R E S S U R ~ WARNING INDICATOR If the indicator does not come on, inspect as follows: Remove the fuel tank (page 5-59).
Page 481 Apply sealant to the oil pressure switch threads as not apply sealant to shown. the thread head 3 - 4 mm (0.1 - 0.2 in). Install the oil pressure switch onto the crankcase, tighten it to the specified torque. TORQUE: 12 N*m (1.2 kgf.m, 9 I b f a ) Connect the oil pressure switch terminal to the switch and tighten the screw t o the specified torque.
Page 482: Ignition Switch
IGNITION SWITCH 4P (NATURAL) CONNECTOR INSPECTION Remove the air cleaner housing (page 5-64). Disconnect the ignition switch wire 4P (Natural) con- n ect o r. Check for continuity between the wire terminals of the ignition switch 4P (Natural) connector in each switch position.
Page 483: Handlebar Switches
HANDLEBAR SWITCHES ENGINE STOP SWITCH Remove the air cleaner housing (page 5-64). Disconnect the handlebar switch connectors. Check for continuity between the wire terminals of the handlebar switch connector. Continuity should exist between the color coded wire terminals as follows: STARTER SWITCH BAT3 FREE...
Page 484 BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors and check for continuity between the terminals. There should be continuity w i t h the brake lever applied, and there should be no continuity w i t h the brake lever released.
Page 485 INSPECTION Open and support the front end of the fuel tank (page 3-4). Disconnect the side stand switch 2P (Green) connec- tor. Check for continuity between the wire terminals of the side stand switch 2P (Green) connector. Continuity should exist only when the side stand is REMOVAL Disconnect the side stand switch 2P (Green) connector.
Page 486 LIGHTS/ M ETERS/S W ITCH ES INSTALLATION SIDE STAND SWITCH the return spring holding pin. Secure the side stand switch with a new bolt. SIDE STAND SWITCH TORQUE: 10 N m 7 Ibf-ft) (1.0 Connect the side stand switch 2P (Green) connector. HORN Disconnect the wire connectors from the horn.
Page 487: Turn Signal Relay
TURN SIGNAL RELAY I M SPECTI ON Remove the upper cowl (page 2-51, Check the following: - Battery condition - Burned bulbs or non-specified wattage Burnedfuse - Ignition switch and turn signal switch function Loose connectors If the above items are all normal, check the following: Disconnect the combination meter multi-connector from the combination meter.
Page 490 21 TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE AT HIGH HARD TO START 21-1 SPEED 21-4 ENGINE LACKS POWER 21-2 POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED 21 -3 ENGINE DOES NOT START OR HARD TO START Possible cause Faulty fuel pump (Section 5 ) 1.
Page 491 TROUBLESHOOTING ENGINE LACKS POWER Possible cause Raise wheel off the ground and spin by Wheels d o not spin Brake dragging hand freely Worn damaged wheel bearing Wheel spins freely Check tire pressure Pressure l o w Faulty tire valve Punctured tire Pressure normal Clutch slipping...
Page 492 TROUBLESHOOTING Possible cause Coolant level low Check for engine overheating Overheating Fan motor not working (faulty fan motor switch) Not overheating Thermostat stuck close Excessive carbon build-up in com- bustion chamber Use of poor quality fuel Wrong type of fuel Clutch slipping Worn piston and cylinder Engine knocks...
Page 493: Poor Performance At High Speed
TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause Faulty ECM Incorrect Correct Faulty pressure regulator (Section 5) 2. Inspect the fuel flow Abnormal Normal See section 5 3. Inspect the fuel injector Abnormal Normal Camshaft not installed properly 4. Check valve timing Incorrect Correct Faulty valve spring...
Page 494 INDEX AIR CLEANER EVAPORATIVE EMISSION CONTROL SYSTEM AIR CLEANER HOUSING (California type only) 5-64 3-19 ALTERNATOR CHARGING COIL FAN CONTROL RELAY 16-7 6-17 ALTER NATO R COVER I N STA LLATlO N FAST IDLE WAX UNIT 10-8 5-7 5 ALTERNATOR COVER REMOVAL FLYWHEEL I N STALL AT1 0 N 10-2 10-7...
Page 495 INDEX REAR MASTER CYLINDER 15-17 5-84 TP SENSOR REAR WHEEL TRANSMISSION 12-9 14-3 REG U LATORIRECTIFI ER 16-7 TROUBLESHOOTING RIGHT CRANKCASE COVER INSTALLATION 10-1 9-17 (ALTERNATORISTARTER CLUTCH) RIGHT CRANKCASE COVER REMOVAL 16-3 SEAT SEAT RAIL 2-1 1 (COOLING SYSTEM) SERVICE RULES (CRAN KCASE/PISTON/CYLI NDER) 11-2 SECONDARY AIR SUPPLY SYSTEM...

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Honda 954 Service Manual

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