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Honda CBR125R Owner's Manual

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Table of Contents

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TYPE CODE
Throughout this manual, the following abbreviations are used to identify individual model.
CODE
AREA TYPE
E
U.K. (Ireland)
F
France
EUROPEAN DIRECT SALES
ED
(Austria, Switzerland, Belgium, Germany, Portugal, Italy, Spain, Israel)
U
Australia
II G
Germany II
CM
Canada
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  • Page 1 Return to Language Selection TYPE CODE Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE U.K. (Ireland) France EUROPEAN DIRECT SALES (Austria, Switzerland, Belgium, Germany, Portugal, Italy, Spain, Israel) Australia II G Germany II Canada...
  • Page 2 Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 3 THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT INDEX THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- GATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITH- OUT WRITTEN PERMISSION.
  • Page 4 ® Example: Molykote G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply locking agent. Use a medium strength locking agent unless otherwise specified.

  • Page 5: Table Of Contents

    1. GENERAL INFORMATION SERVICE RULES ········································· 1-2 REAR WHEEL/SUSPENSION SPECIFICATIONS ····································· 1-10 MODEL IDENTIFICATION··························· 1-2 HYDRAULIC BRAKE SPECIFICATIONS··· 1-10 GENERAL SPECIFICATIONS······················ 1-5 BATTERY/CHARGING SYSTEM SPECIFICATIONS ····································· 1-11 LUBRICATION SYSTEM SPECIFICATIONS········································ 1-7 IGNITION SYSTEM SPECIFICATIONS ···· 1-11 FUEL SYSTEM (PGM-FI) SPECIFICATIONS········································ 1-7 ELECTRIC STARTER SPECIFICATION·····...

  • Page 6: Service Rules

    SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.

  • Page 7: Serial Numbers

    GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. The registered number plate is located on the right side of the frame REGISTERED NUMBER PLATE (Except CM and U type). The engine serial number is stamped on the lower left side of the ENGINE SERIAL NUMBER crankcase.
  • Page 8 GENERAL INFORMATION LABELS The color label is attached on the left side of the frame. COLOR LABEL When ordering color-coded parts, always specify the designated color code. The Safety Certification Label is located on the right side of the frame SAFETY CERTIFICATION LABEL (CM type only).

  • Page 9: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 1,920 mm (75.6 in) Overall width 680 mm (26.8 in) Overall height 1,065 mm (41.9 in) Wheelbase 1,295 mm (51.0 in) Seat height 780 mm (30.7 in) Footpeg height 312 mm (12.3 in) Ground clearance 175 mm (6.9 in) Curb weight...
  • Page 10 GENERAL INFORMATION ITEM SPECIFICATION ELECTRICAL Ignition system Computer-controlled digital transistor- ized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full-wave recti- fication Lighting system Battery...

  • Page 11: Specifications

    Except CM type High quality ethylene glycol antifreeze containing silicate- free corrosion inhibitors CM type only Pro Honda HP coolant or equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibi- tors Standard coolant concentration 1:1 (mixture with distilled water)

  • Page 12: Cylinder Head/Valves

    GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 530 min (rpm) 1,343 kPa (13.7 kgf/cm , 195 psi) – 0.06 ± 0.02 (0.002 ± 0.001) Valve clearance – 0.27 ± 0.02 (0.011 ± 0.001) –...
  • Page 13 GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear I.D. 22.010 – 22.031 (0.8665 – 0.8674) 22.08 (0.869) O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.60 (1.795) CRANKSHAFT/BALANCER/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Runout...

  • Page 14: Hydraulic Brake Specifications

    60 g max. Fork Spring free length 412.4 (16.24) 404.1 (15.91) Pipe runout – 0.20 (0.008) Recommended Except Honda ULTRA CUSHION OIL 10W or – fork fluid CM type equivalent CM type Pro Honda Suspension Fluid SS-8 – only (10W) or equivalent Fluid level 131 (5.2)

  • Page 15: Specifications

    GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V - 6 Ah Current leakage 0.1 mA max. Voltage Fully charged 13.0 – 13.2 V (20°C/68°F) Needs charging Below 12.4 V Charging current Normal 0.6 A/5 – 10 h Quick 3 A/1 h Alternator...

  • Page 16: Engine & Frame Torque Values

    GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt and nut 6 mm screw 9.0 (0.9, 6.6) (Include SH flange bolt) 10 (1.0, 7) 6 mm flange bolt...
  • Page 17 GENERAL INFORMATION COOLING SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Water pump impeller 10 (1.0, 7) Water hose band screw – – See page 6-14 Fan motor shroud mounting bolt 8.4 (0.9, 6.2) Fan motor screw 2.8 (0.3, 2.1) Cooling fan nut 1.0 (0.1, 0.7)
  • Page 18 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Front axle nut 59 (6.0, 44) U-nut Front brake disc bolt 42 (4.3, 31) ALOC bolt; replace with a new one. Fork bolt 23 (2.3, 17) Fork socket bolt 20 (2.0, 15) Apply locking agent...
  • Page 19 GENERAL INFORMATION LIGHTS/METERS/SWITCHES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Turn signal light lens screw 0.9 (0.1, 0.7) Turn signal light mounting nut 8.8 (0.9, 6.5) License light cover screw 1.0 (0.1, 0.7) License light mounting nut 4.5 (0.5, 3.3) 1-15...

  • Page 20: Lubrication & Seal Points

    GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant (Three Left crankcase mating surface See page 12-22 bond 1215 or equivalent) Alternator/CKP sensor wire grommet sealing surface Engine oil Oil pump rotor entire surface Water pump shaft outer surface Starter clutch rolling surface Starter reduction gear shaft outer surface Right crankshaft outer surface...
  • Page 21 Locking agent Ignition switch stay mounting bolt threads Fork fluid Fork bolt O-ring Fork oil seal lips Honda Bond A or equiva- Left handlebar and throttle pipe outer surface (grip lent rubber contacting area) Air cleaner connecting boot matching surface...

  • Page 22: Cable & Harness Routing

    GENERAL INFORMATION CABLE & HARNESS ROUTING FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE THROTTLE CABLE FRONT BRAKE CLUTCH CABLE LIGHT SWITCH WIRE CLUTCH SWITCH WIRE THROTTLE CABLE FRONT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE SPEEDOMETER CABLE RIGHT HANDLEBAR SWITCH WIRE HORN WIRE COMBINATION METER...
  • Page 23 GENERAL INFORMATION FRONT SUB HARNESS POSITION LIGHT WIRE POSITION LIGHT 3P (NATURAL) CONNECTOR Front FRONT SUB HARNESS HEADLIGHT BULB CONNECTORS HEADLIGHT 4P (NATURAL) CONNECTOR 1-19...
  • Page 24 GENERAL INFORMATION INSIDE BOOT CONNECTORS: – HEADLIGHT 4P (NATURAL) CONNECTOR – COMBINATION METER 9P (NATURAL) CONNECTOR – COMBINATION METER 3P (NATURAL) CONNECTOR – DLC 4P (NATURAL) CONNECTOR RIGHT HANDLEBAR SWITCH WIRE COMBINATION METER SUB HARNESS BANK ANGLE SENSOR 3P (GRAY) CONNECTOR THROTTLE CABLE RIGHT TURN SIGNAL LIGHT WIRE CONNECTORS...
  • Page 25 GENERAL INFORMATION View from the bottom SPEEDOMETER CABLE Left Front CLUTCH CABLE Right BANK ANGLE SENSOR 3P (GRAY) CONNECTOR CLUTCH SWITCH WIRE Front LEFT TURN SIGNAL LIGHT WIRE CONNECTORS RIGHT TURN SIGNAL LIGHT WIRE HORN WIRE BANK ANGLE SENSOR WIRE SPEEDOMETER CABLE 1-21...
  • Page 26 GENERAL INFORMATION INSIDE BOOT CONNECTORS: – REGULATOR/RECTIFIER 6P (BLACK) CONNECTOR – NEUTRAL SWITCH WIRE CONNECTOR – ALTERNATOR/CKP SENSOR 6P (NATURAL) CONNECTOR – SIDESTAND SWITCH 3P (GREEN) CONNECTOR THROTTLE CABLE WATER HOSES FUEL FEED HOSE FUEL PUMP WIRE FUEL TANK DRAIN HOSE REGULATOR/RECTIFIER WIRE SIDESTAND SWITCH WIRE FUEL TANK...
  • Page 27 GENERAL INFORMATION RIGHT HANDLEBAR SWITCH 6P (NATURAL) CONNECTOR COOLING FAN MOTOR 2P (NATURAL) CONNECTOR LEFT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR IGNITION SWITCH 2P (NATURAL) CONNECTOR ECM 33P CONNECTOR LEFT HANDLEBAR SWITCH 9P (NATURAL) CONNECTOR THROTTLE CABLE ECT SENSOR 3P (GRAY) CONNECTOR FUEL FEED HOSE IGNITION COIL PRIMARY WIRE INJECTOR 2P (BLACK) CONNECTOR...
  • Page 28 GENERAL INFORMATION STARTER MOTOR CABLE FUEL FEED HOSE MAIN WIRE HARNESS REAR BRAKE LIGHT SWITCH GROUND CABLE 2P (NATURAL) CONNECTOR SIPHON HOSE SIPHON HOSE REAR BRAKE LIGHT SWITCH FUEL TANK BREATHER HOSE CLUTCH CABLE WATER HOSE AIR CLEANER HOUSING DRAIN HOSE WATER PUMP COOLANT RESERVE TANK INSPECTION HOSE...
  • Page 29 GENERAL INFORMATION SPARK PLUG WIRE SIPHON HOSE THROTTLE CABLE CLUTCH CABLE CLUTCH CABLE THROTTLE CABLE LEFT HANDLEBAR SWITCH WIRE SENSOR 2P (NATURAL) WATER HOSE CONNECTOR IGNITION SWITCH WIRE SENSOR CORD WATER HOSE RIGHT HANDLEBAR GROUND CABLE SWITCH WIRE STARTER MOTOR CABLE 1-25...
  • Page 30 GENERAL INFORMATION FUEL PUMP 5P (NATURAL) CONNECTOR FUEL TANK BREATHER HOSE FUEL FEED HOSE FUEL FEED HOSE IACV 4P (BLACK) CONNECTOR INJECTOR 2P (BLACK) CONNECTOR SENSOR UNIT 5P (BLACK) CONNECTOR 1-26...
  • Page 31 GENERAL INFORMATION SPARE FUSE 30 A SPARE FUSE 10 A STARTER MOTOR CABLE TURN SIGNAL RELAY 2P (NATURAL) CONNECTOR BATTERY NEGATIVE (–) CABLE MAIN WIRE HARNESS BATTERY POSITIVE (+) CABLE MAIN FUSE 30 A STARTER RELAY SWITCH SUB FUSE 10 A: (1) SUB FUSE A (2) SUB FUSE B (3) SUB FUSE C...
  • Page 32 GENERAL INFORMATION MAIN WIRE HARNESS DIODE REAR BRAKE RESERVOIR HOSE GROUND CABLE STARTER MOTOR CABLE REAR BRAKE HOSE REAR BRAKE LIGHT SWITCH 2P (NATURAL) CONNECTOR REAR BRAKE LIGHT SWITCH WIRE 1-28...
  • Page 33 GENERAL INFORMATION BRAKE/TAIL LIGHT 3P (NATURAL) CONNECTOR REAR TURN SIGNAL 2P (ORANGE AND LIGHT BLUE) CONNECTORS LICENSE LIGHT WIRE CONNECTORS LEFT TURN SIGNAL WIRE MAIN RELAY BRAKE/TAIL LIGHT 3P (NATURAL) CONNECTOR LICENSE LIGHT WIRE CONNECTORS REAR TURN SIGNAL RIGHT TURN SIGNAL 2P (ORANGE AND LIGHT WIRE LIGHT BLUE) CONNECTORS...

  • Page 34: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems (page 1-31) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.
  • Page 35 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a three-way catalytic converter and PGM-FI system. THREE-WAY CATALYTIC CONVERTER This motorcycle is equipped with a three-way catalytic converter. The three-way catalytic converter is in the exhaust system. Through chemical reactions, it converts HC, CO and NO in the engine’s exhaust to carbon dioxide (CO ), nitrogen (N...

  • Page 36: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems (page 1-33) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.

  • Page 37: Noise Emission Control System

    GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a three-way catalytic converter and PGM-FI system. THREE-WAY CATALYTIC CONVERTER This motorcycle is equipped with a three-way catalytic converter. The three-way catalytic converter is in the exhaust system. Through chemical reactions, it converts HC, CO and NO in the engine’s exhaust to carbon dioxide (CO ), nitrogen (N...
  • Page 38 MEMO...
  • Page 39 2. BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS ························ 2-2 INNER COWL ·············································· 2-7 SERVICE INFORMATION ··························· 2-3 LOWER COWL ············································ 2-8 TROUBLESHOOTING ································· 2-3 MIDDLE COWL ··········································· 2-9 PILLION SEAT ············································· 2-4 UPPER COWL ··········································· 2-10 SINGLE SEAT·············································· 2-4 FRONT FENDER ······································· 2-11 GRAB RAIL ··················································...

  • Page 40: Body Panel Locations

    BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS BODY PANELS/EXHAUST SYSTEM EXCEPT CM AND U TYPE shown: PILLION SEAT GRAB RAIL WINDSCREEN SINGLE SEAT UPPER COWL FRONT FENDER REAR FENDER REAR COWL LOWER COWL INNER COWL MIDDLE COWL FUEL TANK COVER...

  • Page 41: Service Information

    BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels and exhaust system. • Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. •...

  • Page 42: Pillion Seat

    BODY PANELS/EXHAUST SYSTEM PILLION SEAT REMOVAL/INSTALLATION Unhook the pillion seat lock using the ignition key. PILLION SEAT Remove the pillion seat by pulling it rearward. Install the pillion seat by inserting the hooks into the seat retainers. HOOKS Push the pillion seat down to lock it. RETAINERS IGNITION KEY SINGLE SEAT...

  • Page 43: Grab Rail

    BODY PANELS/EXHAUST SYSTEM GRAB RAIL REMOVAL/INSTALLATION Remove the mounting bolts and grab rail. GRAB RAIL Install the grab rail and mounting bolts, tighten the bolts to the specified torque. TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft) BOLTS REAR COWL REMOVAL/INSTALLATION Remove the following: –...

  • Page 44: Fuel Tank Cover

    BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws, rear center cowl A and B from the rear cowls. Assembly is in the reverse order of disassembly. Install the rear center cowl A and B by aligning its tabs with the slits of the both rear cowls. REAR CENTER COWL B REAR CENTER COWL A Align...

  • Page 45: Inner Cowl

    BODY PANELS/EXHAUST SYSTEM INNER COWL REMOVAL/INSTALLATION Remove the screws and inner cowl by pulling it INNER COWL SCREWS rearward. Install the inner cowl in the reverse order of removal. Insert the tabs of the inner cowl to the slits of the middle cowl and upper cowl.

  • Page 46: Lower Cowl

    BODY PANELS/EXHAUST SYSTEM LOWER COWL REMOVAL/INSTALLATION Remove the lower cowl special screws. Remove the lower cowl-to-middle cowl screws and Be careful not to then remove the lower cowl downward. damage the tabs and slits. Install the lower cowl by aligning the tabs of the middle cowl with the slits of the lower cowl.

  • Page 47: Middle Cowl

    BODY PANELS/EXHAUST SYSTEM MIDDLE COWL REMOVAL/INSTALLATION Remove the following: – Fuel tank cover (page 2-6) – Inner cowl (page 2-7) – Lower cowl (page 2-8) – Turn signal light (page 19-5) Release the wires from the clamps. Remove the screws and bolts. Release the boss from the grommet of the frame Be careful not to and remove the middle cowl by pulling it forward.

  • Page 48: Upper Cowl

    BODY PANELS/EXHAUST SYSTEM UPPER COWL REMOVAL/INSTALLATION Remove the middle cowl (page 2-9). Disconnect the headlight/position light 4P (Natural) connector. 4P (NATURAL) CONNECTOR Remove the bolts and release the bosses from the grommets of the upper cowl stay. Disconnect the bank angle sensor 3P (Gray) connector. BOLTS GROMMET BOSS...

  • Page 49: Front Fender

    BODY PANELS/EXHAUST SYSTEM Remove the screws and windscreen. WINDSCREEN Install the windscreen by aligning its holes with the bosses of the upper cowl. Install and tighten the screws. Install the upper cowl in the reverse order of removal. Align SCREWS UPPER COWL FRONT FENDER REMOVAL/INSTALLATION...

  • Page 50: Rear Fender

    BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL/INSTALLATION Remove the following: CONNECTORS – Brake/tail light (page 19-6) – Battery (page 16-5) Disconnect the turn signal light 2P (Orange and Light blue) connectors and license light connectors. Remove the starter relay switch and fuse boxes. FUSE BOXES Release the wire harness from the rear fender.

  • Page 51: Exhaust Pipe/Muffler

    BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the following: – Turn signal light mounting nuts and turn signal lights – Bolts and turn signal light stay – Screws and license light assembly – Grommet – Nuts and number plate bracket (CM type) Assemble is in the reverse order of disassembly.
  • Page 52 BODY PANELS/EXHAUST SYSTEM Remove the muffler mounting bolt, collar, rubber BOLT/COLLAR/ and nut. RUBBER/NUT Remove the exhaust pipe mounting bolt, nut, washer, collar and rubbers. Remove the exhaust pipe/muffler as assembly. BOLT/NUT/WASHER/ COLLAR/RUBBERS Remove the exhaust pipe gasket. GASKET 2-14...
  • Page 53 BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the following: – Bolts, spring washers, washers and exhaust pipe cover – Bolts, nuts and muffler guard – Bolts, muffler and gasket Assembly is in the reverse order of disassembly. Always replace the muffler gasket with a new one whenever the muffler is removed from the exhaust pipe.
  • Page 54 BODY PANELS/EXHAUST SYSTEM INSTALLATION COLLAR RUBBER GASKET RUBBERS EXHAUST PIPE/ MUFFLER WASHER MUFFLER MOUNTING BOLT EXHAUST PIPE COLLAR JOINT NUTS EXHAUST PIPE MOUNTING BOLT WASHER Install a new exhaust pipe gasket to the exhaust port of the cylinder head. Always replace the exhaust pipe gasket with a new one whenever the exhaust pipe is removed.
  • Page 55 BODY PANELS/EXHAUST SYSTEM Tighten the exhaust pipe mounting bolt and nut securely. BOLT/NUT/WASHER/ COLLAR/RUBBERS Tighten the muffler mounting bolt and nut securely. MUFFLER MOUNTING BOLT/NUT After the installation, inspect the exhaust system for leaks. STUD BOLT REPLACEMENT Remove the exhaust pipe/muffler (page 2-13). Fully seated Thread two nuts onto the stud and tighten them together, and use a wrench on them to turn the stud...
  • Page 56 MEMO...
  • Page 57 3. MAINTENANCE SERVICE INFORMATION ··························· 3-2 DRIVE CHAIN············································ 3-16 MAINTENANCE SCHEDULES···················· 3-4 BRAKE FLUID ··········································· 3-21 FUEL LINE ··················································· 3-6 BRAKE PADS WEAR ································ 3-22 THROTTLE OPERATION····························· 3-7 BRAKE SYSTEM ······································· 3-23 AIR CLEANER·············································· 3-8 BRAKE LIGHT SWITCH ···························· 3-23 CRANKCASE BREATHER ···························...

  • Page 58: Service Information

    API service label) JASO T 903 standard: MA Viscosity: SAE 10W-30 CM type only Pro Honda GN4 4-stroke oil or equivalent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30 1,450 ±...
  • Page 59 MAINTENANCE TORQUE VALUES Air cleaner cover screw 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft) Tappet adjusting nut 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply engine oil to the threads and seat- ing surface. Timing hole cap 6.0 N·m (0.6 kgf·m, 4.4 lbf·ft) Crankshaft hole cap...

  • Page 60: Maintenance Schedules

    STEERING HEAD BEARINGS 3-27 Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
  • Page 61 STEERING HEAD BEARINGS 3-27 Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.

  • Page 62: Fuel Line

    MAINTENANCE FUEL LINE FUEL TANK LIFTING Remove the following: BOLTS GROMMET – Single seat (page 2-4) – Fuel tank cover (page 2-6) Remove the bolts. Release the bosses from the grommets of the fuel tank. BOSS Lift the front end of the fuel tank and support it using a suitable support as shown.

  • Page 63: Throttle Operation

    MAINTENANCE Install and tighten the bolts securely. BOLTS GROMMET Insert the rear cowl bosses to the grommets of the fuel tank. Install the following: – Fuel tank cover (page 2-6) – Single seat (page 2-4) BOSS THROTTLE OPERATION Check for any deterioration or damage to the throt- tle cable.

  • Page 64: Air Cleaner

    MAINTENANCE AIR CLEANER REMOVAL/INSTALLATION Lift and support the fuel tank (page 3-6). Remove the screws, air cleaner cover and packings. AIR CLEANER COVER Remove the air cleaner element. Clean and replace the air cleaner element in accor- dance with the maintenance schedule (page 3-4) or SCREWS any time it is excessively dirt or damaged.

  • Page 65: Crankcase Breather

    MAINTENANCE 3. Blow off the remaining bust from the throttle body side. – Position the air blow gun 30 mm (1.2 in) away from the air cleaner element. – Move the air blow gun up to down and side to side alternately five times or more for 30 sec- onds.
  • Page 66 MAINTENANCE Remove the spark plug using a spark plug wrench. Clean around the SPARK PLUG spark plug base Inspect or replace the spark plug as described in the with compressed maintenance schedule (page 3-4). air before removing the spark plug, and be sure that no debris is allowed to enter into the...

  • Page 67: Valve Clearance

    MAINTENANCE VALVE CLEARANCE INSPECTION • Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F). • After the valve clearance inspection, check the engine idle speed (page 5-62). • Inspect and adjust the valve clearance can be ser- viced with the engine installed in the frame.
  • Page 68 MAINTENANCE Check the valve clearance by inserting a feeler ADJUSTING SCREW gauge between the adjusting screw and valve stem. VALVE CLEARANCE: IN: 0.06 ± 0.02 mm (0.002 ± 0.001 in) EX: 0.27 ± 0.02 mm (0.011 ± 0.001 in) FEELER GAUGE ADJUSTMENT Adjust by loosening the lock nut and turning the LOCK NUT...

  • Page 69: Engine Oil

    JASO T 903 standard: MA the indicated range. Viscosity: SAE 10W-30 RECOMMENDED ENGINE OIL (CM type only): Pro Honda GN4 4-stroke oil or equivalent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30...

  • Page 70: Engine Oil Strainer Screen

    MAINTENANCE ENGINE OIL CHANGE Warm up the engine. FILLER CAP/DIPSTICK Stop the engine and remove the oil filler cap/dip- stick. Place an oil pan under the engine to catch the engine oil, then remove the drain bolt/sealing washer. Drain the engine oil completely. Install a new sealing washer onto the drain bolt.

  • Page 71: Radiator Coolant

    RECOMMENDED ANTIFREEZE (Except CM type): High quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors RECOMMENDED ANTIFREEZE (CM type only): Pro Honda HP coolant or equivalent high quality ethylene glycol antifreeze containing silicate-free "LOWER" LEVEL LINE corrosion inhibitors Remove the single seat (page 2-4).

  • Page 72: Drive Chain

    MAINTENANCE Inspect the water hoses for cracks or deterioration, and replace them if necessary. Check the tightness of all water hose band screws (page 6-14). WATER HOSES DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF, support the motorcy- Never inspect and cle on its sidestand and shift the transmission into adjust the drive...

  • Page 73: Cleaning And Lubrication

    MAINTENANCE CLEANING AND LUBRICATION Clean the chain with non-flammable or high flash CLEANING SOFT BRUSH point solvent and wipe it dry. Be sure the chain has dried completely before lubri- cating. SOLVENT Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable.
  • Page 74 MAINTENANCE Check the attaching bolts and nuts on the drive and DRIVE SPROCKET driven sprockets. If any are loose, torque them. TORQUE: Drive sprocket fixing plate bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft) Driven sprocket nut: 64 N·m (6.5 kgf·m, 47 lbf·ft) Install the drive sprocket cover (page 11-5).
  • Page 75 MAINTENANCE Locate the crimped pin ends of the master link from MASTER LINK the outside of the drive chain, and remove the link with the drive chain tool set. TOOL: Drive chain tool set 07HMH-MR10103 Remove the drive chain. DRIVE CHAIN TOOL SET Remove the excess drive chain links from a new Include the master drive chain with the drive chain tool set.
  • Page 76 MAINTENANCE Make sure that the master link pins are installed MASTER LINK PINS properly. Measure the master link pin length projected from the plate. STANDARD LENGTH: Approx. 1.1 mm (0.04 in) Stake the master link pins. Make sure that the pins are staked properly by mea- SLIDE CALIPER suring the diameter of the staked area using a slide caliper.

  • Page 77: Brake Fluid

    MAINTENANCE BRAKE FLUID Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. • Do not mix different types of fluid, as they are not compatible with each other. • Do not allow foreign material to enter the system when filling the reservoir.

  • Page 78: Brake Pads Wear

    MAINTENANCE REAR BRAKE Support the motorcycle on a level surface, and BOLT check the rear brake fluid level. If you will add the brake fluid, remove the bolt. "LOWER" LEVEL LINE Remove the cover screws, reservoir cover, set plate SCREWS COVER and diaphragm.

  • Page 79: Brake System

    MAINTENANCE BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that FRONT: BRAKE HOSE no air has entered the system. If the lever or pedal feels soft or spongy when oper- ated, bleed the air from the system. For brake air bleeding (page 15-6).

  • Page 80: Clutch System

    MAINTENANCE CLUTCH SYSTEM Measure the clutch lever freeplay at the end of the clutch lever. 10 – 20 mm (3/8 – 13/16 in) FREEPLAY: 10 – 20 mm (3/8 – 13/16 in) Minor adjustment is made with the upper adjuster The adjuster may LOCK NUT at the clutch lever.

  • Page 81: Sidestand

    MAINTENANCE SIDESTAND Support the motorcycle using a safety stand or hoist. Check the sidestand spring for damage or loss of tension. Check the sidestand assembly for freedom of move- ment and lubricate the sidestand pivot if necessary. TORQUE: Sidestand pivot bolt: 18 N·m (1.8 kgf·m, 13 lbf·ft) Sidestand pivot nut: 44 N·m (4.5 kgf·m, 32 lbf·ft) NUT/BOLT Check the sidestand ignition cut-off system:...

  • Page 82: Nuts, Bolts, Fasteners

    MAINTENANCE Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground. Check for worn swingarm bushings by grabbing the rear wheel and attempting to move the wheel side to side. Replace the bushings if any looseness to noted. For swingarm service (page 14-12).

  • Page 83: Steering Head Bearings

    MAINTENANCE Check the tire pressure with a tire pressure gauge TIRE PRESSURE GAUGE when the tires are cold. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FRONT REAR Tire pressure Driver only kPa (kgf/cm , psi) (2.00, 29) (2.25, 33) Driver and passenger (2.00, 29) (2.25, 33)
  • Page 84 MEMO...
  • Page 85 4. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ·········· 4-2 TROUBLESHOOTING································· 4-3 SERVICE INFORMATION ··························· 4-3 OIL PUMP ··················································· 4-4...

  • Page 86: Lubrication System Diagram

    LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM CAMSHAFT ROCKER ARM CRANKSHAFT OIL PUMP OIL STRAINER SCREEN MAINSHAFT COUNTERSHAFT...

  • Page 87: Troubleshooting

    – the circular API service label) JASO T 903 standard: MA Viscosity: SAE 10W-30 CM type only Pro Honda GN4 4-stroke oil or equiva- lent motor oil API service classification: SG or Higher – JASO T 903 standard: MA Viscosity: SAE 10W-30...

  • Page 88: Oil Pump

    LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the right crankcase cover (page 10-5). OIL PUMP ASSEMBLY Remove the mounting bolts and oil pump assem- bly. BOLTS DISASSEMBLY Remove the E-clip from the oil pump shaft. E-CLIP OIL PUMP SHAFT Remove the oil pump driven gear assembly and dis- BOLTS COVER assemble them.
  • Page 89 LUBRICATION SYSTEM INSPECTION OIL PUMP DRIVEN GEAR/OIL PUMP SHAFT/LOCK Check the oil pump driven gear, oil pump shaft and DRIVEN GEAR OIL PUMP SHAFT lock pin for wear or damage, replace them if neces- sary. LOCK PIN OIL SEAL Check the oil seal for damage or deterioration, OIL SEAL replace it if necessary.
  • Page 90 LUBRICATION SYSTEM Measure the body clearance. BODY CLEARANCE: SERVICE LIMIT: 0.26 mm (0.010 in) Remove the oil pump shaft. SIDE CLEARANCE: Measure the side clearance using a straight edge and feeler gauge. SERVICE LIMIT: 0.12 mm (0.005 in) ASSEMBLY OIL PUMP BODY OUTER ROTOR INNER ROTOR OIL PUMP COVER...
  • Page 91 LUBRICATION SYSTEM Apply engine oil to the inner and outer rotors entire Align OIL PUMP BODY surface. Install the oil pump inner and outer rotors in to the oil pump body with aligning the both punch marks. OUTER ROTOR INNER ROTOR Install the lock pin into the oil pump shaft, then DRIVEN GEAR OIL PUMP SHAFT...
  • Page 92 LUBRICATION SYSTEM Install the E-clip to the oil pump shaft. Set the flat surface E-CLIP of the E-clip is upward. OIL PUMP SHAFT INSTALLATION Install the oil pump assembly. OIL PUMP ASSEMBLY Install and tighten the mounting bolts securely. Install the right crankcase cover (page 10-8). BOLTS...
  • Page 93 5. FUEL SYSTEM (PGM-FI) COMPONENT LOCATION ·························· 5-2 MIL CIRCUIT TROUBLESHOOTING ········ 5-44 SERVICE INFORMATION ··························· 5-3 FUEL LINE INSPECTION ·························· 5-44 PGM-FI SYMPTOM FUEL PUMP UNIT ···································· 5-48 TROUBLESHOOTING ································· 5-5 FUEL TANK ··············································· 5-51 PGM-FI SYSTEM LOCATION ····················· 5-6 AIR CLEANER HOUSING ·························...

  • Page 94: Component Location

    FUEL SYSTEM (PGM-FI) COMPONENT LOCATION FUEL SYSTEM (PGM-FI) 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

  • Page 95: Service Information

    FUEL SYSTEM (PGM-FI) SERVICE INFORMATION GENERAL • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. • Before disconnecting the fuel feed hose, relieve fuel pressure from the system by disconnecting the quick connect fit- ting at the fuel pump (page 5-44).
  • Page 96 FUEL SYSTEM (PGM-FI) TOOLS Fuel pressure gauge Pressure gauge manifold Hose attachment, 9 mm/9 mm 07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0120 Hose attachment, 6 mm/9 mm Attachment joint, 6 mm/9 mm ECM test harness 33P 07ZAJ-S5A0130 07ZAJ-S5A0150 070MZ-MCA0100 SCS connector Test probe 070PZ-ZY30100 07ZAJ-RDJA110...
  • Page 97 FUEL SYSTEM (PGM-FI) PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 5-14) and begin the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the ECM memory, do the diag- nostic procedure for the symptom, in sequence listed below, until you find cause.

  • Page 98: Pgm-Fi System Location

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION IGNITION SWITCH BANK ANGLE ECT SENSOR SENSOR FUEL PUMP INJECTOR SENSOR SENSOR UNIT: – MAP SENSOR CKP SENSOR IACV – IAT SENSOR – TP SENSOR THROTTLE BODY IACV MAP SENSOR SENSOR UNIT TP SENSOR IAT SENSOR...

  • Page 99: Pgm-Fi System Diagram

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM DIAGRAM ALTERNATOR MAIN R/Bl RELAY IGNITION SWITCH ENGINE STOP SWITCH STARTER (CM AND U TYPE) RELAY SWITCH REGULATOR/ RECTIFIER Bl/W STARTER SENSOR SWITCH BATTERY NEUTRAL INDICATOR Lg/Bl Lg/R Bl/W NLSW NEUTRAL CLUTCH SWITCH SWITCH W/Bl WARN FI INDICATOR 25 SSTAND...

  • Page 100: Pgm-Fi Connector Locations

    FUEL SYSTEM (PGM-FI) PGM-FI CONNECTOR LOCATIONS NOTE 1: Remove the upper cowl (page 2-10). BANK ANGLE SENSOR 3P (GRAY) CONNECTOR (NOTE 1) NOTE 2: Remove the right middle cowl (page 2-9). SENSOR 2P (NATURAL) CONNECTOR (NOTE 2)
  • Page 101 FUEL SYSTEM (PGM-FI) NOTE 1: Lift and support the fuel tank (page 3-6). NOTE 2: Open the rubber sheet (page 6-10). ECM 33P CONNECTOR (NOTE1, NOTE 2) ECT SENSOR 3P (GRAY) CONNECTOR (NOTE 1) INJECTOR 2P (BLACK) CONNECTOR (NOTE 1) IACV 4P (BLACK) CONNECTOR (NOTE 1) SENSOR UNIT 5P (BLACK) CONNECTOR...

  • Page 102: General Troubleshooting

    FUEL SYSTEM (PGM-FI) PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out, the original problem may be intermittent.
  • Page 103 FUEL SYSTEM (PGM-FI) MIL Blink Pattern • If the HDS pocket tester is not available, DTC can be read from the ECM memory by the MIL blink pattern. • The number of MIL blinks is the equivalent the main code of the DTC (the sub code cannot be displayed by the MIL).
  • Page 104 FUEL SYSTEM (PGM-FI) DTC READOUT Start the engine and check the MIL. • If the engine will not start, turn the starter motor for more than 10 seconds and check that the MIL blinks. • When the ignition switch is turned ON (and engine stop switch " ": CM and U type), the MIL will stay on for a few seconds, then go off.
  • Page 105 FUEL SYSTEM (PGM-FI) CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR • Always clean around and keep any foreign material away from the ECM 33P connector before disconnecting it. • A faulty PGM-FI system is often related to poorly connected or cor- roded terminals.

  • Page 106: Dtc Index

    FUEL SYSTEM (PGM-FI) DTC INDEX Refer Refer (MIL Function Failure Symptom/Fail-safe function blinks) (DTC) (MIL) MAP sensor circuit low voltage (less than 0.19 V) • Engine operates normally 1-1 (1) • MAP sensor or its circuit malfunction • Pre-program value: 760 mmHg/ 5-17 1,013 hPa 5-33...

  • Page 107: Sensor Unit Power Line

    FUEL SYSTEM (PGM-FI) SENSOR UNIT POWER LINE INSPECTION BEFORE DTC TROUBLRESHOOTING • When the DTC displays 1-1, 1-2, 8-1, 8-2, 9-1 and 9-2, check the following before DTC trouble- shooting. • Before starting the inspection, check for loose or poor contact on the sensor unit 5P connector and ECM 33P connector.
  • Page 108 FUEL SYSTEM (PGM-FI) BEFORE MIL TROUBLESHOOTING • When the MIL blinks 1, 8 and 9 times, check the following before MIL troubleshooting. • Before starting the inspection, check for loose or poor contact on the sensor unit 5P connector and ECM 33P connector.

  • Page 109: Dtc Troubleshooting

    FUEL SYSTEM (PGM-FI) 4. Sensor Unit Input Voltage Line Open Circuit Inspection Check for continuities between the test harness and sensor unit 5P connector of the wire side. Connection: 6 – White/red 4 – Green/orange Is there continuity? – Intermittent failure –...
  • Page 110 FUEL SYSTEM (PGM-FI) 4. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Check for continuity between the sensor unit 5P (Wire side/female terminal) connector of the wire side and ground. Connection: Light green/yellow – ground Is there continuity? Lg/Y –...
  • Page 111 FUEL SYSTEM (PGM-FI) 3. MAP Sensor System Inspection 2 Turn the ignition switch OFF. JUMPER WIRE Disconnect the sensor unit 5P connector. Connect the sensor unit 5P connector terminals at the wire side with a jumper wire. Connection: Light green/yellow – Green/orange Lg/Y Turn the ignition switch ON (and engine stop switch "...
  • Page 112 FUEL SYSTEM (PGM-FI) 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance between the ECT sensor terminals. Connection: Yellow/blue – Green/orange Standard: 2.3 – 2.6 kΩ (20°C/68°F) Is the resistance within 2.3 – 2.6 k Ω (20 ° C/68 ° F)? –...
  • Page 113 FUEL SYSTEM (PGM-FI) 2. ECT Sensor Inspection Turn the ignition switch OFF. ECT SENSOR 3P CONNECTOR Disconnect the ECT sensor 3P connector. (Wire side/female terminals) Connect the ECT sensor 3P connector terminals at the wire side with a jumper wire. Connection: Yellow/blue –...
  • Page 114 FUEL SYSTEM (PGM-FI) 3. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P connector. (Wire side/female terminal) Check for continuity between the sensor unit 5P connector of the wire side and ground. Connection: Yellow/black –...
  • Page 115 FUEL SYSTEM (PGM-FI) 2. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 5-15). Is the sensor unit power line normal? – GO TO STEP 3. – Replace or repair the abnormal circuit. 3. TP Sensor Resistance Inspection Turn the ignition switch OFF.
  • Page 116 FUEL SYSTEM (PGM-FI) 4. IAT Sensor Voltage Input Line Short Circuit Inspection Check for continuity between the sensor unit 5P SENSOR UNIT 5P CONNECTOR connector of the wire side and ground. (Wire side/female terminal) Connection: Gray/blue – Ground Is there continuity? –...
  • Page 117 FUEL SYSTEM (PGM-FI) 4. IAT Sensor Voltage Input Line Open Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the ECM 33P connector. (Wire side/female terminal) Check the continuity at the Gray/blue wire between the sensor unit 5P and ECM 33P con- nectors.
  • Page 118 FUEL SYSTEM (PGM-FI) 3. Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. INJECTOR 2P CONNECTOR Check for continuity between the injector 2P con- (Wire side/female terminal) nector of wire side and ground. Connection: Pink/green – Ground Is there continuity? –...
  • Page 119 FUEL SYSTEM (PGM-FI) DTC 21-1 (O SENSOR) • Do not get grease, oil or other materials in the O sensor air hole. • Do not reuse O sensor cord, if the O sensor cap is disconnected, replace the O sensor cord with a new one.
  • Page 120 FUEL SYSTEM (PGM-FI) 4. O Sensor Inspection Replace the O sensor and O sensor cord with a known good one (page 5-67). Clear the DTC’s (page 5-12). Connect the O sensor 2P connector and ECM 33P connector. Turn the ignition switch ON (and engine stop switch "...
  • Page 121 FUEL SYSTEM (PGM-FI) 3. IACV Open Circuit Inspection Disconnect the ECM 33P connector. Check the continuities between the ECM 33P and IACV 4P CONNECTOR IACV 4P connectors of the wire side. (Wire side/female terminals) Connection: 20 (Pink/black) – Pink/black 21 (Blue/black) – Blue/black 31 (Brown/yellow) –...
  • Page 122 FUEL SYSTEM (PGM-FI) DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE) 1. Recheck DTC Clear the DTC’s (page 5-12). Turn the ignition switch ON (and engine stop switch " ": CM and U type). Check the bank angle sensor with the HDS pocket tester.
  • Page 123 FUEL SYSTEM (PGM-FI) 4. Bank Angle Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. BANK ANGLE SENSOR 3P CONNECTOR Disconnect the ECM 33P connector. (Wire side/female terminal) Check the continuity between the bank angle sensor 3P connector of the wire side and ground.
  • Page 124 FUEL SYSTEM (PGM-FI) 2. Bank Angle Sensor Power Input Voltage Inspection Turn the ignition switch OFF. BANK ANGLE SENSOR 3P CONNECTOR Disconnect the bank angle sensor 3P connector. (Wire side/female terminals) Turn the ignition switch ON (and engine stop switch " ": CM and U type). Measure the voltage at the bank angle sensor connector of the wire side.

  • Page 125: Mil Troubleshooting

    FUEL SYSTEM (PGM-FI) MIL TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 5-16). Is the sensor unit power line normal? – GO TO STEP 2. – Replace or repair of the abnormal cir- cuit.
  • Page 126 FUEL SYSTEM (PGM-FI) 5. MAP Sensor Output Line Open Circuit Inspection 2 Check the continuity between the ECM test har- SENSOR UNIT 5P CONNECTOR ness and sensor unit 5P connector of the wire (Wire side/female terminal) side. Connection: 27 – Light green/yellow Is there continuity? –...
  • Page 127 FUEL SYSTEM (PGM-FI) 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor termi- nals. Connection: Yellow/blue – Green/orange Standard: 2.3 – 2.6 kΩ (20°C/68°F) Is the resistance within 2.3 – 2.6 k Ω (20 ° C/68 ° F)? –...
  • Page 128 FUEL SYSTEM (PGM-FI) MIL 8 BLINKS (TP SENSOR) 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 5-16). Is the sensor unit power line normal? – GO TO STEP 2. – Replace or repair the abnormal circuit. 2.
  • Page 129 FUEL SYSTEM (PGM-FI) MIL 9 BLINKS (IAT SENSOR) 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 5-16). Is the sensor unit power line normal? – GO TO STEP 2. – Replace or repair the abnormal circuit. 2.
  • Page 130 FUEL SYSTEM (PGM-FI) 5. IAT Sensor Voltage Input Line Open Circuit Inspection Check for continuity at the Gray/blue wire SENSOR UNIT 5P CONNECTOR between the sensor unit 5P connector of the wire (Wire side/female terminal) side and ECM test harness. Connection: 14 –...
  • Page 131 FUEL SYSTEM (PGM-FI) 2. Injector Signal Line Short Circuit Inspection Turn the ignition switch OFF. INJECTOR 2P CONNECTOR Check for continuity between the injector 2P con- (Wire side/female terminal) nector of the wire side and ground. Connection: Pink/green – Ground Is there continuity? –...
  • Page 132 FUEL SYSTEM (PGM-FI) MIL 21 BLINKS (O SENSOR) • Do not get grease, oil or other materials in the O sensor air hole. • Do not reuse O sensor cord, if the O sensor cap is disconnected, replace the O sensor cord with a new one.
  • Page 133 FUEL SYSTEM (PGM-FI) 4. O Sensor Inspection Replace the O sensor and O sensor cord with a known good one (page 5-67). Disconnect the ECM test harness and connect the ECM 33P connector. Turn the ignition switch ON (and engine stop switch "...
  • Page 134 FUEL SYSTEM (PGM-FI) 3. IACV Open Circuit Inspection Connect the ECM test harness to ECM 33P con- nector. Check the continuities between the ECM test har- ness and IACV 4P connector of the wire side. (21) Connection: 20 – Pink/black (20) 21 –...
  • Page 135 FUEL SYSTEM (PGM-FI) 3. Bank Angle Sensor Input Voltage Line Open Circuit Inspection Connect the ECM test harness to the ECM 33P connector. Check the continuities between the ECM test har- ness and bank angle sensor 3P connector of the wire side.

  • Page 136: Mil Circuit Troubleshooting

    FUEL SYSTEM (PGM-FI) MIL CIRCUIT TROUBLESHOOTING If the engine can be started but the MIL does not ECM 33P CONNECTOR come on when the ignition switch is turned ON (and engine stop switch " ": CM and U type), check as follows: Check for the combination meter function.
  • Page 137 FUEL SYSTEM (PGM-FI) 7. Check the fuel quick connect fitting for dirt, and QUICK CONNECT FITTING clean if necessary. Place a shop towel over the quick connect fitting. SHOP TOWEL 8. Pull and release the rubber cap from the retainer. RUBBER CAP RETAINER TABS 9.
  • Page 138 FUEL SYSTEM (PGM-FI) QUICK CONNECT FITTING INSTALLATION • Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected. • If any retainer needs replacing, use the same manufacturer’s retainer as the ones being removed (The various manufactures feature dif- ferent retainer specifications).

  • Page 139: Fuel Pressure Test

    FUEL SYSTEM (PGM-FI) 5. Connect the fuel pump 5P (Natural) connector. Connect the battery negative (–) cable (page 16- 6. Turn the ignition switch ON (and engine stop switch " ": CM and U type). • Do not start the engine. The fuel pump will run for about 2 seconds, and fuel pressure will rise.

  • Page 140: Fuel Pump Unit

    FUEL SYSTEM (PGM-FI) FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick connect fitting (page 5-44). Connect the special tool to the fuel pump joint. Wipe off spilled out gasoline. TOOL: Hose attachment, 6 mm/9 mm 07ZAJ-S5A0130 Place the end of the hose into an approved gasoline container.
  • Page 141 FUEL SYSTEM (PGM-FI) Turn the ignition switch ON (and engine stop switch 5P (NATURAL) CONNECTOR " ": CM and U type). Measure the voltage at the fuel pump 5P (Natural) connector terminals of the wire side. Connection: Black/white (+) – Brown/white (–) Standard: Battery voltage Bl/W...
  • Page 142 FUEL SYSTEM (PGM-FI) INSPECTION Check the fuel pump unit for wear or damage, replace it if necessary. Check the fuel filter for wear or damage. Apply engine oil to the fuel tank contacting area of the fuel pump. FUEL FILTER INSTALLATION Install a new packing onto the fuel pump unit.

  • Page 143: Fuel Tank

    FUEL SYSTEM (PGM-FI) FUEL TANK REMOVAL/INSTALLATION Relieve the fuel pressure and disconnect the quick FUEL PUMP WIRE connect fitting (page 5-44). CLAMPS Release the fuel feed hose and fuel pump wire from the clamps. Disconnect the fuel tank breather hose. FEED HOSE BREATHER HOSE Remove the bolt and fuel tank.

  • Page 144: Air Cleaner Housing

    FUEL SYSTEM (PGM-FI) AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the air cleaner element (page 3-8). Disconnect the crankcase breather hose. BREATHER HOSE Loosen the connecting hose band screw. BAND SCREW Disconnect the fuel tank drain hose. DRAIN HOSE Release the fuel feed hose and fuel pump wire from BOLTS FUEL PUMP WIRE the hose guides of the air cleaner housing.
  • Page 145 FUEL SYSTEM (PGM-FI) Disconnect the IACV 4P (Black) connector and injec- 4P (BLACK) CONNECTOR 2P (BLACK) tor 2P (Black) connector. CONNECTOR Disconnect the injector side of the quick connect fit- ting (page 5-59). QUICK CONNECT FITTING Loosen the insulator band screw (throttle body side) THROTTLE BODY ASSEMBLY and remove the throttle body assembly.
  • Page 146 FUEL SYSTEM (PGM-FI) IACV REMOVAL/INSPECTION The IACV is installed on the throttle body and is SETTING PLATE operated by the step motor. When the ignition switch is turned ON (and engine stop switch " ": CM and U type), the IACV operates for a few sec- onds.
  • Page 147 FUEL SYSTEM (PGM-FI) ASSEMBLY 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) IACV 5.1 N·m (0.5 kgf·m, 3.8 lbf·ft) INJECTOR JOINT SETTING PLATE O-RING INJEDCTOR SEAL RING SENSOR UNIT 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) O-RING THROTTLE CABLE STAY THROTTLE BODY Install the injector (page 5-61).
  • Page 148 FUEL SYSTEM (PGM-FI) IACV INSTALLATION Turn the slide valve clockwise until lightly seated on IACV. SLIDE VALVE Install the IACV aligning its groove with the slide GROOVE valve housing pin. IACV Install the setting plate while aligning the cut-out TORX SCREWS Align with the lug on the IACV as shown.
  • Page 149 FUEL SYSTEM (PGM-FI) Install the throttle body assembly to the throttle Align body insulator by aligning the tab of the throttle body with the groove of the throttle body insulator. THROTTLE BODY ASSEMBLY Tighten the insulator band screw so that the width between the band ends clearance is 7 ±...
  • Page 150 FUEL SYSTEM (PGM-FI) THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE • If the sensor unit is removed, reset the throttle valve fully closed position as following. 1. Lift and support the fuel tank (page 3-6). 2. Clear the DTC’s (page 5-12). 3.

  • Page 151: Injector

    FUEL SYSTEM (PGM-FI) 9. Success pattern see below. If the MIL begins short blink (0.3 seconds), the throttle valve fully closed position is reset. 0.3 sec. within 10 sec. 0.3 sec. 0.1 sec. MIL ON 1.2 sec. MIL OFF REST RECEIVING PATTERN SUCCESSFUL PATTERN If the MIL stays lit, the throttle valve fully closed position is not reset, repeat the reset procedure from step 2.
  • Page 152 FUEL SYSTEM (PGM-FI) 1. Pull and release the connector damper tabs from CONNECTOR DAMPER RETAINER TABS the retainer when disconnecting the injector joint quick connect fitting. 2. Hold the connector with one hand and squeeze the retainer tabs with the other hand to release them from the locking pawls.
  • Page 153 FUEL SYSTEM (PGM-FI) INSTALLATION Apply engine oil to new O-ring and seal ring. INJECTOR INJECTOR JOINT Install the O-ring and seal ring to the injector, being careful not to damage them. SEAL RING O-RING Install the injector into the injector joint, being care- INJECTOR Align ful not to damage the O-ring.

  • Page 154: Engine Idle Speed

    FUEL SYSTEM (PGM-FI) 2. Set the connector damper as shown. CONNECTOR DAMPER Then press the quick connect fitting onto the RETAINER TABS pipe until both retainer pawls lock with a "CLICK". LOCKING POWLS • Align the quick connect fitting with the injector joint.

  • Page 155: Ect Sensor

    FUEL SYSTEM (PGM-FI) ECT SENSOR REMOVAL/INSTALLATION Drain the coolant (page 6-7). Lift and support the fuel tank (page 3-6). Disconnect the ECT sensor 3P (Gray) connector. Replace the ECT sensor while the engine is cold. 3P (GRAY) CONNECTOR Remove the ECT sensor and sealing washer. ECT SENSOR SEALING WASHER Install a new sealing washer onto the ECT sensor...
  • Page 156 FUEL SYSTEM (PGM-FI) Install the bank angle sensor, collars and mounting Install the bank screw/washers. angle sensor with Tighten the mounting screws to the specified its “UP” mark torque. facing up. TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) Install the upper cowl (page 2-10). "UP"...

  • Page 157: Ecm

    FUEL SYSTEM (PGM-FI) INSPECTION WITH ECM TEST HARNESS Connect the ECM test harness (page 5-11). Remove the bank angle sensor (page 5-63). Connect the bank angle sensor 3P connector. Place the bank angle sensor horizontal as shown. Turn the ignition switch ON (and engine stop switch (26) "...
  • Page 158 FUEL SYSTEM (PGM-FI) ECM POWER/GROUND LINE INSPECTION ENGINE DOES NOT START (No DTC and MIL blinking) 1. ECM Power Input Voltage Inspection • Before starting the inspection, check for loose ECM 33P CONNECTOR or poor contact on the ECM 33P connector and recheck the MIL blinking.

  • Page 159: O 2 Sensor

    FUEL SYSTEM (PGM-FI) SENSOR • Do not get grease, oil or other materials in the O sensor air hole. • The O sensor may be damaged if dropped. Replace it with a new one, if dropped. • If the O sensor cap is disconnected, replace the sensor cord with a new one, do not reuse O sensor cord .
  • Page 160 FUEL SYSTEM (PGM-FI) INSTALLATION • Do not use an impact wrench while removing or installing the O sensor, or it may be damaged. Install and hand tighten a new O sensor onto the cylinder head. Tighten the O sensor to the specified torque. TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft) SENSOR Connect the O...
  • Page 161 6. COOLING SYSTEM SYSTEM FLOW PATTERN ························· 6-2 THERMOSTAT HOUSING·························· 6-9 SERVICE INFORMATION ··························· 6-3 RADIATOR ················································ 6-10 TROUBLESHOOTING ································· 6-4 WATER PUMP ·········································· 6-15 SYSTEM TESTING······································ 6-5 RADIATOR RESERVE TANK ···················· 6-19 COOLANT REPLACEMENT ························ 6-6 FAN CONTROL RELAY ···························· 6-20 THERMOSTAT ············································...

  • Page 162: System Flow Pattern

    COOLING SYSTEM SYSTEM FLOW PATTERN COOLING SYSTEM RADIATOR WATER HOSES SIPHON HOSE RESERVE TANK THERMOSTAT WATER HOSES WATER PUMP...

  • Page 163: Service Information

    Except CM type High quality ethylene glycol antifreeze containing silicate- free corrosion inhibitors CM type only Pro Honda HP coolant or equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibi- tors Standard coolant concentration 1:1 (mixture with distilled water)

  • Page 164: Troubleshooting

    COOLING SYSTEM TOOLS Driver Bearing remover shaft Remover weight 07749-0010000 07936-KC10100 07741-0010201 Bearing remover head, 14 mm Oil seal driver attachment, 36 mm 07WMC-KFG0100 07945-4150400 TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or ECT sensor • Thermostat stuck closed •...

  • Page 165: System Testing

    COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the inner cowl (page 2-7). RADIATOR CAP Remove the screw and radiator cap. SCREW Test the coolant gravity using a hydrometer (see HYDROMETER below for "COOLANT GRAVITY CHART"). Look for contamination and replace the coolant if necessary.

  • Page 166: Coolant Replacement

    High quality ethylene glycol antifreeze containing GLYCOL BASE WATER silicate-free corrosion inhibitors SOLUTION) RECOMMENDED ANTIFREEZE (CM type only): Pro Honda HP coolant or equivalent high quality COOLANT ethylene glycol antifreeze containing silicate-free corrosion inhibitors STANDARD COOLANT CONCENTRATION: 1:1 (mixture with distilled water)
  • Page 167 COOLING SYSTEM REPLACEMENT/AIR BLEEDING Remove the following: – Lower cowl (page 2-8) – Radiator cap (page 6-5) – Single seat (page 2-4) Remove the drain bolt on the water pump cover and drain the system coolant. Reinstall the drain bolt with a new sealing washer. Install and tighten the drain bolt securely.

  • Page 168: Thermostat

    COOLING SYSTEM Remove the reserve tank cap and fill the reserve "UPPER" LEVEL LINE tank to the "UPPER" level line. Install the reserve tank cap. Install the following: – Single seat (page 2-4) – Lower cowl (page 2-8) RESERVE TANK THERMOSTAT REMOVAL Drain the coolant (page 6-7).

  • Page 169: Thermostat Housing

    COOLING SYSTEM Heat the water with an electric heating element to Wear insulated operating temperature for 5 minutes. gloves and Suspend the thermostat in heated water to check its adequate eye operation. protection. Keep flammable THERMOSTAT BEGIN TO OPEN: materials away 74 –...

  • Page 170: Radiator

    COOLING SYSTEM RADIATOR REMOVAL Drain the coolant (page 6-7). TRIM CLIP RUBBER SHEET Lift and support the fuel tank (page 3-6). Remove the middle cowl (page 2-9). Remove the trim clip. Open the rubber sheet. Disconnect the fan motor 2P (Natural) connector. 2P (NATURAL) CONNECTOR Disconnect the siphon hose from the radiator.
  • Page 171 COOLING SYSTEM Remove the radiator lower mounting bolt and col- lar. COLLAR BOLT Disconnect the horn connectors. STAY BOLT GROMMET Remove the radiator upper mounting bolt and horn mounting stay. Release the radiator upper grommet from the frame Be careful not to boss by moving the radiator to the right, then damage the radiator remove the radiator assembly.
  • Page 172 COOLING SYSTEM Remove the screws and fan motor from the fan FAN MOTOR motor shroud. SCREWS/WASHERS SHROUD ASSEMBLY RADIATOR 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) COOLING FAN FAN MOTOR FAN MOTOR SHROUD 8.4 N·m (0.9 kgf·m, 6.2 lbf·ft) COLLAR 2.8 N·m (0.3 kgf·m, 2.1 lbf·ft) Install the fan motor onto the fan motor shroud.
  • Page 173 COOLING SYSTEM Install the cooling fan onto the fan motor shaft by Align aligning the flat surfaces. COOLING FAN Apply locking agent to the cooling fan nut threads. Install and tighten the nut to the specified torque. TORQUE: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) Install the fan motor assembly onto the radiator.
  • Page 174 COOLING SYSTEM Install the collar and radiator lower mounting bolt. COLLAR BOLT Connect the upper water hose and tighten the water WATER HOSE hose band screw. Connect the lower water hose and siphon hose. SIPHON HOSE WATER HOSE Tighten the water hose band screws as shown. After installation, check the radiator and radiator hoses for leaks.

  • Page 175: Water Pump

    COOLING SYSTEM Connect the fan motor 2P (Natural) connector. 2P (NATURAL) CONNECTOR Close the rubber sheet. TRIM CLIP RUBBER SHEET Install the trim clip. Install the middle cowl (page 2-9). Remove the suitable support and close the fuel tank (page 3-6). Fill the system with the recommended coolant (page 6-6).
  • Page 176 COOLING SYSTEM Remove the right crankcase cover (page 10-5). IMPELLER Hold the water pump shaft and remove the impeller and plain washer. PLAIN WASHER Remove the water pump driven gear assembly and DRIVEN GEAR ASSEMBLY washer from the right crankcase cover and disas- semble them.
  • Page 177 COOLING SYSTEM Remove the oil seal. OIL SEAL ASSEMBLY/INSTALLATION LOCK PIN WASHER PUMP SHAFT WASHER MECHANICAL SEAL WASHER PUMP COVER PLAIN WASHER O-RING WASHER PUMP DRIVEN GEAR OIL SEAL IMPELLER 10 N·m (1.0 kgf·m, 7 lbf·ft) SEALING WASHER Install a new oil seal to the right crankcase cover. MECHANICAL SEAL Set and drive in a new mechanical seal using the Be careful not to...
  • Page 178 COOLING SYSTEM Install the lock pin to the water pump shaft, then DRIVEN GEAR WATER PUMP SHAFT install the water pump driven gear aligning the driven gear groove with the lock pin. Align LOCK PIN Install the washer to the water pump shaft. DRIVEN GEAR ASSEMBLY Apply engine oil to the water pump shaft outer sur- face.

  • Page 179: Radiator Reserve Tank

    COOLING SYSTEM Install a new O-ring to the water pump cover. O-RING COVER Install the water pump cover. Install and tighten the bolts, drain bolt and new BOLTS sealing washer securely. Fill the recommended coolant mixture to the filler neck and bleed the air (page 6-6). DRAIN BOLT/SEALING WASHER RADIATOR RESERVE TANK REMOVAL/INSTALLATION...

  • Page 180: Fan Control Relay

    COOLING SYSTEM FAN CONTROL RELAY INSPECTION Remove the rear cowl (page 2-5). FAN CONTROL RELAY Remove the fan control relay. Connect a ohmmeter to the fan control relay con- FAN CONTROL RELAY nector terminals. Connect a 12 V battery to the fan control relay con- Bl/Bu nector terminals as shown.
  • Page 181 7. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ·························· 7-2 ENGINE REMOVAL ···································· 7-4 SERVICE INFORMATION ··························· 7-3 ENGINE INSTALLATION···························· 7-6...
  • Page 182 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION 60 N·m (6.1 kgf·m, 44 lbf·ft) 60 N·m (6.1 kgf·m, 44 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 183 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • A hoist or equivalent is required to support the motorcycle when removing and installing the engine. • When removing/installing the engine, tape the frame around the engine beforehand for frame protection. • The following components can be serviced with the engine installed in the frame. –...

  • Page 184: Engine Removal

    ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-14). ADJUSTING NUT CLUTCH CABLE Drain the coolant (page 6-7). Remove the following: – Middle cowl (page 2-9) – Gearshift arm and left step holder (page 10-18) – Throttle body (page 5-52) –...
  • Page 185 ENGINE REMOVAL/INSTALLATION Loosen the water hose band screws and disconnect WATER HOSES the water hoses. BAND SCREWS Disconnect the O sensor 2P (Natural) connector Do not disconnect SPARK PLUG CAP and spark plug cap. the O sensor cap from the O sensor.

  • Page 186: Engine Installation

    ENGINE REMOVAL/INSTALLATION Remove the upper and lower engine hanger bolts and nuts. Remove the engine from the frame. During engine removal, hold the engine securely and be careful not to damage the frame and engine. BOLTS/NUTS ENGINE INSTALLATION • Note the direction of the engine hanger bolts. •...
  • Page 187 ENGINE REMOVAL/INSTALLATION Install the ground cable and starter motor mounting BOLT STARTER MOTOR CABLE bolt. Tighten the mounting bolt securely. Install the starter motor cable and starter motor ter- minal nut. RUBBER CAP Tighten the terminal nut securely and reposition the rubber cap properly on the starter motor terminal.
  • Page 188 ENGINE REMOVAL/INSTALLATION Install and tighten the drive sprocket fixing plate BOLTS bolts to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Connect the alternator/CKP sensor 6P (Natural) con- 6P (NATURAL) CONNECTOR nector and neutral switch wire connector. Install the alternator/CKP sensor and neutral switch Route the wires wires from the clamp.
  • Page 189 8. CYLINDER HEAD/VALVES COMPONENT LOCATION ·························· 8-2 CYLINDER HEAD COVER··························· 8-6 SERVICE INFORMATION ··························· 8-3 CAMSHAFT················································· 8-8 TROUBLESHOOTING ································· 8-5 CAMSHAFT HOLDER ······························· 8-12 CYLINDER COMPRESSION························ 8-6 CYLINDER HEAD ······································ 8-15...

  • Page 190: Component Location

    CYLINDER HEAD/VALVES COMPONENT LOCATION CYLINDER HEAD/VALVES 10 N·m (1.0 kgf·m, 7 lbf·ft) 29 N·m (3.0 kgf·m, 21 lbf·ft) 9 N·m (0.9 kgf·m, 6.6 lbf·ft) 4.0 N·m (0.4 kgf·m, 3.0 lbf·ft)
  • Page 191 CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves, rocker arms and camshaft. • The camshaft service can be done with the engine installed in the frame. The cylinder head service requires engine removal. •...
  • Page 192 CYLINDER HEAD/VALVES TOOLS Valve spring compressor Valve spring compressor attach- Valve guide driver, 5.0 mm 07757-0010000 ment 07942-8920000 07959-KM30101 Seat cutter, 24 mm (45° EX) Seat cutter, 29 mm (45° IN) Flat cutter, 27 mm (32° EX) 07780-0010600 07780-0010300 07780-0013300 Flat cutter, 30 mm (32°...
  • Page 193 CYLINDER HEAD/VALVES Compression gauge attachment Valve guide driver 07RMJ-MY50100 07743-0020000 or equivalent commercially avail- able TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. •...

  • Page 194: Cylinder Compression

    CYLINDER HEAD/VALVES CYLINDER COMPRESSION Warm the engine to normal operating temperature. COMPRESSION GAUGE Stop the engine. Remove the spark plug (page 3-9). Install the compression gauge attachment into the spark plug hole. Connect the compression gauge to the attachment. TOOL: Compression gauge attachment 07RMJ-MY50100 or equivalent com- mercially available...
  • Page 195 CYLINDER HEAD/VALVES Remove the cylinder head cover bolts, rubber seals, BOLTS/RUBBER SEALS cylinder head cover and packing. COVER/PACKING INSTALLATION Install a new packing into the cylinder head cover PACKING COVER groove. Install the cylinder head cover onto the cylinder head. Check the rubber seals are in good condition, "UP"...

  • Page 196: Camshaft

    CYLINDER HEAD/VALVES CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-6). The camshaft can PLUG Make sure the piston is at TDC (Top Dead Center) on be serviced with the compression stroke (page 3-11). the engine installed in the frame. Loosen the lock nuts and adjusting screws.
  • Page 197 CYLINDER HEAD/VALVES Remove the snap ring from the camshaft holder. SNAP RING CAMSHAFT HOLDER Remove the camshaft from the camshaft holder CAMSHAFT while holding the rocker arms to make a good access for camshaft removal. CAMSHAFT HOLDER INSPECTION CAMSHAFT BEARING Turn the outer race of each bearing with your finger.
  • Page 198 CYLINDER HEAD/VALVES INSTALLATION Apply engine oil to the camshaft bearings rotating BEARINGS area. Apply molybdenum oil solution to the cam lobes. LOBES Install the camshaft into the camshaft holder while Make sure the tab holding the rocker arms to make a good access for of the camshaft camshaft installation.
  • Page 199 CYLINDER HEAD/VALVES Apply engine oil to the cam chain entire surface. CAM CHAIN INDEX LINE Install the cam chain over the cam sprocket so that the index line of the cam sprocket is flush with the cylinder head upper surface as shown. Align the bolt holes in the cam sprocket and cam- shaft.

  • Page 200: Camshaft Holder

    CYLINDER HEAD/VALVES CAMSHAFT HOLDER REMOVAL Remove the cylinder head cover (page 8-6). NUTS/WASHERS Remove the cam sprocket (page 8-8). Loosen the cylinder head bolts alternately in several steps. Loosen the camshaft holder mounting nuts in a Be careful not to let crisscross pattern in several steps, and remove the the camshaft holder washers and camshaft holder assembly.
  • Page 201 CYLINDER HEAD/VALVES INSPECTION ROCKER ARM/ROCKER ARM SHAFT Check the sliding surface of each rocker arm and OIL HOLE rocker arm shaft for wear or damage. Check the oil hole for clog of each rocker arm. Measure the rocker arm I.D. SERVICE LIMIT: 10.10 mm (0.398 in) Measure the rocker arm shaft O.D.
  • Page 202 CYLINDER HEAD/VALVES Apply molybdenum oil solution to each rocker arm ROCKER ARMS SHAFTS shaft outer surface. Set the rocker arm into the camshaft holder with the camshaft contact area facing the cylinder head as shown, then install the rocker arm shaft with the threads facing the bolt hole into the camshaft holder through the rocker arm.

  • Page 203: Cylinder Head

    CYLINDER HEAD/VALVES CYLINDER HEAD If the O sensor cap is disconnected, replace the O sensor cord with a new one. REMOVAL Remove the following: CYLINDER HEAD – Engine (page 7-4) – Camshaft holder (page 8-12) Remove the cylinder head bolts and cylinder head. Be careful not to let the cylinder head bolts fall into the...
  • Page 204 CYLINDER HEAD/VALVES Remove the valve spring cotters using the special To prevent loss of VALVE SPRING COMPRESSOR tools. tension, do not compress the valve TOOLS: springs more than Valve spring compressor 07757-0010000 necessary to Valve spring compressor remove the cotters. attachment 07959-KM30101 ATTACHMENT...
  • Page 205 CYLINDER HEAD/VALVES VALVE SPRING Check the valve springs for fatigue or damage. Measure the free length of the inner and outer valve springs. OUTER SPRING INNER SPRING SERVICE LIMITS: INNER: 31.0 mm (1.22 in) OUTER: 34.0 mm (1.34 in) Replace the springs if they are shorter than the ser- vice limits.

  • Page 206: Valve Guide Replacement

    CYLINDER HEAD/VALVES Measure each valve guide I.D. and record it. SERVICE LIMIT: IN/EX: 5.04 mm (0.198 in) Subtract each valve stem O.D. from the correspond- ing guide I.D. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.065 mm (0.0026 in) EX: 0.075 mm (0.0030 in) If the stem-to-guide clearance exceeds the service limit, determine if a new guide with standard...

  • Page 207: Valve Seat Inspection

    CYLINDER HEAD/VALVES While the cylinder head is still heated, take off a new VALVE GUIDE DRIVER valve guides from the freezer. Drive the guides in the cylinder head from the cam- shaft side. TOOL: Valve guide driver 07743-0020000 After installing the valve guides, measure the valve guide height from the cylinder head.
  • Page 208 CYLINDER HEAD/VALVES • Contact area (too high or too low area): – Reface the valve seat. TOO HIGH TOO LOW Inspect the width of the valve seat. The valve seat contact should be within the speci- fied width and even all around the circumference. STANDARD: 0.90 –...
  • Page 209 CYLINDER HEAD/VALVES Use a 45° cutter, remove any roughness or irregu- Reface the valve ROUGHNESS ° larities from the seat. seat with a 45 cutter when a valve TOOLS: guide is replaced. Seat cutter, 24 mm (45° EX) 07780-0010600 Seat cutter, 29 mm (45° IN) 07780-0010300 Cutter holder, 5.0 mm 07781-0010400...
  • Page 210 CYLINDER HEAD/VALVES After cutting the seat, apply lapping compound to HAND the valve face and lap the valve using light pressure. LAPPING TOOL • Excessive lapping pressure may deform or dam- age the seat. • Change the angle of lapping tool frequently to prevent uneven seat wear.
  • Page 211 CYLINDER HEAD/VALVES Install the inner and outer valve springs with the tightly wound coils should face toward the combus- tion chamber. INNER SPRING OUTER SPRING Combustion chamber side Install the spring retainer. Grease the cotters VALVE SPRING COMPRESSOR to ease installation. Compress the valve spring using the special tools To prevent loss of and install the valve cotters.
  • Page 212 CYLINDER HEAD/VALVES INSTALLATION Clean any gasket material from the cylinder mating Do not allow dust DOWEL PINS surfaces. and dirt to enter the crankcase. Install the dowel pins and new gasket. GASKET Route the cam chain through the cylinder head and CYLINDER HEAD install the cylinder head onto the cylinder.
  • Page 213 9. CYLINDER/PISTON COMPONENT LOCATION ·························· 9-2 TROUBLESHOOTING································· 9-3 SERVICE INFORMATION ··························· 9-3 CYLINDER/PISTON ···································· 9-4...

  • Page 214: Component Location

    CYLINDER/PISTON COMPONENT LOCATION CYLINDER/PISTON...

  • Page 215: Troubleshooting

    CYLINDER/PISTON SERVICE INFORMATION GENERAL • This section covers maintenance of the cylinder and piston. To service these parts, the engine must be removed from the frame. • Take care not to damage the cylinder wall and piston. • Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal.

  • Page 216: Cylinder/Piston

    CYLINDER/PISTON CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder head (page 8-15). Remove the cam chain guide. CAM CHAIN GUIDE Remove the cam chain tensioner lifter mounting TENSIONER LIFTER BOLTS bolts. Remove the cam chain tensioner lifter and gasket. GASKET Loosen the water hose band screw and disconnect the water hose.

  • Page 217: Piston Removal

    CYLINDER/PISTON Remove the dowel pins and gasket. GASKET DOWEL PINS PISTON REMOVAL Remove the piston pin clips with pliers. Place a clean shop towel over the crankcase to prevent the piston pin clips from falling into the crankcase. PISTON PIN CLIPS Push the piston pin out of the piston and connecting PISTON rod, and remove the piston.
  • Page 218 CYLINDER/PISTON Clean carbon deposits from the piston ring grooves Never use a wire PISTON PISTON RING with a used piston ring that will be discarded. brush; it will scratch the grooves. INSPECTION CAM CHAIN GUIDE Check the cam chain guide for excessive wear or CAM CHAIN GUIDE damage, replace if necessary.
  • Page 219 CYLINDER/PISTON Check the top of the cylinder for warpage with a straight edge and feeler gauge across the stud and bolt holes. SERVICE LIMIT: 0.05 mm (0.002 in) PISTON/PISTON RING Check the piston for cracks or other damage. Check the ring grooves for excessive wear and car- bon build-up.
  • Page 220 CYLINDER/PISTON Insert the piston ring into the bottom of the cylinder PISTON RING squarely using the piston crown. Measure the piston ring end gap. SERVICE LIMITS: Top: 0.40 mm (0.016 in) Second: 0.70 mm (0.028 in) Oil: 1.10 mm (0.043 in) CONNECTING ROD Measure the connecting rod small end I.D.

  • Page 221: Piston Installation

    CYLINDER/PISTON PISTON INSTALLATION Apply engine oil to the piston ring entire surface. Carefully install the piston rings into the piston ring Be careful not to TOP RING grooves with the markings facing up. damage the piston and rings. MARK • Do not confuse the top and second rings. MARK •...

  • Page 222: Cylinder Installation

    CYLINDER/PISTON Install new piston pin clips into the grooves of the CUT-OUT piston pin hole. • Always use new piston pin clips. Reinstalling used piston pin clips may lead to serious engine damage. • Set the piston pin clip in the groove properly. •...
  • Page 223 CYLINDER/PISTON Install a new gasket on the cam chain tensioner GASKET lifter and install them to the cylinder. Install and tighten the cam chain tensioner mount- TENSIONER LIFTER BOLTS ing bolts. Install the cam chain guide, aligning its tabs with CAM CHAIN GUIDE the cylinder grooves and its end with the left crank- case groove.
  • Page 224 MEMO...
  • Page 225 10. CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION ························ 10-2 CLUTCH ···················································· 10-9 SERVICE INFORMATION ························· 10-3 GEARSHIFT LINKAGE ···························· 10-15 TROUBLESHOOTING ······························· 10-4 GEARSHIFT PEDAL ································ 10-18 RIGHT CRANKCASE COVER···················· 10-5 PRIMARY DRIVE GEAR·························· 10-20 10-1...
  • Page 226 CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION CLUTCH/GEARSHIFT LINKAGE 12 N·m (1.2 kgf·m, 9 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 10-2...
  • Page 227 CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL • This section covers service of the clutch and gearshift linkage. All services can be done with the engine installed in the frame. • Engine oil viscosity and level have an effect on clutch disengagement. Oil additives also effect clutch performance and are not recommended.
  • Page 228 CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the freeplay. Clutch lever too hard to pull in • Damaged, kinked or dirty clutch cable • Improperly routed clutch cable • Damaged clutch lifter mechanism • Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle creeps with clutch disengaged •...

  • Page 229: Right Crankcase Cover

    CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-14). ADJUSTING NUT CLUTCH CABLE Drain the coolant (page 6-7). Loosen the lock nut and adjusting nut, then discon- nect the clutch cable from the clutch lifter arm. LIFTER ARM LOCK NUT Loosen the water hose band screws and disconnect WATER HOSE...
  • Page 230 CLUTCH/GEARSHIFT LINKAGE DISASSEMBLY Remove the following: LIFTER PIECE LIFTER ARM – Clutch lifter piece – Clutch lifter arm – Return spring RETURN SPRING Remove the bolts and plate from the right crankcase BOLTS cover. PLATE Remove the rubber from the right crankcase cover. RUBBER INSPECTION Check the clutch lifter arm oil seal for wear or dam-...
  • Page 231 CLUTCH/GEARSHIFT LINKAGE Check the rubber for damage and replace if neces- RUBBER sary. Check the following: LIFTER ARM – Lifter arm for wear or damage – Return spring for fatigue or damage RETURN SPRING ASSEMBLY Install the rubber to the right crankcase cover. RUBBER Install the plate to the right crankcase cover.
  • Page 232 CLUTCH/GEARSHIFT LINKAGE Apply grease to the clutch lifter arm oil seal lips. Apply molybdenum oil solution to the clutch lifter arm sliding surface and arm end. Install the clutch lifter arm. LIFTER ARM Apply molybdenum oil solution to the clutch lifter Align arm hole inner surface.
  • Page 233 CLUTCH/GEARSHIFT LINKAGE Install the right crankcase cover, clamp and bolts. BOLTS Tighten the bolts in a crisscross pattern in 2 or 3 steps. BOLT/CLAMP Connect the water hoses and tighten the water hose WATER HOSE band screws (page 6-14). BAND SCREWS Connect the clutch cable.
  • Page 234 CLUTCH/GEARSHIFT LINKAGE Install the clutch center holder and tighten the CLUTCH CENTER HOLDER LOCK NUT clutch spring bolts securely. Loosen the clutch center lock nut using the special tools. TOOLS: Clutch center holder 07GMB-KT70101 Lock nut wrench, 20 x 24 mm 07716-0020100 Extension bar/handle 07716-0020500...
  • Page 235 CLUTCH/GEARSHIFT LINKAGE Remove the clutch outer guide and washer from the CLUTCH OUTER GUIDE WASHER mainshaft. INSPECTION CLUTCH LIFTER BEARING Turn the inner race of the lifter plate bearing with BEARING your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the lifter plate.
  • Page 236 CLUTCH/GEARSHIFT LINKAGE CLUTCH DISC Replace the clutch discs if they show signs of scor- Replace the clutch CLUTCH DISC ing or discoloration. discs and plates as a set. Measure the disc thickness of each disc. SERVICE LIMIT: 2.65 mm (0.104 in) CLUTCH PLATE Check the plate for discoloration.
  • Page 237 CLUTCH/GEARSHIFT LINKAGE INSTALLATION CLUTCH SPRING LIFTER PLATE CLUTCH PLATE CLUTCH DISC (four pieces) BEARING (five pieces) 12 N·m (1.2 kgf·m, 0.9 lbf·ft) WASHER WASHER CLUTCH OUTER GUIDE 74 N·m (7.5 kgf·m, 55 lbf·ft) CLUTCH CENTER CLUTCH OUTER PRESSURE PLATE Install the washer to the mainshaft. CLUTCH OUTER GUIDE WASHER Apply molybdenum oil solution to the clutch outer...
  • Page 238 CLUTCH/GEARSHIFT LINKAGE Apply engine oil to the clutch disc entire surfaces. DISCS/PLATES CLUTCH CENTER PRESSURE PLATE Assemble clutch discs, clutch plates and pressure plate onto clutch center, while aligning " " mark of clutch center and pressure plate. Align Install the clutch center assembly into the clutch Install the tabs of CLUTCH OUTER SHALLOW SLOT...

  • Page 239: Gearshift Linkage

    CLUTCH/GEARSHIFT LINKAGE Attach the clutch center holder to the pressure plate CLUTCH CENTER HOLDER LOCK NUT using the clutch spring bolts to hold the clutch cen- ter, then tighten the clutch center lock nut to the specified torque using the special tools. TOOLS: Clutch center holder 07GMB-KT70101...
  • Page 240 CLUTCH/GEARSHIFT LINKAGE Remove the following: STOPPER PLATE WASHER – Shift drum stopper plate bolt – Washer – Shift drum stopper plate BOLT Remove the dowel pins from the shift drum. DOWEL PINS INSPECTION Check the return spring and spindle arm spring for ARM SPRING RETURN SPRING fatigue or damage replace them if necessary.
  • Page 241 CLUTCH/GEARSHIFT LINKAGE Install the shift drum stopper plate, while aligning STOPPER PLATE Align the pins hole with the dowel pins. Install the shift drum stopper plate bolt and washer WASHER OIL SEAL to the shift drum stopper plate and install them. Tighten the bolt to the specified torque.
  • Page 242 CLUTCH/GEARSHIFT LINKAGE GEARSHIFT PEDAL REMOVAL Remove the lower cowl (page 2-8). PINCH BOLT BOLTS Remove the pinch bolt and gearshift arm. When removing the gearshift pedal, Remove the left step holder mounting bolts and left mark the pedal step holder assembly. position to ensure correct reassembly in its original...
  • Page 243 CLUTCH/GEARSHIFT LINKAGE Install the snap ring. Make sure the snap ring is firmly seated in the groove. SNAP RING INSTALLATION Install the left step holder assembly and left step PINCH BOLT BOLTS holder mounting bolts, tighten the bolts to the spec- ified torque.

  • Page 244: Primary Drive Gear

    CLUTCH/GEARSHIFT LINKAGE PRIMARY DRIVE GEAR REMOVAL If you replace the primary drive gear, be careful to select the identification color of the primary drive gear (page 10-22). Remove the following: CLUTCH OUTER/GUIDE/WASHER – Clutch assembly (page 10-9) GEAR HOLDER – Oil pump (page 4-4) Temporarily install the washer, clutch outer guide and clutch outer.
  • Page 245 CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the washer. WASHER WOODRUFF KEY Install the woodruff key onto the crankshaft. Be careful not to damage the key groove and crankshaft. Install the primary drive gear, while aligning the Align groove with the woodruff key. PRIMARY DRIVE GEAR Install the washer.
  • Page 246 CLUTCH/GEARSHIFT LINKAGE PRIMARY DRIVE GEAR SELECTION The primary drive gear has identification color. PRIMARY DRIVE GEAR PRIMARY DRIVE GER SELECTION TABLE ID COLOR WHITE 23121-KGH-900 BLUE 23122-KGH-900 YELLOW 23123-KGH-900 If the primary drive gear is replaced with a new one, select the same colored gear as the original gear.
  • Page 247 11. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ························ 11-2 STATOR/CKP SENSOR···························· 11-6 SERVICE INFORMATION ························· 11-3 FLYWHEEL REMOVAL ····························· 11-7 TROUBLESHOOTING ······························· 11-3 STARTER CLUTCH ··································· 11-8 LEFT CRANKCASE COVER ······················ 11-4 FLYWHEEL INSTALLATION ·················· 11-11 11-1...
  • Page 248 ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH 64 N·m (6.5 kgf·m, 47 lbf·ft) 11-2...
  • Page 249 ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL • This section covers the removal and installation of the flywheel, alternator and starter clutch. These services can be done with the engine installed in the frame. • For alternator inspection (page 16-7). • For CKP sensor inspection (page 17-6). •...

  • Page 250: Left Crankcase Cover

    ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Remove the lower cowl (page 2-8). COVER BOLTS Remove the bolts and drive sprocket cover. Disconnect the alternator/CKP sensor 6P (Natural) 6P (NATURAL) CONNECTOR connector. Release the alternator/CKP sensor wire from the CLAMP clamp. Loosen the left crankcase cover bolts in a crisscross The left crankcase BOLT/WASHER...
  • Page 251 ALTERNATOR/STARTER CLUTCH INSTALLATION Clean any gasket material from the mating surfaces Be careful not to GASKET of the right crankcase and cover. damage the mating surfaces. Install the dowel pins and new gasket. DOWEL PINS Install the left crankcase cover, bolts and washer. The left crankcase BOLT/WASHER cover (stater) is...
  • Page 252 ALTERNATOR/STARTER CLUTCH STATOR/CKP SENSOR REMOVAL Remove the left crankcase cover (page 11-4). CKP SENSOR STATOR Remove the grommet. Remove the CKP sensor bolts, wire guide, CKP sen- sor, stator mounting bolts and stator from the left crankcase cover. GROMMET BOLTS GUIDE INSTALLATION CKP SENSOR...

  • Page 253: Flywheel Removal

    ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL Remove the left crankcase cover (page 11-4). FLYWHEEL HOLDER NUT/ WASHER Hold the flywheel with a special tool and remove the flywheel nut and washer. TOOL: Flywheel holder 07725-0040001 Remove the flywheel using a special tool. FLYWHEEL PULLER TOOL: Flywheel puller, 30mm...

  • Page 254: Starter Clutch

    ALTERNATOR/STARTER CLUTCH Remove the woodruff key. Be careful not to WOODRUFF KEY damage the key groove and crankshaft. STARTER CLUTCH REMOVAL Remove the flywheel (page 11-7). DRIVEN GEAR Remove the starter driven gear while turning it counterclockwise. Hold the flywheel with a special tool and remove FLYWHEEL HOLDER the starter clutch torx screws.
  • Page 255 ALTERNATOR/STARTER CLUTCH DISASSEMBLY Remove the plate. PLATE Remove the rollers, spring guides and springs from ROLLER SPRING GUIDE the starter clutch outer. CLUTCH OUTER INSPECTION Check the rollers, spring guides, springs and starter GUIDE SPRING clutch outer for wear or damage. Replace the rollers for wear or damage.
  • Page 256 ALTERNATOR/STARTER CLUTCH ASSEMBLY STARTER DRIVEN GEAR STARTER CLUTCH OUTER PLATE FLYWHEEL SPRING SPRING GUIDE ROLLER 16 N·m (1.6 kgf·m, 12 lbf·ft) Install the springs, spring guides and rollers into the ROLLER SPRING GUIDE starter clutch outer. Apply engine oil to the starter clutch rolling surface. CLUTCH OUTER Install the plate.

  • Page 257: Flywheel Installation

    ALTERNATOR/STARTER CLUTCH INSTALLATION Install the starter clutch assembly to the flywheel as STARTER CLUTCH ASSEMBLY shown. FLYWHEEL Apply 6.5 ± 0.1 mm (0.26 ± 0.04 in) from tip of lock- TORX SCREWS ing agent to the starter clutch torx screw threads. Install the starter clutch assembly onto the flywheel and install the torx screws.
  • Page 258 ALTERNATOR/STARTER CLUTCH Apply engine oil to the starter reduction gear shaft COLLAR outer surface. Install the shaft, starter reduction gear and collar. SHAFT REDUCTION GEAR Apply engine oil to the left crankshaft starter driven gear sliding surface. Install the flywheel while aligning the woodruff key on the crankshaft with flywheel keyway.
  • Page 259 12. CRANKSHAFT/BALANCER/TRANSMISSION COMPONENT LOCATION ························ 12-2 CRANKSHAFT/BALANCER ····················· 12-8 SERVICE INFORMATION ························· 12-3 TRANSMISSION····································· 12-12 TROUBLESHOOTING ······························· 12-5 BEARING REPLACEMENT ····················· 12-18 CRANKCASE SEPARATION····················· 12-6 CRANKCASE ASSEMBLY ······················ 12-21 12-1...

  • Page 260: Component Location

    CRANKSHAFT/BALANCER/TRANSMISSION COMPONENT LOCATION CRANKSHAFT/BALANCER/TRANSMISSION 12-2...
  • Page 261 CRANKSHAFT/BALANCER/TRANSMISSION SERVICE INFORMATION GENERAL • This section covers crankcase separation for service of the crankshaft, transmission and balancer. • The crankcase must be separated to service the crankshaft, balancer and transmission. To service these parts, the engine must be removed from the frame. •...
  • Page 262 CRANKSHAFT/BALANCER/TRANSMISSION TOOLS Bearing remover head, 12 mm Bearing remover shaft, 12 mm Bearing remover head, 15 mm 07936-1660110 07936-1660120 07936-KC10200 Bearing remover shaft Remover weight Driver 07936-KC10100 07741-0010201 07749-0010000 Pilot, 12 mm Pilot, 15 mm Pilot, 17 mm 07746-0040200 07746-0040300 07746-0040400 Pilot, 20 mm Pilot, 35 mm...
  • Page 263 CRANKSHAFT/BALANCER/TRANSMISSION Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 72 x 75 mm 07746-0010200 07746-0010300 07746-0010600 Universal bearing puller Assembly collar Assembly shaft 07631-0010000 07965-VM00100 07965-VM00200 TROUBLESHOOTING Excessive noise • Worn, seized or chipped transmission gear • Worn or damaged transmission bearing •...

  • Page 264: Crankcase Separation

    CRANKSHAFT/BALANCER/TRANSMISSION CRANKCASE SEPARATION If you replace the crankcase, record the identifica- tion color of the following gears: – Primary drive gear (page 10-22) – Balancer driven gear (page 12-11) Refer to Service Information (page 12-3) for removal CAM CHAIN TENSIONER PLATE of necessary parts before disassembling the crank- case.
  • Page 265 CRANKSHAFT/BALANCER/TRANSMISSION Loosen the left crankcase bolts in a crisscross pat- BOLTS/CLAMPS tern in 2 or 3 steps, and remove the bolts and clamps. BOLTS Disconnect the crankcase breather hose. BREATHER HOSE BOLT/WASHER Loosen the right crankcase bolts in a crisscross pat- tern in 2 or 3 steps, and remove the bolts and washer.

  • Page 266: Crankshaft/Balancer

    CRANKSHAFT/BALANCER/TRANSMISSION CRANKSHAFT/BALANCER REMOVAL Separate the crankcase halves (page 12-6). CRANKSHAFT Remove the crankshaft and balancer assembly from the right crankcase. BALANCER ASSEMBLY CRANKSHAFT INSPECTION CRANKSHAFT RUNOUT Place the crankshaft on V-blocks. Set the dial indicator on the crankshaft. Rotate the crankshaft two revolutions (720°) and read the runout.
  • Page 267 CRANKSHAFT/BALANCER/TRANSMISSION BIG END RADIAL CLEARANCE Measure the radial clearance of the connecting rod big end. SERVICE LIMIT: 0.05 mm (0.002 in) TIMING SPROCKET Check the timing sprocket teeth for wear or damage. If the timing GROOVE sprocket teeth are If you are replacing the timing sprocket, align the worn or damaged, center of the sprocket teeth with the center of the check the cam...
  • Page 268 CRANKSHAFT/BALANCER/TRANSMISSION BALANCER DISASSEMBLY If you replace the balancer driven gear, be careful to select the identification color of the balancer driven gear (page 12-11). Remove the following: WASHER – Snap ring – Thrust spring – Washer THRUST SPRING SNAP RING Remove the balancer damper rubbers, balancer SPRINGS gear springs and balancer driven gear.
  • Page 269 CRANKSHAFT/BALANCER/TRANSMISSION Install the following: Make sure the snap WASHER ring is firmly seated – Washer in the groove. – Thrust spring – Snap ring SNAP RING THRUST SPRING BALANCER DRIVEN GEAR SELECTION The balancer driven gear has ID color. ID COLOR BALANCER DRIVEN GEAR SELECTION TABLE ID COLOR WHITE...

  • Page 270: Transmission

    CRANKSHAFT/BALANCER/TRANSMISSION After installing the crankshaft and balancer assem- bly, make sure to align the two punch marks on the balancer driven gear and crank weight. Assemble the crankcase (page 12-21). PUNCH MARKS TRANSMISSION REMOVAL/DISASSEMBLY Separate the crankcase halves (page 12-6). SHIFT FORK SHAFT Pull the shift fork shaft and remove it from the shift forks.
  • Page 271 CRANKSHAFT/BALANCER/TRANSMISSION Disassemble the mainshaft assembly and counter- MAINSHAFT ASSEMBLY shaft assembly. • Keep track of the disassembled parts (gears, bushings, washers, and snap rings) by sliding them onto a tool or a piece of wire. • Do not expand the snap ring more than neces- sary for removal.
  • Page 272 CRANKSHAFT/BALANCER/TRANSMISSION MAINSHAFT/COUNTERSHAFT Check the spline grooves and sliding surfaces for abnormal wear or damage. Measure the O.D. of the mainshaft and countershaft at the gear and bushing sliding areas. SERVICE LIMITS: Mainshaft (at M5 gear bushing): 16.93 mm (0.667 in) Countershaft (at C1 gear bushing): 14.90 mm (0.587 in)
  • Page 273 CRANKSHAFT/BALANCER/TRANSMISSION SHIFT FORK SHAFT Check the shift fork shafts for damage and straight- ness. Measure the shift fork shaft O.D. at three points. SERVICE LIMIT: 9.93 mm (0.391 in) TRANSMISSION BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly.
  • Page 274 CRANKSHAFT/BALANCER/TRANSMISSION MAINSHAFT WASHER M6 GEAR BUSHING SNAP RINGS SPLINE WASHER M5 GEAR BUSHING THRUST WASHER M2 GEAR (17T) M6 GEAR (26T) SPLINE WASHER M3/M4 GEAR (20/23T) M5 GEAR (24T) MAINSHAFT/ M1 GEAR (11T) COUNTERSHAFT LOCK WASHER SPLINE WASHER C1 GEAR BUSHING C3 GEAR (29T) SPLINE WASHER SNAP RING...
  • Page 275 CRANKSHAFT/BALANCER/TRANSMISSION Check the gears for freedom of movement or rota- : Each gear teeth MAINSHAFT tion on each shaft. ASSEMBLY Apply engine oil to the transmission gear teeth. Engage the mainshaft assembly and countershaft assembly. COUNTERSHAFT ASSEMBLY Install the mainshaft assembly and countershaft Be sure to install MAINSHAFT assembly together into the right crankcase.

  • Page 276: Bearing Replacement

    CRANKSHAFT/BALANCER/TRANSMISSION Apply molybdenum oil solution to the shift fork SHIFT FORKS SHAFT shaft outer surface and insert it through the shift forks into the right crankcase. After installation, check for smooth transmission operation. Assemble the crankcase (page 12-21). BEARING REPLACEMENT CRANKSHAFT BEARING Remove the crankshaft (page 12-8).
  • Page 277 CRANKSHAFT/BALANCER/TRANSMISSION Drive in new right crankshaft bearing into the right DRIVER RIGHT SIDE: crankcase with the marked side facing up until it is fully seated using the special tools. TOOLS: ATTACHMENT Driver 07749-0010000 Attachment, 72 x 75 mm 07746-0010600 Pilot, 35 mm 07746-0040800 Install the crankshaft (page 12-11).
  • Page 278 CRANKSHAFT/BALANCER/TRANSMISSION Drive in new bearings into the right crankcase until ATTACHMENT DRIVER they are fully seated using the special tools. TOOLS: Mainshaft bearing (marked side facing up): Driver 07749-0010000 Attachment, 37 x 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 Countershaft bearing (sealed side facing down): Driver 07749-0010000 Attachment, 32 x 35 mm...

  • Page 279: Crankcase Assembly

    CRANKSHAFT/BALANCER/TRANSMISSION Drive in new bearings into the left crankcase until COUNTERSHAFT BALANCER BEARING they are fully seated using the special tools. BEARING TOOLS: Mainshaft bearing (sealed side facing down): Driver 07749-0010000 Attachment, 32 x 35 mm 07746-0010100 Pilot, 12 mm 07746-0040200 Countershaft bearing (marked side facing up): Driver...
  • Page 280 CRANKSHAFT/BALANCER/TRANSMISSION Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them and check for damage. Apply a light but thorough coating of sealant (TB1215 or equivalent) to left crankcase mating surfaceexcept the oil passage area. PASSAGE Install the dowel pins.
  • Page 281 CRANKSHAFT/BALANCER/TRANSMISSION Install the left crankcase bolts and clamps and BOLTS/CLAMPS tighten the bolts in a crisscross pattern in 2 or 3 steps. BOLTS Install the spring, washer and suitable 3 mm screw 3 mm SCREW SNAP RING to the bearing push plug, then install them into the left crankcase.
  • Page 282 MEMO...
  • Page 283 13. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION ························ 13-2 FRONT WHEEL ······································· 13-13 SERVICE INFORMATION ························· 13-3 FORK ······················································· 13-18 TROUBLESHOOTING ······························· 13-5 STEERING STEM···································· 13-27 HANDLEBARS··········································· 13-6 CLUTCH LEVER ······································ 13-31 13-1...

  • Page 284: Component Location

    FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION FRONT WHEEL/SUSPENSION/STEERING 88 N·m (9.0 kgf·m, 65 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 13-2...
  • Page 285 60 g max. Fork Spring free length 412.4 (16.24) 404.1 (15.91) Pipe runout – 0.20 (0.008) Recommended Except Honda ULTRA CUSHION OIL 10W or – fork fluid CM type equivalent CM type Pro Honda Suspension Fluid SS-8 – only (10W) or equivalent Fluid level 131 (5.2)
  • Page 286 FRONT WHEEL/SUSPENSION/STEERING TOOLS Attachment, 37 x 40 mm Attachment, 42 x 47 mm Pilot, 12 mm 07746-0010200 07746-0010300 07746-0040200 Driver Bearing remover shaft Bearing remover head, 12 mm 07749-0010000 07746-0050100 07746-0050300 Oil seal remover Steering stem driver Steering stem socket 07748-0010001 07946-4300101 07916-3710101...
  • Page 287 FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering • Steering stem adjusting nut too tight • Damaged steering head beatings • Insufficient tire pressure • Faulty tire Steers to one side or does not track straight • Bent fork pipe • Bent axle •...
  • Page 288 FRONT WHEEL/SUSPENSION/STEERING HANDLEBARS REMOVAL Remove the rearview mirrors. REARVIEW MIRRORS Hold the handlebar weight and remove the screw, HANDLEBAR WEIGHT then remove both handlebar weights. SCREW Disconnect the brake light switch connectors. CONNECTORS Remove the bolts, holder and master cylinder. Keep the brake MASTER CYLINDER master cylinder...
  • Page 289 FRONT WHEEL/SUSPENSION/STEERING Remove the screws. SCREWS Separate the throttle housing. THROTTLE HOUSING Disconnect the throttle cable from the throttle pipe, then remove the throttle pipe. Remove the grip rubber, replace it if necessary. THROTTLE CABLE THROTTLE PIPE Disconnect the clutch switch connectors. CONNECTORS Remove the bolts, holder and clutch lever bracket.
  • Page 290 FRONT WHEEL/SUSPENSION/STEERING Remove the screws and separate the left handlebar LEFT HANDLEBAR switch housing. SWITCH HOUSING SCREWS Remove the left handlebar grip rubber. GRIP RUBBER Remove the stopper rings from both fork pipes. HANDLEBAR Loosen the handlebar pinch bolts and remove the handlebars.
  • Page 291 Clean the inside surface of the handlebar grip and outside surface of the handlebar and throttle pipe. Apply Honda Bond A or equivalent to the inside sur- face of the grips and to the clean surface of the left handlebar and throttle pipe.
  • Page 292 FRONT WHEEL/SUSPENSION/STEERING Install the clutch lever bracket, holder ("UP" mark CLUTCH LEVER BRACKET HOLDER facing up) and bolts. Align the end of the clutch lever bracket with the Align punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt. BOLTS "UP"...
  • Page 293 FRONT WHEEL/SUSPENSION/STEERING Install the screws and tighten the forward screw first, then tighten the rear screw. SCREWS Install the master cylinder, holder ("UP" mark facing MASTER CYLINDER Align up) and bolts. Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first, then the lower bolt.
  • Page 294 FRONT WHEEL/SUSPENSION/STEERING Hold the handlebar weight. HANDLEBAR WEIGHT Install and tighten new screw to the specified torque. TORQUE: 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) SCREW Install the rearview mirrors. REARVIEW MIRRORS Adjust the following: – Clutch lever freeplay (page 3-24) –...

  • Page 295: Front Wheel

    FRONT WHEEL/SUSPENSION/STEERING Install the inner weight assembly into the handle- HOLE bar. Turn the inner weight and hook the weight retainer tab with the tab locking hole in the handlebar. INNER WEIGHT RETAINER RING HANDLEBAR WEIGHT FRONT WHEEL REMOVAL Support the motorcycle using a safety stand or hoist, raise the front wheel off the ground.
  • Page 296 FRONT WHEEL/SUSPENSION/STEERING INSPECTION AXLE Place the axle on V-blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) WHEEL RIM Check the wheel rim runout by placing the wheel in a truing stand.
  • Page 297 FRONT WHEEL/SUSPENSION/STEERING WHEEL BALANCE • Carefully check balance before installing the ROTATING BALANCE MARK wheel. DIRECTION MARK • Mount the tire with the arrow mark facing in the direction of rotation. • The wheel balance must be checked when the tire is remounted.
  • Page 298 FRONT WHEEL/SUSPENSION/STEERING Install the bearing remover head into the bearing. REMOVER SHAFT From the opposite side, install the bearing remover shaft and drive out the bearing from the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 12 mm 07746-0050300...
  • Page 299 FRONT WHEEL/SUSPENSION/STEERING Install the speedometer retainer to the left wheel RETAINER hub, while aligning the tabs on the retainer with the slots on the hub. Align Apply grease to a new dust seal lips. DUST SEAL Install the dust seal until it is fully seated to the left wheel hub.

  • Page 300: Fork

    FRONT WHEEL/SUSPENSION/STEERING Install the side collar into the right wheel hub. SIDE COLLAR When installing the front wheel, align the following: AXLE – Brake disc between the brake pads – Speedometer gear box groove with the boss on the left fork leg Be careful not to damage the brake pads.
  • Page 301 FRONT WHEEL/SUSPENSION/STEERING Remove the wire band from the fork pipe. LEFT SIDE: WIRE BAND Remove the stopper rings from both fork pipes. FORK BOLT Loosen the handlebar pinch bolts and remove the handlebars. Loosen the top bridge pinch bolts. When the fork is ready to be disassembled, loosen the fork bolt.
  • Page 302 FRONT WHEEL/SUSPENSION/STEERING Remove the fork spring. SPRING Drain the fork fluid by pumping the fork pipe several times. Set the fork slider in a vise with a piece of wood or Do not over-tighten FORK SLIDER soft jaws to avoid damage. the vise on the fork slider.
  • Page 303 FRONT WHEEL/SUSPENSION/STEERING Remove the dust seal and stopper ring. Be careful not to DUST SEAL STOPPER RING scratch the fork pipe. Remove the oil seal using a special tool. Be careful not to OIL SEAL REMOVER damage the fork TOOL: slider.
  • Page 304 FRONT WHEEL/SUSPENSION/STEERING Check the fork piston and piston ring for wear or PISTON RING FORK PISTON damage. Check the rebound spring for fatigue or damage. Replace any components that are worn or damage. REBOUND SPRING Place the fork pipe on V-blocks. Turn the fork pipe and measure the runout using a dial indicator.
  • Page 305 FRONT WHEEL/SUSPENSION/STEERING Before assembly, wash all parts with a high flash or OIL SEAL DRIVER non-flammable solvent and wipe them dry. Apply fork fluid to a new oil seal lips, then install it into the fork slider with its marking facing up. Drive in the oil seal into the fork slider until the stop- per ring groove is visible, using the special tools.
  • Page 306 Honda ULTRA CUSHION OIL 10W or equivalent 131 mm RECOMMENDED FORK FLUID (CM type only): (5.2 in) Pro Honda Suspension Fluid SS-8 (10W) or equiv- alent FORK FLUID CAPACITY: 206 ± 2.5 cm (7.0 ± 0.08 US oz, 7.3 ± 0.09 Imp oz)
  • Page 307 FRONT WHEEL/SUSPENSION/STEERING Apply fork fluid to a new O-ring and install it onto O-RING FORK BOLT the fork bolt. Loosely install the fork bolt by pushing it to the fork Tighten the fork pipe. bolt after installing the fork pipe into the fork bridges.
  • Page 308 FRONT WHEEL/SUSPENSION/STEERING Install the handlebars to both fork pipes while align- ing the bosses on the handlebars with the cut outs on the top bridge. Align Tighten both handlebar pinch bolts to the specified torque. TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft) Install the stopper rings to the grooves of both fork pipes.

  • Page 309: Steering Stem

    FRONT WHEEL/SUSPENSION/STEERING STEERING STEM REMOVAL Lift and support the fuel tank (page 3-6). 2P (NATURAL) CONNECTOR Open the rubber sheet (page 6-10). Disconnect the ignition switch 2P (Natural) connec- tor. Release the brake hose and wire harness clamps CLAMPS from the stay. Remove the bolts and stay.
  • Page 310 FRONT WHEEL/SUSPENSION/STEERING Remove the following: Be careful not to INNER RACE STEERING STEM loose the steel – Upper bearing inner race balls. – Upper steel ball (18) – Steering stem – Lower steel ball (18) UPPER STEEL LOWER STEEL BALL (18) BALL (18) BEARING REPLACEMENT Drive out the upper and lower outer races using a...
  • Page 311 FRONT WHEEL/SUSPENSION/STEERING Drive in a new upper outer race using the special DRIVER tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 ATTACHMENT OUTER RACE Drive in a new lower outer race using the special OUTER RACE tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm...
  • Page 312 FRONT WHEEL/SUSPENSION/STEERING Apply specified grease (page 1-17) to each inner STEERING STEM UPPER STEEL races and outer races rolling surface. BALL (18) Install the steel balls in the lower inner race and upper outer race. Upper steel ball: 18 Pieces Lower steel ball: 18 Pieces Install the steering stem and upper inner race.

  • Page 313: Clutch Lever

    FRONT WHEEL/SUSPENSION/STEERING Install the top bridge. TOP BRIDGE Install the washer and steering stem nut, but do not tighten the steering stem nut yet. Install the fork legs (page 13-25). Tighten the steering stem left and right, lock-to-lock several times to make sure the steering stem nut to the specified torque.
  • Page 314 FRONT WHEEL/SUSPENSION/STEERING Connect the clutch cable to the clutch lever. BRACKET Install the clutch lever to the clutch lever bracket. CLUTCH CABLE CLUTCH LEVER Apply grease to the clutch lever pivot bolt sliding PIVOT BOLT surface (page 1-17). Install and tighten the clutch lever pivot bolt to the specified torque.
  • Page 315 14. REAR WHEEL/SUSPENSION COMPONENT LOCATION ························ 14-2 REAR WHEEL············································ 14-5 SERVICE INFORMATION ························· 14-3 SHOCK ABSORBER································ 14-11 TROUBLESHOOTING ······························· 14-4 SWINGARM ············································ 14-12 14-1...
  • Page 316 REAR WHEEL/SUSPENSION COMPONENT LOCATION REAR WHEEL/SUSPENSION 39 N·m (4.0 kgf·m, 29 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 14-2...
  • Page 317 • After the rear wheel installation, check the brake operation by applying the brake pedal. • Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE". • Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point. • For brake system information (page 15-3).
  • Page 318 REAR WHEEL/SUSPENSION TOOLS Pilot, 12 mm Pilot, 17 mm Attachment, 37 x 40 mm 07746-0040200 07746-0040400 07746-0010200 Bearing remover shaft Bearing remover head, 12 mm Driver 07746-0050100 07746-0050300 07749-0010000 TROUBLESHOOTING Steers to one side or does not track straight • Drive chain adjusters not adjusted equally •...

  • Page 319: Rear Wheel

    REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a safety stand or NUT/AXLE LOCK NUT hoist, raise the rear wheel off the ground. Loosen the lock nut, drive chain adjusting nut and axle nut. Push the rear wheel forward. Derail the drive chain from the driven sprocket.
  • Page 320 REAR WHEEL/SUSPENSION WHEEL RIM Check the rim runout by placing the wheel in a truing stand. Spin the wheel by hand, and measure the runout using a dial indicator. Actual runout is 1/2 of the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)
  • Page 321 REAR WHEEL/SUSPENSION Remove the damper rubbers and O-ring. DAMPER RUBBERS O-RING Remove the driven sprocket nuts. NUTS Remove the driven flange collar. COLLAR Drive out the driven flange bearing. BEARING Install the bearing remover head into the bearing. REMOVER SHAFT From the opposite side, install the bearing remover shaft and drive out the bearing from the wheel hub.
  • Page 322 REAR WHEEL/SUSPENSION ASSEMBLY 42 N·m (4.3 kgf·m, 31 lbf·ft) BEARING (6003) COLLAR BEARING (6301UU) DRIVEN FLANGE DUST SEAL DUST SEAL BRAKE DISC 64 N·m (6.5 kgf·m, 47 lbf·ft) O-RING BEARING (6301UU) DISTANCE COLLAR DAMPER RUBBER Drive in a new right side bearing squarely with its Never install the old DISTANCE ATTACHMENT...
  • Page 323 REAR WHEEL/SUSPENSION Install the collar to the driven flange bearing. COLLAR BEARING Install the driven sprocket to the driven flange. NUTS Loosely install the driven sprocket nuts. Apply grease to a new O-ring. DAMPER RUBBERS Install the O-ring and wheel damper rubbers into the left wheel hub.
  • Page 324 REAR WHEEL/SUSPENSION Tighten the nuts to the specified torque in a criss- DUST SEAL cross pattern in 2 or 3 steps. TORQUE: 64 N·m (6.5 kgf·m, 47 lbf·ft) Apply grease to a new dust seal lips. Install the dust seal to the driven flange. DRIVEN SPROCKET NUTS Apply grease to a new dust seal lips.

  • Page 325: Shock Absorber

    REAR WHEEL/SUSPENSION Install the rear wheel in the swingarm aligning the Be careful not to brake disc between the brake pads. damage the brake Install the drive chain over the driven sprocket. pads. AXLE Apply a thin coat of grease to the axle rolling sur- face.
  • Page 326 REAR WHEEL/SUSPENSION INSPECTION Visually inspect the shock absorber for wear or RUBBER BUMPER DAMPER ROD damage. Check the following: – Damper rod for bend or damage – Damper unit for deformation or oil leaks – Bushings for wear or damage –...
  • Page 327 REAR WHEEL/SUSPENSION Remove the bolts and chain cover. COVER BOLTS Remove the screw and brake hose guide. HOSE GUIDE CLAMP Release the brake hose from the clamp. SCREW Remove the shock absorber lower mounting bolt and nut. BOLT/NUT Remove the rear brake caliper/bracket assembly SWINGARM from the swingarm.
  • Page 328 REAR WHEEL/SUSPENSION Remove both swingarm pivot caps. Remove the swingarm pivot nut, pivot bolt and SWINGARM NUT/BOLT swingarm. DISASSEMBLY Remove the drive chain adjusters and rubber collar. COLLAR DRIVE CHAIN ADJUSTERS Remove the screw and collar. CHAIN SLIDER Remove the drive chain slider by releasing the slider slits from the swingarm tab.
  • Page 329 REAR WHEEL/SUSPENSION Check the rubber bushings for wear, damage or fatigue and replace if necessary. BUSHINGS ASSEMBLY DRIVE CHAIN SLIDER RUBBER COLLAR COLLAR 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft) DRIVE CHAIN ADJUSTER SWINGARM Install the drive chain slider while aligning the swin- CHAIN SLIDER garm tabs with the slider slits.
  • Page 330 REAR WHEEL/SUSPENSION Install the drive chain adjusters and rubber collar. COLLAR DRIVE CHAIN ADJUSTERS INSTALLATION Apply a thin coat of grease to the swingarm pivot bolt sliding surface. Set the drive chain onto the swingarm and install PIVOT BOLT the swingarm to the frame. Install the swingarm pivot bolt from the left side.
  • Page 331 REAR WHEEL/SUSPENSION Install the shock absorber lower mounting bolt and nut. Tighten the lower mounting nut to the specified torque. TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) BOLT/NUT Install the brake hose to the clamp. HOSE GUIDE CLAMP Install the brake hose guide and brake hose guide screw, tighten the screw to the specified torque.
  • Page 332 REAR WHEEL/SUSPENSION Reposition the left step holder assembly and install BOLTS the left step holder mounting bolts. Tighten the mounting bolts to the specified torque. TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft) STEP HOLDER ASSEMBLY Install the rear wheel (page 14-10). PIVOT NUT Lift down the motorcycle from the safety stand or hoist, and support the motorcycle by your hands as...
  • Page 333 15. HYDRAULIC BRAKE COMPONENT LOCATION ························ 15-2 FRONT MASTER CYLINDER·················· 15-11 SERVICE INFORMATION ························· 15-3 REAR MASTER CYLINDER ···················· 15-15 TROUBLESHOOTING ······························· 15-4 FRONT BRAKE CALIPER ························ 15-20 BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER ·························· 15-23 AIR BLEEDING ·········································· 15-5 BRAKE PEDAL ········································...

  • Page 334: Component Location

    HYDRAULIC BRAKE COMPONENT LOCATION HYDRAULIC BRAKE 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 15-2...

  • Page 335: Service Information

    HYDRAULIC BRAKE SERVICE INFORMATION GENERAL Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilling brake fluid will severely damage instrument lenses and painted surface.

  • Page 336: Troubleshooting

    HYDRAULIC BRAKE TOOL Snap ring pliers 07914-SA50001 TROUBLESHOOTING Brake lever/pedal soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contaminated brake pad/disc • Worn caliper piston seal • Worn master cylinder piston cups • Worn brake pad/disc •...

  • Page 337: Brake Fluid Replacement

    HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING Turn the handlebar until the reservoir is parallel to FRONT BRAKE: FRONT: SCREWS the ground. Remove the reservoir cover screws, reservoir cover, SET PLATE set plate and diaphragm. COVER DIAPHRAGM Support the motorcycle in an upright position. REAR BRAKE: REAR: BOLT...
  • Page 338 HYDRAULIC BRAKE BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir with DOT 3 or DOT 4 brake fluid Do not mix different FRONT: REAR: from a sealed container. types of fluid. They are not compatible. Connect a automatic refill system to the reservoir. If an automatic refill system is not used, add fluid when the fluid level in the reservoir is low.
  • Page 339 HYDRAULIC BRAKE Add the reservoir with DOT 3 or DOT 4 brake fluid to Do not mix different FRONT: REAR: the casting ledge/upper level line. types of fluid. They are not compatible. CASTING LEDGE "UPPER" LEVEL LINE Install the diaphragm, set plate, reservoir cover and FRONT BRAKE: FRONT: SCREWS...

  • Page 340: Brake Pad/Disc

    HYDRAULIC BRAKE BRAKE PAD/DISC FRONT BRAKE PAD REPLACEMENT Push the caliper pistons all the way in to allow Always replace the installation of new brake pads. brake pads in pairs to assure even disc pressure. Check the brake fluid level in the brake master cylin- der reservoir as this operation causes the level to rise.
  • Page 341 HYDRAULIC BRAKE Tighten the brake pad hanger pin to the specified torque. TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft) Operate the brake lever to seat the caliper pistons against the pads. HANGER PIN REAR BRAKE PAD REPLACEMENT Push the caliper pistons all the way in to allow Always replace the installation of new brake pads.

  • Page 342: Brake Disc Inspection

    HYDRAULIC BRAKE Install new brake pads to the brake caliper so their BRAKE PADS RETAINER ends seat against the retainer and brake caliper pin bolt A. Make sure that the retainer is installed to the brake caliper. PIN BOLT A Apply silicone grease to the brake pad hanger pin O-RING O-ring and install it to the pad pin groove.

  • Page 343: Front Master Cylinder

    HYDRAULIC BRAKE Measure the brake discs warpage using a dial indi- cator. SERVICE LIMITS: FRONT: 0.10 mm (0.004 in) REAR: 0.10 mm (0.004 in) Check the wheel bearings for excessive play, if the warpage exceeds the service limit. Replace the brake disc if the wheel bearings are nor- mal.
  • Page 344 HYDRAULIC BRAKE Remove the screw and brake light switch. SCREW BRAKE LIGHT SWITCH Remove the boot. Be careful not to SNAP RING damage the boot. Remove the snap ring using a special tool. TOOL: Snap ring pliers 07914-SA50001 BOOT Remove the washer, master piston/spring and sepa- MASTER CYLINDER PISTON rate them.
  • Page 345 HYDRAULIC BRAKE Measure the master cylinder I.D. SERVICE LIMIT: 11.055 mm (0.4352 in) Measure the master piston O.D. SERVICE LIMIT: 10.945 mm (0.4309 in) ASSEMBLY 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) RESERVOIR COVER SNAP RING MASTER PISTON SET PLATE BOOT...
  • Page 346 HYDRAULIC BRAKE Install the snap ring into the groove of the master Make sure the snap SNAP RING cylinder using a special tool. ring is firmly seated in the groove. TOOL: Snap ring pliers 07914-SA50001 Install the boot securely. BOOT Install the brake light switch to the master cylinder BRAKE LIGHT SWITCH while aligning the brake light switch boss and mas-...

  • Page 347: Rear Master Cylinder

    HYDRAULIC BRAKE INSTALLATION Install the master cylinder, holder ("UP" mark facing HOLDER MASTER CYLINDER up) and bolts. Align the end of the master cylinder with the punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt. BOLTS "UP"...
  • Page 348 HYDRAULIC BRAKE Remove the cotter pin, joint pin and master cylinder from the brake pedal. BRAKE PEDAL MASTER CYLINDER JOINT PIN COTTER PIN Remove the master cylinder mounting bolts and MASTER CYLINDER master cylinder from the right step holder assem- bly.
  • Page 349 HYDRAULIC BRAKE Remove the push rod, master piston/spring and MASTER CYLINDER separate them. PISTON Clean the inside of the master cylinder and master piston with brake fluid. SPRING PUSH ROD INSPECTION Check the master cylinder for scoring, scratches or MASTER PISTON damage.
  • Page 350 HYDRAULIC BRAKE ASSEMBLY 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) RESERVOIR COVER HOSE JOINT SET PLATE 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) O-RING MASTER CYLINDER DIAPHRAGM SPRING RESERVOIR MASTER PISTON SNAP RING PUSH ROD BOOT 17 N·m (1.7 kgf·m, 13 lbf·ft) BRAKE ROD JOINT Replace the piston, spring and cups as a set.
  • Page 351 HYDRAULIC BRAKE Apply silicone grease to the boot groove of the push rod. BOOT Install the boot securely. If the push rod joint is reinstalled, adjust the push LOCK NUT rod length so that the distance from the center of the master cylinder lower mounting hole to the cen- ter of the joint pin hole is 84 –...

  • Page 352: Front Brake Caliper

    HYDRAULIC BRAKE Install the master cylinder to the brake pedal and JOINT PIN install the joint pin and new cotter pin. COTTER PIN Install the right step holder assembly and step MASTER CYLINDER STEP HOLDER holder mounting bolts. MOUNTING BOLTS MOUNTING BOLTS Tighten the step holder mounting bolts to the speci- fied torque.
  • Page 353 HYDRAULIC BRAKE DISASSEMBLY Remove the following: BRACKET PAD SPRING – Caliper bracket – Pin boots – Pad spring PIN BOOTS Place a shop towel over the pistons. Position the caliper body with the piston facing Do not use high down and apply small squirts of air pressure to the pressure air or bring fluid inlet to remove the pistons.
  • Page 354 HYDRAULIC BRAKE ASSEMBLY CALIPER BRACKET CALIPER PISTON DUST SEAL 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) PISTON SEAL BOOT CALIPER BODY O-RING PAD SPRING BRAKE PADS 17 N·m (1.7 kgf·m, 13 lbf·ft) Apply brake fluid to new piston seals. CALIPER BODY DUST SEAL Apply silicone grease to new dust seals.

  • Page 355: Rear Brake Caliper

    HYDRAULIC BRAKE INSTALLATION Install the brake caliper/bracket assembly to the BOLTS STOPPERS right fork leg. Install new mounting bolts and tighten them to the specified torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) Install the brake hose eyelet between the stoppers with brake hose oil bolt and new sealing washers.
  • Page 356 HYDRAULIC BRAKE Place a shop towel over the piston. Position the caliper body with the piston facing Do not use high down and apply small squirts of air pressure to the pressure air or bring fluid inlet to remove the piston. the nozzle too close to the inlet.
  • Page 357 HYDRAULIC BRAKE ASSEMBLY BOOTS CALIPER PISTON DUST SEAL PISTON SEAL CALIPER BRACKET PAD SPRING CALIPER BODY 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) RUBBER PLUG BRAKE PADS O-RING 17 N·m (1.7 kgf·m, 13 lbf·ft) Apply brake fluid to new piston seals. Apply silicone grease to new dust seals.

  • Page 358: Brake Pedal

    HYDRAULIC BRAKE INSTALLATION Install the brake caliper/bracket assembly to the Align SEALING OIL BOLT swingarm by aligning the slot of the bracket and WASHERS boss of the swingarm. Install the rear wheel (page 14-10). Install the brake hose eyelet between the stoppers with brake hose oil bolt and new sealing washers.
  • Page 359 HYDRAULIC BRAKE INSTALLATION BRAKE LIGHT SWITCH STEP HOLDER BRAKE LIGHT SWITCH SPRING COTTER PIN COTTER PIN JOINT PIN 27 N·m (2.8 kgf·m, 20 lbf·ft) RETURN SPRING WASHER BRAKE PEDAL Apply grease to the brake pedal pivot sliding area and install the brake pedal into the right step holder. BRAKE PEDAL Secure the brake pedal with the washer and new RETURN SPRING...
  • Page 360 HYDRAULIC BRAKE Install the right step holder assembly. BOLTS Install and tighten the step holder mounting bolts to the specified torque. TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft) After the installation, check the brake operation and adjust the rear brake light switch operation (page 3- 23).
  • Page 361 16. BATTERY/CHARGING SYSTEM SYSTEM LOCATION································· 16-2 BATTERY ·················································· 16-5 SYSTEM DIAGRAM·································· 16-2 CHARGING SYSTEM INSPECTION········· 16-6 SERVICE INFORMATION ························· 16-3 ALTERNATOR CHARGING COIL ············· 16-7 TROUBLESHOOTING ······························· 16-4 REGULATOR/RECTIFIER ························· 16-7 16-1...

  • Page 362: System Location

    BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY/CHARGING SYSTEM BATTERY MAIN FUSE (30A) REGULATOR/RECTIFIER ALTERNATOR SYSTEM DIAGRAM MAIN FUSE BATTERY 12V 6AH Bl/Bu Bl Bl Black Bl/R Bu : Blue ALTERNATOR Green REGULATOR/ Yellow RECTIFIER 16-2...
  • Page 363 BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 364 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 16-5). Check the battery condition using a recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent Is the battery in good condition? –...

  • Page 365: Voltage Inspection

    BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the single seat (page 2-4). COVER CLIP Turn the ignition switch OFF. Remove the trim clip and open the battery case cover. Disconnect the negative (–) cable first and then the BATTERY positive (+) cable. NEGATIVE (–) CABLE Remove the battery.

  • Page 366: Charging System Inspection

    BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the single seat (page 2-4). NEGATIVE (–) Open the battery case cover (page 16-5). CABLE With the ignition switch turned OFF, disconnect the negative (–) cable. Connect the ammeter (+) probe to the wire harness negative (–) cable and ammeter (–) probe to the bat- tery negative (–) terminal.

  • Page 367: Alternator Charging Coil

    BATTERY/CHARGING SYSTEM ALTERNATOR CHARGING COIL INSPECTION Disconnect the alternator/CKP sensor 6P (Natural) It is not necessary connector. to remove the stator coil to perform this test. 6P (NATURAL) CONNECTOR Measure the resistance between the Yellow wire 6P (NATURAL) CONNECTOR terminals of the alternator side connector. STANDARD: 0.2 –...
  • Page 368 BATTERY/CHARGING SYSTEM REMOVAL/INSTALLATION Remove the left middle cowl (page 2-9). BOLTS 6P (BLACK) Disconnect the regulator/rectifier 6P (Black) connec- CONNECTOR tor. Remove the bolts and regulator/rectifier from the frame. Install the regulator/rectifier in the reverse order of removal. REGULATOR/ RECTIFIER 16-8...

  • Page 369: Ignition System

    17. IGNITION SYSTEM SYSTEM LOCATION································· 17-2 IGNITION SYSTEM INSPECTION············ 17-5 SYSTEM DIAGRAM·································· 17-2 IGNITION TIMING ···································· 17-7 SERVICE INFORMATION ························· 17-3 IGNITION COIL ········································· 17-8 TROUBLESHOOTING ······························· 17-4 17-1...

  • Page 370: System Location

    IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM IGNITION SWITCH IGNITION COIL MAIN FUSE (30 A) BATTERY SUB FUSE INJECTOR CLUTCH SWITCH SPARK PLUG CKP SENSOR NEUTRAL SWITCH SIDESTAND SWITCH SYSTEM DIAGRAM MAIN FUSE SUB FUSE IGNITION SWITCH R/Bl ENGINE To Neutral indicator NEUTRAL STOP SWITCH SWITCH...
  • Page 371 IGNITION SYSTEM SERVICE INFORMATION GENERAL • The ECM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive volt- age may damage the module. Always turn off the ignition switch before servicing. • Use spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine. •...
  • Page 372 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 spark plug cap (Leaking the ignition coil secondary voltage) • If there is no spark at cylinder, temporarily exchange the ignition coil with a known-good one and perform the spark test.

  • Page 373: Ignition System Inspection

    IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at the plug, check all connec- tions for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. •...
  • Page 374 IGNITION SYSTEM Lift and support the fuel tank (page 3-6). IGNITION COIL Open the rubber sheet (page 6-10). With the ignition coil primary wire connected, con- Do not disconnect nect the peak voltage adaptor or Imrie tester to the the ignition coil ignition coil primary terminal and ground.

  • Page 375: Ignition Timing

    IGNITION SYSTEM Turn the ignition switch OFF. Disconnect the alternator/CKP sensor 6P (Natural) connector and connect the tester probes to the con- nector terminals of the CKP sensor side. CONNECTION: Blue/yellow (+) – White/yellow (–) In the same manner as at the ECM 33P connector, measure the peak voltage and compare it to the voltage measured at the ECM 33P connector.

  • Page 376: Ignition Coil

    IGNITION SYSTEM Apply engine oil to a new O-ring and install it to the O-RING timing hole cap. Install and tighten the timing hole cap to the speci- fied torque. TORQUE: 6.0 N·m (0.6 kgf·m, 4.4 lbf·ft) TIMING HOLE CAP IGNITION COIL REMOVAL/INSTALLATION Lift and support the fuel tank (page 3-6).

  • Page 377: Electric Starter

    18. ELECTRIC STARTER SYSTEM LOCATION································· 18-2 STARTER MOTOR ···································· 18-6 SYSTEM DIAGRAM·································· 18-2 STARTER RELAY SWITCH····················· 18-14 SERVICE INFORMATION ························· 18-3 DIODE······················································ 18-15 TROUBLESHOOTING ······························· 18-4 18-1...
  • Page 378 ELECTRIC STARTER SYSTEM LOCATION ELECTRIC STARTER IGNITION SWITCH STARTER SWITCH BATTERY MAIN FUSE (30 A) STARTER RELAY SWITCH DIODE CLUTCH SWITCH STARTER MOTOR NEUTRAL SWITCH SIDESTAND SWITCH SUB FUSE SYSTEM DIAGRAM STARTER RELAY IGNITION SWITCH MAIN FUSE 30A SWITCH R/Bl SUB FUSE STARTER BATTERY...

  • Page 379: Service Information

    ELECTRIC STARTER SERVICE INFORMATION GENERAL If the current is kept flowing through the starter motor turn it while the engine is not cranking over, the starter motor may be damaged. • The starter motor can be serviced with the engine installed in the frame. •...

  • Page 380: Troubleshooting

    ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 1. Fuse Inspection Check for blown main fuse or sub fuse. Is the fuse blown? – Replace the fuse. – GO TO STEP 2. 2. Battery Inspection Make sure the battery is fully charged and in good condition (page 16-5). Is the battery in good condition? –...
  • Page 381 ELECTRIC STARTER 7. Starter Relay Switch Continuity Inspection Remove and check the operation of the starter relay switch (page 18-14). Is there continuity? – Faulty starter relay switch – Loose or poor contact starter relay switch connector The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position except neutral, with the sidestand up and the clutch lever pulled in.

  • Page 382: Starter Motor

    ELECTRIC STARTER STARTER MOTOR REMOVAL Remove the lower cowl (page 2-8). STARTER MOTOR RUBBER CAP Release the rubber cap. CABLE With the ignition Remove the starter motor terminal nut and starter switch OFF , remove motor cable. the negative (–) cable at the battery Remove the stater motor mounting bolts and before servicing the...
  • Page 383 ELECTRIC STARTER Remove the rear cover, shim (s) and seal ring. Record the location ARMATURE REAR COVER SEAL RING and number of Remove the armature from the motor case. shim (s). SHIM (S) Remove the brushes and springs from the brush BRUSHES holder.
  • Page 384 ELECTRIC STARTER Check for continuity between pair of commutator CONTINUITY: COMMUTATOR BARS bars. There should be continuity. Check for continuity between each individual com- NO CONTINUITY: COMMUTATOR BARS mutator bar and the armature shaft. There should be no continuity. ARMATURE SHAFT Check for continuity between the positive brush and CONTINUITY: POSITIVE BRUSH...
  • Page 385 ELECTRIC STARTER Remove the screws, washers, negative brush and NEGATIVE BRUSH SCREWS/WASHERS brush holder from the rear cover. BRUSH HOLDER REAR COVER Remove the insulator plates from the rear cover. REAR COVER INSULATOR PLATES Remove the following: O-RING – Nut –...
  • Page 386 ELECTRIC STARTER Measure the brush length. SERVICE LIMIT: 3.5 mm (0.14 in) Check the bushing of the rear cover for wear or BUSHING damage. Replace the starter motor as an assembly if neces- sary. ASSEMBLY O-RING WASHER MOTOR CASE REAR COVER INSULATOR SET PLATE INSULATOR...
  • Page 387 ELECTRIC STARTER Install the set plate and brush into the rear cover. SET PLATE BRUSH Install a new O-ring, insulators, washer and nut. O-RING Tighten the nut securely. WASHER INSULATORS Install the insulator plates onto the rear cover. REAR COVER INSULATOR PLATES Install the brush holder, negative brush, washers NEGATIVE BRUSH...
  • Page 388 ELECTRIC STARTER Apply engine oil to the oil seal lips. OIL SEAL Install the armature into the motor case while hold- ARMATURE MOTOR CASE ing the armature shaft tightly to keep the magnet of the motor case from pulling the armature shaft against it.
  • Page 389 ELECTRIC STARTER Install the shim (s) and insulator. Install the same SEAL RING FRONT COVER Install a new seal ring to the motor case. number of shim (s) in the same Install the lock washer to the front cover. locations as noted Install the front cover.
  • Page 390 ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION Remove the single seat (page 2-4). STARTER RELAY SWITCH Shift the transmission into neutral. Turn the ignition switch ON (and engine stop switch " ": CM and U type). Push the starter switch. The coil is normal if the starter relay switch clicks. If you don't hear the starter relay switch "CLICK", inspect the starter relay switch using a procedure below.
  • Page 391 ELECTRIC STARTER REMOVAL/INSTALLATION Remove the rear cowl (page 2-5). BOLTS Release the rubber cover. 4P (RED) CONNECTOR Disconnect the starter relay switch 4P (Red) connec- tor. Remove the bolts and disconnect the starter and ground cables. Remove the starter relay switch from the stays with the shock rubber.
  • Page 392 MEMO...
  • Page 393 19. LIGHTS/METERS/SWITCHES SYSTEM LOCATION································· 19-2 IGNITION SWITCH ································· 19-13 SERVICE INFORMATION ························· 19-3 HANDLEBAR SWITCHES ······················· 19-14 HEADLIGHT··············································· 19-4 BRAKE LIGHT SWITCHES ····················· 19-16 POSITION LIGHT ······································ 19-4 NEUTRAL SWITCH································· 19-17 TURN SIGNAL LIGHTS ···························· 19-5 SIDESTAND SWITCH ····························· 19-19 BRAKE/TAIL LIGHT ··································...
  • Page 394 LIGHTS/METERS/SWITCHES SYSTEM LOCATION LIGHTS/METERS/SWITCHES FRONT BRAKE LIGHT SWITCH RIGHT HANDLEBAR SWITCH IGNITION SWITCH FUEL PUMP UNIT COMBINATION METER TURN SIGNAL RELAY ECT SENSOR MAIN RELAY CLUTCH SWITCH LEFT HANDLEBAR SWITCH HORN NEUTRAL SWITCH REAR BRAKE SIDESTAND SWITCH LIGHT SWITCH 19-2...
  • Page 395 LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL • Note the following when replacing the halogen headlight bulb. – Wear clean gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. –...

  • Page 396: Headlight

    LIGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT Disconnect the headlight bulb connector. Remove the dust cover. Unhook the bulb retainer and remove the headlight bulb. Remove the headlight bulb. Align Avoid touching halogen headlight bulb. Finger prints can create hot spots that cause a bulb to break.

  • Page 397: Turn Signal Lights

    LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHTS BULB REPLACEMENT Remove the screw, washer (CM type only), turn sig- EXCEPT CM TYPE: PACKING nal light lens. LENS While pushing in the bulb, turn it counterclockwise to remove it. Replace the bulb with a new one. Check the packing is installed in position and is in good condition, replace it with a new one if neces- sary.

  • Page 398: Brake/Tail Light

    LIGHTS/METERS/SWITCHES REAR Remove the following: CONNECTORS – Rear cowl (page 2-5) – Brake/tail light (page 19-6) Disconnect the turn signal light connectors. Remove the turn signal light mounting nut and turn signal light. Install the turn signal light in the reverse order of Route the wire removal.

  • Page 399: License Light

    LIGHTS/METERS/SWITCHES LICENSE LIGHT BULB REPLACEMENT Remove the screws and license light cover. Remove the bulb from the socket, replace it with a new one. Check the packing is installed in position and is in COVER good condition, replace it with a new one if neces- sary.

  • Page 400: Combination Meter

    LIGHTS/METERS/SWITCHES Disconnect the license light wire connectors. EXCEPT CM TYPE: Remove the screws. CONNECTORS GROMMET Pull out the wire from the rear fender and remove the license light assembly and grommet. CM TYPE ONLY: SCREWS LICENCE LIGHT ASSEMBLY Remove the nuts, collars, reflector and license light EXCEPT CM TYPE shown: REFLECTOR from the license light base.
  • Page 401 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the inner cowl (page 2-7). 3P (NATURAL) CONNECTOR Disconnect the combination meter 9P (Natural) and 3P (Natural) connectors. 9P (NATURAL) CONNECTOR Remove the bolts, collars and grommets. BOLTS/COLLARS/GROMMETS Lift the combination meter assembly while releas- BOSS ing the boss from the grommet. Disconnect the speedometer cable from the combi- nation meter assembly.
  • Page 402 LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY Remove the combination meter assembly (page 19- Remove the following: – Upper cover mounting screws and upper cover – Coolant temperature gauge mounting screws and coolant temperature gauge – Tachometer mounting screws and tachometer – MIL ground wire screw –...

  • Page 403: Tachometer

    LIGHTS/METERS/SWITCHES TACHOMETER INSPECTION Remove the combination meter assembly (page 19- Temporarily connect the combination meter 9P (Natural) and 3P (Natural) connectors. Start the engine and measure the voltage between the Yellow/green (+) and Green (–) wire terminals. There should be at least 6 V pulse voltage. If there is pulse voltage, replace the tachometer (page 19-10).

  • Page 404: Coolant Temperature Gauge

    LIGHTS/METERS/SWITCHES COOLANT TEMPERATURE GAUGE/ ECT SENSOR GAUGE INSPECTION Lift and support the fuel tank (page 3-6). The coolant temperature is too high, but the gauge needle does not moves Disconnect the ECT sensor 3P connector. Ground the ECT sensor 3P connector Green/blue terminal at the wire harness side.

  • Page 405: Ect Sensor Inspection

    LIGHTS/METERS/SWITCHES ECT SENSOR INSPECTION Remove the ECT sensor (page 5-63). THERMOMETER Heat the coolant (1:1 mixture) with an electric heat- Wear insulated ing element. gloves and Suspend the ECT sensor in heated coolant and adequate eye check the continuity through the sensor as the cool- protection.

  • Page 406: Handlebar Switches

    LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the top bridge (page 13-27). IGNITION SWITCH Remove the ignition switch mounting screws and ignition switch. Install the ignition switch onto the top bridge. Install and tighten the ignition switch mounting screws securely. Install the top bridge in the reverse order of removal.
  • Page 407 LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCHS Lift and support the fuel tank (page 3-6). 2P (BLACK) CONNECTOR Open the rubber sheet (page 6-10). Disconnect the left handlebar switch 9P (Natural) and 2P (Black) connectors. 9P (NATURAL) CONNECTOR Check for continuity between the switch side con- EXCEPT CM TYPE: nector terminals in each switch position.

  • Page 408: Brake Light Switches

    LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCHES FRONT Disconnect the front brake light switch connectors and check for continuity between the switch termi- nals. There should be continuity with the brake lever squeezed, and no continuity with the brake lever released. FRONT BRAKE LIGHT SWITCH REAR Remove the rear cowl (page 2-5).

  • Page 409: Neutral Switch

    LIGHTS/METERS/SWITCHES NEUTRAL SWITCH INSPECTION Make sure that the neutral indicator come on with the ignition switch ON and transmission is in neu- tral. If the neutral indicator does not come on, inspect as follows: NEUTRAL INDICATOR Disconnect the neutral switch wire connector. NEUTRAL SWITCH WIRE CONNECTOR Check for continuity between the switch side Light NEUTRAL SWITCH WIRE CONNECTOR...
  • Page 410 LIGHTS/METERS/SWITCHES Remove the neutral switch and O-ring. O-RING NEUTRAL SWITCH Remove the spring cap and spring from the shift drum. SPRING INSTALLATION Check the spring cap for wear or damage, replace if necessary. Bend the spring cap by force or crush the contact point will cause poor electricity connection.

  • Page 411: Sidestand Switch

    LIGHTS/METERS/SWITCHES Install and tighten the neutral switch mounting bolt. Route the wire properly (page 1- Install the drive sprocket cover (page 11-5). 18). Connect the neutral switch wire connector. BOLT SIDESTAND SWITCH INSPECTION Disconnect the sidestand switch 3P (Green) connec- tor.

  • Page 412: Clutch Switch

    LIGHTS/METERS/SWITCHES CLUTCH SWITCH Disconnect the clutch switch wire connectors and CLUTCH SWITCH check for continuity between the switch terminals. There should be continuity with the clutch lever squeezed and no continuity with the clutch lever released. FUEL GAUGE/FUEL LEVEL SENSOR INSPECTION FUEL GAUGE Remove the fuel pump unit (page 5-49).

  • Page 413: Horn

    LIGHTS/METERS/SWITCHES FUEL LEVEL SENSOR Remove the fuel pump unit (page 5-49). FUEL PUMP 5P CONNECTOR Connect the ohmmeter to the fuel pump unit 5P (Wire side/female terminals) connector Yellow/white and Green terminals. Inspect the resistance of the float at the full and FULL empty positions.

  • Page 414: Turn Signal Relay

    LIGHTS/METERS/SWITCHES TURN SIGNAL RELAY INSPECTION 1. Recommended Inspection Check the following: – Battery condition – Burned out bulb or non-specified wattage – Blown sub fuse – Ignition switch and turn signal switch function – Loose connector Are the above items in good condition? –...
  • Page 415 LIGHTS/METERS/SWITCHES Connect an ohmmeter to the main relay connector MAIN RELAY terminals. CONNECTION: Red – Red Connect a 12 V battery to the following main relay connector terminals. CONNECTION: Green – Black There should be continuity only when 12 V battery is connected.
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  • Page 417 20. WIRING DIAGRAMS ED, E, F, II G type:····································· 20-3 U type: ······················································ 20-5 CM type:···················································· 20-4 20-1...
  • Page 418 WIRING DIAGRAMS ED, E, F, II G type: WIRING DIAGRAMS SUB FUSE A (10A) FAN MOTOR STARTER RELAY SWITCH B (10A) BRAKE LIGHT TURN SIGNAL LIGHT TAIL LIGHT LICENSE LIGHT INSTRUMENT LIGHT POSITION LIGHT NEUTRAL INDICATOR HORN MAIN FUSE C (10A) TACHOMETER FUEL GAUGE COOLANT TEMPERATURE GAUGE HEADLIGHT 12V6AH D (10A) STARTER SWITCH FUEL PUMP...
  • Page 419 WIRING DIAGRAMS CM type: SUB FUSE A (10A) FAN MOTOR STARTER RELAY SWITCH B (10A) BRAKE LIGHT TURN SIGNAL LIGHT TAIL LIGHT LICENSE LIGHT INSTRUMENT LIGHT POSITION LIGHT NEUTRAL INDICATOR HORN MAIN FUSE C (10A) TACHOMETER FUEL GAUGE COOLANT TEMPERATURE GAUGE HEADLIGHT 12V6AH D (10A) STARTER SWITCH FUEL PUMP...
  • Page 420 WIRING DIAGRAMS U type: SUB FUSE A (10A) FAN MOTOR STARTER RELAY SWITCH B (10A) BRAKE LIGHT TURN SIGNAL LIGHT TAIL LIGHT LICENSE LIGHT INSTRUMENT LIGHT POSITION LIGHT NEUTRAL INDICATOR HORN MAIN FUSE C (10A) TACHOMETER FUEL GAUGE COOLANT TEMPERATURE GAUGE HEADLIGHT 12V6AH D (10A) STARTER SWITCH FUEL PUMP...
  • Page 421 21. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT TO START ················································· 21-2 HIGH SPEED ············································· 21-6 ENGINE LACKS POWER ·························· 21-3 POOR HANDLING ···································· 21-7 POOR PERFORMANCE AT LOW AND IDLE SPEED··············································· 21-5 21-1...
  • Page 422 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START TROUBLESHOOTING 1. Spark Plug Inspection Remove and inspect spark plug. Is the spark plug in good condition? – • Incorrect spark plug heat range • Incorrect spark plug gap • Dirty air cleaner –...
  • Page 423 TROUBLESHOOTING ENGINE LACKS POWER 1. Drive Train Inspection Raise wheel off the ground and spin it by hand. Does the wheel spin freely? – • Brake dragging • Worn or damaged wheel bearings • Bent axle – GO TO STEP 2. 2.
  • Page 424 TROUBLESHOOTING 7. Ignition Timing Inspection Check ignition timing. Is the ignition timing correct? – • Faulty ECM • Faulty CKP sensor – GO TO STEP 8. 8. Cylinder compression Inspection Test the cylinder compression. Is the compression as specified? – • Improper valve clearance •...
  • Page 425 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Spark Plug Inspection Remove and inspect the spark plug. Is the spark plug in good condition? – • Plug not serviced frequently enough • Incorrect spark plug heat range • Incorrect spark plug gap –...

  • Page 426: Poor Performance At High Speed

    TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Ignition Timing Inspection Check the ignition timing. Is the ignition timing as specified? – • Faulty ECM • Faulty CKP sensor • Improper valve timing – GO TO STEP 2. 2. Fuel Pump Inspection Inspect the fuel flow.
  • Page 427 TROUBLESHOOTING POOR HANDLING Steering is heavy • Steering stem adjusting nut too tight • Damaged steering head bearings • Insufficient tire pressure • Faulty tire Either wheel is wobbling • Excessive wheel bearing play • Bent rim • Improperly installed wheel hub •...
  • Page 428 MEMO...
  • Page 429 22. INDEX AIR CLEANER·································································3-8 ENGINE INSTALLATION··············································· 7-6 AIR CLEANER HOUSING ············································5-52 ENGINE OIL ································································· 3-13 ALTERNATOR CHARGING COIL ································16-7 ENGINE OIL STRAINER SCREEN······························· 3-14 ALTERNATOR/STARTER CLUTCH ENGINE REMOVAL ······················································· 7-4 SPECIFICATIONS···························································1-9 EXHAUST PIPE/MUFFLER ·········································· 2-13 BANK ANGLE SENSOR···············································5-63 FAN CONTROL RELAY ··············································· 6-20 BATTERY······································································16-5 FLYWHEEL INSTALLATION ·····································...
  • Page 430 INDEX REAR FENDER····························································· 2-12 SYSTEM FLOW PATTERN ············································ 6-2 REAR MASTER CYLINDER ······································· 15-15 SYSTEM LOCATION REAR WHEEL ······························································ 14-5 BATTERY/CHARGING SYSTEM····························· 16-2 REAR WHEEL/SUSPENSION SPECIFICATIONS ······· 1-10 ELECTRIC STARTER ··············································· 18-2 REGULATOR/RECTIFIER············································· 16-7 IGNITION SYSTEM ················································· 17-2 RIGHT CRANKCASE COVER ······································ 10-5 LIGHTS/METERS/SWITCHES ·································...

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